INTERNSHIP REPORT

DEPARTMENT OF ELECTRICAL TECHNOLOGY

The University of Lahore, Lahore

INTERNSHIP DERPARTMENT: ELEMETEC TRANSFORMER

Submitted to:

Sir Shizwan

Submitted by: Ali Akbar Bset 01143006

Waqar Younus Bset 01143

Contents
DEDICATION .................................................................................................................................................. 4
ACKNOWLEDGEMENT ................................................................................................................................... 6
EXECUTIVE SUMMARY .................................................................................................................................. 7
INTRODUCTION ............................................................................................................................................. 8
TRANSFORMER ............................................................................................................................................. 9
DISTRIBUTION TRANSFORMER ................................................................................................................. 9
CORE STACKING AND CORE ASSEMBLY ...................................................................................................... 10
Fig 1.1 cores ..................................................................................................................................... 10
Fig 1.2 core stalking .......................................................................................................................... 11
MACHINES ................................................................................................................................................... 11
Fig 1.3 rolling machine ....................................................................................................................... 12
Rolling machine ....................................................................................................................................... 12
Punch press ............................................................................................................................................. 12
Hydraulic machine .................................................................................................................................. 12
WINDING ..................................................................................................................................................... 13
High Voltage Coils ................................................................................................................................... 13
Low Voltage Coils: ................................................................................................................................... 13
HT Side ................................................................................................................................................ 13
LT Side ................................................................................................................................................. 13
Types of windings........................................................................................................................................ 14
Continuous Disk Winding ........................................................................................................................ 14
Fig 1.4 continuous disk winding ......................................................................................................... 15
Packet winding ........................................................................................................................................ 15
Cylindrical winging .................................................................................................................................. 15
COIL ASSEMBLY ........................................................................................................................................... 16
Fig 1.5 core assembly ......................................................................................................................... 16
TANKING ..................................................................................................................................................... 16
OIL FILLING PROCESS .............................................................................................................................. 17
Settling Area............................................................................................................................................ 17
Cooling System of Transformer .................................................................................................................. 17
Tap Changing............................................................................................................................................... 17
 On load tap changing .............................................................................................................................. 18
Off load tap changing .............................................................................................................................. 18
TRANSFORMER TESTING ............................................................................................................................. 18
TTR (transformer turn ratio) ................................................................................................................... 18
Winding resistance test .......................................................................................................................... 18
High voltage test ..................................................................................................................................... 18
Induced voltage test ............................................................................................................................... 18
Copper loss test ...................................................................................................................................... 18
Iron loss test ............................................................................................................................................ 19
Bird protection test ................................................................................................................................. 19
Pressure test ........................................................................................................................................... 19
TYPE TEST .................................................................................................................................................... 19
Impulse test ............................................................................................................................................ 19
Quality control ............................................................................................................................................ 19
Current Transformers ................................................................................................................................. 20
Introduction ............................................................................................................................................ 20
Fig 1.6 current transformer................................................................................................................. 20
PRINCIPAL OF OPERATION ...................................................................................................................... 20
Current Trannsformer (LV).......................................................................................................................... 21
Introduction ............................................................................................................................................ 21
Construction............................................................................................................................................ 21
Application .............................................................................................................................................. 21
Basic Features ......................................................................................................................................... 21
Voltage Transformers (MV) ........................................................................................................................ 22
Fig 1.7 voltage transformer................................................................................................................. 22
VOLTAGE TRANSFORMERS MEASURING ................................................................................................ 23
PROTECTIONS.......................................................................................................................................... 23
Construction............................................................................................................................................ 23
Description of the equipment’s/ Tools and Technique/ Implementation: ................................................. 23
The machines/ Tools Used during the production of Transformer: ........................................................... 24
ROLLING MACHINE ................................................................................................................................. 24
SLITTING MACHINE ................................................................................................................................. 24
WINDER ................................................................................................................................................... 24
SMALL SLITTING MACHINE ..................................................................................................................... 25
 DEDICATION

