INDUSTRIAL TRAINING

DIVISIONAL WORKSHOP TRAINING.

A INDUSTRIAL TRAINING REPORT

submitted to

SSM COLLEGE OF ENGINEERING

by

TABAN MUSHTAQ, YAWAR MANZOOR

&
SHAHID MEHRAJ
in partial fulfilment for the award of the degree
of

BACHELOR OF ENGINEERING
in
ELECTRICAL ENGINEERING

DEPARTMENT OF ELECTRICAL ENGINEERING

SSM COLLEGE OF ENGINEERING

DIVAR PARIHASPORA PATTAN.

AUGUST – 2023

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SSM COLLEGE OF ENGINEERING

DIVAR PARIHASPORA, PATTAN.

CERTIFICATE

This is to certify that the industrial training report entitled “DIVISIONAL WORKSHOP
TRAINING” is a paper presented by TABAN MUSHTAQ, YAWAR
MANZOOR & SHAHID MEHRAJ bearing enrolment number 8439, 8434 & 8426
respectively in partial fulfilment for the award of Degree of Bachelor of Engineering in
Electrical Engineering.

Er. MANZOOR AHMAD [Link] RAFIQI

HOD (Department of EE) [Link] (Department of EE)

PRINCIPAL
SSM COLLEGE OF ENGINEERING

DATE: AUGUST 2023 (DEPARTMENT SEAL)

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ACKNOWLEDGEMENT

We are profoundly thankful to our supervisor, ER. ISHTIYAQ RAFIQI, Assistant Professor
of Department of Electrical Engineering for encouraging and allowing us to present seminar
on the topic; “DIVISIONAL WORKSHOP TRAINING” for the partial fulfilment of the
requirements leading to award of B.E. degree.

We are grateful to PROF. MANZOOR AHMAD, Head of the Department of Electronics and
communication Engineering, that he gave us the opportunity for presenting the seminar in the
first place.

We are in indebt to our family and friends, who have always encouraged us, and never stopped
believing in us.

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ABSTRACT:

The main purpose of workshop includes inspection, testing, refurbishment, core repairs, and
restacking complete rewinds or LTC repairs and adjustments of distribution transformers.
Transformer repair services upgrades include KVA increases, voltage changes, clamping
structure improvements, use of modern iron, and insulating materials. Transformer repair
services offers repair, upgrades, or design modifications for transformers. Transformer repair
services take advantage of the latest developments in transformer repair technologies and
materials to provide potential clients with reliable repairs and effective upgrades.
The repair process for transformers depends on the type of transformer and the specific issue
that needs to be addressed. Some common repairs include replacing damaged insulation,
repairing or replacing damaged windings, and replacing damaged or faulty electrical
components. Professionals use specialized tools and equipment to diagnose and repair
transformer issues safely and effectively.
Transformer repair services include shipping an in-stock replacement transformer within a few
hours. This is extremely helpful in cases where a transformer stops unexpectedly. Also, fast
and reliable transformer repair services provide security, save costs in generator fuel, and
manufacturing down-time. Rental transformers are also provided by many of transformer repair
services.
Transformer repair services can undertake repair or upgrades of electrical power transformers,
dry type transformers, oil filled transformers, station types, distribution types, arc furnace,
regulators, and reactors.
Transformer repair services can redesign transformers to meet the changing requirements for
increased capacity, voltage, or short circuit duty improvements. Reputed transformer repair
services perform all testing to applicable ANSI/IEEE Standards. ANSI (American National
Standards Institute) is a private non-profit organization that oversees the development of
voluntary consensus standards for products, services, processes, systems, and personnel in the
United States. IEEE (Institute of Electrical and Electronics Engineers) is another international
non-profit, professional organization for the advan cement of technology related to
electricity.

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CONTENTS:

TITLE PAGE

ACKNOWLEDGEMENT…………………………………………………iii

ABSTRACT……………………………………………………....................iv

CHAPTER 1: TRANSFORMERS: 6-14

1.1 Introduction………...…………………………………………….…………7
1.2 Principle…………………………………………………………………….9
1.3 Working………………………………………………………………….10
1.4 (3-Ø) connections………………………………………………………….10
1.4.1 Wye-Wye………………………………………………………………..12
1.4.2 Wye-Delta……………………………………………………………….13
1.4.3 Delta-Wye………………………………………………………………13
1.4.4 Delta-Delta………………………………………………………………14

CHAPTER 2: CONSTRUCTION: 15-29

2.1 Core type 3-Ø transformer………….……………………………………15
2.2 Shell type 3-Ø transformer……………………………………………….16
2.3 Construction of a transformer…………………………………………….17

CHAPTER 3: TRANSFORMER REPAIRING: 30-41

3.1 Inspection………………..……………………………………………….30
3.2 Repair……………………..………………………………………………32
3.3 Testing……….…………………………………………………………..40

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CHAPTER 01
TRANSFORMER:

“They are so important in our lives that without them even the electric bulbs
fitted in our homes won’t work”

