TRANSFORMER

CONSTRUCTION
TRANSFORMER IS MANUFACTURED BY USING
FOLLOWING STEPS:-

1. CORE ASSEMBLING
2. LOW VOLTAGE WINDING
3. HIGH VOLTAGE WINDING
4. CORE COIL ASSEMBLING
5. OVENING
6. TANKING
7. TASTING
 CORE ASSEMBLING:-
TRANSFORMER CORE IS THE MAIN PART OF THE TRANSFORMER
WHICH CARRIES THE L.V. & H.V. WINDING AND PROVIDE THE LOW
RELUCTANCE PATH FOR MAGNETIC FLUX. IT IS MADE UP OF SILICON
STEEL,NOW IT IS MADE UP OF CRGO (COLD ROLLED GRAIN
ORIENTED)SILICON STEEL.FOR MAKING TRANSFORMER CORE THIN
STACKS(.35-.4 MM) OF THIS MATERIAL IS CUT INTO REQUIRED
SHAPE IN DIFFERENT PARTS,AFTER THIS ALL PARTS ARE PLACED
SIDE BY SIDE TO FORM TRANSFORMER WINDOW THAT IS
TRANSFORMER LIMBS(WHICH ARE MADE CIRCULAR) AND YOKE
,AND ALSO LAYERS OF STACKS ARE PLACED SIDE BY SIDE SO THAT
THEY FORM A CLOSED,PACKED,COMPACT STRUCTURE.THEN THIS
CORE IS PLACED IN AN IRON FRAME AND INSULATED BY A
CARDBOARD. THEN TIGHTLY BOLTED TO THIS FRAME.
THIN STACKS OF CRGO SILICON STEEL AND CORE WINDOW
 LOW VOLTAGE (L.V.) WINDING:-
LV OF TRANSFORMER IS USED FOR LOW VOLTAGE,IT IS PLACED ON
THE LEGS OF THE TRANSFORMER CORE AND IS INSULATED BY
COTTON TAPE AND A LAYERS OF CARD BOARD ACCORDING TO ITS
VOLTAGE.LV OF TRANSFORMER IS MADE IN SINGLE PART ONLY. IT IS
MADE UP OF COPPER OR ALUMINIUM STRIPS NOT IN ROUND SHAPE.
STRIPS OF CONDUCTOR IS COVERED BY PAPER AND IS WOUND ON
CARDBOARD ACCORDING TO DIAMETER OF LAGS OF CORE AND
NUMBER OF TURNS.DURING THE PROCESS OF WOUNDING STRIPS
ARE TRANSPOSED IN MIDWAY BETWEEN THE LENGTH OF WHOLE LV
SO THAT LENGTH OF EACH CONDUCTOR REMAINS SAME.EACH LAYER
OF STRIPS IS AGAIN INSULATED BY PAPER AND CARDBOARD.
Aso a cotton is used to tightly bind the windings so that they will
not opened and gum is used to joint paper and cotton tape and
each end of lv structure is insulated by cardboard strips.Windings
connections are taken out from one end.

LV OF TRANSFORMER
 HIGH VOLTAGE(HV)WINDING :-
HV OF TRANSFORMER IS USED FOR HIGH VOLTAGE AND IT IS
PLACED ON THE LIMBS OVER THE LV WINDING AND IS INSULATED
FROM IT BY REQUIRED LAYERS OF CARDBOARD.LIKE LV WINDING
HV WINDINGS CONDUCTOR ARE ALSO PAPER COVERED. IT IS
WOUND ON CARDBOARD WITH REQUIRED DIAMETER AND NUMBER
OF TURNS, ITS CONDUCTOR HAS CIRCULAR CROSS SECTION AND IS
MADE UP OF COPPER OR ALUMINIUM EACH LAYRE OF WINDING IS
INSULATED BY PAPER.HV IS MADE IN THE FORM OF DUMBLES, EACH
END OF DUMBLES HAS A CARDBOARD STRIP INSULATION. AFTER
PLACING ON LIMBS THESE DUMBLES ARE CONNECTED TO EACH
OTHER IN SERIES. THESE DUMBLES ARE ALSO INSULATED FROM
EACH OTHER.
HV OF TRANSFORMER
 CORE COIL ASSEMBLING:-

IN THIS PROCESS CORE AND COIL OF TRANSFORMER ARE

ASSEMBLED. FIRSTLY CORE LEGS ARE COVERED BY COTTON TAPE
,THEN IT IS COVERED BY A THICK PAPER AND LV IS PLACED IN
THE LAG. THERE IS A REQUIRED INSULATION BETWEEN CORE
LEGS AND LV. END TERMINALS OF LV ARE TAKEN OUT FROM
UPPER END.NOW HV IS PLACED OVER LV WITH REQUIRED
INSULATION ,NOW UPPER YOKE OF TRANSFORMER IS
ASSEMBLED.COILS ARE ALSO INSULATED FROM UPPER AND
LOWER YOKE AND THEN UPPER FRAME OF CORE IS TIGHTLY
BOLTED.
NOW HV WINDINGS ARE CONNECTED INTO DELTA CONNECTION (FOR
DISTRIBUTION TRANSFORMER) AS
SHOWN IN THIS FIGURE.CONNECTION
ARE TAKEN USING ALUMINIUM OR
COPPER STRIP AS SHOWN IN BELOW
FIGURE.
LV CONNECTIONS
HV
CONNECTIONS
OVENING:-
IT IS THE PROCESS FOR REMOVING MOISTURE OF THE
TRANSFORMER CORE COIL ASSEMBLY.IN THIS TRANSFORMER
CORE COIL ASSEMBLY IS PLACED IN THE OVEN AT A
TEMPERATURE OF ABOUT 112 TO 120 DEGREE CELCIUS.

