Change your life

Project Name: Power Transformer

Department: Marketing PD

Submitted To: Engr. Zain Raza

Submitted By: Waqar Ahmad

Hammad Falak

Zain-ul- Abideen
 Contents

Acknowledgement .......................................................................................................................... 4
Exclusive Summary ........................................................................................................................ 5
Introduction of PEL ........................................................................................................................ 6
1. Appliance Division .............................................................................................................. 6
• PEL Air Conditioners: ...................................................................................................... 6
• PEL Refrigerators:............................................................................................................ 6
• PEL Deep Freezers: .......................................................................................................... 7
2. Power Division..................................................................................................................... 7
ISO 9001 CERTIFICATION ...................................................................................................... 7
Transformer..................................................................................................................................... 8
Power Transformer ......................................................................................................................... 9
Construction of Power Transformer ............................................................................................ 9
• Basic Parts of a Transformer ............................................................................................ 9
• Types of Transformers ................................................................................................... 17
Manufacturing Department ........................................................................................................... 19
Production Planning and Control .............................................................................................. 20
Material Planning Section ......................................................................................................... 20
1. Winding Section ............................................................................................................. 20
2. Core Section ................................................................................................................... 22
3. Assembly Section ........................................................................................................... 23
• Core Coil Assembly ....................................................................................................... 23
4. Tank Section ................................................................................................................... 25
Inspection and quality Control (I & QC) Department .................................................................. 28
• Incoming section ............................................................................................................ 28
• In Processing Section ..................................................................................................... 29
• Testing ............................................................................................................................ 33
 Dedication

To all those who have supported, encouraged, challenged, and inspired me. And specially to my
Beloved Parents, Honorable Teachers and friends for all their guidance, love and attention which
has made it possible for me to make it up to this point and as well as the Internship Supervisors
who bestowed me with courage, the commitment and awareness to follow the best possible way,
by their unmatchable style and by best possible training.
 Acknowledgement

All the praises are for the almighty, Allah who bestowed me with the ability and potential to
complete this internship. I also pay gratitude to the Almighty for enabling me to complete this
Internship within due course of time.

Words are very few to express enormous humble obligation to my affectionate parents for their
prayers and strong determination to enabling me to achieve this job.

I also appreciate the cordial co-operation from all my internship Supervisors in the different
departments of PEL and also of HR management for providing me requisite information and
knowledge for compilation of my complete internship.

All the employers of PEL helped me a lot in performing all the activities and in gaining the
practical knowledge of industry. They gave me best environment and knowledge to enhancemy
skills.
 Exclusive Summary

Pak Elektron Limited (PEL) is the pioneer manufacturer of electrical goods in Pakistan. The
company has always been contributing towards the advancement and development of the
engineering sector in Pakistan by introducing a range of quality electrical equipment, home
appliances and by producing hundreds of engineers, skilled workers and technicians through its
apprenticeship schemes and training programs.

I recently have done my internship in PEL, in which I got training from its Power Transformer
unit. The internship basically revolved around the transformer design, manufacturing, I&QC and
maintenance. The system, the style of working & commitment of the employers in PEL is really
exemplary.

The difference between success & failure is doing things right and doing things nearly right, &
PEL has always tried for the success & that is why it is known to be one of the leading company
in Pakistan.

In this report, I have given a very brief review of what I have seen and learnt during my internship.
This report will give its reader knowledge about the PEL and power division especially about
transformer unit.
 Introduction of PEL

Pak Elektron Limited (PEL) is a Pakistani engineering corporation which manufactures major
home appliances and electrical equipment.

PEL was founded in 1956 through technical collaboration with AEG. In 1978, PEL was acquired
by Saigol Group and was taken public a decade later. Over the years, PEL has formed alliances
with several international giants, including General Electric, Fujitsu and Hitachi. The company
also became the sole distributor of LG Corporation's home appliances in 2009. PEL operates in
two segments - power and appliances. The former includes manufacturing of transformers, grid
stations and energy meters among other goods, while the latter division deals in making,
assembling and distribution of home appliances like refrigerators and air conditioner.

