Report On Industrial
Training
[03/06/2024 to 12/07/2024]
At
NEW SIDDHI Electrical
Submitted by
MISS. SAKSHI PRAKASH HUNDE- 2200090060
Program
Electrical Engineering
Department of Electrical Engg.
Walchand College Of Engineering, Sangli
Academic Year 2024-25 (semester-V)
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Walchand College Of Engineering, Sangli
An autonomous institute Department of
Electrical engineering, Polytechnic wing
Certificate
This is Certify that, Miss. Sakshi Prakash
Hunde, EnrollmentNo.2200090060 has successfully completed the
Industrial Training (22049) at New Siddhi Electrical for six
weeks from 03/06/2024 to 12/07/2024 for partial fulfilment of
the requirement towards completion of Diploma in Electrical
Engineering of Industrial Training subject, prescribed by Maharashtra
State Board of Technical Education For 5th Semester during the year
2024-2025.
Guide H.O.D. Principle
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Abstract
Training is very important aspect of Engineering as it gives practical
knowledge as well as a brief working structure of the company. This
report is the brief description of my work, learning, and conclusion I
have deduced in my six weeks of training.
Attending an industrial training it was an opportunity to expose actual
industrial process. The training has placed us away from the institute
and routine classes. As such, this valuable opportunity has provided a
real working exposure at actual working-setting in order to equip us as
future employees.
In the span of my six weeks industrial training. I have
undergone various industrial etiquettes like discipline, punctuality,
employee relation, and many more. In this period of industrial
training, we got to know about the control panels from its basics.
We learned about control panel uses, their types, construction,
working, wiring, etc. This report details the work we performed
during the 6 weeks internship training.
Finally, I am thankful to all those who have directly or
indirectly helped as during training.
This industrial training has given us great experience.
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Acknowledgement
The opportunities which we got during this period of 6 weeks at New Siddhi
Electrical had helped us to gain a lot of practical
knowledge regarding traformer helped us improve as a
person and as an electrical engineer.
It has provided a opportunity to be perfect in what we have learnt. To
become professional electrical engineer this knowledge
is going to help a lot.
I hereby extend my sincere gratitude and appreciation to our mentor for
guiding and motivating us with their good advices time
to time throughout this period of 6 weeks of industrial
training.
We would like to thank this industry and specially our industry supervisor
Mr. Mahadev Shinde sir for guiding us and giving us this
opportunity to learn something new and extra,
theoretically and practically both. Also I want to thank
all the supportive staff of this industry who helped us
throughout this period of time.
Besides this training programme has helped us to work together as a team
for better understanding and understanding the value of
the work. We will try our best to use this knowledge in
our future and will try to improve ourselves by being
career objective.
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Index
Sr. No Content Page. No
1. Chapter 1-Introduction to industry 6
2. Chapter 2- What is Transformer 7
3. Chapter 3- Major equipment used in the 9
industry
4. Chapter 4- Manufacturing Process of 13
transformer
5 Chapter 5- Types of transformer 16
6. Chapter 6- Stages of Transformer 17
Manufacturing
5. Chapter 8- Testing and Quality of 18
transformer
6. Chapter 9- Safety and Precautions 24
7. Chapter 10- Practical experiences 26
8. Chapter 11- Challenging experiences 27
9. Conclusion 28
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CHAPTER NO -1 INTRODUCTION TO INDUSTRY
New Siddhi Electrical is a manufacturer and supplier of step
down transformer. It is located at, a/p tal malshiras. The owner of this
industry is Mr. Mahadev Shinde sir, he was our industrial supervisor. It
is a private, small scale manufacturing industry.
It has in total of 12 number of employees.
The industry manufactures and supplies step down transformer for
major industries and consumers. They provide their transformer
commercial or industrials customers.
The industry ensures that customer needs is well fulfilled. They also
ensure
that the product they manufacture is of best quality, having long life
span
with low maintenance, and of proper working. They use quality raw
materials to achieve this.
In this report, we have written about everything we learned in this 6
weeks of industrial training. We will know about the machineries,
components the
industries uses and the panel types they manufacture. We will learn in
detail
about the step down transformer their layout, working, construction,
wiring, etc.
