Production and Design of Transformer

A PROJECT REPORT
Submitted in partial fulfilment of the requirements for the award of the degree

of

BACHELOR OF TECHNOLOGY (B.Tech.)

in
Electrical Engineering

Submitted by

Athunuru Durga Prudvinadh Reddy

149106660

Under the Supervision of

Mr. Mahipal Bukya Mr. S.V. Subba Reddy Mr. Devander

Assistant Professor Senior Manager Manager
EEE Department Design Department Production Department
Manipal University Jaipur Hammond Power Solutions Hammond Power Solutions

DEPARTMENT OF ELECTRICAL ENGINEERING

MANIPAL UNIVERSITY JAIPUR
JAIPUR-303007
RAJASTHAN, INDIA

JULY 2019
 DEPARTMENT OF ELECTRICAL ENGINEERING
MANIPAL UNIVERSITY JAIPUR, JAIPUR – 303 007 (RAJASTHAN), INDIA

JAIPUR

Date:________________

CERTIFICATE

This is to certify that the project titled Production and Design of Transformer is a record of the
bonafide work done by Athunuru Durga Prudvinadh Reddy (149106660) submitted in partial
fulfilment of the requirements for the award of the Degree of Bachelor of Technology (B.Tech) in
Electrical & Electronics Engineering of Manipal University Jaipur, during the academic year
2018-19.

Mr. Mahipal Bukya

Assistant professor, Dept of Electrical Engineering
Manipal University Jaipur

Dr. Amit Soni

HOD, Dept of Electrical Engineering
Manipal University Jaipur
 ACKNOWLEDGMENTS

I underwent training program of 4 months from 28th of January 2019 to 28th of May 2019 in Hammond Power
Solutions which is the leading transformer company in India and the largest manufacturer of dry-type transformers
in North America and more than 100 years old company. For this training program I would like to thank
Mr.Devander, Manager, Production Department / Mr. S.V. Subba Reddy, Senior Manager, Design
Department / S.P.Rao, Manager, HR Department of the Hammond Power Solutions who arranged the training
for me. And also I would like to thank the whole staffs of the company for their guidance and kind supervision and
who cooperate with me.

I am also thankful to Dr. Amit Soni, Head Of Department,Dept of Electrical Engineering, Manipal University
Jaipur and Mr. Mahipal Bukya, Assistant professor, Dept of Electrical Engineering, Manipal University
Jaipur who filled confidence in me to go ahead in my life and face all difficulties with courage.

Athunuru Durga Prudvinadh Reddy

149106660

i
 ABSTRACT

A transformer is a device that transfers electrical energy from one circuit to another by magnetic coupling without
requiring relative motion between its parts. It usually comprises two or more coupled windings, and, in most cases,
a core to concentrate magnetic flux. An alternating voltage applied to one winding creates a time-varying magnetic
flux in the core, which induces a voltage in the other windings. Varying the relative number of turns between primary
and secondary windings determines the ratio of the input and output voltages, thus transforming the voltage by
stepping it up or down between circuits. The transformer principle was demonstrated in 1831 by Faraday, though
practical design did not appear until the 1880s.Within less than a decade, the transformer was instrumental during
the "War of current" in seeing alternating current systems triumph over their direct current counterparts, a position
in which they have remained dominant. By transforming electrical power to a high voltage, low current form and
back again, the transformer greatly reduces energy losses and so enables the economic transmission of power over
long distances. It has thus shaped the electricity supply industry, permitting generation to be located remotely from
points of demand. Amongst the simplest of electrical machines, the transformer is also one of the most efficient, with
large units attaining performances in excess of 99.75%. Transformers come in range of sizes from a thumbnail- sized
coupling transformer hidden inside a stage microphone to huge giga VA-rated units used to interconnect portions of
national power grids. All operate with the same basic principles and with many similarities in their parts, though a
variety of transformer designs exist to perform specialized roles throughout home and industry.

To produce a transformer there are certain steps to be followed, first you need to design a transformer with required
power ratios for different transformers. The transformer is designed using TDPro software with 100% accuracy with
high efficiency and low power losses.
Then we need start making different parts of transformers as followed Fabrication Shop, Core And Core Assembly,
Coil Windings, Coil Assembly, Core Coil Assembly, Transformer Tank, Tank Up, Oil Filling Process, Testing Of
Transformer, Accessories, Marshalling Box, Bushing, Cooling Of Transformer, Properties Of Transformer, Oil
Painting And Fittings. Before all this prosses we need check the quality ( QC – Quality Control ) of all the materials
used in the transformers.

ii
LIST OF FIGURES

Figure No Figure Title Page No

01 Operating Principle of Transformer 02
02 Small Transformers 03
03 Large Transformer 05
04 Vertical and horizontal cooling channel 05
05 Magnetic Fields 05
06 Power Transformer 07
07 Distribution Transformer 07
08 Furnace Transformer 07
09 Converter Transformer 08
10 Regulating Transformer 08
11 Multi-Pulse Transformer 08
12 Transformer Parts 09
13 Input & Output Currents 11
14 Flat Wires 12
15 Core Measurements 12
16 Core Files 13
17 Steel Data 13
18 Environment Measurements 14
19 Diverse 14
20 Running Program 15
21 Diagnosis 15
22 Magnetic Field & Temperature of The Core 16
23 Input 17
24 Core 18
25 Winding 19
26 Nominal operating mode 20
27 Measurement Changes in winding 21
28 Load & Time Changes in Winding 22
29 Fabrication Shop 22
30 Core Diagram 24
31 Core 24
32 Core Assembly 25
33 Coil windings 25
34 Continuous Disk Winding 26
35 Helical Disk Winding 26
36 Double Helical Coil (Hobert Helical Coil) 27
37 Winding Prosses 28
38 Coil Assembly( HV & LV ) 28
39 Core Coil Assembly 29
40 Transformer Tank 29
41 Tank Up 30
42 Panel 33
43 Pressure Relief Device 35
44 Buchholtz Relay 36

iii
 45 RTCC 37
46 VFD Panel 38
47 TJB Panel 39
48 Linking Process 39
49 Cooling Of Transformer 40
50 Painting Of Tanks 41
51 Digitalization Of Transformers 46

LIST OF TABLES

Table No Table Title Page No

01 Properties of the Small Transformers Program 04
02 Properties of the Large Transformers Program 06
03 Technical Specification 10
04 Result Analysis 43

iv
 Contents
Page No
Acknowledgement I
Abstract ii
List of figures iii
List of tables iv

Chapter 1 INTRODUCTION 01
1.1 The Company 01
1.2 Design And R & D 01
1.3 Manufacturing Oil-Immersed Power & Distribution Transformers 02
1.4 Introduction About Transformer 02

Chapter 2 BACKGROUND THEORY 02

2.1 Operating Principle 02
2.2 Designing & Programming of Transformer 03
2.3 Power Transformer 07
2.4 Distribution Transformer 07
2.5 Furnace Transformer 07
2.6 Converter Transformer 08
2.7 Regulating Transformer 08
2.8 Multi-Pulse Transformer 08
2.9 Transformer Parts 09

Chapter 3 METHODOLOGY 10
3.1 Designing of Transformer 10
3.2 Fabrication Shop 22
3.3 Core And Core Assembly 23
3.4 Coil Windings 25
3.5 Coil Assembly 28
3.6 Core Coil Assembly 28
3.7 Transformer Tank 29
3.8 Tank Up 30
3.9 Oil Filling Process 30
3.10 Testing Of Transformer 31
3.11 Accessories 33
3.12 Panels Design 33
3.13 Marshalling Box 34
3.14 RTCC 37
3.15 VFD 38
3.16 TJB 39
3.17 Linking Process of Panes 39
3.18 Bushing 39
3.19 Cooling Of Transformer 40
3.20 Properties Of Transformer Oil 40
3.21 Painting And Fittings 41

