Training Module

SANJEEV KADIAN
Presents

TRAINING MODULE
INDEX

Particulars Pages

1. Understanding Transformers

2. Core

3. Conductor

4. Bushings

5. Buchholz Relay

6. Hermatically Sealed T/fs

7. Magnetic Oil Level gauge

8. Silicagel Breather

9. Sub-Assemblies

10. Tap Changer

11. Temperature Indicator

12. Transformer Oil

13. Repairing Distribution Transformers

14. Sales & Marketing

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UNDERSTANDING TRANSFORMERS

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TRANSFORMER BASICS
INTRODUCTION

A transformer is basically an electromagnetic static equipment based on the principal of Faraday’s law of
electromagnetic induction. A transformer essentially consists of magnetic core, build-up of insulated silicon
steel laminations, upon which are wound sets of coils suitably located with respect to each other and
termed as primary and secondary windings. Such a combination may be used to derive a voltage higher
or lower than what is immediately available. In the former case, the transformer is termed as step-up
transformer, while in the later case, it is known as step-down transformer. The primary winding is that
winding to which the supply voltage is applied, irrespective of whether it is higher or lower voltage winding,
the other winding to which the load is connected is termed as secondary winding.

THE WORKING PRINCIPLE

If an alternating voltage is applied to the terminals of the primary winding of a transformer, with the
secondary winding open-circuited, a very small current will flow in the primary circuit only, which serves to
magnetise the core and to supply the iron loss of the transformer. Thus, an alternating magnetic flux is
established in the core which induces an e.m.f. in both primary and secondary windings. As primary and
secondary windings are wound on the same core and as the magnetic flux is common to both windings,
obviously, the voltage induced in the primary and secondary windings are, therefore, in direct proportion to
the number of turns in these windings.

LAMINATED CORE

Diagram showing magnetic

circuit and windings of a
transformer

TRANSFORMER LOSSES

Transformer loss mainly has two components: no-load loss & load loss.

No load loss results from steel materials, used for magnetizing core laminations. It includes hysteresis and
eddy current loss, dielectric loss and copper loss due to no-load current.

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Load loss arises from the resistive components, used for building the primary and secondary windings. It
comprises I2R loss of windings, loss due to eddy current and stray loss in the tank and core clamp.

Total

No-Load Load

Hysteresis Di-electric Copper I2R loss Loss due Stray loss

& eddy loss as a loss due to for both to eddy in tank &
current function of no-load primary & current core
loss primary & current secondary set-up in clamp
secondary windings the
voltage conductor
Diagram showing various components of losses

EFFICIENCY
No-load loss of the transformer is constant and does not change with variation of load. However, load loss
changes in respect of the loading pattern. The transformer will yield maximum efficiency at a load when
no-load loss and load loss are equal.

REGULATION
The regulation of a transformer refers to the change of secondary terminal voltage between no load and
load conditions; it is usually quoted as a per cent or per unit value for full load at given power factor.

GENERAL CONSTRUCTION

Constructional Parts
The transformer is comparatively simple structure since there are no rotating parts, or bearings. The chief
elements of the construction are –
(1) Magnetic circuits, comprising limbs, yokes and clamping structures.
(2) Electric circuits, the primary and secondary windings, formers, insulation and bracing devices.
(3) Terminals, tappings and tapping switches, terminal insulators and leads.
(4) Tank, oil, cooling devices, conservators, dryers and ancillary apparatus.

1. Magnetic Circuit
The magnetic core is built up of laminations of high grade silicon sheet steel, which are insulated from
each other by a special coating of varnish. The usual thickness of laminations are 0.18 mm, 0.23 mm,
0.30 mm and 0.35 mm. The two losses, due to varying flux, occur in the core: the eddy current and the
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hysteresis losses. The silicon content of the iron and the nature of annealing are very important in
determining the hysteresis loss. Silicon makes the material brittle, thus making it difficult to process.

Core Construction
The core built up with high-grade non-aging cold rolled grain oriented silicon steel lamination having high
permeability and low hysteresis loss. A three legged, mitered and interleaved type core construction is
adopted. Main limbs are bound fiberglass types and clamp plates to ensure adequate mechanical
strength, and to prevent vibration during operation rigidly bolt yokes. The clamping structure and core
sheet are specially connected not to make one turn circuit & connected to top of tank at one point.

Core construction of modern core type power Transformers

Cold rolled grain oriented steel laminations are used for cores of all modern power Transformers. This is
because it permits the use of flux densities between 1.6 to 1.8 wb/m2 as compared with 1.3 wb/m2 for hot
rolled steel & consequently the weight of both core and windings is reduced.

Cooling of cores
In transformers of medium and high capacity with diameter of circumscribing circle D>=0.35m the cores
have the relatively small surface / volume ratio so that the temperature gradient in the core is excessive. In
such cases the cooling must be augmented by dividing the core in to different stacks with longitudinal oil
ducts (usually 6mm wide) running parallel to the lamination.

Core-Clamping
All core-clamping bolts shall be effectively insulated with enamel or preferably varnish impregnated but not
insulated with paper. The joints must be of inter leaved type. Liberal axial ducts must be provided so as to
ensure free circulation of oil and efficient cooling of the core, so that the maximum temperature at any
point will be within permissible limits.

Earthing
Positive earthing of the cabinet shall be ensured for providing two separate earthing pads. The earth wire
shall be terminated on to the earthing pad and secured by the use of star of self-etching washer. Using a
separate earth wire shall do earthing of hinged door.

Core Earthing
With the exception of individual laminations and core bolts, all internal metal parts of the transformer
require earthing.

2. Electric Circuits
The windings of a transformer are made of copper or aluminium wire and / or strip. Heavy current capacity
requires conductors of larger cross-section. To reduce eddy current losses within the conductors, several
small wires or parallel strips are preferable than to use one large strip. This gives rise to unequal
reactance components of the conductor, which can be reduced by transposing the conductors.

Two types of coil constructions are commonly used – Concentric or Pancake / interleaved. Between coils
segments, spacers are provided to permit dissipation of heat from the windings either by ventilation or by
a liquid cooling medium.

Double cotton, single cotton with an under layer of enamel or synthetics enamel, or double paper covering
are most commonly being used for winding wires. Strips are generally covered with layers of papers
known as DPC, TPC, QPC, MPC etc.

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Winding Constructions

The windings are arranged to ensure free circulation of oil and to reduce hot spots in the windings. All
materials used in the assembly of windings are insoluble, non-catalytic and chemically inactive in the hot
transformer oil. The windings are supported securely in axially as well as radially using radials spacers,
axial spacers, press board cylinders and clamp rings, so that they will not be displaced or deformed during
short circuits. The coils are clamped by adjustable pressures bolts at are top end and the face is uniformly
distributed to the windings using sturdy and to rings.

A transformer generally consists of LT & HT windings. The L.T. windings shall be circular and concentric
with HT windings on the outer side the electrical and magnetic balance under all conditions of operation.
The arrangement shall permit free circulation of the oil to ensure the absence of hot spots. It is essential
that the windings shall be subjected to through sinking occurring at site.

The general design and construction of the transformers and bracing’s of the windings shall be such that
no mechanical movements of the coils will be possible with dead short on either side of the transformer.
The short circuit ratings of the transformers shall be as per IS 2026 of latest issue. All clearance of
windings and other live parts shall be adequate for the maximum voltage operation plus 10 percent. There
should be sufficient clearance between H.V. and L.V. windings yoke and the coils and between coil in HT
windings to have free oil circulation. Current density in the high voltage and low voltage windings together
with the section of wire that will be used therein shall be clearly stated in the tender.

High Voltage Conductor

For distribution transformers of medium capacity, the conductors being chosen for primary winding are
mostly round in shape.

low Voltage Conductor

In case of low voltage conductors, since the current is generally high, a rectangular conductor is
commonly used. Multiple strips in parallel are also selected for a higher rating transformer.

Insulation
The insulation material to be used for the windings shall be suitable for satisfactory service in tropical
climates in this country and full load operation as per ISS. DFC insulation shall be provided for high
voltage as well as low voltage windings.

The insulation between the H.V. and L.V. windings and core, comprises Bakelite – paper cylinder or
elephantine wrap that is typical. The insulation of conductors may be of paper, cotton or glass tape, glass
tape being used for air – insulated transformers.

Paper insulation usually necessitates the use of round coils, while the cross – over of the several strands
in a conductor must be properly shaped, and not merely twisted. The high voltage winding is separated
from the low – voltage winding by a series of ducts and Bakelite cylinders or barrels.

3 . Lead and Terminals

The connections to the windings are copper rods or bars, insulated wholly or in part, and taken to the bus
– bars directly in the case of air – cooled transformers, or to the insulator bushings on the tank top in the
case of oil – cooled transformers.

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Terminal Arrangement

a) Bushing terminals shall be provided with suitable terminal connectors of approved type & size for
cable/overhead conductors’ termination of HV side & cable termination on LT side.

b) The neutral terminals of 433V winding shall be brought out on a bushing along with the 433V volt phase
terminals to form 4 wires system for the 433V. Additional neutral bushing shall be provided for earthing.

4. Transformer Tank
All the tanks are of double welded construction and are reinforced by stiffener of structural steel. All
bottled connection to the tank is filled with the compressible oil tight gasket. The tank is provided with two
earthing terminals for the purpose of the grounding. The tank and accessories of the transformer can be
withstanding full vacuum of 0.1 Tore. And a maximum positive pressure of 1kg / sq.cm. In order to relive
the excessive gaseous pressure which may build up by a fault or an arcing inside the tank, it is equipped
with a pressure relief device / explosion vent which is designed to operate when the maximum gaseous
pressure in the tank exceeds 0.5 kg / 5q. cm.

Tank bodies for most of the transformer are made from rolled steel plates, which are fabricated to from the
container. While designing tanks for transformer, a large number of factors include keeping the weight,
stray load losses and cost a minimum.

The tanks should be strong enough to withstand stresses produced by jacking and lifting. The size of the
tank must be large enough to accommodate cores, windings, internal connections and also must give the
require clearance between the windings and the walls.

The fittings include thermometer pockets, drain cock, rollers or wheels for moving the transformer in to
position, eye – bolts, for lifting, conservators and breaths. Cooling tubes are welded in, but separate
radiators are individually welded and afterwards bolted on.

Radiators

During service, the tank body can dissipate a total loss equivalent to 500 W/Sq m (maximum) of the tank
surface area. In case the total loss, i.e. (no-load + load loss) is more than the loss dissipated by tank
surface, the loss in excess is required to be dissipated with the help of additional cooling surface which is
commonly called radiator.

Classification of radiators

Radiators commonly being used are of three different types:

1. Elliptical tube radiator

2. Pressed steel radiator
3. Corrugated wall panel

Elliptical tube radiators and pressed steel radiators operate on then convection process of cooling,
whereas a corrugated wall panel performs cooling by radiation only.

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Corrugated wall panel radiators are commonly being used for sealed type transformers and also on such
places where there are restrictions on overall dimensions. The radiators are widely used for transformers
built for export, as corrugated wall panel transformers occupy less space and can accommodate more
transformers in one container during transport.

