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Manufacturing Process
Quality Policy
Manufacturing Process

  • Winding
Both High Voltage (HV) and Low Voltage (LV) windings are done using Coil Winding Machines. The Copper or Aluminium strips/wires used in winding are meticulously selected for its quality to give the best output.

The Copper or Aluminium strips/wires are paper covered and acts as insulators. This helps to increase short-circuit strength, thermal strength and higher efficiency.
  • Core
The Cold Rolled Grain Oriented (CRGO) laminations used in transformers are of high quality. They are in the form of thin sheets and they are cut as per the design varying for different capacities of transformers.

Highly skilled people assemble the laminations on a core channel to form CORE. These are perfectly assembled without any gaps to avoid energy loss.
  • Assembly
The wound coils are placed carefully in the assembled core. Insulations are given wherever required using materials like press board. The CORE bolt and tie rods are fixed in position. The Primary and Secondary windings are connected as per the requirement.

The complete assembly is kept in the Hot Air Chamber and a high temperature is maintained to prevent any moisture in the CORE coil assembly.
  • Tanking & Painting
The tank is fabricated with high quality MS plates. The assembled job is placed carefully inside the tank. The bushings, tap switch drives and lug sockets are fitted on the tank. The oil is filled and the cover is placed on the tank frame and bolted.

2 coats of anticorrosive paint and 2 coats of enamel paint are painted on the outside of the tank. The inner portion of the tank is painted with varnish.
  • Testing
The transformers are individually tested and the following routines tests are conducted in our lab:

No Load Loss, Full Load Loss, Double Frequency Double Voltage Test, High Voltage Test, Insulation Test, Measurement of Resistance, Heat Run Test, Pressure Test on Tank, Break Down Voltage - BDV and Acidity Test on Transformer Oil.

Distribution Transformers
Air Break Switches
Tank fabrication for Power & Distribution Transformers
Tap Switches
Sarayu Contractors and Consultants
Complete Electrical Plan
Cost Effective Designs
Site Drawings and Machine Drawings
Erecting and Energizing
Commissioning and Installation
Sarayu Engineering
LV & HV metal parts
Core bolt
Tie rods

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