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Report AEPL
Report AEPL
INDORE
INTERNSHIP REPORT
2019-2020
A report submitted in partial fulfillment of the requirements for the Award of
Degree of
BACHELOR OF TECHNOLOGY
in
Electrical Engineering
by
Bhagyashri Mathur
16010BTEE00482
Under the Supervision of
2019-2020
DECLARATION
I hereby declare that work, which is being presented in the Internship Report as the partial
fulfillment for the award of degree of Bachelor of Technology in Electrical Engineering in the
Department of Electrical and Electronics Engineering at Shri Vaishnav Institute of
Technology and Science of Shri Vaishnav Vidyapeeth Vishwavidyalaya Indore, is an authentic
record of my work carried out under the Mentorship of Mr. Deepak Rathod Assistant Professor,
Department of Electrical and Electronics Engineering. The matter embodied in this internship
report has not been submitted for the award of any other degree.
Date:
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2
II
II
SHRI VAISHNAV VIDYAPEETH VISHWAVIDYALAYA,
SHRI VAISHNAV INSTITUTE OF TECHNOLOGY AND SCIENCE
2019-2020
INTERNSHIP APPROVAL SHEET
This is to certify that Ms. Bhagyashri Mathur enrollment number 16010BTEE00482 has
successfully completed his industrial internship starting from 6th January 2020 to 21st March 2020
and has submitted the final report. His work has been found satisfactory and it is recommended to
accept it as a partial fulfillment for the award of degree of Bachelor of Technology Electrical
Engineering of the Department of Electrical and Electronics Engineering at Shri Vaishnav
Institute of Technology and Science of Shri Vaishnav Vidyapeeth Vishwavidyalaya, Indore.
II
SHRI VAISHNAV VIDYAPEETH VISHWAVIDYALAYA
SHRI VAISHNAV INSTITUTE OF TECHNOLOGY AND SCIENCE
DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING
CERTIFICATE
This is to certify that Ms. Bhagyashri Mathur (16010BTEE00482) has successfully completed
his industrial internship, starting from 6th January 2020 to 21st March 2020 and has submitted the
final report. He has successfully completed this Internship under the Mentorship of Mr. Deepak
Rathod Assistant Professor, Department of Electrical and Electronics Engineering as a partial
fulfillment of the degree of Bachelor of Technology in Electrical Engineering of the
Department of Electrical and Electronics Engineering at Shri Vaishnav Institute of
Technology and Science of Shri Vaishnav Vidyapeeth Vishwavidyalaya, Indore during the
semester Jan – June 2020.
Internal Mentor
Mr. Deepak Rathod
Assistant Professor
Department of Electrical and Electronics Engineering
HOD
Dr. Namit Gupta
Department of Electrical and Electronics Engineering
Director
Dr. Namit Gupta
Shri Vaishnav Institute of Technology and Science
III
SHRI VAISHNAV VIDYAPEETH VISHWAVIDYALAYA
SHRI VAISHNAV INSTITUTE OF TECHNOLOGY AND
SCIENCE DEPARTMENT OF ELECTRICAL AND
ELECTRONICS ENGINEERING
Acknowledgement
First, I would like to thank Dr. Upinder Dhar, Hon’ble Vice Chancellor of the
University for giving me an opportunity to do the internship with the external
organization.
Secondly, I would like to extend my sincere gratitude towards the Director Mr. Apoorv
Goyal of Apoorv Electricals (India) Private Limited for giving me an opportunity at
their esteemed organization.
I also would like to thank all the people that worked along with me at Apoorv
Electricals (India) Private Limited. With their patience and openness, they created an
enjoyable working environment. It is indeed with a great sense of pleasure and immense
sense of gratitude, that I acknowledge the help of these individuals.
I am highly indebted to Director Dr. Namit Gupta / HOD, Dr. Namit Gupta for the facilities
and continuous support provided by them to accomplish this internship. I would also like to
thank my faculty mentors Mr. Deepak Rathod & Mr. D.P Gour for their constructive
criticism throughout my internship. I would like to thank them for their support and advice to
complete internship in above said organization. I am extremely great full to my department’s
staff members and friends who helped me in successful completion of this internship.
