Tes magazine first issue

MAGAZINEFIRST ISSUE

01/2014

TRANSFORMER ELECTRO SERVICE S.r.l.

TR

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TEEL

Design, construction, testing and commissioning of

INDUSTRIAL & SPECIAL TRANSFORMERS For metallurgical plants

T h e I t a l i a n t a i l o r m a d e

RICCARDO REBOLDI TES Chief Executive Officer

MAGAZINETRANSFORMINGENERGY INTO ART

FIRST ISSUE01/2014

After my 25 years supplying the iron and steel industry and a series of recent TES achieve-ments, we decided to publish our first magazine to encourage exchange between iron and steel manufacturers, who are faced with an exponential increase in the consumption of electricity for processes, subject to rapidly reducing margins and ever shorter produc-tion cycles and delivery times.

We have a thorough knowledge of the steel market – we started out here and are still fully involved. TES was established in the heart of Europe’s main steel region as a division of ASO Siderurgica, an Italian steel mill where we gained experience, repairing and ser-vicing electric transformers. Towards the end of the 1990s we developed innovative and competitive technology for producing new transformers and now have the capability to build special very-high-power transformers for the world’s leading steel mills and Metal-lurgical plants. Working on a daily basis, in various companies in different countries has en-abled us to refine our technology and our ability to adapt to Customer in flux requirements.

We have achieved numerous successes thanks to a fully committed team of dynam-ic young engineers and heavy investments in the various business lines, which focus on R&D, the design and production of special transformers, and the repair, upgrading, main-tenance and testing of transformers of any type, make and application.

This new magazine is a further step forward in the process of supplying manufacturers all over the world, especially in the iron and steel business, and finding the right solution to meet the requirements of a sector that we know better than anyone else.

We open the doors of our company with this in mind, eager to offer steel manufacturers an overview of our products, the only ones of their kind in the world. We will present some of our most representative case histories involving TES’ various divisions, as we believe in sharing experience and promoting innovative solutions and interventions that smack of challenge and uniqueness. We are fully aware that every steel manufacturer, regardless of its background, now has to operate in an increasingly competitive market that rewards those who can truly offer something different.

This is how we do it, proud of our achievements so far and with the enthusiasm and com-mitment of a team of experts dedicated to studying and developing tailor-made solu-tions as only the Italians can do. Our special prime-quality products are built to operate safely and continuously anywhere in the world, with the back-up of a prompt and efficient after-sales service.

The true secret to success is not thinking differently from others,but being different – precisely what TES has always been!

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Riccardo ReboldiTES Chief Executive Officer

CONTENTSTRANSFORMINGENERGY INTO ART

THE COMPANY

Divisions, financial highlightsand sizeFull development of TES operating units, which have extended their range of action to a global level, gathering the opportunities that globali-sation offers players who combine entrepreneurial abilities and techno-logical research.

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PEOPLE

WORLDWIDE SALES

A team of highlyskilled engineersprovide tailor-madesolutions

TES transformersand sales agents at a global level

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WORLDWIDE FOCUS

Innovation andefficiency: a few case histories in the iron & steel industry

THE AMERICAS: SIMEC Corp. Inc. commissions TESto supply its steel mills in two continents

OMAN: Sohar Steel switches from 30 to 80 MVA fur-nace transformer with no intermediate steps

RUSSIA: Jolly turnkey EAF transformers for two plants belonging to the NLMK Group

INDIA: The JSPL Group turns to TES for great new EAF; LF transformers and reactor for its plants

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18THEAMERICAS

RUSSIA

MIDDLEEAST

INDIA

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NEWS IN BRIEF :

TES SERVICE:

CASE HISTORIES:

Worldwide news flashes

The value of experience in providing assistance and revamping used equipments. 4 different divisions ensure production continuity of TES Customers today

Buyer assessment

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FERALPIonce again satifisfied with service efficiency

A REPLACED transformer savesproduction

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R&D

QUALITY

LOGISTICS

EVENTS

BACKSTAGE

TES’ R&D department creates tailor-madesolutions

2013 trade exhibitions and 2014 events to come

Young, dynamic andhighly-motivated peoplefor a successful company

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THE COMPANY

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TES (Transformer Electro Service), which is based in the province of Brescia, the heart of

Italy’s main metal working area, is one of the most highly-evolved and qualified companies

that produce high-power transformers. Specialization in the production of special rectifier

transformers, lengthy experience in the construction of high-voltage machines and an effi-

cient after-sales service, make TES the ideal supplier for the entire iron & steel industry.

