Manufacturing of Power and Distribution Transformer

MANUFACTURING OF POWER AND DISTRIBUTION TRANSFORMER

[EIRI/EDPR/4718] J.C.: 2938XL

INTRODUCTION

We, Himalayan Heavy Electricals (OPC) Pvt. Ltd., Vill & PO-Manuaganj, Near Pallk Allos, PS.Rajganj, District Jalpaiguri, West Bengal are catering to various state utilities and private industrial and real estate customers. We enjoy trust of our customers and have been supplying to them since quite a long time. Currently parent company M/S Siliguri Electric Works is engaged in manufacturing oil filled distribution transformers from 25 KVA, 11/0.433 KV to 1000 KVA, 11/0.433 KV at Matigara, Siliguri.

Presently, in whole of the West Bengal, there are very few transformer manufacturers among them reputed ones are further less. We are in the business for 30 years and got a good market share in this region. Considering the economic growth predictions, we are expecting a big surge in demand of high-quality transformers in this region – West Bengal, Orissa, Jharkhand, Assam and North-eastern states. To gear up ourselves for this demand we are planning to expand our manufacturing capacities.

We are setting up a new manufacturing unit as part of our expansion program. It is a green field project. This new factory will be located at Plain Ghati, Hati More, Manua Ganj, Dist - Jalpaiguri. We will be increasing our product range and volume by addition of this facility. In this plant we will be making oil filled transformers of ratings ranging from 25 KVA, 11/0.433 KV to 16 MVA, 33/0.433 KV. The range may be further extended to 25 MVA, 66/11 KV in near future.

This project, once completed will generate employment opportunities to local youths and will be instrumental in uplifting the economic status of many families.

COST ESTIMATION

Plant Capacity            48 Nos./Day

Land & Building (9975.171 sq.mt.)    Rs. 8.27 Cr

Plant & Machinery                    Rs. 15.26 Cr

Working Capital for 1 Month    Rs. 13.16 Cr

Total Capital Investment          Rs. 37.10 Cr

Rate of Return                          40%

Break Even Point                      40%

CONTENTS

INTRODUCTION OF INVESTER & BACKGROUND

BASIS & PRESUMPTIONS

THE FOLLOWING PRESUMPTIONS HAVE BEEN TAKEN IN TO ACCOUNT –

POWER TRANSFORMERS

DISTRIBUTION TRANSFORMERS

BACKGROUND OF A TRANSFORMER

THE DEVELOPMENT OF THE TRANSFORMER WAS AS FOLLOWS:

TRANSFORMER MARKET MAJOR CONTRIBUTOR

INTRODUCTION

TRANSFORMER

TRANSFORMER SEGMENTATION

BY VOLTAGE:

BY APPLICATION:

DIFFERENT TYPES OF TRANSFORMERS

POWER TRANSFORMERS

DISTRIBUTION TRANSFORMER

HERMETICALLY SEALED TRANSFORMERS

INVERTER DUTY TRANSFORMERS

FURNACE TRANSFORMERS

COMPACT SUB STATION (CSS)

DRY TYPE TRANSFORMERS

PAD MOUNTED TRANSFORMERS

HT-AVR TRANSFORMER WITH BUILT-IN AVR

THE MAIN COMPONENTS OF TRANSFORMERS ARE:

TOP 15 TRANSFORMER MANUFACTURING COMPANIES IN INDIA

1. INDIAN SERVO CONTROLS (ISC):

2. ABB INDIA LIMITED:

3. SIEMENS LIMITED:

4. CROMPTON GREAVES (CG):CG IS A WELL-KNOWN MANUFACTURER OF TRANSFORMERS, INCLUDING POWER TRANSFORMERS, DISTRIBUTION TRANSFORMERS, AND SPECIALTY TRANSFORMERS

5. VOLTAMP TRANSFORMERS LIMITED:

6. EMCO LIMITED:

7. TRANSFORMERS AND RECTIFIERS (INDIA) LIMITED:

8. KIRLOSKAR ELECTRIC COMPANY LIMITED:

9. DIAMOND POWER INFRASTRUCTURE LIMITED:

10. GENUS POWER INFRASTRUCTURES LIMITED:

11. L&T ELECTRICAL AND AUTOMATION:

12. IMP POWERS LIMITED:

13. SHRIRAM TRANSFORMERS AND ELECTRICALS:

14. VIJAI ELECTRICALS LIMITED:

15. TRUTECH PRODUCTS:

MAJOR RAW MATERIALS

MATERIALS USED IN TRANSFORMER MANUFACTURING

1. CORE MATERIAL:

2. WINDING MATERIAL:

3. INSULATION MATERIALS:

4. TRANSFORMER OIL:

5. TANK MATERIAL:

6. BUSHINGS:

7. GASKETS AND SEALS:

8. PAINT AND COATINGS:

QUALITY STANDARDS FOLLOWED BY TRANSFORMER MANUFACTURERS IN INDIA

ADVANTAGES& APPLICATIONS OF TRANSFORMERS

ADVANTAGES OF TRANSFORMERS:

APPLICATIONS OF TRANSFORMERS:

B.I.S. SPECIFICATION

THE BUREAU OF INDIAN STANDARD HAS LAID DOWN SPECIFICATIONS:

MANUFACTURING OF DISTRIBUTION TRANSFORMER

INTRODUCTION

FLOWCHART OF MANUFACTURING A TRANSFORMER

COMPONENTSTANDARDS

THECOMPONENTSTANDARDSTOBEUSEDAREASFOLLOWS:

CONDUCTORS:

PRESS BOARD:

OIL DUCTS:

CRGO LAMINATIONS:

TRANSFORMERTANK:

TRANSFORMER OIL:

CONSERVATOR TANK:

BREATHER:

RADIATOR:

BUSHINGS:

MANUFACTURING PROCESS

PRODUCTION OF 25KVA, 4 STAR LVWINDING

PROCEDURE FOR 25KVA, 4 STAR HVWINDING

COREASSEMBLY

CORE-COILASSEMBLY

HVANDLVCONNECTIONS

DRYINGPROCESS

OILFILLING

LOWERING

TESTING

DISPATCH

 OUTERPARTSOFTRANSFORMER

 YOKE

 BUCHHOLZ RELAY

 CONSERVATORTANK

 OILLEVELINDICATOR

 BREATHER

 WINDINGTEMPERATUREINDICATOR

 COOLINGFANS/RADIATOR

 SYSTEM GROUND TERMINAL

 DRAINVALVE

INNERPARTSOF TRANSFORMER

 CORE

 PRIMARY WINDING (HV-WINDING)

 SECONDARY WINDING (LV-WINDING)

 TRANSFORMEROIL

TESTINGOFDISTRIBUTION TRANSFORMER

1. ACCEPTANCETEST

2. SUBTESTS

3. ROUTINETEST

ACCEPTANCETEST

TENSILESTRENGTHTEST

BREAKDOWNVOLTAGETEST

RESISTANCETESTOFTRANSFORMEROIL

SUBTESTS

COILRATIOTEST

RATIOTESTOFTRANSFORMERANDCHECKOFPHASEDISPLACEMENT

PROCEDUREOFTRANSFORMERRATIOTEST

RESISTANCETEST

VECTORGROUPTEST

MAGNETICBALANCETEST

PROCEDUREOFMAGNETICBALANCETESTOFTRANSFORMER:

ROUTINETESTS

HVANDLVTEST

INDUCEDOVERVOLTAGETEST (OR) DVDF TEST

OPENCIRCUITTEST

SHORTCIRCUITTEST

INDUSTRYOVERVIEW

MARKET POTENTIAL:

TRANSFORMERSINDUSTRY: INDIASCENARIO

GROWTHDRIVERS

POWER SECTOR EXPANSION

GOVERNMENT INITIATIVES

INFRASTRUCTURE DEVELOPMENT

TECHNOLOGICAL ADVANCEMENTS

INCREASED DEMAND FOR ELECTRICITY FROM EMERGING ECONOMIES

INVESTMENT IN TRANSMISSION AND DISTRIBUTION NETWORKS

PRINCIPLES OF PLANT LAYOUT

MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:

PLANT LOCATION FACTORS

PRIMARY FACTORS

RAW-MATERIAL SUPPLY:

MARKETS:

POWER AND FUEL SUPPLY:

WATER SUPPLY:

CLIMATE:

SPECIFIC FACTORS

TRANSPORTATION:

WASTE DISPOSAL:

LABOR:

REGULATORY LAWS:

TAXES:

SITE CHARACTERISTICS:

COMMUNITY FACTORS:

VULNERABILITY TO WARTIME ATTACK:

FLOOD AND FIRE CONTROL:

EXPLANATION OF TERMS USED IN THE PROJECT REPORT

1. DEPRECIATION:

2. FIXED ASSETS:

3. WORKING CAPITAL:

4. BREAK-EVEN POINT:

5. OTHER FIXED EXPENSES:

6. MARGIN MONEY:

7. TERM LOANS:

8. TOTAL LOAD:

9. LAND AREA/MAN POWER RATIO:

UTILITIES

POWER

WORKING

TOTAL MANPOWER AND PAYROLL

UTILITIES

INDIAN MANUFACTURING INDUSTRY

INTRODUCTION

MARKET SIZE

INVESTMENT

SOME OF THE MAJOR INVESTMENTS AND DEVELOPMENTS IN THIS SECTOR IN THE RECENT PAST ARE:

GOVERNMENT INITIATIVES

ROAD AHEAD

PLANT AND MACHINERY MANUFACTURERS

ADDRESSES OF MACHINERY SUPPLIERS:

ADDRESSES OF RAW MATERIALS & SPARES SUPPLIERS:

FIREFIGHTING EQUIPMENTS MANUFACTURERS & SUPPLIERS

LATHE MACHINE MANUFACTURERS

PACKAGING MACHINE

LABORATORTY EQUIPMENTS MANUFACTURERS

D.G. SET MANUFACTURERS & SUPPLIERS

ELECRICAL GOOD & SWITCH MANUFACTURE

SS PIPE & TUBE MANUFACTURER

DOCUMENTS REQUIRED FOR LICENSES

LIST OF DOCUMENTS:

LICENCE OF PLASTIC WASTE IMPORT

DOCUMENTS REQUIRED ARE:-

ADDRESSES OF RELEVANT GOVERNMENT OFFICES

ADDRESSES OF FINANCIAL INSTITUTIONS

SWOT ANALYSIS

STRENGTHS

WEAKNESSES

OPPORTUNITIES

THREATS

ORGANIZATION CHART

PLANT LAYOUT

IMPLEMENTATION SCHEDULE

POLLUTION CONTROL:

ENERGY CONSERVATION:

THE FOLLOWING STEPS MAY HELP FOR CONSERVATION OF ELECTRICAL ENERGY:

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)