Transformer Manufacturing, Repairing and Maintenance

Teacher

Debasis Sahu

Category

Certificate Courses

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Code(Credit) : (0-3-1)

Description

The primary purpose of transformer maintenance is to ensure the internal and external parts of the transformer and accessories are kept in good condition and able to operate safely at all times. A secondary and equally essential purpose is to maintain a historical record of the condition of the transformer. Transformer maintenance can be done periodically or as condition based maintenance.

Course Objectives

  1. Understand the concept of mutual inductance
  2. Understand the operation of ideal transformers.
  3. Use equivalent circuits to determine voltages and currents.
  4. Analyze the operation of the transformer for different transformation ratios.
  5. Understand the concept of a reflected load in a transformer and its application in impedance matching.
  6. Study the application of transformers in electrical energy distribution and power supplies.

Learning Outcomes

  1. Carry out an inspection: To ensure equipment is under healthy state with and to detect any types of faults.
  2. Perform testing activity: for any suspicious inspection testing of the system to be done to detect any faults or working conditions of the equipment.
  3. Repair, Overhaul, and delivery of tested distribution transformer:Carrying out repair and maintenance activity in damaged distribution transformer and ensure the overall health of the distribution transformer
  4. Design different parts of the transformer
  5. Assemble different parts of the transformer and carry out pre and post-manufacturing tests.

Course Syllabus

Module 1: Use Basic Health & Safety practices with power-related work

Practice-  To study uses of PPE equipment during worksite e.g. safety helmet, belt, shoes, protective glasses, earth rod, etc.

Practice   ­-   To understand basic health and safety practices covering CEA safety regulations 2010,        issue of a permit to work, etc

Practice-   Information to the relevant authority for any abnormal situation/behavior of any equipment’s

Practice- To understand Safety practices with power-related work

Module 2: Basics Of Electricity

  Practice-  Identify Basic fundamentals of Electricals

Practice ­-  Carry out Transformer Fundamentals under-standing of schematic drawings of various equipment’s used in a distribution substation, and drawing of Single line diagrams and layout plans

 Module 3: Basics of transformer operation

Practice: Introduction of the transformer, types of the transformer (based on voltage, coil, etc...).

Practice: Demonstration on transformers (laminated core, windings, insulating materials, transformer oil, tap changer, oil conservator, and breather).

Practice: Identification of HT & LT side/winding/terminals of three phase transformer

Module 4: Testing and Inspection of Faults in Distribution Transformer

Practice- Identify and carry out voltage and current transformation ratios

Practice- Demonstration on Details and function of transformer auxiliaries: tap changer, explosion vent, oil temperature indicator, conservator, silica gel, breather etc

Practice- Monitoring of transformer performance and auxiliaries monitoring

Practice- Inspect  all required grounding and shorting connections, perform the insulation-resistance test

practice- Identification of ht & lt side/winding/terminals of the three-phase transformer and oil test of a three-phase transformer.

Module 5: Repair, overhaul, and delivery of test  distribution transformer

Practice- Identify and Repair activity and assembling overhaul of distribution transformer standard procedures, refer maintenance manual and circuit diagram

Practice- Demonstrate repair and maintenance compliance stated in the standard procedure manual in the organization and the general requirements of standards and 5S

Practice- Ensure complete transformer with its components are fitted and packed in its original shape

Practice- Energize distribution transformer at NOLOAD only and checked for any abnormalities for the next 4 hours

Practice-  carry out Open circuit & short circuit test on three phase step-up or step-down transformer and predetermination of (i) efficiency and regulation (ii) calculation of parameters of equivalent circuit)

Practice- identify Polarity test of a three phase transformer in star-star, star-delta, delta-delta & delta-star connection.

Module 6: Maintenance of three phase transformer

Practice - Complete  repair of 16/25 KVA distribution transformer

Practice - Demonstrate repair and maintenance compliance stated in the  standard procedure manual in the organization and  the general requirements  of standards and 5S

Practice- Identify common hazard, Storage of flammable materials and oils safely

Practice - Recognize any abnormalities in the system installed, alarms, noticing parameters

Practice- Ensure complete transformer with its components are fitted and packed in its original shape.

