SPX Waukesha
Transformer Services
     

 

  • condition assessment
  • rigging & hauling
  • installation
  • oil processing
  • FR3 Retrofills
  • painting & encapsulation
  • regasketing

Condition Assessment

Waukesha Service can deliver the peace of mind you need! Waiting for a service outage to occur in order to assess your power equipment is NOT an option. Your customers need reliable electric power and your substation transformers and equipment must be in top condition to deliver. Take the time now for a comprehensive power equipment check-up by contacting your Waukesha Service representative.

Waukesha Service Condition Assessments can help identify the present condition of your transformers and their components, estimate remaining life, make life extension suggestions and help with economic decisions for future repair or replacement actions to improve the performance reliability and extend the life of your assets.

Service recommendations are made based on information gathered from many sources:

External Examinations

  • Transformer Tank
  • Gauges
  • Bushings
  • Arresters
  • Load Tap Changer
  • Control

Transformer ServicesInternal Examinations and Test Results

  • TTR (Transformer Turns Ratio)
  • Doble® Power Factor and Excitation
  • Infrared Scan
  • Megger of Core and Windings
  • Acoustic and Ultrasonic Detection of Partial Discharge
  • Oil Tests for quality, DGA (Dissolved Gas Analysis) and history, furans and LTC DGA

Operational History

  • Maintenance Records
  • Loading History and Overloads
  • Short Circuit History
  • Other Unusual Operational Events

 

Transformer ServicesIf your power transformer is one of thousands of quality units in the Waukesha® family, our analysis will also cover the following:

  • Winding Design (All Windings)
  • Core Design and Construction
  • Core & Coil Condition
  • DETC (De-Energized Tap Changer)
  • Shielding of Frames and Tank
  • Leads
  • Load Tap Changer
  • Bushings
  • Preventative Auto (Reactor)
  • Thermal Analysis

These analyses will be made using the latest state-of-the-art design programs including FEA (Finite Element Analysis) and thermal design programs. Also, any upgrades that can be made will be suggested to allow you to bring your Waukesha® power transformer up to current design standards.

For more detailed information on these assessments or to get a better idea of why transformer assessments can be important to your long-term reliability strategy, download the following brochures (in Adobe Acrobat format):

Substation Transformer Condition Assessment Flyer (210k)
Are Your Spare and Mobile Transformers Ready for Active Duty? Flyer (1.6Mb)

In addition to the assessment, SPX Transformer Solutions has the equipment, experience and capability to complete the repairs and upgrades you may elect to perform as a result of our findings. Services may include transformer dryouts, regasketing or bushing replacements; combining services can minimize costs and transformer downtime.

For more information or assistance during normal business hours, call or e-mail your local Waukesha Sales & Service Representative or complete and submit our Service Project Inquiry form.

 

Transformer Moving or HaulingRigging and Hauling

Waukesha Service possesses the special skills and experience required to move and/or relocate power transformers. Whether it’s a station upgrade, unit relocation due to increased load density and demand, transformer replacement or another need, Waukesha takes total responsibility for getting your valuable equipment from one location to another:

  • Prepare Transformer for Shipment
  • Remove and Transport Oil
  • Disassemble Accessories / Parts
  • Hire and Coordinate a Qualified Rigger and Heavy Hauler to Load and Move your Equipment by Truck, Rail or Barge
  • Unload the Unit onto Foundation
  • Reassemble All Parts Removed for Shipment
  • Vacuum Process and Oil-Fill the Transformer

There are many instances where more than one move is required, such as a second unit or spare—you can be confident that Waukesha Service has the project management skills to coordinate and execute the entire project.

For more detailed information on our haul and install capabilities, download the following brochure (in Adobe Acrobat format):  

Transformer Installations & Relocations Flyer (659k)

For more information on factory shipment of a new Waukesha® transformer, visit the Engineered Shipping section.

In addition to transformer hauling and installations, SPX Transformer Solutions has the equipment, experience and capability to complete other repairs and/or upgrades you may elect to perform while your older transformer is drained of oil such as insulation dryouts, bushing replacements, LTC repairs/upgrades, FR3 retrofill, etc.; combining services can minimize costs and transformer downtime.

For more information or assistance during normal business hours, call or e-mail your local Waukesha Sales & Service Representative, or us directly at the phone number above. You can also complete and submit our Service Project Inquiry form.

 

Installation

You’ve purchased a new transformer, but... there’s SOME ASSEMBLY REQUIRED!

Waukesha Service has installed thousands of transformers and kept them in service delivering the reliable power your customers need.

Waukesha has the capability and equipment to completely assemble your transformers, whether manufactured by SPX Transformer Solutions or other suppliers worldwide. Waukesha Service can also disassemble units that may need to be moved.

We can start with receiving inspection at the rail siding, port of entry, substation site or wherever the unit is located, and then assemble all parts that were removed for shipment to make the transformer operational. If the unit was shipped oil-filled and it is necessary to lower the oil level to install bushings or other parts, Waukesha can get it done.

