An

INTERNSHIP

REPORT
on

“MAINTENANCE & REPAIR OF TRANSFORMER”

Submitted by
Mr. Ankute Ritesh Santosh (243648)
TE Electrical

In partial fulfillment of the requirements for the TE of

Bachelor of Engineering
In
ELECTRICAL ENGINEERING

Under the guidance of

Prof. S. D. Shelar

DEPARTMENT OF ELECTRICAL ENGINEERING

VIDYA PRATISHTHAN’S
KAMALNAYAN BAJAJ INSTITUTE OF ENGINEERING AND TECHNOLOGY
VIDYANAGARI, BARAMATI.
2024-25
 Vidya Pratishthan’s
VPKBIET Kamalnayan Bajaj Institute of Engineering and
Technology, Baramati
Vidyanagari, Bhigwan Road, Baramati, Dist. Pune (Maharashtra) - 413 133,
India.

DEPARTMENT OF ELECTRICAL ENGINEERING

CERTIFICATE

This is to certify that, the Internship Report entitled “MAINTENANCE &

REPAIR OF TRANSFORMER” submitted by Mr.Ankute Ritesh Santosh (243648) to
Savitribai Phule Pune University for the partial fulfillment of the requirements for the
degree Bachelor of Engineering with specialization in Electrical Engineering is a record
of bonafide work carried out by her under my supervision and guidance. Further it is
certified that, the work
done by her is original and carried out under my guidance as prescribed in the TE Electrical
syllabus of Savitribai Phule Pune University during the academic year 2024-25.

Internship Guide (Faculty)

Mr. S. D.Shelar

Assistant Professor
Department of Electrical Engineering
&

Internship Guide (Industry)

Mr. S .B.Tambare

Ass.Engineer/workshop Owner
Shree Jagadamba Electricals,beed

Mr.S.D.Shelar Mr. S. K. Raskar Mrs. P. N. Jaiswal Dr. S. B. Lande

Name of the mentor Internship Coordinator Coordinator Pripncipal
Elect. Engg. Dept. VPKBIET, Baramati
 ACKNOWLEDGEMENT

The satisfaction and euphoria that accompany the successful completion of any task
would be incomplete without the mention of the people who made it possible. Success is the
epitome of hard work, perseverance and most of all those guidance and encouragement
crowned our efforts and success.
I owe a debt of thanks to my mentor Prof. S. D.Shelar. who stood as a backbone to my
seminar work, having worked meticulously all through with special vigilance, zeal and
criticism. This contribution to the seminar is unbounded and mere words are not enough to
express our deepest sense of gratitude.
I thank Mrs. P. N. Jaiswal, Head of the Department for his constant encouragement
throughout this semester. His advice and co-operation in the completion of seminar is really
unforgettable. I am really indebted to him.
I would like to thank our beloved principal Dr. S. B. Lande, for providing me
necessary facilities. He has always been a source of inspiration and strength to me.
I am also grateful to all teaching and non- teaching staff of our department who helped
directly or indirectly for successful completion of seminar work.

Mr. Ankute Ritesh Santosh

 ABSTRACT

This internship at Shree Jagdamba Electricals, Beed, provided extensive hands-on training in
transformer repair and maintenance, covering both theoretical and practical aspects of transformer servicing.
The primary objective of the internship was to develop expertise in diagnosing faults, performing repairs, and
implementing preventive maintenance strategies to enhance transformer efficiency and lifespan.
During the internship, various activities were undertaken, including fault identification, insulation resistance
testing, oil filtration, bushing replacement, coil rewinding, core reassembly, and load testing. Special emphasis
was placed on safety protocols, quality assurance measures, and compliance with industry standards to ensure
optimal transformer performance.
Additionally, the internship provided insights into common transformer failures such as winding short
circuits, overheating, insulation breakdown, and oil contamination. Techniques like vacuum oil dehydration,
thermographic analysis, and power factor testing were explored to ensure reliable transformer operation.
By working closely with experienced professionals, the internship helped bridge the gap between academic
knowledge and practical industry applications. It also enhanced problem-solving skills, troubleshooting
techniques, and an understanding of electrical power distribution systems. The experience gained through this
internship serves as a strong foundation for a future career in electrical engineering and power system
maintenance. Furthermore, the internship included exposure to modern diagnostic tools such as TTR (Turn
Ratio Testers), Megger Insulation Testers, and SFRA (Sweep Frequency Response Analysis) for advanced fault
detection. Emphasis was placed on energy efficiency improvements and cost-effective repair techniques to
enhance transformer reliability. Hands-on experience with HV (High Voltage) and LV (Low Voltage)
transformer components provided a comprehensive understanding of their functionality. Regular site visits and
real-time troubleshooting sessions helped in analyzing practical challenges in transformer maintenance. Overall,
this internship significantly contributed to developing technical expertise, industry readiness, and professional
competency in the field of electrical engineering.
This internship provided in-depth practical experience in transformer repair, maintenance, and fault
diagnosis, enhancing technical skills and industry knowledge. Exposure to advanced testing methods and safety
protocols helped in understanding real-world challenges in transformer servicing.
 LIST OF FIGURES

Figure No. Title Page No.

