Maheshv

Installation & Commissioning of Distribution Transformer 2019-2020
EXECUTIVE SUMMARY
Failure of large Distribution transformers having power rating of (25 MVA) or greater can
lead to wide-spread and long-term interruption of electric service. Distribution
Transformers are typically custom-made and difficult to replace with procurement lead
times of one year or more. Furthermore, their large size and weight make them difficult to
transport, often requiring special permitting and equipment, which can add to costs and
delays. These critical components are vulnerable to aging and damage from extreme
weather events like hurricanes or flooding, as well as potential physical attack,
electromagnetic pulses, and geomagnetic disturbances. In the event of an emergency with
multiple Distribution Transformer failures, manufacturers may struggle to meet the demand
for replacements in a timely manner.
Karnataka Vidyuth Kharkhane (KAVIKA) has undertaken steps for Installation &
Commissioning of Distribution Transformers. Scope of the Project covers Specification of
the Requirement of Supply, Installation and Testing of the Distribution Transformer for
Suitable Applications. Tenders Floated in the Year 2005-2006. Receiving Transformers at
BESCOM, CESCOM, HESCOM, MESCOM, GESCOM, and some Private Industries for
Distribution Purpose of (25-500 KVA) 11KV/0.433KV.
Since Distribution Transformers are generally tailored to customer specifications, units are
not readily interchangeable, and their high costs prohibit extensive spare inventories. This
feasibility study investigates a flexible and adaptable Distribution Transformers design
solution which can facilitate long-term replacement in the event of both catastrophic
failures as well as scheduled replacements, thereby increasing grid resilience.
The work requires the supply of Electrical Equipment’s wherever specified, installation of
free Issue and supply items, testing & commissioning of the Transformer Installation
associated with the Electrical works at Self Employment Training. (Electrical Engineer).
The work is to be carried out under the Contract shall, except as otherwise provided in
these conditions, include all labour, materials, tools, plants, equipment and transport,
insurance.
DEPT OF EEE, SJBIT Page no - 1

TABLE OF CONTENTS
• DECLARATION………………………………………………………………... 1
• ABSTRACT…………………………………………………………………....... 4
CHAPTER 1 – ABOUT KAVIKA
1.1 INTRODUCTION……………………………………………………………...... 2-6
1.3 SERVICES……………………………………………………………………..... 7-10
1.4 PRODUCTS…………………………………………………………………….... 11
1.5 FEATURES OF KAVIKA...................................................................................... 12
1.2 MAJOR MILESTONES………………………………………………………...... 6
1.6 CLIENTS…………………………………………………………………….......... 13
CHAPTER 2 – DEPARTMENTS IN KAVIKA
2.1 INTRODUCTION………………………………………………………………... 14
2.2 ROLES AND RESPONSIBILITIES OF INDIVIDUAL DEPARTMENT…….... 16
2.3 SUMMARY………………………………………………………………………. 16
CHAPTER 3 – TRANSFORMERS
3.1 INTRODUCTION……………………………………………………………..... 17
3.2 BACKGROUND OF TRANSFORMERS…………………………………….... 18-19
3.3 IMPORTANCE OF TRANSFORMERS……………………………………...... 20-21
3.4 CONSTRUCTION OF TRANSFORMERS…………………………………..... 22-26
3.5 WORKING OF TRANSFORMERS…………………………………………..... 27-28
3.6 LOSSES IN A TRANSFORMER………………………………………………. 29-31
3.7 REDUCTION OF LOSSES IN THE TRANSFORMER……………………….. 31
3.8 CLASSIFICATION OF TRANSFORMERS………………………………….... 32-34
3.9 SUMMARY……………………………………………………………………... 34
CHAPTER 4 – INSTALLATION OF DISTRIBUTION TRANSFORMER
4.1 LOCATION……………………………………………………………………... 35
4.2 FOUNDATION…………………………………………………………………. 35
4.3 PROVISION FOR OIL DRIANING……………………………………………. 35

4.4 ASSEMBLY OF DISMANTLED COMPONENTS……………………………... 35

4.5 BUSHING……………………………………………………………………….... 36
4.6 CONSERVATOR & M.O.G…………………………………………………….... 35
4.7 BUCHHOLZ RELAY…………………………………………………………...... 38
4.8 BREATHERS……………………………………………………………………... 37
4.9 RADIATORS…………………………………………………………………....... 39
4.10 MARSHALLING BOX………………………………………………………...... 36
4.11 CABLE BOX…………………………………………………………………...... 36
4.12 OTHER FITTINGS……………………………………………………………..... 37
4.13 OIL SAMPLING & FILTRATIONS…………………………………………...... 37
4.14 AIR RELEASE………………………………………………………………........ 37
CHAPTER 5 – COMMISSIONING OF A DISTRIBUTION TRANSFORMER

• PRE - COMMISSIONING TEST- 5.1…………………………………………........ 40
• RATIO TEST- 5.2………………………………………………………………....... 40
• VECTOR GROUP CHECK TEST- 5.3…………………………………………...... 40
• MAGNETISING CURRENT TEST- 5.4………………………………………........ 41
• MAGNETIC BALANCE TEST- 5.5……………………………………………...... 41
• MEASUREMENT OF INSULATION RESISTANCE - 5.6……………………..... 42
• SHORT CIRCUIT TEST- 5.7…………………………………………………......... 43
• PARALLEL OPERATION- 5.8…………………………………………………...... 43
• OTHER RELEVANT DETAILS - 5.9…………………………………………........ 44
• CHECK POINTS - 5.10…………………………………………………………...... 44
• ENERGISING - 5.11……………………………………………………………....... 44
CHAPTER 6 – REFLECTION NOTES
• WORK EXPERIENCE - 6.1……………………………………………………...... 45

• TECHNICAL OUTCOMES - 6.2………………………………………………...... 46
• NON-TECHNICAL OUTCOMES - 6.3………………………………………........ 46
• CONCLUSION - 7……………………………………………………………......... 47
• REFERENCES - 8…………………………………………………………….......... 48
• LIST OF FIGURES-(1.1–2.5)………………………………………………......... 5-42

ABSTRACT
The internship report consists of the experiences and knowledge gained at KAVIKA LTD
on various aspects of “INSTALLATION & COMMISSIONING OF DISTRIBUTION
TRANSFORMER”. Technical exposure towards Installation of a Transformer in Industry
of such High Standard was very useful. The primary incentive is to make sure that the
Transformer meets the Specification. Technical know-how on Important Aspects of
Procurement for Installation. And Commissioning of Transformer as per the Design and
Indian Standards was a very useful Experience. The knowledge and exposure gained are
present in this internship report systematically. During my internship I made a detailed
study on the whole system of the transformer testing station and the whole transformer
manufacturing system. This documentation includes the details description of my study
during my internship. An internship is a type of work experience for entry-level jobseekers.
Internships involve working in your expected career field, either during a semester. Besides
gaining valuable experience, we get exposed to the business environment and gain valuable
references and network contacts. Career counselors, employers, and others have long
touted the importance for students to work one or more internships during their university
years. Internships are seen by students as potentially valuable tools to explore general
career avenues as well as specific companies. Such arrangements can provide us with
valuable work experience (both practical and for résumé enhancement) and an opportunity
to line up a job before graduation. In addition to securing good work experience, students
also may be able to gain academic credit learning by doing and being exposed to
professionals working in the field provides valuable experience, a professional reference
and often leads to a position upon graduation.

