© ABB Group January 15, 2015 | Slide 1 SWEDE 2009 Conference 2010 National Efficiency Standards Wes...

© ABB Group April 11, 2023 | Slide 1

SWEDE 2009 Conference2010 National Efficiency Standards

Wes Patterson, ABB Transformers North America, May 8, 2009

Over $4.5 billion orders

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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)

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ABB Transformers (2007 data)


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

57 Transformer Factories in 30 countries


World Map ABB Transformer Factories 2007World Map ABB Transformer Factories 2007

South Korea – Chonan-si

USA – South Boston

USA - Jefferson City

USA – Bland

Peru – Lima

Columbia – Pereira

South Africa – Cape Town

South Africa – Booysens

South Africa – Pretoria

Tanzania – Arusha

Egypt – 10th of Ramadan

Saudi Arabia – Riyadh

Ireland – Waterford

Spain – Zaragosa

Finland – Vaasa

Poland – Lodz

Sweden – LudvikaNorway – Steinkjer

Germany – Brilon

Italy– Monselice

Turkey– Istanbu

China– Hefei

China– Shanghai

Vietnam – Hanoi

Singapore – Singapore

New Zealand – New Plymouth

Sweden – PiteaNorway – Drammen

Russia – Khotkovo

Sweden – Mjolby

Sweden – FigeholmGermany – Bad Honnef

Germany – Roigheim

Italy– LegnanoGermany – Halle

Switzerland – Geneve

Spain – Bilbao

Spain – Cordoba

China– Chongquing

China– Zhongshan

Thailand – Bangkok

USA – Alamo

USA – St Louis

Canada – Varennes

India – Baroda

Brazil – Guarulhos

Brazil – Blumenau

Canada – Quebec City

Australia – Darra

Australia – Perth

Australia – Moorebank

Switzerland – Zurich


Jefferson CitySt. Louis

Alamo

PPI-Athens

Bland

Varennes

Quebec

South Boston

Transformer Factories in North America


The largest Transformer manufacturer worldwide

ABB delivers :

2.000 Power Transformers / y

500.000 Distribution Transformers / y

2,5%

2,8%

4,0%

5,0%

9,0%

21,0%

2,0%CGL-PAUWELS

WAUKESHA

HOWARD

SCHNEIDER

AREVA

SIEMENS-VATECH

ABB

Leader in Transformers Business


What ever you need from our broad portfolio -> ABB is your “one-stop” supplier

Complete Transformer Portfolio

IEC & ANSI standards


IEC & ANSI Standards

Distribution Transformers


System System transformerstransformers

Generator Step-Generator Step-Up transformersUp transformers

Power Transformers


Agenda

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






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

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

1997 DOE publishes Notice of Determination

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)

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/


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

Industry Impact: Utility Industrial Construction

* Note: Applies to Puerto Rico, Guam, and all other territories and possessions

10 CFR Part 431 Subpart K October 12, 2007

72 FR 58190

CFR = Code of Federal Regulation



Liquid & Dry Transformers

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

Drive (isolation)

Grounding

Machine-tool (control)

Non-ventilated

Rectifier

Regulating

Sealed

Special Impedance*

Step-up Transformers

Testing

Tap range > 20%

Uninterruptible power supply

Welding

* Note: Standard Impedances



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 side-step the National Efficiency Standard


Benefits – 95 BIL Ventilated Dry Type Example

kVA Typical TSL1 DOE % Watts Annual Savings Add Price Pay Back Yrs15 94.50% 96.80% 97.19% 48.91% 219 192$ 36$ 0.230 95.40% 97.30% 97.63% 48.48% 363 318$ 71$ 0.245 96.00% 97.60% 97.86% 46.50% 454 398$ 107$ 0.375 97.00% 97.90% 98.20% 40.00% 488 428$ 179$ 0.4

