Ensuring Quality and Safety in Transformer Manufacturing: A Focus on Fault Prevention

As a leader in the transformer manufacturing industry, Link-Power is committed to providing products where quality and safety are a priority. Through our extensive experience, we have identified several common transformer failures, their causes, and effective mitigation strategies. Our pursuit of excellence ensures that every transformer we manufacture meets the highest standards of performance and durability.

Common Transformer Faults and Their Causes

Winding Faults Winding faults, including inter-turn short circuits, winding ground faults, phase-to-phase short circuits, broken wires, and joint weld failures, are among the most common issues in transformers. These faults are typically caused by:

Manufacturing or Repair Defects: Localized insulation damage or defects left unresolved during manufacturing or repairs.

Overheating and Overloading: Insufficient cooling or prolonged overloading can lead to insulation aging, resulting from excessive temperatures.

Poor Manufacturing Practices: Inadequate compression and mechanical strength can cause winding deformation and insulation damage under short-circuit conditions.

Moisture Contamination: Moisture ingress leads to insulation expansion and blocked oil channels, causing local overheating.

Deterioration of Insulating Oil: Contamination from moisture or air exposure can increase acid levels, lower insulation quality, or leave windings exposed to air due to low oil levels.

When insulation fails during operation, it can result in winding short circuits or ground faults. Symptoms of inter-turn short circuits include transformer overheating, increased oil temperature, slight increases in primary current, unbalanced phase resistance, and sometimes noises or bubbling sounds in the oil. While minor inter-turn short circuits may activate gas protection, more severe cases can trigger differential or overcurrent protection on the primary side. Addressing these faults promptly is crucial to prevent more severe single-phase ground or phase-to-phase short circuits.

Bushing Faults Common bushing faults such as explosions, flashovers, and oil leaks can be attributed to:

Poor Sealing: Insulation degradation due to moisture ingress or oil leaks.

Improper Breather Design: Failure to properly manage moisture absorption can lead to deterioration.

Capacitor Bushings: Defective capacitor bushings on high-voltage sides (110kV and above), including poor porcelain quality or cracks.

Manufacturing Defects in Capacitor Cores: Defects that lead to internal partial discharge.

Severe Contamination: Accumulation of dirt on bushings.

Core Faults Common core faults include:

Insulation Damage Between Silicon Steel Sheets: This can cause local overheating and melting of the core.

Damage to Insulation of Core Clamping Bolts: This can result in a short circuit between the silicon steel sheets and clamping bolts.

Residual Welding Slag: Leftover slag can cause a two-point grounding fault.

Magnetic Leakage Heating: Magnetic leakage can cause localized overheating and insulation damage, particularly in the top and middle of the transformer oil tank, bushing flanges, and between core and winding clamping parts.

When winding or core faults occur, core lifting inspection is essential. Start by measuring and comparing the DC resistance of each winding phase; significant differences can indicate winding faults. Then, visually inspect the core and measure inter-sheet insulation resistance using a DC voltage and ammeter method. Minor damage can be addressed by applying varnish to the affected areas.

Introducing LP Transformer: Your Reliable Choice

At Link-Power, we take pride in producing transformers that deliver superior quality with minimal faults. Our LP Transformers are engineered for exceptional performance and reliability, ensuring smooth operations with reduced downtime. With advanced manufacturing processes and rigorous quality control measures, we guarantee that our products adhere to the highest industry standards.

Why Choose LP Transformers?

Exceptional Quality: Built for long-term reliability and durability.

Minimal Faults: Precision design and manufacturing lead to fewer faults, reducing maintenance costs.

Advanced Technology: Incorporating the latest advancements to enhance transformer performance and efficiency.

For more information about our products and their benefits, visit our News Centre. Stay informed about the latest trends and innovations that make Link-Power a leader in the transformer industry. We remain committed to advancing transformer technology and enhancing operational safety, reflecting our unwavering dedication to quality and reliability.

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