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1.1 Introduction

A transformer is a static device comprising coils coupled through a magnetic medium

connecting two ports at different voltage levels (in general) in an electric system allowing the
interchange of electrical energy between the ports in either direction via the magnetic field.
The transformer is one of the most important component of a variety of electrical circuits
ranging from low-power, low-current electronic and control circuits to ultra high-voltage
power systems. Transformers are built in an astonishing range of sizes from the tiny units used
in communication systems to monsters used in high-voltage transmission systems, weighing
hundreds of tons. A circuit model and performance analysis of transformers is necessary for
understanding of many electronic and control systems and almost all power systems. The
transformer being an electromagnetic device, its analysis greatly aids in understanding the
operation of electromechanical energy conversion devices which also use magnetic field but
the interchange of energy is between electrical and mechanical ports. The most important tasks
performed by transformers are: (i) changing voltage and current levels in electric power
systems, (ii) matching source and load impedances for maximum power transfer in electronic
and control circuitry, and (iii) electrical isolation (isolating one circuit from another or isolating
dc while maintaining ac continuity between two circuits). Transformers are used extensively
in ac power systems because they make possible power generation at the most desirable and
economical level (10– 20 kV), power transmission at an economical transmission voltage (as
high as 400–1000 kV) and power utilization at most convenient distribution voltages (230/400
V) for industrial, commercial and domestic purposes but in industrial applications voltages may
have to be as high as 3.3, 6.6 or 11 kV for large motors. In communication and electronic
systems where frequency ranges from audio to radio and video, transformers are used for a
wide variety of purposes. For instance input/output transformers (used to connect the
microphone to the first amplifying stage/to connect the last amplifying stage to the
loudspeaker) and interstage transformers are to be found in radio and television circuits. Indeed
the transformer is a device which plays an important and essential role in many facets of
electrical engineering. A transformer, in its simplest form, consists essentially of two insulated
windings interlinked by a common or mutual magnetic field established in a core of magnetic
material. When one of the windings, termed the primary, is connected to an alternating-voltage
source, an alternating flux is produced in the core with an amplitude depending on the primary
voltage, frequency and number of turns. This mutual flux links the other winding, called the
secondary. A voltage is induced in this secondary of the same frequency as the primary voltage
but its magnitude depends on the number of secondary turns. When the number of primary and
secondary turns are properly proportioned, almost any desired voltage ratio, or ratio of
transformation can be achieved. The subscript “1” will be associated with the primary and “2”
with the secondary of Transformers .
If the secondary voltage is greater than the primary value, the transformer is called a step-up
transformer; if it is less, it is known as a step-down transformer; if primary and secondary
voltages arc equal, the transformer is said to have a one-to-one ratio. One-to-one transformers
are used to electrically isolate two parts of a circuit. Any transformer may be used as a step-up
or step-down depending on the way it is connected.

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In order to ensure the largest and most effective magnetic linkage of the two windings, the core,
which supports them mechanically and conducts their mutual flux, is normally made of highly
permeable iron or steel alloy (cold-rolled, grain-oriented sheet steel). Such a transformer is
generally called an iron-core transformer. Transformers operated from 25–400 Hz are
invariably of iron-core construction. However, in special cases, the magnetic circuit linking the
windings may be made of nonmagnetic material, in which case the transformer is referred to
as an air-core transformer. The air-core transformer is of interest mainly in radio devices and
in certain types of measuring and testing instruments. An intermediate type, exemplified by a
type of induction coils and by small transformers used in speech circuits of telephone systems,
utilizes a straight core made of a bundle of iron wires on which the primary and secondary coils
are wound in layers.
A distribution transformer is also introduced as a typical form of an isolation transformer. The
basic function of this transformer is to modify the high voltage to the standard output like
240/120 V to apply in electric energy distribution. There are various forms of transformers
available in the distribution system, such as single-phase, three-phase, pad-mounted,
underground, and pole-mounted distribution transformers.

A distribution device has another term that is a service transformer. It is an instrument that
supplies the final voltage transformation in the power network, stepping down the output
employed in the distribution lines to the users’ rating.

Normally, a distribution transformer level is less than 200MVA, while some national norms
can allow for ratings up to 5000 MVA to be known as distribution transformers. If the level is
more than 200MVA (or 5000MVA in some regions), it’s introduced as a power transformer.

Since distribution transformers are powered for 24 hours a day (even when they don’t use to
carry any load), dropping the iron wastes has an initial role in the transformer’s modelling.
Commonly, they don’t perform at full capacity. At lower potentials, they are constructed to
have optimum efficiency. The voltage adjustment in these devices should be kept to a minimum
in other to have higher efficiency. So, they are constructed to include the small leakage
reactance.

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1.2 PRINCIPLE
The basic principle on which the transformer works is Faraday’s Law of
Electromagnetic Induction or mutual induction between the two coils. The working of the
transformer is explained below. The transformer consists of two separate windings placed over
the laminated silicon steel core.

The winding to which AC supply is connected is called primary winding and to which load is
connected is called secondary winding as shown in the figure below. It works on
the alternating current only because an alternating flux is required for mutual induction
between the two windings.

When the AC supply is given to the primary winding with a voltage of V 1, an alternating flux
ϕ sets up in the core of the transformer, which links with the secondary winding and as a result
of it, an emf is induced in it called Mutually Induced emf. The direction of this induced emf
is opposite to the applied voltage V1, this is because of the Lenz’s law shown in the figure
below:

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Physically, there is no electrical connection between the two windings, but they are
magnetically connected. Therefore, the electrical power is transferred from the primary circuit
to the secondary circuit through mutual inductance.

