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INTERNSHIP REPORT
POWER TRANSOFMRER ENGINEERING
SERVICE UNIT (PTESU)

Presented by:
Muhammad Ali Tehseen
Student of

Swinburne University of Technology, Melbourne

Victoria

Presented to:

Mr. Khalid

Manager PTESU, Kot Lakhpat Lahore

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Contents
1 INTRODUCTION.....................................................................................................................1
2 TRANSFORMERS IN THEORY.............................................................................................1
2.1 Working Principle of Transformers.................................................................................1
3 PTESU.......................................................................................................................................2
3.1 Importance of PTESU.....................................................................................................2
3.2 Organizational Chart.......................................................................................................3
3.3 Standard Operating Procedure........................................................................................4
4 REPAIR WORKSHOP..............................................................................................................5
4.1 Activities in Repair Section.............................................................................................5
4.1.1 Unloading of transformer..................................................................................5
4.1.2 Dismount external fittings.................................................................................6
4.1.3 Un-tanking.........................................................................................................6
4.1.4 Measurements, photographs and nodal marking...............................................8
4.1.5 Dismantling of wooden structure, girders and upper yoke................................8
4.1.6 Inspection...........................................................................................................8
4.1.7 Dismantling the core sheets...............................................................................8
4.1.8 Disconnecting the windings leads and removal of defective winding.............9
4.1.9 Designing of winding & transferring the damage winding to winding section.9
4.1.10 Ordering the damage insulation or re-pairing/making of insulation.................9
4.1.11 Re-assembling....................................................................................................9
5 STRUCTURE OF POWER TRANSFORMER........................................................................9
5.1 Accessories of transformer............................................................................................10
5.1.1 Bushing............................................................................................................10
5.1.2 Oil Level Indicator...........................................................................................11
5.1.3 Dehydrating breather.......................................................................................11
5.1.4 Conservator......................................................................................................12
5.1.5 Contact thermometer.......................................................................................12
5.1.6 Buchholz relay.................................................................................................12
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5.1.7 Rating plate......................................................................................................13

5.2 Active Part of Transformers..........................................................................................13
5.2.1 Core..................................................................................................................13
5.2.2 Windings..........................................................................................................13
5.3 Transformer Oil.............................................................................................................13
5.3.1 Composition of Oil..........................................................................................14
5.3.2 Functions of Transformer Oil..........................................................................14
5.4 Insulation and other components inside the transformer..............................................15
5.4.1 Cylinder and axial Strips.................................................................................15
5.4.2 Spacers.............................................................................................................16
5.4.3 O Rings............................................................................................................16
5.4.4 Angle Rings.....................................................................................................16
5.4.5 End-cap............................................................................................................16
5.4.6 Stiffener...........................................................................................................16
5.4.7 Core belt...........................................................................................................16
5.4.8 Oil Duct...........................................................................................................16
5.4.9 Collar and wall.................................................................................................16
6 ROUTINE TESTING..............................................................................................................17
6.1 Transformer Turn Ratio (TTR) Test..............................................................................17
6.2 Winding Resistance Test...............................................................................................17
6.3 Insulation resistance Test (Megger)..............................................................................18
6.4 Capacitance & DF Test..................................................................................................19
7 VAPOUR PRESSURE DRY (VPD)........................................................................................20
7.1 Purpose..........................................................................................................................20
7.2 Importance.....................................................................................................................20
7.3 Operation.......................................................................................................................20
8 DE-Hydration Plant.................................................................................................................21
8.1 Main parts of De-hydration Plant:.................................................................................22
8.2 Steps of De-hydration:..................................................................................................22
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9 WINDING section...................................................................................................................23
9.1 Activities in winding section.........................................................................................23
9.1.1 Un-coiling........................................................................................................23
9.1.2 Paper Wrapping...............................................................................................23
9.1.3 Re-coiling........................................................................................................23
9.2 Types of windings by construction................................................................................24
9.2.1 Pancake Windings............................................................................................24
9.2.2 Layer (Barrel) Windings..................................................................................24
9.2.3 Helical Windings.............................................................................................25
9.2.4 Disc Windings..................................................................................................25
10 TAP CHANGER......................................................................................................................25
10.1 Accessories of Tap Changer..........................................................................................26
10.1.1 Selector Switches.............................................................................................26
10.1.2 Reactors...........................................................................................................26
10.1.3 Vacuum Switch................................................................................................26
10.1.4 Bypass Switch..................................................................................................26
10.2 Operating Mechanism...................................................................................................26
11 OIL TESTING.........................................................................................................................27
11.1 Tangent Delta Test.........................................................................................................27
11.2 Interfacial Tension Test.................................................................................................28
11.3 Dielectric Strength Test.................................................................................................28
11.4 Acidity Test...................................................................................................................29
11.5 Flash Point Test.............................................................................................................29
11.6 Viscosity Test................................................................................................................29
11.7 Moisture Content Test...................................................................................................30
12 FINAL TESTING....................................................................................................................30
12.1 Short Circuit Test...........................................................................................................30
12.2 No-load losses...............................................................................................................31
12.3 Induced Test (Insulation Test).......................................................................................32
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12.4 High Voltage Test..........................................................................................................32

12.5 Sweep Frequency Response Analyzer...........................................................................33
13 RECOMMENDEDATIONS....................................................................................................34
14 Comparison of Furan Analysis with other Transformer Oil Tests...........................................40
15 Comparison of Metal Contamination Test with other Transformer Oil Tests..........................42
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1 INTRODUCTION
The internship was conducted in power transformer repair workshop, named as Power
Transformer Engineering Service Unit (PTESU) for [no. of weeks] from [start date] to [finish
date]. The internship was about enhancing the knowledge about the working principle, types,
structure and component of transformers. Furthermore, the procedure involves in repairing a
transformer is learned that includes fixing damages in windings and tap changers. In addition to
that, the information about purification of transformer from impure oil and moisture through
Vapour Pressure Dry (VPD) is acquired. Lastly, testing of transformers oil, windings and
insulation are also learned during my tenure in PTESU

2 TRANSFORMERS IN THEORY
Electrical transformer is a static device which uses mutual induction between two windings to
transform electrical energy from one circuit to another without any direct electrical connection.
The input and output power is theoretical equal to each other, however, in practice, 95% to 99%
power is achieved at the output. The frequency at both input and output is same but the current
and voltages vary.

2.1 Working Principle of Transformers

Transformer works on the principle of Faradays
law of induction by linking the electrical circuits
using a common oscillating magnetic circuit.
Magnetic field is produced around a wire in which
electric current is following which is directly
proportional to the electric current. The core in the
transformer is responsible for making a path for the
magnetic flux. There are two coils in a transformer
wrapped on the core of the transformer (as shown
in figure 1) and there is insulation between them, Figure 1: Basic Transformer
one is called primary and other is called secondary.
The input is provided at the primary side of the transformer and the Mutual induction phenomena
allows the primary coil to induce a voltage, magnetically, on the secondary side of the
transformer. Since there is no change in power of an ideal transformer, the variation is only
between voltage and current which depends upon the turns of primary and secondary coil.
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The output voltage will be higher than the input voltage if the number of turns in the output
(secondary) windings is higher than the input (primary) winding, however, in this case, the
current will be lower at the output in comparison with the input current. This type of transformer
is called step-up transformer. The step-down transformer is opposite to step-up transformer. The
output voltage is lower but higher output current in comparison to input voltage and current in
step-down transformer as there are fewer turns in secondary windings than in primary windings.

3 PTESU
Pakistan WAPDA Foundation (PWF) established a power transformer repairing workshop in
1979 under the name of Power Transformer Reclamation Workshop. It went under a major
expansion in 2008 and it was changed into Power Transformer Engineering Service Unit
(PTESU).

3.1 Importance of PTESU

PTESU is one of the very few power transformer repair workshops in Pakistan and we receive
damaged power transformer from all over the Pakistan. The repairs of the transformer cost
extremely less than purchasing a new transformer, in fact, it allow the power companies to save
up to 90% cost as a result of repairing services provided by PTESU.

PTESU also provides services other than repairing of power transformers that includes

On-site testing of power transformers

Oil Testing of in-service power transformers
Vapor Phase Dry (VPD) of new transformers manufactured by PEL
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3.2 Organizational Chart

Flowchart 1: Organizational Chart of PTESU

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3.3 Standard Operating Procedure

Winding section

Flowchart 2: SOP of PTESU

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The repairing of damaged power transformers are done under a standard operating procedure
(SOP) which is described via a flowchart 2 above

4 REPAIR WORKSHOP Deh

O
4.1 Activities in Repair Section
The following activities are performed in the repair workshop

4.1.1 Unloading of transformer

Unloading of transformer is done with the help of cranes. There are two cranes installed in the
repair section, each has the capacity to lift 100tons. Whenever, we have a transformer whose
weight is larger than 100 tons, we join both the cranes with the help of a horizontel bridge.
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Figure 2: Unloading of Transformer

4.1.2 Dismount external fittings

Normally, external accessories such as Bucchloz relay, conservative tank, indicating material etc.
of the transformer are connected with the connection leads and screws. We untie the screws,
disconnect the leads and then with the help of crane dismount the external fittings. Sometimes,
tap changer is a externally fitted and it is also removed before the un-tanking

4.1.3 Un-tanking
Sometimes, the top of the transformer is attached to the active part of the transformer and in
some cases top is attached to the tank of the transformer. If the active part and top is together,
there is a space where we can attached the crane to the top of the transformer with the help of U-
shaped holders and bolts as shown in the figure 3 and 4.

