Tag Archives: Trafo Power Solutions

TRAFO POWER SOLUTIONS HIGHLIGHTS THE GROWING DEMAND FOR DRY-TYPE TRANSFORMERS

As industries continue to prioritise safety, environmental responsibility, energy efficiency and operational reliability, dry-type transformers are increasingly replacing traditional oil-filled units across a diverse range of applications. From mining and mineral processing to manufacturing, commercial buildings, data centres, transport infrastructure and renewable energy projects, the technology is proving its value wherever dependable electrical power is essential.

According to David Claassen, Managing Director of Trafo Power Solutions, the growing adoption of dry-type transformers reflects a broader shift towards electrical infrastructure that delivers long-term performance while reducing operational and environmental risk.

“Customers today are evaluating electrical infrastructure far more strategically than they did in the past,” Claassen says. “They are looking beyond the initial purchase price to consider safety, reliability, maintenance requirements, environmental impact and total cost of ownership. Dry-type transformers offer significant advantages across all of these areas.”

Unlike conventional oil-filled transformers, dry-type units use air rather than insulating oil for cooling. This eliminates the risk of oil leaks and significantly reduces fire hazards, making them particularly well suited to indoor installations and environments where safety, environmental protection and equipment reliability are critical.

These advantages have driven increasing adoption across a wide range of industries. In mining and mineral processing, dry-type transformers provide safe, dependable power for underground operations, processing plants and mobile substations. 

Manufacturing facilities benefit from their low maintenance requirements and ability to perform reliably in demanding industrial environments. Data centres value their high reliability and suitability for indoor installations where uninterrupted power supply is essential, while renewable energy projects increasingly incorporate dry-type technology into solar photovoltaic, battery energy storage and hybrid power systems.

“One of the greatest strengths of dry-type transformer technology is its versatility,” Claassen explains. “Whether it is supporting a remote mine, a modern manufacturing facility, a commercial development or a renewable energy installation, the technology delivers reliable performance while addressing increasingly important safety and environmental requirements.”

Because dry-type transformers eliminate insulating oil, they also reduce the risk of environmental contamination, supporting organisations’ sustainability objectives and simplifying environmental management. Their robust construction allows them to perform reliably under challenging operating conditions while requiring relatively little routine maintenance, contributing to improved equipment availability and lower lifecycle costs.

As industries continue investing in modern electrical infrastructure, Claassen believes the emphasis will increasingly shift towards engineered solutions designed around specific operating environments rather than standardised equipment.

Dry-type transformer technology from Trafo Power Solutions helps improve safety, reduce maintenance and enhance long-term operational reliability.
Dry-type transformer technology from Trafo Power Solutions helps improve safety, reduce maintenance and enhance long-term operational reliability.

“There is no single transformer solution that suits every application,” he says. “Each project has unique operating conditions, load profiles and environmental considerations. By understanding these requirements, we can engineer solutions that deliver reliable performance, maximise operational efficiency and provide long-term value throughout the life of the installation.”

With demand growing across multiple sectors, Trafo Power Solutions continues to support customers with application-specific dry-type transformer solutions designed to improve safety, enhance reliability and meet the evolving power requirements of modern industry.

TRAFO POWER SOLUTIONS BUILDS ON PROVEN SUCCESS TO EXPAND MARKET SHARE

As demand grows across Africa for reliable engineered electrical power solutions, Trafo Power Solutions is continuing to build on a strong track record of delivery, innovation and technical support to expand its market share across key sectors.

Every Trafo Power Solutions solution is engineered to meet the specific demands of each application and operating environment.
Every Trafo Power Solutions solution is engineered to meet the specific demands of each application and operating environment.

Having established itself as a trusted specialist in dry-type transformers and modular electrical infrastructure, the company is strengthening its position in mining, industrial, infrastructure, data centre and renewable energy applications by delivering solutions tailored to increasingly complex operating environments.

According to Managing Director, David Claassen, sustained growth in market share is being driven by a combination of technical expertise, application-specific engineering and a proven ability to respond quickly to customer requirements.

