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T TR RA AN NS SF FO OR RM ME ER RS S
Prepared for
Bureau of Energy Efficiency,
(under Ministry of Power, Government of India)
Hall no.4, 2
nd
Floor, NBCC Tower,
Bhikaji Cama Place,
New Delhi – 110066.
Indian Renewable Energy Development Agency,
Core 4A, East Court,
1
st
Floor, India Habitat Centre,
Lodhi Road,
New Delhi – 110003
.
By
Devki Energy Consultancy Pvt. Ltd.,
405, Ivory Terrace, R.C. Dutt Road,
Vadodara – 390007, India.
2006
2
CONTENTS
1. INTRODUCTION.............................................................................................................................................................4
1.1 BACKGROUND....................................................................................................................................................................4
1.2 A GUIDE TO THIS GUIDE.......................................................................................................................................................4
2. FUNDAMENTALS ..........................................................................................................................................................5
2.1. PRINCIPLE OF TRANSFORMER ACTION..........................................................................................................................5
2.2. SAMPLE CALCULATION...............................................................................................................................................7
2.4 PARALLEL OPERATION OF TRANSFORMERS..................................................................................................................8
2.5. LOSSES IN TRANSFORMERS........................................................................................................................................8
2.5.1. Dielectric Losses...............................................................................................................................................9
2.5.2. Hysteresis Loss.................................................................................................................................................9
2.5.3. Eddy Current Losses in the Core.....................................................................................................................10
2.5.4. Resistive losses in the windings ......................................................................................................................10
2.5.5. Eddy Current Losses in conductors: ................................................................................................................11
2.3.6 Extra Eddy Losses in Structural Parts .............................................................................................................12
3. TRANSFORMER OPERATIONS..................................................................................................................................13
3.1 VARIATION OF LOSSES DURING OPERATION................................................................................................................13
3.1.1. Variation of losses with loading level ...............................................................................................................13
3.1.2. Variation in Constant losses............................................................................................................................14
3.1.3. Variation in Load Losses .................................................................................................................................14
3.2. LOSS MINIMISATION IN APPLICATION & OPERATION ...................................................................................................14
3.2.1. Selection of Rating and Number of Transformers ............................................................................................14
3.2.2. Energy Saving by Underutilisation of transformers .........................................................................................15
3.2.3. Reduction of losses due to improvement of power factor.................................................................................15
3.3. SEGREGATION OF NON LINEAR LOADS.......................................................................................................................16
3.4. EFFECT OF OPERATING TEMPERATURE ......................................................................................................................16
3.5. ASSESSING THE EFFECTS OF HARMONICS..................................................................................................................16
3.5.1. U.S. Practice – K Factor.................................................................................................................................17
3.5.2. European Practice ‘Factor K’..........................................................................................................................18
4. REDUCTION OF LOSSES AT DESIGN STAGE...........................................................................................................20
4.1. INTRODUCTION.........................................................................................................................................................20
4.2. MINIMISING IRON LOSSES.........................................................................................................................................20
4.2.1. Losses in Core................................................................................................................................................20
4.2.2. Amorphous cores............................................................................................................................................21
4.3. MINIMISING COPPER LOSSES ....................................................................................................................................22
4.4. CHOICE OF LIQUIDFILLED OR DRY TYPE.....................................................................................................................22
5. ECONOMIC ANALYSIS................................................................................................................................................24
1.1 INTRODUCTION.................................................................................................................................................................24
5.2 TOTAL OWNERSHIP COST OF TRANSFORMERS ...........................................................................................................24
5.3 DECISIONS FOR CHANGEOVER TO NEW EQUIPMENT ....................................................................................................25
5.4 SAMPLE CALCULATIONS...........................................................................................................................................25
6 CASE STUDIES............................................................................................................................................................27
6.1 INTRODUCTION.........................................................................................................................................................27
6.2 CASE STUDY 1.........................................................................................................................................................27
Illustrative Calculations .....................................................................................................................................................27
