Wes Patterson, ABB Transformers North America, May 8, 2009
SWEDE 2009 Conference
2010 National Efficiency Standards
© ABB Group
March 21, 2016 | Slide 1
ABB Transformers (2007 data)

Over $4.5 billion orders

15,000 employees

Global manufacturing capability: 57 plants

Global presence: revenues in more than 100
countries

Complete range of power and distribution
transformers, associated products and services

Voltage range up to 800 kV (1000 kV)

Homepage: www.abb.com/transformers
57 Transformer Factories in 30 countries
© ABB Group
March 21, 2016 | Slide 3

One Global Factory serving customers
everywhere with a full range of products

Wherever located, you have one transformer
specialist close to you, for you

Wherever your project is, we will produce your
transformers in the factory most suitable to
you
World Map ABB Transformer Factories 2007
World Map ABB Transformer Factories 2007
Sweden – Ludvika
Norway – Steinkjer
Sweden – Pitea
Norway – Drammen
Finland – Vaasa
Ireland – Waterford
Canada – Varennes
Russia – Khotkovo
Sweden – Mjolby
Germany – Brilon
Canada – Quebec City
Sweden – Figeholm
Germany – Bad Honnef
Poland – Lodz
Germany – Roigheim
Germany – Halle
USA – South Boston
Italy– Legnano
Switzerland – Geneve
USA – Bland
Spain – Bilbao
USA - Jefferson City
Spain – Zaragosa
USA – St Louis
China– Hefei
Italy– Monselice
Turkey– Istanbu
China– Chongquing
South Korea – Chonan-si
Switzerland – Zurich
Spain – Cordoba
USA – Alamo
China– Shanghai
Egypt – 10th of Ramadan
China– Zhongshan
Saudi Arabia – Riyadh
Vietnam – Hanoi
India – Baroda
Thailand – Bangkok
Singapore – Singapore
Tanzania – Arusha
Columbia – Pereira
Peru – Lima
Australia – Darra
Brazil – Guarulhos
South Africa – Pretoria
Brazil – Blumenau
South Africa – Booysens
Australia – Perth
South Africa – Cape Town
Australia – Moorebank
New Zealand – New Plymouth
© ABB Group
March 21, 2016 | Slide 4
Transformer Factories in North America
Quebec
Varennes
St. Louis
Jefferson City
Bland
South Boston
Alamo
PPI-Athens
© ABB Group
March 21, 2016 | Slide 5
Leader in Transformers Business

The largest Transformer manufacturer worldwide
ABB
21,0%
SIEMENS-VATECH
9,0%
AREVA
SCHNEIDER
© ABB Group
March 21, 2016 | Slide 6
4,0%
HOWARD
2,8%
WAUKESHA
2,5%
CGL-PAUWELS

5,0%
2,0%
ABB delivers :

2.000 Power Transformers / y

500.000 Distribution Transformers / y
Complete Transformer Portfolio
IEC & ANSI standards
© ABB Group
March 21, 2016 | Slide 7
What ever you need from our broad portfolio ->
ABB is your “one-stop” supplier
Distribution Transformers
IEC & ANSI Standards
© ABB Group
March 21, 2016 | Slide 8
Power Transformers
Generator StepUp transformers
System
transformers
© ABB Group
March 21, 2016 | Slide 9
Agenda
© ABB Group
March 21, 2016 | Slide 10

Describe the new efficiency standards for distribution
transformers for use in or shipped into the United States
and its territories that will be effective January 1, 2010

Review the standard’s development process as well as the
scope of transformers that are effected

Discuss design strategies and associated cost impact of
those strategies

Address the methodologies for insuring conformance with
the standards by the manufacturers
Agenda
© ABB Group
March 21, 2016 | Slide 11

Describe the new efficiency standards for distribution
transformers for use in or shipped into the United States
and its territories that will be effective January 1, 2010

Review the standard’s development process as well as the
scope of transformers that are effected

Discuss design strategies and associated cost impact of
those strategies

Address the methodologies for insuring conformance with
the standards by the manufacturers
National Efficiency Standard – Where did it come from


Energy Policy Act of 1975

Empowers the Secretary of Energy to determine the
need for energy efficiency standards

Establishes definition of “States” that includes US
Territories and Possessions
Energy Policy and Conservation Act (EPACT) of 1992

© ABB Group
March 21, 2016 | Slide 12
Empowers the DOE to determine the need for energy
efficiency standards for Appliances and Commercial

Technologically feasible

Economically justifiable

Produces significant energy savings

Puts the spot light on all distribution transformers

Oak Ridge National Laboratory (ORNL) study initiated
National Efficiency Standard – Where did it come from


Technologically feasible

Economically justifiable

Significant energy saving

2000 DOE publishes it’s Framework for establishing a
standard

2004 DOE publishes it’s Advance Notice of Proposed
Rulemaking (ANOPR)

2006 DOE publishes Notice of Proposed Rulemaking
(NOPR)

© ABB Group
March 21, 2016 | Slide 13
1997 DOE publishes Notice of Determination

Technical Support Documents (TSD’s)

Analytical Spreadsheets
2007 Final Rule issued on October 12th (72 FR 58190)
DOE Web Site
http://www1.eere.energy.gov/buildings/appliance_standards/
© ABB Group
March 21, 2016 | Slide 14
The National Efficiency Standard

Liquid & Dry Distribution Transformers

Domestic and Imported production

Manufactured in or imported into the United States and its
territories* on or after Jan 1, 2010

Product – ABB Operational Impact:
 Overhead – Athens
 Pads, Secondary Unit Subs & Networks
– Jefferson City & South Boston
 Dry Type - Bland
10 CFR Part 431 Subpart K
Industry Impact:
October 12, 2007
 Utility
72 FR 58190
 Industrial
CFR = Code of Federal Regulation
 Construction

* Note: Applies to Puerto Rico, Guam, and all other territories and possessions
© ABB Group
March 21, 2016 | Slide 15
The National Efficiency Standard
Liquid & Dry Transformers
© ABB Group
March 21, 2016 | Slide 16

