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Internship Report
Transformer Unit II
Muhammad Waqas 09-EE-119
University of Engineering and Technology, Taxila
Muhammad Waqas
09-EE-119
UET, Taxila
Change your life
Design Department Name: Designation: Signature: I & QC Department Name: Designation: Signature: Production Department Name: Designation: Signature: HR Department Name: Designation: Signature:
Muhammad Waqas
09-EE-119
UET, Taxila
Change your life
To my family and my teachers who showered their wisdom and knowledge enabling me to come to grips with the worldly life and attain my objectives.
Muhammad Waqas
09-EE-119
UET, Taxila
Change your life
Acknowledgement
‘‘In the name of ALLAH, the most merciful and the most beneficent’’ beneficent’’
Person is not perfect. He has a limited mind and thinking approaches. It is the guidance from the almighty ALLAH that shows the man, light in the darkness and the person finds his way in this light. Without this helping light, person is nothing but a helpless creature.
I am very grate full to ALLAH almighty for granting me the opportunity, perseverance and determination for handling the internship at PEL for the duration june-july 2011. I extend many thanks to all my section in charges for helping and guidance throughout my Internship. They help me a lot in performing all activities and in gaining the practical knowledge. They monitored all my activities and gave me the best suggestions to complete all the assigned tasks in effective manner.
I am very thankful to administration of PEL for giving me the opportunity of o f internship that build my personality and enable me to do some creative work to be successful person in my practical life.
Muhammad Waqas
09-EE-119
UET, Taxila
Change your life
Executive Summary
I have worked as an intern at PEL (Pak Elektron Limited) for the duration of 4 weeks(20th June to 18th July ) 2011. I made this report about the working in the PEL in TRANSFORMER UNIT .I visited three sections of unit and know further details briefly. In the usual education, we have studied only concepts of every subject and do not have practical knowledge. In engineering we have only studied theory and concepts and when a person apply that theory and concepts on an organization that concepts convert in to knowledge that live long with a person the whole life. I learnt a lot from this organization which I mentioned in this report. These three sections include Design, I&QC and Production departments..This report will give its reader the knowledge about the history and background of PEL. In this report, I mentioned the procedures and the processes followed by workers and engineers to get more reliable and best products. The tests performed in incoming section on different products and in quality control section are also included.
Muhammad Waqas
09-EE-119
UET, Taxila
Change your life
PEL Pakistan
Type:
Introduction:
Public
Electronics and Digital Appliances, Power Division
Founded:
1956
Headquarter:
Lahore, Pakistan
Key people:
Mr. Naseem Saigol (CEO), Mr.Azam Saigol , Mr. Murad Saigol
Products:
Refrigerators, Air conditioners, Microwave Ovens, Washing Machines, water Dispensers and Generators, Transformers, Switchgears
Parent:
Saigol Group
Web site:
www.pel.com
Muhammad Waqas
09-EE-119
UET, Taxila
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Vision Statement
To excel in providing Engineering good and services.
Mission Statement
To provide quality products & services to the complete satisfaction of our customers and maximize returns for all stakeholders through optimal use of resources.
To focus on personal development of our employees to meet future challenges.
To promote good governance, corporate values and a safe working environment with a strong.
Slogan
Change your life
Muhammad Waqas
09-EE-119
UET, Taxila
Change your life
Introduction of PEL Pak Elektron Limited (PEL) is the pioneer manufacturer of electrical goods in Pakistan. It was
established in 1956 in technical collaboration with AEG of Germany. In October 1978, the company was bought by the Saigol Group of Companies . Since its inception, the company has always been contributing towards the advancement and development of the engineering sector in Pakistan by introducing a range of quality defined goods and by producing hundreds of engineers, skilled workers and technicians through its apprenticeship schemes and training programs. The company comprises two divisions:
Appliances Division.
Power Division.
Appliances Division:
The Home Appliances Division of PEL P EL is the flag carrier of the Saigol Group, involved in home appliances manufacturing.