Cooling Methods

A Simple cooling
1 AN Natural cooling by atmospheric circulation, without any special devices. The
transformer cores and coils are open all round to the air. This method is confined
to very small units of a few KV, at low voltages.
2 AB In this case the cooling is improved by an air blast, directed by suitable trunking
and produced by a fan.
3 ON The great majority of transformers are oil – immersed with natural cooling, i.e. the
heat developed in the cores and coils is passed to the oil and thence to the tank
walls, from which it is dissipated. The advantages over air cooling include freedom
from the possibility of dust clogging the cooling ducts, or of moisture affecting the
insulation, and the design for higher voltages is greatly improved.
4 OB In this method the cooling of an ON – type transformers is improved by air blast
over the outside of the tank.
5 OFN The oil is circulated by pump to natural air – cooler.
6 OFB For large transformer artificial cooling may be used. The refrigerator, where it is
cooled by air – blast.
7 OW An oil – immersed transformer of this type is cooled by the circulation of water in
cooling tubes is situated at the top of the tank but below oil – level.
8 OFW Similar, to OFB, except that the refrigerator employs water instead of air blast for
cooling the oil, which is circulated by pump from the transformer to the cooler.
b. Mixed cooling
ON/OFN, ON/OFB, ON/OFW, ON/OB/OFB, ON/OW/OFW, ONAN, ONAF, OFAF

Cooling ducts
In large transformers, the cooling surface of the cores must be augmented otherwise temperature rise will
be excessive owing to small surface/volume ratio of the cores. Cooling ducts provides the additional
surface. The cooling may be (I) horizontal or (ii) vertical. The vertical cooling ducts are along the direction
of laminations and hence can be easily provided. The horizontal ducts are across the laminations and
therefore require special punching of core. The oil following through these ducts takes away the heat.

Paintings
Tanks should be sand blasted or cleaned by chemical process before painting. In general a primary coat
of suitable anticorrosive paints followed by two coats of standard grey is applied on the tanks and
radiators.

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SCHEDULE OF TESTS

ROUTINE TESTS

Following tests are conducted on each and every transformer.

 Measurement of Insulation Resistance

 Measurement of Voltage Ratio
 Separate Source Voltage Withstand Test
 Induced Over-voltage Withstand Test
 Measurement of No Load Loss and Current
 Measurement of Impedance Voltage/Short Circuit Impedance and Load Loss
 Measurement of Winding Resistance
 Unbalance Current

TYPE TESTS

Following tests are conducted on only one transformer of each rating for a particular design,
subject to client’s requirement.

 Impulse Test -- (Conducted by recognized govt. testing laboratory)

 Short Circuit -- (Conducted by recognized govt. Testing Laboratory)
 Check of Voltage Vector Relationship
 Temperature Rise Test
 Oil Dielectric Test
 Air Pressure Test
 Vacuum Test
 Oil Leakage Test.

FINAL TEST

Following tests are carried out on the Transformer as per sequence.

 Measurement of Insulation Resistance
 Measurement of Voltage Ratio and Check of Voltage Vector Relationship
 Separate Source Voltage Withstand Test
 Induced Over-voltage Withstand Test
 Measurement of No Load Loss and Current
 Measurement of Impedance Voltage/Short Circuit Impedance and Load Loss
 Measurement of Winding Resistance
 Unbalance Current
 Oil Dielectric Test
 Temperature Rise Test
 Air Pressure Test
 Vacuum Test
 Oil Leakage Test.
 Magnetic balance test
 Measurement of zero sequence impedance
 Measurement of noise level

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TESTING PROCEDURE
INSULATION RESISTANCE:

The Oil/Air Temperature is measured and recorded immediately prior to the test. The insulation resistance of each
windings corresponding to other windings and to earth is measured and recorded.
I.R Value between :
 HV & E : Connect Positive terminal of Insulation Tester to HV Bushing and Negative
Terminal to the Earth.
 LV & E : Connect Positive terminal of Insulation Tester to LV Bushing and Negative
Terminal to the Earth.
 HV & LV: Connect Positive terminal of Insulation Tester to HV Bushing and Negative to
LVBushing.

VOLTAGE RATIO & VOLTAGE VECTOR RELATIONSHIP:

(A) Measurement of voltage Ratio –

To check the voltage ratio of Transformer Ratio Meter is used;

V1 N1
Voltage Ratio = ------ = -------- where, N1 = Primary Turn
V2 N2 N2 = Secondary Turn

(B) Voltage Vector Relationship(Dyn-11)

Transformer’s A-phase of primary side and A-phase of secondary side are shorted, and in primary side 3-
Phase supply (About balance voltage 400 Volts) applied at rated frequency. Voltage is , then, measured
on following points :-
IV-2V =
IV-2w =
1W-2W and !W-2V
In this test IV-2W and IV-2V may be same and 1W-2V may be more than 1W-2W

SEPARATE SOURCE VOLTAGE WITHSTAND TEST:

In this test the full test voltage given below applied for 60 seconds between the winding under test and all terminals
of remaining windings, core, frame and tank of the transformer connected together to earth.

TESTS :

(A) High Voltage Test - In this test secondary side of the transformer and tank are earthed and from primary side
full test Single Phase voltage applied for 60 seconds at rated (50 Hz) frequency.

(B) Low Voltage Test - In this test primary side of the transformer and tank are earthed and from secondary side
full test, Single phase voltage applied for 60 seconds at rated (50 Hz) frequency.

INDUCED OVER VOLTAGE WITHSTAND TEST:

The transformer can be tested on either LV or HV side. Double the rated voltage at double the frequency is applied
at the testing side. The other side is open circuited.
Duration of Test : 60 seconds

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NO LOAD LOSS AND CURRENT:

The test is conducted by a Three Wattmeter Method. The No Load Loss and the no load current are measured at
rated frequency at a rated voltage while the other winding is to be left open circuited. In this way after applying
rated 3 Phase voltage at rated frequency from LV side, the current is measured in Ammeter. This current will be no
load current or magnetizing current, and the total reading of the watt meters will be the Total No Load Loss of the
tested transformer.

To measure the No Load Loss and No Load current of Power Transformer one CT-PT set is connected to an Auto
Transformer.

IMPEDANCE VOLTAGE/SHORT CIRCUIT IMPEDANCE & LOAD LOSS:

The Impedance voltage/short circuit impedance and load loss are measured at rated frequency by applying an
approximately full load current to one winding with the other winding short circuited. The measurements may be
made at any current between 25 percent and 100 percent, but preferably not less than 50 percent of the rated
current (principal tapping) or tapping current to the test current.

The measured value of Load Loss may be corrected by the following formula :

2
Rated Current
Total Loss = --------------------
Test Current

The measured value of the impedance voltage may be corrected by the following formula :

Rated Current
Total Impedance voltage = --------------------
Test Current

MEASUREMENT OF WINDING RESISTANCE:

To measure the resistance of LV and HV Winding , Kelvin and Wheatstone Bridge are respectively used. The
resistance and temperature of each winding are recorded.

UNBALANCE CURRENT:

In this test of the Transformer, all three phases of secondary (Star Connected) are shorted and shorted point linked
to the neutral point of transformer with an Ammeter.Then, full load current at rated frequency is applied to primary
(Delta Connected) of the transformer. The current measured between the shorted secondary and the neutral point is
the unbalance current. Circuit diagram is respectively same as load loss test :-

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TEMPERATURE RISE TEST:

In this test LV winding of the transformer is shorted and from HV winding full losses (Load loss at 75 Deg. Cent. +
No Load Loss) is fed. One thermometer is placed in oil filled thermometer pocket of transformer for oil temp. and
other 3 Nos. thermometers in different directions of the transformer for ambient temp. After feeding the total loss at
transformer, the voltage current, top oil temp. and ambient temp. is measured. These all readings are taken one by
one after every hour. This process is continued till oil temperature rise of transformer remains constant. Keeping oil
temp. rise constant, load is reduced at full rated current for one hour, after one hour supply shut-off. After shutting
off the supply hot resistances of winding are immediately measured. Thus, after plotting the graph between time
and hot resistance, we can find out the highest actual hot resistance at the zero time. In this way the maximum
winding temperature rise can be calculated by the following formula :

(a) Hot Resistance x (225+RT)-225 ........... For Aluminium

. Cold Resistance

(b) Hot Resistance x (235+RT)-235 ........... For Copper

Cold Resistance

where, RT = Ambient Temp. at the time of cold resistance :

OIL DIELECTRIC STRENGTH TEST:

To test the Dielectric strength of oil, a motorised oil testing set is used . Before using this instrument, the oil pot of
this instrument washed with the same oil, which to be tested. After washing the pot, the gap between the electrodes
is set at 2.5 mm and the oil is filled in it. Wait for about 10 minutes, so that the air bubbles disappear. After this, the
instrument is switched ‘ON’ and the flash point (in KV) is noted. This process is repeated for six times and the
average of the six values is the Dielectric Strength of the oil.

AIR PRESSURE TEST:

This is a type test which is conducted on the transformer tank. The tank may be fixed with a dummy cover with all
fittings including bushings in position and subjected to a pressure of
 0.35 Kg/Cm2 (Hg) upto 1000 KVA Transformer Tank
 0.80 Kg/Cm2 (Hg) above 1000 KVA Transformer Tank
created inside the tank and maintained for one hour. The permanent deflection of flat plate, after pressure has been
released should not exceed the values given below:

Horizontal length of flat plate Permanent Deflection

(in mm) (in mm)
Upto and including 750 5
751 - 1250 6.5
1251 - 1750 8
1751 - 2000 9.5
2001 - 2250 11
2251 - 2500 12.5
2501 - 3000 16
Above 3000 19

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VACUUM TEST:

This is a type test , which is conducted on transformer tank. The transformer tank may be completed with all fittings
including bushings in position and shall be subjected to full vacuum corresponding to (-) 0.7 Kg/Cm.sq.(Hg) created
inside the tank for one hour. The permanent deflection of flat plates after the vacuum has been released shall not
exceed the value specified below without affecting the performance of the transformer.

Horizontal length of flat plate Permanent Deflection

(in mm) (in mm)
Upto and including 750 5
751 - 1250 6.5
1251 - 1750 8
1751 - 2000 9.5
2001 - 2250 11
2251 - 2500 12.5
2501 - 3000 16
Above 3000 19

OIL LEAKAGE TEST:

This is a type test, which is conducted on fully completed transformer. The transformer shall be oil filled and
complete with all fittings. Then following air pressure is applied:
1) 0.35 Kg/Cm2 (Hg) pressure – For transformers upto 1000 KVA for one hour
2) 0.80 Kg/Cm2 (Hg) pressure – For transformers above 1000 KVA for 12 hours

During this period no leakage should occur.

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RAW MATERIAL & ACCESSORIES

The following is the list of the major raw-material required for the manufacture and repair of transformers.

