Power plant engineering works

INDUSTRIAL TRAINING
Submitted in partial fulfilment of the requirement under
Apprenticeship for the award of

Department of Electrical and Electronics Engineering

Submitted by

G.Divakar 22009-EE-035

Under the supervision of

Dr. S.B. LINGA MURTHY,

Department of Electrical and Electronics Engineering

 CERTIFICATE

This is to certify that G. Diakar student of GOVERNMENT POLYTECHNIC

COLLEGE, VISAKHAPATNAM has completed his Industrial Training as a part of
his academic course from 15-05-2024 to 11-11-2024 in “Power plant
engineering Works ” for the partial fulfilment of the requirement for the
award of Diploma in Electrical and Electronic Engineering.

Mr. A.Ramesh

Manger partner,

Visakhapatnam.
 CERTIFICATE

This is to certify that G. Divakar student of Government Polytechnic,

Visakhapatnam, has completed his Industrial Training as a part of his
academic course from 15-05-2024 to 11-11-2024 in “Power plant
engineering works” for the partial fulfilment of the requirement for the
award of Diploma in Electrical and Electronic Engineering.

Signature of Project Guide Signature of Head of

Department

Signature of External
 ACKNOWLEDGEMENT

I owe a great many thanks to great many people who helped and
supported me during my industrial training.

I would like to thank Mr. A. Ramesh and other staff of the “Power plant
engineering works “ for providing us necessary information and conducting
viva.

I express my deepest sincere thanks to our Principal Shri. G.V.V.Satya

Narayana Murthy (M.Tech), Shri. K.D.V Narasimha Rao, Shri S.B. LINGA
MURTHY , for guiding and extending their support to complete this industrial
training.

I would also thank the faculty members of Government polytechnic college,

Vishakhapatnam.

On consultation, I shall never forget my experience in my industrial training

in Power plant engineering works and experience to prove my ability and
work for the pride of the organization in the respects whenever I work.
INDEX

S.NO. NAME OF THE CONTENT

Chapter-01 INTRODUCTION

Chapter-02 TRANSFORMERS

Chapter-03 SINGLE PHASE TRANSFORMERS

Chapter-04 THREE PHASE TRANSFORMERS

Chapter-05 TYPES OF MACHINES

Chapter-06 CORE

Chapter-07 CORE HEATING OVEN

Chapter-08 MEGGER

Chapter-09 WINDING

Chapter-10 TYPES OF CONNECTIONS

Chapter-11 METERS

Chapter-12 BUSHINGS

Chapter-13 LIGHTNING ARRESTORS

Chapter-14 CRANE & CRANE OPERATING SYSTEM

Chapter-15 PHASE POWER ANALYSER

Chapter-16 PAPER ROLL AND TYPES

Chapter-17 PAINT
Chapter-18 PROCESS OF REPAIRING TRANSFORMERS

 CONCLUSION

CHAPTER-1
 Introduction

The transformer is a device used for converting a low alternating voltage to a

high alternating voltage or a high alternating voltage into a low alternating
voltage. It is a static electrical device that transfers energy by inductive
coupling between its winding circuits. Transformers range in size from a
thumbnail-sized coupling transformer hidden inside a stage microphone to
huge units weighing hundreds of tons used in power plant substations or to
 interconnect portions of the power grid. All operate on the same basic
principles, although the range of designs is wide. While new technologies
have eliminated the need for transformers in some electronic circuits,
transformers are still found in many electronic devices. Transformers are
essential for high- voltage electric power transmission, which makes long-
distance transmission economically practical. A transformer is most widely
used device in both low and high current circuit. In a transformer, the
electrical energy transfer from one circuit to another circuit takes place
without the use of moving parts. A transformer which increases the voltages
is called a step-up transformer. A transformer which decreases the A.C.
voltages is called a step-down transformer. Transformer is, therefore, an
essential piece of apparatus both for high and low current circuits.
CHAPTER-2
 TRANSFORMER :

Transformer is a static device for transforming electrical energy from one

circuit to another circuit without any chance in frequency.

Purpose of transformer:
 The purpose of using a transformer in power supply is to make electrical
power accessible as it travels from a power utility to an office, home,
worksite or other location. Energy is lost when it travels along transmission
wires from a power plant to a customer. Utilities use a very high voltage to
lose less energy.

