Product Scope: Substation
• Three‐Phase or Single‐Phase, 50 or 60 Hz, • 55ºC, 65ºC, 75ºC, 55ºC/65ºC, 55ºC/75ºC, 65ºC/75ºC
• Envirotemp FR3 fluid or Mineral Oil
• Three‐Phase: 300 – 12,000 kVA
• Single‐Phase: 167 – 6,667 kVA
• Primary Voltage 2400 – 46,000 V
• Secondary Voltage 208Y/120 V ‐ 24,940 V Wye
• Specialty Designs •
•
•
•
•
•
•
•
•
•
Inverter/Rectifier Bridge
K‐Factor
Hazardous Location (Class 1 Div 2)
Internal Circuit Breaker (VFI) and/or Visual Break
Fans
UL Listed & Labeled/ Classified
Factory Mutual (FM) Approved
Differential Protection
6 or 12 Pulse Designs
Grounding Transformers
Substation Product Scope
• Substation Types
• Primary Open
• Secondary Open
• Definition
• Open ‐ Cover mounted Bushings
• Primary ‐ Above 2500 kVA, Secondary voltage above 1000 Volts
• Secondary ‐ 2500 kVA and below with less than 1000 Volt secondary
Substation Product Scope
• Substation Types
• Primary Unit
• Secondary Unit
• Definitions
• Unit ‐ Sidewall mounted bushings typically in a lineup
• Primary/Secondary same as previous slide
Product Scope: Padmount
• Three‐Phase 50 or 60 Hz, • 55ºC, 65ºC, 75ºC, 55ºC/65ºC, 55ºC/75ºC, 65ºC/75ºC
• Envirotemp FR3 fluid or Mineral Oil
• Three‐Phase: 45 – 10,000 kVA
• Primary Voltage 2400 – 46,000 V
• Secondary Voltage 208Y/120 V ‐ 24,940/14,400 V Wye
• Specialty Designs •
•
•
•
•
•
•
•
•
K‐Factor
UL Listed & Labeled/ Classified
Factory Mutual (FM) Approved
Solar/Wind Designs
Differential Protection
6 or 12 Pulse Designs
Grounding Transformers
Internal Circuit Breaker (VFI) and/or Visual Break
Fans
Transformer Design
• Winding Material
• Aluminum or Copper
• Dead Front or Live Front • Secondary under 600 Vac must be Live Front
• Arresters
• Color
• Loop Feed or Radial Feed
• Special Impedance requirements
• Special bushing heights/spacing
Padmount Product Scope
Transformer Design
• Losses other than DOE requirements
• Overcurrent protection inside transformer
• VFI, fuses or none
• Switching inside transformer
• T‐blade, V‐blade, On/Off or none
• Visual Break with VFI or switches
• Containment pans for indoor transformers
• Contacts added to gauges
• UL, c‐UL Listing, UL Classified, FM Approval
Transformer Design – Arc Flash
• Arc‐Flash Issues
• Not able to shut‐down transformers for maintenance due to critical loads and/or system design.
• Padmount – move items external to cable termination compartment
•
•
•
•
•
Nameplate
Liquid‐sample valve
Gauges
Switch operating handle
Add IR windows
External Gauges and Sampling Valve
External Gauges enclosure
DOE Efficiency Requirements – Indoor
Liquid-filled Transformers
IEEE Power & Energy Society
December 09, 2009
DOE 10 Code of Federal
Regulations (CFR) Part 431
Minimum Efficiency
The Ruling and its effects
Background
DOE Minimum Efficiency:
• History
• The Department of Energy (DOE) studied raising distribution transformer efficiency;
• Technologically Feasible,
• Economically Justifiable,
• and Produce Significant Energy Savings
• FINAL RULING PUBLISHED OCTOBER 12, 2007
• The Driver is to Reduce CO2 Emissions
The Ruling
The Ruling (10 CFR Part 431)
• A level between TSL‐4 and TSL‐5 was established for Single‐phase transformers 10‐833 kVA
• Three‐phase 45‐2500 kVA units must meet a level between TSL‐2 and TSL‐3
• The Ruling applies to all units manufactured 01‐01‐2010 and beyond
• Does not affect distributor stock, only manufacturers
• All transformers produced and imported to the U.S.
