ARBA MINCH UNIVERSITY

SAWLA CAMPUS

COLLEGE OF ENGINEERING AND AGRO - INDUSTRIAL

TECHNOLOGY

DEPARTMENT OF ELECTROMECHANICAL ENGINEERING

INTERNSHIP REPORT FROM HOSTING COMPANY ETHIO

ENGINEERING GROUP POWER EQUIPMENT
MANUFACTURING INDUSTRY

INTERNSHIP DURATION: JULY 01, 2022-OCTOBER 30, 2022

BY: ABDATA ABDISA

ID NO: RAMIT/007/11

ACADEMIC ADVISOR: Mr. UMAR RESHID

COMPANY ADVISOR Mr. MAHARI NAGA

SUBMISSION DATE: NOVEMBER 2022 G.C

DECLARATION
I am 4th year Electromechanical Engineering student in Arba Minch University declare that this
report is my original work based on the past consecutive four month’s internship program from
July 2022 to December 2020 at Ethio-engineering Group Power Equipment Manufacturing
Industry.

In doing so, assuring that I agree with all written above with signature as follows.

Abdata Abdisa __________________ ____________

Name signature Date

This report has been approved by my supervisor and mentor:

In his stay in our company he has been excellent in performing work tasks accurately and on
time. He also developed team playing skills, communication skills and work ethics. To the best
of his knowledge and as per his declaration, the report is an authentic work on the issue and has
not been submitted to anywhere.

Umer Rashid ____________ ____________

Name of mentor Signature Date

I
ACKNOWLADGMENT
Words are in adequate to compensate the help of God and a great many people. Firstly, I would
like to thank Arba Minch University department of Electromechanical engineering for its
opportunity providing role and support. I would like to appreciate the engineer’s cooperation
their presence for consultation in their office and work shop. I would like to express my deepest
gratitude and appreciation to my advisor Mr. Umer Rashid whose suggestions and
encouragement helped me to coordinate and conduct this internship project and report. The next
thanks go to brotherly supervisor Mr. Mehari for his best advice and follow up helped me a lot. I
would like to express my deep sense of gratitude and appreciation to the workers of transformer
body manufacturing mechanical shop and electrical workshop that helped me to acquire lots of
knowledge and practices throughout my stay. My last thank goes to Ethiopian Power
Engineering Industry who made any type of contribution in my performance of this internship
session.

II
Table of Contents
DECLARATION..........................................................................................................................................I
ACKNOWLADGMENT.............................................................................................................................II
EXECUTIVE SUMMERY........................................................................................................................VII
CHAPTER ONE..........................................................................................................................................1
1. BRIEF HISTORY OF ETHIO- ENGINEERING GROUP..................................................................1
1.1 INTRODUCTION TO EEG..........................................................................................................1
1.2 VISSION AND MISSION.................................................................................................................1
1.2.1 VISSION....................................................................................................................................1
1.2.2 MISSION....................................................................................................................................2
1.3 MAIN PRODUCT.............................................................................................................................2
1.4 MAIN CUSTOMER OF THE FACTORY........................................................................................3
1.5 ORGANIZATIONAL STRUCTURE OF THE COMPANY.............................................................3
CHAPTER TWO.........................................................................................................................................4
2. OVER ALL INTERNSHIP EXPERIENCE.........................................................................................4
2.1 HOW CAN I GET INTO THE COMPANY..................................................................................4
2.2 THE SECTION OF THE COMPANY..............................................................................................5
2.2.1 THE SECTION OF THE COMPANY IN WHICH I HAVE BEEN WORKING.......................5
2.3 ELECTRICAL SHOP WORK FLOW...............................................................................................6
2.4 CALIPERING SYSTEM...................................................................................................................6
2.5 INSULATION...................................................................................................................................7
2.5.1 PAPER INSULATION...................................................................................................................7
2.5.2 VARNISH INSULATION..........................................................................................................9
2.6 WINDING OF TRANSFORMER.....................................................................................................9
2.6.1 AUTOMATIC WINDING..........................................................................................................9
2.6.2 MANNUAL WINDING...........................................................................................................10
2.6.3 HIGH VOLTAGE WINDING..................................................................................................10
2.6.4 LOW VOLTAGE WINDING...................................................................................................11
2.7 CONSTRUCTION OF CORE.........................................................................................................11
2.7.1 CORE TYPE TRANSFORMER...............................................................................................12
2.7.2 SHELL TYPE CORE CONSTRUCTION................................................................................12
2.8 TRANSFORMER CORE LOSS......................................................................................................13
2.8.1 HYSTERESIS LOSSES...........................................................................................................13

III
 2.8.2 EDDY CURRENT LOSSES.....................................................................................................14
2.9 TRANSFORMER NO LOAD LOSSES..........................................................................................14
2.9.1 NO LOAD CURRENT.............................................................................................................14
2.10 TRANSFORMER WIRE LOSS....................................................................................................14
2.10.1 FULL LOAD LOSS OR COPPER LOSS...............................................................................14
2.11 FINAL ASSEMBLY.....................................................................................................................14
2.12 TESTS OF THE TRANSFORMER...............................................................................................16
2.12.1 TURNS RATIO TEST............................................................................................................16
2.12.2 FULL LOAD TEST................................................................................................................16
2.13.3 NO LOAD TEST....................................................................................................................16
2.14.4 SHORT CIRCUIT TEST........................................................................................................17
2.15 OILING OF TRANSFORMER.....................................................................................................17
2.16 TRANSFORMER BODY PRODUCTION...................................................................................19
2.16.1 Raw material entry..................................................................................................................19
2.16.2 Sheet metal forming................................................................................................................19
2.16.3 Cutting of metal......................................................................................................................20
2.16.5 SHEARING MACHINE.........................................................................................................20
2.17 TYPES OF SHEARING MACHINE.............................................................................................21
2.17.1 STRAIGHT KNIFE SHEARING MACHINE........................................................................21
2.17.2 PNEUMATIC SHEARING MACHINE.................................................................................21
2.17.3 ROTARY SHEARING MACHINE........................................................................................21
2.18 AUTOMATIC SHEARING MACHINE.......................................................................................22
2.19 DRILLING MACHINE.................................................................................................................22
2.19.1 AUTOMATIC DRILLING MACHINE..................................................................................23
2.20 BENDING.....................................................................................................................................23
2.21 ROLLING......................................................................................................................................24
2.22 FIN AREA.....................................................................................................................................25
2.22.1 CORRUGATED FIN MACHINE...........................................................................................25
2.23 WELDING.....................................................................................................................................25
2.23.1 ARC WELDING.....................................................................................................................26
2.23.2 OXYACETYLENE WELDING.............................................................................................26
2.23.3 METAL INERT GAS.............................................................................................................26
2.24 CONSERVATOR TANK WELDING...........................................................................................26