To all those who have supported, encouraged, challenged, and inspired us. And specially to our
Beloved Parents, honourable teachers and friends for all their guidance, love & attention which
has made it possible for us to make it up to this point and as well as the Internship Supervisors
who bestowed us with the courage, the commitment and the awareness to follow
the best possible route, by their unmatchable style and by best possible training.n
this report I have given a very brief review of what I have seen and learnt duringmy internship. I
have mentioned all these as I have made an internship asaccording to the schedule. This report
will give its reader knowledge about the elmatec and power division especially about transformer
unit
ACKNOWLEDGEMENT

All the praises are for the almighty, Allah who bestowed us 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 us to achieve this job. we also appreciate the cordial co-
operation from all my Internship Supervisors in the different departments of Elmetec
and also of HR management for providing us requisite information and knowledge
for compilation of our complete Internship .All the employers of Elmetec helped us a lot in
performing all the activities and in gaining the practical knowledge of industry. They gave us
best environment and knowledge to enhance our skills.
EXECUTIVE SUMMARY

Elmetec Private Limited 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 by producing hundreds of engineers,
skilled workers and technicians through its apprenticeship schemes and training programmes. We
recently have done our internship in Elmetec, in which we 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 Elmetec is really exemplary. The difference between the success & failure is doing
things right and doing things nearly right, & Elmetec has always tried for success & that iswhy it is
known to be one of the leading companies in Pakistan. In this report we have given a very brief review of
what we have seen and learnt during our internship. we have mentioned all these as we have madean
internship as according to the schedule. This report will give its readerknowledge about the Elmetec
and power division especially about transformer unit.

We have made it possible to write each and every thing that we have learnt here. We have all our practical
efforts in the form of this manuscript that’s the asset for our future career
INTRODUCTION

Elmetec (Pvt.) Ltd. was incorporated in 1999 and over the years it has developed into a leading
manufacturer of Electrical Distribution Equipment in Pakistan. Elmetec has a professional team of
engineering personnels and utilizes the services of highly experienced European Consultants &
Engineers. Elmetec is an ISO 9001:2008, ISO 14001:2004, OHSAS 18001:2007 & certified from TUV
NORD, Germany. It is a Pre-qualified/Registered Manufacturer of Water and Power Development
Authority of Pakistan (WAPDA) and Distribution and Electric Supply Companies, for Distribution
Transformers, Low Voltage/Medium Voltage Current Transformers, Potential Transformers &
Switchgear. It is also an approved supplier of Karachi Electric Supply Company(KESC) and Govt. of
Azad Jammu & Kashmir (AJK). It is registered with Pakistan Engineering Council (PEC) as well.

Elmetec is a very progressive Indenting and Trading company of Pakistan. It represents foreign
principals/manufacturers from different countries for supply of their products in Pakistan. It is a regular
Supplier of Grid Station Equipment up to 500KV including Power Transformers, Circuit Breakers,
Current Transformers (CTs), Potential Transformers (PTs), Disconnectors/Isolators and Capacitor Banks.

Elmetec is also supplying equipment to Pakistan Railways. It represents suppliers of Locomotives,

Wagons and Air Brake Systems.

Elmetec in collaboration with leading Russian Companies in the Petroleum sector, offers various
solutions for the Petroleum Industry for both upstream and downstream Companies. We provide state of
the art material such as Oil drilling Rigs, Equipment including pumps, valves, pipeline, refurbished
drilling bits with guarantee, down hole equipment etc. We also provide, through our Russian partners, all
Oilfield related services and processing solutions for Refinery upgradation to meet Euro IV standards. We
also provide solutions and equipment for fast track development of Marginal wells and Fields. Our
Petroleum division can also provide training courses both in Pakistan and in Russia for all Upstream and
downstream related activities. The division is manned by experts with over 40 years of Local and
International experience in the Petroleum sector.
TRANSFORMER
Transformer is an AC machine that transfers electrical energy from one electrical circuit to
another without changing frequency by the principle of electromagnetic induction. Since its basic
construction requires no moving parts so it is often called the static transformer and it

DISTRIBUTION TRANSFORMER
Transformer of rating up to 200kva, used to step down the distribution voltage to a standard service
voltage is known as distribution transformer. They are kept in operation all the 24 hours a day. In such
transformer iron loss occurs for all the time where copper loss occurs only when they are loaded.
Therefore, distribution transformers should be designed with iron loss smaller in comparison to full load
copper loss(say with iron loss to full load copper loss

