Power outages are a major inconvenience, disrupting homes, businesses, and infrastructure.

One of the leading culprits behind these outages is power transformer failures. 

This not only disrupts the smooth operation of devices but can also cause serious damage to the equipment which in turn poses safety risks. 

Read along to learn more about the most common transformer failures, their causes, and solutions to your problem. 

Here are the Top 9 causes of Transformer Failure

1. Overloading

Transformers are designed to handle a specific amount of electrical current. If you consistently demand more power than the transformer is rated for, it will work overtime to meet that demand. 

This overexertion leads to excessive heat generation. The transformer’s insulation system is designed to withstand normal operating temperatures, but prolonged overheating can break down the insulation, allowing current to flow where it shouldn’t. 

This can lead to arcing, and faults, and ultimately, becomes a cause of transformer failure.

2. Aging

Like any machine, transformers degrade over time. The insulating materials that are used to separate the transformer’s windings weaken due to natural processes and constant electrical stress. 

This weakens the transformer’s ability to contain the electrical current, increasing the risk of faults and breakdowns. 

Regular maintenance and condition monitoring become even more crucial as transformers age.

3. Moisture Ingress

Transformers typically use insulating oil to cool the windings and prevent arcing. However, if moisture gets into the oil, it significantly reduces its insulating properties. 

Water conducts electricity much better than oil, and even small amounts of moisture can create a path for current to flow incorrectly. 

This can lead to arcing, and overheating, and eventually becomes a cause of transformer failure.

4. Lightning Strikes

Power surges from lightning strikes can induce high voltages in transformers, even if they don’t strike the transformer directly. 

These surges can damage the transformer’s delicate windings and insulation, leading to short circuits and permanent damage.

5. Loose Connections

Over time, connections within the transformer, particularly at terminals and tap changers, can loosen due to vibration or thermal cycling. 

Loose connections create high resistance points, which act like bottlenecks for electricity. 

This localized resistance generates excessive heat, which can damage surrounding components and eventually lead to a more serious fault.

6. Faulty Bushings

Bushings are specially designed insulators that allow high-voltage cables to enter and exit the transformer. They are critical for maintaining the electrical integrity of the system. 

If the bushings crack, leak oil, or experience internal faults, they can compromise the transformer’s insulation and lead to flashovers or short circuits.

7. Tap Changer Issues

Many transformers have tap changers that adjust the output voltage. These tap changers have moving parts that can wear out mechanically or develop electrical problems. 

A malfunctioning tap changer can result in incorrect output voltage, overloading downstream equipment, or even internal faults within the transformer itself.

8. Improper Maintenance

Regular inspections, oil testing, and cleaning are crucial for keeping transformers operating efficiently and preventing problems.  

Neglecting these maintenance practices can lead to a buildup of dirt and contaminants in the insulating oil, increasing the risk of overheating and faults. 

9. Environmental Factors

Transformers are not immune to their surroundings. Extreme temperatures, high humidity, dust, and corrosive environments can all accelerate the deterioration of transformer components. 

Excessive heat can degrade insulation materials, while dust and contaminants can accumulate on windings, reducing heat dissipation and increasing operating temperatures. 

Corrosive environments can attack metal components which leads to premature failure.

How to Reduce the Risk of Transformer Failure

• Regular Maintenance: Scheduled inspections, oil testing, and cleaning are crucial for preventing problems and identifying minor issues before they create issues.
• Proper Loading: Ensure transformers aren’t overloaded. Consistently exceeding capacity significantly increases the risk of overheating and failure.
• Environmental Controls: Reduce environmental factors that contribute to deterioration. Shelter transformers from extreme weather or implement dust filtration in dusty areas.
• Moisture Monitoring: Regularly monitor insulating oil for moisture content to prevent water contamination and potential outages.
• Connection Tightening: Regularly tighten electrical connections to prevent loose connections, hot spots, and arcing faults.

By implementing these preventative measures, you can significantly increase the lifespan and reliability of your transformers and reduce the cause of transformer failure.

How EVR Power Can Help You? 

At EVR Power, we understand the important role that transformers play in your operations. 