CHAPTER 1 – ABOUT KAVIKA
1.1 INTRODUCTION
The KARNATAKA VIDYUTH KARKHANE LIMITED, a fully owned Government

of Karnataka undertaking, is the successor to the Government Electric Factory, the first
ever manufacturer of electrical transformers in the country, established way back in the
year 1933 by the erstwhile Maharaja of Mysore.
Today after eight decades of successful operation KAVIKA has emerged as a renowned
name for distribution transformers in range of 2kVA to 500kVA up to 11kV class as well
as custom built or special type of transformers as per specific requirements.
The secret behind the popularity of KAVIKA transformers is the strict adherence quality
norms at every stage of manufacture. Every product in KAVIKA goes through strict quality
checks at every stage to ensure only the best comes out of the factory. KAVIKA is an
esteemed and renowned organization with a mission and vision. They are as follows:
VISION: “KAVIKA committed to supply energy efficient transformers as per agreed

specifications in time at most competitive rate with enchanted customer satisfaction and to
put efforts continuously to improve the quality of the products supplied and Quality
Management system (QMS)”.
MISSION: “To become a globally competitive transformer production industry while

working as an instrument for achieving self-reliance in design, manufacture and
maintaining the quality of the equipment and diversifying to related areas, managing the
business and commercial lines in a scenario of growing professional contempt.”
Fig . 1.1 Transformers in KAVIKA.LTD

KAVIKA has the following features:
• India’s oldest, largest and the first ever transformer manufacturer
• Excellent infrastructure with trained engineers, technicians, latest technology and

skilled manpower.
• The net worth of KAVIKA (as on 31.03.2016) is ₨ 2275.65 lakhs.
• Possessing crucial processing equipment like Annealing, Furnace, Vacuum Drying

Plant, Oil filtering equipment.
• Strict quality checks at all stages of manufacture.
• Routine tests for all transformers at KAVIKA and is also tested at CPRI, Bangalore.
1.2 MAJOR MILESTONES

• The company was established in 1933 as a Government Electric Factory for
manufacturing of electrical accessories.
• In 1976, the company was incorporated as KAVIKA.
• It was converted into a Government PSU in 1976 with ₨600 lakhs as Authorised
share capital and paid up capital of ₨562 lakhs.
• All the shares are with Government of Karnataka.
• In 1976, company manufacturing only conventional transformers
• The company has obtained Approval/Certification from Bureau of Energy

Efficiency (BEE) for manufacture of star rated transformers.
• The company is shifting its focus from producing the conventional transformers to
the star rated category of transformers of different capacities.
• After 1995 onwards, KAVIKA started using Auto Cad for designing the
transformers.

1.3 SERVICES
The various services which KAVIKA is currently offering are as follows:
1.3.1 REPAIR SERVICES:
WITHIN WARRANTEE PERIOD: The warrantee period for a distribution transformer is

usually 3 years. If there is any problem within the warrantee period, then the company
provides repair services to the customers.
MORE THAN WARRANTEE PERIOD: If any problem occurs in the transformer after
the warrantee period, the company provides repair services to consumer with changes.
1.3.2 ENGINEERING SERVICES:
Utilities processing any problems at the time of installation or in operation condition of

the transformers will be solved by the services engineers.
1.3.3 DESIGN & DEVELOPMENT:
The Design and Drawings Division is computerized, and we are adopting the latest
technology in designing the transformers as per the Indian Standards and customers
specifications. The various documents for procurement of raw-materials, manufacturing
activities, etc., will be issued from this department, in line with the requirement for
manufacture of transformers as per the customers specification.
b. QUALITY CONTROL & TESTING:
This Division will monitor the various manufacturing activities, up to final testing of
transformers to ensure that the transformers coming out will conform to the Indian
standards and customers requirement. The various inspection procedures adopted are as
under o Inspection of raw materials received from various vendors. o Stage inspection at
various levels in manufacturing shops. o Final Testing of the transformers as per Indian
Standards. o Inspection at the dispatch area before dispatch to ensure that the transformers
are fitted with all accessories etc.,

The various procedures and tests conducted are as per the Indian Standards which are quite
elaborative. This department is headed by qualified and experienced engineers and is
having a team of qualified personnel at various stages and they will be independent from
production department to ensure that the quality parameters are complied with, at various
stages of manufacture.
1.3.4 PROCUREMENT OF RAW-MATERIALS:
The major raw materials required for manufacture of good quality of transformers are as
follows:
Silicon Steel Laminations – Cold Rolled Grain Oriented Steel.
Electrical Grade Double Paper Covered Copper/Aluminum Conductors.
Transformer Oil
Insulating Materials like, Insulating Paper, Press Boards, Porcelain Insulators, Varnish,
Paper Tubes, Varnish & Paints etc.,
Bushing Metal Parts and various other MS Items.
Various other fittings like Oil Gauges, Silica gel Breathers, etc.
Mild Steel Tanks
Silicon Steel Laminations:
The laminations are very important raw material, used in manufacture of transformers
which constitutes nearly 50% of the material cost. The quality of this material will maintain
the losses within the specified limits and also life expectancy of the transformer.
Electrical Grade Double Paper Covered Copper/Aluminum Conductors:
We are procuring this material from various reputed suppliers, who can supply the
conductors as per our specification. The material received will be tested at our works, for
resistivity, insulation, tensile strength, etc., before they are put into use.
Transformer Oil:

This material is very important in the performance of the transformer particularly,

longevity. We are procuring the Oil conforming to latest IS 335 from reputed firms. Each
batch of Oil Tankers received at our works will be subject to sample testing. We will
conduct BDV resistivity and Tan Delta tests etc., before the same is accepted. The
Transformer oil will be once again subject to filtration, before filling up into the
transformer in hot condition. This ensures that any moisture or impurities in the transformer
is removed before filling into the transformer.
Insulating Materials :
like, Insulating Paper, Press Boards, Porcelain Insulators, Paper Tubes, etc., These raw
materials are important items in the manufacture of Transformers. Any defects will result
in early failure of transformers. We are procuring these materials from reputed firms and
various other items like Porcelain Insulators, Bushing Metal Parts will be procured from
suppliers who can supply as per our specifications. We will carry out required inspection
and tests on these items before they are used.
1.3.5 MARKETING:
The Company has a long list of satisfied customers. the major customers are the state
Electricity Companies such as Bangalore Electricity Supply Company Ltd., Hubli
Electricity supply company Ltd., Mangalore Eletricity Supply Company Ltd., Gulbarga
Electricity Supply Company Ltd., and Chamundeshwari Electricity Supply Corporation,
Karnataka Power Corporation Ltd., etc., The list not only includes the state Electricity
Companies, but also many Industrial and Commercial Customers such as Bharat Heavy
Electrical Ltd Karnataka State Women’s University, BGS College and other private
institutions, etc.,
The Company has Shown an impressive growth since past five years which is evident from
the audited balance sheet. the sales of transformers has increased from 168 Nos with a
turnover of RS 869 lakhs in 2005-06 to 14610 Nos with a turnover of Rs 7623 lakhs in
2010-11, from loss of Rs 130 lakhs in 2005-06 to a profit of Rs 152 lakhs in
2010.However,the employee strength has reduced from 321 Nos to 210 Nos in
corresponding period.

