A

Summer Training Report

On

Assembly of Power Transformer

At

Bharat Heavy Electricals Limited, Jhansi

Submitted By: Submitted to: Under the
Dr. Dhruv guidance of:
Bhargav Mr. Sushant
Dy. General Tiwari
Manager Senior Engineer
BHEL, Jhansi Power
Transformer
Assembly
TRM, BAY-9
BHEL, Jhansi
Submitted On: Signature:

1
 Acknowledgement

I am extremely thankful & indebted to the numerous BHEL engineers &

technical staff that provided vital information about the functioning of
their respective departments by giving their valuable time, thus helped me
to gain the overall idea about the working of the organization. I am
thankful for the support & guidance of each of them.
The technical staff has shown great interest & were always ready to help
in understanding the working of various machineries.
I express my gratitude to HRD Department as they allowed me for training
in BHEL, Jhansi.
I am very thankful to Mr. Sushant Tiwari (BAY-09) for guiding me &
approving my project report successfully.
I would like to thank my parents, teachers & fellow trainees who have been
a contrast source of encouragement & inspiration during my studies and
provided me support in every walk of my life.

2
 Abstract

As we know transformers are very important part of the power system.

They are used for the stepping up and stepping down the voltages and
current levels so that the power can be transmitted and distributed
effectively and efficiently. This report is divided in two parts.
First part of the report gives a brief introduction to Transformer
manufacturing plant of Bharat Heavy Electricals Limited (BHEL) which was
set up in Jhansi (U.P.) i.e. BHEL, Jhansi. This part contains brief idea about
the working and roles of various departments and units of BHEL, Jhansi.
Second part of the report is on the Assembly of Power Transformer and
Testing that are done here. There is also some details related to the parts
and accessories of the power transformer that are used to manufacture a
power transformer. As testing is an important phase to ensure the
specifications, losses and outputs of any equipment and machinery. So
some of the technical details related to various tests that are performed
on the power transformers are also given in this report.

3
 Contents

1. BHEL
a. History
b. Overview
c. Main Manufacturing Facilities
d. Products & Services
2. BHEL, Jhansi
a. Brief Intro
b. Products
c. Upcoming Developments
3. Rotation Report
a. Sections of BHEL, Jhansi
b. TRC
c. TRE
d. TRM
e. LMC
f. LME
g. LMM
h. Store
i. Testing
4. Power Transformer Assembly
5. Power Transformer Tests
6. Conclusion
7. References

4
 BHEL
History
 Established in 1964.
 Merged with Heavy Electricals (India) Limited in 1974.
 In 1982, it entered into power equipment. Developed the capability
to produce a variety of equipment for various sectors.
 In 1991, it was converted into a public limited company.
 By the end of 1996, the company had handed over 100 electric
locomotives to Indian Railway and installed 250 Hydro-sets across
India.

5
 An Overview

BHEL, owned by the Government of India, is an integrated power plant

equipment manufacturer and one of the largest engineering and
manufacturing company of its kind in India engaged in the design,
engineering, manufacturing, construction, testing, commissioning and
servicing of a wide range of products and services for core sectors of the
economy, viz. Power, Transmission, Industry, Transportation (Railways),
Renewable Energy, Oil & Gas, Water and Defense with over 180
products offerings to meet the needs of these sectors.
BHEL constitutes 20,000 MW p.a. capacity out of the available 35,000
MW p.a. capacity for power plant equipment manufacturing in the
country.
The wide network of BHEL consists of 17 Manufacturing Divisions, 2
Repair Units, 4 Regional Offices, 8 Service Centre, 6 Overseas Offices, 6
Joint Ventures, 15 Regional Marketing Centre and current project
execution at more than 150 project sites across India.
It has been granted the prestigious Maharatna (big gem) status in 2013
by Government of India for its outstanding performance.

6
 Main manufacturing facilities

 Centralised Stamping Unit & Fabrication Plant (CSU & FP), Jagdishpur
 Insulator Plant (IP), Jagdishpur
 Electronics Division (EDN), Bangalore
 Electronic System Division (ESD), Bangalore
 Electro-Porcelains Division (EPD), Bangalore
 Heavy Electrical Plant (HEP), Bhopal
 Industrials Valves Plant (IVP), Goindwal
 Heavy Electrical Equipment Plant (HEEP), Ranipur(Haridwar)
 Central Foundry Forge Plant (CFFP), Ranipur(Haridwar)
 Heavy Power Equipment Plant (HPEP), Hyderabad
 Transformer Plant (TP), Jhansi
 Boiler Auxiliaries Plant (BAP), Ranipet
 Component Fabrication Plant (CFP), Rudrapur
 High Pressure Boiler Plant (HPBP), Tiruchirappalli
 Seamless Steel Tube Plant (SSTP), Tiruchirappalli
 Power Plant Piping Unit (PPPU), Thirumayam
 Heavy Plates & Vessels Plant (HPVP), Visakhapatnam

7
 Products & Services

Thermal power plant Nuclear power plant

Gas based power plant Hydro power plant
DG power plant Boilers (steam generator)
Boiler Auxiliaries Gas generator
Hydro generator Steam turbine
Hydro turbine Gas turbine
Transformer Switchgear
Oil field equipment Boiler drum
Piping system Soot blowers
Valves Seamless steel tubes
Condensers Heat exchangers
Pumps Desalination & Water treatment
plant
Automation & Control Power electronics
Systems
Transmission system control Semiconductor devices
Bus ducts Insulators
Control panels Capacitors
Bushings Electrical machines
DC, AC heavy duty motors Compressors
Control gears Traction motors
8
 BHEL Jhansi

This plant was set up in 1974 at an estimated cost of Rs. 16.22 crores
inclusive of Rs. 2.1 crores for township.This plant of BHEL is equipped
with most modern manufacturing processing and testing facilities for the
manufacturing of Power, Special transformer and Instrument
transformer, Diesel shunting locomotives and AC/DC locomotives. The
layout of the plant is well streamlined to enable smooth material flow
from the raw material stages to the finished goods. All the feeder bays
have been laid perpendicular to the main assembly bay and in each
feeder bay raw material smoothly gets converted to sub assemblies,
which after inspection are sent to main assembly bay.
The raw material that are produced for manufacture are used only after
through material testing in the testing lab and with strict quality checks at
various stages of productions.
This unit of BHEL is basically engaged in the production and
manufacturing of various types of transformers and capacities. With the
growing competition in the transformer section, in 1985-86 it under took
the re-powering of DESL, but it took the complete year for manufacturing
to begin. In 1987-88, BHEL has progressed a step further in under taking
the production of AC locomotives, and subsequently it started
manufacturing AC/DC locomotives also.

9
 Products
Transformers
Type Range
Power transformer upto 400 kV/315 MVA
Rectifier transformer upto 132 kV/120 kVA
Furnace transformer upto 33 kV/60 MVA
Transformer for ESP upto 95 kV/1400 mA
Voltage transformer upto 220 kV
Current transformer upto 400 kV
Traction transformers
Single Phase Freight Loco 25 kV/5400 kVA,6500kVA
Three Phase Freight Loco 25 kV/7475 kVA
Transformer for ACEMU upto 25 kV/1550 kVA
Single Phase 25 kV/1000 kVA
Three Phase 25 kV/1385kVA
Cast Resin Dry Type Transformer upto 33 kV/15 MVA

Dry Type Reactors 300 mH. 120 Amp

Smoothing Reactors 3.3 mH. 2700 Amp
DC Choke 0.5 mH. 4600 Amp

10
 Development Project Undertaken in TRM

Project
220 kV Live Tank CT
Optimization of Dry Type
transformer
Indigenization of Al. Tank for three
phase Loco transformer
0.2 accuracy class 300 UAEMVT
Status
Status under progress
Material under procurement
RDSO approval being obtained
Material under procurement

Hermetically sealed HVR Material under procurement

transformer

Upcoming developments in LMM

1) Development of mobile charger for all types of DSEL.