Bhagyashri Mathur
16010BTEE00482
Electrical Engineering
IV
Acknowledgement
I express my deepest and sincere gratitude to my mentor Mr. D.P. Gour who personally
supervised, supported and encouraged me all through this internship. Thanks to the
Director of company Mr. Apoorv Goyal for providing me the internship in his company.
I also pay my gratitude to the Almighty for enabling me to complete this Internship
Report within due course of time.
Words are very few to express enormous humble obligation to my affectionate Parents
for support and strong determination to enabling us to achieve this job. I am extremely
great full to my friends who helped me in successful completion of this internship.
I also appreciate the cordial co-operation and guidance to all my internship supervisors
Mr. Sandeep Paliwal, Mrs. Jessy Mathew, Mr. Nilesh Kushwaha and also of HR
management for providing the requisite information and knowledge for compilation of
complete internship.
All the employers of the company helped me a lot in performing all the activities and
in gaining the practical knowledge of industry. They gave us best environment and
knowledge to enhance my skills.
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Executive Summary
This is the internship report bases on the three months long internship program that I
had experienced in the Apoorv Electricals (India) Pvt. Ltd. From 6th Jan 2020 to 21st
March 2020. As a requirement of my B. Tech program under Department of Electrical
and Electronics Engineering.
This company is the pioneer manufacturer of transformer in India. The company has
always been contributing towards the advancement and development of the country. I
have recently done my internship in this company, in which I got training from its
Distribution Transformer unit. The internship basically revolved around the transformer
design, manufacturing and maintenance. At the beginning of the internship I had several
learning goals regarding industry working style.
In conclusion, the internship was a useful experience. During this period, I have learned
about this organization and its work environment, which inspire me to work. I have also
found out my strengths and weaknesses are; I gained new knowledge and skills and met
many new people and learned from their experience. I achieved most of my learning
goals.
At last this internship has given me new insights and motivation to pursue a career in
the field. To prepare myself for my future career I can improve several things. I have
made it possible to write each and every thing that I have learnt in the organization. I
have all my practical efforts in the form of this report that is the asset for future career.
VI
List of Figure
4.2.1 Transformer 15
VII
List of Table
VIII
Table of Content
Declaration I
Certificate III
Acknowledgment IV
Acknowledgment V
Executive Summary VI
1.1 Introduction 1
1.1.1 Role of manufacturing industry 1
1.1.2 Manufacturing industry features and progress in India 2
4.2.4 Design 15
5.3.3 Responsibility 34
5.3.4 Time Management 34
5.4 The most challenging task performed 34
CHAPTER 6 – SWOT ANALYSIS 35-37
CHAPTER 8 – CONCLUSION 41
8.1 Conclusion 41
REFERENCES 42
APPENDICES
Appendix – A
Appendix – B
Appendix – C
APOORV ELECTRICALS PVT. LTD.
CHAPTER 1
INTRODUCTION
1.1 Introduction
The history of transformer was commenced in the year 1880. In the year 1950, 400KV
electrical power transformer was introduced in high voltage electrical power system. In
the early 1970s, unit rating as large as 1100MVAwasproduced and 800KV and even
higher KV class transformers were manufactured in the year of 1980.
As power sector is the key indicator of economic growth. With the increase in
awareness related to CO2 emissions, the adoption of smart grid is expected to grow.
Currently, the “Go Green” revolution drives the demand for smart grids across the
globe.
India is on the verge of becoming major power nation among developing economies.
Electricity is the key constituent for the economic growth of the country and is directly
linked to GDP of the country. There has been a surge in demand for power in India due
to increase in capacity utilization. industrialization, urbanization, and population
sharing views on the power and distribution equipment. Currently through reforms such
as “Power for all”, government plans to add 93GW by 2022, this would fuel the demand
for power transmission and distribution equipment. The Indian power and distribution
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Presently the government is taking major steps to strengthen the power transmission
and distribution network and has undertaken imitativeness such as UDAY for financial
turn-around of power distribution companies. Further, the government has projected an
investment of Rs 146,000 crore. In transmission sector by FY 2019 which results in
demand for distribution and power transformers. As per various researchers, the
industry is going to increase by more than 10 percent CAGR in the next five years.