1. Manufacturer of Quality Oil filled Transformers.
2. Product range - 25KVA to 500KVA 11/0.433kV,3 phase Distribution transformers.
3. Major utility Customers Bangalore Electricity Supply Company Ltd.,
o Hubli Electricity Supply Company Ltd.,
o Mangalore Electricity Supply Company Ltd.,
o Gulbarga Electricity Supply Company Ltd.,
o Chamundeshwari Electricity Supply Corporation Ltd.,
o Karnataka Power Corporation Ltd., Raichur / Shaktinagar.
4. Major Commercial Customers Karnataka Power Transmission Corprn.ltd.,

Tumkur,Belllary,
o Karnataka State Women’s University, Belgaum,
o BGS Institution, and
o Other Private Customers
1.3.6 THE BASIC FACILITIES:
The basic facilities required for manufacturing of good quality transformers are as under
a. Design and Development Division
b. Quality Control and Testing facilities
c. Use of good quality raw materials
d. Various machinery/equipment’s and other infrastructure for manufacturing process.

1.4 PRODUCTS
The Company is manufacturing Distribution Transformers ranging from 10 kVA to 500
kVA, 11 kV Class.
Serial Description Ratings in kVA High kVA Low

No KVA Voltage Voltage
Conventional Transformers
1 3 Phase Aluminum wound 25 to 500 11000 433

Transformers (with or without taps)
2 3 Phase Copper wound Up to 750 11000 433

Transformers
3 Four & Five Star rated transformers Up to 500 11000 433
Special Trans formers
1 Single Phase Neutral Grounding Up to 50 4000 400

Transformers
2 Booster Transformers Up to 2400 13200 11000
3 Special Design Transformers (As per requirements)
Table. 1.1 Types of Transformers manufactured in KAVIKA

1.5 FEATURES OF KAVIKA TRANSFORMERS:
• Vacuum chamber is used in the process of drying the active parts, which helps to
maintain very high insulation resistance (minimum of 1000 Mega ohms at 90o C)
is maintained.
• Good quality lamination of cruciform core from the heart of the transformer.
• Electrolytic Conductor grade conductors of proper tensile strength are used.
• Multi paper covered copper conductor leads of sufficient cross section are used on
the high voltage side.
• “S” type jumpers of sufficient cross section are used in Low voltage connection.
• Solid packing piece made of 100% wood pulp are used for supporting the low
voltage and high voltage coils, which offers sufficient electrical breakdown strength
between the windings and earth parts.
• Proper arrangement for lifting is provided for job as well as tank for proper
handling. In addition to the above all the raw materials are conforming to Indian
Standards.
• In all the stage process quality checks are made and in the final testing stage all the
routine tests are conducted as per BIS on Each and Every transformer before
dispatch.
• Type tests are conducted in CPRI Bangalore from time to time (short circuit, high
voltage and temperature rise test.
The total production capacity is 2000 MVA and about 48,000 number of transformers are
manufactured annually. There are number of satisfied clients and few of them are listed
below:
BESCOM, CESCOM, HESCOM, MESCOM, GESCOM.

1.6 CLIENTS
The main customers are ESCOMs in Karnataka. The company sells approximately 95% of
their products to 5 ESCOMs. Being a State PSU, KAVIKA has an advantage of being
considered on priority given their quality and delivery performance in the past.
Party Total Sales Value (Rs.) Total Received Amount Total

(Rs.) Monthly
receipt
Total Receipt for the year Percentage
BESCOM Rs. 80,24,57,980.98 Rs. 48.24%
75,18,55,185.00
CESCOM Rs. 19,32,60,517.33 Rs. 11.61%
18,10,12,634.00
GESCOM Rs. 23,54,47,691.48 Rs. 12.81%
19,96,77,483.69
HESCOM Rs. 23,58,82,026.74 Rs. 13.23%
20,62,12,105.00
MESCOM Rs. 23,83,26,957.99 Rs. 14.10%
21,97,93,011.00
Total for the Rs. Rs. 100.00%
year 1,70,53,75,174.52 1,55,85,50,418.69
Table . 1.2 Sales value and amounts received for the year 2012 - 2013

CHAPTER - 2
2.1 DEPARTMENT AND THEIR FUNCTIONS

A company is divided into different departments so that the work can be divided amongst
all the departments. All departments work as separate organs for the overall growth and
development of the company. The overall working process of the company involves all the
departments which are interconnected right from design, procurement of materials up to
the dispatch of the finished product. The list of departments are as follows:
1. Design Department
2. Purchase Department
3. Store Department
4. Production Department
5. Quality Control Department
6. Marketing Department
7. Maintenance Department
8. Human Resource and Finance Department
2.1.1 DESIGN DEPARTMENT
Before manufacturing any product, one of most the important step is to design how the
product should be, this designing is done by the design department. The main function of
the design department is to give the design specification of the different types of
transformers as per the quality standards. Transformer Solutions’ design process utilizes
an optimization strategy with the goal of providing the lowest total ownership cost (selling
price + cost of losses) and best transformer design for each customer’s application. To
achieve this goal, an experienced team of engineers most familiar with the customer’s
specification.

2.1.2 PURCHASE DEPARTMENT
After designing the transformer according to the quality standards, the next step is to gather
the raw materials required to manufacture the product. This is done by the purchase
department. The purchase department lists the materials required for manufacturing a
transformer and purchases it as per the requirement.
2.1.3 STORE DEPARTMENT
The materials that are purchased are stored and used whenever the need be, the store
department fulfils this function. The raw materials are distributed to the production
department as per its needs. The store department not only store the raw materials but also
the finished product (transformers) until dispatch.
2.1.4 PRODUCTION DEPARTMENT
The production department uses the raw materials to produce transformers as per the design
and specifications. There are many processes involved in the production of transformers.
The production department is again sub-divided as per the needs of manufacturing a
transformer. After the manufacture of a transformer, its quality is tested before dispatch.
2.1.5 QUALITY CONTROL DEPARTMENT
The objective of the QC department is testing of the raw material as well as the final
product (transformers) as per the specified requirement to ensure the quality of raw
materials used and the quality of the final product remains as per specification. The QC is
responsible for receiving, inspection and testing of the incoming items as per applicable
procedure and maintain records.

2.1.6 MARKETING DEPARTMENT
Marketing department plays several roles in helping the company deliver high quality
goods and services to target consumers. To increase the sales of the transformers annually,
to provide customer care and services, to identify potential customers are few of its
functions.
2.1.7 MAINTAINANCE AND REPAIR DEPARTMENT
The main function of this department is to maintain the equipment and avoid breakdown
problems as much as possible. Also, to ensure the repair of the equipment in case there is
breakdown of the equipment.
2.1.8 HUMAN RESOURCE AND FINANCE DEPARTMENT
The main function of this department is to ensure that trained and qualified man power is
available at the right time and place. It also reviews the minimum qualification on basis of
the future requirements. HRD is a continuous process to ensure development of
employee’s competencies, motivation and effectiveness in a planned and systematic way.

