As a leading provider of transformer solutions, CHH Power prioritizes proactive fault management to ensure the safe and stable operation of its equipment. Transformer faults, if unaddressed, can lead to power outages, economic losses, and safety hazards. Below, CHH Power analyzes four common transformer faults, their root causes, and the targeted strategies the company employs to diagnose, resolve, and prevent them.
1. Circuit Faults: Short-Circuit Risks and Resolution
Circuit faults in transformers primarily include short circuits at the outlet, inter-lead short circuits, internal winding-to-ground short circuits, and phase-to-phase short circuits. These are among the most frequent issues encountered in CHH Power’s field maintenance records, with low-voltage outlet short circuits being particularly common.
- Impact & Resolution: A short circuit can damage windings irreparably. CHH Power’s standard response involves:
- Conducting a thorough fault location assessment using infrared thermal imaging and electrical testing.
- Replacing the faulty winding(s); in severe cases, all windings are replaced to eliminate residual risks. CHH Power uses high-temperature-resistant, corrosion-proof winding materials to enhance post-repair durability.
- Preventive Focus: CHH Power emphasizes pre-installation circuit testing and regular insulation checks to minimize short-circuit probabilities, thereby reducing potential economic losses and safety risks associated with power outages.
2. Winding Faults: Types, Causes, and CHH Power’s Interventions
Winding faults encompass joint cracking, phase-to-phase short circuits, turn-to-turn short circuits, and winding ground faults. CHH Power’s engineering team categorizes the root causes into three key areas, each addressed with targeted solutions:
| Fault Cause Category | Specific Factors | CHH Power’s Mitigation Measures |
|---|---|---|
| Insulation Degradation | Aging insulators, contaminated windings (e.g., dust, debris), moisture ingress | Conducts quarterly insulation resistance tests and uses vacuum drying to remove moisture. |
| Mechanical Stress | Winding deformation due to overloads or short-circuit forces | Adopts anti-deformation winding designs and enforces load capacity limits during operation. |
| Thermal Overload | Excessively high operating temperatures damaging winding insulation | Installs real-time temperature monitoring sensors and optimizes cooling systems (e.g., upgraded radiators). |
CHH Power’s proactive winding maintenance includes annual ultrasonic inspections to detect early signs of cracking or insulation wear.
3. Transformer Oil Seepage Faults: Environmental and Operational Risks
Oil seepage is the most prevalent fault in oil-immersed transformers—CHH Power’s data shows it accounts for over 40% of all reported transformer issues. This fault poses multiple risks:
- Environmental Pollution: Leaked oil contaminates soil and air.
- Economic Loss: Increases operational costs due to oil replacement and cleanup.
- Operational Failure: Severe leakage can disable the transformer’s insulation and cooling functions, leading to shutdowns.
- CHH Power’s Prevention & Response:
- Preventive Design: Uses advanced rubber-gasket sealing technology and laser-welded oil tanks to minimize leakage points.
- Leakage Management: Deploys oil level sensors for real-time monitoring. Upon detection, CHH Power dispatches teams to repair leaks (e.g., replacing gaskets) and recover spilled oil through eco-friendly processes to reduce environmental impact.
- Long-Term Maintenance: Conducts bi-annual oil tank pressure tests to identify potential seepage risks before they escalate.
4. Overheating at Current-Carrying Joints: A Critical Safety Hazard
Current-carrying joints are vital components in transformer design, but unstable connections can cause rapid temperature rises—even exceeding the joint’s ignition point, leading to burnout and catastrophic failures. CHH Power’s analysis of electrical accidents highlights this as a leading cause of unplanned outages.
- CHH Power’s Temperature Control Strategy:
- Real-Time Monitoring: Equips joints with fiber-optic temperature sensors that transmit data to a central control system, alerting operators to abnormal rises (exceeding 80°C for copper joints).
- Preventive Maintenance: During routine inspections, technicians tighten loose connections and apply anti-oxidation paste to reduce contact resistance. Annual infrared scans are conducted to detect hidden overheating issues.
- Material Upgrades: Uses high-conductivity copper alloy for joints to improve heat dissipation, lowering the risk of temperature spikes.
By integrating advanced monitoring technology, rigorous maintenance protocols, and innovative design upgrades, CHH Power effectively mitigates transformer fault risks, ensuring reliable power supply for its clients.