JULY 3, 2019

A PROJECT ON “TRANFORMERS”

PREPARED BY :
AMAN SRIVASTAVA
YARA Fertilizer India private ltd, Babrala, UP
 | 1

INDEX
S. NO. CONTENTS Page
No.
1. Certificate 2
2. Declaration 3
3. Acknowledgement 4
4. Preface 5
5. Introduction to the Company 6
6. Fire and Safety 8
7. Transformers 10
a) What are Transformers. 10
b) Operating Principle. 11
c) Types of Transformers. 12
d) Construction of Transformer. 17
e) Description of parts of 18
Transformers.
f) Name plate of TML, TMM, TLL 22, 23,
Transformers. 24

g) Mounting details of 25
Transformers.
h) Protection of Transformers. 26

i) Number of Transformers at 29 - 31
YARA.
 | 2

CERTIFICATE

This is to certify that the summer project report titled “TRANSFORMERS“,

Out by Mr Aman Srivastava at YARA FERTILIZERS INDIA Pvt. Ltd. as a
partial fulfilment of the requirement for the degree of Bachelors in technology
(B.Tech) for the academic year 2018 – 19.

Project guided by:

Mr. Nitin Mahesh Gupta.

( Electrical department {Manager} )
 | 3

DECLARATION

I hear by declare that the summer project report titled “TRANFORMERS” is

an original piece of work done by me for the fulfilment of the award of degree
of Bachelors in Technology (B.Tech). And whatever information is taken from
different sources has been duly acknowledged.

I further declare that, this project is carried out for academic purpose only

Aman Srivastava
KIET Engineering College
(Electrical and Electronics)
 | 4

ACKNOWLEDGEMENT

It is a great pleasure for me to express my deep, sincere, whole hearted gratitude

and thanks to Mr. Nitin Mahesh Gupta, Manager - Electrical for his valuable
direction and guidance throughout the project work.

My heartiest and special thanks to Mr. Arindam Samanta, Deputy Manager -

ELECTRICAL for rendering exquisite guidance, suggestion, inspiration and
encouragement during the project.

I would also like to express my gratitude to Dr. Neeraj Gupta department of

Electrical and Electronics, KIET, Ghaziabad who encouraged & supported me.

I am thankful to Mr. Amit Yadav, Executive - Human Resources, YARA

Fertilizer India Pvt. Ltd. Babrala for extending his co-operation and support.

I would like to express my thanks to my associates who helped me directly &

indirectly during my project work.
 | 5

PREFACE

The research provides an opportunity to a student to demonstrate his/her skills,

knowledge and competencies required during the technical session. Research
also helps the student to devote his/her skill to analyse the problem to suggest
alternative solution, to evaluate them and to provide feasible recommendation
on the provided data.

The research is on the topic “TRANSFORMERS”. Although I have tried my

level best to prepare this report. An error free report, every effort has been made
to offer the most authenticated position with accuracy.
 | 6

YARA Fertilizers Pvt. Ltd.

The Mission:

Yara’s mission is both simple and very ambitious: to responsibly feed the world
and protect the planet.

Yara’s crop nutrition solutions and precision farming offerings allow farmers to
increase yields and improve product quality while reducing environmental
impact. Their environmental and industrial solutions improve air quality and
reduce emissions.

Yara has a worldwide presence with more than 16,000 employees and
operations in over 60 countries.
 | 7

YARA Fertilizers INDIA Pvt. Ltd.

Yara has a long history in India and has supplied fertilizers as well as fertilizer
raw materials to the Indian market for more than two decades.

YARA Fertilizer India Pvt. Ltd. at Babrala

Towards the end of the 1990s, Yara recognized that with the changing
economic scenario, the Indian consumer was seeking higher quality of fruits and
vegetables. This change implied that the Indian growers needed to relook at the
nutrition of crops, to improve their yields and quality.
 | 8

Fire and Safety :

Like other chemical industries, Fertilizer industries are also having four inherent
types of potential hazards namely:
a. Fire
b. Explosion
c. Spills
d. Toxic gases.

