baner-image

Successfully meeting power challenges

At Prime-Meiden Limited (PML) - a leading transformer manufacturer, 18 ElectroMech cranes integrate the handling requirements in their state of the art plant; from incoming raw material to complete transformers weighing 300 MT, through various processes and assembly stations.

background-logoBACKGROUND

background

About Prime-Meiden Ltd.

Prime-Meiden Limited (PML) is one of largest transformer manufacturers in India, catering to the requirements of Indian and international markets for power utilities, EPC companies, substations, power generation, transmission and distribution companies and large industries from various sectors (steel, cement, petroleum, petrochemicals, etc.) using bulk power. PML is one of the most significant activities of the Prime Group. The Prime Group has rich experience 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 1000MVA/500kV. PML's production capacity, projected to 35000MVA, makes it one of the largest manufacturers in India, producing world-class extra high voltage power transformers for users across the globe. PML’s manufacturing plant at Nayudupet Special Economic Zone in Nellore district in India is spread over 100 acres of land.

challenge-logoCHALLENGES

challenge

The handling challenges at Prime-Meiden Ltd.

The task assigned by Prime-Meiden to ElectroMech was challenging in several aspects. ElectroMech cranes are expected to integrate the handling of transformers through various processes and assembly stations right from the incoming raw material stage to the final despatch bay. The cranes were expected to cover the entirelengthand width of the shop-floor, providing maximum hook approach, reaching every nook and corner of the shop floor. The most critical part of the transformer manufacturing process is filling oil in assembled transformers. For this, the transformer needs to be lowered into a vacuum chamber where it is completely dried to make it moisture free. Here, precision positioning using the cranes is extremely important. After this, the transformer is filled with oil and is to be moved without any spillage due to jerks. Hence, the cranes should be able to handle the load ensuring absolutely jerk-free movement. As the transformers pass through this process, their weight gradually increases, the heaviest transformers weighing in at 300MT which need to be carefully lifted and taken to the despatch area.

solution-logoSolutions

solution-banner

Solutions from ElectroMech

The ElectroMech solution comprises 18 cranes ranging from 5MT, 8.5m span to 150/30MT, 30m span to ensure complete integration of handling on the shop-floor while covering every process station and reaching every corner of the plant. These cranes cover the handling requirements through various stages of the manufacturing process, including handling of raw material such as steel coils and copper plates, operations at various assembly stations, core winding stations, vacuum chamber, oil filling station, testing room and finally, the dispatch bay. The most interesting part of the solution is in the form of two 150/30 MT cranes which work in tandem to lift the large transformers weighing 300MT, using a specially designed lifting beam. This ensured safe handling of heavy components of 300MT with ease and precision. The lifting beam is designed so as to ensure equal division of the 300 MT load between both cranes, thus allowing the crane structure to be optimized, enabling savings in the factory structure due to a reduction in weight.

solution-banner-2

Team ElectroMech on the project

From ElectroMech the entire project was efficiently co-ordinated by our sales, design and project engineering teams. ElectroMech is proud to be associated with Prime-Meiden Ltd. for one of their largest transformer manufacturing facilities in India. We have achieved another milestone by adding the Prime-Meiden Group to our client list. The plant is already commissioned and all ElectroMech cranes are operational round-the-clock, helping them achieve the desired productivity.

Synopsis

Challenges

  • Lifting of completely assembled transformers weighing 300MT
  • Jerk-free handling of heavy, oil-filled transformers
  • Integration of handling in the complete plant
  • Lowering of transformers in vacuum chamber required precise positioning

Solutions

  • Two synchronised cranes of 150MT each, working in tandem to lift 300MT loads
  • Anti-sway device to avoid jerks
  • Carefully planned 18 cranes
  • Smoothly operating drives with inching facility

Total number of cranes: 18

Sr No.SWLSpanHeight of liftNos.
1150/30MT30m16m3
250/10MT30m17m1
330/10MT30m17m1
430/10MT15m11m1
515MT15m11.4m1
615MT10m11.4m1
710/2MT20m11.4m2
810/2MT10m11.4m1
95MT30m22.7m1
105MT10m11.7m1
115MT10m11.7m1
1232/18MT18.75MT13.5m1
1316/5MT18.75MT13.5m1
1416MT18.75MT13.5m1
1510MT18.75MT13.5m1
Total 18

Benefits

How PEL benefitted from ElectroMech solution

  • Integration of various processes and maximum coverage
  • Saving in project costs through use of appropriate capacity cranes of compact and light weight design
  • Ensuring jerk-free handling of transformers at critical work stations and through various processes
  • Higher up time of cranes and higher productivity through optimally designed cranes
  • Enhanced plant aesthetics, thanks to the sleek design of the cranes and high quality paint finish
  • Tandem lifting of mammoth 300MT loads by two 150MT cranes providing stability and substantial saving on proj cost