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CHAPTER -2 What is a transformer
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Chapter-3 MAJOR EQUIPMENTS AND
MACHINARIES USED
1. Oil filtration:-
The Transformer Oil Filtration Machine is a maintenance
equipment used for power transformers, switches,
capacitors, etc. It mainly filtrates, dewater and degas the
transformer oil, greatly improve the characteristics of
transformer oil, such as insulating function. After filtration,
the breakdown voltage and dielectric strength of transformer
oil will be greatly improved, meet the requirements of
insulating oil for electrical appliances.
Benefits of transformer oil filtration:-
Insulation properties of the oil is improved
Longer life span of transformers
Lessens transformer’s breakdown
Good returns on investment for having a quality machine
2. Welding machine:-
A welding transformer is a device that is used to convert high voltage, low
current AC power to low voltage, high current AC power. The low voltage,
high current power produced by the transformer is used to generate an arc
between the welding electrode and the metal workpiece, which creates a
heat that melts the metal and forms a weld.
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1. Welding transformer is a step-down transformer.
2. It has a magnetic core with primary winding which is thin and has large number
of
turns on one arm.
3. A secondary winding with a smaller number of turns and high cross-sectional
area
on the other arm.
4. Due to this type of windings in primary and secondary it behaves as step down
transformer. So, we get less voltage and high current from the secondary winding
output. This is the construction of AC welding transformer.
5. A dc welding transformer also has same type of winding the only difference is
that
we connect a rectifier at the secondary to get dc output.
6. Inductor or filter is used to smooth the dc current.
3 Transformer heating oven:-
Transformer heating oven is made up of mild steel which gives
rigidity and toughness. When it is used extensively and
continuosly For transformer heatig it carries out desired task to
perfection. Transformer heating oven provides the kind of
stability and strength that is needed by huge transformers to
function normally. Over a period of time they can get worn out
and their functionality gets damaged due to contact with water
or cold temperature.
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4. Spray painting Machine:-
A Spray paining Machine is used to colour the transformer. Transformer
using an alkyd paint.
5. Multimeter :-
multimeter to measure resistance and touch the probes to the primary and
secondary terminals separately. A functioning transformer should
display a finite resistance value. A reading of infinity suggests an open
circuit, while a reading close to zero indicates a short circuit.
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6. Digital transformer check machine:-
It is used for testing electrical devices like transformer. It is
useful for conduction load and no load test.
7. Welding Machine:-
To get required current of the voltage a welding
transformer is required which converts high voltage
and low Current into a low voltage and high current.
i.e step down transfomer
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Chapter 4- Manufacturing of transformer
Each step in the manufacturing process requires skilled personnel and
adherence to strict quality control measures to ensure the final product
is reliable, safe, and meets the customer’s needs. Manufacturing a
control panel involves following steps-
1. Core
The core is made up of silicon steel to reduce Eddy current loss .
2. Winding
HV winding
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LV winding
3. Bushing
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HV bushing and LV bushing
4. Oil filling in transformer
Transformer oil is poured into it. This is called Naphtenic mineral coil. A type
of petroleum oil is used in the transformer. It does not catch fire quickly and is a
good conductor of heat and a poor conductor of electricity.
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5. Conservator
There is a tank of cylindrical shape which is attached to the upper
part with the body of the transformer.
6. Cooling tubes
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Cooling tubes are used to cool the transformer fans are used in large
transformer because large transformers heat up quickly.
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Chapter 5- Types of Transformer
Types of transformers:
The different types of transformers are given as follows:
1. Power transformer: Power transformers are quite large.
They are appropriate for high voltage power transmission
applications (more than 33 kv). It is found in power plants
and transmission sub-stations. It has a high amount of
insulation.
2. Autotransformers: The primary and the secondary windings
of standard transformers are oriented in opposite directions,
but in autotransformer windings, the primary and secondary
windings are physically and magnetically connected in series.
3. Air-core transformer: The main and secondary windings are
both coiled on a non-magnetic strip, with the flux linkage
between them being through the air. In an air-core type
transformer, however, hysteresis and eddy current losses are
fully eliminated
4. Iron core transformer: The main and secondary windings are
both wound on several iron plate bunches, providing a great
linkage path to the generated flux.
5. Distribution transformer: The main purpose of a distribution
transformer is to lower the voltage for distribution to
commercial and residential consumers.
