BHAILALBHAI & BHIKHABHAI INSTITUTE OF TECHNOLOGY,

VALLABH VIDYANAGAR - 388120

Three Week Industrial Training
GAIN REPORT
Name of Faculty: JIGAR MAHESHBHAI PATEL
Designation & Department: Lecturer, Electronics & Communication Engineering
Industrial Training Conducted by: Atlanta Electricals Pvt. Ltd., V. U. Nagar – 388121.
Period of Industrial Training: 17 / 06 /2024 to 06 / 07 / 2024
Subject / Area of Teaching Relevance: Fundamentals of Electrical Engineering, Electronics
Workshop.

Gain Details:
About Company:

AEPL, incorporated in the year 1983, has consolidated its position in the power generation
and transformer industries as a leading manufacturer and transformer exporter. They
manufacture a wide range of Power, Distribution & Special application transformers which
conform to the quality expectations of both domestic and international markets.

Their top-notch infrastructure is instrumental in delivering world-class quality and timely

delivery. Their facility is spread over a total land area of 26,000 square metres and a built-up
area of 20,000 square metres. They can manufacture 21,000 MVA transformers per annum,
up to & including 200 MVA, 220 kV class power transformers.

The Vision of the Company is “To become market leader for power, distribution and special
application transformers for Indian and as well as global market, known for its quality,
technology, ethical behavior and healthy business relationship. To be the preferred and
trusted partner for long term association”.

The Mission of the company is “We are dedicated to offer trust, reliability, quality and
transparency and have made it our mission to create value for all stake holders through -
‘Quality & Delivery at the right time each and every time’”.

They have infrastructure like Core Assembly, Winding, Core Coil Assembly & Connection,
Drying, Tanking, Final Fitting, Testing & Dispatch.

In last 35 years, they have grown by leaps & bounce to 500 Crores. They have established
market leadership and have presence in all most all states of India and catering to global
market too. They have been able to cross the 50,000-mark transformers.

In Special Purpose, they have clients like Alfanar, Saudi Arabia, Bilecik Demir Celik,
Turkiye, Central Power Research Institute, National Test House, R. L. Steels & Energy Ltd,
SRJ Peety Steels Pvt. Ltd., UL India Pvt. Ltd., Viraj Profiles Pvt. Ltd., GE Power Systems
India Pvt. Ltd.

In Renewables, they have clients like Adani Green Energy Ltd., Aditya Birla Renewables
Energy Ltd., Alfanar Power Services Pvt. Ltd., Amp Energy Pvt. Ltd., Amplus Rj Solar Pvt.
Ltd., CGE Hybrid Energy Pvt. Ltd., Enrich Energy Pvt. Ltd., Four Square Green Energy LLP
Inox Wind Ltd., Larsen & Toubro Ltd., O2 Power Pvt. Ltd., Prozeal Infra Engineering Pvt.
Ltd., Refex Energy Ltd., Siemens Gamesa Renewable Power Pvt. Ltd., SITAC Kabini
Renewables Pvt. Ltd., Sun Drops Energia Pvt. Ltd., Sunedison Infrastructure Ltd., Suzlon
Energy Ltd., Tata Power Solar Systems Ltd., Vikram Solar Ltd., Voith Hydro Pvt. Ltd.,
Waaree Energies Ltd.

At Atlanta Electricals, they emphasize on conscientious Corporate Citizenship and strongly

follow the concept of CSR. Hence, they have tied-up with Government Women ITI, Anand in
form of a public-private partnership agreement.

They are certified as ISO 9001, 14001 & 45001 company since 2002. They also have 4 test
labs that are NABL accredited for testing of transformers as per IS, IEC and specifications as
per customer requirements

Products:
They are manufacturing different products like Power Transformer, Furnace Transformers,
Inverter Duty Transformer (IDT), Green Transformer, Testing Transformer and Special
Application Transformer.

1. Power Transformer:
They manufacture a comprehensive suite of transformers (230 kV class) from small (5 MVA)
to large (200 MVA) ratings. All their transformers are equipped with protective devices and
tested for all routine/type tests conforming to IS-2026, IEC-60076 and all applicable
international standards. Suited for high voltage power transfer applications, their transformers
can be used in power generation stations and transmission substations. All their transformers
deliver optimum performance and quality with advanced design and testing capabilities.

