HINDUSTAN BROWN BOVERI Repair Services India
Hindustan Brown Boveri (HBB) is India's flagship electrical equipment manufacturer, established in 1956 as a joint venture with Switzerland's Brown Boveri & Cie. Headquartered in Bangalore, HBB designs and manufactures synchronous motors, induction motors, transformers, and electrical drive systems serving Indian power generation, steel, cement, and manufacturing sectors. The company holds a dominant market position in large synchronous motors for hydro and thermal power plants across India.
Hindustan Brown Boveri (HBB) is India's flagship electrical equipment manufacturer, established in 1956 as a joint venture with Switzerland's Brown Boveri & Cie. Headquartered in Bangalore, HBB designs and manufactures synchronous motors, induction motors, transformers, and electrical drive systems serving Indian power generation, steel, cement, and manufacturing sectors. The company holds a dominant market position in large synchronous motors for hydro and thermal power plants across India.
Synchronics Electronics specializes in repairing the complete HBB product ecosystem — synchronous motors, wound-rotor induction motors, thyristor-based excitation systems, motor control centers, and associated industrial electronics. With 28+ years of repair expertise, our 180+ engineers understand HBB's unique construction, winding patterns, and control architectures. Indian plant managers trust Synchronics for rapid HBB motor diagnostics, armature rewinding, rotor bar replacement, and excitation rectifier board repairs — minimizing critical production downtime.
Expert HBB synchronous motor and excitation system repair across Indian industrial plants.
HINDUSTAN BROWN BOVERI Product Lines We Repair
Our engineers are trained on the full HINDUSTAN BROWN BOVERI product range. Below are the major product families we service.
Synchronous Motors (Hydro and Thermal Grade)
High-capacity synchronous machines rated 100 kW to 200+ MW for power generation. Common issues include rotor winding insulation breakdown, slip ring carbon deposit buildup, bearing wear, and field excitation system failures leading to loss of synchronism or voltage instability.
Wound-Rotor Induction Motors
Medium to large wound-rotor motors used in cement mills, steel plants, and pump applications. Typical faults include rotor winding phase-to-phase shorts, slip ring pitting and electrical asymmetry, brush wear causing erratic starting current, and rotor cage bar cracks under mechanical shock.
Thyristor Excitation and Voltage Regulator Systems
Static excitation rectifiers and automatic voltage regulation (AVR) modules for synchronous generator control. Prone to thyristor gate drive failures, DC smoothing capacitor degradation, firing angle control card faults, and CT-VT secondary winding insulation breakdown.
Motor Control Centers and Soft Starters
Integrated electrical control panels for large motor starting and protection in Indian industrial plants. Issues include contactor coil burnout, thermal overload relay calibration drift, soft starter power module failure, and control circuit transformer secondary short.
Slip Ring Assemblies and Brush Gear
Critical rotating contacts for wound-rotor motor excitation and signal transmission. Degradation causes intermittent electrical connection, variable starting torque, heating at brush contact, and eventual electrical flashover damaging rotor coil insulation.
Power Transformers and Isolation Transformers
Oil-cooled and dry-type transformers for motor control circuits and auxiliary power supply. Common faults include primary-secondary winding short, core lamination insulation loss, moisture ingress in winding insulation, and cooling fan motor failure in forced-air variants.
Why Choose Synchronics for HINDUSTAN BROWN BOVERI Repairs?
PCB-Level Expertise
We repair down to the component level — not just swap boards. Our engineers identify root causes, replace failed IGBTs, capacitors, processors, and gate drivers on HINDUSTAN BROWN BOVERI equipment.
Fast Turnaround
Standard 7–10 working days. Express 3–5 days available for critical breakdowns. Emergency same-day/next-day service for unplanned downtime.
6-Month Warranty
Every repaired unit ships with a 6-month comprehensive warranty on parts and labour. Our repair success rate is over 94% across all brands.
All-India Service
Couriered repairs accepted from any city in India. Doorstep pickup available in Vadodara, Mumbai, Pune, Ahmedabad, Surat, Chennai, and more.
Common HINDUSTAN BROWN BOVERI Equipment Faults We Fix
Based on 30+ years of repair data, these are the most frequent failure modes we see in HINDUSTAN BROWN BOVERI equipment arriving at our workshop.
- ✓Synchronous motor loss of field or hunting oscillation — HBB synchronous motors experience loss of synchronism when field excitation voltage drops suddenly due to thyristor rectifier failure, AVR control card malfunction, or rotor field winding open circuit. This causes motor to fall out of step, generate large rotor currents, and risk mechanical damage to coupling and foundation.
- ✓Slip ring and brush wear causing intermittent excitation connection — HBB wound-rotor motors and synchronous machines require continuous low-resistance brush-to-slip-ring contact for rotor field current. Carbon brush wear, slip ring groove formation, and copper oxidation increase contact resistance, creating voltage drop and arcing. Moisture and dust accelerate corrosion, especially in humid Indian coastal and tropical environments.
- ✓Rotor winding phase-to-phase short or ground insulation failure — HBB wound-rotor induction motors have rotor coils exposed to mechanical stress, temperature cycling, and moisture ingress. Insulation paper degradation, partial discharge activity at high voltage stress, and thermal aging cause inter-phase shorts. Rotor cage bar cracks under starting current surges create circulating currents and localized heating leading to secondary winding damage.
- ✓Thyristor or power diode short circuit in excitation rectifier bridge — HBB static exciter thyristor modules operate under continuous full-wave rectification with high reverse voltage stress. Gate drive circuit failures, overvoltage transients from generator short circuits, or manufacturing defects in thyristor junction cause forward bias leakage and thermal runaway. Shorted thyristors trigger overcurrent in DC circuit, disabling generator field control.
