Vacuum pressure impregnation unit

Introduction:

VPI technology can be used in a wide range of applications from insulating electrical coil windings to sealing porous metal castings. It normally produces better product in less time and lower cost than other available procedures.Our VPI systems can be configured in a variety of ways, depending on the size and form of the product to be impregnated, the type of impregnant used and other production factors.

Application:


1 High Voltage Machines
2 High Temperature Apparatus
3 Transformers
4 HID Ballasts
5 Random Wound Stators
6 Chemical Duty Motors
7 Rugged Duty Motors
8 Inverters
9 Form Wound Coils
10 Armatures With Coils Installed
11 Precision Wound Transformers
12 Ferro-Resonant Units

Characteristics:

1. The vacuum component of the process is the removal of air that occupies the migration path commonly known as porosity in cast or pressed metals.
2. The impregnation part of the process is replacing the void with a durable and stable material suitable for field of use.
Vacuum impregnation prevents the migration of fluids or gases out of or into a manufactured component:
1. From contained areas to the atmosphere as in hydraulic pumps and transmissions;
5. From adjacent independent passages as in oil and water circuits in an engine and graphite plates used in fuel cells;
6. And from atmospheric conditions to the internals of a component as in insert or over-molded plastic connectors, wire, cable and connector assemblies.

Vacuum impregnation as an industrial process has been in commercial use for more than 60 years. For the world's largest manufacturers, it continues to be the preferred process through which to guarantee the pressure-proof, leak-proof, and corrosion-proof requirements of parts and components in critical operations.

1. VACUUM IMPREGNATION SYSTEM

  A fully automatic Vacuum Pressure Impregnation System consists of Impregnation Chamber and Resin Storage Tank 1   No. Individual pumping system for impregnation system or single Vacuum Pumping System for both impregnation   chambers will be selected as per the customers wish

  1.  

Operating Temperature / Pressure

Room Temperature

  1.  

Test Pressure

9  m.bar/ as per customer specification

  1.  

Operating Pressure

6 m.bar maximum/ As per customer specification

  1.  

Ultimate Vacuum Level (Optional)

5 x 10 -3 m.bar in 25 minutes ( if Roots and Rotary combination is used)
5 x 10 -2 m.bar (If rotary pump is used)

  1.  

Compressed Air

Facility should be provided by Customer

  1.  

Operating height

Approximately 1 meter above ground level and the rest submerged underground pit/ Entire system above ground level with stairs and checkup plate

  1.  

Sequence of Operation

As per customer specifications

2. CONTROLS:

  1.  

PLC Controller

GE Funuc/ Mirsubishi (optional)

 

 

Human interface through man machine interface, touch screen MMI

  1.  

 

Emergency Stop Button incorporated

  1.  

 

Manual lock and key for operation control

3. IMPREGNATION CHAMBER 1 No/ 2 Nos (optional):

  1.  

Chamber Design

Round Shape/ Rectangular (optional

  1.  

Material

IS – 2062/ SS304 Optional

  1.  

Dimension

Based on job size

  1.  

Effective Working height

Based on job size

  1.  

Wall Thickness

Based on chamber size and 1mp pressure

  1.  

Lid

Flange with toro spherical dish end

  1.  

Clamping / Lifting

Hydraulic

  1.  

Bottom Portion Shape

Toro spherical Dish End

  1.  

Port

Lamp Port of 4" with Light

 

 

View Port of 4" dia

  1.  

Mesh

Drain Mesh will be provided to drain out the resin during the idle time after the impregnation pressure is completed.  The drain mesh thickness will be based on job size

  1.  

Drain mesh dia

Depending on chamber dia

4. STORAGE VESSEL - 1 No

  1.  

Chamber Design

Round

  1.  

Material

IS – 2062 / SS304 optional

  1.  

Dimension

Based on storage vol

  1.  

Storage Capacity

As per procurement

  1.  

Top    Lid

Hinged toro spherical dish end

  1.  

Bottom Lid

 Toro spherical dish end

  1.  

Port

View Port of  4" Size – 1 No.

 

 

Lamp Port of  4 " Size – 1 No.

  1.  

Stirrer

Stirrer with suitable gear motor with 15-20 rpm will be provided on the storage tank.

  1.  

Filling

Storage Tank filling shall be through differential pressure method

5. VALVES :

  1.  

Vacuum Isolation Valve

Suitable size electro pneumatically operated Ball Valve

  1.  

Air Admittance Valve

Suitable size  electro pneumatically operated ball valve

  1.  

Compressed Air Admittance Valve

Suitable size electro pneumatically operated Ball Valve

  1.  

Resin Inlet Valve

Suitable size electro pneumatically operated Ball Valve

  1.  

Material of construction

Cast Steel

7. VACUUM PUMPING SYSTEM :

Rotary Vane Vacuum Pump with 2 stages with an ultimate vacuum level of 5 x 10-3 m.bar of either Global Vacuum Products or as per customer specification

8. resin condenser with chiller/ cold water: Resin condenser

1.

Dust Filter

Will be provide to prevent resin and dust particles from entering the vacuum pump

2.

Drawings

All important drawings of mechanical, electrical, hydraulic and any other important information  shall be provided during the validation and set up

With suitable inlet and outlet for water in and water out is provided along with cold water circulation or chiller water circulation