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    Manufacturing Process - KVA Process Transformers

    Uploaded by

    Raghavendra M R
    The document describes the process for manufacturing transformers. It involves 8 key steps: 1) design, 2) winding creation, 3) core building, 4) assembly of core and windings, 5) tank construction, 6) implementation of a cooling system, 7) use of insulating oil, and 8) testing before distribution. The design confirms to various standards and considers factors like losses and temperature rise. Windings use copper conductors and insulation to reduce hotspots. Cores use silicon steel laminations and are clamped precisely. Tanks provide protection and withstand pressure. Different cooling systems are used depending on transformer capacity and installation conditions.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    Manufacturing Process - KVA Process Transformers

    Uploaded by

    Raghavendra M R
    24 views12 pages
    The document describes the process for manufacturing transformers. It involves 8 key steps: 1) design, 2) winding creation, 3) core building, 4) assembly of core and windings, 5) tank construction, 6) implementation of a cooling system, 7) use of insulating oil, and 8) testing before distribution. The design confirms to various standards and considers factors like losses and temperature rise. Windings use copper conductors and insulation to reduce hotspots. Cores use silicon steel laminations and are clamped precisely. Tanks provide protection and withstand pressure. Different cooling systems are used depending on transformer capacity and installation conditions.

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    Manufacturing Process _ KVA Process Transformers

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    The document describes the process for manufacturing transformers. It involves 8 key steps: 1) design, 2) winding creation, 3) core building, 4) assembly of core and windings, 5) tank construction, 6) implementation of a cooling system, 7) use of insulating oil, and 8) testing before distribution. The design confirms to various standards and considers factors like losses and temperature rise. Windings use copper conductors and insulation to reduce hotspots. Cores use silicon steel laminations and are clamped precisely. Tanks provide protection and withstand pressure. Different cooling systems are used depending on transformer capacity and installation conditions.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    24 views12 pages

    Manufacturing Process - KVA Process Transformers

    Uploaded by

    Raghavendra M R
    The document describes the process for manufacturing transformers. It involves 8 key steps: 1) design, 2) winding creation, 3) core building, 4) assembly of core and windings, 5) tank construction, 6) implementation of a cooling system, 7) use of insulating oil, and 8) testing before distribution. The design confirms to various standards and considers factors like losses and temperature rise. Windings use copper conductors and insulation to reduce hotspots. Cores use silicon steel laminations and are clamped precisely. Tanks provide protection and withstand pressure. Different cooling systems are used depending on transformer capacity and installation conditions.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 12

       

    TRANSFORMER
    MANUFACTURING
    PROCESS
    1. TRANSFORMERS
    TECHNOLOGY & DESIGN

    Our experience of transformer designing spanning more than a


    decade is our strength to satisfy customer requirement. Our team of
    well qualified expert engineers & technocrats has developed
    optimized designs, which are most reliable and affordable for recent
    market scenario. Our design activity confirms to the various
    standard like BIS/IEC/BS/ANSI, NEMA. All the drawings are CAD for
    quick review while getting approval and thereafter, the final
    drawings can be submitted on a CD along with a print copy as
    required. All aspects of transformer design (Electrical & Mechanical)
    comprising Losses, % Impedance, Guaranteed Temperature Rise,
    Pressure & Vacuum withstand capability etc. are taken care of in our
    design development. Further our fault detection, Analysis and their
    solutions are gracefully welcomed by many reputed customers with
    their entire satisfaction.
    2. WINDINGS

    Transformer windings are designed to meet three fundamental


    requirements, viz. mechanical, thermal and electrical. They are
    cylindrical in shape and are assembled concentrically. Paper
    insulated conductors of high conductivity and soft drawn
    Electrolytic grade copper is used which comply with the latest
    Indian as well as international standards. Windings are made with
    great care by well experienced skilled Disc Winding workers in dust
    free & temperature controlled environment.

    Insulation between layers and turns is based upon the electrical and
    mechanical strength level. Inter layer cooling ducts (Axial & Radial)
    are provided to minimize the temperature gradient between
    windings and oil, and hence the hot spot temperature is kept to a
    minimum. This also ensures that the rate of insulation deterioration
    is minimized and high life expectancy is achieved. Transpositions
    are made in multiple conductor windings, to ensure uniform current
    distributions, minimize circulating currents, decrease eddy current
    loss and improve the lamination factor.

    Multiple conductor layer wound coils are most suitable for low
    voltage windings of large power transformers to mitigate high
    current designs requirement. For High voltage windings the disc
    coils with excellent mechanical strength are used to take the
    stresses due to voltage level. Special interleaved or shielded
    construction offers most uniform voltage distribution despite
    system transient. Specialized disc winding and inter-leaved disc
    windings are used having very high series capacitance giving a very
    good impulse voltage performance. For better short circuit
    withstand ability under fault conditions, would coils are pressed,
    clamped and dried in oven prior to impregnation in oil. Cooling
    ducts formed with rigid, high density spacers and horizontal and
    vertical ducts are provided to save hot spots.
    3. CORE BUILDING

    The most significant material in a transformer is the core. KVA


    PROCESS uses high quality Cold Rolled Grain Oriented Magnetic
    Silicon Steel to ensure optimum losses and most efficient working
    of the Transformer. The type of magnetic steel is chosen according
    to the desired loss level. The laminations are cut geometrically to
    ensure optimum flow of magnetic flux and minimum air gap
    between the joint of two consecutive sheets. The supporting
    structures and clamping devices of the core contribute to the
    compactness of the design and also ensure low sound levels.

    The core is designed with safe flux density to minimize core loss and
    magnetizing current. But-lap, miter or step-lap-miter construction is
    chosen based on the application and core-loss requirements.
    Laminations are burr free fully annealed with low Loss and very thin
    between 0.23 mm and 0.30 mm, varying no more than + 0.05 mm in
    length for lowest sound level and excitation currents. Each
    lamination is covered with a high-resistance, inorganic coating to
    reduce eddy currents.

    The Laminations are handled with utmost care to preserve


    magnetic properties. The core is clamped in a rigid frame with
    uniform pressure to reduce mechanical effect on performance. Core
    is built with Cold Rolled Grain Oriental, low loss silicon steel
    lamination. Bonded core design / technique is used to eliminate
    hole punching and to minimize fixed losses and Magnetizing
    current. Use of Hib grade & Laser scribed Laminations and Rigid
    clamps significantly reduce vibrations and noise level. Cooling ducts
    are provided in large transformers for efficient circulation of oil to
    keep temperature of core well within limit without affecting the flux
    distortion and also in the core suitable insulation paper are inserted
    between some laminations for the purpose of reducing eddy
    currents and also minimizing magnetic short circuit.
    4. CORE AND ASSEMBLY

    KVA PROCESS uses high electrical grade Precompressed Pressboard


    & kraft paper, as per IS : 1576. The insulating papers are routinely
    checked for high dielectric strength. Permali wood is also used in
    top and bottom for mechanical strength

    L.V. Windings are normally placed near core over insulating cylinder
    and oil ducts. HV windings are assembled co-axially with respected
    to L.V. Spacers between coils are 'T' shaped for added firmness.
    Coils are assembled with best insulating materials and are
    adequately clamped. The winding is rigidly supported by a common
    spacer ring of densified wood at the top and bottom for precise
    alignment. Well profiled angled rings are placed between LV & HV
    windings to reduce voltage stress level. The ends & tapping leads of
    all windings are connected by special extra flexible, insulated
    copper cables which are rigidly braced in position.

    Coil design and quality are keys to transformer efficiency and


    longevity. KVA Process design coils specially for each application.
    We use thermally upgraded paper for longest insulation life.

    5. TANK CONSTRUCTION

    All our tanks are fabricated with high grade tested mild steel. The
    design of the tanks incorporated adequate wall and base thickness
    so as to withstand the pressure build up in the tank.

    Protection of active part in transformer is very important. While


    achieving the optimized size of transformer to suit the site condition
    for installation. The main role of the tank is to protect the active part
    and tank is manufacture to have sufficient strengths to withstand
    internal & external faults that may occur during operation. Tanks are
    fabricated from low carbon M.S. Sheet of best quality proceeds by
    qualified welders. The tank is designed to withstand vacuum and
    pressure test as per Indian/International standards. A robust skid
    under base is provided, and guide bars are located inside the tank to
    securely fix the core and windings assembly in position, and to
    prevent any movement during transportation.

    Each transformer tank is tested for leakage by filling them with oil
    and keeping then under pressure of 0.5 KG / Cm2 or above for
    several hours. With this test even minute leaks are detected.
    6. COOLING SYSTEM

    The transformer while in service gets heated and Electrical Losses


    like Load Loss & No Load Loss which must be dissipated to avoid the
    exceeding the Temperature Rise limit specified by Customers. To
    achieve Temperature Rise well within limit, a suitable cooling
    method is be adopted. Generally, the cooling method suitable for
    the transformer is determined by the customer after due
    consideration of transformer capacity and the circumstances at the
    installation site. KVA PROCESS can design and manufacture
    transformer with various types of cooling systems according to the
    customer's requirement.

    1. ONAN: For ONAN Cooling Pressed sheet steel radiators are


    used for cooling ensuring that greater surface area is available
    for high dissipation. The radiators are independently pressure
    tested and then mounted on the tank.
    2. ONAF: For ONAF Cooling, Fans are mounted vertically near the
    radiators for their optimum use For OFWF Cooling, Heat
    Exchangers, oil pumps, oil flow meter, water flow meter,
    pressure meters, differential pressure gauge is used to suit the
    losses of transformers at 150% loading condition.
    3. OFAF
    4. AN

    7. OIL

    The insulating oil used is low viscosity with good resistance to


    oxidation and formation of sludge and acids. Moisture content,
    dielectric strength etc is determined and certified by conduct
    relevant tested as per IS : 335/1993. Generally we use “TRANSOL”
    brand, 'SAVITA' make EHV grade oil.

    8. TESTING

    Our testing lab is fully equipped with digital and computerised


    testing meters and accessories to conduct all routine tests as per ISS
    & IEC upto 25 MVA and upto 132 KV Voltage grade. The list of routine
    test are as follows :

    1. Measurement of winding resistance.


    2. Measurement of voltage ratio and check of voltage vector
    relationship.
    3. Measurement of impedance voltage (principal tappings) and
    Load Loss.
    4. Measurement of No load loss and current.
    5. Measurement of insulation resistance.
    6. Dielectric Test and
    7. Test on On Load Tap Changers, where appropriate.
    Transformer Test Control Pan

    EXPLORE

    KVA Process Transformers Pvt.  About us


    Ltd. Is a leading transformers  Site Map
    manufacturing company in India.
    We are an established  Contact us
    manufacturer of power &  Blog
    distribution transformers of
    various types, grades and
    capacities.

        

    CONTACT

     246/1k, Banaras Road, J. D.


    Casting Compound Kona
    Check Post, Howrah-711
    114, West Bengal, India

    [email protected]

     +91 98318 23173 /


    98302 52113

    KVA Process Transformers Pvt. Ltd. © Copyrights 2022 | Designed By:


    Indraprastha Design Co.

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