Manufacturing & Testing of Distribution Transformers

Manufacturing & Testing of Distribution Transformers
CHAPTER 1
INTRODUCTION
1.1 Distribution transformers:
A distribution transformer is a static device used to reduce the primary voltage of the electrical
power distribution system to the utilization voltage serving the customer by electromagnetic
induction from one circuit to another at the same frequency.
1.2 Transformer uses in electrical networks:
In the alternating current (AC) electrical supply system that is used in all countries for supply to
consumers, the transformer is an indispensable component. It is not possible to operate viable
electrical supply systems without it. In the normal distribution of power to consumers, the power is
generated at the power stations (Hydro /Thermal) at 3.5-15 kV. It is then passed through its first
transformer stage to increase the voltage to the transmission voltage of 220-500 kV. Power is
transmitted at high Voltage (512-1020 kV) to reduce the transmission losses. At end of the
transmission line it is then transformed to the 132 – 33kV at sub-transmission level. It is then sent
to local substations, where it is transformed down to 11 kV and is then sent on its final path to local
street transformers where it is reduced down again to the final voltage of 415/240 volts. There are
hundreds of thousands of transformers working in this final leg of power transmission, called as
Distribution transformers. All the transformers involved will have energy losses and hence thus any
reduction in the transformer loss will mean less generation requirement and less greenhouse gas
emissions. Most of the transformers operate cyclically, sometimes at very high peak loads and
sometimes at very light loads. The operating temperature depends on the season with peak
temperatures occurring in summer with peak loads. Most of the Distribution transformers fail in
summer, when the demand is peak. In some cases, it takes one or two weeks to replace them.
Disruption of power to agriculture in tropical countries will reduce the farm output and affects the
supply chain mechanism of the industries. Thus, even a small improvement in transformer
efficiencies and life would lead to significant reductions in repair and maintenance charges and in
generation capacity.
DEPARTMENT OF EEE,GCE,RAMANAGARAM 1
CHAPTER 2
ABOUT THE COMPANY
2.1 Introduction:
The Karnataka Vidyuth Karkhane Limited, a fully owned Government of Karnataka undertaking,
is the successor to the Government Electrical Factory, the first ever manufacturer of electrical
transformer in the country, established way back in 1933 by the erstwhile Maharaja of Mysore.
Today, after six decades of successful operations, KAVIKA has emerged as a renowned name for
distribution transformers in the range of 25kVA to 3150kVA up to 11kV Class as well as for
custom built / special type transformers as per specific requirements.
The secret behind the popularity of KAVIKA transformers is the strict adherence quality norms,
at every stage of manufacturer. Starting from the imported prime quality CRGO oil indigenous
raw materials, the product goes through strict quality checks at every stage to ensure that only the
best comes out the factory to reach a select band of customers, across the country.
KAVIKA has following features:
 India’s oldest transformer manufacturer.

 Largest manufacturer of distribution transformers in the country.
 Latest technology in design, manufacturer and testing.
 Excellent infrastructure with trained engineers, technicians and skilled manpower.
 Processing crucial processing equipment’s like Annealing Furnace, Vacuum
Drying Plant, Oil filtering equipment, etc.
 Strict quality checks at all stages of manufacture.
 Routine tests as per IS: 2026 for all transformers.
 Type tested is CRPI, Bangalore.
KAVIKA has a long list of satisfied clients who have stood by it for decades-a testimony to
trouble-free performance and reliability.
The internship was done at Karnataka Vidyuth Karkhane Limited, Bangalore which is one of the
current leading manufacturers of distribution transformers in the country. The purpose of this
internship was to study a manufacturing company in particular to get an insight into all the
activities that make up the organization structure. It was much more helpful to obtain a real time
work experience in an organization and get to know thins much better and to have a much more
clear understanding on all the integrated functions in an industry.
The major customers the state Electricity Companies of India. KAVIKA has ESCOM customers
all over India. Frequent customers are given below:
 Bangalore Electricity Supply Company Limited.

 Hubli Electricity Supply Company Limited.
 Mangalore Electricity Supply Company Limited.
 Gulbarga Electricity Supply Company Limited.
 Chamundeshwari Electricity Supply Company Limited.
 Karnataka Power Corporation Limited, etc.
2.2 Major milestones:
 The Company was established in 1933 as a Government Electricity Factory for

manufacturing of electrical accessories.
 In 1976 the company is renamed to Karnataka Vidyuth Karkhane(KAVIKA)
 Converted into a government PSU in 1976 with Rs.6 crore as Authorized share
capital and paid up capital of Rs.561.92 lakhs. All the shares are with Govt. of
Karnataka.
 In 1976, company manufacturing only conventional transformers.
 The Company has obtained Approval/Certification from Bureau of Energy
Efficiency (BEE) for manufacture of State rated transformers. In the financial year
2012-13, the company sold 22053 transformers in the year 2011-12.
 The company is shifting its focus from producing the conventional transformers to
the star rated category of transformers of different capacities.
 Before 1995 KAVIKA uses drawing boards for design the transformers.
 After 1995 KAVIKA uses AutoCAD for designing the transformers.
2.3 Services:
The various services which Karnataka Vidyuth Karkhane is offering are as follows:
Repair Services:
 Within warrantee period- Within the warrantee period means 3years, if any
problem occurs the company provide repair services to customers.
 More than warrantee period- If any problem or fault occurs in the transformer
more than warrantee period, the company provides repair services to customer with
charges.
Engineering services:
 Utilities possessing any problems at the time of installation or in operating