THE ITALIAN TAILOR-MADE PRODUCTTHAT MEETS CUSTOMER REQUIREMENTSALL OVER THE WORLD

TRANSFORMINGENERGY INTO ART

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THE COMPANYTHE ITALIAN TAILOR-MADE PRODUCTTHAT MEETS CUSTOMER REQUIREMENTS ALL OVER THE WORLD

Range of activities

After-sales service

Design, construction, testing and commissioning of new transformers with capacities up to 400 MVA and insulation class up to 420 kV

Design, construction, testing and commissioning of new transformers for use in the iron and steel industry and series reactors

Design, construction, testing and commissioning of new rectifier transformers for straighteners

Trading and rental of power and furnace trans-formers, suitably overhauled and guaranteed

Repair of faulty transformers, including redesign, repowering and rewinding

On-site testing and inspections to identify mal-functions or problems with any installed trans-formers

On-site ordinary and extraordinary preventive maintenance of transformers and related acces-sories

OPERATION FIELDS

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WORKSHOP 2 Assembly and testing

Well aware of the need to optimise customer lead times, TES today has a well-organised sales

network consisting of technically qualified personnel who can provide practical assessments and

solutions in tune with new market dynamics. By speeding up the development of on-site solu-

tions, TES can guarantee supplies in record time worldwide. TES currently supplies over 160 com-

panies in 50 different countries.

TES’ policy of providing direct on-site assistance, allows to offer solutions in full compliance with

national and international safety and quality standards, which permit Customers the production

continuity, avoiding serious losses caused by production stoppage.

TURN-OVER

8 PEO

PLE

TES

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TES boasts a team with great potential: dynamic and innovative top management focused

on market changes; a pragmatic technical sales team continuously updated, with consolidat-

ed international experience and highly skilled production people for carrying out research into

new solutions.

We are a young and close-knit team of industry leaders and innovators ready to take on any

challenges posed by our customers and to implement them when possible.

Working with passion is worthy reward for our commitments: TES enjoys ongoing growth and

its evermore skilled, competent and hardworking team of technicians has led it to strongly

believe that research and development are the hallmarks of a corporate philosophy aimed at

optimising processes, tools and resources.

PEOPLE: COMPETENCE AND KNOW-HOW AT THE SERVICE OF TES’ CUSTOMERS

PEOPLE

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GIUSEPPE MERCURELLI ASO Siderurgica and TES

Chairman

MAGAZINETRANSFORMINGENERGY INTO ART

FIRST ISSUE01/2014

TES: IN A COUPLE OF DECADES,FROM SPIN-OFF OF ASO SIDERURGICATO A WORLD-CLASS COMPANYTES took its first confident steps in the world of iron and steel industry and started working on the machines of the steel mill from which it derived. We then specialised in revamping transformers built by other manufacturers at a time – the 1980s – when the Italian iron and steel industry was starting to reduce steel output and ASO specialised in the acquisi-tion of decommissioned systems for restoring and reusing industrial machinery.TES improved in the construction of ever larger and technically more complex transform-ers to become one of the few companies in the world today capable of making industrial transformers with a power in excess of 200 MVA.The key concepts, representing the main strengths of the companies in the ASO GROUP are continuous renewal and enhancement of human resources, backed up by major in-vestments approved by management each year to increase and internationalize its know-how. This gives the group the versatility and expertise required to meet the challenges of globalisation. TES has brought to the many metallurgical plants, in the 50 countries in which it operates, the excellent quality typical of Italian manufacturers, establishing a synergy to optimise both production capacity and the range of services provided.A sense of cooperation, focus on reseach, willingness to change and transparency are the values we share within the Group, where we manage to maintain the atmosphere of a cooperative family, within companies of considerable size, that are efficiently run and ex-tremely well organised.Ours, is a commercial approach focusing on extending the Group’s presence abroad by means of green field takeovers and initiatives.This enables us to increase the number of foreign customers, maximize the group’s effi-ciency in terms of logistics and set up a sales network, based specifically on internal know-how. The work is endless, but the results are encouraging.ASO today can be considered one of the main players in the niche sector of forging ingots and forged bars. We’re now the world’s leading producer of hydraulic components, and TES, which started out as a small workshop, ranks among the most highly evolved and qualified companies, producing power and special transformers for various applications, especially for iron & steel production, where guaranteed safety and production continuity are mandatory requirements.

