Internship Report of Pak Elektron Limited

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Muhammad Waqas 09-EE-119 UET, Taxila

Internship Report

Transformer Unit II

Muhammad Waqas

09-EE-119

University of Engineering and Technology, Taxila

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Design Department

Name:

Designation:

Signature:

I & QC Department

Name:

Designation:

Signature:

Production Department

Name:

Designation:

Signature:

HR Department

Name:

Designation:

Signature:

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Dedication

To my family and my teachers who showered their wisdom and

knowledge enabling me to come to grips with the worldly life

and attain my objectives.

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Acknowledgement

‘‘In the name of ALLAH, the most merciful and the most beneficent’’

Person is not perfect. He has a limited mind and thinking approaches. It is the guidance from the

almighty ALLAH that shows the man, light in the darkness and the person finds his way in this

light. Without this helping light, person is nothing but a helpless creature.

I am very grate full to ALLAH almighty for granting me the opportunity, perseverance and

determination for handling the internship at PEL for the duration june-july 2011.

I extend many thanks to all my section in charges for helping and guidance throughout my

Internship. They help me a lot in performing all activities and in gaining the practical knowledge.

They monitored all my activities and gave me the best suggestions to complete all the assigned

tasks in effective manner.

I am very thankful to administration of PEL for giving me the opportunity of internship that

build my personality and enable me to do some creative work to be successful person in my

practical life.

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Executive Summary

I have worked as an intern at PEL (Pak Elektron Limited) for the duration of 4 weeks(20th

June to 18th July ) 2011.

I made this report about the working in the PEL in TRANSFORMER UNIT.I visited three

sections of unit and know further details briefly.

In the usual education, we have studied only concepts of every subject and do not have practical

knowledge. In engineering we have only studied theory and concepts and when a person apply

that theory and concepts on an organization that concepts convert in to knowledge that live long

with a person the whole life.

I learnt a lot from this organization which I mentioned in this report. These three sections include

Design, I&QC and Production departments..This report will give its reader the knowledge about

the history and background of PEL.

In this report, I mentioned the procedures and the processes followed by workers and engineers

to get more reliable and best products. The tests performed in incoming section on different

products and in quality control section are also included.

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PEL Pakistan

Type: Public

Introduction: Electronics and Digital

Appliances, Power Division

Founded: 1956

Headquarter: Lahore, Pakistan

Key people: Mr. Naseem Saigol (CEO),

Mr.Azam Saigol , Mr. Murad Saigol

Products: Refrigerators, Air conditioners, Microwave Ovens, Washing

Machines, water Dispensers and Generators, Transformers,

Switchgears

Parent: Saigol Group

Web site: www.pel.com

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Vision Statement

To excel in providing Engineering good and services.

Mission Statement

To provide quality products & services to the complete satisfaction of our

customers and maximize returns for all stakeholders through optimal use of

resources.

To focus on personal development of our employees to meet future

challenges.

To promote good governance, corporate values and a safe working

environment with a strong.

Slogan

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Introduction of PEL

Pak Elektron Limited (PEL) is the pioneer manufacturer of electrical goods in Pakistan. It was

established in 1956 in technical collaboration with AEG of Germany. In October 1978, the

company was bought by the Saigol Group of Companies. Since its inception, the company has

always been contributing towards the advancement and development of the engineering sector in

Pakistan by introducing a range of quality defined goods and by producing hundreds of

engineers, skilled workers and technicians through its apprenticeship schemes and training

programs.

The company comprises two divisions:

Appliances Division.

Power Division.

Appliances Division:

The Home Appliances Division of PEL is the flag carrier of the Saigol Group, involved in home

appliances manufacturing.

Air conditioners.

Refrigerator.

Deep freezers.

Microwave oven.

Washing machine.

Generators.

Vacuum Cleaner

http://en.wikipedia.org/wiki/Pakistan

http://en.wikipedia.org/wiki/AEG

http://en.wikipedia.org/wiki/Germany

http://en.wikipedia.org/wiki/Saigol_Group

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Power Division:

PEL Power Division manufactures energy meters,

Transformers

Switchgears

Compact stations

Shunt capacitor banks

Energy meters

Generators

Power Division:

PEL Power Division consists of three plants. These are Energy Meter Plant, Transformer Plant,

and Switch Gear Plant. All these plants are now ISO 9001:2000 Certified. PEL Power Division

manufactures energy meters, transformers, switch gears, Kiosks, compact stations, and shunt

capacitor banks and specially Transformers.

