Manufacturing 3-phase Transformer, LT Switchgear

and HT Switchgear at
Asian Powertec Co. LTD

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 Practicum Report
On

Manufacturing 3-phase Transformer, LT Switchgear

and HT Switchgear at
Asian Powertec Co. LTD

Prepared as a part of the fulfillment of the requirement of Bachelor of Science

in Electrical and Electronics Engineering Degree at IUBAT

IUBAT—International University of Business Agriculture and Technology.

Date: December 15, 2015

Prepared By

Ripon Matubbar
ID # 12105028
Department of Electrical & Electronics Engineering

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 Letter of Transmittal

December15,2015
To
Engr. Md. Abul Bashar
Faculty & Course Coordinator
Department of Electrical and Electronic Engineering
IUBAT- International University of Business Agriculture and Technology
4, Embankment Drive Road, Sector-10, Uttara, Dhaka-1230, Bangladesh

Dear Sir,

I have pleasure in submitting the practicum report on “Manufacturing 3-phase Transformer,

LT Switchgear and HT Switchgear”. According to your requirement I had worked on the
sector of 3phase transformer manufacture at Asian Powertec Co.LTD. It was a challenging work
because in our country Asian Powertec Co.LTD is the national dealer and servicing company of
Bangladesh.

I have tried my level best to prepare this report to the required standard. It was certainly a great
opportunity for me to work on this paper to actualize my theoretical knowledge in the practical
arena.

I express my heart full gratitude to you to go through this report and make your valuable
comments. It would be very kind of you, if you please evaluate my performance regarding this
report.

Thank you, for benevolent me the endorsement to do the research paper. I have learned a
lot of things with the passage of making this thesis. No doubt, these have enriched our
acquaintance.

Thank you
with regards

……………………………………….
Ripon Matubbar
ID: 12105028
Progam- BSEEE

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 Student Declaration

I am Ripon Matubbar ID: 12105028 student of the Department of Electrical and Electronics
Engineering under the College of Engineering and Technology (CEAT) would like to declare
that the project paper on “Manufacturing 3phase Transformer, LT Switchgear and HT
Switchgear” is prepared for the fulfillment of Practicum, as the partial requirements of academic
purpose from my own concept and idea, after completion of three months practicum in Asian
Powertec Co.LTD.

We also confirm that the report is only prepared to fulfill the academic requirement and not for
any other purposes.

Faithfully yours,

………………………………

Ripon Matubbar

ID: 12105028

Program: BSEEE

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 Acknowledgement

In the process of doing and preparing my practicum Report, I would like to pay our gratitude and
respect to some persons for their immense help and enormous co-operation.

First of all I would like to pay us gratitude to our respected faculty Engr. Md. Abul Bashar
Faculty and Course Coordinator of Electrical and Electronics Engineering Department of
IUBAT- International University of Business Agriculture and Technology. Who gave us the
opportunity to do the report on „„Manufacturing 3phase Transformer”.

Then I would like to pay my gratitude to Engr. Shamsur Rahman, Work shop Manager of
Asian Powertec Co.LTD. Who helped us a lot to prepare this report successfully.

Finally we would like to thank again to the respected Vice Chancellor Prof. Dr. M Alimullah
Miyan because he gave us the opportunity to study in such a beautiful university to acquire
knowledge on BSEEE that will be very helpful for my prospective career.

I would also like to thank all the faculty members of IUBAT and for their critical advice and
guidance.

I have given my best effort to prepare and represent the report. I hope my endeavor will be
beneficial to the audience and urge for exonerate eye for any mistake or error found in the report.

Yours truly,

………………………………………..

Ripon Matubbar

ID: 12105028

Program: BSEEE

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 Executive Summary

Transformer is the inseparable part of a power system. Proper functioning of transmission

and distribution cannot be possible without the transformer. For the stable and proper operation
of the power system transformer should be available.

Power Transformer was invented towards the end of nineteenth century. The invention of
transformer led to the development of constant power AC supply systems. Before the invention
of transformer DC systems were used for the supply of electricity. Installation of the power
transformers made the distribution system more flexible and more efficient.

Transformers are one of the most basic yet practical devices used today. It’s used
throughout alternating-current (AC) systems from generating plants. Power companies use
transformers to increase the voltage for their long distance power lines, the voltage is than
reduced by other transformers before the power enters.

A Transformer does not generate electrical power, it transfers electrical power. A

transformer is a voltage changer. Most transformers are designed to either step voltage up or to
step it down, although some are used only to isolate one voltage from another. The transformer
works on the principle that energy can be efficiently transferred by magnetic induction from one
winding to another winding by a varying magnetic field produced by alternating current. An
electrical voltage is induced when there is a relative motion between a wire and a magnetic field.
Alternating current (AC) provides the motion required by changing direction which creates a
collapsing and expanding magnetic field.

Transformers are used in the power system in order to step up or step down the voltages.
In the transmission end the voltage is stepped up and in the distribution side the voltage is
stepped down in order to reduce the power loss (i.e.) copper loss or I2R loss.

