Assembly Manual

Table of Contents
Titles
1. 1.Introduction
2. Objective
2.1 Core assembly details
2.2 Coil assembly
2.3 Core and Coil assembly
2.4 Making connection
2.5 Top covering .
2.6 Tanking

1. INTRODUCTION
Transformer
A transformer is basically electromagnetic static equipment based on
the principle of Faradays law of electromagnetic induction. A transformer
essentially consists of a 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 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 magnetize the core and to supply the iron loss of the transformer. Thus, an
alternating magnetic flux is established in the core which induces an emf in both primary and
secondary winding.The formula connecting induced voltage, flux and number of turns is:
V/N=BmxAnxf/22.51x102
V/N=volts per turn, which is the same for both windings
Bm =maximum flux density in the core in tesla.
An=net cross-sectional area of core in sq. cm.
F=supply frequency in Hz.
The productivity of the transformers produced based on the rated power measured in KVA
mainly depends up on proper design of processes. Among the activities deployed during
designing, assembly process takes vital role to get good transformer product achieving the

demand of the country. So this manual is intended for proper assembly of each and every parts of
the transformer and to take precaution during complete as well as semi assemblies.

2. OBJECTIVE
The target of the factory is producing as well as maintaining the transformers by
following clear cut procedures of assembly. So this manual is intended for all individuals
participated in assembly process to increase the productivity and providing good services
for the customers.
To mention some of those benefits:

Using all the accessories needed for the product

To use appropriate tools
Durability of the product
Time management
To mitigate unnecessary check up after test
Providing knowledge and skills for works

2. ASSEMBLY
2.1 Core Assembly Details
Selection of core diameter
Based on the requirement of no-load loss and no-load curent , a suitable working flux density
is chosen. In some cases, the buyer also specifies the requirment of maximum flux density.
Once the number of turns and flux density are known, the gross core area may be calculated by
using the formula
Et=Phase voltage/Turns=4.44*f*Bm*Ag*0.97*10-4
Where, f is the rated frequency which is 50 Hz
Bm is the maximum flux density in tesla
Ag is the gross core area in sq. cm (to be calculated)
0.97 is the staking factor (assumed)
Once the gross area Ag is known, the approximate core diameter can be calculated by using the
following formula
Ag=k1*pi*d2/4
Where k1 is a factor to be selected on the basis of the number of core steps and d is the required
core diameter we are looking for.
The approximate vulue of k1 may be assumed as follows:
For 6 steps,the approximate value of k1=0.92
For 7 steps,the approximate value of k1=0.925
For 8 steps,the approximate value of k1=0.93
For 9 steps,the approximate value of k1=0.935

For 10 steps,the approximate value of k1=0.94

For 11 steps and above ,the approximate value of k1=0.945
Various type of core stacking for three-phase transformers has commonly been adapted during
manufacture. In designing core lamination the designer should look in to the applicability of the
scheme before going in to the final design.
The iron lamination that serves as the magnetic circuit can be constructed in different ways with
respect to the winding. The core-type, in which the iron forms a low reluctance path for the
magnetic flux set up by the voltage impressed on the primary. The core of the shell type consists
of two or more paths through which the flux divides.
The magnetic core is built up of laminations of high grade silicon sheet steel, which are
insulated from each other by special coating of varnish. The usual thickness of laminations is
0.18mm, 0.23mm, 0.27mm, 0.30mm, and 0.35mm.

Fig. 2 Core assembly detail

details.

Fig.1 core part structure

Core limb center = C/L

Core window height = W/H
Core sheets are assembled step by step according to their size.

Keep the core center and limb center to build the core sheet

Pulling the upper yoke to assemble the

winding

Fig.3 3D view of core assembly, bundles of core in

3D.