Chapter 4 RESULT ANALYSIS 42

a
Chapter 5 CONCLUSIONS & FUTURE SCOPE 44
5.1 Work Conclusions 44
5.2 Future Scope of Work 44

REFERENCES 47
PROJECT DETAILS 48

b
1. Introduction

1.1 The Company

Hammond Power Solutions have developed a reputation as the most capable and broadest manufacturer of dry-type
magnetics in the world. Our products can be found on every continent, every ocean and have even orbited in space.
Our engineering database contains over one million designs ranging from the smallest control transformers to the
largest dry-type transformers ever manufactured. Our customers have come to rely on us for support at the most
critical stages of their needs. Our stability and integrity as a supplier are paramount in an industry where demands
must be resolved quickly and effectively. HPS has grown to become the largest dry-type transformer manufacturer
in North America.
In the last 99 years, HPS has grown from a small family-owned business in the shortwave radio market to the industry
leader in magnetic transformer design and manufacturing. HPS now has multiple manufacturing facilities throughout
Canada, United States, Mexico, Italy and India. HPS currently has 11 regional distribution centres throughout North
America.
HPS is well positioned for growth and has several long term and short term plans to continue on this path of success.
As North America’s leader in the dry-type transformer industry, we have every intention of staying there and getting
stronger.

1.2 Design and R & D

Hammond Power Solutions Transformers are designed to meet all the latest national and international standards,
including IS, IEC, ANSI, BS, DIN etc. All Hammond Power Solutions Transformers are designed in accordance
with customers' specific requirement. High levels of experience and expertise in transformer design and regular
investment in research and development has enabled Marson's to ensure excellence and competitiveness in quality,
performance, price and delivery. Wide range of Transformers are tested and validated by authorized testing
laboratories. All material used are of best quality and of the class most suitable for working under the specified
conditions withstanding variations of temperature and atmospheric conditions. Above all, the design incorporates
every reasonable precaution and provision for the safety of all those concerned in the operation and maintenance.

We use TDPro software to design the transformers. There is only one reason to use any software package and that is
to have another tool in your company to help you increase profits. Because of the software design and the ease of
making multiple iterations of the same design, it is easy to optimize the transformer design to use a minimum
of expensive materials. You can customize the design to meet you own inventory needs using wire sizes and steel
grades that cost less for you to purchase and are best for easy production. Engineering time required to complete a
design is reduced to mere minutes. This is especially valuable when you need to get quick and accurate quotations
to your potential customers. Because all calculations are done within the program, human errors are eliminated which
in turn eliminate costs associated with these. This aspect is also very important to the productive capacity of your
design engineers as design stress is alleviated. The TDPro software gives you the opportunity to simulate the designed
transformer under varying conditions and observe how the transformer will react under those conditions. You will
obtain information exactly as if you had built a prototype and made actual measurements in your own laboratory.
Therefore, until you have a design iteration that meets all of your requirements you do not need to build any test
transformers. Eliminating expensive prototypes will have a real positive effect on your final profits. The TDPro
software immediately generates three important pages when your design is completed. The first page gives you
detailed input data with a schematic. The second page provides details on the Mechanical Part including the bobbin,
core and windings. The third page provides details on the electrical, magnetic, and thermal data (nominal, no-load,
short circuit, and duty cycle operations). Some of this documentation can be used immediately to accompany
customer quotations thereby eliminating the need to create time consuming and difficult documentation just for a

1
quote. The TDPro software also gives you the option to create your own pages in your own format for production
requirements.

1.3 Manufacturing Oil-immersed Power & Distribution Transformers

Hammond Power Solutions thinking is driven by the commitment to quality. The complete in house manufacturing
process helps us to ensure optimum quality of the transformer. We have complete testing facility to test and check
all the major raw materials used in manufacturing the transformer. CRGO laminations are cut and annealed in house
to achieve minimum magnetic flux distortion. To ensure the best quality of the Coils of the transformer, winding
wires and strips are also manufactured in house. Fabrication section ensure the robustness, quality and fine finish of
the tank and radiators of the transformer. Hammond Power Solutions produces several types of transformer as
corrugated wall panel,self protected type, ground mounted, hermetically sealed type with gas cushion.

The manufacturing process of Transformer cover the following

 Fabrication of tanks
 Core Assembly
 Coil Winding
 Core-Coil Assembly
 Tank-up
 Transformer Tank Painting & Finishing

1.4 Introduction About Transformer

Transformer is an ac machine that transfers electrical energy from one electrical circuit to another without changing
frequency by the principle of electro magnetic induction. Since it’s basic construction requires no moving parts so it
is often called the static transformer and it is very rugged machine requiring the minimum amount of repair and
maintenance. Owing to the lack of rotating parts there are no friction or winding losses. Further ,the other losses are
very low so that the efficiency should be high. The efficiency varies from 97% to 99%.

2. BACKGROUND THEORY

2.1 Operating 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.

Operating Principle of Transformer

Fig.No-01
2
2.2 Designing & Programming of Transformer

Small Transformers Program

The Small Transformers Program is the most frequently used program. It is used to design transformers with bobbins
and tubes in a power range up to 10kVA per phase and a frequency range up to 500kHz.

Small Transformers
Fig.No-02

Power range per phase at 50/60

10kVA per phase
Hz
Frequency range 10Hz ...500kHz
Input /Output voltage range and
1V ...10kV, independent of the form (sine wave, rectangular,...)
form
Primary Max. 8 taps for the inputs and the outputs in autotransformer operation mode.
Max. 8 secondary, connected to the load direct or via the rectifiers with R, RL or
Secondary
RC load, together with autotransformer operation available
Wire Cu- round and flat wires, with 3 insulation grades
Steels Cold rolled, grain oriented, Ne-Fe alloys, ferrite, amorphous and powder
Single section, double section and single section without flange, open and closed
Bobbins The cores and bobbins, which do not exist in the core data pools, can be created
by user.
Case Potted and not potted
Alternately stacked EI,UI,..., C-cores, welded, ready cores, modulus cores and
Core assembly
alternately stacked strips
Primary inside or outside, alternately windings 50%/100%/500%,
Winding assembly
33%/66%/66%/33% and 25%/50%/50%/50%/25%
One cooling channel, only in the front and in the back of the winding, between
Cooling channel
the primary and the secondary
3
Ventilation Max. 5m/sec
Impregnation Dry, one component varnish and 2 components varnish, under vacuum.
Chassis Wood, printed board, metal
Duty cycle operation mode Min. time 5 seconds, with 2 times and 2 loads
Regulation of the output voltage: 1% to 150%
or
Criterion of the design:
Temperature rise in nominal, short-circuit or duty cycle operation: 10°K
...250°K
Optimized in accordance with the temperature rise, no-load operation and the
Induction
inrush current
Ambient temperature -100°C ... 120°C
EI, EE,..., UI, LL,..., 3PhEI, C-cores, EC, ETD, RM, PM, P, EFD, EPC, RS, DS,
PQ,...
Core families data pool
The cores and bobbins, which do not exist in the core data pools can be created
by user.
Design mode In this mode the program designs in accordance with the input data.
In this mode the user can change manually the turns, wire sizes, loads, input
Test and simulating mode
voltage, frequency, duty cycle, steel,... and recalculate the transformer.
DC/DC converters :
The program supports fly back, forward (simultaneous too) and all transformers,
driven by the "impressed" input voltage or "impressed" input current (bridge,
push-pull, resonant,... converters)

Battery chargers, Adapters:

The program supports the operation of the one and three phase transformers with
the rectifiers on the R, RL or RC load

Inherently short-circuit proof, not-inherently short-circuit proof and not short-

circuit proof transformers

Typical applications
Medical transformers
Control transformers
Universal transformers or universal autotransformers
Autotransformers
Motor starting transformers or autotransformers
Voltage transformers
Current transformers
Toy transformers
Bell transformers
Audio transformers
Transmitters
K-factor transformers

Properties of the Small Transformers Program

Table.No-01

4
Large Transformers Program

The Large Transformers Program is used to design air & oil cooled transformers with cooling-channels technology
in a power range from 0.1kVA up to 10MVA per phase and a frequency range up to 1000Hz.

