Practicum Report On

“Transformer Protection & Protective device coordination

at Innova engineering Ltd”

Prepared By
Md Kawser Ahmd
ID-14305014

Department of Electrical and Electronics Engineering

IUBAT-International University of Business Agriculture & Technology

Practicum Report On
 “Transformer Protection & Protective device coordination at Innova
engineering Ltd”

Name: Md Kawser Ahmed

ID: 14305014
Program: BSEEE

……………………… …………………… ……………………….

Khadiza Akter Bonna Dr. Bishwajit saha Dr. Md. Shariful Islam
Supervisor Coordinator Chairperson

Department of Electrical and Electronics Engineering

IUBAT-International University of Business Agriculture & Technology
 Letter of Transmittal
15th August, 2018
Dr. Bishwajit Saha
Coordinator, Department of Electrical & Electronics Engineering
International University of Business Agriculture and Technology
4 Embankment Drive Road, Sector 10, Uttara Model Town, Dhaka-1230, Bangladesh.

Subject: Letter of Transmittal of the Practicum Report.

Sir,

It is a great pleasure for me to submit my practicum report on the topic of “Transformer

Protection & Protective device coordination at Innova engineering Ltd”. I have prepared
this report, as partial fulfillment of the course EEN 490 Practicum. I have tried my level best
to prepare this report to the required standard. It was certainly a great opportunity for me to
work on this paper to actualize my theoretical knowledge in the practical area.

I express my heart full gratitude to you to go through this report and make your valuable
comments. It would be very kind of you if you please evaluate my performance regarding
this report.

Sincerely

……………………
Md.Kawser Ahmed
ID-14105108
 Student’s Declaration

I am a student of Bachelor of Science in Electrical and Electronics Engineering (BSEEE), in

the College of Engineering and Technology at the IUBAT–International University of
Business Agriculture and Technology and declaring that, this practicum report on
“Transformer Protection & Protective device coordination at Innova engineering Ltd”
After completion of three months internship at Innova engineering Ltd.

I also confirm that the report is only prepared to fulfill the academic requirement and not for
any other purposes. It will not be used with the interest of any other competitor.

Sincerely

-------------------------
Md. Kawser Ahmed
ID-14305014
 Acknowledgement

It was a very remarkable and memorable time during my internship at Innova Engineering
Ltd. I am very thankful to Innova Engineering Ltd for giving me the opportunity to complete
my internship in their organization.

First of all, I would like to pay my gratitude to our respected course coordinator, Dr.
Bishwajit Saha Department of Electrical & Electronics Engineering who gave me the
opportunity to do the report on “Transformer Protection & Protective device
coordination at Innova engineering Ltd”.

Here, I am very grateful to Engr. Farduse Alam, Automation Engineer & Director of
(ISDTC) at Innova Engineering Ltd, who helped me a lot to prepare this report on
“Transformer Protection & Protective device coordination at Innova engineering Ltd”.
I would like to thank Khadiaza Akter Bonna, my supervisor for his constant support and
many suggestions, also for his patience and gentleness in those times, where I had to slug
through problems.

Finally, I would like to thank again to the respected Vice Chancellor of IUBAT, Prof. Dr.
Abdur Rab because I got the opportunity to acquire knowledge under BSEEE program, and
that will be very helpful for my prospective career.

Sincerely

----------------------
Md. Kawser Ahmed
ID- 14105108

1) i
 Table of Content
Chapter 1:ORGANIZATION OVERVIEW5
Concerning Organizations .....................................................................................5

Parent Company Information.................................................................................5

Company Mission ..................................................................................................6

Yearly Production Capacities ................................................................................6

Organization Chart .................................................................................................7

Chapter 2:Introduction of Transformer8

Basic Theory of Transformer .................................................................................8

Main Constructional Parts of Transformer ..........................................................10

Secondary Winding of Transformer10

Classification of transformer ...............................................................................10

Transformers Based on Voltage Levels10

Step-Up Transformer11
Air Core Transformer12
Iron Core Transformer12
Transformers Based on Winding Arrangement13
Auto Transformer13
Transformers Based on Usage13

Transformer Accessories .....................................................................................16

Laminated core16
Winding17
Insulating Materials17

1
 Conservator18
Breather18
Tap Changer18
Cooling Tubes18
Buchholz Relay19
Explosion Vent19

Chapter 3:Design Parameters20

Proposed specification .........................................................................................21

Current density .....................................................................................................21

Primary Coil: ........................................................................................................22

Secondary Coil .....................................................................................................24

Core Diameter ......................................................................................................25

Step Width ...........................................................................................................25

Core Area .............................................................................................................26

Flux Density .........................................................................................................27

Core Details .........................................................................................................27

Approximate Weight of Core ..............................................................................28

Step-Wise Weight Calculate of Core ...................................................................29

Winding Details ...................................................................................................33

Coil Assembly ......................................................................................................35

Weight of LV and HV Aluminium ......................................................................36

Winding Resistance and Load Loss .....................................................................37

2
Design Outputs.....................................................................................................38

The Design of Tank .............................................................................................39

Radiators ..............................................................................................................41

Conventional elliptical tube radiators:41

Presses steel radiators44
Corrugated wall panel radiators47

Weight of Tank ....................................................................................................49

Weight of tank with pressed steel radiators51

Weight of tank with corrugated wall panel51

Volume of oil .......................................................................................................51

Volume of oil in the tank only:51

Volume of oil in the radiators:52

Chapter 4:Essential Elements of Transformer54

Pre-Manufacturing Test .......................................................................................55

Transformer Copper test55

Transformer Core Test:56
Transformer oil test:57

Pre-Commissioning Test of Transformer ............................................................59

Transformer Single Phase Test59

Transformer Insulation resistance Test61
Transformer Winding resistance test65
Turns Ratio / Voltage ratio Test.68
Open-circuit Test or No-load loss71
Short-circuit impedance and load loss Test73

3
 Chapter 5:Conclusion76
Limitations ...........................................................................................................76

Recommendations ................................................................................................76

References ............................................................................................................76

Appendix ..............................................................................................................76

4
 ORGANIZATION OVERVIEW

Concerning Organizations
INNOVA ENGINEERING LTD is leading integrated power and Energy Company. Their
success is driven by their people and their commitment to get results the right way—by operating
responsibly, executing with excellence, applying innovative technologies and capturing new
opportunities for profitable growth. They manufacture and sell power products generate power
and produce distribution transformer provide renewable energy and energy efficiency solutions
and develop the energy resources of the future. The company has full-equipped workshop with
expert technicians & Engineers.
1) Company was established in December 25, 2013 (Dhaka, Bangladesh).
2) Mission - is a reliable and high-quality supply with electric power produced from
conventional and renewable energy sources.
3) Vision - is the Company’s formation as a leader in the field of power and energy sector in
Bangladesh.
4) 100% subsidiary company of Innova electric a power company (www.innovaelectric.biz).

Parent Company Information

“Innova Electric” was established on 24th April 2012 and officially registered on 25th
December2013 as Innova Engineering Ltd; 100% of equity is fully owned by “INNOVA
ELECTRIC”. The group incorporates 3 entities and is a vertically integrated power and energy
product provider, operating within the borders of Bangladesh. Its key focus areas are:
1) Production of electric transformer and switchgear.
2) Transmission and distribution for govt, manufacturing industry and telecom.
3) Telecom surge protection and earthling and lightning protection system.
4) Supply of global renowned product on power and energy.
5) Reconstruction, expansion and construction of power generating facilities and units.
6) Erection, testing & commissioning of sub-station.
7) Installation of Electrical Equipment’s and 33/11/0.4 KV Sub-station.
8) Installation of Electrical Equipment’s and 33/11/0.4 KV Sub-station.

5
Company Mission
Provide high quality products and solutions together with comfortable service to meet the
customer’s requirements.

Yearly Production Capacities

SL Products Capacity (Nos.)

01. Distribution Transformer 100 Nos.

02. H.T. Switchgear 100 Nos.

03. L.T. Switchgear 150 Nos.

04. P.F.I. Plant 200 Nos.

05. L.T. Metering Unit 100 Nos.

06. H.T. Metering Unit 100 Nos.

07. Solar Panel 100 Nos.

6
 Organization Chart

Chairman

Managing Director
System Engineer

Engineer–in-Charge Senior Engineer

Sub-Station Distribution
Foreman (Grade-C) Maintenance
Foreman (Grade-B) Trouble Shooting

Electrical Technician Break Down

Electrical Fitter Production

Helper Manager
Technician
Assistant

Helper

Admin Officer
Accountant

Office Assistant
Co-ordinator
(COSS)
Supervisor (Com.) Supervisor (Tech.)
Meter Reader Lineman
Bill Server Asstt. Lineman

7
 TRANSFORMER OVERVIEW

Introduction of Transformer
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 frictions or winding losses. Further, the other losses are very low so
that the efficiency should be high. The efficiency varies from 97% to 99%3.2 Working Principle
of Transformer
The working principle of transformer is very simple. Mutual induction between two or more
windings is responsible for transformation action in an electrical transformer.

