Training programme on Energy Efficient technologies for climate
change mitigation in Southeast Asia
Development of Standards
& Specifications for Energy
Efficient
Transformers & Motors
suraponss@gmail.com
Southeast Asia network of climate change focal points
Contents
1
Standards & Specification of Transformers
Benefits of Energy Efficient Transformers
2
3
4
5
Standards & Specification of Electric Motors
Benefits of Energy Efficient Motors
Conclusion
Southeast Asia network of climate change focal points
Introduction
● Develop the technical working
group (TWG) with members from
the LMS utilities to discuss on
low loss transformer
specifications
● Delivery of Handbook &
Specifications for Distribution &
Power transformers
● Seminar Program on Loss
Reduction from Experiences
inside & outside LMS utilities
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Final Outcome
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Principle Specification
Rating
Reference Standard
Max. voltages:
Tap changing:
Frequency:
Outdoor:
kVA rating:
Temperature rise:
HV rating:
L V rating
No. of Taps:
Vector group:
Special Features
IEC 60076
series:
National
standards:
Type test:
Routine test:
Special test:
Southeast Asia network of climate change focal points
Efficient
surge
protection:
Low loss:
Noise level:
Main Component Function
Lightning Arrester
(Type & Location)
•Sound level
•Cooling System
(Design &
workmanship)
Winding
(Shall be Copper)
Short circuit test
(Design &
workmanship)
Core material
(Structure & Thickness)
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Sound level
58 to 68 decibels
If not, we may get 72 decibels up
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Losses in Transformers
No load
losses
Load
losses
Core
Winding
Hysteresis and
Eddy currents losses
contribute to over
99% of the no-load
loss on ferromagnetic
core
8
Current flowing
through the
windings
causes resistive
heating of the
conductors
Southeast Asia network of climate change focal points
Distribution Transformers
•Reduce the primary voltage of the electric distribution system to the utilization
voltage serving the customer.
•A static device constructed with two or more windings used to transfer
alternating current electric power by electromagnetic induction from one circuit to
another at the same frequency but with different values of voltage and current.
•Recent Survey commissioned by
CDA UK reveals that 23 % of
network distribution transformer
losses from the UK system.
•Under peak load condition these
amount to 1,300MW, equivalent to
the output of one large power
station.
Southeast Asia network of climate change focal points
The Nature of Transformer Losses
•Transformer losses falls into three categories
•For larger transformers there are also losses absorbed by fan and pumps providing forced cooling
No – Load Loss, or iron loss
Arises within the laminated steel core of the transformer and is due to the energy
consumed in hysteresis and eddy current within the material as it is taken through its
alternating cycles of magnetization
Amorphous steel can be used to reduce the loss to one tenth of those conventional steels
Load loss, or copper loss
Load losses are maximum at the time of maximum demand on the system and so place an
extra drain on this at the very time when it is least able to meet it.
Copper loss arises due to resistance to windings, it is the I2R loss produced by the flow of
the load current within the windings.
Stray Loss
Which occur in lead and tank and
other structural metal works
Southeast Asia network of climate change focal points
Relative Losses for Different Transformer Types
This graph shows the very poor efficiencies of the smaller distribution
transformers- even when supposed of the low-loss types- compared to the larger
sizes of transformers. As distribution makes up 23 % of the total population ,
considerable saving can be made by increasing their efficiency.
Southeast Asia network of climate change focal points
Evaluation of Standard Transformers
•Many industrial users do not evaluate losses at all when procuring
transformers.
•They either consider transformers to be so efficient that the losses can be
neglected or
•they take it that the manufacturer's design process will automatically provide
them with the most appropriate value of losses.