60 Hz, < 34.5 kV Input & < 600 V Output

Oil-filled Capacity
 1Φ
10 to 833 kVA
 3Φ
15 to 2500 kVA

Dry-type Capacity

20-45 kV BIL : 15 to 833 (1Φ) & 2500 (3Φ) kVA

46-95 kV BIL : 15 to 833 (1Φ) & 2500 (3Φ) kVA

> 95kV BIL
: 75 to 833 (1Φ) & 225 to 2500 (3Φ) kVA
National Standard - Transformer Exclusions

Autotransformer

Sealed

Drive (isolation)

Special Impedance*

Grounding

Step-up Transformers

Machine-tool (control)

Testing

Non-ventilated

Tap range > 20%

Rectifier

Uninterruptible power supply

Regulating

Welding
* Note: Standard Impedances
© ABB Group
March 21, 2016 | Slide 17
The National Efficiency Standard
© ABB Group
March 21, 2016 | Slide 18

Re-builders exempt unless found to be circumventing the
“spirit” of the standard

Inventories manufactured before start date can be sold
after the start date however…

Inventory build up in advance of the start date also seen as
circumventing the “spirit” of the standard

DOE forewarning manufacturers not to take steps to sidestep the National Efficiency Standard
Benefits – 95 BIL Ventilated Dry Type Example
kVA
15
30
45
75
112.5
150
225
300
500
750
1000
1500
2000
2500
Dry-Type Medium Voltage Three Phase (46-95 kV BIL)
Loss Reduction
Efficiency (%)
DOE to Typical
$$$$
Typical
TSL1
DOE
%
Watts Annual Savings
94.50%
96.80%
97.19%
48.91%
219 $
192
95.40%
97.30%
97.63%
48.48%
363 $
318
96.00%
97.60%
97.86%
46.50%
454 $
398
97.00%
97.90%
98.20%
40.00%
488 $
428
97.20%
98.10%
98.30%
39.29%
671 $
588
97.50%
98.20%
98.42%
36.80%
749 $
656
97.80%
98.40%
98.57%
35.00%
940 $
823
98.10%
98.50%
98.67%
30.00%
928 $
813
98.50%
98.80%
98.83%
22.00%
895 $
784
98.80%
98.90%
98.95%
12.50%
610 $
535
98.82%
99.00%
99.03%
17.80%
1139 $
998
98.95%
99.00%
99.12%
16.19%
1383 $
1,212
98.97%
99.20%
99.13%
15.53%
1736 $
1,521
99.10%
99.20%
99.23%
14.44%
1763 $
1,544
Notes:
1. Efficiency and Losses at 50% Load and PF=1.0
2. Savings assumes 8760 h/yr and $0.10/watt
© ABB Group
March 21, 2016 | Slide 19
Add Price Pay Back Yrs
$
36
0.2
$
71
0.2
$
107
0.3
$
179
0.4
$
268
0.5
$
357
0.5
$
536
0.7
$
715
0.9
$
829
1.1
$ 1,138
2.1
$ 2,382
2.4
$ 2,988
2.5
$ 3,147
2.1
$ 3,934
2.5
National Benefits of The National Energy Standard



© ABB Group
March 21, 2016 | Slide 20
Saves 2.74 quads (1015 BTU’s) of energy over 29 years

1 Quad = 1 Quadrillion (1015) Btu (1,000,000,000,000,000)

Energy of 27 million US households in a single year

Eliminating need for 6 new 400 MW power plants
Reduce greenhouse gas emission of ~238 million tons of CO2

Equivalent to removing 80% of all light vehicles for one year

Others emission reductions not included in final justification

Greater than 46 thousand tons (kt) of nitrous oxide (NO2)

Greater than 4 tons of mercury (Hg)
Payback ranges from 1 to 15 years based on design line

Net present value of $1.39 billion using a 7% discount rate

Net present value of $7.8 billion using a 3% discount rate

Cumulative from 2010 to 2073 in 2006$
Consumer Benefits

Increased system capacity due to lower loads

Lower input load requirements leads to less heat
generated



Lower A/C & ventilation costs/requirements if located indoors

Lower temperature rise

Longer transformer life expectancy

May not need use of forced air (FA) to fulfill capacity
requirements
Better efficiency means less input energy required to
produce equal output energy

Decreased operating costs = increased profits

Decreased environmental impact from input energy generation
emissions
Shorter payback period due to increased profits

© ABB Group
March 21, 2016 | Slide 21
Lower total ownership costs over the life of the transformer
Electronic Code of Federal Regulations
http://ecfr.gpoaccess.gov/cgi/t/text/text-idx?c=ecfr&tpl=/ecfrbrowse/Title10/10cfr431_main_02.tpl
© ABB Group
March 21, 2016 | Slide 24
Agenda
© ABB Group
March 21, 2016 | Slide 25

Describe the new efficiency standards for distribution
transformers for use in or shipped into the United States
and its territories that will be effective January 1, 2010

Review the standard’s development process as well as the
scope of transformers that are effected

Discuss design strategies and associated cost impact of
those strategies

Address the methodologies for insuring conformance with
the standards by the manufacturers
The Oak Ridge Study
44,000+ Designs evaluated
© ABB Group
March 21, 2016 | Slide 26
Combination Lines
Design Lines
TOC Variation relative to TSL0
National Efficency Standard impact on Total Owning Cost (TOC) relative to TSL0
Liquid-Filled 1ph 10-167 kVA Pad
9
6
5
RU
RU
DL 2
"B" values (coil loss evaluation) $/watt
7
RU
DL 3
10
15
25
37.5
50
75
100
167
250
333
500
667
833
DL 1
kVA
8
Liq-1ph
PC1
Rect
Round
Tank
Tank
> 1.25
≤ 1.25
≤ 1.15
≤ 1.05
≤1
4
3
2
1
0
0
© ABB Group
March 21, 2016 | Slide 31
Max: 1.33
1
2
3
4
5
6
"A" values (core loss evaluation) $/watt
7
8
9
10
Evolution of a National Standard
DOE publishes Notice of Proposed Rulemaking (NOPR)

Defined 6 levels of efficiency – August 4, 2006

TSL1 = NEMA TP1

TSL2 = 1/3 difference between TSL1 and TSL4

TSL3 = 2/3 difference between TSL1 and TSL4

TSL4 = minimum LCC (Life Cycle Cost)

