The company enters 132 kV class transformers business

PETE Transformers (Pan Electro Technic Enterprises Private Limited), Hyderabad, a major player in transformer business since 1988, renders quality services nationally and internationally. The company has grown steadily from one unit to 6 units in 22 years and from 25 kVA Distribution to 50 MVA, and now, 132 kV Power Transformers level in terms of production.

K Linga Reddy, Chairman, is the promoter of the company. An experienced and well-respected first generation entrepreneur, Mr Reddy has been honoured with the National Award for Quality Products 2009 from MSME - Industries Department, Goverment of India.

Mr Reddy is also active in the industry, serving on various trade bodies and associations. Prominent among these are: Vice President (Southern Region), Indian Transformers Manufacturing Association (ITMA); Member (Task Force) Finalisation of Standards for Energy Efficient Transformer (Star Ratings); Senate Member, NIT Warangal; and Past President of NIT Alumni Association Warangal.

The total production is distributed among the six manufacturing units, which are in close proximity of each other.

• Unit I: Manufacturing of oil-filled transformers up to rating 1000 kVA in 11 kV class and dry type transformers (both varnish impregnated and cast-resin) up to rating 5 MVA in 33 kV class
• Unit II: Manufacturing of oil-filled transformers up to 15 MVA rating in 33 kV class
• Unit III: Manufacturing of medium and large power transformer up to 50 MVA rating 132 kV class (provision for expansion up to 100 MVA in 220 kV class)
• Unit IV: Servicing/repair of both dry type and oil-filled transformers, independent
• Unit V: Grit blasting and painting of tank and other fabricated parts, and
• Unit VI: Manufacturing of transformer radiators for internal use as well as external market.

Product Mix

The company has a wide range of products, briefly described as follows:

Oil-filled Power Transformers

• Up to 25 MVA 33 kV/66 kV class
• Up to 50 MVA 132 kV class

Distribution Transformers (conventional with radiator and corrugation design) Dry Type Transformers (cast resin and varnish impregnated)

• Up to 5 MVA 33 kV class

Induction Furnace

• - 6 Pulse,
• - 12 Pulse
• - 18 Pulse
• - 24 Pulse
• - 36 Pulse

Submerged arc Furnace Transformers

• Single phase shell type and core type
• Three phase core type

Ring Main Unit and Unitised Substation with cast resin, VPI and oil filled transformers. Ring Main Unit with Corrugation Transformer.

Design Strength

The Design Wing is headed by a graduate engineer with over 45years of experience in various transformer industries in India, ably assisted by a team of 15 engineers and draftsmen.

The design facility is equipped with high end computer system and the latest software in 3D and CAD. Continual verification and validation of designs depending upon the test results and site performance is the regular practice and also upgradation to latest technologies.

The team can re-engineer the design of transformers of any other make, Indian or foreign in origin.

Quality Assurance

PETE Transformers has bagged the National Award as best MSME (Micro, Small and Medium Enterprises) entrepreneur under "Quality Products" category this year. It is an ISO certified company since 1997 and re-certified for ISO 9001 - 2008 in 2009. Continuous quarterly internal audits and annual external audits are followed.

All the incoming materials are tested in the company's laboratory before acceptance. All the fabricated parts are verified and tested at fabricator's works by PETE inspectors. All the in-process stages are checked and cleared before it proceeds to next stage by quality.

The final verification of the products by electrical testing is performed in the presence of customers through calibrated instruments. Quality improvement projects are taken up through quality circles.

Laboratory Facility

The laboratory verification of incoming materials is done for the following characteristics:

• Conductivity, elongation and compression checks on winding copper conductor.
• Loss measurement on core laminations.
• Leakage test on valves, pressure relief device, gas operated relay, oil surge relay, etc., on complete supplies.
• Dielectric strength (BDV) Tan Delta and resistively on transformer oil.
• Paint thickness measurement on fabricated parts.

Production Infrastructure

The production infrastructure comprises the following:

• Coil winding in dust-free chamber to avoid ingress of dust into coil sections.
• Core building on platform for proper stability of cores.
• Stabilisation of coils in heating oven and tightening with hydraulic jacks for better short circuit withstand capabilities.
• Vacuum drying oven for effective and quick extraction of moisture, and long life even for 11 kV and 33 kV class transformers.
• Pressure and vacuum tests on tanks for leak-proof withstands.
• Grit blasting and painting for better aesthetic looks and to check chalking/peeling of paint and also for with standing atmospheric conditions for longer durations.
• Overhead EOT cranes of 5T, 10T, 20T and 60 tonnes capacity.
• Resin mixing and pouring oven under vacuum for cast resin type dry type transformers.
• Varnish impregnation chambers under vacuum for varnish impregnated dry type transformers.
• Diesel generator set to accomplish uninterrupted power during power cuts.

