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1. ABSTRACT
The Electricity sector in India supplies the world's 6th largest energy consumer, accounting for 3.4% of global energy consumption.In a country like India,the Power Distribution is an important aspect and power transformers play an important role in distribution. These static devices are designed with an average service life of 10 to 20 years depending upon type of insulation and quality of material used.This figure may not be necessarily be met and transformers often fail due increase in load therefore repair of power transformers is a crucial as replacement would require more capital investment. In the repair of power transformers, insulation failure is the most important issue as 90% of the time, damage occurs in the winding insulation that would result in the transformer failure.New technologies in manufacturing has been developed (such as improve the winding insulation characteristics and retain and enhance the mechanical strength of the paper insulation due to strengthening of hydrogen bonds in macro molecules of cellulose and improve the crystal grating.) however transformer failures are common and emphasis on it is required. In the present project we have made a detailed study of repairing of power transformers including rewinding , oil filtration and reassembly process at JeevanJyoti transformers and in our view repairing is an economical process.

Project Associates:

CH.Nagarjuna Reddy G.Vijaya Kumar J.Nagaraju SHAIK.Zillani T.Sreenath Chowdary

(08U91A0205) (08U91A0213) (08U91A0236) (08U91A0251) (08U91A0255)

TABLE OF CONTENTS
1. ABSTRACT 1.1. ABOUT JEEVANJYOTI TRANSFORMERS.. 4 1.2. PREFACE..
2. INTRODUCTION . 2.1. HISTORY OF POWER TRANSFORMERS.. 2.2. GENERAL DESIGN 3. VARIOUS PARTS OF TRANSFORMER.. 3.1.CORE. 3.2.WINDING SECTION 3.3. INSULATION

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3.4.CONNECTION..
4. REPAIR OF TRANSFORMERS. 4.1.INTRODUCTION 4.2.COMMON ENCOUNTERS.. 4.2.1.CORE DEFORMATION.. 4.2.2.WINDING INSULATION FAILURE. 4.2.3.OIL INSULATION FAILURE.. 5. REPAIRING EQUIPMENTS AND PROCESS.. 5.1.DEASSEMBLING. 5.2.FAULT IDENTIFICATION

3 5.3.OIL FILTRATION 5.4.REWINDING. 5.5.HEATING CHAMBER 5.6.RECYCLING PROCESS. 5.7.ASSEMBLYING

6. TRANSFORMER TESTING
6.1.RATIO TEST
6.2.CONTINUITY TEST. 6.3.MEGGER TEST.

7. CONCLUSION.

JEEVANJYOTHI TRANSFORMERS
JeevanJyoti transformers was established on 1991 under ther

2.INTRODUCTION
It is important to understand or to know about the basics and history of power transformers before dealing with the repairs. Electricity or power has become the major part of our daily life and without electricity we cannot imagine a life today. Most of our household appliances work on electric current. We face various power problems due to voltage fluctuations. Sometimes our home appliances malfunction due to voltage problems. The solution for all these problems can be rectified only through a transformer. Power transformers or a transformer is an electrical device that is used to change an alternating current voltage from one electric circuit to another through electromagnetic induction. These transformers are employed in various mechanisms to reduce the incoming voltage or increasing the voltage of electrical equipments. These transformers have two or more windings wounded on a laminated iron core and the number of windings is based on the requirement of electric voltage that the transformer is used to supply. There are many types of transformers like isolation transformer, power transformers, electrical transformer, audio transformer, current transformer, high voltage and low voltage transformers, step-up and step-down transformers etc. Each of these kinds has their own properties and usages in transferring voltage based on the appliance it is attached with. Electric transformer is a device that is employed in increasing or lowering the voltage of alternating current or voltage. Electric transformers have two sets of coils called primary and secondary coils linked around magnetic fields that work as conductors. This number of windings determines the workability of the transformer. There are various forms of electrical transformers like step up transformers to raise voltage or step-down transformer to lower voltage levels that can be used in power lines or household appliances to regulate current supply and reduce electricity bill costs. Current transformers are used to get secondary or additional current to produce current from the transformer and this helps the customers t o get ample current for their various applications like metering and protective relaying in electrical power industry to get safe measurement of large currents even from high voltages. Audio transformers are designed with epoxy resin that facilitates improvements in sound qualities by removing disturbing audio signals that is sourced from other devices. Flyback transformers can convert the input voltage and current to the expected output voltage and current and these transformers are available in variety of models and sizes.

2.1.HISTORY OF POWER TRANSFORMERS

What is a Transformer?

A transformer is is a device that transfers electrical energy from one circuit to another through inductively coupled conductorsthe transformer's coils.
How is it used?

