BHARAT HEAVY ELECTRICALS LIMITED, JHANSI

SUMMER VOCATIONAL TRAINING-2019

This document contains:

 Rotational Report
 Project report on Insulation materials used in power transformer
and testing of power transformer

Submitted by: Under the guidance of: Submitted to:

Anjali Kumari Mr. Prabhat Katihar, Mr. Dhruv Bhargav,
B.tech 2nd year, Deputy Manager, Sr D.G.M, HRD
NIT Patna TRM Bay 9 BHEL Jhansi

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 ACKNOWLEDGEMENT
I am highly thankful and indebted to B.H.E.L. engineers and technical staff for
providing me vital and valuable information about the different facts of an
industrial management system and their respective departments thus helping me
to gain an overall idea about the working of organization.
I express my gratitude to Human Resource and Development Department and Mr
A. K. Agnihotri Sir for giving me a chance to feel the industrial environment and
working in one of maharatnas and leading companies of India, B.H.E.L.
I am also thankful to Mr. Prabhat Katihar (Deputy Manager, Bay 9), Mr. Pradeep
Kumar (Senior Engineer, Bay 7), Mr. Mahesh Shankar (Deputy Engineer, bay 7)
and Mr. Sumit Bhargav (Senior Engineer, Testing) for giving their precious time
and helping me in understanding various theoretical and practical aspects of my
project on Insulation materials used in Power Transformer and testing of power
transformers, under whose kind supervision I accomplished my project.

I would like to thank my parents who have been a constant source of

encouragement & inspiration during my studies & have always provided me
support in every walk of life.

Anjali Kumari
B.tech (2nd year), Electrical
Engineering
NIT Patna

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 PREFACE

At the very outset of the prologue it becomes imperative to insist that vocational
training is an integral part of engineering curriculum. Training allows us to gain
an insight into the practical aspects of the various topics, with which we come
across while pursuing our B.Tech. Vocational training gives us practical
implementation of various topics we already have learned and will learn in near
future. Vocational training always emphasizes on logic and common sense
instead of theoretical aspects of subject.

On my part, I have pursued six weeks training at B.H.E.L. Jhansi. The training
involved a study of various departments of the organization as per the time
logically scheduled and well planned given to me.

The rotation in various departments was necessary in order to get an overall idea
about the working of the organization.

ANJALI KUMARI
ELECTRICAL ENGINEERING
B.Tech. (2ND YEAR)
NIT Patna

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4|Page
 TABLE OF CONTENTS

TITLE PAGE No.

1. About BHEL…………………………………………………………...7
2. Manufacturing units of BHEL………………………………………..9
3. Activity profile of BHEL…………………………………………….. 10
4. VISION, MISSION AND VALUES OF BHEL…………………….. 12
5. BHEL, Jhansi…………………………………………………………. 14
6. GROWTH OF PRODUCTION AND MILESTONES…………….. 19
7. HEALTH, SAFETY AND ENVIRONMENT PROTECTION…… 21
8. BHEL PERFORMANCE……………………………………………. 22
9. ROTATION REPORT
i. Bay 0.......................................................................................................26
ii. Bay 1…………………………………………………………………...27
iii. Bay 2 ………………………………………………………………….. 27
iv. Bay 3………………………………………………………………….. 28
v. Bay 4…………………………………………………………………. 28
vi. Bay 5…………………………………………………………………. 29
vii. Bay 6…………………………………………………………………. 30
viii. Bay 7…………………………………………………………………. 31
ix. Bay 8…………………………………………………………………. 31
x. Bay 9 ………………………………………………………………… 33
xi. Transformer Engineering …………………………………………. 34
xii. Technology…………………………………………………………... 34
xiii. Transformer Commercial……………………………………………. 34
xiv. Locomotive Commercial…………………………………………….. 36
xv. Locomotive Manufacturing………………………………………….. 36
xvi. Locomotive Engineering…………………………………………….. 37
xvii. Store ………………………………………………………………… 38
xviii. Central Quality Services ………………………………………… 38
xix. Testing……………………………………………………………….. 38
xx. Work Engineering Services………………………………………… 39

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10. REPORT ON INSULATION AND TESTING OF POWER TRANSFORMER
A. Insulation
i. Introduction…………………………………………..41
ii. Transformer oil……………………………………….42
iii. Insulating paper……………………………………….47
iv. Pressboard…………………………………………… 52
v. Wood……………………………………………........ 60
vi. Sealing materials…………………………………… 63
B. Testing
i. Introduction…………………………………………. 67
ii. Transformer ratio test………………………………. 69
iii. Winding resistance test…………………………….. 72
iv. Magnetizing current test……………………………. 76
v. Magnetic balance test………………………………. 77
vi. Transformer vector group test……………………… 78
vii. Insulation resistance test…………………………… 81
viii. Separate source voltage withstand test……………. 84
ix. No load loss test………………………………….... 84
x. Load loss test……………………………………… 87
xi. Double voltage double frequency………………… 92
xii. Heat run test………………………………………. 92
xiii. Tan delta test……………………………………… 93
xiv. Impulse test……………………………………….. 96
xv.

11. CONCLUSION………………………………………………………...105

14. REFERENCES………………………………………………………...106

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ABOUT B.H.E.L.

B.H.E.L. is an integrated power plant equipment manufacturer and one of the

largest engineering and manufacturing companies in India in terms of turnover.
They were established in 1964, ushering in the indigenous Heavy Electrical
Equipment industry in India - a dream that has been more than realized with a well-
recognized track record of performance. The company has been earning profits
continuously since 1971-72 and paying dividends since 1976-77.
They are engaged in the design, engineering, manufacture, construction, testing,
commissioning and servicing of a wide range of products and services for the core
sectors of the economy, viz. Power, Transmission, Industry, Transportation
(Railway), Renewable Energy, Oil & Gas and Defence . They have 16
manufacturing divisions, two repair units, four regional offices, eight service
centres and 15 regional centres and currently operate at more than 150 project sites
across India and abroad. They place strong emphasis on innovation and creative
development of new technologies.
They have a share of 57% in India’s total installed generating capacity contributing
69% (approx.) to the total power generated from utility sets (excluding non-
conventional capacity) as of March 31, 2013.
They have been exporting our power and industry segment products and services
for over 40 years. BHEL’s global references are spread across over 75 countries.
The cumulative overseas installed capacity of BHEL manufactured power plants
exceeds 9,000 MW across 21 countries including Malaysia, Oman, Iraq, the UAE,
Bhutan, Egypt and New Zealand. Our physical exports range from turnkey projects
to after sales services.
Most of our manufacturing units and other entities have been accredited to Quality
Management Systems (ISO 9001:2008), Environmental Management Systems
(ISO 14001:2004) and Occupational Health & Safety Management Systems
(OHSAS 18001:2007).
POWER GENERATION

Power Generation sector comprises thermal, gas hydro and nuclear power plant
business. BHEL supplies sets account for nearly 65% of the total installed capacity
in the country.

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TRANSMISSION AND DISTRIBUTION

BHEL offers wide-ranging products and systems for T&D applications. Products
manufactured includes power transformers, Instrument Transformers, Dry type
transformers, Series and Shunt Reactors, Capacitor banks, Vacuum & SF6 circuit
breakers, Gas-insulated switchgears and insulators.

INDUSTRIES

BHEL is a major contributor of equipment and systems to industries, cement,

sugar, fertilizer, refineries, petrochemicals, paper, oil and gas, metallurgical and
other process industries. The range of system and equipment supplied includes
capacitive power plants, co-generation plants, industrial steam turbines, industrial
boilers, gas turbines, heat exchangers and valves, seamless steel tubes, electrostatic
preceptors, fabric filters, reactors, fluidized bed combustion boilers, chemical
recovery boilers and process controls.

TRANSPORTATION

BHEL is involved in the development, design, engineering, marketing, production,

installation and maintenance and after sales service of rolling stock and traction
propulsions systems. BHEL manufactures electric locomotive up to 5000 HP,
diesel electric locomotives from 350 HP to 3100 HP, for both main line and
shunting duty applications. It also produces rolling stock for applications viz.
overhead equipment cars, special well wagons and Rail-cum road vehicle.

TELECOMMUNICATION

BHEL also caters to Telecommunication Sector by way of small, medium and large
switching systems.

RENEWABLE ENERGY

Technologies that can be offered by BHEL for explaining non-conventional and

renewable sources of energy include: wind electric generators, solar photovoltaic
systems, solar heating systems, solar lanterns and battery-powered road vehicles.

OIL AND GAS

BHEL’s products range includes Deep Drilling Oil Rigs, Mobile Rigs, Work Over
Rigs, Well Heads and X-Mas trees, choke and Kill Manifolds, full Bore Gate
valves, Mud line Suspension system, Casting support system, Sub-Sea well heads,
Block valves, seamless pipes, Motors, Compressor, Heat exchangers etc.

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 INTERNATIONAL OPERATIONS
BHEL is one of the largest exporters of engineering products & services from
India, ranking among the major power plant equipment suppliers in the world.

MANUFACTURING UNITS OF BHEL

First Generation Units:

BHOPAL (Heavy Electrical Plant)
HARIDWAR (Heavy Electrical Equipment Plant)
HYDERABAD (Heavy Electrical Power Equipment Plant)
TIRUCHY (High Pressure Boiler Plant)

Second Generation Units:

JHANSI (Transformer and Locomotive Plant)
HARIDWAR (Central Foundry and Forge Plant)
TIRUCHY (Seamless Steel Tube Plant)

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Unit through Acquisition and Merger:
BANGALORE (Electronic Porcelain Division)

New Manufacturing Units:

RANIPAT (Boiler Auxiliaries Plant)
JAGDISHPUR (Insulator Plant)
RUDRAPUR (Component and Fabrication Plant)
BANGALORE (Industrial System Group)
Repair Shop:
BOMBAY (Motor Repair Shop)
VARANASI (Heavy Repair Shop)

ACTIVITY PROFILE OF BHEL

1. POWER SECTOR PROJECTS

 Thermal sets and Auxiliaries.

 Steam generators and Auxiliaries.
 Industrial fans.
 Electrostatic precipitators.
 Air pre heaters.
 Nuclear power equipments.
 Hydro sets and Auxiliaries.
 Motors.
 Transformers.
 Rectifiers.
 Pumps.
 Heat Exchangers.
 Capacitors.
 Porcelain/Ceramics insulators.
 Seamless steel tubes.
 Casting and forging.

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2. SYSTEMS/SERVICES

 Turnkey power station.

 Data acquisition Systems.
 Power systems.
 HVDC Commissioning systems.
 Modernization and Rehabilitation.

3. TRASPORTATION SECTOR

 Diesel Electric generators.

 AC/DC locomotives.
 DC locomotives and loco shunters.
 Traction system for railways.
 Electric trolley buses.

4. INDUSTRY SECTOR

 Boilers.
 Valves.
 T.G. sets.
 Power devices.
 Solar Cells.
 Photo Voltaic cells.
 Gas Turbines.
 Compressors.
 Drive Turbines.
 Oil rigs.
 Blow out preventers.
 Wind mills.
 Control systems for electric devices.

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VISION, MISSION AND VALUES OF B.H.E.L.

VISION:

“A world class innovative, competitive and profitable engineering enterprise

providing total business solution”. A world class engineering enterprise committed
to enhancing stakeholder value.
MISSION:

To be an Indian Multinational Engineering Enterprise providing total business

solution through quality products, system and services in the fields of energy,
industry, transportation, infrastructure and other potential areas.

VALUES:

 Zeal to Excel and Zest for change.

 Integrity and Fairness in all matters.
 Respect of Dignity and potential of individuals.
 Strict adherence to commitments.
 Ensure speed of response.
 Foster learning creativity and teamwork.
 Loyalty and pride in the company.

BHEL OBJECTIVES:

A dynamic organization is one which keeps its aim high, adopts itself quickly to
changing environment. So here we are in BHEL.

