MPTC MALAPPURAM 2018-2019

ACKNOWLEDGEMENT
At this pleasing of having successfully completed our industrial training, wish to
convey our sincere thanks to our principal, Mr ABDUL HAMEED C.P who provided
the necessary facilities to proceed with the Industrial Training, and gratitude to our
Head of Department Mr MUHAMMED ASIF.K for allowing us to do our industrial
training and offering adequate duration in complete our industrial training with deep
sense of gratitude. We extend our sincere thanks to Mr SYAM MOHAN.N for his
constructive suggestion during this industrial training
We would like to express our sincere gratitude to everyone who assisted us in making
this industrial training successful. We also thank other staff and trainees for their
support and guidance.
We also express our indebt thank to all our teaching staff of electrical and electronics
engineering department, MADIN POLYTECHNIC COLLEGE, MALAPPURAM

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ABSTRACT
Established in 1964 in the state of Kerala, India, the Kerala Electrical & Allied
Engineering Co.Ltd. (KEL) is a multifaceted company fully own by the state
government. Through its five production facilities, located in various district of state,
this ISO 9001: 2000 complaint company provides basic engineering service/products
besides executing projects of national significance for high profile client like the
various defence establishment.
The company manufactures and markets products like general purpose brushless
alternators, brushless alternators for lighting and air-conditioning of rail coaches,
medium power and distribution transformers as well as structural steel fabrications.
The products categories for defence applications include high frequency alternators,
frequency convertors, special alternators and power pack for missile projects. The
power pack designed and supplied by the company for missile project like Falcon,
Prithvi, Trishul, and akash have been pioneering effort. The company has also
supplied special alternators to the army (Military Power Cars) and air force (Radar
Application)
The company’s all India marketing network with regional offices in all metro cities
carter to major institutional clients like the state electricity boards, Indian railways
and various defence establishment the general marketing clients.

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INDEX
TITLE PAGE NO
➢ INTRODUCTION 4
➢ OIL COOLED TRANSFORMER 5
o BASIC CONSTRUCTION OF TRANSFORMER 6
o CORE BUILDING 7
o COIL WINDING 8
o ASSEMBLING 9
o REBLADING 10
o TERMINAL GEAR ASSEMBLY 11
o TANKING 12
o PAINTING 13
o INSULATION RESISTANCE TEST 14
o WINDING RESISTANCE TEST 16
o BREAKDOWN VOLTAGE 17
o DV-DF TEST 19
o TESTING OF TRANSFORMER 21
➢ CAST RESINE TRANSFORMER 23
o THE CAST RESINE TRANSFORMER 24
o PROPERTIES OF RESINE QUARDS 26
o ADVANTAGES OF CRT 27
➢ CONCLUSION 28

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INTRODUCTION

KEL is one among the largest, most vibrant, and productive Public Sector
Undertaking, and is fully owned by the Government of Kerala. A multi-product
engineering company, consistently catering to an envious client base, ranging from
the army and air force of India to world-renowned space research organizations,
highly competent engineering companies to mammoth institutions likes the Indian
Railways. The company with four state-of-the-art manufacturing units spread across
Kerala has a pan India presence with marketing offices in major metros and select
cities. To be a globally recognized enterprise committed to enhancing stakeholder
value by providing world class engineering and power system solutions.
The company manufactures and markets products like general purpose brushless
alternators, brushless alternators for lating and air conditioning of rail coaches,
medium power and distribution transformers as well as structural steel fabrication
The product categories for defense application includes high frequency alternators ,
frequency convertors , special alternators and power packs for missile project , the
power packs designed and supplied by the company for missile project like falcon,
prithvi, trishul and akash have been pioneering efforts’. The company has also
supplied special alternators to the army (military power cars) and air force (radar
applications)
The companies all India marketing network with regional offices in all metro cities
cater to major institutional clients like the state’s electricity boards , Indian railways
and various defense establishments besides the general market clients

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OIL COOLED
TRANSFORMER

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BASIC CONSTRUCTION OF TRANSFORMER