6. Step-up transformer: The voltage level on the secondary side
is increased by the step-up transformer. By increasing the
number of turns in the secondary winding, the low primary
voltage is increased. The primary winding to secondary
winding ratio is less than 1.
7. 7.Step-down transformer: The voltage level on the
secondary side is reduced in the step-down transformer. By
reducing the number of turns in the secondary winding, the
high primary voltage is decreased to a low secondary
voltage. The primary winding to secondary winding ratio is
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more than 1.
Chapter 6 STAGE OF TRANSFORMER
MANUFACTURING
• Core assembly
• Core coil
assembly
• Tank up process
• Paint process
• Finishing
• Testing of
transformer
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1. CORE ASSEMBLY
• The basic rae material cold rolled grain
oriented(crgo) Silicon steel.
• It is in the form of thin sheet and cut to size as
per design.
• Generally three different shapes of core
laminations are used in one assembly.
• The laminations are put through annealing
process
• The laminations are assembled in such a manner
that there is no air gap between the joints of two
consecutive sheets
• The entire assemly is done on a frame commonly
known as core channel
• These frame being used as Clamping support of
the core assembly
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2. CORE COIL ASSEMBLY
• The core assembly is vertically placed with the foot
plate touching with the ground.The top yoke of the
core is removed. The limbs of the core are tightly
wrapped with the cotton tapeand then varnished
• Cylinder made out of insulating press board/
pressphan paper is wrapped in the three limbs
• Low voltage coil is placed on the insulated core
limbs. Insulating block of specified thickness and
numbers are placed both at the top and bottom of
the L.V coil
• H.V coils are placed over the cylinder
• Gap between each section of H.V coils including
top and bottom clearances is maintained with the
help of coil duct as per the design/drawings
• The top yoke is refilled. Top core frame incluing
core bolts and tie rods are fixed in position
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3. TANK UP PROCESS
• The core coil assembly process taken out of the
oven and the megger test is carried out.
• The tanks supplied by fabrication deptt.are
brought to tank up department duly painted.
• Fittings like drain valves , HV and LV, bushing,
conservator, oil level indicator and explosion vent
are fitted in tanks.
• The core coil assembly is placed into the tank and
propery locked up .
• Pure filtered transformer oil is filled in the tank to
immerse the assembly only
• Connections of primary and secondary to the
terminal bushings are made. operating handle for
ratio switch is fitted wherever required.
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2121
4. Paint process
Cleaning of tanks:-
• The cleaning of tank is normally done
by/chipping or grinding
• The outside surface of the tank is short blasted to
achieve a very fine and smooth finish
Painting of tanks:-
• After cleaning the tanks, a coat of hot oil
resistance paint is applied in the internal surface
of the tank
• The outside surface is painted with a red oxide
primer and subsequently with one coat of
enamel paint as per customes requirement
5. Finishing
• Fittings and accessories as per as customers
specification and drawing are checked
• Transformers are filled with oil upto
minimum level marking , wherever necessary
• Loose accesories like earthing terminals,
bimetallic connectors, dial type themometer
are aslo check for proper fittings
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6. Testing of
transformer
• Measurement of winding
resistance test
• Measurement of insulation
resistance
• Ratio test
• Measurement of no load loss and
no load current
• Oil dielectric
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Chapter-7 Safety and precautions
• Inspect your transformer thoroughly to prevent or
minimize breakdowns. Before installation, monitor your
transformer by checking for any burnt odor, damaged
power cords and connectors or any parts that are
improperly installed.
• Use protective equipment and pay close attention to
specific ratings for the transformer’s voltage output.
Keep over current protection of conductors and circuits
set to the manufacturer’s standards.
• Keep the power off when working on the transformer.
Make sure there is zero electrical leakage or continuity
between the current source and the system
• .Be careful of system overload from a single
transformer, with the understanding that multiple
transformers help balance the impedance of each load.
• Transformer grounding should be in place at all times. It
prevents the accumulation of static charges and
protects the windings from coming in contact with the
core or enclosures.
• Keep spare nuts, bolts and other objects away from
your work so that they don’t touch or fall into the
transformer.
• Always keep your transformer and all of its components
dry and free from any moisture or water. To protect
unskilled onlookers, set up caution signs that warn
people to keep away from danger.