Theory of transformer:

A transformer works on the principle that energy can be transferred by

magnetic induction from one set of coils to another set by means of a varying
magnetic flux. The magnetic flux is produced by an AC source.

Function of transformer:

Transformers are used in electric circuits to change the voltage of electricity

flowing in the circuit. It is used to increase the voltage (called ‘stepping up’)
or decrease the voltage (‘stepping down’) in AC circuits

TRANSFORMER:-

Transformer is a static device for transforming electrical energy from one

circuit to another circuit without any chance in frequency,

Types of single-phase transformers:

1. Step-up transformer

2. Step-down transformer

Step-up transformer: The secondary voltage will be more than primary

voltage and such a transformer is known as step-up transformer.

Step-down transformer: The secondary voltage will be less than primary

voltage and such a transformer is known as step-down transformer any
chance in frequency.
 TRANSFORMER LOSSES:-

The output energy of a transformer is always less than the input energy,
because energy losses occur due to a number of reasons as explained below

1. Loss of Magnetic Flux: The coupling between the coils is seldom

perfect. So, whole of the magnetic flux produced by the primary coil is
not linked up with the secondary coll.

2. Iron Loss: In actual iron cores in spite of lamination, Eddy currents are
produced. The magnitude of eddy current may, however be small. And
a part of energy is lost as the heat produced in the iron core

3. Copper Loss: In practice, the coils of the transformer possess

resistance. So a part of the energy is lost due to the heat produced in
the resistance of the coil.

4. Hysteresis Loss: The alternating current in the coil tapes the iron core
through complete cycle of magnetization. So Energy is lost due to
hysteresis.

5. Magneto restriction: The alternating current in the Transformer may

be set its parts in to vibrations and sound may be produced. It is called
humming. Thus, a part of energy may be lost due to humming.
CHAPTER-3
 Construction of a single-phase transformer:

Transformer essentially consists of two windings, which are wound on a

common laminated magnetic core. The core is made with soft iron of silicon
steel laminations to provide a path of low reluctance for the magnetic flux.
The windings are insulated from both core and each other The winding which
is connected to supply mains is known as “primary winding” and the winding
connected to the load circuit is known as “secondary winding There is no
electrical or mechanical connection between the two windings, but there is a
magnetic linkage between the two For the sake of simplicity and for
analysing transformer theory the two windings are shown on opposite sides
of the core But in actual construction the two windings are wound one over
the other.

Working of single-phase transformer:-

 When the primary winding is connected to an acc. Supply source of voltage
VI’ and frequency hertz, a current ‘11’ will flows through it. This current
produces an alternating flux ‘D’ in the core which varies with time. This flux
first links with primary winding hence produces self induced e.m.f “E1” in the
primary winding which opposes the applied voltage. The e.m.f sometimes
known as known as back e.m.f of the primary.

The flux ‘’ passes through the magnetic core, and links with secondary
winding also, so induces an e.m.f. called mutual induced e.m.f ‘E2’ in the
secondary winding. The magnitude of e.m.f. induced is proportional to the
rate of change of flux linkages and number of turns. The frequency of the
e.m.f. induced In the secondary winding is same as that of the flux or that of

Supply voltage. The emf. In the secondary winding will able to circulate the
current ‘12’ in the load circuit. Thus the energy is transferred from primary
winding to the secondary winding through the medium of magnetic field by
electromagnetic induction principle without any change in frequency.

Construction details of transformer:

1. Core 2. Windings

2. Tank 4.Transformer oil

6. Conservator 6. Breather
 7. Terminals and bushings

8. Exhaust pipe, oil guage, temperature guage.

9 cooling system Core:

The transformer core provides a magnetic path to channel flux. The use of
highly permeable material (which describes the material’s ability to carry
lux), as well as better core construction techniques, helps provide a desirable,
low reluctance flux path and confine lines of flux to the core. The core is
constructed of numerous thin strips of grain-oriented silicone steel, called
laminations, which are electrically isolated (yet still magnetically coupled)
from each other by thin coatings of insulating material. This is important to
reduce the no-load losses of the transformer. The core is a source of heat in
the transformer and as a core increases in size, cooling ducts within the core
may become necessary. Problems such as short-circuited core laminations
will result in increased losses and possibly overheating of the transformer
core.

Windings:

The winding are made with copper conductor and are placed on the cores.
The winding which is connected to supply is known as primary and the
winding which is connected to load is known as secondary winding. The
winding which is connected to low voltage is known as low voltage winding
LV and the winding which is connected to high voltage HV is known as high
voltage winding.