Waukesha oil tank trucks can be summoned to the site for oil storage or hauling, and we can bring in one of our many oil-processing rigs. Using your specifications, the transformer supplier’s specifications or ours, Waukesha Service can vacuum degasify and prepare new oil for installation, pull vacuum on the transformer and professionally complete the vacuum oil-filling process.

A wide range of tests can also be performed to verify that your transformer is ready for service:

  • Doble® Power Factor Test of Windings
  • Doble® Power Factor Test of Bushings
  • Doble® Surge Arrester Test
  • Core Resistance (Megger)
  • TTR (Transformer Turns Ratio)
  • Winding Insulation Resistance
  • Winding Excitation
  • Winding Resistance
  • CT (Current Transformer) Ratio, Polarity and Saturation
  • Operational Check of Controls
  • Calibration of Gauges
  • Thermal Scans
  • Doble® Sweep Frequency Response Analysis
  • Phase Relation
  • Materials & Oil Testing:
    • Oil General Chemistry
    • DGA (Dissolved Gas Analysis)
    • Furfural Analysis
    • Particle Count
    • Metals-in-Oil Analysis
    • Degree of Polymerization

Your transformer is one of the most expensive and important components in your substation, and you can be confident that the skilled Waukesha Service team will assemble and install it right.

For a brochure on our installation capabilities, download the following Adobe Acrobat file:

Transformer Installations & Relocations Flyer (659k)

Your local rep may involve an experienced Waukesha Service Project Engineer to thoroughly understand the scope of your work before providing a quotation. Waukesha Field Service Managers are also ready to guide our Service Technicians to efficiently and accurately complete the contracted work to your satisfaction within the agreed timeframe.

In addition to transformer installation and assembly, SPX Transformer Solutions has the equipment, experience and capability to complete repairs and/or upgrades you may elect to perform on your older transformers such as insulation dryouts, bushing replacements, LTC repairs/upgrades, FR3 retrofills, etc.; combining services can minimize costs and transformer downtime.

For more information or assistance during normal business hours, call or e-mail your local Waukesha Sales & Service Representative, or us directly at the phone number above. You can also complete and submit our Service Project Inquiry form.

 

Oil Processing

Waukesha Service is ready to respond when your transformer is ready for oil. An experienced team of Field Service Technicians and Service Project Engineers are available with the latest equipment and tools to handle your oil processing needs:

  • Drain Oil from Transformer / Equipment
  • Store Oil On-Site in Tank Trucks (either your trucks or ours)
  • Pull Vacuum on Transformer (to your specifications or ours)
  • Vacuum Degasify and Dehydrate New or Used Oil
  • Reclaim / Improve Physical and Chemical Characteristics (using Fullers Earth Processing, if necessary)

Waukesha has more than a dozen vacuum processing rigs in the USA with characteristics that many other service providers may not have:

  1. State-of-the-Art Equipment and Technology
  2. Totally Self-Contained Rigs
  3. 350 KW Generator with 490 Gallons of Fuel Storage
  4. Air-Conditioned Control Room for Instrumentation and Operators
  5. Oil Processing Capability at Rates Up to 2400 Gal/Hour
  6. Designed to De-Gas Oil to Approximately 1% Total Dissolved Gas — In-Line TDG Analyzer Provides Real-Time Analysis
  7. Designed to Dehumidify Oil to Approximately 1ppm Moisture
  8. Able to Raise Oil Temperature 70 degrees F in One Pass Using 190 KW of Heat NOTE: Oil is typically processed at approximately 140 degrees F, but higher temperatures are possible at customer’s request.
  9. Inlet Oil Filtered at 10 microns
  10. Outlet Oil Filtered at 0.5 microns
  11. High Vacuum Capability with two 171 scfm Vacuum Pumps and a 1449 scfm Booster

For a brochure on our oil processing capabilities, download the following Adobe Acrobat file:

Transformer Dryouts & Oil Processing Flyer (880k)

In addition to oil processing, SPX Transformer Solutions has the equipment, experience and capability to complete other repairs and/or upgrades you may elect to perform while your transformer is drained of oil such as insulation dryouts, bushing replacements, LTC repairs/upgrades, FR3 retrofill, etc.; combining services can minimize costs and transformer downtime.

For more information or assistance during normal business hours, call or e-mail your local Waukesha Sales & Service Representative or complete and submit our Service Project Inquiry form.

 

FR3® Retrofills

Waukesha Electric can provide complete turnkey installation of Envirotemp® FR3® dielectric fluid for almost any substation-size transformer on your system. We can advise on the suitability of a unit for retrofilling, suggest other alterations and repairs you may want us to make at the same time and take care of disposing of your non-PCB oil. With many FR3 fluid retrofills successfully completed, we have the training and expertise to get the job done right!