Fig 1 Transformer
CORE STACKING AND CORE ASSEMBLY
Core is magnetic link between the two systems connected to the transformer. The core material
and it’s construction should be such that the maximum flux is created with minimum
magnetizing current and core loss. Steel core causes total flux linking of primary to secondary.
The high content of silicon increases the resistivity of the core, hence reduces the eddy current
loss.It also has a high permeability at low flux density and narrow hysteresis loop. The steel used
for cores may be hot or cold rolled .The cold rolled has more flux density (1.8T) than hot
rolled(1.45T) as it has better magnetic properties in the direction of rolling and it also reduces the
amount of core material. As the flux in the core is pulsating one,so cores must be laminated. The
laminations are put through annealing process. The thickness of lamination varies from 0.35mm
to 0.5mm. These laminations are assembled in such a manner that there is no air gap between the
joints of two consecutive sheets. The core assembly is done according to the weight of the core
as the number of plates is decided on the basis of it.

Fig 1.1 cores

The entire assembly is done on a frame commonly known as core channel. These frames being
used as a clamping support of the core assembly. Three-phase transformer usually employ three-
leg core. The sectional areas of the yoke and side leg are 50% of that of the main leg; thus, the
core height can be reduced to a large extent compared with the two leg core. For core material,
high-grade, grain oriented silicon steel strip is used connected by a core leg tie plate; fore and
hind clamps by connecting bars. As a result, the core is so constructed that the actual silicon strip
is held in a sturdy frame consisting of clamps and tie plates, which resists both mechanical force
during hoisting the core-and-coil assembly and short circuits, keeping the silicon steel strip
protected from such force. In large-capacity transformers, which are likely to invite increased
leakage flux, nonmagnetic steel is used or slits are provided in steel members to reduce the width
for preventing stray loss from increasing on metal parts used to clamp the core and for
preventing local.

Fig 1.2 core stalking

MACHINES

Slitting machine is used to cut the big roll of silicon steel sheet in required sizes (widths)
according to the rating of transformer.

Power press machines are used to make limbs. They are operated manually.
 After cutting of limbs V punching is done on the yoke limb which is called yoke notching.

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.

L.A.E measuring table is used to check errors in angle, width and length.

Fig 1.3 rolling machine

Rolling machine
This is used to straighten or to roll the sheets as per requirement. Roll can be at any extent .After
cutting of sheets, they are introduced into it for straightening

Punch press
This is used to cut different shapes on sheet by using different dies. The dies are made of steel.
Bend

Hydraulic machine
This machine is used to bend sheets without any distortion. These machines are known for
sturdiness, higher efficiency and reliability. They bend the sheets at an angle of 90 degree.
WINDING
Windings form another important part of transformers. In a transformer, the high and low voltage
windings are so designed that the axial short circuit force is reduced to minimum. Transformer
winding are made of copper or aluminium strip conductor. Heavy current capacity needs
conductors of large cross section. To reduce eddy current losses in the conductors, several small
wires or parallel straps are preferred to one large strap. This give rise to unequal reactance of the
component of the conductors which can be eliminated by transposition of conductors Instead of
placing primary on one limb and secondary on the other limb it is usual practice to wind one half
of each winding on each limb. This ensures tight coupling between the two windings.
Consequently leakage flux is reduced. The positioning of the HV and LV winding with respect to
core is also very important from the point of view of insulation requirement. If HV winding were
placed next to the core, it would be necessary to insulate it from the core and lv winding and two
layer of HV insulation would be required. By placing HV winding outside and around the LV
winding only one layer of HV insulation would be required. The one which is connected to a
voltage source and creates the flux is called as a primary winding. The second winding where the
voltage is induced by induction is called a secondary. It may be more appropriate to designate
the windings as High Voltage (HV) and Low Voltage (LV) windings. The winding with more
number of turns will be a HV winding.

High Voltage Coils

Generally round insulated wire of either copper (Cu) or Aluminum (Al) is used as basic raw material for
high voltage coil. The coils are made in number of layers. The starting and finishing leads of each coil are
terminated on either side of the coil. These leads are properly sleeved and locked at number of points.
(3)

Low Voltage Coils:

The shape of the basic raw-material (Al or Cu) is rectangular.