 CORE  CORK SHEET

 COPPER  GASKET WASHER
 OIL  BUSHING CLAMP
 STEEL (TANKS)  CLAMPING MEMBER
 RADIATORS / WALL PANELS  ARCING HORNS
 TAP CHANGER OFF LOAD, ON LOAD  BIMETALLIC CONNECTOR
 BUSHINGS & FITTINGS  EARTHING LUGS
 COPPER SHEET & FLAT  SRBP TUBE
 OIL CONSERVATOR  COTTON TAPE
 BREATHER  EMPIRE SLEEVING
 DIAL TYPE THERMOMETER  PRESS BOARD
 OIL LEVEL GAUGE  INSULATING KRAFT PAPER
 PRESSURE RELIEF DEVICE  INLINE CONNECTOR
 BUCHHOLZ RELAY  BAKELITE SHEET
 OIL & WINDING TEMP. INDICATOR  CI PLUG
 RATING & DIAGRAM PLATE  BRIGHT ROD
 BI-DIRECTIONAL ROLLERS  BOLTS, NUTS, WASHER
 CABLE BOX  PRIMER & FINISH PAINT
 LIFTING LUGS  INSLULATING VARNISH
 TERMINAL MARKING PLATE  SOLDER WIRE
 AIR RELEASE PLUG  LUGS
 VALVES  GROUNDING TERMINALS

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CORE

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CORE
The need for electrical steel sheets of highest quality has increased in recent years
due to rapid development of electrical machinery industry in many countries. Grain
Oriented steel sheets namely ORIENTCORE, ORIENTCORE H1-B & ORIENTCORE
HI-B.LS are some of the finest quality of core.

ORENTCORE.HI-B is a breakthrough in that it offers higher magnetic flux density,

lower core loss and lower magnetostriction than any conventional grain-oriented
electrical steel sheet.

ORIENT.HI-B.LS is a novel type with marked lower core losses, produced by laser
irradiation of the surface of ORIENTCORE.HI-B sheets.

Quality

 Stable product quality

 Core loss are extremely low in rolling direction
 Permeability is extremely high in rolling direction
 Lamination factor is higher
 Excellent Insulation coatings

Standard Sizes

ORIENT.HI-B ORIENT.HI-B.LS
Coils Thickness 0.23mm & 0.27mm 0.23mm,0.27mm
0.30mm & 0.35mm
Standard Width 914 mm & 950 mm
Available Width From 50mm to 1000 mm From 50mm to 950 mm

Cut length Thichness Same as for coils

Length Lengths upto 3100 mm are available in 840 mm and
914 mm widths
Core cut in customer specified sizes can also be provided

Annealing of stacked electrical sheets

Though ORIENTCORE and ORIENTCORE.HI-B are grain orient steel sheets with
excellent magnetic properties, mechanical stress during such operations as cutting,
punching and bending affect their magnetic properties adversely. When these stress
are excessive, stress relief annealing is necessary.

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Following method is observed for stress relief annealing

1. Stacked electrical steel sheets are heated thoroughly in the edge-to-edge

direction rather than in the face-to-face direction, because heat transfer is far
faster in side heating.
2. A cover is put over sheets stacked on a flat plate. Because ORIENTCORE and
ORIENTCORE.HI-B have extremely low carbon content and very easily
decarburized at annealing temperatures, the base, cover and other accessories
used are of very low carbon content .
3. To prevent oxidation so as to protect the coating on the sheets, a nonoxidizing
atmosphere free from carbon sources is used having less than 2%hydrogen or
high-purity nitrogen gas. Due point of the atmosphere is maintained at 0ºC or
less.
4. Care is taken to the flatness of annealing base, because an uneven base
distorts cores, leading to possible distortion during assembly.
5. Annealing temperature ranging from 780ºC to 820ºC is maintained for more
than 2 hours or more. Cooling is done upto 350ºC in about 15 hours or more.

Available Grades

 ORIENTCORE
o M1, M2, M3, M4, M5 & M6
 ORIENTCORE.HI-B
o 23ZH90, 23ZH95, 27ZH95,27ZH100,30ZH100
o M-0H,M-1H,M-2H,M-3H
 ORIENTCORE.HI-B.LS
o 23ZDKH90,27ZDKH95

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Conductor

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CONDUCTOR
Conductors are one of the principal materials used in manufacturing of transformers.
Best quality of copper rods are procured from indigenous as well as foreign sources.
Normally 8 mm & 11 mm rods are procured. For each supply of input, test certificate
from suppliers is obtained and at times, such input is got tested from reputed test labs.

Various sizes as specified by customers can be drawn. At each stage of drawing of

copper wires & strips, the dimension is measured all around and in case found
oversize particular die is replaced forthwith. During final stage of drawing smoothness
and brightness is strictly observed. Elongation, Springiness & Tensil strength are
thoroughly tested. While drawing, care is taken that the physical properties of the
conductors are maintained.

After the wires & strips are drawn as per clients requirements they are moved on to
paper covering process. To prevent the inclusion of copper dust or other extraneous
matter under paper covering the conductor is fully cleaned by felt pads or other suitable
means before entering the paper covering machine. As per the customers
requirements DPC, TPC & MPC conductors are produced. It is ensured that each layer
of paper is continuous, firmly applied and substantially free from creases. No bonding
or adhesive material is used except to anchor the ends of paper. Any such bonding
materials used to anchor the ends do not have deleterious effect on transformer oil,
insulating paper or the electric strength of the covering. It is ensured that the
overlapping percentage is not less than 25% of the paper width.

Arrangement of layers
According to the number of layers used the paper is applied as follows.

Two layers:-
Where there are two layers both of them are wound in opposite directions.

More than two layers

Where there are more than two layers all the layers are applied in the same direction,
all, except the outermost layer is butt wound, and the outermost layer is overlap
wound. Within each group of papers the position of the butt joints of any layer relative
to the layer below is progressively displaced by approximately 30 percent of the paper
width.

Note: Overlapping can also be done as per customer requirements.

Grade of paper
The paper, before application, is ensured to be free from metallic and other injurious
inclusions and have no deleterious effect on insulating oil. The thickness of paper
used is between 0.025 mm to 0.075 mm.

Enameled Conductor
Apart from paper covered conductors, we have all the facilities of producing enameled
conductors as per customer specified requirements.

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BUSHINGS

20
Training Module

BUSHINGS
Insulators and Bushings are built with the best quality Porcelain shells manufactured by
wet process. The materials that go into the manufacture of these insulators offer best
quality mechanical and electrical characteristics. The standard colour of the glaze is
brown, but white glazed insulators can also be made available on request.

Manufacturing process

For manufacture of electro porcelain, high quality indigenous raw materials viz, China
Clay, Ball Clay, Quartz and Feldspar is used. The raw materials in lots undergo
thorough test in quality control laboratory before being user for manufacture.

Quartz and feldspar are ground to required finesses and then intimately mixed with ball
and china clay in high speed blungers. They are then passed through electromagnetic
separators, which remove iron and other magnetic impurities. The slip produced is
passed to a filter press where extra water is removed under pressure and the resulting
clay cakes are aged over a period. The aged cakes are extruded to required form viz.,
cylinders, on high vacuum de-airing pug mill. The extruded blanks or cylinders are
given shapes of Insulators / Bushings which are conditioned and are shaped on
copying lathes as the case may be.

These shaped insulators / bushings are then dried under controlled conditioned and
then they are glazed, Trade mark, month, year and country of manufacture are marked
before firing. The glazed shells are fired in fuel efficient kilns having temperature
controls to ensure uniformity of firing high strength in porcelain shells. Metal parts used
in the assembly of Insulators, are of blackheart and malleable cast iron and are hot dip
galvanized to conform to international standards.

Testing, Assembly & packing

All insulators & bushings undergo routine electrical and mechanical tests. The tests
before and after assembly are carried out according to IS Specifications, to ensure
their suitability for actual conditions of use. Porosity tests are also carried out regularly
on samples from every batch, to ensure that the insulators are completely vitrified.
These insulators are then visually checked and sorted, before they are packed in sea
worthy packing, to withstand transit conditions.

Types of Insulators & Bushings

 Bushing Insulators
o Hollow Porcelain Bushings upto 33 KV
o Application : Transformers, Capacitors, Circuit Breakers etc.
 Pin Insulators
o Pin Insulators conforming to ISS, B.S., IEC and other international
standards upto 33 KV

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 Post type Insulators

o Post type insulators, complete with metal fittings, generally IS
Specifications and other International Standards upto 33 KV
 Solid Core Insulators
o Line Post
o Long Rod
o Support
 Special Type Insulators
o C.T. upto 66 KV
o P.T. toto 33 KV
o Weather Casing
 L.T. Insulators
o Shackel Type
o Spool Type
o Pin Type
o Guy strain

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Training Module

Product Specification
1. H.V. Bushings (IS:3347) 1. 12-17.5 KV / 250 amps
2. 12-17.5 KV / 630 amps
3. 12-17.5 KV / 1000 amps
4. 12-17.5 KV / 2000-3150 amps
5. 24 KV / 250 amps
6. 24 KV / 630 amps
7. 24 KV / 1000 amps
8. 24 KV / 2000 – 3150 amps
9. 36 KV / 250 amps
10. 36 KV / 630 amps
11. 36 KV / 1000 amps
12. 36 KV / 2000-3150 amps

2. L.V. Bushings (IS:3347) 1. 1 KV / 250 amps

2. 1 KV / 630 amps
3. 1 KV / 1000 amps
4. 1 KV / 2000 amps
5. 1 KV / 3150 amps

3. H.V. Bushings (IS:8603) 1. 12 KV / 250 amps

2. 12 KV / 630 amps
3. 12 KV / 1000 amps
4. 12 KV / 2000-3150 amps
5. 36 KV / 250 amps
6. 36 KV / 630 amps
7. 36 KV / 1000 amps
8. 36 KV / 2000-3150 amps

4. C.T. Bushings (IS:5612) 1. 12 KV

2. 24 KV
3. 36 KV

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Training Module

EPOXY BUSHINGS
All Epoxy Resin Cast Components are made from hot setting reins cured with
anhydrides; hence these provide class-F Insulation to the system. In an oxidizing
atmosphere, certain amine cured Epoxy Resins can start to degrade at 150ºC whereas
the anhydride cured systems are stable at 200ºC therefore our epoxy components are
cured with anhydrides which gives them a longer life.

Electrical & Mechanical Properties

Compressive Strength 1500-2000 Kg/cm2

Tensil Strength 650-850 Kg/cm2
Di-electric Strength 18-22 KV/mm

Range of products available in the market

1. All designs of bushings for sealed type distribution transformers

2. All designs of Spouts, Trolley bushings etc for 1.1 KV oil circuit breakers
3. Resin cast CT’s & PT’s for 1.1 KV Instrument panels
4. Any design of Bus Bar supports for control panels

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Buchholz Relay

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Training Module

BUCHHOLZ RELAY
Power transformers are considered to be highly reliable type equipment, yet, in order to
ensure the continuity of service that modern conditions demand, protective devices are
required. The purpose of such devices is to disconnect faulty apparatus before large
scale damage caused by a fault to the apparatus or to other connected apparatus.
Such devices generally respond to a change in the current or pressure arising from the
faults and are used for either signaling or tripping the circuits.

