Report $

Shankersinh Vaghela Bapu Institute of Technology
Department of Electrical Engineering

Internship (3180901) Year 2022
Title:“ MANUFACTURING OF TRANSFORMER ”
INTERNSHIP REPORT
Prepared by:
ZILS GOSAI_180750109001
In partial fulfillment for the award of the degree of
BACHELOR OF ENGINEERING
In
[Electrical Engineering Department]
[Shankersinh Vaghela Bapu Institute of Technology, Gandhinagar]
Internal Guide: -
Prof. KINAL J. PATEL
(M)+917567312622
Email Id: [email protected]
0
CERTIFICATE
This is to certify that the project report submitted along with the project entitled
Manufacturing of Transformer has been carried out by MR. ZILS KIRANGIRI
GOSAI under my guidance in partial fulfillment for the degree of Bachelor of
Engineering in Electrical Department, 8th Semester of Gujarat Technological
University, Ahmedabad during the academic year 2021-22.
Sign Sign
Prof. Kinal J Patel Prof. Kinal J Patel
Internal Guide Head of the Depart.
I
Company Certificate
II
DECLARATION
We hereby declare that the Internship report submitted along with the Internship
entitled Manufacturing of Transformers submitted in partial fulfillment for the
degree of Bachelor of Engineering in Electrical Department to Gujarat
Technological University, Ahmedabad, is bonafide record of original project
work carried out by me at PowerLite Electricals Ltd. under the supervision of
Prof. Kinal J Patel and that no part of this report has been directly copied from any
student’s report or taken from any other source, without providing due reference.
Name of the Student Sign of Student
1) ZILS KIRANGIRI GOSAI ____________
III
Acknowledgement
First I would like to thank Lord almighty for his providence and for being the
guiding light throughout the my Internship. I have taken efforts in this Internship.
However, it would not have been possible without the kind support and help of
many individuals persons. I wish to express my sincere gratitude to our beloved
Department. I take this opportunity to express my gratitude to my Mentor/Internal
Guide and head of the department Prof. Kinal J Patel . I also wish to express my
sincere gratitude my company manager Mr. Milind Shah and his co-workers who
were always with me in this internship duration and taught me, very well explained
me with their best experiences and knowledge about the Transformers. They all
were so kind to me and also continuous motivated about my work in industry.
Finally I would like to thank my family and especially my father who has so much
knowledge about Transformers and his valuable advice and support throughout the
internship.
IV
ABSTRACT
So I was doing internship at PowerLite Electricals Ltd. which is the company of the
manufacturing and repairing the Transformers. This company is recognized as a
leader in its circle for manufacturing and repairing of the transformers.
Transformer is a device that transfer electrical energy from one circuit to another by
magnetic coupling without requiring relative motion between its parts, either
increasing (stepping up) or reducing (stepping down) the voltage. Coils are the main
parts of it and most of its copper wires are used in it because as we know ohms law
the copper wire’s resistance will oppose any magnetizing currents flowing through
it. As we know the transformer has 3 limbs and each phase winding is wound
around one of the limbs and also each limbs has two windings: primary and
secondary. On each limb, the low voltage winding is placed nearer to the steel core
and the high voltage winding is placed over the low voltage winding. It is important
that how we’ll assemble the core after the coils are ready. It has star and delta
connections in the between of core wire’s connections. The toplet which is
connected with bushing: LV and HV bushing which after that connect with
different terminals. There is large cylindrical tank know as conservator tank where
we topping the oil. There is one whole big tank which is contain the this toplet
connect with assemble core inside it with full of oil filling after the testing of
transformer.
V
List of Figures
Fig 2.1 Distribution Transformer…………………………….................1
Fig 2.2 Core type & Shell type transformer…………… ………………2
Fig 3.1 Cylindrical Winding……………………………………………3
Fig 3.2 Cross Over Winding……………………………………………4
Fig 3.3 Continuous Disc Winding………………………………………5
Fig 3.4 Sandwich Winding……………………………………………..6
Fig 3.5 Transformer Core………………………………………………7
Fig 3.6 Core Coil Assembly……………………………………………8
Fig 4.1 Off Circuit Tap Changer………………………………….....…9
Fig 4.2 On Load Tap Changer…………………………………………10
Fig.5.1 Short Circuit Test.......................................................................11
VI
Table of Contents
Acknowledgement………………………………………………… …..1
Abstract…………………………………………………………………2
List of Figures…………………………………………………………...3
Table of Contents………………………………………………………..4
Chapter 1 Introduction………………………………………………5
1.1. Overview…………… ………………………………………6
Chapter 2 About Transformers………………………………………7
2.1.Definition……………………………………………………8
2.2. Construction………………………………………………..9
Chapter 3 Assembling…………………………………………………10
3.1. Classification of Windings…………………………………..11
3.2. Core Construction……………………………………………12
3.3. Core Coil Assembly………………………………………….13
3.4. Losses in Transformer…………………………………………14
VII
Chapter 4 Tanking………………………………………………………...15
4.1. Transformer Tank……………………………………………….16
4.2. Oil Filling Process………………………………………………17
4.3 Tap Changer……………………………………………………..18
Chapter 5 Testing of Transformer………………………………………..19
5.1. Transformer Test Types…………………….........................….20
5.2. Winding resistance Test………………………………………..21
5.3. Transformer Ratio Test………………………………............….22
5.4. Vector Group Test………………………………………………23
5.5. Short Circuit Test……………………………………………….24
5.6. Open Circuit Test……………………………………………….25
5.7. Insulation Resistance Test………………………………………26
5.8. Dielectric Test of Transformer………………………………….27
5.9. DVDF Test……………………………………………………...28
5.10. Oil BDV Test…………………………………………………...29
Chapter 6 Cooling of Transformer………………………………………30
6.1. Methods of Cooling………………………………………………31
VIII
IX
Chapter 1
Introduction
1.1 Overview:
The Powerlite Electricals is recognized as a leader in the Manufacturing and Repairing of

