SUMMER INTERNSHIP

A REPORT
ON

TRANSFORMERS
BY : ANIKET BAPAT
COLLEGE OF ENGINEERING, PUNE

INTRODUCTION
A transformer is a static piece of apparatus used for transferring power from one circuit to another without change in frequency. It can raise or lower the voltage with a corresponding decrease or increase in current. The physical basis of a transformer is mutual inductance between to circuits linked by a common magnetic flux through a path of flow reluctance. Though a transformer is a simple and static electrical equipment, its outage can cause interruption to all sphere of daily life.

1.

DESIGNING :
Before the design for any transformer is finalised the basic document required is the specification of the transformers. Basic specifications that any customer needs to provide are: kVA Line voltage Primary voltage Secondary voltage Vector group Losses (load loss and no load loss) Impedance Temperature rise above ambient For selection of the core, core area is calculated by using the formula, *4.15 (approx) with 5% tolerance

Diameter of the core, total lamination stack height is calculated from available data using proper calculations. Core diameter of a transformer depends upon a number of factors like rating, percentage, impedance between windings, basic insulation level, transport height, type of core and quality of steel. Number of

oil ducts and their location are calculated further. The cores are made of CRGO steel which is available in various grades having different properties. Suitable grade of steel is chosen to suit the performance requirements and overall economy. Volts per turn of the transformer can be calculated by using the formula given below,

f : is frequency B : is flux density and is usually taken as 1.5 T for normal transformers A : is cross section area.

After calculating volts/turn HV turns and LV turns are calculated. To calculate the number of LV turns the rated phase voltage on LV side is divided by the volts per turn calculated by using the above formula. Similarly the number of turns on HV side can be calculated by using the relation between the ratio of number of turns and voltages. Designing process further includes allocution of current through LV windings, HV windings, size of copper to be used depending on its density, phase clearance etc. Also the losses occurring in core, no load and load losses are determined.

Next is the incoming of material as per the requirements of the design. After the basic electrical design is complete and raw material is available the next process is manufacturing.

2. MANUFACTURING.
Manufacturing and assembly of the transformers involves the following main stages and the manufacturing techniques basically depend on the designing. Core building Preparation of the windings Core and winding assembly Processing Servicing and tanking Mounting of accessories for testing

I.

CORE BUILDING : The core forms the magnetic circuit of the transformer. Core is built up from cold rolled grain oriented, silicon alloy sheet steel of the best magnetic properties. The size, type, and construction of the core like the number of steps, number of limbs, height etc. depends on the number of phases and size of the transformer.

The sequence of operations for core building and assembly are as follows: a) b) c) d) e) f) g) h) Slitting of core steel rolls to required width. Cropping and mitring to required dimensions. Hole punching in laminations wherever required. Stacking of laminations of different size to the required thickness. Laying of clamp plates and end frame and levelling. Core building. Clamping of core after assembly of the top end frame. Tightening of the core.

The core assembly is ready for further processing and testing. II. PREPARATION OF WINDING : The windings form the circuit of the transformer. Various types of windings are used, i.e. spiral, helical, disc, layer etc are used depending upon the rating of the transformer and design consideration. Generally low voltage windings are either spiral or helical and high voltage windings are either layer or disc type. Low voltage windings are generally prepared from strip copper or strip aluminium. Windings are manufactured using mould of required size and mounting then on winding machines. Windings are pressed hard on each other with insulation paper placed after each turn. CORE AND WINDING ASSEMBLY : Core is placed on suitable levelled platform. Top-end frame and yoke laminations are removed. Bottom insulation items are placed on bottom yoke or end frame of each core leg. Various windings are then inserted in each core leg. After lowering of the windings top insulation arrangement is completed. Top-end frame and yoke laminations are placed back in position.

III.

IV.

PROCESSING : The assembled active part of the transformer before tanking is heated in an oven for extraction of the moisture under vacuum. Sometimes vacuum drying is done by drawing vacuum in its own tank and keeping the whole transformer in an oven. Once the moisture is extracted to the desired level, oil is filled under vacuum and the transformer is soaked in oil. TANKING : The transformer tank cover is placed in position and the transformer is now ready for further assembly of bushings etc. After servicing the transformer is assembled with all the necessary fittings. The oil is filled under vacuum and it is circulated in order to get

V.

the desired ppm and BDV levels before being offered for final testing and subjected to high voltage testing.

After proper assembling and manufacturing of the transformer next step is testing. Various tests are performed on transformer to check losses, insulation, clearance etc.