Our team of experts can help you identify potential problems before they cause outages. We offer the following services, including:

• Transformer testing and diagnostics: We use advanced techniques to assess the health of your transformers and identify any developing issues.
• Preventative maintenance: Regular maintenance helps extend transformer life and prevent costly failures.
• Repair and refurbishment: Our skilled technicians can restore your transformers to optimal performance.

EVR Power transformers are built with the highest quality materials and expertise.  We offer several advantages such as:

Durability and Reliability

We use only the finest, proven materials in our transformers. This ensures they can withstand demanding operating conditions, including high temperatures, vibrations, and electrical stresses.

Our transformers are built to meet strict engineering standards and undergo thorough quality control checks throughout the manufacturing process. This minimizes the risk of defects and ensures consistent performance.

Efficiency

EVR transformers are designed to minimize energy losses during operation. This helps to obtain significant cost savings on your electricity bills over the transformer’s lifespan.

We incorporate efficient cooling mechanisms to keep operating temperatures within optimal ranges. This not only improves efficiency but also extends the life of the transformer.

Safety

EVR transformers come equipped with a range of safety features designed to protect personnel and equipment in case of faults or malfunctions. 

These may include:

• pressure relief valves
• liquid level gauges
• fire-retardant materials

Our transformers are manufactured with all relevant safety regulations. This ensures they meet the highest safety standards for personnel working around them.

Final Thoughts

We have seen the top 9 causes of transformer failure and how to reduce the risk of transformer failure.

Keep in mind the points before being confused about how the transformer failure occurred. 

By choosing EVR Transformers, you gain more than just a reliable piece of equipment. You gain peace of mind knowing you are in safe hands for the long run.

FAQs 

1. What are the signs of transformer failure?

• Excessive heat is a common indicator of potential trouble. Unusual hot spots on the transformer or abnormally high oil temperatures can signal overloading, failing insulation, or cooling system issues.
• Transformers typically produce a low hum during operation. However, if you hear a significant increase in noise levels, crackling sounds, or hissing, it could indicate loose connections, internal faults, or arcing.
• A burning smell emanating from the transformer is a serious cause for concern. It could indicate overheating insulation or electrical faults, and immediate action is necessary.
• Fluctuations in output voltage, significant drops in voltage, or asymmetrical voltages can all be signs of internal problems within the transformer.
• Physical damage to the transformer, such as bulging, cracks, leaks, or oil spills, can indicate internal faults or stress on the transformer.

2. What happens if a transformer fails?

• Power Outages: A transformer failure can disrupt power delivery to the surrounding area, leading to outages for homes and businesses.
• Equipment Damage: The surge of voltage or current caused by a failing transformer can damage other electrical equipment connected to the system.
• Fire Hazards: In severe cases, transformer failures can lead to electrical fires, posing a significant safety risk.

It’s essential to have a plan in place to deal with transformer failures. This may involve having backup power supplies or procedures for safely isolating and repairing failed transformers.

3. How long do transformers last?

The lifespan of a transformer depends on several factors, including:

• Quality of Manufacturing: Well-built transformers from reputable manufacturers tend to last longer.
• Operating Conditions: Transformers subjected to overloading, extreme temperatures, or harsh environments will have a shorter lifespan.
• Maintenance Practices: Regular maintenance and timely repairs significantly extend the life of a transformer.

Under ideal conditions, with proper maintenance, transformers can last anywhere from 20 to 40 years or even longer. However, it’s crucial to monitor their health and replace them before they fail completely.

4. How much does a transformer cost?

The cost of a transformer varies depending on several factors, including:

• Size and Capacity: Larger transformers with higher capacities naturally cost more.
• Features: Transformers with advanced features, such as on-load tap changers or special cooling systems, will be more expensive.
• Manufacturer: Different manufacturers may have varying pricing structures.

The cost of a transformer can range from a few thousand dollars for small distribution transformers to hundreds of thousands of dollars for large power transformers.

5. How do I get in touch with EVR Power?

You can either visit their website or give them a call for a more personalized approach. You can reach out to their customer service team at +91 44 29570117. Or you can email your questions to info@evrpower.com.