Auto Transformers are single windings that serve both as primary windings as well as
secondary windings. They are used in power applications to interconnect systems operating at
different voltage classes.

Generator Transformers are the largest in a power station and connect the generator output
to the grid. They are also used to limit the fault level of the generator in case of a fault.

2. Furnace Transformer:
Several industries and manufacturing units have arc furnace, ladle furnace and induction
furnace for which they need a highly dependable furnace transformer to supply power. They
have designed and supplied various types of furnace transformers up to 24 pulses with
multiple windings, up to and including 50 MVA, 66 kV Class. Their heavy-duty range of
transformers is tested to work under rigorous conditions and can overcome any fluctuations
in currents and voltages.

3. Inverter Duty Transformer (IDT):

They are used to transfer electrical energy without changing the frequency and are mostly
suitable for solar and wind applications. They are specialized, high-efficiency transformers
with robust construction, high overload capability, reduced noise and vibration levels,
designed for applications like solar power plants, wind farms, VFDs and renewable energy
systems. Their Solar transformers are designed to deliver optimum performance and are
tested under all conditions.

4. Green Transformer:
Green Power Transformers offer a new alternative for customers who want to preserve the
environment by providing a lower carbon footprint, reduced pollution risk and optimized life
cycle costs due to less maintenance. Other advantages include reduced ageing, lower noise
levels and increased fire safety.

Their Ester Oil Transformers are substitutes for conventional petroleum-based oil. Plants
such as soya, sunflower and rapeseed are the sources of natural ester oil, which serves as a
substitute for mineral oil.

5. Testing Transformer:
Transformers are some of the most important and expensive equipment for operating a power
supply system. This is why it has to go through rigorous testing before usage. One such form
of testing is short-circuit testing which is done to examine the mechanical strength of the
transformer windings and their ability to withstand high forces during a short-circuit fault.
They are the Indian manufacturer who has supplied testing transformers to CPRI (Central
Power Research Institute) and UL (Underwriters Laboratories), which are used in their test
labs for testing short circuit capability of switchgear and transformers.

6. Special Application Transformer:

They take challenge in designing & manufacturing any special application for high altitude,
sub-zero climatic conditions, up to 36 pulse, environment friendly with special bushing etc.

Procedure to manufacture the transformer:

In first stage, they are doing different tendering also they are doing bargaining with other
tenders. After that process the Purchase orders are generated by the marketing department. As
per the requirement and specification of client, there job number is created and it is sent to the
design department.
In Second stage, the job sent to the design department which is further divided in to two
division. One is mechanical department and other is electrical department.

Figure 1 shows the different components of the transformer. There are to parts: Active
components and passive components. The core coil windings are the active components
which are place in to the Main tank of the transformer which is called passive components.
There are also different parts which are assembled after the made of the transformer.

Figure: 1 Components of Transformer

The both divisions mechanical and electrical are parallelly design the structure of
transformer. The active components are designed by the electrical division and the passive
components are designed by the mechanical division. For design of the structure of
transformers, there are so many software are available but they are using AutoCAD software
for designing of the transformers.

After completion of design of the transformer, it is shared with the client for the approval of
the design. There is a log book in which they are communicating the changes as per both side
company and client. Once the approval is done, the manufacturing starts.

The parts like core and coil windings are made by Core and Coil winding section. Then the
core coil winding and connections are done at Core Coil winding Assembly & Connection
Section.
Making of Transformer is shown as below in stepwise:
Core Assembly:
Categorically virgin, prime grade electrical steel is utilized for the assembly of cores. Their
facility is well equipped to assemble 80MT of electrical steel at 8 stations per day per shift.
Step lap method is adopted for the core assemblies ensuring minimum stray and streamlining
of the magnetic flux paths.

Winding:
One of the largest transformer coil winding facilities in the country. With 34 machines
capable of producing 30MT of insulated copper conductors per day. Coil winding sections
are temperature controlled and maintained under positive air pressure to curb dust.
Thoroughly trained and amply experienced team of winders can accomplish disc, helical,
interleaved, layered, counter shield type of winding, be it parallel conductors or continuously
transposed conductors.

Core Coil Assembly & Connection:

12 assembly stations and the finest team, 80MVA per day of core coil assembly is being
throughput. The finest, most modern well maintained and cared tools, equipment and systems
are deployed for the assemblies.

