Blog

ETE, once again, showcased why we are one of the most highly regarded transformer manufacturers nationwide after successful completion of, not one, but, two 500kVA custom-built transformers – the biggest bespoke transformers we have ever been asked to design.

When dealing with custom-built requests our technical team work closely with the customer to ensure the transformer is designed in line with their exact requirements based on the function of the transformer and taking into consideration its environment. Input and output voltages, power rating, number of outputs, safety standards, insulation class, protection devices, enclosure, exposure to hazardous areas, dimensions, and finish should all be decided upon during the specification process.

Once all of these aspects have been determined our design team gets to work on producing a detailed drawing and raising a works order. This is when the production process officially begins. The various elements of the manufacturing process are assigned to the specialist members of our production team and work commences on making the drawing a reality.

Step 1: Winding the Transformer 
The first step during the production of our 500kVA transformers was for them to be wound.
 

Step 2: Provisionally Assembling the Windings 
The next stage was for the basic structure of the transformers to be provisionally assembled.

Step 3: Initial HV Flash Tests 
Initial HV flash tests were then carried out to ensure everything was working as it should be at this early stage. As both transformers passed these tests they could be moved on to the next stage of fabrication.

Step 4: Assembling the Core 
The core material was the next component to be added.

Step 5: Clamping the Core 
Next, the outside weldings and rings were added.

Step 6: Varnish Impregnation
The transformers were then fully varnish impregnated with Class H polyester varnish.

Step 7: Final Assembly 
During the final assembly the transformer were wired to the required specification.

Step 8: Final Tests
The transformers were tested again and, having passed all tests, were ready to be fitted into their enclosures.

Step 9: Fitting into the Specified Enclosure
The final stage of production involved the transformers being enclosed to IP23.

Step 10: Despatch
Upon the transformers completion, they embarked on a journey to the Bahamas where they are to be used aboard a Caribbean ship.

For further information on our custom-built range of transformers visit our ‘Custom Built‘ page on our website. Alternatively, you can get in touch with our technical team by calling 01284 388 033 or by sending an email to sales@ete.co.uk. 

Tony Harper
Marketing Manager