Академический Документы
Профессиональный Документы
Культура Документы
Internship Report
The University of Lahore
14
Elmetec Private Limited Lahore
INTERNSHIP REPORT
Submitted To:
GM Elmetec
Submitted By
Imtiaz Ahmad Bsme01113115
Internship Department:
Elmetec Transformer
TABLE OF CONTENTS
Dedication……………………………………………………………………………..5
Acknowledgement…………………………………………………………………6
Exclusive Summary…………………………………………………………………7
Introduction……………….………………………………………………………….8
Transformer…………………………………………………………………………..9
Distribution Transformer……………………………………………………….11
Internship Schadule……………………………………………………………….11
Manufacturing Department…………………………………………………..12
QC Department………………………………………………………………….….22
PT & CT………………………………………………………………………………….25
Dedication
To all those who have supported, encouraged, challenged, and inspired us. And
specially to our Beloved Parents, honorable teachers and friends for all their
guidance, love & attention which has made it possible for us to make it up to this
point and as well as the Internship Supervisors who bestowed us with the courage,
the commitment and the awareness to follow the best possible route, by their
unmatchable style and by best possible training.
Acknowledgement
All the praises are for the almighty, Allah who bestowed us with the ability and
potential to complete this Internship. I also pay my gratitude to the Almighty for
enabling me to complete this Internship Report within due course of time.
All the employers of Elmetec helped us a lot in performing all the activities and in
gaining the practical knowledge of industry. They gave us best environment and
knowledge to enhance our skills.
Executive Summary
Elmetec Private Limited is the pioneer manufacturer of electrical goods in
Pakistan. The company has always been contributing towards the advancement
and development of the engineering sector in Pakistan by introducing a range of
quality electrical equipments by producing hundreds of engineers, skilled workers
and technicians through its apprenticeship schemes and training programmes.
We recently have done our internship in Elmetec, in which we got training from its
Distribution Transformer unit. The internship basically revolved around the
transformer design, manufacturing, I&QC and maintenance. The system, the style
of working & the commitment of the employees in Elmetec is really exemplary.
The difference between the success & failure is doing things right and doing things
nearly right, & Elmetec has always tried for success & that is why it is known to be
one of the leading companies in Pakistan.
In this report we have given a very brief review of what we have seen and learnt
during our internship. we have mentioned all these as we have made an internship
as according to the schedule. This report will give its reader knowledge about the
Elmetec and power division especially about transformer unit.
we have made it possible to write each and every thing that we have learnt here.
We have all our practical efforts in the form of this manuscript that’s the asset for
our future career.
Introduction
Elmetec (Pvt.) Ltd. was incorporated in 1999 and over the years it has developed into a leading
manufacturer of Electrical Distribution Equipment in Pakistan. Elmetec has a professional team
of engineering personnels and utilizes the services of highly experienced European Consultants
& Engineers.
Elmetec is an ISO 9001:2008, ISO 14001:2004, OHSAS 18001:2007 & certified from TUV
NORD, Germany. It is a Pre-qualified/Registered Manufacturer of Water and Power
Development Authority of Pakistan (WAPDA) and Distribution and Electric Supply Companies,
for Distribution Transformers, Low Voltage/Medium Voltage Current Transformers, Potential
Transformers & Switchgear. It is also an approved supplier of Karachi Electric Supply Company
(KESC) and Govt. of Azad Jammu & Kashmir (AJK). It is registered with Pakistan Engineering
Council (PEC) as well.
Elmetec is a very progressive Indenting and Trading company of Pakistan. It represents foreign
principals/manufacturers from different countries for supply of their products in Pakistan. It is
a regular Supplier of Grid Station Equipment upto 500KV including Power Transformers,
Circuit Breakers, Current Transformers (CTs), Potential Transformers (PTs),
Disconnectors/Isolators and Capacitor Banks.
Elmetec in collaboration with leading Russian Companies in the Petroleum sector, offers various
solutions for the Petroleum Industry for both upstream and downstream Companies. We provide
state of the art material such as Oil drilling Rigs, Equipment including pumps, valves, pipeline,
refurbished drilling bits with guarantee, down hole equipment etc. We also provide, through our
Russian partners, all Oilfield related services and processing solutions for Refinery upgradation
to meet Euro IV standards. We also provide solutions and equipment for fast track development
of Marginal wells and Fields. Our Petroleum division can also provide training courses both in
Pakistan and in Russia for all Upstream and downstream related activities.The division is
manned by experts with over 40 years of Local and International experience in the Petroleum
sector.
Transformer
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.
Complete Transformer
Control & Relay Panels, Bus Tie Duct, Distribution Boards, Power Factor Improvement Plant
(PFI), Draw Out Motor Control Centers, Overhead Bus Bars are the other products. Elmetec also
manufactures Low & Medium Voltage Instrument Transformers.
Indoor Substation
Rated Output (KVA):250,400,500,630,750 ,1000,1250,1500 2000,2500 upto 5000KVA.
Auto Transformers
6 to 9 August
Core stacking.
11 to 13 August
Core coil assembly .
14 to 16 August
H.V and L.V connections.
18 to 20 August
L.V and H.V windings shop.
