INTRODUCTION OF TRANSFORMERS

2.1 WHAT IS TRANSFORMER?

A transformer is a device that transfers electrical energy from one

circuit to another through inductively coupled conductors—the
transformer's coils. A varying current in the first or primary winding creates
a varying magnetic flux in the transformer's core and thus a varying
magnetic field through the secondary winding. This varying magnetic field
induces a varying electromotive force (EMF), or "voltage", in the secondary
winding. This effect is called inductive.
If a load is connected to the secondary, current will flow in the
secondary winding, and electrical energy will be transferred from the
primary circuit through the transformer to the load. In an ideal transformer,
the induced voltage in the secondary winding (Vs) is in proportion to the
primary voltage (Vp) and is given by the ratio of the number of turns in the
secondary (Ns) to the number of turns in the primary (Np) as follows:

By appropriate selection of the ratio of turns, a transformer thus

enables an alternating current (AC) voltage to be "stepped up" by making Ns
greater than Np, or "stepped down" by making Ns less than Np. The windings
are coils wound around a ferromagnetic core, air-core transformers being a
notable exception.
Transformers range in size from a thumbnail-sized coupling
transformer hidden inside a stage microphone to huge units weighing
hundreds of tons used to interconnect portions of power grids. All operate on
the same basic principles, although the range of designs is wide. While new
technologies have eliminated the need for transformers in some electronic
circuits, transformers are still found in nearly all electronic devices designed
for household ("mains") voltage. Transformers are essential for high-voltage
electric power transmission, which makes long-distance transmission
economically practical.

2.2 PRINCIPLE OF TRANSFORMER

The transformer works on the principle of ‗MUTUAL INDUCTION‘. An

alternating flux in the primary coil will create an alternating flux in the
transformer core, which is linked with the other coil which produces a
mutually induced emf according to faraday‘s laws of electromagnetic
induction.

A current flowing through a coil produces a magnetic field around the

coil. The magnetic field strength H, required to produce a magnetic field of
flux density B, is proportional to the current flowing in the coil. Figure 1
shown below explains the above principle
Figure 1: Relationship between current, magnetic field strength and flux

A transformer is a static piece of apparatus used for transferring

power from one circuit to another at a different voltage, but without change
in frequency. It can raise or lower the voltage with a corresponding decrease
or increase of current.

Vp = -Np A Vs = -Ns A

Figure 2: Transformer schematic

When a changing voltage is applied to the primary winding, the back

e.m.fs generated by the primary is given by Faraday‘s law,

EMF = Vp = -Np A --- (1)

A Current in the primary winding produces a magnetic field in the

core. The magnetic field is almost totally confined in the iron core and
couples around through the secondary coil. The induced voltage in the
secondary winding is also given by Faraday‘s law

Vs = -Ns A --- (2)

In Figure 2, the primary and secondary coils are shown on separate

legs of the magnetic circuit so that we can easily understand how the
transformer works. Actually, half of the primary and secondary coils are
 wound on each of the two legs, with sufficient insulation between the two
coils and the core to properly insulate the windings from one another and
the core. A transformer wound, such as in Figure 2, will operate at a greatly
reduced effectiveness due to the magnetic leakage. Magnetic leakage is the
part of the magnetic flux that passes through either one of the coils, but not
through both. The larger the distance between the primary and secondary
windings, the longer the magnetic circuit and the greater the leakage. The
following figure shows actual construction of a single phase transformer.

Figure 3: Transformer construction

The voltage developed by transformer action is given by

E = 4.44×f×N×Bmax×Acore
Where, E = rated coil voltage (volts),
f = operating frequency (hertz),
N = number of turns in the winding,
Bmax = maximum flux density in the core (tesla), and
Acore = cross-sectional area of the core material in Sq.
meters.

In addition to the voltage equation, a power equation expressing the

volt-ampere rating in terms of the other input parameters is also used in
transformer design. Specifically, the form of the equation is

VA = 4.44×f×N×Bmax×Acore×J×Acond
Where, N, Bmax, Acore and f are as defined above, J is the current
density (A/ sq. mm), and Acond is the coil cross-sectional area (mm2) in the
core window; of the conducting material for primary winding. J depends
upon heat dissipation and cooling.
2.3 TYPES OF TRANSFORMER

A. Oil filled Transformers

  
Power Transformers
  
Mobile Transformers
  
Distribution Transformers
 
Furnace Transformers

a. Induction Furnace Duty
b. Arc Furnace Duty
  
Motor Starting Transformers
  
Neutral Grounding Transformers
  
Rectifier Duty Transformers
 
 Testing Transformer

B. Encapsulated & VPI transformers

  
Air Cooled Transformers
  
Cast Resin Transformers
 
Boosters & Voltage Regulators


C. Reactors
  
Air Core Reactors
 
Gap Core Reactors

MANUFACTURING PROCESS OF
TRANSFORMER
  
Winding Construction
  
Core Assembly
  
Core & Winding(Coil) Assembly (CCA)
  
Tapping &Tap Changer
  
Drying Process
  
Tank Construction
  
Tanking & Final Fitting
  
Fittings & Accessories
  
Painting
  
Oil Filling & Filtration
 
Testing

3.1 Winding Construction:-

Conducting material is used in the windings of the transformer.

