REPORT ON GTU

SUMMER INTERNSHIP 2022

NAME OF COMPANY:
NEEKI ELECTRICAL

PREPARED BY:

PARMAR DARSHIT RAVJIBHAI

(219890309006)

(KRISHNA INSTITUTE OF ENGINEERING AND

TECHNOLOGY, JAMNAGAR)

SEM.: 3RD (BRANCH: ELETRICAL)

Internship Starting Date:-17/09/2022

Internship Ending Date:-01/10/2022

1
 INDEX
No Title Page
No
1 Transformer 4
2 Oil BDV Test 13
3 Analyzer 17
4 HV Winding Machin 20
5 Transformer Winding Machin 23
6 High Voltage Transformer 27

TRANSFORMER

Working principle
 Physical basis of a transformer is mutual Induction between
two circuits linked by a common magnetic flux.
 If one coil is connected to a source of alternating voltage, an
alternating flux is set up in the laminated core, most of which is
linked with the other coils in which it produces mutually
induced emf.
 A transformer is a static device which is used to step up or step
down volateges at constant frequency
 It consists of two coile, that are electrically isolated but
magnetically linked
 The primary coil is connected to the power sourece and the
secondary coil is connected to the load
 Voltage is stepped up or stepped down proportional to turns
ratio
The turns ratio is the ratio between the number of turns on the
secondary [Ns] to the number of turns on the primary [Np]
Type of transformers according to
voltage
1. Step-up Transformer
2. Step-down Transformer

1. Step-up Transformer

A Step-up Transformer is a transformer that increases the

voltage from the primary coil to the secondary coil while
managing the same power at the rated frequency in both
coils.
It converts low voltage and high current from the primery side
to the high voltage and high current on the secondary side of the
tranceformer
 2. Step-down Transformer

A Step-down Transformer is a transformer that convert a

high voltage at primery windings to a low voltage at the
secondary windings. in terms of the coil windings , a step-
down transformers primary winding has more turns than the
secondary winding.

Transformer Classification
 Based on construction
Core type
Shell type
Berry type
 Based on application
Power transformer
Distribution transformer
 Based on cooling
Oil filled self cooled
Oil blast type

Losses in a transformer
 No load losses or core losses
 Load losses or copper losses
 NO LOAD LOSSES

 No load losses remains the same irrespective of the load

connected to the transformer.
 It is the power consumed to sustain the magnetic field in the
transformers core.
 It is of two types-hysteresis loss and eddy current loss.
 Hysteresis loss is the energy lost by reversing the
magnetizing field in the core as the AC changes direction in
every cycle.
 Eddy current loss is a result of induced current circulating in
the core.
 Hysteresis loss is minimized by using steel of high silicon
content for the core.
 Eddy current loss is minimized by using very thin
laminations polished with varnish.

No load loss = IL( Va / Vr ) ²

 Load losses
 It is associated with load current flow in the
transformer windings.

 Copper loss is power lost in the primary and

secondary windings of a transformer due to the
ohmic resistance of the winding.
Type of transformer according to K V A
 5KVA Transformer
 10 KVA Transformer
 25KVA Transformer
 63KVA Transformer
 100KVA Transformer
 200KVA Transformer
 Transformer connection
 Star-star
 Delta-Delta
 Delta-Star
 Star-Delta

Transformer picture
 OIL BDVTEST
Output Voltage:0-80KV/100KV
Voltage distortion rate:<3%
Booster capacity:1.5KVA
Measuring accuracy:+-3%
Supply valtage:AC230V,
50Hz
Power consumption:200W
Temperature: 0℃～45℃

SEAFTY RATING IEC 61010-1-2010 EMC 2014/EU CE CERTIFIED

INTERFACE USB 2.0 , USB 3.0 for Data Storage, Inbuilt Printer
  Overview

Many power systems, railway systems, large-

scale petrochemical plants and enterprises have
a lot of electrical equipment whose internal
insulation are mostly oil-filled insulation type,
and therefore, test on insulating oil dielectric
strength is common and necessary. To meet the
needs of the market, we have developed and
produced a series of insulating oil dielectric
strength testers according to national standard
GB/T507-2002, industry standard DL429.9-91
and the latest Electric Power Industry Standard
DL/T846.7-2004 by ourselves. This instrument,
by using a single-chip microcomputer as the
core, can operate in full automation with high
accuracy, greatly improving work efficiency and
reducing the labor intensity of workers.
Moreover, it is small in size and convenient to
carry.
  Key Features