HT Side
In HT side, the voltage is high and current is low. For this reason the insulation must be higher than LT
side insulation. HT insulation paper is used in HT side.

LT Side
In LT side, the voltage is low and current is high. For LT side coil insulation, LT insulation paper or DPC
paper is used
Types of windings
• Disc winding

• Packet winding

• Layer winding

• Foil winding

Continuous Disk Winding

The disc coils as the name suggest, consist of number of flat coils or discs connected in series or
parallel. The coils are formed with rectangular strips wound spirally from centre outwards in the
radial 15direction. The conductor used is in such length as are sufficient for complete winding or
section of winding between tappings. The conductor can be single strip or number of strips in
parallel, wound on the flat side. This gives robust construction for each of the discs. The discs
are wound on an insulating cylinder spaced from it by strips along the length of cylinder .The
discs are separated from each other with press board sectors attached to vertical strips. The
vertical and horizontal spacers provide radial and axial ducts for free circulation of oil which
comes in contact with every turn. Continuous discs winding are reliable and strong and,
therefore, they are widely employed both as lv and hv windings in large rating transformers.
Fig 1.4 continuous disk winding
The discs are wound on an insulating cylinder spaced from it by strips along the length of
cylinder .The discs are separated from each other with press board sectors attached to vertical
strips. The vertical and horizontal spacers provide radial and axial ducts for free circulation of oil
which comes in contact with every turn. Continuous discs winding are reliable and strong and,
therefore, they are widely employed both as lv and hv windings in large rating transformers

Packet winding
These are made of circular conductors not exceeding 5 to 6 sq mm in cross section. These are
used for HV 16

These are windings of relatively small transformers. These turns are wound in several layers. The
length and thickness of each packet is made in line with replaceable requirement. A number of
such packets can be connected in series, leaving cooling ducts in between the packet, as required
by design.

There are total six packets in which two middle packets have tapings for controlling or adjusting
the voltage rating as required. These tapings are controlled by tape changer according to the
voltage requirement.

Cylindrical winging
One very common cylindrical coil arrangement is the helical winding. For windings of low
voltage (20kV or below) and large current, a is helical coil is used which consists of a large
number of parallel conductors piled in the radial direction and wound. This is made up of large
cross section rectangular conductor wound on its flat side. The coil progresses as a helix. This is
commonly used for LV windings. The insulation requirement also is not too high. Between
layers no insulation (other than conductor insulation) is needed as the voltage between layers is
low. The complexity of this type of winding rapidly increases as the current to be handled
becomes more. The conductor cross section becomes too large and difficult to handle. The eddy
current losses in the conductor rapidly increase. Hence two or more conductors have to be wound
and connected in parallel. The parallel circuits bring in problems of current sharing between the
circuits. Transpositions of the parallel paths have to be adopted to reduce unequal current
distribution. The modern practice is to use continuously. Transposed and bunched conductors.
COIL ASSEMBLY
The components produced in the coil windingand core assembly stage are then taken intocore-
coil assembly stage. The core assembly isvertically placed with the foot plate touching the
ground. The top yoke of the core is removed. The limbs of the core are tightly wrapped with
cotton tape and then varnished. Cylinder made out ofinsulating press board/ pressphan paper is
wrapped on all the threelimbs. Low Voltage Coil is placed on the insulated core limbs. Insulating
block of specified thickness and number are placed both at the top and bottom of the L.V.Coil.
Cylinder made out of corrugated paper or plain cylinder with oil ducts are provided over
L.V.Coil. H.V. Coils are placed over the cylinder. Gap between each section of H.V. Coils
including top & bottom clearances is maintained with the help of oil ducts, as per the
design/drawings. The Top Yoke is refilled. Top core frame including core bolts and tie rods are
fixed in position. Primary and secondary windings are connected as per the requirements. Phase
barrier between H.V. phases are placed as per requirement. Connections to the tapping switch (if
required) are made. Finally, the component is placed in the oven.