Usually the windings are in concentrically to minimize the flux leakages.
There are two types of windings. The coils are wound on the limbs and are
insulated from each other in the basic transformer the two windings wound
on the two different limbs. Due to this leakage flux increases which affects
the transformer efficiency or performance so it should be necessary that the
windings should be very close to each other to increase the mutual
inductance and stray capacitance to improve the high frequency response.
Such cylindrical coils are used in core type transformers and sandwich coils
are very commonly used in shell type transformer here each high voltage
winding lies between two low voltage windings such subdivisions of windings
into small portions reduce the flux leakages.
Transformer windings are designed to meet three fundamental
requirements, viz. mechanical, thermal and electrical. They are cylindrical in
shape and are assembled concentrically. Paper insulated conductors of high
conductivity & soft drawn E.C. Grade copper is used which comply with the
latest Indian as well as international Standards.
Windings are made with great care by well experienced skilled
workers in dust free & temperature controlled environment.
 Insulation between layers and turns is based upon the electrical and
mechanical strength level. Interlayer cooling ducts (Axial & Radial) are
provided to minimize the temperature gradient between windings and oil,
and hence the hot spot temperature is kept to a minimum. This also ensures
that the rate of insulation deterioration is minimized and high life
expectancy is achieved.
Transpositions are made in multiple conductor windings, to ensure
uniform current distribution, minimize circulating currents, decrease eddy
current loss and improve the lamination factor.
3.1.1 TYPES OF WINDING:-

1) Helical Winding
2) Layer Winding
3) Disc Winding
4) Interleaved Winding
Helical/Layer windings are most suitable for low voltage windings of
large power transformers to mitigate high current design requirement. For
High voltage windings the disc coils with excellent mechanical strength are
used to take the stresses due to voltage level. Special interleaved or shielded
construction offers most uniform voltage distribution despite system
transient. Specialized disc winding and inter-leaved disc windings are used
having very high series of capacitance giving a very good impulse voltage
performance.
Transpositions are made in multiple conductor windings, to ensure
uniform current distribution, minimize circulating currents, decrease eddy
current loss and improve the lamination factor.
Transformer windings are made almost exclusively of copper, or to be
precise, high-conductivity copper. Copper has made possible much of the
electrical industry as we know it today because, in addition to its excellent
mechanical properties, it has the highest conductivity of the commercial
metals. Its value in transformers is particularly significant because of the
benefits which result from the saving of space and the minimizing of load
losses.
The load loss of a transformer is that proportion of the losses
generated by the flow of load current and which varies as the square of the
load current.
This falls into three categories:
 Resistive loss within the winding conductors and leads.
 Eddy current loss in the winding conductors.
 Eddy current loss in the tanks and structural steelwork.

