This document summarizes Mohammad Aabid Dar's industrial internship project on manufacturing transformers at Alba Manufacturing. It discusses the internship's major fields including single and three phase transformers, servo stabilizers, and control panels. For transformers, it describes core components, principles of operation, autotransformers, and wye and delta connections for three phase transformers. Servo stabilizers and their main components' functioning are also outlined. Finally, it provides details on the structure and electrical components of control panels, including enclosures, back panels, main circuit breakers, and PLCs.

1. ALBA MANUFACTURING OF
TRANSFORMERS.
A MAJOR PROJECT OF INDUSTRAIL TRAINING.
SUBMITTED TO DEPARTMENT OF ELECTRICAL
ENGG.

2. BHARGAVA COLLEGE OF ENGG AND
TECHNOLOGY
• SUBMITTED BY: MOHAMMAD AABID DAR
• ROLL NO :181402008
• SEMESTER:8TH
• UNIVERSITY OF JAMMU

3. CONFIRMATION LETTER

4. ACKNOWLEDGEMENT
• I wish to acknowledge the untiring,
dedicated efforts of the task force, under the
leadership of MR ZAMEER , in
scanning the contents of this Reference
Manual through a series of iterations and
bringing it to its present shapeI also grasp an idea of
state-of-the-art technology and MANUFACTURING OF
TRANSFORMERS. I am also grateful to each of my chief
instructor MR. SHARIQ who provided me every help
and removed my doubts about the SAME.
• NAME MOHAMMAD AABID DAR

5. TOPICS
• SYNOPSIS OF INDUSTRIAL INTERNSHIP
• MAJOR FIELDS OF MY INTERNSHIP.
• 1.SINGLE AND THREE PHASE
TRANSFORMERS
• 2. SERVO STABLIZERS
• 3. CONTROL PANELS

6. TRANSFORMERS
• INTRODUCTION: A transformer has no internal moving parts, and it transfers energy from one
circuit to another by electromagnetic induction. External cooling may include heat exchangers,
radiators, fans, and oil pumps. Radiators and fans are evident in figure 1. The large horizontal tank
at the top is a conservator. Transformers are typically used because a change in voltage is needed.
Power transformers are defined as transformers rated 500 kVA and larger. Larger transformers are
oil-filled for insulation and cooling; a typical GSU transformer may contain several thousand gallons
of oil. One must always be aware of the possibility of spills, leaks, fires, and environmental risks this
oil poses. Transformers smaller than 500 kVA are generally called distribution transformers. Pole-
top and small, pad-mounted transformers that serve residences and small businesses are typically
distribution transformers. Generator step-up transformers, used in Reclamation powerplants,
receive electrical energy at generator voltage and increase it to a higher voltage for transmission
lines.
• Conversely, a step-down transformer receives energy at a higher voltage and delivers it at a lower
voltage for distribution to various loads. All electrical devices using coils (in this case, transformers)
are constant wattage devices. This means voltage multiplied by current must remain constant;
therefore, when voltage is “stepped-up,”

7. SINGLE PHASE TRANSFORMER

8. TRANSFORMERS
• the current is “stepped-down” (and vice versa).
Transformers transfer electrical energy between circuits
completely insulated from each other. This makes it
possible to use very high (stepped-up) voltages for
transmission lines, resulting in a lower (stepped-down)
current. Higher voltage and lower current reduce the
required size and cost of transmission lines and reduce
transmission losses as well. Transformers have made
possible economic delivery of electric power over long
distances. Transformers do not require as much attention
as most other equipment; however, the care and
maintenance they do require is absolutely critical. Because
of their reliability, maintenance is sometimes ignored,
causing reduced service life and, at times, outright failure.

9. CORE

10. PRINCIPLE OF OPERATION
• 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. See figure 2 which shows internal construction of one phase. 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 highvoltage and low-voltage windings around each leg. Special
paper and wood are used for insulation and internal structural support.
•

11. AUTOTRANSFORMERS
•
• It is possible to obtain transformer action by means of a single coil,
provided that there is a “tap connection” somewhere along the winding.
Transformers having only one winding are called autotransformers, shown
schematically in figure 9.
• An autotransformer has the usual magnetic core but only one winding,
which is common to both the primary and secondary circuits. The primary
is always the portion of the winding connected to the
• AC power source. This transformer may be used to step voltage up or
down. If the primary is the total winding and is connected to a supply, and
the secondary circuit is connected across only a portion of the winding (as
shown), the secondary voltage is
• Stepped down
•

12. 3 PHASE TRANSFORMERS DIAGRAM

13. 3 PHASED TRANSFORMERS
• A three-phase transformer is made of three sets of primary and secondary
windings, each set wound around one leg of an iron core assembly.
Essentially it looks like three single-phase transformers sharing a joined
core.
•
• Three-Phase Transformer Connections.
• Three-phase power is attainable with one three-phase transformer, which
is constructed with three single-phase units enclosed in the same tank or
three separate single-phase transformers. The methods of connecting
windings are the same, whether using the one three-phase transformer or
three separate single-phase transformers.
•
• 2.20 Wye and Delta Connections
• The two common methods of connecting three-phase generators, motors,
and transformers are IN FIG .