Fig 1.5 core assembly

TANKING
The tank is manufactured by forming and welding steel plate to be used as a container for
holding the core and coil assembly together with insulating oil. Transformer tank offers the
following features:

Subjected to automatic beam welding machine and other special facilities, the tank possesses
high quality and strength. Transformers to be transported by ship are structured in a semioval
shape on both ends of the tank and provided with reinforcement members rationally arranged,
resulting in increased strength and decreased weight. The tank bottom is fitted with a skid base
by welding and provided with pull lugs to facilitate rolling in the longitudinal and transverse
directions. Capable of withstanding a high vacuum of 0.1 torr or below, the tank can be filled
with oil under a vacuum; to thoroughly remove gases and moisture from the insulation. The tank
is of completely enclosed, welded construction. Oil proof nitrile rubber gaskets are used on those
parts which must be removed from the standpoint of assembly in the field or during
maintenance; flanges thereon are provided with machined grooves or gasket retainers to ensure
proper tightening of gaskets. Consequently, there is no possibility of oil leakage over an
extended period.

OIL FILLING PROCESS

The job is put in the tank and the oil is filled into the tank after the clearance checking.The oil is filled
from up and the valve is closed when the oil is below 2 inch of the tank. The cover is putted on the tank
and after it oil is filled trough conservator and at last conservator is closed trought conservator cap.

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.

Cooling System of Transformer

In transformers, the cooling has a special importance to ensure safe operation and to increase the
lifetime of the transformer. The heat occurred in the transformers is dissipated at the cooling unit by the
help of oil. The simplest and mostly used cooling system is ONAN (Natural Air Cooling with Radiators).
ONAF (Radiators Additionally Cooled by Fans) cooling system, in which cooling air is blown to the
radiators by fans, is also used.

Tap Changing
Tap changing means the changing of voltage by a switch. It is provided in HT coil for changing purpose.
Sometimes taps are getting from HT coil; also sometimes an extra coil is used for taps. Taps are also
depending on the winding.
On load tap changing

Off load tap changing

On load tap changing means that the taps are changed during the loading condition but in that condition
off load tap changing cannot work properly. It is dangerous to change the taps of off load tap changer
during loading condition. Because when it moves from one tap to another tap it can be sparked and
fired.

TRANSFORMER TESTING
Those test which are held in Elmetec on daily or weekly bases.

TTR (transformer turn ratio)

In this test we check the turn ratio of the transformer coil that the turn ratio is exact the same as
we decided while designing or being changed by as some error occur due to human faults.

The turn ratio is 11kv / 415v.

Winding resistance test

This test is required due to checking the value of resistance of winding that may not exceed the
required value .

High voltage test

This test is for checking the insulation of winding .we test that if the voltage is exceed from
required specification of winding insulation in that case our winding withstand that much
voltages or not .

This test is held on 34 kilo volt .

Induced voltage test

This test is for checking the insulation and losses of individual turn of winding.

415 50hz

830 100hz

Time duration of this test is 1 minute.

Copper loss test

This test is held on no load.
 415v

Iron loss test

This test is held on full load and required rated current .

Bird protection test

This test is for checking the insulation of top plate of transformer and its whereabouts .we gave
8kv on top plate for testing.

Pressure test
We take this test for checking the leakage in transformer . we insert nitrogen in tank at 15 psi for
this test.

TYPE TEST
Impulse test
Chop wave and full wave are two types of impulse test.

Quality control
.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
CT AND PT
Current Transformers
Introduction
A Current Transformer is the principal measuring device for protection and metering schemes in
any power system. The primary current of the CT is transformed into the required secondary
current, usually 5A or 1A. Not only is the accuracy of the transformation of prime importance,
but also the isolating function. This means no matter what the system voltage on the primary
circuit, the secondary circuit need to be insulated only for a low voltage.

Fig 1.6 current transformer

PRINCIPAL OF OPERATION
The Current Transformer works on the principle of available flux. In the ideal Current
Transformer, secondary current would be exactly equal (when multiplied by the turns ratio)and
opposite to the primary current. But some of the primary current or the primary ampere-turns is
utilized for magnetizing the core, thus leaving less than the actual primary ampere turns to be
 transformed into the secondary ampere-turns. This introduces an error in the ratio of the Current
Transformer, which is classified as current (ratio) error and phase error. This error is measured at
rated burden, specified power factors and rated frequency. Elmetec designs take care of various
factors to keep the errors with in the specified limits.

