Transformer Manufacturing Process

2015 Article

The main process line of the Virdi’s HT transformers is:

Core: The core is made with laminated and low loss electrical steel sheets that is imported, grain oriented, cold rolled and sheets of high grade steel. The cores are assembled in
a manner that they reduces the noise caused by vibration;
individual stamping are coated with insulation varnish which
is resistant to heat and oil on both sides. The core is connected
to the clamp which ensures that it is effectually earthed. The
core legs are bounded with heavy duty insulating tape. The
yokes are rigidly and securely clamped between the folded
steel channels. Clamps on top and bottom are firmly attached
to each other by the means of tie rods. Tie rods serves the
dual purpose of transferring the load from the bottom to the
top clamps and securing the winding in place. This prevents
tensile stress being setup in the core legs, which could
adversely affect the iron losses.

Winding: Transformer windings also known as ‘Coils’ are precisely designed to meet three basic requirements: thermal, mechanical and electrical. These windings wound concentrically and are cylinder shaped. Both HV and LV type windings are wound with adequate securing and brazing
tapes in order to get a sturdy, robust and self-supporting structure.

Winding Connections: Tapping and phase leads run in paper covered conductors. Adequate barriers are used to separate the phase leads from the tapping. Rigidly brazed tubes are used to maintain the required clearance from coil to tank.