this report made by IIuc Student

1. ii
REPORT ON
INDUSTRIAL TRAINING
AT
GENERAL ELECTRIC MANUFACTURING CO. LTD.
(An Organization of Bangladesh Steel and Engineering Corporation)
North Patenga, Chattogram-4204
Department of Electrical and Electronic Engineering
INTERNATIONAL ISLAMIC UNIVERSITY CHITTAGONG
Kumira, Chattogram-4318
JANUARY 9, 2022 to JANUARY 20, 2022

2. ii
CERTIFICATE OF APPROVAL
The report on 10 days of industrial training at General Electric Manufacturing Co.
Ltd., submitted by the following students bearing the mentioned Matric ID. of session
Spring 2018 from the Department of Electrical and Electronic Engineering of
International Islamic University Chittagong, to the General Electric
Manufacturing Co. Ltd., has been accepted as satisfactory in partial fulfilment of the
requirements for the completion of industrial training held on January 9, 2022 to
January 20, 2022 .
Sl. Student Name Matric ID.
01 MD. MUSFIQUR RAHMAN MAZUMDER ET181003
02 ASIFUL ISLAM ET181004
03 MD. ARAFAT BIN ZAFAR ET181005
04 SHEIK ERFAN AHMED HIMU ET181010
05 JOBAER ALAM ET181012
06 MD. ZILLUR RAHMAN ET181013
07 MD TAJBID TARIK ET181020
08 MD FEROZ KHAN FAHIM ET181026
09 SAYED SAHRIAR HASAN ET181028
10 ABDUL WAZED ERFAN ET181032
11 ISTIAQ HOSSAIN CHOWDHURY ET181035
12 S.M.SHIHAB UDDIN ET181036
13 WAKIL HASAN ET181037
14 MD. SAJJAD-UL ISLAM ET181045
15 MAHATAB UDDIN KHAN ET181047
16 MUHAMMAD MOINUL HASAN SAJIB ET181065
17 MD. SIHABUL SAKIB ET181070
18 MD. ENAYET SHAHNEWAZ CHY. ET181071
19 AHNAK TAJWAR KHAN ET181072
20 MD NAZMUL HOSSAIN SHOAIB ET181073
21 ASHFAQUL HAQ ET181075
22 AEER SHAAD ET181081
23 K. M. SAKAWAT HOSSAIN MISKAT ET181085
24 ABDUL ASAD ET193071
Training In-charge
Engr. Md. Masudur Rahman
Engineer (Electrical)
In-charge, CPL &Training
General Electric Manufacturing Co. Ltd

3. iii
ACKNOWLEDGMENT
All praises and thanks to Allah, the Lord of the world, the most Beneficent, the
most Merciful for helping us to accomplish this industrial training.
We would like to thank Engr. Md. Shahid Ullah, Assistant Professor, Dept.
of EEE, IIUC, for arranging this precious industrial training for us to get the practical
experience of an industry.
We also want to express our deepest thanks to Dr. Sikder Sunbeam Islam,
Associate Professor and Chairman, Dept. of EEE, IIUC, for supporting us in getting
this opportunity.
We are grateful to General Electric Manufacturing Co. Ltd. for giving us this
opportunity. We are also grateful to Engr. Md. Masudur Rahman, Engineer
(Electrical), In-charge (CPL & Training), General Electric Manufacturing Co.
Ltd., for guiding us and giving us a wonderful training session. We are also grateful to
Engr. MD Zahid-Al-Mamun, Sub-Assistant Engineer (Electrical), General
Electric Manufacturing Co., Ltd., for managing our activities and training us.
We are beholden to a number of people, who supported us to carry out this
industrial training successfully.

