CATHODIC PROTECTION

TRANSFORMER RECTIFIER
REMOTE MONITORING &
CONTROL SYSTEM
SWITCH MODE
POWER SUPPLY
SOLAR POWER
SYSTEM
LIFCLINC FCP PIPCLINC



INDUSTRIAL
ELECTRONICS
DIVISION
The Company
Business
Industry
Power
Telecommunication Electronics
Oil 8 Gas f Water Narine 8 Offshoref
Fire f Petrochemicals
Exports
Raychem RPG Limited was incorporated in 198+.
Raychem RPG is a S0 : S0 Joint venture between Tyco Electronics, U.S.A and RPG Group, !ndia
Tyco Electronics is a US$ 13 billion global provider of engineered electronic components for thousands of consumer and
industrial products; network solutions and systems for telecommunications and energy markets; wireless systems for
critical communications, radar and defense applications. They design, manufacture and market products for customers in
industries ranging from automotive, appliance, aerospace and defense to telecommunications, computers and consumer
electronics.
RPG Group is one of the leading business houses in !ndia with a group turnover exceeding US$ 3 billion and Narket
Capitalization of US$ 2 billion. RPG is one of the largest diversified business groups in !ndia owning over 20 companies in 6
business sectors - Retail, Technology, Entertainment, Power, Transmission 8 Tyre.
Raychem RPG is involved in technologies serving the infrastructure segment of economy.
Cable Accessories 8 Raysulate
!ndustrial Products for power transmission and distribution
!ndustrial Transformers
Transformer 8 !ndustrial Rectifier Units
Contracts 8 Services
Copper Cable Accessories
Fibre Cable Accessories
Fibre Distribution Nanagement Systems
Circuit Protection Devices
Pipeline Joint Coating
!nternal 8 External Pipe Coating
Cathodic Protection
Electric Heat Tracing
Gas Neters
Warning and Caution Tapes
Casing !nsulators
Rockshield
Polymer Noulded Components
Sheet Netal Precision Components
Aluminum Die Cast Products
Precision Polymer Components
Cable Ties and Clamping Solutions
SBU
Transmission 8 Distribution
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!nfocom
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Corrosion Protection Group
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!nternational Business
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Design parameters to meet long and

trouble free operations
Quality management system to enhance
product reliability
Stringent component selection

