Transformer Production

This activity direction includes the following companies:  PJSC "Zaporozhtransformator",  PJSC "Zaporozhye Cable Factory", PJSC "Zaporozhye Super-Power Transformers Plant", PJSC "Zaporozhye Small-Size Transformers Plant" (hereinafter jointly referred to as "ZTR").

  • Production of power and special oil-immersed transformers and electric reactors ranges as to their power from 0.1 to 1250 MVA and as to their voltage up to 1150 kV in accordance with the requirements of any national or international standards.  
  • ZTR is one of the largest manufacturers of transformer equipment of 500-1200 kV voltage class in the world.
  • More than 50% of the transformer equipment (block transformers, autotransformers, auxiliary, start-up and standby transformers) installed at the generation facilities of the RF is manufactured by ZTR, including almost all the block transformers.
  • ZTR’s equipment constitutes approximately 80% of 300 thousand MVA transformer stock of facilities of Federal Grid Company of Unified Energy System (FGC UES).
  • Nuclear power engineering of the Russian Federation is at 95% equipped with ZTR’s transformers that meet the reliability and safety requirements established for this type of equipment.
  • Productive capacity is 60,000 MVA, per year.
  • The market share constitutes 50% in the CIS.
  • ZTR's sales geography covers 86 countries of the world.
  • ZTR customers include the greatest network, generation and industrial enterprises in Russia, the CIS and the world, including FGC UES, Interregional Distribution Grid Co (IDGC), RusHydro, Atomstroyproekt, Rosenergoatom, RZD (Russian Railways), Lukoil, Rosneft, SamrukEnergo, KEGOC, Iberdrola, Siemens, Alstom, Power Grid Corporation of India and others.
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    PJSC "Zaporozhtransformator"
    • About
    • Management
    • Products
    • Technical possibilities
    • Clients
    • Partners
    • Contacts
    • Representative offices

    For more than 60 years of its activities in the market PJSC "Zaporozhtransformator" (ZTR) has attained the world-wide fame and excellent reputation as a Manufacturer of high-quality and functionally reliable transformers and reactors. Today ZTR is an up-to-date and dynamically developing enterprise that supplies its products to the customers from 86 countries of the world.

    With a production capacity of 60,000 MVA per year, the company is considered to be a leader in the CIS market that holds a worthy position among the global transformer producers. High qualification and experience of its design staff can successfully resolve the most difficult technical problems that can be set by its customers.

    Modern production technology, new production equipment and efficient quality control system provide the output of products that meet the highest quality requirements and operational reliability of the equipment produced.

    ZTR is a certified supplier for SIEMENS, AREVA, ALSTOM, IBERDROLA, ABENGOA, MITSUBISHI HEAVY INDUSTRIES, ABB, ECOBANA, UNION FENOSA, E.ON, TECHINT, GAMMA POWER, ENKA, MAPNA, POWER GRID CORPORATION OF INDIA.

    The Company is able to meet the requirements of any national and international standards, such as: GOST, DSTU, IEC, ANSI, BS, IRAM, UNE and IEEE.

    Mr. Igor V. Kleyner
    ZTR’s General Director since 2005.

    In 1977 he graduated from the Zaporozhye State Technical University. His career at ZTR began in 1977 after his graduating from the university as an engineer-technologist of a welding shop. His managerial experience started in 1983.

    Mr. Leonid N. Kontorovich
    ZTR’s Technical Director since 2007.

    In 1971 he graduated from the Kharkov State University; he is a candidate of technical sciences. In 1971 he started his career as an engineer in the transformer business at the All-Soviet Research Transformer Production Institute (VIT) in Zaporozhye, Ukraine. From 1981 to 1991 he worked as the head of the Mathematical methods and research laboratory in the Department of Computer Engineering.

    Mr. Victor K. Ibadullaev
    ZTR’s Production Director since 2000.

    In 1984 he graduated from the Zaporozhye State Technical University and in 1998 he graduated from the Kiev National Economic University. His career at ZTR began as an engineer of Quality Department in 1984.  Tree years later he occupied the position of the Head of Quality Bureau. Since 1991 he has worked as Deputy Head of the 1st transformer shop and in 1994 he was appointed the head of the 1st transformer shop.

    Mr. Mikhail Y. Oservaser
    ZTR’s Quality Director since 2004.

