When the power goes out, everything comes to a stop. This can be devastating for businesses that rely on computers, machinery, and other electrical equipment for daily operations.
Electrical transformers are responsible for keeping things running smoothly behind the scenes, but like any piece of equipment, they need a little TLC. Routine transformer maintenance can’t be overlooked. It’s the only way to avoid costly downtime, expensive emergency repairs, and the nightmare of trying to find a new transformer since we’re currently facing a shortage.
Let’s explore how a little effort can save a ton of trouble down the line.
A failed transformer can become a safety hazard
In addition to costly downtime, some transformer failures present major safety hazards that cause property damage, personal injury, and sometimes death. The most common hazards are fires and explosions.
While oil-filled transformers are more prone to catastrophic failures like explosions, some of these incidents can be avoided with routine maintenance. Dry-type transformers are known for reliability and safety, but they also require maintenance. Just like their oil-filled counterparts, dry-type transformers can fail if maintenance is neglected.
Transformer failures that become safety hazards can result in lawsuits and steep regulatory fines, depending on the situation. If a failed transformer leaks or spills oil, there could be significant financial penalties. For example, a company in Massachusetts was fined $10,000 for failing to report a 95-liter spill after a vehicle hit an electric pole and damaged a transformer.
Downtime is a major wallet drain
When a transformer fails, businesses lose money by the minute. According to the U.S. Department of Energy, power outages cost American businesses $150 billion each year. Regular maintenance is the only protection against preventable downtime. This applies to all types of transformers, no matter the size or how well they’re built.
Lost productivity, customer disruptions, and supply chain shutdowns all lead to lost profits. However, the cost of downtime from a lack of productivity is just the beginning of the financial strain caused by transformer failure. Businesses also need to pay for emergency repairs, and service rates to be inflated because the work requires short notice and overtime from expert technicians.
The transformer shortage has skyrocketed prices
In a situation where a transformer is beyond repair and needs to be replaced, the cost can be sky-high. A good transformer has never been cheap, but the United States is currently experiencing a transformer shortage and prices have increased between four to nine times. The lead time on new units can be anywhere from a few months to two years.
Thanks to ongoing shortages of raw materials like copper and steel, transformer production has slowed down worldwide. When a transformer fails and a backup is not immediately available, the only option is to get a refurbished, used transformer to use while waiting on a new unit. Used transformers are fine temporarily, but should not be relied on long-term. Unfortunately, even though this is a workable solution, it will cost more overall.
Routine maintenance prolongs the life of an existing transformer, reducing the need for costly replacements and repairs. When a transformer is properly maintained, it’s less likely to fail prematurely, unexpected downtime can be avoided, and there’s no need to wait years for a new unit.
Basic transformer maintenance
The following tasks are necessary routine maintenance for transformers.
Visual inspections
Routine, monthly visual checks for leaks, corrosion, and discoloration can catch small problems before they escalate.
Oil analysis
For oil-filled transformers, it’s crucial to test the oil for contaminants, moisture, acidity, and dissolved gases. This process can help identify internal problems early. A degraded insulation system is the primary cause for electrical faults.
Thermal imaging
An infrared scan can reveal components that are starting to overheat, which can be a sign of loose connections and/or impending failure.
Cleaning and tightening
The transformer enclosure should be opened and cleaned. Cooling fins need to be cleaned regularly, and connections should be tightened. These tasks will reduce the heat build-up that can cause major problems.
Monitoring load levels
Transformers are rated for specific load capacities and it’s critical to monitor loads to prevent thermal stress.
Making repairs
It’s important to replace degraded or wet insulation, replace worn components, and make other necessary repairs in a timely manner.
Regular monitoring
Monitoring transformer performance using sensors and an app will identify red flags before they cause failure.
Maintenance extends the life of a transformer
A quality transformer should last for many decades, but only when well-maintained. Routine maintenance can help a transformer last up to 40 years or even longer. In a world where transformer shortages and rising costs are the new reality, proactive maintenance is the key to avoiding major expenses while maintaining smooth business operations.
