Ways to Troubleshoot Common Factory Power Issues of Transformer

1. Overheating

Increased temperatures are the most common problem in industrial transformers. It can be caused by too much load on the transformer, insufficient cooling and ventilation, or faults in other operational factors. Excessive overheating causes the insulation to melt, leading to lower transformer efficiency.

2. Fluctuating Voltage

The irregular and uncontrolled voltage output to devices such as motors, CNC machines, electronic test equipment, etc, severely damages the industrial processes. This problem usually stems from an inconsistent power supply, transformer overloading, or loose connections to the transformer.

3. Oil Leakage In Oil-Immersed Transformers

Oil leakage in the transformer greatly reduces the insulating and cooling mechanisms, ultimately (and usually) resulting in transformer failure. Such leakages usually occur due to ageing gaskets, container ring cracks, or insufficient sealing after maintenance.

4. Humming/Vibrating Transformers

The general sound in a working transformer is a faint humming sound, but in the case of loose components, the sound changes to dynamic or excessive vibrations. This results in issues such as core bolted lamination coming loose, increased magnetostriction, or failure in mounting. Such issues could allow energy to go to waste and cause eventual mechanical damage.

5. Insulation Breakdown

Poor insulation tends to be one of the leading factors in transformer breakdowns. As a result of aging, moisture exposure, or chemical contamination, this leads to short circuits or lowered performance.

Addressing Overheating

Overheating in transformers can be caused due to overloading. So, the first step is ensuring that the transformer operates at its rated load capacity. In addition, systems available can be installed to monitor and best manage transformer load, which are recommendable.
Transformers should also be effectively ventilated to address overheating. This can be done by ensuring air circulation around and inside the transformer and cleaning or replacing any fans and radiators that may be blocked.
Moreover, the oil or air cooling systems should be regularly checked alongside their components to ensure the finest transformer operations.

Resolving Voltage Fluctuations

When there is a change in voltage variation, loose connections in the cables and terminal block should be tightened. Thermal imaging could be used to help find hidden “hot spots.”
Go one step further and install voltage regulators; these could be automatic voltage regulators or tap changers, but the goal is to maintain better output voltage stability.
Eliminating power fluctuations could also be done by redistributing electrical loads that are typically unbalanced. Instead, they can be distributed evenly to all the transformer phases, vertical imbalance.

Fixing Oil Leakage

The first step in reducing oil leaks is a regular inspector of the transformers. Infrared thermography and oil level indicators can also be used to detect leakage.
Furthermore, if the gaskets are subjected to damage or amplification, these should be replaced as they should always ensure sealing.
Newer gasket methods could prevent future leaks, any cracks in oil tanks or other structure components must be addressed immediately.

Reducing Humming or Vibrations

Loosage of core bolts could take place. Check them and the frame to tighten all core bolts. This will result in a vibration reduction.
Use pads and bolts to fix the transformer, to securely prevent vibrations.
Loose core laminations should be either repaired or replaced.

Preventing Insulation Failure

To prevent insulation With a megger, conduct insulation resistance tests to get an idea of the insulation’s condition.
Prevent Moisture Ingress: Dehumidifiers and vent breathers with silica gel to keep the transformer dry.
Use the Best Materials: Replace insulation that is worn out with materials that are high-quality and long-lasting.

What causes overheating in transformers?

Poor ventilation, excessive load, and lack of cooling systems are the red flags of overheating. Constant performance checks can sort this issue out.

How to detect the leakage of oil from transformers?

All it takes is visually looking around, carrying out infrared thermography, and regularly monitoring oil levels with the indicators.

My transformer is making a loud humming noise. What could be the reasons?

Humming sounds can be associated with loosening bolts, poor mounting, or core lamination. If these problems are analyzed and solved, the noise should go away.

Insulation failure in transformers can be prevented by?

Moisture exposure is a common problem for transformers. Regular insulation resistance tests should be carried out, and high-quality insulation materials should be used.

Which tools are needed to troubleshoot transformers?

Troubleshooting transformers require the usage of thermal imaging cameras, meggers, soil testing kits, and even voltage regulators. These tools are necessary for effective inspection.
Make sure that factory operations remain uninterrupted using reliable transformers from Makpower Transformer. Reach out today to find out more about our products and services. Together, we’ll power your success!