The Challenge: Complexity
When Kruger called Precision, the challenge of removing the old transformer and replacing it with a new one was explained in detail. Due to extremely tight confines in their mill, it was decided that the transformers could not be moved through the facility. Instead, a wall would need to be removed to create a clear path for the operation. Because the block wall was load-bearing, it would require extensive engineering to support during removal and rebuilding. This solution required:
- engineering design and approvals
- structural wall removal and reinstatement
- extended timelines and permitting
The team from Precision understood the challenge and summarized the technical and operational constraints as such:
- extremely tight clearances: in some areas as little as two inches
- operating facility environment: with immovable overhead piping
- elevation changes between rooms and corridors
- limited space for maneuvering and rotation of the transformer
The Solution: Alternative Approach
Precision respected the perspective of the mill’s engineers, yet they felt compelled to explore all options for the operation. The team conducted a detailed on-site assessment, including:
- full path walk-through and dimensional verification
- identification of an alternate internal route through the plant
- precise measurement of all pinch points and overhead interferences
Despite initial concerns from the mill’s team, Precision validated that the move could be completed within existing constraints.
Precision’s alternative approach required the following execution strategy:
- navigating the transformer through tight corridors with minimal clearance margins
- managing vertical transitions by:
- carefully staging movement across stepped floor elevations
- lowering the load incrementally to clear overhead obstructions
- working around live piping systems that could not be modified
- engineering a controlled 90-degree rotation within a confined space by:
- utilizing a small “nook” area to reposition the load
- resetting skates to complete the directional change
Once the leadership at the mill was convinced of the alternative approach, the team from Precision executed the entire move—first by removing the old, oil-filled transformer and then by replacing it with a new dry transformer—with precision coordination, controlled handling, and zero disruption to plant systems.
The Outcome: Satisfied Client
The team at Kruger Pulp and Paper was extremely happy with the transformer relocation, especially because Precision’s alternative approach had accomplished the following results:
- eliminated need for structural demolition
- avoided engineering and permitting delays
- reduced project cost from an estimated $250,000 to approximately $20,000
- completed the move safely, efficiently, and ahead of expectations
- enabled rapid turnaround for installation of the replacement unit
According to Shea Linton, Project Construction Manager at the mill, Kruger was impressed with Precision’s professionalism and attitude, highlighting the ease and efficiency of the execution despite complexity.
“This job was executed perfectly,” Linton said. “Safe, ahead of schedule, on budget and with a great level of confidence. You guys have a great group of people there and it would be my pleasure to work with you again in the future.”
Linton also noted that this level of service was rare among contractors and offered to provide a formal letter of recommendation for Precision.