TSL5 = maximum efficiency with no change in the LCC

TSL6 = theoretical maximum possible efficiency

Recommended that TSL2 become the National Standard

Set Sep 2007 target for establishing the Final Rule

Solicited comments from concerned parties
TSL = Trial Standard Level
© ABB Group
March 21, 2016 | Slide 33
Transition between NOPR to Final Rule


© ABB Group
March 21, 2016 | Slide 34
DOE received numerous comments to liquid-filled

Technical discrepancy in liquid 3Φ curves

3-1Φ would be less efficient than one equivalent 3Φ
liquid
DOE resolution creates 4 new efficiency levels for liquid
called Design Lines (DL) combining TSL levels:

TSLA: DL1-TSL5 & DL3-TSL4

TSLB: DL4-TSL2 & DL5-TSL4

TSLC: DL4-TSL2 & DL5-TSL3

TSLD: DL1-TSL4, DL3-TSL2, DL4-TSL2 & DL5-TSL3
NOPR Liquid-Filled 3Φ Discontinuity
NOPR Liquid-Filled Three Phase
100.0%
99.5%
99.0%
0-Min
Efficiency
0-Avg
TSL1
98.5%
TSL2
TSL3
98.0%
TSL4
The efficiency of the 300/500
kVA being more than the
750/1000/1500 kVA’s would
artificially disrupt the markets
of the 300/500 kVA units
97.5%
TSL5
TSL6
97.0%
96.5%
15
30
45
75
112.5
150
225
300
kVA
© ABB Group
March 21, 2016 | Slide 35
500
750
1000
1500
2000
2500
Final Rule – The National Standard