Giuseppe MercurelliASO Siderurgica and TES

Chairman

WORLDWIDE

TES

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TES TRANSFORMERS IN OPERATION ALL OVER THE WORLD

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WORLDWIDE

Capillary sales networkKhan B. & International Bangladesh [email protected] Eduardo Fernandes ME Brazil [email protected] Metallurgical Service China [email protected] Greece [email protected] India India [email protected] Sanat Pasargad Iran [email protected] Group S.r.l. Iraq [email protected]. Di Lorenzato Alberto Italy [email protected] Construction and Oil Libya [email protected] S.A. Mexico [email protected] Vladimir Russia and Ukraine [email protected] Foadia Group Saudi Arabia [email protected] Representaciones S.L Spain [email protected] Dick South Africa [email protected] Elteknik AB Sweden [email protected] Muhendislik Mumessillik Turkey [email protected] Company USA [email protected]

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THE INTERVENTION STEP-BY-STEPSupply and installation of a furnace transformer with a rated power of 80 MVA (2010) to

replace the existing 30 MVA one, prepared for the future installation of a series reactor to be

connected Internally to the primary delta of the transformer .

Final supply and installation of the series reactor (2012) with a rated power of 19.4 Mvar.

OMAN: Sohar Steel switches from 30 to 80 MVA furnacetransformer with no intermediate steps

DANILO DOSI TES Sales Director

The installation of the furnace transformer and the series reactor has allowed the UAE-based

steel mill to increase its output considerably, avoiding unnecessary high costs.

Transformer technical specificationsFURNACE TRANSFORMER

Rated power: 80 MVA

Primary voltage: 33 kV

Secondary voltages: 950-680-435 V

Maximum secondary current: 68 kA

Frequency: 50 Hz

OLTC: MR VACUTAP HD

Secondary connection: internally closed delta

Cooling system: OFWF

Weight: 124 tonnes

SERIES REACTOR

Rated power: 19.4 Mvar


Frequency: 50 Hz

OLTC: MR VACUTAP HD


Weight: 41.5 tonnes

An MR VACUTAP HD (Heavy-Duty) on-load tap changer is used in the 80 MVA furnace transformer and the series reactor: this key transformer device (MR®) allows to reduce the mainte-nance required on this equipment to a minimum.

TES PRODUCTION

MIDDLE EASTWORLDWIDE

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TES’ PROPOSAL TES presented a solution that excluded the installation of an intermediate 50 MVA

transformer and envisaged the installation of an 80 MVA transformer designed for

connection to a series reactor.

This solution clearly proved to be cost-saving for the steel mill, which awarded the

contract to TES for the supply of a 19.4 Mvar series reactor, with on-load a changer.

This kind of action permitted to our Customer to improve furtherly its productivity.

CUSTOMER’S REQUESTTo increase the output in the steel mill in two stages: switching from a first partial in-

crease in output by installing a 50 MVA transformer to a final upgrading by installing

an 80 MVA transformer, using a series reactor.

DELIVERY SCHEDULE- 9 months for the supply of the EAF transformer (2010)

- 7 months for the supply of the reactor (2012)

MIDDLE EAST

Danilo Dosi - TES Sales Director

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TES presented this iron and steel group a winning technical solution and produced a unique

138 MVA EAF transformer, the so-called “Jolly”, built in such way as to be used in two different

steel plants. The design took into account all the features and requirements of both produc-

tion plants and the final technical solution, proved to be fully safe and reliable – the result of

the skilful use of exclusive technology in the production of high-power transformers that are

fully interchangeable with existing ones.

RUSSIA:Jolly turnkey EAF transformer for two plantsbelonging to the NLMK Group. A logistics challenge

THE INTERVENTION STEP-BY-STEPThe NLMK Group purchased a unique 138 MVA EAF transformer with a 31Mvar series reactor

for its steel works at Ekaterinburg JSC “NSMMZ” and its plant in Kaluga to increase steel out-

put and build up stocks where necessary, which is a widespread trend amongst steel makers.

Transformer technical specificationsFURNACE TRANSFORMER

Rated power: 138 MVA



Maximum secondary current: 72.4 kA

Frequency: 50 Hz

OLTC: MR Germany



Weight: 135 Tonnes

SERIES REACTOR

Rated power: 31.1 Mvar


Frequency: 50 Hz

OLTC: MR Germany


Weight: 65 Tonnes

TES PRODUCTION

RUSSIAWORLDWIDE

FABIO MARTONTES Technical Director

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CUSTOMER’S REQUESTThe Customer requested the supply and the installation of an innovative, reliable

transformer and a series reactor to improve the performance of its steel mills.

The big size and heavy transformer, had to be turnkey, including transport, unload

and installation.

TES INTERVENTION TES designed both units in full compliance with the particular requirements and

completed the construction of both transformer and reactor, within the agreed lead

time and carried out successfully all the tests in accordance with IEC standards.

The transformer design and construction stages involved changes to the original

project to meet customer’s requirements. TES customized the design as required,

which involved a particular positioning of the on load-tap changer and the cooling

system to ensure they fully satisfied the needs of the two different plants.

