Transformer services

Lifecycle Management

The BRUSH transformer lifecycle management programme can be applied from the beginning of a transformer’s life, or when changes may need to be made to existing equipment.

Overview

Through our transformer lifecycle management programme, we carry out a series of tests to offer the best possible performance of your transformer – enhancing its longevity and improving its reliability.

The programme is a combination of the services listed below and can be applied from the beginning of a transformer’s life, or when you feel changes may need to be made to your existing equipment.

Key benefits

Asset maintenance & upgrades
Reduced equipment downtime
Asset life extension
Safeguard against outages
VIEW FROM THE TEAM

What are the typical advantages of transformer lifecycle management?

A lifecycle management programme gathers vital data on the condition of your transformer.

This information tells us about factors such as suspected transformer faults, condition assessment for network planning, details on condition pre/post relocation, confirmation of condition on delivery, transformer failure investigation and the plotting of degradation.

Capabilities

Transformer inspections and health checks

Preventative maintenance is the key focus of our lifecycle management programme. Available to all BRUSH transformer products and those of third parties, this comprehensive inspection scheme provides a continuous appraisal of your equipment’s current condition.

The benefit of regular inspections and checks is that potential problems can be found and addressed – before they become bigger issues. The programme can also be tailored to your operational needs, giving you control over aspects such as when to schedule the required equipment outage time needed for inspections to take place.

Transformer maintenance contracts

We believe prevention is better than cure, and we ensure your transformer is always functioning at its best by putting in place a fully-customised support package that’s right for your system and your business.

Ongoing maintenance gives advanced warning of your transformer’s deterioration, highlights high priority assets, reduces the risk of unexpected outages and provides proof of condition upon delivery. And because all previous results are kept on file, we’re uniquely placed to compare data and address issues before they become expensive, real problems.

Transformer testing and condition monitoring

We can carry out a series of crucial tests that help determine the condition of your transformer to see if it has been damaged or if it should even be removed from service. These tests are as follows:

SFRA (Sweep Frequency Response Analysis)

This is a reliable method of monitoring the physical condition of a transformer and its components. It can efficiently detect displacement of transformer cores, deformation of windings, faulty core grounds or broken and/or loose connections.

Capacitance and dissipation factor

Measuring capacitance and dissipation factor helps us determine the insulation condition between windings or within bushings.

Changes in capacitance can indicate mechanical displacements of windings or partial breakdown in bushings. Ageing and degradation of the insulation, together with the presence of moisture, increase the amount of energy that is converted to heat in the insulation. The rate of these losses is measured as dissipation factor.
 

Polarisation Index

Polarisation Index is used to indicate the condition of transformer insulation. It’s a ratio of the insulation resistance measured for 10 minutes to the insulation resistance value measured after one minute.
 

DFRA (Dielectric Frequency Response Analysis)

The dryness and condition of paper insulation is a key factor in both short and long-term power transformer reliability. DFRA testing is an excellent tool for diagnosing transformer insulation issues and is effective in assessing moisture in power transformers.
 

Winding resistance

Measuring a transformer’s DC winding resistance from one external terminal to another assures that the windings are intact, and the internal connections are correct. The resistance measurements also indicate there’s no severe mismatches or open circuits throughout the tapping range.
 

Dissolved gas analysis

When insulating oil is subjected to high thermal and electrical stress, gasses are generated from the decomposition of the oil. Different types of faults generate different gasses. Analysing these gasses tells us a lot about the condition of your transformer.

Transformer oil analysis

By studying the oil in your transformer, we can monitor the health of your system and identify ways to optimise its performance. The testing and analysis of the samples also lets us highlight and fix issues that could lead to costly shutdowns or repairs if left unresolved.

All testing is done without the need to stop your system, avoiding disruption to service.

Find out more…

For more information on our transformer services, download our brochure below. Alternatively, book a consultation, contact us today.

Transformer services

Transformer Servicing & Repair

Our servicing and repair services help to ensure your operation remains up and running and that your liquid-filled power transformers remain operating at peak performance.