Constant design validation

Design to ensure high Nean Time
between failures
Design based on interaction with customers
Capabilities
Design Philosophy
Raychem RPG Limited (RRL) manufactures high quality
automatic 8 manual transformer rectifier units (TRUs) required
for Cathodic Protection applications of buried structures, storage
tanks at storage terminals f refineries and cross country
pipelines which is critical to the hydrocarbon sector of any
country. The TRUs are rugged in construction, designed to
withstand the harsh and unattended conditions they operate in.
RRL has a large, modern and well-equipped design 8
manufacturing facility. Highly experienced team ensures reliable
and quality products capable of meeting exacting delivery
schedules.
RRL has several types of TRU designs, validated and operational
in the fields for several years. All vital components of the units
like transformers, rectifier stacks, control cards are
manufactured under stringent quality assurance system to
achieve highest quality standards.
RRL offers a great deal of flexibility in custom designing of units
to suit specific field requirements, while maintaining high quality
standards and meeting quick delivery schedules.
RRL is certified for !SO9001: 2000 and !SO1+001 standards for
its manufacturing activities at the state-of-art plants in and
around Numbai, operating in an ERP enabled environment.
The TRUs have been approved by all the reputed consulting f
independent inspection agencies in !ndia like Nfs Engineers
!ndia Limited, Det Norske veritas, Bureau veritas !ndustrial
Services, Necon, UHDE (!ndia) Ltd., Nfs Project Development
Corporation of !ndia Ltd, Nfs ABS, Chief !nspectorate of Naval
Supplies (C!NS) to name a few.
Nore than thousand automatic 8 manual units are in operation
in !ndia and other countries. All these units have proved their
performance 8 reliability in field service to the complete
satisfaction of customer. Constant customer training sessions
ensure that product knowledge is shared with all customers to
derive maximum benefits.
Product Features and Benefits
TYPES OF UNITS
CLIMATIC CONDITIONS
TRANSFORMER
RECTIFIERS
PROTECTION
CONTROLS
Natural Air Cooled or Oil cooled, !ndoor or Outdoor, Wall mounted or Base mounted.
AC Operated, DC Operated, ACfDC Operated and Solar Power Operated.
o
Units are designed to work under severe environmental conditions with temperature range up to SS C ambient 8
protection class upto !PSS f !PS6 8 !P6S.
All transformers are designed to give low losses and high efficiencies. The core material is high grade, high permeability,
low loss CRGO silicon steel. The coils are wound with high conductivity, annealed, insulated electrolytic copper
conductors. The insulation material used is of high standard to suit Class F grade. The Transformers manufactured and
tested as per !EC76,
Rectifiers are based on international quality diodes and Silicon Controlled Rectifiers. Rectifier circuits have different circuit
topology based on customer need, specification and efficiency. Single phase bridge is used up to SKW output and above
that three phase bridge or hexa-phase with inter phase transformer scheme is used for higher efficiency . Rectifiers are
designed and tested as per !EC 1+6 standards.
Generally following protection is provided:
- NCB and f or HRC fuses in AC input, DC output for short circuit protection, overload protection 8 ONfOFF operation.
- Fast acting electronic over current limit 8 short circuit protection for output.
- Glass cartridge fuses in the live line of all lamps 8 in the auxiliary power lines to control circuit.
Additional protections are provided as per customer specifications.
Following one or more modes of controls are provided:
a)
The DC output voltage of the TRU in this mode is controlled in 2+ symmetrical steps by means of a separate
autotransformer with coarse 8 fine tapping. Autotransformer can have steps of 16, 2+ or 6+ as per customer
specification.
b)
The DC output voltage of the TRU in this mode is controlled by stepless separate autotransformer connected in primary
of main transformer.
Manual Mode
Tap switch control method.