Fig. 3.4(A) No load test 10

Fig. 3.4(B) On load test 11

Fig. 3.4(C) Insulation resistance test 11

Fig. 3.4(D) Oil testing 12

Fig. 3.5 Methodology 13

Fig 4.2 Equipment kit 15

 CONTENTS

Sr. No. Title Page No.

Abstract
List of figures

Chapter 1: Introduction
1.1 Introduction 1

Chapter 2 : Company Overview 3

Chapter 3 : Working Overview 4

3.1 Objective of transformer Maintenance 4

3.2 Types of transformer used 6
3.3 Common transformer Issues 8
3.4 Diagnostic testing method 10
Chapter 4 : Methodology 13
4.1 Methodology 13
4.2 Tools and equipment used 15
Chapter 5 : Challenges faced in maintenance 17

Chapter 6 : Role of interns in maintenance activities 19

Chapter 7 : Attendance record 21

Chapter 8 : Conclusion and futurescope 23

Internship Certificate
25
References
 CHAPTER 1

INTRODUCTION
1.1 INTRODUCTION

Transformers play a critical role in electrical power systems by ensuring efficient voltage regulation
and power distribution. Proper maintenance is essential to prevent failures, reduce downtime, and enhance
performance. Transformer maintenance includes periodic inspections, testing, and repairs, which help in
identifying faults before they lead to major breakdowns. Various studies emphasize the significance of
transformer maintenance in industrial settings, where reliability and efficiency are crucial. Research on
industrial electrical systems highlights that transformers require regular maintenance to ensure smooth
operations. According to IEEE standards, maintenance activities such as oil testing, insulation resistance
measurement, and thermographic analysis are essential for preventing overheating and insulation failures.
Several studies have reported that improper maintenance or negligence in monitoring transformer health leads
to increased energy losses and higher operational costs.

The internship at Jagdamba Electricals, Beed, provides a valuable opportunity for students to gain
practical experience in the electrical engineering field. This program is designed to bridge the gap between
theoretical knowledge and real-world applications by exposing interns to various aspects of electrical
systems, wiring, maintenance, and troubleshooting. Under the guidance of experienced professionals,
interns work on live projects, enhancing their technical skills and problem-solving abilities. The internship
aims to develop industry-ready professionals by offering hands-on training in electrical components, safety
protocols, and project management. This experience not only strengthens their academic learning but also
prepares them for future career opportunities in the electrical industry. The internship at Jagdamba
Electricals, Beed, is a structured training program designed to provide students with practical exposure to
electrical engineering concepts and industrial applications. A key focus of this internship is transformer
maintenance, along with other essential electrical operations such as wiring, panel designing, and power
distribution. Interns gain hands-on experience in diagnosing transformer faults, oil testing, insulation
checking, and preventive maintenance to ensure efficient performance and longevity of electrical systems.

Under the guidance of experienced professionals, interns learn about transformer installation, testing,
troubleshooting, and repairing. They also get familiar with modern safety protocols, industry standards, and
the latest electrical technologies. Working on real-world projects enhances their technical skills, problem-
solving abilities, and teamwork, preparing them for future roles in the electrical industry. Transformer
maintenance is a critical aspect of ensuring the reliability and efficiency of power distribution systems. This
1
report provides an in-depth study of transformer maintenance practices at Jagdamba Electricals, Beed. The
objective is to understand the maintenance techniques, preventive measures, and challenges associated with
transformers in an industrial setup.

This internship serves as a valuable opportunity for students to bridge the gap between theoretical
knowledge and practical applications, making them industry-ready professionals with specialized skills in
transformer maintenance and electrical system management. By participating in this internship, students not
only strengthen their understanding of electrical systems but also develop confidence in handling industrial
challenges. This practical exposure prepares them for future career opportunities in electrical engineering,
making them industry-ready professionals.

2
 CHAPTER 2

COMPANY OVERVIEW

Jagdamba Electricals is a leading electrical service provider specializing in transformer maintenance,

power distribution, and industrial electrical solutions. The company is known for its expertise in maintaining
transformers used in various industrial applications. Jagdamba Electricals, located in the MIDC area of
Beed, is a well-established company specializing in the repair and maintenance of transformers. The
company has built a strong reputation for providing high-quality transformer services, catering to industrial,
commercial, and government sectors. With a team of skilled engineers and technicians, Jagdamba
Electricals ensures that transformers operate efficiently and safely, minimizing power disruptions and
improving energy reliability.

The company focuses on repairing distribution and power transformers, diagnosing faults, and
implementing preventive maintenance strategies to enhance transformer lifespan. It follows industry-
standard maintenance protocols, including oil filtration, insulation testing, and load analysis, ensuring
compliance with safety and operational guidelines.Jagdamba Electricals, Beed, is equipped with advanced
diagnostic tools and testing facilities that allow for precise fault detection and corrective measures. The
company serves various industries, including manufacturing plants, power distribution companies, and
industrial setups requiring reliable transformer performance. Their services include transformer rewinding,
core rebuilding, bushing replacements, and routine inspections.

