More on Electrical Distribution Equipment Failure – Should It Be Kept or Discarded?

As we promised in our last installment, we will continue the discussion on equipment failure.  We will continue to dive into various electrical components and how they work, their longevity, usage, and testing. 

Transformers

Transformers are large scaled pieces of equipment that are used to either reduce or increase the voltage produced by a current.  Liquid filled transformers are most often installed outdoors on a concrete slab, under a canopy to protect against the elements.  The liquid serves two purposes, it cools the transformer coils and provides insulation between the coils and the grounded tank. 
Older transformers use insulating mineral oils where as newer transformers use either a silicon based, fluorinated hydrocarbon, or combustion resistant vegetable oil based dielectric fluid or synthetic esters.  These insulating fluids break down first due to the entrance of moisture, impurities, and intermittent periods of heating and cooling.  Liquid transformers can deliver consistent service for more than 30 years with regular maintenance, fluid replacement, testing, and repairs.

Low Voltage Circuit Breakers

LV distribution systems commonly use molded case circuit breakers.  These systems contain two elements that deteriorate when used, a spring-loaded operating mechanism and copper contacts.  These two components will wear out from abrasion while closing and arching when the breaker is opened.  Larger breakers can be replaced. 

As these systems age the mechanisms that operate will start to slow down which delays clearing times.  The springs operating the mechanism are strong and hardly ever need to be fixed or repaired.  Lubrication however will deteriorate and need to be replenished to avoid the slower clearing times.  When a breaker operates above the normal trip rate it should be replaced.  These systems often last upwards of 20 years.  After 20 years replacement is most often recommended whether or not you are seeing slower clearing times during testing.

Low Voltage and Medium Voltage Cables

For most of us cables are quiet simple consisting of a stranded aluminum or copper conductor that is wrapped in insulation as well as a jacket that is resilient to the weather.  The manufacturing of electrical power and control cables sounds fairly simple however this industry is one that is in fact highly specialized.

Assessing the integrity of electrical cabling and its remaining longevity is important however can be quite complicated.  Cables can quickly lose electrical integrity while it is in use because of air pockets, gas pockets, and the voids found in the insulation.  This occurs due to thermal expansion and contraction.  If cables are in water their deterioration will occur at a faster rate.  Testing and analysis on these voids will offer up an estimate on the life that remains for the cable.

J & P Electrical Company is a full-service electrical company that supplies contractors, end users, and supply houses with new surplus, quality reconditioned, and obsolete electrical equipment. We purchase a wide range of electrical equipment such as bus plugs, bud ducts, panel switches, substations, and transformers.  More information can be found at https://www.jpelectricalcompany.com

Electrical Distribution Equipment Failure – Keep or Discard

When dealing with electrical equipment and components it is inevitable that they will fail, and you will have to deal with the consequences.  The minute electrical equipment is put into place, from transformers to circuit breakers and panel switches and tap boxes, they start to decline.  Deterioration of electrical products happens for a number of reasons including:

• Moisture Absorption
• Differing Temperature Cycles
• Dust and Particles Settling
• Condensation Buildup
• Fragile Operating Springs
• Insulation Material Breakdown
• Rusted Out Switchgear Enclosures
• Dried Out Capacitors

When electrical components within distribution systems age vulnerabilities start to appear. With automation being what it is today, electrical technology can often run unassisted, without issue for years. Because of this maintenance on these systems tend to be ignored which can lead to unpredicted failures which lead to catastrophic failures; the most common being fire.  Thus, in order to keep electrical components operating at their peak and delivering consistent power renovations and maintenance are critical.
The two biggest nemeses of electrical equipment and the components within are moisture, condensation, dust, and loose particles. When equipment is installed outdoors or in spaces that offer no type of temperature or humidity control deterioration occurs more rapidly then in spaces where there are controls, just at a slower, more gradual pace. 
Based on the quality, maintenance schedule, and environment of electrical equipment and components that are installed the deterioration rate varies.  When planning for maintenance, upkeep, and refurbishment of electric components and equipment it is important to establish the age and overall condition of each piece. 

Electrical Equipment and Component Insulation

Components within each piece of equipment must be inspected individually.  Insulation is the component of electrical equipment that degrades the quickest.  Paper and solid synthetic insulation is used throughout equipment around motors, capacitors, cables, transformers, circuit breaker trip coils, operating coils of contractors, and reactors.  The breakdown of insulation depends a great deal on the temperatures that it is exposed to.  To increase longevity of equipment and decrease the breakdown of insulation it is important for equipment not to be operated above optimal temperature ratings.

