SUPERVISED INDUSTRIAL TRAINING REPORT

TransfoPower Industries (Pvt) Ltd Lahore

Supervisor Name: Engr. Mouzzam Rehman

Submitted By: Muhammad Ashfaq
Roll. No: 15947
Class: B.S.C Electrical Engineering
Technology 8(M)
Reg. No: GCUF- 15947-2014
Training Period 15-02-2018 to 15-06-2018

DEPARTMENT OF ELECTRICAL ENGINEERING

GOVERNMENT COLLEGE UNIVERSITY FAISALABAD
SAHIWAL CAMPUS
PUNJAB PAKISTAN
2018
 Certificate

I hereby certify that I have completed the fifteen weeks training in partial fulfillment of the
requirements for the award of BS ELECTRICAL ENGINEERING TECHNOLOGY. I did my
training in Transfopower industries from 15-02-2018 to 15-06-2018.
The matter presented in this report has not been submitted by me for the award of any other
degree elsewhere.

Student Signature:
Muhammad Ashfaq
2014-GCUF-15947

Examined by:
Engr. Mouzzam Rehman

Incharge HOD:
Electrical Engineering Technology Department
 ACKNOWLEDGMENT

First of all, I would like to thanks my Institute, GCUF (Sahiwal Campus), for arranging the
internship program for me. I am also grateful to Transforpower industry Lahore for recruiting
me as an intern. I would like to place on record my deep sense of gratitude to Engr Javeed
Iqbal.
I would like to place on record my deep sense of gratitude to HR Manager and faculty member.
I take this opportunity to express me profound gratitude and deep regards to my Team Leader
for his exemplary guidance, monitoring and constant encouragement throughout the course of
this internship. The blessing, help and guidance given by him time to time shall carry me a
long way in the journey of life on which I am about to embark. I am extremely grateful and
remain indebted to Transfopower industry for being a source of inspiration and for his constant
support in intern.
I am obliged to all my team members, for the valuable information provided by them in their
respective fields. I am grateful for their cooperation during the period of my internship.
I am obliged to all my team members, for the valuable information provided by them in their
respective fields. I am grateful for their cooperation during the period of my internship.
I‘m thankful to them for their continual constructive criticism and invaluable suggestions and
help, which benefited me a lot at my intern.
I would like to specially thanks Engr. Mouzzam Rehman for his proper assistance and
guidance.

I
 Table of Contents

Actnowledgement......................................................................................................................I

List of Abbreviations..................................................................................................................V

List of Figures............................................................................................................................VI

List of Tables.............................................................................................................................VII

Chapter No.1: Introduction to Industry...................................................................................1

1.1 Introduction of TransfoPower industry..................................................................................2

Chapter No .2 Training Work..................................................................................................5

2.1 Introduction of Transformer..................................................................................................6

2.2 Quality Control Section .......................................................................................................9

2.2. 1 Enamel Copper wire...........................................................................................................9

2.2.2 Paper insulated copper strip...............................................................................................11

2.2.3 Flat and round copper bus bars..........................................................................................12

2.2.4 Mild steel material.............................................................................................................13

2.2.5 Craft paper sheet................................................................................................................14

2.2.6 Neoprene rubber material..................................................................................................15

2.2.7 Insulating varnish..............................................................................................................16

2.2.8 Hardware material.............................................................................................................17

2.3 Transformer Windings.........................................................................................................18

2.4 Transformer cores................................................................................................................20

2.5 Transformer tank section.....................................................................................................22

2.6 Transformer Assembly........................................................................................................26

2.7 Pad mounted transformer.....................................................................................................27

II
Chapter No.3 Skill Attaining...................................................................................................42

3.1 Transformer Testing.............................................................................................................43

3.1.1 Voltage ratio test................................................................................................................43

3.1.2 Mugger test procedure.......................................................................................................45

3.1.3 Winding resistance test......................................................................................................46

3.1.4 Load losses test..................................................................................................................47

3.1.5 No load losses test.............................................................................................................47

3.1.6 Induced voltage test...........................................................................................................48

3.1.7 High voltage test................................................................................................................49

3.1.8 Bird protection test ...........................................................................................................49

3.1.9 Pressure test.......................................................................................................................49

3.2 Oil Tests to Check its Quality.............................................................................................50

Chapter No.4 Feedback & Recommendations.......................................................................56

4.1 Conclusion............................................................................................................................57

4.2 Recommendation..................................................................................................................58

4.3 References.............................................................................................................................59

List of Abbreviations

WAPDA Water and Power Development Authority

KESC Karachi Electric Supply Company
ONAN Oil Natural Air Natural

BDV Break Down Voltage

TTR Transformer Turn Ratio

ACT After Connection Test

III
BCT Before Connection Test

CT Current Transformer

PT Potential Transformer

VCB Vacuum Circuit Breaker

DC Direct Current

AC Alternating Current

E/F Earth Fault

O/C Over Current

CNC Computer Numerical Control

LB Load Breaker

MS Mild Steel

SS Stainless Steel

PMT Pad Mounted Transformer

List of Figures

Figure: Title: Page:

2.1 Working of transformer 6

2.2 Parts of transformer 8

2.3 Enamel copper wire 9

IV
2.4 sample of heat shock test 11

2.5 Paper insulated copper wire 11

2.6 flat & round copper bus bar 12

2.7 Mild steel sheet 13

2.8 Neoprene Rubber materials 15

2.9 Hardware materials 17

2.10 Transformer core 20

2.11 Transformer assembly 24

2.12 CT 28

2.13 CT Structure 29

2.14 PT 31

3.1 TTR meter 39

3.2 Mugger 43

List of Table

Table: Title: Page:

2.1 BDV procedure of enamel wire 10

2.2 Through bolt rating for LT and HT side 18

2.3 Transformer tapping steps 21

2.4 Core stacking for 25 KVA 23

V
2.5 Breaker and fuse rating for PMT 28

2.6 WAPDA turns ratio values for 3 phase transformer 29

2.7 Karachi turns ratio values for 3 phase transformer

2.9 Pressure test procedure 50

VI
Chapter 1
Introduction
Introduction of Transfopower Industry
Transfopower Industries (Pvt) Limited is a leading company in Pakistan’s transformer
manufacturing sector. Established in 1990 by a team of engineers who literally pioneered
transformer manufacturing and design in the country, the company has quickly risen to
consolidate its position as a technology leader and, one of the most esteemed producers of high
performance transformers both in terms of quality and innovation.
With a strong commitment to engineering excellence at the core of company philosophy and a
dedicated research and development focus on transformers the company has the capability to
produce a wide range of products including Distribution transformers , Power transformers,
Furnace transformers, Dry type and Non inflammable transformers. special purpose
transformers designed for specific application offering the best in price, delivery & quality.
Presently, we are manufacturing transformers in 5KVA to 5000KVA range, for WAPDA Area
Electricity Boards, DISCO’s, KESC, AJK (WAPDA House, Mangla and Tarbela Power
Projects) and leading projects in the private sector (Bahria Town, DHA, GHQ, Shell, KSB
Pumps, Chashma Nuclear Power Plant, Sui Northern, CWO and other industries both local and
multinational of all sectors).
Due to a total quality orientation Transfopower Industries (Pvt) Ltd has been achieving
customer satisfaction, catering to both the local and export markets. We aim to further
strengthen our established base and achieve and exceed customer expectation by striving for
continuous improvement in product development, design and services, keeping abreast of the
latest developments in global technology and ensuring human resource development through
training, motivation and provision of suitable work environment.
The manufacturing process is supervised and quality assured by a team of highly focused
technical staff at all stages in compliance with all international quality standards at our state of
the art manufacturing facility. Also tests according to relevant standards are carried out before
dispatch. Transfopower is ISO 9001:2000 Certified Company. We believe in environmentally
friendly manufacturing.
The scope of all our certifications according to international standards is for the design
manufacture and sale of Distribution, Power, Furnace and Special transformers.
Since 2013, Transfopower Industries (Pvt) Ltd has stepped into the Energy Metering market
and has become one of the fastest growing Energy Meter Manufacturers in Pakistan. Our
products range from both conventional Single phase/Three Phase/CTO meters to Smart
Metering solutions offering state of the art features for meter data collection, data storage and

2
billing. Transfopower’s Energy Metering division caters for a range of Clients including
WAPDA and its distribution companies, AJK, K-Electric (formerly KESC) and for the private
sector. Due to total quality orientation Transfopower Industries (Pvt) Ltd has been achieving
customer satisfaction, catering to both the local and export markets. Transfopower Industries
(Pvt) Ltd is an ISO 9001:2008, ISO 14001:2004 and OHSAS 18001:2007 Certified Meter
Manufacturer.
Quality Policy
Presently, we are manufacturing Transformers from 5KVA to 5000KVA for WAPDA Area
Electricity Boards, KESC, AJK and the Private Sector like Housing Societies, Shopping
Plazas, Fuel Stations, Industries (Sugar, Textile, Cement, and Engineering etc.). Also Furnace
Transformers have been manufactured for STEEL MILLS in Pakistan and Africa.
To achieve this aim, the Management at Transfopower is committed to:
• Implement an effective management system for the continual improvement.
• Increasing our business and performance through excellent QHSE awareness.
• Conducting business in a manner that protects public, Environment, occupational health and
safety (prevention of injury & ill health) of employees.
• Striving to eliminate all accidents and incidents.
• Making QHSE consideration a priority in our business.
• Reducing emissions, wastes, energy and natural resources efficiently and intelligently.
• Complying with QHSE laws and regulations & other requirements.

3
4
Chapter 2
Training Work
2.1 Introduction of Transformer
Definition:

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.

Working of Transformer

Figure: 2.1 working of transformer

it works on the principle of mutual induction of two coils or Faraday Law’s Of

Electromagnetic induction. When current in the primary coil is changed the flux linked to the
secondary coil also changes.hence an EMF is induced in the secondary coil due to Faraday
law’s of electromagnetic induction.

6
The transformer is based on two principles: first, that an electric current can produce a
magnetic field (electromagnetism), and, second that a changing magnetic field within a coil of
wire induces a voltage across the ends of the coil . Changing the current in the primary coil
changes the magnetic flux that is developed. The changing magnetic flux induces a voltage in
the secondary coil.

Parts of transformer:

Main parts of transformer are following

1) Steel tank
2) Core
3) Windings
4) Conservator
5) Breather
6) Thermometer
7) Pressure relief pipe
8) Valves
9) Buchholz relay
10) Bushings
11) Tap changing switch
12) Oil gauge
13) Radiator
14) Cooling fans
15) oil pumps
16) Transformer insulation
(1)Conservator
Conservator is a type of tank , used to help oil filling this is situated upper portion of the
power transformer . mainly these are cylindrically shaped.
2) Tank
Basically this is a container used to keep windings(both) and cooling oil.
3) Buchholz Relay
This is a protecting device used to protect our transformer windings . this is a double ended
device one end is connect to conservator other is connected to tank. there are two windings
inside the relay one for detecting oil level gain to empty and other is connected to a alarm

7
circuit for warning.
4) Breather
Breather is a device used for absorb the moisture content of a oil and sucked air
5) Silica jell
It is a chemical material these are the only one main component inside the breather basically
silica jell is a brown colour one after the absorbtion silica jel become pink.
6) Oil level scale
This is a ordinary part situated on the side of the conservator for proper oil checking oil tank
wants a specific amount of oil
7) Primary winding
In the case of power transmission primary windings are the main element external
connection from the power is connected to winding
8) Secondary winding
This is a another winding for reducing power(in the case of step down purpose)
9) Drain valve
This valve is used for taking damaged oil from the oil tank for the proper oil collection this
valve is situated under the oil tank.
10) Purceline bush
This is a outer unit , this is used to prevent unwanted leakage of electricity
11) Radiator
This device is used to cooling oil.

