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RR-MANUFACTURING (PROCESS)
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It is our standard practice to incorporate the following procedures (any specific Customer requirements will be adhered to as well) druing Remanufacturing of power transformers:
 
CORE : The core is removed from the structure to completely re-insulate it from the structure. The complete core is re-built “lamination-by-lamination” after cleaning and visual checking of each lamination. Damaged laminations/stacks get replaced by new ones.
 
TANK : The tank is pressure tested to ensure integrity and any areas of concerns are either machined (in the case of gasket surfaces) or welded to ensure leak proof performance.
 
COILS : The coils are made NEW using NEW Copper. The existing windings are totally scrapped. All coils are balanced to minimize short circuit forces. A computer short circuit analysis of the new design is made to determine short circuit forces and stresses the coils will receive. The program analyzes the windings in their rated position and all extreme taps. The axial and radial forces are computed for all winding segments along with the total force transmitted to the upper and lower clamps. The latter allows our mechanical designers to analyze the clamping structure components. Accordingly, if required, steel clamping structure, tie rods, and jack bolts are modified to meet the short circuit forces. High density insulation material is used for coil forms, spacers, etc. All coils with thermally upgraded paper insulation are wound utilizing latest techniques.
 
GASKETING : If require new gaskets are installed to seal tank, all accessories, bushings, and other devices attached to the transformer both oil to oil and oil to air. The interior of the tank, the radiators, and the core structure will be flushed and cleaned.
 
INSULATION : The original insulating material used between the core and the tank will be replaced with new insulation.
 
DEHYDRATION : After rewinding and assembly of the re-built core and coils, the entire unit will be dried in our State of the Art "Vapor Phase Drying" (VPD) Oven. This insures that the final product will maintain a power factor of less than 0.5%. After the transformer has been placed back into the tank a secondary dry-out will occur, that involves vacuum and hot oil treatment prior to testing.