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H P O S M 5 0 1 –
ELECTRICAL STATIC MACHINES WINDING / REWINDING
HPOSM 501 Wind / Rewind electrical static machines
REQF Level: 5 Learning hours
Credits: 5 50
Sector: Energy
Sub-sector: All
Issue date: June, 2016
Purpose statement
This particular module describes the skills, knowledge and attitude required to wind electrical static
machines. The electrician will be able to mount/ dismount a static machine, prepare the winding
diagram and wind accordingly. It applies to electricians working in maintenance.
Learning assumed to be in place
Mathematics
Basics of electricity
Elements of competence and performance criteria
Learning units describe the essential outcomes of a competence.
Performance criteria describe the required performance needed to demonstrate achievement
of the learning unit.
By the end of the module, the trainee will be able to:
Elements of competence Performance criteria
1. Collect data related to the machine to be wound /rewound
1.1. Proper interpretation of the machine’s nameplate 1.2. Proper interpretation of electrical drawing of the
machine 1.3. Proper determination of winding configurations 1.4. Adequate calculations of machine parameters
2. Select tools, equipment and materials
2.1. Appropriate identification of tools, equipment and materials
2.2. Proper arrangement of tools, equipment and materials at working area
2.3. Proper identification of Personal Protective Equipment (PPE)
3. Wind / Rewind electrical static machines
3.1. Proper dismantling of the machine 3.2. Proper preparation of winding diagrams 3.3. Proper use of laminated sheets 3.4. Accurate winding of the coil 3.5. Proper insulation of windings 3.6. Proper reassembling of the machine
4. Test the work done 4.1. Proper testing of the machine faults 4.2. Proper checking of the machine characteristics on
load/no load 4.3. Proper reporting the work done
LU 1: Collect data related to the machine to be wound /rewound
1
Learning Outcomes:
1. Interpret static machine’s nameplate. 2. Interpret electrical drawing of the static machine 3. Determine the winding configurations 4. Calculate parameters of static machines
10 Hours
Learning Outcome1.1 : Interpret static machine’s nameplate
Definition of electrical static machine (transformer)
Types of transformers Single phase transformer Three phase transformer Special transformer
Transformer construction form. Shell Core
Transformer windings connections, symbols and terminations.
Information on transformer nameplate
o Group discussion on contents of transformer nameplate, types of transformers, construction forms of transformers and on transformer windings connections.
o Physical demonstration of transformer nameplates
o Practical exercises on how to interpret transformer nameplate and the transformer winding connections diagrams
o Documentary Research
- Books - Internet - Electrical
drawings - Manual - Transformers
Formative Assessment 1.1
Performance criterion
Proper interpretation of the machine’s nameplate
Resources Learning activities Content
Assessor may collect among the following evidences and make judgements on whether the
performance criterion has been achieved.
Types of evidence Portfolio assessment tools
Written evidence
Oral evidence
Multiple choice questions Matching questions Open questions Presentation
Checklist Score
Yes No
Identification of number of phases
Identification of Power rating
Identification of Frequency rating
Identification of Voltage ratings
Identification of Connection diagram
Identification of Polarity (for 1-phase)
Identification of Conductor material
Identification of IP rating
Observation
Learning Outcome 1.2: Interpret electrical drawing of the static machine
Definition of electrical static machine (transformer)
Types of transformers Single phase transformer Three phase transformer Special transformer
Transformer construction form. Shell Core
Transformer windings connections, symbols and terminations.
Information on transformer nameplate
o Group discussion on contents of transformer nameplate, types of transformers, construction forms of transformers and on transformer windings connections.
o Physical demonstration of transformer nameplates
o Practical exercises on how to interpret transformer nameplate and the
- Books - Internet - Electrical
drawings - Manual - Transformers
Resources Learning activities Content
transformer winding connections diagrams
o Documentary Research
Formative Assessment 1.2
Assessor may collect among the following evidences and make judgements on whether the
performance criterion has been achieved.
Types of evidence Portfolio assessment tools
Written evidence
Matching questions Open questions
Checklist Score
Yes No
Identification of symbols
Identification of terminations
Interpretation of windings connection diagrams
Observation
Learning Outcome 1.3 : Determine the winding configurations
Definition of electrical static machine (transformer)
Types of transformers Single phase transformer Three phase transformer Special transformer
o Group discussion on contents of transformer nameplate, types of transformers, construction forms of transformers and on
- Books - Internet - Electrical
drawings - Manual - Transformers
Resources Learning activities Content
Performance criterion
Proper interpretation of electrical drawing of the static machine
Transformer construction form. Shell Core
Transformer windings connections, symbols and terminations.
