Wilson Power Solutions

Sometimes, just occasionally I am asked ‘as an engineer why did you become involved in transformers, after all they really are very boring – just sitting there doing nothing apart from a constant hum supplying power’. Well I can agree, most of the time it is or seems that way. However sometimes exciting things do happen and you are NEVER prepared for the inconvenience – particularly when a transformer fails mechanically due to short circuit.This results in scrambled windings (very quickly) and very occasionally with an oil filled unit if the tank is weak and splits (at a weld) releasing insulating oil a fire may be the result. In this case much of the evidence which is combustible disappears and the fire also consumes whatever is in the locality of the transformer. Definitely a scenario to be avoided. The Coy has just examined a transformer, rated at 800kva, recently returned from site due to possible mechanical failure under short circuit conditions. How the transformer was short circuited is an open question still to be considered but the results are interesting – see the reproduced photos.  

 As can be seen A phase coils are somewhat of a mess - the outer half (4 layers) of the HV coil has compressed against the top yoke of the transformer, likewise the inner lv (not really seen in photos) has also moved in an upwards direction. Meanwhile the inner part of the HV coil has compressed itself against the bottom core yoke and clamp frames. The end packing blocks, made from natural hard wood have come away completely – splitting & breaking up thereby eliminating the physical support essential to maintaining the integrity of the transformer ( interesting question, how can you predict and control the properties of natural wood ? unless subject to a rigorous selection programme. What happened to industrially produced laminated wood which has guaranteed minimum mechanical characteristics? Simple - probably more expensive to purchase, but where was protection for the client, the user ?A visit to B phase is also interesting because things are happening here – the top set of blocks has again gone, the lv coil has moved up to the underside of the top yoke BUT the HV coil has not yet moved. Also the bottom packing /support blocks are still in position although one has already split thro’ its overall thickness !  

Meanwhile at C phase nothing has really happened, the coil combination has not moved and the top and bottom pack blocks are entire, all still in place.So in 3 phases we progress from the apparently normal state with HV/lv in proper order (C phase) to complete disaster (A phase). Other items of interest are: movement within the core structure, possible opening of mitred core joint at bottom of A limb . Current arc activity at OCS moving contacts for A & B phase some movement and distortion of clamp frames particularly adjacent bottom yoke. This particular transformer is now fit only for scrap; the cost of recovery/repair would be too high and so will be replaced by a new transformer of similar rating. Fortunately no one was injured, there was no fire – the user only suffered the inconvenience of supply loss for a day or two. Sometimes the outcome can be different, somebody gets hurt or worse, there is a fire, a business is not properly insured so may disappear and people are put out of work. So be warned! That grey box which looks so dull and uninteresting may one day briefly develop a life of its own and cause trouble with an exciting failure. If it is a short circuit you now have some idea what to expect and what needs to be done to get you going again, so its as well to be prepared. If you have been reading, please make comment if you feel so inclined – we all learn in the process.

The department specifically chosen to introduce 5S into the business has been the previously untouched “Trip-unit” assembly, test and dispatch areas.5S is a Japanese business improvement tool with many variations upon the same theme. Based upon,

1. Set
2. Sort
3. Shine
4. Standardise
5.  Sustain

“Set” is to clearly define the area for improvement, with an agreed work-flow allowing adequate storage and presentation of necessary materials, tools and information required to complete the pre-determined tasks.“Sort” is to remove all unnecessary materials, tools, equipment from the workplace.“Shine” is generally to clean the workplace to an agreed standard.“Standardise” is to agree how materials, tools and work instructions are to be presented and this should be repeated wherever possible at other work-stations within the business.“Sustain” is to create a system of making sure that the agreed standards are maintained, usually with the aid of visual aids and a routine daily checksheet. The team so far consists of Terry Martin and Nicky Winter. They are working extremely hard making sure of “business as usual” while still making dramatic changes to their working environment. Currently they are approximately 50% through the Sort and Shine stages and should soon be able to move onto “Standardising “the first work station.

It’s been a busy time of late in the Sales/engineering offices of Wilson Power Solutions in the last few weeks. But that doesnt stop when here when the phones stop ringing. When the Office doors shut, Anthony replaces his Shirt and Trousers with his Mucky Overalls and moves into the Wilson Power Solutions Workshops to work on the Company F1 Stock Car.

This weeks main project has been to get some paint on the car, to allow it to become available for the Sign Writer to apply the Wilson Power Solutions Decals ASAP. 

A query often asked by buyers (or users) goes reasonably as follows:

‘Why use refurbished or partially rebuilt equipment, thereby continuing old technology?

Surely newly designed & manufactured equipment would be more suitable?’ Fair questions & for many new prestige projects the answer would be affirmative. However there are still many situations, taking fitness for purpose & reliability as paramount considerations, and where particular oil filled equipment is already installed,risk assessment(s) in place and maintenance routines well understood & established that the older equipment will perform the required function and the client can save money.

Why should this be?

Historically, in the UK, much equipment purchased and installed by the Public Utilities in the past – C E G B, Scottish Electricity & Area Boards – was fully maintained and underutilized.

Hence when de commissioned at original site, whether oil filled transformer or switchgear, the condition is usually excellent and much operational life remains.

An example : a standard pattern distribution transformer recently acquired, 1000kva, produced 40 years ago by a well known manufacturer located in the east midlands on examination is in pristine condition, virtually no insulation deterioration or loss of life – ready to work for another 20 – 30 years if needed.

Yes the no load loss may have increased slightly but losses are still comparable with modern ‘standard loss’ units & the physical design, particularly HV disc coils (NOT a usual feature with modern units of same rating due to cost) make it inherently mechanically strong. This coupled with an attractive price saving compared to a new unit fulfills a market need particularly if req’d for relatively short time usage. Such units carry a 2 year warranty demonstrating our company’s confidence in these selected items.

