New Intern Report

Manufacturing and testing of distribution transformer
EXECUTIVE SUMMARY
This is internship report is based on one month internship program that I had successfully completed
in KAVIKA from 11-02-2023 to 11-03-2023 as per the requirement of my Bachelor of Engineering
Degree in Department of Electrical and Electronic engineering, at Bangalore Institute of technology.
Distribution transformer places a very important role in an Electrical network as it step-down the low
transmission voltage to distribution voltage or distribution voltage to service voltage for consumer
applications. The company supplies mainly distribution transformer with capacities 25kVA, 63kVA,
100kVA, 250kVA and 500kVA.
This internship covers the study on manufacturing and testing of distribution transformers, the material
used for particular rated transformer kVA. It also explains the tests that the transformer undergoes to
determine the various parameters which interns decides its efficiency and lifestyle.
Initially the designer decides the transformer as per the customer's specification. After which in the
manufacturing unit the raw materials required for manufacturing is imported and the materials are tested
to match Indian standards (IS) before commencing the process. The tested materials are stored in the
storage room. Whenever there is a requirement, the raw materials are procured from the storage mass
and involved in manufacturing of HV and LV winding, core formation, core coil assembly and finally
it is connected to form an active element. This active element is then placed in special chamber called
vacuum chamber. Where the moisture content of the active part is removed. The element is then dried
and bushings were connected . Finally, the active part is low-ward into the tank consisting of calculated
amount of transformer oil and fastened using fasteners.
Dept. of EEE, BIT, 2023 1

CHAPTER 1
ABOUT THE COMPANY
1.1. INTRODUCTION
KAVIKA (Karnataka Vidyuth Karkhane Limited) was established in 1933 by Maharaja of Mysore as
Government Electrical Factory, the first ever manufacturer of Electrical transformers in India. The
company supplies mainly distribution transformer with capacities 25kVA, 63kVA, 100kVA, 250kVA
and 500kVA.
KAVIKA is one of the largest selling transformers in India as the product goes through strict quality
checks at every stage to ensure best comes out of the factory to reach the customers through the country.
The secret behind the popularity of KAVIKA transformers is the strict adherence quality norms, at
every stage of manufacturing. Starting from the imported prime quality CRGO coil 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.
Today, after 9 decades of successful production and operations, KAVIKA has emerged as a renowned
name for Distribution Transformers in the range of 25 kVA to 500 kVA up to 11 kV/433V Class as well
as for custom built / special type transformers as per specific requirements.

1.2. KAVIKA has following features:
❖ 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.
❖ 3 Types of tests are done in CRPI for prototype , Bangalore.
❖ Largest manufacturer of distribution transformers in the country.
❖ Latest technology in design, manufacturer and testing
❖ India's oldest transformer manufacturer.
Vision
KAVIKA committed to supply energy efficient transformers as per the agreed specifications in time at
most competitive rate with enhanced customer satisfaction and to put efforts continually to improve the
quality of the products supplied and QMS.
Mission
To become a globally competitive transformer production industry while working as an instrument for
achieving self-reliance in design, manufacture and maintaining the quality of the equipment and
diversifying to related areas, managing the business and commercial lines in a scenario of growing
professional competent.
Products
Energy Efficient 3, 4 & 5 star category transformers Fully as per IS Specifications. All materials used in
the manufacture are as per IS specifications. All the materials are tested to meet the IS requirements.
Sufficient cooling is provided to dissipate the guaranteed losses and to maintain the guaranteed
temperature rises – which gives longer life to Transformer.

Company Profile
1.3.MAJOR MILESTONES
❖ The company was established in 1933 as a Government Electric Factoryfor manufacturing of electrical
accessories.
❖ In 1976, the company was incorporated as KAVIKA.

❖ It was converted into a Government PSU in 1976 with ₨600 lakhs asAuthorized share capital and
paid up capital of ₨562 lakhs.
❖ All the shares are with Government of Karnataka

❖ In 1976, company manufacturing only conventional transformers
❖ The company has obtained Approval/Certification from Bureau of Energy Efficiency (BEE) for
manufacture of star rated transformers.
❖ The company is shifting its focus from producing the conventional trans-formers to the star rated
category of transformers of different capacities.
❖ After 1995 onwards, KAVIKA started using Auto Cad for designing thetransformers.

SERVICES
The various services which KAVIKA is currently offering are as follows:
REPAIR SERVICES:
WITHIN WARRANTEE PERIOD: The warrantee period for a distribution transformer is usually 3
years. If there is any problem withinthe warrantee period, then the company provides repair services
to thecustomers.
MORE THAN WARRANTEE PERIOD: If any problem occurs in the transformer after the warrantee
period, the company provides repair services to consumer with changes.
ENGINEERING SERVICES:
Utilities processing any problems at the time of installation or in operationcondition of the transformers
will be solved by the services engineers.
CLIENTS
The major customer of the state Electricity Company in 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.

CHAPTER 2
ABOUT THE DEPARTMENT
2.1. Different departments in the company are

❖ Purchase Department
❖ Design Department
❖ Store Department
❖ Quality Control Department
❖ Production Department
❖ Testing Department
❖ Marketing Department
❖ Maintenance Department
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.
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.
Quality Control:
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.
The following steps are followed for inspection of raw materials:
❖ 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.
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.
Testing department:
After manufacturing, conduct different test to check the operational performance and withstanding
capacity of transformer. Test details are explained later.
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.
2.2. 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.
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 labor union.
❖ Extending promotions as per the settlement.
2.3. Working Hours
Working hours for the employees are 8: 15am to 4: 15pm. The employees are provided with uniforms
within two months of joining.

CHAPTER 3
TRANSFORMERS
3.1 INTRODUCTION
We have also acknowledged Electrical Engineering as an important domain of engineering and

technology. Indian Government’s efforts to improve the quality of Electrical Engineeringeducation in
India through internet based interactive online tools and its endeavors
to decrease the rising levels of greenhouse emissions for the betterment ofour environment has been
appreciated in this paper. We have analyzed a plethora of Electrical Computer Aided Design (ECAD)
simulation tools, available for the welfare of electrical engineering academia, as well as industry based
electrical engineering applications. Electrical Engineers are destined to play a decisive role in the socio-
economic future of India and the world, as they have been doing this since the 19th century. Keeping this
fact in mind, we have decided to refer to the present employment opportunities available in India
covering the private sector as well as the public one. The role of renewable energy in the creation of
numerous sustainable jobs for the already huge and exponentially growing youth population of India has
a mention in this paper. In conclusion we have formulated some recommendations to educational
institutes and Indian Government which will help Electrical Engineering academia- industry flourish in
the near future.
DEFINITION: A transformer is a passive component that transferselectrical energy from one electrical
circuit to another circuit.

3.2. HISTORY OF A TRANSFORMER

First hand made transformer :-
In Hungary Ottó Bláthy had suggested the use of closed-
cores, Károly Zipernowskythe use of shunt connections,
and Miksa Déri had performed the experiments. They
found the major flaw of the Gaulard-Gibbs system were
successful in making a high voltagecircuit work using
transformers in parallel. There design was a toroidal
shape which made it expensive to make. Wires could
not be easily wrapped around it by machine during the
manufacturing process.
The development of the transformer was as follows:
1830s - Joseph Henry and Michael Faraday work with electromagnets and discover the property of
induction independently on separate continents.
1836 - Rev. Nicholas Callan of Maynooth College, Ireland invents theinduction coil.
1876 - Pavel Yablochkov uses induction coils in his lighting system. 1878 -1883 - The Ganz Company
(Budapest, Hungary) uses inductioncoils in their lighting systems with AC incandescent systems. This
is thefirst appearance and use of the toroidal shaped transformer.
1881 - Charles F. Brush of the Brush Electric Company in Cleveland, Ohio develops his own design of
transformer (source: Brush Transformers).
1880-1882 - Sebastian Ziani de Ferranti (English born with an Italian parent) designs one of the
earliest AC power systems with WilliamThomson (Lord Kelvin). He creates an early transformer.
Gaulard and Gibbs later design a similar transformer and loose the patent suit in English court to
Ferranti.

