ASSEMBLY

After our calculations and tests, we then move forward to the manufacturing process. For
this we divide our work in different steps like core cutting and insulating.

Core Cutting:
This step involves the cutting of silicon cores for stacking them to form a transformer.
We cut the cores in two different ways in EI type laminations for shell type. As the name
suggests, the cores are cut in the shape of E and I. They are stacked on top of each other.

WAPDA 0.23mm

PRIVATE COMPANIES 0.27mm

Silicon Steel Lamination Thickness

These are further graded depending on the flux density and cost. WAPDA copes with the
laser grade (lesser losses) because of high flux density and the private sector uses m4
grade laminations.

Following is an illustration of how it is set up:

This way we have our structure including two side limbs and a center limb to form the shape
of E. After this we fit our coil inside the formed structure. The coil is perfectly fitted and we
also add I type cores to stack it better and to avoid losses between core sheets. The core
dimensions are as follows:
Coil Assembly:

Coil assembly focuses on the winding type, conductor type and the insulation
components. After we have chosen our components, our coil is manufactured and the
windings are done. It is upto the client to suggest what kind of winding he wants.

The following is a figure of disc winding:

After the assembly we arrange the connections and wires.

Removal of Moisture:

Then the whole assembly is dried in a furnace under 100 degree celsius temperature
to remove the moisture from the transformer. This is the vapor phase cycle method and in
this we keep note of the power factors and water extraction. Everything is being monitored to
avoid harm to the transformer.

Tank:
 After this the transformer is taken to the tank fitting shop and it is fitted into a tank
(made of high grade mild steel) which is grit-blasted, cleaned and then painted on. After
fitting our transformer into the tank, we cover it using a tank cover. This cover has flanges
that prevent water from entering and damaging the transformer. Each transformer tank is
tested for leakage by filling them with oil and keeping then under pressure of 0.5 kg /c m 2 or
above for several hours. The bushings that are present on the tank cover facilitate the
passage of the conductor through the grounded tank. They are insulated and reduce friction.

Bushes

11kVA 355mm

33kVA 510mm
Creepage Distance of Bushings

Cooling System:
In some transformers, which are used to generate high power and bear high load,
they are fitted with a cooling system to cool them off.

Pressure Relief Device:

Pressure relief device is used to remove the excessive volume of pressure in the
transformer.This device operates during a serious fault that has occurred in the transformer
tank. It operates by letting air pass out using a diaphragm which opens and closes to set a
suitable pressure inside.
At the end the transformer is inspected thoroughly and is exposed to the normal temperature
for a few hours. Then it is ready for dispatch.