Projects

Reference Books:
1) Operation and Maintenance of Transformers HAND BOOK by H.N.S. GOWDA
2) The Performance and Design of Alternating Current Machines by M.G.Say

Session Plan

Session 1

To study uses of PPE equipment during worksite e.g. safety helmet, belt, shoes, protective glasses, earth rod, etc.

https://www.youtube.com/watch?v=qayTdbC7av0

Session 2

To understand basic health and safety practices covering CEA safety regulations 2010, issue of a permit to work, etc

https://www.youtube.com/watch?v=1uXi2rT2LIg

Session 3

Information to the relevant authority for any abnormal situation/behavior of any equipment.

https://www.youtube.com/watch?v=1uXi2rT2LIg

https://www.youtube.com/watch?v=yAz9Ungv2Xc

Session 4

To understand Safety practices with power-related work.

https://www.youtube.com/watch?v=4bkr5lpKGUM

https://www.youtube.com/watch?v=yAz9Ungv2Xc

Session 5

Identify Basic fundamentals of Electricals.

https://www.youtube.com/watch?v=mc979OhitAg

Session 6

Carry out Transformer Fundamentals, understanding of schematic drawings of various equipment’s used in a distribution substation, and drawing of Single line diagrams and layout plans

https://www.youtube.com/watch?v=94WvB9Gx5_Q

Session 7

Introduction of the transformer, types of the transformer (based on voltage, coil, etc...)

https://www.youtube.com/watch?v=YQQ-mgjCpn8

https://www.youtube.com/watch?v=4Ly-p93Z1go

Session 8

Demonstration on transformers (laminated core, windings, insulating materials, transformer oil, tap changer, oil conservator, and breather).

https://www.youtube.com/watch?v=94WvB9Gx5_Q

Session 9

Identification of HT & LT side/winding/terminals of three phase transformer.

https://www.youtube.com/watch?v=9rCgd7wPxw8

Session 10

Identify and carry out voltage and current transformation ratios.

https://www.youtube.com/watch?v=7JRUgQPzxnA

Session 11

Demonstration on Details and function of transformer auxiliaries: tap changer, explosion vent, oil temperature indicator, conservator, silica gel, breather etc.

https://www.youtube.com/watch?v=94WvB9Gx5_Q

Session 12

Monitoring of transformer performance and auxiliaries monitoring.

https://www.youtube.com/watch?v=wFWF1hesmAs

Session 13

 Inspect  all required grounding and shorting connections, perform the insulation-resistance test.

https://www.youtube.com/watch?v=SANLOEHALq4

Session 14

Identification of HT & LT side/winding/terminals of the three-phase transformer and oil test of a three-phase transformer.

https://www.youtube.com/watch?v=yOfbz2QL1z4

Session 15

Identify and Repair activity and assembling overhaul of distribution transformer standard procedures, refer maintenance manual and circuit diagram.

https://www.youtube.com/watch?v=UBTRNwGx2bY

Session 16

Demonstrate repair and maintenance compliance stated in the standard procedure manual in the organization and the general requirements of standards and 5S.

https://www.youtube.com/watch?v=8gKJ3_Hm3dM

Session 17

Ensure complete transformer with its components are fitted and packed in its original shape.

https://www.youtube.com/watch?v=94WvB9Gx5_Q&t=40s

Session 18

Energizing distribution transformer at NOLOAD only and checking of any abnormalities for the next 4 hours.

https://www.youtube.com/watch?v=uj-HDHEXzx8

Session 19

Carrying out of the Open circuit & short circuit test on three phase step-up or step-down transformer and predetermination of

(i) efficiency and regulation

(ii) calculation of parameters of equivalent circuit

https://www.youtube.com/watch?v=LFML3c9leUI

Session 20

Conducting the polarity test of a three phase transformer in star-star, star-delta, delta-delta & delta-star connection.

https://www.youtube.com/watch?v=mkb8vHm1uhU

Session 22

Demonstrate the maintenance compliance stated in the  standard procedure manual in the organization and  the general requirements  of standards and 5S.

https://www.youtube.com/watch?v=8gKJ3_Hm3dM

Session 23

Identify common hazard, Storage of flammable materials and oils safely.

https://www.youtube.com/watch?v=-Xe5fbYy2SE

Session 24

Recognize any abnormalities in the system installed, alarms, noticing parameters.

https://www.youtube.com/watch?v=hrqmkiXpz34

Session 25

Performing all types of tests in a transformer.

https://www.youtube.com/watch?v=LFML3c9leUI

Session 26

Assignment

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