IV
 2.25 GRINDING...................................................................................................................................27
2.26 INSPECTION AND PAINTING...................................................................................................28
2.27 TYPE OF ELECTROMECHANICAL TOOLS, METHODS, AND TECHNIQUES I HAVE
BEEN USING WHILE PERFORMING MY WORK TASK................................................................28
2.28 THE WORK TASKS I HAVE EXECUTTING.............................................................................28
2.29 CHALLENGES I HAVE BEEN FACED DURING MY INTERN TIME....................................28
2.30 THE MEASURES I HAVE TAKEN (WHAT I HAVE PROPOSSED A SOLUTION FOR THE
IDENTIFIED PROBLEMS) IN ORDER TO OVER COME THE PROBLEM....................................29
2.31 THE RECOMMENDATION I HAVE MADE REGARDING TO THE IDENTIFIED PROBLEM
...............................................................................................................................................................29
CHAPTER THREE...................................................................................................................................30
3. OVERALL BENEFITS GAINED FROM INTERNSHIP.................................................................30
3.1 In terms of improving practical skill................................................................................................30
3.2 In terms of upgrading theoretically knowledge................................................................................31
3.3 In terms of improving interpersonal communication skill................................................................31
3.4 In terms of improving team playing skill.........................................................................................31
3.5 Improving Leadership skill..............................................................................................................32
3.6 Understanding work ethics related issues........................................................................................32
3.7 Improving entrepreneurship skills....................................................................................................33
CHAPTER FOUR.....................................................................................................................................34
4. CONCLUSIONS AND RECOMMENDATIONS.............................................................................34
4 .1 Conclusions....................................................................................................................................34
4.2 Recommendation.............................................................................................................................34
4.2.1 For the University.....................................................................................................................35
References.............................................................................................................................................37

V
 LIST OF FIGURE

Figure 1 structural organization work flow...................................................................................................3

Figure 2 work flow of the section...................................................................................................................6
Figure 3 Insulation Paper..............................................................................................................................9
Figure 4 Automatic winding.........................................................................................................................10
Figure 5 High voltage winding.....................................................................................................................10
Figure 6 low voltage winding.......................................................................................................................11
Figure 7 core material..................................................................................................................................12
Figure 8 core construction material..............................................................................................................13
Figure 9 Insertion of transformer.................................................................................................................15
Figure 10 Testing area of transformer..........................................................................................................17
Figure 11 Oiling of transformer....................................................................................................................19
Figure 12 shearing machine.........................................................................................................................22
Figure 13 Drilling machine..........................................................................................................................23
Figure 14 Rolling machine...........................................................................................................................24
Figure 15 Grinding machine.........................................................................................................................27

VI
EXECUTIVE SUMMERY
The central aim of this study is to attempt the back ground of the internship hosting company,
Ethio-engineering group (EEG), at Tatek starting with explanting the brief history of the
company and serves. Then tries to discuss about the Four months’ general internship experience
in the section of the company I have been working in that are electrical and mechanical shop
with the main activities performed in each work shop and the project that I performed in the
company. In addition to that the challenges those have been faced and measures taken to solve
the challenges.

Also, I tried to explain the overall benefit gained from the internship experience that are in terms
of improving our practical skills, upgrading theoretical knowledge, improving interpersonal
communication skill, improving our team playing skill, improving our leader ship skill,
understanding about work ethics relation issues and entrepreneurship skill.

Lastly, I discussed with conclusion and recommended the problem that is really presented in the
company and activities they must take to solve the problem.

VII
 CHAPTER ONE
1. BRIEF HISTORY OF ETHIO- ENGINEERING GROUP
1.1 INTRODUCTION TO EEG
Ethio-Engineering group is established after reformation of metal and technology corporation
(METEC), EEG is the governmental business enterprise re-established in September 2020 under
the FDRE council of minister regulation number of 475/2020. The main purpose of the
reestablishment of the group is to enable it play a leading role in the development of heavy
industries in the country towards meeting of national vision of transforming an industrial-led
economy. EEG is, therefore; engaged, among others, the manufacturing and trading of
automotive products, agricultural machineries, power and electronic equipment, metal and
products plastic, polymer product. Currently, EEG has nine subsidiary industries that have their
own manufacturing facilities in different parts of the country. These are:

 Akaki basic metal industry.

 Metal fabrication industry.
 Construction machinery manufacturing industry.
 Electronic equipment manufacturing industry.
 Addis machineries and spare part manufacturing industry.
 Adams agricultural machinery manufacturing industry.
 Bishoftu automotive manufacturing industry.

Power equipment manufacturing industry PEMI, one industry established under EEG. This
industry contains five manufacturing industries: Transformer product, factory, wire and cable
production factory,

1.2 VISSION AND MISSION

1.2.1 VISSION
To make Ethio-Engineering group by 2022 E.C, sector dependable manufacturer and center of
excellence.

1
1.2.2 MISSION
To develop and transfer technologies that accelerate the growth of the manufacturing industry,
and the service sector. To substitutes imports that created market gaps and demanded high
foreign currency with local products that have decisive roles in the country economic
development.

To design, produce, erect, renovate, and improve manufacturing and service providing plants. To
make our products and services accessible to foreign market.

Core values:

 Costumers focused
 Quality
 Integrity
 Efficiency
 Innovation
 Effectiveness

1.3 MAIN PRODUCT

Tatek transformer, production Factory produces different KVA rating power distribution
Transformer. A transformer is considered a passive device capable of storing and delivering
finite amounts of energy. Practically all transformers utilize magnetic material for shaping the
magnetic fields which act as the medium for transferring energy. The relationship between the
magnetic-field quantities and electric circuits with which they interact play an important part in
describing the operation of the device.