Overview

BRUSH provides a range of transformer servicing and repair options. These include refurbishments, supply of spare parts, modifications and cooler bank replacements.

Key benefits

Asset maintenance & upgrades
Reduced equipment downtime
Asset life extension
Safeguard against outages

Capabilities

Transformer servicing and repair

Our servicing and repair services help to ensure your operation remains up and running and your liquid-filled power transformers stay at peak performance.

All servicing and repairs are carried out by our experienced engineers in accordance with the appropriate ISO and health & safety standards.

Whether working with BRUSH or third-party transformers, the peace of mind our support offers is invaluable to your business.

Repairs and refurbishments

We provide a comprehensive range of repair services including transformer refurbishment, radiator repair or replacement, cooler equipment replacement, cable box replacement, oil processing, analysis and replacement, tapping switch modification/replacement, gasket seal replacement, transformer relocation and transformer up-rating.

Our engineers can carry out work at one of our factories or on site, saving downtime and transport costs. We also have considerable experience working in the field in both onshore and offshore environments.

Transformer spare parts

We stock a vast array of spare parts which can be used at short notice by our engineers to keep your transformer operating at its best. Just some of the spare parts available include: bushings, radiators, gaskets, tap changer contacts, Buchholz relays, pumps, drier elements, temperature sensors, fan motors, oil alarm and indicators, valves and terminal lugs.

Bulk ordering of bespoke kits is available, with us storing your spares ready for you to quickly access when you need them.

Transformer up-rating and modifications

A transformer represents significant investment and replacement can be disruptive and expensive. Up-rating, or modifying, your existing transformer is a more cost-effective way to increase its performance and lifespan.

One common example of this is the retrofit of replacement tap changers, which greatly improves transformer efficiency and longevity, providing a worry-free solution for many years.

Transformer cooler bank replacements

One of the most common ways of breathing new life into a transformer is to replace the cooler bank. Our expert engineers can carry out a transformer cooler bank replacement on-site with minimum disruption to your business.

Transformer training and supervision

Keeping your transformer running at peak performance requires specialist technical skills. We offer a comprehensive training programme that shows your employees how to get the best from your transformer, as well as bringing them up to speed on the latest safety considerations.

Led by our product experts, training can be delivered off site in a classroom environment, or at your location. Training focus is on up-skilling your team during commissioning or with previously installed equipment.

24/7 transformer support

We are renowned not just for the quality of the transformers we produce, but for the level of support and care we offer our customers.

Our engineers offer first rate service to help keep your system operating at its best, whether that’s through a customised support package or 24/7 technical support and repairs.

Find out more…

We provide tailored servicing and repair solutions to meet the specific business needs of every customer. To book a service or repair, or to find out more about our transformer services, contact us today.

Generator services

Spare Parts

We offer a wide variety of quality parts and expert advice on strategic parts management plans.

Overview

In order to increase the operating life of machines and equipment, BRUSH offers a replacement parts service.  We offer a wide variety of high quality parts for our own machines and from other manufacturers including:

  • Individual components, such as diodes and fuses
  • Integral parts, such as shaft seals and bearings
  • Essential parts, such as maintenance kits and consumables

Since it is important that your machine continues to operate properly, we advise keeping a supply of basic parts for your machine on hand.  This can, in combination with a good maintenance program, considerably reduce the duration of production failure should a breakdown occur.  

All commonly used parts for BRUSH generators are in stock in our extensive parts facilities in the UK and US. Parts can then be quickly delivered to the necessary location. 

Key benefits

Asset maintenance & upgrades
Reduced equipment downtime
Asset life extension
Safeguard against outages
Generator services

Replacement Generators

We specialise in providing custom-engineered replacement generator packages that are electrically and mechanically interchangeable.

Overview

BRUSH has broad experience in supplying generators for all types, ratings and configurations of turbines. We do not supply one generator to fit one turbine – we have multiple generator selections to match the outputs of all major generator manufacturers.