PEL has two divisions of its business:

1. Appliances Division
2. Power Division

1. Appliance Division
PEL’s Appliances Division is the flag carrier of the Saigol Group involved in home appliances
manufacturing.

• PEL Air Conditioners:

PEL window-type air conditioners were introduced in 1981 in technical collaboration with General
Corporation of Japan. Ever since their launch, PEL air conditioners have a leading position in the
market. Recognizing the shift in consumers' preference from window-type to split-type air
conditioners, PEL has focused its manufacturing efforts on split-type air conditioners.

• PEL Refrigerators:
The manufacturing of refrigerators started in 1986-87 in technical collaboration with M/s IAR-
SILTAL of Italy. Like air conditioners, PEL's refrigerators are also in great demand. Today, PEL
Crystal has 30% market share across Pakistan.
• PEL Deep Freezers:
PEL deep freezers were introduced in 1987 in technical collaboration with M/s Ariston of Italy.

2. Power Division
PEL's Power Division consists of three Main Products:

1. Energy Meters
2. Transformers
3. Switch gears

PEL's Power Division also manufactures Kiosks, compact stations, and shunt capacitor banks.

PEL is one of the major electrical equipment suppliers to Water and Power Development Authority
(WAPDA) and Karachi Electric (K-Electric), which are the largest power utilities in Pakistan.

ISO 9001 CERTIFICATION

PEL was 16th Company in Pakistan that got ISO 9001 Certification in 1997, since then PEL
Management is applying this International Standard Practices for Effectively Managing Quality of
Products and Services that Company Offers.
 Transformer
A transformer is an electrical device that transfers electrical energy between two or
more circuits through electromagnetic induction. A varying current in one coil of the transformer
produces a varying magnetic field, which in turn induces a voltage in a second coil. Power can be
transferred between the two coils through the magnetic field, without a metallic connection
between the two circuits. Faraday's law of induction discovered in 1831 described this effect.
Transformers are used to increase or decrease the alternating voltages in electric power
applications.

Working Phenomena of Transformer

 Power Transformer
Power transformers are used for transmission & receiving purpose, whereas distribution
transformers are used only for distribution purpose. Power transformers are used in transmission
network of higher voltages for step-up and step-down application (400 kV, 200 kV, 110 kV, 66
kV, 33kV) and are generally rated above 200MVA. Large generators are designed to generate
voltage ranging from 11 kV to 28 kV and frequency in 50 Hz or 60 Hz range. But To generate at
33kV, the size of the generator might be twice as large as the size of the 11kV generator.

Now this generated energy is transmitted over the transmission lines of several hundred kilometers.
When current flows through a wire some energy is lost as heat. The higher the current, the more
heat is lost. Hence, we need to transmit the power at low current to minimize the conductor size
and losses. To reduce the current, we need to increase the voltage. In transmission/generating
stations we use Step-up transformer to increase the voltage to say 220 kV or above, these
transformers are called as power transformers.

Power transformers generally operate at nearly full – load and the performance of the power
transformers is generally judged from commercial efficiency.

PEL power transformers are available in following ratings:

1. 10/13 MVA
2. 20/26 MVA
3. 31.5/40 MVA

Construction of Power Transformer

The construction of a power transformer varies throughout the industry. The basic arrangement is
essentially the same.

• Basic Parts of a Transformer

These are the basic components of a transformer.

1. Laminated core
 2. Windings

3. Insulating materials

4. Transformer oil

5. Tap changer

6. Conservator

7. Breather

8. Cooling tubes

9. Buchholz Relay

10. Explosion vent

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

Parts of Power Transformer

1. Laminated Core:
The core, which provides the magnetic path to channel the flux, consists of thin strips of high-
grade steel, called laminations, which are electrically separated by a thin coating of insulating
material. The strips can be stacked or wound, with the windings either built integrally around the
core or built separately and assembled around the core sections.