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Core Loss Curves of Hi-B & CGO
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The Way Forward
Target Loss
5-10%
Transformer
Evaluation:
A = B + XC + YD
Based on Utilities
factors such as:
transformer service
life, load factor,
operation and
maintenance cost,
interest rate and
inflation rate, etc
Excess loss
penalty
Individual transformer
with losses beyond the
limits will be rejected,
unless agree to
increase the
guaranteed values,
compensation at 1.5 2.0 times is applied
Southeast Asia network of climate change focal points
Formula Analysis
20 years
Transformer life
0.3803
Loss factor
29.29 $/kW/Year
O&M expenses
Criteria for
calculation
of loss
0.0597 $/kWh
Electricity unit purchased
6.26 %
Interest rate
1.56 %
Inflation rate
Southeast Asia network of climate change focal points
Minimum Energy Performance Standards (MEPS)
China
The “S9”
standard:
introduced in
1999
distribution
and power
transformers
limits the
maximum Loss
of NL & LL
Japan
Top Runner
Program:
highest
efficiency level
achievable
Greenmeets the
minimum
standard
 other
orange label
Europe
Various
National
standards:
introduced
before 1999
distribution
and power
transformers
9 possible
combinations
USA
Various
National
standards:
Introduced
1996
Distribution
transformers
US
Department of
Energy (DOE)
will set MEPS
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Countries’ Efficiency Standards
Japan
USA
Europe
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Transformer Efficiency & Loading
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Loading Guide
Maximizing Low Loss Transformers
Best Practice Management
Power
efficiency
Load
factor
Reference
standards
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Service
Life
Transformers Load Management
The Communication
Systems can be
widely operated by
other media such
as SMS, Trunk
radio and Internet
Southeast Asia network of climate change focal points
1
Standards & Specification of Transformers
High Efficiency Transformer Benefit
2
3
4
5
Standards & Specification of Electric Motors
High Efficiency Motor Benefits
Conclusion
Southeast Asia network of climate change focal points
1
Reducing Energy Loss
2
Transformer Efficiency
3
Life Cycle Cost
4
Environmental Savings
Southeast Asia network of climate change focal points
Distribution System Energy Losses
Plant
Distribution
EGAT
MEA
Which parts of the system
encounter losses?
115 / 24 kV or 69 / 12 kV.
(delta - wye ground)
Sub-transmission
Primary Feeder
Secondary Feeder
Sub-station
69 or 115 kV Customer
12 or 24 kV Customer
Southeast Asia network of climate change focal points
380 / 220 V Customer
Reducing Energy Loss
Increase with
Load Connected
Constant
Reduction of
No-Load Loss
Reduce Flux
density
Hi-B, ZDKH
( M4, M5)
Concept
Reduction of
Load Loss
Copper
conductor
Copper
foil
Reduction of Transformer Losses
Southeast Asia network of climate change focal points
Energy Loss Cost
Standard
Loss
Low Loss
Rated Power (kVA)
100
100
No Load Loss(w)
250
255
Load Loss at 75 ̊c(w)
Purchase Price (Bath)
1550
840
156,700
258,000
Transformer life (Years)
20
20
Interest Rate (%)
8.5
8.5
Electric Price (Bath/kWh)
2.35
2.35
Average Load factor
0.5
0.5
Annual Energy Loss (kWh)
5584.5
4029.6
Annual Energy Loss Cost (Bath)
13123.6
9469.56
Life Time Energy Loss Cost (Bath)
124192.8
89613.6
Eloss = (PNL + PLL*I2)*8760
Life Time Energy Cost Savings
Bath 34579.2 or USD 1,038.-
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High & Low Efficiency Evaluation
50% saved
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Transformer Life-Cycle Cost
Initial Cost of Transformer
Cost of the No-load Losses
Cost of the Load Losses
Transformer
Life-Cycle
Cost (Total
Owning
Cost)
• Initial
transformer
cost
• Operation cost
• Maintenance
cost
