Industrial Training presentation on GEMCO (general electric manufacturing company) that produces transformer & other electrical appliances.

1. ME 370 : INDUSTRIAL TRAINING
Industry
General Electric Manufacturing Company Limited
(GEMCO)
Trainee Students
Md. Abdullah Al Yasin (1110146)
Md. Iftakhar Khan (1210009)
Tanvir Ahmed (1210082)
Rohan Saha (1210144)
Md. Rahatul Asekin (1210145)
Md. Abu Aiub Chisty (1210166)

2. Introduction
• General Electric Manufacturing Company, popularly known as GEMCO,
is the one of the leading distribution transformer manufacturing companies
in Bangladesh.
• As an enterprise of Bangladesh Steel and Engineering Corporation
(BSEC), it was emerged as “Public Limited Company” in 1979 and
renamed to “General Electric Manufacturing Company Limited
(GEMCO)”.
• Located at North Patenga of Chittagong, it was established in 1967 under
supervision and with financial and technical aid from the-then United
States of Soviet Russia (USSR).

3. Industry at a glance:
 Industry Complex Area: 100 acres
 Production of Transformers comprises of Two Units:
- General Production Building ( Mechanical Section)
- Main Building ( Electrical Section)

4. Industry at a glance:
• Production Cost: 53 Crore BDT
• Administrative Cost: 6 Crore BDT
• Distribution Cost: 1.5 Crore BDT
• Research & Development: 3.5 Lakh BDT
• Production Target: 65 Crore BDT
• Sales Target: 70 Crore BDT
 Installed Annual Production Capacity of the Industry : 6923 M. Tons
 Average Monthly Electricity Consumption : 50000 KWH
Approximate Cost in 2016-2017 Fiscal year:
 Attainable Annual Production Capacity: equivalent of 1875 No. of 200
kVA Transformer

5. • GEMCO is now manufacturing and supplying a major portion of Electrical
Distribution equipment required by the power sector of the country.
• Though it was built to manufacture all electric goods required for
Bangladesh, now it only manufacture distribution transformer and drop-out fuse.
Products/Services
i) Transformers:
• Distribution Transformer, 3 Phase, 11/0.415 KV, 50 KVA to 500 KVA
• Distribution Transformer, 1 Phase, 6.35/0.24 KV, 5 KVA to 25 KVA
• Distribution Transformer, 1 Phase, 11/0.24 KV, 15 KVA to 25 KVA
ii) Other Electrical Items:
• Drop out Fuse, 11 KV
• Lightning Arrestor, 11 KV

6. Manufacturing Process
• the construction of “Tank” (transformer body),radiator and conservator
• making of “Core”
• winding of High Tension (HT) and Low Tension (LT) Coil
• Testing (Megger test, Ratio test, No-load test, Full-load test etc..)
• Maintenance
The overall manufacturing process can be divided into two categories:
The total manufacturing process of a distribution transformer can be divided by:

7. The Process Of Shaping Raw Materials
(Cutting, Shearing, Bending Etc.)
Fabrication Of ‘Transformer’ Body
(Known As ‘Tank’) , Radiator & Conservator
Painting Of
Transformer Body
Mechanical Process:

8. Manufacturing Process of Transformer Body:
Mechanical Manufacturing Process can divided into 3 portion:
Mechanical
Manufacturing
Construction of
(i) Transformer body
(ii) Radiator
(iii) Conservator
Leak Testing Painting
Mechanical Process:

9. Construction Process:
Channel
Shear
Machine
Die-punch
Machine
Bottom
Yoke Beam
Mild Steel
Sheet
Plate
Straitening
Machine
Shear
Cutting
Machine
Rolling Conservator
Die-punch
Machine
Tank Wall
Oval Pipe
Mechanical
Press
Welding Corner
Plates
Radiator
Mechanical Process:

10.  Construction of Tank
It is the main body of a transformer which accommodates Transformer Core
(HT and LT Coils) and Transformer Oil.
Mechanical Process:
Fig: Construction of a “Tank” Fig: Tank wall

11.  Construction Of Radiator:
Mechanical Process:
Radiator
When high current passes through the core of a transformer it produces
excessive heat which in turn increases the temperature of transformer oil. Oil
is circulated through the radiator which is exposed to the atmosphere. Thus
the radiator of transformer accelerates the cooling rate of transformer.
Construction Process:
Oval shape pipe of Mild Steel are first cut by mechanical press machine.
Then they are arranged vertically and parallel to each other and welded to
the crates which acts as an interlink between Tank and Radiator.

