Why does every degree of temperature matter for the life of a transformer?

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.

How to protect a transformer from overheating and failures? The customer's challenge

A manufacturer of medium-power transformers in the energy industry faced a significant challenge: developing a reliable system to continuously monitor the temperature of its equipment. The aim was not only to monitor thermal parameters on an ongoing basis, but above all to provide adequate protection against sudden failures that could threaten the stability of the network. Every transformer, especially high-powered ones, requires precise temperature control, which directly affects its service life. Even short-term overheating accelerates the degradation of insulation materials, which can lead to costly repairs and unplanned downtime. Avoiding these risks required a measurement system that provides a fast reading and immediate response to any temperature change, while also having high precision and robustness.

The transformer operates in a variety of often demanding environments - changing ambient temperatures, high humidity and strong vibrations are daily challenges. Therefore, the company needed solutions that are highly resistant to these factors and comply with the stringent safety standards that apply in the power industry. Every sensor and component in the monitoring system had to function reliably under extreme temperature fluctuations, high load levels and demanding weather conditions. The system had to be not only accurate and durable, but also easy to integrate into the existing monitoring infrastructure, giving the company full operational control and long-term reliability of the equipment's performance.

How do bimetallic and resistance temperature sensors for transformers improve safety? Our solution

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.

How does real-time temperature measurement prevent sudden transformer failures? Customer benefits

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!

About the author

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.

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