Prime Electric Ltd's State-of-the-Art Transformer Manufacturing Facility

PRIME ELECTRICLIMITED
www.primeelectricltd.com
PRIMEGROUP
PrimeGroup
Aleadingforceforover25years Adiversifiedgroupofcompanies HighTechnologyequipmentsandsystemscovering theentirespectrumofpowersector
Generation,Distributionandtransmission;precision engineeringpowerconditioning,CNCmachinetoolsetc.
PRIMEELECTRICLTD
PrimeElectricLtd APrimeGroupCompany Stateofartfacilities
Design,Manufacturing,TestingandServicesfor
Upto1000MVA/500KVPowerTransformerswithannual capacityof10,000MVA(PhaseI) Willupgradeto765KVandabovewithannualcapacityof 35,000MVA(PhaseII) Sprawlingover100acres,locatedinaSpecialEconomicZone, AndhraPradeshhavingthreeports(Krishnapatnam,Ennore andChennaiPort)withinamere150kilometerradius
PrimeElectricLtd
Oneofthelargest,fullyplannedandequipped mostmodernStateoftheartmanufacturing facilityinthecountry.
PrimeElectricLtd.
Comparabletothebestacrosstheworldwith thelatestandthemostmodernmachinesfrom worldleaders
SwingSheartechnologybased,CRGOcuttingand slittingmachinesfromGeorg,Germany TransformertestPlantfromHighvolt,Germany
Paperinsulatedcopperconductorforwindings producedwithintheplanttomaintaincritical qualityrequirements.

PrimeElectricLtd
Technology transferred and supplied by world renowned OSC VIT, a part of the Electrozavod Group, the world largest manufacturer of Power Transformer
Electrostatic field distribution under lightening & switching impulse and induced over voltage conditions Electromagnetic field distribution Magnetizing inrush currents Shortcircuit strength of windings Temperatures of windings and structures including hot spots.
MANUFACTURINGFLOWDIAGRAMFOR TRANSFORMER
PLANTORGANISATIONCHART
CHIEFEXECUTIVE
Chief Operations
Finance
Purchase
Marketing
Administration
Production
Design
Quality&Testing
ORGANIZATIONCHARTOFPRODUCTION DEPARTMENT
HeadProduction
Office Assistant
InchargeFabrication
InchargeProduction
Corecutting CoreAssembly
Insulation
Winding Conductor
Winding
Coil Assembly
Corecoil assembly& Wiring
Final Assembly
ORGANISATIONCHARTOFPRODUCTION DEPARTMENT(FABRICATION)
HeadProduction
InchargeFabrication
FabricationPreparation
FabricationAssembly
DESIGNFLOWCHART
Design
ELECTRICALDESIGN
Basicdesign&issueofdocumentationto production Windingdesign Coredesign Corecoilassembly Connections Cooling DesignVerification Overalllayout Customerdrawingslikegeneralarrangement foundationdetails,shippingdrawing,control circuitdrawingsetc. TestSchedule ExternalWiring.
MECHANICALDESIGN
Basicdesign Tank Coreframeassembly Conservator CoolerPipework Oilquantities
ORGANISATIONCHARTOF DESIGNDEPARTMENT
HeadDesign
ElectricalDesignEngineers
MechanicalDesignEngineers
ORGANISATIONCHARTOF TESTINGDEPARTMENT
HeadQuality&Testing
ORGANISATIONCHARTOF QUALITYDEPARTMENT
InchargeTesting
InchargeQuality
TestingEngineers
QA&QCEngineers
FLOWCHART
Customer
Marketing
Design Documentation for material Procurement and Production Material Purchase Dispatch to customer Production
Customer
ADVANCEDDESIGN MEETS INTERNATIONALSTANDARDS

PEL range exhibits a customer-centric approach especially in areas relating to usage of enhanced materials and globally latest technologies such as Capability to withstand systemic short circuits Capability to withstand systemic lightning and switching surges Advanced user-friendly technology for keeping the oil and winding temperatures and hot spots under control.
PRODUCTIONCAPACITY
Installedcapacity10,000MVAPeryear FirstPhaseupto1000MVA/500KV Willgohigherupto765KVclass/1200KVclass inthenextphaseandtheproductioncapacity willbeupgradedto35000MVA
HUMANRESOURCE
Direct employment in the first phase - approximately 550 people 150 skilled 250 Semi - skilled 150 for administration, Commercial, personnel, Accounts, Support services etc.
Majorfacilities windingshop
WINDING SHOP Fully air-conditioned to avoid dust & moisture
20 MT Vertical Winding Machines 10 MT Horizontal Winding Machines 5 MT Horizontal winding machines
Coil upending Machine
Autoclave with heating and vacuum facility Iso-static system of coil stabilization 30 MT & 15 MT EOT Cranes
Majorfacilities Coreshop
CORE SHOP Automatic Core Slitting Machine (Georg make) Automatic Core Cutting Machine (Georg Make) Core Assembly and lifting platform 150 MT Capacity 10 MT EOT Crane
Majorfacilities InsulationShop
All machines required for processing insulating wood and press-board
INSULATION SHOP
Press Board Taper Cutting M/C Press Board Cylinder Rolling M/C Running SAW Router M/C Circular Cutting M/C Drying Oven Angular Circular Saw Band Saw Shearing M/C Drilling M/C Milling M/C Press Board Jointing Press Dust Collectors 10 MT EOT Crane
Majorfacilities Core coilassembly
Fully air conditioned to avoid dust and moisture. Equipped crimping press from Novo press, Germany Water cooled brazing machines.
Major facilities Processing
Processing
2nos. VaporPhaseDryingOven OilFiltrationPlants 6KL 10KL EOTCranes(Remote&CabinControl) 2nos.150MT 1no.50MT
Majorfacilities Testlaboratory
Fullyequippedtoconductall routinetestsandtemperature risetest,Lighteningand SwitchingImpulsevoltagetests asperInternationalStandards. Equipments

