Dry Type Transformer Products & Solutions

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Dry Type Transformer Products & Solutions

▪ This presentation is to help and understand the three Solutions a customer has

for replacing Medium Voltage Dry style transformers.

▪ This will focus on replacement opportunities only, not new construction.

▪ The Three topic’s will be.

1) New Core & Coil replacement

2) In-House Rebuilds

3) On-Site Rebuilds

Which is the best option for you.

Dry Type Transformer Solutions

▪ Typical KVA Range: 500 KVA – 10,000 KVA

▪ Typical Winding Voltage: 600V up to 15 KV

▪ Winding Configurations

• Distribution

• Multiple Pulse (6, 12, 18, 24, etc.)

▪ Accessory Equipment that could also be upgraded

at this time:

• Fan Packages of units with FFA rating

• Three phase digital temperature Monitor

• Lightning Arrestors

• CPT

New Dry Type Product

Does your transformer fall with-in DOE 2016 efficiency?

▪ For replacement of an existing transformer that is 2500 KVA and smaller and in a distribution application, the new transformer must meet 2016-DOE efficiency requirements. Any transformer over 2500 KVA or outside distribution application is not require to meet this efficiency. To be sure your application does or does not meet these requirement, you can look at IEEE 12.57 or we are happy to aid you.

▪ To meet the new efficiency requirements, more core steel and conductor is required in the new transformer construction which increases the over all size of the transformer by 15-25% depending on the transformer parameter.

▪ This increase in size, due to the DOE 2016 efficiency, can make installing a new Core & Coil very difficult if not imposable without costly modifications (i.e. complete new enclosure, moving of existing gear, re-routing cables, and pouring a larger mounting pad) which most electrical rooms aren’t able to accommodate these mod’s.

▪ If your application does not fall with-in the DOE 2016 requirements then we can provide you a new Core & Coil that will be built in likeness of the original unit and to todays standards & mat’lupgrades.

New Dry Type Product (cont’d)

▪ What is required to determine fitment of a new Core & Coil back into an existing enclosure

and application. This would be for DOE or non-DOE transformers

Pictures, lots of pictures of the original unit including name plate. This will quickly show

us how tight the existing C&C is with-in the original enclosure and any special

requirements the unit may have.

Providing the existing enclosure size (H” x W” x D”)

Measurement of Primary & Secondary connections coming off the existing enclosure.

These measurements do not have to be detailed at this stage, just well enough so the

engineer can see if the existing connections can be met if the DOE 2016 requirement is

needed.

▪ AMR PEMCO will take this provided information and determine if a new Core & Coil can be

provided.


▪ In some cases, when the enclosure is larger then normal we can actually increase the transformer size to accommodate increased power demands.

▪ Adding fans to an FFA rating is one of the quickest and least costing ways to add additional KVA.

▪ Custom Designs to fit existing line-ups (i.e. connections, retro fit designs.)

▪ Custom Bus Work to meet existing connections

▪ Provide Custom options on existing Enclosure Screens, filters, or replacement panels Add accessories (i.e. IR viewing windows, digital

monitor, etc. )▪ UL approved Varnish and VPI System▪ Meeting all IEEE/CSA Standards


▪ Examples of C&C replacements.

150 KVA, 24kV – 480V


▪ Examples of C&C replacements.

750 KVA, 5kV – 480V


Examples of C&C replacements. USPS - 3900 Crown Rd

Rebuilds - Dry Type Product

AMR PEMCO - In-House Rebuild Solution

• The In-house rebuild option has many positive reason for having it a part of your solution.

• With the already discussed DOE 2016 requirement and a new Core & Coil not working/fitting in many applications, you can rebuild the existing transformer.

• Rebuilds are exempt from the DOE requirements

• No matter what style of winding construction it may be, we can provide new coils (i.e. Cast or open wound).

• By rebuilding your existing transformer, it gives you the guarantee of an exact fit, for reconnections and operation location.

• Our coil design will have the 220°C insulation system which exceeds a lot of OEM’s construction on the older, existing transformers

Rebuilds - Dry Type Product (cont’d)

• AMR PEMCO’s coil construction is of a Barrel design which gives you a smooth vertical surface. Most transformer OEM’s use a disk wound construction which allows the build up of dust and other foreign material which over time could result in a flash over and a coil failure.

• During the Rebuild we can update the accessories by replacing the fan package, temperature monitor, LA’s etc.

• The existing enclosure & base can also be refurbished if need be which includes cleaning & resurfacing the metal and applying new primer and dry power paint.

• We provide a 12/18 month warranty which is the same as a new transformer with Extended Warranty options.

• Lead time is shorter with a Rebuild. Typical turnaround for most applications is 5-7 wks.

• Cost is typically 20-30% less then the price of a new unit when looking at total pricing.

• This work is all performed at AMR PEMCO’s factory located in Bluefield, VA.


• This solution would require the Core & Coil to be removed from the electrical room and sent to AMR PEMCO. Freight can be part of the total door to door package offered.

• New Coils are reverse engineered so to have the same fit and function as the original build however, updated to the most recent standards and mat’l along with processed through our VPI system for protection.

