BHARAT HEAVY ELECTRICALS

LIMITED, JHANSI (U.P)

VOCATIONAL
INDUSTRIAL
TRAINING 2013

PROJECT REPORT ON
DRY TYPE TRANSFORMER

Submitted To:

Mr. DHRUV BHARGAVA

SR. D.G.M. (H.R.D)
BHEL JHANSI (U.P)
Submitted By:

Under Guidance of: TILKENDRA SHARMA

Mr. B.D. RICHHARIA B.TECH 3rd Year

T.R.M. BAY-4 ELECTRICAL AND

ELECTRONICS
B.H.E.L. JHANSI (U.P) ENGINEERING

S.R.M.S.C.E.T ,BAREILLY
 PREFACE

Vocational training is an integral part of engineering curriculum. Training allows us to

gain insight into the practical aspects of the various topics, with which we came
across while pursuing B.Tech Degree.

On my part, I pursued four weeks training at B.H.E.L. Jhansi. The training involved a
study of various departments of the organization as per the time schedule given to
us.

The rotation in various departments was necessary in order to get an overall idea
about the working of the organization.

-TILKENDRA SHARMA

ELECTRICAL AND ELECTRONICS ENGG.

 ACKNOWLEDGEMENT
I am extremely thankful and indebtful to the numerous BHEL engineers and technical
staffs who provided vital information about the functioning of their respective
departments thus helping me to gain an overall idea about the working of
organization.

I am thankful to Mr. Dhruva Bhargava (Sr. Manager-HRD) for providing me the

opportunity to undergo this training and I also express my thanks to Mr.B.D.Richharia
(Manager BAY4) without whom hard efforts I would not been able to grab the
practical aspects of my project work on CAST RESIN DRY TYPE TRANSFORMER and this
report would have been remain only mere piece of paper. Special thanks to and I
am highly indebted to my project guide Mr. Mohd. Sagir (Supervisor DTT Plant BAY5)
for giving me his valuable time and helping me to grasp the various concepts of
power transformers and their process of manufacturing and testing.

Last but not the least, I would like to thank my parents and all my fellow trainees who
have been a constant source of encouragement and inspiration during my studies
and have always provided me support in every walk of life.

-TILKENDRA SHARMA

ELECTRICAL AND ELECTRONICS ENGG.

 VISION, MISSION AND VALUES OF BHEL

VISION

A global engineering enterprise providing solutions for a better tomorrow

MISSION
Providing sustainable business solutions in the fields of Energy, Industry &
Infrastructure

VALUES
GOVERNANCE: We are stewards of our shareholders investments and we take that
responsibility very seriously. We are accountable and responsible for delivering
superior results that make a difference in the lives of the people we touch.

RESPECT: We value the unique contribution of each individual. We believe in

respect for human dignity and we respect the need to preserve the environment
around us.

EXCELLENCE: We are committed to deliver and demonstrate excellence in

whatever we do.

LOYALTY: We are loyal to our customers, to our company and to each other.

ENTEGRITY: We work with highest ethical standards and demonstrate a behavior

that is honest, decent and fair. We are dedicated to the highest levels of personal
and institutional integrity.

COMMITMENT: We set high performance standards for ourselves as individuals and

our teams. We honour our commitments in a timely manner.

INNOVATION: We constantly support development of newer technologies,

products, improved processes, better services and management practices.

TEAM WORK: We work together as a team to provide best solutions & services to our
customers. Through quality relationships with all stakeholders we deliver value to our
customers.
 AN OVERVIEW OF BHEL

BHEL is the largest engineering and manufacturing enterprise in India in the

energy/infrastructure sector today. BHEL was established more than 40 years ago
when its first plant was set up in Bhopal ushering in the indigenous Heavy Electrical
Equipment industry in India, a dream that has been more than realized with a well-
recognized track record of performance.
BHEL caters to core sectors of the Indian Economy viz., Power Generation &
transmission, Industry, Transportation, Telecommunication, Renewable Energy,
Defense, etc. The wide network of BHEL’s 17 manufacturing divisions, four Power
Sector regional centers, over 100 project sites, eight service centers and 18 regional
offices, enables the company to promptly serve its customers and provide them with
suitable products, systems and services-efficiently and at competitive prices. BHEL
has already attained ISO 9000 certification for quality management, ISO 27000 for
Information Technology and ISO 14001 certification for environment management.