Tie the bottom yoke by either metal or

wood frame

Fig.4 Tie the bottom yoke by either metal or

wood frame

Fig. 5 Describes tightened bottom yoke Assembly

2.2 Coil assembly

Winding (Coil)
Winding wires and strips are selected on the bases of the requirement of the current for
which they have been designed. While selecting the size of a conductor, a designer must keep in
mind the winding material as well as the current density. The current density may be based on
the following values:
For aluminum winding: 1.5 A/mm (max),
For copper winding: 3.0 A/mm (max)
The rated current may be calculated on the bases of its KVA, number of phase and the rated
voltage.
KVA
3

KVA =
x V x I (for three phase transformer),
or
I =
3 x V
Conductor area =

current per p h ase

current density

which is

A= r 2 for round copper , and A = w x d

for rectangular strip.

Selection of number of turns

The number of turns of a transformer is directly related to its KVA rating and ia approximately
calculated by the formula:
Et = K Q
Where, Et is the voltage per turn
Q is the rated KVA
K is the factor to be decided.
For instance, K for aluminium- wound transformers may be taken in the range of 0.32 to 0.35,
whereas, it is between 0.37 and 0.45 for copper wound transformers.
For our calculation, let us assume, K = 0.4, Q = 100 KVA and copper wire
Therefore, Et = 0.4 100
= 4V
No. of secondary turns =

secondary phase voltage

Et

400/ 3
4

= 57.75 turns let round it

off to 58 turns
No. of primary turns at normal =
=

Primary phase voltage

secondary phase voltage
15000
400/ 3

x 58

x sec. turns

= 64.935 x 58

= 3766 T
Additional turns toward 5% tapping voltage = (3766 x 5)/100 = 188
Total primary turns = 3766 + 188 = 3954
Example ,

Specifications of a 100 KVA transformer

Rating
No load voltage ratio
No. of phase / frequency
Connection
Winding material
Maximum flux density
Maximum Current density

100
15000/400
3ph / 50 Hz
Delta / Star Dyn 5
Copper
1.8 Tesla
2.5 A/sq m

I.
Primary Coil (Connected in Delta)
Voltage per phase
: Vp = 15000 V
100
Current per phase
: Ip = 3 x 15 = 2.22 A

Current density

Conductor area

: A=

= 2.5 A/sq mm
2.22
2.5

= 0.889 sq mm

Equivalent conductor diameter from (

A=

d2
4 )d=

4A

4 x 0.889

( 3.1415

)=

1.13067 = 1.07 mm next round figure: d = 1.1mm

Area of the proposed conductor

the working current density is

A=

d
4

2.2 A
0.95 sq mm

3.1415 x 1.1 x 1.1

4

= 0.95 sq mm therefore,

= 2.315 A /sq mm

a. Winding Height (axial Length)

Description
Bar conductor
Covering thickness toward
DPC
Covered conductor
Gap b/n two consecutive
conductor
Insulated size of conductor

Length
1.1 mm
(+) 0.2

Radial
1.1 mm
(+) 0.2

1.3 mm
(+) 0.05

1.3 mm
0.05

1.35 mm

1.35 mm
(+) 0.1 (4mil inter layer insulator)

Turns per layer

3954
16

+1=

248
Axial length of HV coil
round of

X 248

1.45mm
(x)16

334.8 mm
335 mm

24.2 mm
25 mm

As of now we have concluded that there is one coil per phase, having 3954 turns, the winding
length is 335 mm, the radial built of coil being 25 mm, and inter layer insulation 4 mil Kraft
paper.
Estimating the Core window height
Total axial length of the coil
Gap between yoke top and bottom coil
Therefore, core window height
II.

: 1 x 335 mm = 335 mm
: 2 x25 mm = 50 mm
= 385 mm

Secondary Coil (connected in Star)

Voltage per phase

Vs =

Current per phase

Current density
Conductor area

Is =

400
3
100
3 x 0.4

= 231 v
= 144.3 A

Cd = 2.5 A / sq mm (max)
144.3
=
= 57.72
2.5

A=w x d

in the case of

low voltage conductor, since the current is generally high, a rectangular conductor is commonly
used. Multiple strips in parallel are also selected for a higher rating transformer. The section of
the size of strips plays a very vital role on the performance of the transformer. In general, the
depth of a strip not be more than half of the strip width, and not less than 1:6. But for all practical
purpose we narrow down to 1: 4.
width