Information on transformer nameplate
transformer windings connections.
o Physical demonstration of transformer nameplates
o Practical exercises on how to interpret transformer nameplate and the transformer winding connections diagrams
o Documentary Research
Formative Assessment 1.3
Assessor may collect among the following evidences and make judgements on whether the
performance criterion has been achieved.
Types of evidence Portfolio assessment tools
Written evidence
Multiple choice questions Open questions
Checklist Score
Yes No
Determination of type of construction form
Determination of winding connection type (if three-phase):
Determination of type of transformer
Observation
Performance criterion
Proper determination of winding configurations
Learning Outcome 1.4 : Calculate parameters of static machines
Transformer equivalent circuit
No-load and On-load characteristics
Transformer losses Eddy current losses Coil losses
Efficiency of transformer
Voltage regulation
o Group discussion on transformer equivalent circuit
o Practical exercise on transformer losses, voltage regulation and efficiency calculations
o Documentary research
- Books - Internet - Manuals
Formative Assessment 1.4
Assessor may collect among the following evidences and make judgements on whether the
performance criterion has been achieved.
Types of evidence Portfolio assessment tools
Written evidence
Multiple choice questions Open questions
Checklist Score
Yes No
Determination of transformer equivalent circuit
Calculation of iron losses
Calculation of copper losses
Calculation of impedances
Calculation of voltage regulation
Observation
Performance criterion
Adequate calculations of static machine parameters
Resources Learning activities Content
LU 2: Select tools, equipment and materials
2
Learning Outcomes:
1. Identify tools, equipment and materials 2. Arrange tools, equipment and materials 3. Identify personal protective equipment
5 Hours
Learning Outcome 2.1: Identify tools, equipment and materials
Tools used to wind and rewind electrical static machines Electrician knife Hammer Cutting pliers Nose pliers Crimping tool Multimeter Mega-ohmmeter Soldering iron Brushes Vernier calipers Measuring tape
Equipment used to wind and rewind electrical static machines Bench work Coil winding machine Vise
Materials used to wind and rewind electrical static machines Tin Wires Laminated sheets (E, I and U forms) Insulators
o Brainstorming tools, equipment and materials used to wind and rewind transformers
o Group discussion tools, equipment and materials used to wind and rewind transformers
o Physical demonstration of tools, equipment and materials used to wind and rewind transformers
o Documentary Research
- Books - Internet - Electrical
drawings - Manual - Electrician knife - Hammer - Cutting pliers - Nose pliers - Crimping tool - Multimeter - Mega-ohmmeter - Soldering iron - Brushes - Vernier calipers - Measuring tape - Bench work - Coil winding
machine - Vise - Tin - Wires - Laminated sheets
(E, I and U forms)
Resources Learning activities Content
- Insulators
Formative Assessment 2.1
Assessor may collect among the following evidences and make judgements on whether the
performance criterion has been achieved.
Types of evidence Portfolio assessment tools
Written evidence
Oral evidence
Performance evidence
Multiple choice questions Open questions Matching questions Task: select tools/ equipment/ materials used to wind or rewind
a transformer Observation checklist
Checklist Score
Yes No
Identification of tools to be used
Identification of equipment to be used
Identification of materials to be used
Observation
Performance criterion
Appropriate identification of tools, equipment and materials
Learning Outcome 2.2: Arrange tools, equipment and materials
Classification of tools, equipment and materials according to the nature
Handling of tools and equipment according to the nature
Disposition of tools, materials and equipment according to the type and nature.
o Brainstorming on classification, disposition and handling of tools, equipment and materials used to wind and rewind transformers according to the nature
o Group discussion on classification, disposition and handling of tools, equipment and materials used to wind and rewind transformers according to the nature
o Practical exercises on how to handle, to dispose materials and equipment according to the type and nature.
o Documentary Research
- Books - Internet - Electrical drawings - Manual - Electrician knife - Hammer - Cutting pliers - Nose pliers - Crimping tool - Multimeter - Mega-ohmmeter - Soldering iron - Brushes - Vernier calipers - Measuring tape - Bench work - Coil winding
machine - Vise - Tin - Wires - Laminated sheets
(E, I and U forms) - Insulators
Formative Assessment 2.2
Assessor may collect among the following evidences and make judgements on whether the
performance criterion has been achieved.