Trafo Power Solutions delivers engineered electrical power solutions for reliable performance across mining, industry and infrastructure.
Trafo Power Solutions delivers engineered electrical power solutions for reliable performance across mining, industry and infrastructure.

“Growth in our market share is a direct result of consistently delivering dependable solutions that address the operational realities faced by our customers,” Claassen says. “Clients are looking for partners who understand the risks around power reliability, uptime and safety -and who can engineer solutions that perform in demanding conditions.”

Originally recognised for its expertise in dry-type transformer technology, the business has successfully broadened its offering over the years to become a comprehensive provider of electrical power solutions. This includes transformers, mini substations, switchgear integration and containerised power systems designed for rapid deployment and long-term reliability.

Trafo Power Solutions continues to expand across Africa by delivering dependable, engineered electrical power solutions.
Trafo Power Solutions continues to expand across Africa by delivering dependable, engineered electrical power solutions.

The company’s growth strategy has focused strongly on sectors where dependable electrical infrastructure is business-critical. In mining, for example, reliable power distribution is essential to maintaining production continuity across both surface and underground operations.

“In industries such as mining, any interruption to power can have a direct impact on productivity, safety and operational efficiency,” Claassen says. “Our focus is therefore not only on supplying equipment but on understanding the application and engineering a solution that supports long-term performance.”

A key differentiator for the business has been its emphasis on engineered solutions rather than standard off-the-shelf supply. By working closely with clients during the design and specification phase, Trafo Power Solutions ensures that each installation is aligned to site-specific requirements, environmental conditions and future expansion plans.

Trafo Power Solutions combines engineering expertise with practical solutions to improve power reliability and efficiency.
Trafo Power Solutions combines engineering expertise with practical solutions to improve power reliability and efficiency.

This consultative approach has helped the company secure repeat business and strengthen long-term relationships with customers across southern and central Africa.

The business also continues to invest in technical capability, regional support structures and partnerships that improve response times and after-sales service – all of which contribute to growing customer confidence and market penetration.

As infrastructure investment, mining development and energy projects continue to gather momentum across the continent, Trafo Power Solutions believes its growth trajectory remains strong.

From transformers to containerised power systems, Trafo Power Solutions delivers integrated electrical infrastructure for demanding applications.
From transformers to containerised power systems, Trafo Power Solutions delivers integrated electrical infrastructure for demanding applications.

“Our growth is built on performance, trust and engineering excellence,” Claassen says. “By continuing to deliver solutions that meet evolving market needs, we are well positioned to further strengthen our footprint and expand our share of the market.”

TRAFO POWERS UP MINE IN PAKISTAN WITH TRANSFORMERS BUILT FOR EXTREME CONDITIONS

South Africa-based Trafo Power Solutions is boosting the power infrastructure of a mining project in Pakistan, being built on one of the world’s largest undeveloped copper-gold reserves. 

Supplying one of the engineering, procurement and construction (EPC) contractors to the project, Trafo Power Solutions is providing 13 dry-type transformers for inclusion in e-houses on the remote site. The project is located in the Chagai district of Balochistan, close to the borders of Afghanistan and Iran, with terrain that is arid and semi-arid, characterised by deserts, mountain ranges, sparse vegetation and regular dust storms. 

According to David Claassen, Managing Director of Trafo Power Solutions, the transformers have been designed to meet the challenges of this remote and demanding mining environment.

“The range of dry-type transformers that we are supplying to this copper-gold project in its early works phase of development include smaller isolation transformers rated at 5 kVA, lighting transformers of 75 kVA, and larger units of between 250 kVA and 1,000 kVA for power distribution functions,” Claassen says. 

While Trafo Power Solutions has designed the transformers for indoor operation in the e-houses, the high ambient temperatures of the site have been taken into account. The design therefore caters for daytime temperatures of over 50 degrees Celsius – with Class H insulation. 

“To improve the turnaround time, we manufactured the enclosures in South Africa and importantly these could be flat-packed for easier logistical handling to site,” he explains. “The dry-type transformers themselves were shipped by our manufacturing partners TMC Transformers in Italy, directly to the site in Pakistan.”