Final Rule Published Oct 12, 2007

Federal Register - 72 FR 58190

DOE Final Selection

© ABB Group
March 21, 2016 | Slide 40

TSLC for 1Φ and 3Φ Liquid-filled

TSL2 for Dry-types
Liquid and dry-type distribution transformers
manufactured in or imported into the United States
and its territories on or after Jan 1, 2010
5
10
15
DL2
25
37.5
DL1
50
75
100
167
250
333
DL3
500
667
833
Product Class 2
Table EA.4
KVA
15
30
45
75
112.5
DL4
150
225
300
500
750
1000
DL5
1500
2000
2500
0-Avg
98.42%
98.57%
98.74%
98.86%
98.97%
99.04%
99.11%
99.22%
99.24%
99.29%
99.36%
99.40%
99.44%
0-Avg
98.06%
98.37%
98.53%
98.70%
98.83%
98.91%
99.02%
99.08%
99.19%
99.24%
99.29%
99.36%
99.40%
99.44%
97.77%
98.40%
98.40%
98.44%
98.48%
98.69%
97.99%
98.60%
98.56%
98.59%
98.63%
98.82%
98.23%
98.70%
98.73%
98.76%
98.79%
98.96%
98.40%
98.80%
98.85%
98.88%
98.91%
99.06%
98.56%
98.90%
98.90%
98.90%
99.04%
99.19%
98.66%
99.00%
99.04%
99.06%
99.08%
99.21%
98.75%
99.00%
99.10%
99.12%
99.14%
99.26%
98.90%
99.10%
99.21%
99.23%
99.25%
99.35%
98.89%
99.20%
99.26%
99.36%
99.45%
99.69%
98.97%
99.20%
99.31%
99.40%
99.49%
99.71%
99.07%
99.30%
99.38%
99.46%
99.54%
99.74%
99.13%
99.40%
99.42%
99.50%
99.57%
99.76%
99.18%
99.40%
99.45%
99.52%
99.60%
99.77%
Liquid-Immersed Medium Voltage Three Phase Transformer
TSL
0-Min
1
2
3
4
5
97.19%
98.10%
98.36%
98.68%
98.68%
99.25%
97.64%
98.40%
98.62%
98.89%
98.89%
99.37%
97.87%
98.60%
98.76%
99.00%
99.00%
99.43%
98.12%
98.70%
98.91%
99.12%
99.12%
99.50%
98.30%
98.80%
99.01%
99.20%
99.20%
99.55%
98.42%
98.90%
99.08%
99.26%
99.26%
99.58%
98.57%
99.00%
99.17%
99.33%
99.33%
99.62%
98.67%
99.00%
99.23%
99.38%
99.38%
99.65%
98.83%
99.10%
99.32%
99.45%
99.45%
99.69%
98.97%
99.20%
99.24%
99.31%
99.37%
99.66%
99.04%
99.20%
99.29%
99.36%
99.41%
99.68%
99.13%
99.30%
99.36%
99.42%
99.47%
99.71%
99.19%
99.40%
99.40%
99.46%
99.51%
99.73%
99.23%
99.40%
99.44%
99.49%
99.53%
99.74%
A
B
C
D
98.62%
98.76%
98.91%
99.01%
99.08%
99.17%
99.23%
99.25%
99.32%
99.36%
99.42%
99.46%
99.49%
98.79%
98.91%
99.04%
99.13%
99.19%
99.27%
99.32%
99.40%
99.45%
99.49%
99.54%
99.57%
99.60%
98.62%
98.76%
98.91%
99.01%
99.08%
99.17%
99.23%
99.32%
99.37%
99.41%
99.47%
99.51%
99.53%
98.62%
98.76%
98.91%
99.01%
99.08%
99.17%
99.23%
99.32%
99.31%
99.36%
99.42%
99.46%
99.49%
98.48%
98.63%
98.79%
98.91%
99.04%
99.08%
99.14%
99.25%
99.26%
99.31%
99.38%
99.42%
99.45%
6
Standard
99.31%
98.36%
99.42%
98.62%
99.47%
98.76%
99.54%
98.91%
99.58%
99.01%
99.61%
99.08%
99.65%
99.17%
99.67%
99.23%
99.71%
99.25%
99.66%
99.32%
99.68%
99.36%
99.71%
99.42%
99.73%
99.46%
99.74%
99.49%
A
98.56%
98.79%
98.91%
99.04%
99.13%
99.19%
99.27%
99.32%
99.40%
99.45%
99.49%
99.54%
99.57%
99.60%
TSL
B
C
98.36%
98.36%
98.62%
98.62%
98.76%
98.76%
98.91%
98.91%
99.01%
99.01%
99.08%
99.08%
99.17%
99.17%
99.23%
99.23%
99.32%
99.27%
99.37%
99.31%
99.41%
99.36%
99.47%
99.42%
99.51%
99.46%
99.53%
99.49%
D
98.36%
98.62%
98.76%
98.91%
99.01%
99.08%
99.17%
99.23%
99.32%
99.31%
99.36%
99.42%
99.46%
99.49%
Max
Energy
Savings
TSL
6
99.32%
99.39%
99.46%
99.51%
99.59%
99.59%
99.62%
99.66%
99.70%
99.72%
99.75%
99.77%
99.78%
Standard
Note: National Standard Efficiency calculated using load at 50% & PF (COS θ) = 1.0
© ABB Group
March 21, 2016 | Slide 41
Combination of
DL1-TSL4, DL4TSL2
DL3-TSL2, DL5-
KVA
Product Class 1
Table EA.3
KVA
Combination of
DL4-TSL2 and
DL5-TSL4
Design
Line
Ave
Base
Case
Eff
Combination of
DL1-TSL5 and
DL3-TSL4
National Standard - Liquid-filled
Combination of
DL4-TSL2 and
DL5-TSL3
Max
Energy
Savings
Min
1/3 Diff
2/3 Diff
with
Base
between between
No
Case
TP1 and TP1 and
Change
Eff
TP1
Min LCC Min LCC Min LCC in LCC
Liquid-Immersed Medium Voltage Single Phase Transformer
TSL
0-Min
1
2
3
4
5
National Standard - Liquid-filled
Loss Reduction @ 50% Load compared to TLS1 (NEMA TP-1) as the base case
Single-Phase
kVA
10
15
25
37.5
50
75
100
167
250
333
500
667
833
© ABB Group
March 21, 2016 | Slide 42
Efficiency (%)
DOE
98.62%
98.76%
98.91%
99.01%
99.08%
99.17%
99.23%
99.25%
99.32%
99.36%
99.42%
99.46%
99.49%
TLS1
98.40%
98.60%
98.70%
98.80%
98.90%
99.00%
99.00%
99.10%
99.20%
99.20%
99.30%
99.40%
99.40%
Three-Phase
Loss
Reduction
13.7%
11.4%
16.2%
17.5%
16.4%
17.0%
23.0%
16.7%
15.0%
20.0%
17.1%
10.0%
15.0%
kVA
15
30
45
75
112.5
150
225
300
500
750
1000
150
2000
2500
Efficiency (%)
DOE
98.36%
98.62%
98.76%
98.91%
99.01%
99.08%
99.17%
99.23%
99.25%
99.32%
99.36%
99.42%
99.46%
99.49%
TLS1
98.10%
98.40%
98.60%
98.70%
98.80%
98.90%
99.00%
99.00%
99.10%
99.20%
99.20%
99.30%
99.40%
99.40%
Loss
Reduction
13.7%
13.7%
11.4%
16.2%
17.5%
16.4%
17.0%
23.0%
16.7%
15.0%
20.0%
17.1%
10.0%
15.0%
National Standard - Dry-type
Product Class 5
Table EA.5
KVA
15
25
37.5
50
75
DL9
100
167
250
333
DL10
500
667
833
Product Class 6
Table EA.6
KVA
15
30
45
75
112.5
150
225
DL9
300
500
750
1000
DL10
1500
2000
2500
Product Class 7
Table EA.7
KVA
15
25
37.5
50
75
DL11
100
167
250
333
DL12
500
667
833
0-Avg
98.02%
98.26%
98.43%
98.54%
98.68%
98.77%
98.92%
99.01%
99.08%
99.17%
99.23%
99.27%
0-Avg
97.40%
97.81%
98.02%
98.26%
98.43%
98.54%
98.68%
98.77%
98.92%
99.01%
99.08%
99.17%
99.23%
99.27%
0-Avg
97.46%
97.77%
97.98%
98.12%
98.30%
98.42%
98.61%
99.02%
99.09%
99.18%
99.24%
99.28%
Dry-Type Medium Voltage Single Phase Transformer (20-45 kV BIL)
TSL
0-Min
1
2
3
4
5
97.45%
97.60%
98.10%
98.46%
98.81%
99.05%
97.75%
97.90%
98.33%
98.64%
98.95%
99.17%
97.97%
98.10%
98.49%
98.77%
99.05%
99.25%
98.11%
98.20%
98.60%
98.86%
99.12%
99.30%
98.29%
98.40%
98.73%
98.97%
99.20%
99.37%
98.41%
98.50%
98.82%
99.04%
99.26%
99.41%
98.60%
98.80%
98.96%
99.16%
99.35%
99.48%
98.56%
98.90%
99.05%
