Case Studies
Real-world examples of how our technical expertise and precision engineering solve critical challenges for power utilities and heavy industries.
132kV Substation OLTC Overhaul for Major Steel Plant
Client: National Steel Corporation
The Challenge
Frequent voltage fluctuations were causing emergency shutdowns in the arc furnace operations. The existing OLTC was 20 years old and failing to maintain stable secondary voltage.
Our Solution
Complete mechanical overhaul of the MR Type diverter switch, replacement of transition resistors, and installation of a modern RTCC panel with SCADA integration.
Key Results
- Zero voltage-related shutdowns since installation
- Tap change response time improved by 40%
- Extended transformer lifespan by an estimated 15 years
Technical Specs: 132/33kV, 50MVA Transformer. MR Type M Diverter Switch.
Emergency Transformer Oil Filtration for State Grid
Client: Maharashtra State Electricity Transmission
The Challenge
Routine BDV testing revealed critical moisture levels (35ppm) and low dielectric strength (22kV) in a critical 220kV distribution transformer's OLTC compartment.
Our Solution
Deployed emergency high-vacuum mobile filtration unit. Conducted 4 passes of 0.5 mbar vacuum dehydration and fine particle filtration over 48 hours.
Key Results
- Restored BDV to 65kV (exceeding minimum requirement of 50kV)
- Reduced moisture content to 8ppm
- Prevented a multi-district power outage
Technical Specs: 220/132kV, 100MVA Auto Transformer. Filtration: 3 micron absolute, 0.5 mbar vacuum.
Predictive Maintenance Implementation for Chemical Plant
Client: Global Chem Industries
The Challenge
The plant operated 14 transformers with varying ages and maintenance histories, leading to unpredictable maintenance costs and occasional minor failures.
Our Solution
Implemented an annual health monitoring program including DGA, contact resistance testing, and thermography for all OLTC units.
Key Results
- Identified 3 failing transition resistors before catastrophic failure
- Reduced annual maintenance budget by 22% through predictive scheduling
- Achieved 100% uptime for the past 3 years
Technical Specs: Fleet of 14 transformers ranging from 5MVA to 25MVA. Various OLTC makes (ABB, CTR).
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