Bob Ruzensky
Regional Sales Director – Gulf Region
© 2012 Eaton Corporation. All rights reserved.
Agenda
• Peak Transformers
• VFI Protected Transformers
• Addressing Arc Flash when doing preventive
maintenance on transformers
© 2013 Eaton, All Rights Reserved.
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A NEW ERA IN
TRANSFORMER DESIGN
© 2013 Eaton, All Rights Reserved.
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Envirotemp™ FR3™ Fluid
• High Fire-Point
• Mineral Oil: 155°C
• EnvirotempTM FR3TM: ≈360°C
• Non-Toxic
• Renewable
PEAK Transformers Include all the Benefits of
Envirotemp™ FR3™ Fluid
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Envirotemp™ and FR3™ are licensed trademarks of Cargill, Incorporated.
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Transformer Customer Challenges
 Electrical Consumption and Demand are Growing
 Load Growth and Future Demand May Stress
Transformers Beyond Nameplate Ratings
− Some Loads are Variable
− Some Load are Predictable
 Some Projects Have Size and Weight Constraints
for Transformers
 Customers Prefer Flexibility in Loading
Transformers
 PEAKTM Transformers May Be Part of the Solution
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PEAK Transformer Family
 PEAK transformers from Cooper Power Systems are designed to:
 Provide enhanced capability compared to traditional transformers in
today’s market
 Utilizes an advanced high temperature insulation system
 Thermally upgraded kraft paper
 EnvirotempTM FR3TM dielectric fluid
 Optimized core and coil design.
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Envirotemp™ and FR3™ are licensed trademarks of Cargill, Incorporated.
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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%
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Envirotemp™ and FR3™ are licensed trademarks of Cargill, Incorporated.
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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
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Envirotemp™ and FR3™ are licensed trademarks of Cargill, Incorporated.
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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 ⁰ C AWR
• 65 °C AWR and 75 °C AWR kVA ratings
on the nameplate
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Envirotemp™ and FR3™ are licensed trademarks of Cargill, Incorporated.
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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
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Envirotemp™ and FR3™ are licensed trademarks of Cargill, Incorporated.
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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
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Envirotemp™ and FR3™ are licensed trademarks of Cargill, Incorporated.
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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
• All PEAK Transformers are filled with
EnvirotempTM FR3TM Fluid
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Envirotemp™ and FR3™ are licensed trademarks of Cargill, Incorporated.
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Why Increased Overload Capacity?
 Ideal for Expectation of Increasing
Demand and for Withstand of Peak
or Prolonged Overload Conditions
− Application: serve building with
expectation of growth in tenants
over time
•
Eliminates need to replace
transformer with larger kVA unit
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Why Increased Overload Capacity?
 Ideal for Expectation of Increasing
Demand and for Withstand of Peak or
Prolonged Overload Conditions
− Application: Serve building with
expectation of growth in tenants over time
•
Eliminates need to replace transformer
with larger kVA unit
− Application: Double-ended substation with
shared load on each end capable of
serving full load on one side for periods of
time
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Why Increased Overload Capacity?
 Ideal for Expectation of Increasing
Demand and for Withstand of Peak or
Prolonged Overload Conditions
− Application: serve building with
expectation of growth in tenants over time
•
Eliminates need to replace transformer
with larger kVA unit
− Application: double-ended substation with
shared load on each end capable of
serving full load on one side for periods of
time
− Application: for critical loads where
overload is a concern, 65/75 °C AWR
provides an alternative, or complementary,
solution to forced air (fans) and
transformer oversizing
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Increased Reliability
Longer Insulation System Life Than Conventional
Mineral Oil-Filled Transformers

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.