Figure 3: Connection b/w top of t/f and crane

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Figure 4: Worker attached top of t/f with crane by using

U-shaped holder Figures 5 and 6 illustrates pictorially, how the
active part is taken out from the transformer
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Figure 5: Un-tanking
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Figure 6: Taking Active part out of t/f tank

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Figure 7: Active part

Figure 7 shows the active part of the transformer after it is taken out of the tank. The top cover is
removed from the active part by un-securing the bolts

When the top is a part of the transformer tank, we remove the top of the transformer first and
then by using crane and L shape holder we take out the active part of the transformer

4.1.4 Measurements, photographs and nodal marking

After the inspection we take pictures of the arrangements of the insulation between the windings
and insulation between winding and core. Additionally, we take the photographs of the
arrangement of leads connecting the tap changer with the windings. All the nodes are marked so
there is less hustle at the time of re-assembling and all the parts can be mount on their previous
positions.

4.1.5 Dismantling of wooden structure, girders and upper yoke

The girders which is used on the top of the active part of the transformer is removed. The
wooden structure and other components holding the active part is removed. Similarly, the upper
yoke is removed as well. The process of dismantling involves mostly un-screwing. There should
be a specific order in which these components should be removed and this order depends upon
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the design of the transformer. Sometimes wooden structure are dismantle before the girders and
in other cases the opposite is done.

4.1.6 Inspection
Once, the active part is separated from its supporting accessories, we conduct a physical
inspection to see any faults in the insulation or windings of the transformer. The turn ratio test of
all the windings are conducted to investigate the faults in the windings. If the transformer
damages are not excessive and can be repaired, we prepare a list of repair activities that need to
be conducted, otherwise, we contact the company to inform about the extent of damages. In such
cases, mostly the transformer is disposed of.

4.1.7 Dismantling the core sheets

The core sheets which are on the top of the windings need to be removed to take the windings
out. We try to fully understand the design of the core at this time, so we can re-assemble the
sheets properly after the repairs. We count the number of the sheets and also how many sheets
are fitted between each other and mark them. We also note any different shapes of sheets because
sometimes there are different are two or three or four shapes of sheets and are designed in a way
that the when different parts of the core are stack together, they joint properly without any
disconnections.

4.1.8 Disconnecting the windings leads and removal of defective winding.

After inspection, we disconnect the winding leads by cutting the conductor of the windings
leads.And then using L-shape rods and crane

4.1.9 Designing of winding & transferring the damage winding to winding

section.
Once the damaged windings are taken out, the repair section informed the design department
about it. They take several measurements and design the exact copy of the winding. The
windings is then transferred to the winding section

4.1.10 Ordering the damage insulation or re-pairing/making of insulation

All the supporting components are having insulating paper on it, so there is no short connection
between the active parts and these components. These kind of damages are sort it out by the
repair section. However, some of these components such as O-rings are made of insulation board
or insulation paper. There are also several types of insulations (e.g. cap-ends, angle rings) etc.
which are sometimes also get damage and needs to be changed. These components are re-made
in the insulation section.
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4.1.11 Re-assembling.
When the windings damages are repaired and insulations are either repaired or re-made, the
repair section re-assemble all the components of the transformer. It is a reverse process of de-
assembling and workers make use of all the nodal marking, pictures etc. to re-assemble all the
parts in the original form.

5 STRUCTURE OF POWER TRANSFORMER

The working experience in the repair section helps in understanding the structure of the power
transformer more efficiently. Therefore, in this section we discuss all the internal and external
accessories that are being observed during this internship

The following diagram (figure 8) shows the outer structure of a transformer and the accessories
of a power transformer.

Figure 8: Structure of Transformer

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5.1 Accessories of transformer

5.1.1 Bushing
A bushing serves to insulate conductors that are carrying high-voltage current through a
grounded enclosure. It is used to insulate the incoming or outgoing conductor into or out of a
grounded barrier (i.e. transformer main tank). The bushing connect the windings of the
transformer to the supply line and insulate the feed through conductor from the transformer main
tank.

There are two types of bushing; Firstly, the solid-type bushing, is typically made with a central
conductor and porcelain or epoxy insulators at either end and is used primarily at the lower
voltages through 25 kV. Capacitance graded bushings construction is used for virtually all power
transformers or systems where voltage ratings are above 25-kV system voltage and has been
used for bushings through 1500-kV system voltage.

5.1.1.1 Capacitance Graded Bushings:

This construction uses conducting layers at predetermined
radial intervals within oil-impregnated paper or some other
insulation material that is located in the space between the
central conductor and the insulator.

Different manufacturers have used a variety of materials

and methods for making capacitance-graded bushings.
Early methods were to insert concentric porcelain cylinders
with metallized surfaces or laminated pressboard tubes with
embedded conductive layers. Later designs used conductive
foils, typically aluminum or copper, in oil-impregnated
Kraft paper.

An alternative method is to print semi conductive ink

(different manufacturers have used different conductivities)
on all or some of the oil-impregnated Kraft-paper wraps.

The principal elements are the central circular conductor, as

shown in figure 8onto which the capacitance-graded core is
wound; the top and lower insulators; the mounting flange;
the oil and an oil-expansion cap; and the top and bottom
terminals. Figure 9: Capacitance Graded Bushing
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Capacitance-graded bushings involve many technical and manufacturing details. These details
include the insulation/conducting layer system including the dimensions, equipment to wind the
capacitor core, and the oil to impregnate the paper insulation.

5.1.2 Oil Level Indicator

An oil-level indicator is a standard feature on oil-filled transformer tanks, since the oil medium is
critical for cooling and insulation. This indicator is typically a round-faced gauge on the side of
the tank, with a float and float arm that moves a dial pointer as the oil level changes

5.1.3 Dehydrating breather

Dehydrating breather uses a material such as silica gel to allow air to enter and exit the tank,
removing moisture as the air passes through. Most tanks are somewhat free breathing, and such a
device, if properly maintained, allows a degree of control over the quality of air entering the
transformer

5.1.4 Conservator
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.

5.1.5 Contact thermometer

Contacttemperature indicators measure the temperature of the internal liquid at a point near the
top of the liquid using a probe inserted in a well and mounted through the side of the transformer
tank.

5.1.6 Buchholz relay

Buchholz relay is a safety device i.e. a type of oil and gas actuated protection relay which is
generally used in large oil immersed transformers

Buchholz relay consists of an oil filled chamber. There are two hinged floats, one at the top and
other at the bottom in the chamber. Each float is accompanied by a mercury switch. The mercury
switch on the upper float is connected to an alarm circuit and that on the lower float is connected
to an external trip breaker.

Whenever a minor fault occurs inside the transformer, heat is produced by the fault currents. The
produced heat causes decomposition of transformer oil and gas bubbles are produced. These gas
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bubbles flow in upward direction and get collected in the Bucchloz relay. The collected gas
displaces the oil in Bucchloz relay and the displacement is equivalent to the volume of gas
collected. The displacement of oil causes the upper float to close the upper mercury switch which
is connected to an alarm circuit. Hence, when minor fault occurs, the connected alarm gets
activated. The collected amount of gas indicates the severity of the fault occurred. During minor
faults the production of gas is not enough to move the lower float. Hence, during minor faults,
the lower float is unaffected.

During major faults, like phase to earth short circuit, the heat generated is high and a large
amount of gas is produced. This large amount of gas will similarly flow upwards, but its motion
is high enough to tilt the lower float in the Bucchloz relay. In this case, the lower float will cause
the lower mercury switch which will trip the transformer from the supply, i.e. transformer is
isolated from the supply

5.1.7 Rating plate

Following are the minimum technical information and Data which to be shown on a transformer
nameplate or rating plate

Name of manufacturer
Serial number
Voltage and power ratings
Frequency
Tap voltages.
Connection diagram.
Cooling class
Rated temperature in C
Phasor or vector diagram (For Polyphase or Three Phase Transformers)
% impedance.
Approximate mass or weight of the transformer
Type of insulating liquid.
Conductor material of each winding.
Oil volume (of each transformer Container/Compartment)
Instruction for Installation and Operation

5.2 Active Part of Transformers

5.2.1 Core
The core provides the magnetic path to channel the flux and consists of thin strips of high-grade
steel, called laminations, which are electrically separated by a thin coating of insulating material.
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The strips can be stacked or wound; the windings are built separately and assembled around the
core sections

5.2.2 Windings
The windings consist of the current-carrying conductors wound around the sections of the core
and these must be properly insulated, supported, and cooled to withstand operational and test
conditions. The terms winding and coil are used interchangeably

5.3 Transformer Oil

The insulating fluid that has the greatest use in electrical equipment is mineral oil because of its
die-electric and thermal properties as well as because of the comparatively low price.

