Transformer Flange Leak Repair: A Case Study

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Transformer Flange Leak Repair

13th January 2025

A substation in New Zealand required a transformer flange leak repair due to persistent oil leaks from degraded gaskets, 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.


Resimac’s Transformer Flange Leak Repair Solution

  • Surface prepared by abrasive blasting to SA2.5 standard.
  • Bolt heads stripe coated with 209 EIP PU for enhanced leak protection.
  • Flange joints coated with 209 EIP PU, reinforced with 808 Reinforcement Tape.
  • Final overcoat of 209 EIP PU applied to seal the entire area.

Application Details

The 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.


Products Used


Results and Benefits

The combined application of 209 EIP PU and 808 Reinforcement Tape created a durable, leak proof seal, restoring the transformer’s flange integrity and minimising maintenance demands. This solution extended the service life of the transformer by mitigating environmental risks associated with oil leakage and improving overall operational reliability for the substation.


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