TES completed the work and organised the shipment and the installation of the

transformers at the Revda plant, near Ekaterinburg successfully.

RUSSIA

Fabio Marton - TES Technical Director

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The JSPL Group (Jindal Steel and Power Limited) has purchased from TES a 220 MVA EAF

transformer, a 40 MVA LF transformer and a 25 Mvar series Reactor. It has chosen to award

TES this impressive purchase order, even if TES was a new supplier for them. In various meet-

ings on the customer’s premises, TES has been able to overcome the scrupulous Indian tech-

nical selection, thanks to the competence and ability of its technicians and sales agents cov-

ering the territory by coming up with innovative solutions.

INDIA: The JSPL Group turns to TES for the purchase of new and powerful special transformers for its plants

FILIPPO BUTTINITES Furnace & Rectifier

Transformers Sales Engineer

Transformer technical specificationsEAF FURNACE TRANSFORMER

Rated power: 240 MVA



Maximum secondary current: 101,5 kA

Frequency: 50 Hz

OLTC: MR Germany



Weight: 220 Tonnes

LF FURNACE TRANSFORMER

Rated power: 36 MVA



Maximum secondary current: 55,4 kA

Frequency: 50 Hz

OLTC: MR Germany

Secondary connection: open delta


Weight: 55 Tonnes

TES PRODUCTION

INDIAWORLDWIDE

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CUSTOMER’S REQUESTSupply of 2 transformers which had to be fully interchangeable with the existing

ones, capable of guaranteeing fast and easy replacement of the existing units with-

out any civil engineering works. If requested, the existing units have to be simply

disconnected and the new ones installed thus, guaranteeing production continuity.

Furthermore, the transformers should boast different technical solutions to enhance

the performance of the plants compared to those in existence.

TES INTERVENTION TES designed both transformers in full compliance with the requested features,

completed construction and supplied a reactor in the agreed short lead times. The

equipment passed all the tests, including a “temperature rise test” carried out in the

presence of the customer in accordance with the IEC standards adopted by TES.

The degree of satisfaction was such that the customer decided to order 2 further

spare transformers for another steel plant in OMAN, one EAF transformer of 240

MVA and an LF one of 36 MVA.

DELIVERY TIME6 months from order date to completion of both transformers.

INDIA

Filippo Buttini - TES Furnace & Rectifier Transformers Sales Engineer

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TES PRODUCTION

THE AMERICAS

MVA TYPE COOLING kV Q.TY CUSTOMER

135 three-phase EAF transformer EAF OFWF 34.5/1.15÷1.015÷0.647 1 REPUBLIC STEEL

134,4 three-phase power transformer POW ONAF 230 ± 2 x 2.5% / 13.8 1 GRUPO SIMEC S.A.B. de C.V.

80 three-phase EAF transformer EAF OFWF 34.5/1.02÷0.85÷0.55 1 GRUPO SIMEC S.A.B. DE C.V.

70 three-phase EAF transformer EAF OFWF 23/1÷0.8÷0.6 1 SIMEC U.S.A. CORPORATION

70 three-phase EAF transformer EAF OFWF 13.8/1÷0.8÷0.6 1 SIMEC U.S.A. CORPORATION

60 three-phase EAF transformer EAF OFWF 23/0.99÷0.834÷0.6 1 SIMEC U.S.A. CORPORATION

60 three-phase EAF transformer EAF OFWF 34.5/0.9÷0.834÷0.6 1 ACEROS DM SA DE CV

42 three-phase EAF transformer EAF OFWF 13.8/0.745÷0.65÷0.5 1 SIMEC U.S.A. CORPORATION

10 three-phase LF transformer LF OFWF 34.5/0.28÷0.26÷0.18 1 GRUPO SIMEC S.A.B. DE C.V.

10 three-phase LF transformer LF OFWF 34.5/0.28÷0.26÷0.18 1 ACEROS DM SA DE CV

TOT 671,4 MVA

THE INTERVENTION STEP-BY-STEPTES plays a leading role in the 2012-2014 three-year period in the production of 5 transform-

ers and the upgrading of the existing systems at SIMEC Corp. Inc. production plants in the

USA, Mexico and Brazil.

TES, which enjoys the full trust of the NYSE-listed Mexican iron and steel group, has been

awarded a contract for the supply of a total of 10 transformers for American manufacturers,

5 of which to be designed and built and the other 5 to be upgraded on site in accordance with

the revamping TES technique for a total of 671 MVA which will implement the American steel

sector.