5.3.1 Composition of Oil

Mineral oil can vary greatly in its composition. All mineral oils are mixtures of hydrocarbon
compounds with about 25 carbon atoms per molecule. The blend of compounds that is present in
a particular oil is dependent on several factors, such as the source of the crude oil and the
refining process. Crude oilsfrom different geographical areas will have different chemical
structures (arrangement of the carbonatoms within the molecules). The refining of crude oil for
the production of dielectric fluids reduces the aromatic and polyaromatic content to enhance the
dielectric properties and stability of the oil.

Crude oils from some sources are higher in paraffinic compounds and other are higher in
paraffinic compounds.The terms paraffinic and naphthenic refer to the arrangement of carbon
atoms in the oil molecule. Carbon atoms that are arranged in straight or branched chains, i.e.,
carbon atoms bonded to one another in straight or branched lines, are referred to as being
paraffinic. Carbon atoms that are bonded to one another to form rings of generally five, six, or
seven carbons are referred to as being naphthenic.

A particular oil will contain a mixture of many different molecular species and types of carbon
atoms. Whether a particular oil is considered paraffinic or naphthenic is a question of degree. If
the oil contains more paraffinic carbon atoms than naphthenic carbons, it is considered a
paraffinic oil and vise versa.The differences in the chemical composition will result in
differences in physical properties and in thechemical behavior of the oils.

For power transformers, the main concerns are:

Paraffinic oils tend to form waxes (solid compounds) at low temperature.

Paraffinic oils have a lower thermal stability than that of naphthenic and aromatic oils.
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Paraffinic oils have a higher viscosity at low temperature than that of naphthenic and
aromatic oils

5.3.2 Functions of Transformer Oil

1 The primary function of insulating oil is to provide a dielectric medium that acts as insulation
surroundingvarious energized conductors.
2 Another function of the insulating oil is to provide a protective coatingto the metal surfaces
within the device. This coating protects against chemical reactions, such as oxidation, that
can influence the integrity of connections, affect the formation of rust, and contribute to the
consequent contamination of the system.
3 A secondary function of the insulating fluid is to serve as a dissipater of heat. This is of
particularimportance in transformers where localized heating of the windings and core can be
severe. The oil aids in the removal of heat from these areas and distributes the thermal energy
over a generally large mass of oil and the tank of the device. Heat from the oil can then be
transferred by means of conduction, convection, and radiation to the surrounding
environment.
4 The fourth function of the insulating fluid is to serve as an indicator of the operational
condition of the liquid-filled equipment. The condition (both chemical and electrical) of the
insulating fluid reflects the operational condition of the electrical device. When faults
develop in liquid-filled equipment, they cause energy to be dissipated through the liquid.This
energy can cause a chemical degradation of the liquid. An analysis for these degradation
products can provide information about the type of fault that is present.

5.4 Insulation and other components inside the transformer

Figure 9 shows all the insulation and other components inside the transformer
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Figure 10: Transformer inner components

5.4.1 Cylinder and axial Strips

Cylinder and Axial Strips are used to provide insulation between the HV and LV windings. The
axial strips are also aim to provide a gap between cylinder and the winding so that there is a flow
of oil for the removal of heat

5.4.2 Spacers
Spacers are used between the turns in the winding to regulate the flow of oil between the turns so
the temperature of these conductors doesnt rise too much. Another function of spacers are to
maintain the height of the winding.

5.4.3 O Rings
O rings are basically to provide space between the top of the core and winding and also to
maintain the height. They are made out of transformer board, so provide insulation as well.

5.4.4 Angle Rings

Angle rings are specifically for insulation purposes between the core and winding and between
the windings. They are somewhat similar to half cylinders and therefore provide support to the o
rings as well as proper insulation between the windings.
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5.4.5 End-cap
End caps are install right at the top of the windings after o rings and angle rings. The purpose is
to isolate the core from winding and provide insulation. Another function of it is to provide
support to the cylinder.

5.4.6 Stiffener
Stiffeners are aim to provide support to the core of the transformer.

5.4.7 Core belt

Core belt are use tightens up the core so there is no movement of the strips of de-location of the
core once the transformer is in operation

5.4.8 Oil Duct

Oil ducts lie within the peripheral of optimum core circle and provides oil circulation around the
core of the transformer, thus, removing heat from the core. In some cases i.e. in high power
transformer oil ducts are also make between the winding to provide heat dissipation from the
conductor

5.4.9 Collar and wall

Collar provides insulation between the phases and also supports a wall between the windings of
different phases. The wall is to isolate and insulate the

6 ROUTINE TESTING
6.1 Transformer Turn Ratio (TTR) Test
Transformer Turns Ratio (TTR) test is performed to verify that, on all taps, the ratio of primary
to secondary voltage is equivalent to the ratio between turns of primary and secondary voltage.

Purpose of test and types of faults detected: The purpose of this test is to verify the turn ratio of
the transformer. This test helps us in detecting any damages in the windings of the transformer
such as shorted turns, open windings, incorrect winding connections and other faults

Importance of test: The operation of the power transformer is to transform an input voltage to a
higher or lower output voltage according the specified turn ratio. If the output voltage is not
corresponding to the turn ratio of the windings, then the purpose of the transformer is not
fulfilled. Therefore, it is necessary to make sure we are getting the desired output.

Procedure: An AC voltage is applied on the LV (low voltage) windings of the transformer and
the induced voltage at the HV (high voltage) side is measured against every tap setting. The input
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is provided on the LV side as it is easily available. The measured turn ratios are compared with
calculated turn ratio. For example, there is a 10/13MVA, 132/11 KV transformer and on a middle
tap position, the turn ratio is 11.887 (as specified by the company), therefore, when we apply 8V
on the LV side, the output voltage is measured and the turn ratio is calculated from measured and
applied voltage. After that specified turn ratio is compared with measured turn ratio and the
difference is under 0.1% then the transformer is working fine

PTESU uses Raytech 3 kit for this test and HV (high voltage) and LV (low voltage) windings are
directly connected to the instrument via bushes. For a 3-phase transformer, a voltage supply of
between 10V to 100V is selected and for a 1-phase transformer, a voltage supply of 8V is
applied. For each tap position, we have calculated results the results for all three phases are
measured and compared.

6.2 Winding Resistance Test

Winding Resistance Test is performed to determine any damages or connection errors in the
windings of the transformer by measuring the DC resistance of primary windings for each phase
and all taps and also resistance of secondary winding for each phase.

Purpose and types of faults diagnosed: There are multiple purposes of performing this test. First
of all, the losses in the windings depends upon the resistance in it according to IR 2, thus, the
resistance of winding is compared with the specified values of the company for each tap to make
sure that the losses are minimum. Secondly, the three phase system should be balanced,
therefore, the resistance of all the phase windings should be same to have an equal impedance for
all phases. Thus, we also check the difference between the readings of the phases. The length and
area of the conductor in all windings is the same and since the resistance of the conductor
depends upon the area and length of it, this test will able to show any short windings or any
damages in the winding. The test also diagnose and pinpoint defects such as loose connections,
and poor tap changer operation and also verify make before break operation. The symmetry
from the middle tap for each phase helps us in determining these defects.

Importance: If the resistance of the winding is higher than the specified values, then, there
would be more losses than expected. Thus, the efficiency of the transformer is decreased.
Furthermore, the higher resistance shows the decrease in the performance of the conductor which
is not a healthy sign for the performance of the transformer in a long run. This test also verify the
balanced three-phase system which is extremely important in the electrical system. First of all,
almost all of the electrical three phase equipment are designed for a balanced three phased
system, therefore, any unbalancing in the transformer output will result in faults and
complications in the whole system. Secondly, it is easier to do calculations on a balanced three
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phased system.

