Practicum Report On

“250 kVA Transformer Manufacturing and Transformer

Testing at Powermann Bagnladesh Limited, Gazipur”

Pronoy Kumar Sarker

Program: BSEEE
ID#12205113

Department of Electrical and Electronic Engineering, IUBAT

IUBAT‒ International University of Business Agriculture and Technology

i
 Practicum Report On “250 kVA Transformer Manufacturing and Transformer Testing at
Powermann Bangladesh Limited, Gazipur”

Pronoy Kumar Sarker

Program: BSEEE

ID: 12205113

-------------------------- -------------------------- --------------------------

Dr. Khandaker Mohammad Raisul Amin Dr. Bishwajit Saha Dr. Md. Shariful Islam
Supervisor Coordinator Chairperson

Department of Electrical and Electronic Engineering

IUBAT‒International University of Business Agriculture and Technology

ii
 Letter of Transmittal

th
15 April, 2019
Dr. Bishwajit Saha

Associate Professor & Coordinator

IUBAT‒International University of Business Agriculture and Technology

4, Embankment Drive Road, Uttara Model Town

Sector 10, Uttara, Dhaka-1230, Bangladesh.

Subject: Letter of Transmittal of the Practicum Report.

Dear Sir,

It is a great pleasure for me to submit the final practicum report regarding “250 kVA
Transformer Manufacturing and Transformer Testing at Powermann Bangladesh
Limited, Gazipur” as a partial fulfillment of the requirements of B.Sc. Engineering
degree in Bachelor of Science Electrical and Electronic Engineering (BSEEE) from
IUBAT. To make this a good report I have tried my level best.

Sincerely Yours,

-------------------------------------

Pronoy Kumar Sarker

ID: 12205113

Program: BSEEE

iii
Certification

iv
 Student’s Declaration

I am Pronoy Kumar Sarker, a student of Bachelor of Science in Electrical and

Electronic Engineering, in the College of Engineering and Technology (CEAT) at the
IUBAT‒International University of Business Agriculture and Technology declaring
that, this practicum report on the topic of “250 kVA Transformer Manufacturing and
Transformer Testing at Powermann Bangladesh Limited, Gazipur” that only been
prepared for the fulfillment of the course of EEN490, Practicum as the partial
requirement of BSEEE.

It has not been prepared for any other purpose, reward, or presentation.

Sincerely Yours,

-------------------------------------

Pronoy Kumar Sarker

ID: 12205113

Program: BSEEE

v
 Acknowledgement

In the process of doing and preparing report, I would like to pay my gratitude and
respect to some persons for their immense help and enormous co-operation.

I express my humble gratitude to esteemed former Vice Chancellor of IUBAT

Prof. Dr. M. Alimullah Miyan because he gave me the opportunity to study in
such a beautiful university to acquire knowledge that will be very helpful for my
prospective career.

Thanks to Engr. S.M. Mehedi Hasan, Engr. Masud Kaysar Rajib, M. Shrfiul
Islam, Javed of Powermann Bangladesh Ltd. for their advice and help.

Furthermore, I am very grateful to my supervisor Dr. Khandaker Mohammad

Raisul Amin, coordinator, Dr. Bishwajit Saha and chairperson Dr. Md. Shariful
Islam for his kind advice and direction during internship.

Sincerely Yours,

-------------------------------------

Pronoy Kumar Sarker

ID: 12205113

Program: BSEEE

vi
 Executive Summary

Our world is moving towards the new era of electricity. The demand of electricity is
increasing day by day. Electricity has reached the rural areas also. As the demand of
electricity is increasing the demand of transformer is also increasing. Powermann
Bangladesh Limited is of the leading substation equipments supplier in Bangladesh. It
supplies the equipments all over the country.

During my four months internship I learnt about manufacturing 250 kVA transformer
at Powermann. 250 kVA transformers are most commonly used in our country. This
report covers two main sections. They are manufacturing and testing of transformers.

At the beginning of this report some basic information about source, background,
objectives, scope, methodology and limitations are given. Then in next chapter some
basic theoretic topics are discussed about transformer. They are parts of transformers,
connection type of transformers, voltage and current calculation of three phase
transformer and many more.

Chapter four contains three main sections. They are design section, manufacturing
section and testing section. Design section contains the design of core, coil turn,
tapping and wire size. Manufacturing section contains some steps like making the
accessories, core assembly, core and coil assembly, top cover fitting, welding,
primary checking, tank-up, conservator tank fitting and oil filling. Testing section
contains voltage ratio test, vector group test, no load test, full load test, high voltage
test.

This report contains full manufacturing procedure of transformer in details with

necessary photos. I wrote some recommendations at the end of this report. In
conclusion section I wrote about my overall experience. I tried my level best to make
the report simple but informative.

vii
 Table of Contents

Preparatory part
SL. NO. Topics Page
Title page i

Signature page ii

Letter of Transmittal iii

Certification iv

Student’s Declaration v

Acknowledgement vi

Exclusive Summary vii

Chapter-01 (Introduction)
1.1 Source of the information 2

1.2 Objectives 2

1.3 Scope 2

1.4 Methodology 3

1.5 Limitations 3

Chapter-02 (Literature Review)

2.1 Definition of Transformer 5

2.2 Faraday's law of electromagnetic induction 5

2.3 Transformer working principal 6

2.4 Main parts of transformer 8

2.4.1 Laminated core 8

2.4.2 Winding 9

2.4.3 Insulating materials 10

viii
2.4.4 Transformer oil 11

2.4.5 Tap changer 11

2.4.6 Conservator 12

2.4.7 Breather 13

2.4.8 Radiator 13

2.4.9 Buchholz relay 14

2.4.10 Explosion vent 15

2.5 Types of transformers 16

2.5.1 Core type transformer 16

2.5.2 Shell type transformer 17

2.5.3 Single phase transformer 18

2.5.4 Three phase transformer 19

2.6 Delta and Wye connection 20

2.7 Transformer losses 21

2.7.1 Core loss 21

2.7.2 Eddy current loss 21

2.7.3 Hysteresis loss 21

2.7.4 Copper loss 25

2.8 Transformer efficiency 21

2.9 Three phase voltage and current 22

2.10 Star-Delta turns ratio 23

2.11 Delta-Star turns ratio 23

2.12 Three phase transformer line voltage and current 23

Chapter-03(250 kVA transformer

manufacturing )
3.1 250 kVA transformer design 26
3.1.1 Core design 27

ix
3.1.2 Primary coil current and wire size calculation 30
3.1.3 Secondary coil current and wire size calculation 30
3.1.4 Coil turns calculation 31
3.1.5 Tapping calculation 32
3.1.6 Tapping connection 32
3.2 Manufacture steps 35
3.3 Making the accessories 35
3.4 Core assembly 36
3.4.1 Collecting core from core section 36
3.4.2 Core stacking 37
3.4.3 Core assembly & tightening 37
3.4.4 Core lifting 38
3.4.5 Channel tightening 39
3.4.6 Cotton tape lapping 39
3.4.7 Top core opening for insertion of coil 40
3.5 Core and coil assembly 41
3.5.1 Core cylinder setting 41
3.5.2 LT sticks setting 42
3.5.3 Collecting coil from the coil section 42
3.5.4 Bottom separator & wood setting 45
3.5.5 LT coil assembly 46
3.5.6 Cotton tape lapping 46
3.5.7 Joined stick setting 47
3.5.8 LT & HT separator setting 47
3.5.9 HT coil assembly 47
3.5.10 Top core assembly 48
3.5.11 Channel setting & tie rod and core bolts tighten 48
3.6 Top cover fitting 49
3.6.1 Top cover setting by SP Rod 49
3.6.2 HT bushing setting 49
3.6.3 LT bushing setting 50
3.6.4 Tab changer fitting 50
3.6.5 Tube setting 51

x
3.7 Welding 51
3.7.1 Wye-connection 51
3.7.2 Tap changer 51
3.7.3 HT terminal 53
3.7.4 LT terminal 53
3.8 Primary checking (before heat chamber) 54
3.9 Tank-up 54
3.9.1 Height matching 54
3.9.2 Tightening and checking 54
3.9.3 Tank body receiving from paint section 55
3.9.4 Preparation of tank body 55
3.9.5 Tanking 56
3.9.6 Top nut holes tightening 57
3.10 Conservator tank fitting and oil filling 57
3.11 Receive from paint section 57

Chapter-04 (250 kVA transformer testing)

4.1 Testing 60
4.1.1 Megger test 60
4.1.2 Winding resistance test 61
4.1.3 Voltage ratio test 61
4.1.4 Vector group test 63
4.1.5 No load test 64
4.1.6 Full load test 65

Chapter-05 ( Complementary part)