POWER GENERATION
Power generation sector comprises thermal, gas, hydro, and nuclear power plant
business.

TRANSMISSION AND DISTRIBUTION (T&D)

BHEL offers wide-ranging products and systems for T&D applications. Products
manufactured include: power transformers, instrument transformers, dry type
transformers, series &shunt reactors, capacitor banks, vacuum &SF6 circuit breakers,
gas-insulated switchgears and insulators.

INDUSTRIES
BHEL is a major contributor of equipment and systems to industries, cement, sugar,
fertilizer, refineries, petrochemicals, paper, oil and gas, metallurgical and other
process industries. The range of systems & equipment supplied includes: captive
power plants, co-generation plants, DG power plants, industrial steam turbines,

industrial boilers and auxiliaries, waste heat recovery boilers, gas turbines, heat
exchangers and pressure vessels, centrifugal compressors, electrical machines,
pumps, valves, seamless steel tubes, electrostatic precipitators, fabric filters, reactors,
fluidized bed combustion boilers, chemical recovery boilers and process controls.
TRANSPORTATION
BHEL manufactures electric locomotives up to 5000 HP, diesel electric locomotives
from 350 HP to 3100 HP, both for mainline and shunting duty applications.

INTERNATIONAL OPERATIONS

BHEL is one of the largest exporters of engineering products & services from India,
ranking among the major power plant equipment suppliers in the world.

VARIOUS BHEL UNITS

FIRST GENERATION UNITS
Bhopal : Heavy Electrical Plant.

Haridwar : Heavy Electrical Equipment Plant.

Hyderabad: Heavy Electrical Power Equipment Plant.

SECOND GENERATION UNITS

Tiruchy : High Pressure Boiler Plant.

Jhansi : Transformer and Locomotive Plant.

Haridwar : Central Foundry and Forge Plant.

Tiruchy : Seamless Steel Tube Plant.

UNITS THROUGH ACQUISTION & MERGER

Bangalore : Electronics Division

Electro Porcelain Division.

NEW MANUFACTURING UNITS

Ranipet : Boiler Auxiliaries Plant.

Jagdishpur: Insulator Plant.

Govindwal : Industrial Valve Plant.

Rudrapur : Component and Fabrication Plant.

Bangalore : Energy Systems Division

BHEL is growing concern to meet the changing needs of the nation has taken it
beyond power into the total gamut of energy, industry and transportation BHEL is
able to offer a service in each of this fields. It;s manufacturing capability is supported
by a corporate R&D division at Hyderabad works closely with the research and
development cells at various units and Welding Research Institute at Tiruchinapalli.

ACTIVITY PROFILE OF BHEL

POWER SECTOR PROJECTS

 Thermal sets and Auxiliaries.

 Steam generators and Auxiliaries.
 Industrial fans.
 Electrostatic precipitators.
 Air pre heaters.
 Nuclear power equipments.
 Hydro sets and Auxiliaries.
 Motors.
 Transformers.
 Rectifiers.
 Pumps.
 Heat Exchangers.
 Capacitors.
 Porcelain/Ceramics insulators.
 Seamless steel tubes.
 Casting and forging.

SYSTEMS/SERVICES
  Turnkey power station.
 Data acquisition Systems.
 Power systems.
 HVDC Commissioning systems.
 Modernization and Rehabilitation.

TRASPORTATION SECTOR

 Diesel Electric generators.

 AC/DC locomotives.
 DC locomotives and loco shunters.
 Traction system for railways.
 Electric trolley buses.

INDUSTRY SECTOR

 Boilers.
 Valves.
 Power devices.
 Solar Cells.
 Photo Voltaic cells.
 Gas Turbines.
 Compressors.
 Drive Turbines.
 Oil rigs.
 Control systems for electric devices.
 BHARAT HEAVY ELECTRICALS LIMITED JHANSI (UNIT)
A BRIEF INTRODUCTION

By the end of 5th five-year plan, it was envisaged by the planning commission that
the demand for power transformer would rise in the coming years. Anticipating the
country’s requirement BHEL decided to set up a new plant, which would
manufacture power and other types of transformers in addition to the capacity
available in BHEL Bhopal. The Bhopal plant was engaged in manufacturing
transformers of large ratings and Jhansi unit would concentrate on power
transformer upto 50 MVA, 132 KV class and other transformers like Instrument
Transformer s, Traction transformers for railway etc.

