Report on internship at JDS Transformers

UJJAIN ENGINEERING
COLLEGE, UJJAIN

Report on internship
at
JDS Transformers Industries Pvt. Ltd.
ON MANUFACTURING OF DISTRIBUTION TRANSFORMERS.

UNDER THE GUIDANCE OF: SUBMITTED BY:

PRASHANT TAJNE SACHIN CHOURE
(Works Manager) (0701EE191046)

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 Report on internship at JDS Transformers

TABLE OF CONTENTS
1. DEDICATION
2. ACKNOWLEDGEMENT
3. INTRODUCTION
a. Mission
b. Infrastructure
c. Management
d. Quality Assurance
e. History of organization
f. Products manufactured
g. Service offered
4. ABOUT TRANSFORMERS
a. Defination
b. Parts
c. Principle of operation
d. Working
5. ABOUT THE DEPARTMENT
a. Design department
b. Purchase department
c. Production department
d. Quality control or testing department
e. Testing in transformer
6. EXPERIENCE
7. CONCLUSION

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Dedication
To all those who have supported, encouraged, challenged and
inspired me. And specially to my beloved parents and uncle,
honourable teachers for all their guidance, love & attention
which has made it possible for me to make it upto this point as
well as the internship supervisors who bestowed me with the
courage, the commitment and the awareness to follow the best
possible route, by their unmatchable style and by best possible
training.

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Acknowledgement

First of all I would like to express my gratitude towards

Almighty God to enabling me to complete this report on
“internship at Jds transformer “.
I hereby thank Mr. Prashant Tajne sir for giving me opportunity
to have an experience in the company and my uncle Mr.
Bhagirath choure for advising me to join company.
I also appreciate the cordial co-operation from all my internship
supervisors in different department of Jds and the Internship
coordinator Mr. Hemant Parmar sir and Sourabh Gupta sir.
All the employees of Jds helped me a lot in performing all the
activities and in gaining the practical knowledge of industry.
They gave me best environment and knowledge to enhance my
skills.

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Introduction
JDS Transformer Ind. P. Ltd was established in the year 1999,is
among the prominent manufacturers, wholesaler exporter of
high quality Power Distribution Transformer, Aerial Bundled
Cable, Insulated Aerial Bunched Cable, ACSR Conductors, AAC
Conductors, AAAC Conductors, Aluminium Wires and many
more. These Aluminium Rods and Conductors are precisely
designed from high quality aluminium that is sourced from
trusted and reliable vendors of the industry. For the purpose of
manufacturing premium quality aluminium rods and
conductors in compliance with the industry set norms, the
cutting-edge machinery and latest technology is used. The
resistance to corrosion, high tensile strength, accurate
dimension, high electrical conductivity and longer serving life,
makes these aluminium rods and conductors highly demanded
in the market. These aluminium rods and conductors can be
customized as per the specifications provided by the
customers.
Since the establishment of our company, we have been backed
by a team of skilled professionals and a state-of-the-art
infrastructure. It is due to our customer centric approach,
ability to manage bulk orders, ethical business policy and
transparent business dealing, has helped us in gaining a
remarkable position this domain. For ensuring best possible
quality, we have set up a huge in-house quality testing unit,
which is well-equipped with advanced tools and equipment.

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• MISSION
Our mission is to develop, produce and deliver products and
services which consistently meet our customers needs. JDS
Alloy Conductors (P) Ltd. Is committed to a quality system of
continuous improvement for use in the manufacturing of
Aluminium wire products (EC Grade/Alloy/T4/De-oxi Aluminium
Wire Rod, AAC Conductor, ACSR Conductor, AAAC Conductor,
Bare & Insulated Aluminium Wire & Strip, Aerial Bunched
Cable).
• INFRASTRUCTURE
JDS transformers is supported by spacious and technically
equipped state-of-the-art infrastructure. Its manufacturing unit
has a capacity of producing 36,000 MT per annum that enables
to meet the demands of clients. A team of well versed and
highly qualified professionals from diverse backgrounds are one
of its biggest strengths. These professionals take care of
flawless work process and quality, management of products
and enables them meeting bulk demands. They impart their
employees with regular training sessions to polish their skills
• MANAGEMENT
JDS is a professionally managed group in distribution &
transmission sector involved in executing contracts for national
& international power sector utilities & contractors. Since
inception company has adopted professional management with
ISO certification a team of highly qualified and experienced

