1. Tesar

2. The Company
Tesar, 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 History
Tesar, 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 Transformers
Production range: rated power from 100 up to 3150 kVA, rated voltage from 1 up to 36 kV.
Special Transformers
Rated 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 Transformers
Special transformers supplied at CERN
Special transformers supplied acc. to
Kahramaa spec.

6. Certification 1994 - ISO EN 9002 certificate
ENEL homologation for classes E1-C1-F1 c/o CESI
ENEL homologation for classes E2-C2-F1 c/o CESI
Iso EN 9001:2000 Certificate
2005 – 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 F1
E2 Ambiental
Transformer suitable to be installed in ambient with substantial condensation and pollution
C2 Climatic
External installation. Transformer suitable to be kept and used with ambient temperature up to -25°C
F1 Fire behavior
Transformer 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 than
transformers
actually working

9. Products: Measurement Transformers
Voltage transformers
Type:
Phase/Earth (included type with fuses holder)
Phase/Phase
Current transformers
Rated current up to 2500 A.
Insulation level up to 36 kV.
Ring-type transformers cl. 0,72 kV.

10. Products: Measurement Transformers
Voltage transformer
Current transformer
Ring-type transformer
Voltage transformer with fuse holder

11. Application fields
BUILDINGS
ELECTRICAL PLANT
EOLIAN PLANT
OIL PLANT

12. Application fields
AIRPORT
SEA PORT
RAILWAYS
METRO

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°C
Maximum temp. : +40°C
SPECIAL INSTALLATION CONDITION
When requested, transformers are designed for special climatic condition and we guarantee our transformers for an ambient temperature up to +55° C

14. Design
Every design, planning and drawing phase is made using the most up-dated software and CAD instruments:
AUTODESK Autocad©
Wintrasf 3.0

15. Rules RULES IEC IEC 60076-1 Power transformer – part 1 : General
IEC Power transformer – part 2 : Temperature Rise
IEC Power transformer – part 3 : Insulation levels, dielectric tests and external clearances in air
IEC Power transformer – part 4 : Guide to the lightning impulse and switching impulse testing - Power transformers and reactors
IEC Power transformer – part 4 : Ability to withstand short circuit
IEC Power transformer- part 10 : determination of sound levels
IEC Power transformer- part 11 : Dry-type transformers IEC TC 14
IEC Terminal and tapping markings for power transformers
HD 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. Components
MAGNETIC CORE
The magnetic core realized with silicon cold-rolled grain-oriented steel sheet give low specific losses
The interweaving system is step-lap type and it is realized thanks to the most modern cut and assembling technologies
The 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 product
The 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 together
The coils are casted into moulds under vacuum using class F epoxy-resin
The casting under vacuum process, electronically monitored, allows to obtain windings with a total resin homogeneity, so free from partial discharges

19. Department
Casting
Winding
Core Coils
Storage
Assembling

20. Tests Main Testing Room In line Testing Room
All Tesar products are scrupulously tested in its our modern testing rooms in Chiaveretto plant .
Main Testing Room
In line Testing Room

21. Tests
In the Tesar testing rooms routine, type and special test are carried out using the most up-dated softwares :
Trafotest ©
Heat run test
SP 2K ©
Type and special test

22. Accessories ENCLOSURE standard enclosure
enclosure with HV- LV cable boxes

23. Accessories Tesar TSX 1s THERMOCONTROLLER with digital exit
RS232 – RS485
transmission protocol
Modbus®

24. Accessories
FAN Bar 600
FAN Bar 1800

25. Accessories
COOLING
Tesar TSX 2
control board for fan

26. Transport
Tesar transformers are delivered assembled and ready to be connected to the high and to the low voltage network.

27. Installation
AIR FLOW
To 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 table
insulation
Distances “D” mm KV
Sheet steel wall
Louvered wall
7,2
150
300 12
17,5
220 24
240 36
320

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 pression
Clean of the cooling and fan channel between the coil to avoid over temperature during the working
Verify the tightness of the bolts and nuts of the HV/LV connections, of the bar of the tap-changer and of the frames
Check 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
Maintenance
Table for periodical check
The 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 table
Pos
Check to be performed
Check Interval
Instrument / Equipment
Results 1
Cleaning from dust, dirt, unlikely presence on the windings
Yearly and/or after exceptional events
Dry compressed air and cloths
General cleaning 2
Tightening of the bolts of the main and secondary electrical connections
Torque wrench
Tightening torque see paragraph 5.1. 3
Tightening of the mechanical parts bolts and transformer clamping to the ground 4
Tightening of plate for adjusting the spacer blocks 5
Functioning check of thermo-controller and thermo-resistances
Hot air gun for thermo-resistance simulated heating
Intervention of the siren of alarm level, opening of switch and trip level 6
Functioning check of the overloading and short-circuit relay
Power generator for simulation of damage
Opening of the switch on reaching the pre-set threshold. 7
Condensate deposited on the windings
After a long transformer stop
Hot dry air and cloths
Coil surface and internal ducts perfectly dry 8
Insulation check of the windings among them and towards ground
Megger with voltage of at least 2500 V
Minimum values showed at paragraph 5.2

33. Main reference in Italy
Falck
ILVA
Nuovo Pignone
Piaggio
ACEA
AEM
ENEL
Pirelli
Ministero della difesa
Ministero delle finanze - Roma
Metropolitana di Milano
Metropolitana di Roma
Barilla
Buitoni
Auchan
Alfa Romeo
FIAT
FIAT Avio
Piaggio
Iveco
Ferrari
Pirelli
Montedison
Ansaldo
IBM
Zanussi
Agip
ERG
ESSO
SNAM
Stadio Olimpico –
Roma
Stadio Meazza – Milano
Stadio S.Paolo –
Napoli
Teatro La Pergola -
Firenze
Teatro alla Scala –
Milano
Fiera di Milano
Fiera di Bologna
Fiera del Levante –
Bari
Telecom Italia
RAI
Aeroporto di Fiumicino – Roma
Corriere della Sera – Milano

34. Main reference All over the World
Hydro alluminium - Norway
Sandvik Steel - Sweden
Thyssen Krupp - Germany
Magnitogorsk Integrated Iron & Steel - Russia
Orly airport Paris - France
CERN - Switzerland
Wind Mills Power Plant - Danemark
Copenhagen metro - Danemark
Electrabel - Belgium
Aquarium Lisboa – Portugal
British Telecom –U.K.
Heathrow Airport – U.K.
DEWA – Dubai Electricity & Water Authority
ADWEA – Abu Dhabi Water & Electricity Authority
MEW – Ministry Electricity & Water - Kuwait
DCA Dubai Airport - Dubai
Deira City Center - Dubai
Conference Palace Hotel - Abu Dhabi
Shangri-la Barr al Jissah Resort - Oman
Mosul Dam Crude Oil Pipeline - Iraq
Can and Afsin Power Plant - Turkey
FIAT - Brasil
Metrovias - Argentina
Renault - Argentina
Hong Kong Metro – Hong Kong
Toshiba Plant - Singapore
ST Microelectronics - Singapore