Transformers are important components in electrical systems that function to increase or decrease electrical voltage. However, like other equipment, transformers can also experience problems that affect performance and pose a risk of serious damage.

 

Here are 5 common problems with transformers and solutions to overcome them:

1. OVERHEATING

Explanation:

Overheating is a condition in which the temperature of the transformer exceeds the safe threshold (usually 65–75°C for the top of the oil). Excessive heat can damage insulation, reduce efficiency, and accelerate component degradation within the transformer.

Common Causes:

• Overload

• Poor ventilation

• Faulty cooling system (oil cooler/fan)

• Excessively hot environment

Solutions:

Ensure the cooling system is operating optimally (check the fan, radiator, or pump)

Clean the cooling fins and ensure they are not obstructed by dust

Monitor the temperature using a transformer thermometer or automatic sensor

Avoid operating the transformer beyond its rated load capacity

2. OVERLOAD (Exceeding Capacity)

Explanation:

A transformer has a specific power capacity (e.g., 250 kVA). If forced to supply a load exceeding this capacity continuously, internal temperatures will rise sharply, accelerating damage to windings and internal components.

Common Causes:

• Adding loads without recalculation

• Failure to conduct regular energy audits

• Lack of overload protection systems

Solutions:

Conduct a load audit at least every 6 months

Increase transformer capacity if load growth increases

Install circuit breakers and overload protection relays

Educate users not to use peak loads simultaneously

3. DETERIORATION OF TRANSFORMER OIL QUALITY

Explanation:

Transformer oil serves as an insulator and coolant. Over time, oil quality can deteriorate due to water contamination, oxidation, and metal particles. Contaminated oil can no longer protect the transformer from voltage surges and heat.

Common Causes:

• Long service life

• Never tested for quality (BDV, DGA, moisture)

• Exposed to humid air or leaks

Solutions:

Conduct transformer oil testing (at least once a year): BDV, moisture content, and dissolved gases

Replace the oil if test results do not meet standards

Use an oil purifier to extend oil lifespan

Ensure the transformer tank is airtight (properly sealed)

4. INSULATION BREAKDOWN

Explanation:

The insulation in a transformer prevents short circuits between windings. If it is damaged due to heat, age, or contamination, a short circuit or even an explosion can occur.

Common Causes:

• Overheating

• High humidity

• Old transformer age

• Mechanical damage or corrosion

Solutions:

Conduct regular insulation resistance testing (megger test)

Maintain transformer room humidity (use a dehumidifier if necessary)

Replace insulation or transformer windings if worn out or degraded

Use transformers with high-class insulation (Class A/B/H)

5. VOLTAGE SURGE / LIGHTNING  SURGE

Explanation:

Sudden voltage surges caused by lightning strikes or network switching can enter the transformer system. These voltages far exceed the transformer's design limits and can instantly damage the windings.

Common Causes:

• No lightning protection system

• Grounding system does not meet standards

• Damaged or missing arrester

Solutions:

Install a surge arrester (lightning arrester) at the input panel

Ensure grounding resistance < 5 ohms (ideally < 1 ohm)

Inspect the arrester and protection system at least every six months

Use a protection relay capable of detecting and responding to surges quickly

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