• Does not apply to rebuilt transformers
• Enforcement mechanisms are not fully defined
DOE Ruling – Single and Three-phase
Efficiency Standard Comparison
kVA
NEMA TP-1
Efficiency (%)
DOE 10 CFR Part
431
Efficiency (%)
15
98.1
98.36
30
98.4
98.62
45
98.6
98.76
75
98.7
98.91
112.5
98.8
99.01
150
98.9
99.08
225
99
99.17
300
99
99.23
500
99.1
99.25
750
99.2
99.32
1000
99.2
99.36
1500
99.3
99.42
2000
99.4
99.46
2500
99.4
99.49
All efficiency values are at 50 percent of nameplate-rated load
DOE Ruling – Dry Type
Liquid vs. Dry
DOE 10 CFR Part 431 Efficiency (%) Comparison
kVA
Liquid-Filled Transformers
Dry Transformers
45-95 kV BIL
15
98.36
97.18
30
98.62
97.63
45
98.76
97.86
75
98.91
98.12
112.5
99.01
98.30
150
99.08
98.42
225
99.17
98.57
300
99.23
98.67
500
99.25
98.83
750
99.32
98.95
1000
99.36
99.03
1500
99.42
99.12
2000
99.46
99.18
2500
99.49
99.23
Efficiency Levels
So, Does 0.3% Difference in Efficiency Matter?
• Efficiency = Rated output
Rated output + Total losses
• Example If Performing a “Loss Evaluation” on 1500 kVA Transformers
• Based on $.06/kW‐Hr
• Present Value Factor based on 6% interest over 10 years
• Overall conservative evaluation
Efficiency Levels
So, Does 0.3% Difference in Efficiency Matter?
• Efficiency = Rated output
Rated output + Total losses
• Example If Performing a “Loss Evaluation” on Transformers
• Based on $.06/kW‐Hr
• Present Value Factor based on 6% interest over 10 years
• Overall conservative evaluation
• Example for Efficiency Difference for 1500 kVA • Liquid‐filled transformer
• 99.42% efficient @ 50% load per DOE
• Total losses ~ 4375 watts (@50% load)
• Present value of cost of losses ‐ $16,922
• Annual cost of losses ‐ $2300 @ 50% Load
~ $3548 @ 75% Load
Efficiency
Levels
So, Does 0.3% Difference in Efficiency Matter?
• Efficiency = Rated output
Rated output + Total losses
• Example If Performing a “Loss Evaluation” on Transformers
• Based on $.06/kW‐Hr
• Present Value Factor based on 6% interest over 10 years
• Overall conservative evaluation
• Example for Efficiency Difference for 1500 kVA • Liquid‐filled transformer
• 99.42% efficient @ 50% load per DOE
• Total losses ~ 4375 watts (@50% load)
• Present value of cost of losses ‐ $16,922
• Annual cost of losses ‐ $2300 @ 50% load
~ $3548 @ 75% load
• Dry transformer
• 99.12% efficient @ 50% load per DOE
• Total Losses ~ 6659 watts (@50% load)
• Present value of cost of losses ‐ $25,757
• Annual cost of losses ‐ $3500 @ 50% load
~ $5322 @ 75% load
$1200 ‐1750 savings per y
DOE Efficiency Requirements
2010 vs. 2016
DOE Liquid Filled 2010 vs. 2016
Efficiencies
kVA
2010
2016
15
98.36
98.65
30
98.62
98.83
45
98.76
98.92
75
98.91
99.03
112.5
99.01
99.11
150
99.08
99.16
225
99.17
99.23
300
99.23
99.27
500
99.25
99.35
750
99.32
99.4
1000
99.36
99.43
1500
99.42
99.48
2000
99.46
99.51
2500
99.49
99.53
2016 DOE Manufacturer Implications
• Manufacturers will need to revise most of their active catalog numbers before 1‐1‐2016 to meet requirements
• The new efficiency levels will shift some raw material usage to amorphous cores. • There may be new manufacturing challenges for many manufacturers in terms of design, manufacturing, or material procurement.