4. iv
TABLE OF CONTENTS
CERTIFICATE OF APPROVAL ii
ACKNOWLEDGEMENT iv
TABLE OF CONTENTS iv
CHAPTER 1 INTRODUCTION 1
1.1 Introduction 1
CHAPTER 2 COMPANY PROFILE 2
2.1 Background 2
2.2 Companies Controlled by BSEC 2
2.3 Installed Capacity of GEMCO 2
2.3.1 Single Phase Transformer 2
2.3.2 Three Phase Transformer 2
CHAPTER 3 TRANSFORMER COMPONENT 3
3.1 Major Parts of a Transformer 3
3.3.1 Non-Active Parts 3
3.3.2 Active Part 3
CHAPTER 4 CENTRAL PLANT LABRATORY 4
4.1 Introduction 4
4.2 Transformer Oil Test 4
4.2.1 Break Down Voltage Test 4
CHAPTER 5 MANUFACTURING OF TRANSFORMER 5
5.1 Manufacturing Process 5
5.2 Mechanical Section 5
5.2.1 Construction Process 5
5.2.2 Welding Leakage Test 6
5.2.3 Painting 6
5.3 Electrical Section 6
5.3.1 Core Assembly 6

5. v
5.3.2 Coil Assembly 7
5.3.2.1 HT Winding 7
5.3.2.1.1 Configuration of Tap Changer 7
5.3.2.2 LT Winding 8
5.3.2.3 Insulation of HT and LT 8
5.3.3 Assembling Coils inside the Core 8
5.3.4 Soldering and Connection 8
5.3.5 Drying Chamber 8
5.3.6 Final Assembly 8
5.3.7 Transformer Test 8
5.3.8 Transformer Maintenance 9
CHAPTER 6 ADMINISTRATION & COMERCIAL
DEPARTMENT
10
6.1 Administration 10
6.2 Organogram 10
6.3 Commercial Department 10
CHAPTER 7 Conclusion 12
6.1 Conclusion 12

6. 1
CHAPTER 1
INTRODUCTION
1.1 Introduction
The Department of Electrical and Electronic Engineering of International Islamic
University Chittagong arranged a 10-day long industrial training for 24 undergraduate
students of 8th
semester at General Electric Manufacturing Co. Ltd. From January 9,
2022 to January 20, 2022 for better technical knowledge enhancement of the students.
Training is especially important in the field of engineering, as the practise of
engineering has an inherent impact on society. These programmes can be a powerful
tool to create a positive industrial climate. Overall, the aim of all this training is to
familiarise the students with the industrial process. After the visit, students can identify
their own efficiency and performance, which is important for their career, improving
work efficiency and confidence.
Industrial training is an integral part of engineering and acknowledgement of
technological upgradation. The purpose of industrial training for students is to provide
technical knowledge about technological development in the industry and to understand
the gap between the theoretical and practical knowledge that could be applied in the
future. This experience can help students provide information regarding the functioning
of various industries and associated problems and limitations.
Industrial training also provides insight into how businesses operate, as well as useful
information about the practical aspects of the course that cannot be visualised in
lectures. With the aim of going beyond academics, this training is arranged to develop
the insights of the students—acquiring practical knowledge and theoretic applications
thereof.
Industrial training enables the students to apply their classroom learning to a real-life
situation while being mentored by a variety of industry experts.