Thickness ranges from 0.23 mm to upwards of 0.36 mm. The core cross section can be circular or
rectangular, with circular cores commonly referred to as cruciform construction. Rectangular cores
are used for smaller ratings and as auxiliary transformers used within a power transformer.
Rectangular cores use a single width of strip steel, while circular cores use a combination of
different strip widths to approximate a circular cross-section.

The type of steel and arrangement depends on the transformer rating as related to cost factors such
as labor and performance. Just like other components in the transformer, the heat generated by the
core must be adequately dissipated.

While the steel and coating may be capable of withstanding higher temperatures, it will come in
contact with insulating materials with limited temperature capabilities. In larger units, cooling
ducts are used inside the core for additional convective surface area, and sections of laminations
may be split to reduce localized losses.

The core is held together by, but insulated from, mechanical structures and is grounded to a single
point in order to dissipate electrostatic buildup. The core ground location is usually some readily
accessible point inside the tank, but it can also be brought through a bushing on the tank wall or
top for external access.

This grounding point should be removable for testing purposes, such as checking for unintentional
core grounds. Multiple core grounds, such as a case whereby the core is inadvertently making
contact with otherwise grounded internal metallic mechanical structures, can provide a path for
circulating currents induced by the main flux as well as a leakage flux, thus creating concentrations
of losses that can result in localized heating.

The maximum flux density of the core steel is normally designed as close to the knee of the
saturation curve as practical, accounting for required overexcitations and tolerances that exist due
to materials and manufacturing processes.
For power transformers, the flux density is typically between 1.3 T and 1.8 T, with the saturation
point for magnetic steel being around 2.03 T to 2.05 T.

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

Windings can be classified in two different ways:

1. Based on the input and output supply

2. Based on the voltage range

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

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

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

Within the voltage range classification, windings are further categorized:

1. High voltage winding - These are made of copper coil. The number of turns is the multiple
of the number of turns in the low voltage windings. The copper coils are thinner than those
of the low voltage windings.
 2. Low voltage windings - These have fewer turns than the high voltage windings. It is made
of thick copper conductors. This is because the current in the low voltage windings is higher
than that of high voltage windings.

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

In power transformer, another winding wound on the core known as “Regulating Voltage”
winding. This winding is used for tap-changing.

3. Insulating Materials:
Insulating paper and cardboard are used in transformers to isolate primary and secondary windings
from each other and from the transformer core.

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

5. Tap Changer:
The output voltage may vary according to the input voltage and the load. During loaded conditions,
the voltage on the output terminal decreases, whereas during off-load conditions the output voltage
increases. In order to balance the voltage variations, tap changers are used. Tap changers can be
either on-load tap changers or off-load tap changers. In an on-load tap changer, the tapping can be
changed without isolating the transformer from the supply. In an off-load tap changer, it is done
after disconnecting the transformer. Automatic tap changers are also available.
6. Conservator:
The conservator conserves the transformer oil. It is an airtight, metallic, cylindrical drum that is
fitted above the transformer. The conservator tank is vented to the atmosphere at the top, and the
normal oil level is approximately in the middle of the conservator to allow the oil to expand and
contract as the temperature varies. The conservator is connected to the main tank inside the
transformer, which is completely filled with transformer oil through a pipeline.

7. Breather:
The breather controls the moisture level in the transformer. Moisture can arise when temperature
variations cause expansion and contraction of the insulating oil, which then causes the pressure to
change inside the conservator. Pressure changes are balanced by a flow of atmospheric air in and
out of the conservator, which is how moisture can enter the system. If the insulating oil encounters
moisture, it can affect the paper insulation or may even lead to internal faults. Therefore, it is
necessary that the air entering the tank is moisture-free.

