Structured, scheduled maintenance programmes that keep critical transformers inspected, tested, and documented — reducing the risk of unplanned failure and extending operational life.

✓  Scheduled site visits  1, 2, or 4 per year to requirement

✓  Oil sampling and BDV testing

✓  Insulation resistance (IR) and winding resistance measurement

✓  Thermographic inspection  thermal imaging for hot-spot detection

✓  Silica gel breather inspection and replacement

✓  Buchholz relay, pressure relief, and gauge checks

✓  Maintenance history log maintained per unit

✓  Priority emergency response for AMC contract holders

Transformer oil degrades over time through moisture absorption, oxidation, and particle contamination. Our mobile oil filtration service restores dielectric strength on-site — without removing the transformer from service.

✓  Hot oil circulation filtration  removes moisture and particles

✓  Vacuum oil filtration  moisture extraction under vacuum

✓  BDV improvement  raising breakdown voltage to target specification

✓  Oil moisture content measurement before and after treatment

✓  Oil acidity and dissolved gas analysis (DGA) sampling

✓  Top-up with treated, tested oil to correct level

✓  Treatment report issued with before/after BDV readings

Factory-trained engineers deployed to site for fault diagnosis, repair, and restoration of transformers of any make and any capacity — with fast response and comprehensive on-site capability.

✓  Fault diagnosis and root cause analysis

✓  Bushing replacement  LV and HV, all types

✓  Gasket replacement and oil leak repair

✓  Tap changer inspection, adjustment, and repair

✓  On-site winding repair where structurally feasible

✓  Oil filtration and top-up as part of repair scope

✓  Post-repair testing  IR, BDV, ratio, and polarity checks

✓  Commissioning support after repair completion

When a transformer’s performance degrades below acceptable levels, full reconditioning restores it to near-original specification — extending operational life significantly at a fraction of new unit replacement cost.

✓  Full disassembly, inspection, and condition assessment

✓  Core inspection  lamination integrity and joint condition

✓  Winding assessment  resistance, IR, and turns ratio measurement

✓  Rewinding where conductor or insulation is beyond repair

✓  Insulation refurbishment  paper and pressboard replacement

✓  Tank and radiator rehabilitation  cleaning, repainting, leak repair

✓  Vapour Phase Drying (VPD) after rewinding

✓  Vacuum oil filling with fresh, tested transformer oil

✓  Complete retesting to original specification parameters

✓  Reconditioned unit report with before/after performance data

Independent testing and commissioning services for transformers of all makes — verifying performance before energisation, after repair, and as part of regular condition monitoring programmes.

✓  Pre-commissioning testing  new units before first energisation

✓  Post-repair acceptance testing after service or repair

✓  Routine condition-based testing  IR, BDV, winding resistance

✓  Voltage ratio and polarity verification

✓  On-load tap changer (OLTC) performance testing

✓  Dissolved gas analysis (DGA)  incipient fault detection

✓  Partial discharge (PD) measurement  available on request

✓  Compliance testing  BIS, IEC, and ANSI standards as required

✓  Third-party witnessed testing  certified inspector attendance

✓  Test report issued with all measurements and pass/fail status

Critical spare parts for KLR-manufactured transformers and compatible replacements for other makes — reducing lead times for planned maintenance and emergency repair.

✓  HV and LV bushings  porcelain and oil-filled types

✓  Tap changers  OLTC and OCTC types, major brands

✓  Buchholz relays and pressure relief devices

✓  Winding temperature indicators (WTI) and oil temperature indicators (OTI)

✓  Conservator tanks and drain valves

✓  Radiators and cooling fans

✓  Gaskets and sealing sets  all flange sizes

✓  Transformer oil  new and reclaimed, tested stock

✓  Silica gel breathers and oil level indicators

✓  Available for KLR units and third-party makes on enquiry