transformers intended to cover the widest spectrum of the world’s transformer
applications. Whether it is general purpose requirements for the commercial, industrial and utility
customer to designing for the unique conditions like Snow, humid and corrosive offshore oil
platforms, high elevation mining operations or desert solar farms, our “customer designed”
transformers provide unparalleled performance in any application.
Since 1982, Powerlite Electricals has produced Oil-immersed Transformers to meet our clients’
demands for high quality, engineering flexibility and optimum performance particularly for
applications involving drive duty, arc furnace, induction furnace and inverter duty. Over three
X
decades of Repairing and Manufacturing experience has nourished our ability to provide customer
oriented- best quality transformer with on time delivery assured.
Powerlite Electricals is a well-respected supplier to the utility industry, providing medium voltage
power substation transformers (with and without on load tap changers) to over 500 utilities, both
through individual procurements, as well as through multi-year investor owned utility blanket
agreements.
The assurance of providing world class quality is our primary goal. Powerlite Electricals is an
ISO 9001:2015 & BIS(up to 2500 KVA)certified company .We have been audited and have
passed many detailed in depth quality audits conducted by respected third party agencies, large
international OEMs and major investor owned, municipal and rural electrical utilities like
GWSSB, UGVLC, GETCO etc. Our reputed clientele includes many rolling mill companies,
Pharmaceutical companies, Government & Private sector industries.
Another product on offer is Compact Sub-Station up to 33 KV Class. This substation is a compact

enclosure consisting of MV switchgear, a transformer and an LV switchboard located in three
separate compartments which are segregated from each other by means of partitions in order to
ensure personnel safety. Accessibility to operate or maintain the equipment is through lockable
doors provided for each compartment to maximize security. Assembly of the complete substation
is factory ready to minimize site installation time and cost. All equipment is of high quality and
tested as a complete unit.
XI
Chapter 2
About Transformers
2.1 Definition of Transformer:
A transformer is a device that transfers electric energy from one alternating-current circuit to one
or more other circuits, either increasing (stepping up) or reducing (stepping down) the voltage.
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Fig.2.1 Distribution Transformer
2.2 Construction:
The construction of transformer is of iron core laminated with steel bands. Core laminations are
constructed from insulated metal thin metal strips. These laminations are separated and wound
around the limb using a sheet of coat or parchment. The winding consists of two types, main and
secondary winding. These windings are isolated from each other and are made by an electric coil.
The principal feature of the core is to facilitate the winding of the magnetic flow and to provide a
low reticence direction with a useful flow
.
The construction of transformer parts is as follows:
1. Magnetic circuit
2. Electric circuit
3. Core Type Construction
4. Shell Type Construction
5. Dielectric Circuit
6. Conservator
7. Breather
8. Explosion Vent
9. Radiator
10. Bushing
11. Windings
12. Buchholz Relay
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1. Magnetic circuit
A transformer’s magnetic circuit consists of a core and a yoke. The direction of the magnetic flux
flow is given by the circuit. A laminated steel core and the two coils form the transformer. From
each other and also from the core, the two coils are shielded. The transformer’s core is made of
steel sheet or silicon steel laminations assembled to provide a continuous magnetic path. The
silicon steel material has minimal hysteresis losses at normal flux densities. The vertical position
in which the coil is wound is called the limb, while the yoke is known as the horizontal position.
2. Electric circuit
The transformer electrical circuit consists of the main and secondary copper windings.
Rectangular cross-section conductors are commonly used for low voltage winding as well as for
high voltage winding for large transformers. Circular cross-section conductors are used for high
voltage winding in a small transformer. Depending on the main structure and how the main and
secondary windings are mounted around it, the transformer is referred to as the core type and shell
type.
In the construction of transformer, the core of the transformer is typically built with a high
permeability material, such as silicon steel laminations. Based upon the configuration of the main
and secondary windings, a transformer core may be formed in two ways. Those two approaches
are:
1. Core Type construction

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Fig 2.2 Core type & Shell type Transformer
3. Core Type Construction

In the basic core style construction of the transformer, a rectangular lamination of the frame is
formed to shape the core of the transformer. The laminations are cut in the form of L-shaped
strips. To prevent high resistance to joints where laminations are bolted against each other,
alternative layers are arranged accordingly to remove continuous joints. The main and secondary
windings are interleaved to reduce the flow of leakage. Half of the winding is wound around each
limb of the core in this type and is enclosed such that there can be no magnetic flux losses and the
flux leakages can be reduced. This form of the structure appears to be very helpful for the
propagation of the flux, in that the windings cover each limb and thus the flux circulates through
the entire heart.
XV