5.1 Recommendations 68
5.2 Conclusion 68
5.3 References 69

xi
 List of figures

SL No. Figure name Page

2.1 Transformer 5

2.2 Electromagnetic Induction 6

2.3 Magnetic flux 7

2.4 Circulating eddy current 7

2.5 Transformer working principal 8

2.6 Laminated core 9

2.7 Windings 10

2.8 Insulating materials 11

2.9 Tap changer 12

2.10 Conservator 12

2.11 Breather 13

2.12 Radiator 14

2.13 Buchholz relay 14

2.14 Explosion vent 15

2.15 Core type transformer 17

2.16 Shell type transformer 17

2.17 Single phase transformer 19

2.18 Three phase transformer 19

2.19 Delta and Wye connection 20

3.1 Different core design 26

3.2 Tapping turns 33

3.3 Tapping connection 34

3.4 Core plates stacking 37

3.5 Core assembly 38

xii
3.6 Ready core for lifting. 39

3.7 Top core opening 40

3.8 Secondary coil manufacturing 42

3.9 Secondary coil inside structure 43

3.10 Primary coil winding 44

3.11 Primary coil close up view 45

3.12 Bottom separator and wood setting 45

3.13 LT coil assembly 46

3.14 Joined stick setting 47

3.15 Top core assembly 48

3.16 Top channel tighten 48

3.17 Top cover 49

3.18 LT bushing setting 50

3.19 Tap changer mechanism 52

3.20 Tap changer connection with HT winding 52

3.21 HT and LT welding 53

3.22 Gasket on tank body 55

3.23 Tanking 56

3.24 Paint section 58

4.1 Vector group test 63

4.2 Transformer wire connection for vector group test 63

4.3 Full load test 66

5.1 Observing transformer 69

xiii
 List of Tables

SL No. Name of tables Page

2.1 Star and delta voltage, current calculation 23

2.2 Three phase transformer line voltage and current 24

3.1 Core plates dimension with quantity 27

3.2 Turn ratio and primary voltage 34

3.3 Voltage ratio test (open circuit test) 62

3.4 HT versus LT voltage 62

3.5 Vector group test 64

3.6 No load test 65

3.7 Full load test 66

xiv
Chapter-01
Introduction

1
1.1 Source of the report

My report entitled as “250 kVA Transformer Manufacturing and Transformer Testing

at Powermann Bagnladesh Limited, Gazipur” an elaborated representation of twelve
weeks long internship program with IUBAT‒International University of Business
Agriculture and Technology as a partial requirement of my BSEEE program. The
purpose of this report is to know the 250 kVA transformer manufacture and test at
Powermann Bangladesh Limited, Gazipur. I have worked under the instruction of
Engr. S.M. Mehedi Hasan, Engr. Masud Kaysar Rajib, M. Shrfiul Islam and Mr.
Jabed.

1.2 Objectives

The main objectives are to extrovert my theoretical knowledge to the practical field
with adequate conceptualization and understanding the design and manufacturing
process of a transformer in Powermann Bangladesh Ltd. The specific objectives of
this report include:
 Study on working principles of transformer.
 Study on raw materials of transformer.
 Study about transformer connections.
 Study about classification of transformers and their uses.
 Learn about manufacturing of transformer.
 Learn about testing of transformer.
 Learn about transformer faults finding and solution of the fault .

1.3 Scope
Actually, I have studied vastly about the whole constituents of manufacturing
transformers, their working principle, ratings etc. I think this will enlarge my
electrical engineering knowledge about substation designing, installation as well as
help me more about the future. Without any doubt, it can be said that this report that I
made will be very helpful in my next stage.

2
1.4 Methodology

Both primary and secondary data are being collected for the purpose of the report.
This report in mainly concentrated of 250 kVA transformer manufacturing and
testing.

• Primary data: Primary data was collected from the books, engineers and
workers at Powermann Bangladesh Limited, Gazipur. They provide us with
necessary books.
• Secondary data: Secondary data was collected from the online internet
resources, books, journals.

1.5 Limitations

Some limitations are given below,

• Three months are not enough to learn all the things that is available in
Powermann Bangladesh Limited.
• Due to traffic we often fall into long traffic jam on the way of Powermann
Bangladesh Limited.
• As the time to reach Powermann Bangladesh Limited is long and we had to stand
for most of the time we were unable to visit Powermann Bangladesh Limited every
day. We decided to go there two or three days in a week.
• Sometimes engineers and technicians remain busy with their own work. For this
reason this took us more time to gather information from them.
• Quality of the foods available in the restaurants outside Powermann Bangladesh
Limited is poor. That’s why most of them time we do not lunch there and leave
Powermann Bangladesh Limited as early as possible.

3
 Chapter-02
Literature Review

4
2.1 Definition of Transformer:

Electrical power transformer is a static device which transforms electrical energy

from one circuit to another without any direct electrical connection and with the help
of mutual induction between two windings. It transforms power from one circuit to
another without changing its frequency but may be in different voltage level [3].

Figure 2.1: Transformer

It works on the principle of Faraday’s Law of electromagnetic induction which

states that “ the magnitude of voltage is directly proportional to the rate of change of
flux.” [3].

2.2 Faraday's law of electromagnetic induction:

According to the Faraday's law, "Rate of change of flux linkage with respect to time is
directly proportional to the induced EMF in a conductor or coil" [3].

5
 Figure 2.2: Electromagnetic Induction

Consider the conductor is moving in magnetic field, then

flux linkage with the coil at initial position of the conductor = NΦ1
(N is speed of the motor and Φ is flux)
flux linkage with the coil at final position of the conductor = NΦ2
change in the flux linkage from initial to final = N(Φ1 - Φ2)
let Φ1 - Φ2 = Φ
therefore, change in the flux linkage = NΦ
and, rate of change in the flux linkage = NΦ/t
taking the derivative of RHS
rate of change of flux linkages = N (dΦ/dt)

According to Faraday's law of electromagnetic induction, rate of change of flux

linkages is equal to the induced emf

So, E = N (dΦ/dt) (volts)

2.3 Transformer working principle:

The working principle of transformer is very simple. It depends upon Faraday's law
of electromagnetic induction. Actually, mutual induction between two or more
winding is responsible for transformation action in an electrical transformer.
According to the Faraday's law, "Rate of change of flux linkage with respect to time
is directly proportional to the induced EMF in a conductor or coil". When an electric
current passes through a long, hollow coil of wire there will be a strong magnetic
field inside the coil and a weaker field outside it. The lines of the magnetic field
pattern run through the coil, spread out from the end, and go round the outside and in
at the other end.

6
 Figure 2.3: Magnetic flux

These are not real lines like the ones you draw with a pencil. They are lines that we
imagine, as in the sketch, to show the pattern of the magnetic field: the direction in
which a sample of iron would be magnetized by the field. Where the field is strongest,
the lines are most closely crowded with a hollow coil the lines form complete rings. If
there is an iron core in the coil it becomes magnetized, and seems to make the field
become much stronger while the current is on.

Figure 2.4: Circulating eddy current

The iron core of a transformer is normally a complete ring with two coils wound on it.
One is connected to a source of electrical power and is called the 'primary coil'; the
other supplies the power to a load and is called the 'secondary coil'. The magnetisation
due to the current in the primary coil runs all the way round the ring. The primary and
secondary coils can be wounded anywhere on the ring, because the iron carries the
changes in magnetisation from one coil to the other. There is no electrical connection
between the two coils. However they are connected by the magnetic field in the iron
core. When there is a steady current in the primary there is no effect in the secondary,
but there is an effect in the secondary if the current in the primary is changing. A
changing current in the primary induces an e.m.f. in the secondary. If the secondary is
connected to a circuit then there is a current flow [3].

7
 Figure 2.5: Transformer working principal

2.4 Main parts of transformer

The basic components of a transformer:

1. Laminated core

2. Windings

3. Insulating materials

4. Transformer oil

5. Tap changer

6. Conservator

7. Breather

8. Radiator

9. Buchholz Relay

10. Explosion vent

According to the above, first four are found in almost all the transformers, whereas
the rest are found only in transformers that are more than 50 KVA..

2.4.1 Laminated Core

The core is used to support the windings in the transformer. It also provides a low
reluctance path to the flow of magnetic flux. It is made of laminated soft iron core in

8
order to reduce eddy current loss and Hysteresis loss. The composition of a
transformer core depends on such factors as voltage, current, and frequency. The
diameter of the transformer core is directly proportional to copper loss and is
inversely proportional to iron loss. If the diameter of the core is decreased, the weight
of the steel in the core is reduced, which leads to less core loss of the transformer and
the copper loss increase. When the diameter of the core is increased, the opposite
occurs [4].

Figure 2.6: Laminated Core

2.4.2 Windings

There are two windings wound over the transformer core that are insulated from each
other. Windings consists of several turns of copper coils bundled together, and each
bundle is connected in series to form a winding.

