USA Vacuum Technologies & Control Systems. Sinhagad Road, Pune, Maharashtra

Vacuum Impregnation Plant The Vacuum Impregnation Plants can be designed as per clients’ requirements and is provided with the following specifications.   IMPREGNATION CYCLE:It is designed as per the schematic diagram attached and is used for varnish impregnation to be carried out in following steps: Pre-heating the jobs in either Impregnation Chamber or Oven.Evacuation of Impregnation Chamber (after putting the jobs) to make the voids in the jobs       clear and drying of jobs for specific time & required temperature / vacuum.Induction of impregnant (Varnish) in the Impregnation Chamber from impregnant Tank to        submerge the jobs in it.Pressurize the Impregnation Chamber with dry air or nitrogen to fill the voids with impregnant.Return the varnish to impregnant Tank.Evacuate the Impregnation Chamber and cure the jobs either in impregnation Chamber or in     Oven for specific time.   Impregnation chamber specifications:Working Volume: 100 Ltrs to 5000 Ltrs. constructed from M.S. plates, bars, structural etc.Working Pressure: @ 4 kg/ cm2 & Vacuum: As per process requirement.Lid Opening: Screw Davit type for quick opening & closing.Chamber Dimensions: as per job Size and Quantity.Added provisions are Oil Heating / cooling Jacket, Quick Clamping bolts, Stirrer, Neoprene     Gaskets, Sight glass, Illuminating Lamp, Pressure Safety Valve, Vacuum & Pressure gauge.

Our Vacuum Drying Autoclaves are designed and manufactured as per the specifications provided by our clients. We have the capability to manufacture high performance autoclaves which increase the efficiency and performance of any plant. This equipment comprises a vacuum autoclave in which a cylinder containing a piston is situated at one end and can be closed at the end by a hollow piston containing a condenser casing. The cylinder is evacuated through a port and the piston is lowered to close the port immediately an injection valve is opened to fill the cylinder with an impregnating substance. When the injection valve is shut the piston slowly presses the impregnant out through the neck of the condenser casing. The pressure is increased till the ejection valve opens. A blast of gas cleans the cylinder to remove any remaining impregnant.  