With implementation of UDAY and other discom schemes there is a huge acceleration
of infrastructural amendment in India. This has influenced invitation for bids for
refurbishment and up-gradation of existing power transmission and distribution
network. Naturally transformers are on demand all across India because energy
distribution always needs this single most important device in the network that is
transformer.
Both power as well as distribution network is getting strengthened all across the
country. Also, the discoms are instructed to reduce losses to the tune of 10 to 12 percent
which means they have to go for efficient transformers. Infrastructure segment
(especially Metro Rail Projects) are witnessing increase in demand for distribution
transformers and increased government spending in this segment is set to drive demand
in future.
For power transformers, intra-state transmission projects (400KV and below) are
expected to drive demand. State TRANSCOS will majorly drive this demand and float
new transmission projects through different model. PGCIL, which is mainly in
executing and implementing interstate projects, is planning to aggressively enter
intrastate projects by forming joint ventures with state utilities. Hence transformer
manufacturer has to manufacture and supply these new transformers in million to the
discoms.
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CHAPTER 2
OVERVIEW OF ORGANIZATION
The present-day electrical power system is a.c. i.e. electric power is generated,
transmitted and distributed in the form of alternating current. The distribution of power
to various consumers requires to step down the voltage to different levels as per
requirement. There is various manufacturer of transformer in India. Apoorv Electricals
(India) Pvt. Ltd. is listed in trade India’s list of verified sellers offering supreme
quality of transformer.
The products manufactured by us incorporate the best and most modern technology to
ensures a good quality. Our designs are time tested and type tested as per IS/IEC
standards at various government approved laboratories. We have modern infrastructure
and a well experienced staff which enables us to deliver bulk quantities in short time.
We also have a fully equipped testing laboratory where each and every product is tested
foe all routine test as per IS/IEC standards.
Over the years, the company has successfully carved a nice for itself in the industry.
Providing conductive environment for the professional and personal growth of
employees. Company has inculcating a spirit of integrity both vertically and
horizontally.
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The Apoorv Electricals (India) Pvt. Ltd. authorized share capital is Rs. 6,000,000 and
its paid-up capital is Rs. 5,100,000. Apoorv Electricals (India) Private Limited’s
Annual General Meeting (AGM) was last held on 29 September 2018 and as per
record from Ministry of Corporate Affairs (MCA), its balance sheet was last filled on
31 March 2018. Directors of Apoorv Electricals (India) Pvt. Ltd. are Satish Goyal,
Apoorv Goyal and Kamlesh Goyal. There are total 84 employees in the company.
The quality Management system of the company are in accordance with and are
certified for ISO 9001: 2015. The Apoorv Electricals are committed to achieve
technical excellence in design, manufacture and services while maintaining high
quality and timely delivery.
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b. Potential transformer
Potential transformer (PT), are used for voltage metering and protection in high voltage
network system. They transform the high voltage into low voltage adequate to be
processed in measuring and protection instruments (Secondary equipment, such as
relays and recorders). A potential transformer (PT) also isolates the measuring
instruments from the high voltage of the monitored circuit. Voltage transformers are
used for metering and protection in the electrical power industry.
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2.4 Competitors
Market analysis gives the idea that it is the need of present era to replace aging
distribution transformers offers significant growth opportunities revival in orders and
planned investments offer strong business case for distribution transformers. Hence
there is a significant increase in the competitors for the manufacturer of transformers.
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Rising demand for power to drive growth in the distribution transformer market.
Government initiatives to improve power infrastructure boosts market prospects and
increasing competition ABB Ltd. is the leading company in the world distribution
transformers market. The other top most companies are Schneider Electric, Siemens,
GE Power India, BHEL, Crompton Greaves, TBEA, Transformers & Rectifiers India.