112.5 97.20% 98.10% 98.30% 39.29% 671 588$ 268$ 0.5150 97.50% 98.20% 98.42% 36.80% 749 656$ 357$ 0.5225 97.80% 98.40% 98.57% 35.00% 940 823$ 536$ 0.7300 98.10% 98.50% 98.67% 30.00% 928 813$ 715$ 0.9500 98.50% 98.80% 98.83% 22.00% 895 784$ 829$ 1.1750 98.80% 98.90% 98.95% 12.50% 610 535$ 1,138$ 2.1

1000 98.82% 99.00% 99.03% 17.80% 1139 998$ 2,382$ 2.41500 98.95% 99.00% 99.12% 16.19% 1383 1,212$ 2,988$ 2.52000 98.97% 99.20% 99.13% 15.53% 1736 1,521$ 3,147$ 2.12500 99.10% 99.20% 99.23% 14.44% 1763 1,544$ 3,934$ 2.5

Efficiency (%)

Dry-Type Medium Voltage Three Phase (46-95 kV BIL)Loss Reduction DOE to Typical $$$$

Notes: 1. Efficiency and Losses at 50% Load and PF=1.02. Savings assumes 8760 h/yr and $0.10/watt

USWEPAT

Bland's typical

USWEPAT

Watts at 50% Load

USWEPAT

Watts Saved * 8760 hours * $0.10 per WattSavings: 24*365 = 8760 hoursat $0.10 per Hour

USWEPAT

Payback = Additional Price / Annual Savings


National Benefits of The National Energy Standard

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 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


Agenda






The Oak Ridge Study

Design LinesCombination Lines

44,000+ Designs evaluated


National Efficency Standard impact on Total Owning Cost (TOC) relative to TSL0

0

1

2

3

4

5

6

7

8

9

0 1 2 3 4 5 6 7 8 9 10

"A" values (core loss evaluation) $/watt

"B"

va

lue

s (

co

il l

os

s e

va

lua

tio

n)

$/w

att

> 1.25

≤ 1.25

≤ 1.15

≤ 1.05

≤ 1

TOC Variation relative to TSL0

Liquid-Filled 1ph 10-167 kVA Pad

RectTank

RoundTank

101525

37.55075100167250333500667833

kVA

Liq-1phPC1

DL

1

DL

2D

L 3

RU

RU

RU

RU

Max: 1.33


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


Transition between NOPR to Final Rule

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

96.5%

97.0%

97.5%

98.0%

98.5%

99.0%

99.5%

100.0%

15 30 45 75 112.5 150 225 300 500 750 1000 1500 2000 2500

kVA

Eff

icie

ncy

0-Min

0-Avg

TSL1

TSL2

TSL3

TSL4

TSL5

TSL6

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


Final Rule – The National Standard

Final Rule Published Oct 12, 2007

Federal Register - 72 FR 58190

DOE Final Selection

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


National Standard - Liquid-filledDesignLine KVA

AveBaseCaseEff

MinBaseCaseEff TP1

1/3 DiffbetweenTP1 andMin LCC

2/3 DiffbetweenTP1 andMin LCC Min LCC

Max EnergySavings withNo Changein LCC

MaxEnergySavings C

ombi

natio

n of

DL1

-TS

L5 a

ndD

L3-T

SL4

Com

bina

tion

ofD

L4-T

SL2

and

DL5

-TS

L4

Com

bina

tion

ofD

L4-T

SL2

and

DL5

-TS

L3

Com

bina

tion

ofD

L1-T

SL4

, D

L4-

TS

L2D

L3-T

SL2

, D

L5-

KVA 0-Avg 0-Min 1 2 3 4 5 6 Standard A B C D5

10 98.42% 97.77% 98.40% 98.40% 98.44% 98.48% 98.69% 99.32% 98.62% 98.79% 98.62% 98.62% 98.48%15 98.57% 97.99% 98.60% 98.56% 98.59% 98.63% 98.82% 99.39% 98.76% 98.91% 98.76% 98.76% 98.63%

DL2 25 98.74% 98.23% 98.70% 98.73% 98.76% 98.79% 98.96% 99.46% 98.91% 99.04% 98.91% 98.91% 98.79%37.5 98.86% 98.40% 98.80% 98.85% 98.88% 98.91% 99.06% 99.51% 99.01% 99.13% 99.01% 99.01% 98.91%