14. 3 PHASED TRANSFORMERS
• The method shown in at figure 17a is known as a delta connection,
because the diagram bears a close resemblance to the Greek letter,
called delta.
• The other method, figure 17b, is known as the star or wye
connection. The wye differs from the delta connection in that it has
two phases in series. The common point “O” of the three windings
is called the neutral because equal voltages exist between this point
and any of the three phases. When windings are connected wye,
the voltage between any two lines will be 1.732 times the phase
voltage, and the line current will be the same as the phase current.
When transformers are connected delta, the line current will be
1.732 times the phase current, and the voltage between any two
will be the same as that of the phase voltage.
•

15. 3 PHASE TRANSFORMERS

16. Y CONNECTION

17. SERVO STABLIZER
• A Servo Stabilizer is a Servo motor controlled stabilization system that
performs optimum voltage supply using a BuckBoost transformer booster
that captures voltage fluctuations from input and regulates current to the
correct output. An AC synchronous motor adjusts voltage in clockwise or
anticlockwise direction and manages the output voltage with components
like control card, dimmer, comparator, transistors, mocs, etc.
• Main Components & their Functioning
• There are seven main components in a servo voltage stabilizer:-
• 1. Dimmer (Variable Transformer)
• 2. Carbon Brush
• 3. Servomotor – Synchronizing Motors
• 4. Buck Boost Transformer (Series Transformer)
• 5. Contactor or Relay
• 6. MCB, MCCB

18. SINGLE LINE DIAGRAM
• CONTROL PANELS:
• In its simplest terms, an electrical control panel is a
combination of electrical devices which use electrical
power to control the various mechanical functions of
industrial equipment or machinery. An electrical control
panel includes two main categories: panel structure and
electrical components.
•
• PANEL STRUCTURE OF ELECTRICAL CONTROL PANELS
• The structure of an electrical control panel is a combination
of an enclosure and a back panel, similar to a breaker box
in a home or office

19. ENCLOSUERE
• The enclosure is a metal box which varies in size and is typically
made of aluminium or stainless steel. The number of doors (usually
one or two) needed on the enclosure determines its size in most
industrial applications. The enclosure will come with a UL safety
rating (508A is typical) an IP rating, and/or a NEMA classification.
These listings help users determine properties such as:
• Indoor/outdoor use
• Waterproof/water resistance
• Dust/solid contaminants proofing
• Hazardous conditions rating
• Explosion-proof rating
• These various classifications should be printed on a metal plate and
attached to the enclosure for easy identification and reference.

20. BACK PANELS
• A back panel is a metal sheet mounted inside the enclosure that provides
structural support for DIN rail mounting and wiring ducts. DIN metal rails feature
standardized dimensions and provide a mounting structure for electrical devices.
Wiring ducts provide for the routing and organization of wires while also assisting
in the control of electrical noise between devices inside the box.
• ELECTRICAL CONTROL PANEL ELECTRICAL COMPONENTS
• Eight types of electrical components exist within an electrical panel enclosure
which define and organize the several different functions carried out by the panel.
These components include:
• Main circuit breaker. This is like the disconnect of the main electrical panel leading
into a home or office. Main circuit breakers handle between 120V–480V in most
industrial applications.
• Surge arresters. This component prevents lightning strikes or utility power surges
from damaging the electrical components inside the panel due to overvoltage

21. PARTS
• Transformers. Depending on the incoming voltage,
transformers may reduce voltage to 120V for various
components or stepdown voltage to 24V in instances where
incoming power is 120V.
• Terminal blocks. These blocks help to organize and
distribute the array of wires coming from various sources to
different electrical devices.
• Programmable Logic Controller (PLC). This is essentially a
CPU contained inside the control panel. This unit is the
brains of the control panel, providing monitoring and
control of the various mechanical processes. In will include
various inputs and outputs to and from mechanized
functions of the production equipment.

22. PARTS
• Relays and contactors. These on/off switches control
mechanized functions based on commands from the PLC.
Smaller relays control functions like lights and fans. Larger
relays, called contacts, control more advanced functions
like motors.
• Network switches. The communication hub of the control
panel, network switches facilitate communication between
the PLC and the various network compatible devices on the
production line.
• Human Machine Interface (HMI). These components allow
an operator to monitor or control certain functions of the
machinery. Common HMIs include video monitors,
joysticks, buttons, switches, and keyboards

23. During the internship period the panel
on which I worked was low voltage
control panel whose fabrication and
single line diagram are as follows
• THANKYOU