Procedure: Megger Transformer ohmmeter (catalogue no: 8302080-47) is used in PTESU for
the winding resistance test. The readings for all phases are taken separately, for example, for a
star connection, the resistance of AB winding is taken first, then BC and then CA and for a delta
connection, readings of an, bn and cn are taken one-by-one. For an AB connection, the top of A
phase (i.e. connection from the A phase bush) and bottom of B phase is connected to the meter is
connected to the meter. It is extremely important to clean the bushes before connecting it to the
meter because any contact resistance will disturb the results of the test. Usually, a supply of 30V
DC and a 500mA current is given to each phase and the corresponding resistance is measured. If
different tap changers are used for different phases, then normally, the specified resistance of all
phases are the same, but if one tap changer are used for multiple windings then, there would be a
slight difference between the specified values of each winding. The reasons behind is, conductor
use for connecting different tapes would have different lengths, and therefore, the resistance will
be changed. For the HV side, the resistance readings for each winding is taken for all tapes while
for the LV side, we just take readings on central tap position.

6.3 Insulation resistance Test (Megger)

Purpose and types of fault diagnosed: Megger Test is used to determine the strength of
insulation of the windings in a transformer by measuring the resistance of the insulation.

Importance: Transformer insulation resistance deterioration is one of the most common causes
of transformer failure: a failing transformer is a costly replacement in an electrical system with
the potential for a long downtime. If you fail to maintain your transformer with regular insulation
resistance testing then its likely to fail before reaching its maximum operating life

Procedure: There is a DC supply given to test the insulation resistance of the transformer.
Megger leads to be connected to LV and HV bushing studs to measure insulation resistance IR
value in between the LV and HV windings. Megger leads to be connected to HV bushing studs
and transformer tank earth point to measure insulation resistance IR value in between the HV
windings and earth. Megger leads to be connected to LV bushing studs and transformer tank
earth point to measure insulation resistance IR value in between the LV windings and earth. All
the readings are taken for 15 seconds and 60 seconds and then we calculate the F.F

60 seconds value
FF = 15 seconds value

FF value should be less than 1.2. There is also a table of required resistance of insulation for
given DC voltage and all the resistance are checked corresponding to that table. If the resistance
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is lower than the required

6.4 Capacitance & DF Test

Purpose and type of faults diagnosed: Capacitance and Dissipation Factor (C&DF) Test Sets are
used for evaluating the nature and quality of electrical insulation materials and systems. By
measuring dissipation factor losses in electrical insulation, these units can indicate the presence
of contaminants, fractures and punctures.

Importance: As part of a routine maintenance program or routine test, capacitance and

dissipation factor testing can aid in predicting potential failure of deteriorating insulation. These
deteriorating insulation can lead to potential transformer failure which may be quite costly. The
health of the electrical bushing can also be investigated through this test. It also tells about the
losses as if the DF factor is high, the losses will be higher as well.

Procedure: Clear the rust or dust from the bushings of the transformer because it change the
value of C and DF factor. Use a silver or copper wire to short the Hv terminals, similarly, short
the LV terminals throughout by the use of wire. Connect Power supply cables to the test set.
Different modes are available for different types of tests. For example in two winding
transformer mode 3, 4 and 5 is used and in three winding transformer mode 3 4 and 5 is used.
The mode 3 5 and 6 are used to calculate capacitance from high to low (CHL), capacitance
between high to low and hight to ground (CHL + CHG) and lastly capacitance low to ground
(CLG). The capacitance and DF value is check against the specific values of the transformer
company which is written mostly on the rating plate or the IC standards.

7 VAPOUR PRESSURE DRY (VPD)

7.1 Purpose
The aim of the VPD is to remove the moisture content from the insulation used between the
different parts of the transformer and also to remove any moisture content and impurities from
the active part of the transformer.

7.2 Importance
The water acts as a conducting material and can weak the insulation, thus, providing a path of
electric flow between different parts of the transformer. For instance, if the insulation between
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the two windings is weak and allow the electric flow between them, the windings will get short
and damage.

7.3 Operation
The drying process consists of 5 main operating phases:

1 Prepare phase
2 Heating phase with intermediate pressure lowering
3 Pressure reduction with distillation
4 Fine vacuum
5 Aeration

Prepare Phase:

After feeding the T/F into the autoclave and select a parameter set with w.r.t the insulation
weight, rating and HV. Voltage of T/F. the vacuum process start and autoclave is evacuated to
7mbar which is normally achieved in one hour.

Heating Phase with Intermediate Pressure Lowering:

Solvent oil (kerosene oil) up to 2000 liter is filled into the autoclave. The cascade evaporator is
heated up and solvent is circulated over condensate autoclave, filter system and cascade
evaporator, where a portion of solvent evaporates. Under the given temperature 120C and
pressure conditions, the water contained in the T/F diffuses to the surface and evaporates. The
gas mixture containing solvent and water vapors is pumped over the vapor into the main
condenser, where water and solvent re-condensates. The two liquids are perfectly separated by
their differences in specific weight. Pressure in autoclave is kept 60mbar through inbuilt that
programmed is I.P.L. during the I.P.L phase the solvent inlet is closed thus no new solvent vapor
is produced, resulting in the pressure decrease. Heating and I.P.L phase takes about 30 to 40
hours.

Pressure Reduction with Distillation:

A distillation is required when oil impregnated T/F is drying. In this phase the solvent is
circulated through filters, evaporator and autoclave. When the solvent passes through the
evaporator, it changes into vapor form and these vapors are re-condensate by condenser and
return the main collecting tank in form of liquid. At a certain pressure vacuum pump starts and
decreases the autoclave pressure to 5mbar. After completely emptying the evaporator the oil that
was collected in autoclave is discharged to the waste oil tank. It takes about 3 to 4 hours.

Fine Vacuum:
24 | P a g e

At the stage when autoclave is fully evacuated from residual solvent, T/F oil and pressure
reduces to 5mbar, the fine vacuum is started. In the phase of fine vacuum, any leftover moisture
and solvent vapors absorbed in insulation is dried up that makes the insulation completely dry.
This process takes about 28 to 38 hours to achieve the 0.25mbar.

Aeration:

When vacuum attains the level of 0.25mbar and mean object temperature reach to 115C, the T/F
is ready to be pulled out from the V.P.D. for opening the autoclave the inside pressure is
increased from 0.25mbar to 960mbar that s called aeration. At this point the door of autoclave is
opened and T/F is picked up by crane.

8 DE-HYDRATION PLANT
The first major function done on the T/F is to de-tank the oil from the transformer and shift in the
plant. Hydro carbon mineral oil uses in the transformer for cooling and insulation purpose. This
oil continuously rotates in the tank and radiator tubes. Radiator tubes transfer the temperature in
the air. With the passage of time strength and quality of oil reduces which decrease the efficiency
of T/F. impurities and moisture add in the oil with its age. We have to purify this oil. Three
different processes perform on this plant:

Shifting
Heating
De-hydration

It depends on our requirement either we want to shift the oil from T/F tank to the storage tank, or
we just want to heat the oil mostly oil filling is done on C temperature. We can also De-hydrate
the oil in this plant.

8.1 Main parts of De-hydration Plant:

1 Inlet pump
2 Mechanical boaster
3 Heater
4 Storage chamber
5 Filters
6 Vacuum chamber
7 Outlet pump

8.2 Steps of De-hydration:

1 Heating
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2 Filtration
3 Vacuum

Oil enters through inlet pump and heat with the help of heater. New oil heats till 65C and old oil
heats till 75C depends on the condition of oil. Now the oil is being stayed for a while in the
storage chamber. Now the oil is filtered in the filtration section. Oil is completely filtered from
all the impurities then it is being transferred to vacuum chamber. Moisture is removed by
vacuum process and this moisture knocks out in the atmosphere.

Two plants are available in the PTESU, one has capacity of 10,000liters/hour and second has
capacity of 5,000liters/hour.

Specification of each plant is given below:

Plant of capacity 10,000liters/hour Plant of capacity 5,000liters/hour

Heater Heaters
40kw/hour 80kw/hour
Bore of inlet/outlet Operating temperature 20 to
75mm 40C
Evacuation capacity Mechanical boaster
1000m3/min 600m3/hour
Operating temperature 20 to Operating vacuum 0.5
50C Torr
Discharge pressure Filter pressure
7kg/cm2 3kg/cm2
Power supply 4W, Electric supply
415/240V 400V
Power for oil pump 10 Vacuum pump capacity
kw*2 500L/M
Power for vacuum pump 3.7kw----- Weight
3.7kw 2800kg

9 WINDING SECTION
9.1 Activities in winding section
9.1.1 Un-coiling
There are horizontal and vertical windings machines are available for the uncoiling of the
winding. An empty reel is put on the horizontal winding machine and winding which is lifted by
the crane. Then copper the copper from the winding is connected to the empty reel. After that, we
26 | P a g e

turn on the winding machine and the process of uncoiling started. For different types of winding
we have to decide whether to start from the top of the winding or from the bottom of the
winding, e.g. in helical winding we start from the top but in disc winding we start from the
bottom. We also have to cut the risers from the winding before we start the uncoiling process.
While the uncoiling is in process, we have to cut the copper from every transpose. Most of the
copper from the uncoiling can be re-used by putting new insulation on it because copper doesnt
get damage, it is the insulation or the shape of the winding which gets damage in case of fault.
The pictorial presentation of the uncoiling process is shown in figure

9.1.2 Paper Wrapping

Paper wrapping machine is capable of wrapping different thickness of the insulation paper on the
copper. The thickness of the insulation depends upon the winding design. We put the insulation
paper reels in the paper wrapping machines according to the thickness we required. The different
sections of paper wrapping machine is capable of wrapping different thicknesses and we can
have several combinations to achieve the same thickness. The Wreels of the copper are installed
on one end of the paper wrapping machine and we get the new insulated copper on the other end
where we collect it in another empty reel. There is a worker who is responsible to remove the old
insulation paper through a cutter. Several joints are made through welding of the copper. The
images below in figure shows the paper wrapping process.

