On-Site Transformer Services, Breaker Retrofits & Protection Relay Testing
Specialized electrical engineering field services across India. From 2500 LPH mobile transformer oil filtration and intelligent ACB retrofits to 100kV dielectric hipot verification and numerical relay calibration — executed under certified Class-A electrical contractor licenses.
Mobile testing vans equipped with motorized 100kV sets, CRM meters, secondary injection kits, and transformer filtration plants.
Diagnostic Testing, Transformer Services & Switchgear Retrofits
Eliminate unplanned industrial outages. Our certified engineers bring precision testing instrumentation and mobile plants directly to your facility floor.
High-Vacuum Transformer Oil Filtration & Dehydration
On-site transformer oil regeneration utilizing a multi-stage high-vacuum mobile dehydration plant. Removes dissolved gases, moisture, suspended carbon particles, and sludge to restore dielectric breakdown voltage (BDV) above 70kV while extending transformer operational lifespan.
- ✓Two-Stage High-Vacuum Heating & Dehydration (2500 LPH Flow Rate)
- ✓Pre & Post Dielectric Breakdown Voltage (BDV) Certification
- ✓Dissolved Gas Analysis (DGA) & Karl Fischer Moisture (<10ppm) Sampling
- ✓Transformer Gasket Overhauls, Silica Gel Breathers & Bushing Maintenance
Air Circuit Breaker (ACB) & VCB Retrofitting & Modernization
Engineered retrofits replacing obsolete, high-maintenance breakers (English Electric, older C&S, Alstom, L&T) with modern micro-processor trip unit breakers. Specialized roll-in replacement cradles and custom copper busbar adapters eliminate shutdown risks.
- ✓Engineered Roll-In & Draw-Out Cradle Conversions (800A to 4000A)
- ✓Microprocessor Electronic Trip Units (ETU) with LSIG Protection Curves
- ✓Secondary Disconnect Terminal Alignment, Interlocks & Shunt Trips
- ✓Factory-Trained Retrofit Engineers with Minimal Shutdown Downtime
Protection Relay Testing & Primary/Secondary Current Injection
Comprehensive diagnostic calibration of numerical, static, and electromechanical protection relays. Multi-phase current injection sets and calibrated timing kits ensure discrimination between primary and backup protection devices.
- ✓Primary Current Injection up to 2000A for CT Ratio & Polarity Validation
- ✓Secondary Current Injection for Overcurrent (50/51) & Earth Fault (50N/51N)
- ✓Transformer Differential (87T), REF & Voltage/Frequency Relay Calibration
- ✓Certified Dynamic Trip Time Characteristic Curves & NABL Reports
Annual Maintenance Contracts (AMC) & Diagnostic Audits
Structured preventive maintenance regimens for industrial substations, high-rise buildings, and manufacturing plants. Includes Contact Resistance Meter (CRM) audits, dynamic circuit breaker timing, insulation resistance (IR) trending, and statutory CEIG renewal audits.
- ✓Digital Contact Resistance Testing (CRM 100A) on Breaker Main Contacts
- ✓Dynamic Open/Close Travel Curve & Contact Bounce Timing Verification
- ✓Pre-Monsoon Substation Yard Overhaul & Transformer Neutral Grounding Audits
- ✓Infrared Thermographic Hotspot Audits & Statutory CEIG Compliance Files
NABL-Traceable Electrical Diagnostic Testing Instruments
We own, maintain, and mobilize our own specialized testing laboratory equipment. Every instrument undergoes annual calibration with traceable certificates submitted with all field test reports.
High Voltage (HV) Tester up to 100kV
Motorized 0 - 100kV AC/DC Hipot Set
Dielectric withstand & breakdown testing of HT switchboards, vacuum interrupters, busducts, and extra-high-voltage power cables
Substations up to 400kV, Thermal Power Plants (NTPC Kudgi, Panki TPS)
Substation Trip, Transformer Fault, or Main Breaker Breakdown?
Unplanned downtime costs millions per hour in heavy manufacturing. Our 24/7 emergency response team mobilizes within 2 to 4 hours with calibrated diagnostic test sets, spare retrofit kits, and specialized engineers to restore energization safely.
Real-World Testing, Retrofit & Commissioning Case Studies
Industrial plants, thermal power stations, and commercial complexes trust Manki Engineers for zero-defect electrical field engineering.
11kV VCB Switchgear Overhaul, Relay Coordination & Contact Audits
Comprehensive on-site overhaul of indoor 11kV vacuum circuit breakers, dynamic open/close timing verification, CRM contact resistance audits, and re-setting of numerical overcurrent relays.
- ✓Restored breaker contact timing within 45ms IEC tolerance
- ✓Micro-ohm CRM resistance reduced by 35% via contact alignment
- ✓Zero unplanned trips during subsequent explosive chemical production cycle
WFGD HT Switchgear Pre-Commissioning & Secondary Current Injection
Full pre-commissioning diagnostic testing of 3.3kV & 415V auxiliary switchgear panels for flue gas desulfurization (WFGD) package. Performed CT ratio/polarity, secondary injection, and busbar hipot.
- ✓100% test reports verified and approved by NTPC site engineering head
- ✓Calibrated primary CT loops preventing false trips during plant synchronization
- ✓Certified zero dielectric breakdown across 415V PMCC and MCC panels
Ash Handling Plant Substation 33kV/11kV Hipot & Cable Testing
Field diagnostic verification of 33kV HT XLPE power cables, motorized 100kV dielectric hipot withstand testing, transformer neutral grounding resistance audits, and CEIG energization clearances.
- ✓100kV AC/DC continuous variable dielectric test with zero leakage faults
- ✓Complete substation grounding grid resistance verified below 0.8 Ohms
- ✓Expedited statutory CEIG safety certification for early unit commissioning
Ready to Upgrade Your Switchgear, Restore Transformer BDV, or Schedule a Testing Crew?
Connect directly with our senior site engineers. Receive customized technical proposals, calibrated test schedules, and transparent mobilization estimates within 24 hours.