Industrial training report at kaizen swithgear products in testing department.

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A REPORT ON INDSTRIAL TRAININIG
AT
KAIZEN SWITCHGEAR PRODUCTS
(Waghodiya)
BY STUDENTS OF ITMVU
PUJA PATIL(VAD2016B.TECH-EE3F003)
NAZIYA KHOKHAR(VAD2016B.TECH-EE3F004)
DHAVAL SOLANKI (VAD2016B.TECH-EE3F005)

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INDEX
1.Company Profile……………………...……………………3
2.Abstract…………………………………………………….4
3.Introduction………………………………………………...5
4.Types of switchgear products ……………………………..6
5.Flow chart…………………………………………………..7
6.Electrical testing……………………………………………8
P.D.Test
Helium Test
X-ray Test
7.LTCT introduction………………………………………..13
8.Types of LTCT……………………………………………13
9.Flow chart of LTCT………………………………………14
10.Electrical testing of LTCT………………………………15
11.Conclusion………………………………………………17

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KAIZEN SWITCHGEAR PRODUCTS
Company Profile
Contact details
Kaizen switchgear products.
Address - Plot no-1414,GIDC Industrial Estate,
Waghodiya, Dist-Vadodara-391760
Phone No. 91-2668-262494
Contact Person Mr.Arvind Patel(Managing partner)
Profile details
Business type Exporter/Manufacture
Products
ManufacturingAnd
Exporting
Molded components for medium
voltage switchgear, Transformer
application , resin Cast CT, PT,
control transformers Up to 33kv.

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Abstract
This training at kaizen switchgear and products who wish
to understanding of what involved in testing ,verifying and
certifying switchgear component.there are different type of
testing as per product. main aim to understanding electrical
testing of all switchgear product. In electrical testing high voltage
and partial discharge.
LTCT electrical test only high voltage.

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Introduction
With the overwhelming support from the
domestic market and demand for exports for the group’s
products the management envisioned the prospect for export
market for its products. As a result Kaizen Switchgear Products
a 100% Export Oriented Unit under India laws and regulations
came into existence in 1995 started with Malaysian Switchgear
Market the company progressed in leaps and bounds & today its
Clientele spread through entire globe. Company has been
awarded half a dozen export excellence awards from
Engineering Export Promotion Council for the highest Export
registered in its category.
We have different facility for each of the product
mentioned above located at Waghodiya Vadodara

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Types of Switchgear products

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Flow chart of testing of electrical component.
CASTING
RUNNER CUTTING
FINISHING
THREAD
AIR PRESSURE TEST
X-RAY TEST
HELIUM TEST
ELECTRICAL TEST (HV AND PD TEST)
QC (QUALITY
CHECK)
PACKING

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Electrical testing of switchgear products.
PARTIAL DISCHARGE AND HIGH VOLTAGE TEST
To take action on weak insulations quickly, the failure location must
be known. Upcoming insulation defects already produce measurable
partial discharges (PD). These partial discharges emit electrical
impulses and acoustic signals at the same time.
Then the software determines the failure location using the time
difference of all incoming signals. Making precise partial discharge
measurements is one step closer to determining fault locations.
Depending on the test object and environment, OMICRON offers the
MPD 500 and MPD 600 for these electrical measurements.
Fig- HV&PD Test on bushings.

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Key features
 Efficient because repairs and spare parts are predictable when
failure location is known
 Easy creation of reports and records
 Safe due to galvanic separation of operator from high-voltage
 Convenient and handy through light weight, small size and
battery operation

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X-ray
Industrial radiography is a method of non-destructive testing where
many types of manufactured components can be examined to verify
the internal structure and integrity of the specimen. Industrial
Radiography can be performed utilizing either X-rays or gamma rays.
Both are forms of electromagnetic radiation. The difference between
various forms of electromagnetic energy is related to the wavelength.
X and gamma rays have the shortest wavelength and this property
leads to the ability to penetrate, travel through, and exit various
materials such as carbon steel and other metals.
Fig- X-ray machine
Fig- x ray image
The accuracy of the digital image reduces the subjective nature of an
internal inspection while eliminating the need to handle SF6 gas and
also preventing personnel errors during breaker disassembly and
reassembly.