Protective devices in the ideal case must be sensitive to all faults, simple in operation,
robust for services and economically feasible. Considering liquid immersed
transformer, a near ideal protective device is available in the form of gas and oil
operated relay described here. The relay operates on the well known fact that almost
every type of electric fault in a liquid immersed transformer gives rise to a gas. This gas
is collected in the body of the relay and is used in some way or the other to cause the
alarm or the tripping circuit to operate.

The principle of the gas and oil relay was first successfully demonstrated and utilized
by “Buchholz” many years back.

Applications

Double element relays can be used in detecting minor and major faults in a
transformer. The alarm element will operate, after a specified volume of gas has
collected to give an alarm indication. Examples of incipient faults are.

1) Broken down core bolt insulation

2) Shorted lamination
3) Bad contacts
4) Overheating of parts of windings

The alarm element will also operate in the event of oil leakage, or if air gets into the oil
system. The trip element will be operated by an oil surge in the event of more serious
faults such as

1) Earth faults
2) Winding short circuit
3) Puncture of bushings
4) Short circuit between phases

The trip element will also be operated if a rapid loss of oil occurs.

Available range

Relays for users outside India

Type SRIE GORIE GOR2E GOR3E

No. of Switching 1 2 2 2
System

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Pipe bore in mm 25 25 50 80
Transformer rating ≤ 1.6 ≤ 5.0 > 5.0 > 10.0
In MVA ≤ 10.0

Relays for users in India

Type GOR1 GOR2 GOR3 SRI SRI/V

No. of Switching 2 2 2 1 1
System
Pipe bore in mm 25 50 80 25 25
Transformer rating < 1.0 > 1.0 > 10.0 For < 1.0
In MVA ≤ 10.0 OLTC

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Hermatically Sealed T/fs

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HERMETICALLY SEALED TRANSFORMERS

Sealed from environment by

a) Welded Lid
b) Bolted Lid

For fin type radiators For corrugated tanks

Nitrogen gas cushion Transformer is

located above the totally filled with fluid
liquid level and level being
indicated on the
liquid level indicator
positioned at the
highest point on
the lid

A pressure relief device may be fitted to regulate the inernal pressure

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Magnetic Oil Level Gauge

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MAGNETIC OIL LEVEL INDICATOR

Magnetic oil level indicators are used for varied purposes. In Transformer they are
mounted on the conservator to read oil level and to set off an alarm when the oil level
falls below a predetermined level.

It consists of following parts.

a. Gear assembly
b. Magnetic couple
c. Float with arm
d. Cam assembly with mercury switch
e. Dial and pointer.

The float is hinged and swings up or down when oil level rises or falls. This rise or fall
rotates the bevel gear and thus the pinion of the gear assembly. The pinion on turn
rotates the driving magnet inside the conservator. The follower magnet positioned
outside carries a pointer and a cam. The pointer reads oil level and the cam is set to
operate the mercury switch at a predetermined low level.

One normally open mercury switch is provided to actuate low level alarm. The switch is
adjustable to compensate error in orientation of pad. Leads of this switch are
connected to the terminals.

Specifications

1. Operating Liquids Transformer oil to IS:335 & other oils

2. Working temperatures 0 to 100ºC of oil
3. Working pressure 0 to 4 Kg/Sq.cm.
4. Environment Suitable for indoor & outdoor use
5. Electric Switch One SPST Mercury Switch
6. Contact rating 5 Amps 240 V A.C. 0.5 Amp 240 V.D.C.
7. Switch Operation Normally open, closes when oil level drops
to near empty condition, recovers
automatically on rising of oil level.

Model SO-4 SO-6

Dial Size 100 150
Weight 2.2 2.9

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Silica gel Breather

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SILICAGEL BREATHERS
Breathing Process

Breathing is the process wherein Transformer sucks the air inside or pushes the air
outside its body. When Transformer is loaded or unloaded, the oil temperature inside
the transformer tank rises or falls. Accordingly, the air volume inside the tank changes
by either sucking in or pushing out the air. This phenomenon is called “Breathing” of
the transformer.

Now, the air which is being sucked in contains either foreign impurities and / or
humidity which changes dielectric strength of oil. For proper working of Transformer, it
is absolutely necessary that dielectric strength of transformer oil remains unimpaired.
Hence, it is necessary that air entering into the transformer is free from moisture &
foreign impurities.

Window Type Silicagel Breathers

The breather is made out from Aluminium (Gravity) die cast in two parts i.e. Top shell &
bottom shell and a gel compartment is made out from Tin plate which is known as
removable inner container. The inner gel container can be withdrawn by unscrewing
the wing-nuts removing the top shell or bottom shell portion of the breather in case of
two piece model.

A sight windows have been provided to observe / inspect the condition of Slicagel &
Oil level.

An oil seal made out of aluminium sheet is fitted in the base of the breather to prevent
diffusion of moisture into silicagel when no breathing is taking place.

Clear view type Silicagel Breather

Is based on DIN standard 42567. Visibility is excellent, because the entire

compartment is transparent. The change in colour of gel in any part of the mass is
clearly visible, even from a distance as against very poor visibility in window type
design.

The entire oil cup is also transparent. Hence, change in the level of oil as well as any
sedimentation in oil is clearly visible as against invisibility in window type

Available range

From 0.125 Kg to 15 Kg capacity

Sn Silicagel Content Transformer rating Suitable for transformer

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(in Kgs) (in KVA) holding oil

(in litres)
1 0.125 200 300
2 0.250 300 450
3 0.500 500 750
4 1.000 2000 1400
5 1.500 5000 3000
6 3.000 7000 7500
7 4.000 10000 15000
8 6.000 15000 21000
9 8.000 20000 27000
10 10.000 25000 32000
11 15.000 30000 47000

Above table is just a guide line. The gel content or the size of the breather is
determined by the volume of air passing through the breather, the oil contents of the
transformer and the atmospheric conditions at the place of installation. Hence the
ultimate user should decide the size and gel content of the breather that would suit to
him.

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Training Module

Sub-Assemblies

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Training Module

SUB ASSEMBLIES

Sub Assemblies are categorized as under:-

 HV & LV Coils
 Core Assembly
 Core-Coil Assembly
 Pressed Steel Radiators & Panels
 MS Tanks Corrugated & Radiator type

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Training Module

COILS
Coils are of two type
a) High Voltage Coils
b) Low Voltage Coils.

1. HIGH VOLTAGE COILS.

H.V. Coils are one of the components of finished transformers. High voltage
coils are made on automatic layer setting winding machines. A solid cylindrical
former of predetermined diameter and length is being used as base over
which the coil is made. Generally round insulated wire of either copper or
aluminium is used as basic raw-material. The coils are made in no. of layers.
The starting and finishing leads of each coils are terminated on either side of
the coil. These leads are properly sleeved and locked at no.of points.

2 LOW VOLTAGE COILS:

L.V. Coils are also one the components of transformer. The procedure of
making low voltage coil is generally same as described above, except that the
shape of the basic raw-material is rectangular.

Disc Winding in process Finished Disc winded coil

CORE ASSEMBLY
1. Core is one of the components of finished transformer. Core assembly is
done manually.

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Training Module

2. The basic raw-material is Cold Rolled Grain Oriented Silicon Steel and 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. Notching is performed to
increase the magnetic path. The laminations are put through annealing process.

3. These laminations are assembled in such a manner that there is no air gap
between the joints of two consecutive sheets.

4. The entire assembly is done on a frame commonly known as core channel

These frames are used as a clamping support of the core assembly. Hooks
are provided on the core frame for easy movement of core assembly. The
entire assembly is tightened by corebolt.

Core Assembly of Core Assembly in process of

Distribution Transformer Power Transformer

CORE - COIL ASSEMBLY:

The components produced in the coil winding and core assembly stage are taken
into Core-Coil assembly Stage.

1. The Core assembly is vertically placed with the foot plate touching the
ground. The top yoke of the core is removed and is kept in a safe place. The
limbs of the core are tightly wrapped with cotton tape and then varnished.

2. 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.

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Training Module

Insulating block of specified thickness and number are placed both at the top
and bottom of L.V. Coil.

3. Cylinder made out of corrugated paper or plain cylinder with oil ducts are
provided over LV Coil. HV Coils are placed over the cylinder. Gap between
each section of HV coils including top and bottom clearances is maintained with
the help of oil ducts; as per the design/drawings.

4. The Top Yoke is refilled. Top core frame including core bolts and tie rods are
fixed in position.

5. Primary and secondary windings are connected as per the requirements.

Phase barrier between HV Phases are placed as per requirement. Connections
to the tapping Switch (if required) are made. Finally, the entire component is
placed in the Oven for removal of moisture content. After drying the component
is ready for tanking.

Distribution Transformer Power Transformer

Core Coil Assembly Core Coil Assembly

TANKS
Best quality MS Sheets, Press Steel Radiators and Corrugated Panels are procured
from indigenous and foreign sources. These radiators and panels are welded with the
tanks fabricated in-house. In case of Power Transformers Radiators provided are of
detachable form due to large in size and ease of shipment.

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Training Module

Tank Fabrication in process Corrugated Tank

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Tap Changer

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OLTC
On Load tapchangers marketed by us are tested as per IS 8468-1977 Amendment 1-1980. On
Load Tapchanger (OLTC) are also suitable for off circuit furnace duty application. It comprising
of driving mechanism and high speed selector switch. Optional equipments include Remote
Tapchanger Control Cubicle (RTCC) with indicating apparatus, fitted with devices to prevent
malfunctioning. Designed for unidirectional power flow but can be used for bidirectional power
flow under certain combinations of current rating and step voltage.

The tap changer is designed for operation at current upto 300 amperes. The Selector Switch
which is capable of making and breaking load current in addition to selecting tapping, is
housed in an oil filled container and separated from the transformer oil by an oil-tight cast
epoxy resin Terminal Board.

At one end of the container a separate chamber houses the motor and driving mechanism. A
weather proof door provides access to the operating mechanism and a suitably positioned
window allows easy reading of the tap position indicator.

Available Range

Sn Rated Max. Max. Max. Oil Tappings Flange SC withstand

Voltage Steps Step Rated Content Dimension
Voltage Current
KV Nos. Volts Amps Ltrs mm K Amps for
2 Sec.
1 11 8 600 300 440 Linear 840 x 832 3.5
2 11 4 220 100 300 Linear 1035x990 2.0
3 33 8 1200/750 125/300 440 Linear 840 x 832 3.5
4 33 16 1200/750 100/300 780 Linear 1043x1035 3.5
5 33 20 1200/750 125/300 780 Linear 1043x1035 3.5
6 33 16 1200/850 100/300 380 Coarse/ 1066x830 3.5
fine plus-
minus
7 33 9 1200/850 100/300 380 Linear 1066x830 3.5
8 33 16 1000/750 300/500 1200 Linear 1499x1207 5.0
9 66 16 1200/750 125/300 1200 Linear 1499x1207 3.5
10 66 16 1200/750 125/300 850 Linear 1072x1110 3.5
11 66 20 1200/750 125/300 850 Linear 1072x1110 3.5

OFF CIRCUIT TAP CHANGER

Off Circuit Tap changers are used for adjusting the voltage of oil immersed transformers under
de-energised condition by adding or cutting out turns of primary or secondary windings.