Large Transformer
Fig.No-03

Vertical and horizontal cooling channel

Fig.No-04

Magnetic Fields
Fig.No-05

Power range per phase at

0.1kVA...10MVA per phase
50/60 Hz
Frequency range 10Hz ...1000Hz
Input /Output voltage range 1V ...110kV, independent of the form (sine wave, rectangular,...), included max 5
and form voltage harmonics
Max. 8 windings, which can be declared as primary or secondary, connected in
Primary/Secondary
parallel or in series
Output current Max. 100kA, included max 5 current harmonics

5
 To each winding can be assigned 7 combinations of cooling channel and
insulation, in front/back or/and in the window of the core: WIW, WCW, WICW,
WCIW, WCICW, WICIW, WICICIW, where:
Vertical and horizontal cooling I => Insulation
channel C => Cooling channel
W => Winding
and
using horizontal cooling channel or insulation between sectors, discs or turns
Cu and Al , round wires, flat wires and foil, litz, with 3 insulation grades.
Wire
The wires, which do not exist in the wire data base can be created by user
Steels Cold rolled, grain oriented, Ni-Fe,Co-Fe, amorphous and ferrites
Concentric, disc and "screw" within max 8 sectors per winding; round, oval or
Windings technology
rectangular form
Cabinet Closed, open on the top and bottom, ventilated (open and closed)
Alternately stacked EI,UI,..., welded, ready cores, modulus cores and alternately
stacked strips. The cross section of the limb and of the yoke can be used
Core assembly rectangular, "round" and oval (max. 8 steps)
The cores, which do not exist in the core data base can be created by user or
optimized by program for min. price at precribed Ucc and losses.
Ventilation Max. 5 m/sec, inside and outside of the cooling channels
Impregnation Dry, one component varnish and 2 components varnish, under vacuum.
Duty cycle operation mode With 2 times and 2 loads, per each winding
Numerical calculation of the magnetic
fields allows precise calculation of :
- eddy current losses
Magnetic fields
- steel losses
- short circuit voltage and
- transposition.
Winding losses 1% to 10%
Criterion of the design: or
Temperature rise in nominal, short-circuit or duty cycle operation: 10°K ...250°K
Criterion of the optimization Price or weight at prescribed Ucc and losses
Optimized in accordance with the temperature rise, no-load operation, the inrush
Induction
current, efficiency, weight and price
Ambient temperature -100°C ... 120°C
Cooling air or oil
EI, EE,..., UI, LL,..., 3PhEI, C-cores,...
Core families data pool
The cores, which do not exist in the core data base can be created by user.
Design mode In this mode the program designs in accordance with the input data.
In this mode the user can change manually the turns, wire sizes, loads, input
Test and simulating mode
voltage, frequency, duty cycle, steel,... and recalculate the transformer.

Properties of the Large Transformers Program

Table.No-02

6
2.3 Power Transformer

The term is used to include all transformers of large sizes (250kva and above) used in generating stations and
substations for transforming the voltage at each end of a power transmission line. They may be single or three phase
and voltage rating of 220/11kv or in high voltage range. They are put in operation during load hours and disconnected
during light load hours or operated on full load. So power transformer are designed to have maximum efficiency at
full load(i.e. With iron loss to full load copper loss ratio of 1:1).

Power Transformer
Fig.No-06
2.4 Distribution Transformer

Transformer of rating up to 200kva,used to step down the distribution voltage to a standard service voltage are known
as distribution transformer. They are kept in operation all the 24 hours a day. In such transformer iron loss occur for
all the time where copper loss occur only when they are loaded. Therefore, distribution transformers should be
designed with iron loss smaller in comparison to full load copper loss(say with iron loss to full load copper loss ratio
1:3)

Distribution Transformer
Fig.No-07
2.5 Furnace Transformer

Furnace transformers are widely utilized where there are high current requirements such as in the steel and cement
industries. They require high current levels that must also be variable due to the frequent short-circuits. These
transformers must be designed to resist the high levels of electrical, thermal and mechanical stresses to which they
are subject to during utilization. They are highly regarded for their high level of quality and reliability for many
demanding applications. Various types of furnace transformers are available such as Arc Furnace, Submerged Arc
Furnace, Ladle Furnace and Induction Furnace.

Furnace Transformer
Fig.No-08
7
2.6 Converter Transformer

Converter transformers are used in industries such as cement and steel plants, and other related applications.
Converter transformers are designed and manufactured to meet specific application needs.

Converter Transformer
Fig.No-09
2.7 Regulating Transformer

Regulating transformers are available using both liquid filled and dry-type technology to regulate the outgoing
voltage on the system. With requirements becoming increasing demanding for constant voltage supply, these
transformers incorporate reliable on-load tap changers designed to provide a constant output voltage from a variable
input voltage.

Designs allow for low impedance values while maintaining a high degree of reliability.

Regulating Transformer
Fig. No-10
2.8 Multi-Pulse Transformer

Multi-Pulse transformers are designed specifically for inherent harmonics, voltage distortion and other unique
characteristics associated with drive systems. They provide required supply voltage with the desired phase angle
between secondary voltages for VFD systems/converters. Oil filled and dry-type options are available.

Multi-Pulse Transformer
Fig. No-11

8
2.9 Transformer Parts

Transformer Parts
Fig.No-12

9
3. METHODOLOGY

3.1 Designing of Transformer

We use TDPro software for designing of transformer with different KVA. It is the fist step to produce a transformer.
We design the transformer as per customer requirement. Checkout an example 50KVA transformer.

Example

Designing a simple 50 kVA, 50Hz three phase dry transformer with cooling channels

General Information

Input voltage 3 x 400V, star

Output voltage 3 x 230V, delta

Output power 50kVA, K-Factor=1, continuous

operating mode

Frequency 50Hz

Ambient temperature 40°C

Temperature rise Max. 80°K

Steel & Core M6, not annealed,3 phase EI lamination,

alternated stacking

Technical Specification
Table.No-03

Creating Input

There are 4 input screens to set the input parameters for the designing of a transformer:

 Winding parameters per limb

 Core
 Environment
 Diverse

end 3 screens for selection and set up of material :

 wires
 steels
 cores.

10
Winding

In this power range you normally use a 3 phase EI core with grain oriented steel M111 (M6). Due to the relative
small window width of this core type there is no enough space for more than one cooling channel (15mm) between
the primary and the secondary. In order to increase the cooling surface the primary and the secondary are created with
2 one-sector-windings with the cooling channels (15mm) between them located only outside of the core window.
Around the core leg is the tube (3mm). There are cooling channels (15mm) between the first primary winding and
the tube located only outside of the core window. The primary and secondary windings have the same distance
(15mm) to the yokes. The transformer works in continuous operating mode on the sine wave input voltage and the
sine wave output current.

The program has to use Cu flat wires with the layer insulation of 0.1mm (100 micron). In a case where the program
needs to use 2 or more parallel connected wires the program does not need to use the transposition. The factor of the
eddy current losses (RacRdc = Pcu_total/Pcu_dc) must not exceed 1.05.

Input & Output Currents

Fig.No-13

Note that at this point in the design you can not prescribe the wire size. You can prescribe only the wire family which
the program has to use in order to select the applicable wires for your application.

