As electrical and manufacturing requirements continue to expand, older versions of transformers are becoming outdated, overwhelmed with current workloads and are more prone to failure. Modern designs are therefore being incorporated into transformers to make them more efficient, less prone to failure, and less costly to operate.
Modern transformer design aims at being practical and realistic for many different applications. From residential to industrial processes, the modern transformer needs to be flexible and adaptable. This requires a fundamental shift from the previous methods that were used to power transformers.
A combination of a more efficient design, more frequent testing, and dependable maintenance routines have helped to make modern transformers useful for today's processes.
More efficient transformer components
As transformers take on a more advanced design, their internal components also need to be upgraded. Therefore, you will find that modern transformers have more efficient bushings, arrestors, and load tap changers (LTCs). These parts are designed to be more flexible and to produce power under a wider range of conditions. They are also built to be more durable so that failure of the transformer becomes less likely.
Older transformers were typically built in a bulky and cumbersome design that was more prone to failure. In fact, it was common to see these older models experiencing a deterioration of their cellulose insulation systems, bushings, fluid leaks, and contacts.
A thorough testing process
Another feature of modern transformers is that they undergo a more thorough testing process before they can be availed to customers for purchase. After being manufactured with cost-effective designs, they are also fitted with materials and fabrication that undergoes a comprehensive testing process.
Computer testing is done for more accurate results, and advanced methods such as heat runs and three-phase current tests are carried out with the help of computer software packages.
Drier insulating materials
In the past, older models of transformers did not completely maintain a dry insulating material before shipment. Wet insulation often causes a loss of insulation ability and reduces the transformer's lifespan. Moisture also elevates acidity levels in the dielectric fluid of the transformer, and this acidity, in turn, damages the cellulose paper and interferes with power generation.
Modern transformer design incorporates a manufacturing process that keeps the insulation paper at under 0.5% of moisture before and after shipment. This makes the end product more efficient at generating power while reducing the cost of maintenance over its lifespan.
As a result, modern transformer features have provided products that operate with increased efficiency for many different applications.