Over the
transformer’s
life
Southeast Asia network of climate change focal points
Transformer Life-Cycle Cost’s Benefits
Heat loss
Reduction
Cooler
Operation
Lower
failure
Rate
Reduces the
emission of
Greenhouse’s effect
Lower
losses
Transformer
Life-Cycle Cost
or TOC
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Case Study: Olsun Electrics Corporation
Life Cycle Cost Comparison for Dry type transformer 75 kVA
LCC = Initial cost of transformer + Cost of the No-load Losses + Cost of the Load Losses
low-efficiency aluminumwound
high-efficiency
copper-wound
Initial cost of
transformer
USD 1,979
USD 2,064
Cost of the No-load
Losses
(1.50/watt)(350 watts)
(1.50/watt)(320 watts)
Cost of the Load
Losses
(0.35)(1874)
(0.35)(1670 watts)
Cost of No-load Losses = A x NL
Cost of Load Losses = B x LL
A=
1.50 USD / W
B=
0.35 USD / kWh
LCC or TOC
3,159.90
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3,128.50
Simplified LCC (without time value of money)
Cost of Transformer (over 15 years) = purchase price+ [(value of load loss) +
(value of no load loss)] x 15
Standard Loss
Low Loss
Purchase price(USD)
10,194
10,845
Annual cost of no-load
losses(USD)
1.647 kW x 8760 h/y x
0.075/kWh = 1,082.08
1.018 kW x 8760 h/y x
0.075 = 668.83
Annual cost of load
losses(USD)
5.348 kW x 6000 h/y x
0.075/kWh = 2,406.60
3.808 kW x 6000 h/y x
0.075 = 1,713.60
TOC for 15 years of
transformer service life
(USD)
10,194 + (2,406.60 x 15)
+ (1,082.08 x 15)
= 62,524.20
10,845 + (1713.60 x 15)
+ (668.83 x
15) = 46,581.45
15-year savings with
energy-efficient
transformer(USD)
62,524.20 - 46,581.45 = 15,942.75
Conclusion
ONE AND ONE-HALF TIMES its initial purchase
price over the 15-year
Southeast Asia network of climate change focal points
Environmental Savings
Thailand’s Emission of Greenhouse Gases
Unit
(1,000 tons)
344.2
Million
tons)
TOTAL
HOW MUCH & WHERE
COME FROM ??
Energy
Industry
Others
Agricult
ures
Forest &
Real estate
Southeast Asia network of climate change focal points
Waste
Environmental Savings
Energy Sector’s Emission of CO₂ Year 2006
90,000
Oil & Fossil etc.
80,000
ั CO2
พ ันต น
M. Tons
70,000
Other
พลัenergy
งงานอืน
่
60,000
Residential
บ้านอยูอ
่ าศ ัย
10%
ไฟฟ้ า
Electricity
50,000
Business
ธุรกิจการค้า
14%
6%
40,000
Electricity
40%
30,000
20,000
Industries
อุตสาหกรรม
43%
Transportation
10,000
0
อุต
ร
หก
า
ส
รม
ส
ขน
่ง
ธรุ
รค
กา
ิ
จ
ก
เกษ
า้
นอ
บา้
ตร
ย
ศัย
ู่อา
่อ
/ก
รม
ร
ก
เห
า้ ง/
ร
ส
ร
งแ
มอื
Agriculture,
เกษตรกรรม/
construction,
ก่อสร้าง/เหมืองแร่
mines &
่
Southeast Asia network of climate change focal points
ขนส่ง
27%
Environmental Savings
100%
Electricity
Consumption in each Categories
1%
0%
0%
ปมน
าเพื่อการเกษตร
Agriculture
4%
3%
1%7%
90%
80%
หน่
ยงานราชการ
Government
19%
40%
70%
ธุรSpecial
กิจเฉพา อย่Business
าง
Large
Industries/Business
60%
ธุรกิจ/อุต ขนา ให ่
50%
ธุรกิจ/อุต Medium
ขนา กลาง
22%
40%
Industries/Business
73%
ธุรกิจขนา เลก
Small Business
30%
10%
Residences
(≥150
บ้านอยู
่อาศัย (>150 หน่
ย/เ ือน)
20%
13%
units/month)
8%
บ้านอยู
่อาศัย (<150 หน่
ย/เ ือน)
Residences
(≤150
10%
0%
จาน นผู้
้
Number of Customers
ปริมา
การ
้
units/month)
า
Energy Consumption
Copy right is reserved by S Soponkanaporn
Southeast Asia network of climate change focal points
Environmental Savings
123
81
Siam
Paragon
Energy Consumption Comparison
Maboonkong
278
Million
Units
75
Central
Department
MUnits
MUnits
Mehongsorn
65
Mahasarakarm
8
Amnartchareon
45
Satoon
11
Mookdahan
17
Samutsongkarm
7
Nongbualumpu
20
Leor
9
Nan
26
Prea
7
Yasotorn
13
Pattalung
4
Uthaitanee
5
Narathiwart
5
Prayao
18
Ranong
15
Total
278
Southeast Asia network of climate change focal points
Environmental Savings
Energy Loss Cost on Carbon Credit
Standard
Loss
Low Loss
Rated power (kVA)
100
100
No-Load Loss (W)
250
255
1,550
840
5,584.5
4,029.6
111.7
80.6
Details
Load Loss at 75°C(W)
Annual Energy Loss (kWh)
