TRANSFORMER

AN OFFLINE INTERNSHIP REPORT

Submitted by

Trivedi Rudra Romeshkumar

In fulfillment for the award of the degree of

BACHELOR OF ENGINEERING
in

Electrical Engineering

Government Engineering Collage, BHARUCH

Gujarat Technological University, Ahmedabad

June, 2021

1
 Acknowledgement

I express my sincere thanks to my Project Guide MRS Pallavi Gamit, assistant professor,
Government Engineering College, Bharuch, for guiding me right from the beginning till the successful
completion of the Project. I sincerely acknowledge her for spending her valuable time for guiding me
right from the beginning and for all the support provided to me in all the stages of this Offline
Internship report.

I express my sincere thanks to my Employee of Tushar Trans Equipment Pvt Ltd MR Sujal Patel,
Employee of company, Tushar Trans Equipment Pvt Ltd, Bharuch, for guiding me right from the
beginning till the successful completion of the Project. I sincerely acknowledge him for spending his
valuable time for guiding me right from the beginning and for all the support provided to me in all the
stages of this Offline Internship report.
 Abstract

A transformer is a device that transfers electrical energy from one circuit to another by magnetic
coupling without requiring relative motion between its parts. It usually comprises two or more coupled
windings, and, in most cases, a core to concentrate magnetic flux.

In this report, I have mentioned what I have learned from Tushar Trans Equipment Company. All the
different type of transformer and their tests are being performed to make transformer.
 LIST OF FIGURES

Figure No Figure Description Page No

1 Tushar Trans Equipment Pvt Ltd 1

2 Schematic Diagram of Transformer 5

3 Schematic Diagram of Resin Transformer 6

4 Cores 6

5 Clap paper 7

6 Secondary Winding Insulated 8

7 Transformer 9

8 AITTS-98 10

9 Potential Transformer Burden 10

10 Current Transformer Burden 11

11 AITTS’s output 11

12 Specifications of AITTS-98 12-13

13 Transformer 14

14 Resin Transformer 15

15 Induce Test Panel 15

16 HV Test Panel 17

TABLE OF CONTENTS
 Acknowledgement I
Abstract ii
List of Figures iv
List of Tables vii
List of Abbreviations x
Table of Contents xi
Chapter: 1 VIEW OF THE COMPANY
1.1 History 1
1.2 Products 2
1.3 Capacity of Plant 2

Chapter: 2 Overview of different plant/ unit/

department of the organization
2.1 Number of departments 3
2.2 List of technical specification of equipment: 4

Chapter: 3 Layout of the production being carried out in

company

3.1 Schematic diagram/layout of manufacturing of end 5

product.

3.2 Stages of production: 6

3.2.1. Tests of Transformer 9

3.2.2. Resin Transformer 18
Chapter: 4 Skills

4.1 Skills / techniques during training: 20

Chapter: 5 Conclusion 21
Chapter - 1: Overview of the company

 History:

 Tushar Trans Equipment Pvt Ltd in Bharuch is one of the leading businesses in the
Transformer Manufacturers.
 It was established on year 1992 in Bholav.
 Tushar Trans has two plants in Bharuch.
 It is one of top suppliers of transformer in India.
 This well-known establishment acts as a one-stop destination servicing customers both
local and from other parts of Bharuch.

 Tushar Trans Equipment Pvt Ltd is an ISO-9001-2008 Certified Company Manufacture.

 Products:

1) LT transformer,
2) Current transformer,
3) Potential transformer,
4) Instrument transformer,
5) Resin transformer.

 Capacity of plant:

 Tushar Trans Equipment can hold up to 500 Transformers.

 It can produce minimum, 25 numbers of transformers daily.
Chapter – 2: Overview of different
plant/ unit/ department of the
organization

 Number of departments:
 Assembly Area:
 Test Area 1:
 Test Area 2:
 Oil Filtration / Ovening:
 Resin Cast Area:

1) Assembly Area:
 Here the core of transformer gets winding of copper.
 Also, after the testing, winding gets mounted on outer body of transformer and also get
connection soldered.

2) Testing Area 1:

 Here windings, Current transformer, Potential transformer, Resin transformer, core,

unfinished transformers get test using different instruments.

 Also finishing of transformer done at this area.

 After getting finished, transformer get dispatched through there.
 At this area transformer up to 33kV gets tested and finished.
3) Test Area 2:
 Here transformer of 66kV and 132kV get test.

4) Oil Filtration / Ovening:

 Over here oil for transformer gets ready over here.

5) Resin Cast Area:

 Resin transformer are tested in test area 1.

 And then it gets molded in Resin in this area.
 After getting mound it being test once more.

