At Bowe & Gant, our proficiency in transformer retrofit design & installation in Delaware was central to executing a critical modernization project for a major industrial facility. The client faced the urgent need to upgrade their aging power infrastructure to ensure operational stability and mitigate the substantial risks associated with equipment nearing its end-of-life.
Integrating New Components in an Existing Transformer
The project’s scope focused on a 5KV oil-filled substation apparatus where key components showed signs of degradation. Our team was tasked with the precise replacement of three 2400 Amp high-voltage bushings. Given that bushing failure can be catastrophic, leading to sudden equipment destruction and costly plant shutdowns, this targeted replacement was a vital step in preserving the client’s transformer assets. The most significant technical hurdle, however, was integrating these modern components with the facility’s legacy bus-duct system. A standard approach would have necessitated disruptive and expensive demolition of the existing infrastructure.
Custom Fabrication for Transformer Retrofit Design & Installation in Delaware
This is where our capacity for integrated design and in-house fabrication delivered a superior solution. Instead of proposing a costly rebuild, our team engineered and fabricated new 4-inch solid copper busbars tailored to the exact specifications of the project. As evidenced by the clean, secure connections in the image, these custom busbars were installed directly within the existing duct system, creating a seamless and highly conductive pathway. To guarantee the connection’s longevity and resilience, we installed heavy-duty flexible copper transitions. These are engineered to absorb mechanical vibrations and thermal cycling, preventing stress fractures at critical connection points.
A Successful Transformer Retrofit Design & Installation
The successful completion of this retrofit delivered a fundamentally safer, more efficient, and more reliable power system. 1 Our ability to design and build a custom interface on-site saved the client significant capital expenditure and avoided weeks of operational disruption. 2 The facility now benefits from reduced energy loss, minimized risk of unplanned outages, and an extended operational life for its critical power equipment, demonstrating how Bowe & Gant’s expert, hands-on approach solves complex electrical challenges. 3
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