Overview & Maintenance Philosophy
In modern manufacturing and commerce, unplanned electrical downtime translates directly into substantial financial loss, compromised production schedules, and safety hazards. VOLTCORE delivers structured maintenance programs engineered to detect equipment degradation long before catastrophic failures occur.
Our field engineers provide structured Annual Maintenance Contracts (AMC) and emergency breakdown services adhering to IEC 60076, IEC 62271, and BNBC guidelines. By combining scheduled physical servicing with advanced predictive diagnostics like thermographic thermal imaging and oil dielectric analysis, we extend the operational lifespan of your high-value electrical assets by up to 15 years.
Core Substation Equipment Maintenance Scopes
Our maintenance engineers service all major primary and secondary electrical distribution assets:
1. Power & Distribution Transformer Servicing
Full-lifecycle preventative maintenance for 11kV & 33kV transformers:
- On-Site Oil Filtration & Dehydration: High-vacuum oil processing to remove moisture, dissolved sludge, and microscopic particulates, restoring dielectric BDV to >50kV.
- Silica Gel Breather Servicing: Regenerating or replacing moisture-saturated silica gel beads and refreshing oil sealing cups.
- Bushing & Gasket Maintenance: Cleaning HV/LV porcelain bushings, torquing terminal palms, and replacing degraded cork-nitrile gaskets to eliminate oil leaks.
- Off-Circuit Tap Changer Servicing: Exercising and inspecting tap-changer contacts to clear carbonization and verify contact tension.
2. HT & LT Switchgear Maintenance
Mechanical endurance and electrical integrity for VCB, LBS, and ACB cubicles:
- Breaker Mechanism Overhaul: Cleaning, degreasing, and re-lubricating VCB/ACB operating linkages, charging springs, and trip/close coils.
- Contact Resistance Testing: Micro-ohm measurements across main power contacts to detect pitting and prevent localized thermal runaway.
- Busbar Retorquing & Insulation Cleaning: Calibrated torque-wrench tightening of copper busbar joints and high-voltage vacuum extraction of industrial dust.
- Interlock & Safety Shutter Check: Testing mechanical door interlocks, racking mechanisms, and automatic earth switches for personnel protection.
3. Power Factor Improvement (PFI) Plant Tuning
Ensuring your facility maintains power factor above 0.95 to eliminate utility low-PF penalties:
- Capacitor Bank Health Audit: Measuring capacitance (µF) across each individual dry-type capacitor step to identify degraded or blown units.
- Microprocessor Relay Re-Calibration: Tuning automatic power factor controllers (APFC) switching thresholds and target PF settings.
- Switching Contactor & Fuse Replacement: Servicing inrush damping resistors on capacitor-duty contactors and testing HRC fuse links.
- Harmonic Detuned Reactor Inspection: Checking 7% / 14% detuned series reactors for overheating and thermal insulation integrity.
4. Predictive Thermography & Earthing Audits
Non-invasive diagnostic audits performed while plant systems operate under full load:
- Infrared Thermographic Scanning: Calibrated FLIR thermal imaging of all cable terminations, busbar splices, and breaker jaws to pinpoint hotspots.
- Comprehensive Thermal Reports: Supplying radiometric images with temperature deltas (ΔT) and prioritized severity classifications.
- Earth Pit Resistance Testing: Testing grounding resistance of all substation earth pits, lightning arresters, and neutral ground connections (< 1.0 Ohm).
- Chemical Earth Treatment: Re-treating high-resistance pits with bentonite conductive compound and moisture replenishment.
Annual Maintenance Contract (AMC) Tiers
We provide flexible, customized AMC arrangements tailored to your factory operational demands:
Official Service Logs & Statutory Compliance
Every maintenance visit is formally documented to maintain full compliance with regulatory authorities:
- Formal Substation Logbook: Maintaining an on-site physical log and cloud digital archive of all operating temperatures, oil levels, and voltage readings.
- Chief Electrical Inspector (CEI) Compliance: Our certified test and service documentation fulfills periodic statutory electrical inspection requirements in Bangladesh.
- Fire Safety & Insurance Verification: Providing accredited thermography and breaker test certificates required by industrial fire safety and insurance underwriters.