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The power transformer is the “heart” of the project’s power supply system, and its stability directly determines the normal operation of the project. But have you thought deeply about the causes of transformer failure? What are the symptoms of transformer failure? How much loss will the project suffer if there is a power transformer failure?
This article will provide an in-depth analysis of the consequences, root causes, and early warning symptoms of transformer failures, helping you build a “defense line” before choosing a supplier.
For buyers, a power transformer failure is not simply a piece of equipment malfunction; it can trigger a series of chain reactions: production stoppages, decreased customer trust, and even safety hazards. You are not just buying a piece of equipment, but a “power supply guarantee” for your project.
Transformer failures can lead to power outages for downstream equipment, production lines, or the entire region, potentially causing sudden shutdowns of industrial projects and resulting in direct economic losses.
When the power grid’s relay protection device detects a fault, it will trip, but this will cause the power supply range to expand further, and it will take time and effort to restore power after troubleshooting and resetting the system.
Faults can cause internal damage such as winding short circuit, core burning, and insulation damage. Minor faults can be repaired, but in severe cases, the transformer needs to be replaced as a whole.
When an oil-immersed transformer malfunctions, the insulating oil may overheat and burn, producing dense smoke; if the internal pressure is too high, it may also cause an explosion, endangering personnel safety and surrounding facilities. Chuanli oil-immersed transformers are equipped with explosion-proof oil tanks and pressure relief devices to minimize such risks.
Even if the fault does not cause a complete power outage, it may cause voltage fluctuations and potentially damage sensitive electronic equipment and precision instruments, resulting in secondary losses.
Troubleshooting, purchasing spare parts, and repairing or replacing equipment typically takes several hours or even days. Excessive downtime can cause even greater losses to the project (such as order delays and customer loss).
O failure of power transformers is not accidental, but the result of the accumulation of problems in design, use, and maintenance.
The insulating material is the “protective barrier” of the transformer. After long-term use, it will age due to high temperature and the electric field action. If the insulating strength is reduced to a certain extent, it will cause a short circuit and trigger a fault. Chuanli adopts F-class and above aging-resistant insulating materials, combined with the vacuum impregnation process, the insulation life is 50% longer than that of ordinary products.
Long-term overload operation will cause the copper loss and iron core iron loss of the winding to increase sharply, and the temperature rise will accelerate the aging of insulation; Even short-term overload may cause failure due to local overheating. Chuanli’s transformador supports 120% of the rated load for short-term operation, but will provide load planning guidance for buyers to avoid long-term overload.
The failure of the cooling system will cause the heat to be unable to be dissipated, and the oil temperature or winding temperature will continue to rise. The transformador de potência equipped with an adaptive cooling system also has built-in temperature monitoring sensors, which can timely warn of cooling failure and reduce the risk of overheating.
Moisture, dust, and chemicals can enter the transformer, causing the insulation to become damp and the metal parts to corrode. The outdoor transformer of Chuanli has a protection grade of IP65, excellent sealing performance, and can operate stably in the environment of -40 ℃ ~ + 70 ℃, high humidity, and a lot of dust.
Electrical stresses such as lightning strikes, voltage fluctuations, and internal winding short circuits can instantly impact the insulation and windings of transformers, leading to faults. A lightning arrester is added to the high-voltage side of the transformer, and the winding adopts a segmented winding process, which can withstand the impact of short-circuit current.
Collision during transportation and installation, or vibration during long-term operation, may cause the iron core to loosen and the winding to deform. Chuanli adopts laser cutting and automated welding technology to ensure the structure is stable. It is equipped with customized shockproof packaging during transportation and provides professional guidance during installation.
The insulating oil of the oil-immersed transformer will lose its insulation and cooling function due to oxidation, moisture, and pollution. Chuanli recommends regular oil quality testing and provides high-quality insulating oil, which has 30% better antioxidant properties than ordinary oil and a longer service life.
This is the “innate hidden danger” that buyers need to be most vigilant about – poor quality materials, unreasonable design, and rough craftsmanship will bury the fault seed of the transformer from the factory. Through 100% raw material inspection, automated production process monitoring, 75kV voltage withstand test, and more than 10 strict inspections, the transformer of Chuanli can eliminate congenital defects.
Lack of regular maintenance can cause small problems to accumulate into major failures, such as loose joints, low oil levels, and blocked heat sinks. Chuanli provides detailed maintenance manuals for buyers, and can also provide remote monitoring programs to monitor temperature, oil quality, and other data in real time, and provide early warning of hidden dangers.
Early detection of fault precursors can prevent minor problems from expanding into serious faults. The following 7 symptoms must be checked immediately if they appear:
If the operating temperature consistently exceeds the rated value, or if the temperature suddenly spikes, this may be a sign of overload, cooling failure, or insulation aging.
If the noise is uniform during operation, but the “humming” sound becomes louder, mixed with “crackling” discharge sounds, or the vibration intensifies, it may be due to problems such as a loose iron core, a short circuit in the windings, or component damage.