According to Faraday’s rule of electromagnetic induction, this alternating flux links the
transformer primary and secondary windings magnetically and generates EMFs E 1 in the
primary winding and E2 in the secondary winding. The EMF (E1) is referred to as the primary
EMF, while the EMF (E2) is the secondary EMF.

and

Dividing above equations, to obtain the ratio as:

From the expression above, it is clear that the size of EMFs E 1 and E2 is dependent on the
number of turns in the transformer primary and secondary windings, respectively. If N 2 > N1,
then E2 > E1, and the transformer will be a step-up transformer; if N2 < N1, then E2 < E1, and
the transformer will be a step-down transformer.
If a load is now connected across the secondary winding, the load current I 2 will flow
through the load as a result of the EMF E 2. As a result, a transformer makes it possible to
transfer electricity with a change in voltage level from one electric circuit to another.

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1.3 WORKING

The figure below shows the three-phase transformer, wherein three cores are placed at 120˚
from each other. This figure is simplified to show only primary windings and their
connection to the three-phase power supply. As soon as the three-phase supply is excited,
the currents IR, IY, and IB are carried by the primary windings and thus inducing the fluxes
ɸR, ɸY, and ɸB individually in each core. The center leg will carry the sum of all the fluxes,
and the center leg combined all the legs of a core.

For instance, if the sum of the currents IR+IY+IB is zero in a three-phase system, then the
sum of all the three fluxes also becomes zero, resulting in the center leg carrying no flux.
Therefore, removing the center leg makes no difference for other transformer conditions.

1.4 Three-Phase Transformer Connections

Primary Configuration Secondary Configuration

Wye Wye

Wye Delta

Delta Wye

Delta Delta

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 Various three-phase transformer connection is described below:

Wye and Delta configurations are applied for three-phase transformers because Wye
connections provide the options to have multiple voltages, whereas delta configurations
offer high reliability. The phase diagram of Wye and Delta is given below. For Wye
connection, either all the minus or all the plus points of windings shall be tied together.
However, in delta connection, polarities of winding are connected in a converse way.
The phase difference between any two phases is 120˚.

(Phase Windings)
1 Wye-wye Connection

The diagram of Y-Y connected transformers is shown below. It can serve both single-phase
and three-phase loads. In this connection, all the windings ending with dots are connected
to phases A, B, and C, while non-dots endings are connected to become the centers of “Y”
configuration.

(Wye Wye Connection)

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2 Wye-Delta Connection
The Y-Delta connection shown in the figure below shows that the secondary windings
(which are at the bottom in the figure) are connected to form a chain. The windings
with dot connection on one side are connected with the non-dot connection of the other
side to form the “Delta” loop.

(Wye Delta Connection)

3 Delta-Wye Connection

The connection of Delta-Y is shown in the figure below. This type of configuration
allows wye-connected secondary to connect multiple voltages such as line-to-line or
neutral. As the delta-wye configuration presents a 30˚ phase shift between primary and
secondary, it cannot be used to connect in parallel with delta-delta and Y-Y
configurations.

(Delta Wye Connection)

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4 Delta-Delta Connection

The diagram of the delta-delta connection is shown below. These connections can be
made either with three identical single-phase transformers or one three-phase
transformer. The delta-delta configuration is preferred due to its inherent reliability.

(Delta-Delta connection)

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CHAPTER 02
CONSTRUCTION:

Similar to the single-phase transformer the core of the three-phase transformer is constructed
either in core type or shell type. The LV and HV windings of the 3-phases are placed on the
three limbs of the core.

2.1 Core Type 3-Phase Transformer:

In a core type 3-phase transformer, the core is divided into three limbs in which each limb
carries both high-voltage HV and low-voltage LV windings of the three phases. The flux
produced by the primary ampere-turns will be linked by the secondary [Link] primary
and secondary of each phase on each limb is placed such that the LV winding is placed over
the core limb and HV winding is placed on the LV winding. The main reason to place LV
winding next or nearer to the core is the amount of insulation required is low to insulate the
LV winding from the core as shown below.

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The three core limbs of the three-phase winding are 120° apart. In a core type three-phase
transformer at any instant, one limb out of three will act as a return path for the magnetic flux
of the other two limbs.
The above represents the direction and magnitude of fluxes of a particular instant. It is seen
that the sum of fluxes in the two limbs (downward direction) is equal to the flux in one limb
(upward direction) that acts as a return path.

2.2 Shell Type 3-Phase Transformer:

A 3-phase shell type transformer can be combined with three single-phase shell-type
transformers as shown in the below figure.

The shell-type core construction of a three-phase transformer is less commonly used. It consists
of five limbs and the core surrounds the windings made on three limbs. The other two limbs
(between phases) hold the three limbs as a one-unit and also provides a return path for the
fluxes.

The whole construction is similar when three single-phase transformers are put side by side.
Compared to the core type structure each phase has its independent magnetic circuit and return
path for flux. Hence three phases are more independent in shell-type construction. The entire
core structure (either core or shell type) with windings is placed inside the transformer tank
filled with oil. The winding connections of the three phases are made inside the transformer
tank. The terminals of primaries and secondaries of three phases are taken out of the tank
through bushings for external connections. The most commonly used three-phase transformer
winding connections are,

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 Star-to-Star
 Delta-to-Delta
 Star-to-Delta, and
 Delta-to-Star

2.3 Construction of a transformer:

A complete distribution transformer built up with many parts. All of the parts play an essential
role in its activity. Now given a list of the parts of the distribution transformer.

