INDUSTRIAL TRAINING ON

TRANSFORMERS & SWITCHGEARS

MANUFACTURING PROCESS

An Internship Report submitted in partial fulfillment of the requirements for

the Award of Degree of
Bachelor of Science in Electrical and Electronic Engineering

By
Md. Ashik Ali
ID: 2019000520014

Supervised by
Dr. Nahid Akhter Jahan
Associate Professor and Chairperson

DEPARTMENT OF ELECTRICAL AND ELECTRONIC ENGINEERING

SCHOOL OF SCIENCE AND ENGINEERING
SOUTHEAST UNIVERSITY
November 2022
 Certification
This is to certify that this Internship entitled “INDUSTRIAL TRAINING ON
TRANSFORMER & SWITCHGEARS MANUFACTURING PROCESS” is done by the
following students under my direct supervision and this work has been carried out by them in the
BENGAL TELECOMMUNICATION & ELECTRIC CORP. (PVT.) LTD. in partial
fulfillment of the requirements for the degree of Bachelor of Science in Electrical and Electronic
Engineering. The presentation of the work was held on 11 November, 2022.

Signature of the candidate

------------------------
Md. Ashik Ali
ID: 2019000520014

Countersigned

-------------------------------------------------
Dr. Nahid Akhter Jahan
Associate Professor and Chairperson
Department of Electrical and Electronic Engineering
Southeast University.

ii
Industrial Training Certificate

iii
The Internship entitled “TRANSFORMERS & SWITCHGEARS MANUFACTURING
PROCESS AT POWERMANN BANGLADESH LTD”, submitted by Md. Ashik Ali, ID No:
2019000520014, Session: Spring 2019 has been accepted as satisfactory in partial fulfillment of
the requirements for the degree of Bachelor of Science in Electrical and Electronic
Engineering on 11 November, 2022.

BOARD OF EXAMINERS

____________________________
Dr. Nahid Akhter Jahan Chairperson
Associate Professor and Chairperson
Department of EEE,
Southeast University.

____________________________
Engr. Abdullah Al Mahfazur Rahman Internal Member
Senior Lecturer & Coordinator
Department of EEE,
Southeast University.

____________________________
Dr. Nur Hosain Md. Ariful Azim Internal Member
Associate Professor & Coordinator
Department of EEE,
Southeast University.

iv
Dedicated to,

My Parents

Industrial Training is dedicated to My Parents. Without their endless love and encouragement, I
will never have been able to complete my graduate studies and research. I appreciate everything
that they have done for me.

v
 CONTENTS

List of Tables ix
List of Figures x-xi
List of Abbreviations xii
Acknowledgment xiii
Abstract xiv

Chapter 1: Introduction Of BETELCO 01-07

1.1 Introduction 01
1.2 Company Profile 01
1.2.1 Mission and Virion of BETELCO 02
1.2.2 Future Plan of BETELCO 02
1.2.3 BETELCO’s Product Features 03
1.3 Manufacturing Process of BETELCO 03
1.4 BETELCO Product Specification 03
1.5 BETELCO Switchgear Specification 05
1.6 Objective of Internship 07
1.7 Scope of Internship 07
1.8 Internship Report Outline 07

Chapter 2: Transformer 08-13

2.1 Introduction 08
2.2 Application of Transformer 09
2.3 Working Principle of Transformer 09
2.4 Types of Transformers 10
2.5 Distribution Transformer 10
2.5.1 HV Distribution Transformer 11
2.5.2 LV Distribution Transformer 11
2.6 Power Transformer 11
2.6.1 Step-Down Transformer 12
2.6.2 Step-Up Transformer 13
2.6.3 Auto Transformer 13

vi
Chapter 3: Transformer Components and Assembling 14-33

3.1 Components of Transformer 14

3.2 Outer Parts of Transformer 15
3.2.1 Bushing 15
3.2.2 Bushing Cap 16
3.2.3 Terminal 16
3.2.4 Temperature Meter 17
3.2.5 Radiator 18
3.2.6 Breather Pot 19
3.2.7 Conservator Tank 20
3.2.8 Horn Gap 21
3.2.9 Tapper 21
3.2.10 Intake Valve 22
3.2.11 Drain Valve 23
3.2.12 Buchholz Relay 23
3.2.13 LT and HT Rod 24
3.2.14 Gasket 25
3.3 Inside Components 25
3.3.1 Core 25
3.3.1. a Making of Core in Machine 26
3.3.1. b Core Assembling 26
3.3.2 Coil Winding 27
3.3.2. a Primary Winding 28
3.3.2. b Secondary Winding 29
3.3.2. c Making of Windings 30
3.3.2. d Coil Assembly 31
3.3.2. e Delta Connection 31
3.3.2. f Star Connection 31
3.3.3 Transformer Oil 32
3.3.4 Insulating Materials 32
3.4 Final Assembly 33

Chapter 4: Transformer Testing 34-39

4.1 Introduction 34
4.2 Testing of Transformer 34
4.2.1 Insulation Resistance Test (Megger Test) 35
4.2.2 Ratio Test 35

vii
4.2.3 Winding Resistance Test 36
4.2.4 Vector Group Test 37
4.2.5 No Load Test 38
4.2.6 Full Load Test 39
4.2.7 High Voltage Test 39

Chapter 5: Switchgear 40-56

5.1 Introduction 40
5.2 HT Panel 40
5.2.1 Main Function of this Panel 41
5.2.2 Parts of HT Switch Gear 41
5.2.2. a Load Break Switches (LBS) 42
5.2.2. b Vacuum Circuit Breaker (VCB) 43
5.2.2. c Current Transformer (CT) 44
5.2.2. d Potential Transformer (PT) 44
5.2.2. e Ammeter 45
5.2.2. f Voltmeter 46
5.2.2. g Selector Switch 46
5.2.2. h Thermostat 47
5.2.2. i Bus Bar 47
5.2.2. j Push Button Switch 48
5.2.2. k Indicator Lamp 48
5.2.2. l IDMT Relay 49
5.3 LT Panel 49
5.3.1 The Main Parts of LT Panels 50
5.3.2 Circuit Breakers 50
5.3.2. a ACB 50
5.3.2. b MCCB 51
5.3.2. c MCB 52
5.4 PFI Panel 52
5.4.1 HRC 54
5.4.2 MC 54
5.4.3 APFC Relay 55
5.4.4 Power Capacitor 55

viii
Chapter 6: Conclusions 57-58

6.1 Internship Experience 57

6.2 Limitations in Internship 57
6.3 Safety Guidelines 57
6.4 Difference Between Theory Course and Internship 58
6.5 Conclusion 58

References 59

LIST OF TABLES

Table Table Caption Page

1.1 Profile of BETELCO 02

1.2 Specification of 11000/4l5V 3 Phase TR 04
1.3 Specification of 33000/4I5V 3 Phase Transformer 05
1.4 Specification of Switchgear Panel 06
Standard transformer Capacity for Required PFI
5.1 56
Panel KVA of 60%(KVAR)

ix
 LIST OF FIGURES

Figure Conclusions Page

1.1 BETELCO Factory at Pager, Tongi, Gazipur 02

2.1 Transformer 08
2.2 Power Transformer 11
2.3 Basic Step-Down Transformer 12
2.4 Basic Step-Up Transformer 13
3.1 Transformer Composition 14
3.2 HT Bushing 15
3.3 LT Bushing 15
3.4 Bushing Cap 16
3.5 Internal View of Terminal 16
3.6 Top View Terminal of Transformer 17
3.7 Temperature Meter 17
3.8 Temperature Meter in Power Transformer 18
3.9 Transformer Radiator 18
3.10 This radiator is madding 19
3.11 Breather Pot with Silica Gel 20
3.12 Silica Gel Breather Used in Power Transformer 20
3.13 Conservator Tank 21
3.14 Horn Gap 21
3.15 Tapping Switch 22
3.16 Open View of Tapping Switch Installing in Transformer 22
3.17 Intake Valve 23
3.18 Drain Valve 23
3.19 Buchholz Relay 24
3.20 LT and HT Rod 24
3.21 Gasket 25
3.22 Core 25
3.23 Core Slitting Machine 26
3.24 Core Assembling 27
3.25 LT Coil 28
3.26 LT Coil Winding 28
3.27 HT Coil 29
3.28 HT Coil Winding 29
3.29 Coil Winding Machine 30
3.30 Coil Assembling 31