The competitors of the Apoorv Electricals (India) Pvt. Ltd. are Mamta Transformers,
AK Surya, Universal Transformers, Kirloskar Electric Company Limited, Gujrat
Transformers Pvt. Ltd., Urja Techniques Electricals (India) Pvt. Ltd, Danish Private
Limited.
Design Department
The design and drawings division are computerized and the company is adopting the
latest technology in designing the transformers as per the IS standards and customer’s
specifications. Every transformer is individually designed to its specific requirements
and applications.
Purchase Department
Purchase department serves to all the requirements. The main functions of the purchase
department are defined as follows, procurement of stores through indigenous sources
as required in accordance with the rules in force, checking of requisition/purchase
indents, selection of suppliers for issue of inquiries, analyzing quotation and bids etc.,
and preparation of comparative statements (quotation charts), negotiating contracts,
issue of purchase orders.
Production Department
It is the responsibility of the manufacturing department to manufacture different parts
of transformer and then assemble them to make a transformer. Production department
has following sections: Winding section, Core section, Tank section, Assembly
section
Quality Control and Testing Department
Quality control and testing department will monitor the various manufacturing
activities, up to final testing of transformers to ensure that the transformers coming out
will confirm to the Indian standards and customers requirement. The various inspection
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procedures adopted are as under:
1. Inspection of raw materials received from various vendors.
2. Stage inspection at various levels in manufacturing shops.
3. Final testing of the transformers as per Indian standards.
4. Inspection at the dispatch area before dispatch to ensure that the transformers
are fitted with all the accessories etc.
The various procedures and tests conducted as per the IS which are quite elaborative.
This department is headed by qualified and experienced engineers and is having a team
of qualified personnel at various stages.
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CHAPTER 3
PLAN OF INTERNSHP PROGRAM
The internship started from 6th Jan 2020 and come to end at 21st March 2020.
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then assemble them to make a transformer. There I trained for 3 weeks from 3rd Feb to
23rd Feb. Quality control and testing department will monitor the various manufacturing
activities, up to final testing of transformers to ensure that the transformers coming out
will confirm to the Indian standards and customers requirement. Duration of in these
department is from 25th Feb. the raw materials are tested to ensure that the quality is up
to the recommended standards, these tests are done to check durability, strength of the
material. There are two types of tests that are being performed on transformer are Type
test and Routine test.
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CHAPTER 4
TRAINING PROGRAM
This company is the pioneer manufacturer of transformer in India. The company has
always been contributing towards the advancement and development of the country. I
have recently done my internship in this company, in which I got training from its
Distribution Transformer unit. The internship basically revolved around the transformer
design, manufacturing and maintenance. At the beginning of the internship I had several
learning goals regarding industry working style.
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In the first week of my intern I was assigned to look after to the purchase department,
there I understood their working style, the main function of this departments are
procurement of stores through indigenous sources as required in accordance with the
rules in force, dealing with different suppliers, transports offices, checking of
requisition/purchase indents, selection of suppliers for issue of inquiries, analyzing
quotation and bids etc., and preparation of comparative statements (quotation charts),
negotiating contracts, issue of purchase orders. Once they assigned me the task to
analyze the legal condition of the contracts, and summarized it. This department issues
the purchase orders, follow-up of purchase orders for delivery in due time, verification
and passing of supplier’s bills to see that payments are made promptly. Correspondence
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and dealing with suppliers, carriers etc. regarding shortages, rejections etc. maintenance
of purchase records, maintenance of progressive expenditure statements, sub head wise.
I usually get the task in these department, to maintain the record of the vendor
performance and enlist the information of the employees. Keeping various
department/divisions informed of the progress of their indents in case of delay in
obtaining suppliers, servicing as an information center on the materials knowledge i.e.
their prices, source of supply, specification and other allied matters. Development of
reliable and alternate sources of supply.
