April 12,2025 By T Power
April 12,2025 By T Power
At T Power, the manufacturing of a power transformer is a highly sophisticated process involving precise engineering, advanced machinery, and strict quality protocols. The journey begins with the design stage, where our engineering experts define all technical specifications, including capacity (kVA), voltage ratio, phase type, insulation level, and core material.
Once the design is finalized using advanced software like AutoCAD and electrical simulation tools, the actual production kicks off.
The transformer core is made from high-grade, cold-rolled grain-oriented (CRGO) steel. Sheets are cut using CNC machines to ensure precision. These sheets are then stacked and clamped tightly to reduce core losses and optimize magnetic performance. At this stage, the core’s size and structure directly affect efficiency and load handling.
Windings are the heart of a transformer, and we take meticulous care to ensure perfection. Depending on the type of transformer, either copper or aluminum conductors are wound on precision machines in a layered or disc pattern. Proper insulation materials like Kraft paper or Nomex are used to ensure safety and long life.
Every coil is tested for turns ratio, resistance, and dielectric strength before moving to the next stage.
The windings are carefully placed around the core with perfect alignment. The entire assembly is clamped under pressure to minimize vibrations and losses. Epoxy resins or vacuum drying processes are applied depending on the transformer type—oil-filled or dry-type.
In oil-filled transformers, the core-coil assembly is inserted into a tank made of mild steel. It’s then vacuum dried to eliminate any trapped moisture. High-grade insulating oil is filtered and filled into the tank under vacuum to prevent oxidation and enhance cooling.
We use high-end filtration and degassing systems to ensure the highest oil quality before sealing the unit.
This is the most critical part of the transformer manufacturing process. Each transformer goes through stringent routine, type, and special tests as per IS 2026, IEC, or ANSI standards. Some of the key tests include:
Insulation Resistance TestOnly after passing all these tests is a transformer approved for dispatch.
The tank is painted with a high-quality anti-corrosive coating using powder coating or spray-paint techniques. It is then fitted with accessories such as conservator tanks, Buchholz relays, breather units, and control panels. Nameplates, serial numbers, and test certificates are affixed at this stage.
Each transformer is packed carefully to prevent transit damage. For exports, wooden crates, bubble wraps, and vacuum sealing are used as per international standards. GPS-based tracking is enabled for real-time monitoring of logistics.
T Power offers annual maintenance contracts (AMC), periodic servicing, oil testing, and condition monitoring. Our responsive after-sales team is equipped to handle emergencies, repairs, and upgrades nationwide.
We provide smart grid-ready transformers embedded with IoT sensors, remote control units, and performance dashboards. These transformers integrate seamlessly with solar plants, wind farms, and hybrid renewable setups—making T Power a key contributor to India’s green energy mission.
Our products meet CE and IEC standards, making them suitable for international clients. T Power exports transformers to the Middle East, Africa, and Southeast Asia. Clients across borders appreciate our commitment to durability, safety, and performance.
We are among the first in the transformer sector to implement Digital Twin technology. Real-time simulation, data capture, and predictive analytics help improve performance and longevity. Our Industry 4.0 compliant plant ensures minimal errors and high automation in manufacturing.
T Power’s mission goes beyond manufacturing. We aim to power India with sustainable, reliable, and intelligent energy solutions. Whether it’s powering rural schools or massive data centers, our transformers are silently working behind the scenes to keep the nation energized.
We welcome partners, clients, and students to visit our advanced manufacturing facility and experience our process firsthand. To book a site tour, request a quote, or get technical advice, contact us today.
At T Power Transformer, we don’t just build transformers—we build trust. With a combination of world-class technology, skilled manpower, and customer-centric values, we aim to remain a top transformer manufacturer in India. From ideation to installation, you can count on T Power for excellence at every stage.
Want to know more? Call us, write to us, or visit our official website to explore our wide range of power solutions.