2016 DOE Consumer
Implications
• Transformer weights will change
• Depends greatly on specific customer designs & specific product designs, but in general…
•
•
•
•
Increase in core/coil weight
Decrease in fluid volume (core/coil displacement)
Overall weight increases slightly
Dimensions don’t appear to change dramatically
• Transformer costs and prices will increase
• Estimates of a 5‐15% price increase over the previous efficiency standard for qualifying 3‐phase transformers
• Actual price increases are a function of what customers are paying today, movements in the materials markets, and are design specific.
NEC® Compliance
• Indoors
• Liquid‐Filled Transformers
• Less‐flammable fluid‐filled – NEC 450‐23
•
•
•
•
•
Minimum 300°C fire point
In Type I or Type II non‐combustible building
No combustible materials around transformer
Liquid containment
Installation to comply with all fluid listing restrictions.
• UL Classification
• FM Approval UL Classification of Envirotemp™ FR3™
• Listed less flammable fluids
• 45 – 10,000 kVA 3Ø transformers
• Substation
• Pad‐mounted
• 12 psig internal pressure tank withstand rating
• Minimum pressure relief device ratings* • Either current‐limiting fusing or other over‐current protection* • Other over‐current protection may include:
• Externally mounted expulsion fusing
• Primary breakers
• Only natural ester based fluid is permitted to use either CL fusing or other over‐current protection. *In accordance with UL Classification Marking
UL Classification of Envirotemp™ FR3™
FM Approved transformer requirements
• Developed Approval Standard 3990
• FM Approved transformer
• 1998
• Restrictions based on transformer protection very similar to the UL Classification except in addition to fusing, pressure relief and tank withstand ratings:
• Alarm contacts on pressure relief devices for indoor installations >500 kVA
• Rapid rise relays >2500 kVA
• Temperature, level and pressure‐vacuum gages
• Ground fault CT on neutral
• Installation limitations, i.e. clearances to walls, etc.
Envirotemp™ FR3™ fluid
Benefits
• Fire safety characteristics
• Environmental characteristics
• Performance characteristics / enhanced life
FR3™ and Envirotemp™ are licensed trademarks of Cargill, Incorporated.
Fire point
• Mineral oil: 155 C
• Less‐flammable: min. 300 C (Required by NEC 450‐
23) • Envirotemp™ FR3™ : 360 C
FR3™ and Envirotemp™ are licensed trademarks of Cargill, Incorporated.
Why Choose a Less-Flammable
Fluid-Filled Transformer
Fire Safety
Fire safety
• Envirotemp™ FR3™
• 17 Years of service
• >450,000 installations
• No reported fires ‐ NFPA
• R‐Temp fluid –
•
•
•
•
Predecessor to FR3
35 Years of service >250,000 installations
No reported fires – NFPA
FR3™ and Envirotemp™ are licensed trademarks of Cargill, Incorporated
FM Approved Transformer
• 1994 ‐ FM Changes Approval Restrictions
• Revised Less‐Flammable Fluid Approval
• Developed New Transformer Approval Standard 3990 National Electric Code 450.23
• 450.23 Less‐Flammable Liquid‐Insulated Transformers.
Transformers insulated with less‐flammable liquids that have a fire point of not less than 300C shall be permitted to be installed in accordance with 450.23(A) or 450.23(B).
NFPA 70 450.23(B)
• (B) Outdoor Installations.
Less‐flammable liquid‐filled transformers shall be permitted to be installed outdoors, attached to, adjacent to, or on the roof of buildings where installed in accordance with (1) or (2):
(1) For Type I or Type II buildings, the installation shall comply with all listing restrictions provided for in the listing of the liquid.
FPN: Installations adjacent to combustible material, fire escapes, or door or window openings may require additional safeguards such as those listed in 450.27
(2) In accordance with 450.27.
Making Your Medium Voltage Transformer
Installations NEC® Compliant
≤10,000(38)
>10,000(38)
NFPA 70 450.23(A)
• (A) Indoor Installations. Indoor installations shall be permitted in accordance with the following:
(1) In Type I or Type II buildings, in areas where all of the following requirements are met:
a. The transformer is rated 35,000 volts or less.
b. No combustible materials are stored.
c. A liquid confinement area is provided.
d. The installation complies with all the restrictions provided for in the listing of the liquid.
