MA’DIN POLYTECHNIC COLLEGE, MALAPPURAM

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING INDUSTRIAL

TRAINING REPORT

AT

KEL(Kerala Electrical & Allied Engineering

Co.Ltd)

GUIDED BY:

Mr. RAGESH P

( LECTURER IN DEPT.OF ELECTRICAL & ELECTRONICS ENGINEERING)

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING 2017-2020

 MA’DIN POLYTECHNIC COLLEGE, MALAPPURAM

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING INDUSTRIAL

TRAINING REPORT

AT

KEL(Kerala Electrical & Allied Engineering

Co. Ltd)

SUBMITTED BY:

NAAMSHID AMEEN .K, REG.NO:17031491

MOHAMMAD SADIQUE .T, REG.NO:17031479

MOHAMME0D JASEEL, REG.NO:17031477

UNAIS MUHSIN .K, REG.NO:17031504

MOHAMMED MUSTHAFA.P, REG.NO:17031478

MOHAMMED FIZAL.P,REG.NO:17031473

ISMAIL.P.P,REG.NO:17031465

SHAHID RIBSHAN.V,REG.NO:

GUIDED BY:

Mr. SYAM MOHAN

( LECTURER IN DEPT.OF ELECTRICAL & ELECTRONICS ENGINEERING)

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING 2017-2020

 DECLARATION

We hereby declare that the report of the industrial training at KEL division

PUTHUPARAMB which is being submitted to the MA'DIN POLYTECHNIC COLLEGE,

MALAPPURAM under Board of Technical Education Department in ELECTRICAL AND

ELECTRONICS ENGINEERING in the department of Electrical Is a bonafide report of

the work carried out by us. The material contained in this report has not been

submitted to any institute or university for the award of any degree.

Place: Malappuram

Date: 0-0-2
MPTC MALAPPURAM 2018-2019

ACKNOWLEDGEMENT

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

DEPARTMENT OF ELECTRICAL AND ECTRONICS ENGINEERING

MPTC MALAPPURAM 2018-2019

ABSTRACT

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

DEPARTMENT OF ELECTRICAL AND ECTRONICS ENGINEERING

MPTC MALAPPURAM 2018-2019

CONTENTS

PAGE NO
 INTRODUCTION 4
 COMPANY PROFILE… 5
 PROFILE OF KEL EDARIKODE… 7
 GENARAL DETAILS OF A TRANSFORMER 9
 OIL COOLED TRANSFORMER… 11
 CAST RESIN TRANSFOEMER 26
 PROPERTIES OF RESIN QUARTZ 28
 ADVANTAGES OF A CAST RESIN TRANSFORMER 29
 CONCLUTION 30

DEPARTMENT OF ELECTRICAL AND ECTRONICS ENGINEERING

MPTC MALAPPURAM 2018-2019

INTRODUCTION

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

DEPARTMENT OF ELECTRICAL AND ECTRONICS ENGINEERING

MPTC MALAPPURAM 2018-2019

Kerala Electrical & Allied Engineering

Co.Ltd(KEL)

A Multi-Product Engineering Company with 50 plus years of experience and

expertise in Engineering Industry, and now proudly serving an envious client base
including Defence, Irrigation and Power Projects, Space Research Organizations,
State Electricity Boards, Indian Railways and the General Public both in India and
abroad. The Company which is a Public Sector Undertaking fully owned by Govt.
of Kerala has four state-of-the-art manufacturing units spread across Kerala and
has a pan India presence with its Sales and Service unit in all major metros and
selected cities.

History
The company started its first operation in 1964 by incorporating technology from
the French firm EVR for the manufacturing of brushless alternators, required
for Indian Railways in lighting & air-conditioning of coaches. KEL owns five
production units for the development of a number of equipment for Indian
Army, Indian Air Force, Indian Space Research Organization and many other space
research institutions.
Mission
The mission of the company are,

 Applying state-of-the-art technology, processes and innovative solutions

 Building long term relationship with stakeholders in an environment of fair
business ethics and values
 Creating value through sustainable and profitable growth
 Leveraging productivity through highly motivated and empowered team
MPTC MALAPPURAM 2018-2019

Division
KEL owns five division located in four districts of kerala.

