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Capacitor Manufacturing Projects Divn.

 

§ Capacitor Manufacturing Projects Divn :

Rectiphase has recently established an engineering division to cater to those customers interested in setting up their own Capacitor manufacturing projects on a turnkey basis. However this division indulges in activities of technology transfer only for MV & HV Power Capacitor products.

 

§ The Products‚ Technology & Scope :

 

We are technocrats with 30 years experience in HV Capacitors‚ special application capacitors and Reactive Power Compensation products. We specialize in design‚ application engineering and manufacture of Electrical Power Capacitors for every segment of industry‚ e.g. LV & HV Power Factor Correction‚ Induction Heating & Melting‚ Harmonnic filters‚ Plasma Physics‚ High energy / Impulse discharge‚ Surge suppression‚ etc.

We offer our expertise in the form of trunkey consultancy to prospective enterpreneurs for setting up Capacitor manufacturing projects. We impart technology to manufacture capacitor products to national‚ international standards and IEC specifications.

The range of Capacitor products offered under our trunkey package :

•  Medium & High Voltage Power Capacitors : 1.1 kV to 145 kV‚ Banks from 300 kVAr to 40 MVAr.

•  Medium & High Frequency Water–cooled Capacitors for Induction heating and melting. (Not offered to Indian Market).

•  Surge protection Capacitors : 3.6 kV to 36 kV‚ from 0.125µF to 0.5µF.

•  Energy Storage Capacitors up to 100 kV DC (10 kilo joules) for Pulse discharge / High–energy discharge applications‚ Medical    equipment‚ Lasers‚ Plasma physics‚ Impulse generators‚ etc.

 

§ Technology / Basic Construction :

Amongst most electrical products‚ Power Capacitors are highly susceptible to premature failures if improperly installed or if the application or load profiles are non–linear or sstem parameters are erratic. It is therefore of utmost importance that a capacitors is designed to sustain and perform under such adverse conditions. Hence proper quality inputs‚ design‚ manufacturing and processing parameters assume vital importance. A properly selected design‚ supported with a good quality manufacturing‚ processing & testing infrastructure will not only guarantee strict adherence to quality assurance norms and international standards but will also ensure that all products perform to the highest levels of safety‚ realiabilit and life expectancy.

 

§ The Raw Material :

High Voltage Power Capacitors are generally manufactured using the folling raw material inputs‚ unless special end ues applications necessitate use of alternative material.

 

Dielectric : Hazy BOPP Film.

Dielectric : Hazy BOPP Film.

Electrode : Aluminum Foil.

 

•  Impregnant : Phenly Xylyl Ethane (PXE)‚ NON–PCB‚ Non Toxic‚ Biodegradable.

•  Housing : Stainless Steel / Mild Steel Sheet. Aluminum / Brass sheets for other applications.

•  Bushings : Soldered or welded‚ Brown / Gray‚ glazed porcelain insulators‚ Bakelite molded & Epoxy cast for other applications.

Porcelain bushings for HT Capacitor

Bakelite Bushings for Water–cooled Capacitor

   

Epoxy Bushings for Energy Storage Capacitor

Post Insulator & Expulsion Fuse for HT Capacitor

 

Other general components used are solder wire/sticks‚ copper tubing insulating paper & board‚ wire rope / cords‚ post & pedestal insulators‚ expulsion fuses‚ resistors‚ rubber components‚ connection hardware‚ aluminum strips‚ structural material etc.

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§ The Critical Manufacturing Processes & Departments :

 

•  Element Winding :

Winding is done in air–conditioned and dust–free clean–rooms equipped with special apparatus. The elements are wound using layers of Electrical grade BOPP Film interleaved with two layers of aluminum foil. The winding method adopted is the extended foil construction‚ i.e. one edge of each electrode foil protrudes out in opposite directions. The inner edges of the foils are concealed within the element‚ but are edge folded throughout the length of the winding‚ and also end–folded at the beginning and end of the winding cycle.