2) Development of single battery voltmeter for all types of DSEL.
3) Implementation of wagon terminal board assembly in 700 hp TPP on
developmental basis. After success, it shall be implemented in all
types of DESL.

11
 Sections of BHEL, Jhansi
As BHEL, Jhansi is a production plant which mainly concerns on the
production of Transformers and Locomotives, it has various
manufacturing and assembling units. The production and administrative
departments for different units are separate viz. for Transformer and
Locomotive sections the commercial, engineering and productions units
are separate.
So a brief introduction to various units of BHEL is given below:

1 Transformer Section:
1.1 Transformer Commercial (TRC):
The objective of this department is to interact with the customers related
to transformers. It brings out tenders and notices and also responds to
them. It is this department that bags contracts of building transformers.
After delivery regarding faults, this department does failures and
maintenance. All such snags are reported to them and they forward the
information to the concerning department.
The commercial department plays a major role in the progress of the
company as they have to negotiate with the customers, to satisfy them
that the company can provide them with their needs while keeping in
mind the necessary profit for their company.
One of the major tasks of this department is to earn decent profit over all
negotiations.
The main work of the TRC is classified as:
 Tenders and Notices.
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  Interaction with design department.
 Place of the work.
 Approximate cost of the work.
 Earnest money.
 Place and time where contract documents can be seen.
 Place and time where tender documents can be obtained.
 Time up to which the documents will be sold.
 Amount if any to be paid for such documents.
 Place, date and time when tenders are to be submitted and are to
be opened.
 Any other information relevant in tender notices.

1.2 Transformer Engineering (TRE):

The transformer manufactured in BHEL Jhansi are of different ratings and
types. The Engineering department does all the work related to
designing, estimation of cost and time in manufacturing the transformer.
The designs & drawings that are provided to the TRM units for
manufacturing a transformer are made by this department along with
given time to make that part. They also provide the necessary guidelines
to the workers to make the product effectively if necessary.
As the company is established many years ago the designs to make the
different parts of the transformers are readily available in present time.

13
Nowadays they have to do just necessary modifications according to the
requirements.
The various transformers manufactured in the TRM units are, so the
transformers that are designed here are:
 Power Transformer:

 Auto Transformer.

 Generator Transformer.

 System Transformer.
 Special Transformer:

 Dry Type Transformer.

 ESP Transformer.

 Instrument Transformer.

 H V Rectifier Transformer.

 Traction Transformer.
All above types are oil cooled except dry type, which is air cooled.

1.3 Transformer Manufacturing (TRM):

The manufacturing of transformer is carried out in a systematic manner
with work assigned to the following sections to smoothly carry out the
job within the promised time. The designs & drawings are provided by
the TRE department. The staff in the TRM department just follow the
drawings and instructions as given by TRE. TRM department is divided in
various units as follows:
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1.3.1 Fabrication:
Fabrication is nothing but production. It comprises of 2 bays i.e. Bay0 &
Bay1.
It is the preparation shop while the other two bays form the
assembly shop.
This section has following machines:
 Planning machine: To reduce thickness.
 Shearing machine.
 CNC/ANC Flame Cutting machine: To cut complicated shaft
items using Oxy-Acetylene flame.
 Bending machine.
 Rolling machine.
 Flattening machine.
 Drilling machine.
 Nibbling machine.
 Pantograph flame cutting machine.

1.3.1.1 BAY-0:
It is an assembly shop where different parts of tanks come from
fabrication shop.
Here welding process are used for assembly, after which a rough
surface is obtained Grinder operating at 1200rpm is used to
eliminate the roughness.
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1.3.1.2 BAY-1:
It is an assembly shop dealing with making different objects
mentioned below:
 Tank assembly
 Tank cover assembly
 End Frame assembly
 Foot assembly
 Cross feed assembly
 Core clamp assembly
 Pin and pad assembly
Before assembly, short blasting (firing of small materials i.e. acid pickling)
is done on different parts of jobs to clean the surface before painting.
After assembly some test are done which are known as NON
DESTRUCTIVE TEST
1) Ultrasonic test: To detect the welding fault on the CRO at the fault
place high amplitude waves are obtained.
2) Die penetration test: Red solution is put at the welding and then
cleaned. After some time white solution is put. Appearance of red
spot indicates a fault at the welding.

16
 3) Magnetic crack detection: Magnetic field is created and then iron
powder is put at the welding. Sticking of the iron powder in the
welding indicates a fault.

1.3.2 BAY-2: In this section mainly cores for different transformers

are made. They assemble the CRGOS sheets in the prescribed order
to make the core of transformer. The cutting of CRGO is done with
the help of CNC machine in BAY-5. The stacked sheets are fitted with
circular rods of fibre glass or wood in the steps formed during the
stacking so that the sheets do not displace during the unlacing, coil
assembly or relacing of the core and are tightly clamped using the
tapes.

1.3.3 BAY-3:
There are basically three sections in this bay:
1) Machine section
2) Copper section
3) Tooling section

1.3.3.1 Machine section:

The operations to form small components of power and traction
transformer are done in this section. The shop consists of following
machines:
a) CENTRAL LATHE: It consist one tailstock, headstock, lower part of
tail is fixed and tail stock spindle is moving. On this machine facing,
turning and threading is done.

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 b) TURRET LATHE: Its function is same as central lathe but it is used
for mass production. Here turret head is used in presence of
tailstock because turret head consist many tailstocks around six.
c) CAPSTAN LATHE: It is belt drive.
d) RADIAL ARM DRILLING MACHINE: It is used for drilling and boring.
e) HORIZONTAL BORING MACHINE: It is computerized and used for
making bore, facing etc.
f) MILLING MACHINE:
a) Horizontal milling machine: It is used for making gear and
cutting operations.
b) Vertical milling machine: By the machine facing cutting and
T-slot cutting is done.

1.3.3.2 Copper Section:

All the processes related to copper are done here.
a) TUBE SLITTING MACHINE: This machine is used for cutting the tube
along its length and across its diameter. Its blade thickness is 3mm.
b) SHEARING MACHINE: It is operated hydraulically and its blade has V-
shape and a thickness of 15mm.
c) DIE & PUNCHING MACHINE: It is also hydraulically operated and has
a die and punch for making holes.
d) HYDRAULIC BENDING MACHINE: It is used for blending the job up to
90°.
e) SHAERING MACHINE: It is fully mechanical and is used to cut the job
along its width.
f) FLY PRESS MACHINE: It is used to press the job. It is operated
mechanically by a wheel, which is on the top of the machine.
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 g) BEND SAW MACHINE: This machine is used for cutting job having
small thickness. It has a circularly operated blade, around 5.1mtr
long.
h) WATER COOLED BRAZING MACHINE: It consists of two carbon
brushes. The sheet is put along with a sulfas sheet and the carbon
brushes are heated. A lap joint is formed between the sheets as the
sulfas sheet melts.
i) LINCHING BELT MACHINE: It creates a smooth surface.
j) HYRRAULIC PRESS MACHINE: To press the job.
k) SOLDER POT MACHINE: It has a plot that contains solder. Solder has
a composition of 60% Zn and 40% Pb.
1.3.3.3 Tolling Section:
In this section the servicing of tool is done.
a) BLADE SHAPE MACHINE: It sharpens the blade using a circular
diamond cutter. Blade of CNC cropping line machine is sharpened
here.
b) MINI SURFACE GRINDER MACHINE: It serves grinding purposes. It
has a grinding wheel made of “Aluminum Oxide”.
c) TOOL & SURFACE GRINDIN MACHINE: This is specially used to grind
the tools used in bay 7.
d) DRILL GRINDING MACHINE: To grind the drills.