conditions of the transformer that can be solved by service engineers.
2.4 Department and their functions:
The overall working process of the company involves all the departments which are
interconnected right from design, procurement of materials up and dispatch of finished product.
 Design Department.
 Purchase Department.
 Store Department.
 Production Department.
 Quality Control Department.
 Marketing Department.
 Maintenance and Repair Department.
 Human resource and Finance.
 Dispatch.
Design Department:
The design department gives the design specification of the different types of transformers as per
the quality standards. Latest technology being used which is in accordance to BIS and all the
designs are computer generated. By using computer design software drawing is generated quickly
and in less time.
Purchase Department:
Purchase department purchase the material, needed to manufacture the transformers as per
requirements.
Store Department:
After purchasing, check the quality of materials as per IS and finally store the materials to
distribute for different sections like winding section, core assembly sections as per requirements.
Production Department:
The production department involves the following process:
 LV Winding.
 HV Winding.
 Core Assembly.
 Core-Coil Assembly.
 LV and HV connections.
 Drying Process.
 Oil Filtering.
 Lowering Process.
 Test Bed.
 Name Plate Fixing.
 Dispatch.
Quality Control Department:
The objective of QC department is testing of materials/products to verify conformance to specified

requirement and applies to all procured by the company such as raw materials, components for
production including the outsourced items. The responsibilities of QC departments is responsible
for receiving, inspection and testing of incoming items as per applicable procedure and
maintenance records.
Quality test is done in between the process, namely
 Coil ratio test-To check the number of turns of winding and to check for shorting and
disconnection.
 Final testing-Tests done after final assembly to approve for dispatch.
This department is responsible for various quality tests that are conducted right from the inspection
stage of procured raw materials until the final testing of the transformers. The following activities
done at different stages of production:
 Sampling inspection of raw materials.

 Process inspection at different level of manufacturing.
 Final testing of the transformers based on star rating adhering to ISO quality standards.
 Before dispatch, each transformer is checked for its completeness and various accessories
are fitted. Final visual inspection is done.
Marketing Department:
Marketing department plays several role in helping the company deliver high quality goods and
services to target customers. It is headed by the executive director followed by deputy general
manager. Marketing manager and staff work under the deputy general manager.
Main objective is to market transformer in all segments of the state. It is followed by the following
network.
 To make people to know about reputation of the company.

 To consider immediate response to customer wants.
 To increase the target number of selling transformer annually.
 To identify potential customers.

 To research on new products development.
 To provide customer service and care.
 Strict adherence to quality to achieve customer satisfaction.
Maintenance and Repair Department:
Design and quality control manager heads the maintenance department followed by deputy
manager, additional engineer and junior engineer for maintenance. Supervisors for mechanical and
electrical maintenance are under the junior engineer.
The main function is to maintain the equipment to avoid breakdown problems as soon as possible.
The other function is:
 To maintain the machine which are in use by lubrication and other measures.
 Maintain the raw material which is procured for manufacture of transformers by applying
suitable measures.
 To procure the spare parts necessary for the machine as and when they worn out to avoid
delay in work and also to maintain the efficiency of machines used.
Human resources and Finance:
To ensure that trained and qualified man power can be made available at the right time, right place
and to right person and reviewing the minimum qualification on the basis of future requirements.
Human resource department is a continuous process to ensure the development of employee’s
competencies, motivation and effectiveness in a systematic and planed way.
2.5 Summary:
In this chapter, it has been substantiated about the major milestones of the company, various
services that the company provides and different departments and their roles in the company.
In the next section it has been discussed in detail about the department.
CHAPTER 3
ABOUT DEPARTMENTS
3.1 Introduction:
The overall working process of the company involves all the departments which are interconnected
right from design, procurement of materials up and dispatch of finished product. The study was
approached with interdisciplinary view that, all the departments come under the prospective as
given below:
 Design Department.
 Purchase Department.
 Store Department.
 Production Department.
 Quality Control Department.
 Marketing Department.
 Maintenance and Repair Depart.
The study and analysis of production department and quality control department was mainly
concentrated upon as the company has earned its reputation through ISO quality certification of
transformer production. The various stages of production and quality control observation are
necessary to prepare the process flow charts. Apart from this, study of other department as
mentioned above that contribute in achieving the company’s monthly and yearly goals.
The design department gives the design specification of the different types of transformers as per
the quality standards. The procurement of materials is done by the purchase and store department
and is sent for quality testing. Sampling test is done which determines whether the materials fall
within the quality limits or not. Next, the materials are sent to production where all the production
operations take place as per the monthly schedule and the number of allotted to different types of
operations. Quality checking is done in between the processes and sent to the next. Then, final
testing of the transformer takes place followed by dispatch.
3.2 Roles and responsibilities of an individuals in the department:
Design Department:
The design department gives the design specification of the different types transformers as per
quality standard. Latest technology is being used which is in accordance to BIS and all the designs
are computer generated. By using computer design software, accurate drawings are generated
quickly and in less time. Final document required for production, purchase of material etc. will be
generated by the design department send to the respective departments for further process.
Purchase Department:
Purchase department purchase the material, needed to manufacturer the transformer as per
requirement. The purchase department is headed by the purchase manager followed by assistant
purchase manager and staffs. All purchase by KAVIKA and order issue by the company are
subjected to the terms and conditions mentioned here under, unless the company confirm them in
writing, they are not binding on the company. The acceptance of the order is deemed as the
acceptance of the following terms and conditions, some exception mutually agreed upon.
Inspection:
The following steps are followed for inspections:
 The goods supplied will be subject to inspection by quality control department.

 The decision of the inspection department as to the acceptance of otherwise, shall be final
and binding on the supplier. In the end, the supplier company shall have the right on the
rejected materials.
 To demand the replacement of the rejected materials by the suppliers within the extra
cost of the supplier.
 To terminate the contract and buy an equal quantity of goods rejected or others of similar
nature elsewhere at the risk and expenses of the supplier of any further consignments due
under the purchase order, damages for such losses will be recovered by the supplier.
 All material provisionally accepted since 100% check of goods is impossible and it is
binding on the supplier to replace or compensate the value for such materials that are
rejected during the course of actual use of materials. The limiting period is one year from
the date of receipt of the respective items in KAVIKA stores.
Store Department:
Storages are used for functions of receiving, storing and issuing materials for assembly of
transformers and proper maintenance of information regarding receipt, issue and requirement of
materials. Store departments headed by deputy general manager-stores/purchase followed by
assisted general manager. Commercial superintendent and store keeper work under them along
with supporting staff.
Objectives:
The main objective is to define the procedure for preserving product conformity during internal
processing and delivery to the intended destination. It includes,
 Product identification, handling, packing, storage and protection.

