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Transformer Factory Repair Services

Typical transformer factory repair services are essential for ensuring the reliability, efficiency, and longevity of transformers and associated high-tension (HT) electrical equipment. These services include a comprehensive range of maintenance, refurbishment, and upgrading activities tailored to address various issues that transformers may encounter over their operational lifespan. Here's a more detailed breakdown of these services:
1. Winding Re-winding
  • Purpose: Re-winding involves replacing or repairing the copper or aluminum windings within the transformer, which may degrade due to electrical stress, overheating, or age.
  • Process: The damaged or aged windings are carefully removed, and new windings are installed with precision to restore the transformer's capacity to handle its rated load and voltage.

2. Core Replacement

  • Purpose: The transformer's core, made of laminated steel, may suffer from insulation breakdown, short circuits, or saturation issues, leading to efficiency loss or overheating.
  • Process: The existing core is dismantled and replaced with a new core, often with enhanced materials or design, to improve the magnetic performance and reduce energy losses.

3. Transformer Up-rating

  • Purpose: Up-rating is performed to increase the transformer's capacity beyond its original design, enabling it to handle higher loads and meet growing power demands.
  • Process: This may involve upgrading windings, insulation, cooling systems, and other components to safely accommodate higher voltages or currents.

4. Reconditioning of HT Switchgears

  • Purpose: High-tension switchgears, which control and protect electrical circuits, may deteriorate over time due to mechanical wear, corrosion, or electrical faults.
  • Process: Reconditioning involves cleaning, repairing, or replacing worn-out parts, re-lubricating moving components, and testing the switchgear to ensure it functions like new.

5. Testing of Transformer and HT Switchgear

  • Purpose: Regular testing is crucial to detect potential issues before they lead to failure, ensuring the safe and reliable operation of transformers and switchgear.
  • Process: Tests may include insulation resistance tests, dielectric tests, thermal imaging, partial discharge analysis, and load testing to assess the health of the equipment.

6. Tank Replacement

  • Purpose: The transformer tank, which houses the core and windings, can suffer from corrosion, leaks, or physical damage over time, compromising the transformer's safety and performance.
  • Process: The damaged tank is removed and replaced with a new, corrosion-resistant tank, designed to protect the internal components and maintain the required cooling and insulation.

7. Tap-changer Overhaul & Replacement

  • Purpose: Tap-changers adjust the transformer’s output voltage to compensate for variations in load or supply voltage. Over time, they may experience wear, carbonization, or contact issues.
  • Process: The tap-changer is thoroughly inspected, cleaned, and serviced. Worn contacts are replaced, and in cases of severe wear or outdated design, the entire tap-changer may be replaced with a modern equivalent.

8. Resin Cast Coils

  • Purpose: Resin cast coils are used in transformers to provide superior insulation, especially in environments with high humidity or contamination.
  • Process: The process involves casting the transformer coils in resin, which solidifies into a durable, protective layer, enhancing the coil's resistance to moisture, dust, and chemical exposure.

9. Reconditioning of Unitized Substations

  • Purpose: Unitized substations, which integrate transformers, switchgear, and control equipment, may require reconditioning to maintain their functionality and safety.
  • Process: Reconditioning may include cleaning, repairing, or replacing internal components, upgrading safety features, and ensuring all parts operate harmoniously.

10. Replacement of HT Panel Enclosures & Spares

  • Purpose: HT panel enclosures protect switchgear and control equipment from environmental factors and mechanical damage. Over time, they may corrode, suffer physical damage, or become outdated.
  • Process: The replacement process involves fitting new enclosures designed to current standards, along with replacing any worn or obsolete spares, to ensure the panels continue to operate safely and efficiently.

These transformer factory repair services are vital for maintaining the operational integrity of electrical infrastructure. By addressing wear and tear, upgrading outdated components, and ensuring that all systems are functioning optimally, these services help prevent costly breakdowns, improve energy efficiency, and extend the lifespan of transformers and related equipment.