7. 2
CHAPTER 2
COMPANY PROFILE
2.1 Background
General Electric Manufacturing Company Limited one of the leading transformer
manufacturing companies in Bangladesh, established in 1972 by the Government of
Bangladesh. The feasibility study was done in 1965 by the help of UK. It was built with
the technical assistance of M/s. Promash Export, a company from the Soviet Union, to
manufacture electric equipment like power transformers, distribution transformer and
was completed in 1978. It was transformed into a limited company in 1979. It owns the
largest transformer factory in Bangladesh. It started commercial production in 1980. It
is a 100% government-owned company controlled by Bangladesh Steel and
Engineering Corporation.
2.2 Companies Controlled by BSEC
At present there are 9 companies which are controlled by BSEC under the Ministry of
Industries.
Sl. Company Name Location
01 Bangladesh Blade Factory Limited (BBFL) Dhaka
02 Eastern Cables Limited (ECL) Chattogram
03 Eastern Tubes Limited (ETL) Dhaka
04 Gazi Wires Limited (GWL) Chattogram
05 General Electric Manufacturing Company Limited (GEMCO) Chattogram
06 National Tubes Limited (NTL) Dhaka
07 Atlas Bangladesh Limited (ABL) Dhaka
08 Pragoti Industries Limited (PIL) Chattogram
09 Dhaka Steel Work Limited. (DSWL) Dhaka
2.3 Installed Capacity of GEMCO
The installed capacity of GEMCO was from 5KVA to 5MVA. GEMCO used to
produce both single-phase and three-phase transformers. The whole manufacturing
process is based on Russian technology.
2.3.1 Single Phase Transformer
In the single phase transformer category, GEMCO manufactured stack core type
transformers at 5KVA, 10KVA, 15KVA, 25KVA, 37.5KVA, 75KVA, 100KVA, and
167 KVA ratings. However, after some time, consumers started using wound core
transformers as they are more efficient than stack core type transformers. But GEMCO
does not manufacture wound-core type transformers. So they discontinued
manufacturing single-phase transformers.
2.3.2 Three Phase Transformer
In the three-phase transformer category, GEMCO manufactured transformers at 50KVA,
100KVA, 200KVA, 250KVA, 315KVA, 630KVA, 750KVA, 1000KVA, 1500KVA,
2000KVA, 3000KVA, and 5000KVA ratings. At present, GEMCO manufactures
transformers based on demand, such as 100KVA, 200KVA, and 250KVA.

8. 3
CHAPTER 3
TRANSFORMER COMPONENT
3.1 Major Parts of a Transformer
Transformer contains active and passive part. The active part contains the core and coil,
while the passive part contains the mechanical components.
3.1.1 Non-Active Parts
The non-active parts of a transformer are the conservator, tank, radiator, temperature
gauge, oil indicator, channel, bushing, tap changer, breather etc.
3.1.2 Active Part
The active parts of the transformer are the core and coil. The core is made of silicon
electrical steel sheet and coil are made of copper.
Figure 3.1: Major Component of a Transformer.
Figure 3.2: Transformer Manufactured by GEMCO

9. 4
CHAPTER 4
CENTRAL PLANT LABRATORY
4.1 Introduction
In the central plant laboratory, the raw materials that are going to be used to
manufacture transformers are examined to maintain quality. Several tests are carried out,
and the results are analysed to determine whether the material met the standard or
requirement. The main material required for manufacturing transformer are mentioned
Sl. Material Sl. Material
01 Silicon Steel Sheet 11 Stoving Red oxide
02 P.l.Copper Strip 12 Oil Resistant Paint
03 Super Enamelled Wire 13 Stoving Enamel Paint
04 Transformer Oil 14 Cotton Tape
05 Insulated Paper Board 15 Tap Changer
06 Insulated paper 16 Silkorol Wood
07 MS Pipe 17 HT Insulator
08 MS Sheet 18 LT Insulator
09 MS Channel 19 Silica Gel
10 Copper Strip 20 MS Screw/Bolt/Nut/Washer
4.2 Transformer Oil Test
GEMCO manufactures oil-natural-air natural cooling transformers. Transformer oil is a
special type of oil which has excellent electrical insulating properties and is stable at
high temperatures. The active part of the transformer is placed inside the tank and filled
with the transformer oil. So the standard of the oil must be maintained. Otherwise, the
transformer may get damaged.
The following tests are performed to measure the quality of oil,
 Break Down Voltage Test (30KV)  Viscosity Test (below 12)
 Density Test (0.8 gm/cm3
-0.82 gm/cm3
)  Flash Point Test ( 140 C+)
4.2.1 Break Down Voltage Test
Breakdown voltage is measured by observing at what voltage, sparking strands between
two electrodes immersed in the oil, separated by a specific gap. A low value of BDV
indicates presence of moisture content and conducting substances in the oil. For
measuring BDV of transformer oil BDV measuring kit is available at CPL. In this kit,
oil is kept in a pot in which one pair of electrodes are fixed with a gap of 2.5 mm
between them Now slowly rising voltage is applied between the electrodes and observe
the voltage at which sparking starts between the electrodes. That means at which
voltage dielectric strength of transformer oil between the electrodes has been broken
down. This measurement is taken 3 to 6 times in the same sample of oil, and we take
the average value of these readings. BDV is an important and popular test of
transformer oil, as it is the primary indicator of the health of oil Minimum breakdown
voltage of transformer oil or dielectric strength of transformer oil at which this oil can
safely be used in transformer, is considered as 30 KV.