The current decreases with increase in voltage. Hence the voltage is stepped up at the
transmission end to minimize the transmission losses. At the distribution end the voltage is
stepped down to the required voltage in order as per the rating of the required load.

Transformer works on the principle of Faraday’s law of electromagnetic induction. Faraday’s

law states that, “Rate of change of flux linkage with respect to time is directly proportional to
the induced EMF in a conductor or coil”.

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 Tabel of content

Prefatory Part
TITLE FLY……………………………………………………………………………………………….. I

TITLE PAGE…………………………………..………………………………...……………………..…….…….II

LETTER OF TRANSMITTAL…….…………………………...….…………….………………...…..……... III

TO WHOM IT MAY CONCERN …….……………….....…………………………..…………...………….. IV

STUDENT‟S DECLARATION………………………...………………………………………..……………....V

ACKNOWLEDGEMENT…………………………………………………………..…………..……………… VI

EXECUTIVE SUMMARY……………………………………………………….………..…….……………..VII

TABLE OF CONTENT……………………………………………..……………………………….……….. VIII

LIST OF TABLES………………………………………………………………………………………………...XI

LIST OF FIGURES………………………………………………………….…………………………....…..…XII

Body Part
1.0.0 ORIGIN OF THE REPORT ............................................................................................................. 2

1.2.0 OBJECTIVE ...................................................................................................................................... 2

1.2.1 SPECIFICATION ............................................................................................................................ 2

1.3.0 SCOPE ................................................................................................................................................ 2

1.4.0 BACKGROUND OF THE STUDY .................................................................................................. 2

1.5.0 METHODOLOGY ............................................................................................................................ 3

1.5.1 PRIMARY SOURCE....................................................................................................................... 3
1.5.2 SECONDARY SOURCE ................................................................................................................ 3

1.6.0 DATA COLLECTION INSTRUMENTS ........................................................................................ 3

1.6.1 PRIMARY DATA COLLECTION ................................................................................................. 3
1.6.2 SECONDARY DATA COLLECTION ........................................................................................... 3

2.1.0 COMPANY PROFILE ...................................................................................................................... 5

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2.2.0 OUR VISION ..................................................................................................................................... 5

2.3.0 OUR MISSION .................................................................................................................................. 5

2.4.0 LOCATION ........................................................................................................................................ 6

2.5.0 CONTACT DETAILS ....................................................................................................................... 6

2.6.0 APPROVED BY ................................................................................................................................. 6

2.7.0 MEMBER ........................................................................................................................................... 6

3.1.0 BACKGROUND ................................................................................................................................ 8

3.2.0 SIGNIFICANCE .............................................................................................................................. 10

3.3.0 BASIC OPERATION OF TRANSFORMER ............................................................................... 11

3.4.0 E.M.F. EQUATION OF TRANSFORMER .............................................................................. 11

4.1.0 TRANSFORMER RATING IN KVA ............................................................................................ 14

4.2.0 STANDARD TRANSFORMER RATING .................................................................................... 14

4.3.0 SELECTION OF TRANSFORMER RATING............................................................................. 15

4.4.0 TYPES OF TRANSFORMER ........................................................................................................ 16

4.4.1 STEP-UP TRANSFORMER ......................................................................................................... 16
4.4.2 STEP-DOWN TRANSFORMER .................................................................................................. 17
4.4.3 THREE PHASE TRANSFORMER............................................................................................... 17
4.4.4 Single phase transformer ................................................................................................................ 17
4.4.5 POWER TRANSFORMER ........................................................................................................... 18
4.4.6 DISTRIBUTION TRANSFORMER ............................................................................................. 18
4.4.7 TWO WINDING TRANSFORMER ............................................................................................. 18
4.4.8 AUTO TRANSFORMER .............................................................................................................. 19
4.4.9 INDOOR & OUTDOOR TRANSFORMER ................................................................................. 19

5.0.0 CONSTRUCTION ........................................................................................................................... 21

5.1.0 CORE ............................................................................................................................................ 21
5.2.0 COIL ............................................................................................................................................. 25
5.2.1 SECONDARY COIL ................................................................................................................. 25
5.2.2 PRIMARY COIL ....................................................................................................................... 26
5.3.0 STRUCTURAL PARTS ............................................................................................................... 29
5.3.1 TANK ........................................................................................................................................ 29
5.3.2 TAP CHANGER ........................................................................................................................ 30
5.3.3 BUCHHOLZ RELAY................................................................................................................ 31
5.3.4 CONSERVATOR TANK .......................................................................................................... 34

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 5.3.5 TRANSFORMER OIL .............................................................................................................. 36
5.3.6 OIL LEVEL INDICATOR ........................................................................................................ 39
5.3.7 FANS AND RADIATOR .......................................................................................................... 40
5.3.8 SILICA GEL & BREATHER POT ........................................................................................... 40
5.3.9 BUSHING .................................................................................................................................. 42
6.1 Definition of Low Tension Switchgear …………………………......…………………………………….45
6.2 Component of Low Tension Switchgear…………………………………………………...…………..….46
6.2.1 Circuit Breaker…………………………………..…………..……………...………………………..….46
6.2.2 Bus bar……………………………………………………………………………………………...….....51
6.2.3 Current Transformer (CT) ………………………...……………….…..………… …………………..52
6.2.4 Ammeter……………………………………………………..…...……………...………...…………….53
6.2.5 Voltmeter….………………………...…………………..…………………………….…………………54
6.2.6 LT Cable…………………………………..……………………………………………………………..55

