Introduction

This is our fifth visit in a manufacturing plant. This is a transformer manufacturing

plant where four type of distribution transformer is manufacture. The rating of the
transformer is 25KVA, 63KVA, 100KVA and 25KVA. All transformers supply to the KPTCL in
Karnataka state only. In this plant all the transformer is manufactured in a U shape building.

About the KAVIKA

The title of this article is actually an acronym of three kannada words namely
Karnataka Vidyuth Kharkhane which means a factory of government of Karnataka. This
naming of the factory was after the erstwhile state of Mysore was renamed as Karnataka.
Earlier the factory was known as GEF or government electric factory. It is one of the oldest
factories in India started by the then doyen Diwan of Mysore state Sir M.Vishweswaraiah
in the year 1933; fifteen years earlier to independence of the country.

In the beginning a good lot of other electrical items were manufactured. But later re-
assigned to manufacture of distribution transformers only. The transformer capacities
earlier also varied vary widely. But now the transformers manufactured are 25, 63,100 and
250KVA only. The raw materials required like insulated wires and flats, core materials and
stampings etc were all manufactured here only. But now they are all outsourced i.e.,
purchased from outside agencies. Certain materials like CRGO laminations were directly
imported from foreign countries. But now a day they are also purchased from competent
private suppliers.

Different shops: There are different shops in the U shape building for the
manufacturing of transformer:

 Winding shop
 Carpentering
 Core formation area
 Core coil assemble area
 Connection
 Vacuum chamber
 Lowering
 Testing
 Dispatch

KAVIKA visit Page 1

Winding Shop
The whole factory is in a U-shaped building. The various stages of manufacturing,
assembling, testing, readying for dispatch etc commence from one end of the U and ends in
another end. But winding shop or area is the first area in starting of the visit of KAVIKA in a
U shape building. The windings are made out of aluminum wires and flats of different
gauges.

The wires/flats are as below.

Sl.No Transformer L.V H.V

Capacity
1 25KVA 8.75x2.15mm flat 1mm dia wire
2 63KVA Two numbers of 7.5 x3.5mm flats 1.414mm dia
wire
3 100KVA 10.9mmx4mm flats (two runs) 1.71mm dia
wire
4 250KVA 3 radial numbers of 10.4x4.5mm flat 3mm dia wire
and 3 radial numbers of 12x4mm flat

All these wires and flats with DPC (double paper covered) of class D insulations were
earlier manufactured in the factory. But now they are purchased from outside sources. As
per I.S. the HV/LV should be provided with 28/3KV insulations respectively.

As you enter the U- shaped works zone one can find coil winding machines with
counters for allowing the exact number of turns. To the left LV winding machines and to the
right side HV winding machines. The windings are provided with oil circulating ducts at this
stage itself The number of turns provided are as below for a transformation ratio of 44 with
a tolerance of +-0.5%.

Number of turns:

Sl.No Transformer Capacity L.V H.V

1 25KVA 166 7304
2 63KVA 94 3136
3 100KVA 80 3520
4 250KVA 47 2120

The ratio of 44+- 0.5% is ascertained by conducting a ratio test immediately after assembly
of active part, but before ovening or drying. If there is any discrepancy in the ratio, the
active part is sent back to the winding assembly section for necessary correction.

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Core formation Area/Shop

In this area the core of the transformer is made, different size of care is use for the
different rating of the transformer. The thickness of the core is 0.35mm to 0.5mm as per the
50Hz frequency. The entire transformers are shell type and three phase transformer. the
core of the transformer is cut in different sizes and placed in a place. All the windings of the
transformers, which come from the winding shops after the completing the LV and HV
windings, put into the core center area. In the 100KVA or 250KVA transformer have the
tapping in the hive voltage side.

Core coil assemble area

In the core coil assemble area, the winding of the transformer put in to the core of
the transformer. both LV/HV winding put into a single core, as transformer is a three phase
transformer, so all three LV/HV winding put into the three core of the transformer. all the
winding tight in to the core so that they not move. If any winding of the transformer is loss
they create the noise inside the transformer. so by using some insulating material all the
three winding of the transformer is fixed into the transformer core.

After the completing of the core coil assembly, the ratio of 44+- 0.5% is ascertaining
by conducting a ratio test immediately, but before ovening or drying. If there is any
discrepancy in the ratio, the active part is sent back to the winding assembly section for
necessary correction. After collecting the right value of the transformer they ready to drying
process. If the value of the transformer is out of range, they goes to one more time into the
winding shop for rewinding the coil.

Connection
After conducting the ratio test of the coil of the transformer, place on a connection
area. In the connection area all the transformer winding connected into star-delta (YΔ)
format. HV winding of the transformer connected to Delta (Δ) and LV winding connected to
star (Y). In case of 250KVA or 100KVA transformer tapping of the HV winding side also
connected with a moving contact. So that by using the moving contact we can change the
tapping of the transformer. all the connection of the transformer in the high voltage winding
side doing by the heating the aluminum material and make joint. After completing the
connection of the transformer put into a vacuum chamber.

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Vacuum chamber
The windings of the transformers put into a vacuum chamber of removing the
moisture in insulating material. There vacuum chamber is big and in one time 50 to 70
transformer active part put inside of the vacuum chamber as per the size of the active part
of the transformer. the active part of the transformer put into the chamber for 24Hr. after
removing the transformer active part inside the vacuum chamber put into a hot oil so that
no moisture come into the insulating material of the transformer. Hot oil is use because, if
we use a cold oil they may be the possibility to have any moisture in the oil, so hot is put
into the tank.

The transformer tank already colored as par the rating of the transformer. 25KVA
transformer in a blue color, 63KVA transformer in a Silver gray and 100KVA transformer in
Green color. And for 250KVA transformer tank no color is used. These color system only use
in Karnataka state, all other state not follow this color coding.

Before testing of the transformer all the fitting of the transformer is assembled.
Bushing, breather, conservator..etc.

Testing
After putting the active part into a transformer tank, testing of the transformer is
start. First we cool the transformer because in the hot oil condition rating of the megger is
not correct. So first cool the transformer for 4 to 6 hr as per the weather condition.

First test start with meggering of the winding of the transformer. in the meggering
process, first LV side of the transformer connect to the megger and other wire of the
megger connect to the ground and start rotating of the megger and note the reading of the
meggere, it must be in 1000 MΩ, and then save process for the HV winding. And last we
connect the LV winding and HV winding of the active part to the megger and notice the
reading.

Now by using the two watt meter method conduct all other test of the transformer,
like a short circuit test, open circuit test…etc. after the test transformer is ready to dispatch.

Dispatch
Before dispatch the transformer rating of the transformer is put on a paper and
attach with the transformer. And all the transformers put into storage for dispatching.

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