THE AMERICAS: SIMEC Corp. Inc. has commissioned TES to supply its steel mills in two american continents.A case of exceptional trust

DANIELE BERTUSSITES Project Manager

Engineer

WORLDWIDE

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CUSTOMER RELATIONSOne of the most prestigious awards to TES’ high quality standards is the given trust

by the leading steel manufacturer Group SIMEC Corp. Inc., which has decided to use

the services of the Italian company in all its production plants in the Americas. The

fruitful relationship established with this Customer commenced with some installa-

tions in its Mexican plants, followed by the supply of a new system in Brazil and the

upgrading of its plants in the United States. TES met the technical requirements of

the different plants and complied with the specific standards in force in the different

countries where the group operates. It offered a customized technological study and

product based on international high quality standards, which enables it to become a

qualified supplier for the American giant.

In order to guarantee service continuity and fulfil contract obligations, Tes provided

new spare transformers which are perfectly interchangeable with the already exist-

ing ones produced by others long time ago.

This italy-based company proves to be a versatile, reliable and efficient partner for

the supply of transformers operating in different working conditions, being always

very competitive.

THEAMERICAS

Daniele Bertussi - TES Project Manager Engineer

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SHO

RT NEWSSHORT NEWS

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The Swedish company has been using the same mobile substation transformer since 2010 in

different plants as it is fast, cheap and easy to transport. For E.ON, TES manufactures a highly

versatile product that is able to supply all high- and medium-voltage electric power transmis-

sion and generation in Sweden high voltage grid.

The design and building capacity of TES faced the challenge of making a dual-level high-volt-

age and three-level medium-voltage transformer, which had to be flexible and compact at

the same time. The transformer had to meet strict technical and design requisites allowing

it to be moved at Customer’s will in any plants of the company. A solution was found thanks

to the use of Pfisterer insulators for high- and medium-voltage connection, which featured

an optimal geometric structure, that ensured easy handling and installation wherever it was

needed at low costs.

SWEDEN: a 35 MVA transformer for mobile substation for E.ON plants

WORLDWIDE

In 2013 General Electric commissioned TES to design and manufacture 8 conversion trans-

formers for the electrification of Australian railways. This one-of-its kind contract covers the

supply of an exclusive solution: a 50 Hz transformer supplying trains with AC instead of DC

voltage, as in the past.

TES was awarded the pilot project after lengthy negotiations in which the main international

players were defeated. TES is required to complete the Australian plants by the end of 2014.

AUSTRALIA: General Electric giant awards TESan unprecedented order

OFAF 35 MVA 145-72,5/57,5-23-11,5 kV OLTC

ONAN 8,7/3X2,9/2 MVA 132/3X5,4/10 kV

ONAN 8,8/8,8/4 MVA 50/16,5/6 kV

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SHORT NEWSWORLDWIDE

Posco has chosen TES to supply two 3-phase 36.3 MVA iron-alloy SAF furnace transform-

ers, maximum current 87.3 kA, used for the production of nickel. The record lead time met

the customer’s need for speed without sacrificing the quality and safety of the product. The

transformers complied with all the requirements of Korean standards, even exceeding the ex-

pectations and obtained the highest score by the inspectors from the Korea Electrical Safety

Corporation, who supervised the different test stages at the Italian plant. The transformers

received the stringent KESCO certification.

KOREA: two 3-phase special transformers producedfor Posco have obtained KESCO certification

OFWF 60 Hz 31 steps OLTC

36,3 MVA 22000 / 290÷240÷140 V at delta connection configuration

21,2 MVA 22000 / 167÷139÷81 V at star connection configuration

In 2009, Metalleghe renewed the metal ferro-silicon plants of its Bosnian subsidiary

BSI (BiH) and commissioned TES to replace the existing single-phase transformers

with 7 modern installations of the same overall dimensions.

The supply consisted of 6 single-phase units and one three-phase unit already sup-

plied plus 3 further single-phase transformers to be supplied.

This intervention, carried out by TES technicians, enabled BSI to increase its yearly

output by 30%.

The customer was so satisfied with this service, that in 2014 the End User recom-

mended TES to the Main Contractor, TENOVA/PIROMET, for the supply of a turnkey

transformer to be installed in its subsidiary R-S Silicon in Bosnia BiH.

BOSNIA: with Metalleghe, TES doubles the supplyof transformers for SAF

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TES’ SERVICE26

TES’ SERVICE

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Always faithful to its core business, TES has upgraded its Service Dept. by opening a new

4,000 m2 Workshop for this division.

Dedicating its specialized personnel and uploading a new portal called 24/7 for the merchan-

dising of used transformers.