1. Fire Prevention :

Fire prevention can be done in two ways:

a. Eliminate sources of ignition
b. Eliminate combustible substances

Fire prevention through elimination of ignition source :

To prevent fire, the first step is to remove the causes of fire. Studies made by fire
insurance companies shows that majority of fires are caused by following general
sources of ignition:
 Electrical short circuiting, sparking,
 Smoking,
 Frictional sparks,

Prevention of fire through elimination of combustible materials :

a. Waste and combustible materials:

Good House Keeping is key to all safety and specially fire safety.

b. Tins and cans of flammable materials like paints, oils, greases, spirits
etc.:

These should be handled carefully ensuring that no undue spillages take place
during their use and any spillage should be cleaned immediately.
 | 9

c. Fuelling of vehicle tanks :

Engine should always be switched off while fuelling a vehicle. If diesel or

petrol spills over during fuelling, dry sand should be covered over the spill
immediately till only dry sand is visible on the spilled area.

2. Personal Protective Equipment’s (PPEs):

 Helmets for head protection.
 Goggles and eye protection.
 Ear plugs and muffs for ear protection.
 Gloves for hand protection.
 Safety shoes for foot protection.
 | 10

TRANSFORMERS

What is Transformer ?

 A Transformer is a static device which transfers electrical energy from

one circuit to another through the process of electromagnetic induction.

 It is most commonly used to increase (“Step up”) or decrease (“Step

down”) voltage levels between the circuits.

 Transformers are electrical devices consisting of two or more coils of wire

used to transfer electrical energy by means of a changing magnetic field.

 Transformers are capable of either increasing or decreasing the voltage

and current levels of their supply, without modifying its frequency, or the
amount of electrical power being transferred from one winding to another
via the magnetic circuit.

 In other words, for a transformer there is no direct electrical connection

between the two coil windings, thereby giving it the name also of
an Isolation Transformer.
 | 11

Operating Principle .

 The operating principle on which the Transformer works in “The Mutual

Induction”.

 The operating principle of a transformer is very simple. Mutual

Induction between two or more windings (also known as coils) allows
for electrical energy to be transferred between circuits.

 According to Faraday’s law of electromagnetic induction, there will be

an EMF induced in the second winding. If the circuit of this secondary
winding is closed, then a current will flow through it. This is the basic
working principle of a transformer.
 | 12

Types of Transformers .

CONNECTION COOLING WIRE VOLTAGE WIRE

WIRE

3-PHASE OIL NATURAL AIR STEP UP

NATURAL(ONAN) TRANSFORMER
TRANSFORMERS

1-PHASE OIL NATURAL AIR STEP DOWN

FORCED(ONAF) TRANFORMER
TRANSFORMERS

OIL FORCED AIR

FORCED(OFAF)

OIL FORCED
WATER FORCED
(OFWF)

We’ll summarize them one by one.

 | 13

 Three Phase Transformer :

Three phase transformers are more economical for supplying large loads and
large power distribution. Even though most of the utilization equipment’s are
connected by the single phase transformers, these are not preferred for large
power distribution in the aspect of economy.

The three-phase power is used in almost all fields of electrical power system
such as power generation, transmission and distribution sectors, also all the
industrial sectors are supplied or connected with three phase.

 Single Phase Transformers :

A single-phase transformer is a type of power transformer that utilizes single-
phase alternating current, meaning the transformer relies on a voltage cycle that
operates in a unified time phase. They are often used to step-down long distance
and localized transmission currents into power levels more suitable for
residential and light-commercial applications.
 | 14

 Oil Natural Air Natural (ONAN) :

This method is used for oil immersed transformers. In this method, the heat
generated in the core and winding is transferred to the oil.

According to the principle of convection, the heated oil flows in the upward
direction and then in the radiator. The vacant place is filled up by cooled oil
from the radiator.

 Oil Natural Air Forced (ONAF) :

The heat dissipation can be improved further by applying forced air on the
dissipating surface. Forced air provides faster heat dissipation than natural air
flow.

In this method, fans are mounted near the radiator and may be provided with an
automatic starting arrangement, which turns on when temperature increases
beyond certain value.
 | 15

 Oil Forced Air Forced (OFAF) :

In this method, oil is circulated with the help of a pump. The oil circulation is
forced through the heat exchangers.

Then compressed air is forced to flow on the heat exchanger with the help of
fans.

 Oil Forced Water Forced (OFWF) :

This method is similar to OFAF method, but here forced water flow is used to
dissipate hear from the heat exchangers.

The oil is forced to flow through the heat exchanger with the help of a pump,
where the heat is dissipated in the water which is also forced to flow. The
heated water is taken away to cool in separate coolers.
 | 16

 Single Phase Transformers :

A single-phase transformer is a type of power transformer that utilizes single-
phase alternating current, meaning the transformer relies on a voltage cycle that
operates in a unified time phase. They are often used to step-down long distance
and localized transmission currents into power levels more suitable for
residential and light-commercial applications.

