INDUSTRIAL TOUR REPORT

On
ENERGYPAC ENGINEERING LIMITED – FACTORY

Prepared By: Prepared To:

Md. Borhan Uddin Mr. Naimul Hasan
BSc. (12th Semester) Lecturer
ID no: 191800037 Department of EEE
Department of EEE Faculty of Engineering & Technology
Eastern University Eastern University
Dhaka, Bangladesh

Date of Submission: 3rd March, 2023

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 Letter of Submission

March 3
To
Mr. Naimul Hasan
Lecturer
Department of Electrical and Electronics Engineering
Eastern University

Subject: Submission of tour report on Energypac Engineering Ltd. - Factory

Sir,
With the greatest pleasure, I would like to submit my report on “Energypac Engineering Ltd. -
Factory” that have assigned to me to prepare as the analytical requirement of my BSc. (4th year)
course under the Dept. of Electrical and Electronics Engineering, Eastern University. During the
tour and preparation of report on it, I have seen and learnt how a productive and manufacturing
industry does really work. It has been a very positive and uplifting experience as I have learnt
practically a lot that would not be possible otherwise.

I sincerely hope that you would be gracious enough to accept my tour report for evaluation and
thus oblige thereby.
Sincerely yours,

Md. Borhan Uddin

ID no: 191800037
BSc. (4th Year)
Department of Electrical and Electronics Engineering
Eastern University

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 Preface

The Industrial Tour is a program that is essential for gathering practical knowledge, because
practical knowledge has no alternative. A perfect co-ordination between through and practice is a
paramount importance in the context of the modern electronic world. In order to resolve the
dichotomy between these two areas, the Dept. of Electrical and Electronics Engineering, Eastern
University arranges ‘Industrial Tour Program’ a practical complication of final examination BSc.
courses. This program is very important to complete his/her BSc. course. Industrial Tour Program
brings closer to the business practical and thereby help them to substantiate knowledge so that they
can prepare themselves to start a successful career.

As the student of Engineering and Technology Faculty, I got the adventurous through of the
program under our Dept. of Electrical and Electronics Engineering. The program intends to
provide practical training in handling of engineering jobs as well as integrate the knowledge of
fault analysis, ratio check of a transformer, mechanism of isolator, about a transformer bushing,
about Transformer, Switchgear, Switch and Isolator etc.

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 Acknowledgments

(All the praises and thanks be to Allah)

I have the immense pleasure and satisfaction in presenting report which is termination of
my project work at Energypac. I am grateful to all those who spare their time to share their
mindfully art of judging of merits and faults and have given valuable suggestions.

From the very outset, I would especially like to extend thank to my departmental guide honorable
teacher Mr. Naimul Hasan (Lecturer, Department of EEE), Mr. Sujon Mia (Lecturer,
Department of EEE), Mr. Asad-Uz-Zaman (Lecturer, Department of EEE ) and Mr. Pranta Saha
(Lecturer, Department of EEE) whose inspiration and consideration during the entire program
made it possible to prepare this report.

I also would like to thank to all of the field staffs of the Energypac and special thanks to honorable
Mst. Monalisa (The employee of HR department) for giving us necessary information about the
industry.

Finally, I am thankful to all of my group members who assisted me to make my tour report as
success.

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 Table of Content
Sl No. Topics Page No.
1 Title page 1
2 Letter of Submission 2
3 Preface 3
4 Acknowledgement 4
5 Introduction 6
6 Objectives of the study 8
7 Organogram of the study 9
8 Company profile 10
9 Literature review 12
10 Power Transformer 15
11 Instrument Transformer 16
12 Distribution Transformer 19
13 Switchgear 21
14 Breaker 24
15 Switch & Isolator 25
16 SWOT Analysis 27
17 Findings 28
18 Recommendations 29
19 Conclusion 30

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 Introduction

Energypac is one of the leading power engineering companies in Bangladesh. Continual research
and development, state of the art production facility, quality products, competent services, and
countrywide operations have made it warmly acceptable to the customers.

Energypac was incorporated in 1982 as a private limited business enterprise. It is powered by 1200
skilled manpower of which 150 are graduated engineers. The relentless efforts and dedication of
these people are providing continual help to improve technology to innovate and develop new
products, just in time delivery, pre and post sales services to maintain a long term business
relationship with the customers.

To meet countrywide demand of its products and services, Energypac has extensive distribution
network throughout Bangladesh with full-fledged offices in the major cities like Chittagong,
Khulna, Rajshahi, Sylhet and Bogura. In an effort to introduce its products globally, Energypac
has established its offices in India, Nepal, Italy and China. Energypac has already experienced its
products and service supply to India, Nepal, Yemen, Ghana, Uganda, Nigeria, Saudi Arabia,
Vietnam, Korea, Philippines and United Kingdom.

Energypac Engineering Limited is a comprehensive solution provider for all electrical

engineering requirements, offering a wide range of products and services that cater to various
industries. The company’s product portfolio includes Power Transformers, Oil Type
Distribution Transformers, Cast Resin Transformers (CRT), Single Phase Transformer,
Instrument Transformer, Busbar Trunking Systems, Control & Relay Panel, Indoor VCB
Panels, Ring Main Unit (RMU), Load Break Switch, Gas Insulated Switchgear (GIS), Power
Factor Improvement Panel (PFI) and other Medium & Low Voltage Switchgear Panels,
Outdoor Vacuum Circuit Breaker, Outdoor Off Load Disconnectors & Bypass Switches, Auto
Circuit Reclosers (ACR), Automatic Voltage Regulator (AVR) and Rectifier for power

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generation, transmission & distribution systems. Energypac also provides fireproof electrical
equipment solutions for residential, commercial, and industrial use.

Energypac Engineering Limited is not just a manufacturer of electrical products, but also a
turnkey substation provider. The company has established itself as a reliable and trustworthy
partner in the electrical engineering industry.

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 Objective of the study

This study is aimed at providing me invaluable practical knowledge about the “Energypac
Engineering Ltd”. It will help me to develop my concept of electrical industry and its operation.
The objectives are:

(i) To relate theoretical knowledge with practical experience in several functions of the electrical
industry.
(ii) To know about the production department of Energypac Engineering Ltd.
(iii) To be acquainted with how electrical industry perform its operations.

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Organogram

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 Company profile

1. Name of the company Energypac Engineering Limited – Factory

2. Director & Chief Executive Engr. Rabiul Alam
officer
3. Director Mr. Humayun Rashid
4. Managing Director Mr. Enamul Haque Chowdhury
5. Head Office Energy Center, 25 Tejgaon, Tejgaon I/A, Dhaka-1208
6. Other Branches Energypac Electronics Ltd: Novo Tower, 270
Tejgaon I/A, Dhaka 1208

Energypac Engineering Limited: 1st & 2nd Fl,

Energy Center, 25 Tejgaon I/A, Dhaka 1208

Energypac Engineering Ltd: i/a, 25 Tejgaon,

Dhaka 1208

Etc.
7. Year of establishment 1982
8. Year of operation 1982
9. No. of employees About 1200
10. Nature of ownership Wholly Owned
11. Type of company Manufacturer of electrical products and Turnkey
substation provider

Vision:
We will be the most preferred business partner of our customers.

Mission:
We will provide total power solutions to enhance the business of our customers, concurrently
creating better technologies that benefit both the customers and the environment.

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 Values
Our strategic aim is to strengthen the leading position we enjoy in our markets, and to ensure
continued growth. We rely on our capability to integrate and deliver solutions from our broad
equipment and service portfolio which meet the specific needs of our customer segments globally.
Our priority is to offer the best efficiency, reliability and value available.

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 Literature review

 2023

Gold Medal, National Export Trophy FY 2019-2020

Recipient of the Gold medal, National Export Trophy for FY 2019-2020 for its outstanding performance in the
country's export earnings

 2022

Gold Medal, National Export Trophy FY 2018-2019

Winner of the Gold medal, National Export Trophy for FY 2018-2019 for its laudable performance in the
country's export earnings.

 2021

Gold Medal, National Export Trophy FY 2017-2018

Winner of the Gold medal, National Export Trophy for FY 2017-2018 thanks to its commendable performance
in the country's export earnings.

 2020

President’s Industrial Development Award 2018

Winner of the award in recognition of its remarkable contribution to industrial development.

 2019

300MVA Power Transformer, Gold Medal, National Export

Trophy FY 2016-2017
Manufactures the 300MVA Power Transformer for the first time in Bangladesh and wins National Export
Trophy for FY 2016-2017.

 2018

Type-Tested 120MVA Power Transformer

Successful short circuit type testing of 120MVA, 132/33kV power transformer completed from CPRI, India.

 2015

Production Unit in Kolkata

Established production unit in Kolkata, India.

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 2014

Production Unit in Italy

Founded new production unit in Brescia, Italy.

 2013

Fireproof Solution
Manufactured Fireproof Transformer/ Cast Resin Transformer, Busbar Trunking System (BBT) and 230kV
high voltage (HV) instrument transformer for the first time in Bangladesh.

 2012

Foil Type Distribution Transformer

First time in Bangladesh, manufactured Foil type Distribution Transformer.

 2010

50MVA Power Transformer

Manufactured 50MVA Power Transformer with on load tap changer for the first time in Bangladesh.

 2007

132kV HV Power Transformer

First time in Bangladesh, manufactured 132kV high voltage (HV) power transformer.

 2005

132kV HV Instrument Transformer

First time in Bangladesh, manufactured 132kV high voltage (HV) instrument transformer.

 1997

Power Transformer
Production of 10MVA, 33kV Class Power Transformer.

 1986

Distribution Transformer
Production of Distribution Transformer.

 1982

Inception
Inception of Energypac.

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 Power Transformer

Transformers are one of the primary components for the transmission and distribution of electrical
energy. The scope of transformer types starts with generator transformers and ends with
distribution transformers. Transformers which are directly connected to the generator of the power
stations are called generator transformers. Energypac’s standard range goes up to 520MVA and
400kV. The connection between the different high voltage system levels is made via network
transformers. Energypac is able to offer network transformers up to 520MVA, 400kV.

 Designed to withstand short circuit forces acts

radially and axially during faults.
 High efficiency is ensured by implementing the
technology of magnetic material and CU
conductor.
 Thermally upgraded insulation paper(Class A)
results in Long
 Lower PD value, lower sound level
 High withstanding capability against TOV,
lightning strikes, switching phenomenon, over
flux conditions.
 Leakproof, pressure, and vacuum tested as per
standard.

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 Instrument Transformer

Energypac has been manufacturing reliable instrument transformers for more than 30 years.
Instrument Transformers are designed to provide reliable performance, according to the latest
stringent global design standards like IEC and IEEE/ANSI. This ensures a product with less
maintenance, low weight, flexible mounting facilities, high reliability, high mechanical strength,
and high short circuit capability. The main applications are metering, control, signal, and
protection. Instrument transformer plays a vital role in the power system. Our instrument
transformers are in successful operation worldwide including countries like Vietnam, the
Philippines, Nepal apart from Bangladesh. Our products provide safe and reliable performance in
both indoor and outdoor applications.

Energypac produces different types of instrument transformer. They can be broadly classified into
two types-

 Current Transformer (CT)

 Potential Transformer (PT)

Basic parts:

 Core
 Coil
 Tank Figure: Current transformer &
Potential transformer

Current Transformer
(CT):

 Two terminals (P1, P2),

 Connected in series.
 Multiple layers of
windings.
 Paper type insulation.
 Filled with oil
 Core is circular in ct.

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 Potential Transformer (PT):

 One terminal in PT is grounded.

 Has a vertical shaft ,connected in parallel with the
main line.
 Primary windings are placed on the top of the
secondary windings.
 The core used here is rectangular in shape.

High Voltage Instrument Transformer

 Current Transformers, Oil Type Up To

245kv
 Potential Transformers, Oil Type Up To
245kv

Medium Voltage Instrument Transformer

 Current Transformers, Oil Type Up To
36kv
 Potential Transformers, Oil Type Up To
36kv
 Current Transformers-Outdoor, Dry Type,
Up To 36kv
 potential Transformers-Outdoor, Dry Type
Up To 36kv
 current Transformers-Indoor, Dry Type
Up To 36kv
 potential Transformers-Indoor, Dry Type
Up To 36kv

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 Low Voltage Instrument Transformer
 Current Transformer, Dry Type Below 1.1 Kv

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 Distribution Transformer

Distribution Transformer-Oil Filled

Transformers from 5kVA to 2500kVA and up to 36kV on the high voltage side and 3.6kV on the
low voltage side are referred to as distribution transformers. In the last step, they distribute the
electrical energy to the consumers by feeding from the high-voltage into the low-voltage
distribution network. These are designed either as liquid-filled or as dry-type transformers.

 Power rating from 5kVA to 2500kVA

 Type Test certification for 5000 kVA
Transformer
 Available with both OCTC and OLTC
 Cooling Type: ONAN, ONAF both
can be provided
 33/11 kV; 33/11 kV; 11/.415 kV
products are manufactured mainly but
effective solutions are provided if the
client requires them.
 Cooling Material: Mineral oil and
synthetic ester oil

 OIL TYPE DISTRIBUTION TRANSFORMERS

 DRY TYPE DISTRIBUTION TRANSFORMERS

Distribution Transformer-Dry Type

Energypac offers a full range of dry-type transformers up to 10MVA, with 36kV on the high
voltage side and 12kV on the low voltage side. These are built according to all major standards
including IEC, IS and ANSI and when required as per the loss directives of ECBC-2018. To
minimize environmental contamination and fire hazard, customers are specifying dry-type
transformers more frequently. These transformers meet strict parameters with respect to electrical
system demands and functioning in areas with extreme climatic conditions. Energypac refers to its
dry type distribution transformer as "cast resin transformer." Moreover, Energypac's cast resin
transformers are virtually maintenance free and are manufactured in accordance with industry and
international standards including ISO 9001.

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 Self extinguishing material
 Compact footprint and environment friendly
 Easy installation
 Maintenance free
 Designed to withstand the highest mechanical short
circuit stress that may occur during operation
 High voltage coil windings are cast to prevent
humidity
 High resistance against overvoltage
 Low decibel, high capacity and high performance
 Low partial discharge

 DISTRIBUTION TRANSFORMER, CAST RESIN, UP TO 36kV

 DISTRIBUTION TRANSFORMER, CAST RESIN, UP TO 36kV (AS PER ECBC)

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 Switchgear

High Voltage Switchgear

 Control, Relay & Protection Panel Up To 400kv For Transformer Feeder

The Transformer protection and control panel consists of all sorts of control, protection, metering,
and monitoring of the transformer feeder. This panel is a combination of transformer differential
protection, over current, earth fault and restricted earth fault relays associated with other auxiliary
relays in the protection part of the panel. We have the flexibility to customize the requirement for
any special scheme requirement. In the control panel parts, we are providing all sorts of metering
like ampere, voltage, megawatt, mega var, etc. We use a standard annunciator module, discrepancy
control switches, and different types of control switches as per scheme requirements. Remote
monitoring capabilities are available and the transfer of analog and digital data from the control
panel to SCADA system is also possible. CONTROL, RELAY & PROTECTION PANEL consists
of:

1. Transformer Feeder
2. Incoming & Outgoing Feeders
3. Bus Coupler
4. Busbar Protection Panel,
5. Automation Panel

 Distance protection
 Transformer differential protection.
 Line differential protection.
 Overvoltage and under-voltage
protection.
 Over-current and earth fault protection.
 Low and high impedance type busbar
protection.
 IEC and ANSI standard.
 Production up to 400kV.

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 Medium Voltage Switchgear

 Indoor Vacuum Breaker

ENERGYPAC remains the first and only company in Bangladesh to introduce horizontal isolated,
horizontal draw out type vacuum circuit breaker. The motivation of the top management together
with the innovative skills of its R&D team made it possible for this circuit breaker to meet highly
demanding needs for performance from all quarters including consultants, contractors, industries
and utilities. Large numbers of this circuit breaker are in operation today in Bangladesh and other
parts of the world. This 12 kV horizontal isolated, horizontal draw out vacuum circuit breaker type
EHHV-12 is highly effective and easy to operate and maintain equipment for distribution at 12 W.

This specially designed equipment offers the following advantages:

 User-friendly
 High degree of safety and operational reliability
 Rugged design, Simple in construction
 Modular and compact
 Easy maneuverability of the truck
 Extensible with high degree of customization

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 Low Voltage Switchgear

 Motor Control Center (MCC)

Electric motors might be used in commercial or industrial applications and that needs to be
controlled from a central location. EEL manufacture wide range of motor control center (MCC)
with a combination of different components such as:

Motor protection circuit breaker/ MMS

(manual motor starter)
Motor application contactor
Overload relay with different trip class.

 Power Factor Improvement (PFI)

The ecological importance of the power factor correction. In electrical circuits, the current is in
phase with the voltage whenever are in presence of resistors, whereas the current is lagging if the
load is inductive (motors, transformers with no load conditions), and leading if the load is
capacitive (capacitors).

 Intelligent ventilation and Tailor-made design.

 IEC 60831-1 & -2 complied
 High life expectancy.
 Harmonic management by filter or reactor.
 Wide range of the advanced controller.
 Up to 2400kVAR

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 Breaker

Circuit breaker is used to trip the line when the incoming voltage or current exceeds the rated
value.

Different positions for circuit breaker:

• Service position
• Test position

Types of Circuit Breaker:

• Air Circuit Breaker (ACB)

• Vacuum Circuit Breaker (VCB)

 Indoor Vacuum Circuit Breaker

Energypac remains the first and only company in Bangladesh to introduce horizontal isolated,
horizontal draw out type vacuum circuit breaker. The motivation of the top management together
with the innovative skills of its R&D team made it possible for this circuit breaker to meet highly
demanding needs for performance from all ends including consultants, contractors, industries, and
utilities. Large number of circuit breakers are in operation today in Bangladesh and other parts of
the world. This 12 kv horizontal isolated, horizontal draw out vacuum circuit breaker type EHHV-
12 is highly effective and easy to operate and maintain equipment for distribution at 12W.

 User friendly
 High degree of safety
 High operational reliability
 Rugged design
 Simple in construction
 Modular and compact
 Easy maneuverability
 Extensible with a high degree of customization

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 Switch & Isolator

Vertical Break Disconnector

The vertical-break disconnector consists of one arm which, by moving on the plane of the
insulators supporting it, closes the circuit on a fixed contact located on the side insulator. Since the
movement of the arm takes place on the same plane as that of the insulators, the phase-to-phase
spacing is minimized. The model is ESB, where the arm is operated by a driving insulator directly
connected to it, which moves on the same plane as that of the two post insulators.

 Rated voltage – 12 to 36 kV
 Rated continuous current – up to 4000 A
 Rated short time withstand current up to 40 kA
for 3 seconds
 Manual operation

 DISCONNECTOR 12 kV CENTER BREAK WITH EARTHING SWITCH

 DISCONNECTOR 36 kV CENTER BREAK WITH EARTHING SWITCH
 DISCONNECTOR 145 kV CENTER BREAK WITH EARTHING SWITCH

Double Break Disconnector

The double-break disconnector consists of one arm which is moved by the central insulator
supporting it and closes the circuit on two fixed contacts, each of them placed on one of the two
side insulators. There is direct entry banging type and the other one arm, upon completing its
movement perpendicularly to the plane of the insulators, rotates around its own longitudinal axis
leading to complete engagement and locking of the moving contacts into the fixed ones

 Rated voltage – 12 to 245 kV

 Rated continuous current – up to 6000 A
 Rated short time withstand current up to 63
kA for 3 seconds
 Manual operation and motorized operation.

 DISCONNECTOR 12 kV DOUBLE BREAK WITH EARTHING SWITCH

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  DISCONNECTOR 36 kV DOUBLE BREAK WITH EARTHING SWITCH
 DISCONNECTOR 145 kV DOUBLE BREAK WITH EARTHING SWITCH
 DISCONNECTOR 245 kV DOUBLE BREAK WITH EARTHING SWITCH

Switches
The line switcher has been specifically designed to switch transformers and, more generally, loads
like lines and cables, in a cheap and reliable manner. It is a switch-disconnector combining the
features of the Disconnector with arc chamber extinguish chamber. The interrupting chamber is
operated by the arm of the disconnector, which prevents the risk of performing erroneous operation
sequences.

 Rated voltage – 12 to 245 kV

 Rated continuous current – up to 6000 A
 Rated short time withstand current up to 63 kA
for 3 seconds
 Manual operation and motorized operation.

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 SWOT Analysis

Strength

 Near about 1200 experience & trained people working here.

 Efficiency and effectiveness of the employees.
 Large product range.
 Varieties of product.
 Competitive price.
 Good distribution channel.
 Own transportation system.
 Formal training program for new employee.

Weakness

 Lack of development program for existing employees.

 Sales persons are not properly knowledgeable.
 Promotional offer are not attractive enough.
 Lack of monitoring system about customers’ satisfaction level.

Opportunity

 Attractive promotional offers can be effective to increase sales.

 Introduce more quality full product for capture new market.
 Opportunity to capture the foreign market.

Threat

 Existing strong competitors.

 New entry of competitors.
 Lack of promotional activities for the customers.
 Need to modernize the training program.

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 Findings

After analyzing the overall performance of Energypac Engineering Ltd., I have identified some
sort of issues which are given in below:

 Most of the customers are strongly agreed for quality full product.
 Most of the customers are strongly agreed that the company’s response to query is superior.
 Most of the customers are strongly agreed that the company’s firmness of commitment to
maintain delivery schedule is excellent.
 Some customers are not happy about the delivery schedule.
 The price of the product is reasonable and most of the customers are strongly agreed.
 Most of the customers are strongly agreed that the company have healthier customer
satisfaction.
 Most of the customers are strongly agreed that the company introduce time needed products
for better service is good.
 Company has its own transportation system.
 Company’s distribution channel is good.
 There is lack of promotional activities of Energypac Engineering Ltd.
 By the behavior of the employees customers are very much satisfied.

· All employees of Energypac Engineering Ltd. are efficient and responsive.

 Energypac Engineering Ltd. is very much committed to their customers.

 Energypac Engineering Ltd. should offer better compensation plan for employee motivatio

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 Recommendation

Energypac Engineering Ltd. has an efficient and excellent management team and performing with
a great expertise and care. The limitations can be overcome by some measures to make the
performance outstanding. I have some suggestions for Energypac Engineering Ltd. resulting from
my observations out of my survey. Those are given below:

 Introduce more high quality full product.

 Try to maintain the delivery schedule.
 Develop the distribution channel.
 Training program should be developed.
 Company should give more emphasis on training program to make the employees more
expert.
 Achieve customer relationship management.
 The employees must be smart and energetic to serve the customers efficiently.
 Adopt new technology for production.
 Need for excellent advertising support.
 Increase promotional activities for growth and expansion.
 Introduce more sales deport.

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 Conclusion

Industrial tour on Energypac Engineering Limited - Factory really opened an arena of knowledge
of real situation. I think that Energypac Engineering Limited - Factory has a deep concern about
its better quality assurance, modern production technology, meeting customer demand, effective
marketing strategies etc. It meets a large portion of demand of electrical components in
Bangladesh. Only better quality product and strategic marketing helped Energypac Engineering
Limited - Factory. Bangladesh is a small developing country. In accelerating it’s development
process will must help to develop a country. Electrical equipments are one of the most important
elements for this purpose. It became indispensable part of development activities in the industrial,
power of electrical energy or in the communication sector globally etc. It is expected that perfectly
produce electrical equipments (Transfomers, Switchgears, Breakers etc) will satisfy the consumers
in view of quality. To satisfy their customer they introduce new products according to target
market’s demand. They also have some special incentives for specified performance, which is
encouraging for the employees. From customer satisfaction analysis I found, almost all customers
are satisfied about Energypac Engineering Ltd. The employees are also satisfied with Energypac
Engineering Ltd. This is very important for a company to achieve employee satisfaction and make
a path to achieve customer satisfaction. The customers of this company are highly satisfied for
product, price, distribution channel and other things that the company serves them.

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