PEL Transformer Unit Internship Report

Pak Elektron limited
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INTERNSHIP REPORT
Department of Electrical Engineering,

University of the Punjab, Lahore
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INTERNSHIP REPORT
Submitted To:
HR PEL
Submitted By:
Muhammad Ahsen
Internship Department:
PEL Transformer
Department of Electrical Engineering,

University of the Punjab, Lahore
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TABLE OF CONTENTS
Dedication……………………………………………………………………………..2
Acknowledgement…………………………………………………………………3
Exclusive Summary…………………………………………………………………4
Introduction……………….………………………………………………………….5
Transformer…………………………………………………………………………..6
Distribution Transformer……………………………………………………….8
Design Department……………………………………………………………….9
Manufacturing Department………………………………………………….13
I&QC Department…………………………………………………………………27
Maintenance Department…………………………………………………….34
Department of Electrical Engineering, PU, LHR Page 1

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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.

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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.

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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.

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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.

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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.

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Complete Transformer
Active Part of Transformer
Distribution Transformer

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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:
 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
Manufacturing Department
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 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
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

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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
windings, tapping details, HV and LV winding layout, the description regarding the material
required in winding and core.

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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 .

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Start (Client)
Enquiry
Feedback
Marketing
Department
Costing Sketch
Datasheet Order
Enquiry Approve
Design
Department
Order
Approved
Electrical Mechanical
Design Starts Design Starts
Sales Advice
Terminate

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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.

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Marketing and Production

Customer sales planning and
control
Annual Sales Plan for WAPDA

No Sales Plan for Private
Master Production Plan(month wise)
Purchase Material planning

Store department section
Local Foreign Material Requirement Plan or BOM
I &QC Production
Flow Chart of How Manufacturing Department

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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
 Paper insulated flat copper wire (For 10KVA to 50KVA)
 Copper foil (For 100KVA and above)
For H.V winding
 Enamel copper wire (For 10KVA to 200KVA)

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 Paper insulated flat copper wire (400KVA and above)
 Type of Insulation Material
 Diamond dotted paper (For insulation between layers of windings)
 Press pan sheet (For end collars)
 Creep paper pipe (For insulation of terminal of tap changer)
 Craft paper (Used for insulation in disc winding)
 Thermo ducts
 Types of Windings
 Disc winding
 Packet winding
 Layer winding
 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
 Slitting machine is used for the cutting of bundles of insulation material.
 L.V Foil winding machines are used for foil winding on L.V side for
transformers of the rating 100KVA and above.
 L.V paper insulated copper winders are used for winding of P.I copper wire
for transformers of the rating 10KVA to 50KVA.
 H.V P.I copper winders are used for the winding of P.I copper wire for
transformers of the rating 400KVA and above.
 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

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Supply of raw
materials
Paper slitting
L.V foil winding P.I winding (10

(100 &above) to 50)
H.V enamel Foil winding

(10k to 50k) (400 &above)
Storage area
for coils
Process Flow Chart of Winding Section

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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
 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.
 Iron Losses
Iron losses are the flux losses in core. Major factors in iron losses are;
 Quality of material.
 Bur.
 Air gap.
To reduce iron losses
 Material should be of good quality.

 Limbs should be bur free.
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 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.

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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

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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 ½ hours.

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 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.

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Supply of coils Core coil Supply of core and

upper yoke limbs
assembly
Before Connections
connections test
Furnace Assembly of After

cover plate connections test
Unloading Oil filling
Settling area
For testing
Process Flow Chart of Assembly Section

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4. Tank Section
In the tanking section cover plate, tank, and other mechanical components of the
transformer are made. Tank has following parts;
 Frame
 Cover plate
 Bottom
 Side plate
 Fin Walls
 Conservator
 Raw Material
Raw material for tank and other components are
 MS sheet (Mild steel sheet)
 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.

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 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.

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Mild steel and Cold roll sheet bundles
Beams Frame Bottom Fins Under Cover Plate and Bus

Carriage Conservator Bars
Welding and making Tank
Leakage Testing
Degreasing and
Shoot blasting
Paint
Stock
Process Flow Chart of Tank Section

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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
Purchase Receiving
Supplier department store
QUA INSPECTORS
(Incoming)

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 Tests on Different Materials to Check there Quality
 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 C o to 166 Co
for ½ hour and again mandrill test will be performed for test compliance.
 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.
 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.

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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.
 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 ½ 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.

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b) Viscosity
Viscosity meter is used for this test. Reading is taken at two different temperatures. AT
-20 Co reading should be less than 40mm 2/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 C o. 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 C o
to pass this test.

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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
 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
 Cutting of the limbs is checked.

 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
 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.

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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. Transformer Turns Ratio Test (TTR Test)

II. Winding Resistance Test
III. Insulation Resistance Test (Meager Test)
IV. Induced Voltage Test
V. High Voltage Test (Separate source voltage)
VI. No Load Losses (Open circuit test)
VII. On Load Losses (Short circuit test)
VIII. Dielectric Tests
1. Transformer Turn Ratio: (TTR Test)

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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 (Ω) and phase to neutral resistance should be in
milliohms (Ω).
3. Insulation Resistance Test: (Meager test)
This test is used to check insulation between
H.V Ground
L.V Ground
H.V 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.
6. No Load Losses: (Open circuit test)

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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.
Maintenance department classify the system in to two parts:

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A. Common
It includes AUTO, ELECTRICAL and MECHANICAL.
B. TR unit 2
It includes all the machines used in the factory.

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Comments
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Design In charge Signature___________________
Comments
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Production In charge Signature________________
Comments
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I&QC In charge Signature________________
Comments
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Maintenance In charge Signature________________

PEL Transformer Unit Internship Report

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Pak Elektron limited

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Department of Electrical Engineering,

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Department of Electrical Engineering,

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Department of Electrical Engineering, PU, LHR Page 1

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Department of Electrical Engineering, PU, LHR Page 2

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Words are very few to express enormous humble obligations to my affectionate

I take this opportunity to record my deep sense of gratitude and appreciation to

Department of Electrical Engineering, PU, LHR Page 3

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Department of Electrical Engineering, PU, LHR Page 4

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PEL has two divisions of its business.

ISO 9001 CERTIFICATION:

Department of Electrical Engineering, PU, LHR Page 5

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Department of Electrical Engineering, PU, LHR Page 6

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Active Part of Transformer

Department of Electrical Engineering, PU, LHR Page 7

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PEL transformers are available for various applications:

 Distribution Transformers (Pole /Pad Mounted)

Start of Internship at PEL UNIT-2

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Working Procedure of the Design Department

 Estimation of the Cost

Department of Electrical Engineering, PU, LHR Page 9

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Department of Electrical Engineering, PU, LHR Page 10

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Department of Electrical Engineering, PU, LHR Page 11

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Department of Electrical Engineering, PU, LHR Page 12

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Department of Electrical Engineering, PU, LHR Page 13

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Marketing and Production

Annual Sales Plan for WAPDA

Purchase Material planning

Local Foreign Material Requirement Plan or BOM

Flow Chart of How Manufacturing Department

Department of Electrical Engineering, PU, LHR Page 14

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Material Planning Section:

For H.V winding

 Enamel copper wire (For 10KVA to 200KVA)

Department of Electrical Engineering, PU, LHR Page 15

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Department of Electrical Engineering, PU, LHR Page 16

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L.V foil winding P.I winding (10

H.V enamel Foil winding

Process Flow Chart of Winding Section

Department of Electrical Engineering, PU, LHR Page 17

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To reduce iron losses