He highlights that while the manufacturing of the transformers takes place in Italy, Trafo Power Solutions conducts the factory acceptance testing with the customer. The order also includes 18 neutral earth resistors (NERs) which are connected to the star point of the transformers to limit the earth fault current. 

“We are supplying a number of 690 V air-type NERs as well as 11 kV NERs which are rated at 300 amps for 10 seconds – also capable of operating in air temperatures of up to 50 degrees Celsius,” Claassen says. 

He points to the reliability of dry-type transformers as an important benefit to users on remote sites such as this one in Pakistan, as well as the limited maintenance they require. Unlike conventional oil-cooled transformers, where the oil needs regular testing and replacement, dry-type units are air-cooled and seldom require any active maintenance. 

With its depth of experience in installing and commissioning its transformers and other electrical power solutions, Trafo Power Solutions supports the customer during these phases and provides technical support into the future. 

“We will work closely with our EPC customer who is installing the e-houses to ensure that the transformers are adequately protected from the severe external environment conditions such as heat and dust,” he says. 

This ensures that the transformers require minimal attention after being commissioned, limiting the need for anyone to undertake the costly and time consuming journey to the site. This factor further reduces the total cost of ownership of these units over their operating lifetime. 

TRAFO POWER SOLUTIONS DELIVERS FUTURE-READY ELECTRICAL INFRASTRUCTURE FOR EVOLVING MINE NEEDS

The ability to design and scale electrical infrastructure for mines’ changing needs has become a critical competitive advantage for Trafo Power Solutions, allowing customers to avoid costly re-engineering as their mines evolve.

“Mining is dynamic by nature, and this fundamentally shapes our approach to designing transformers, modular substations and other solutions for the sector,” David Claassen, Managing Director of Trafo Power Solutions, explains. “Mines often need to move equipment around, for instance, and even the load requirements may change over time – so we design with that in mind.” 

This requires that Trafo Power Solutions be engaged with the customer from the very earliest stages of a mining project, often even before formal feasibility studies begin. Mines typically require high-level estimate numbers during concept or desktop studies and this is where the company begins helping mines to shape their longer-term electrical strategy.

“We get involved at pre-feasibility or even concept stage,” Claassen says. “Our tender and proposals department is geared to provide indicative costing very quickly – using our wide reference base where we have detailed data on our extensive installed footprint.”

By entering the process early, the company can add technical value to foundational decisions, to avoid costly re-designs at a later stage. Customers are guided through the available options in aspects such as transformer sizing, substation placement and modular configurations – aligning not only with initial load requirements but with the entire life-of-mine plan.

“By talking to customers early and asking the right questions, we develop an understanding of what their future plans are and can design accordingly,” he explains. “Instead of providing a 2 MVA transformer, we might suggest a 3 MVA unit that fits the same footprint, to avoid the cost and operational disruption of upgrading.”

This approach can also help to control initial start up costs, while providing flexibility as the project evolves. He notes that containerised modular substations are increasingly favoured by mining customers for their mobility, scalability and reduced civil works requirements. In contrast to brick-and-mortar substations, modular units can be moved as the mine develops, supporting phased expansions or shifting production priorities.

“Modular substations lend themselves to flexibility because of their plug-and-play design,” Claassen says. “Our skid-mounted or mobile options are ideal for mining operations where relocation is expected, whether underground or on surface.”

This lifecycle-focused mindset allows Trafo Power Solutions to align electrical infrastructure with long-term operational realities rather than short-term project constraints. It ensures that mines can increase production, shift layouts or accelerate expansion plans without being constrained by equipment designed only for the initial build.

“Our aim is to give our clients the best possible experience at all levels – and at every stage in the life of their project,” he concludes. “We take responsibility, we ask the right questions and we make sure the infrastructure we supply keeps supporting them long into the future.”

ENGINEERING THE FUTURE: TRAFO POWER SOLUTIONS AND TMC TRANSFORMERS SET NEW STANDARDS IN DRY-TYPE TECHNOLOGY

As demand grows for safer more reliable and environmentally responsible power infrastructure, dry-type transformer technology is gaining ground globally – and leading the charge in Africa is Trafo Power Solutions, in partnership with renowned Italian manufacturer TMC Transformers.

