REPORT OF INDUSTRIAL TRAINING

INTRODUCTION

We the following students of fifth semester Electrical & Electronics Engineering ,St.Josephs College of Engineering & Technology had our Industrial training at M/s UNIPOWER SYSTEMS Pampady & UNIPOWER TRANSFORMERS Nellad from 26th November 2012 to 1st December 2012

1.ABY TOM MODOOR 2.CHRIS SEBASTIAN DOMINIC 3.JOHNS JOSE 4.JITHIN M JOLLY JOHN 5.NIRMAL CHERIAN 6.NITHIN JOHN 7.SONU JOHNY

During the training period we had the opportunity to study the various functions of the company such as design,construction and testing of diffrent types of transformers,panel boards &unitised substations. The Engineers and Technicians of the company explained in detail the various processes and the training was of immense use for us students of Electrical Engineering.

About the company M/s UNIPOWER Company, a leading manufacturer of transformers and connected equipments has two units situated at Kottayam district and Ernakulam district. The unit situated in Kottayam district is at Kothala near Pampady. This unit named UNIPOWER SYSTEMS is engaged in the manufacture and testing of Oil Cooled Transformers.The Nellad unit M/s Unipower Transformers Pvt Ltd is located in the Kinfra Industries Park Nellad, twenty five km by east of kochi and this unit is manufacturing the Dry type Transformers.The company supplies various types of Transformers to KSEB,commercial buildings and apartments,Hotels,Hospitals,Schools, Cranes,Power plants etc.

TRAINING PROGRAMME Based on our request, we were allowed to do our training programme at the Pampady Unit first.We started our training on 26th November morning. During the 3 days we spent in the Pampady unit,we were given classes and site visit to study the various stages of transformer construction and testing.We started with the core construction procedure.M/s UNIPOWER SYSTEMS uses Cold Rolled Grain Oriented Steel Laminations (CRGO) for the construction of transformer core.The laminations are stacked and coated with carlite to increase the interlamination resistance and to reduce eddy current losses.All cores utilise the step lap principle in the corner joints to reduce losses,magnetising current and sound level.The core is clamped using Structural steel clamps which provide high strength under both static and dynamic mechanical loads. Windings are of circular design with concentric coil placement.This arrangement provides the highest short-circuit strength while providing good cooling of conductor surfaces.Both copper and aluminium conductor can be supplied depending upon customer requirements.Generally only copper conductor is used in medium and large MVA design.Conductors are either paper-or Nomex covered magnetic wire or continously transposed cable.Conductors cross sections are chosen to be as large as possible to minimize short-circuit stress, while ensuring that eddy losses in the conductors are kept under control.Low voltage (LV) Winding is placed adjacent to the core and the High voltage(HV) Winding over the LV winding.Winding types are selected by the design engineer depending upon the specific application.Strip,barrel,layer,helical,disc,shielded, and interleaved disc types are all available to the designer,depending on the voltage and current requirements of the design.Oil flow through the windings is directed in a zigzag

pattern to ensure cooling of all conductor surfaces and to limit the hot spot temperature. Careful attention is paid to ensure an even distribution of oil to all sections of all windings. All major INSULATION is manufactured from Nomex insulation material, fully oil impregnable to eliminate internal partial discharge from voids. Care is taken in the manufacturing of the insulation components to ensure that all critical surfaces have an adequate supply of oil during impregnation and service in order to limit partial discharges.Insulation can be provided using standard paper,upgraded paper or Nomex. In the case of CORE AND COIL ASSEMBLY ,the individual windings are assembled one over the other to form the entire phase assembly.The radial gaps between the windings are subdivided by means of solid transformer board barriers. Stress rings and angle rings are placed on top and bottom of the windings to achieve a contoured and insulation design for optimal control of the oil gaps and creepage stresses. The complete phase assemblies are then carefully lowered over the separate core legs and solidly packed towards the core to assure optimal short- circuit capability.The top core yoke is then repacked and the complete core and coil assembly is clamped. The company is also manufacturing transformers with ON LOAD TAP CHANGING facility. Small capacity transformers are ONAN(OIL NATURAL AIR NATURAL) cooled.Forced cooling is provided for large capacity power Transformers. At present the company is manufacturing mainly ONAN cooled Transformers.

Prior to delivery all Transformers are tested for various parameters. Short circuit (SC) test & Open Circuit (OC) test are conducted at the factory.For short circuit test 28 Volts(V) is applied to the High Voltage (HV) winding & for open circuit test double voltage is applied to the HV winding .Other tests such as loss measurement,interturn resistance tests are also conducted. We had the opportunity to witness and study the various tests conducted at the factory.we had our training at the pampady factory for 3 days. It was really a valuable experience. After the training at the pampady unit we proceeded for the Nellad Unit,M/s UNIPOWER TRANSFORMERS.The factory is situated in KINFRA Park at Nellad in Ernakulam district.In this unit the company design,develop,engineer and manufacture cast resin transformers.The senior engineering team of the company is highly skilled,with decades of experience in design and manufacture. The company has an ongoing programme of quality management,governed by ISO procedures and in house testing systems to check quality starting from raw material to final acceptance test.Company is manufacturing dry type transformers upto 1600 KVA capacity. Cast resin transformers are of high reliability.Low loss compact size copper coils are wound and en capsulated using vaccum casting plant.Coils are assembled on high permiable,low loss CRGO, sillicon steel cores,using necessary clamping systems are in powder coated enclosures. The epoxy resin cast coils exhibits self fire extinguishing performance.It possess very high electrical and mechanical strength.Epoxy coils are assembled in a robust manner enabling to withstand higher electro-mechanical forces occuring during short circuit as well as external impacts.They are moisture proof,compact

size and have high overload capacity. During the 3 days of training at Nellad we had the opportunity to study the manufacturing process and various testings of drytype transformers.

Unitised substations(USS) manufactured by thecompanyare of compact size and convinent for use in residential and commercial buildings.In the USS,primary switching unit is attached to the transformer unit.There are units in which secondary side breaker and outlet feeder switches attached with the unit. These units are manufactured and assembled as per the requirement of consumers. Various protective and control devices can be attached to the unit.Remote tripping facility, over load and earth fault protective tripping arrangements are normally provided for the breakers in the unitised substation.

CONCLUSION

Our Industrial training at M/s UNIPOWER SYSTEMS & UNIPOWER TRANSFORMERS was of immence use and we acquired good knowledge regarding various transformers,their manufacture and testing.We express our gratitude to the management of the company for giving us this great opportunity.We also thank our Head of Department and staff in charge of Electrical Engineering Department for thier valuable support and for giving permission to this programme.