The document describes the design, construction, testing and simulation of a 500VA, 230V/115V shell type transformer by a group of students. Key steps included specifying design parameters, fabricating coils, assembling the core and coils, insulating and painting. Tests on the completed transformer such as no load, short circuit and insulation tests were performed and results analyzed. A computer simulation was also developed and compared to practical test data. The project provided hands-on experience in transformer manufacturing and testing processes while enhancing electrical engineering knowledge.

1. DESIGN, CONSTRUCTION, TESTING &
SIMULATION OF A SMALL, SINGLE
PHASE, SHELL TYPE TRANSFORMER
Submitted By:
SubmittedBy:
Sourav Bhattacharya
Soumyakanti Kundu
Rizia Sultana
Kaushik Das
Souvik Das
Underthe Guidance Of
Asst. Prof. Amrita Dhar
Electrical Engineering Dept.
Greater Kolkata College of Engineering
& Management, Baruipur

2. ACKNOWLEDGEMENT
We wish to offer our heartfelt thanks and gratitude to our project supervisor,
Assistant Prof. Amrita Dhar, for her guidance and encouragement throughout
the project.
We would like to thank Prof. Prasanta Mukherjee, H.O.D. of the department
of Electrical Engineering for providing us with the necessary facilities for
carrying out the project.
We would also like to thank Dr. S. Sengupta, Director Cum Principal of Greater
Kolkata College of Engineering And Management for providing us with the
necessary facilities for carrying out the project work.
We thank to all my classmates for their support and encouragement.

3. CONTENTS
 IMPORTANCE
 WHAT WE HAVE ACTUALLY DONE SO FAR?
 SPECIFICATION
 DESIGNED VALUE VS. MARKET AVAILABLE VALUE
 FABRICATION
 COIL WINDING
 CORE COIL ASSEMBLY
 VARNISHING AND PAINTING
 FINISHING
 ANALYSIS OF DATA
 TESTING
 SIMULATION
 CONCLUSION
 FURTHER SCOPE OF WORK

4. IMPORTANCE
 A transformer is a very essential and integral part of every electrical system.
 The complete construction procedures of transformer give a brief idea about
transformer which enhance our knowledge in the practical field of machines.
 This project gave us an opportunity to visit an actual transformer
manufacturing industry.
 This project topic also helped us become familiar with the various transformer
tests performed in an industry.

5. WHAT WE HAVE ACTUALLY
DONE SO FAR?

6. SPECIFICATION
500VA 230V/115V
±10%
Tappings
Transformer
to be
designed

7. DESIGNED VALUE VS.
MARKET AVAILABLE VALUE
Core Design
Core size
Market available size
Length of core =
50.8 mm (core no. 7)
Designed value :
Length of core =
47.1mm
Primary coil
Cross -
sectional area
Designed value =
0.804 mm2
Market Available
Size = 0.811mm2 (19
SWG)
Secondary coil
Cross -
sectional area
Designed value =
1.55 mm2
Market Available
Size = 1.59mm2 (17
SWG)

8. FABRICATION
Coil Winding
Core-Coil Assembly
Varnishing and Painting
Finishing

9. COIL WINDING
Bobbin
Insulation
HV
Winding
LV
Windings
Insulation
Tappings
Pre-
heating
Varnishing
Curing

10. CORE COILASSEMBLY

Two (E and I) shapes of
core laminations made of
COLD ROLLED GRAIN
ORIENTED (CRGO) Silicon
Steel is used in one
assembly in such a manner
that there is no air gap
between the joints of two
consecutive sheets.
The entire assembly is put
on a frame known as core
channel for clamping
support of the core
assembly.
After the completion of
core coil assembly clamps
are added and fixed with
the help of washers, nuts
and bolts

11. VARNISHING & PAINTING
•After the frames have been fixed on both sides of the
transformer core assembly, a coat of F-type varnish is
applied over the visible portion of the E-I stack and is left
to dry.
• After the varnish has dried up, a secondary coating of
colour is applied over it.