DL1 50 98.97% 98.56% 98.90% 98.90% 98.90% 99.04% 99.19% 99.59% 99.08% 99.19% 99.08% 99.08% 99.04%75 99.04% 98.66% 99.00% 99.04% 99.06% 99.08% 99.21% 99.59% 99.17% 99.27% 99.17% 99.17% 99.08%

100 99.11% 98.75% 99.00% 99.10% 99.12% 99.14% 99.26% 99.62% 99.23% 99.32% 99.23% 99.23% 99.14%167 99.22% 98.90% 99.10% 99.21% 99.23% 99.25% 99.35% 99.66% 99.25% 99.40% 99.32% 99.32% 99.25%250 99.24% 98.89% 99.20% 99.26% 99.36% 99.45% 99.69% 99.70% 99.32% 99.45% 99.37% 99.31% 99.26%333 99.29% 98.97% 99.20% 99.31% 99.40% 99.49% 99.71% 99.72% 99.36% 99.49% 99.41% 99.36% 99.31%

DL3 500 99.36% 99.07% 99.30% 99.38% 99.46% 99.54% 99.74% 99.75% 99.42% 99.54% 99.47% 99.42% 99.38%667 99.40% 99.13% 99.40% 99.42% 99.50% 99.57% 99.76% 99.77% 99.46% 99.57% 99.51% 99.46% 99.42%833 99.44% 99.18% 99.40% 99.45% 99.52% 99.60% 99.77% 99.78% 99.49% 99.60% 99.53% 99.49% 99.45%

KVA 0-Avg 0-Min 1 2 3 4 5 6 Standard A B C D15 98.06% 97.19% 98.10% 98.36% 98.68% 98.68% 99.25% 99.31% 98.36% 98.56% 98.36% 98.36% 98.36%30 98.37% 97.64% 98.40% 98.62% 98.89% 98.89% 99.37% 99.42% 98.62% 98.79% 98.62% 98.62% 98.62%45 98.53% 97.87% 98.60% 98.76% 99.00% 99.00% 99.43% 99.47% 98.76% 98.91% 98.76% 98.76% 98.76%75 98.70% 98.12% 98.70% 98.91% 99.12% 99.12% 99.50% 99.54% 98.91% 99.04% 98.91% 98.91% 98.91%

112.5 98.83% 98.30% 98.80% 99.01% 99.20% 99.20% 99.55% 99.58% 99.01% 99.13% 99.01% 99.01% 99.01%DL4 150 98.91% 98.42% 98.90% 99.08% 99.26% 99.26% 99.58% 99.61% 99.08% 99.19% 99.08% 99.08% 99.08%

225 99.02% 98.57% 99.00% 99.17% 99.33% 99.33% 99.62% 99.65% 99.17% 99.27% 99.17% 99.17% 99.17%300 99.08% 98.67% 99.00% 99.23% 99.38% 99.38% 99.65% 99.67% 99.23% 99.32% 99.23% 99.23% 99.23%500 99.19% 98.83% 99.10% 99.32% 99.45% 99.45% 99.69% 99.71% 99.25% 99.40% 99.32% 99.27% 99.32%750 99.24% 98.97% 99.20% 99.24% 99.31% 99.37% 99.66% 99.66% 99.32% 99.45% 99.37% 99.31% 99.31%

1000 99.29% 99.04% 99.20% 99.29% 99.36% 99.41% 99.68% 99.68% 99.36% 99.49% 99.41% 99.36% 99.36%DL5 1500 99.36% 99.13% 99.30% 99.36% 99.42% 99.47% 99.71% 99.71% 99.42% 99.54% 99.47% 99.42% 99.42%

2000 99.40% 99.19% 99.40% 99.40% 99.46% 99.51% 99.73% 99.73% 99.46% 99.57% 99.51% 99.46% 99.46%2500 99.44% 99.23% 99.40% 99.44% 99.49% 99.53% 99.74% 99.74% 99.49% 99.60% 99.53% 99.49% 99.49%

TSL

TSLProduct Class 2

Table EA.4

Product Class 1Table EA.3

Liquid-Immersed Medium Voltage Three Phase TransformerTSL

TSLLiquid-Immersed Medium Voltage Single Phase Transformer

Note: National Standard Efficiency calculated using load at 50% & PF (COS θ) = 1.0


National Standard - Liquid-filled

Loss Loss

DOE TLS1 Reduction DOE TLS1 Reduction

10 98.62% 98.40% 13.7% 15 98.36% 98.10% 13.7%15 98.76% 98.60% 11.4% 30 98.62% 98.40% 13.7%25 98.91% 98.70% 16.2% 45 98.76% 98.60% 11.4%

37.5 99.01% 98.80% 17.5% 75 98.91% 98.70% 16.2%50 99.08% 98.90% 16.4% 112.5 99.01% 98.80% 17.5%75 99.17% 99.00% 17.0% 150 99.08% 98.90% 16.4%

100 99.23% 99.00% 23.0% 225 99.17% 99.00% 17.0%167 99.25% 99.10% 16.7% 300 99.23% 99.00% 23.0%250 99.32% 99.20% 15.0% 500 99.25% 99.10% 16.7%333 99.36% 99.20% 20.0% 750 99.32% 99.20% 15.0%500 99.42% 99.30% 17.1% 1000 99.36% 99.20% 20.0%667 99.46% 99.40% 10.0% 150 99.42% 99.30% 17.1%833 99.49% 99.40% 15.0% 2000 99.46% 99.40% 10.0%

2500 99.49% 99.40% 15.0%

Efficiency (%) Efficiency (%)

Single-Phase Three-Phase

kVA kVA

Loss Reduction @ 50% Load compared to TLS1 (NEMA TP-1) as the base case


National Standard - Dry-type

KVA 0-Avg 0-Min 1 2 3 4 5 6 Standard

15 98.02% 97.45% 97.60% 98.10% 98.46% 98.81% 99.05% 99.05% 98.10%25 98.26% 97.75% 97.90% 98.33% 98.64% 98.95% 99.17% 99.17% 98.33%

37.5 98.43% 97.97% 98.10% 98.49% 98.77% 99.05% 99.25% 99.25% 98.49%50 98.54% 98.11% 98.20% 98.60% 98.86% 99.12% 99.30% 99.30% 98.60%75 98.68% 98.29% 98.40% 98.73% 98.97% 99.20% 99.37% 99.37% 98.73%

DL9 100 98.77% 98.41% 98.50% 98.82% 99.04% 99.26% 99.41% 99.41% 98.82%167 98.92% 98.60% 98.80% 98.96% 99.16% 99.35% 99.48% 99.48% 98.96%250 99.01% 98.56% 98.90% 99.05% 99.17% 99.27% 99.42% 99.42% 99.07%333 99.08% 98.66% 99.00% 99.11% 99.23% 99.32% 99.46% 99.46% 99.14%

DL10 500 99.17% 98.79% 99.10% 99.20% 99.30% 99.39% 99.51% 99.51% 99.22%667 99.23% 98.87% 99.20% 99.26% 99.35% 99.43% 99.54% 99.54% 99.27%833 99.27% 98.93% 99.20% 99.30% 99.38% 99.46% 99.57% 99.57% 99.31%


15 97.40% 96.64% 96.80% 97.50% 97.97% 98.44% 98.75% 98.75% 97.50%30 97.81% 97.17% 97.30% 97.90% 98.29% 98.68% 98.95% 98.95% 97.90%45 98.02% 97.45% 97.60% 98.10% 98.46% 98.81% 99.05% 99.05% 98.10%75 98.26% 97.75% 97.90% 98.33% 98.64% 98.95% 99.17% 99.17% 98.33%

112.5 98.43% 97.97% 98.10% 98.49% 98.77% 99.05% 99.25% 99.25% 98.49%150 98.54% 98.11% 98.20% 98.60% 98.86% 99.12% 99.30% 99.30% 98.60%225 98.68% 98.29% 98.40% 98.73% 98.97% 99.20% 99.37% 99.37% 98.73%