TES usually picks up damaged transformers from the own-

ers and repair them in this Workshop, in which all the stages

of the intervention can be handled. This is the ideal place for

carrying out routine and extraordinary upgrades and main-

tenance operations on transformers, with rated power up to

400 MVA and insulation class up to 420 kV.

The speed of the interventions, the technical skills, the quality

of the products and the offered services, have made TES’ Ser-

vice an indispensable ally for companies who face unexpect-

ed problems or simply want to do the routine maintenance,

for keeping their equipment in perfect working conditions.

TES’ Service also rents transformers that can be put into

operation immediately and used for the time needed for the

reparations of the damaged one, or sells used transformers

to companies as spares.

THE VALUE OF EXPERIENCE IN THE ASSISTANCE AND REVAMPINGOF USED TRANSFORMERS

THE 4 DIVISIONS

SERVICE IN FIGURES- total number of transformers repaired or upgraded in 2013: 14 transformers + 1 reactor

- total number of MVA repaired in 2013: 500 MVA transformers

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TES’ SERVICETHE VALUE OF EXPERIENCEIN THE ASSISTANCE REPAIRING AND REVAMPING OF USED TRANSFORMERS

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REVAMPINGThis division offers companies, the chance to revamp their transformers by optimizing its ex-

isting technical characteristics without buying a new machine.

Thanks to our specialist’s on-site and in-house experience, prevention, routine and extraordi-

nary maintenance of all types of transformers, plus its continuous commitment to technolog-

ical innovation, TES has made of revamping one of its centre of excellence.

Revamping or upgrading means to work on the active parts of the transformers without mod-

ifying its existing structure or those parts that do not need to be replaced.

The revamping process signif-

icantly improves the perfor-

mance of transformers in use

and can be performed whether

the transformer in issue, is dam-

aged or is being frequently used

in overload by the customer who

has increased, during the years,

its productivity.

TES offers this service both for

its own products and third-party

products and can guarantee the

final result by carrying out IEC’s

final tests in its testing room.

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AFTER-SALES SERVICESince being set up, TES has always wanted, sometimes even against the tide, to maintain

its origins and to apply the latest state of art of the new technologies, in sense of materials,

design, components and electrical schemes, normally used for the production of new trans-

formers, to the art of repairing.

After-sales service, includes all maintenance and diagnostic control activities on transform-

ers, monitoring of machine reliability, prevention of any malfunctions and prompt remedies to

avoid any stop in the production cycles of our Customers.

TES has dedicated means and resources to promptly react in

case of problems. The on-site inspection and the performing

of physical, chemical and gaschromatographical oil analysis,

are the first actions to take in these cases, and basing on the

results TES’ technicians will decide if the repairing will be

possible on site or in TES’ factories.

TES has a mobile testing room for carrying out the following

tests at the customer’s site:

- insulation tests up to 110 kV DC

- winding resistances measurement

- SFRA and winding inductance measurement

- measurement of winding capacity and tg δ,

and HV bushing

- infrared thermographic inspections

- water content in oils (with time trend)

and dielectric strength.

TES has a large stock of reconditioned transformers ready for use, which, in cases of need or

in emergency, can be made available to customers with flexible rental or purchase terms and

conditions.

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TES’ SERVICETHE VALUE OF EXPERIENCEIN THE ASSISTANCE REPAIRING AND REVAMPING OF USED TRANSFORMERS

ASSISTANCETES is an international benchmark of transformer assistance. The ex-

clusive after-sales and emergency service, backed up by the most ad-

vanced diagnostic investigation techniques for the detecting of faults

or malfunctionings, allows to solve problems on installed transform-

ers and to restore them in the shortest possible time.

The awareness of the great importance that the production conti-

nuity has for our Customers together with the fact that TES is one of

the few companies in the world, certified ISO 9001 for the repairing,

revamping, repowering and rewinding of all kind of oil-filled trans-

formers, make TES an ideal partner for the worldwide Metallurgical

Industry.

TES’ Service branch organization covers over 50 countries worldwide

guaranteeing fast assistance, repairs and temporary unit replace-

ments to avoid costly downtimes.

The in-house testing room can perform both standard tests required

by the international standards and special type tests required by Cus-

tomers.

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24/7 ON-LINE SHOWCASETES experience is now online for all Metallurgical producers. With the advent of the 24/7 ser-

vice, companies have direct access from their offices to a showcase, where they can buy and

sell used transformers ready for delivery and spare parts.

The portal was conceived to offer companies support in real time and guarantee continuity of

production via an immediate internet link.

The 24/7 service, which operates 24 hours per day, procures and delivers second hand trans-

formers, components and spare parts.

In a few easy steps, you can obtain quotes and details of warehouse stocks and delivery

times, to help you find what your are looking for, either a new

transformer or your own one restored to the conditions required

by your production.