The ratio of primary (input) windings to secondary (output) windings

determines the change in current.

 Three Phase Transformer :

Three phase transformers are more economical for supplying large loads and
large power distribution. Even though most of the utilization equipment’s are
connected by the single phase transformers, these are not preferred for large
power distribution in the aspect of economy.
 | 17

Construction of a Transformer.

Where:
1. VP - is the Primary Voltage.
2. VS - is the Secondary Voltage.
3. NP - is the Number of Primary Windings.
4. NS - is the Number of Secondary Windings.
5. Φ (phi) - is the Flux Linkage.

 If we notice that there are two coil windings which are not electrically
connected but are only linked magnetically.
 When a transformer is used to “increase” the voltage on its secondary
winding with respect to the primary, it is called a Step-up transformer.
 When it is used to “decrease” the voltage on the secondary winding with
respect to the primary it is called a Step-down transformer.
 | 18

Parts of a Transformer and their description.

These are the basic components of a transformer.

1. Windings
2. Laminated core
3. Insulating materials
4. Transformer oil
5. Tap changer
6. Oil Conservator
7. Breather
8. Cooling tubes
9. Buchholz Relay
10.Explosion vent
Now, We will have a brief description of all these component one by one.

1. Windings :

The three main parts of a windings are :

1. Primary Winding of Transformer.
2. Magnetic Core of Transformer.
3. Secondary Winding of Transformer.

 Primary Winding of Transformer.

Which produces magnetic flux when it is connected to the electrical source.
 Magnetic Core of Transformer.

The magnetic flux produced by the primary winding, that will pass through this
low reluctance path linked with secondary winding and create a closed magnetic
circuit.
 | 19

 Secondary Winding of Transformer.

The flux, produced by primary winding, passes through the core, will link with
the secondary winding. This winding also wounds on the same core and gives
the desired output of the transformer.

2. Core :

 The core acts as support to the winding in the transformer.

 It also provides a low reluctance path to the flow of magnetic flux.
 It is made of laminated soft iron core in order to reduce eddy current loss
and Hysteresis loss.
 The composition of a transformer core depends on such as factors
voltage, current, and frequency.
 The diameter of the transformer core is directly proportional to copper
loss and is inversely proportional to iron loss.

3. Insulating materials :

 Insulating paper and cardboard are used in transformers to isolate primary

and secondary winding from each other and from the transformer core.
 Transformer oil is another insulating material.

4. Transformer oil :
Transformer oil performs two important functions:
 In addition to insulating function, it can also cool the core and coil
assembly.
 The transformer's core and winding must be completely immersed in the
oil.

Normally, hydrocarbon mineral oils are used as transformer oil.

 | 20

5. Tap changer :

 The output voltage of transformers vary according to its input voltage and
the load. During loaded conditions, the voltage on the output terminal
decreases, whereas during off-load conditions the output voltage
increases. In order to balance the voltage variations, tap changers are
used.
 Tap changers can be either on-load tap changers or off-load tap changers.
In an on-load tap changer, the tapping can be changed without isolating
the transformer from the supply.
 In an off-load tap changer, it is done after disconnecting the transformer.
Automatic tap changers are also available.

6. Oil conservator :
 The conservator conserves the transfer oil.
 It is an airtight, metallic, cylindrical drum that is fitted above the
transformer.
 The conservator tank is vented to the atmosphere at the top, and the
normal oil level is approximately in the middle of the conservator to
allow the oil to expand and contract as the temperature varies.
 The conservator is connected to the main tank inside the transformer,
which is completely filled with transformer oil through a pipeline.

7. Breather :

 The breather controls the moisture level in the transformer. Moisture can
arise when temperature variations cause expansion and contraction of the
insulating oil, which then causes the pressure to change inside the
conservator.
 The transformer's breather is a cylindrical container that is filled with
silica gel.

8. Colling tubes :

 Cooling tubes are used to cool the transformer oil.

 The transformer oil is circulated through the cooling tubes.
 | 21

9. Buchholz Relay :

 The Buchholz is a protective device container housed over the connecting

pipe from the main tank to the conservator tank.
 It is used to sense the faults occurring inside the transformer.
 It helps in sensing and protecting the transformer from internal faults.