1.3.4 BAY-4:
This is the winding section. The winding consist of the current carrying
conductors wound around the sections of the core, and these must be
properly insulated, supported and cooled to withstand operational and

19
test conditions. Copper is primarily used as conductors in transformers
windings here.
Types of winding:
 Reverse section winding.
 Helical winding.
 Spiral winding.
 Interleaved winding.
 Half sectional winding.
There are four types of coil fixed in a transformer, they are:
1) Low voltage coil (LV).
2) High voltage coil (HV).
3) Tertiary coil.
4) Tap coil.
The type of winding depends upon on job requirement. Also, the width
and thickness of the conductors are designed particulars and are decided
by design department. Conductors used for winding is in the form of very
long wound on a spool, the conductor is covered by cellulose paper for
insulation.
For winding first the mould of diameter equal to inner diameter of
required coil is made. The specifications of coil are given in drawing. The
diameter of mould is adjustable as its body is made up of wooden

20
sections that interlock with each other. This interlocking can be increased
or decreased to adjust the inner diameter of coil.
The moulds are of following types:
1) Belly types.
2) Link types.
3) Cone types.

1.3.5 BAY-5:
It is core and punch sections. The lamination used in power, dry, ESP
transformers etc. for making core are cut in this section.
CRGO (Cold Rolled Grain Oriented) silicon steel is used for lamination,
which is imported in India from Japan, U.K. & Germany. It is available in
0.27 and 0.28mm thick sheets, 1m wide and measured in Kg. The sheets
are coated with very thin layer of insulating material called “caritas”.
For the purpose of cutting and punching the core three machines are
installed in shop:
1) SLITTING MACHINE: It is used to cut CRGO sheets in different width.
It has a circular cutter whose position can be changed as per the
requirement.
2) CNC CROPPING LINE PNEUMATIC: It contains only one blade, which
can rotate 90° above the sheet. It is operated pneumatically.
3) CNC CROPPING LINE HYDRAULIC: It is also used to cut CRGO sheets.
It contains two blades, one is fixed and the other rotates 90° above
the sheet. It is operated hydraulically.

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1.3.6 BAY-6:
Single-phase traction transformer for AC locomotives is assembled in this
section. The freight locomotive transformers are used where there is
frequent change in speed. In this bay core winding and all the assembly
and testing of traction transformer is done.
Three-phase transformers for ACEMU are also manufactured in this
section. The supply line for this transformer is of 25KV and power of the
transformer is 6500KVA.
The tap changer of rectifier transformer is also assembled in this bay.
Rectified transformer is used in big furnace like the thermal power
stations.

1.3.7 BAY-7:
This is the insulation shop. The various types of insulations used in the
transformers are given a proper shape and specification in this unit.
Various types of insulation materials are:
a) AWWW (All Wood Water Washed Press Paper): The paper is 0.2-
0.5mm thick cellulose paper and is wound on the conductor for
insulation.
b) PRE-COMPRESSED BOARD: This is widely used for general
insulation & separation of conductors in the forms of blocks.
c) PRESS BOARD: This is used for separation of coils e.g. L.V. form
H.V. It is up to 36mm thick.
d) UDEL: Un Demnified Electrical Lamination wood or Permawood.
This is special type of plywood made for insulation purposes.

22
 e) FIBRE GLASS: This is a resin material and is used in fire prone
areas.
f) BAKELITE: A kind of plastic insulator highly resistive of heat.
g) GASKET: It is used for the protection against leakage.
h) SILLICON RUBBER SHEET: It is used for dry type transformer.
The machines used for shaping the insulation material are:
a) Cylindrical machines
b) Circle cutting machine
c) Scarping machines
d) Punching press machines
e) Drilling machines
f) Guillotine machines
g) Bench saw (special for OD)
h) Jig saw (special for ID)
i) Circular saw
j) Lines in machines
The Cast Resin Dry Type Transformer (CRT) are also assembled here. As
we know the Dry Type transformer never uses any insulating liquid where
it’s winding with core be immerged. Rather windings with core are kept
within a sealed tank that is pressurized with air.
Cast Resin Dry Type Transformer (CRT) is used in the high moisture prone
areas. It is because of its primary and secondary windings are
encapsulated with epoxy resin. This encapsulation helps to prevent
moisture to penetrate to affect the winding material. Complete
protection is achieved by this cast resin encapsulation so that the
23
transformer can work without disruption in highly moisture prone area.
The insulation of these transformers are of insulation class F (90 C
temperature rise). Advantages of these transformers are:
1) Better over load capacity.
2) Low partial discharge along with low loss. Hence efficiency is very
good.
3) As it is with non-inflammable winding insulation, it offers zero risk to
fire hazard. So it is suitable for indoor installation.
4) Can be fitted outdoor in IP 45 enclosure.
5) This transformer is non hygroscopic.

1.3.8 BAY-8:
It is the Instrument transformer and ESP transformer manufacturing
section.
Instrument Transformer:
These are used for measurement. They are high accuracy class electrical
devices used to isolate or transform voltage or current levels. The most
common usage of instrument transformers is to operate instruments or
metering from high voltage or high current levels, safely isolating
secondary control circuitry from the high voltages or currents. The
primary winding of transformer is connected to the high voltage or
current circuit, and meter or relay is connected to secondary side. They
are used in AC systems for measuring of current, voltages and energy and
can also be used for measuring power factor, frequency and for
indication of synchronism. They find application in protection of power
systems & for the operation of over voltage, over current, earth fault and

24
various others types of relays. Also be used as an isolation transformer so
that secondary quantities may be used in phase shifting without affecting
other primary connected devices.
They are of two types:
1. Current Transformer: It is a series connected type of instrument
transformer. They are designed to present negligible load to the
supply being measured and have an accurate current ratio and
phase relationship to enable accurate secondary connected
metering.
The CT is typically described by its current ratio from primary to
secondary. Standard secondary current ratings are 5 amperes or 1
ampere, compatible with standard measuring instruments.

The primary circuit of a CT is generally a single turn winding (a bar

conductor) and carries the full load current. The secondary winding
of CT has large number of turns to limit the secondary current as per
the relation,

25
 𝑁𝑝 𝐼𝑠
=
𝑁𝑠 𝐼𝑝
The number of turns in winding is inversely proportional to the
current carried by that winding.
2. Voltage Transformer: They are parallel connected type of
instrument transformers. A Voltage Transformer (VT) may be
defined as an instrument transformer for the transformation of
voltage from a higher value to lower value. The voltage to be
measured or controlled is applied to the primary winding. The
terminals of the secondary winding are connected to the meter or
instrument. The standard voltage at secondary terminals is 110V.
ESP Transformer:
The Electro Static Precipitator transformer is used for environmental
application. It is used to filter in a suspended charge particles in the
waste gases of the industry. They are of particular use in thermal power
station and cement industry.

