A REPORT ON INDUSTRIAL SUMMER TRAINING (IST) AT TBEA ENERGY (INDIA) PVT LTD INTRODUCTION 09 2 LAYOUT OF TBEA ENERGY PVT. LTD. 10 3 BASICS OF TRANSFORMER 11 4 INFORMATION FLOW DIAGRAM 12 5 INFORMATION OF STORE 13 6 EQUIPMENT’S AND TOOLS ARE USED IN TBEA 17 7 CORE ASSEMBLY 18 8 TRANSFORMER WINDING 21 9 LEAD ASSEMBLY 26 10 FINAL ASSEMBLY 28 11 TESTING OF TRANSFORMER 29 12 PACKING PROCEDURE OF TRANSFORMER 30 13 DISPATCH 32 14 CONCLUSION 33

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A
REPORT
ON
INDUSTRIAL SUMMER TRAINING (IST)
AT
TBEA ENERGY (INDIA) PVT LTD
Prepared as a part of the requirements for the gained knowledge at TBEA
ENERGY
B. E. Semester – VI
(Branch: ELECTRICAL ENGINEERING)
SUBMITTED BY:
RAVIRAJSINH SOLANKI( 150990109011 )
TO
Ms. RICHA DUBEY Mr. PRAFUL CHUDASAMA
Assistant Professor Head of the DEE
IST coordinator
Department of EE
Academic year 2018-19
Shroff S.R. Rotary Institute of Chemical Technology
Principal Supporter & Sponsor-United Phosphorus Ltd(UPL)/ Shroff family
Managed By Ankleshwar Rotary Education Society
Approved by AICTE, New Delhi, Govt. of Gujarat & GTU Affiliated

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CERTIFICATE
This is to certify that the dissertation entitled “ Industrial Summer Training at
TBEA ” has been carried out by RAVIRAJSINH SOLANKI under the valuable
guidance of human resource team of above industry in fulfilment of the degree of
Bachelor of Engineering in ELECTRICAL ENGINEERING (6th
Sem) of Gujarat
Technological University, Ahmadabad during the academic year 2018-19.
Dr.Anantkumar Desai
In-charge.Wenayak – T&P
Ms. Richa Dubey Mr. Praful Chudasama
Training coordinator Head of the DEE
Assistant Professor
Department of EE

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TBEA ENERGY (INDIA) PVT. LTD.

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ACKNOWLEDGEMENT :
An individual cannot do training of this scale. I take this opportunity to express my
acknowledgement and deep sense of gratitude to the individuals for rendering valuable
assistance and gratitude to me. Their input have played a vital role in success of this
report and formal piece of acknowledgement may not be sufficient to express the
filings of gratitude towards the people who had help me to successfully completion of
my training. I got my vocational training as a analytics in Quality Department I would
like to wish my sincere thanks to my training guide Mr. XITYZ SAGAR
(Department of In process Quality) for his keen interest and giving valuable guidance
at every stage of this training. I take this opportunity to thank all respondents who
spared their precious time to provide with me valuable input for project without which
it would have not been possible. I firmly believe that there is always a scope of
improvement.

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INDEX
Sr. No. Contents Page No.
1 INTRODUCTION 09
2 LAYOUT OF TBEA ENERGY PVT. LTD. 10
3 BASICS OF TRANSFORMER 11
4 INFORMATION FLOW DIAGRAM 12
5 INFORMATION OF STORE 13
6 EQUIPMENT’S AND TOOLS ARE USED IN
TBEA
17
7 CORE ASSEMBLY 18
8 TRANSFORMER WINDING 21
9 LEAD ASSEMBLY 26
10 FINAL ASSEMBLY 28
11 TESTING OF TRANSFORMER 29
12 PACKING PROCEDURE OF TRANSFORMER 30
13 DISPATCH 32
14 CONCLUSION 33

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LIST OF FIGURE
Sr. NO. Figure Name Page No.
1 Layout of TBEA 10
2 Transformer 11
3 Information flow diagram 12
4 Effect and causes 13
5 CRGO 14
6 Tank 14
7 Frame 14
8 OLTC 14
9 Conservative Tank 14
10 PICC 15
11 Breather 15
12 Bushing 15
13 Current transformer 15
14 Press board material 15
15 Fibre Glass material 15
16 Gasket 16