Additionally, the company provides hands-on training and internship opportunities for engineering
students, enabling them to gain practical knowledge of transformer maintenance and industrial safety
practices. Jagdamba Electricals is committed to continuous innovation and adopts modern technologies such
as infrared thermography and dissolved gas analysis (DGA) to ensure top-notch transformer servicing.

The company’s strategic location in the MIDC industrial area of Beed allows it to serve a broad
client base efficiently. With a focus on quality, safety, and customer satisfaction, Jagdamba Electricals has
become a trusted name in transformer repair and maintenance in the region.

3
 CHAPTER 3
WORKING OVERVIEW
3.1. OBJECTIVES OF TRANSFORMER MAINTENANCE:-

Transformer maintenance is essential for ensuring the efficient and reliable operation of electrical systems.
The key objectives of transformer maintenance include:
1. Enhancing Reliability: Regular maintenance helps prevent unexpected failures, ensuring a
continuous power supply.
2. Extending Transformer Lifespan: Proper care reduces wear and tear, increasing the operational
life of the transformer.
3. Preventing Electrical Failures: Maintenance helps detect and rectify issues like insulation
breakdown and overheating before they cause major failures.
4. Ensuring Safety: Periodic inspections minimize risks like short circuits, electrical fires, and
explosions, protecting workers and equipment.
5. Maintaining Efficiency: Keeping transformers in good condition ensures minimal energy losses and
optimal performance.
6. Reducing Downtime: Preventive maintenance reduces the chances of sudden breakdowns,
minimizing production and operational disruptions.
7. Compliance with Industry Standards: Regular servicing ensures that transformers meet regulatory
and safety standards set by electrical authorities.
8. Minimizing Maintenance Costs: Identifying minor issues early prevents expensive repairs or
replacements.
9. Improving Load Management: Well-maintained transformers can handle varying load conditions
efficiently, preventing overload-related failures.
10. Monitoring Oil Quality: Transformer oil testing helps detect contamination, moisture, and gas
formation, which can lead to insulation failure.
11. Enhancing Cooling System Performance: Checking and maintaining cooling fans, radiators, and
oil levels prevent overheating.
12. Avoiding Voltage Fluctuations: Properly functioning transformers help stabilize voltage supply,
ensuring smooth power distribution.
13. Detecting Internal Faults: Regular testing methods like Dissolved Gas Analysis (DGA) and
insulation resistance tests help in early fault detection.
14. Preventing Corrosion and Rusting: Maintaining proper sealing and coatings prevents moisture

4
 entry and corrosion of transformer components.
15. Optimizing Energy Consumption: Well-maintained transformers operate with lower energy losses,
contributing to cost savings.
16. Ensuring Proper Grounding and Earthing: Regular inspection of grounding connections prevents
electrical hazards and ensures operational safety.
17. Identifying Winding and Coil Issues: Testing for short circuits, partial discharges, and insulation
degradation helps avoid catastrophic failures.
18. Assessing Mechanical Integrity: Checking for loose connections, worn-out parts, and structural
stability ensures transformer durability.
19. Facilitating Predictive Maintenance: Using advanced diagnostic tools allows for condition-based
maintenance instead of reactive repairs.
20. Supporting Industrial and Commercial Operations: Reliable transformers are essential for
uninterrupted power in industries, factories, and commercial buildings.
By implementing a structured transformer maintenance program, companies like Jagdamba Electricals,
Beed can enhance the efficiency, reliability, and safety of electrical systems while reducing long-term costs.

5
3.2 TYPES OF TRANSFORMERS USED:-

At Jagdamba Electricals, Beed, different types of transformers are repaired and maintained to ensure
efficient power distribution and industrial applications. The major types of transformers used include:
1. Power Transformers
o Used in high-voltage transmission networks to step up or step down voltage levels.
o Typically found in substations and power plants.
o Designed for high efficiency and minimal energy losses.
2. Distribution Transformers
o Used for supplying power to residential, commercial, and industrial areas.
o Operates at lower voltage levels (11kV, 6.6kV, 0.4kV).
o Ensures proper voltage regulation for local electricity supply.
3. Step-Up Transformers
o Increases voltage levels from lower to higher for long-distance power transmission.
o Reduces energy losses during transmission.
o Used in power generation stations.
4. Step-Down Transformers
o Reduces high voltage to a lower voltage suitable for industrial and domestic use.
o Essential for ensuring safe and usable power supply.
5. Oil-Cooled Transformers
o Uses transformer oil for insulation and cooling.
o Requires regular oil testing and filtration to prevent breakdowns.
o Common in high-power applications.
6. Dry-Type Transformers
o Uses air instead of oil for cooling and insulation.
o Suitable for indoor applications like hospitals, malls, and commercial buildings.
o Safer as there is no risk of oil leakage or fire hazards.
7. Isolation Transformers
o Used to separate two electrical circuits to prevent electrical shocks and interference.
o Commonly used in sensitive electronic equipment and industrial control systems.
8. Autotransformers
o Has a single winding that acts as both primary and secondary winding.
o More compact and efficient but lacks electrical isolation.

