PEL Transformer Unit Internship Report

Pak Elektron limited
Change your life
Change your life

INTERNSHIP REPORT
Department of Electrical Engineering, University of the Punjab, Lahore
Change your life
Change your life
INTERNSHIP REPORT
Submitted To: HR PEL Submitted By: Muhammad Ahsen Internship Department: PEL Transformer
Department of Electrical Engineering, University of the Punjab, Lahore
Change your life
TABLE OF CONTENTS
Dedication Acknowledgement Exclusive Summary Introduction Transformer Distribution Transformer Design Department Manufacturing Department I&QC Department Maintenance Department .
..2 3 4 .5 ..6 .8 .9 .13 27 .34
Department of Electrical Engineering, PU, LHR
Page 1
Change your life
Dedication
To all those who have supported, encouraged, challenged, and inspired me. And specially to my Beloved Parents, honorable teachers and friends for all their guidance, love & attention which has made it possible for me to make it up to this point and as well as the Internship Supervisors who bestowed me with the courage, the commitment and the awareness to follow the best possible route, by their unmatchable style and by best possible training.
Page 2
Change your life
Acknowledgement
All the praises are for the almighty, Allah who bestowed me with the ability and potential to complete this Internship. I also pay my gratitude to the Almighty for enabling me to complete this Internship Report within due course of time. Words are very few to express enormous humble obligations to my affectionate Parents for their prayers and strong determination to enabling me to achieve this job. I take this opportunity to record my deep sense of gratitude and appreciation to my teacher Mr. Murad Habib and Chairman Dr. Rafiq Ahmed, Department of Electrical Engineering, University of the Punjab, Lahore for their constant encouragement and inspiring guidance with their Wisdom. I also appreciate the cordial co-operation from all my Internship Supervisors in the different departments of PEL and also of HR management for providing me requisite information and knowledge for compilation of my complete Internship. All the employers of PEL helped me a lot in performing all the activities and in gaining the practical knowledge of industry. They gave me best environment and knowledge to enhance my skills.
Page 3
Change your life
Executive Summary
Pak Elektron Limited (PEL) is the pioneer manufacturer of electrical goods in Pakistan. The company has always been contributing towards the advancement and development of the engineering sector in Pakistan by introducing a range of quality electrical equipments, home appliances and by producing hundreds of engineers, skilled workers and technicians through its apprenticeship schemes and training programmes. I recently have done my internship in PEL, in which I got training from its Distribution Transformer unit. The internship basically revolved around the transformer design, manufacturing, I&QC and maintenance. The system, the style of working & the commitment of the employees in PEL is really exemplary. The difference between the success & failure is doing things right and doing things nearly right, & PEL has always tried for success & that is why it is known to be one of the leading companies in Pakistan. In this report I have given a very brief review of what I have seen and learnt during my internship. I have mentioned all these as I have made an internship as according to the schedule. This report will give its reader knowledge about the PEL and power division especially about transformer unit. I have made it possible to write each and every thing that I have learnt here. I have all my practical efforts in the form of this manuscript that s the asset for my future career.
Page 4
Change your life
Introduction
It was established in 1956 in technical collaboration with M/s AEG of Germany. In October 1978, the company was taken over by Saigol Group of Companies. At that juncture, the company was only manufacturing transformers and switchgears. With the Saigols in management, PEL started expanding its product range by entering into Air Conditioner manufacturing. PEL has two divisions of its business. 1. Appliances Division 2. Power Division
Appliances Division
PEL s Appliances Division is the flag carrier of the Saigol Group. Appliances Division includes the products; Air Conditioner, Refrigerator, Washing Machine, Water Dispenser and Microwave Oven. Today, PEL has become a household name. Its products are not only in great demand in the local market but the Company has also started exporting its appliances to foreign markets.
Power Division
PEL Power Division is one of the major electrical equipment suppliers to WAPDA & KESC. Since 1956 the company manufactures transformers, energy meters, switchgears, kiosks, compact stations and shunt capacitor banks. PEL also has had the privilege of getting its equipment approved and certified from well-reputed international consultants.
ISO 9001 CERTIFICATION:

PEL was 16th Company in Pakistan that got ISO 9001 Certification in 1997, since then PEL Management is applying this International Standard Practices for Effectively Managing Quality of Products and Services that Company Offers.
Page 5
Change your life
Transformer
A transformer makes use of Faraday's law and the ferromagnetic properties of an iron core to efficiently raise or lower AC voltages. It of course cannot increase power so that if the voltage is raised, the current is proportionally lowered and vice versa.
Transformer figures are shown below in which its parts are labeled.
Page 6
Change your life
Complete Transformer
Active Part of Transformer
Distribution Transformer
Department of Electrical Engineering, PU, LHR Page 7
Change your life

PEL made distribution transformer s range includes oil immersed core type transformers, Dry type (VP impregnated) transformers and autotransformers. These transformers are tailor made for various ratings. IEC or national standards are followed. PEL offer distribution transformers voltage up to 33 kV and ratings up to 30 MVA. PEL offers transformer tanks with corrugated walls, detachable radiators and tubular arrangement. The corrugated tanks have a better cooling efficiency, since the fins are expandable. Tanks are hermetically sealed where possible. In order to meet sophisticated requirements of customers PEL has also started manufacturing transformers with foil winding. Foil winding efficiently uses space which results in size reduction. It has better heat dissipation and also increases potential to withstand short circuit current. PEL transformers are available for various applications:
y y y y y y
Distribution Transformers (Pole /Pad Mounted) Auto Transformers Furnace Transformers Welding Transformers Chokes for furnace Transformers Any other special requirement
Start of Internship at PEL UNIT-2

On my first day at PEL, unit 2, we were first briefed by the Mr. Ali Kamran Human Resource Manager. We were informed that we will be following a specific plan during our internship. All the internees were divided into three groups. I was in Group C, there were around 10 internees in total. Our group was given the following schedule:
11 to 15 July
Transformer design
16 to 20 July
Maintenance Department
20 to 25 July
Page 8
Change your life

Manufacturing Department
26 to 30 July
Inspection and Quality Control Department
31 July to 6 August
Internship Report has been written in such an order that first I will explain my experience and learning in Design Section, Production Department, I&QC department and finally in the maintenance department.
Design Department
The Design department is the most important department of the Transformer division. Because the basis of any transformer is laid here. It is the starting step in the production of any type of transformer. This department can be subdivided into two main categories: Electrical Design Mechanical Design When we first came to this department, we were first briefed about the working of the department by Mr. Amir Sharif (representing the electrical section) and Mr. (representing the Mechanical section).
Working Procedure of the Design Department

Whenever any client wants to purchase any transformer, it sends its required specifications to the Marketing department of PEL. This is called Enquiry. The marketing department then sends this enquiry to the design department. The design department performs three main tasks: Estimation of the Cost Dimensional Sketch Datasheet
Page 9
Change your life

These three things are then sent to the marketing department, which is the feedback to the client s enquiry. If the client feels satisfied with these things, then it gives the order to the marketing department. The marketing department then sends the Sales Advice to the design section, which mainly defines the number of transformers to be produced and the duration of the supply. Once the ordered is confirmed, then the design department starts its working in full swing. The work is then divided into two subsections; electrical team performs the electrical design, whereas the mechanical team is mainly concerned with mechanical design. The electrical design team is mainly involved in the designing of the Core, LT and HT windings. The mechanical design team works on the layout, body of the transformer. The design is made on Pro-E and AutoCad software. The electrical design generally works with a faster pace, because it has to inform the Material Planning Control section that this much material is required for the production. Same is the case with the mechanical team, but since core and winding are to produce first, so there production starts a bit earlier. Most of us were doing electrical engineering and but there was a mechanical engineering student as a internee with us , so we were told about the electrical part and little about mechanical as well. The design and its calculations are mainly done via software. Once a design is finalized and is according to the requirements of the client, a TR document is prepared that defines each and everything regarding the design.
TR File:
TR file describes the production department that what is actually being required by the customer and how it us to be achieved. The production is then done keeping in view the TR file. Following are the few important things: TR no, Fb no, KVA rating, connection type(vector group), cooling mechanism, design no, taps, losses quoted and calculated, temperature rise, the cross sections of HV and LV windings, the dimensions (cross section area, height, width, steps etc) of core, type of HV and LV winding, total no. of layers in HV and LV, turns in each winding, the inner and outer diameter of HV and LV, the nature of conductor used in winding, the level and layers of insulation, the number of thermo ducts, the clearance distances, the end collar dimension, the total weight of HV and LV
Page 10
Change your life