The magnetic material determines the size of the equipment, its capability, and introduces
limitations because of saturation and loss on the performance. Essentially, a transformer consists
of two or more windings interlinked by a mutual magnetic field. These windings are simply
coiling of wires, inductors. In Tatek transformer production factory there are eight shops to
manufacturing transformer such as; Body production shop, Insulation production shop, winding
production shop, Core production shop, core/ coil assembly and Connection shop, final assembly
shop, oil filling shop and final testing shop. In Tatek transformer production factory there are
eight shops to manufacturing transformer such as Body production shop, Insulation production

2
shop, winding production shop, Core production shop, core/ coil assembly and Connection shop,
Final assembly shop, Oil filling shop and final testing shop. Transformers Main supplier of the
production factory Dubai Emirate, China, METEC different industries, Tabor ceramic

1.4 MAIN CUSTOMER OF THE FACTORY

 Ethiopian electric utility.
 Telecommunication.
 Private sector

1.5 ORGANIZATIONAL STRUCTURE OF THE COMPANY

General Manager

Executive director

Planning and
monitoring

Internal audit
service

Operation Marketing & sales Chief financial

officer

Production Finance &

department Sales & department accounting
department

Engineering department
ICT service
department
Maintenance
department

Quality control
department

Figure 1 structural organization work flow

3
 CHAPTER TWO
2. OVER ALL INTERNSHIP EXPERIENCE
2.1 HOW CAN I GET INTO THE COMPANY
The university industry linkage program is planned to create a good interaction between
universities and industries, and also create students that have the capability of facing and solving
practical problems.

because of these reasons Arba Minch University has given a great deal attention to this program
in helping students, starting from searching company that are willing to part of this program to
giving essential documents and schedules. As an Electromechanical engineering student, after I
graduate I can work on different sectors of Electromechanical engineering infrastructure
sectors .so there was no good opportunity than this internship program to know more about
power transformer and its working environment.

When I first gone the company I found a good service from the general the manager of intern
ship linkage Mr. Yesemwerk, and I try to illustrate and give information about the internship
program, so that she should gave me special attention to the request paper what the university
had given me, because the firm will also gain some advantageous from the program.

As I went to the firm on the first day of the internship, I had to wait for the general manager and
give necessary documents and papers that will be filled by the firm. So as to make my stay on
the firm according to the university program. On the second day I have been introduced to my
supervisor and other employees of the firm. When they heard were I came from and for what
reason I came, they were very much happy to show me around, give me necessary information
about the work and cooperate with me.

THE REASON WHY DID I SELECT THIS COMPANY

As the name implies Ethio- engineering group is the center of research in the Ethiopia. And it
was the company which has so many branches, which facilitate, infrastructures for the Ethiopian
as well as for the country side. Most of the engineers in Ethiopia prefers to have the relation
with this industry, because it creates most of creative engineers before this time up to now. Also
I hope it made me more knowledgeable. That why I prefer to select the Ethio-engineering group

4
for my university and the industry linkage program and I spent most of my time for four months
in this company.

2.2 THE SECTION OF THE COMPANY

 Electrical shop section
 Mechanical or body production section

2.2.1 THE SECTION OF THE COMPANY IN WHICH I HAVE BEEN

WORKING
There are two section in which I have been working during my internship period. The power
equipment and manufacturing equipment at TATEK have three sections. But I have been
working in two sections that why I selected to work in transformer industry. Therefore, the
transformer industry includes two sections electrical shop where all the active parts of the
transformer has been producing and mechanical shop where the body of the transformer has been
producing. In transformer body production there are so many processes of transformer have been
doing like welding, cutting, drilling, linkage testing, conservator making, and so many other
processes are there. Also in electrical shop some processes are there like insulation making,
winding, core making area, testing area and etc.The reason why I have been working in those
two sections of the transformer industry is that, these two sections are interrelated with each
other. We could not see them separately and active part of the transformer is once done, its
covering part must be made.

5
2.3 ELECTRICAL SHOP WORK FLOW

Insulation Cutting stage

making stage

Bending

Winding stage
Drilling

Core making stage

Winding

Core and winding

assembling
Inspection and painting

Insertion of core and winding into transformer

body

Figure 2 work flow of the section

2.4 CALIPERING SYSTEM

Calipers are used to measure the distance between two opposite sides of an object. They are very
simple measuring instruments and have an inward and out ward point, just like a compass. Also
calipers are used to measure the dimension of objects with precision and often used in
laboratories. Caliper is made of steel. However; sometimes carbon material (plastic) can be used.
It comes to measuring the diameter of cylindrical objects, the caliper is right to choice to use.
Whether the inside or outside diameter, with a single instrument, the task can be finished easily
accurately.

To measure thickness, length, and width, you can certainly use this device. You can also use it as
well for measuring depth. A caliper is equipped with a thin stick on the backside. Thanks to its
benefits, a caliper is one of the key measuring instruments that is usually used in various fields

6
such as engineering, construction, and metal working. A caliper is a precision measuring
instrument that has the good flexibility and very complete tool to support you’re your multiple
dimension measurement.

2.5 INSULATION
This section is the main and the important section for making transformer. Here in this section
where insulator materials are formed. Those materials are made up of different size papers and
other materials.

We use insulation for almost all transformer making system or processes. Most works here are
cutting the insulator materials in different size and shapes in order to make it simple to insulate
the materials which are in the transformer.

This is the material that used to provide electrical insulation between transformer winding at
different voltage levels and also between the energized parts and the metal tank of the
transformer. Generally, for large transformers used in power application.

Depending on their source there are different types of insulations.

2.5.1 PAPER INSULATION

An electrical insulation papers are paper types that are used as electrical insulation in many
applications due to pure cellulose having outstanding electrical properties.

7
A) white paper

B) paper insulation

D) H-Paper

8
 E) cotton tap

Figure 3 Insulation Paper

2.5.2 VARNISH INSULATION

Electrical insulating varnishes are resins like exposes or alkyds used to protect high voltage
transformers, from electrical failure.

They are applied over electrical conductors to provide layer of electrical isolation and prevent
shorting.

2.6 WINDING OF TRANSFORMER

Winding is one or more turns of wire that forms a continuous coil through which an electric
current can pass, as used in transformers and generators

2.6.1 AUTOMATIC WINDING

This types of winding generally named as automatic or self-winding. It consists of rotor or
oscillator that is powered by the movement of wearers twist. As twist moves, it automatically
moves the rotor, which, as it swings, winds the mainspring inside its barrel. This type of winding
is the most common and best one to save the time. It is more accurate and precise for
manufacturing the transformer winding parts.