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Helium test
Helium is the best choice to find leaks because it is non-
toxic, inert, non-condensable, non-flammable, present in the
atmosphere in trace amounts (5 ppm). Due to its small atomic size,
helium passes easily through leaks. The only molecule smaller than
helium is hydrogen which is not inert. Helium is lighter than the next
inert gas neon, which is more expensive. It is also relatively
inexpensive and is available in various size cylinders and also in pure
form easily. There are other leak detection methods but none of them
is as accurate in terms of localization and quantification, as helium
leak detection method.
This application note covers production leak testing of gas
insulated high voltage switchgear and associated subassemblies.
The helium hard vacuum chamber leak test method will give
the best sensitivity, fastest production cycle time as well as improved
capability of locating leaks compared to other methods.
Fig- process of helium test
Procedure of leak detection in the testing chamber or test piece (TP):
There are two main methods to leak test units using helium:
Vacuum Testing (outside-in) and Pressure Testing (Inside-out). The
detection method should be selected based on the working conditions

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of the part to be tested. It is important to maintain the same pressure
conditions during the test as will exist during the actual use of the
part. Vacuum systems should be tested with a vacuum inside the
chamber. A compressed air system should be tested with high
pressure inside the system.
Fig- Graph of air gap

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LTCT (Low tensioncurrent transformer)
A current transformer (CT) is a type of transformer that is used to
measure alternating current (AC). It produces a current in its
secondary which is proportional to the current in its primary. Current
transformers are the current-sensing units of the power system and are
used at generating stations, electrical substations, and in industrial and
commercial electric power distribution.
TYPES OF LTCT
METERING
PROTECTION
SPECTIAL PROTECTION

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Flow chart of LVCT
TESTING (WINDING STAGES)
FINAL POLYESTER
FIBER TAPE/ COTTON TYPE/BLACK PVC TAPE/YELLOW PVC TAPE,
VARNISHING, LABELING &
FINAL TESTING
FINAL QC
BOX PACKING
CORE INSULATION
WINDING & POYESTER BTWEEN
LAYER
LEAD SET & INSULATION
REMOVE
CALBE CUTTING& SOLDERING
FINAL TEST & TERMINATING

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Electrical testing of different LTCT
CT secondary wiring phase and polarity measurements
.Composite error measurements for nominal current . Ratio error and
phase displacement measurement for no load and rated load
.Measurement of excitation characteristics (voltage/current) > Knee
point voltage from 1 V up to 4 kV > Knee point voltage from 0.1 V
up to 40 kV > Automated calculation of knee points according to IEC
and IEEE > Comparison of excitation curve to a reference curve . CT
winding resistance measurement (primary and secondary) . CT
accuracy measurements (ratio error and phase displacement
depending on burden and current)> IEC 61869 / 60044, or IEEE
C57.13 classes ≥ 0.1 .Composite error measurement for overcurrent
conditions (ALF/ALFi, FS/FSi for IEC and Vb for
IEEE).Determination of ALF and FS for IEC or Vb for IEEE
.Secondary burden measurement.
METERING LTCT
Metering current transformers are specified by
(1) Burden and
(2) Accuracy class typically the errors are guaranteed specified
limits. The nature of errors is current (Ratio) error and phase
displacement.
PROTECTION LTCT
These are used in detecting earth faults of very small
magnitude. A three phase cable is passed through these CTs &
the unbalanced currents in the three phases set up a differential
flux giving rise to a current on the secondary side of these CTs
sufficient to actuate a relay

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RESIN CAST
Cast-resin power transformers encase the windings in epoxy
resin. These transformers simplify installation since they are dry,
without cooling oil, and so require no fire-proof vault for indoor
installations. The epoxy protects the windings from dust and corrosive
atmospheres. However, because the molds for casting the coils are
only available in fixed sizes, the design of the transformers is less
flexible, which may make them more costly if customized features
(voltage, turns ratio, taps) are required.

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Conclusion
We conclude that while going through entire industrial training, the
cooperation is found to be very well organized, development & most
ideal industry in every walk of its protection, administration &
management aspect .