Types of evidence Portfolio assessment tools
Performance evidence
Oral evidence
Performance evidence
Multiple choice questions Matching questions Open question
Performance criterion
Proper arrangement of tools, equipment and materials at working area
Resources Learning activities Content
Task: Arrange tools/ equipment/ materials used to wind or rewind a transformer at the working area
Observation checklist
Checklist Score
Yes No
Tools arrangement according to their nature
Tools arrangement according to their type
Materials arrangement according to their nature
Materials arrangement according to their type
Equipment arrangement according to their nature
Equipment arrangement according to their type
Observation
Learning Outcome 2.3: Identify personal protective equipment
Types of PPE used in winding and rewinding of static machines Overall Overcoat Goggles Gloves Nose mask Helmet Security shoes
Use of PPE
o Brainstorming on types of personal protective equipment
o Group discussion on how to use PPE.
o Physical demonstration of PPE.
- Books - Internet - Journals - Overall - Overcoat - Gloves - Nose mask - Helmet - Security shoes
Formative Assessment 2.3
Assessor may collect among the following evidences and make judgements on whether the
performance criterion has been achieved.
Performance criterion
Proper identification of Personal Protective Equipment (PPE)
Resources Learning activities Content
Types of evidence Portfolio assessment tools
Written evidence
Oral evidence
Performance evidence
Multiple choice questions Matching questions Open question Presentation
Checklist Score
Yes No
Identification of PPE to be used
Use of PPE
Observation
LU 3: Wind / rewind electrical static machines
3
Learning Outcomes:
1. Dismantle the machine 2. Prepare winding diagram 3. Use laminated sheets 4. Wind the coil 5. Insulate winding 6. Reassemble the machine 30 Hours
Learning Outcome 3.1: Dismantle the machine
Main parts of transformer Coils or windings Core material Enclosure
Accessories Oil tank Buchholz relay
Transformer dismantling process Enclosure removing Removal of core and windings Removal of windings Disassemble of core material
o Brainstorming on major parts of the static machine, assembling and disassembling of static electrical machines
o Group discussion on major parts of the static machine, assembling and disassembling of static machines
o Physical demonstration of major parts of the static machine, assembling and disassembling of static machines
o Practical exercises on assembling and disassembling of rotating static machines
o Documentary Research o Video show
- Books - Internet - Screw drivers - Electrician’s
knives - Hammers - Coil tamping tools - Mallet - Wire brushes - Wire strippers - Slotting files - Connectors - Cutting pliers - Neon tester - Crimping tool - Multimeter - Wattmeter - Energy meter - Nose Pliers - Line tester - Soldering iron - Standard wire
gauge - Motorized coil
Resources Learning activities Content
winding machine - Hand operated
coil winding machine
- Tin - Lamination paper - Insulation
materials - Electromechanical
tool kit
Formative Assessment 3.1
Assessor may collect among the following evidences and make judgements on whether the
performance criterion has been achieved.
Types of evidence Portfolio assessment tools
Written evidence
Oral evidence
Performance evidence
Open questions Presentation Task: Dismantle a transformer Observation checklist
Checklist Score
Yes No
Identification of main parts of a transformer
Removal of the enclosure
Removal of core and windings
Removal of windings
Disassembly of core material
Identification of main parts of a transformer
Observation
Performance criterion
Proper dismantling of the machine
Learning Outcome 3.2: Prepare winding diagram
Transformer windings connection diagrams Delta-delta Wye-delta Delta-wye Wye-wye Delta-zigzag Auto transformer V-V connection T-T connection (Scott connection)
Transformer windings termination/ labelling
o Brainstorming on transformer windings connection diagrams
o Physical demonstration of transformer windings connection diagrams
o Practical exercises on the preparation of winding diagrams
o Documentary Research
o Books o Internet
Formative Assessment 3.2
Assessor may collect among the following evidences and make judgements on whether the
performance criterion has been achieved.
Types of evidence Portfolio assessment tools
Written evidence
Open questions
Checklist Score
Yes No
Identification of types of windings connections
Identification of transformer winding termination/labelling
Winding
Observation
Performance criterion
Proper preparation of winding diagram
Resources Learning activities Content
Learning Outcome 3.3: Use laminated sheets
Construction materials of transformer laminated sheets
Types of transformer laminated sheets U-I lamination E-E lamination E-I lamination L-L lamination
o Brainstorming on transformer windings connection diagrams
o Physical demonstration of transformer windings connection diagrams
o Practical exercises on the preparation of winding diagrams
o Documentary Research
o Books o Internet
Formative Assessment 3.3
Assessor may collect among the following evidences and make judgements on whether the
performance criterion has been achieved.