1. With a microprocessor, automatically fulfill the withstand

voltage test for oil circulation with a range of 0～80KV /
100 KV (including boosting, maintaining, mixing, standing,
calculation, printing and other operations).
2. Display by large-screen LCD and prompt by English menu.
3. Simple operation .the machine will automatically complete
the withstand voltage test on one cup of sample oil after by
the operator .breakdown voltage value of 1 to 9 times and
recurrent times will be automatically saved . after the test
the thermal printer will print each breakdown voltage value
and average value.
4. Power-down preservation. It can save 100 tested results.
5. Adopt a single-chip microcomputer to boost the voltage at
an even speed. The voltage is accurate at 50HZ, ensuring
the whole process easy for control.
6. Equipped with over-voltage, over-over-current and limit
protections to ensure the safety of operators.
7. With the function of displaying the measured temperature
and system clock. Communicate with computer with a
standard RS232 interface. （Optional）
 Analyzer

MODEL NAME:- DPATT-3Bi

 The DPATT-3Bi instrument is indigenously designed and developed by

UMA Electronics to make the testing of stabilizers transformer ,motors and
other Electrical machines simpler, faster, accurate and reliable with its high
performing DSP based circuitry and user friendly operational features The
high speed simultaneous sampling of all the channels using 24-bit ADC
ensures true RMS measurement of the wide range of input voltage & input
current, this instrument displays voltage, current, frequency, Active power
And power factor, both phase wise and Total/Average, The measurement is
valid at all power factors and gives accurate result even in the presence of
harmonics in the system.

 It has two displays, one is Blue moon display for simultaneous display of the
related parameters and another is seven segment display for long distance
view. the keys on the front panel provide navigation of different parameters
as well as range selection and hold facility. The functionally of the meter is
further enhanced with PC interfacing facility through USB port. The
accompanying software is capable of Data logging, set point Alarm, and
viewing the meter variables in real time on computer using the GUI
provided. The Data can be saved in SD memory card which can have 10,000
test result.
MODEL:-DPATT-3Bi

 Parameters voltage(V)-V1,V2,V3&AVg voltage

 Current(A):I1,I2,I3&AVg current
 System Frequency: Hz
 Active Power (W): W1,W2,W3& Total waltage
 Power factor(cos):PF1,PF2,PF3& System
 Apparent Power(VA): Total
 Measurement :True RMS
 Phase Current : 50mA-80A AC
 System Frequency :40 to 70 Hz
 For Power Factor :0.05 Lead to unity to 0.05 Lag

MODEL: DPATT-3Bi

Ideal for transformer testing, motor testing, analyzing energy consumption

of buildings. Current range : 100mA to 80 A with selector switch.
FEATURES

 Input Voltage: 30 to 600V

 Available in Current ranges: 5A,10A,20A,80A & 200A With inbuilt
CT.
 Accurate over 0.1% to 100% of full-scale current
 Power Factor : Works in wide range of power factor , from 0.05 lag
to 0.05 lead Accuracy Class 0.20 accuracy
 Display:20*4 bright blue moon display
 HV WINDING MACHINE
DESCRIPTION
 The Smart Winder HV machine is designed & equipped to produce High Voltage Coils
for the Distribution Transformers. This machine is built to automate certain critical
processes during winding process & to feed inter layer full-width paper in sulation for
the coils with minimum interventions by the operator.
 A high performance multi-axes motion controller governs the motion of the spindle and
traverse driven by asynchronous and synchronous servo motors respectively.
 Closed loop tension control with AC servo motor and dancer feedback delivers superior
and consistent tension of con ductorduring winding. The inter-layer insulation paper is
fed at precise tension with the help of Pneumatic Caliper Braking System.
 PLC Based control system enhances the productivity by precisely controlling the motion
of both spindle and traverse and eliminates any operator intervention during winding,
making it best suited for high volume production.
 FEATURES

