SAIEE Accredited

Transformer Design and

Manufacturing Training Course

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Transformer Design andManufacturing Training Course

Overview

A transformer is a static device with two ormore windings that are linked to each otherby means of a strong magnetic field.Transformers are designed for specificpurposes. The design requirements oftransformers depend on the application.

Large power stations where the electricenergy is generated are often situated faraway from the numerous places where theenergy is consumed. Therefore it is vitallyimportant that proper maintenance and checksare done on transformers to ensure that theyare operating correctly.

It is recommended that during the first yearof operation the checks should be carried outfrequently.

Considerations whether the transformer mustbe isolated, energized or loaded duringmaintenance must also be taken into account.

Powertech Transformers is offering atransformer design and manufacturing trainingcourse which covers various elements ofpower transformers over a five day period.

Course Content

The course covers design processes, bothelectrical and mechanical; fabrication;insulation; paper-lapping; core-cutting; corestacking, winding manufacture; windingassembly; quality assurance and control;factory testing; active part assembly; oilprocessing and tanking; protectioncomponents, first line maintenance andtransport and dispatch of the transformers.

Format of the Course

The course will take the format of both practicaland classroom training.

The course content will be covered over fivefull days at our factory in Pretoria West.

Competent Trainers will be covering therelevant topics in the course.

The course is accredited with the SAIEE—ref:SAIEE-0889-V and CPD and 4 points can beclaimed.

A d m i s s i o n R e q u i r e m e n t s

Personnel from utilities, consulting engineers,etc. including Test Technicians andmaintenance personnel.

Manufacture of windings for different

applications

This topic comprises the different types of windingswhich can be designed for various applications.The selection and arrangement of windingsrequired are also covered in the course.

Mechanical fabrication

This is the last module covered in Day 1 andencompasses all aspects of the transformer tankwhich is primarily the container for the oil and aphysical protection for the active part. It alsoserves as a support structure for the accessoriesand control equipment.

Transformer Design andManufacturing - Day 1

A power transformer mainly consists of windingsarranged concentrically around a high grainmagnetic core. The combination of the windings,core and associated harness structure is calledthe active part. The electrical designer isresponsible for dimensioning of the active part byrunning various calculations and simulations.

Once the active part design is completed, themechanical designer will design the structural tankthat contains the active part. The purpose of thetank is to contain the cooling and insulating mediumfor the active part. The tank also structurallyprotects the active part against the environmentalconditions the power transformer will be exposedto.

The active part and associated tank sizing is basedon the voltage level and the transformer powerrating. The higher the voltage level of thetransformer the larger the internal and externalclearances must be. The larger the power ratingthe higher the requirement would be for the coolingof the active part. All the electrical and mechanicaldesign concepts are discussed during thepresentat ion of the design concepts.

Powertech Transformers training modules coverpower transformers only.

Course Content

Day 1 of the course involves the following:

Manufacturing of power transformers

The topic involves all aspects of the overallmanufacture of power t ransformers .

Design and processing of power transformers

This topic comprises the importance of writingstandardized specifications as well as technicalschedules. Also covered is the basic layout of atransformer and the design processes, bothelectrical and mechanical and the importance ofexternal design reviews.

Tr a n s f o r m e r D e s i g n a n dManufacturing - Day 2

A power transformer consists of various parts thatare manufactured for various purposes byPowertech Transformers. Transformer cores arebuilt from thin sheets of special high grain magneticsteel metal. These sheets are manufacturedspecifically for use in transformers. There arevarious types of conductor material that may beused on the windings which are namely papercovered copper strip conductor, enamelled coatedcopper or continuously transposed cable (CTC) oraluminum. The choice of conductor materialdepends on design requirements, price andavailability. Insulation material must be able towithstand the operating temperatures that occurin the transformer during its l i fet ime.

Course Content

Day 2 of the course involves the following:

Insulation structures and cooling

This topic covers mechanical and dielectric strengthof materials, oil impregnation and the specificationsregarding moisture content.

Different types of cooling systems available i.e.ONAN, ONAF, OFAN, OFAF, OFWF as well asODAF.

Mechanical design covers the following topics:

• Mechanical Design Process Flowchart

• Design Procedure

• Automated Design Tools

• Mechan ica l Des ign System (MDS)

• Active part, core, cleats and leads, tanking anddesign verification

A session in various parts of the factory is the finaltopic covered in Day 2. This session focuses oninsulation, paper-lapping, core cutting, corestacking, winding manufacturing and windingassembly.

Topics covered here include the following:

• Documented procedures and documentationdevelopment process.

• Internal audits.

• Incoming and on-the-job Inspections

• Customer complaints, NCR's, etc

• Customer complaints, NCRís, etc

• Testing of transformersThe purpose is to provide a guideline for customerrepresentatives, as well as other interested parties,on routine and type tests. This covers test methodsand sequences normally used.

The final session of the day focuses on active partassembly, oil processing and tanking. This sessionis in the format of a practical session in the factory.

T r a n s f o r m e r D e s i g n a n dManufacturing - Day 3

The functional reliability of transformer installationsdepends on the suitability and quality of thetransformer, components and the processesemployed. Powertech Transformers adheres tothe international standard of quality managementsystems, namely ISO 9001-2008.

Course Content

Day 3 of the course involves the following:

Quality Assurance and Control

Quality control (QC) is a process by which themanufacturing quality of all factors involved inproduction is checked against set designrequirements and manufacturing tolerances.Quality control focuses on in process testing ofproducts to uncover defects and report tomanagement.

