Replacement of transformers

Replacing 19 transformers with modern low-loss units achieved energy savings of 747 MWh and 244,000 PLN per year.

The challenge

The audited plant had 19 transformers with capacities from 800 kVA to 1,600 kVA. Most of them dated back to the 1970s and had been in operation for over 35 years. Despite functioning correctly, their continued use was uneconomical – generating high energy losses due to aging effects such as:

degradation of winding insulation,
deformation of windings under electromagnetic forces,
increased no-load losses, occurring independently of load.

The goal was to reduce transformation losses and improve the energy efficiency of the plant's power supply system.

Our approach

The DB Energy team carried out:

an audit of transformer operation using measurement data,
determination of the load factor β for each unit, allowing calculation of their annual energy losses,
comparative analysis of the costs of continuing to operate old transformers versus purchasing new units,
development of a transformer replacement plan maintaining rated power but significantly reducing energy losses.

Solution

All 19 transformers were replaced with modern units of the same rated power but with significantly lower energy losses, particularly no-load losses.

Investment costs amounted to 510,200 PLN.

Results

The actions taken by DB Energy resulted in:

annual energy savings: 747.07 MWh,
avoided costs: 244,350 PLN per year,
improved transformation efficiency and reduced no-load losses,
increased reliability of the plant's power supply system,
long-term reduction of operating costs.

Conclusions

Replacing transformers is an investment that – despite significant initial costs – generates a quick return through substantial energy and cost savings. The modernization provides benefits not only financial but also technical: improved efficiency, safety, and reliability of the plant's power system.

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