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Sr. NO. Figure Name Page No.
17 Fibre optic temperature sensor 16
18 Air cell 16
19 Radiator 16
20 Core Assembly flowchart 18
21 Stacking of CRGO 19
22 Upending of core table 20
23 Horizontal Winding machines 21
24 Vertical Winding machines 21
25 Types of winding conductor 21
26 Flowchart of winding process 22
27 Winding process 22
28 Shielded conductor 24
29 Winding assembly flowchart 25
30 Process of lead assembly 26
31 Winding placed in core 27
32 Process of final assembly 28
33 Winding & Core placed in the tank 28

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Sr. NO. Figure Name Page No.
34 Testing lab for transformer 29
35 Packing procedure of transformer 30
36 Dispatch of transformer 32
-

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(1) Introduction :-
 TBEA group invested 19.1cr USD in UHV exported job centre of TBEA Energy (India) PVT
LTD. The investment was allowed to the 265000m UHV main workshop and 20 million
KVA (KVAr) annual outputs.
 It is equipped by over 300 sets of machines including the most advanced cut to length line
and hydraulic roll over table.
 With winning section, core active section, final assembly section, UHV testing lab, it is a
fully enclosed air conditioner equipped class we have maintain less than 100000 clean
workshop Which can maintain constant temperature and humidity.
 Capable in the research of+-1000kv and below UHVDC and amp UHVAC jobs, it is one the
most advanced equipped and highest capacity UHV centre in the world.
 Tebian Electric Apparatus (TBEA) is a Chinese manufacturer of power transformers and
other electrical equipment, and a developer of transmission projects. Along with competitors
Tianwei Bambian Electric (TWBB) and the XD Group, it is one of the major Chinese
manufacturers of transformers.
 The company builds transformers and also develops transmission lines as an EPC contractor.
In Ethiopia, TBEA was in 2009 awarded the contract to develop the transmission line to
Addis Ababa for the Gilgal Gibe III Dam. In September 2010 in Zambia, the state power
company ZESCO signed an EPC contract with TBEA to build 334 million USD 330 kV high
voltage transmission lines, which would supply power to Eastern, Luapula, Northern and
Muchinga Provinces. The project held a ground breaking on July 2012.
 The project is to include two transmissions lines: one from Pensulo substation in Serenje to
Kasama via Mpika, another transmission line from Pensulo substation to Chipata via Msoro
and extension of the existing Pensulo substation to accommodate the two transmission line
bays.Outside of China, TBEA is also coming up with a manufacturing base for transformers,
solar equipments& cables in Gujarat, India.
 The Indian division is registered under the name TBEA Energy (India) Pvt. Ltd. and will
cater to India, African, Middle East and other markets. In india the tbea has following types
of products manufacturing. Power Transformer ,Reactor ,Bushing , C.T and also Power
Transmission and transformer testing is also done in TBEA in India.

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(2) Layout of TBEA Energy (India) PVT. LTD.
(fig. 2.1)
DISPATCH AREA
H.V.
TEST
SHALL
STORE
ASSEMBLY
VPD
DT
WORK
SHOP
ASSEMBLY
WORKSHOP
WINDING
WORKSHOP
INSULATION
WORKSHOP
WINDING
VPD
ADMIN

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(3) Basics Of Transformer :-
 Transformer function is based on the principle that electrical energy is transferred efficiently
by magnetic induction from one circuit to another. When one winding of a transformer is
Energized from an alternating current (AC) source, an alternating magnetic field is
established in the transformer core. Alternating magnetic lines of force, called “flux,”
circulate through the core. With a second winding around the same core, a voltage is induced
by the alternating flux lines. A circuit, connected to the terminals of the second winding,
results in current flow.
 Each phase of a transformer is composed of two separate coil windings wound on a common
core. The low-voltage winding is placed nearest the core; the high-voltage winding is then
placed around both the low voltage winding and core. The core is typically made from very
thin steel laminations, each coated with insulation. By insulating between individual
laminations, losses are reduced. The steel core provides a low resistance path for magnetic
flux. Both high- and low-voltage windings Are insulated from the core and from each other,
and leads are brought out through Insulating bushings.
 A three-phase transformer typically has a core with three legs and has both high voltage and
Low - voltage windings around each leg. Special paper and wood are used for insulation and
Internal structural support
(fig. 3.1)

