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    Manufacturing and Testing of Distribution Transformer

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    Saurabh Kumar
    1) The document summarizes an internship presentation on the manufacturing and testing of distribution transformers at KAVIKA in Bangalore. 2) It describes the various stages of manufacturing including winding, core assembly, vacuum drying and megger testing. 3) Key stages include low voltage and high voltage winding using aluminum and copper, lamination of silicon steel sheets to form the core, and vacuum drying the core coil assembly at high temperatures to improve insulation resistance.

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    Manufacturing and Testing of Distribution Transformer

    Uploaded by

    Saurabh Kumar
    509 views17 pages
    1) The document summarizes an internship presentation on the manufacturing and testing of distribution transformers at KAVIKA in Bangalore. 2) It describes the various stages of manufacturing including winding, core assembly, vacuum drying and megger testing. 3) Key stages include low voltage and high voltage winding using aluminum and copper, lamination of silicon steel sheets to form the core, and vacuum drying the core coil assembly at high temperatures to improve insulation resistance.

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    kavika internship ppt

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    Snehashish internship

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    1) The document summarizes an internship presentation on the manufacturing and testing of distribution transformers at KAVIKA in Bangalore. 2) It describes the various stages of manufacturing including winding, core assembly, vacuum drying and megger testing. 3) Key stages include low voltage and high voltage winding using aluminum and copper, lamination of silicon steel sheets to form the core, and vacuum drying the core coil assembly at high temperatures to improve insulation resistance.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    509 views17 pages

    Manufacturing and Testing of Distribution Transformer

    Uploaded by

    Saurabh Kumar
    1) The document summarizes an internship presentation on the manufacturing and testing of distribution transformers at KAVIKA in Bangalore. 2) It describes the various stages of manufacturing including winding, core assembly, vacuum drying and megger testing. 3) Key stages include low voltage and high voltage winding using aluminum and copper, lamination of silicon steel sheets to form the core, and vacuum drying the core coil assembly at high temperatures to improve insulation resistance.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    of 17

    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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