INDUSTRIAL TRAINING AT KERALA ELECTRICAL & ALLIED ENGINEERING.pdf

1. INDUSTRIAL TRAINING AT KERALA ELECTRICAL &
ALLIED ENGINEERING CO.LTD MAAMALA (KOCHI)
• Group Members
1. Harith M M
2. Yadul Vinod
3. Vishnu VK
4. Avirag KP
5. Yadukrishnan VK

2. INTRODUCTION
Conducted5days Industrial training at KEL (Kerala Electrical &Allied Engineering
Co.Ltd)Maamala – Kochi.
The KEL established in 1964 in the Stateof Kerala, India, the Kerala Electrical & Allied
Engineering Co.Ltd. (KEL) is a multifaceted company fully owned by the State government.
Through it’s four productionfacilities, located in various districts of the State, this ISO 9001 :
2000 complaint company provides basic engineering services / productsbesides executing
projects of nationalsignificance for high profile clients like the various defence establishments.
The company manufactures and markets productslike-
• Brushless alternators
• Air conditioningof rail coaches
• Medium power & Distribution transformer

3. KEL owns following divisions locatedin four districts of kerala Train Lighting
AlternatorDivision kundara Unit in Kollam District
▪ Transformer division Mamala unit
▪ Structural Unit Division Mamala Unit in ErnakulamDistrict.
▪ LT Switchgear Division Olavakkode Unit in Palakkad District.
▪ Cast Resin Transformer Division.
▪ EdarikodeUnit in MalappuramDistrict.

4. We organized the training at Transformer Division at Maamala unit.
The division established in 1969 at Mamala, about 15 km from Kochi. This unit was initiated with
technical assistance from Bharat Heavy Electricalsto manufacture distributiontransformers. Now it is
one of the major players in the transformer industry. This unit is one of the first transformer industries in
Kerala to obtain BIS certification for distributiontransformers and first few in India to get 150 0001
certification.

5. Transformer
▪ Transformer is the device that transfers electric energy from one alternating-currentcircuit to
one or more other circuits, either increasing (stepping up) or reducing (steppingdown) the
voltage.
The working principleof transformer is based on Faraday’s Law of MutualInduction or
ElectromagneticInduction, which happensbetween two circuits connectedby a mutual
magnetic flux. Let’s first investigate the mechanism of electromagnetic inductionbefore
moving on to the operationof transformer.

6. MAIN PARTS OF TRANSFORMER

7. ▪ They mainly manufacture stepdown transformers.
▪ They manufacture this with properdesign, size,specification and rating which given by the
customer
Various sections of the Transformer divisions
Winding
Various type of windings are used according to the applications Winding the
conductors wrapped in various forms like helical, disc.
LV Winding – Strip type conductor - spiral type - secondary windings
HV Winding – Wire type conductor – Cross over type – Primary windings
• Material used for conductor winding – Aluminium & Copper

8. ASSEMBLY
• The parts assembling carried out at this section
• The coils are insulated with wrapper board
• Test for checking correctness

9. TERMINALGEAR
Connectionsare of two types
▪ Delta connection
▪ Star connection
In HV side, the three terminals are connected in Delta connection LV side requires neutral.
Hence Star connectionis used
Steps involved in Terminal Gear
1 Cuttingof leads as required
2 Bracing of leads with cable
3 Bracing of busbar
4 Bracing of cables with terminal legs
5 Mountingof tap changers

10. TANKING
The removal of the core and coil assembly from vapour phase is the initial step of assembly begins.
The excess moisture has been removed by an engineering specified pressure to ensure tightness. Metals
and fibres are tightened. Core and coil assembly is placed inside its tank, to stop the exposureto air by
filling hydrocarbonmineral oil in the tank, a cover assembly is added and bushing connectionsmade.
After this the cover is welded and check the leakage and then galvanized radiatorsare assembled to the
tank, for final testing, the unit is drained and the transformer is filled with vacuum
During the tanking, the controlbox and any othercustomer-specified monitors and componentsare
installed and wired. All external welded assemblies are mounted to ensure fit to the tank and before
removed the finished transformer moves on for factory acceptancetesting

12. CONCLUSION
The internship at KEL has enabled to acquire practical knowledge regarding the production of a
transformer. The wholeproduction is divided into various processes like core building, tanking, and testing of
transformer. It also helped to understandvarious aspects of winding and terminal gear assembly.