Some customers have made substantial winding repairs more than once, in some cases spending excessive amounts of money. BRUSH can offer an alternative solution to endless repairs with a customised solution for a replacement generator.

We specialise in creating a package that is both electrically and mechanically interchangeable, matching the existing footprint and ancillary components, which removes the need for civil works and dramatically reduces plant down time on site.

Contact us today to explore if a generator swap out could be a cost efficient investment option. 

Key benefits

Asset maintenance & upgrades
Reduced equipment downtime
Asset life extension
Safeguard against outages
Generator services

Upgrades

Committed to maximise the operational life of your equipment. BRUSH solutions are carefully engineered and planned to minimise downtime and the risk of power outages.

Overview

BRUSH products are manufactured to deliver high performance, year after year.

One important part of the success of our services support lies with our ability to upgrade and modify equipment to keep your plant functioning well and at peak performance levels.

Key benefits

Asset maintenance & upgrades
Reduced equipment downtime
Asset life extension
Safeguard against outages

Product Upgrades

Replacing major assemblies, such as stators and rotors, in both BRUSH and third party products can improve the operation of your plant and extend the life of your equipment. We offer engineered solutions for the following upgrade packages: 

  • MW output 
  • Equipment cooling system 
  • Machine excitation system 
  • Retrofit rotor earth fault monitor 
  • Generator auxiliary equipment
  • Analogue to digital excitation controller
  • Power management system  

Plant Upgrades 

Because of our extensive knowledge of your existing equipment and design, we can tailor fully engineered solutions which are electrically and mechanically compatible with the existing units and power system.

Modifications

If the demands of your business change and you need your equipment to respond, we can carry out modifications to your existing BRUSH equipment, such as power management systems and exciter systems, which bring it up to date and enable you to optimize operations.

Re-Engineering & Reverse Engineering

Our expert BRUSH engineers don’t just specialize in our own products. They have comprehensive technical skills and are able to carry out extensive work on equipment produced by third party manufacturers, such as reverse engineering, re-engineering and servicing. 

Their extensive engineering capabilities include: 

  • Mechanical engineering 
  • Electrical/electromagnetic engineering 
  • Thermal engineering 
  • Insulation engineering 
  • Control and protection
Generator services

Engineering Design

Our expert teams are highly experienced in the design, manufacture, maintenance and testing of brushless exciters and they can re-engineer components to improve performance.

Re-engineering & Reverse Engineering

Our expert BRUSH engineers don’t just specialise in our own products. They have comprehensive technical skills and are able to carry out extensive work on equipment produced by third party manufacturers, such as reverse engineering, re-engineering and servicing.

Their extensive engineering capabilities include:

  • Mechanical engineering 
  • Electrical/electromagnetic engineering 
  • Thermal engineering 
  • Insulation engineering 
  • Control and protection

Key benefits

Asset maintenance & upgrades
Reduced equipment downtime
Asset life extension
Safeguard against outages
Generator services

Exciter Services

Our expert teams are highly experienced in the design, manufacture, maintenance and testing of brushless exciters and they can re-engineer components to improve performance.

Overview

Our expert teams are highly experienced in the design, manufacture, maintenance and testing of brushless exciters and they can re-engineer components to improve performance.  If you’re due an upgrade, we can now supply new brushless exciters to our clients too.

Key benefits

Asset maintenance & upgrades
Reduced equipment downtime
Asset life extension
Safeguard against outages

From Straight Forward Repairs To Performance Enhancements

Our services include:

  • Repairs
  • Rebuilding components
  • Refurbishment program to disassemble all removable components, testing each electrical component to identify its status
  • Component replacement
  • Re-banding services
  • Complete rewinds of the stator and rotor winding assemblies
  • PMG rewinds
  • Full speed balance of all exciter rotors in a state-of-the-art balance facility
  • Emergency excitation services including:
    • A mobile exciter, which can be brought to site
    • Swap-out brushless exciters for use during refurbishments
  • Electrical testing, including:
    • RTD Resistance Test
    • RTD Insulation Resistance
    • Thermocouple Continuity
  • Supply of new brushless exciters
  • Exciter Housing Modifications