6.2.1 Factor for Harmonics.......................................................................................................................................28
6.2.2 Percentage of Eddy Losses in Load Losses: ...................................................................................................29
6.2.3 Full load losses for Harmonic Loading: ............................................................................................................29
6.2.4 Relative economics for low loss transformers (All Dry type).............................................................................29
6.2.5 Summary:........................................................................................................................................................31
6.3 CASE STUDY2: NON FERROUS METAL SECTOR .........................................................................................................31
6.4 CASE STUDY3: PAPER & PULP COMPANY................................................................................................................32
6.5 CASE STUDY4 CHEMICAL INDUSTRY .....................................................................................................................33
6.6 CASE STUDY 5 CASE OF A LARGE DATA HOTEL START UP.......................................................................................33
6.7 SUMMARY OF EUROPEAN CASE STUDIES: .................................................................................................................34
6.8 CASE STUDY 6: TEA INDUSTRY (INDIA) ......................................................................................................................34
6.9 CASE STUDY 7: STEEL MILL (INDIA) ..........................................................................................................................35
6.10 CASE STUDY8: AUTOMOBILE PLANT (INDIA).............................................................................................................36
6.11 CASE STUDY 9: IMPROVING RELIABILITY AND AVAILABILITY.......................................................................................37
6.12 CASE STUDY10: USE OF AMORPHOUS CORE TRANSFORMERS...................................................................................38
ANNEXURE1: GUIDELINES FOR INSTALLING TRANSFORMERS.....................................................................................39
ANNEXURE2: MAINTENANCE GUIDELINES.......................................................................................................................42
REFERENCES........................................................................................................................................................................46
3
List of figures
Figure 21: Relationship between current, magnetic field strength and flux ............................................................................................ 5
Figure 22: Transformer schematic ........................................................................................................................................................................ 5
Figure 23: Transformer construction .................................................................................................................................................................... 6
Figure 24: BH Loop................................................................................................................................................................................................... 9
Figure 25 Core lamination to reduce eddy current losses .......................................................................................................................... 10
Figure 26: Sectionalised transformer winding  Schematic ........................................................................................................................ 11
Figure 41: Amorphous core ribbons.................................................................................................................................................................. 21
List of Tables
Table 31: Comparison of transformer losses................................................................................................................................................... 15
Table 32: Estimation for K factor.......................................................................................................................................................................... 18
Table 33: Estimation of Factor K.......................................................................................................................................................................... 19
Table 41: Evolution of core material ................................................................................................................................................................... 21
Table 42: Comparison of Losses – Oil type and dry type ........................................................................................................................... 23
Table 51: Comparison of transformers .............................................................................................................................................................. 25
Table 61input data 1250 kV transformer........................................................................................................................................................... 27
Table 62 1250 kVA transformer ........................................................................................................................................................................... 30
Table 63 1600 kVA transformer ........................................................................................................................................................................... 30
Table 64 : Outcome 1000 kVA transformer...................................................................................................................................................... 32
Table 65: Annual savings potential .................................................................................................................................................................... 32
Table 66: Input data of 3150 kVA transformer ................................................................................................................................................ 32
Table 67 Outcome of 3150 kVA transformer ................................................................................................................................................... 33
Table 68: Parameter sensitivity on the payback period............................................................................................................................... 34
Table 69: electricity losses over a year.............................................................................................................................................................. 37
Table 610: Costs over 10 years. .......................................................................................................................................................................... 37
4
1. INTRODUCTION
1.1 Background
Distribution transformers are very efficient, with losses of less than 0.5% in large units. Smaller units have
efficiencies of 97% or above. It is estimated that transformer losses in power distribution networks can
exceed 3% of the total electrical power generated. In India, for an annual electricity consumption of about
500 billion kWh, this would come to around 15 billion kWh.
