Company Details
  • Name : Astor Transformatör Enerji Turz.İnş.Ve Petrol San.Tic.AŞ.
  • Address : 1. Organize Sanayi Bölgesi Ahi Evran Mahallesi Anadolu Caddesi No:6 Sincan/ANKARA
  • City State : Ankara
  • Country : Turkey
  • Web Page : www.astoras.com.tr
  • E-Mail : ayfer.ensari@astoras.com.tr
  • Telephone : (312)-267 01 56
  • Fax : (312)-267 00 34
  • Trade Marks : ASTOR - BESE - EFG
Company Profile
Corporate

Today, when we line in the age of energy, a major part of the energy that we need is electric energy. Our firm producing the transformers used in the electric energy transmission and distribution assess the energy sources in an efficient and environmentally-sensitive way and proceeds to become the leader firm in its sector by increasing its investments on a daily basis in order to contribute to prosperity of the country and the world.

It make production of cast resin dry type and oily type transformers and 220 KV 150 MVA power transformers in its factory having 26000 meter square indoor area on 36000 meter square in Ankara Sincan 1st Organized Industrial Zone.

Astor AŞ having the biggest production capacity of Turkey with the monthly distribution transformer capacity of 2000 units is among the first 5 firms of the world in its sector.

In our production:

-Economic, safe, low loss, long-life oily type distribution transformers with the power range of 250 – 2500 kVA and up to 36 kV voltage level and also special type of transformers depending on the customer demands with the brand of ASTOR and EFG,

-With the ASTOR brand, power transformers up to 150 MVA 220 KV,

-With the brand of EFG, Cast Resin Dry Type Distribution Transformer production having ISO 9001 quality standard with the power range of 25 0 – 3150 kVA up to 36 kV voltage level with selections of natural air-cooled or fan-cooled (AF), productions are carried out.



Product range and area of use

1. Distribution type transformers (160 – 3150 kVA)

2. Mono-phased transformers

3. Power transformers (4000 – 25000 kVA)

4. Transformers having tap-changer at the OLTC load

5. Rectifier-type transformers

6. Water and air-cooled transformer with IP54 protection class (Submarine, Marine, Vessel and Oil Drilling Platforms)

7. Wind power turbine transformers (Maintenance and repair may be made in tower)

8. It minimizes fire and explosion risk in the environments in which people intensely live such as subway, tunnel, mines, airports, shopping malls, schools, hospitals, skyscrapers.

9. It may be produced external and enclosure type depending on the protection classes of IP20, IP23, IP33 optionally.

Out of them, our international test reports of product series in our product range have continuously been updated and certificated by international test institutions such as KEMA, IPH, and CESI.

Our project prepared by our experienced design team under the leadership of more than 30 engineers ensure that the material purchased as raw material is transformed into semi-finished product with all stages being its own body, they are mounted and transformed into transformers.

As Astor Transformer, we are aware of how important the Research and Development step are for our firm and country. So, our firm works with quality personnel and takes decisive and solid steps in order to have a up-to-date and comprehensive Research and Development centre since 2011.

Duties of Research and Development Centre of our firm which is sensitive in always following the world technology are;
•• To increase production efficiency and resolve the problems aroused,
• To develop the best and innovative designs in terms of functionality, performance, reliability, cost, and reproducibility,
• To support design and production process with analyses and simulations,
• To prepare and track Research and Development projects,
• To provide training support to its production and design personnel in relation with transformer,

Research and Development Projects carried out in cooperation with Tübitak,
•• Transformer design with SF6 gas isolation and prototype manufacture,
• Design of distribution transformer with high-energy efficiency and amorphous core and prototype manufacture
• Design of power transformer with 65 MVA, 132/33-11,5 kV double low voltage coil and prototype manufacture
• Design of transformer resistant against short-circuit and consisting of two conductors of which 154 kV coils are different and prototype manufacture
• Design, development, and application of robotic welding cell for body construction of distribution transformers
• Design of coiling machine with PLC control for transformers and prototype manufacture
• Development of solvent vapour drying system for transformers and prototype manufacture
• High-speed train transformers

European originated materials are used in our coil winding department working with coiling machines having the most advanced technology.

Oily Type Transformers

In coils of distribution transformers, round and flat electrolyte copper with enamel and paper isolation or aluminium conductors are used as conductive material. Insulation material used has water and voltage resistance. Regular distribution of voltage forces has been ensured in high voltage coils with special coiling application by increasing insulation of input and output layer insulations.

Coils of power transformers are made in inversed or layered coil depending on the design conditions. Coil machines with press system are used in layer coils in vertical and lateral directions in order to ease manufacture and remove the spaces on contact surfaces of the coils.

Coiling process is carried out with CNC-controlled automatic machines.

Dry Type Transformers

Depending on the projecting, foil coiling technology and copper or aluminium foils are used in low voltage coils because of its technical advantages. By using resin-absorbed material according to insulation class between threads, radial short circuit forces are controlled. By exposing coils to the hardening process after coiling, it is ensured that they gain resistance against hard conditions and dielectric characteristics.

High voltage coils are manufactured by using copper and aluminium flat or round conductors insulated with For H class according to project. Effective distributed cooling channels are provided as a good natural cooling in our designs. Also, it gives advantage against high voltage forces.

Core is manufactured from places with M5, M4 silicon alloys with thickness of 0.30, 0.27, and 0.23 mm of which crystals have been directed. Bent-cut plates are used in the transition regions of magnetic circuits. All plates used in magnetic circuit are cut in CNC-controlled cutting machines and core manufacture is carried out according to project. Magnetic circuit cutting and composition is made with a method used to decrease iron losses called step-lap into minimum level. Cross and longitudinal step-lap applications are aligned with core.