Tank:

Transformers are generally housed in a tightly fitted sheet metal tanks filled
with special insulation Oil The core winding are completely immersed in the
Oil inside the tank In case small transformers, the tanks are made with iron
sheets or sheet steel, whereas in case of large transformers, the tanks are
made with plain boiler plates or cast aluminum plates. The sheets or plates
are properly welded and a waterproof gasket being used at the joints so the
 oil may not come out of tank. When the transformer is winding. Heat is
produced in the tank hence needs cooling.

For cooling purpose, cooling tubes are welded around the tank in case of
large transformers separate radiator are welded to the tank which provides
better cooling. A tank must be also to withstand the stresses developed
inside and has provision for connecting to the load and supply

TRANSFORMER OIL:

The insulation oil which is used in the tank of a transformer is called

transformer oil it has three functions.

1. It acts as insulation medium between windings and tank

2. It provides better cooling by correcting through the cooling tunes

3. It carries away the heat generated in the core and windings and
quenches the arc if any.

CONSERVATOR:

It is a small oil tank mounted about the transformer and connected to the
main tank by a pipe The oil level of a transformer changes with change in
temperature of oil which in turn depend upon the load on the transformer.
The conservator receives the increased volume of Oil during expansion and
discharged the oil during contraction and keeping the main tank full of oil
The conservator is not filled completely with oil to facilitate the expansion.
As it receives the oil during expansion it is also called as expansion tank.
 BREATHER:

A breather consists of a silica gel crystal or CaC12 and is connected to the

conservator through vent pipe. The silica gel absorbs the moisture from the
air and clean moisture less air is allowed into the transformer. Silica gel is
blue in color when dry and becomes whitish pink when it absorbs moisture
in sufficient quantity. When silica gel changes into whitish pink, it should
be replaced. The color can be observed through the glass window provided in
front of the breather.

TERMINAL AND BUSHINGS:

The connections to the windings are copper rods or bars insulated from the
tank the windings are connected to the HV and LV line’s through insulator
bushing mounted on the top of transformer tank the bushing consist of a
Current carrying element and a porcelain cylinder upto 33KV voltage ordinary
porcelain insulator are used and above 33KV oil filled orcondenser type
bushings are used.

Exhaust pipe, oil guage, temperature guage:

Many transformers are provided with exhaust pipe made of steel. It’s
connected to the tank and has some bend at its end and is provided with a
glass disc at top. It protects the tank from the large expansion of the
accidental gas formation in large quantity and abrupt rise in pressure in case
of short circuit etc. Every transformer is provided with oil gauge and
temperature gauges Oil gauge indicates the level of oil in the tank. The oil
gauge is also provided with an alarm which gives an alarm when the oil level
has dropped below certain level due to oil leak. The temperature gauge
indicates the temperature of the oil.

Cooling system:

Whenever current is flowing through the windings, heat is produced which

should be dissipated. If the heat is not dissipated properly, it may damage
the windings end insulation. Hence, cooling is necessary for a transformer,
which can be provided by different methods such as natural air cooling, oil
immersed forced air, water and oil cooling and air- blast cooling.
CHAPTER-4
Three Phase Transformer:-
 A three-phase transformer consists of three primary coils and three
secondary coils and is represented as 3-phase or 34. A three-phase system
can be constructed using three individual identical single-phase transformers,
and such a 3-phase transformer is known as the bank of three transformers.
On the other hand, the three-phase transformer can be built on a single core
The windings of a transformer can be connected in either delta or wye
configurations. The working of the 3-phase system is similar to a single-phase
transformer, and they are normally employed in power generation plants.

Construction:-

A Three-phase transformer of a single unit is used widely because it is lighter,

cheaper and occupies less space than the bank of three single-phase
transformers. The three-phase transformer construction is of two types: Core
type and Shell type.

Core Type Transformer:

In this type of construction, there are three cores and two yokes. Each core
has both primary and secondary windings wounded spirally as shown in the
figure. Each leg of the core carries high voltage as well as low voltage
windings. The core is laminated to minimize eddy current losses on core and
yoke. As it is easier to laminate low voltage (LV) winding than the high
voltage (HV) winding. The LV windings are positioned near the core with
appropriate insulation and oil ducts in between them whereas, the HV
windings are placed above the LV windings with appropriate insulation and
oil ducts between them.