Resistive loss can be lessened by reducing the number of winding turns, by

increasing the cross-sectional area of the turn conductor, or by a
combination of both. Reducing the number of turns requires an increase in
8m, i.e. an increase in the core cross-section, which increases the iron
weight and iron loss. So load loss can be traded against iron loss and vice
versa. Increased frame size requires reduced winding length to compensate
and thus retain the same impedance, although as already explained there
will be a reduction in the number of turns (which was the object of the
exercise) by way of partial compensation. Reduction of the winding axial
length means that the core leg length is reduced, which also offsets the
increase in core weight resulting from the increased frame size to some
extent. There is thus a band of one or two frame sizes for which loss
variation is not too great, so that optimum frame size can be chosen to
satisfy other factors, such as ratio of fixed to load losses or transport height.
The paths of eddy currents in winding conductors are complex. The
effect of leakage flux within the transformer windings results in the presence
of radial and axial flux changes at any given point in space and any moment
 in time. These induce voltages which cause currents to flow at right angles
to the changing fluxes. The magnitude of these currents can be reduced by
increasing the resistance of the path through which they flow, and this can
be effected by reducing the total cross-sectional area of the winding
conductor or by subdividing this conductor into a large number of strands
insulated from each other. (In the same way as laminating the core steel
reduces eddy current losses in the core.) The former alternative increases
the overall winding resistance and thereby the resistive losses. Conversely, if
the overall conductor cross-section is increased with the object of reducing
resistive losses, one of the results is to increase the eddy current losses. This
can only be offset by a reduction in strand cross-section and an increase in
the total number of strands. It is costly to wind a large number of
conductors in parallel and so a manufacturer will wish to limit the total
number of strands in parallel. Also, the extra insulation resulting from the
increased number of strands results in a poorer winding space factor.
Compact size is important for any item of electrical plant. In transformer windings
this is particularly so. The size of the windings is the determining factor in the size
of the transformer. As explained above the windings must have a sufficiently large
cross-section to limit the load losses to an acceptable level, not only because of the
cost of these losses to the user but also because the heat generated must be
removed by the provision of cooling ducts. If the losses are increased more space
must be provided for ducts. This leads to yet larger windings and thus a larger core
is needed to enclose them. Increasing the size of the core increases the no-load loss
but, along with the increase in the size of the windings, also means that a very
much larger tank is required which, in turn, results in an increased oil quantity
and so the whole process escalates. Conversely, any savings in the size of windings
are repaid many times over by reductions in the size of the transformer and
resultant further savings elsewhere. As the material which most economically
meets the above criteria and which is universally commercially available, high-
conductivity copper is the automatic choice for transformer windings.
2 Core Assembly:-

Core is built with Cold Rolled Grain Oriented Silicon Steel, low loss
silicon steel lamination . Bonded core design/ technique is used to eliminate
hole punching and to minimize fixed losses and Magnetizing Current. Use of
HiB grade & Laser scribed Laminations and Rigid clamps significantly
reduce vibrations and noise level. Cooling ducts are provided in large
transformers for efficient circulation of oil to keep temperature of core well
within limit without affecting the flux distortion and also in the core suitable
insulation paper are inserted between some laminations for the purpose of
reducing eddy currents and also minimizing magnetic short circuit.
Core of the transformer is either in square or rectangular in size. It is
further divided into two parts. The vertical position of the core is limbs and
horizontal position of the core is yoke of the core. Core is made up of
laminations to reduce the eddy current losses get minimized. This
lamination is insulated by using insulations line varnish or thick paper.
Paper insulation is used for low voltage transformer and varnish is used for
high voltage transformer.
The step lap or Mitred joints at the core corners ensure a stream line
magnetic flux path. The core limb are held with resin bonded glass bands to
eliminate limb bolts. Yokes are clamped by solid mild steel plates with yoke
stud ensuring high rigidity for withstanding mechanical socks during
transportation & Short Circuits. The leg core in a which hard wooden bars
are inserted, are tighten with synthetic resin impregnated fibre glass tape.
The transformer core is closed magnetic circuit built up of thin
laminations of electrical sheet steel. It is intended to concentrate the main
magnetic flux linking with the winding and consists of limbs which carry the
windings and yokes which close the magnetic circuit. The core laminations
are insulated from one another by a film of heat-resistant coating or varnish,
or by a combination of both. There may be forms of magnetic circuit: the
shell type and the core type.
A magnetic circuit of the shell types is branched: there are two yokes
per limb, which encircle the limbs on both sides. As the magnetic flux leaves
a limbs, it branches off into two parts, therefore, in shell-type transformers,
the cross-sectional area of the limbs is twice that of the yokes. The limbs
and yokes are rectangular in section, which necessitates the use of
rectangular disk windings. Because of the insufficient strength of such
windings in the event of short circuits, complications in assembly and also
somewhat greater mass of the shell-type magnetic circuits as compared with
the core types circuits using cylindrical windings, the shell type in the Soviet
Union is employed only for single-phase transformers in household
appliances and for some special-purpose transformers.
The core-type magnetic circuits of butt-joint or interleaved construction
are used in power transformers. In such circuits, two or three vertical
circuits are bridged over by two horizontal yokes the top and the bottom one
so that a closed magnetic circuit is formed.
The core limbs and yokes are built up of separate laminations of
electrical sheet steel 0.35 or 0.5 mm think.
The core is built horizontally by stacking laminations, usually two or three
per lay, on a jig or stillage. The lay-down sequence must take account of the
need to alternate the lengths of plates to provide the necessary overlaps at
the mitred corners as shown in shows a large core being built in the
manufacturer‘s works. The clamping frames for top and bottom yokes will be
incorporated into the stillage but this must also provide support and rigidity
for the limbs until the core has been lifted into the vertical position for the
fitting of the windings. Without clamping bolts the limbs have little rigidity
until the windings have been fitted so the stillage must incorporate means of
providing this. The windings when assembled onto the limbs will not only
provide this rigidity, in some designs the hard synthetic resin-bonded paper
(s.r.b.p.) tube onto which the inner winding is wound provides the clamping
for the leg laminations. With this form of construction the leg is clamped
with temporary steel bands which are stripped away progressively as the
winding is lowered onto the leg at the assembly stage. Fitting of the windings
requires that the top yoke be removed and the question can be asked as to
why it is necessary to build it in place initially. The answer is that some
manufacturers have tried the process of core building without the top yokes
and have found that the disadvantages outweigh the saving in time and cost
of assembly. If the finished core is to have the lowest possible loss then the
joints between limbs and yokes must be fitted within very close tolerances.
Building the core to the accuracy necessary to achieve this without the top
yoke in place is very difficult. Once the windings have been fitted the top
yoke can be replaced, suitably interlaced into the projecting ends of the leg
laminations, followed by the top core frames. Once these have been fitted,
together with any tie bars linking top and bottom yokes, axial clamping can
be applied to the windings to compress them to their correct length.
The reason we laminate the iron cores in transformers is because we
want to limit what are called eddy currents. Transformers are basically two
coils of wire wrapped around a core of iron. They work by induction.
Induction occurs when current flows in one conductor (or one set of
windings in the transformer) and the magnetic field that forms around that
conductor (that set of windings) sweeps the other conductor (the other set of
windings) and induces a voltage. In order to increase the effectiveness of the
transformer, we need to improve the way the magnetic fields are coupled
from one set of windings to the other set. Iron conducts magnetic lines of
force well, so we use that to help conduct the magnetic lines of force from
coil A to coil B. Problem is, iron is also a conductor, and it's being swept by
the magnetic field as well. If we didn't use laminations, the iron core would
provide a place for the magnetic lines to produce (induce) current, and that
current flowing in the core would heat the core up really fast and waste
energy.

