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Manufacturing facilities in Lucknow are spread out over an 8 acre area with approximately 6000 sq, mtrs, of covered sheds. The shops are of adequate height with liberal floor area and are equipped with E.O.T. cranes and other material handling facilities. Separate facilities have been earmarked for assembly of Distribution and Power transformers. Unlike most transformer manufacturers, TAL has invested heavily in backward integration and does in-house production of major raw materials. Separate shops have been provided for:  
  1. Core processing (Slitting, Cutting and Annealing)
  2. Conductor manufacturing (Drawing, Annealing and Paper covering)
  3. Transformer Oil Processing
  4. Tank fabrication
  5. Winding
  6. Assembly and tanking

TAL, Lucknow has a manufacturing capacity of approx 5,000 MVA per annum of mixed transformer ratings.

 
Distribution & Power transformer assembly bays have independent test facilities with the ability to conduct all routine tests as per IEC 60076 and IS 2026. In-house test facilities have also been created to conduct all type tests (except Short Circuit test) as per IEC 60076 and IS 2026 in-house. The test facilities are further in the process of being certified by NABL (National Accreditation Board for Testing & Calibration Laboratories) for compliance with ISO 17025.
 
The manufacturing plant at Sitarganj is spread out over 12.5 acres and is fully equipped to manufacture EHV Power transformers upto the 765 kV voltage class. The manufacturing sheds occupy a total covered area of aprox. 23000 sq mtrs. ranging from 4 mtrs. to 24 meters in height, and spans of 16 mtrs to 23 mtrs.
 
The Plant has designed for optimal material and work flow, and integrated manufacturing operations with separate bays for:
 
  1. Single phase and Three phase 11 kV Distribution Transformers
  2. Three phase 33 kV Distribution Transformers
  3. Three phase 66 & 132 kV Power Transformer
  4. Single phase and Three phase 220 & 765 kV Power Transformers
  5. Coil Windin
  6. Insulation processing
  7. Mild steel fabricatio
  8. Impulse Testing set-up
 
 
TAL, Sitarganj has a manufacturing capacity of approx 14,000 MVA per annum of mixed transformer ratings, which is equivalent to being able to deliver one transformer of 40 MVA, per day!
 
The Sitarganj plant of TAL is one of the most modern and aesthetic transformer plants in North India. Key features of this plant include:
 

1. Dust free environment: The factory environment including the interior & exterior planning ensure minimal dust inside the shop floors. Further measures like air conditioned winding shops are being created for winding of high voltage transformer windings in a sanitised area. All winding and assembly areas are further provided with epoxy flooring which further aids in reduction of ambient

2. Well planned material movement: The factory has been scientifically designed to ensure minimum loss of efficiency on account of movement of raw materials. Specially designed rail tracks & causeways ensure minimum time spent on movement of raw material as well as the least possible exposure to the environment

 
 

3. Adequate material handling facilities: With 7 cranes ranging from 5 MT to 150 MT capacity (including 2 cranes of 150 MT with the capability to work in tandem), the Sitarganj plant has capability for handling loads upto 300 MT weight. In addition air castors are being procured for easy movement of power transformers during assembly.

4. Fully functional material testing laboratory: In order to have a high degree of control on the inputs going into the transformers a fully functional Material testing laboratory is being set up which will have the capability to conduct all required tests on critical raw material being used in the transformers

5. Superior testing facilities: The testing facilities in Sitarganj are world-class. Each manufacturing area has independent test facilities with the most modern instrumentation. Computerised test benches are used reduce human intervention and provide the necessary confidence to our customers. All routine tests as per IEC 60076 and IS 2026 are done in-house. It is also possible to conduct all type tests (except Short Circuit test) as per IEC 60076/IS 2026 in-house. An Impluse generator of 1600 kVP, 160 kJ (expandable to 2400 kVP, 240 kJ) procured from Haefely, Switzerland is used to test transformers for Impulse withstand voltage.  
     

S. No.

Description

Installed

Proposed/Under Installation

Total

1

11 KV & 33 KV Transformers (T1 & T2):

 

 

 

a

Winding Machines for 11 KV Distribution Transformer HV & LV circular coils

40

-

40

b

Winding Machines for 11 KV Distribution Transformer HV & LV rectangular coils

2

-

2

c

Winding Machines for 33 KV Distribution Transformer HV & LV circular coils

6

-

6

d

Air Drying Ovens

4

-

4

e

Filter Machines 1.2 KL/hr and 3.0 KL/hr capacity

2

-

2

f

EOT Cranes - 2MT, 5MT, 25/5 MT each      

3

-

3

g

Compressors, Vacuum Pumps, Weighing Scales, Butt Welding, Arc Welding, material handling equipment, work stations etc.

-

2

Insulation Cutting & Processing (T4):

 

 

 

a

Multi Purpose Wood working Machines

4

-

4

b

Wood working saws

2

-

2

c

Router machine

1

-

1

d

Air Drying Oven

1

-

1

e

Scarfing, Block punching, Shearing, Sanding Machines, Compressor, Weighing Scales Material Handling equipment etc.

