DISTRIBUTION TRANSFORMER MANUFACTURING AND REPAIRING UNIT

A transformer is a device that transfers electrical energy from one circuit to another through inductively coupled conductors—the transformer’s coils. A varying current in the first or primary winding creates a varying magnetic flux in the transformer’s core and thus a varying magnetic field through the secondary winding. This varying magnetic field induces a varying electromotive force (EMF), or “voltage”, in the secondary winding. This effect is called inductive.

If a load is connected to the secondary, current will flow in the secondary winding, and electrical energy will be transferred from the primary circuit through the transformer to the load. In an ideal transformer, the induced voltage in the secondary winding (Vs) is in proportion to the primary voltage (Vp) and is given by the ratio of the number of turns in the secondary (Ns) to the number of turns in the primary (Np) as follows:

By appropriate selection of the ratio of turns, a transformer thus enables an alternating current (AC) voltage to be “stepped up” by making Ns greater than Np, or “stepped down” by making Ns less than Np. The windings are coils wound around a ferromagnetic core, air-core transformers being a notable exception.

Transformers range in size from a thumbnail-sized coupling transformer hidden inside a stage microphone to huge units weighing hundreds of tons used to interconnect portions of power grids. All operate on the same basic principles, although the range of designs is wide. While new technologies have eliminated the need for transformers in some electronic circuits, transformers are still found in nearly all electronic devices designed for household (“mains”) voltage. Transformers are essential for high-voltage electric power transmission, which makes long-distance transmission economically practical.

A transformer is a device for transferring energy in a system from one circuit to another. It consists of two independent electric circuits linked with a common magnetic circuit. This energy at low voltage may be transformed to energy at high voltage, or vice versa. In the like manner, current of a given value in one circuit may be transformed into current of another value in a different circuit. the winding of the  transformer connected to the supply circuit is termed as primary winding and these  windings of  the transformer that are connected to the receiver  circuits  are called secondary windings. Transformers having more than one primary or secondary winding etc.