Envirotemp® FR3® fluid is a biodegradable dielectric coolant made from a formulation which includes food-grade vegetable oils and is proven to add value to new and retrofilled power equipment, possibly SAVING YOU MONEY in several ways:

  • Lower total life cycle costs due to extended insulation paper thermal life by a factor of 5–8 times (verified by Cooper Power Systems using IEEE standard tests).
  • Delayed asset replacement because FR3 fluid-cooled transformers experience a slower aging rate of cellulose insulation compared to mineral oil-filled transformers.
  • Lower personnel and equipment costs due to greater flexibility when selecting installation sites along with simplified fire safety and installation requirements.
  • Lower insurance and liability costs due to greatly reduced risk of fire (dependent on insurance company policies).
  • Lower clean-up costs in the event of a leakage (dependent on geographical regulations and other factors).
  • Slower insulation aging during periods of overload if increased output, rather than longer equipment life, is a primary goal.

In addition to retrofills, SPX Transformer Solutions has the equipment, experience and capability to complete repairs and upgrades you may elect to perform while your transformer is drained of oil such as transformer dryouts, regasketing or bushing replacements; combining services can minimize costs and transformer downtime.

For more information or assistance during normal business hours, call or e-mail your local Waukesha Sales & Service Representative, or us directly at the phone number above. You can also complete and submit our Service Project Inquiry form.

 

Painting and Encapsulation

Waukesha Service can repaint all of your substation equipment including transformers, circuit breakers, switchgear, regulators, control cabinets and housings, structures, etc; our experience includes everything from pad-mounted transformers through 765kV equipment. Maintenance painting can minimize equipment downtime; repainting of radiators at the first signs of wear, for instance, can save you from the higher costs of radiator replacement at a later date.As a full service maintenance supplier, we can incorporate painting into a contract with other repair work, saving you from hiring multiple contractors to accomplish a complete scope of work.

We can comply with your paint specifications or use our own. Paint can be applied by spray, brush or roller on the main tank and by flow coat on radiators. Surfaces are prepared in a number of ways depending on their condition: grinding, sandblasting, needlegun, phosphoric acid wash, degreasers, pressure washing, sodium hydroxide stripping of radiators and special rinse for salt removal. All unpainted surfaces are either taped off or bagged prior to painting.

Waukesha Service understands environmental regulations and knows how to comply. If lead exists in the paint, our crews have the proper protective equipment for working with lead paints. We can collect the wash water in order to do the job in an environmentally-friendly manner; our painting system then encapsulates the lead paint so it doesn't get carried into the ground.

In addition to painting, SPX Transformer Solutions possesses the equipment, experience and capabilities to complete other service work you may elect to perform prior to painting such as fixing leaks, vacuum oil-filling, insulation dryouts, bushing replacements, LTC repairs/upgrades, FR3 retrofill, etc.; combining services can minimize costs and transformer downtime.

For more information or assistance during normal business hours, call or e-mail your local Waukesha Sales & Service Representative or complete and submit our Service Project Inquiry form.

 

Regasketing

Leaking transformers can be a costly problem:

  • Moisture and oxygen can enter a transformer through leaking gaskets causing accelerated aging of insulation and insulation failure.
  • Oil getting onto the ground and possibly into groundwater can be expensive to remedy; leaking oil can carry lead from transformer paint (if paint is lead-based) into the ground causing further contamination.
  • Leaks above the transformer oil can allow the nitrogen blanket to escape, causing more frequent nitrogen bottle replacement if provided with a positive pressure system.

Waukesha Service can help solve your leak problems! We can either fix just the leaking location(s) or completely regasket all transformer openings and reprocess the oil to put equipment back in good condition; the scope of the job is up to the customer.

Transformer RegasketingSteps Involved In Regasketing a Transformer:

  1. Acceptance of Clearance
  2. Ground Transformer
  3. Establish Baselines
  4. Analyze Baseline Data for Problems
  5. Drain Oil
  6. Regasket All Openings on Outside of Tank
  7. Visually Inspect LTC for Problems and Advise
  8. Pressure Test with Dry Air
  9. Perform Vacuum Drop Test
  10. Pull Vacuum/Process Transformer per Customer Specifications
  11. Refill Transformer with Vacuum Degasified Oil
  12. Implement System Checks
  13. Compare System Checks to Baselines
  14. Walk-Through with Customer
  15. Unground Transformer
  16. Issue Final Project Report

For more detailed information on these steps, download the following brochure (in Adobe Acrobat format):

 Regasketing Expertise (510k)

In addition to regasketing, SPX Transformer Solutions has the equipment, experience and capabilities to complete other repairs and/or upgrades you may elect to perform while your transformer is drained of oil such as insulation dryouts, bushing replacements, LTC repairs/upgrades, FR3 retrofill, etc.; combining services can minimize costs and transformer downtime.

For more information or assistance during normal business hours, call or e-mail your local Waukesha Sales & Service Representative or complete and submit our Service Project Inquiry form.

 

 

 

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