 It also covers rising of purchase requisition and it applies to all raw materials such as
CRGO coils, craft paper, copper wires, components like studs, capital equipment, spare
tools, measuring instruments, in process items and finished products.
Production department:
 HV and LV winding.
 Core assembly.
 Connection and tapping.
 Drying.
 Lowering.
 Oil filling.
 Name plate fixing.
 Dispatch.
The general process flow is as follows. The materials process from carpentry section such as press
board sheets and craft paper are sent to the winding and coil assembly process. Core assembly is
done for which the HV and LV coils are assembled and sent to the coil ratio testing area. Passing
this test, the assembly is further sent to connecting process followed by heating the assembly in
the heating chamber. The coils that do not pass the ratio test to rework. Following the heating
process, the coils are lowered rig assembly is into the tanks and filled with oil. The final ring is
done along with terminal and bush assembly and sent to the quality testing area. Transformers
passing these tests are sent to dispatch which others are sent to rework.
Quality Control department:
QC department is headed by the chief quality assurance manager followed deputy manager.
Assistant engineer for final testing, raw materials inspection and stage inspection are under the
Deputy Manager. Under Assistant engineer and junior engineer are present for checking mainly
for winding, coil assembly and core assembly. To ensure quality and to reduce the defective
product being further process, inspection and testing at the following stages is done:
 Incoming material inspection.

 In process inspection.
 Final inspection of outgoing product.
Maintenance and Repair Department:
Design and quality control manager heads the maintenance department followed by deputy
manager, additional engineer and junior engineer for maintenance. Supervisors for mechanical and
electrical maintenance are under the junior engineer.
Objectives:
To define the process for maintenance of infrastructure used by the company like building and
workspace, production equipment, material handling equipment and utilities, stand by generators
and communication systems.
Human Resources and Finance:
To ensure that trained and qualified man power can be made available at the right time, right place
and to right person and reviewing the minimum qualification on the basis of future requirements.
Human resource department is a continuous process to ensure the development of employee’s
competencies, motivation and effectiveness in a systematic and planed way.
Functions:
The functions of personnel and administration departments are as follows
 To maintain on personnel functions of the organization.

 Maintaining officer/employees personnel records.
 Casual leave, privilege leave, sick leave etc.
 Grievance handling.
 Retirement benefit payment, gratuity, gift cheque etc.
 Discussing with the management and top taking guidance in personnel matters.
 Extending benefits to employees as per memorandum of settlement entered between
management and labour union.
 Extending promotions as per the settlement.
Working hours:
Working hours for the employees are 08:15am to 04:15pm
3.3 Summary:
In this chapter, it has been discussed in detail about the roles and responsibility of individuals in
the department is also explained. In next session about various task performed in the company are
highlighted.
CHAPTER 4
TASKS PERFORMED
4.1 Task Assigned:
The internship work carried out was on technical know how’s of the manufacturing and testing of
distribution transformers.
Electrical energy is the backbone of the economy of a country. Power is must and should require
for development of country. Transformer is the heart of the power system network. It is an essential
equipment to get electrical energy at desired voltage. Transformer makes electrical generation
possible at the most economical generator voltage, power transfer at the most economical
transmission voltage for the particular utilization device. Transformer in electrical system is
important for generation, transmission, distribution and utilization of electrical power.
Transformer definition:
Transformer is a static electrical device which transforms electrical energy from one circuit to
another circuit without changing its frequency but may be different in voltage level.
Transformer works on the principle of Faraday’s Laws of Electromagnetic Induction. Mutual

induction between two or more winding is responsible for transformation action in an electrical
transformer. It follows laws of physics viz.
 Induction Laws: Faraday’s law of electromagnetic induction states that ‘‘the

magnitude of induced EMF in a coil is directly proportional to the rate of change of
flux linkages with the coil’’.
 Lenz’s Law: When an EMF induced in a circuit, the current set up always opposes the
motion, or change in current, which produce it.
 Maxwell’s field theorems: Electric flux lines, if they end at all, will do so on electric
charges. Magnetic flux lines never terminate. Rate of change of magnetic flux threading
a circuit equals the EMF or based on Ampere’s experiment on steady currents which
show that the line integral of magnetic intensity H around a closed curve equals the
current encircled.
Need/Importance of Transformer:
Generation of electrical power in low voltage level i.e. 11kV is very much cost effective.
Theoretically, this low voltage level power can be transmitted to the receiving end. This low
voltage power if transmitted results in greater line current which indeed causes more line losses.
But according to Ohm’s law if the voltage level of a power is increased, the current of the power
is reduced which causes reduction I2R losses in the system. As per ISO 9000 the maximum
conductor limitations is 1 to 1.5 inch, due to limitations reduction in cross section area of the
conductor that is reduction in capital cost of the system and it also improves the voltage regulation
of the system. Because of this low level power must be stepped up the voltage at desired
transmission voltage. As the generating end step up transformer will be used to step up the voltage
at desired transmission voltage. As this high voltage power may not be distributed to the consumers
directly, this must be stepped down to the desired voltage level at the receiving end with help of
step down transformer. From the above we know that transformer plays an important role in power
system network.
Functions and Duty of a Transformer:
The function of a transformer is to transform voltage of AC from one voltage to another, without
a change in frequency. Whereas, the duty of a transformer must be defined in a more restricted
manner in relation to operation under the stresses imposed in service and in particular on its ability
to perform satisfactorily throughout its life. Capacity of the transformer is the kVA available from
a fully loaded transformer.
Construction and Working Principle of Transformer:
The Three Main Constructional Parts of Transformer are:
Primary Winding of Transformer- Primary winding of a transformer produces magnetic flux

