Professional Documents
Culture Documents
Internship Report
Transformer Unit II
Muhammad Waqas
09-EE-119
UET, Taxila
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
Dedication
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
Acknowledgement
In the name of ALLAH, the most merciful and the most 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 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
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
PEL Pakistan
Type: Public
Introduction:
Founded:
1956
Headquarter:
Lahore, Pakistan
Key people:
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
Vision Statement
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
Muhammad Waqas
09-EE-119
UET, Taxila
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 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
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 Energy Meter Plant, Transformer Plant, and Switch Gear Plant. All these plants are now ISO 9001:2000 Certified. 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, France. 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
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 g Data sheet
Electrical
Mechanica l
Design Department
H.O.D
Mr Sadiq
Mr Masood Electrical
Sr. Engr Adnan Shahid Engr Aamir Sharif Aamir Sharif Sub Engr Fahad Zahid Rehan Irfan
Sr. Engr Adnan Ch. Abid Engr Javid Mohsin Butt Sub Engr Adnan Amjad Draughtman Riaz Asim Umer Sajid
Muhammad Waqas
09-EE-119
UET, Taxila
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.
Work Order:
Includes the time and sequence of parts to be manufactured.
Step I
Ratings (Data)
Kva, Voltages, Type (Step Up/Down), Connections (Y/D), Power Factor Step I I Current Calculations
Muhammad Waqas
09-EE-119
UET, Taxila
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 must provide details of specifications to the 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 Tappings and tap switch Service conditions and type installations like indoor and outdoor
Muhammad Waqas
09-EE-119
UET, Taxila
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
Quality of gas kits and hardware Pitch distance and size of top cover bolts etc.
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: Put wire in Electric oven for 155-160o C for half hour Again Mandrill Test
Muhammad Waqas
09-EE-119
UET, Taxila
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
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: Steps: On High Port Tester 09-EE-119 UET, Taxila High port tester Stop watch
Muhammad Waqas
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: 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% Beaker Transformer oil Thermometer Electric oven Digital weighing scale
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
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:
Muhammad Waqas
09-EE-119
UET, Taxila
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
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
Copper Losses (short circuit): HT side rated current LT side short 09-EE-119 UET, Taxila
Muhammad Waqas
R1 unit II
R1 unit II
Inspector No. 1
Muhammad Waqas
09-EE-119
UET, Taxila
Production Department
Hierarchy of Production Department
Jahanzeb Ahmad manager
DT transformer factory
Testing
Servicing
Customer comlaints Salman Rafiq testing Engr E3 Muhammad Arshad asst. Supervisor S2 Arif Husain Sr.Inspector C
PM transformer testing/PDI/inspectio n
Muhammad Sageer Sub Engr S1
Muhammad Waqas
Inspector No. 3
09-EE-119
UET, Taxila
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.
Cutting
Core Stacking
09-EE-119
UET, Taxila
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 120oC for 48 hours. Cover plate is joined. Then assembly is put into the tank.
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 09-EE-119 UET, Taxila
Muhammad Waqas
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% CO2 TIG o tungsten inert gases 100% argon back side of cover plate carrying beams, cover plate stiffner stud to tight insulator
Frame punching machine: only punches the frame cutting Bending Notching Welding
Used to cut lifting lugs and to cut sheets of max width Oxygen is used
Fins
CNC machine: Data entry o pitch o height o extra sides on both sides o number of fins 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 fins) are bended and then welded.
Tank assembly: Pad mounted o 3sides fins areas where wires are undergrounded.
Muhammad Waqas
09-EE-119
UET, Taxila
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: 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
Bottom End
MS sheet cutting
Molding/Bending in NC machine
Welding of angles
Muhammad Waqas
09-EE-119
UET, Taxila
Frame
MS sheet cutting
Molding/Bending in NC machine
Muhammad Waqas
09-EE-119
UET, Taxila
Fins
Tank Assembly
Complete welding (MIG, TIG, ARC)
Leakage test
Diesel filling test Air pressure test
Degreasing
Shot blasting
Sand blasting
Rinsing
Derusting
Rinsing
Phosphating
Color coating
Inside red oxide Outer gray color coating and the placed in furnace
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. It ensures the safety and the health of people 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 specially trained in this regard.
Muhammad Waqas
09-EE-119
UET, Taxila