6
 o Used in industrial machinery and power regulation applications.
9. Instrument Transformers
o Includes Current Transformers (CTs) and Voltage Transformers (VTs) for measuring and
monitoring electrical parameters.
o Used in power systems for protection and metering.
10. Furnace Transformers
• Specially designed for industrial applications like arc furnaces and induction heating.
• Handles high currents and fluctuating loads efficiently.

7
 3.3 COMMON TRANSFORMER ISSUES :-

Transformers are critical components in electrical power systems, but they can develop issues over time
due to operational stress, environmental conditions, and improper maintenance. At Jagdamba Electricals,
Beed, various transformer problems are diagnosed and repaired to ensure reliable performance. Below are
some of the most common transformer issues:
1. Overheating
• Caused by excessive load, poor ventilation, or insulation failure.
• Leads to insulation degradation and reduces transformer lifespan.
2. Oil Contamination and Leakage
• Transformer oil loses its insulating properties due to moisture, oxidation, or contamination.
• Leakage can result in insulation breakdown and fire hazards.
3. Winding Failures
• Short circuits, aging insulation, and overheating can cause winding failures.
• Leads to reduced efficiency and potential transformer breakdown.
4. Insulation Breakdown
• High temperatures, moisture, and electrical stress weaken the insulation.
• Causes internal short circuits and equipment failure.
5. Voltage Fluctuations
• Unstable input voltage can damage transformer components.
• Leads to poor performance and reduced efficiency.
6. Bushing Failures
• Damaged or cracked bushings can lead to insulation failure and electrical arcing.
• Results in power interruptions and potential transformer explosions.
7. Harmonic Distortion
• Caused by non-linear loads such as industrial machinery and electronic devices.
• Leads to overheating and excessive losses.
8. Core Saturation
• When excessive voltage is applied, the transformer core becomes saturated.
• Increases losses and reduces efficiency.
9. Corrosion and Rusting
• Transformer components corrode over time due to humidity and environmental exposure.
• Weakens mechanical integrity and leads to oil leaks.

8
10. Cooling System Malfunctions
• Faulty cooling fans, blocked radiators, or insufficient oil levels can cause overheating.
• Leads to insulation failure and transformer damage.
11. Partial Discharge (PD) Issues
• Small electrical discharges occur in insulation voids, leading to gradual deterioration.
• Can be detected through advanced diagnostic techniques.
12. Short Circuits
• Caused by insulation failure, overloading, or electrical faults.
• Can severely damage windings and internal transformer components.
13. Load Imbalance
• Unequal load distribution across transformer phases leads to inefficiencies.
• Results in overheating and voltage instability.
14. Tap Changer Failure
• Load tap changers (LTCs) help regulate voltage but can fail due to mechanical wear or
contamination.
• Leads to voltage irregularities and unstable power supply.
15. Mechanical Vibrations and Noise
• Loose core laminations or electrical imbalances can cause abnormal vibrations.
• Increases wear and may indicate internal faults.
16. Water and Moisture Ingress
• Moisture in transformer oil reduces dielectric strength and insulation performance.
• Leads to internal short circuits and faster degradation.
17. Arcing and Flashover
• High-voltage stress can cause arcing inside the transformer.
• Leads to insulation failure and potential transformer explosions.
18. Frequent Tripping
• Transformers may trip due to overload, short circuits, or relay malfunctions.
• Indicates underlying electrical or mechanical faults.
19. Neutral and Earthing Problems
• Improper grounding can cause potential differences, leading to electrical hazards.
• Increases risk of shocks and equipment damage.
20. Aging and Wear Over Time
• Transformers degrade naturally over decades of use.
9
3.4 DIAGNOSTIC TESTING METHODS :-

1. No-Load Test of Transformer (Open-Circuit Test)

The No-Load Test, also known as the Open-Circuit Test, is performed to measure the core (iron)
losses, magnetizing current, and no-load power factor of a transformer. In this test, the primary winding is
connected to a rated AC voltage source, while the secondary winding remains open (no external load is
connected). A wattmeter, voltmeter, and ammeter are used to measure the input power (P₀), applied voltage
(V₁), and no-load current (I₀). Since the secondary winding is open, there is no secondary current, and the
primary current is very small, primarily used for magnetizing the core. The power measured by the
wattmeter represents the core losses (hysteresis and eddy current losses), as copper losses are negligible
under no-load conditions. Additionally, the no-load test helps in calculating the magnetizing reactance (Xm)
and core loss resistance (Rc) of the transformer equivalent circuit. This test is crucial because core losses
remain constant at all loading conditions, making it an essential factor in transformer efficiency calculations.

FIG 3.4 (A) NO LOAD TEST

2. Load Test of Transformer (Full-Load Test or Direct Loading Test)

The Load Test, also known as the Full-Load Test or Direct Loading Test, is conducted to determine
the transformer’s efficiency, copper losses, voltage regulation, and performance under actual working
conditions. In this test, the primary winding is connected to a rated voltage source, and a variable load is
connected to the secondary winding to allow the transformer to operate at different load conditions. The

10
load can be adjusted to observe performance under full-load and part-load conditions. Measuring
instruments such as wattmeters, voltmeters, and ammeters are used to record the primary and secondary
voltages, currents, and power readings. The difference between input and output power represents the
copper losses (I²R losses), which vary with load. The efficiency of the transformer is calculated as the ratio
of output power to input power, while voltage regulation is assessed by measuring the voltage drop from no-
load to full-load conditions. Since copper losses depend on the square of the load current, the load test is
essential for evaluating how efficiently the transformer operates in real-world applications. This test ensures
that the transformer performs within the design specifications and provides stable and reliable power supply
in industrial and commercial applications.