Construction

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Training Module

Tap changing is done by rotating an insulating driving shaft. Bridgings are made between two
terminal stud contacts either by snap action of self centering spring loaded ring or by sliding
palm fixed with centre drive shaft. The centre shaft is operated by means of an externally
mounted hand wheel on a double sealed stuffing box having spring loaded positioner with tap
position indicator. Indicator mechanically shows the tap number of which the tap changer is
operating. Provision is made for pad locking in any tap position. Between first and last position
stoppers are provided to avoid bridiging across range.

Material of construction

Sn. Parts Material Specification

1. Centre driving shaft FRP pultruded rod Epoxy based
2. Phase Board Phenolic laminated paper Gr. P3 of IS:2036
base sheet
3. Terminal Stud High conductivity Hard IS:613
Copper OR Free IS:319
machining Brass
4. Bridiging Ring Hard Copper (Medium) Conductivity to BS 1977
Oxygen free OR Free C 103 IS:319
machining Brass Tube
5. Tie rod insulating tube & Phenolic laminated paper Gr. P3 Epoxy Based
spacers tube & FRP tube
6. Spring Spring Steel IS:4454 Part I Gr. II
7. Stuffing Box CI or CS
8. Handle CS or Aluminium
9. Supporting Structure CS Gr. Fe 540 W-HT
IS:961

Available Range
KV AMPS POSITION TYPE HANDLE
11 30 5 SB T
30 7 SB T
30 9 TR T
30 11 TR W
60 5 SB T
60 7 SB T
60 9 SB T
60 5 TR W
60 7 TR W
60 9 TR W
60 11 TR W
100 5 SB W
100 7 SB W
100 5 TR W

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KV AMPS POSITION TYPE HANDLE

100 7 TR W
100 9 TR W
100 11 TR W
150 5 TR W
150 9 TR W
250 5 TR W
250 7 TR W
250 9 TR W
500 5 TR W
500 9 TR W

22 30 5 SB T
30 7 SB T
30 5 TR T
30 7 TR T
30 9 TR T
60 5 SB T
60 7 SB T
60 5 TR W
60 7 TR W
60 9 TR W
100 5 TR W
100 7 TR W
100 9 TR W
150 5 TR W
150 7 TR W
150 9 TR W
250 5 TR W
250 7 TR W
250 9 TR W
22/11 30 5 SB T
30 7 SB T
30 5 TR W
30 7 TR W
30 9 TR W
60 5 SB T
60 7 SB T
60 7 TR W
60 7 TR W
60 9 TR W
100 5 TR W
100 7 TR W
33/11 30 7 TR W

33 30 5 TR T
30 7 TR T
30 9 TR T
60 5 TR W
60 7 TR W
60 9 TR W
60 11 TR W
100 5 TR W

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Training Module

KV AMPS POSITION TYPE HANDLE

100 7 TR W
100 9 TR W
150 5 TR W
150 7 TR W
150 9 TR W
400 5 TR W

SB : Side Base Construction T : ‘T’ handle

TR : Tie Rod Construction W : Wheel Handle

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Training Module

Temperature Indicator

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Training Module

TEMPERATURE INDICATOR (Dial Type)

Measuring System
When heated, volumetric expansion of liquid will be proportional to the rise in
temperature. A sensing bulb, a measuring bellows and a small bore capillary tube
connecting the two from the measuring system which is filled with liquid. When the bulb
is exposed to a rise in temperature, the liquid inside the measuring system expand
proportionately causing corresponding volumetric changes in the bellows. Since one
end of the bellows is anchored it will move linearly in proportion to the measured
temperature.

World Class Product

 Ergonomically designed 270º part circular scale
 Complete temperature and head compensation for bellows & capillary line
 No periodic site adjustment
 Upto four electrically isolated heavy duty control switches
 Winding temperature indication by thermal image device
 Remote transmission for electrical repeater
 Switch & circuit testing facility from outside the case.
 All circuits to ground tested at 2500 volts A.C. 50 Hz for 60s
 Maximum temperature indicating pointer
 Ventilated weather proof case (Protective class IP 55 of IEC 529)

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SPECIFICATIONS
1. Dial 140 mm diameter with 270º part circular scale
marked boldly for rapid reading.
2. Standard Ranges 0-120ºC, 20-240ºC, 30-150ºC, 0-150ºC
3. Accuracy of indication ±1.0% f.s.d
4. Control Switches Upto 4 numbers, electrically isolated normally
open S.P.S.T. dry electrode mercury and glass
switches.
5. Switch Rating 5 Amps continuous at 250 Volts A.C. or D.C.
overload rating of 10 Amps in A.C. circuit only
for short duration such as motor starting.
Switches are independently adjustable for
making and breaking contacts at pre-set
temperatures.
6. Capillary Standard Lengths 5m, 6m, 10m and 12m
stainless steel armour sheathed
7. Bulb Type F or Type M
8. Case Finish Stove enameled hammerstone deep blue
outside and all white inside.
9. Case Mounting Projection mounting with back straps. Weather
proof case (protective class IP 55 of IEC 529) is
suitable for outdoor service. However a canopy
type weather shield will improve visibility under
tropical conditions.
10. Capillary Entry Bottom or Top of case – vertical
11. Electrical Entry Bottom of case – vertical through 2 holes (19
mm or 26 mm)
12. Maximum Pointer Resettable from outside by means of a
screwdriver is fitted to the instrument window. A
special damping device ensures accuracy of
readings even under vibration conditions.
13. Switch Testing A switch testing knob is fitted on the instrument
lid to facilitate checking of the switch settings
from outside, without removing the instrument
lid.
14. Electrical Connection Are made to the terminal blocks inside the
instrument case. Approved insulating materials
are used and all circuits to ground tested at
2500 Volts A.C. 50 Hz for 60 seconds. A wiring
diagram is fixed inside the instrument case.
Temperature Indicators with dials of 60º segmental scale & 240º part circular scale is
also available.

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Training Module

Transformer Oil

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Training Module

TRANSFORMER OIL
Transformer oil is a petroleum base mineral oil used extensively in power and
distribution electrical equipments such as transformers, switchgears, capacitors and
allied equipments. It provides insulation between windings, winding to core, winding to
tank and acts as a coolant to take away the heat generated by power losses and also
acts as an arc quenching medium.

Quality
Quality of transformer oil marketed by us has to undergo tests and checks conforming
to IS-335 of BIS (Bureau of Indian Standards) and also international standards:
Oxidation stability, gas absorption, chemical deterioration, break down voltage,
resistivity, dielectric dissipation factor etc. Physical characteristics tests are also
conducted in a routine manner. We offer following distinct advantages:-

1. High Volume Resistivity at 27ºC & 90ºC

High insulation resistance between transformer windings or higher megger
value.

2. Very low dielectric dissipation factor

Reduces temperature rise during service, because of lower electrical losses.

3. Highly refined oil

Reduces aromatic content and sulphur content.

4. Low Viscosity
Improves cooling

5. Higher initial interfacial tension

Smoother functioning of oil with lesser maintenance due to low deterioration.

6. Low S.K. value

Optimum Refining

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Technical Characteristics

1 Appearance : Clear, transparent and free from

suspended matter or sediment.
2. Density at 29.5ºC (Max) : 0.89 g/cm3
3. Kinematic Viscosity at 27ºC (Max) : 27 cst
4. Interfacial tension at (Closed) (Min) : 0.04 N/m
5. Flash point Pensky-Marten (Closed) (Min) : 140ºC
6. Pour Point (Max) : -6ºC
7. Neutralisation Value (Total Acidity) (Max) : 0.03 mg KOH/gm
8. Corrosive Suplhus : Non-Corrosive
(in terms of Classification of copper strip)
9. Electric Strength (Min)
a) New untreated oil : 30 KV
b) After treatment : 60 KV
10. Dielectric Dissipation factor (tan delta) at 90ºC (Max) : 0.002
11. Specific Resistance (Resistivity)
12
a) at 90ºC (Min) : 35 x 10 ohm cm
12
b) at 27ºC (Min) : 1500 x 10 ohm cm
12. Oxidation Stability
a) Neutralisation value after Oxidation (Max) : 0.40 mg KOH/gm
b) Total Sludge after oxidation (Max) : 0.10 by weight
13. Presence of Oxidation inhibitor : Absent
14. Water Content (Max) : 50 PPM
15. Tests on Sample aged for 96 hours as per ASTM
Open Beaker method with Copper catalyst
A) Dielectric dissipation factor at 90ºC (Max) : 0.2
B) Specific Resistance (Resistivity) Ohm-cm (Min)
12
a. at 90ºC : 0.20 x 10
a. at 27ºC : 2.5 x 1012
C) Neutralisation Value mg KOH/gm (Max) : 0.05
D) Sludge by n-heptane (Max) : 0.05
16. S.K. Value % (Typical) : 8

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Repairing Distribution Transformers

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Training Module

PROCEDURE FOR REPAIRING DISTRIBUTION TRANSFORMERS

The procedure for repairing

transformers is divided into three main
stages. These are (1) pre-repair stage (2)
repair stage & (3) post repair stage. All
these stages are detailed below:
I. Pre-repair Stage
The pre-repair stage is further broken down into sub stages, each sub stage being
enumerated as follows:

1. Preliminary Inspection (Site / Depot)

If required by the client then the damaged transformer is examined at the
installation site or at the client's depot by the firm's representative in presence of
the client's representative (normally the substation in-charge or the Depot
manager).

All observations are recorded on a pre-formatted table in the preliminary

inspection report (format enclosed). Photographs of the transformer in a)
installed i.e., undisturbed state, b) opened state i.e., after de-tanking the
transformer must be snapped. Care should be taken to snap all necessary views
of the transformer in both the states.

The transformer is checked for the following:

i) State of the main tank
ii) State of the conservator vessel
iii) State of the Radiators
iv) State of Bushings and Fittings (viz. Arcing Horn etc.)
v) State of the Dehydrating Breather
vi) State of Windings
vii) State of the Core
viii) State of the Transformer Oil
ix) State of the Valves (viz. PRV, Drain Valves etc.)
x) Missing parts, if any.

A site / preliminary inspection report is prepared and signed by the firm's

representative and counter signed by the client's representative.

If undertaking the repair of the transformer is expected by both the concerned

parties to be economical then suitable transportation of the same to the repair
works is arranged.
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Note : At the time of receiving the damaged transformer the repair firm's
representative must ensure that the state of transformer is clearly indicated on the
receipt slip i.e., all the missing and damaged items must be clearly mentioned.

2. Lifting:

The damaged transformers are lifted

from the client's depot and brought to
our works.
3. Unloading:
The transformer are unloaded at the unloading bay by the loading / unloading
personnel.
-2-

4. Offer for Joint Inspection:

The client is intimated of the transformer arrival. Date and time of joint
inspection is finalised.

5. Joint inspection:
All observations made must be recorded on a pre-formatted table in the
inspection report.
(format enclosed)

i) On the arrival of the Inspector/s deputed by the client the transformer /s is /

are brought inside the shed to the ear marked inspection area.

ii) If sealed, the seals are broken in the presence of the inspector.