 

•  Dry Element Testing :

All elements are tested with a DC voltage to verify its voltage withstand capacity and to detect weak spots across the dielectric‚ which may puncture during operation. This is absoiutely essential before elements are connected into the pack.

 

•  Element Pack Assembly :

Each element is placed on the inclined press for building the capacitor pack A number of elements are compressed to form a pack. Inter–phase insulation/series group barriers and end stiffeners are inserted here and the pack is firmly held in by insulated strips and locking devices. No metal parts are used.

 

•  Soldering & Connections :

The electrode connections are done by soldering the extended portions of the foils of the elements on either side of the pack. A special solder composition is smeared along pre–defined paths with help of a special gas–flame gun. This is referred to as edge soldering. Internal fuse–boards‚ discharge resister assemblies and external connections are done and group & pack capacitance values measured.

 

•  Dry Packtesting & Insulation Wrapping :

After soldering and connections‚ each pack and it´s external leads are wrapped in multiple layers of Electrical grade insulating paper to achieve desired terminal to case insulation level‚ and relevant DC voltage proof tests are conducted. The insulated packs are then inserted into the sheet steel container‚ (The top plate pre–fitted with the porcelain insulators). These have an opening for pre–dring and oil impregnation. The container base & inner surfaces are also covered with insulating pre–compressed board.

 

•  Vacuum Drying And Impregnation :

Capacitors loaded in a tray (6A) are lowered into a vacuum chamber (6B) where are subject to drying under elevated temperature and rough vacuum prior to being impregnated with a pre–treated electrical grade insulating oil under high vacuum‚ and left soaking(6C) for a specific period.

 
 

•  Leakage & Electrical Testing :

After impregnation is complete‚ inlet valves are sealed and units undergo leakage tests in a chamber at elevated temperature to detect leakages if any.

The units undergo all relevant routine electrical tests as also some type tests to the extent of testing facilities available.

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§ The Package & Scope :

 

Package

Capacity

Time Period

TCP-A

≥450 MVAr

6 months

TCP-B

≥900 MVAr

8 months

TCP-C

≥1200 MVAr

10 months

•  Plant capacities indicated are based on the winding and the impregnation plant capacity‚ & assuming that HV Power Capacitors will constitute 80% of production & with an average unit rating of 200 kVAr‚ 7.3 kV.

 

§ The Equipment :

Winding machine‚ Inclined stacking press‚ Element testing‚ Clean room equipment‚ Vacuum drying and impregnation chambers‚ Oil treatment and storage plant‚ Insulation cuttirig‚ Soldering‚ Fabrication equipment (process welding) Electrical test equipment with HV test bay‚ Leakage testing chamber‚ Shot blasting equipment‚ Container treatment‚ Paint shop.

 

Semi automatic & fully automatic microprocessor based element winding machine with element testing

Precision testing equipments

Inclined element stacking press

     

High voltage testing bay with all equipments

Clean Rooms for Winding, Element Testing‚ Stacking‚ Soldering & Connection‚ & Insulation Departments

Oil processing & Storage + vacuum drying & impregnation plants

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§ The Highlights :

•  Supply of all critical plant and machinery. (Some dies also included).

•  Pre–shipment inspection & trials‚ installation‚ commissioning of all supplied equipment.

•  Vendor development for all raw material and components.

•  Training in usage of design software‚ manufacturing‚ testing‚ QC‚ trouble–shooting‚ etc.

•  Prototype production trials of all types of capacitors.

•  Initial lot of raw material required for pre–shipment inspection to prototype manufacture.

•  100% assistance in manufacturing initial lots of commercial production.

•  Training in capacitor bank installation‚ testing & commissioning‚ operation & maintenance.

•  Guidance in selection of capacitor bank switching & protection equipment! accessories.

•  Ensuring successful testing of prototype HT capacitor unit at an independent laboratory.

•  Guidance in devising marketing strategies.

•  Project will be personally handled/implemented by technocrats wifh 30 years experience‚ who are currently manufacturing and    exporting identical range of capacitors.

 
 

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