Projects

2025

ABB Power Transformer Motor Drive Unit Repair

+1

ABB Power Transformer Motor Drive Unit Repair

Eastern Province, KSA
2025

ElectroCore Arabia successfully executed the replacement of the drive belt and rectification of electrical faults in the Motor Drive Unit (MDU) of an ABB power transformer at Eastern Cement Company. The project involved comprehensive diagnostics, control panel inspection, belt replacement, and full electrical fault rectification to restore optimal transformer operation.

Scope of Work

Diagnostic inspection of Motor Drive Unit and control system
Transformer oil condition assessment via sight glass inspection
Replacement of worn drive belt on motor drive pulley assembly
Electrical fault identification and rectification in control circuits
Control panel wiring inspection and terminal verification
Tap changer mechanism inspection and calibration check
Contactors and relay testing in MDU control cabinet
Full functional testing and commissioning of the MDU

RESULTS Motor Drive Unit restored to full operational condition. All electrical faults rectified. Transformer tap changer operating within manufacturer specifications. Zero defects reported during post-maintenance testing.

2025/2026

Multiple Transformer Internal Inspection, Overhauling & Testing

+8

Multiple Transformer Internal Inspection, Overhauling & Testing

ElectroCore Workshop, Dammam
2025/2026

ElectroCore Arabia carried out multiple power transformer internal inspections, overhauls, and comprehensive testing at our Dammam workshop. The projects involved complete disassembly of transformer active parts, detailed inspection of core and winding assemblies, leakage rectification, gasket replacement, oil filtration, and full electrical testing using OMICRON instruments to restore transformers to reliable operating condition.

Scope of Work

Transformer receipt, external inspection, and oil sampling at workshop
Oil draining and safe disposal per environmental regulations
Removal of transformer active part (core & windings) from tank
Detailed visual inspection of all winding insulation and connections
Core lamination inspection for looseness and hot spot damage
Inspection and testing of OLTC (On-Load Tap Changer) mechanism
Bushing connection and internal lead inspection
Leakage rectification — tank, flanges, manholes, and bushings
Complete gasket replacement on all access points
Oil filtration, vacuuming, and dielectric strength restoration
Reassembly and comprehensive electrical testing (TTR, IR, SFRA, BDV, DGA)
Final commissioning and performance verification

RESULTS All transformers successfully overhauled and tested. Oil BDV restored to above 65kV on all units. Zero leakage confirmed after pressure testing. All electrical parameters within IEC 60076 and manufacturer specifications. Transformers returned to service with extended operational life and warranty documentation.

2025/2026

On-Site Slipring Machining — Multiple Cement Plants

+4

On-Site Slipring Machining — Multiple Cement Plants

Multiple Sites, KSA
2025/2026

ElectroCore Arabia successfully carried out multiple on-site slipring machining jobs at Saudi Cement and Eastern Province Cement facilities. Our mobile machining team performed precision re-machining of worn slipring surfaces on large motor and generator slipring assemblies, restoring proper contact surface finish and runout tolerance to eliminate sparking, overheating, and brush arcing issues. All work was performed on-site to minimize equipment downtime.

Scope of Work

On-site inspection and measurement of slipring wear condition
Runout measurement and surface roughness assessment
Setup of portable slipring machining equipment on motor/generator shaft
Precision machining of slipring contact surfaces to restore original diameter
Groove machining and chamfering of slipring edges
Surface finish verification to Ra 0.8 or better
Concentricity and runout verification post-machining
Brush holder alignment check and adjustment
Brush replacement with correct grade carbon/copper-graphite brushes
Brush seating and contact pressure adjustment
Insulation testing of slipring assembly to earth
Commissioning run and spark-free operation verification

RESULTS All slipring surfaces successfully re-machined to within OEM tolerances. Surface finish restored to Ra 0.8. Runout maintained within 0.05mm. Spark-free operation achieved on all units post-machining. Zero downtime for equipment removal — all work performed on-site. Brush life extended significantly with restored contact surfaces.

2025/2026

Multiple MV/LV Motor Rewinding, Overhauling & Testing

+11

Multiple MV/LV Motor Rewinding, Overhauling & Testing

ElectroCore Workshop, Dammam
2025/2026

ElectroCore Arabia carried out multiple MV and LV motor rewinding, overhauling, and testing projects at our Dammam workshop. The scope included complete stator rewinding for medium and low voltage motors, armature rewind for DC machines, insulation system upgrades, VPI (Vacuum Pressure Impregnation) treatment, and comprehensive electrical and performance testing to restore motors to OEM specifications.

Scope of Work

Motor receipt, identification, and pre-inspection documentation
Complete stripping and removal of old/burnt windings
Stator core cleaning and slot preparation
New coil forming and winding insertion (form wound and random wound)
Inter-turn insulation and phase insulation installation
Connection and lacing of winding leads
Vacuum Pressure Impregnation (VPI) with Class F or H resin
Curing and baking of impregnated windings
DC armature rewinding and commutator inspection
Insulation resistance (IR) and polarization index (PI) testing
Surge comparison testing for inter-turn fault detection
Hi-Pot testing, run testing, and performance verification

RESULTS All motors successfully rewound and tested. Surge comparison and Hi-Pot tests passed on all units. IR values exceeded 500 MΩ. VPI impregnation achieved full penetration with no voids. All motors delivered to clients with test certificates and warranty documentation.

2025

60MVA Power Transformer Bushing Oil Leakage Rectification

+1

60MVA Power Transformer Bushing Oil Leakage Rectification

Jubail Industrial City, KSA
2025

ElectroCore Arabia successfully attended HV and LV bushing oil leakage rectification on a 60MVA power transformer at JANA Chemicals Plant. Our team identified and addressed oil seepage points from the HV and LV bushings, replaced worn-out gaskets and O-rings, and restored the transformer to a stable and reliable operating condition. This intervention ensured improved reliability, minimized downtime, and enhanced overall performance of the transformer.

Scope of Work

Visual inspection and identification of oil seepage points on HV and LV bushings
Oil leakage assessment from top cover gasket and bushing bases
Replacement of worn-out gaskets on all HV porcelain bushings
Replacement of worn-out gaskets on all LV bushings
O-ring replacement on bushing connection interfaces
Bushing base cleaning and surface preparation
Torque verification of all bushing mounting bolts
Oil level check and top-up in conservator
Pressure testing and leak verification on all bushing joints
Insulation resistance testing of windings post-maintenance
Bushing power factor and capacitance testing
Final inspection and handover documentation

RESULTS All HV and LV bushing oil leakages fully rectified. All gaskets and O-rings replaced with OEM-grade material. Zero leakage confirmed after 24-hour pressure test. Transformer restored to stable and reliable operating condition. Downtime minimized and overall transformer performance enhanced.

2025

60MVA Power Transformer OLTC Overhauling & Maintenance

60MVA Power Transformer OLTC Overhauling & Maintenance

Jubail Industrial City, KSA
2025

ElectroCore Arabia performed a complete overhaul and maintenance of the On-Load Tap Changer (OLTC) on a 60MVA power transformer at JANA Chemicals Plant. The project involved full disassembly of the OLTC diverter switch, detailed inspection and cleaning of all contact assemblies, replacement of worn components, and comprehensive functional testing to ensure reliable voltage regulation and extended service life.

Scope of Work

OLTC unit removal from transformer main tank
Complete disassembly of diverter switch assembly
Detailed inspection of all contact fingers and springs
Contact resistance measurement of each tap position
Cleaning of all insulating components and arc chutes
Replacement of worn contact fingers and spring assemblies
Inspection and lubrication of motor drive mechanism
Inspection of transition resistors and reactors
Oil compartment cleaning and oil replacement
Reassembly with all components torque-verified
Timing and synchronization testing of switching sequence
Full functional testing across all tap positions ( Raise & Lower )

RESULTS OLTC diverter switch fully overhauled with all worn contacts replaced. Contact resistance normalized across all tap positions. Timing and synchronization verified within manufacturer specification. Motor drive mechanism lubricated and tested. Transformer returned to service with reliable voltage regulation and extended OLTC service life.

2025

+3

Power Transformer Complete Overhaul

Jubail Industrial City, KSA
2025

ElectroCore Arabia successfully completed the complete overhaul of a power transformer for Gulf Packaging in Jubail. The transformer was safely transported to our workshop after identifying oil leakages from the top cover, bushings, and radiators. Our team carried out a complete overhaul including leakage rectification, servicing, oil filtration, detailed inspection, testing, and reassembly. After successful completion of all maintenance activities, the transformer was reinstalled and commissioned at the client’s site.

Scope of Work

Safe transportation of transformer to ElectroCore workshop
Oil draining and internal/external leakage assessment
Oil leakage arresting from top cover and manholes
Bushing gasket inspection and replacement (all phases)
Radiator gasket replacement and valve servicing
Conservator and Buchholz relay inspection
Oil filtration and vacuuming to remove moisture/contaminants
Complete internal inspection of core and windings
Detailed electrical testing (IR, TTR, SFRA, BDV, DGA)
Reassembly with all new gaskets and seals
Reinstallation and commissioning at client site
Post-commissioning monitoring and handover documentation

RESULTS All oil leakages fully rectified. Oil BDV restored to 68kV. All gaskets replaced with OEM-grade material. Transformer successfully reinstalled and commissioned at Gulf Packaging site. Full compliance with IEC standards and client safety procedures. Extended operational life achieved.

2025

100MVA Power Transformer Corrective Maintenance

+1

100MVA Power Transformer Corrective Maintenance

Riyadh Al Kharj Substation
2025

ElectroCore Arabia carried out comprehensive corrective maintenance on a 100MVA power transformer at SEC National Grid Riyadh Al Kharj substation. The scope included leakage arresting, gasket replacement across all flanges and access points, transformer oil filtration and vacuuming, and PRD & Buchholz relay gasket replacement to restore transformer integrity and prevent future oil leaks.

Scope of Work

Leakage arresting from transformer tank, flanges, and bushings
Complete gasket replacement on all manholes and handhole covers
Bushing gasket inspection and replacement
Transformer oil filtration and vacuuming to remove moisture and particulates
Oil dielectric strength (BDV) testing before and after filtration
PRD (Pressure Relief Device) gasket replacement
Buchholz relay gasket replacement and float testing
Conservator and silica gel breather inspection
Radiator valve and connection gasket replacement
Final pressure test and leak verification
Post-repair testing (TTR, IR, SFRA, PD, BDV)
Post-maintenance electrical testing (IR, TTR, SFRA)
Re-commissioning and energization support

RESULTS All oil leaks successfully arrested. Oil BDV improved from 35kV to 72kV after filtration. PRD and Buchholz relay resealed and function-tested. Transformer returned to service with zero leakage and all electrical parameters within SEC specifications.

2026

Transformer Internal Inspection — PD Root Cause Analysis

Transformer Internal Inspection — PD Root Cause Analysis

ElectroCore Workshop, Dammam
2026

ElectroCore Arabia conducted a comprehensive internal inspection of a power transformer at our Dammam workshop to identify and resolve the root cause of elevated partial discharge (PD) levels detected during routine testing. The project involved complete disassembly, detailed visual and dimensional inspection of all windings and insulation systems, and root cause determination with corrective recommendations.

Scope of Work

Transformer transportation to ElectroCore workshop
Complete oil draining and safe disposal
Core and windings removal from transformer tank
Detailed visual inspection of all winding insulation
Dimensional check of winding geometry and clearances
Insulation barrier and shield inspection
Tap changer contact and mechanism inspection
Bushing connection and lead inspection
Partial discharge source identification and documentation
Corrective repair plan and reassembly
Post-repair testing (TTR, IR, SFRA, PD, BDV)
Final commissioning and energization support

RESULTS Root cause of partial discharge successfully identified as insulation degradation and winding displacement. Corrective repairs implemented. Post-repair PD levels reduced to within IEC 60076-3 acceptable limits. Transformer returned to full service with extended operational life.

2024

132kV Power Transformer Overhaul

Dammam Substation
2024

Complete overhaul of a 50MVA, 132/13.8kV power transformer including oil replacement, bushing replacement, and full electrical testing schedule.

Scope of Work

Oil draining and internal inspection
Bushing replacement (HV & LV)
Oil purification and refilling
Complete electrical test schedule (TTR, IR, SFRA, DGA)
Commissioning and energization support

RESULTS Transformer returned to service with all tests passing. Client reported improved performance and reduced noise levels.

2024

33kV Switchgear Commissioning

Jubail Industrial City
2024

Installation, testing, and commissioning of new 33kV switchgear panels including protection relay settings and coordination studies.

Scope of Work

Switchgear installation supervision
Primary and secondary injection testing
Protection relay calibration and settings
CT/VT polarity and ratio verification
End-to-end protection testing

RESULTS Successful energization on first attempt. All protection schemes verified and coordinated per client specifications.

2023

11kV Cable Fault Location & Repair

Eastern Province
2023

Emergency response for cable fault on critical 11kV feeder supplying production facility. Fault located, excavated, and repaired within 48 hours.

Scope of Work

Cable fault location using TDR and surge generator
Excavation and fault identification
Cable jointing and termination
VLF testing and PD measurement
Route documentation update

RESULTS Power restored within 48 hours of initial call. Zero production downtime for the client facility.

ABB Power Transformer Motor Drive Unit Repair

Scope of Work

Multiple Transformer Internal Inspection, Overhauling & Testing

Scope of Work

On-Site Slipring Machining — Multiple Cement Plants

Scope of Work

Multiple MV/LV Motor Rewinding, Overhauling & Testing

Scope of Work

60MVA Power Transformer Bushing Oil Leakage Rectification

Scope of Work

60MVA Power Transformer OLTC Overhauling & Maintenance

Scope of Work

Power Transformer Complete Overhaul

Scope of Work

100MVA Power Transformer Corrective Maintenance

Scope of Work

Transformer Internal Inspection — PD Root Cause Analysis

Scope of Work

132kV Power Transformer Overhaul

Scope of Work

33kV Switchgear Commissioning

Scope of Work

11kV Cable Fault Location & Repair

Scope of Work

Location :

Dahan Trading Center, Al Sinaiyah District, Dammam, 32443

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Location :

Abu Hurairah Street, ⁠An Nadim District, Dammam , Al Khodaryah, 32243

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Location :

Al Muhajir Bin Abi Umayah Street, An Nada District, Dammam, Al Khodaryah, 32435

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