3. TESTING OF TRANSFORMERS :
Testing is an important activity in the manufacture of any transformer. Certain preliminary tests are carried out at different stages of manufacture. These tests provide an effective tool which assures quality and conformation of design calculations. Final tests are performed on fully assembled transformer. These tests guarantee the suitability of the equipment for satisfactory performance in service. Different tests that are performed on transformers at various stages are as follows:

1) Core Insulation : After the core is assembled some kilo volts are applied through the core to ensure that the insulation between clamp plates, core bolts and core is adequate. 2) Core Loss : This is conducted on core assembly to ensure its soundness. Some turns are wound over the core and it is energised at normal flux

density. Core loss and magnetizing current are noted and compared with the design values. 3) Megger : This test is performed to measure the resistance between high voltage windings and earth, low voltage windings and earth, high voltage windings and low voltage windings by using a properly calibrated megger meter. 4) Ratio Test : Ratio test is conducted to ensure the correctness of voltage ratio between different windings on each tapping. The tolerance allowed for ratio is 0.5% of declared ratio. In order to get accurate ratio, a ratio meter is used. It also indicates the polarity of transformer windings. 5) Vector Relationship : For a three phase transformer it is more usual to carry out a vector relationship test, in which one of the high voltage and low voltage line terminals are jointed together. This test is performed by measuring the voltage between R, Y, B phases and voltage between neutral and phase. For various vector groups the measured voltages should satisfy certain relations. Eg: for vector group Dyn11, Yy=Yb VBb<VBn<VBy.

6) Winding Resistance : For calculation of I2R losses in the winding, it is necessary to measure dc resistance of each winding. Temperature of the winding must be stable and for this reason, this test is carried out

usually before load loss measurement. A resistance meter is used to measure the winding resistance on both HV and LV side. After calculating the rsistance of all three windings, average resisstance is calculated. If HV is connected in delta, Avg. Resistance per phase(R) = avg resistance *1.5 Losses are given by, where, I is the saturated current through HV. Similarly I2R losses on LV side are calculated by using appropriate formulae.

7) No Load loss test : The measurement of no load loss and current is important not only for the propose of assessing the efficiency of the transformer, but also as a check that high voltage tests have not caused any damage to winding insulation. Measurement of no-load loss is carried out at rated frequency feeding usually LV side. Since the no-load current is very small, the I2R losses in the windings will be negligible. To perform this test HV side is kept open and rated phase voltage is apllied to the LV side. The core-loss consists of hysteresis and eddy current losses. The hysteresis loss is dependent on average value and the eddy current loss on rms value of supply voltage. Three wattmeter method is used for measuring losses. Before performing the test check if oil is full and do air release for oil cooled transformers.

8) Full Load loss test : Load loss comprises the sum of I2R losses and stray losses. Yto perform this test, LV is short-circuited and rated phase current is allowed to flow through HV terminals. Stray losses vary with frequency and hence the supply should be given at rated frequency. Load losses are measured at ambient temperature but are guaranteed at 75oC. Therefore the measured loss is corrected to the reference temperature (75oC). Three wattmeter method should be used instead of two wattmeter method to avoid large value of wattmeter multiplier constant. The power factor during load loss test can be less than 0.1. it is known that I2R losses are directly proportional to temperature and stray losses are inversely proportional. 9) Separate Supply Voltage Test : This test is performed to check the adequacy of main insulation to earth and between windings. The line terminals of the windings inder the test are connected together and the appropriate test voltage is applied to them while the other windings and tank are connected together to the earth. The duration of application of the test is 60 sec. The supply voltage should be nearly sinusoidal. This test also gives information on clearance between the windings and tank. If there is any contact between the transformer and tank or the insulation is weak then the MCB on the panel gets tripped indicating failure of the test. 10) Induced High Voltage test : This test is also known as DVDF (Double Voltage Double Frequency) test. This test in intended to check the interturn and line end insulation as well as main insulation to earth and between windings. For transformers with non-

uniformly insulated windings, the test voltage is twice the corresponding rated voltage. For high values, it is the usual practice to raise each HV terminal in turn, to specified test voltage by applying single phase voltage to LV winding. Test duration is determined by the following formula : Test duration is seconds =

11)

Magnetic Balance : Magnetic balance of transformer is obtained by measuring the voltage between two different phases. Supply is given to RY, YB and BR one at a time. When supply is given voltage between phases is measured by using a voltmeter. For example, say voltage is applied to RY phase, voltages between RY, YB, BR, rn, yn, bn is measured.

When the transformer passes all the above tests and is cleared during inspection it is cleaned and dispatched for installation at site. Transformer is tested once again at site and is installed ready to be used...