when it is connected to 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.
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.
Working Principle of Transformer:
The basic principle behind working of a transformer is the phenomenon of mutual induction
between two windings linked by common magnetic flux. The above figure shows the simplest
form of a transformer. Basically a transformer consists of two inductive coils; primary winding
and secondary winding. The coils are electrically separated but magnetically linked to each other.
When, primary winding is connected to a source of alternating voltage, alternating magnetic flux
is produced around the winding. The core provides magnetic path for the flux, to get linked with
the secondary winding. Most of the flux gets linked with the secondary winding which is called as
‘useful flux’ or ‘main flux’, and the flux which does not get linked with secondary winding is
called as ‘leakage flux’. As the flux produced is alternating (the direction of it is continuously
changing), EMF gets induced in the secondary winding according to Faraday's law of
electromagnetic induction. This EMF is called ‘mutually induced EMF’, and the frequency of
mutually induced EMF is same as that of supplied EMF. If the secondary winding is closed circuit,
then mutually induced current flows through it, and hence the electrical energy is transferred from
one circuit (primary) to another circuit (secondary).
4.2 Technical tasks performed:
The internship work involved manufacturing and testing of distribution transformers.
Manufacturing process of Transformers:
Manufacturing is the process of translation of raw materials into finished part or product to perform
a specified purpose or function. Processing describes the act of taking something through an
established and usually routine set of procedures and at certain converts from one form to another
in a series of sequence of operation or events.
The manufacturing capability is the key for reliable transformers. The process must be clearly
defined and the operator’s skill must have the highest levels. Manufacturing of a transformer
include the major stages, they are:
 LV Winding.
 HV Winding.
 Core Assembly.
 Core-Coil Assembly.
 LV and HV connections.
 Drying.
 Oil Filling.
 Lowering.
 Testing.
 Name Plate Fixing.
 Dispatch
Flowchart of manufacturing process:
LV Winding HV Winding Core Assembly
Core-Coil
Assembly
Ratio Test
LV & HV side
Connections
Vacuum
Chamber
Lowering
Testing
Dispatch
LV & HV Windings:
LV Winding HV Winding carried out over

LV winding
The winding allow the flow of oil around the conductor in between sections. These windings are
made of high grade electrolytic copper or aluminium which is designed to optimize thermal,
mechanical and electrical stresses depending upon the current and voltage requirements. Spiral,
Cross-over, Helical and Continuous Disc winding with multiple copper conductors are usually
adopted for transformers. The coil is lowered on the core legs. In order to give extra strength to
the winding and for axial cooling oil ducts are used between LV and HV windings.
For 25kVA 4star transformer:
 The width & thickness of LV conductor without insulation is 9.8mm×4.2mm.

 The width & thickness of LV conductor with double layer insulation is 10.13mm×4.53mm.
 The thickness of HV conductor without insulation is 1.1mm.
 The thickness of HV conductor with insulation is 1.36mm.
 The thickness of pressboard for these transformer will be 1mm.
Procedure for 25kVA 4star LV Winding:
1. In the first step we have to wind the pressboard (which is having thickness of 1mm) around
the bobbin (which is having the length of 447mm and dia of 81mm) for the purpose of
insulation between LV winding and core.
2. Then we have to apply the glue to the pressboard.
3. After that we have to stick the cotton tape in order to avoid slipping of the conductor.
4. Then we have to wind the end-strip as per design at one edge of the pressboard to protect
the insulation of LV conductors.
5. After that we have to wind the rectangular shaped conductor made up of Aluminium of the
size with insulation will be 10.13mm×4.53mm.
6. Then we have to wind the conductor in such a way that there should be 41.25 conductor in
one layer (This is according to catalogue of LV winding of 25kVA 4star transformer).
7. After the completion of winding of one layer of the conductor, end-strip should be wind on
another edge of the pressboard as per design.
8. Then we have to wind Epoxy Diamond Doted Kraft Paper of the size 0.1mm thickness
around the first layer of conductor.
9. After the completion of above procedure we have to repeat the step number 6 to 8 in order
to obtain 165 conductor in 4 layers of set-up (This according to catalogue of LV winding
of 25kVA transformer). While doing last layer of the setup we have to pull the cotton tape
and bind it tightly to avoid loosening of the set-up.
10. After that we have to wind the oil ducts of 7mm thickness around the set-up as a cooling
agent. Thereafter we have to wind the pressboard (which is having thickness of 1mm)
around the oil ducts and at last we have to bind the cotton tape tightly over the pressboard.
Oil ducts and pressboard together gives minimum clearance between LV and HV winding.
Procedure for 25kVA 4star HV Winding:
1. HV and LV are two separate sections. After completion of LV winding it brought into
HV section and placed over a bobbin which contain 17mm aluminium rings on both of
its sides.
2. Then we have to remove the cotton tape and put the glue on the pressboard.
3. After that we have to stick the cotton tape at both the edges of pressboard.
4. Then we have to wind the end strip as per design at one edge of pressboard in order to
protect the insulation of HV conductor.
5. After that we have to wind the round shaped conductor made up of aluminium of
thickness with insulation will be 1.36mm
6. Then we have to wind the conductor in such a way that there should be 290.4 conductor
in one layer.
7. After the completion of winding of one layer of the conductor, end-strip should be wind
on another edge of the pressboard as per design.
8. Then we have to wind Epoxy Diamond Doted Kraft Paper of the size 0.1mm thickness
around the first layer of conductor.
9. After the completion of above procedure we have to repeat the step number 6 to 8 in
order to obtain 7260 conductor in 25 layers of set-up (This is according to catalogue of
HV winding of 25kVA transformer). While doing last layer of the setup we have to pull
the cotton tape and bind it tightly to avoid loosening of the set-up. Then we have to
wind the last layer of Epoxy Diamond Doted Kraft Paper for the set-up.
10. At the starting and ending part of Aluminium winding, it is crimped with 1.6 thickness
of Copper wire with 12 layers of insulation by using ferules of 4sq mm. Epoxy Diamond
Doted Kraft Paper is provided near the crimped point. Epoxy Diamond Doted Kraft
Paper is highly insulating Class A material; it can withstand 1050C, it can normally
withstand 8KV and it can go up to 32KV.
Core Assembly:
Core of the transformer is similar to the heart of a living being. Type of core is cruciform; the
specialty of cruciform core is reduces the leakage flux in the core.
Core Type Transformer Cruciform Section
KAVIKA uses CRGO (cold rolled grain oriented) laminations. It has 0.23mm thickness & 2 to 3%
of silicon content and it helps to reduce the core losses. Beyond these limit, increases in silicon
concentration impairs the steel’s mechanical properties, causing difficulties for rolling due to
brittleness.
Core-Coil Assembly:
The magnetic part of the transformer consists of the magnetic core with windings and accessories.
The winding are placed over the core limbs and necessary connections are made as per the tapings
and vector group. The packing pieces of 8mm thick is provided for HV windings and 12mm thick
is provided for both HV & LV windings to hold the conductors fitly and also to avoid the short
circuit that take place in the core-coil assembly. Totally 48 packing pieces are used in the core-
coil assembly.
Core-Coil Assembly
Best quality insulation is provided at joints and gaps and at the time of core-coil assembly, core
bolts, tie rods, core fixture and pressure blocks provide mechanical strength and avoids damages
of lightning.
LV and HV Connections:
LV Connection HV Connection
The LV is star connected and HV is delta connected. The neutral available on the primary can be
earthed to avoid distortion. The Star-Delta connection has no problem of third harmonic
component due to circulating current in delta. It is also more stable to unbalanced loads since the
delta partially redistributes any imbalance that occur. The LV and HV connections in the form of
Dyne 11 d indicates type of connection of the HV winding. Y indicates type of connection of the
LV winding, n indicates neutral and according to vector group 11 means 30 degree phase shift
between LV and HV.
The polarity of a winding refers to the direction of induced e.g. in the winding at a particular
instant, foe a three phase transformers; polarity alone is insufficient to represent the relation
between HV and LV windings. In addition to the thermal marking on HV and LV side voltage
vector diagram are required to show the angular displacement between HV and LV windings.
Drying process/Heat test:
Heating chamber
After connection, active part is kept inside the vacuum chamber to remove moisture contents,
keeping it there 14 to 16 hours with continuous heating by thermal oil at 120 degree Celsius to
remove water content. At a time 150 active parts of 25kVA or 90 active parts of 63kVA or 70 parts
of 100kVA transformer are kept into vacuum chamber.
Oil Filling:
Oil Filling
Filtered and degassed transformer insulating oil is then filled into the tank under the vacuum and
this oil is circulated through the vacuum filter plants until the required insulation level is achieved.
Lowering:
Lowering
After drying winding, clamping and connection are checked and tightened before lowering onto
tank.
Testing:
After manufacturing, conduct different test to check the operational performance and withstanding
capacity of transformer. Test details are explained later.
Dispatch:
Dispatch
Before dispatch check the oil level and fix the horn gap fuse, breather and name plate.
Tests on Transformer:
Testing of transformer consist of two types. They are,
4.2.1 Acceptance test:

Quality testing for the material used in the transformers is done when the material are produced.
The following tests are conducted to check the quality of materials:
4.2.1.a Tensile strength test.
4.2.1.b Breakdown voltage test of transformer oil.
4.2.1.c Resistance test for transformer oil.
4.2.1.a Tensile strength test:
Tensile strength test is conducted for conductors, pressboard and insulation papers. For
conductors up to 3mm tensile strength is 100-110N/m2 and for pressboard the tensile
strength is 60-80N/m2.
4.2.1.b Breakdown voltage test:
To determine the insulating property of transformer oil, a sample of the transformer oil is
taken and the breakdown voltage is measured using the following steps.
 The oil is filled in the vessel of the tester. Two test electrodes with a typical
clearance of 2.5mm are present in the vessel surrounded the dielectric oil.
 A pre-determined voltage is applied to the electrodes and continuously increased.
It is done up to the voltage where a spark is breakdown of oil.
 At a certain voltage level breakdown occurs and an electric arc is formed due to
which the voltage build up instantaneously comes down.
 Immediately after the ignition of the arc, the voltage is switched off, automatically
by the device. This helps in immediately marking the voltage null. If, it is continued,
it results in carbon formation and many pollute the oil and damages the electrodes.
 The voltage at which the test oil breaks down is noted and checked whether it is
desirable or not.
 After this initial test, the same procedure is repeated for other trials. Between echo
trial, oil is stirred so that it is properly distributed and is repeated for other trials.
Between each trial, oil is stirred so that it is properly distributed and also cooled to
the room temperature.
 The final results gives the mean breakdown voltage and is calculated as mean value
of all measurement trials.
 It can be concluded that higher the resulting breakdown voltage, more the quality
of the transformer oil.
4.2.1.c Resistance Test of Transformer oil:
Resistance test is conducted to check the resistivity of transformer oil. The resistance of
transformers oil is measured at room temperature and at 90 degree Celsius by applying
500V DC supply. It can be concluded that higher the resistance value more the quality of
the transformers oil.
4.2.2 Sub Tests:

Sub tests are conducted in between the manufacturing of a transformer. They are,
4.2.2.a Coil ratio test
4.2.2.b Resistance test
4.2.2.c Vector group test
4.2.2.d Magnetic balance test
4.2.2.a Coil ratio test:
The performance of a transformer depends upon the number of turns so that perfection of
specific turns is very important. The turns ratio for step-down distribution transformer is 1:44.
Coil ratio test meter
The procedure of coil ratio test is as follows.

 Inside the bridge (ratio meter) there is a 1:2 ratio step-down transformer. These
transformer step-downs the input voltage 240V to 120V. This step-down voltage is
applied to a meter as well as to the HV terminals in parallel.
 As per mutual induction the EMF is induced in LV winding. These induced voltage
is applied to another terminals of meter such that the meter has to read null
deflection, if the turns ratio is same as that of 1:44.
 If any variation i.e. ± in the turns then the meter will reads the difference in turns.
4.2.2.b Resistance test:
Resistance test meter
Transformer clearance measurement is carried out to calculate the I2R losses and to
calculate and to calculate the resultant temperature at the end of a voltage raise test. It is
mainly done to ensure healthiness of a transformer. Many defects like loose connection,
high contact resistance in tapping apparatus, high voltage leads and bushing etc.
4.2.2.c Vector group test:

This test is conducted to confirm the connection of LV and HV winding
4.2.2.d Magnetic balance test:
Magnetic balance test is conducted to check the equal distribution of voltage per phase.
4.2.3 Routine tests:

Routine tests of transformer are mainly for confirming operational performance of
individual unit in a production lot. Routine tests of transformer includes,
4.2.3.a HV and LV test.
4.2.3.b Induced over voltage test (or) double voltage double frequency test.
4.2.3.c Open circuit test [OC test].
4.2.3.d Short circuit test [SC test]
4.2.3.a HV and LV test:

In HV test, LV is shorted and supply is given to the HV. As per Indian standard for 11KV
transformers 28KV is applied to the HV of the transformer. This test is passed only if the
transformer should withstand for one minute without any tripping of the circuit breaker.
The transformer is withstand 28KV supply up to one minute without any damage it indicate
the withstanding capacity and dielectric strength of transformer is more.
In LV test, HV is shorted and supply is given to the LV. As per Indian standards for 11KV
transformer 3KV is applied to the LV of the transformer. This test is passed only if the
transformer should withstand for the minute without any tripping of the circuit breaker.
The transformer is withstand 3KV supply up to one minute without any damage it indicate
the withstand capacity and dielectric of transformer is more.
4.2.3.b Induced over voltage test (or) Double voltage frequency test:
The induced voltages test of transformer is mainly done to check the turns and insulation
as well as main to casting, earthing and between winding wires.
The procedure is as follows:
 The LV winding of the transformer is kept as open circulated.
 Three phase 433 volts are applied to the LV winding. The applied voltage should
be two times of rated voltage of HV winding in magnitude and frequency.
 The duration of the test is about 60 seconds or as specified by the quality standards.
 Initial test is started by applying one third the full test voltage, and it is gradually
increased up to two times of the desired voltage value.
 If breakdown does not occur at the highest voltage applied, then the test is
successful.
4.2.3.c Open circuit test [OC test]:

The connection diagram for open circuit test on transformer is shown in the figure. A
voltmeter, wattmeter, and an ammeter are connected in LV side of the transformer as
shown. The voltage at rated frequency is applied to that LV side with the help of a variac
of variable ratio auto transformer. The HV side of the transformer is kept open. Now with
the help of variac, applied voltage gets slowly increased until the voltmeter gives reading
equal to the rated voltage of the LV side. After reaching rated LV side voltage, we record
all the three instruments reading (Voltmeter, Ammeter and Wattmeter readings).
The ammeter reading gives the no load current Ie. As no load current Ie is quite small
compared to rated current of the transformer, the voltage drops due to this current that can
be taken as negligible.
Since voltmeter reading V1 can be considered equal to the secondary induced voltage of
the transformer, wattmeter reading indicates the input power during the test. As the
transformer is open circuited, there is no output, hence the input power here consists of
core losses in transformer and copper loss in transformer during no load condition. But as
said earlier, the no-load current in the transformer is quite small compared to the full load
current so, we can neglect the copper loss due to the no-load current. Hence, can take the
wattmeter reading as equal to the core losses in the transformer.
Therefore it is seen that the open circuit test on transformer is used to determine core losses
in transformer.
4.2.3.d Short circuit test [SC test]:

The connection diagram for short circuit test on transformer is shown in the figure. A
voltmeter, wattmeter, and an ammeter are connected in HV side of the transformer as
shown. The voltage at rated frequency is applied to that HV side with the help of a variac
of variable ratio auto transformer. We short-circuit the LV side of the transformer. Now
with the help of variac applied voltage is slowly increased until the wattmeter, and an
ammeter gives reading equal to the rated current of the HV side. After reaching rated
current of HV side, we record all the three instruments reading (Voltmeter, Ammeter and
Watt-meter readings). The ammeter reading gives the primary equivalent of full load
current IL. As the voltage applied for full load current in short circuit test on transformer
is quite small compared to the rated primary voltage of the transformer, the core losses in
transformer can be taken as negligible here.
Let’s say, voltmeter reading is Vsc. The watt-meter reading indicates the input power
during the test. As we have short-circuited the transformer, there is no output; hence the
input power here consists of copper losses in the transformer. Since the applied voltage
Vsc is short circuit voltage in the transformer and hence it is quite small compared to the
rated voltage, so, we can neglect the core loss due to the small applied voltage. Hence the
wattmeter reading can be taken as equal to copper losses in the transformer.
Therefore it is seen that the short circuit test on transformer is used to determine copper
loss at full load.
4.3 Components standard to be followed

In this section the materials used in the transformer are described in detail.
Conductors:
Distribution transformer with HV winding made of copper conductor is less susceptible to metal
fatigue than aluminium. Copper is harder, stronger and more ductile than aluminium, expands less
and does not flow at terminations. Copper displays low level of creep. Under the extreme loading
and temperature condition transformer windings, creep rates of aluminium can be up to 25 times
higher than of copper. This results in aluminium wound distribution transformers having
propensity to failure than copper.
Epoxy Diamond Dotted Insulation Paper:
Epoxy diamond dotted insulation paper
Diamond Dotted Paper (DPP) is also referred as Epoxy Diamond or varnished paper. The thickness
and width can be made according to customer’s specifications. Diamond dotted paper is made of
electric grade Kraft paper with B-stage heat curable epoxy resin coating. Diamond doted paper is
thermally upgrade Kraft paper and used in oil-filled transformer for layer insulation between the
coils.
Pressboard:
Pressboard is a special product based on the purest cellulose, extracted from long-fibered
coniferous tress. These are formed into a non-woven material without using any additional binding
agents and then pressed. The high chemical purity means pressboard in an extremely suitable
insulation material for electrical machines, capacitors and particularly oil-filled transformers. The
material properties allow classification in insulation class A (105 degree Celsius) and are
manufacture in accordance with IEC standard.
Oil ducts:
Oil ducts
Oil ducts are used in between LV and HV winding of the transformer for oil circulation and
insulation purpose.
CRGO laminations:
CRGO laminations
CRGO laminations is used for the core of the power and distribution transformers, cold-rolled
grain-oriented steel is often abbreviated to CRGO. CRGO is usually supplied by the producing
mills in coil from and has to be cut into ‘‘laminations’’, which are then used to form a transformer
core, which is an integral part of any transformer.
Transformer tank:
Transformer tank with bushings
Protection of active part in transformer is very important. While achieving the optimized size of
the transformer to suit the site condition for installation. The main role of the tank is to protect the
active part of the transformer and tank is manufacture to have sufficient strength to have sufficient
strength withstand internal and external fault that may occur during operation.
Transformer oil:
Insulation oil in an electrical power transformer is commonly known as transformer oil. It is

normally obtained by fractional distillation and subsequent treatment of crude petroleum. That is
why this oil is known as mineral insulating oil. Transformer oil serves mainly two purposes one in
installation in electrical power transformer and other one is it dissipate heat of the transformer that
is acts as coolant. Generally there are two types of the transformer oil used in transformer,
 Paraffin based transformer oil.

