Transformer Radiator Fin Defect

Potentially a really bad idea. It looks like a front-end loader really hit that row very hard. What you can't see is the internal damage that may have taken place, I don't know if the inside of the tank and/or fins has any protective coating, bit if there is then any flakes of paint or dislodged pieces of welding slag from the manufacturing process could have been loosened and may find their way into the windings with disastrous consequences. We also don't know if the transformer was on its pad or in transit when it was hit, therefore there's a strong possibility of internal damage to the core and/or windings due to the mechanical shock. Some of that damage may only be found after a rigorous internal inspection. Call me super cautious but I would never sign off on energizing it until it were cleared by a competent third party.

<...urgently need to commission our Plant as schedule...>

If it goes BANG, will it affect the schedule?

Let the top management take the decision, you will be on the side of caution, waiting for the replacement fin section to be fitted. I've been in large plants where the cost and production is the main or only consideration. In your country in fact at CIMA cement, a large fan breakdown shut the line with huge losses in production and some customers went to other suppliers. It may delay commissioning of lots of other systems if power is not available, the management will be aware of all this, start-up dates, penalties, cost.

I doubt if this transformer has been designed to run immediately at full load so there should be a margin to allow for the lack of cooling. You would need to check the design calculations and original specifications.

Ask some mechanical engineer to check for fractures in the dents, if it's only bent but still mechanically sound then personally I'd go for it, with the management aware of the risk when the pressure builds up, ( I'm assuming it's a sealed transformer with a gas pocket at the top). Ask the mechanicals about some of the super strong epoxy metal materials they have these days, I've got some that's good to 300 C, oil and watertight, and cover the seriously bent bits.

Spell out the risks to the management bosses, what's the worst case scenario? If it doesn't leak then it could overheat and trip upstream, let them contemplate a sudden shut down. Have they any stand-by power?

Find out when the remedial action is likely, from insurers, carriers, manufacturers, and let the management know when the future shut down will be needed.

Another point...does the fin section have valves so that it can be isolated. If it does you could valve this section off and run it. In Saudi, really hot , hotter than Malaysia, ABB transformers were uprated by 40% with a set of fans at the bottom of the fins, so you consider some temporary fans.

Lastly, I can't believe that you have a single transformer feeder, rather than redundant two in parallel, who designed it? You may be able to run with one feeder, with this damaged transformer out of service.

Whoever broke it should buy you a new one.

Replace the damaged fins before energising the transformer. Sudden, undetected leaks could result in catastrophic damage.

Engineers vary in their attitude to a calculated risk, I never killed anyone or caused a serious accident in 50 years construction & commissioning. At the same time I reckon I've saved millions of dollars by getting things moving when others were throwing their hands up or looking the other way.

There's an old management ditty "the only guys who never made mistakes are those who never did anything". Taking a calculated risk takes knowledge and experience, so probably the fact that you are asking what to do means you had better take the safe way and wait for the repair.

IF NOT LEAKING ALREADY- will not leak after energizing.

If you consider "Overdesign" by the original designer-- you will never need to replace the bashed radiator.

Take a deep breath and switch on and watch for a few hours .

Dear Mr.Yasser,

From the photo it appears DAMAGE DURING TRANSIT.

My suggestion, Pl. do not take risk, get it repaired and use. Once energised, any leakage(likely) will interrupt your working - leading to difficulties and losses. Prevention is better than cure.

By the way - what is the caapacity of the Transformer.?

DHAYANANDHAN.S

PLEASE tell us the History

5 years we waited!