For the first month I was assigned the task to look after the control/testing panel that
were installed in the testing room, also they were installed for readings of test and
maintenance, So I have to look if they are properly installed as my mentor said they
should be. After this there was also the routine checks of transformer and the furnace
having high temperature should be set within the limits as prescribed, then I was
assigned the task to explain the connection diagram specify by the customer. As I
wasn’t good in that but later, they explained the whole connection with the reasons why
it is so.
A transformer is a device that transfers electrical energy from one circuit to another
without changing frequency through inductively coupled conductors- transformer’s
coils. A varying current in the primary winding creates a varying magnetic flux in the
transformer’s core and thus a varying magnetic field through the secondary winding.
This varying magnetic field induces a varying electromotive force (EMF) or “voltage”,
in the secondary winding. This effect is called inductive coupling.
If a load is connected to the secondary, current will flow in the secondary winding, and
electrical energy will be transferred from the primary circuit through the transformer to
the load in an ideal transformer, the induced voltage in the secondary winding (Vs) is
in proportion to the primary voltage (Vp) and is given by the ratio of the number of
turns in the secondary (Ns) to the number of turns in the primary (Np) as follows:
Vs/ Vp = Np / Ns
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4.2.4 Design
The winding forms the vital part of the transformer. Highly sophisticated design
techniques are applied for electrical, mechanical and thermal stability. Helical and
continuous disc type windows are made as they provide maximum strength and short
circuit with stand capabilities. The coils are pressed before core-coil assembly to ensure
proper trouble-free service. Clamping rings are placed on top and bottom of the winding
to ensure high short circuit withstand capability to the transformer.
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The test is conducted on low voltage (LV) side of the transformer whereas the high
voltage (HV) side is open circuited.
The test is conducted on high voltage (HV) side of the transformer whereas the low
voltage (LV) side is short circuited.
c. Turns ratio test: Turns ratio test/voltage ratio test are done in transformer to
find out the open circuited turns, short circuited turns in transformer winding.
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• Dielectric test
a. Induced voltage test [DVDF test]: The induced voltage test of transformer is intended
to check the inter turn and line end insulation as well as main insulation to earth and
between windings. Double voltage and double frequency test panel is used to perform
DVDF test for power and distribution transformers. This test set provides a
continuously variable output voltage at double frequency to test the insulation between
turns of coils, layer to layer.
b. Separate source voltage withstand test: This dielectric test is intended to check the
ability of main insulation to earth and between windings.
c. Insulation resistance test: This test is conduct to check insulation resistance across
HV winding and across HV and LV windings. Also known as IRT test. Insulation
resistance test are commonly measured directly in megaohms or may be calculated from
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the applied voltage and leakage current. The recommended practice in measuring
insulation resistance is to always ground the tank (and the core).
2. Type test: To prove the transformer prove the customer specifications and design
expectations, the transformer has to go through different testing procedures in
manufacturer premises. These tests are mainly done in a prototype unit not in all
manufactured units on a lot.
a. Winding resistance test: Transformer winding resistance measurement is
carried out as a type test; it helps in determining the following:
• Calculation of the I2R losses of transformer.
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• Calculation of winding temperature at the end of temperature rise test of
transformer.
b. Lightning impulse test: lightning is a common phenomenon in transmission
Lines because of their tall height. The lightning stroke on the conductor causes
impulse voltage the terminal equipment of transmission line such as power
transformer then experiences this lightning impulse voltages. The magnitude of
switching impulses may be about 3.5 times the system voltage.
The purpose of these test is to secure that the transformer insulation withstands the
lightning overvoltage which may occur in service.
3. Special tests: These tests are done as per the customer requirement to obtain
information useful to the user during operation and maintenance. Special test of
transformer includes
1. Measurement of zero-sequence impedance of three phase transformers.
2. Vector group test
3. Measurement of harmonics of no-load current.
4. Measurement of the power taken by fans and oil pumps.
5. Test on bought out components/accessories such as buchholz relay,
temperature indicator, pressure relief device, oil preservation system.
The inspection and test plan for transformer provides the information about transformer
test and transformer inspection in manufacturing industry.
The IEC, NEC, NEMA, ISO ANSI, CI standards requirements normally are applied for
inspection and test plan. The witness of inspection and test by third party inspector is
mandatory and cannot be waived.