CHAPTER - 3
TRANSFORMERS
3.1 INTRODUCTION
Transformer is an ac machine that transfers electrical energy from one electrical circuit to
another without changing frequency by the principle of electromagnetic induction. Since
its 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%. The action of a transformer is based on the principle that energy may be efficiently
transferred by induction from one set of coils to another by means of varying magnetic flux
, provided that both the sets of coils are on a common magnetic circuit. The emfs are
induced by the variation in the magnitude of flux with time. It is based on Faradays law of
electromagnetic induction. Transformers are capable of either increasing or decreasing the
voltage and current levels of their supply, without modifying its frequency, or the amount
of electrical power being transferred from one winding to another via the magnetic circuit.
A single-phase voltage transformer basically consists of two electrical coils of wire, one
called the “Primary Winding” and another called the “Secondary Winding”. For this
tutorial we will define the “primary” side of the transformer as the side that usually takes
power, and the “secondary” as the side that usually delivers power. In a single-phase
voltage transformer, the primary is usually the side with the higher voltage.

3.2 BACKGROUND OF A TRANSFORMER

1886
1885
William Stanley's First Transformer built in

1885. Single phase AC power.
Stanley's first transformer which was used
in the electrification of Great Barrington,
Massachusetts in 1886.
Fig . 1.2 History of Transformers
In 1831 Michael Faraday discovered the principles that make transformers possible.
Using an induction ring Faraday discovered that an electric current flowing through one
wire could have the effect of creating or “inducing” an identical current in a nearby wire.
This only happens when the voltage is changing—such as when the power is snapped on
and the voltage rises from 0 to its peak.
In 1881, in Paris, Lucien Gaillard and John Dixon Gibbs demonstrated the first
commercially successful transformer. In 1886, William Stanley would build upon ‘Gaillard
and Gibbs' idea to provide alternating current electrification to offices and stores on Main
Street in Great Barrington, Massachusetts.

In 1831Michael Faraday discovered the principle of induction (Faraday's induction law)

and did the first experiments with induction between coils of wire, including building a
pair of coils on a toroidal closed magnetic core.
In 1878Thomas Alva Edison an American inventor, founds the Edison Electric Light
Co. in New York. In 2979, he presents his first incandescent light bulb, which stays lit for
45 hours.
In 1882Edison Inaugurates the first "electric plants" (producing DC power), built in

London and New York. The first DC electric power transmission line is constructed in
Germany: 2400V, 59 km
In 1886George Westinghouse, an American inventor and industrial entrepreneur, shows

an interest in industrial electricity and founds the Westinghouse Electric Corporation.
After having obtained a patent in 1887 for a transformer, he creates the first AC supply
system for lighting in Buffalo, NY. He wins an installation contract, defeating Edison, for
all electric infrastructure in the US. It's for this reason that AC distribution is imposed
throughout the entire world today.
1924: Construction of the north-south 110 Kv overhead power line linking German coal-
fired electric power plants located near the Rhine to hydro-electric plants in the Alps.
1967: The extra-high voltage networks (380 kV) of France, the Federal Republic of
Germany and Switzerland are interconnected for the first time at the Laufenberg substation
in Switzerland

3.3 IMPORTANCE OF TRANSFORMERS
In this present world, two things are very important, and they are electricity and vehicles
and without these things, many people struggle a lot. I think, I am not wrong when
considering these points because without electricity the world gets stumbled and many
activities do not take place, and this depletes the economy of any country. Hope, not much
more introductions needed for vehicles and the same drawbacks suits for vehicles. Waste
neither time nor money but make the best use of both. Without industry and frugality,
nothing will do, and with them everything." Says Benjamin Franklin and I hope everyone
will accept his quotes with the help of industries both the people and country economy get
improved.
In our daily life, electricity has become the major part of a life and life without electricity
can't be imagined. Industries definitely need continuous supply of electricity and they
definitely need transformers for avoiding voltage fluctuations and the malfunction of some
machines is due to voltage problems. A transformer is a solution for all these problems,
and it has the capacity to rectify it. Different types of transformers exist, and each have
their own benefits and rectify the voltage fluctuations in one or other way. Custom current
transformer, fly back transformer, high transformer voltage, high voltage transformer and
electrical transformer are the different types of transformers available.
There are different types of transformers based on size, color, design, voltage rating and
various other parameters ,thus, one can buy based on one’s industrial’s current needs.
Transformers are quite simple to install and handle and prove to be hassle free in
maintenance.
Transformers are low maintenance, easy to install and thus require less workforce. They
make the industrial work smoother and faster. They prove to be a low-cost solution for
high capacity machines and correction of the voltage to prevent accidents. Therefore, any
Production or efficient functioning of any industry requires installation of a transformer.
simple words, transformers are very important for the constant working of your industry.

PRINCIPLES INVOLVED IN WORKING OF A TRANSFORMER
FARADAY’S FIRST LAW OF ELECTROMAGNETIC

INDUCTION: Whenever a conductor is placed in a varying magnetic field an EMF gets
induced across the conductor (called as induced emf), and if the conductor is a closed
circuit then induced current flows through it.
FARADAY’S SECOND LAW OF ELECTROMAGNETIC

INDUCTION: The magnitude of induced emf is proportional to the rate of change of flux
linkages with the coil.
LENZ’S LAW: When an emf is induced according to Faraday's law, the polarity (direction)
of that induced emf is such that it opposes the cause of its production.
PRINCIPLE OF MUTUAL INDUCTION: When two or more coils

are magnetically linked to each other, then an alternating current flowing through one coil
causes an induced emf across the other linked coils. This phenomenon is called as mutual
induction.
Fig . 1.3 Transformer Parts and Accessories

3.4 CONSTRUCTION OF A TRANSFORMER
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.
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.

TYPES OF WINDING:-
1) Helical Winding
2) Layer Winding
3) Disc Winding
4) Interleaved Winding
Fig . 1.4 Helical and Interleaved Windings
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.

3.4.1 – CORE ASSAEMBLY
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 Hi 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 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 metered corners as shown in shows a large
core being built in the manufacturer’s works.
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.

3.4.2 - 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.
Fig . 1.5 Core and Coil Assembly

Fig . 1.6 Core Assembly
Fig. 1.7 E &I Shape Assembly

3.5 WORKING OF A TRANSFORMER
Fig. 1.8 Transformers

Where:
VP - is the Primary Voltage
VS - is the Secondary Voltage
Manufacturing & Testing of Distribution Transformers
NP - is the Number of Primary Windings
NS - is the Number of Secondary Windings
Φ (phi) - is the Flux Linkage
Notice that the two coil windings are not electrically connected but are only linked
magnetically. A single-phase transformer can operate to either increase or decrease the
voltage applied to the primary winding. When a transformer is used to “increase” the
voltage on its secondary winding with respect to the primary, it is called a Step-up
transformer. When it is used to “decrease” the voltage on the secondary winding with
respect to the primary it is called a Step-down transformer. However, a third condition
exists in which a transformer produces the same voltage on its secondary as is applied to
its primary winding. In other words, its output is identical with respect to voltage, current
and power transferred.