11
 Flat Wires
Fig.No-14

Core

On this input screen you can : select and manipulate a steel (M111<=>M6)

 set the operating induction (1.55T)and the frequency (50Hz)

 select the core assembly (EI)
 and choose the core selection.

Core Measurements
Fig.No-15
12
Using the following screen for the selection of the core family the program will pick up the first sufficiently
large core for your application out of the selected core familyLTCM_EI_3_L_1.USR Note that you can also select
or create a new core within this screen

Core Files
Fig.No-16

Normally for this application use and M11, 0.35mm (M6, 14mil) grain oriented, not annealed after stamping, 3 phase
EI lamination.

Steel Data
Fig.No-17
13
Environment

The cooling medium is air with an ambient temperature of 40°C.

The cooling surface of the core is increased by using 4 L-brackets on the core.
The impregnation is practically "dry" because there is only 10% varnish (90% air) in the windings and in all the
gaps between the insulations and the layers of the windings.

Environment Measurements
Fig.No-18

Diverse

Diverse
Fig.No-19
14
The selected criterion of the design is the temperature rise of 100°K for insulation class F.
The oval space between the first winding and the tube (stomach), all gaps between the insulations & windings, and
the varnish fill factor play a very important roll from the thermal point of view.

Output

The first step of the design is the selection of the core:

Running Program
Fig.No-20

and the next step is the presentation of the output screen DIAGNOSIS: it is the summery of the most important
calculated parameters of your transformer.

Diagnosis
Fig.No-21

15
The following 3 screens will not be printed. Note that the program uses the numerical calculation of the magnetic
fields and the temperature rises. Due to this technology the calculations of the eddy current losses, the steel losses,
the short-circuit voltage, the circulating current and the transposition are very powerful.

Magnetic Field & Temperature of The Core

Fig.No-22

Finally, here are 4 printed pages with all the results of the design

 Input
 Core
 Windings
 Nominal operating mode

Each page has accurate values / results of the transformer to be manufactured in the workshop with exact
measurements. With this values the transformer will work efficiently and effectively for a long pried of time. The
results as followed.

16
Input

Input
Fig.No-23

17
Core

Core
Fig.No-24
18
Windings

Winding
Fig.No-25
19
Nominal operating mode

Nominal operating mode

Fig.No-26
20
Test Mode

If you are not satisfied with the solution made by the program you can switch into the Test Mode and change your
transformer manually:

 Turns
 Wire size
 Material (Cu or Al)
 Number of parallel connected wires and their order in strand
 Cooling channels and insulations
 Margin
 Steel
 Technology parameter (impregnation, gaps,...)

and then you can set it under an operation mode changing:

 Input voltage
 Frequency
 Loads and their K-factors
 Duty cycle of each winding
 Ambient temperature
 Air flow

Note that the program could not create full layer windings at the prescribed temperature rise of 100°K. In order to
get the full layer windings you have to select the wire size and number in parallel connected wires manually.

Measurement Changes in winding

Fig.No-27

21
The following Test Mode input shows the operation mode with:

 The input voltage on the overvoltage of 10%

 The decreased load resistance for 50%
Setting the load resistance to 0 you can simulate the short circuit operation of the winding.
Setting the load resistance to >1000 you can simulate the "no-load" operation of the winding.
 The duty cycle operation with 5 minutes on and 60 off.

Load & Time Changes in Winding

Fig.No-28

3.2 Fabrication Shop

Transformer tanks are fabricated in this department. Fabrication include cutting of sheets, straightening, bending,
welding of sheets and parts of tank.
It has three sub shop
1.Sheet cutting
2.Machine shop
3.Welding shop

Fabrication Shop
Fig.No-29
22
Machine shop has following machines

CNC Hypertherm Automation Machine

It is used for cutting metal based on design automatically. Gas used methane hydrogen operating plasma system
completes an electric circuit between the torch and the workpiece. Specification microprocessor control system.
Model FINCUT DP
Rail length 10000mm
Rail garage 3500mm
Input voltage 220v ac
Total power 5000VA
IS NO.10138

Pneumatic Searing Machine

This machine is used to cut large sheets and thick sheets but up to certain limit .The machine holds the sheet firmly
as pressure is given through compressor chamber. The pressure is being set manually. These are provided with
pneumatic clutch brake.

Punch Press

This is used to cut different shapes on sheet by using different dies .The dies are made of steel.

Bend Hydraulic Machine

This machine is used to bend sheets without any distortion. These machines are known for sturdiness, higher
efficiency and reliability. They bend the sheets at an angle of 90 degree.

Rolling Machine

This is used to straightened or to roll the sheets as per requirement. Roll can be at any extent .After cutting of sheets
,they are introduced into it for straightening.

Lathe Machine

It is multipurpose machine and is used for giving shape to the fittings of transformer tank like lifting lugs and jacking
lugs.

3.3 Core And Core Assembly

Core is magnetic link between the two systems connected to the transformer. The core material and it’s construction
should be such that the maximum flux is created with minimum magnetizing current and core loss. Steel core cause
total flux linking of primary to secondary. The high content of silicon increases the resistivity of the core, hence
reduces the eddy current loss. It also has a high permeability at low flux density and narrow hysteresis loop. The
steel used for cores may be hot or cold rolled .The cold rolled has more flux density (1.8T) than hot rolled(1.45T) as
it has better magnetic properties in the direction of rolling and it also reduces the amount of core material. As the
flux in the core is pulsating one, so cores must be laminated. The laminations are put through annealing process. The
thickness of lamination varies from 0.35mm to 0.5mm. These laminations are assembled in such a manner that there
is no air gap between the joints of two consecutive sheets.

23
The core assembly is done according to the weight of the core as the number of plates are decided on the basis of it

.
Core Diagram
Fig.No-30

The entire assembly is done on a frame commonly known as core channel. These frames being used as a clamping
support of the core assembly. Three-phase transformer usually employ three-leg core. The sectional areas of the yoke
and side leg are 50% of that of the main leg; thus, the core height can be reduced to a large extent compared with the
two leg core. For core material, high-grade, grain oriented silicon steel strip is used connected by a core leg tie plate;
fore and hind clamps by connecting bars.

As a result, the core is so constructed that the actual silicon strip is held in a sturdy frame consisting of clamps and
tie plates, which resists both mechanical force during hoisting the core-and coil assembly and short circuits, keeping
the silicon steel strip protected from such force. In large-capacity transformers, which are likely to invite increased
leakage flux, nonmagnetic steel is used or slits are provided in steel members to reduce the width for preventing stray
loss from increasing on metal parts used to clamp the core and for preventing local.

Core
Fig.No-31

24
The core interior is provided with many cooling oil ducts parallel to the lamination to which a part of the oil flow
forced by an oil pump is introduced to achieve forced cooling. When erecting a core after assembling, a special
device shown is used so that no strain due to bending or slip is produced on the silicon steel plate. The steel strip
surface is subjected to inorganic insulation treatment.. Yokes are jointed at an angle of 45 degree to utilize the
magnetic flux directional characteristic of steel strip. A computer-controlled automatic machine cuts grain-oriented
silicon steel strip with high accuracy and free of burrs, so that magnetic characteristics of the grain-oriented silicon
steel remains unimpaired. Silicon steel strips are stacked in a circle-section. Each core leg is fitted with tie plates on
its front and rear side, with resin-impregnated cotton tape wound around the outer circumference. Sturdy clamps
applied to front and rear side of the upper and lower yokes are bound together with tape. And then, the resin undergoes
heating for hardening to tighten the band so that the core is evenly clamped .Also, upper and lower clamps are evenly
tight.