Current Trannsformer (LV)

Introduction
Elmetec produces a comprehensive range of Low Voltage Current Transformers according to
International/Local Standards. A variety of designs are available to suit individual
requirements.Ring Type (bus bar mounted) CTs with different sizes of windows are available that
provides easy mounting for any position in LV Switchgear

Construction
All current transformers are constructed from high-grade material and are individually tested for
compliance with the specifications. A team of qualified and experienced staff is assigned for the
design and testing of current transformers. Strict quality control is exercised to provide a reliable
product.

Application
Elmetec Low Voltage Current Transformers are indoor type and used for the operation of
Ammeter. Protection Relays, Kilo Watt-Hour Meters, Earth Fault Relays and other purposes.

Basic Features
- Reliable operation under ambient temperature of - 20 C to +55 C

- Capable of withstanding short time thermal and dynamic stresses.

- LV terminal can be sealed.

- Can either be mounted direct on the bus-bars or any other locations

with the help of mounting feet supplied loose.

- A comprehensive range of ratio, burden, and accuracy class is available

as required in various International & local standards.

- A strict quality control is enforced at various stages of production to

ensure compliance of the CTs with rating assigned.

- All material and component used in the manufacturing of CTs are

subject to strict receiving inspection.

- Accuracy tests have been performed at Research & Test Laboratory,

Rawat.

- Test certificates are provided on request

Voltage Transformers (MV)

Voltage Transformers consist of primary and secondary windings which are electricallyisolated
but coupled magnetically by a core. Their role in electrical systems is of primaryimportance as
they bstep downbthe voltage of a system to measurable values, such as110 V or 100 V, thus
enabling Standardization of equipment.

Fig 1.7 voltage transformer

VOLTAGE TRANSFORMERS MEASURING
A voltage Transformer with typical accuracy class: 0.1, 0.2, 0.5, 1.0 and 3.0 used mainly for
measuring through meters and similar apparatus.

PROTECTIONS
A Voltage Transformer with typical accuracy class 3P, 6P are used mainly for protection Relays.
Basic Features Reliable operation under ambient temperature of -20 C to + 55 C.

Construction
Elmetec produce custom-made VTs according to WAPDA, IEC, BSS, ANSI or any other
Local/International Standard specifications. These Voltage Transformers are single pole, double
pole and three poles.

Description of the equipment’s/ Tools and Technique/ Implementation:

A transformer is a power converter that transfers electrical energy from one circuit to another
through inductively coupled conductors—the transformer's coils. A varying current in the first
or primary winding creates a varying magnetic flux in the transformer's core and thus a varying magnetic
field through the secondary winding. This varying magnetic field induces a varying electromotive force
(EMF), or "voltage", in the secondary winding. This effect is called inductive coupling.
If a load is connected to the secondary winding, current will flow in this winding, and electrical energy
will be transferred from the primary circuit through the transformer to the load. In an ideal transformer,
the induced voltage in the secondary winding (Vs) is in proportion to the primary voltage (VP) and is
given by the ratio of the number of turns in the secondary (Ns) to the number of turns in the primary
(Np) as follows:

By appropriate selection of the ratio of turns, a transformer thus enables an alternating current (AC)
voltage to be "stepped up" by making Ns greater than Np, or "stepped down" by making Ns less than Np.
The windings are coils wound around a ferromagnetic core, air-core transformers being a notable
exception.
The machines/ Tools Used during the production of Transformer:

ROLLING MACHINE
The machine in which we can bound the silicon sheet bundle on it. Rolling machine can open
the silicon sheet bundle with a constant speed which is set by the worker.