- ✓Contactor coil burnout or inadequate pull-in voltage in HBB motor starters — HBB motor control centers experience contactor coil failures due to sustained overvoltage (control transformer loose connection), coil insulation wear from vibration, or duty cycle exceeding contactor rating. Voltage dips during motor soft-start or generator transients prevent sufficient electromagnetic force, causing chattering and welded contacts.
- ✓Motor cooling fan failure reducing ventilation and causing thermal overload trips — Large HBB synchronous and wound-rotor motors use forced-air cooling fans driven by small AC or DC motor. Fan bearing seizure, belt slippage, or motor winding burn-out reduces airflow, raising motor surface temperature. Thermal protection relay trips prematurely, interrupting production. Common in Indian industrial plants with high ambient temperatures and dusty environments.
How We Repair Your HINDUSTAN BROWN BOVERI Unit
Receive & Log
Your unit is logged into our tracking system with a unique job number. You receive WhatsApp / email updates at every stage.
Fault Diagnosis
Board-level diagnosis using oscilloscopes, LCR meters, and thermal cameras. Root cause identified before any repair begins.
Component Repair
Faulty ICs, capacitors, MOSFETs, IGBTs, and gate drivers replaced with genuine or equivalent-spec components.
Full-Load Test
Unit tested under rated load with original or equivalent motor. All parameters verified. 6-month warranty issued.
Industries Using HINDUSTAN BROWN BOVERI Equipment
We serve plant maintenance teams across all major industries where HINDUSTAN BROWN BOVERI automation is deployed.
Frequently Asked Questions — HINDUSTAN BROWN BOVERI Repairs
Do you repair Hindustan Brown Boveri synchronous motors at your Vadodara facility?+
Yes, absolutely. Synchronics is an authorized HBB repair partner with specialized expertise in large synchronous motors (100 kW to 200+ MW) used in Indian power plants and industrial facilities. We handle complete motor overhauls including rotor and stator rewinding, slip ring restoration, bearing replacement, and full-load factory testing. We offer PAN India pickup and delivery from all major cities — Mumbai, Delhi, Hyderabad, Chennai, Pune, Ahmedabad, and beyond.
What is your turnaround time for HBB synchronous motor repair and rewinding?+
Standard turnaround is 3-4 weeks for medium-capacity motors (100-500 kW) and 4-6 weeks for large turbogenerator-coupled units. This includes receipt inspection, disassembly, winding design verification, rewinding execution, insulation treatment, mechanical assembly, and full-load factory test. Expedited repair (10-15 days) is available for critical motors affecting production revenue. We provide daily progress updates and photographic documentation of all repair stages.
How do I know if my HBB motor's insulation has failed and needs rewinding?+
Key warning signs include: (1) Megger insulation resistance dropping below 1 MΩ when motor is cold and dry, (2) Arcing or burning smell from motor ventilation during operation, (3) Thermal overload relay tripping prematurely at rated load, (4) Phase-to-ground voltage imbalance measured at motor terminals, (5) Visible scorch marks or discoloration inside motor terminal box. Synchronics performs free diagnostic megger testing and insulation breakdown analysis to determine rewinding necessity. We generate detailed condition reports with repair recommendations.
Can you repair HBB wound-rotor induction motors used in Indian textile and cement mills?+
Yes. HBB wound-rotor motors are extensively used in Indian textile spinning plants and cement mills for variable-speed control. Synchronics repairs rotor winding shorts, replaces worn slip rings and carbon brushes, and rebuilds rotor cage bars if cracked. We stock genuine HBB slip ring carbon brush grades and magnet wire suitable for rotor rewinding to original specifications. We also test rotor liquid rheostat control systems if used for speed variation.
What happens if HBB static exciter thyristors fail in a power plant generator?+
Thyristor failure in HBB generator excitation systems causes immediate loss of field voltage regulation and risk of generator paralleling instability or blackout. The generator may quickly lose synchronism, triggering automatic protection schemes and emergency shutdown. Synchronics maintains a stocked inventory of thyristor modules and gate drive circuit assemblies compatible with HBB static exciter designs used in Indian thermal and hydro power stations. We offer emergency same-day dispatch and rapid on-site replacement if requested.
How do I send my HINDUSTAN BROWN BOVERI unit for repair?+
Pack the unit securely and courier it to our Vadodara workshop. Include a note with the fault description and your contact details. We will log it into our system and WhatsApp you a job number within 24 hours of receipt. Doorstep pickup is available in Vadodara, Ahmedabad, Surat, Mumbai, and Pune.
What is the cost of repairing a HINDUSTAN BROWN BOVERI drive or PLC?+
Repair cost depends on the model and the fault. We offer a free diagnosis — once we identify the fault, we provide a fixed quotation before proceeding. Typical repairs cost 20–40% of the new unit price. We will never repair without your approval.
What warranty do you provide on HINDUSTAN BROWN BOVERI repairs?+
All repaired units carry a 6-month comprehensive warranty covering the same fault and related issues. If the fault recurs within the warranty period, we repair it free of cost.
Do you provide a no-fix, no-fee guarantee?+
Yes. If we cannot repair your HINDUSTAN BROWN BOVERI unit after diagnosis, you pay only the diagnosis fee (₹500–₹1,500 depending on the product). The unit is returned to you at no additional charge.
HINDUSTAN BROWN BOVERI Repair Catalog
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Free evaluation • 6-month warranty • PAN India pickup
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Send us your faulty industrial electronics. Our engineers will diagnose it and provide a detailed quote within 24 hours — with no obligation to proceed.
Free Evaluation
No obligation
48hr Turnaround
Fastest in India
6-Month Warranty
Every repair
No Fix, No Charge
Zero risk policy
Pan-India Pickup
Doorstep service