windings, tapping details, HV and LV winding layout, the description regarding the material required in winding and core.
Terms
Data Sheet Data sheet includes all specification of a transformer BOQ BOQ (Bills of Quantity) contains the amount of material used for the construction of a transformer. Work order Work order includes the true and sequences of parts to be manufactured.
Page 11
Change your life
Start (Client)
Enquiry
Feedback
Marketing Department
Costing Sketch Datasheet
Enquiry
Order Approve
Design Department
Order Approved
Electrical Design Starts
Mechanical Design Starts
Terminate Department of Electrical Engineering, PU, LHR
Sales Advice
Page 12
Change your life
Manufacturing Department
It is the responsibility of the manufacturing department to manufacture different components of transformer and then assemble them to make a transformer. Production department has following sections: Winding Section Core Section Tank Section Assembly Section
How manufacturing department starts manufacturing? First, customer gives order to the marketing and sales department. Marketing and sales department makes annual sales plan for WAPDA. Marketing and sales department sends this order to Production planning and control department which makes a master production plan (Month wise). This plan is sent to Material planning section which makes Material requirement plan or Bill of material according to the master production plan. This plan is sent to the purchase department which buys material according to this plan. Material is received in store where quality inspectors from I&QC department check its quality than this material is sent to manufacturing department where manufacturing of transformer starts.
Page 13
Change your life
Customer
Marketing and sales
Production planning and control
Annual Sales Plan for WAPDA
No Sales Plan for Private
Master Production Plan(month wise)
Store
Purchase department
Material planning section
Local
Foreign
Material Requirement Plan or
I &QC
Production
Flow Chart of How Manufacturing Department
Page 14
Change your life Production Planning and Control:

Production planning and control department receives order from marketing and sales department. For WAPDA orders there is an annual sales report which is sent to the production planning and control while for private orders are received from time to time and there is no annual sales report for these orders. Production planning and control makes the master production plan accordingly to the orders sent by marketing and sales department. Master production plan is month wise and it can be changed. After making the master production plan PPC makes a weekly production plan which is sent to sectional in charges.PPC also makes the daily production plan. PPC apart from making the master production plan and weekly production plan it monitors the production to ensure that the production is running accordingly to the plan.
Material Planning Section:

Material planning section is responsible for the procurement of material and it ensures that material arrives timely for the production. Material can be purchased from foreign companies and also from the local companies. In local procurement material can be purchased in less than a month so it is done once a month. In foreign procurement more time is required because it takes more time for the arrival of material from foreign countries by ships so foreign procurement is done after every three months. In foreign procurement bank opens the letter of credit or LC, it pays the foreign company for the material and the stock is pledged with the bank and when company needs the material for production it pays the bank and material is given to the company for the production. After the procurement of the material, material planning section follows the material to ensure that it arrives on time for production.
1. Winding Section
In the winding section L.V and H.V windings of the coil are made. Raw Material For L.V winding y Paper insulated flat copper wire (For 10KVA to 50KVA) y Copper foil (For 100KVA and above) For H.V winding y Enamel copper wire (For 10KVA to 200KVA)
Page 15
Change your life

