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David Claassen of Trafo Power Solutions highlights the advantages of engineered modular substation solutions that are factory-built to include integrated dry-type transformers.

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Purpose engineered modular substations

A 3 000 kVA dry-type transformer supplied by Trafo Power Solutions is housed in a modular substation, providing a robust and efficient power solution tailored for demanding site conditions.

Well known for its role in bringing dry-type transformer technology to South Africa, Trafo Power Solutions’ success is now based on the company’s in-house design and engineering capability. “We supply complete, customised solutions that include dry-type transformers as one of many components,” says David Claassen, MD of Trafo Power Solutions.

Modular substations, also known as E-houses, have become increasingly popular in recent years, originally as a solution for remote mining locations in Africa. Now, they are fast becoming a preferred alternative to brick-built substations.

“From a cost perspective, modular substations are significantly cheaper, primarily because they are manufactured off-site and housed in a transportable steel structure. On-site construction involves labour issues and health and safety requirements, which can cause delays and uncertainty. When manufacturing a modular substation, these issues fall under normal factory operations, allowing for quicker, higher-quality, and more cost-effective builds,” he says.

Other benefits include the installation, commissioning, and testing, all of which can be conducted under tightly controlled factory conditions.

The most important aspect of any solution provided by Trafo Power Solutions, Claassen notes, is thoroughly understanding the client’s application. Modular substations are critical to the reliable operation of production equipment. Not only must the solution meet all operational requirements, but it must also be protected from dust, moisture, temperature, and other site-specific environmental hazards.

Trafo Power Solutions manages the entire electrical design of its modular substations, which can include any of the equipment typically found in conventional substations, including the dry-type transformer, low- and medium-voltage switchgear, motor controllers, and automation equipment.

“We're not typical product suppliers; we are solution providers. We ask the correct and appropriate questions before we start designing because we aim to provide the best possible solution. We need to understand harmonics, load requirements, transport restrictions, site conditions, and all aspects of the operating environment,” says Claassen.

Another major advantage for Trafo Power Solutions clients is that the company has experience with all tier one electrical product suppliers. Preferences are based solely on client requirements, reliability, and fitness for purpose in the given environmental conditions.

The dry-type transformer advantage

Dry-type transformers are now widely accepted, and their inherently safer nature enables Trafo Power Solutions to fully integrate them into its mobile substations.

“It is possible to use an oil-filled transformer in a modular substation, but compared to dry-type transformers, these require a host of additional safety systems and protections. Structurally, a sealed base is required to contain any oil leaks, and fire detection and suppression systems must be included, all of which add cost,” Claassen says.

The core premise of a modular substation is the ability to transport the system to the site for ‘plug-and-play’ installation. Modular substations using dry-type transformers are lighter and more robust. On rough roads, despite suspension and packaging measures, peripheral equipment such as thermometers and relays on oil-filled transformers is likely to sustain damage, while oil leaks may develop, which will require additional onsite intervention.

Dry-type transformers are simpler, lighter, more compact and robust. They can be designed to fit on standard road transport trailers and quickly offloaded and connected to the supply and client distribution networks without the need to repair transport damage.

Export success

Claassen notes that Trafo Power Solutions recently supplied a skid-mounted mobile substation to a coal mine in Queensland, Australia. This unit was designed, manufactured, and tested in South Africa before being shipped and delivered. The solution included a transformer and MV and LV switchgear for a step-up application from a 400 V generator to 6.6 kV. “This mobile substation solution accompanies the customer's generator set to deliver power where needed on the mine,” he explains.

“Although we're a South African-based company, we understand and can operate within the standards and specifications of any country. This mobile substation for Australia is a typical example,” says Claassen.

Trafo Power Solutions was also involved in the design and engineering of dry-type transformers for a large intake substation for a data centre in the Netherlands that meets all EU standards. With a global upswing in demand for data centres, Trafo Power Solutions has built a strong reputation for meeting the 100% uptime requirements for the substations powering data centres in South Africa, Africa and Europe.

The Renewable Energy market

Another growth area for Trafo Power Solutions is the renewable energy sector, where transformer design is critical due to significant non-linear loading. “At PV solar plants, high levels of harmonics from inverters increase the temperature in the transformer windings,” Claassen explains. This is in addition to the already high ambient temperatures typical of solar installations.

“Moreover, the transformers cycle from full to zero load every day, which causes expansion and contraction that must be accounted for,” he adds.

While dry-type transformers are typically cooled using natural ventilation, forced ventilation can also be used, and where space is limited or heat loads are high, water cooling options are also available.

“In the global renewable energy market, our strategic partner TMC is one of the largest suppliers of dry-type transformers, with thousands of custom-designed units sold annually into the PV sector in the US – a sector that demands the highest reliability with lowest losses,” he says.

“We continually strive to understand our clients’ needs and to identify the best possible solutions to meet them. This enables us to engineer tailored electrical power solutions that reliably and consistently deliver,” Claassen concludes.

www.trafo.co.za

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