BUSINESS MISSION:

To maintain a leading position as a supplier of quality equipment, system and

services in the field of conversion, transmission, utilization and conservation of
energy for applications in the areas of electric power, transportation, oil and gas
exploration industries. Utilized company is capabilities and resources to expand
business into allied areas and other priority sectors of the economy like defence,
communications and electronics.

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GROWTH

To ensure a steady growth by enhancing the competitive edge of BHEL in

existing new business areas and international market so as to fulfil national
expectation from BHEL.
PROFITABILITY

To provide an adequate return on capital employed, primarily through

improvements in operational, efficiency, capital utilization, productivity and
adequate internal resources to finance the company’s growth.
PEOPLE ORIENTATION

To enable each employ to achieve his potential, improve his capabilities, perceive
his role and responsibilities and participate and contribute to the growth and
success of the company.

TECHNOLOGY

To achieve technological excellence in operations by developments of indigenous

technologies and efficient absorption and adoption of imparted technologies to suit
business and priorities and provide competitive advantage to the company.

IMAGE

To fill the expectation which state holders like government as owner, employees,
customers and the country at large have from BHEL.

BHEL is growing concern to meet the changing needs of the nation has taken it
beyond power into the total gamut of energy, industry and transportation. BHEL is
also to offer a service in each of this field. Its manufacturing capability is supported
by a corporate R&D division at Hyderabad which works closely with the research
and development cells at various units and Welding Research Institute at
Tiruchirapalli.

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 BHARAT HEAVY ELECTRICALS LIMITED, JHANSI
A BRIEF INTRODUCTION

By the end of the fifth year plan, it was envisaged by the planning commission that
the demand for the power transformer would raise in the coming years.
Anticipating the country’s requirement, in 1974, BHEL started a new plant in
Jhansi which would manufacture power and other type of transformer in addition
to the capacity available at BHEL in Bhopal. The Bhopal plant was engaged in the
manufacture transformers of large rating and Jhansi unit would concentrate on
power transformers, instrument transformers, traction transformers for railway etc.

This unit of Jhansi was established around 14 km from the city on the N.H. No 26
on Jhansi Lalitpur road. It is called second-generation plant of BHEL set up in 1974
at an estimated cost of Rs 16.22 crores inclusive of Rs 2.1 crores for township. Its
foundation was laid by late Mrs Indira Gandhi the prime minister on 9 th Jan. 1974.
The commercial production of the unit began in 1976-77 with an output of Rs 53
lacs since then there has been no looking back for BHEL Jhansi

The plant of BHEL is equipped with most modern manufacturing processing and
testing facilities for the manufacture of power, special transformer and instrument
transformer, Diesel shunting locomotives and AC/DC locomotives. The layout of
the plant is well streamlined to enable smooth material flow from the raw material
stages to the finished goods. All the feeder bays have been laid perpendicular to
the main assembly bay and in each feeder bay raw material smoothly gets
converted to sub-assemblies, which after inspection are sent to main assembly bay.
The raw material that are produced for manufacture are used only after thorough
material testing in the testing lab and with strict quality checks at various stages of
productions. This unit of BHEL is basically engaged in the production and
manufacturing of various types of transformers and capacities with the growing
competition in the transformer section, in 1985-86 it under took the re-powering of
DESL, but it took the complete year for the manufacturing to begin. In 1987-88,
BHEL has progressed a step further in under taking the production of AC
locomotives, and subsequently it manufacturing AC/DC locomotives also.

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 PRODUCT PROFILE OF B.H.E.L., JHANSI

A. PRODUCT PROFILE OF TRANSFORMER DIVISION :

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 B. PRODUCT PROFILE OF LOCOMOTIVE DIVISION:

1. ELECTRIC LOCMOTIVES

 WAG-5 HB AC
 WCAM-2 AC-DC
 WCAM-3 AC-DC
 WCAG-1 AC-DC
 WAG- 7 AC

2. DEISEL ELECTRIC SHUNTING LOCOMOTIVES

 350HP
 450HP
 700HP-SPP
 700HP-TPP
 1400HP
 800HP-DH LOCO

3. TRACK MAINTENANCE EQUIPMENTS

 OHE CAR
 RAIL CUM ROAD VEHICLE
 DIESEL ELECTRIC TOWER CAR
 UTILITY VEHILCE
 DYNAMIC TRACK STABILISER
 BALLAST CLAENING MACHINE

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4. OTHER NEW PRODUCTS

 WELL WAGON
 BATTERY LOCOMOTIVE
 ELECTRICS OF DG SET FOR DLW / NPCIL
 HOIST ASSEMBLIES FOR SYNCROLIFT
 BATTERY TROLLEYS
 BPRV - Discontinued

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GROWTH OF PRODUCTION AND MILESTONES

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HEALTH, SAFETY AND ENVIRONMENT MANAGEMENT

BHEL, as an integral part of business performance and in its endeavor to becoming

a world class organization and sharing the growth global concern on issues related
to Environment, Occupational Health and Safety, is committed to protecting
Environment in and around its own establishment, and providing safe and healthy
working environment to all its employees. For fulfilling these obligations,
Corporate Policies have been formulated as:

ENVIRONMENTAL POLICY:

 Compliance with applicable Environmental Legislation/Regulation;

 Continual Improvement in Environment Management Systems to protect
our natural environment and control pollution;
 Promotion of activities for conservation of resources by Environmental
Management.
 Enhancement of Environmental awareness amongst employees, customers
and suppliers.

OCCUPATIONAL HEALTH AND SAFETY POLICY:

 Compliance with applicable Legislation and Regulations.

 Setting objectives and targets to eliminate/control/minimize risks due to
Occupational and Safety Hazards.
 Appropriate structured training of employees on Occupational Health and
Safety (OH&S) aspects.
 Formulation and maintenance of OH&S Management programs for
continual improvement;

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  Periodic review of OH&S Management System to ensure its continuing
suitability, adequacy and effectiveness;
 Communication of OH&S Policy to all employees and interested parties.

BHEL PERFORMANCE

1. CORPORATE LEVEL :

PARAMETER 2011 - 12 2012 - 13

Turnover (Rs. /Cr.) 49510 50015
Order Inflow (Rs. /Cr.) 22096 31528
Net Profit (Rs. /Cr.) 7040 6485
Net Worth (Rs. /Cr.) 25373 30315
Megawatts Commissioned 9270 10340
R & D Investment (Rs. /Cr.) 1199 1248
Patents/Copyrights Filed (Nos.) 351 385

2. MAJOR UNITS TURNOVER (IN Rs ./ Crores ) :

DIVISION 2011 – 12 2012 – 13

(Actual) (Provisional
JHANSI 1300 1365
CFFP HARDWAR 506 523
HEEP HARDWAR 5415 6375
BAP RANIPET 4210 3703
HPBP TRICHY/SSTP 14571 14970
EDN BANGALORE 2301 1650
BHOPAL 4790 4703

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 HEEP HYDERABAD 7072 6408
BHEL NET 49301 50015

3. FINANCIAL (IN Rs. / Crores ) :

PRODUCT 2011 – 12 2012 – 13 Growth %

(Actual) (Provisional)
Power Transformer 564 457 –19
Non Power Transformer 304 376 24
Loco 430 532 24
Total 1300 1365 5

4. PHYSICAL :

PRODUCT Unit 2011 – 12 2012 – 13

(Actual) (Provisional
POWER TRFR NOS 161 135
MVA 9585 10101
ESP TRFR NOS 1280 1745
FRT LOCO TRFR- NOS 90 108
1 PH
FRT LOCO TRFR- NOS 30 44
3PH
ACEMU TRFR NOS 161 240
DRY TYPE TRFR NOS 125 105
INSTRUMENT NOS 335 404
TRFR

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DESL NOS 15 10
AC LOCOMOTIVE NOS 53 62
WAGON/WHEEL NOS 2 12
AXLE SET

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 BAY 0
Bay 0 is a part of fabrication shop. It deals with fabrication shop. It deals with
fabrication work of transformers.
Different machines in bay 0:
CNC Flame Cutting machine-for cutting of sheets with the help of oxy-
acetylene flame. This machine is ESAB Germany made.
Bending Machine-Used for bending of sheets. It is hydraulically
operated and stops by nut-screw mechanism.
Rolling Machine-This machine is used to decrease the roll thickness.
The roller material used is high carbon steel.
Flattening Machine-This machine is used to flatten the job. The
flattening load is applied by hydraulic method where suitable quality
hydraulic oil is used.
Radial Drilling Machine-This machine is used for drilling. In this
machine cutting oil is used for cooling (1 litre oil in 20 litre water)
Shearing Machine-It is hydraulically operated. It is used for simple
cutting in metal sheets. Cutting range is 2 mm to 6 mm. Suitable
materials for use are Al, Standard steel and Cu.

Rolling Machine

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 BAY 1
In this shop, welding of different parts of tank is done. Three types of welding
is done:
 Metal Inert Gas(MIG)
Submerged Arc
Manual Arc
Grinder is used to eliminate the roughness.

 BAY 2
In this shop, Shot blasting is done to remove carbon layer from the surface of
tank. In Shot blasting we use small rings with the high pressure of 7kg.
And following assembly is done:
 Tank assembly and tank cover assembly
 End frame assembly
 Cross feed assembly
 Pin and Pad assembly
 Foot assembly
And then some NON-DESTRUCTIVE TESTS are done.

 Ultrasonic tests (to detect the fault in welding)

 Die penetration test
 X-Ray test

Power Transformer Tank

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 BAY 3
There are three sections in this bay:
 Machine Section
 Copper Section
 Tooling Section
There are various machines used here:
 Tool Cutter Grinder
 Hydraulic Surface Grinder
 Drill Sharp Machine
 Vertical Grinder Machine
 Resistance brazing machine
 Bend Saw machine (for cutting circular objects)
 Electric Furnace
 Lathe Machines : 1.Turret lathe (for heavy duty) Range: 250 mm to 350
mm
2. Capstone Lathe: Range_20 mm to 150 mm
3. Centre Lathe: Range_20mm to 200 mm
 Tube Slitting Machine
 Fly Press Machine
 Lincing Belt Machine
 BAY 4
Here, winding of dry type transformers and power transformers is made.
The coil of transformers is of four types:
 Low voltage coil
 High voltage coil
 Tap coil
 Tertiary coil
All the winding are wrapped by Paper Insulation Copper Conductor (PICC)
or by Continuously transposed conductor (CTC). They can be arranged in
different ways.
 Reverse Section Winding
 Helical Winding
 Interlinked Winding

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  Half Section Winding
Arrangement and type of coil depends on job requirements. Also, the width
and thickness of conductor is designed by design department. Conductors used
for winding is in the form of a very long spiral wound on a spool, conductor
is covered by cellulose paper insulation.
For winding, first the winding mould of diameter equal to inner diameter of
required coil is made. The specification of the coil is given in thr drawing
section that interlocks with each other. This interlocking can be increased and
decreased to adjust the inner diameter of coil.
The moulds are of following types:
 Belly type
 Link type
 Cone type

Transformer winding
 BAY-5
It is core and punch section but in a part of it cast resin coil encapsulation plant
is situated. The coils of dry type transformer are casted, cut and finally prepared.
In this bay, laminations of side leg, central leg and yoke are formed.
CRGO (Cold Rolled Grain Oriented) silicon steel is used for lamination which
is imported in India from Japan, U.K. and Germany.

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  Slitting Machine- It is used to cut CRGO sheets in different width. It has
a circular cutter whose position can be changed as per the requirement.
 CNC Cropping line pneumatic- It contains only one blade which can
rotate 90 about sheet and is operated pneumatically.
 CNC Cropping line hydraulic-It is also used to cut the CRGO sheets. It
contains two blades, one is fixed and other rotates 90 above the sheets.
It is operated hydraulically. M4 quality sheets 0.23-0.27mm thickness is
used.

