Power Transformers Blog – Expert Safety and Usage Info

MIDWEST was called to check out an old 3750 kva oil filled transformer. The owner was trying to decide whether to reclaim the oil in the old power transformer or to go ahead and replace it with a new 5000 Kva transformer. They actually needed a 5 Mva replacement power transformer. They had the history of the oil test results. It was apparent the transformer had slowly absorbed moisture over the years and there was serious paper degredation. They wanted MIDWEST to do an under the cover inspection to see if there were visual signs of sludge and tank rust. Pretty straight forward stuff. Their electricians asked if they could look inside the transformer while we had the access cover open. They had to follow our safety precautions.  They were absolutely amazed to see all the wood used inside the transformer. Almost the entire top of the core and coils was hidden under wood.  The wood was used for blocking, for support of the tap changer, and for making the high voltage connects going to the line side of the windings. The electricians were a little skeptical when we explained how much wood was actually used in transformer construction. How common it was. And that 15 Kv high voltage terminations were made on the wood. They were also surprised how clean the inside of the transformer looked, even though the oil was dark and there was visible sludge on flat surfaces, especially on the wood. For the electricians, seeing was believing. High voltage oil filled power transformers are made with wood.

What do you do if your manufacturing company suddenly loses its main 5000 kva, 34.5 kv to 480 volt transformer? You have orders pending. And if you can’t fill them, a key account may go elsewhere. You have employees suddenly out of work.  You need to heat the buildings.  And you are told it will take 10 weeks to get a new replacement transformer. This is one of a manufacturer’s worse nightmares. What to do? This happens more frequently than one may realize. MIDWEST actually recommends a “Disaster Action Plan,” on the shelf, ready to go, in case of such a nightmare.

MIDWEST receives these calls all too frequently. You might be fortunate and MIDWEST have a replacement reconditioned or used 5000 kva transformer that can be shipped immediately. No one has new transformers this size in stock. And many companies will not accept anything but a new replacement power transformer. In that case, the best solution is to rent a temporary transformer that will provide power until a new replacement transformer can be specified and manufactured. A new replacement transformer may take 10 weeks.

Renting transformers, and other electrical equipment, is a common solution to this critical problem. The first big question to ask when such an emergency occurs is, “Do you want power back on permanently as quickly as possible or do you just want power back on as quickly as possible?”  There is a huge difference in the time to perform either of these solutions. And way too often there is the presumption that one just must get power back on permanently. This presumption continues until the customer realizes how long it will actually take. Meanwhile many hours, even days, are wasted by chasing the wrong solution.

So the most critical event is to decide how fast one wants power restored.  MIDWEST has transformers, temporary high voltage cables and low voltage cables, and switches in stock.  But, more important, is the knowledge that temporary power installations can be a life saver for a facility that is suddenly down.