Our oil filtration plants are used to remove impurities from transformer and switchgear oil such as moisture, dirt, air and other gases. This is a `low temperature and high vacuum` principle based equipment as per the International Standards 6034 (1989) and its latest revision. We manufacture plants of variable capacities of 1200 to 25,000 lph which can be customized to special capacities if required by the clients. This plant takes the impure oil into the system through the inlet ball valve and then pumps it through by a positive displacement pump. A filter prior to this removes solid particles up to 1mm size and magnetic particles. After heating the oil up to 60°c it passes through the cartridge filters, where particles up to 5 microns are filtered. A specially designed vacuum chamber removes moisture, air and all the gases with the help of vacuum. The oil falls by way of gravity over the media inside forming a thin film of oil, exposing a larger surface area. The dissolved moisture and gases are evacuated and the oil is ready.   Releted Links:  Transformer Oil Filtration PlantOil Filtration PlantMobile Transformer Oil Filtration PlantVacuum Impregnation PlantVacuum Drying AutoclaveAir Drying OvenB.D.V Testing KitCartridge FiltersBag FiltersOil Hoses O-Rings  High-Vacuum Transformer Oil Filtration and Dehydration Plants Our Oil Filtration Plants are used to remove impurities from transformer and switchgear oil such as moisture, dirt, air and other dissolved gases. This is a `Low Temperature and High Vacuum` principle based equipment as per the International Standards 6034 (1989) and its latest revision. We manufacture plants of variable capacities of 600 to 25000 LPH which can be customized to special capacities if required by the clients. This plant takes the impure oil into the system through the inlet ball valve and then pumps it through by a positive displacement pump. A filter prior to this removes solid particles up to 1mm size and magnetic particles. After heating the oil up to 60°C t passes through the cartridge filters, where particles up to 5 microns are filtered. A specially designed vacuum chamber removes moisture, air and all the gases with the help of vacuum. The oil falls by way of gravity over the media inside forming a thin film of oil, exposing a larger surface area. The dissolved moisture and gases are evacuated and the oil is ready.   Transformer Oil Filtration and Dehydration Plants / Purifiers are available for   Transformer and Capacitor Manufacturers – Skid mounted plants for preparation of new oils prior to apparatus filling and impregnation.   Transformer Repairers - Complete plants for preparation of new oils and regeneration of used oils for reuse. We can provide the purification system you need as well as vacuum storage tanks and transformer filling and emptying / pumping station.   Transformer Owners - Portable plants are available in a variety of trailer-types and sizes to allow on-site servicing of transformer oil right in the substation. Trailers are available with a wide variety of options including laboratory space, oil-testing equipment. Plants are designed for drying out of the transformer insulation and oil filling and impregnation under vacuum. Hot oil circulation and hot oil spray methods can also be used.   The filtration plant will be designed for high vacuum & low temperature of oil for achieving required results.The plant will be Mobile, to be mounted on your Vehicle or Skid Mounted, with or without enclosure, suitable for outdoor or indoor use.All components will have adequate strength & rigidity to withstand normal conditions of handling & transport.   The plant will consist of the following :   Inlet Pump   A 600 to 25000 LPH capacity positive displacement gear type pump will be provided. The pump will be suitable for vacuum & continuous trouble free operation. A pressure release valve will be provided across the gear pump, to control the accidental pressure rise in the plant.     Capacity – 600 to 25000 LPH   Operating Pressure - 2 Bar   Suction - 4-5 mtrs   By pass arrangement will be provided in between Inlet & Outlet     Heaters   Nicrome or Kanthal wire heater elements inserted in refractory formers will be provided in protection tubes to avoid localized overheating, hot spot formation & breaking of oil. Heaters will be capable of heating oil from 200 C. to 600 C., as recommended in IS 6034 – 1989. Total heater power will be 9 to 248 kW divided into two/three groups. Each group of heaters will be controlled by TIC. An additional thermostat will be provided as a safety to control the temperature during accidental temperature rise.The surface density of the heater pipes will not be more than 2.5 watts/cm2.A drain valve for the heater tank will be provided.     Indirect type, Wound elements placed in ceramic formers located in Protection Tubes.   Heater Power : 9 to 248 KW.   A Pressure Safety Valve & a Drain Valve will be provided.   A Control Thermostat and a Safety Thermostat will be provided.     Filtration System   Filtration system will consist of the following,   A Preliminary filter   This filter will be provided to prevent any damage to inlet pump by straining magnetic & all other particles above 1mm size. The cleaning of the filter is possible without dismantling the filter from the pipeline.   Cleanable without dismantling     Flow capacity – 600 to 25000 LPH   Rating - 50 mm   Arrests magnetic particles B Pre-Filter   Filters will be easily changeable. It will be suitable for removal of particles larger than 20 microns. It will be suitable for removal of sludge content in the used oil. This will enhance the life of fine filter. C Cartridge Filter (fine filter)   Throw away type, non-hygroscopic cartridge filter elements of one-micron rating will be provided. The cartridges are easy for replacement & have large dust holding capacity.   Cartridge Filter (fine) placed in a steel housing.     Flow capacity – 600 to 25000 LPH   Rating - 1 Micron     Ionic Reaction Column   An Ionic Reaction Column of 10 to 40 Kg activated alumina will be provided for reduce the acidity in the oil. A bypass arrangement will be provide for after first filling with IRC.     Degassing Chamber (Single Stage as well as Two Stage)   It will be of M.S. welded construction. The chamber will be designed to withstand the suitable vacuum. In the degassing chamber, dissolved gases & moisture from the oil will be removed. A specially designed media will be provided in the degassing chamber to offer maximum surface area, to form a thin film of oil, to achieve maximum possible removal of dissolved gases & moisture at the rated flow rate. One high level & one low level float switch will be provided to control the oil level in the degassing chamber.   Two stages will be separated by a siphon seal.Highly efficient Two Stage degasser packed with Raschig Rings & equipped with the following :     Totally Welded   Sight Glass & Lamp Shade   Raschig Ring Trays   Low Level and High Level Float Switches   Level Sensor will provided in Degassing Chamber     Outlet Pump   A centrifugal pump will be provided at the outlet. The capacity of the pump will be 12000 LPH and it will be suitable for sucking oil from degassing chamber, held under vacuum.     Capacity - 12000 LPH.   