SIX WEEKS INDUSTRIAL TRAINING REPORT

At :
AT GTB TRANSFORMERS
VILL. TIBBA
LUDHIANA

SUBMITTED BY : SUBMITTED TO:

PRABHLEEN SINGH Prof. Jaswinder Singh Sra
B.TECH (GNDEC) HOD EE DEPARTMENT
D3EEA2 1606880 (URN)
  Preface
This Report is made after 6-Weeks Industrial Training at GTB Transformers at Tibba
Village, Ludhiana, Punjab from 16th June, 2018 to 30th July, 2018 (45 days).

I have learnt the process and various techniques involved with the help machine
infrastructure for making different types of Transformers here

I have learnt a lot about the team work required to manage such big industry.

Making of Transformers and then testing it for better quality.

So I have presented what I have learnt at GTB Transformers via this Industrial
Report.

I have been privileged to have training here as a part of GTB's work force.

I thank all the GTB team members, HR Mam, GTB's Partners for providing me this
opportunity to come and learn with you all.

I also thank my college for this opportunity.

Thank you
  Acknowledgment
The real spirit of having us through the way of excellence and adulterous
discipline. I would never have succeeding in finishing it. So I am indebted to
various personalities who have helped, inspired and given moral support and
encouragement in various ways to complete this task.

I am humbly expressing my cordial to Head of Department. He has always been a

source of encouragement and an inspiration to me. I am hugely thankful to my
teachers, for their encouragement and support without which I would never able
to complete this report.

I am thankful to Senior Executive and the Engineers of GTB TRANSFORMERS for

granting the permission to undergo 6 weeks industrial training from their industry
and giving the information and knowledge about Transformers. It has been a
wonderful experience and I am deeply indebted to all those who made it possible.
➢TABLE OF CONTENTS

● INTRODUCTION
● PARTNERS
● INFRASTRUCTURE
● TYPES OF TRANSFORMERS MADE HERE
● LIST TAP CHANGER TYPE AS WELL
● EXPLANATION TO EACH
● ITS PARTNERS
About GTB
GTB Group has been providing solutions for energy management for the last 22
years & professionally managed by professionals and technocrats with more than
30 years of experience.

GTB Group was founded in the year 1992 by Mr. Harjot Singh as Guru Teg Bahadur
Metal Works which focused primarily on manufacturing high quality copper and
aluminium conductors used in Electric Distribution/Power Transformers, Welding
Machines, Servo Voltage Stabilizers.

In GTB All the major components and raw materials are procured as per IS
standard and from standard reputed sources like copper from Hindalco, Core
(CRGO) imported from Japan, Transformer oil from Apar/Savita from Silvasa , Steel
from SAIL/TATA.

All the in house arrangements are available, right from Copper, Aluminum wire &
strip drawing, annealing & insulation, core cutting, tank fabrication etc.

A separate quality control department is always having a check on these

departments to ensure proper quality of the products manufactured by us.

Today GTB is one of the leading manufacturers of Distribution transformers from

10 KVA. to 5000 KVA up to 33 KV Class, having different voltage ratios.

Being an engineering company that to driven by its customers- where customers

are not only the responsibility of a single sales department but company-wide
undertaking that drives the company’s vision, mission and strategic planning.

Such interdepartmental harmony can only build not customers but partners..

“We just don’t go for customer acquisitions,we build relation.

GTB – where customers are our partners

 Transformer Manufacturing
 1. Transformer Core & Coil Manufacturing
GTB transformer features core form construction. Both our medium and large
power transformers are built with copper windings in a circular configuration
and are continuous disc and/or helical in design. This helps to ensure quality and
reliability throughout the internal structure of the transformer.
2. COIL WINDING
Copper and silver alloyed copper magnet wire—or continuously transposed
copper cable—is used for the winding conductors on all GTB power
transformers. Continuously transposed copper cable is used to minimize losses
and hot-spot temperatures and to produce a more compact winding with
improved short-circuit performance.

All windings are circular, concentric type and provide maximum through-fault
withstand capability. High voltage and low voltage windings use a
continuous-disc or helical winding design. This construction provides
maximum strength and short-circuit withstand capability, increased
predictability and lower hot-spot temperatures for loading and overloading.

Multiple conductor continuous disc and helical windings are transposed

throughout the winding to minimize circulating current losses. State-of-the-art
design techniques are used to provide maximum impulse strength in the
windings and to minimize voltage stresses. Special design consideration is
also given to the line end discs to control voltage stress distribution.

Ampere-Turn balancing techniques are used to minimize radial leakage flux

and to minimize axial short-circuit forces. In order to ensure short circuit
performance, windings are manufactured to meet stringent design tolerances
for coil winding electrical height, tap locations and spread section locations.