OVEN
Drying out of the transformer core-winding assembly is an extremely
important aspect in transformer manufacturing. This should be done in
order to remove moisture from the core-winding assembly. This mainly
consists of insulation materials such as pressboard, paper, wood and
insulating tape. Degradation of transformer insulation which reduces the
withstand capability of insulation for mechanical and electrical stresses is
the main factor for transformer failures, and presence of moisture leads
to increase the rate of degradation. Transformer Oven The transformer
core-winding assembly is put into the oven (figure 2) for up to 36 hours
to remove this moisture. It is required that the temperature inside the
oven should be kept at a defined value throughout the drying process in
order to get complete bonding between windings and insulation and also
to remove the moisture inside the core-winding assembly. Since moisture
evaporates at over 100o C, the oven temperature is set between 112 oC
to 120 oC. It is heated up to a temperature above the ambient before
loading the transformer core assemblies.
TANKING:-
AFTER REMOVING MOISTURE FROM TRANSFORMER CORE COIL
ASSEMBLY,IT IS TIGHTLY FIXED TO JOB(FRAME) USING NUT BOLTS.
NOW IT IS READY FOR TANKING.
Protection of active part in transformer is very important. While achieving
the optimized size of transformer to suit the site condition for installation.
The main role of the tank is to protect the active part and tank is
manufacture to have sufficient strengths to withstand internal & external
faults that may occur during operation. Tanks are fabricated from low carbon
M.S. Sheet of best quality proceed by qualified welders. The tank is
designed to withstand vacuum and pressure test as per national/
International standards. A robust skid under base is provided, and guide
bars are located inside the tank to securely fix the core and windings
assembly in position, and to prevent any movement during transportation.
Welding is done as per ASME section lX by qualified welders as per
approved WPS and leak test assured 100 % leak proof seams and
maximum mechanical strength. During fabrication process ,welding quality
is assessed by DP test. Completed tank fabrication is followed by shot
blasting process to remove all dust & spatters before painting.
NOW AFTER MANUFACTURE OF TANK CORE COIL ASSEMBLY IS LIFTED
UP AND IS PLACED IN THE TANK. NOW CONNECTION TERMINALS ARE
CONNECTED TO THE LV AND HV BUSHINGS TIGHTLY AND PACKED,
NOW JOB IS FIXED TO THE TANK TIGHTLY.

THEN IT IS TAKEN FOR OIL FILLING,AFTER OIL IS FILLED UP TO THE

REQUIRED LEVEL UPPER PART OF TANK IS TIGHTLY BOLTED SO THAT OIL
CAN NOT LEAK. NOW REMAINING OIL IS FILLED THROUGH A HOLE IN
THE CONSERVATOR TANK, OIL IS FILLED UP TO A CERTAIN LEVEL OF
CONSERVATOR TANK.
ALSO THERE IS A DRAIN OFF NEAR THE BOTTOM OF TANK TO REMOVE
THE OIL IF REQUIRED.
Transformer Insulating Oil and Types of Transformer Oil
Introduction of Insulating Oil
Insulating oil in an 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 e.i. acts as 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.
Types of Transformer Oil
Generally there are two types of transformer Oil used in transformer
1. Paraffin based transformer oil
2. Naphtha based transformer oil
Naphtha oil is more easily oxidized than Paraffin oil. But oxidation product, i.e., sludge in
the naphtha oil is more soluble than Paraffin oil. Thus sludge of naphtha-based oil is not
precipitated in the bottom of the transformer. Hence it does not obstruct convection
circulation of the oil, means it does not disturb the transformer cooling system. But in the
case of Paraffin oil although oxidation rate is lower than that of Naphtha oil the oxidation
product or sludge is insoluble and precipitated at the bottom of the tank and obstruct the
transformer cooling system. Although Paraffin-based oil has the above mentioned
disadvantage but still in our country it is used because of its easy availability. Another
problem with paraffin-based oil is its high pour point due to the wax content, but this does
not affect its use due to warm climate condition of India.
TESTING:-
● OIL BDV TEST
● RESISTANCE OF WINDINGS
● TURNS RATIO OF LV & HV
● POLARITY TEST
● NO LOAD TEST OR OPEN CIRCUIT
● FULL LOAD TEST OR SHORT CIRCUIT
● MEGGER
● HIGH VOLTAGE TEST
● LOAD TEST
OIL BDV TEST
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 straits between two electrodes emerged 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 4 mm) between them. Now slowly rising voltage is applied between the
electrodes. Rate of rise of voltage is generally controlled at 2 KV/s and observe
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.