Discharge Head - 8 Mtrs     Vacuum Pumping System   A combination of roots & rotary vacuum pumps will be provided for evacuation of degassing chamber. An additional connection with an isolation valve will be provided in the system, to facilitate evacuation of transformer tank, simultaneously.The vacuum pumping system will be equipped with all-necessary accessories like Vapour trap, condenser, valves & gauges etc.The specifications of the vacuum pumps will be as follows:   Rotary Oil Sealed Pump Pumping speed (Minimum) Ultimate vacuum Make Indo Vacuum/Dicon/Tuthill/Leybold/Woo Sung/ Shinko Seiki/Reputed   Mechanical Booster (Roots) Pump   Pumping speed (Minimum) Ultimate vacuum Make Indo Vacuum/Dicon/Tuthill/Leybold/Woo Sung/ Shinko Seiki/Reputed   The Vacuum System will be equipped with the following :     Vacuum Gauge (Bourdon Type), Range: 0 to -760 mm of Hg   Vacuum Gauge (Digital Type), Range: 1 Torr   Airing Valve   Non return Valve     Cooling System   For cooling, a condenser will be provided in the vacuum line. A condenser will be provided, to maintain ambient temperature of the water which will be circulated through this condenser for collecting water in to the trap. One water tank will be provided in to the top of the mobile van having capacity to hold 100 liter water.     Non Return Valve   One non return valve will be provided at the inlet and one at the outlet, which will prevent mixing of filtered & unfiltered oil, in case of power failure.     Valve & Piping   Two airing valves will be provided for airing the vacuum system. All inline valves will be Ball Valve in case of Fully Automatic System then Valves will Solenoid Valves with carbon steel body & S.S. ball, suitable for vacuum application.     Oil & Vacuum Valves will be of Solenoid type or Ball Valve.   Piping will be of Normal Steel.   Mechanical Non Return Valves before Degassing Column & at Plant outlet   Oil Sampling Valve   Isolation Valve at Plant Inlet & Outlet   One pressure gauge at the inlet of the cartridge filter will be provided. One bourdon type vacuum gauge & one digital gauge (for measurement of fine vacuum) will be provided in the vacuum system.Independent electric drives will be provided for all pumps. Motors will confirm generally to is 325 (testing) & will be of CGL / Hindustan Motors / Siemens or any other reputed make. Starters will be of direct on line type.     Control Panel   The enclosure will be fabricated out of CRCA sheets & will be suitably coated to protect from weather. All electrical control gears, mains isolating arrangement, starters, contactors, pilot lamps, push buttons, HRC fuses, relays, indicating lamps and interlocking arrangements will be housed in the enclosure. All wiring will be neatly routed & all wire terminations will be suitably identified with ferrules.A tube light will be provided for plant illumination. The plant will be suitable for operation on 415 V, 3 Phase, 50 Hz. A.C. supply.Incoming Power Supply Cable for Control Panel is to be arranged by the Customer and is not included in scope of our supply.   Electrical Interlocks     The inlet pump will be interlocked with the heaters, in such a way that unless the oil is actually flowing in the system, the heaters cannot be energized. The electrical interlock between heater supply and motor supply will also be provided so that as soon as the inlet motor trip due to some fault in the drive/due to supply failure, the heater supply will also be automatically cut off.   In case of power failures, electro magnetically operated inlet and outlet solenoid valves will be closed and prevent oil from entering the degassing chamber. The moment oil inlet pump or discharge pump is switched on the corresponding valves will open automatically.   The suction pump and the level controller in the degassing chamber will be interlocked in such a way that when the oil/foam level in the degassing chamber increases beyond the desired level, the suction pump will be automatically cut off so that there is no further flow of oil in the degassing chamber.   The temperature indicator of digital type, together with thermostat provided will automatically switch on/off the heater elements in groups so that temperature of the oil during treatment will not be permitted to rise above the pre-set value.   A pre-set safety thermostat provided on the heater vessel will switch off all the heaters in case of any accidental temperature rise of the oil above safe temperature levels so that any likelihood of fire hazard is fully eliminated.   The inlet gear pump will be provided with built in relief valve to take care of accidental pressure increase at the outlet side of the gear pump.   An external relief valve will be provided on the heater vessel to take care of any accidental pressure rise above the safe level in the heater vessel.     Oil Hoses   Two numbers Nitrile Rubber Hoses each 10 to 15 Meters long with quick connect coupling end connection on both sides shall be provided. One is for inlet & one for outlet. Oil Hoses will be capable of handling the transformer oil at 135oC (max.) and hoses will be will be suitable for full vacuum operating conditions.     Lifting Hook   Lifting Hooks for Plant will be provided to facilitate ease of Plant Loading and unloading.     On Line Moisture Meter (As per clients requirement)   A panel mounted Digital Moisture (PPM) Meter will be provided in the outlet line to measure the moisture content in the oil.     Oil Flow Meter with Totalizer (As per clients requirement)   A panel mounted digital oil flow meter of Vatturkar / Inconel / reputed make will be provided in the outlet line to measure the oil flows.     Sleeping Arrangement (As per clients requirement)   A frame mounting arrangement for sleeping purpose of the operator will be provided in the mobile van on top of the heater tank. The bed will make from foam sheet and Rexene cover. Cooling fan will be provided in the rest room. Two persons easily sleep in to the rest bed.     Platform for Bike (As per clients requirement)   The platform will be provided for hanging bike in to the mobile van. The arrangement will be making as per your requirement and it will easy to handle in all situations.     Painting   A suitable anti rust primer will be applied on the interior and exterior surface of all steel parts, which shall followed by application of two coats of suitable durable paints to serve as base and binder for the finished coat. Under body of carriage will be painted with special black anti rust paint     Inspection Testing & Commissioning   Inspection & Testing of Transformer Oil Filtration Plant will be carried out by Consignee before dispatch.Commissioning will be done at site; our Engineer will be available on schedule date mutually decided by both parties.Our one person will be provided at your site to train and educate the operators for the period of one month. Site expenditure of the person will be at your scope.     Drawings & Manuals   One set of Schematic drawings & Guaranteed Technical Particulars of the Transformer Oil Filtration Plant will be provide with the offer and detail drawing with general arrangement of Filtration Plant, Electrical Wiring Diagram and User Manual will be provided at the time of supply.     Performance Guarantee   We give guarantee for performance of the Plant for a period of 12 months from the date of commissioning of the Plant or 18 months from the date of dispatch, whichever is earlier. During guarantee period we undertake upon written request of the purchaser to repair or replace at our discretion & as soon as possible any parts of goods delivered which can be proved to be damaged or unfit due to bad material, faulty design or poor workmanship. This guarantee does not cover damages resulting out of normal wear & tear, improper maintenance, failure to observe the operating instructions, incorrect operation, excessive loading, the use of unsuitable material, & other reasons beyond our control. This guarantee does not cover Consumables, Rubber Parts (including Oil/Vacuum Hoses) & Electrical Components-Motors.  