9
 Figure 4 Automatic winding

2.6.2 MANNUAL WINDING

2.6.3 HIGH VOLTAGE WINDING
It is an insulated coil of copper wire, with a low cross section built to receive or deliver the
highest voltage of the electric power transformer. When the electric power transformer is
installed, the winding that is connected to the source is called primary winding (high voltage
winding). In step down transformer the high voltage winding has large number of turns. It is
where the high voltage is supplied to the transformer. The conductor of high voltage winding,
have lower thickness than the low voltage side.

Figure 5 High voltage winding

10
2.6.4 LOW VOLTAGE WINDING
The side of the transformer which consists of low voltage winding is called low voltage side. The
transformer low voltage side carries low voltage or low voltage winding. The transformers low
voltage side carries low voltage and high current. The transformer low voltage side winding
having fewer turns than the high voltage side. The conductor of the low voltage winding having
a higher thickness than the high voltage side. The resistance of the low voltage winding is always
lesser than the high voltage winding. The low voltage winding of transformer having less
insulation than the high voltage winding. For large transformer, low voltage winding, are
generally star connected.

Figure 6 low voltage winding

2.7 CONSTRUCTION OF CORE

Generally, the name associated with the construction of a transformer is dependent up on how
the primary and secondary winding are wound around the central laminated steel core.

The two most common and basic design of transformer construction are the closed core
transformer and shell core transformer.

In the “closed core” type (core form) transformer, the primary and the secondary winding are
wound outside and surround the core ring. In the shell type transformer, the primary and the
secondary winding pass inside steel magnetic circuit (core) which forms a shell around the
winding.

11
2.7.1 CORE TYPE TRANSFORMER
In core type construction of transformer, the magnetic circuit consist of two vertical legs called
legs and two horizontal section called yokes. The low voltage winding is placed next to the core
while the high voltage winding is placed around the low voltage winding. Hence the primary and
secondary winding are arranged as concentric coils, thus known as concentric winding or
cylindrical winding. The major advantages of a core type transformer that it is easier to dismantle
repair and maintenance.

2.7.2 SHELL TYPE CORE CONSTRUCTION

In shell type construction of transformer, the magnetic core consists of three vertical legs and
two vertical sections. Both primary and secondary winding are wound on the central limb and the
two outer limbs provide the low reluctance. The low voltage winding is placed next to the core
and around low voltage winding the high voltage winding is placed. This arrangement reduces
the requirement of insulating material.

The shell type core construction of the transformer provides better support against the
electromagnetic forces between the current carrying conductors, which are very under short
circuit conditions. The shell type transformers are mainly used in low voltage and high output
application.

Figure 7 core material

12
Figure 8 core construction material

2.8 TRANSFORMER CORE LOSS

The ability of iron or steel to carry magnetic flux is much greater than it is in air, and this ability
to allow magnetic flux to flow is called permeability. Most transformer cores are constructed
from low carbon steels which can have a permeability in order of 1500 compared with just 1.0
for air. This means that a steel laminated core can carry a magnetic flux 1500times better than
that of air. However, when a magnetic flux flows in the steel core of a transformer, two types of
losses occur within steel. One termed “eddy current losses” and the other losses termed as
“hysteresis losses”.

2.8.1 HYSTERESIS LOSSES

Transformer hysteresis losses are caused because of the friction of the molecules against the flow
of the magnetic lines of force required to magnetize the core, which are constantly changing in
value and direction first in one direction and then the other due to the influence of the sinusoidal
supply voltage.

This molecular friction causes heat to be developed which represents an energy loss to the
transformer. Excessive heat loss can over time shorten the life of the insulating materials used in
the manufacture of the windings and structures. Therefore, cooling of transformer is important.
Also, transformers are designed to operate at particular supply frequency lowering the frequency

13
of the supply will result in increased hysteresis and higher temperature in them on core. So
reducing the supply frequency from 60 Hertz to 50 Hertz will raise the amount of hysteresis
present, decreased VA capacity of the transformer.

2.8.2 EDDY CURRENT LOSSES

Transformer eddy current losses on the other hand are caused by the flow of circulating currents
induced into the steel caused by the flow of the magnetic flux around the core. These circulating
currents are generated because to the magnetic flux the core is acting like a single loop of wire.
Since the core is a good conductor, the currents induced by a solid iron core will be large.

Eddy currents do not contribute anything towards the usefulness of the transformer but instead
they oppose the flow of the induced current by acting like a negative force generative resistive
heating and power loss with in the core. Is also the current that flows in the transformer core and
results from the voltage that is induced in the core by the primary winding.

2.9 TRANSFORMER NO LOAD LOSSES

2.9.1 NO LOAD CURRENT
When a transformer is not connected to any load but consumes some electric current, current
consumed by the transformer is called no load current.

2.10 TRANSFORMER WIRE LOSS

2.10.1 FULL LOAD LOSS OR COPPER LOSS
Load loss or copper loss occur in the primary and secondary coils of transformers, is the result of
coil resistance. It is load dependent. It is proportional to the square of current and resistance of
the coils.

2.11 FINAL ASSEMBLY

Low voltage windings are placed near the core and high voltage winding are assembled and co-
axially placed with respect to low voltage windings. Spacers are added for adding strength. Coils
are assembled using high end insulating materials and adequately clamped.

 Sufficient ducts are provided between the coils to ensure heat dissipation through the
circulation of oil. Best quality insulations are provided at all joints and gaps.

14
  The optimum design of core coil assembly is achieved by considering the required
technical particulars including cooling, size compactness and tapping arrangement.
 All leads and conductors are rigidly supported by a special clamping arrangement.

Core and coil assembly is placed inside its tank, tank is filled with oil to stop exposure to air, a
cover assembly added and bushing connections made. Once the cover is welded and leak
checked, galvanized radiators are assembled to the tank, the unit is drained and the transformer is
vacuum filled for final testing. During this same time, the control box and any other customer-
specified monitors and components are installed and wired. All external welded assemblies are
mounted to ensure correct fit to the tank and removed before the finished transformer moves on
for factory acceptance testing
Highly skilled people assemble the laminations on a core channel to form CORE. These are
perfectly assembled without any gaps to avoid energy loss.
The complete assembly is kept in the Hot Air Chamber and a high temperature is maintained to
prevent any moisture in the CORE coil assembly.