Reducing losses can increase transformer efficiency. There are two components that make up
transformer losses. The first is "core" loss (also called noload loss), which is the result of the
magnetizing and demagnetizing of the core during normal operation. Core loss occurs whenever the
transformer is energized; core loss does not vary with load. The second component of loss is called
coil or load loss, because the efficiency losses occur in the primary and secondary coils of the
transformer. Coil loss is a function of the resistance of the winding materials and varies with the load
on the transformer.
In selecting equipments, one often conveniently avoids the concept of life cycle costing. But the truth is that
even the most efficient energy transfer equipment like a transformer, concept of life cycle cost is very much
relevant. The total cost of owning and operating a transformer must be evaluated, since the unit will be in
service for decades. The only proper method to evaluate alternatives is to request the manufacturer or
bidder to supply the load and noload losses, in watts. Then, simple calculations can reveal anticipated
losses at planned loading levels. Frequently, a small increase in purchase price will secure a unit with lower
operating costs.
The load profile of electronic equipment—from the computer in the office to the variable speed drive
in the factory—drives both additional losses and unwanted distortion. Since transformer
manufacturers test only under ideal (linear) conditions, a substantial gap exists between published
loss data and actual losses incurred after installation. In fact, test results published in a 1996 IEEE
Transaction paper documented an almost tripling of transformer losses when feeding 60kW of
computer load rather than linear load. Slightly different practices are followed in USA and UK to
account for harmonics while selecting transformers.
1.2 A guide to this guide
This Best Practice Manual for Electric Transformers summarise the approach for energy conservation
measures pertaining to selection, application and operation of electric distribution transformers.
The details of design methodology and the varied approaches for materials, construction are not in the
scope of this manual. However, some theoretical aspects are discussed where ever deemed fit.
Chapter2 discusses principles of transformer action, description of losses and effect of non linear loads on
transformer efficiency.
Chapter3 discusses design aspects of transformers to improve efficiency
Chapter4 discusses loss Minimisation in application and operation
Chapter5 discusses principles of economic evaluation of transformers
Chapter6 discusses case studies from Indian and International scenario
Annexures are given to familiarize the users with the installation and maintenance of transformers
5
2. FUNDAMENTALS
2.1. Principle of transformer action
A current flowing through a coil produces a magnetic field around the coil. The magnetic field strength H,
required to produce a magnetic field of flux density B, is proportional to the current flowing in the coil. Figure
2.1 shown below explains the above principle
Figure 21: Relationship between current, magnetic field strength and flux
The above principle is used in all transformers.
A transformer is a static piece of apparatus used for transferring power from one circuit to another at a
different voltage, but without change in frequency. It can raise or lower the voltage with a corresponding
decrease or increase of current.
V
p
I
p
N
p
I
s
N
s
V
s
R
t
B
A N V p p
∆
∆
− =
t
B
A N V s s
∆
∆
− =
p
s
p
s
N
N
V
V
=
field Magnetic
Figure 22: Transformer schematic
When a changing voltage is applied to the primary winding, the back e.m.fs generated by the primary is
given by Faraday’s law,
EMF =
t
B
A N V p p
∆
∆
− =  (1)
A Current in the primary winding produces a magnetic field in the core. The magnetic field is almost totally
confined in the iron core and couples around through the secondary coil. The induced voltage in the
secondary winding is also given by Faraday’s law
6
t
B
A N V s s
∆
∆
− =  (2)
The rate of change of flux is the same as that in primary winding. Dividing equation (2) by (1) gives
p
s
p
s
N
N
V
V
=
In Figure 2.2, the primary and secondary coils are shown on separate legs of the magnetic circuit so
that we can easily understand how the transformer works. Actually, half of the primary and secondary
coils are wound on each of the two legs, with sufficient insulation between the two coils and the core
to properly insulate the windings from one another and the core. A transformer wound, such
as in Figure 2.2, will operate at a greatly reduced effectiveness due to the magnetic leakage.