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(4) Information Flow Diagram In General Transformer
Manufacturing Company :-
(fig. 4.1)
CUSTOMER SPECIFICATIONS
I.S. / RELEVANT
STANDARDS
COMPANY
DESIGN DATABASE
DESIGN
PURCHASE DEPARTMENT
STORES
CORE
ASSEMBLY
L.V.
WINDING
H.V.
WINDING
CORE COIL
ASSEMBLY
VPD
CONNECTION L.V. & H.V.
OIL FILLING &
TANKING
TESTING
DISPATCH

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(5) Information Of Store :-
 Quality department
 Most of the industries are depends on the materials, equipment, process and measurement.
 If any causes are produce in materials, equipment, process and measurement Then effect is
produced in Quality.
(fig. 5.1)
 All the materials are used for manufacturing of transformer are come first in Quality
department. This department is checked all the materials and than approved it. This approved
material are stored in Store Room
 Such materials are like CRGO [cold rolled grain oriented], TANK, Current Transformer,
PICC [Paper Insulated Copper Conductor] , Bushing , Different type of Insulation Materials ,
Frame , Oil , Breather , Radiator , Buchholz Relay , Conservative Tank , Air cell , Marking
Plates , Gravity Plates , Gasket , etc.
(1) CRGO [Cold Rolled Grain Oriented] :-
 CRGO is used to making core of transformer. The manufacturing of CRGO is in Japan , US ,
Korea.
 CRGO steel are low carbon, silicon iron alloys with a silicon contents of approximately 3 %
in which low core loss and high permeability in the direction of rolling are achieved by
appropriate metallurgical processing.
Material
Process
Measurement
Equipment
Quality
Causes Effect

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(fig. 5.2)
 The BIS [ Bureau of Indian Standard] number of CRGO is IS:3024.
(2) Tank :- (3) Frame
(fig. 5.3) (fig. 5.4)
(4) Conservative Tank (5) OLTC [On Load Tap Changer]
(fig. 5.5) (fig. 5.6)

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(6) PICC [Paper Insulated Copper Conductor] :- (7) Breather :-
(fig. 5.7) (fig. 5.8)
(8) Bushing :- (9) Press board material :-
(fig. 5.9) (fig. 5.10)
(10) Fibre Glass material :- (11) Current Transformer :-
(fig. 5.11) (fig. 5.12)

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(12) Gasket :- (13) Fibre Optic Temperature Sensor :-
(fig. 5.13) (fig. 5.14)
(14) Air cell :-
(fig. 5.15)
(15) Radiator :-
(fig. 5.16)

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(6) Equipment’s And Tools Are Used In TBEA :-
1. Platform
2. Cranes
3. Crimping Machine
4. Vacuum Cleaner
5. Continuity Tester
6. Player
7. C – Clamps
8. Files
9. Ratchet Belts
10. Gas Brazing Machine
11. Hexagonal Crimping Dies
12. Rounding Disc
13. Electrically Operated Rechargeable Conductor Cutter
14. Vernier Callipers
15. D – Shackles
16. Allan Key
17. Torque Wrench
18. Enamel Remover Container
19. Laser Distance Measuring Ruler
20. Active Part Box Bim
21. Jig Saws
22. Fire Proof Canvas
23. Sand Paper
24. PVA Glue
25. White Cotton Clothes
26. Steel Brush
27. Torch
28. Measure Tap
29. Insulation Resistance Tester
30. Standard Tool Kit
31. Nose Mask
32. Hydraulic Jack
33. Multi Meter
34. Drill Machine
35. Four Jaw Lifting
Etc.…

