Quality First

At Arishein transformer, we put quality control in the most important position. We are committed to the most strict quality control plan for the production of distribution transformers to ensure that all our supplied transformers pass the international standards like: IEC, EN, CSA, IEEE, NEMA, ANSI, and DOE. The plan covers the entire production process from raw material receipt to final packaging with below details.

Quality Control Plan for Distribution Transformer Production

1. Raw Material Receipt

Objective: Ensure all materials meet specified quality and regulatory standards before use.

Steps:

1. Supplier Qualification:

-Verify suppliers are approved and meet IEC, EN, CSA, IEEE, NEMA, ANSI, and DOE standards.

-Maintain up-to-date records of supplier certifications.

2. Incoming Material Inspection:

-Visual Inspection:Check for physical damage and verify labeling.

-Documentation Review:Ensure certificates of compliance and test reports are available.

-Material Testing:Conduct tests (e.g., chemical composition, tensile strength) as required by relevant standards.

-Acceptance Criteria:Materials must meet predefined specifications and pass all tests.

3. Material Storage:

-Store materials in a controlled environment to prevent contamination or degradation.

-Implement inventory management practices to track material usage and ensure traceability.

2. Winding

Objective:Achieve precision in winding to ensure transformer performance and reliability, as winding is the most critical process in transformer production.

Steps:

1. Winding Machine Calibration:

-Regularly calibrate winding machines according to manufacturer specifications.

-Document calibration schedules and results.

2. Winding Process Control:

-Monitor winding tension, alignment, and insulation thickness.

-Inspect windings for defects (e.g., wire breaks, insulation gaps) during and after winding.

3. Experienced Workforce:

-Expert Technicians:We employ only experienced winding operators to ensure the highest quality and precision. Our team includes two master technicians with over 30 years of experience each, as well as several other winding operators with over 20 years of experience. The average winding experience among our operators exceeds 10 years.

-Skills and Training:All operators receive continuous training and updates on best practices to maintain the highest standards in winding quality.

3. Core Assembly

Objective:Ensure core assembly meets design specifications and operates efficiently.

Steps:

1. Core Material Inspection:

-Verify core steel meets CSA, IEEE, NANSI, and DOE standar  ds for magnetic properties.

-Inspect for physical damage or defects.

2. Core Assembly Process:

-Assemble core laminations with precise alignment and spacing.

-Inspect core assembly for physical integrity and alignment.

3. Core Testing:

-Conduct core loss and excitation current tests to verify performance.

-Ensure results are within specified limits.

4. Tank Assembly

Objective:Ensure that the transformer tank and associated components are properly assembled and sealed.

Steps:

1. Tank Material Inspection:

-Verify tank materials (steel, seals) comply with relevant standards.

-Inspect for defects, such as rust or physical damage.

2. Assembly Process:

-Follow detailed assembly instructions to ensure correct alignment and sealing.

-Inspect welds and joints for integrity and quality.

3. Leak Testing:

-Perform pressure and vacuum tests to ensure no leaks.

-Address and rectify any detected issues before proceeding.

5. Drying

Objective:Properly dry transformer components to avoid moisture-related issues.

Steps:

1. Drying Equipment Calibration:

-Ensure drying equipment is properly calibrated and maintained.

2. Drying Process:

-Follow specified drying procedures for core and windings.

-Monitor temperature and humidity levels to ensure consistent drying.

3. Inspection:

-Verify the absence of moisture in the transformer components.

-Conduct insulation resistance tests post-drying.

6. Oil Filling

Objective:Ensure correct oil filling and prevent contamination.

Steps:

1. Insulating Oil Inspection:

-Verify oil quality and compliance with standards.

-Test for dielectric strength and moisture content.

2. Oil Filling Process:

-Fill the transformer with oil under controlled conditions to prevent contamination.

-Monitor oil levels and ensure proper filling procedures.

3. Inspection:

-Inspect for air bubbles or leaks in the oil system.

-Test for proper insulation properties.

7. Testing

Objective:Validate the performance and safety of the completed transformer.

Steps:

1. Routine Testing:

-Conduct electrical tests, including insulation resistance, power factor, and winding resistance.

-Perform short-circuit and open-circuit tests as per standards.

2. Performance Testing:

-Test under load conditions to ensure transformer operates within specified parameters.

-Monitor temperature rise and ensure it is within acceptable limits.

3. Safety Testing:

-Conduct high-voltage tests to ensure dielectric strength.

-Verify grounding and protection systems are functional.

8. Pre-Shipment Inspection

Objective:Perform a final quality check before shipping.

Steps:

1. Final Quality Inspection:

-Conduct a comprehensive inspection covering all aspects of the transformer.

-Verify documentation and ensure compliance with all applicable standards.

2. Quality Control Specialist Review:

-A qualified quality control specialist performs a detailed review and confirms all quality checks are complete.

-Address any issues or discrepancies before shipment.

3. Documentation and Certification:

-Prepare and verify all necessary documentation,including test reports and compliance certificates.

-Ensure documentation is included with the shipment.

9. Packaging

Objective:Ensure safe and secure packaging for transport.

Steps:

1. Packaging Materials:

-Use high-quality, protective materials to prevent damage during transit.

2. Packaging Process:

-Follow standard procedures for packaging, including proper labeling and securing of the transformer.

3. Inspection:

-Inspect the packaged product to ensure it is secure and ready for shipment.

-Verify that packaging meets all shipping and handling requirements.

Note:This quality control plan should be reviewed and updated regularly to reflect changes in standards, processes, and technology. Compliance with IEC, EN, CSA, IEEE, NEMA, ANSI, and DOE standards should be continuously monitored and enforced throughout the production process.