Capacitors in Electrical Equipment

There are various types of capacitors used in both low and medium voltage distribution systems including:

• Surge Capacitors
• Power Factor Correcting Capacitors
• Commutating Capacitors
• Capacitors in Active and Passive Filters
• Pole-Mounted Capacitors

The most common capacitor to use in ratings up to several hundred kVAR is power factor correction.  They are sealed in airtight, insulated units for protection.  The insulating material that is used is a metalized polypropylene film that is compressed in a thermal setting resin.  In the event of internal failure, pressure sensitive interrupters are used to disconnect the capacitor. Capacitors are always fused externally because their failure is most often due to circuit shorts.

There is a nonstop loss of power internally because of lag thus causing the insulating resin to dry.  This often goes unnoticed.  Most capacitors have an average life expectancy of about seventeen years when in continuous operation. This of course decreases depending on the environment in which it operates.  Many systems have a decrease in this average life expectancy due to being exposed to over use and variation in frequency.  To check measurements for capacitors, use clamp-on ammeter to test and detect disparity over time. 

In our next installment we will dive deeper into more electrical components and how they work, their longevity, usage, and testing.  Such components we will inspect will include transformers, circuit breakers, reactors, cables, relays, and more.

J & P Electrical Company is a full-service electrical company that supplies contractors, end users, and supply houses with new surplus, quality reconditioned, and obsolete electrical equipment. We purchase a wide range of electrical equipment such as bus plugs, bud ducts, panel switches, substations, and transformers.  More information can be found at https://www.jpelectricalcompany.com

Sorting Through The Misconceptions of Reconditioned Products

A lot of misconceptions surround products labeled as reconditioned, refurbished, and as-is.  Reconditioned products are products that have been returned to the manufacturer or a third-party company to thoroughly be checked, taken apart, repaired, put back together, tested, and sold.  They are unable to be sold as new without going through the refurbishing process, even if they are in mint condition.  Many electronics, large scaled manufacturing equipment, appliances, and electrical goods are sold in this manner.

Purpose of Factory Reconditioning

There are a number of reasons that product reconditioning exists. One reason, consumers will return items that are defective or may have become damaged.  Sometimes however there is nothing wrong with the item but once it has been purchased and returned, electric items and manufacturing components can’t be sold as new.  Other times equipment and components are becoming obsolete and the only way to have replacement parts for repair is for manufacturers to refurbish components and manufacturing equipment.  This is common in transformers, panel switches, and bus ducts & plugs.

The Reconditioning Process

Each product reconditioning specialist has their own set of standards that refurbished products and components need to go through before being resold.  Some reconditioned products are sold “as new” which means that they have run through a series of checks and balances to ensure all the issues, cosmetic and functional, are fixed. Other companies disassemble, inspect, repair, reassemble, tests, and then and only then is a product fit for resale.  This is often the case in manufacturing and larger scaled equipment like transformers, disconnect, and such.

Advantages with Reconditioning

Obviously, reconditioning comes with cost savings over buying new. Manufacturers can’t charge the new prices for products that are refurbished.  Prices will vary on reconditioned components based on the supplier and of course the product.  As do new products, most refurbished products offer a warranty.  It is important to research the warranty and return policy of any reconditioned/refurbished product you purchase.

Difference between Factory Reconditioning and Third-Party Refurbishment 

Most often when a product is labeled as “factory reconditioned” it means that it has been refurbished by either the manufacturer or a third-party that is certified.  When you purchase a reconditioned part or equipment you should expect that it has been tested and repaired to meet all of the original standards of a new product.

J & P Electrical Company is a full-service electrical company that supplies contractors, end users, and supply houses with new surplus, quality reconditioned, and obsolete electrical equipment. We purchase a wide range of electrical equipment such as bus plugs, bud ducts, panel switches, substations, and transformers.  More information can be found at https://www.jpelectricalcompany.com

Benefits of Installing Refurbished Equipment

In a manufacturing facility there are many different pieces of equipment working in conjunction with one another to ensure the process runs smoothly.  When one of the pieces breaks down and needs to be repaired or replaced time is of the essence in keeping downtime to a minimal.  The goal for most facilities is to repair equipment as purchasing new equipment is timely, availability is often scarce, and it is not always cost effective.  When large scaled manufacturing equipment cannot be repaired, and new equipment is not readily available the next logical step is to consider refurbished equipment.