Nitrile Rubber Hoses with quick connect coupling end connection or round flanges on both sides: Hose pipe should be steel wire braided. It will be oil resistance & capable of withstanding oil     temp of 1000 C continuously during oil filtration & it will       not deform. Wire braiding will be provided at the centre of       material throughout its length. Both ends of each hose pipe should be connected with round flanges/ quick connect coupling.The hose pipe will flexible for winding up easily for transporting/shifting conveniently. The hose pipe will be able to withstand absolute vacuum without shrinkage. 

OIL FILTRATION PLANTS CAN BE SUCCESSFULLY MODIFIED & AUTOMATED FOR VARIABLE FLOW RATE. A brief description is given for your reference.   INLET & OUTLET PUMPS : The pump will be driven by suitable sized AC drive to control the flow rate. By using these settings we can control the flow rate from i.e. If Plant is 6000 LPH then it will vary from 1000 LPH to 6000 LPH. HEATER TANK : It is also necessary to select proper heat output for variable flow rates. This will avoid localized heating of oil for small flow rates.This section will incorporate PLC which will control the heaters.PLC will be used for control of heater groups, once certain flow rate has been selected, heaters will be configured automatically to suit that flow rate. This control panel will be designed for reliable & trouble free operation.By using the above system the major benefit is to have a single machine instead of different models for different capacities. In this case, flow rate can be kept variable from 1000 LPH to 6000 LPH. Power saving of 30% can be achievable by using this system as compared with traditional oil filter system designs.   OPERATIONAL & PROCESS AUTOMATION Press 'START' to start the oil filtration process. All airing valves, oil inlet & outlet valve will close. The rotary vacuum pump will start to achieve coarse vacuum. After achieving coarse vacuum level, which the 'Vacuum Switch' will sense. After achieve the desired level of fine vacuum in the plant, oil inlet valve & intermediate valve will open and the oil inflow will start due to vacuum inside the plant. The flow switch provided in the suction line of the plant will sense the oil flow & that signal will start the oil inlet pump. In case, the incoming oil flow is not there, HMI on the control panel will display 'LOSS OF OIL', with annunciation. One pressure release valve, provided across the inlet pump will control the excessive pressure rise in the plant. As oil is filled in the degassing chamber, the high level float switch will operate & that will put 'OFF' the inlet pump & start the outlet pump. The starting signal to the outlet pump will open the outlet valve. As the oil level in the degassing chamber comes down, the high level float switch will start the inlet pump, again. Thus the oil circulation through the filtration plant will start. After the continuous oil flow through the plant, the heaters will be 'ON'. Temperature of oil will be controlled by TIC (Temperature Indicating Controller) & one safety thermostat will control the accidental temperature rise. Thus the hot oil circulation through filters & degassing chamber will start resulting in the effective separation of solid impurities as well as dissolved moisture & gases from the oil. During the filtration process, the necessary interlocks provided will avoid malfunctioning of the plant, like   1. High level float switch will stop the inlet pump, to avoid flooding of the degassing chamber. 2. Unless the inlet pump is 'ON' the heaters will not be energized. 3. Low level float switch will stop the outlet pump to avoid dry running of the pump During the filtration process, the moisture meter, installed in the inlet line, will display the moisture content in PPM, continuously, on it's indicator, on the control panel. Once the desired PPM (moisture) content is achieved, the moisture meter installed in the inlet line, will shut down the plant, automatically. This plant will also run with Manual Interference means with Manual Operation.

