2 The CompanyTesar, whose sales amount in 2004 has been 22,7 million € is one of the most important reality operating in UE in the field of designing and manufacturing of CAST-RESIN Transformers.The continuous developments, research, studies and tests, as well as the up-to-date of its own staff has allowed Tesar to reach a high degree of reliability and to satisfy any particular request of our Customers, and to develop new tailor made projects/products.
3 The HistoryTesar, acronym of Electrical Transformers Special Application in Resin, has been founded in 1980 as Company of Eni Group, introducing, first in Italy, the Cast-Resin technique for power transformers.In 1986 Tesar has been acquired by a private group and the production has been expanded also to measurement transformers.Today Tesar is a leader at international level.All the Tesar production, carried out in the 2 production plants in Chiassa Superiore and in Chiaveretto, is the results of a continuous research and development and it is based on the use of advanced technologies and of selected materials.
4 Products: Power Transformers Distribution TransformersProduction range: rated power from 100 up to 3150 kVA, rated voltage from 1 up to 36 kV.Special TransformersRated power up to 18 MVA, rated voltage up to 36 kV, for rectifier, traction, induction oven application and for motors starting.Extreme installation as: offshore, windmill, crane and in extremely polluted ambients.Autotransformers
5 Products: Power Transformers Standard TransformersSpecial transformers supplied at CERNSpecial transformers supplied acc. toKahramaa spec.
6 Certification 1994 - ISO EN 9002 certificate ENEL homologation for classes E1-C1-F1 c/o CESIENEL homologation for classes E2-C2-F1 c/o CESIIso EN 9001:2000 Certificate2005 – Successful tests for E2-C2-F1 to IEC c/o CESI
7 Conformity to classes E2 C2 F1 Tesar transformers are designed and manufactured according to the following classes, required by CENELEC and today by IEC standards, since more than 10 years:E2 C2 F1E2 AmbientalTransformer suitable to be installed in ambient with substantial condensation and pollutionC2 ClimaticExternal installation. Transformer suitable to be kept and used with ambient temperature up to -25°CF1 Fire behaviorTransformer with characteristics of self-extinction and of non-emission of toxic substances and gases
8 Reliability More than 28.000 transformers actually working The annual statistique shows a total of Tesar transformers working all around the world, underlining the remarkable reliability of our transformers.More thantransformersactually working
9 Products: Measurement Transformers Voltage transformersType:Phase/Earth (included type with fuses holder)Phase/PhaseCurrent transformersRated current up to 2500 A.Insulation level up to 36 kV.Ring-type transformers cl. 0,72 kV.
10 Products: Measurement Transformers Voltage transformerCurrent transformerRing-type transformerVoltage transformer with fuse holder
13 Installation NORMAL INSTALLATION CONDITION The max. altitude of installation is 1000 m above see level.The ambient temperature in the room, when the transformer is working, must be within the following limits:Minimum temp. : -25°CMaximum temp. : +40°CSPECIAL INSTALLATION CONDITIONWhen requested, transformers are designed for special climatic condition and we guarantee our transformers for an ambient temperature up to +55° C
15 Rules RULES IEC IEC 60076-1 Power transformer – part 1 : General IEC Power transformer – part 2 : Temperature RiseIEC Power transformer – part 3 : Insulation levels, dielectric tests and external clearances in airIEC Power transformer – part 4 : Guide to the lightning impulse and switching impulse testing - Power transformers and reactorsIEC Power transformer – part 4 : Ability to withstand short circuitIEC Power transformer- part 10 : determination of sound levelsIEC Power transformer- part 11 : Dry-type transformers IEC TC 14IEC Terminal and tapping markings for power transformersHD S1 Three-phase dry type distribution transformers 50Hz, from 100 kVA to 2500 kVA with highest voltage for equipment not exceeding 36 kV part 1 general requirements and requirements for transformers with highest voltage for equipment not exceeding 24 kV
16 ComponentsMAGNETIC COREThe magnetic core realized with silicon cold-rolled grain-oriented steel sheet give low specific lossesThe interweaving system is step-lap type and it is realized thanks to the most modern cut and assembling technologiesThe proper geometry and strength of the frames, together with the appropriate bolt techniques, enable to obtain low noise level, constant during the time
17 Components LOW VOLTAGE WINDINGS The LV windings are made using aluminium or copper sheet, with pre-impregnated class F insulating material.The coils are subjected to a thermal treatment of polymerization to obtain the finished productThe special constructive geometry allows, moreover an high resistance to the electrodynamic stresses
18 Components HIGH VOLTAGE WINDINGS The HV windings are composed from more coils in aluminium or in copper (wire or tape) connected togetherThe coils are casted into moulds under vacuum using class F epoxy-resinThe casting under vacuum process, electronically monitored, allows to obtain windings with a total resin homogeneity, so free from partial discharges
25 AccessoriesCOOLINGTesar TSX 2control board for fan
26 TransportTesar transformers are delivered assembled and ready to be connected to the high and to the low voltage network.
