Transformer Solution for Industrial Projects in Saudi Arabia (50°C High-Temperature Environment)

Jubail, located on the western coast of the Persian Gulf in eastern Saudi Arabia, has developed into a major global hub for the petrochemical and heavy industries, anchored by the Jubail Industrial City. The region is subject to persistent high temperatures, high humidity, intense salt spray, and dusty conditions; summer ambient temperatures frequently exceed 50°C. Furthermore, the salinity of the coastal air places rigorous demands on the corrosion resistance and long-term operational reliability of outdoor power equipment.

Under such operating conditions,Saudi Aramco Power Plant ProjectConstruction is progressing smoothly. The project addresses the extreme climate conditions of the Middle East.A complete plant power supply system was constructed using SCB series epoxy resin cast-dry-type transformers, compact substations, and associated medium- and low-voltage power distribution equipment.

The main substation is equipped with three SCB dry-type transformers—rated at 2500 kVA, 2000 kVA, and 1000 kVA—responsible for power conversion and ensuring a stable power supply to the manufacturing areas. The plant's power distribution zones feature multiple dry-type transformers and package substations; these package substations integrate high-voltage switchgear, transformers, and low-voltage distribution cabinets to facilitate medium-voltage power intake, voltage transformation, and the supply of power for machinery and lighting on the low-voltage side.

The project utilizes a total of 22 transformer units—comprising 12 dry-type transformers and 10 box-type substations (pre-fabricated substations)—to serve the engine assembly workshop, marine pump production workshop, auxiliary buildings, and plant utility facilities, thereby ensuring a reliable and continuous power supply for operations.

Using this project as a case study, this article analyzes the practical application of dry-type transformers and box-type substations in Middle Eastern industrial projects—covering aspects such as adaptation to high-temperature environments, anti-corrosion design, product selection, system configuration, and on-site installation—to provide a reference for the selection of power equipment in overseas engineering projects.

I. Project Background: A Key Project Supporting Saudi Arabia's Industrial Manufacturing Upgrade

The Saudi Aramco Power Workshop project is located in the Ras Al-Khair Industrial City within Jubail, in Saudi Arabia's Eastern Province. It serves as a supporting facility for the King Salman International Complex for Maritime Industries and Services project, sharing the same industrial park as the maritime facility project in which our company is also participating.

Our company signed the EPC contract for this project with Saudi Aramco; it is a key supporting project for advancing industrial localization under Saudi Arabia's "Vision 2030."

The main construction components of the project include:

·Engine assembly workshop;

·Marine pump assembly workshop;

·Ancillary production buildings;

·Power and utility facilities.

Upon completion, the project will undertake the manufacturing of industrial marine propulsion systems and marine pump equipment, thereby enhancing the capabilities of Saudi Arabia's maritime industry supply chain.

For large-scale manufacturing plants, a stable and reliable power supply is a crucial foundation for ensuring continuous production. As key components of the power system, the operational reliability of transformers directly impacts the plant's overall production efficiency and safety.

Consequently, selecting transformers capable of withstanding high temperatures, salt spray, and sandy, dusty environments became a critical aspect of the electrical system design for the project.

II. Environmental Challenges: Extreme Heat (50°C) and Coastal Salt Spray Test Equipment Reliability

A defining characteristic of industrial projects in the Middle East is the demanding operating environment, which far exceeds that of typical regions.

Under the IEC 60076 series of standards, conventional transformer designs typically use an ambient temperature of 40°C as a reference point; however, summer temperatures in parts of Saudi Arabia can exceed 50°C.

Consequently, transformers manufactured to standard specifications cannot directly meet the local requirements for long-term, stable operation.

1. High ambient temperatures reduce equipment heat dissipation capacity.

During transformer operation, the windings and core generate losses that convert into heat, which must be promptly dissipated via the cooling system.

When the ambient temperature rises:

· the temperature difference for heat dissipation decreases;

· cooling efficiency drops;

· the internal temperature rise increases;

· prolonged operation at high temperatures accelerates the aging of insulation materials and affects the equipment's service life.

Therefore, projects in the Middle East typically require specialized designs to address high-temperature environments, including:

· Increasing heat dissipation surface area;

· Optimizing cooling structures;

· Upgrading the thermal rating of insulation materials;

· Verifying capacity based on ambient temperature.

2. High-salinity environments increase corrosion risk

The project is located near the Persian Gulf, where the air contains high concentrations of salt.

