Page | 2

Introduction Of Koyna Engineers :

Koyna Engineers Pvt. Ltd. is a Nashik-based company specializing in the design and manufacture
of instrument transformers, such as current transformers (CTs) and potential transformers (PTs).
Established in 1987 by Mr. D. K. Shirole and Mrs. H.D. Shirole, the firm has grown to employ
between 100 to 200 individuals.

Their products are integral to power transmission and distribution networks, providing accurate
measurement and protection in electrical systems. The company's manufacturing facility is
located at Plot No. 106, Street No. 19, MIDC Satpur, Nashik, Maharashtra, 422007, India.

Koyna Engineers Pvt. Ltd. is recognized for its commitment to quality and innovation in the
electrical engineering sector, serving both domestic and international markets.

Manufacturing Components :

1) Current Transformer (CT) :

A Current Transformer (CT) is a crucial component in electrical power systems, designed to

measure and monitor high currents by stepping them down to a safer, measurable level. It is
classified as an instrument transformer, primarily used for metering and protection purposes in
power transmission, distribution networks, and industrial applications. The CT operates on the
principle of electromagnetic induction, where an alternating current (AC) in the primary winding
induces a proportional but reduced AC in the secondary winding. This allows measuring
instruments, such as ammeters and energy meters, to handle high currents indirectly without
direct exposure to dangerous voltage levels. Additionally, CTs provide electrical isolation between

Page | 3
 high-power circuits and sensitive measuring devices, ensuring safety and reliability.

The construction of a CT typically consists of a primary winding, which carries the main power
circuit’s current, a magnetic core made of high-permeability silicon steel to enhance flux transfer,
and a secondary winding, which is connected to measuring instruments or protective relays. The
insulation system ensures electrical separation between different components, while the CT
enclosure provides mechanical protection. The primary winding can be a single turn, a few turns,
or even just a straight conductor (bar type), while the secondary winding consists of multiple
turns designed to produce an appropriate stepped-down current ratio.

Current transformers come in various types based on their applications and designs. Bar-type CTs
have a solid conductor passing through the core and are commonly used in high-voltage
substations. Wound-type CTs have multiple turns in the primary winding and are used in low-
voltage applications. Toroidal CTs do not have a dedicated primary winding; instead, the
conductor carrying current acts as the primary, making them ideal for differential protection and
earth-fault detection. Split-core CTs are designed to be opened and clamped around an existing
conductor, making them useful for retrofit installations without disconnecting power lines.

2) Potential Transformer ( PT )

A Potential Transformer (PT), also known as a Voltage Transformer (VT), is a specialized type of
instrument transformer designed to step down high voltages to a safe, measurable level for
metering and protection in electrical power systems. PTs are essential in high-voltage transmission
Page | 4
and distribution networks, where direct measurement of high voltage is impractical due to safety
concerns and equipment limitations. By reducing high voltages to standardized values, PTs enable
accurate voltage measurement, power quality monitoring, and relay protection in substations,
switchgear, and industrial applications.

The construction of a PT is similar to that of a power transformer but optimized for precision
rather than power transfer. It consists of a primary winding, a magnetic core, and a secondary
winding, all enclosed within an insulated housing. The primary winding is connected to the high-
voltage side of the power system, while the secondary winding provides a proportionally reduced
voltage output, typically 110V or lower, suitable for standard measuring instruments and
protective relays. The magnetic core, usually made of laminated silicon steel or an amorphous
alloy, ensures efficient flux transfer with minimal energy loss, maintaining high accuracy in voltage
transformation. The insulation system, made from epoxy resin or oil-filled materials, prevents
electrical breakdown and enhances safety in high-voltage environments.

Potential transformers are classified into two main types based on their insulation and
construction: Resin Cast PTs and Oil-Immersed PTs. Resin Cast PTs are commonly used in indoor
switchgear, where compact, dry-type insulation is required. They offer excellent insulation
properties, mechanical strength, and resistance to environmental factors. Oil-Immersed PTs, on
the other hand, are preferred for outdoor high-voltage applications due to their superior cooling
and insulation properties. These PTs are housed in a metal tank filled with insulating oil, which
helps in heat dissipation and dielectric strength enhancement. Additionally, oil-immersed PTs are
equipped with bushing insulators, made of porcelain or polymer composite, to provide safe
electrical connections and prevent leakage currents.

Page | 5
3) Distribution Transformer

A distribution transformer is a crucial component of the electrical power distribution system,

designed to step down the high voltage from transmission lines to a lower voltage suitable for
end-user consumption in residential, commercial, and industrial applications. It ensures that
electricity is safely and efficiently delivered from substations to homes, businesses, and factories.
Typically, distribution transformers operate at voltage levels below 33 kV in India (or 36 kV in
some other countries), with output voltages commonly at 11 kV, 6.6 kV, 3.3 kV, 440V, or 230V,
depending on the requirements of the electrical load. These transformers are classified based on
their insulation type (oil-filled or dry-type), mounting type (pole-mounted, pad-mounted, or
underground), and phase configuration (single-phase or three-phase). Oil-filled transformers use
mineral oil for cooling and insulation, while dry-type transformers use air or resin-based
insulation, making them suitable for indoor or environmentally sensitive areas. The core of a
distribution transformer is usually made of laminated silicon steel to reduce energy losses due to
eddy currents and hysteresis. Copper or aluminum windings are used to conduct electricity
efficiently. One of the critical design aspects is the efficiency and regulation of the transformer,
as energy losses in the form of iron (core) losses and copper (winding) losses affect the overall
system performance. No-load losses (core losses) occur due to magnetizing currents even when
there is no load, whereas load losses (copper losses) increase with the current flow in the
windings. Cooling mechanisms include natural air cooling (AN), forced air cooling (AF), and oil
Page | 6
natural (ONAN) or oil forced (OFAF) cooling, depending on the power rating and application.
Distribution transformers are often equipped with protective devices like Buchholz relays,
temperature sensors, and pressure relief valves to ensure safety and prevent failures. Voltage
regulation is another crucial function, often achieved using on-load tap changers (OLTC) or off-
load tap changers (OLTC), which adjust voltage levels to compensate for fluctuations in the grid.
Efficiency standards for distribution transformers are governed by regulations such as BEE
(Bureau of Energy Efficiency) star ratings in India, aiming to reduce power losses and enhance
energy savings. These transformers are widely used by electricity distribution companies,
industries, and even in renewable energy applications like wind and solar power distribution. The
reliability of a distribution transformer is vital for maintaining stable power supply, reducing
electrical faults, and ensuring the seamless operation of electrical networks. Proper
maintenance, periodic oil testing, insulation resistance checks, and thermal imaging are crucial to
extending the lifespan and efficiency of distribution transformers.

4) Resin Cast And Oil Immersed Transformer

Transformers are vital components of electrical power systems, responsible for voltage
conversion and efficient energy transmission. Based on their insulation and cooling methods,
they are classified into two major types: Resin Cast Transformers (Dry-Type Transformers) and
Oil-Immersed Transformers. Both have distinct characteristics, advantages, and applications,
making them suitable for different operating environments. A Resin Cast Transformer, also
known as a Dry-Type Transformer, is a transformer in which the windings are encapsulated in
epoxy resin insulation, eliminating the need for liquid insulation such as oil. This design provides
excellent dielectric strength, protects against moisture and contaminants, and makes the
Page | 7
transformer highly resistant to fire hazards. Since it does not contain flammable substances, it is
widely used in indoor and fire-sensitive environments such as commercial buildings, hospitals,
underground metro stations, tunnels, and wind or solar power installations. The construction of a
resin cast transformer includes a primary and secondary winding, which are coated with an epoxy
resin compound that prevents electrical breakdown and extends operational lifespan. The core,
made of high-quality silicon steel or amorphous alloy, is designed to reduce core losses and
improve efficiency. One of the key advantages of resin cast transformers is their low
maintenance requirement, as there is no need for periodic oil testing, filtration, or replacement.
Additionally, they are moisture-resistant, making them ideal for highly humid or polluted
environments where conventional oil-based transformers might suffer from insulation
degradation. However, resin cast transformers also have certain limitations, including a higher
initial cost due to the advanced manufacturing process of epoxy resin insulation. They are
typically designed for low to medium power ratings, generally up to 30 MVA, and have a lower
overload capacity compared to oil-immersed transformers, making them less suitable for heavy
industrial loads or high-voltage transmission networks. Unlike oil-based transformers, they rely
on natural air cooling (AN) or forced air cooling (AF), meaning they may require additional
ventilation or cooling fans in high-load conditions to prevent overheating.

On the other hand, Oil-Immersed Transformers are the most commonly used transformers in
high-voltage transmission and distribution networks, industrial plants, and substations due to
their higher efficiency, superior cooling capacity, and ability to handle heavy loads. These
transformers use insulating oil, typically mineral oil or synthetic oil, as both a coolant and an
insulating medium. The oil absorbs heat generated by the windings and core, transferring it to
radiators or cooling fins, where it dissipates into the surrounding air. The construction of an oil-
immersed transformer includes primary and secondary windings submerged in transformer oil, a
core made of laminated silicon steel, cooling tubes or radiators, and a conservator tank, which
allows for oil expansion due to temperature variations. Buchholz relays are installed in oil-filled
transformers to detect gas accumulation, which indicates internal faults such as insulation
breakdown or overheating. Oil-immersed transformers are classified based on their cooling
methods, including ONAN (Oil Natural Air Natural), ONAF (Oil Natural Air Forced), OFAF (Oil
Page | 8
Forced Air Forced), and OFWF (Oil Forced Water Forced) cooling techniques, depending on the
required cooling capacity. The main advantages of oil-immersed transformers include their
higher power handling capacity, better overload tolerance, longer lifespan, and higher efficiency
compared to resin cast transformers. They are suitable for outdoor installations, industrial plants,
high-voltage substations, and renewable energy applications where large-scale voltage
transformation is required. However, oil-immersed transformers also have certain drawbacks,
including a higher risk of fire hazards due to the presence of flammable oil, environmental
concerns related to oil leakage, and higher maintenance requirements, as the oil must be
periodically tested for moisture content, acidity levels, and dielectric strength to ensure reliable
performance. These transformers require additional protective devices, such as explosion vents
and oil temperature monitoring systems, to enhance safety in case of faults.

5) High Voltage (HV) Windings

The HV winding is the coil designed to handle higher voltage levels. It is typically placed on the
outer layer of the transformer core to improve insulation and reduce stress.

Material: HV windings are usually made of copper or aluminum conductors with high dielectric
strength. Copper is preferred due to its superior conductivity and mechanical strength, while
aluminum is used for cost-effective solutions.
Insulation: In resin cast transformers, the HV windings are completely encapsulated in epoxy
resin, which provides excellent insulation against moisture and environmental contamination. In

Page | 9
oil-immersed transformers, HV windings are insulated with high-grade Kraft paper, Nomex
insulation, or oil-impregnated paper.
Cooling Mechanism: In dry-type transformers, HV windings are cooled using natural air (AN) or
forced air cooling (AF). In oil-immersed transformers, they rely on oil circulation for heat
dissipation.

Design: The HV winding is typically designed as disc-type, layer-type, or helical winding,

depending on the voltage rating and load requirements.

Advantages:
High insulation resistance, preventing breakdown at high voltages.
Improved heat dissipation for enhanced efficiency.
Ability to withstand transient overvoltages and surges.
Designed to minimize eddy current losses and improve overall transformer performance.

Common Voltage Ratings:

11 kV, 22 kV, 33 kV, and above for distribution and power transformers.

6) Low Voltage (LV) Windings

The LV winding is designed to handle lower voltage levels and is typically placed closer to the
transformer core to reduce leakage flux and enhance efficiency.

Material: LV windings are made of copper or aluminum conductors, with copper being
preferred for high-efficiency applications.
Insulation: In dry-type transformers, LV windings are coated with resin or varnish for enhanced
protection. In oil-immersed transformers, they are insulated using pressboard, Nomex, or paper
insulation.
Cooling Mechanism: LV windings rely on air cooling (in dry-type transformers) or oil cooling (in
Page |
10
 oil-immersed transformers).
Design: The LV winding can be helical, foil, or layer-wound, depending on the current capacity
and transformer size.

Advantages:
High mechanical strength to withstand short-circuit forces.
Low resistance, minimizing energy losses.
Designed for high current carrying capacity.
Effective insulation ensures durability and reliability.

Common Voltage Ratings:

415V, 690V, 1.1kV, and 3.3kV for industrial and commercial applications.

7) Auxillary Components Used In Transformer Manufacturing

1. Insulating Tape & Insulating Paper

Insulating tape is a protective material used to cover and insulate electrical conductors,
preventing short circuits, electric shocks, and environmental damage. It is widely used in
transformer manufacturing, wiring, and electrical repairs.

Types of Insulating Tape:

1. PVC (Polyvinyl Chloride) Tape – Most commonly used, flexible, and resistant to moisture and
corrosion.
2. Rubber Tape – Provides excellent insulation in high-voltage applications and is self-fusing.
3. Glass Cloth Tape – Used in high-temperature applications (up to 200°C) due to its heat-resistant
properties.
4. Mastic Tape – Soft, stretchable tape used for sealing and waterproofing joints.
5. Polyester Film Tape – Used in electrical motors and transformers for coil insulation.

Applications in Transformers:

Page |
11
Wrapping windings to prevent direct electrical contact.
Providing additional mechanical strength to insulated conductors.

Insulating Paper

Insulating paper is a specially designed dielectric material used in transformers, capacitors, and
electrical cables to provide electrical insulation and mechanical support.

Types of Insulating Paper:

1. Kraft Paper – Made from wood pulp, commonly used in oil-filled transformers.

2. Nomex Paper – A high-temperature-resistant synthetic insulation material used in dry-type

transformers.

3. Pressboard Paper – A dense, rigid paper used for insulation between transformer windings.

4. Crepe Paper – Flexible and stretchable, used for insulating transformer leads and bushing
areas.

Applications in Transformers:
Layer insulation between primary and secondary windings.
Insulating conductors and terminals to prevent arcing.
Acting as an oil-absorbing medium in oil-immersed transformers to enhance dielectric strength.

2. Cooling Fans & Radiators

Cooling fans are used in transformers and electrical systems to dissipate excess heat generated
during operation. Overheating can degrade insulation materials, reducing transformer efficiency
and lifespan.

Types of Cooling Fans:

1. Axial Fans – Compact and efficient, commonly used in dry-type transformers and switchgear.

2. Radial Fans – Used in large power transformers for uniform air circulation.

3. Forced Air Cooling (ONAF – Oil Natural Air Forced) – Uses high-power fans to accelerate cooling
in oil-filled transformers.

Applications in Transformers:
Used in dry-type and oil-cooled transformers to regulate temperature.
Enhancing natural convection to prevent overheating.
Activated automatically when transformers exceed preset temperature limits.
Page |
12
Radiators

Radiators in transformers are metallic heat-exchanging devices designed to cool the transformer
oil by increasing its exposure to ambient air.

Types of Radiators:
1. Tubular Radiators – Consist of vertical tubes that allow oil circulation and heat dissipation.

2. Finned Radiators – Have metal fins to increase the surface area for better heat exchange.

3. Pressed Steel Radiators – Common in large transformers, designed for efficient thermal
management.

Applications in Transformers:
Used in oil-immersed transformers to cool transformer oil.
Ensuring optimal thermal regulation to prevent insulation degradation.
Working with fans and oil pumps in high-load conditions.

3. Protective Relays & Fuses

Protective relays are automated electrical devices that detect faults in a power system and trigger
circuit breakers to isolate faulty sections, preventing damage to transformers and electrical
networks.

Types of Protective Relays:

1. Electromechanical Relays – Operate based on electromagnetic forces (used in older systems).

2. Static Relays – Use solid-state electronics (faster response than electromechanical relays).

3. Digital & Numerical Relays – Use microprocessors and software algorithms for advanced fault
detection.

4. Differential Relays – Compare current between primary and secondary windings to detect
internal faults in transformers.

5. Overcurrent Relays – Activate when current exceeds a preset limit, protecting against short
circuits.

6. Buchholz Relay – A gas-operated relay that detects internal transformer faults in oil-immersed
transformers.

Page |
13
Applications in Transformers:
Detecting short circuits, overloads, ground faults, and overheating.
Ensuring transformers shut down before severe damage occurs.
Integrated with SCADA systems for remote monitoring and control.

Fuses are sacrificial protection devices designed to break the circuit when excessive current flows
through them, preventing equipment damage due to faults.

Types of Fuses:
1. High Voltage (HV) Fuses – Used in substations to protect power transformers.

2. Low Voltage (LV) Fuses – Installed in switchgear and control panels.

3. Cartridge Fuses – Cylindrical fuses with metal end caps, used in industrial applications.

4. Drop-Out Fuses – Mounted on overhead power lines to protect transformers from lightning
strikes and surges.

5. Current Limiting Fuses – Designed to break the circuit rapidly, limiting short-circuit currents.

Applications in Transformers:
Installed on both primary and secondary sides to protect against overcurrents.
Used in HV and LV distribution transformers to prevent catastrophic failures.
Provides a cost-effective protection mechanism in power grids.

Conclusion :

The visit to Koyna Engineers Pvt. Ltd. in Nashik was an enriching and insightful experience,
providing a deep understanding of transformer manufacturing, testing, and quality control
processes. As aspiring electrical engineers, we had the opportunity to witness firsthand how
distribution transformers, current transformers (CTs), and potential transformers (PTs) are
designed and produced to meet industry standards. The visit helped bridge the gap between
theoretical knowledge and practical applications, reinforcing concepts related to power
distribution, voltage regulation, and transformer efficiency. Observing the fabrication process,
core assembly, winding techniques, and insulation methods highlighted the precision and
expertise required in transformer manufacturing. The company’s adherence to ISO 9001:2008
quality standards, along with rigorous testing protocols at NABL-accredited labs, demonstrated
the importance of maintaining reliability and efficiency in electrical equipment. Additionally,

Page |
14
learning about Bureau of Energy Efficiency (BEE) star ratings, loss minimization techniques, and
protective devices like Buchholz relays and pressure relief valves enhanced our understanding of
modern advancements in transformer technology. The interaction with experienced engineers
and industry professionals provided valuable insights into career opportunities in power
distribution, transmission, and electrical engineering research. The visit also highlighted the role
of companies like Koyna Engineers in supporting major power utilities, railways, defense sectors,
and private industries, emphasizing the significance of electrical infrastructure in national
development. Overall, this industrial visit was an eye-opening experience, reinforcing our
passion for electrical engineering and motivating us to explore innovative solutions for future
challenges in power systems and energy efficiency.

Page |
15