Therefore we may write, maximum ratio

2
and minimum ratio
depth
width
depth

In case a coil has been designed with more than one strip and if the strips are placed one above
the other, then the transposition is must. The purpose of transposing the strips is to make the
length of the strips almost similar, thereby making the resistances of both the strips equal.
1
2

1
2

1
2

2
1

(a)

(b)
Schematic diagram of transposition
An Example: A coil is designed with two strips in parallel to share a total of 150 A. Each strip
should carry half of the total, i.e. 75A. In non transposed coil, because of unequal length and
unequal resistance, the strip placed below will draw more current (say 80A) because of its low
resistance, whereas the upper strip will draw less current (say 70 A) because of its high
resistance.

2.3 Core and Coil Assembly

After Wind the Primry and the secondary windings correctly they are ready for core
coil assembly.
Plugging the top yoke
Insert the windings

Fig.6 core with inserting coils

Assembled

Fig. 7 Describes active part Assembled or core and coil

Clamping the top yoke by either metal or wood frame

It gives strength and it can easy to handle.

Fig.8 describes active Assembled both

the top and bottom yoke

2. 4 Making connection

Fig.9 Delta connection of winding

For Dyn5 type connect tap5 with the
start of the next phase.
i.e.

3.1.3
3.1.4

3.1.5

Tap connection
Tapings are provided on the high voltage
winding for adjusting the winding turns in
accordance with the available incoming voltage.

3.1.6
3.1.7

3.1.11
1

3.1.8
3.1.9 C
o
n
n
e
c
t
i
o
n
3.1.12 1

3.1.10

3.1.13

3.1.14
2

2
3.1.15 2
3

3.1.16

3.1.17
3

3.1.18 3

3.1.19

3.1.20
4

4
3.1.21 4

3.1.22

3.1.23
5

5
3.1.24 5

3.1.25

6
3.1.26

3.1.27

3.1.28

3.1.29 E= indicates END

3.1.30 S= indicates start of the wire
3.1.31
Adjustment of tapping turns will offer a fairly constant secondery voltage at load.
There are five tapping positions for distribution transformer expressed as percentage of
high voltage which are:- +5% , +2.5% , N , -2.5%, -5%
tap changer
plate
3.1.32
3.1.33
3.1.34
3.1.35
3.1.36
3.1.37
3.1.38
3.1.39
3.1.40
3.1.41
3.1.42
3.1.43
3.1.44
3.1.45
3.1.46
3.1.47
3.1.48
3.1.49

3.1.50
3.1.51
3.1.52
3.1.53
3.1.54
3.1.55
3.1.56
3.1.57
3.1.58 Fig.10 showing the tap changer
connection of a transformer
3.1.59
3.1.60
3.1.61
3.1.62
3.1.63
3.1.64

3.1.65 2.5 Top Covering

3.1.66
3.1.67
3.1.68
3.1.69
3.1.70
3.1.71

Fig.11 Describes
All parts with top
cover tank.

3.1.72
3.1.73
3.1.74
3.1.75
3.1.76
3.1.77
3.1.78
3.1.79
3.1.80
3.1.81
3.1.82
3.1.83
3.1.84
3.1.85
3.1.86
3.1.87
3.1.88
3.1.89
3.1.90
3.1.91
3.1.92
3.1.93
3.1.94
3.1.95
3.1.96
3.1.97
3.1.98 Fig. 17 Describes final Assembled tank
3.1.99
3.1.100
3.1.101
3.1.102

2.6 Tanking

Transformer Oil Treatment Manual

Insulating oil is the mineral oil, which acts as a di-electric and coolant media in
transformers, should meet the long time uninterrupted service, which are the prime
requirements of the day.

3.1.103

Transformer oil is manufactured by refining of petroleum feed stocks which

obtained as first distillate under vacuum distillation of crude oil after taking out
lighter cuts like gasoline, keo sene diesel atmospheric pressure. Is characteristic
proper lies are much dependent or hydro carbon composition. These petroleum
products are compounded in to aromatic, naph the nie and paraffinic containing small
amount of polar compounds to carry out the function of di-electric and coolant media
in transformer oil must have certain specific properties, which can be classified,
physical, chemical and electrical categories.