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• If any irregularity or abnormality is observed
in the functioning of the electrical
transformer, it must be shut off, and all the
cables and power cords must be unplugged
before analyzing which part of the
transformer is malfunctioning.
• Any maintenance work must only be
undertaken after the equipment is de-
energized and tagged out and the circuit is
shut down. This is necessary to ensure that
there is no leakage of current or continuity
between the horse current and the system.
• Set up caution signage to prevent unqualified
individuals from performing maintenance on
your transformer.
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Chapter -8 Practical Experiences
Practical experiences in cTransformers manufacturing often involve a
range of challenges and solutions encountered throughout the design,
assembly, testing, and deployment phases. Here are some common
experiences:
Design Phase
1. Requirements Gathering:
-Accurate and detailed specifications are crucial.
-Miscommunication with clients can lead to design changes later, which
can be costly.
2.Component Selection:
- Choosing high-quality components ensures reliability and longevity.
- Balancing cost and performance can be challenging.
3.Panel designing:
- Making precise designs of panel as per the customers’ requirements.
Assembly Phase
1.Wiring and Connections:
- Proper wiring practices are essential to avoid short circuits and ensure
safety.
- Labelling wires and connections clearly helps during troubleshooting
and maintenance.
2.Quality Control:
- Regular inspections during assembly catch errors early.
- Automated testing equipment can speed up the process and improve
accuracy.
Testing Phase
1. Functional Testing:
-Verifying that all functionalities work as intended prevents issues in the
field.
-Real-world testing conditions can uncover problems not seen in
controlled environments.
2. Safety Testing:
-Ensuring compliance with safety standards is non- negotiable.
-Testing emergency stops and interlocks is critical.
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Chapter 9- Challenging Experiences
• Distribution transformer is one of the most critical
equipment deployed in the power distribution network,
used to step down voltage to its application value.
• The growth drivers for distribution transformer market
have been the growing urbanisation, industrialisation and
consumerism, the boost in the renewable and
infrastructure projects and the upgradation and
augmentation of existing distribution network, facilitated
by the government schemes.
• There are basically three major challenges faced in the
distribution transformer trade:-
1. First being the Covidinduced lockdowns. There is an
overall observed contracted demand in the market due
to projects being delayed or cancelled, especially in the
retail sector, leading to an underutilisation of plant
capacities and further delaying return on investments
in the business.
2. The increase in the commodity prices is also denting
the industry since many projects booked at firm prices
are to be executed at a loss but such trends are
generally short lived and the market correction will
follow.
3. Thirdly, in the transformer industry there is a lack of
uniformity as far as guidelines for installation and
maintenance of transformers are concerned. For
instances such as overloading of transformers, theft of
transformer oil during
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transport or from the site leading to
transformer failure, inadequate installed
transformer protection equipment, inadequate
transformer earthing, power theft leading to
overloading of transformers. All these result in
the transformer failure of which cost many a
times have to be borne by the manufacturer
within warranty periods.
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Conclusion
Our Industrial training at New Siddhi Electrical in the Transformer
manufacturing industry has been an invaluable experience, offering a
comprehensive understanding of the various facets involved in the design,
assembly and quality assurance of cTransformers Throughout this
period, I gained practical insights into complexities and challenges faced
by the industry and learned how these are effectively managed through
meticulous planning, robust processes, and continuous improvements.
This training has not only enhanced my technical skills but also developed
my problems solving abilities and understanding of industry standards. I
have observed first-hand the importance of teamwork, communication,
and continuous learning in overcoming the day-to-day challenges of
control panel manufacturing.
I extend my gratitude to the industry, my supervisors, my mentor, and
colleagues for their guidance and support throughout this training. Their
willingness to share knowledge and provide constructive feedback has
been instrumental in my learning journey.
Armed with knowledge and experience gained from this training, I am
confident in my ability to contribute effectively to the field of control
panel manufacturing. I look forward to applying these insights in future
projects and continuing to develop my skills in this dynamic and essential
industry.
In conclusion, my industrial training has been a highly educational and
rewarding experience. It has provided a solid foundation in Transformers
manufacturing and instilled a deeper appreciation for intricacies and
importance of the industry. I am excited to take this experience forward
and make meaningful contributions to the field.
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