Brand: Pahsa Enerji
Transformer Cover Manufacturing Process
The transformer cover is one of the most critical components of the transformer tank. Its sealing, mechanical strength, and precision connection ensure the transformer's longevity and safe operation. The manufacturing process requires high engineering and quality control.
1. Design and Technical Preparation
The cover dimensions are determined based on the transformer body drawings and connection details provided by the customer. All details, such as screw holes, gland connections, bushing openings, and oil level indicator slots, are 3D modeled in a CAD environment.
2. Material Selection and Cutting
Depending on capacity and operating conditions, S235JR or similar grade steel sheet is generally preferred. Sheet metal is cut to precise dimensions using CNC plasma or laser cutting machines and prepared for manufacturing.
3. Forming and Bending
The cut sheets are shaped using press and roll bending machines, depending on the cover type (flat, curved, oval, etc.). This stage requires great precision, as it directly affects the cover's fit to the body and sealing.
4. Welding Procedures
The formed parts are joined using MIG/MAG by certified welders. After welding, the surfaces are ground, and any burrs and deformations are removed. The cover's connecting flanges, oil filler, and vent connections are installed at this stage.
5. Hole Drilling and Accessory Installation
Depending on the cover's intended use:
Bushing holes,
Pressure relief valve housing,
Oil gauge and thermometer connections,
Screw and connection holes are drilled.
All dimensions are checked to standard tolerances.
6. Leakage and Pressure Tests
The welded areas and flange surfaces of the cover are subjected to a leakage test under air pressure. This test is usually performed at 1 bar. If any leaks are detected, the weld repair is performed, and the test is repeated.
7. Surface Cleaning and Painting
The lid surfaces are sandblasted (to SA 2.5 standard). Following this, an industrial primer and topcoat are applied to protect against corrosion. The paint color is determined according to customer specifications (e.g., RAL 7033, RAL 7032, etc.).
8. Final Inspection and Packaging
Completed lids undergo a final inspection for size, surface quality, and paint thickness. Approved products are packaged to prevent damage during shipping and prepared for delivery.