Sr. Contents Page no.

no.
1 Introduction
i) Brief about Swagat Program. 2
ii) Shop floor visit on 20th March 2019.

2 Day 1- 25th March 2019

i) Cell-1 4
3 Day 2- 26th March 2019
i) Cell-2 5
ii) Winding & Final assembly stores.

4 Day 3- 27th March 2019

i) Plant maintenance. 7
ii) Basic industrial safety.

5 Day 4- 28th March 2019

i) Quality incoming & In-process inspection. 8
ii) Oil test lab.
iii) Process cell

6 Day 5- 29th March 2019

i) HV test laboratory. 10
ii) Control Panel & CMS.

7 Feedback & Suggestions

i) About Prcocess. 11
ii) About Safety.

8 Approximate Cycle Time in The Previous Organization for

Transformer Production 13

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 INTRODUCTION

i) Brief about Swagat Program.

Swagat program was held from 18th March 2019 to 20th March 2019. In this program, first L
& D team welcomed us. Senior management team gave us the information about financial year
of siemens & Vision 2020+ - Operating model based on purpose and ownership culture.

Value Creation through business focus & Flexibility

Vision 2020+

The HR manager introduced us about integrated structure of organization, various HR persons,

GRIP structure, Compensation & Benefits, Meal card, various schemes, retiral benefits, NPS
system, employee insurance, Performance & incentive scheme, siemens equity system, Leave
& Travel policies, work life balance, Education & ERP policies and code of conduct & work
culture.
Senior management team gave us information about structure of operating & Strategic
companies, and verticals of siemens organization. We got informed about various divisions
like Process industry & drives (PD), Digital factory (DF), Building technology (BT), Mobility,
Energy management (EM), Siemens Healthcare (HC) and Wind power (WP).
We got basic compliance training in which we are told business conduct guidelines by
compliance manager, transparency international (TI), Corruption perception index (CPI),
Antitrust, Anti money laundering.

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 We also got informed about IT policies & procedures,

i) IT Hardware / Software / Devices – Usage

ii) Information technology & Internal regulation
iii) IT Asset Lifecycle Management
iv) Mobile Device Procedure
v) PC Procurement and PC Lifecycle Process
vi) Notifications during IT related outages.

Corporate Social responsibility (CSR)

Siemens has always endeavored to be an integral part of the India’s Society for more than 5
decades in various projects like Upgradation of industrial training institutes, Project Aasha
(mokhada village), Siemens Scholarship program, Sanjeevan- The mobile healthcare clinic,
Drought mitigation project, Education scholarship to destitute children, And Skill development
centre.

ii) STI plant round on 20th March 2019

In the afternoon at 4:00 pm we visited Siemens transformer India, Kalwa factory. We had an
interaction with Mr. Sanajay Lokhande, he guided us about our department, & motivated us to
work in siemens culture. He introduced us to our reporting manager Mr. Vivek Dugdhe, we had
factory round with him starting cell 1 to cell 3. He introduced us to various departmental heads &
supervisors. We were shown various running activities in plant by him. We have seen very
attractive devices, tools & equipments in the plant that we haven’t seen before like Air Caster,
Various JLG’s, Centralized vacuum system etc. He also planned induction schedule for us from
25th March 2019.

