Assembling large transformer and inductor cores
Overview
This standard identifies the competences you need to assemble large transformer and inductor cores, in accordance with approved procedures. This will involve selecting the correct components and materials, cutting and forming components, constructing the cores, applying insulation, completing the curing process and checking electrical and mechanical integrity of the transformer/inductor core. You will be required to select the appropriate tools and equipment to use, based on the operations to be performed and type of components to be fitted and to check that they are in a safe and serviceable condition. In carrying out the operations, you will be required to follow laid-down procedures and specific assembly techniques. The assembly activities will also include making all necessary checks and adjustments to ensure that components are correctly positioned and free from damage.
Your responsibilities will require you to comply with organisational policy and procedures for the assembly activities undertaken and to report any problems with the assembly activities, components or equipment that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with a minimum of supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.
Your underpinning knowledge will provide a good understanding of your work and will provide an informed approach to applying assembly techniques and procedures to large transformer or inductor cores. You will understand the transformer or inductor core being assembled and its application and will know about the assembly techniques, tools and methods, in adequate depth to provide a sound basis for carrying out the activities to the required specification.
You will understand the safety precautions required when carrying out the assembly activities and when using the associated tools and equipment, especially those for lifting and handling the components safely and correctly. You will be required to demonstrate safe working practices throughout and will understand the responsibility you owe to yourself and others in the workplace.
Performance criteria
You must be able to:
P1 work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
P2 follow the relevant instructions, assembly drawings and any other specifications
P3 ensure that the specified components are available and that they are in a usable condition
P4 assemble the components in their correct positions, using appropriate methods and techniques
P5 secure the components using the specified connectors and securing devices
P6 check the completed assembly to ensure that all operations have been completed and it meets the required specification
P7 deal with problems within your control and report those that cannot be solved
P8 complete and store all relevant documentation in accordance with organisational requirements
P9 leave the work area in a safe condition on completion of the activities, as per organisational requirements
Knowledge and Understanding
You need to know and understand:
K1 how to work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
K2 the importance of wearing the appropriate personal protective equipment (PPE), and of keeping the work area clean and tidy
K3 how to obtain and interpret drawings, planning sheets and records and other documents needed for the core assembly activities
K4 the basic operating principles of the transformers and inductors being assembled
K5 the factors to consider when selecting steels to fabricate large transformer or inductor cores
K6 the methods and techniques to be used when assembling large transformer or inductor cores
K7 the different types of core insulation used, and the methods used to cut and form them
K8 the various core construction-laying techniques that are used
K9 the methods and techniques used to build yokes and limbs, limb cores, inductor cores and magnetic shields and shunts
K10 the methods used to fit the core clamp
K11 the factors to consider when fitting foundation feet, core and tie bolts and insulation and earth strips
K12 the purpose of core limb banding tape
K13 the different methods used for curing
K14 the procedures that will ensure full strength processing in respect of steel banding, removal of core limbs, drying procedure and application of suitable varnish
K15 the methods used to check for electrical insulation of the completed assembly and the importance of these checks
K16 the visual checks and preparation requirements for components to be used in large transformer or inductor core assembly activities
K17 the methods, tools/equipment used to transport, handle and lift the components into position and
K18 how to check that the tools/equipment are within current certification dates, free from damage and defects, in a safe and usable condition, and configured correctly for purpose
K19 the extent of your own responsibility and to whom you should report if you have problems that you cannot resolve
K20 how to access, use and maintain information to comply with organisational requirements and legislation
Scope/range
Scope Performance
- Assemble the transformer or inductor cores by carrying out all of the following activities:
- use the correct assembly drawings, specifications and job instructions
- adhere to health and safety regulations, systems and procedures to realise a safe system of work
- ensure that components are free from damage, foreign objects, dirt or other contamination
- check that all tools and equipment are within calibration date, where appropriate
- use safe and approved techniques to assemble transformer cores and related components
- leave the work area in a safe and tidy condition
- Assemble transformer or inductor cores, using six of the following methods and procedures:
- cutting and forming laminates
- impregnating and curing components
- orientating and positioning components
- electrical bonding of components
- aligning components
- soldering/brazing
- assembling and clamping
- securing/using mechanical fasteners/threaded devices
- assembling components by pressure
- torque setting
- setting clearances
- applying threaded locking methods
- Carry out assembly operations using all of the following components:
- electrical steels
- clamps
- laminates
- foundation feet
- core limb binding tape
- core and tie bolts
- insulating materials
- earth strips
- Assemble transformer or inductor cores using four of the following assembly aids and equipment:
- cutting and punching machines
- lifting and moving equipment
- workholding devices
- measuring equipment
- laminate cutting machines
- specialist assembly tools
- Assemble three of the following transformer or inductor core types:
- rectangular
- elliptical
- multi-limb cores
- multi-step
- plain yokes/limbs
- multi-gap inductor cores
- round
- stepped yokes/limbs
- magnetic shields and shunts
- Assemble transformer or inductor cores, using three of the following core construction/laying techniques:
- butt joints
- square junctions
- single lamination
- overlap joints
- mitred junctions
- multiple lamination
- Carry out the required checks using appropriate equipment, to include six of the following:
- positional accuracy
- electrical continuity
- dimensions
- component security
- orientation
- completeness
- alignment
- freedom from damage or foreign objects
- Assemble cores which comply with one of the following standards:
- organisational drawings and procedures
- customer requirements
- current industry standards, codes of practice and procedures
- other international standards