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RCM & PM OLTC Overhauling and Leakage Repair on 67MVA Power Transformers N.G SA

RCM & PM OLTC Overhauling and Leakage Repair on 67MVA Power Transformers N.G SA Our company successfully carried out the RCM and Preventive Maintenance based Overhauling of the On Load Tap Changer (OLTC) and Leakage Repair of a 67MVA power transformer for National Grid Saudi Arabia. The scope included complete OLTC disassembly, inspection, contact replacement, mechanical cleaning, calibration of switching mechanisms, and full restoration of leakage points across gaskets, flanges, and valves. In addition, our team conducted comprehensive PM testing such as DGA, IR Thermography, OLTC Timing Tests, and Oil Filtration to ensure the transformer meets National Grid operational and safety standards. The transformer was fully tested, commissioned, and returned to service with improved performance, zero leakage, and enhanced reliability. OLTC Overhauling Saudi Arabia has become one of the most important services for ensuring reliable power supply across the Kingdom. Power transformers used in National Grid SA carry heavy electrical loads every day, and their health directly affects the stability of the entire network. https://aljazeeragc.com/wp-content/uploads/2025/12/newVideo.mp4 Our company delivers professional RCM (Reliability Centered Maintenance) and Preventive Maintenance (PM) services for 67MVA power transformers, focusing on OLTC overhauling and transformer oil leakage repair. These services help National Grid Saudi Arabia reduce failures, avoid shutdowns, and increase transformer lifespan. What is OLTC and Why Overhauling is Important? An On-Load Tap Changer (OLTC) is a device inside a transformer that adjusts voltage levels while the transformer is still running. It helps keep electricity stable even when demand changes. Common OLTC Failure Signs Why Overhauling Matters If the OLTC fails, the transformer can shut down immediately, causing power outages. Overhauling ensures: This is why National Grid Saudi Arabia requires strict OLTC maintenance standards across all major substations. Scope of Work – 67MVA Transformer Overhauling Our team followed complete RCM and PM workflows while servicing the 67MVA power transformer for National Grid SA. OLTC Disassembly & Inspection We fully opened the OLTC chamber, removed switching components, inspected for carbon deposits, overheating, oil contamination, and worn contacts. Contact Replacement Worn and burnt contacts reduce performance. We replaced: This ensures smooth and fast switching. Mechanical Cleaning All parts were cleaned to remove sludge, carbon, and moisture. This improves oil performance and reduces chances of internal faults. Switching Mechanism Calibration We calibrated: This ensures the OLTC changes taps accurately and safely under load. Transformer Leakage Repair (Oil Leakage) Transformer oil leakage is common in older or heavily loaded units. Oil must remain inside the transformer to cool and insulate internal components. Types of Oil Leakages Causes of Leakage Complete Leakage Repair Steps This guarantees zero leakage after testing. RCM (Reliability Centered Maintenance) Approach National Grid Saudi Arabia uses RCM to reduce faults and increase transformer availability. Why RCM is Important Using RCM, we analyze OLTC failure causes, load cycles, and environmental conditions to plan the best maintenance actions. Preventive Maintenance (PM) Activities Performed To meet maintenance standards in Saudi Arabia, our PM activities include: DGA Testing (Dissolved Gas Analysis) Detects faults inside oil like arcing, overheating, or insulation breakdown. IR Thermography Identifies hotspots on bushings, connections, and OLTC. OLTC Timing Test Checks switching speed and mechanical movement. Oil Filtration & Dehydration Removes: Bolts Tightening & Torqueing Ensures all flanges, valves, and radiators stay leak-free. These PM tasks ensure the transformer stays in excellent operating condition. Testing & Commissioning After Overhaul After completing overhauling and leakage repair, our engineers perform: Functional Testing Load Testing Checks OLTC performance under real power load. Final Inspection Checklist Only after passing all tests, the transformer is returned safely to operation. FAQs 1) What is an On-Load Tap Changer (OLTC) and why does it need overhauling? An On-Load Tap Changer (OLTC) is a critical transformer component that regulates voltage under load conditions. Over time, OLTC contacts and oil degrade due to arcing and continuous operation, making overhauling necessary to maintain grid stability, reduce failures, and increase transformer lifespan. 2)How often should a 67MVA power transformer OLTC be serviced in Saudi Arabia? For National Grid Saudi Arabia–level installations, OLTC inspection is recommended every 3–5 years, while major overhauling should be performed every 6–8 years, depending on operational load, environmental conditions, and oil test results. 3)What is included in the OLTC overhauling process? Typical OLTC overhauling includes: 4) What causes oil leakage in power transformers? Oil leakage usually occurs due to: Improper previous maintenance 5)Why is OLTC and leakage repair important for National Grid Saudi Arabia? Reliable transformers ensure stable power distribution, reduced downtime, and operational safety. Overhauling and repairing a 67MVA transformer prevents unplanned outages and complies with Saudi National Grid operational standards. 6)How long does transformer OLTC overhauling usually take? A complete OLTC overhauling and leakage repair for a 67MVA transformer typically takes 1 day, depending on damage, spare part availability, and testing requirements. 7)Do you provide OLTC overhauling and leakage repair services across Saudi Arabia? Yes, services are available across Riyadh, Dammam, Jeddah, Makkah, Madinah, Tabuk, Abha, and all regions in Saudi Arabia. 8)How do you ensure quality and compliance during transformer maintenance? We follow IEC standards, National Grid Saudi Arabia maintenance guidelines, and complete all repairs with certified engineers, calibrated tools, and documented test reports. Final Results & Benefits for National Grid Saudi Arabia After completing the OLTC overhauling and leakage repair, the 67MVA transformer showed significant improvements:  Zero oil leakage Smooth and fast OLTC switching Stable transformer temperature Improved voltage regulation Reduced risk of sudden shutdowns Increased reliability of the power network Extended asset lifespan Thanks to our RCM + PM approach, the transformer is now performing at optimum capacity, supporting National Grid SA operations reliably.

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