99.17%
99.27%
99.42%
98.66%
99.00%
99.11%
99.23%
99.32%
99.46%
98.79%
99.10%
99.20%
99.30%
99.39%
99.51%
98.87%
99.20%
99.26%
99.35%
99.43%
99.54%
98.93%
99.20%
99.30%
99.38%
99.46%
99.57%
Dry-Type Medium Voltage Three Phase Transformer (20-45 kV BIL)
TSL
0-Min
1
2
3
4
5
96.64%
96.80%
97.50%
97.97%
98.44%
98.75%
97.17%
97.30%
97.90%
98.29%
98.68%
98.95%
97.45%
97.60%
98.10%
98.46%
98.81%
99.05%
97.75%
97.90%
98.33%
98.64%
98.95%
99.17%
97.97%
98.10%
98.49%
98.77%
99.05%
99.25%
98.11%
98.20%
98.60%
98.86%
99.12%
99.30%
98.29%
98.40%
98.73%
98.97%
99.20%
99.37%
98.41%
98.60%
98.82%
99.04%
99.26%
99.41%
98.60%
98.80%
98.96%
99.16%
99.35%
99.48%
98.56%
98.90%
99.05%
99.17%
99.27%
99.42%
98.66%
99.00%
99.11%
99.23%
99.32%
99.46%
98.79%
99.10%
99.20%
99.30%
99.39%
99.51%
98.87%
99.20%
99.26%
99.35%
99.43%
99.54%
98.94%
99.20%
99.30%
99.38%
99.46%
99.57%
Dry-Type Medium Voltage Single Phase Transformer (46-96 kV BIL)
TSL
0-Min
1
2
3
4
5
96.87%
97.60%
97.86%
98.14%
98.41%
98.54%
97.24%
97.90%
98.12%
98.36%
98.60%
98.71%
97.51%
98.10%
98.30%
98.52%
98.73%
98.84%
97.68%
98.20%
98.42%
98.62%
98.82%
98.92%
97.90%
98.40%
98.57%
98.75%
98.94%
99.02%
98.05%
98.50%
98.67%
98.84%
99.01%
99.09%
98.28%
98.80%
98.83%
98.98%
99.13%
99.20%
98.58%
98.90%
98.95%
99.08%
99.23%
99.42%
98.68%
99.00%
99.03%
99.15%
99.28%
99.46%
98.81%
99.10%
99.12%
99.23%
99.35%
99.51%
98.89%
99.20%
99.18%
99.28%
99.40%
99.54%
98.95%
99.20%
99.23%
99.32%
99.43%
99.57%
6
Standard
99.05%
98.10%
99.17%
98.33%
99.25%
98.49%
99.30%
98.60%
99.37%
98.73%
99.41%
98.82%
99.48%
98.96%
99.42%
99.07%
99.46%
99.14%
99.51%
99.22%
99.54%
99.27%
99.57%
99.31%
6
Standard
98.75%
97.50%
98.95%
97.90%
99.05%
98.10%
99.17%
98.33%
99.25%
98.49%
99.30%
98.60%
99.37%
98.73%
99.41%
98.82%
99.48%
98.96%
99.42%
99.07%
99.46%
99.14%
99.51%
99.22%
99.54%
99.27%
99.57%
99.31%
6
Standard
98.54%
97.86%
98.71%
98.12%
98.84%
98.30%
98.92%
98.42%
99.02%
98.57%
99.09%
98.67%
99.20%
98.83%
99.42%
98.95%
99.46%
99.03%
99.51%
99.12%
99.54%
99.18%
99.57%
99.23%
Product Class 8
Table EA.8
KVA
15
30
45
75
112.5
150
225
DL11
300
500
750
1000
DL12
1500
2000
2500
Product Class 9
Table EA.9
KVA
75
100
167
250
333
500
DL13
667
833
Product Class 10
Table EA.10
KVA
225
300
500
750
1000
1500
DL13
2000
2500
0-Avg
96.66%
97.19%
97.46%
97.77%
97.98%
98.12%
98.30%
98.42%
98.61%
99.02%
99.09%
99.18%
99.24%
99.28%
0-Avg
98.72%
98.81%
98.95%
99.05%
99.12%
99.20%
99.26%
99.30%
0-Avg
98.72%
98.81%
98.95%
99.05%
99.12%
99.20%
99.26%
99.30%
Dry-Type Medium Voltage Three Phase Transformer (46-96 kV BIL)
TSL
0-Min
1
2
3
4
5
95.88%
96.80%
97.19%
97.55%
97.91%
98.08%
96.53%
97.30%
97.63%
97.94%
98.24%
98.38%
96.87%
97.60%
97.86%
98.14%
98.41%
98.54%
97.24%
97.90%
98.12%
98.36%
98.60%
98.71%
97.51%
98.10%
98.30%
98.52%
98.73%
98.84%
97.68%
98.20%
98.42%
98.62%
98.82%
98.92%
97.90%
98.40%
98.57%
98.75%
98.94%
99.02%
98.05%
98.50%
98.67%
98.84%
99.01%
99.09%
98.28%
98.80%
98.83%
98.98%
99.13%
99.20%
98.58%
98.90%
98.95%
99.08%
99.23%
99.42%
98.68%
99.00%
99.03%
99.15%
99.28%
99.46%
98.81%
99.00%
99.12%
99.23%
99.35%
99.51%
98.89%
99.20%
99.18%
99.28%
99.40%
99.54%
98.95%
99.20%
99.23%
99.32%
99.43%
99.57%
Dry-Type Medium Voltage Single Phase Transformer (>96 kV BIL)
TSL
0-Min
1
2
3
4
5
98.22%
98.40%
98.53%
98.79%
99.05%
99.22%
98.34%
98.50%
98.63%
98.88%
99.12%
99.28%
98.54%
98.70%
98.80%
99.01%
99.22%
99.36%
98.68%
98.80%
98.91%
99.11%
99.30%
99.42%
98.77%
98.90%
98.99%
99.17%
99.35%
99.46%
98.89%
99.00%
99.09%
99.25%
99.41%
99.52%
98.97%
99.00%
99.15%
99.30%
99.45%
99.55%
99.03%
99.10%
99.20%
99.34%
99.48%
99.57%
Dry-Type Medium Voltage Three Phase Transformer (>96 kV BIL)
TSL
0-Min
1
2
3
4
5
98.22%
98.40%
98.53%
98.79%
99.05%
99.22%
98.34%
98.50%
98.63%
98.88%
99.12%
99.28%
98.54%
98.70%
98.80%
99.01%
99.22%
99.36%
98.68%
98.80%
98.91%
99.11%
99.30%
99.42%
98.78%
98.90%
98.99%
99.17%
99.35%
99.46%
98.89%
99.00%
99.09%
99.25%
99.41%
99.52%
98.97%
99.00%
99.15%
99.30%
99.45%
99.55%
99.03%
99.10%
99.20%
99.34%
99.48%
99.57%
Note: National Standard Efficiency calculated using load at 50% & PF (COS θ) = 1
© ABB Group
March 21, 2016 | Slide 45
6
Standard
98.08%
97.18%
98.38%
97.63%
98.54%
97.86%
98.71%
98.12%
98.84%
98.30%
98.92%
98.42%
99.02%
98.57%
99.09%
98.67%
99.20%
98.83%
99.42%
98.95%
99.46%
99.03%
99.51%
99.12%
99.54%
99.18%
99.57%
99.23%
6
Standard
99.22%
98.53%
99.28%
98.63%
99.36%
98.80%
99.42%
98.91%
99.46%
98.99%
99.52%
99.09%
99.55%
99.15%
99.57%
99.20%
6
Standard
99.22%
98.53%
99.28%
98.63%
99.36%
98.80%
99.42%
98.91%
99.46%
98.99%
99.52%
99.09%
99.55%
99.15%
99.57%
99.20%
National Standard - Dry Type
Loss Reduction @ 50% Load compared to TLS1 (NEMA TP-1) as the base case
kVA
15
25
37.5
50
75
100
167
250
333
500
667
833
© ABB Group
March 21, 2016 | Slide 46
Single-Phase Dry-type
Efficiency (%)
Loss
DOE
TLS1
Reduction
97.86%
97.60%
10.8%
98.12%
97.90%
10.5%
98.30%
98.10%
10.5%
98.42%
98.20%
12.2%
98.57%
98.40%
10.6%
98.67%
98.50%
11.3%
98.83%
98.80%
2.5%
98.95%
98.90%
4.5%
99.03%
99.00%
3.0%
99.12%
99.10%
2.2%
99.18%
99.20%
-2.5%
99.23%
99.20%
3.8%
kVA
15
30
45
75
112.5
150
225
300
500
750
1000
1500
2000
2500
Three-Phase Dry-type
Efficiency (%)
Loss
DOE
TLS1
Reduction
97.18%
96.80%
11.9%
97.63%
97.30%
12.2%
97.86%
97.60%
10.8%
98.12%
97.90%
10.5%
98.30%
98.10%
10.5%
98.42%
98.20%
12.2%
98.57%
98.40%
10.6%
98.67%
98.50%
11.3%
98.83%
98.80%
2.5%
98.95%
98.90%
4.5%
99.03%
99.00%
3.0%
99.12%
99.00%
12.0%
99.18%
99.20%
-2.5%
99.23%
99.20%
3.8%
Final Rule: Liquid and Dry Comparison
© ABB Group
March 21, 2016 | Slide 49
Agenda
© ABB Group
March 21, 2016 | Slide 50