Basic Theory of Transformer

Say you have one winding which is supplied by an alternating electrical source. The alternating
current through the winding produces a continually changing and alternating flux that surrounds
the winding. If any other winding is brought nearer to the previous one, obviously some portion
of this flux will link with the second. As this flux is continually changing in its amplitude and
direction, there must be a changing flux linkage in the second winding or coil. According to
Faraday's law of electromagnetic induction, there must be an EMF induced in the second. If the
circuit of the later winding is closed, there must be a current flowing through it. This is the most
basic thing on which the working principle of transformer stands. The winding which takes
electrical power from the source, is known as the primary winding. Here in our above example, it
is first winding.

8
The winding which gives the desired output voltage due to mutual induction is commonly known
as the secondary winding. Here in our example, it is second winding.
The form mentioned above of a transformer is theoretically possible but not practically, because
in open air very tiny portion of the flux of the first winding will link with second; so the current
that flows through the closed circuit of later, will be so small in amount that it will be difficult to
measure.
The rate of change of flux linkage depends upon the amount of linked flux with the second
winding. So, almost all flux of primary winding should link to the secondary winding. This is
effectively and efficiently done by placing one low reluctance path common to both of the
winding.

9
This low reluctance path is core of transformer, through which the maximum number of flux
produced by the primary is passed through and linked with the secondary winding. This is the
most basic theory of transformer.

Main Constructional Parts of Transformer

The three main parts of a transformer are,
1) Primary Winding of Transformer
2) Which produces magnetic flux when it is connected to electrical source
3) Magnetic Core of Transformer
The magnetic flux produced by the primary winding, that will pass through this low reluctance
path linked with secondary winding and create a closed magnetic circuit.

Secondary Winding of Transformer

The flux, produced by primary winding, passes through the core, will link with the secondary
winding. This winding also wounds on the same core and gives the desired output of the
transformer

Classification of transformer
Transformers can be categorized in different ways, depending upon their purpose, use,
construction etc. The types of transformer are as follows
1) Transformers Based on Voltage Levels
2) Transformer Based on the Core Medium Used
3) Transformers Based on Winding Arrangement
4) Transformers Based on Usage

Transformers Based on Voltage Levels

These are the most commonly used transformer types for all the applications. Depends upon the
voltage ratios from primary to secondary windings, the transformers are classified as step-up and
step-down transformers.

Step-Up Transformer
Step-Down Transformer

10
Step-Up Transformer

As the name states that, the secondary voltage is stepped up with a ratio compared to primary
voltage. This can be achieved by increasing the number of windings in the secondary than the
primary windings as shown in the figure. In power plant, this transformer is used as connecting
transformer of the generator to the grid.

Step-Down Transformer
It used to step down the voltage level from lower to higher level at secondary side as shown
below so that it is called as a step-down transformer. The winding turns more on the primary side
than the secondary side. In distribution networks, the step-down transformer is commonly used
to convert the high grid voltage to low voltage that can be used for home appliances.

11
Transformer Based on the Core Medium Used

Based on the medium placed between the primary and secondary winding the transformers are
classified as Air core and Iron core

Air Core Transformer

Iron Core Transformer

Air Core Transformer

Both the primary and secondary windings are wound on a non-magnetic strip where the flux
linkage between primary and secondary windings is through the air.

Iron Core Transformer

Both the primary and secondary windings are wound on multiple iron plate bunch which provide
a perfect linkage path to the generated flux. It offers less reluctance to the linkage flux due to the
conductive and magnetic property of the iron. These are widely used transformers in which the
efficiency is high compared to the air core type transformer.

12
Transformers Based on Winding Arrangement

Auto Transformer

Standard transformers have primary and secondary windings placed in two different directions,
but in autotransformer windings, the primary and the secondary windings are connected to each
other in series both physically and magnetically as shown in the figure below. On a single
common coil which forms both primary and secondary winding in which voltage is varied
according to the position of secondary tapping on the body of the coil windings.

Transformers Based on Usage

According to the necessity, these are classified as the power transformer, distribution transformer
measuring transformer, and protection transformer.

Power Transformer
Distribution Transformer
Measurement Transformer
Protection Transformers

Power Transformer

13
The power transformers are big in size. They are suitable for high voltage (greater than 33KV)
power transfer applications. It used in power generation stations and Transmission substation. It
has high insulation level.

Distribution Transformer

In order to distribute the power generated from the power generation plant to remote locations,
these transformers are used. Basically, it is used for the distribution of electrical energy at low
voltage is less than 33KV in industrial purpose and 440v-220v in domestic purpose.

 It works at low efficiency at 50-70%

 Small size
 Easy installation
 Low magnetic losses
 It is not always fully loaded

14
Measurement Transformer
Use to measure the electrical quantity like voltage, current, power etc. These are classified as
potential transformers, current transformers etc.

Protection Transformers
This type of transformers is used in component protection purpose. The major difference
between measuring transformers and protection transformers is the accuracy that means that the
protection transformers should be accurate as compared to measuring transformers.

15
Transformer Accessories
These are the basic components of a transformer.
1. Laminated core
2. Windings
3. Insulating materials
4. Transformer oil
5. Tap changer
6. Oil Conservator
7. Breather
8. Cooling tubes
9. Buchholz Relay
10. Explosion vent

Laminated core

The core acts as support to the winding in the transformer. It also provides a low reluctance path
to the flow of magnetic flux. It is made of laminated soft iron core in order to reduce eddy
current loss and Hysteresis loss. The composition of a transformer core depends on such as
factors voltage, current, and frequency. The diameter of the transformer core is directly
proportional to copper loss and is inversely proportional to iron loss. If the diameter of the core is
decreased, the weight of the steel in the core is reduced, which leads to less core loss of the
transformer and the copper loss increase. When the diameter of the core is increased, the vise
versa occurs.
Why Are Windings Made of Copper?
Copper has high conductivity. This minimizes losses as well as the amount of copper needed for
the winding (volume & weight of winding).
Copper has high ductility. This means it is easy to bend conductors into tight windings around
the transformer's core, thus minimizing the amount of copper needed as well as the overall
volume of the winding.

16
Winding

Two sets of winding are made over the transformer core and are insulated from each other.
Winding consists of several turns of copper conductors bundled together, and connected in
series.

Winding can be classified in two different ways:

1. Based on the input and output supply

2. Based on the voltage range

Within the input/output supply classification, winding are further categorized:

1. Primary winding - These are the winding to which the input voltage is applied.
2. Secondary winding - These are the winding to which the output voltage is applied.

Within the voltage range classification, winding are further categorized:

1. High voltage winding - It is made of copper conductor. The number of turns made shall
be the multiple of the number of turns in the low voltage winding. The conductor used
will be thinner than that of the low voltage winding.
2. Low voltage winding - It consists of fewer number of turns than the high voltage
winding. It is made of thick copper conductors. This is because the current in the low
voltage winding is higher than that of high voltage winding.

Input supply to the transformers can be applied from either low voltage (LV) or high voltage
(HV) winding based on the requirement.

Insulating Materials

Insulating paper and cardboard are used in transformers to isolate primary and secondary
winding from each other and from the transformer core.
Transformer oil is another insulating material. Transformer oil performs two important functions:
in addition to insulating function, it can also cool the core and coil assembly. The transformer's
core and winding must be completely immersed in the oil. Normally, hydrocarbon mineral oils
are used as transformer oil. Oil contamination is a serious problem because contamination robs
the oil of its dielectric properties and renders it useless as an insulating medium.

17
Conservator

The conservator conserves the transformer oil. It is an airtight, metallic, cylindrical drum that is
fitted above the transformer. The conservator tank is vented to the atmosphere at the top, and the
normal oil level is approximately in the middle of the conservator to allow the oil to expand and
contract as the temperature varies. The conservator is connected to the main tank inside the
transformer, which is completely filled with transformer oil through a pipeline.

Breather

The breather controls the moisture level in the transformer. Moisture can arise when temperature
variations cause expansion and contraction of the insulating oil, which then causes the pressure
to change inside the conservator. Pressure changes are balanced by a flow of atmospheric air in
and out of the conservator, which is how moisture can enter the system.
If the insulating oil encounters moisture, it can affect the paper insulation or may even lead to
internal faults. Therefore, it is necessary that the air entering the tank is moisture-free.
The transformer's breather is a cylindrical container that is filled with silica gel. When the
atmospheric air passes through the silica gel of the breather, the air's moisture is absorbed by the
silica crystals. The breather acts like an air filter for the transformer and controls the moisture
level inside a transformer. It is connected to the end of breather pipe.