Core Assembly
Fig. No-32

3.4 Coil Windings

Windings form another important part of transformers. In a transformer, the high and low voltage windings are so
designed that the axial short circuit force is reduced to minimum. Transformer winding are made of copper or
aluminium strip conductor. Heavy current capacity needs conductors of large cross section. To reduce eddy current
losses in the conductors ,several small wires or parallel straps are preferred to one large strap. This give rise to
unequal reactance of the component of the conductors which can be eliminated by transposition of conductors.
Instead of placing primary on one limb and secondary on the other limb it is usual practice to wind one half of each
winding on each limb. This ensures tight coupling between the two windings.

Coil windings
Fig.No-33

25
Consequently leakage flux is reduced. The positioning of the HV and lv winding with respect to core is also very
important from the point of view of insulation requirement. If HV winding were placed next to the core ,it would be
necessary to insulate it from the core and lv winding and two layer of HV insulation would be required. By placing
HV winding outside and around the lv winding only one layer of HV insulation would be required. The one which
is connected to a voltage source and creates the flux is called as a primary winding. The second winding where the
voltage is induced by induction is called a secondary. It may be more appropriate to designate the windings as High
Voltage (HV) and Low Voltage (LV) windings. The winding with more number of turns will be a HV winding.

Continuous Disk Winding

Fig.No-34

Continuous Disk Winding

The disc coils as the name suggest, consist of number of flat coils or discs connected in series or parallel. The coils
are formed with rectangular strips wound spirally from centre outwards in the radial direction. The conductor used
is in such length as are sufficient for complete winding or section of winding between tapping’s. The conductor can
be single strip or number of strips in parallel, wound on the flat side. This gives robust construction for each of the
discs. The discs are wound on an insulating cylinder spaced from it by strips along the length of cylinder .The discs
are separated from each other with press board sectors attached to vertical strips. The vertical and horizontal spacers
provide radial and axial ducts for free circulation of oil which comes in contact with every turn. Continuous discs
winding are reliable and strong and ,therefore, they are widely employed both as LV and HV windings in large rating
transformers.

Helical Disk Winding

Fig.No-35

26
Interleaved Disk Winding

In this winding, electrically isolated turns are brought in contact with each other as shown. Thus, the winding is
termed "interleaved disk winding." Since conductors 1 - 4 and conductors 9 - 12 assume a shape similar to a wound
capacitor, it is known that these conductors have very large capacitance. This is the most general type applicable to
windings of a wide range of voltage and current. This type is applied to windings ranging from 350kV to
1550kV.Rectangular wire is used where current is relatively small, while transposed cable is applied to large current.
When voltage is relatively low, a transformer of 100MVA or more capacity handles a large current exceeding 1000A.
In this case, the advantage of transposed cable may be fully utilized. Further, since the number of turns is reduced,
even conventional continuous disk construction is satisfactory in voltage distribution, thereby ensuring adequate
dielectric characteristics. Also, whenever necessary, potential distribution is improved by inserting a shield between
turns.

Cross Over Winding

These are made of circular conductors not exceeding 5 to 6 sq mm in cross section. These are used for HV windings
of relatively small transformers. These turns are wound in several layers. The length and thickness of each block is
made in line with cooling requirements. A number of such blocks can be connected in series, leaving cooling ducts
in between the blocks, as required by total voltage requirement.

Helical Winding

One very common cylindrical coil arrangement is the helical winding. For windings of low voltage (20kV or below)
and large current, a is helical coil is used which consists of a large number of parallel conductors piled in the radial
direction and wound. This is made up of large cross section rectangular conductor wound on its flat side. The coil
progresses as a helix. This is commonly used for LV windings. The insulation requirement also is not too high.
Between layers no insulation (other than conductor insulation) is needed as the voltage between layers is low. The
complexity of this type of winding rapidly increases as the current to be handled becomes more. The conductor cross
section becomes too large and difficult to handle. The eddy current losses in the conductor rapidly increases.
Hence two or more conductors have to be wound and connected in parallel. The parallel circuits bring in problems
of current sharing between the circuits. Transpositions of the parallel paths have to be adopted to reduce unequal
current distribution. The modern practice is to use continuously. transposed and bunched conductors.

Double Helical Coil (Hobert Helical Coil)

Fig.No-36

27
 Winding Prosses
Fig.No-37

3.5 Coil Assembly

High Voltage Coils

H.V. Coils are the components of finished transformers. They are made on automatic layer setting winding machines.
A solid cylindrical former of predetermined diameter and length is being used as base over which it is made.
Generally round insulated wire of either copper (Cu) or Aluminium (Al) is used as basic raw material. The coils are
made in number of layers. The starting and finishing leads of each coil are terminated on either side of the coil. These
leads are properly sleeved and locked at number of points.

Low Voltage Coils

L.V. Coils are also one of the components of transformer. The procedure of making low voltage coil is generally
same as described earlier. The shape of the basic raw-material (Al or Cu) is rectangular. The Test: The "Turn Test"
is carried out on the H.V. Coils as per the specifications.

Coil Assembly( HV & LV )

Fig.No-38

3.6 Core Coil Assembly

The components produced in the coil winding and core assembly stage are then taken into core-coil assembly stage.
The core assembly is vertically placed with the foot plate touching the ground. The top yoke of the core is removed.
The limbs of the core are tightly wrapped with cotton tape and then varnished. Cylinder made out of insulating press

28
board/pressphan paper is wrapped on all the three limbs. Low Voltage Coil is placed on the insulated core limbs.
Insulating block of specified thickness and number are placed both at the top and bottom of the L.V Coil.

Core Coil Assembly

Fig.No-39
Cylinder made out of corrugated paper or plain cylinder with oil ducts are provided over LV Coil. H.V. Coils are
placed over the cylinder. Gap between each section of H.V. Coils including top & bottom clearances is maintained
with the help of oil ducts, as per the design/drawings. The Top Yoke is refilled. Top core frame including core bolts
and tie rods are fixed in position. Primary and secondary windings are connected as per the requirements. Phase
barrier between H.V. phases are placed as per requirement. Connections to the tapping switch (if required) are made.
Finally, the component is placed in the oven.

3.7 Transformer Tank

Hammond Power Solutions will have an in-house facility for manufacturing transformer tanks. All tanks are made
of high quality steel and can withstand vacuum as specified by the international standards and the customer. All
welds are tested, ensuring 100% leak proof of seams and mechanical strength. All transformer tanks are given a
smooth finishing by using the "SHOT BLASTING" process.
Transformer tanks commonly used are of the following types;
1. Plain sheet steel tank.
2. Sheet steel tank with external cooling tubes.
3. Radiator tanks.
4. Tanks with corrugated wall panels

Transformer Tank
Fig.No-40

29
The tank is manufactured by forming and welding steel plate to be used as a container for holding the core and coil
assembly together with insulating oil. Transformer tank offers the following features: Subjected to automatic beam
welding machine and other special facilities, the tank possesses high quality and strength. Transformers to be
transported by ship are structured in a semi oval shape on both ends of the tank and provided with reinforcement
members rationally arranged, resulting in increased strength and decreased weight. The tank bottom is fitted with a
skid base by welding and provided with pull lugs to facilitate rolling in the longitudinal and transverse directions.
Capable of withstanding a high vacuum of 0.1 torr or below, the tank can be filled with oil under a vacuum; to
thoroughly remove gases and moisture from the insulation. The tank is of completely enclosed, welded construction.
Oilproof nitrile rubber gaskets are used on those parts which must be removed from the standpoint of assembly in
the field or during maintenance; flanges thereon are provided with machined grooves or gasket retainers to ensure
proper tightening of gaskets. Consequently, there is no possibility of oil leakage over an extended period.