Housing Modifications Reduce Risks And Improve Operation

  • BRUSH Service can carry out a Positive Pressure Vent Modification (PPVM) to your existing exciter housing which has been proven to significantly reduce the rate of dirt contamination and mitigate the potential hazard of hydrogen ingress.
  • Housings are modified so the inside pressure is at a higher level than the outside, which reduces the intake of dirt and contamination during operation.
Generator services

Stator Services

In the event of an unplanned outage, the quickest way to return the generator to service is to repair on site.

Overview

For every aspect of generator maintenance, our service is as thorough and well thought through as our approach.  And we like to think our standard services are anything but standard, as they’re carried out with such precision and expertise.

Services include:

  • Inspections, electrical and mechanical testing
  • Coil replacement
  • Complete rewind
  • EL-CID, loop test and end winding stiffness (“Bump”) testing and analysis
  • Patented end winding vibration services
  • Vibration monitoring
  • Full or partial re-wedge

Key benefits

Asset maintenance & upgrades
Reduced equipment downtime
Asset life extension
Safeguard against outages

End Winding Vibration Resolution Services (for non-BRUSH generators)

To expand our services, we’ve developed a series of patented retrofit solutions for non-BRUSH generators to end winding vibration that do not require a rewind of the stator.  These options have been developed on a building block approach and we’ve been using them successfully since 1993. 

Vibration Monitoring Systems

Stator winding vibration monitoring systems provide information on both electrically and mechanically inducted vibrations being experienced on the end windings.  Depending on your set up, the systems can be configured to provide information at the generator itself or via continuous monitoring in the control room. 

Generator services

Rotor Services

BRUSH Services can offer advanced OEM testing in both our European and North American facilities

Overview

Rotor Balancing

BRUSH offers expert and technologically advanced rotor balancing.

Developed in conjunction with rotor balance technology leaders Schenck, the US based Pittsburgh facility is world class. A below ground bunker arrangement with DH9 pedestals and CABFLEX3 software shortens testing cycles that result in significant time savings compared with dated technology alternatives.

Investing in a state of the art high speed balance pit ensures that BRUSH Services can offer advanced OEM testing in both our European and North American facilities.

  • Unbeatable low cost rotor balancing
  • Unmatched 130 years of OEM expertise in designing, manufacturing & servicing rotors
  • Uncompromising investment in the very latest rotor balance technology
  • Urgent 24 hour turnaround capability to minimise downtime

Contact us now to discover rotor balancing at very competitive prices.

Key benefits

Asset maintenance & upgrades
Reduced equipment downtime
Asset life extension
Safeguard against outages
Generator services

Factory Repair

With a combination of trained engineers, technical equipment and project managers on hand, repairs and overhauls can be carried out quickly and professionally.

Overview

It may not always be possible to carry out repairs on site, owing to space constraints or unsuitable environments. If this is the case, we would transport the equipment to the factory facilities at one of our manufacturing bases.

Our factory-based facilities in the UK, USA and Czech Republic include:

  • Workshops with cleaning facilities and vacuum drying ovens
  • Modern machining and fabrication facilities
  • Coil manufacturing and vacuum pressure impregnation facilities
  • Assembly workshops including large capacity cranage
  • High voltage test facility 3D measuring facilities
  • Decontaminating processes required for handling hazardous materials including asbestos based insulation found in older products

Key benefits

Asset maintenance & upgrades
Reduced equipment downtime
Asset life extension
Safeguard against outages

Generators

Typical generator factory repair services include:

  • Stator core replacement
  • Stator rewind
  • Bearing refurbishment
  • Rotor overhaul and end winding refurbishment
  • Rotor-end cap/retaining rings
  • Rotor rewind
  • Rotor high speed balancing including over speed
  • High voltage testing