Tap Changer

The output voltage of transformers varies according to its input voltage and the load. During
loaded conditions, the voltage on the output terminal decreases, whereas during off-load
conditions the output voltage increases. In order to balance the voltage variations, tap changers
are used. Tap changers can be either on-load tap changers or off-load tap changers. In an on-load
tap changer, the tapping can be changed without isolating the transformer from the supply. In an
off-load tap changer, it is done after disconnecting the transformer. Automatic tap changers are
also available.

Cooling Tubes

Cooling tubes are used to cool the transformer oil. The transformer oil is circulated through the
cooling tubes. The circulation of the oil may either be natural or forced. In natural circulation,

18
when the temperature of the oil rises the hot oil naturally rises to the top and the cold oil sinks
downward. Thus the oil naturally circulates through the tubes. In forced circulation, an external
pump is used to circulate the oil.

Buchholz Relay

The Buchholz Relay is a protective device container housed over the connecting pipe from the
main tank to the conservator tank. It is used to sense the faults occurring inside the transformer.
It is a simple relay that is operated by the gases emitted during the decomposition of transformer
oil during internal faults. It helps in sensing and protecting the transformer from internal faults.

Explosion Vent

The explosion vent is used to expel boiling oil in the transformer during heavy internal faults in
order to avoid the explosion of the transformer. During heavy faults, the oil rushes out of the
vent. The level of the explosion vent is normally maintained above the level of the conservatory
tank.

Chapter 3

19
 Design Parameters of Transformer

Design Parameters
For designing a transformer, we need,
1) Proposed specification
2) Primary Coil ( Connection Delta )
3) Secondary coil ( Connection Star)
4) Core Diameter
5) Step with
6) Core Stack
7) Flux Density
8) Core Details
9) Approximate Weight of Core
10) Stepwise Weight Calculation
11) Winding Details
12) Coil Assembly Specification
13) Weight of LV & Weight HV
14) Winding Resistance and Load Loss
15) Design of Outputs
16) Designs of Tank
17) Radiators
18) Volume of Oil
19) Conclusion

20
Proposed specification
Here, we shall establish a working design of a 100KVA transformer, the brief specifications of
which are as follows:

Ratting 100KVA
No-Load voltage ratio 11000/433 Volts
No. of phase/Frequency 3 Phase/50 Hz
Connection Delta/ Star Dyn-11
Winding Material Aluminium / Copper
Tapping On HV At +2.5%, +5% for HV variation
No-Load and Load Loss (Maximum) 260/1760W (Maximum)
Impedance 4.5%
Maximum flux density 1.6 tesla
Maximum current density 1.5 A/sq mm
Temperature rise 40/50 c

Current density
We know that transformer primary side Delta connection.
Voltage per phase Vp =11000V
Current Per phase Ip=P/√3 11KV=100KV/√3 ×11KV
=5.24 A
Let us
Current density (Assumed) Cd=1.5A /sq mm (Max)
𝐼𝑝
Conductor Area =
𝐶𝑑
=5.24/1.5
=3.5 sq mm (Mim)
𝜋×(d)2
Equivalent Conductor diameter = 3.5
4
d=2.11 mm
Let us, Select next higher round figure (d) = 2.1 mm

21
 𝜋×(d)2
Area of proposed conductor = 4
= 3.5 sq mm
5.24
Therefore, the working current density = = 1.5 A/sq mm
3.5

Primary Coil:
Number of turns of Primary coil: (Connection of Delta)
We are know
Voltage per turn (Et) = K√𝜃
Here
𝜃 =Rated Voltage (KVA)
K=0.37≈0.44 (Only Copper) and 0.32≈0.35 (Aluminium)
Et = K√𝜃
=0.33×√100 (let us assumed K=0.33)
= 3.3
Secondary phase voltage
No of secondary turns= Voltage per turn(Et)

433/√3
= 3.3

=75.75 Turns
Let us round it off to = 76 Turns

Now we are find out the primary turns

Primary phase Voltage
Primary turns = Secondary × Secondary turns
Phase Voltage
11000
= 433/√3 × 76

=3344 Turnss
Additional Turns for (5%) =3344×5%
=168 Turns
Total primary turns =2684+168 = 3512 Turns
No of coil per phase (Assumed) = 4 Nos.

22
 2818
Turns per coil = = 705 T
4

The HV winding design may proceed as follow:

Vp 11000V
Ip 3.03A
Wire size 1.7 mm diameter
Area 2.27 sq mm
Cd (Current density) 1.335A/sq mm

Turns (N) = 3344 T & 5% additional 168 T

Total HV Turns per phase = 3344+168 = 3512 T
Coil per phase =4 Nos
Turns per coil = 3512/4 = 878 T

Sl No Description Length Radial

1 Bare conductor 1.7 mm 1.7 mm
2 Covering thickness toward DPC + 0.2 + 0.2
3 Covered conductor 1.9 mm 1.9 mm
Gap between two consecutive conductors + 0.05 + 0.05
(assumed)
4 Insulated size of conductor with working 1.95 mm 1.95 mm
tolerance + 0.1 (4 mil inter-
layer insulation)
1.95 mm
878 ×53 ×17 (No. of layer-
Turns per layer : + 1= 53 & layer 17
17
17 which must be
odd)
5 Axial length of HV coil Rounded off to 103.35 = 104 mm 34.85 =35 mm

23
As of now we have concluded that there are 4 HV coils per phase, each having 878 turns, the
winding length of each coil being 104 mm, the radial build of coil being 35 mm, and the inter-
layer insulation 4 mil Kraft paper.

Estimating the core window height:

Total axial length of four coils= 4×104 mm = 416 mm
Gap between yoke to top and bottom coil= 2× 25 mm = 50 mm
Gap between two tap coils at the center = 1 × 10 mm = 10 mm
Gap between plain coils = 2 × 7 mm = 14 mm
……………………………………………………
Therefore, core window height = 490 mm

Secondary Coil
Number of turns of secondary coil: (Connection of star)
Voltage per phase Vs = 433/√3
=250V
100KVA
Current per phase Is = = 133.34A
433×√3

Current density (Assumed) Cd= 1.5/sq mm

133.34
Conductor area =
1.5
=89 sq mm
No of strips processed to be used in parallel = 2 Nos
89
Approximate area of each strip =
2
=44.5 sq mm
Disposition of strips = 1 width× 2depth
No of turns per phase (as calculate above) = 61 T
No of layers =2 layers
Turns per layer =30 Turns
Space required to accommodate 30T = (30+1) = 31 turns

24
Core Diameter
The approximate core diameter may be calculated as follow:
433/√3
Voltage per turn (Et) =
76
=3.289
Flux density (available from specification) (Bm) =1.6 Tesla
Stacking factor (assumed) = 0.97
Gross core area (to be calculate) = Ag in sq mm
Et = 4.44×f×Bm×Ag×0.97×10-4
Where, f=50Hz
The above equation may be rewrite after putting the value of frequency as:
Et = 4.44×50×Bm×Ag×0.97×10-4
Et = 2.22×102 ×Bm×Ag×0.97×10-4
= 2.22×Bm×Ag×0.97×10-2
Et×102
Therefore, Ag = sq mm
2.22× Bm ×0.97
3.289×102
= 2.22× 1.6 ×0.97
=95.5 sq mm
Let us conceive a core stack of 9 steps having rounding off factor 0.945(assumed)
d2
𝜋 ×0.935=95.5(where d = core diameter)
4

118.94×4
d=√ 𝜋×0.935

= 11.403 cm
Let us conceive a round figure of Core Diameter = 114 mm

Step Width
The core has a diameter of 127 mm and has 9 steps. The first and 9th steps may be taken as 120
mm and 40 mm. The balance nine steps may be chosen as 110 mm, 100 mm, 90 mm, 80 mm, 70
mm, 60 mm, and 50 mm,

25
While selecting the step width, we must bear in mind that there should be at least a difference of
5 to10 mm between consecutive steps and those should be in descending order.

1st step 120 mm (L1)

2nd step 110 mm (L2)
3rd step 100 mm (L3)
4th step 90 mm (L4)
5th step 80 mm (L5)
6th step 70 mm (L6)
7th step 60 mm (L7)
8th step 50 mm (L8)
9th step 40 mm (L9)

Core Area
The gross core area can be calculation from the core steps and core stacks as given table.
Core stack K=√𝑑2 + 𝐿2 where, d is the core diameter and L is the step width.