Windings can be classified in two different ways:

1. Based on the input and output supply

2. Based on the voltage range

Within the input/output supply classification, windings are further categorized:

1. Primary windings - These are the windings to which the input voltage is applied.

2. Secondary windings - These are the windings to which the output voltage is
applied.

Within the voltage range classification, windings are further categorized:

9
 1. High voltage winding - These are made of copper coil. The number of turns is
the multiple of the number of turns in the low voltage windings. The copper coils
are thinner than those of the low voltage windings.

2. Low voltage windings - These have fewer turns than the high voltage windings.
It is made of thick copper conductors. This is because the current in the low
voltage windings is higher than that of high voltage windings [4].

Transformers can be supplied from either low voltage (LV) or high voltage (HV)
windings based on the requirement.

(a) Primary windings (b) Secondary windings

Figure 2.7: Windings

2.4.3 Insulating Materials

Insulating paper and cardboard are used in transformers to isolate primary and
secondary windings from each other and from the transformer core. Transformer oil is
another insulating material. Transformer oil can actually have two functions: in
addition to insulating it can also work to cool the core and coil assembly. The
transformer's core and windings must be completely immersed in the oil. Normally,
hydrocarbon mineral oils are used as transformer oil. Oil contamination is a serious
problem because contamination robs the oil of its dielectric properties and renders it
useless as an insulating medium [4].

10
 (a) Insulating paper (b) Insulating cardboard
Figure 2.8: Insulating Materials

2.4.4 Transformer Oil

Transformer oil or insulating oil is an oil that is stable at high temperatures and has
excellent electrical insulating properties. It is used in oil-filled transformers, some
types of high-voltage capacitors, fluorescent lamp ballasts, and some types of high-
voltage switches and circuit breakers [4].

2.4.5 Tap Changer

The output voltage may vary according to the input voltage and the load. During
loaded conditions, the voltage on the output terminal decreases, whereas during off-
load conditions the output voltage increases. In order to balance the voltage
variations, tap changers are used. Tap changers can be either on-load tap changers or
off-load tap changers. In an on-load tap changer, the tapping can be changed without
isolating the transformer from the supply. In an off-load tap changer, it is done after
disconnecting the transformer. Automatic tap changers are also available.

A tap changer is a mechanism in transformers which allows for variable turn ratios to
be selected in discrete steps. Transformers with this mechanism obtain this variable

11
turn ratio by connecting to a number of access points known as taps along either the
primary or secondary winding.

Tap Changer

Figure 2.9: Tap changer

2.4.6 Conservator

The conservator conserves the transformer oil. It is an airtight, metallic, cylindrical

drum that is fitted above the transformer. The conservator tank is vented to the
atmosphere at the top, and the normal oil level is approximately in the middle of the
conservator to allow the oil to expand and contract as the temperature varies. The
conservator is connected to the main tank inside the transformer, which is completely
filled with transformer oil through a pipeline.

Conservator

Figure 2.10: Conservator

12
2.4.7 Breather

The breather controls the moisture level in the transformer. Moisture can arise when
temperature variations cause expansion and contraction of the insulating oil, which
then causes the pressure to change inside the conservator. Pressure changes are
balanced by a flow of atmospheric air in and out of the conservator, which is how
moisture can enter the system.

If the insulating oil encounters moisture, it can affect the paper insulation or may even
lead to internal faults. Therefore, it is necessary that the air entering the tank is
moisture-free.

The transformer's breather is a cylindrical container that is filled with silica gel. When
the atmospheric air passes through the silica gel of the breather, the air's moisture is
absorbed by the silica crystals. The breather acts like an air filter for the transformer
and controls the moisture level inside a transformer. It is connected to the end of
breather pipe.

Breather

Figure 2.11: Breather

2.4.8 Radiator

Radiator is used to cool the transformer oil. The transformer oil is circulated through
the Radiator. The circulation of the oil may either be natural or forced. In natural
circulation, when the temperature of the oil rises the hot oil naturally rises to the top

13
and the cold oil sinks downward. Thus the oil naturally circulates through the tubes
(Radiator). In forced circulation, an external pump is used to circulate the oil.

Radiator

Figure 2.12: Radiator

2.4.9 Buchholz Relay

The Bochholz Relay is a protective device container housed over the connecting pipe
from the main tank to the conservator tank. It is used to sense the faults occurring
inside the transformer.

Figure 2.13: Buchholz relay

14
It is a simple relay that operates by the gases emitted due to the decomposition of
transformer oil during internal faults. It helps in sensing and protecting the
transformer from internal faults [4].

2.4.10 Explosion Vent

The explosion vent is used to expel boiling oil in the transformer during heavy
internal faults in order to avoid the explosion of the transformer. During heavy faults,
the oil rushes out of the vent. The level of the explosion vent is normally maintained
above the level of the conservatory tank.

An explosion vent or rupture panel is a safety device to protect equipment or

buildings against excessive internal, explosion-incurred pressures, by means of
pressure relief. An explosion vent will relieve pressure from the instant its opening (or
activation) pressure pstat has been exceeded.

The purpose of the explosion vent in a transformer is to prevent damage of the

transformer tank be releasing any excessive pressure generated inside the transformer.

Explosion vent

Figure 2.14: Explosion vent

15
2.5 Types of transformer
The Transformer is basically a very simple device. It mainly consists of a core,
windings and insulations. The windings are wound over the laminated magnetic core.
These windings are insulated from the core and from each other.
With regards to the application transformers can be classified as follows

1. Step up transformer
These transformers raise the input voltage to a higher voltage level.
2. Step down transformer
These transformers reduce the input voltage to a lower voltage level.

Transformer is a reversible device. Therefore each transformer can be used as both

step up and step down transformer. For example, if we supply a low voltage (within
the LV rating) to the low voltage terminal, we will be getting the stepped up voltage
at the high voltage terminals and if we supply a high voltage (within the HV rating) to
the high voltage terminal, we will be getting the stepped down voltage at the low
voltage terminals.
Transformer can also be classified based on the type of construction used. There are
two types of cores namely core type and shell type. Depending upon the type of core
used transformers can be classified into two categories as:

• core type transformer

• shell type transformer

2.5.1 Core type transformer

In this type of transformer the core is in the form of rectangular frame with the
windings wound on the limbs of the core. A single phase transformer may be
designed with the primary windings over on limb and the secondary windings over
another limb. But on doing so, the leakage reactance will be large leading to a heavy
power loss. In actual practice both the limbs of the frame contains half of secondary
and primary windings. By doing, so the leakage reactance can be reduced.

The low voltage windings are placed inside the high voltage windings. This is to
reduce the insulation requirement of high voltage windings [4].

16
 Figure 2.15: Core type transformer

2.5.2 Shell type transformer

In shell type transformer, the core has three limbs: a central limb and two side limbs.
The windings are made around the central limb. The width of the central limb is twice
that of the side limb. Both the HV and LV windings are divided into number of coils
and are arranged alternatively. The HV windings are sandwiched between the LV
windings [4].

Figure 2.16: Shell type transformer

17
Classification based on the number of phases.

1. Single phase

2. Three phase

Classification based on the method of cooling

a. Self-air–cooled (dry type)

b. Air-blast–cooled (dry type)

c. Liquid-immersed, self-cooled

d. Oil-immersed, combination self-cooled and air-blast

e. Oil-immersed, water-cooled

f. Oil-immersed, forced-oil–cooled

g. Oil-immersed, combination self-cooled and water-cooled

2.5.4 Single phase transformer

A single phase voltage transformer basically consists of two electrical coils of wire,
one called the “Primary Winding” and another called the “Secondary Winding”. For
this tutorial we will define the “primary” side of the transformer as the side that
usually takes power, and the “secondary” as the side that usually delivers power. In a
single-phase voltage transformer the primary is usually the side with the higher
voltage.
These two coils are not in electrical contact with each other but are instead wrapped
together around a common closed magnetic iron circuit called the “core”. This soft
iron core is not solid but made up of individual laminations connected together to help
reduce the core’s losses.
The two coil windings are electrically isolated from each other but are magnetically
linked through the common core allowing electrical power to be transferred from one
coil to the other. When an electric current passed through the primary winding, a
magnetic field is developed which induces a voltage into the secondary winding as
shown.

18
 Figure 2.17: Single phase transformer

In other words, for a transformer there is no direct electrical connection between the
two coil windings, thereby giving it the name also of an Isolation Transformer.
Generally, the primary winding of a transformer is connected to the input voltage
supply and converts or transforms the electrical power into a magnetic field. While
the job of the secondary winding is to convert this alternating magnetic field into
electrical power producing the required output voltage as shown [4].

2.5.5 Three phase transformer

The combinations of the three windings may be with the primary delta-connected and
the secondary star-connected, or star-delta, star-star or delta-delta, depending on the
transformers use. When transformers are used to provide three or more phases they
are generally referred to as a Polyphase Transformer.

Figure 2.18: Three phase transformer

A three-phase transformer is made of three sets of primary and secondary windings,
each set wound around one leg of an iron core assembly. Whether the winding sets

19
share a common core assembly or each winding pair is a separate transformer, the
winding connection options are the same: Primary – Secondary [4].

2.6 Delta and Wye connection

A delta-wye transformer is a type of 3-psase design that employs delta -connected
windings on its primary and wye/star connected windings on its secondary. A neutral
wire can be provided on wye output side.

Primary side Secondary side

Figure 2.19: Delta star configuration.

Delta-wye transformers are common in commercial, industrial, and high-density

residential locations, to supply three -phase distribution system. Three phase three
wire system is derived from Delta Connections (3-Phase, 3 Wires System) and three
phase four wire system is derived from Star Connections (3-Phase, 4 Wires System)
We may Also derived 3-Phase 3 Wire System from Star Connection [4].

2.7 Transformer losses:

As the electrical transformer is a static device, mechanical loss in transformer

normally does not come into picture. We generally consider only electrical losses in
transformer. Loss in any machine is broadly defined as difference between input
power and output power.

20
2.7.1 Core loss:

Eddy current loss and hysteresis loss depend upon the magnetic properties of the
material used for the construction of core. Hence these losses are also known as core
losses or iron losses.

2.7.2 Eddy current loss:

In transformer, AC current is supplied to the primary winding which sets up

alternating magnetizing flux. When this flux links with secondary winding, it
produces induced emf in it. But some part of this flux also gets linked with other
conducting parts like steel core or iron body or the transformer, which will result in
induced EMF in those parts, causing small circulating current in them. This current is
called as eddy current. Due to these eddy currents, some energy will be dissipated in
the form of heat.

2.7.3 Hysteresis loss:

Hysteresis loss is due to reversal of magnetization in the transformer core. This loss
depends upon the volume and grade of the iron, frequency of magnetic reversals and
value of flux density.

2.7.4 Copper loss:

Copper loss is due to ohmic resistance of the transformer windings. Copper loss for
the primary winding is I12R1 and for secondary winding is I22R2. Where, I1 and I2
are current in primary and secondary winding respectively, R1 and R2 are the
resistances of primary and secondary winding respectively. It is clear that Cu loss is
proportional to square of the current, and current depends on the load. Hence copper
loss in transformer varies with the load.

2.8 Transformer efficiency

An ideal transformer is 100% efficient because it delivers all the energy it receives.
Real transformers on the other hand are not 100% efficient and at full load, the
efficiency of a transformer is between 94% to 96% which is quiet good. For a
transformer operating with a constant voltage and frequency with a very high

21
capacity, the efficiency may be as high as 98%. The efficiency, η of a transformer is
given as:
Output Power
Efficiency, η = × 100 %
Input Power

Input Power - Losses

=
Input Power
× 100 %
Losses
= 1 −
Input Power
× 100 %
Where: Input, Output and Losses are all expressed in units of power.

Generally when dealing with transformers, the primary watts are called “volt-amps”,
VA to differentiate them from the secondary watts. Then the efficiency equation
above can be modified to:
Secondary Watts (Output)
Efficiency, η =
Primary VA (Input)

2.9 Three phase voltage and current

VL is the line-to-line voltage, and VP is the phase-to-neutral voltage on either the
primary or the secondary side.
Other possible connections for three phase transformers are star-delta Yd, where the
primary winding is star-connected and the secondary is delta-connected or delta-star
Dy with a delta-connected primary and a star-connected secondary.
Delta-star connected transformers are widely used in low power distribution with the
primary windings providing a three-wire balanced load to the utility company while
the secondary windings provide the required 4th-wire neutral or earth connection.
When the primary and secondary have different types of winding connections, star or
delta, the overall turns ratio of the transformer becomes more complicated. If a three-
phase transformer is connected as delta-delta ( Dd ) or star-star ( Yy ) then the
transformer could potentially have a 1:1 turns ratio. That is the input and output
voltages for the windings are the same.

22
 Table 2.1: Start and delta voltage, current calculation

Connection Phase Voltage Line Voltage Phase Current Line Current

Star VP = VL ÷ √3 VL = √3 × VP IP = IL IL = I P

Delta VP = VL VL = VP IP = IL ÷ √3 IL = √3 × I P

2.10 Star-Delta turns ratio

However, if the 3-phase transformer is connected in star–delta, ( Yd ) each star-

connected primary winding will receive the phase voltage, VP of the supply, which is
equal to 1/√3 × VL.
Then each corresponding secondary winding will then have this same voltage induced
in it, and since these windings are delta-connected, the voltage 1/√3 × VL will become
the secondary line voltage. Then with a 1:1 turns ratio, a star–delta connected
transformer will provide a √3:1 step-down line-voltage ratio.

NP VP
TR = =
NS √3VS

2.11 Delta-Star turns ratio

Likewise, for a delta–star ( Dy ) connected transformer, with a 1:1 turns ratio, the
transformer will provide a 1:√3 step-up line-voltage ratio. Then for a delta-star
connected transformer the turns ratio becomes:

NP √3VP
TR = =
NS VS

2.12 Three phase transformer line voltage and current

For the four basic configurations of a three-phase transformer, we can list the
transformers secondary voltages and currents with respect to the primary line voltage,
VL and its primary line current IL as shown in the following table.

23
 Table 2.2: Three phase transformer line voltage and current

Primary-Secondary Line Voltage Line Current

Configuration Primary or Secondary Primary or Secondary
I𝐿
Delta-Delta VL = √3 ∙ nVL IL =
n
I𝐿
Delta-Star VL = √3 ∙ nVL IL =
√3∙ n
nV𝐿 I𝐿
Star-Delta VL = IL = √3 ∙
√3 n
I𝐿
Star-Star VL = nVL IL =
n

Where:
n = the transformers “turns ratio” (T.R.) of the number of secondary windings
NS, divided by the number of primary windings NP.
VL= the line-to-line voltage .
VP = the phase-to-neutral voltage.
IL= line to line current.
IP= phase to neutral current

24
 Chapter-03
250 kVA transformer manufacturing

25
3.1 250 kVA transformer design

The design is divided into some steps…..

i. Core design
ii. Primary coil current and wire size calculation
iii. Secondary coil current and wire size calculation
iv. Coil turns calculation
v. Tapping calculation
vi. Tapping connection

3.1.1 Core design:

Core design is a very essential for manufacturing transformer. Step lap core
laminations reduce no load loss up to 8%, no load current up to 50% and it also
reduce noise.
At Powermann Bangladesh Ltd. they have the expertise, experience and equipment,
required to convert any non step lap core design to efficient step tap design. There are
three type of core. They are:
i. A core
ii. B core
iii. C core

Figure 3.1: Different cores design.

For this particular transformer a table is given below including the number of plates
with dimension for each core.

26
 Table 3.1: Core plates dimension with quantity

A-Core

Length
Width(b) Length (L2) Stack Weight
(L1)
(mm) (mm) (mm) (kg)
(mm)

155 650 340 60 35.25

150 640 340 39 21.68

145 630 340 26 14.23

140 620 340 21 10.84

135 610 340 18 8.73

125 590 340 29 12.99

115 570 340 23 9.41

105 550 340 19 6.97

95 530 340 16 5.20

85 510 340 14 3.85

75 490 340 12 2.81

65 470 340 10 2.00

55 450 340 8 1.37

45 430 340 7 0.89

35 410 340 5 0.53

27
 B-Core

Width(b) Length (L1) Length (L2) Stack Weight

(mm) (mm) (mm) (mm) (kg)

155 495 340 30.00 14.87

150 490 340 19.26 9.18

145 485 340 13.21 6.05

140 430 340 10.53 4.63

135 475 340 8.89 3.74

125 465 340 14.59 5.62

115 455 340 11.74 4.11

105 445 340 9.74 3.07

95 435 340 8.20 2.31

85 425 340 6.95 1.73

75 415 340 5.89 1.28

65 405 340 4.96 0.92

55 395 340 4.12 0.64

45 385 340 3.35 0.42

35 375 340 2.63 0.25

28
 C-Core

Width(b) Length (L1) Length (L2) Stack Weight

(mm) (mm) (mm) (mm) (kg)

155 715 125 60 34.37

150 710 130 39 21.46

145 705 135 26 14.31

140 700 140 21 11.06

135 695 145 18 9.05

125 685 150 29 13.90

115 675 155 23 10.39

105 665 160 19 7.95

95 655 165 16 6.11

85 645 170 14 4.68

75 635 175 12 3.97

65 625 180 10 3.34

55 615 185 8 2.77

45 605 190 7 2.25

35 595 195 5 1.77

29
3.1.2 Primary coil current and wire size calculation

The primary side has HT Delta connection system. We know that for delta
connection,

E-line = E-phase = 11 kV and

I-line = √3 × I-phase = ?

Now,

Power = E-line × I-line × √3

Or, I-line = Power / ( E-line × √3)

Or, I-line = 250kVA / (11 kV × √3)

Or, I-line = 13.1216 Amp

Or, I-phase = 13.1216 / √3 Amp

Or, I-phase = 7.58 Amp

From international Engineering tables or standard wire gauge chart sheet I found that
for carrying 6.27 Amps the cross sectional area of copper wire should be minimum
1.52 mm square.

For 7.58 Amp minimum area in needed = (7.58 × 1.52 )/ 6.27 = 1.83 m.m.2.

In powermann they used 14 gauge wire which has a cross sectional area of 3.23
m.m.2.

3.1.3 Secondary coil current and wire size calculation

The secondary side has LT Star connection system. We know that for star connection,
E-line = E-phase × √3 = 415 V and

I-line = I-phase = ?

30
Now,

Power = E-line × I-line × √3

Or, I-line = Power / (E-line × √3)

Or, I-line = 250 kVA / (415V × √3)

Or, I-line = I-phase = 347.80 Amp

They used four copper wires in parallel connection. So each of the copper wire has to
carry 347.80 / 4 = 86.95 Amp

From international Engineering tables or standard wire gauge chart sheet I found that
for carrying 73.7 Amp the cross sectional area of copper wire should be minimum
18.7 m.m.2.

So, for carrying 86.95 Amp minimum area in needed = (86.95 × 18.7) / 73.7 = 22.06
m.m.2.

The secondary wires used in Powermann is 8.8 mm in height and 3.4 mm in width.
So the area is = 8.8 ×3.4 = 29.92 m.m.2.

This is more than the required value 22.6 m.m.2.

3.1.4 Coil turns calculation

In Powermann the primary turns are calculated depending of the turns of the
secondary coil.

The secondary coil has total 38 turns. (Ns)

In the secondary coil, line to line voltage is 415 volt. (Vs)

In the primary coil, line to line voltage is 11 kV. (Vp)

Primary coil turns = ? (Np)

Now,

31
 NP √3× VP
=
NS VS

√3× VP × NS
or, NP = VS

√3× 11×1000×38
or, NP = 415

or, NP = 1744.57 turns

Final Np value is given after tapping calculation.

3.1.5 Tapping calculation

Tapping ratio is 2.5 % and total six tapping will be used in two segments of primary
coil.
Tapping turns =1744×2.5% = 43.61 which is almost 44 turns.

After 44 turns each tapping will happen.

For better voltage control the total primary turns will be= 1744+44 = 1788 turns.

3.1.6 Tapping connection

That is a five step tapping. Generally for round 200 kVA transformer fives taps are
given. In case of high rating transformer so many taps are used according the
requirements.

The primary coil is divided into two different sections for better oil flow. It cools the
transformer more efficiently.

The top primary coil has total 905 turns and the bottom coil has 883 turns. Total 1788
turns. The top primary coil tapping are given at the end of the turns. The three tapping
connections for the top primary coil are in,

C = 905 turns

B = 905-44 = 861 turns

A = 861-44 = 817 turns

32
The bottom primary coil tapping are given at the beginning of the turns. The
three tapping connections for the bottom primary coil are in,

D = 883 turns

E = 883-44 = 839 turns

F = 839-44 = 795 turns

0 S

Top primary coil

A = 817

B = 861

C = 905

D = 883

E = 839

F = 795
Bottom primary coil

0 S

Figure 3.2: Tapping turns

33
The final connection of the tapping is given below -

C D B E A F

Figure 3.3: Tapping connection

Any adjacent two of them can be connected together. Such as CD or DB or AF.

The ideal turn number in the primary side is Np = 1744 in which the primary voltage
is 11kv and the secondary voltage is exactly Vs = 415 volts as we want. But due to
transmission loss and load variation at line, we do not get exactly Vp = 11 Kv at
primary side. In which primary voltage which no of tapping should be activate is
given below with the final turn ratio,
The formula is, where Vp = ? for each primary turns. Here Ns = 38
Np √3×Vp
=
Ns Vs

Table 3.2: Turn ratio and primary voltage

Tapping Tapping Turns addition Total turns Voltage

number combination (volts)

1 CD 905 + 883 1788 11274

2 DB 883 + 861 1744 11000

3 BE 861 + 839 1700 10719

4 EA 839 + 817 1656 10442

5 AF 817 + 795 1612 10164

34
3.2 Manufacture steps

Powermann follow some steps in their manufacturing section. Those steps are,

i. Making the accessories

ii. Core assembly
iii. Core and coil assembly
iv. Top cover fitting
v. Welding
vi. Primary testing (Before heating)
vii. Tank up
viii. Conservator tank fitting and oil filling
ix. Final testing
x. Receive from paint section and final finishing

Manufacturing engineering or manufacturing process are the steps through which raw
materials are transformed into a final product. The manufacturing process begins with
the product design, and materials specification from which the product is made. These
materials are then modified through manufacturing processes to become the required
part.

3.3 Making the accessories

There are so many accessories that are needed to make the transformer. The
accessories are,

i. Channel ready
ii. Channel separator cutting
iii. Top & bottom separator cutting
iv. Wood processing (cutting, grinding, hole)
v. Core & coil cylinder (press board) cutting
vi. LT & HT stick cutting and joining
vii. LT & HT separator cutting and joining
viii. Surface cleaning (Tie, core bolt, SP Rod)
ix. HT coil tapping
x. Tube making (Tape changer & delta)
xi. HT rod welding

35
 xii. HT & LT gasket preparation
xiii. Aluminum gotka hole
xiv. HT ring making hole
xv. LT rod & flange setting
xvi. Foot plate preparation
xvii. Arcing horn ready
xviii. Tap changer soldering
xix. Jumper preparing
xx. HT coil ring cutting
xxi. Footplate wood, pressboard washer processing
xxii. Delta separator preparing
xxiii. Numbering and nameplate hole making
xxiv. Arranging all nut bolts, washer, tools and equipments.

3.4 Core assembly

Some main steps in the core assembly section are,

i. Collecting core from core section

ii. Core stacking

iii. Core assembly & tightening

iv. Core lifting

v. Channel tightening

vi. Cotton tape lapping

vii. Top core opening for insertion of coil

3.4.1 Collecting core from core section

In the core section the core is made and the cores are needed to be collected before
core stacking.

36
3.4.2 Core stacking

In the core cutting section the core plates are made from big silicon steel. There are

Figure 3.4: Core plates stacking

different cores named A core, B core and C core. To make the core round different
size of core plates are needed. In the cutting section those plates are made and
supplied to the core making section.

3.4.3 Core assembly & tightening

The plate dimension depends on according the transformer rating. Then they start
making the core. At first they arrange the channel ready plate and start with small
width plates with the same height. As the structure of the core increases only the
width of the plate increases and height of the core remains the same. At the midpoint
the core reaches its maximum width. Then the width decreases and goes to the lowest
width the end of making the laminated core. They can cut the plates directly from the
main sheet directly but lot of materials will waste and the core also will not be so
strong enough. Instead of this they cut individual plates from the sheet with high
efficiency and assembly them later. It increases the bonding of the core. This is a long
time process and most sensitive process in transformer making. The perfect the
structure of the core the more will be the efficiency.

37
 A

C B C

Core

Figure 3.5: Core assembly

here,

A = A core

B = B core

C = C core

3.4.4 Core lifting

To make the core tight for lifting them they use some cotton tape and tighten the
cores up. After that the put the other channel ready and use some long nut & bolts to
tighten the core. After tighten the core they use manpower and lift the core up and put
it at a corner in a safe place for the next step.

38
 Figure 3.6: Ready core for lifting.

here,

A = A core

B = B core

C = C core

3.4.5 Channel tightening

After lifting the core they tighten the core by using some nut bots in both top and
bottom. This gives the core a strong structure.

3.4.6 Cotton tape lapping

Cotton Tape is made from 100 % premium quality fine Cotton Yarn. The Cotton yarn
used both in warp and weft for the manufacture of this tape are free from neps, slubs,
knots, kinks etc. This tape is strong and flexible and dimensionally stable. Cotton tape
is available in with Selvedge as well as without selvedge as per requirement of client.

39
CHARACTERSTICS:

• High tensile strength

• Extremely flexible

• Good electrical properties

They use the cotton tape and make some round around the three middle cores where
the primary and secondary coils are going to be inserted. This makes the core
stronger. After using cotton tape they add some glue on it. Then they use some
insulating sheet and wrap the cotton tape strongly. This makes the core structure very
strong.

3.4.7 Top core opening for insertion of coil

At the top the nuts and bolts are removed for disassembly the top core. The top core is
removed very carefully to insect the secondary and the primary coil. In this figure 3.6
we can see that the top core is opened but the bottom core is untouched. While
making the core and assembly it on the other area the primary and secondary coil is
making at the same time. This parallel process reduces the manufacturing time a lot.
We can also see some woods lying beside the core. They are waiting of the
installation. In the next part of core and coil assembly we will see how to assemble
the coil inside the core.

Figure 3.7: Top core opening

40
3.5 Core and coil assembly
In this section there are some steps. They are,

i. Core cylinder setting

ii. LT stick setting

iii. Collecting coil from the coil section

iv. Bottom separator & wood setting

v. LT coil assembly

vi. Cotton tape lapping

vii. Joined stick setting

viii. LT & HT top and bottom separator setting

ix. HT coil assembly

x. Top core assembly

xi. Channel setting & tie rod and core bolts tighten

3.5.1 Core cylinder setting

There are two types of low-voltage windings available, both of which provide
protection from hostile environments. One type is vacuum cast like the high-voltage
winding. The other type uses a "nonvacuum" technique of epoxy application to
achieve strength. Sheet insulation, such as Nomex or fiberglass, is impregnated with
uncured epoxy, then interleaved on the heavy low-voltage conductors to literally
"wind-in" the epoxy. During oven curing of the low-voltage coil, the epoxy flows
onto the conductor and cures into a solid cylinder of great strength. These "non-
vacuum" coils are then fully sealed by pouring epoxy into the "margins" or ends of
the windings. Both procedures provide good protection from hostile environments.

Core cylinder is made to arrange the primary and secondary coil and to fit it inside the
core perfectly.

41
3.5.2 LT sticks setting

Separator hard sheets are used to make the low tension sticks. They are cut according
to the size needed. The sticks almost looks likes a twelve inch scale available in the
market. The sticks are put in between the secondary coil and the core. This creates the
bonding between core and secondary coil stronger and also allow oil to flow for
cooling.

3.5.3 Collecting coil from the coil section

Primary coil and secondary coils are made in two different areas.

Secondary coil:

Pure copper is used both for primary and secondary coil. During making the
secondary coil first they use cotton tape and wrap the coil frame with the tape. The
core diameter is 150 mm.

Figure 3.8: Secondary coil manufacturing

Interior diameter: 161 mm

Outside diameter: 196 mm

Wire size: 6.5 × 3 mm

Height: 247 mm

42
At this height the secondary coil has 19 turns in one loop and they use 4 copper coils
in parallel. After one complete loop they put a separator which has some cross shape.
This allows flowing transformer oil in between them for better cooling. Then another
19 turns are given. Total 38 turns in secondary coil. As the current is high in
secondary side the copper wire gauge is also high.

Figure 3.9: Secondary coil inside structure

here,
ID = Interior diameter,
OD = Outside diameter
Secondary coil has only two layers of winding. The secondary coil has two terminals.
Shorts terminal goes for neutral connection and the long terminal goes to phase
connection. This takes around 15 minutes to make a secondary coil.

Primary coil:

Pure copper coil is also used for primary coil. The coil cross sectional area as well as
gauge size is mentioned in the earlier section. The primary coil is divided into two
sections. The top and the bottom section. This is done for better oil flow around the
coil. The more the sections of the primary coil the better the oil flow. Larger rating
transformer has more sections in the primary coil.

They placed a frame on a rolling machine which has a counter on it. Then they started
to make coil roll. After 44 turns a first tap comes out and after 88 turns second tap

43
comes out. Each layer completed at 98 turns. They use cotton tape and placed them
inside the core in such a way that it makes the core bonding strong. This takes around
45 minutes to 1 hour to make a primary coil. Expert people can do it in less time.
For primary coil,

Interior diameter: 228 mm

Outside diameter: 278 mm

Wire gauge: 17

Height: 247 mm

Figure 3.10: Primary coil winding

There is a counter at the left of this machine. It is needed to give accurate turns in
primary winding. One turns might change the value and working behavior of the
transformer. There is a paddle which is located at the bottom of the machine. When it
is pressed by foot the coil started to gather in the coil frame.
The top coil has total 905 turns and the bottom coil has 883 turns. After each layer
they used some epoxies and put some straight insulating paper. After few layers they
use some cross bend type strong insulating paper. They use it for better cooling
purpose. At the start, end and at the tapping they use some insulating copper wrapper
which prevents the copper from being damage by pressure.

44
 Figure 3.11: Primary coil close up view

3.5.4 Bottom separator and wood setting

It is needed to place the primary and the secondary coil inside the core. But this will
create a pressure to the middle of the C-core. As a result the C-core has a chance to
displacement. So they place some wood which is situated over the rod and matches

Figure 3.12: Bottom separator and wood setting

the height and makes a straight level. After the wood alignment the bottom separator
is placed. The bottom separator is a insulator. The separator is cut in a certain way

45
that it can go and fit inside the core properly. They are tightening properly. Now the
core is ready for inserting the low tension secondary coil.

3.5.5 LT coil assembly

The LT secondary coil is stored at a particular place. After putting the bottom
separator and tickli in a particular circular way it is time to put LT secondary coil on
the core. An insulating paper is used to cover the top part of the core so that
secondary coil will not get any scratch by the sharpness of the core. This helps
inserting LT secondary coil safely. After putting the coil they insert some joined
sticks between the

Figure 3.13: LT coil assembly

core and LT coil. This makes LT coil tighten with core and also allows oil to pass
through the gap for better cooling.

3.5.6 Cotton tape lapping

This part is done after making the secondary coil on the coil making section. After
making two layers of coil wound they use cotton tape and warp the whole coil. Then
they apply glue on it and wrap a separator sheet. This makes LT coil strong.

46
3.5.7 Joined stick setting

Bore placing primary or HT coil over secondary or LT coil joined sticks are needed to
place over LT coil with glue. This is done to for assembly between secondary coil and
primary coil. This creates a little gap which allows to flow oil ensuring a tight

Figure 3.14: Joined stick setting

between primary and secondary coil. After installing joined sticks it is time to insert
HT coil. As the HT coil is divided into several sections for better cooling so that after
each section Tikli is used.

3.5.8 LT & HT top and bottom separator setting

LT & HT top and bottom separator provides oil flow between primary and secondary
coil. On the figure 4.29 we can see that after putting first HT coil some LT & HT top
and bottom separators are used in a circular way to put another HT coil on it. This
also ensures zero scratches between adjacent HT coils.

3.5.9 HT coil assembly

After putting Tikli it is time to install another coil on it. The process continues until
all the coils are installed. All the HT coils are aliened properly by hand force. The
connection of HT and LT coils are kept at opposite side of each other. Then top Tickli
and top separator is placed as like as bottom separator.

47
3.5.10 Top core assembly

After placing all the accessories to their right place it is time to reassemble top core.

Figure 3.15: Top core assembly

This is done carefully. Each corner should perfectly sit together with each other.

3.5.11 Channel setting & tie rod and core bolts tighten

Channel plate is paced with the top core and tighten it by using tie rod and core bolts.
Before placing channel plate channel separator must be inserted between top core and
channel. This is the last step of core and coil assembly. The core with the coil is now

Figure 3.16: Top channel tighten

48
completed. In this figure we can see that two men are tightening channel plate.

3.6 Top cover fitting

In this section there are some steps. They are,
i. Top cover setting by SP Rod
ii. HT bushing with gasket, aluminum gotka hole and ring
iii. LT bushing setting with gasket
iv. Tab changer fitting
v. Tube setting

3.6.1 Top cover setting by SP Rod

Top two channel plates have two holes for each one for mounting top cover. Top
cover has three big holes for installing HT bushing and four small holes for LT
busing. It has also tab changer, gas pressure and oil conservator installation system.
The top cover is installed on top channel using SP Rod.

Figure 3.17: Top cover

3.6.2 HT bushing setting

HT busing is bigger than LT bushing. Large bushing needs extra support. HT bushing
ring gives the support. First HT bushing is inserted through HT bushing hole by using

49
a HT gasket at top cover. Then aluminum gotka hole is placed with some nut bolts
and HT busing ring is installed on it. This gives most tighten but secure HT
connection. HT coil wire then tighten by some bolts on the top of HT bushing. Under
the bolt some aluminum ring is used to hold connector with bushing. For HT bushing
the primary delta wire is welded directly with the HT rod which is passed through
bushing.

3.6.3 LT bushing setting

LT bushing system is same like HT bushing system but one main difference is that
HT bushing needs supporting HT bushing ring but LT bushing does not need that. As
LT star connection needs to carry more current, it is welded with wide copper plates.

Figure 3.18: LT bushing setting

At the end of copper plates there is a hole to mount a screw or nuts bolts which goes
outside of LT bushing. LT gasket is needed before putting LT bushing on the top
cover.

3.6.4 Tab changer fitting

Tab changer has direct mounting system with top cover. Tap changer frame are
installed with top cover using tab changer mounting accessories. It is an easy process.

50
3.6.5 Tube setting

All the wire connected should be arranged in a particular way that it never goes close
to the transformer body or close to the other cables. Sufficient gap should be present
between them. Some tubes are used to tie all the cable in a suitable system.

