Special Transformer

Custom Special Transformer for Industrial and Renewable Energy Applications

Industrial operations and renewable energy projects require power transformation beyond standard distribution specs. Jiangsu Yuantong Electric engineers and manufactures heavy-duty special transformers tailored to rigorous electrical, thermal, and mechanical demands. Operating from our ISO-certified facility in Jiangsu, we provide direct factory production for electric furnaces, solar farms, wind installations, and industrial rectification systems.

Special Transformer Configurations and Types

Electric Furnace Transformers: Built for steel smelting and alloy production. Engineered with reinforced mechanical structure to withstand frequent short-circuits and heavy current fluctuations. Features high secondary current ranges and multiple voltage regulation taps.

Solar PV Transformers: Designed for utility-scale solar photovoltaic power generation. Optimized for high harmonic distortion, variable load profiles, and outdoor ambient temperature extremes. Available in both oil-immersed and dry-type configurations.

Wind Power Transformers: Compact footprint units engineered for wind turbine nacelles or tower-base installations. Built to withstand continuous vibration, seismic stress, and wide temperature shifts (-40 deg C to +50 deg C).

Rectifier Transformers: Converts AC supply to DC power for electrochemical, electroplating, and traction drives. Designed to handle high multi-pulse configurations (6-pulse, 12-pulse, or higher) and mitigate harmonic pollution in the power grid.

Technical Specifications

Parameter	Specification
Rated Capacity	50 kVA to 120 MVA
Primary Voltage	Up to 110 kV class, including 10 kV, 35 kV and 66 kV
Secondary Voltage	Customized according to load requirements, from low voltage to medium voltage
Frequency	50 Hz / 60 Hz
Vector Group	Dyn11, YNd11, or customized multi-winding configurations
Cooling Methods	ONAN, ONAF, OFAF; Air Natural (AN) / Air Forced (AF) for dry-type transformers
Impedance Voltage	4%–18%, engineered according to fault-level requirements
Compliance Standards	IEC 60076, IEEE Std C57.12.00, ISO 9001

Design and Construction

01/

Core Material: Constructed from high-permeability grain-oriented cold-rolled silicon steel sheets (CRGO), step-lap joint stacked to minimize no-load losses and acoustic noise.

02/

Winding Configuration: Manufactured using 100 percent oxygen-free electrolytic copper conductors (foil or continuous strand round/rectangular wire). Windings are paper-insulated or Nomex-insulated, vacuum-pressure impregnated (VPI) for dry types or vacuum-oil impregnated for liquid-filled units.

03/

Tank and Enclosure: Fabricated from heavy-gauge structural steel plates. Tanks undergo shot-blasting, anti-corrosive epoxy priming, and polyurethane top-coating for C4/C5 marine or heavy industrial environments.

04/

Insulation System: Mineral oil conforming to IEC 60296 or synthetic ester fluids, filtered and degassed under high vacuum to maintain dielectric strength (greater than 75 kV) and eliminate moisture pockets.

Applications

Our special transformers integrate directly into heavy industrial and green energy infrastructure:

Electric Arc Furnaces (EAF) and Ladle Furnaces (LF)

Steel mills and ferrous metallurgy plants.

Utility-Scale Solar Farms

Step-up transformation at photovoltaic inverter stations.

Onshore Wind Farms

Nacelle and pad-mounted substations for wind turbine generators.

Electrolytic and Industrial Rectification

Aluminum smelting, chlorine-caustic production, and DC traction substations.

Manufacturing and Quality Control

Core Cutting and Stacking

Automated CNC slitting and stacking lines ensure precise dimensional tolerances on silicon steel sheets.

Winding Workshop

Controlled tension winding machines paired with horizontal/vertical winding rigs prevent conductor deformation under electromagnetic stress.

Vacuum Drying

Large-scale heat-controlled vacuum drying ovens remove residual moisture from assembled coils prior to tanking.