Life Time Energy Loss (MWh)
Life Time Energy Loss Saving
(MWh)
31.1
Reduce CO2 emission (Ton)
15.7
Reduce CO2 emission (Ton), Base
on 10,000 Units of 100 kVA
Transformers
157,000
Southeast Asia network of climate change focal points
Environmental Savings
New Environtemp FR3
Vegetable Oils (Environtemp FR3)
High Fire Resistant Dielectric Fluid
Fire Safety
Environmental Benefits
Improved Transformer
Performance
Southeast Asia network of climate change focal points
1
Standards & Specification of Transformers
Benefits of Energy Efficient Transformers
2
3
4
5
Standards & Specification of Electric Motors
Benefits of Energy Efficient Motors
Conclusion
Southeast Asia network of climate change focal points
Energy Efficient Motors
“An electric motor can consume electricity to the equivalent of its
capital cost within the first 500 hours of operation - a mere three
weeks of continuous use, or three months of single shift
working. Every year, the running cost of the motor will be from four
to sixteen times its capital cost. Over its working life, an average
of thirteen years, it may consume over 200 times its capital cost in
energy. Clearly, the lowest overall cost will not be achieved unless
both capital and running costs are considered together.”
CDA Publication 116
Southeast Asia network of climate change focal points
Energy Losses
Windage + Friction 13 %
Air resistance and bearing
friction are essentially
independent of motor load.
Can be reduced by
improving bearing and seal
selection, air flow and fan
design. Energy efficient
motors produce less heat
and use a smaller fan
Stray Loss 9 %
The result of leakage fluxes
induced by load currents.
Can be improved by
improving slot geometry
Rotor losses 20%
Heating in the rotor winding
can be reduce by increasing
the size of the conductive
bars and end rings to
produce lower resistance
Iron loss 23%
Energy required to overcome
opposition to changing
magnetic fields in the core
material. Can be decreased
by using better quality steel
and by lengthening the core
to reduce magnetic flux
density
Copper Loss 20%
Commonly refer to as I2R loss, this is
caused by heating due to current flow
through the resistance of the stator
winding. Can be reduced by modifying
the stator slot design or by decreasing
insulation thickness to increase the
volume of wire in the stator
Southeast Asia network of climate change focal points
Energy Losses
Distribution of losses in a Standard 75kW
Induction Motor
•Losses are categorized into 2 groups
Relative independent of load
Constant losses
Increase with Load
Load dependent losses
Southeast Asia network of climate change focal points
Energy Losses
Loss Against Load for a Typical Standard
Motor
Southeast Asia network of climate change focal points
Energy Losses
Comparison of efficiencies of Standard and HEM
Motors
The increase in efficiency is accompanies by an increase in power factor
Southeast Asia network of climate change focal points
1
Standards & Specification of Transformers
Benefits of Energy Efficient Transformers
2
3
4
5
Standards & Specification of Electric Motors
Benefits of Energy Efficient Motors
Conclusion
Southeast Asia network of climate change focal points
Heating, Ventilating and Air Conditioning Plant (HeVAC)
The BBC’s Library and Archive premises uses a number of chillers and air conditioning units to
maintain a constant cool environment for stored films and video tapes. A detailed study was
undertaken on four motors so that the performance of high-efficiency motors could be compared
directly. Table 2-3 gives details of the motors selected & table 2-4 shows the comparison between
Standard and HEM in these 4 applications . The overall payback period on the replacements was
1.1 years
Southeast Asia network of climate change focal points
Why Chooses High Efficiency Motors?
