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Frequently Asked Questions
Ask JT: Can you increase the ratings on our current transformer?
This is a great question that we received from a smaller electric co-op who ultimately determined that remanufacturing with JT would be their best course of action. Smaller electric co-ops like this one, sometimes have difficulty purchasing new transformers at a price they can afford. As a result, some OEMs offer a lower-cost transformer to meet their needs, but quality and performance often suffer.
By redesigning, reinforcing, and remanufacturing this unit, we met the client’s need for increased capacity and delivered a unit that boasted new, state-of-the-art materials and engineering design principles in a robust tank that had already stood the test of time by lasting more than 60 years before its first failure.
Ask JT: Is remanufacturing green?
Remanufacturing a substation transformer is definitely an eco-friendly option! The term “environmentally friendly” is usually associated with power distribution only when discussing renewable sources of electricity generation like solar or wind power. Repairing large equipment is the most eco-friendly route when the alternative is throwing the transformer in a landfill and buying new. So how does JT save transformers from landfills by remanufacturing?
Specifically:
1. We reuse the steel - When a transformer is remanufactured, the core steel; the tank; the original radiators; the steel laminations that make up the core legs; and the steel form that clamps the top and the bottom can–often all can and will be reused. Reusing the steel makes the most sense from an environmental standpoint as well as an economic standpoint (for our customers) considering the volatility of pricing in the steel industry today.
2. We recycle the copper - At Jordan Transformer, when we remanufacture a transformer and recycle that conductor, whether copper or aluminum, we credit the transformer owner for the value of that recycled material. The price per pound of copper varies, but the credit adds up, and the environmental value is also high.
3. We recycle the mineral oil - A transformer’s insulating mineral oil that has deteriorated and no longer meets its service requirements must be recycled. If its dielectric properties can be restored, transformer oil can be reclaimed and reused. More often, the oil is recycled and repurposed for other uses.
After your transformer is remanufactured, it fits perfectly on its original pad. The lines are the correct length for the leads and all external components secured in place as before. By reusing so much existing material, you’re reducing the need for new equipment. This saves time as well as manufacturing costs.
Remanufacturing makes economic and environmental sense. If you want to learn more about reusing equipment you already own, please reach out!
Ask JT: What remanufacturing options can you offer for a failed transformer with rectangular core & coil design?
In incredibly rare cases, Jordan Transformer can “convert” some transformers from rectangular to a circular core & coil design with all new core steel and new disc windings. As a general rule, we only remanufacture circular core transformers.
Ask JT: Do you buy surplus transformers?
No, we remanufacture your substation power transformers that are failed or gassing.
Ask JT: What are your base ratings capabilities?
We handle power substation transformers with base ratings from 10MVA-80MVA and 69kV-230kV, and mobile substations with base ratings from 5MVA-50MVA and 69kV-161kV.
Ask JT: Reconditioning vs. Remanufacturing: What's the difference?
This is a question that comes up frequently when we are helping to determine the correct course of action for a customer's transformer. We are passionate about remanufacturing in the right situation for all of the reasons below.
Reconditioning: Reconditioning involves minor repairs or upgrades to the transformer, such as replacing gaskets, pumps, radiators, bushings, breakers, etc. It does not include replacing the windings or insulation, which are the most critical components of the transformer. Reconditioning is cheaper and faster than remanufacturing, but it does not extend the transformer’s life significantly.
Remanufacturing: This involves replacing the windings and insulation of the transformer, as well as the components covered in reconditioning. Remanufacturing restores the transformer to a like-new condition. Remanufacturing is more expensive and time-consuming than reconditioning, but it can extend the transformer’s life by decades and provide long-term value.
Factors to consider: The choice between reconditioning and remanufacturing depends on the condition of the transformer, its load history, its usage frequency, and its availability. A thorough inspection and testing of the transformer is needed to determine the best option. Remanufacturing is recommended for transformers that have degraded windings and insulation, or that operate at high loads or in harsh environments. Reconditioning may suffice for transformers that have low loads or intermittent use, or that have minor issues with other components.
Ask JT: Why remanufacture? Isn't new better?
Because of supply chain issues, for many of our customers, remanufacturing is the only option. It's all about time. We can remanufacture your vintage transformer in half the time it would take to get an OEM.
If time is on your side and you are in a planning phase, remanufacturing is still a very attractive option. Many of our customers still choose to remanufacture over purchasing an OEM for the following reasons:
Prior to the use of modern computers and optimization programs that perform thousands of iterations to take every ounce of “excess” material out of the transformer, design engineers tended to design with higher safety margins, resulting in lower day-to-day electrical stresses than what is frequently found in new “optimized” designs.
Having a transformer remanufactured involves reusing the components that can be fixed and updated, and adding new copper wiring, insulation, and oil. The result is a good-as-new transformer built with a solid, vintage tank and core. And “vintage” means a steel tank that’s thick and was designed to last for decades, not one designed with today’s thinner cost-saving steel.
A remanufactured transformer can be put back into service with minimal design changes. The design process alone on a new transformer can add months to the process, as the utility company and manufacturer discuss things like the transformer’s footprint and bushing locations. When you remanufacture your existing transformer, it will fit perfectly into its original location.
It's important to note that remanufacturing a transformer does not mean making 1960s era equipment as good as it was in 1960. Remanufacturing uses the best from the original–namely the tank and core– while repairing or replacing components to today’s standards. It truly is the best of both worlds.
Ask JT: What are advantages of remanufacturing a substation transformer versus the alternative of buying new?
1. Reusing the core steel and tank of an existing transformer offers substantial savings in both price and lead time.
2. The savings are even more dramatic when reusing the LTC within a transformer, which is often!
3. Our turnaround time is typically months less than new OEM manufacturers which require extensive design time for new transformers.
4. No sacrifice in life expectancy and all transformers are upgraded to today’s short circuit design standards.
5. Your remanufactured transformer will have a drop-in form, fit, and function, whereas new typically requires substation design modifications.
Ask JT: What are your crane capabilities?
Utilizing both 80-ton and 50-ton cranes in tandem (using our custom engineered spreader bar) an engineered lift of up to 120-ton is possible. We can accommodate the largest medium power transformers when using our untanking pit.