Stepless autotransformer method.
Constant Voltage Constant Current Mode
Automatic Mode
Air cooled
Oil cooled
Interrupter timer
Stand alone Interrupter timer - Synchronisable Interrupter timer - GPS Synchronisable timer
!n this mode the unit can be operated in either constant voltage or constant current mode.
!n constant voltage mode the DC output voltage will be adjustable from 0 to rated value in stepless manner by means of a
voltage setter potentiometer. DC voltage regulation will be better than 0.S. The controller will maintain constant voltage
at set value under input supply variation and load current variation to keep the structure protected.
!n constant current mode the DC output current will be adjustable from 0 to rated value in stepless manner by means of a
current setter potentiometer. DC Current regulation will be better than 1. The controller will keep current limited at set
value under input supply variation and load current variation to avoid excessive current to the structure.
The operation of the unit in this mode will be fully automatic and will be controlled by the reference electrode feedback.
The unit will automatically maintain reference voltage or pipe to soil potential (P.S.P.) within 10mv of the set value under
all conditions. The controller will maintain the structure protected to set PSP value under input supply variation, load
current variation and external Changes. Reference selector logic selects the lowest (least protected) reference signal and
maintains the protection level.
Enclosures are fabricated from CRCA NS sheet of upto 3.0 mm f 10 SWG thickness. Special type of enclosures made from
stainless steel, aluminum or glass reinforced polyester are also provided as per customer specification. Polycarbonate
windowis provided for viewing meters and indications. Lockable doors are provided in the front and back.
Oil tanks are fabricated from CRCA NS sheet up to 3.00mmf 10 SWG thickness. Control cabinet is fabricated from CRCA
NS sheet up 2.Smmf12 SWG thickness. Oil tank is provided with oil filling inlet, oil drain, oil sight gauge 8 silica gel
breather. Sunshades are provided as per customer specification.
Enclosures are cleaned with seven tank process. Zinc rich primer is applied on cleaned surface and painted with coats of
epoxy baked paint of desired shade. Special type of painting process like hot zinc spray or polyurethane paint can also be
provided as per customer specification.
Following additional features are provided as per customer specifications along with Rectifiers
a)
The !nterrupter timer is used for carrying out ONfOFF CP survey using the current interruption technique. !nterrupter
timer has three options :
-
ENCLOSURES
PAINTING
ADDITIONAL FEATURES
b)
!solated +-20mA transducers are provided for DC output voltage, DC output current and pipe to soil potential (PSP).
Potential free contacts are provided for monitoring critical alarms.
Units can be remotely monitored with this facility and manpower cost can be saved.
c)
The parameter values can be remotely monitored using the GSN based remote monitoring system consisting of multi
channel data logger with built in GSN Nobile phone interface. The data can be monitored using SNS over standard
GSN mobile phone.
d)
The CP TR units can be monitored and controlled through PLC using serial communication. The PLC would be of a
reputed make with international standards. All the critical parameters can be monitored as well as controlled remotely
through the PLC.
e) f)
Raychem RPG has developed a solar powered CP unit
that can be deployed on cross-country pipelines where
the availability of solar power makes it viable to use it as
a cost effective alternative source of energy.
The system consists of a Solar Panel" which consists of
arrays to capture the solar power. This is given to a
Charging Unit" which acts as a terminal through which
the DC potential is given to the CP unit as well as for
charging the batteries. During normal operation the
supply is given directly to the CP units. During times
when the solar supply is disrupted due to some technical glitch or when solar power is unavailable, the power for the CP
units can be taken from the charged batteries through the
Charger Unit".Since the system offers back up in terms of
batteries, which can be charged and later used to power the CP
units, the CP units can be guaranteed to be operational without
any breakdown.
SCADA Monitoring Facility
Remote Monitoring through GSM
Remote monitoring &control through PLC
Hours Run Meter J Time Totaliser KWHmeter
SOLAR POWER
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Types of TRUs manufactured by Raychem RPG Limited
AC Operated TR Units
Input Supply
Output Supply
Single Phase or Three phase
as per customer specification.
Standard Ratings are
DC volt : 12, 2S, S0, 7S, 100v
DC Amp: S, 10, 2S, S0, 7S,
100, 1S0, 200, upto 1200A
2+v, 36v, +8v DC Battery f
Solar Power supply as per
customer specification.
Standard Ratings are
DC volt : 10, 20, +0 v
DC Amp: S, 10, 2S, S0 A
Input Supply
Output Supply
DC Operated CPPSM Units
A6 0perated TR Un|ts
Single Phase or Three phase as
per customer specification.
2+v, 36v, +8v DC Battery supply
as per customerfspecification
requirements.
Standard Ratings are
Single phase supply as per customer specifications
Upto 1 kW
DC volt : 12, 2S, S0 v
DC Amp: S, 10, 2S, S0 A
Input Supply
Output Supply
Input Supply
Output Supply
AC-DC Operated Units
Switch Mode Power Supply
Cathodic Protection
Unit for Hazardous
area Operation
Single Phase or Three
phase as per customer
specification.
Standard Ratings are
DC volt : 2S, S0, 7S, 100v
DC Amp: 2S, S0, 7S, 100A
Input Supply
Output Supply
visit us at www.raychemrpg.com
Some of special TRUs supplied by Raychem RPG
Outdoor type oil cooled S0vf1S0A TRU for
Kuwait with !PSS Protection.

l
!ndoor type air cooled 2Svf1100A TRU
for Jetty application, !ndia.
Outdoor Type Air Cooled Nulti output
2Sv f 2SA AutofNanual TRU for !OCL
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