KAVIKA

MEASURES FOR IMPROVEMENT OF QUALITY OF TRANSFORMERS

1. Quality of Transformers mainly depends on-

a) Design features
b] Raw-materials
c] Production process
i) Trained Manpower (Skilled)
ii) Machineries

a) Features in the Design –

a] Conductor Insulation
b] Inter turn insulation
c] Major insulation (i.e., distance between Core & Coil, Coil to Coil
& Coil to Tanks]
d] Suitable current density and flux density of the chosen
conductor and core material respectively.
e] Proper sizes of leads for LV & HV conductors (suitable to the
capacity of the transformers]
f] Proper sheet thickness for tank both body and lid.
g] Provision of proper cooling surface
h] Equalizing the heights of HV & LV windings
i] Proper fixing arrangement of Core Coil assembly to arrest the
Unnecessary movement while transit.

b) Raw-materials-

Major raw materials are –

a] Conductors

Conductors are of suitable dimension to carry current for the

capacity of the transformer (i.e., current density is within the
limits for the chosen material Aluminium & Copper]

It should be properly insulated i.e., without any break and proper

thickness and the quality of insulation paper should meeting the
specific electric strength (BDV] and should have sufficient
mechanical strength to withstand the tension during
manufacturing of conductors as well as the winding process.

b] CRGO Silicon Steel

Core Material– The CRGO Silicon Steel needs a good handling

while it is processed from the coil to the cut lamination ready for
assembly. The Improper handing will induce stresses which will
 in turn add to the no load losses. One of the processes to bring
back the original properties is to anneal the material as per the
procedure laid down. We should also confirm before taking up
full process that the material would give the required losses by
proper test method. It is very difficult to reduce the no load
losses. In the normal working flux densities of 1.6 T, 1.25 to 1.35
kg of M4 grade material is required to reduce 1 W of no load loss
in a normal transformer.

b] Transformer Oil
Transformer Oil is very important material as it provides
insulation to high voltages by completely surrounding the
transformer windings and act as insulation between tank and
windings and core and windings and all earth parts & electrically
conducting material. Hence its BDV is one of the main
properties. Next property is resistivity, which is also very
important as the voltages are very high. Tan δ (dielectric
constant) it is a property connected with Capacitance created by
oil between the earth and electrical parts. Hence these
properties are to be maintained while accepting the transformer
oil.

c] Electrical Insulating Kraft Paper

It has many important properties, like, 1) electric strength, 2)
Moisture content, 3) Air Permeability, 4) Tensile strength, 5)
Tearing strength.
All these properties are very important and to be maintained as
per the requirements of Indian Standards.

d] Press Board
Press Board has also many important properties like 1) electric
strength 2) Moisture content 3) Tensile Strength 4) Oil
absorption 5) Flexibility 6) Conductivity of organic extract.
All these properties are very important and which will add to the
performance of the transformer

c) Production Process-

1) Trained manpower –
There are many important processes in the manufacture of
transformers like Brazing, Welding, Winding, Core Assembly,
Connections (delta and star) etc,

All these processes requires well trained skilled manpower so

that the output quality is ensured to withstand the severity of
the tests, as well as the special conditions that are faced in the
life cycle of the transformers like that short circuit forces,
lightening impulse voltages, switching surges etc.,
2) Machineries – The Transformers manufacturing require –

i) Machinery for Testing (testing equipment]

ii] Machineries for Manufacturing
iii] Machineries for conditioning

Machineries for testing –

The raw materials used in the transformers are to be tested by

using tensile testing machinery. Break down voltage, Tan δ
tester, resistivity equipment etc,

Final testing is carried out using self-excited DC Generator

coupled alternator with induction motor as prime mover, is used
to get three-phase sine wave electrical source. This is required
as no load loss measurement is very sensitive and it depends on
the quality of the sine wave power source.

High voltage test equipment

Every transformer is to be tested with the prescribed high voltage value as

per the requirement of Indian standards. Every transformer undergoes this
test to make sure that proper major insulation is provided.

Machineries for manufacturing are –

1 Winding Machineries – LV
2 Winding Machineries – HV
3 Insulation Cutters
4 Drilling machinery etc.

All these machineries are to be in proper working condition

along with the skill of the manpower to give the desired
properties and performance to the transformer for which it is
designed.

Machineries for conditioning –

Vacuum Impregnating Chamber

With the help of vacuum impregnating chamber the full moisture in the
transformer is removed and IR value is maintained which in turn will
increase the life of the transformer.

Conclusion

By managing manpower, materials, machineries and processes

properly KAVIKA is able to produce quality transformers over the
years.