1.3.9 BAY-9:
In this bay power transformer are assembled. After taking different input
from different bays 0-9, assembly is done. Power transformer is used to
step down voltages at generation and sub stations. There are various
ratings: 11KV, 22Kv manufactured, they are:
a) Generator Transformer System
b) Auto Transformer

26
A transformer in a process of assembling is called job. The design of the
transformer is done by the design department and is unique of each job;
depends upon the requirement of the customer. The design department
provides drawing to the assembly shop, which assembles it accordingly.
The steps involved in assembly are:
 Core building
 Core lifting
 Unlacing & Core coil assembly
 Relacing & End frame mounting
 H.V.&L.V. terminal gear
 Vapor phasing & oil soaking
 Final serving and taking
 Case fitting

2 Locomotive section:
This section was introduced in 1985 and in 1987-88 they started
manufacturing diesel shunting locomotives and AC/DC locomotives.
Similar to Transformer section, Locomotive section also has three main
departments.

2.1 Locomotive Commercial (LMC):

The objective of this department is to interact with the customers related
to locomotives. It brings out tenders and notices and also responds to
them. It is this department that bags contracts of building locomotives.
After delivery regarding faults, this department does failures and
27
maintenance. All such snags are reported to them and they forward the
information to the concerning department.
The work of TRC & LMC is similar.
The main work of the LMC is classified as:
 Tenders and Notices.
 Interaction with design department.
 Place of the work.
 Approximate cost of the work.
 Earnest money.
 Place and time where contract documents can be seen.
 Place and time where tender documents can be obtained.
 Time up to which the documents will be sold.
 Amount if any to be paid for such documents.
 Place, date and time when tenders are to be submitted and are to
be opened.
 Any other information relevant in tender notices.

2.2 Locomotive Engineering (LME):

The locomotives manufactured in BHEL Jhansi are of different types. The
Engineering department does all the work related to designing,
estimation of cost and time in manufacturing that locomotive or its parts.

28
The designs & drawings that are provided to the LMM units for
manufacturing a locomotive are made by this department along with
given time to make that part. They also provide the necessary guidelines
to the workers to make the product effectively if necessary.

2.2.1 The Diesel Locomotive:

Salient features:
 Flatbed under frame

 All pneumatic valves provided in single panel

 All electrical equipments provided in single panel

 Improved filtration system

 Brush less traction alternators

 Fault display on control desk with alarm

 Simple driving procedure

 Automatic wheel slip detection & correction

 Multiple unit operation up to three locomotives

 Air & vacuum brakes

2.2.2 The AC Locomotive:

Salient features:
 Operate on 25 KV AC 1-Ø lines

29
  Driving cab at both ends
 Corridors on both sides for maintenance
 All pneumatic valves at one place
 Automatic wheel slip detection & correction
 Multiple unit operation up to three locomotives
 Fault display on driver’s desk
 VCB in AC circuit
 Air & vacuum brakes

2.2.3 The AC/DC Locomotive:

Salient features:
 Designed to operate both in 1500V DC & 25 KV AC lines
 Driving cabs at both ends
 High adhesion bogie
 Corridors on both sides for maintenance
 All pneumatic valves at one place
 Automatic wheel slip detection & correction
 Multiple unit operation up to three locomotives
 Fault display on driver’s desk
 Static inverter for auxiliary supply

30
  FRP control desk
 VCB in AC circuit
 Air & vacuum brakes
 Air dryer for brake system

2.3 Locomotive Manufacturing (LMM):

Locomotives of different types are manufactured/assembled in this
department. At present they are only manufacturing diesel shunting loco.
The designs fulfilling the specifications and requirements of customers
are provided by LME department.

3 Store:
All of the raw material that is imported here is kept in a place which is
given the name of store. The details related to the materials, company
which provide that materials etc. are also with the staff that is assigned in
this section. The details of the stock left in the store, how much raw
material they have to import, its cost, time etc. is handled by the staff in
this section. The commercial details related to the materials in store or to
be ordered is done by the commercial department.

4 Testing:
Testing is a way to ensure that the product that has been manufactured
meets the specified requirements or not. Various tests related to the
transformers that are manufactured here are carried in the respective
manufacturing section.
The materials that are used to manufacture the products are also tested
before putting into use in the testing lab.
31
The tests which are done at various production stages are also carried
out in the respective manufacturing section.

5 Quality Check:
There is also a separate department which ensures the quality of the
product under manufacturing or manufactured. They keep on regular
check on the quality of the various parts under process. Also the quality
of the material that is imported in the company is ensured by this
department.

32
 Power Transformer
Power transformers are used in generating stations or substations at
each end of power transmission line for stepping up or stepping down
the voltage. They are put in operations during load periods and are
disconnected during light periods. They are designed to have maximum
efficiency at or near full load. Power transformers are designed to have
considerably greater leakage reactance. For power transformers the
voltage regulation is less important than the current limiting effect of
higher leakage reactance.
Two winding transformers are generally used where ratio of high voltage
and low voltage is greater than 2. It is cost effective to use auto
transformer where the ratio between high voltage and low voltage is less
than 2. Again a single unit three phase transformer is more cost effective
than a bank of three single phase transformers unit in a three phase
system. But a single three phase transformer unit is a bit difficult to
transport and have to be removed from service entirely if one of the
phase winding breaks down.

Need of Power Transformer

Electrical power is generated at low voltage level as it is very much cost
effective. Theoretically, this low voltage level power can be transmitted
to the receiving end. But if low voltage power is transmitted through
transmission lines it will result in greater line current which indeed causes
more line losses. To minimize the losses the voltage level of a power is
increased, which reduces the current of the power which causes
reduction in ohmic or I2R losses in the system. This reduction in line
33
current reduces the cross sectional area of the conductor i.e. reduction in
capital cost of the system and it also improves the voltage regulation of
the system. Because of these, low level power must be stepped up for
efficient electrical power transmission. This is done by step up
transformer at the sending side of the power system network. As this
high voltage power may not be distributed to the consumers directly, this
must be stepped down to the desired level at the receiving end with the
help of step down transformer. Electrical power transformer thus plays a
vital role in power transmission.

Manufacturing of Power Transformer (Assembly and testing)

1. Operations performed during the assembly of the power transformer

are
a. Core building
b. Unlacing of core
c. Core-Coil assembly
d. Relacing of core
e. Terminal-gear assembly
f. Primary testing
i. Resistance test
ii. Ratio test
iii. 2 kV test
g. Processing
h. Tanking
i. Case fitting
2. After these operations final testing of the transformer is done
34
a. Flash test
b. Transformer Ratio test
c. Magnetizing current
d. Magnetic balance
e. Transformer Winding Resistance Measurement
f. Vector group test
g. Insulation Resistance Test or Megger test
h. Open circuit test
i. Short circuit test
j. Over potential test
k. Temperature rise test
l. Noise level
m. Tan and capacitance
n. Harmonics test
o. Impulse test
p. Vector group test

35
1 Assembly of Power Transformer
1.1Core of Transformer: A brief idea
1.1.1 Purpose of core
In an electrical transformer, there are primary, secondary and may be
tertiary windings. The performance of a transformer mainly depends
upon the flux linkages between these windings. For efficient flux linking
between these windings, one low reluctance magnetic path common to
all windings should be provided in the transformer. This low reluctance
magnetic path in transformer is known as core of transformer.