CNC Per hour consumption-75Kwh

CNC Per hour expenditure-₹375

CRGO stacked to form core

 BAY 6
This shop has two parts:
 Traction transformer winding
 Assembly of traction transformer
Traction transformers are used in AC Locomotives and are also called Freight
locomotive transformers. They are both of single phase and three phase.
Three phase transformers for ACEMU are also manufactured here. The supply
line of this transformer is 25 kV and the power of this transformer

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 is600KvA.The tap changer of Rectifier transformer is also assembled in this
bay. Rectified transformer is used in big furnaces like thermal power plant

 BAY 7
This is insulation shop-Various types of insulation are prepared here:
 AWWW-All wood water washed press paper. It is 0.2-0.5 mm thick
cellulose paper and it is wound on the conductor for insulation
 Pre-Compressed board-This is widely used for general insulation and
separation of conductor in the form of blocks.
 Press board-It is up to 38 mm thick and is used for separation of hv coil
from lv coil.
 UDEL-Undemnified Electrical laminated wood or permawood is a
special type of wood for insulation purpose.
 Gasket-It is used for protection against leakage
 Silicon Rubber Sheet-It is used for dry type transformers
The machines used for shaping the insulation materials are-
 Cylindrical and circle cutting machine
 Scarfing machine
 Punching press machine
 Drilling machine
 Guillotine Machine
 Bench Saw
 Jig Saw
 Circular Saw
 Lincing machine

 BAY 8
It is the instrument transformer and ESP manufacturing section. Instrument
transformer are of two types:
 Current Transformer (CT)
 Voltage Transformer (VT)

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  CURRENT TRANSFORMER
This transformer is used to step down current as high value of current
cannot be measured.
The main body is a bushing made up of porcelain which acts as an
insulator in which winding is placed. It has top and bottom chamber.
The top chamber is a cylindrical tank made of mild steel. It has
terminals for connection of hv coils and a glass window to indicate
the oil level. Bottom chamber house is secondary winding. There is
also connection box to which the connection low voltage is made.
Windings- The primary winding consists of hollow Cu/Al pipe bent
in the form of ‘U’ with copper wire passing through it. The bent
portion of primary is in lower chamber, the straight one inside the
bushing. The primary is wound with crepe paper insulation that goes
on increasing as we move downwards. The free ends of primary
winding are connected with ‘ferrules’. The secondary winding is
divided into number of coils for different sets of tapping. Each coil
has an annular core of CRGO (silicon steel).

 VOLTAGE TRANSFORMER
This is also a step down transformer with outer construction same
as that of current transformer.
Windings-Primary Winding is of thick wire having few turns. The
winding is heavily insulated with paper insulation. It has hollow
cylinder passing through it, which houses the secondary winding. It
is cleaned up and painted with enamel and epoxy paint.
 ESP TRANSFORMER
It is a step up transformer which is used to control environmental
pollution by filtering the suspended charges. It is mainly used in
thermal station and cement industry. The core is laminated and
made up of CRGO sheets. An AC reactor is in series with the
primary coil and AC output is rectified using bridge rectifier. RF
choke is in series with DC output to protect secondary circuit and
filter circuit. Output is negative as suspended charge particles are
positive.

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 Instrument Transformers

 BAY 9
It is one of the largest bays involved in assembly of power and rectifier
transformers. A transformer in the process of assembly is called job. The main
processes involved in this shop are-
 Core building
 Core lifting (by crane and placed vertical)
 Unlacing, in which yoke of the transformer is removed to place bottom
insulation in the form of 50mm thick permawood sheet.
 Relacing and end frame mounting
 H.V. terminal and L.V.T.G. mounting
 Final servicing and tanking-job is inserted in mild-steel tank after passing
some pre-tests and oil filling
 Case fitting-tank cover , fixing bushing, Fixing valves etc. are done

Power transformer Power transformer

Transformer Engineering (TRE)

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 The works taking place here are:
 Designing of transformer plans
 Order taking and technical analysis of tenders
 Specifying the budget of making of transformers
 Customer drawing is prepared
 Warranty related issues are covered

 Technology Department
Technology function can be classified as:
 Writing down the method of manufacturing
 Preparing the method sheet of every part of transformer.
 To maintain uniformity in collective orders
 To increase the durability of transformer
 To maintain incentive schemes

 Transformer Commercial (TRC)

This department interacts with customers. It brings out tenders and also responds
to them. It is mainly divided into two cells:
1. Tender Cell-
 Tender requirements of the customer comprises of following
specifications:
A. Technical specifications
B. Estimated cost of project
C. Estimated time for completion
D. Other information
 Types of tenders:
A. Open tender-published in news, dailies etc.
B. Limited tender-issued to limited parties
C. Single Party Tender-issued to single party on proprietary
basis
 Enquiry- On the receipt of tender forms, enquiries are issued to-

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 A. Engineering department for technical acceptance
B. Production planning and control for delivery period
C. Central dispatch cell for mode of transportation and
transportation charges.
 Offer- If tender is feasible, as obtained from reports of other
departments, offer is submitted to the customer
 Contract agreement- On the opening of technical bid, the
commercial bid of technically qualified tenders is opened and order
is placed on the lowest value tender, which is followed by
negotiations if required
2. Contract Execution Cell-
 Issue of work orders
 Type of work orders
 Monitoring
 Payment Collection
 Contract closing
 After Sale services:
A. Within Warranty Period- Free of cost servicemen and
replacement of material is required.
B. Beyond warranty period-on chargeable basis

Locomotive Commercial (LMC)

Locomotive Commercial does the same work which TRC does but for the
locomotive.

 Locomotive Manufacturing
Two types of locomotives are produced in BHEL Jhansi:
 Diesel-Electric Shunting locomotive- It has low speed in range of 10-
20 Kmph. It is used in coal, cement and other industry.
 WAG-9 (6000hp)- Wide gauge AC goods. It has less speed than
passenger’s loco but more hauling power.
The incoming 25 kV is first converted to 1000V through step down
transformer. Then this DC current is converted into AC through two
converters:
 Traction Converter(SR)- for traction motor(3 phase
induction motor)

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  Auxiliary Converter (BUR) - for lights, fans, blowers,
compressors etc.
Distribution system- The output coming from converter then passes
through distribution system.
 HB (Auxiliary system)
 SB (Main system)  Traction Motor  Axle
There are 5 types of braking system in WAG-9:
 A9
 SA9
 Emergency
 Regenerative
 Parking
A9, SA9 and Emergency are pneumatic braking system. Regenerative
is electric brake whereas parking is mechanical brake.
Some other components of locomotive are:
 Step down transformer
 Machine room blower
 Oil Cooler blower
 FB (Earth Choke)- Filter Cubicle for removing harmonic
distortions
The roof components are-
 Pentograph
 VCB
 Resistance of blower
Each bogie contains:
 3 axle
 6 wheels, each axle containing two wheels
 3 TM, one for each axle
Testing of loco is done in many ways-
 Loco testing- testing of wires, leakage in pipes etc.
 Water testing- to ensure that the loco is suitable for
coupling or not.
 Short run test
 Long run test
 MU (Multiple unit test) - to ensure that the loco is
suitable for coupling or not.

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 WAG 9 locomotive

 Locomotive Engineering (LME)

 Does the study of technical part of tender
 Calculates the EFC(Estimated Factory Cost)
 To make the manufacturing summary and drawing
 To give assistance to the work if needed
 To provide training to workers for new product
 To prepare purchase indent (PI) for materials that are to be purchased
for the loco to be made
 To prepare operational manual for both customers and workers

 Store
Here, all the raw materials that are needed for the manufacturing of
transformers and locomotives are stored. The planning department of both
transformers and locomotives categorize the raw materials into electrical,
mechanical and proprietary. All the raw materials enter the store through
material gate. First, they are sent to CRX (Central receipts) where validation
and quality check of incoming material is done. Then SRV is given and
material is sent to store location. There are 14 stores in BHEL Jhansi. At

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 factory main store (FMS), their SRV is checked and material is collected.
FMS keeps updating number of materials in store.

 Central Quality Services

It has two sections:
 Quality control (QC)
 Quality Assurance (QA)
A. Controls the quality of product with inspection of checklist
B. Study of client, engineering specification, quality plan, sheet etc.
C. Quality assurance plan (QAP) is formed
D. Inspection detail of every part is made
E. CHP (Customer Hold Queries) are taken.

 Testing
For power transformer:
 Ratio test- Special equipment transformer from routine meter
 Resistance test- Special equipment: Kelvin and Wheatstone bridge
 Insulation Resistance test
 Separate source voltage withstand test-Special equipment-HV
transformers with associated control and measuring disks, standard
capacitor potential divider
 Iron loss measurement test-
Special equipment: a) Electro dynamometer
b) Rms Voltmeter
c) Average Voltmeter
d) Precision class measuring VT
e) Variable frequency sine wave generator

For current transformer:

 Polarity test-instrument used-polarimeter, analog multimeter
One of the winding is supplied with 15V DC supply and other is
connected to ammeter.
 Accuracy Test-for rechecking various parameters like turns ratio,
phase angle etc.
 Inter turn insulation test-
A. First current is given to the primary coil, secondary is open
circuited

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 B. Either of rated primary current or the 4.5 kV peak voltage
secondary voltage, whichever occurs first is allowed to
withstand one minute.
C. Then if the insulation can withstand it, it is said to be okay.

 Work Engineering and Services (WE&S)

This section deals with service and maintenance. It has following jobs:
 Plant Equipment- electronics and electrical mechanical maintenance
 Services: Air, Stream and power equipment
 Telephone exchange
 Township electrical maintenance

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PROJECT REPORT ON:

Insulation Materials used

in power transformer
and
Testing of power
transformer

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Insulation materials used in
power transformer
 INTRODUCTION
The primary and secondary coils of a transformer are the key components in
performing its basic function of transforming voltage and current. Materials
are used to insulate the primary and secondary coils. In transformers, in addition
to the primary and secondary coils, there are several other important components
and accessories. The insulating material is one of the most critical
components of a transformer. Sufficient insulation between different active
parts of the transformer is necessary for its safe operation. Adequate insulation
is not only necessary to isolate coils from one another, or from the core and
tank, but also ensures the safety of the transformer against accidental
overvoltages.
The insulation system in a transformer can be categorized as follows.
• Major insulation:
– between core and low-voltage (LV) winding;
– between LV and high-voltage (HV) winding;
– between top and bottom of winding and yoke;
– between HV and tank;
– bushings.
• Minor insulation:
– between conductors;
– between turns;
– between layers;
– between laminations;
– between joints and connections.
The insulation material commonly used between the grounded core and the LV
coil to ground, and also between HV and LV coils, is oil-impregnated solid
pressboard.
Solid insulation, including pressboard or paper, can have small internal air
voids. This reduces the insulating strength of the solid insulation as well as
reducing
its heat dissipation capacity. When transformer oil is used to impregnate
solid insulation, the voids are filled with oil, resulting in an improvement of both
the insulation strength and the heat dissipation capacity of the solid insulation. In

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larger transformers, cellulose-based paper tape is usually wrapped over individual
conductors. Layer-to-layer or disc-to-disc insulation is mostly provided by
oil-impregnated Kraft paper or even thick pressboard or transformer board in
case of higher-rating transformers.

 Transformer Oil
It is a very significant part of insulation. It is used to serve purposes of electric
insulation as well as coolant. The raw material for transformer oil is a low viscosity
lube called Transformer oil base stock (TOBS). TOBS is obtained by fractional
distillation and subsequent treatment of crude petroleum.
Characteristics of TOBS:
 Viscosity at 40C  9-14cSt
 Pour point (maxm.)  -9C
 Flash point  145C
(Pensky-marten closed
Cup method)
These characteristics of TOBS are required to maintain for good quality transformer
oil. It is further refined by acid treatment process to yield transformer oil.
A. Chemical Composition Transformer oil is composed of a major
generic class of organic compounds which includes paraffin, naphthalene,
aromatics and olefins. All of these are hydrocarbons. Therefore, transformer
oil is also called pure hydrocarbon mineral oil. For good and fresh oil, there
should be more amount of saturated paraffin, less amount of naphthalene
and/or aromatics and no olefins. But of better stability of properties optimum
amount of aromatics and/or naphthalene is required. Depending upon the
predominance, the oil is classified as paraffin based or naphtha based.