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 DAY1
CELL-01

On 1st day of shopfloor induction Cell 1 leader Mr. Rajendra karale gave us brief introduction of
cell one Winding section and winding block assembly and informed about shift supervisor and no
of workmen. There are 15 winding machines including 9 Vertical winding machines of 35T
capacity & 6 Horizontal winding machines of 15T (5 Nos),20T(1nos.) Capacity. For winding
stabilization and height achievement there are two VPD ovens One is ABB Micafill and other one
is hedrich make.
All equipemnts are well arranged in Four bays. One bay having Horizontal and vertical machines
other two bays are for bobbins stands and last bay is for 3 newly arranged vertical machines.
There are some good practices incorporated by Cell 1 Team
1) Masking tape for copper burr removing.
2) Shadow board for tools on each machine
3) Butt joint for CTC and PICC copper
4) Certified Permanent marker for bay numbering and other use.
5) In House plant 1:8,1:12 to avoid wastage, cost reduction and improved shelf life of glue.
6) Slot on Strip spacers for block insertion and extra-long length.
7) Tension arrangement for Bobbin drums.
8) Oil impregnation within VPD to minimize contact of insulation with atmosphere.
9) Use of Air caster for inter bay transport.
10) Fiber optic sensor maintaining very good power after so much bending at top end insulation
of HVDC Job.
All workmen are well trained and technically strong.
Need for improvement:
Use of SER tapping machine instead of hand tapping will improve productivity by 2 shifts &
quality of overlap also improve.
Making winding cylinder on vertical machines with help of scrap copper bobbins or ratchet straps.
Edges of ride-over paper to be rounded to avoid sharp corners.
Use of frames made of wooden/plastic board with transparent sheet to display drawings.
Access to door of the vertical winding machines to be change from inside opening to the outside
opening improving safety in case of any emergency.

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 DAY – 2
CELL-2

On 2nd day of shopfloor induction Cell 2 leader Mr. Chandrakant Jadhav gave us brief introduction
of cell two Assembly section & Core building section. He also gave us information about shift
supervisor and no of workmen. There are 3 Work stations for Assembly and connection. One work
station is separate for core building. There is also space for advance connection preparation of
core coil assembly. There are Two VPD ovens for active part drying. One is of ABB mica filled,
and other one is of hedrich make.
There are some good practices incorporated by cell 2 team:
1) Advance cleats and connection arrangement which gives 3 days of lead time improving
productivity and quality.
2) Separate shadow board for each work station having color coding.
3) Top yoke filling from both sides, again improving productivity.
4) Covering core coil assembly while working on job, that helps us to prevent the entry of dirt
and foreign particles
5) Platform extension available with safety guards while working on CCA and yoke filling.
6) Digital display on each work-station, which helps to view drawings whenever needed.
7) Use of 8-Point lifter to lift Core, improving quality.
8) Resin glass binding on core limbs with binding machine, helps to bind tightly and firmly
the limbs, adding to quality improvement.
9) Use of Air caster eases the inter-bay transportation.
10) Use of safety harness while working on height.
Need for Improvement:
Use of crimping instead of brazing at tap lead connection on coil side, that will improve
productivity & quality.

Winding & Assembly Stores

Store manager Mr. Swapnil Shilwant introduced us to store engineers and workmen. He also
helped us to understand working and layout of store area. The winding & assembly stores are
separated from each other. The material which require care from moisture like insulation are
unloaded in winding store. Generally, all final assembly material is stored in assembly stores and
some material on outside also. The winding stores is air conditioned to prevent from dust and
moisture. After receipt of material at security stage, store person visually checks and enters into
the system, forwarding to the quality for further checks. They issue the material to concerned cells
with the help of pick list given to them by planner.
There are some good points incorporated by the team:

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1) Good 5’s practice within store.
2) Air-conditioned storage area for winding.
3) Distributed arrangement of stores.
Need for Improvement:
Final assembly material lying outside the stores & shop due to which material needs to be
cleaned or washed while mounting.

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 DAY-3
PLANT MAINTENANCE
Maintenance in-charge introduced us to maintenance engineers and contractual workmen
involved. He also helped us to understand layout and working of maintenance department. They
have well prepared charts showing all equipment’s used in shop floor right from 400T EOT crane
to office area maintenance. This chart is having color codes which shows the condition of
equipment showing whether it is working healthily, under breakdown or in preventive
Maintenance. This Chart also shows the total quantity of EOT cranes, JLG devices, Boom lifters,
AHUs, Air casters, VPds etc
They used to carry three types of maintenance:
1) Preventive Maintenance
2) Predictive Maintenance
3) Breakdown Maintenance
The first two maintenance helps the department in equipment availability reducing the downtime
of the equipment.

