Transformer Processing
We handle the field end of transformer work: regasket leaking tanks, process wet or contaminated oil, service or rebuild the load tap changer, and commission units before re-energization. We own and operate our own Baron oil processing equipment, machine replacement parts in-house, and don’t subcontract the technical scope.
Gaskets fail from age hardening, thermal cycling, and improper original installation. A leaking transformer loses oil and admits moisture. We replace gaskets on tanks, radiators, bushings, and accessories, and confirm oil integrity before the job is done.
- Tank cover, manhole, and drain valve gaskets
- Radiator header and radiator drain gaskets
- Bushing flange and throat gaskets
- PCB check before work begins and before oil disposal
- Oil sample and dielectric verification after sealing
- Leak inspection before re-energization
We bring the Baron rig to your substation. Vacuum dehydration, hot oil circulation at 60–70°C, and depth filtration run continuously on-site until oil meets dielectric and moisture targets. We stay until the numbers are met, not until the clock runs out.
- Vacuum dehydration — removes moisture and dissolved gas
- Hot oil circulation — draws moisture from paper insulation
- Depth filtration — removes particulates and carbon
- Degassing — vacuum chamber strips dissolved gases
- ASTM D877 / D1816 dielectric · ASTM D1533 moisture
- Before / after oil samples and written field report
Load tap changers accumulate carbon, arcing damage, and mechanism wear on every operation. We inspect contacts, service the LTC oil, verify mechanism timing, and replace worn contacts when needed. We machine the replacement contacts ourselves — no waiting on a supplier.
- Contact inspection — arcing damage and wear measurement
- LTC oil drain, clean, and refill
- Mechanism inspection and lubrication
- Tap changer timing and transition resistance test
- Contact replacement when worn — parts machined in-house
- Full LTC rebuild available in our Palm Harbor shop
After major overhaul, rewind, or core inspection, a transformer has to go back together correctly. We gasket and assemble the tank, fill under vacuum, run a hot oil treatment cycle, verify insulation resistance and power factor, and produce a commissioning report before the switch is closed.
- Tank assembly and full gasket installation
- Vacuum oil fill — prevents air entrapment in insulation
- Hot oil treatment cycle post-fill
- Insulation resistance, PI / DAR, and power factor verification
- TTR and excitation current confirmation
- Commissioning documentation package
One crew. Full scope.
Each of these services can stand alone, or they can run together in a single mobilization. Regasketing paired with oil processing is the most common combination: seal the leaks, then process the oil that absorbed moisture while the gaskets were failing. LTC maintenance fits naturally into any transformer outage window alongside an oil service run.
Combining services in one mobilization reduces total outage time, cuts travel costs, and produces a complete condition picture in one report. We scope it that way when the work supports it.
When utilities and contractors use this service.
Aging fleet with deferred maintenance. Need oil processing and LTC service to extend asset life without a capital replacement.
Installing or relocating transformers. Need commissioning, vacuum fill, and pre-energization testing to hand off the job clean.
Failed transformer leaking oil. Need immediate regasketing, oil recovery, and processing to restore service quickly.
Scheduled maintenance window. Bundle oil processing, LTC service, and regasketing to complete the full scope while the unit is down.
Equipment and backing.
- Baron vacuum dehydration rigsTwo mobile units — EPA licensed — available 24/7
- In-house machine shopCustom gaskets, machined LTC contacts, replacement hardware
- Field testing equipmentPower factor, TTR, insulation resistance, oil dielectric
- Southeast-based crewsFL, GA, AL, MS, TN, NC, SC — same-day dispatch for emergencies
- No subcontracted technical workOur crew, our equipment, our accountability
- Written documentationTest reports, oil sample results, photos, commissioning package
One-page summary of our transformer processing services. Save it, forward it, or hand it to your team.
Tell us the transformer size, voltage class, and what you need done. We’ll respond within one business day with crew availability and a scope.
DGA, Doble power factor, TTR, SFRA, winding resistance, and tap-changer maintenance.
Documented acceptance tests on new substation equipment before energization.
NFPA 70B and IEEE-aligned periodic testing to keep substation equipment in service.
24/7 availability with same-day or next-day field dispatch.
Gasket selection, leak diagnosis, the regasketing sequence, and when to combine it with oil processing.
The technical case for oil processing: vacuum dehydration, hot oil circulation, leak repair, and what it takes to extend transformer service life.
What the lab results actually tell you: dielectric strength, moisture content, DGA, acidity, and when each reading requires action.
How to evaluate whether repair and processing make economic sense vs. buying a new unit.
IEEE and manufacturer-recommended service intervals for load tap changers by operation count and calendar.
How moisture content is measured, what the readings mean, and when to process vs. when to replace oil.