In a detailed technical demonstration, Jim Dukart of T&D How Videos documents a field operation conducted by Kansas City Power & Light, showcasing a complete overhead transformer change-out on a distribution line. The video walks viewers through the real-world steps taken by journeymen and apprentice linemen during this essential utility maintenance procedure.
The process involves replacing an older cylindrical overhead transformer with a new unit on a freshly installed distribution pole. The operation is carried out high above the streets of St. Joseph, Missouri, using manual and mechanical rigging techniques.
Key Elements and Steps in the Change-Out
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Climbing and Setup:
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A journeyman lineman climbs the new pole, equipped with a helmet-mounted GoPro, offering a first-person view of the work.
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The old transformer remains mounted on the adjacent, older pole as the new installation begins.
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Hoisting the New Transformer:
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Using a “pole gin” and a three-rope assembly, linemen on the ground carefully raise the new transformer to the top of the new pole.
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The journeyman manually guides the transformer into position and secures it using metal brackets.
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Electrical Connections:
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With the transformer mounted, connections are made to two “hot legs” and one neutral wire.
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A tool known as a “shotgun” stick (a type of insulated hot stick) is used to safely connect and secure energized lines while maintaining proper clearances and insulation from live current.
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Removing the Old Transformer:
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The team then removes the old transformer using the same gin and rope system, carefully lowering the heavy unit — estimated between 300 and 500 pounds — to the ground.
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Apprentices on the ground transport the retired equipment for disposal or refurbishment.
Throughout the video, the emphasis on safe rigging, proper handling, and communication is apparent. Terms like “go easy” from above and deliberate, coordinated motions reflect standard practices in utility line work, where precision and safety are paramount due to the high-voltage environment and heavy equipment involved.