According to the ISO 12944 corrosion protection classification, coastal industrial environments typically fall under the C5-M high-corrosivity category.

In such environments, the surfaces of standard equipment are prone to:

· corrosion of metal structures;

· degradation of protective coatings;

· reduced sealing performance of the enclosure.

Consequently, outdoor transformers and enclosed equipment require higher-grade anti-corrosion measures, such as:

· C5-M grade anti-corrosion coatings;

· enhanced surface treatment processes;

· improved enclosure protection capabilities.

3. Dusty environments require higher degrees of protection

Certain regions of Saudi Arabia experience dusty conditions year-round; large quantities of fine particles can easily penetrate the equipment, potentially affecting insulation components and electrical connections.

Consequently, the project equipment must feature:

· robust sealing structures;

· high degrees of protection;

· stable environmental adaptability.

This represents a key distinction in equipment selection between overseas industrial projects and standard domestic projects.

III. Equipment Configuration: Combined Application of Dry-Type Transformers and Box-Type Substations

To meet the operational requirements of different areas, the project employs a combined power supply scheme featuring indoor dry-type transformers and outdoor box-type transformers.

This configuration balances safety requirements in production areas with the need for distributed power supply across the facility, representing a common application model for large-scale industrial projects in the Middle East.

1. Indoor configuration: Dry-type transformer ensures power supply to the production workshop.

The project's main substation is equipped with three dry-type transformers:

The total weight of the three pieces of equipment reaches 17.18 tons.

As the production workshop involves the manufacturing of industrial equipment such as engines and marine pumps—requiring high standards for power supply safety and continuous operation—dry-type transformers have been selected as the primary power supply units.

The key advantages of dry-type transformers include:

Operation without insulating oil

Dry-type transformers utilize a solid insulation structure and do not require transformer oil; this eliminates the risk of oil leakage, making them more suitable for installation within industrial facilities.

Reduced maintenance requirements

Compared to oil-immersed equipment, dry-type transformers eliminate maintenance tasks such as oil quality testing and oil replenishment, thereby helping to lower long-term operation and maintenance costs.

Superior fire safety performance

Dry-type transformers offer enhanced safety suitability for production areas characterized by high personnel density and concentrated equipment.

Three main transformer units serve as the core power supply nodes for the project, ensuring a stable power supply for the manufacturing areas.

2. Outdoor Configuration: Box-type Transformers Establishing the Plant's Power Supply Network

According to the project configuration plan, a total of 22 transformers are deployed across the facility—comprising 12 dry-type transformers and 10 box-type substations (pre-assembled transformer units)—to form a comprehensive power supply network covering the main substation, production workshops, and auxiliary facilities.

Among these, the 12 dry-type transformers—specifically three-phase epoxy-cast resin units—are primarily used to supply power to indoor production areas and critical loads, with capacities ranging as follows:

·2500kVA Dry-type Transformer

Model: SCB18-2500/10

Rated Capacity: 2500kVA

High-voltage Side: 10kV

Low-voltage Side: 0.4kV

Insulation Class: F

Cooling Method: AN/AF (Natural Air Cooling/Forced Air Cooling)

·2000kVA Dry-type Transformer

Model: SCB18-2000/10

Rated Capacity: 2000kVA

High-voltage Side: 10kV

Low-voltage Side: 0.4kV

Suitable for continuous industrial load operation

·1000kVA Dry-type Transformer

Model: SCB18-1000/10

Rated Capacity: 1000kVA

High-voltage Side: 10kV

Low-voltage Side: 0.4kV

Primarily supplies power to auxiliary buildings and motive power loads

The remaining dry-type transformers are configured according to the varying load requirements of the buildings, with capacities primarily ranging from 630 kVA to 2,000 kVA, ensuring a stable power supply for production equipment, lighting systems, control systems, and auxiliary facilities.

Ten box-type transformers are primarily installed in the outdoor areas of the plant site to supply power to the perimeter of the production workshops and to distributed loads. The equipment utilizes a pre-assembled package substation structure, with the following typical configuration:

Model: ZGS11/ZGS13 Series Box-type Substation

· Capacity Range:

1000 kVA

1250 kVA

1600 kVA

· High-Voltage Side:

11 kV (compatible with Saudi industrial power grids)

· Low-Voltage Side:

0.415 kV

· Protection Class:

IP54 or higher

· Cooling Method:

ONAN (Oil-immersed natural cooling)

Prefabricated substations integrate high-voltage switchgear, oil-immersed transformers, and low-voltage power distribution systems into one unit, possessingquick installation, resistant to sand and dust, resistant to salt spray corrosion, and compact footprint other characteristics, making it suitable for the long-term operating environment of coastal industrial parks in Saudi Arabia.

