Wilson Power Solutions

OWL competition winner!

June 11th, 2009

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Launching the Wilson E2: UK's first super low loss amorphous transformer

April 6th, 2009

The Wilson E2 transformer is the first super low loss amorphous transformer available in the UK. Super low loss transformers are the most energy efficient distribution transformers offered today.

Why uper low loss?

Two types of energy losses are inherent in the running of distribution transformers:

Load losses (copper losses) that vary depending on transformer loading, and no-load losses (iron losses) that occur in the magnetic cores and take place over the life of the transformer regardless of the load.

Using proven technology and design, Wilson E2 transformers combine amorphous metal cores with low current density copper conductors to provide unrivalled savings in both core and copper losses.

Key features

• Built to IEC76/BSEN60076 standard

• Interchangeable with most existing installations

• Flange heights to EA35-1

• Midel or oil filled

• Tappings as no cost option

Tap into our transformers to optimise site voltage

In addition to the improved transformer performance, our Wilson E2 transformer comes with added tappings as a no cost option, allowing you to optimise voltage requirements from 415V to 380V according to your site’s need. Depending on your site’s load you can achieve total energy cost reductions of up to 12%, making substantial savings without the need for installing additional voltage optimisation equipment.

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Olympic Glory?

October 22nd, 2008

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Nuclear Power - The mighty Atom?

August 19th, 2008

The Mighty Atom - now I’ve started shall I continue?

When I was a schoolboy a few years ago – in the late 40’s/early 50’s if you must know – we used to frequently get regaled with the triumphs of British Technology.

The coronation in 1953 saw a UK climber (alright New Zealander really but who is going to complain about a few miles down the road) and his Sherpa companion conquer Everest and the dawn of the new Elizabethan age was declared.

In Power Engineering, UK manufacturing was still a force to be reckoned with and the Nuclear Age had arrived. Sellafield was there to quietly produce Plutonium so that the UK foreign ministers ‘did not go naked into world’s council chambers’ when nuclear warheads and strikes were discussed and the new Queen opened Calder Hall – promoted as the first commercial nuclear power station in the world.

At the time I heard responsible scientists and engineers proclaim that the energy produced by nuclear reactors would be ’so cheap it would hardly be worthwhile sending a bill out for it’.

Even as late as mid 70’s the then Chairman of Yorkshire Electricity Board was still peddling the same story at an I E E Dinner in Leeds – no mention of the rubbish even at that time left behind in the nuclear dustbin to pollute the environment.

Strange that as we now reflect on the huge costs of dealing with the leftovers of that fledgling nuclear industry and also ponder moving into the next nuclear age – again to save ourselves from an energy famine and keep the air clean. This time the general public are a little more informed about consequences, ‘how green is my nuclear dustbin and how many generations will pass and disappear before the radio active remnants can be removed ?’

No doubt the scientists and engineers of the 1950’s realized the dream which ultimately turned into a nightmare but with alternatives running down or not desirable because of the carbon footprint, renewables not able to provide base load satisfactorily we appear to have little recourse but to take a walk with the nuclear demon again.

Will it be cheap – don’t believe it; but then almost every other energy source is expensive too and will cost more, probably a lot more ….so two sweaters or a good old fashioned heavy coat and woolly gloves will be the order of the day. Just like the lovely lady who used to run a farm all by herself deep in the Yorkshire Dales without any modern power and little heat; or the scenarios from films set in times when the concept of central heating did not exist – perhaps you thought thick curtains around a 4 poster bed was just for privacy not draughts!

I was able to visit the site at Sellafield this May to see the former glory – much of the original infra structure is de commissioned and dismantled or encased. Work proceeds on the modern plant to re process spent fuel. The adjacent power station (Calder Hall) is shut down and awaits demolition; present power requirements at site are fed from a gas fired source – the final ignominy perhaps.

Now we hear that the fortunes of the industry will be taken over by EDF, Electricitie de France, a nationalized concern controlled by the French Government instead of a UK authority. Mon Dieu, could this perhaps stimulate the great Wellington to oscillate a little in his lead lined coffin. For the Brits ‘sic transit gloria mundi’ as they say.

Have you the intelligent reader any thoughts or comments?

Bob Bennett

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Wilson Power Solutions is supporting local schools in Chennai, India

August 6th, 2008

Power and Distribution Transformers Ltd, trading as Wilson Power Solutions, today announced that it has partnered with the Rotary Club of Chennai Mambalam (RCCM), India, in their community service projects.