This unit of Jhansi was established around 14 km from the city on the N.H. No 26 on
Jhansi Lalitpur road. It is called second-generation plant of BHEL set up in 1974 at an
estimated cost of Rs 16.22 crores inclusive of Rs 2.1 crores for township. Its foundation
was laid by late Mrs. Indira Gandhi the prime minister on 9th Jan. 1974. The
commercial production of the unit began in 1976-77 with an output of Rs 53 lacs
since then there has been no looking back for BHEL Jhansi.

The plant of BHEL is equipped with most modern manufacturing processing and
testing facilities for the manufacture of power, special transformer and instrument
transformer, Diesel shunting locomotives and AC/DC locomotives. The layout of the
plant is well streamlined to enable smooth material flow from the raw material stages
to the finished goods. All the feeder bays have been laid perpendicular to the main
assembly bay and in each feeder bay raw material smoothly gets converted to sub
assemblies, which after inspection are sent to main assembly bay.
The raw material that are produced for manufacture are used only after thorough
material testing in the testing lab and with strict quality checks at various stages of
productions. This unit of BHEL is basically engaged in the production and
manufacturing of various types of transformers and capacities with the growing
competition in the transformer section, in 1985-86 it under took the re-powering of
DESL, but it took the complete year for the manufacturing to begin. In 1987-88, BHEL
has progressed a step further in under taking the production of AC locomotives, and
subsequently it manufacturing AC/DC locomotives also.

PRODUCT PROFILE OF BHEL JHANSI UNIT

1. Power transformer up to 400 KV class 250 MVA

2. Special transformer up to 180 KV

3. ESP transformer 95 KVp, 1400 m.

4. Freight Loco transformer 3900 to 5400 KVA & 7475 .

KVA for 3 phase

5. ACEMU transformer up to 1000 KVA (1-phase)

1385 KVA (3 phase)

6. Dry type transformer up to 6300 KVA 33 KV class

7. Instrument transformer VT & CT up to 220 KV class

8. Diesel electric locomotives up to 2600 HP

9. AC/DC locomotives 5000 HP

10. Over Head Equipment cum Test Car

11. Well wagon 200 tone

12. Rail cum road vehicle

13. Dynamic track stabilizer

BHEL PERFORMANCE (CORPORATE LEVEL)

PARAMETER 2011 - 12 2012 – 13

Turnover (Rs. /Cr.) 49510 50015

Order Inflow (Rs. /Cr.) 22096 31528

Net Profit (Rs. /Cr.) 7040 6485

Net Worth (Rs. /Cr.) 25373 30315

Megawatts Commissioned 9270 10340

R & D Investment (Rs. /Cr.) 1199 1248

Patents/Copyrights Filed (Nos.) 351 385

MAJOR UNITS TURNOVER (In Rs. /Crores)

DIVISION 2011 – 12 2012 – 13

(Actual) (Provisional

JHANSI 1300 1365

CFFP HARDWAR 506 523

HEEP HARDWAR 5415 6375

BAP RANIPET 4210 3703

HPBP TRICHY/SSTP 14571 14970

EDN BANGALORE 2301 1650

BHOPAL 4790 4703

HEEP HYDERABAD 7072 6408

BHEL NET 49301 50015

VARIOUS DEPARTMENTS/FUNCTIONS AT BHEL JHANSI

TRANSFORMER COMMERCIAL (TRC)
The objective of the department is interaction with the customers. It brings out
tenders and notices and also responds to them. It is this department that bags
contracts of building transformers. After delivery regarding faults, this department
does failures and maintenance. All such snags are reported to them and they
forward the information to the concerning department.
One of the major tasks of this department is to earn decent profits over all
negotiations. Transformer industry has become very competitive. The company
offering the lowest price gets the contract but this process may continue does the
work on very low profits. To avoid such a situation, a body by the name of India
Electrical and Electronics Manufactures Association (IEEMA) was set up. This
association helps to maintain a healthy competitive atmosphere in the
manufacturing of electrical appliances.
TRANSFORMER ENGINEERING (TRE)

The transformer manufactured in BHEL Jhansi range from 10 MVA to 250 MVA and up
to 400 KV. The various transformers manufactured in this unit are:-

POWER TRANSFORMER
a) Generator transformer
b) System transformer.
c) Auto transformer.