 Train Lighting Alternator Division Bundara Unit in Kollam District.

 Transformer Division Mamala Unit

 Structural Division Mamala Unit in Ernakulam District.

 LT Switchgear Division Olavakkod Unit in Palakkad District.
 Cast Resin Transformer Division Edarikode Unit in Malappuram District.

Projects
Some of the project done by KLE are listed following
 Falcon Missile Project
 Thrisul Missile Project
 Prithvi Missile Project
 Pinaka Project
 Akash Missile System
 Military Power Car
 Battery Chargers - Battle Tanks
 General
 Radar Application

Values
The values that they are hold to
 Uncompromised Product Quality
 Highly Durable and Reliable Products
 Experienced Technical Competency
 Skilled Workforce
 Fairness, Transparency, Integrity
 Corporate and Social Responsibility
 Responsive and courteous service
MPTC MALAPPURAM 2018-2019

KEL EDARIKODE
To cater to the growing demands of dry type transformer ,a most modern plant
with semi-automated manufacturing and testing facilities was established at
Edarikode in Malappuram District ,with a plant area of 1350 sq.m and an annual
production capacity of 300 MVA,this units has every means to supply good quality
transformers with remarkable delivery period. Every single transformer
manufactured and tested in this plant undergo stringent quality checks and
measures to ensure its lives up to the brand name KEL has gained over these years.
In 2010 semi-automated manufacturing and testing facilities was established at
Edarikode in Malappuram district for manufacture Dry type transformers . KEL ‘s
Edarikode unit was commercially operational since januvary 2010 and had alredy
sold more then ,2400 units of 100 –KVA distribution transformers worth Rs 24 crore
to KSEB.

Product Range
 Cast Resin Transformer (CRT) up to 1600 KVA
 Oil Cooled transformers (OCT)up to 500 KVA

Genaral manager : Shri.A.J.Mathew

Address:
KEL

Puthuparambu P.O.

Kottakkal Via

Edarikode -676501

ph:0483 2750421/ 2750422

Email:[email protected]
MPTC MALAPPURAM 2018-2019

Quality for perfomance

The quality of the CRT is ensured in the automatic test lab equipped with most
modern high quality measure instrument and testing equipment including partian
discharge measurment system . All routine test as per relevent IS including
temperature rise measurement and partial discharge mearsurement are carried
out in a each transformer.

Designed for relability

Through in house R&D effort of the division, KEL CRT&OCT are custamised to suite
stringent requirement and trends innovation continue as and on going process to
deliver specific transfermer types and design of various ratings.
MPTC MALAPPURAM 2018-2019

GENARAL DETAILS OF A TRANSFORMER

A transformer is an electrical device which, by the principles of electromagnetic
induction, transfers electrical energy from one electric circuit to another, without
changing the frequency. The energy transfer usually takes place with a change of
voltage and current. Transformers either increases or decreases AC voltage.
Transformers are used to meet a wide variety of needs. Some transformers can be
several stories high, like the type found at a generating station or small enough to
hold in your hand, which might be used with the charging cradle for a video camera.
No matter what the shape or size, a transformers purpose remains the same:
transforming electrical power from one type to another. There are
many different types of transformers in use today. This resource will take a closer
look at Power Transformers, Auto Transformers, Distribution Transformers,
Instrument Transformers, Isolation Transformers, Potential Transformers and
Current Transformers.

How Transformers Work

It is important to remember that transformers do not generate electrical power;
they transfer electrical power from one AC circuit to another using magnetic
coupling. The core of the transformer is used to provide a controlled path for the
magnetic flux generated in the transformer by the current flowing through the
windings,which are also known as coils.
There are four primary parts to the basic transformer. The parts include the Input
Connection, the Output Connection, the Windings or Coils and the Core.