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FR3™ Fluid & Moisture
• Higher Moisture Content in
Insulation than Fluid
FR3™ and Envirotemp™ are licensed trademarks of Cargill, Incorporated
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FR3™ Fluid & Moisture
• Higher Moisture Content in
Insulation
• FR3™ - Higher Affinity for and
Tolerance of Moisture
• 25 C Saturation Levels
• Mineral Oil: 70 ppm
• EFR3™ : 1200 ppm
FR3™ and Envirotemp™ are licensed trademarks of Cargill, Incorporated
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FR3™ Fluid & Moisture
• Higher Moisture Content in
Insulation
• FR3™ - Higher affinity for and
tolerance of moisture
• 25 C Saturation Levels
• Mineral Oil: 70 ppm
• FR3™ : 1200 ppm
• Maintains Dielectric Strength
Similarly to Mineral Oil in Terms
of Relative Saturation
FR3™ and Envirotemp™ are licensed trademarks of Cargill, Incorporated
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VFI Transformer
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Vacuum Fault Interrupter (VFI) Transformer
Switchgear Protection Inside a Transformer
•
Internal under-oil vacuum fault interrupter
•
Three-phase gang operated
•
Trip function through Tri-Phase Ground control w/ SCADA
- Gauge contacts wired into SCADA control
- Trip/open function only, won’t automatically reclose
•
Optional Trip Function and Protection with Cooper IDEA Relays
•
Optional Motor Operator for Remote Closure
•
Optional contact switches are wired for alarm or control
functions outside transformer
•
User defined schematic based on system requirements
Available on Pads & Substations
Optional Motor Operator
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VFI Transformer
• 3Ø Primary over-current
protection and switching
(Vacuum Fault Interrupter)
installed integral to
transformer.
• Resettable medium voltage
breaker with electronic
control
• Over 100 minimum trip
settings
Guentert, J. (2012). Protection, Arc Flash Mitigation Using VFI [Photograph].
CSE Magazine.
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VFI transformer
• Up to 35 kV rating
• 600 or 900 A continuous rating
• 12 kA & 16 kA interrupting rating
• Optional secondary relay
• Used to trip VFI on secondary
fault
• Helps mitigate secondary arc
flash hazards
Guentert, J. (2012). Protection, Arc Flash Mitigation Using VFI [Photograph].
CSE Magazine.
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Standard VFI Controls
Tri-Phase
TPG (Tri-Phase w/Ground)
TPG w/SCADA
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Smart-Grid ready VFI
VFI switchgear can be customized to be Smart-Grid Ready
•
Equipped with iDEA Platform
Controls
•
Remote open/close option
•
Internal PTs/CTs for voltage
sensing
•
Wide range of communication
options available with the
iDEA controls (Ethernet, Fiber
Optic, RS 485)
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Improved System Coordination
• Improved Coordination with Other
System Protective Equipment
Eliminates Unnecessary Outages
• Tri-Phase Control Improves
Coordination for Maximum Uptime
•
•
•
•
•
•
•
Selectable TCC Curves
Pickup Settings from 10-1290 A
Instantaneous
Ground Element
Min Response Time Accessory
Cold Load Pickup Capable
SCADA Capable for Automation
Solves complex coordination problems
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VFI transformer
VFI
Handle
Selector Switch
Dual Feed Bushings
Dry Transformer
• Switchgear-type overcurrent protection for
large pad-mounted or
substation transformers
• Provides smallest
footprint for primary
switching and overcurrent protection
HV Duplex Load-break
Air Switches
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VFI transformer w/ visible break
Visible break
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Pad-mounted VFI transformer
• Available in pad-mounted
design eliminating padmounted switchgear
• VFI control in HV
termination compartment
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Complete 35kV Connector System
•
•
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•
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•
•
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Bushing
Tee body
Junctions
200 A tap plugs
Insulating plugs
Connector plugs
Bushing extender
200 A caps
600 A caps
“200 kV BIL”
Product markings match 200 kV BIL
bushing color
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Voltage Ratings and Characteristics
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Addressing Arc Flash
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Addressing Arc Flash
IEEE C57.12.34 requires opening LV compartment door before accessing HV.
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Addressing Arc Flash
• Essential Monitoring
Equipment Accessible
Outside Termination
Compartments
• Drain Valve & Sampler
• Gages
• Load-break switches
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Addressing Arc Flash
• Externally operable visible
break switching
• Reduces unnecessary arc
flash exposure
• Improved visibility and safety
compared to standard loadbreak switch mounting
• Ability to ground transformer
windings with on/off/ground
• Reduce maintenance costs
• Maintains tamper resistance
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Externally operated visible load-break switch
Visible break window
Gages
Load-break
switch handle
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Externally operated visible load-break switch
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Seismic
• OSHPD Certified.
