manufacturing of transformers

Technical Associates

Limited

Energising India since 1969

An ISO 9001:2008 Company

2About Us

Manufacturers of

Power and Distribution

Transformers

Turnkey Transmission &

Distribution EPC Projects

We offer solutions spanning the full length of

Transmission & Distribution Opportunities

3About Us

Currently manufacturing transformers from 5 KVA,

11 kV up to 200 MVA 220 kV class.

Planned production of Power Transformers upto

765 kV at new plant in India.

Manufacturing Capacity 18,000 MVA Per Annum.

Turnkey Projects for building electrical substations,

transmission & distribution lines upto 400 kV.

Aggressive Targets, Confidence to grow

4About Us: Milestones

1967: Technical Associates was founded as a partnership firm.

1973: Present manufacturing location at Lucknow established

1985: Indian Transformer Manufacturers Association (ITMA) set up with TAL as a founder member

1991: TA gets ISO 9000 certification for complete transformer manufacturing process

2001: TA becomes regular manufacturer of 40.0 MVA, 132 kV Power Transformers

2006: Turnkey Power Projects division set up for executing Transmission & Distribution EPC projects.

2007: Work commences on setting up a state of the art manufacturing plant in Sitarganj, Uttarakhand

for manufacture of Extra High Voltage Power transformers up to 765 kV class.

2008: State of the art plant commissioned at Sitarganj (Uttarakhand). It will enlarge TALs transformer

product portfolio to include EHV Transformers up to 765 kV; a quantum leap in manufacturing

and technology.

2009: TAL Sitarganj Unit raised first Invoice.

2009: TAL commissions Vapour Phase Drying Plants and Impulse Generators (HAEFELY,

Switzerland).

2010: Both plants of TAL certified for compliance with ISO 9001:2008 standard.

2011: TAL delivers it's first 100 MVA 220/132 kV Auto Transformer to APTRANSCO.

2011: TAL executes it's first export order for Power Transformers for ZESCO, Zambia.

2011: TAL manufactured 160 MVA, 220/132 kV voltage class Power Transformer and successfully

Impulse tested by ERDA Vadodra.

2012: TAL executes export order for Power Transformers for Tokai Power Products Ltd., Bangladesh

and Distribution Transformation for ABERME, Republic of Benin, West Africa.

2012: TAL installed UP's first 2 MWp Solar Photovoltaic Power plant in District Barabanki Inaugurated

by Honorable Chief Minister of Uttar Pradesh.

2013: TAL executes export order for Power & Distribution Transformers for Energie du Mali, Africa.

2013: TAL received approval from RDSO for manufacturing and supply of Traction Transformers

upto 30MVA, 220 KV.

2013: TAL Sitarganj unit approved by Power Grid corporation of India Ltd. (PGCIL) & NTPC.

2013: TAL testing facilities duly approved and accredited to NABL.

2013: TAL approved for repair of 400/220/132 KV Power Transformers by Power Grid corporation

of India Ltd. (PGCIL).

5Pan India Presence

Sales Network

Plant Locations

6Overseas Supplies

7Products Portfolio

8Power Transformers

S. No Rating Voltage Class

33 kV Power Transformer

1 3.15 MVA 33/11 kV

2 5 MVA 33/11 kV

3 6.3 MVA 33/11 kV

4 7.5 MVA 33/11.5 kV

5 8.0 MVA 33/11 kV

6 10 MVA 33/11 kV

7 20 MVA 33/11.5-6.25 kV


1 12.5 MVA 66/11 kV

2 12.5/ 16 MVA 66/11 kV

3 20 MVA 66/11 kV

4 16/ 20 MVA 66/11 kV

5 25/ 31.5MVA 66/11 kV


1 10/16 MVA 132/11 kV

2 12.5 MVA 132/11 kV

3 20 MVA 132/11 kV

4 20/25 MVA 132/33 kV

5 31.5 MVA 132/33 kV

6 40 MVA 132/33 kV


1 60 MVA 220/132/11 kV

2 100 MVA 220/132/11 kV

3 160 MVA 220/132 kV

100 MVA, 220/132/11 kV Power Transformer

12.5 MVA, 66/11 kV Power Transformer 40 MVA, 132/33 kV Power Transformer

9Distribution transformers Three phase

All the above rating can also be manufactured for 33 kV or 22 kV voltage range Transformers upto 300 kVA, 11/0.433 kV are generally manufactured with