y Paper insulated flat copper wire (400KVA and above) Type of Insulation Material y Diamond dotted paper (For insulation between layers of windings) y Press pan sheet (For end collars) y Creep paper pipe (For insulation of terminal of tap changer) y Craft paper (Used for insulation in disc winding) y Thermo ducts Types of Windings y Disc winding y Packet winding y Layer winding y Foil winding File and layer winding are used in LV.File, packet and disc winding is used in HV.Disc and packet winding are easy to repair. Machines Used y Slitting machine is used for the cutting of bundles of insulation material. y L.V Foil winding machines are used for foil winding on L.V side for transformers of the rating 100KVA and above. y L.V paper insulated copper winders are used for winding of P.I copper wire for transformers of the rating 10KVA to 50KVA. y H.V P.I copper winders are used for the winding of P.I copper wire for transformers of the rating 400KVA and above. y H.V enamel copper winders are used for the winding of enamel copper wire for the transformer of the rating 10KVA to 400KVA. Standard Ratings of WAPDA Standard ratings of WAPDA are 10KVA, 15KVA, 25KVA, 50KVA, 100KVA, 200KVA, 400KVA, 630KVA
Page 16
Change your life Supply of raw materials
Paper slitting
L.V foil winding (100 &above)
P.I winding (10 to 50)
H.V enamel (10k to 50k)
Foil winding (400 &above)
Storage area for coils
Process Flow Chart of Winding Section
Page 17
Change your life

HV winding is done over LV winding, both are insulated from each other. Connections are made from start and end in LV and HV winding. But in HV we give taping connection at different places according to design. On HV winding we used DDP paper to insulate it from tank. Oil is also used for this purpose. Winding turns are according to design. At the end of this section testing of winding is done using transformer turns ratio (TTR) meter which gives no. of turns. we check it according to design.
2. Core Section
In the core section upper, side and yoke limbs of the core are made. Raw Material Raw material used for the making of core is M4 grade silicone steel sheet which is an alloy of iron and silicon. Silicon is used to increase the permeability of iron. Machines y Slitting machine is used to cut the big roll of silicon steel sheet in required sizes (widths) according to the rating of transformer. y Power press machines are used to make limbs. They are operated manually. y After cutting of limbs V punching is done on the yoke limb which is called yoke notching. y PLC cutting machines are also used to make limbs. There are two PLC machines. SDRI machine has a capacity of 40,000 limbs per day. L.A.E machine has a capacity of 60,000 limbs per day. In CNC machines length, width and angle are given as input. y L.A.E measuring table is used to check errors in angle, width and length. Iron Losses Iron losses are the flux losses in core. Major factors in iron losses are; y Quality of material. y Bur. y Air gap. To reduce iron losses y y Material should be of good quality. Limbs should be bur free.
Page 18
Change your life

y y Limbs should be rust free. Weight of core should be according to Tr. Design
After cutting of the limbs, they are stacked in a way that there is no air gap between the limbs. All the limbs are joined except the upper yoke limb which is filled in the assembly section. Outer side of the core is varnished to avoid rusting. Core is tightened using upper and lower pressing beams. Then its goes to assembly section.
Page 19
Change your life
Silicon sheet
Slitting of bundles
Cutting
Side limb
Center limb
Yoke limb
Core stacking
Varnishing of core
Checking of core
Stock
Process Flow Chart of Core Section
Change your life

3. Assembly Section
In the assembly section there are 17 processes in which all the components of the transformer are put together to form a transformer. Important processes in the assembly section are; Core Coil Assembly In the core coil assembly coil is fitted in the core and upper yoke limb is inserted to complete the core, then core is tightened using upper and lower pressing beams. For coil to coil insulation and core to coil insulation press pan sheet is used. For insulation between bottoms pressing beam and coil wooden base is used. Before Connection Test (BCT) In the BCT area turns ratio of the coil is checked using TTR meter. H.T, L.T Connections In this section Y-Delta connections are made. Tap changer is connected with the coil. Connections are made according to work order specifications given by the design department. Taping is done on these connections to avoid any short circuit. After Connection Test (ACT) In the ACT area turns ratio of the transformer is checked using TTR meter. Furnace After ACT transformer is kept in the furnace for 48 to 72 hours according to its rating. It is done to evaporate all the moisture from core or coil. Temperature of the furnace is 120o to 130o. Cover Plate Assembly In this section H.T, L.T bushings, through bolts, eye bolts connectors, arcing horns and other parts are inserted in cover plate. Pre Tanking Section When transformer is unloaded from the furnace it is inserted in the tank as quickly as possible to avoid the getting of moisture in the live part. Live part of the transformer should be inserted in the tank in 50mins to 1 hours.
Page 21
Change your life

