Step Down Transformers are built for business. Depending on your sites’ power distribution requirements, you may need a local step-down transformer.
Power Transformers play a critical role in the energy infrastructure of the UK as a whole, as well as that of many individual organisations.
What is a Transformer? and what are Transformers used for?
A transformer is an electrical device which is designed to convert the alternating current from one voltage to another. Electrical transformers are often used to “step-up”, or “step-down” the voltages to the required levels.By allowing electricity to be transferred from one circuit to another at changing voltage levels, electrical transformers improve the safety and efficiency of power systems across a wide range of applications. Electric Power transformers are solid-state devices which should insure a long operating lifespan.
However, the UK’s extensive transformer fleet is facing a looming potential resilience crisis. Over 70% of electrical transformers in the UK have been in operation for 25 years or more, with these lengthy average lifespans increasingly exceeding intended design-life. This has seen demonstrable growth in the need for transformer maintenance and refurbishment. For organisations embracing a robust power resilience strategy, it is vital that aging transformers do not become a point of failure.
How Overhauling Your electrical Transformer Fleet Can Help
The extensive age of much of the UK’s power transformer fleet means that in many cases, there is ample potential for aging hardware to be replaced by newer, more advanced, energy-efficient models. This brings with it a range of benefits, including greater reliability, lower maintenance requirements and significantly reduced losses.
The losses a power transformer experiences vary significantly depending on age, size, design and use. For the largest modern transformers, energy efficiency can be as high as 99.75%. For smaller transformers or aging models, this can fall to 90% or even 85%. With many distribution transformers operating at high loads, these losses are both significant and costly.
Similarly, our high-efficiency, low-loss transformers can significantly reduce overall power consumption, helping to reduce both energy costs and carbon footprint. Voltage management & optimisation technologies incorporated into some modern transformers offers further improvements in energy efficiency and lower costs.
As technology advances, newer energy-efficient power transformers are ready to support the transition to Industry 4.0, defined as the next phase of digitisation in the manufacturing sector. Remote monitoring of electricity transformers allows 24/7 visibility of their performance and health, significantly improving power resilience and efficiency.
Implementing New Low-loss Transformer Technology
An upgrade to an aging transformer fleet offers enhanced power resilience, lower costs and greater energy efficiency. As well as significantly reducing the risk of your transformer becoming a point of failure, it also offers the ability to protect sensitive equipment and machinery from fluctuations in grid power.
Powerstar offers a wide range of distribution transformers, as well as custom pieces to fit your exact specifications. Our amorphous core products offer as much as a 75% reduction in core losses compared to traditional Cold Rolled Grain Oriented (CRGO) transformers, as well as better savings, lower emissions and reduced operating costs. Our Super Low Loss Amorphous core transformers are wound here in the UK saving you even more in emissions and costs through shipping.
The internal structure of amorphous alloy is more flexible than CRGO, meaning easy magnetisation and demagnetisation can take place. The ability to switch magnetisation at a quicker rate is what delivers the lower losses. Benefits of amorphous core transformers include reduced losses, higher efficiencies and asset longevity.
The amorphous core transformer advantage
The Powerstar SO-LO amorphous metal distribution transformers contribute to improving site resilience and can assist in protecting against issues in the grid supply voltage, such as fluctuations. It allows for HV infrastructure upgrades to be carried out in a cost-effective way with minimal disruption to operations, a big advantage for many commercial sites.
Distribution transformers are critical infrastructure for many companies, yet they are not connected and online. Therefore, their health, performance, and efficiency are typically unknown or reliant upon manual inspections of antiquated gauges/meters.
Our smart distribution transformers and their benefits are explained in the animated video. This video explains how they change the landscape for distribution transformers through its amorphous core, manufactured right here in the UK. Additionally, the video explains how the online remote monitoring capabilities ensure that it is Industry 4.0 ready. Furthermore, the video explains the bespoke options that can be applied to as well as the popular applications and sectors for the smart transformer.
Powerstar SO-LO’s remote monitoring capability using our energy management software allows 24/7 visibility to help you better understand how your electricity transformers are performing and where efficiencies can be made to obtain the best return on investment.
Developed with Industry 4.0 in mind, which is defined by Mckinsey and Company as the next phase in the digitalisation of the manufacturing sector, Powerstar SO-LO remote monitoring provides comprehensive data and intelligence to provide useful grid information, conditional performance data, and energy efficiency reports. It has been designed to complement maintenance activities and allows for the remote monitoring of core temperatures, winding currents, oil temperature and, when integrated, the performance of voltage management functionality.