• The original transformer will have the old/failed coils removed and undergo a complete clearing to remove any dust and/or contaminants & baked dry.

• New insulators, cables, blocking, and barriers would be installed.

• Once fully assembled, the entire unit is dip in our Isnal varnish for a complete over-all environmental protection coating.

• Std Testing per IEEE is performed with a signed test report provided to the customer.


In-House Dry Style Transformer Rebuilds

Old Failed Unit - 2000 KVA Newly Rebuilt Unit


In-House Dry Style Transformer Rebuilds

Newly Rebuilt UnitOld Failed Unit - 2000 KVA


In-House Dry Style Transformer Rebuilds Old Failed Unit - 420 KVA


In-House Dry Style Transformer Rebuilds Newly Rebuilt Unit

On-Site Rebuilds - Dry Type Product

AMR PEMCO’s – On-Site Rebuild Solution (Only manufacture capable of offering this service)

• This solution is for situations when removing the old/failed transformer from the building is next to imposable and would be very costly where demolition, street closures, cranes, etc. are required for the removal of the old or failed transformer and installation of a new one.

• AMR PEMCO will bring the skills of their very successfully in-house rebuild service to the job site.

• We send a qualified technician to take all necessary measurement, sketches, and pictures of the failed transformers. We evaluate and determine what work needs to be done, the same as if the transformer was at our factory.

• We discuss the over-all logistics of how the Rebuild will take place with the contactor. This included the work scope of AMR PEMCO and that of the contractor.

• This information is taken back for engineering to reverse design New Coils that will have the same Electrical Characteristic and that will fit on the existing Core legs.

On-Site Rebuilds - Dry Type Product (cont’d)

AMR PEMCO’s – On-Site Rebuild Solution

• The new coils are manufactured, tested, VPI Vanished, and Shipped to the site.

• AMR PEMCO then will coordinate with the contractor and schedules for (2) service technicians to return to the site to perform the Rebuild service.

• The rebuild takes place over a 3-4 day time line where the PEMCO technicians and (1) helper provided by contractor will breakdown the failed/old transformer, remove all coils, clean the unit, re-install the new coil and complete the rebuilding of the entire assembly.

• Once the rebuild is completed, then the contactor has a third party test group finalize the rebuild by performing standard field tests.

On-Site Rebuilds - Dry Type Product (cont’d)Pictures of past Projects


Our service technician takes measurements of the transformer that is being replaced. Also, determining if any accessories or bus needsto be replaced or modified.

AMR PEMCO will use the existing unit’s core, bus work, clamp assembly, termination connections, and enclosure unless its determined that any of these items needs to be replaced.

The New Coils are engineered, manufactured, and tested at our facility located in Bluefield, VA. If any additionalModifications are required (i.e. Bus sections or Fan Brackets.) Then these would be completed at the factory.

All Coils, Modification pieces, and Accessories (if needed)Will be then shipped to the site or contactors location.

AMR PEMCO will then send two technician’s along with the necessary tools to the site to perform the rebuild. The technician’swill have the ability to perform additional site modifications, Brazing,Bus fabrication and drilling.

Further Explanation of How does this work?


During the site visit AMR PEMCO’s service technician will preform a thorough walk through of the job site and rigging path with the contactor. Also during this time discussions will take place regarding rigging of the new coils, finalizing a equipment list of what will be supplied by PEMCO and what will need be supplied by the contactor.

Thorough discussions will takes place about the over-all Rebuild sothat everyone is understanding what will take place, who is to do what and when. We want to make the best use of everyone’s time and do it safely.

AMR PEMCO will do all of the work with regards to the disassembly and re-assembly of the Core & Coil. All accessories (Fans, brackets, CPT, Temperature monitor, LA’s, etc.) will be done by the AMR PEMCO’s service technician during the re-assembly process.

From a failed transformer to an fully operational transformer with new Coilsand a warranty without leaving the facility.

Further Explanation of How does this work?


Who is this Unique and VERY beneficial service for?

▪ Universities

▪ Hospitals

▪ High Rise Building

▪ Older/Historic Building

▪ Building where demolition, street closures, cranes, etc. are required for the removal of the old or failed transformer.

▪ Customers who want a quick/need a quick turnaround with minimal rental expense.

▪ Buildings with a substation foot print that can’t grow with the installation of a new DOE required transformer.

▪ Buildings with very limited access to the Electrical room and the logistics for changing out of equipment will be a nightmare.


Why should you choose the In-House & On-Site Rebuild service?

For both the Rebuild solutions, the following are items to worth highlighting.

▪ Guaranteed fit and re-connection to existing gear.

▪ Environmentally friendly and cost effective since we reuse several key components of the existing transformer.

▪ Backed by an experienced manufacture of over 60 years.

▪ Warrantied the same as a fully new transformer.

▪ When considering total cost, the rebuild service saves the customer money with the same results, less effort, and with a quicker turn around time.

For more information please contact us at:

Mike S taf ford

1. 540. 616.4269

MDSTAFFORD@ PEMCO . NET

Dry Type Transformer Products & Solutions

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