Multi-Site Transformer Relocation in Colorado

Location

Colorado

Timeframe

September 2025

Scope of Work

Turnkey relocation of two large power transformers, including disassembly, rigging and transport, reassembly, and commissioning.

Services

Electrical testing (turn-turn ratio (TTR), winding resistance, sweep frequency response analysis (SFRA), etc.), installation of impact recorders, hot oil vacuum fill, and logistics coordination.

Customer Challenge

A major power plant expansion required relocating two oversized transformers from separate sites. Each unit weighed 374,000 lbs and contained more than 27,000 gallons of oil, making transport highly complex. The size and scale of the transformers made this project incredibly niche, requiring a transport entourage including three bucket trucks, two Colorado State Troopers, and three support vehicles for safe travel.

The IPS Solution

IPS deployed a team of high voltage transformer specialists from the Denver Kingston Service Center to execute the project end to end:

• Pretesting: Performed testing to establish baselines including turn-turn ratio (TTR), insulation resistance (megger), winding resistance, and doble power factor/excitation.
• Disassembly & Rigging: Safely disassembled and prepared both transformers for super load transport.
• Transport Coordination: Coordinated all pre- and post-transport preparations to ensure units could be moved safely.
• Oil Handling: Extracted and properly stored 27,525 gallons of oil per transformer; completed hot oil vacuum fill after relocation.
• Testing & Verification: Evaluated the condition of the transformers before and after the move by performing TTR, winding resistance, doble power factor/excitation, doble SFRA and insulation resistance testing. Tested gages, alarms, and current transformers. Drew samples for comprehensive oil and dissolved gas in oil (DGA).
• Reassembly & Recommissioning: Ensured both units were in service-ready condition at the new site.

Results

• Relocation completed on time and without incident, minimizing downtime.
• Successfully consolidated equipment from 2 remote locations.

With two 230 kV transformer rewind facilities and a national field services network, IPS brings unmatched capability for high voltage transformer projects. Our Denver team specializes in complex relocations, turnkey transformer solutions, and innovative approaches such as mobile transformer weight reduction programs. This depth of experience made IPS the ideal partner to deliver this project safely and on schedule.

About Integrated Power Services (IPS)

Headquartered in Greenville, South Carolina, Integrated Power Services (IPS) operates one of the leading independent aftermarket service networks focused on the critical repair, field service, and replacement solutions for all the mission-critical equipment that both delivers and consumes power within our customers’ facilities throughout North America, the United Kingdom, and the Caribbean. Each of IPS' over 115 locations is equipped to respond, rethink, and resolve complex power management and electromechanical reliability challenges, offering access to an extensive highly skilled talent pool and engineering resources for seamless, single-source solutions.