 List of technical specification of equipment:

 At assembly area, Winding machine is used to winding. Mostly winding of core is done by
hands. But sometimes it is used.
 At test area 1, serval machines are used for testing,
I. AITTS-98(Automatic Instrument Transformer Test Set):
II. Induced Test Panel:
III. HV Panel:
IV. Core Test Panel:
 Oil chamber is an equipment itself.
 At test area 2, it has same equipment as test area 1.
 Resin Cast area has molding station for molding of transformer.
Chapter – 3: Layout of the production
being carried out in company

 Schematic diagram/layout of manufacturing of end product.

1) Current, Potential and Instrument Transformer:

 2) Resin Transformer:

Please watch diagram with zoom.

 Stages of production:
1)Selection of core:
 Core is the main part of any transformer.
 It is also called as secondary winding because it is placed at secondary winding with
winding on core.
 Different types of cores are available for transformer.
 But here core is used is Laminated silicon steel core in Current Transformer.
 Mostly, Potential transformer contains IRON core.
 Core get tested in Core test panel.
2) Insulation of core and winding:
 Insulation of a core is very essential part for any transformer.
 Because core has to control very high voltages.
 Therefore, core gets insulation.
 Insulation is used for core is called clap paper.
 Turns of secondary winding is decided by the ratio we want.
 For example, if we want ratio of 500 and current is 5A. Then number of turns are 100.

Number of Turns = Ratio

amperes

 Core is wounded by winding and two ends of winding keeps out and then core and
winding gets insulated by clap paper.
3) Testing of insulated winding (Clap paper insulation):
  Insulated core is bring to the testing area.
 Core’s two ends are connected with secondary 1 and secondary 2 of a machine.
 And the primary winding goes through the ring of secondary winding.
 Then machine gives power and reading has been taken.
 If we get satisfactory result then core goes in next stage.
 If core failed in result, then whole winding is taken out and then again, we do same
process of winding.
4) Second layer of winding and testing:
 After insulated core is passed through test, it gets insulated with polymer as
shown in figure.
 Another winding is wound on insulated core and then it gets insulated with
polymer insulation.
 And again, it gets tested as same as first time we saw.

5) Assembly of Polymer insulated core and oil transformer:

 Now after passing through the test, now insulated core gets wounded by primary winding.
 Now it gets assembled in either 1 – phase or 3 – phase.
 For current transformer, 3 – phase is used.
 Therefore, 3 windings are present in transformer base.
 Now end of winding get soldered and then two ends of secondary winding get insulated.
 These current transformers are oil cooled.
 Now base of transformer made is put in an outer body.
 Outer body is galvanized body.
  Now whole transformer gets fully filled with oil.

6) Testing of Partial complete transformer:

 Now the transformer is bringing to Induce Test Panel.
 Induce test panel is used to test the oil insulation.
 And now after passing induce test it brings to High Voltage test.
 After passing through HV test, top part of transformer is getting fit.
 And then again get oil up to top part of transformer.
 Top part of transformer is made out of porcelain clay.
 With help of porcelain clay, we can touch even though current pass through it.

7) Final test and finalization of transformer:

 Now completed transformer again brings to AITTS-98 and secondary windings are being
tested.
 All 3 phases are being tested in this test.
 After completion of test, it is getting finalization and it is ready for sell.

 There are some machineries used for transformer as mentioned technical

specification.
1) AITTS-98:
 It is one of the main machineries used for production of transformer.
  Its full form is Automatic Instrument Transformer Test Set.
 It is used to test Secondary winding of transformer.
 It is as shown in figure.

 It used for both Current transformer and Potential transformer.by using switch on
machine we can change the type of transformer from current to potential
transformer.
 There is another panel connected with AITTS-98 for VA. It is called Transformer
Burden.
 It is used for different reading of windings.
 There are different types of winding therefore we need to take different readings.
 There are two types of burden.
1) Potential Transformer Burden:
 2) Current Transformer Burden:

 There are variacs connected with AITTS-98. One them is Voltage variac and
another is current variac.
 Voltage variac provide up to 440V.
 There is Source transformer is connected with AITTS-98 of 40kV and also standard
is connected with AITTS-98 of 11kV.There are 3 standards used for AITTS-98 and
each standard is 1 – phase. And also, a source transformer of 40kV is connected
with AITTS-98.
 Source transformer used in AITTS-98 is step-up transformer.
 Mainly, AITTS-98 shows current and ratio error in percentages, phase error in
minutes, Burden at 5A in VA and accuracy class.
 AITTS-98 have some specification shown in figure.
 There is a ratio selection table for AITTS-98 so they can change it for different
windings.
 There is S1 and S2 on the AITTS-98. There is a dial to change the value of S1 and
S2.

 This all above is specification and how AITTS-98 being combined.

 AITTS-98 also contains primary winding in it.

 So, before connection windings to S1 and S2 of AITTS-98, they short both end of
winding so current can flow in the winding.
 After shorting ends, primary winding is made between through windings and then
connected to the machine.