Air conditioners.
Refrigerator.
Deep freezers.
Microwave oven.
Washing machine.
Generators.
Vacuum Cleaner
Muhammad Waqas
09-EE-119
UET, Taxila
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Power Division:
PEL Power Division manufactures energy meters,
Transformers
Switchgears
Compact stations
Shunt capacitor banks
Energy meters
Generators
Power Division: PEL Power Division consists of three plants. These are Energ y Meter Plant, Transformer Plant, 9001:2000 Cert Cert if ied and Switch Gear Plant. All these plants are now I SO 9001:2000 . PEL Power Division manufactures energy meters, transformers, switch gears, Kiosks, compact stations, and shunt capacitor banks and specially Transformers. All these electrical goods are manufactured under strict quality control and in accordance with international standards. PEL is one of the major electrical equipment suppliers to Water and Power Development Authority (WAPDA) and Karachi Electric Supply Corporation (KESC), which are the largest power utilities in Pakistan. Over the years, PEL electrical equipment has had been used in numerous power projects of national importance within Pakistan. PEL has the privilege of getting its equipment approved and certified by well-reputed international consultants such as, Preece Ensa, Fra nce. In spite of stiff competition from emerging local and multinational brands, PEL Group's appliances and electrical equipments have remained in the spotlight due to constant innovation. Strategic partnership with multinationals of repute have enabled the PEL Group to incorporate new technologies into existing product ranges, thus giving the Pakistani market access to innovative, affordable and quality products
Muhammad Waqas
09-EE-119
UET, Taxila
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Design Department Deals with the designing and finalizing the details & specifications of a transformer. Design department follows the IEC rules and regulations to ensure a standardized design. In design department the following procedure is followed.
Marketin
Data sheet
Design Department H.O.D
Electrical
Mechanica
Rough
Cost Cost Mate Materi rial al Time Time
Design OK Marketin
Design Department
Electrical Specifications, coil, core
Mechanica
Work Order
Structure, Tank, Parts
Production Muhammad Waqas
09-EE-119
UET, Taxila
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Hierarchy of Design department
Mr Sadiq
Mr Masood
Sr. Manager (M4)
Assistant Manager (M1)
Electrical
Mechanical
Sr. Engr
Sr. Engr
Adnan Shahid
Adnan Ch.
Engr
Abid
Aamir Sharif
Engr
Aamir Sharif
Javid
Sub Engr
Mohsin Butt
Fahad
Sub Engr
Zahid
Adnan
Rehan
Amjad
Irfan
Draughtman
Riaz Asim Umer Sajid
Muhammad Waqas
09-EE-119
UET, Taxila
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Tools:
Auto CAD
Pro E
Microsoft Excel
Electrical engineer: Perform the designing of electrical parts of the transformer.
Mechanical engineer: Perform the design of mechanical parts of a transformer. On software they also perform some simple tests that are to determine the feasibility of the transformer.
Terms: Data sheet: Includes all the specifications of a transformer.
BOQ (Bill of Quantity): Contains the amount of material used for the con struction of a transformer.
Work Order: Includes the time and sequence of parts p arts to be manufactured.
Transformer Design Steps:
Step I
Ratings (Data)
Kva, Voltages, Type (Step Up/Down), Connections (Y/D), Power Factor Step I I
Current Calculations
Current in Primary Windings, Flux in Coil, Current Density
Muhammad Waqas
09-EE-119
UET, Taxila
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Step I I I
Coil Design
Coil Cross-Sectional Area, Material Radius, Length, Number of Turns, Tappings, Insulation Step I V
Core Design
Window Height, Stepping, Weight, Height Step V
Tank and Accessories Outer Accessories, Insulators, Contacts
Specifications: The design of a transformer depends to a large extent on specific requirements of a customer. So, the manufacturer manufacturer must provide details of specifications to the customer. customer. The information provided to the customer may be of three types.