Basically a transformer consists of two inductive windings and a laminated steel core.
The coils are insulated from each other as well as from the steel core. A transformer
may also consist of a container for winding and core assembly (called as tank),
suitable bushings to take or the terminals, oil conservator to provide oil in the
transformer tank for cooling purposes etc. The figure above illustrates the basic
construction of a transformer.
In all types of transformers, core is constructed by assembling (stacking) laminated
sheets of steel, with minimum air-gap between them (to achieve continuous
magnetic path). The steel used is having high silicon content and sometimes heat
treated, to provide high permeability and low hysteresis loss. Laminated sheets of
steel are used to reduce eddy current loss. The sheets are cut in the shape as El and
L. To avoid high reluctance at joints, laminations are stacked by alternating the sides
of joint. That is, if joints of first sheet assembly are at front face, the joints of
following assemble are kept at back face.

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CORE BUILDING

• The basic raw-material is COLD ROLLED GRAIN ORIENTED (CRGO) Silicon Steel

• It is in the form of thin sheets & cut to size as per design.

• Generally three different shapes of core laminations are used in one assembly.

• Notching is performed to increase the magnetic path.

• The laminations are put through annealing process.

• These laminations are assembled in such a manner that there is no air gap between
the joints of two consecutive sheets.

• 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.

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COIL WINDING
1. 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 length is being used as base
over which is made.

• Generally round insulated wire of either copper or Aluminum (Al) is

used as basic raw material. The coils are made in up of 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.

2.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.

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ASSEMBILING

• 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 board/preshrank 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.

• Cylinder made out of corrugated paper or plain cylinder with oil ducts are provided
over L.V 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.

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REBLADING

• 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 board 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 Coils Cylinder made out of corrugated paper or plain cylinder with
oil ducts are provided over L.V Coils.

• 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.

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TERMINAL GEAR ASSEMBLY

Terminal gear assembly done as described below:

• Cutting the leads as required.

• Crimping/brazing of the leads with cables.

• Brazing of bus bars

• Crimping/brazing of cables with terminal lugs.

• Mounting of the tap changer/tap switch.

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TANKING

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 depth. Are brought to tank-up department duly
painted.

• Fittings like drain valves, HV& LV Bushings, conservator, oil level indicator and
explosion vet fitted in the tanks.

• The Core-coil assembly is then placed in to 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 tatted, wherever required

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PAINTING

The entire procedure of painting is done under two stages:

1. 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

2. 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.

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INSULATION RESISTANCE TEST

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
 First disconnect all the line and neutral terminals of the transformer.

 Megger leads to be connected to LV and HV bushing studs to measure insulation

resistance IR value in between the LV and HV windings.

 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.

 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.

 Measurements are to be taken as Three winding transformer: HV to LV, LV to HV, HV

to LV, HV to EARTH

 Oil temperature should be noted at the time of insulation Resistance test of

transformer. Since the IR value of transformer insulating oil may vary with
temperature. IR values to be recorded at interval of 15 seconds, 1 minute and 10
minutes.

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WINDING RESISTANCE TEST

Transformer winding resistance measurement is carried out as a type test, routine test
and also as a Field test. In the factory, it helps in determining the following:
➢ Calculation of the ilk losses in transformer.

➢ Calculation of winding temperature at the end of temperature rise test of

transformer.

➢ As a benchmark for assessing possible damages in the field. It is done at site in order
to check for abnormalities due to loose connections, broken strands of conductor,
high contact resistance in tap changers, high voltage leads and bushings.

Procedure of Transformer Winding Resistance Measurement

For star connected Winding, the resistance shall be measured between the line and
neutral terminal. For star connected autotransformers the resistance of the HV Side is
measured between HV terminal and LV terminal, then between LV terminal and the
neutral. For delta connected windings, measurement of winding resistance shall be
done between pairs of line terminals as in delta connection the resistance of individual
winding cannot be measured separately, the resistance per winding shall be calculated
as per the following formula:

Resistance per winding = 1.5 x Measured value The resistance is measured at ambient
temperature and then converted to resistance at 75°C for all practical purposes of
comparison with specified design values, previous results and diagnostics. Winding
Resistance at standard temperature of 75° C
Rts = Rt( 235+75)/(235+t)
Rt=winding resistance at temperature t t = Winding temperature.