SPECIAL TRANSFORMER
a) Freight loco transformer.
b) ESP transformer.
c) Instrument transformer.
d) Dry type transformer.
.
 PROJECT
REPORT
ON
POWER TRANSFORMER
(MANUFACTURING OF
DIFFERNET TYPE OF
TRANSFORMER)
 TRANSFORMER: An OVERVIEW
A transformer is a device or a piece of apparatus used for transferring power from
one circuit to other without change in frequency. It can raise or lower the voltage
with a corresponding decrease or increase in the current.

Types of Windings:

 PRIMARY WINDING: Receives power from external source

 SECONDARY WINDING: Receives electric power from primary by magnetic
induction

Above windings are linked together by common magnetic flux through a low
reluctance path.

TYPE OF TRANSFORMER
A wide variety of transformer designs are used for different applications, though they
share several common features. Important common transformer types include:

 Generator transformer : The generator transformer is the largest transformer on

a power station and connects the generator output to the grid.
 Autotransformer: Transformer in which part of the winding is common to both
primary and secondary circuits.
 Distribution transformer, power transforme: International standards make a
distinction in terms of distriburtion transformers being used to distribute energy
from transmission lines and networks for local consumption and power
transformers being used to transfer electric energy between the generator and
distribution primary circuits.
 Dry type transformer: Dry type transformers are voltage changing (Step-up or
Step-down) device.
 ESP Transformer: It is a filtration device that removes fine particles, like dust and
smoke.
Instrument transformer: Potential or current transformer used to accurately and
safely represent voltage, current or phase position of high voltage or high power
circuits

MAIN CONSTRUCTIONAL PARTS:

1. Primary Winding of transformer - which produces magnetic flux when it is connected to
electrical source.
2. Magnetic Core of transformer - the magnetic flux produced by the primary winding, will
pass through this low reluctance path linked with secondary winding and creates a closed
magnetic circuit.
3. Secondary Winding of transformer - the flux, produced by primary winding, passes
through the core, will link with the secondary winding. This winding is also wound on the
same core and gives the desired output of the transformer.

USE OF POWER TRANSFORMER:

Generation of Electrical Power in low voltage level is very much cost effective. Hence
Electrical Power is generated in low voltage level. Theoretically, this low voltage leveled
power can be transmitted to the receiving end. But if the voltage level of a power is
increased, the electric currentof the power is reduced which causes reduction in ohmic or I2R
losses in the system, reduction in cross sectional area of the conductori.e. reduction in capital
cost of the system and it also improves the voltage regulation of the system. Because of these,
low leveled power must be stepped up for efficient electrical power transmission. This is
done by step up transformer at the sending side of the power system network. As this high
voltage power may not be distributed to the consumers directly, this must be stepped down to
the desired level at the receiving end with help of step down transformer. These are the use of
electrical power transformer in the Electrical Power System.
MANUFACTURING PROCESS OF DRY TYPE
TRANSFORMER
The dry type cast resin transformers are manufactured using copper conductors for
winding and glass and epoxy resin for insulation. The process is as follows:

1) WINDINGS:

Winding copper conductors make both L.V. and H.V. windings over steel formers.
The windings are densely embedded in glass fibres and are held tightly by glass
tapes. L.V. windings are generally helical in shape and H.V. windings are generally
made spiral or disc type. Both the windings are made separately except for very
small ratings where H.V. and L.V. are made together because of small diameter.
After winding is complete the wound coils are placed in separate steel moulds and
pre-dried in heating oven or heated vacuum chamber before casting.