Oil Filling Section In oil filling section oil is filled in the tank under vacuum. Amount of oil to be filled can be found from bill of quantity (BOQ). For 10kv to 200kv oil filling chambers are used and for transformers above 200kv oil is filled manually. Settling Area After oil filling every transformer is kept for 12 hours in the settling area to check for oil leakage and oil level.
Page 22
Change your life Supply of coils
Core coil assembly
Supply of core and upper yoke limbs
Before connections test
Connections
Furnace
Assembly of cover plate
After connections test
Unloading
Oil filling
Settling area
For testing
Process Flow Chart of Assembly Section

Change your life

4. Tank Section
In the tanking section cover plate, tank, and other mechanical components of the transformer are made. Tank has following parts; y Frame y Cover plate y Bottom y Side plate y Fin Walls y Conservator Raw Material Raw material for tank and other components are y MS sheet (Mild steel sheet) y MSCR sheet (Mild steel cold rolled sheet) Shearing Machine Shearing machine is used to cut the MS sheet in different sizes. This machine is used for the cutting of frame, side wall, bottom wall and cover plate. CNC Nibbling and Punching Machine CNC nibbling and punching machine has 32 tools to make holes of different size. It can make holes of the shape round, square, rectangle. Bending Machine This machine is used to bend cover plate and frame. Embossing Machine This machine is used for the embossing of holes on cover plate. Component Welding In this area lifting lugs, carrying beams and studs are welded using arc welding. Frame Punching and Welding Machine Frame is punched and then welded in this machine.MIG welding is used in this machine.
Page 24
Change your life

Fin Folding Machine This machine is used for fin folding. Digital control panel is used to enter height, weight and pitch. Pitch is the distance between two adjacent fins. Fin Welding After fin folding they are welded. MIG welding is used in this machine. Automatic Fin Welding Machine MIG welding is used in this machine. Metal strip is welded to support the panel. Bottom Side Plate Welding In this section bottom and side plates are welded together. Tank Assembly Here all the parts of the tank are joint together. Tank Welding Tank is welded to stop leakage. Shot Blasting To remove oil particles from tank s body and make its surface smooth shot blasting is done. After that tank is dipped in degreasing, rinsing and phosphate tank to remove oil particles. Sand Blasting It is used for removal of oil particles from tanks make its surface smooth for transformer rating above 200KVA. Tank Testing For tanks up to 200KVA diesel spray testing is used. Above 200KVA pressure testing is used to check leakage. Powder Coating Tank is first passed through a chamber for pretreatment and then powder coating is done. Tank is painted with machines at end.
Page 25
Change your life Mild steel and Cold roll sheet bundles
Beams
Frame
Bottom
Fins
Under Carriage
Cover Plate and Conservator
Bus Bars
Welding and making Tank
Leakage Testing
Degreasing and Shoot blasting
Paint
Stock
Process Flow Chart of Tank Section