3.1.104

Out of many characteristics which specified to evaluate the quality of transformer

oil, electrical properties and stability characteristics are important.

3.1.105

Electrical properties

A) Electrical strength:- is the minimum electrical stress in KV that case a break down in the
insulating ability of the medium. It is very sensitive external impurities, particularly P(56,
Paralas)
3.1.106
Presence of moisture, metallic particle, fiber and are found to affect the electrical
strength drastically
B) Specific resistance:- it is the ratio of D.C potential radiant in volts per centimeter
paralleling the current flow with in the specimen in the current density in ampere per
square centimeter at a given instant of time under prescribed conditions and affected by
moisture and water.
C) Di-electric dissipation factory is the tangent of the angle (delta) by which the phase
difference b/n applied voltage and resulting current deviates from /2 radian when the
dielectric of the capacitor consists exclusively of the insulating oil.
3.1.107

Stability characteristics

3.1.108

In view of the longer time required to assess the behavior of insulating fluids in
the actual system, various types of accelerated tests have been developed.

3.1.109
a) Accelerating ageing test:- a known amount of oil (300ml) is taken in a beaker with
copper catalyst in the ratio of 0.0575 sq cm/g and aged at 115 oC for 96 hours. After
the stipulated period the samples are tested for electrical properties such as resistivity,
dissipation factor, acidity and the quantity of sludge.
b) Oxidation stability test. The hydro carbon easily under goes oxidation a part from
the external imparities, the oxidation products are the main cause of deter ration in the
quality of oil. In severe cases, the oil insoluble sludge is formed due to oxidation and
deposits on the core and windings and impairs the heat transfer characteristics.
3.1.110
3.1.111
3.1.112
3.1.113
Flash point
3.1.114
The temperature at which the oil gives off so much vapor that this vapor,
when mixed with oil, forms an ignitable mixture and gives a momentary flash on the
application of a small pilot flame under the prescribed condition of test.

3.1.115
3.1.116
Pour point
3.1.117
The lowest temperature expressed as a multiple of 3 oC at which the oil is
observed to flow when cooled and examined under prescribed condition.
3.1.118
3.1.119
Storage and handling
3.1.120
The right kind of storage, handling and transportation also increase the
reliability of the transformer oil.
3.1.121
3.1.122
Compatibility and contaminants
3.1.123
3.1.124
Transformer oil is compatible with insulating material used in a
transformer and care should be taken a bout compatibility with materials used in the
tanks. Line material l.e rubber gaskets etc. as the solubility of these products will
greatly affect the properties of the transformer oil when used for topping up.
3.1.125
Transformer oil properties may be deteriorate due to contamination
occurring during handling. Transportation, storage and during transformer operation.
Major contaminants could be water particles, chemical base oils or solvents possibly
corrective action to be taken to remove these contaminates.
3.1.126
3.1.127
A) Water
3.1.128
Water is the most contaminant in transformer oil during storage, handling
transport and operation, especially in humid climate.
3.1.129
B) particles
3.1.130
Suspended particles, together with water lower the breakdown voltage.
3.1.131
3.1.132
Oil Treating Method
3.1.133
Transformer oil properties may be deteriorate due to contamination due to
water and suspended particlesand chmical Inmurities . They must be avoided through
oil treatment.Free water can be drained off from the bottom of the tank or container.
Dissolved water can be removed by bubbling dry air or nitrogen at slightly elevated
temperature. The most suitable and recommended method is degassing by vacuum
filtration. Here the oil heated up to 65 to70 oC, vacuum treated and filtered through
particle filter. The particles can be simuntineusty removed by degrading through finemicron filter. By using Oil Treatment Machine we filtrate use and new transformer
Oil. After Treatment.
I.
Electrical breakdown vlotage for new Untreated : 30KV, rms(min)
II.
Electrical Breakdown voltage after flitation : 60KV, rms (min)
3.1.134
3.1.135
3.1.136
.
3.1.137
3.1.138
3.1.139
3.1.140
3.1.141
3.1.142

3.1.143
3.1.144
3.1.145
3.1.146

TESTING MANUAL

All transformers, whether power or distribution, are subjected to the following routine tests
after completing the manufacturing activities and prior to dispatch from the factory.
The tests are generally conducted as per IEC 60076.
For explaining the test circuits the transformer is taken as Dyn5 connected.

