Addressing Emergency Industrial Power Supply Challenges — Huawan New Energy’s 5000 kVA Dry-Type Transformer Project in Spain

The International Energy Agency (IEA), in its Electricity 2025 report, notes that global electricity demand is expected to grow at an average annual rate of nearly 4% from 2025 to 2027, representing one of the fastest periods of growth in recent years. Industrial electrification, data centers, air-conditioning loads, and transport electrification are becoming the major drivers of rising electricity demand.

As a core piece of equipment in industrial power distribution systems, transformers not only perform the essential function of electrical energy conversion, but also directly affect the stable operation of production lines. A failure can result not only in equipment downtime, but also in production delays, lost orders, and substantial maintenance costs. As a result, an increasing number of European companies are focusing on medium-voltage dry-type transformers that comply with international standards, offer reliable operation, and can be delivered efficiently.

Recently, Huawan provided a 5,000 kVA three-phase cast-resin dry-type transformer solution for a Spanish industrial company, meeting the customer’s need to replace and upgrade aging equipment.

Spain’s Transformer Market: New Growth Opportunities Driven by the Energy Transition

Table 1 position: Original chart retained unchanged — Spain Electricity Demand (GWh)

Source: Red Eléctrica

According to data released by Red Eléctrica, Spain’s transmission system operator, electricity demand in Spain increased by 2.8% year on year in 2025, exceeding the 0.5% average growth rate among members of the European Network of Transmission System Operators for Electricity (ENTSO-E). This indicates a continued recovery in industrial and electrification-related demand. As wind and solar power and other renewable energy sources continue to be integrated into the grid, renewable generation accounted for approximately 56.6% of Spain’s total electricity generation in 2025, further driving demand for grid upgrades and medium-voltage power distribution equipment.

At the same time, an increasing number of traditional industrial companies are undergoing digital transformation and demanding higher levels of power supply reliability. From automotive manufacturing, food processing, metallurgy, and logistics centers to data centers, companies are increasingly inclined to adopt dry-type transformers that offer safety, environmental benefits, and lower maintenance requirements, in order to meet modern industry’s requirements for continuous power supply and sustainable development.

Compared with conventional oil-immersed products, dry-type transformers offer oil-free operation, low maintenance requirements, flexible installation, and strong fire-safety performance. Their application in industrial plants, public buildings, and renewable energy projects is therefore continuing to increase, and they have gradually become an important option in Europe’s medium-voltage power distribution sector.

For exporters, manufacturing capability alone is no longer sufficient to establish a competitive advantage. The ability to respond rapidly to project requirements, provide products that comply with international standards, and deliver comprehensive international logistics and technical support is increasingly becoming a key competitive factor in the European market.

A Time-Critical Overseas Project: From “Restoring Power” to “Safeguarding Production”

For continuous-production businesses, a stable power supply means not only production efficiency, but also business performance.

The following is a market-price-based calculation for a 5,000 kVA cast-resin dry-type transformer, provided as a reference for comparing the total cost of ownership (TCO) of equipment purchase and rental solutions:

Table 2 position: Original table retained unchanged — Basic Calculation Assumptions

Net cost formula for the purchase option: Purchase price + installation + cumulative maintenance − residual value at the end of the period

Total cost formula for the rental option: Monthly rental × number of months + one-time installation fee

Table 3 position: Original table retained unchanged — Cost Calculation

In this project, the customer’s original 5,000 kVA transformer could no longer operate due to a failure. To maintain production, the customer had to use a temporary rental unit as an interim solution. However, long-term rental of large power equipment is not only costly, but also unable to meet the company’s need for stable long-term operation. The customer therefore wanted to complete the replacement as quickly as possible and restore normal production.

Faced with the tight project schedule, Huawan New Energy quickly coordinated its technical, production, and logistics teams to respond jointly. After gaining a thorough understanding of the site operating conditions and technical requirements, the company developed an integrated solution covering product manufacturing, factory testing, and international transportation. While ensuring product quality and compliance with testing requirements, Huawan minimized the manufacturing and delivery lead time to the greatest extent possible, helping the customer shorten equipment waiting time, reduce the risk of downtime, and ensure smooth project implementation.

It is worth noting that in international projects, customers are often concerned not only with the equipment purchase price, but also with overall lifecycle costs. Compared with continuously paying equipment rental fees and bearing potential production losses caused by unstable power supply, completing equipment replacement quickly can often create greater overall value. This was also an important factor behind the successful implementation of this project.

A 5,000 kVA Dry-Type Transformer Designed for Industrial Power Distribution Applications

The product used in this project is a 5,000 kVA three-phase cast-resin dry-type transformer independently developed and manufactured by Huawan New Energy. It is primarily designed for medium-voltage industrial power distribution systems and can be widely used in manufacturing plants, renewable energy projects, data centers, commercial buildings, and public infrastructure.

The product is designed and manufactured in accordance with IEC international standards, balancing safety, reliability, and economical operation. While meeting the requirements of different national grid standards, it can also be configured flexibly according to specific project requirements.

