KAILASH TRANSFORMERS PRODUCTION & SALES

Production department

Production is the process by which, raw material and other input are covered into finished products. The other word for production is manufacturing.

PRODUCTION

To ensure the best quality of the Coils of the transformer, winding wires and strips are also manufactured in house. Fabrication section ensure the robustness, quality and fine finish of the tank and radiators of the transformer.

Distribution Manufacturing process

The manufacturing process of transformer cover the following departments.

1. Coil winding (LV & HV)

2. Core Assembly

3. Core-Coil Assembly

4. Moisture removing of oil

5. Moisture removing of transformer

6. Transformer Tank

7. Painting and Finishing

8. MIS (Testing section)

1) Coil Winding is of two types:-

a) High Voltage Coils: H.V. Coils are the components of finished transformers. They are made on automatic layer setting winding machines.

· A solid cylindrical former of predetermined diameter and length is being used as hase over which is made.

· Generally round insulated wire of either copper (Cu) or Aluminium (Al) is used as basic raw material.

· The coils are made in number of layers.

· The starting and finishing leads of each coil are terminated on either side of the coil.

· These leads are properly sleeved and locked at number of points.

b) Low Voltage Coils:

· L.V. Coils are also one of the components of transformer. The procedure of making low voltage coil is generally same as described earlier.

· The shape of the basic raw-material (Al or Cu) is rectangular.

The Test: The "Turn Test" is carried out on the H.V. Coils as per the specifications.

2) Core Assembly

• The basic raw-material is COLD ROLLED GRAIN ORIENTED (CRGO) Silicon Steel
• It is in the form of thin sheets & cut to size as per design.
• Generally three different shapes of core laminations are used in one assembly.
• Notching is performed to increase the magnetic path.
• The laminations are put through annealing process.
• These laminations are assembled in such a manner that there is no air gap between the joints of two consecutive sheets.
• The entire assembly is done on a frame commonly known as core channel. These frames being used as a clamping support of the core assembly.

3) Core-Coil Assembly

• The components produced in the coil winding and core assembly stage are then taken into core-coil assembly stage.
• The core assembly is vertically placed with the foot plate touching the ground. the top yoke of the core is removed. The limbs of the core are tightly wrapped with cotton tape and then varnished.
• Cylinder made out of insulating press board/ pressphan paper is wrapped on all the three limbs.
• Low Voltage Coil is placed on the insulated core limbs.
• Insulating block of specified thickness and number are placed both at the top and bottom of the L.V.Coil.
• Cylinder made out of corrugated paper or plain cylinder with oil ducts are provided over L.V.Coil.
• H.V. Coils are placed over the cylinder.
• Gap between each section of H.V. Coils including top & bottom clearances is maintained with the help of oil ducts, as per the design/drawings.
• The Top Yoke is refilled. Top core frame including core bolts and tie rods are fixed in position.
• Primary and secondary windings are connected as per the requirements. Phase barrier between H.V. phases are placed as per requirement.
• Connections to the tapping switch (if required) are made.
• Finally, the component is placed in the oven.

4) Moisture Removing of Oil:

In this department the transformer oil which is brought from the railway tank is supplied to ovening machine in which the access moisture of the oil is removed by heating with suitable temperature.

5) Moisture removing of Assembly:

In this section the whole assembly before being tank up the moisture is removed by keeping the whole assembly into heating chamber at suitable temperature, for suitable period depending upon the atmospheric condition.

6) Transformer Tank:

We have a state-of-art in-house facility for manufacturing transformer tanks.

All tanks are made of high quality steel and can withstand vacuum as specified by the international standards and the customer. All welds are tested, ensuring 100% leak proof of seems and mechanical strength. Transformer with Corrugated Fin-Type radiators can also be supplied. The fins are manufactured of Gold-rolled steel. The fin height and length are according to customer's specifications and fins can be plain or embossed. All transformer tanks are given a smooth finishing by using the "SHOT BLASTING" process.

7) Painting and Finishing:

a) Painting

The entire procedure of painting is done under two stages:

1. Cleaning of tanks

· The cleaning of tank is done normally by chipping/grinding.

· The outside surface of the tank is short blasted to achieve a very fine and smooth finish

2. Painting of tanks

· After cleaning the tanks, a coat of hot oil resistence paint is applied on the internal surface of the tank.

· The outside surface is painted with a coat of Red Oxide primer and subsequently with one coat of enamel paint as per customer's requirement.

b) Finishing

· Fittings and accessories as per customer's specification and drawing are checked.

· Air Pressure test is subjected to avoid any leakage and seepage on all transformer.

· Transformers are filled with oil upto the minimum level marking, wherever necessary.

· Loose accessories like, earthing terminals, bimetallic connectors, dial type thermometers are also checked for proper fittings.

8) MIS (Testing Section) :

In this section the distribution transformer is tested by using megger and other computerized machines. From this test we will able to know easily the quality and condition of distribution transformer.

MARKETING

Marketing is the “process of planning and executing the conception, pricing, promotion and distribution of ideas, goods and services to create exchanges that satisfy individual and organizational goals”.

The organization has covered market area comprising of whole North Karnataka covering Gulbarga, Raichur, Koppal, Bellary, Bijapur, Dharwad, Belgaum cities (Districts).

Marketing department is responsible for monitoring of commercial marketing and its components. It is responsible for allowing activities:

Ø Market analysis and planning

Ø Product analysis and competition analysis, knowing customer satisfaction, regular customer interaction.

Ø Price updating

Ø Authority and responsibility of marketing manager

Functions of marketing department:

Price fixation:

Price fixation is done on basis

Ø Comparing of other competitors

Ø View marketing conditions

Ø On the tender basis

Sale Promoters:

Performs certain functions like

Ø Price fixation

Ø Timely disposal of stocks

Ø Timely collection of payments

The marketing department of this organization mainly concerned with marketing promotion activities, distribution networking, marketing research activities and handling consumer grievance.

Sales: Classified

Ø Government Tenders

Ø Private tenders

Distribution Situation:

Distribution takes place through government tender, private tender and unit sale depending on the customer requirement.

Product situation:

There are various types of distribution transformer, whose output ranging from 25 Kv to 250 Kv.

Advertising:

Is any paid form of non – presentation and promote the ideas, goods as services by an identified sponsor. Organization handles their advertising by some one in the sales or marketing department who works with an advertising department who works with an advertising agency.

Modes of Advertising:

1. Wall paintings

2. Stickers

3. Telephone Index

4. Calendars and Diaries

5. Girt Articles (pens, diaries, wall-clocks cash bags) etc.

SALES AND DISTRIBUTION

The Distribution transformer of Kailash is not selling their products through distributors. They are selling only (by) through the where ever the government and private tenders issued and also unit selling depending on the customer requirements.

The kilowatts are selling the customer prescribed data on their tenders are taken by the industry.

The industry sale various ratings of the distributin transformer as shown in the table for the year 2005-2006.

KV Ratings	Approximate Sale of Unit per annum	Price (Excluding Tax)
25 KV	2,500	42,500=00
60 KV	5,000	85,000=00
100 KV	500	1,05000=00
250 KV	300	1,85,000=00

QUALITY:

Each and every transformer undergoes routine tests as per requirement:

In accordance with ISO: 9001:200 AND NABCB & ICS following tests are carried out on finished transformer as per sequence

Routine Test conducted on all transformers

1. Measurement of Insulation resistance.

2. Measurement of Voltage Ratio and Check of Voltage Vector Relationship

3. Separate source voltage withstand Test

4. Induced Over – voltage withstand Test

5. Measurement of No load Loss and Current

6. Measurement of Impedance Voltage/Short Circuit Impedance and Load Loss

7. Measurement of Winding Resistance

8. Unbalance Current

9. Oil Dielectric Test

10. Temperature Rise Test

11. Air Pressure Test

12. Vaccum Test

13. Oil leakage test.