Introduction

A transformer is a static electromagnetic device consists of two or more

windings which link with a common magnetic field. One of these windings,
the primary, is connected to an alternating voltage source, an alternating flux
is produced whose amplitude depends on the primary voltage and number of
turns.
Py.induced voltage is Ep=4.44m*f*Tp.
Where f=frequency, m= mutual flux,Tp= no.of primary turn
This flux linkage with the secondary winding induces in it a voltage whose
value is Es=4.44m*f*Ts, where Ts=no.of secondary turns. Ratio of
voltages Es/Ep=Ts/Tp.
A transformer is not an energy conversion device but a device that
transforms electrical energy from one or more primary a.c circuits to one or
more secondary a.c circuits with changed value of voltage and current.
Transformer allows the power to be generated at the most economical
transmission voltage and power utilisation at the most suitable voltage for
different application.
Transformer may be classified as :
1)Step up transformer: raises voltage
2)Step down transformer: Lowers voltage
In fact each transformer may be used as both step up and step down because
it is a reversible device.
Power transformer have a remarkably high efficiency ranging from 95 to
99.5% depending upon power rating. The greater power rating, higher the
efficiency.

Construction of transformer

Two types:
-core type
-shell type
Core type construction is universally followed for better heat dissipation
facility

Transformer core :
Cold rolled grain oriented steel (CRGO) sheet is used to build up core.
Core of the transformer are laminated to reduce eddy current loss.
Laminations are made 0.3 mm to 0.5mm thick. Core laminations are
varnished.

Longitudinal ducts are provided into different stacks of core for flow of oil.
The core clamping takes care of all the force produces in the windings in the
event of any short circuit.
Core earthing:
With the exception of individual laminations and core bolts, all internal parts
of the transformer require earthing
Due care is taken for earthing system to avoid multiple paths which may
initiate partial discharges because of circulating currents inducing relatively
high voltages across high impedences of an arc path.

WINDING
THE WINDING USED FOR CORE TYPE TRANSFORMERS ARE:
Cylindrical winding
Helical winding
Cross-over winding
Disc & Continuous disc winding.
High capacity transformers are made of continuous disc type generally. A number of flat
coils connected in series or parallel. The coils are transposed for ensuring equal flux
linkage & to reduce losses. Axial mechanical strength is more in this type.All winding
coil conductors are paper insulated. Continuously transposed conductors (CTC) also used
in some transformers. Insulation spacers in the winding are arranged such that oil is
directed through the entire windings for ensuring proper cooling.

TANK & COVER

Transformer tank & cover are manufactured by welding steel plates and are
suitable for withstanding full vacuum and positive pressure of 0.35
kg/cm.Transformers below 20MVA and below 72KV class are designed to
withstand 500mm Hg vacuum rather than full 760 Hg vacuum.
Construction of the tank and cover are such that these can be transported by
railways / road / waterways as per customer specs.
Construction of tank may be of BELL type or Welded cover construction
type.

Cooling of Transformer

The losses in the transformer appear as heat and it is dissipated in the

surroundings. The coolant used in transformers are
i)AIR
ii)
OIL
The method of cooling are:
AN : Air natural - small transformers
ON: Oil natural small oil filled transformers

ONAN:
Oil natural air natural.- Transformers fitted with external
radiators, upto 5.0 MVA
ONAF: Oil natural air forced
OF: Forced circulation of oil.
OFAN:
Oil forced air natural
OFAF:
Oil forced air forced
OFWF:
Oil forced water forced.
Example: GTs are OFAF cooling, U.Ts are ONAF cooling, 11kv/415V or 6.6
kv/415V transformers are ONAN cooling.

TERMINALS & LEADS:

The shape and size of terminal leads are important in high voltage
transformer owing to dielectric stress and corona which are caused at bends
and corners. So sharp edges & corners shall be avoided.

BUSHING:
The high voltage connection pass from the winding to terminal bushings.
Bushings up to 36KV class, 3150 amps are normally of plain porcelain and
oil communicating type. Higher current rated bushings and bushings of 52
KV and above are of oil impregnated paper condenser type. Th oil inside the
condenser bushing will not be communicating with the oil inside the
transformer. Oil level gauge is provided on the expansion chamber of the
condenser bushing.

TAP CHANGERS:
Tap changers of power transformers are two types:
On load tap changer
Off load tap changer.
In case of Off load tap changer , the tap changing takes place only when the
transformer is de-energized., but in case of on load tap changer the tap
changing takes place when transformer is in operation.
On load tap changers a self contained unit housed in the main transformer
tank. This consist of diverter unit & selector unit. In selector unit the
termination is made. Since some amount of arcing always takes place during
on-load operation, the oil inside the diverter unit deteriorate fast & not
allowed to mix up with main tank oil. Hence a separate conservator & oil
surge relay is provided.

CONSERVATOR
Conservator is provided to take care of the expansion and contraction of
transformer oil which takes place during normal operation of the
transformer.
A conservator can be with air cell or without air cell type. Air cell is
provided to avoid direct contact of air with transformer oil.
Magnetic oil level gauge is fitted on the main conservator which can give
alarm in the event of oil level goes down below certain level as preset.
A gauge glass is also provided to see actual level.

PRV or PRESSURE RELIEF DEVICE:

A device for oil pressure relief for the transformer tank and cooling system is
filled with a trip relay. It allows for the rapid release of excessive pressure
that may be generated in the event of a serious fault.
A PRD is a spring loaded device which provides rapid amplification of its
actuating force.
A bright colour indicator pin in the cover moves with the valve disc during
operation of PRD and is held in position by some mechanism. This is clearly
visibe indicating that device has operated.
The indicator can be manually reset along with the valve disc / diaphragm. A
micro switch is provided which operates along with the valve disc to give an
alarm/ trip.

Buchholzs Relay (Gas & Oil actuated relay)

Relay is a gas actuated relay used for protection against all types of faults
occurring within oil immersed transformers and makes use of the fact that
the faults are accompanied by the generation of gases which the heat
liberates from the oil.
It comprises a cast housing which contains two pivoted aluminum buckets,
each bucket being counter-balanced by a nickel-plated mild steel weight.
Each assembly carries a mercury switch, the leads from which are taken to a
molded terminal box. The upper assembly is called the alarm element
assembly and the lower assembly is called the surge-element assembly.
When a slight or incipient fault (such as insulation faults between turns,
breakdown of core insulation, core heating, bad switch contacts, faulty
joints) occurs in the transformer, small bubbles of gas will be generated and
this and attempt to pass from the tank to the oil conservator will be trapped
in the relay housing. As this gas accumulates at the top, the oil level in the

relay will fall, leaving the top bucket full of oil. As this bucket will not now
be fully immersed the extra weight due to the contained oil will overcome
the balance weight and cause the whole assembly to tilt thereby closing its
mercury switch and completing the alarm circuit. With a serious fault, the
gas generation is repaid, causing the displaced oil to surge through the relay.
This oil flow will impinge on the baffle plate and cause the bottom bucket
assembly to tilt, closing the mercury switch and completing the trip circuit to
the circuit - breakers.

SILICAGEL BREATHER:
Expansion and contraction of oil cause breathing action. Any humidity in the
air breathed is absorbed by the silica gel dehydrating breather. An oil seal in
the air intake prevents external moisture being absorbed when no breathing
occurs.
The breather container is filled with silica gel crystals of color deep blue. If
color changes to pink then the silica gel is saturated with moisture and the
charge container should be replaced by a new reactivated one.

WINDING TEMPERATURE INDICATORS:

The winding temperature indicator indicates the winding temperature of the
transformer and operates alarm, trip and cooler control contacts.
It consists of a sensor bulb placed in oil filled pocket in the transformer tank
cover. The bulb is connected to the instrument through capillary tubes. One
capillary is connected to the measuring bellow of the instrument and the
other to a compensating bellow. The measuring system is filled with a liquid
which changes its volume with rise of temperature.
Inside the instrument fitted with a heating resistance which is fed by current
proportionate to the current flowing through the transformer winding
measured by a CT. The increase in temperature of the resistance is
proportional to that of winding. The sensor bulb of the instrument is located
in the hottest oil of the transformer. Therefore, the winding temp indicates a
temp of hottest oil plus the wdg. Temp rise above hot oil.

OIL TEMPERATURE INDICATOR:

The oil temperature indicator consist of a sensor bulb, capillary tube and a
dial thermometer. The sensor bulb is fitted at the location of hottest oil. The
sensor bulb and capillary tube are fitted with an evaporating liquid. The
vapor pressure varies with temperature and is transmitted to a bourdon tube
inside the dial thermometer which moves in accordance with the changes in
pressure which is proportional to temperature.

LOSSES IN TRANSFORMERS
IRON LOSS
HYSTERESIS LOSS f
EDDY CURRENT LOSS f
COPPER LOSS OR IR LOSS

TRANSFORMER OIL
Broad

classifications

are:

Napthenic
base
Pareffnic
base
Mixed base
In India parafinic oil is generally used because of its availability and warm
climatic conditions.
Parameter of oil required for 420KV grade transformer:
BDV: 70 KV and moisture ppm: 10

CONDITION MONITORING OF TRANSFORMER

Since Regular Internal Inspection of the transformers is not possible
Only "Diagnostic tests" mentioned below are possible:
Dissolved Gas Analysis (DGA) of insulating oil
- the most significant hydrocarbons (gases) generated due to decomposition
of oil are:
Hydrogen (h2)
Methane (ch4)
Ethane (c2h6)
Ethylane (c2h4)
Acctelene (c2h2)
Due to decomposition of cellulose: co and co2 are formed
Partial Discharge (PD) Tests.

 Sonic and Ultrasonic detection

Infrared Thermographic inspection