x
3.31 Final Assembly 33
4.1 Transformer Testing 34
5.1 HT Panel 41
5.2 LBS 42
5.3 VCB 43
5.4 CT 44
3.5 PT 45
3.6 Ammeter 45
3.7: Voltmeter 46
3.8: Selector Switch 47
3.9: Bus Bar 47
3.10: Push Button Switch 48
3.11: Indicator Lamp 48
5.12 LT Panel 49
5.13 ACB 51
5.14 MCCB 51
5.15 MCB 52
5.16 PFI Panel 53
5.17 HRC 54
5.18 Magnetic Contactor 55
5.19 APFC Relay 55
5.20 Power Capacitor 56

xi
 LIST OF ABBREVIATIONS

SEU Southeast University

EEE Electrical And Electronic Engineering
EMF Electromotive Force
MMF Magneto Motive Force
HT High Tension
LT Low Tension
LBS Load Break Switch
VCB Vacuum Circuit Breaker
CT Current Transformer
PT Potential Transformer
LVDT Low-Voltage Distribution Transformers
IDMT Inverse Definite Minimum Time
ACB Air Circuit Breaker
MCB Miniature Circuit Breaker
MCCB Molded Case Circuit Breaker
LV Low Voltage
HV High Voltage
V Voltage
C Current
PFI Power Factor Improvement
MC Magnetic Contactor
APFC Automatic Power Factor Control
HRC High Rupturing Capacity

xii
 ACKNOWLEDGEMENT

First of all, I give thanks to Allah. Then I would like to take this opportunity to express our
appreciation and gratitude to our internship supervised Dr. Nahid Akhter Jahan, Associate
Professor and Chairperson of Department of EEE for being dedicated in supporting,
motivating and guiding us through this internship. This internship can’t be done without his
useful advice and helps. Also thank you very much for giving me opportunity to choose this
internship.
I also want to convey our thankfulness to Dr. Nur Hosain Md. Ariful Azim, Associate
Professor & Coordinator of the Department of EEE for her help, support and constant
encouragement.

Apart from that, I would like to thank Engr. Zakaria Hossain, General Manager
(Production), BENGAL TELECOMUNICATION & ELECTRIC CORP. (PVT.) LTD. for
sharing knowledge, information and helping me in making this project a success.

To my beloved family, I want to give them my deepest love and gratitude for being very
supportive and also for their inspiration and encouragement during my studies in this University.

xiii
 ABSTRACT
During a period of two months training at Bengal Telecommunication & Electric Corp. (Pvt.)
Ltd. At Tongi, Gazipur. I have been achieved the practical experience thought observing the
Transformer and Switchgears manufacturing process. The aim and motivation of this industrial
training is to receive discipline, skills, teamwork and technical approach to problem solving,
based on a broad understanding of process and mode of operation of organization. Brief
discussion on transformer, switchgear, power generation, transmission and distribution process
etc are described in this internship report.

xiv
 Chapter-1
Introduction

1.1 Introduction
Industrial training is an important phase of a student's life. A well-planned, properly executed,
and evaluated industrial training helps a lot in developing a professional attitude. I have been
achieved for training at Bengal Telecommunication and Electric Corp. (Pvt.) Ltd. BETELCO
Bangladesh offers customers a complete substation and the transformer is one of the key items
on which the company has achieved a milestone in quality. Due to this, the company has earned
good faith from more than thousands of Private entrepreneurs and Government policy makers.

1.2 Company Profile

BETELCO (Bengal Telecommunication and Electric Corp. (Pvt.) Ltd.) is based in Dhaka,
Bangladesh. It was established in October, 1991. Initially activities of BETELCO were focused
in both Telecommunication and Power sectors. Over time focus of BETELCO has shifted away
from telecommunication related work and more to power side. Batelco is one of the largest
manufacturers of distribution-transformer in the country. Activities of BETELCO include:
manufacturing of power and distribution transformers and related substation equipment.

From government sector BPDB, DPDC, BREB and PGCP are clients of BETELCO. And from
private sectors T.K. Group, VF Asia, BRAC, BIRDS group, DEKO Group etc are clients of
BETELCO. Main factory of BETELCO is located in Pagar, Tongi, Gazipur where they
manufacture transformers and assemble switchgear panels. Major raw materials they use are
Silicon Steel (for the core), Copper (for the coils), and transformer-grade oil which is imported
from reputable sources from around the world. Switchgear components are sourced from brands
such as ABB, LG/LS, SIEMENS, Togami, FRAKO, Suzuki, EPCOS, Ducati and many others.

Page | 1
 Table 1.1: Profile of BETELCO
Name Bengal Telecommunication and Electric
Corp. (Pvt.) Ltd.
Year of establishment 1991
Corporate office Bijoy Nagar, Dhaka.
Factory Pagar, Tongi, Gazipur.
Main work Manufacturing Transformers and
Switchgear Panels.

Figure 1.1: BETELCO Factory at Pager, Tongi, Gazipur.

1.2.1 Mission and Virion of BETELCO

Betelco’s mission is continuous improvement of product and services. They aspire to be a

leading export-oriented company in terms of the products manufacture by them.

1.2.2 Future Plan of BETELCO

Betelco’s future plan is to grow their business and make it better. They will increase their
productivity and enhance effectiveness.

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1.2.3 BETELCO’s Product Features

• Quality assured
• Cost competitive
• Designed for engineering efficiency
• After-sales service on call
• Universal mounting/moving facilities
• Warranted

1.3 Manufacturing Process of BETELCO

1. Making of the Core.
2. Coil Winding.
3. Core and Coil Assembling.
4. Transformer Body Making.
5. Installing Cores & Coil inside the Body.
6. Final Assembly.
7. Necessary Safety Equipment Attaching and Testing.

1.4 BETELCO Product Specification

During manufacturing transformer routine test are carried out. Each transformer is issued with an
official test certificate and an oil test report.

Transformers comply with the following specifications:

• Three-Phase transformers, for indoor or outdoor use (installation to be specified).
• Step-Down type, Step-Up on request.
• Rated frequency: 50Hz, 60Hz on request.
• Maximum ambient temperature 40°C.
• Mineral oil immersed (Other dielectric on request).
• Breathing-type transformers with integral filling.
• Cover bolted-on tank and final color BETELCO Medium-Grey.
• Standard anti-corrosion surface treatment and coating.

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 Table 1.2: Specification of 11000/4l5V 3 Phase Transformer.
Capacity Losses % % Out Line Oil Total
(KVA) (W) Regulation Efficiency Dimensions (Liters) Weight (kg)
at Unity at Unity Approx.(cm)
NO Load Power Power
at 70°C Factor Factor
Load

At full H L W
Load
50 150 925 1.68 97.85 118 94 58 140 580
100 245 1700 1.62 98.05 132 100 63 180 650
150 320 2412 1.40 98.17 145 105 88 220 900
200 435 2880 1.20 98.37 150 112 93 2S0 975
250 520 3265 1.22 98.48 158 113 95 270 1100
315 580 4500 1.15 98.38 157 120 97 350 1250
400 722 5420 1.10 98.44 162 123 98 390 1450
500 865 6275 1.05 98.57 165 124 102 425 1725
630 920 7740 0.98 98.62 170 136 103 500 1970
750 1150 8850 0.94 98.66 185 155 112 625 2250
800 1300 9800 0.96 98.61 225 170 113 650 2575
1000 16â0 11600 0.99 98.67 215 185 115 800 2850
1250 1820 12300 0.95 98.87 225 190 116 1000 3725
1500 2100 13275 0.87 98.97 230 200 120 1200 4300
2000 2650 16470 0.83 99.04 250 210 135 1450 4750
2500 3140 19700 0.82 99.08 285 220 150 1800 5600
3000 3420 22860 0.77 99.12 300 230 170 2050 6350

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 Table 1.3: Specification of 33000/4I5V 3 Phase Transformer.
Capacity Losses % % Out Line Oil Total
(KVA) (W) Regulation Efficien Dimensions (Liter) Weight
at Unity cy Approx. (CM)
NO Load
power at Unity
Load at 70°C
Factor Power
Factor
H L W
100 269 1706 1.60 98.45 133 102 63 198 79
150 340 2530 1.42 98.08 146 107 88 240 95
200 465 2950 1.63 9819 151 114 93 285 101
250 580 3340 1.20 98.43 155 116 95 360 114
315 640 4725 118 98.29 158 122 97 245 130
400 750 5760 1.13 98.37 163 125 98 495 152
500 900 6500 1.10 9852 167 127 102 560 1800
630 975 8125 0.95 98.55 172 138 103 700 2020
750 1240 9200 0.92 98.60 l87 158 112 785 334
800 135O 10000 0.90 98.58 202 173 113 820 267
1000 1725 12100 0.97 98.61 220 188 115 870 296
1250 1880 12950 0.93 98.81 227 193 116 1150 385
1500 2200 13940 0.85 98.92 232 195 120 1260 4425
2000 2750 17300 0.86 98.99 253 197 135 1510 4870
2500 3400 20700 0.83 98.03 287 203 150 1865 573
3000 3575 24000 0.79 99.08 303 233 170 2150 6475

1.5 BETELCO Switchgear Specification

BETELCO make various types of switchgear panel accosting to client’s requirement The table
below shows the specification of HT, LT and PFI switchgear.

