Common Electrical Transformer Problems and How Reconditioning Solves Them

Common Electrical Transformer Problems and How Reconditioning Solves Them

Common Electrical Transformer Problems and How Reconditioning Solves Them

Electrical transformers are crucial components in power distribution systems, converting voltage levels to ensure electricity can travel efficiently across vast distances. However, transformers, like any piece of equipment, can encounter problems over time. To address these issues effectively, one solution stands out: reconditioning. In this blog post, we’ll delve into common electrical transformer problems and explore how reconditioning your transformers can resolve them.

1. Insulation Deterioration

Over time, the insulation material within a transformer can degrade due to factors like temperature fluctuations, moisture, and contaminants. This deterioration can result in reduced dielectric strength and ultimately lead to electrical breakdowns.

Reconditioning Solution:

Testing during the reconditioning process can detect insulation deterioration, which can be fixed by rewinding the core & coil. During the rewinding process, new conductor as well as insulation is used.

2. Bushing Deterioration

The load that transformers hold in normal use leads to heat. Heat can start to erode the bushing material. Additionally, the thermal stress from the varying load conditions can weaken the insulation material. Moisture can enter through small cracks, joints, or damaged insulation. Moisture further degraded the insulation.

Reconditioning Solution:

If there is significant damage to the bushings, then they are replaced during reconditioning. Which would solve these problems. If these signs aren’t present, then only the inserts are replaced.

3. Oil Contamination

Transformers use oil for cooling and insulation purposes. Over time, this oil can become contaminated with moisture, dirt, or other foreign substances. Contaminated oil can lead to decreased cooling efficiency and even reduced electrical insulation.

Transformers Use

Reconditioning Solution:

Reconditioning addresses oil contamination by emptying the old oil and flushing all of it out. After that is done the oil is replaced with new transformer oil. If your transformer has silicone fluid it has to stay as silicone fluid.

4. Overheating

Overheating is a common issue in transformers, often due to inadequate cooling or overloading. Excessive heat can accelerate insulation aging and cause catastrophic failures.


Reconditioning Solution:

Reconditioning prevents overheating by optimizing the cooling system and upgrading it if necessary. Improved cooling mechanisms ensure that the transformer operates within safe temperature limits, increasing its longevity. New oil can also contribute to better cooling.

5. Oil Leaks

Oil leaks can occur due to aging gaskets or seals, which can lead to a loss of insulating oil, reduced cooling, and increased risk of fire. Leaks also lead to moisture ingress into the transformer tank, which can quickly lead to reduced dielectric strength and insulation breakdown. 

Reconditioning Resolves Oil Leaks

Reconditioning Solution:

Reconditioning resolves oil leaks by inspecting and replacing deteriorated gaskets and seals. Proper sealing ensures the integrity of the transformer’s oil tank. During the reconditioning process leaks around the radiators or tank joints can be welded.

In conclusion, reconditioning is a cost-effective and sustainable solution to address common transformer problems, ensuring their longevity and efficient operation. Although some transformers are too far gone to be reconditioned. That is the downside of it being cost effective. A rewind has a heftier cost in comparison to reconditioning, but a rewind is replacing nearly all components of a used transformer. One of the only parts reused is the tank of the transformer.  By addressing issues like insulation deterioration, oil contamination, winding damage, overheating, reduced efficiency, and oil leaks, reconditioning helps extend the lifespan of transformers, reducing downtime, and enhancing the overall reliability of power distribution systems.

If you are interested in getting reconditioning done to your unit or units, feel free to reach out to our sales team. You can contact us at [email protected] , or by calling in at 855-214-0975.