This dynamic collaboration, now in its seventh year, continues to push the boundaries of dry-type transformer design and application. According to Trafo Power Solutions Managing Director David Claassen, the company has played a pivotal role in introducing this technology to a wide range of industries across Africa, from mining and manufacturing to renewable energy and infrastructure.

“Our work with TMC Transformers enables us to deliver custom engineered dry-type transformer solutions that meet even the most demanding specifications,” says Claassen. “Our success lies in a shared culture of innovation, agility and technical excellence.”

TMC Transformers Sales Director Andrea Ghidini explains that the company is known for tackling complex challenges with highly specialised solutions. “We are often approached for non-standard applications, such as transformers with ratings up to 25 MVA or primary windings at 50 kV, or units handling extreme harmonic distortion or secondary currents of up to 30,000 amps,” he says.

In African mining operations – one of Trafo Power Solutions’ primary markets – the challenges extend beyond electrical performance. Transformers must be robust enough to endure long and difficult transport routes, severe vibration, high dust levels and extreme temperatures.

“Dry-type technology is ideal in these environments, especially as safety and environmental concerns grow,” Claassen notes. “Unlike oil-filled transformers, dry-type units are air-cooled and present minimal fire risk, making them suitable for installation near operational areas and personnel.”

Once confined to indoor use, dry-type transformers are now widely used in outdoor applications thanks to technological advancements. Higher protection ratings and improved cooling options, including forced-air, air-to-water and direct or indirect water cooling, allow these units to operate reliably even in Africa’s toughest climates.

What sets this partnership apart is its commitment to engineering precision. TMC uses advanced simulation tools, including finite element analysis and thermo-dynamic modelling, to verify every design before production. This ensures optimal performance, long-term reliability and reduced operational risk.

“Rather than just meeting the brief, we interrogate every application to offer smarter alternatives or highlight potential issues,” says Ghidini. “That is the value of custom engineering.”

Claassen adds that customers benefit from this depth of expertise: “We don’t just sell transformers – we deliver engineered power solutions that support long-term operational success.”

With this collaboration, Trafo Power Solutions and TMC Transformers continue to redefine what is possible in dry-type transformer technology – setting new benchmarks for innovation, safety and performance across the continent.

TRAFO POWER SOLUTIONS STRENGTHENS PRESENCE IN AFRICAN MINING WITH TRANSFORMER SUPPLY TO MOZAMBIQUE

Providing tailored electrical power solutions to the African market has positioned Trafo Power Solutions as a key player in the region. The company’s success is rooted in its deep expertise, extensive experience and thorough understanding of the needs of mining operations across the continent. This has enabled Trafo Power Solutions to meet the unique challenges associated with electrical power supply in these harsh and demanding environments.

One of the company’s latest projects highlights its ability to provide specialised transformer solutions suited to the rigorous conditions of mining applications. Trafo Power Solutions recently supplied nine transformers to an electrical contractor for installation at a mineral sands operation in Mozambique. 

This delivery included seven 800 kVA transformers designed for skid mounting, ensuring ease of mobility across the expansive mining site. The remaining two units, rated at 160 kVA, will be pole-mounted. All transformers in this order are rated at 22 kV to 415 V, aligning with the site’s specific voltage requirements.

David Claassen, Managing Director of Trafo Power Solutions, explains that this latest order follows a previous successful supply of four dry-type transformers directly to the mining operation. The earlier batch included 3150 kVA transformers, also rated at 22 kV to 415 V, and installed within IP23 enclosures. These transformers were equipped with the necessary control and protection equipment to ensure robust performance in the highly corrosive operating environment of the mineral sands mine.

“The mineral sands mining environment is particularly harsh, with high humidity and salinity levels that can accelerate corrosion. Our transformers are specifically designed to withstand these conditions, ensuring longevity and reliability in such an aggressive setting,” says Claassen.

A key factor in this repeat business was the mine’s confidence in the performance of the previously supplied transformers. “When the need arose for additional transformers, the customer specifically requested Trafo Power Solutions, which underscores our commitment to delivering quality solutions that meet the exact needs of mining operations,” Claassen adds.