Describe the new efficiency standards for distribution
transformers for use in or shipped into the United States
and its territories that will be effective January 1, 2010

Review the standard’s development process as well as the
scope of transformers that are effected

Discuss design strategies and associated cost impact of
those strategies

Address the methodologies for insuring conformance with
the standards by the manufacturers
What is transformer efficiency?
%Efficiency = 100 x Output Watts / Input Watts
Output being less than input due to losses in form of heat
L . kVA . COS q . 105
% Efficiency =
L . kVA . COS q . 103 + Fe + L2 . (LL)
No-Load
Losses (A)
Load
Losses (B)
r
V
L (pu) = Load
Note: National Standard Efficiency calculated using load at 50% & PF (COS θ) = 1
© ABB Group
March 21, 2016 | Slide 51
Transformer Losses

Total Loss = No-Load Loss + Load Loss

No Load Losses - Core Loss

© ABB Group
March 21, 2016 | Slide 52

Hysteresis Loss - steel chemistry, coating, processing

Eddy Loss - steel thickness
Load Losses - Conductor loss

I2R Loss - material (CU vs. AL), size and length

Eddy Loss - geometry, proximity to steel parts
Load Losses – Conductor I2R

I = Rated Current

R = Resistance of the conductor
Resistivit y  Conductor Length
R
Conductor Area
Resistivity - property of the material
© ABB Group
March 21, 2016 | Slide 53

Copper = 0.017

Aluminium = 0.028
Load Losses - Conductor Eddy Loss

Less of an impact than I2R

Eddy loss in the conductor


Eddy loss in adjacent ferrous metal

© ABB Group
March 21, 2016 | Slide 54
Thin conductors have less eddy loss
LV Lead close to tank wall sets up eddy currents in the
tank
No Load Losses – Core Eddy Loss
0.006 inch = M2
0.009 inch = M3
0.014 inch = M6
© ABB Group
March 21, 2016 | Slide 55
No Load Losses – Core Eddy Loss
Constant  Rated voltage
Induction 
Turns  f  Core Area
Where
© ABB Group
March 21, 2016 | Slide 56

Rated voltage and number of turns refer to either the high voltage
or low voltage coil

Induction is a function of the electrical steel limited by its
saturation value

f is the frequency
How to Reduce Losses?
Ways to Reduce No-Load Loss
Ways to Reduce Load Loss
Use better grade of core steel
Use copper rather than aluminum
Use thinner core steel laminations
Use a conductor with a larger area
Use more turns in the coil
Use fewer turns in the coil
Use a core with larger leg area
© ABB Group
March 21, 2016 | Slide 57
Amorphous Cores

© ABB Group
March 21, 2016 | Slide 58
Note: TSL6 was computed
with Amorphous Cores
ABB performed considerable research on amorphous core
steel in the early 1990’s

Numerous patents granted

Prototypes built – all type test performed (passed)

Production units produced thru 2002

However, during this time, the cost of the material was
prohibitive to maintain a commercial line

With the recent upswing in the cost of CGO (conventional
grain oriented) steel and the reduction in the cost of
Amorphous material the economic equation has changed

With loss evaluations in the range of $5/w NL the
Amorphous material approaches economic viability

Further potential improvements in the cost model may
produce an economic option to meet the DOE standard
Impact to the Customer

Increased price of transformer

Increased size & weight

Financial valuation & justification


Transition strategy

© ABB Group
March 21, 2016 | Slide 60
A/B factors related to National Standard
Wait to last minute or move now

Potential pre-buy decision based on applicable date

Risk of delayed projects that cross the applicable date
% Shipments Meeting Final Ruling

