Every degree of temperature in a transformer can determine its service life and the stability of the entire power grid. Even small thermal deviations carry the risk of degradation of winding insulation, overloads and, ultimately, costly downtime and repairs. A transformer, especially one with medium to high power, operates under extreme conditions and the heat it generates requires constant monitoring. Only precise transformer temperature monitoring systems can maintain its safe operation, minimising the risk of overheating and extending the life of the equipment. In this case study, we discuss how an advanced monitoring system helped our client maintain the stability of transformers' thermal performance, increase their efficiency and avoid unexpected failures. Read on to find out how proper temperature control of transformers translated into reduced costs, increased reliability and more sustainable operation!
A transformer is the foundation of any power network. Whether it powers a wide-area transmission network or supports smaller industrial applications, its stable operation is crucial for the entire system. In this context, temperature becomes one of the most important parameters. A transformer operates under extreme conditions - the current flowing through the windings generates heat which, if not controlled, leads to insulation degradation and the risk of overloads. Just a few degrees above acceptable levels can shorten the life of the unit by years, increasing the risk of breakdowns, costly repairs and power outages.
Precise temperature control in a transformer is therefore not just a matter of optimisation, but the foundation of its safe and long-term operation. Constant monitoring ensures ideal thermal conditions, which minimises energy losses and overloads and allows the unit to operate more efficiently without excess energy consumption. For operators, this means less strain on the grid and lower operating costs, as well as greater confidence that the transformer will remain reliable and not fail at a crucial time.
In response to the challenges of temperature control, the customer implemented JUMO's advanced measurement solutions. The monitoring system is based on a combination of high-performance thermometers and sensors that provide full thermal control in transformers. A key role is played by contact-connected bimetallic thermometers, which respond mechanically to temperature changes and are independent of the power supply. This is ideal for industrial monitoring, where the stability of measurements must be undisturbed even under harsh environmental conditions.
In addition, the system uses temperature transmitters based on Pt1000 sensors, which are characterised by high accuracy and a wide operating range - from -50 to even 600°C. These transmitters not only provide precise readings, but are also resistant to vibration and varying ambient temperatures, making them reliable in the demanding environment of medium-power transformers. The high-quality materials and robust construction of JUMO devices guarantee stable measurements and minimise the risk of failure.
From left: bimetallic thermometer for transformers (608005), push-in temperature sensor (902120)
Through precise temperature monitoring, the client has achieved a significant improvement in the reliability of transformers. Stable thermal conditions have extended their service life, resulting in less maintenance and a reduced risk of failure. A transformer operating at the optimum temperature is not only more efficient, but also safer. The risk of overheating and associated insulation damage is reduced. The customer is reassured that the equipment can operate smoothly even under the most demanding conditions.
The continuous monitoring system also allows any anomalies to be detected in real time. The detection of a sudden rise in temperature gives an indication that internal short circuits or insulation problems may be occurring. If this is the case, a quick response prevents further damage to the equipment and possible downtime. Furthermore, temperature control helps to keep energy efficiency high. Optimal operating conditions reduce energy loss, which is both a financial and environmental benefit - less energy used unproductively means lower costs and more sustainable operation.
Check out our temperature sensors for dry resin and oil transformers, among others!
My name is Ewelina Szmit and I have been working in content marketing for several years, combining my professional skills with my passion for writing. I am convinced that even the most technical topics can be presented in an interesting and accessible way for everyone. Outside of work, I unleash my creativity by creating newspaper collages. I like to spend my free time being active, walking my dog or running.
We encourage you to leave your comments via the form below. They will be posted online once they have been approved through our review process.