Quality Assurance of Transformer: - Ronnie Minhaz, P.Eng

Quality Assurance of Transformer
- Ronnie Minhaz, P.Eng.
Transformer Consulting Services Inc.

Ronnie Minhaz, P.Eng

Why Quality Assurance?

Purpose of Quality Assurance
• Operational reliability
• Life expectancy

Operational reliability
• Withstand capability during

fault (mainly electrical fault)

Life expectancy
• Due to thermal
• Due to electrical

Factory Location
Dry Area
Vs
Wet/Humid Area

Age of the Factory
Old Factory
Vs
New Factory

Old Factory Layout
Only the insulation shop, core coil assembly area, oven, vapor phase, test
control room and paint are closed area. Rest are open.
New Factory Layout
Insulation shop, Winding shop, Core building area, Core coil assembly area
and tanking area are fully climate controlled.
Climate control in Factory
Fully climate control
Vs
Partially climate control
Vs
No climate control

Is everyone using it?

Inside Factory
Clean room
Vs
Non-clean room

Cleaning approach
All employees part of cleaning process
Vs
Cleaning company in charge of cleaning

Transformer Manufacturing Flow chart:
Receive
Dispatch
Indent
Issue of Order
Painting
Acceptance
Final
Design /
Inspection &
Project Cell
testing
Procurement Tanking
Inward Core Coil

Inspection Assembly
Core
Building
Winding

Procurement Flow chart:

Procurement : Core Steel
Pre-Cut by supplier
Procurement : Core Steel
Cut steel in house

Procurement : Conductor
Types of Conductor

Procurement : Insulation
Types of Insulation Paper

Types of Spacer
Line Shield Types of Cooling Ducts
Types of Molded component
Types of Strips
Riding Block
Transformer cylinder, end ring

Making insulation in house

Inward Inspection
Hole in the
packing of the
conductor
reel/drum
Core steel on the

floor
Core steel packed to

prevent rust
Quality Assurance: Shop floor
Iron filing in the shop floor
Iron filing from the crane operation can cause failure

Core Building/Stacking
Core Stacking without

stacking bed
Core Stacking in
stacking bed

Quality Assurance: Core
Rust in Core
Winding: Horizontal Winding Machine
Old Horizontal winding

machine without breaking
mechanism
New Horizontal winding

machine with breaking
and tension mechanism

Winding: Vertical Winding Machine
Old Vertical winding machine New Vertical winding machine with

without breaking mechanism breaking and tension mechanism

Quality Assurance: Winding
Loose turn to create space for 400 millimeter reduction during coil sizing
conductor to move

Core Coil Assembly
Coil preparation for nesting Coil nesting in Core

Quality Assurance: Core Coil Assembly
Lead Braising
Gas welding Induction machine

Pre-Vapor Phase
Extended period of vapor phase will require a lot of energy usage

Vapor Phase
Extract moisture up to certain point to have certain Power Factor during FAT
Quality Assurance: FAT
Passed FAT but still reliability and longevity compromised
Pure refined oil and controlled FAT environment can compensate aggressive
design and contamination (dust, moisture etc.) during manufacturing
QA/QC management
Is ISO certification good enough?

QA/QC management
• Is there any check and balance in the QA/QC process?
• Is the process properly documented?
• How often auditing take place?

Non-Conformance Report (NCR)
• Is NCR a good indication for factory compliance to QA/QC?
• Is there any lesson learned session on issued NCR?

Subcontractors/Suppliers
• Is there any procedure to ensure subcontractors/suppliers

are compliant to QA/QC?
• How often subcontractors/suppliers are being audited?

Training for all employees
Continuous training
Vs
Occasional/no training

What could be viable solution?

Viable Solution
• Factory audit
• Design review
• QA inspection during manufacturing

Factory Audit
What to look into during factory audit?

Design Review
How design review helps to ensure quality?

QA inspection(s)
• Core and Coil inspection
• Coil nesting in core
• Pre-vapor phase inspection
• Pre-tanking inspection
• FAT witness
• Inspection prior to shipping

Ronnie Minhaz, P.Eng.
President
Phone: (403) 919-7664
Email: [email protected]
http://www.tc-servicesinc.com

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Quality Assurance of Transformer

- Ronnie Minhaz, P.Eng.

Transformer Consulting Services Inc.

Ronnie Minhaz, P.Eng

Transformer Consulting Services Inc.

Transformer Consulting Services Inc.

• Withstand capability during

Transformer Consulting Services Inc.

Transformer Consulting Services Inc.

Transformer Consulting Services Inc.

Transformer Consulting Services Inc.

Climate control in Factory

Fully climate control

Partially climate control

Transformer Consulting Services Inc.

Transformer Consulting Services Inc.

Transformer Consulting Services Inc.

All employees part of cleaning process

Cleaning company in charge of cleaning

Transformer Consulting Services Inc.

Inward Core Coil

Transformer Consulting Services Inc.

Transformer Consulting Services Inc.

Cut steel in house

Transformer Consulting Services Inc.

Transformer Consulting Services Inc.

Types of Insulation Paper

Line Shield Types of Cooling Ducts

Types of Molded component

Transformer cylinder, end ring

Making insulation in house

Core steel on the

Core steel packed to

Iron filing from the crane operation can cause failure

Core Stacking without

Transformer Consulting Services Inc.

Old Horizontal winding

New Horizontal winding

Transformer Consulting Services Inc.

Old Vertical winding machine New Vertical winding machine with

Transformer Consulting Services Inc.

Transformer Consulting Services Inc.

Coil preparation for nesting Coil nesting in Core

Gas welding Induction machine

Extended period of vapor phase will require a lot of energy usage

Is ISO certification good enough?

Transformer Consulting Services Inc.

• Is there any check and balance in the QA/QC process?

• Is the process properly documented?

• How often auditing take place?

Transformer Consulting Services Inc.

Non-Conformance Report (NCR)

• Is NCR a good indication for factory compliance to QA/QC?

• Is there any lesson learned session on issued NCR?

Transformer Consulting Services Inc.

• Is there any procedure to ensure subcontractors/suppliers

• How often subcontractors/suppliers are being audited?

Transformer Consulting Services Inc.

Transformer Consulting Services Inc.