1.1.2 Material for transformer core

The main problem with the transformer core is, it’s Hysteresis and Eddy
current loss.
Hysteresis loss in transformer mainly depends upon its core materials. It
is found that, a small quantity of silicon alloyed with low carbon content
steel produces material for transformer core, which has low hysteresis
loss and high permeability. Because of increasing demand of power, it is
required to further reduce the core losses and for that, another
technique is employed on steel, which is known as cold rolling. This
technique arranges the orientation of grain in ferromagnetic steel in the
direction of rolling. The core steel which has under gone through both
the silicon alloying and cold rolling treatments is commonly known as
CRGOS or Cold Rolled Grain Oriented Silicon Steel. This material is now
universally used for manufacturing transformer core. Although this
material has low specific iron loss but still, it has some disadvantages,
like, it is susceptible to increase loss due to flux flow in direction other
than grain orientation and it is also susceptible to impaired performance
36
due to impact of bending and blanking the cutting CRGOS sheet. Both the
surfaces of the sheet are provided with an insulating of oxide coating.
Since Hysteresis loss depends on the material of the core they are
minimized by using CRGOS.
In transformer, we supply alternating current in the primary, this
alternating current produces alternating magnetizing flux in the core and
as this flux links with secondary winding, there will be induced voltage in
secondary, resulting current to flow through the load connected with it.
Some of the alternating flux of transformer, may also link with other
conducting parts like steel core or iron body of transformer etc. As
alternating flux links with these parts of transformer, there would be a
locally induced emf. Due to these emf, there would be currents which will
circulate locally at that parts of the transformer. These circulating
currents are known as Eddy Currents. They will not contribute in output
of the transformer but dissipate as heat. This type of energy loss is called
Eddy Current loss of transformer.
In order to reduce the eddy current loss, the resistance of the core should
be increased. In other words, low reluctance should be retained. So the
core of the transformer is made up of laminations of CRGOS, each
lamination being insulated from others. As the laminations are thin, they
will have relatively high resistance. Each lamination sheet will have an
eddy current circulating within it but the sum of individual eddy current
of the laminations are very less as compared to that of using single solid
iron core.
Eddy Current loss are minimized by using thin sheets called laminations
for designing the core.

37
1.1.3 Influence of diameter of core
Let us consider, the diameter of transformer core be ′D′ Then, cross-
sectional area of the core,
𝜋𝐷2
𝐴=
4
Now, voltage per turn,
𝐸 = 4.44∅𝑚 𝑓
𝐸 = 4.44𝐵𝑚 𝐴𝑓
where 𝐵𝑚 is the maximum flux density of the core.
4.44𝜋𝐵𝑚 𝐷2 𝑓
𝐸=
4
⇒ 𝐸 ∝ 𝐷2
Therefore voltage per turn is increased with increase in diameter of
transformer core.
Again if voltage across the winding of transformer is V.
𝑉 = 𝐸𝑁
Where, N is the number of turns in winding.
If V is constant, then
1
𝑁∝
𝐸
1
⇒𝑁∝ 2
𝐷
So, if diameter of the core is increased, the number of turns in the
transformer winding is reduced. Reduction of number of turns, results in
38
the reduction of height of the core legs. In-spite of reduction of core leg’s
height increased core diameter, results in the increase in overall diameter
of magnetic core of transformer.
This increased steel weight ultimately leads to increased core losses in
transformer.
Increased diameter of the core leads to increase in the main diameter on
the winding. In-spite of increased diameter of the winding turns, reduced
number of turns in the windings, leads to less copper loss in transformer.
So, we go on increasing diameter of the transformer core, losses in the
transformer core will be increased but at the same time, load loss or
copper loss in transformer is reduced.
On the other hand, if diameter of the core is decreased, the weight of
the steel in the core is reduced, which leads to less core loss of
transformer, but in the same time, this leads to increase in number of
turns in the winding, means increase in copper weight, which leads to
extra copper loss in transformer.
So, diameter of the core must be optimized during designing of
transformer core, considering both the aspects.
As it is clear that we cannot use a single solid core for transformer
instead we have to use laminations of CRGOS for making the core of the
transformer. So how they are stacked together to make the core is given
in the sections below.

1.1.4 Optimum design of cross-section of core

The maximum flux density of CRGO steel is about 1.9 Tesla. Means the
steel becomes saturated at the flux density 1.9 Tesla. One important

39
criteria for the design of transformer core, is that, it must not get
saturated during the transformer’s normal operation mode. Voltages of
transformer depend upon its total magnetizing flux. Total magnetizing
flux through core is nothing but the product of flux density and cross-
sectional area of the core.
Hence, flux density of a core can be controlled by adjusting the cross
sectional area of the core during its design.
The ideal shape of cross-section of a transformer core is circular.
For making perfect circular cross section, each and every successive
lamination steel sheet should be cut in different dimension and size. This
is absolutely uneconomical for practical manufacturing. In reality,
manufacturers use different groups or packets of predefined number of
same dimension lamination sheets. The group or packet is a block of
laminated sheets with a predefined optimum height (thickness). The core
is an assembly of these blocks in such a successive manner as per their
size from core central line, that it gives an optimum circular shape of the
cross-section. Such typical cross-section is shown in the figure below.
Oil ducts are needed for cooling the core. Cooling ducts are necessary
because hot-spot temperature may rise dangerously high and their
number depends on the core diameter and materials that get used for
core.

40
 Lamination
Blocks

Oil Ducts H
Fig. a

Clamp Plates

In addition to that, clamp plates made of steel are needed on either sides
of the core to clamp the lamination. The steel sheet lamination blocks, oil
ducts, and clamping plates, all should lie within the peripheral of
optimum core circle. The net sectional area is calculated from the
dimensions of various packets and allowance is made for the space lost
between lamination (known as stacking factor) for which steel sheet of
0.28 mm thickness with insulation coating is approximately 0.96. Area is
also deducted for oil ducts.
The ratio of net cross sectional area of core to the gross cross - sectional
area inside the imaginary peripheral circle is known as Utilization factor
of transformer core. Increasing numbers of steps improve the Utilization
factor but at the same time, it increases manufacturing cost. Optimum
numbers of steps are between 6 (for smaller diameter) to 15 (larger
diameter).
41
1.1.5 Corner Jointing of Limbs with Yokes
Core losses in transformer happen mainly due to,
1. Magnetic flux flow along the direction of the grain orientation,
2. Magnetic flux flow perpendicular to the direction of the grain
orientation, this is also known as cross grain iron losses. The cross grain
loss mainly occurs in the zones of corner jointing of limbs with yokes and
it can be controlled to some extent by applying special corner jointing
techniques.
There are normally two types of joints used in transformer core
1. Interleaved joints
2. Mitred joints
Interleaved Joints
Interleaved joint in transformer core is the simplest form of joints. This
joint is shown in the figure. The flux leaves and enters at the joint
perpendicular to grain orientation.

Fig. b

42
Hence cross grain losses are high in this type of joints. But considering the
low manufacturing cost, it is preferable to use in small rating transformer.

Mitred Joints
Here the lamination's are cut at 45°. The limbs and yoke lamination edges
are placed face to face at the Mitred joints in transformer core. Here the
flux enters and leaves the lamination, gets smooth path in the direction
of its flow. Hence, cross grain loss is minimum here.

Fig. c

However it involves extra manufacturing cost but it is preferable to use in

electrical power transformer where loss minimization is the main criteria
in designing of transformer core.

1.1.6 Core building

The CRGOS sheets which are of about 0.28mm thickness are cut into four
shapes for making the core of three limbs core for single phase
transformer with the help of CNC machine which is in BAY-05 of this unit.