SO-LO Amorphous Core Transformer Features
- 36-month guarantee*
- Bespoke to meet client’s requirements
- Simple upgrade to HV infrastructure that can provide significant energy and cost savings
- Surpasses 2021 EU Ecodesign Directive standards set by European Commission
- Dedicated customer service 24/7, 365 days a year
- Experienced UK manufacturer of quality amorphous core transformers
- Variety of fittings and applications to suit every site
*Guarantee applies to systems installed within the UK. The guarantee will be voided if yearly maintenance performance inspections are not undertaken.
SO-LO Amorphous Core Transformer Benefits
- Up to 75% lower core losses compared to CRGO transformers
- Delivers greater consumption savings, on average, compared to traditional CRGO transformers
- Contributes towards CSR by reducing CO2 emissions
- Simple non-invasive energy efficiency system
- Gain instant energy consumption savings
- Remote monitoring allows for greater visibility of transformers operations
- Reduce operating costs
- Expected lifespan of up to 50 years
- UK Manufacture saves extra costs and emissions from shipping from abroad
A bespoke transformer solution for your business
Whilst Powerstar SO-LO is an 11kV to 415V amorphous core smart distribution transformer, as manufacturers, we can provide a variety of bespoke amorphous core solutions to suit a wide range of applications, all manufactured in the UK. We offer numerous fittings and accessories to help maximise the impact of the technology on each site. These options can be discussed with our specialists at any time, and a no-obligation evaluation of a site’s needs can be arranged to assist in this decision.
Powerstar SO-LO is the only amorphous core transformer manufactured in the UK, and Powerstar meets the highest quality standards including UL Quality Assurance (E472553), Quality Assurance ISO 9001:2015 (FS579032) and Environmental Management ISO 14001:2015 (EMS600861), resulting in a full solution of unparalleled quality.
Specialist Custom Built Transformers
Due to the diversity of businesses operations across the UK, Powerstar provides bespoke distribution transformers for specialist applications based on specific size, power or environment requirements to ensure maximum resilience and efficiency, even within challenging applications.
Whatever your requirements, our in-house team of expert engineers will work tirelessly to design and deliver a transformer that is fit-for-purpose based on your needs. As a customer focused manufacturer, we strive to overcome our customers’ challenges by offering a personalised approach from the initial product specification stage right through to after-sales support.
Throughout our history, we have overcome a diverse range of challenges from customers and therefore have experience in delivering bespoke solutions designed with the harshest conditions and environments in mind. We recognise that distribution transformers are often required in difficult areas or demanding applications so we offer a variety of different designs, such as specially designed dry type naturally air-cooled flameproof Class C insulated transformers that are robustly manufactured to withstand open cast mine environments or underground.
Did you know? The largest power rating ever used underground in the UK of 4500MVA, was a mining transformer manufactured by our facility in Bromsgrove.
Voltage Management for High Voltage Transformers with HV-MAX
By combining a low-loss amorphous core distribution transformer with our electronic-dynamic voltage management technology, inefficiencies in the HV infrastructure can be greatly reduced in addition to generating additional savings in energy consumption savings and reductions in carbon emissions through the low voltage side technology.
Powerstar HV-MAX provides a combined solution to two common problems, combining a super low-loss amorphous core high voltage/low voltage transformer with integrated electronic-dynamic voltage optimisation technology, allowing for 11,000V input (other inputs available) and regulated 380V, or user-defined, output.
Voltage optimisation is required because in the UK, the majority of sites are supplied with voltage that is higher than necessary to run on-site electrical equipment optimally, leading to increased energy consumption, energy costs, CO2 emissions, and wear and tear on electrical equipment.
Other Types of Transformers
Dry-type or ‘air-cooled’ distribution transformers are considered a low maintenance, reliable, and robust solution due to the fact that they have no moving (or serviceable) parts.
A Cast Resin Transformer is a static transformer which means it doesn’t have moving parts and because of this are often the transformer of choice for high-service reliability situations.
Liquid filled distribution transformers are also often utilised in situations where a higher capacity is required as they are noticeably more efficient in this application.
Discuss your requirements with us today for a quote on a bespoke, efficient transformer
Related case studies
Powerstar was commissioned to replace the site’s ageing transformer with modern, low-loss replacements, that incorporated voltage optimisation technology to provide more stable voltages across the site.
Powerstar identified PFF Group’s aging transformers as a a potential power resilience risk, as well as an area where their energy efficiency could be significantly bolstered.
A combination of voltage regulation and low-loss transformers saved this leading food manufacturer over £71,000 on their annual energy bills.
Newport City Council used low-loss transformers and voltage regulation to improve their sustainability performance, reducing their annual consumption by over 165,000 kWh
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