Gasket Repair: Transformer Flange, New Zealand

13th January 2025

Industry: Power
Location: New Zealand
Application: Gasket Repair
Products: 209 EIP PU

The Challenge

A substation in New Zealand required a gasket repair on a transformer due to persistent oil leaks from the flange joint, which posed operational and environmental risks. Oil leaks not only create maintenance challenges but can also lead to environmental contamination, making a reliable, long term repair solution essential. The maintenance team needed a product capable of providing a strong, flexible seal to withstand the stresses on flange joints in high demand environments.

The Solution

The gasket repair process began with abrasive blast-cleaning of the steel substrate to an SA2.5 finish, achieving a 75-micron profile in accordance with ISO 8501/4 Standard SA2.5 (SSPC SP10 / NACE 2). This prepared surface allowed optimal adhesion of the 209 EIP PU coating.

Bolt heads received a targeted stripe coat of 209 EIP PU, applied by brush to ensure full coverage on vulnerable areas prone to leakage. For the flange joints, an initial layer of 209 EIP PU was followed by the application of 808 Reinforcement Tape to strengthen the joint and provide additional flexibility to withstand operational stresses. Finally, the entire treated area was overcoated with 209 EIP PU, forming a continuous, robust seal that effectively prevents oil leakage.

Results & Benefits

The gasket repair system combined 209 EIP PU and 808 tape creating a durable, leak proof seal
Restore the flange integrity and minimise maintenance needs
Extend the service life of the transformer by mitigating environmental risks
Improve the overall operational reliability for the substation