One of the critical design considerations for these transformers was minimising electrical losses while ensuring the ability to handle large non-linear loads from the mine’s Variable Speed Drives (VSDs). These transformers were engineered according to SANS 780 Edition 5.1 standards to achieve the lowest possible losses. Additionally, due to the site’s known voltage supply instability, the transformers were designed to withstand fluctuations while maintaining consistent and reliable power.

Aside from the technical specifications, the project also posed significant logistical challenges. The remote location of the mine required careful planning to ensure the seamless transportation and installation of the transformers. “Logistics is always a key factor when supplying equipment to mining operations in remote areas. We worked closely with our partners to ensure a smooth delivery process despite the challenges,” says Claassen.

Further reinforcing its relationship with the electrical contractor and the mine , Trafo Power Solutions has secured an additional order for 18 transformers, which are scheduled for delivery by the third quarter this year. This ongoing partnership underscores the company’s reputation as a trusted supplier of high quality, purpose-built transformers tailored for mining applications in Africa.

As Trafo Power Solutions continues to expand its footprint across the continent, its commitment to delivering reliable, durable and efficient electrical power solutions remains at the forefront of its strategy. With a strong focus on engineering excellence and a deep understanding of mining conditions, the company is well-positioned to support the sector’s evolving power infrastructure needs.

DRY-TYPE TRANSFORMERS PUSH BOUNDARIES IN DUTCH INTAKE SUBSTATION

A data center in the Netherlands is the site of a recent innovation on the transformer landscape, where TMC Transformers has designed, manufactured and installed dry-type transformers in a large intake substation. Managing Director of Trafo Power Solutions, David Claassen explains the significance of this pioneering project.

“Trafo Power Solutions was involved in this project from inception having been the first point of contact with the substation engineering team, and TMC Transformers gratefully accepted the challenge,” he says. “Following multiple conceptual studies, the design was completed and the project started.”

The supply of three dry-type transformers for a large intake substation in the Netherlands has pushed the boundaries of this technology’s application, according to Claassen.

The substation project, for a data center expansion, also led to the manufacture of the largest dry-type transformers yet by leading Italy-based multinational TMC Transformers. The scope of supply for the data center included three 22,5 MVA transformers operating at a voltage level of 50 kV, stepping down to 13,8 kV. 

Claassen highlights that the use of dry-type transformers in a large substation like this is unusual, as they are more often used in lower power distribution applications in data centers. 

“This is an exciting flagship project for both TMC and Trafo Power Solutions, as it is a strong affirmation of our efforts to expand the application of dry-type technology to projects that demand higher power and voltage,” says Claassen. “It also adds considerably to the options for customers in many industrial applications.”

By selecting the dry-type transformer option for its substation, the data center could locate the transformers inside the facility, where it could be built in close proximity to the indoor switchgear. 

“An important challenge in implementing this design is the dissipation of heat,” he explains. “Dry-type transformers are predominantly used indoors and their application on such a large scale required innovative cooling strategies.”

This is where the design ingenuity of Trafo Power Solutions and TMC Transformers won through, leading to the implementation of the appropriate design and cooling strategies. The final result was achieved through a number of design iterations by Trafo Power Solutions, worked through with TMC, the substation provider and the end-client.

The installation means that the intake transformer now gains from the established benefits of dry-type transformers. A key advantage is their high level of reliability and the minimal maintenance they require. 

“In this data center application, these benefits are particularly important, as these facilities prioritise uptime,” he says. “As a critical item of equipment, the intake transformer needs to ensure minimal downtime which dry-type transformers typically deliver.”

The success of this project was underpinned by Trafo Power Solutions’ synergy with TMC Transformers, he says, who are known not only for the manufacturing quality of their standard-type transformers but for their expertise in special designs. This capability includes producing dry-type transformers that need to cater for a high voltage or power range. 

“While many companies in Europe tend to be more conservative than we are in South Africa, we have found an innovative partner in TMC,” he argues. 

TRAFO EVOLVES TO OFFER RANGE OF ELECTRICAL POWER SOLUTIONS

Having rapidly carved a niche in dry-type transformer applications in Africa, Trafo Power Solutions has steadily grown its offerings – and now sees a future as a leading provider of electrical power solutions. 

