8 Signs It’s Time to Repair or Replace Your Transformer

When it comes to electrical power, a single hour of downtime can cost manufacturers between $500,000 and $5 million, which makes transformer maintenance crucial. All transformers need periodic repairs and maintenance to keep them running properly, although a good transformer won’t need too much maintenance. 

Still, there will come a time when you’ll need to replace your transformer, and if you pay attention to the follwing signs, you’ll have the chance to replace it before it completely fails.

 1. Your transformer is more than 30 years old

The average transformer should last around 40 years, but if yours is more than 30 years old, it’s time to consider a replacement. Many facilities practice planned replacement when a transformer is approaching the end of its useful life. By replacing your transformer before it fails, you’ll avoid the catastrophic failure that would otherwise occur unexpectedly.

Although 40 years is average, how long your transformer will last is dependent upon many factors, like the workmanship, the materials used, and the conditions of its use over time.

2. Your transformer was purchased used

If you purchased a refurbished or used transformer, there’s a good chance you’ll need to replace it with a new unit sooner than later. Refurbished units are excellent for temporary needs, but they aren’t a good long-term solution. If it’s been a while since you installed a used transformer, start thinking about getting a new unit.

Since there has been a transformer shortage for several years, get on a waiting list as soon as possible. There’s no guarantee when the shortage will end, and the lead time to get a new transformer from just about any manufacturer is currently a couple of years out.

 3. You hear unusual noises

Even quieter transformers make noise, but it shouldn’t get louder or change pitch over time. If you’ve been noticing a different sound coming from your transformer, or if it’s just gotten louder, that can be a sign that trouble is brewing. It might be fixable, but you might be better off getting a new transformer. The only way to know is to get it inspected by a professional.

4. There’s an increase in vibration

Transformers naturally vibrate from magnetostriction, but the vibration shouldn’t get more intense as time passes. An increase in vibration can be a sign that the pad is wearing down or there could be something wrong internally. Most of the time, an increase in vibration is caused when the pad is less efficient at absorbing the vibration. In this case, you can replace the pads. However, a professional opinion is needed to make that determination.

5. It’s overheating

A transformer that overheats, even just occasionally, is potentially on its way to failure. Overheating means the insulation is not dissipating the heat properly. This can be due to poor craftsmanship, poor insulation materials, or some kind of damage.

An overheated transformer is at risk for fires and explosions, especially if it’s an oil-filled transformer, since those use flammable liquid as insulation.

 6. You’ve had a fire

According to the data, 2.4% to 4% of all transformers should be expected to cause a fire throughout their 40-year expected lifespan. Fires can be caused by a variety of factors, including being struck by lightning, voltage surges that create short circuits in the secondary windings, insulation failure, being overloaded, inadequate oil flow, poor mechanical contacts, and more.

Once a transformer has caught on fire, there’s a good chance much of the internal components will be damaged. Using a transformer after it’s caught fire isn’t a good idea unless you’ve had it thoroughly inspected and repaired by a professional. The damage may not be recoverable, and if that’s the case, you’ll need to buy a new transformer.

7. You’ve had issues with power quality

A failing transformer won’t perform as well as one that is in good shape. If you’ve been experiencing issues with power quality, it could be a sign of impending failure. As with any major issue, get it inspected as soon as possible because what might appear to be a simple inconvenience could eventually lead to a major failure.

8. You smell something burning

If there is a burning smell coming from your transformer, it could be the insulation burning inside. If this happens, get your transformer professionally inspected and repaired if necessary.

Catch the signs of failure early

Never ignore these signs or put off an inspection. By staying alert, you can avoid the consequences of being caught off guard by an unexpected catastrophic transformer failure.