This type of transformer is called an “Impedance Transformer” and is mainly used for
impedance matching or the isolation of adjoining electrical circuits. The difference in
voltage between the primary and the secondary windings is achieved by changing the
number of coils turns in the primary winding (NP) compared to the number of coil turns
on the secondary winding (NS). As the transformer is basically a linear device, a ratio now
exists between the number of turns of the primary coil divided by the number of turns of
the secondary coil. This ratio, called the ratio of transformation, more commonly known
as a transformer “turns ratio”, (TR). This turns ratio value dictates the operation of the
transformer and the corresponding voltage available on the secondary winding. It is
necessary to know the ratio of the number of turns of wire on the primary winding
compared to the secondary winding. The turns ratio, which has no units, compares the two
windings in order and is written with a colon, such as 3:1 (3-to1). This means in this
example, that if there are 3 volts on the primary winding there will be 1 volt on the
secondary winding, 3 volts-to-1 volts. Then we can see that if the ratio between the number
of turns changes the resulting voltages must also change by the same ratio, and this is true.
Transformers are all about “ratios”. The ratio of the primary to the secondary, the ratio of
the input to the output, and the turns ratio of any given transformer will be the same as its
voltage ratio. In other words, for a transformer: “turns ratio = 3:1”
The most important uses and application of Transformer are:
• It can rise or lower the level of level of Voltage or Current (when voltage increases,
current decreases and vice versa because P =V x I, and Power is same ) in an AC
Circuit.
• It can increase or decrease the value of capacitor, an inductor or resistance in an AC

circuit. It can thus act as an impedance transferring device.
• It can be used to prevent DC from passing from one circuit to the other.
• It can isolate two circuits electrically.

3.6 LOSSES IN A TRANSFORMER
Fig . 1.9 Losses in Transformer
3.6.1 COPPER LOSSES: Current flowing through the windings causes resistive
heating of the conductors. At higher frequencies, skin effect and proximity effect create
additional winding resistance and losses.
Total copper losses. = I12. R1+ I22R2 = I12. R 01+ I22R 02
3.6.2 CORE-LOSSES: There are two types of core or iron losses in a Transformer.
3.6.2.1 Hysteresis Losses: Each time the magnetic field is reversed, a small amount
of energy is lost due to hysteresis within the core. For a given core material, the transformer
losses are proportional to the frequency, and is a function of the peak flux density to which
it is subjected.
We can find Hysteresis losses by this formula.
Wh = ηB1.6maxf.v watt.

3.6.2.2 Eddy Current Losses
Ferromagnetic materials are also good conductors, and a core made from such a material
also constitutes a single short-circuited turn throughout its entire length. Eddy currents
therefore circulate within the core in a plane normal to the flux and are responsible for
resistive heating of the core material.
The eddy current loss is a complex function of the square of supply frequency and inverse
square of the material thickness.
We = PB2max.f2t2 Watt.
3.6.3 Stray losses (leakage Flux)
Leakage inductance is by itself largely lossless, since energy supplied to its magnetic fields
is returned to the supply with the next halfcycle. However, any leakage flux that intercepts
nearby conductive materials such as the transformer’s support structure will give rise to
eddy currents and be converted to heat. There are also radiative losses due to the oscillating
magnetic field, but these are usually small and negligible. Dielectric Loss
In the solid insulation or transformer oil i.e. insulation material of the transformer,
dielectric loss occurs when the solid insulation gets damaged or the oil gets deteriorated or
its quality decreases over the time. Hence, the overall efficiency of transformer may be
affected due to this loss.
3.6.4 Other Losses
3.6.4.1 Magnetostriction Losses
Magnetic flux in a ferromagnetic material, such as the core, causes it to physically expand
and contract slightly with each cycle of the magnetic field, an effect known as
magnetostriction. This produces the buzzing sound commonly associated with
transformers and can cause losses due to frictional heating.

3.6.4.2 Mechanical losses
In addition to magnetostriction, the alternating magnetic field causes fluctuating forces

between the primary and secondary windings. These incite vibrations within nearby metal
work, adding to the buzzing noise, and consuming a small amount of power.
3.6.5 Reduction of Losses

1. COPPER LOSSES: To reduce copper losses the resistance of the wire must be
reduced. The resistance can be reduced by increasing the cross-sectional area of the
wire and reducing the
length of the wire. i.e.
2. CORE LOSSES: There are two types of core losses:
• HYSTERISIS LOSS: In view of minimizing hysteresis

losses, soft magnetic materials for ex: Si steel, steel alloys, Mn-Zn ferrite
are used because they have high saturation magnetization, Low coercivity,
High magnetic permeability etc. which reduce losses due to hysteresis.
• EDDY CURRENT LOSSES: In view of reducing eddy

current losses, the magnetic core of the transformer is not made from a
single magnetic material; because in this case the circulating eddy current
flowing will be higher. Instead the magnetic core is a stack of thin silicon
steel lamination and the laminations are insulated from one another by thin
layer of varnish to reduce eddy current and hence eddy current losses.
3. STRAY LOSSES: These types of losses can be reduced by use of small

dimensioned conductors for windings, use of CTC conductors in case of higher
current windings, optimum transposition of the parallel strands, magnetic shielding
of the inner tank walls, use of non-magnetic shield in area of strong magnetic fields.

3.7 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
There are two general types of transformers
1. Core type transformer
2. Shell type transformer
These two differ by the manner in which the windings are wound around the magnetic core.
The advantages of each type are:
core-type (or three limbs) is the most commonly used method of construction, the
smaller core means less weight and expense. Core-type provides better insulation between
the primary and secondary because of its inherent two windings.

shell-type (or five limbs) is used for larger transformers because they can be made with
a reduced height. Shell-type provides a higher degree of mechanical protection to the
winding because it is surrounded by core.
Core Type Transformer:

In the core-type, the windings surround a considerable part of steel core as shown in fig
(a). The core type transformers require more conductor material and less iron when
compared to shell type. The vertical portions of the core are usually called limbs or legs
and the top and bottom portions are called the yoke. For single phase transformers, core-
type has two-legged core. In order to reduce leakage flux, half of the L.V. winding is placed
over one leg and other half over other leg. For H.V. winding also, half of the winding is
placed over one leg and the other half over the other leg. L.V. winding is placed adjacent
to the steel core and H.V. winding outside, in order to minimize the amount of insulation
required.
Fig . 2.0 Core and Shell Type Transformers
Shell Type Transformer: In the core-type, the steel core surrounds a considerable part of
the windings as shown in fig (b). Shell-type transformer has three-legged core. The L.V.
and H.V. windings are wound on the central limb. In order to reduce leakage flux, the
windings are interleaved or sandwiched. The shell type transformers require more iron and
less conductor material when compared to core-type.

