Deeply Customized One-Stop Special Transformer Solution
Ⅰ. Addressing Core Industry Pain Points
Targeting prevalent challenges in special transformer scenarios:
- Lack of engineering validation capability for non-standard designs
- High coordination costs for multi-system interfaces
- Non-compliance in special testing execution
- Industry status quo of commissioning failure rate >8%
This solution, through the EPC (Engineering, Procurement, Construction) contracting model, achieves:
[Deep Custom Design × Full-Chain Control × System Integration] integrated delivery
II. Full-Process Solution Architecture
▶ Stage 1: Operation-Driven Custom Design (Design for Specials)
|
Key Dimension |
Implementation Path |
Technical Tool |
|
Grid Compatibility |
Short-circuit capacity dynamic simulation (≤300kA) |
EMTP-RV/ATP-EMTP |
|
Non-linear Load Compensation |
Harmonic suppression winding topology optimization |
ANSYS Maxwell 3D Magnetic Simulation |
|
Space-Constrained Design |
3D thermal field simulation (≤0.9㎡/kVA) |
COMSOL Multiphysics |
|
Special Requirement Realization |
Phase-shift angle precision control (±0.25°) |
Proprietary Winding Layout Algorithm |
|
✦ Typical Success Case: 48-pulse rectifier transformer designed for an offshore platform, THDi <3% |
▶ Stage 2: Penetration Engineering Management
- Critical Raw Material Dual-Control Mechanism
- Special Testing Execution Framework:
User –>> Laboratory: SCT test witness appointment request
Laboratory –>> User: Provide pre-test report
User –>> Certification Body: Apply for IEEE C57.12.00 witness
Certification Body –>> Test Bench: Real-time data direct transmission
▶ Stage 3: Deviation-Free System Integration
- Package of Supporting Equipment:
|
System Module |
Technical Specification |
Interface Protocol |
|
Intelligent Online Monitoring |
Dissolved Gas Analysis (DGA) + Temperature Field Tracking |
IEC 61850 GOOSE |
|
Oil Processing System |
Micro-water content control ≤15ppm |
MODBUS RTU |
|
On-Load Tap Changer |
Mechanical lifespan ≥500,000 cycles |
Built-in AI module for mechanical wear prediction |
- Installation & Commissioning SDM Model:
- 3D laser scanning → Equipment positioning simulation (Accuracy ±2mm)
- High-current bus bridge current-carrying verification (40kA/3s temperature rise ≤65K)
- 72-hour continuous load test pre-commissioning (Including ≥6 short-circuit impulse tests)
III. Value Quantification System
|
Dimension |
Traditional Model |
This Solution |
Improvement Rate |
|
Design Change Response Cycle |
14-21 days |
≤72 hours |
↑ 300% |
|
First-Pass Rate for Special Tests |
68% |
92% |
↑ 35% |
|
First-Year Failure Rate Post-Commissioning |
5.7% |
0.8% |
↓ 86% |
|
Lifecycle Cost |
Baseline 100% |
82% |
↓ 18% |
IV. Deliverables List
- Fully Parameterized Custom Transformer Main Body (including third-party type test report)
- Integrated Intelligent Monitoring Platform (Web/Mobile access supported)
- "Precision Installation Engineering Package": Includes 3D laser positioning drawing sets
- Signed Performance Guarantee Protocol (PGP): Ensures ≥30-year service life
Solution Highlight: Through the self-developed Transformer Digital Twin Platform™, the solution previews equipment lifecycle behavior in a virtual environment, eliminating on-site failure risks during the design stage.
This solution has been successfully applied to:
- ±800kV UHVDC Converter Transformer Site Capacity Expansion
- Rail Transit Regenerative Braking Energy Recovery System
- Ultra-High Power Electric Arc Furnace Dedicated Rectifier Transformer Cluster
