Is your power system performing below expectations but you can’t pinpoint why?
If your energy bills are creeping up or your transformer feels hotter than usual, the problem might be deeper than you think. Hidden behind the casing, your transformer’s core could be quietly draining efficiency and profits.
In power systems, efficiency isn’t just a technical metric; it’s a direct line to your bottom line. At the heart of every transformer lies the core, a structure responsible for channeling magnetic energy with minimal loss. But when that core begins to degrade, even slightly, the impact can ripple through your entire operation.
Made from Cold Rolled Grain Oriented (CRGO) steel, the transformer core is designed to limit energy loss. Yet over time, wear and poor assembly can lead to rising hysteresis and eddy current losses that are often invisible until they hit your performance or wallet.
Here are five warning signs to watch out for:
1. Unusual Heat Build-Up Without Load Increase
Transformers naturally warm up during operation. However, if you notice a persistent temperature rise even when the transformer is idle or lightly loaded, it could indicate excessive no-load (core) losses.
This happens when the magnetic properties of the core deteriorate or when laminations are poorly stacked, leading to increased energy dissipation as heat. Overheating isn’t just a maintenance issue, it’s a red flag that your transformer is working harder than it should.
2. A Louder Hum Than Usual
Transformers hum due to the magnetostriction effect, but if that hum becomes louder or uneven, it may point to issues inside the core.
Loose or poorly clamped laminations can vibrate more intensely, causing not only noise but also mechanical stress and higher energy loss. Over time, these vibrations can damage the core further, amplifying the problem.
Pro tip: A transformer’s sound can tell you a lot if you listen closely.
3. Rising Energy Bills or Falling System Efficiency
Sometimes, the signs aren’t mechanical, they’re financial.
If your facility’s energy usage has increased without any major load changes, an inefficient transformer core might be to blame. Outdated or low-quality core materials can lead to consistent energy wastage, especially in older transformers that weren’t designed with modern efficiency standards.
Solution? Run an energy audit or a no-load loss test. You may be surprised by what you find.
4. Visible Damage or Misalignment in Laminations
If your transformer is due for maintenance or inspection, take a close look at the core stack.
Rust, burrs, uneven edges, or misaligned laminations can disrupt the magnetic path and increase losses. These defects may seem minor, but they allow magnetic flux to leak or circulate inefficiently, making your system less effective over time.
Precision in core manufacturing like laser-cut edges and mitred joints can prevent this from happening in new installations.
5. Malfunctioning Nearby Equipment or Interference
This is one of the more unexpected symptoms. If nearby electrical equipment is experiencing unexplained interference, it could be due to flux leakage from the transformer core.
When laminations degrade or insulation weakens, stray magnetic fields can escape and disrupt sensitive electronics. This not only affects efficiency it becomes a safety and reliability issue.
EMI issues may not scream “core problem,” but often, that’s exactly where it starts.
Why It Matters
A transformer core is like the silent engine room of your power system. You don’t see it, and you rarely think about it until something goes wrong. But the impact of a faulty core can ripple across your energy consumption, operational costs, and system lifespan.
The good news? These losses are preventable.
With high-quality CRGO laminations, precision manufacturing, and regular maintenance, transformer cores can deliver long-term efficiency with minimal loss.
At Sarjani Coretech, we’ve spent over two decades perfecting transformer core solutions that reduce energy losses at their source.
From mitred and rectangular laminations to customized core assemblies, our products are built for performance, precision, and peace of mind.
Not sure if your transformer core is holding you back?
Let’s talk. Sometimes, solving an energy problem starts with going back to the core.