(2) With an automatic fire extinguishing system and a liquid confinement area, provided that the transformer is rated 35,000 volts or less.
(3) In accordance with 450.26
Why Choose a Less-Flammable
Fluid-Filled Transformer
• What Happened to the Indoor Liquid‐Filled Transformer?
• PCB‐insulated transformers were the indoor transformer of choice until the mid 1970’s.
• Fears developed regarding replacement fluids
• Environmental concerns
• What was the EPA going to ban next?
• Some transformer manufacturers leaped from the frying pan into the fire – Introduced non‐flammable alternatives
• Freon
• Tetrachloroethylene (dry cleaning fluid) • Fire Safety Concerns
• Operational Concerns Why Choose a Less-Flammable FR3
Fluid-Filled Transformer
What Did You Give Up?
•
•
•
•
•
Higher efficiency / lower losses
Greater overload capability
Greater contamination resistance Higher BIL’s
Smaller footprint •
•
•
•
•
Lower temperature operation
Lower noise levels
Full diagnostic capabilities Longer life
Dramatic cost savings
Transformer Ratings
Envirotran PLUS kVA Ratings
FR3® - Filled
65ºC Rise
KNAN
(+12%)
75ºC Rise
KNAN
(+9%)
55ºC Rise
KNAF
(+15% or 25%)
65ºC Rise
KNAF
(+12%)
75ºC Rise
KNAF
(+9%)
500
560
610
575
644
702
750
840
916
863
966
1053
1000
1120
1221
1150
1288
1404
1500
1680
1831
1725
1932
2106
2000
2240
2442
2300
2576
2808
2500
2800
3052
3125
3500
3815
3750
4200
4578
4688
5250
5722
5000
5600
6104
6250
7000
7630
7500
8400
9156
9375
10500
11445
10000
11200
12208
12500
14000
15260
Fan Cooled
55ºC Rise
KNAN
55/65/75°C Rise
With Forced FA KVA FA KVA Base KVA Available KVA @ Available KVA '@ Available Available Available Air @ 55 °
@ Ampacity
Ampacity
@ 55 ° C Ampacity 65 ° C Ampacity 75 ° C Ampacity
Cooling C
65 ° C
Fans
FA
Available KVA @ Ampacity
75 ° C
500
601
560
674
610
734
→
575
692
644
775
702
844
750
902
840
1010
916
1102
→
863
1038
966
1162
1053
1267
1000
1203
1120
1347
1221
1469
→
1150
1383
1288
1549
1404
1689
1500
1804
1680
2021
1831
2202
→
1725
2075
1932
2324
2106
2533
2000
2406
2240
2694
2442
2937
→
2300
2766
2576
3098
2808
3378
2500
3007
2800
3368
3052
3671
→
3125
3759
3500
4210
3815
4589
3000
3608
3360
4041
3662
4405
→
3750
4511
4200
5052
4577
5505
Why Choose a Less-Flammable
Fluid-Filled Transformer
• Greater Overload Capability
Why Choose a Less-Flammable
Fluid-Filled Transformer
• Full Diagnostic Capabilities
• Dry‐type
• Megger
Power Factor Infra‐Red Scan
• Liquid‐filled
• Color
Acidity
Dielectric Breakdown Voltage
Dissolved Gas Analysis Metals Analysis
Inhibitor Content
Interfacial Tension
Infra‐Red Scan Power Factor
Furan Analysis
Water Content
Specific Gravity
Lower sound level
• 750 – 2500 kVA
• Liquid‐filled transformers operate at 5‐6 db less than dry transformers*
• 3db doubles sound power to your ear
*NEMA TR‐1
Less-Flammable
Fluid-Filled
Transformer
• Lower Sound Levels
• 750 – 2500 kVA
• Liquid‐filled will be 5‐6 db less than dry type
• 3db doubles sound power
Dry Type
Liquid Filled
Why Choose a Less-Flammable
Fluid-Filled Transformer
• Higher Basic Impulse Level (BIL)
• 15kV • Liquid – 95kV Standard
• Dry – 60kV Standard • 35kV • Liquid – 200kV Standard