 Naphthalene based transformer oil.
Conservator tank:
Conservator tank
Function of a conservator tank is when transformer when transformer is loaded and when ambient
temperature rises, the volume of the oil inside transformer increases. A conservator tank of
transformer provides adequate space to this expanded transformer oil. It is also act as a reservoir
for transformer insulating oil.
Breather:
Silica Gel Breather of Transformer
Whenever load on the electrical transformer is increased, the temperature of the transformer
insulating oil increases, consequently the volume of the oil is increased. As the volume of the oil
is increased, the air above the oil level in conservator will come out. Again at low oil temperature;
the volume of the oil is decreased, which again causes air to enter into conservator tank. The natural
air always consists of more or less moisture in it and this moisture can be mixed up with oil if it is
allowed to enter into the transformer. The air moisture should be resisted during entering of the air
into the transformer, because moisture is very harmful for transformer insulation. A silica gel
breather is the most commonly used way of filtering air from moisture.
Silica gel breather for transformer is connected with conservator tank by means of breathing pipe.
Radiator:
Radiator of Transformer
Oil immersed transformer is always provided with radiator. In case of electrical power transformer,
the radiators are detachable and transported separately to the site. The upper and lower portions of
the radiator unit is connected with the transformer tank via valves. These values are provided to
prevent draining of oil during detaching a radiator unit from the transformer for cleaning and
maintenance purposes.
Operation and Purpose of Radiator in Transformer:
When transformer is in the loaded condition, the hot oil comes up in the main tank, and enters into
the radiator tank through upper valve. As the heat transfer surface of the radiator is quite large, the
oil gets cooled and enters into the transformer tank via lower value of radiator units. The
convectional flow of oil in the tank and radiator of transformer continues. The cooling effect of
radiator can be accelerated by applying force air to the radiator outer wall by air fans.
Bushings:
Bushings of a Transformer
In electrical power, a bushing is an insulated device that allows an electrical conductor to pass
safely though a grounded conducting barrier such the case of a transformer. In order to maintain
creeping distance petticoats are made. More the number of petticoats, more will be the voltage
withstanding capacity. Bushings are gazed like circular roof tops for the quick escape of rain water.
Name plate of rating of a transformer:
The data on the name plate of transformer contains of kilo watts rating, voltage rating frequency,
number of phases, temperature, types of cooling, percentage impedance and reactance, name of
manufacture and year of manufacture etc.
4.4 Non-technical tasks performed:

 Purchase the required material.
 Receiving the ordered materials required for manufacture transformer.
 Being in charge of store of responsible to provide all necessary component to different
section in shop floor, store stroke checking done and maintaining the log book for
material used for manufacture.
 Prepared bill of quantity after manufacture.
4.5 Summary:
In this section we have focused on various task performed in the organization like technical and
non-technical skills. In the next chapter we highlighted the technical and non-technical
experiences.
Chapter 5
REFLECTION NOTES
5.1 Work experience:
I was started an Internship about manufacturing and testing of distribution transformer at

Karnataka Vidyuth Karkhane from 09.07.2018 to 08.08.2018. In this duration for the above
mentioned topic I was guided under an Assistant Engineer who was a very knowledgeable
person and also having a 20 years of experience in industry. He was thought the topic from the
basics till the final stages of distribution of transformer.
During this internship we have the opportunity to interact with several employees which
strengthen our communication skills and also a task which they are performed further enabled
in strengthening our knowledge in technical aspects. The following are the some of the
experience gained.
 Overseeing the planning, operation and interdepartmental function that contributes

to the smooth functioning of the organization.
 Strategic planning of production that helps in achieves the monthly and yearly
targets with less discrepancy.
 Chance to work on existing production process with revising and developing the
process and operations.
 Interacting with various staffs such as managers, supervisors, workers and the
employees for gaining their experience and increasing the practical skills of real
time working in an organization.
 Identifying any drawbacks in the present process and improving upon it for further
optimization of the production process and betterment of quality.
 Performing the above related work assigned.
 The discipline followed to achieve customer satisfaction about the quality structure
of the management, management function systems and the procedures of
management in achieving adept quality control.
5.2 Technical outcomes:
 Learnt safety procedure to be followed while performing each and every task and
completing it without causing and damage to self or others.
 Learnt about safety procedures to be followed in case of emergency like first aid.
 Had a chance to witness S.C and O.C tests on larger kVA transformers.
5.3 Non-Technical outcomes:

 Learnt how to manage a store and track the usage of the materials and how to
economically use the materials available.
 Learnt the working of commercial department, as to how do they procure the
materials and how to they choose the best vendor.
 Learnt the functioning of Admin and HR department and gathered information
about hoe do they train the new employee.
 Handling the work alone did learn to be punctual and completing the tasks on right
time.
 After completion of internship overall confidence was boosted and could
successfully handle the work and complete it on time.
 Internship exposure helped in improving verbal and written communication skills.
5.4 Key learning:
After detail study of all the process, departments and overall organization structures, the
following points can be stressed upon for key learning.
 The company’s strict policy of adherence to quality standards.