There are two types of windings employed for transformers.
1. Concentric coils.
2. Interleaved coils.
On basis of their purpose
• Step up transformer: Voltage increases (with subsequent decrease in current) at

secondary.
• Step down transformer: Voltage decreases (with subsequent increase in current) at

secondary. On basis of type of supply
• Single phase transformer
• Three phase transformers On basis of their use
• Power transformer: Used in transmission network, high rating
• Distribution transformer: Used in distribution network, comparatively lower rating

than that of power transformers.
• Instrument transformer: Used in relay and protection purpose in different

instruments in industries
1. Current transformer (CT)
2. Potential transformer (PT)
On basis of cooling employed
• Oil-filled self-cooled type

• Oil-filled water-cooled type
• Air blast type (air cooled)

CHAPTER – 4
INSTALLATION
This section illustrated procedure for installation & Commissioning of our transformers. A
format of “Commissioning Report” is included at the end of this section. Results of various
pre commissioning tests as well as well as confirmation of check point are to be recorded
in this report. This Report then would saver as a handy record for future reference.
4.1.1 Location
The transformer should be kept in a well-ventilated place, free from excessive dust,
corrosive fumes etc. Adequate ventilation is necessary for tank radiators so that they can
dissipate heat. There should be clear space of about 1.25 m on all sides of the transformers
if it is enclosed in a room.
4.1.2 Foundation
Foundation should be firm, horizontal and dry. Where rollers are fitted, suitable rails should
be provided.
4.1.3 Provision for oil draining

Necessary provisions for oil draining, in the event of a fire, should be made by way of oil
soak pits. Fire separation walls should also be provided when necessary.
4.1.4 Assembly of Dismantled components

Various components dismantled for transportation should be duly assembled.
4.1.5 Conservator & M.O.G.

Note details of M.O.G. in the “Commissioning Report”. If the M.O.G. is provided with a
locking lever, it should be removed. Mount the conservator. When there is as OLTC its
conservator is sometimes provided separately or by making a partitioned compartment in
the main conservator. OLTC conservator, if separate, should also be mounted

4.1.6 Bushing
Clean the bushings and check that there are no hair-cracks or other damages. Test IR value
of each bushing with a 500V Megger. It should be 100 M ohms or greater. Note details of
Bushings in the “Commissioning Report.” Mount all the bushings . Ensure that the test tap
cap is fully tightened, thus positively grounding the same. Adjust the Arcing Horn Gaps in
accordance with the Insulation Co-ordination Note these values in the “Commissioning
Report”.
Fig . 2.1 Bushing
4.1.7 Marshalling Box

Marshalling box should be fitted in position. Pockets of O.T.I. & W.T.I. should be filled
with transformer oil. Bulbs of O.T.I. & W.T.I. should be fitted in position in their respective
pockets.
Set the ‘Alarm’ & ‘Trip’ contacts of O.T.I & W.T.I. at required values. O.T.I. setting as
A=85 C & T=95 C W.T.I. setting of A-95 C & T+ 105 C are considered good. They can
be worked out to suit local conditions.
4.1.8 Cable Box

When Cable Boxes are provided, they should be mounted, and cable terminations done.
Oil filled cable-boxes should be duly filled with oil. In case of “Bus-Duct” connections,
transformer is provided with a flange to receive the bus-duct. Due connection and fitting
should be done to over-head line by a terminal connector.

4.1.9 Other fittings

Note the details of other important fittings like fans in the “Commissioning Report” and
mount these fittings.
4.1.10 Oil Sampling & Filtrations

Taking usual precaution, draw oil samples from Bottom & Top of main tank and from
OLTC. They should be tested for BDV. If they meet the requirements of I.S. 1866 for new
transformers, no further processing is required. However, if they do not meet the
requirements, oil needs to be filtered till the required BDV is obtained. Note the BDV
values in the “Commissioning Report”.
4.1.11 Air Release

Release air by slowly unscrewing Air Release Plugs provide at Bushings, Bushing Pockets,
Buchholz Relay, Main Tank Cover, Oil Surge Relay etc. From plain porcelain bushing of
11, 22 & 33 KV, air can be released by loosening the nut pressing the rubber gasket and
pressing the metal part down.
4.1.12 Breathers
Note details of Breathers, in the “Commissioning Report.” If OLTC is provided, it may
have its own separate breather
Fig . 2.2 Breathers
If OLTC is provided, it may have its own separate breather. Note details of these Breathers
also in the “Commissioning Report”. Check that the colour of silica Gel in Main Breather
is Blue. Remove the rubber cap closing the breather pipe and fit the

breather. Fill oil in the oil cup and remove the seal which closes the breather opening.
Similarly mount the OLTC breather. Silica gel crystal has tremendous capacity of
absorbing moisture. When air passes through these crystals in the breather; the moisture of
the air is absorbed by them. Therefore, the air reaches to the conservator is quite dry, the
dust particles in the air get trapped by the oil in the oil seal cup.
4.1.13 Buchholz Relay

Note details of “Buchholz Relay” for the transformer and of “Oil Surge Relay” for the
OLTC in the “Commissioning Report.” Buchholz Relay floats are tied to prevent transit
damage. They should be released. Also, if ‘ Test’ lever is provided, it should be in the
working position. Mount the “Buchholz Relay” and the shut off valves as described in
Similarly mount “Oil Surge Relay”.
Fig . 2.3 Buchholz Relay

4.1.14 Radiators
(i) Radiators are to be assembled only one at time.
(ii) Oil required to fill in the radiators is sent separately in drums. Test oil sample from
each drum for BDV. Ensure it is more than minimum specified in I.S. 1866 for New
Transformer.
(iii) Fill the conservator full using an oil filter machine, if available.
(iv) Clean one radiator externally. Remove blanking plates and clean the gaskets and
radiator flanges. If gaskets are damaged, use spare gaskets.
(v) If blanking plates are not in position and it is suspected that foreign material might
have entered the radiators, clean them internally by flushing fresh and clean
transformer oil.
(vi) Oil might seep through the tank side radiator valves and be retained by the blanking
plates. This oil should be collected in a clean container at the time of removing top
and bottom blanking plates.
(vii) Open the bottom radiator valve using the operating handle. Gradually unscrew the
air release plug on the top of the radiator, until air starts escaping. Air release plug
should not be removed from the engaging threads as it would be difficult to control
oil coming out of it.
Fig . 2.4 Radiators

CHAPTER – 5
COMMISSIONING
5.1 Pre-Commissioning Test

Prior to energizing the transformer, several pre-commissioning test are done. The objective
of these tests is confirmed that the transformer has not suffered damage during transit and
also to check any inadvertent slips in the factory tests, or supply.
5.2 Ratio Test

Ratio between all the three corresponding H.V. & L.V. phases is to be measured on all
taps. It is desirable to do this test by a Ratio-meter. But if it is not available, a simple test
of measuring voltages can also serve the purpose.
Referring to R&D plate, fine out which terminals of H.V. & L.V. correspond to one phase
e.g. for a vector Group of Dyn-11, H.V. Terminals 1U, 1V, & L.V. terminals 2U, 2N
correspond to U phase. Apply single phase, 415 V or 240 V, AC., 50 Hz to H.V. side and
measure voltage on the L.V. side. Measure these voltages on all taps and note them in
“Commissioning Report” Repeat for the other two phase. These observations should
indicate a consistent trend of variation in line with the details given in R&D Plates.
Numerical values should approximately check with the voltage ratio
5.3 Vector Group Check Test

Connect terminals 1U, 2U together. Apply 3 phase, 415 V, 50 Hz. AC. To H.V. terminals
1U, 1V, 1W. Measure voltages between terminals 1V-2V, 1V-2W & 1W-2V, 1W-2W (or
suitable other voltages if required). Check that the measured Voltages confirm the relative
position of H.V. & L.V. vector group. For vector group Dyn-11.
H. V. & L.V. vectors are shown independently positioned for Dyn-11, For the condition
1U & 2U connected together, L.V. Vectors are redrawn as shown. With this configuration,
Voltages 1V-2V & 1V-2W will be equal while 1W-2V will be greater than 1W-2W. The
method can be extended to any other Vector Group. Note the observations in the
“Commissioning Report”.