Change your life
Inspection and quality Control

Inspection and quality control department ensures; material purchased by the purchase department is according to the criteria suggested by IEC in their recommendations(Incoming), during the manufacturing of transformers all the components of transformer are according to transformer design(in processing),do all the quality tests so that transformer does not fail in real conditions(Testing). Inspection and quality control department is further divided into three sections Incoming In processing Testing
1. Incoming Section:
Incoming section is responsible for the checking of all the material which is purchased to ensure that all the material is according to international standards. When the material is purchased it first comes in the receiving where it is inward gate pass (IGP) number. Incoming section checks through the system if material has arrived, then quality inspectors from the incoming go to the store and check the material if material is according to standards set by IEC than material is approved otherwise it is rejected and supplier compliant application form(SCAF) is sent to supplier.
Material rejected SCAF generated
Supplier
Purchase department
Receiving store
QUA INSPECTORS (Incoming)
Page 27
Change your life
Tests on Different Materials to Check there Quality y Bird Protection Test This test is used to check the thickness of paint so that cover plate will not short. In this test 8kv voltage is applied to the cover plate for 1 minute if cover plate does not stand it for I minute than it is rejected. Micron Meter Micron meter is also used to check the thickness of paint on cover plate. The reading should be greater than .25mm according to IEC recommendations. Mandrill Test This test is used to check the quality of enamel on enamel copper wire. For mandrill test all sizes of enamel copper wire will be wound over its own diameter for at least 8 to 10 turns and will be checked for zero cracks. Heat Shock Test This test is used to check the quality of enamel on enamel copper wire. The sample prepared for the mandrill test is placed in electric oven at temperature 155 Co to 166 Co for hour and again mandrill test will be performed for test compliance. y Break Down Test The specimen of wire approximately 600mm is doubled and twisted for a distance of 125mm.The tension of wire pair while being twisted and a number of twists will be as per specification (IEC-60317 and BS-4516).Enamel is removed from the wire at one pair of ends and test voltage is applied between the conductors through high port test set as per specification (IEC-60317). Note the reading where break down has occurred.
y Peel Off Test

This test is applicable to sizes over 1.0mm. A sample of the wire of about 500mm length is placed in tester consisting of two fixing devices 500mm apart on the same axis. One of these is able to rotate. Specific weight is attached on the fix side of device as mentioned in specification by IEC-60317. By means of a scraper on opposite sides of wire.
Page 28
Change your life

The rotating device is driven at 60 to 100 revolutions per minute. The number of revolutions of fixing device is calculated from R=175/d. After applying specified number of revolutions chipping off of the enamel is checked. Zero chipping off is required to qualify for enamel copper wire. y Iron Loss Test Iron losses of the silicon sheet (alloy of iron and silicon) are found using direct reading iron loss tester. First diameter of the sheet is measured using micrometer screw gauge. Diameter is fed in the iron loss tester. Tester is energized for hour and then iron losses are found. If 1.5 Tesla are applied in tester than losses should not exceed .89 Tesla.
2. In Processing Section
In processing section ensures that during the manufacturing of transformers all the components of transformers are according to design specifications. It is also responsible for the testing of oil to check its quality. Oil Tests to Check its Quality There are seven tests done in oil testing lab to check the quality of oil. If the oil fails in one of these tests than it is rejected not used in transformers. Seven tests are I. Visual Inspection II. Specific Gravity III. Viscosity IV. Flash Point V. Dielectric Strength VI. Acidity Value VII. Pour Point a) Visual Inspection It should be free from contamination as per IEC-296 and IEC-60296 recommendations.
Page 29
Change your life

b) Viscosity Viscosity meter is used for this test. Reading is taken at two different temperatures. AT 20 Co reading should be less than 40mm2/sec and at 40 Co reading should be less than 12mm2/sec as per IEC-296 and IEC-60296 specifications. c) Specific Gravity Specific gravity meter is used for this test. Reading is taken at -30 Co. Before use specific gravity of oil should be less than .895 g/mil. After use reading should be less than .895 g/mil as per IEC-269 and IEC-60296 recommendations. d) Flash Point The point at which the oil catches fire is known as flash point. Flash point of transformer oil should be greater than 140 Co as per new recommendation of IEC in IEC-60296. e) Dielectric Strength Test Dielectric strength tester is used for this test. Oil is filled in a box which has electrodes which are 2.5mm apart. Voltage is applied to the box which increases at the rate of 2kv per sec. Reading is taken at point where breakdown has occurred. Seven readings are taken and their arithmetic mean is the breakdown voltage. Oil which is purchased should have dielectric strength greater than 30kv. When oil is stored and all the moisture and impurities are removed than its strength should be greater than 70kv. For the oil which is used reading should not be less than 55kv. All these values are according to the recommendations of IEC mentioned in IEC-60296. f) Acidity Value Acidity value meter is used for this test. For unused oil reading of meter should be less than .03 mg KOH/g and for used oil it should not be less than .01 mg KOH/g. Readings are according to recommendations of IEC given in IEC-60296. g) Pour Point The point at which oil freezes is known as pour point. Oil should not freeze before -30 Co to pass this test.
Page 30
Change your life