The portal also contains a restricted access area for each TES

Customer providing the following:

- technical data for purchased transformers

- updated standard requirements

- user guides for purchased transformers

- tutorial videos

- check-up of in-service transformers, with all the related

documentation allowing maintenance to be scheduled

and performed to guarantee efficient operation.

In addition, any company that has signed up, can post its sales

adv regarding their own second hand transformers, in a dedicat-

ed area and take advantage of the enhanced visibility and the

large number of users accessing the portal.

www.tes247.it

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TES SERVICECASE HISTORY

FERALPI. ONCE AGAIN SATIFISFIED BY OURPROMPT ACTION TES INTERVENTIONRepair of the EAF’s 105 MVA transformer following a fault that affected the secondary con-

nection and hence the transformer as well.

Replacement of damaged LV outputs, maintenance of the on load-tap changer (3 sin-

gle-phase OLTC) with replacement of switches and contacts. Replacement of on-board

equipment and auxiliary switchboard, replacement of gaskets and complete painting.

Time taken: 4 months from the withdrawal of the faulty transformer to testing of the repaired

transformer.

TES RESPONSE: RESPONSE ACTION TIMES & MADE DIAGNOSIS The transformer was delivered to TES’ workshop on 6 August.

Activities performed:

- transformer downloaded from truck

- tank opened and all oil drained out (stored in a tank)

- active part removed

- transformer tank and active part inspected in customer’s presence.

The transformer was tested on 29 December.

EAF’S 105 MVA TRANSFORMERFaulted

EAF’S 105 MVA TRANSFORMERRepaired

LUCA BARUZZI TES Sales Department

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CUSTOMER’S COMMENTSThe Technical Director, Lorenzo Angelini, commented the quality of TES’ service and ex-

plained the problem that occurred at the plant in Riesa (Germany).

“The transformer was taken out of service due to an external fault involving the secondary con-

nection. A sudden stoppage meant losing capital every day and buying a new transformer was

very unlikely. It required considerable investments, not contemplated at the time. So we turned to

TES. We’ve been going to their technical staff for long time and over the years they’ve supplied us

with new reliable transformers and done a lot of accurate repairs, maintenance and preventive di-

agnostics on our fleet of in-service transformers and the ones in stock at the Feralpi plants in Italy

and abroad. Once again our expectations were met. TES repaired the transformer to a high stand-

ard of quality and they kept to the deadlines, which saved us from buying a new transformer.”

The rigorous tests conducted at TES’ Workshop, were executed professionally. The operator

quickly identified the faults and solved the problem. We’ve agreed to share on the Internet the

know-how of this experience for the iron & steel industry in the world, because it’s an opportu-

nity for understanding the way TES can solve problems, a vital ally allowing our Customers to

keep producing.

Luca Baruzzi - TES Sales Department

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TES SERVICECASE HISTORY

A REPLACED TRANSFORMER SAVES PRODUCTION TES INTERVENTIONA contract for the repairing of a 25 MVA transformer suddenly faulted and on fire, replaced by

an existent 30 MVA transformer supplied by TES in rental to the Customer for the complete

reparation time.

Various interventions on both transformers included dismantling, installation and two-way

transportation of the same, held by TES directly to the Customer.

TES RESPONSE: RESPONSE ACTION TIMES & MADE DIAGNOSIS First contact with the customer, photographs of fault received: 18/06/2012

Repaired transformer delivered and start up: 07/11/2012

CLAUDIO ZANINITES Service Unit Technical

Department Manager

25 MVA TRANSFORMERFaulted

30 MVA TRANSFORMERRepaired

35

CUSTOMER’S COMMENTSThe person in charge of production added the following comments.

“TES engineers intervened appropriately and immediately. The transformer damaged by the un-

dergone short circuit, was removed and transported to the Brescia’s plant for an accurate diagno-

sis in a few time.

They immediately installed a spare 30 MVA transformer, enabling production to resume promptly.

The idea of a fleet of used transformers to be rented to manufacturers is a service offered by TES

that we caught immediately, so that we could considerably limit the damage that a stoppage in

production normally causes, even if for a few days only, which was certainly not the case here!

I have to add that the repair technicians were extremely efficient. Our damaged transformer was

repaired and delivered back to us in a mere 4 months.”

The solution we offered and the record delivery time, considering the extent of the damage

caused by the fire, helped our Customer to avoid a significant loss in production and confirmed

the strategic importance of entrusting to TES, the entire ordinary and extraordinary mainte-

nance of the installed transformers installed at our Costomer’s plants.