5.4 Magnetising Current Test

Apply 415 volts, 2 phases, AC. to the H.V. terminals, keeping the L.V. terminals open and
tapping switch in the normal position. Measure the 3-line currents, if possible,
simultaneously, otherwise one after the other. Because the 3 phases of the magnetic circuit
of the core are not similar, the 3-line currents will be approximately equal & v phase current
around 80% of either of them. If H.V. is delta connected, V & W phase currents will be
approximately equal and U phase current around 110 %
In case of Power Transformers, such a test is done, sometimes, along with routine tests at
the manufacturer works. When done at site and results compared with the factory test
confirms that there are no transit damages to the core and windings. Note the observations
in the “Commissioning Report”.
5.5 Magnetic Balance Test

This is a simple test to detect shorted turns is a winding. Its principle is that shorted turns
oppose establishment of flux in that limb because of the current that circulates through the
shorted turns.
As indicated in 3.3.2 apply single phase, 415 or 240 V. A.C. to such H.V. line terminals
which would energies U phase. (outer limb) Use an averaging instrument like a Multimeter
Measure the voltages induced in the V phase (Centre limb and W phase (other outer lime).
Measure also the current drawn by the energized phase. In case the H.V. Voltage is 66 KV
and above, the current drawn may be very small. In that case L.V. would, generally, be 11
KV or more. This test can, then, be carried out on L.V. Side. Centre limb being nearer to
the energized limb, more flux passes through it and less flux in the outer limb. The division
is around 70-30 % & hence the measured voltages will be having approx. this proportion.
Next, energies W phase and measure the other two voltages as before. Results should be
similar to previous ones. Then energies V phase (Centre limb). As both the outer limbs are
symmetrically located W.R.T. centre limb, flux will divide equally between them. Hence
the voltages measured on outer phases will be approx. equal.
In case one of the phases has shorted turns, it will draw a comparatively large current
when it is energized. When other phases are energized, flux and hence voltage in the

shorted phase will be significantly reduced. Hence all three observations will indicate the
shorted phase. Note the observations in the “Commissioning Report”.
5.6 Measurement of Insulation Resistance
Measure Insulation Resistance (IR) between windings and between windings and earth
with a 2500/1000V Megger, preferably motor driven otherwise hand driven. Before
measuring I.R., thoroughly clean all the bushings with clean cotton cloth, if required using
Carbon Tetrachloride. Also, there should be no external connections to the transformer
terminals. Check and adjust, if required, the infinity setting of the Megger. Lead wires from
the Megger to the transformer should run independently and be permanently clamped. They
should not have any joints. It is known that the I.R. reading continues to increase initially
and for comparison purpose, reading continues to increase initially and for comparison
purpose, reading is to be taken at 1 minute of energizing. It is also known that I.R. value is
dependent on temperature. Hence temperature at the times of measurement should be
noted. Compare the I.R. values measured, with the Factory results keeping in view the
temperature at the time of measurement. Note the observations in “commissioning Report.
Fig. 2.5 Insulation Resistance Test

5.7 Short-Circuit Test

For the H.V. side voltage and the % impedance, it would be possible to calculate the current
which would flow in the H.V. side, with 415V applied to it, while keeping L.V. side
shorted. If the 415 V source can feed that current, a short-circuit test can be carried out.
This test would confirm proper contact engagement at all tap positions. Apply 3 ph. 415
V, 50 Hz to H.V. side, keeping L.V. side shorted. Measure the 3-line currents at all tap
positions. If the switch is an OFF-CIRCUIT switch, supply has to be disconnected before
changing tap. Note the observations in the “Commissioning Report”. Note also details of
OLTC, if any.
A Consistent trend indicates healthiness. If short-circuit test is not possible due to limitation
of source, carry out one tap changing operation over the entire range increasing as well as
decreasing. Check the other modes of OLTS operation and note in “Commissioning
Report”.
5.8 Parallel Operation

Sometimes the transformer to be commissioned is required to run in parallel with an
existing transformer. In is case, the following conditions must be fulfilled by the incoming
transformer.
(1) Its voltage ratio is same as the existing transformer on all tapings.
(2) Its % Impedance is within +1% of value of existing transformer.
(3) Rated KVAs of the two transformers to be connected in parallel should not differ
by more than 1:3 as otherwise only marginal increase will be obtained in the
capacity of the combination.
(4) Vector group is compatible. If the vector groups of the two are such that terminals to
be paralleled have a phase different then they cannot be connected in parallel. Hence
only certain Vector Groups are compatible with each other.
NOTE: Due to difference in % impedances, when one transformer reaches its rated load,
the other would share less than its rated load. As a result, the combination can supply load
less than the sum of the two KVAs.

5.9 Other Relevant Details

Other controlling and protecting equipment like C.T.s, Breakers, relays etc. from a part of
the transformer installation. Note their details in “Commissioning Report”
5.10 Check Points

After completing installation and pre-commissioning tests, check that the various points
mentioned in the “Commissioning Report” have been complied with. Compliance nothings
should be made in the “Commissioning Report”.
5.11 Energising
When all the pre-commissioning tests are found satisfactory and all the check points are
confirmed the transformer can be energized on No load. It is preferable to keep settings of
all protective relays to the minimum. The transformer should be allowed to run on No-
Load for about 3 hours. During this period, the transformer should be observed for any
abnormality in the hum and gas collection in the Buchholz Relay. Sometimes during this
period, trapped air is released and gets accumulated in Buchholz Relay.
At the end of this 3 hours period, transformer should be de-energized, and air released from
Bushings, Bushing pockets, Buchholz Relay, Main tank cover, Radiators etc. The
transformer should, then, be energized again and then relays set at their desired setting.
Transformer should then be gradually loaded reaching full load in about 3 hours’ time.
During the period and for further 3 hours, (i.e. total of 6 hours) transformer should be under
observation. Check that all instruments, O.T.I & W.T.I, M.O.G. are reading properly and
that all radiators are uniformly hot. The “Commissioning Report” should be duly signed
by the Authorized representatives of all the participating organizations.