Before concluding the description of core construction, mention

should be made of the subject of core earthing. Any conducting metal parts
of a transformer, unless solidly bonded to earth, will acquire a potential in
operation which depends on their location relative to the electric field within
which they lie. In theory, the designer could insulate them from earthed
metal but, in practice, it is easier and more convenient to bond them to
earth. However, in adopting this alternative, there are two important
requirements:
1. The bonding must ensure good electrical contact and remain secure
throughout the transformer life.
2. No conducting loops must be formed, otherwise circulating currents
will result, creating increased losses and/or localised overheating.

Metalwork which becomes inadequately bonded, possibly due to

shrinkage or vibration, creates arcing which will cause breakdown of
insulation and oil and will produce gases which may lead to Buchholz relay
operation, where fitted, or cause confusion of routine gas-in-oil monitoring
results by masking other more serious internal faults, and can thus be very
troublesome in service.
The core and its framework represent the largest bulk of metalwork
requiring to be bonded to earth. On large, important transformers,
connections to core and frames can be individually brought outside the tank
via 3.3 kV bushings and then connected to earth externally. This enables the
earth connection to be readily accessed at the time of initial installation on
site and during subsequent maintenance without lowering the oil level for
removal of inspection covers so that core insulation resistance checks can be
carried out.
In order to comply with the above requirement to avoid circulating
currents, the core and frames will need to be effectively insulated from the
tank and from each other, nevertheless it is necessary for the core to be very
positively located within the tank particularly so as to avoid movement and
possible damage during transport. It is usual to incorporate location
brackets within the base of the tank in order to meet this requirement.
Because of the large weight of the core and windings these locating devices
and the insulation between them and the core and frames will need to be
physically very substantial, although the relevant test voltage may be
modest.

Core & Winding(Coil) Assembly (CCA):-

L.V. Windings are normally placed near core over insulating cylinder
and oil ducts. HV Windings are assembled co-axially placed with respect to
LV. Spacers between coils are 'T' shaped for added firmness. Coils are
assembled with best insulating materials and are adequately clamped. SPA
methodology is now a day widely adopted to have it's special beneficial
characteristics. The winding is rigidly supported by a common spacer ring of
densified wood at the top and bottom for precise alignment. Well profiled
angled rings are placed between LV & HV windings to reduce voltage stress
level. The ends & tapping leads of all windings are connected by special
extra flexible, insulated copper cables which are rigidly braced in position.

Tapping &Tap Changer:-

Generally Taps are provided on HV Windings for HV Variation or LV

Variation as specified by customer. These are brought up to a gang operated
switch, suitable for external manual operation and can be locked in any
desired position to avoid unauthorized operation.