Figure: 2.2 parts of transformer

8
Following sections are included in manufacturing transformers.

1. Designing
2. Quality control
3. Windings
4. Cores
5. Assemble Testing

2.2 Transformer Quality Control

Objectives
In this section , I have studied how to test different materials used in making transformer.
Materials include enameled copper wire, paper insulated copper strip , round and flat copper
bus bars, copper sheet, mild steel material, hardware materials and rubbers material.

2.2.1Enamel copper wire

Figure: 2.3 Enamel copper wire

Magnet wire or enameled wire is a copper coated with a very thin layer of insulation. It is used
in the construction of transformers, inductors, motors, speakers, hard disk head actuators,
electromagnets, and other applications that require tight coils of insulated wire.Copper is used
because it has a low electrical resistance. This means that it is easy for the current to flow
through it. Also, copper wire can be easily shaped to make a coil.

9
Work Instruction
1)Take the sample of 1000 mm of all copper reels and label the serial numbers on
each copper wire and reels with stickers.
2)Remove the enamel from each wire (about 3 to 4 inches from ends) with help of
sulfuric acid (H2SO4) or by burning.
3)Measure the insulated enamel wire size and copper bare size.
4)Calculate the standard resistance* at room temperature.
Rs = pl/A*235+Temp/235+20 ( p= 0.0172, A=3.14 d^2/4 )
5)Measure the resistance of enamel copper wire with Ohm Meter.
6)Check the difference between measured and standard resistance.
7)The difference should be with in tolerance (max +1%).
8)Make the sample of twisted enamel wire for high voltage test.
9)The twisted area should be 125 mm and number of turns* & break down voltage*(BDV)
should be according to copper bare size.
Table 2.1: BDV procedure of enamel wire
Sr.No Size Turns BDV
1 0.11 mm – 0.25 mm 32 1.7KV
2 0.25 mm – 0.35 mm 28 2.0KV
3 0.35 mm – 0.51 mm 16 2.8KV
4 0.51 mm – 0.75 mm 12 3.2KV
5 0.75 mm – 1.05 mm 8 4.0KV
6 1.05 mm – 1.50 mm 6 4.3KV
7 1.50 mm – 2.15 mm 4 4.4KV
8 2.15 mm – 2.50 mm 3 5.0KV

Equipments Used
 Mili Ohm Meter
 Digital Micro meter
 High Voltage Transformer (0 – 15 kV)
 Thermometer

10
Heat Shock Test
This test is used to check the quality of enamel on enamel copper wire. The sample prepared
for the mandrill test is placed in electric oven at temperature 155 Co to 166 Co for ½ hour and
again mandrill test will be performed for test compliance.

Figure: 2.4 Sample of heat shock test

2.2.2 Paper Insulated Copper Strip

Work Instructions:

Figure 2.5 Paper Insulated Copper Strip

1)Take the sample of 1000 mm from each PI Copper Strip.

2)Measure the copper size with insulation paper and without insulation paper (bare size).
3)The paper insulation must be maximum 0.6 mm.
4)Calculate the measured area of PI Copper Strip (with measured size).
5)Subtract the edge factor* (round off) from measured area according to thickness
6) Calculate the standard area of PI Copper Strip (with standard size).
As = thickness * width – factor
7) Measure weight of PI Copper Strip and calculate weighted area with density of copper*.

11
Weight = area * copper density (d=8.9 g/cm^3) , Aw = weight/density
8)Check the difference between measured and standard area.
The difference should be with in tolerance (max +4 %).
9)Calculate the standard resistance* at room temperature.
Rs = pl/A*235+temp/235+20
10) Measure the resistance of PI Copper Strip with Ohm Meter.
11)Check the difference between measured and standard resistance.
12)The difference should be with in tolerance (max +1%).
* The edge factor according to thickness
0.00 mm to 1.70 mm => 0.1 mm
1.71 mm to 3.99 mm => 0.3 mm
4.00 mm to above => 0.9 mm
Equipments Used:
Micro Ohm Meter
Digital Micro meter
Digital Vernier Calliper
Digital Weighing Scale
Thermometer

2.2.3 Flat & Round Copper Bus Bars

Figure 2.6 Flat & Round Copper Bus Bars

12
Work Instructions:

1)Take the sample of 200 mm from each copper length.

2)Measure the size of each copper sample.

3)Calculate the standard area of flat copper (with standard size).

As = weight / density * 1000/ Length

4)Calculate the measured area of flat copper (with measured size).

5)Check the difference between measured and standard area.

6) The difference should be with in tolerance (- 3% to + 5%).

7) Calculate the standard resistance* at room temperature.[ Rs=pl/A*235+temp/235+20]

8) Measure the resistance of flat copper with Ohm meter.

9) Check the difference between standard and measured resistance.

10) The difference should be with in tolerance (< +15%).

Equipments Used:
Micro Ohm Meter
Digital Micro meter * The standard resistance * The density of
Digital Vernier Calliper R = ρ x L/A copper
Digital Weighing Scale At 20o C 8.89 g / cm3
Thermometer

2.2.4 Mild Steel Material

Figure 2.7 Mild Steel Sheet

13
Work Instructions:1)Check the MS material (Sheet, Angle, Channel, Flat& Elliptical
Tubes) physically.

2)Measurethe dimensions of MS material.

3) The size should be as per requirement and within tolerance.
4) Take the sample of MS material for hardness test.
5)60mm x 90mm for MS sheet, 2 to 3 inches for channel, angle and flat.

6) Place the sample under diamond cone (hardened steel ball indenter) on Rockwell
Hardness Tester and set it at 60 N with zero setting.

7)Rotate the round lever until the big needle complete three rotations.

8)Make sure that the small needle should not cross the red mark.

9)Pull the loading lever and release it and wait for stability of big needle.

10)Check the reading from corresponding scale.

The reading should be 24 – 44 HRA.