Cooling ducts are formed between discs in the continuous-disc and helical
windings by keyed radial spacers made of special high-density pressboard
insulation. These spacers are aligned in column to provide axial support for
the windings and high short-circuit strength.
All windings are manufactured in a clean winding environment. This isolated
“factory within a factory” is humidity and temperature controlled 24 hours a day
with controlled access to minimize contamination.

3. CORE CONSTRUCTION
All GTB transformers employ core form construction. Cores are manufactured from
high permeability-grade, domain-refined “H” grade, cold-rolled grain-oriented
silicon steel (“M” grade steel is used in some applications). Annealing all core steel
after slitting provides optimal loss performance.

Core designs utilize a multiple step circular cross section with fully mitered joints.
Laminations cut to length on special high-speed, computer-controlled, automatic
shears to high dimensional accuracy ensure tight-fitting joints with minimal gaps to
minimize core loss, exciting current and sound levels.

Insulating the core from the frame and connecting to ground at only one point
prevents any accumulation of static charges. Grounding at a single point also
eliminates circulating currents and associated combustible gas generation. The
grounding strap is brought out to a convenient location adjacent to an access hole
opening on the cover or through a bushing on the tank cover to facilitate testing the
core insulation.

After stacking, a two-part epoxy is applied to bind the core legs together, then
banding is installed to form a rigid structure. Sturdy steel end frames provide a
complete core structure of high mechanical strength to withstand heavy
stresses during shipment or under short-circuit conditions without distortion of
the core or windings.
 4. CORE AND COIL ASSEMBLY — PUTTING THEM
TOGETHER
After the cores are banded together and uprighted and the coils have been wound,
processed, pressed and sized, its time to put them together in a process called
“l.anding the coils.” Each limb, or leg, of the core will have 2 to 5 windings landed
on it after which the entire core and coil assembly goes through a thorough cleaning
and careful inspection process before proceeding to a pressing operation that aids
the final assembly of the core.

Once the assembly is under pressure, it is cleaned and inspected again and then put
through a process called top yoking, where top yoke steel is assembled to the limbs
within very close tolerances to ensure no core loss issues on the test floor. Upon
completing the top yoking, the unit is “pulled in.” This “pulling in” procedure
includes tightening the core clamps onto the steel, tightening up the yoke bands and
adding all the extra insulation required in the design. Precise, pre-calculated
methods of clamping the core and coil assembly together assure a positive clamping
pressure on the coils at every point and provide maximum through-fault protection
no matter how dry the transformer may become while in service.

Pre-assembled cleat and lead structures (wood frames with the insulated cable and,
oftentimes, a de-energized tap changer assembled to them) are now attached to the
assembly. All connections are crimped and wrapped according to engineering
specifications, with each crimp signed by the operator for quality auditing purposes;
special care is taken when wrapping crimps to minimize dielectric stresses. Once all
connections are made, the assembly is ratioed and tested again, inspected and then
released to Vapor Phase.
  Transformer Manufacturing Process - Vapor Phase
The two primary motivators in efficient dry out of cellulose insulation are
temperature and vacuum. SPX Transformer Solutions’ vapor phase dry out
technology optimizes both of these, making it one of the most efficient methods to
deplete power transformer internals of degrading moisture.

Our systems are designed to optimize heat transfer, insulation stress and process
time. The excellent heat distribution and higher operating temperatures of the vapor
phase process are vital factors in its ability to maximize paper-oil dielectric
properties. Higher operating temperatures are possible as the entire process is done
under an oxygen-depleted atmosphere, thereby not accelerating aging of the
insulation.
FINAL DRY OUT — VAPOR PHASE PROCESSING
Final dry out begins by loading the entire core and coil assembly into one of SPX
Transformer Solutions vapor phase vacuum chambers. The cycle begins by
evacuating the chamber to a low pressure, removing the majority of oxygen from
the atmosphere. At this point, solvent vapor is introduced which begins to condense
on the core and coil. As this vapor condenses, it transfers its latent heat which
results in a consistent and even heating of the transformer internal assembly. Once
process temperatures have stabilized, the system begins its high vacuum cycles,
further reducing the pressure below 0.5 torr. Moisture removal begins during the
heating cycles and progresses through the remaining vacuum cycles.

Flooding the vapor chamber with processed transformer oil begins the process of
impregnating the insulation materials. After a minimum impregnation hold, all oil is
drained and the core and coil assembly removed for final adjustments prior to
encasement in its tank. For large power units, the core and coil assembly bypasses
oil impregnation in the vapor chamber. The core and coil are removed and placed in
a low humidity environment to minimize moisture ingress.

After a thorough final inspection, the assembly is immediately tanked and covered
with transformer oil to inhibit moisture absorption. The oil is again drained and the
transformer placed on high vacuum to remove any surface moisture. Vacuum-filling
the transformer with hot processed transformer oil for its final impregnation
follows, and, after appropriate “sit time”, electrical testing begins.