Transformer Tank & Conservator Vessel

iii) If present, drain oil from the transformer tank and conservator vessel into a
separate marked drum. Visually inspect the conservator vessel for cracks /
damages. Remove the vessel.

iv) Check transformer tank for leakages / damages, especially the radiator fins /
tubes. Check if there are any parts missing. Also check the pressure relief
valve.

v) Transformer Oil
Check the dielectric strength of the oil drained from the transformer tank.
Make note of its colour and any adour arising from it. Also check for any
foreign material.

Bushing & Accessories

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vi) Check the condition of bushings i.e., whether cracked or broken. Remove
them. Note their specification.

vii) Check the condition of terminal rods whether it is "pitted" or damaged.

Remove them. Note down their specifications.

viii) Dehydrating Breather

Check the silica gel in breather

assembly. Note its colour and
quantity. Also check oil in the oil
cup. Note its colour and quantity.
ix) Opening the transformer
Open the transformer lid and raise the transformer core-coil assembly. Wait
for some time to allow excess oil to drip into the tank. Now place the
assembly on to a oil tray.

x) Metallic Pieces
Check if there are any metallic pieces on the yoke or else where.

-3-

xi) Tap Changer

Check the condition of the tap changer contacts and connections. Check
whether its functioning is proper or not. In most cases the tap changer is
found damaged beyond salvage and has to be replaced.

The connections & windigns

xii) Check whether the terminal leads and lugs are broken or burnt.

xiii) Check if the inter coil connections, delta connections and its neutral
connections are loose, broken or burnt. Check whether the windings appear
burnt.

Subsequent to visual examination of the core-coil assembly continuity and

ratio tests should be performed on all windings to locate the fault and its
nature. (if necessary the inter coil connection may be cut)

xiv) Remove the yoke. Take out the windings and if necessary re-perform the
continuity test to positively identify the fault. (If in the windings)

xv) The Core

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Training Module

Check the condition of the core whether it is pitted, scratched, melted, has
any hot spots, and has any foreign material deposits. The diameter, cross-
sectional Area, window height and limb size of the core must be recorded.

xvi) Conductor size and current density

The conductor size of both LV and

HV windings must be measured and
recorded. The current density as per
observed sizes be also calculated
and recorded. It should be checked
whether this current density is in
conformity with the magnitude
stipulated. In case of irregularity it
must be recorded and the inspector
appraised of the same.
xvii)Weighing
The terminal rods and the windings must be weighed and their weights
recorded. These must also be tagged and authenticated by the inspector.

Note : In case any warranty / guarantee on the repaired transformer is

required by the client and if any of the winding is found damaged during the
joint / preliminary inspection then all the windings have to be replaced.

xviii)Joint Inspection Report

The inspection report presenting all the observations must be counter
signed by both the inspector and the repair firm's representative.

-4-

6. Preparation for repair

i) List of works : For each damaged transformer under consideration, a list of
works to be carried out for its repair is prepared.

ii) Estimate for repair work

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Training Module

In consonance with the list of works,

an estimate of repair cost be made.
(format enclosed)
iii) Economic viability

In context to economic limitations, if

any, imposed by the client and in
reference to the guide lines, if any,
laid down by the client the economic
viability in taking up the repair of
the transformer be worked out.
iv) Submission of Estimate
The estimate is sent to the client for approval.

v) Approval of Estimate
The next phase is to be taken up only upon receipt of approved estimate /
work order placed by the client for repair of specific damaged transformers.
If, for any reason, the client disapproves the estimate then the cost of to and
fro transport of the transformer must be realised from the client.

vi) Design
If the repair work is found cost effective and the repair work entails major
overhauling then electrical design is made by the design engineers keeping
in mind the required C.D, core diameters, core cross-sectional area, window
height, limb size, total copper weight, maximum flux density, rating, vector
group, voltage class, no load losses and the load losses.

vii) Material procurement

The design department submits the bill of materials along with the electrical
design to the WM (Works Manager). The WM informs the store officer of the
material requirements if the material is unavailable or short the store officer
accordingly advises the WM. If necessary, the WM then indents the
purchase of the requisite material.

The purchase manager procures the material and places it with the store.

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Training Module

The store on receipt of the material invites the QC manager to inspect the
same. Only subsequent to the QC manager's approval can the store accept
and issue the material.

viii) Work Orders

Meanwhile in reference to each list of works and corresponding design the
WM prepares and issues the work orders to various departmental heads.

-5-
ix) Requisition of material

On the basis of work orders issued

to them, the departmental heads
requisition the necessary materials
from the store.

II. The Repair Stage

The scope of repair works essentially
depends on the technical condition of
the transformer and the nature of its
failure. The transformer repair may be
sub divided into two types.
(a) minor : This entails tightening of
connections or replacement of one
or more individual components
excluding the windings and the
core.
(b) major : This involves the
replacement of winding and
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Training Module

insulation, re-insulation of core

laminations etc.

All minor repairs are carried out

without necessitating redesign or major
material procurement.

The repair stage (major) or the actual /

physical repair process is comprised of
a number of steps, each entailing the
contribution of one or more
departments. These steps along with
the pivotal department and its role are
enumerated as follows:

1) Preparation of winding formers

This is done by the maintenance
department. The maintenance
department is also responsible for the
upkeep of all machines, sub-station,
and various other equipment.

2) Preparation of the windings

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Training Module

i) The LV Winding Deptt.: This

department prepares the LV
winding as per the work order
issued to them. It should be noted
that the work orders are specific i.e.,
they relate to a particular design.
This work is carried out adhering to
certain work instructions, which are
general in nature, but pertain to the
department.

ii) The HV winding department

This department prepares the HV
winding as per the work order
issued to them. They also have their
own work instructions.

3) Insulation
The insulation cutting department is
responsible for cutting and providing
the insulation material required by
various departments. This is done as
per work orders issued to them.
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Training Module

Note : Stage inspection

Quite often the client requires to
inspect the prepared windings. Thus it
becomes necessary to invite the client
for stage inspection of the prepared
windings. The clients representative
visits the works and inspects the
windings for conductor size, CD and
weight. These are recorded on the stage
inspection report, which is counter
signed by both the inspector and the
firm's representative. On the written
approval of the inspector, and if not
already done the estimate of cost of
repair is filed with the clients for
approval. Only after the receipt of the
clients concurrence or in strong
anticipation of the same, the next step
is taken up.

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Training Module

4) Preparation of the core

The core assembly department cleans,
varnishes and reassembles the core
laminations as per the work orders
issued to them.

5) Core-Coil Assembly
The coil assembly department with
inputs from the winding, insulation
cuttings and the core assembly
department assembles the windings
on the core, placing the requisite
insulation material at the specified
places. It also makes the necessary
delta, neutral and inter coil
connections. It brings out terminal
leads and solders / brazes the
connection lugs on them. It also
assembles and connects the tap
changers. This all is done as per the
work orders issued to them.
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Training Module

On completion of the core coil

assembly the departmental head
invites the testing engineer to perform
the ratio and the resistance tests on
the completed assemblies. If the tests
are in conformity with specifications
the assemblies are put in the drying
ovens.

6) Drying of Transformer
The core-coil assembly in the drying
oven are periodically checked for
insulation resistance values with a
suitable megger by personnel of the
tank-up department. Only when the
stipulated megger values (about 1500
Mohms) have been attained do the
tank up people take these assemblies
out for tanking up.

7) Tank cleaning & Leakage testing

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Training Module

The tank cleaning department

thoroughly cleans and checks the
transformer tanks & the conservator
vessel for any leakages. If any lekages
are found they are plugged with
welding by the maintenance people.

8) Painting of transformer tank &

Conservator Vessel
The painting department paints the
transformer tank and the conservator
vessel as per the work order issued to
them.

9) Tank-up
The tank-up department mounts the
transformers into the cleaned and
painted tanks as per work orders
issued to them. The transformer tank
is topped up with oil of dielectric
strength of breakdown value 60 KV at
2.5 mm electrode gap. The

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Training Module

transformer oil should also be free of

any contaminants.

Note : In all cases of transformer

repair the old transformer oil is to be
replaced with new transformer oil.

10) Transformer Oil Treatment

The oil treatment Plant Operator
should ensure that high quality
transformer oil (Clear and BDO 60
KV at 2.5 mm gap) is available at all
times for topping up the transformers.

11) Quality Control in the repair stage

The QC department is responsible for
maintaining a strict vigil on all in
process, regularly sampling and
inspecting at each inprocess stage the
quality of work and material. Thus,
ensuring snag free end product.

12) Testing of transformers

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Training Module

After tank up the repaired

transformers are lined up in the
testing area. The testing engineer
carries out on them all routine and
any other tests specified by the client.
Any anomalies found are referred to
the responsible department for
correction. After error correction, the
transformers are re-tested. Only after
the testing engineer, QC manager &
the works manager are satisfied with
the results the transformers are to be
moved out by the loading / unloading
personnel to the ear marked storage
bay.

III. Post Repair Stage

1. Intimation to the client

On completion of the repairs the client
is intimated and invited to carry out

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Training Module

the final inspection of the

transformers.

2. Final Inspection
The client's representative shall
examine and conduct tests on the
transformers to satisfy himself of their
worthiness. If any minor anomalies
are noticed, they are put right. The
final inspection report is prepared
and counter signed by both the
client's representative and the firm's
representative. (normally the testing
engineer)

3. Pre-despatch inspection & Despatch

On receipt of the schedule of despatch
from the client for the repaired
transformers they are subjected to a
pre-despatch check by the QC
department. Any irregularity is
corrected and only thereafter the

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Training Module

transformers are loaded on to the

carrier.

4. Invoicing
As per the approved estimate the
invoice for repairs carried out is duly
prepared including applicable taxes
and duties and presented to the client
for realisation.

Note : In case of doubt or difficulty of

any nature the WM / Testing
Engineer / QC Manager / Finance
Manager / Purchase Manager / Sales
Manager shall approach the Manager
(Engineering) / Chief Engineer and
seek his directions.