B. Schedule of characteristics of transformer oil

S.no Characteristics Requirement
 Density at 29.5C 0.89g/cm3
 Kinematic Viscosity (27c, max) 27cSt
 Interfacial Tension (27c, min) 0.04 N/m
 Flash point, Pensky-Marten (open), min -140C
 Pour point, max -6C

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  Neutralization value(total acidity) 0.03 mg KOH/g
 Corrosive Sulphur Non-Corrosive

 Electric strength (BDV) min

a) As received 30 kV(Rms)

b) After filtration 60kV(Rms)

 Dielectric dissipation (tan delta) at 90C, 0.002

max.
 Specific resistance(resistivity)

a) At 90C 30 ×1012 Ώ cm
b) At 27C 1500 × 1012Ώ cm
 Oxidation stability

a) Neutralization value after oxidation,0.40 mg KOH/g

max
b) Total sludge after oxidation, max 0.10% by weight
 Presence of oxidation inhibitor The oil should not
contain antioxidant
additives
 Water content (as received), max 50 ppm by weight

C. Physical constants of oil

S.no. Properties Value
 Permittivity 2.2(-0.001)
 Specific heat 2.06KJ/kgC(0.0038)
 Thermal conductivity 0.12W/mC
 Coefficient of expansion 0.00078/C
 Mean density correction factor over the 0.00065/C
normal range of operating temperature

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D. Physical properties 
 Interfacial Tension (IFT) - It is a measure of attractive forces between oil
and water molecules at their interface. I provides a means of detecting
soluble polar contaminants and products of deterioration which reduces
the attraction force between oil and water molecules. IFT gives an
indication of degree of sludging of oil

 Moisture Content- The amount of free and dissolved water molecules present
in oil is its moisture content. It is expressed in ppm or mg/kg. Presence of
moisture is harmful since it adversely effects electric characteristics of oil and
deteriorates insulation paper of windings.
 Flash point- It is the temperature at which oil produces so much vapour that
this vapour when mixed with air forms an ignitable mixture which produces
momentary flash on application of flame under prescribed condition. Flash
point of oil is measured to avoid fire in transformer.
 Viscosity- It is a measure of oil resistance to its continuous flow under no
external force applied. The oil must be mobile as the heat transfer in
transformer is mainly in form of convection currents. The viscosity of oil
increases with decrease in temperature. Therefore, it is necessary that the
viscosity of oil is low at low temperatures.

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 Pour point- The temperature at which the oil will just flow under prescribed
conditions is called pour point. If the oil becomes too viscous or freezes at
low temperatures, it will hinder the formation of convection currents and the
cooling of transformer will be severely affected.

E. Electrical properties 
 Electric strength (breakdown voltage) - Breakdown voltage (BDV) is
the voltage at which spark occurs between two electrodes in an applied
electric field under prescribed conditions. Electric strength is the basic
parameter of insulation to be designed in a transformer. It detects the
presence of contaminations inside the oil like moisture, fibrous
materials, carbon particles, precipitable sludge and sediments.

BDV testing kit

 Resistivity- It is the most sensitive quantity to be measure. The resistivity
of transformer oil is measured in ohm cm which is the resistivity between
opposite sides of a centimetre cube of oil. The low value indicates
presence of moisture and conductive contaminants. The resistance of
windings also depends upon the resistance of transformer oil.
 Dielectric dissipation factor (DDF) - It is numerically equal to the
sine of loss angle (approximately equal to the tangent of loss angle in
dielectrics). It is a good method to identify the quality of transformer
oil. The high value of DDF indicates presence of contaminants and
deterioration products in oil like water, soap metals, resins, oxidation
products, soluble varnishes etc.

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F. Chemical Properties
 Neutralization value (Total acidity) - There are many free organic and
inorganic acids present in oil. Total acidity is the amount of KOH in mg
to neutralize acids in 1g of oil. These acids along with sludge are formed
due to oxidation of hydrocarbons. The oxygen for oxidation can come
through atmosphere during breathing of oil, or it may be pre dissolved in
oil due to negligence in degassing of oil or may be liberated due to effect
of heat on cellulose insulation. Copper acts as a strong catalyst for the
oxidation process. So bare copper is nowhere used in transformer. It is
used either through insulation or enamel painted or electro tinned. Acid
formed gives rise to sludge and precipitates on winding and different
parts of transformers which highly affects the electric properties. The
acids also promotes deterioration of insulation such as paper, wood etc.
Water is also a product of oxidation which corrodes metals and
deteriorates insulation products. So, calculating the acidity of oil is best
way to determine the amount of acids present in oil.
 Sediment and precipitable sludge- These are the oxidation and
deterioration products that are insoluble in oil when diluted with n-
heptane. However, sludge is soluble in solvent mixture containing equal
amounts of acetone, toluene and alcohol. But sediment is not soluble in
any solvent. This sludge and sediment amount is determined for oil in
service. If sludge or sediment is detected in oil then it is not fit to use.
 Corrosive sulphur- It is usually present in crude petroleum which is
removed in the refining process. The test for presence of any corrosive
sulphur present in oil is done because thi sulphur pittens and deposit on
any bare copper in transformer thus affecting heat dissipation abilities of
transformer.
G. Stability of oil 
The paraffinic base oil produces indigenously have shown deterioration of
electric properties during use at a rate little more than naphtha base oil
produced in USA and UK. Efforts are being made to improve the
deteriorating rate of paraffinic based oil to increase the stability of oil.

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  Insulating Paper
Paper is a fabric made of vegetable fibre which are felted into web or sheet. The raw
material of fibre comes from plants like cotton, hemp, manila, straw and
coniferous/deciduous trees. The cells and fibres of these plants contain cellulose in
them. The molecular formula of cellulose is (C6 H10 O5)n. The degree of polymerisation
n varies from plant to plant. It is 2500 or more in cotton fibre whereas 1200 or more
in wood pulp. Various other materials such as lignin, hemicellulose, mineral matters,
resins etc. are present along with cellulose as contaminants. To remove these
contaminants, sulphate process treatment of wood pulp and water washing is done.
Terminal gear and high voltage leads are insulated using crepe Kraft paper for higher
flexibility and smaller radii at bends. The crepe Kraft paper have high stretchability
from 50 to 100%.

Crepe paper

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 Different types of paper used and their applications
S.no. Material Application
 Kraft insulating paper of Layer winding
medium air permeability insulation, condenser
core of oil
impregnated bushing
 Kraft insulating paper of high Covering over
air permeability Rectangular copper
conductor, covering
over continuously
transposed copper
conductor, covering
over stranded copper
cable
 Crepe Kraft paper Covering over
flexing cable,
winding lead
insulation
 Press paper Backing paper for
axial cooling duct
 Kraft paper with aluminium Line and common
bands shield of winding
 Crepe Kraft paper with aluminiumMetallization of
foils high voltages leads
and shield

Physical properties

48 | P a g e
 Mechanical properties

Electrical Properties

49 | P a g e
Chemical properties

Methods of tests

Physical properties
 Substance (grammage) - It is the ratio of mass to area, which is a very basic
property to determine most of the mechanical and electric properties of
insulation paper. It is an important property of paper making process.
 Density- It is a function of thickness and grammage of paper. It is a basic
property for determining process parameters for manufacture of paper. Papers
of density 0.6 gm/cm3 to 1.3g/cm3 are used for manufacture of transformer.
 Moisture content- Cellulosic fibres are hygroscopic. Water leads to
plasticization of cellulose and relaxing and weakening of interfibre bonds.
Thus, moisture affects various properties of insulation paper.
 Oil and water absorption- Paper attains a high value of electric strength when
impregnated in oil under vacuum. Vacuum drying lets oil takes place of water
50 | P a g e
 in its molecular structure. Oil impregnation depends upon air permeability and
density of paper. Sometimes, water is also used in place of oil for impregnation.
 Air permeability- It is the measure of the rate at which paper allows air to
penetrate through it. It depends on both internal structure as well as surface
finish. Electric strength of paper is inversely proportional to its air permeability.

Mechanical properties
 Mechanical strength- Paper should be able to withstand exertion of tensile
force on it during overlapping. Overlapping of insulation is done on windings
and cables with overlapping machine under a specified tension force. If the
machine is successful in exerting that force then paper will not break. It has
been proved theoretically that the displacement between windings on short
circuit is directly proportional to the young’s modulus of insulation paper. It
shows the importance of tensile strength and elongation tests.
 Internal tearing resistance- This gives the load under which paper will tear
under specific conditions and thus gives the capability of paper against tearing.
 Bursting strength- This gives the pressure under which disc of paper will burst
which is held firmly on one side of periphery and pressure is applied on the
other side in the form of liquid. It also gives the mechanical strength of paper.
 Heat stability- It is the capability of paper to withstand thermal stresses during
service time of transformer.it is determined by analysing decrease in internal
tearing resistance, bursting strength and degree of polymerisation under
accelerated temperatures.

Electrical properties
 Electric strength- It is a basic property to determine the insulation design of
transformer. It depends mainly on air permeability and density of paper.
 Dissipation factor- It is a very good measure to determine the quality of paper.
The high value of dissipation factor indicates presence of contaminants and
depolymerisation of fibre.
 Freedom from conducting paths- Electric strength of paper is adversely affected
by presence of conducting paths and hence these are undesirable impurities.

51 | P a g e
Chemical properties

Pressboard
Pressboard is a widely used insulating material used for making various electrical,
mechanical and thermal components in manufacture of transformer. It is also made
from vegetable fibres whose cell mainly consists of cellulose. The raw materials used
for making pressboard are:
 Sulphate wood pulp
 Cotton
 Mixture of sulphate wood pulp and cotton or jute hemp
 Mixture of cotton and jute hemp

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Types of pressboard and their applications

53 | P a g e
54 | P a g e
Physical characteristics of pressboard

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Mechanical and electric properties of pressboard

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Chemical properties of pressboard

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Solid pressboard up to 6 mm thick calendared and 8 mm precompressed is used.
It is made by compressing solid pressboard when it is wet at elevated
temperature. For pressboard of higher thickness laminated pressboard and precom
compressed pressboard is made by making laminae of pressboard using adhesives
(polyvinyl alcohol, polyester resin, and casein glue) for strong intermolecular
bonding under high pressure and high temperature.
Moulding
The most difficult practical insulation problem in high voltage transformers occur
at the ends of the windings and at the leadouts from the windings. Pressboard
moulded components can be made to any required shape to follow the contour of
the equipotential determined from the field plot. Angle rings and caps are the
widely used mouldings.

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Other types of mouldings used in EHV transformers are snouts, angle sectors and
leadouts etc.
Advantage of pressboard over other insulating materials
In EHV transformers care is taken to use such insulating materials in stress zones
which will have the least partial discharge. Synthetic resin bonded paper based
laminates, cylinders and laminated wood are prone to give more P.D. in such zones
compared to pressboard, since air voids are trapped due to excessive use of resin
as the bonding material. Oil absorption in resin bonded insulation materials is much
less than that in pressboard. Therefore, cylinders, winding cleats and supports are
made of pressboard as far as possible.