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executives and a team of renowned consultants. Management

has over 30 years of experience in the Aluminium industry and
their past track and ability to identify business opportunity will
set the growth path on the fast track. The management and
advisors have rich experience of more than three decades in
the industry.
• QUALITY AASSURANCE
JDS is quality centric organization engaged in manufacturing
products that can easily meet the international standards. A
huge clientele in national and international markets are the
proof of trust that their clients have. Manufactured using
premium quality raw materials, the products passes through
stringent quality tests conducted by quality experts at every
stage of development.
The internship basically revolved around the distribution
transformer manufacturing and maintenance. This report
stated a very brief review of what I have seen and learnt during
my internship.
I have mentioned all these as I have made an internship as
according to the schedule. This report will its reader knowledge
about the transformer unit of JDS Transformer Ind. P. Ltd.

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HISTORY OF ORGANIZATION
Established in 1999,JDS Transformers is leading manufacturer
of distribution transformer Started in Nagpur, Maharashtra. In
2007-08 new plant at Chhindwara, Madhya Pradesh was
established which basically produced Aluminium wire products.
In 2014-15 JDS started its new plant which started the
production of Distribution transformer at chhindwara. And then
till now the company is producing the effective and quality
distribution transformers to contribute towards the society.
PRODUCTS MANUFACTURERD
Manufacturing of Distribution Transformer: A distribution
transformer or service transformer is a transformer that
provides the final voltage transformation in the electric power
distribution system, stepping down the voltage used in the
distribution lines to the level used by the customer.
Rated Output (KVA): 16, 25, 63, 100, 200, 315, 500, 630, 1000,
1600 to 5000 KVA.
SERVICES OFFERED
Repairing of existing Transformers: JDS will also undertake the
repairing of existing transformers from various customers for
any different types of faults that results in distribution
transformers.

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ABOUT TRANSFORMERS

DEFINITION: A transformer is a passive component that

transfers electrical energy from one electrical circuit to another
circuit, or multiple circuits.

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Transformers are most commonly used for increasing low AC

voltages at high current (a step-up transformer) or decreasing
high AC voltages at low current (a step-down transformer) in
electric power applications.

PARTS OF TRANSFORMER
Basic Parts of a transformer:
The following are the basic components of a transformer.
1. Laminated core
2. Windings
3. Insulating Materials
4. Transformer oil
5. Tap changer
6. Conservator
7. Breather
8. Cooling tubes
9. Bushing
10.Lightning arrester
Of the above mentioned, Tap changer can be found only in
transformers more than 50KVA.

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• CORE :
Core is used to support the windings in the transformer. It also
provides a low reluctance path to the flow of magnetic flux. It is
made up of laminated soft iron core in order to reduce eddy
current loss and Hysteresis loss.

Core of a 100 KVA Transformer

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• WINDINGS :
Windings are one of the most important part of the
transformer. In a transformer there are two windings wound
over the transformer core which are insulated from each other.
The windings are designed to optimize dynamic, thermal,
mechanical & electrical stresses depending upon the current &
voltage requirements.

H.V winding at the left and L.V winding at right.

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• INSULATING MATERIALS :
Insulating papers and card boards are used in transformers of
to isolate primary and secondary winding from each other and
from transformer core. Transformer oil is also a insulating
material.

Insulating papers, boards, ducts.

• TRANSFORMER OIL :
Transformer oil performs two important functions of insulation
as well as cooling for the core and coil assembly.

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• TAP CHANGER:
The output voltage may vary according to the input voltage and
the load. During loaded conditions the voltage on the output
terminal fall and during off load conditions the output voltage
increases. In order to balance the voltage variations tap
changers are used. Automatic tap changers are also available.
• CONSERVATOR :
Conservator conserves the transformer oil. It is an airtight
metallic cylindrical drum which is fitted above the transformer.
The normal oil level is approximately in the middle of the
conservator to allow expansion and contraction of oil during
the temperature variations. It is connected to the main tank
inside the transformer.