Many advantages exist by using a vapor phase process in the manufacture of power
transformers:
Heating of insulation materials under vacuum — Reduced oxygen levels minimize
oxidation and thermal aging of cellulose materials resulting in less loss of life than
can be achieved in rapid oven drying or radiation processes.
Excellent heating characteristics of the vapor condensation process — Heat is
transferred to all parts of the core and coil assembly uniformly, quickly and more
efficiently than can be achieved with hot air or radiation processes, which further
reduces thermal aging and loss of insulation life over other drying processes.
Excellent cleaning action — Soluble process materials and contaminants are
washed off the core and coil assembly in the vapor phase process which is not
possible without condensing vapors.
  TRANSFORMER MANUFACTURING PROCESS -
TANK FABRICATION & INSULATION
Tank integrity is essential for reliability and long transformer life. To ensure a
perfect fit to the application, SPX Transformer Solutions designs all transformer
tanks to high internal standards and customer specifications.
  GTB TRANSFORMER TANKS ARE DESIGNED WITH
FEATURES TO HELP ENSURE INTEGRITY & LONG
LIFE
Constructed from hot-rolled, low carbon steel plates plasma cut to critical
tolerances then joined via submerged arc welding to ensure against cracked seams
and irregularities
Built with tank wall stiffeners so walls are braced to withstand full vacuum and
pressures 25% greater than achieved during normal operation
Manufactured with bent corners (no corner welds)
Designed with jack pads and lifting hooks for lifting, jacking or pulling
Engineered with guides used to solidly “fit” and brace the completed core and coil
assembly inside the tank to prevent shifting during shipment
Produced with slightly domed covers to help prevent water accumulation
Constructed with raised flanges and machined gasket grooves in cover openings
Fabricated with conveniently located hand holes and/or manholes for easy access to
the lower end of bushings, terminal boards and the upper portion of core and coil
assembly
Additionally, SPX Transformer Solutions’ standard coating system exceeds the
requirements of ANSI C57.12.28, the specification for pad-mounted equipment:
TRANSFORMER INSULATING FLUIDS
SPX Transformer Solutions typically uses inhibited mineral oil in its transformers
which is refined especially for use in transformers in accordance with ANSI/ASTM
D3487. In addition to extensive testing by an independent laboratory to determine
approved sources of supply, SPX Transformer Solutions performs acceptance tests
on each shipment of oil received.

All mineral oil is received in dedicated tank cars and trucks. Samples are taken from
the cars before placing the oil in bulk containment units. New oil is then vacuum
degassified and stored for use. We reprocess oil again at each point of use
throughout the plant. All oil used in GTB transformers is PCB-free per EPA
definition 7-179.

Although mineral oil is the most common insulating fluid used at both plants, we
have built and shipped a number of units with natural ester fluid for special projects
and conditions.
  FINAL ASSEMBLY
Final Assembly begins with the removal of the core and coil assembly from vapor
phase. All internal assemblies are re-pressed to an engineering-specified pressure to
ensure tightness now that excess moisture has been removed. Metal and fiber nuts
are tightened or torqued as required and electrical clearances verified again.

Core and coil assembly is placed inside its tank, tank is filled with oil to stop
exposure to air, a cover assembly added and bushing connections made. Once the
cover is welded and leak checked, galvanized radiators are assembled to the tank,
the unit is drained and the transformer is vacuum filled for final testing. During this
same time, the control box and any other customer-specified monitors and
components are installed and wired. All external welded assemblies are mounted to
ensure correct fit to the tank and removed before the finished transformer moves on
for factory acceptance testing.
  TAP CHANGERS
The purpose of a tap changer is to regulate the output voltage of a transformer by
altering the number of turns in one winding and thereby changing the turns ratio of
the transformer. There are two types of tap changers: a de-energized tap changer
(DETC) and an on-load tap changer (LTC). GTB transformer designs can
accommodate both/either types of tap changers to meet customer specifications.
  DE-ENERGIZED NO-LOAD TAP CHANGERS (DETC)
SPX Transformer Solutions’ de-energized tap changers are designed to last with no
maintenance under normal operating conditions. The tap changer, a manually
operated device, includes an external operating handle with a clearly marked
position-indicating dial. Provisions are made for padlocking in each tap position
and for the addition of key interlocks.