12. FINISHING
 The starting and finishing ends of the primary and secondary
terminals, as well as the tappings taken out and properly arranged
 then ring-lug’ is clamped to the ends and is soldered to it to ensure it
does not come off
 and entire terminals are taken out at top the transformer and fixed
with the help of bolt and Bakelite sheet

13. Designed
Data
Practical
Data

14. ANALYSIS OF DATA
Analysis of theoretical and practical Weight:
0.0000
1.0000
2.0000
3.0000
4.0000
5.0000
6.0000
Iron (Kg) Copper (Kg)
Analysis of Designed & Practical values of Weight Iron & Copper
Design Practical

15. 740
760
780
800
820
840
860
880
900
920
940
960
Iron (Rs.) Copper (Rs.)
Analysis of Practical & Designed Cost of Iron & Copper
Design Practical
Analysis of Cost:

16. Analysis of Loss:
0
5
10
15
20
25
30
35
Iron Loss (Watt) Copper Loss (Watt)
Analysis of Design & Practical Losses(Iron & Copper)
Design Practical

17. TESTING
DC RESISTANCE TEST
MEGGER TEST
SHORT CIRCUIT TEST
NO LOAD TEST
HV TEST
DVDF TEST

18. MEGGER TEST
 This test is carried out to ensure the healthiness of overall insulation system of
an transformer.
 The overall insulation of the transformer is perfect.
Place of Meggar’s Terminals Resistance
High voltage winding to low voltage winding Above 200 MΩ
High Voltage winding to ground Above 200 MΩ
Low voltage winding to ground Above 200 MΩ

19. NO LOAD TEST
 Open circuit test or no load test on a transformer is performed to determine 'no
load loss (core loss)' and 'no load current I0
 By performing this test, we calculate the core losses which is well within
limits.
Applied Primary
Voltage(V1)
No Load Current
(I0)
No Load Loss
(W)
230 Volts 110 mA 6 W

20. SHORT CIRCUIT TEST
 The purpose of this test is to determine the series branch parameters of the
equivalent circuit and Load loss.
Voltage(Vsc) Current(I1) Wattage(W)
11.87 Volts 2.17 A 40 Watts

21. DC RESISTANCE TEST
 To determine a faulty winding.
Winding Resistance
Primary 2.27Ω
Secondary 710.6 mΩ
At Temperature 320C
 By performing this test, we determine the primary and secondary
resistances, which are within considerable limits.

22. HV TEST
 To Check the Insulation between HV & LV, HV & Earth and LV & Earth.
 By performing this test, we conclude that both the HV an LV winding are
able to withstand a high voltage for a considerable amount of time.
Winding Applied
Voltage
Duration Remarks
Between HV &
LV
3KV 1 min OK
Between HV &
Earth
3KV 1 min Ok
Between LV &
Earth
3KV 1 min Ok

23. DVDF TEST
 To check inter-turn insulation.
 By performing this test, we ensure that the inter-turn insulation of the windings
has not been damaged during construction.
Applied Voltage
Volts
Applied
frequency
Hz
Withstand time Remarks
460 100 1 min OK

24. SIMULATION
A computer simulation, a computer model, or a computational model
is a computer program, or network of computers, that attempts to
simulate an abstract model of a particular system.

25. Steps Undertaken during Simulation
Algorithm is done based on
our design details from which
the c programming is done.
The result from the C
programming is obtained via
MS Excel.
Parameters are practically
found using ROUTINE
TEST
Comparison between the
programming result and
practical result.

26. IDEAL
PRACTICAL

27. ANALYSIS OF SIMULATED AND PRACTICAL DATA:
-300
-200
-100
0
100
200
300
0 1 2 3 4 5 6 7
Voltage
Theta
Primary Voltage
Primary Voltage
-150
-100
-50
0
50
100
150
0 1 2 3 4 5 6 7
Voltage
Theta
V2 simulation
V2 Practical
Secondary Voltage

28. ANALYSIS OF SIMULATED AND PRACTICAL DATA:
-0.4
-0.3
-0.2
-0.1
0
0.1
0.2
0.3
0.4
0 1 2 3 4 5 6 7
Current
Theta
I1 simulation
I1 practical
Primary Current
-0.8
-0.6
-0.4
-0.2
0
0.2
0.4
0.6
0.8
0 1 2 3 4 5 6 7
Current
Theta
I2 simulation
I2 practical
Secondary Current

29. CONCLUSION
It is now clear that the theoretical design outputs can never be generated from
the actual construction
It always has to differ to some extent, considering the losses.
From the simulation technique it is much better to understand that how much
actual transformer efficiency can differ from an ideal scenario.
Overall, designing, constructing, testing and simulating a transformer helped us
gain an in-depth knowledge on this topic, which will help us in future.

30. FURTHER SCOPE OF WORK
 The working model constructed by us is a generalized one.
 This procedure can be used to construct and effectively simulate
any kind of core/shell, small/big transformers.
 Thus it gives a solid guideline behind designing of any kind of
transformer and prediction of its behaviour.

31. Thank You
Thank You