Figure 9 Insertion of transformer

15
2.12 TESTS OF THE TRANSFORMER
2.12.1 TURNS RATIO TEST
 The transformer turns ratio is one of the most common test used to assess the condition
of the transformers winding and core. It is performed as a part of acceptance and
maintenance test procedure to determine any problems due to poor design, assembly,
handling, overloading, fault conditions or poor maintenance.
 A phase voltage is applied to the one of the winding by means of bridge circuit and the
ratio of induced voltage is measured at the bridge. When testing transformer for turns
ratio, the connections are determined by machining parallel vectors. Transformer turns
ratio test sets come in variety of styles and test connections. However; all turn ratio
testers have at least two high leads and two low leads. Basic setup procedures are
explained below.
 Make certain that all terminals of the transformer are disconnected from line or load at
the transformer.

2.12.2 FULL LOAD TEST

 The full load current is measured by the ammeter connected across their secondary
winding
 The low voltage source is applied across the secondary winding, which is approximately
5 to 10% of normal rated voltage.

2.13.3 NO LOAD TEST

 No load tests are tests that apply rated voltage in the primary side at the no load state of
the secondary side. No load tests are tests that apply rated voltage in the primary side at
no load state of the secondary side. Current only flow to the primary side in the no-load
test, but this current cause’s excitation and iron loss of the iron core.
 Current only flows to the primary side in no load test, but this current cause’s excitation
and loss of the iron core.

16
 2.14.4 SHORT CIRCUIT TEST
 The input voltage is increased from zero until the ammeter in the primary circuit
indicates normal primary current. When this occurs the normal full load secondary
current is circulating in the secondary winding
 The first step in finding a short circuit is to look for physical sign. This may include
visible burns or melted metal on wires, burning smells, etc. In this test generally, the
high voltage side is connected to the AC supply and low voltage side is short
circuited with help of thick copper wire. The short circuit test on the transformer is
performed at the primary and secondary rated currents. Therefore; the total copper
loss is the full load copper loss.

Figure 10 Testing area of transformer

2.15 OILING OF TRANSFORMER

The primary function to insulate and cool a transformer. Also designed to operate effectively at
high temperature, and act as coolant for the winding.
Transformers are electricity storage devices that convert electric current from one location to
another. As a result of their resistance, transformers help to reduce power loss. Multiple types of
transformers are available on the market and they have different specifications. Factors such as
capacity, frequency range, cooling type, class, application, and many more classify transformers.
If you look at it in terms of the cooling mechanism used, transformers can be separated into two

17
kinds. Those are the Dry-type or Cast Resin transformers and Liquid Filled or Oil Filled
Transformer.
Oil distribution transformers are essential components for delivering energy to households. It
can come in different types depending on the requirement of the application. This article will
focus solely on Oil Immersed Transformer.

What Is an Oil Immersed Transformer?

Distribution transformers are the end-converter of currents before they reach the households.
These machines are responsible for “stepping down” high voltage current to lower usable ratings.
There are a variety of cooling design transformers, and one of them is oil-cooling. In which, oil
distribution transformers are among the types which use oil for cooling. An oil filled transformer
utilizes dielectric oil to insulate and cool the transformer winding. It is filled with highly refined
transformer oil used to isolate the transformers mechanical working components.

The oil-filled transformer is a voltage transformation device that uses an oil cooling technique to
minimize transformer temperature. It is placed in a welded steel oil tank filled with insulating oil.
When an oil-filled transformer is in operation, the coil’s heat and iron core are converted first to
insulating oil. Then it is converted to the cooling medium. It may also be split into two types
based on capacity: immersed natural cooling transformers and forced air cooling transformers.
Standard ratings of Oil Immersed Transformer are below 200 kVA. However, exceptions are to
be made, especially in situations where higher ratings are needed.
An Oil Immersed Transformer involves the oil cooling method to reduce its temperature. Its
body is connected to the welded steel oil tank, which is full of insulation oil.
These transformers work because the heat of the coil and iron core is transferred into the
insulation oil. After that, it is then converted into a cooling medium. Capacity sizes allow it to be
divided into immersed forced air cooling and immersed natural cooling transformers,
respectively. Here are the main function of oil in distribution transformer.
 Oil distribution transformer transforms high voltage to low voltages for house hold or
commercial use.
 It reduces voltage rating by the induction principle or Faraday law

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  This transformer type distributes electricity to a smaller cluster of end users.
Electricity from power plants needs distribution transformer.

Figure 11 Oiling of transformer

2.16 TRANSFORMER BODY PRODUCTION

Here in this section the transformer body is produced, by using sheet metals there are many
stages for making the body of the transformer, and the machine that is used for the production of
the body. The process is located in the mechanical work shop section. There are several steps for
the transformer body being produced.

2.16.1 Raw material entry

A raw material for transformer body is sheet metal made of mild steel. Which thickness is
different depend on the transformer power. Mild steel contains 0.15% to 0.3% of carbon content.
And it is used very extensively for structural work. The reason to choose mild steel is it has
better welded than other alloy.

2.16.2 Sheet metal forming

The sheet metal which is checked by the laboratory to fulfill the minimum standard enter to the
body work shop. Then it goes via different sheet metal forming.

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2.16.3 Cutting of metal
Cutting of sheet metal is accomplished by a shearing action between two sharp cutting edges.

Shearing is used to cut large sheets into smaller sections of subsequent press working operation.

Also the mild steel sheet metal is cut by hydraulic CNC shear machine into desired shape or
width and length. If the thickness is more than the machine can handle, the sheet metal can be cut
by CNC plasma cutter.

2.16.4 PLASMA AREA

 CNC PLASMA MACHINE

CNC plasma machine uses a plasma cutter to cut thin to thick metal along a multi- axis grid. The
CNC method provides an advantage over handled plasma cutting tools due to the cut being
programmed and controlled by a computer instead of human motion. CNC plasma is where high
speed and precision meet low cost among a vast array of additional benefits.

2.16.5 SHEARING MACHINE

Shearing machine are multipurpose device used in cutting of the sheet metal. It uses scissors like
angular shear action to cut metal into sheets or strips. The process of shearing consists of cutting
of sheet metal, bars, and plates by exerting shear stress by the use of a die and punch which is
quite similar to the paper punching action. The punch and die can be various shapes like straight
or circular blades which can be somewhat like scissors. The process of shearing of plate, sheet or
strip is based on the type of blade used for shearing which can be either rotatory blade or straight
blade.