3.3. IMPORTANCE OF TRANSFORMERS
When a transformer steps up the voltage level of a circuit, it decreases thecurrent because the power
remains constant. Therefore, ac power can be generated at one central station. The voltage is stepped up
for transmissionover long distances at very low losses. The voltage is stepped down againfor final use.
Since the transmission losses are proportional to the square of the current, raising the voltage by a factor
of 10 will reduce the transmission losses by a factor of 100. Also, when the voltage is increasedby a factor
of 10, the current is decreased by a factor of 10. This allowsthe use of much thinner conductors to
transmit power.
In modern power stations, power is generated at 12 to 25 kV. Transformers step up the voltage to 110 to
1000 kV for transmission overlong distances at very low losses. Transformers then step it down to 12 to
34.5 kV for local distribution and then permit power to be used in homesand industry at 120 V.
3.4. PRINCIPLES INVOLVED IN WORKING OF A TRANSFORMER

FARADAY’S FIRST LAW OF ELECTROMAGNETICINDUCTION:
Whenever a conductor is placed in a varying magnetic field an EMF gets induced across the conductor
(called as induced emf), and if the conductor is a closed circuit then induced current flows throughit.
FARADAY’S SECOND LAW OF ELECTROMAGNETIC INDUC-TION:
The magnitude of induced emf is proportional to the rate of change of fluxlinkages with the coil.
LENZ’S LAW: When an emf is induced according to Faraday's law, the polarity (direction) of that

induced emf is such that it opposes the cause of its production.

PRINCIPLE OF MUTUAL INDUCTION: When two or more coils
are magnetically linked to each other, then an alternating current flowingthrough one coil causes an
induced emf across the other linked coils. Thisphenomenon is called as mutual induction.
3.5. CONSTRUCTION OF A TRANSFORMER
Basically, a transformer consists of two inductive windings and a laminated steel core. The coils are
insulated from each other as well as from the steel core. A transformer may also consist of a container
for winding and core assembly (called as tank), suitable bushings to take theterminals, oil conservator
to provide oil in the transformer tank for cooling purposes etc .In all types of transformers, core is
constructed by assembling (stacking) laminated sheets of steel, with minimum air-gap between them (to
achieve continuous magnetic path). The steel used is having high silicon content and sometimes heat
treated. The sheets are cutin the shape as E, I and L.

3.6WORKING OF A TRANSFORMER
The transformer works on the principle of Faraday’s law of electromagneticinduction and mutual
induction.
There are usually two coils primary coil and secondary coil on the transformer core.The core
laminations are joined in the form of strips. The two coils have high mutual inductance. When an
alternating current pass through the primary coil it creates a varying magnetic flux. As per
faraday’s law of electromagnetic induction, this change in magneticflux induces an emf
(electromotive force) in the secondary coil which is linked to the core having a primary coil.
This is mutual induction.
Overall, a transformer carries the below operations:
1. Transfer of electrical energy from circuit to another

2. Transfer of electrical power through electromagnetic induction
3. Electric power transfer without any change in frequency
4. Two circuits are linked with mutual induction
The figure shows the formation of varying magnetic flux lines around a wire-wound. The interesting
part is thatreverse is also true, when a magnetic flux line fluctuates around a piece of wire, a current
will be induced in it.
This was what Michael faraday found in1831 which is the fundamental workingprinciple of electric
generators as well as transformers.

3.7 LOSSES IN A TRANSFORMER
3.7.1 COPPER LOSSES:

Current flowing through the windings causes resistive heating of the conductors. At higher frequencies,
skin effect and proximity effect createadditional winding resistance and losses.
Total copper losses. =
3.7.2 CORE LOSSES:

There are two types of core and iron losses in a Transformer.
3.7.2.1Hysteresis Losses
Each time the magnetic field is reversed, a small amount of energy is lost due to hysteresis within the
core. For a given core material, the transformer losses are proportional to the frequency, and is a function
of the peak flux density to which it is subjected.

3.7.2.2 Eddy Current Losses

Ferromagnetic materials are also good
conductors, and a core made from such a
material also constitutes a single short-
circuited turn throughout its entire length.
Eddy currents therefore circulate within the
core in a plane normal to the flux and are
responsible for resistive heating of the core
material.
3.8 Stray losses (leakage Flux)

Leakage inductance is by itself largely lossless, since energy supplied to its magnetic fields is returned
to the supply with the next half cycle. However, any leakage flux that intercepts nearby conductive
materials such as the transformer’s support structure will give rise to eddy currentsand be converted to
heat. There are also radiative losses due to the oscillating magnetic field, but these are usually small and
negligible.
Dielectric Loss :-
In the solid insulation or transformer oil i.e. insulation material of the transformer, dielectric loss occurs
when the solid insulation gets damagedor the oil gets deteriorated or its quality decreases over the time.
Hence, the overall efficiency of transformer may be affected due to this loss.
3.9 Other Losses

3.9.1 Magnetostriction Losses
Magnetic flux in a ferromagnetic material, such
as the core, causes it to physically expand and contract
slightly with each cycle of the magnetic field, an effect
known as magnetostriction. This produces the buzzing sound
commonly associated with transformers and can
cause losses due to frictional heating.

3.9.2 Mechanical losses

In addition to magnetostriction, the alternating magnetic field causes fluctuating forces between the
primary and secondary windings. These initiate vibrations within nearby metal work, adding to the
buzzing noise, and consuming a small amount of power.
3.10 REDUCTION OF LOSSES

1. COPPER LOSSES: To reduce copper losses the resistance of the wire must be reduced. The
resistance can be reduced by increasing the cross sectional area of the wire and reducing the length
of the wire. i.e.
2. CORE LOSSES: There are two types of core losses:
• HYSTERISIS LOSS: In view of minimizing hysteresis losses soft magnetic materials for ex: Si
steel, steel alloys, Mn-Zn ferrite are used because they have high saturation magnetization, Low
coercivity, High magnetic permeability etc. which reduce losses due to hysteresis.
• EDDY CURRENT LOSSES: In view of reducing eddy current losses, the magnetic core of the
transformer is not made from a single magnetic material; because in this case the circulating eddy
currentflowing will be higher. Instead the magnetic core is a stack of thin siliconsteel lamination and
the laminations are insulated from one another by thin layer of varnish to reduce eddy current and
hence eddy current losses.
3. STRAY LOSSES: These types of losses can be reduced by use of smalldimensioned conductors for
windings, use of CTC conductors in case of higher current windings, optimum transposition of the
parallel strands, magnetic shielding of the inner tank walls, use of non-magnetic shield inarea of strong
magnetic fields.

3.11 TYPES OF TRANSFORMERS
On basis of construction the transformers can be classified into
• Core type transformer: In core type transformer, windings are

cylindrical former wound, mounted on the core limbs.
• Shell type transformer: A shell type transformer may have simple

rectangular form, or it may havea distributed form.
On basis of their requirement
• Step up transformer: Voltage increases,

while there is a decrease in current at
secondary.
• Step down transformer: Voltage decreases,

while there is a increase in current at
secondary. On basis oftype of supply
• Single phase transformer

• Three phase transformers On basis of their use.
• Power transformer: Used in sub-station, transmission network, highrating.
• Distribution transformer: Used in distribution network, comparativelylower rating than that of

power transformers.