All the moving contacts are spring loaded to ensure proper pressure
and good contacts.
To achieve precise voltage regulation on load tap changer is used
instead of OCTC. Usually Higher capacity transformers i.e above 5000 KVA
ratings, can be supplied with On Load Tap Changer along with necessary
controls to make it suitable for manual, local electrical or remote Electrical
operation.
3.5 Drying Process:-

The core- coil assembly is placed in Vacuum Auto Enclave to eliminate

moisture content which is targeted less than 0.5 % moisture. Drying process
is to be carried out @ 90°C & respective vacuum cycle at rated interval to
improve Insulation resistance and remove ingress of moisture in insulation
material.
Drying of grain involves exposing grain to air with low relative humidity
(RH) which will lead to evaporation of the moisture in the grain and then the
moisture‘s removal away from the grain. Since drying practices can have a
big impact on grain or seed quality, it is important to understand some
fundamentals of grain drying.

3.5.1 Moisture removal

In paddy grain, moisture is present at two places: at the surface of the

grain, ‗surface moisture‘, and inside the kernel, ‗internal moisture‘. Surface
moisture will readily evaporate when grain is exposed to hot air. Internal
moisture evaporates much slower because it first has to move from the
kernel to the outside surface. As a result, surface moisture and internal
moisture evaporate at a different rate. This difference results in a different
‗drying rates‘ for different period of drying. The drying rate is defined as the
rate at which grain moisture content declines during the drying process. It
is normally expressed in percent moisture removed per hour [%/hr]. Typical
drying rates of rice dryers are in the 0.5%/hr to 1%/hr range.
A drying curve, as illustrated in the figure below, shows how the grain
moisture content (MC) and grain temperature change over time. As can be
seen in the chart, the drying rate is not constant but changes over time. The
temperature of the grain equally changes over time.
 Theoretical drying curves with different drying periods.

3.5.1.1 Drying periods and implications optimal drying

There are three different drying periods which will occur consecutively
in time:

 I. Preheating period (drying rate is almost 0): When wet grain is

exposed to hot air, initially only a very slight change in MC is
observed. This happens because all the heat provided in the drying
air is used to heat up the grain to the drying temperature.

 II. Constant-rate period (drying rate is constant in time): Once the

grain is at the drying temperature, water starts to evaporate from the
surface of the grain. During this period, all the heat from the drying
air is used to evaporate surface moisture and the amount of moisture
removed from the grain is constant in time. It is therefore called the
constant-rate period. During this period, grain temperature
is constant as well.
 III. Falling-rate period (drying rate declines over time): As time
passes, it takes more time for internal moisture to appear at the
surface, and evaporation of water is no longer constant in time. As a
result, drying rate will decline, and some of the heat from the drying
air will heat up the grain. For paddy grain, the falling-rate period
typically occurs at around 18% grain moisture content.

By using the 18% MC and the drying curve characteristics as a

guideline, a few recommendations can be made in regard to grain drying
procedures. These guidelines can be used regardless whether grain is dried
in the sun or by using artificial grain dryers.

3.5.2 Drying rate and temperature

Above 18% MC the grain drying rate can be increased (that is, drying
will occur faster) by providing a higher temperature or more drying air
without major changes in grain temperature. Below 18%MC increase in
drying air temperature will not increase the drying rate but will increase
grain temperatures and potentially damage the grain. Therefore, higher
drying air temperatures can be used to dry grain quickly down to 18% MC
(to remove "surface moisture") but lower temperatures should be used to
remove internal moisture from the grain.

For seed purposes, drying air temperatures should never exceed

43ºC, regardless of the MC, to avoid overheating of the grain which kills the
germ. Exposing paddy to 60ºC for one hour can reduce the seed germination
rate from 95% to 30%. Two hours at 60ºC will reduce the germination rate to
5%.

3.5.3 Uniform drying

 During the drying process there is always variability in MC of
individual grains. Especially in fixed-bed dryers the grains at the air inlet dry
faster than at the air outlet resulting in a moisture gradient in the grain bulk
at the end of the drying process. For production of good quality grain or
seed, this variability should be kept as low as possible. Frequent stirring in
sun drying, grain turning in fixed bed dryers or circulation in re-circulating
batch dryers will improve uniformity of drying, minimize the re-wetting of
dried grains and thus maintain grain quality.

3.5.4 Tempering

When the drying of grain is temporarily stopped the moisture within the grain
equalizes due to diffusion. When drying is restarted, the drying rate becomes higher
compared to continuous drying. The process of stopping intermittently is called
tempering. In addition during tempering the moisture differences between grains
equalize. Tempering therefore also ensures that moisture gradients in the grain
bulk that develop during drying in certain dryer types are minimized.
To maintain grain quality, including a tempering period is
recommended to allow for redistribution of internal moisture in the grain. In
modern re-circulating grain dryers, grain is not dried continuously but goes
through a cycle of drying followed by tempering. This improves drying rates,
grain quality and reduces energy costs.