DL9 300 98.77% 98.41% 98.60% 98.82% 99.04% 99.26% 99.41% 99.41% 98.82%500 98.92% 98.60% 98.80% 98.96% 99.16% 99.35% 99.48% 99.48% 98.96%750 99.01% 98.56% 98.90% 99.05% 99.17% 99.27% 99.42% 99.42% 99.07%

1000 99.08% 98.66% 99.00% 99.11% 99.23% 99.32% 99.46% 99.46% 99.14%DL10 1500 99.17% 98.79% 99.10% 99.20% 99.30% 99.39% 99.51% 99.51% 99.22%

2000 99.23% 98.87% 99.20% 99.26% 99.35% 99.43% 99.54% 99.54% 99.27%2500 99.27% 98.94% 99.20% 99.30% 99.38% 99.46% 99.57% 99.57% 99.31%


15 97.46% 96.87% 97.60% 97.86% 98.14% 98.41% 98.54% 98.54% 97.86%25 97.77% 97.24% 97.90% 98.12% 98.36% 98.60% 98.71% 98.71% 98.12%

37.5 97.98% 97.51% 98.10% 98.30% 98.52% 98.73% 98.84% 98.84% 98.30%50 98.12% 97.68% 98.20% 98.42% 98.62% 98.82% 98.92% 98.92% 98.42%75 98.30% 97.90% 98.40% 98.57% 98.75% 98.94% 99.02% 99.02% 98.57%

DL11 100 98.42% 98.05% 98.50% 98.67% 98.84% 99.01% 99.09% 99.09% 98.67%167 98.61% 98.28% 98.80% 98.83% 98.98% 99.13% 99.20% 99.20% 98.83%250 99.02% 98.58% 98.90% 98.95% 99.08% 99.23% 99.42% 99.42% 98.95%333 99.09% 98.68% 99.00% 99.03% 99.15% 99.28% 99.46% 99.46% 99.03%

DL12 500 99.18% 98.81% 99.10% 99.12% 99.23% 99.35% 99.51% 99.51% 99.12%667 99.24% 98.89% 99.20% 99.18% 99.28% 99.40% 99.54% 99.54% 99.18%833 99.28% 98.95% 99.20% 99.23% 99.32% 99.43% 99.57% 99.57% 99.23%



Dry-Type Medium Voltage Three Phase Transformer (20-45 kV BIL)


Dry-Type Medium Voltage Single Phase Transformer (46-96 kV BIL)TSL

TSL

Dry-Type Medium Voltage Single Phase Transformer (20-45 kV BIL)TSL


15 96.66% 95.88% 96.80% 97.19% 97.55% 97.91% 98.08% 98.08% 97.18%30 97.19% 96.53% 97.30% 97.63% 97.94% 98.24% 98.38% 98.38% 97.63%45 97.46% 96.87% 97.60% 97.86% 98.14% 98.41% 98.54% 98.54% 97.86%75 97.77% 97.24% 97.90% 98.12% 98.36% 98.60% 98.71% 98.71% 98.12%

112.5 97.98% 97.51% 98.10% 98.30% 98.52% 98.73% 98.84% 98.84% 98.30%150 98.12% 97.68% 98.20% 98.42% 98.62% 98.82% 98.92% 98.92% 98.42%225 98.30% 97.90% 98.40% 98.57% 98.75% 98.94% 99.02% 99.02% 98.57%

DL11 300 98.42% 98.05% 98.50% 98.67% 98.84% 99.01% 99.09% 99.09% 98.67%500 98.61% 98.28% 98.80% 98.83% 98.98% 99.13% 99.20% 99.20% 98.83%750 99.02% 98.58% 98.90% 98.95% 99.08% 99.23% 99.42% 99.42% 98.95%

1000 99.09% 98.68% 99.00% 99.03% 99.15% 99.28% 99.46% 99.46% 99.03%DL12 1500 99.18% 98.81% 99.00% 99.12% 99.23% 99.35% 99.51% 99.51% 99.12%