PROCESS CELL
Process in- charge Mr. Kushal Patil gave us the brief idea about workmen involved, layout and
function of the cell. He also helped us to understand the area under which they coordinate with
other departments.
They monitor 4 VPD ovens used for drying, 2 are of ABB mica filled having dimension of 15.2 m
x 5.2 m x 6 m having evaporator of 400 kW, wall heating is done through pipes. It has the vacuum
pumping system of 14100 m3/hr. Other two ovens of Hedrich make having dimension of 15 m x 5
m x 6.05 m. It has thin film evaporator of 500 kW; wall heating is done through limped coils. It
has the vacuum pumping system of 26890 m3/hr. They also use brickets i.e. agricultural waste to
heat the boiler reducing the carbon and energy efficient.
They have two types of vacuum system, one is fixed vacuum system having capacity of 9000 m3/hr
and portable having capacity of 4500 m3/hr.
For oil storage purpose, they have 5 oil tanks having total capacity of 300 kL. For oil filling they
have 4 stations having 1 HMI. They also have 3 oil filtration units having capacity of 10kl/hr and
6 kl/hr. They also have the high-speed flushing machine to control the contamination of
hydrocarbon fluid. It has acceptance criterion of NAS<3.

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 DAY-4
IN-COMING & IN-PROCESS QUALITY
Quality incoming is headed by Mr. Rahul patil. He introduced us to the staff working under him
and explained basic process and layout of his department. All material received at stores is checked
by incoming quality. Some of material is also checked at the vendors end, depending on the
situation or need. After all quality check they labelled them as GREEN (accepted), YELLOW
(hold) and RED (rejected) depending on the results. The rejected material is sent back to supplier,
hold type material is rectified or corrected either at inhouse or at vendor end. They also have team
for fabricated and tank related component inspection at supplier’s end. Two engineers are present
at Bhopal for tank inspection in that area.
Quality in-process is headed by Mr. Lyndon Johnson. He introduced us to the staff working under
him and explained basic process and layout of his department. His Department crucially involved
with each department within company. They have quality checklist for each department. They also
conduct quality gate at certain stages to transfer job between departments in presence of concerned
department person to deliver job with acceptance quality criterion.
Quality gate is conducted at following stages:
1) Cell 1 to Cell 2
2) Cell 2 to Cell 3
3) Cell 3 to Testing department
4) Cell 3 to Dispatch.

OIL TEST LAB

Oil test lab is headed by Mr. Chetan Patil. He introduced us to the staff working under him and
explained basic process of his department. Oil test lab is air conditioned and humidity controlled.
The lab is having NABL accreditation.
They take the sample of oil at different intervals:
1) Prior to all test.
2) Before Dielectric test.
3) After Dielectric test.
4) Before Temperature rise.
5) After Temperature rise.
The test lab is well equipped with the various equipment which conduct following tests:
1) BDV test: Acceptance criterion is 70 kV
2) PPM test: Acceptance criterion is below 10 ppm
3) Tan-delta resistivity test.
4) DGA: before and after temperature rise test.

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 5) Furan analysis to examine degree of polarization.
6) Viscosity test: To check oil at extreme weather conditions depending on location.
7) IFT test:
8) Flash point test.
9) Pour point test.

BASIC INDUSTRIAL SAFETY

We had a brief introduction of industrial safety given by safety persons. He gave us information
about siemens safety guidelines. Also given us details of assembly point in case any emergency,
ambulance details, first-aid kits. He helped us to understand safety vs injury curve. He also told us
what precautions need to be taken in our day to day activities by suitable examples. Use of PPE’s
is compulsory inside the plant. It is compulsory for permanent as well as contractual workmen.

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 DAY-5
HV TEST LABORATORY

On last day of shop-floor induction testing in-charge Mr. Gopinath Reddy gave us brief
introduction of Testing bay. He also gave us information about shift supervisor and no of work-
mens. He shared us the capacity of the test facility available in the plant. The highest rating of
transformer tested is 500 MVA 765 kV. And for reactor it is 125 MVAr, 550 KV.
He explained us various tests carried out on transformers like voltage test ratio, polarity, CT test,
no load current measurement, short circuit impedance test, measurement of winding resistance,
measurement of insulation resistance and polarization test, impedance and load loss test, no load
loss test, OLTC test , test on oil, lightning impulse test, switching impulse test, applied switching
test, applied voltage withstand test, partial discharge test, and temperature rise test.
He also explained us about the safety instruction and precautions while testing the job. He shown
us the emergency exit door locations available in testing bay.