Equipments Used
Digital Micro meter
Digital Vernier Calliper
Rockwell Hardness Tester

7) 2.2.5 Craft Paper Sheet

Work Instructions:
1)Check all the Craft Paper Sheets physically.
2)Measure entire dimensions of all the craft paper sheets specially thickness.
3)Take a sample of 60 x 100 mm from all CP sheets from Break Down Voltage Test.
4)Fill the beaker of Di – Electric Tester with fresh transformer oil (Mineral Oil).
5)Put craft paper sheet sample in beaker and tight the electrodes firmly.
6)Close the lid and press the power button to supply the voltages.
7)Check the break down voltage of craft paper sheet.
8)The break down voltage should not less than standard voltage i.e.

Equipments Used:
Di – Electric Tester

14
 Electric Cutter
Digital Vernier Caliper

2.2.6 Neoprene Rubber Material

Figure 2.8 Neoprene Rubber Material

Work Instructions:
1)Check all the rubber material (Gasket, Ring Washers and Round Washer) physically.
2) Check the entire Dimensions according to specific drawings.
3) Burn the rubber material and it should extinguish itself after burning.
4) Wound the enamel copper wire on rubber material and burn it, the Green flame should be
observed.
5) Crush the rubber material into pieces for Chemical Test.
6) Drop the crushed rubber material in Hydrochloric Acid (HCL), the pungent smell should
be observed.
7)Drop the crushed rubber material in Nitric Acid (HNO3) and boil it, brown smoke should
be observed.
8) Check the Hardness of rubber material with shore Durometer (60 – 90).
9)Take a sample of rubber material and check its weight for Change in Mass Test.
10) Dip that sample of rubber material in mineral oil and place it in the furnace for 72 hours at
temperature of 110o C. %E = Fw-Iw/Iw*100
11)Check the difference in mass that should be in accepted tolerance (-5% to +15%)
12)Crush the rubber material and check its mass for Specific Gravity Test.
13)Drop the crushed rubber material in water filled jar and check the water volume difference.
14)Multiply that difference with factor 1.15 and 1.35 to determine the required accepted
weight range.
15)The weight of rubber material should be with in calculated range.

15
2.2.7 Insulating Varnish

Work Instruction:
1) Make the box tray of size 1 ½ x 1 ½ inch with press pan paper (0.1 mm thickness).
2)Take the samples of Insulating Varnish from each can (canister) and put in the trays.
3)Fill the trays with entire varnish samples up to 5mm.
4)Put the varnish filled trays in furnace for 24 hours at temperature of 120 °C.
5)Take the trays out from furnace and wait for cool them down to normal temperature.
6)The varnish should be flexible, it should not be breakable.
7)The varnish should be completely dried.

Equipments Used:
Thermostatic Electric Furnace
Digital Vernier Caliper

16
2.2.8 Hardware Material

Connectors Through Bolt

Bushing
Fuse clamp

Tap changer

Figure 2.9 Hardware Material

17
Work Instructions:
Check the following hardware material physically:

HT & LT Connectors HT & LT Bushing Assembly

HT & LT Through Bolt HT & LT Insulator
HT & LT Fuse Clamp HT Insulating Tubes
Oil Filling Plug & Collar Oil Level Gauges
Press Pan Papers Craft Paper Rings
Silica Gel Breather Arcing Horns
Lifting and Jacking Lugs MS Flange Gate & Drain Valves
Tap Changer Guide & Pins Tap Changer Components & Assembly
Tank Gaskets Rating Plates & Circuit Diagrams
Arc Stranglers Earthing Terminals

MS, SS and Brass Nut, Bolt & Washers (Spring & Round)
Check entire dimensions of all hardware material according to specific drawings.
Perform High Voltage Test to check Break Down Voltage of following material:
Press Pan Papers, HT Insulating Tubes, HT Insulator, Arc Stranglers
Equipments Used:
High Voltage Transformer
Digital Varnier Caliper
Digital Micro Meter

Table 2.2: Through Bolt

Sr.No Transformer LT Through Bolt HT Through Bolt

Rating (KVA) rating (A) rating (A)
1 10,25,50,100 200 200
2 200,250 600 200
3 400,500 1000 200
4 630,750,1000 2000 200
5 1500 3000 600
6 3000 4500 600

18
2.2.9 Method of Testing Panel Box According To
Drawing & Specification
1. Check the length of panel frame.
2. Check the width of panel frame.
3. Check the Height of panel frame.
4. Check the distance of roof to body.
5. Check the door gaps.
6. Check the size of L.T Compartment side.
7. Check the C2C distance b/w base plate angle.
8. Check the length of base plate angle.
9. Check the size of fitting accessories.
10. Check the distance between foundation supports.
11. Check the door alignment.
12. Make report and get it signed By GM Works/S.E.D.

2.2.10 Method of testing Tank Size according To Drawing

1. Check the length of tank frame.

2. Check the width of tank frame.

3. Check the Height, length and width of tank body from inner side.

4. Check the total length and width of tank.

5. Check the distance of tank tubes from tank frame.

6. Check the distance of tank tubes from tank bottom.

7. Check the gaps from tubes.

8. Check the distance from wheel to wheel.

9. Check the length of channel.

10. Check the quantity of tubes.

11. Check the size and numbers of holes on tank frame.

12. Check the distance between core guides.

19
 13. Check the distance between stiffeners.

14. Make report and get it signed By GM Works/S.E.D.

2.3 Winding Section

In the winding section L.V and H.V windings of the coil are made.

Raw Material

For LV winding:

(1)Paper insulated flat copper wire

(2)Copper foil

For HV winding:

(1)Enamel copper wire (usually for 10KVA to 200KVA)

(2)Paper insulated flat copper wire (usually for 400KVA and above)

Type of Insulation Material:

(1)Diamond dotted paper (For inter-layer insulation)

(2)Press pan sheet (For end collars)
(3)Creep paper pipe (For insulation of terminal of tap changer)
(4)Craft paper (Used for insulation in disc winding)
(5)Thermo ducts

Types of Windings:

(1)Disc winding
(2)Packet winding
(3)Layer winding
(4)Foil winding

Foil and layer windings are usually used in LV. Layer, packet and disc winding is usually used
in HV. HV winding is done over LV winding, both are insulated from each other. Connections
are made from start and end in LV and HV winding. But in HV we give taping connection at
different places according to design. On HV winding we used paper to insulate it from tank.