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Training Module

LIST OF RAW MATERIALS

1. Winding & Connection Wires

a) LV Winding Wire (DPC Copper)
b) HV Winding Wire (SE Copper)
c) Terminal Lead Wire (MPC
Copper)
d) Copper Flat
e) Copper Foil

2. Insulation
a) Kraft Paper
b) Pressboard
c) Pre-compressed Pressboard
d) Cotton Tape
e) Empire Sleeve
f) Glass Sleeve
g) Bakelite Flat
h) SRBP Tube
i) Permali Wood
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Training Module

j) Haldi Wood
k) Press Paper
l) Crepe Paper
m) Webbing Tape

3. Transformer Oil

4. Tapping Switch ( Of relevant tap

nos. & specifications )

5. Adhesives
a) Synthetic Gum
b) PVA Emulsion

6. Connection Lugs

7. Solder Wire
a) Sn:Pb=70:30
b) Sn:Pb=60:40

8. Brazing Rod

9. Welding Electrode
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Training Module

10. Bolt, Nuts and Washers

11. Porcelain Bushings, Accessories

and Fittings

12. Rubberised Cork Sheet

13. Shellac Gasket Sealing Compound

14. Talc Powder

15. Borax

16. Soldering Flux

17. Dehydrating Breather

18. Pressure Relief Valve

19. Silica Gel

20. Oil Temperature Indicator

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Training Module

21. Winding Temperature Indicator

22. Valves
a) Wheel Valve
b) Flange Valve

23. Radiators
a) Elliptical Tube
b) Pressed Steel
c) Corrugated Panel

24. Oil Level Gauge

25. Air Release Plug and Socket

26. Cable Glands

27. Paints and Varnishes

a) Insulating Varnish
b) Red Oxide Primer
c) Paints of various colours
d) Thinner
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Training Module

e) EC Thinner

28. Asbestos Sheet (Red Jointing Sheet)

29. Lock

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Training Module

LIST OF ESSENTIAL EQUIPMENT &

MACHINERY

WINDING DEPARTMENT:

HT Winding Machine
Motorised 3 H.P. 3 Phase “V” Belt Drive with Automatic Layer Setter, Mechanical
Clutches & Turn counter, Spool Stand with brakes. Foot speed control.

LT Winding Machine
Motorised 3 H.P. 3 Phase “V” Belt Drive with Mechanical Clutches & Turn counter,
Spool Stand & Foot speed control.

TURN COUNTER
Direct digital display of number of turns, complete with detachable “Yoke Assembly”
and sunmica working table. Range: 0-2200 Turns
Accuracy: ±0.1%, ±1 Turn
Power : 230 V. AC + 10%, 50 Hz.
COIL ASSEMBLY DEPARTMENT :
Gas Welding Set

PAPER COVERING DEPTT.:

Vertical Strip Covering Machine
Motorised Vertical type Single head TPC Strip Covering Machine with Reduction Gear
and Friction Clutch. Complete with electrical and standard accessories.

Vertical Wire Covering Machine

Motorised 2 HP Vertical type Tripple head DPC Wire Covering Machine. Complete with
electrical and standard accessories.

Vertical Wire Covering Machine

Motorised Vertical type Double head TPC Wire Covering Machine. Complete with electrical and standard accessories.

Paper Slitting Machine

20 inch. Capacity. Complete with electrical and standard accessories.

Butt Welding Machine

for Strips 25 KVA

for Wire 8 KVA

for thin wire 1.5 KVA

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Training Module

INSULATION DEPARTMENT :
4' Power Sharing Machine

3' Triddle Sharing Machine

10 Tonne Power Press

Geared, Heavy Duty fitted with Gear Guard. 3 Phase Electric motor with Prestige push
button type starter “V” Belt set & fitting with automatic lubrication system.

Portable Jigsaw
Motorised, single phase power input 580 W.
Hand Operated Small Circle Cutting Machine

Spacer Deburring Machine

Motorised with complete electrical and standard accessories.
MAINTENANCE DEPARTMENT
Lathe Machine 6'

Motorised fitted with quick change

Norton type Gear Box, having Hardened
& ground Bed slideways, spindle, Tail
Stock Quill, Ground spliced shaft in Gear
box complete with steady guide.
Traveling guide face plate and driving
guide with reversing switch with Dog
Chuck and Single slot, self centering
chuck, 3 H.P. 3 phase Electric motor "V"
Belts & Fittings.
Shaper 2'
Two feet stroke length. With electrical motor and standard accessories.

Bench Grinder (8”)

With electrical motor and standard accessories.

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Training Module

Radial Drill Machine 1"

Motorised 1 H.P. 3 Phase ‘V’ Belt Drive with Starter.
Capacity 40 mm

Pillar Drill Machine (3/4”)

With Gears and motorised.

Arc Welding Set

3 Phase, 440 Volts oil filled with welding

holder and welding cable. Machine
having Tapping for 75 Amp. 100 Amp.
150 Amp. 200, 250, 300 & 350 Amp.
Gas Welding Set

For Brazing and Soldering. Complete

with Torch, nozzles, trolley and hose.
Threading Machine
(Capacity: 25 mm diameter)
Motorised 1 H.P. 3 Phase motor with Reversing switch, Mechanical clutch, “V” Belt and
multi speed pulley and die head chaser in mm size/inch size.

Circular Saw Motorised

For steel cutting.

Vices - Size 3
Size 2
M.S. Forged Body, Slid Hand Operated.

Portable Hand Drill

Capacity 12.5 mm.

Portable Hand Drill

Capacity 6mm.

Portable Hand Grinder

Capacity 4”.

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Training Module

Portable Angle Grinder

Capacity 100 mm
180 mm

PAINTING AND TANK TESTING DEPARTMENT :

Air Compressor with 2 nos. Spray Gun
Capacity 3 H.P
1 H.P.

Air Pressure Gauge 0 - 30

Size 75 mm Dia

MATERIAL HANDLING :

5 Tonne Electric Hoist with Gantry and End Carriage

Hydraulic Pallet Truck (2.5 T)

TANK UP DEPARTMENT :

Portable Air Blower

Portable Hot Air Blower

Hydraulic Lugs Crimping Machine with set of dies

Manual Lugs Crimping Machine

TRANSFORMER OIL DEPARTMENT :

Oil Storage Tank

Capacity 5000 KL

Oil Filtering Machine

(Capacity - 250 litres/hour Output)
With a pair of Hoses 10 mtrs. And vacuum pump. Electrically heated with thermostat
controls.
Heater consumption 21.6 Kw and 1 H.P., 3 phase motor for circulating transformer oil

Suction Pump 1 H.P

2 H.P.
Complete with motor, hose and clamps.

Vacuum Pump
1 HP, 3 Phase, 415 Volt. Capacity 650 mm of Hg.

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Training Module

OTHERS :

Heating Chamber with Elements and Control Panel

Dimensions : 8’ x 8’ x 8’

Weighing Scale (Electronic)

1 Tonne
300 Kg.
50 Kg.

GENERATORS :

Capacity 125 KVA

Capacity 30 KVA

Capacity 10 KVA

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 Training Module

LIST OF ESSENTIAL HAND TOOLS FOR REPAIR OF DISTRIBUTION TRANSFORMERS

Sl.No Item Size Quantity

1. 'D' SPANNERS 1/4” x 5/16” 4 Nos.
5/16” x 3/8” 4 Nos.
3/8” x 1/2” 3 Nos.
5/8” x 3/4” 6 Nos.
3/4” x 1” 4 Nos.
1” x 1 1/4” 4 Nos.
1/2” x 5/8” 4 Nos.
1 1/2" x 1 1/4" 4 Nos.
18 x 19 mm 3 Nos.
10 x 11 mm 4 Nos.
16 x 17 mm 4 Nos.
19 x 22 mm 4 Nos.
30 x 32 mm 4 Nos.
27 x 24 mm 4 Nos.

2. RING SPANNERS 1/4” x 5/16” 2 Nos.

5/16” x 3/8” 2 Nos.
3/8” x 1/2” 2 Nos.
1/2” x 5/8” 2 Nos.
5/8” x 3/4” 2 Nos.
3/4” x 1” 2 Nos.
10 x 11 mm 4 Nos.
16 x 17 mm 4 Nos.
19 x 22 mm 4 Nos.
30 x 32 mm 4 Nos.
27 x 24 mm 4 Nos.

3. BOX SPANNERS 1/4” x 5/16” 4 Nos.

5/16” x 3/8” 6 Nos.
3/8” x 1/2” 6 Nos.
1/2” x 5/8” 6 Nos.
5/8” x 3/4” 12 Nos.
3/4” x 1” 8 Nos.
10 x 11 mm 4 Nos.
16 x 17 mm 4 Nos.
19 x 22 mm 4 Nos.
30 x 32 mm 4 Nos.
27 x 24 mm 4 Nos.

4. SLIDE WRENCH Small size 4 Nos.

Medium size 4 Nos.
Big size 4 Nos.

5. PIPE WRENCH 14” 2 Nos.

18” 2 Nos.
24” 2 Nos.

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 Training Module

Sl.No Item Size Quantity

6. HAMMER 250 Gms. 6 Nos.
Boll Type 500 Gms. 6 Nos.
1 Kg. 4 Nos.

7. PLIER 8” 6 Nos.

8. NOSE PLIER 6” 12 Nos.

9. CUTTER PLIER 6” 6 Nos.

10 MICRO METER SCREW 0 to 25 mm 2 Nos.

GAUGE
(Manual Reading)

11 (a) VERNIER CALLIPER 0 to 300 mm 4 Nos.

11 (b) VERNIER CALLIPER 0 to 200 mm 4 Nos.

12. I.D. CALLIPERS 10" 6 Nos.

12" 6 Nos.
18" 4 Nos.

13. O.D. CALLIPERS 10" 6 Nos.

12" 6 Nos.
18" 4 Nos.

14. KNIFE 12” 12 Nos.

15. 4” 2 Nos.
RIGHT ANGLE 6" 2 Nos.
(Tri square)
12” 2 Nos.

16. TAPE SCALE 3 Mtr. 6 Nos.

17. STEEL SCALE 1 Ft. 6 Nos.

2 Ft. 6 Nos.
3 Ft. 4 Nos.

18. SCREW DRIVER 4” 6 Nos.

6” 6 Nos.
12” 6 Nos.

19. HAND HACKSAW 12” 4 Nos.

HAND HACKSAW BLADE 1/2"x12" 4 Nos.

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 Training Module

Sl.No Item Size Quantity

(HIGH SPEED)

20 (a) SLING ROPE 3/8” Thick 2 Nos.

1/2” Thick 3 Nos.
5/8” Thick 3 Nos.
3/4” Thick 3 Nos.

20 (b) JUTE ROPE 1 1/2" Thick 20 Mtrs.

21. SLING HOOK & U CLAMP 3/8” 6 Nos.

1/2” 6 Nos.
5/8” 6 Nos.
3/4” 6 Nos.
1” 4 Nos.
1 1/4” 4 Nos.

22. SCISSORS 12” (10 No.) 12 Nos.

23. LEATHER MALLET 50 mm 6 Nos.

75 mm 4 Nos.

24. STRIP BENDER & According to the Strip 6 Nos.

TWISTER size

25. FIBRE SETTER 6 Nos.

26. CENTRE PUNCH 2 Nos.

27. CUTTING TOOLS 2 Sets each

V Tool
Left Tool
Right Tool
Cobalt Tool

28. CHISEL 6 Nos.

29. OIL CAN 200 Ml. 10 Nos.

30. DIVIDER Small size 3 Nos.

Big size 3 Nos.

31. LATHE MACHINE 2 Nos.

MARKING BLOCK

32. “C” CLAMP 18” 2 Nos.

10” 2 Nos.
15” 2 Nos.
4” 6 Nos.

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 Training Module

Sl.No Item Size Quantity

33. DRILL STRAIGHT SHANK 3/16” 6 Nos.

1/4” 12 Nos.
5/16” 12 Nos.
3/8” 6 Nos.

34. DRILL TAPER SHANK 7/16” 12 Nos.

1/2” 12 Nos.
9/16” 12 Nos.
11/16” 12 Nos.
5/8” 12 Nos.
3/4” 12 Nos.
1” 6 Nos.
11/4” 6 Nos.
1 1/2” 6 Nos.
2” 4 Nos.