The next part in the construction of transformer is the individual laminations of a shell-type
transformer that are cut into the shape of a long E and I strip. It has two magnetic circuits, and its
heart has three limbs. The central limb carries the whole flow, while the side limbs carry half of
the flow. The diameter of the middle is also twofold, to that of the outer limbs. The windings
travel around the interior of the main ring in the shell style structure of the core so that the core
forms a shell outside of the windings. As all the windings are wound around the same middle arm,
this arrangement also eliminates flow leakages.
5. Dielectric Circuit
The dielectric circuit consists of insulations that are used to insulate leading components in various
positions on the transformer. The center is laminated to reduce eddy current loss. The laminations are
insulated from each other by a light covering of varnish or an oxide layer. The thickness of the
laminations ranges from 0.35 mm to 0.5 mm at a frequency of 50 Hz.
6. Conservator
A cylindrical tank on the top or roof of the transformer’s main tank is used for the preservative. A
wide cover is provided that can be opened from time to time for proper servicing and cleaning of
the transformer. It serves as a buffer for the insulating oil transformer. When the transformer is
fully charged and the temperature of the transformer is high, there is a rise in the amount of air
inside the transformer. If the oil level rises and falls at the same time, the conservatory provides
sufficient room for this increased oil inside the transformer.
XVI
7. Breather
A wind functions like a heart in the construction of transformer. As the temperature of the
transformer increases, the insulating oil in the transformer heats up. When the oil heats up and
spreads, the transformer breathes air in and the oil is cooled down and the oil level is consumed.
The oil level in the chamber rises and reduces as the breather brings the air in and out to cool the
oil. This air carries moisture, which contaminates the oil and thus deteriorates the consistency of
the oil. The breather is packed with Silica Gel to remove this moisture content. The key purpose
of the silica gel is to isolate the moisture from the oil while preserving the consistency of the
insulating oil. The color of the silica gel becomes pink as it absorbs moisture from the oil.
8. Explosion Vent
It is important for the construction of transformer to be safe and avoid damage; hence, there is an
explosion vent, a thin aluminum pipe that is mounted at both ends of the transformer. As the
temperature rises rapidly in the transformer and the excess pressure is produced, the explosive
vent helps to relieve the pressure.
9. Radiator
Cooling the oil in the transformer is the key feature of the radiator. The radiator is a detachable
tube, the upper and lower portions of which are attached to the transformer tank by a valve. When
the washing and repair of the transformer are completed, the valve keeps the oil from draining
when the radiator is removed from the transformer. The transformer oil is hot and moves up in the
main tank while the transformer is in operating order and reaches the radiator through the upper
valve. It gets cooled there, and the oil reaches the transformer tank again from the lower valve of
the radiating unit and this mechanism continues.
XVII
10. Bushings
Bushings are the insulating system in the construction of transformer that enables an electrical
conductor to safely transfer electrical energy through it. When a significant volume of electrical
energy travels through it, it provides electrical field power to withstand the insulation of the
conductors. In smaller transformers, solid porcelain type bushing is used, and in large
transformers, oil-filled condenser type bushing is used. The most common cause of bushing
failure resulting in damage to the transformer is the moisture inlet. The power factor of the
bushing will still be in a stable state, so if the power factor difference is seen, the insulation will
deteriorate. The measures known as acceptance or routine tests and Double Power Factor Tests
will define this.
11. Windings
Winding arrangements are also an important concern in the construction of transformer. A
transformer’s windings are made up of a conducting material to allow the magnetic flow to build
up and the current can then be transferred from one winding to another. To raise the magnetic
flux, these windings are wound on two different iron limbs, as iron is an important conductor and
exhibits excellent magnetic properties. They are often insulated from each other by these coils.
Since both of these coils are wound on two different limbs, flow leakages often occur due to the
distance between them, decreasing the magnetic flow density and resulting in a decreased
magnetic coupling between the two coil windings.
XVIII
12. Buchholz Relay

The Buchholz relay working principle and operation is very simple. The function of this relay
depends on the mechanical phenomenon, that means it activates by mechanically. When there will
be a small internal error in the transformer like insulation errors among turns, stop working on the
core of the transformer, core high temperature, the transformer oil will be decayed in
diversehydrocarbon gases, Co, and CO2. The Buchholz relay gas analysis s generated due to a
decay of transformer oil will build up in the higher part of the Buchholz container which reasons
drop of oil level in it.
XIX
Chapter 3
Assembling
3.1 Classification of Windings:

• The windings used in the transformer are usually of two types:
1. Concentric Windings
2. Sandwich Windings
1.Concentric Windings:
• Concentric windings are classified into four following groups:

(i) Cylindrical winding
(ii) Helical winding
(iii) Cross-over winding
(iv) Continuous disc winding
i) Cylindrical Winding:
Cylindrical windings are low voltage windings used up to 6.6 kV for kVA up to 600-750, and
current rating between 10 to 600 A.
We often use cylindrical windings in its multi-layer forms. We use rectangular conductors in
two-layered type because it is easy to secure the lead-out ends. Oil ducts separate the layers of the
windings this arrangement facilitates the cooling through oil circulation in the winding.
In multi-layered cylindrical windings, we use circular conductors, wound on vertical strips
to improve cooling conditions. The arrangement creates oil ducts to facilitate better cooling. We
use this types of winding for high voltage ratings up to 33 kV, 800 kVA and current ratings up to
80 A. The maximum diameter we use for a bare conductor is 4 mm.
XX
Fig.3.1 Cylindrical Winding
ii) Helical Winding:
We use helical windings low voltage, high capacity transformers, where the current is higher, at
the same time windings turns are lesser. The output of the transformer varies from 160 – 1000
kVA from 0.23-15 kV. To secure adequate mechanical strength the cross-sectional area of the
strip not made less than 75-100 mm square. The maximum number of strips used in parallel to
make up a conductor is 16.
There are three types:

• Single Helical Winding
• Multi Helical Winding
• Disc-Helical Winding
XXI
• Single Helical Windings consist of winding in an axial direction along a screw line with
an inclination. There is only one layer of turns in each winding. The advantage of Double
Helical Winding is that it reduces eddy current loss in conductors. This is on account of
the reduced number of parallel conductors situated in the radial direction.
• In Multi Helical Windings, We use it commonly for high voltage ratings for 110 kV and
above. These types of winding consist of several cylindrical layers concentrically wound
and connected in series.
• In Disc-Helical Windings, the parallel-connected strips are placed side by side in a radial
direction to occupy the total radial depth of winding.
iii) Cross Over Winding:
We use these windings for high voltage windings of small transformers. The conductors are paper
covered round wires or strips. The windings are divided into a number of coils in order to reduce
the voltage between adjacent layers. These coils are axially separated by a distance of 0.5 to 1
mm. The voltages between adjacent coils should not be more than 800 to 1000 V.
The inside end of a coil is connected to the output side end of the adjacent one as shown in
the above figure. The actual axial length of each coil is about 50 mm while the spacing between
two coils is about 6 mm to accommodate blocks of insulating material.
The width of the coil is 25 to 50 mm. The crossover winding has a higher strength than cylindrical
winding under normal conditions. However, the crossover has lover impulse strength than the
cylindrical one. This type also has higher labor costs.
XXII
Fig.3.2 Cross Over Winding
iv) Continuous Disc Winding:
Primarily used for a high capacity transformer. The winding consists of a number of flat coils or
discs in series or parallel. The coils are formed with rectangular strips wound spirally from the
center outwards in the radial direction as shown in the figure below.
The conductors can be a single strip or multiple strips in a parallel wound on the flat side.
This makes robust construction for this type of windings. Discs are separated from each other
with press-board sectors attached to vertical stripes.
XXIII
The vertical and horizontal spacers provide radial and axial ducts for the free circulation of oil
which comes in contact with every turn. The area of the conductor varies from 4 to 50 mm square
and limits for current are 12 – 600 A. The minimum width of the oil duct is 6 mm for 35 kV. The
advantage of the disc and continuous windings is their greater mechanical axial strength and
cheapness.
Fig.3.3 Continuous Disc Winding
2.Sandwich Winding:
Allow easy control over the reactance the nearer two coils are together on
the same magnetic axis, the greater is the proportion of mutual flux and the less is the leakage
flux.
XXIV
Leakage can be reduced by subdividing the low and high voltages sections. The end low voltages
sections contain half the turns of the normal low voltage sections called half coils.
In order to balance the magneto motive forces of adjacent sections, each normal section whether
high or low voltage carries the same number of ampere-turns. The higher the degree of
subdivision, the smaller is the reactance.
Fig.3.4 Sandwich Winding
3.2 Core Construction:
In both types of transformer core design, the magnetic flux linking the primary and secondary
windings travels entirely within the core with no loss of magnetic flux through air. In the core
type transformer construction, one half of the winding is wrapped around each leg (or limb) of the
transformer’s magnetic circuit as shown above.
XXV
The coils are not arranged with the primary winding on one leg and the secondary on the other but
instead half of the primary winding and half of the secondary winding are placed one over the
other concentrically on each leg in order to increase magnetic coupling allowing practically all of
Fig. 3.5 Transformer Core
the magnetic lines of force go through both the primary and secondary windings at the same time.
However, with this type of transformer construction, a small percentage of the magnetic lines of
force flow outside of the core, and this is called “leakage flux”.
Shell type transformer core’s overcome this leakage flux as both the primary and secondary
windings are wound on the same center leg or limb which has twice the cross-sectional area of the
two outer limbs. The advantage here is that the magnetic flux has two closed magnetic paths to
flow around external to the coils on both left and right hand sides before returning back to the
central coils.
XXVI
3.3 Core Coil Assembly:
• The copper windings determine the voltage a transformer can handle without any
complications. Perfect ratio figures for large or medium powered transformers are applied.
• The windings may have a circular or helical configurations. Winding in the transformers
ensure reliability, quality, and sustainability.
• Once the purpose is known. Accordingly, the windings ratio is calculated and configured
for a transformer.
Fig.3.6 Core Coil Assembly
XXVII
3.4 Losses in Transformer:
Transformer Core Losses
The ability of iron or steel to carry magnetic flux is much greater than it is in air, and this ability
to allow magnetic flux to flow is called permeability. Most transformer cores are constructed from
low carbon steels which can have a permeability in the order of 1500 compared with just 1.0 for
air.
This means that a steel laminated core can carry a magnetic flux 1500 times better than that of air.
However, when a magnetic flux flows in the steel core of a transformer, two types of losses occur
within the steel. One termed “eddy current losses” and the other one termed “hysteresis losses”.
Hysteresis Losses
Transformer Hysteresis Losses are caused because of the friction of the molecules against the
flow of the magnetic lines of force required to magnetize the core, which are constantly changing
in value and direction first in one direction and then the other due to the influence of the
sinusoidal supply voltage.
This molecular friction causes heat to be developed which represents an energy loss to the
transformer. Excessive heat loss can overtime shorten the life of the insulating materials used in
the manufacture of the windings and structures. Therefore, cooling of a transformer is important.
Also, transformer’s are designed to operate at a particular supply frequency. Lowering the
frequency of the supply will result in increased hysteresis and higher temperature in the iron core.
So reducing the supply frequency from 60 Hertz to 50 Hertz will raise the amount of hysteresis
present, decreased the VA capacity of the transformer.
XXVIII
Eddy Current Losses