• Instrument transformer: Used in relay and protection purpose indifferent instruments in industries
1. Current transformer (CT)
A current transformer is a device used to produce an alternating current in its secondary, which is
proportional to the AC current in its primary. This is primarilyused when a current or voltage is too
high to measure directly.
2. Potential transformer (PT)
On basis of cooling employed

• Oil-filled self-cooled type
• Oil-filled water-cooled type
• Air blast type (air cooled)

CHAPTER 4
MANUFACTURING OF DISTRIBUTIONTRANSFORMER AND
SPECIFICATION OF DISTRIBUTIONTRANSFORMERS
11kV/433– 250V and 33 kV / 433-250V
4.1INTRODUCTION
Manufacturing is the process of translation of raw materials into finishedproducts to perform a specified
function or purpose. Processing describesthe act of taking something through an established and usually
routine setof procedures and at certain times converts from one form to another in aseries of sequence
of operations 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. Major stages of manufacturing a transformer are:
• Gathering of raw materials

• Production of LV windings
• Production of HV windings
• Core Assembly
• Core-Coil Assembly
• LV and HV connections
• Drying
• Oil filling
• Lowering
• Testing
• Name plate fixing
• Dispatch
SCOPE:
i)This specification covers design, engineering, manufacture, assembly, stage testing, inspection and
testing before supply and delivery at site of oil immersed, naturally cooled 3-phase 11 kV/433 - 250 V
and 33 kV/433-250 V distribution transformers for outdoor use.
ii)The equipment shall conform in all respects to high standards of engineering, design and
workmanship and shall be capable of performing in continuous commercial operation, in a manner
acceptable to the purchaser, who will interpret the meanings of drawings and specification and shall
have the power to reject any work or material which, in his judgment is not in accordance therewith. The
offered equipment shall be complete with all components necessary for their effective andtrouble free
operation. Such components shall be deemed to be within the scope of bidder’s supply irrespective of

whetherthose are specifically brought out in this specification and / orthe commercial order or not.
iii) The transformer and accessories shall be designed to facilitateoperation, inspection, maintenance
and repairs. The design shall incorporate every precaution and provision for the safetyof equipment
as well as staff engaged in operation and maintenance of equipment.
iv) All outdoor apparatus, including bushing insulators with theirmountings, shall be designed so
as to avoid any accumulationof water.
STANDARD RATINGS:
The standard ratings shall be 16, 25, 63, 100,160, 200, 250, 315, 400, 500,
630, 1000, 1250, 1600, 2000 and 2500 kVA for 11 kV distribution
transformers and 100, 160, 200, 315, 400, 500, 630, 1000, 1250,
1600,2000, 2500 kVA for 33 kV distribution transformers
STANDARDS:
The major materials used in the transformer shall conform in all respectsto the relevant/specified Indian
Standards and international Standards with latest amendments thereof as on bid opening date, unless
otherwise specified herein. Some of the applicable Indian Standards are listed.
Indian Title International

Standards Standards
IS -2026 Specification for Power Transformers IEC 76
IS 1180 (Part- Outdoor Type Oil Immersed Distribution Transformers
I): 2014
upto and including 2500kVA, 33kV-Specification
IS 12444 Specification for Copper wire rod ASTM B-49

IS-335 Specification for Transformer/Mineral Oil IEC Pub 296
IS-5 Specification for colors for ready mixedpaints
IS -104 Ready mixed paint, brushing zincchromate,

priming
IS-2099 Specification for high voltage porcelainbushing
IS-649 Testing for steel sheets and strips andmagnetic

circuits

IS- 3024 Cold rolled grain oriented electrical sheetsand strips
IS - 4257 Dimensions for clamping arrangements forbushings
IS - 7421 Specification for Low Voltage bushings

IS - 3347 Specification for Outdoor Bushings DIN 42531 to 33
IS - 5484 Specification for Al Wire rods ASTM B - 233
IS - 9335 Specification for Insulating Kraft Paper IEC 554
IS - 1576 Specification for Insulating Press Board IEC 641
IS - 6600 Guide for loading of oil Immersed IEC 76
Transformers
Determination of water content in oil forporcelain

IS - 2362
bushing of transformer
IS - 6162 Paper covered Aluminium conductor
IS - 6160 Rectangular Electrical conductor forelectrical
machines
IS - 5561 Electrical power connector
Testing of specific resistance of electricalinsulating

IS - 6103
liquids
Method of test for power factor and dielectricconstant of
IS - 6262
electrical insulating liquids
IS - 6792 Determination of electrical strength ofinsulating
oil
IS - 10028 Installation and maintenance of transformers.

4.2. FLOWCHART OF MANUFACTURING

4.3. COMPONENT STANDARDS

Explanation of component with there specific standards to be used are as follows:
4.3.1.CONDUCTORS:
As per the Indian standards IS 6162 part1;IS 6162 part2 - 1972 Distribution
transformer with HV winding made of copper conductors is less susceptible to metal fatigue
than aluminium. Coper is harder, strongerand more ductile than aluminium, expands less and
does not flow at terminals. Copper displays low levels of creep. Under the conditions of
extreme loading and temperature conditions of distribution transformer windings, creep rates
of aluminium can be up to 25 times higher than copper. This results in aluminium wound
distribution transformers havinga higher propensity than copper.
4.3.2. EPOXY DIAMOND DOTTED INSULATIONPAPER:
As per the Indian standards (amended) IS 9335 part3 of section 1 - 1994
Diamond dotted paper (DDP) is also referred as epoxy adhesivediamond paper or varnished
paper.
The thickness and width of the papercan be
made according to the customer’s
specifications. Diamond dotted paper is made
of electrical grade kraft paper with Bstage
heat curable epoxy resin coating. DDP is
thermally upgrade kraft paper and used in
oilfilled transformer for layer insulation
between the coils.
4.3.3. PRESS BOARD:
As per the Indian standards IS 1576 - 1992Press board is

a special product based on the purest cellulose, extracted
from long-fibered coniferous trees. These are formed into
non- woven material without using any additional
binding agents and then press. The high chemical purity
means pressboard is an extremely suitable insulation

material for electrical machines, capacitors and particularly oil filled transformers. The material
properties allow classification in insulation class A (105C) and aremanufactured in accordance with
the IEC standard.
4.3.4. OIL DUCTS: oil ducts are used in between

LV and HV winding of the transformer for oil
circulation, insulation and cooling purpose.
4.3.5. CRGO LAMINATIONS:

CRGO lamination is used for the core of the power,
Distribution transformer. cold rolled grain-
orientedsteel is often abbreviated as CRGO.
CRGO is usually supplied by the producing
mills in coil form and have to be cut into
“laminations”, which are then used to form a
transformer core, which is an integral part of any
transformer.
4.3.6. TRANSFORMER TANK:

• Transformer tank construction shall conform in all respect
to clause 15 of IS 1180(Part- 1):2014.
• The internal clearance of tank shall be such, that it shall
facilitate easy lifting of core with coils from the tank
without dismantling LV bushings.
• All joints of tank and fittings shall be oil tight and no
bulging should occur during service.