Apart from checking the quality of oil, in processing section ensures that different components of transformers which are manufactured according to transformer design and are free from dimensional errors and other faults.
In processing Inspection of Winding
y y y y y
Diameter of the round side of L.V is measured to check if it is according to Tr. Design. Diameter of the straight side of L.V is measured to check if it is according to Tr. Design. Diameter of the H.V is measured to check if it is according to Tr. Design. Overall diameter coil is measured to check if it is according to Tr. Design. Winding insulation is checked.
If any one of these things is not according to Tr. Design and out of tolerance limits than it is rejected and fault card is issued.
In processing Inspection of Core
y Cutting of the limbs is checked. y Limbs should be smooth and bur free.
If these criteria are not met than that machine is closed for maintenance.
In processing Inspection of Tank

y Pressure Test is used to check that there is no leakage in tank. In this test tank is completely closed and pressure air is filled in the tank than a solution of washing powder and water is dropped on every joint if there is leakage than bubbles will be formed. Dimensions of tank are checked. They should be according to Tr. Design.
Page 31
Change your life

3. Testing
It is the responsibility of the testing section that the transformer does not fail in real conditions. To check that it will not fail in real environment a number of tests are done on the transformer before it is ready to dispatch. There are three types of tests which are done on a transformer. i. Routine Tests ii. Type Tests iii. Special Test a) Routine Tests Tests which are performed on each and every transformer are called routine tests. Every transformer must pass these tests before dispatch. b) Type Tests Tests which are done on samples taken from a whole lot are called type tests. c) Special Tests Tests which are done occasionally on the requirement of customer are called special tests. d) Routine Tests: There are eight routine tests done in testing section. I. II. III. IV. V. VI. VII. VIII. Transformer Turns Ratio Test (TTR Test) Winding Resistance Test Insulation Resistance Test (Meager Test) Induced Voltage Test High Voltage Test (Separate source voltage) No Load Losses (Open circuit test) On Load Losses (Short circuit test) Dielectric Tests
Page 32
Change your life

1. Transformer Turn Ratio: (TTR Test) Transformer turn ratio test is done twice on a transformer. Once before the connection and once after the connection. Transformer turn ratio meter is used for this test. Turn ratio should be as defined in Tr. Design to pass the test. 2. Winding Resistance This test is used to check the phase to phase and phase to neutral resistance of transformer. Phase to Phase resistance should be in ohms ( ) and phase to neutral resistance should be in milliohms ( ). 3. Insulation Resistance Test: (Meager test) This test is used to check insulation between H.V L.V H.V Ground Ground L.V
4. Induced Over Voltage Test This test is used to check the winding insulation. In this test voltage is applied on the L.V side because it is easy to provide. On the L.V side twice the rated voltage at four times the normal frequency is applied. Test time should be greater than 15 seconds and can be found using the formula Time = Rated frequency * 120 Test frequency 5. High Voltage Test: (Separate source voltage) This test is used to check whether winding is insulated from other parts of transformer or not. First, all the L.V terminals and body of transformer are earthed. Than 33kv voltage is applied on the H.V side. IT is checked whether the transformer will stand this voltage for 1 minute or not.
Page 33
Change your life

