3-13-1/109, 1/1, FCI Godown Rd, GUlmohar Garden,

Surya Nagar, Mallapur, Hyderabad, Secunderabad, Telangana 500076

An Internship report
on
TRANSFORMER MANUFACTURING

Submitted for
partial fulfilment for the award of the degree for
Bachelor of Engineering
In
Department of Electrical and Electronics Engineeering
Submitted by
B.SAHISHNU [1608-21-734-307]
V.MOHAN [1608-21-734-304]
P.PRABHAS [1608-21-734-010]
MANOHAR [1608-21-734-001]
HEMANTH [1608-21-734-005]

Under the esteemed guidance of

NAGARAJU SIR

MATRUSRI ENGINEERING COLEGE

HYDERABAD
 ABSTRACT

This report provides a comprehensive overview of transformer

manufacturing, covering key aspects such as the industrial visit , the
manufacturing process, materials used, challenges faced, and future
trends in the industry .

ACKNOWLEDGEMENT

I underwent training program of two weeks from 6th of may 2024 to 18th of
may in Hyderabad Tejaswini Industries which is the leading transformer
company in India. For this training program I would like to thank Mr.Nagaraj sir,
Manager of the Tejaswini Industries who arranged the training for us.And also I
would like to thank the whole staffs of the company for their guidance and kind
supervision and who cooperate with us.
I am also thankful to Mr. DR.G. Ravindranath ,Head of department(HOD)of
electrical engineering and Mr.MV. subrmanyam Training Incharge
 Table of Contents

1. Introduction
2. Methodology
3. Transformer Manufacturing Process
4. Materials Used in Transformer Manufacturing
5. Challenges in Transformer Manufacturing
6. Future Trends in Transformer Manufacturing
7. Conclusion and Recommendations
8. Appendices
Introduction
Transformers plays a crucial role in electrical systems by stepping up
or stepping down the voltage levels, enabling the efficient
transmission and distribution of electricity. The manufacturing
process of transformer involves various stages, from design to testing,
each requiring precision and expertise. So that an efficient transformer
is made which would be helpful in transmission and distribution of
electricity.

INTRODUCTION ABOUT TRANSFORMER

Transformer is an ac machine that transfers electrical energy from

one electrical circuit to another without changing frequency by the
principle of electromagnetic induction. Since it’s basic construction
requires no moving parts so it is often called the static transformer
and it is very rugged machine requiring the minimum amount of
repair and maintenance. Owing to the lack of rotating parts there are
no friction or winding losses. Further ,the other losses are very low so
that the efficiency should be high. The efficiency varies from 97% to
99%.

POWER TRANSFORMER
The term is used to include all transformers of large sizes(250kva and
above) used in generating stations and substations for transforming
the voltage at each end of a power transmission line. They may be
single or three phase and voltage rating of 220/11kv or in high voltage
range. They are put in operation during load hours and disconnected
during light load hours or operated on full load. So power transformer
are desined to have maximum efficiency at full load (i.e.with iron loss
to full load copper loss ratio of 1:1).
DISTRIBUTION TRANSFORMER
Transformer of rating upto 200kva,used to step down the distribution
voltage to a standard service voltage are known as distribution
transformer. They are kept in operation all the24 hours a day. In such
transformer iron loss occur for all the time where copper loss occur
only when they are loaded. Therefore, distribution transformers
should be designed with iron loss smaller in comparision to full load
copper loss(say with iron loss to full load copper loss ratio1:3)

.
 Methodology
This report is based on a comprehensive review of literature, industry
reports , industrial visit and expert interviews to gather insights into
transformer manufacturing processes and challenges.
 Working principle of Transformer

Transformer Definition: A transformer is a passive device that

transfers electrical energy from one circuit to another using
electromagnetic induction.

Working Principle: The working principle of a transformer involves

mutual induction between coils to transfer electrical energy.The basic
principle behind working of a transformer is the phenomenon of
mutual induction between two windings linked by common magnetic
flux. Basically a transformer consists of two inductive coils; primary
winding and secondary winding. The coils are electrically separated
but magnetically linked to each other. When, primary winding is
connected to a source of alternating voltage, alternating magnetic flux
is produced around the winding. The core provides magnetic path for
the flux, to get linked with the secondary winding. Most of the flux
gets linked with the secondary winding which is called as 'useful flux'
or main 'flux', and the flux which does not get linked with secondary
winding is called as 'leakage flux'. As the flux produced is alternating
(the direction of it is continuously changing), EMF gets induced in the
secondary winding according to Faraday's law of electromagnetic
induction. This emf is called 'mutually induced emf', and the
frequency of mutually induced emf is same as that of supplied emf. If
the secondary winding is closed circuit, then mutually induced current
flows through it, and hence the electrical energy is transferred from
one circuit (primary) to another circuit (secondary)
Core Function: The core of a transformer provides a path with low
reluctance, essential for efficient flux linkage between the windings.

Voltage Conversion: Depending on the turns ratio between the

primary and secondary windings, a transformer can either step up or
step down the voltage.
Efficiency of Transformer
Just like any other electrical machine, efficiency of a transformer can
be defined as the output power divided by the input power. efficiency
= output / input .
Transformers are the most highly efficient electrical devices. Most of
the transformers have full load efficiency between 95% to 98.5% . As
a transformer being highly efficient, output and input are having
nearly same value, and hence it is impractical to measure the
efficiency of transformer by using output / input. A better method to
find efficiency of a transformer is using, efficiency = (input - losses) /
input = 1 - (losses / input).
Condition for maximum efficiency
Let,
Copper loss = I12R1
Iron loss = Wi
Transformer Manufacturing Process
The manufacturing process typically includes design engineering,
core assembly, winding, insulation, tank fabrication, assembly,
testing, and final inspection. Each step demands meticulous attention
to detail to ensure the reliability and performance of the transformer.
As per above, the explanation of several key process involved in the
transformer Manufacturing is as follows:
1. Design: Engineers design transformer according to specifications
such as voltage, current, and application requirements. This includes
determining the core material, winding configurations, and insulation.

Distribution Transformer Power Transformer

2. Materials Procurement: Raw materials like copper, aluminum , and

iron are sourced for the core and windings. Quality control is crucial
to ensure materials meet specifications.
3. Core Assembly: The core, typically made of laminated steel sheets,
is assembled. Cores may be constructed in various shapes like
toroidal, shell-type, or core-type.
Three phase Core type assembly
4. Winding: Copper or aluminum wires are wound around the core to
create coils. This process requires precision to achieve the desired
voltage and current ratios.

WINDING: L.V. & H.V.

Use of purely electrolytic grade Aluminium / copper conductor with high

insulating grade paper of fiberglass covering.
Designed to withstand compressive radial forces under short circuit conditions.
Windings are thoroughly dried in the oven & are subject to shrink under
hydraulic press to get desired height which could withstands short circuit
forces.
Bare size is checked before winding
Electrical continuity test with indicator lamp
I.D. & O.D. is confirmed
Winding resistance is checked & confirmed
5. Insulation: Insulating materials are applied to the windings to
prevent short circuits and ensure safety and reliability. Insulation can
include paper, varnish, or epoxy coatings.
Insulation materials
6. Assembly: Windings and core are assembled into the transformer's
casing, which may be filled with insulating oil or gas to enhance
cooling and insulation.
7. Testing: Transformers undergo rigorous testing to ensure they meet
performance standards and safety regulations. This includes dielectric
tests, insulation resistance tests, and load tests.
• Winding Resistance Test
• Transformer oil test using Megger
• Winding ratio test kit
• Continuity test of winding

Calibration Kit
 Turn Ratio meter
8. Packaging and Shipping: Once tested and approved, transformers
are packaged for shipment to customers. Proper packaging is essential
to prevent damage during transit , Materials Used in Transformer
Manufacturing Materials such as silicon steel , copper or aluminum
conductors,insulating oils, and various types of insulation materials
are crucial for transformer manufacturing. The selection of materials
impacts the efficiency, reliability, and longevity of the transformers.

Insulating oils
Challenges in Transformer Manufacturing
Challenges in transformer manufacturing include ensuring consistent
quality, managing costs, complying with regulations, and adapting to
technological advancements. Addressing these challenges is vital to
meet the growing demand for transformers worldwide.
Future Trends in Transformer Manufacturing
Advancements in materials science , digitalization , automation, and
sustainable practices are shaping the future of transformer
manufacturing . Innovations such as smart transformers, eco -friendly
insulation materials , and predictive maintenance technologies are
expected to revolutionize the industry
 Conclusion and Recommendations
Transformer manufacturing is a complex and critical process that
requires continuous innovation and improvement to meet the evolving
needs of the electrical industry . To stay competitive , manufacturers
should invest in research and development , adopt sustainable
practices , and leverage digital technologies to enhance efficiency and
product quality.

SUMMARY
At last I would like to say that this training was a success for us, as we
learned a lot about the manufacturing, design and other aspects of
transformer which could not have been learned otherwise.the staffs
are very experienced and guide with interest.
 Appendix
- Glossary of Terms
- Additional Resources
- Interview Transcripts
- Figures and Tables