There are projects where there is zero margin for error. The transformer cannot be late, cannot be oversized or undersized, and definitely cannot fail when the operation needs it most. This is one of those projects.
GECOLSA, a leading distributor of industrial machinery and equipment in Colombia, needed a high-specification encapsulated dry-type transformer to power its 2,500-kW diesel plant in Soledad, Atlántico—one of the areas with the most demanding environmental conditions in the country.
Below, we’ll explain how we tackled the challenge, what technical decisions we made, and why each specification was chosen.
The challenge: a backup system that has to be ready when everything else fails
When a customer comes to us with a need for backup power, the bar is raised considerably. This isn’t a transformer that operates under normal conditions—it’s equipment that remains on standby and must come online immediately, reliably, and without failure, the very moment the main system shuts down.
In GECOLSA’s case, there were three critical variables that we had to address simultaneously:
✔ Harsh coastal environment: Soledad, on the Atlantic coast, is characterized by high humidity, salinity, and ambient temperatures that accelerate the degradation of conventional materials.
✔ Nonlinear loads: a mechanical workshop operates with variable-speed drives, industrial motors, and equipment that generates harmonics. A standard transformer in this environment ages prematurely.
✔ Critical backup function: the transformer could not be a generic unit. It had to be precisely specified for the 2,500 kW diesel plant at 0.8 power factor that it would back up.
They didn’t need a standard transformer. They needed a transformer that would be ready when everything else fails.
The solution: custom design for demanding conditions
Our engineering team analyzed every variable in the project and defined specifications that were tailored to the actual operating conditions, rather than based on a generic catalog.
Technical specifications of the manufactured equipmentfi
| Parameter | Specifications |
| Type | Class F Encapsulated Dry-Type Transformer |
| Power | 3.200 kVA |
| Configuration | Step-up (1.2 / 15 kV series) |
| K-Factor | K4 — nonlinear loads / harmonics |
| Insulation | Epoxy resin cured in an autoclave (155 °C) |
| Temperature kit | Integrated monitor with PT-100 thermocouples |
| Overvoltage protection | SPD (Surge Protection Device) |
| Cell | Galvanized — resistant to coastal environments |
| Standards | NTC, RETIE, IEC-EN |
| Installation location | Soledad, Atlántico | Colombian Caribbean Coast |
| Application | Backup for a 2,500 kW diesel plant at a mechanical workshop |
Why Does Every Specification Matter?
Factor K4: The Protection Required by Harmonics
Standard transformers are not designed to absorb the harmonic distortions generated by variable-frequency drives and industrial motors. Over time, these harmonics cause the windings to overheat, significantly shortening the equipment’s service life. The K-factor is a parameter that indicates a transformer’s ability to withstand nonlinear loads without accelerated degradation. A K4 rating means that the equipment is designed to operate reliably in environments with high harmonic distortion, such as GECOLSA’s mechanical workshop.
Simply put: a standard transformer inside there is a transformer that ages prematurely. The K4 Factor ensures that doesn’t happen.
Galvanized cell: because the coastal environment is too harsh for ordinary materials
Soledad, Atlántico, is located on Colombia’s Caribbean coast. The combination of high relative humidity, salt particles in the air, and high temperatures makes any conventional metal structure prone to accelerated corrosion. A galvanized enclosure is not an optional accessory. It is the decision that ensures the equipment’s structure will last as long as the transformer is meant to: decades, not years.
Encapsulated in Class F epoxy resin: protection from the inside
Epoxy-encapsulated dry-type transformers provide a continuous physical barrier between the windings and the environment. This means real protection against moisture, dust, vibrations, and contaminants; they are oil-free, pose no risk of spillage, and can be installed indoors. Class F insulation ensures reliable operation up to 155 °C, with sufficient margin for the temperature spikes typical of backup equipment that comes online under immediate load.
Temperature and DPS Monitoring Kit: Reliability Is Managed, Not Assumed
The built-in temperature monitor with PT-100 thermocouples allows for real-time monitoring of the equipment’s thermal behavior, with alarm and trip alerts before an abnormal condition develops into a failure. Surge Protection Devices (SPDs) protect the transformer from voltage transients that can irreversibly damage the insulation; this is especially critical in backup equipment that comes online during an emergency.
Why Choose Tesla Transformadores for High-Specification Projects?
The GECOLSA case is not an exception in our operations. It is the norm.
✔ 42 years of experience manufacturing electrical transformers for industry, infrastructure, and special projects in Colombia and Latin America.
✔ A 10,000 m² facility in Funza, Cundinamarca, with 85% more production capacity and manufacturing times reduced by up to 30%.
✔ Custom design: each project is analyzed by our engineering team. We don’t manufacture off-the-shelf products; we manufacture solutions.
✔ Guaranteed regulatory compliance: ISO 9001:2015, RETIE 2024, NTC, IEEE, and IEC.
✔ Comprehensive technical support: from initial specifications through commissioning and after-sales support.
✔ National and international coverage: presence in more than 13 countries and over 75 cities in Colombia.
Clear specification is the first step toward reliability
An electrical transformer is not chosen based on price or immediate availability. It is chosen based on the actual environmental conditions, the nature of the load, and the criticality of the application. The case of GECOLSA in Soledad, Atlántico, is a clear example of how a well-designed technical specification—K4 factor, Class F encapsulation, galvanized enclosure, and integrated monitoring—directly translates into operational reliability and a long service life.
Every specification has a reason. No detail was left to chance.
If your project involves special conditions, harsh environments, nonlinear loads, critical backup requirements, or non-standard specifications, our engineering team is ready to discuss it with you.
Does your project require a high-performance transformer?
Tell us about your installation’s specifications. Our engineering team designs the solution based on sound technical criteria.
✉ servicioalcliente@tesla.com.co
📞 +57 318 282 6314
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