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 Significance of pressboard characteristics
1. Compressibility- It is a very important property and is a measure of reduction
in thickness of dried specimen when compressed under load, under
prescribed conditions. Transformer windings are designed on the basis of
expected thickness of compressed dovetail block used for providing radial
ducts between turns and sections. If compressibility of the board is less than
that of the value taken in design, the height of the coil will be less than the
design value after vacuum drying and oil impregnation of transformer and
this reduction can lead to serious problems in transformer such as short
circuit if not rectified.
2. Shrinkage- It is the measure of reduction in length, width and thickness of
specimen after it is dried under specified conditions. Effect of shrinkage is
also considered in the design.
3. Cross-breaking strength- It is determined to check proper adhesion of
laminae in a laminated pressboard and ensures against delamination.
4. Electric strength edgewise- It measures the creep strength against glue line
of the laminated pressboard.

 WOOD
Wood is manufactured from veneers (most of them 2 mm thick) from timber. The
veneers are dried and partially or fully impregnated with phenol formaldehyde resin
based on the type of laminate required and then densified under heat and pressure. The
placement of veneers one over other is as such to obtain a specific grain orientation to
achieve the mechanical strength in desired direction.

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Types of wood based laminates and their applications
S.no Material Applications
 Unimpregnated densified laminated wood- Cleats and supports,
low density core/coil clamps, wedge
block, winding support
block, sector, core to coil
packing

 Unimpregnated densified laminated wood- Coil clamping ring, cleat,

high density block, support

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Properties of wood based laminates

Haldu and teak wood seasoned planks are also used as filler materials between
core limbs and enveloping coils and as yoke-step fillers.

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The quality of laminated wood differs from batch from batch and sometimes from
sheet to sheet. The reason of this difference are many e.g.- species of wood
selected for veneers, their age, location, no.of joints to get the required width, gap
in joints, defects in timber etc. Hence, utmost care is taken in use.

SEALING MATERIALS
For all sealing purpose, to prevent oil leakage at joints, gaskets and moulded
components are made from nitrile rubber or nitrile rubber bonded cork. PTFE and
polyamide washers, tapes etc. are used for plugs and taps.

Nitrile Rubber bonded cork

This is the most widely used general purpose gasket. Cork gasket is adaptable to
even rough unmachined surface due to its compressibility under light seating loads.
This gasket is made by compounding of the granular cork by nitrile butadiene
rubber. The cork used is clean, soft-grade type, uniformly granulated and free from
hard board, wood flour, dust and any other foreign material. Nitrile corks provides
the sealibility factor that gives gasket a tight seal property under light seating loads
and also allows distortion of gasket without any crack and damage. The presence
of cork allows compression without excessive spreading associated with solid
rubbers

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Nitrile Rubber
This is normally used with metals to avoid excessive compression and as sealing
rings and mouldings etc. It is a combination of butadiene and acrylonitrile rubber
conforming to a compound BA60 of BS2751. The resilience of nitrile rubber allows
to reuse the gasket after opening a gasketted joint. However this requires a machine
flanged joints. For smaller flanges, a groove is cut into flange for sealing of nitrile
rubber gasket. In such a case, a limiter is not actually required.

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Machines used in Insulation shop-
 Scarfing machine
 Rolling cylinders
 Circle cutting machine
 Shearing machine
 Jigsaw
 Radial drill machine
 Bend saw
 Circular saw

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 Gasket scarfing machine
 Grinder
 Liniching machine
 Toggle press

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 Testing of power transformers
 Introduction
For confirming the specifications and performances of an electrical power
transformer it has to go through a number of testing procedures. Some tests are
done at a transformer manufacturer premises before delivering the transformer.
Transformer manufacturers perform two main types of transformer testing –
type test of transformer and routine test of transformer.
Some transformer tests are also carried out at the consumer site before
commissioning and also periodically in regular and emergency basis throughout
its service life.

Types of Transformer Testing

Tests done at factory:
 Type tests
 Routine tests
 Special tests

Tests done at site:

 Pre-commissioning tests
 Periodic/condition monitoring tests
 Emergency tests

 Type Test of Transformer

To prove that the transformer meets customer’s specifications and design
expectations, the transformer has to go through different testing procedures in
manufacturer premises. Some transformer tests are carried out for confirming the
basic design expectation of that transformer. These tests are done mainly in a
prototype unit not in all manufactured units in a lot. Type test of transformer confirms
main and basic design criteria of a production lot.

 Routine Tests of Transformer

Routine tests of transformer is mainly for confirming the operational performance
of the individual unit in a production lot. Routine tests are carried out on every unit
manufactured.
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 Special Tests of Transformer
Special tests of transformer is done as per customer requirement to obtain information
useful to the user during operation or maintenance of the transformer.

 Pre Commissioning Test of Transformer

In addition to these, the transformer also goes through some other tests, performed on
it, before actual commissioning of the transformer at the site. The transformer testing
performed before commissioning the transformer at the site is called the pre-
commissioning test of transformer. These tests are done to assess the condition of
transformer after installation and compare the test results of all the low voltage tests
with the factory test reports.

Type test of transformer include:

1. Winding resistance test of transformer
2. Transformer ratio test
3. Transformer vector group test
4. Measurement of impedance voltage/short circuit impedance (principal tap)
and load loss (Short circuit test)
5. Measurement of no-load loss and current (Open circuit test)
6. Measurement of insulation resistance
7. Dielectric tests of transformer
8. Temperature rise test of transformer
9. Tests on on-load tap-changer
10. Vacuum tests on tank and radiators

Routine tests of transformers include:

1. Winding resistance test of transformer
2. Transformer ratio test
3. Transformer vector group test
4. Measurement of impedance voltage/short circuit impedance (principal tap)
and load loss (Short circuit test)
5. Measurement of no load loss and current (Open circuit test)
6. Measurement of insulation resistance
7. Dielectric tests of transformer.
8. Tests on on-load tap-changer.

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 9. Oil pressure test on transformer to check against leakages past joints and
gaskets
That means Routine tests of transformer include all the type tests except temperature
rise and vacuum tests. The oil pressure test on transformer to check against leakages
past joints and gaskets is included.

Special tests on transformer include:

1. Dielectric tests.
2. Measurement of zero-sequence impedance of three-phase transformers
3. Short-circuit test
4. Measurement of acoustic noise level
5. Measurement of the harmonics of the no-load current.
6. Measurement of the power taken by the fans and oil pumps.
7. Tests on bought out components / accessories such as buchholz relay,
temperature indicators, pressure relief devices, oil preservation system etc.

 Transformer ratio test

Power transformer turns ratio test is an AC low voltage test which
determines the ratio of the high voltage winding to all other windings at
no-load. The turns ratio test is performed on all taps of every winding.
The Transformer Turns Ratio tester (TTR) is device used to measure the
turns ratio between the windings.

Voltage is applied on the H marked leads and measured of the X marked

lead by the test set.

Ratio measurements are conducted on all tap positions and calculated by

dividing the induced voltage reading into the applied voltage value. When
ratio tests are being made on three-phase transformers, the ratio is taken on
one phase at a time with a three-phase TTR until the ratio measurements of
all three phases are completed.

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 Three phase transformer turn ratio tester connection diagram

Measured ratio variations should be within 0.5% of the nameplate markings.

Some TTR can perform transformer ratio measurement and also assess if on-load
tap changer contacts are making satisfactorily during its transition from one tap
position to the next position.

Example of single phase, hand-cranked TTR – Transformer Turns Ratio Test Set (Measures the
turns ratio and exciting current of windings in power, potential and current transformers.)

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Turns Ratio Test Procedure, Step by Step

 Step 1.Isolate the equipment, apply working grounds to all incoming and
outgoing cables and disconnect all incoming and outgoing cables from the
transformer bushing terminals connections. Disconnected cables should
have sufficient clearance from the switchgear terminals greater than the
phase spacing distance. Use nylon rope to hold cable away from incoming
and outgoing terminals as required.
 Step 2.Connect the H designated three-phase test lead with the military
style connector at one end to the mating connection on the test set marked
with an H. Ensure that the connector’s index notch lines up properly.
 Step 3.Connect the X designated three-phase test of lead military style
connector at one end to the mating connection on the test set marked with
an X. Ensure that the connector’s index notch lines up properly.

 Step 4.Connect the H1, H2, H3 designated test lead to the

corresponding H1, H2, H3 transformer terminal / bushing. Connect the H0
test lead if H0 terminal/bushing is present.
 Step 5.Connect the X1, X2, X3 designated test leads to the corresponding
X1, X2, X3 transformer terminals / bushings. Connect the X0 test lead if
X0 terminal/bushing is present.

Step 6.Perform turns ratio measurements for all tap positions.

Step 7.Confirm that the measured ratios is within 0.5% of the calculated
ratios.

Important Note:

Transformers that have wye connections but do not have the neutral of the wye
brought out shall be tested for ratio with three-phase power supply.

Any inequality in the magnetizing characteristics of the three phases will then
result in a shift of the neutral and thereby cause unequal phase voltages. When
such inequality is found, the connection should be changed, either to a delta or to
a wye connection, and the line voltages measured.

When these are found to be equal to each other and the proper values (1.732 times
the phase voltages when connected in wye), the ratio is correct
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  Winding Resistance Test
A winding resistance test of a transformer is carried out as a type test, routine test
and also as a field test.

In the factory, it helps in determining the following:

1. Calculation of the I2R losses in transformer.

2. Calculation of winding temperature at the end of temperature rise test of
transformer.
3. As a benchmark for assessing possible damages in the field.
It is done at site in order to check for abnormalities due to loose connections,
broken strands of conductor, high contact resistance in tap changers, high voltage
leads and bushings.
 Procedure of Transformer Winding Resistance Measurement

For star connected winding, the resistance shall be measured between the line and
neutral terminal.

For star connected autotransformers the resistance of the HV side is measured

between HV terminal and LV terminal, then between LV terminal and the
neutral.
For delta connected windings, measurement of winding resistance shall be done
between pairs of line terminals. As in delta connection the resistance of
individual winding cannot be measured separately, the resistance per winding
shall be calculated as per the following formula:
Resistance per winding = 1.5 × Measured value
The resistance is measured at ambient temperature and then converted to
resistance at 75oC for all practical purposes of comparison with specified design
values, previous results and diagnostics.
Winding Resistance at standard temperature of 75oC

Rt = Winding resistance at temperature t

t = Winding temperature
Generally, transformer windings are immersed in insulation liquid and covered
with paper insulation, hence it is impossible to measure the actual winding
temperature in a de-energizing transformer at the time of transformer winding

72 | P a g e
resistance measurement. An approximation is developed to calculate the
temperature of winding at that condition, as follows:
Temperature of winding = Average temperature of insulating oil
The average temperature of insulating oil should be taken 3 to 8 hours after de-
energizing transformer and when the difference between top and bottom oil
temperatures becomes less than 5oC.
The resistance can be measured by a simple voltmeter ammeter method, Kelvin
Bridge meter or automatic winding resistance measurement kit (ohm meter,
preferably 25 Amps kit).
Caution for voltmeter ammeter method: Current shall not exceed 15% of the rated
current of the winding. Large values may cause inaccuracy by heating the winding
and thereby changing its temperature and resistance.

Note: The measurement of winding resistance of a transformer shall be carried

out at each tap.

Current Voltage Method of Measurement of Winding Resistance

The transformer winding resistances can be measured by current voltage method.
In this method of measurement of winding resistance, the test current is injected
to the winding and corresponding voltage drop across the winding is measured.
By applying simple Ohm’s law i.e. Rx = V I, one can easily determine the value
of resistance.

Procedure of Current Voltage Method of Measurement of Winding Resistance

1. Before measurement the transformer should be kept in OFF condition
without excitation at least for 3 to 4 hours. During this time the winding
temperature will become equal to its oil temperature.
2. Measurement is done with D.C.
3. To minimize observation errors, polarity of the core magnetization shall be
kept constant during all resistance readings.
4. Voltmeter leads shall be independent of the current leads to protect it from
high voltages which may occur during switching on and off the current
circuit
5. The readings shall be taken after the current and voltage have reached steady
state values. In some cases this may take several minutes depending upon
the winding impedance.
6. The test current shall not exceed 15% of the rated current of the winding.
Large values may cause inaccuracy by heating the winding and thereby
changing its resistance.