aluminum winding, though copper wound transformers can be manufactured if

required

Transformers of 315 kVA and higher ratings are with copper winding


1 10 kVA 11/0.433 kV

2 15 kVA 11/0.433 kV

3 16 kVA 11/0.433 kV

4 25 kVA 11/0.433 kV

5 40 kVA 11/0.433 kV

6 63 kVA 11/0.433 kV

7 100 kVA 11/0.433 kV

8 200 kVA 11/0.433 kV

9 250 kVA 11/0.433 kV

10 250 kVA 33/0.4 kV

11 300 kVA 11/0.433 kV

12 315 kVA 11/0.433 kV

13 400 kVA 11/0.433 kV

14 400 kVA 6/0.42 kV

15 400 kVA 11/0.42 kV

16 500 kVA 11/0.433 kV

17 630 kVA 11/0.433 kV

18 750 kVA 11/0.433 kV

19 1000 kVA 11/0.433 kV

20 1500 kVA 11/0.433 kV

21 2000 kVA 11/0.433 kV

8 MVA, 33/11 kV Distribution Transformer

Distribution Transformers (11 kV) Distribution Transformers (33 kV)

10

Distribution transformers Single phase wound core

Transformer of 10 kVA are copper / aluminum wound Transformer of 16 kVA and higher rating can be made either with copper or

aluminum or composite windings

Transformer with primary voltage of 11 kV and intermediate ratings are also manufactured


1 5 kVA 6.3/0.240 kV

2 5 kVA 25/0.240 kV

3 5 kVA 11/3 kV/240 kV4 10 kVA 6.3/0.240 kV

5 10 kVA 25/0.240 kV

6 10 kVA 11/0.250 kV

7 16 kVA 6.3/0.240 kV

8 25 kVA 6.3/0.240 kV

9 50 kVA 6.3/0.240 kV

11

Manufacturing Facilities

12

Core Conductor Insulation Tank fabrication

Ready cut core

End frame

fabricationCore assembly

Aluminum / Copper rod

Bare Strip / Wire to size

Paper covering for Strip /

Wire

Coil winding LV & HV

Coil pre heating & pressing

Core coil assembly

Ratio check

Main assembly connections

Ratio Check

Vacuum Drying/ Vapour

Phase Drying

Press Board, Insulating

paper, Permawood

Slit paper, blocks, spacers,

supports, strips

Tanking

Oil filling

Filtration

Testing

Inspection

Dispatch

Manufacturing process

Fabricated Tank

CRGO Coil

13

Manufacturing Facilities Lucknow

Spread out over 8 acre area with ~ 6,000 sq. meters of covered sheds

Shops are of adequate height with liberal floor area and are equipped with E.O.T cranes and other material handling facilities

Separate facilities have been earmarked for assembly of Distribution and Power Transformers

TAL has invested heavily in backward integration and does in-house production of major raw materials

Core processing (Slitting, Cutting and Annealing)

Conductor manufacturing (Drawing, Annealing and Paper covering)

Transformer oil processing

Tank fabrications

Winding

Assembly and tanking

Manufacturing capacity of ~ 4,000 MVA per annum of mixed transformer ratings

Distribution Transformer Bay Power Transformer Test StationPower Transformer Bay

14

Lucknow plant

Core Cradles designed especially for high quality large

Core Assembly

Winding Machines for handling heavy weight coil winding

at variable speeds upto 10.0 MT capacity

15

Complete facilities for Insulation cutting/ processing

Lucknow plant

16

Complete facilities for Drawing of Round/ Rectangular Copper/ Aluminium conductor for use in Transformer windings