 Input Connections - The input side of a transformer is called the primary side
because the main electrical power to be changed is connected at this point.
 Output Connections - The output side or secondary side of the transformer
is where the electrical power is sent to the load. Depending on the
requirement of the load, the incoming electric power is either increased or
decreased.
 Winding - Transformers have two windings, being the primary winding and
the secondary winding. The primary winding is the coil that draws power
from the source. The secondary winding is the coil that delivers the energy
MPTC MALAPPURAM 2018-2019

at the transformed or changed voltage to the load. Usually, these two coils
are subdivided into several coils in order to reduce the creation of flux.
 Core - The transformer core is used to provide a controlled path for the
magnetic flux generated in the transformer. The core is generally not a solid
bar of steel, rather a construction of many thin laminated steel sheets or
layers. This construction is used to help eliminate and reduce heating.
Transformers generally have one of two types of cores: Core Type and Shell
Type. These two types are distinguished from each other by the manner in
which the primary and secondary coils are place around the steel core.
o Core type - With this type, the windings surround the laminated core.
o Shell type - With this type, the windings are surrounded by the
laminated core.

When an input voltage is applied to the primary winding, alternating current starts
to flow in the primary winding. As the current flows, a changing magnetic field is
set up in the transformer core. As this magnetic field cuts across the secondary
winding, alternating voltage is produced in the secondary winding. The ratio
between the number of actual turns of wire in each coil is the key in determining
the type of transformer and what the output voltage will be. The ratio between
output voltage and input voltage is the same as the ratio of the number of turns
betweenthe two windings. A transformers
output voltage is greater than the input voltage if the secondary winding has more
turns of wire than the primary winding. The output voltage is stepped up, and
considered to be a "step-up transformer". If the secondary winding has fewer turns
than the primary winding, the output voltage is lower. This is a "step-down
transformer".
 MPTC MALAPPURAM 2018-2019

OIL COOLED
TRANSFORMER

DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING

 MPTC MALAPPURAM 2018-2019

BASIC CONSTRUCTION OF TRANSFORMER

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

DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING

 MPTC MALAPPURAM 2018-2019

CORE BUILDING

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

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

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

 Notching is performed to increase the magnetic path.

 The laminations are put through annealing process.

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

 The entire assembly is done on a frame commonly known as core channel. These
frames being used as a clamping support of the core assembly.

DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING

 MPTC MALAPPURAM 2018-2019

COIL WINDING
1. High Voltage Coils: H.V. Coils are the components of finished transformers. They
are made on automatic layer setting winding machines.
 A solid cylindrical former of predetermined length is being used as base
over which is made.

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

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

 The starting and finishing leads of each coil are terminated on either side
of the coil.

 These leads are properly sleeved and locked at number of points.

2.Low Voltage Coils:

 L.V. Coils are also one of the components of transformer. The procedure
of making low voltage coil is generally same as described earlier

 The shape of the basic raw-material (Al or Cu) is rectangular.

The Test: The Turn Test is carried out on the H.V. Coils as per the specifications.

DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING

 MPTC MALAPPURAM 2018-2019

ASSEMBILING

 The components produced in the coil winding and core assembly stage are then
taken into core-coil assembly stage.

 The core assembly is vertically placed with the foot plate touching the ground. The
top yoke of the core is removed. The limbs of the core are tightly wrapped with
cotton tape and then varnished

 Cylinder made out of insulating press board/preshrank paper is wrapped on all the
three limbs.

 Low Voltage Coil is placed on the insulated core limbs.

 Insulating block of specified thickness and number are placed both at the top and
bottom of the L.V Coil.

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

 H.V. Coils are placed over the cylinder.

 Gap between each section of H.V. Coils including top & bottom clearances is
maintained with the help of oil ducts, as per the design/drawings.

 The Top Yoke is refilled. Top core frame including core bolts and tie rods are fixed in
position.

 Primary and secondary windings are connected as per the requirements. Phase
barrier between H.V. phases are placed as per requirement.

 Connections to the tapping switch (if required) are made.

DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING

 MPTC MALAPPURAM 2018-2019

REBLADING

 The core assembly is vertically placed with the foot plate touching the ground. The
top yoke of the core is removed.

 The limbs of the core are tightly wrapped with cotton tape and then varnished.
Cylinder made out of insulating press board is wrapped on all the three limbs. Low
Voltage Coil is placed on the insulated core limbs.

 Insulating block of specified thickness and number are placed both at the top and
bottom of the L.V Coils Cylinder made out of corrugated paper or plain cylinder with
oil ducts are provided over L.V Coils.