The transformer's breather is a cylindrical container that is filled with silica gel. When the
atmospheric air passes through the silica gel of the breather, the air's moisture is absorbed by the
silica crystals. The breather acts like an air filter for the transformer and controls the moisture level
inside a transformer. It is connected to the end of breather pipe.
8. Cooling Tubes:
Cooling tubes are used to cool the transformer oil. The transformer oil is circulated through the
cooling tubes. The circulation of the oil may either be natural or forced. In natural circulation,
when the temperature of the oil rises the hot oil naturally rises to the top and the cold oil sinks
downward. Thus, the oil naturally circulates through the tubes. In forced circulation, an external
pump is used to circulate the oil.

9. Buchholz Relay:
The Buchholz Relay is a protective device container housed over the connecting pipe from the
main tank to the conservator tank. It is used to sense the faults occurring inside the transformer. It
is a simple relay that operates by the gases emitted due to the decomposition of transformer oil
during internal faults. It helps in sensing and protecting the transformer from internal faults.

Schematic Arrangement of Buchholz Relay

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

• Types of Transformers
There are two basic Types of Transformers

Single Phase Transformer

1. Three Phase Transformer

Below are the more types of transformer derived via different functions and operation etc.

 Types of Transformers w.r.t Cores

1. Core Type Transformer: In core type transformer, windings are cylindrical former
wound, mounted on the core limbs as shown in the figure below. The cylindrical coils have
different layers and each layer is insulated from each other. Materials like paper, cloth or
mica can be used for insulation. Low voltage windings are placed nearer to the core, as
they are easier to insulate.
 2. Shell Type Transformer: The coils are former wound and mounted in layers stacked with
insulation between them. A shell type transformer may have simple rectangular form (as
shown in above fig), or it may have a distributed form.

 Types of Transformer w.r.t uses

1. Power transformer: Used in transmission network, high rating
2. Distribution transformer: Used in distribution network, comparatively lower rating than
that of power transformers.
3. Instrument transformer: Used in relay and protection purpose in different instruments in
industries
▪ Current transformer (CT)
▪ Potential transformer (PT)

 Types of Transformer w.r.t Cooling

• Self-Air Cooled or Dry Type Transformer
• Air Blast-Cooled Dry Type
• Oil Immersed, Self-Cooled (OISC) or ONAN (Oil natural, Air natural)
• Oil Immersed, Combination of Self Cooled and Air blast (ONAN)
• Oil Immersed, Water Cooled (OW)
• Oil Immersed, Forced Oil Cooled
• Oil Immersed, Combination of Self Cooled and Water Cooled (ONAN+OW)
• Oil Forced, Air forced Cooled (OFAC)
• Forced Oil, Water Cooled (FOWC)
• Forced Oil, Self-Cooled (OFAN)
 Manufacturing Department
It is the responsibility of the manufacturing department to manufacture different components of
transformer and then assemble then to make a complete transformer. Production department has
following sections:

• Winding Section
• Core Section
• Tank Section
• Assembly Section

First of all, customer gives order to the marketing and sales department. Marketing and sales
department makes annual sales plan for WAPDA. Marketing and sales department send this order
to Production Planning and Control department which makes a master production plan (Month
wise). This plan is sent to Material planning section which makes Material requirement plan or
Bill of material according to the master production plan. This plan is sent to the purchase
department which buys material according to this plan. Material is received in store where quality
inspectors from I&QC department check its quality than this material is sent to manufacturing
department where manufacturing of transformers starts.
 Production Planning and Control
Production planning and control section receives order from marketing and sales department. For
WAPDA orders, there is an annual sales report which is sent to the production planning and control
while for private orders are received from time to time and there is no annual sales report for those
orders. Production planning and control makes the master production plan accordingly to the
orders sent by marketing and sales department. Master production plan is month wise and it can
be changed. After making the master production plan, PPC makes a weekly production plan which
is sent to sectional in charges. PPC also makes the daily production plan. PPC apart from making
the master production plan and weekly production plan it monitors the production to ensure that
the production is running accordingly to the plan.