43
The Four shapes of the cutting of the sheets are shown below:

Yoke

Centre
Side

Fig. d Limb

Fish

44
The cuttings shown in Fig.d are stacked together to make a core of
transformer of cross-section as shown in Fig.a and the forming a shape of
three limb core as shown in Fig.c.
During core manufacturing in factory some factors are taken into
consideration,
1. Higher reliability.
2. Reduction in iron loss in transformer and magnetizing current.
3. Lowering material cost and labor cost.
4. Abatement of noise levels.
Quality checking is necessary at every step of manufacturing to ensure
quality and reliability. The lamination should be properly checked and
inspected visually, rusty and bend lamination should be rejected. For
reducing the transformer noises, the lamination should be tightly
clamped together and punch holes should be avoided as far as possible to
minimize cross flux iron losses. The air gap at the joint of limbs and yokes
should be reduced as much as possible for allowing maximum smooth
conducting paths for magnetizing current.

45
The picture shows the cuttings of CRGOS in different dimensions and how
they are put for making the core. These sheets are stacked to make the
core of transformer using end frames and are tightly held by fitting
circular rods of Permawood in the steps formed during stacking and then
wound using the tape.

46
A core after stacking and clamping is shown in the picture.

1.2Coil winding
The winding consist of the current carrying conductors wound around the
sections of the core, and these must be properly insulated, supported
and cooled to withstand operational and test conditions. Copper is
primarily used as conductors in transformers windings here. The copper
which is used is paper covered rectangular copper conductor.
Types of winding:
 Reverse section winding.
 Helical winding.
 Spiral winding.
 Interleaved winding.
47
  Half sectional winding.
1. R-S Winding:
In this winding one section is given the reverse winding while one
section is given the forward winding. This can be manufactured is
various sizes say five parallel or two parallel conductors as suggested
by the designer. The layer depth or LD of the winding is defined as the
number of turns to the number of segments available in the section.
Generally one to eight numbers of conductors are used in this kind of
winding.
2. Helical Winding:
It is winded in shape of a spring. Here the numbers of conductor are
more in numbers than others and all are insulated from each other in
order to reduce EDDY current losses. Transposition in this kind of
winding is done to make the conductors equal in length so that no
possibility of spark should be there due to differences of voltages
induced due to length of conductors. Two kinds of transposition are
usually done in this kind of winding:
1) Section wise transpose
2) Three numbers of transpose are provided in between
conductor turns
3. Spiral Winding:
This is the simplest kind of winding the conductors are simply wounded
on the base. The side from where the winding is started is known as
the start lead and where it is finished is known as the finish lead.
4. Half sectional Winding:

48
 These kind of coil can be classified on the basis of winding direction if
the winding is started by rotation of conductors in anticlockwise
direction it is known as standard half sectional coil whereas if the
rotation is clock wise it is termed as non-standard half sectional coil.
The brazing leads required in some cases of the transformer are also
provided in this kind of the winding.
5. Interleaved Winding:
In some cases the conductors are wounded in such a fashion that the
interleaved winding current rotates in same conductor. When
interleaved the number of conductor gets doubled than initial number.
After that section is made the conductors are connected using entries.
6. Composite Winding:
In this kind of winding more than one conductor is winded with
other on the same machine. These windings are generally used for
the purpose of tapped coils.
Terms connected with the windings are:
1. ID: This is known as the inner depth or diameter of the coil. This is
basically the width of the base on which the conductors are
wounded.
2. OD: This is known as the outer depth or diameter of the coil. This is
basically the width of the wounded conductors starting from first
turn to the last turn.
3. MD: This is known as the mould diameter and same as the ID or
inner depth of the coil.
4. CD: This is known as the coil dimension and is basically taken as the
length measured form starting lead point to the finishing lead point.

49
The coils that are presently used for the power transformer are reverse
section wound.

1.3Unlacing of the core

The coils are wound in the BAY-4 section and the core is assembled in
either BAY-2 or BAY-9 section. Now in order to put the coil in core some
part of the core has to be removed. So the top end frame of the core is
removed and the yoke of the transformer core i.e. the sheets of CRGOS
from the upper part of the core are removed one by one so as to obtain a
shape of the core as shown in Fig.e.

Fig. e

50
The main purpose of unlacing the core is to remove the top end frame
and yoke of the core. An unlaced core is shown in the picture below:

1.4 Core-Coil Assembly:

After the unlacing of the core the core is kept in the erect position and
coils are lowered/mounted on the core. Before lowering the coil over the
core the bottom insulation which separates the core and coils is fitted.

51
The coils are that present in the power transformer are also insulated
from one another using press board and blocks of wood. The picture
below shows the insulation between two coils. The press board is also
wound by using tapes.

52
1.5Relacing of Core:
After the coils have been mounted on the core the top yoke is again
attached to the rest of the core, this process is known as the relacing of
the core. Before relacing top insulation to separate the coils from the top
yoke is also inserted. The sheets are attached one by one or in packets to
the core limbs in erect position.

1.6Terminal Gear Assembly:

In TG stages the various connections of leads are completed. The
connections available in this stage are either of the following two types
or a combination of these two types:
1. Star Connection: Also called Wyes winding. Each phase terminal
connects to one end of a winding and other end of a winding
connects to other at a central point, so that the configuration
resembles a capital letter Y. The central point may or may not be
connected outside of the transformer.
53
 2. Delta Connection: Also called mesh winding. In delta connection the
bottom position lead of one coil is joined to the top or starting
position lead of the second coil and the bottom lead of second coil
are joined to top lead of the third coil and the top lead of the first
coil is connected to bottom lead of third coil.
In H.V. side the H.V. main lead is taken out and the various tap leads
are then joined to OLTC (On Load Tap Changer) through conductors
either copper leads or bus bars.

The copper leads or bus bars used during TG assembly are insulated
using Crepe paper.
The conductors to the tap changer can be observed in the H.V. marked
in numbers these are then connected to the tap changer. All the leads
are properly brazed for accurate connections so that same amount of
current flows through each conductor and the ratio can be achieved. In
L.V. side the bottom leads of the L.V. coils are joined together to form
neutral. Whereas the top lead positions are taken out for respective 3-
Ø connection.

1.7Processing and Dry Out:

The paper insulation and pressboard material, which make up a
significant proportion by volume of transformer windings, have the
54
capacity to absorb large amounts of moisture from the atmosphere. The
presence of this moisture brings about a reduction in the di-electric
strength of the material and also an increase in its volume.
The final drying out is commenced either when the core and windings are
placed or when they are fitted into tank, all main connections made, and
the tank placed in an oven and connected to the drying system. The
tapping switch may be fitted at this stage, or later, depending on the
ability of the switch components to withstand the drying process.

1.8Tanking:
The tank gives mechanical protection to the windings and core and also
provide weather protection. It holds the insulating oil that insulates the
windings and acts as a cooling agent. The tanks are made of steel. In
tanking the assembled job after terminal gear assembly and processing is
put into the tank and oil is filled.
The tank cover is designed to prevent water collection and the raised
flanges are provided to prevent water entry.

1.8.1 Transformer Oil

Insulating oil in an electrical power transformer is commonly known as
transformer oil. It is normally obtained by fractional distillation and
subsequent treatment of crude petroleum. That is why this oil is also
known as mineral insulating oil. Transformer oil serves mainly two
purposes one it is liquid insulation in electrical power transformer and
two it dissipates heat of the transformer i.e. acts as coolant. In addition
to these, this oil serves other two purposes, it helps to preserve the core
and winding as these are fully immersed inside oil and another important
purpose of this oil is, it prevents direct contact of atmospheric oxygen
55
with cellulose made paper insulation of windings, which is susceptible to
oxidation.
The transformer oil used here is provided by the Poweroil.