10. 5
CHAPTER 5
MANUFACTURING OF TRANSFORMER
5.1 Manufacturing Process
The total manufacturing process is comprised of two sections: the mechanical section
and the electrical section. The mechanical section manufactures the mechanical parts of
a transformer. The Electrical Section manufactures the active parts of the transformer
and assembles the transformer and carries out tests for quality assurance.
Manufacturing
Mechanical Electrical
conservator, tank, radiator,
channel, painting
Core, Coil, Insulation
5.2 Mechanical Section
For manufacturing the mechanical parts of the transformer, GEMCO owned several
machines to make the different required shapes. Three processes are performed in the
mechanical section.
Mechanical Process
Construction
(1) Tank (2) Radiator
(3) Conservator (4)
Chanel
Welding Leakage Test Painting
5.2.1 Construction Process

11. 6
5.2.2 Welding Leakage Test
This test is performed to identify any remaining leakage. As the tank will be filled with
transformer oil, it is necessary to seal every leakage to oppose the oil leakage.
Furthermore, it is necessary to isolate the inner part of the transformer from the outer
environment to make it moisture and dust free.
A test bath is used to detect the leak in the tank and the radiator. The tank is intercepted
with a clamp and then dipped into the water, and compressed air is passed through it. If
any bubbles are observed, it means there is a leakage and the tank will be sent for
welding, otherwise it will be sent for shot blasting.
5.2.3 Painting
Painting of transformer mechanical parts is important to isolate the MS steel from the
environment and protect it from rust.
Before painting, the transformer body is inserted into the shot blasting machine where
small grains of cast iron are shot to remove rust and polish. The painting is done by
following the process. Firstly, a layer of red oxide is painted to ensure no corrosion,
then the outer surface is painted with Enamel paint. The inner surface is painted with
oil-resistant paint as the inner surface will be in direct contact with transformer oil for a
long time. After the painting is done, the body is sent to a heating chamber where it will
be heated for 3 hours at a temperature of 120 C.
5.3 Electrical Section
The electrical section performs the following process:
5.3.1 Core Assembly
The core is made of silicon electrical steel sheet. That steel contains 3%-4% silicon.
The steel is CRGO steel. CRGO is the abbreviation for Cold Rolled Grain Oriented
Steel, which is used in particular to laminate any heavy transformer as a core. The
width of the sheets is 0.27 mm. In these sheets, a 0.95W/Kg loss is generated. For a
100KVA transformer, 210 kg of those sheets are needed. To reduce losses, angle-cut
sheets are used. The core is made by attaching the sheets one by one in an order of
decreasing dimension from mid-plan, which is called a step. For a 100 kVA
Transformer the number of step was 5.