Material Planning Section

Material planning section is responsible for the procurement of material and it ensures that material
arrives timely for the production. Material can be purchased from foreign companies and also from
the local companies. In local procurement material can be purchased in less than a month so it is
done once a month. In foreign procurement, more time is required because it takes more time for
the arrival of material from foreign countries by ships so foreign procurement is done after every
three months. In foreign procurement bank open the letter of credit or LC, it pays the foreign
company for the material and the stock is pledged with the bank and when company needs the
material for the production it pays the bank and material is given to the company for the production.
After the procurement of the material, material planning section follows the material to ensure that
it arrives on time for production.

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

• Raw Material
For L.V winding

• Paper insulated flat copper wire

• Copper foil

For H.V winding

 • Enamel copper wire
• Paper insulated flat copper wire

• Type of Insulation Material

• Diamond dotted paper (For insulation between layers of windings)
• Press pan sheet (For end collars)
• Creep paper pipe (For insulation of terminal of tap changer)
• Craft paper (Used for insulation in disc winding)
• Thermo ducts

• Types of Windings
• Disc winding
• Packet winding
• Layer winding
• Foil winding

• Machines Used
• Slitting machine is used for the cutting of bundles of insulation material.
• L.V Foil winding machines are used for foil winding on L.V side.
• L.V paper insulated copper winders are used for winding of P.I copper wire.
• H.V P. I copper winders are used for the winding of P.I copper wire.
• H.V enamel copper winders are used for the winding of enamel copper wire.
2. Core Section
In the core section upper, side and yoke limbs of the core are made.

• Raw Material
Raw material used for the making of core is M4 grade silicone steel sheet which is an
alloy of iron and silicon. Silicon is used to increase the permeability of iron.

• Machines
• Slitting machine is used to cut the big roll of silicon steel sheet in required sizes
(widths) according to the rating of transformer.
• Power press machines are used to make limbs. They are operated manually.
• After cutting of limbs V punching is done on the yoke limb which is called yoke
notching.
• PLC cutting machines are also used to make limbs. There are two PLC machines.
SDRI machine has a capacity of 40,000 limbs per day. L.A.E machine has a
capacity of 60,000 limbs per day. In CNC machines length, width and angle are
given as input.
• L.A.E measuring table is used to check errors in angle, width and length.

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

• Quality of material.
• Bur.
• Air gap.

• To reduce iron losses

• Material should be of good quality.
• Limbs should be bur free.
• Limbs should be rust free.
• Weight of core should be according to Tr. Design
3. Assembly Section
In the assembly section, there are several processes in which all the components of the transformer
are put together to form a transformer. Important processes in the assembly section are;

• Core Coil Assembly

In the core coil assembly coil is fitted in the core and upper yoke limb is inserted to complete the
core, then core is tightened using upper and lower pressing beams. For coil to coil insulation and
core to coil insulation press pan sheet is used. For insulation between bottoms pressing beam and
coil wooden base is used.

• Before Connection Test (BCT)

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

• H.T, L.T Connections

In this section Y-Delta connections are made. Tap changer is connected with the coil.
Connections are made according to work order specifications given by the design department.
Taping is done on these connections to avoid any short circuit.
• After Connection Test (ACT)
In the ACT area turns ratio of the transformer is checked using TTR meter.

• Furnace
After ACT transformer is kept in the furnace for 48 to 72 hours according to its rating. It is
done to evaporate all the moisture from core or coil. Temperature of the furnace is 120o to
130o.

• Cover Plate Assembly

In this section H.T, L.T bushings, through bolts, eye bolts connectors, arcing horns and other
parts are inserted in cover plate.

• Pre-Tanking Section
When transformer is unloaded from the furnace it is inserted in the tank as quickly as possible
to avoid the getting of moisture in the live part. Live part of the transformer should be inserted
in the tank in 50mins to 1 ½ hours.

• Oil Filling Section

In oil filling section oil is filled in the tank under vacuum. Amount of oil to be filled can be
found from bill of quantity (BOQ) (e.g for 40 MVA transformer’s tank contain 21,000 litres
oil).