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BREAKDOWN VOLTAGE

To assess the Insulating property of dielectric transformer oil a sample of the

transformer oil is taken and is break down voltage is measured
• The transformer oil is filled in the vessel of the testing device. to standard compliant
test electrodes with a typical clearance of 2.5mm are surrounded by the dielectric oil

• a test voltage is applied to the electrodes and is continuously increased up to the

break down voltage with constant, standard compliant slew rate of e.g.2KV/S

• At a certain voltage level breakdown occurs in an electric arc. leading to a collapse of

the test voltage

• An instant after ignition of the arc, the test voltage is switched of automatically by
the testing devise. ultra-fast switch off is highly desirable as the carbonization due to
electric arc must be limited to keep the additional pollution as low as possible

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DOUBLE VOLTAGE AND DOUBLE FREQUENCY TEST

DVDF (Double voltage and double frequency) test is popular test conducted on the
Transformer before it is commissioned. In this test double the rated voltage and
double the rated frequency is applied to the Transformer under test and observed for
its withstand capability usually for 1 min. Double voltage is applied to test the
Transformer withstand capability for higher voltages which are sometime: occur in
the form of lightning surges and faults on the transformer. But, practically no
transformer is subjected to double the rated frequency as the frequency variations
are not allowed beyond 0.5% by the power supply grid controlling authority. In such a
case. Is it essential to test the transformer at 200% i.e. double the rated frequency
conditions.
When alternating electrical source is applied to the primary winding of the
transformer, it draws magnetizing current which produces alternating that in the
core of the transformer. This flux links both primary and secondary winding: and due
its alternating nature BMF in induced across both windings and Erms can deduced by
the equation.
Erms= 4.440.mfN volts
Where Erms is RMS voltage induced
m is maximum flux linked
f is the operating frequency
N to the number of turns in the winding.

As per the above equation. When double the rated voltage in applied while testing
the transformer. Without doubling the frequency. The maximum
Amount of flux linked will also be doubled as the number of turns is always constant
for a particular design. This causes the abnormal heating of core of the transformer
under test and the M G properties of the core are disturbed permanently hence , to
avoid this abnormal heating of the transformer due to increase in flux applied
frequency will also be doubled along with applied voltage to test the high Voltage
with land capability of the TR. Thus the test is named as DVD TEST.

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TESTING OF TRANSFORMER

a) Short circuit test

The test is conducted on the high-voltage (HV) side of the transformer where the
low-voltage (LV) side or the secondary is short circuited A wattmeter is connected to
the primary. An ammeter is connected in series with the primary winding. A
voltmeter is optional since the applied voltage is the same as the voltmeter reading.
The LV side of the transformer is short circuited. Now with the help of varies applied
voltage is slowly increased until the ammeter gives reading equal to the rated current
of the HV side. After reaching at rated current of HV side, all three instruments
reading (Voltmeter, Ammeter and Watt-meter readings) are recorded the meter
reading gives the primary equivalent of full load current IL. As the voltage applied for
full load current in short circuit test on transformer is quite small compared to the
rated primary Voltage of the transformer, the core losses in transformer can be taken
as negligible here.

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b) Open Circuit Test;

The connection diagram for open circuit test on transformer is shown in the figure. A
voltmeter, Wattmeter, And an ammeter are connected in LV side of the transformer
as shown. The voltage at rated frequency is applied to that L V side with the help of a
varies of variable ratio auto transformer. HV side of the transformer is kept open.
Now with the help of varies. Applied voltage gets slowly increased until the voltmeter
gives reading equal to the rated voltage of the LV side. After reaching at rated LV side
voltage. All three instruments reading (Voltmeter Ammeter and Wattmeter readings)
are recorded.