Conservator of a transformer

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• BREATHER:
The change in pressure due to expansion and contraction of oil
during the temperature variations is balanced by the flow of
atmospheric air into and out of the conservator. It is necessary
that the air entering the tank is moisture free because
insulating oil on reaction with moisture can affect the paper
insulation or can cause some internal faults. Transformer
breather is a cylindrical container which is filled with silica gel.
When the atmospheric air passes through the silica gel breather
the moisture contents are absorbed by the silica crystals. Silica
gel breather is acts like an air filter for the transformer and
controls the moisture level inside a transformer.

Silica gel breather

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• COOLING TUBES:
Cooling tubes are used to cool the transformer oil. The tubes
are provided on the sides of a transformer tank The oil in the
tank is taken to the tubes. The heat developed inside the
transformer is taken outside with the help of oil. The oil is
cooled with the help of fins, tubes or external radiations by
natural circulation of air. The circulation of oil through tubes
causes the cooling. The circulation of the oil may either be
natural or forced circulation.

Radiator or cooling tubes

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PRINCIPLE OF OPERATION
A Transformer is basically is very simple static(or stationary)
electromagnetic passive electrical device that works on a
principle of faraday’s electromagnetic induction by converting
electrical energy from one value to another. The transformer
does this by linking together two or more electrical circuits
using common oscillating magnetic circuit which is produced by
the transformer itself. A transformer operates on the principle
of electromagnetic induction.
Mutual induction is the process by which a coil of wire
magnetically induces a voltage into another coil located in close
proximity to it. Then we say that transformers work in the
“magnetic domain” and transformers get their name from the
fact that they transform one voltage or one current level to
another.

Flux linkage in a transformer

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WORKING
The processes occurring inside the transformer can be grouped
into two:
1. Magnetic flux is produced in a coil whenever there is a
change in current flowing through the coil.
2. Similarly change in magnetic flux linked with the coil
induces EMF in the coil.
The first process occurs in the windings of the transformer.
When the ac supply is given to the primary winding alternating
flux is produced in the coil .
The second process occurs in the secondary winding of the
transformer. The flux alternating flux produced in the
transformer links the coils in the secondary winding and hence
emf is induced in the secondary winding.

Working of step-up transformer

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ABOUT DEPARTMENTS

DESIGN DEPARTMENT :
The design and drawings of transformer is fully computerized
and the company is adopting the latest technology in designing
the transformers as per customers specifications. The design is
either made by the team of the company according to the
customer requirements or the customer themselves provides
the design to the company. Every transformer is individually
designed to its specific requirements and applications.
Sometimes the design is done in coordination with some
consultancies.
Before issuing the design to the plant, designs are reviewed by
a team consisting of representatives from Engineering, Quality
Assurance, Manufacturing and Testing. Each project engineer
carefully follows and checks progress throughout the
manufacturing process. All the department works on to the
transformer manufacturing according to design.

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PURCHASE DEPARTMENT :
The main functions of the purchase department are defined as
follows :
• Checking of requisitions/purchase indents.
• Selection of suppliers for issue of enquiries.
• Issuing enquiries/tenders and obtaining quotations.
• Analysing quotations and bids .
• Negotiating contracts.
• Checking legal conditions of contracts. Consulting
Administrative Officer or Secretary.
• Issue of purchase orders.
• Follow-up of purchase orders for delivery in due time.
• Verification and passing of suppliers' bills to see that
payments are made promptly.
• Correspondence and dealing with suppliers, carriers etc.
regarding shortages, rejections etc. reported by the Stores
Department.
• Maintenance of purchase records.
• Maintenance of progressive expenditure statement.
• Maintenance of vendor performance records/data.
• Keeping various Departments/Divisions informed of the
progress of their indents in case of delay in obtaining
supplies.
• Servicing as an information centre on the materials
knowledge i.e. their prices, source of supply, specifications
and other allied matters.