This evolution has been underpinned by the company’s strong design and engineering capability, and its in-depth technical understanding of various aspects of electrical projects. Managing Director of Trafo Power Solutions, David Claassen, says the success to date has been based on its customised design and rapid execution of solutions that fit perfectly into the broader project requirements.

“We have a reputation for how well we understand the conditions and applications in which our transformers must operate,” says Claassen. “This broad technical knowledge has also allowed us to build more complete solutions that include a transformer as one of the many components.”

For instance, Trafo Power Solutions has been growing into the field of integrated modular substations for the mining and other sectors. These installations have seen particularly enthusiastic uptake in mining due to often remote locations at which power is required. Building a traditional brick-and-mortar substation on site can be complex and time consuming, whereas a modular substation or e-house can be constructed and tested in a specialised workshop – and then shipped to site.

“Our dry-type transformers are ideally suited for these installations, as their high safety rating allows them to be integrated into the substation structure during assembly,” he says. “In contrast, conventional oil-cooled transformers carry a higher safety risk, so must usually be located separately; they also need protective infrastructure to ensure that any oil leakage does not cause environmental contamination.”

Trafo Power Solutions’ depth of expertise and experience allows it to design and supply entire modular substations, which have been supplied to customers around Africa. A recent order, for a skid-mounted solution, was even undertaken for a mining customer in Australia, and completed in a short timeframe that could not be matched by competitors. 

The company’s strategy to further grow its range of electrical power solutions is supported by its established relationships with blue-chip customers, who include end-users, engineering, procurement and construction (EPC) firms and electrical consultants. 

“We see engineering capability as the heart of our business, and so we focus on value addition in our customer relationships,” he says. “We are also strengthening our footprint across Africa to be closer to customers, developing links with specialist in-country partners as we develop and apply high value solutions.”

MINIMAL MAINTENANCE FOR DRY-TYPE TRANSFORMERS

With minimal levels of maintenance needed, dry-type transformers offer reliable performance over lengthy lifespans, with few of the risks and hazards associated with oil cooled transformers. 

According to David Claassen, Managing Director of dry-type transformer specialist Trafo Power Solutions, the fact that these units are air cooled means much of the limited servicing required relates involves maintaining clear air channels, which can be compromised by the accumulation of dust layers.

“To allow for the transformer to cool effectively, it is important to regularly check that there is not an excessive build-up of dust on or around the transformer,” Claassen explains. “Depending on the ambient conditions, dust can build up in these confined spaces and start to impede the free flow of air.”

Dust accumulation can be easily addressed by using a leaf blower or similar appliance to remove the dust from the transformer. This method quickly disperses the dust, leaving the surfaces clean and allowing for more efficient heat transfer. 

He highlights that a regular maintenance schedule is especially vital in applications such as coal mines, where there are often high dust levels. Where dust layers prevent adequate cooling, the transformer could run at temperatures higher than its design parameters. This, in turn, degrades the insulation material faster and could significantly reduce the unit’s lifespan. Even in the event that a completely sealed enclosure is used (≥ IP55), it is possible for dust to enter the enclosure while the doors are opened or in cases where the doors are left open accidently. 

“It is also important to check that the temperature probes are measuring accurately,” he notes. “This, of course, ensures that any unexpected temperature rise will trigger the necessary alarm, and that the feed-in circuit breaker to the transformer is tripped in the event of overheating.”

Terminals on the transformer should be checked, as it is possible for these connections to loosen due to vibrations or other factors. This is a simple process of checking the torque on these connection points, as any looseness could lead to partial discharge, heat build-up and further damage.

To guide the customer in their maintenance planning, Trafo Power Solutions provides a maintenance manual with each installation. This details the required frequency of service interventions, which in a clean indoor environment is usually only once a year. Under dusty conditions that might be encountered outdoors, the maintenance should normally be conducted every six months.

“Beyond our standard requirements, we also provide our customers with site-specific servicing guidelines that suit their application and environment,” says Claassen. “Indeed, we can provide the actual maintenance service should the customer require – ensuring that they have access to a detailed log of results and recommended interventions.”