• Inside of tank shall be painted with varnish/hotoil resistant

paint.
• The top cover of the tank shall be slightly sloping to drain
rain water.
• The tank plate and the lifting lugs shall be of such strength
that thecomplete transformer filled with oil may be lifted
by means of liftingshackle.
• Manufacturer should carry out all welding operations as
per the relevant ASME standards.
4.3.7. TRANSFORMER OIL:

Insulation oil is commonly known as transformer oil when it is used for a power transformer. It is
obtained by fractional distillation and subsequent treatment of crude petroleum.
That is the reason this oil is also known as mineral insulating oil. Transformer oil mainly serves the
purpose of insulation and dissipation ofheat and thus acts as a coolant. Generally, there are two types of
transformer oil used:
• Paraffin based transformer oil.

• Naphthalene based transformer oil.
4.3.8.CONSERVATOR TANK:
Transformers of rating 63 kVA and above with plain tank construction, the provision
of conservator is mandatory. For corrugated tank and sealed type transformers with or
without inert gas cushion, conservator is not required.
• When a conservator is provided, oil gauge and the plain or dehydrating

breathing device shall be fitted to the conservatorwhich shall also be provided
with a drain plug and a filling hole [32 mm
(1¼”)] normal size thread with cover. In addition,
the cover of the main tank shall be provided with
an air release plug.
• The capacity of a conservator tank shall be
designed keeping in view the total quantity of oil
and its contraction and expansion due to
temperature variations.
• The inside diameter of the pipe connecting the conservator to the main tank should be within 20 to
50mm and it should be projected into the conservator so that its end is approximately 20mm above

the bottom of the conservator so as to create a sump for collection of impurities. The minimum oil
level(corresponding to -5degree Celsius) should be above the sump level.
4.3.9. BREATHER:
The breather tank is fitted with a breather containing
silica gel through which air is expelled when
transformer is loaded with losses causing the oil
temperature to increaseand expand. During light loading
conditionsoil cools down and contract in volume so air
is inhaled from the atmosphere. This air
contains moisture and the moisture is observed by the
silica gel crystals and the allowed to enter the conservator
tank.

4.3.10 RADIATOR: When an electrical transformer is

loaded, the current starts flowing through its windings. Due
to this flowing of electric current, heat is produced in the
windings, this heat ultimately rises the temperature of
transformer oil. We know that the rating of any electrical
equipmentdepends upon its allowable temperaturerise limit.
Hence, if the temperature of the transformer rises insulating
oil is controlled, the capacity or rating of transformer can be
extended up to significant range.
The radiator of transformer accelerates the cooling rate of transformer. Thus, it plays a vital role in
increasing loading capacity of an electrical transformer. This is basic function of radiator of an
electrical powertransformer.
4.3.11. BUSHINGS:
In electrical power, a bushing is an insulated device that

allows an electrical conductor to safely through a ground
conducting barrier such that case of a transformer. To,
maintain creepingdistance petticoats are made. More number
of petticoats, more the voltage withstanding capacities.
Bushings are grazed like circular roof tops for the quick escape
of rain water.

4.4. MANUFACTURING PROCESS

HV AND LV WINDING: The winding allows 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 stress depending on the current and voltage requirements. Spiral,
cross-over, helical and continuous disc winding withmultiple copper conductors are usually adopted for
transformers. The coilis lowered on the core legs, to give extra strength to the winding and for axial
cooling air ducts are used between LV and HV windings. Thicknessof conductors for 25kVA 4-star
(star-1) transformer is
LV conductors(rectangular) :-
• 9.8 x 4.2 mm (without insulation)
• 10.13 x 4.53 mm( with insulation)
HV conductors(round/circular) :-
• 1.1 mm (without insulation)
• 1.32 mm ( with insulation)
WINDINGS:
HV and LV windings shall be wound from Super Enamel covered/Double Paper covered
Aluminium / Electrolytic Copper conductor.
➢ LV winding shall be such that neutral formation will be at top.
➢ The winding construction of single HV coil wound over LV coil ispreferable.

➢ Inter layer insulation shall be Nomex /Epoxy dotted Kraft Paper.
➢ Proper bonding of inter layer insulation with theconductor shall be ensured. Test for bonding strength
shall be conducted.
➢ Dimensions of winding coils are very critical. Dimensional tolerances for winding coils shall be within
limits as specifiedin Guaranteed Technical Particulars (GTP Schedule I).
➢ The core/coil assembly shall be securely held in position to avoidany movement under short circuit
conditions.
➢ Joints in the winding shall be avoided. However, if jointing is necessary the joints shall be properly
brazed and the resistance of the joints shall be less than that of parent conductor. In case of foilwindings,
welding of leads to foil can be done within the winding.

4.5. PRODUCTION OF 25kVA,4 star LV WINDING
• First we want to get the conductor material’s from store department then we want to start
the winding process.
• We want to design the machine aperture as per required winding size for specific KVA
mentioned by the design department
• In the first step, we need to wind the pressboard around the bobbin.
• Then we apply gum( PVA) around the pressboard.
• After that the cotton tape is struck at the edge of the pressboard
for insulation at both ends
• Then the end strip is provided at both the ends for mechanical
support and to hold the LVwinding.
• The rectangular shaped conductor made of aluminium of size
9.8 x 4.2 mm is wound.
• It is wound in such a way that there should be about 41.25 turns per layer.
• Then it is covered with Epoxy Diamond Dotted Kraft Paper of size 0.1mm thickness around
the first layer of the conductor.
• Then the procedure is repeated four times to get a total of 165 turns.
• After that the cotton tape is pulled and bound tightly to avoid looseningof the setup.
• Oil ducts are provided as a cooling agent
• At the end the press board is bound with the cotton tape tightly.
• The oil duct and pressboard separate the LV and HV windings fromeach other and it will
acts as insulation.

4.6. PROCEDURE FOR 25kVA,4 star HV WINDING
• As soon as the LV winding done it will brought into HV department
• Then the cotton tape is removed, and gum is applied on the pressboard.
• After this, the cotton tape is stick to both the edges of the pressboard.
• Then the end strips of dimension as per mentioned in the design is wound at both edges of the press
board which wound on the coil to avoid the slipping of the conductor.
• The round conductor made up of aluminium of size 1.1mm is wound.
• The conductor is wound in such a way that there are 290.4 turns in onelayer.
• Epoxy Diamond Dotted Kraft Paper of thickness 0.1 mm around thefirst layer of the conductor
• The above procedure is repeated 25 times so that there is a total of7260 (290.4*25) turns of
the conductor.
• After that cotton tape is pulled and bound tightly to avoid loosening ofthe winding.
• Then the last layer of Epoxy Diamond Doted Kraft Paper of thesetup.
• Epoxy Diamond Dotted Kraft Paper is highly insulating material, itcan withstand up to 8Kv
without oil and it can go up to 28kV with oil.

4.7. CORE ASSEMBLY

Core will be main part of the transformer, it will play a important role intransformer for its durable life.
The design of core will be like cruciform(different circular blocks), the specialty of cruciform core is it
reduces theleakage flux in the core.
KAVIKA uses CRGO (cold rolled grain oriented) laminations, which isof 0.23 mm thickness and flux
density of 1.7 Tesla.
The core shall be stack / wound type of high grade Cold Rolled Grain Oriented or Amorphous Core
annealed steel lamination having low loss and good grain properties, coated with hot oil proofinsulation,
bolted together and to the frames firmly to prevent vibration or noise. The core shall be stress relieved
by annealing under inert atmosphere if required. The complete design of core must ensure permanency
of the core loss with continuous working of the transformers. The value of the maximum flux density
allowed in the design and grade of lamination used shall be clearly stated in the offer. The transformers
core shall be suitable for over fluxing (due to combined effect of voltage and frequency) up to 12.5%
without injurious heating at full load conditions and shall notget saturated. The bidder shall furnish
necessary design data in support of this situation.
No-load current up to 200kVA shall not exceed 3% of full load current and will be measured by
energizing the transformer at ratedvoltage and frequency. Increase of 12.5% of rated voltage shall not
increase the no-load current by 6% of full load current.
or
No-load current above 200kVA and up to 2500kVA shall not exceed2% of full load current and will be
measured by energizing the transformer at rated voltage and frequency. Increase of 12.5% of rated
voltage shall not increase the no-load current by 5% of full loadcurrent.