Transformer Eddy Current Losses on the other hand are caused by the flow of circulating currents
induced into the steel caused by the flow of the magnetic flux around the core. These circulating
currents are generated because to the magnetic flux the core is acting like a single loop of wire.
Since the iron core is a good conductor, the eddy currents induced by a solid iron core will be
large.
Eddy currents do not contribute anything towards the usefulness of the transformer but instead
they oppose the flow of the induced current by acting like a negative force generating resistive
heating and power loss within the core.
Copper Losses
But there is also another type of energy loss associated with the transformer called “copper
losses”. Transformer Copper Losses are mainly due to the electrical resistance of the primary and
secondary windings. Most transformer coils are wound using copper wire which has a resistive
value in Ohms ( Ω ), and as we know from Ohms Law, the copper wire’s resistance will oppose
any magnetizing currents flowing through it.
When an electrical load is connected to the secondary winding of a transformer, large electrical
currents start to flow in both the primary and the secondary windings, electrical energy and power
( the I2 R ) losses occur as heat. Generally copper losses vary with the load current, being almost
zero at no-load, and at a maximum at full-load when current flow is at maximum.
A volt-amperes (VA) rating of a transformer can be increased by better design and construction in
order to reduce these core and copper losses. A transformer with high voltage and current ratings
require conductors of large cross-section to help minimize their copper losses. Increasing the rate
of heat dissipation (better cooling) by forced air or oil, or by improving it’s insulation so that it
can withstand higher temperatures, thereby increasing the VA rating of the transformer.
XXIX
Chapter 4
Tanking
4.1 Transformer Tank:
Transformer tank is used to hold, protect, cool the winding and core in one Electrical distributor
transformer. The tank body provides isolation of oil and the core from the outside environment.
When transformer is loaded and when ambient temperature rises, the volume of oil inside
transformer increases. A conservator tank of transformer provides adequate space to this
expanded transformer oil. It also acts as a reservoir for transformer insulating oil.
4.2 Oil Filling Process:
In order to avoid during the assembly of the transformer direct contact of the winding and the
insulation with the atmosphere, it is recommended to fill up the transformer previously with
insulating oil up to a level that is 25 cm below the cover of the tank, In the case of a transformer
equipped with expansion tank or 85°C labeled on the indicator level in the case of a sealed
transformer. Before filling up with oil, it is necessary to conduct the dielectric resistance test of
the oil stored in drums.
Take a sample from each drum and make sure that the dielectric characteristic correspond or not
to the specified. IEEE Guide for Acceptance and Maintenance of Oil in Equipment. In a negative
case, that is to say, the oil does not possess the dielectric characteristics specified, filter totally the
content of the oil. The Fill up with oil must be done only after the test values are found to be
within the specified values. There are two methods to conduct an oil fill up. The first of them
consists of filling the tank with oil through the drainage valve while gradually the nitrogen
contained in the tank is released. The pressure of the nitrogen contained in the transformer tank
XXX
must be kept between 0,05 and 0,2 kg/cm2 during the oil fill up. The second method consists of
filling with oil after reaching vacuum in the transformer. See fill up with oil under vacuum. This
method is recommended by ABB by being the safest method of the two.
4.3 Tap Changer:
A tap changer is a mechanism in transformers which allows for variable turn ratios to be selected
in distinct steps. This is done by connecting to a number of access points known as taps along
either the primary or secondary winding.
Tap changers exist in two primary types, no-load tap changers (NLTC), which must be de-
energized before the turn ratio is adjusted, and on-load tap changers (OLTC), which may adjust
their turn ratio during operation. The tap selection on any tap changer may be made via an
automatic system, as is often the case for OLTC, or a manual tap changer, which is more common
for NLTC. Automatic tap changers can be placed on a lower or higher voltage winding, but for
high-power generation and transmission applications, automatic tap changers are often placed on
the higher voltage (lower current) transformer winding for easy access and to minimize the
current load during operation.
• No-load tap changer:
No-load tap changer (NLTC), also known as Off-circuit tap changer (OCTC)
or De-energized tap changer (DETC), is a tap changer utilized in situations in which a
transformer's turn ratio does not require frequent changing and it is permissible to de-energize the
transformer system. This type of transformer is frequently employed in low power, low voltage
transformers in which the tap point often may take the form of a transformer connection terminal,
requiring the input line to be disconnected by hand and connected to the new terminal.
Alternatively, in some systems, the process of tap changing may be assisted by means of a rotary
or slider switch.
XXXI
No load tap changers are also employed in high voltage distribution-type transformers in which
the system includes a no load tap changer on the primary winding to accommodate transmission
system variations within a narrow band around the nominal rating. In such systems, the tap
changer will often be set just once, at the time of installation, although it may be changed later to
accommodate a long-term change in the system voltage profile.
Fig.4.1 Off Circuit Tap Changer
• On-load tap changer:

On-load tap changer (OLTC),is a tap changer in applications where a supply
interruption during a tap change is unacceptable, the transformer is often fitted with a more
expensive and complex on load tap changing mechanism. On load tap changers may be generally
classified as either mechanical, electronically assisted, or fully electronic.
These systems usually possess 33 taps (one at Centre "Rated" tap and sixteen to increase and
decrease the turn ratio) and allow for ±10% variation (each step providing 0.625% variation) from
the nominal transformer rating which, in turn, allows for stepped voltage regulation of the output.
XXXII
Tap changers typically use numerous tap selector switches which may not be switched under load,
broken into even and odd banks, and switch between the banks with a heavy-duty diverter
switch which can switch between them under load. The result operates like a dual-clutch
transmission, with the tap selector switches taking the place of the gearbox and the diverter switch
taking the place of the clutch.
Fig.4.2 On Load Tap Changer
XXXIII
Chapter 5
Testing of Transformer
5.1 Transformer Test Types:
Routine tests of transformer include:

1. Winding resistance test of transformer
2. Transformer ratio test
3. Transformer vector group test
4. Measurement of impedance voltage/short circuit impedance (principal tap) and load loss
(Short circuit test)
5. Measurement of no load loss and current (Open circuit test)
6. Measurement of insulation resistance
7. Dielectric tests of transformer.
8. DVDF Test.
9. Oil BDV Test
5.2 Winding Resistance Test

Transformer winding resistance measurement is carried out to calculate the I2R losses and to
calculate winding temperature at the end of a temperature rise test. It is carried out as a type test
as well as routine test. It is also done at site to ensure healthiness of a transformer that is to check
loose connections, broken strands of conductor, high contact resistance in tap changers, high
voltage leads and bushings etc.
XXXIV
There are different methods for measuring of the transformer winding, likewise:
• Current-voltage method of measurement of winding resistance.

• Bridge method of measurement of winding resistance.
• Kelvin bridge method of Measuring Winding Resistance.
• Measuring winding resistance by Automatic Winding Resistance Measurement Kit.
5.3 Transformer Ratio Test

The performance of a transformer largely depends upon perfection of specific turns or voltage
ratio of transformer. So transformer ratio test is an essential type test of transformer. This test also
performed as a routine test of transformer. So for ensuring proper performance of electrical power
transformer, voltage and turn ratio test of transformer one of the important tests.
The procedure of the transformer ratio test is simple. We just apply three phase 415 V supply to
HV winding, with keeping LV winding open. We measure the induced voltages at HV and LV
terminals of the transformer to find out actual voltage ratio of the transformer. We repeat the test
for all tap position separately.
5.4 Vector Group Test

In a 3 phase transformer, it is essential to carry out a vector group test of transformer. Proper
vector grouping in a transformer is an essential criteria for parallel operation of transformers.
There are several internal connections of three-phase transformer are available on the market.
These several connections give various magnitudes and phase of the secondary voltage; the
magnitude can be adjusted for parallel operation by suitable choice of turn ratio, but the phase
divergence cannot be compensated.
XXXV
5.5 Short Circuit Test
The connection diagram for the short circuit test on the transformer is shown in the figure. A
voltmeter, wattmeter, and an ammeter are connected in HV side of the transformer as shown. A
low voltage of around 5-10% is applied to that HV side with the help of a variac (i.e. a variable
ratio auto transformer). We short-circuit the LV side of the transformer. Now with the help of
variac applied voltage is slowly increased until the wattmeter, and an ammeter gives reading
equal to the rated current of the HV side.
After reaching the rated current of the HV side, we record all the three instrument readings
(Voltmeter, Ammeter and Watt-meter readings). The ammeter reading gives the primary
equivalent of full load current IL. As the voltage applied for full load current in a short
circuit test on the transformer is quite small compared to the rated primary voltage of the
transformer, the core losses in the transformer can be taken as negligible here.
Fig.5.1 Short Circuit Test
XXXVI
5.6 Open Circuit Test
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 LV side with the help of a variac of variable ratio
auto transformer.
The HV side of the transformer is kept open. Now with the help of variac, applied voltage gets
slowly increased until the voltmeter gives reading equal to the rated voltage of the LV side. After
reaching rated LV side voltage, we record all the three instruments reading (Voltmeter, Ammeter
and Wattmeter readings).
5.7 Insulation Resistance Test
Insulation resistance test of transformer is essential type test. This test is carried out to ensure the
healthiness of the overall insulation system of an electrical power transformer.
1. Disconnect all the line and neutral terminals of the transformer.