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Some materials and suppliers

Sr. No Name of the material Name of the supplier
1. Lamination (core) J. K Corporation, Nagpur
2. DPC Aluminium wire & Vidharbha Alloy Conductors, Borgaon
strips
3. Copper winding wire Redisson Metals & Alloys Pvt. Ltd,
Ahmedabad
4 Aluminium Super Enamel Top Notch Insulation, Indore
wire
5. DPC Rectangular Copper Tapadia Instruments, Nagpur
Winding Wire
6. G.I wires and bolts Reliable Sales Corporation, Nagpur
7. Bolts Super Precision Fastner, Nagpur
8. Copper Flexible Cables JUS Enterprises, Nagpur
9. Brass Metal Plates J. P Industries, Jamnagar
10. Wooden bidings Nagpur Trading Company
11. Paints Indokote Industries Pvt. Ltd. Haryana
12. Transformer lamination Regal Transcare Lamination, Jaipur
core
13. Transformer oil Savita Oil Technology, Daman & Diu
14. Servo Super Multicare Oil Indian Oil Corporation, Nagpur
15. MS- Channel Rathi Steel , Nagpur
16. Transformer MS- Tank Vidharbha Alloy Conductors, Borgaon
17. Breather Bharat Forgings, Meerut
18. Oil Gauge Anushree Electricals, Meerut
19. Bushings R.R Industries , khurja
20. Oil Filters Machine Kristorr Vaccum Equipment Pvt. Ltd,
Pune

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PRODUCTION DEPARTMENT:
It is the responsibility of the manufacturing department to
manufacture different components of transformer and then
assemble them to make a transformer. Production department
has following sections:

• Winding section
• Core section
• Tanking section
• Assembly section
1.WINDING SECTION: Based on voltage windings can be
classified as follows ;
A). High voltage winding : Windings which carry high voltage in
a transformer are called High voltage windings .Windings are
made of super enamel circular aluminium conductor with
insulation paper wounded around it.
B). Low voltage winding: Windings which carry low voltage in a
transformer are called Low voltage windings. Rectangular
aluminium conductor insulated with paper is used for L.V
winding.
The number of turns in H.V winding is the multiple of the
number of turns in the L.V windings because turns are
proportional to voltage. Due to high current value at L.V
winding the conductor used in L.V winding is thick
(rectangular) in shape while for H.V it is circular or thin. Both

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the windings are manufactured over winding machine with

proper insulation and locking. steel winding mandrels are used
to ensure tight tolerances and the winding machines are
equipped with hydraulic braking devices which ensure that the
proper tension is maintained on the winding.

Winding machines

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INSULATION : Cotton tape and insulating cardboards are used

to insulate core and windings. Conductors of windings are
insulated using 2 mill insulating paper (40 mill =1mm). The
windings of the transformer are also isolated using papers and
boards and craft tape is also used.

2.CORE SECTION: Material used for the making of core is cold

rolled grain oriented (CRGO) M4/M3 grade silicone steel sheet
which is an alloy of iron and silicon. Silicon is used to increase
the permeability of iron.

Core assembly
Core leg and yoke limbs are inserted in mitred joints in order to
facilitate the passage of the magnetic flux, to avoid hot spots
and to reduce no load losses. Then by using gauges and jigs, the
limbs are stacked in a way that there is no air gap between the
limbs. All the limbs are joined and are assembled into a core,

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taking much care to reduce the air gaps between the

laminations to the minimum. Outer side of the core is varnished
to avoid rusting. Core is tightened using upper and lower
pressing beams. Then it goes to assembly section.

3.ASSEMBLY SECTION : In the assembly section there are many

processes in which all the components of the transformer are
put together to form a transformer. Important processes in the
assembly section are :
• CORE LOSS TESTING :Once the limbs are assembled then
a test is conducted for iron losses.

