4 Batches of VPI Dry-Type Transformers for Industrial Power Upgrades in Houston, Texas, USA

Project Snapshot

To support a customer’s plant upgrades and expansion in Houston, Texas, Winley Electric supplied custom VPI dry-type transformers designed to extend 480Y/277V power distribution from the facility’s existing 6.9kV and 4.16kV medium-voltage supplies as new production and auxiliary loads came online.

Engineered to fit diverse site requirements, the units featured:

• Base capacities ranging from 1500kVA to 2500kVA, with active fan-cooling upgrades integrated where peak loads demanded higher output.

• Rugged NEMA 3R weather-protective enclosures built for reliable outdoor performance.

• Custom cable and bus duct interfaces engineered for seamless integration with existing low-voltage distribution gear.

Built in strict compliance with ANSI/IEEE C57.12.01 and DOE 2016 energy-efficiency standards, these transformers deliver the robust performance, safety ratings, and low operational losses required by industrial facilities across North America.

Spanning four separate orders—three of which came from the same repeat customer as facility expansion progressed—every order was fully engineered, manufactured, individually tested, and delivered within a strict 45-day window.

1. Project Background

The customers were working to tight construction schedules for plant upgrades and expansion in Houston, Texas. New production lines, pumps and ventilation systems needed 480V power, and transformer delivery had to keep pace with equipment installation and planned start-up dates.

Each installation required a custom design to match the existing medium-voltage supply, connected loads, available space and site connections. The customers required delivery within 45 days of design approval, leaving a demanding manufacturing and testing schedule. Winley needed to deliver the specified configurations on time, with dimensions and interfaces confirmed early enough for site preparation.

2. Custom Engineering

Customer Challenges

The facility teams needed reliable transformers to tap into existing medium-voltage systems for new equipment. Every installation site presented unique load capacities, physical space limits, and distinct connection layouts, with some units requiring built-in headroom for future capacity growth. Additionally, the equipment had to withstand outdoor environments while remaining easy to inspect and maintain.

Winley Solution

• Tailored Electrical Specs: Voltage, base capacity, and cooling were configured for each site, including fan-cooled ratings to handle peak loads.
• Proactive Site Planning: Detailed drawings mapped out dimensions and terminal positions early, letting site teams prepare foundations and cabling before delivery.
• Outdoor Durability & Easy Access: Robust weather-protective enclosures, integrated temperature monitoring, and accessible service panels supported hassle-free daily maintenance.

3. Manufacturing

Backed by our 45,000m² of manufacturing facilities, Winley synchronized production workflows across core processing, winding, insulation treatment, and enclosure fabrication to keep all four custom orders firmly on a 45-day delivery schedule.

3.1 Winding Production

Experienced operators wound the copper or aluminum coils using dedicated winding forms, controlling conductor placement, winding tension, and interlayer insulation throughout the process. The coils were then pressed, shaped, and checked for dimensions and lead positions.

These steps helped maintain a compact winding structure and consistent insulation, while ensuring the coils fitted the core assembly and planned connections.

3.2 Insulation Treatment

The insulation process combined vacuum drying, vacuum pressure impregnation (VPI), and oven curing. Drying removed moisture before impregnation, while vacuum and pressure helped resin penetrate the windings. Subsequent curing bonded the winding components, improving mechanical strength and insulation performance.

3.3 Enclosure Fabrication

Enclosures were precision-built to exact spatial dimensions, integrating custom ventilation louvers, access panels, and specialized cable or bus duct interfaces. Through expert metal fabrication, welding, surface preparation, and corrosion-resistant painting, we delivered robust NEMA 3R outdoor enclosures.

3.4 Core Assembly & Final Inspection

The silicon-steel core was assembled with the finished coils, paying strict attention to lamination alignment, coil positioning, and secure mechanical clamping. Heavy-duty insulating supports and structural clamps locked the core-and-coil assembly firmly in place to maintain a rigid, stable structure capable of withstanding transport and operational stresses.

4. Factory Testing

Testing for these units covered winding and insulation resistance, voltage ratio, vector group, losses, impedance, and dielectric withstand, with individual test reports traceable to each unit's serial number.

The four 2000kVA transformers demonstrated closely grouped loss and impedance results, offering a practical record of high manufacturing consistency across separate production runs.

These reports provide clients with verifiable performance data for technical review and equipment acceptance. Winley also accommodates customer-witnessed Factory Acceptance Testing (FAT) and third-party inspections upon request.

5. Packing & Shipment

Following successful factory testing, we managed all export packaging, container loading, and logistics coordination. Protective measures were applied to all enclosures, terminal blocks, and sensitive accessories to safeguard the equipment against transit hazards, with each transformer securely anchored for the journey.

6. Why Winley Electric for Your Industrial Power Projects

North American Standards Compliance

Built in strict accordance with ANSI/IEEE C57.12.01 and DOE 2016 energy-efficiency mandates, these transformers meet the rigorous performance, safety, and regulatory benchmarks expected across North American industrial installations.

Project-Specific Customization

Backed by a 35-person R&D engineering team, Winley tailors every unit to exact medium-voltage supplies, load characteristics, and interface constraints. Comprehensive electrical design, cooling strategies, enclosure styles, and terminal layouts are fully coordinated via detailed engineering drawings prior to production.

Fast Delivery & Batch Production

By efficiently managing diverse configurations across four separate orders, Winley maintained a strict 45-day turnaround from design sign-off to export packing. Three consecutive repeat orders from the same industrial client highlight our proven capability to support phased plant expansions while honoring tight project delivery schedules.

Partner with Winley Electric for your next industrial power project.
Send RFQ: steven@winley-electric.com

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