Claudio Zanini - TES Service Unit Technical Department Manager

36

TES R&DTRANSFORMINGENERGY INTO ART

TES R&D DEPARTMENT PRODUCES TAILOR-MADE TRANSFORMERSTAKING INTO ACCOUNT DIFFERENT VARIABLES AND SPECIFIC REQUIREMENTSThe services offered to the metallurgical companies, are the result of the minded corporate

policies, undertaken by the company and its directors, who always reinvest a suitable share of

the company profits in research and development.

TES R&D department works with expert systems and advanced software design packages

and can develop transformers and electromagnetic parameters with exceptional speed.

The use of 3D CAD tools such as Autodesk Inventor and programmes in the MathCad and

MatLab environment, accelerate product optimization because in the early design phases,

comparisons are made between historical data and data from reliable simulations.

PAOLO DALLERA TES Engineer

37

PROJECTS UNDERWAYToday, TES employs its own staff for developing dedicated calculation software, ca-

pable of interfacing with the Finite Element Program. The goal of the research team

is to adapt the software to a specific sector, to obtain the high performance process-

ing, accuracy and reliability of the transformer from the very early design phases.

This software can offer Metallurgical companies and Power distribution companies

a truly innovative and avant-garde solution. Virtually, subjecting the transformer to

electrical, magnetic and mechanical stress before being built, significantly reduces

product development times and costs and in the same time, they help to increase

transformers operating capacity.

Paolo Dallera - TES Engineer

38

TES QUALITYTRANSFORMINGENERGY INTO ART

QUALITYTES has implemented Quality, Health & Safety and Environmental Management Systems in

accordance with ISO 9001, ISO 14001 and ISO 18001:2008 for many years.

TES quality assurance is described in the Quality Manual and implemented by means of

Quality Control Plans drawn up for each job and Dept. Product conformity is verified by quali-

fied experts, who carry out in-process controls and final inspections in the testing room.

The Health & Safety System, which is implemented to protect all TES employees and com-

pany visitors within the workplace, together with the Environmental Management System,

are monitored by other experts, who identify the potential internal and external risks for the

company and take actions to avoid them. TES Quality, Health & Safety and Environmental

Management Systems are certified by SQS and IQNet.

GERMANO ZACCHETTI TES Quality

Assurance Manager

Germano Zacchetti - TES Quality Assurance Manager

39

40

LOG

ISTI

CS

TES LOGISTICS

41


SPECIAL TRANSFORMERS, SPECIAL LOGISTICSA well-managed logistics operation, is streamlined to offer better Customer service.

For this reason TES gives a great importance to this part of the business considered a tangible

and further service to our Customers who often rely directly on us for the execution of these

special transports till their final destinations.

Total weight* 160 Tonnes

Heigh* 4,85 mt.

Large* 4,87 mt.

Length* 6,32 mt

Extract from the special transport, executed for the delivery of an EAF 220 MVA transformer.

*referring to transport weight and dimensions.

TES EVENTSTRANSFORMINGENERGY INTO ART

PASSED EVENTS:

- USA AisTech - Pittsburgh

- CHINA 10th China International Metallurgy Industry Expo – Beijing

- ITALY Service MCM – Verona

- SWEDEN Elfack - Gothenburg

- ITALY Made In Steel – Milan

- GERMANY METEC – Dusseldorf

42 43

2014 EVENTS TO COME:

- CHINA exibition Metal + Metallurgy China 2014 – Beijing 19 - 22 May 2014 - Stand no. I 19

- USA exibition AISTech 2014 – Indianapolis – USA 05 - 08 May 2014 - Stand no. 1146

WELCOME EVENTFOR AISTech USA’SDELEGATIONvisiting TES.

- SAUDI ARABIA exibition Metal & Steel KSA – Ryadh 07 - 10 April 2014 - Stand no. B22

TES BACKSTAGE

44


YOUNG, DYNAMIC ANDHIGHLY-MOTIVATED PEOPLE, WHO KNOW THAT TEAMBUILDING CREATESA SUCCESSFUL COMPANY

TES AT MOTO GP:Energy on racetrack

Mr. DOSIReceivingAIST’s membership

MADONNADI CAMPIGLIO

TES on ice

RALLY RACEFast & TES

WORLD’STOP FIVE EAFTRANSFORMER Leaving!

Contact Us

Via Seriola, 7425035 Ospitaletto (BS)ITALY

[email protected] +39 030.6840628

FURNACE TRANSFORMERS

Special Transformers Power Transformers Service

WHATWEDO

We want to keep being one of the most qualified businesses in the high power and special transformers market. The high quality standards of our products, the efficient after sales service, and most of all, the customization of our products basing on Customers’ needs, are the pillars of our work, because what we want to be for the worldwide Metallurgical Industry, more than simply a supplier, is an ideal partner.

POWERFULLY SPECIAL

www.testransformer.com

Documents

Tes magazine first issue