25 to 27 August
Tank manufacturing shop.
28 to 29 August
Paint shop.
1 to 3 September
Assembly section.
4 to 5 september
Testing.
8 to 10 September
Quality Control.
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
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)
Machines Used
Slitting machine is used for the cutting of bundles of insulation material.
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
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.
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.
Slitting of bundles
Cutting
Core stacking
Testing
Checking of core
Stock
3. Assembly Section
In the assembly section there are many processes in which all the components of the
transformer are put together to form a transformer. Important processes in the assembly
section are;
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.
In the BCT area turns ratio of the coil is checked using TTR meter.
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.
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 120 o to 130o.
In this section H.T, L.T bushings, through bolts, eye bolts connectors, arcing horns and other
parts are inserted in cover plate.
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.
Settling Area
After oil filling every transformer is kept for 12 hours in the settling area to check for oil leakage
and oil level.
Before Connections
connections test
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
Raw Material
Component Welding
In this area lifting lugs, carrying beams and studs are welded using arc welding.
Frame is punched and then welded in this machine.MIG welding is used in this machine.
Fin Welding
After fin folding they are welded. MIG welding is used in this machine.
Tank Assembly
Tank Welding
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.
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.
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.
I. Visual Inspection
II. Specific Gravity
III. Viscosity
IV. Flash Point
V. Dielectric Strength
VI. Acidity Value
VII. Pour Point
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
Routine Tests
Tests which are performed on each and every transformer are called routine tests. Every
transformer must pass these tests before dispatch. Test included in routine tests are
Type Tests
Tests which are done on samples taken from a whole lot are called type tests. Tests included in
type tests are
INSTRUMENT TRANSFORMERS
Introduction
Voltage Transformers consist of primary and secondary windings which are electrically isolated
but coupled magnetically by a core. Their role in electrical systems is of primary importance as
they bstep downbthe voltage of a system to measurable values, such as 110 V or 100 V, thus
enabling Standardization of equipment.
ERRORS OF TRANSFORMATION
Errors are introduced in the operations of the Voltage Transformer because some voltage drops
in the primary and secondary winding due to leakage reactance, winding resistance and
magnetization of the core. This creates a (voltage) ratio error and phase error. Elmetec design
Voltage Transformer with minimum voltage drop, which is due to the resistance of the winding
and other losses of the transformer, by using best quality copper wire and electrical steel M-4.
The Voltage Transformers are encapsulated with high quality resin under vacuum, which
ensures the insulation of LV from HV, but also keeps the partial discharge at a low level as
required by the international Standards.
A voltage Transformer with typical accuracy class: 0.1, 0.2, 0.5, 1.0 and 3.0 used mainly for
measuring through meters and similar apparatus.
PROTECTIONS
A Voltage Transformer with typical accuracy class 3P, 6P are used mainly for protection Relays.
Basic Features
- A comprehensive range of ratio, burden and accuracy class is available as required in various
International & Local Standards.
- A strict quality control is enforced at various stages of production to ensure compliance of the
VTs. with assigned ratings.
- All material and components used in the manufacture of VTs. are subject to strict receiving
inspection.
- Guarantee of the performance of Medium Voltage VTs. according to rating plate data.
Construction
Elmetec produce custom-made VTs according to WAPDA, IEC, BSS, ANSI or any other
Local/International Standard specifications. These Voltage Transformers are single pole, double
pole and three poles.
Current Transformers
Introduction
A Current Transformer is the principal measuring device for protection and metering schemes
in any power system. The primary current of the CT is transformed into the required secondary
current, usually 5A or 1A. Not only is the accuracy of the transformation of prime importance,
but also the isolating function. This means no matter what the system voltage on the primary
circuit, the secondary circuit need to be insulated only for a low voltage.
PRINCIPAL OF OPERATION
The Current Transformer works on the principle of available flux. In the bidealbCurrent
Transformer, secondary current would be exactly equal (when multiplied by the turns ratio)
and opposite to the primary current. But some of the primary current or the primary
ampere-turns is utilized for magnetizing the core, thus leaving less than the actual primary
in the ratio of the Current Transformer, which is classified as current (ratio) error and phase
error.
This error is measured at rated burden, specified power factors and rated frequency. Elmetec
designs take care of various factors to keep the errors with in the specified limits.
Basic Features
- All material and components used in the manufacturing of CTs are subject to
plate data.
Construction
Elmetec produces custom made CTs according to WAPDA, IEC, BSS, ANSI or any other
Local/International Standard specifications.
Introduction
Elmetec produces a comprehensive range of Low Voltage Current Transformers according to
International/Local Standards. A variety of designs are available to suit individual requirements.
Ring Type (bus bar mounted) CTs with different sizes of windows are available that provides
easy mounting for any position in LV Switchgear.
Construction
All current transformers are constructed from high-grade material and are individually tested
for compliance with the specifications. A team of qualified and experienced staff is assigned for
the design and testing of current transformers. Strict quality control is exercised to provide a
reliable product.
Elmetec Low Voltage Current Transformers are indoor type and used for the operation of
Ammeter. Protection Relays, Kilo Watt-Hour Meters, Earth Fault Relays and other purposes.
Basic Features
Rawat.