12. 7
5.3.2 Coil Assembly
The core of the transformer is used to provide a controlled path for the magnetic flux
generated in the transformer by the current flowing through the coils, which are also
known as windings. Transformer contains two windings known as HT and LT. The
expected operation of the transformer and the corresponding voltage required on the
secondary winding depends on the turn ratio. The winding is done by the winding
machine. The windings for a 100KVA 11/0.415 KV transformer is discussed here.
5.3.2.1 HT Winding
 SWG 18 copper wire is used for HT windings.
 14 layer each consist of 66 turns.
 After certain Number of turns, a wire is bought out to be connected with the tap
changer which act as voltage regulator.
 2mm insulation cleat between the layers for oil circulation.
 Total weight for single HT 19.6 Kg
5.3.2.1.1 Configuration of Tap Changer
Tap changer is used to regulate the voltage from +2.5% to -7.5%
Figure 5.1: Configuration for tap changer at HT

13. 8
5.3.2.2 LT Winding
 Copper strip 3.15 *8.5.
 2 Layer each consist of 29 turn.
 Cotton tap is used for binding the layers.
 3mm insulation cleat for between each layer for oil circulation.
 Total weight for a single LT is 14 Kg.
5.3.2.3 Insulation of HT and LT
Insulation is provided to avoid direct contact between coil and core, to separate the
layers of coil.
Two type of insulations are provided in the active part.
 Wood insulation
 Paper Insulation.
5.3.3 Assembling Coils inside the Core
Firstly paper insulation is provided around the core. Secondly, LT coil is fitted around
the core and the terminal which were brought out after certain turns are kept isolated.
Thirdly, HT coil made of super Enamel wire are fitted around the core along with LT
Coils. Finally a board insulation and 10mm wood insulation is provided between the
yoke beam and coils in bottom side and 30mm wood insulation on the top side.
5.3.4 Soldering and Connection
In this process the terminal of the coils are configured and soldering is done. The
terminals contains the wire number and depend on these number the whole process is
done.
5.3.5 Drying Chamber
The active part placed inside the drying chamber for 72 hour in 120 C temperature So
that the whole structure become moisture free.
5.3.6 Final Assembly
At that stage, the active part is assembled inside the tank and the top cover of the tank is
fitted, on which the bushing, tap changer casing, and temperature gauge are assembled.
Then the tank is filled with transformer oil.
5.3.7 Transformer Test
The following Routine test are done to measure the quality of a transformer
 Insulation Test
 Power frequency withstand test
 Induce over voltage test
 Ratio Test
 No Load Test
 Full Load Test
 DC Winding Test
 Vector group test

14. 9
5.3.8 Transformer Maintenance
The followings are considered for maintenance of a transformer
 Cooling System
 Dust /moisture free
 Oil level
 Humming and jarking due to load variation.

15. 10
CHAPTER 6
ADMINISTRATION & COMERCIAL DEPARTMENT
6.1 Administration
Administration is the management of the organization. The administration of an
organization includes the management of business operations.
The purpose of administration
 To administrate business operations.
 To implement rules and regulations.
 Decision making.
 Working on company policy.
6.2 Organogram
6.3 Commercial Department
The commercial department deals with marketing and purchase section.
 Marketing
This section handles sales by DPM( Direct Procurement Method). A flowchart of the
working procedure of this section is given below

16. 11
 Purchase
a) Government Process
b) PPR (Public Procurement Regulation (2008) maintained
c) Takes both national and international tender.
d) International tender 42 days.
e) Local tender 28 days.

17. 12
CHAPTER 7
CONCLUSION
7.1 Conclusion
We gathered vast experience in the process of 3 phase distribution transformer
production. We realised that there are some differences between theoretical and
practical knowledge. We also learnt the criteria that we should consider during
designing a transformer, which will help us in the future. We also learned that keeping
a healthy workplace environment and communicating with workers is no less important
than having technical knowledge in large-scale mass production. The majority of the
industry's highly productive machinery is not in operation, which is a sad state of affairs.
The corporation may boost its production efficiency by adopting the right procedures to
operate these machines. In addition, the corporation should hire more trained personnel
since large-scale mass production requires a huge number of skilled workers. This firm
has the potential to become one of the largest transformer manufacturers in our nation if
it makes more stringent administrative choices.