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7. For expressing resistance, the corresponding temperature of the winding at
the time of measurement must be mentioned along with resistance value. As
we said earlier that after remaining in switch off condition for 3 to 4 hours,
the winding temperature would become equal to oil temperature. The oil
temperature at the time of testing is taken as the average of top oil and bottom
oil temperatures of transformer.

8. For star connected three-phase winding, the resistance per phase would be
half of the measured resistance between two line terminals of the
transformer
9. For delta connected three-phase winding, the resistance per phase would be
0.67 times of measured resistance between two line terminals of the
transformer.
10. This current voltage method of measurement of winding resistance of
transformer should be repeated for each pair of line terminals of winding at
every tap position.

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Bridge Method of Measurement of Winding Resistance
The main principle of the bridge method is based on comparing an unknown
resistance with a known resistance. When currents flowing through the arms of the
bridge circuit become balanced, the reading of galvanometer shows zero deflection
that means at balanced condition no current will flow through the galvanometer.

A very small value of resistance (in milli-ohms range) can be accurately measured
by the Kelvin bridge method whereas for higher value Wheatstone bridge method
of resistance measurement is applied. In bridge method of measurement of winding
resistance, the errors are minimized.

The resistance measured by Kelvin Bridge,

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 All other steps to be taken during transformer winding resistance measurement in
these methods are similar to that of current voltage method of measurement of
winding resistance of transformer, except the measuring technique of resistance.
The resistance measured by Wheatstone bridge,

 Magnetizing Current Test of Transformer

Magnetizing current test of transformer is performed to locate defects in the
magnetic core structure, shifting of windings, failure in between turn insulation or
problem in tap changers. These conditions change the effective reluctance of the
magnetic circuit, thus affecting the current required to establish flux in the core.
Steps to perform magnetization current test
1. Keep the tap changer in the lowest position and open all HV and LV
terminals
2. Then apply three phase 415 V supply on the line terminals for three-phase
transformers and single phase 230 V supply on single phase transformers
3. Measure the supply voltage and current in each phase
4. Now repeat the magnetizing current test of transformer test with keeping tap
changer in normal position

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 5. Repeat the test while keeping the tap at highest position
Normally, there are two similar higher readings on two outer limb phases on
transformer core and one lower reading on the centre limb phase, in the case of
three phase transformers.

An agreement to within 30% of the measured exciting current with the previous
test is usually considered satisfactory. If the measured exciting current value is 50
times higher than the value measured during factory test, there is a likelihood of a
fault in the winding which needs further analysis.

Caution: This magnetizing current test of a transformer is to be carried out before

DC resistance measurement.

 Magnetic balance test

The Magnetic Balance test is conducted on Transformers to identify inter turn
faults and magnetic imbalance. The magnetic balance test is usually done on the
star side of a transformer. A two phase supply 440V is applied across two phases,
say, 1U and 1V. The phase W is kept open. The voltage is then measured between
U-V and U-W. The sum of these two voltages should give the applied
voltage. That is, 1U1W + 1V1W will be equal to 1U1V.

For instance, if the voltage applied is 440V between 1U1V, then the voltages
obtained can be

1U1V = 1U1W + 1V1W

440V = 260V + 180V

The voltages obtained in the secondary will also be proportional to the voltages
above.

This indicates that the transformer is magnetically balanced. If there is any inter-
turn short circuit that may result in the sum of the two voltages not being equal to
the applied voltage.

The Magnetic balance test is only an indicative test for the transformer. Its results
are not absolute. It needs to be used in conjunction with other tests.

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 Transformer Vector Group Test
The vector group of transformer is an essential property for successful parallel
operation of transformers. Hence every electrical power transformer must
undergo through vector group test of transformer at factory site for ensuring the
customer specified vector group of transformer.
The phase sequence or the order in which the phases reach their maximum
positive voltages, must be identical for two paralleled transformers. Otherwise,
during the cycle, each pair of phases will be short circuited.
The several secondary connections are available with respect to various primary
three phase connection in a three phase transformer. So for same primary applied
three phase voltage there may be different three phase secondary voltages with
various magnitudes and phases for different internal connection of the
transformer.
Let’s have a discussion in detail by example for better understanding.
We know that, the primary and secondary coils on any one limb have induced
emfs that are in time-phase. Let’s consider two transformers with same number
of primary turns and the primary windings are connected in star. The secondary
number of turns per phase in both transformers are also same. But the first
transformer has star connected secondary and other transformer has delta
connected secondary. If same voltages are applied in primary of both
transformers, the secondary induced emf in each phase will be in same time-
phase with that of respective primary phase as the primary and secondary coils
of same phase are wound on the same limb in the core of transformer. In first
transformer, as the secondary is star connected, the secondary line voltage is √3
times of induced voltage per secondary phase coil. But in case of second
transformer, where secondary is delta connected, the line voltage is equal to
induced voltage per secondary phase coil. If we go through the vector diagram
of secondary line voltages of both transformer, we will easily find that there
will be a clear 30o angular difference between the line voltages of these
transformers.
Now, if we try to run these transformers in parallel then there will be a
circulating current flowing between the transformers as there is a phase angle
difference between their secondary line voltages. This phase difference cannot
be compensated. Thus two sets of connections giving secondary voltages with
a phase displacement cannot be used for parallel operation of transformers.
The following table gives the connections for which from the view point of
phase sequence and angular divergences, transformer can be operated in
parallel. According to their vector relation, all three phase transformers are
divided into different vector group of transformer. All electrical power
transformers of a particular vector group can easily be operated in parallel if
they fulfil other conditions for parallel operation of transformers.

78 | P a g e
GROU Connection Connection
P

0(0) Yy0 Dd0

1(30)
Yd1 Dy1

6(180)
Dd6
Yy6

79 | P a g e
11(-30)
Yd11 Dy11

Procedure of Vector Group Test of Transformer

Let’s have a YNd11 transformer.

1. Connect neutral point of star connected winding with earth.
2. Join 1U of HV and 2W of LV together.
3. Apply 415 V, three phase supply to HV terminals.
4. Measure voltages between terminals 2U-1N, 2V-1N, 2W-1N, that means
voltages between each LV terminal and HV neutral.
5. Also measure voltages between terminals 2V-1V, 2W-1W and 2V-1W.

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 For YNd11 transformer, we will find,
2U-1N > 2V-1N > 2W-1N
2V-1W > 2V-1V or 2W-1W.

 Insulation Resistance Test

The insulation resistance test (meggering) is of value for future comparison and
also for determining if the transformer is to be subjected to the applied voltage test.
The winding insulation resistance test is a DC high voltage test used to determine
the dryness of winding insulation system. The test measures the insulation
resistance from individual windings to ground and/or between individual windings.

MEGGER - Insulation resistance test device

The measurement values are subject to wide variation in design, temperature,
dryness and cleanliness of the parts. This makes it difficult to set minimum

81 | P a g e
acceptable insulation resistance values that are realistic for wide variety of
insulation systems that are in use and performing satisfactorily. If a transformer
is known to be wet or if it has been subjected to unusually damp conditions, it
should be dried before the application of the applied voltage test.

Low readings can sometimes be brought up by cleaning or drying the apparatus.

The insulation resistance test should be performed at a transformer temperature
as close as possible or at 20 °C. Test conducted at other temperature should be
corrected 20°C with the use of temperature correcting factor.

The test equipment is calibrated to read in Mega ohm and commonly known as a
HV Megger. Typical maximum test set voltage values may be 1kV, 5kV or 15kV.
The 30kV Megger is also available.
Duration of the test voltage shall be 1 minute. In the absence of manufacture’s
recommended values, the following readings may be used.

Table 1 – Transformer Insulation Resistance Acceptance Testing

Winding Insulation Class, Insulation Resistance,
kV MΩ*

1.2 600

2.5 1000

5.0 1500

8.7 2000

15 3000

Normally dried transformers may be expected to have readings 5 to 10 times the

above minimum values.

Important Notes:

1. Other references noted a general rule of thumb for acceptable insulation values
at 1MΩ per 1kV of nameplate rating plus 1MΩ.

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2. Under no condition should the test be made while the transformer is under
vacuum.
3. The significance of values of insulation resistance test requires some
interpretation depending on design, dryness and cleanliness of the insulation
involved. It is recommended that the insulation resistance values be measured
during periodic maintenance shutdown and trended. Large variation in the
trended values should be investigated for cause.
4. Insulation resistance may vary with applied voltage and any comparison
should be made with the same measurements at the same voltage and as close
as possible to the same equipment temperature and humidity as practically
possible.

Insulation Resistance Test Procedure:

1. Isolate the equipment, apply working grounds to all incoming and
outgoing cables and disconnect all incoming and outgoing cables from the
transformer bushing terminals connections. Disconnected cables should have
sufficient clearance from the switchgear terminals greater that the phase
spacing distance. Use nylon rope to hold cable away from incoming and
outgoing terminals as required.
2. Ensure the transformer tank and core is grounded.
3. Disconnect all lightning arresters, fan system, meter or low voltage
control systems that are connected to the transformer winding.
4. Short circuit all winding terminals of the same voltage level together.
5. Perform a 1 minute resistance measurements between each winding group
to the other windings and ground.
6. Remove all shorting leads after completion of all test.

Table 2 – Insulation Resistance Test Connections for Two Winding Transformer

Test Single-phase transformer Three-phase transformer
No.

1 High voltage winding to High voltage winding to low

low voltage winding and ground voltage winding and ground

2 High voltage winding to High voltage winding to low

low voltage winding voltage winding

3 High Voltage winding High voltage winding to ground

to ground with low voltage winding to guard

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 4 Low Voltage winding to Low voltage winding to high
high voltage winding and voltage winding and ground
ground

5 Low voltage winding to ground Low voltage winding to ground and

high voltage winding to guard

 Separate source voltage withstand test

The test is successful if no breakdown in the dielectric of the insulation occurs
during test. During the Separate source AC withstand voltage test, the frequency of
the test voltage should be equal to the transformer’s rated frequency or should be
not less than 80% of this frequency.
To confirm the insulation strength of the transformer line and neutral connection
terminals and the connected windings to the earthed parts and other windings.
This test checks the insulation property between primary to earth, secondary to earth
and between primary and secondary.
 HV High Voltage Test: - LV Winding connected together and earthed. HV
Winding connected together and given 28 KV (for 11 KV Transformer) for 1
Minute.
 LV High Voltage Test: - HV Winding connected together and given 3 KV for
1 Minute.
Equipment Used: - High Voltage Tester (100 KV & 3 KV)

 No-Load Loss Test

A transformer dissipates a constant no-load loss as long as it is energized at
constant voltage, 24 h a day, for all conditions of loading. This power loss
represents a cost to the user during the lifetime of the transformer.

Maximum values of the no-load loss of transformers are specified and often
guaranteed by the manufacturer. No-load-loss measurements are made to verify
that the no-load loss does not exceed the specified or guaranteed value.

Transformer no-load loss, often called core loss or iron loss, is the power loss in a
transformer excited at rated voltage and frequency but not supplying load.

84 | P a g e
The no-load loss comprises three components:

1. Core loss in the core material

2. Dielectric loss in the insulation system
3. I2R loss due to excitation current in the energized winding

The no-load loss of a transformer is primarily caused by losses in the core steel.
The remaining two sources are sometimes ignored. As a result, the terms no-load
loss, core loss, and iron loss are often used interchangeably. Core loss and iron
loss, strictly speaking, refer only to the power loss that appears within the core
material.

The magnitude of no-load loss is a function of the magnitude, frequency, and

waveform of the impressed voltage. These variables affect the magnitude and
shape of the core magnetic flux waveform and hence affect the value of the core
loss.
It has been verified through measurements on power and distribution transformers
that core loss also depends, to some extent, upon the temperature of the core.