Multi Layer Paper strip covering machines for Winding conductor

Lucknow plant

17

Cranes of 5, 10, 25, 35, 150 MT lifting capacity

Lucknow plant

18

New manufacturing facility at Sitarganj

New Plant in Uttarakhand, North India

T1: 11 kV

transformer

assembly

T2: 33 kV

transformer

assembly

T3: Central

Store

T6: 66/ 132

kV

Assembly &

Testing

EHV Test

Area

T8:

Fabrication

T7: Core

Slitting,

cutting,

annealing

T5: 66/ 132/

220/ 400 kV

Winding

T4:

Insulation

Processing

T9: Impulse

Test Area

T9: 220/ 400

kV

Assembly

19

Manufacturing facilities Sitarganj Spread out over 12.5-acre area and is fully equipped to manufacture EHV power transformers upto 765 kV voltage class

The manufacturing sheds occupy a total covered area of ~ 23,000 sq.m. ranging from 4 m to 24 m in height, and spans of 12 m to 24 m

The plant has been designed for optimal material and work flow, and integrated manufacturing operations with separate bays planned for:

Single phase and Three phase 11 kV distributions transformer

Three phase 33 kV distribution transformer

Three phase 66 & 132 kV power transformer

Single phase and three phase 220 to 765 kV power transformer

Coil winding

Insulation processing

Mild steel fabrication

Impulse testing set-up

Manufacturing capacity of 14,000 MVA per annum of mixed transformer ratings. Would be able to manufacture and deliver one 132 kV

transformer per day

Distribution Transformer Bay Power Transformer Test StationMaterial Handling Facility up to 300MT (2 X 150) Power Transformer Bay

20


21


22

66/132 kV Winding Area

23


24


25

66/ 132 kV - Assembly

26

66/ 132 kV - Assembly

27

100 MVA 220/132/11 kV Auto Transformer CCA

28

Autoclave & Vapour Phase Drying Oven (VPD)

29

132 kV transformers under test

30

132 kV transformers under test

31

66/132 kV test station

32

220/ 400 kV assembly with 2x150 MT EOT cranes

33

Impulse Test area: 1600 kVP, 160 KJ Impulse Generator

34

Design & engineering and R&D EXPERT DESIGN & ENGINEERING TEAM

TALs GM and senior consultant are both Ex GMs of BHEL The director of the design & engineering has been working with TAL for last 41 years

TAL has a very strong, highly experienced design & engineering and R&D team capable of taking new challenges

STRONG R&D

TAL has strong R&D team having capabilities of

developing new products in house

All the products manufactured by the company

have been developed in-house including the 220

kV & 132 kV transformers

The company has a fully computerized design

office and all transformer designs are done on

the basis of in-house developed software

For mechanical design, Computer Aided Design

tools like AutoCad & Solidworks are used

extensively

Large number of TAL transformers have

successfully cleared Impulse Voltage Withstand

Capability tests at 3rd party, Government

accredited Laboratories like CPRI (Central

Power Research Institute)