• Settling Area
After oil filling every transformer is kept for 12 hours in the settling area to check for oil
leakage and oil level.
4. Tank Section
In the tanking section cover plate, tank and other mechanical components of the transformer are
made. Tank has following parts;

• Frame
• Cover Plate
• Bottom
• Side Plates
• Fin Walls
• Conservator

• Raw Material
Raw material for tank and other components are

• Mild Steel Sheet (MSS)

• Mild Steel Cold Rolled Sheet (MSCRS)
• Shearing Machine
Shearing Machine is used to cut the MS sheet in different sizes. This machine is used for the
cutting of frame, side wall, bottom wall and cover plate.

• CNC Nibbling and Punching Machine

CNC nibbling and punching machine has 32 tools to make holes of different sizes. It can
make holes of the shape round, square, rectangular.

• Bending Machine
This machine is used to bend cover plate and frame.

• Embossing Machine
This machine is used for the embossing of holes on cover plate.

• Component Welding
In this area lifting lugs, carrying beams and studs are welded using arc welding.

• Frame Punching and Welding Machine

Frame is punched and then welded in this machine. MIG welding is used in this machine.

• Fin Folding Machine

This machine is used for fin folding. Digital Control Panel is used to enter height, weight and
pitch. Pitch is the distance between two adjacent fins.

• Fin Welding
After fin folding they are welded. MIG welding is used in this machine.

• Bottom Side Plate Welding

In this section bottom and side plates are welded together.

• Tank Assembly
Here all the parts of the tank are joint together.

• Shot Blasting
To remove oil particles from tank’s body and make its surface smooth shot blasting is done.
After that tank is dipped in degreasing, rinsing and phosphate tank to remove oil particles.
• Sand Blasting
It is used for removal of oil particles from tanks and making its surface smooth; for transformer
rating above 200KVA. After that tank is dipped in degreasing, rinsing and phosphate tank to
remove oil particles.

• Tank Testing
For tank air pressure testing is used to check leakage.

• Powder Coating
Powder coating is tank done on transformer tank and then it is passed through furnace that
melts the powder and finally get tank painted.
 Inspection and quality Control (I & QC) Department
Inspection and quality control department ensures; material purchased by the purchase department
is according to the criteria suggested by IEC in their recommendations(Incoming), during the
manufacturing of transformers all the components of transformer are according to transformer
design (in processing), do all the quality tests so that transformer does not fail in real
conditions(Testing). Inspection and quality control department is further divided into three
sections

• Incoming
• In processing
• Testing

• Incoming section
Incoming section is responsible for the checking of all the material which is purchased to ensure
that all the material is according to international standards. When the material is purchased it first
comes in the receiving where it is inward gate pass (IGP) number. Incoming section checks through
the system if material has arrived, then quality inspectors from the incoming go to the store and
check the material if material is according to standards set by IEC than material is approved
otherwise it is rejected and supplier compliant application form(SCAF) is sent to supplier.
• In Processing Section
In processing section ensures that during the manufacturing of transformers all the components of
transformers are according to design specifications. It is also responsible for the testing of oil to
check its quality.

• Oil Tests to Check its Quality

There are nine tests done in oil testing lab to check the quality of oil. If the oil fails in one of
these tests than it is rejected not used in transformers. These tests are performed as per IEC-
60296 and IEC-60422.These tests are:

• Tangent Delta Test (DTL)

• Interfacial Torsion Test
• Acidity Test
• Break Down Test / Dielectric Strength Test
• Viscosity Test
• Moisture Analyzer Test
• Flash Point Test
• Dissolved Gases Analysis
• Oxidation Stability Test

1) Tangent Delta Test (DTL)

Tangent delta indicates the dielectric loss of transformer oil

B A

Tangent Delta (Loss Angle)

IC IL

O IR C V

(Leakage current associated with watts loss) of the transformer oil.