The approximate rate of change of no-load loss with core temperature is

0.00065p.u. Core loss increase for each °C reduction in core temperature.

The two main components of the core loss are hysteresis loss and eddy-current loss.

The change in eddy-current loss, due to a change in the resistivity of the core steel
as temperature changes, appears to be one factor that contributes to the observed
core-loss temperature effect. The hysteresis loss magnitude is a function of the peak
flux density in the core-flux waveform.

When the impressed voltage waveform is distorted (not a pure sine wave), the
resulting peak flux density in the flux waveform depends on the average absolute
value of the impressed voltage wave.

Eddy-current loss is a function of the frequency of the power source and the
thickness of the core-steel laminations. Eddy loss is strongly influenced by
harmonics in the impressed voltage.

Excitation current is the current flowing into the high voltage winding with the low
voltage side open. This current should be proportional to the No-load acceptance

85 | P a g e
 test but with the difference resultant from the use of test voltages different from
nominal values.
It shouldn’t exist excessive deflection from values measured between phases and
its normal a slight difference (geometric) between extreme and central windings.
It will exist great changes when appear heat points, degradation in the magnetic
package, loose core or detached magnetic shunt.

How no-load loss is measured

Average-voltage voltmeter method

The measurement of no-load loss, according to the average-voltage voltmeter

method, is illustrated in Figure 1. Voltage and current transformers are required to
scale the inputs for voltmeters, ammeters, and wattmeters.

Three-phase no-load-loss measurements are carried out the same way, except that
three sets of instruments and instrument transformers are utilized.

Figure 1 – Test circuit for no-load-loss measurement

The test involves raising voltage on one winding, usually the low-voltage winding,
to its rated voltage while the other windings are in open circuit. Two voltmeters
connected in parallel are employed.

The voltmeter labelled Va in Figure 1 represents an average-responding, rms-

calibrated voltmeter. The voltmeter labelled Vr represents a true rms-responding
voltmeter.

86 | P a g e
 Harmonics in the impressed voltage will cause the rms value of the waveform to
be different from the average-absolute (rms-scaled) value, and the two voltmeter
readings will differ. When the voltage reading, as measured by the average-
responding voltmeter, reaches a value corresponding to the rated voltage of the
excited winding, readings are taken of the rms current, the rms voltage, and the no-
load power.
The ratio of the measured rms current to the rated load current of the excited
winding, expressed in percent, is commonly referred to as the percent excitation
current. The measured no-load loss is corrected to a sine-wave basis by a formula
given in the mentioned IEEE test code, using the readings of the two voltmeters.

The correction is shown below. The corrected value is reported as the no-load loss
of the transformer.

where:

 Pc is the corrected (reported) value of no-load loss

 Pm is the measured value of no-load loss
 Va is the reading of the average-responding, rms-calibrated voltmeter
 Vr is the reading of the true-rms-responding voltmeter
 P1 and P2 are the per-unit hysteresis and per-unit eddy-current losses,
respectively
According to the mentioned IEEE test code, if the actual values of P1 and P2 are
not available, it is suggested that the two loss components be assumed equal in
value, assigning each a value of 0.5 p.u.

 Measurement of impedance voltage- Load loss test

The measurement is carried out to determine the load-losses of the transformer and
the impedance voltage at rated frequency and rated current.

87 | P a g e
The measurements are made separately for each winding pair (e.g., the pairs 1-2, 1-
3 and 2-3 for a three-winding transformer), and furthermore on the principal and
extreme tappings.

Figure 4.1 – Circuit for the impedance and load-loss measurement

 G1 – Supply generator
 T1 – Step-up transformer
 T2 – Transformer to be tested
 T3 – Current transformers
 T4 – Voltage transformers
 P1 – Wattmeters
 P2 – Ammeters (r.m.s. value)
 P3 – Voltmeters (r.m.s. value)
 C1 – Capacitor bank
The supply and measuring facilities are not described here. Current is generally
supplied to the h.v. winding and the l.v. winding is short-circuited.

If the reactive power supplied by the generator G1 is not sufficient when

measuring large transformers, a capacitor bank C1 is used to compensate part of
the inductive reactive power taken by the transformer T2.The voltage of the
supply generator is raised until the current has attained the required value
(25…100 % of the rated current according to the standard 4.1).
In order to increase the accuracy of readings will be taken at several current values
near the required level. If a winding in the pair to be measured is equipped with
an off-circuit or on-load tap-changer, the measurements are carried out on the
principal and extreme tappings.

88 | P a g e
The readings have to be taken as quickly as possible, because the windings tend
to warm up due to the current and the loss values obtained in the measurement
are accordingly too high.
If the transformer has more than two windings all winding pairs are measured
separately.

Corrections caused by the instrument transformers are made to the measured

current, voltage and power values. The power value correction caused by the
phase displacement is calculated as follows:

eqn. 4.1
Where:
 Pc = corrected power
 Pe = power read from the meters
 δu = phase displacement of the voltage transformer in minutes
 δi = phase displacement of the current transformer in minutes
 ϕ = phase angle between current and voltage in the measurement (ϕ is
positive at inductive load)
 K = correction
The correction K obtained from equation 4.1 is shown as a set of curves

Figure 4.2 – Phase displacement of instrument transformers

The corrections caused by the instrument transformers are made separately for
each phase, because different phases may have different power factors and the
phase displacements of the instrument transformers are generally different.

89 | P a g e
If the measuring current Im deviates from the rated current IN, the power Pkm and
the voltage Ukm at rated current are obtained by applying corrections to the values
Pc and Uc relating to the measuring current.
The corrections are made as follows:

eqn 4.2

eqn 4.3
Where:
 K – correction in percent,
 δu – δi – phase displacement in minutes
 cosδ – power factor of the measurement.
The sign of K is the same as that of δu – δi.

Mean values are calculated of the values corrected to the rated current and the
mean values are used in the following. According to the standards the measured
value of the losses shall be corrected to a winding temperature of 75° C (80° C,
if the oil circulation is forced and directed).

The transformer is at ambient temperature when the measurements are carried out
and the loss values are corrected to the reference temperature 75° C according to
the standards as follows.

The d.c. losses POm at the measuring temperature ϑm are calculated using the
resistance values R1m and R2m obtained in the resistance measurement (for
windings 1 and 2 between line terminals):

Equation4.4

The additional losses Pam at the measuring temperature are:

Here Pkm is the measured power, to which the corrections caused by the
instrument transformer have been made, and which is corrected to the rated
current according to equation (4.2).

90 | P a g e
The short-circuit impedance Zkm and resistance Rkm at the measuring temperature
are:

Equation 4.6

Equation 4.7

 Ukm is the measured short-circuit voltage corrected according to

Equation (4.3);
 UN is the rated voltage and
 SN is the rated power.
The short circuit reactance Xk does not depend on the losses and Xk is the same
at the measuring temperature (ϑm) and the reference temperature (75 °C), hence:

Equation 4.8

When the losses are corrected to 75° C, it is assumed that D.C. losses vary directly
with resistance and the additional losses inversely with resistance. The losses
corrected to 75° C are obtained as follows:

Equation 4.9

Where:
ϑs=235°C for Copper
ϑs = 225° C for Aluminium
Now the short circuit resistance Rkc and the short circuit impedance Zkc at
the reference temperature can be determined:

Equation 4.10

Equation 4.11

Results
The report indicates for each winding pair the power SN and the following values
corrected to 75° C and relating to the principal and extreme tappings.

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  D.C. losses POc (PDC)
 Additional losses Pac (PA)
 Load losses Pkc (PK)
 Short circuit resistance Rkc (RK)
 Short circuit reactance Xkc (XK)
 Short circuit impedance Zkc (ZK)

 Double voltage double frequency test

Induced Over Voltage Test Set (DVDF) is used for testing the strength of
insulation between turns and between other points of the transformers etc. as
stipulated by BIS or other standard specification. For this test Double Voltage is
applied across L.T. terminals for one minute, and to limit the magnetizing current
over frequency is utilized.
It is a mechanically coupled unit having motor and Generator with power and
control panel to regulate the output voltage.
A suitable control panel is utilized for motor starting, generator output control,
measurement of all three phases, voltage and current for input and output with
protection circuit.

 Heat run/ Temperature rise test

Heat run test is one of the type tests on power transformer. This test is also called
temperature rise test. This test reproduces conditions of continuous rated load and
the temperature rise occurring during the load.
For conducting heat run test on the three phase transformer, full rated voltage is
applied to one of the windings which accounts for full load iron losses and other
winding is connected in delta, because of balanced condition of all three phases
voltage in the delta loop is zero and with the help of external source full load current
is circulated in the delta connected winding of the transformer to account for full
load copper losses.
With the help of RTD provided in the winding of transformer temperature of the
transformer winding is recorded. Steady state temperature of winding indicates the
full load temperature rise of the transformer.
PROCEDURE
1. Make the connections as per the circuit diagram given in Fig. attached.
2. Increase the voltage in the primary winding with the help of 3 phase
variac to rated voltage.
3. Adjust the current in the closed delta secondary winding to the rated
current of the secondary winding.

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 4. Record the temperature of the winding after every 15 minutes till
temperature of winding reaches to a steady state condition i.e.
temperature does not rise any more.
5. Time taken to reach the final temperature give idea about the thermal
time constant of the transformer and final temperature gives the full load
temperature rise of the transformer.

 Tan delta test of transformer

A pure insulator when is connected across line and earth, it behaves as a
capacitor. In an ideal insulator, as the insulating material which acts as dielectric
too, is 100 % pure, the electric current passing through the insulator, only have
capacitive component. There is no resistive component of the current, flowing
from line to earth through insulator as in ideal insulating material, there is zero
percent impurity.
In pure capacitor, the capacitive electric current leads the applied voltage by 90o.
In practice, the insulator cannot be made 100% pure. Also due to the aging of
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 insulators, the impurities like dirt and moisture enter into it. These impurities
provide the conductive path to the current. Consequently, an electric leakage
current flowing from line to earth through the insulator has a resistive
component.
Hence, it is needless to say that, for good insulator, this resistive component of
electric leakage current is quite low. In another way, the healthiness of an
electrical insulator can be determined by the ratio of the resistive component to
the capacitive component. For good insulator, this ratio would be quite low. This
ratio is commonly known as tanδ or tan delta. Sometimes it is also referred to as
dissipation factor.

In the vector diagram above, the system voltage is drawn along the x-axis.
Conductive electric current i.e. resistive component of leakage current, IR will
also be along x-axis.
As the capacitive component of leakage electric current IC leads system voltage
by 90o, it will be drawn along y-axis.
Now, total leakage electric current IL(Ic + IR) makes an angle δ (say) with y-axis.
Now, from the diagram above, it is cleared, the ratio, IR to IC is nothing but tanδ
or tan delta.

This δ angle is known as loss angle.

Method of Tan Delta Testing
The cable, winding, current transformer, potential transformer, transformer
bushing, on which tan delta test or dissipation factor test to be conducted, is first
isolated from the system. A very low-frequency test voltage is applied across the
equipment whose insulation to be tested. First, the normal voltage is applied. If the
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value of tan delta appears good enough, the applied voltage is raised to 1.5 to 2
times of normal voltage, of the equipment. The tan delta controller unit takes
measurement of tan delta values. A loss angle analyser is connected with tan delta
measuring unit to compare the tan delta values at normal voltage and higher
voltages and analyse the results.
During the test, it is essential to apply test voltage at a very low frequency.

Reason of applying Very Low Frequency

If the frequency of the applied voltage is high, then capacitive reactance of the
insulator becomes low, hence the capacitive component of electric current is
high. The resistive component is nearly fixed; it depends upon applied voltage
and conductivity of the insulator. At high frequency as capacitive current, is
large, the amplitude of the vector sum of capacitive and resistive components of
electric current becomes large too.
Therefore, required apparent power for tan delta test would become high enough
which is not practical. So to keep the power requirement for this dissipation
factor test, very low-frequency test voltage is required. The frequency range for
tan delta test is generally from 0.1 to 0.01 Hz depending upon size and nature of
insulation.
There is another reason for which it is essential to keep the input frequency of the
test as low as possible.
As we know,

That means, dissipation factor tanδ ∝ 1/f.