    In 1971 he graduated from the Zaporozhye State Technical University. His career at ZTR began in 1971 as an engineer of the central laboratory of the plant. In 1982 he was appointed head of the Polymeric Materials Solid Insulation Laboratory in the central plant laboratory, and from 1987 till 1993 he worked as the Deputy Chief Metrologist.  Starting from 1993 he held the position of the Head of Testing and Diagnostics Department at ZTR’s Service Company ‘Service’. From 2002 to 2004 he simultaneously held the positions of a Chief Metrologist and Head of ZTR’s central laboratory.

    Mrs. Lydia S. Gorbaneva
    ZTR’s Financial Director since 2013.

    She graduated from the Dnepropetrovsk State University in 1988, with the speciality of economic cybernetics. Her career at ZTR began in 1988 as an economist. In 2008 she occupied the position of the Head of the Economic Activity Analysis Department and in 2010 she began performing her duties of the Head of the Management Accounting Department.

    Mr. Alexander G. Tsier
    ZTR’s Sales Director since 2008.

    In 1986 he graduated from the Zaporozhye State Technical University.  He began his career at ZTR in 1985 as an electrician. Starting from 1986 he worked as an engineer of the External Installation Supervision Department and as a Design Engineer of the General Design Department.  Starting from 1991 he worked as a Leading Engineer and Head of the Export Group at ZTR’s Foreign Trade Company. In 2002 he was appointed Head of the Export Group, and in 2005 he was in office of the Head of ZTR’s Sales Department.

    Mr. Alexander M. Bass
    ZTR’s General Designer since 2004.

    In 1984 he graduated from the Zaporozhye State Technical University. He began his career at ZTR in 1984 as an engineer and constructor, and his specialization included all transformers calculations. In 1996 he occupied the position of the Chief Transformers Designer up to 150 kV – and Deputy General Designer.

    Mr. Sergey N. Yeryomin
    ZTR’s Procurement and Logistics Director since 2011.

    In 1999 he graduated from the Zaporozhye State University. In 2002 he started his career at ZTR as the Director of Information Technology.

    The range of ZTR PJSC’s products includes power and oil-immersed transformers designed for different purposes and for various climate and seismic conditions with the capacity ranging from 1 MVA up to 1250 MVA and voltage class from 10 kV up to 1150 kV inclusive, electrical reactors and controlled shunt reactors.

    Range of Products:
    1. Generator transformers
    2. Autotransformers
    3. Transformers for substations of distribution trunk electric lines and industrial enterprises
    4. Auxiliary transformers of power stations, start-up and stand-by transformers
    5. Transformers for direct current electric lines and high-capacity converter tie-line substations
    6. Special transformers
    6.1 Transformers for metallurgical enterprises
    6.2 Transformers for railway substations
    6.3 Line regulating transformers
    6.4 Furnace transformers
    6.5 Mining transformers
    7. Electrical reactors
    7.1 Shunt reactors
    7.2 Neutral reactors
    8. Controlled shunt reactors

    At customer’s request the equipment can be furnished with the fire-fighting system, “on-line” monitoring and diagnostics system as well as with a specialized commissioning and diagnostic equipment.

    ZTR’s equipment is designed in compliance with the requirements of GOST, IEC, ANSI, BS, IEEE, IRAM or other technical requirements of national standards and customers. ZTR PJSC’s service centre operates to ensure the trouble-free and long-term operation of the equipment supplied to the customers during the whole service life.

    At present the Service Centre is a scientific and production complex with its own production and technical department, commercial service, separate subdivision to implement complex projects and mobile diagnostic laboratories on the territory of Ukraine and the Russian Federation.

    ZTR possesses a modern production technology of power transformers and reactors. The production process includes all operations for manufacture of main units of transformers and reactors such as magnetic cores, windings, tanks, tap changers and other units and parts, as well as assembling and testing of the finished products.

    Magnetic Core Production

    For producing magnetic systems at ZTR they use siliceous anisotropic electrical sheet steel with low and very low specific losses including with laser treatment.

    Longitudinal cutting of steel is carried out at automatic slitting lines COMEC (France) and GEORG (Germany) with simultaneous scraping of side strip edges with the help of a special tool.

    Magnetic system plates are manufactured on high-precision automatic cross-cutting lines ТUR and GEORG (Germany), equipped with programmed control and carbide-tipped tools, including V-notches, ensuring simultaneous stacking of magnetic system sections.

    Technical performance of the lines and their software allows to produce plates of required shapes, including for laminating Step-Lap schemes (biased joint).

