Potential transformer savings -
The expensive, unseen basement child
The losses from unused potential savings quickly add up to several thousand euros per year. This also applies to transformers: they have been in the basement for decades, but are often operated inefficiently. This means that the savings potential of transformers is often underestimated.
However, energy losses occur with every energy conversion. Potential savings beyond an acceptable level should therefore be localized and eliminated. But how can malfunctions in transformers be identified and how can efficient operation be achieved?
Greatest potential in supply technology
In the manufacturing and processing industries, energy losses can occur in three areas:
- Administration (e.g. in the ventilation system or lighting)
- Production (operating times, inefficiencies or standby of machines)
- Energy supply technology (e.g. at the transformer or the heating system)
It is obvious that the greatest savings potential lies dormant where the greatest energy throughput is, i.e. in energy supply technology.
A practical example:
At a Freiburg food manufacturer, the energy flows at the transformers operated in parallel were checked and EUR 88,000 was saved annually by temporarily switching off one transformer.
An isolated case? How is your basement child doing?
"ENIT uncovered previously unknown
efficiency potential in the transformers.
This enabled us to save
EUR 88,000 p.a. in just a few weeks."
- Managing director of the company
Losses due to inefficiency
Transformer stations are usually designed as single transformers, in parallel operation of several transformers or as a three-phase bank (in which all three-phase phases are transformed individually). In all three cases, losses can occur due to outdated technology, poor system design, operation at an inefficient operating point or other faults. The easiest way to determine the efficiency of the transformers is to measure them individually. A comparison of the upstream transfer meter and the downstream measuring points can quickly reveal inefficiencies.
It is often possible to use existing measuring points. Transformers are optimally designed at the time of installation. If the connected production facilities are expanded in subsequent years or the load is reduced by using more efficient systems, the transformer often slips into an inefficient operating point. Depending on the characteristic curve, this can quickly lead to significant energy losses. If the efficiency of your transformers is reduced by an average of 1%, your electricity bill will increase by the same amount!
Potential transformer savings and fast return on investment
Increasing the efficiency of individual transformers can often only be achieved by replacing the transformer, installing a parallel-connected transformer or adapting the connected load - which has a major impact on production processes. However, investments at this point can quickly pay for themselves. Easier with transformers connected in parallel. This is because modular connection and disconnection of the individual transformers is possible here, which means more efficient operation close to the optimum operating point. Incomprehensibly, this option is rarely used in practice!
To ensure efficient operation of the transformers, the currents and loads should be monitored in real time. Inefficient operating points are also identified for individual transformers and the optimally coordinated connection or disconnection of parallel-operated systems is made possible.
We develop analyses with the help of energy data that provide transparency about the status of the electrical system in industrial plants and thus offer approaches for optimization. In this video, we would like to show you how we do this and what options are available on this topic.