The losses of unused savings potential quickly add up to several thousand euros and cost cash year after year. Transformers, for example, have their place in the basement for decades; they are often operated inefficiently. Energy losses occur with every energy conversion. Savings potential should be localized and exploited outside a reasonable range. But how can dysfunctions be identified in transformers and how can efficient operation be achieved?
In the manufacturing and processing industry, energy losses can occur in three areas: in administration (e.g. in the ventilation system or lighting), in production (operating times, inefficiencies or standby of machines) or in 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.
Practical experience: At a food manufacturer in Freiburg, the energy flows at the transformers operated in parallel were checked and 88,000 euros were saved annually by temporarily switching off a transformer. An individual case?
„ENIT uncovered previously unknown efficiency potentials for transformers. This enabled us to save EUR 88,000 p.a. in just a few weeks.“
(Managing Director of the company)
Transformation stations are usually constructed as single transformations, 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 In all three cases, losses can occur due to outdated technology, poor system design, operation at an inefficient operating point or other faults.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 simplest way to determine the efficiency of the transformers is to take a single measurement. The comparison of the upstream transfer meter and the downstream measuring points can show inefficiencies within a short time.
Often it is possible to use existing measuring points. Transformers are optimally designed at the time of their installation. If in the following years the connected production plants are enlarged or the load is reduced by using more efficient plants, 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 rise by the same order of magnitude!
The increase in efficiency of individual transformers can often only be achieved by replacing the transformer, by installing a transformer in parallel or by adapting the connected load – which deeply interferes with production processes. However, investments in this area can quickly pay off. Easier with transformations connected in parallel. This is because modular connection and disconnection of the individual transformers is possible here, thus enabling more efficient operation close to the optimum operating point. It is incomprehensible that this option is rarely used in practice!
In order to ensure efficient operation of the transformers, the currents and loads should be monitored in real time. Inefficient operating points are also indicated for individual transformers and the optimally coordinated connection or disconnection of parallel operated systems is possible.