These units are responsible for providing a stable power supply to:

· 44 medium-voltage switchgear panels;

· 69 low-voltage switchgear panels;

· building lighting systems;

· power equipment;

· control systems.

Box-type transformers (pre-fabricated substations) integrate high-voltage switchgear, transformers, and low-voltage power distribution equipment within a single enclosure.

Compared to traditional substation construction methods, box-type transformers offer the following features:

·Factory prefabrication and high on-site installation efficiency

Equipment is assembled and tested at the factory, allowing for rapid on-site installation and a shortened construction schedule.

·Sealed structure suitable for challenging environments

The enclosure design minimizes the impact of environmental factors—such as dust and salt spray—on internal components.

·Flexible power supply for plant facilities

The equipment has a small footprint, enabling distributed installation tailored to the plant's layout.

Ultimately, the project utilizes 22 transformers to establish a comprehensive power supply network, extending electricity coverage from the main substation to production workshops and auxiliary facilities.

IV. Precision Installation: 22 Transformers Delivered to the Project Site

On July 10, 2026, the three dry-type transformers for the project's main substation were successfully hoisted into position.

The transformer installation process encompasses multiple stages—including transportation, foundation acceptance, equipment hoisting, positioning adjustments, and safety protection—placing high demands on construction precision and on-site management.

Pre-installation Preparation Phase

Before the equipment arrives on site, the following must be completed:

· Transport route planning;

· Inspection of the installation foundation;

· Verification of elevation and centerlines;

· Confirmation of load-bearing capacity.

Ensure that the conditions for equipment installation meet design requirements.

Hoisting and Installation Phase

The transformer installation process encompasses multiple stages—including transportation, foundation inspection, equipment hoisting, positioning, and safety protection—placing high demands on construction precision and on-site management.

Project Quality Control

The entire project—from the approval of construction plans and on-site technical briefings to the supervision of the lifting process—was executed in accordance with international standards for overseas project management.

The successful installation of the transformer marks the entry of the project's electrical construction phase into a critical stage, laying the foundation for subsequent equipment commissioning and operation.

V. Lessons from the Case: The Middle East Market Sets Higher Requirements for Power Equipment

The Saudi Aramco power plant project is not merely an industrial manufacturing undertaking; it also serves as a practical case study for Chinese power equipment enterprises entering the Middle East market.

1. Extreme environments serve as a critical test of equipment capabilities

Conditions such as 50°C high temperatures, high salt spray, and dusty environments impose rigorous demands on transformer design.

To enter the Middle East market, equipment must not only meet basic performance standards but also undergo targeted optimization in areas such as:

· Heat dissipation design;

· Anti-corrosion treatment;

· Insulation systems;

· Protective structural design.

2. International projects place a premium on equipment reliability and manufacturing capabilities

Large-scale overseas industrial projects typically employ strict supplier vetting systems.

Manufacturers must not only provide products that meet standard specifications but also demonstrate:

· Stable production capacity;

· A robust quality management system;

· Extensive experience with overseas projects.

3. The "dry-type transformer + box-type substation" combination is a common configuration for industrial projects

As illustrated by this project:

Indoor production areas prioritize safety, making dry-type transformers the more suitable choice;

Outdoor plant areas prioritize environmental adaptability and rapid deployment, giving box-type substations a distinct advantage.

Selecting the appropriate equipment type based on the operating environment is a key principle in the electrical design of overseas industrial projects.

Summary: Power Supply Requirements for Middle East Industrial Projects—Insights from 22 Transformers

The 22 transformers installed for the Saudi Aramco power plant project not only supply power for industrial operations but also demonstrate the adaptability of Chinese power equipment to complex overseas environments.

From equipment design for 50°C high-temperature environments and anti-corrosion protection for coastal areas with salt-spray conditions to the precision on-site installation of large-scale equipment, every aspect demonstrates that the core of competition in overseas power projects lies not merely in product pricing, but in equipment reliability, engineering expertise, and an understanding of local operating environments.

For power equipment enterprises planning to enter the Middle East market, a deep understanding of local standards and application requirements is key to achieving long-term growth.