• SDS
• Design spectral response acceleration
• Japanese earthquake SDS =1.0
• Cooper transformers certified to SDS = 1.93
• Manufacturers vary greatly in terms of kVA ratings being
OSHPD certified
• Transformers Will Also Comply With IBC Seismic
Requirements
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DOE defined benefits of 2016 standard
• Increased efficiency standards provide the
following perceived national benefits over 30
year period
• 3.63 quadrillion (1015) Btu of energy
• Roughly equivalent to the energy consumed by 40 million
American households in one year
• 264.7 million metric tons (Mt) of carbon dioxide (CO2)
• Average passenger car emits 4.75 metric tons
CO2E/vehicle/year
•
http://www.epa.gov/cleanenergy/energyresources/refs.html
• Roughly equivalent to removing over 55 million light duty
passenger cars for one year
• 203.0 thousand metric tons of nitrogen oxides (NOX)
• 182.9 thousand metric tons of sulfur dioxide (SO2)
• 1,200 pounds of mercury (Hg)
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Source: “Energy Efficiency Program For Certain Commercial And Industrial Equipment” 10 “CFR” 431.2
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3-Phase liquid-filled: DOE 2010 vs. DOE 2016
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Inefficiency reduction (%)
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14
12
10
8
6
4
2
0
15
30
45
75
112.5
150
225
300
500
750
1000
1500
2000
2500
3-Ph kVA at DOE (50%) load
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Impact of DOE 2016
• Transformer sizes, weights, and prices likely to
change
• Changes dependent upon specific customer
requirements and transformer type and rating
• General observations
• Core/coil weight increases are likely
• Footprint may change
• Eaton can design to meet dimensional constraints
The redesign process must be completed in order to provide firm size, weight,
and price changes
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Weight change example:
3-phase pad-mounted
20%
18%
Average Weight Change
16%
14%
12%
10%
8%
6%
4%
2%
0%
75
112.5
150
225
300
500
kVA
750
1000
1500
2000
2500
Graph is representative of a subset of designs transitioning from DOE 2010 to DOE 2016.
Individual designs may have increases above or below averages presented above.
Transformers with high-current secondary's (i.e. 750kVA+, 208Y/120) will have weight increases well above average
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3-Phase liquid-immersed efficiency and
base losses
kVA
DOE 2010
Efficiency (%)
DOE 2016
Efficiency (%)
DOE 2010 Base
Losses (W)
DOE 2016 Base
Losses (W)
Change In
Base Losses
15
98.36
98.65
123
101
-18%
30
98.62
98.83
207
176
-15%
45
98.76
98.92
279
243
-13%
75
98.91
99.03
409
364
-11%
112.5
99.01
99.11
557
501
-10%
150
99.08
99.16
690
630
-9%
225
99.17
99.23
934
866
-7%
300
99.23
99.27
1155
1095
-5%
500
99.25
99.35
1875
1625
-13%
750
99.32
99.4
2550
2250
-12%
1000
99.36
99.43
3200
2850
-11%
1500
99.42
99.48
4350
3900
-10%
2000
99.46
99.51
5400
4900
-9%
2500
99.49
99.53
6375
5875
-8%
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Think “MITS” for convenience
MITS – Modular Integrated Transportable
•
Fully Integrated
•
•
Modular
•
•
Factory-assembled, wired, and
tested to minimize on-site labor
costs, quality issues, and time
Flexible, and expandable design
allows a variety of equipment
configurations
Transportable
•
Structural base allows for
assembled units to be lifted and
transported, and relocated.
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Voltage Regulators
 Single-phase or three-phase
 Self contained
 +/- 10% regulation
 32 Steps, 5/8% increments
 55/65 °C average winding rise
(12% more capacity)
 25 to 2000 A
 2400 V to 34500 V (60-200 BIL)
 FR3 or Mineral Oil
 Fan cooling option (33% more
capacity)
 Substation, pole and pad-mounted
designs
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Success Story: Overhead Regulators
• Arizona mining customer having
power quality issues on their shovels
• Eaton CPS and EESS reps sold
benefit of Voltage Regulators over
Substation Load Tap Changers
(LTC’s) for power factor correction
•
Minimum outage required for maintenance
•
Regulation separate from main
transformer
•
Lower Cost
•
Designs optimized for the application
•
Full 3 phase power quality monitoring
•
Readily available replacements
•
Communications integration and
automation
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