170KV,2000KW(expandableto 4000KWinPhaseII)Statictesting systemfromHighVoltGermanyfor allroutinetestandtemperature risetest.70MVAr(expandableto 140MVAr)capacitorbank.
Majorfacilities TestLaboratory
2400KVp,240kJ(expandableto 3000KVp,300kJ)Impulse GeneratorfromHighVolt, Germany.
QUALITYASSURANCE
"With worldclass design technology and manufacturing facilities, PEL sets highest standards in quality of the transformers produced, following the best grades of materials and manufacturing processes and practices through standard and customized Quality Assurance Plans. PEL believes in the customer satisfaction through quality of products and service after sales. PEL is committed to the concept of Total Quality Management driven from the top management".
StaticTestSystem
We are procuring the equipment for conducting all the routine and type tests on the transformers from High Volt, Germany, world leaders in this field. We would be using the static converter equipment developed by them for carrying out the no-load loss test, load loss test and induced over voltage test besides other routine tests. This equipment would also be used for conducting the temperature rise test, a type test, which ensures that all the parts of the transformer are within the temperature limits stipulated by the customer. This is the largest system to be supplied by them to any power transformer manufacturer in the world. In fact, we are the first
company in India to use such equipment for testing transformers in the works.
ADVANTAGES
Over the conventional motor-generator set is that the output voltages and currents are distortionfree and very near to sinusoidal waves required. Better control on the voltages and currents to be applied to the transformer under test. No other manufacturer has such facility in their works.
PRIMEELECTRICLIMITED ADVANTAGES
HighqualityEHVPower transformerssuitableforawide rangeofneeds Advanceddesignmeeting internationalstandards Stateoftheartmanufacturing withsuperiorcontrolonprocesses Highlyskilledmanpowerresource AdvancedSchedulingfortimely deliveries
PRESSREVIEWS
Cover page of the magazine
Padma Shri Surinder Mehta Chairmans interview

EI PEL is being much talked about these days. What areas does it address and where do you see it in the near-term future?
Prime Electric Limited (PEL), is one of the most significant thrust areas of Prime Group. Backed by the rich experience of Prime Group in addressing the most exacting needs of the Power Sector and through its range of eco-friendly (low noise), aesthetically designed Extra High Voltage power transformers up to 1000 MVA / 500 KV. PEL shall address the needs of the Power Electricity Utilities; EPC companies; Sub- station, Power generation &Transmission and Distribution companies. It shall also cater to large industries in various sectors such as Steel, Cement, Petroleum, Petrochemicals and others using bulk power. PEL's production capability, projected to 35000 MVA, makes it one of the largest manufacturers from India producing world-class extra high voltage power transformers for users across the globe. PELs 100-acre manufacturing location at Nayudupet Special Economic Zone in Nellore district of Andhra Pradesh has excellent transport connectivity and three major ports within a radius of 150 KM radius gives PEL customers - in India and overseas an additional advantage of timely, cost effective & easy movement of supplies and production. www.primeelectricltd.com
Page No. 247
THANKYOU
HEADQUARTER:
PRIME ELECTRIC LIMITED PRIME GROUP BUILDING 11/5B, Pusa Road, New Delhi - 110005 (India). Phone: 91-11-41 888 999 (30 lines), 41 888 888, 25762562-63-64, 25762552-53, 25813338,25813339 FAX : 91-11-25755815, 25821623 Email : pe@primeelectricltd.com
Hyderabad Office :
Contact Person :- Mr. J. S. Sastry Sr Vice President (Operations) Prime Electric Limited 1-8-619, 1st Floor Sai Arcade, Prakash Nagar Begumpet, Hyderabad 500016 India Mobile : 91-9848369393, Ph. :- 91-40 - 42606999, Fax : 91-40 - 40115124, Email : jsastry@primeelectricltd.com
Site Address :
Prime Electric Limited Multi Product SEZ Menakuru Village Naidupeta Mandal Nellore - District Andhra Pradesh 524126 India

Prime Electric Ltd's State-of-the-Art Transformer Manufacturing Facility

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PRIME ELECTRICLIMITED

Paperinsulatedcopperconductorforwindings producedwithintheplanttomaintaincritical qualityrequirements.

Corecoil assembly& Wiring

ADVANCEDDESIGN MEETS INTERNATIONALSTANDARDS

Installedcapacity10,000MVAPeryear FirstPhaseupto1000MVA/500KV Willgohigherupto765KVclass/1200KVclass inthenextphaseandtheproductioncapacity willbeupgradedto35000MVA

WINDING SHOP Fully air-conditioned to avoid dust & moisture

20 MT Vertical Winding Machines 10 MT Horizontal Winding Machines 5 MT Horizontal winding machines

Coil upending Machine

Majorfacilities Core coilassembly

Major facilities Processing

Fullyequippedtoconductall routinetestsandtemperature risetest,Lighteningand SwitchingImpulsevoltagetests asperInternationalStandards. Equipments

2400KVp,240kJ(expandableto 3000KVp,300kJ)Impulse GeneratorfromHighVolt, Germany.

Padma Shri Surinder Mehta Chairmans interview

Page No. 247

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