Gross core area Total gross core

Step No Step width (mm) Core stack (mm)
(sq mm) area (mm)
01 110 mm (L1) 29.93 (K1) 3292.3 (L1×K1)
02 105 mm (L2) 14.46 (K2) 1518.3 (L2×K2)
03 100 mm (L3) 10.34 (K3) 1034.0 (L3×K3)
04 90 mm (L4) 15.24 (K4) 1371.6 (L4×K4)
05 80 mm (L5) 11.24 (K5) 899.2 (L5×K5) 9594.2
06 70 mm (L6) 8.76 (K6) 613.2 (L6×K6)
07 60 mm (L7) 6.96 (K7) 417.6 (L7×K7)
08 50 mm (L8) 5.52 (K8) 276.0 (L8×K8)
09 40 mm (L9) 4.30 (K9) 172.0 (L9×K9)

26
Net core area can be calculated as:
Net core area =Gross core * Stacking factor
Stacking factor may be assumed as 0.97 for all practical purposes.
Therefore, Net Core Area = 9594.2×0.97=9306.374 sq mm

Flux Density
Flux density can be calculated by utilizing equation no.2 as follows:
Et = 4.44×f×Bm×Ag×0.97×10-4
Et×104
Or Bm = tesla
4.44× Ag ∗0.97

250
Where Et = =4.0983
61
f=50 Hz
Ag=118.94 sq mm
4.098×104
Therefore, Bm = 4.44× 50×118.94 ×0.97

Bm= 1.5999 Tesla or Bm=1.6 tesla

Core Details
Since the mitered cut core has enormous advantage over the conventional rectangular cut core,
we have conceived a core frame, details of which have been shown as follows:
Core frame size and other core details:
Core diameter = 127 mm
Winding height (W/H) = 490 mm
Limb center (C/L) = 265 mm
Grade of core = 27-M4
Gross core area = 95.942 sq mm
No. of core steps = 9
Core step width: 120/110/100/90/80/70/60/50/40 mm
Core stack = 41.58/21.89/14.81/11.32/9.04/7.32/5.96/5.81/3.80
Total core stack = 106.75 mm

27
 Fig. 3.8 Core assembly details

Approximate Weight of Core

Without going for detailed calculation, the approximate core weight may be calculate with the
following formula:
Weight of the complete set core in kg
=[(3×(W/H)+4×(C/L)+(2×width of 1st step ×0.86)*Gross core area × density of core
material×0.97×10-3]
Where, W/H, C/L and width of the 1st step are in cm, gross core area in sq cm and density of
material 7.65 g/cc
Therefore, the approximate weight of the complete set of core:
[(3×49+4×26.5)+(2×11×0.86)]×95.942×7.65×0.97×10-3
=193.6 kg

28
Step-Wise Weight Calculate of Core
Details of Step (A), i.e. two side limbs:

The shape of lamination-A has been shown in fig- .while calculating the number of places. the
thickness of individual lamination will be taken as 0.27 mm.

The length of the lamination is represented by L and the width by W

The length can be calculated as : (W/H+2W) mm where W/H and W are in mm

The weight of each step can be calculated as:

(L-W)×W×K×7.65×0.97×10-3 kg

Where L,W and K are in cm.

Fig. 3.10 Details of set A

Details of step A
Step No. Step width (W) Step length Step stack (K) No of pieces Weight (kg)
(mm) (L) (mm) (No.)
(mm)
1 110 710 2×29.93 220 29.32
2 105 700 2×14.46 108 13.41
3 100 690 2×10.34 76 9.05
4 90 670 2×15.24 112 11.81
5 80 650 2×11.24 84 7.61
6 70 630 2×8.76 64 5.10

29
7 60 610 2×6.96 52 3.41
8 50 590 2×5.52 40 2.21
9 40 570 2×4.30 32 1.35
Total 2×106.75 788 83.27

Note: The number of pieces should be adjust in such a way that it is divisible by ‘4’, as such, the
calculated figures are rounded off to the nearest numbers, which are divisible by ‘4’.
Details of step (B) i.e. center limb

Fig. 3.10 Details of step B

The shape of lamination (B) has shown below.

The length can be calculate as (W/H+W) and the weight of each step can be calculate as
(L-1/2W)×W×K×7.65×0.97×10-3
Where, L, W and K are in cm

30
Details of step B

Step No. Step width (W) Step length Step stack (K) No of pieces Weight (kg)
(mm) (L) (mm) (No.)
(mm)
1 110 600 29.93) 110 13.31
2 105 595 14.46 54 6.11
3 100 590 10.34 38 4.14
4 90 580 15.24 56 5.44
5 80 570 11.24 42 3.54
6 70 560 8.76 32 2.39
7 60 550 6.96 26 1.61
8 50 540 5.52 20 1.05
9 40 530 4.30 16 0.65
Total 106.75 Total 38.24

Note: The number of pieces should be exactly half of A-step

The shape of lamination (B) has shown below.

Fig: 3.10 Details of step C

The length may be calculate as (2×(C/L)+W)

31
Weight of each step may be calculate as
((L-W)×W-1/2 W2)×K×7.65×0.97×10-3
Where, L, W and K are in cm

Details of Step (C)

Step No. Step width (W) Step length Step stack (K) No of pieces Weight (kg)
(mm) (L) (mm) (No.)
(mm)
1 110 640 2×29.93 220 24.55
2 105 635 2×14.46 108 11.35
3 100 630 2×10.34 76 7.75
4 90 620 2×15.24 112 10.5
5 80 610 2×11.24 84 6.81
6 70 600 2×8.76 64 4.66
7 60 590 2×6.96 52 3.19
8 50 580 2×5.52 40 2.12
9 40 570 2×4.30 32 1.33
Total 2×106.75 Total 72.09

The number of pieces should be exactly same as that of step A

Total weight of core:
Weight of step A = 83.24 kg
Weight of step B = 38.24 kg
Weight of step C = 72.09 kg
Total weight core = 193.60 kg

Core chart specification

Material: CRGO, grade- 4
Thickness: 0.27 mm
Core diameter: 127 mm
Window height: 490 mm
32
Limb center : 265 mm
Core stack : 106.75 kg
Weight/set: 193.6 kg

Winding Details
Low voltage winding

No. Description Designs parameters

1 Conductor material Aluminium, Electrolytic grade

2 Type of coil Spiral
3 Connection Star
4 Size of bare conductor 11×4.5 mm×2 in parallel
5 Covering DPC – 0.4 mm
6 Size of covered conductor 11.4×4.9 mm
7 Conductor disposition 1 width × 2 depth (1W×2D)
8 Transposition ( if provided ) Yes, at the center of each layer
9 Turn per phase 76 T
10 Number of coil per phase 1 no
11 Turns per coil 76 T
12 Number of layer 2 layer
13 Turns per layer 38 T
14 Inter layer insulation 10 mil
15 Tapping details Nil
16 Inside diameter of coil 120 mm
17 Outside diameter of coil 162 mm (Maximum)
18 Winding length of coil 460 mm
19 End packing details 5 mm on either
20 Overall length of coil 470 mm
Approximate bare weight of
21 27.1 kg
conductor per transformer

33
 Approximate covered weight of
22 conductor per transformer including 27.1×1.07= 29.0kg
leads

High voltage winding

No. Description Designs parameters

1 Conductor material Aluminium, Electrolytic grade

2 Type of coil Cross –over or sectional
3 Connection Delta
4 Size of bare conductor 1.7 mm diameter
5 Covering DPC – 0.2 mm
6 Size of covered conductor 1.9 mm diameter
7 Conductor disposition Nil
8 Transposition ( if provided ) Nil
9 Turn per phase 3344+168 for tapping=3512 T (total)
10 Number of coil per phase 4 Nos.
11 Turns per coil 878 T
12 Number of layer 17 layer
13 Turns per layer 52/51 T (average)
14 Inter layer insulation 4 mil (0.1 mm)
15 Tapping details 0-(710)-(794)-(878)(F)
(3) (4) (5)
Tap turns and letters
(8) (7) (6)
16 Inside diameter of coil 182 mm
17 Outside diameter of coil 252 mm
18 Winding length of coil 104 mm
19 End packing details Nil
20 Overall length of coil 104 mm

34
 Approximate bare weight of
21 45 kg
conductor per transformer
Approximate covered weight of
22 conductor per transformer including 45×1.14= 51.5 kg
leads

Coil Assembly
Coil Assembly Specification:
Customer :
KVA/KV:100KVA, 11000/433 KV
Name of operator:

No of LV coil/limb 1 no.
No of HV coil/limb (plain) 2 nos.
No of HV coil/limb (tap) 2 nos.
HV coil 1.D.×0.D×length 182φ×252φ×104 mm
LV coil 1.D.×0.D×length 120φ×162φ×470 mm
Gap between plain coil 7 mm
Gap between tap coil 10 mm
Gap between HV to yoke 25 mm
Gap between LV to yoke 10 mm
Size of plain block N/A
Between LV to yoke 40×65 mm
Size of dovetailed block between HV coil 40×40 mm× 8 nos./circle.
Delta wire size 2.3φ (cu)
Size of thimble to be used 95 sq mm
Size of LT bus bars N/A
Taping switch if any 5 Position, 30 A/11KV

