Bushing Replacement Tool

Compact Lift Assist Tooling For Generator Transformers 

Maintaining generator transformers in confined nuclear power plant environments demands innovative, efficient solutions. The challenge of safely replacing heavy high-voltage bushings in tight spaces while adhering to strict safety and regulatory requirements calls for a specialized approach. This case highlights a compact, non-electrical lift assist tool designed to streamline operations, improve worker safety, and reduce downtime in these demanding conditions.

The Challenge:

Replacing 100lb high-voltage bushings in the confined space of generator transformers presented significant safety and efficiency challenges. The confined environment required a non-electrical solution to avoid the costly and time-consuming approval process for motors and controls, while ensuring ergonomic safety for maintenance crews working in the restricted nuclear power plant environment.

The Solution:

A compact, lightweight bushing removal tool was designed and fabricated specifically for use in confined spaces. The tool employs a flexible hand drill drive mechanism that is already approved for use in restricted areas, eliminating the need for additional electrical certification. With a manual, mechanical design, the tool is safe for the reactor room environment, quick to deploy, and easy to transport through tight spaces. It features UHMW contact components to protect precision bushings and includes a custom-built simulation enclosure for factory acceptance testing.

The Benefit:

The lift assist tool streamlines maintenance operations, allowing for efficient and safe replacement of high-voltage bushings. By eliminating the need for electrical certification, costly delays are avoided. The ergonomic design minimizes worker strain and reduces radiation dose exposure, enhancing safety and operational efficiency. This solution saves man-hours, accelerates maintenance schedules, and ensures a reliable, cost-effective approach to confined space applications.