(Case Study)
Introduction
When engineering, operations, and field execution work in perfect harmony, extraordinary results can be achieved. This is the account of the fabrication, transportation, and installation of the largest transformer ever produced by a multinational company in Brazil, designed to serve the United States power system.
The Project
With a capacity of 868 MVA and a voltage rating of 500 kV, the transformer was manufactured in Brazil, measuring 14.123 m in length, 4.806 m in width, and 5.276 m in height. After fabrication, it was shipped to Louisiana (USA), where it currently supplies electricity to over 500,000 households per year, contributing to the reliability of the local power system.
Transportation Challenge
Moving such a massive piece of equipment required meticulous logistical planning, combining specialized trailers and road transport under technical coordination. A record for special cargo transport on a Brazilian road segment was established, highlighting the unprecedented and challenging nature of the project.
Project Challenges
The execution demanded:
Specialized design and manufacturing, adhering to strict international standards;
Quality control at every stage of production;
Integration of engineering, production, testing, logistics, and quality teams;
Risk management to ensure the integrity and functionality of the equipment until final delivery.
Participation and Responsibility
As production coordinator, I closely monitored the transformer’s preparation for factory testing, ensuring that all quality, performance, and safety criteria were met.
Field Assembly and Commissioning
During the field phase, I accompanied the assembly and commissioning, supporting multidisciplinary teams to safely install and energize the transformer. Efficient communication and collaborative work were decisive to achieve reliable operation.
Impact
This project demonstrated the power of teamwork and global cooperation. Engineering, testing, logistics, assembly, project management, safety, and quality functions worked together to overcome technical challenges and deliver a robust, reliable product.
Final Message
This record-breaking transformer represents what can be achieved when technology, commitment, and international collaboration come together around a common purpose. It is a historic milestone, and I had the privilege of being part of it.
About the Author
https://www.linkedin.com/in/thiago-ferreira-5642bb1b5
Thiago Ferreira has over 18 years of experience in the same global organization. He has worked as production leader, production coordinator, contract manager, and currently works in quality in the USA, contributing to process excellence at one of the largest multinational energy companies. He holds an MBA and is a member of the IEEE Power & Energy Society