4.7.1CORE-COIL ASSEMBLY
Transformer Core coil Assembly

The core assembly is vertically placed with the
foot plate touching the ground. the top yoke of the
core is removed. The limbs of the core are tightly
wrapped with cotton tape.
Cylinder made out of insulating press board
paper is wrapped on all the three limbs. Low
Voltage Coil is placed on the insulated core limbs
Insulating block of specified thickness and number
are placed both at thetop and bottom of the L.V.
Coil. Cylinder made out of corrugated paper or
plain cylinder with oil ducts are provided over L.V
Coil. H V Coils are placed over the cylinder.
Gap between each section of H.V.Coils including top & bottom clearances is maintained with the help
of oil ducts, as per the design/drawings. The Top Yoke is refilled. Top core frame including core bolts
and tie rodsare fixed in position. Primary and secondary windings are connected as per the requirements.
Phase barrier between H.V.phases are placed as per requirement. Connections to the tapping switch or
oltc (if required) are made.
4.7.2 HV AND LV CONNEC

The LV side is star connected and HV side 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 unbalancedloads since the delta partially redistributes any imbalances
that occur.
The LV and HV connections in the form of Dyn 11 , D indicatetype of connection of the HV winding. Y
indicates the type of connection of the LV winding, n indicates neutral and according to vector group
11 means 30 phase degree displacement between LV and HV.
The polarity of a winding refers to the direction of the induced emf e.g. inthe winding at a particular
instant, for a three-phase transformer; polarityalone is insufficient to represent the relation between LV
and HV winding. In addition to the terminal marking on HV and LV side voltage vector diagram are
required to show the angular displacement between HV and LV windings.
4.8. DRYING PROCESS
After connection, active part is kept inside the vacuum chamber to removemoisture contents,
keeping it there for about 8 to 10 hours with continuousheating by thermal oil at 120C to remove
water content.
Vacuum drying method.
This drying method is based on air as the heat
carrier, under atmospheric pressure, the
transformer body or winding is gradually pre
heated to about 105℃, and then vacuum treatment
is started. Due to slow heat transfer and uneven
internal and external heating(internal cooling and
external heating), transformers with high voltage and
large capacity often need more than 100h for
preheating due to thick insulation layer, long
production cycle and incomplete drying, so it is
difficult to meet the insulation requirements of
transformers. But the equipment is simple and
easy to operate.

4.9. OIL FILLING

➢ The insulating oil shall comply with the requirements of
IS 335. Use of recycled oil is not acceptable. The specific
resistance of the oil shall not be less than 35 X1012 ohm-
cm at 27oC when tested as per IS 6103.
➢ Oil shall be filtered and tested for break down voltage
(BDV) andmoisture content before filling.
➢ The oil shall be filled under vacuum.
➢ The design and all materials and processes used in the

manufactureof the transformer, shall be such as to
reduce to a minimum the risk of thedevelopment of
acidity in the oil.
➢ Filtered and degassed transformer insulating oil(Naphthalene oil ) is then filled in the tank.
This oil is circulated through out the tank and that will also acts as acoolant. It will filled upto
30 degree indicator as per the oil gauge indicator.
4.10.LOWERING
After drying, the connections are checked again and tightened before lowering onto the tank.
4.11.BUSHINGS:
The bushings shall conform to the relevant standards specified and shall be of outdoor type. The bushing
rods and nuts shall be made ofbrass material 12 mm diameter for both HT and LT bushings. The bushings
shall be fixed to the transformers on side with straight pockets and in the same plane or the top cover for
transformers above 100 kVA. For transformers of 100 kVA and below the bushing can be mounted on
pipes. The tests as per latest IS 2099 and IS 7421 shallbe conducted on the transformer bushings.
➢ For 33 kV, 52 kV class bushings shall be used for transformers ofratings 500 kVA and above. And
for transformers below 500 KVA,33 kV class bushings, for 11 kV, 17.5 kV class bushings and
for 0.433 kV, 1.1 kV class bushings shall be used.
➢ Bushing can be of porcelain/epoxy material. Polymer insulator bushings conforming with relevant
IEC can also be used.

➢ Bushings of plain shades as per IS 3347 shall be mounted on the side of the Tank and not on top
cover.
➢ Dimensions of the bushings of the voltage class shall conform to the Standards specified and
dimension of clamping arrangement shall be as per IS 4257
➢ Minimum external phase to phase and phase to earth clearances ofbushing terminals shall be as
follows:
Voltage Clearance
Phase to phase Phase to earth
33 kV 350mm 320mm
11 kV 255mm 140mm
LV 75mm 40mm
➢ Arcing horns shall be provided on HV bushings.
➢ Brazing of all inter connections, jumpers from winding to bushingshall have cross section larger
than the winding conductor. All the Brazes shall be qualified as per ASME, section – IX.
➢ The bushings shall be of reputed make supplied by those manufacturers who are having
manufacturing and testing facilities for insulators.
➢ The terminal arrangement shall not require a separate oil chambernot connected to oil in the main
tank.
4.12. FASTENERS
All fasteners of 12 mm diameter and less, exposed to atmosphere shall beof stainless steel and those
above 12 mm diameter shall preferably be of stainless steel or of mild steel hot dip galvanized. The
material of the stainless steel fasteners shall conform to IS: 1570 (Pt. V) Grade 04, Cr 17Ni 12 Mo 2.

4.13. PAINTING
All steel surfaces in contact with insulating oil shall be painted with heatresistant, oil insoluble insulating
varnish.
TESTING OF DISTRIBUTIONTRANSFORMER
It is important to test the transformer to make sure it can be used inpractical applications. The
tests performed are as follows:
1. ACCEPTANCE TEST
a. Tensile strength test
b. Breakdown voltage test of transformer oil
c. Resistance test for transformer oil
4.13.1TENSILE STRENGTH TEST
This test is performed only to confirm tensile strength of aluminium wires used for conductor,
pressboard and insulation papers. For conductor up to 3mm tensile strength is 100-110N/m2. This test
is significantly performed on conductor material to judge the strength of this material. A cable conductor
is often subjected to pull from one end during laying , insulating and manufacturing hence it should be
strong enough to tolerate the pulling force as well. Hence it becomes necessary to ensure that the
conductor material has sufficient tensile strength.
A specimen of conductor with length little bit longer than gauge length (gauge length is the length of
the specimen on which test is carried out) is first taken. To be careful that the minimum length of the
entire specimen shall be such that it should have extra length at two ends after its gauge length for
holding the same by grips of tensile testing machine. No preconditioning of the specimen is required for
tensile test.