10. Explosion Vent :

 The explosion vent is used to expel boiling oil in the transformer during
heavy internal faults in order to avoid the explosion of the transformer.
 | 22

Name plate of a TML Transformer

HIGH VOLTAGE LOW VOLTAGE

VOLTS Ext Tappings Connected VOLTS AMPS Connected

Position connected Lines to Line to
11660 1 5-4

11275 2 4-6
AcBcCc 333 2000 A2b2c2

11000 3 6-3

10725 4 3-7

10450 5 7-2

KVA 1500 TYPE OF COOLING ON

HV 11000

VOLTS AT IMPEDENCE VOLTS

LV
NO LOAD

HV WT. OF CORE

AMPERES QUANTITY OF OIL

LV 2000 WT. OF OIL

TEMP. RISE ( 0C) 10/50 TOTAL WEIGHT

PHASES 3/3 SERIAL NO.

FREQUENCY 60 ≈ YEAR OF
MANUFACTURE

MADE IN INDIA BY - POWER & CONTROL Tf INDUSTRIES (P) LTD. BOMBAY

 | 23

Name plate of a TMM Transformer

HIGH VOLTAGE LOW VOLTAGE

VOLTS Ext Tappings AMPS VOLTS AMPS Connected

Position connected Line to

11550 1 5-6 80.0

11275 2 6-4 82.0

333 2000 A2b2c2

11000 3 4-7 84.0

10725 4 7-3 86.0

10450 5 3-8 88.5

KVA 1600 TYPE OF COOLING ON

HV 11000

VOLTS AT IMPEDENCE VOLTS

LV 433
NO LOAD

HV 84.0 UNTANKING 2250

MASS(kg)
AMPERES
MASS OF OIL(kg) 970

LV 2134 VOLUME OF OIL(ltrs) 1130

SERIAL NO. 3627 TOTAL WEIGHT (kg) 5700

PHASES 3/3 TRANSPORTATION 4800

MASS(kg)

FREQUENCY 60 ≈ YEAR OF 1999

MANUFACTURE

MADE IN INDIA BY - BHARAT BIJLIEE LTD. BOMBAY

 | 24

NAME PLATE OF A TLL TRANSFORMER

KVA 100 TYPE OF COOLING ON

PRI 415

VOLTS AT FREQUENCY 50
SEC 415
NO LOAD

IMPEDENCE VOLTS 4.12%

AMPERES PRI 139.12 VECTOR GROUP DY011

SEC 134.27 INSULATION LEVEL KVP

TOTAL WEIGHT (kg) 850

PHASES PRI 03 MAKERS SER NO RD – 3773/1

SEC 6.3 YEAR OF 1999

MANUFACTURE

MADE IN INDIA BY - VOLTAS LTD. ELEC. BUSINESS GP Tf DIVISION PUNE

 | 25

Mounting Arrangements of a Transformer.

Before mounting any Transformer, certain points should be kept in

mind :
 The free flow of air is important as is the air temperature.
 A transformer must be mounted so that air can freely circulate all around
and through it.
 A transformer room must have adequate ventilation and should not be
used for storage.

Of all Mountings, Pole mounting is the most common in

practice.

Pole mounted Transformer.

It is the most common type of outdoor type substation. Normally, single phase
DT up to 25 KVA capacities are installed on single pole/2 pole structure and 3
Phase DTs up to 500 KVA capacities are mounted on 2 pole or 4 pole structure.
The two poles structure is made of poles with channels and associated
accessories creating a H type pole configuration to locate the DT at certain
minimum height from the ground level to meet the ground clearance. This area
also to be provided with suitable fencing and lockable doors to prevent
unauthorized access to Distribution box. In case of single phase transformers up
to 25KVA capacity, the transformers can normally be installed on single pole or
on H pole structure at appropriate height from the ground on the roadside which
is easily accessible. These single phase transformers do not require distribution
boxes as it directly feed to a group of consumers and no additional ground space
is required.
 | 26

Protection for Transformers .

There are certain types of protection for Transformers.

Protection used :
 Differential
 Overcurrent
 Restricted Earth Fault (REF)

There are certain types of faults which occurs in Transformers.

We’ll discuss the faults in a tabular form and the protection used to avoid those
faults.

S. No. Fault Type Protection used

1 Primary winding Phase-Phase Differential, Overcurrent

fault
2. Primary winding Phase-Earth Differential, Overcurrent
fault
3. Secondary winding Phase- Differential
Phase fault
4. Secondary winding Phase- Differential, Restricted Earth Fault
Earth fault (REF)
5. Interturn Fault Differential
6. Core Fault Differential
7. Oil tank Fault Differential
 | 27

1. Differential Protection:

A differential protection system can be arranged to cover the

complete transformer. This is possible because of the high efficiency
of transformer operation, and the close equivalence of ampere-turns developed
on the primary and secondary windings.