    For producing magnetic systems of transformers and autotransformers with power up to 150 MVA they use an automatic line of magnetic core assembling (Е-stacker) produced by GEORG.

    The automatic line manufactured by GEORG is used for production of magnetic system elements of shunt reactors.

    Magnetic cores of transformers of higher capacity are assembled on special tilting stands ensuring the production of magnetic systems weighting up to 350 tones.

    Magnetic cores weighting up to 180 tones without the upper yoke are assembled by using a new assembly stand manufactured by GEORG.

     A vertical banding machine produced by GEORG is used for tightening (molding) of magnetic cores rods.

    Winding Production

    Windings of different types and designs, such as: helical, continuous and interlaced windings, including the windings made of hardened transposed conductor are reeled in by using the wide range of horizontal and vertical reeling machines that allow to reel in the windings weighing from a few kg up to 20 tons with adjusting a conductor tension.

    High quality of windings is provided by using special universal expandable mandrels, complex technology of axial dimension stabilization with using the hard electric cardboard distant spacers and hard electric cardboard cylinders, vacuum drying of the windings under the constant fixed pressure, cyclic pressing with special pressing systems manufactured by Guenter Seibold, (Germany), etc.

    At the production areas of the assembly workshop there is a section with a special microclimate. This section is equipped with special-purpose facilities, allowing to maintain optimal parameters of the microclimate, such as air temperature, relative humidity, dust content in air, and is an insulated area of the site of reeling coils of transformers and reactors furnished with technological equipment for reeling in the windings with voltage class 400 кV and higher, electro bridge crane, air-cushion transporter for moving technological fittings, reels with and without conductors, windings and components.

    Developed technologies of reeling in the windings exclude up to the minimum extent the performance of brazed joints of winding conductors, and unavoidable structural joints are made with silver-containing brazes with pre-treatment of the brazing area.

    Insulation Production

    Insulation production includes the manufacture of the whole range of insulation parts and assembly units used in the production of transformers and reactors.

    The available base of modern technological equipment allows manufacturing of pressing and capacitive rings, bars, spacers, cylinders, angle washers, yoke insulation and others.

    Parts of complex configuration, such as pipes, elbows, couplings and flanges are manufactured by applying a «moulding» method. They also produce wood-chip plastic and wood-chip plastic parts as well as paper-bakelite items.

    The use of technologies connected with the utilization of remote winding elements calibrated by thickness and  hard electric insulating cardboard cylinders allows ensuring of constant axial dimension of windings and high electro-dynamic stability.

    At ZTR they widely use a laminated cardboard manufactured by Weidmann and ENPAY as a material to produce insulation parts. The use of such material provides high quality of the insulation parts, complicates the access to their thickness and reduces technological cycles of insulation production.

    Processing of laminated plates and manufacture of parts are carried out on the specialized numerical programme control equipment made by Biesse Group and SCM Group S.P.A. (Italy) that provides high level of accuracy, quality and stable dimensions of the parts.

    A cutting centre equipped with numerical programme control of Biesse Group was designed for cutting and sawing of rectangular billets and for producing finished insulation parts of rectangular cross section.  

    The processing centre equipped with numerical programme control of Biesse Group performs profiled cutting of laminated carton that results in obtaining of ready-made insulation parts: pressing, supporting and capacitive rings, stepped parts, segments, sectors of equalizing insulation, and others.

    A planing and milling machine manufactured by SCM Group S.P.A. and equipped with a quick tool-change system allows to produce profiled insulation parts (bars) made of laminated carton characterized by improved quality and precision features. This miller provides processing of 3 billet surfaces and making a part profile for a single-pass operation.

    Reducing of insulation distances in the active section within the implementation of the program aimed at improving of the transformer design is achieved through the application of a labyrinth-type oil circulation in windings that results in significant improvement of the condition of their cooling.

    Spacers for labyrinth-type oil circulation as well as complex shaped insulation made of electric insulating cardboard with thickness of 0,5 mm are manufactured by means of a laser machine made by Yueming (China).

    Thermal and Vacuum Treatment

    Thermal and vacuum treatment of transformer active sections and insulating components is carried out by using about 150 units of equipment, including vacuum driers, oil degassing units, oil drying vessels, filter-presses, vacuum-fillers and so on.

    The insulation drying process used by the factory provides removing of moisture from the insulation up to the residual water content less than 0, 2 % that gives a great margin of electric strength of insulation.

