Winder Technicians - Transformers

Key Responsibilities 1. Winding Operations & Coil Assembly • Operate specialized horizontal and vertical winding lathes, tensioners, and wire-coiling machinery to produce high-quality transformer coils. • Wind LV and HV coils using multiple conductor styles, including round wire, rectangular copper, strip/sheet foil, and continuously transposed conductors (CTC). • Execute different winding configurations based on engineering drawings, such as helical, disc, cylindrical, and crossover designs. • Perform precise lead handling, including stripping, bending, and preparing tap leads for final configurations. • Manage hot work connections by performing high-quality brazing, soldering, or TIG welding on copper/aluminum leads and busbars. 2. Technical Specifications & Material Application • Read and accurately interpret complex engineering blueprints, winding sheets, geometric tolerances, and wiring diagrams. • Size and apply specialized insulation materials (e.g., Nomex, crepe paper, pressboard, mica, and fiberglass) tailored to distinct thermal insulation classes. • Properly place inter-layer insulation, cooling ducts, radial spacers, and axial blocking to guarantee structural integrity during short-circuit conditions. 3. Dry-Type vs. Power Transformer Specializations • Dry-Type Specifics: Assemble and wind coils with emphasis on air-cooling clearances, VPI (Vacuum Pressure Impregnation) or dip-and-bake varnish preparation, and solid-resin cast or open-ventilated systems. • Power/Liquid-Filled Specifics: Wind large-scale, high-voltage coils with deep consideration for dielectric fluid circulation, moisture prevention, and high mechanical clamping pressures. 4. Diagnostic, Repair & Testing • Dismantle damaged units and collect detailed internal "as-found" winding data (turns count, wire gauge, connection layout) for repair or rewinding projects. • Conduct core evaluation and preparation, checking for lamination damage, and completing full or partial core re-stacking if necessary. • Perform routine quality and electrical checks using micrometers, calipers, meggers, and resistance/turns-ratio testers to verify coil parameters before final assembly. ________________________________________ Required Skills & Qualifications • Education: High school diploma, GED, or vocational technical certification in electrical/mechanical engineering or a related trade. • Experience: Minimum of 2–5 years of proven experience winding or rewinding coils for distribution, power, or dry-type transformers. • Technical Literacy: Demonstrated ability to read electrical schematics, winding charts, and mechanical drawings. • Mechanical Aptitude: Proficient with industrial hand tools, wire-stripping equipment, brazing torches, and precision measuring devices. • Material Knowledge: Comprehensive understanding of copper/aluminium conductor handling, insulation classes, and varnish/epoxy curing processes. • Physical Demands: Manual dexterity for intricate wire placement, with the ability to stand for long periods and safely operate overhead cranes or material handling equipment for heavy coils.