3.4.(B)ON LOAD TEST

3. Insulation Resistance (IR) Test

Measures the insulation resistance between transformer windings and ground using a megger
(megohmmeter).
Helps assess insulation health and detect moisture presence.
Typically performed at 500V, 1000V, or 5000V depending on transformer rating.

FIG3.3(C) INSULATION RESISTANCE

11
4. Transformer Oil Testing:-

Transformer oil plays a vital role in insulation, cooling, and arc suppression within a transformer.
Over time, due to electrical, thermal, and chemical stresses, the oil deteriorates, leading to a reduction in its
insulating properties and overall performance. Transformer oil testing is essential to assess the oil’s
dielectric strength, moisture content, acidity, dissolved gases, and contamination levels to ensure the
transformer operates reliably. One of the most critical tests is the Dielectric Strength Test, which measures
the breakdown voltage of the oil to detect the presence of moisture or impurities. The Moisture Content Test
evaluates the water content in the oil, as excess moisture reduces insulation performance and can cause
electrical breakdowns. The Dissolved Gas Analysis (DGA) is another crucial test that detects gases such as
hydrogen, methane, ethylene, and acetylene, which indicate different faults like overheating, arcing, or
partial discharge. Additionally, the Acidity Test determines the acid content in the oil, as excessive acidity
leads to sludge formation and corrosion of transformer components. The Interfacial Tension (IFT) Test
helps in identifying oil degradation, while the Flash Point and Fire Point Test ensures oil safety by
determining its ignition characteristics. Other important tests include Specific Gravity Test, which detects
contamination, and the Sludge and Sediment Test, which identifies solid impurities that can block cooling
channels. Regular transformer oil testing helps in preventive maintenance, early fault detection, and
extending the life of the transformer, thereby reducing maintenance costs and preventing unexpected
failures.

Figure3.4(D) OIL TESTING

12
 CHAPTER 4
METHODLOGY
4.1 METHODOLOGY

The methodology for transformer maintenance at Jagdamba Electricals, Beed, follows a structured
approach to ensure efficient performance, longevity, and reliability of transformers. The maintenance
process involves inspection, testing, fault diagnosis, corrective measures, and preventive actions.

Figure 4 METHODOLOGY

1. Initial Inspection and Data Collection

The maintenance process begins with a visual inspection of the transformer to check for physical
damage, oil leaks, rusting, overheating marks, and loose connections. Data from transformer nameplates,
operating conditions, and previous maintenance records are reviewed to understand the history of faults and
repairs.

2. Transformer Oil Testing

To assess the insulation properties and cooling efficiency of transformer oil, various oil quality tests
are conducted. These include the Dielectric Strength Test, Moisture Content Test, Dissolved Gas Analysis
(DGA), Acidity Test, and Interfacial Tension Test. The results help in determining whether the oil needs
filtration or complete replacement.

3. Electrical Testing and Diagnosis

Electrical tests are performed to check the transformer's performance and identify potential failures.
These tests include:
• Insulation Resistance Test (Megger Test): Measures insulation resistance to detect winding

13
 deterioration.
• Winding Resistance Test: Checks for abnormalities in transformer windings.
• Turns Ratio Test (TTR): Verifies the ratio between primary and secondary windings.
• Short Circuit and Open Circuit Tests: Determine core and copper losses to evaluate efficiency.
• Partial Discharge Test: Detects internal insulation defects.

4. Preventive and Corrective Maintenance

Based on the test results, necessary maintenance actions are taken. Preventive maintenance includes
cleaning, tightening electrical connections, replacing aged gaskets, and monitoring load conditions.
Corrective maintenance involves repairing or replacing damaged components such as bushings, windings,
tap changers, and cooling systems.

5. Transformer Load and No-Load Testing

To evaluate the performance under actual operating conditions, no-load and full-load tests are
conducted. The no-load test determines core losses and magnetizing current, while the load test assesses
copper losses, efficiency, and voltage regulation.
6. Cooling System and Ventilation Check
The cooling system, including radiators, fans, and oil circulation pumps, is inspected to ensure proper heat
dissipation. Overheating can lead to insulation failure and transformer breakdown.

7. Final Testing and Re-Energization

After all maintenance and repairs, the transformer undergoes final testing to verify its proper
functioning. Once cleared, it is safely re-energized and monitored for stable operation.

8. Documentation and Reporting

A detailed maintenance report is prepared, documenting test results, maintenance actions, repairs,
and recommendations for future servicing. This helps in keeping track of transformer health and scheduling
timely maintenance.
By following this systematic methodology, Jagdamba Electricals ensures that transformers operate
efficiently, safely, and with minimal downtime, thereby enhancing power system reliability.