3.1.147
3.1.149
T
Sr. No.
est
3.1.148
3.1.1543.1.159
M
1
easu
3.1.155
reme
3.1.156
nt of
3.1.157
insul
3.1.158
ation
resis
tanc
e
3.1.160

3.1.150
3.1.151

Test procedure

The insulation resistance is measured in

the following configurations and the
measurement is usually done at 2500
Volts.
1. HV-LV and Earth
2. LV-HV and Earth
3. HV-LV
The value in Mega Ohms at the end of
60 sec. Of the voltage application is
recorded.
3.1.161
Result:
3.1.1653.1.167
M The ratio between the HV and LV
2
easu
windings is measured directly by a ratio
3.1.166
reme
comparator. The measurement is done
nt of
on various taps of the windings are on
volta
all the phases.
ge
Result: Ratio = 0.5 of rated value
ratio
3.1.168

3.1.152

Equipments used /
test circuit

3.1.153
3.1.162
3.1.163

Digital insulation
tester
3.1.164
Make MEGGER
(AVO International, UK).

3.1.169

Transformer Ratio
Meter
3.1.170
Make
M/s.H.Tinsley & Co.
England

3.1.1713.1.173
C
3
heck
3.1.172
for
phas
e
displ
ace
ment
(vect
or
grou
p
chec
k)
3.1.174

3.1.1893.1.190
S
4
epar
ate
sour
ce
pow
er
freq
uenc
y
volta
ge
with
stan
d
test
3.1.191
3.1.192
3.1.193
3.1.194

The line terminals A and a

respectively of the HV and LV
windings are shorted externally.
Three phases voltage
3.1.175
( say 200Volts) is applied on
the HV winding and the voltages
across different terminals are
measured

3.1.176

The
necessary condition to be
satisfied for the vector to be Dyn
5 are the voltages Bb=Bc
3.1.177
Cb<Cc
3.1.178
BA+AN=BN
The test is done by applying single
phase voltage at 50 Hz on one of the
windings with all its terminals of
other windings and tank are
connected to earth. The test voltage
is applied for duration of 60 sec.
The test is repeated for other
windings.
3.1.195
3.1.196
Result: The transformer
under test must with stand for
1minute

3.1.179
3.1.180
3.1.181
3.1.182

Voltmeters
Variable voltage
source

3.1.183
3.1.184
3.1.185
3.1.186
3.1.187
3.1.188

3.1.197

CASE A LV
WINDING

3.1.198

3.1.199

CASE B- HV
WINDING

3.1.2003.1.201
I
5
nduc
ed
over
volta
ge
with
stan
d
test

3.1.202
Three phase voltage is applied on
the LV windings with the HV side
open circuit.
Magnitude of the applied voltage is
increased to avoid saturation of core.
The test voltage is maintained for
duration of 60 seconds.
3.1.203
3.1.204
Result: The transformer
under test must with stand for
1minute

3.1.205

3.1.2063.1.207
M
6
easu
reme
nt of
NoLoad
loss
and
NoLoad
curre
nt

3.1.209
3.1.210
AC power analyzer
3.1.211Make Norma. Austria
3.1.212
Digital power meter
3.1.213
Make Yokogawa,
Japan
3.1.214

3.1.218
The resistance of HV and LV
windings and of all the three phases
shall be measured.
The measurements shall be done
with the leads connected across the
line terminals.
3.1.219

3.1.220
3.1.221

3.1.2153.1.216
7
3.1.217

M
easu
reme
nt of
wind
ing
resis
tanc
e

The no- load loss and no- load

current are measured on one of the
windings (normally LV) after
applying the rated voltage.
All other windings are kept open
circuited.
The applied voltage, the no-load
current are
Measured by digital power meter/
power analyzer.
3.1.208
Result: The measured value
must not greater than 1.5% of the rated
Value

Digital micro ohm

meter
3.1.222
Make- M/s.
H.Tinsley & Co.
England.