3.6 Tank Construction:-

Small capacity tanks are fabricated from sheet steel while larger ones
are assembled with cast aluminium. For cooling purpose the tank is welded
with cooling tubes. These are some types of transformer tanks.
Protection of active part in transformer is very important. While
achieving the optimized size of transformer to suit the site condition for
installation. The main role of the tank is to protect the active part and tank
is manufacture to have sufficient strengths to withstand internal & external
faults that may occur during operation. Tanks are fabricated from low
carbon M.S. Sheet of best quality proceed by qualified welders. The tank is
designed to withstand vacuum and pressure test as per Indian /
International standards. A robust skid under base is provided, and guide
bars are located inside the tank to securely fix the core and windings
assembly in position, and to prevent any movement during transportation.
3.7 Tanking & Final Fitting:-

Dried out Core & Coil Assembly is tightened before application of hot oil
shrinkaging for 24 hours. The oil shrinkaging process avoids looseness of
active parts during it's service at site. At last uniform pressing is done on
Core & Coil Assembly. High mechanical rigidity is achieved by hydraulic
pressing at circulated force and tightening all pressure screws. Pressed Core
& Coil Assembly is put in to the tank with proper locating & locking
arrangements which is of prime importance to achieve high resistivity
against transient damages, vibrations during service and Forces develop
during fault occurrence.
 After completion of Core & Coil Assembly insertion in tank, hot, degassed
oil is then allowed into the transformer tank under vacuum. This oil is then
circulated through the transformer and the oil degassing plant until all gas
trapped in the core, windings, and the insulation is removed. This ensures a
high degree of stability in the insulation structure and early attainment of its
mature condition, which would not otherwise be achieved until the
transformer had been in service for some time.
The transformer is made ready for testing after assembly of bushings,
conservators, radiators & all other protective devices .All the joints are
gasketed to avoid leakage with the help of rubberized cork sheets/Nitrite
Rubberized ORing, which can withstand high oil temperature and do not
deteriorate nor contaminate oil in its contact.

3.8 Fitting & Accessories:-

3.8.1 Rating & Terminal Marking Plate

The transformer is supplied with rating and terminal marking plate

made out of non-corrosive metal. The plate contains information concerning
the rating, voltage ratio, weights, oil quantity, vector group, etc. The plate
also includes unit Sr. no. and year of manufacturing.

3.8.2 Tap Changing Arrangement

3.8.2.1 Off-circuit Switch

The transformer is normally fitted with an off-circuit tap changing

switch to obtain required voltage ratio. It can be hand-operated by a switch
handle mounted either or tank cover or on the tank side. The locking device
is fitted to the handle to lock in any tap position. The switch mechanism is
such that it can be locked only when it is located in its proper position and
not in any intermediate position.

The transformer must be isolated from all time the live lines, before operating the
switch.
Operating the switch when transformer is energized, will damage the
switch contacts due to severe arcing between the contacts and many damage
transformer winding.
When switch handle is provided on the side wall, it is necessary that
switch handle assembly is dismantled before undertaking.

Off circuit ratio changing links

Some times links are provided inside the transformer tank to obtain
required voltage ratio. Links are required to be loosened and fixed in new
required position as given in R & D plate. Links are accessible from the
inspection cover. In case of conservator units, oil level has to be lowered
below the inspection cover before unbolting inspection cover.

3.8.2.3 On load tap changer

 The on load tap changer is an optional fitting. The on load tap
changers are provided with local manual control, local electrical control and
remote electrical control. The automatic voltage regulation can also be
provided as an optional fittings.
The tappings are located on high voltage winding.
For further details, please refer to the attached manual of OLTC and
schematics.

3.8.3 Earthing terminals

The core laminations assembly is connected to core clamping frame

which is in turn connected to the tank. Two earthing terminals are provided
on the transformer tank. The earthing terminals should be connected to the
earthing.
3.8.4 Lifting Lugs

Two or four lifting lugs of adequate capacity are provided on a tank

sides/top cover to lift fully assembled transformer filled with oil.
All lugs are designed for simultaneous use and must be used
according. Two or four lifting lugs are provided for undertaking the core and
windings of larger capacity transformer.
All heavy fittings are also provided with individuals lifting lugs.
3.8.5 Valves

Every transformer is provided with drain cum filter valve at bottom of

tank, and filter valve at top of the tank. Valves are fitted with plugs/blanking
plates to stop oil coming out.
Mainly two types of valves are provided.
1. Wheel valves.
2. Butterfly valves.

