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MANUFACTURING PROCESS                                    

BRUSH TRANSFORMERS GULF LLC ...

 

DESIGN PROCESS MANUFACTURING PROCESS TESTING FACILITIES

THE CORE

Each transformer core is produced using a computer-controlled

Georg cutting machine. Using interleaved laminations of cold

rolled, grain orientated, low loss electrical sheet steel conforming to BSEN 10107. The core employs a mitred step-lap design ensuring minimum noise and loss levels with uniform flux distribution throughout the magnetic circuit.

 

WINDINGS

All windings are manufactured to established standards in order to maintain strict dimensional tolerances (Continuous Double Diisc, Counter Shield & Interleaving, Helical, Layer etc). Windings are manufactured with CTC, PICC and Thermally upgraded PICC. Clamping to a pre-determined load pressure during manufacturing ensures that each winding is able to withstand the excessive axial forces which may result from external and short-circuit events. All principal components of insulation are pre-fabricated from electrical grade insulating board; pre-shrunk to ensure electrical and mechanical stability throughout the temperatures found in operational service.

                     

CORE-COIL ASSEMBLY

Each core-coil assembly is rigidly braced using steel frames,

distributing the axial clamping forces around the entire

circumference of the windings. Connections are made by brazing or crimping as per customer preference. Fibre optic sensors can be installed in the core & windings if required

 

VACUUM DRYING OVEN

Optimum dielectric strength is achieved via processing the active parts in our vacuum drying oven as per rigorous in-house quality procedures. After tanking the active part the transformer is filled with processed oil under vacuum.

 

 

TANK CONSTRUCTION and FINISH

Transformer tanks are manufactured using mild steel,

which is electrically welded and primed. Cooling is

effected by pressed steel plate radiators, electrically

welded and independently pressure tested. Metal is

pre-treated by shotblasting, then immediately covered

with corrosion inhibiting zinc phosphate primer. This

finish is designed to give maximum world-wide

protection in coastal, industrial, and general environments

with suitable heat and oil resistance. A micaceous iron ore

finish, proven to afford excellent long-term barrier

protection, is then applied. Hot dipped galvanizing is available

on request

                              

FINAL ASSEMBLY

When the tanking process is complete all accessories are fitted.

  • Bushings (Oil to Oil, Oil to SF6, Oil to Air Condenser, Porcelain, Plug-in type, Monoblock)

  • Conservator with hydrocompensator (Air bag)

  • Maintenance free Breathers

  • Remote Control Panels for automatic voltage regulation of OLTC

  • Hydran / Callisto online gas monitoring devices

  • Other customer specific fittings / instruments

Subsequently transformers are prepared for test.

 

SHORT CIRCUIT & IMPULSE CAPABILITY

In order to prevent deformation when subjected to short

circuit forces, solid block end insulation, backed-up by

substantial supporting frames is utilized. The axial end

thrust under fault conditions is minimized by the suitable 

distribution of Ampere turns over the length of the

windings, and by ensuring that the design dimensions

are closely adhered to during manufacture.

Transformers designed and constructed in this way are

capable of withstanding the effect of short-circuit testing

as defined by National and International standards

MEETING YOUR TRANSFORMER DEMANDS . . .

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