Why Refurbished May Be Best Option

Refurbished equipment is often considered better than brand new equipment for a number of reasons.  First, older equipment that has gone through the refurbishment process are sure to have the “new equipment” bugs worked out.  Equipment that has been refurbished is beneficial because it often costs less.  The equipment you can purchase refurbished is often of a higher quality than would be purchased new at the same cost.  Lastly, each piece of refurbished electrical equipment goes through a strict testing process.  It is almost guaranteed you will not experience downtime due to equipment failure soon after refurbished components are installed at your facility.

The Refurbishing Process

During the refurbishing process equipment is completely disassembled.  Parts within the piece are inspected and if needed replaced with new or refurbished electrical components to ensure the safety of each piece.  Once the components are all tested and put back together equipment must go through and pass rigorous testing.  The reconditioning process consists of disassembling, testing, cleaning, inspecting, replacing or repairing the piece from the inside out.

Refurbished equipment is readily available.  It is possible to find the same system you have been working with for years refurbished which makes replacement as simple as disconnecting malfunctioning equipment and replacing it with the refurbished unit.  Often when installing new equipment there will need to be some reconfiguration of systems already in place to make room the layout of the new equipment.

Refurbished Parts Are Readily Available

Another major benefit of installing refurbished equipment is the availability of components if something does break down.  New equipment is often harder to access parts for as they are new to the market and manufacturers are not prepared for the need for parts for repair.  Many suppliers of reconditioned equipment also have warehouses of new, obsolete, and refurbished components that are readily available if a repair is needed.  Again, improving downtime due to equipment failure.
There are many myths out there surrounding the purchase and use of refurbished equipment and components in equipment repair.  It is important to do research before purchasing any equipment from suppliers that you are unfamiliar with.  Developing a relationship with a supplier of new, refurbished, & obsolete components and equipment helps prevent downtime in production.  Companies like J and P also offer services including asset recovery, plant clean out, and refurbishing which is beneficial in the removal of equipment should the need arise.

J & P Electrical Company is a full-service electrical company that supplies contractors, end users, and supply houses with new surplus, quality reconditioned, and obsolete electrical equipment. We purchase a wide range of electrical equipment such as bus plugs, bud ducts, panel switches, substations, and transformers.  More information can be found at https://www.jpelectricalcompany.com

How Will We Know if We Should Replace or Recondition Large Scaled Electrical Equipment?

Transformers are used in industrial and manufacturing settings as a way to control the electricity infrastructure within a facility.  They are used to step up and power down different voltages of electricity to equipment throughout.  The longevity of transformers comes down the environment in which they are ran and the amount of usage received.  A typical end of life period for transformers under average usage is somewhere between twenty to forty years.  Factors other than age are often used to consider if a transformer should be replaced.  With this in mind, many facilities are considering refurbishing older transformers that are still showing signs of good health instead of replacement. 
In the following installment we will look at the many reasons that refurbishment of transformers is becoming popular verse replacement.  We will also look at why some transformers can be refurbished and why others shouldn’t be.  There are limitations to refurbishing transformers that we will look into as well.

Why Choose to Refurbish Verse Replace?

 

Refurbishing Transformers Saves Money and Time 

The cost to refurbish a transformer is substantially less than purchasing a brand new one.  Cost is definitely a factor in refurbishing, but it is also important to recognize the time saving.  The time to refurbish a transformer is substantially less than the time it takes to procure a new piece of electrical equipment for your facility, such as a transformer.
Buying new equipment often comes about through a lengthy process that requires approval from a number of sources before it can be completed.  It is also considered a capital expense which many facilities try to budget ahead for.  Refurbishment is often classified as a revenue expense which doesn’t often require approval.  Extending the life of quality assets is good for business and refurbishing can achieve this without risk.

Extended Transformer Life

We are all responsible for doing our part in creating a sustainable environment to leave to generations to come.  The environmental impact of manufacturing and equipment disposal is not something that is taken lightly.  Reconditioning transformers and other large scaled equipment helps to demonstrate environmental sustainability which is not only showing corporate responsibility but also regulatory consciousness.  Prolonging the life of large scaled equipment through reconditioning is just one way to exhibit your company’s commitment to environmental impact as well as to the confidence that the plant will continue to operate efficiently without risk of unexpected failure.

If you do find that you have had to replace a transformer for a reason other than failure, the older transformer can be refurbished and kept as a spare.  In order to determine if a transformer can be refurbished it is necessary to assess the transformer.  The extent of reconditioning needed to make it like new again may be deemed too much.  However, when refurbishment is deemed appropriate, the transformer is brought to a dedicated facility where reconditioning can be performed.