A transformer is used to bring voltage up or down in an AC electrical circuit. A transformer can be used to convert AC power to DC power. There are transformers all over every house, they are inside the black plastic case which you plug into the wall to recharge your cell phone or other devices. These types are often called "wall worts". They can be very large, as in national utility systems, or it can be very small embedded inside electronics. It is an essential part of all electronics today.

Who invented the transformer? Lucien Gaulard, Sebstian Ferranti, and William Stanley perfected the design.

When was the transformer invented? The property of induction was discovered in the 1830's but it wasn't until 1886 that William Stanley, working for Westinghouse built the first practical transformer. His work was built upon some rudimentary designs by the Ganz Company in Hungary (ZBD Transformer 1878), and Lucien Gaulard and John Dixon Gibbs in England. Nikola Tesla did not invent the transformer as some dubious sources have claimed. The Europeans mentioned above did the first work in the field, George Westinghouse and Stanley made the transformer cheap to produce, and easy to adjust for final use.

Sabastian de Ferrabti(England)

lucien Gaulard(France)

William Stanly(USA)

Where were the first transformers used? The first AC power system that used the modern transformer was in Great Barrington, Massachusetts in 1886. Earlier forms of the transformer were used in Austro-Hungary 1878-1880s and 1882 onward in England. Lucien Gaulard (Frenchman) used his AC system for the revolutionary Lanzo to Turin electrical exposition in 1884. In 1891 mastermind Mikhail Dobrovsky designed and demonstrated his 3 phase transformers in the Electro-Technical Exposition at Frankfurt, Germany.

1885

1886

(a)

(b)

(a) stanley's first transformer which was used in the electrification of Great Barrington, Massachusetts in 1886
(b) William Stanley's First Transformer built in 1885

The discovery of property of Induction by Micheal Faraday lead to the invention of transformers.the below time line shows the early historic developments and ideas that lead to the development of the modern transformer right from the beginning since 1830s to till now the everpopular property of electromagnetic induction has made almost every aspect of living soother and comfortable whose credit belong to all those who has their conrtibution right from the start.

Transformer development timeline:

1830s - Joseph Henry and Michael Faraday work with electromagnets and discover the property of induction 1836 - Rev. Nicholas Callan of Maynooth College, Ireland invents the induction coil 1876 - Pavel Yablochkov uses induction coils in his lighting system 1878 -1883 - The Ganz Company (Budapest, Hungary) uses induction coils in their lighting systems with AC incandescent systems. This is the first appearance and use of the toroidal shaped transformer. 1881 - Charles F. Brush of the Brush Electric Company in Cleveland, Ohio develops his own design of transformer (source: Brush Transformers Inc.)

1880-1882 - Sebastian Ziani de Ferranti (English born with an Italian parent) designs one of the earliest AC power systems with William Thomson (Lord Kelvin). He creates an early transformer. 1882 - Lucien Gaulard and John Dixon Gibbs first built a "secondary generator" or in today's terminology a step down transformer which they designed with open iron core, the invention was not very efficient to produce. It had a linear shape which did not work efficiently. It was first used in a public exhibition in Italy in 1884 where the transformer brought down high voltage for use to light incandescent and arc lights. Later they designed a step up transformer. Gaulard (French) was the engineer and Gibbs (English) was the businessman behind the initiative. They sold the patents to Westinghouse. Later they lost rights to the patent when Ferranti (also from England) took them to court.

(Ott Blthy, Miksa Dri, Kroly Zipernowsky created the "Z.B.D Transformer")

1884 - In Hungary Ott Blthy had suggested the use of closed-cores, Kroly Zipernowsky the use of shunt connections, and Miksa Dri had performed the experiments. They found the major flaw of the Gaulard-Gibbs system were successful in making a high voltage circuit work using transformers in parallel. There design was a toroidal shape which made it expensive to make. Wires could not be easily wrapped around it by machine during the manufacturing process. 1884 - Use of Lucien Gaulard's transformer system (a series system) in the first large exposition of AC power in Turin, Italy... This event caught the eye of George Westinghouse bought Gaulard and Gibbs Transformer design. The 25 mile long transmission line illuminated arc lights, incandescent lights, and powered a railway. Gaulard won an award from the Italian government of 10,000 francs. 1885 - George Westinghouse orders a Siemens alternator AC generator) and a Gaulard and Gibbs transformer. Stanley begin experimenting with this system. 1885 - William Stanley makes the transformer more practical due to some design changes: "Stanley's first patented design was for induction coils with single cores of soft iron and adjustable gaps to regulate the EMF present in the secondary winding. (See drawing at left.) This design was first used commercially in the USA in 1886". William Stanley explains to Franklin L. Pope (advisor to Westinghouse and patent lawyer.) that is design was salable and a great improvement. Pope disagrees but Westinghouse decides to trust Stanley. George Westinghouse and William Stanley create a transformer that is practical to produce (easy to machine and wind in a square shape, making a core of E shaped plates) and comes in both step up and step down variations. George Westinghouse understood that to make AC power systems successful the Gaulard design had to be changed. 1886 - William Stanley uses his transformers in the electrification of downtown Great Barrington, MA.This was the first demonstration of a full AC power distribution system using step and step down transformers.

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Later 1880s - Later on Albert Schmid improved Stanley's design, extending the E shaped plates to meet a central projection. 1889 - Russian-born engineer Mikhail Dolivo-Dobrovolsky developed the first three-phase transformer in Germany at AEG. He had developed the first three phase generator one year before. Dobrovolsky used his transformer in the first powerful complete AC system (Alternator + Transformer + Transmission + Transformer + Electric Motors and Lamps) in 1891.

2.2 GENERAL DESIGN:

(Step-by-step transformer design procedure )

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3.0 PARTS OF A TRANSFORMER

3.1CORE:
A magnetic core is a piece of magnetic material with a high permeability used to confine and guide magnetic fields in electrical, electromechanical and magnetic devices such as electromagnets, transformers, electric motors, inductors and magnetic assemblies. It is made of ferromagnetic metal such as iron, or ferromagnetic compounds such as ferrites. The high permeability, relative to the surrounding air, causes the magnetic field lines to be concentrated in the core material. The magnetic field is often created by a coil of wire around the core that carries a current. The presence of the core can increase the magnetic field of a coil by a factor of several thousand over what it would be without the core. The use of a magnetic core can enormously concentrate the strength and increase the effect of magnetic fields produced by electric currents and permanent magnets. The properties of a device will depend: crucially on the following factors. the geometry of the magnetic core. the amount of air gap in the magnetic circuit. the properties of the core material (especially permeability and hysteresis). the operating temperature of the core. whether the core is laminated to reduce eddy currents.

In many applications it is undesirable that the core itself retains magnetization and become magnetized by the external field. This property, called hysteresis can cause energy losses in applications such as transformers. Therefore 'soft' magnetic materials with low hysteresis, such as silicon steel, rather than the 'hard' magnetic materials used for magnets, are usually used in cores. For three phase transformers is E-core is commonly used where three limbs are provided with each phase winding on each limb, the primary and the secondary windings are located on the same limb with a insulation is provided in between. The effect of inner winding capacitance may exist between them which generally not considered but for the high frequency transformers a electrostatic place is placed between the primary and secondary windings.

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Laminated steel plates with silica gel is used on the surface that acts as protective layer and prevents corrosion which results in effective increase in the plate thickness lower the thickness lower the eddy current losses, this is the reason why the laminations are provided ,in order to decrease the eddy current losses.90% of the transformer is due to its oil, winding and the core.

E cores are wound from Cold Rolled Grain Oriented (CRGO) silicon steel strip and are annealed in a high vacuum furnace under protection atmosphere. The impregnation is undertaken with vacuum impregnating equipment, using low-stress high-viscosity resin. Fine polishing process of cutting surface ensures very good performance of the cores, with low core loss and high saturation. E cores (E-cores or C-cores) for mains transformers; low noise, low magnetizing current, fast assembly, low cost. Cores are wound from cold rolled grain oriented (CRGO) silicon steel strips

THICKNESS Vs IRON LOSSES

TheThe equation loss and eddy current loss is hysteresis for the iron losses is given by given by the equation Ph=KhBm^1.6f and Pe=KeBm^2f2 This linear relationship with frequency increases the losses in the transformer core. the losses can be maintained constant to a certain limit if the V/F relationship is maintained constant since the magnetic flux density Bm is varied.

E I-CORE

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Effect of Eddy Currents

The effect of laminations is to confine eddy currents to highly elliptical paths that enclose little flux, and so reduce their magnitude. Thinner laminations reduce losses, but are more laborious and expensive to construct. Thin laminations are generally used on high frequency transformers, with some types of very thin steel laminations able to operate up to 10 kHz. One common design of laminated core is made from interleaved stacks of Eshaped steel sheets capped with I-shaped pieces, leading to its name of "E-I transformer". Such a design tends to exhibit more losses, but is very economical to manufacture. The cut-core or C-core type is made by winding a steel strip around a rectangular form and then bonding the layers together. It is then cut in two, forming two C shapes, and the core