SLITTING MACHINE

Slitting machine can get the silicon sheet to rolling machine. Slitting machine has a long blade
which cut’s the silicon sheet into further four parts. Four parts can depend on the transformer
rating. Transformer rate can tells which size of silicon steel sheet should be required.
Slitting machine cut into these pieces
For 50 KVA:
300mm,210mm,230mm,260mm(from left to right in the slitting machine)
For 200KVA:
280mm,230mm,210mm,280mm(from left to right in the slitting machine)

WINDER

Winder is the machine which can roll the four pieces of silicon steel sheet coming out to the
slitting machine. Winder can roll these bundles into four small bundles with constant speed.
Speed can be controlled by the worker with speed button in winder and can also be controlled
on slitting machine. Slitting machine and winder can interlink to control by the worker in any of
these machine.
SMALL SLITTING MACHINE

Small slitting machine can also works like slitting machine but the difference is it can
produce two bundles. Small slitting machine can also linked with rolling machine and
winder. Rolling machine can get silicon sheet bundle to the winder of slitting machine
and then divide into two parts through small slitting machine and rolled on the roller.

CORE CUTTING MACHINE (POWER PRESS)

Fig 1.8: Core cutting machine.

After the small slitting machine can make these bundle into small size. Then bundles goes to
the worker who can cut into further small pieces to build the core. There are three types core
A, B and C which can make three phase core according to the design of the customer. The
power press can cut the A, B and C core with the specific angle and design. All types A, B and C
core cutting with machine one or two end of the core.

Precautions:
• Size and angle must be accurate according to the design and transformer rating.
• Blades are not loss their position.
• First and last piece of the silicon sheet must be loss when they roll into the winder
because they should not loss their position set by the worker.
• On core cutting machine one core can at one time more than one core can make error
and can change the accuracy of the core.

WELDER

All connection should be combined with gas welding.

CYLINDER

Cylinder is made up of press pane sheet. Cylinder is used on the H.T’s winding. It’s providing
good insulating property on H.T winding.

PIPES

Pipe is made up of cellulous paper which is used for the insulations of rivet.

L.T strips

L.T strips are made up of press pane sheet and used to insulate after every layer of the L.T
winding.

Oil ducts:

Oil duct is used for freely circulation of the oil in the transformer’s winding.

CYLINDER RINGS

Rings are used in the cylinder winding. Different types of rings are used in the cylinder winding
like L-ring etc.
RAW MATERIAL

Raw material for tank and other component are

• Mild steel sheet (MS sheet)
This sheet have different sizes for tank, bottom plate and top plate are 3mm, 4mm and 6mm
respectively.

SHEARING MACHINE

Shearing machine is used to cut the MS sheeting different sizes. This machine is used for the
cutting of frame, side, wall, bottom wall and cover plate.

PUNCHING MACHINE

Punching machine has 32 tools to make holes of different size. It can make holes of the shape
round, square and 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 the area lifting lugs, carrying beams and studs are welding using arc welding.

Frame punching and welding machine

Frame is punched and the welded in this machine. MIG welding is used in this machine.
Bottom side plate welding

In this section bottom and side plates are welded together. Bottom plate size is 4mm.

Furnas

After assembly and connection it put into Furnas for 18 to 20 hour 105 Celsius. Oil temperature
of transformer is 6oC to 70C.

WELDING MACHINE
Welding machine widely applied in hardware, electrical appliances, automobiles, tank and
other manufacturing industries.

Fig 1.9: Welding machine

MACHINE DRILLS

There are two types of machine drill, the bench drill and the pillar drill. The bench drill is used
for drilling holes through materials including a range of woods, plastics and metals. It is
normally bolted to a bench so that it cannot be pushed over and that larger pieces of material
can be drilled safely.
Figure 2.0: Drilling machine

PAPER MACHINE

This machine is use to provide insulation on a copper material we are use insulation paper for
insulation purpose.

SHAPING MACHINE

A shaping machine is used to machine surfaces. It can cut curves, angles and many other
shapes. It is a popular machine in a workshop because its movement is very simple although it
can produce a variety of work.