Test before core coil assembly

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• CORE COIL ASSEMBLY : In the core coil assembly the

windings are slipped over the legs of the core and the
limbs of the upper yoke are inserted to complete the core,
then core is tightened using upper and lower pressing
beams or channels. First the L.V windings is fitted on the
core and after that H.V windings are fitted over it.
For coil to coil insulation and core to coil insulation cotton
tape and insulating sheet are used. Axial and radial cooling
ducts are used between sections of the windings which
allow the free flow of oil around the conductor and ensures
heat dissipation through circulation of oil. Best quality
insulation is provided at all joints and gaps. For insulation
between bottoms pressing beam and wooden base is used.

Core Coil Assembly

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• H.T AND L.T CONNECTIONS : In this section Y-Delta

connections are made. The high voltage side is connected
as delta and low voltage side is connected as star. The
connections are done by a process called BRAZING using
ALOTETIC (brazing powder). The connections between the
high voltage lapping and the tap changer are also made.
Connections are made according to work order
specifications given by the design department. The Tap
changer allows the increase or decrease of a certain
number of turns in the high voltage winding in order to
compensate for a voltage drop or to adapt the transformer
to an unstable supply and to avoid any short circuit., so
that the rated low voltage can be maintained.

Connection of H.V winding

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Connection of L.V winding

• TURNS RATIO TEST : Once all the connections are made
properly then the turns ratio test is conducted. The ratio
of turns should be 44 with 5-10 % tolerance. In L.V side
rightmost conductors is named as R then from right to left
R Y B are named and in H.V side the leftmost one is named
as R and from left to right R Y B.

• FURNANCE/OVEN : In order to remove the moisture

content in the ACTIVE PART of the transformer and to
increase the insulation resistance the transformer is kept
in the furnace or oven and is heated for 48 to 72 hours at
the temp. of 120 Celsius. After removing job from oven
MEGGER TEST is done for L.V and H.V side.

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Furnance
• TANKING SECTION: After the transformer is furnanced, it
is placed in the tank. Before tanking blower is used to
remove dust particles from job. The tank has L.V and H.V
(sometimes) bushings connected to it and after putting the
job in tank it is insured that any part of job do not touch
the tank body only the connections of bushing between
earth and phase is done. And finally top cover is
assembled.

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• TOP COVER ASSEMBLY : Top cover of the transformer

has bushings which are connected on member with clamp,
gasket and bots so that there is no leakage of oil. Oil
Gauge is also fitted in top cover which indicates the
amount of oil in transformer.

H. V Bushing and L.V Bushing

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• OIL FILLING SECTION : In oil filling section oil is filled in

the transformer tank. Core and windings of the
transformer must be completely immersed in the oil. Oil
should be free of moisture and its BDV should be 30KV to
60KV.

Oil filtering plant

• PAINTING AND VARNISHING: The tank is first varnished

and then painted for good look and to prevent RUST.

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• FINISHING: Many tests are conducted and finally

Lightning arrester which is used to earth the voltage at the
time of thunderstorm is set and specification plate is fitted
before transformer is ready for dispatch.

Lightning arrester connected to H.V winding

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QUALITY CONTROL AND TESTING DEPARTMENT:

Inspection and quality control department ensures whether the
material purchased by the purchase department is according to
the required standards. During the manufacturing of
transformers all the components of transformer are according
to given transformer design. It conducts all the quality tests to
ensure that the transformer does not fail at the time of testing
and monitors the various manufacturing activities, up to final
testing of transformers to ensure that the transformers
manufactured is upto the Indian Standards and costumers
requirement.
The various inspection are as follows:
1. Inspection of raw materials received from various vendors.
2. Stage inspection at various levels in manufacturing shops.
3. Final testing of the transformers as per Indian Standards.
4. Inspection at the dispatch area before dispatch to ensure
that the transformers are fitted with all accessories etc.
The raw materials are tested to ensure that the quality is up to
the recommended standards, these tests are done to check the
durability, strength of the material.
The raw materials that are being tested are oil, Aluminium
conductors, bushings, cork sheet.
OIL:
Breakdown voltage test(BDV)

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DPC ALUMINIUM CONDUCTOR:

Tensile strength test
Resistance test

BUSHINGS:
BDV test
Wet and Dry Bushing test.