All these electrical goods are manufactured under strict quality control and in accordance with

international standards. PEL is one of the major electrical equipment suppliers to Water and

Power Development Authority (WAPDA) and Karachi Electric Supply Corporation (KESC),

which are the largest power utilities in Pakistan.

Over the years, PEL electrical equipment has had been used in numerous power projects of

national importance within Pakistan. PEL has the privilege of getting its equipment approved and

certified by well-reputed international consultants such as, Preece Ensa, France.

In spite of stiff competition from emerging local and multinational brands, PEL Group's

appliances and electrical equipments have remained in the spotlight due to constant innovation.

Strategic partnership with multinationals of repute have enabled the PEL Group to incorporate

new technologies into existing product ranges, thus giving the Pakistani market access to

innovative, affordable and quality products

http://en.wikipedia.org/wiki/WAPDA

http://en.wikipedia.org/wiki/Karachi_Electric_Supply_Corporation

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Design Department

Deals with the designing and finalizing the details & specifications of a transformer. Design

department follows the IEC rules and regulations to ensure a standardized design. In design

department the following procedure is followed.

Design OK

Marketin

g

Design Department

H.O.D

Electrical Mechanica

l

Rough

Design

Data

sheet

Cost, Material, Time

Marketin

g

Design Department

H.O.D

Electrical Mechanica

l

Work Order

Production

Specifications,

coil, core Structure, Tank,

Parts

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Hierarchy of Design department

Sr. Manager (M4)

Assistant Manager (M1)

Electrical Mechanical

Mr Sadiq

Mr Masood

Sr. Engr

Adnan Shahid

Engr

Aamir Sharif

Aamir Sharif

Sub Engr

Fahad

Zahid

Rehan

Irfan

Sr. Engr

Adnan Ch.

Abid

Engr

Javid

Mohsin Butt

Sub Engr

Adnan

Amjad

Draughtman

Riaz

Asim

Umer

Sajid

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Tools:

Auto CAD

Pro E

Microsoft Excel

Electrical engineer:

Perform the designing of electrical parts of the transformer.

Mechanical engineer:

Perform the design of mechanical parts of a transformer.

On software they also perform some simple tests that are to determine the feasibility of the

transformer.

Terms:

Data sheet:

Includes all the specifications of a transformer.

BOQ (Bill of Quantity):

Contains the amount of material used for the construction of a transformer.

Work Order:

Includes the time and sequence of parts to be manufactured.

Transformer Design Steps:

Step I Ratings (Data)

Kva, Voltages, Type (Step Up/Down), Connections (Y/D), Power Factor

Step I I Current Calculations

Current in Primary Windings, Flux in Coil, Current Density

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Step I I I Coil Design

Coil Cross-Sectional Area, Material Radius, Length, Number of Turns, Tappings, Insulation

Step I V Core Design

Window Height, Stepping, Weight, Height

Step V Tank and Accessories

Outer Accessories, Insulators, Contacts

Specifications:

The design of a transformer depends to a large extent on specific requirements of a

customer. So, the manufacturer must provide details of specifications to the customer.

The information provided to the customer may be of three types.

Mandatory

Supplementary

Additional

Mandatory specification:

The information without which it is difficult to proceed a single step for designing a transformer

and that information is critical as well for the purpose of design electrically and mechanically is

termed as mandatory specification.

The specifications are listed below:

Kva ratings

Voltage ratio

System earthing

The number of phase and frequencies

Connection and vector group

Tapping’s and tap switch

Service conditions and type installations like indoor and outdoor

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Requirements of terminations

Cooling

Winding materials

Altitude of installation

Type of mountings

Supplementary specifications

The specifications which are not mandatory in nature but are essential for designing an efficient

transformer are supplementary specifications.

These specifications are as under:

No load losses and no load current

Load losses and percentage impedance

Temperature rise limit over the ambient temperature limit

Basic insulation level

System fault

Specific requirement of fitting and accessories

Limitations of flux density and current density

Dimensions and limitations

Evaluations of cost by way of loss capitalization.

Additional specification

Additional specifications are not much critical for the working and operation of a transformer but

it is essential for the design to know the requirements of buyer that includes grade of core,shape

of tank etc. to offer a good transformer by the designer to the customer for particular site

conditions.

These are listed below:

Minimum acceptance and thickness of core laminations

Type of core construction

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Stray losses

Noise level

Shape of tank body

Quality of gas kits and hardware

Pitch distance and size of top cover bolts etc.

Inspection & Quality Control Department:

Incoming:

Tests performed in incoming on to be purchased items so that they should pass the quality test.

Enameled Copper Wire Test

Apparatus:

Electric oven

High port tester set/bench

Testing device for peeling off and breakdown test

Elongation tester

Micrometer

Mandrill Test:

Twist wire along its own diameter 8-10 times

Check for zero cracks

Heat Shock Test:

Put wire in Electric oven for 155-160o C for half hour

Again Mandrill Test

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Break Down Test:

400mm length taken

Doubled and twisted

Checked for twists in 125mm length

Twists as per IEC 60317 BS 4516

Ends cut, enamel removed

Rated voltage applied

Peel Off Test:

Applicable upto 1mm diameter

600mm length taken

Fixing devices 500mm apart

One rotatable part

Weight attached to the wire

From scraper enamel is removed

Speed of rotation 60-100 rev/min

Specified revolution R=175/d

Chipping off is tested

Zero chipping required

Elongation Test:

Elongation tester

200-250mm length taken

Rate of elongation 5mm/sec

Till Fracture stress is applied

Length measured

Not less than IEC 60317 BS 4516

Bird protection test for cover plate

Apparatus:

High port tester

Stop watch

Steps:

On High Port Tester

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Zero kV

Cover plate placed

Ground cover plate

High Port Tester to cover plate copper strip

On breaker of High Port Tester

Up to 8kV applied

Stopwatch to 1min at 8kV

Must sustain 8kV for 1 min

Change of Mass Test of Gaskit (NBR)

Apparatus:

Beaker

Transformer oil

Thermometer

Electric oven

Digital weighing scale

Steps:

Transformer oil 400-500ml

Record initial weight of gas kit

Dip sample in oil

Place for 72 hours in oven at 110 C

Take sample weight after 72 hours

Calculate = ((final weight – initial weight)/initial weight)X100

TDD 05 11

Tolerance +15% and -5%

In process Testing:

Core & Winding Assembly

Final Assembly

Cover Plate Assembly

Fin Folding

Mechanical Fitting Shop

Tank Assembly

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Transformer Oil Testing

Transformer oil is tested before unloading it from the tanker. These tests are recommended by

IEC 60296.

These tests include:

Visual inspection

Specific gravity

Viscosity

Flash point

Dielectric strength

Acidity value

Pour point

When the oil is unloaded it is processed for 5 to 8 hours before filling tanks with it.

Testing

Routine Tests:

TTR (Transformer Turn Ratio)

Winding Resistance Test

Megger Test

Induced Voltage Test

High Voltage Test

Iron Losses

Copper Losses

Type Test:

Temperature Rise

Impulse Test

Short Circuit Test

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TTR:

It is performed:

Before connection

After connection

Before dispatch

Winding Resistance Test:

DLRO (Digital Low Resistance Ohm) meter is used to perform this test.

It is used to check resistance of

o HV winding

o LV to LV winding

Megger Test:

Special meter is used to perform this test.

Induce Voltage Test:

LT side

o Double voltage 415 -> 830V

Frequency 4 times 200Hz

Time of test 30 sec

It is to check the turn to turn insulation

High Voltage Test:

EC 28kV

HT side short and applied 34kV

LT side short with body (grounded)

Time of test 1min

Iron Losses (no load):

LT side 415kV

HT side open

Copper Losses (short circuit):

HT side rated current

LT side short

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Hierarchy of I & QC department

Jahanzeb

Ahmed

Manager I &

QC

Usman

Harooni

Incharge R1

R1

unit II

Mirza Islam Ul

Haq Engr

Khurram

Shehzad Sub

Engr

Inspector No. 1

R1

unit II

Inspector No. 1

PDI at vendor

end

WAPDA

material

Inspection

Khurram

Shehzad Sub

Engr

Inspector No. 1

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Production Department

Hierarchy of Production Department

Jahanzeb Ahmad

manager

Asfand Ali

testing Engr

DT transformer factory DT test field unit I

Testing Servicing Customer

comlaints

PM transformer

testing/PDI/inspectio

n

Private rating

transformer

Noor

Muhmmad

Jalbani

Engr

Abdul Hameed

Assit. Supervisor

S2

Inspector No. 1

Salman Rafiq

testing Engr

E3

Muhammad

Arshad asst.

Supervisor S2

Arif Husain

Sr.Inspector

C

Muhammad Sageer

Sub Engr S1

Inspector No. 2

Salman Rafiq

testing Engr

E3

WAPDA

rating

transformer

Atiq ur Rehman

SubEngr testing

S1

Inspector No. 3

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Winding Section:

In this section

Slitting machine cuts insulation paper according to the sizes given.

LV winding is performed. Which includes:

o Foil winding

o Coil winding

Thermo duct is placed.