    The drying is performed in petroleum products vapours according to the advanced technology by using the units manufactured by Micafil (Switzerland). Such process is completely automated; its temperature and vacuum modes are recorded. The measuring outfits allow to estimate the residual moisture content in the insulation within the real time operation.

    The transformers manufactured by the factory are filled with up-to-date high-quality oils that meet the requirements of IEC 60 296. While filling the transformers the oil is additionally refined, dried and degassed by the oil purifiers produced by the factory itself and by Maksey (France) as well.

    Welding Fabrication

    The factory has its own welding fabrication with a complete cycle of manufacture that fully meets the company’s in-house needs for tanks and other metal structures of any dimension and type of production.

    All the rolled metal going into production is subject to shot-blasting for removal of surface oxides.

    The rolled metal is cut out at the thermal cutting section fitted up with such machines as Cristal, Ukraine and Suprarex manufactured by ESAB (Sweden) and equipped with programmed control.  This technology allows to cut out up to 70 sheets of ferrous and stainless rolled metal per day, with thickness from 7 up to 65 mm along with  simultaneous plasma marking and layout of outlines for installed parts.

    The parts are mechanically processed by the machinery that provides the performance of drilling, threading, turning, milling, planing, rotary, stamping, bending and roll-forging operations.

    The main welding works are performed by means of semi-automatic arc welding in shielding gas medium by using the welding machinery manufactured by EWM, (Germany).

    The metal structures that can be welded in a low position are made automatically by applying TWIN method under the flux layer by using the portal unit produced by ALW (France).

    The quality of welding seams is verified be such methods as ultrasonic control, luminescent method, bubble method, dye penetrant flaw detection, with mandatory subsequent control carried out by a column of oil by assembling.

    All the welding operations are performed by the staff certified according to NPAOP 0.00-1.16-96, EN 287, ISO 9606.

    Painting

    Prior to painting the surfaces are processed by a shot-blasting method up to Sa 2,5–3 level by meeting the requirements of ISO 12944.

    Painting is carried out by high-technology machines manufactured by WAGNER, KREMLIN, GRACO and SATA of airless, combined and airstream atomization, both in spray cabinets and  painting and drying chambers equipped with three-stage dry cleaning of supply and exhaust air and mechanized lifting platforms.

    The high-quality materials manufactured by a European producer - NOVATIC (Germany) are used for applying a rust-preventing protective coat. The quality of these materials is certified by ISO 9001.

    The systems that meet the requirements of ISO 12944 are used to provide a long-term service life and proper external coating for such corrosion categories as: С3, С4, С5I, С5М, depending upon conditions of operating of transformers and reactors.

    Coating colour can be performed according to the customer’s requirements in compliance with the following catalogues: RAL, ANSI, MUNSELL, and others.

    Internal oil-proof surfaces of transformer metal structures are painted with high-quality oil-resistant quick-drying white material, namely: Celerol primer manufactured by Mankiewicz Gebr. & Co (Germany).

    Painting operations are carried out by the Company’s well-trained and certified personnel.

    Hardware Production

    The hardware production ensures the manufacture of a wide range of units and articles such as tap changers of regulation under pressure and excitation-free switching, transformer control cabinets, including those equipped with monitoring systems, cut-off and safety valves, rotary shutters, fans for cooling systems and other hi-technology products.

    High-precision mechanical production of tap changers motor-drive parts is performed by using the stock of about 50 units of modern numerical program control machines.

    The general-purpose equipment available at the plant allows manufacturing of all kinds of metal processing, including blanking, bending and stamping, cold-forming, grinding, turning, milling and other types of processing.

    Assembling Production

    The transformers are assembled on the stands equipped with mechanized lifting racks, soldering and welding machines, hydraulic equipment for winding pressing and set of lifting and special gears.

    Handling operations are conducted by means of electric bridge and bracket cranes with elevating capacity up to 500 tons.

    The technology of transformer movement on air cushion is also used at the plant by providing mobile and operable  performance of assembling operations.

    Special load-lifting gear ensures the execution of complete control assembling of a transformer, with installation of all components (radiators, coolers, pumps, filters, fans, control devices, and others).

    Other Production Activities

    The company’s production capacities allow to make castings of ferrous and nonferrous metals, the centrifugal welding is also available at the plant. There is a forging shop and galvanic coating section at the plant as well.

    Production Test

    ZTR has own testing facilities that allow  to conduct a full set of testing of its output products in the volume established by the national, inter-state and international standards, as well as in accordance with special requirements of the customers.

