INTERNSHIP REPORT

Manthan ardeshan
MAHALAXMI TRANSFORMERS
10-07-2024
A Summer Internship In

MAHALAXMI TRANSFORMERS
Mansukhbhai Dhameliya
(Transformer Rewinding)
(Company Owner)

Submitted by
Manthan Ardeshna
ENR.NO: 236190309004
( 3rd sem)

government polytechnic

junagadh
 ABSTRACT

We learnt and got the practical knowledge about distribution Transformer. We

learn different outer and inner part of transformer like core, winding, relay
anddifferent type of transformer testing. We got the idea how to find
outtransformer’sfault and how to resolve it. And also observed that how to
change transformer oiland winding. Then we learnt the importance of core
design of transformer andhow core design is important to improve
transformer efficiency. We also observeand learn how to purify the
transformer oil with the use of oil filter. Thenobserved that winding place
din core then core is put in industrial oven in 2 to 3days (85` to 90` C).
 GENERAL INFORMATION
The Universal Transformer Maintenance and repairing is the unit of repair
the PGVCL faulty transformer and test after repair the transformer.
Generally the transformer working on demand load, but the transformer
design on maximum load. When the Connected load is over the maximum
load that time possibility of burned out of transformer winding is high.
The Unit is replace the burned winding and other burned-out part of
transformer and fill up the transformer fresh oil.
 After repair the transformer they perform below
tests
1. Open Circuit Test
2. Short Circuit Test
3. Turns Ratio Testing
4. Megger Test
 1. Open Circuit Test

Open circuit test or no load test on a transformer is performed to

determine 'no load loss and 'no load current I0'.The circuit diagram
for open circuit test is shown in the figure.
 Open Circuit Test

Usually high voltage (HV) winding is kept open and the low voltage
(LV) winding is connected to its normal supply. A wattmeter (W),
ammeter (A) and voltmeter (V) are connected to the LV winding as
shown in the figure. Now, applied voltage is slowly increased from
zero to normal rated value of the LV side with the help of avaria.
When the applied voltage reaches to the rated value of the LV
winding , readings from all the three instruments are taken.
 2.Short Circuit Test

The connection diagram for short circuit test or impedance test on

transformer is as shown in the figure below. The LV side of transformer
is short circuited and wattmeter, voltmeter and ammeter are connected on
the HV side of the transformer . Voltage is applied to the HV side and
increased from the zero until the ammeter reading equals the rated
current. All the readings are taken at this rated current.
 Short Circuit Test

The ammeter reading gives primary equivalent of full load current. The
voltage applied for full load current is very small as compared to
rated voltage. Hence, core loss due to small applied voltage can be
neglected. Thus , the wattmeter reading can be taken as copper loss in
the transformer.
 3. Turns Ratio Testing
The transformer turns ratio test is one of the fundamental routine tests for
transformer inspection. This test is used as an indicator of various
problems with the transformer windings, such as shorted turns.
According to international standards, the pass/fail criterion for turns ratio
deviations is ±0,5 %. This places high demands on the accuracy of the
test devices. The measurement accuracy depends on the test device
accuracy and test voltage applied. A higher test voltage applied to the
high voltage (HV) transformer side will induce a higher voltage on the
low voltage (LV) side providing a more accurate measurement. Also,
higher test voltage will result in a higher level of transformer saturation
that also leads to more accurate results. The relation between test voltage
and accuracy will be elaborated and the implications for the turns ratio
test will be discussed. Case studies that support the importance of using
the higher test voltage when the transformer turns ratio test is performed
will be presented as well.
 4. Megger Test
Megger Test The most common method used to measure the insulation
resistance of a transformer is the Megger test. By using a Megger, we can
measure the insulation resistance of the transformer by creating a high
voltage, low current DC charge across the insulation material of the
transformer. This causes a small current to be drawn and the
measurement of the resistance is then taken.The results of the Megger
test are usually expressed in megohms (MΩ). The acceptable insulation
resistance values for transformers vary based on the voltage rating of the
transformer. A rule of thumb is that the insulation resistance should be at
least 100 times the operating voltage of the transformer.
 TYPE OF TRANSFORMER

(1) Core Type Transformer

(2) Shell Type Transformer
(3) Auto transformers
(1) Core Type Transformer
In core-type transformer, the windings are given to a considerable part
of the core. The coils used for this transformer are form-wound and
are of cylindrical type. Such a type of transformer can be applicable
for small size dand large sized transformers. In the small sized type,
the core will berec tangular in shape and the coils used are
cylindrical.
In the case of circular cylindrical coils, they have a fair advantage of
having good mechanical strength. The cylindrical coils will have
different layers andeach layer will be insulated from the other with
the help of materials like paper, cloth, mica board and so on.
(2) Shell Type Transformer
In shell-type transformers the core surrounds a considerable portion of
the windings. The coils are form-wound but are multi layer disc type
usually wound in the form of pancakes. Paper is used to insulate the
different layersof the multi-layer
 WORKING PRINCIPLE
The basic principle behind working of a transformer is the phenomenon of
mutual induction between two windings linked by common magnetic
flux. Basically a transformer consists of two inductive coils; primary
winding and secondary winding. The coils are electrically separated but
magnetically linked to each other.
The core provides magnetic path for the flux, to get linked with the
secondary winding. As the flux produced is alternating (the direction of it
is continuously changing), EMF gets induced in the secondary winding
according to Faraday's law of electromagnetic induction.
 CONSTRUCTION OF
TRANSFORMER
Basically a transformer consists of two inductive windings and a laminated
steel core. The coils are insulated from each other as well as from the
steel core. A transformer may also consist of a container for winding and
core assembly suitable bushings to take our the terminals, oil conservator
to provide oil in the transformer tank for cooling purposes.
 PARTS OF TRANSFORMER