9.1.3 Re-coiling
Before we start the re-coiling process, we make the cylinder and axial strips for the winding on
which the copper will be winded. We also bend the copper and make riser that will be use for the
connecting the winding. Figure shows the bending of the copper. Vertical and horizontal winding
machines are used for re-coiling purposes. There is a reel stand which is use to hold reels of the
copper. We also arrange the copper conductor in a holder to make the winding process easier.
The number of reels depends upon the number of conductors require in the winding. The
transpose of the conductors are done by cutting and welding process. Simply when we have to
transpose, we cut the copper and then move that reel on the top position and with the help of a
bend connecter we connect the bottom layer with the top layer. The process is shown in figures

9.2 Types of windings by construction

When considering concentric windings, it is generally understood that circular windings have
inherently higher mechanical strength than rectangular windings, whereas rectangular coils can
have lower associated material and labor costs. Rectangular windings permit a more efficient use
of space, but their use is limited to small power transformers and the lower range of medium-
power transformers, where the internal forces are not extremely high. As the rating increases, the
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forces significantly increase, and there is need for added strength in the windings, so circular
coils, or shell-form construction, are used.

9.2.1 Pancake Windings

Several types of windings are commonly referred to as pancake windings due to the
arrangement of conductors into discs. However, the term most often refers to a coil type that is
used almost exclusively in shell-form transformers. The conductors are wound around a
rectangular form, with the widest face of the conductor oriented either horizontally or vertically.
Figure illustrates how these coils are typically wound. This type of winding lends itself to the
interleaved arrangement previously discussed

9.2.2 Layer (Barrel) Windings

Layer (barrel) windings are among the simplest of windings in that the insulated conductors are
wound directly next to each other around the cylinder and spacers. Several layers can be wound
on top of one another, with the layers separated by solid insulation, ducts, or a combination.
Several strands can be wound in parallel if the current magnitude so dictates. Variations of this
winding are often used for applications such as tap windings used in load-tap-changing (LTC)
transformers and for tertiary windings used for, among other things, third-harmonic suppression.

9.2.3 Helical Windings

Helical windings are also referred to as screw or spiral windings, with each term accurately
characterizing the coils construction. A helical winding consists of a few to more than 100
insulated strands wound in parallel continuously along the length of the cylinder, with spacers
inserted between adjacent turns or discs and suitable transpositions included to minimize
circulating currents between parallel strands. The manner of construction is such that the coil
28 | P a g e

resembles a corkscrew. Figure shows a helical winding during the winding process. Helical
windings are used for the higher-current applications frequently encountered in the lower-voltage
classes. There are number of transposes in helical winding which are one less than the number of
conductors so all the conductor is have a round in all the layers. Transposes are necessary to
maintain the length of the all the conductor.

9.2.4 Disc Windings

A disc winding can involve a single strand or several strands of insulated conductors wound in a
series of parallel discs of horizontal orientation, with the discs connected at either the inside or
outside as a crossover point. Each disc comprises multiple turns wound over other turns, with the
crossovers alternating between inside and outside. Typical crossovers during the winding
process. Most windings of 25-kV class and above used in core form transformers are disc type.
Given the high voltages involved in test and operation, particular attention is required to avoid
high stresses between discs and turns near the end of the winding when subjected to transient
voltage surges. Numerous techniques have been developed to ensure an acceptable voltage
distribution along the winding under these conditions

10TAP CHANGER
On-load tap changers (or circuit tap changers), as the name suggests, permit tap changing and
hence voltage regulation with the transformer on-load. Tap changing is usually done on the HV
winding because the currents are lower, the tap changer contacts, leads, etc., can be smaller.
Secondly, as the HV winding is wound outside the LV winding, it is easier to get the tapping
connections out to the tap changer.

10.1Accessories of Tap Changer

10.1.1 Selector Switches

These switches select the physical tap position on the transformer winding and, because of their
construction, cannot and must not make or break the load current.

10.1.2 Reactors
The load current must never be interrupted during a tap change. Therefore, during each tap
change, there is an interval where two voltage taps are spanned. Reactors (inductors) are used in
the circuit to increase the impedance of the selector circuit and limit the amount of current
circulating due to this voltage difference. Under normal load conditions, equal load current flows
in both halves of the reactor windings and the fluxes balance out giving no resultant flux in the
29 | P a g e

core. With no flux, there is no inductance and, therefore, no voltage drop due to inductance.
There will be however, a very small voltage drop due to resistance. During the tap change, the
selector switches are selected to different taps and a circulating current will flow in the reactor
circuit. This circulating current will create a flux and the resulting inductive reactance will limit
the flow of circulating current.

10.1.3 Vacuum Switch

This device performs the duty of a circuit breaker that makes and breaks current during the tap
changing sequence.

10.1.4 Bypass Switch

This switch operates during the tap changing sequence but, at no time, does it make or break load
current, though it does make before break each connection.

10.2Operating Mechanism
The operating mechanism for the on-load tap changer is motor driven. Manual operation is used
in the event of motor failure. The sequence of operation is mechanically linked, or interlocked, to
ensure that all contacts always operate in their correct order. Any failure of the operating
mechanism can result in severe damage to the transformers and tap changers.

1. Present position tap changer selected to tap 1, bypass switch in, A + B, home position.
2. Bypass switch selects lower circuit arm.
3. Vacuum switch opens, removing load current from upper circuit arm freeing one half of
selector switch for move.
4. As there is no load current on upper arm of selector switch, it moves to tap 2.
5. Vacuum switch closes both selector switches onload, circulating current is limited by
reactors.
6. Bypass switch selects upper arm circuit arm. No arcing occurs as vacuum switch is closed
and in parallel.
7. Vacuum switch opens, removing load current from lower circuit arm, freeing lower selector
switch for move.
8. As there is no load current on lower arm of selector switch, it moves to tap 2.
9. Vacuum switch closes both selector switches onload, in parallel, on tap 2.
10. With vacuum switch closed and selector switch on a single tap, the bypass switch can now
return to its home position. Both reactor circuits stay normally in parallel. The tap change is
now complete.

11 OIL TESTING
In the oil testing, it is necessary that we wash all the containers and measuring instruments that
30 | P a g e

are being used, three times with the sample so there is no contamination of previous samples

11.1 Tangent Delta Test

Purpose: To investigate leakage current in the insulation oil as it is associated with losses and to
check the resistance of the insulation oil.

Importance: If the losses in insulation is high because of high resistivity, there is higher wastage
of power as well as higher chances of electrical fault in the transformer.

Procedure: Tettex Instrument is use in this experiment. The test chamber is heated up to 90
degrees Celsius in the temperature control unit. 40ml sample is inserted in the cell and again
heated until temperature reaches 90 degree Celsius. Apply 1-KV supply from the power unit and
then turn on the null indicator and null set. The instrument will then calculate the Tangent Delta
Value and resistivity of the oil. Both positive and negative resistivity is taken in this test

Passing Criteria: The resistivity and the tangent delta value is compared with the application
standard which are IEC60296 and IEC60422 which is as follows

New Oil Tangent Delta (%) Oil in service Tangent Delta (%)
Drums <0.005 500 and 220KV <0.20
Transformer <0.015 132 and 66KV <0.50

11.2 Interfacial Tension Test

Purpose: To investigate the attractive force between the water and the oil. .

Importance: If the IFT level is high, the rate at that water will be dissolved in the oil will be
higher and hence risking of having a water acting as an electric bridge between two active
components will be higher.

Procedure: The instrument has a platinum ring and a measuring scale which measures the
measures the force in dyne/Cm. First we put 20ml distilled water and calibrate the instrument.
Insert the ring inside the water. After that we slowly apply force and try to pull the ring. Once
there is enough force, the platinum ring comes out of the water surface. The value of calibration
should be in range of 71 to 74 dyne/Cm. After than we put 20ml sample of the oil and similarly
measures the force require by the platinum ring to come out of the water surface.

Passing Criteria: IFT value should be greater than 28 dyne/Cm.