 Sampling process done for inspection of the quality of the procured materials whether
they fall within the prescribed limits of quality dimension or not. This is approved and
checked by various departments like procurement, quality control and production to

ensure the quality.
 The production plan is done monthly, based on the number of orders and the workers
allotted to each operation so production process is optimized.
 Each transformer assembly route card with a number to specify the operation it has
gone through the worker’s name who have worked on it observed. It helps in finding
out which operation has gone wrong if the final unit is failed.
 All the workers skilled in performing all the types of operations are seen. Work rotation
is being done efficiently.
 Material transport system used such as roller guide ways, hangers and forklift to
transfer in-process and final assemblies quickly and smoothly.
 Final quality check that is done for different parameters so that the transformer passes
in all aspects.
 Some machine tools that used are obsolete which require tedious setup process and
susceptible to many problems.
 Use of mechanical countess severely limits the accuracy of the winding process which
results in much rework.
 There is no accurate guide ways for the wire to be wound perfectly without any gaps
in the winding.
 Much of tedious manual activities are done to control the process accuracy.
 Majority of activities are manual which involves co-ordination of workers for working
on one part of the assembly which again required much time.
 Coil ratio test accurately tests whether the turns are within the specified limit or not.
However much rework is done during the stage.
 There are no specified scale for the length of wire terminals that are attached to the
coil. That is left to worker to make necessary adjustment in this process which again
might be responsible for certain amount of transformer failure.
5.5 Suggestions and Recommendations:
The company is into the manufacture of only distribution transformer. Product diversification
makes it to face the contingencies of business market. They are:
 Facilitating the customer to buy and interacting through E-marketing can enhance the
scale and also helps to attract potential customers.
 Frequent participation in interstate and international trade fairs helps in promoting the
product and bringing the branch identity.
 Management should take initiative in building quality circle among the employees
which would help in bringing closeness among them and also increased the
productivity level of the company.
5.6 Summary:
In this section we explained about various technical and non-technical experienced gain in the
company is discussed in detail.
CONCLUSION:
A study was done for every activity of the production process and it should be mapped. The
unprocessed assemblies of coil was sent to rework because of inaccuracy of winding process. The
core assembly process was studied in detail and steps were suggested to make it more accurate and
efficient.
Finally, a study of failure mode and effect of analysis of transformers was done and also the main
causes for the failure of a transformer was studied. The occurrence of these causes and the severity
& rectification for these causes were found. Some of these causes were found in the production of
the transformer for which alternative method were suggested in order to eliminate the occurrence
of causes of failure.
As one of the oldest serving company today, KAVIKA Limited has emerged as manufacture of
quality transformer which is ISO: 9001-2008 certified. The integration of the entire department
towards manufacturing of distribution transformer was well made and efficiently use of staffs,
workers and assists in the key to its success. Integration with all the staff and workers gave an idea
of how each and every operations are involved.
Apart from manager, workers were also well versed with all the processes which were mainly due
to the work rotation. Real time experience on production scheduling, labour management and work
force allocation was gained. Even though the company does not use the latest technology, it makes
up for it in skill of the other workers. Preference to quality one of the most important things that
help the company gains reputation. Real time problem arising in the shop floor were observed and
step taken immediately to curb the seen. It also gave an opportunity to study the weakness of some
process along with their strength. Detailed study of problem helped in gaining in practical
knowledge on how the improvement process can actually be applied such as QC tools, quality
control and improvement processes.
REFERNCES:
1. Literature titled company profile available at URL:http:www.kavika.co.in

2. Literature titled electrical transformer-Basic Construction, Working and Transformer
testing available at URLhttps://www.electricaleasy.com, URLhttps://www.electrical4u.com.

Manufacturing & Testing of Distribution Transformers

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Manufacturing & Testing of Distribution Transformers

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Manufacturing & Testing of Distribution Transformers

1.1 Distribution transformers:

1.2 Transformer uses in electrical networks:

KAVIKA has following features:

 India’s oldest transformer manufacturer.

 Bangalore Electricity Supply Company Limited.

2.2 Major milestones:

 The Company was established in 1933 as a Government Electricity Factory for

 After 1995 KAVIKA uses AutoCAD for designing the transformers.

 Utilities possessing any problems at the time of installation or in operating

2.4 Department and their functions:

The production department involves the following process:

Quality Control Department:

The objective of QC department is testing of materials/products to verify conformance to specified

Quality test is done in between the process, namely

 Sampling inspection of raw materials.

 To make people to know about reputation of the company.

 To identify potential customers.

Maintenance and Repair Department:

Human resources and Finance:

3.2 Roles and responsibilities of an individuals in the department:

The following steps are followed for inspections:

 The goods supplied will be subject to inspection by quality control department.

 Product identification, handling, packing, storage and protection.

Quality Control department:

 Incoming material inspection.

Maintenance and Repair Department:

Human Resources and Finance:

The functions of personnel and administration departments are as follows

 To maintain on personnel functions of the organization.

Working hours for the employees are 08:15am to 04:15pm

4.1 Task Assigned:

Transformer works on the principle of Faraday’s Laws of Electromagnetic Induction. Mutual

 Induction Laws: Faraday’s law of electromagnetic induction states that ‘‘the

Functions and Duty of a Transformer:

Construction and Working Principle of Transformer:

The Three Main Constructional Parts of Transformer are:

Primary Winding of Transformer- Primary winding of a transformer produces magnetic flux

Working Principle of Transformer:

4.2 Technical tasks performed:

The internship work involved manufacturing and testing of distribution transformers.

Manufacturing process of Transformers:

Flowchart of manufacturing process:

LV Winding HV Winding Core Assembly

LV Winding HV Winding carried out over

For 25kVA 4star transformer:

 The width & thickness of LV conductor without insulation is 9.8mm×4.2mm.

Procedure for 25kVA 4star LV Winding:

Procedure for 25kVA 4star HV Winding:

Core Type Transformer Cruciform Section

Drying process/Heat test:

Testing of transformer consist of two types. They are,

4.2.1 Acceptance test:

4.2.2 Sub Tests:

4.2.2.a Coil ratio test:

Coil ratio test meter

The procedure of coil ratio test is as follows.

4.2.2.b Resistance test:

Resistance test meter

4.2.2.c Vector group test:

4.2.3 Routine tests:

4.2.3.a HV and LV test: