Industrial Training

Industrial Electronics Engineering Programme

Under the Guidance of :

Prof. S. U. Chavan

Industrial Electronics Diploma Programme

Maharashtra State Board of Technical Education
Mumbai
( Autonomous )(ISO-9001-2008) (ISO/IEC 27001:2013)
 Abstract
Industrial Training is an important phase in every student’s life. A well-planned,
properly executed as well as evaluated industrial training has helped us a lot in
developing the professional attitude. And has also improved our technical skills.
The aim of this Industrial Training is to receive Discipline, Skills, Teamwork and
the most important technical knowledge through a proper training environment,
which will definitely help me as a student in the future.
For the 6 weeks Industrial Training program, I was assigned to the Company
named ‘Magnewin Energy Pvt. Ltd.’, which is the Capacitors Manufacturing
Company. Magnewin’s capacitor is known to satisfactorily cater to the demands of
its customer base. It stands located at M.I.D.C. Kupwad -416436. The business
strives to make for a positive experience through its offering. Ensuring a positive
customer experience, making available goods or services that are of top-notch
quality is given prime importance. During this period of training programme, we
observed the different departments present in the company. Also observed their
methods of work as well as took the guidance from the employees to know about
the company and its Manufacturing techniques.
During the period of 6 weeks, from 07/06/2023 to 22/07/2023, I was Assigned To
do the daily tasks, which includes to welding, as well as to solder it. Throughout
this program, I have learned and improved a lot of technical skills like soldering,
winding etc., as well as Developed professional skills which includes the team
work, Responsibilities and sincerity towards the given tasks.
Like any good industry, you are allowed to settle in after joining and get used to
industry’s working style, post which you are allocated a designated work and
expected to complete it within reasonable time. The Team I worked with was
gracious enough to pay heed to whatever difficulties I faced during completion of
work I was entrusted upon. During the period of industrial training in Magnewin
Energy Pvt. Ltd. , I had the chance to experience in real environment.
 Acknowledgement
I consider it a great privilege & honour to have had the opportunity to
undergo the Industrial training work in ‘Magnewin Energy Pvt. Ltd.’
Hence, I would like to offer my heartiest thanks to Mr. V. S. Bolaj,
(Director of Techinacal)
I convey my heartiest thanks to Mr. V. S. Chippalakatti (Director of
commerical ) for his most valuable suggestions, constant
encouragement, and affectionate guidance during the period of training.
I would like to thank all trainees and staffs, who help me very much and
without whom support and guidance it was impossible for me to
complete the training programme successfully.
I owe deep gratitude to the Mr. Sachin Mane (HR Manager) for her
support and guide to carry out the tasks assigned to us while we are in
the training.
At last, I am greatly thankful to all my seniors and colleagues in
Magnewin Energy Pvt. Ltd. for extending their constant cooperation
which went a long way towards the completion of this training. I
consider it my to convey me deep sense of gratitude and pay respectful
regards towards Prof. S.U Chavan ( Industrial Electronics, WCE) For
their valuable guidance.

Contents

Content
Sr.
No.
1. Organizational Structure
2. Introduction of Industry
3. Types of Major Equipment
4. Manufacturing Process
5. Testing
6. Major Material Handling Product
7. Safety Procedure
8. Particulars of Practical Experience
9. Short Report
10. Special Experiences Encountered During
Training

Chapter 1. Organisational structure of Industry

MAGNEWIN ENERGY PVT. LTD. is well-known company for

capacitor manufacturings.
 Magnewiners have developed excellent management &
departmental system. Overlook of functions of various departments are taken
in this report.
Capacitors are commonly used in power transmission &
distribution, but now days it is taking importance in power quality
improvement point of view in applications like power factor
improvement. Magnewin product enables connection of additional loads
within the existing sanctioned load. Non- PCB, synthetic fluid used for
impregnation is non-toxic, bio gradable, environmental friendly.
Magnewin High Voltage Power Capacitors feature with latest design
innovation i.e. Film Foil design, Extended foil (Corona ring)
construction with edge soldering and edge end folding of electrode foil.

Chapter 2. Introduction of Industry

MAGNEWIN ENERGY PVT. LTD.

L-49, M.LD.C, KUPWAD-416436
DIST.: SANGLI MAHARASHTRA,
INDIA.
DIRECTORS : Mr. V. S. BOLAJ - TECHNICAL
Mr. V. S. CHIPPALKATTI - COMMERCIAL

CERTIFICATION: ISO 9001: 2000.

YEAR OF ESTABLISHMENT: September 1994

CONSTITUTION: Private Limited Company

PRODUCT RANGE:

1. High voltage capacitor: Upto 145 KV

2. Power factor improvement capacitors: upto 50kwar.
3. Surge protection capacitor: Upto 33 kV System.
4. Water cooled capacitor: Upto 33 kV System.

Chapter 3. Types of Major Equipment

High voltage capacitor:

These capacitors are used for compensating transmission line
losses. As well as power factor improvement.
Magnewin High Voltage Power Capacitors feature with latest
design innovation i.e. Film Foil design, Extended foil (Corona ring)
construction with edge soldering and edge end folding of electrode foil.
Rated output: Units up to 400 kVAr & Bank up to 40 MV Ar
Rated voltage: 3.3 kV to 145 kV.

Power factor improvement capacitors:

These capacitors can be installed indoor and outdoor for power
factor improvement.
Altitude of installation should not excedding 100 m. above Sea
Level. These are 1 Phase and 3 Phase with internally delta connected of
rated frequency 50 Hz/60 Hz.

Surge protection capacitor:

Power apparatus is continuously subjected to abnormal voltages
due to internal or external reasons. These may occur on account of
lightening, switching operations, system faults and other abnormal
conditions. Surge capacitors are capable of bringing down the steepness
or slope of over voltage transients, that may appear across transformer
and other A.C. line connected equipments. Unless the transients are
swamped effectively they may cause catastrophic failure of devices.

Water cooled capacitor:

Water-cooled capacitor are specially designed and manufactured for
induction heating and melting applications.
Folding of the electrode (aluminum foil) is done during the
winding process. This feature greatly reduces the possibility of corona
discharge and increases partial discharge inception voltage (PDIV)
levels.
 Chapter 4. Manufacturing Process
1. TOP MANAGEMENT:
This department is concern with decision making activities.
Top management includes M. (Managing Directors) & E.D. (Executive
Directors).

2. PRODUCTION:
This department is directly concern with manufacturing,
testing & dispatch of capacitors & capacitor bank.
Operations under production department:

1. Winding
2. Element stacking/pressing
3. Soldering & Wire connection
4. Welding & Fabrication
5. Wrapping & Pack can
6. Impregnation
7. Leakage testing
8. Electrical final/Routine testing
9. Painting
10. Dispatch

1.1 WINDING:
Material: Al Foil, Pp (Polypropylene film). Machine: Winding machine,
Dry testing machine.

Procedure:
1. Decide KVR rating, KV capacity, phases in case of AC capacitor, No.
of windings, Pp layers. thickness of Al foil & Pp as per specified in
design sheet.
2. Specify foil extension, foil fold.
3. Machine setting-
1. Choose mandrel as per mentioned in design sheet.
 2. Set extension & width.
3. Set folding specifications.
4. Set proper turn rate.
4. Prepare sample winding.
5. Test the sample winding (Dry testing).
6. If result is Ok carry out above procedure for each winding.

Precaution:
1. Machine setting should be exactly match with design sheet.
2. Machine should be feed with proper turn rate.
3. Operation should be clean, special precaution should be taken while
handling sharp slit edge of foil.
4. Winding should be store in air conditioned room.
5. Winding must protected from dust, moisture.
6. Keep OK & faulty windings separate.
7. If any dry MFD is out of datasheet then inform to supervisor.

1.2 STACKING & PRESSING:

Material: Internal fuse, clamping plates, separator,
Machine: Stacking machine (pneumatic)
Procedure:
1. Choose proper material as per mentioned in design sheet.
3mm clamping plate,
2 Separator of 5mm thick
2. Prepare stack of sections as mentioned in design on stacking machine.
3. Stack properly.
4. Test the stack on capacitance meter.

Precaution:
1. Stack height should match with height in data sheet.
2. No any element should displace from stack.
3. Stacking should be tightly & properly made.
4. Stack must store in low temperature.

1.3 SOLDERING & WIRE

CONNECTION:

Material: Zn soldering metals, Cu connecting wires, Cu links, and

internal discharge devices (registers) wrapping paper & accessories.
Machine: Soldering gun working on acetylene gas.

1. Connect internal fuse wires to Cu link & short winding elements on

either side as per mentioned in design data sheet.
2. Solder Cu wire, internal discharge devices, in case of water cooled
capacitor cooling tube soldered to stack.
3. Cover Cu terminals & resisters with insulating ferrule.

Precaution:
1. Optimum soldering metal should be used such that no significant
change in mfd of capacitor
2. Skilled & wel-trained person should be employed for soldering.
3. Stacks should be protected from dust, moisture.

1.4 Fabrication:

Material: MS sheets, steel sheets.

Machine: Shearing machine, drilling machine, bending machine.
Procedure:
1. Check gauge of sheet.
2. Make cutouts of sheet as per mentioned in design
3. Form container.

Precaution:
1. Container should not have any leakage
2. Machines should be periodically inspected.

Chapter 5. Testing LEAKAGE

TESTING:

Machine: Oven.

Procedure:
1. Checks whether all jobs unload from plate are cooled
2. Seal all jobs.
3. Clean all jobs using thinner & compressor air.
4. Put all cleaned jobs in oven in horizontal position for leakage testing.
5. Set temperature at 80°C.
6. Start the oven.
7. Remove all jobs from oven & Check whether all jobs are Ok.
8. Mark Ok jobs.
9. If any leakage is detected inform to supervisor:

1.8 ELECTRICAL FINAL/ROUTINE

TESTING:
Machine: 30A semiautomatic capacitance machine, AC/DC high voltage
tester, tan-delta tester, thermal stability testers.

Procedure:
1. Check MFD of job & put for testing.
2. Carry Thermal stability test. Terminal to container test.
3. Discharge capacitor properly & check MFD of job.
4. For change in MFD remark job as fail.

IMPREGNATION:

Material: Jyralec oil. Oil tray.

Machine: Impregnation plant.

Procedure:
1. Weigh capacitor before loading.
2. Check all capacitors are clean before loading.
3. Temp of controller is set to 80"
4. After completing cycle of 12hr, on the vacuum pumps, Note date &
time.
5. At least 12hrs vacuum should be applied. 6. Impregnation is carried
out for Jyralec oil.
7. After sure that oil is fully filled.
8. Close valve & keep temp steady for some hrs.
 Chapter 6. Major Material Handling Product

RESEARCH & DEVELOPMENT: This one of important activities in

every company. They carry out experiments for improvement in job
performance & inform to top management. Main function of this
department is maintaining record of all kinds of economic & legal affairs

ACCOUNTS: Here economic condition of company is monitored, &

report to top management

TRAINING: Various parameters are developed & inspected in trainees

like working skills, keeping quality record, commercial soundness,
decision making etc. On the basis of inspection trainee is categorized in
skilled, need to train, expert, or not required.

MAINTENANCE: As a preventive measurement all machines has its history

card' in which purchase date, frequency of inspection, parameters to be
checked, cost of maintenance is recorded.
On basis of these records performance of machine & product quality is
determined.
QUALITY ASSESMENT: Besides all maintenance quality plan
controlled copy is distributed to all operation locations for frequent
product quality records, Rate of manufacturing, material use for
manufacturing.
 Chapter 7. Safety Procedure

STORE:
1. Store Available Stock in good condition
2. Receive requirements on requisition slip
3. Inform to Purchase department for required material
4. Maintain inward & outward entries
5. Check received material & inform to purchase department if any
poor quality material is detected

WRAPPING & PACK CAN:

Material: Tested stacks, wrapping paper, containers. Procedure:

1. Wrap the stack such that terminals are kept outside on connecting
edge.
2. Connect terminals to terminal plat.
3. Fix proper bushing to the terminal plate.
4. Put wrapped stack in respective container.
5. Weld terminals to stud.
Precaution:
1. Total size of wrapped stack should match with data sheet.
2. Care should be taken that wrapping will not damage.
3. Container should be clean, dry & leakage free before pack can.
Chapter 8. Particulars of practical experiences in industry

The purpose of Industrial Training is to provide exposure

practical statistical fields and exposure to real working environment.
Throughout this exposure, we had better understand of real working
environment and apply the knowledge of statistic. During the period of
Industrial Training in Magnewin energy Pvt. Ltd., I have the chance to
experience the real working environment. When I involved in the
projects, I was experiencing the responsible, stress and challenge as
trainee. Last but not least, after the Industrial Training, I knew that what
you had studied not really affect what you will work on future. During
this period of industrial training of 6 weeks we did various tasks related
with manufacturing process of capacitors.
 Chapter 9. Short report
Overall, the 6-week industrial training in the electronic
department at Magnevin Capacitor Manufacturing Industry provided
invaluable hands-on experience, deepened understanding of capacitor
manufacturing, and developed essential skills for a career in the
electronic industry.

Chapter 10. Special Experience encountered during the training

During this 6-week industrial program, we were introduced to

various new tasks which we were unfamiliar with. So, during initial days
some tasks were challenging and we made some mistakes. But
eventually we got our hands on those tasks and did them in effective
manner. The social interaction helped in improving our communition
skills and confidence level.

REFERANCE

• https://www.magnewin.com
• https://www.magnewinenergy.com
• https://in.linkedin.com
• https://tracxn.com