For cutting and squaring flat stock in desired size and shapes straight knife shearing is basically
used for producing rectangular and square shapes and straight sided shapes can also be obtained
from straight knife. Generally, the operation of shearing is performed with the help of two blades
in which one blade is fixed to the shear bed and the other blade moves in vertical direction with
no or little clearance. Shearing operation is done in progressive manner from one side to the
other side of the material.

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The punching or shear cutting actions are the result of close motion of two sharp edges which are
closely adjoined and the material placed in between edges. These shear stress is applied at the
point of fracture in three styles.

1. Deformation: As the cutting edges begin to close on the material, deformation occurs on
both sides of the material next to the cut edge.
2. Penetration: The cutting edges cut or penetrate the material, causing fracture lines.
3. Fracture: The point where the upper and the lower fracture line meets. At this point the
work is done, but in punching, punch must continue to move through the material to clear
the slug.

2.17 TYPES OF SHEARING MACHINE

2.17.1 STRAIGHT KNIFE SHEARING MACHINE
In straight-knife shearing, the flat work piece is placed between the stationary lower knife
and movable upper knife. When the upper knife is forced in downward direction then the
upper knife cuts metal in two parts. This type of shearing is economical for cutting of
straight plates.

2.17.2 PNEUMATIC SHEARING MACHINE

Pneumatic shearing machines are most widely used for the shearing of thin metal which is
less thick than 1.50mm and short pieces but less long than 1.5m. Shear blade beams are
moved by the activation of air cylinder for making cut.

2.17.3 ROTARY SHEARING MACHINE

Circle shearing or rotary shearing are cutting process of plate and sheet in counters or in
straight lines using two revolving and tapered circular cutters. The shearing by rotary
shearing machine needs holding fixtures for allowing rotation to the work piece for
generating the desired circle.

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 2.18 AUTOMATIC SHEARING MACHINE
A machine that shears a sheet by reciprocating linear motion with one blade relative to the other
it uses a moving upper blade and fixed lower blade to apply a shearing force to the metal sheets
of various thickness with a reasonable blade gap to break the sheets in the required size.

It has display which is used to insert input data to machine to get required output.

Figure 12 shearing machine

2.19 DRILLING MACHINE

Drilling is used to create round hole. It is accomplished by rotating tool that typically has two
cutting edges. The tool is fed in a direction parallel to its axis of rotation to the work part to form
the round hole.

In transformer body forming there are many holes starting from the small hole to a big one.

Also it’s the machine for drilling, reaming, counter boring, and taping holes especially, a power
machine for drilling holes in a metal, (as a drilling press or radial press). Drill press are used
mainly for drilling holes, they can also be used for enlarging holes with boring tool or finishing
holes with a reamer. They can also reduce threads. Those which are bigger are drawn or drilled
by plasma cutter.

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When the power is given to the motor, the spindle rotates and thereby the stepped pulley attached
to it also rotate. Now the drill bit also rotates which was placed in the chuck and which was in
connection with the spindle. As the pulley rotates, the spindle also rotates which can rotate the
drill bit.

2.19.1 AUTOMATIC DRILLING MACHINE

Also it is the straight brace for bits the shank of which consists of a screw of vey coarse pitch
sliding within correspondingly threated tube handle at the end, the tool being actuated by
pushing the handle. It has display which used to insert input data to machine to get required
output.

Figure 13 Drilling machine

2.20 BENDING
Bending is one of the most common sheet metal fabrication operation. This method is used to
deform a material to an angular shape, whether into a V-shape or into other desired design. This
is done through the application of force on the work peace. To force an object, especially a
straight form into curved, or angular one, from a curved or angular to different shape.

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In transformer body forming sheet metals are bend as need by the design by using hydraulic
CNC bending machine. Bending machine is also referred to as a primarily used machine which is
mainly used to form a bend on any required work piece. The machine is used to make use of the
bending tool which is present in it and is responsible for the process. There are different various
types of bending machines which are commonly available in the market. Some of them are
mentioned below:

The sheet bending machine is mainly selected for the purpose of creating a bend inside the metal
sheet. The metal pieces are initially fixed on the clamping device which is known to hold them
during the complete operating process. The nature of this bending machine is found due to an
unknown fact which is that they are manufactured by using a very high grade raw material.

A sheet folding machine is referred to as an instrument which is used to bend the object at any
particular angle. The profile bending machines are the ones which are used due to their highly
accurate quality and amongst most of the users.

2.21 ROLLING

Figure 14 Rolling machine

A rolling machine is a piece of equipment that contains two or more rollers through which the
raw metal is fed. The main purpose of the rolling machine is, to compress the raw metal into
thinner and more uniform shape which is essential when producing sheet metal. Plate
rolling ,round processing and forming. The plate rolling machine is also known by plate bending

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roller. This machine is a type of machine tool which is employed for creating continuous point
metal sheet bending. The plate rolling machine holds special importance in the sheet metal
industry. This piece of machinery can be used to produce cylindrical part, conical part, and other
parts having different shapes. machine is a type of metal forming machine which utilizes work
rollers to produce sheet metal

This is a compressive deformation process in which the thickness of the slab or plate is reduced
by two opposing cylindrical tool called rolls. The rolls rotate so as to draw the work in the gap
between them and squeeze it.

2.22 FIN AREA

This is the corrugated radiator (fin) production area by using corrugated fin machine.

2.22.1 CORRUGATED FIN MACHINE

Corrugated fin folding machine is designed to provide an automated solution for the fabrications
of corrugated wall tanks for electrical transformers the machine which is comprised of fin
folding machine, and automatic welding utilizes a control system. The easily to use system
allows the operator to focus on fabrication of tank assemblies and not of machine programing.

2.23 WELDING
Welding is the metal joining process in which two or more parts are joined at their contacting
surface by suitable application of heat or pressure. In some welding a filler material is added to
facilitate coalescence. In transformer body shop there are different types of welding takes place.
Welding is the fabrication process whereby two or more parts are fused together by means of
heat, pressure, or both forming a join as the parts cool. Welding is usually used on metals and
thermoplastics but can also be used on wood. The completed welded joint may be referred to as
weldment.

Welding is done by joining two materials together without any adhesive. Unlike soldering and
brazing, which use low melting point adhesives, welding joins two work pieces directly. Most of
the welding that is done is divided into some categories.