2000 99.24% 98.89% 99.20% 99.18% 99.28% 99.40% 99.54% 99.54% 99.18%2500 99.28% 98.95% 99.20% 99.23% 99.32% 99.43% 99.57% 99.57% 99.23%


75 98.72% 98.22% 98.40% 98.53% 98.79% 99.05% 99.22% 99.22% 98.53%100 98.81% 98.34% 98.50% 98.63% 98.88% 99.12% 99.28% 99.28% 98.63%167 98.95% 98.54% 98.70% 98.80% 99.01% 99.22% 99.36% 99.36% 98.80%250 99.05% 98.68% 98.80% 98.91% 99.11% 99.30% 99.42% 99.42% 98.91%333 99.12% 98.77% 98.90% 98.99% 99.17% 99.35% 99.46% 99.46% 98.99%500 99.20% 98.89% 99.00% 99.09% 99.25% 99.41% 99.52% 99.52% 99.09%

DL13 667 99.26% 98.97% 99.00% 99.15% 99.30% 99.45% 99.55% 99.55% 99.15%833 99.30% 99.03% 99.10% 99.20% 99.34% 99.48% 99.57% 99.57% 99.20%


225 98.72% 98.22% 98.40% 98.53% 98.79% 99.05% 99.22% 99.22% 98.53%300 98.81% 98.34% 98.50% 98.63% 98.88% 99.12% 99.28% 99.28% 98.63%500 98.95% 98.54% 98.70% 98.80% 99.01% 99.22% 99.36% 99.36% 98.80%750 99.05% 98.68% 98.80% 98.91% 99.11% 99.30% 99.42% 99.42% 98.91%

1000 99.12% 98.78% 98.90% 98.99% 99.17% 99.35% 99.46% 99.46% 98.99%1500 99.20% 98.89% 99.00% 99.09% 99.25% 99.41% 99.52% 99.52% 99.09%

DL13 2000 99.26% 98.97% 99.00% 99.15% 99.30% 99.45% 99.55% 99.55% 99.15%2500 99.30% 99.03% 99.10% 99.20% 99.34% 99.48% 99.57% 99.57% 99.20%



Dry-Type Medium Voltage Three Phase Transformer (>96 kV BIL)TSL

TSLDry-Type Medium Voltage Single Phase Transformer (>96 kV BIL)

TSLProduct Class 8

Table EA.8Dry-Type Medium Voltage Three Phase Transformer (46-96 kV BIL)

Note: National Standard Efficiency calculated using load at 50% & PF (COS θ) = 1


National Standard - Dry Type

Loss Reduction @ 50% Load compared to TLS1 (NEMA TP-1) as the base case

DOE TLS1 DOE TLS115 97.86% 97.60% 10.8% 15 97.18% 96.80% 11.9%25 98.12% 97.90% 10.5% 30 97.63% 97.30% 12.2%

37.5 98.30% 98.10% 10.5% 45 97.86% 97.60% 10.8%50 98.42% 98.20% 12.2% 75 98.12% 97.90% 10.5%75 98.57% 98.40% 10.6% 112.5 98.30% 98.10% 10.5%

100 98.67% 98.50% 11.3% 150 98.42% 98.20% 12.2%167 98.83% 98.80% 2.5% 225 98.57% 98.40% 10.6%250 98.95% 98.90% 4.5% 300 98.67% 98.50% 11.3%333 99.03% 99.00% 3.0% 500 98.83% 98.80% 2.5%500 99.12% 99.10% 2.2% 750 98.95% 98.90% 4.5%667 99.18% 99.20% -2.5% 1000 99.03% 99.00% 3.0%833 99.23% 99.20% 3.8% 1500 99.12% 99.00% 12.0%

2000 99.18% 99.20% -2.5%2500 99.23% 99.20% 3.8%

Single-Phase Dry-type

kVAEfficiency (%) Loss

Reduction

Three-Phase Dry-type

kVAEfficiency (%) Loss

Reduction


Final Rule: Liquid and Dry Comparison


Agenda






What is transformer efficiency?

