UNIQUE POLYMER SYSTEMS is committed to providing high-quality repair and protection solutions for critical infrastructure. This case study details the successful repair of HVDC transformers at an electricity substation using our UPS 120 XFF FAST CURING METAL FLUID.

At an electricity substation, HVDC transformers were experiencing significant issues with oil leakage and water ingress. These problems, if left unaddressed, could compromise the efficiency and safety of the transformers, potentially leading to system failures and costly repairs.

The challenge was to effectively seal and protect the transformers' pipework connections and fittings to prevent further leakage and ingress. The solution needed to be durable and capable of withstanding the demanding conditions of an HVDC substation.

UNIQUE POLYMER SYSTEMS provided a robust repair solution using our UPS 120 XFF. The repair process was carried out as follows:

Surface Preparation:

- The steel substrate was abrasive blast cleaned to achieve a surface cleanliness of Sa2.5, with a 75-micron profile, in accordance with ISO 8501/4 Standard Sa2.5 (SSPC SP10 / NACE 2). This preparation ensured optimal adhesion of the repair materials.

Application of Repair Materials:

- The bolt heads were stripe coated with UPS 120 XFF, applied by brush and plastic applicator, to protect against further corrosion and leakage.

- Flange joints and other mating surfaces were coated with UPS 120 XFF. A layer of UPS 998 FLEXTECH REINFORCEMENT TAPE was encapsulated within this coating to enhance durability and provide addtional protection.

- Finally, all repaired sections were over-coated with a finial layer of UPS 120 XFF to completely seal the area and ensure a long-lasting repair.

The application of UPS 120 XFF successfully sealed the HVDC transformers, preventing oil leakage and water ingress. The solution provided a durable and reliable repair, ensuring the continued safe and efficient operation of the transformers within the substation.

This case study illustrates the effectiveness of UNIQUE POLYMER SYSTEMS' UPS 120 XFF in addressing critical issues with HVDC transformers. Our advanced repair solution not only resolved the immediate problems but also provided long-term protection against further damage.