There are some considerations which must be applied before applying

differential protection.

1. Correction for possible phase shift across the transformer windings

(phase correction).
2. The effects of the variety of earthing and winding arrangements.
3. The effect of magnetizing inrush during initial energization.

2. Overcurrent Protection :
Fuses may adequately protect small transformers, but larger ones require
overcurrent protection using a relay and CB, as fuses do not have the required
fault breaking capacity.
 Fuses :
Fuses commonly protect small distribution transformers typically up to
ratings of 1MVA at distribution voltages. In many cases no circuit breaker is
provided, making fuse protection the only available means of automatic
isolation.
 | 28

 Overcurrent relays :
Overcurrent relays are also used on larger transformers provided with standard
circuit breaker control. A high-set instantaneous relay element is often provided,
the current setting being chosen to avoid operation for a secondary short circuit.

3. Restricted earth fault protection (REF) :

Conventional earth fault protection using overcurrent elements fails to provide

adequate protection for transformer windings. This applies particularly to a star-
connected winding with an impedance earthed neutral.
The degree of protection is very much improved by the application of restricted
earth fault protection (or REF protection). This is a unit protection scheme for
one winding of the transformer. It can be a high impedance type or a biased
low-impedance type.
 | 29

Number of Transformers at YARA Fertilizer India :

 There are total of 41 Transformers in Yara Fertilizers India pvt ltd

situated in Babrala, Sambhal.

 These Transformers are divided into different substations i.e 10

substations.

Substation 1 – Power Plant

Substation 2 – Urea 1
Substation 3 – Urea 2
Substation 4 – Ammonia
Substation 5 – Cooling Tower
Substation 6 – DM Plant
Substation 7 – Ammonia Storage
Substation 8 – Maintenance and Services
Substation 9 – Water Pumping
Substation 10 – Bagging Plant
 | 30

 Substation 1 i.e “POWER PLANT” :

Consist of 4 transformers namely:
1. TML – 1/1A, 11KV/.433 KV, 2 MVA.
2. TML – 1/1B, 11KV/.433 KV, 2 MVA.
3. TMM – 1/1A, 11KV/3.3 KV, 3.15 MVA.
4. TMM – 1/1B, 11KV/3.3 KV, 3.15 MVA.

 Substation 2 i.e “UREA 1” :

Consist of 5 transformers :
1. TMM – 2/1A, 11/3.45 KV, 4 MVA.
2. TMM – 2/1B, 11/3.45 KV, 4 MVA.
3. TML – 2/1A, 3.3/.433 KV, 1.6 MVA.
4. TML – 2/1B, 3.3/.433 KV, 1.6 MVA.
5. TLL – 2/1, 415/430 KV, 250 KVA.

 Substation 3 i.e “UREA 2” :

Consist of 5 transformers :
1. TMM – 3/1A, 11/3.45 KV, 4 MVA.
2. TMM – 3/1B, 11/3.45 KV, 4 MVA.
3. TML – 3/1A, 3.3/.433 KV, 1MVA.
4. TML – 3/1B, 3.3/.433 KV, 1MVA.
5. TLL – 3/1, 415/430 V, 250 KVA.

 Substation 4 i.e “AMMONIA” :

Consist of 5 transformers :
1. TMM – 4/1A, 11/3.45 KV, 12.5 MVA.
2. TMM – 4/1B, 11/3.45 KV, 12.5 MVA.
3. TML – 4/1A, 3.3/.433 KV, 1.6 MVA.
4. TML – 4/1B, 3.3/.433 KV, 1.6 MVA.
5. TLL – 4/1, 415/430V, 250 KVA.

 Substation 5 i.e “COLLING TOWER” :

Consists of 6 Transformers :
 | 31

1. TML – 5/1A, 11/.433 KV, 1600 KVA.

2. TML – 5/1B, 11/.433 KV, 1600 KVA.
3. TML – 5/2A, 11/.433 KV, 1000 KVA.
4. TML – 5/2B, 11/.433 KV, 1000 KVA.
5. TMM – 5/1B, 11/3.3 KV, 12.5 MVA.
6. TMM – 5/2B, 11/3.3 KV, 12.5 MVA.

 Substation 6 i.e “DM PLANT” :

Consists of 2 Transformers :

1. TML – 6/1A, 11KV/.433 KV, 1600 KVA.

2. TML – 6/1B, 11KV/.433 KV, 1600 KVA .

THE END.
| 32