35
 Fig.3.12 Coil assembly of specification

Weight of LV and HV Aluminium

Weight calculation of LV and HV Aluminium coil:
Particulars LV coil HV coil
Inside diameter of coil (D1) 120 mm 182 mm
Outside diameter of coil (D2) 162 mm 252 mm
Mean diameter of coil (Dm)
𝐷1+𝐷2 141 mm 217 mm
[ Dm= ]
2

Mean length of turns (L1)(L1=π×Dm) 443 mm 682 mm

No of turns (T) 76 T 3344+168=3512 T
Total length of conductor (L)
33668 mm 2395184 mm
L=L1×T
Specific gravity of Aluminium (s) 2.76g/cc 2.76 g/cc
Cross sectional area of the conductor
97.28 sq mm 2.27 sq mm
(A)

36
Bare weight of conductor or being
9.0kg 15.0 kgs
used in one phase (L1×A×S×10-6)
Bare weight of conductor being used
27kg 45kg
for 3phase
Weight of the conductor (considering
a coverage of 7% for LV strip and 27×1.07=29kg 45×1.14 =51.5kg
14% for HV wire, including leads)

Winding Resistance and Load Loss

Particulars LV coil HV coil
Inside diameter of coil (D1) 120 mm 182 mm
Outside diameter of coil (D2) 162 mm 252 mm
Mean diameter of coil (Dm)
𝐷1+𝐷2 141 mm 217 mm
[ Dm= ]
2

Mean length of turns

443 mm 682 mm
(L1)(L1=π×Dm)
No of turns (T) 76 T 3344 T
Total length of conductor (L)
33668 mm 2395184 mm
L=L1×T
Resistivity of Electrolytic 0.0345 ohm-cm at 750 C 0.0345 ohm-cm at 750 C
Aluminium (K)
Cross sectional area of the 97.28 sq mm 2.27 sq mm
conductor (A)
Winding Resistance per phase 0.012 ohms 34.7 ohms
𝐿×𝐾×10−3
at 750 C [ R= ]
𝐴

Current per phase (I) 133.34A 3.03A

I2R×3 phase at 750 C 214×3=642 W 319×3=957 W
Total I2R (LV+HV) 642+957=1599W

37
Approximate stray loss for 100 W
100 KVA
Load loss at rated load and at 1599+100=1699 W
750 C
Load loss (Guaranteed) 1760 watts (Maximum)

Design Outputs
Design outputs as tabulated as a ready reference

No Particulars Design output Guaranteed value

1 Core diameter 114 mm
2 Core window height 490 mm
3 Core limb center 265 mm
4 Core stack 106.75 mm
5 No. of core steps 9
6 Gross core area 9594.2 sq mm
7 Net core area 9306.37 sq mm
8 Grade of core 27 M-4 27 -M-4
9 Flux density 1.592 tesla 1.6 tesla
10 Weight of core 193.6kg
11 Size of the LV conductor (bare) 11×4.5 mm ×2 nos.
12 Size of the LV conductor (covered) 11.4×4.9 mm
13 Covering DPC-0.4 mm DPC
14 Area of LV conductor 97.28 sq mm
15 LV current density 1.37 A/sq mm 1.5 A/sq mm
16 LV turns per phase 76 T
17 LV coil inside diameter 120 mm
18 LV coil outside diameter 162 mm

38
19 LV coil length 470 mm
20 LV resistance per phase at 75 C 0.012 ohm
21 LV conductor material Aluminium Aluminium
22 Gap between LV coil to yoke 10 mm 10 mm
23 Weight of LV covered conductor per 29 kg
transformer
24 Size of the HV conductor (bare) 1.7 mm diameter
25 Size of the HV conductor (covered) 1.9 mm diameter
26 Covering DPC-0.2 mm DPC
27 Area of HV conductor 2.27 sq mm
28 HV current density 1.335 A/sq mm 1.5 A/sq mm
29 HV turns per phase 3525 T
30 No. of coil per phase 4 nos.
31 Turns per coil 878 T
32 LV coil inside diameter 182 mm
33 LV coil outside diameter 252 mm
34 LV coil axial length 104 mm
35 Gap between plain coil 7 mm
36 Gap between tap coil 10 mm
37 Gap between HV to yoke at top and 25 mm 25 mm
bottom
38 HV resistance per phase at 75 C 34.7 ohms
39 Conductor material Aluminium Aluminium
40 Gap between HV limbs 13 mm 10 mm
41 Weight of HV covered conductor 51.5 kg

The Design of Tank

Though the tank acts as an external encloser to the active part (core coil assembly), still, the
performance of the transformer mostly depend on the right kind of tank design. Various internal

39
gaps and clearance, easy and safe termination arrangement, locking fixing etc. are some of the
areas where much attention is needed.
1. The following assumptions are made while calculating the tank dimensions:
2. Gap between HV coil to the inside of tank on length side-25 mm
3. Gap between HV coil to the inside of tank on length side-40 mm
4. Gap between core yoke to tank bottom-40 mm
5. Gap between core yoke to ratio switch base-20 mm
6. Height of ratio switch-90 mm
7. Gap between ratio switch top to the inside of tank cover-40 mm

Base on the above internal clearness let us from the tank dimensions as follows:
Length of tank (inside): 2× C/L of core +HV coil O.D.+2×25 mm
: 2×265+253+50
: 833 mm
: 853 mm (after being rounded off)
Breadth of tank (inside): HV coil O.D. +2×40 mm
: 253+80
: 333 mm
335 mm (after being rounded-off)
Height of tank (up to tank flange):
40+bottom yoke insulation +W/H of core+2×width of 1st core step +20+R/s height+40 mm
= 40+5+490+2×110+20+90+40
= 905 mm
Therefore, the final tank dimensions are:
Length = 835 mm
Breadth = 335 mm
Height = 905 mm

40
Radiators
Use of radiators:
During service, the tank body can dissipate a total loss equivalent to 500 W/sq m (maximum) of
the tank surface area. In case the total loss. i.e. (no load+ load loss) is more than the loss
dissipated by the tank surface, the loss in excess is required to be dissipated with the help
additional cooling surface which is commonly call as radiator.
Classification of radiators:
Radiators commonly being used are three different types:
1. Conventional round/elliptical tube radiator
2. Pressed steel radiator
3. Corrugated wall panel

Conventional elliptical tube radiators:

The standard length of an elliptical tube available in the market is 6.1 meters. It is cut into a
number of pieces and welded together to form a radiator bank. Each radiator bank has an inlet
and an outlet for free flow of coil.

Fig.17 Formation of elliptical tube radiators and flow of oil

When a transformer is in service, it emits losses which transform into heat energy. As we know,
liquid, when heated up, becomes lighter since it loses its density and causes increase in volume.

41
The heated oil become lighter and tries to come-up by displacing the heavier oil on the top. The
heavier oil, in the process of displacement, has no other alternative but to push through the inlet
of the header pipe.
When the heated oil gets into inlet header pipe, it loses its heat and become heaver again. Due to
gravity, this oil will fall down through the pipe and reach the outlet header pipe. Thus the
sequence of oil flow by natural convection is completed. The circulation of flow oil has been
shown in fig-

In a transformer, we are required to provide more tubes, having certain fixed length according to
the tank height as indicated in fig-3.17(b)
Let us select the length of each tube as 590 mm, which will yield 10 tubes from a 6.1 m length
without much wastage.
The number of elliptical tubes required can be calculated from the following formula:
1 𝐾
No, of tubes = [ − 12.5 × 𝐴]
8.8×𝑋×𝑌 𝐿

Where,
A = Tank surface area in sq meter (only side wall to be considered.)
K = Total loss in watts (i.e. guaranteed no-load plus load loss)
L = Average oil temp. Rise in degrees C (Maximum guaranteed oil temperature rise multiplied)
Y = Unit length of each tube in meter.

42
X = Surface length of elliptical tube in meter.

Tank dimensions:
Length = 835 mm = 0.835 meter
Breadth = 335 mm = 0.335 meter
Height = 905 mm = 0.905 meter
Therefore, Tank surface area for side walls only: A
A = 2×(0.835+0.355)×0.905
= 2.1177 sq meter
Guaranteed on-load + load loss: K
K = 260+1760
= 2020 W
Average oil temperature rise: L
L = 40×0.8
= 320 C
Unit length of each tube in meter: Y
Y = 0.590 m
Surface length of elliptical tube: X
X = 2× (75+15) × 0.9
= 162 mm
= 0.162 m
1 2020
Therefore, no. of tubes = 8.8×0.162×0.59 [ − 12.5 × 2.1177]
32

= 43.58 nos.

