1. Project Overview
Nanke Electric has completed the delivery, deployment, and official commissioning of the automated distribution transformer testing system for Igor New Energy (USA)’s Fort Worth plant. The parent company of the project partner, Igor Electric Co., Ltd., was founded in 1999 and is headquartered in Foshan, Guangdong. It is a well-known listed enterprise in China, primarily engaged in the R&D, manufacturing, and global sales of power transformers and new energy electrical equipment. The company’s core products include single-phase pole-mounted distribution transformers, single-phase pad-mounted transformers, three-phase American-style transformers, and three-phase oil-immersed distribution transformers, with business operations spanning many regions worldwide.
To meet the needs of Igor New Energy (USA)’s Fort Worth plant for mass production and factory inspection, Nanke Electric custom-built two integrated test lines, equipped with its independently developed automated distribution transformer testing system. The entire solution strictly adheres to North American power industry standards, enabling fully automated testing of oil-immersed single-phase and three-phase transformers throughout the entire process, effectively improving inspection efficiency, testing accuracy, and overall production capacity, thereby providing reliable assurance for product quality and timely delivery in the North American market.
2. Maximum Testing Capacity
The project features two independent test lines, suitable for various oil-immersed transformer testing tasks. Both lines support dual-frequency testing at 50Hz/60Hz, with a short-circuit impedance test limit of 6%, operating on a standard 7-hour shift schedule, featuring streamlined staffing and stable output. Detailed parameters are as follows:
(1) Test Line No. 1
Compatible with equipment rated at high voltage 35kV and low voltage 0.24kV/0.48kV and below, capable of testing oil-immersed single-phase and three-phase transformers up to 333kVA. The line is staffed by two operators, with a minimum daily testing capacity of 40 units, and additionally equipped with a transformer temperature-rise test function, expanding the scope of testing.
(2) Test Line No. 2
Also compatible with equipment rated at high voltage 35kV and low voltage 0.24kV/0.48kV and below, focusing on testing oil-immersed single-phase transformers up to 167kVA. This line likewise employs two operators, with a minimum daily testing capacity of 40 units, meeting the demand for large-scale batch testing of small-capacity single-phase transformers.
3. Test Items
The system can perform 12 standardized tests on transformers, fully compliant with North American power industry standards, automatically generating English-language test reports to satisfy product release verification requirements. Specific test items include:
(1) Transformer insulation resistance test
(2) Transformer DC resistance measurement
(3) Transformer turns ratio and winding group measurement
(4) Transformer no-load loss and no-load current measurement
(5) Calculation of transformer no-load current percentage
(6) Transformer no-load harmonic measurement
(7) Transformer load loss measurement and standard temperature conversion
(8) Transformer short-circuit impedance (short-circuit loss) measurement and standard temperature conversion
(9) Transformer induced withstand voltage test
(10) Transformer power-frequency withstand voltage test
(11) Transformer temperature-rise test (exclusive to Test Line No. 1)
(12) Transformer lightning impulse test
4. Project Highlights
(1) Independently developed system, deeply adapted to North American standards
Equipped with Nanke Electric’s self-developed automated distribution transformer testing system, the equipment supports seamless switching between automatic and manual operating modes. The system integrates data acquisition, real-time computation, temperature conversion, result determination, and report export functions, producing test reports fully aligned with North American industry norms and seamlessly interfacing with existing overseas factory quality-control management systems.
(2) Dual-line configuration, efficiently balanced production capacity
The two lines feature differentiated task assignments, handling large-capacity comprehensive transformers and small-capacity single-phase transformers respectively, with a combined minimum daily testing capacity of 80 units, effectively accommodating large-volume testing orders.
(3) Comprehensive test coverage, ensuring safe and reliable quality control
The system covers all mandatory pre-shipment tests related to electrical performance, insulation performance, dielectric strength, temperature rise, and lightning impact, completing type tests and routine inspections in one stop, providing all-round oversight of product quality prior to shipment.
(4) Extensive overseas implementation experience, with a well-established delivery and maintenance system
We provide end-to-end services including equipment installation, wiring and commissioning, on-site trial runs, and hands-on operator training. The test site is divided into separate high-voltage and low-voltage testing areas, supported by standardized safety protection facilities that comply with overseas factory safety management regulations.
(5) Dual-frequency compatibility, adaptable to diverse global grid conditions
The lines support both 50Hz and 60Hz grid frequency testing standards, satisfying domestic U.S. production and inspection needs while also adapting to the grid conditions of most countries worldwide, helping customers expand their global sales markets.
5. Commissioning Information
The complete set of test lines for this project was officially commissioned at Igor New Energy (USA)’s Fort Worth plant in August 2025. The equipment has been running smoothly over the long term, delivering precise test data, and continues to provide automated quality-control services to the plant, making it a benchmark project for Nanke Electric’s deep engagement in the North American market.