6. No Load Losses: (Open circuit test) In this test H.V side is kept open and voltage is applied on the L.V side. Than V, I, PF and other quantities are measured. 7. Load Losses: (Short circuit test) In this test L.V side is short and current is passed through the L.V side. Than V, I, PF and other quantities are measured. 8. Dielectric Test This test is done in the oil testing laboratory and break down voltage should be less than mentioned in the IEC-60296.
Maintenance Department
Maintenance Department is the mother of all departments as it look to every department, and is being called by every department in case of need. Maintenance department has to maintain every thing of the factory with and without the call of the department. Department in which the problem arises send a request for their problem to maintenance department. Maintenance department generates a work order towards for the solution of their problem. After the matter is solved (repair) maintenance department send a feedback report to the concerned department to inquire their satisfactory. If the department is satisfied then the work order is closed. This all communication is done electronically by software developed by PEL known as MMS. Maintenance Monitoring System(MMS) Receives the maintenance request. Generates the work order. Updates the status. Feedback. There are two types of Maintenances: Preventive Maintenance is a precautionary maintenance to avoid certain breakdowns. This may include service, tuning, oil checking etc of the machines frequently. Breakdown Maintenance is special maintenance or repair in case any machine certainly stops working and is on request.
Page 34
Change your life

Maintenance department classify the system in to two parts: A. Common It includes AUTO, ELECTRICAL and MECHANICAL. B. TR unit 2 It includes all the machines used in the factory.
Page 35
Change your life Comments ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ Design In charge Signature___________________ Comments ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ Production In charge Signature________________ Comments ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ I&QC In charge Signature________________ Comments ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ Maintenance In charge Signature________________
Page 36

PEL Transformer Unit Internship Report

Diunggah oleh

Informasi Dokumen

Hak Cipta

Format Tersedia

Bagikan dokumen Ini

Bagikan atau Tanam Dokumen

Opsi Berbagi

Apakah menurut Anda dokumen ini bermanfaat?

Apakah konten ini tidak pantas?

Hak Cipta:

Format Tersedia

PEL Transformer Unit Internship Report

Diunggah oleh

Hak Cipta:

Format Tersedia

Pak Elektron limited

Change your life

Change your life

Department of Electrical Engineering, University of the Punjab, Lahore

Pak Elektron limited

Change your life

Pak Elektron limited

Change your life

Department of Electrical Engineering, University of the Punjab, Lahore

Pak Elektron limited

Change your life

..2 3 4 .5 ..6 .8 .9 .13 27 .34

Department of Electrical Engineering, PU, LHR

Pak Elektron limited

Change your life

Department of Electrical Engineering, PU, LHR

Pak Elektron limited

Change your life

Department of Electrical Engineering, PU, LHR

Pak Elektron limited

Change your life

Department of Electrical Engineering, PU, LHR

Pak Elektron limited

Change your life

ISO 9001 CERTIFICATION:

Department of Electrical Engineering, PU, LHR

Pak Elektron limited

Change your life

Department of Electrical Engineering, PU, LHR

Pak Elektron limited

Change your life

Active Part of Transformer

Pak Elektron limited

Change your life

Start of Internship at PEL UNIT-2

Department of Electrical Engineering, PU, LHR

Pak Elektron limited

Change your life

Working Procedure of the Design Department

Department of Electrical Engineering, PU, LHR

Pak Elektron limited

Change your life

Department of Electrical Engineering, PU, LHR

Pak Elektron limited

Change your life

Department of Electrical Engineering, PU, LHR

Pak Elektron limited

Change your life

Costing Sketch Datasheet

Electrical Design Starts

Mechanical Design Starts

Terminate Department of Electrical Engineering, PU, LHR

Pak Elektron limited

Change your life

Department of Electrical Engineering, PU, LHR

Pak Elektron limited

Change your life

Marketing and sales

Production planning and control

Annual Sales Plan for WAPDA

No Sales Plan for Private

Master Production Plan(month wise)

Material planning section

Material Requirement Plan or

In processing Inspection of Winding