-

3

Coil Winding Area (T5):

 

 

 

a

Horizontal Winding Machines up to 10 MT capacity

10

-

10

b

Horizontal Winding Machines up to 15 MT capacity (Proposed)

-

4

4

c

Vertical Winding Machines (Under installation)

-

2

2

d

Formers of various sizes

e

Air Drying Ovens

2

-

2

f

Pneumatic Coil Processing fixtures

2

-

2

g

EOT Cranes - 25/7.5 MT

1

-

1

h

Compressors, Vacuum Pumps, Weighing Scales, Butt Welding,  Weighing Scales, material-handling equipment etc.

-

4

66 KV & 132 KV Transformers Assembly (T6):

 

 

 

a

Core Cradles 3 limb upto 50 MT (Under installation)

-

2

2

b

Autoclave 5.3x4.0x4.5 Mtrs size with 0.3 Torr Vacuum         

1

-

1

c

Air Drying Oven

1

-

1

d

Filter Machines 6 KL capacity, high vacuum

1

-

1

e

EOT Crane - 70/10 MT

1

-

1

f

Compressors, Vacuum Pumps, Weighing Scales, Brazing/ Crimping machinery, Material handling equipment, work stations etc.

-

5

Core Cutting Area (T7):

 

 

 

a

Wound Core Making machine

1

-

1

b

Bell Furnace for Wound Core annealing

1

-

1

c

CNC Slitting & Cut to length line for CRGO lamination (Proposed)

-

1

1

d

EOT Crane - 5 MT

1

-

1

e

Shearing Machines

1

-

1

f

Punching Machines

1

-

1

g

Compressor, Weighing Scales, Grinding Machine etc.

-

6

Fabrication Area (T8):

 

 

 

a

Plate Shearing machines, Brake Press, Presses, Drills, MIG welding, AC/DC Arc welding sets, Compressor, Vacuum Pump, Weighing Scales, Grinding Machines etc.

-

b

Shot blasting booth

1

-

1

c

Painting booth with dust free environment

1

-

1

d

EOT Crane - 25/5 MT        

1

-

1

7

220 KV to 765 KV Transformers Assembly (T9):

 

 

 

a

Core Cradles 5 limb upto 150 MT (Proposed)

-

1

1

b

Vapour Phase Drying 11.5x6.0x5.5 Mtrs size

1

1

2

c

Filter Machines 12 KL capacity, high vacuum

1

-

1

d

Air castor unit for movement of transformers (Proposed)

-

1

1

e

EOT Cranes  - 150/25 MT with beam for tandem lifting (total 300 MT)

2

-

2

f

Compressors, Vacuum Pumps, Weighing Scales, Drill, Grinding Machines, material handling equipment, work stations etc.

-

8

Common Facilities:

 

 

 

a

Raw Transformer Oil Storage Tanks 90 KL capacity each

2

-

2

b

Processed Transformer Oil Storage tanks (Total capacity 144 KL)

5

-

5

c

Thermic Oil heating system, 1.6 Mn K. Cal capacity

1

-

1

d

Diesel Generating Sets

2

-

2

e

Power S/S and distribution facility

-

9

Testing Equipment:

 

 

 

a

Distribution Transformers (11 KV - T1)
All test equipments for conducting all routine tests and Temperature rise test. Meters and CT/PT with 0.5 % accuracy and Yokogawa make power analyzer for loss measurement.

-

b

Distribution Transformers (33 KV - T2)
All test equipments for conducting all routine tests and Temperature rise test. Meters and CT/PT with 0.2 % accuracy and Yokogawa make power analyzer for loss measurement. All test readings transferred thru RS 232 Port for direct print out of test results

-

c

Medium Power Transformers (66 KV & 132 KV - T6)
All test equipments for conducting all routine tests and Temperature rise test. Meters and CT/PT with 0.2 % accuracy and Yokogawa make power analyzer for loss measurement. All test readings transferred thru RS 232 port for direct print out of test results. 300 KV Potential divider, Sphere gaps, SFRA equipment, etc.

-

d

Large Power Transformers (220KV to 765 KV - T9)
All test equipments for conducting all routine tests and Temperature rise test - best International makes. Meters and CT/PT with 0.1 % accuracy and Yokogawa make power analyzer for loss measurement. All test readings transferred thru RS 232 Port for direct print out of test results. 800 KV Potential divider, Sphere gaps, Partial discharge measurement, SFRA equipment, 3 Phase MG Sets (50 Hz – 180 Hz), 2x4 MVAr Reactor, Testing Transformers, Noise Level Meter, Non contact temperature measuring gun, Corona Shields, etc.

-

e

Common Facility (T9)
Impulse Generator 1600 KVp, 160 Kj with RSG, extendable to 2400 KVp, 240 KJ

-



 

 

 

 

 

 

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