Mandatory
Supplementary
Additional
Mandatory specification:
The information without which it is difficult to proceed a single step for designing a transformer and that information is critical as well for the purpose of design electrically and mechanically is termed as mandatory specification.
The specifications are listed below:
Kva ratings
Voltage ratio
System earthing
The number of phase and frequencies
Connection and vector group
Tapping’s and tap switch
Service conditions and type installations like indoor and outdoor
Muhammad Waqas
09-EE-119
UET, Taxila
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Requirements of terminations
Cooling
Winding materials
Altitude of installation
Type of mountings
Supplementary Supplementary specifications
The specifications which are not mandatory in nature but are essential for designing an efficient transformer are supplementary specifications. These specifications are as under:
No load losses and no load current
Load losses and percentage impedance
Temperature rise limit over the ambient temperature limit
Basic insulation level
System fault
Specific requirement of fitting and accessories
Limitations of flux density and current density
Dimensions and limitations
Evaluations of cost by way of loss capitalization.
Additional specification
Additional specifications are not much critical for the working and operation of a transformer but it is essential for the design to know the requirements of buyer that includes grade of core,shape of tank etc. to offer a good transformer by the designer to the customer for particular site conditions. These are listed below:
Minimum acceptance and thickness of core laminations
Type of core construction
Muhammad Waqas
09-EE-119
UET, Taxila
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Stray losses
Noise level
Shape of tank body
Quality of gas kits and hardware
Pitch distance and size of top cover bolts etc.
Inspection & Quality Control Department:
Incoming:
Tests performed in incoming on to be purchased items so that they should pass the quality test.
Enameled Copper Wire Test Apparatus:
Electric oven
High port tester set/bench
Testing device for peeling off and breakdown test
Elongation tester
Micrometer
Mandrill Test:
Twist wire along its own diameter 8-10 times
Check for zero cracks
Heat Shock Test: o
Put wire in Electric oven for 155-160 C for half hour
Again Mandrill Test
Muhammad Waqas
09-EE-119
UET, Taxila
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Break Down Test:
400mm length taken
Doubled and twisted
Checked for twists in 125mm length
Twists as per IEC 60317 BS 4516
Ends cut, enamel removed
Rated voltage applied
Peel Off Test:
Applicable upto 1mm diameter
600mm length taken
Fixing devices 500mm apart
One rotatable part
Weight attached to the wire
From scraper enamel is removed
Speed of rotation 60-100 rev/min
Specified revolution R=175/d
Chipping off is tested
Zero chipping required
Elongation Test:
Elongation tester
200-250mm length taken
Rate of elongation 5mm/sec
Till Fracture stress is applied
Length measured
Not less than IEC 60317 BS 4516 Bird protection test for cover plate
Apparatus:
High port tester
Stop watch
Steps:
On High Port Tester
Muhammad Waqas
09-EE-119
UET, Taxila
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Zero kV
Cover plate placed
Ground cover plate
High Port Tester to cover plate copper strip
On breaker of High Port Tester
Up to 8kV applied
Stopwatch to 1min at 8kV
Must sustain 8kV for 1 min Change of Mass Test of Gaskit (NBR)
Apparatus:
Beaker
Transformer oil
Thermometer
Electric oven
Digital weighing scale
Steps:
Transformer oil 400-500ml
Record initial weight of gas kit
Dip sample in oil
Place for 72 hours in oven at 110 C
Take sample weight after 72 hours
Calculate = ((final weight – initial weight)/initial weight)X100
TDD 05 11
Tolerance +15% and -5%
In process Testing:
Core & Winding Assembly
Final Assembly
Cover Plate Assembly
Fin Folding
Mechanical Fitting Shop
Tank Assembly
Muhammad Waqas
09-EE-119
UET, Taxila
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Transformer Oil Testing
Transformer oil is tested before unloading it from the tanker. These tests are recommended by IEC 60296. These tests include:
Visual inspection
Specific gravity
Viscosity
Flash point
Dielectric strength
Acidity value
Pour point
When the oil is unloaded it is processed for 5 to 8 hours before filling tanks with it.
