High Frequency and Voltage Transformer Suppliers in Hyderabad

Design that Enhances performances

KPEL has in house design skills to customize a transformer for particular specifications which enables the flexibility to offer transformers to wide variety markets in terms of Design.
Design activity is continuously reviewed as per ISO 9001 requirement during periodic internal and external audits.
KPEL has following unique features that is distinguishes it from other conventional designs.

CRGO Core Laminations with step LAP

CRGO grade steel mainly finds applications as core material for power transformers and distribution transformers.
Slit coils confirming to international standards are surrounded from reputed mills. The individual stamping are coated on both sides with insulating material that is both oil and temperature resistant.

CORE STACKING INPROCESS

STEP LAP LAMINATION BUILT CORE

STEP LAP LAMINATION CUT ON CNC CORE CUTTING LINE

CORE LIMB

The lamination are assembled in jigs tapped and clamped in such a way so as to reduce vibration and inherent noise to a minimum.
Reduces Iron Losses
Reduces Excitation current

IS Standard – 2%
KPEL Standard – 0.2%

Minimized inherent noise
Standard Process for All Transformers

Amorphous Core Transformers

Amorphous Metal Distribution Transformer (AMDT) from KPEL represents the ultra – Low loss design solution, delivering the highest efficiencies. Amorphous metal – A technological advantages amorphous metal (AM) enables a significant reduction in no load losses as compared to CRGO.

Losses in Amorphous core Material

The laminations comprises thin ribbons and the thickness of the sheet is about 1/10th that of the CRGO, i.e approximately 0.025 to 0.030mm.
Amorphous Core Transformers offer 70 to 80% reduction in no-load losses compared to Transformers using CRGO core material. KPEL draws immense cost advantages due to its in-house Amorphous core facilities.

Automated Amorphous Core Cutting & Stacking Line

KPEL has in house automated core manufacturing line and is among handful of companies with such capability.

Amorphous Metal Distribution Transformers (AMDT), are REPAIRBLE as equally as CRGO Transformers, and easily serviced by our skilled services team at site or at our works.

Must for 5-Star Energy Efficient Transformers
In house capability to manufacture Amorphous Core
Amongst very few companies with such capabilities
Only 30% of iron loss of CRGO Transformers
Savings to Customer in terms of low TCO

Heat drying vacuum oven

Vacuum Drying and Filling
Most effective in removing moisture
Reduces Partial Discharge and potential fault points

The core and coil assembly with respective connections is dried in vacuum oven for a pre determined oven cycle based on insulation structure, At a vacuum level up to 1 torr@100C temperature, Which eliminates complete moisture from insulation material and also use of Micro processor based temperature for controller to record Temperature for controller to record Temperature v/s time for improvement of insulation resistance values.

Windings

Using pure & properly annealed Copper Conductor Owing to the lower resistivity of this conductor, copper losses are minimal.
Low Running Cost
Windings are designed with special diamond dotted paper insulation between layers

LV Foil Wound Coils

Foil windings are best preferred to reduce the axial forces under fault conditions.
Ability to withstand a short circuit force /current.
As compared to Round/Rectangular conductors the winding efficiency of foil allows 50% increase in the power output.
The lower core cost of this transformer will offset the higher cost of Foil Winding.

FOIL WOUND COILS

RECTANGUALAR CONDUCTOR

ROUND CONDUCTOR

HV Coils

High voltage coils are generally with round/rectangular strips with PVA covered or paper covered insulations.
Windings or coils are made from high quality electrolytic grade copper/aluminum conductors sourced from reputed manufacturers.
The windings are concentric circular or elliptical or rectangular in shape based on the design.
Various types of design constructions namely layer, crossover, disc, etc are adopted.