20
Oil is also used for this purpose. Winding turns are according to design. At the end of this
section testing of winding is done using transformer turns ratio (TTR) meter which gives no. of
turns. we check it according to design

Machines Used:

Slitting machine

Slitting machine is used for the cutting of bundles of insulation material.

LV Foil winding machines

LV Foil winding machines are used for foil winding on L.V side for transformers of the rating
100KVA and above.

LV paper insulated copper winders

LV paper insulated copper winders are used for winding of P.I copper wire for transformers of
the rating 10KVA to 50KVA.

HV paper insulated copper winders

HV paper insulated copper winders are used for the winding of P.I copper wire for
transformers of the rating 400KVA and above.

HV enamel copper winders

HV enamel copper winders are used for the winding of enamel copper wire for the transformer
of the rating 10KVA to 400KVA.

Table 2.3: Transformer Tapping steps

Sr.No Voltages
1 11275
2 11000 (principle tap)
3 10725
4 10450
5 10175

21
2.4 Transformer Core Section

In the core section upper, center, side and yoke limbs of the core are made.

Figure 2.10 Transformer Core

22
Table 2.4: Core stacking for 25 KVA

Sr.No Side limb size(mm) Center limb size(mm) Yoke size (mm)
W L NOS W L NOS W L NOS
1 30 285 104 30 245 52 30 440 104
2 55 310 104 55 To 52 55 465 104
3 70 325 160 70 255 80 70 480 160
4 85 340 176 85 88 85 495 176
5 95 350 300 95 150 95 505 300
Raw Material

Raw material used for the making of core is M4 grade silicone steel sheet which is an alloy

of iron and silicon. Silicon is used to increase the permeability of iron.

Machines

 Slitting machine is used to cut the big roll of silicon steel sheet in required sizes

 (width) according to the rating of transformer.

 Power press machines are used to make limbs. They are operated manually.

 After cutting of limbs V punching is done on the yoke limb which is called yoke
notching.

PLC cutting machines are also used to make limbs. There are two PLC machines.

Iron Losses

Iron losses are the flux losses in core. Major factors in iron losses are;

 Quality of material.
 Bur.
 Air gap.
Reduce iron losses

Material should be of good quality.

Limbs should be bur free.

23
Limbs should be rust free.

Weight of core should be according to Tr. Design

After cutting of the limbs, they are stacked in a way that there is no air gap between the limbs.
All the limbs are joined except the upper yoke limb which is filled in the assembly section.
Outer side of the core is varnished to avoid rusting. Core is tightened using upper and lower
pressing beams. Then its goes to assembly section.

2.5 Transformer Tank Section

In the tanking section cover plate, tank, and other mechanical components of thetransformer
are made. Tank has following part

 Frame
 Cover plate
 Bottom
 Side plate
 Fin Walls
 Conservator

Raw Material:
Raw material for tank and other components are
Shearing Machine
Shearing machine is used to cut the MS sheet in different sizes. This machine is used for the
cutting of frame, side wall, bottom wall and cover plate.
CNC Nibbling and Punching Machine
CNC nibbling and punching machine has 32 tools to make holes of different size. It can make
holes of the shape round, square, rectangle.
Bending Machine
This machine is used to bend cover plate and frame.
Embossing Machine
This machine is used for the embossing of holes on cover plate.
Component Welding
In this area lifting lugs, carrying beams and studs are welded using arc welding.
Frame Punching and Welding Machine
Frame is punched and then welded in this machine.MIG welding is used in this machine.
24
Fin Folding Machine
This machine is used for fin folding. Digital control panel is used to enter height, weight and
pitch. Pitch is the distance between two adjacent fins.
Fin Welding
After fin folding they are welded. MIG welding is used in this machine.
Automatic Fin Welding Machine
MIG welding is used in this machine. Metal strip is welded to support the panel.
Bottom Side Plate Welding
In this section bottom and side plates are welded together.
Tank Assembly
Here all the parts of the tank are joint together.
Tank Welding
Tank is welded to stop leakage.
Shot Blasting
To remove oil particles from tanks body and make its surface smooth shot blasting is done.
After that tank is dipped in degreasing, rinsing and phosphate tank to remove oil particles.
Sand Blasting
It is used for removal of oil particles from tanks make its surface smooth for transformer
rating above 200KVA.
Tank Testing
For tanks up to 200KVA diesel spray testing is used.
Above 200KVA pressure testing is used to check leakage.
Powder Coating
Tank is first passed through a chamber for pre treatment and then powder coating is done.Tank
is painted with machines at end

25
 2.6 Transformer Assembly Section

Figure 2.11 Transformer Assembly

In the assembly section there are 17 processes in which all the components of the

transformer are put together to form a transformer. Important processes in the assembly

section are;

Core Coil Assembly

In the core coil assembly coil is fitted in the core and upper yoke limb is inserted to

complete the core, then core is tightened using upper and lower pressing beams. For

coil to coil insulation and core to coil insulation press pan sheet is used. For insulation

between bottoms pressing beam and coil wooden base is used.

Before Connection Test (BCT)

In the BCT area turns ratio of the coil is checked using TTR meter.

H.T, L.T Connections

In this section Y-Delta connections are made. Tap changer is connected with the coil.

26
Connections are made according to work order specifications given by the design

Department. Taping is done on these connections to avoid any short circuit.

After Connection Test (ACT)

In the ACT area turns ratio of the transformer is checked using TTR meter.

Furnace

After ACT transformer is kept in the furnace for 48 to 72 hours according to its rating. It

is done to evaporate all the moisture from core or coil. Temperature of the furnace is 120 to
130.

Cover Plate Assembly

In this section H.T, L.T bushings, through bolts, eye bolts connectors, arcing horns and

other parts are inserted in cover plate.