3.1.2233.1.224
8
3.1.225

3.1.226
Three phase voltage at power
frequency shall be applied on the
HV winding with the LV winding
short circuited.
The magnitude of the voltage shall
be such that a current not less than
50% of the current passes through
the windings.
The value of the currents, voltages
and losses are measured using power
analyzer / Digital power meter. The
measured kW is the load loss and
the voltage corresponding to the
applied current.

3.1.227
3.1.228
3.1.229

3.1.2333.1.234
9

3.1.235

3.1.236

M
easu
reme
nt of
short
circu
it
impe
danc
e
and
load
losse
s

AC power analyzer
Make- Norma,
Austria/
3.1.230
Digital power meter
3.1.231
Make- Yokogawa,
Japan
3.1.232

3.1.237
3.1.238
3.1.239
3.1.240
3.1.241
3.1.242
Tap
3.1.246
Tap 1

11. Testing parameter of transformer

11.1 Voltage ratio for 15 / 0.4 KV

3.1.243 3.1.244

Vol
tage ratio For 15/0.4
KV
3.1.247 3.1.248
157
10
50/231= 68.1818

3.1.245
+ 5 % tolerance
3.1.249
67.84 to 68.52

3.1.250
Tap 2

3.1.251 3.1.252
153
10
75/231 = 66.5584

3.1.253
66.23 to 66.89

3.1.254
Tap 3

3.1.255 3.1.256
150
10
00/231 = 64.9351

3.1.257
64.61 to 65.26

3.1.258
Tap 4

3.1.259 3.1.260
146
97
25/231 = 63.3117

3.1.261
62.99 to 63.63

3.1.262
Tap 5
3.1.266

3.1.263 3.1.264
142
95
50/231 = 61.6883

3.1.265
61.38 to 61.99

3.1.267
3.1.268

3.1.3

Tap

11.2 Voltage ratio for 33 / 0.4 KV

3.1.5 Voltage ratio For 33/0.4

3.1.4

KV

3.1.7

3.1.8

Tap 1

10

3.1.11

3.1.12

Tap 2

10

3.1.15

3.1.16

Tap 3

10

3.1.19

3.1.20

Tap 4

97.

3.1.23

3.1.24

Tap 5
3.1.269
3.1.2703.1.271
N

3.1.6 + 5 %

3.1.9

tolerance
34650 / 231= 150

3.1.10 149.25 to

150.75
3.1.13 33825 / 231 = 146.42

3.1.14 145.69 to

147.15
3.1.17 33000 / 231 = 142.86

3.1.18 142.14 to

143.57
3.1.21 32175 / 231 = 139.28

3.1.22 138.58 to

139.98
3.1.25 31350 / 231 = 135.71

3.1.26 135.03 to

95

136.39
11.3 Summary of test parameters
Types of test

3.1.272

par
ameters

3.1.2733.1.274
Ohm (Coils
1
resistance measurement)

3.1.275

3.1.2763.1.277
2

3.1.278

Ratio test

3.1.2793.1.280
Measurement of
3
impedance & load

bala
nce
+
0.5 of the rated value

3.1.281

Z<
5.6 % as per KVA

3.1.2823.1.283
4
load current

Measurement of no

3.1.284
1.5% of the rated

3.1.2853.1.286
5

HV test (for 15 KV)

3.1.287

3.1.2883.1.289
6

HV test (for 33 KV)

3.1.2913.1.292
7

DVDF test

3.1.294
3.1.295
3.1.296

38
KV for 1 minute

3.1.290

70
KV for 1 minute

3.1.293

800
V for 1 minute