1.8.1.1 Parameters of Transformer Oil

The parameters of transformer oil are categorized as,
1. Electrical parameters: Dielectric strength, specific resistance,
dielectric dissipation factor.
2. Chemical parameter: Water content, acidity, sludge content.
3. Physical parameters: Inter facial tension, viscosity, flash point,
pour point.
1.8.1.2 Loss Angle
Dielectric dissipation factor is also known as loss factor or tan delta of
transformer oil. When an insulating materials is placed between live part
and grounded part of an electrical equipment, leakage current will flow.
As insulating material is dielectric in nature the current through the
insulation ideally leads the voltage by 90. Here voltage means the
instantaneous voltage between live part and ground of the equipment.
But in reality no insulating materials are perfect dielectric in nature.
Hence current through the insulator will lead the voltage with an angle

56
little bit shorter than 90°.
Tangent of the angle by which it is short of 90° is called dielectric
dissipation factor or simply tan delta of transformer oil. More clearly, the
leakage current through an insulation does have two component one is
capacitive or reactive and other one is resistive or active. Again it is clear
from above diagram, value of ′δ′ which is also known as loss angle, is
smaller, means resistive component of the current IR is smaller which
indicates high resistive property of the insulating material. High resistive
insulation is good insulator. Hence it is desirable to have loss angle as
small as possible. So we should try to keep the value of tanδ as small as
possible. High value of this tanδ is an indication of presence of
contaminants in transformer oil. Hence there is a clear relationship
between tanδ and resistivity of insulating oil. If resistivity of the insulating
oil is decreased, the value of tan-delta increases and vice versa. So both
resistivity test and tan delta test of transformer oil are not normally

57
required for same piece of insulator or insulating oil. In one sentence it
can be said that, tanδ is measure of imperfection of dielectric nature of
insulation materials like oil.

1.9Case Fitting:
After tanking the accessories of the transformer are fixed to give the final
touch to the job. Also the terminals for low, high and tap changing
terminals are brought out of the tank by using bushings.

1.9.1 Conservator Tank of a Transformer

This is a cylindrical tank mounted on supporting structure on the roof the
transformer main tank. The main function of conservator tank of
transformer is to provide adequate space for expansion of oil inside the
transformer.
58
1.9.1.1 Function of Conservator Tank of a Transformer
When transformer is loaded and when ambient temperature rises, the
volume of oil inside transformer increases. A conservator tank of
transformer provides adequate space to this expanded transformer oil. It
also acts as a reservoir for transformer insulating oil.
1.9.1.2 Construction of Conservator Tank
This is a cylindrical shaped oil container closed from both ends. One large
inspection cover is provided on either side of the container to facilitate
maintenance and cleaning inside of the conservator.

Conservator pipe, i.e. pipe comes from main transformer tank, is

projected inside the conservator from bottom portion. Head of the
conservator pipe inside the conservator is provided with a cap. This pipe
is projected as well as provided with a cap because this design prevent oil
sludge and sediment to enter into main tank from conservator. Generally
silica gel breather fixing pipe enters into the conservator from top. If it
enters from bottom, it should be projected well above the level of oil
59
inside the conservator. This arrangement ensure that oil does not enter
the silica gel breather even at highest operating level.
1.9.1.3 Working of Conservator Tank
When volume of transformer insulating oil increases due to load and
ambient temperature, the vacant space above the oil level inside the
conservator is partially occupied by the expanded oil. Consequently,
corresponding quantity of air of that space is pushed away through
breather. On other hand, when load of transformer decreases, the
transformer is switched off and when the ambient temperature
decreases, the oil inside the transformer contracts. This causes outside
air to enter in the conservator tank of transformer through silica gel
breather.

1.9.2 Buchholz relay

The provision of a conservator also permits the installation of a Buchholz
relay. This is installed in the run of pipe connecting the conservator to the
main as shown in figure below. In this location, relay collects any gas
produced by a fault inside the tank. The presence of this gas causes a
float to be depressed which is then arranged to operate a pair of contacts
which can be set to ‘alarm’. In order to ensure that any gas evolved in the
tank is vented to the conservator it is necessary to vent every high point
on the tank cover.

60
1.9.3 Bushings:
A bushing is a mean of bringing an electrical connection from the inside
to the outside of the tank. It provides the necessary insulation between
the winding electrical connection and enabling the necessary vacuum to
be drawn for the purpose of oil impregnation of the windings. It must
ensure freedom from leaks during the operating lifetime of the
transformer and be capable of maintaining electrical insulation under all
condition such as rain, ice and fog and has to provide the required
current-carrying path with an acceptable temperature rise. There is a
current carrying stem usually of copper and the insulation is provided by
a combination of the porcelain shell and the transformer oil.
Before fitting the bushings on the transformer, they should be checked
for any damage or crack. Bushings are normally delivered in complete
assembled form.

61
1.9.4 Motor Driving Unit
The main function of this unit is to operate the tap changer. Using this
unit the tap changer can be operated manually and required voltage can
be achieved.

1.9.5 Explosion Vent of Transformer

The purpose of the explosion vent in a transformer is to prevent damage
of the transformer tank be releasing any excessive pressure generated
inside the transformer.
1.9.5.1 Construction of Explosion Vent of Transformer
This is nothing but a bent pipe with thin aluminum diaphragms at both
ends. A wire mesh is provided at lower end of the explosion vent to
prevent the pieces of rutted diaphragm from entering the tank. A wire
mesh is also provided at upper end of vent pipe to protect mechanical

62
damages of upper diaphragm. Near the lower end, a small oil level
indicator is provided to lower diaphragm ruptures; transformer oil rises in
the vent pipe and is visible through the indicator indicating the failure of
the lower diaphragm. If even after brushing the lower diaphragm, there is
enough pressure and is not reduced, the upper diaphragm then bursts
out to give way to release the inside pressure of transformer tank by
thronging out oil and gases. In this way, explosion vent of transformer
prevents mechanical damage to the transformer tank. Sometimes, upper
portion of conservator tank is connected with explosion vent with an
equalizer pipe with or without a valve.

1.9.6 Cooling Equipment

When an electric transformer is loaded, the current starts flowing
through its windings. Due to flowing of electric current, heat is produced
in the windings, this heat rises the temperature of the transformer oil.
We know that the rating of any electrical equipment depends upon its
allowable temperature rise limit. Hence, if the temperature rise of
transformer oil is controlled, the capacity or rating of the transformer can
be extended upto significant range. The radiator of the transformer
accelerates the cooling rate of the transformer. Thus, it plays a vital role
in increasing loading capacity of an electrical transformer. They just
increases the surface area for dissipating heat of the oil.
Oil immersed power transformer is generally provided with detachable
pressed sheet radiator with isolating valves.

