Detailed Project Report on MANUFACTURING OF POWER AND DISTRIBUTION TRANSFORMER

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.

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ENGINEERS INDIA RESEARCH INSTITUTE
4/54, Roop Nagar, Delhi-110007 (India)
Phone: [phone]
E-mail: [email protected]
Website: www.eiriindia.org




MANUFACTURING OF POWER AND
DISTRIBUTION TRANSFORMER
[EIRI/EDPR/4718] J.C.: 2938XL



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.

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

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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 T HE TRANSFORMER WAS AS FOLLOWS:
TRANSFORMER MARKET MAJOR CONTRIBUTOR
INTRODUCTION
TRANSFORMER
TRANSFORMER SEGMENTA TION
BY VOLTAGE:
BY APPLICATION:
DIFFERENT TYPES OF T RANSFORMERS
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 COMPANI ES IN INDIA
1. INDIAN SERVO CONT ROLS (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.

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5. VOLTAMP TRANSFORMERS LIMITED:
6. EMCO LIMITED:
7. TRANSFORMERS AND RECTIFIERS (INDIA) L IMITED:
8. KIRLOSKAR ELECTRI C 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:

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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
 OUTERPARTSOFTRANSF ORMER
 YO KE
 BUCHHOLZ RELAY
 CONSERVATORTANK
 OILLEVELINDICATOR
 BREATHER
 WINDINGTEMPERATUREINDICATOR
 COOLINGFANS/ RADIAT OR
 SYSTEM GROUND TERM INAL
 DRAINVALVE
INNERPARTSOF TRANSFORMER
 CORE
 PRIMARY WINDING (H V-WINDING)
 SECONDARY WINDING( LV-WINDING)
 TRANSFORMEROIL
TESTINGOFDISTRIBUTION TRANSFORMER
1. ACCEPTANCETEST
2. SUBTESTS
3. ROUTINETEST
ACCEPTANCETEST

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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 EXPANSI ON
GOVERNMENT INITIATIVES
INFRASTRUCTURE DEVELOPMENT
TECHNOLOGICAL ADVANCEMENTS
INCREASED DEMAND FOR ELECTRICITY FROM EMERGING ECONOMIES
INVESTMENT IN TRANSMISSION AND DISTRIBUT ION 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:

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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 MAT ERIALS & SPARES SUPPLIERS:
FIREFIGHTING EQUIPMENTS MANUFACTURERS & SUPPLIERS
LATHE MACHINE MANUFACTURERS
PACKAGING MACHINE
LABORATORTY EQUIPMENTS MANUFACTURERS
D.G. SET MANUFACTURERS & SUPPLIERS

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ELECRICAL GOOD & SWI TCH 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 FINANCI AL 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 ELECTRI CAL
ENERGY:

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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)

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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%