14
4.2 Tools and Equipment Used:-
To ensure effective transformer maintenance and repair, Jagdamba Electricals, Beed, utilizes various
specialized tools and equipment. These tools help in diagnostics, testing, repair, and preventive maintenance
to enhance transformer performance and longevity.

FIG 4.2 EQUIPMENT KIT

1. Electrical Testing Equipment

• Megger (Insulation Resistance Tester): Measures the insulation resistance of windings to detect
insulation deterioration.
• Winding Resistance Tester: Measures the resistance of transformer windings to detect faults like
loose connections or short circuits.
• Dielectric Strength Tester: Tests the breakdown voltage of transformer oil to assess its insulation
properties.
• Partial Discharge Tester: Detects internal insulation defects before major failures occur.
• Short Circuit and Open Circuit Testing Kit: Determines core losses and copper losses to evaluate
efficiency.
2. Mechanical Tools
• Wrenches and Spanners: Used for tightening or loosening transformer bolts, terminals, and
connections.
• Torque Wrench: Ensures accurate torque application on bolts to prevent over-tightening or
loosening.
• Hydraulic Jacks and Lifting Equipment: Used for handling heavy transformer components like
windings and cores.
• Cooling System Cleaning Tools: Brushes, scrapers, and high-pressure air blowers for cleaning
15
 radiators and cooling fins.
3. Oil Testing and Filtration Equipment
• Oil Test Kit: Includes instruments for testing acidity, moisture content, and interfacial tension.
• Oil Filtering and Dehydration Machine: Removes moisture, dirt, and gases from transformer oil to
restore its insulating properties.
• Vacuum Pump: Used for vacuum drying the transformer tank to eliminate moisture before refilling
with oil.
4. Safety Equipment
• Personal Protective Equipment (PPE): Includes insulated gloves, safety glasses, helmets, and flame-
resistant clothing.
• Grounding Rods and Earthing Equipment: Ensures safety during transformer maintenance by
preventing electric shock.
• High-Voltage Detector: Identifies the presence of high voltage before working on the transformer.
• Fire Extinguishers: Used to handle fire hazards in case of transformer oil or electrical fires.
5. Cooling System Monitoring Tools
• Infrared Thermometer (Thermal Imaging Camera): Detects overheating in transformer components,
bushings, and windings.
• Temperature and Pressure Gauges: Monitors oil temperature and pressure levels in the cooling
system.
• Oil Level Indicator: Checks the transformer oil level to ensure proper insulation and cooling.
6. Documentation and Monitoring Tools
• Data Loggers: Records temperature, voltage, and load variations for performance analysis.
• Digital Multimeter: Measures voltage, current, and resistance for electrical diagnostics.
• Vibration Analyzer: Detects mechanical issues such as loose connections or misalignment.

16
 CHPATER 5
CHALLENGES FACED IN MAINTENANCE

Challenges Faced in Transformer Maintenance at Jagdamba Electricals, Beed

Maintaining transformers involves several challenges due to complex electrical components, environmental
conditions, and operational risks. At Jagdamba Electricals, Beed, the following challenges are commonly
encountered during transformer maintenance:
1. Oil Contamination and Degradation
Transformer oil degrades over time due to moisture, oxidation, and contamination by dust or metal particles.
This reduces the dielectric strength of the oil, leading to insulation failure and increased chances of short
circuits. Regular oil testing and filtration are required to maintain oil quality.
2. Overheating Issues
Excessive heating due to overloading, poor ventilation, or cooling system failures can cause insulation
breakdown and winding damage. Detecting hot spots using thermal imaging cameras is essential, but
external environmental factors make temperature control challenging.
3. Electrical and Mechanical Failures
Wear and tear of components like bushings, tap changers, windings, and core laminations lead to
mechanical stress and electrical failures. Identifying faults early through diagnostic tests like insulation
resistance and partial discharge analysis is crucial but sometimes difficult due to unpredictable failure
patterns.
4. Moisture Ingress and Humidity Effects
Moisture is one of the biggest threats to transformer insulation, leading to reduced dielectric strength,
corrosion, and increased partial discharge activity. Preventing moisture entry during repairs and ensuring
proper sealing of bushings and gaskets is a continuous challenge.
5. Load Fluctuations and Unbalanced Loads
Frequent overloading or underloading affects the efficiency and lifespan of the transformer. Sudden load
variations can cause voltage instability and excessive heating. Proper load distribution and real-time
monitoring are required, but unpredictable industrial demand makes this difficult.
6. Aging and Deterioration of Components
Older transformers have weakened insulation, corroded connections, and degraded oil, increasing the risk of
failure. Finding replacement parts for aging transformers can be difficult, leading to extended downtime.
7. Safety Hazards and Electrical Risks
Working with high-voltage transformers poses risks such as electric shocks, arc flashes, and fire hazards due
17
to oil leakage or insulation failure. Strict safety procedures, PPE (Personal Protective Equipment), and
grounding methods are necessary to protect maintenance workers.