Drying:
Moisture content in the insulating materials of a transformer plays a major role in life of the
transformer. Ovens with auto programmed vapour phase drying technology are deployed for
moisture removal from the insulating materials of the entire core coil assembly. Their ovens
have a capacity of producing 60MVA per day, of fine dried core coil assemblies.

Tanking:
Microprocessor based transformer oil filtration plant that is functional round the clock to
provide shortened delivery time. The plant adequately provides hot, degassed oil to all the 6
stations of final assembly of transformers, be it mineral, natural or synthetic oil used as a
dielectric and cooling media for the transformer.

Final Fitting:
1. Shrinkaging: Dried out core and coil assembly is tightened before application of hot oil
shrinkaging for 24 hours. The oil shrinkaging process avoids looseness of active parts during
its service at site.
2. Pressing: At last uniform pressing is done on Core and Coil Assembly. High mechanical
rigidity is achieved by hydraulic pressing at circulated force and tightening all pressure
screws. Pressed Core & Coil Assembly is put in to the tank with proper locating & locking
arrangements which is of prime importance to achieve high resistivity against transient
damages, vibrations during service and forces developing during fault occurrence.
3. Degassed Oil: After completion of Core & Coil Assembly insertion in tank, hot, degassed
oil is then allowed into the transformed tank under vacuum. This oil is then circulated
through the transformer and the oil degassing plant until all gas trapped in the core, windings,
and the insulation is removed. This ensures a high degree of stability in the insulation
structure and early attainment of its mature condition, which would not otherwise be achieved
until the transformer had been in service for some time.
4. Gasket: The transformer is made ready for testing after assembly of bushings,
conservators, radiators and all other protective devices. All the joints are gasketed to avoid
leakage with the help of rubberized cork sheets / Nitrite Rubberized O-Ring, which can
withstand high oil temperature and do not deteriorate nor contaminate oil in its contact.

Testing:
Engineering resource planning software
ERP system enables superior coordination with all internal departments from marketing to
dispatch and after sales services, finance & HR to meet customer quality and delivery needs.
Allows management to focus, moderate and neutralise any internal and customer related
issues.

Dispatch:
Main body of transformer is covered by polyethylene sheets. Seaworthy packing is done for
other loose accessories required to be shipped along with the transformer. Many transformers
are dispatched with VCI packing, to suit climatic conditions of ultimate customer’s
destination. They take care of balancing of the weight while loading the transformer on
transport vehicle. Proper welding is done on the base so that there is no scope of vibrations
during transportation irrespective of quality of roads.

With this other main parts also connected like RTCC, AVR and Marshalling Box.

Remote Tap Changer Control Cubicle (RTCC): It is a conventional equipment to control

the output of the Transformer from the OLTC unit fitted in the transformer. The desired
voltage will be achieved accordingly by controlling the OLTC with respect to the tap position
through RTCC system. The output voltage of the transformer will be maintained through an
AVR (Automatic Voltage regulator), which continuously verifies the output power with the
set / programmed reference voltage and will trigger the OLTC accordingly. RTCC panel
controls are same irrespective of OLTC type whether in tank or external mount OLTC.

AVR (Automatic Voltage Regulator): It is an electronic programmable device. With this

AVR we can set the Output Voltage of the transformers. The Output Voltage of the
transformer is fed into the AVR through the LT Panel. The AVR Compares the SET voltage
and the Output Voltage and gives the error signals, if any, to the OLTC through the RTCC
Panel for tap changing. This AVR is mounted in the RTCC.

Marshalling box/ FCC (Fan Control Cubicle): It is a local controlling unit mounted near
the Transformer. All types of transformer protection accessories like winding & oil
temperature indicators and other necessary components are assembled and wired up into this
marshalling box. For remote monitoring of these instruments, their potential free contacts are
wired up to the RTCC panel or the incomer panel through multi core cables.

On Load Tap Changer (OLTC): It is mounted on the transformer. It consists of a motor,

controlled by the RTCC, which changes the Taps in the transformers.
Both the Transformers should have same voltage ratio at all the taps and when you run
transformers in parallel, it should operate as same tap position. If we have OLTC with RTCC
panel, one RTCC should work as master and other should work as follower to maintain same
tap positions of transformer.

Date: Signature of Faculty