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Transport of Large Transformers

Transport of Large Transformers

Transport of Large Transformers

(OP)
Transport of heavy transformers from factory to site is a major activity where transformer engineers will have many stories to share.Let me share my part of the experience.

I have seen a photo( at a US history gallery) of a 2.5 MVA  transformer being pulled by 12-16 horses in a wooden cart with wooden wheels on its way to Electra Power station,,California during 1900-02. About the same period, for the first hydro power station in south India (  Mysore State)equipment were brought from Europe ( must be England) to Madras port( now Chennai)and handled by elephants.I have seen photo of the generator package being  hauled by an elephant.Transformer also must have been carried by an elephant by its trunk!Even today elephants are used in parts of India, instead of  fork lift,  for hauling logs  in forests.A good elephant will cost more than a small truck.

Up to 1990, in India, transformers were transported exclusively over rail in well wagons( 50,90,130 Tonnes carrying capacity)This was because of the poor road infrastructure in the country and also there was no incentive for other means of transporting as  the rail freight charges were on a telescopic  rate.Rate/km was coming down  with distance so that difference for  freight charges for 1000 kms and 2000kms was not appreciable.Since the opening up of economy in 1991, the transformer transport is entirely over road using hydraulic trailers.

In early 1970's when India went for 200 MW thermal sets, self had to design the first 250 MVA GSUs for such stations.Transport weight of heaviest package was more than  170 Tonnes and Indian Railway had no suitable wagon.The only 180 tonne rail wagon available at that time was with a utility in Eastern India and we used that bottom less well wagon( transformer will hang on the side beams during transport) for transport.The utility got that  wagon in early 1960's and it remained unused for a decade.Utility had ordered a large transformmer on a US manufacturer and the designer never checked how it would  be transported from Calcutta( Kolkatta) port to site.The transport weight was more than 130 tonnes and there was no rail wagon available.Finally transformer manufacturer had to order a 180 tonne railwagon from Italy to transport the transformer from port to site.Since the wagon was designed exclusively for Indian rail gauge, transformer manufacturer had to leave the wagon with the utility. This wagon was rented out continuously for nearly two decades for transporting heavy transformers and generator rotors !!

RE: Transport of Large Transformers

prc-

Good story!  You might want to google "Schnabel Car" as another approach to moving transformers by rail.  In effect the transformer structure becomes part of the car.  Naturally, the transformer has to be designed with this mode of transportation in mind, but it give yet another avenue for large loads.

 

old field guy

RE: Transport of Large Transformers

(OP)
Schanabel cars were first made  in Germany during 1920's.In this car, transformer is suspended between the two ends of the cars,thereby the load it self makes up part of the car.Maximum carrying carrying capacity of Schanabel is 500 Tonnes, eventhough one of the ABB owned Schanabel carried  678 tonnes load in Canada, a record for rail transport.Maximum weight of transformer ever transported is around 500 Tonnes, but in  many countries max transport weight is  only up to 375 Tonnes ( China ,India) with max consignment height of 5 metres.Advantages of Schanabel cars-Maximum height of transformer can be increased as the bottom of tank will be only 60-70mm  above rail, more permissible width(4.4 Metre).These are used  in North America, Europe, Japan and Australia.

In special  situations large transformers were transported by air using Ukraine owned Antonov An-225 which can carry maximu pay load of 250 tonnes.VA Tech transported a 220 MVA GSU from Austria to US in 2003.

RE: Transport of Large Transformers

I remember a long time ago when I worked at another utility, we had a gsu transformer shipped from Schmitt transformers (Netherlands) to the US by sea of course. If memory serves me right, it came up the Mississipi river to Ohio river to the power plant on the banks of the Ohio.  I guess that is pretty routine. I had some pictures but can't find those.

Two weeks ago, we had a large motor return from repair to our site.  How large: It is 3500hp 324rpm, which is torque equivalent of roughly 35,000hp 2-pole motor.... weighs 50,000 poundes.

Attached is a picture of what it looked like when it arrived. You didn't need an eagle eye to tell something was wrong as the truck pulled up in the distance. The timbers below the motor either crumbled or fell out on a bump during the trip, allowing the whole motor to fall.  It would have continued falling except luckily the  coupling landed on a frame at the very bottom of the truck, preventing the whole thing from falling off the truck. Driver tightened the chains and kept on going another 30 miles to the plant (by the way the shipping company and shop usually do top-notch work). How'd you like to see this barreling down the opposite lane of the highway at you at 55 miles per hour?
 

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(2B)+(2B)'  ?

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