Manufacturing and Testing of Distribution Transformer

Internship Presentation over
“MANUFACTURING AND TESTING OF DISTRIBUTION

TRANSFORMER”
Under – Hussain Shek, Deputy Manager at KAVIKA
Venue- KAVIKA, Post Box No 2610, Mysore Road, Bangalore - 560
026
BACHELOR OF ELECTRICAL AND ELECTRONIC ENGINEERING
Presented by Under the

guidance of
Snehashish Debnath Yaswanth
Kumar B
COMPANY OVERVIEW
• The KARNATAKA VIDYUTH KARKHANE
LIMITED, a fully owned Government of Karnataka
undertaking, is the successor to the Government Electric
Factory, the first ever manufacturer of electrical
transformers in the country, established way back in the
year 1933 by the erstwhile Maharaja of Mysore.
• KAVIKA has emerged as a renowned name for

distribution transformers in the range of 25 KVA to 500
KVA up to 11 KV Class as well as for custom built or
special type transformers as per specific requirements.
Sri. Gaurav Gupta, IAS
Principal Secretary to the Government
Dept. of Commerce and Industries
Government of Karnataka
Chairman
Sri. G. Ashok Kumar

Karnataka Vidyuth karkhane Limited
Managing Director
Smt. N R
Smt.R.Rangapriya,
Smt.C.Shikha, IAS Shri.M.Sudareshba Smt.R.Snehal, IAS Dr.Sri.H.N.Gopalkr Jaganmatha
IAS Smt.H.A.Shobha
Managing bu, IAS Managing ishna, IAS Special Secretary
Managing Deputy Secretary
Director Managing Director Managing to Government
Director to Government
Bangalore Director Mangalore Director Dept. of
Gulbarga Finance
Electricity Supply Hubli Electricity Electricity Supply Chamundeshwari Commerce &
Electricity Supply Department (FR &
Company Limited Supply Company Company Limited Electriciy Supply Industries
Company Limited, BCC) Director
Director Limited Director Director Company Director Goverment of
Director
Karnataka Director
MAJOR CUSTOMERS OF KAVIKA

KAVIKA

Human Resource and Production Maintenance Marketing
Purchase Department Design Department Quality Department Store Department
Finance Department Department Department Department
STAGES OF
MANUFACTURING
LOW VOLTAGE WINDING
• First step is manufacturing of LV winding.
• The material used for LV winding is aluminium provided with paper insulation.
• The thickness and number of turns in the LV winding depends upon the ratings of the
transformers.
Wrapping Paper/Press Board
• EPOXY DIAMOND DOTTED INSULATION
PAPER: -
• This is a creped board of up to 2mm thickness.
• Epoxy Diamond Dotted Kraft Paper is highly
insulating Class A material.
• It can withstand 105 C, it can normally
withstand 8kV and it can go up to 32kV.
• PRESS BOARD: -
• Press board is extracted from long-fibered
coniferous trees.
• These are formed into non- woven material
without using any additional binding agents and
then press.
HIGH VOLTAGE WINDING
The oil duct is followed by HV winding. The turns of HV winding is done with layers with insulating layer between each
layer. The material used for HV winding is copper.
CORE FORMATION
1. This silicon sheet steels cut into particular sizes and
shapes are stocked together to form the core.
2. Reduce eddy current losses.
3. Various types of stampings and lamination are employed
in the construction of the transformer
1. L-shaped laminations or U-shaped
2. I-shaped laminations .
Cold-Rolled Grain-Oriented steel
1. Grain oriented steel usually has a silicon level of 3%. The magnetic
flux density is increased by 30% in the coil rolling direction, although
its magnetic saturation is increased by 5%
Optimum design of cross section of transformer core
• The ideal shape of the of cross section of the transformer

core is circular.
• Making perfect circular cross section absolutely
uneconomical for practical manufacturing.
• In general manufacturer use different groups or packets of
predefined number of same dimension lamination sheets this
gives an optimum circular shape of cross section from
central core
• In addition to that clam plates made of steel are needed on
either side of the core for clamping the lamination.
• The sheet steel is lamination blocks, oil ducts and clamping
plates all should lie within the peripheral of optimum core
circle.
CORE COIL ASSEMBLY
• The active part of the transformer consists of the
magnetic core with windings and accessories.
• Winding are placed over the core limbs and necessary
connections are made as per the tapings and vector
group.
• The core is tightly packed by cloth.
• Packing pieces: -
• It is used in the gaps to fix the coils firmly. When
fault occurs, it withstands stresses.
• Tap changing switch:-
• Off load switch: Tap changing switches are

connected with high voltage side of the transformer,
used only in transformer off condition.
• On load switch: - On load tap changer switch can

be used with on load transformer.
TRANSFORMER THREE PHASE
CONNECTION
• Windings of a three phase transformer can be connected in various
configurations as
• star-star,
• delta-delta,
• star-delta,
• delta-star,
Heating of Transformers and Megger test
• A vacuum drying system consists of a vacuum chamber, a
mechanical vacuum pump with gauge and valve as well as a
source for providing heat to the transformer to be dried.
• The process followed during drying is: -
• Units are placed in the chamber for about 16 hours.
• The temperature inside the chamber is maintained at about
120 deg Celsius to 150 deg Celsius.
• Insulation resistance of low voltage to ground must be
1000MΩ.
• Megger test:-
• After heat treatment, the core coil assembly is brought out
from the vacuum chamber and is subjected to the megger
test.
• The insulation resistance of the transformer is checked and if
the value is found to be less than 1000ohm it is again placed
inside the vacuum chamber for heat treatment.
FITTING OF ASSEMBLED CORE INTO TRANSFORMER TANK
Conservator
Lowering
• Paraffin based • Insulated device Tank • This air contains
transformer oil. • More number of moisture and the
• Naphthalene based • Cranes are used for the petticoats, more the • Ambient temperature moisture is observed by
transformer oil. lifting purpose voltage withstanding rises, the volume of oil the silica gel crystals and
capacities. increases. the allowed to enter the
• Acts as a reservoir for conservator tank.
transformer insulating oil
Fitting of
Oil Filling Breather
bushing

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Internship Presentation over

“MANUFACTURING AND TESTING OF DISTRIBUTION

BACHELOR OF ELECTRICAL AND ELECTRONIC ENGINEERING

Presented by Under the

• KAVIKA has emerged as a renowned name for

Sri. G. Ashok Kumar

Cold-Rolled Grain-Oriented steel

• The ideal shape of the of cross section of the transformer

• Tap changing switch:-

• Off load switch: Tap changing switches are

• On load switch: - On load tap changer switch can

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