RCCM concentrates its efforts on grass root level projects such as developing the infrastructure of village schools.

In the last two years, RCCM adopted two village schools near Chennai (Thiruneermalai and Kattankulathur) and helped to significantly improve the schools infrastructure by building toilets, classrooms, compound walls and providing class room furniture. RCCM further supports these schools by providing text books, uniforms and rewarding outstanding students every year.

In their effort to continue their community service RCCM has identified another school near Chennai (Manapakkam) which urgently needs structural improvements. During 2008-09 RCCM will be building a reinforced cement concrete building (to replace the old, tiled roof building, see photo) housing three classrooms.

The important community work of the Rotary Club is only possible through generous donations. Wilson Power Solutions pledge of continuous support and contribution towards RCCMs community service projects is very much appreciated, said Srini Sudarsanam, local RCCM represenative.

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Transformer Rating - Its the loading that confuses.

May 23rd, 2008

Transformer Rating - this can cause some confusion particularly to anyone who has to be an occasional player - occasional player being the person who got the job of ordering that electrical power equipment which is needed for the new site location or modification and who is not, by their own admission, an expert in these matters.

The voltage of the supply, incoming, is usually known, what exactly is to be supplied may not be as clear so a round up of required loading is made. This can be a little difficult: is that machine running all the time ? How does the load vary from idle to operational mode? Are several machines being loaded at any one time? A survey can provide a load utilization factor. Now it is possible to play for safe and add everything together, add a safety factor or two and go with the end result OR you could decide that in some circumstances it is possible to overload the transformer (exceed the stated nameplate rating) for short periods (say).

Unfortunately it is not possible to overload on a permanent basis; or you can ignore the facts of life and do it anyway and the transformer will run over temperature and may be permanently damaged. To apply the latter approach requires some intelligence and skill to apply but can be rewarding IF practical possibilities allow. For example it will allow some money to be saved – the initial buying cost of a lower rated transformer and the general running costs (no load loss) if standing idle but energized for lengthy periods.

IMPORTANT : this approach may not work with load losses as the load loss of a smaller unit running near to nameplate rating may exceed that of a larger more highly rated transformer operating at the same loading.

Some help/guidance can be got by looking at the following std publications IEC 60076 Pt 8 ‘Application Guide’ or more useful IEC 354, BS 7735 ‘Loading of Oil Immersed Power Transformers’ (if your transformers are OIL IMMERSED, look elsewhere if not) or you may obtain some suitable software to do all the hard work for you.

Whatever way you choose it would be good to accept the challenge and save your Coy some money. Just be SURE you understand what the loading is to be, does it have any harmonic content? If so what is the extent of the frequency spectrum and the overall effect on transformer rating. Are there relatively large motors to be started? Are same unloaded or loaded at time of start ? Is there an unsatisfactory p f (low) to be considered ? which may cause a larger than required regulation (volt drop).

So why all this concern about loading and NOT overloading a given transformer?

It’s all to do with the temperature capability of the insulating materials and preserving their longevity – overloading causing high temperature rise/high temperature which can rapidly shorten the life of any equipment and in the worst of circumstances terminate the insulation system almost immediately. SO IT IS IMPORTANT to know what you are about.

How then do you monitor the maximum temperature(s) that are likely to occur ? Ideally place a very small temperature sensing device in a position where the maximum temperature is likely to be found. Unfortunately dealing with oil filled transformers, particularly if working at high voltage, this is not always convenient so that other means of measurement (indirect) have to be employed. Traditionally this would be a Winding Temperature Indicator set up to give a reasonable read out of the average winding or coil temperature. It is normally provided with means to ensure it provides alarm & trip facilities. It can be purely analogue or electronic. The latter is a step forward as it is possible to log temperature variation with load and we begin to have a means of controlling load & time of load by means of temperature. More sophisticated means can be employed IF NEEDED, the principle being to monitor temperature and control the loading (a model can be established) accordingly with the benefit of saving energy and hence costs. It would be interesting to hear of some real life operational experiences where the principle of controlling overload without exceeding given temperature parameters has been used.

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EXCITEMENT YOU DON’T REALLY WANT AND DEFINITELY DON’T NEED

May 15th, 2008

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.

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Introducing the “5S” at Wilson Power Solutions

May 7th, 2008

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,

Set
Sort
Shine
Standardise
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.

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Stock Car Team Update, 01/05/2008

May 1st, 2008

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.

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Full support for refurbished or partially rebuild equipment

April 24th, 2008

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.