 After this process, shorted winding gets open and both ends are connected to the
AITTS-98.

 Then we change voltage and current for reading which we get on the screen of
AITTS-98.

 Above process is apply for secondary winding insulated with clap paper and
polymer insulation.

 For testing of transformer, there are several pins we can see as shown in above
figure.
 Bottom 6 pins are for secondary winding. So, each phase of secondary winding is
get tested in AITTS-98.
  There is a failure in this case. It is the reverse polarity.so then they have to open the
transformer and then they have to reverse the side we mounted the insulated
winding.
 The process of testing resin transformer is same as 3 - phase CT

 And the also, AITTS-98 also help to check the top 6 insulated windings of Current
transformer.
 Readings are taking in AITTS-98 is at 120%,100%,20% and 5% current.

2) Induce Test panel:

 It is used to check that oil cooling is working properly or not.
 Induced Test Panel is shown in figure.
 Induced Test Panel get power by a generator. Generator output is 500V and 150Hz.
 A voltage variac is connected with machine for different readings.
 There are 3 red indicators are shown. It indicated 3 – phase of current transformer.
R, Y, and B. We can change it by yellow switch below red indicators.
 There are Off, R, Y, and B is shown on switch to change mode.
 There is also Test Voltage indicator and Test Frequency indicator as shown in
figure.
 It works as same as RYB.
 There are 3 ammeters connected with the Induce test panel. It helps to measure the
current which transformer provides.
 For each phase, there is one ammeter. Every reading of ammeter is being taken
carefully of each transformer.
 Here, secondary winding of transformer is get connected with the machine then
machine gives reading.
  Sometimes transformer fails in Induced test.
 Reason for that is Base of transformer touches the galvanized body. In simple
language, there is fault in ground connection or absence of ground.
 It is also called as puncher.
 So, the insulation of oil is taken out and they check the windings and then after
solving the problem it gets filled with oil and get check again.

3) HV Test Panel:

 Full form of HV test is High Voltage test.

 It is used to test the insulations in secondary winding and transformer. HV test panel
is shown in figure

 HV test panel is connected with transformer to be tested and a source transformer.

The source transformer is 50kV and 1 - phase.
 We can do it no load and load conditions. There is an emergency stop button.
  In this test, the voltage is given this way, if we want to test 11kV transformer then
applied voltage is 28kV.
 If we want to test 22kV then applied voltage is 50kV.
 They apply high voltage to make sure it is keep working in harder condition of high
voltages.

4) PD Test (For Resin Transformer):

 PD test is called Partial Discharge Test.
 It is only for Resin Transformer. Because PD test checks that molding of Resin
Transformer got fully covered or not.it means that, there is air / air bubble is present in
molding then the transformer gets fail.
 To perform the PD test, secondary of transformer must be shorted.
 Then if we get high reading then it is failure.

5) Core Testing:
 A core is placed inside of machine for testing and then the machine gives the reading of
core.

6) Oil filtration plant:

 It is plant where the oil is being keep for later process.
 It contains 66kV Potential transformer which is 1 – phase, 360kV of high Voltage
source provide the power to the plant.
 Also, capacitor of 100kV and 100kV of test panel are placed inside of Oil filtration
plant.
 There is chart also drawn for process in oil filtration.

7) Test for Current transformer above 66kV:

 There is same testing is done for these transformers. But there is big place for doing
these tests.
  There are also 132kV of source transformer and standard transformer which is step up
transformer.

 Tushar Trans Equipment makes step down transformer, we can understand because as I
mentioned earlier those amperes were 5 in turns equation.

 They make 5A and 1A output transformer.

 Resin Transformer:

 Secondary winding of resin transformer made same as current transformer.

 Then it is fitted on a base.
 Then it gets soldered and winding gets out.
 At resin cast area, this base brings over there.
 The machine pressure the cast and after sometimes the cast get in solid form.
 Then transformer is going through the Potential Difference Test.
 Then the resin transformer is going through the winding test.
 Before starting testing of resin transformer, bottom part of transformer gets hit harder by
the hammer.
 Because of pressure in molding transformer core reading gets changed.
 Therefore, it hits through bottom and sides.
 That is why the core gets moved so the machine gets more accurate value of core.

 Tushar has a 160A and 440V in line. There is PCC panel to see this.
Chapter – 4:

 Skills / techniques during training:

 Accuracy of taking readings.

 Taking notes of every reading.
 Taking more products for reading.
 Time and work managing skill.
 Taking readings for different transformer at a time.
 Time punctuality.
Chapter – 5:

 Conclusion:

 Production of transformer from core to end product is not a very hard task.
 But at every work we have to be so accurate so we can provide the good transformer to
customer.
 Tushar is a well-known transformer company. Which makes their product very carefully
and accurate?