HV winding is performed. Which includes:

o Coil winding

o Disk winding

o Packet winding

The type of winding is decided by the design department according to the rating.

Core Section:

Silicon Steel Sheet Bundles

Slitting

Cutting

Gauge Assembly

Weighing Of Core Plates

Core Stacking

Varnishing Of

Core

Checking Of Core

Side,

Center &

Yoke

Degree

Cutting

Yoke

Notching

Stock

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Assembly Section

In this section

Core and coils are put together.

They are tightened by supporting beams.

Before connection tests are performed.

Connections are made according to the TR.

After connection tests are performed.

Then the assembly is placed in the furnace at 120oC for 48 hours.

Cover plate is joined.

Then assembly is put into the tank.

Oil Filling Section

In this section

Transformer is filled with oil.

Special container is used for oil filling.

Up to -5 bar pressure is maintained.

Tank Section

MS Sheet 1mm-50mm

Shearing machine:

It cuts & bends :

o Frame

o Bottom

o Side wall

o Angles

o Fins

o Cover plate

NC only numerical control

CNC Machine:

Dimensions code

Nibbling or Punching machine

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Program on Auto CAD and feed in SS tool to cut MS

Bending Machine:

V -slots according to thickness

Capacity 1-12mm

Embossing machine:

Squeezing

Drawing

Imposing

It bends it to the lower side

It applies only on cover plate

Die is used

Component welding:

ARC

o electrode is used

MIG

o metal inert gases sound, 80% argon, 20% CO2

TIG

o tungsten inert gases 100% argon

back side of cover plate carrying beams, cover plate stiffner

stud to tight insulator

Conservator rolling machine:

size 3mm

conservator supporting beams

Frame punching machine:

only punches the frame

cutting

Bending

Notching

Welding

CNC flame cutting machine:

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Used to cut lifting lugs and to cut sheets of max width

Oxygen is used

Universal cutting machine:

Stiffener

angle

round bar

punching

notching

Fins

CNC machine:

Data entry

o pitch

o height

o extra sides on both sides

o number of fins

1.2 mm thickness of CR sheet

Width 400-1220mm

Can not bend more than that

Fin welding:

Automatic machine CNC MIG welding

Manual TIG welding

Panel sides bending machine:

2 small, 2 large endings.

The two large (A,B) or small size of fins (side fins) are bended and then welded.

Tank assembly:

Pad mounted

o 3sides fins areas where wires are undergrounded.

Under carriage fitting:

Beams

Wheels

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Blasting

Shot blasting:

o To get rubbed surface

o Oil free surface

o Steel is shot on it which absorbs oil in it

Sand blasting:

Degreasing, Rinsing, Phosphating:

Choice is there only one is chosen

200kV->shot

>200kV->sand

<200kV->D,R,P

Leakage testing:

Diesel filling machine applied 5psi

Air pressure test applied 5psi

Above 630kVA, less pressure is required

Powder coating:

Rough surface and powder is coated. It is melted in furnace.

Gray

Green

Blue

Creamy

Process

Degreasing,

Rinsing

Derusting

Rinsing

Phosphating

Hot Rinsing

Important terms:

PDI Pre Dispatch Inspection

IR Industrial Relation

RI Receiving Inspection

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Bottom End

MS sheet cutting

Molding/Bending in

NC machine

Welding of side

walls

Welding of angles

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Frame

MS sheet cutting

Molding/Bending in

NC machine

Notching (universal

machine)

Welded with angles

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Fins

CNC machine for

molding pitch 45mm

Welding of round

rod

Welded with angles

in assembly

CR sheet of

thickness 1.2mm

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Tank Assembly

Complete welding (MIG, TIG, ARC)

Leakage test

Diesel filling test

Air pressure test

To get smooth surface

Degreasing

Rinsing

Derusting

Rinsing

Phosphating

Hot Rinsing

Shot blasting

Sand blasting

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Color coating

Inside red oxide

Outer gray color coating and the placed in furnace

Quality check:

Moved to assembly

Final Stage

The quality parameters as per requirement are checked and the tests are again

performed on the transformer. When the transformer is checked and it fulfils the

requirements then it is moved to the dispatch section.

In the dispatch section name plate is welded with the body of the transformer and the

bushings are painted.

Health, safety and Environment Department

In an organization health and safety of the people and environment insurance is much

important. In PEL there is a separate department which is known as HSE department.

It ensures the safety and the health of people and take measures in this regard. There are

different notice boards which carry information about this. The workers uniform, personal

safety equipment is much important. The workers are specially trained in this regard.

Documents

Internship Report of Pak Elektron Limited