Testing
Routine Tests:
TTR (Transformer Turn Ratio)
Winding Resistance Test
Megger Test
Induced Voltage Test
High Voltage Test
Iron Losses
Copper Losses
Type Test:
Temperature Rise
Impulse Test
Short Circuit Test
Muhammad Waqas
09-EE-119
UET, Taxila
Change your life
TTR:
It is performed:
Before connection
After connection
Before dispatch
Winding Resistance Test:
DLRO (Digital Low Resistance Ohm) meter is used to perform this test.
It is used to check resistance of o
HV winding
o
LV to LV winding
Megger Test:
Special meter is used to perform this test.
Induce Voltage Test:
LT side o
Double voltage 415 -> 830V
Frequency 4 times 200Hz
Time of test 30 sec
It is to check the turn to turn insulation
High Voltage Test:
EC 28kV
HT side short and applied 34kV
LT side short with body (grounded)
Time of test 1min
Iron Losses (no load):
LT side 415kV
HT side open
Copper Losses (short circuit):
HT side rated current
LT side short
Muhammad Waqas
09-EE-119
UET, Taxila
Change your life
Hierarchy of I & QC department
Jahanzeb Ahmed Manager I & QC
Usman Harooni Incharge R1
R1 unit II
Mirza Islam Ul Haq Engr
R1 unit II
PDI at vendor end
WAPDA material Inspection
Inspector No. 1
Khurram Shehzad Sub Engr
Khurram Shehzad Sub Engr
Inspector No. 1 Inspector No. 1
Muhammad Waqas
09-EE-119
UET, Taxila
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Production Department Hierarchy of Production Department Jahanzeb Ahmad manager
Asfand Ali testing Engr
DT test field unit I
DT transformer factory
Testing
Customer
Servicing
Salman Rafiq testing Engr
Salman Rafiq testing Engr
Noor Muhmmad Jalbani
Inspector No. 1
Muhammad Waqas
Muhammad Sageer Sub Engr S1
Muhammad Arshad asst.
Inspector No. 2
Private rating transformer
PM transformer testing/PDI/inspectio
Arif Husain Sr.Inspector
WAPDA rating
Atiq ur Rehman SubEngr testing
Abdul Hameed Assit. Supervisor S2
Inspector No. 3
09-EE-119
UET, Taxila
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Winding Section:
In this section
Slitting machine cuts insulation paper according to the sizes given.
LV winding is performed. Which includes: o
Foil winding
o
Coil winding
Thermo duct is placed.
HV winding is performed. Which includes:
o
Coil winding
o
Disk winding
o
Packet winding
The type of winding is decided by the design department according to the rating.
Core Section:
Silicon Steel Sheet Bundles
Slitting
Cutting
Side, Center &
Degree Cutting
Yoke Notching
Gauge Assembly
Weighing Of Core Plates
Core Stacking
Varnishing Of
Checking Of Core
Stock Muhammad Waqas
09-EE-119
UET, Taxila
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Assembly Section In this section
Core and coils are put together.
They are tightened by supporting beams.
Before connection tests are performed.
Connections are made according to the TR.
After connection tests are performed.
Then the assembly is placed in the furnace at 120 C for 48 hours.
Cover plate is joined.
Then assembly is put into the tank.
o
Oil Filling Section In this section
Transformer is filled with oil.
Special container is used for oil filling. fill ing.
Up to -5 bar pressure is maintained.