Application Standard:

IEC-60296 Tangent Delta IEC-60422 Tangent Delta

(New Oil) (%) (Oil in Service) (%)
Drums <0.005 500 and 220KV class <0.20
Transformer <0.015 132 and 66KV class <0.50

Procedure:

1. Power ON the Tettex Instruments and temperature control unit.

2. Set temperature 90℃.
3. Power OFF the temperature control unit when test chamber temperature will reach 90℃.
4. Take out the test chamber cell from the Heating unit, open test cell, wash and take test oil
sample with carefully.
5. Insert cell in the test chamber and again power ON the temperature control unit.
6. Take 40ml oil sample in a syringe and put in the test chamber cell.
7. When temperature will reach 90℃, power OFF the temperature control unit.
8. Apply 1KV supply from Power unit.
9. Now power on Null indicator and null set step by step with null indicator and bridge unit.
10. Note Capacitance & Tangent Delta value from the bridge unit.
11. At the end power OFF instruments units.

2) Interfacial Torsion Test (IFT)

Interfacial Torsion measure molecular attractive force between water and oil.

Application Standard: IEC 60422

Limit: > 28 dyne/Cm

Procedure:

1. Put the distilled water in the sampling beaker at the bottom line of sampling beaker.
2. Take 10ml test oil in the sampling beaker.
3. Now Balance the “O” ring at the balancing mirror line.
4. Move the knob manually of the meter.
 5. When ring left oil surface that is IFT result point.

3) Acidity Test
This test is performed to check the acidity in the oil. Increase in acidity indication insulation
degradation and formation of sludge.

Application Standard:

IEC-60296 Acidity IEC-60422 Acidity

(New Oil) (mg koh/g) (Oil in Service) (mg koh/g)
Drums <0.01 500 and 220KV class <0.15
Transformer <0.03 132 and 66KV class <0.20

4) Break Down Test / Dielectric Strength Test

This test measures the voltage at which the oil electrically breaks down.

Application Standard:

IEC-60296 Break Down IEC-60422 Break Down

(New Oil) Limit(KV) (Oil in Service) Limit(KV)
Drums >30 500 and 220KV class >60
Transformer >60 132 and 66KV class >50

5) Viscosity Test
Good oil should have low viscosity so that it offers less resistance to the conventional flow of
oil.

Application Standard: IEC 60296

Limit: <12.0 mm2/s at 40℃.

Procedure:

1. Power ON YN-5 Kinematic Viscosity meter.

2. Heater ON adjusts at 40℃ and Rotate ON adjust rooter speed at 100 RPM and Timer ON.
3. When water temperature reached at 40℃, add sample in test tube & leave for 15 minutes.
 4. Test tube have two pints “A & B”. A is top point and B is lower.
5. Sample oil suck with sucking pump from the test tube when sample oil come at point A,
start the timer. When sample reached at lower point B, stop the timer. Note this time.
6. This procedure repeated 4 times.
7. Take the average value of 3 nearest readings with multiplying by test tube coefficient factor
is for final result.

6) Moisture Test
Any increase in moisture content can reduce the insulating properties of the oil.

Application Standard:

IEC-60296 Moisture IEC-60422 Moisture

(New Oil) Content(mg/kg) (Oil in Service) Content(mg/kg)
Drums <30 500 and 220KV class <10
Transformer <10 132 and 66KV class <15

Procedure:

1. Power ON the AVO® MEEGER® KF 875 Karl Fischer Test Set.

2. Press starts Key.
3. When meter display ready option on the screen, press start and when meter display add
option, add 1-ml oil sample in the vessel of the meter.
4. Press the start Key and wait few second.
5. Meter point out the result.

7) Flash Point Test

Flash Point is fire catching point of transformer oil.

Application Standard: IEC 60422

Limits: >135 ℃

Procedure:

1. Open LPG gas valve.

 2. Power ON the BS-2 Flash Point Tester.
3. Select “Method ASTM D93” and set date.
4. Press Pre-Arranged Key and temperature set in ℃.
5. Press “In Put” key and press “Start” Key.
6. When electronics heater ON pass LPG gas from control gas knob and make flame about
4 mm.
7. When oil sample flashed, the LPG gas closed from knob.
8. Wait for cooler tester for next oil sample test or turn OFF.