2) CASTINGS:

Dried moulds containing the windings are placed in vacuum chamber for casting.
Casting is done by utilizing the unique properties offered by pure liquid epoxy
system. Various constituents of liquid epoxy resins are first heated in separate
vacuum pots to eliminate dissolved gases and moisture. Then these are mixed in
precise proportion as per the requirements and supplied to dried windings placed
inside the moulds under high vacuum to give void less embedment of windings by
epoxy. The epoxy is slowly absorbed by the fibreglass reinforcement provided
during winding to form a dense fibrous mass. When the moulds are filled by liquid
epoxy ensuring complete void less encapsulation they are taken for further
processing in post curing ovens. The whole process is controlled by computer and
carried out automatically as high degree of accuracy is required.

The epoxy reinforced by glass after curing forms a solid dense mass, which
encapsulates and hermetically seals the copper winding. The process gives the
windings better mechanical strength than any other known form of manufacturing
process at the same time epoxy system employed provides a high dielectric
strength.

3) CUTTING AND DRESSING:

After the coils are cured they are taken out of the moulds. The cured and dried coils
are hard enough to carry out machining. Rather the hardness of fibre glass
reinforced epoxy resin cast cols require tools and blades for machining as ordinary
steel tools for cutting steels and other metals wears out quickly.
Excess epoxy deposited on the top of cols is sawn off required dimensions and sharp
edges are removed and smoothened by milling or grinding. Touching up paints is
applied to coils if required and finished coils are tested and sent to assembly.

Different Manufacturing Processes carried out in manufacturing of DRY TYPE

TRANSFORMERS
 DRY CAST RESIN TRANSFORMERS
PRODUCT RANGE
Ratings (KVA) 100-10,000

Rated Voltage Up to 33KV

BIL Up to 170KVP

Insulation Class F

Frequency 50 Hz to 60 Hz

Winding Arrangement Dual Ratio and 3 windings

Voltage Variation Off circuit

INSTRUMENT TRANSFORMER:

These are used for measurement. Actual measurement is done by measuring instruments
but these transformers serve the purpose of stepping down the voltage to protect the
measuring instrument. They are used in AC system for measurement of current voltage and
energy and can also be used for measuring power factor, frequency and for indication of
synchronism. They find application in protection of power system and for the operation of
over voltage, over current, earth fault and various other types of relays.

In power lines current & voltage handled is very large & therefore direct measurement are
not possible as these current & voltage are for too large for any other of reasonable size &
cost. The solution lies in steeping down the current & voltage with instrument transformers
that would be mattered with instruments of moderate size. The transformers are also used for
protective purpose.

Body:

 The main body is a bushing which also acts as insulators in which the winding is
placed.
 It has a top and bottom chamber.
 The top chamber is the cylindrical tank of mild steel. It has terminals for connection
of HV coils.

a) Current transformer: It is a step down transformer. The body is divided in to three

parts – top chamber, bushing, bottom chamber. Top chamber is the cylindrical tank of
mild steel. It has terminal for connection of HV coil. It also has oil window to indicate
the oil level. Below it is bushing which houses the winding and also act as insulator. It
has several folds or rain sheds to provide specific electric field distribution and long
leakage path. Some bushings are cylindrical while modern ones are conical, as the
amount of oil porcelain used is reduced without any undesirable effects. Bottom
chamber houses the secondary winding. There is also a connection box to which the
connection of low voltage coil is made.

b) Voltage Transformer: It is also an step down transformer and outer construction is same
as that of CT. the difference is only in winding.

ESP TRANSFORMER:

The Electrostatic Precipitator transformer is used for environmental application. It is used to

filter in a suspended charge particle in the waste gases of an industry. They are of particular
use in thermal power stations and cement industry.

The ESP is a single-phase transformer. It has a primary and secondary. The core is laminated
and is made up of CRGOS. It is a step up transformer. An AC reactor is connected in series
with primary coil. The output of the transformer must be DC this is obtained by rectifying
AC using a bridge rectifier (bridge rectifier is a combination of several hundred diodes). A
radio frequency choke (RF choke) is connected in series with the DC output for the
protection of the secondary circuit and filter circuit. The output is chosen negative because
the particles are positively charged. The DC output from the secondary is given to a set of
plates arrange one after the others. Impurity particles being positively charged stick to these
plates, which can be jerked off. For this a network of plates has to be setup all across the
plant. This is very costly process in comparison with the transformer cost. A relive vent is
also provided to prevent the transformer from bursting it higher pressure develops, inside it. It
is the weakest point in the transformer body. An oil temperature indicator and the secondary
supply spark detector are also provided.

