Comprehensive Transformer AMC — Textile Manufacturing Unit, Tamil Nadu
A textile mill in Tamil Nadu operating six distribution transformers (250 kVA to 1000 kVA) had suffered two transformer failures in two years — both attributed to oil degradation and moisture ingress that went undetected. After the second failure, management moved to a proactive AMC model.
The Challenge
The mill's transformers were running 24/7 in a high-humidity environment. Without BDV testing, oil sampling, or periodic thermal inspection, insulation degradation and moisture ingress were invisible until failure. Two transformer replacements cost over ₹22 lakh, excluding production loss. The operations team needed a structured maintenance programme that could identify faults before they escalated.
The Actaan Solution
Actaan Electric put all six transformers on a Comprehensive AMC — quarterly visits covering BDV testing, oil sampling and analysis, silica gel breather replacement, winding resistance and IR testing, thermographic (IR) scanning under load, and Buchholz relay function testing. On the third quarterly visit, thermographic scanning identified a hotspot on the LV bushing of the 630 kVA unit — the transformer was scheduled for controlled oil processing and terminal retorquing before any failure occurred.
Scope of Supply & Work
- ·Quarterly BDV (breakdown voltage) testing on all six units
- ·Oil sampling and dissolved gas analysis (DGA)
- ·Silica gel breather inspection and replacement
- ·Winding resistance and insulation resistance (IR) testing
- ·Thermographic (IR) scanning under full load conditions
- ·Buchholz relay and pressure relief device function testing
- ·Detailed service report after every visit — full audit trail
Results
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