• Dry – 150kV Standard • 480V
• Liquid – 30kV Standard
• Dry – 10kV Standard Why Choose a Less-Flammable
Fluid-Filled Transformer
Ease of Installation
Why Choose a Less-Flammable
Fluid-Filled Transformer
Smaller footprint
• Transformer
• Primary switchgear • Lower Cost for lineup
• Overall benefit: • Fit same equipment into smaller electrical rooms
• Reduced cost
Liquid vs. Dry Dimension Comparison
Close Coupled Liquid-filled
Foot print comparison
•
Based upon published standard sizes for
•
•
CPS Liquid Filled Transformers
Cast Coil Dry Type Transformers
Higher Efficiency = Reduced
Losses
Efficiency
kVA
500
750
1000
1500
2000
2500
Liquid
99.25%
99.32%
99.36%
99.42%
99.46%
99.49%
Dry
98.83%
98.95%
99.03%
99.12%
99.18%
99.23%
Liquid
Liquid
Efficiency
Advantage
35.9%
35.2%
34.0%
34.1%
34.1%
33.8%
Losses
(Watts)
3,750
5,100
6,400
8,700
10,800
12,750
$
$
$
$
$
$
Dry
D.O.E.
Liquid
16,425
22,338
28,032
38,106
47,304
55,845
Losses
(Watts)
5,850
7,875
9,700
13,200
16,400
19,250
Higher Efficiency = Reduced Losses
D.O.E. Dry
$
25,623
$
34,492
$
42,486
$
57,816
$
71,832
$
84,315
• Save nearly $30,000 in Energy Costs
• Directly tied to Losses
• Savings based upon D.O.E. Efficiency for 2500kVA Liquid vs Dry
Per D.O.E. Ruling; Liquid Filled Transformers up to 2500kVA are approximately 35% more efficient than their Dry Type counterparts.
* “Liquid Savings” Evaluated over 5 years, based upon $.10kW Energy Rate, Load + No Load Losses
Liquid
Savings
$
9,198
$
12,154
$
14,454
$
19,710
$
24,528
$
28,470
Higher Efficiency = Reduced
Losses
Cost of Losses
5 Year Cost of Losses
$90,000
$85,000
$80,000
$75,000
$70,000
$65,000
$60,000
$55,000
$50,000
$45,000
$40,000
$35,000
$30,000
$25,000
$20,000
$15,000
$10,000
$5,000
$-
$28,500 Savings
$24,500 Savings
$19,700 Savings
$14,450 Savings
$12,150 Savings
$9,200 Savings
500
750
1000
1500
2000
kVA
For all kVA Ratings; Liquid Filled Transformers = Lowest Cost of Losses
2500
D.O.E. Liquid
D.O.E. Dry
Efficiencies
Considerably Less Total Losses than Cast Resin or VPI Dry Type Transformers
Sound Levels
Significantly Reduced Sound Levels and Vibration
Operating Temperatures
Cooler Operating Temperatures than Cast Resin and VPI Dry
LEED Accreditation
LEEDS Accredidation Points for Distribution Transformers
Criteria
Energy & Atmosphere
Material & Resources
Indoor Environmental Quality
Innovation & Design
up to 19 points
--------
--------
--------
Description
Up to 24% more efficient than
equivalent non-DOE design
Liquid Filled vs. Dry Type
--------
--------
--------
--------
20% less HVAC required
FR3 Envirotemp Fluid
Total Possible Points
-------19 Points
1 point
1 point
1 point
1 point
5 points
5 points
Positive carbon footprint
DOE Transformer
Obtain up to 26 LEED Points towards building installations
26 points
Operation at Higher “Base”
Temperature
Introduction of the 75°C rise
transformer
Lockie Test Series (ANSI/IEEE
C57.100)
Insulation life extension
• Aging of paper depends primarily on temperature and water content.
• Paper aged in seed‐oil based fluid took 5‐8 times longer
to reach end of life parameters than paper aged in mineral oil.