CORK SHEET:
Tensile strength test

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TESTING IN TRANSFORMER:
Testing is an important activity in the manufacture of a
transformer. To check that it will not fail in real environment
and to prove that the transformer meets customer’s
specifications and design expectations, tests are done on the
transformer before it is ready to dispatch. The witness of some
inspection and test by third party inspector is mandatory and
cannot be waived.
Routine tests of transformer is mainly for confirming
operational performance of individual unit in a production lot.
Routine tests are carried out on every unit manufactured.
Routine tests of transformer include:
• No Load Losses (Open circuit test)
• Full Load Losses (Short circuit test)
• Winding Resistance Test
• Transformer Turns Ratio Test
• High Voltage (HV) test
• Double the voltage-double the frequency (DVDF) test
• Insulation Resistance Test (Megger Test)
• Transformer vector group test.
• Magnetic Balance Test
• Dielectric Strength of Transformer Oil

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1.No Load Losses or Open Circuit Test

Open circuit test or no load test on a transformer is performed
to determine No load loss (core loss) and No load current.
Usually high voltage (HV) winding is kept open and the low
voltage (LV) winding is connected to its normal supply. A
wattmeter (W), ammeter (A) and voltmeter (V) are connected
to the LV winding as shown in the figure.

Open circuit test on transformer

• The applied voltage of 433V is slowly increased from zero
to normal rated value of the LV side with the help of a
variac.
• When the applied voltage reaches to the rated value of
the LV winding, readings from all the three instruments
are taken.
• The ammeter reading gives the no load current Io. As lo
itself is very small, the voltage drops due to this current
can be neglected.

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• The input power is indicated by the wattmeter (W). But, as

the other side of transformer is open circuited, there is no
output power. Hence, this input power only consists of
core losses and copper losses.
But as short circuit current is so small that these copper losses
can be neglected. Hence, now the input power is almost equal
to the core losses. Thus, the wattmeter reading gives the core
losses of the transformer.
THE READING OF THE WATTMETER GIVES THE CORE LOSS OF
THE TRANSFORMER

2.Full Load Losses or Short Circuit Test

Short circuit test or full load test on a transformer is performed
to find the copper losses of the transformer. The connection
diagram for short circuit test on transformer is shown in the
figure. A voltmeter, wattmeter, and an ammeter are connected
in HV side of the transformer .

Short circuit test on transformer

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• The voltage at rated frequency is applied to that HV side

with the help of a variac of variable ratio auto transformer.
• The LV side of the transformer is short circuited. Now with
the help of variac applied voltage is slowly increased until
the ammeter gives reading equal to the rated current of
the HV side.
• After reaching at rated current of HV side, all three
instruments reading (Voltmeter, Ammeter and Watt-
meter readings) are recorded.
• The ammeter reading gives the primary equivalent of full
load current.
As the voltage applied for full load current in short circuit test
on transformer is quite small compared to the rated primary
voltage of the transformer, the core losses in transformer can
be taken as negligible here.
THE READING OF THE WATTMETER GIVES THE COPPER LOSS OF
THE TRANSFORMER.

3.Winding Resistance Test

Transformer winding resistance measurement is carried out to
calculate the I²R losses and to calculate winding temperature at
the end of a temperature rise test. It is also done at site to
ensure healthiness of a transformer that is to check loose
connections, broken strands of conductor, high contact
resistance in tap changers, high voltage leads and bushings etc.

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There are different methods for measuring of transformer

winding:
• Current voltage method of measurement of winding
resistance.
• Bridge method of measurement of winding resistance.
• Kelvin bridge method of Measuring Winding Resistance.
• Measuring winding resistance by Automatic Winding
Resistance Measurement Kit.
In case of power transformer winding resistance measurement
shall be carried out at each tap
FROM THIS TEST THE RESISTANCE OF THE WINDINGS IS FOUND
WHICH ENSURES HEALTHINESS OF A TRANSFORMER.