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2.23.1 ARC WELDING
Arc welding refers to a group of welding process in which heating of metal is accomplished by
arc. In transformer body most structures are welded by this type of welding. Arc welding uses an
electric arc to melt the work material and filler material (sometimes called a welding rod) to
welding joints. Arc welding involves connecting a ground wire to the welding material or other
metal surfaces.

Another wire called electrode lead is placed in the material to be welded. An electric Arc occurs
when that lead moves away from the material. The Arc melts the work piece along with the filler
material that helps to bond parts together. As the rod melts, the welder must continuously feed
the filler into the joint using small, steady back and forth motions. These movements are what
give weld its unique look. Moving the Arc too fast or too slow, too close or too far from the
material can result in poor weld.

2.23.2 OXYACETYLENE WELDING

These joining process use oxy-fuel gas, such as mixture of oxygen and acetylene, to produce a
hot flame for melting of the base metal and filler metal if one is used. In transformer body this
welding type is used for the fine side alignment in case of TIG welding is not work.

2.23.3 METAL INERT GAS

Here in which the electrode is consumable bar metal wire, and shielding is accomplished by
flood in the arc with gas. The bare wire is fed continuously and automatically from a spool
through a welding gun. In transformer body this welding type is used for joining the fins with the
main transformer body with high accuracy.

2.24 CONSERVATOR TANK WELDING

Conservator tank is simply a tank that is used to provide enough space for the oil in the
transformer to spread after heating. It is placed on the roof of the transformer. The main function
of the conservator tank is that once the transformer is loaded, its temperature rises, and the oil in
it starts spreading. That is why the conservator tank acts like a pond for the insulation of the
transformer.

The shape of the conservator tank is cylindrical and the ends of the tank is air tight closed. A
large cover is placed on one side of the tank for periodic cleaning and maintenance. The pipe of

26
the conservator tank is connected to the main tank of the transformer. The pipe is connected to
the bottom of the conservator tank. In the tank, a cap is attached to the top of the pipe so that any
kind of oil waste does not enter the main tank from the conservator tank.

The work of the conservator tank starts to heat up once due to the load of the insulating oil
transformer and leaves in the tank facing up wards. As a result, the same amount of air in that
distance is moved away with the help of breathing. As the load on the transformer decreases, the
transformer cools down and shuts down.

2.25 GRINDING
Grinding is generally called as fine machining or finishing operation of removing materials from
surface usually 0.25-0.5mm in most operation through the use of grinding wheel. It may be used
to finish almost all surface, which has been previously roughly shaped by some other process or
remove extra material which is too hard to be removed by other machining process.

Figure 15 Grinding machine

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2.26 INSPECTION AND PAINTING
After transformer body is finished, it may be passing through the inspection process to check up
if there is any linkage. The process is done by using compressor and detergent. If there is any
linkage found in in transformer body it will be welded again. After inspection it goes to final
process of painting and galvanizing.

2.27 TYPE OF ELECTROMECHANICAL TOOLS, METHODS, AND

TECHNIQUES I HAVE BEEN USING WHILE PERFORMING MY WORK
TASK
TOOLS

CRANE: Used to carry the heavy material from one place to other place.

REMOTE: Used to guide a crane to move back, forth, and to different side.

TECHNIQUE: Using remote to save time and energy.

I have been using some especial techniques what I had learn as one course in the class. Which is
what we call AUTOCAD display. And also I have used excel to disprove the data.

2.28 THE WORK TASKS I HAVE EXECUTTING

 Cutting of insulation paper into different dimensions.
 Winding of copper wire both primary and secondary.
 Cutting of core metal in different shapes and arrange them properly.
 Putting the core and winding into the assembly

2.29 CHALLENGES I HAVE BEEN FACED DURING MY INTERN TIME

 The first challenges I have been facing was the distance of the transformer factory from
my home I spent most of my intern money for transportation in three months. After that I
faced many problems related to absence of money.
 One day as I came from the company to my home, some car crash happened. But I would
like to thanks my God no one could not put into danger.

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2.30 THE MEASURES I HAVE TAKEN (WHAT I HAVE PROPOSSED A
SOLUTION FOR THE IDENTIFIED PROBLEMS) IN ORDER TO OVER
COME THE PROBLEM
This measure focus mainly on the design of transformer to reduce no load loss and
also reduce the accumulation of core in the store in company which have high
watt/kg. When we mixed two different core material which have different watt/kg, I
increase the efficiency of the transformer. This identified solution play a great role
for the host company and it could be learning material for new joining other intern
ship student.

2.31 THE RECOMMENDATION I HAVE MADE REGARDING TO THE

IDENTIFIED PROBLEM
I recommend the company to use the identified solution, using such solution made the
company more benefit and no load loss will be reduced. Also as the company accept
more engineers for the intern and more solution will be made for the future. Also the
watt/kg of the core will be reduced what I have been doing during my intern period.

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 CHAPTER THREE
3. OVERALL BENEFITS GAINED FROM INTERNSHIP
Internship program is a method of letting the students to assume themselves as potentially
responsible workman for a particular work by assigning them to actively participating in
production control as well as maintenance in industrial company. And such trends help to have
valuable work experience. Internship programs are also potentially valuable to the company. In
this internship, I have observed what the outside industrial world looks like more than the regular
classes. In this internship, I have got good opportunity to face difficulties in the real world.

The overall benefits of internship are not limited to the practical skill only. The overall benefits
that I have gained in terms of different daily activities. Such as:

 Upgrading theoretical knowledge.

 Entrepreneurship skill.
 Increasing communication skill.
 Become better in practical skills.
 Improving leadership skill.
 Get more knowledge about ethics related issue.

3.1 In terms of improving practical skill.

Since from lower grade our mind loaded with theoretical concepts even in campus. Having a
good practical skill is not that much available due to lack of materials but, in this internship,
program have got lots of practical skills and experiences. Also, it can assist students to bridge the
gap between the academic learning process and the Practical world. There are many benefits that
we get from our internship program. These includes: -.

 Controlling of large machines (shearing, lath, bending and drilling machines).

 How to weld different metal with different welding methods.
 Arrangement of equipment in the workshop.
 How to use working materials.
 Develop the habit of safe working.