3.8 Tank Up

The core-coil assembly and tank supplied by the fabrication depth are taken into tank-up stage. The procedure is:
The core-coil assembly is taken out of the oven and the "Megger test" is carried out. Only if the megger value is as
per the specification, the assembly may be taken for tank-up. The tanks, supplied by fabrication department are
brought to tank-up department duly painted. Fittings like drain valves, HV& LV Bushings, conservator, oil level
indicator and explosion vent are fitted in the tanks.

Tank Up
Fig.No-41

The Core-coil assembly is then placed into the tank and properly locked up. Pure filtered transformer oil is filled in
the tank to immerse the assembly only. Connections of primary and secondary to the terminal bushings are made.
Operating handle for ratio switch is fitted, wherever required.

3.9 Oil Filling Process

The job is put in the tank and the oil is filled into the tank after the clearance checking. The oil is filled from up and
the valve is closed when the oil is below 2 inch of the tank. The cover is putted on the tank and after it oil is filled
trough conservator and at last conservator is closed trough conservator cap.

30
3.10 Testing Of Transformer

Hammond Power Solutions carries away almost all type of routine test. Testing is done as per IS 2026. Routine test
to be carried out on all jobs.

 Measurement of winding resistance

 Measurement of insulation resistance
 Separate source voltage withstand test (High Voltage tests on HV & LV)
 Induced Over voltage Withstand test (DVDF test)
 Measurement of voltage ratio
 Measurement of NO LOAD LOSS & current.
 Measurement of LOAD LOSS & IMPEDENCE.(EFFICIENCY & REGULATION)
 Vector Group Verification

Measurement Of Winding Resistance

This test measures the resistance of the HV & LV winding. The values of resistance should be balance for all three
phases and should match the designed values.

Equipment used : Digital resistance meter.

Measurement Of Insulation Resistance

Measures the insulation resistance of HV & LV windings with respect to earth (body) and between LV & HV
winding. Recommended Values are 2000Mohms for HV & 500M ohms for LV and between Primary & Secondary
high voltage test : LV winding connected together and earthed. HV winding connected together and given 28 KV
(for 11KV transformer) for 1 minute.

INSULATION TESTER OR MEGGER IS USED.

Separate Source Voltage Withstand Test (High Voltage Tests On HV & LV)

HV winding connected together and earthed. LV winding connected together and given 3 KV for 1 minute.
Equipment used : High Voltage tester ( 100KV & 3KV)3.Seperate source voltage withstand test (High Voltage tests
on HV & LV)- This test checks the insulation property between Primary to earth, Secondary to earth.

Induced Over Voltage Withstand Test (DVDF Test)

This test checks the inter turn insulation. For a 11KV/433V transformer,866 Volts are applied at the 433V winding
with the help of a Generator for 1 minute. This induces 22KV on 11KV side. The frequency of the 866V supply is
also increased to 100HZ.

Equipment used : MOTOR GENERATOR SET

Measurement Of Voltage Ratio

This test measures the voltage ratio as per the customer’s requirement.
V1/V2 = N1/N2
The voltage ratio is equal to the turns ratio in a transformer.

31
Using this principle, the turns ratio is measured with the help of a turns ratio meter. If it is correct , then the voltage
ratio is assumed to be correct.

Equipment used : Turns Ratiometer

Measurement Of No Load Loss & Current

The iron losses and no load current are measured in this test. The 433V winding is charged at 433V supply & the
11KV winding is left open .The power consumed by the transformer at no load is the no load loss in the transformer.
Effect of actual frequency must be taken into account.

Equipment used : Wattmeter’s analyser or power.

Measurement Of Load Loss & Impedance.(Efficiency & Regulation)

This test measures the power consumed by the transformer when the 433V winding is short circuited and The rated
current is passed through the 11KV winding.

Equipment used : Wattmeter’s or power analyser.

Vector Group Verification

This test verifies the Dyn-11 vector group of a distribution transformer. Let the transformer vector group is DYn11;

1.1U 1V 1W-which is primary -Delta Connection

2.2U 2V 2W 2N- Which is secondary-Star connection
3.By connecting terminals 1U& 2U
4.Then three phase Supply is given to 1U-1V-1W
5.By measuring the terminal given below

We get

a. 1U-1V
b. 1V-1w
c. 1W-1U
d. 1W-2W
e. 1V-2W
f. 1V-2V
g. 1W-2V
h. 1U-2N
i. 1V-2N

THE BELOW GIVEN CONDITION IS SATISFIED THEN DYn11 IS CONFIRMED

1.1V-2W=1V-2V
2.1W-2V>1W-2W
3.1U-1V=1V-2N+1U-2N

Equipment used : voltmeter.

32
3.11 Accessories

Conservator With Drain Plug And Filling Hole

Conservator is normally provided on all ratings of transformers which provides the space for the expansion /
contraction of oil on account of the variation of oil temperature during service. It prevents the oil in the tank from
coming in direct contact with the atmosphere and protects it from deterioration. Conservator is provided with silica
gel breather, oil level gauge, oil filling hole with blanking plate and drain plug for draining/ sampling of oil
contaminated by moisture and sludge.

Magnetic Oil Gauge

This is a dial type gauge, mounted directly on the conservator to indicate oil level. This is supplied with low level
alarm contacts and the electrical connections of which are brought out to a terminal box of the oil gauge. Suitable
alarm circuit may be connected to these terminals. This oil gauge is not dispatched separately, but is mounted on the
conservator, with float arm adjusted to correct length.

Dehydrating Breather

Regarding moisture absorbent, to display the extent of moisture absorption of the moisture absorbent, it is used. It
mixed the kind of moisture absorbent which is blue colour under a dry state and changes to pink as moisture
absorption progresses. When no breathing is conducted, the breather is isolated from the open air by oil to prevent
the moisture absorbent from needlessly absorbing moisture.

3.12 Panels Design

Panels are used for the protection of transformer. The different protection schemes of transformer are employed by
using panels. Panels mainly serve the purpose of control and giving indication of the faults that occur.

Panel
Fig.No-42
33
Types of Panel

● Marshalling Box - [Fan, pump, CT, 4-20V Analog ]

● RTCC - Remote Tap Changer Control Cubical - [Raise, Lower, AVR, RWTI, ROTI, RTPI etc]
● TJB- Thermo Junction Box [Only for WTI & OTI]
● CM. Box - Common Marshalling Box
● DM Box - Drive Mechanism Box - [Raise Lower]
● VFD - Variable Frequency Drive
● PLC Panels

3.13 Marshalling Box

The transformer is provided with certain fittings directly mounted on the transformer at various locations. These
fittings are having electrical contacts or terminals which are required to be connected to the protection schemes to
give alarm/annunciation under abnormal conditions and if further required to disconnect the transformer from mains.
In order to facilitate connections of all such devices to the protective scheme, the cables from all such contacts are
wired up to a weather proof terminal box. This box called marshalling box, is also used for housing Oil Temperature
Indicator (OTI) and winding Temperature Indicator (WTI)The Marshalling box is made of sheet metal and is
provided with a glass window for observing OTI & WTI .Is has a hinged door with locking facility to prevent
unauthorised access. The capillaries from OTI& WTI come out from the bottom of the Marshalling box through
suitably recessed gland plate thus preventing ingress of dust.

Liquid Temperature Indicator

Liquid temperature indicator is used to measure oil temperature as a standard practice. The dial temperature detector
is used to measure maximum oil temperature. The indicating part, provided with an alarm contact and a maximum
temperature pointer, is of airtight construction with moisture absorbent contained therein; thus, there is no possibility
of the glass interior collecting moisture whereby it would be difficult to observe the indicator.