8) Dissolved Gas Analysis

This test is performed to determine the dissolved gases in transformer oil.

9) Oxidation Stability Test

Oxidation Stability test determine the amount of acid and sludge products formed in
transformer oil.

Application Standard: IEC 60296

Test Description/Units Limits

Acidity (mg koh/g) <1.2
Sludge (%) <0.8
Tangent Delta at 90℃ (%) 0.500

• Testing
It is the responsibility of the testing section that the transformer does not fail in real conditions. To
check that it will not fail in real environment a number of test are done on the transformer before
it is ready to dispatch. There are three types of tests which are done on a transformer.

i. Routine Tests
ii. Type Tests
iii. Special Test
a) Routine Tests
Tests which are performed on each and every transformer are called routine tests. Every
transformer must pass these tests before dispatch.

b) Type Tests
Tests which are done on samples taken from a whole consignment are called type tests.

c) Special Test
Tests which are done occasionally on the requirement of customer are called special tests.

Routine Tests

There are ten routine tests done in testing section.

• Transformer Turns Ratio Test (TTR Test)

• Winding Resistance Test
• Insulation Resistance Test (Meager Test)
• Induced Voltage Test
• High Voltage Test (Separate source voltage)
• No Load Losses (Open circuit test)
• On Load Losses (Short circuit test)
• Capacitance & Distribution Factor (C&DF)
• Impulse Test
• Sweep Frequency Response Analysis (SFRA)

1. Transformer Turn Ratio: (TTR Test)

It is low voltage test. Transformer turn ratio test is done twice on a transformer. Once before
the connection and once after the connection. Transformer turn ratio meter is used for this test.
Turn ratio should be as defined in IEC (± 0.5 Variation) to pass the test.
2. Winding Resistance
It is also low voltage test. This test is used to check the phase to phase and phase to neutral
resistance of transformer. Phase to Phase resistance should be in ohms (Ω) and phase to neutral
resistance should be in milliohms (Ω). After calculate the values, compare these values with
IEC standard.

3. Insulation Resistance Test: (Megger test)

This test is used to check insulation between

H.V Ground

L.V Ground

H.V L.V

4. Induced Over Voltage Test

To verify coil and lead insulation levels by inducing the transformer under test to twice its
rated voltage at high frequency for 100Hz for 1-minute. This test verifies turn to turn and layer
to layer insulation, as well as lead to lead insulation within the high voltage and low voltage
lead assemblies. This test is performed using a high frequency generator. Since frequency and
inductive reactance are inversely proportional, the double voltage required for this test is made
possible because the core does not saturate. There should be no collapse or pull down of the
test voltage. Smoke and bubbles from coils or lead assemblies may also indicate an insulation
failure.

5. High Voltage Test: (Separate source voltage)

This test is used to check whether winding is insulated from other parts of transformer or not.
First, all the L.V (11KV) terminals and body of transformer are earthed. Than 275KV voltage
is applied on the H.V side. It is checked whether the transformer will stand this voltage for 1
minute or not.

Second, all the H.V (132KV) terminals and body of transformer are earthed. Than 38KV
voltage is applied on the L.V side. It is checked whether the transformer will stand this voltage
for 1 minute or not.
6. No Load Losses: (Open circuit test)
In this test, we calculate iron losses in transformer. In this test H.V side is kept open and voltage
is applied on the L.V side.

7. Load Losses: (Short circuit test)

In this test, we calculate copper losses in transformer. In this test L.V side is short and apply
voltage on H.V up to rated current is passed through the L.V side. Than V, I, PF and other
quantities are measured.

8. Capacitance & Distribution Factor (C&DF)

In this test, we determine the capacitance between body and winding of the transformer. The
distribution factor must be less than 1 as per IEC standard.

9. Impulse Test

This test performed normally on new transformer for lighting inspection. In this test, apply 650
KV voltage at H.V (132KV) side and 110 KV voltage apply at L.V (11 KV) side.

10. Sweep Frequency Response Analysis (SFRA)

This test is performed to verify mechanical displacement of transformer.