Everything You Need to Know About Reconditioned Transformers

Everything You Need to Know About Reconditioned Transformers

Everything You Need to Know About Reconditioned Transformers

Reconditioned transformers are used electrical devices that have been rebuilt, repaired, or overhauled to restore them to their original operating condition. They are often used as an alternative to purchasing new transformers, as they can provide cost savings and quicker lead times.

One of the key advantages of using reconditioned transformers is their cost-effectiveness. 

Opting for a reconditioned transformer can save a significant amount of money compared to purchasing a new unit. Additionally, lead times for reconditioned transformers are often shorter than for new units, which can be beneficial for projects with tight timelines.

Another advantage of reconditioned transformers is that you can customize them to meet specific needs. This can include redesigning the transformer to meet ANSI and IEEE standards, as well as any requests from the customer. 

This level of customization is not always possible with new transformers. Furthermore, rewinding and reconditioning a transformer will extend its life by a significant factor.

Initial Transformer Reconditioning Inspection

Before making any significant changes or repairs, an initial inspection and testing of the transformer are necessary. This includes checking the bushings, radiators, gauges, cabinets, and main tank for any damage that requires immediate attention and repair. 

All electrical and mechanical components are also tested for proper operation. This initial inspection is essential to determine the overall condition of the transformer and identify any issues that need to be addressed.

The next step of the reconditioning process is the removal and inspection of the internal components of the transformer. This includes cutting the top off the transformer and pulling out the core and coils. Once the internal components of the transformer are removed, they are inspected for defects.

Based on the inspection results, a decision is made on whether the transformer can be reconditioned or needs to be rewound. 

The transformer will be set aside for rewinding if there are any issues with the internal parts, such as structural integrity, insulation deterioration, grounding issues, or winding discontinuity. If the transformer’s internal components pass the inspection, the transformer will continue in the reconditioning process to be repaired.

The decision of whether to rewind or recondition a transformer can have a significant impact on the overall cost and timeline of the project. 

Reconditioning is generally a less extensive and time-consuming process than rewinding and is typically the preferred option when the transformer is in good condition. However, rewinding may be the best option to extend the transformer’s life and ensure reliable performance if the transformer is in poor condition.

The Transformer Rewinding Process

The transformer rewinding process begins with data collection and design phases. This includes gathering information about the internal components of the transformer to assist in the design phase. 

The design will be based on both ANSI and IEEE standards, as well as any customer requests. This step ensures that the transformer will meet the specific needs and requirements of the customer.

Once the design phase is complete, the transformer will be disassembled for inspection. This includes removing the core, coils, and all of the leads. All parts will be checked for damage, and the coils will be unwound from the core. The core will be un-stacked. 

The data collected in the design phase is used to redesign the transformer to meet the standards and requests of the customer. New materials will be sourced for the transformer, including new copper windings, new insulation, and any materials required for rebuilding the tap changers, gauges, cabinets, and all other parts of the transformer. 

After sourcing new materials, the transformer will begin to be reassembled. The final step is testing to ensure it functions correctly and meets the desired specifications.

Reconditioning Process

The reconditioning process begins with the repair of the internal components of the transformer. This includes fixing any issues identified during the initial inspection and testing phase, such as structural integrity, insulation deterioration, grounding issues, or winding discontinuity.

Once the internal components have been repaired, the tank and radiator of the transformer will be inspected and repaired, if necessary. This includes checking for leaks or oil flow blockages and making necessary repairs. 

After the tank and radiator have been inspected and repaired, the internal components are dropped back into the tank and fixed. The tank is then sealed back up, and the transformer is vacuum filled with either new mineral oil or FR3 fluid. This step ensures the transformer will function properly and have a long lifespan.

The final step of the reconditioning process is testing. 

This includes various tests such as

  • Turns Ratio Test.
  • Insulation Resistance Tests.
  • Power Factor Tests.
  • Resistance Tests.
  • And any tests that the customer requests.

This step is the final quality control barrier that guarantees the transformer functions correctly and meets the desired specifications. Once the testing has been completed and all parts of the transformer have been reassembled, the transformer is sandblasted and painted to the customers’ specifications.

Benefits of Reconditioned Transformers

Reconditioned transformers offer several benefits to those in need of a new transformer. 

One of the key benefits is cost savings. Reconditioned transformers are often significantly less expensive than purchasing a new unit, making them a cost-effective solution for many businesses and organizations. 

Another benefit is that the lead times for reconditioned transformers are often shorter than for new units, which can be beneficial for projects with tight timelines. 

Reconditioned transformers can be customized to meet specific needs; this can include redesigning the transformer to meet ANSI and IEEE standards and any customer requests. Buyers don’t always have this level of customization when purchasing a new transformer.

Find Reconditioned Transformers At UTB Transformers

If you need a transformer, look no further than UTB Transformers. UTB Transformers specializes in servicing, repairing, and reconditioning transformers of all types. 

If you need a new transformer or are looking to repair or recondition an existing one, UTB Transformers has the expertise and experience. In addition to our reconditioning services, UTB also buys and sells used transformers, making it a one-stop shop for all your transformer needs. 
Don’t let the daunting task of obtaining a new transformer stress you out. Contact us today to see how we can help you with your transformer needs. With our commitment to quality, reliability, and customer satisfaction, you can rest assured that you’re in good hands.