 Closed loop servo tension control with dancer feedback mechanism for
conductor.
 Air shaft mounted inter layer paper insulation feeders with constant tension
control & tailstock support.
 Paper edge cutting arrangement for the full width insulation paper and edge
fill paper feeder.
 Precise pneumatically operated tension control for the end fill tape.
 Adjustable Wire guide unit close to winding.
 High performance PLC based control along with color touch-screen user
interface.
 TECFNICAL SPECIFICATONS
Particulars Model : Hv 400 Model : Hv Model : Hv Model : Hv
600 800 1200
Coil
Length 400mm(max) 700mm(max) 900mm(max) 1300mm(max)
winding 400mm(max) 500mm(max) 700mm(max) 800mm(max)
Swing Diameter 450mm(max) 600mm(max) 800mm(max) 1000mm(max)
Weight(Lv+hv) 50Kg(max) 250Kg(max) 500Kg(max) 800Kg(max)
Conductor
No. of round 1 1 or 2 1 or 2 1 or 2
conductor
Round of Wire 0.3 – 2.0 mm 0.5 – 2.5 mm 0.8 – 3.5 mm 1.2 – 4.0 mm
Diameter (CU)
Round of Wire 0.5 – 2.5 mm 0.8 – 3.0 mm 1.0 – 4.0 mm 1.5 – 4.5 mm
Diameter (Al)
Dual wire Size N/A N/A 2 x3.0 mm 2 x3.5 mm (max)
(Cu/Al)

No. Strip N/A 1 1 or 2 1 or 2

Conductors
Strip Wire Size N/A 4 x2 TO 12 x 3 4 x 2 to 15 x 4 4 x 2 to 15 x 5
(cu/Al) mm mm mm

Double Strip N/A N/A 75 100Sq.mm(max)

Sizes(Cu/Al) Sq.mm(max)
 Transformer Winding Machin
DESCRIPTION
 The machine is designed and equipped to produce high and low voltage coils
for power transformers. This machine is built to automate the winding
process using either strip or round conductors & to carry out layer
insulation / end filling of the coils with minimal intervention from the
operator’s part.
 A high performance multi-axes motion controller governs the motion of the
spindle & traverse units driven by AC Induction &Servo motors
respectively.
 Tail stock can move forward and backward, fitted with a linear rack &
pinion arrangement driven by AC motor.
 Equipped with two synchronous wire guides, it is possible to work on two
totally independent coils at the same time, thus cons iderably reducing the
time of manufacturing of the transfor
 FEATURES

 Cylindrical/ rectangular winding

 End filling arrangement
 Programmable controls
 Motor is ed tail stock (with geared brake motor)
 Motorized de-coiler for strips/ foils

De-Reeler Carriage
 Technical Specifications

 Winding Diameter : 800 mm (Max)

 Winding Width : 1000 mm (Max)
 Coil Weight : 1500 Kg s (Max) including mandrel
 Centre Height : 900 mm (from ground level)
 Tail Stock : Motorise d adjustment with geared brake
motor
 No. of Spindles : One
 Spindle Speed : 0 -160 RPM
 Spindle Torque : 1200 Nm (Max)
 Spindle Drive : AC Motor with Helical reduction
gear box& brake. Closed loop vector drive with
encoder feedback.
 Air Supply : 5 Bar
 Power supply : 20 kW, 415 V AC, 3 Phase, 50Hz.
 Floor Area (W x L x H) : 2700 x 4500 x 2800 mm
(Without de-reeler)
 Machine Weight : 10000 Kg s (Approx)
 Control System : High performance multi axes
motion control &modular servo drives

Round Conductors each of:

 Wire Size : Round - Ø 1.5 - 4 mm

 Rectangular - 3 x 1 mm to 12 x 5 mm
 CTC - 6 x 4 mm to 15 x 15 mm
 Conductor Spools : Weight - 600 Kg s (Max)
 OD - 650 mm (Max)
 ID - 75 mm
 Width - 650 mm (Max)
 Conductor Tension : 320 N (Max) control by AC servo
motor
 Conductor De-reeler : Common stand for 6 spools
mounted on rails with motorise d movement to track
wire guide axis
 Conductor Guides : 2 sets driven by independent servo
motor
 End Fill Guides : 2 sets driven by independent servo
motor
 Insulation : Simple holder for 2 Spools (W/o Brake)
 Weight : 200 Kg s
 OD : 540 mm (Max)
 ID : 75 mm
 Width : 1100 mm.

High Voltage Transformer

 High voltage transformers convert voltages from

one level or phase configuration to another,
usually from higher to lower. They can include
features for electrical isolation, power distribution,
and control and instrumentation applications.