Our Products

Our manufacturing facilities are located in Hyderabad. Power transformers up to 63 MVA 132 KV Class are regularly manufactured and supplied. Tejaswini is equipped to manufacture transformers with a wide range of internationally recognized standards such as:

✔ Unitised substation comprises of the following main components

✔ Vacuum Circuit Breaker Panel in outdoor enclosureup to II KV.1 250 A complete with CT / PT Relay & Instrument Chamber.

✔ The outdoor circuit breaker panel is directly coupled to HT -Flange of the transformers with Copper Bus Bars.

✔ The incoming of the HT panel is provided either with plug socket or cablebox. Alternatively a Load Break Switch or Ring Main Unit (RMU)

Can also be coupled with the HT bushing of the transformer.

Outdoor transformers are manufactured up to 1600KVA, 11KV, -6.6KV-3.3 KV /415 KV DYII ONAN with off loadtap changing switch and standard fittings as per IS, incoming HT panel and LT Flange to outgoing LT Panel. The Transformers can be either oil-immersed type Or Dry type with nomex insulation. With dry type transformers the total unit can be housed in single outdoor type enclosures in place of three separate Enclosures.

Setting high Standards as a consistent guarantee of the highest quality the company have achieved ISO 9001 certification for all its transformers. Regular internal and external quality audits ensure full and continuos conformity with the international standards. The company's material and components suppliers are also required to satisfy these ISO standards

Quality control is earned out a teach stage of production on a self-assessment basic. Each employee regards the next workstation as his customer and performs a series of quality checks before passing on a product down the line. The quality development department monitors all qualitycontrol documents and carries out its own additional inspection at strategic points in the production process. This system of checks and counter checks allows immediate action to be taken and modification to be made as required. All transformer tanks are tested before being released.to the customer. Testing includes leakage test and pressure test

Winding Connections

Tapping and phase leads are run in paper-covered conductors. the phase leads being separated from the tapping leads by adequate barriers. These tubes are rigidly brazed to ensure that required clearance from coil to tank is being maintained. L.V.Leads. larger in cross section, arc generally sufficient robust. but where necessary supports are provided.

Tank Construction

All tanks are made from mild sheet of adequate thickness with pressed steel fins cooling tube for heat dissipation. All tanks are checked by magna flux ultraviolet ray die penetrating system to ensure that there is absolutely no leakage from any part of the tank.

Quality Finish Through Use Of Shot

Blasting Technology

Tanks are shot blasted/ Grit blasted to remove mill and welding scale and then a primeary coat is immediately applied to the exterior to eliminate rust formation. After priming all tanks receive a coat of high gloss paint, applied by spray. This ensures high coverage helping to combat corrosion in inacceSSible places.

Insulation And Impregnation

The principal component of insulation is insulating Pre-compressed Press Board. The Components like rings, duct , dovetailed spacers, blocks etc are put under Compression along with the coil assembly for pre-shrinking . Providing additional insultation compensates the slight recovery

This reduces Ihe probabilily of coils getting loose during operation an also minimizes the failure due to circuit forces.

In Order to prevent deformation under short-circuit forces, solid insulator end blocks and rings are used. Windings are compressed under top and bottom clamping members with the help of tie rods. The axial end thrust under fault Condition is minimized by the suitable balance to the ampere-turns over the length of windings. In case of bigger transformers, the HV taping leads are taken out from two positions to balance the short circuit forces in a much better way. At Tejaswani each and every component used in transformer undergoes a series of stringent checks and controls at each stage of manufacturing and it is ensured that strict technical & qualitative specifications are adhered to Utmost care is taken while manufacturing and assembling every component of a transformer. The main process line of a transformer is:

Core

The core is constructed from lamination of imported Cold Rolled Grain Oriented (CRGO), low loss electrical steel. The cores are assembled in jigs prior to tapping and clamping in a manner that reduces vibration and inherent varnish, which is both oil and heat resistant and complete core isconnected to the clamps to ensure that it is effectively earthen.

The Core legs are surely bound with heavy duty insulating tape and the yokes are firmly clamped between folded steel channels. Tops & bottoms clamps are secured to each other by means of tie rods which serve the dual purpose of securing the windings in the place and of transferring the load form the bottom to the top clamps when the core and windings are lifted. This prevents any tensile stress heing setup in the core legs which could adversely affect the iron losses.

Winding

Windings, or Coils are designed to meet three fundamental requirements, mechanical, Thermal & electrical. They are cylindrical in sharwand are wound concentrically. Both H.V.& L.V. windings are wounds with adequate brazing and securing tapes in order to achieve a strong and self-supporting structure. Inter layer ducts arc provided to ensure low temperature gradient between winding and oil and thus any hot spot temperature is kept to minimum. This insures that the rate of insulation deterioration is minimized and high life expectancy is achieved.

Indoor High-voltage Air Break / Load Break Switches are based on a modular principle, which is suitable for the power system of 3.6kV to 36kV. They represent an attractive solution as a key breaking current for application in enclosed Switchgear, Ring Main Unit and Compact Substations. In combination with current limiting fuses, Switch fuse unit ensure control over the full range of over load and short circuit currents. It is used for switching the transformers, Capacitors, protecting cables and overhead lines, etc. Load Break Switch has been tested at CPRI.

Features:

Switch can make and break the normal rated current.

Switch can withstand short circuit making current.

Mechanism has a quick make-make and quick-break feature and the speed of make and break being entirely independent of the operator.

The handle is trip free and a trip coil can be fitted if desired.

Switch is available with Earth Switch for cable earthing with safety interlocking.

Compact modular Load Break Switch fuse Unit Panels are available suitable for Indoor / Outdoor installations. LBSFU Panels are offered with dynamic mimic and extensible on both sides. It meets the special need for Small Industries, Residential Apartments, Commercial Complexes, Hospitals, Educational Institutions, secondary substation, as well as large capacity power transformer.

LBS Panels are offered as single panel or multi line-up panels as well as Ring Main systems. The Ring Main Systems / Multi panel configuration finds application in public and industrial voltage medium voltage distribution networks.

Optional Fittings:

Local / Remote Electrical Trip facility through 220V AC Shunt Trip Coil.

Auxiliary Switch contacts for local / remote ON, OFF Indications.

Note: The HT HRC fuse ratings would be in accordance with the transformer rating.