J & P Electrical Company is a full-service electrical company that supplies contractors, end users, and supply houses with new surplus, quality reconditioned, and obsolete electrical equipment. We purchase a wide range of electrical equipment such as bus plugs, bud ducts, panel switches, substations, and transformers.  More information can be found at https://www.jpelectricalcompany.com

Are There Benefits of Purchasing Reconditioned Electrical Parts and Equipment?

Reconditioned electrical components and equipment are a popular option within the industry because of the benefits and tangible environmental, social, economic, and political climate benefits they provide.  Manufacturing, industrial, and organizational facilities are interested in saving money when purchasing and maintaining electrical equipment and parts thus the popularity of reconditioned electrical products.  There are many immeasurable benefits that are attached with refurbished electrical products some of which we will discuss below.

Saving Electrical Jobs

Manufacturing jobs are scarce no matter where in the world you are.  The industry on a whole has seen stagnated growth.  Not only is manufacturing taking a hit but so are the training programs and schools that prepare skilled workers.  Refurbishing is a trend in that is helping to turn those statistics around.  Reconditioning offers on-the-job training which increases the demand for skilled workers. 

Good for the Environment

A major concern we are facing is how our daily lives are affecting the environment and world we are leaving for our children.  This is another benefit that comes with reconditioning.  Industrial plants are a major source of usable electrical equipment and components.  When plants close companies like J & P Electrical are called in to strip usable electrical assets from the location to be refurbished and resold.  This process helps prevent usable electrical products from filling up landfills and converting them into refurbished equipment and components.  Reconditioning electrical components guarantees that they are disassembled, cleaned, plated, updated, tested, inspected, and finally able to be resold.

Increased Safety

Electrical equipment such as circuit breakers and transformers can cost tens of thousands of dollars to replace.  Often what this means is that facilities will continue to use faulty equipment far past the point at which it is safe.  Reconditioned circuit breakers or refurbished transformers are a game changer as they cost significantly less than new.  By using reconditioned parts not only do organizations save money, they significantly reduce downtime.  Manufactures save money while increasing safety by using quality reconditioned electrical components. 
It is important to recognize that reconditioned products are not counterfeit products.  Refurbishment is the process that brings older electrical equipment and components back to a level that often exceeds original manufacturer requirements.  Some components are obsolete, and reconditioning allows equipment that is still useable to run.  Newer components are often not supported by older machines.

J & P Electrical Company is a full-service electrical company that supplies contractors, end users, and supply houses with new surplus, quality reconditioned, and obsolete electrical equipment. We purchase a wide range of electrical equipment such as bus plugs, bud ducts, panel switches, substations, and transformers.  More information can be found at https://www.jpelectricalcompany.com

What Is an Air Breaker and How Do They Work?

Just as molded case circuit breakers, MCCB, air circuit breakers, ACB, is device that is in place to provide protection from an electrical surge or short-circuit.  The main difference is the amps they protect; ACB can withstand higher short circuit currents and mechanical stress because of the arc extinguisher element then MCCB can.  There are a variety of air circuit breakers and switching gears available to purchase.  Air circuit breakers have replaced oil circuit breakers because of their resiliency, performance, ease of installation, and low maintenance level. 

Three Types of Air Break Circuit Breaker

The three main types of air break circuit breakers include: plain break, magnetic blowout, and air chute.  Their main application is for use in maintaining indoor voltage and switch gears.

Plain Break 

The simplest of all air circuit breakers is the plain brake.  Two horns shape the main point of contact.  This creates an arc that extends from the tip of one to the other.

Magnetic Blowout

In higher voltage capacity’s, up to 11KV, magnetic blowout air circuit breakers are used.  The arc extension gets by the magnetic field that is made from the current in blowout coils.

Air Chute

Air chute air break circuit breakers have main contacts of copper and conduit which are in the closed position.  They are most often silver plated and have a low contact resistance.  The arching contacts are created from copper alloy and are resistant to heat and are solid.

Air circuit breakers are most often used for controlling the power station auxiliaries and industrial plants.  They provide protection to electrical machinery such as transformers, capacitors, and generators.  Where ever there is a possibility of fire or explosion, air circuit breakers are most often installed.   They offer a higher resistance to power that allows an increase in the resistance of the arc by splitting, cooling, and lengthening.  The main drawback in air circuit breakers is that the arc chute principle is less efficient under low currents where electromagnetic fields are weak.

J & P Electrical Company is a full-service electrical company that supplies contractors, end users, and supply houses with new surplus, quality reconditioned, and obsolete electrical equipment. We purchase a wide range of electrical equipment such as bus plugs, bud ducts, panel switches, substations, and transformers.  More information can be found at https://www.jpelectricalcompany.com