63
1.9.7 Nitrogen in Transformers
Oil filled Transformers usually have a conservator which maintains the
level of oil. The conservator has a layer of air on top of the oil. This air
communicates with the atmosphere through a breather containing a
desiccant, usually, silica gel.
In some transformers, the tank of the transformer is filled with a layer of
nitrogen above the oil in which the windings and the core are immersed.
Nitrogen, being an inert gas, reduces the risk of a fire hazard. It also
protects the transformer oil and the transformer insulation from reacting
with oxygen in the air and deteriorating.
In transformers containing nitrogen, the nitrogen is led into the space
above the conservator through a pressure reducing valve. When the oil
level in the transformer rises and the transformer breathes out, the
nitrogen inside is released into the atmosphere. When the oil levels fall
due to a reduction in ambient temperature or the load, fresh nitrogen is
released into the conservator through the cylinder and the valves.
After all the steps a power transformer looks like as shown in the picture
below:
After the assembly of the power transformer final testing is carried out to
ensure proper working of the transformer, some of the tests are given
below:

64
2 Final Testing
2.1Transformer Ratio Test
The performance of a transformer largely depends upon perfection of
specific turns or voltage ratio of transformer. So transformer ratio test is
an essential type test of transformer. This test also performed as routine
test of transformer. So for ensuring proper performance of electrical
power transformer, voltage and turn ratio test of transformer one of the
vital tests.
The procedure of transformer ratio test is simple. We just apply three
phase 415 V supply to HV winding, with keeping LV winding open. Then
we measure the induced voltages at HV and LV terminals of transformer
to find out actual voltage ratio of transformer. We repeat the test for all
tap position separately.

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2.2Magnetic Balance Test of Transformer
Magnetic balance test of transformer is conducted only on three phase
transformers to check the imbalance in the magnetic circuit.
Procedure of Magnetic Balance Test of Transformer:
1. First keep the tap changer of transformer in normal position.
2. Now disconnect the transformer neutral from ground.
3. Then apply single phase 230 V AC supply across one of the HV
winding terminals and neutral terminal.
4. Measure the voltage in two other HV terminals in respect of
neutral terminal.
5. Repeat the test for each of the three phases.
In case of auto transformer, magnetic balance test of transformer should
be repeated for LV winding also.

2.3Vector Group Test of Transformer

In three phase transformer, it is essential to carry out a vector group test
of transformer. Proper vector grouping in a transformer is an essential
criteria for parallel operation of transformers.
There are several internal connection of three phase transformer are
available in market. These several connections gives various magnitudes
and phase of the secondary voltage; the magnitude can be adjusted for
parallel operation by suitable choice of turn ratio, but the phase
divergence cannot be compensated. So we have to choose those
transformer for parallel operation whose phase sequence and phase
divergence are same. All the transformers with same vector ground have
same phase sequence and phase divergence between primary and

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secondary. So before procuring one electrical power transformer, one
should ensure the vector group of the transformer.

2.4Temperature Rise Test of Transformer

Temperature rise test of transformer is included in type test of
transformer. In this test we check whether the temperature rising limit of
the transformer winding and oil as per specification or not. In this type
test of transformer, we have to check oil temperature rise as well as
winding temperature rise limits of an electrical transformer.

2.5Insulation Resistance Test or Megger Test of

Transformer
Insulation resistance test of transformer is essential type test. This test is
carried out to ensure the healthiness of overall insulation system of an
electrical power transformer.
Procedure of Insulation Resistance Test of Transformer
1. First disconnect all the line and neutral terminals of the transformer.
2. Megger leads to be connected to LV and HV bushing studs to
measure insulation resistance IR value in between the LV and HV
windings.
3. Megger leads to be connected to HV bushing studs and transformer
tank earth point to measure insulation resistance IR value in
between the HV windings and earth.
4. Megger leads to be connected to LV bushing studs and transformer
tank earth point to measure insulation resistance IR value in
between the LV windings and earth.

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2.6Method of Tan Delta Testing
The cable, winding, current transformer, potential transformer,
transformer bushing, on which tan delta test or dissipation factor test to
be conducted, is first isolated from the system. A very low frequency test
voltage is applied across the equipment whose insulation to be tested.
First the normal voltage is applied. If the value of tan delta appears good
enough, the applied voltage is raised to 1.5 to 2 times of normal voltage,
of the equipment. The tan delta controller unit takes measurement of tan
delta values. A loss angle analyzer is connected with tan delta measuring
unit to compare the tan delta values at normal voltage and higher
voltages, and analyze the results. During test it is essential to apply test
voltage at very low frequency.

2.7Impulse test
Lighting is a common phenomenon in transmission lines because of their
tall height. This lightning stroke on the line conductor causes impulse
voltage. The terminal equipment of transmission line such as power
transformer then experiences this lightning impulse voltages. Again
during all kind of online switching operation in the system, there will be
switching impulses occur in the network. The magnitude of the switching
impulses may be about 3.5 times the system voltage. Insulation is one of
the most important constituents of a transformer. Any weakness in the
insulation may cause failure of transformer. To ensure the effectiveness
of the insulation system of a transformer, it must confirms the dielectric
test. But the power frequency withstand test alone cannot be adequate
to demonstrate the dielectric strength of a transformer. That is why
impulse test of transformer performed on it.
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2.8Transformer Winding Resistance Measurement
Transformer winding resistance measurement is carried out to calculate
the I2R losses and to calculate winding temperature at the end of a
temperature rise test. It is carried out as a type test as well as routine
test. It is also done at site to ensure healthiness of a transformer that is
to check loose connections, broken strands of conductor, high contact
resistance in tap changers, high voltage leads and bushings etc.
There are different methods for measuring of transformer winding,
likewise
 Current voltage method of measurement of winding resistance.
 Bridge method of measurement of winding resistance.
 Kelvin bridge method of Measuring Winding Resistance.
 Measuring winding resistance by Automatic Winding Resistance
Measurement Kit.

2.9Magnetizing Current Test of Transformer

Magnetizing current test of transformer is performed to locate defects in
the magnetic core structure, shifting of windings, failure in turn to turn
insulation or problem in tap changers. These conditions change the
effective reluctance of the magnetic circuit, thus affecting the current
required to establish flux in the core.
1. First of all keep the tap changer in the lowest position and open all
IV & LV terminals.
2. Then apply three phase 415 V supply on the line terminals for three
phase transformers and single phase 230 V supply on single phase
transformers.
3. Measure the supply voltage and current in each phase.
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 4. Now repeat the magnetizing current test of transformer test with
keeping tap changer in normal position.
5. And repeat the test with keeping the tap at highest position.
Generally there are two similar higher readings on two outer limb phases
on transformer core and one lower reading on the Centre limb phase, in
case of three phase transformers. An agreement to within 30% of the
measured exciting current with the previous test is usually considered
satisfactory. If the measured exciting current value is 50 times higher
than the value measured during factory test, there is likelihood of a fault
in the winding which needs further analysis.

3 Dispatch
After successful completion of testing, transformer is handed over to
dispatch sections.

At this stage after checking oil leakage, dismantling of all bushings,

turrets etc. and covered with the blanking plates and the tank is fitted
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with nitrogen gas and then the transformer is dispatched to the
concerned site.
Conclusion
This report gives the idea about the various departments of BHEL, Jhansi.
The assembly of the power transformer, its parts and their working and
some of its test are also given in this report.
This report can provide a general idea of how a power transformer is
manufactured.
BHEL, Jhansi although a smaller unit in comparison to other units of BHEL,
is a very productive one with the manufacturing of the electric
locomotives, power transformers etc.
The work load here can be accessed from the fact that the order of the
locomotives has forced the company to shift its Bus Duct section to other
unit of BHEL.

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 References:

 Guidance from the technical staff and working staff of BHEL,

Jhansi
 Ashfaq Hussain, Electric Machines, Second Edition, Dhanpat
Rai& Co.
 J.B. Gupta, Electrical Machines
 www.bhel.com
 www.wikipedia.org
 www.bheljhs.com
 www.eletrical4u.com
 www.quora.com
 electrical-engineering-portal.com
 answers.yahoo.com

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