Three factors to keep in mind whether you’re replacing an
old work out motor or specifying for a new piece:
 Energy efficient motors only provide savings when they’re
running, and the more the motors run, the more energy and
money they save.
 Maximum savings ( and the fastest returns on investment) are
attained in regions where utility rates are highest. Even so,
energy-efficient motors are highly recommended even in low
energy-cost areas because they provide savings that justify
their initial cost over time.
 Select motor for its intended application . Every new installation
should only be made after conduction a thorough analysis of
the economic and technical factors involved.
Southeast Asia network of climate change focal points
Aluminium Vs Copper
1. Aluminium resistivity is greater and for the same length and
resistance:
 Aluminium cross-section must be 1.65 times that of copper.
 Very much larger core window to accommodate the increased cross-section, means
that coil diameters are increased, The length of mean turn increases, which in
consequence increases the winding resistance, cross-section must be increased still
further and so the process continues.
 Increase in the size of core and windings results in increased tank size and a larger oil
quantity.
 Any savings in the cost of the winding conductors is soon more than offset by increased
costs in every other item.
2. Larger transformers is its poorer mechanical strength. Short-circuits,
or even severe overloads:
 Transformers impose large mechanical forces on the windings; axial compressive
forces within the windings, axial displacement forces if there is any magnetic imbalance
between the windings.
 All of these forces must be resisted by the strength of the winding conductor itself, a
duty for which none of the alloys of aluminium can compare with work-hardened silverbearing copper.
Southeast Asia network of climate change focal points
Conclusion
Setup
Technical
Working
group
Best
Practice
Handbooks
Capacity
Build-up
The Way Forward
Without the Volunteer
initiative, the Promotion of
Electrical Energy Efficiency
Transformers and Motors in
LMS would have come in
much more slowly.
Interactive
Workshops
with other
Developed
Countries.
Southeast Asia network of climate change focal points
Acknowledgement
1. SELVER CORHODZIC: MEng (RMIT), BEng (University of
Sarajevo)
“A NEW APPROACH TO ASSESSMENT AND UTILISATION OF
DISTRIBUTION POWER TRANSFORMERS”
2. Leonardo Energy (Transformer):
“ The Potential for Global Energy Savings from High Effciency
Distribution Transformers”
3. Roman Targosze: Leonardo Energy Transformer
“Network Losses”
4. Bob Saint : National Rural Electric Cooperative Association
USA
“DOE Distribution Transformer Efficiency Standards”
Southeast Asia network of climate change focal points
Acknowledgement
5. T R Blackburn: Equipment Energy Efficiency Program
“Distribution Transformers Proposal to Increase MEPS Levels”
6. Intelligent Energy Europe
“Potentials & Impacts of Energy-Efficient DTs “
7. Carlos Gaytan: Proleg GE
“DOE Distribution Transformer Efficiency Regulation
Evaluation of Impact on the Industry”
8. Premium-Efficiency Motors and Transformers:
“Transformer Life-Cycle Cost (Total Owning Cost)”
ื่ ม สง่าราศรี กรีเซน: พล ัง ท (Thai Paper)
9.
น
้ งงานนโยบายพลังงานแล ภา โลกร ้อน”
“การใชพลั
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For further inquiries Contact
suraponss@gmail.com
Southeast Asia network of climate change focal points