TAL also has some of the largest no. of

transformers that have cleared 3rd party short

circuit tests, amongst companies of TALs size

S.No Designation Qualification Years of

Experience

1 GM (Technical) M.E. (Elect) 38

2 Sr. Consultant B.Sc. (Elect. Eng.) 45

3 Director B.E. (Elect. Eng.) 42

4 Plant Head B.E. (Elect.) 39

5 General Manager B.E. (Mechanical) 37

6 Deputy General Manager BE (Electrical Engg.) 14

7 Deputy General Manager Diploma in Electrical 15

8 Deputy General Manager B.Tech (Electrical) 18

9 Manager B.Tech (Mechanical) 20

10 Sr. Engineer B.Tech (Elect) 5

11 Sr. Engineer B.Tech (Elect)+Pursuing M.Tech 3.6

12 Sr. Draftsman B.A.+ ITI 6

13 Sr. Draftsman B.A.+ ITI 5

14 Engineer BE(Power Electronics) 7

15 Engineer B. Tech (Electrical & E.) 2

16 Engineer Diploma in Mechanical 3

17 Trainee Engineer B.Tech (Mech)+Pursuing MBA 2

18 Trainee Engineer B. Tech (Mech.) 1

19 Trainee Engineer M.E. (High Voltage) 0.1

20 Trainee Engineer M.E. (High Voltage) 0.1

21 Draftsman ITI & Diploma (Mech) 3

35

Testing facilitiesOVERVIEW

Independent testing facilities for Power and Disttibution transformers at bothLucknow and Sitarganj plant.

TALs Test lab has been assessed and accredited in accordance with thestandard ISO/IEC 17025:2005 by National Accreditation Board for Testing

Calibration Laboratories (NABL).

All routine tests/Impulse test & Temperature rise tests as per IS2026/IEC60076are performed in house using fully automated, computerized test benches &

advanced testing software. TAL can also conduct specialized advance tests

such as measurement of Partial Dischargge, SFRA etc. at its works.

Short circuit tests are conductted at CPRI (Indias leading, independent testcenter).

Impulse voltage withstand ability tests are carried out through two impulsegenerators (1600 kVp, 160 kJ and 900 kVp, 45 kJ) from Haefely, Switzerland

with expandable capacity to test transformers of 765 kV voltage class.

Testing with Yokogawa Power Analyzer

Impulse Testing

Facility

36

Our Quality Policy

We, at Technical Associates, are committed to achieve total satisfaction of our customers by:

Effectively implementing and continually improving the Quality System.

Delivering on time, products conforming to agreed specifications at competitive prices.

Collectively and individually striving to do things right the first time and every time - both in personal life as well as at the workplace.

Continuous up-gradation of technology and active involvement of all employees and associates in productivity improvement.

37

Turnkey Projects

38

Turnkey Projects

TAL Engineering Projects Division (EPD) was established in 2006 to

enhance and capitalize Technical Associates strong presence in the power T&D sector

It undertakes complete execution of turnkey electrification projects from

conceptualization , design, engineering, procurement, erection and

commissioning

The tasks taken up by TAL EPD include Rural Electrification Works,

Distribution & Transmission lines from LT (440 V) to 220 kV, and electrical

Substations from 11 kV to 220 kV

Scope of works undertaken include:

Complete design, engineering & planning

Procurement & project management

Erection / construction / commissioning / testing

Handing over to customer / training

Works undertaken include:

Planning, erection and commissioning of HVDS network

Rural electrification planning and commissioning

Setting up of LT lines for urban / Rural networks

Setting up of 11 kV distribution substations and lines

Setting up 33/66/132/220 kV switch-yards and lines

Energy auditing

Planning, erection and commissioning of intelligent rural load management systems

Main strengths :

Experienced engineers, technicians & support staff from the field of project

tendering, engineering, execution, erection, commissioning and testing

High level of quality control

66 kV Sub-station with TAL transformer 132 kV Sub-station under construction

66 kV Sub-station at Mohra, Haryana

39

CustomersCUSTOMER SEGMENTS

Key customer segments catered by TAL include: State (regional) electricity utilities

Overseas electricity boards.

Government & private power companies

Government and private power equipment manufacturing

companies

Infrastructure companies

Other manufacturing companies

KEY CUSTOMERS

40

Partnering with us - the advanTAge

Your Partner in Progress

A proven track record

Historically proven capabilities in

engineering / design

State-of-the-art infrastructure

40 year old credibility

Close proximity

Documents

manufacturing of transformers