He explains that, while the maintenance tasks are generally straightforward, the transformer does need to be de-energised by a qualified technician before this work is conducted. This ensures the necessary compliance to regulations relating to medium voltage equipment, including procedures for lock-out and isolation. 

“A key advantage of dry-type transformers is that this maintenance is relatively quick and simple compared to oil cooled transformers,” he notes. “A key difference in the servicing of these two technologies is that conventional oil cooled transformers require oil samples to be regularly taken and sent away for testing and analysis. This is a costly and time consuming addition to their total cost of ownership.”

SPECIFY YOUR TRANSFORMER WITH TOTAL COST OF OWNERSHIP IN MIND

Rather like a vehicle, the total cost of running and maintaining a transformer over its lifespan will be considerably higher than its purchase price; these other cost factors therefore deserve close consideration before any purchasing decision is made. 

“The rated power of a transformer is usually among the key determinants of its capital cost, but there are various design differences which will also come into play,” says David Claassen, Managing Director of Trafo Power Solutions. 

To help the purchaser to effectively assess the capital cost, transformer manufacturers need to provide a detailed data sheet indicating required parameters such as losses, windings material and environmental conditions to name a few. . 

“The next main area of costs is operational – in other words, the running and maintenance costs,” explains Claassen. “Running cost is essentially the cost of electricity, measured in kWh. These costs are affected by the efficiency of the transformer. All transformers have both no-load losses and load losses. The monthly cost of electricity for low loss transformers is lower than that of those with higher losses. However, the capital cost of a low loss transformer will be higher due to the design requirements to meet lower losses.” 

Turning to the maintenance costs, he points out that these vary considerably between oil cooled transformers and dry-type transformers – the latter being cooled by air. Oil samples from oil type transformers need to be regularly taken and analysed as this provides valuable insight into the condition of the unit and any possible areas of underperformance.

“These oil checks are similar to taking a blood sample, as the analysis allows the owner to predict the necessary steps to keep the transformer in optimal condition,” he says. “In dry-type transformers, the absence of oil as a coolant significantly reduces the maintenance cost.”

Other important maintenance tasks include testing of a transformer’s instrumentation such as temperature and pressure gauges, as well as relays. Dry-type transformers will tend to have less instrumentation, with a focus on temperature variation and surge protection. On all types of transformers, it is vital to regularly test that the probes are accurately measuring the unit’s temperature. Another basic check is the torque measurement on the termination points. 

“The next big cost factor to consider is the installation cost of the transformer,” he says. “There are regulations that govern where and how transformers are installed, depending on their characteristics – such as their fire hazard level and their potential danger to the environment.”

Oil cooled transformers are, generally speaking, classified as hazardous in terms of their fire risk, so must be located at a safe distance from human activity. Systems need to be in place to both detect and suppress a fire in the transformer, should this occur. There is also a requirement for containment of oil, in case of a leak or rupture – to avoid environmental damage. 

The inherent safety of dry-type transformers means that they can be installed indoors without this added infrastructure. Rated as Class F1 for fire safety, this dry-type technology can even be safely installed in confined spaces. Where an outdoor location is required, a concrete plinth is usually sufficient as a base. 

“When considering the total cost of ownership – in other words, the capital cost plus operational cost plus installation cost – there is a compelling argument in favour of dry-type transformers, particularly for applications of 5MVA and below up to a voltage level of 33kV,” Claassen says. “This argument becomes stronger with the number of transformers present on a single site.”

On a large mining or industrial site, which may have dozens if not hundreds of transformers, it reduces the cost and workload substantially if they are low maintenance dry-type units. As these operations look to become safer and more streamlined, there are great opportunities offered by dry-type transformers, he says. 

As the price of electricity continues to rise, there is also a focus on reducing the energy losses incurred by transformers. This, he explains, highlights why transformer suppliers must be able to quantify the predicted losses over time. 

“By specifying a lower-loss design, a purchaser could calculate whether it is worth spending more upfront on the capital cost, in order to save on losses over the 20 to 30 year lifespan of the transformer,” he concludes.