Winding Temperature Indicator

The winding temperature indicator is a conventional oil temperature indicator supplemented with an electrical
heating element. The relay measures the temperature of the hottest part of the transformer winding. The temperature
sensing system is filled with a liquid, which changes in volume with varying temperature. The sensing bulb placed
in a thermometer well in the transformer tank cover senses the maximum oil temperature.

Protective Relays

The following protective devices are used so that, upon a Fault development inside a transformer, an alarm is set off
or the transformer is disconnected from the circuit. In the event of a fault, oil or insulations decomposes by heat,
producing gas or developing an impulse oil flow. To detect these phenomena, a Buchholtz relay is installed.

Off-Circuit Tap Changer

The transformer is fitted with an off-circuit tap changing switch to obtain required tap voltage. It can be hand operated
by a switch handle mounted on the tank. Locking device is fitted to the handle to padlock it on any tap position and
also to prevent any unauthorized operation of switch. The switch mechanism is such that it can be locked only when
34
it is bridging two contacts on any particulars tapping position and cannot be locked in any intermediate position. It
is important that the transformer should be isolated from the live lines, before moving the switch. Operating the
switch when transformer is energized, will damage the switch contacts due to severe arcing between the contacts,
and may damage windings also.

Pressure Relief Device

When the gauge pressure in the tank reaches abnormally to 0.35 - 0.7kg/cm2 the pressure relief device starts
automatically to discharge the oil.

Pressure Relief Device

Fig.No-43
When the pressure in the tank has dropped beyond the limit through discharging, the device is automatically reset to
prevent more oil than required from being discharged.

ON Load Tap Changer

The on-load tap changer is employed for changing the turn ratio of the transformer to regulate the system voltage
while the transformer is delivering load. The tapping’s are provided at the neutral end of HV windings of a generator
transformer. The changer is operated by a motor operated driving mechanism by local or remote control and a handle
is also fitted for manual operation in case of an emergency. All type of on load tap changing circuit are provided with
an impedance. The impedance may be either a resistor or centre tapped reactor.

Temperature Gauges

A Temperature Gauge is a common safety device installed on transformers, regulators and other electrical equipment
when filled with liquid insulating fluids for dielectric insulation and cooling.. A temperature gauge is installed to
35
measure the changes in the temperature of the liquid insulating fluids. Temperature gauges provide a positive system
to measure and indicate the insulating fluids temperature in transformers, regulators and other electrical equipment.

Buchholtz Relay

The Buchholtz relay is installed at the middle of the connection pipe between the transformer tank and the
conservator. There are a 1st stage contact and a 2nd stage contact as shown.

Buchholtz Relay
Fig.No-44
The 1st stage contact is used to detect minor faults. When gas produced in the tank due to a minor fault surfaces to
accumulate in the relay chamber within a certain amount, the float lowers and closes the contact, thereby actuating
the alarm device. The 2nd stage contact is used to detect major faults. In the event of a major fault, abrupt gas
production causes pressure in the tank to flow oil into the conservator. In this case, the float is lowered to close the
contact, thereby causing the circuit breaker to trip or actuating the alarm device.

Pressure Vacuum Gauge

Pressure-Vacuum Gauges are commonly installed as safety devices on liquid insulating fluid(s) filled transformers,
regulators and other electrical equipment that provides a gas space above the oil.

36
Liquid Level Gauge

This type of gauge is a common safety device installed on transformers, regulators and other electrical equipment
when filled with liquid insulating fluids for dielectric insulation and cooling.

Radiators

The function of radiators is to limit the temperature of oil and winding by dissipating heat that is generated due to
losses within the transformer while in service. The number of sections per radiator and the number of radiators per
transformer will depend upon the losses and permissible temperature rise. Distribution Transformers are normally
provided with Radiators welded to tank. Each radiator consists of number of "Sections made from pressed sheets
forming channels for oil flow.

These "Sections" are welded to Header Pipes at Top & Bottom.

Circuit Breaker

Circuit Breakers provide short circuit and thermal protection for both pad mounted and overhead distribution
transformers. These are applied immersed in the transformer oil on the low voltage side to protect the transformer
against secondary faults and excessive overloads.

3.14 RTCC

RTCC is Remote Tap Changer Control Cubicle is connected to OLTC drive mechanism of Transformer through
control cables. It raises & lower the voltages remotely specified by controlling the motor drive in OLTC electrically
(and manually through Push Buttons). In RTCC an AVR (Automatic Voltage Regulator) is fixed to maintain the
output voltage level (raise & lower) by controlling the motor. Annunciators, Indications circuits are also incorporated
in RTCC panels.

RTCC
Fig.No-45
37
3.15 VFD

The main component of the motor control panel. The VFD inside will vary in voltage, horsepower, full load amps
(FLA), and other specifications. Sometimes you may find redundant VFDs installed in case of a VFD failure.

 Line reactors : 3% or 5% to reduce harmonic distortion

 Harmonic filters : A more effective way to reduce harmonic distortion
 Circuit breaker : Protects the electrical circuit from overload or short
 Circuit bypass : Keeps the system running even if the VFD fails
 PLC (Programmable Logic Controller) : For more advanced operations
 Modem : For communication purpose
 AC or other cooling units : Keeps the panel at a certain temperature depending on surrounding environment
 Soft-starter : starts motor slowly but without speed control
 Surge protector : Protects the system from voltage spikes
 Multiple motor overloads : An option for powering multiple motors off one VFD, typically used on fan
walls
 Anti-condensation heater (available in NEMA 3R panels) : Eliminates the buildup of dew inside the VFD
panel
 Motor starters : For running motors across the line

VFD Panel
Fig.No-46

38
3.16 TJB

It is a special kind of panel designed only if the customer demands for it. It is mainly used when the space available
is less for the marshalling box. It only consist of winding temperature indicator and oil temperature indicator.

TJB Panel
Fig.No-47

3.17 Linking Process of Panel

Linking Process
Fig.No-48

3.18 Bushing

 Bare Bushing

Draw Through Bushing (Oil Flood Type)

Winding lead is soldered to the stem of bushings which is drawn through the hole in porcelain and is fixed outside
the porcelain with leak proof gasket. Oil is flooded through the hole of the porcelain which acts as an insulation
between the lead and earth in addition to the porcelain insulation.
39
Solid Bushing (Through Stem Type)

Through stem protruding out of porcelain on either side is provided with nuts and washers to take windings lead on
one side and supply cable on the other side. Bushing is completely sealed on one end for oil tightness.

 Outdoor through stem type porcelain bushings.

 Cable box type porcelain bushings.
 Cable box type epoxy bushings.

3.19 Cooling Of Transformer

Cooling of the transformer is the most important for it’s durability. As the rating increases better cooling techniques
are needed. Simple air cooling of the transformers is adopted in dry type transformers. The limit for this is reached
by the time the rating is a few kVA. This method of cooling is termed as AN(Air Natural). Air Blast(AB) method
improves on the above by directing the blast of air at the core and windings. ON (Oil Natural) This method permits
the increase in the surface available for the cooling further by the use of ducts, radiators etc.(Oil Blast) method is an
improvement over the ON-type .and it directs a blast of air on the cooling surface. In the above two cases the flow
of oil is by natural convective forces. OFN (Oil Forced Natural)in this a forced blast of oil is employed. When there
is blast of air, the cooling method become OFB(Oil Forced Blast). A forced circulation of oil through a radiator is
done with a blast of air over the radiator surface. Next comes OFW which is similar to OFB except that instead of
blast of air a forced circulation of cool water in the radiator is used in this.