4.13.2 BREAKDOWN VOLTAGE TEST
To access the insulating property of dielectric transformer oil , a sample of the transformer oil is taken
and its breakdown voltage is measured . the lower the resulting breakdown voltage, the poorer the
quality of the transformer oil.
• The transformer oil is filled in the vessel of the

testing device.
Two standard compliant test electrodes with a
typical clearance of 2.5mm are surrounded by the
dielectric oil.
• A test voltage is applied to the electrodes and is continuously increased up to the breakdown voltage
with a constant, standard complaints lenz rate of e.g. 2kv/s.
e.g. 2 kV/s.
• At a certain voltage level breakdown occurs in an electric arc, leading to a collapse of the test voltage.
• An instant after ignition of the arc, the test voltage is switched off automatically by the testing device.
Ultra-fast switch off is highly desirable, as the carbonization due to the electric arc must be limited to
keep the additional pollution as low as possible.
• The transformer oil testing device measures and reports the root mean square value of the breakdown
voltage.
• After the transformer oil test is completed, the insulation oil is stirred automatically, and the test
sequence is performed repeatedly:typically, 5 repetitions, depending on the standard.
• As a result, the breakdown voltage is calculated as mean value of the individual measurements.
• It can be concluded that higher the resulting breakdown voltage,more the quality of the
transformer oil.
4.13.3 RESISTANCE TEST OF TRANSFORMER OIL

Resistance test is conducted to check the resistivity of transformers oil. The resistance of transformer
oil is measured at room temperature and at90C by applying 500V DC supply. It can be concluded
that higher theresistance value more the quality of transformers oil.

4.14. TYPE TESTS

Sub tests are conducted before the routine tests of a transformer. They are as follows:
• Ratio test
• Winding test
• Vector group test
• Vacuum test
• Coil ratio test
• Resistance test
• Vector group test
• Magnetic balance test
4.14.1. COIL RATIO TEST

The performance of a transformer largely depends upon perfection ofspecific turns or voltage
ratio of transformer. So, transformer ratio test is an essential type test of transformer. The voltage
should be applied only in the high voltage winding in order to avoid unsafe voltage.
Ratio Test of Transformer and Check of PhaseDisplacement
Actually, the no load voltage ratio of transformer is equal to the turn ratio.So, ratio test of transformer.
Procedure of Transformer Ratio Test
1. First, the tap changer of transformer is kept in the lowest position and LV terminals are kept open.
2. Then apply 3-phase 415 V supply on HV terminals. Measure the voltages applied on each phase
(Phase-phase) on HV and induced voltages at LV terminals simultaneously.
3. After measuring the voltages at HV and LV terminals, the tap changerof transformer should be raised
by one position and repeat test.
4. Repeat the same for each of the tap position separately.

4.14.2. RESISTANCE TEST

Transformer winding resistance measurement is carried out as a type test,routine test and it also carried
out as a field test. In the factory, it helps indetermining the following:
1. Calculation of the I2R losses in transformer.
2. Calculation of winding temperature at the end of temperature rise testof transformer.
3. As a benchmark for assessing possible damages in the field.
4.14.3. VECTOR GROUP TEST

The vector group of transformers is an essential property for successful parallel operation of
transformers. Hence every electrical power transformer must undergo through vector group test of
transformer at factory site for ensuring the customer specified vector group of transformer. The phase
sequence or the order in which the phases reach their maximum positive voltages, must; be identical for
two paralleled transformers. Otherwise, during the cycle, each pair of phases will be short circuited.
4.14.4. MAGNETIC BALANCE TEST

Magnetic balance test of transformer is conducted only on three-phase transformers to check the
imbalance in the magnetic circuit.
Procedure of Magnetic Balance Test of Transformer:
1. First keep the tap changer of transformer in normal position.
2. Now disconnect the transformer neutral from ground.
3. Then apply single phase 230 V AC supply across one of the HVwinding terminals and
neutral terminal.
4. Measure the voltage in two other HV terminals in respect of neutralterminal.
5.Repeat the test for each of the three phases

4.15. SPEICAL TESTS TO BE CONDUCTED ON ONE UNIT:

➢ In addition to the tests mentioned in clause 30 and 31 following testsshall be conducted:
➢ Temperature rise test for determining the maximum temperature rise after continuous full load run. The
ambient temperature and timeof test should be stated in the test certificate.
➢ Impulse voltage test: with chopped wave of IS 2026 part-III. BILfor 11 kV shall be 75 kV peak.
➢ Short circuit withstand test: Thermal and dynamic ability.
➢ Air Pressure Test: As per IS – 1180 (Part-1):2014.
➢ Magnetic Balance Test.
➢ Un-balanced current test: The value of unbalanced current indicated by the ammeter shall not be more
than 2% of the full loadcurrent.
➢ Noise-level measurement.
➢ Measurement of zero-phase sequence impedance.
➢ Measurement of Harmonics of no-load current.
➢ Transformer tank shall be subjected to specified vacuum. The tankdesigned for vacuum shall be tested
at an internal pressure of 0.35 kg per sq cm absolute (250 mm of Hg) for one hour. The permanent
deflection of flat plates after the vacuum has been released shall notexceed the values specified below,
Horizontal length of flat plate (in mm) Permanent deflection (in mm)
Upto and including 750 5.0
751 to 1250 6.5
1251 to 1750 8.0
1751 to 2000 9.0

➢ Transformer tank together with its radiator and other fittings shall be subjected to pressure
corresponding to twice the normal pressureor 0.35 kg / sq.cm whichever is lower, measured at the base
of the tank and maintained for an hour. The permanent deflection of the flat plates after the excess
pressure has been released, shall not exceed the figures for vacuum test.
➢ Pressure relief device test: The pressure relief device shall be subject to increasing fluid pressure. It
shall operate before reaching the test pressure as specified in the above class. The operating
pressure shall be recorded. The device shall seal-off after the excesspressure has been released.
➢ Short Circuit Test and Impulse Voltage Withstand Tests: The purchaser intends to procure
transformers designed and successfullytested for short circuit and impulse test. In case the transformers
proposed for supply against the order are not exactly as per the tested design, the supplier shall be
required to carry out the short circuit test and impulse voltage withstand test at their own cost in the
presence of the representative of the purchaser.
➢ The supply shall be accepted only after such test is done successfully, as it confirms on successful
withstand of short circuit and healthiness of the active parts thereafter on un-tanking after a short
circuit test.
➢ Apart from dynamic ability test, the transformers shall also be required to withstand thermal ability test
or thermal withstand abilitywill have to be established by way of calculations.
➢ It may also be noted that the purchaser reserves the right to conduct short circuit test and impulse voltage
withstand test in accordance with the IS, afresh on each ordered rating at purchaser cost, even if the
transformers of the same rating and similar design are already tested. This test shall be carried out on
a transformer to be selected by the purchaser either at the manufacturer’s works when they are offered
in a lot for supply or randomly from the supplies already made to purchaser’s stores. The findings and
conclusions of these tests shall be binding on the supplier.
➢ Special test certificates for the tests carried out on prototype of same specifications shall be submitted
along with the bid. Thepurchaser may select the transformer for type tests randomly

4.16. Routine test

Every AT shall be subjected to the routine tests in accordance with relevant parts of IS:2026 in the
presence of the purchaser’s representative.impedance and load loss.
1. Visual examination
2. Verification of terminal marking and polarity
3. Measurement of voltage ratio on all tap positions
4. Measurement of winding resistance
5. Measurement of insulation resistance
6. Measurement of impedance voltage on principal tap, short circuit,impedance and load loss
7. Measurement of no load loss and current
8. Induced over voltage withstand test for primary winding.
9. Separated source power frequency withstands voltage test
4.16.1. Visual Examination

A general examination shall be made to check that the transformers conforms to the approved drawings,
various item are accessible for maintenance, the quality of workmanship and finish are of acceptable
standards and all parts, fittings and accessories are provided
4.16.2.Measurement of winding resistance
The resistance of the winding shall be measured and computed at 750 C.
4.16.3. Measurement of voltage ratio
Voltage ratio of primary and secondary winding shall be measured on all tap positions.
4.16.4. Verification of terminal markings and polarity

The making of the Terminal and the polarity shall be verified.
4.16.5. Insulation resistance

The insulation resistance of each of the windings with respect to earth andwith respect to each other
shall be measured by using 2.5 kV megger.
4.16.6. Measurements of impedance voltage, short circuitimpedance and load

losses
Load losses shall be measured with rated maximum current, achieved at lowest primary voltage of 19kV
at ambient temperature and computed at750 C. The percentage impedance voltage at principal tap shall
be measured with rated maximum current, achieved at lowest primary voltage of 19kV at ambient
temperature and computed at 750 C.
4.16.7. Measurement of No-load loss and current.