Pre Tanking Section

When transformer is unloaded from the furnace it is inserted in the tank as quickly as

possible to avoid the getting of moisture in the live part. Live part of the transformer

should be inserted in the tank in 50mins to 1 ½ hours.

Oil Filling Section

In oil filling section oil is filled in the tank under vacuum. Amount of oil to be filled canbe
found from bill of quantity (BOQ). For 10kv to 200kv oil filling chambers are used andfor
transformers above 200kv oil is filled manually.
Settling Area
After oil filling every transformer is kept for 12 hours in the settling area to check for oil
leakage and oil level.
2.7 Padmount transformer

A padmount or pad-mounted transformer is a ground mounted electric power distribution

transformer in a locked steel cabinet mounted on a concrete pad. Since all energized
connection points are securely enclosed in a grounded metal housing, a padmount transformer

27
can be installed in places that do not have room for a fenced enclosure. Padmount transformers
are used with underground electric power distribution lines at service drops, to step down the
primary voltage on the line to the lower secondary voltage supplied to utility customers. A
single transformer may serve one large building, or many homes.

Pad-mounted transformers are made in power ratings from around 75 to around 5000 kVA and
often include built-in fuses and switches. Primary power cables may be connected with elbow
connectors, which can be operated when energized using a hot stick and allows for flexibility
in repair and maintenance.

Table 2.5: breaker and fuse rating for PMT

Sr.No Fuse rating Main breaker Sub breaker Transformer

rating (A) rating (A) rating
(KVA)

1 10 250 100 100

2 20 630 250 200

3 40 1000 250,400 400

4 50 1600 100,250,400 630

5 100 2000 250,400,630 1250

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Pad mounted transformer:
Main components of this unit are medium voltage switchgear arranged to function as a Ring
Main Unit (2- TP disconnect switches and 1-fused T-off), transformer, LV Switchgear and
control gear, corresponding interconnections and auxiliary equipment .Enclosure is made of 2-
3 mm sheet steel. These sub-stations are manufactured for outdoor use, suitable for mounting
on a concrete pad. Door interlocks and other safety features are inherent part of the design.
These compact substations are used in distribution centers and industrial installations having
underground cabling.

29
Chapter 3
Skill Attaining

30
31
3.1:Transformer Testing

3.1.1: Voltage Ratio Test

Purpose :

This test method is used to measure the rated turn ratio of the transformer.

Testing Equipment:

Transformer Turn Ratio (TTR) meter.

Figure 3.1Transformer Turn Ratio (TTR) meter.

Operational Steps:

 Connect the HV side leads to the HT side of transformer under testing accordingly i.e.
H1 to red phase , H2 to yellow phase and H3 to blue phase.
 Connect the LV side leads to the LT side of transformer under testing accordingly i.e.
X1 to red phase, X2 to yellow phase, X3 to blue phase and X0 to Neutral.

32
  Select the phase configuration of transformer (star and delta configuration) and start the
test.
 Note down the voltage ratio from screen for 3 phase voltage ratio of transformer.

Safety Precautions during testing:

 Make sure the transformer under testing in non energized.

 Use proper bench / stole for placing the TTR meter during test.
 Use the safety gloves when handling and connecting the equipment leads to the
transformer.
 Do not touch the connection leads, earth wire and transformer connector during testing.

WAPDA Ratio values:

Table 3.1: WAPDA Turns ratio values for 3 phase transformer

Steps No Exact value Maximum value Minimum value

1 47.05 47.28 46.81
2 45.91 46.14 45.68
3 44.76 44.98 44.54
4 43.61 43.83 43.39
5 42.46 42.67 42.25

Karachi ratio value:

Table 3.2: Karachi Turns ratio values for 3 phase transformer

Steps No Exact value Maximum value Minimum value

1 47.631 47.869 47.393
2 46.496 46.729 46.265
3 45.363 45.590 45.136
4 44.229 44.450 44.008
5 43.095 43.310 42.880
6 41.960 42.170 41.750

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 3.1.2: Mugger test procedure
Let’s take 100KVA transformer as an example as shown in figure For normal working
transformer, both windings must be electrically isolated from each other and from ground. So
Mugger test is done to check

 Insulation between HV and LV winding

 Insulation between HV and body

 Insulation between LV and body

To check the insulation level between HV and LV winding, put one terminal on HV winding
and one on LV winding. Apply the correct value of voltage (voltage values shown in above
table) and check the reading of the megger. Megger test equipment will show resistance
between the HV and LV winding. The value of resistance will show the insulation strength
between HV and LV winding.

Figure 3.2 Mugger test

Safety precaution:
 Testing yard should be properly cordoned off and warming light should be on during
testing.
 Make sure the transformer under testing is on floor / ground.
 Use HV safety cloves when handling and connecting the power line and earth wire to the
transformer.
 Make sure the distance of at least 15 feet from transformer under testing.

34
 Do not touch connection leads, earth wire and transformer connection and body during
testing.
 Make sure no body should not be entered in testing area / yard during testing.

3.1.3: Winding Resistance Test

Purpose:

This test used to measure the resistance of primary winding and secondary winding of
the transformer.

Testing Equipment:

Ohm meter.

Operational Steps:

 Connect the red, yellow, blue phase of HT winding of under testing transformer with
leads of winding ohm meter accordingly i.e. RY, YB, BR.
 Note the reading of winding ohm meter when readings become stable for measurement
of HT winding resistance of subjected transformer.
 Connect the red, yellow, blue phase of LT winding with neutral phase of under testing
transformer with leads of winding ohm meter accordingly i.e. rn, yn, bn.
 Note the reading from winding ohm meter when reading become stable for
measurement of LT winding resistance of subjected transformer.

Safety precaution during testing:

(1)Make sure the transformer under testing in non-energized.

(2)Use proper bench/stole for placing the winding ohm meter during testing.
(3)Make sure the winding ohm meter is connected to earth wire before using.
(4)Use the safety gloves when handling and connected leads to the transformer.
(5)Do not touch the connector of transformer while performing test and when meter is power
ON.
(6)Make sure the power OFF before disconnecting the leads from transformer.

35
3.1.4:Load losses (Copper losses) test

Purpose:

This test is used to measure the load losses is called short circuit test.

Testing equipment:

Power quality analyzer

Operational steps:

1) Short the LT side of transformer under testing with copper bus bar.
2) Connect the leads of 3 power phase supply to HT side.
3) Apply the 3 phase power supply at rated frequency (50 HZ) and allow the rated current to 4)
flow in HT side of transformer under testing .
5) Get reading of absorbed active power in 3 phase (W1, W2, W3) from the power analyzer
meter .
6) This losses should be nearly same.
7) Tolerance should be +5%.

Safety precaution:

1)Testing yard should be properly cordoned OFF and warming should be ON during test.
2)Make sure the transformer under testing is on floor /ground.
3)Make sure equipment using for testing is properly ground by using earth wire .
4)Make sure the distance of at least 15 feet from transformer under testing.
5)Do not touch the connection leads, earth wires, transformer connector and body during
testing.

3.1.5:No Load Losses Test

No load losses test also called iron losses test or open circuit test.
Purpose:
This test is used to measure the no load losses .
Operational steps:
 Keep the HT side of transformer under testing open.
 Connect the leads of 3 phase power supply to LT side of subjected transformer
accordingly.

36
 Apply the 3 phase rated voltage ( 415v for WAPDA & 420v for K-Electric) at rated
frequency (50Hz) on LT side of transformer under testing.
 Get reading of absorbed active power in 3 phase (W1, W2, W3) from the reference
equipment(power quality analyzer, AC power analyzer).
 Take algebraic sumof 3 reading that give measurement of no load losses for transformer
under testing.
 Take the average of three reading that give measurement of no load losses.
Safety Precautions:
 Testing yard should be properly cordoned off and warming light should be on during
testing.
 Make sure the transformer under testing is on floor or ground.
 Make sure the equipment using for testing is properly ground by using earth wire.
 Do not touch the connection leads, earth wire and transformer connector and body during
testing.

3.1.6: Induced Voltage Test

Purpose:
This test is used to check insulation between layer to layer and turn to turn for only LT
side.
Operational Steps:
 Keep the HT winding of Transformer under testing open .
 Apply 3 phase test voltage ( 830v for WAPDA & 840v for K-Electric) at twice rated
frequency(100Hz) 0n LT winding including natural of transformer under testing.
 Keep applied test voltage for 60 seconds and check there should not any collapse of test
voltage occur.
 Check the phase current for indication of insulation failure.
Safety precaution:
 Testing yard should be properly cordoned off and warming light should be on during
testing.
 Make sure the transformer under testing is on floor / ground.
 Use HV safety cloves when handling and connecting the power line and earth wire to the
transformer.
 Make sure the distance of at least 15 feet from transformer under testing.
 Do not touch connection leads, earth wire and transformer connection and body during
testing.
37
 Make sure no body should not be entered in testing area / yard during testing.

3.1.7: High Voltage Test

Purpose:
This test is used to check short circuit between LT to HT winding , LT to body , HT to body
and main purpose check insulation between LT and HT windings.
Operational Steps:
 Ground neutral and body of transformer under testing by using earth wire.
 Apply voltage (34kv for WAPDA and 28 kv for k-electric) on HT winding.
 Keep apply test voltage on sixty second at this instand should not collapse.
Safety precaution:
 Testing yard should be properly cordoned off and warming light should be on during
testing.
 Make sure the transformer under testing is on floor / ground.
 Use HV safety cloves when handling and connecting the power line and earth wire to the
transformer.
 Make sure the distance of at least 15 feet from transformer under testing.
 Do not touch connection leads, earth wire and transformer connection and body during
testing.
 Make sure no body should not be entered in testing area / yard during testing.

3.1.8: Bird Protection Test

This test is used to check the thickness of paint so that cover plate will not short. In this test
8kv voltage is applied to the cover plate for 1 minute if cover plate does not stand it for I
minute than it is rejected.
3.1.9: Pressure Test
This test is used to check that there is no leakage in tank. In this test tank is completely closed and
pressure air is filled in the tank than a solution of washing powder and water is dropped on every joint if
there is leakage than bubbles will be formed.
Dimensions of tank are checked. They should be according to Tr. Design.

38
 Table 3.3: Pressure Test procedure
KVA rating Pressure rating(PSI) Time(hours)
25 1 8
50 1 8
100 1 8
200 1 8
250 1 8
400 10 8
630 10 8
1000 15 8

3.2: Oil Tests to Check its Quality

There are seven tests done in oil testing lab to check the quality of oil. If the oil fails inone of
these tests than it is rejected not used in transformers. Seven tests are

 Visual Inspection
 Specific Gravity
 Viscosity
 Flash Point
 Dielectric Strength
 Acidity Value
 Pour Point

a)Visual Inspection
It should be free from contamination as per IEC-296 and IEC-60296recommendations.
b)Viscosity
Viscosity meter is used for this test. Reading is taken at two different temperatures. AT -20 Co
reading should be less than 40mm 2
/sec and at 40 Co reading should be less than12mm 2/sec as per IEC-296 and IEC-60296
specifications.
c)Specific Gravity
Specific gravity meter is used for this test. Reading is taken at -30 Co Before
use specific gravity of oil should be less than .895 g/mil. After use reading should be less
than .895g/mil as per IEC-269 and IEC-60296 recommendations.
39
d)Flash Point
The point at which the oil catches fire is known as flash point. Flash point of transformer oil
should be greater than 140 Co
as per new recommendation of IEC in IEC-60296.
e)Dielectric Strength Test
Dielectric strength tester is used for this test. Oil is filled in a box which has electrode switch
are 2.5mm apart. Voltage is applied to the box which increases at the rate of 2kvper sec.
Reading is taken at point where breakdown has occurred. Seven readings are taken and their
arithmetic mean is the breakdown voltage. Oil which is purchased should have dielectric
strength greater than 30kv. When oil is stored and all the moisture and impurities are removed
than its strength should be greater than 70kv. For the oil which is used reading should not be
less than 55kv. All these values are according to the recommendations of IEC mentioned in
IEC-60296.
f)Acidity Value
Acidity value meter is used for this test. For unused oil reading of meter should be less
g)Pour Point
The point at which oil freezes is known as pour point. Oil should not freeze before -30 Co
to pass this test.

3.3: Tests at CTs and PTs

The tests are conduct at CTs and PTs mostly similar. Following tests are performed at both
instrument transformers. The test is very necessary because both transformers compiled with
protection and measuring instruments.
Insulation Resistance Test
For measure the insulation resistance between winding to winding, winding to ground and core
to winding. The measuring instrument used for insulation test mugger used.
Procedure:
1. Mugger have three terminals E, L and G. These are terminal connected with CT and PT one
by one and measure insulation resistance.
2. When the measure resistance between primary winding to ground than L terminal connected
with primary and E with earth and apply voltage trough Mugger and note the reading.
3. And measure resistance between secondary to ground than L terminal attached with
secondary and other similar to last and apply voltage and note reading.

40
4. Insulation resistance measure between core to core than L terminal connected one side of
core and other connected with other side of core and applies voltage and note reading.
5. When the measure the insulation resistance than L terminal connected with primary and E
with secondary and apply voltage and measure reading at scale.

Turns Ratio Test

TTR test used to identify the primary to secondary turns ratio. This test is similar to power
transformer TTR. Mugger instrument used for check turns ratio test of CTs and PT.
Procedure:
1. Testing equipment disconnected from supply.
2. Primary side short together and secondary side connected with testing instrument step by
step.
3. Mugger has two terminals one connected with primary and other connected with secondary
terminal one by one.
4. Now mugger generate voltage and measure the primary to secondary turn ratio.
5. It is repeated more than one than time.
DES Test
Dielectric test used to calculated dielectric strength of oil. Both PT and CT are filled with oil. It
used for cooling and insulation purpose. This test is necessary to keep in healthy condition CT
and PT.
Procedure:
1. This test also similar to power transformer test.
2. Take a sample of oil from CT and PT porcelain.
3. Calculated to dielectric strength of oil two electrodes are immersed in oil sample.
4. Now applied specified voltage across electrode for one minute.
5. If flash over occur within one minute than test fail and if not occur than test pas and oil has
good dielectric strength.

41
 Chapter 4
Feedback&
Recommendations

42
4.1: Conclusion

In conclusion, I am well satisfied on our training in Transfopower and PEL industries. I have
learned new technical subjects and very new technical skills. It is very strongly related to my
academic through this increase my theoretical skill into practical skill. Inside the university, I
learned details about electrical appliances but not see in physical form but in training period I
saw all appliances in physical form and learned how it is operate and work. I may count our
technical skill learned and improved at training site are following:

1. In Transfopower industries which installed Electrical appliances, Measuring devices,

Protection devices and Feedback system.

2. The main component of Transfopower industries is power Transformer and electric panel.
I learned inside university about transformer at theoretical biases but at training site I learned
actual function of transformer and physical structure of power transformer.

3. Protection devices used for provide protection to system, this system is helpful for me how it
is protect all electrical system or in live form.

4. Through tests increase my testing skill, inside university labs, I performed small test but at
training site performed all types of test conduct at installed equipment.

5. Annul test conduct at control room relays, these relay sense fault occur in circuit and out of
circuit. If any relay fail then system under dangerous condition.

6. Inside University learned function and working of relays but at training site physical
function of relay and how it is operates and how trip the circuits.

7. Trip circuit of relays are operate at DC supply therefore, design DC supply structure it
contains at several units of batteries that connected in series. If DC supply fails than all
protection system faulty condition.

It is so good to acquire such a large number skills in 4 month of training period. So training
in132kv Grid Station is very valuable.

43
4.2: Recommendation

Recommendation which tell how many step takes university in labs that helpful for internship
students. It is contains at following steps;

1. I’m done sixteen week internship in Transfopower industries. We know main equipment
here power transformer and electric panel it has many other accessories to perform good
function. I give here recommendation, the university arranged transformer labs which student
learned and physical see firstly transformer structure and other accessories that attached with
transformer and how worked therefore, save time in training period and learned extra technical
skills.

2. In Transfopower industries manufactures transformer . We are learned theoretical how it

construct, operate and working principle but the physical structure differ than theoretical form.
So, my recommendation here university design one labs of these devices where see how it
performed physical.

3. Control system is a complex and important part of any firm. Where control and monitor
whole system it is contains at panels. These are panel has switches, relays and measuring
instruments. So control main part of any firm one lab design related to control circuit where
student learn how control circuit construct and operate.

4. When the students move for internship it is short time to learned about firm. Inside grid
station mostly equipment high voltage. At internship site we are not see internal structure of
equipment therefore it is unauthorized. While the annual shutdown occurs at this time only test
and maintenance performed at installed appliances not it’s open. So learned about internal
circuit of instrument, appliances and equipment design labs where student by self-open
equipment and see internal circuit and reassemble. Through this student skills increase very
much and will not any problem come inside at internship site.

However, valuable benefit I gained from training at Transfopower industries lets my overall
evaluation of training there be very good. So I’m learned and enjoy training period at
Transfopower industries. It is very helpful to increase my all technical and non-technical
skills.

44
4.3: References

https://www.emworks.com/application/3-phase-transformer

https://www.electronics-tutorials.ws/transformer/three-phase-transformer.html

https://www.electricaleasy.com/2014/05/three-phase-transformer-connections.html
electrical-engineering-portal.comt

https://www.electrical4u.com/transformer-cooling-system-and-method

https://www Power transmission and protection system:

http://electrical-engineering-portal.com/power-transformer-turns-ratio-t

www.ganpatielectricals.com/electric-panels.html

www.voltaicpower.in/products/lt-panels-ht-panels

www.inspection-for-industry.com/power-transformer-testing.html

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