Insulation Reliability
for Hydroelectric Drive Systems
1. Customer Profile
- Direct customer: Electronic design firm
- End-use sector: Drive systems for hydroelectric power plants
- Relationship type: Design partner for a major end customer
- Relationship with Sirio: Exclusive supplier of this component for 8 years
2. The Challenge
The design firm contacted Sirio Elettronica after their key client – a manufacturer of hydroelectric power plants – reported repeated insulation failures in the pulse transformers used in their drive systems. Upon analyzing failed units from the previous supplier, the design engineers found:
- Burn marks inside the components
- Signs consistent with partial discharges
- Likely cause: insulation degradation
- They needed a more robust and reliable solution, capable of withstanding demanding operating conditions.
3. The Sirio Solution
Sirio responded quickly and effectively:
- Within just 2 weeks, Sirio developed a custom transformer only 2 mm larger than the original
- The design was tailored specifically to the project’s needs, optimizing clearances and materials to maximize dielectric strength
- The components were vacuum resin encapsulated to ensure durability and resistance to aging
- At the customer’s request, Sirio conducted insulation and partial discharge tests at multiple operating temperatures
4. The Results
- The new solution has been in use for 8 years without failures
- Sirio is now the sole supplier for this component
- The design firm successfully restored trust with their end customer, reinforcing the reliability of their project
5. Looking Ahead
This successful collaboration strengthened the partnership between Sirio and the design firm, paving the way for further co-engineering opportunities in high-reliability, technically demanding projects.