7.1 HT Switchgear…………………………………………………………………...…………………………….57

7.2 Component of HT Switchgear……………………………………………………..………………………..58

7.2.1 Vacuum Circuit Breaker………………………………………………………………….…………..…………………………58

7.2.2 High Rupturing Capacity (HRC) Fuse……………………………………….…………………………………………..59

8.0.0 PROBLEM AND PURPOSE………………………….……………..………..………………………...………………………..63

8.1.0 LOSSES IN TRANSFORMERS……………………………………………………………………………………….63

8.1.1 HYSTERESIS LOSS…………………………………………………………………………………………………..63

8.1.2 EDDY CURRENT LOSS…………………………………………………….………………………………………64

8.1.3 COPPER LOSS…………………………………………………………………………………………………………66

8.1.4 STRAY LOSS………………………………………………………………………..………………………………….67

8.1.5 DIELECTRIC LOSS…………………………………………………………..………………………………………67

8.2.0 TESTING OF TRANSFORMER ...…………………………………………..….……………….….67

8.2.1 OPEN CIRCUIT (OCC) TEST………………………………...………..…………...……………68

8.2.2 SHORT CIRCUIT (SC) TEST………………………………………………….…..……………………………..69

8.2.3 MEGGER TEST………………………………………………………………….………….……………………70

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9.0.0 MAINTENANCE OF TRANSFORMER ...................................................................................... 73
9.1.0 VIBRATION.................................................................................................................................. 73
9.2.0 GAS LIMITS ................................................................................................................................. 73
9.3.0 FANS AND RADIATORS ............................................................ Error! Bookmark not defined.
9.4.0 AGE ............................................................................................... Error! Bookmark not defined.

10.1.0 RECOMMENDATION…………………………………………………………………………………..76
10.2.0 CONCLUSION………………………………………………………….……………..…………….……………………………………76

SUPPLEMENTARY PART
11.1.0 BIBLIOGRAPHY………………………………………………………………………….……………..80

11.2.0 APPENDIX………………………………………………………………….………….………………….80

LIST OF TABLE
STANDARD APPARENT POWERS FOR MV/LV TRANSFORMERS AND RELATED NOMINAL
OUTPUT CURRENTS …………………………………………………………………………… ……..15

CONNECTING POINT OF COIL & TAP CHANGER……………..……………...………………………….31

PHYSICAL CONSTANTS OF TRANSFORMER OIL………………………………….……………………37

TOTAL CORE LOSS OF TRANSFORMER…………………………..……………………………………….65

PERMISSIBLE COPPER LOSS OF TRANSFORMER………………………………………………………67

PHASE TO PHASE MEGGER TEST RESULT…………………………….…………………………………70

PHASE TO EARTH MEGGER TEST RESULT……………………………….………………………………71

GAS LIMITATION INSIDE OF TRANSFORMER………………….………………………………………..74

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LIST OF FIGURE
PICTURE OF ASIAN POWERTEC CO. TDT……………..………………………………………………….. I

LAMINATION OF CORE………………………………………………………………….……………………..21

AFTER COMPLETE CORE LAMINATION…………………………..……………………………..………..24

3-PHASE TRANSFORMER COIL………………………………………………………………..……………..25

SECONDARY WINDING……………………….………………………………………………………………..25

PRIMARY COIL WINDING …………………………………….………………………………………………26

MAGNETICALLY COUPLED WINDING IN PARALLEL TO EACH OTHER ………………..….……28

TAP CHANGER ……………………………………………………………………………..……………………30

CONSERVATOR TANK……………………………………………………….…………………………………34

INTER SYSTEM OF CONSERVATOR TANK ………………………………………………………………34

TRANSFORMER OIL LOADING FROM DRUM ............................................................................................36

OIL LEVEL INDICATOR …………………………………………………………..……………………………39

FAN & RADIATOR OF TRANSFORMER ……………………………………...…………………………….40

SILICA GEL & BREATHER POT ………………………………………………...…………………………….41

BUSHING OF TRANSFORMER PRIMARY & SECONDARY ……………………………………………42

LOW TENSION SWITCHGEAR BOX …………………………………...……………………………………45

OIL CIRCUIT BREAKER …………………………………………………………….…………………………47

VACUUM CIRCUIT BREAKER ………………………………………………………………………………..49

BUS BAR …………………………………………………………………………………………….……………..51

CURRENT TRANSFORMER …………………………………...………………………………………………53

HT SWITCHGEAR BOX ……………………………………………………………………………….………..57

HRC CONSTRUCTION FUSE ………………………………………………………………………….……….59

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