In an electricity-centric world, long-lasting power transformers are more important than ever. Transformers help transfer electricity from generating stations to load centers by regulating electrical energy fluctuations.
While the average transformer life expectancy is typically twenty to thirty years, how long a transformer lasts and how efficiently it runs can range widely.
This blog will explore the four main factors that affect a transformer’s lifespan and the preventative measures that can help extend a transformer’s working years.
Factors Influencing Power Transformer Life Expectancy
Understanding the main factors contributing to a power transformer’s working life allows for informed decision-making that can extend a transformer’s lifespan, saving money and resources along the way.
So, how can investors get the most out of their transformer? Here are four key factors to look for that greatly influence the longevity of a transformer.
Prioritizing the lifespan of a transformer starts with the selection process. Considering the quality of the transformer’s design and manufacturing process is essential.
Transformers built with precision engineering and high-grade materials like silicon steel cores and copper windings will likely have better longevity than transformers made with laminated steel and aluminum windings.
Be sure to check the manufacturer implements a rigorous auditing process for quality control and assurance (QC&A), risk minimization, and inline monitoring processes when selecting a transformer.
While a high-quality transformer may be a more significant initial investment, having a solid foundation can help support other factors that jeopardize life expectancy.
Insulation and Cooling System Failures
One of the primary culprits behind a shortened transformer lifespan is the failure of insulation and cooling systems.
These systems safeguard a transformer’s windings by preventing potential damage from electrical and thermal stresses. Insulation failure can lead to dielectric failure, which puts the transformer at risk of short-circuiting. Without a properly functioning cooling system, heat generated from the transformer during operation will not dissipate, increasing the transformer temperature and risk of overheating.
In addition to regular inspections, oil and gas analyses, and temperature monitoring, a proactive step in protecting the cooling and insulation systems is to use the most optimal fluid.
Most oil-filled transformers still use mineral oil as their insulating and cooling material due to its excellent insulating properties under normal conditions. However, mineral oil can quicken insulation decay, has a low fire point, and high combustibility. With transformer lifespan in mind, vegetable-based oil, such as the FR3 Insulating Fluid, is a more efficient and environmentally friendly alternative.
One study found that vegetable oil can improve a power transformer’s life expectancy due to its slower aging effects on the cellulose paper used in a system’s insulation. Over time, as the transformer ages, the paper undergoes chemical reactions and physical changes from temperature, moisture, and the oil it’s immersed in.
The same study also showed vegetable oil has a 4.4°C higher top oil temperature, which can help reduce the fire threshold. Oil-filled transformers face a 0.25% higher chance of experiencing an oil fire per service year, which can lead to catastrophic equipment damage, accelerating the aging process.
Power transformers experience various load profiles and characteristics over their lifespan, including continuous overloading, abrupt load swings, and overvoltage. Such characteristics can lead to thermal stresses, insulation degradation, breakdown, and internal equipment damage.
Knowing how to manage the different types of load profiles and characteristics can help enhance a transformer’s performance, reliability, and durability, improving longevity.
Ways to manage loading characters include:
- Installing real-time monitoring systems
- Utilizing load forecasting
- Implementing load management strategies
- Conducting regular maintenance
Environmental conditions significantly influence how a transformer can age. Humidity, ambient temperatures, altitude, dust, and pollutants can undermine insulation properties and cooling efficiency.
Transformers in harsh environments without the proper protection experience accelerated aging and heightened thermal and electrical stresses. Protective measures such as breathers, conservator tanks, and enclosures can help alleviate these risks.
The Importance of Extending the Lifespan of a Transformer
Reliable, long-lasting power transformers are indispensable as the demand for clean energy increases amidst transformer shortages.
Taking proactive steps to persevere a transformer’s operating life, such as choosing high-quality materials, switching to more efficient oil, and installing the needed protective equipment, will foster a consistent and uninterrupted power supply and avoid transformer failure.
At Meta Power Solutions, our team of power transformer experts offers guidance for prolonging a transformer’s working life. Contact us for tailored solutions for your transformer.