UNIVERSITY OF GAZIANTEP

FACULTY OF ENGINEERING
DEPARTMENT OF ELECTRIC-ELECTRONC
ENGINEERING

EEE 299
SUMMER PRACTICE REPORT

Student Name : Sefer Serhat Yazgan

Student ID : 201193838

Summer Practice Date : 15.08.2014 to 11.09.2014

Summer Practice Company Name : Schneider Electric

Related Field : Production of Transformers

Company Location :
ayrova/KOCAEL
1. INTRODUCTION

I had the chance to conduct my EEE 299 summer practice in Schneider Electric, which
is one of the most biggest electric companies in the world. Since I am planning to
select one of the power cores next semester, it was good for me on the way for
improving myself in the practical area. I made my internship at one of the Schneider
Electric factory which produces power transformers. The company is related to my
departments requirements due to producing different kinds of transformer. In fact, the
company has a lot of projects and customers from all world due to having huge quality
and high effectiveness. 90 percent of transformers production has been exporting
foreign countries such as France, Japan and Germany.

My summer practice started on 15th August and finished on 11th September. The
purpose of my summer practice in Schneider Electric Company was to be familiar
with the power system electronics, to get familiar with work environment and to
develop my problem solving skills.

I was supervised by Recep Tayi who is an electrical and electronics engineer and
director in this company. This report includes the brief information of the company
and the detailed steps of my work there. It starts with a detailed description of the
company and followed by the weekly description all the work I have conducted,
learned and observed within my summer practice period. After the explanations of my
works, the report has a conclusion part and followed by a reference list.
2.DESCRIPTION OF THE COMPANY
 Figure 1 : Schneider Electric Transformer Factory

2.1 COMPANY NAME:

SCHNEIDER ELECTRIC

2.2 COMPANY LOCATION:

TOSB Organize Sanayi Blgesi, 1.Cad. No:6

41420 ayrova/ Kocaeli Turkey

Phone: (+90 262) 648 05 18

Fax : (+90 262) 658 99 71
E-mail: semra.yilmaz@schneider-electric.com
2.3 Brief History of Company

From 1836 to 2014, Schneider Electric has become one of the global specialists in
energy management. It started originally with the iron and steel industry, heavy
machinery and ship building. After a while, it moved into electricity and automation
management. After 170 years of history, Schneider Electric has become today the
solution provider that will help you make the most of your energy today. The followed
steps of Schneider Electric may be found below respectively.

19th century

1836: The Schneider brothers took over the Creusot foundries. Two years later, they
created Schneider & Cie.

1891: Having become an armaments specialist, Schneider innovated by launching itself

into the emerging electricity market.

First half of the 20th century

1919: Installation of Schneider in Germany and Eastern Europe via the European
Industrial and Financial Union (EIFU). In the years that followed, Schneider
associated with Westinghouse, a major international electrical group. The Group
enlarged its activity to manufacturing electrical motors, electrical equipment for power
stations and electric locomotives.

Post war: Schneider gradually abandoned armaments and turned to construction, iron
and steel works and electricity. The company was completely reorganized in order to
diversify and open up to new markets.

Second half of the 20th century

1981-1997: Schneider Group continued to focus on the electrical industry by separating

from its non-strategic activities. This policy was given concrete form through strategic
acquisitions by Schneider Group: Telemecanique in 1988, Square D in 1991 and
Merlin Gerin in 1992.
1999: Development of Installation, Systems and Control with the acquisition of Lexel,
Europes number two in electrical distribution. In May 1999 the Group was renamed
Schneider Electric, to more clearly emphasize its expertise in the electrical field. The
Group engaged in a strategy of accelerated growth and competitiveness.

2000-2014: Period of organic growth, positioning itself in new market segments: UPS
(uninterruptible power supply), movement control, building automation and security
through acquisitions of APC, Clipsal, TAC, Pelco, Xantrex, and more.

Detail of Schneider Electric, Factory of Transformers in Kocaeli Turkey

AEG ETI was created under Turkish German partnership by AEG AG and
ETIBANK in 1966. The production was started in currently available factory which
located in Gebze.

Process of the producing transformers however operationalized in 1969. Transformers

were produced under the name of GEC ALSTROM in 1997, and then the name of
ALSTROM in 1998. Although transmission and Distribution Department of
ALSTROM Group was sold to AREVA A. in 2004, manufacturing transformers had
been continued under the named of AREVA T&D until 2010. AREVA T&D was
incorporated into ALSTROM Schneider Electric as a result of mutual arragements in
2010 and factroy was relocated from Gebze to ayrova. Producing has been still
continuing under the name of Schneider Electric Transformers Factory since 2010.

2.4 Company by Numbers

1.100 employees, 200 dealers and partners

18 sales offices, 3 production factories

 Figure 2: Wide Sales and After Sales Support Network

Figure 3: Pie Chart of Number of Employees

Figure 4: Pie Chart of Educational Situation of Employees

2.5 Organizational Structure of Company

Table 1: Organizational Structure of Company

 Schneid
er

Saling

2.6 Main Area of Business

Company main productions are 15k 25MVA Dry type cast resin transformers, 25k 4MVA
oil distribution type transformers and 1M 80MVA medium power oil cooled type of
transformers. They can be modified and also adjusted from high voltage windings to different
desired voltage level.
2.6.1 Cast Resin Transformers (CRT)

Cast-resin power transformers simplify installation since they are dry, without cooling
oil, therefore they do not require fire-proof vault for indoor installations. These transformers
windings are encased in epoxy resin. The epoxy protects the windings from dust and corrosive
atmospheres. However, because the molds for casting the coils are only available in fixed
sizes, the design of the transformers is less flexible, which may make them more costly if
customized features (voltage, turns ratio, taps) are required. These type of transformers are
exported to France and used in mostly wind turbine and high speed train systems. While

some kind of windings produced in factory, some kind Figure 5: CRT

are of windings are imported from France due to low

cost.

