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INTERNSHIP REPORT
Submitted To:
GM Elmetec
Submitted By
Imtiaz
Bsme01113115

Ahmad

Umair
Bsme01113126

Tariq

Khawar
Bsme01113139

Saeed

Muaaz
Bsme01113094

Ali

Haseeb
Bsme01113037

Zahid

Hasan
Bsme01113031

Jan

Irfan
Bsme01113098

Ali

Muhammad
Bsme01113026

Shoaib

Mukhtar

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Internship Department:
Elmetec Transformer

Department of Mechanical
Engineering,
The
University of Lahore, Lahore
TABLE OF CONTENTS
Dedication
..5
Acknowledgement
6
Exclusive
Summary
7
Introduction.
.8
Transformer
..9
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Distribution
Transformer.1
1
Internship
Schadule
.11
Manufacturing
Department..12
QC
Department
..22
PT &
CT
.25

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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.

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Acknowledgemen
t
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.
Words are very few to express enormous humble obligations to
my affectionate Parents for their prayers and strong
determination to enabling us to achieve this job.
we also appreciate the cordial co-operation from all my Internship
Supervisors in the different departments of Elmetec and also of
HR management for providing us requisite information and
knowledge for compilation of our complete Internship.
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.

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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.

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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 thats 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 is also supplying equipment to Pakistan Railways. It represents suppliers of
Locomotives, Wagons and Air Brake Systems.
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

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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.

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Complete Transformer

Active Part of Transformer

Elmetec (Electrical & Mechanical Technologies) Pvt. Ltd. manufactures 11 KV
Distribution Transformers from 10 KVA to 630 KVA as per WAPDA

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specifications and all other capacities up to 5000 KVA. In addition to that, it
also manufactures
medium and low voltage switchgear incorporating
Vacuum Circuit Breakers, Oil Circuit Breakers and Load Break Switches,
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.
Elmetec transformers are available for various applications:

Distribution Transformers (Pole /Pad Mounted)

Pole Mounted Substation
Rated Output (KVA): 10,15,25,50,100,200

Indoor Substation
Rated Output (KVA):250,400,500,630,750 ,1000,1250,1500 2000,2500 upto 5000KVA.

Pad Mounted Distribution Transformer

Rated Output (KVA): Up to 630KVA

Auto Transformers

Start of Internship at Elmetec

On my first day at Elmetec, we were first briefed by the Mr. Mudassir. We
were informed that we will be following a specific plan during our internship.
All the internees were divided into 2 groups. There were around 10 internees
in total. Our group was given the following schedule:

6 to 9 August
Core stacking.

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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.

21 to 23 August
P.T and C.T manufacturing 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:

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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 department
which makes a master production plan (Month wise). This plan is sent to
Material planning section which makes Material requirement plan or Bill of
material according to the master production plan. This plan is sent to the
purchase department which buys material according to this plan. Material is
received in store where quality inspectors from I&QC department check its
quality than this material is sent to manufacturing department where
manufacturing of transformer starts.

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)

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For H.V winding

Type

Enamel copper wire (For 10KVA to 200KVA)

Paper insulated flat copper wire (400KVA and above)
of Insulation Material
Diamond dotted paper (For insulation between layers of
windings)
Press pan sheet (For end collars)
Creep paper pipe (For insulation of terminal of tap changer)
Craft paper (Used for insulation in disc winding)
Thermo ducts
Types of Windings
Disc winding
Packet winding
Layer winding
Foil winding
File and layer winding are used in LV.File, packet and disc winding is
used in HV.Disc and packet winding are easy to repair.
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

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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

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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.

To reduce iron losses

Material should be of good quality.

Limbs should be bur free.

Limbs should be rust free.

Weight of core should be according to Tr. Design

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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.

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Silicon sheet

Slitting of bundles

Cutting

Side limb

Center limb

Yoke limb

Core stacking

Testing

Checking of core

Stock
Process Flow Chart of Core Section

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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;
Core Coil Assembly
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.

Before Connection Test (BCT)

In the BCT area turns ratio of the coil is checked using TTR meter.

H.T, L.T Connections

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.

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After Connection Test (ACT)

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 120o to 130o.
Cover Plate Assembly
In this section H.T, L.T bushings, through bolts, eye bolts connectors, arcing
horns and other parts are inserted in cover plate.
Pre Tanking Section
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 hours.
Oil Filling Section

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In oil filling section oil is filled in the tank under vacuum. Amount of oil to be
filled can be found from bill of quantity (BOQ). For 10kv to 200kv oil filling
chambers are used and for transformers above 200kv oil is filled manually.

Settling Area
After oil filling every transformer is kept for 12 hours in the settling area to
check for oil leakage and oil level.

Supply of coils

Supply of core and upper yoke limbs

Core coil assembly

Before connections test

Furnace

Unloading

Connections

Assembly of cover plate

After connections test

Oil filling

Settling area

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Process Flow Chart of Assembly Section

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

Conservator

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Raw Material
Raw material for tank and other components are

MS sheet (Mild steel sheet)

MSCR sheet (Mild steel cold rolled sheet)

Component Welding
In this area lifting lugs, carrying beams and studs are welded using arc
welding.