Compared with conventional oil-immersed transformers, the key advantage of dry-type transformers is their cast-resin insulation structure, which eliminates the need for insulating oil and therefore removes the risks of oil leakage and oil combustion. This makes them particularly suitable for industrial plants, commercial complexes, hospitals, rail transit systems, and other locations with stringent fire-safety requirements.

For large industrial enterprises, long-term stable equipment operation is far more important than one-time purchase cost. During product design, Huawan New Energy optimized the core materials, winding structure, and insulation system to provide good mechanical strength and short-circuit resistance, enabling stable electrical performance over long-term operation.

The product also combines natural cooling with forced-air cooling, allowing heat-dissipation capacity to be adjusted flexibly according to the actual load. This helps ensure reliable equipment operation while maintaining operational efficiency.

In addition, to address the practical requirements of different overseas projects, the product can be configured according to customer requirements with different voltage levels, vector groups, impedance parameters, and accessory packages, meeting diverse applications such as industrial power distribution, renewable energy step-up applications, and large commercial buildings.

Beyond the Product: A Strong Focus on End-to-End Project Delivery Quality

For the 5,000 kVA dry-type transformer project in Spain, Huawan New Energy designated the project as a priority production order. Once the technical solution was confirmed, the company completed equipment manufacturing in just 12 days and carried out the full set of routine factory tests, including winding resistance, turns ratio, insulation performance, withstand voltage, losses, and impedance. The transformer has a rated capacity of 5,000 kVA under natural-air cooling (AN) operating conditions and is equipped with auxiliary cooling fans. The measured no-load loss was approximately 5.27 kW, while the load loss at 120°C was approximately 31.05 kW. The calculated Peak Efficiency Index (PEI) reached 99.488%, exceeding the EU Ecodesign Tier 2 minimum efficiency requirement of 99.387% and meeting the applicable EU energy-efficiency standard.

The biggest highlight of this project was its efficient end-to-end delivery capability. From production launch, equipment manufacturing, and factory testing, through international air freight and arrival in Spain, followed by on-site installation and wiring by a local electrical contractor, no-load and load testing, and final commissioning, the entire process took only about one month. The transformer is currently operating normally on site. After commissioning, Huawan New Energy has continued to provide comprehensive technical support, including factory test reports, operation and maintenance documentation, and PEI/Tier 2-related calculations.

Huawan New Energy focuses not only on the product itself, but also on end-to-end delivery quality throughout overseas projects. The company takes into full consideration differences in national grid standards, transportation conditions, and installation environments, and can provide one-stop services including technical communication, solution optimization, factory testing, export packaging, and international logistics coordination. In this Spanish project, all stages were closely coordinated. While safeguarding product quality, Huawan fulfilled its commitment to rapid delivery and, through lifecycle-oriented services, helped the overseas customer reduce project risks, ensure successful project implementation, and improve return on investment.

Continuing to Expand in International Markets and Create Long-Term Value for Global Customers

As global industrial electrification, renewable energy development, and investment in green infrastructure continue to advance, dry-type transformers will play an increasingly important role in future power systems.

Huawan New Energy has consistently based its approach on international standards and customer requirements, continuously strengthening its capabilities in product R&D, intelligent manufacturing, and global delivery. From industrial manufacturing to renewable energy projects, and from commercial buildings to public infrastructure, the company continues to provide global customers with safe, reliable, and efficient medium-voltage power distribution solutions.

Looking ahead, Huawan New Energy will continue to leverage its mature manufacturing system and international service capabilities, working with global partners to jointly promote the development of safer, more efficient, and greener power infrastructure.

FAQ

Q1: Why are an increasing number of European industrial companies choosing dry-type transformers?

Dry-type transformers use cast-resin insulation and do not require insulating oil. They offer strong fire-safety performance, low maintenance requirements, and good environmental adaptability, making them particularly suitable for industrial plants, commercial buildings, hospitals, rail transit systems, renewable energy projects, and other applications with high safety and environmental requirements.

Q2: What customization services can Huawan New Energy provide?

The company can provide customized solutions based on customer project requirements, including capacity, voltage level, vector group, impedance, cooling method, and installation configuration. Products are designed and manufactured in accordance with IEC international standards and can meet the requirements of power distribution systems in different countries and regions.

Q3: What industries are 5,000 kVA dry-type transformers mainly used in?

The products are widely used in medium-voltage power distribution systems for industrial manufacturing, renewable energy generation, data centers, mining, commercial complexes, rail transit, municipal infrastructure, and large public buildings.

Q4: Does Huawan New Energy have experience with international projects?

Yes. Huawan New Energy has established a one-stop service system covering product design, manufacturing, testing, export packaging, and international logistics coordination, enabling the company to provide comprehensive technical support and delivery services according to project requirements in different countries.

Q5: What should overseas customers focus on when selecting a transformer supplier?

In addition to product specifications, customers are advised to assess whether the supplier complies with international standards, has a mature manufacturing and quality-management system, possesses overseas project experience, and can provide timely technical support and reliable international delivery capabilities. These factors often directly affect project implementation efficiency and the long-term operational reliability of the equipment.