%Efficiency = 100 x Output Watts / Input Watts

Output being less than input due to losses in form of heat

% Efficiency =L . kVA . COS . 105

L . kVA . COS . 103 + Fe + L2 . (LL)

L (pu) = Load V

r

No-Load Losses (A)

Load Losses (B)

Note: National Standard Efficiency calculated using load at 50% & PF (COS θ) = 1


Transformer Losses

Total Loss = No-Load Loss + Load Loss

No Load Losses - Core Loss

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

AreaConductor

Length Conductor y Resistivit R

Resistivity - property of the material

Copper = 0.017

Aluminium = 0.028


Load Losses - Conductor Eddy Loss

Less of an impact than I2R

Eddy loss in the conductor

Thin conductors have less eddy loss

Eddy loss in adjacent ferrous metal

LV Lead close to tank wall sets up eddy currents in the tank


No Load Losses – Core Eddy Loss

0.20.40.60.8

11.21.41.61.8

22.22.4

1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8Induction (Tesla)

ARMCO .17mmARMCO .23mmARMCO .36mm

0.014 inch = M6

0.009 inch = M3

0.006 inch = M2


AreaCore Turns

voltage Rated Constant

f

Induction

Where

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

No Load Losses – Core Eddy Loss


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

How to Reduce Losses?


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

Note: TSL6 was computed with Amorphous Cores


Impact to the Customer

Increased price of transformer

Increased size & weight

Financial valuation & justification

A/B factors related to National Standard

Transition strategy

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 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

Estimated based on high volume styles

1Φ (kVA)ABB Base

CostTP1 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


Price Impact - Padmount

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

1Φ (kVA)ABB Base

CostTP1 DOE

25-50 1.00 1.04 1.18

75-100 1.00 1.02 1.18

250 1.00 1.00 1.12

3Φ (kVA) 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


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

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

Open Wound ABB Base

Cost TP1

ABB Base

Cost TP1Cast Coil

DOE

DOE

Note: Actual Price impact is dependent on:• KVA• Temperature Rise• Conductor• BIL• Impedance

Price Impact – Dry Type


National Efficency Standard impact on Unit Footprint relative to TSL0

0

1

2

3

4

5

6

7

8

9

0 1 2 3 4 5 6 7 8 9 10


"B"

va

lue

s (

co

il l

os

s e

va

lua

tio

n)

$/w

att

> 1.09

≤ 1.09

≤ 1.06

≤ 1.03

≤ 1

Footprint Variation relative to TSL0

RectTank

RoundTank

101525

37.55075100167250333500667833

kVA

Liq-1phPC1

DL

1

DL

2D

L 3

RU

RU

RU

RU


Max: 1.10


National Efficency Standard impact on Unit Weight relative to TSL0

0

1

2

3

4

5

6

7

8

9

0 1 2 3 4 5 6 7 8 9 10


"B"

va

lue

s (

co

il l

os

s e

va

lua

tio

n)

$/w

att

> 1.25

≤ 1.25

≤ 1.15

≤ 1.05

≤ 1

Weight Variation relative to TSL0


RectTank

RoundTank

101525

37.55075100167250333500667833

kVA

Liq-1phPC1

DL

1

DL

2D

L 3

RU

RU

RU

RU

Max: 1.29


Impact of A/B factors

Loss Evaluation

Cost Of Losses (COL) =

(A x No Load Loss) + (B x Load Loss)

($/watt x watts) + ($/watt x watts)

Total Owning Cost (TOC) =

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

Loss

Cos

t

Cost ofLosses

TransformerCost

Note: A = PW Inflation x Annual $/kW x n yrs; B = A x (load p.u.)2 x Conductor Temp Correction


Where: EL = Purchaser’s cost of electricity ($/kWH) N = Number of years P = Per unit Load = 50% for Medium Voltage> 600 volt class transformers D = Duty Cycle = % of daily usage NL = No load (core) loss at 20C in watts LL = Load loss at its full load reference temperature consistent with C57.12.00 (liquid)

and C57.12.01(dry) in watts. T = Load loss temperature correction factor to correct specified temperature, i.e., 75C for

dry- and 85C for liquid-transformers.

