INDUSTRIAL TRAINING REPORT 2019-20

CONTENT
CHAPTER 1: INTRODUCTION
1.1 COMPANY PROFILE
1.2 GENERAL INFORMATION
1.3 ABOUT TRANSFORMER
I. TYPES
II. PARTS
CHAPTER 2: PURPOSE OF VISIT
CHAPTER 3: COMPANY PRODUCTION
3.1 LV WINDING
3.2 HV WINDING
3.3 MANUFACTURING PROCESS
CHAPTER 4: EQUIPMENT DETAILS
4.1 LV WINDING MACHINE
4.2 HV WINDING MACHINE
4.3 OVEN
4.4 MEGGER
4.5 TENSIONER
CHAPTER 5: TYPE OF TESTS
5.1 OPEN CIRCUIT
5.2SHORT CIRCUIT

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CHAPTER 6: OUTCOME
CHAPTER 7: SUGGESTION
CHAPTER 8: CONCLUSION

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ACKNOWLEDGEMENT

We are gladly & thankful to Director as well as Principal, Dr. R. P. Kulkarni and Head
of the Departments Prof. S. V. Kolambkar and our faculties who give us a great guidance
regarding training and instruct us the importance of training in electrical field. So we decided to
take Training in Shree Dhananjay Electrical.

We are especially thankful to respected owner of this unit because they granted us
permission for taking visit and assistant engineers of this unit who gave the proper guidance to us
and gave practical based approach learning to us.

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CHAPTER 1:-INTRODUCTION

1.1 COMPANY PROFILE

Fig 1.1 company image

Company Name:-Shree Dhananjay Electricals

Address:-Plot No.W-76 Additional MIDC Kodoli ,Satara,415004, Maharashtra,India
Contact person:-Mr.Rahul Jadhav (Proprietor)
Mobile:-8888241731

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1.2GENERAL INFORMATION

The Shree Dhananjay Electrical is the unit of repair the faulty transformer and test after
repair the transformer.

Generally the transformer working on demand load, but the transformer design on
maximum load. When the Connected load is over the maximum load that time possibility of burned
out of transformer winding is high.

The Unit is replace the burned winding and other burned- out part of transformer and
fill up the transformer fresh oil.

After repair the transformer they perform below tests

I. Open Circuit tests
II. Short Circuit test
III. Turn Ratio Test

Fig1.2 faulty transformers

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1.3ABOUT TRANSFORMER

On 28th may. ,2019 at 10:00 am we reached at shree dhananjay electrical satara.

When We Reached, we saw many distribution transformer are there in faulty condition.

At the beginning the assistant engineer explained general knowledge of Basic

transformer construction and working.

Then learn different parts of transformer like….

1.3.1 Type of Transformer

I. Core type transformer

In core-type transformer, the windings are given to a considerable part of the core. The
coils used for this transformer are form-wound and are of cylindrical type. Such a type of
transformer can be applicable for small sized and large sized transformers. In the small sized type,
the core will be rectangular in shape and the coils used are cylindrical. In the case of circular
cylindrical coils, they have a fair advantage of having good mechanical strength. The cylindrical
coils will have different layers and each layer will be insulated from the other with the help of
materials like paper, cloth, mica board and so on.

II. Shell Type Transformer

In shell-type transformers the core surrounds a considerable portion of the windings. The
coils are form-wound but are multi layer disc type usually wound in the form of pancakes. Paper
is used to insulate the different layers of the multi-layer discs.

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1.3.2Outer Parts Of Transformer

i. Yoke
It is use to protect the transformer inner part to bad environment condition.

ii. Buchholz Relay

It is a very sensitive gas and oil operated instrument which safely detect the information of
gas or sudden pressure inside the oil transformer. It is a electrical and mechanical both type
operated device. Electrical type relay is vary accurate as compare to mechanical type relay.
iii. Conservator Tank
This is a cylindrical tank mounted on supporting structure on the roof of the transformer's main
tank. When transformer is loaded, the temperature of oil increases and consequently the volume
of oil in the transformer gets increased. Again, when ambient temperature is increased, the volume
of oil is also increased. The conservator tank of a transformer provides adequate space for
expansion of oil. Conservator tank of transformer also acts as a reservoir of oil.

iv. Oil Level Indicator

It is used to show the oil level in the transformer.

v. Breather

When the temperature changes occur in transformer insulating oil, the oil expands or
contracts and there an exchange of air also occurs when transformer is fully loaded. When
transformer gets cooled, the oil level goes down and air gets absorbed within. This process is called
breathing and the apparatus that pass through the air is called breather. Actually, silica gel breathers
controls the level of moisture, entering electrical equipment during the change in volume of the
cooling medium and airspace caused by temperature increasing. So it sucks the moisture
from the air which is taken by transformer so that dry air is taken by transformer.

vi. Winding Temperature Indicator

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Used to show the temperature of transformer winding.

