Transformers are one of the most useful components of bringing in the right current into our homes, offices and industries. Thus, it is very important to assess this equipment to check if they are fit for use or need replacement or reinstallation. Transformers form a very important part of the costs involved, thus utilities are pressurized to use existing units for as long as possible until and unless the overall system is at risk. But, it is also important to realize that the appropriate checks need to be made to check for the reliability of the transformers installed. Miracle Electronics is a name where transformers are not only manufactured, but they are built with comprehensive standards, excellence in design and a rigorous code of conduct that ensures complete reliability of their products.
Apart from the design and make of the transformer, the environment in which it is to be installed plays a major role in affecting its reliability. The location, weather conditions, electrical loading, operating method and applications all need to be considered. Each of these factors needs to be acknowledged. Let us take a look at the checks that need to be made for the reliability of a transformer right from the time it is planned up till its installation.
Every transformer needs to describe the function that it is to perform and the limitations and restrictions set for it. What kind of operating conditions may affect the transformer should also be mentioned.
The design of the transformer should be at par with the specifications mentioned for it. The transformer manufacturer must convert the specifications into concrete design parameters and usable information. The design engineer should consider and address every environmental condition because any error or exclusion may result in failure, risk and decreased service life.
Manufacturing is when the paper design is converted into the physical product. Here, complete care is taken of manufacturing the product as close as possible to the design by using quality techniques. However, the reliability after manufacture differs from that demonstrated in the paper design because of variations in the materials used, processing, handling, machinery and personnel.
Even if the product is designed and manufactured with complete care, it can fail or damage due to mishandling during shipment. Because transformers are shipped by road or rail, conditions may decline at any point of time. Thus, the ride history of the transformer is recorded and monitored. The recording accelerometer can track either 2 or 3 axis movement and can investigate rough handling, thus deciding whether any damage has been done to the transformer. All kinds of horizontal, vertical and side-to-side movements are recorded. In case of any doubt, immediate documentation takes place.
After the transformer is accepted, it should be located to where it needs to be installed. Every step involved is clearly written by every manufacturer in the form of an instruction book. Tests including insulation resistance, insulation power factor, winding ratio and winding resistance are performed to find out whether any changes have taken place during shipment.
The checks do not end at installation. Checks need to be regularly made. Regular maintenance of transformers is important. Lubrication and adjustment to the components must be provided, and the transformer should be monitored to check for its ability to perform its function. Any in-service failure or malfunctioning should be repaired right away to restore the transformer to its working condition as soon as possible.
The life of transformers should be prolonged as much as possible. Both transformer manufacturer and user must take up the responsibility of ensuring the reliability of transformers. With increasing demand of products and faster and efficient delivery, dedicated solutions are important to help utilities and power producers to manage transformers more efficiently.