In-Process Inspection

Dimensional checks, turn-ratio verification, DC resistance testing, and inter-turn insulation testing conducted at interim production stages.

Custom Transformer Solutions

Standard catalog units rarely fit specialized industrial footprints or electrical demands. Our engineering team collaborates directly with project specifiers to deliver bespoke units:

Electrical Customization

Specific impedance matching, dual-voltage primary/secondary ratios, tertiary winding additions, and specialized tap-changer integration (ONTC or DETC).

Mechanical Adaptation

Non-standard physical dimensions, restricted height/width profiles for retrofits, custom cable box placement, and busbar terminal orientations.

Environmental Hardening

Seismic reinforcement for high-activity earthquake zones, salt-fog resistant coatings for coastal installations, and hermetically sealed corrugated tanks.

Testing and Documentation

Routine Tests (Performed on 100 percent of units):
Measurement of winding resistance
Voltage ratio measurement and vector group check
Measurement of short-circuit impedance and load loss
Measurement of no-load loss and current
Separate-source voltage withstand test and induced overvoltage test
Dielectric breakdown and oil quality tests (for oil-immersed units)

Type and Special Tests (Available upon request):
Temperature rise test
Lightning impulse test
Sound level determination
Short-circuit withstand capability verification

Documentation Package: Includes certified test reports, electrical schematic drawings, dimension outline drawings, user manuals, and material mill test certificates.

Packaging and Delivery

Packaging

Units are secured on heavy-duty fumigated wooden skids or steel cradles, bolted down to prevent shifting. External surfaces are wrapped in moisture-barrier poly film and weatherproof tarps. Accessories (bushings, radiators, Buchholz relays) are packed in sealed, shock-absorbent export-grade plywood cases.

Lifting and Handling

Equipped with welded lifting lugs, jacking pads, and bi-directional pulling skids for safe crane and forklift positioning at the job site.

Shipping

Coordinated containerized transport (open-top or flat-rack for oversized units) or break-bulk vessel shipping from major ports, supported by complete customs clearance documentation (Bill of Lading, Certificate of Origin, Packing List).

Report on Product Qualifications

FAQ

Q: What is the standard lead time for custom special transformers?

A: Production lead times range from 4 to 8 weeks depending on capacity, core material availability, and structural complexity. Detailed production schedules are issued alongside technical proposals.

Q: Can you manufacture transformers compliant with IEEE/ANSI standards instead of IEC?

A: Yes. While IEC 60076 is our baseline standard, we regularly engineer, manufacture, and test transformers to meet IEEE C57.12.00, CSA, or GOST standards based on project export destinations.

Q: What is the difference between a rectifier transformer and a standard power transformer?

A: Rectifier transformers are designed to feed power converter equipment. They feature modified winding arrangements to handle high harmonic current components, prevent DC magnetization of the core, and supply lower secondary voltages with high current output.

Q: How do you manage harmonic distortion in solar and wind power transformers?

A: Units destined for renewable applications are engineered with increased cross-sectional core area, specialized copper foil shielding, and enhanced cooling margins to suppress eddy current losses and limit temperature rise caused by inverter harmonics.

Q: What factory acceptance testing (FAT) options are available for international clients?

A: Clients or their designated third-party inspection agencies (such as SGS, TÜV, or Bureau Veritas) are welcome to witness physical Factory Acceptance Testing on-site. Alternatively, we provide recorded video test sessions and certified digital test reports prior to shipment.

Q: What warranty terms and after-sales support do you provide?

A: We provide a standard 24-month operational warranty from the date of delivery (or 18 months from commissioning). Technical support, remote troubleshooting, and on-site engineering dispatch are available for installation and commissioning assistance.

As one of the most experienced special transformer manufacturers and suppliers in China, we also support customized service. Please rest assured to wholesale bulk high quality special transformer in stock here from our factory. Contact us for more details.

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