CONTROL PANEL & CMS

Control panel engineer Mr. Premraj Patil took us around the plant and showed us marshalling and
RTCC panels. He also briefed us various meters and switches used in panels. He also introduced
us about the latest technology used by the siemens to predict the expected life time of the working
transformer. Sensformer is the technology in which it takes 3 readings from temperature sensor
P T 1 0 0 , B u c h h o l z r e l a y , W T I s e n s o r .

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 SUGGESTIONS/FEEDBACK
Cell 1:
1) Use of SER tapping machine instead of hand tapping will improve productivity by 2 shifts.
2) This Also improve Paper overlapping and paper tightening.

Crepe paper overlap is not uniform

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3) Making winding cylinder on vertical machines with help of scrap copper bobbins or
ratchet straps.
4) Edges of ride over paper and winding radial block to be rounded to avoid sharp corners.

5) Use of frames made of wooden/plastic board with transparent sheet to display drawings.

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 6) Access to door of the vertical winding machines to be change from inside opening to the
outside opening improving safety in case of any emergency.

Cell-2
Use of crimping instead of brazing at tap lead connection on coil side, that will improve
productivity & quality.
Cell-3
1) Legs of forklift (Stacker) should have extension to shift radiator boxes. It has risk of falling
with present method.

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 APPROXIMATE CYCLE TIME IN THE PREVIOUS ORGANIZATION FOR
TRANSFORMER PRODUCTION

Type of Voltage Rating MVA rating Upto Final Upto Dispatch

transformer testing Stage
GT & System <=132 <=75 30 36

Auto 220 <=100 32 39

GT & System 220 <=100 36 43

Auto 220 100<V<315 40 47

GT & System 220 100<V<315 44 51

Auto 400 315 60 70

Traction 25 31.5 25 30

Locomotive 25 7.5 25 30

Winding:
Winding department consist of winding, Clamping & Ovening and SPA area. There are total 12
nos of winding machines running currently out of which 6 are horizontal type and 6 are vertical
type. There is VPI oven for coil drying with 3 iso-static devices for coil stabilization. For GT &
Auto upto 100 MVA, Winding preparation & ovening takes upto 8 days considering 2 shifts / day.
In case of 315 MVA it takes 13-15 days. In case of short circuit job 2 times ovening is to be done.
For SPA (separate phase assembly), it takes 3 days for 132 kV & 5 to 6 days for 315 MVA.
For SPA stabilization, ovening cycle of 24 hrs to 48 hrs in fine vacuum is carried out after
achieving fine vacuum. After achieving temperature & vacuum criterion SPA are handed over to
erection department.

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Erection:
Core assembly, Core coil assembly & Connection comes in this department. Generally, Core
building of 132kV unit takes 3 days. For 400 kV it takes 4-6 days. There 4 core building fixtures
with different capacities. There are 3 work stations for top yoke filling & connection it takes 5 to
10 days depending upon rating & MVA level.
After CCA joint inspection and balance point completion it is loaded in VPD oven for final drying.
There are 2 VPD ovens. Drying of transformer having rating of 132kV takes 4 days. For 400 kV
it takes 6 – 8 days. In period of monsoon they do double ovening of active part.
Tanking:
Servicing, tanking & Final fitting comes in this section, we also have exposure time in previous
organization, it is 8 hours for 132 kV, 12 hours for 220 kV, 18 hours for 400 kV. Tanking &
Vacuum application generally takes 3-5 days. For oil filling it takes 1-2 days. After Final fitting &
panels connection job handed over to testing department, it takes 3-5 days for final fitting. Testing
& customer inspection generally takes 3 to 6 days. After final testing, for dismantling, it takes 1 to
2 days. After that dismantle PT for 8 to 12 hours, we apply vacuum for 12-24 hours, then N2 or
Dry air is to be filled as per customer requirement. After achieving dew point upto -36 degrees,
job is handed over to dispatch department.
Dispatch:
For main unit it takes 1-2 days for dispatch with tarpaulin covering. For accessories dispatch it
might take 5-12 days as per requirement.

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