35. TAPER SOCKET 2 Sets

36. FILES 10" Flat file 6 Nos.

Round file 6 Nos.
Half Round 6 Nos.

37. NAIL FILE Flat 2 Nos.

Round 2 Nos.
Half Round 2 Nos.

38. BLADE 12 Packet

39. COTTON 2 Kg.

40. FELT PAD 10 Nos.

41. POWER HACKSAW 50 Nos.

BLADE

42. HAND HACKSAW BLADE 50 Nos.

43. STRIP CUTTER 2 Nos.

44. CHASER SET 3/8” 2 Set

1/2” 2 Set
5/8” 2 Set
3/4” 2 Set

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 Training Module

Sl.No Item Size Quantity

1” 2 Set

45. CRIMPING TOOLS 35 Sqr. mm 2 Set

WITH DIE 400 Sqr. mm

46. HAND DIE (In Inch) WITH 1/4" 3 Nos.

ONE HANDLE AND TAP 5/16" 3 Nos.
SET 3/8" 3 Nos.
1/2" 3 Nos.
5/8" 3 Nos.
3/4" 3 Nos.
1 1/4" 3 Nos.
1 1/2" 3 Nos.
1 3/4" 3 Nos.
2" 3 Nos.

47. HAND DIE ( In mm) WITH 6 mm 3 Nos.

ONE HANDLE AND TAP 8 mm 3 Nos.
SET 12 mm 3 Nos.
16 mm 3 Nos.
20 mm 3 Nos.
25 mm 3 Nos.
30 mm 3 Nos.
42 mm 3 Nos.
48 mm 3 Nos.

48. METAL TRAYS 4 Nos.

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 Training Module

LIST OF INSTRUMENTS & EQUIPMENT FOR

ELECTRICAL TESTING OF DAMAGED / REPAIRED
TRANSFORMERS

1. MEASUREMENT OF WINDING RESISTANCE

a) KELVIN BRIDE
Measuring Range - 0.2 micro ohm to 11 ohm Accuracy ±0.05% micro or ±1 slide wire
divn, which is greater rated current: Upto10 Amp. D.C. with light spot Galvanometer
D.C. Power source of 6 V. 10 Amp. OVERALL DIMENSION: Length 430 mm, width 280
mm, height 165 mm, galvanometer Length 280 mm, width 180 mm, Height 140 mm

b) WHEAT STONE BRIDGE

Measuring Range - 1 milli ohm to 11.11 mega ohms. Measuring Accuracy: within
±0.075%. Accuracy of series arm = ±0.05% with null detector Galvanometer conductor
clamp and 3 D.C. cell of 1.5V. each OVERALL DIMENSION: Length 370 mm, width
260 mm, height 155 mm.

2. POLARITY CHECK & MEASUREMENT OF VOLTAGE RATIO

TURN RATIO METER

Measuring Range - 100-1000
10-100
1-10
Accuracy -0.1% Null balancing Type
Mains operated with Polarity checking switch

3. MEASUREMENT OF LOSSES AND IMPEDANCE VOLTAGE

a) VOLTMETER
Measuring Range - 0-150/300/600 V. Accuracy ±0.5% Portable Precision grade Moving
Iron Low Powerfactor (0.2) A.C. Voltmeter in wooden case provided with Knife edge
pointer antiparallex mirror scale.

b) AMMETER
Measuring Range 0-1/5 Amp. Accuracy ±0.5% Portable Precision Moving Iron Low
power factor (0.2) A.C. Ammeter in wooden case provided with knife edge pointer
antiparallex mirror scale

c) WATTMETER
Portable low power factor low wattage analogue wattmeter (0.2 L.P.F) single phase
moving coil built in transducer in wooden case provided with knife edge pointer
antiparallex mirror scale.
Current coil 2.5/5A Potential Coil - 600 V

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 Training Module

Accuracy ±0.5% Measuring Scale 0-300 Watts

d) CURRENT TRANSFORMER
Ratio: 10-15-30-50-100/5A Rated Burden 15 VA
Accuracy Class 0.2 Frequency 50 C/s
Voltage Class 660 V Effectively earthed system
Portable current Transformer in Teak Wood case

e) DIMMERSTAT (VARIAC)
Continuously variable voltage auto transformer indoor oil cooled construction,
motorised with single phase supply portable type suitable to work on 3 phase 50 C/s
A.C. Supply with base channel & four wheels. Input: 415 Volts, 3 Phase, 50 C/s A.C
Output: 0-470 Volts, 3 Phase, 50 C/s A.C
Capacity: 200 Amp.

f) AUTO TRANSFORMER
Capacity: 200 KVA, 3 Phase oil cooled and having 2 Nos. Taps of 800 & 1200 Volts,
input voltage 400 Volts with base channel & four wheels

g) POWER CAPACITORS
Capacity : 100 KVAR Rated Voltage : 440 V. AC
50 C/s, 3 Phase with internal delta connection

h)
FREQUENCY METER
Range 0-70 Hz.

i)
STEP-UP TRANSFORMER
Capacity 100 KVA, Ratio 220 / 3000 volts with 2 Nos. tapping (150 & 300) in HV Side

4. MEASUREMENT OF INSULATION RESISTANCE

INSULATION TESTER (MEGGER)

Voltage:2500 V. Insulation Range: 0-5000 meg. ohms
Hand generator and metal body

5. DIELECTRIC STRENGTH OF TRANSFORMER OIL (BREAK DOWN VOLTAGE

TEST OF TRANSFORMER OIL)

OIL TESTING SET

Motorised, and switch controlled raise or lower the voltage at rate of 2 KV/second
(approx.) Input: 240 V, 50 C/s, Single phase Output: 0-100 KV 96 mm2 moving iron
meter marked in KV with memory effect. Corona free acrylic type test cell with
electrodes, stirring facility, epoxy Treated oil cooled Transformer housed in fibre glass
tank, HV Chamber and Zero start inter locking, A fast acting D.C. relay provided to

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protect the unit 2.4 mm/2.5 mm “GO” “NO GO” gauge for gap adjusting, Table mounting
type with fibre glass tank for H.V. Transformer and metallic box for control panel.

6. HEAT RUN TEST

a) Stop Watch

b) Thermometer 0-120oC (Stem Type)

c) All equipment used for measurement of losses shall be reused here.

7. INDUCED OVER VOLTAGE WITHSTAND TEST (DOUBLE FREQUENCY DOUBLE

VOLTAGE TEST)

a) SLIPRING INDUCTION MOTOR

3 Phase, 25 H.P. Slipring motor as generator and frequency changer

b) Squirrel Cage Induction Motor

3 Phase, 10 H.P Induction motor for primemover, auto Star Delta Starter

c) VOLTMETER
Moving Iron A.C. Voltmeter of 1.5 class
Accuracy Measuring Range 0 - 1200 V.

d) AMMETER
Moving Iron A.C. Ammeter of ±1.5 Class
Accuracy, Measuring Range 0-80 A.

e) FREQUENCY METER
Accuracy class: 1.0 Measuring Range: 0-150 Hz.

f) DIMMERSTAT (VARIAC)
Capacity 28 A, 3 Phase 50 Hz. 0-470 V, output

g) STEP-UP TRANSFORMER
Range : 110V / 1100 V

8. MEASUREMENT OF UNBALANCED CURRENT

a)
MILLI AMP. METER
Range 0-500 MA

b) TONG TESTER
Measuring Range 600 volts, 500 Amp. 1000 ohms

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9. SEPARATE SOURCE VOLTAGE WITHSTAND TEST (HIGH VOLTAGE TEST)

a) HIGH VOLTAGE TRANSFORMER

Single phase oil cooled transformer: Input Voltage 220 Volts, Output Voltage: 0-40-80
KV, KVA Rating: 15

b) VOLTMETER
Moving iron A.C. P.T. operated voltmeter accuracy ±1.5%, Range: 0-40/80 KV, P.T.
Ratio: 40-80 KV/220 V.

c) AMMETER
Moving Iron A.C. Ammeter
Accuracy ±0.5%
Measuring Range: 0-20 A.

d) DIMMERSTAT
Continuously variable voltage auto-transformer, indoor oil cooled, construction
motorised with single phase supply portable type suitable to work on single phase 50
C/s A.C. supply with base channel and four wheels Input: 240 Volts, single phase 50
C/s A.C.
Capacity: 60 Amp. / 28 A

10. SEPARATE SOURCE VOLTAGE WITHSTAND TEST(LOW VOLTAGE TEST)

HIGH VOLTAGE TRANSFORMER

Single phase oil cooled Transformer
Input voltage: 220 Volts, Output Voltage: 0-4 KV

11. DIGITAL POWER METER WITH HARMONIC ANALYSIS

Voltage rating 600 Volts and Current rating 20 Amps.

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Sales & Marketing

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SALES & MARKETING TRANSFORMERS

TENDER / ENQUIRY IDENTIFICATION

Generally tenders are floated by power utilities all over the world. Feasibility of such
tenders are studied and thereafter quoted. Some utilities require prior registration
which involves factory inspection. Registration of the Company as Quality Product
Manufacturer and Supplier with end users, consultants, Turnkey project executors,
service organizations, Government/Private Bodies etc. wherever applicable needs to
be done. Information regarding product requirements are collected through personal
contacts, Newspapers, Magazine, Professional Journal or by any other means.

The techno-commercial team gets involved and the needs of the various potential
customers is assessed for technical requirements. The collected technical data
is compared with company's manufacturing range to identify that the requirement
falls within company's production range.

TENDER PARTICIPATITION & QUOTATIONS:

All inquiries for supply of product are received directly from end users or from other
sources.

Tenders/ Inquiries are scrutinized against the standard Tender Review format.
The salient features of the tender enquiries are listed and discussed with the
concerned departments.

If any discrepancies are noticed, confirmations and / or clarifications are

sought from the customer. The cost-sheet is prepared based on material cost
estimated. Commercial terms & Technical Particulars describing product specifications
are made. Tenders are then prepared and submitted, clearly highlighting any
deviations considered.

All Technical and Commercial terms including prices are negotiated, wherever
necessary and acceptable, to get maximum advantage.

Successful Tenders/Purchase Orders(P/O) are once again reviewed against the

Tender / Contract Review Form before final acceptance.

After acceptance of clients order, P/Os are converted to order confirmation and
released to the Design department for the preparation of drawings and the Bill of
Material (B.O.M.)

Amendment desired by the Purchaser:

Technical and commercial implications are studied. For technically possible
amendments financial/commercial concessions are asked. Proper negotiations are
conducted prior to taking decision on acceptance or rejection of amendment. Copy
of accepted amendment with necessary comments is issued to the concerned
departments for necessary implementation.

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Amendment required by the Company:

The details of required amendment with full justification and reasoning is
conveyed to the Purchaser. The conditions of Contract affecting due to amendment
are re-negotiated. After receipt of amendment, a copy is issued to the
concerned Departments for necessary implementation.

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THANKS

SANJEEV KADIAN

Mob. 9812415555

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