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Industrial & Manufacturing

Protecting Power to Critical Production

Industrial production depends on continuous, high-power electrical supply.
A single transformer failure can halt entire production lines, with immediate operational and financial consequences.

Industrial facilities rely on large, custom-built power transformers to sustain continuous production.
When one of these assets fails, recovery can take weeks or months — disrupting supply chains, contractual commitments and operational continuity.

Critical Industrial Environments

While industrial sectors operate under different processes and constraints, they share the same exposure to high-energy electrical failures and limited tolerance for downtime.

Chemical & Petrochemical Plants

Continuous processes, hazardous materials and tight layouts require protection against internal faults and cascading failures.

Steel & Metal Industries

High-energy furnaces and rolling mills depend on uninterrupted power. Transformer failure immediately disrupts production flow.

General Manufacturing & Heavy Machinery

Automated production lines and just-in-time operations leave little tolerance for electrical failure or extended downtime.

Industrial Failure Mechanisms

Across industrial facilities, transformer failures follow a limited number of physical mechanisms that determine the scale, duration and impact of an incident.

Harsh Environments

High thermal loads, vibration and dust accelerate transformer aging and increase fault probability.

40 Years

Aging, custom-built transformers extend replacement timelines and increase exposure to unplanned outages.

Months to Replace

Once damaged, bespoke transformers require long manufacturing, testing and logistics cycles before restart.

Standards & Compliance

Industrial transformer protection must align with international electrical and fire-risk frameworks to ensure insurability and regulatory acceptance.

NFPA 850

Regulation for power plants and heavy industry transformers, addressing hazard group techniques and fire protection.

IEC / IEEE

SERGI solutions meet international manufacturing and safety standards for industrial transformers.

Why SERGI for Industrial Facilities?

Protecting transformers means protecting production continuity.

Risk assessment & engineering study

Evaluate transformer behavior under real operating constraints and failure scenarios.

Simulation & testing

Validate protection concepts through multiphysics simulation and real-world testing.

Implementation & support

Deploy mechanically passive systems designed to operate without electronics or external power.

Operational Insight

A steel mill retrofitted SERGI’s protection system on a 100 MVA transformer, preventing rupture during an internal fault and enabling rapid restart of production without major asset damage. The solution operated passively, without sensors or control systems.

In industrial environments, protecting transformers is not about redundancy — it is about preserving production continuity when failure occurs.