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1 Oil filter valve 17 Oil drain valve

2 Conservator 18 Jacking boss

3 Buchholz relay 19 Stopper

4 Oil filter valve 20 Foundation bolt

5 Pressure-relief vent 21 Grounding terminal

6 High-voltage bushing 22 Skid base

7 Low-voltage bushing 23 Coil

8 Suspension lug 24 Coil pressure plate

9 B C T Terminal 25 Core

Terminal box for protective

10 Tank 26
devices

11 De-energized tap changer 27 Rating plate

12 Tap changer handle 28 Dial thermometer

13 Fastener for core and coil 29 Radiator

Lifting hook for core and

14 30 Manhole
coil

15 End frame 31 Lifting hook

16 Coil pressure bolt 32 Dial type oil level gauge

The basic parts of transformer are its core, primary and secondary windings. Apart from these,
there are many different types of equipment installed in transformers that are also considered
as parts of transformer, such as its cooling arrangements, protection relay ( Buchholz relay ),
HT and LT terminals and bushings, breather, conservator, oil tank, explosion vent, tap changer,
etc. So let’s discuss all these different parts of transformer and their functions in detail.

As laminated soft iron core, windings, and insulating material are the basic parts of
transformer. These three are available in all types of transformers. Whereas rest of all these
parts of transformer can be seen generally in power transformer of rating more than 100 kVA.
So let's discuss each part of transformer one by one in detail and their functions.

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 Laminated core

Laminated core is the most important parts of transformer, used to support the windings of
transformer. It is made up of laminated soft iron material to reduce eddy current loss and
hysteresis loss. Nowadays in the core of transformer laminated sheets are used to minimize
eddy current losses and CRGO steel material is used to minimize hysteresis losses. The
composition of core material depends on the voltage, current, and frequency of supply to the
[Link] diameter of transformer core becomes directly proportional to copper losses
and inversely proportional to iron losses or core [Link] core also provides a low
reluctance path for the magnetic flux that minimize leakage flux and maximize the strength of
main working flux for transformer.

 Windings
In a transformer always two sets of windings are placed on laminated core and these are
insulated from each other. Winding consists of several no of turns of copper conductors that is
bundled together and connected in [Link] main function of windings is to carry current and
produce working magnetic flux and induce mutual EMF for transformer action.

Windings are classified in two ways:

 Based on the input and output of supply

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 Based on the voltage level of supply

Based on the input and output of the supply, windings are further classified as:

1. Primary winding:- the winding at which the input supply is connected is known as the
primary winding.
2. Secondary winding:- the winding from which output is taken to the load is known as the
secondary winding.

Whereas based on the voltage level of supply, windings are further classified as:

1. High voltage (HV) winding :- the winding that is connected with higher voltage is known
as high voltage winding. It is made up of a thin copper conductor with a large no of turns.
It can be either primary or secondary winding of the transformer.
2. Low voltage (HV) winding :- the winding that is connected with lower voltage is known
as low voltage winding. It is made up of a thick copper conductor with few no. of turns. It
can also be either primary or secondary winding of the transformer.

Hence input and output to the transformer can be connected either on LV-winding or HV-
winding as per requirement.

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 Insulating material

Since insulation failure can cause the most severe damages to the transformer. So insulation
and insulating material should be high grade and it is the most important part of transformer.
Insulation is required between each turn of windings, between windings, winding and core, and
all current-carrying parts and tank of [Link] main function of insulating material is
to protect transformer against short circuits by providing insulation to windings so that it does
not come in contact with the core and any other conducting [Link] material of
transformer should have high dielectric Properties and also good mechanical strength and
temperature withstand [Link] material, papers,nawar tape ,cotton tape, press
cardboard and cotton cloth, etc are used as insulating material in transformer.

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 Main Tank
Main tank is the robust part of transformer that serves mainly two purposes:

1. It protects core and windings from the external environment and provide housing for them.

2. It is used as a container for transformer oil and provides support for all other external
accessories of the transformer.

Tanks are made up of fabricated rolled steel plates. They are provided with lifting hooks and
inbuilt cooling tubes. In order to minimize the weight and stray losses, aluminum sheets are
also being used instead of Steel plates. However, due to its light weight property, now-a-days
aluminum tank is more familiar and costly than a steel tank.

 Terminals and bushings

Terminals and bushings are also important parts of the transformer that are used to connecting
incoming and outgoing cables of supply and load. These are connected with the ends of the
windings conductor.
Bushings are mainly an insulators made up of porcelain or epoxy resins. They are mounted
over the tank and forms a barrier between terminals and tank. They provide safe passage for
the conductor connecting terminals to the windings.

As windings are of two types and so bushings are also of two types as named below:

1. High-voltage bushing
2. Low-voltage bushing

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 Transformer oil
The function of transformer oil is to provide insulation between windings as well as cooling
due to its chemical properties and very good dielectric strength.
It dissipates the heat generated by the core and windings of a transformer to the external
environment. When the windings of transformer gets heated due to flow of current and losses,
the oil cools down the windings by circulating inside the transformer and transfer heat to the
external environment through its cooling tubes.

Hydro-carbon mineral oil is used as transformer oil and acts as coolant. It is composed of
aromatics, paraffin, naphthenes, and olefins.

 Tap changer
The main function of the tap changer is to regulate the output voltage of transformer by
changing its turns ratio. There are two types of tap changers.