Tank Section
MS Sheet 1mm-50mm
Shearing machine:
It cuts & bends : o
Frame
o
Bottom
o
Side wall
o
Angles
o
Fins
o
Cover plate
NC only numerical control
CNC Machine:
Dimensions code Nibbling or Punching machine
Muhammad Waqas
09-EE-119
UET, Taxila
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Program on Auto CAD and feed in SS tool to cut MS
Bending Machine:
V -slots according to thickness
Capacity 1-12mm
Embossing machine:
Squeezing
Drawing
Imposing
It bends it to the lower side
It applies only on cover plate
Die is used
Component welding:
ARC o
electrode is used
MIG o
metal inert gases sound, 80% argon, 20% CO 2
o
tungsten inert gases 100% argon
TIG
back side of cover plate carrying beams, cover plate stiffner
stud to tight insulator
Conservator rolling machine:
size 3mm
conservator supporting beams
Frame punching machine:
only punches the frame
cutting
Bending
Notching
Welding
CNC flame cutting machine: Muhammad Waqas
09-EE-119
UET, Taxila
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Used to cut lifting lugs and to cut sheets of max width
Oxygen is used
Universal cutting machine:
Stiffener
angle
round bar
punching
notching
Fins CNC machine:
Data entry o
pitch height
o o
extra sides on both sides number of fins
o
1.2 mm thickness of CR sheet
Width 400-1220mm
Can not bend more than that
Fin welding:
Automatic machine CNC MIG welding
Manual TIG welding
Panel sides bending machine:
2 small, 2 large endings.
The two large (A,B) or small size of fins (side f ins) are bended and then welded.
Tank assembly:
Pad mounted o
3sides fins areas where wires are undergrounded.
Under carriage fitting:
Beams
Wheels
Muhammad Waqas
09-EE-119
UET, Taxila
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Blasting
Shot blasting: o
To get rubbed surface
o
Oil free surface
o
Steel is shot on it which absorbs oil in it
Sand blasting:
Degreasing, Rinsing, Phosphating: Phosphating:
Choice is there only one is chosen
200kV->shot
>200kV->sand
<200kV->D,R,P
Leakage testing:
Diesel filling machine applied 5psi
Air pressure test applied 5psi
Above 630kVA, less pressure is required
Powder coating:
Rough surface and powder is coated. It is melted in furnace.
Gray
Green
Blue Creamy
Process
Degreasing, Rinsing
Derusting
Rinsing
Phosphating
Hot Rinsing
Important terms:
PDI Pre Dispatch Inspection
IR Industrial Relation
RI Receiving Inspection
Muhammad Waqas
09-EE-119
UET, Taxila
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Bottom End
MS sheet cutting
Molding/Bending in NC machine
Welding of side walls
Welding of angles
Muhammad Waqas
09-EE-119
UET, Taxila
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Frame
MS sheet cutting
Molding/Bending in NC machine
Notching (universal machine
Welded with angles
Muhammad Waqas
09-EE-119
UET, Taxila
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Fins
CR sheet of thickness 1.2mm
CNC machine for molding pitch 45mm
Welding of round rod
Welded with angles in assembl Muhammad Waqas
09-EE-119
UET, Taxila
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Tank Assembly
Complete welding (MIG, TIG, ARC)
Leakage test
Diesel filling test
Air pressure test
To get smooth surface
Degreasing
Shot blasting
Sand blasting
Rinsing
Derusting
Rinsing
Phosphating
Hot Rinsing Muhammad Waqas
09-EE-119
UET, Taxila
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Color coating
Inside red oxide
Outer gray color coating and the placed in furnace
Quality check:
Moved to assembly
Final Stage The quality parameters as per requirement are che cked and the tests are again performed on the transformer. When the transformer is checked and it fulfils the requirements then it is moved to the dispatch section. In the dispatch section name plate is welded with the body of the transformer and the bushings are painted.
Health, safety and Environment Department Department
In an organization health and safety of the people and environment insurance is much important. In PEL there is a separate department which is known as HSE department. d epartment. It ensures the safety and the health of people peo ple and take measures in this regard. There are different notice boards which carry information about this. The workers uniform, personal safety equipment is much important. The workers are speciall y trained in this regard.
Muhammad Waqas
09-EE-119
UET, Taxila
