Extending the Life of Critical Energy Infrastructure at a UK Waste-to-Energy Facility
18 February | Castlet
Sector: Industrial
We are delivering a rolling transformer rectifier refurbishment programme at a UK waste-to-energy facility, extending the life of 20-year-old equipment while keeping the plant fully operational.
THE CHALLENGE
In waste-to-energy facilities, electrostatic precipitators (ESPs) rely on transformer rectifiers (TRs) to operate safely, efficiently, and continuously. Castlet has worked with this waste-to-energy plant for over 20 years, having initially supplied five ESPs – each with two TRs – and routinely serviced them ever since.
During a recent proactive site visit, our engineers identified that some of the equipment originally supplied by Castlet had been operating in challenging conditions – with the steel TR tanks becoming heavily corroded due to prolonged exposure to standing water.
While the TRs themselves remained largely functional and some of the internal transformer components were still serviceable, the integrity of the tanks posed a growing risk.
The client required a solution that would:
As a long-standing service provider, we proactively recommended a detailed site survey and refurbishment strategy spanning several months.
We visited the site and performed a survey of the control cubicles and TR units, then agreed on a mix of new equipment and rehabilitation of existing units. With this approach, we were able to reduce costs and the time required to complete the work to ensure minimum plant downtime. It was a pleasure to continue our longstanding relationship with the client and work on this project with our production staff!
Ian Fox, Industrial Sales Manager at Castlet
Our Solution
A bespoke refurbishment strategy
We began with a full site survey and comprehensive testing of all ten TR units on site. This involved electrically testing each transformer to assess its condition and identify any underlying issues.
Following this, we designed a rolling refurbishment programme, allowing two TRs to be removed at a time and refurbished off-site while the remaining units continued to run, supporting plant operations. This ensured no disruption would be caused to the waste-to-energy process, with ESPs taken offline one at a time.
The refurbishment and re-tanking process
We collected and transported two TR units at a time to Castlet’s Lincoln facility to undergo a detailed diagnostic and refurbishment process.
This started with full electrical testing in a high-voltage test cage to assess the transformer’s condition and performance. The transformers were then drained of oil, the internal assembly lifted clear, ready for visual inspection to determine reuse or replacement.
Where tanks were heavily corroded, we manufactured new steel tanks. We reused transformer components that were still serviceable, only integrating new components where necessary.
The units were then reassembled, refilled with oil, and electrically tested before we returned them to the client’s site.
Extending equipment lifetime and avoiding downtime
Our approach delivered a cost-effective solution for this waste-to-energy plant, reusing components of the transformers from the old tanks where feasible and reducing waste.
Most importantly, however, we were able to reduce the time required to implement the work to ensure minimum plant downtime, so they could maintain optimal performance. We successfully extended the life of the units by many more years.
This project highlights our long-term commitment to the equipment we supply, from initial manufacture through to mid-life extension and beyond.
Supporting equipment through its full lifecycle through planned maintenance and refurbishment is a key part of how we help our clients maintain optimal performance. As ESP systems across the industrial sector continue to age, planned refurbishment programmes are a valuable alternative to whole replacement.
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