Quality Assurance (QA) attempts to improve andstabilize production (and associated processes) toavoid, or at least minimize, issues which led tothe defect(s) in the first place.

The focus from QA is on process improvementthrough trend analysis of reported defects.

T r a n s f o r m e r D e s i g n a n dManufacturing - Day 4

The transport, installation and commissioning isan important part in the supply chain of a powertransformer. After the Factory Acceptance Test(FAT), the transformer is disassembled and madeready for transporting. Depending on the weightand size of the transformer special transport isrequired and should be performed by experts inhandling heavy goods.

Course Content

Day 4 of the course involves the following:

Despatch of the power transformer from factoryto site

Topics covered here include the following:

Use of impact recorders during transport, externaland internal inspections, dry air pressure system,packaging of all components, preliminarycommissioning test and oil handling on site.Power system protection deals with the protectionof electrical power systems from faults throughthe isolation of faulted parts from the rest of theelectrical network. The objective of a protectionscheme is to keep the power system stable byisolating only the components that are under fault,whilst leaving as much of the network as possiblestill in operation. Thus, protection schemes mustapply a very pragmatic and pessimistic approachto clearing system faults. For this reason, thetechnology and philosophies utilized in protectionschemes can often be old and well-establishedbecause they must be very reliable.

Protection on the transmission and distributionnetwork serves two functions: Protection of plantand protection of the public (including employees).At a basic level, protection looks to disconnectequipment which experience an overload or ashort to earth.

Protection components include the following:

• Bucholtz

• Pressure relief valve• Rapid rise relay• Bag leak detector• Rubber bag• Breathers• Marshalling Kiosk• Sudden flow stop valve• Oil level indicator• Temperature indicators

Commissioning tests covers when and under whatcircumstances transformers should be tested, theterminology as well as the recommended fieldtests that need to be performed and the reasoningbehind the tests.

First Line Maintenance (FLM) is aimed atOperations Technicians with the purpose to trainthem in the basic maintenance tasks related totransformers in service. The training entailsapplicable product knowledge and the maintenancetasks that operators can perform themselves toproactively identify abnormal conditions andmeasure deterioration before it affects thetransformer or leads to a failure.The final topic of the day covers factory trainingin the test and despatch areas.

Transformer Design andManufacturing - Day 5

The Powertech Transformers laboratory has beenin existence since 1973. The main activities ofthe laboratory are testing of materials fortransformers and calibration of instruments. Thetesting of transformer oil forms a large part of thetesting activities, and this service is also offeredto external companies. Calibration work isperformed for our in-house customers.

Transformer oil testing

The testing of transformer oil is part of apreventative maintenance plan, also known ascondition monitoring. The oil inside a transformerforms an integral part of the insulation system,but is unfortunately subject to quick deteriorationif the preventative maintenance schedule is notadhered to. Adverse load conditions also affectthe oil. It is therefore common practice to havethe oil tested annually. Certain tests also give anindication of the condition of the transformer itselfand, if interpreted correctly, and acted upon, canprevent catastrophic failure of a transformer. Thelaboratory is well equipped to perform all theimportant tests related to condition monitoring,using some of the best equipment available onthe market.

Course ContentDay 5 of the course involves the following:

• Certifications and Accreditations• Laboratory Services• CalibrationThe various laboratories which are available for:• Material Testing• Insulation• Core Steel• Winding Conductor• Oil Testing• Abbreviations used in Transformer Oil Testing• Purpose of Transformer Oil in Transformers• Shortening of the Transformer’s l ife

• Enhancing the life expectancy of a Transformer

• Pitfalls in Transformer Oil Testing• Classification of Tests for Insulating Oils• Classification of Transformers and Switchgear• Oil Sampling• Transformer Oil Tests - why, what and how• Dissolved Gas Analysis• Choosing a Laboratory• Zero Tolerance• Process Instrumentation• Various types of Transformer Designs

Transformer R&D within Design

The development of cutting edge technology fortransformers involves an in-depth understandingof the fundamental phenomena experienced bythe transformer under normal, transient and faultconditions involving voltages and currents. Thesecomplex phenomena are extensively studiedthrough the development of virtual prototypemodels and experiments (including FEM and 3Dsimulations). Essentially, the research teamscontinually assess the improvements of materials,test methods, manufacturing processes and designphilosophies. Tools for computing the designparameters are being developed and verified usingthe virtual experimentation platforms based onnumerical methods. The Technology Departmentparticipates in the development of internationalstandards responsible for benchmarking the designof power transformers. This comes in a form ofcontributions to CIGRE and IEEE working groups.The following disciplines are covered under theR&D section:• Magnetostatic Core and Acoustic performance• Dielectric Integrity• Short Circuit Durability• Thermal Stability

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Terms and Conditions• All registrations will be deemed confirmed and subject to these terms and conditions.• All pricing excludes VAT.• A full refund is available for cancellations received in writing at least 15 working days’ prior to course commencement.• The course fee is non-refundable if less than 15 working days’ notice of cancellation is given.• Registrations received less than the 15 days prior to the course can therefore not be cancelled

Powertech Transformers reserves the right to cancel any advertised course due to insufficent enrolments or to conditions beyond Powertech Transformers control.Payment is required prior to the starting date of the course. please send the payment advice to info@pttransformers.co.za

Date: Reference Code: SAIEE-0889-V

Price: On request

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Branch: CCS Johannesburg Branch Code: 145405 Reference: Company Name - Transformer Training

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Please return your completed registration form to fax: 086 524 6239 or email: training@pttransformers.co.za

Transformer Design andManufacturing - Enrollment Form