4.Transformers Turns Ratio Test

Transformer turns ration test is performed to check the specific
turns ratio of the transformer.
The performance of a transformer largely depends upon
perfection of specific turns or voltage ratio of transformer. So
for ensuring proper performance of electrical power
transformer, voltage and turn ratio test of transformer is
important.
• We just apply three phase 433 V supply to HV winding,
with keeping LV winding open.

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• Then we measure the induced voltages at HV and LV

terminals of transformer to find out actual voltage ratio of
transformer.
• We repeat the test for all tap position separately.

Reading of turns ratio at R terminal

THE TURNS ARE CHECKED AND IF THE TURNS RATIO IS LESS THE
TURNS ARE ADDED AND IF TURNS RATIO IS MORE THE TURNS
ARE REMOVE TO GET THE PROPER RATIO.

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5. High Voltage ( H.V) Test

High voltage test also called as Separate Source Voltage
Withstand Test of Transformer of transformer is intended to
check the ability of main insulation to earth and between
winding.
• All three line terminals of the winding to be tested are
connected together.
• Other winding terminals which are not under test and also
tank of the transformer should be connected to earth.
• Then a single-phase power frequency voltage of shape
approximately sinusoidal is applied for 60 seconds to the
terminals of the winding under test.
• The test shall be performed on all the windings one by
one. The test is successful if no breakdown in the dielectric
of the insulation occurs during test.

In this transformer testing, the peak value of voltage is

measured. The peal value multiplied by 0.707 (1/√2) is the test
voltage.
THE TEST IS SUCCESSFUL IF NO BREAKDOWN IN THE DIELECTRIC
OF THE INSULATION OCCURS DURING TEST.

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6.Double the voltage-double the frequency (DVDF) test or

induced Voltage Test
Induced voltage test or double the voltage- double the
frequency test of transformer is intended to check the inter
turn and line end insulation as well as main insulation to earth
and between windings.
Double voltage Double Frequency test panel is used to perform
DVDF Test for Power and distribution transformers. This test
set provides a continuously variable output voltage at double
frequency to test the insulation between turns of coils, layer to
layer, terminals of windings with either uniform or graded
insulation and also between the windings and earth, with
graded insulation of both Distribution and Power transformers.

DVDF Set
An alternating voltage of sine wave form (as much as possible)
at double frequency (100 Hz.) and double in amplitude can be
applied at one side of the transformer under test while the

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windings, which are not connected to the source of excitation,

are left on open circuit. This higher frequency is considered to
avoid excessive excitation current during the testing. The
duration of the test shall be 60 second.The test shall start with
a voltage lower than 1/3 the full test voltage, and it shall be
quickly increased up to desired value.

THE TEST IS SUCCESSFUL IF NO BREAK DOWN OCCURS AT FULL

TEST VOLTAGE DURING TEST.

7.INSULATION RESISTANCE TEST OR MEGGER TEST

Megger test is performed to ensure proper insulation system in
the transformer
Insulation resistance test of transformer is essential. This test is
carried out to ensure the healthiness of overall insulation
system of an electrical power transformer.
• First disconnect all the line and neutral terminals of the
transformer
• Megger leads are to be connected to LV and HV bushing
studs to measure insulation resistance IR value in between
the LV and HV windings.
• Megger leads are to be connected to HV bushing studs and
transformer tank earth point to measure insulation
resistance IR value in between the HV windings and earth.

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• Megger leads are to be connected to LV bushing studs and

transformer tank earth point to measure insulation
resistance IR value in between the LV windings and earth.

Reading of Megger test

FROM IR TEST THE INSULATION IS CHECKED THE RESISTANCE IS
ABOVE 2000 MEGA OHM PROPER INSULATION IS MUST FOR A
TRANSFORMER.