27 InstallationAIR FLOWTo guarantee the respect of the rated condition of service and to avoid that the temperature rises are passed, in the room where the transformers are installed an air-exchange is necessary to discharge the heat produced during their operation.
28 Installation SAFETY DISTANCES The transformer supplied without enclosure (IP00) has to be installed in an adequate room respecting the insulation distances showed in the tableinsulationDistances “D” mmKVSheet steel wallLouvered wall7,21503001217,52202424036320
29 Installation HV AND LV CONNECTIONS Transformer without enclosure (IP00)The cable and the bus-bar to be connected to the transformer must be moored in an adequate way to avoid mechanical stresses on LV and HV transformer bushings.
30 Installation HV AND LV CONNECTIONS Transformer with enclosure (IP20 – IP21 – IP23 – IP31)The cable and the bus-bar to be connected to the transformer must enter the enclosure only through the holes/flanges foreseen during the order stage.
31 Maintenance Ordinary maintenance A deep check of the transformer during the work allow to avoid damages and to extend the expected life. In normal working condition it is enough to do the following operation one time per year:Clean of the HV/LV windings from the eventual dust, condensation or dirty, with dry air at low pressionClean of the cooling and fan channel between the coil to avoid over temperature during the workingVerify the tightness of the bolts and nuts of the HV/LV connections, of the bar of the tap-changer and of the framesCheck of the correct running of thermal protection (PT100 or PTC and relevant thermo-controller) and also the correct intervention of the protection for surcharge and for the short circuit and the intervention of the automatic switch
32 Instrument / Equipment MaintenanceTable for periodical checkThe main periodic checks to be performed on the transformer, the check intervals, the equipment to be used and the results to be obtained are reported in the following tablePosCheck to be performedCheck IntervalInstrument / EquipmentResults1Cleaning from dust, dirt, unlikely presence on the windingsYearly and/or after exceptional eventsDry compressed air and clothsGeneral cleaning2Tightening of the bolts of the main and secondary electrical connectionsTorque wrenchTightening torque see paragraph 5.1.3Tightening of the mechanical parts bolts and transformer clamping to the ground4Tightening of plate for adjusting the spacer blocks5Functioning check of thermo-controller and thermo-resistancesHot air gun for thermo-resistance simulated heatingIntervention of the siren of alarm level, opening of switch and trip level6Functioning check of the overloading and short-circuit relayPower generator for simulation of damageOpening of the switch on reaching the pre-set threshold.7Condensate deposited on the windingsAfter a long transformer stopHot dry air and clothsCoil surface and internal ducts perfectly dry8Insulation check of the windings among them and towards groundMegger with voltage of at least 2500 VMinimum values showed at paragraph 5.2
33 Main reference in Italy FalckILVANuovo PignonePiaggioACEAAEMENELPirelliMinistero della difesaMinistero delle finanze - RomaMetropolitana di MilanoMetropolitana di RomaBarillaBuitoniAuchanAlfa RomeoFIATFIAT AvioPiaggioIvecoFerrariPirelliMontedisonAnsaldoIBMZanussiAgipERGESSOSNAMStadio Olimpico –RomaStadio Meazza – MilanoStadio S.Paolo –NapoliTeatro La Pergola -FirenzeTeatro alla Scala –MilanoFiera di MilanoFiera di BolognaFiera del Levante –BariTelecom ItaliaRAIAeroporto di Fiumicino – RomaCorriere della Sera – Milano
34 Main reference All over the World Hydro alluminium - NorwaySandvik Steel - SwedenThyssen Krupp - GermanyMagnitogorsk Integrated Iron & Steel - RussiaOrly airport Paris - FranceCERN - SwitzerlandWind Mills Power Plant - DanemarkCopenhagen metro - DanemarkElectrabel - BelgiumAquarium Lisboa – PortugalBritish Telecom –U.K.Heathrow Airport – U.K.DEWA – Dubai Electricity & Water AuthorityADWEA – Abu Dhabi Water & Electricity AuthorityMEW – Ministry Electricity & Water - KuwaitDCA Dubai Airport - DubaiDeira City Center - DubaiConference Palace Hotel - Abu DhabiShangri-la Barr al Jissah Resort - OmanMosul Dam Crude Oil Pipeline - IraqCan and Afsin Power Plant - TurkeyFIAT - BrasilMetrovias - ArgentinaRenault - ArgentinaHong Kong Metro – Hong KongToshiba Plant - SingaporeST Microelectronics - Singapore