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 Table 1.4: Specification of Switchgear Panel
Components Rated Rated Current in Power Rated Standard
Voltag Busbar Frequency Frequency
e (kV) Withstand (Hz)
(A) Voltage
(kV/1min)

LBS 12 6307800/1250 28
HT from 315
Switchgear KVA
(630A-
1250A) Up to 630
KVA
Substation 50 IEC

VCB
above
630kVA
Substation

LT TP ACB 0.415 1000/1500/2000 3

Switchgear TP MCCB
(25A-6300A)
TP MCB
SP MCB
PFI Plant Capacitor 0.415 500/1000/2000 3
(1OKVAR- PFC Relay
3400 KVAR)
Magnetic
Contactor

Page | 6
1.6 Objective of Internship
The objectives of this internship are as follows:

• To develop discipline, skills and practical knowledge through this training.

• To implement the technical knowledge in accordance with the theoretical
knowledge.
• To gather practical knowledge on transformer design, manufacturing and testing process.
• To gather practical knowledge on substation arrangement, switchgear
manufacturing and their operating process.
• To adjust myself with a challenging environment.

1.7 Scope of Internship

Bengal Telecommunication and Electric Corp. (Pvt.) Ltd. gives us the opportunity to learn and
work independently in various sections. All the staff of BETELCO Bangladesh ltd are friendly
and cooperate with all our activities. They provide us with information and help us do practical
work like several tests of the transformer, and connection of switchgear panel are done by us
correctly. We completed our internship in twenty-eight days. Based on the experience of this
internship and our academic knowledge we have prepared this report.

1.8 Internship Report Outline

This Internship report is organized as follows:

Chapter 1: Introduces to the Bengal Telecommunication and Electric Corp. (Pvt.) Ltd.
Chapter 2: Describes the transformer and types.
Chapter 3: Discuss transformer’s components and assembling.
Chapter 4: Discuss of transformer testing.
Chapter 5: Discuss about switchgear, equipment of switchgear and their operations.
Chapter 6: Conclusions with some discussion.

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 Chapter-2
Transformers

2.1 Introduction
The transformer is a static device that transforms electrical energy from one circuit to another
without any direct electrical connection. It works on the principle of mutual induction. Although
the primary and secondary windings are electrically isolated from each other are magnetically
linked through the common core allowing electrical power to be transferred from one coil to the
other. It transfers power from one circuit to another without changing its frequency but may be
in different voltage or current levels. Transformers are capable of either increasing or decreasing
the voltage and current levels of their supply, without modifying their frequency, or the amount
of electrical power being transferred from one winding to another via the magnetic circuit.
Because there is no moving part its efficiency is very high about 97%. It needs lower
maintenance, as compared to other devices. Transformers are an important component in our
current life and they make large power systems possible. Transformers are employed in both
electrical and electronics systems for widely varying purposes.

Figure 2.1: Transformer

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2.2 Application of Transformer
To reduce the voltage of conventional power circuits to operate low-voltage devices and to raise
the voltage from electric generators so that electric power can be transmitted over long distances.
To effectively transfer hundreds of megawatts of power over long distances, it would be
impossible to develop High-frequency transformers are used in medical X-ray power supply and
welding machines. Rotary transformers are used for high-speed motors; generators. Pulse
transformers are one of the most used PCB-mounted transformers that produce electrical pulses
in a constant amplitude. It is used in various digital circuits. The audio transformer is used in
audio related applications where impedance matching is required it balances the amplifier circuit.
Transformers can also be used as a protection device from faults.

2.3 Working Principle of Transformer

The transformer works on the principle of Faraday’s law electromagnetic induction and mutual
induction. The transformer consists of two separate windings placed over the laminated silicon
steel core. Winding to which AC supply is connected is called primary winding and to which
load is connected is called secondary winding. It works on the alternating current only because
an alternating flux is required for mutual induction between the two windings. When the AC
supply is given to the primary winding with a voltage an alternating flux sets up in the core of
the transformer, which links with the secondary winding and as a result of it, an E.M.F. is
induced in it called mutually Induced E.M.F. The direction of this induced E.M.F. is opposite to
the applied voltage. This is because of Lenz’s law which states that induced electromotive force
with different polarities induces a current whose magnetic field opposes the change in magnetic
flux through the loop to ensure that the original flux is maintained through the loop when the
current flows in it. The induced E.M.F in the primary and secondary windings depends upon the
rate of change of flux linkage. Physically, there is no electrical connection between the two
windings, but they are magnetically connected. Therefore, the electrical power is transferred
from the primary circuit to the secondary circuit through mutual inductance. The induced E.M.F
in the primary winding is proportional to the number of turns of the primary windings. Similarly
induced E.M.F in the secondary winding is proportional to the number of turns on the secondary

Page | 9
side. If there are more turns on the primary coil than on the secondary coil then the voltage will
decrease (step down). If there are fewer turns on the primary coil than on the secondary coil then
the voltage will increase (step up).

2.4 Types of Transformers

In a transformer there are two types of winding arc couples through a magnetic medium.

These two windings work at different voltage level called,

a) High voltage winding and

b) Low voltage winding

These two types of windings are wound on a common core. One is connected to AC supply and
it is called primary. The other winding is connected to load and it is called secondary. The
transformer is used to transfer electrical energy from high voltage winding to low voltage
winding or vice-versa through magnetic field. The construction of transformers varies greatly,
depending on their applications, winding voltage and current ratings and operating frequencies.

The two major types of construction of transformers are:

c) Core type Transformer and

d) Shell type Transformer

BETELCO mainly produces core type transformers because it is cheaper than shell type. Now
core type is widely used in industries.

2.5 Distribution Transformer

A pole-type distribution transformer is used to supply relatively small amounts of power to
residences. It is used at the end of the electrical utility's delivery system.

1. HV Distribution Transformer
2. LV Distribution Transformer

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2.5.1 HV Distribution Transformer

High voltage transformers convert voltages from one level or phase configuration to another,
usually from higher to lower. They can include features for electrical isolation, power
distribution, and control and instrumentation applications. The kind of transformer design
depends on the principle of magnetic induction between oils to convert voltage and/or current
levels. They can be configured us either a single-phase primary configuration or a three-phase
configuration. The size and cost of a transformer increases when you move down the listing of
primary high power voltage windings.

2.5.2 LV Distribution Transformer

Low-voltage distribution transformers (LVDT) are generally used inside buildings to reduce
voltage to the values necessary to power appliances, lighting and other products.

2.6 Power Transformer

A power transformer is a static machine used for transforming power horn one circuit to another
without changing the frequency. As there is no rotating or moving parts, a transformer is
classified as a stack device. Transformer operates on an AC supply.

Figure 2.2: Power Transformer

Page | 11
Power Transformers ere larger in size and used to transfer the energy to the substation or the
public electricity supply. This transformer acts ae a bridge between the power generator and the
primary distribution grid. Depending on the Power rufin8 and specification, Power transformer
can further-be classified into three categories:

1. Small Power Transformer

2. Medium Power Transformer
3. The Large Power Transformer

The rating can be more dun 30KVA to the 500•700KVA or in some cases that can be equal to or
more than 7000KVA for small rated power transformer. The medium rated power transformer
can be up to 50-100 MVA whereas large rated power transformer is capable to handle more than
1OOMVA.