2. Megger leads to be connected to LV and HV bushing studs to measure insulation
resistance IR value in between the LV and HV windings
3. Megger leads to be connected to HV bushing studs and transformer tank earth point to
measure insulation resistance IR value in between the HV windings and earth
4. Megger leads to be connected to LV bushing studs and transformer tank earth point to
measure insulation resistance IR value in between the LV windings and earth.
5.8 Dielectric Test of Transformer
Dielectric test of a transformer is one kind of insulation test. This test is performed to ensure the
expected overall insulation strength of the transformer. There are several tests performed to
ensure the required quality of transformer insulation; the dielectric test is one of them. Dielectric
test of the transformer is performed in two different steps.
XXXVII
First one is called Separate Source Voltage Withstand Test of transformer, where a single phase
power frequency voltage of prescribed level, is applied on transformer winding under test for 60
seconds while the other windings and tank are connected to the earth, and it is observed that
whether any failure of insulation occurs or not during the test.
The second one is the induced voltage test of Transformer where, three-phase voltage, twice of
rated secondary voltage is applied to the secondary winding for 60 seconds by keeping the
primary of the transformer open circuited.
The frequency of the applied voltage should be double of power frequency too. Here also if no
failure of insulation, the test is successful.
In addition to dielectric tests of transformers, there are other types of test for checking insulation
of transformer, such as lightning impulse test, switching impulse test and partial discharge test.
5.9 DVDF Test:
This test set provides a continuously variable output voltage at double frequency to test the
insulation between turns of coils, layer to layer, terminals of windings with either uniform or
graded insulation and also between the windings and earth, with graded insulation of both
Distribution and Power transformers. An alternating Voltage of sine wave form (as much as
possible) at double frequency (100 Hz.) and double in amplitude can be applied at one side of the
transformer under test while the windings, which are not connected to the source of excitation, are
left on open circuit. This tester setup is generally used to perform induced voltage test on the
transformers. This set up consists of the used motor and generator combination to develop the
required voltage and frequency.
XXXVIII
5.10 Oil BDV Test
BDV test means Breakdown Voltage Test. It is done for checking the dielectric strength of the oil
of the Transformer. Dielectric strength means the maximum capacity to withstand voltage of
insulating oil. This test shows the dielectric strength of Transformer oil.
In transformer oil has mainly two purposes, first for insulation, second as cooling of Transformer
core and other winding. So while designing Transformer oil use in transformer depends on voltage
rating. So testing of oil is done according to voltage rating.
XXXIX
Chapter 6
Cooling of Transformer
6.1 Methods of Cooling:
Basically, there are two types of transformer one is the dry type, and another one is oil-
immersed type. For the cooling of transformers, the following cooling methods listed below are
used.
1. Air Natural
2. Air Blast or forced
3. Oil Natural Air Natural
4. Oil Natural Air Forced
5. Oil Forced Air Forced
6. Oil Natural Water Forced
7. Oil Forced Water Forced
1. Air Natural (AN)
By Air Natural method the generated heat in the transformer is cooled by the circulation of natural
air. When the temperature of the transformer becomes higher as compared to the temperature of
the surrounding air, thus by the process of natural convection, heated air is replaced by the cool
air. This method is also known as a self-cooled method. This method is used for cooling the
smaller output transformer rating that is up to 1.5 MVA.
XL
2. Air Forced (AF) or Air Blast
In this method, the heat generated is cooled by the forced air circulation method. With the help of
fans and blowers, high velocity of air is forced on the core and the windings of the transformer.
As the temperature inside the transformer goes beyond the standard safe level, an alarm is
activated, and the fans and blowers are switched ON automatically. This method is used for
transformer rating up to 15MVA.
3. Oil Natural Air Natural (ONAN)
Natural convection process is used for this type of cooling. The assembly of the core and
windings are placed in the oil-immersed tank. As the core and the windings heat up the
temperature of the oil in the transformer rises. As a result, the oil moves upward and flows from
the upper portion of the transformer tank. This hot oil dissipates heat in the air by natural
convection and conduction process, the oil gets cooled by the circulation of natural air and passes
through the radiator again for the use of the transformer. This type of cooling is used for the
transformer rating up to 30 MVA.
4. Oil Natural Air Forced (ONAF)
ONAF method is used for the cooling of the transformer of rating up to 60 Mega volts ampere. As
discussed above that in ONAN method, the dissipation of heat is taking place by the convection
process in which air is naturally circulated to cool down, but in this type, the forced air is used for
the purpose of cooling the transformer.
The cooling of oil will be faster if the area of the tank of the transformer is increased finally,
which result in the increase in heat dissipation level. As the fans and blowers are installed, a high
velocity of air is forcefully applied to the radiator and cooling towers which will help in cooling
oil more quickly and efficiently.
XLI
5. Oil Forced Air Forced (OFAF)
As the name itself says that both the oil and the air are applied by force for cooling of a
transformer. The Heat Exchanger is installed through which hot oil is circulated with the help of a
pump. Air is forced to pass on the heat exchanger with the help of high-speed fans.
This method is similar to ONAN, as when there is low load on the transformer the cooling is done
by a simple ONAN method. However, as soon as the load is increased, the generated heat will
also be more and therefore the sensor gives an alarm that the dissipation of heat has exceeded the
safe value and as a result, the fans and pumps are switched on automatically. Thus, the cooling
takes place by OFAF method.
6. Oil Natural Water Forced (ONWF)
In Oil Natural Water Force cooling method, the transformer core and the windings are immersed
in the oil tank. A radiator is installed outside the tank, as the temperature rises and the oil heats up
and moves upward, the heat is dissipated by the natural process of convection and oil is passed
through the radiator, but the water is pumped and passed through the heat exchanger for cooling
of the oil.
7. Oil Forced Water Forced (OFWF)
A heat exchanger is installed through which both oil and water are passed with the help of a
pump. The level and pressure of the oil are always kept higher than that of water so that if any
leakage occurs in the system the oil mixes with the water, but water does not get mixed up with
the oil.
This type of method is suitable for large capacity of the transformer having rating as several
hundred MVA or where banks of transformers are installed. Mainly this type of cooling is done
for the transformer installed at the hydropower plant.
XLII
Learning Outcomes
• The knowledge we received here has made me more confident