LATHE MACHINE
Lathe machines are capable of cutting or grinding symmetrical shapes into materials
such as wood and metal. There are countless practical applications associated with lathe
machines. The definition of a lathe is a machine that shapes objects by rotating them
while a shaping tool such as a chisel is applied to its surface. To avoid injury, care should
be taken while operating lathe machines.
Implementation of theoretical knowledge:

All electrical power that is supplied to consumers has to pass through transformers at some
stage and in some cases the power may pass through at least four or five transformers between
the generator and the user. Usually, at least two of those transformers can be classed as
distribution transformers. There will be power and thus energy losses at each transformer and
thus reduction of loss in transformers will add greatly to reduction of greenhouse gas
emissions.
Specifically, AS 2374.1.2 gave, in addition to the normal specified general levels of efficiency, a
set of “high efficiency” levels that were not mandatory but were desirable levels. Only products
which met these levels could use the “high efficiency” designation in promotional or advertising
materials.
The review process of the original levels is now underway and this technical report has been
prepared to put the case for replacing the original general MEPS levels with the “high
efficiency” levels quoted in the present Standard.
In the alternating current (AC) electrical supply system that is used in all countries for supply to
consumers, the transformer is an indispensable component. It is not possible to operate viable
electrical supply systems without it. In the normal propagation of power to consumers, the
power is generated at about 11,000-15,000 volts (11-15 kV).
It is then passed through its first transformer stage to increase the voltage to the transmission
level somewhere between 220-500 kV. When it reaches the end of the transmission route it is
then transformed again this time down to the 132 – 33kV sub transmission level. It is then sent
to distribution utility zone substations where it is again transformed down to 11-22 kV and is
then sent on its final path to local street or pole transformers where it is broken down again to
the final voltage of 415/240 volts.
All of the transformers involved will have energy losses and thus any reduction in the
transformer loss will mean less generation requirement and less greenhouse gas emissions.
Skills and Techniques learnt during the internship:
The goal of the internship experience is to gain field experience, have the opportunity to
apply information and skills we have learned in the program curriculum, and learn new skills.
The internship will simulate a real job as much as possible.
Internship provides us with pertinent information on the internship program, our
responsibilities for participation, and suggestions on making the most of your experience. Also
included are forms to summarize us experience, and evaluate us performance and our
internship site.

• Familiar with current theory and knowledge in various fields.

• Familiar with the historical background for various areas can bring artistic / aesthetic
sensibilities to projects.
• Can identify and use strategies for enhancing organizational and individual
effectiveness in the workplace.
• Knowledgeable in group decision-making techniques.
• Knowledgeable of conflict management techniques.

INTERPERSONAL / ORGANIZATIONAL SKILLS

• Effective group communication and teamwork skills
• Knowledgeable in group decision-making techniques
• Knowledgeable of conflict management techniques
• Skilled/experienced in managing conflict, buildinG teams, etc.
• Strong interpersonal skills
• Experienced in working in teams
• Reasoning logically and critically
• Aware of the influence of non-verbal elements of communication

SKILLS
We have outlined ten goals for what we would like our interns to be able to “do.” These goals in
particular have been phrased in a very general way in order to keep them flexible. The skill
goals for interns are:
• To develop the ability to apply an analysis of institutional knowledge to local and global
issues.
• To improve skills dialoguing with groups and individuals to increase their understanding
of issues of engineering knowledge
• To develop cross-cultural communication skills and ability to work across difference.
These skills include an awareness of how their attitudes affect their work.
• To increase community organizing skills. These skills will come through working on a
specific campaign with partner organization. This goal may include skills such as
campaign publicity, strategizing for a public hearing, and organizing weekly meetings.
• To increase group facilitation tools and techniques.
• To increase skills in conducting self-directed research.
• To increase the ability to participate in an egalitarian, democratically structured
organization.
• To learn new non-profit management skills. This goal may include skills such as
producing mass mailings, publicizing events, and communicating with the Board of
Directors.
• To expand general skills such as: creative thinking, time management, organization,
documentation, cooperation and collaboration.
• Additional goal(s), defined by intern. Interns may create their own goals related to
skills, along with their own methods for working on those goals, indicators of “success”
and evaluation methods.

Methods refer to the ways in which interns are able to work on each goal. These include both
working on projects and exposure to new situations. The atmosphere in the office is one of
learning and action and provides an opportunity for constant modeling of these values. We
come together regularly to process our reactions to events and discussions, reflecting together
to enhance our learning. The methods outlined in this framework reflect the organic nature of
our work and our daily interactions in which we collaborate with one another.