Overheads




© ABB Group
March 21, 2016 | Slide 61
20%
Padmount*

1Φ - 47%

S3Φ < 750 kVA - 53%

L3Φ > 750 kVA – 59%
Cast Coil

20-45 kV BIL 6%

46-95 KV BIL 20%

> 95 KV BIL
3%
Open Wound

20-45 kV BIL 1%

46-95 KV BIL 10%

> 95 KV BIL
0%
*Note: All customer segments
for shipments from 10/06 to
08/07
Price Impact – Overhead
ABB Base
Cost
TP1
DOE
10 - 25
1.00
1.07
1.20
37.5 - 50
1.00
1.07
1.20
75 - 100
1.00
1.06
1.18
1Φ (kVA)
Estimated based on high volume styles
© ABB Group
March 21, 2016 | Slide 62
Price Impact - Padmount
ABB Base
Cost
TP1
DOE
25-50
1.00
1.04
1.18
75-100
1.00
1.02
1.18
250
1.00
1.00
1.12
ABB Base Cost
TP1
DOE
75-150
1.00
1.01
1.10
225-500
1.00
1.01
1.18
750-1000
1.00
1.01
1.08
1500-2000
1.00
1.01
1.04
2000-3000
1.00
1.01
1.12
1Φ (kVA)
3Φ (kVA)
Note 1: Analysis of all active designs
Note 2: Using current manufacturing limitations
Note 3: Average estimations across kVA range
Note 4: 7200 HV + Taps; 240/120 LV 1 Φ; 480Y/277 LV 3 Φ
© ABB Group
March 21, 2016 | Slide 63
Price Impact – Dry Type
ABB Base
Cost
TP1
DOE
20-45 KV BIL
1.00
1.10
1.10-1.15
46-95 KV BIL
1.00
1.10
1.05-1.10
> 95 KV BIL
1.00
1.20
1.05-1.15
ABB Base
Cost
TP1
DOE
20-45 KV BIL
1.00
1.10
1.10-1.20
46-95 KV BIL
1.00
1.10
1.10-1.15
> 95 KV BIL
1.00
1.20
1.10-1.20
Cast Coil
Open Wound
Note: Actual Price impact is dependent on:
• KVA
• Temperature Rise
• Conductor
• BIL
• Impedance
© ABB Group
March 21, 2016 | Slide 64
Footprint Variation relative to TSL0
National Efficency Standard impact on Unit Footprint relative to TSL0
Liquid-Filled 1ph 10-167 kVA Pad
9
"B" values (coil loss evaluation) $/watt
7
6
5
RU
RU
DL 2
10
15
25
37.5
50
75
100
167
250
333
500
667
833
RU
DL 3
8
Liq-1ph
PC1
Rect
Round
Tank
Tank
DL 1
kVA
> 1.09
≤ 1.09
≤ 1.06
≤ 1.03
≤1
4
3
2
1
0
0
© ABB Group
March 21, 2016 | Slide 65
Max: 1.10
1
2
3
4
5
6
"A" values (core loss evaluation) $/watt
7
8
9
10
Weight Variation relative to TSL0
National Efficency Standard impact on Unit Weight relative to TSL0
Liquid-Filled 1ph 10-167 kVA Pad
9
"B" values (coil loss evaluation) $/watt
7
6
5
RU
RU
DL 2
10
15
25
37.5
50
75
100
167
250
333
500
667
833
RU
DL 3
8
DL 1
kVA
Liq-1ph
PC1
Rect
Round
Tank
Tank
> 1.25
≤ 1.25
≤ 1.15
≤ 1.05
≤1
4
3
2
1
0
0
© ABB Group
March 21, 2016 | Slide 66
Max: 1.29
1
2
3
4
5
6
"A" values (core loss evaluation) $/watt
7
8
9
10
Impact of A/B factors
Loss Evaluation

Cost Of Losses (COL) =
(A x No Load Loss) + (B x Load Loss)
Transformer
Cost
Cost

Cost of
Losses
($/watt x watts) + ($/watt x watts)

Total Owning Cost (TOC) =
Loss
Transformer Price + COL

A & B factors result in most cost-effective design over product life cycle
based on customers’ cost of energy

ABB & PPI recommend customers’ re-evaluate and/or establish factors at
or above the national efficiency standards
Note: A = PW Inflation x Annual $/kW x n yrs; B = A x (load p.u.)2 x Conductor Temp Correction
© ABB Group
March 21, 2016 | Slide 67
Standard A/B Calculation

TOC = A (NL) + B (LL) + Sell price

A = $EL x 8760 hr/yr x N (Core Contribution NL)

B = $EL x (P)2 x T x D x 8760 hr/yr x N (Load Loss Contribution LL)
Where:
EL
N
P
D
NL
LL
T
© ABB Group
March 21, 2016 | Slide 70
= Purchaser’s cost of electricity ($/kWH)
= Number of years
= Per unit Load = 50% for Medium Voltage> 600 volt class transformers
= Duty Cycle = % of daily usage
= No load (core) loss at 20C in watts
= Load loss at its full load reference temperature consistent with C57.12.00 (liquid)
and C57.12.01(dry) in watts.
= Load loss temperature correction factor to correct specified temperature, i.e., 75C for
dry- and 85C for liquid-transformers.
TOC Variation relative to TSL0
National Efficency Standard impact on Total Owning Cost (TOC) relative to TSL0
Liquid-Filled 1ph 10-167 kVA Pad
9
6
5
RU
RU
DL 2
"B" values (coil loss evaluation) $/watt
7
RU
DL 3
10
15
25
37.5
50
75
100
167
250
333
500
667
833
DL 1
kVA
8
Liq-1ph
PC1
Rect
Round
Tank
Tank
> 1.25
≤ 1.25
≤ 1.15
≤ 1.05
≤1
4
3
2
1
0
0
© ABB Group
March 21, 2016 | Slide 74
Max: 1.33
1
2
3
4
5
6
"A" values (core loss evaluation) $/watt
7
8
9
10
Impact to the Customer

Increased price of transformer

Increased size & weight

Financial valuation & justification


Transition strategy

© ABB Group
March 21, 2016 | Slide 77
A/B factors related to National Standard
Wait to last minute or move now

Potential pre-buy decision based on applicable date

Risk of delayed projects that cross the applicable date
Impact to Customer


Transition Strategy – now or later

Generally there is an economic benefit for any unit
where to A/B are A <= $3.00, B<= $1.00

NEMA Premium Transformer initiative
Potential pre-buy decision based on ‘applicable’ date


Risk of delayed projects that the ‘applicable’ date

© ABB Group
March 21, 2016 | Slide 78
DOE cautions against ‘building stock’ prior to
circumvent to standard
Standard applies to ALL units shipped after
January 1, 2010
Impact to Manufacturer
© ABB Group
March 21, 2016 | Slide 79

Redesign and re-optimize

Impact of unit weight and size

Material selection and availability

Compliance & Enforcement
Design Impact

© ABB Group
March 21, 2016 | Slide 80
Increase in conductor cross section

Copper consumption for overheads

Copper and aluminum for pads

Weights and dimensions increase in most cases

Transportation cost increase as less units per truck load

Average oil volume per unit increases due to wider &
deeper tanks not being offset by reduction in tank height

Some cases higher efficiency leads to lower losses, less
heating and a reduction in tank size and/or elimination of
radiators
% Shipments Meeting Final Ruling