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11.3 Dielectric Strength Test

Purpose: To investigate the voltage at which the oil electricity breaks down.

Importance: To make sure that insulation oil can bear voltages to a certain extend before its
electricity breaks down and causes the faults

Procedure: MEGGER FOSTER OTS100AF/2 instrument is use in this experiment. There are
two electrodes in this instrument and we insert 0.5mm oil between them. Then when we turn on
the instrument, there is voltage in one of these electrodes and the oil insulation between the
electrodes prevents any flow of current between the electrodes. The voltage level increases
automatically after certain period of time. Test takes 10 minutes to complete the test and takes 6
readings of voltage at which oil allows the passage of electricity. IEC156-1995 is the test method

Passing Criteria: Application standard and break down limits are as follows

IEC 60296 (New Oil) Limit (KV) IEC 60422 (Oil in Service) Limit (KV)
Drums > 30 500 and 220 KV > 60
Transformer > 60 132 and 66KV > 50

11.4 Acidity Test

Purpose: To measure the acidity level of the transformer oil.

Importance: Increase in acidity indicate the insulation degradation and formation of sludge as
well. Higher acidity results in higher rate of chemical reaction of oil and oxygen or oil with other
components. Acid also results in breaking and weakening of the molecular chain in the oil,
therefore, it is necessary to keep the acidity level at check

Procedure: Put taurine 60ml, ethanol 60ml in a breaker or any other container. Then neutralize
this by adding potassium hydroxide (alkyne blue, KOH). Note the value in ml of the amount of
KOH added. Then add 20ml sample and again neutralize the solution with KOH. Again measure
the amount if KOH added in ml. add both the value then multiply with 56.1 and divide by the
weight of the solution

Passing Criteria:

IEC 60296 (New Oil) Acidity (mg KOH/g) IEC 60422 (Oil in Acidity (mg KOH/g)
Service)
Drums <0.01 500 and 220 KV <0.15
Transformer <0.03 132 and 66KV <0.20
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11.5 Flash Point Test

Purpose: To measure the fire catching temperature or flash point of the transformer.

Importance: If transformer oil catches the fire, it can severely damage the transformer.
Therefore, it is necessary to check the transformer doesnt catch fire at low temperature

Procedure: BS-2 Flash Point Tester uses Method ASTM D93 to do the flash point. After turning
on the instrument we set up the temperature at which the instrument should start testing the flash
point and the temperature increase 1 degree Celsius at a time. After the set temperature is
reached, LPG valve is opened and flame is set at about 4mm. The instrument try to ignite the oil
as the temperature increases and note the temperature at which oil flashes

Passing Criteria: Standard IEC 60422 is used and acceptable limit is greater than 135 degree
Celsius

11.6 Viscosity Test

Purpose: To measure the viscosity of transformer oil i.e. its ability to flow.

Importance: Higher Viscosity will result in slow movement of oil and thus the oil will not be
able to dissipate heat at the required level.

Procedure: Test method IEC60422/ASTM-D455/ISO-3104 is used. Turn on the YN-5 Kinematic

Viscosity Meter and set the temperature at 40 degree Celsius and rooter speed at 1000 RPM. Add
sample in the test tube and leave it for 15 minutes. After that with the help of suction pump, suck
the oil so it reaches the top point in the vessel which is named as A. Turn on the timer and note
the time it takes to reaches bottom point which is B. The time taken should be in seconds and
multiply it by the factor of the vessel which is 2.7xx

Passing Criteria: Application Standard IEC 60296 state the limit as less than 12.0 mm 2/s at 40
degree Celsius

11.7 Moisture Content Test

Purpose: To measure the water content in the transformer oil.

Importance: Any increase in moisture content can reduce the insulating properties of the oil.

Procedure: MEGGER NF 875 Mart Fisher Test Set is use in this experiment. After turning on,
give some time to the instrument to get ready and once it is ready add the sample oil and press
start. The moisture content will automatically be measured
33 | P a g e

Passing Criteria:

IEC 60296 (New Oil) Moisture Content IEC 60422 (Oil in Moisture Content
(mg /kg) Service) (mg /kg)
Drums <0.01 500 and 220 KV <0.15
Transformer <0.03 132 and 66KV <0.20

12 FINAL TESTING
12.1Short Circuit Test
Purpose: The value of the short circuit impedance Z% and the load (copper) losses (I 2R) are
obtained in this test.

Importance: If the losses are high then there is wastage of power. Additionally, it also shows the
performance of the insulation at high voltages.

Procedure: Suitable Low AC Voltage (3-phase 415V, 50/60Hz) will be applied to the terminals
of one winding (usually the H.V.) with the other winding short circuited with cable. (Usually the
L.V.) The applied voltage is adjusted to pass the needed current in the primary/secondary. In
order to simulate conditions nearest to full load, it is customary to pass 100%, 50% or at least
25% of full load current. Voltage to be increased gradually till the current in the energized
winding reaches the required value (50% to 100% rated current).

Measure the 3 Phase line currents at all tap position. If the tap-switch is an Off-Circuit tap-
switch, the supply has to be disconnected before changing the tap. A consistent trend in the
increase or decrease of current, as the case may be, confirms the healthiness of the transformer.

Three phase LT supply is applied on HV side of power transformer at normal tap with rated
current on HV side and currents measured in all the phases on HV side and phases & neutral on
LV side values noted. Readings to be taken as quickly as possible as the windings warm up and
the winding resistance increases. Hence, the losses value will increase accordingly.

Passing Criteria: Firstly there should be a symmetry between the values from the middle tap
position in all the phases. Secondly, there shouldnt be high differences between the current
values of different phases. The unbalancing between the phases results in neutral current, which
should be less than 1A, otherwise the losses will be too high. The current values and I 2R should
not be more than specified by the manufacturer.
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12.2No-load losses
Purpose: In this test, the value of the No-Load current (Io) are measured at rated voltage &
frequency to measure the no-load losses of the transformer

Importance: No-load losses allow us to investigate about the core losses of the transformer. The
previous test tell us about the losses in the winding and insulation of the transformer

Procedure: Test is performed at rated frequency. The supply is given to the LV side of the
transformer and the HV side is open. Voltage applied to winding (usually to L.V. windings), it
will be in a range from 90% of winding rated voltage to 110% of the same in steps, each of 5%
Readings. For all the readings we measure the current and voltages value and then using the
previous resistance values, we calculate the loses of the transformer

.Passing Criteria: The current readings and the calculated loses should be lower than the
specified values of the manufacturer.

12.3Induced Test (Insulation Test)

Purpose: The aim of this test is to check the insulation both between phases and between turns
of the windings and also the insulation between the input terminals of the graded insulation
windings and earth

Importance: It investigate strength of the transformer insulation at the rated voltage and check
all types of insulation in details, so, it is an extremely important test as the working of the
transformer depends upon the health of insulation. If insulation is weak, there is more and more
chances of the faults.

Procedure: During test, normally the test voltage is applied to the low voltage winding.
Meanwhile HV windings should be keeping open and earthed from a common point. Since the
test voltage will be much higher than the transformers rated voltage, the test frequency should
not be less than twice the rated frequency value, in order to avoid oversaturation of the
transformer core.

The test shall start with a voltage lower than 1/3 the full test voltage and it shall be quickly
increased up to desired value. Test period which should not be less than 15 seconds. It is
calculated according to the equation

Test period=120 seconds x ( Rated frequency / Test frequency )

The duration of the test shall be 60 second so we adjust the frequency according to that.
35 | P a g e

.Passing Criteria: The test is accepted to be successful if no surges, voltage collapses or extreme
increases in the current have occurred. The test is successful if no break down occurs at full test
voltage during tes

12.4High Voltage Test

Purpose: To check the performance and tolerance of the transformer in case of voltages higher
than the rated voltages.

Importance: There are chances in the field that the voltage exceeds from the rated voltage due to
any faults in the supply of the transformer, so, it is important to check whether transformer will
be able to withstand such situation or not

Procedure: HV high voltage test: LV winding connected together and earthed. HV winding
connected together and given the double frequency and double rated voltage at HV Side for 1
minute. LV high Voltage test: HV winding connected together and earthed. LV winding
connected together and given the double frequency and double rated voltage at HV Side for 1
minute.

.Passing Criteria: The transformer should withstand the high voltages to pass the test. The
leakage current is also measured and compared with previous values or manufactured specified
values for high voltage test and it shouldnt be more than that.

12.5Sweep Frequency Response Analyzer

Purpose: Sweep Frequency Response Analysis Test or in short SFRA Test can detect efficiently,
displacement of transformer core, deformation and displacement of winding, faulty core grounds,
collapse of partial winding, broken or loosen clamp connections, short circuited turns, open
winding conditions etc.