1. On-load tap changer:- in an on-load tap changer, tapping can be changed without isolating
the transformer from the supply. Hence it is capable to operate without interrupting the
power supply.
2. Off-load tap changer:- in off-load tap changer, the transformer needs to isolate from supply
to change its tapping (turns ratio).

An automatic tap changer is also available.

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 Buchholz relay
Buchholz relay is the most important part of a power transformer rated more than 500kVA. It
is a gas-actuated relay mounted on the pipe connecting the main tank and conservator tank.
The function of the Buchholz relay is to protect the transformer from all internal faults such as
short circuit fault, inter-turn fault, etc.
When short circuit occurred in winding then it generates enough heat to decompose transformer
oil into gases ( hydrogen, carbon monoxide, methane, etc). These gases move towards the
conservator tank through a connecting pipe, then due to these gases, Buchholz relay gets
activated. It sends signal to trip and alarm circuits and activate it. Then circuit breaker
disconnects the transformer from the supply.

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 Oil Conservator:

The function of the oil conservator tank is to provide adequate space for expansion and
contraction of transformer oil according to the variation in the ambient temperature of
transformer oil inside the main tank.

It is a cylindrical drum-type structure installed on the top of the main tank of the transformer.
It is connected to the main tank through a pipe and a Buchholz relay mounted on the pipe. A
level indicator is also installed on the oil conservator to indicate the quantity of oil inside the
conservator tank. It is normally half-filled with transformer oil.

 Breather

Breather is a cylindrical container filled with silica gel and directly connected with the
conservator tank of the [Link] main function of the breather is to supply moisture-
free fresh air to the conservator tank during the expansion and contraction of transformer oil.
This is because the transformer oil when reacting with moisture can affect the insulation and
cause an internal fault in a transformer. That's why the air entering in conservator tank should
be moisture free for better life of transformer [Link] a breather, when air passes through silica
gel then moisture present in the air is absorbed by silica gel crystal and hence a moisture-free
dry air is supplied to the conservator tank. Thus we can also say that breather is acting as an air
filter for the transformer.

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 Explosion vent

Explosion vent is a metallic pipe with a diaphragm at one end and installed on the main tank
slightly above than conservator tank. It is available only in high rated power [Link]
main function of the explosion vent is to protect power transformer against explosion during
excessive pressure build up in the main tank due to severe internal faults. It acts as an
emergency exit for oil and hot air gases inside the main tank of the [Link] explosion
vent works on the same principle as the safety valve works in the pressure cooker. Hence In
other words we can also called the explosion vent as safety valve of the transformer.

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 Radiators and Fans

The transformer is made up of exterior radiator tubes, which are cooled by air from fans
installed on the tank’s walls. Most of the time, heat is produced as a result of the power that is
lost in the transformer. Most dry transformers use natural air cooling.
However, various cooling techniques are used when it comes to oil-immersed transformers.
Radiators and cooling fans are mounted on the transformer tank based on the kVA rating, power
losses, and level of cooling requirements.
The surrounding transformer oil absorbs the heat produced in the core and winding. At the
radiator, this heat is released. Using cooling fans attached to the radiators, forced cooling is
accomplished in bigger transformers.

 Cooling Tubes
In order to cool the transformer oil, cooling tubes are used, as their name suggests. It’s possible
for oil to circulate naturally or artificially inside the transformer.

When the oil temperature rises, the hot oil naturally rises to the top during natural circulation.
In contrast, the cold oil naturally lowers, whereas an eternal pump is used to move the oil
between the hot and cold zones in forced circulation.

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 Temperature Gauge
An instrument used to monitor the temperature of a power transformer is called a temperature
gauge. It is placed on top of the tank to measure the temperature of the transformer. There is
an alarm or light on this meter which alerts you when the temperature rises.

 Pressure Relief Valve (PRV)

Winding of the transformer is housed in the transformer oil tank. The oil is used in the oil filled
transformer for insulation as well as for cooling purpose. In case of the fault inside the
transformer caused by sudden and severe short circuit , the transformer oil gets heated up and
enormous gases are evolved in the transformer tank which cause substantial increase in the
internal pressure develops the pressure in the transformer tank. If the increased pressure is not
vented outside of the transformer tank there may be potential hazard of transformer tank
explosion. in this case, PRD of transformer is used to protect the transformer.

The transformer tank is not designed to sustain pressure as it is not considered as a pressure
vessel, and if the gas pressure is not vented outside of the transformer tank, the tank can
explode. Therefore, to release the excess pressure of transformer tank pressure relief device
or PRD of transformer is installed for oil filled transformer to protect the transformer under
severe fault condition

A Pressure Relief device (PRD of Transformer) is also called Pressure Relief Valve(PRV).
A (PRV) is a type of valve used to release stored gas in various equipment in order to maintain
an optimal pressure level. PRV opens gradually as pressure builds up in order to release the
necessary amount of pressure.