Overheads




© ABB Group
March 21, 2016 | Slide 81
20%
Padmount*

1Φ - 47%

S3Φ < 750 kVA - 53%

L3Φ > 750 kVA – 59%
Cast Coil

20-45 kV BIL 6%

46-95 KV BIL 20%

> 95 KV BIL
3%
Open Wound

20-45 kV BIL 1%

46-95 KV BIL 10%

> 95 KV BIL
0%
*Note: All customer segments
for shipments from 10/06 to
08/07
Impact to Manufacturer
© ABB Group
March 21, 2016 | Slide 82

Redesign and re-optimize

Impact of unit weight and size

Material selection and availability

Compliance & Enforcement
Impact on E-Steel Grade Distribution
© ABB Group
March 21, 2016 | Slide 83
Materials – E-Steel MOST Critical
© ABB Group
March 21, 2016 | Slide 84

Greatest impact of all commodities

Limited worldwide production

Limited capacity of higher grades

Expanding global demand

US Producers raising prices to match world levels
Availability
E-Steel – DemandE-steel
& Supply
Sensitivity
2,650,000
Metric Tons
2,450,000
2,250,000
2,050,000
1,850,000
1,650,000
1,450,000
2005
E-steel Capacity
© ABB Group
March 21, 2016 | Slide 85
2006
E-steel req. 9.2/2.7
From 2007 thru 2010 …

E-steel req. 09.2/2.7

E-steel req. 15.0/2.7

E-steel req. 20.0/3.0

E-steel req. 25.0/3.0
=
=
=
=
2007
E-steel req. 15.0/2.7
China CAGR
China CAGR
China CAGR
China CAGR
= 9.2%,
= 15%,
= 20%,
= 25%,
2008
2009
E-steel 20.0/3.0
all others 2.7%
all others 2.7%
all others 3.0%
all others 3.0%
2010
E-steel 25.0/3.0
Impact to Manufacturer
© ABB Group
March 21, 2016 | Slide 86

Redesign and re-optimize

Impact of unit weight and size

Material selection and availability

Compliance & Enforcement
Agenda
© ABB Group
March 21, 2016 | Slide 87

Describe the new efficiency standards for distribution
transformers for use in or shipped into the United States
and its territories that will be effective January 1, 2010

Review the standard’s development process as well as the
scope of transformers that are effected

Discuss design strategies and associated cost impact of
those strategies

Address the methodologies for insuring conformance with
the standards by the manufacturers
National Standard Enforcement
© ABB Group
March 21, 2016 | Slide 88

Standard requires the manufacturer to comply no
matter country of origin

Enforcement - assumes and Honor System
- depends on third party or other source
reporting suspected ‘violators’ to the DOE

DOE meets with suspect manufacturer reviewing
its underlying test data as to the models in question

DOE commences enforcement testing procedures if
previous step does not resolve compliance issues

Non-compliance results in manufacturer “ceasing
distribution of the basic model” until dispute resolution

DOE might seek civil penalties
National Standard Compliance

© ABB Group
March 21, 2016 | Slide 89
Manufacturer determines efficiency of a basic model either
by testing or by an Alternative Efficiency Determination
Method (AEDM).

Basic model being same energy consumption along
with electrical features being kVA, BIL, voltage and taps

Calculated load at 50% & PF=1.0; NL 20°C & LL 55°C

Auxiliary devices – circuit breakers, fuses and switches
– excluded from calculation of efficiency

AEDM approach is offered in 10 CFR 431 “to ease the
burden on manufacturers”

ABB & Power Partners have elected to use the AEDM
approach for asserting compliance
DOE Compliant
Similar to quoting
average losses today
The mean efficiency of a
basic model will be at or
above the standard
Distribution of
efficiencies for
all units of a
basic model
Higher
Standard Level for Efficiency per
Table I.1. of 10 CFR 431; example,
99.08% for 50 kVA Single Phase
© ABB Group
March 21, 2016 | Slide 90
Efficiency
Compliance by Test

If 5 or fewer units of a Basic Model are produced over 180
days then the manufacturer must test each unit

If more than 5 units of a Basic Model are produced over
180 days then the manufacturer may select and test a
random sample of at least 5 units

Determine the average efficiency of the sample
1 n
X   Xi
n i 1

© ABB Group
March 21, 2016 | Slide 91
where…

Xi is the measured efficiency of unit (i)

n is the number of units in the sample
Criteria:
X
100
 0.08  100 
1  1 
 1

RE
n




RE is the required efficiency

n is the number of units tested
where…
Compliance by AEDM

Randomly select 5+ Basic Models

Two must be the highest volume unit in the prior year

No two shall have the same power / voltage rating

At least one shall be 1-ph and at least one 3-ph

Calculate the Power Loss ( POSC i ) for each Basic Model (i, i  5 )

Determine the Power Loss by Test ( POST ) for at least 5 units (j, j  5)
of each Basic Model (i, i  5)
ij

Determine the mean tested power loss ( POST ) for each Basic Model
 POSTi
1 n
  POSTij
n j 1
i
mean tested power loss of Basic Model (i)

Criteria #1: for each Basic Model (i) 0.95 POST  POSC  1.05 POST

Criteria #2: for all Basic Models
i

% POSCi 
POSCi
POSTi
i
97%  % POSC  103%
100 for Basic Model (i), the calculated power loss as a
percentage of the mean tested power loss

% POSC
1 m
  POSCi the average of all Basic Model percentages of
m i 1
calculated as percentage of mean tested power loss
© ABB Group
March 21, 2016 | Slide 92
i
Specified Minimum Efficiency >> DOE
mean
ABB
Preferred
Specification
Distribution of
efficiencies for
all units of a
basic model
The mean efficiency
of a basic model will
be above the standard
Higher
Efficiency
Standard Level for Efficiency per
Table I.1. of 10 CFR 431; example,
99.08% for 50 kVA Single Phase
© ABB Group
March 21, 2016 | Slide 93
Specified Minimum Efficiency >> DOE
© ABB Group
March 21, 2016 | Slide 94

100% of the units to meet or exceed efficiency standard

Customer should clearly state in its specification

Suggested wording could be, “The tested efficiency of all
units shipped by serial number and/or stock code must
meet or exceed the values in 10 CFR 431, Table I.1. for
liquid-immersed distribution transformers. Certified test
data by serial number must be provided to confirm
compliance with this requirement.”