Manufacturing Process

Winding

Features: All windings are made by experienced and qualified winders with at least 2 years of experience.

Dry type windings are made on fibre glass mandrels to ensure there is no inadvertent tearing of the insulations.

All windings are designed to withstand short circuit and to minimize copper usage.

Windings are made using either copper or aluminium, and can be offered for oil filled transformers, VPI dry type transformers or cast resin transformers.

Core Assembly

Features: Core used is grain oriented steel and manufactured and designed considering the Step Lap method, including mitred joints.

Using optimal design and manufacturing, air gaps are reduced between yokes and legs for reducing noise &losses.

Core is bound to reduce noise & losses.

Core is sourced from quality vendors to achieve best quality as well as ensure long life. Each core is inspected and losses measured PRIOR to next process.

Core Coil Assembly

Features: Windings are taken after consolidation and placed on individual limbs of cores.

Proper insulation scheme, spacers and routing of cables ensured.

Reblading, brazing of busbars and final fitting completed.

Core coil assembly is dried for over 12 hours at upto 105 degrees, until completely dry.

33kv and above are processed under vacuum.

Final Assembly

Features: Fully dried and consolidated core coils are taken and inserted into tanks.

After tightening, fixing and cover closure, fittings and accessories are mounted.

Tanks are pressure tested for 4 hours in Hot Oil Condition.

Transformers are painted and paint thickness is checked and maintained.

Custom painting system according to customers requirements are offers in Epoxy, Hot Zinc Spray, Powder Coating and Polyurethane.

Testing and Inspection

Features: All transformers are tested in our Lab to National and International Standards ( IS : 2026, IEC 76, etc. ) And IS 1180(Part I 2014).

• Voltage ratio
• Winding resistance
• Impendence voltage
• No load current
• Dielectric tests
• Noise level measurement
• DGA - Dissolved Gas Analysis for testing oil
• Harmonic measurement and analysis
• Temperature rise test plant
• Vacuum and pressure test plant
• Oil test facilities

Specific type tests at approved laboratories can be offered such as Measurement of zero sequence impedance

• Lighteningimpulse test
• Dynamic short circuit test