INTRODUCTION
PRINCIPLE OF TRANSFORMER
DISTRIBUTION TRANSFORMER
IMPORTANT FEATURES
PROPERTIES OF DISTRIBUTION TRANSFORMER:
TYPES OF DISTRIBUTION TRANSFORMERS:
TRANSFORMER CONSTRUCTION
CORE
WINDINGS
USES AND APPLICATION
OF DISTRIBUTION TRANSFORMER
B.I.S. SPECIFICATION
PROCESS FLOW CHART
MANUFACTURING PROCESS
OF DISTRIBUTION TRANSFORMER
HIGH VOLTAGE COIL
LOW VOLTAGE COIL
1. INSULATION RESISTANCE TEST
2. DC RESISTANCE OR WINDING RESISTANCE TEST
KELVIN BRIDGE
DC WINDING RESISTANCE TEST (CURRENT-VOLT METHOD)
REQUIRED PRECAUTION
3. TURNS RATIO / VOLTAGE RATIO TEST
METHOD NO 1 TURNS RATIO TESTING
BRIDGE CIRCUIT
METHOD NO 2 VOLTAGE RATIO TESTING
TEST INSTRUMENT    60
SHORT CIRCUIT TEST (WITHOUT USING CT, PT)
SHORT CIRCUIT TEST (WITH CT)
6. OPEN CIRCUIT / NO LOAD TEST
7. CONTINUITY TEST
8. MAGNETIC CURRENT TEST
9. MAGNETIC BALANCE TEST
10. HIGH VOLTAGE TESTS ON HV & LV WINDING
11. DIELECTRICAL TEST
METHOD NO 1 (SEPARATE SOURCE VOLTAGE WITHSTAND TEST)
DIELECTRIC TEST (SEPERATE VOLTAGE SOURCE WITHSTAND TEST)
12. TEMPERATURE RISE TEST OF TRANSFORMER
MARKET SURVEY
PRODUCT INSIGHTS
REGIONAL INSIGHTS
COMPETITIVE INSIGHTS
GLOBAL ELECTRICITY TRANSFORMERS MARKET TO REACH
US$53.6 BILLION, 9.7 MILLION UNITS BY 2017
TRANSFORMER INDUSTRY IN INDIA FACES CRGO BOTTLENECKS
INDIA IS KNOWN TO BE AN ACTIVE SUPPLIER OF TRANSFORMERS TO NATIONS WORLDWIDE. WHAT HAS LED TO ITS GROWTH IN EXPORT IN
THE RECENT YEARS?
WHAT SHIFTING MARKET TRENDS AND OPPORTUNITIES ARE YOU WITNESSING IN THE INDIAN TRANSFORMER MARKET?
IS RURAL ELECTRIFICATION A DEMAND DRIVER FOR TRANSFORMERS
IN INDIA?
CHINA HAS ALREADY ENTERED THE INDIAN POWER TRANSFORMER
MARKET, HOW DO YOU RATE COMPETITION FROM CHINA?
ACCORDING TO YOU, HOW CAN GOVERNMENT BOOST GROWTH
OF THE INDIAN POWER TRANSFORMER INDUSTRY?
THE MOST IMPORTANT RECOMMENDATIONS FROM MY SIDE TO
THE GOVT. WOULD BE:
WHAT IS YOUR OUTLOOK ON THE INDIAN TRANSFORMER MARKET
AND WHAT DO YOU RATE AS THE KEY CHALLENGES?
THE INDIAN TRANSFORMER INDUSTRY IS FACING SOME KEY
CHALLENGES, WHICH RESTRICT IT FROM GROWING OF ITS FULL
POTENTIAL AND TARGETS. SOME OF THESE CHALLENGES INCLUDE:
OPPORTUNITIES
POWER TRANSFORMERS MARKET TO RIDE ON INCREASING GLOBAL
ENERGY DEMAND TO REACH US$28.69 BILLION BY 2019
GLOBAL POWER AND DISTRIBUTION TRANSFORMERS MARKET
FORECAST AND OPPORTUNITIES, 2019
INDIA POWER AND DISTRIBUTION TRANSFORMERS MARKET TO
GROW AT OVER 10%, CONCLUDES TECHSCI RESEARCH STUDY
ABOUT TECHSCI RESEARCH
GLOBAL POWER TRANSFORMERS MARKET GROWING
POWER AND DISTRIBUTION TRANSFORMER MARKET IN INDIA 2014
AND 2020
EXPORT DATA OF DISTRIBUTION TRANSFORMER
IMPORT DATA OF DISTRIBUTION TRANSFORMER
PLANT LAYOUT
MANUFACTURERS/SUPPLIERS    113
OF DISTRIBUTION TRANSFORMER
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF HOT ROLLED SHEETS
M.S CHANNELS AND ANGLES
M.S. FLAT
M.S. PLATE
M.S. PIPE
SUPPLIERS OF CARGO LAMINATION
SUPPLIERS OF DPC COPPER WIDING WIRE
SUPPLIERS OF TRANSFORMER OIL
SUPPLIERS OF CRAFT PAPER
SUPPLIERS OF M.S BOLTS AND NUTS
SUPPLIERS OF TRANSFORMER BUSHINGS
SUPPLIERS OF PAINT
SUPPLIERS OF PLANT AND MACHINERIES
TRANSFORMER COIL WINDING MACHINE
SUPPLIERS OF OIL FILTER MACHINE
SUPPLIERS OF VACCUME IMPREGNATION PLANT
SUPPLIERS OF ELECTRICAL MEASURING INSTRUMENT
SUPPLIERS OF TRANSFORMER OIL TESTING KIT
SUPPLIERS OF BENCH GRINDER
SUPPLIERS OF DRILLING MACHINE
SHEARING MACHINE
WELDING MACHINE
AIR COMPRESSORS
MATERIAL HANDLING EQUIPMENTS
SUPPLIERS OF PAINTING EQUIPMENTS
FIRE FIGHTING EQUIPMENTS
SUPPLIERS OF EOT CRANE
AIR POLLUTION CONTROL EQUIPMENTS
PLATEFARM WEIGHING MACHINE
SHOT BLASTING MACHINE

APPENDIX – A:

1.      COST OF PLANT ECONOMICS
2.      LAND & BUILDING
3.      PLANT AND MACHINERY
4.      FIXED CAPITAL INVESTMENT
5.      RAW MATERIAL
6.      SALARY AND WAGES
7.      UTILITIES AND OVERHEADS
8.      TOTAL WORKING CAPITAL
9.      COST OF PRODUCTION
10.      PROFITABILITY ANALYSIS
11.      BREAK EVEN POINT
12.      RESOURCES OF FINANCE
13.      INTEREST CHART
14.      DEPRECIATION CHART
15.      CASH FLOW STATEMENT
16.      PROJECTED BALANCE SHEET