Types of evidence Portfolio assessment tools
Written evidence
Product evidence
Multiple choice questions Open questions Matching questions Task: Cut different forms of lamination sheets
Checklist Score
Yes No
construction materials of transformer laminated sheets
Identification of laminated sheets form
Cutting of lamination sheets forms
Observation
Performance criterion
Proper use of laminated sheets
Resources Learning activities Content
Learning Outcome 3.4: Wind the coil
Steps of coils winding Calculation of turn ratio Wind secondary coil Wind primary coil
Winding insulation techniques By insulating papers By varnish
o Brainstorming on steps of coils winding and winding insulation techniques
o Demonstration on winding the coil and insulating winding
o Practical exercises on winding the coil and insulating winding
o Documentary Research
- Books - Internet - Coils - Insulating papers - Varnishes
Formative Assessment 3.4
Assessor may collect among the following evidences and make judgements on whether the
performance criterion has been achieved.
Types of evidence Portfolio assessment tools
Written evidence
Performance evidence
Open questions Task: Wind the coil of a single-phase transformer
Checklist Score
Yes No
Use of Layer winding rolling technique
Use of Bank winding rolling techniques
Observation
Performance criterion
Accurate winding of the coil
Resources Learning activities Content
Learning Outcome 3.5: Insulate winding
Steps of coils winding Calculation of turn ratio Wind secondary coil Wind primary coil
Winding insulation techniques By insulating papers By varnish
o Brainstorming on steps of coils winding and winding insulation techniques
o Demonstration on winding the coil and insulating winding
o Practical exercises on winding the coil and insulating winding
o Documentary Research
- Books - Internet - Coils - Insulating papers - Varnishes
Formative Assessment 3.5
Assessor may collect among the following evidences and make judgements on whether the
performance criterion has been achieved.
Types of evidence Portfolio assessment tools
Written evidence
Performance evidence
Open questions Task: Insulating the winding of a single-phase transformer
Checklist Score
Yes No
Identification of types of insulating materials
Winding insulation
Observation
Performance criterion
Proper insulation of windings
Resources Learning activities Content
Learning Outcome 3.6: Reassemble the machine
Steps for transformer assembling Core assembling Coil winding Terminals labelling Insert the core into the coil Insert the core and the wound coil
into the enclosure Windings connection Transformer leads fixing
o Brainstorming on steps of transformer assembling
o Demonstration on transformer assembling
o Practical exercises on transformer assembling
o Documentary Research
- Books - Internet - Coils - Transformer
Formative Assessment 3.6
Assessor may collect among the following evidences and make judgements on whether the
performance criterion has been achieved.
Types of evidence Portfolio assessment tools
Written evidence
Performance evidence
Open questions Task: reassemble a single phase transformer Observation checklist
Checklist Score
Yes No
Assembling of core
Terminals/marking
Insert the core into the coil
Insertion the core and the wound coil into the enclosure
Windings connection
Fixation of Transformer leads
Observation
Performance criterion
Proper Reassembly of the machine
Resources Learning activities Content
LU 4: Test the work done
4
Learning Outcomes:
1. Test the machine faults 2. Check machine characteristics 3. Report the work done
5 Hours
Learning Outcome 4.1: Test the machine faults
Transformer faults Insulation breakdown between
winding and earth Insulation breakdown in between
different phases Insulation breakdown in between
adjacent turns i.e. Inter - turn fault
Continuity faults Transformer core faults
Transformer tests Winding continuity test Insulation test
o Brainstorming on transformer faults
o Brainstorming on transformer tests
o Demonstration on transformer testing
o Practical exercises on transformer testing
o Documentary Research
- Books - Internet - Coils - Transformers
Formative Assessment 4.1
Performance criterion
Test the transformer faults
Resources Learning activities Content
Assessor may collect among the following evidences and make judgements on whether the
performance criterion has been achieved.
Types of evidence Portfolio assessment tools
Written evidence
Performance evidence
Open questions Task: test a single phase transformer Observation checklist
Checklist Score
Yes No
Identification of transformer faults
Winding continuity test
Insulation test
Observation
Learning Outcome 4.2: Check machine characteristics
On-load characteristics
No-load / Open circuit characteristics
Short-circuit characteristics
o Brainstorming on machine characteristics
o Demonstration on checking machine characteristics
o Practical exercises on checking machine characteristic
o Documentary Research
- Books - Internet - Coils - Transformer
Formative Assessment 4.2
Assessor may collect among the following evidences and make judgements on whether the
performance criterion has been achieved.