Frame Punching and Welding Machine

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.

Bottom Side Plate Welding

In this section bottom and side plates are welded together.

Tank Assembly
Here all the parts of the tank are joint together.

Tank Welding
Tank is welded to stop leakage.

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Inspection and quality Control

Inspection and quality control department ensures; material purchased by
the purchase department is according to the criteria suggested by IEC in
their
recommendations(Incoming),
during
the
manufacturing
of
transformers all the components of transformer are according to transformer
design(in processing),do all the quality tests so that transformer does not
fail in real conditions(Testing). Inspection and quality control department is
further divided into three sections
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.
Tests on Different Materials to Check there Quality

Bird Protection Test

This test is used to check the thickness of paint so that cover plate will
not short. In this test 8kv voltage is applied to the cover plate for 1
minute if cover plate does not stand it for I minute than it is rejected.

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

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over its own diameter for at least 8 to 10 turns and will be checked for
zero cracks.

Heat Shock Test

This test is used to check the quality of enamel on enamel copper
wire. The sample prepared for the mandrill test is placed in electric
oven at temperature 155 Co to 166 Co for hour and again mandrill
test will be performed for test compliance.

Break Down Test

The specimen of wire approximately 600mm is doubled and twisted
for a distance of 125mm.The tension of wire pair while being twisted
and a number of twists will be as per specification (IEC-60317 and BS4516).Enamel is removed from the wire at one pair of ends and test
voltage is applied between the conductors through high port test set
as per specification (IEC-60317). Note the reading where break down
has occurred.

Peel Off Test

This test is applicable to sizes over 1.0mm. A sample of the wire of

about 500mm length is placed in tester consisting of two fixing
devices 500mm apart on the same axis. One of these is able to rotate.
Specific weight is attached on the fix side of device as mentioned in
specification by IEC-60317. By means of a scraper on opposite sides of
wire.
The rotating device is driven at 60 to 100 revolutions per minute. The
number of revolutions of fixing device is calculated from R=175/d.
After applying specified number of revolutions chipping off of the
enamel is checked. Zero chipping off is required to qualify for enamel
copper wire.

Iron Loss Test

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 hour and then iron losses are found. If 1.5 Tesla are
applied in tester than losses should not exceed .89 Tesla.

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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.
Oil Tests to Check its Quality
There are seven tests done in oil testing lab to check the quality of oil.
If the oil fails in one of these tests than it is rejected not used in
transformers. Seven tests are
I.
II.
III.
IV.
V.
VI.
VII.

Visual Inspection
Specific Gravity
Viscosity
Flash Point
Dielectric Strength
Acidity Value
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
I.
II.
III.
IV.
V.
VI.
VII.

Transformer Turns Ratio Test (TTR Test)

Winding Resistance Test
Insulation Resistance Test (Meager Test)
Induced Voltage Test
High Voltage Test (Separate source voltage)
No Load Losses (Open circuit test)
On Load Losses (Short circuit test)

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VIII.

Dielectric Tests

Type Tests
Tests which are done on samples taken from a whole lot are called type tests.
Tests included in type tests are
Impulse Voltage With-Stand Test
Temprature Rise Test
Short Circuit Test

INSTRUMENT TRANSFORMERS

Voltage Transformers (MV)

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.

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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.
VOLTAGE TRANSFORMERS MEASURING
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
Reliable operation under ambient temperature of -20 C to + 55 C.

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- Capable of withstanding short time thermal and dynamic stresses.
- Capable of withstanding impulse voltage up to 110 kV.
- Voltage transformer has been designed so that it can be installed in any MV
panel.
- LV terminal can be sealed.
- 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.

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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
ampere turns to be btransformedbinto the secondary ampere-turns. This
introduces an error
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.
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Basic Features
- Reliable operation under ambient temperature of -20 C to + 55 C.
- Capable of withstanding short time thermal and dynamic stresses.
- Capable of withstanding impulse voltage up to 110 kV.
- Current transformer has been designed so that it can be installed in any MV
panel.
- LV terminal can be sealed.
- 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 CTs with assigned Ratings.
- All material and components used in the manufacturing of CTs are subject
to
strict receiving inspection.
- Guarantee of the performance of medium voltage CTs are according to
rating
plate data.
Construction
Elmetec produces custom made CTs according to WAPDA, IEC, BSS, ANSI or
any other Local/International Standard specifications.

Current Trannsformer (LV)

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.
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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.
Application
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
- Reliable operation under ambient temperature of - 20 C to +55 C
- Capable of withstanding short time thermal and dynamic stresses.
- LV terminal can be sealed.
- Can either be mounted direct on the bus-bars or any other locations
with the help of mounting feet supplied loose.
- 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 CTs with rating assigned.
- All material and component used in the manufacturing of CTs are
subject to strict receiving inspection.
- Accuracy tests have been performed at Research & Test Laboratory,
Rawat.
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- Test certificates are provided on request.

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