Transformer Chemistry Services for Mining Operations

“Our transformer team is standing by to partner with mines to power up their mining operation for a brighter, more sustainable future.”

The heart of any mine beats to the rhythm of a constant power flow. And at the core of this flow lies the unassuming hero – the transformer. These silent giants tirelessly convert voltage levels, ensuring efficient electricity distribution across sprawling mine sites. But just like any unsung hero, transformers are susceptible to fatigue and failure. When they falter, the consequences can be catastrophic – production grinds to a halt, costs skyrocket, and safety concerns arise.

This is where WearCheck’s transformer oil testing services emerge as the knight in shining armour. Tailored specifically for the unique challenges of the mining industry, these services offer a comprehensive suite of solutions that go beyond mere monitoring. WearCheck doesn’t just identify problems; the company predicts them, empowering mining operations to manage transformer proactively health and maximise productivity.

The mining landscape – where transformers face unique threats

‘Mining environments are notorious for their harshness,’ says WearCheck’s transformer division manager, Gert Nel. ‘Dust, moisture, and extreme temperature fluctuations combine to create a battleground for transformer oil. These elements accelerate oil degradation, leading to a cascade of issues,’ Nel explains. ‘These include:

• Increased acidity:this weakens the oil’s insulating properties, increasing the risk of arcing and short circuits, potentially igniting dangerous fires.
• Dissolved gases:faulty equipment or overheating can produce telltale gases like hydrogen and CO₂, hinting at internal faults waiting to happen.
• Sludge and metal particles:wear and tear generate microscopic debris that contaminates the oil, further accelerating insulation breakdown.’

Nel warns that if these issues are left unchecked, they can snowball into catastrophic transformer failures, with consequences that echo across the entire operation, such as:

• Production stoppages: a single transformer failure can bring an entire mine to a standstill, resulting in lost revenue and productivity, impacting every facet of the operation.
• Safety hazards:transformer fires pose significant safety risks to personnel and equipment, making early detection and mitigation crucial.
• High repair costs:replacing or repairing transformers can be incredibly expensive, putting a significant strain on budgets.

Instead of waiting for disaster to strike, WearCheck’s transformer oil testing services team takes a proactive approach, acting as a shield against potential failure. Nel outlines the company’s multi-faceted approach:

1. Regular Oil Sampling and Advanced Analysis

• Trained sample-takers ensure timely and accurate oil sample collection at prescribed intervals. WearCheck offers on-site sampling, alternatively, a member of the mine’s maintenance crew, who is trained in sampling, can take the sample.
• The samples undergo rigorous analysis in WearCheck’s accredited laboratories, utilising cutting-edge techniques, such as:
• Furanic testing (HPLC instrument): assesses levels of furans, which are organic compounds formed during oil degradation, serving as indicators of transformer insulation deterioration. This diagnostic method detects furan derivatives through gas chromatography, revealing the oil’s condition and predicting potential transformer faults. By quantifying furans, technicians gauge the extent of thermal and electrical stress on insulation, crucial for pre-emptive maintenance scheduling. Elevated furan levels signify increased risk of transformer malfunction, prompting corrective action to prevent failures. Furanic testing thus plays a vital role in ensuring transformer reliability, extending equipment lifespan, and averting costly downtime in electrical power systems.
• Dissolved Gas Analysis (DGA):detects even minute traces of dissolved gasses, acting as early warning signs of internal faults and overheating.
• Physical and chemical tests:measure key parameters like viscosity, acidity, and moisture content, providing a holistic picture of oil health.

2. Detailed Reports and Trend Analysis

• Results are presented in clear, concise reports tailored to the mine’s specific needs, offering actionable insights that go beyond raw data.
• By tracking oil condition over time, trend analysis empowers the WearCheck team to identify subtle changes and predict potential problems before they escalate.

3. Expert Interpretation and Recommendations

• WearCheck’s team of seasoned transformer oil specialists don’t just analyse data; they translate it into actionable insights.
• They conduct root cause analysis of any identified issues, pinpointing the exact source of the problem.
• They provide clear recommendations for corrective actions, like oil filtration, additional testing, or even equipment adjustments.
• Additionally, they offer predictive maintenance advice, empowering the mine’s maintenance team to prevent future failures before they even have a chance to occur.

4. Customised Service Packages

WearCheck understands that no two mines are alike. The company offers a variety of service packages to cater to individual requirements, ensuring that each mining operation gets the level of coverage and support they need, without unnecessary expense.

5. On-site Training and Support

Empowering the maintenance team is key. WearCheck offers training programmes designed to equip mining maintenance personnel with the knowledge to understand transformer oil analysis reports and make informed maintenance decisions. Additionally, their ongoing support ensures the efficient implementation of their recommendations, keeping transformers operating at peak performance.

The Payoff: Powering Up Productivity and Profitability

The benefits of WearCheck’s transformer monitoring services go far beyond merely avoiding downtime. They empower mining operations to:

• Reduce Downtime:by proactively identifying and addressing potential issues, mines can prevent unplanned outages, ensuring smooth and uninterrupted operations.
• Extend Equipment Life:timely intervention and optimised maintenance practices significantly extend the lifespan of transformers, saving the mines money on replacements.
• Improve Operational Efficiency:reliable transformers translate to a consistent power supply, minimising disruptions and optimising mining processes for maximum efficiency.
• Enhanced Safety:early detection of potential hazards like overheating and incipient faults prevents transformer fires and accidents, safeguarding mine-based personnel and equipment.
• Cost Savings: the combined impact of reduced downtime, extended equipment life, and optimised operations translates to significant cost savings. By preventing failures, WearCheck helps mines to avoid hefty repair costs and lost production revenue, optimising the bottom line.
• Transparency and Trust: WearCheck operates with complete transparency, providing detailed reports and clear explanations of their findings and recommendations. This fosters trust and collaboration, empowering mines to make informed decisions about transformer health management.
• Sustainable Operations: by ensuring efficient power usage and minimising transformer-related downtime, WearCheck contributes to sustainability goals. By optimising equipment life and reducing waste, mining operations can minimise their environmental footprint and operate more responsibly.

Nel and his team understand that mining operations face inherent risks and uncertainties. When it comes to transformers, however, mines don’t have to operate in the dark. WearCheck’s transformer oil testing services offer peace of mind by providing predictability, control and confidence.

Nel reaffirms that these services are not just an expense; they are an investment in the future of the mine, and the greater environment in which it operates. “By ensuring reliable power, minimising downtime, extending equipment life, and optimising operations, a mine can gain a competitive edge and maximise profitability,” he said.

“In today’s competitive mining landscape, reliable power is not a luxury; it’s a necessity. WearCheck offers a powerful solution, empowering mines to operate with confidence, optimise productivity, and achieve full potential. Our transformer team is standing by to partner with mines to power up their mining operation for a brighter, more sustainable future.”