CNC-controlled plasma and wave wall machines are used in boiler manufacture. Welding processes of boilers are made with CNC-controlled robots. In manufacturing of hatches of transformers, CNC-controlled plasma machines are used and welding processes of hatches are made with CNC-controlled robots. We produce standard-quality products by minimizing human errors with CNC-controlled robots. Boilers of which installation and welding processes have been completed are exposed to the impermeability test under pressure according to IEC standards.

Vacuum resistance of wave walled boilers are designed to be 0,65 bars and the same of radiator boilers are designed to be 1 bar. Painting process is completed according to the relevant standards. Boilers of which manufactures are completed according to customer demands are exposed to sanding process. Painting process is completed according to relevant standards. Boiler hatch is designed to stick out coil ends.

Parts are sanded after leakage controls are made; tank part is prepared to painting process by being passed through chemical baths. It is prepared for use by first priming and then, last layer electrostatic power paint by automatic conveyor system. Completely homogenous products with the highest quality and having the desired paint thickness are passed through quality control studiously.

Laths are mounted on to the core in order to tighten the core to balance and carry the radial forces by first placing the coils on the cores carefully in order to constitute the active part. Then, upper core section is aligned and transoms are tightened. Thus, by increasing the pressure surfaces, movement probability of the transformer on the load decreased to zero. Hatch installation of the active part is made and required connections of commutator and setting ends are made with silver electrodes. Then, AG and YG isolator installations on the hatch are fixed with special gaskets by paying maximum attention for oil leakage. Active part is prepared for firing in this way.

Heating and vacuum are carried out in determined heats in order to remove existing humidity on the solid insulation materials of the active part in our drying furnaces. Thus, maximum drying process is carried out. Humidity and temperature values in our furnaces are examined by being continuously analysed with graphics in digital screens.Active part from drying furnaces is placed into the boiler within maximum 15 minutes at the environmental temperature of 20oC. Oil filling is carried out under vacuum and under the determined temperature in oil-filled vacuum furnaces.

Lastly, gauge valve, valve, thermometer etc. accessories are mounted on the transformer of which oil filling has been realized and installation process is completed by delivering it to the test department.

We transfer each transformer by applying routing tests mentioned in IEC 60076 (TS 267) standards in our laboratories accredited with the accreditation number AB-0650-T dated 12.06.2013 by TÜRKAK.

In our test laboratories, all tests demanded under IEC and TSE standards excluding mechanical resistance test against short-circuits can be conducted for our oily distribution transformers, dry type distribution transformers and power transformers.

Our systems:

1. Test area of transformers having 150 MVA power and of which the highest operation voltage is 220 kV.
2. Test area of transformers having 30 MVA power and of which the highest operation voltage is 36 kV.

Transformer Routing Tests:

They are the tests conducted for every transformer produced.

Measurement of voltage cycle rate and control of voltage vector phase shift (TTR test)

Measurement of coil resistance

Test of AC resistance voltage with separate source (Test of applied voltage)

Test of Induced AC voltage (Induced voltage test)

Measurement of idle loss and current

Measurement of short-circuit impedance and loss in the load

Capacity and tan ∂ measurement

Measurement of DC insulation resistance

Transformer Type Tests:

They are the tests conducted on the transformer with the same characteristics on customer demand.
Measurement of noise (volume)
Lightning impulse test
Temperature increase test
If there are fan cooling or liquid pump system, measurement of fan or liquid pump losses

Transformer Special Tests:

There are the test conducted on the customer demand.

Idle current and measurement of harmonic compounds

Measurement of zero compound impedance

Measurement of partial discharge

Insulation Liquids – Breakdown Voltage Assignment on Power Frequency (measurement of oil dielectric resistance)

Tests of level changer under load
Function and isolation tests of protection, alarm and command equipment

Transformers taken to the final installation to be prepared for the transfer are labelled after the last controls and packaged to be ready to be transferred.

Our company providing service to electric infrastructure of more than 50 countries have the justified pride of awards bestowed in export.

We are with you for every kind of support with our young, cheerful, fast, and dynamic sale team.

Our firm working customer satisfaction-focused focuses on the quality in production and service as primary target.

In direction of this target, all processes of production is controlled in every stage by our experienced expert quality control team. Our firm has many management systems including TS EN ISO 9001, TS EN ISO 14001, TS EN ISO 17025, and OHSAS 18001. It ensures that the production is completed in compliance with the relevant project and quality management system and relevant incompliances are removed by applying corrective and preventive operations. All processes are recorded and followed. Data obtained in the processes are examined and kaizen studies are conducted in processes considered required.

Customer feedbacks are carefully examined by taking the customer satisfaction into consideration by our customer relations department and planning of our service team is made in a way that they provide service 7/24.

Our firm paying utmost attention for worker heath and occupational safety provide trainings to our workers regularly on a weekly basis and support is taken from relevant expert establishments when required.
NO HS Code HS Code Description
1 850421 Liquid Dielectric Transformers Having A Power Handling Capacity Not Exceeding 650 Kva
2 850422 Liquid Dielectric Transformers Having A Power Handling Capacity Exceeding 650 Kva But Not Exceeding 10,000 Kva
3 850423 Liquid Dielectric Transformers Having A Power Handling Capacity Exceeding 10,000 Kva
4 850433 Electrical Transformers , Having A Power Handing Capacity Exceeding 16 Kva But Not Exceeding 500 Kva
5 850434 Electrical Transformers , Having A Power Handling Capacity Exceeding 500 Kva
6 850431 Electrical Transformers , Having A Power Handing Capacity Not Exceeding 1 Kva
7 850432 Electrical Transformers , Having A Power Handing Capacity Exceeding 1 Kva But Not Exceeding 16 Kva