On arrival the transformer is unloaded with the help of 150 MT EOT Crane.

After unloading, the Transformer is inspected thoroughly by our team of Engineers & Supervisors. Any damages/ discrepancies/ shortages observed are noted down and communicated to the client immediately.

#1. Burned Winding of Transformer Received for Repairs.

All the accessories (OLTC, WTI's, OTI's, Bucholz relay, OSR's etc...) of the transformer are neatly dismantled and again examined, these parts are neatly stored so that they can be used or replaced by new ones if found to be faulty.

#2. Dismantled Winding of a Transformer. Kept for inspection.

The winding of the transformer are carefully scrutinized. This is the place where the faults normally uncover. The HV & the LV windings are separately analyzed. Our designer is Mr. R. C. Nandankar who has experience of over 40 years in the field of transformers. He takes down the relevant data which he needs to ascertain the cause of the fault of the transformer. Once the fault of the transformer is ascertained the designer goes through the windings and other details provided to us by the customer. If there is a fault in the design of the transformer it is documented. Then our designer tries to rectify the faults with his own design.

#3. Drawing & Design Department.

Accordingly the designer makes the specification sheets for the winding of the transformer. While making the specification sheets it is always seen to it that the design is of the most up-to-date type and there is no compromise on the quality of the windings.

The amount and the size of copper, paper and insulation material which is required are then ascertained. Premium quality of copper is procured for this purpose. After the delivery of the copper, it is specifically examined for its quality. The roundness of edges, its current carrying capacity, resisitivity, softness, malleability and ductility are proper gauged.

The paper which is utilized by us is of international standard, once the paper is procured it is also put through rigorous tests and then it is given for slitting. This slit paper is then used for Paper Covering of the copper.

We have a modern 9 layered, 2 HP, 960 RPM paper covering machine for paper covering of rectangular copper conductors. The insulation materials (Paper boards, Kraft Paper, Wooden Blocks etc…) are procured of the finest quality. These materials are again tested on delivery.

We have indigenously made machines to cut our requirement of insulation material so that quality is not compromised.

The specification sheet is handed over to our winding section. Our winding section is administered by Mr. C. N. Sawant with an experience of over 43 years and ably assisted by Mr. B. G. Pandre (Supervisor Winding Department, 14 years+ experience). Our winding department boasts of highly skilled workers with an average experience of more than 12 years.

#4. Winding in Progress.

These highly skilled workers are well trained and competent to do the most complicated of windings. Our winding quality has been acknowledged and appreciated by our clientele and even by our own competitors. We have 5 Nos of horizontal winding machines of 20HP, 1440 RPM and 10 Nos of formers of different sizes capable of winding coils of inside diameter 500mm onwards to winding coils of inside diameter of 1500mm. Electrical brazing of copper is accomplished with a 7.5KVA transformer, current capacity of 1200 Amps, there are 5Nos. of transformers of this kind which are indigenously made.

We have 5Nos indigenously manufactured hydraulic operated mechanical benders to bend copper conductors up to 15mm thick.

There are 2 Nos. Electrically Operated Over Head cranes with a maximum capacity of 15MT. These overhead cranes are used for loading/unloading of coils on the winding machine and also by the Assembly Department.

There are checklists provided for each winding so that they are properly scrutinized at different stages. Once the windings are completed they are inspected by our supervisors and/or by the representative of our client.

#5. Assembled Coil.

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After the winding of the coils, comes the assembly stage, we have a proficient group of workers to take care of assembly and these people are managed by our works manager.

We have Mr. Dinesh Kewale who has over 15 years of experience in this field as our works manager who is ably assisted by Mr. K. A. Mote (Supervisor - Assembly Department, 16 years+ experience).

We employ the latest technology to assemble the coils. Our plant is fully equipped to handle the most gigantic of coils which come in for assembly.

For the assembly of coils we have a high-tech Hot Air oven which can go to a maximum temperature of 120oC and one smaller oven of 18KW. For pressing of coils we have a Hydraulic Press which can exert pressure of up to 200MT.

Equipped with this machinery the assembly of the coils is seamless completed by our workers. After the assembly of coils it is tested by our testing department. Here the preliminary tests like V/T ratio, conductivity etc... are conducted on the individual coils of the transformers before the coils are assembled to form a whole unit.

#6. Coil Pressing Process Under 200MT Hydraulic Press.

#7. Core Assembled.

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After these preliminary tests the coils are taken in for final assembly. The core of the transformer is examined.

If the core is found to be intact it is used as it is. If found to be damaged the designer is notified about it. The designer then according to the design of the transformer decides what amount and dimension of CRGO will be required and necessary actions are taken to procure the highest quality CRGO for building up of the Core.

After the delivery of the CRGO, it is tested for its flux carrying capacity, grain orientation, malleability and ductility. Then the core is cut and mounted on its frame. Care is taken so that the core is properly build up and there are no incongruities while building up of the core. Then the coils are carefully mounted on these cores.

To aid the final assembly of the coil we have an Electrically Operated Over Head Crane with a capacity of 100MT and a smaller Crane with geared trolley with a capacity of 15MT. Then after the assembly of the coils and core it is again tested for V/T ratio, conductivity, coil to coil meggar, coil to core meggar etc..

#8. Complete Core & Winding Assembled.

#9. Vacuum Oven Plant.

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