Performance criterion
Proper Checking of machine characteristics
Resources Learning activities Content
Types of evidence Portfolio assessment tools
Written evidence
Performance evidence
Open questions Task: check the open-circuit of a transformer Observation checklist
Checklist Score
Yes No
Checking of On-load characteristics
Checking of No-load / Open circuit characteristics
Checking of Short-circuit characteristics
Observation
Learning Outcome 4.3: Report the work done
Elaborate the work report Report format Cost estimation
Keeping records of current machine state
o Brainstorming on how to prepare the report
o Group discussion on taking records
o Practical exercises on billing the work
o Documentary Research
- Books - Internet - Service manuals - Hand-out notes
Formative Assessment 4.3
Assessor may collect among the following evidences and make judgements on whether the
performance criterion has been achieved.
Types of evidence Portfolio assessment tools
Written evidence
Open questions
Performance criterion
Proper reporting the work done
Resources Learning activities Content
Checklist Score
Yes No
Types of report
Identification of report contents
Writing a report
Reporting methods
Preparation of service manual and catalogue
Observation
Summative Assessment
Integrated situation Resources
One of the transformers of INYANGE industries located at Masaka sector, KICUKIRO district was found burnt due to overvoltage faults. You as electrical static machine winder, you are requested to rewind this transformer within five hours. The transformer information is as follow: Power rating: A 100 kVA,
Voltage ratings: 230V/115 V,
Frequency: 50 Hz
Type: Single-phase- shell-type
N2: 100 turns
Assesment Criterion 1: Quality of Process
Checklist Score
Yes No
Indicator: The machine’s nameplate is well interpreted
Number of phase
Power rating
Frequency rating
Voltage ratings
Connection diagram
Polarity
Conductor material
IP rating
Indicator: Tools are well selected
Electrician knife
Hammer
Cutting plier
Nose plier
Crimping tool
Multimeter
Mega-ohmmeter
Soldering iron
Brushes
Vernier calliper
Measuring tape
Indicator: Equipment are well selected
Bench work
Coil winding machine
Vise
Indicator: Materials are well selected
Tin
Wires
Laminated sheets (E and U forms)
Insulators
Indicator: Personal Protective Equipment (PPE) are well selected
Gloves
Safety shoes
Over all
Nose mask
goggles
Indicator: Tools, equipment and materials are well arranged at working area
Arrangement of tools according to nature
Arrangement of tools according to type
Arrangement of equipment according to nature
Arrangement of equipment according to type
Arrangement of materials according to nature
Arrangement of materials according to type
Indicator: The transformer is well dismantled
Removal of enclosure
Removal of core and windings
Removal of windings
Disassembly of core material
Indicator: Parameters of the transformer are well determined/calculated
Cross-sectional area of primary winding wire
Cross-sectional area of secondary winding wire
Number of turns of primary winding
Indicator: The coil is well wound
One of coil rolling techniques is applied
Indicator: The transformer is well reassembled
The lamination type is respected
Insertion of the coil in the core
Insertion of the core-coil in the enclosure
The enclosure is fixed
Connection of windings terminals
Indicator: The transformer is tested
Use of testing instrument
Windings continuity is tested
No-load characteristics are tested
On-load characteristics are tested
No abnormal noise
No overheat
No insulation fault between windings and core material
Indicator: The parts of transformer are well fixed
Compactness
Fitness
Tightness
Observation
Assesment Criterion 2: Quality of product
Checklist Score
Yes No
Indicator:
Observation
Assesment Criterion 3: Relevance
Checklist Score
Yes No
Indicator: The time is respected
The work is done within the given time (five hours)
Indicator: Rated output voltage
Output voltage of the given transformer
Indicator: Rated power
Power rating of the given transformer
Observation
Perfection
Checklist Score
Yes No
Indicator: Innovation
Improving efficiency of transformer
Indicator: Creativity
Observation
Reference books:
1. http://www.idc-online.com/sites/default/files/TG.pdf
2. http://www.electrical4u.com/external-and-internal-faults-in-transformer/
3. http://www.udeyraj.com/html/hipots.asp
4. http://electrical-engineering-portal.com/transformer-winding-faults
5. http://www.esito.org.nz/docs/default-source/about-industry-training-files/19323.pdf?sfvrsn=0