The wheel valves are used either with female screw threads or with
flanges. These are of gun metal/cast iron type.
Generally, one isolating valve also known as shut off valves is
provided for transformer up to 2000KVA between conservator and buchholz
relay.
The butterfly type cast steel valves with the machined flanges are used at points of
connection between tank and detachable radiators.
3.8.6 Bushings
3.8.6.1 Oil Communicating Type

Transformers windings are connected to the external circuit through

terminal bushings. The bushings are installed on the cover or on side walls
of the transformer tank. The lower end of the bushing protrudes in to the
tank and at both their ends are provided with suitable fasteners to connect
the line leads in side the transformer and external conductors out side it.
The shape and size of the bushings depends on the voltage class, type
of current. Electrical performance of these bushings conforms to I.S 2099
and I.S 7421. dimensional details and associated parts generally conform to
I.S 3 up to 36 KV class. Bushings of 1000 volts are of two piece construction
with out arcing horns, whereas all other bushings is possible without
disturbing the active part. For bushings of two piece construction, tank
cover is required to be removed for necessary access to the inner (lower) end
of the bushings. These bushings are not detached at the time of
transportation.
3.8.6.2 Condenser Bushings

Generally, condenser bushings are used for 72.5KV and above. These
bushings contain their own oil and are sealed to retain the same. Whenever
these bushings are mounted on bushings pockets or raised truncated
portions, air vent pips are provided for carrying away air or gases from these
pockets to Buchholz relay during service typical assembly.
These bushings are detached from the transformers and dispatched
separately. They are packed as per manufacturer‘s instructions. The draw
through type lead is coiled and kept temporarily below the bushing blanking
plate. The equipment required for mounting the bushings are
(1) Rope slings.
(2) Flexible steel wire approx 2mm in diameter, of suitable length.

3.8.7 Cable Boxes

Cable boxes are designed for receiving & protecting cables ends.
Insulating paper is most hygroscopic & all paper insulated cable ends must
be protected by suitable insulating compound. These cable boxes are
provided with brass wiping glands & designed with clearances insides the
box suitables for compound filling. The cable box in such case must be filled
with compound as marked as indicated in the drawling.

Cable boxes of PVC are XLPE cables are designed with air clearances
and hence these boxes are not required to be filled with compound.

Cable boxes of 3.6 KV & above are provided with detachable gland
plates. Earthing terminals are also provided on these cable boxes for
earthing the amounting of individual cable when cable boxes are provided
with disconnecting chambers they permit removal of transformers for
servicing without disturbing cable terminations.

3.8.8 Bus-duct\trunkings

Some users prefer connections to load by means of bus-duct. Bus-

duct is supplied by some other agency However, we provide suitable flanges/
trunkings around transformer bushings for receiving the bus-duct.
The level of the bus-duct flanges from ground/rail level is indicated in
the general Arrangement drawings of the transformer. the complete details
of bus-duct flange is furnished by us giving dimensional details for the
matching flanges, bolt spacing, bushing terminal details, etc
3.8.9 Marshalling Box

The transformer is provided with curtain fittings directly mounted on

the transformer at various location these fittings are having electrical
contacts or terminals which are required to be connected ton the protection
schemes to give alarm/annunciation under abnormal condition and if further
required to disconnect the transformer from mains. in order to facilitate connection
of all such device to the protective scheme, the cable form 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.
It has a hinged door with locking facility to prevent un-authorised
access. The capillaries from OTI & WTI come out from to the bottom of the
marshalling through suitably recessed gland plate thus preventing ingress of
dust.

3.8.10 Magnetic Oil level Gauge (MOG)

This is a dial type oil level indicting device provided on large transformers
with conservator at relatively high levels from the ground. In large
transformers conventional glass oil level indicators are difficult to observe
due to their heights and color change/dust accumulation on the glass.
Further, the low oil contacts provided on the magnetic oil level indicator can
be used for automatic alarm when the oil level in the conservator falls to a
low level. This Protection feature and clear visibility justify the cost of MOG
on a bigger transformer.

It consists of two compartments

(a) The oil side compartment which is fixed on the opening in the
conservator.
(b) The pointer side compartment.