Likewise with Switchgear – users with existing sets or suites of oil filled equipment having a long & reliable pedigree of satisfactory operation find the availability of similar/identical equipment attractive. Said equipment(s) are factory checked to original manufacture specifications and items replaced with original manufacturer approved parts if needed (eg current breaking contacts). Back in time it was assumed that ALL refurbishment of oil switchgear would have ceased by the year 2000. In 2008 quantity may have reduced but definite demand still exists & will probably continue unless finally ended by specific dictate from Europe.

Wilson’s ensure that both refurbished transformers & switchgear are routine factory tested to original BS and/or IEC Std. requirements prior to shipment to site. Some American Std requirements can also be accommodated.

Still concerned ? Yes – the Coy does also regularly scrap transformers and switchgear where existing condition does not meet the defined criteria set by the Coy for reliable re use and recovery is un economic. So the Coy advocates the continuing use of equipment where it can be demonstrated it is STILL fit for purpose and norms arising from current legislation and safety can be satisfied.

Why simply destroy every item of existing resource simply to feed the expanding need for scrap metal in China ?

bob bennett.

New for 2008 is the Wilson Power solutions BRISCA F1 Stock Car Racing team. The Team Driver will be Anthony Flanagan (133) who by day is part of the Wilson Power Solutions Sales team, and in his spare time is a F1 Stock Car Driver.

Anthony is currently in the final stages of preparing his car for the 2008 Season, and should hopefully have some photographs of the car when it returns from the paint shop by the time I enter the next post.

Anthony is also currently in the middle of preparing the Wilson Power solutions Transporter, which has had all the external conversions done.

At this moment in time the Transporter is at a local motorhome manufacture having all the living quarters installed, so hopefully it will all be ready in the next few weeks.

Wilson Power Solutions, home of Richard Wilson Dencol Ltd and Power & Distribution Transformers Ltd today announced their plans to be the first UK based electrical engineering company to go carbon neutral.

We have decided to act on the challenge of climate change and will commit to be a CarbonNeutral® company by this summer. We will be the first electrical engineering company to achieve this status in the UK and are looking to become one of the environmentally responsible pioneers in our industry.

Why are we doing this?

Climate change is increasingly recognised as a major global threat. It is widely accepted that the greenhouse gas emissions caused by humans are having a negative impact on the environment. The most important greenhouse gas arising from human activity is carbon dioxide [CO₂].

By using electricity generated from fossil fuels, burning gas for heating, driving a petrol (or diesel) car, every person is responsible for CO₂ emissions. We recognise our responsibility for emissions generated by running our business and pledge to decrease our energy consumption, business travel and waste generation to help reduce CO₂ emissions.

What is a carbon footprint?

The total set of greenhouse gas emissions caused directly by an individual, a company, an event or a product is called their carbon footprint. We calculate our carbon footprint by measuring our energy usage, petrol / diesel consumption and company travel and convert these figures to the equivalent in tons of CO₂ emissions.

What means CarbonNeutral?

Carbon neutral stands for achieving a net zero carbon footprint through both internal and external reductions of CO₂ emissions.

Internal reductions are things we do within our business and the way all our people behave i.e. switching off lights, recycling waste appropriately, cycling to work and installing more energy efficient operating equipment.

External reductions (called ‘carbon offsetting’) are reductions we make happen outside of our business. The way it works is that for every one ton of CO₂ we produce, we pay for an equivalent one ton of CO₂ to be saved through a project somewhere else in the world – like swapping kerosene in remote areas of India for ‘clean’ solar panels. One ton ‘offsets’ the other.

Our carbon offsetting will be organised by The CarbonNeutral Company.

Since the earliest attempts at utilizing the technology of a c (as opposed to d c), the transforming of voltage from one level to another has been in use.

The economics of moving power from one point (say generation) to another (usage) at higher voltage and lower current have been well understood – smaller x section of conductor etc. So having moved your power to the point of usage it is usually necessary to ensure it is available at the required or a convenient voltage. So devices to transform voltage were required at either end and a manufacturing technology was brought into being.

With production of transformers came the requirement for some insulating medium, not least between turns and particularly to earth, to ensure NO breakdown caused by voltage with consequent equipment failure occurring The original transformers were small, low kva, air cooled insulated with a variety of tapes and shellac or varnish to bind together. Demand for larger thro’put kva soon led to other thoughts and a system using forms of paper and refined oil came into being which in developed, modified form still exists today.

The perceived advantages were

• Various grades of paper were available. Paper can be an absorbent medium and by asorbing, say oil, can assume a di electric factor not unlike oil itself.

• Various fluids were available, crude oil being one such and even then being fractionally distilled to produce a variety of by products.

Specific disadvantages

• Water absorbent, reducing or eliminating insulant properties.

• General deterioration in properties of cellulose (irreversible) and oil (partly treatable).

The establishment of paper and oil as a suitable system of insulation came about by experiment (pure water might have been used, but its properties as an insulating medium are quickly compromised by a low degree of contamination). The other useful property provided by oil is as a cooling medium – oil possessing a reasonable thermal capacity and so usable to assist the cooling of any working transformer by acting as a heat transfer vehicle between the coils of the transformer and the means of dissipating such waste heat from the transformer.

So the paper/oil system came into being as the major technology supporting the manufacture of transformers of most voltages (except the very lowest) and power thro’put (again except the lowest) in use world wide. Since the early days much research has been conducted to improve the long term performance of materials used but the basic concept remains the same even in the 21^st Century. 

Bob Bennett