FR3™ and Envirotemp™ are licensed trademarks of Cargill, Incorporated
PEAK Transformer family
•
•
IEEE Std C57.154™-2012 lists 75°C rise transformers
PEAK transformers from Cooper Power Systems are designed to:
•
Utilizes an advanced high temperature insulation system
•
•
•
Thermally upgraded Kraft paper
EnvirotempTM FR3TM dielectric fluid
Optimized core and coil design.
67
Envirotemp™ and FR3™ are licensed trademarks of Cargill, Incorporated.
PEAK Transformers – Three Options
1. Increased Overload Capacity
• PEAK 65/75 ⁰C Average Winding Rise (AWR)
• Operate PEAK transformers beyond full rated base load
• Single‐phase at least 9%
• Three‐phase at least 12%
Envirotemp™ and FR3™ are licensed trademarks of Cargill, Incorporated.
PEAK Transformers – Three Options
1. Increased Overload Capacity
• PEAK 65/75 ⁰C Average Winding Rise (AWR)
• Operate PEAK transformers beyond full rated base load
• Single‐phase at least 9%
• Three‐phase at least 12%
• More precisely size transformers based on periods of peak demand—without accelerated reduction of insulation life
• Continuous overload capabilities to 75⁰ C AWR
• Maintains IEEE® per unit life requirements at 75 ⁰C AWR
Envirotemp™ and FR3™ are licensed trademarks of Cargill, Incorporated.
PEAK Transformers – Three Options
1. Increased Overload Capacity
• PEAK 65/75 ⁰C Average Winding Rise (AWR)
• Operate PEAK transformers beyond full rated base load
• Single‐phase at least 9%
• Three‐phase at least 12%
• More precisely size transformers based on periods of peak demand—without accelerated reduction of insulation life
• Continuous overload capabilities to 75⁰ C AWR
• Maintains IEEE® per unit life requirements at 75 ⁰C AWR
• 65 °C AWR and 75 °C AWR kVA ratings on the nameplate
• Complies with IEEE Std C57.154™‐2012 standard
• UL Listed
Envirotemp™ and FR3™ are licensed trademarks of Cargill, Incorporated.
PEAK Transformers – Three Options
2. Increased Overload Capacity
• PEAK 55/75 ⁰C Average Winding Rise (AWR)
• Operate PEAK transformers beyond full rated base load
• Three‐phase at least 22%
• More precisely size transformers based on periods of peak demand—without accelerated reduction of insulation life
• Continuous overload capabilities to 75⁰ C AWR
• Maintains IEEE® per unit life requirements at 75 ⁰C AWR
• 55 °C AWR and 75 °C AWR kVA ratings on the nameplate
• Complies with IEEE Std C57.154™‐2012 standard
• UL Listed
Envirotemp™ and FR3™ are licensed trademarks of Cargill, Incorporated.
PEAK Transformers – Three Options
3. Smaller, Lighter Transformers
• PEAK 75 ⁰C Average Winding Rise
• Smaller and lighter than traditional 65 °C AWR transformers of the same kVA rating
• Typically use less material and fewer gallons of dielectric fluid
─resulting in better value
• Complies with IEEE Std C57.154™‐2012 standard
• UL Listed
Envirotemp™ and FR3™ are licensed trademarks of Cargill, Incorporated.
PEAK™ transformer
PEAK™ Transformer kVA Ratings
Temp Rise (55 to 65-12%, 65 to 75-9%, 55 to 75-22%)
Fans (500 to 2000-15%, 2500 to 10000-25%)
55ºC Rise
KNAN
65ºC Rise
KNAN
75ºC Rise
KNAN
55ºC Rise
KNAF
65ºC Rise
KNAF
75ºC Rise
KNAF
500
560
610
575
644
702
750
840
916
863
966
1053
1000
1120
1221
1150
1288
1404
1500
1680
1831
1725
1932
2106
2000
2240
2442
2300
2576
2808
2500
2800
3052
3125
3500
3815
3750
4200
4578
4688
5250
5722
5000
5600
6104
6250
7000
7630
7500
8400
9156
9375
10500
11445
10000
11200
12208
12500
14000
15260
Questions?
Thank You For Your Time