Hengfengyou Electric Successfully Ships 12MVA Electric Furnace Transformer to Russia: Replacing a 30-Year-Old ABB Unit, Writing a New Chapter in Metallurgical Power
Writer： Hengfeng you electric Time：2026-08-14 views：times
Hengfengyou Electric recently successfully shipped an HKSSPZ-12000/10.5 three-phase oil-immersed on-load tap-changing electric furnace transformer to a major Russian steel equipment enterprise. This unit will replace an aging ABB electric furnace transformer that has been operating stably for over 30 years at the client's site. Through precise in-situ replacement design and exceptional overload capacity, it completely resolves the core pain points of discontinued spare parts and declining energy efficiency in the old equipment, injecting new vitality into the client's electric furnace smelting production line.
I. Market Overview: Surging Demand for Power Equipment Upgrades in Russia's Metallurgical Industry
As a globally significant steel producer, Russia is undergoing a deep cycle of equipment renewal in its metallurgical sector. Many steel plants built in the 1990s face issues with their core power equipment—such as electric furnace transformers and rectifier transformers—including long operational lifespans, outdated technology, and difficulty sourcing spare parts. In particular, equipment introduced early on from European brands like ABB and Siemens, while robust in quality, incurs increasingly high maintenance costs. Against this backdrop, Chinese-made power equipment offering high cost-performance, customization based on original factory drawings, and "plug-and-play" replacement solutions is seizing tremendous market opportunities. According to industry analysis, over the next three years, the transformer replacement market in Russia's metallurgical sector alone is expected to exceed $500 million, with particularly urgent demand for high-end electric furnace transformers featuring long-term overload capability and on-load tap-changing functions.
II. Hengfengyou's 12MVA Electric Furnace Transformer: The "Best Successor" for Aging ABB Equipment at Russian Steel Plants
The client in this project owned an ABB electric furnace transformer that had been in service for over 30 years. Due to discontinued core components and insulation aging, production efficiency and product quality were severely constrained. Upon receiving the request, Hengfengyou Electric conducted one-to-one precision reverse engineering based on the original ABB drawings provided by the client, ensuring that the newly manufactured HKSSPZ-12000/10.5 electric furnace transformer perfectly matches the original equipment in external dimensions, interface flanges, and foundation mounting points, enabling a "remove old, install new, zero-modification" setup. This 12MVA electric furnace transformer not only flawlessly inherits all functions of the original equipment but also achieves a generational leap in performance and reliability, making it the premier choice for replacing aging imported units.
III. Deep Adaptation of Technical Standards: HKSSPZ-12000/10.5 Engineered for Demanding Conditions
To ensure the equipment perfectly adapts to Russia's harsh cold climate and high-load electric furnace smelting conditions, Hengfengyou Electric carried out comprehensive technical optimization and standard adaptation for this transformer.
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Robust Load Capacity: Rated capacity of 12,000 kVA, with the ability to operate under a long-term 30% overload, confidently handling peak load surges during electric furnace smelting and significantly boosting production efficiency.
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Precise On-Load Tap-Changing: Equipped with a Shanghai Huaming MIII500Y-72.5/12120 on-load tap-changer, supporting 12-step electric on-load voltage regulation. It offers a wide voltage adjustment range and fast response, ensuring optimal voltage output at different smelting stages to improve product quality.
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Efficient Cooling System: Adopts OFWF (Forced Oil, Forced Water) cooling, paired with an LYSF-200×2 water cooler. Heat exchange efficiency is extremely high, keeping oil temperature within an ideal range even during Russian summer heat or prolonged full-load operation.
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High-Quality Insulation Materials: Filled with No. 25 Karamay insulating oil, combined with high-grade insulation paperboard and electromagnetic wire, ensuring excellent insulation performance and fluidity even in extreme cold.
Core Parameters at a Glance:
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Item
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Parameter
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Model
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HKSSPZ-12000/10.5
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Rated Capacity
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12,000 kVA (with 30% long-term overload capability)
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Rated Voltage
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10.5 kV / 328 V
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Cooling Method
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OFWF (Forced Oil, Forced Water)
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Voltage Regulation
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12-step on-load tap-changing (electric)
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On-Load Tap-Changer
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Shanghai Huaming MIII500Y-72.5/12120
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Transformer Oil
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No. 25 Karamay insulating oil
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Total Weight
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Approx. 37.97 tons (oil-filled)
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External Dimensions
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4950 × 2700 × 4400 mm
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IV. Efficient Execution and Delivery: Precise Collaboration from Drawings to Shipment
Hengfengyou Electric demonstrated exceptional professionalism and execution efficiency in this Russian project:
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Precise Technical Alignment: The project team meticulously studied the 30-year-old ABB drawings provided by the client and held multiple video conferences with Russian technical staff to confirm details such as interface dimensions, connection groups, and protection configurations one by one, ensuring a "zero-error" design plan.
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Strict Quality Control: From silicon steel sheet cutting and coil winding to final assembly, every process underwent rigorous quality inspection. Before shipment, the transformer successfully passed a full suite of type tests, including no-load loss, load loss, induced overvoltage, partial discharge, and temperature rise tests, with outstanding data performance.
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Professional Logistics Shipping: A meticulous international logistics plan was developed for this nearly 38-ton behemoth, including custom steel frame fixation, moisture-proof vacuum packaging, and full-transit cargo insurance, guaranteeing safe and timely arrival at the Russian client's site.
V. Localized Service and Warranty Commitment: Peace of Mind for Russian Clients
For this project, Hengfengyou Electric provides a 12-month warranty from the date of commissioning. Alongside the equipment shipment, a complete set of Russian/English technical documentation, installation manuals, and dedicated spare parts have been delivered simultaneously. Hengfengyou Electric commits to offering 7x24 remote technical support and, when necessary, dispatching engineers to Russia for on-site installation guidance and commissioning, ensuring this electric furnace transformer can be put into operation quickly and smoothly.
VI. Far-Reaching Impact: Hengfengyou Sets a Benchmark for Domestic Transformers Replacing Imports
This successful replacement of a 30-year-old ABB unit with a 12MVA electric furnace transformer marks another milestone for Hengfengyou Electric in the field of specialized metallurgical transformers. It not only proves Hengfengyou's top-tier technical capability in reverse-engineering based on drawings of aging imported equipment but also demonstrates that Chinese power equipment can fully match—and even surpass—international brands in performance, lifespan, and service.
Luna Song, Sales Manager at Hengfengyou Electric (luna@hengfengyou.com), stated: "This project holds great significance for us. Initially, the client had doubts about replacing an ABB unit they had trusted for decades with Chinese equipment. However, our professional attitude of 'one-to-one replica design' and product strength that 'exceeds original performance' dispelled their concerns. The successful shipment of this transformer provides a perfect 'China Solution' for the vast replacement market of thousands of aging imported transformers across Russia and CIS countries."
Conclusion
From a yellowed set of ABB drawings to a 12MVA electric furnace transformer brimming with Hengfengyou's wisdom and craftsmanship, this journey across Eurasia is more than just a physical delivery of goods; it is a relay of technological inheritance and innovation. With "precision replacement" at its core and "superior performance" as its foundation, Hengfengyou Electric continues to provide stable, efficient, and reliable power cores for the transformation and upgrading of the global metallurgical industry. This transformer, soon to roar to life on Russian soil, will stand as the finest testament to "Made in China" deeply integrating into the global industrial chain.
For more information on customized electric furnace transformers, rectifier transformers, or on-load tap-changing transformers, please contact us:
