Field training in

Transformer company
Presented
by
Shridhar
B. kulkarni
RIT
Islampur

Company Profile
Company name:

Datta electricals, Engineers

and Contractors
Government of India approved,ISO 9001:2008

certified company, Govt. Licened Electrical

contractor
Name of the business: manufacturer,

Supplier,service

Stages of transformer manufacturing:

Design and drawing
Core assembly
Core-coil assembly
Tank-up process
Paint process
Finishing
Testing of transformer

Design
Voltage class
Rating
Frequency
Purpose
Type of winding

Note: Basic factors are given above . Design is done theoretically

and also by using MATLAB software

Core Assembly

The basic raw-material is COLD ROLLED

GRAIN ORIENTED (CRGO) Silicon Steel

It is in the form of thin sheets & cut to size as

per design.

Generally

three different shapes of core

laminations are used in one assembly.

The laminations are put through annealing

process.

These laminations are assembled in such a

manner that there is no air gap between the

joints of two consecutive sheets.

The entire assembly is done on a frame

commonly known as core channel.

These frames being used as a clamping

support of the core assembly

Core-coil assembly
The core assembly is vertically placed with the

foot plate touching the ground. the top yoke of

the core is removed. The limbs of the core are
tightly wrapped with cotton tape and then
varnished.
Cylinder made out of insulating press board/
pressphan paper is wrapped on all the three
limbs.
Low Voltage Coil is placed on the insulated core
limbs. Insulating block of specified thickness and
number are placed both at the top and bottom of
the L.V.Coil.
H.V. Coils are placed over the cylinder.
Gap between each section of H.V. Coils including
top & bottom clearances is maintained with the
help of oil ducts, as per the design/drawings.
The Top Yoke is refilled. Top core frame including
core bolts and tie rods are fixed in position.

Tank up process
The core-coil assembly is taken out of the

oven and the "Megger test" is carried out.

The tanks, supplied by fabrication deptt. are

brought to tank-up department duly painted.

Fittings like drain valves, HV& LV Bushings,

conservator, oil level indicator and explosion

vent are fitted in the tanks.
The Core-coil assembly is then placed into

the tank and properly locked up.

Pure filtered transformer oil is filled in the

tank to immerse the assembly only.

Connections of primary and secondary to the

terminal bushings are made. Operating handle

for ratio switch is fitted, wherever required.

Paint Process
Cleaning of tanks
The cleaning of tank is done normally by chipping/grinding.
The outside surface of the tank is short blasted to achieve a very fine and smooth

finish
Painting of tanks
After cleaning the tanks, a coat of hot oil resistence paint is applied on the internal

surface of the tank.

The outside surface is painted with a coat of Red Oxide primer and subsequently
with one coat of enamel paint as per customer's requirement.

Finishing
Fittings and accessories as per customer's specification and drawing are checked.
Transformers are filled with oil upto the minimum level marking, wherever

necessary.
Loose accessories like, earthing terminals, bimetallic connectors, dial type

thermometers are also checked for proper fittings.

Testing of transformer
Measurement of winding resistance test
Measurement of insulation resistance
Ratio test
Measurement of No load loss & No Load Current
Oil Dielectric Test

 Problem Formation of sludge in the oil of transformer after 10

to 20 years
Suggested method use OM4 optical fiber for detection

Oil deterioration in transformers

Atmospheric oxygen and moisture serve as source of oxygen
The rate of oxidation depends on oil temperature
As temp. increases oxidative breakdown becomes faster
This process of oxidation results in formation of sludge
Cause-

1)insulation failure
2)SC occurs between turns
3)Breakdown of transformer

Model for sludge estimation

Conclusion
During these 15 days of training, I analysed the typical

manufacturing process and testing methods. But

almost all transformers have 97-98% efficiency.
Therefore it is difficult to make new design which
gives more than 98%.
But I found one problem of sludge formation in the oil
of transformer and I suggested one novel method to
the company and company is satisfied with this
solution

Contact details:
Shreedhar.kulkarni65@gmail.com