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CHAPTER 03
TRANSFORMER REPAIRING

3.1 Inspection:
A quick onsite inspection of a failed transformer is necessary to collect the vital data which
may be destroyed during restoration of supply. Onsite inspection consists of examining the
external conditions around the failed transformer and thorough examination of transformer.
External Conditions: On arriving at site before starting the visual inspection the conditions all
around the transformer, first examine, interview the peoples in the vicinity at site about any
abnormality they saw during normal operation or during the time of failure. Investigator has to
look for any unusual sounds, odors, debris expelled from transformer or accessories, foreign
objects in area, any evidence of vandalism, load on transformer, system disturbances and any
dead animal in [Link] conditions: Investigator to look for following visible
abnormalities in the transformer main tank for bulging, cracks, leaks, sign of overheating, oil
spill or fire, oil level in main tank, oil level in conservator, damage to radiators, damage to
conservator and bushings for leaks, broken porcelain, holes in caps and tracking. If no visible
damage is found externally, then next step is to conduct diagnostic testing of transformer .When
there is no visible damage is found in external examination of transformer. Then diagnostic
tests are conducted to find out fault and to give indication of repair. Test data should be
recorded carefully and several tests may be interpreted together to diagnose a problem. Samples
of insulating oil for testing must be taken prior to opening the transformer for inspection.
Following tests can be conducted on [Link] Resistance: Winding to winding,
winding to ground, core to ground, dielectric absorption (Polarization Index).Other tests:
Transformer Turn ratio; Winding DC Resistance;Oil dielectric breakdown; Excitation (low
voltage)Before performing field tests, safety precautions should be taken to ensure that the
transformer is disconnected from all power and auxiliary sources and has been properly
[Link] the results of diagnosis test indicate the failure of transformer, an internal
inspection is performed on site to determine the location of fault and extent of
[Link] oil is removed for inspection, the exposure timemust be kept to a
minimum to reduce moisture entrance into the tank. Internal abnormalities may [Link] case
of a breakdown of a transformer or a decision to upgrade a transformer in a power network, the
company responsible for the operation of the network, the owner of the equipment or a service
company assigned to handle the operation of the network contacts experts on the type of
transformer that has broken down or has been decided to be upgraded. The experts, together
with repair personnel on the site, perform failure analysis and provide support for decision
about repair/ upgrade method. The analysis allows reducing the total down- time since experts
can take informed decisions earlier. For example they can anticipate ordering of needed
material which is often a bottle-neck during the repair process.

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When the decision about repair/ upgrade method is taken a global network of available
workshops is utilised for manufacturing, ordering and supplying of failed components of the
transformer. The components are shipped to the location of the failed transformer.
Establish temporary repair facilities at site One vital step in the system according to the present
invention is to establish a temporary repair facility. A site repair of a power transformer has to
be performed indoors in a facility that makes it possible to maintain a controlled environment
and the cleanliness and orderliness required. The facility should as far as possible allow for
performance of all critical steps of the repair inside the facility including the heavy lifting of
active part and windings. One solution is to use a rigid type of tent having a sturdy and rigid
frame covered with heavy duty cover. The tent should be openable in many directions in order
to be able to enter with spare parts, trucks, lifting equipment and the like. The size of the tent
should be of a size capable able of handling the repair, temporary storage of material and
components. The dimensions should also be large enough for the space required for the internal
transportation and the lifting of the active part and the windings, in the case of shell type
transformer the tank and the phases. The tent should be designed to handle the local weather
conditions and to fulfil the local building codes.
To keep all the critical parts clean and dry during the repair process the core, windings,
insulation parts etc. should be wrapped with plastic film or be placed in a closed container and
supplied with over pressure of dry air. Dry air should be supplied to encapsulated components
also during and after assembly of the active part until the active part has been placed in the tank
and the cover has been put on and dry air may be supplied into the tank.
It is possible to have an enclosure consisting of steel tubing which is easily raised, and then
cover the structure with walls and a ceiling of a moisture impermeable material in order to
protect the active part against contamination and moisture. The whole space may preferably be
kept at an overpressure with dry air. The ceiling may be opened for short durations to transport
material into the tent.
It is necessary that the repair facility is equipped with a foundation that is designed to handle
the weight of the transformer and built according to the local regulations. For example a spare
transformer foundation can be used, that may be available to build the facility on. The spare
transformer foundation may have a system to handle the oil. However, it is recommended that
the transformer be drained of oil before it is moved to the repair facility. An advantage of using
a spare foundation is that means for hauling of the transformer may already be available.
Lifting of components One critical step in the system of the present invention is to lift some
components of the transformer. The most heavy lifting at a repair of a core type transformer is
the lifting of the active part for untanking and tanking of the transformer. At a factory this is
made by using the overhead crane. The active part may for the largest transformers have a
weight of up to 400 metric tons.
For lifting on site, different types of equipment can be used, depending on weight and size of
the components to be lifted. For smaller transformers the lifting may be performed with a
mobile crane. For larger and heavier transformers a lifting device using four hydraulic vertical
boom style gantries using steel booms similar to hydraulic cranes may be utilized. Each pair of
booms has a crossbeam between the booms. The booms can be operated simultaneously to lift
or lower a component.
The present method comprises a number of steps for repairing a transformer or the like on site.
Fig. 1 shows a schematic flow chart of the different steps.