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(7) Core Assembly :-
(fig. 7.1)
Receive And Study Drawings
Incoming Material Inspection
Surface Of Lamination And Pallet
Laying Of Core Table & Arrangment Of Clamp
Assembly
Stacking Of CRGO Lamination
Clamping Of Core
Core Assembly
Welding Of TIE Rods
Upending Of Core Table
Core Inspection Before Storeg

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 Operation Points Of Core Assembly :
(1) Receive and study drawings
(2) Incoming material inspection
 Check the part during inspection and material acceptance. Check certificates are provided. No
stain or obvious defect shall be found on the surface.
 Insulation pieces should be kept on clean platform and properly covered when stored.
(3) surface of lamination and pallet
 Surfaces of lamination and pallet should be clean and dust free.
 Also it should be checked that the laminations are not damaged
(4) Laying of core table and arrangement of clamp assembly
 Core table should be made ready and supporting structures should be placed below it.
 level of upper surface of supporting structures should be guaranteed and pitch of these
Structures should be less than 350 mm.
 Place part of clamp assembly flitch plate insulation pieces.
 Measure the diagonal length of clamp assembly frame. Maximum acceptable tolerance 2mm.
 Place clamp insulation on the clamp as per drawings.
(5) Stacking of CRGO lamination
 Lamination stacking. Allowable gap between limb and yoke should be less than 1.5 mm.
 Vertical alignment. Outer face acceptable tolerance is 0.5 mm and inner tolerance 0.3 mm.
 Placement and cutting of rubber. Place and rubber m and as per the drawing. Stack 10 mm
lamination on over it. Then cut the extra rubber.
 Inserting the earthing strip. Place one end of the earthing strip between lamination such that
150 mm strip is left outside. It after stacking 2 layers of lamination.
 Place oil duct and measure in such resistance.
(fig. 7.2)

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(6) clamping of core
 Measure total thickness. Core with modular fixture clamping measures total thickness
Tolerance 0 -+ 4.
 Clamp the core with four pressure cylinders. And by clamping tools on all sides. Care for no
damage the clamp.
(7) core assembly
 Install tensile belt, core foot, side beam, top beam etc to core. Bolts should be tights with
required tightening torque
(8) welding of TIE Rods
 Tighten the tie rods at the bottom. Weld the out Wardly projecting end with the bottom plate
such that become one assembly.
(9) upending of core table
 Temporarily bind upper yoke clamp to core table firmly and operate stacking platform
(10) core inspection before storage
 Measure vertical alignment and waviness of core.
 waviness should not be more then 2.0mm for main limb, 3.0mm for return limb
 Measure the insulation resistance of screw and clamp. With 2500v megger measure
insulation resistance from screw to clamp. The value should be larger than 0.5 m
(fig. 7.3)

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(8) Transformer winding :-
Types Of Winding Machines :
 Winding Machines are of two types:
(1) Horizontal Windingmachines
(2) Vertical Windingmachines
(fig. 8.1) (fig. 8.2)
 Types Of Windings:
(1) Spiral Winding(L.V.L.C.)
(2) Helical Winding(L.V.H.C.)
(3) Disc Winding
(4) Interleaved Disc Winding
 Types Of Winding Conductors
 The various types of conductors used in coil winding are
(1) CTC (Continuously Transposed Conductor)
(2) PICC (Paper Insulated Copper Conductor)
(3) BPICC (Bunch Paper Insulated Copper Conductor)
PICC BPICC CTC
(fig. 8.3)

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 PROCESS OF WINDING:
(fig. 8.4)
(fig. 8.5)
Drawing Study
Acceptance of material
mould insullation
conductor drum loading
insullation of cylinder on the mould
winding manufacturing