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THE CAST RESIN TRANSFORMER

Transformers are electric equipment that changes the voltage and the current of
electricity to facilitate its efficient transmission and distribution Transformers are
commonly used at power generation facilities to increase voltage and to decrease
current in order to transport electric energy across transmission lines. When the
electricity reaches the end user, transformers are used to reduce voltage and to
increase current to make the electricity suitable for general use. The process of
transforming voltage results in energy loss that is released in the form of heat and
therefore transformers must contain effective cooling systems. Transformers are
differentiated by their cooling systems (this is one of several ways that the
transformer industry classifies its products) Dry type transformers dissipate heat
directly into the ambient air. Liquid cooled transformers (e.g. oil filled transformers)
dissipate heat into liquid mediums.

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The cast resin transformer is a dry type transformer first developed in Germany in
the 1960 as an alternative to oil-Filled transformers. In contrast to an oil Filled
transformer, which immerses coils in oil to absorb and disperse heat, the coils of a
cast resin transformer are coated with epoxy resin, which is able to withstand
temperatures as high as 188 degree Celsius. Heat passes through the epoxy and
dissipates into the surrounding air. The cast resin transformer does not compete with
oil filled transformers in all applications. Most step up transformers at power plants
that increase the voltage to hundreds of thousands of volts are oil Filled
transformers, because at such high voltages the amount of heat generated is more
efficiently dissipated through a liquid medium. However, many step down
transformers located in the electricity distribution network and at the end user’s site
are dry type transformers. Certain wind and solar farms also use dry type
transformers to step up electricity for transmission. The cast resin transformer has
several advantages over the oil filled transformer, including greater efficiency, less
maintenance, greater fire resistance, and more environmentally friendly (the lack of
cooling liquids eliminates the possibility of oil leaks). While oil-filled transformers are
still widely used in China and throughout the world. we believe cast resin
transformers are increasing in popularity because of these advantages.

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PROPERTIES OF RESIN QUARTZ

Cast resin transformers are insulated with an epoxy resin/ Quartz ,powder mixture
this is environmentally friendly material that makes the winding maintanance-
free,moisture resistant, flame retardant and self-Extinguishing this eliminates the
needs for additional flame-retardant chemicals such as aluminum oxide, which can
negatively affect mechanical properties of as well as aging even when the insulation
is exposed clamped between resilient spacers that provide effective Vibration
insulation both from the iron core and mutually between windings
The copper coils are insulated with quartz powder and then cast with epoxy resin in
an automated vacuum casting machine to provide further insulation the vacuum
casting machine removes all moisture and condensation between the copper wire
and the resin coating Material in order to ensure that none of the windings crack
Wen heat is produced in the transformer as the expansion of coefficient of copper is
similar to the expansion coefficient of epoxy felon and fiberglass.

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ADVANTAGES 0F CAST RESIN TRANSFORMER

Safety

• .Cast resin transformers are fire resistant as opposed to oil-filled transformers. Which
are highly flammable and potentially very dangerous.

• In the case of a short circuit. Cast resin transformers won‘t cause catastrophic
damage. Because cast resin has better structural integrity, it will withstand a short
circuit much better than oil-filled or VPI transformers.

Environmental Friendliness

• Unlike oil-Filled transformers. Cast resin transformers contain no contaminants that

could leak or otherwise escape into the environment.

• Cast resin never requires expensive cleanup.

Efficiency

• Cast resin is very efficient -equal or ≤ 98% and especially more efficient than VPl.

• Cast resin transformers are air-cooled, so they have considerably Lower losses.

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CONCLUSION
The Industrial Visit to Kerala Electrical & Allied Engineering Co.Ltd helps team a lot of
things which I had never learned from my academics. The culture of the organization,
office etiquettes and the unique management model will give a deep insight about
the industry and definitely it will pave my way to success. During this visit I got the
opportunity to familiar with the different steps of making transformer. I took this
opportunity to thank all the staffs of Kerala Electrical & Allied Engineering Co.Ltd,
especially our instructor Mr.YAHKOOB.P.T and M'ADIN POLYTECHNIC COLLEGE,
MALAPPURAM without them, I couldn't have completed this Industrial Visit.

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