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There are some of inspection points which need to be checked, monitored and reviewed
by third party inspector in transformer manufacturing industry.
Important points:
• Witness of out of tank inspection, consisting of check of wiring for adequacy of
insulation, cleaning and termination. If tap changer switch fitted, check for all
electrical connections and switch mechanism.
• Final inspection after tanking, consisting of witness full tests, including heat run or
standard abbreviation test as may be specified, check tank seams for signs of oil
leakage.
• Check of handling for all ancillary equipment fitted as requisitioned, dimensional
check to GA drawing and check for rating plate and general paint etc.
a. Current Transformer
Current Transformer (CT) are used for current metering and protection in high voltage
network system. They transform the high current on the high voltage side into low
current (1 or 5Amps) adequate to be processed in measuring and protection instruments
(Secondary equipment, such as relays and recorders). A current transformer also
isolates the measuring instruments from the high voltage of the monitored circuit.
Current transformers are commonly used for metering and protection in the electrical
power industry.
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Features:
• Meets all latest IEC and IS metering and protection classes, including special core
classes (other standards available on request).
• Successful field experience since the manufacture of the first current instrument
transformer in 2001.
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145
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33
132
One-minute power KV 28
frequency dry withstand 70
voltage on primary winding
275
170
650
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b. Potential transformer
Potential transformer (PT), are used for voltage metering and protection in high voltage
network system. They transform the high voltage into low voltage adequate to be
processed in measuring and protection instruments (Secondary equipment, such as
relays and recorders). A potential transformer (PT) also isolates the measuring
instruments from the high voltage of the monitored circuit. Voltage transformers are
used for metering and protection in the electrical power industry.
Features:
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• Successful field experience since the manufacture of the first voltage instrument
transformer in 2001.
One-minute power KV 28
Frequency dry withstand 70
voltage on primary winding
One-minute power KV 3 KV
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33KV
Features:
• Meets all latest IEC and IS metering and protection classes, including special core
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Successful field experience since the manufacture of the first current instrument
transformer in 2001.
One-minute power KV 28
voltage on primary
Winding
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One-minute power KV 3 KV
170
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4.2.10 Advantages
1. This instrument transformer can be used to extend the range of measuring
instruments like ammeters and voltmeters.
2. The power losses in is very small as compared to power loss due to resistance of
shunts and multipliers.
3. The measuring instruments can be placed far away from high voltage side by
connecting long wires to instrument transformer. This ensures the safety of
instruments as well as the operator.
4. By using current transformer with tong tester, the current in a heavy current circuit
can be measured.
5. A transformer with lower losses reduces the amount of power generation needed to
accommodate the losses. This in turn reduces the emission of greenhouse gases.
4.2.11 Disadvantages
1. For large transformers, above a few MVA, the cost is so high that transformers are
custom built.
2. Low impedance hence high short circuit currents for short circuit on secondary side.
3. If a section common to primary and secondary is opened, full primary voltage
appears across the secondary resulting in higher voltage on and danger of accidents.
4.2.12 Applications
1. Transmission lines.
2. Radar system.
3. Tool machines.
4. Data processing equipment. Telecommunication system.
5. Test control and measuring systems.
6. Safety alarm and lightning plants.
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5. High current injection sources with control unit.
6. Digital CTPT automatic test set.
7. Automatic capacitance set and Tan delta set.
8. Fluke multimeters.
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CHAPTER 5
LEARNING EXPERIENCE
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You should always have positive attitude towards the worker and people around, and a
clear mind to solve the problem. We need to confident and first try to analyze the
problem before reaching to conclusion. I also learnt that in the industries that there
should not be any kind leniency with respective paper and it has to be procedural
manner, as under a supervisor I have also learned that you have to be prepared for
problems that may arise and also you should know that where the problem may arise
and what measures have to be taken in account because ‘measures are better than cure’.
Also, there should be proper communication with your workers so they can convey the
issue or problem faced by them. A team can consist of numbers of workers say 5-10
person, which have their specialty in different works, so there is a team work.