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3.2 In terms of upgrading theoretically knowledge.
This internship program provided chances to build intellectual knowledge and practical skills. I
have been familiarized with different types of machines such as shearing machine, lath machine,
bending machine, CNC machines, winding machines and CNC plasma cutting machines which
helped to have a better understanding on what I have learned in class. Internship program is not
only used to improve practical skill, but also used to impose theoretical knowledge by correlating
the practical skill with theoretical knowledge. The appropriate measures we undertake to
improve theoretical knowledge are:

 To know what system the machine, use to work, also its controlling system.
 To know the details parts of the machine one by one.

3.3 In terms of improving interpersonal communication skill

Communication skill can involve one to one conversations or individuals interacting with many
people within a society. It also helps us to understand how and why people behave and
communicate in different ways to construct and negotiate a social reality. Company that I have
been involved in has different people with various background came together.

They are can vary in educational level, economic situations, cultural backgrounds, life standards
and etc. Since the aim of the company is to accomplish the work in good way, to have good
communicative skills is important. During internship time, I have improved communication skill
by communicating starting from daily labor to project manager learning different type of
production terms.

3.4 In terms of improving team playing skill

When different individuals come together to work for common goals of the company for
increasing productivity, the most important point is just reaching an agreement on different
points on the work to be done at a time. A person with good team playing skill will upgrade the
following:

 To help and co-operate with others.

 To give comment to the team.
 To demonstrate reliability.
 To treat others in respectful and supportive manner.

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  To increase the ability of active participant.
 To become a problem solver on time

3.5 Improving Leadership skill

Leading a team or an organization holds the most basic and key place of profession, hence
requires well trained person. We have learned a good leading skill from our supervisor and all be
responsible and trusted. The engineers that we work together some of the leader ship skills that
we have performed are:

 To share our problems openly and get the team involved in solutions whenever there is a
setback.
 As a leader to be clear, active by working, to have goals, mission and vision in our
ability.
 During our working time, always ready to show smiley face for the workers and
supervisor.
 Respecting differences of all team members.
 Listening and accepting the ideas of our supervisor.
 To recognize, tell and solve mistakes and problems

3.6 Understanding work ethics related issues

Work ethics is a system of values in which central importance is described to work, or
purposeful activity, and to qualities of character believed to be promoted by work. EEGPEMI
workers and interns through the following work ethics.

 Punctuality: This means arriving at work on time.

 Honesty: Honesty at work means spending working hours and resources totally on
work.
 Willingness to learn: This means understanding the way things are done at your work
place and trying to do it better.
 Initiative: Being prepared to see what needs doing and to do the work without always
being asked or told to do it.
 Loyalty: Do what best for the growth of the organization.

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  Maximizing productivity: This is the ability to do high quality work faster and
efficiently.

3.7 Improving entrepreneurship skills

Entrepreneur means undertake the risk of new enterprises. This creation called entrepreneurship.
Being an intern student built an individual’s knowledgeable in Selection of the effective way of
doing work and develops entrepreneurship skills. In this company we understand the following
point which is related to the entrepreneurship.

 Risk taking ability

 Increasing efficiency of work.
 Able to invent new ideas.
 Creative mind in solving the problem of company and Work discipline.

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 CHAPTER FOUR
4. CONCLUSIONS AND RECOMMENDATIONS
4 .1 Conclusions
I have mentioned earlier, I spent the last four months on an internship practice in Ethio-
engineering group with the aim of reinforcing my theoretical knowledge with practical works
Since the industrial business is one of the fastest growing sectors along with other sectors in our
country I have managed to gather a lot of experience through practical work during my
internship program. The objective of this program is to upgrade the theoretical knowledge
learned in the university to practical skill. So the internship program gave me more
understanding of my theoretical knowledge by exercising practical work. This, on the job
training mission is very important should not be avoided. Due to this the university arranged this
valuable program.

Following this program, I joined the Ethio-engineering group at TATEK to accomplish my

practical exercise. The organization has different branch offices in all over the country. The part
of the organization that I joined was the transformer manufacturing industry. They perform
different projects under them. All the staffs of the organization were very experienced,
professional and sociable.

During my internship period I got satisfactory knowledge and well informed about the
maintenance. Due to this I gained a great sense of responsibility increased my productivity. This
assisted me in moving forward career goals by combining what I had learned from school and on
the job training. This I advise every student to undergo this process in order to lead good life.

Considering the working I have been taking part, my performance on the tasks I was given in the
company, the responses I have been getting from the staff members I have been working with
and the benefits I have gained professionally, socially and ethically, I can conclude that I have
completed the internship program effectively.

4.2 Recommendation
The company I have been working as an internship student was very good in creating an
opportunity of work (sharing experience) for the students who want to work as an intern student.
The company also provides some of our basic needs. So I would like to recommend the company

34
to continue their assistance for the students in order to create properly learned and experienced
future generations

In my stay in the organization I have tried to observe some encouraging and also some defects on
the organization. As we know Ethio-engineering have a great experience in manufacturing
transformer most of the raw materials have been doing waste out because of the mishandling and
the worker of the company did not pantual for the work time. As an intern I tried to give some
recommendation for the organization.

The organization has stopped the tire recapping factory and is wasting a lot of money because
all the highly integrated machineries do not have any application or use. And they are getting this
product from other organization by losing a lot of money

In the machine shop there are different kinds of machineries even some of these machineries are
only found in that organization in our country but most of the machineries do not have any
application they are always on standby. Even though the organization has a lot of skilled man
power. So they should be more versatile and use different designing opportunities for their
income.

Very low mobile garage and transporting vehicles.

Material wastage

4.2.1 For the University

Having an internship offer a list of importance to the student. But I recommended the university
to improve the internship program for the next program are must have good relationship with
different major organization to create opportunities for the students.

During intern time, I have faced financial problem as the ongoing inflation outpaced the
allocated budget. Therefore, I recommend the budget allocation inconsideration with the broad
economic instability.

Before the internship the student must take essential courses such as PLC, in order to have more
understandability about the information of the industry linkage program. Also the intern ship
program could not enough (shortage of time means four months), so the company should
improve about the program.

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As Arba Minch University so many problems are there concerning to the budget spent for the
intern students is very small when we compare this cost with the national economy, not for four
month it is less for two months, so the concerning body must think for future generation.

A student must have an insurance in the inter ship program

This is what I have to recommend for the university.

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References
1 The Ethio-engineering group library text book Daskufta.

1 Internet
2 Electrical machine one module of Arba Minch University
3 My self what I have been doing during my intern time

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