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Is it safe to buy a reconditioned converter? Should I buy new instead? Reconditioned transformers can be a good option. They are reliable and will operate safely.
The article primarily covers medium voltage oil-filled distribution transformers, but you can apply the same logic to other transformer types.
We should first understand why a reconditioned converter is a good investment. By design, some equipment is not suited for reconditioning. This is not the case for most transformers.
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Why Reconditioning Transformers is Practical
A product must meet certain criteria to be reconditioned economically.
- It is not subject to rapid technological obsolescence.
- Use with caution.
- The cost of rebuilding must be lower than that of building new.
Transformers meet all three requirements!
- Despite improvements in manufacturing, the basic technology of How transformers work remains unchanged since its invention.
- Transformers do not have moving parts to wear out due to mechanical stress. The secret is to maintain the transformers for a 30-year average lifespan.
- You can repair transformers relatively cheaply compared to building a new one, unless they need a complete rewinding.
After establishing that remanufactured converters are indeed economically viable, we will analyze their benefits and risks.
The Benefits
1) Delivery Speed
In the US, lead times for new converters range between 10 and thirty weeks depending on market conditions. You cannot complete many projects within this timeframe, especially in emergency replacement situations. The US also has an old, and colloquial, distribution system, which means that there are dozens of different voltages. The lack of standardization means manufacturers still make nearly every transformer to order. The cost of maintaining an adequate inventory is therefore out of reach for most electrical distributors. This gives rebuilders the opportunity to keep a wide range of voltages in stock to meet their needs.
2) Lower Cost
Remanufactured transformers typically cost 10% to 40% less than new ones. What about the savings in energy costs from newer, more efficient designs? Although transformer design has gained 1% to 2% in efficiency (as of DOE 2016), the power bill savings will not offset the cost of a new transformer.
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3) Lower Risk Of Failure
Transformer failures are most common immediately after energization. Fewer than 1% of transformer failures happen between years 3 and 30. If a transformer has been energized and in service for some time before removal, the secondary purchaser can be assured it has already been tested.
4) Lower Environmental Impact
Some claim that more efficient, newer transformers are better for the environment due to their lower losses. The slight gains in efficiency made over the past few years won’t be enough to offset the environmental impact associated with manufacturing a new Transformer. According to the EPA, manufacturing accounts for 5% of all greenhouse gas emissions in the United States. Rebuilding produces virtually no greenhouse gases. So go green–buy reconditioned!
The Risks
1) Problems Caused by Low-Quality Rebuilders
A transformer that was taken out of service without any issues may have had a problem introduced by a rebuilder who did not do a good job.
2) Lifespan is reduced due to unknown history
The transformer may have been thrown out by a previous owner because of a known problem.
Minimizing the Risks
Quality rebuilders can mitigate these risks. It is important to check not only the product but also the rebuilder. Be sure to check that any transformer you buy is reconditioned by a company that can at least:
- Test the transformer after it has been rebuilt and provide an ANSI C.57 test report.
- Be willing to participate in factory tours and witness tests
- Before rebuilding, provide the results of the Transformer Oil analysis.
- Reconditioning is documented in a formal manner
- At least one year warranty
Conclusion
Transformer reconditioning is a niche business that has existed since the advent of transformer technology. When you have to meet deadlines or budgets, buying a reconditioned converter is a great option. Reconditioned isn’t always better than new, but it is important to do your research and make sure you get a high-quality product.
Electrical Transformer Buyers is a specialist in transformers. We keep thousands of them in stock.
Contact us today and see what we can do for you! Electrical Transformer Buyers offers both new and reconditioned products for any project.