No load loss and current, referred to the primary winding shall be measured at maximum rated voltage
of 27.5 KV.
4.16.8. Induced over voltage withstand test.
The secondary winding shall be fed at a convenient voltage and frequency,so as to obtain 80 kV between
the primary terminals which shall be kept open circuited with one terminal earthed. Duration of the test
at full test voltage shall be 60 s for any test frequency upto and including twice the rated frequency.
When the test frequency exceeds twice the rated frequency, the duration of the test in second shall be:
120 x RatedFrequency
Test Frequency
But not less than 15 s.
4.16.9. Separate source power frequency withstand voltage test.

This test shall be done as per clause 10 of IS:2026 (Part III). A voltage of3000 V shall be applied between
line terminal of the secondary winding,the other terminal of the primary winding, the core, the frame
and the steel enclosure of the transformer, connected together and then to earth.
4.17. HV AND LV TEST
In HV test, LV is shorted, and supply is given to the HV. As per Indian standard for 11kVA transformer
28kV is applied to the HV of the transformer. In LV test, HV is shorted, and supply is given to the LV.
Asper Indian standard for 11kVA transformer 3kV is applied to the LV of the transformer. This test is
passed only if the transformer withstands thevoltage for one minute without any tripping of the circuit
breaker. The transformer withstands 28kV (for HV test) and 3kV (for LV supply) supply up to one
minute without any damage it indicates that the withstanding capacity and dielectric strength of the
transformer is more.

4.18 INDUCED OVER VOLTAGE TEST (OR) DVDF TEST

DVDF means Double Voltage Double Frequency test. Induced Over Voltage Test Set (DVDF) is
used for testing the strength of insulation between turns and between other points of the
transformers etc. as stipulated by BIS or other standard specification. For this test Double Voltage is
applied across L.T. terminals for one minute, and to limit the magnetizing current over frequency is
utilized.
It is a mechanically coupled unit having motor and Generator with powerand control panel to regulate
the output voltage. If the breakdown voltagedoes not occur at the highest voltage applied, then the test
is successful.
4.19. OPEN CIRCUIT TEST
A voltmeter, wattmeter, and anammeter are
connected in LV sideof 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 ammeterreading 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 thiscurrent that can be taken as negligible. Since voltmeter reading V1 can beconsidered equal to the
secondary induced voltage of the transformer, wattmeter reading indicates the input power during the
test. As thetransformer is open circuited, there is no output, hence the input power here consists of core
losses in transformer and copper loss in transformerduring 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.

4.20. SHORT CIRCUIT TEST

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 thehelp of variac applied voltage
is slowly increased until the wattmeter, and an ammeter gives reading equalto 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 appliedfor full load current in short circuit test on transformer is
quite small compared to the rated primary voltage of the transformer, the core lossesin transformer can
be taken as negligible here.
4.21. TERMINAL MARKINGS:
High voltage phase windings shall be marked both in the terminal boards inside the tank and on the
outside with capital letter 1U, 1V, 1W and low voltage winding for the same phase marked by
corresponding small letter 2u, 2v, 2w. The neutral point terminal shall be indicated by the letter 2n.
Neutral terminal is to be brought out and connected to local grounding terminal by an earthing strip.

4.22. RATING PLATE
Transformer shall be provided with a rating plate (both in Hindi and English) of weather proof material,
fitted in a visible position, showing theitems indicated below: -
1. Type of transformer.
2. Governing specification.
3. Manufacturer’s name.
4. Manufacturer’s serial number
5. Year of manufacture.
6. Rated output.
7. Rated frequency.
8. Highest voltage for equipment.
9. Rated Voltage.
a)Primary
b) Secondary
10. Rated current.
a)Primary
b)Secondary
11. Maximum temperature rise over an ambient of 500 c.
a) of oil
b) of winding.
12. Total weight
13. Class of insulation.
14. Insulation levels.
15. Connection diagram indicating the taps.
The letters/ figures on the plate shall be indelibly marked by etching,engraving or stamping.
4.23. DISPATCH
Before dispatch the oil level is checked, and the horn gap fuse, breather and name plate are fixed.
4.24. 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.

4.25. ENERGY CONSERVATION:

With the growing energy needs and shortage coupled with rising energy cost, a greater thrust in energy
efficiency in industrial sector has been given by the Govt. of India since 1980s. The Energy
Conservation Act 2001 has been enacted on 18th August, 2001, which provides for efficientuse of energy,
its conservation & capacity building of Bureau of Energy Efficiency created under the Act.
The following steps may help for conservation of electrical energy: -
i) Adoption of energy conserving technologies, production aids andtesting facilities.

ii) Efficient management of process/manufacturing machineries and systems, QC and testing equipments
for yielding maximum Energy Conservation.
iii) Optimum use of electrical energy for heating during soldering processcan be obtained by using efficient
temperature-controlled soldering and de-soldering stations.
iv) Periodical maintenance of motors, compressors etc.
v) Use of power factor correction capacitors. Proper selection and layout of lighting system; timely
switching on-off of the lights; use of compact fluorescent lamps wherever possible etc.
4.26. 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:
We started an internship about manufacturing and testing ofdistribution transformer

at Karnataka Vidyuth Karkhane from 13.7.2022 to 12.7.2022. In this duration for the above-mentioned
topic, we were guided under an Assistant Engineer who was a very knowledgeable person and also
having 20 years of experience in industry. He thought the topic from the basics till the final stages of
distribution of transformer.
During this internship we have the opportunity to interact with severalemployees which strengthen our
communication skills and also a taskwhich 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 functionthat contributes to the smooth
functioning of the organization
• Strategic planning of production that helps in achieves the monthlyand yearly targets with less
discrepancy.
• Chance to work on existing production process with revising anddeveloping 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 anorganization.
• Identifying any drawbacks in the present process and improvingupon 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 systemsand the procedures of management 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 orothers.
• Learnt about safety procedures to be followed in case ofemergency like first aid.
• Had a chance to witness S.C and O.C tests on larger kVAtransformers
5.3. Non – Technical outcomes :
• Learnt how to manage a store and track the usage of the materialsand how to economically use the
materials available.
• Learnt the working of commercial department, as to how do theyprocure the materials and how to they
choose the best vendor.
• Learnt the functioning of Admin and HR department and gatheredinformation about how do they train
the new employee.
• Handling the work alone did learn to be punctual and completingthe tasks on right time.
• After completion of internship overall confidence was boosted andcould successfully handle the work
and complete it on time.
• Internship exposure helped in improving verbal and writtencommunication 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 keylearning.
• The company's strict policy of adherence to quality standards.
• Sampling process done for inspection of the quality of the procuredmaterials whether they fall within
the prescribed limits of quality dimension or not. This is approved and checked by varies departments
like procurement, quality control and production to ensure the quality.
• The production plan is done monthly, based in the number of ordersand 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 go through the
worker's name who have worked onit 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 areseen. Work rotation is being done
efficiently.
• Material transport system used such as roller guide ways, langersand forklift to transfer in-process and
final assemblies quickly andsmoothly.
• Final quality check that is done for different parameters so that thetransformer passes in all aspects.
• Some machine tools that used are obsolete which require tedioussetup process and susceptible to many
problems.
• Use of mechanical countess severely limits the accuracy of thewinding process which results in much
rework.
• There is no accurate guide ways for the wire to be wound perfectlywithout any gaps in the winding.
• Much of tedious manual activities are done to control the processaccuracy.
• Majority of activities are manual which involves co-ordination ofworkers for working on one part of
the assembly which again required much time.
• Coil ratio test accurately tests whether the turns are within thespecified limit or not.
However, much rework is done during the stage.
• There is no specified scale for the length of wire terminals that areattached 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 mandatory of only distribution transformer, Product diversification makes it
to face the contingenciesof business market. They are:
• Facilitating the customer to buy and interacting through E- marketing can enhance the scale and also
helps to attract potentialcustomers.