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 OPERATION POINTS OF WINDING :
(1) Drawing study :-
 Before winding start , collect and learn the winding drawings and sub components drawing.
(2) Acceptance of material :-
(a) Inspection acceptance of insulation paper
 Smooth surface , no damage , no Sharp edges , laminated insulation must not be delaminated.
(b) Inspection acceptance of copper conductor
 Bright and clean surface, no sharp edges , no crack , no scratches , no pin holes , no oil or
metal powder , no enamel damage , no oxide layer over the surface.
 Testing : continuity test
 There must not any short circuit between any conductors
(3) Mould insulation :-
 As per winding select the inner diameter , height and weight
 Cleanliness and no damage
(a) Vertical machine :
 Load the mould directly on the machine and tight all the hardware properly before removing
the lifting equipment
(b) Horizontal machine :
(4) Conductor drum loading :-
(5) Insulation of cylinder on the mould :-
(a) Pasting cylinder visually and measure the dimensions
Cylinder OD (mm) Tolerance (mm)
≤ ∅ 1000 0 - + 2.5
∅ 1001 − ∅ 2000 0 - + 3.0
> ∅ 2000 0 - + 3.5
 Tolerance of OD for 5mm thick cylinder is 0 - + 3.5
(b) Insulation of pasted cylinder over the mould
 Tolerance for height of cylinder is 0 - + 5.0 mm
 Tolerance for distance between two strips is +- 5 mm

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(6) Winding Manufacturing :-
(a) Bottom insulation and static end ring insulation
(b) Winding start
 Winding radial depth shall be controlled with in tolerance of +- 2 mm
 Tolerance for winding lead paper insulation wrapping thickness is 0 -+ 1 mm
(c) Transposition
 Insulate it by 50 % overlap wrapping two layers of micro creep paper
 Minimum distance between edge of transposition wrapping and edge of spacer shall be o – 5
mm
(d) Butt joint
 Similar conductor
 Different conductor
(e) Shield conductor and preparation
(fig. 8.6)
(f) Continuity test for interleaved winding
 Before brazing of inter leaved conductors check the continuity by continuity tester
(g) Spacer alignment
 Check the distance between to radial spacers by measuring tape
(h) Insulation items placement
 Place insulation items
1) Basic spacer
2) Rider block
3) Axial oil duct
Shielding
lead
Semi-conductor
black paper
40 70

25. Page | 25
4) Deflector
5) Angle ring / cap
6) 1mm pressboard strips
 Tolerance between two radial spacers is +- 5 mm
 Total distance between two spacers is 110 mm
(i) Winding top finishing
(j) Visual check and cleaning
(k) Winding unloading
 PROCESS OF WINDING ASSEMBLY :-
(fig. 8.7)
WINDING AND INSULATION PART
INSPECTION
PREPARATION FOR WINDING
ASSEMBLY
INNER WINDING PLACEMENT
PLACEMENT OF INSULATION B/W
WINDING
LOWER THE OUTER WINDING
PLACE WINDING TOP INSULATION
WINDING ASSEMBLY INSPECTION

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(9) Lead assembly :-
 Process of lead assembly
(fig. 9.1)
 OPERATION POINTS OF LEAD ASSEMBLY :
(1) Preparation
 Material check
 Check support
 Check tap changer
(2) Cabling and connection
• Check the position of all the lead terminal of winding.
• Prepare the conductor bunch at the winding exit and bend it as per drawing requirement
(3) Brazing and crimping
 Before crimping & brazing remove enamel coating from winding conductor.
(4) Surface treatment
 To remove sharp edges.
 Clean the joint thoroughly after removing Sharp edge & burrs.
(5) Lead shielding and insulation wrapping
 Do the shielding of the joint with semiconductor paper (carbon paper).
1.Preparation
2. Cabling And
Connection
3.Brazing/ Crimping 4.Surface Treatment
5.Lead Shielding &
Insulation Wrapping
6.Pre Assembly Of
Tap Changer
7.Tap Changer
Connection
Sheilding And
Wrapping
8.Cleaning And
Testing

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(6) Pre assembly of tap changer
 Put active part in the tank.
 Check lead length.
 Measure the lead length.
 Pass the lead from the centre of bushing shield.
 Checking of tap changer position.
(6) Tap changer connection
 Do the proper connection of tap changer as per design.
(7) Cleaning
 Remove the dust particle.
(fig. 9.2)