12.  Conservator:
Mechanical Process:
Construction Process:
 In a Hydraulic Rolling Machine, Mild
Steel sheet is given cylindrical shape.
 The gap between two edges is welded
by Electric Arc Welding.
 Two circular metal plate produced in
“Dye-Punch machine” are welded with
this part to complete the manufacturing
of Conservator.
Fig: Conservator
When the temperature of the oil is raised due to Joule Heating, it
expands and vaporizes. This oil vapor causes corrosion to the
transformer body and core components. A conservator tank of
transformer contains breather which has silica gel which absorbs this
vapor. It also acts as a reservoir for transformer insulating oil. It also
accommodates arrester, earthen plug and thermometer casing.

13.  Leak Testing:
Mechanical Process:
Fig: Leak Testing
 It is used to detect the leakage of oil in Tank during its operation in future.
 A testing bath is used for leak detection of the tank and the radiator.
 The Tanks with Radiators are fastened with a clamp and then immersed in
a water tank and compressed air is passed into the tank.
 If bubbles are produced there is leakage and the bodies are sent for
repairing purpose otherwise these are sent to the painting shop for painting
purpose.

14.  Before Painting, a batch of transformer body is inserted into a “Shot
Blasting Machine” with cast iron to remove irregularities if there is any.
Mechanical Process:
 Painting:
Fig: Shot Blasting Machine

15. • After Painting is done, the body is
heated to temperature of about 120° C
for about 2.30-3 hours.
• A Paint meter gauge is used to check
whether the thickness of painting is in
the required range
 The painting of the tank is accomplished
in two steps:
 The inner side of the tank is painted
with “Oil resistant” paint. Additive MTT
is added with it to maintain viscosity of
paint.
 The outer surface is first painted with
“Red Oxide” for ensuring no corrosion.
Xylene is also used as an additive and
then coated with “Ash Color” for
aesthetic appeal.
Fig: Painting With Red Oxide

16. Core Assembly And Coil Assembly
Insertion Of ‘Core’ Into The ‘Tank’
And Insulation Assembly
Filling ‘Tank’ And ‘Core’ With
Transformer Oil
Testing
Electrical Manufacturing Process:

17.  Core Material: Laminated silicon Steel
 Shape: Angular Cut
 The “Core” is made by attaching the sheets one by one in an order of
decreasing dimension from mid-plane. So, at present angular cut
sheets are used for reducing losses.
 The reason behind using “Angular Cut” shape instead of “Straight
Cut” is to reduce “Eddy Current Loss”
 Making of Core:
Electrical Manufacturing process:
Fig: Core Assembly

18. Electrical Manufacturing Process:
 HT and LT Winding:
 HT Winding:
• HT Winding Machine is used in
producing HT Coil.
• HT Coil Material: SWG(Standard
wire gauge)-14 (250 KVA);SWG-
21(100 KVA) Wire
• Total Layers: 26 (separated by
Paper Insulation)
• Total Active Turns: 193 turns/layer
• Machine RPM:165
• After certain number of turns, a wire
is brought out to be connected with
the “Tap Changer” which acts as
‘’Voltage Regulator”.
 LT Winding:
(for 100 KVA Transformer)
• Copper Strips (8.6x 3.8 mm) are
wounded around a bobbin in a
LT Winding Machine.
• Number of Layers: 2
• Turns in Each layer: 19
• Cardboard strips are inserted
between two layers.
• Cardboard Strip Thickness: 2mm

19. Electrical Manufacturing Process:
 Insulation of HT and LT Coils:
Insulation is provided-
• to avoid direct contact between core and coil
• to maintain separation between different layers of coil.
Two types of insulation are provided:
 Wood insulation:
• Wood insulation is provided so that the current passing through the core
doesn’t get shorted with the tank
• Using a dye, a half round shape is given to the cardboard because the
Core is flat and the coils are round in shape.
• “Shil-karai” (Albizia lebeck) is used for carpentry shop.
 Paper Insulation:
• Paper insulation is provided in LT Coils.
• A “Lapping machine” is used where copper strips pass through a middle
channel and two tilted wheels rotate on either side of the channel. As the
strips pass around the wheels, these get wrapped with paper insulation.

20. Electrical Manufacturing Process:
 Inserting LT and HT Coils to the Core:
• Firstly Paper insulation is provided around the Core.
• Secondly, Low Tension Coil is fitted around the “Core” and the
terminals which were brought out after certain turns are kept isolated.
• Thirdly, High Tension Coils made of Super Enamel Wire are fitted
around the core along with LT Coils.
• Finally, a board insulation and 10 mm wood insulation is provided
between the Yoke Beam and coils in bottom side and a 30 mm Wood
insulation on the top side.
• Thus the final assembly is made ready to get inserted.

