MR. RUSHIKESH PATEL

Q.Could you give a summary of the company’s development from its inception to its present-day operations?

This Company was Established in 1986 by 2 Technocrates namely Mr S A Patel and Mr Manoj Vyas, in 1997 this company went into Colloboration with M/s Electtromeccanica Italy for Dry Type and Cast Resin transformer, eversince then we are regularly manufacturing Cast Resin and ONAN transformer. Presently we are among leading manufacturer catering to Major EPC and Manufacturing Companies like BHEL, ABB, L&T, SIEMENS, NHPC, NTPC and many others.

Q.How has the company adapted to the ever-evolving transformer industry over the past 25+ years?

We started with ONAN transformer and Since 1997, we also added Dry type transformer. Further as the requirement / Recognition for ALUMINIUM DRY TYPE TRANSFORMER / ALUMINIUM OILFILLED TRANSFORMER has increased we have started manufacturing both in Copper and Aluminium wound transformer.

Q.Could you elaborate on the materials used in your transformers, particularly the coldrolled silicon steel in the transformer cores, and how these materials impact the overall quality and longevity of your products?

Benefits for Quality and Longevity:

• Efficiency: The high magnetic permeability of CRGO silicon steel improves the transformer’s efficiency by reducing core losses and magnetizing current, resulting in less energy waste.

• Noise Reduction: The material’s smooth flux conduction minimizes core vibrations, leading to quieter transformer operation.

 • Lower Heat Generation: Reduced core losses help maintain lower temperatures, preventing overheating and extending the lifespan of the transformer.

• Durability: With proper coatings and corrosion resistance, CRGO steel contributes to a longerlasting transformer, even in challenging environments.

 • Cost-Effectiveness: While the material might have a higher initial cost, it provides a better long-term return due to its efficiency, reduced maintenance, and prolonged operational life. Overall, the use of cold-rolled silicon steel significantly impacts the performance, efficiency, and durability of transformers, making them more reliable and cost-effective over their operational lifetime.

Q.Will you explain the step-lap core process and also how it benefits transformers in terms of load, load current, and core noise reduction?

The step-lap core process is a technique used in transformer manufacturing, specifically in the design of the core, which plays a key role in the transformer’s performance. The process involves the careful cutting of the laminations (thin sheets of steel) that make up the core. The laminations are cut in a stepped manner, rather than being aligned in a straight line.

Step-Lap Core Process:

1. Lamination Cutting: In the traditional transformer core, the laminations are often cut in a way that their edges are aligned to form a continuous path for the magnetic flux. In contrast, with the step-lap process, the laminations are cut with overlapping steps at the joints. This means that each lamination overlaps the one below it at the joints, forming a “staircase” effect when viewed from the side.

2. Joints and Overlap: The overlap reduces the overall length of the joints, which helps in reducing the core’s magnetizing current (the current that is needed to establish the magnetic flux in the transformer core).

3. Compression and Assembly: The individual lamination blades are then stacked and compressed to create the core structure. The step-lap configuration enhances the uniformity of the magnetic path by minimizing the air gaps at the joints, which leads to a more efficient flux flow.

Benefits of Step-Lap Core Process:

1. Reduction of Core Losses (Load Current Efficiency): The step-lap process minimizes the air gaps at the joints of the core laminations. This helps in reducing the eddy currents and hysteresis losses, which occur due to the magnetic flux reversing direction. These losses tend to heat up the core and reduce overall efficiency. With fewer and smaller air gaps, magnetic flux can travel more smoothly and uniformly, leading to lower losses and better load current efficiency. This makes the transformer more efficient under load conditions.
2.  Reduction of Core Noise: Transformers generate noise as a byproduct of magnetic flux changes within the core. This is primarily caused by the vibrations of the core laminations, which occur when the magnetic flux changes direction. In traditional transformer cores, these vibrations can be more pronounced at the joints between laminations. The step-lap design reduces the number and size of these joints, leading to less vibration and, therefore, a reduction in core noise. This makes transformers with step-lap cores quieter compared to traditional designs.
3.  Reduced Magnetizing Current: The reduction in air gaps due to the step-lap design leads to a more uniform magnetic path, which results in a lower magnetizing current. The magnetizing current is the current required to establish the magnetic field in the core. By reducing this current, the transformer operates more efficiently, especially under no-load or light-load conditions. This not only improves efficiency but also reduces the thermal stress on the transformer.
4.  Improved Load Handling: Because of the smoother magnetic flux flow and reduced losses, transformers with step-lap cores can handle higher loads more efficiently. This means the transformer can operate under heavy load conditions without excessive heating or reduced efficiency. This contributes to the long-term reliability and performance of the transformer.

Summary:

• Step-lap process involves cutting laminations with a stepped overlap to reduce air gaps and joints in the transformer core.

Benefits:

• Lower core losses lead to better load current efficiency.

•  Reduced core noise due to less vibration at joints.
•  Reduced magnetizing current for improved efficiency, especially at no-load and light-load conditions.
•  Improved load handling and overall transformer reliability.                                                                                  
• This technique ultimately makes transformers more energy-efficient, quieter, and better suited for handling varying load conditions.

 Q. What kind of after-sales support do you provide to clients, especially for large and complex transformer installations?

 We do provide after sales services round the clock within 48 hrs, in all the major Metros of the country we have service network.

Q.What innovations or trends do you expect to emerge in the transformer manufacturing industry, and how is your company preparing for these changes?

As far Trend is concern, we are also concentrating in big way in Renewables energy sector, further hopefully requirement of Aluminium wound transformer is likely to increase in furture.

 Q.Do you see any future developments in transformer technology that could significantly reduce their environmental impact?

As we see increasing popular demands of using cast Resin Transformers with environment friendly & Fire safe approach, we have an core expertise to undertake not only standard Distribution requirements, but also converter duty, Inverter Duty & other customized solutions in this range. Further, an additional alternative is also available with enhanced energy Efficiency for liquid filled Transformers i.e. Natural Ester oil which is also environment friendly, biodegradable & Fire Safe. These both products are offered as per customer’s customized needs