vii. Cooling Fans/Radiator

These are used for cooling of the transformer oil. The capacity of the transformer is
dependent to its temperature that is why it is imperative for it to have a cooling mechanism for
better performance and higher efficiency.

viii. System Ground Terminal

System ground terminals in a power transformer are usually present whenever the
connection type of the transformer windings has in it. This terminal can be found in-line with
the main terminals of the transformer
ix. Drain Valve

Can be usually found in the bottom part of the transformer tank. Drain valves are used
whenever oil replacement provides a low reluctance path to the flow of magnetic flux. It is made
up of laminated soft iron core in order to reduce eddy current loss and Hysteresis loss.
The composition of a transformer core depends on such factors as voltage, current, and
frequency. Diameter of the transformer core is directly proportional to copper loss and is inversely
proportion to the iron loss. If diameter of the core is decreased, the weight of the steel in the core
is reduced which leads to less core loss of transformer and the copper loss increase. The vice versa
happen when the diameter is increased.

Generally the core is made by many single strip ( Width 0.5 to 0.6- mm).Because the
eddy current loss. stripe is made up of aluminum and silicon composite material.

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x. Transformer Oil
Transformer oil performs two important functions of insulation as well as cooling for
the core and coil assembly. Core and windings of the transformer must be completely immersed
in the oil. Normally hydrocarbon mineral oils are used as transformer oil

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CHAPTER 2:-PURPOSE OF VISIT

Our main purpose for this visit is to be familiar with industrial environment and to get
practical knowledge of Construction of Transformer, Repairing of Distribution Transformer and
transformer testing. In addition it would help me to decide my final year project on industrial
based.

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CHAPTER 3:-COMPANY PRODUCTION

3.1Primary Winding ( HV-Winding)

Generally in primary winding has low current and high voltage winding. Primary Windings (
HV Winding ) are made up of copper coil. The number of turns in it is the multiple of the number
of turns in the low voltage windings. It has copper coils thinner than that of the low voltage
windings.
Primary Winding is placed on secondary winding because of insulation purpose.

Fig 3.1.1 HV winding

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3.2Secondary Winding ( LV-Winding)

Generally the secondary winding has high current and low voltage winding. Low voltage
winding has lesser number of turns than that of the high voltage windings. It is made up of the
thick copper conductors. This is because the current in the low voltage windings is higher than
that of high voltage windings.
The secondary winding are placed between core and primary winding.

fig 3.2 LV winding

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3.3MANUFACTURING PROCESS

 Winding

Both High Voltage (HV) and Low Voltage (LV) windings are done using Coil Winding
Machines. The Copper or Aluminium strips/wires used in winding are meticulously selected for
its quality to give the best output.
The Copper or Aluminium strips/wires are paper covered and acts as insulators. This
helps to increase short-circuit strength, thermal strength and higher efficiency.

 Core

The Cold Rolled Grain Oriented (CRGO) laminations used in transformers are of high quality.
They are in the form of thin sheets and they are cut as per the design varying for different
capacities of transformers.
Highly skilled people assemble the laminations on a core channel to form CORE. These are
perfectly assembled without any gaps to avoid energy loss.

 Assembly

The wound coils are placed carefully in the assembled core. Insulations are given wherever
required using materials like press board. The CORE bolt and tie rods are fixed in position. The
Primary and Secondary windings are connected as per the requirement.
The complete assembly is kept in the Hot Air Chamber and a high temperature is
maintained to prevent any moisture in the CORE coil assembly

• Tanking & Painting

The tank is fabricated with high quality MS plates. The assembled job is placed carefully inside
the tank. The bushings, tap switch drives and lug sockets are fitted on the tank. The oil is filled
and the cover is placed on the tank frame and bolted.

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2 coats of anticorrosive paint and 2 coats of enamel paint are painted on the outside of the
tank. The inner portion of the tank is painted with varnish.

Testing

The transformers are individually tested and the following routines tests are conducted in our lab:
No Load Loss, Full Load Loss, Double Frequency Double Voltage Test, High Voltage
Test, Insulation Test, Measurement of Resistance, Heat Run Test, Pressure Test on Tank, Break
Down Voltage - BDV .

Fig3.3 manufacturing process

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CHAPTER 4:-EQUIPMENT DETAILS

4.1 LV WINDING MACHINE

LV winding machine is as shown in below figure.which is used for making LV coil. This
machine is semi-automatic.

Following are its features:

 Friction less speed control in its paddle.

 High and low speed models are available.
 Optional Fail safe brake on winding spindle for slack less tight winding.
 Very low operative noise.
 Well processed spindle shaft avoids bending.
 Consumes Less Power
 Smooth in functioning
 Max. Conductor Area : 0.3 to 30.00 mm Dia.
 Max. Winding Weight : Up to 1 0,000 Kg.
 Max. Winding Length : Up to 3000 mm.
 Machines from : 5 HP to 25 Hp

Figure 4.1;LV winding machine

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4.2 HV WINDING MACHINE

HV winding machine used for making HV coils, section coils, cross over coils of Distribution
Transformers.

