The Customer
Arkansas Electric Cooperative Corp. (AECC), based in Little Rock, is one of the top generation and transmission cooperatives in the nation. It provides wholesale electricity to the state's 17 electric distribution cooperatives.
The Situation
AECC contracted with Waukesha Electric Systems to produce custom-engineered electric transformers. An essential part of the transformer manufacturing process is the testing phase in which a series of dielectric tests — tests that determine the capability of insulating materials to withstand breakdown — are conducted to ensure the equipment meets industry standards, as well as customer specifications.
For regulatory or any of a number of other reasons, customers such as AECC often need to be at the manufacturing site to witness these tests in person.
The Challenge
Rising fuel prices, fluctuating schedules and other issues make it increasingly difficult for customers to travel to production facilities to view the testing of their products.
Solution
Waukesha Electric Systems developed a process, dubbed “Windows into Waukeshaw,” that offers its customers the “next thing to being there” when it comes to witnessing dielectric tests.
By means of a live webcast, the company enables its customers to remotely view the tests being peformed on their transformers from any location where they have access to a computer and the Internet.
Waukesha Electric Systems piloted the program using AECC representatives and one of Waukesha’s channel partners as test participants.
The Details
Four webcams were strategically located through the Goldsboro plant. With 22X zoom power and a 350-degree range, the cameras can zoom in on nameplates, coils and other components of the transformers being produced and show the most minute details with exceptional clarity.
Webcast participants received an e-mail providing them with password-protected log-in information and a web link they could click on to go to the live webcast at a predetermined time.
At the start of the session, the participants dialed in by phone. Waukesha Electric Systems representatives hosted the web cast, talking through the testing process while participants watched on their computer screens as the test technician, in real time, conducted various tests.
The participants observed the technician resetting leads on the transformer as required for the tests, viewed the actual digitizer traces during impulse tests and literally watched over the technician’s shoulder as he conducted the hi-pot (high potential or high voltage) test to ensure the safety and quality of the transformer’s electrical circuits.
Participants could ask questions and comment on the testing procedures.
During lull periods, such as in between the tests, the Waukesha Electric Systems “web hosts” presented a virtual tour of the Goldsboro plant. The AECC customers were able to view the areas where operators wind the transformer coils, where core cutting and stacking take place, as well as see the vapor phase chambers (where liquid-filled and vaporization-cooled transformers are tested) and the final assembly area.
Outcomes/Results
The customers from AECC not only observed the various dielectric tests. When a test issue arose, they were able to watch firsthand as investigative work was undertaken by Waukesha employees to correct the situation.
Feedback from the AECC customers has been overwhelming positive. Waukesha Electric Systems is continuing to gather customer feedback and fine-tune the process. Once “Windows into Waukesha” has been thoroughly tested and documented at the Goldsboro facility, it will be rolled out at the company’s manufacturing facility in Wisconsin to bring even more customers the benefits of remote test viewing.
Learn More
Waukesha Electric Systems has long been recognized as a leading manufacturer of medium and large-power transformers, transformer accessories, engineered substations, transmission lines and complete substation service solutions for the transmission and distribution of electric power.
Find out more about how Waukesha Electric Systems is transforming the way it does business to better meet customer needs at www.waukeshaelectric.com