     ZTR’s testing laboratory is certified in compliance with DSTU ISO / IEC-17025.

    PJSC "Zaporozhtransformator" (ZTR) supplies its equipment to 85 countries to generation objects, electric power transmission and distribution objects, as well as to industrial facilities. The equipment operates effectively in various climatic and seismic conditions from cold Polar regions up to hot deserts of Central Asia and Africa. About 80% of the total transformer equipment that operates nowadays in the CIS is produced by ZTR. This enterprise constantly improves its technologies and products quality and their specifications in order to fulfil the requirements of ZTR’s customers.

    The reference list provides the information on the supply of power transformers and shunt reactors produced by PJSC "Zaporozhtransformator" from 1970 till 2011 inclusive, and contains details about the object of delivery, type and quantity of the equipment supplied. This information is compiled according to geographical regions and voltage classes.

    Ukraine

    • AMK
    • UGMK
    • Metinvest
    • Malyn Paper Factory
    • ISD Сorporation
    • Dneprospetsstal and others.

    Russia

    • NLMK
    • CJSC “Normetimpeks”
    • “Red October” and others

    Far Abroad

    • ThyssenKrupp
    • Stalprodukt
    • Nippon Steel
    • JFE
    • Weidmann
    • Trench UK
    • ABB AB
    • Maschinenfabrik Reinhausen
    • Menk
    • EMB
    • EPRO
    • AKM
    • Qualitrol
    • Messko
    • Renzmann
    • Schormann
    • Pergam
    • Morgan Schaffer
    • Sergi
    • Schneider Electric and others

    “Zaporozhtransformator” Public Joint-Stock Company

    http://www.ztr.com.ua

    Address:

    Dnepropetrovskoe Shosse, 3

    69600, Zaporozhye, Ukraine

    Information office

    Telephone: +38 (061) 270-3309

    Reception hall of Director General Mr Igor Vsevolodovich Kleyner

    Tel: +38 (061) 270-39-00

    Fax: +38 (061) 270-37-39

    E-mail: office@ztr.com.ua

    Reception hall of Sales Director Mr Alexander Garrievich Tsier

    Tel.: +38 (061) 270-30-33

    Fax: +38 (061) 270-39-39

    E-mail: sales@ztr.com.ua

    Reception hall of Purchase and Logistics Director Mr Sergey Nikolayevich Eryomin

    Tel.: +38 (061) 270-31-31

     E-mail: Sergey.Yeryomin@ztr.com.ua

     

    Representative Office in the Russian Federation

    Address:
    Russian Federation,
    119049, Moscow,
    B. Yakimanka Street 33/13, building 1, office 5/1

    Tel.: +7 (495) 745-88-40
    Fax: +7 (495) 238-24-15
    E-mail: i.kuzmenko@ztr.msk.ru

    Head of the Representative Office - Mr Igor Petrovich Kuzmenko

    Representative Office in Kazakhstan and Middle Asia

    Address: Kazakhstan, 005009, Almaty,
    Pr. Abaya 151/115, "Alatau" Business-Centre, office 701

    Tel.: +7 (727) 333-46-92
    Fax: +7 (727) 333-46-96
    E-mail: office@ztr.kz

    Head of the Representative Office - Mr Sergey Vladimirovich Nadenenko

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    Publications
    Full-Time LEO’s Call-Center Will Start Working in March 2014

    New structural department will significantly improve the quality of services rendered to the electricity consumers.

    Shipment of Equipment to Yurkharovskoye Field

    PJSC “Sumy Frunze NPO" started shipping of the equipment to Yurkharovskoye oil and gas condensate field.

    ZTR at "Energy 2013" Exhibition

    PJSC "Zaporozhtransformator" (ZTR) participates in the annual specialized exhibition of energy technologies, industrial electronics and electrical technique "Energy-2013".

    ABOUT FUND

    Energy Standard Fund Ltd. was founded on 31 December 2007 in Cyprus  in accordance with the Cyprus Company Act, Cap. 113 under the Company’s  registration number - HE 219165.

    On 28 January 2008 Energy Standard Fund Ltd obtained an international private joint investment fund license, issued by the Central Bank of Cyprus (http://www.centralbank.gov.cy).

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    PRESS CENTRE

    Presentation of the Fund

    Overview of Energy Standard Fund's Ltd assets

    • Production of transformers and electrical equipment
    • Production of equipment for oil and gas industry
    • Distribution of Electricity
    • Transport and Logistics
    • Real Estate Development
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