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and what not! But it is only when we are introduced to the actual environment that we
learn work ethics.
5.3.3 Responsibility
Often missed out in the list of soft skills, being responsible is an integral skill required
in the job arena. My internship experience makes you me responsible and accountable
for what decisions you make and how I, execute what’s been allocated to me.
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CHAPTER 6
SWOT ANALYSIS
6.1.1 Strength
The best testimony of company’s technology, quality and service can be seen by the
gamut of repeat orders given to it by esteemed clients. Good corporate image, complete
range of products for distribution. Established brand name, company to be having
technology and design ability. The company has strong and wide network of manpower.
In the field the main strength is your workers and knowledge with never giving up spirit
because if you are a supervisor in the field you should know your work and should be
able to convey to the worker and make sure the output is best. Also, in the situation if
we are stuck and cannot find a solution we should not give up or loose hopes it may
create a chaos in worker’s mind.
Long life and safety of personnel: the operational life of good quality instrument
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6.1.2 Weaknesses
it is imperative to be open to innovative procurement policies considering the extent
of time before new opportunities for any transformer reinvestment occurs. Transformer
operates very efficiently and have life expectancies that exceeds 25-40 years and more.
Unlike other sectors, the window for new replacement opportunities do not reoccur for
at least another 25-40 years. The other weakness is:
Low exposure to the and dynamics of distribution business.
Role clarity on the requirement of being an equipment supplier or a solution provider.
Acceptance of customers to execute low value high volume jobs.
6.1.3 Opportunities
India is on the verge of becoming major power nation among developing economies.
Electricity is a key constituent for the economic growth of the country and is directly
linked to GDP of the country. There has been a surge in demand for power in India due
to increase in capacity utilization, industrialization, urbanization and population.
The government initiatives like DDUGJY, IPDS and growing FDI in power industry
are few growth drivers in the industry. The growth in renewable energy sector also
substantially helps in increase in demand for transformers.
Informing about the major growth drivers design team of transformers should be very
strong and is one of the major growth drivers in industry. They need to make the designs
in such a way that material required for manufacturing transformers should be available
freely (many suppliers) and less customized materials need to be ordered. The windings
should be made easy so that workmen find them easy to assemble. The other growth
driver is coordination between different departments (active path and tanks).
Apart from manufacturing transformers, transformer service industry can also be
started thus achieving third-party contracts from governments or other private players.
Current transformers and potential transformers can be manufactured from the wastage
of distribution and power transformers reducing the manufacturing costs.
The prevalent scenarios suggest a optimistic growth potential within the organized
sector of the industry. Initiative like rural electrification, privatization of utilities and
‘Make in India’ shall be the primitive drivers towards the growth story of the industry.
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However, to our understanding, only efficient and quality focused organization can be
benefited from such drivers.
6.1.4 Threats
There are always new technologies on horizon, which include the IoT, robotics, and
manufacturing software. The emergence of these advanced technologies certainly gets
manufacturers overwhelmed.
India’s transformer market is predominantly unorganized with many small participants
catering to the smaller distribution transformer markets. However, many are slowly
graduating to the medium-sized category, thus expanding the organized participants’
base. This makes the market more competitive and price sensitive rather than quality.
If an organization focuses on quality manufacturing of transformers, they can sustain
the competition and have incremental growth.
Informing about the major growth drivers design team of transformers should be very
strong and is one of the major growth drivers in industry. They need to make the designs
in such a way that material required for manufacturing transformers should be available
freely (many suppliers) and less customized materials need to be ordered. The windings
should be made easy so that workmen find them easy to assemble. The other growth
driver is coordination between different departments (active path and tanks).
Underground wire is insulated properly but, if a leakage occurs it can electrify the
ground and condition of shock can occur if someone comes in contact with the ground,
also if the live wire fell off to the ground it can be harmful to humans as well as animal.
High voltage fluctuations can be said as most severe threat because as you know small
fluctuation can result in minute damage but if the voltage is high it can even result in
bursting of transformer also the feeder connected may experience a high voltage surge
and many electrical machines like refrigerator, Television, PC etc. can be damaged.
