Remanufacture Your Substation Transformer

Why Remanufacturing Wins


“They don’t make ‘em like they used to.” Your substation transformer is valuable. Don’t throw that away: remanufacture, reuse, and save. In the 20th century, substation transformers were designed with reliability in mind—thick steel tanks, spacious tank interiors, and plenty of copper. This “greater design margin” approach kept substation transformers running cooler, extending their life expectancy. Solid, older substation transformers are the key to remanufacturing America’s power grid to be stronger than ever.

Value for You


Shorter delivery time
Reuse original high reliability design concepts
Reuse steel components—tank, core, and frame
Upgrades only when requested or needed

Remanufacturing Substation Transformer Process Flow

1
DISCOVERY

Freight

Un-Tank

Inspection

FSOW Report

2
REENGINEER
Electrical

Leads

Controls
3
RE-BUILD

Rewind

Core re-Build

Radiators

Assemble

Tank*

4
TEST

Preliminary

Full IEEE Testing*

 

* indicates typical customer witnessing opportunities during the process

5
IN SERVICE

Final Paint

Freight

Installation

Dedicated Remanufacturing Facility Capabilities

Rewinding means a custom rebuild for your unique transformer and substation requirements.

This effort requires and is performed in our dedicated 70,000 sq foot remanufacturing facility situated on 15 acres in Jordan, MN, which contains:

  • Winding room environmentally controlled 
    • 9 specialized winding machines with an 80-ton and 200-ton coil sizing apparatus
  • Core and coil assembly room temperature controlled  
  • Drying oven for completed coil assemblies 
  • Drying oven for completed core and coil assemblies 
  • Sandblasting booth, external dedicated building 
  • 8 separate oil tanks (total 40,000-gallon oil farm)
  • 8 storage buildings for components in waiting 
  • 13 cranes and hoists
dedicated winding room

The dedicated high-bay has a 50-ft ceiling to accommodate large substations. The bay includes:

  • An 80-ton overhead crane
  • A 50-ton overhead crane 
  • Custom engineered spreader bar for tandem crane use to lift up to 120-tons
  • Two paint booths with high ceiling for transformers and components
  • Hot oil processing system—customized for transformer application
  • Welding cell 3,600 sq ft with 50-ft ceiling
dedicated high bay

The dedicated test facility

  • Impulse and partial discharge testing
  • Impulse generator GTU 1000 kV - 50 kJ with SDA12-bit digital scope
  • 300 kVA / 180 Hz generator with partial discharge monitoring
  • 300 kV hi-pot transformer
dedicated test facility

Experience Remanufacturing These OEM Transformers

ABB
Allis-Chalmers
Brown-Boveri
Central
CG Power
CGE
Delta Star
Eastern
ELCO
Federal Pacific

Federal Pioneer
Ferranti-Packard
General Electric
H.K Porter
Hevi-Duty
Howard
ITE
Kuhlman
MagneTek
McGraw-Edison

Moloney
Neeltran
Niagara
North American
Pacific Crest
Pauwels
Pennsylvania
Prolec
RTE/ASEA
Siemens

Sonmez
Standard
Tamini
Uptegraff
Virginia
Wagner
Waukesha
Westinghouse

Available Upgrade Options

On most transformers:
New accessories
Radiator replacements
Updated or new controls and wiring
75°C and 95°C insulation systems using Nomex® insulation
On select transformers:
LTC retrofit
KVA potential increases
Voltage changes
Bushing relocations

FAQ

What are the advantages of remanufacturing a substation transformer versus the alternative of buying new?

A1: Reusing the core steel and tank of an existing transformer offers substantial savings in both price and lead time.

A2: The savings are even more dramatic when reusing the LTC within a transformer, which is often!

A3: Our turnaround time is typically months less than new OEM manufacturers which require extensive design time for new transformers.

A4: No sacrifice in quality or life expectancy and all transformers are upgraded to today’s short circuit design standards.

A5: Your remanufactured transformer will have a drop-in form, fit, and function, whereas new typically requires substation design modifications.

Do you work on furnace transformers and rectifiers?
Yes—we are experts with both.
Do you buy surplus transformers?
No, we remanufacture your substation power transformers that are failed or gassing.