HVDC Transformer Repair: Oil Leak, Mexico

5th December 2024

Industry: Power
Location: Mexico
Application: HVDC Transformer
Products: 104 Metal Repair Fluid XF

The Challenge

At an electricity substation in Mexico, an HVDC transformer repair was urgently needed to address persistent oil leakage and water ingress through pipework connections and fittings. These issues risked compromising transformer performance, safety, and longevity. To prevent further deterioration, a durable and reliable sealing solution was essential to maintain operational integrity and protect the transformers from harsh environmental conditions.

The Solution

The steel substrate was abrasive blasted to SA2.5 with a 75-micron profile, following ISO 8501/4 SA2.5 (SSPC SP10/NACE 2) standards. To ensure proper surface preparation and optimal adhesion. Bolt heads, flange joints, and other mating surfaces were precisely stripe coated with 104 Metal Repair Fluid XF, applied using a brush and plastic applicator to create a uniform base layer.

To reinforce the repair, a layer of Resimac 808 Reinforcement Tape was embedded within the coating at flange joints and critical areas, enhancing mechanical strength and long term durability. This combination ensured the repaired sections could withstand operational stresses and resist environmental challenges. Finally, all treated areas were overcoated with an additional layer of 104 XF, fully encapsulating the repair and providing robust sealing against oil leakage and water ingress.

Results & Benefits

HVDC repair system created a durable seal for the transformer components
Effectively stopped the oil leak and water ingress
Ensured consistent transformer operation
Integration of 808 Reinforcement Tape added strength and ensured the repair could withstand the challenging HVDC environment
Reduce the risk of future leaks & minimised maintenance requirements
Continuous power delivery, enhancing both safety and efficiency at the facility