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3.1 Repair:

The first step is When a transformer has broken down to identify and understand the defect(s)
by using advanced diagnostics and simulation tools in order to reduce time of investigation
after untanking and to anticipate the decision. A suitable repair method is decided together with
expertise as mentioned above, and replacement parts are ordered and shipped to the repair site.
Then the temporary repair facility is to be erected at the site covering the transformer. As
mentioned above, a flexible and economical solution is to use rigid tent constructions covering
the necessary ground area to house the transformer, additional replacement and disassembled
parts as well as lifting equipment. It should also have the necessary height in order for the
lifting equipment to be able to be accommodated as well as to be able to lift components to the
necessary heights. For some very large transformers it might be necessary to have the roof of
the tent openable and to perform the lifting during good weather conditions. As suggested the
ground area may also include an inner tent or enclosure provided with equipment that can create
an over-pressure in the enclosure for storing critical parts during the repair process.
The next step is to ship lifting equipment, mobile cranes or hydraulic vertical boom cranes as
well as a foundation for the transformer to the site. When the necessary equipment is at the
repair site the actual repair work can begin. Before the active part of the transformer is lifted
the transformer is preferably drained from oil. The active part is then lifted with the aid of the
lifting equipment. When using a mobile crane the active part can be put on the foundation
placed at a suitable spot on the ground area. When using hydraulic vertical boom cranes the
tank is preferably moved away and the active part can be set on the floor without lateral
movement of the hydraulic vertical boom.

The active part is then disassembled as showen in figures below

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As in the above figure the windings of transformer are damaged o usings nuts and bolts we de-
assemble the transformer to take the windings off and replace them with the new ones.
Step by step de-assembling process is shown in figures below:

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the critical parts are stored in the over-pressure enclosure and in addition using plastic or the
like moisture impermeable material to cover critical parts or certain surfaces thereof.
After de-assemble part,the core is cleansed and covered with insulation tape as shown in
figure;

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The HV and LV windings are designed according to below table:

KVA RATING MATERIAL SIDE SIZE NO. OF TURNS

AL HV 16 85/88/90
63KVA
AL LV 10X4/6X3/8X4 26X19
AL HV 14 66
100KVA
AL LV 2(10X4)/8X4 66X26
AL HV 12 40-45
250KVA
AL LV 4(10X4) 40X26

CU HV 12 40-45

CU LV 4(10X4) 40X26

CU HV 12 30-35
400KVA
CU LV 4(10X4) 30X26
CU HV 10/9 24
630KVA
CU LV 9(6X3) 24X26

TABLE FOR 6.6KV

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KVA RATING MATERIAL SIDE SIZE NO. OF TURNS

AL HV 18 80-90
63KVA
AL LV 10X4 19X44
AL HV 16 65-70
100KVA
AL LV 2(10X4)/8X4 66X44
AL HV 13 40-45
250KVA
AL LV 4(10X4) 40X44

CU HV 14/13 40-45

CU LV 4(10X4)/ 40X44
4(6X3)
CU HV 13 30-35
400KVA
CU LV 4(10X4) 30X44
CU HV 11 24-28
630KVA
CU LV 9(6X3) 24X44

TABLE FOR 11KV

Then measurements are taken to design the LV windings, outer diameter of core becomes inner
diameter of HV windings. LV windings are covered with the press cardboard stickes and
insulation tape to prevent the damage caused by high voltages and currents.

After the construction of LV windings ,the measurement is taken to design the HV windings,

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Outer diameter of LV windings become inner diameter of HV windings. Two coils of HV are
separated by the small strips of cardboard ,they also help in oil circulation.
Sleeve is used to protect the connection of HV [Link] is covered with glass wool and
Bakelite rods for insulation purposes.

After designing LV and HV windings connections are made, i.e., star and delta connections
Delta connection is from HV side and star connection is from LV side.

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In the below fig. red circles represents the HV connection and greens ones represent the LV
connections.

In a conventional manner the core is tested and repaired if necessary, after which the
active part then is assembled.

The active part is then lifted back into the tank with the aid of the required lifting equipment.
Drying of the transformer One important step according to the present invention is to dry the
repaired and assembled transformer. Fig. 3 shows a schematic view of a method of drying a
transformer. Moisture in power transformers speeds up paper degradation as well as presenting
an operational risk when free water or vapour bubbles are created. Onsite drying is a main
process during an onsite repair or midlife refurbishment. There are several onsite-drying
methods known in the market. The main criteria for any of the drying processes are the
achievable temperature and the vacuum, as they determine the process time as well as the
dryness value after the process. According to the present invention a Low
Frequency Heating (LFH) method has been utilized. The purpose is to reach a high quality of
drying, i.e. low remaining moisture, within a short time (in the region of 50 to 70 % shorter
time than a conventional hot oil circulation drying method). In combination with the LFH
method either hot oil circulation or hot oil spray is used. The two different combinations will
be described in separate parts below.