3.7 Welding

Sometimes welding section is done before installing the top cover and bushing.
Welding section is divided into some parts. They are,
i. Y-connection
ii. Tab changer
iii. HT terminal
iv. LT terminal

3.7.1 Y-connection

On secondary LT side start connection is given. Sometimes it is need to run both

single phase and three phase machine at the same time. This Y-connection provides
us with the opportunity. Secondary coil has two terminals. One of the terminals is
short and the other is long. All of the three short terminals are welded together with a
copper plate and that is the neutral connection. The other three long terminals are the
phase terminals. The three phase terminals and one neutral terminal are also soldered
with copper plates. Copper plate size depends on the output current. Sometimes
multiple of them are joined in parallel connection to ensure safe current flow. At the
end of all the terminals a hole is made to pass the LT bushing rod and tighten the
bushing screw.

3.7.2 Tap changer

Tap changer is used to make output voltage 415 even the input voltage is lower or
higher than 11kv. In this particular 200 kVA transformer we used five steps off load

51
 Figure 3.19: Tap changer mechanism

tap changer. As the terminals of the tap gets open before changing the tap it is not
possible to change the tapping position in on load condition. Huge arc will produce.

Figure 3.20: Tap changer connection with HT winding

In this five step tap changer we can see that there are six wires for each phase. The
tapping calculation and wire combination for each number of tap was discussed on
3.1.5 and 3.1.6 with figure 3.1 and 3.2. In figure 3.34 shown that a metal plate for
each phase to make connection which is mounted on a plastic case. Tapping no 1 is
the right most wires combination and tapping no 5 is the left most wires combination.

52
When the tapping number goes from one to five the connection plates goes from right
to left. In figure 3.35 it is shown that which terminals of primary HT wire goes to
which tapping wire. They are welded together and make the wire insulated by using
insulating paper.

3.7.3 HT terminal

Primary HT terminal has delta connection. To make this delta connection jumper wire
is used. The end of one coil goes to the start of another coil. Common terminals of
two coils are the phase terminal. After welding of each terminal they are wrapped

Figure 3.21: HT and LT welding

with insulating paper. At right side of the figure 3.36 shown that the delta connection
in HT terminal.

3.7.4 LT terminal

Secondary LT terminal has wye connection. After soldering LT terminals with copper
wires the whole area has to be covered by cotton tape. Here cotton tape works as
insulator.

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3.8 Primary checking (before heat chamber)
After welding and arranging top cover it is time to test transformer for the first time.
As it is tested on air without emerged in oil so that only no load test will be done just
for checking voltage ratio. If the test succeed then we can assume that the transformer
will function without any problem as Powermann has a long time of transformer
manufacturing experience. After successful primary checking, transformers will be
sent to heat chamber. Where transformer is going to get some heat for a particular
amount of time. Any type of moisture can damage insulation and might lead
transformer into dangerous situation. Heat also makes the glue more strong and core
more stable.

3.9 Tank-up
Tank up process is mainly installing core and winding settings inside transformer
body. It has some steps. They are,
i. Height matching
ii. Tightening and checking all internal nut-bolts, separator settings
iii. Tank body receiving from paint section after primary paint
iv. Preparation of tank body with gasket setting
v. Tanking
vi. Top nut bolts tightening

3.9.1 Height matching

Height of transformer should match with the height of the interior section of tank. By
reducing the height of SP rod which connects channel plate and top plate together,
transformer height can be adjusted according to tank interior height.

3.9.2 Tightening and checking

Finally it is time to check nuts bolts, separator settings. Sometimes after assembling
so many contents some nuts bolts or separator remains little lose after receiving from
heat chamber. Those are needed to be checking and tightening before putting
transformer into transformer body.

54
3.9.3 Tank body receiving from paint section

Making a tank body is a big process. As this is also a part of transformer I am going
to write a short description on it. Transformer body is made from iron plate. Larger
iron plate is cut via cutting machine. Then it is bended and welded and makes a
square shape. After that they make some holes for flowing oil through fins or
transformer cooling tubes. Cooling tubes or fins are also made form iron plates but a
thin one. They are also cut by cutting machine and bended in a separate banding
machine for a particular shape. Two fin plates are joined together and this makes a
frame which is hollow inside. A lot of them are connected together via a pipe and sent
to leak checking. There they use 2kg air pressure and soap water to check if there is
any leakage or not. They will fix it if leakage is found. Cooling tubes then attach with
transformer body. The tank is then tighten with a temporary top cover to check
leakage between transformer body and cooling tubes. After getting passed from there
it is sent to the paint section. It is painted in red color for initial coating. After drying
the body is then send to assembly area.

3.9.4 Preparation of tank body

A layer of gasket is applied. Five millimeter thin insulator is called gasket which is
also found in bushing gasket. As this has spongy behavior, this makes most tight
arrangement without damaging anything. Transformer gasket is cut according to the

Figure 3.22: Gasket on tank body

55
size of top layer of tank body. By applying glue it is being attached with tank body.
The shape of gasket should be very accurate. If it is not then it will create problem
with tight and perfect fitting.

3.9.5 Tanking

After packing tank gasket it is time to insert transformer inside its tank. Top cover of
transformer has two suspension hocks and by using a lifting system is being
suspended on air. Transformer tank is being placed under transformer core by a slider
when core goes above tank level. After that core is put inside the tank with great care.

Figure 3.23: Tanking

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Any mistake can damage transformer core and coil connection. In the figure 3.38
shown that one man is controlling suspension cable, one is adjusting core direction
and another person is placing tank to it’s proper position.

3.9.6 Top nut holes tightening

After inserting core inside tank some nuts bolts are used to tightening top cover with
tank.

3.10 Conservator tank fitting and oil filing

Conservator tank is not manufactured by Powermann. Powermann doesn’t have

enough space in their current factory to manufacture. It is imported and stored in a
separate place after painting. There are some major steps in this section. They are,

i. Oil gas and gasket preparing (cutting, drilling, grinding)

ii. Oil level fitting
iii. Flange gasket cutting and grinding
iv. Drilling for ABC/abcn marking
v. Oil centrifuging and fitting

Conservator tank is then collected form paint section and give fitting with transformer
tank. Then transformer tank is going to be filled with transformer oil. Then some
drilling is done for ABC and abcn mounting pates. It takes some time to fill the whole
core section with oil. After oil centrifuging again some oil is added for fitting.

3.11 Receive from paint section

Before paint any kind of dust and rust are removed. After cleaning surface of
transformers it is time for final paint. All the transformers are painted in silver color.
It is very practical to use light color because it reflects sun light and heat.

57
 Figure 3.24: Paint section
Then it is time for final finishing. In this step four things are done. They are,

i. Max-min numbering setting

ii. LT and HT bushing cleanin
iii. Earthing nut, Arking horn, Thermometer setting
iv. Short oil filling

At oil conservator tank max-min number plate is set up for having a clear view on oil
level. Generally it is an oil level indicator. After coloring LT and HT bushing need to
clean. Earthing nut is installed at any bottom corner of transformer. Arking horn is
installed on HT line and transformer body. A thermometer is set up for measuring oil
temperature. During doing those steps some oil is absorbed by some materials like
cotton tape, wood, insulation paper. At the final step some oil is added for short oil
filling.

58
 Chapter-04
250 kVA transformer testing

59
4.1 Testing

In powermann twelve transformer tests are available. Only five of them are used for
regular transformer testing before sending to consumers and the others are used to
detect fault of any faulty transformer. If new transformer has any fault that can be
easily be understood by this five main test .

Tests that are carried out in Powermann are,

i. Insulation resistance test (Megger test)
ii. Winding resistance measurements
iii. Voltage ratio test
iv. Vector group test
v. No load loss test
vi. Full load test

4.1.1 Megger test:

Insulation Resistance or IR Test is carried out by maintenance engineers to

ensure the healthiness of overall insulation system of an electrical power
transformer. It reflects the presence or absence of harmful contamination, dirt,
moisture and gross degradation. IR will be usually high (several hundred Mega
ohms) for a dry insulation system. Maintenance engineers use this parameter as
an index of dryness of the insulation system.

The procedure of insulation resistance tests are given below:

1. First disconnect all the line and neutral terminals of the transformer.
2. Megger leads to be connected to LV and HV bushing studs to measure
Insulation Resistance IR value in between the LV and HV windings.
3. 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.
4. 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.

60
Test result:
LT + Body (MΩ) = 525 (MΩ)
HT + Body (MΩ) = 1113 (MΩ)
LT + Body should be more than 500 (MΩ) and HT + Body should be more than
1000 (MΩ) of 250KVA transformer otherwise less insulation should be cause of
short circuit in the transformer.