2.6.1 Step-Down Transformer

A Step-down Transformer is a device which converts high primary voltage to a low secondary
voltage. In a Step-down Transformer, the primary winding of a coil has more turns than the
secondary winding. A step-down transform has a wide variety of applications in electrical
systems and transmission lines.

Figure 2.3: Basic Step-Down Transformer

Page | 12
2.6.2 Step-Up Transformer

A step-up transformer is a type of transformer that converts the low voltage (LV) and high
current from the primary side of the transformer to the high voltage (HV) and low current value
on the secondary side of the transformer. The reverse of this is known as a step-down
transformer. A transformer is a piece of static electrical equipment which transforms electrical
energy (from primary side windings) to the magnetic energy (in the transformer’s magnetic core)
and again to the electrical energy (on the secondary transformer side). A step-up transformer has
a wide variety of applications in electrical systems and transmission lines.

Figure 2.4: Basic Step-Up Transformer

2.6.3 Auto Transformer

The auto transformer is a special type of power transformer. It consists of a single, continuous
winding that is tapped on one side to provide either a step-up or a step-down function This is
different from a conventional two-winding transformer, which has the primary and secondary
completely isolated from each other, but magnetically limped by a common core. The
autotransformer's windings are both electrically and magnetically interconnected.

An auto transformer is initially any in similarly-rated two-winding transformer has better

regulation (smaller voltage drops), and greater efficiency. Furthermore, it can be used to obtain
tire neutral wire of a three-wire 240/120-volt service, just like the secondary of a two-winding
transformer. The autotransformer is considered unsafe for use on ordinary distribution circuits.
This is because the high-voltage primary circuits arc connected directly to the low-voltage
secondary circuit.

Page | 13
 Chapter-3
Transformer Components and Assembling

3.1 Components of Transformer

Transformers are used to transfer electrical energy from one circuit to another through
electromagnetic induction. They are used either to step-up or step-down voltage levels. A
transformer is made of several different parts that function in their own different ways to
enhance the overall functioning of a transformer. These include core, windings, insulating
materials, transformer oil, tap changer, conservator, breather, cooling tubes, Buchholz Relay and
explosion vent.

Figure 3.1: Transformer Composition

Page | 14
3.2 Outer Parts of Transformer

3.2.1 Bushing

In electric power, a bushing is a hollow electrical insulator. It allows an electrical conductor to

pass safely through a conducting barrier such as the case of a transformer or circuit breaker
without making electrical contact with it. Typically, a bushing is made from porcelain.

In a Transformer the HT-side bushing I larger in size than a LT-side bushing. Because in LT side
the power is less than the HT side.

Here is a real-life transformer bushing pictures are given bellow.

Figure 3.2: HT Bushing

Figure 3.3: LT Bushing

Page | 15
3.2.2 Bushing Cap
Bushing cap are used top of the Bushing of a transformer to tight it up. And after installing the
cap it colored for identifying the phases of the transformer.

Typically, the HT bushing cap is larger than the IT bushing cap. Here are the pictures given

Figure 3.4: Bushing Cap.

3.2.3 Terminal

A terminal of a Transformer where the phase is connected. This terminal number may vary based
on the internal connection of' the transformer. In our practical lesson the connection was, A-
connection in the primary winding and Y-connection the Secondary winding. So, in total we
need 7 terminals where 3 terminals for HT-side and 4 terminals for the LT-side and neutral.

Figure 3.5: Internal View of Terminal

Page | 16
 Figure 3.6: Top View Terminal of Transformer.

3.2.4 Temperature Meter

A temperature indicator of power transformer is specially designed for protection of transformer

in addition to its temperature indication and cooling control features.

Typically, there are three kind of temperature meter used in a transformer. They are,

1. Oil temperature indicator (OTI)

2. Winding temperature indicator (WTI)
3. Remote temperature indicator (RTI)

But in BETELCO they only use the oil temperature indicator which shows us the oil temperate
during the operation.

Figure 3.7: Temperature Meter

Page | 17
 Figure 3.8: Temperature Meter in Power Transformer

3.2.5 Radiator

The Radiator of Transformer accelerates the cooling rate of Transformer. Thus, it plays a vital
role in increasing loading capacity of Transformer. Cooling of Transformer Oil is the basic and
mciv purpose of Radiator.

Because of flow of electric current through the winding of Transformer and due to core losses,
heat is produced in the windings and core. Because of this heat the temperature of Transformer
oil increases. Therefore, if the temperature rises of the Transformer insulating oil is controlled,
the rating of Transformer can be extended up to significant limit.

Figure 3.9: Transformer Radiator

Page | 18
This radiator is made from a Steel banding machine. And the below machine is used for this
application.

Figure 3.10: This Radiator is Madding

3.2.6 Breather Pot

During tire breathing cycle of a transformer, it is crucial to prevent atmospheric moisture from
entering the transformer, which can contaminate the oil and cause damage over time to internal
parts. And in the breather pot silica get is present which capture the moisture from the
atmosphere.

The transformer windings are insulated with cellulose paper and fully submerged in insulating
oil, both of which have very high dielectric strength. When tire insulating oil becomes
contaminated with moisture, it can cause a number of issues inside the transformer.

But when the moisture enters in the tank it decreases in the dielectric strength of the oil and
cellulose, accelerated breakdown of the insulating cellulose paper increasing the risk of partial
discharge, increased risk of bubble formations at higher temperature. and the condensation or
accumulation of this moisture during cooling which can causes corrosion inside the tanks leading
to further problems.

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 Figure 3.11: Breather Pot with Silica Gel

Figure 3.12: Silica Gel Breather used in Power Transformer

3.2.7 Conservator Tank

This is a cylindrical tank mounted on supporting structure on the roof the transformer main tank.
The main function of conservator tank of transformer is to provide adequate space for expansion
of oil inside the transformer.

When transformer is loaded and when ambient temperature rises, the volume of oil inside
transformer increases. A conservator tank of transformer provides adequate space to this
expanded transformer oil. It also acts as a reservoir for transformer insulating oil. And the
conservator is not fully filled. Because if it is fully filled then the camber will blast when the
temperature of the oil increases.

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 Figure 3.13: Conservator Tank

3.2.8 Horn Gap

The spark gap between the horn conductors is maintained to avoid the arc Under Normal
condition. During lightning condition, the voltage in the transmission conductors is increased.
Hence this high voltage ionizes further the air surrounding insulator.

Figure 3.14: Horn Gap

3.2.9 Tapper

Tapper is the part where we can get different voltage by switching. Typically, in a transformer
there are 5 tapping point where we can change the voltage level in the primary winding. These

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tapping connections are constructed in the primary winding. This is the outer part of tapping
switch.

Figure 3.15: Tapping switch.

Figure 3.16: Open View of Tapping Switch Installing in Transformer

3.2.10 Intake Valve

From the intake valve the oil are putting in the transformer and during this process it make sure
that the conservator is half filled.

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 Figure 3.17: Intake Valve

3.2.11 Drain Valve

Through the drain valve the oil of the transformer is drained. When the viscosity of the oil is
damaged due to long term use it is necessary to change the oil and then it need to drain from the
tank.

Figure 3.18: Drain Valve

3.2.12 Buchholz Relay

This relay is mechanical relay of transformer. This relay is directly connected with the
transformer. When there is a fault in the HT-side and the transformer operating for a long time in
that situation, the oil started heating and the level of oil is starts to rise. There is limit fixed in the
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Buchholz relay and when the rising oil reach the level then the Buchholz relay mechanically
open the transformer and safe the transformer.

Figure 3.19: Buchholz Relay

3.2.13 LT and HT Rod

These rods are used as terminals of transformer. Transformer power and load is connected to this
rod. Thickness of the rods depends on current flow. These are solid rods and made with brass.

Figure 3.20: LT and HT Rod

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3.2.14 Gasket

Gasket are used in between the transformer tank and the top head to make sure that through this
connection there is no leakage.

Figure 3.21: Gasket

3.3 Inside Components

3.3.1 Core

The transformer core is designed to provide a path for the magnetic field to flow around. This
magnetic path is necessary for the induction of voltage between the two input and output
windings. It is also used to support the windings. Core materials should have a low reluctance
path to the flow of magnetic flux to reduce Hysteresis loss. To reduce eddy current loss stack of
the thin sheet is used. Therefore, Core is made of soft iron or thin stacks of silicon sheets which
have the best properties for reducing hysteresis loss.

