Case Study - THUNGELA

Overview

The primary challenge faced by Thungela Mining was the lack of a systematic approach to assess and rank the health of their transformer fleet. This gap hindered proactive maintenance strategies, potentially leading to unexpected failures and operational disruptions. Thungela sought a robust solution to accurately identify the condition of transformers and prioritize maintenance based on the criticality and health of each unit.

To address these challenges, we introduced a comprehensive transformer assessment program that includes both online and offline evaluations. This program is designed to form the basis for fleet ranking by detecting weaknesses in condition indicators such as dielectric and thermal properties.

The service encompasses the following key components: gathering essential data from the transformer’s nameplate to understand specifications and operational parameters; conducting thorough inspections to identify any external signs of wear, corrosion, or potential failure points; analysing insulating oil for contaminants and degradation products, which can indicate the condition of the transformer and the likelihood of internal issues; using infrared technology to detect hot spots and other anomalies that are indicative of electrical faults; detecting and measuring discharge as an indicator of the insulation system’s health.

Each transformer is scored based on the outcomes of these assessments, enabling Thungela to rank their fleet from healthiest to those requiring immediate attention.

The implementation of this assessment protocol was spearheaded by Mr. Sipho Ndlovu, the contact person at Thungela. Our team worked closely with Mr. Ndlovu to tailor the assessment criteria to align with Thungela’s specific operational needs and infrastructure.

The process involves regular scheduled assessments and the integration of real-time monitoring tools that provide continuous insights into the condition of each transformer. This proactive approach allows for timely interventions before potential failures escalate into costly repairs or replacements.

What we did