One side of the transformer output is taken and other side has a ‘marshalling box’ which is
the control box of the transformer.

ESP is of two types.

1. Si oil type.
2. Transformer oil type.
It is also known as Rectifier Transformer as it converts AC into DC.

GENERATOR TRANSFORMER:
.generator transformer is the largest transformer on a power station and connects the
generator output to the grid.
.Generator transformer is a type of power transformer where the primary winding is
connected to the generator and secondary to the transmission system.
.Generator transformer for each generating unit and it is rated according to the size
of that unit.
. This is a type of Power Transformer where the LV winding is connected to the generator
through the bus duct and HV winding to the transmission system
. The generator transformer is the first essential component for energy transmission,
allowing energy supplied by the generator to be transferred to the network at the
required voltage.

AUTO TRANSFORMER:

TESTING OF TRANSFORMERS
Testing is an important activity in the manufacture of any equipment. Whilecertain
preliminary tests carried out at different stages of manufacture provide aneffective tool which
assures quality and conformation to design calculations, thefinal tests on fully assembled
equipment guarantee the suitability of the equipmentfor satisfactory performance in service.
The basic testing requirements and testingcodes are set out in the national and international
standards.
Transformers can be subjected to a wide variety of tests for a number of reasons,
including:
• Compliance with user specifications
• Assessment of quality and reliability
• Verification of design calculations
• Compliance with applicable industry standards

Preliminary tests are carried out on the transformer before it is put into thetank. Final tests are
carried out on completely assembled transformer.

1. Preliminary Tests
Following tests are carried out in the works at different stages, before thecore and coil
assembly of the transformer is placed in its tank. These checks helpin detecting any fault at
an early stage.

(a) Core Insulation

After the core is assembled, 2 kV test is done to ensure that the insulationbetween clamp
plates, core bolts and core is adequate.

(b) Core loss Test

This is conducted in the core assembly to ensure its soundness. Someturns are wound over
the core and it is energized at normal flux density. Corelossand magnetizing current are noted
and compared with design value.

(c) Check of Ratio, Polarity, Vector Relationship and Winding Resistanceof

Transformer Assembly
Ratio test is conducted to ensure the correctness of voltage ratio betweendifferent windings
on each tapping. The tolerance allowed for ratio is + 0.5% ofthe declared ratio or + 10% of
the percentage impedance voltage, whichever issmaller. The latter tolerance limit is not
applicable for auto-transformers and boostertransformers, where impedance value is small. In
order to get accurate ratio, aratiometer is employed. It also indicates the polarity of
transformer windings.
For a three-phase transformer, it is more usual to carry out a vectorrelationship test, in which
one of the high-voltage and low-voltage line terminalsare jointed together as shown in Fig. 1.
Three-phase 400 V supply is connectedacross high voltage line terminals.

(d) Preliminary Load Loss and Impedance Voltage Measurement

Preliminary load loss and impedance measurements at reduced currentare carried out to
ensure that these are within guaranteed limits.

2. Final Tests
The completely assembled transformer is tested in accordance with theInternational
Standards. The tests comprise the following:
(a) Routine tests
(i) Measurement of winding resistance- The DC resistances of both HV and LV
windings can be measured simply by the voltmeter/ammeter method, and this
information provides the data necessary to permit the separation of I2R and eddy-
current losses in the windings.

(ii)Measurement of voltage ratio and check of voltage vector relationship-

Measurements are made on every transformer to ensure that the turn ratio of the
windings, tapping positions and winding connections is correct. The tolerance as per
relevant standard at no-load on the principal tapping is ±0.5% of the declared ratio.
These measurements are usually carried out during assembly of both the core and
windings, while all the connections are accessible, and finally when the transformer
is fully assembled with terminals and tap changing mechanism.

(iii) Measurement of impedance voltage (principal tapping) short circuit impedance and
load loss

(iv)Measurement of no load loss and current- The no-load loss and the no-load
current shall be measured on one of the windings at rated frequency and at a
voltage corresponding to rated voltage if the test is performed on the principal
tapping, or to the appropriate tapping voltage if the test is performed on another
tapping. The remaining winding or windings shall be left open-circuited and any
windings which can be connected in open delta shall have the delta closed.