4.1.2 Winding resistance test

In winding resistance test, we will measure resistance of the HT side coil. LT side
resistance does not need to check because LT side coil resistance always will become
at µΩ. If the each phase of the HT side resistance becomes same or approximately
same then, we can say that the coil resistance level of the transformer is good. For this
purpose a multi meter uses for measuring. Minimum 1 minute need to hold the
terminals of the multi meter during checking period. RAB, RBC, RCA as this procedure
winding resistance test has to find out. After getting result a result sheet uses for
collecting it. HT side resistance level measured in Ω. When the getting result become
same or approximately.

4.1.3 Voltage ratio test

In earlier sections I discussed about turns ratio according to primary delta and
secondary wye voltage. Higher voltage might have risk for initial testing. That’s why
primary supply voltage is limited to around 450 volts. If the primary and secondary
voltage turns ratio is exactly or around the original turn ratio then the transformer is
okey.
NP √3 × VP
=
NS VS
Now for all the tapping we are going to test the ratio at primary supply voltage around
450 volt. At table 3.2 shown that measured the primary voltage according to
secondary voltage which is fixed. But in this test our primary voltage is fixed and
secondary voltage is changed for each tapping. We will find turn ratio for original
high primary voltage (11 kV) and low secondary voltage (415) for each tapping by
mathematics. And we will compare this result for each tapping number with our
practical measured voltage.

61
If the ratio turn results out the same that means our transformer has passed in turn
ratio test. In this test the secondary side is open. All the test voltages are taken from
Vbc.
Table 3.3: Voltage ratio test (open circuit test)

Original Original Test Test

Original Test
Tapping primary secondary primary seconday
turn turn
number voltage voltage voltage voltage
ratio ratio
(volt) (volt) (volt) (volt)

1 11274 415 426 15.38 47.05 47.97

2 11000 415 426 15.77 45.91 46.78

3 10719 415 426 16.55 44.74 44.58

4 10442 415 426 16.57 43.58 44.53

5 10164 415 426 17.00 42.42 43.40

In the table shown that test turn ratio is almost equal to original turn ratio. In our
practical life supply voltage fluctuates a lot. Also we did not count any reactance or
resistance loss in our mathematical calculation. Overall the transformer is passed in
open circuit test.

For each phase the result is given below.

Table 3.4: HT versus LT voltage

HT voltage (volts)

VAB = 430 VBC = 426 VCA = 432

LT voltage (volts)

Tap-1 Tap-2 Tap-3 Tap-4 Tap-5

Vab 15.48 15.78 16.55 16.68 17.10

Vbc 15.38 15.77 16.55 16.57 17.00

Vc 15.24 15.65 16.68 16.80 17.00

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If the secondary voltages of Vab, Vbc, Vca is continuously increasing with tap- 1
to tap- 5 than the ratio test has been passed.

4.1.4 Vector group test

The transformer we are dealing with is DYn11 transformer [5]. Through vector group
test of a transformer we can know that the winding configuration of a transformer.
Like if a transformer is having a vector group DYn11. It means

i. Primary HT side has delta connection

ii. Secondary LT side has wye connection
iii. Neutral is brought out
iv. LT leads with 30 degree from HT
Vector group configuration after connecting the transformer image is given below-

Figure 4.1: Vector group test

The connection with transformer is given below-

Figure 4.2: Transformer wire connection for vector group test

Then we need to measure the voltage of VB1-b2, VB1-c2, VC1-b2 and VC1-c2. As the
distance between B1b2 and B1c2 are equal so that they should have similar voltage.

63
And the distance between C1b2 and C1c2 are not equal. They should have different
voltage. The equation is given below,

i. VB1-b2 = VB1-c2
ii. VC1-b2 > VC1-c2
The result of this vector group test is given below,

Table 3.5: Vector group test

Connection Voltage (V)

VAB 430 V
VBC 426 V
VCA 432 V
VB1-b2 420 V
V B1-c2 420 V
VC1-b2 442 V
V C1-c2 420 V

By doing this vector group test we can ensure the connection type.

4.1.5 No load test

On this test generally secondary side is needed to be kept open. This test is done to
find out leakage current. This current is responsible for supplying the iron losses
(hysteresis and eddy current losses) in the core and a very small amount of copper
losses in the primary winding. The angle of lag depends upon the losses in the
transformer.

But in Powermann Bangladesh Limited they reverse that test. Instead of doing this
test on primary side they do this in secondary side. This has two benefits.
i. Working with lower voltage is safe than higher voltage
ii. Clamp-on multi-meter is less accurate below 100mA current. We need to CT.

We can easily convert secondary leakage current value to primary leakage current.

64
This procedure is done in Powermann.

The result is given below,

Table 3.6: No load test

Measured voltage (V)

Parameter Vab Vbc Vca
Value 420 417 420
Measured current (A)
Parameter Ia Ib Ic
Value 3.99 3.30 3.80

Average voltage is Vs = (420+417+430)/3 = 422.33 V.

Average current is Is = (3.99+3.30+3.80)/3 = 3.7 A.
Primary voltage is ,
NP √3 × VP
=
NS VS

1744 √3×𝑉𝑃
or, =
38 422.33
17744 ×422 .33
or, VP = = 11190.62
38 × √3

At this voltage primary leakage current Ip is,

IP VS NS IP
= another way, =
IS VP NP IS × √3
VS × IS NS × IS × √3
or, IP = or, IP =
VP NP
422.33 × 3.7 38 × 3.7 × √3
or, IP = =0.14 A or, IP = =0.14 A
11190.62 1744

After calculation primary leakage current is 0.14 A.

4.1.6 Full load test

Secondary terminals are short circuited by a rod using some nuts bolts. This test
ensures the ampere rating of transformer. This time constant current supply is

65
provided in primary side which is around the value of line current on primary side.
Voltage is kept around 420 volts.

The result is given below,

Table 3.7: Full load test

Measured voltage (V) Measured HT current (A) Measured LT current (A)

VAB 426 IA 10.43 Ia 275

VBC 424 IB 10.29 Ib 266

VCA 426 IC 10.25 Ic 275

During the design of the transformer we found max output current is round 278 A. It
proves that the transformer can deliver that much of current.

Figure 4.3s: Full load test

In this figure 3.41 shown that measuring current between A and B on primary side
using a clamp-on meter.

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 Chapter-05
Complementary part

67
5.1 Recommendations

After completing 3 months internship, I think- something should be better in the

factory of “Powermann Bangladesh Limited”.

 The work place too much small. Its need proper space in every section.

 They cut the core manually. But it should be cut by automatic core cutter
for more production.

 In factory, the safety of the workers is too small. They should maintain
more safety for workers. They should keep proper safety device and
equipment for the workers.

 Generally they take 7 tests of a transformer but they should go over more
transformer test.

 For safety, the wire use in HT and LT coil should be more from rated
value of wire.

 In factory, there have not sufficient washroom for workers.

 The factory should have proper ventilation system because it is a very hot
place.

5.2 Conclusion

After completing 3 months internship, I have learnt lots of things about

Transformer design, manufacturing and testing. I also learn about different fault of
transformer and how it can be detected. Not only transformer but I also learn
about different switchgear equipments, like- HT panel (VCB, LBS), LT panel, PFI
Panel etc. From there I also learnt how to install a substation. After completing
internship, I think it increases my practical knowledge which will be very helpful
to my feature life. At last, I fell very lucky for doing internee in such a company
like Powermann Bangladesh Limited.

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 Figure 5.1: Observing transformer

5.3 Reference

[1] Theraja, B.L. & Theraja, A.K. A text book of Electrical Technology, Volume-
II.

[2] “Powermannbd.”<http://www.powermannbd.net/view_text.php?iden=f
_p&id=1>. March 12, 2019.

[3] “electrical4u.com”<https://www.electrical4u.com/what-is-transformer-
definition-working-principle-of-transformer>. March 28, 2019.

[4] “electronics-tutorials”<http://www.electronics-tutorials.ws/transformer/three-
phase- transformer.html>. April 4, 2019.

[5] “quora.com” <https://www.quora.com/What-is-the-test-procedure-of-vector-

group-of-a-transformer-having-vector-group-Dyn11>. April 10, 2019.

[6] “electrical4u.com”<https://www.electrical4u.com/transformer-testing-type-
test-and-routine-test-of-transformer/#>. April 15, 2019.

69
 Appendix

kVA = Kilovolt Ampere

A = Ampere
V = Voltage
( A / L)LT = Axial length of LT coil

W/H = Window height

HT-OD = Outer diameter of HT coil
VL = Line voltage

VP = Phase voltage
Ip = Phase Current

I L = Line Current
N P = Primary turns

N s = Secondary turns

O/D = Outer Diameter

I/D = Inner Diameter
A/L = Axial Length
LT = Low tension
HT = High tension
ϕm =Magnetic flux
HV =High voltage
LV = Low voltage
Yd = Star-delta
Dy = Delta-star
PT = Potential transformer
CT = Current transformer

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