Cooling Of Transformer
Fig.No-49

Cooling System Capacity Cooling Equipment

Self-cooling type
(ONAN) 30,000kVA or below Panel-type radiators
Forced-air-cooled type
(ONAF) 30,000kVA~150.000kVA Panel-type radiators and cooling fans
Forced-oil, forced-air-cooled type
(OFAF) 150,000kVA or more Unit cooler or panel-type radiator, and Installation of cooling fans and pumps

3.20 Properties Of Transformer Oil

Even though the basic functions of the oil used in transformers are heat conduction and electrical insulation, there
are many other properties which make a particular oil eminently suitable. Organic oils of vegetative or animal origin

40
are good insulators but tend to decompose giving rise to acidic by-products which attack the paper or cloth insulation
around the conductors.
Mineral oils are suitable from the point of electrical properties but tend to form sludge. The properties that are
required to be looked into before selecting an oil for transformer application are as follows: Insulting property.
Viscosity Purity Sludge formation. Flash point And Fire point Flash point of an oil is the temperature at which the
oil ignites spontaneously. This must be as high as possible (not less than 160◦C from the point of safety). Fire point
is the temperature at which the oil flashes and continuously burns. This must be very high for the chosen oil (not less
than 200◦.

3.21 Painting And Fittings

The Entire Procedure Of Painting Is Done Under Two Stages

Cleaning Of Tanks

The cleaning of tank is done normally by chipping/grinding. The outside surface of the tank is short blasted to achieve
a very fine and smooth finish.

Painting Of Tanks

After cleaning the tanks, a coat of hot oil resistance paint is applied on the internal surface of the tank. The outside
surface is painted with a coat of Red Oxide primer and subsequently with one coat of enamel paint as per customer's
requirement.

Painting Of Tanks
Fig.No-50

41
4. RESULT ANALYSIS

Transformer shall be oil immerged ,hermetically sealed with corrugated tank. The Result of the transformer shall be
as below.

42
Result Analysis
Table.No-04

43
5. CONCLUSIONS & FUTURE SCOPE

5.1 Work Conclusions

The aim of Production and Design of Transformers ( In various Power ratios ) to supply high quality electricity for
all users without out any high or low fluctuations in voltage & long durability of transformers.

5.2 Future Scope of Work

The country’s power system is witnessing disruptive changes. Alongside a phenomenal growth in installed
generation capacity in recent years, the system is becoming increasingly complex, with the integration of a huge
quantum of renewable sources and new demand loads like electric vehicles emerging. Further, with multiple
generators, prosumers and decentralized generation sources, the grid needs to handle power flows in different
directions, 24×7. Moreover, ageing infrastructure and a greater focus on performance and safety targets are also
posing challenges.

Energy utilities are responding to these challenges by adopting digital technologies with the aim of helping users get
actionable information and insights that enable better decision-making and asset management. Transformers are the
immediate candidates for the integration of digital and smart grid technologies since they are the centrepiece of
electricity networks today and are expected to play a much bigger role in the future power grid as it expands.

Digital transformers are becoming an integral part of the new electricity grid, which independently regulates voltage
and maintains contact with the smart grid in order to allow remote administration and real-time feedback on power
supply parameters. The use of these transformers is gaining ground at the distribution and transmission levels. These
transformers are equipped with intelligent electronic devices, and smart monitoring and diagnostics features.

Need for digital

Over the years, a number of technological improvements have been made to transformers, which perform the
important function of adapting voltage levels, stepping up for efficient long-distance high-voltage transmission and
stepping down for distribution of electricity to consumers. These include ultra high-voltage AC & DC technologies,
biodegradable oil-filled transformers, ultra-low sound transformers and high efficiency distribution transformers.

However, for many utilities, improving monitoring and optimising maintenance remain the top priorities. For
instance, load peaks – predictable as well as unexpected – generate high temperatures that shorten the transformer
life. In some cases, sudden failures may occur, causing havoc in the network and leading to financial and other
penalties. Utilities are thus keen to control and monitor the status and condition of their transformer fleet so that they
can intervene before a failure or malfunction occurs. Further, renewable power plants, operated by a large number
of small, local energy producers, change the flow of power in the distribution network at the consumer end of the
grid. The growing uptake of electric vehicles and the charging of these in residential areas introduce dramatic changes
in consumption patterns. Heavy local charging activity can cause overloads on distribution transformers. There are
many other indications that the number of critical nodes at the distribution transformer level will multiply, which
will lead to a demand for the type of monitoring and control that has until now been limited to large power
transformers.

To cater to the new and emerging grid challenges, digital transformers are increasingly gaining traction. Digital
transformer solutions largely have three

blocks – hardware, software and services – that work seamlessly to deliver reliability, efficiency and future-readiness
to utilities. Built-in components like digital sensors, dissolved gas analysers and digital safety devices collect data

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for monitoring, diagnostics and control at the local level. The same data can also be monitored and used for control,
and preventive and predictive maintenance at the station control level via the cloud.

Benefits

Transformers that come enabled with digital capabilities can enable remote monitoring and data analytics of its vital
parameters in real time. This enhances reliability and enables higher utilisation of grid assets and power networks.
Further, such transformers come equipped with a digital hub that can leverage a portfolio of smart devices on a
modular platform with plug-and-play capabilities. In addition to enhancing efficiency and product life, digital
capability can boost reliability and mitigate outages through preventive action.

A digital transformer provides the precise amount of power required and immediately responds to fluctuations in the
power grid, acting as a voltage regulator. These features make digital transformers ideal for power systems that are
designed for renewable energy integration. Meanwhile, at the distribution transformer level, digital distribution
transformers provide intelligence to maximise reliability, optimise operations and maintenance costs, and manage
the asset more efficiently. Technology providers are working towards integrating sensing technology directly into
the transformer during the manufacturing process, thus resulting in higher accuracy.

Digital technologies are also being embedded by technology providers in dry-type transformers. Transformers
typically use oil for cooling and insulation, but dry-type transformers are designed to work without oil, where the
core and the coil are cooled by air and non-flammable solid insulation material. This makes them safer and more
environmentally friendly. Such transformers are ideally suited for high-risk applications such as in offshore and
densely populated areas, and in sensitive ecosystems. In digitally enabled dry-type transformers, smart sensors collect
data and combine them to provide powerful analytics.

Digital technologies can also help improve safety. To this end, submersible transformer inspection robots are making
inroads in the market. These wireless robots can be manoeuvred through a liquid-filled power transformer to perform
fast, safe and cost-effective internal inspection, which can be shared remotely, in close to real time, with experts.
This approach enhances safety by reducing personnel risk, reduces downtime with inspection performed in hours
versus days, and brings inspection costs down by 50 per cent or more. Apart from the various aforementioned
technical functionalities incorporated in the transformers, new digital transformers also address customers’
cybersecurity concerns. This is being done by adding additional layers of security such as RFID access card-enabled
Wi-Fi. Moreover, the data stored is encrypted and the user needs a decryption key to be able to read the data. Also,
the traditional cooling controls of power transformers are moving towards digitalisation. The traditional cooling
control of power transformers has many limitations. One such limitation is that the cooling is grouped into banks,
where the only possible operational states are no-cooling, half-cooling or full-cooling. For large power transformers,
one such bank may consist of many pumps and fans. Using digital systems removes this limitation by allowing
independent control of the cooler banks and thus providing a more fine-grained regulation of cooling capacity.

The way ahead

The massive growth in renewables-based power generation is resulting in greater voltage fluctuations in the
distribution network and sometimes, even violations of the permitted voltage band. Inevitably, this will call for a
healthy transmission and distribution system, which can act as a support for the smart grid. Grid communication will,
therefore, become critical in the distribution network so that power generation and consumption can be balanced and
voltage fluctuations eliminated. In this way, continuous, reliable and efficient supply of power will be maintained
and voltage band constraints complied with. Obviously, transformers play a central role in power transmission and
distribution networks and, going forward, as nodes of intelligence in the grid, will do a lot more than adapting
voltages.

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Digitalization Of Transformers
Fig.No-51

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