KIRLOSKAR TRANSFORMERS

INTRODUCTION

Kirloskar Electric started manufacturing Power and Distribution

transformers in the year 1954 with collaboration from Brush Electric
(Hawker Sydley Group), UK. Since then, Kirloskar Electric has been
manufacturing power, distribution and many other special
transformer conforming to National and International standards like
BS, IEC, ANSI, AS.

Kirloskar Electric is pioneer in the manufacture of special

transformers like HV Testing transformers and Short Circuit
testing transformers required in testing laboratories. Also, High
Current Furnace transformers, Earthing / Neutral Grounding
transformers, Shunt and Series Reactors, Cast Resin Dry type
transformers and many other special transformers as per customer
requirement.

The company has won many import substitution awards for

successful indegenisation of many special transformers like HV
testing transformers, Flameproof mining transformers and Arc
Suppression Coils.
The company had collaboration with MWB of Germany for HV
Testing transformers. All other special transfor mers are
developed with our own in house R & D.
Kirloskar Electric is the first transformer manufacturing company
in India to get certified for ISO 9001 by BVQI.

OUR PRODUCT RANGE

* Distribution Transformers : 160 kVA to 2500 kVA, upto 33 kV class

* Power Transformers : 2500 kVA to 50000 kVA, upto 220 kV class

SPECIAL TRANSFORMERS
* Furnace Transformers : Upto 25000 kVA, 66 kV class
* Converter Transformers : Upto 20000 kVA, 33 kV class
* HV Power Frequency : Upto 1200 kV, 1200 kVA
Testing Transformers
* Short Circuit Testing Transformers : Upto 100 kA for 1 second.
* Cast Resin Transformers : Upto 10000 kVA, 33 kV class
* Earthing Transformers / : For system upto 33 kV class
Neutral Grounding Transformers
* Flameproof Dry Type Mining : 200 kVA to 500 kVA, upto 6.6 kV class
Transformers/Transwitch Units
 STANDARDS
Kirloskar Transformers are designed and tested to the following standards:
* Distribution and Power Transformers : IS : 2026, BS : 171 & IEC : 76
* Converter Transformers : IS : 4540, IEC : 146 & IEEE : 444
* Furnace Transformers : IS : 2026
* System Earthing Transformers : IS : 3150 & BS : 4944
The company is capable of manufacturing transformers to any other standards as per customers /
consultants requirement.

MANUFACTURING FACILITIES
Kirloskar Electric has a highly skilled and motivated
workforce. The operators at different levels undergo
regular training in various skills, so that we keep abreast
of latest practices in manufacturing processes.
We have an array of sophisticated facilities like coil winding
machines, hydraulic press, heating and vacuum ovens, EOT
cranes etc.,

ENGINEERING DEPARTMENT
* Manufacturing and contract drawings on CAD.
* Estimation of stray losses, stresses in tank and other View of Mysore works
fabricated items and analysis of flux distribution in
core using FEM package.

CORE – ASSEMBLY

* CRGO Silicon steel.

* Hi-B / Laser Irradiated.

* Step lap construction and Mitred joints.

* Optimised cooling ducts.

Core Assembly on specially designed
jerk free tilting fixture
* Core banding – Fibre glass tape and epoxy.

* No yoke bolts, only yoke banding.

* Low noise level.

* Reduced no – load current.

* Strategically placed oil ducts for cooling of core.

* Directed oil flow between core stacks for effective

cooling. Power Transformer
Core Assembly
 WINDINGS

* Windings designed for thermal, electrical and mechanical

stresses.
* Paper insulated high conductivity soft drawn copper
conductor.
* CTC (Continuously Transposed Conductors) for low
voltage high current windings.
* Use of only pre-compressed press board material.
* Axial and radial banding for sturdiness.
* Interleaved disc windings for EHV class transformers.
* Layer type of windings for LV and HV for better impulse
voltage distribution.
* Taps at winding middle or outermost layer for better 25 MVA, 110/22 kV HV Winding
ampere turn distribution and increased short circuit Two Section Interleaved
withstand.
* Directed oil flow in disc and layer windings.
* HV wound over LV for good control over dimensions.

PRE-SHRINKAGE OF WINDINGS

* 100 tons hydraulic press to apply pre-calculated shrinkage

force.

* Smooth control of shrinkage force.

* No further shrinkage of windings under short circuit

forces in the system.

* Rigid windings for increased dynamic ability to withstand

short circuit forces.

Completed Power Transformer Windings

undergoing Pre-compression
CORE – COIL ASSEMBLY
* Pre-compressed Press Board material / supreme grade
insulating material.
* Copper tubes in 220 kV class HV windings for uniform
field distribution.
* Silver coated tap switches for high current transformers
and linear tap switches.
* Proper distribution of clamping force for better clamping
of windings.
* Defined routing of tap and line leads for better voltage Core-Coil Assembly under Progress
distribution. (220 kV Class Power Transformer)
 HEAT DRYING OVENS
The transformers windings and core-coil assembly is preheated
in heat drying ovens prior to vacuum process.

25 MVA Core Coil Assembly Under

Pre- Heating
VACUUM OVEN
Vacuum impregnation of core-coil assembly and oil filling
under vacuum.

* Vacuum level upto 1 torr at 1000C.

* Complele elimination of moisture from insulation

material.

* Higher oil BDV and hence better Voltage withstand.

* Use of Micro Processor based Temperature for Controller

to record Temperature v/s Time.

Core-coil assembly of 35 MVA, 33/6.9 kV

transformer in Vacuum Oven
TANKING, PAINTING AND FINISHING

* Fabricated from mild steel procured from reputed firms

like TATA steel / SAIL / Essar.
* Electrically welded with cooling effected by tank
mounted, welded or detachable radiators.
* Radiators are of pressed steel and are independently
pressure tested.
* All tanks are pressure and vacuum tested.

In order to make them weather proof, the tanks are :

* Shot blasted to remove rust and welding scale.
* Applied with a primer coat of zinc chromate on external
surfaces.
* Sprayed with two coats of grey, weather resistant, epoxy
finish paint, highly resistant to chemicals and oil.

On all interior surfaces coming in contact with transformer The core-coil assembly of 35 MVA, 33/6.9 kV
transformer 33/6.9 kV transformer being lowered
oil, a coat of heat and transformer oil resistant insulating clear into its tank, prior to vacuum impregnation
lacquer varnish is applied.
 TESTING

Tests Conducted

Routine Tests
* Measurement of winding resistance.
* Measurement of voltage / turns ratio.
* Measurement of impedance voltage / short.
* Circuit impedance and load loss.
* Measurement of no load loss and no load current.
* Measurement of insulation resistance.
* Dielectric test. 25 MVA, 110/33 KV
Power Transformer under test
* Test on OLTC (on-load tap changers)
Special Tests Type Tests
* Zero sequence impedance test. * Temperature rise test.
* Capacitance and tan delta. * Impulse test.
* Noise level Measurement . Short Circuit Test
* Harmonic Analysis. * At CPRI, Bangalore / Bhopal.
* Power measurement for fans, oil pumps. * ERDA Vadodara.

IMPULSE GENERATOR

* Rating : 1000 kVP, 50 kJ, 5 stages, 200 kV per stage.

Hafely Make.

* Used to test transformers for Type Test as per

standards, Lightening Impulse (both HV and LV) upto
50 MVA, 220 kV class.

* Has all the necessary controls and impulse recording

system required for Testing.

Impulse Generator

SHIPPING
Where weight considerations do not permit units to be despatched with oil,
arrangements are made for despatching the transformer filled with either dry air or
inert gas under slight pressure.
 SOME OF OUR TRANSFORMERS AT A GLANCE

25 MVA, 110/33kV Power Transformer installed at Compact distribution transformers for export
TNEB, Coimbatore 315 kVA, 11000/433 V

31.5 MVA, 220 kV Power Transformer a/c

Kalyani Ferrous, Hospet

16 MVA, 110 kV Generator Transformer at 7.5 MVA, 110 kV Power Transformer at

Maniyar Hydro Electric Power Station M/s Madras Cements
 OUR NETWORK IS AS VAST AS THE RANGE OF TRANSFORMERS
WE MANUFACTURE

Location Tel. No. Fax No. E-mail

North
New Delhi 011-26233788 011-26233791 kpel@ndl.vrkec.com
Lucknow 0522-2789035 0522-2789091 kecl@satyam.net.in
Jaipur 0414-5108212 0141-5108212 kecjpr@datainfosys.net
Ludhiana 0161-2773985 0161-2773983 kecldh@satyam.net.in

East
Kolkata 033-24798391 033-24861358 trf@cal.vrkec.com
Guwahati 0361-2668736 0361-2668736 kecgau@satyam.net.in
Bhubaneswar 0674-2555774 0674-2555694 kecbbsr@vsnl.net
Jamshedpur 0657-2226326 0657-2237419 kecjsr@satyam.net.in

West
Mumbai 022-24965540 022-24950352 anm@bmb.vrkec.com
Nagpur 0712-2545901 0712-2542418 mnhkecnp-ngp@sancharnet.in
Pune 020-27011025 020-27011227 kpel@vsnl.com
Ahmedabad 079-27541428 079-27541418 kbn@ahd.vrkec.com
Surat 0261-2687920 0261-2687920 kecsurat@sify.com
Durg 0788-2324236 0788-2210375 kecdurg@sify.com
Indore 0731-2528922 0731-2534796 mksoni@eth.net
Raipur 0771-5092693 0771-5092693 kecryp@sify.com

South
Chennai 044-26614785 044-26615861 nsv@mds.vrkec.com
Bangalore 080-23572111 080-23377706 trf@unit5.vrkec.com
Cochin 0484-2356709 0484-2357605 kecochin@md5.vsnl.net.in
Hyderabad 040-23310218 040-23311336 bjd@hyd.vrkec.com
Madurai 0452-2300651 0452-2300651 kecmdu@sify.com

National
Accreditation
of

EN 29001/ISO 9001/BS 5750

KIRLOSKAR ELECTRIC COMPANY LIMITED

Belavadi Industrial Area, Mysore – 570 018
Tel : 0821 - 2403862/63/64 Fax : 0821-2403186
Visit us at www.vrkec.com
Regd Office : Industrial Suburb, Rajajinagar, Bangalore - 560 010