Figure 3.22: Core

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3.3.1.a Making of Core in Machine

Transformer Core Cutting Machine is used for developing silicon pieces in different shapes and
sizes with hole punching and V notching. This machine is providing excellent performance when
it comes to cut silicon steel coils into different lamination strips to be further used in welding
machine cores, transformer cores, reactor cores, etc. It is designed with a swing shear and PLC
control to ensure full automation process for availing different angles, hole positions, cutting
lengths and V notching position. The machine is designed with highly powerful servo motor
feeding. In addition, it is designed with servo motor punching and cutting features. Its touch
screen operation makes the process simpler and more efficient. With easy-to-use screen, users
can easily set the cutting shapes as well as parameters. Moreover, it can be designed with a fully-
automatic lamination separating as well as stacking device as options according to the demands
of the users.

Figure 3.23: Core Slitting Machine

3.3.1.b Core Assembling

The core assembly is done manually. The core frame is set according to the size of the cores. On
top of which core will be assembled. Cores are stacked alternately to each other to produce an
overlapping joint with more lamination pairs being added to make up the correct core thickness.
Cores can be further divided into side limb, center limb, top yoke, and bottom yoke. B core is
referred to as s Center limb, a core as the side’s limbs, and C core as the top and bottom yokes.
Center limbs are placed first then the top and bottom yokes are set in a way that the Center limb

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is set in the pocket of yokes. The side limbs are placed. This process is carried out. The core is
knotted tightly with cotton straps after assembly is finished.

Figure 3.24: Core Assembling

3.3.2 Coil Winding

Transformers have two windings, the primary winding, and the secondary winding. The power
source is connected to the primary winding the Load is connected to the secondary winding.
Normally secondary windings are kept inside of primary winding. So that tap changing operation
can be done easily. In the power transformer, both primary and secondary connection is
connected in the delta. In the case of distribution, the transformer primary is connected in delta,
and secondary windings are connected in star connection. Windings consist of several coppers or
aluminum coil turns bundled together, each bundle connected to form a complete winding.
Mostly These windings are made of copper due to high conductivity and ductility. High
conductivity minimizes the amount of copper needed and minimizes losses. Moreover, high
ductility results in easy bending of conductors into tight winding around the core. The turns
dependents on the required voltage or current level.

Page | 27
3.3.2.a Primary Winding

A step-up transformer such as this one will have fewer turns on the primary side than there are
on the secondary winding. The current in the primary winding will be much larger than the
current in the secondary winding. If we consider a simple case of a single-phase transformer, the
input will be 440 volts and, for example, 100 amps. The output from the secondary winding will
be 11000 volts and 4 amps. There could be 440 turns on the primary winding and 11000 turns on
the secondary winding.

Figure 3.25: LT Coil

Figure 3.26: LT Coil Winding

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3.3.2.b Secondary Winding

A step-up transformer such as this one will have more turns on the secondary side than there are
on the primary winding. The current in the secondary winding will be much less than the current
in the primary winding.

If we consider a simple case of a single-phase transformer, the input will be 440 volts and, for
example, 100 amps. The output from the secondary winding will be 11000 volts and 4 amps.
There could be 440 turns on the primary winding and 11000 turns on the secondary winding.

Figure 3.27: HT Coil

Figure 3.28: HT Coil Winding

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3.3.2.c Making of Windings

Transformer coils are wound in a form. Before wounding insulating paper is wrapped around the
form and several Cotton stapeses are placed horizontally. Then the wire is wounded over the
stripes and insulation paper. Wires should be tightly closed together. To do so cotton straps are to
create an axial force to tighten the wire. No wires should be overlapping this should be taken
care of. After finishing one layer and before starting another layer insulation paper and cotton
stripes are placed as done before. Burnish is given by brush. Then another layer is completed in
the same process. When the number of turns is complete extra cotton stripes are cut off. For tap
changing, operation leads are taken out from the first layer by bending the wire. The secondary
winding is being burnished. LV windings that have low voltage and high current need a higher
cross-sectional area of wires to flow high current. If we use a single higher cross-sectional area,
it would be difficult to bend and wind the wire. Therefore, multiple wires are used to fulfill the
current carrying capacity instead of one wire. These wires are wrapped with insulation paper for
better heat resistance and insulation as the same process of HV winding.

Figure 3.29: Coil Winding Machine

The conventional winding machine is mainly composed of a clamping mechanism, a coil, an

electric motor, and a wire mold. The working principle is that the motor drives the wire mold to
rotate, and the copper wire is wound around the wire mold to obtain the required coil, as shown
in figure.

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3.3.2.d Coil Assembly

Transformer Core coil Assembly The core assembly is vertically placed with the foot plate
touching the ground. the top yoke of the core is removed. The limbs of the core are tightly
wrapped with cotton tape. Cylinder made out of insulating press board/preshrank paper is
wrapped on all the three limbs.

Figure 3.30: Coil Assembling

3.3.2.e Delta Connection

In distribution transformer delta connection is given to primary winding. To form a delta

connection first lead of a coil is connected to another limb’s last lead of the coil then its first lead
is connected to another limb’s last lead of the coil. The remaining two lead of two side limb coil
is connected. Rods are connected from each top lead of each limb. That will be three terminals of
HV winding.

3.3.2.f Star Connection

In distribution transformer star connection is given to secondary winding. To forms a star

connection, the lower leads of three limbs coil are connected to a common bus bar. The terminal

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is taken out from the common bus bar which will be the neutral terminal of the transformer and
it’s grounded. The top leads of each limb are connected to three terminals. That will be three
terminals of LV winding.

3.3.3 Transformer Oil

Transformer oil is used to preserve the transformer’s core and windings – as these are fully
immersed inside the oil. Another important property of the insulating oil is its ability to prevent
oxidation of the cellulose-made paper insulation. The transformer oil acts as a barrier between
the atmospheric oxygen and the cellulose – avoiding direct contact and hence minimizing
oxidation. The level of transformer oil is typically measured using a Magnetic Oil level Gauge.
The insulation liquid commonly used is petroleum-based mineral oil. The mineral oil is supposed
to absorb the excess heat to protect the mechanical parts of the transformer. The fire point of
mineral oil is 165°C, and the flashpoint is 145°C.

3.3.4 Insulating Materials

Insulating materials like papers and cardboards are used to isolate primary and secondary
windings from each other as well as the transformer core. These are cellulose base products that
degrade over time. The condition of the paper is determined by the degree of polymerization.
Insulation materials are made of dielectric materials. If an insulator has more thickness, then the
dielectric strength also is more. The dielectric strength of an insulator depends upon the applied
voltage across. If we apply a high voltage above its capacity then the dielectric strength will be
weak and the insulator goes into the breakdown. When an insulator goes into breakdown, it lost
its insulation property and it starts to conduct current. The electrostatic pressure creates changes
in the molecular structure of the insulator and forced it to go to the breakdown. More thickness
of the insulator is required to prevent damage. So, when a conductor is used to carry high
voltage, its insulation should be more.

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3.4 Final Assembly
Primary & Secondary winding (LT side) is placed around the core, after installing the primary
winding tapping connection is done. Then Bushing attached to LT and HT terminal rods. This is
mounted on the top cover. The offload taps changer’s dial gauge and on-load tap changer’s
motor unit are installed. Then with the help of a pulley whole system is raised and installed in the
oil tank. The top cover is attached to the body with nuts and bolts. With a pump, transformer oil
is filled through the cap of the conservator. Then safety equipment is attached to the transformer.

Figure 3.31: Final Assembly

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 Chapter-4
Transformer Testing

4.1 Introduction
Physical size, voltage class, and kVA rating are the major factors that dictate the amount of
preparation required to put transformers in service. Size and kVA rating also dictate the kind and
number of auxiliary devices a transformer will require. All of these factors affect the amount of
testing necessary to certify that a transformer is ready to be energized and placed in service.

4.2 Testing of Transformer

Several tests are done on transformer before transformers are set on operation:

1. Insulation resistance test (Megger test).

2. Ratio Test
3. Winding Resistance Test
4. Vector group test
5. No-load test
6. Full-load test
7. High voltage test
8. Transformer Oil test

Figure 4.1: Transformer Testing

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4.2.1 Insulation Resistance Test (Megger Test)

Deterioration of the transformer insulation resistance is one of the most common causes of
failure of the transformer. Insulation can degrade over time due to excessive temperature or
moisture or exposure to a higher voltage than the ratings. The levels of leakage currents depend
on the integrity of the winding insulation. The purpose of the insulation resistance on a
transformer is to test the integrity of the winding insulation. Better insulation will mean lower
leakage currents and better performance and safety. Insulation test is carried out to ensure the
healthiness of the overall insulation system of an electrical power transformer. To test insulation
of transformer coil, megger is used.

Testing procedure:

1. Isolate the transformer from power and load.

2. Normally 5kv is applied to coil through megger and Resistance is measured in
Mega\ohm.
3. Test should be continued for 60 sec.
4. Resistance is measured between HT and LT.
5. Resistance of HT and LT with Respect to ground measured.

Result: Measured Resistance should be high.

4.2.2 Ratio Test

Transformer turns ratio test is low voltage AC test which determines the ratio of the high voltage
winding to low voltage winding at no-load. The performance of a transformer largely depends
upon perfection of specific turns or voltage ratio of transformer. Throughout the life of a
transformer, turn ratio results are compared against the nameplate ratings to reveal insulation
deterioration, shorted turns, core heating or other abnormalities. Turns ratio test is performed on
all taps of every winding.

Page | 35
Testing procedure:

1. First tap changer is positioned at lowest level and LV side is open.

2. Three phases 415V is supplied to HT terminal and Voltage is measured in each terminal
of HV.
3. Induced voltage at LV is measured.
4. Then LV terminal voltage is measured with respect to N.
5. Tap changer position is changed and process is carried out through last tap changing
position.

Result: Calculate the average voltage in every position of tap changer of LT and HT terminal.
Then divided HT average voltage by LT average voltage. The result should be matched to an
expected standard ratio. Deviation must be under +- .5%.

4.2.3 Winding Resistance Test

The winding resistance test is used to find open windings, shorts to ground, wrong turn count,
wrong wire gauge, resistive connections, round wires in hand that are not connected in a coil,
some connection mistakes, the resistance balance between phases, and in some cases shorted
turns. It is carried out at the site in order to inspect abnormalities due to loosen connections, poor
environments, overloading or poor maintenance, high contact resistance in tap changers, broken
strands of conductors, high voltage leads, and bushings. The resistance is measured at ambient
temperature and then the measured resistance should be corrected to a common temperature such
as 75°C. If the transformer is measured without oil, the winding temperature is normally
assumed the same temperature as the surround air otherwise the winding temperature is assumed
the same as the oil temperature.

Testing Procedure:

1. Ensure that the transformer is first grounded.

2. Both Transformers HV and LV side is opened.
3. HT side’s A-B, B-C, C-A terminal resistance is measured.

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 4. LT side Resistance is measure with respect to neutral (a-n, b-n, c-n) which is very low
resistance. Special meter is used to measure the resistance of LV side.

Result: Resistance is converted in 75°c using this formula: Corrected Resistance = Measured
Resistance * (Correction factor +Corrected Temperature /Corrected Temperature + winding

Temperature) were,

• The correction factor for copper (234.5) or aluminum (225) windings

• The corrected temperature (75°C or 85°C)
• The winding temperature (°C) at time of test.

If the resulted resistance meets the designed resistance or according to nameplate resistance that
assures that the connections are correct and there are no severe mismatches or opens.

4.2.4 Vector Group Test

If we connect transformers in parallel one with star and other with delta in their secondary side.
Then in star connected side line voltage will be √3 of the induced voltage on the other hand delta
connected side line voltage will be equal to induced voltage. So, the phase difference will make
circulating current between the transformers. That can’t be ignored. So, the phase sequence must
be identical for two parallel connected transformers. Vector group test is essential for parallel
transformer operation. Otherwise, during the cycle, each pair of phases will be short circuited.

Testing procedure:

1. ‘A’ terminal of HT and ‘a’; LT is shorted.

2. 415 voltage is given to HT
3. HT terminals voltages are measured.
4. Then Voltage of HV B-C, HV B-LV C, HV C - LT C, LV C-B is measured.

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Result: For Dyn11 we will find that voltage between HV B-LT C and HV B- LT C terminal is
equal and voltage of HV C-LT C is smaller than voltage of HV C-LV B. Dyn11 means
transformer primary is connected in Delta connection that is denoted by ‘D’ at the beginning and
secondary is connected in star connection that is denoted by ‘y’; after neutral is given to
secondary star connected side that is denoted by last letter ‘n’ after which side neutral is
connected. The number 11 represents secondary phase voltage is lagging by 30° by primary
phase voltage and it correspond to 11 o’clock.

4.2.5 No Load Test

Also known as open circuit or Core loss test. Voltage is given to LT side in No load Test because
if we choose HV side we have to supply great amount of voltage in primary. That will make the
test difficult. When we supply rated voltage to the LV side, a small current about 2-5% current of
full load will pass therefore negligible copper loss. So, we are getting core loss that can be
measured by wattmeter.

Testing procedure:

1. HT side is opened and Voltage is applied to LV side. As HV is open no current will flow
therefore no copper loss in HV side.
2. Rated voltage of LV side is given to LV side
3. Terminal voltage a-b, b-c, c-a and Current of Ia, Ib, Ic is measured.

Result: Difference between a-b and b-c terminal wattage is determined then value is multiplied
by multiplying factor and CT ratio of wattmeter. Then this value is corrected to 75°C. Corrected
Resistance = Measured Resistance *(Correction factor + Corrected Temperature /Corrected
Temperature + winding Temperature). This calculated value is core loss of transformer at 75°C.

Page | 38
4.2.6 Full Load Test

It is also known as short circuit or copper loss test. If transformer is operated at full load how
much copper loss will occur that is determined by full load test.

Testing procedure:

1. LV side is shorted with a copper or aluminum bar. Copper bar size is determined by rated
current of LV side.
2. Low voltage is applied to HV about 4-10% rated of HV voltage so core loss is neglected
in HV side and LV side.
3. Full rated current of HV is given to HV side.
4. Voltage is applied to HV and raised until rated current of HV is archived.
5. LV side current is measure Ia, Ib, Ic.
6. Voltage and current of HT is measured terminal A-B, B-C, C- A. and IA, IB, IC.

Result: Difference between A-B and C-A terminal wattage is determined then value is
multiplied by multiplying factor and CT ratio of wattmeter. Then this value is corrected to 75°C.
Corrected Resistance = Measured Resistance *(Correction factor + Corrected Temperature
/Corrected Temperature + winding Temperature). This calculated value is copper loss of
transformer at 75°C.

4.2.7 High Voltage Test

The purpose of the impulse test or high voltage test is to determine the ability of the insulation of
the transformers to withstand the transient voltages due to lightning.

Testing Procedure:

1. High voltage is applied for 60 sec. normally 2.5 times of rated voltage is given. Then the
current is measured.

Result: If the current increases slowly with a voltage the transformer passes the test. If the
current is increased rapidly that means the transformer can’t tolerate high voltage.
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 Chapter-5
Switchgear

5.1 Introduction
In Electrical Power system switchgears are integral parts of the system. It also referred as
switching device. It Includes Fuse, Circuit Breaker, Isolator, relay, lightning arrestor, CT, PT,
indicating instruments, auto- recloser and various associated equipment. The purpose of these
devices is controlling, protection and isolation of electrical equipment. These components act as
regulators of current in electrical equipment, thereby ensuring a smooth flow of operation.
Switchgears can be divided into two groups High voltage switchgears and low voltage
Switchgear. According to handling of power level and the operation these switchgears can be
arranged in different panels.

These panels are known as,

1. HT Panels
2. LT panels
3. PFI panels

5.2 HT Panel
High Voltage switchgears are enclosed in this panel. HT circuit breakers and measuring
instrument are arranged here. 3 phases Power Supply from Pole is given to this panel.
Transformers incoming voltage is supplied from this panel.

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 Figure 5.1: HT Panel

5.2.1 Main Function of This Panel

1. To receive 11kv or 33kv power.

2. To make or break HT power supply.
3. Protection against faults.
4. Measuring the power supply parameter.

5.2.2 Parts of HT Switch Gear

1. VCB /LBS
2. CT
3. PT
4. Ammeter
5. Voltmeter
6. Selector switch
7. Thermostat
8. Bus bar
9. Push button switch
10. Indicator lamp
11. IDMT relay

Page | 41
5.2.2.a Load Break Switches (LBS)

They are mechanical switching devices that can make, break, and carry currents under normal
circuitry conditions. It disconnects the electrical current from an electric device or circuit when
the current exceeds the nominal value. Load break switches work with a spring mechanism for
switching the power supply on or off.

Figure 5.2: LBS

LBS consist of

1. Spring mechanism
2. Changing handle
3. Contacts or Switchblade
4. HRC fuse

Moving contacts through where current flows. It is connected with springs. By moving the
changing handle, the spring is compressed and decompressed therefore moving contacts closes
and opens the circuit. When the circuit is opened arc is produced in the moving contacts. As
length are increases between fixed and moving contacts dielectric strength increases. When
connecting blades are fully detached dielectric strength is increased along with separation
distance. Therefore, arc can’t maintain its power and it’s extinguished.

Page | 42
5.2.2.b Vacuum Circuit Breaker (VCB)

The uses Vacuum as an arch extinguishing medium. As there is no ionized molecule in vacuum
the dielectric strength of vacuum is eight times greater than that of air and four times greater than
that of sf6 gas. This high dielectric strength makes it possible to quench arc with a minimum
contact gap. The vacuum in the chamber is typically maintained in the order of range from 10-6
torr.

Figure 5.3: VCB

Main part of VCB

1. Power Contacts.
2. Spring Charge motor.
3. Relays.
4. Tripping relay.
5. Anti-pumping relay.
6. Arch Extinguishing chamber.

A breaker which used vacuum as an arc extinction medium is called a vacuum circuit breaker. In
this circuit breaker, the fixed and moving contact is enclosed in a permanently sealed vacuum
interrupter. The arc is extinct as the contacts are separated in high vacuum. It is mainly used for
medium voltage ranging from 11 KV to 33 KV.

Page | 43
5.2.2.c Current Transformer (CT)

As current is high in transmission that can’t be measured by traditional measuring meter. CT Is

used to step down the current so that current can be measure. A current transformer provides a
secondary current that is accurately proportional to the current flowing in its primary. CT ratio
determines how much current will flow through secondary of CT. For example, A CT ratio a
300:1 means CT secondary winding will supply an output current of 1 ampere when the primary
winding current is 300 amperes. The secondary current ratings are of the order of 5A, 1A and
0.1A. The current primary ratings vary from 10A to 3000A or more.

Figure 3.4: CT

5.2.2.d Potential Transformer (PT)

A potential transformer (P.T.) is an instrument transformer which is used for the protection and
measurement purposes in the power systems. Power lines have higher voltages this voltage can’t
be measured by traditional Voltmeter. So, PT step down the voltage such level that it can be
measure by measuring instrument. How much voltage will be stepped down is determined by PT
ratio. PT ratio 11kv/110v means if primary voltage reaches 11kv then in the secondary we will
get 110v.

Page | 44
 Figure 3.5: PT

5.2.2.e Ammeter

An ammeter works by measuring the voltage drop on a shunt resistor. The ammeter is connected
in series with the circuit it measures, so that the current flow is the same. The main characteristic
of the ammeter is that it must have very low resistance and inductive reactance. When the
primary side of the CT is energized, the measurement equipment nearly acts as a short circuit
which keeps the secondary voltage very low. This voltage will increase significantly if the short
circuit is removed. Accuracy of reading and reliability over long durations of time are the two
critical requirements of measuring instruments such as ammeters. Current transformers help to
perform these critical functions. AC ammeters even come with built-in current transformers.

Figure 3.6: Ammeter

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5.2.2.f Voltmeter

Voltmeter is an instrument used for measuring voltage, that is the potential difference present
between any two points within a circuit. To measure a voltage, a voltmeter must be connected in
parallel with the component whose voltage you wish to measure. Voltmeters can be used to
measure the voltage drop across a single component or supply, or they can be used to measure
the sum of voltage drops across two or more points or components within a circuit.

Figure 3.7: Voltmeter

5.2.2.g Selector Switch

Selector Switch works on a general principle; they contain a simple selector switch on the front
of the panel, and a broad range of potential contact combinations (via the contact blocks), on the
inside of the enclosure. The major difference between the selector switch and the pushbutton is
that, while a pushbutton has a plate that pushes down both contact plungers at the same time, a
selector switch has a rotating came with ridges and flats, allowing to actuate the plungers
independently. Selector switches are available in 2, 3, or 4-position versions, and are often used
when more than one control option is needed. In general, the center position of the selector
switch is the starting cam position. Left position presses the left plunger in the selector switch.
Turning the selector switch to the right presses down the right plunger.

Page | 46
 Figure 3.8: Selector Switch

5.2.2.h Thermostat

A thermostat is a regulating device component which senses the temperature of a physical

system and performs actions so that the systems temperature is maintained near a desired set
point.

5.2.2.i Bus Bar

In electric power distribution, a busbar (also bus bar) is a metallic strip or bar, typically housed
inside switchgear, panel boards, and busway enclosures for local high current power distribution.
They are also used to connect high voltage equipment at electrical switchyards, and low voltage
equipment in battery banks. They are generally uninsulated, and have sufficient stiffness to be
supported in air by insulated pillars. These features allow sufficient cooling of the conductors,
and the ability to tap in at various points without creating a new joint.

Figure 3.9: Bus Bar

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5.2.2.j Push Button Switch

A push button switch is a mechanical device used to control an electrical circuit in which the
operator manually presses a button to actuate an internal switching mechanism. They come in a
variety of shapes, sizes, and configurations, depending on the design requirements. The current
and voltage ratings of switches are particularly important to ensure they are compatible with a
design’s performance criteria. When it comes to mounting style, push button switches are
typically found in either surface mount, through-hole, or panel mount options.

Figure 3.10: Push Button Switch

5.2.2.k Indicator Lamp

Indicator lamp is an instrument which identifies the phase sequence of three phase supply
system. Phase sequence or often called phase rotation of 3 phase supply system is defined as the
sequence or order in which voltage in R, Y and B phase is attains their maximum value.
Normally the phase sequence is RYB. This means, first R phase voltage attains its peak value
followed by Y and B phases. This phase sequence is determined by this indicator.

Figure 3.11: Indicator Lamp

Page | 48
5.2.2.l IDMT Relay

IDMT relay is inverse definite minimum time relay. It is one in which Time of operation is
inversely proportional to magnitude of fault current near pickup value and becomes substantially
constant slightly above the pickup value of the Relay.

5.3 LT Panel
Low Tension Panel normally works under 3 phase 440V. Low tension switchgear is arranged in
this panel. It controls the load power supply. All Incoming power supplies (output of transformer
generators) are fed to this panel. Then From this panel powers are distributed to the load. LT
panel carries a whole load of a building.

Figure 5.12: LT Panel

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5.3.1 The Main Parts of LT Panels

1. Circuit Breakers
2. Bus bar
3. CT
4. Voltmeter
5. Ammeter
6. Selector switch
7. Thermostat
8. Bus bar
9. Push button switch
10. Indicator lamp

5.3.2 Circuit Breakers

Circuit breakers are essentially switches installed inside a breaker box that protects the electrical
components from overheating or catching fire. When an electrical short or overload occurs, a
circuit breaker mitigates the problem by interrupting the flow of electricity.

The Circuit breaker used in LT panels,

1. ACB
2. MCCB
3. MCB

5.3.2.a ACB

ACB is an electrical switching device used to protect electrical circuits from over current, under
voltage, and short circuits. It operates in the air as an arc extinguishing medium, at a given
atmospheric pressure. Air circuit breakers are operated manually or electrically. When the
incident of current overload or failure happens, ACB will instantly cut off the circuit acting as a
combination of a fuse switch and an overheating relay. Under-voltage protection, and short-

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circuit protection are effective in solving the problems of power equipment and lines. It is mainly
used for medium current ranging from 160A to 800A.

Figure 5.13: ACB

5.3.2.b MCCB

A molded case circuit breaker (MCCB) is a type of electrical protection device that is used to
protects the electrical circuit from excessive current, which can cause overload or short circuits.
It’s an updated version of MCB. Its trip current may be fixed as well as adjustable for overload
and magnetic settings. It is mainly used for current ranging from 6A to160A.

Figure 5.14: MCCB

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5.3.2.c MCB

Miniature Circuit Breaker (MCB) is automatically switches OFF electrical circuit during any
abnormal condition in the electrical network such as overload & short circuit conditions.
However, fuse may sense these conditions but it has to be replaced though MCB can be reset.
The MCB is an electromechanical device which guards the electric wires &electrical load from
overcurrent so as to avoid any kind of fire or electrical hazards. Handling MCB is quite safer and
it quickly restores the supply. When it comes to house applications, MCB is the most preferred
choice for overload and short circuit protection. MCB can be reset very fast & don’t have any
maintenance cost. MCB works on bi-metal respective principle which provides protection
against overload current & solenoid short circuit current.

Figure 5.15: MCB

5.4 PFI Panel

The power factor of an ac power system is defined as the ratio of the real power absorbed by the
load to the apparent power flowing in the circuit. Power factor means the angular difference
between voltage and current. Due to energy stored in the load and returned to the source, or due
to a non-linear load that distorts the wave shape of the current drawn from the source caused
phase difference in voltage and current. if there is no difference between voltage and current then
it is called the unity power factor. Reactive power is the reason for the low power factor.
Inductive loads absorb reactive power and capacitive loads provide reactive power. A power
factor of -0.7 indicates that only 70% of the power supply is being used effectively and 30% is
being wasted. The wasted power is the reactive power. In an electric power system, a load with a

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low power factor draws more current than a load with a high-power factor for the same amount
of useful power transferred. The higher currents increase the energy loss in the distribution
system and require larger wires and other equipment. Normally in substation Power Factor is
improved by installing capacitor banks that work as silent reactive power generators. Improving
the power factor results in less current being drawn, therefore fewer electricity costs, less heat
produced, and greater longevity of the electrical system.

Figure 5.16: PFI Panel

PFI Panels Consist of

1. MCCB
2. Bus bar
3. HRC
4. MC
5. APFC Relay
6. Power capacitor
7. Voltmeter
8. Ammeter
9. Selector switch

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 10. Thermostat
11. Push button switch
12. Indicator lamp

5.4.1 HRC

HRC consists of highly heat resistant material Fuse (such as ceramic) body having metal-end
caps, which is welded by silver current carrying element. The fuse body internal space is
completely packed with a filling powder. The material, which has filled the insider space, may be
plaster of Paris, quartz, chalk, marble, dust and cooling mediums etc. That’s why it carries
normal current without overheating. The heat being produced vaporizes the silver melted
element. Chemical reaction taking place between silver vapor and filling powder results in high
resistance substance, which helps in quenching the arc in fuse.

Figure 5.17: HRC

5.4.2 MC
Magnetic Contactor (MC) is a device that is powered by magnetism. Used to open and close the
contacts in the motor control circuit, may also be called a magnetic switch or a contactor. A
magnetic contactor is a device that is very often used in industry. Commercial, large industries
are very much dependent on this device. We can easily control heavy loads such as high-capacity

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power. Basically, a magnetic contactor works on the same principle as a relay, connecting and
disconnecting electricity. The actuators are similar, this device uses a coil, which when an
electrified coil creates a magnetic field. When an electric current flows to the magnetic field coil
located in the center leg of the coil core. This will create a magnetic field in which the magnetic
field forces overcome the spring force to cause the steel core to move down in this state (ON).

Figure 5.18: Magnetic Contactor

5.4.3 APFC Relay

Automatic power factor controller is designed to improve the power factor automatically, when
the power factor falls below a predefined value.

Figure 5.19: APFC Relay

5.4.4 Power Capacitor

Power Capacitor is a special type of capacitor, which can operate at higher voltages and has high
capacitances, which is used to store electric charges temporarily. Power capacitors provide a
static source of reactive power in electrical distribution systems. They consist of two conducting
plates separated by insulating material called dielectric materials. The capacitor is connected in

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parallel to an inductive load; it will start to charge when the voltage rises above the current level
of the load. The difference between the voltage and current levels is called a phase angle. In
distribution systems, these capacitors provide reactive power to offset inductive loading from
devices like motors, arc furnaces, and lighting loads. Capacitors into a power distribution system
offer economical and operational benefits including increasing system load capacity. The
Required KVAR rating for good power factor depends on the capacity of the transformer.

Figure 5.20: Power Capacitor

Table 5.1: Standard transformer Capacity for Required PFI Panel KVA of 60%(KVAR).
World Wide Standard Transformer Capacity Required PFI Panel KVA of 60%(KVAR)
100 KVA 60
150 KVA 90
200 KVA 120
250 KVA 150
315 KVA 189
500 KVA 300
630 KVA 378
750 KVA 450
800 KVA 480
1000 KVA 600
1250 KVA 750
1500 KVA 900
1600 KVA 960
2000 KVA 1200
2500 KVA 1500
3000 KVA 1800
3500 KVA 2100
4000 KVA 2400

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 Chapter-6
Conclusions

6.1 Internship Experience

It gives us the flavor of the corporate life. We learn how we should maintain a relationship both
with our superior. We get familiar with various find of manufacturing machines which we did
not learn through our departmental courses. We learn about various types of modelling. Every
company tries to follow a unique idea/design to sustain a competition in the market. Our trainer
and mentors gave us some short tips about many things as like choosing the raw materials, wire
diameter selection, insulation paper selection which are very helpful information’s.

6.2 Limitations in Internship

We only saw the whole things with our eyes but we did not do anything with tour hand. We
didn't saw some of' the products because of the shortage of orders. That’s why we could not learn
about them practically.

6.3 Safety Guidelines

There we observe some safety guidelines as like,

• Due to corona pandemic they compulsory on wearing mask and sanitize hands.
• During transformer testing when high voltage is applying, we should make a safe
distance from the transformer.
• Always need to wear a full shoe.
• Do not anything with bare hands in the manufacturing department.
• Need abide by some caution stickers were applied on with a heading like “High voltage”,
“Do not touch", “High voltage area” etc.

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6.4 Difference Between Theory Course and Internship
Both theory and Practical knowledge in important for an engineer. An engineer cannot claim
himself an engineer without the knowledge of those. In theory we learn about the working
principle, the characteristics of components and get a deep learning about those. And in practical
life we get know that for apply those theorem and equipment’s/components which device we
should use. Besides theory some time we deal with some of machines which we never learn
before. And tire most interesting part of internship is we can team about the new things very fast.
And it stays in our mind for very long time.

6.5 Conclusion
It was a great opportunity to visit BETELCO and achieve practical knowledge on Transformer,
Switchgear. We gather practical knowledge how to test transformer. Without doing the
internship it is difficult to test our capability in the practical field. But so far in the internship
with the help of our supervisor we try to recover our lacking. Though it was only 28 days
twining or internship we tried to get good feedback for our future progress especially on this
such field. We are thankful to all the instructor of BETELCO for their supports.

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 References

1. http://www.powermannbd.net
2. https://www.brighthubengineering.com
3. https://en.wikipedia.org, retrieved on 04 November 2018.
4. V.K. Mehta, Rohit Mehta, & Principles of Power System, 4st ed. 2008.
5. Indrajit & Power Transformers Dasgupta, Quality Assurance; 1st ed New Age
International Limited Publishers, 2009.
6. Electrical Power Transformer: Definition & Types of Transformers ‘Electrical 4U, 2021.
https://www.e1ectrical4u.com/electrical-power-transformer-definition-and-types-of-
transformer [Accessed: 27- Jan- 2022].
7. http://electrical4u.com/conservator tank of transformer, retrieved on 22 November 2018.
8. http://en.wikipedia.org/wiki/Switchgear, retrieved on 14 December 2019.
9. http://en.wiktionary.org/wiki/connector, retrieved on 02 January 2021.
10. https://www.allaboutcircuits.com, retrieved on 16 January 2022.
11. http://eeeinterviewtips.blogspot.com/2011/09/define-power-factor-what-are-ways-o.html
12. Electrical Power Transformer: Definition & Types of Transformers ‘Elecmical4U, 2021.
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transformer/ [Accessed: 27- Jan- 2022].
14. W Daware. "Open circuit and Short circuit Test on transformer", Electricaleasy.com
https://www.e1ectrica1easy.com/2014/04/open-apd-short-circuit-test-ontransformer.html.
[Accessed: 27- Jan- 2022].
15. M. Badan. ’Step Down Transformer Working Principle, Equation, Types, Advantages &
Disadvantages”, https://electricalfundablog.coin/step-down-transformer [27- Jan- 2022].
16. Gupta, "Different Types of Transformers and Their Applications”, Circuit Digest. 2019.
https://circuitdigest.com/tutorial/different-types-of-transfoimmand-their-applications

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