Following are its features:

 Frictionless speed controll in its paddle.

 High and low speed models are available.
 Very low operative noise.
 Well processed spindle shaft avoids bending.
 Comes with mechanical or electronic counter.
 Auto count function available.
 Max. Conductor Area : 0.3 to 5.00 mm Dia.
 Max. Winding Weight : Up to 30 Kg.
 Max. Winding Length : Up to 300 mm.
 Machines from : 1 HP to 3 Hp

Figure 4.2;HV winding machine

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4.3 OVEN
In the process of vacuum drying the insulation material of transformer, the transformer is
placed in vacuum drying oven. A vacuum drying oven consists of heating facility and a vacuum
system to develop low pressure in the oven/chamber. The transformer is first heated to a desired
level. The insulation material should be uniformly heated and its temperature should be elevated
to acceptable levels. After heating the material, it is subjected to vacuum. Vacuum in the oven is
developed by a vacuum system consisting of vacuum pumps. Due to low gas pressure in the
vicinity of the material, i.e. in the oven, the moisture absorbed by the insulation is released and
extracted by the vacuum system. The vacuum system consists of the water condensation system
where this water vapour can be condensed and also measured.

Fig 4.3 oven

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4.4 MEGGER

Resistance to be measured is connected across the terminals i.e. connected in series with
the deflecting coil and across the generator. When the current is supplied to the coils then they
have torque in opposite directions.

If resistance to be measured is high, no current will flow through the deflecting coil, the
controlling coil, will therefore, set itself perpendicular to the magnetic axis and hence set the
pointer to the infinity.

If the resistance to be measured is small, a high current flow through the deflecting coil
and the resulting torque sets the pointer to zero.

For intermediate value of resistance, depending upon the torque production, the pointer
is set at a point between zero and infinity.

Fig 4.4 megger

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4.5 TENSIONER

An accessory for winding machine but our tensioners are being well appreciated by our
customers because of following reasons:

 Basically we have two type of tensioners heads: Plate type and Rolling type.
 Free running – Srew based – Motorised options available for head travel.
 Ample space for insulation and transposition.
 Four pillar guided system makes tension application reliable & easy.
 Min max multiple conductor tensioning capacity ranging of 50 to 1500 sq.mm.
 Min max head travel from 300 to 3000mm

fig 4.5 tensioner

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CHAPTER 5:-TYPE OF TESTING

5.1 OPEN CIRCUIT TEST

Mainly Open circuit test is perform to find out the transformer losses. A voltmeter,
wattmeter, and an ammeter are connected in LV side of the transformer. The voltage at rated
frequency is applied to that LV side with the help of a variac of variable ratio auto transformer.
The HV side of the transformer is kept open. Now with the help of variac, applied voltage gets
slowly increased until the voltmeter gives reading equal to the rated voltage of the LV side. After
reaching at rated LV side voltage, all three instruments reading (Voltmeter, Ammeter and
Wattmeter readings) are recorded. This reading is shows that losses of transformer.
Below fig. shows that open circuit test diagram.

Fig 5.1.1.open circuit test of transformer

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5.2 SHORT CIRCUIT TEST

The LV side of the transformer is short circuited. Now with the help of variac applied
voltage is slowly increased until the ammeter gives reading equal to the rated current of the HV
side. After reaching at rated current of HV side, all three instruments reading (Voltmeter, Ammeter
and Watt-meter readings) are recorded. The ammeter reading gives the primary equivalent of full
load current . As the voltage applied for full load current in short circuit test on transformer is quite
small compared to the rated primary voltage of the transformer, the core losses in transformer can
be taken as negligible here.
As the transformer is short circuited, there is no output, hence the input power here
consists of copper losses in transformer.
Below fig. shows that short circuit test diagram.

Fig 5.2.1.short circuit test of transformer

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Fig 5.2.2.short and open circuit test kit

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CHAPTER 6:-OUTCOME

I. we got the information and practical knowledge about Distribution Transformer .

II. We got the knowledge about different outer and inner part of transformer like core, winding, relay
and different type of transformer testing.

III. We got the knowledge about how to make HV and LV winding and also how to make assembly.

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CHAPTER 7:-SUGGESTION

I. If you start working with more shifts,it will help you to increase the mass production.

II. You can also try for the manufacturing of transformer.

III. You can try it by adding automation , it will help to improve productivity

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CHAPTER 8:-CONCLUSION

From this visit, we got the information and practical knowledge about Distribution
Transformer . We got the knowledge about different outer and inner part of transformer like core,
winding, relay and different type of transformer testing. They got the idea how to find out
transformer fault and how to solve it, and also see that how change transformer oil and winding.
Then we learn the importance of core design in transformer that core design is important to
improve transformer efficiency. Then after we see that how to purify the transformer oil with the
use of oil filter. Then we see that winding placed in core then core is put in industrial oven in 2 to
3 days (85` to 90 ` c).

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