Understanding transformer replacement
If not acted upon in a timely and efficient manner, a faulty or outdated transformer can very quickly escalate into a crisis when trying to maintain the supply of electrical power to a business. It can also impact the ability to provide maximum safety for customers, staff and business infrastructure. A transformer is a very important business asset, and as such, needs to be treated appropriately.
When considering replacing a transformer, there are several implications to think about:
- The consequences on the business of its failure in terms of costs, wasted energy
- What the current condition of the transformer is
- How much corrective and preventative maintenance costs have increased by with its age
- Whether it has become a safety risk
If a transformer was to suddenly fail and not be repairable, the business could face significant downtime, overall disruption and lost sales while waiting for a new one to be installed and come online.
Replacement time considerations
There are some important considerations that can affect how long it can take to replace a transformer. Choosing the most appropriate one for the requirements of the business is a vital part of the process. The entire replacement process should be undertaken while the existing transformer is still viable so as not to disrupt the business through potentially avoidable downtime.
Assessment and Planning
It is important to factor in any time spent assessing the condition of the existing transformer and the time taken to decide the replacement. While there can be no denying transformers can be costly, do not waste time awaiting the inevitable.
Proactive monitoring
During their active lifetime, transformers should always be monitored. They may be workhorses with an expected lifespan of anywhere between 20 and 40 years, but as they approach ‘middle age’ it is important to be more proactive and look for signs of deterioration. This can include:
- Reduced efficiency: it’s not performing as it used to
- Noise levels: increasing humming and buzzing and even increased vibration
- Heat emissions: the transformer generating more heat than normal, which can indicate internal issue and perhaps imminent failure
- Leaks and internal fluid problems: oil seeping out or insulating fluids changing color are indicative of internal issues
- Visible signs: rust, excessively peeling paint or flaking metal
All the above signs are indicative of internal transformer stress and that components are starting to wear out. This means that both its performance and reliability will be compromised leading to potential full failure.
Visual inspection
Regular visual inspections used as part of a transformer maintenance program will help identify potential issues well in advance of any transformer failure. It is not as hard as it may appear for the untrained. It’s a case of looking around your transformer for any paint condition problems, leakages, metal fatigue (flaking metal) and of course checking any gauges on the transformer are neither in the red or reading zero when they should be registering something.
Preparing the site
Regardless of it seeming a like for like (or better) replacement, it is important for the site to be inspected and surveyed by a transformer installation specialist. Something that may have contributed to the deterioration of the existing transformer and modification may be required prior to installation of the replacement.
Safety issues
Allow time for implementation of safety measures and ensuring the new transformer will be installed in a compliant manner with current regulations and in keeping with standards required by professional electrical and mechanical bodies.
Existing power requirements
There may be a need for temporary power provision to avoid too much disruption to the business. Do seek professional advice, especially if you are very dependent on your transformer.
The old transformer
Time will be required to shut down the old transformer safely and disconnect it. It is not just a large scale version of replacing your phone charger. It will take considerable time to dismantle and remove the old transformer safely and to consider handling any hazardous chemicals/parts and old lubrication oil, as well as to accommodate recycling and/or disposal of its constituent parts.
From order to installation of the new transformer summed up
If the required transformer is existing stock, delivery and installation can be relatively speedy. However, if it’s too hasty a decision and the transformer is replaced for speed of delivery by a stock transformer that is either rated too low or too high for the required installation, this may cause problems for consistency of electrical power for the business. If the precise replacement transformer is required to order, then the ordering, shipping, delivery and installation (the latter more than likely being the simplest part of the process) all must be factored in relative to any business downtime.
Preparing immediately before the installation
Once the new transformer has been delivered, time will have to be allocated for positioning and mounting the transformer as per your transformer expert’s recommendations. If the recommendations have been followed, the installation should be relatively problem-free. The transformer will then have to be connected to the main electrical grid or the network used by the business and then tested to ensure it is working safely to specification
Following installation
Once in place, the transformer is then “powered up” (or “re-energized”) as per the manufacturer’s recommendations and monitored to check it is running and performing as expected. Time will have to be allocated to complete any documentation and to file reports and update maintenance records.
Some other replacement considerations
We have already looked at the general replacement timeframe at the start of this blog, but there are other considerations to take into account.
Emergency replacements: Even for an emergency replacement, it is important to follow all the steps already mentioned, although obviously the new installation will be
Small or large: You need to factor in the time comparison in relation to the size of the transformer required. The obvious rule of thumb is, the larger the transformer, the more complex the installation.
Urban or remote: Access may prove to be the major challenge to the installation of the larger transformer.
Other challenges
Unexpected weather conditions, the site having access problems previously not noted and unfirm ground for a large transport trailer are just some of the unexpected conditions that may be encountered during installation. It is important to have a contingency plan for such occurrences which should be discussed with the transformer expert in advance.
Conclusion
- Key factors: Continually monitor your existing transformer for visible, physical or performance problem signs.
- Best practices: Have a contingency plan available should your transformer appear that it may have the potential to fail or otherwise be nearing its end of life. Have a viable and well-researched action plan in place for the replacement of your transformer, including a potential supplier and methods of ensuring a continuous power supply for your business.
- Final thoughts: Always work with established, qualified professionals in the transformer industry.
