Manufacturing Process – kvatransformer.com

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Transformers Technology & Design

At kVA Process Transformers Pvt. Ltd., with over a decade of experience, our expert team delivers optimized, reliable, and cost-effective transformer designs that meet evolving market demands. We adhere to international standards such as BIS, IEC, BS, ANSI, and NEMA, ensuring full compliance and interoperability.

Using advanced CAD technology, we provide fast design reviews and supply final drawings digitally and in print upon request. Our designs comprehensively address key electrical and mechanical parameters, including losses, impedance, temperature rise, and pressure withstand capabilities.

Windings

Our transformer windings are designed for optimal mechanical, thermal, and electrical performance. Made from high-conductivity electrolytic copper with paper insulation, they meet both Indian and international standards.

Skilled technicians wind the coils in a dust-free, temperature-controlled environment. Cooling ducts (axial & radial) minimize hot spots and prolong insulation life.

Techniques like conductor transposition improve current distribution and reduce losses. Low-voltage windings use multi-layer coils for high current, while high-voltage windings feature durable disc coils for stress resistance.

Interleaved designs enhance voltage distribution and impulse handling. Coils are pressed, clamped, oven-dried, and oil-impregnated for superior short-circuit strength and thermal performance.

Core Construction

The transformer core is vital to performance, and we use premium Cold Rolled Grain Oriented (CRGO) silicon steel to ensure low losses and high efficiency. Laminations are precisely cut to minimize air gaps and maximize magnetic flux flow.

We select core materials and construction types—such as butt-lap, miter, or step-lap miter—based on loss requirements. Laminations are burr-free, fully annealed, and coated to reduce eddy currents. Their thin profile (0.23–0.27 mm) ensures low noise and excitation current.

Core &
Coil Assembly

At kVA Process, we use high-grade precompressed pressboard and kraft paper (as per IS:1576) for insulation, along with Permali wood for added mechanical strength. Insulating materials are tested for high dielectric performance.

LV windings are placed near the core over insulating cylinders with oil ducts, while HV windings are co-axially assembled with LV windings. ‘T’-shaped spacers ensure added firmness, and densified wood rings provide precise coil alignment. Angled rings between LV and HV windings help reduce voltage stress.

Flexible, insulated copper leads connect all windings and are securely braced. Our coil designs are tailored for each application, using thermally upgraded paper for extended insulation life—ensuring maximum efficiency & durability.

Tank Construction

All our tanks are fabricated with high grade tested mild steel. The design of the tanks incorporated adequate wall & thickness so as to withstand the pressure build up in the tank.

Protection of active part in transformer is very important. While achieving the optimized size of transformer to suit the site condition for installation. The role of the tank is to protect the active part and tank is manufacture to have sufficient strength to withstand internal & external faults that may occur during operation. Tanks are fabricated from low carbon M.S. Sheet of best quality by qualified welders. The tank is designed to withstand vacuum and pressure test as per Indian/International standards.

Each transformer tank is tested for leakage by filling them with oil and keeping then under pressure of 0.5 KG / Cm2 or above for several hours. With this test even minute leaks are detected.

Cooling System

kVA Process designs and manufactures transformers with various cooling methods based on customer requirements and site conditions.

ONAN: Uses pressed steel radiators for natural air cooling, offering a large surface area for effective heat dissipation.

ONAF: Adds cooling fans near radiators to enhance airflow and cooling efficiency.

OFWF: Uses heat exchangers, oil pumps, and flow/pressure meters for water-cooled systems, ideal for high-load conditions (up to 150%).

OFAF / AN: Other systems like OFAF and AN are available as per specific needs.

Transformer Oil

We use premium-grade insulating oil to ensure optimal performance and longevity of our transformers. Selected for its low viscosity and high oxidation resistance, the oil efficiently dissipates heat and minimizes sludge and acid formation.

Each batch ensures rigorous testing for moisture content, dielectric strength, and chemical stability, in full compliance with IS: 335/1993 standards. We primarily use TRANSOL EHV oil by SAVITA, a trusted brand known for its purity, stability, and suitability for extra high voltage applications.

Testing Facilities

At kVA Process Transformers Pvt. Ltd., our state-of-the-art testing laboratory is equipped with advanced digital and computerized instruments to perform routine tests on transformers up to 25 MVA and 132 kV in accordance with IS and IEC standards.

We conduct the following precise tests:

Winding Resistance Measurement
Voltage Ratio and Vector Group Verification
Impedance Voltage and Load Loss Measurement
No-Load Loss and Excitation Current Measurement
Insulation Resistance Measurement
Dielectric Strength Test
On-Load Tap Changer (OLTC) Testing, where applicable

All tests are managed via a centralized control panel to ensure accuracy and reliability. Our strict quality protocols guarantee that every transformer meets the highest standards of performance, safety, and dependability.

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kVA Process Transformers Pvt. Ltd. is a leading transformers manufacturing company in India. We are a proud established manufacturer of [Submerged Arc Furnace, Electric Arc Furnace, Ladle Refining Furnace, Induction Melting Furnace, and Power & Distribution] TRANSFORMERS of various types, grades and capacities.