Hence, at low frequency, the tan delta number is higher, and the measurement
becomes easier.
How to Predict the Result of Tan Delta Testing
There are two ways to predict the condition of an insulation system during tan delta
or dissipation factor test.
First, one is, comparing the results of previous tests to determine, the deterioration
of the condition of insulation due to aging effect.
The second one is, determining the condition of insulation from the value of tanδ,
directly. No requirement of comparing previous results of tan delta test.
If the insulation is perfect, the loss factor will be approximately the same for all
range of test voltages. But if the insulation is not sufficient, the value of tan delta

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 increases in the higher range of test voltage.

From the graph, it is clear that the tan and delta number nonlinearly increases with
increasing test very low-frequency voltage. The increasing tan delta, means, high
resistive electric current component, in the insulation. These results can be
compared with the results of previously tested insulators, to take the proper
decision whether the equipment would be replaced or not.

 Impulse Test
Lighting is a common phenomenon in transmission lines because of their tall
height. This lightning stroke on the line conductor causes impulse voltage. The
terminal equipment of transmission line such as power transformer then
experiences this lightning impulse voltages. Again during all kind of online
switching operation in the system, there will be switching impulses occur in the
network. The magnitude of the switching impulses may be about 3.5 times the
system voltage.
Insulation is one of the most important constituents of a transformer. Any weakness
in the insulation may cause failure of transformer. To ensure the effectiveness of
the insulation system of a transformer, it must confirms the dielectric test. But the
power frequency withstand test alone cannot be adequate to demonstrate the
dielectric strength of a transformer. That is why impulse test of transformer
performed on it. Both lightning impulse test and switching impulse test are
included in this category of testing.

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 Lightning Impulse
The lightning impulse is a pure natural phenomenon. So it is very difficult to
predict the actual wave shape of a lightning disturbance. From the data compiled
about natural lightning, it may be concluded that the system disturbance due to
natural lightning stroke, can be represented by three basic wave shapes.

 Full wave
 Chopped wave and
 Front of wave
Although the actual lightning impulse disturbance may not have exactly these three
shapes but by defining these waves one can establish a minimum impulse dielectric
strength of a transformer.

If lightning disturbance travels some distance along the transmission line before it
reaches the transformer, its wave shape may approach to full wave. If during
traveling, if flash-over occurs at any insulator of the transmission line, after the
peak of the wave has been reached, the wave may become in form of chopped
wave.
If the lightning stroke directly hits the transformer terminals, the impulse voltage
rises rapidly until it is relieved by a flash over. At the instant of flash-over the
voltage suddenly collapses and may form the front of wave shape.
The effect of these waveforms on the transformer insulation may be different from
each other. We are not going here in detail discussion of what type of impulse
voltage waveforms causes what type of failure in the transformer. But whatever
may be the shape of lightning disturbance voltage wave, all of them can cause
insulation failure in the transformer. So lightning impulse test of transformer is one
of the most important type test of transformer.

Switching Impulse
Through studies and observations reveal that the switching over voltage or
switching impulse may have front time of several hundred microseconds and this
voltage may be periodically damped out. The IEC – 600060 has adopted for their
switching impulse test, a long wave having front time 250 μs and time to half value
2500 μs with tolerances.

The purpose of the impulse voltage test is to secure that the transformer insulation
withstand the lightning overvoltage which may occur in service.

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Testing equipment

a) Impulse generator

Figure 1 – Basic circuit diagram of the impulse generator

Where:

 C1 – Impulse capacitor
 Rc – Charging resistor
 Rs – Series resistor
 Ra – Low-ohmic discharging resistor for switching impulse,
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  Rb – High-ohmic discharging resistor for switching impulse
 F1…Fn – Main spark-gaps,
 Fal…Fan – auxiliary spark-gaps
The impulse generator design is based on the Marx circuit. The basic
circuit diagram is shown on Figure 1 above. The impulse capacitors Cs (12
capacitors of 750 nF) are charged in parallel through the charging resistors Rc (45
kΩ) (highest permissible charging voltage 200 kV).

When the charging voltage has reached the required value, breakdown of the
spark-gap F1 is initiated by an external triggering pulse. When F1 breaks down,
the potential of the following stage (points B and C) rises. Because the series
resistor Rs is of low ohmic value compared with the discharging resistor Rb (4.5
kΩ) and the charging resistor Rc, and since the low-ohmic resistor.

Ra is separated from the circuit by the auxiliary spark-gap Fa1, the

potential difference across the spark-gab F2 rises considerably and the breakdown
of F2 is initiated. Thus the spark-gaps are caused to break down in sequence.

Consequently the capacitors are discharged in series-connection. The high ohmic

discharge resistors Rb are dimensioned for switching impulses and the low-ohmic
resistors Ra for lightning impulses. The resistors Ra are connected in parallel with
the resistors Rb, when the auxiliary spark-gaps break down, with a time delay of
a few hundred nanoseconds.
This arrangement is necessary in order to secure the functioning of the generator.

The required voltage is obtained by selecting a suitable number of series

connected stages and by adjusting the charging voltage. In order to obtain
the necessary discharge energy parallel or series-parallel connections of
the generator can be used. In these cases some of the capacitors are connected in
parallel during the discharge.

Max.test voltage amplitudes: 2.1 MV lightning impulse. 1.6 MV

switching impulse.

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Figure 2 – Equivalent diagram of the impulse test circuit

Where:

 Cr – Resulting impulse capacitance

 Rsr – Resulting series resistance
 Rar – Resulting discharge resistance
 Lr L p – Stray inductances
 Ci – Input capacitance of transformer
 Li – Transformer inductance
 C1 – Capacitance of voltage divider
 F1 – Spark gaps of impulse generator
 F2 – Calibration sphere gap
 R2 – Protective resistor.
The required impulse shape is obtained by selecting the series and
discharge resistors of the generator suitably.
The front time can be calculated approximately from the equation:

T1 ≈ 2.5 · Rsr · (Ci + C1) (formulae 1)

And the time to half value from the equation:

T2 ≈ k · √ (Li · Cr) (formulae 2)

The factor k depends on the quantities Rsr, Rar, Li and Cr. In practice the testing
circuit is dimensioned according to experience.

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Voltage measuring circuit
The impulse shape and the peak value of the impulse voltage are measured by
means of an oscilloscope and a peak voltmeter which are connected to the voltage
divider (Figure 3). The measuring range can be changed by short circuiting part
of the high voltage capacitors or changing the low voltage capacitor of the divider.

Figure 3 – The impulse voltage measuring circuit

Where:

 E – Damped capacitive voltage divider

 W – Measuring cable (= wave impedance = Rp)
 P1 – Oscilloscope
 P2 – Peak voltmeter
 Rp – Terminal resistance of the measuring cable
 R1 – Damping resistor of voltage divider
 C1 – High voltage capacitor of voltage divider
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  C2 – Low voltage capacitor of divider.
The measuring circuit is checked in accordance with the standards (formulae 2)
and (formulae 3). If necessary the sphere-gap calibration of the measuring circuit
can be performed in connection with the testing according to the standard (figure
4 below).

Transformer testing and fault detection connections

The lightning impulse test is normally applied to all windings. The impulse
frequency is applied successively to each of the line terminals of the tested
winding. The other line terminals and the neutral terminal are earthed (single
terminal test, Figure 4a and 4b).

Figure 4 – Transformer impulse testing and fault detection connections

Where:

 a, b – 1-terminal testing
 c – 3-terminal testing
 d – 2-terminal testing
 e – test with transferred voltages
 f – neutral terminal testing

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When testing low voltage windings of high power the time to half-value obtained
is often too short. However, the time to half-value can be increased by connecting
suitable resistors (Ra in Figure 4b) between the adjacent terminals and earth.

According to the standard IEC 76-3 the resistances of the resistors must be
selected so that the voltages at the adjacent terminals do not exceed 75 % of the
test voltage and the resistance does not exceed 500 Ω.
A delta-connected winding (and star-connected winding, unless the neutral is
available) is also tested with an impulse test-sequence applied to the line terminals
of the tested winding connected together, while the other windings are earthed
(three-terminal test, Figure 4c).

For delta-connected windings the single and three-terminal testing can be

combined by applying the impulse to two line terminals at a time, while the other
line terminals are earthed (two-terminal testing, Figure 4d). In this case two
phases are simultaneously tested in a single-terminal connection and one phase
in a test connection corresponding to three-terminal testing.

The two- and three-terminal testings are not included in the standard, but they can
be done if it is so agreed.

When the low voltage winding cannot in service be subjected to lighting

overvoltages from the low voltage system (e.g. step-up transformers, tertiary
windings) the low voltage winding may (by agreement between customer and
manufacturer) be impulse tested simultaneously with the impulse tests on the high
voltage winding with surges transferred from the high voltage winding to the low
voltage winding (Figure 4e, test with transferred voltages).

According to IEC 76-3 the line terminals of the low voltage winding are
connected to earth through resistances of such value (resistances Ra in Figure 4e)
that the amplitude of transferred impulse voltage between line terminal and earth
or between different line terminals or across a phase winding will be as high as
possible but not exceeding the rated impulse withstand voltage.
The resistance shall not exceed 5000 Ω. The neutral terminal is normally tested
indirectly by connecting a high-ohmic resistor between the neutral and earth
(voltage divider Ra, Ru) and by applying the impulse (Figure 4d) to the line
terminals connected together.

The impulse test of a neutral terminal is performed only if requested by the

customer.

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For fault detection in single-terminal and two-terminal tests the neutral of star-
connected windings are earthed via a low-ohmic resistor (Ru). The current
flowing through the detection resistor during the test is recorded by means of an
oscilloscope. Evidence of insulation failure arising from the test would be given
significant discrepancies between the calibration impulse application and the full
voltage applications in recorded current wave-shapes.

Certain types of faults give rise to discrepancies in the recorded voltage wave-
shapes as well.

For fault detection in three-terminal tests and tests on the neutral terminal the
adjacent winding is earthed through a low-ohmic resistor. The fault detection is
then based on recording the capacitive current which is transferred to the adjacent
winding.

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 Conclusion
Insulation is a very important part of transformer. Without insulation there are many
serious risks to transformer. Insulation oil acts as a major coolant in transformer and
also supresses arcs and corona. Paper insulation is mainly used for covering windings
and leadouts which protects from the risks of short circuits and also impregnates well
in oil. Pressboard is an insulation material used for clamping and also as an insulation
between winding and other components of transformers. It is also used in yoke
insulation and also acts as a spacer. Wood insulation acts as support in many places
and as core/coil clamps, core to coil packing and coil clamping ring.
30 % of failure in transformers after 15-20 years is due to failure on insulation. Hence,
insulation is a very significant part that should be maintained properly in a transformer.

Testing is also a mandatory process without which a transformer cannot be declared

fit to be installed for work. At every stage of manufacture, testing has to be done to
ensure that all parameter are matched and that the customer’s demands are met.
Various tests are done to check various important parameter such as transformer turn
ratio, no load loss, load loss, winding resistance, insulation resistance, tan delta
measurement, impulse withstand capability, magnetic balance of core etc. These
parameters are mandatory to be matching their specified values for the healthy working
of transformer. Keeping the transformer to dispatch without proper testing of all the
above parameter can be very risky.

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 REFERENCES
 www.bhel.com
 www.bheljhs.co.in
 “Transformers” by Bharat Heavy Electricals Limited.
 www.electrical4u.com
 www.re_india.com
 www.electrical-engineering-portal.com
 www.cicpl.in

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