21. Electrical Manufacturing Process:
 Fitting Active Body into the tank:
 Tank is dried for 36-48 hours before it is fitted inside the tank.
 HT and LT insulators are used. The material of the insulator is ceramic.
It consists of Aluminum cap and gasket to avoid leakage of oil from both
sides.
Fig: Transformer Oil Drum
 Filling The Tank With
Transformer Oil:
. At first, oil is tested in CPL for viscosity and
breakdown voltage.
. Then, this oil is distributed by a centrifugal
pump. Then, it is filtered to remove dust
and other impurities and then it is refined.
After that tank is filled with transformer oil.

22. Electrical Manufacturing Process:
 Testing:
For confirming the specifications and performances of an electrical
power transformer it has to go through numbers of testing procedures.
 Power Frequency Withstand Test:
 It is intended to check the ability of maintaining insulation to earth and
between windings.
 This is test is performed in both HT and LT Side.
 Megger test:
 This test is performed to check
 Insulation between HV Coil and LV Windings
 Insulation between HV Coil and “Tank”
 Insulation between LV Coil and “Tank”
 Breakdown voltage of oil:
It is done at CPL. The main goal of this test is to check the specific gravity
and flashpoint of transformer oil.

23. Electrical Manufacturing Process:
 Ratio test:
This test is performed to find out the turns ratio at different tap position.
 Induced Over Voltage Test:
This test is intended to check the inner turn and line end insulation to
ground and between Windings.
 Vector Group Test:
 A-a is shorted and 400V is applied on HV side(ABC).
 Voltage across C-c, B-c and C-b are determined.
 DC Resistance Measurement Test:
This test is performed to detect any problem in the
soldering and at which portion the problem occurs.
 Full Load Test:
This test determines the Copper Loss in the Transformer.
 No Load test:
This is done to determine “Core Loss” on XFR

24. Administration:
 Administrative Section:
Administration is the management of the
organization. The administration of an
organization includes the management of
business operations.
Key Functions:
1)To administrate business operations.
2) To implement rules and regulations.
3)Decision making
4) working on company policy

25. Organogram:

26. Maintenance and Accounting Section:
 Maintenance Section:
Functions:
• The function of this section is to repair all
kinds of machines in case of sudden
failure (Mechanical and Electrical).
• This section is also responsible for
maintaining a Constant Voltage and
Current Ratio.
 Accounts Section:
Functions:
1) Records and provides all information.
2) supervises all financial deals.
3) All sorts of financial transactions are
recorded in this section.
4) Monitors the overall cost of the industry.
5) determines profit or loss.

27. Marketing and Purchase:
 Marketing:
This section handles sales by DPM(Direct Procurement Method).
Letter Gives Rate
Terms & Condition
Acceptance
Technical
Check-up
Call & Negotiation
NOA
(Notification of
Acceptance)
Acceptance
A flowchart of the working procedure of this section is given below:

28.  Purchase:
• Government process
• PPR (public procurement regulation,
• 2008) maintained
• Takes both local and international tender)
• International tender------42 days
• Local tender-----28 days
• Can get up to 2 crore BDT by its own authority)
Purchasing
Requisition
Tender or
Quotation
Purchase
Order
Receiving &
Inspecting
Checking &
Passing of
Bills for
Payment
Marketing and Purchase:

29. Conclusion:
The industrial training was a great opportunity for us to acquire practical
knowledge of production processes of an industry and we were able to learn
how our theoretical knowledge can be applied in industrial field. We gathered
vast experience on the process of 3 phase distribution transformer
production. We realized that there are some differences in theoretical and
practical knowledge which will help us in the future in our job life. We also
learnt keeping a healthy workplace environment and communicating with
workers is no less important than having technical knowledge in large scale
mass production. From our observations we realized that if Bangladesh
government takes adequate steps and invest sufficiently in this industry it can
be one of the leading transformer manufacturing company in the country.
Most of the highly productive machines of the industry are not in operation
which is a matter of sorrow. By taking proper steps to use these machines
efficiently the company can increase its production efficiency. Government
should also take steps to export the highly reliable transformers of the
industry to foreign countries which will create a large market for the products
of the industry. Also, the company should employ more skilled labour as there
weren’t enough skilled manpower to produce large scale mass production. By
taking more strict administrative decision and properly utilizing their asset this
company can be one of the biggest transformer manufacturing company in
our country.

31. THANK YOU ALL !!