2.6.2 Oil Distribution Transformers (ODT)

Oil distribution transformers are used to reduce medium voltage to low voltage. Insulating
medium of oil distribution transformers is mineral oil or synthetic (silicon) oil. They are
produced with ONAN (oil-natural air natural) ONAF (oil-natural air forced -fan) cooling
systems. These type of transformers have oil channels in
order to cool the core between their spins according to the
design. In these channels oil flows and cool the system. It
also provides part of the electrical insulation between
internal live parts, transformer oil must remain stable at
high temperatures for an extended period. Although they
can be produced more cheaply than cast resin types, they
need to be controlled and renewed periodically.

Figure 6: ODT

2.6.3 Medium Power Transformers (MPT)

Medium Power Transformers with a power range from 40 to 250 MVA and a voltage of over
72.5 kV are used as network and generator step-up transformers. Medium Power
Transformers are also widely used to step up power from on- and offshore-wind parks, and
may even be installed in offshore-substations. However, in Schneider Electric Medium Power
Transformers are produced with range from 1M to 80M. They are
produced with ONAN, ONAF, ODAF and ODWF cooling
systems. These type of transformers also have oil channels in
order to cool the core between their spins according to the design.

Figure 7: MPT

3. STUDIES
3.1 General Procedure of Producing Transformer
The customers contacts to the sales department of Schneider Electric and specify what
features they expect. These features can be given as like below;
S: Power

V: Voltage

Uk= Short Circuit Voltage

F: Frequency

Special Request

After that the sales department get these information and delivers them to Engineering
Department. Having regard to suitable cost of the transformer, Engineering department design
a prototype project. This project is prepared according to the following criterias.

Po= Iron Loss

Pk= Copper Loss

Cooling System

The materials that will be used under the different kind of weather condition

Cost of the transformer is calculated according to these two steps and then the last design is
sent to the sales department. The sales department delivers these documents to the customer
after that wait their confirmation. If the customers dont satisfy with these documents, another
project is designed and calculated by engineering department and sends to the customer again.
If the customer is approved the project, the figures, designs and materials are sent to the
factory and the production is started in factory immediately. Manufacture and assembly steps
are established respectively in the production area. These are;

Core cutting and stacking,

Winding,

Active part assembly,

Tank assembly.

All of the processing steps are ended in regard to the technical information that is desired by
the customers datas. After this, Electrical test are applied on transformers. The transformers
is delivered to the customer only if transformers get passed from electrical tests. The
production steps are given in table 2 in detail.

Table 2: Steps of Producing a Transformer

3.2 Magnetic Core Material and Properties

Slitting
Slitting Line
Line

CRT
CRT -
- (Cast
(Cast ODT
ODT - - (Oiled
(Oiled MPT
MPT -- (Medium
(Medium
Rasin
Rasin Distribution
Distribution Power
Power
Transformer)
Transformer) Transformer)
Transformer) Transformer)
Transformer)

Core Cutting
Core Cutting Core
Core Cutting
Cutting Core Cutting
Core Cutting

Core
Core Stacking
Stacking Core
Core Stacking
Stacking Core Stacking
Core Stacking

Winding
Winding Winding
Winding Winding
Winding

Active Part
Active Part Active Part
Active Part
Cast
Cast Rasin
Rasin Assembly
Assembly Assembly
Assembly

Drying Drying Drying

Retouching
Retouching Tank Assembly
Tank Assembly T
Tank
ank Assembly
Assembly

Active Part
Active Part Electrical Test
Electrical Test Electrical
Electrical T
Test
est
Assembly
Assembly

Last
Last Assmebly
Assmebly
Last
Last Assmebly
Assmebly And
Electrical Test
Electrical Test
And And Packing
Packing
And Packing
Packing

Last Assmebly
Last Assmebly
And Packing
And Packing

Magnetic core is a high permeability material which is used for to guide magnetic fields in
transformer. Lately, transformers magnetic cores were produced by sheet steel punching
firmly clamped together. However, recently, core construction consists of a continuous strip of
silicon steel which is wound in a tight spiral around the insulated windings and firmly held by
spot welding at the end. These type of metal sheet is named as Si- Fe composition metal sheet.
This new technique reduces the cost of manufacture and reduces the power loss in the core
due to eddy currents. Sometimes the laminations are coated with a thin varnish to reduce
eddy-current losses. This kind of magnetic core production is cheap and easy. Schneider
Electric are using this type metal sheet for constructing transformer cores. Eddy current losses
can be found in following formula.

kB 2 f 2 D2
P=

Figure 8: Explanation of Variables of Eddy corrent losses formula

3.3 Observation of Production

3.3.1 Slitting Line

Figure 9: XBJ1-05-05 Slitting Line Machine

First of
all,
the

producing of a transformer start with slitting metal sheet into varied dimension. Crosscut
sliced Si Fe composition metal of sheets are provided from slitting line machine named by
XBJ1-05-05, to ODT, CRT and MPT core cutting departments. Rolls of the metal sheet are
imported from foreign countries. With respect to what customers desire, different types of
metal sheets are used in the transformers magnetic core parts. As it could be seen in figure 1,
in Schneider Electric, there are six types of metal sheets that are called as M3, M5, M5
LAZER, MOH, H0 and H1. According to data sheet of construction department engineers,
slitting line machine operators arrange the range of cutting length observantly before moving
on the core cutting. After that, the arrangement of machine metal sheets are sliced widthwise.
One of the example data sheet is given in figure 2. The machine is controlled from a control
panel by operators. Besides operators can observe the process from machine monitor. If there
is a problem, they may stop machine from this panel.