Detailed Project Report (DPR) on distribution transformer manufacturing and repairing unit

DISTRIBUTION TRANSFORMER MANUFACTURING AND REPAIRING UNIT
[CODE NO.3291]

A transformer is a device that transfers electrical energy from one circuit to another through inductively coupled conductors—the transformer's coils. A varying current in the first or primary winding creates a varying magnetic flux in the transformer's core and thus a varying magnetic field through the secondary winding. This varying magnetic field induces a varying electromotive force (EMF), or "voltage", in the secondary winding. This effect is called inductive.

If a load is connected to the secondary, current will flow in the secondary winding, and electrical energy will be transferred from the primary circuit through the transformer to the load. In an ideal transformer, the induced voltage in the secondary winding (Vs) is in proportion to the primary voltage (Vp) and is given by the ratio of the number of turns in the secondary (Ns) to the number of turns in the primary (Np) as follows:
 
By appropriate selection of the ratio of turns, a transformer thus enables an alternating current (AC) voltage to be "stepped up" by making Ns greater than Np, or "stepped down" by making Ns less than Np. The windings are coils wound around a ferromagnetic core, air-core transformers being a notable exception.

Transformers range in size from a thumbnail-sized coupling transformer hidden inside a stage microphone to huge units weighing hundreds of tons used to interconnect portions of power grids. All operate on the same basic principles, although the range of designs is wide. While new technologies have eliminated the need for transformers in some electronic circuits, transformers are still found in nearly all electronic devices designed for household ("mains") voltage. Transformers are essential for high-voltage electric power transmission, which makes long-distance transmission economically practical.

A transformer is a device for transferring energy in a system from one circuit to another. It consists of two independent electric circuits linked with a common magnetic circuit. This energy at low voltage may be transformed to energy at high voltage, or vice versa. In the like manner, current of a given value in one circuit may be transformed into current of another value in a different circuit. the winding of the  transformer connected to the supply circuit is termed as primary winding and these  windings of  the transformer that are connected to the receiver  circuits  are called secondary windings. Transformers having more than one primary or secondary winding etc.

COST ESTIMATION

Plant  Capacity                                            :       1.30 Nos./day                                    
land & Building (2000 Sq.mt)                   :      Rs. 51.00 Lacs
Plant & Machinery                                       :      Rs. 71.87 Lacs
Working Capital for 1 Month                     :      Rs. 56.47 Lacs
Total Capital Investment                           :       Rs. 1.94  Cr
Rate of Return                                             :     34%
Break Even Point                                        :      61%

INTRODUCTION    
PRINCIPLE OF TRANSFORMER    
DISTRIBUTION TRANSFORMER    
IMPORTANT FEATURES    
PROPERTIES OF DISTRIBUTION TRANSFORMER:    
TYPES OF DISTRIBUTION TRANSFORMERS:    
TRANSFORMER CONSTRUCTION    
CORE    
WINDINGS    
USES AND APPLICATION    
OF DISTRIBUTION TRANSFORMER    
B.I.S. SPECIFICATION    
PROCESS FLOW CHART    
MANUFACTURING PROCESS    
OF DISTRIBUTION TRANSFORMER    
HIGH VOLTAGE COIL    
LOW VOLTAGE COIL    
1. INSULATION RESISTANCE TEST    
2. DC RESISTANCE OR WINDING RESISTANCE TEST    
KELVIN BRIDGE    
DC WINDING RESISTANCE TEST (CURRENT-VOLT METHOD)    
REQUIRED PRECAUTION    
3. TURNS RATIO / VOLTAGE RATIO TEST    
METHOD NO 1 TURNS RATIO TESTING    
BRIDGE CIRCUIT    
METHOD NO 2 VOLTAGE RATIO TESTING    
TEST INSTRUMENT    60
SHORT CIRCUIT TEST (WITHOUT USING CT, PT)    
SHORT CIRCUIT TEST (WITH CT)    
6. OPEN CIRCUIT / NO LOAD TEST    
7. CONTINUITY TEST    
8. MAGNETIC CURRENT TEST    
9. MAGNETIC BALANCE TEST    
10. HIGH VOLTAGE TESTS ON HV & LV WINDING    
11. DIELECTRICAL TEST    
METHOD NO 1 (SEPARATE SOURCE VOLTAGE WITHSTAND TEST)    
DIELECTRIC TEST (SEPERATE VOLTAGE SOURCE WITHSTAND TEST)    
12. TEMPERATURE RISE TEST OF TRANSFORMER    
MARKET SURVEY    
PRODUCT INSIGHTS    
REGIONAL INSIGHTS    
COMPETITIVE INSIGHTS    
GLOBAL ELECTRICITY TRANSFORMERS MARKET TO REACH
US$53.6 BILLION, 9.7 MILLION UNITS BY 2017    
TRANSFORMER INDUSTRY IN INDIA FACES CRGO BOTTLENECKS     
INDIA IS KNOWN TO BE AN ACTIVE SUPPLIER OF TRANSFORMERS TO NATIONS WORLDWIDE. WHAT HAS LED TO ITS GROWTH IN EXPORT IN
THE RECENT YEARS?    
WHAT SHIFTING MARKET TRENDS AND OPPORTUNITIES ARE YOU WITNESSING IN THE INDIAN TRANSFORMER MARKET?    
IS RURAL ELECTRIFICATION A DEMAND DRIVER FOR TRANSFORMERS
IN INDIA?    
CHINA HAS ALREADY ENTERED THE INDIAN POWER TRANSFORMER
MARKET, HOW DO YOU RATE COMPETITION FROM CHINA?    
ACCORDING TO YOU, HOW CAN GOVERNMENT BOOST GROWTH
OF THE INDIAN POWER TRANSFORMER INDUSTRY?    
THE MOST IMPORTANT RECOMMENDATIONS FROM MY SIDE TO
THE GOVT. WOULD BE:    
WHAT IS YOUR OUTLOOK ON THE INDIAN TRANSFORMER MARKET
AND WHAT DO YOU RATE AS THE KEY CHALLENGES?    
THE INDIAN TRANSFORMER INDUSTRY IS FACING SOME KEY
CHALLENGES, WHICH RESTRICT IT FROM GROWING OF ITS FULL
POTENTIAL AND TARGETS. SOME OF THESE CHALLENGES INCLUDE:    
OPPORTUNITIES    
POWER TRANSFORMERS MARKET TO RIDE ON INCREASING GLOBAL
ENERGY DEMAND TO REACH US$28.69 BILLION BY 2019    
GLOBAL POWER AND DISTRIBUTION TRANSFORMERS MARKET
FORECAST AND OPPORTUNITIES, 2019    
INDIA POWER AND DISTRIBUTION TRANSFORMERS MARKET TO
GROW AT OVER 10%, CONCLUDES TECHSCI RESEARCH STUDY    
ABOUT TECHSCI RESEARCH    
GLOBAL POWER TRANSFORMERS MARKET GROWING    
POWER AND DISTRIBUTION TRANSFORMER MARKET IN INDIA 2014
AND 2020    
EXPORT DATA OF DISTRIBUTION TRANSFORMER    
IMPORT DATA OF DISTRIBUTION TRANSFORMER    
PLANT LAYOUT    
MANUFACTURERS/SUPPLIERS    113
OF DISTRIBUTION TRANSFORMER    
SUPPLIERS OF RAW MATERIALS    
SUPPLIERS OF HOT ROLLED SHEETS    
M.S CHANNELS AND ANGLES    
M.S. FLAT    
M.S. PLATE    
M.S. PIPE    
SUPPLIERS OF CARGO LAMINATION    
SUPPLIERS OF DPC COPPER WIDING WIRE    
SUPPLIERS OF TRANSFORMER OIL    
SUPPLIERS OF CRAFT PAPER    
SUPPLIERS OF M.S BOLTS AND NUTS    
SUPPLIERS OF TRANSFORMER BUSHINGS    
SUPPLIERS OF PAINT    
SUPPLIERS OF PLANT AND MACHINERIES    
TRANSFORMER COIL WINDING MACHINE    
SUPPLIERS OF OIL FILTER MACHINE    
SUPPLIERS OF VACCUME IMPREGNATION PLANT    
SUPPLIERS OF ELECTRICAL MEASURING INSTRUMENT    
SUPPLIERS OF TRANSFORMER OIL TESTING KIT    
SUPPLIERS OF BENCH GRINDER    
SUPPLIERS OF DRILLING MACHINE    
SHEARING MACHINE    
WELDING MACHINE    
AIR COMPRESSORS    
MATERIAL HANDLING EQUIPMENTS    
SUPPLIERS OF PAINTING EQUIPMENTS    
FIRE FIGHTING EQUIPMENTS    
SUPPLIERS OF EOT CRANE    
AIR POLLUTION CONTROL EQUIPMENTS    
PLATEFARM WEIGHING MACHINE    
SHOT BLASTING MACHINE    

        
APPENDIX – A:

 1.      COST OF PLANT ECONOMICS      
 2.      LAND & BUILDING                                      
 3.      PLANT AND MACHINERY                                  
 4.      FIXED CAPITAL INVESTMENT                             
 5.      RAW MATERIAL                                         
 6.      SALARY AND WAGES                                     
 7.      UTILITIES AND OVERHEADS                              
 8.      TOTAL WORKING CAPITAL                                
 9.      COST OF PRODUCTION                                   
10.      PROFITABILITY ANALYSIS                               
11.      BREAK EVEN POINT                                     
12.      RESOURCES OF FINANCE                           
13.      INTEREST CHART                                       
14.      DEPRECIATION CHART                                   
15.      CASH FLOW STATEMENT                                   
16.      PROJECTED BALANCE SHEET