Discover our innovative monitoring and management solutions that help energy operators secure better customer outcomes and realise greater returns from their network infrastructures.
At Camlin we’re engineering better futures. We want tomorrow to be better than today. For our customers. For their customers. For our own people. And for the wider world around us.
Discover our innovative monitoring and management solutions that help energy operators secure better customer outcomes and realise greater returns from their network infrastructures.
At Camlin we’re engineering better futures. We want tomorrow to be better than today. For our customers. For their customers. For our own people. And for the wider world around us.
Transformers are integral to the success of renewable power projects, stepping up or stepping down voltages to ensure the reliable transmission of electrical power. While they are engineered for long service life, transformers can fail due to various internal and external factors. Understanding the critical components of a transformer and their failure modes is crucial for asset maintenance teams seeking to prevent costly downtime and extend transformer lifespan.
Key Transformer Components
Core
The core of a transformer is made of laminated sheets of silicon steel, which are magnetically coupled to the windings. It serves as the pathway for the magnetic flux created by the electrical current.
Failure Causes: Core faults are rare but can occur due to mechanical stress, overheating, or contamination from moisture or oils.
Windings
These copper or aluminum wire coils are essential for creating the transformer’s magnetic field. They are divided into primary and secondary windings.
Failure Causes: Overloading, short circuits, or insulation breakdown can cause the windings to overheat and ultimately fail. The windings are also vulnerable to damage from external physical stress.
Insulation System
The insulation is critical for preventing electrical short circuits between windings and ensuring the safe operation of the transformer. The most common materials used are paper, oil, and synthetic compounds.
Failure Causes: Insulation failure typically results from overheating or the ingress of moisture. Poor maintenance or operating outside design limits accelerates the aging of insulation materials.
Tap Changer
The tap changer allows for adjusting the voltage ratio between primary and secondary windings, typically under load. This component is vital for voltage regulation.
Failure Causes: Tap changer failure can occur due to mechanical wear, excessive electrical stress, or contamination within the device. Malfunctioning tap changers can lead to voltage instability, causing severe system disruptions.
Bushings
Bushings are the insulated conductors through which electricity enters and exits the transformer, linking it to the external power network.
Failure Causes: Bushing failure is often caused by moisture, electrical flashovers, or physical damage, which can lead to dangerous faults.
Cooling System
Transformers generate heat during operation, and cooling systems (such as oil or air coolers) are used to dissipate this heat and prevent overheating.
Failure Causes: Cooling system failures typically result from low oil levels, pump failures, or blocked vents. Inadequate cooling accelerates wear on transformer components and can lead to catastrophic failure.
Why Transformers Fail: Common Causes
Overload and Overheating: Excessive current can cause overheating, leading to insulation failure and winding damage.
Electrical Faults: Faults like short circuits or ground faults can damage windings and other transformer components.
Moisture and Contamination: Moisture intrusion can compromise insulation, leading to short circuits and rapid degradation of components.
Mechanical Stress: Physical damage or vibrations can affect core alignment, winding integrity, or other sensitive parts.
Aging: Over time, components like insulation degrade, increasing the likelihood of failure.
How can Kelvatek's TOTUS proactively help prevent failures
TOTUS is a powerful tool designed to provide real-time health monitoring for your transformer assets. By continuously tracking key performance indicators (KPIs) such as temperature, oil level, and tap changer status, the TOTUS monitor helps identify early signs of stress or failure, allowing maintenance teams to intervene before problems escalate.
Key Benefits of TOTUS:
Real-Time Monitoring: It provides up-to-the-minute data on transformer health, including windings, insulation condition, and cooling system performance.
Proactive Alerts: TOTUS generates alerts for abnormal conditions such as overheating, excessive vibration, or moisture, enabling pre-emptive action.
Predictive Insights: By analysing trends over time, the monitor can predict potential failures, reducing the risk of unexpected downtime.
Easy Integration: TOTUS can be easily integrated with existing transformer setups to provide seamless monitoring without disrupting operations.
Transformers are essential but vulnerable components of electrical power systems, and their failure can result in significant downtime and repair costs. Understanding the key components and their failure modes is vital to keeping these assets in top working condition. With the correct transformer monitoring solution, operators can ensure the ongoing health of transformers, enabling efficient and reliable power distribution.
