A critical part of the electrical grid, transformers are a complex assembly of many components that perform sensitive operations. When they are placed outside, they face fluctuating weather conditions, from extreme heat and cold to hailstorms and heavy rains. Even if they are installed within a compact enclosure, their components are subjected to electromagnetic variations which causes wearing after prolonged operation. The typical life cycle of a transformer is 20 to 30 years. But with proper maintenance, it can be extended. For ideal performance for the long service life of a transformer, it requires optimal build quality and regular maintenance. In both of these requirements, transformer manufacturers play a crucial role. In this blog, we will learn what role transformer manufacturers play in transformer life-cycle management.
Role of Manufactures in Transformer Maintenance
Quality Controlled Manufacturing
The manufacturer establishes a streamlined production unit to source premium quality raw materials, perform various quality checks during the design stage using advanced software and fabricate with cutting-edge technology. Every production stage is monitored by quality engineers who ensure consistency and optimal quality and direct corrective measures. Through quality control, manufacturers get the desired output with high longevity and efficient performance. They maintain the best standard regulations and government-prescribed codes.
On-site Assistance
The installation and early-stage performance are vital and give a sign of long-term performance. To avoid failure at the early stage, the manufacturers assist with installation and technical guidance for smooth setup.
Sustainable Disposal and Recycling
When the transformer reaches its end of life, the manufacturer provides sustainable disposal of transformer elements so that the electric waste does not harm the environment. They dismantle the parts and send them for recycling. The parts that can still perform reliable functions are refurbished.
Emergency Support
Whenever there is an emergency failure or fault detected, the manufacturer sends their maintenance team to correct the faults and take the necessary steps like removal of worn out or damaged parts.
Annual Maintenance Services
Many manufacturers sign an annual contract with the commissioning bodies to provide regular maintenance services. This includes comprehensive inspection, tests & analysis, repair works and documentation. Here’s what is included in the annual maintenance service:
- Inspection to check worn-out, damaged parts like windings. Analysis of insulation, moisture content in oil, and fault checks
- Preventive Measures like cleaning, fixing loose connections, and replacing sealants and gaskets.
- Oil checking, replacement, analysis and specific tests like dissolved gas tests.
- The load is optimized to meet new demands. Overload and overheating are prevented.
- Every stage is documented in a report. Upgrades and replacements are suggested.
Conclusion
Transformer maintenance is an essential service in ensuring its consistence performance. It requires a holistic approach- right from manufacturing to end-of-life management. Transformer manufacturers are involved in the maintenance throughout its life cycle. Macroplast Transformers is a leading manufacturer of transformers. We have established a quality-controlled manufacturing unit and provide on-site support and annual maintenance services to ensure our transformers last for years delivering reliable performance.