A Geneva drive is typically used to move the contacts to the correct position and
also lock them in place for operation. Other benefits of the modular DETC include:

No coking on contacts
Allows for reduction in tank size
Ease of operation due to simple design and few moving parts
No need to exercise switch
Easy contact replacement
Moveable copper contacts fitted with multi-contact bands
Location flexibility within transformer
Ample ampacity and BIL
Meets IEEE PC57.131 and IEC 60214-1 test requirements
VACUUM ON-LOAD TAP CHANGERS
GTB transformers can be designed with either arcing-in-oil or vacuum tap
changers, as specified by the customer.
  TESTING TO ANSI, IEEE & NEMA STANDARDS
Prior to shipment, highly trained factory experts using accurate state-of-the-art
equipment conduct testing on all Waukesha® transformers in accordance with the
latest ANSI, IEEE and/or NEMA standards. Our test system is verified for
conformance with the requirements

ROUTINE TESTS PERFORMED

ON ALL TRANSFORMERS
• Ratio and Polarity
• Power Factor
• Winding Resistance
• No-Load Loss and Excitation Current
• Load Loss and Impedance
 INFRASTRUCTURE
Coil Assembly comprise of
advanced 3 EOT cranes. 3 baking
furnaces, several micro-controllers
to have better precision and high
sensitive sensors for temperature
and time control. Furnaces are
operated by diesel, electricity and
LPG. This facility enable products
to be totally dry, moisture free
which is then proceeded to the
tanking up section. Ensuring high
product reliability and
performance in the field.

Annealing Line

Core Slitting Facility

Diesel
Oven
Winding Section Crane
  TYPES OF TRANSFORMERS

1. Distribution Transformers

RANGE OF TRANSFORMER
5 KVA – 5000 KVA (6.6 KV , 11 KV , 22 KV, 33 KV)
The winding have a compact size,excellent heat transmission, low load loss,
high lighting impulse resistivity and outstanding anti-short-circuit strength.
APPLICATIONS

● Isolated houses
● Rural distribution
● Farmyards
● Pumping stations
 2. Distribution Transformers with OLTC

RANGE OF TRANSFORMER
UPTO 3500 KVA
On load tap changer (OLTC) is used with higher capacity transformers
where HT side voltage variation is frequent and a nearly constant LT voltage
is required. OLTC is coupled with the transformer itself. Multiple tapings
from HV windings are brought to the OLTC chamber and connected to fixed
contacts. Moving contacts rotates with the help of rotating mechanism
usually a Geneva mechanism having a spindle.
Applications

● Chemical plant, Bottling plant.

● Paper mills, Sugar mills, Rolling mills, Steel mills.
● Industries which rely heavily on automation, where electronic cards,
PLC and VFDs are used in operations and actuation.
 3. Dry Type Transformers (VPI)

Range upto 2500KVA.

Application
Dry type transformers are widely used in indoor situations where oil leakage
could cause a fire or significant environment hazard. For example in places
such as schools, institutions, mails hotels, malls and commercial buildings
where reliability and safety are mandatory. Relative ease in maintenance of
the transformers explains why GTB dry type transformer is often the choice
of the customer.

4. Servo Voltage Stabilizers

Range 30-2500 KVA.
Inspite of the best efforts by all the state electricity boards across the
country , the voltage received at the end user is never constant. This erratic
power supply is the main cause of breakdown of electrical equipment.
Voltage varies in a fashion that generally it is low during day time and high
during night hours. Moreover on the holidays, peak hours, rainy days and
when agriculture load is switched off, the voltage rises sharply which is
more dangerous. In India all the electrical equipment are rated at 400 / 415
Volts three phase and 220 / 230 Volts single phase

5. Special Purpose Transformers

Isolation Transformers Furnace Transformers

Range includes Induction Furnace Transformer, Isolation/Ultra Isolation
Transformer.
IsolationIsolation transformers like ultra isolation transformers, power
isolation transformers, super isolation transformers, which protect the
Isolating sensitive equipment from Line Voltage transients, spikes & D.C
Leakage etc. These ultra isolation transformers are specially designed for
 sensitive critical equipment like industrial, computers & peripherals, medical
instrumentation, digital communication telemetry systems, CNC Machines
etc. and stopping such disturbances generated by the noisy equipment load
from being injected into the power line.
Furnace transformers are widely used in steel plants, aluminum industries ,
gas factories, calcium carbide and various other industries.

6. Compact Substation

GTB Compact Substation is tailor made unit built to meet customer’s

specific demand.
GTB’s Compact Substation is used for feeding power form high voltage to
low voltage in open cast mines, construction sites, metro cities etc
Design Combinations
HT COMPARTMENT

▪ Ring Main Unit

▪ Vacuum Circuit Breaker
▪ Load Break Switches
TRANSFORMER COMPARMENT

▪ Oil Cooled Transformer or Cast

▪ VPI dry Type
▪ Low Losses Design
▪ Tap Changer
LT COMPARTMENT

▪ Air circuit breaker

▪ Molded case circuit breaker
▪ Fuse units
▪ Fuses
CONCLUSION
During the period of my training, I have learnt the
process and various techniques involved with the help machine
infrastructure for making different types of Transformers here
I have learnt a lot about the team work required to manage such
big industry.
Making of Transformers and then testing it for better quality.