This document summarizes the manufacturing process and maintenance of power transformers. It describes the key components of a transformer like the core, windings, bushings, oil filling, and conservator. The manufacturing process involves preparing the raw materials, winding the coils, assembling the core and coils, connecting accessories, drying, oil filtration and filling. Regular maintenance is needed to monitor the transformer hourly, daily, weekly, monthly, yearly and every 2-5 years to ensure proper functioning. Transformers are important equipment that allow transmitted power to be stepped up or down to usable voltages without changing frequency.

1. MANUFACTURING OF POWER
TRANSFORMERS AND MAINTENANCE
PRESENTED BY:
J.SUMAN
EEE
(Student)

2. CONTENTS
1. Introduction of KRK company
2. Introduction to transformer
3. Manufacturing process of transformer
4. Assembly
5. Maintenance

3. KRK COMPANY

4. KRK COMPANY
• This company was established in the year
1978 for manufacturing power transformers.
• KRK Company is to satisfy the customer needs
by providing excellent service, present
technology, meticulous planning and
implementing cost effective technology.

5. INTRODUCTION OF TRANSFORMERS
• Transformer is a static device, which transfers
electrical power from one voltage level to
another voltage level with out changing the
frequency.

6. Raw materials,Core,Copper,Tank,Oil&Insulation etc..
Wrapping HV&LVCore building
Winding HV &LV(coils)
Core coil
assembling
Connections(brazing) Tank preparation fitting accessories
Drying process
Pre-tanking
Oil filtration , tanking &oil filling
painting
dispatch
TRANSFORMER MANUFACTURING PROCEDURE:

7. Manufacturing process of transformers
PARTS OF TRANSFORMER:
1. Core
2. Winding
3. Bushings
4. Oil filling & Oil filtration
5. Conservator
6. Buchholz relay
7. Breather
8. Explosion vent

8. CORE:
• The purpose of core is to provide a path of low
reluctance for the magnetic flux.
• Fully mitered & step lapped in corner joints
Manufacturing process
Parts of transformer:

9. Manufacturing process:
Parts of transformer:
Core:

10. Insulating of Coils
Manufacturing process
Parts of transformer

11. Manufacturing process
Parts of transformer:
COIL WINDING:
• Conductor are either copper magnetic wire or
continuously transposed conductor.
• Winding type chosen according to voltage &
application are: Cont. Disc, Helical, etc.

12. COIL WINDING:
Manufacturing process
Parts of transformer:

13. Manufacturing process
Parts of transformer:
WINDING PROCESS:
• Windings are clamped using external or internal
tie rods to provide additional support for axial
forces.

14. Manufacturing process
Parts of transformer:
Winding assembly

15. Manufacturing process
Parts of transformer:
Dump the windings:
• Dumping of LV and HV windings into the tank.

16. Manufacturing process
Parts of transformer:
Tap changers:

17. Manufacturing process
Parts of transformer:
BUSHINGS:

18. Manufacturing process
Oil filling & oil filtration:
• Transformer oil is usually a highly-refined mineral oil
that is stable at high temperature and has excellent
electrical insulating property.

20. Manufacturing process
Parts of transformer:
Conservator:

21. Manufacturing process
Parts of transformer
Buchholz relay:
• The Buchholz relay is used as a protective
device sensitive to the effects
of dielectric failure inside the equipment.
• connected between the conservator and oil
tank of a transformer.

22. Manufacturing process
Parts of transformer:
Buchholz relay

23. Manufacturing process
Parts of transformer
Breather:

24. Manufacturing process
Parts of transformer
Radiators :

25. Manufacturing process
Parts of transformer
Explosion vent :

26. ASSEMBLY:
• Installation of set of winding, conservator,
radiators, pumps, fans, etc.

27. FINAL ASSEMBLY

28. MAINTENANCE
1. Hourly wise
2. Daily wise
3. Weekly wise
4. Monthly wise
5. Yearly wise
6. 2 years
7. 5years

29. Conclusion
Transformer is the of the major equipment in
the power system , because even though we
generate power without transformer we can
not use directly it.

30. THANK YOU
ANY QUERIES?