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The drying is characterized by moisture-moving forces helping the diffusion of the moisture
through a porous material. The diffusion is strongly dependent on temperature, moisture
content, and pressure difference over the diffusion path and material properties.
Temperature and vacuum are the main factors for the drying speed and quality. For an
optimised drying, the transformer should be heated at the same time as vacuum is applied.
During onsite preparation the electrical circuitry for LFH operation, the vacuum circuit, the hot
oil circuit, the regulation valve for LFH operation and the temperature sensors to control the
temperatures in the windings or other parts are assembled, Fig. 3. Optionally a temperature
sensor is placed in oil circuit with hot oil spray, alternatively the oil distributor and the nozzles
for oil spray are optionally assembled.
The connection on the transformer should be done in order to assure a LF heating current
circulation in all windings.
Optionally the transformer is covered with heat insulation mats or tarpaulin.
Combined LFH- and hot oil spray / vacuum drying process technology This process starts with
the drainage of the oil so that only a small amount is left in the transformer. This oil is then
circulated over the oil treatment plant, where it is heated and then sprayed over the transformer.
Vacuum is applied from the beginning and the oil spray continues until the intermediate
temperature step is finished. Only then, all the oil is drained from the transformer.
According to Fig. 4 the process is carried out in the following main phases: heating-up of the
oil filled transformers by means of LF heating and parallel with hot oil spray; temperature
stabilization: pulsation of
LF current intermittent with full vacuum; vacuum and LF heating: increasing temperature to
next level + oil drainage of the spray oil; vacuum + temperature stabilization: heating with LFH
only to final drying temperature+ final vacuum phase; and oil filling after drying and
simultaneous oil treatment, the transformer is again filled with processed oil.
Temperatures The drying temperature besides the vacuum is the most important parameter
concerning the drying result and time. The temperature also influences the depolymerisation
of the insulation material, therefore an optimal temperature control is essential. The drying
process using LFH drying is controlled in three different temperature steps, see Figs. 4 and 5.
Step 1 : at low temperature) in order to extract as much water as possible in an early stage to
limit the ageing effect.
Step 2 : at intermediate level. Normally this temperature is chosen according to the max. oil
temperature.
Step 3 : step at the final drying temperature. At this step, all the oil is drained from the
transformer and only LFH is active.
Drying time The time of the different temperature steps is depending on the moisture extraction
rate and the moisture level in the insulation paper.
The drying time is to be understood as the time needed for the drying of the insulation when
temperature is reached and vacuum applied. Heating time without vacuum comes in addition
(different for the different drying techniques).
The drying time required in order to achieve a predetermined moisture level of critical
components might be monitored by means of continuous measurement of the moisture content
in said components, directly or indirectly. Preferably, for that purpose, there are provided one
or more reference bodies or blocks of a material and an initial moisture level corresponding to
those of said component or components, said bodies or blocks being placed in the same
environment as said components. The moisture content of said components of the transformer
is measured indirectly by means of a continuous measurement of the moisture level in said
bodies or blocks during the drying of said components. Preferably, the measurement is
performed by means of dielectric spectroscopy. The drying characteristics of said bodies or

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blocks should correspond to, or have a known relation to, the drying characteristics of said
components in order to enable the moisture level thereof to be translated into a correct,
corresponding moisture level of said components.

After drying ,housing is provided to the job and the LV side three phases and neutral is
connected to the outer bushing through crok and same is done on the HV side.
Different tools used to brought the HV and LV connections out from the tank are shown in
figure:

3.1 Testing:

An essential step after drying of the transformer is to perform a number of tests to verify that
the transformer will operate correctly when taken into operation.
The following high voltage tests shall be performed to verify the quality of an On-Site repair:
- induced voltage tests, including measurement of partial discharges
- applied voltage tests, preferably with measurement of partial discharges (PD measurement).
Optionally the following tests/ measurement may be performed:
- no-load loss measurement - load loss measurement
As a further alternative, impulse voltage testing might be performed on site, even though, at
the time being, such tests are rather difficult and expensive from a technical-economical point
of view.
The high voltage tests are performed using a specially designed Mobile High Voltage Test
Field based on a variable frequency power electronic converter. The rating and control features
of the test field are chosen for testing of the whole range of transformers from distribution
transformers to large power transformers.
As an interface to the test object there is an adaptation transformer with variable taps to best fit
the voltage level of the transformer to be tested. For easy transportation including loading and
unloading, the test field is assembled in a 40 foot container. When delivered to the test site the

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container is easily and quickly converted to a fully fledged and flexible test field containing
control room and all test, measurement, recording and connection equipment required.
The Mobile High Voltage Test Field used for Induced voltage test The arrangement of the test
circuit for Induced voltage test of a transformer is shown in Fig 5. The test voltage is normally
fed to the test object through the tertiary winding or through the low voltage windings. Through
induction in the test object the relevant test voltage is generated. The test system will
automatically adjust the test frequency for minimum load on the test field. Typically this occurs
at a frequency between 100 and 200 Hz.
The Induced voltage test including measurement of Partial discharge is performed according
to the IEC standard 60076-3.
The Mobile High Voltage Test Field used for Applied voltage test
Fig. 6 shows a principle block diagram of test circuit for Applied voltage test. Opposite to the
Induced voltage test the test object may not be used for induction to generate the high voltage
level required. Therefore the test voltage for Applied voltage test is generated by means of a
resonance circuit. The resonance will occur between the resonance reactor and the capacitance
of the transformer together with any added capacitance to achieve desired frequency.
The Applied voltage test is performed according to the IEC standard 60076-3
Mobile High Voltage Test Field used for measurement of no load and on load losses. For the
measurement of losses the test circuit is arranged in the same way as for the Induced voltage
test with the addition of capacitor banks for reactive compensation and high precision
measurement and recording equipment. The additional reactive compensation is required as
this in opposite to the Induced voltage test has to be performed at the fundamental frequency,
50 or 60 Hz.
Impulse voltage system
As an option, the repaired transformer could also be tested using a transportable module
impulse generator built with several stages.
When the tests have been performed and the results are satisfactory, all equipment used for the
repair is removed from the site as well as the temporary repair facility. The transformer is now
ready to be put into operation again.
It is to be understood that the embodiments described above and shown in the drawings are
only to be regarded as non-limiting examples of the invention and that it may be modified
within the scope of the patent claims.

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