Technically.
• Knowledge I gained related to testing, Winding was truly helpful.
• Regularity in work
• Consistency in performance
• Time Management
• Improvisation in problem analysis & solving ability
• Effective Communication & Interaction skills.
XLIII
Conclusion
My overall experience at “Power Lite Electrical Ltd.” was just phenomenal

and with guidance of persons made it more knowledgeable and useful.
The experience and knowledge I have gained here has made me more
confident to take up the concepts of transformers as my project interest.
Thereby I am enough confident technically.
I learnt to emerge as one of the finest technical and electrical engineer of

higher learning to develop engineering professional who are technically
competent, ethical and environmental friendly for betterment of society and
to accomplish stimulating learning environment through high quality
internship in Industry.
XLIV
References
https://www.powerlitetransformers.com/wp-content/uploads/2019/10/powerlite-electricals-
brochure.pdf
https://www.powerlitetransformers.com/#:~:text=The%20Powerlite%20Electricals,in%20a
ny%20application.
ELECTRICAL MACHINE DESIGN Sawhney, A.K., “A Course in Electrical Machine
Design”, 6thEdition, Dhanpat Rai and Sons, 2006
AC Machine Design Electrical Semester 7 GTU Degree Engineering Book Paperback (Atul)
D M Patel.
https://edurev.in/studytube/Problem-solving-on-Transformers/e28812e7-7c8e-48fb-9317-
96cadefcdf08_t
XLV

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Shankersinh Vaghela Bapu Institute of Technology

Department of Electrical Engineering

Title:“ MANUFACTURING OF TRANSFORMER ”

In partial fulfillment for the award of the degree of

[Electrical Engineering Department]

[Shankersinh Vaghela Bapu Institute of Technology, Gandhinagar]

Prof. Kinal J Patel Prof. Kinal J Patel

Internal Guide Head of the Depart.

Name of the Student Sign of Student

1) ZILS KIRANGIRI GOSAI ____________

Fig 2.1 Distribution Transformer…………………………….................1

Fig 2.2 Core type & Shell type transformer…………… ………………2

Fig 3.1 Cylindrical Winding……………………………………………3

Fig 3.2 Cross Over Winding……………………………………………4

Fig 3.3 Continuous Disc Winding………………………………………5

Fig 3.4 Sandwich Winding……………………………………………..6

Fig 3.5 Transformer Core………………………………………………7

Fig 3.6 Core Coil Assembly……………………………………………8

Fig 4.1 Off Circuit Tap Changer………………………………….....…9

Fig 4.2 On Load Tap Changer…………………………………………10

Fig.5.1 Short Circuit Test.......................................................................11

1.1. Overview…………… ………………………………………6

Chapter 2 About Transformers………………………………………7

3.1. Classification of Windings…………………………………..11

3.2. Core Construction……………………………………………12

3.3. Core Coil Assembly………………………………………….13

3.4. Losses in Transformer…………………………………………14

4.1. Transformer Tank……………………………………………….16

4.2. Oil Filling Process………………………………………………17

4.3 Tap Changer……………………………………………………..18

Chapter 5 Testing of Transformer………………………………………..19

5.1. Transformer Test Types…………………….........................….20

5.2. Winding resistance Test………………………………………..21

5.3. Transformer Ratio Test………………………………............….22

5.4. Vector Group Test………………………………………………23

5.5. Short Circuit Test……………………………………………….24

5.6. Open Circuit Test……………………………………………….25

5.7. Insulation Resistance Test………………………………………26

5.8. Dielectric Test of Transformer………………………………….27

5.9. DVDF Test……………………………………………………...28

5.10. Oil BDV Test…………………………………………………...29

Chapter 6 Cooling of Transformer………………………………………30

6.1. Methods of Cooling………………………………………………31

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2.1 Definition of Transformer:

Fig.2.1 Distribution Transformer

1. Core Type construction

Fig 2.2 Core type & Shell type Transformer

3. Core Type Construction

4. Shell Type Construction

12. Buchholz Relay

3.1 Classification of Windings:

• Concentric windings are classified into four following groups:

Fig.3.1 Cylindrical Winding

ii) Helical Winding:

There are three types:

iii) Cross Over Winding:

Fig.3.2 Cross Over Winding