CHAPTER – 6
REFLECTION NOTES
6.1 WORK EXPERIENCE

Internship at KARNATAKA VIDYUTH KARKANE LIMITED
was started from 10.07.2019 for a period of one month. Getting internship was really a
tough task after a month of search, internship was granted in this esteemed company.
Before starting the internship, we had visited the company and finally the Deputy Manager
of the company agreed to provide internship. The Deputy Manager is very knowledgeable
person with 20+ years of experience in the industry. Personnel Officer assigned topic,
which is manufacturing and testing of distribution transformer.
During the internship period we had the opportunity to interact with several employees, a
task which further enabled us to access their knowledge and experience in technical and
non-technical aspects. The experience gained is vast and they are briefed in points below.
• Overseeing the planning, operation and interdepartmental function that contributes to

the smooth functioning of the organization.
• Strategic planning of production that helps in achieving the monthly and yearly targets
with less discrepancy.
• Chance to learn on the existing production process with revising and developing and
the processes and operations.
• Interacting with various staffs for gaining their experience and increasing the practical
skills of real time working in an organization.
• Identifying drawbacks in the present process and improving it for further optimization
of the production process and betterment of the quality.
• Performing the above related work as assigned.
• The discipline followed to achieve customer satisfaction about quality structure of the
management, management information systems and the procedures of management in
advance adept quality control.

6.2 TECHNICAL OUTCOMES

• Learnt about the safety precautions to be followed while performing every task and
completing it without causing damage to life and property.
• Learnt about safety procedure like first aid to be followed in case of emergency.
• Increased our knowledge on transformers’ practical construction.
• Had a chance to witness SC and OC test on larger kVA transformer.
6.3 NON-TECHNICAL OUTCOMES
• Learnt how to manage a store and track the usage of materials and how to
economically use the materials available.
• Learnt the working of commercial department, as to how they produce the materials
and how they choose the best vendor.
• Learnt the functioning of Admin and HR department and gathered information

about how they train the new employee.
• Handling the work alone did learn to be punctual and competing the tasks on right
time.
After completion of the internship in overall confidence was boosted and could
successfully handle the work alone and complete it on time
Summary
In this section focus is on various task performed in the organization and technical
and non-technical skill acquired. In the next chapter technical and non-technical
experiences is highlighted.

7. CONCLUSION
Process study was done for every activity of the production process and mapped. Much of
the in-process assemblies of the coil was sent to rework because of inaccuracy of winding
process and core assembly process which was studied in detail and steps were suggested
to make the more accurate and efficient.
Finally, a study of failure mode and effects analysis of transformers was done in which the
main caused for the failure of a transformer was studied. The occurrence of these causes,
the severity of the causes and rectification of these causes were found. Some of these causes
were found in the production of the transformer for which alternative method were
suggested in order to eliminate the occurrence of causes of failure.
As one of the oldest serving company today, KAVIKA Limited has emerged as
manufacturer of quality transformer which I ISO: 9001-2008 certified. The integration of
the entire department towards this was well made use of and the efficient use of existing
staff, workers and assists in the key to its success. Interaction with all the staff and workers
gave an idea of how each function is performed with pin to pin detail of each and ever),
operation involved.
Apart from manager, workers were also well versed with all the processes which were
mainly due to work rotation. Real time experience on production scheduling, labour
management and work force allocation was gained. Even though the company does not use
the latest technology, it makes up for it in skill of the workers. Preference to quality one of
the most important things that help the company gains reputation. Real time problem
arising in the shop floor were observed and step taken immediately to curb be seen. It also
gave an opportunity to study the weakness of some process along with their strength.
Detailed study of problem helped in gaining in practical knowledge on how the
improvement process can be applied such as QC tools, of quality control and improvement
processes.

8.REFERENCES
1.Literature titled company profile available at URL: http: www.kavika.co.in
2.Literature titled Transformer testing available at URL: http://www.electrical4u.com

3. Literature titled Electrical Transformer - Installation, Commissioning and Types at
“Installation & Commissioning of Electrical Equipments by S.Rao”

Maheshv

Încărcat de

Informații document

Titlu original

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

Maheshv

Încărcat de

Drepturi de autor:

Formate disponibile

Installation & Commissioning of Distribution Transformer 2019-2020

DEPT OF EEE, SJBIT Page no - 1

DEPT OF EEE, SJBIT Page no - 2

4.4 ASSEMBLY OF DISMANTLED COMPONENTS……………………………... 35

CHAPTER 5 – COMMISSIONING OF A DISTRIBUTION TRANSFORMER

CHAPTER 6 – REFLECTION NOTES

• WORK EXPERIENCE - 6.1……………………………………………………...... 45

DEPT OF EEE, SJBIT Page no - 3

DEPT OF EEE, SJBIT Page no - 4

CHAPTER 1 – ABOUT KAVIKA

The KARNATAKA VIDYUTH KARKHANE LIMITED, a fully owned Government

VISION: “KAVIKA committed to supply energy efficient transformers as per agreed

MISSION: “To become a globally competitive transformer production industry while

Fig . 1.1 Transformers in KAVIKA.LTD

DEPT OF EEE, SJBIT Page no - 5

KAVIKA has the following features:

• India’s oldest, largest and the first ever transformer manufacturer

• Excellent infrastructure with trained engineers, technicians, latest technology and

• The net worth of KAVIKA (as on 31.03.2016) is ₨ 2275.65 lakhs.

• Possessing crucial processing equipment like Annealing, Furnace, Vacuum Drying

• Strict quality checks at all stages of manufacture.

1.2 MAJOR MILESTONES

• In 1976, the company was incorporated as KAVIKA.

• All the shares are with Government of Karnataka.

• In 1976, company manufacturing only conventional transformers

• The company has obtained Approval/Certification from Bureau of Energy

DEPT OF EEE, SJBIT Page no - 6

The various services which KAVIKA is currently offering are as follows:

1.3.1 REPAIR SERVICES:

WITHIN WARRANTEE PERIOD: The warrantee period for a distribution transformer is

1.3.2 ENGINEERING SERVICES:

Utilities processing any problems at the time of installation or in operation condition of

1.3.3 DESIGN & DEVELOPMENT:

b. QUALITY CONTROL & TESTING:

DEPT OF EEE, SJBIT Page no - 7

1.3.4 PROCUREMENT OF RAW-MATERIALS:

Silicon Steel Laminations – Cold Rolled Grain Oriented Steel.

Electrical Grade Double Paper Covered Copper/Aluminum Conductors.

Bushing Metal Parts and various other MS Items.

Mild Steel Tanks

Silicon Steel Laminations:

Electrical Grade Double Paper Covered Copper/Aluminum Conductors:

DEPT OF EEE, SJBIT Page no - 8

This material is very important in the performance of the transformer particularly,

DEPT OF EEE, SJBIT Page no - 9

1. Manufacturer of Quality Oil filled Transformers.

2. Product range - 25KVA to 500KVA 11/0.433kV,3 phase Distribution transformers.

3. Major utility Customers Bangalore Electricity Supply Company Ltd.,

o Hubli Electricity Supply Company Ltd.,

o Mangalore Electricity Supply Company Ltd.,

o Gulbarga Electricity Supply Company Ltd.,

o Chamundeshwari Electricity Supply Corporation Ltd.,

o Karnataka Power Corporation Ltd., Raichur / Shaktinagar.

4. Major Commercial Customers Karnataka Power Transmission Corprn.ltd.,

o Karnataka State Women’s University, Belgaum,

o BGS Institution, and

o Other Private Customers

1.3.6 THE BASIC FACILITIES:

b. Quality Control and Testing facilities

c. Use of good quality raw materials

d. Various machinery/equipment’s and other infrastructure for manufacturing process.

DEPT OF EEE, SJBIT Page no - 10

Serial Description Ratings in kVA High kVA Low