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 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, Waukesha Electric Systems 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.
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.
Steps Involved In Regasketing a Transformer:
- Acceptance of Clearance
- Ground Transformer
- Establish Baselines
- Analyze Baseline Data for Problems
- Drain Oil
- Regasket All Openings on Outside of Tank
- Visually Inspect LTC for Problems and Advise
- Pressure Test with Dry Air
- Perform Vacuum Drop Test
- Pull Vacuum/Process Transformer per Customer Specifications
- Refill Transformer with Vacuum Degasified Oil
- Implement System Checks
- Compare System Checks to Baselines
- Walk-Through with Customer
- Unground Transformer
- 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, Waukesha Electric Systems 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.
Transformer Repairs
Waukesha Service has the information, equipment, suppliers, experienced personnel and know-how to make many transformer repairs on almost any manufacturer's transformer.
Waukesha Electric Systems has designed, manufactured and installed transformers for over 30 years. Evolving through mergers, acquisitions and name changes, we acquired historical information on many brands of transformers besides our own current brand including RTE-ASEA, ASEA Electric, ABB Electric, Magnetek, Federal Pacific, North American, Hevi-Duty and General Signal. These brands, however, do not encompass our full range of capabilities: we can work on almost ANY transformer, performing repairs such as these:
Radiator and Cooler Replacement
Combining engineering expertise with high quality suppliers, Waukesha Service provides replacement radiator and/or cooler packages ready to install. Installation packages can include everything-installation drawings, radiators/coolers, pumps, piping, gaskets and hardware-or any combination of these items. In addition to supplying the parts, Waukesha Service can then field install the equipment for a seamless, hassle-free experience. Specifications and/or drawings need to be supplied by the customer, or a Waukesha Service technician/engineer can make a site visit to acquire any necessary dimensions and/or information.
Bushing Replacement
Waukesha Service works with Waukesha Electric Systems' bushing suppliers to acquire a direct replacement bushing or determine an acceptable replacement for bushings that are obsolete and no longer manufactured; modifications to leads and/or connections to accommodate dimensional differences would be identified and adapter leads and/or connections can be made during installation. Complete installation service can include oil handling, lead modification (if necessary), vacuum fill (if required) and testing. The customer needs to provide information on the bushing requiring replacement, or a Waukesha Service technician/engineer can make a site visit to acquire any needed dimensions and/or equipment information.
Gauge Replacement and Calibration
In addition to replacing existing gauges, Waukesha Service can add gauges to transformers originally supplied without gauges. Scope of work can include supplying new or replacement gauges, mounting gauges on tank, running line for temperature probe, modifying tank to add probe well, wiring from the control box to gauges, calibrating the equipment and verifying operation.
Leak Repair
Oil and nitrogen leaks are a nagging problem found with many power transformers. Due to extreme operating and environmental conditions, leaks do occur at gaskets, fittings, welds and points of physical damage. Most leaks are repairable, and Waukesha Service has the ability to find leaks and make repairs. Some of our resources include experienced personnel; equipment necessary to handle, store oil and vacuum-fill; certified, experienced welders and specialized processes/procedures for all kinds of transformer repairs.
In addition to repairs, Waukesha Electric Systems has the equipment, experience and capabilities to complete other service work you may elect to perform while your transformer is being repaired such as condition assessments, insulation dryouts, bushing replacements, LTC repairs/upgrades, FR3 retrofill, etc.; combining services can minimize costs and transformer downtime.
For more information or to discuss your specific needs, call or e-mail your local Waukesha Sales & Service Representative or 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, Waukesha Electric Systems 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.
Upgrades
Waukesha Service has the information, equipment, suppliers, experienced personnel and know-how to perform upgrades on almost any transformer. Waukesha Electric Systems has designed, manufactured and installed transformers for over 30 years. Evolving through mergers, acquisitions and name changes, we acquired historical information on many brands of transformers besides our own current brand including RTE-ASEA, ASEA Electric, ABB Electric, Magnetek, Federal Pacific, North American, Hevi-Duty and General Signal. These brands, however, do not encompass our full range of capabilities: we can work on almost ANY transformer, upgrading items such as these:
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Thermal Upgrades
Waukesha Service can provide thermal studies and upgrades on most transformers manufactured under the Waukesha Electric Systems' umbrella. A variety of studies can be provided to determine feasibility of the following:
- Increase capacity by adding cooling
- Overload capability by adding cooling
- Loss of life due to overload
- Capacity change due to use of natural ester fluids such as Envirotemp® FR3® dielectric fluid
These studies normally address items that limit performance of the transformer components such as bushings, DETC, LTC, conductor/cable size, cooling, etc. They also help determine the effects of adding radiators, larger radiators, pumps, cooling fans and/or higher speed fans as well as establishing a maximum rating taking into account the added cooling and limiting factors (such as temperature rise), leading to options that could upgrade any limiting factors.
Waukesha Service can provide a complete furnish, install and test package which includes installation instructions/drawings, bill of materials and parts.
Current transformers Additions
Current transformers can be installed internally if there is available space or externally using slip-over CTs; a feasibility study is required to determine if CTs can be installed. Transformers manufactured by Waukesha Electric Systems can be done simply by giving us the transformer serial number. Transformers from other manufacturers require drawing submittals from the customer and/or a site visit. The site visit may require an internal inspection of the transformer to determine available space, dimensions and material requirements. Waukesha Service can provide a complete furnish, install and test package which may include installation/wiring drawings, CTs, mounting kits, conduit, wiring, terminal blocks and other miscellaneous items.
Control Upgrades
Waukesha Service combines experienced engineering, quality suppliers and highly skilled field technicians/engineers to provide many types of control upgrades. A control upgrade could be a single component, a completely new control box or anything in between including a complete furnish, install and test package. Upgradeable control components include LTC controls, fan/cooling controls, auxiliary and seal-in relays, gauges and protective devices.
Condition Monitoring Equipment/Systems Installation
Waukesha Service works with the monitoring equipment supplier to provide a package that meets your needs. Recently, we successfully completed projects using Dynamic Ratings and Qualitrol monitoring equipment. Other devices such as water and gas monitors, LTC position indicators, gauges and RTD can be included in the package. The customer needs to provide control drawings/schematics to incorporate the monitoring equipment into the existing equipment.
In addition to upgrades, Waukesha Electric Systems possesses the equipment, experience and capabilities to complete other service work you may elect to perform while your transformer is being upgraded such as condition assessments, 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. You can also complete and submit our Service Project Inquiry form.