 H.V. Coils are placed over the cylinder. Gap between each section of H.V. Coils
including top & bottom clearances is maintained with the help of oil ducts, as per the
design/drawings. The Top Yoke is refilled. Top core frame including core bolts and tie
rods are fixed in position. Primary and secondary Windings are connected as per the
requirements.

DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING

 MPTC MALAPPURAM 2018-2019

TERMINAL GEAR ASSEMBLY

Terminal gear assembly done as described below:

 Cutting the leads as required.

 Crimping/brazing of the leads with cables.

 Brazing of bus bars

 Crimping/brazing of cables with terminal lugs.

 Mounting of the tap changer/tap switch.

DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING

 MPTC MALAPPURAM 2018-2019

TANKING

The core-coil assembly and tank supplied by the fabrication depth. Are taken into
tank-up stage. The procedure is:
The core-coil assembly is taken out of the oven and the "Megger test" is carried out.
 Only if the merger value is as per the specification, the assembly may be taken for
tank-up.

 The tanks, supplied by fabrication depth. Are brought to tank-up department duly
painted.

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

 The Core-coil assembly is then placed in to the tank and properly locked up.

 Pure Filtered transformer oil is filled in the tank to immerse the assembly only.

 Connections of primary and secondary to the terminal bushings are made. Operating
handle for ratio switch is tatted, wherever required

DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING

 MPTC MALAPPURAM 2018-2019

PAINTING

The entire procedure of painting is done under two stages:

1. Cleaning of tanks.
 The cleaning of tank is done normally by chipping / grinding

 The outside surface of the tank is short blasted to achieve a very fine and smooth
finish

2. Painting of tanks
 After cleaning the tanks, a coat of hot oil resistance paint is applied on the internal
surface of the tank,

 The outside surface is painted with a coat of Red Oxide primer and subsequently with
one coat of enamel paint as per customer’s requirement.

DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING

 MPTC MALAPPURAM 2018-2019

INSULATION RESISTANCE TEST

Insulation resistance test of transformer is essential type test. This test is carried out
to ensure the healthiness of overall insulation system of an electrical power
transformer.
Procedure of Insulation Resistance Test of Transformer
 first disconnect all the line and neutral terminals of the transformer.

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

resistance IR value in between the LV and HV windings.

 Mugger leads to be connected to HV bushing studs and transformer tank earth point
to measure insulation resistance IR value in between the His windings and earth.

 Mugger leads to be connected to LV bushing studs and transformer tank earth point
to measure insulation resistance IR value in between the LV windings and earth.

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

to LV, HV to EARTH

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

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

DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING

 MPTC MALAPPURAM 2018-2019

WINDING RESISTANCE TEST

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

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

transformer.

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

Procedure of Transformer Winding Resistance Measurement

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

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

DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING

 MPTC MALAPPURAM 2018-2019

BREAKDOWN VOLTAGE

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

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

 a test voltage is applied to the electrodes and is continuously increased up to the break
down voltage with constant, standard compliant slew rate of e.g.2KV/S

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

the test voltage

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

DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING

 MPTC MALAPPURAM 2018-2019

DOUBLE VOLTAGE AND DOUBLE FREQUENCY TEST

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

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

DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING

 MPTC MALAPPURAM 2018-2019

TESTING OF TRANSFORMER

a) Short circuit test

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

DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING

 MPTC MALAPPURAM 2018-2019

b) Open Circuit Test;

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

DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING

 MPTC MALAPPURAM 2018-2019

THE CAST RESIN TRANSFORMER

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

DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING

 MPTC MALAPPURAM 2018-2019

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

DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING

 MPTC MALAPPURAM 2018-2019

PROPERTIES OF RESIN QUARTZ

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

DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING

 MPTC MALAPPURAM 2018-2019

ADVANTAGES 0F CAST RESIN TRANSFORMER

Safety

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

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

Environmental Friendliness

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

could leak or otherwise escape into the environment.

 Cast resin never requires expensive cleanup.

Efficiency

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

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

DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING

 MPTC MALAPPURAM 2018-2019

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

DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING