OUR DESIGN PRINCIPLES
We ensure ZERO percent
rejection of our transformers in
third party testing.
Our unique computer aided design tool & over 20 years of experience enable us to develop electrical & mechanical design of transformers with quality along with better efficiency. Transformers are designed as per latest national & international standards (IS/IEC etc.) & keeping customer requirements in focus. This ensures ZERO percent rejection of our transformers in third party testing.
Unique Design Process which involves -
- Requirements Analysis: Identify specifications based on application needs , including voltage , ratings , and environmental conditions. Consider factors like efficiency, temperature rise, and regulatory compliance.
- Use of suitable grade of Electrical steel (CRGO) which ensures optimal magnetic properties & low iron loss.
- Choose winding arrangement (e.g., concentric, layer, or disc) to optimize space and minimize resistance.
- Liberal electrical clearance that ensures Higher Dielectric Strength & Longevity of transformer.
- Overall robust design to handle electrical, mechanical as well as thermal stresses ensuring maximum efficiency
Core Assembly
Core is designed & built with prime silicon lamination. Grade is selected as per required value of no load loss.
Step lap design with full metered joints is used to ensure minimum building factor which ensures minimum air gap, low noise & optimum flow of magnetic flux. After raising the core test turns are applied & No Load Loss is recorded. Insulation test for core bolts.
Use of BIS certified prime CRGO steel
Step lap core assembly with miter joints to ensure minimum air
gap & optimum flow of magnetic flux.
Control Point :
1. Measure core window dimensions, diameter a stack.
2. Testing of ready assembly for designed No-Load Loss.
WINDING: L.V. & H.V.
Use of purely electrolytic grade Aluminium / Copper conductor with high insulating grade paper of fiber glass covering.
Designed to withstand compressive radial forces under short circuit condition.
Cross over, Layered, CTC & Continuous disc type winding as per requirement.
I.D. & O.D. is confirmed
Control Point :
1. Conduct resistance tests on windings to detect faults and verify
design specifications.
2. Designed with great mechanical strength to withstand short
circuit forces & electrical strength to withstand over-voltage
conditions.
Core Coil Assembly & Tanking
The core-coil assembly process in transformer manufacturing is a
critical step that ensures the efficient operation and reliability of
the transformer. It is done with precision alignment for mechanical
stability. Insulation of extremely high density is used to withstand
axial & radial forces while in service.
achieved in such way that it withstands axial forces & radial forces
generated in short circuit conditions.
Control points :
1. Electrical Testing: Conducting insulation resistance and turns ratio
tests after assembly to verify performance and safety.
2. Dimensional Checks: Ensuring that all components meet design
specifications through precise measurements
Fabrication
Tanks are fabricated from low carbon High-Strength M.S. material
after precisely cutting using CNC plasma machine. Welding is
done by CO2 welding machine with strong stiffeners to withstand
pressure. All tanks are then pressure tested for possible leakage.
Cooling is provided either by pressed steel type radiators or
corrugated radiator panels with safe correction factor. After
surface cleaning, tanks are then painted internally with heat & oil
resistant paint/varnish & externally with two coats of polyurethane
paint after applying one coat of epoxy red oxide
Testing
Before declaring a readiness of the transformer for service, it undergoes a series
of rigorous tests categorized as Routine Tests as per IS 2026 using industry best
test equipments
Our various ratings of (including 2500 kVA, 33kV) Distribution Transformers are Type Tested at NABL accredited Labs like CPRI, ERDA & ERTO.