Standard Series of O-Rings in AS568 / British Imperial 1806 / British Metric 4518 / Swedish & French Metric R NFT47-501 / Japanese Standards J&P Series / ISO & DIN / Italia Standards available in Nitrile (Buna-N) / EPDM / Silicone / Neoprene / Viton / Polyurethane / PTFE Encapsulated / HNBR suitable for Vacuum application.  

During its operation of generating, transmitting and distributing power transformers give out heat which is absorbed by insulating oils. This oil has a tendency to absorb moisture from windings which leads to gradual deterioration of dielectric strength. Our filtration systems provide economical and efficient methods of purifying this lubricant. The unit consists of:Filter Unit, Indirect system of Oil Heating, Vacuum Dehydration / degasification Unit Condenser and condensate receiver Feed and delivery pump Piping & Valves Control Panel Components of Plant:The filter unit is a coarse strainer with a wire mesh filter element for retaining solid particles and a powerful magnet for retaining magnetic particles. It has round filter paper discs held under spring compression. Specially designed heaters with low watt density heat the auxiliary heating oil, which in turn heats the transformer oil maintaining a temperature of 70-80 C. The cylindrical external pressure vessel is fitted with various shallow drip trays and a specially designed spray pipe to increase surface area. The vapor from dehydration chamber is condensed in a condensate receiver of welded M. S. construction. There are feed and delivery pump of rotary gear type coupled directly with motors. Water Separator Collect the water produced. A centralized control panel has indicators for all electrical devices.   Imported thermostat Thermometer for measuring temperature Pressure & Vacuum gauges Flow control indicator lectronic Float Control Electrical instruments, voltometers and ammeters Electrical overloads and overload releases for safety of motors.