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)


National Efficency Standard impact on Total Owning Cost (TOC) relative to TSL0

0

1

2

3

4

5

6

7

8

9

0 1 2 3 4 5 6 7 8 9 10


"B"

va

lue

s (

co

il l

os

s e

va

lua

tio

n)

$/w

att

> 1.25

≤ 1.25

≤ 1.15

≤ 1.05

≤ 1

TOC Variation relative to TSL0


RectTank

RoundTank

101525

37.55075100167250333500667833

kVA

Liq-1phPC1

DL

1

DL

2D

L 3

RU

RU

RU

RU

Max: 1.33


Impact to the Customer

Increased price of transformer

Increased size & weight

Financial valuation & justification

A/B factors related to National Standard

Transition strategy

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

DOE cautions against ‘building stock’ prior to circumvent to standard

Risk of delayed projects that the ‘applicable’ date

Standard applies to ALL units shipped after January 1, 2010


Impact to Manufacturer

Redesign and re-optimize

Impact of unit weight and size

Material selection and availability

Compliance & Enforcement


Design Impact

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 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 on E-Steel Grade Distribution


Greatest impact of all commodities

Limited worldwide production

Limited capacity of higher grades

Expanding global demand

US Producers raising prices to match world levels

Materials – E-Steel MOST Critical


E-Steel – Demand & Supply Sensitivity

From 2007 thru 2010 … E-steel req. 09.2/2.7 = China CAGR = 9.2%, all others 2.7% E-steel req. 15.0/2.7 = China CAGR = 15%, all others 2.7% E-steel req. 20.0/3.0 = China CAGR = 20%, all others 3.0% E-steel req. 25.0/3.0 = China CAGR = 25%, all others 3.0%

1,450,000

1,650,000

1,850,000

2,050,000

2,250,000

2,450,000

2,650,000

2005 2006 2007 2008 2009 2010

Me

tric

To

ns

E-steel Capacity E-steel req. 9.2/2.7 E-steel req. 15.0/2.7 E-steel 20.0/3.0 E-steel 25.0/3.0








Agenda






National Standard Enforcement

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

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


Distribution of efficiencies forall units of abasic model

Standard Level for Efficiency perTable I.1. of 10 CFR 431; example,99.08% for 50 kVA Single Phase

Higher

Efficiency

Similar to quoting average losses today

The mean efficiency of a basic model will be at or above the standard

DOE Compliant


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

where…

Xi is the measured efficiency of unit (i)

n is the number of units in the sample

Criteria: where…

RE is the required efficiency

n is the number of units tested

n

iiXn

X1

1

1

10008.011

100

REn

X


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 ( ) for each Basic Model (i, ) Determine the Power Loss by Test ( ) for at least 5 units (j, ) of

each Basic Model (i, ) Determine the mean tested power loss ( ) for each Basic Model

mean tested power loss of Basic Model (i)

Criteria #1: for each Basic Model (i) Criteria #2: for all Basic Models

for Basic Model (i), the calculated power loss as a percentage

of the mean tested power loss

the average of all Basic Model percentages of calculated as

percentage of mean tested power loss

iOSCP

ijOSTP 5j

5i

n

jOSTOST ijiP

nP

1

1

iii OSTOSCOST PPP 05.195.0

%103%%97 OSCP

100% i

i

i

OST

OSCOSC P

PP

m

iOSCOSC iP

mP

1

1%

iOSTP

5i


Distribution of efficiencies forall units of abasic model

Standard Level for Efficiency perTable I.1. of 10 CFR 431; example,99.08% for 50 kVA Single Phase

Higher

Efficiency

The mean efficiencyof a basic model willbe above the standard

mean

Specified Minimum Efficiency >> DOE

ABBPreferred

Specification


Specified Minimum Efficiency >> DOE

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.”

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