These Compartments are sealed against leakage of oil by a metallic

diaphragm. On the oil side compartment, there is a bevel gear wheel and it is
positioned near the diaphragm. Movement of the float due to rise and fall of
oil level in the conservator results into circular motion of the driving magnet.
A follower magnet is positioned in the pointer side compartment near the
diaphragm. This magnet has its poles face to face to the poles of driving
magnet from the oil side compartment coupling them magnetically. The
movement of float is, therefore, transferred through the diaphragm,
eliminating direct oil light mechanical coupling.
At the other end of the axis of the driven magnet an indication pointer
is fitted. The dial is calibrated to show the oil level in the conservator. The
dial and the pointer area housed behind the front glass. The dial has three
positions marked. The follower magnet has also a cam fitted on it which
operates a mercury switch. When this magnet is at a position corresponding
to low oil level the mercury switch closes the Normally open (NO) contacts.
These contacts are normally wired to give audible alarm. The contacts are
brought to a terminal box at the lower end of the dial, for external
connections.
3.8.11 Oil Temperature indicator (O.T.I.)


Oil Temperature indicator (O.T.I.) is generally provided on all
transformers except for very small ratings. The direct reading
pointer arrangement in this Instrument greatly facilitates
observation of working temp. of oil. It also helps, if need be, in
 deciding the permissible overloads in accordance with  I.S. 6600-
1972. Guide for loading of oil immersed transformers.
  
A Typical - Oil temperature indicator consists of a

Bourdon tube with a pointer arrangement mounted in a case
comprising of a reading dial and a glass cover. There is a
 temperature sensing bulb which communicated
 to the Bourdon
tube through the armoured capillary.

The oil temperature indicator is provided with two pointers and
associated contacts for protection of transformers. Both the
pointers are independently adjustable and can be set to desired
temperature. Setting of these pointers at required temperatures
 can be done form outside through the knob by using special keys.

The OTI is generally housed and wire upto terminal strip in the

observation.
marshalling box having a glass window on the door for
The length of capillary does not influence the accuracy of
measurement and extra length of capillary tubing must not be cut,
as it would break communication between bulb and Bourdon tube.

If the oil temperature increases beyond set limit due to overload or

inadvertent closure of radiator valves or insufficient air draft, the indicating
pointer touches the present alarm pointer actuates the alarm contacts. The
alarm contacts, when duly wired give an alarm. If the alarm is not attended
and there is a further increase of temperature, the trip contacts which are
wired to the trip circuit will operate and isolate the transformer from mains.
3.8.12 Winding Temperature Indicator

Generally for transformers of high power rating a Winding

Temperature Indicator is also required and provided.
A typical - Winding Temperature Indicating (W.T.I.) arrangement
provided in a transformer comprises of the following:
(a) W.T.I. Pot
(b) Image Coil
(c) W.T.I. C.T.
(d) W.T.I.
The W.T.I. Pot is mounted at the top of the transformer tank. Hence
the oil in the W.T.I. pot is at a temperature of TOP OIL. The image coil is a
heater coil and develops additional heat raising the temperature of the oil
inside the heater coil. There is a W.T.I. C.T. mounted on one of the line leads
with its secondary feeding the image coil. As the load on the transformer
varies, the line current varies, the W.T.I. C.T. secondary current passing
through the Image Coil varies, the heat developed by Image coil varies and
hence the temperature of the oil inside the Image Coil varies. The bulb of the
W.T.I. is immersed in the oil inside the Image Coil and as seen above the
temperature of this oil is dependent on Top Oil Temperature and the Load on
the transformer.
The W.T.I. Image coil is designed and calibrated to indicate the
Winding Hot Spot Temperature (HST) because this is the temperature which
decides the life of the transformer. Thus the winding Temperature Indicator
(W.T.I.) reads temperature.

Ambient Air Top Oil

Temperature Temp. Rise 1.1 x GRADIENT
Winding Temperature Indicator is also housed in the marshalling box. W.T.I. also has
an alarm and trip contacts which are wired up to terminal strip. For fan cooled
transformers, the auxiliary contacts of W.T.I. are use for switching ON and OFF the
fans.
3.9 Painting:-

Metal which has been pre-treated by means of shot blasting to remove rust
and welding scale is thoroughly cleaned, and then a coat of epoxy zinc
chromate primer paint is immediately applied to all external surfaces. This
anticorrosive primer has rust inhibitive properties and excellent chemical
resistance. Two coats of Epoxy or PU paint , which is highly resistant to
chemicals and oil, are then applied. Inside surface of the tank is applied with
HOR paint.

3.10 Oil Filling & Filtration:-

All the Transformers are supplied with first filling of oil conforming to IS
335. Before filling, oil is heated, filtered and vacuum treated in filter machine
to remove any foreign particles, moisture and air.
3.11 Testing:-

Before dispatch, each and every transformer is subjected to all routine

tests as specified by IS/IEC/BS/ANSI standards.

TYPES OF TESTING