43
 Fig.17 (e) Construction of tank with elliptical radiator

Presses steel radiators

These radiators are produced from 1.0 to 1.2 mm clod rolled continuously annealed (CRCA)
sheet having a width varying from 230 mm, 300 mm and 250 mm. The unit lengths of radiators
are from 400 mm to 3000 mm in multiples of 100 mm. the number of fins per radiator is
calculated on the basis of guaranteed losses.
Tank surface area = 2.117 sq m (calculated before)
The loss dissipated per sq m of tank area = 500 W/sq m

44
Therefore, the tank surface will dissipate a loss equivalent to:
2.177×500 = 1069 W

Fig. 3.17 (f) Formation of pressed steel radiator

Total loss to be dissipated = (260+ 1760) = 2020 W

Additional cooling surfaces are to be added in the form of radiators for dissipation of excess loss
= (2020-1059) = 961 W
Radiator center distance as chosen from the height of tank is 700 mm and width of each fin
having 3 channels of oil flow is 230 mm.
Standard tables will indicated heat dissipation for oil excess temperature which are also available
here as reference.
Heat dissipation per fin for oil excess temperature of 400 C for 700 C/d = 112 W/ fin

45
 Fig.3.17 (g) To find our correction factor vertical distance between
Transformer core and radiator center line.

Correction factor
a) Vertical distance between transformer core center line and radiator center line 80 mm
b) Horizontal distance between two radiators 500 mm, Correction factor = 1.0
c) No. of sections per radiator (4-5) nos, Correction factor = 1.06
Total correction factor = a× b × c = 0.85× 1.0 × 1.06 = 0.901
Therefore, heat dissipated by each fin after taking into consideration the correction factor:
= 112× 0.901
= 101 W
The number of fins required to dissipate 961 watts for a temperature rise of 400 C = 961/101 =
9.5 nos.
We propose to use two radiators each having 5 fins with C/d = 700 mm and width 230 mm.

46
 Fig. 3.17 (h) Construction of tank with pressed steel radiators.

Corrugated wall panel radiators

In recent times, in response to the increase in the cost materials and labour, z new concept in heat
exchange by use of build in corrugations on transformer tank wall has virtually eliminated the
radiator concept, particularly for distribution transformers in all advanced countries.

47
The corrugated wall panels are manufactured from CRCA steel sheet of thickness ranging
between 0.75 mm and 1.2mm, using a special purpose machine, The plain wall, top collar and
tank bottom are constructed in a conventional manner using regular mild steel materials.
Structural steel items like angles, channels etc. are being used wherever required for strength and
support.
Apart from the benefit of compactness, elegant appearance, saving in steel, oil, freight cost and
space, are the major advantages with such construction that lends itself ideally in marking
hermetically sealed transformers, Bellows action of the corrugations itself wall accommodate the
expansion and construction of the transformer oil. Thus, with the elimination of contact of the oil
with the outside atmosphere, the whole arrangement becomes totally maintenance free.
The entire losses are dissipated through the wall of corrugated fins. Based on the tank height, the
dimension (L) can be suitable chose. In this case, we have estimated L as 700 mm, the gap
between consecutive fins= 45 mm, and the end space = 25 mm.
835−(2×25)
No. of fins on longer side = +1
45

= 18.44
= 18 nos.
335−(2×25)
Similarly, no. of fins on shorter side = +1
45

= 7.33 or =7 nos.
Total no. of fins = (2×18) + (2×7) = 50 nos.
Total loss to be dissipated = 260+1760 = 2020 W
2020
W/ fin meter = 50×0.7 = 57.71 = 60

48
 Fig.3.17 (i) Formation of tank with corrugated wall panel
Note:
1. Wall panel corrugated radiators
a) Please adopt your practice for spot weld etc.
b) Inside dimensions of tank are required
Length : 835 mm
Width : 335 mm
2. Radiator depth (D) : 40 mm
3. Radiator height (H) : 700 mm
4. All dimensions are in mm.

Weight of Tank
There are three types.
1) Weight of tank with elliptical tube radiator
2) Weight of tank with pressed steel radiators
3) Weight of tank with corrugated wall panel
Weight of tank with elliptical tube radiator
Weight of tank may be calculated with +5% accuracy. The weight of individual parts will be
calculated and added together to form the total weight. A standard table may be consulted while

49
calculated the weight of channels, flats, pipe, tubes etc. For general information, the approximate
weight of each meter of elliptical tube having section 57 is approximately 1.5 kg.

The approximate calculated weight of individual item is as given in table:

Sl Particulars Description
No.
1 Weight of side sheet (3.15 mm) 52 kg
2 Weight of bottom sheet (5 mm) 11 g
3 Weight of top sheet (5 mm) 15 kg
4 Base channel (75×40×460 mm long)- 2 nos. 7 kg
5 Tank flange (40×8 mm) 6.5 kg
6 Stiffeners on all four sides (40×6 mm)- 2 nos. 9.7 kg
7 Conservator and its supports 10 kg
8 LV box 3 kg
9 HV bushing adopter (3 nos.) 4 kg
10 Explosion vent (it provided) 3.5 kg
11 Lifting lugs (8 mm)- 2 nos. 2 kg
12 Elliptical tube (26 meter× 1.5 kg per meter) 39 kg
13 Radiators header – 4 nos. 20 kg
14 Miscellaneous items, including deposition of wielding 4 kg
electrode, etc. (which is about 2.5% of above)
Total 186.7 k

50
The actual weight of tank will be slightly less than the calculated value as the box cut-out
punched holes for elliptical tubes, drilled hole for bolts, etc. will cause a reduction of approx. 2%
on the calculated value. However, costing may be done on the calculated weight plus 10%
towards scraps and wastage.

Weight of tank with pressed steel radiators

The weight of the tank may be calculated as stated above, excluding the elliptical tube and
radiator header, where the weight of pressed steel radiator shall be added. we may refer to the
standard tables available from the radiator manufactures for calculating the weight of radiator.

Weight of tank with corrugated wall panel

The weight of tank with corrugated wall panel may be calculated with further accuracy as it has
sheet metal on all four sides in the form of corrugation. The development length of the
corrugated wall shall be calculated first. However, equivalent surface area equal to the tank
length, breadth and height of radiator is to be reduced while calculating the weight of the tank.

Volume of oil
Calculation of volume of oil two types,
1) Volume of oil in the tank only
2) Volume of oil in the radiators

Volume of oil in the tank only:

Volume of oil the tank = tank volume – approximate volume of coil assembly
Tank volume = Length × Breadth ×Height ×10-3 liters
Where the dimensions are in centimeters
Therefore, tank volume = 83.5×33.5×90.5×10-3
= 253 liters

51
And approximate volume of core coil assembly
= volume of core + volume of aluminum + volume of core fittings + volume of insulating
materials.
193.6 (29+51.5) 30
= + + 7.8 + 10
7.65 2.76

= 25.3+ 29.2 +3.8 + 10

=68.3 rounded off to 68 liters
Therefore, volume of oil in the tank = 253 -63 = 185 liters

Volume of oil in the radiators:

1. The first alternative having elliptical tube radiator:

The volume of each meter of electrical tube is 0.9 liter. We have provide 26 meter tubes,
which means that oil in the tube = 26 × 0.9 = 23.4 liters, Therefore, oil in the tube = 24
liters (approx.)

2. The second alternative having pressed steel radiators:

For calculating the oil volume in pressed steel radiators, we shall refer to the heat
transmission table indicated earlier.
For center distance pipe 700 mm, the oil content per section of fin in 0.97 liters, Add 0.6
liter per section to include oil in the header pipe.
Therefore, oil content per section = (0.97+0.6)= liters
No. of section used = 10 nos.
Therefore, oil for complete radiator = 1.57 × 10 = 15.7 liters (Rounded off to 16 liters)
3. The third alternative having corrugated wall panels:
Volume of oil per fin = Width × Depth × Height ×10-3 liters
Where, dimensions are in centimeters,
= 4.0×0.8×70×10-3
= 0.224 liter

52
 Fig.3.19 Details of bottom foot channel
No. of fins used = (2×18×2×7)
= 50 fins
Therefore, volume of oil in the corrugated wall panel = 50 ×0.224 = 11.2 liters
(Rounded off to 12 liters)
Summaries of volume of oil the tank and radiators
The first alternative having elliptical tube radiators = 185 +24 + 6 =215 liters

53
The second alternative having pressed steel radiators = 185 + 16 = 201 liters
The third alternative having corrugated radiators = 185 +12 = 197 liters

Transformer Testing

Essential Elements of Transformer

 Copper or coli
 Core
 X-F oil
 Board.
 Heavy metal
 Insulation material
54
Copper or Coil: Copper is the material of choice for power transformer conductors due to its
superior short-circuit with stand capabilities.
Core: A magnetic core is a piece of magnetic material with a high magnetic permeability used to
confine and guide magnetic fields in electrical, electromechanical and magnetic devices such as
electromagnets, transformers, electric motors, generators, inductors, magnetic recording heads,
and magnetic assemblies.
X-F oil: Insulating oil in an electrical power transformer is commonly known as transformer oil.
It is normally obtained by fractional distillation and subsequent treatment of crude petroleum.
That is why this oil is also known as mineral insulating oil. Transformer oil serves mainly two
purposes one it is liquid insulation in electrical power transformer and two it dissipates heat of
the transformer i.e. acts as a coolant.
Board: Transformer board (T.B.) is a laminated electric insulator made from extremely pure
craft pulp

Types of Transformer test

There are 2 types of Transformer test

Pre-Manufacturing Test.
Pre-Commissioning Test.