8. Environmental and Weather Conditions

Extreme temperatures, humidity, and pollution can accelerate transformer wear and tear. In outdoor
installations, dust, water ingress, and corrosion affect transformer performance. Special weatherproofing
measures are required, adding to maintenance complexity.
9. Testing and Diagnostic Equipment Limitations
Some faults, such as incipient insulation breakdowns or intermittent faults, are difficult to detect using
standard diagnostic tools. Advanced testing methods like Dissolved Gas Analysis (DGA) and Frequency
Response Analysis (FRA) require specialized expertise and expensive equipment.
10. Cost and Time Constraints
Transformer maintenance requires significant investment in tools, skilled labor, and replacement parts.
Scheduling maintenance without affecting power supply or industrial operations is challenging, especially in
high-demand areas.

18
 CHAPTER 6
ROLE OF INTERNS IN MAINTENANCE ACTIVITIES

Interns play a crucial role in assisting, learning, and contributing to transformer maintenance
activities at Jagdamba Electricals, Beed. Their involvement helps in gaining practical knowledge, improving
technical skills, and supporting maintenance teams in various tasks. The key responsibilities of interns in
transformer maintenance include:

1. Assisting in Visual Inspection

Interns participate in visual inspections of transformers to identify oil leaks, loose connections, rust, or
physical damage. They assist senior engineers in preparing inspection checklists and maintenance reports.

2. Supporting Transformer Oil Testing

Interns help in collecting oil samples and conducting basic oil tests such as dielectric strength, moisture
content, and acidity level. They learn how to use oil testing kits and filtration machines to assess oil quality.

3. Involvement in Electrical Testing

Under supervision, interns assist in performing electrical tests such as:
• Insulation Resistance Test (Megger Test) to check insulation health.
• Turns Ratio Test (TTR Test) to verify winding conditions.
• Winding Resistance Measurement to detect faulty connections.
• Breakdown Voltage Test to evaluate oil insulation strength.

4. Learning Preventive Maintenance Techniques

Interns observe and assist in preventive maintenance activities like:
• Cleaning transformer parts (bushings, radiators, cooling fins).
• Tightening electrical connections to prevent overheating.
• Monitoring cooling systems (fans, oil pumps) for efficient performance.

5. Assisting in Fault Diagnosis and Repairs

Interns get hands-on experience in identifying and troubleshooting transformer faults. They assist
technicians in repairing or replacing:

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 • Damaged bushings and tap changers.
• Faulty insulation components.
• Cooling system parts like fans and radiators.
6. Supporting Load and No-Load Testing
Interns assist in conducting no-load and full-load tests to evaluate transformer performance. They help in
recording test readings and analyzing data under the guidance of senior engineers.

7. Learning Safety Procedures and Compliance

Interns are trained in safety protocols such as:
• Proper usage of Personal Protective Equipment (PPE).
• Understanding high-voltage safety guidelines.
• Following lockout/tagout (LOTO) procedures during maintenance.

8. Documentation and Report Preparation

Interns help in maintaining test records, maintenance logs, and diagnostic reports. They assist in preparing
technical reports that document transformer performance, test results, and recommendations for future
maintenance.

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 CHAPTER 7
ATTENDANCE RECORD
Sr. Date Day Check-in Check- out Total Remarks
No. Time Time Hours (Leave/Work
Worked Done)
1 22-12- Sunday --- --- Holiday Weekly Off
2024
2 23-12- Monday 09:00 05:00 PM 8 Hours Transformer
2024 AM Inspection
3 24-12- Tuesday 09:00 05:00 PM 8 Hours Oil Testing &
2024 AM Analysis
4 25-12- Wednesday 09:00 05:00 PM 8 Hours Electrical Testing
2024 AM
5 26-12- Thursday 09:00 05:00 PM 8 Hours Cooling System
2024 AM Check
6 27-12- Friday 09:00 05:00 PM 8 Hours Tap Changer
2024 AM Inspection
7 28-12- Saturday 09:00 05:00 PM 8 Hours Load & No-Load
2024 AM Testing
8 29-12- Sunday --- --- Holiday Weekly Off
2024
9 30-12- Monday 09:00 05:00 PM 8 Hours Preventive
2024 AM Maintenance
10 31-12- Tuesday 09:00 05:00 PM 8 Hours Report
2024 AM Documentation
11 01-01- Wednesday 09:00 05:00 PM 8 Hours Transformer Oil
2025 AM Testing
12 02-01- Thursday 09:00 05:00 PM 8 Hours Insulation
2025 AM Resistance Test
13 03-01- Friday 09:00 05:00 PM 8 Hours Cooling System
2025 AM Maintenance
14 04-01- Saturday 09:00 05:00 PM 8 Hours Transformer Load
2025 AM Analysis
15 05-01- Sunday --- --- Holiday Weekly Off
2025
16 06-01- Monday 09:00 05:00 PM 8 Hours Tap Changer
2025 AM Testing
17 07-01- Tuesday 09:00 05:00 PM 8 Hours Fault Diagnosis &
2025 AM Repair
18 08-01- Wednesday 09:00 05:00 PM 8 Hours Preventive
2025 AM Maintenance
19 09-01- Thursday 09:00 05:00 PM 8 Hours Transformer
2025 AM Winding Test
20 10-01- Friday 09:00 05:00 PM 8 Hours Transformer Core
2025 AM Inspection
21 11-01- Saturday 09:00 05:00 PM 8 Hours Cooling System