Load variation or increase in the load can also cause the DPTR to burst due to sudden
increment in load.
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CHAPTER 7
PROBLEM IDENTIFICATION & SOLUTION
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and project cancellations. In a recent move, Indian government imposed 70 per cent
safeguard duty on imported solar cells; this could increase the overall project cost and
is further expected to impact growth in solar projects and will cause low spending in
associated transmission projects.
Challenges remain always for quality manufacturers because MKT Realization versus
cost always will race with each other. The cost of manufacturing of quality transformers
as per Level 3 is quite high (IS 1180 transformer almost costs double of IS 2026) so
few competitors are finding nook and corners to sacrifice on materials to bag orders
which ultimately does not serve the basic purpose that is to reduce distribution losses
by supply highly efficient transformer.
What remains to be seen, is how our industry can cope the challenges that we face
today. Right from the lack of technology for Indian produced CRGO core, which in-
turn translates to utilization of poor quality, or pre-used / scraped core in the majority
market; to the lack of awareness in the mid-sized industries towards reliable
management of transformer and power system; what we need is a paradise shift in our
approach as a nation.
manufacturers have been looking for effective ways to reduce costs and improve
efficiency at their plants. Many of them choose to sacrifice the quality of their products
to reduce their production costs, but this will only reduce their profitability, because
dissatisfied customers will stop buying from them.
7.2 Solutions
The immediate target for the transformers industry as well as the policy makers will be
to curb the losses associated with distribution transformer failure which are relatively
higher in the Indian context compared to global benchmark. In addition, standardize
and improve the efficiency of the transformers over a period of time which will add to
overall efficiency gains and savings across the T&D grid operation.
Transformers account for significant capital expenditure for the utilities. One of the key
goals for the industry will be to gradually move from capital expenditure (CAPEX)
based mindset to look at the transformer total cost of ownership which in long run will
benefit the utilities.
Government has to come forward and promote quality suppliers to permanently raise
the health level of electrical network. It is worth to mention that more and more
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inefficient transformers in distribution circuit actually make the total T&D system
paralyzed because there is huge line losses on 24×7 basis totaling millions of rupees.
wastage which otherwise could have helped the country to progress.
Explaining about the key targets to achieve in transformer business, the market analysis
indicates that, we are known to be a quality manufacturer and have established our
credentials in specialized application. Most of customers are repeat in nature because
they seek to maintain good relationship with their client on a long-term basis and hence
always prefer ET make low loss transformers. Specialized field always need odd ratings
and hence are not very popular as design and manufacturing expertise are basic
mandates in these kinds.
One of the most effective ways to optimize efficiency at manufacturing plants is to
modernize the processes and systematize the workflows. Manufacturers need to
minimize time-consuming and labor-intensive tasks, reduce material waste, optimize
the use of equipment by minimizing damage, and simplify their supply chains.
Enterprise Resource Planning (ERP) systems can facilitate all of them, thus enabling
manufacturers to achieve optimal efficiency.
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CHAPTER 8
CONCLUSION
8.1 Conclusion
The overall internship experience at Apoorv Electricals (India) Pvt. Ltd. was just
phenomenal. With guides and mentor, it is more knowledgeable and useful. As
internship in the company started from. The experience and the knowledge I have
gained here has made me more confident. Internship provide me opportunities to gain
experience in the relevant field which “bridges the gap” between the academic
environment and a practical work environment. Besides, this internship program made
me to realize the value of teamwork and as new experience in working environment,
which challenges every minute.
Power sector is the most important and developing sector in India. Distribution
transformer is one of the key elements of power system. Apoorv Electricals (India) Pvt.
is listed in trade India’s list of verified sellers offering supreme quality of transformer.
The main reason working behind this success is their manufacturing process and
materials. The company has a good future as it is proving a quality product.
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REFERENCE
1. www.apoorvelectricals.com
2. www.eprmagazine.com
3. www.grandviewresearch.com
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