• 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 amongthe employees which would help in
bringing closeness among themand also increased the productivity level of the company In this section
we explained about various technical and non-technical experienced gain in the company is discussed
in detail.
5.6. Summary:
CONCLUSION:
A study was done for every activity of the production process and itshould be mapped. The
unprocessed assemblies of coil were sent to rework because of inaccuracy of winding process. The
core assembly process was studied in detail and steps were suggested to make it moreaccurate and
efficient.
Finally, a study of failure mode and effect of analysis of transformerswas 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
manufacturingof distribution transformer was well made and efficiently use of staffs, workers and
assists in the key to its success: Integration with all the staffand workers gave an idea of how each and
all 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, labor 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. Detailedstudy 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.
Special Features of KAVIKA Transformers
• Vaccum chamber is used in the process of drying the active parts, which helps to maintain very high
insulation resistance (minimum of 1000M ohm at 900 C) is maintained.
• Good quality lamination of cruciform core from the heart of the transformer.
• Electrolytic conductor grade conductors of proper tensile strength are used. Because of the sufficient
cross section are used on the highvoltage side.
• Multipaper covered copper conductor leads of sufficient cross section are used in low voltage side.
• “S” type jumper of sufficient cross section is used in low voltage connection.
• Solid packing piece made of 100% wood pulp are for supporting thelow voltage and high voltage coils,
which offers sufficient electeicalbreakdown strength between the windings and the earth parts. Also,solid
packing supports the windings better under short circuit conditions.
• Proper arrangements for lifting is provided for job as well as tank for proper handling.
• In addition to the above all the raw materials are conforming to Indian standards.
• In all the stage process quality checks are made and in the final testing stage all the routine tests are
conducted as per BIS on each and every transformer before dispatch.
• Type tests are conducted in CPRI Bengaluru. From time to time (short circuit, high voltage and
temperature rise test)

Conclusion
Thus, the Distribution transformers play a vital role in converting the comparatively high voltage into
distribution voltage, say 11kv to 433v.Thus, demand for distribution transformers is more compared to
any other transformers. Therefore, manufacturing is a very crucial and happens in bulk. The life of the
transformer is the life of insulation. The life of transformer may be introduced as the change of its
condition ofcellulose insulation. Considering all these factors best quality and considerable amount of
insulation must be provided. If more insulationis provided, it then leads to less heat being dissipated
which is an alarming condition as transformer heats tremendously. Thus, to overcome all these adverse
effects transformers are tested after being manufactured. Transformers do not die but are killed due to
poor maintenance, operational accidents and over loading. Overloading is the main cause for all above
factors. Thus, a transformer to some extentcan be prevented from overloading by using a next higher
capacity transformer in place of actual desired capacity if not constraint.

Referances :
1. Literature titled company profile available at

URL:https:www.kavika.co.in – 17:52:45 – 12/8/2022
2. https://en.m.wikipedia.org/wiki/Transformer - 18:15:10
- 12/8/2022
3. https://byjus.com/jee/transformer/ - 10:30:13 – 14/8/2022
4. https://edisontechcenter.org/Transformers - 20:42:22 -14/8/2022
5. https://electrical-engineering-portal.com/routine-tests-dry- type-
transformer - 08:14:55 - 15/8/2022
6. https://vietnamtransformer.com/our-news/types-of-
transformer-testing - 13:59:08 - 15/8/2022
7. https://esennar.com/core-coil-assembly-for-transformer-in- india.php -
14:50:32 - 15/8/2022
8. https://electricalmag.com/transformer-construction-types- cores/ -
16:23:58 – 15/8/2022
9. https://www.electrical4u.com/transformer-insulating-oil-and- types-of-
transformer-oil/ - 18:22:39 – 15/8/2022


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Manufacturing and testing of distribution transformer

Dept. of EEE, BIT, 2023 1

ABOUT THE COMPANY

Dept. of EEE, BIT, 2023 2

1.2. KAVIKA has following features:

❖ Excellent infrastructure with trained engineers, technicians and skilled manpower.

Dept. of EEE, BIT, 2023 3

❖ In 1976, the company was incorporated as KAVIKA.

❖ All the shares are with Government of Karnataka

Dept. of EEE, BIT, 2023 4

Dept. of EEE, BIT, 2023 5

ABOUT THE DEPARTMENT

2.1. Different departments in the company are

Dept. of EEE, BIT, 2023 6

The following steps are followed for inspection of raw materials:

Dept. of EEE, BIT, 2023 7

Maintenance and Repair Department:

2.2. Human Resources and Finance:

Dept. of EEE, BIT, 2023 8

❖ Casual leave, privilege leave, sick leave etc.

❖ Extending benefits to employees as per memorandum of settlement entered between

❖ Extending promotions as per the settlement.

2.3. Working Hours

Dept. of EEE, BIT, 2023 9

We have also acknowledged Electrical Engineering as an important domain of engineering and

Dept. of EEE, BIT, 2023 10

3.2. HISTORY OF A TRANSFORMER

Dept. of EEE, BIT, 2023 11

3.3. IMPORTANCE OF TRANSFORMERS

3.4. PRINCIPLES INVOLVED IN WORKING OF A TRANSFORMER

Dept. of EEE, BIT, 2023 12

induced emf is such that it opposes the cause of its production.

3.5. CONSTRUCTION OF A TRANSFORMER

Dept. of EEE, BIT, 2023 13

1. Transfer of electrical energy from circuit to another

Dept. of EEE, BIT, 2023 14

3.7 LOSSES IN A TRANSFORMER

3.7.1 COPPER LOSSES:

3.7.2 CORE LOSSES:

Dept. of EEE, BIT, 2023 15

3.7.2.2 Eddy Current Losses

3.8 Stray losses (leakage Flux)

3.9 Other Losses

Dept. of EEE, BIT, 2023 16

3.9.2 Mechanical losses

3.10 REDUCTION OF LOSSES

Dept. of EEE, BIT, 2023 17

3.11 TYPES OF TRANSFORMERS

On basis of construction the transformers can be classified into

• Core type transformer: In core type transformer, windings are

• Shell type transformer: A shell type transformer may have simple

On basis of their requirement

• Step up transformer: Voltage increases,

• Step down transformer: Voltage decreases,

• Single phase transformer

Dept. of EEE, BIT, 2023 18

• Three phase transformers On basis of their use.

• Power transformer: Used in sub-station, transmission network, highrating.

• Distribution transformer: Used in distribution network, comparativelylower rating than that of

Dept. of EEE, BIT, 2023 19

1. Current transformer (CT)

2. Potential transformer (PT)

On basis of cooling employed