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8.VECTOR GROUP TEST

Vector group test is performed to check the Proper vector
grouping which is an essential criteria for parallel operation of
transformers. In three phase transformer, it is essential to carry
out a vector group test of transformer. Proper vector grouping
in a transformer is an essential criteria for parallel operation of
transformers.
There are several internal connection of three phase
transformer are available in market. These several connections
gives various magnitudes and phase of the secondary voltage;
the magnitude can be adjusted for parallel operation by
suitable choice of turn ratio, but the phase divergence cannot
be compensated. So we have to choose those transformer for
parallel operation whose phase sequence and phase divergence
are same. All the transformers with same vector ground have
same phase sequence and phase divergence between primary
and secondary. So before procuring one electrical power
transformer, one should ensure the vector group of the
transformer, whether it will be matched with his or her existing
system or not.
THE VECTOR GROUP TEST OF TRANSFORMER CONFIRMS FOR
PARALLEL OPERATION WHOSE PHASE SEQUENCE AND PHASE
DIVERGENCE ARE SAME.

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9.Magnetic Balance Test

Magnetic balance test of transformer is conducted only on
three phase transformers to check the imbalance in the
magnetic circuit.
• First the tap changer of transformer is kept in normal
position and transformer neutral is disconnect from
ground.
• Then apply single phase 230 V AC supply across one of the
HV winding terminal and Measure the voltage between
the terminals.
• Compare the measured values with the standard values
THE MEASURED VOLTAGE VALUES OF THE TERMINALS GIVES
THE DISTRIBUTION OF THE FLUX IN THE TERMINALS

10.Dielectric Strength of Transformer Oil

To check the dielectric strength of the transformer oil and to
measure the break down voltage testing of transformer oil is
conducted before filling it in tank .
Dielectric strength of transformer oil is also known as
breakdown voltage of transformer oil or BDV of transformer oil.
Break down voltage is measured by observing at what voltage,
sparking strands between two electrodes immerged in the oil,
separated by specific gap . low value of BDV indicates presence
of moisture content and conducting substances in the oil.

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• For measuring BDV of transformer oil, portable BDV

measuring kit is generally available.
• In this kit, oil is kept in a pot in which one pair of
electrodes are fixed with a gap of 2.5 mm (in some kit it
4mm) between them.
• Now slowly rising voltage is applied between the
electrodes.
• Rate of rise of voltage is generally controlled at 2 KV/s and
observe the voltage at which sparking starts between the
electrodes that means at which voltage dielectric strength
of transformer oil between the electrodes has been
broken down.
• Generally this measurement is taken 3 to 6 times in same
sample of oil and the average value of these reading is
taken. BDV is important and popular test of transformer
oil, as it is primary indication of health of oil and it can be
easily carried out.
Dry and clean oil gives BDV results, better than the oil with
moisture content and other conducting impurities. Minimum
breakdown voltage of transformer oil or dielectric strength of
transformer oil at which this oil can safely be used in
transformer, is considered as 30 KV.

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Oil BDV Test Set

BY CONDUCTING THE BDV TEST THE DIELECTRIC STRENGTH

AND BREAKDOWN VOLTAGE IS FOUND AND IF LESS THE OIL IS
FURTHER FILTERED TO IMPROVE THE DIELECTRIC STRENGTH.

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Experience

At JDS Transformer I gained the knowledge related to

manufacturing, testing, winding, heating of transformers which
was truly helpful. The knowledge I received here has made me
more confident technically. My theoretical ideas and thoughts
were implemented practically.
I am gratified for the acceptance and glad that the atmosphere
and the working skills made me learn things stage by stage and
level by level.
The Communication and interaction of the respectful mentors
made me feel comfortable to ask questions and clarify my
doubts.
The over all experience has made me learn many professional
ethics such as Time management, Regularity in work,
Consistency in performance, Improvisation in problem analysis
and solving ability.

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Conclusion

My overall experience at “JDS TRANSFORMERS” was just

phenomenal.
It was an exposure to my future industrial life. My learning
experience here for 2 weeks will remain as a very good memory
in my electrical life.
I have gained a overall practical view of what transformer is!!!!
This 2 week experience have inspired me to get into core
industries. It has held my ideas towards hardware. I learnt to
emerge as one of the finest technical and electrical engineer of
higher learning to develop engineering professional who is
technically competent. The experience and the knowledge I
have gained here has made me more confident technically.
Overall was an awesome experience and would surely insist our
juniors and friends to visit JDS TRANSFORMERS.

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