Fitting small transformer and inductor cores

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This standard identifies the competences you need to fit commonly used cores in small transformers or inductors and to check the electrical and mechanical integrity of transformer core assemblies, in accordance with approved procedures. 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 for small transformer and inductor cores. You will understand the transformer or inductor 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 operations. You will be required to demonstrate safe working practices throughout and will understand the responsibility you owe to yourself and others in the workplace.

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1. work safely at all times, complying with health and safety legislation, regulations, directives and other relevant guidelines
2. follow the relevant instructions, assembly drawings and any other specifications
3. ensure that the specified components are available and that they are in a usable condition
4. assemble the components in their correct positions, using appropriate methods and techniques
5. secure the components using the specified connectors and securing devices
6. check the completed assembly to ensure that all operations have been completed and it meets the required specification
7. deal promptly and effectively with problems within your control and report those that cannot be solved
8. ensure that work records are completed, stored securely and available to others, as per organisational requirements
9. leave the work area in a safe condition on completion of the activities, as per organisational and legal requirements

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1. the specific safety precautions to be taken whilst carrying out the  activities (including any specific legislation, regulations or codes of practice relating to the activities, equipment or materials)
2. the health and safety requirements of the work area  and the activities, and the responsibility these requirements place on you
3. the hazards associated with  the activities, and how to minimise them and reduce risks
4. the personal protective equipment and clothing (PPE) to be worn during the activities
5. how to obtain and interpret drawings, planning sheets and records and other documents needed for the core fitting activities
6. the basic operating principles of the transformers and inductors being assembled
7. the assembly methods and techniques to be used when fitting small transformer/inductor cores
8. the different types of core that are used
9. the methods used to fit the core clamp
10. the factors to consider when fitting foundation feet, core and tie bolts/ insulation and earth strips
11. the purpose of core limb banding tape
12. the methods used to check for electrical insulation of the completed assembly and the importance of these checks
13. the visual checks and preparation requirements for components to be used in small transformer and inductor core fitting activities
14. the methods and equipment used to handle and fit cores into position and the procedures to be followed when doing so
15. how to check that tools and equipment are free from damage or defects, are in a safe and usable condition and are configured correctly for purpose
16. the extent of your own responsibility and whom you should report to if you have problems that you cannot resolve
17. how to access, use
    and maintain information to comply with organisational requirements and
    legislation

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1. Fit small transformer or inductor cores  carrying out all of the following activities:

   1. use the correct assembly drawings, specifications and job instructions
   2. adhere to health and safety regulations, systems and   procedures to realise a safe system of work
   3. ensure that components are free from damage, foreign objects, dirt or other contamination
   4. check that all tools and equipment are within calibration date, where appropriate
   5. use safe and approved techniques to assemble transformer cores and related components
   6. leave the work area in a safe and tidy condition

2. Fit cores using four of the following methods and procedures:

   1. cutting and forming laminates         
   2. impregnating and curing components
   3. orientating and positioning components 
   4. electrically bonding components
   5. aligning components                                
   6. soldering/brazing
   7. assembling and clamping                         
   8. securing using mechanical fasteners/threaded devices
   9. assembling components by pressure       
   10. torque setting
   11. setting clearances                                  
   12. applying bolt locking methods

3. Fit cores using all of the following components:

   1. insulating materials                                            
   2. core and tie bolts
   3. clamps                                                           
   4. earth strips
   5. foundation feet                                             
   6. banding strips
   7. clips

4. Fit two of the following cores to transformers or inductors:

   1. stampings/lamination cores       
   2. cut-wound cores        
   3. ferrite cores

5.  Use appropriate equipment to carry out six of the following quality checks:

   1. positional accuracy               
   2. alignment                  
   3. completeness
   4. dimensions                   
   5. component security 
   6. freedom from damage or foreign objects
   7. orientation

6. Fit transformer/inductor cores which comply with one of the following quality and accuracy standards:

   1. organisational drawings and procedures  
   2. current industry standards, codes of practice and procedures
   3. customer drawings and requirements
   4. other international standards

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2

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2023

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Current

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Original

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Semta

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SEMEEE3-25

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Engineering, Engineering and Manufacturing Technologies, Engineering Technicians, Maintenance Team Technician, Manufacturing Technologies, Production and Process Engineers

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3113

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Engineering; electrical; electronic; fitting; small transformers; inductors; cores; methods; equipment; integrity

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