(v) Measurement of insulation resistance- Insulation resistance tests are carried out
on all windings, core and core clamping bolts. The standard Megger’s testing
equipment is used, the ‘line’ terminal of which is connected to the winding or core
bolt under test. When making the test on the windings, so long as the phases are
connected, together, either by the neutral lead in the case of the star connection or
the interphase connections in the case of the delta, it is only necessary to make one
connection between the Megger and the windings.

(vi) Dielectric tests- The insulation of the HV and LV windings of all transformers is
tested before leaving the factory. These tests consist of:
(a) separate-source voltage withstand test
(b) Induced over voltage withstand test

a) Separate source AC voltage:

This test is intended to check the adequacy of main insulation to earth and between
windings. The line terminals of the windings under test are connected together & the
appropriate test voltage is applied to them, while the windings & tank are
connected together to the earth. Winding with graded insulation, which have
neutral intended for direct earthing, are tested at 38 kV.The supply voltage should
be nearly sinusoidal and the peak voltage is measured from digital peak voltmeter
associated with capacitive voltage divider. The duration of test is 60 seconds.

b) Induce over voltage withstand test:

The test is intended to check the inter-turn and line end insulation as well as main
insulation to earth & between windings.
In order to avoid core saturation at the test voltage, it is necessary to use a supply
frequency higher than the normal. When frequency is chosen in the range of 100-
200 Hz, capacitive reactance is reduced, and in draws significant capacitive current
at test voltage, which causes heavy loading on the generator can be reduced by
connecting a variable reactor across the generator terminals.

Test duration is determined by the following formula-

 120∗Rated frequency
Test duration in seconds= test frequency
but not less than 30 sec.

The test is applied to all the non-uniformly insulated windings of the transformer. The
neutral terminal of the winding under test is earthed. For other separate windings, if
they are star connected they are earthed at the neutral and if they are delta
connected they are earthed at one of the terminals.

(vii) Tests on-load tap changers (where appropriate)

(b) Type tests
Type tests are tests made on a transformer which is representative of othertransformers to
demonstrate that they comply with specified requirements notcovered by routine tests.
1. Temperature rise test.
2. Noise level test.

(c) Special tests

Special tests are tests, other than routine or type tests, agreed between manufacturerand
purchaser, for example:
(i) Dielectric special tests.
(ii) Measurement of zero-sequence impedance of three-phasetransformers
(iii) Short-circuit test
(iv)Measurement of acoustic noise level
(v) Measurement of harmonics of the no load current
(vi)Measurement of power taken by the fans and oil pumps
(vii) Measurement of capacitances between windings to earth and betweenwindings.
(viii)Measurement of transferred surge voltage on low voltage windings.
(ix) Measurement of insulation resistance to earth of the windings, ormeasurement of
dissipation factor (tan delta) of the insulation systemcapacitances.

Fig.26. Shooter
 CONCLUSION
The power transformer is the most important component of the power
transmission and distribution.A transformer works on the principles of induction
which states that only the current and voltages shall be transformed and energy
will only get ‘transferred’.

BHEL is a leading Engineering Enterprise which Supplies wide Spectrum of

Power Transformers. These transformers undergo several stages of
manufacturing process and at the end of every process various tests like type
tests, routine tests etc. are performed on them to ensure its status during
manufacture and a reliable operation after manufacturing.

These four weeks helped me a lot in gaining the knowledge on power

transformers. It made me aware of various stages of transformer manufacturing
processes and different tests that are conducted on them.

This report clearly replicates the tremendous growth of a company which

continuously renovated its technology to contribute not only in the
infrastructure building in India but also of the world.

It is an asset for our country to have such a public sctor industry which has
fulfilled the dream of our first Prime Minister Sh. Jawaharlal Nehru by
operating in 65 countries and making it to global.

The vision and mission of this company are successful can be adjudged with the
faith of the stake holders in this company.
BHEL Jhansi although a smaller unit in comparision to otherunits of BHEL, is
a very productive one with the manufacturing of the electric locomotives, power
transformers etc.

The work load here can be accessed from the fact that the order of the
locomotives has forced the company to shift its Bus Duct section to other unit of
BHEL.

In future also the company is having orders of metro coaches and this clearly
shows why this company is still recession proof.