Oil leakage or darkening/turbidity of the oil in oil-immersed transformers, and dust accumulation or discoloration in the windings of dry-type transformers, can all indicate malfunctions and require immediate attention.
If the dissolved gas content is found to be excessive, it indicates internal overheating or discharge, requiring immediate repair.
After the relay repeatedly trips, after excluding the problem of the power grid, it is most likely that there is a fault in the internal transformer, which needs to be stopped and repaired.
If the output voltage fluctuates by more than ±2% or downstream equipment frequently reports errors, it may be due to transformer winding deformation or tap switch failure.
If there is too much water in the oil of an oil-immersed transformer, the insulation performance will be reduced, and the risk of breakdown will increase. It is necessary to dehydrate or change the oil in time.
| Fault Causes | Core Risks | Chuanli Fault Prevention Solutions | Buyer Action Recommendations |
| Insulation Aging | Dielectric breakdown, short circuit | Insulation materials of Class F or higher + vacuum impregnation process | Choose high-grade insulation products to avoid prolonged high-temperature operation |
| Overload overheating | Accelerated insulation aging, winding burnout | Precise Capacity Selection + Temperature Monitoring and Early Warning | Select based on actual load to avoid long-term overload |
| Cooling Failure | Temperature runaway, oil deterioration | Adaptive Cooling System + Fault Warning | Regularly clean heat dissipation components and inspect cooling fans/oil pumps |
| Moisture Contamination | Insulation dampness, component corrosion | IP65 Protection + Sealed Design | Avoid installation in humid, dusty environments |
| Short circuit impact | Winding damage, insulation breakdown | Surge arrester + reinforced winding structure | Equipped with power grid protection devices to prevent frequent short circuits |
| Manufacturing Defects | Inherent Potential Faults | End-to-end quality inspection + international standards | Choose qualified suppliers like Chuanli with proven project experience |
| Insufficient maintenance | Minor issues escalate | Maintenance Manual + Remote Monitoring | Perform regular maintenance as required and retain test records |
A certain chemical enterprise once purchased a 10kV oil-immersed transformer from a small factory at a low price. After only one year of operation, the transformer showed abnormal heat and oil leakage. Finally, the fault was caused by a short circuit in the winding, leading to a three-day shutdown of the production line and a direct loss of more than one million yuan. After investigation, it was found that the transformer used low-quality insulating materials, the cooling system design was unreasonable, and it had not undergone strict factory testing.
Later, the enterprise chose the 10kV oil-immersed transformer of Chuanli, and we accurately selected it according to its load characteristics, equipped with an adaptive cooling system and a remote monitoring function, and there was no fault in operation for 3 years. The buyer frankly said, “At first, I only looked at the price and ignored the risk of failure. Now I understand that choosing a supplier that can avoid failure is really saving money.”
This case is not an exception, and too many buyers have paid a heavy price for low-cost products due to ignoring the risk of failure. And the customers of Chuanli, relying on the high-quality products and fault-proof design, can achieve long-term stable operation.
As a buyer, you must be aware that the cost of a transformador de potência failure is much higher than the value of the equipment itself. When selecting suppliers, we should not only pay attention to the price, but also focus on their strength in “fault prevention” – material quality, design rationality, production process, testing standards, and after-sales service. These are the key factors that determine whether the transformer can operate stably.
The essence of purchasing transformadores de potência is to purchase “stability and peace of mind”. By choosing Chuanli, you will not only get a device that meets international standards, but also a full life cycle fault prevention plan, which will help your project avoid the trouble of power transformer failure and achieve stable operation.
Q1: How long can Chuanli provide response service if there are transformer failure symptoms?
A: Chuanli provides 24-hour emergency response service. After receiving the notification of the fault, the local customer will come to the door within 2-4 hours, and the out-of-town customer will arrive at the scene within 48 hours. Routine failures can be repaired within 24 hours, and serious failures provide backup equipment support to minimize downtime.
Q2: Will maintenance training be provided after purchasing the transformer from Chuanli? Help us identify the symptoms of the fault?
A: Yes. We will provide free training for your operation and maintenance team, including daily maintenance points of transformers, identification of common transformer failure symptoms, and simple fault handling. At the same time, detailed maintenance manuals and online technical support are provided to help you discover and deal with hidden dangers.
Q3: Which type of transformer, oil-immersed or dry-type, has a lower failure risk?
A: There is no absolute high or low risk of failure for both; the key is to look at the application scenario and product quality. Oil-immersed faults are often related to oil quality and cooling systems, while dry-type faults are often related to insulation moisture and overload.
Q4: How to reduce the risk of power transformer failure from the source through the procurement process?
A: The core is 3 points: 1. Choose suppliers with qualifications and project cases, such as Chuanli; 2. Clearly inform the load characteristics and installation environment, so that the supplier can accurately select the model; 3. Require suppliers to provide material inspection reports and factory inspection data to ensure that products do not have congenital defects. These 3 points can help you avoid 80% of the failure risk.