PURE-BOND Resin Bonded Cartridge filters feature an Acrylic Fiber-Phenolic resin/ Cellulose Fibers-Melamine Resin construction that produces an extremely rigid pore structure. This construction allows the filter to withstand extreme viscosities and temperature without compression or collapse. In addition, a true graded density construction allows complete utilization of the filter's depth, with coarse particles captured in the outer zones and finer particles captured in the inner qualifying zone.    Application:Transformer OilCapacitor Oil Adhesives Lacquers, Varnishes Fuel Oils, Crude Oils Machine Coolants Dielectric Oils Lube Oil Cutting Oil Plasticizers   Filter specification  Media:Acrylic Fibers bonded with Phenolic ResinCellulose Fibers bonded with Melamine Resin (CFR 21 Listed )   Removal Ratings:: 1, 2, 3, 5, 10, 25, 50, 75, 100,125 150 µm   Dimensions:  Nominal lengths: 9.75, 10, 20, 30, 40 inchesOutside Diameter: 2.6 inches (6.6 cm)Inside Diameter: 1 inch (2.54 cm)   Operating Conditions:  Maximum operating Temp: 149oC Recommended Change out differential pressure: 35psig 

Bag filters are produced using advanced manufacturing process using high performance Polypropylene and Polyester felt media. A specially designed plastic 'V' collar is welded to the media using a thermal welding process. The 'V' collar assures a positive seal and thereby eliminates possibility of channeling and media migration.   Specification:MOC: Polypropylene, Polyester, Nylon (NMO) Size: 7" Dia 16" L, 7" Dia 32"L 4" dia 8" L, 4" dia 14" L Max. operating Temp - PP : 80°C, Polyester: 135°C Removal Ratings: 1, 5, 10, 25, 50, 100, 200 µm 

Oil Test set is ideal for speedy and acurate testing of di-i-electric strength of transformer and circuit breaker oil undertest room condition in acordance with IS:6792-1972 for oil testing   Ratings: Input: 230 Volts, Single Phase, 50 Hz, AC.   Output:Continuously variable from 0 to 50 Kv'or' 0 to 60 Kv,'or' 0to 100Kv,':   Capacity:1000VA(1KVA ) DUTY: The Oil Test set will be designed for"INTERMITTENT" RATING   Nature Of Cooling:The transformer will be epoxy resin cast type air-cooled type.   Generak Arrangement: The set will be comprising of the H.T.transformer, controlcircuity Test cell with electrod & guage and will be supplied in portable air cooled sheet metal casing with powder coating of control cubical & H.T.transformer.   Control: One continuously variable Auto-Transformer for smooth variation of out put voltage.Beside the ON/OFF switch, fast acting Automatic tripping mechanism for protection of H.T.     Transformear gains to verloading on flash over.One zero start inter locking device.Two pilot lamps to indicate mains 'ON' & H.T.circuit 'ON'.One input supply cable with 3- pin plug.One memory effect voltmetetor show the break down voltag even I after the high voltage     circuiti stripped off.   Mode Of Operation: Sets are available either in manual or in motor; operated mode. Beside motorized auto-transformer regulator for motorizesd et motoro perated Auto-transform can be operated in manual through switch.   H.T. Transformer: High voltage Transrormer ration is 230v/ 50 Kv or 60 Kv or 100Kv or 120Kv with centre tap HV winding earthed .   Test Vessel: The test vessel (OilCell)fittedwith two brasss pheres of diameter between12.7 to 13mm, placed at a distance of 4 mm or 2.5mm on sides of test vessel made from non-absorbenint sulating material.   Cover: Sets will be provided with transper an hight impacat crylic sheet cover for covering the H.T.side with suitable inter-locking device

We are engaged in manufacturing of drying oven which has the insulation of high density rock wool which helps in averting 100% heal loss. These ovens are engineered to maintain exact temperature control at different stages. Safety and maintenance aspect is also covered at the initial design stage and it can be customized according to the client specifications and details. Our ovens save lot of energy, very cost effective thus ensure profitability in competitive market.