Shell Type Transformer:

The three-phase shell type transformer is generally constructed by stacking

three individual simplephase transformers. Three phases of a shell-type
 transformer are independent than the core-type transformer, while each
phase has an individual magnetic circuit. These magnetic circuits are parallel
to each other and flux induced by cach winding is in phase Shell type
transformer is highly preferred as the voltage wave forms are less distorted

Working of 3-Phase Transformer

The primary winding of the three phase transformer is energized from a

three phase supply. Then, the flux is produced in the core by the primary
currents in the three windings. The core has three limbs, where any two
limbs act as return path for the flux in the third lamb. The flux produced by
the primary windings induces emf in the secondary windings depending on
the transformation ratio of the 3-phase transformer

Three-Phase Transformer Connections

There are two three-phase windings in a three-phase transformer, primary

winding and secondary winding.

The connection of primary winding and secondary winding can be a star or

delta connection.

According to the application of a transformer, the primary winding and

secondary winding can be connected in four possible configurations as
follows:

• Delta-Delta (A-A)

• Star-Star (Y-Y)

• Delta-Star (A-Y)
 • Star-Delta (Y-A)

Delta-Delta (A-A) Connection:

In the delta-delta transformer connection, primary and secondary are

connected in the

Delta connection

This connection is generally used even if the lead is unbalanced and for large,
low-voltage transformers. The number of required phases/turns is relatively
greater than that for star-star connection.

The ratio of line voltages on the primary and secondary sides is equal to the
transformation ratio of the transformers.

Besides that, this connection is that even if one transformer is disabled, the
system can continue to operate in an open delta connection but with
reduced available capacity.

Star-Star (Y-Y) Connection

In this connection, the primary winding and secondary winding are

connected in a star connection.

This connection is generally used only if the connected load is balanced for
small, high voltage transformers. Because of the star connection, the number
of required turns/phase is reduced (as phase voltage in star connection is
1/43 times of line voltage only). Therefore, the amount of insulation required
is also reduced.

The ratio of line voltages on the primary side and the secondary side is equal
to the transformation ratio of the transformers.

Line voltages on both the primary side and the secondary side are in phase
with each other.
 Delta-Star (A-Y) Connection

In a Delta-star connection of a three-phase transformer, the primary winding

is connected in a Delta connection, and the secondary winding is connected
in a star connection.

The primary winding is connected in a Delta connection. Therefore, in the

primary winding, the phase voltage is equal to the line voltage.

The secondary winding is connected in a star connection. Therefore, in the

secondary winding. The line voltage is √3 times the phase voltage.

The primary winding is connected in the delta and the secondary winding is
connected in the star with neutral ground. Therefore, it can be used to
provide a 3-phase 4-wire service.

This connection is mainly used in a step-up transformer at the beginning of

the transmission line.

The ratio of secondary to primary line voltage is 13 times the transformation

ratio Thure is a 30 shift between the primary and secondary line voltages.

Star-Delta (Y-A) Connection

In a star-delta connection, the secondary winding is connected in a delta

configuration primary winding is connected in a star configuration

The secondary winding is delta connected and the primary winding is star
star (Y) connected with grounded neutral,

This star-delta connection is mainly used in step-down transformers at the

substation end of the transmission line.
 The ratio of secondary to primary line voltage is 1/43 times the
transformation ratio. There is a30° shift between the secondary and primary
line voltages.

Advantages of transformer:

• A transformer will increase or decrease basically AC voltage,

current It is efficient for highfrequency range

• The available power cannot change but will slightly too much
decrease depending on the efficiency of the transformer

• It has the advantage of preventing condensed flux leakage as

well as iron loss

• It offers good mechanical strength

• The transformer is widely used in power transmission

Disadvantages of transformer:-

• A transformer will not work with DC voltage under any

condition.

• The transformer size becomes un widely

• The physical size of the transformer is directly related to the

amount of power to be desired.

• It is not good to use outdoors.

• It can be noisy.
 APPLICATIONS OF TRANSFORMERS:-

• A transformer is used in almost all a.c. operations

• In voltage regulator for TV refrigerator, computer, air

conditioner etc.

• In the induction furnaces.

• A step down transformer is used for welding purposes

• A step down transformer is used for obtaining large current

• A step up transformer is used for the pro