Pre-Manufacturing Test
1. Copper test
2. Core test
3. Oil test

Transformer Copper test

Transformer Copper Losses are mainly due to the electrical resistance of the primary and
secondary windings. Most transformer coils are made from copper wire which has resistance in
Ohms, (Ω). This resistance opposes the magnetizing currents flowing through them.

55
Test Purpose:
To identify purity of copper
1. Mathematical Result:
Law of Resistance (R) = (⍴L)/A
Using screw gage (h x w) in mm
Suppose,
h= Height of copper=10mm
w= Width of copper=2.8mm
So, A = (h x w) = (10 x 2.8) mm2 = 28 mm2
So, we are known,
Resistance, (R) = (⍴L)/A
= (0.019*1000)/28 Ω =0.67 Ω [Theoretical value]

2. Practical Result:
Using resistance Meter
Resistance meter value should be
less than or equal of theoretical
value. If the value of resistance is
greater than theoretical value, so it’s
not perfect, we have to change the
copper.

Transformer Core Test:

The transformer core provides a magnetic path to channel flux. The use of highly permeable
material (which describes the material's ability to carry flux), as well as better core construction
techniques, helps provide a desirable, low reluctance flux path and confine lines of flux to the
core.

56
Test Purpose
To identify power loss of core
Testing Equipment
 Iron Loss Tester
Testing Procedure
 Using screw gage measure only w in
mm
 Iron Loss Must less than 1.0 watt/Kg
We are known that,
1Kg copper =2 watt

Transformer oil test:

Transformer oil serves mainly two purposes one it is liquid insulation in electrical power
transformer and two it dissipates heat of the transformer i.e. acts as a coolant. In addition to
these, this oil serves other two purposes, it helps to preserve the core and winding as these are
fully immersed inside oil, and another important purpose of this oil is, it prevents direct contact
of atmospheric oxygen with cellulose made paper insulation of windings, which is susceptible to
oxidation.

Test Purpose
• To ensure good Brake down Voltage of Oil.
• Must need <25KV
Testing Equipment
• X-F Oil Tester

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 Properties of Transformer Insulating
Oil
Parameters of Transformer Oil
The parameters of transformer oil are
categorized as,
Electrical parameters: – Dielectric
strength, specific resistance, dielectric dissipation factor.
Chemical parameter: - Water content, acidity, sludge content.
Physical parameters: - Inter facial tension, viscosity, flash point, pour point.

Parameters of Transformer Oil or Dielectric strength of transformer oil is also known as

breakdown voltage of transformer oil or BDV of transformer oil. Break down voltage is
measured by observing at what voltage, sparking strands between two electrodes immersed in the
oil, separated by specific gap. Low value of BDV indicates presence of moisture content and
conducting substances in the oil. For measuring BDV of transformer oil, portable BDV
measuring kit is generally available at site. In this kit, oil is kept in a pot in which one pair of
electrodes are fixed with a gap of 2.5 mm (in some kit it 4mm) between them. Now slowly rising
voltage is applied between the electrodes. The rate of rising voltage is controlled at 2 KV/s and
observes the voltage at which sparking starts between the electrodes. That means at which
voltage dielectric strength of transformer oil between the electrodes has been broken down.

Suppose,
1st time = Breakdown voltage 30 kv
2nd time= Breakdown voltage 32 kv
3rd time= Breakdown voltage 35 kv
4th time= Breakdown voltage 37 kv

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5th time= Breakdown voltage 36 kv
𝟑𝟎+𝟑𝟐+𝟑𝟓+𝟑𝟕+𝟑𝟔
So, Average Breakdown voltage = = 34 KV
𝟓

Why this oil is also known as mineral insulating oil:

Transformers are used by the electrical industry to transfer electrical energy from one circuit to
another. The oil surrounding the coils in a power transformer provides cooling, insulation and
protection against corona and arcing. It is normally obtained by fractional distillation and
subsequent treatment of crude petroleum. This is why this oil is also known as mineral insulating
oil.

Pre-Commissioning Test of Transformer

There are 2 types of Pre-Commissioning Test
1) Routine Test
2) Type Test

Transformer Routine Test classification

1) Single Phase Test
2) Insulation resistance Test.
3) Winding resistance Test
4) Turns Ratio / Voltage ratio Test.
5) Polarity / Vector group Test.
6) Open-circuit Test or No-load losses
7) Short-circuit impedance and load loss Test.
8) High Voltage Test.

Transformer Single Phase Test

The operation principle of the single-phase transformer is: the AC voltage source injects the AC
current through the transformer primary winding.

59
The AC current generates the alternating electromagnetic field. The magnetic field lines are
moving through iron transformer core and comprise the transformer secondary circuit. Thus the
voltage is induced in the secondary winding with the same frequency as the voltage of the
primary side. The induced voltage value is determined by Faraday’s Law.

Where,
f → frequency Hz
N → number of winding turns
Φ → flux density Wb
If the load is connected on the secondary transformer side the current will flow through
secondary winding. Basically, the single phase transformers can operate as step up transformer
or step down transformers.

Single Phase Transformer Test:

Test Purpose
 To identify any kind of short in transformer.
 Testing Procedure
 Neutral (n) to a phase
 Neutral (n) to b phase

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  Neutral (n) to c phase

Transformer Insulation resistance Test

Insulation resistance test of transformer is one of the most important transformer tests.
Purpose
To ensure the insulation of Tx-F is OK or Not
Testing Procedure
Standard 2000+ Mega ohm
 LT to Ground
 HT to Ground
 LT to HT
Testing Equipment
 Megger Meter

Purpose of this test:

Insulation resistance test of transformer is performed on the transformer to:
 Verify insulation integrity due to the moisture and impurity contents of insulation.
 Ensure that no leakage paths between phases or transformer body.
Precautions before do these tests:
 Disconnect the electrical current from the transformer and grounding it.
 We should discharge any electrical static charge that may have been accumulated on the
transformer by means of the discharge stick or using a measuring device with automatic
discharge of
the charges.
Clean
the terminals
of the
transformer.

61
Steps of this test:
Insulation resistance test of transformer is divided into three parts:
Firstly Measure insulation resistance between low voltage windings and the main body of the
transformer

We use MEGGER test at low voltage side as shown in fig.

1. Adjust MEGGER tester at 1000 V DC.
2. Record the value of insulation resistance measured by MEGGER tester after applying 1
min.
3. Repeat this test between another phase and transformer body as example (a & TR body, b
& TR body , c & TR body)
4. Insulation resistance of new transformer should be greater than 1 Giga ohm and old
transformer should greater than 300 Mega ohm.

62
Secondly Measure insulation resistance between low voltage windings and high voltage
windings.

We also use MEGGER tester as shown in fig.

1. Adjust MEGGER tester at 2500 V DC.
2. Record the value of insulation resistance measured by MEGGER tester after applying 1
min.
3. Repeat this test between other phases as example (A & a , A & b , A & c , A & n , B & a ,
B & b , B & c , B & n , C & a , C & b , C & c , C & n ).
4. Insulation resistance at all mentioned phases should greater than 1 GIGA ohm.

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Thirdly Measure insulation resistance between high voltage windings and the main body of the
transformer

We use MEGGER test at low voltage side as shown in fig.

1. Adjust MEGGER tester at 5000 V DC.
2. Record the value of insulation resistance measured by MEGGER tester after applying 1
min.
3. Repeat this test between another phase and transformer body as example (A & TR body,
B & TR body , C & TR body)
4. Insulation resistance of new transformer should be greater than 1 Giga ohm and old
transformer should greater than 300 Mega ohm.
The summary is that if the Insulation resistance test of transformer between high voltage
windings and the transformer body is less than 300 Mega Ohm indicates on the weakness of
insulation that means contact between transformer body and high voltage windings.