Monitoring Production

• Preparation of schedules for all activities starting from order receipt till dispatch.
• Monitoring the schedules stage wise for meeting the committed deliveries.
• Timely purchase of materials to control large inventories as well as to avoid hold ups during production.
• A unique system (History Card) to record all stages if in process including their quality checks and non conformities.

Final Electricals Test Facilities

• Full fledged automated in-house test facility to carry out all routine tests and temperature rise tests for all our ranges of products as per IS/IEC or any other international standards.
• All these tests are offered for witness by customers/consultants/third party inspectors.
• These tests are conducted as per approved test plan and test results are tabulated through computers.
• Other type tests (impulse and short circuit tests) are conducted at CPRI (Central Power Research Institutes) Bhopal/Bangalore/Hyderabad and have success fully withstood in first go itself.

Service Back Up

• An independent service unit with all required infrastructure like winding machines, vacuum oven and test facilities to provide highest priorities for servicing.
• Three 6000 ltrs/hr filter machines with high vacuum filters and onsite testing equipments and for site repairs.
• Whole range of standby transformers for supporting needy customers.
• Can handle Annual Maintenance contracts and services like: oil filtrations, repair/reconditioning, erection/commissioning, and consultancy services on substations on all subjects related to transformers, allied equipments energy conservation.

Major Achievements

Among the major achievements of the company are:

• Development of 5 MVA convector transformer of 20 kV and 44 kV for South African railways.
• Process of execution of an export order for 20 MVA rating in 33 kV class for Oman Petroleum Company.
• Process of design for 25 MVA rating power transformers in 132 kV class (first order).
• Repair of foreign make transformers including: a) 31.5 MVA China make by replacing LV coil at MALCO (Mettur) site; b) 62 MVA ABB (Sweden) make generator transformer by replacing all coils and part core laminations at IMFA (Cuttack) site; and c) 9 MVA Furnace ABB (Sweden) make shell type transformer repair by replacing coils for IMFA (Cuttack) at the PETE works.
• Upgradation and overhauling of 40 MVA, 132 kV transformer for providing ONWF cooling by replacing ANAF cooling at ESSAR, Visakhapatnam, site.

Safety

All norms of international standards of safety are followed and no major accidents has taken place at the company's works.

Exports

PETE Transformers has already exported its transformers to several countries. The list includes South Africa, Ghana, Bangladesh, Kuwait, Zimbabwe, Malaysia, Abu Dhabi, Zambia, Nigeria and Sri Lanka. Presently under execution is an order to Oman for two transformers of 20 MVA.

Diversification & Expansion Plans

The company has ambitions plans for expansion and future growth. For diversification, it has acquired 12 acres of land near Visakhapatnam, AP, to enhance capabilities up to 400 kV class ultra high voltage transformers by 2013.

Further, it is launching fabrication facilities for transformer tanks at Anakapalle, and a separate unit for servicing of transformers at Bhubaneswar (Orissa).

Next on the anvil are the design, manufacture and type testing of prototype energy efficient transformers of star ratings up to 5 MVA.

In terms of expansion, the turnover during the previous year 800 MVA and ` 65 crore. For the present year the company has planned for 1000 MVA and ` 85 crore.

The target for the year 2014 is to reach 2000 MVA and ` 200 crore. Efforts are in full swing to book orders for achieving this target.

Registrations

PETE Transformers is registered as approved vendors for supply of transformers by a number of organisations: NTPC, BHEL, HPCL, CPWD, DRDO, PGCIL, MALCO, MECON, DGS&D, BESCOM, AP Telecom, TATA Projects, Hindustan Petroleum, APCPDCL, ESSAR Power, NLC, RIN, Indian oil, DAE, Interim Test Range and Hindustan Shipyard, among others.

(PETE Transformers, Hyderabad. Mobile: 098489-90184/85. Tel: 040-23813593, 23812291. Fax: 91-40-23706741. Email: marketing@pete transformers.com,info@petetrans formers.com)