Importance: This is very reliable and sensitive method or tool for condition monitoring of the
physical condition of transformer windings. The winding of transformer may be subjected to
mechanical stresses during transportation, heavy short circuit faults, transient switching impulses
and lightening impulses etc. These mechanical stresses may cause displacement of transformer
windings from their position and may also cause deformation of these windings. Windings
collapse in extreme cases, such physical defects eventually lead to insulation failure or dielectric
faults in the windings.

Procedure: In most cases the resistance, inductance and capacitance of an equipment have non
zero values. Hence most of the electrical equipments can be considered as RLC circuit hence
they response to the sweep frequencies and produce a unique signature. As in a transformer each
36 | P a g e

winding turn is separated from other by paper insulation which acts as dielectric and windings
themselves have inductance and resistance, a transformer can be considered as a complicated
distributed network of resistance, inductance, and capacitance or in other words a transformer is
a complicated RLC circuit. In Sweep Frequency Response Analysis a sinusoidal voltage Vi is
applied to one end of a winding and output voltage Vo is measured at the other end of the
winding. Other windings are kept open. As the winding is itself a distributed RLC circuit it will
behave like RLC filter and gives different output voltages at different frequencies. If we plot
these output voltages against the corresponding frequencies we will get a particular pattern for a
particular winding. These patterns are compared with the earlier patterns when the transformer
was newly built.

Passing Criteria: After transportation, heavy short circuit faults, transient switching impulses
and lightening impulses etc. if we do same Sweep Frequency Response Analysis test and
superimpose the present signature with the earlier patterns and observe some deviation between
these two graphs, we can assess that there is mechanical displacement and deformation occurred
in the winding.
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13 RECOMMENDEDATIONS
S RECOMMENDED IMPROVEMENT REMARKS
R
PROJECT MANAGEMENT TOOL AND TECHNIQUES
It is understood that PTESU concerns with the repair work and direct
imsplementation of project management techniques are not required but with the
help of management tools we can enhance the performance of the workshop.
The most important factor that determines an industry performance is the
production and maximum production in an industry is possible when the
management utilize all of the working time. Another important reason that we
should increase our repair work is that there are various damaged transformers
that have not been shifted to workshop for repair due to lack of space.
1 Scheduling and deadlines
The speed of the repair work can be increased through proper time management
and scheduling. There is an element of leniency in amount of work completed
on daily basis that leads to employers not working at their best. It results in extra
time taken on each process in a repair work. The problem behind this is,
although, the division of repair work into small tasks such as dismantling the
transformer is divided into un-tanking, removing of top, disconnecting tap
changer etc. has been practiced, but workers has not been given any specific
deadlines for these small tasks. For instance, the assembling of core of Siemens
transformer has started almost 2 weeks ago, but no deadline is given to workers
that when it should be finished. There are very minimum chances that there
would be any complications would occur during this process but still the
approximate time to finish the core has not been specified. Similarly, the
dismantling of another Siemens transformer is in process and the transformer
was un-tanked on 7th February. From the next day, the process of extracting the
B-phase winding is in process and no planning is implemented i.e. the specific
deadlines for different tasks involving this process are not mentioned and we
dont have an idea when the inspection of the B-phase winding would be
completed.
Therefore it is recommended that once we un-tank and inspect the transformer
and have an idea about the necessary repair work, we make a schedule in which
the repair work should be carried out. If we plan our repair projects well and
know when a certain transformer work is finishing, we can plan our next project
more precisely and without wastage of time. For example, if a transformer is
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finishing in next two weeks, we can plan the transport of it pre-hand and another
damaged transformer can be shifted to workshop and checking of their
2 accessories can be done within these two weeks, thus, saving time
Making teams with team leaders
Another factor that causes reduced speed in repair work is the rotation of
workers from one transformer to another on the daily basis especially in the
repair section where dismantling and assembling of the transformer is done.
When we have a different worker on a transformer almost every day, obviously
he will take time to understand the design of the transformer and work which is
going on and hence take longer time then the worker who was working on it
before. It is understandable that absence of people on certain days force us to
rotate the workers to keep the working going, however, most of the time we
have availability of all the workers. Thus, we should first have different teams
for different transformers in the repair section. All the teams should have a team
leader who would be responsible to carry out the work according to the given
schedule. Same teams should be responsible for dismantling the transformer and
assembling of transformer once the repair work is finished. In this case, the
planning, scheduling and meeting deadlines will be more important to make
sure that all the teams are on certain repair work every day.
3 RENT ON KEEPING THE REPAIRED TRANSFORMERS IN THE
WORKSHOP
It has been observed that quite a few transformers work has been completed but
not shifted to the customer. Such transformers are hurdle in repairs of other
transformer as they acquire space which could be used to repair some other
transformer
Thus, there should be strict regulations on the amount of time PTESU will wait
for joint inspection or dispatching of repaired transformer and in case companies
want extra time before they shift their repair transformer, there should be extra
charge for it per day. Secondly, There should be a separate place where all such
repaired transformers should be kept so they are not a hurdle in next projects.
4 INTRODUCING NEW TESTS FOR OIL TESTING
There is various equipment available in the PTESU oil testing laboratory for
quite a few different tests but still we dont have the facilities to perform all the
tests on transformer oil. There are numerous companies that are sending their oil
samples in PTESU and increasing the oil testing facilities will be helpful in
increasing the reputation and profits of the company in upcoming years. The
important tests facilities that can be added along with its application standard
and significance is as follows:
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1) Furan Analysis - IEC61198

This test determines the contents of insulation paper in the oil of the
transformer. It is an important test which can be helpful in determining the
condition of the paper insulation of windings etc. and hence can be helpful
in suggesting the companies about the actions that can be taken to avoid any
damages to the transformer.

2) Metal contamination test IEC60666

Metal contamination test is as important as moisture content test. Just as
moisture, metal contaminates in oil can also act as a bridge and can be cause
of electric flow. Hence, it reduces the performance of the insulation oil and
increases the risk of faults inside the transformer.
5 PROVIDING TRAINING OF OXIDATION STABILITY TEST
Oxidation stability test is an extremely important test in determining the quality
and health of the oil of the transformer. It helps us in determining the amount of
sledge which is being built in the transformer over a period of time. Despite we
have the equipment and facilities to do oxidation stability test, we are not
performing it due to lack of training and laboratory staff to operate the test after
hours as this test takes around 164 hours or 500 hours. Instead of wasting the
equipment we should use it by providing training of this test to the workers and
organizing workers that can supervise the test after hours as well.
6 INCREASE SPACE OF VPD
The VPD installed in the PTESU workshop is limited for the transformers with
the size of 7500mm by 3500mm by 4500mm. Now a days, there are various
transformers that are bigger in size and in the past as well, there were couple of
occasions when we had to transfer the transformer to other company for VPD.
Secondly, It is only one chamber VPD which can hold maximum 2 transformers
at a time. It is also observed that PEL is regularly sending transformers at urgent
basis for VPD which results in delays in VPD of our repaired transformers
because of the capacity issues. Keeping these matters in mind, it is advised that
VPD capacity should be increased. Not only the dimension but also a dual
chamber system should be installed to increase the efficiency and reduce the
timing of VPD process.
7 PROPER MAINTENACE OF VPD
Over the years, the efficiency of VPD is decreasing due to lack of maintenance.
To achieve the targets, we are operating VPD at higher temperature and
sometimes the process takes longer than expected. First of all, we dont attend
any minor problem in VPD in urgency, for instance, one of the pumps in VPD is
making noise and the supervisor has already informed the authorities in the last
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report about the issue. However, nothing has been done or decided about it and
it is effecting the life and performance of the VPD and this minor problem can
become a major problem in a while. Secondly, VPD plants require major
maintenance service every 5 or 10 years depending upon the plant. PTESU
hasnt organized any major maintenance for its VPD plant from the time it was
installed that was 11 to 12 years ago. Unfortunately, there is no planned major
maintenance for VPD as well. Therefore, PTESU should understand the
importance of the maintenance of VPD plant and there should be scheduled
minor and major service of the VPD plant. There should be urgency in fixing
any minor issues in VPD plant so its life span can be increased.
Through research, I also came to know that VPD plants should be under dust-
proof environment to enhance its life and performance but in PTESU the VPD
plant is inside the repair section. The dirt and humidity in the air are effecting
the performance of the VPD and also decreasing its life span.
8 FORKLIFT
Surprisingly, we dont have a forklift in the workshop and it is a big problem in
moving the heavy objects. Sometimes we have to shift the heavy objects such as
windings, tap changers etc. and we dont have a forklift for this purpose. In the
winding section we have to move reel stand with the help of 4 to 5 workers;
similarly, the movement of the transformer on the track is only possible by
pushing with the help of 8 to 10 workers. It is a hazard for the workers and this
practice should be stopped. Therefore, it is recommended to purchase a forklift
as soon as possible.
9 INSTALLATION OF CRANE OUTSIDE THE REPAIR SECTION
Outside the repair section, we only have a track for the movement of
transformers. On this track we have either transformers or bodies of
transformers which are several in numbers. For instance, if we have to move the
body of a transformer in the repair section for assembling which is right at the
end of the track, we have to move all the other bodies or transformer from the
track to the repair section, only then we can lift the required body. Then again
we have to move back all the other transformers or bodies. The whole process
can take a whole week sometimes. Due to which, it is recommended to install a
crane outside the repair section. Now a days, there are cranes available which
can be supported by the poles and doesnt require the support of walls. There is
an option of terrain crane as well which is also capable of lifting 200tons or
more. Such cranes can be installed outside.
10 DUST-PROOF WINDING SECTION
All over the world, all the transformer repairing and manufacturing companies
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emphasis on having dust-proof winding section to minimize any impurities and