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 2025 AM Cleaning
22 12-01- Sunday --- --- Holiday Weekly Off
2025
23 13-01- Monday 09:00 05:00 PM 8 Hours Load Testing
2025 AM Procedure
24 14-01- Tuesday 09:00 05:00 PM 8 Hours Transformer Oil
2025 AM Change
25 15-01- Wednesday 09:00 05:00 PM 8 Hours Preventive
2025 AM Maintenance
26 16-01- Thursday 09:00 05:00 PM 8 Hours Transformer Test
2025 AM Reports
27 17-01- Friday 09:00 05:00 PM 8 Hours Electrical Safety
2025 AM Audit
28 18-01- Saturday 09:00 05:00 PM 8 Hours Load Balancing
2025 AM Test
29 19-01- Sunday --- --- Holiday Weekly Off
2025
30 20-01- Monday 09:00 05:00 PM 8 Hours Transformer Efficiency
2025 AM Analysis
31 21-01- Tuesday --- --- Leave Final certificate
2025 issued

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 CHAPTER 8
CONCLUSION AND FUTURESCOPE

8.1 CONCLUSION

The internship at Jagdamba Electricals, Beed, was a valuable learning experience that provided a
deep understanding of transformer maintenance, repair, and diagnostics. Throughout the training period,
various maintenance activities such as insulation testing, oil filtration, load and no-load testing, cooling
system inspection, and preventive maintenance techniques were performed. These activities enhanced the
knowledge of practical troubleshooting methods, safety protocols, and industry standards in transformer
servicing.
Regular maintenance is essential for transformers as it ensures high efficiency, reliability, and
extended lifespan of power distribution systems. By following proper maintenance procedures, unexpected
failures and costly downtimes can be minimized, leading to improved operational performance. The
internship also highlighted the importance of diagnostic testing methods, such as transformer oil analysis,
insulation resistance measurement, and winding resistance tests, which play a crucial role in identifying
potential faults before they become critical.
In addition to technical learning, the internship helped in developing problem-solving skills,
teamwork, and professional communication. Working under industry experts provided a better
understanding of real-world challenges, safety measures, and practical applications of electrical engineering
concepts. The experience gained will be highly beneficial for future career growth in the field of power
systems, electrical maintenance, and industrial automation.
Furthermore, the knowledge acquired during this period will aid in implementing modern
maintenance strategies, adopting new technologies, and contributing to the development of advanced
electrical systems. With continuous research and innovation, transformer maintenance practices will
continue to evolve, ensuring more efficient, reliable, and sustainable electrical power distribution.

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8.2 FUTURESCOPE

• Automation in Transformer Maintenance – The implementation of IoT-based monitoring can

help track transformer performance in real time and predict failures before they occur.

• Use of Advanced Diagnostic Tools – Adoption of modern testing equipment like DGA (Dissolved
Gas Analysis), Frequency Response Analysis (FRA), and Thermal Imaging can enhance fault
detection.

• Eco-friendly Transformer Oils – Research on biodegradable and non-toxic oils can help improve
environmental sustainability in transformer operations.

• Condition-Based Maintenance (CBM) – Instead of periodic maintenance, transformers can be

monitored through sensors and AI-driven analytics, enabling efficient and cost-effective servicing.

• Smart Grid Integration – Upgrading transformers for smart grid compatibility can improve energy
efficiency and demand-side management in electrical networks.

• Enhanced Safety Measures – Development of automated safety systems for transformer handling
and maintenance to minimize electrical hazards.

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CERTIFICATE

25
 REFERENCE

Below are some standard references that can be included in your internship report on Transformer
Maintenance at Jagdamba Electricals, Beed:
1. Books & Study Materials:
o M. V. Deshpande, Electrical Power System Design, Tata McGraw-Hill, 2001.
o B. L. Theraja & A. K. Theraja, Electrical Technology – Vol II, S. Chand, 2005.
o J. J. Grainger & W. D. Stevenson, Power System Analysis, McGraw-Hill, 1994.
2. Technical Standards & Guidelines:
o Bureau of Indian Standards (BIS) – IS 1180 (Part 1):2014 – Outdoor Distribution
Transformers.
o IEEE Standards – IEEE C57.12.00-2015 – IEEE Standard for General Requirements for
Liquid-Immersed Distribution, Power, and Regulating Transformers.
o IEC Standards – IEC 60076: Power Transformers (Series).
3. Research Papers & Articles:
o K. J. Thomas, “Condition Monitoring of Power Transformers,” IEEE Transactions on Power
Delivery, Vol. 28, No. 1, 2013.
o P. K. Dash, “Transformer Fault Diagnosis Using Dissolved Gas Analysis and Machine
Learning,” Elsevier Energy Reports, 2020.
4. Company Reports & Manuals:
o Jagdamba Electricals, Beed – Internal Maintenance Manuals & Technical Reports.
o Manufacturer Catalogs for Transformer Parts & Testing Equipment.
5. Online Resources & Websites:
o Electrical Engineering Portal – www.electrical-engineering-portal.com
o National Institute of Standards and Technology (NIST) – www.nist.gov
o International Electrotechnical Commission (IEC) – www.iec.ch

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