(1) Yoke
(2) Buchholz Relay
(3) Conservator Tank
(4) Silica Gel Brether
(5) Oil Level Indicator
(6) Transformer Bushing
(7) Radiator
(8) Winding Temperature Indicator
(9) System Ground Terminal
(10) Drain Valve
 (1) Yoke
It is use to protect the transformer
inner part to bad environment
condition.
The parts of the core joining the
three limbs are known as the
yokes. In the three-limb
arrangement the yokes have the
same cross-sectional area as the
limbs. With two extra unwound
limbs the top and bottom yokes
can be reduced to half the cross-
section of the three wound limbs.
 (2) Buchholz Relay
It is a very sensitive gas and oil operated instrument which safely detect
the formation of gas or sudden pressure inside the oil transformer. It is a
electrical and mechanical both type operated device. Electrical type relay
is vary accurate as compare to mechanical type relay.
 (3) Conservator Tank
This is a cylindrical tank mounted on supporting structure on the
roof of the transformer's main tank. When transformer is
loaded, the temperature of oil increases and consequently the
volume of oil in the transformer gets increased. Again, when
ambient temperature is increased, the volume of oil is also
increased. The conservator tank of a transformer provides
adequate space for expansion of oil. Conservator tank of
transformer also acts as a reservoir of oil.
 (4) Silica Gel Brether
When the temperature changes occur in
transformer insulating oil, the oil
expands or contracts and there an
exchange of air also occurs when
transformer is fully loaded. When
transformer gets cooled, the oil level
goes down and air gets absorbed
within. This process is called breathing
and the apparatus that pass through the
air is called breather Actually, silica gel
breather controls the level of moisture,
entering electrical equipment during the
change in volume of the cooling
medium and airspace caused by
temperature increasing. So it sucks the
moisture from the air which is taken by
transformer so that dry air is taken by
transformer.
 (5) Oil Level Indicator
It is used to show the oil level in the transformer. this is a ordinary part
situated on the side of the conservator for proper oil checking oil tank
wants a specific amount of oil. The oil level indicator displays if air
bubbles have remained in the transformer, if gas has been generated
because of an internal failure or if there is a leakage at the transformer
tank.
 (6) Transformer Bushing
the term bushing is used to
represent a hollow electrical
insulator that helps us to safely
pass an electrical conductor
through a conducting barrier like
a transformer case, or circuit
breaker case without making any
electrical connection with it. A
typical bushing is made up of
porcelain. But, in practice, several
other insulating materials like
polymer, ceramic, glass, etc. may
also be used for the same purpose
 (7) Radiator
These are used for the purpose for the cooling of the transformer oil. The
capacity of the transformer is dependent to its temperature that is why it
is imperative for it to have a cooling mechanism for better performance
and higher efficiency

(8) Winding Temperature Indicator

This device measures the LV and HV winding temperature and is also used
to protect the transformer.
 (9) System Ground Terminal
system ground terminalsin a power transformer are usually present
whenever the connection type of the transformer windings has in it. This
terminal can be found in-line with the main terminals of the transformer.

(10) Drain Valve

Can be usually found in the bottom part of the transformer tank.
Drainvalves are used whenever oil replacement is necessary. Through
this valve, the replacement of oil in an oil-filled transformer can be easily
done simply by opening this valve like that of a faucet.
 Inner Parts Of Transformer
(1) Core
Core is used to support the windings in the
transformer. It also provides a low
reluctance path to the flow of magnetic
flux. It is made up of laminated soft iron
core in order to reduce eddy current loss
and Hysteresis loss. The composition of a
transformer core depends on such factors
as voltage, current, and frequency.
Diameter of the transformer core is
directly proportional to copper loss and is
inversely proportion to the iron loss. If
diameter of the core is decreased, the
weight of the steel in the core is reduced
which leads to less core loss of
transformer and the copper loss increase.
The vice versa happen when the diameter
is increased.
 (2) Primary Winding (HV Winding)
Generally in primary winding has low
current and high voltage winding.
Primary Windings (HV Winding) are
made up of copper coil. The number of
turns in it is the multiple of the number
of turns in the low voltage windings. It
has copper coils thinner than that of the
low voltage windings. The primary
winding is analogous to the input shaft
and the secondary winding to the output
shaft. primary winding is the winding
of a transformer that is connected to
and receives energy from an external
source of electrons. Primary Winding is
placed on secondary winding because
of insulation purpose.
(3) Secondary Winding (LV Winding)
A secondary winding is the winding of a
transformer that receives its energy by
electromagnetic induction from the primary
winding. The secondary winding is
facilitated with larger-gauge wire because of
the increase in current, whereas the primary
winding is made up of smallergauge wire
due to less current conduction. The
electromotive force in the secondary
winding, if connected to an electrical circuit,
will cause current to flow in the secondary
circuit. Generally the secondary winding has
high current and low voltage winding. Low
voltage winding has lesser number of turns
than that of the high voltage windings. It is
made up of the thick copper conductors. This
is because the current in the low voltage
windings is higher than that of high voltage
windings. The secondary winding are placed
between core and primary winding.
 (4) Transformer Oil

Transformer oil is used in oil-filled electrical

power transformers to insulate, stop arcing
and corona discharge, and to dissipate the
heat of the transformer. Transformer oil
preforms two important function of
insulation as well as cooling for the core and
coil assembly. Core and winding of the
transformer must be completely immersed in
the oil. Normally hydrocarbon mineral oil
and used as transformer. Transformer oil
Transformer oil is also used to preserve the
transformer’s core and windings as these are
fully immersed inside the oil. Another
important property of the insulating oil is its
ability to prevent oxidation of the cellulose-
made paper insulation.