moisture in the insulation of the windings. Thus, to increase the quality and life
span of the repaired transformers it is necessary that PTESU should make the
winding section dust-proof to minimize the addition of impurities during
winding process
11 ORGANISATION AND MAINTENANCE OF TAP CAHNGER
ACCESSORIES & PARTS
The accessories and parts of the tap changer are kept randomly in a room
without any arrangement or organization. I am sorry to say but the room looks
more like a wreckers storage area, not a storage place for tap changer
accessories. No care and maintenance towards these accessories and parts are
provided and hence some of them are useless now and others are rusting. Due to
these reasons, there should be a proper organization and maintenance policy of
such accessories and parts
12 SEPARATE AREA FOR TAP CHANGER REPAIRS
Normally, in PTESU, any faults in the tap changer are deal by the testing
department. There is a room next to the oil laboratory where all the tap changer
accessories are kept. However, the room is small and doesnt have any facilities
of lifting the tap changer via crane. So, some of the tap changer repairs are done
in the repair section which is sometimes disturbing the other work in the repair
section. Moreover, workers in testing department are always moving accessories
of tap changers from and to the repair section. Thus, it would be better to have a
separate area for tap changer repairs where they have the facilities of lifting and
moving the tap changer via machinery and also space for the storage of
accessories of tap changer

SAFTEY MEASUREMENT FOR WORKERS

Workers safety should be number one priority of an organization and
unfortunately, PTESU lacks both in the safety equipment and safety
arrangements.
13 Fire proof and shock proof gloves
First of all, there should be electric shock proof available for the workers. While
performing different tests on a transformer, foreman and helpers have to do
connect the transformer to the electrical system. Although, the electrical system
is off at that moment, but it is still recommended that shockproof gloves are use.
Similarly, during the short-circuit test, we short-circuit the A, B and C phase of
the LV side and then take the test inspector take current readings while standing
on the top of transformer via connecting the clump meter on the wires used to
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short circuit the phases. It is a dangerous way of testing and appropriate safety
measure should be taken.
Likewise, fire gloves are required for the workers who perform the welding of
the copper and there should be strict rules of keeping a working fire extinguisher
near the welding process.
14 Helmets, harnessing and stable ladders
There should be strict regulations on wearing the helmets in the repair section to
avoid injuries. There should also be arrangement of harness for people who
work on certain height to perform various dismantling or repair activities.
Workers in PTESU do various activities while standing on the platform ladder,
drums or on the top of transformer without having any helmets or harness which
is extremely dangerous. Lastly, the platform ladders which are in use are not
stable and needs to be changed or repaired for the safety of workers.
15 WORKSHOPS & TRANINGS TO ENCHANCE KNOWLEDGE OF
WORKERS
There are several workers in the workshop who has the practical experience in
working in the transformer workshop but dont have the higher qualifications,
especially, the helpers. To increase the quality of production, reduce errors and
to decrease the burden on senior workers we should enhance the knowledge of
our workers by organizing regular training sessions about the transformers, its
structure, accessories and importance of each of them. We can also organize
workshops to discuss the new technologies and improvements that have been
introduced in the fields of power transformers in recent years.
16 RENOVATION
The overall condition and environment of the PTESU workshop is like an
abandoned house. In repair section the floor is broken; the glass of various
windows are smashed both in repair and winding section. There is an urgent
need of repainting the whole workshop.
Appearance and presentation is extremely important for such a highly rated
organization. If we want to meet the standards of international organization we
have to focus on such issues of the workshop.
17 RELOCATING THE DUST-PROOF ROOM
There is a dust-proof room in the repair section which was built for the repairs
of transformer which are extremely sensitive to dust and moisture. The problem
is the location of the room, it is in the middle of the left hand side wall of the
repair section. It reduces the effective working space sometimes disturb the
work because of its location. It would be better if it is relocated in the one of the
corners of the repair section and it would not be difficult if it is done during the
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renovation work
18 BETTER WORK ENVIORNMENT FOR BETTER EFFICENCY
Sadly, workers in PTESU are not working in suitable work environment most of
the times. It has been observed that, there are very few fans in the workshop and
even they are old and doesnt work properly which forces the employees to
work in hot environment in summer. No proper lighting arrangements are in
place to work properly in cloudy weather or at night when there is no sunlight
Sorry to say, even we dont have clean and working coolers for drinking water.
How we can expect that the staff would work at their maximum abilities in these
kind of work conditions.
Furthermore, No facilities are available to heat up the food in the workshop.
There is neither a sitting arrangement, nor a cafeteria for the staff. The staff is
unhappy because of these issues and nothing has been done. The staff is not
sincere to the workshop. They think when the authorities are not sincere for us
and dont take any steps to improve our working condition, why should they
perform at their best and sincerely? Therefore, these issues should be resolved
as soon as possible.
FUTURE PLANS
19 Production of new transformers
20 Core Section
21 Marketing Department
22 Advertisement and Website

14COMPARISON OF FURAN ANALYSIS WITH

OTHER TRANSFORMER OIL TESTS
Tangent Delta Test and Dielectric test are concerned with electric properties of the transformer
oil while furan analysis concerns with chemical properties of transformer oil.

Viscosity, IFT and Flash point are concerned with physical characteristics of transformer oil,
therefore, cant be compared with furan analysis.

Moisture Content Analysis measures the amount of water particles in oil that can act as an
electric bridge between the active parts of transformer, while, furan analysis measures the
degradation on insulation paper

Furan Analysis Dissolved Gas Analysis

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As the cellulose chain in the insulation
breakdown furans are released into the oil and
this analysis measures the quantity of these
furans in the transformer oil
Furans are a direct indication of the rate of
degradation of the paper insulation within the
windings of the transformer.
Five most prevalent derivatives of furan that
also arises from the degradation of the
cellulose and that are soluble in the oil to an
appreciable degree are the following: 2-
Furaldehyde, Furfuryl alcohol, 2-Acetylfuran,
5-Methyl-2-furaldehyde, and 5-
Hydroxymethyl-2-furaldehyde
High amount of furans in the transformer oil
doesnt mean that the oil of the transformer
needs to be changed but instead it means that
the paper insulation of the between windings
or other active parts need to be changed
The DGA test measures various gas ppm
levels that are present.
Different gasses will dissolve in the oil that
indicate various types of thermal and
electrical stress occurring within the
transformer by testing the condition of
transformer oil.
Normally, Insulation overheating, oil
overheating, Corona and arcing are the type
of faults indicated by this test
Due to faults that is happening inside the
transformer heat will be formed and due to
this energy the long organic oil chain is
getting broken. As a result so many gases is
formed such as CO2, C2H4, C2H2, C2H6, C3H6,
C3H8, CH4, CO, H2, O2, N2 etc. The analyzing
of these gases is a good indication of
transformer oil insulation health
High amount of gases in the transformer oil
indicates that transformer oil needs are not
providing enough protection and require to be
changed.

Furan Analysis Acidity Test

Furan Analysis measures the exact quantity of This test indicates the level of acidity in the
furans present in the transformer oil. Furans transformer oil. The specific acidic
are not acidic components are not analyzed in this test, only
the overall acidity is measured.
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15COMPARISON OF METAL CONTAMINATION

TEST WITH OTHER TRANSFORMER OIL
TESTS
Tangent Delta Test and Dielectric test are concerned with electric properties of the transformer
oil while metal contamination test concerns with chemical properties of transformer oil.

Viscosity, IFT and Flash point are concerned with physical characteristics of transformer oil,
therefore, cant be compared with metal contamination test.

Moisture Content Analysis measures the amount of water particles in oil that can act as an
electric bridge between the active parts of transformer, while, metal contamination test measures
the metal contents such as copper, zinc, iron, aluminum in the transformer oil.

Metals are not acidic in nature, so their present in the transformer oil cant be analyzed with
acidic test

The analysis of gases in the transformer oil through DGA cant be use in indicating the level of
metals present in the transformer oil.