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(10) Final Assembly :-
(fig. 10.1)
Tank Preparation
Dismantle And Store For Dispatch
Active Part Retightening And Checking
Re - Dry The Job Into VPD
Inside Tank Inspection
Final Assembly
Vacuum Oil Filling
Hot Oil Circulation
Leakage checking And Settling
Testing

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(11) Testing Of Transformer :-
 The following tests are generally performed on the transformer
(1) Routine tests :
 Measurement of winding resistance
 Measurement of voltage ratio, polarity and check of voltage vector relationship
 Measurement of no-load loss and excitation current
 Measurement of short-circuit impedance and load loss
 Measurement of insulation resistance
 Switching impulse voltage with stand test
 Lightning impulse voltage with stand test
 Temperature rise test
 Determination of capacitances and tan delta between winding-to-earth and between windings
(2) Mechanical Tests :
 Vacuum test on transformer tank
 Oil pressure test on completely assembled transformer
(FIG. 11.1)

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(12) Packing Procedure Of Transformer :
 Process flow :-
(FIG. 12.1)
 Main Unit & Trailer Packing Check Sheet Points :
(1) Trailer Details
 Transporter name.
 Details of the trailer.
 Details of driver.
(2) Transport Dimension Of The Tank
 Ensure that the transport dimension is within the limits as per drawing requirements.
(3) Lashing Of The Job To Trailer
 Lashing should be adequate thickness.
 Lashing should not foul with the Transformer tank at any place.
 Locations of lashing should be proper.
 Lashing should be tight.
 Rubber pads should be put below lashing lug.
(4) Final Dispatch Clearance
 All gate points cleared.
 Job cleared for dispatch by quality.
Identify components as per part marking
drawing
Find and check component and accessories
as per loose part list
Labelling of packing box

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(5) Loading Of Other Accessories On Trailer
 Packing list of all accessories loaded on trailer.
 Should be placed properly with rubber pad and wrapped with stretchable plastic cover.
(6) Condition Of Trailer After Loading And To Prior To Movement
 Trailer should be healthy and should not tilt to one side.
 All tyre should be in good condition.
(7) Any Possibility Of Transit Damage
 There should be any sharp and unsupported protections outside the tank
(8) Check Nitrogen/Dry Air
 Nitrogen/dry air pressure should be 5 psi.
 No leak/drop in pressure.
 The pipes should be protected.
 Gauges in working condition.
 Cylinders should be full.
 Cylinders protected and anchored.
(9) Rain Protection Cover On Main Unit(If Applicable)
 Main unit shall be covered with rain protection cover from all sides and cover.
(10) Painting Of Transformer Main Unit And All Blanking Plate
 All temporary blanking plates should be red colour.
(11) The Main Tank Prior To Loading
 Clean and free from dust and air.
 No visible damage to Transformer tank.
 Hardware should be with respective item approved vendor( if applicable).
(12) Loading Of Tank On Trailer
 Ensure that the tank is in centre of trailer with respect to the centre of gravity of job.
(13) Photographs Prior To Dispatch
 Take photographs from all sides.

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(13) Dispatch :
 After successful completion of testing, transformer is handed over to dispatch sections. At
this stage after checking oil leakage, dismantling of all bushings, turrets etc. and covered with
the blanking plates and the tank is fitted with nitrogen gas and then the transformer is
dispatched to the concerned site.
 There are generally three separate shipments made:
(1) The main tank c/w core and coils,
(2) The accessories that have been removed and packaged
(3) The insulating oil.
(fig. 13.1)

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(14) CONCLUSION :
The summer training was an excellent opportunity for me to get to the ground level and
experience the things that we would have never gained through going straight into a job. I am
grateful to the Shroff S. R. Rotary Institute of Chemical Technology for giving me this wonderful
opportunity. The main objective of the industrial training was to provide an opportunity to
undergraduates to identify, observe and practice how engineering is applicable in the real
industry. It is not only to get experience on technical practices but also to observe management
practices and to interact with fellow. Workers. During 21 days training period, a lot of
experience, knowledge and exposure that I have handy the training was more than hope to me
and also help me to understand about manufacturing process of transformer & dispatch process.