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Transformer Winding resistance test

Test Purpose
To find out the total Loss of Tx-F (Both LT & HT)
Testing Procedure
 HT phase to Phase
(AB, BC, CA)
 LT phase to Phase
(ab, bc, ca)
 LT Phase to Neutral Resistance
(na, nb, nc)
Testing Equipment
Megger Tester

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Purpose of transformer winding resistance test:
This test is performed on the transformer to:
 Check continuity of all internal connections.
 Check loose connections of bushing or tap changer that may cause high contact
resistance.
Precautions before do these tests:
 Disconnect the transformer electrically.
 Clean the terminals of transformer.
Steps for transformer winding resistance test:
Firstly we Measure the resistance value of high voltage windings:

66
 1. Measure resistance between each phase with another phase as shown in previous fig.
2. Repeat this test at all tap changer points.
3. These values of resistances should be same and identical with the nameplate value
recorded on the transformer with error permeability of 5% maximum, if higher than 5%,
transformer test fails.

Secondly we measure the resistance value of Low voltage windings:

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 1. Measure resistance between each phase and another phase as shown in previous fig.
2. No tap changer points at Low voltage side.
3. Measured values should be identical with the nameplate value of the transformer
But when measuring the resistance of low voltage winding in this way we do not get accurate
results because of the small value of resistance to low voltage winding so, In this case, we can
use any resistance bridge law

Turns Ratio / Voltage ratio Test.

Purpose of this test:

We perform Transformer turns ratio test to:

 Determine the turn’s ratio between the primary and secondary windings.
 Calculate the error ratio between the design value and the actual value, this value shall
not exceed limit given in relevant standards, normally 0.5% at no load.

𝑀𝑒𝑎𝑠𝑢𝑟𝑒𝑑 𝑣𝑎𝑙𝑢𝑒 − 𝑟𝑎𝑡𝑒𝑑 𝑣𝑎𝑙𝑢𝑒

× 100 ≤ ±0.5%
𝑟𝑎𝑡𝑒𝑑 𝑣𝑎𝑙𝑢𝑒

 Detect any short circuit between winding in a single side.

 Verify that transformer winding are connected for the correct vector group.

Precautions before turn’s ratio test:

 Disconnect the transformer electrically.

 Clean the terminals of transformer.
 Disconnect the voltage source before changing the voltage tap changer.

Steps for transformer ratio testing:

We have two cases to do this transformer testing, Firstly using measurement device as shown in
figure:

68
On the device, adjust the test device by specifying the vector group of the transformer, for
example DY 11.
 Also determine the number of voltage tap changer points, for example 7 points.
 The amount of voltage step 2.5.
 And determine the normal number of voltage tap changer for example point 4.
 Determine the value of the voltage on the primary winding is 11 kV and value
Voltage on the secondary winding is 415 volts corresponding to the point of the
normal voltage tap changer which is No. 4
 Then, through the test device, which has two voltage values of 40 volts or 80 volts
AC, select one of them.
 Then starts injecting that voltage onto one of the high voltage windings of the
transformer.
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  Measure the voltage on the two ends of the secondary windings, the ratio of which is
the transformer ratio.
 Disconnect the voltage source before changing the voltage tap changer.
 Change The voltage tap changer mode and the test frequency.
 Repeat the test at another tap changer point and compare the output with the existing
data of transformer.
Practical Turns Ratio Test Purpose
• Tx-F Taping position is ok or not.

Procedure
(+1 x 2.5, 0, 3 x 2.5) = 102.5%, 100%, 97.5%, 95%, 92.5% [here, 0 position means 100%. +1 x
2.5 means, ADD 2.5 with 100% in L.H.S only one time. 3 x 2.5 means Subtract 2.5 with 100% at
R.H.S in three times. So, we get 5 tap changing position of x-former

 1st position = 102.5%=11275v/415=27.16, (415/27.16=15.28).

 2nd position=100%=11000/415=26.5, (415/26.5=15.68).
 3rd position=97.5%=10725/415, (415/25.84=16.06).

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  4th position= 95%=10450/415=25.18, (415/25.18=16.48).
 5th position=92.5%=10175/415=24.52, (415/24.52=16.92)

11000/415 V
415 to HT
Testing Equipment
• AV meter/clamp meter

AB BC CA ab bc ca avg
415 v 415 v 415 v 15.27 15.28 15.27
415 v 415 v 415 v 16.05 16.07 16.06
415 v 415 v 415 v
415 v 415 v 415 v
415 v 415 v 415 v

Test result:
Measure the voltage ratio for each tapping connection of the transformer. In the test report the
specified tapping voltage ratios are stated, as well as the measured ratios. If the error rate exceeds
0.5%, the transformer has failed the test and is rejected.

Open-circuit Test or No-load loss

Open circuit test of transformer this test very important, it considered backbone of transformer
testing .Through this test we will calculate no load losses of transformer at no load condition
Purpose of this test:
1. Determine the no load iron losses (P0)
2. Determine the no load current (I0) of the transformer at rated voltage and frequency.
3. Verify guaranteed values to prove the quality of the core steel and the workmanship of
core staking.
4. Determine core resistance and reactance.

71
Precautions before do these tests:
1. Disconnect the electrical current from the transformer.
2. Clean the terminals of the transformer.
Steps of open circuit test of transformer:

72
  Connect secondary winding with AC source 380 Volt as shown in fig.
 Keep primary winding without any load (open circuit).
 Measure Voltage, Current and power at secondary side with voltmeter, ammeter and
watt-meter as shown in fig.
 Current Drawn at this case (I0) should not exceed 1% of rated current of transformer as
transformer opened at primary.
 So, we can neglect power loss at primary side.
 We can also neglect voltage drop that’s mean the measured power at this case represent
iron loss (P0) only.
 For more accuracy we can repeat this test 5 times at 90% , 95% , 100%, 105% , 110%
of rated voltage and at every time we can measure Voltage, Current and power at
secondary side.
 If the measured values differ significantly from the nameplate values, it means that we
have an iron core problem and there may be short in lamination or there are gaps
between the iron core layers or protrusions in the iron core sections.
 This test is also useful to see if there is an unsymmetrical structure of the iron core or
not.
 If it is observed that the current drawn in one of the phases is very different from the
other two phases, there were unsymmetrical structures of the iron core.

Short-circuit impedance and load loss Test

Short circuit test of transformer this test very important and classified under type test, routine test
and Emergency test of transformer.

Purpose of Short circuit test of transformer:

1. Determine the load losses (Pcu) copper losses and the impedance voltage of the
transformer.
2. Verify guarantees, design calculations and manufacturing quality.
3. Determine the resistances and reactance of windings (R1, R2, X1, X2) of transformer at
primary and secondary sides.

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 4. Determine percentage impedance (Z%) of transformer that used at short circuit
calculation at electrical network and for selecting proper Circuit breaker that protect the
transformer .
5. Detection of deformation defects in windings due to shipping and transportation or due to
internal short or faulty ground connections.
6. And is also used in the case of an unjustified rise in temperature in the transformer where
the defective phase is known if there is a higher current than the other two Phases and
then the transformer is stopped and checked for reasons.

Precautions before do Short circuit test of transformer:

1. Disconnect the electrical current from the transformer.
2. Clean the terminals of the transformer.

Inject voltage on the primary winding as shown in figure.

 Control this voltage from zero until we reach the current in the secondary winding to
equal the full load current of the transformer.
 Take the voltmeter readings from the primary winding.
 Divide Voltmeter reading on applied voltage and multiply by 100 We get the percentage
impedance as example: When testing a 33/11 kV , 5 Mega volt ampere transformer, we
inject voltage at primary side as shown in figure and increase this voltage then the
applied voltages reached 2280 volts to reach rated current at other side when dividing

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 2280/33000 = 0.069. If the result were multiplied by 100, the output would be 6.9%,
which is called percentage impedance of transformer (Z%).
 We can neglect value of core resistance, reactance and core losses as the current that
paths through core is very small

Now we can determine parameters of transformer as follows :

Such as:
Psc = Wsc power load losses (known value)
Vsc : applied voltage (known value)
Isc : short circuit current (known value)
Acceptable error at all parameters is 10% of nameplate values which records on the transformer
nameplate.
4.3.7 High Voltage Test.
Test Purpose
• To ensure the Tx-F will be run at station or not with safely.
Testing Purpose
• 11000V connect to HT
• Short LT with N
• LT to Ground
Testing Equipment
• HV Panel
If here leakage current shown more than 18 mA than its mean, have some problem, need to fix, if
the leakage current limit is not more than 18 mA, that’s mean its ok

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 Chapter 5

Supplementary Part

Conclusion
I have spent remarkable days at Innova Engineering Ltd, during my internship program. I have
learnt theories at my University and during my internship I have observed those thing practically
at Innova Engineering Ltd. Internship program has enlarged my thinking capacity about practical
operations of the different equipment’s. It gives me an opportunity to compare the theoretical
knowledge with practical facts and thus develop my knowledge and skills.

The management of Innova Engineering Ltd was very organized, pro-active and co-operative. At
last, I would like to say that practical training widened my thinking as a professional.

Limitations

Recommendations

References

Appendix

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