Magnetic leakage is the part of the magnetic flux that passes through either one of the coils, but not
through both. The larger the distance between the primary and secondary windings, the longer the
magnetic circuit and the greater the leakage. The following figure shows actual construction of a
single phase transformer.
Figure 23: Transformer construction
The voltage developed by transformer action is given by
E = core max A B N f 4.44 × × × ×
Where E = rated coil voltage (volts),
f = operating frequency (hertz),
N = number of turns in the winding,
B
max
= maximum flux density in the core (tesla), and
A
core
, = crosssectional area of the core material in Sq. metres.
In addition to the voltage equation, a power equation expressing the voltampere rating in terms of
the other input parameters is also used in transformer design. Specifically, the form of the equation is
VA = cond core max A J A B N f 4.44 × × × × × ×
Where, N, B
max
, A
core
and f are as defined above, J is the current density (A/ sq. mm), and A
cond
is the
coil crosssectional area (mm
2
) in the core window; of the conducting material for primary winding. J
depends upon heat dissipation and cooling.
7
2.2. Sample calculation
A 50 Hz transformer with 1000 turns on primary and 100 turns on secondary, maximum flux density
of 1.5 Tesla and core area of 0.01 m
2
. J is taken as 2 Amps/Sq. mm and A
cond
as 30 mm
2
for this
illustration. Voltage developed is given by
In primary winding,
E
primary
= 4.44 x f x Np x B
max
x A
core
,
= 4.44 X 50 X 1000 X 1.5 X 0.01
= 3330 Volts
In secondary winding
E
secondary
= 4.44 x f x Ns x B
max
x A
core
,
= 4.44 X 50 X 100 X 1.5 X 0.01
= 333 Volts
Voltampere capability is given by the following relationship:
Power rating = 4.44 x f x Np x B
max
x A
core
x J x A
cond
, X 0.001 KVA.
= 4.44 X 50 X 1000 X 1.5 X 0.01 X 2 X 30 X 0.001
= 200 kVA approximately.
Actual Rated KVA = Rated Voltage X Rated Current X 10
3
for single phase transformers.
Rated KVA = V

3 X Rated Line Voltage X Rated Line Current X 10
3
for three phase transformers.
2.3. Winding connection designations
The winding connections in a transformer are designated as follows.
High Voltage Always capital letters
Delta  D
Star  S
Interconnected star  Z
Neutral brought out  N
Low voltage Always small letters
Delta  d
Star  s
interconnected star  z
Neutral brought out  n
Phase displacement: Phase rotation is always anticlockwise. (International adopted convention).
Use the hour indicator as the indicating phase displacement angle. Because there are 12 hours on a
clock, and a circle consists out of 360°, each hour represents 30°.
Thus 1 = 30°, 2 = 60°, 3 = 90°, 6 = 180°and 12 = 0°or 360°.
The minute hand is set on 12 o'clock and replaces the line to neutral voltage (sometimes imaginary)
of the HV winding. This position is always the reference point. Because rotation is anticlockwise, 1 =
30°lagging (LV lags HV with 30°) and 11 = 330°lagging or 30°leading (LV leads HV with 30°)
To summarise:
Dd0:Delta connected HV winding, delta connected LV winding, no phase shift between HV and LV.
Dyn11:Delta connected HV winding, star connected LV winding with neutral brought out, LV is
leading HV with 30°
8
YNd5: Star connected HV winding with neutral brought out, delta connected LV winding, LV lags HV
with 150°
2.4 Parallel operation of transformers
The parallel operation of transformers is common in any industry. This mode of operation is
frequently required. When operating two or more transformers in parallel, their satisfactory
performance requires that they have:
1. The same voltageratio
2. The same perunit (or percentage) impedance
3. The same polarity
4. The same phasesequence and zero relative phasedisplacement
Out of these conditions 3 and 4 are absolutely essential and condition 1 must be satisfied to a close
degree. There is more latitude with condition 2, but the more nearly it is true, the better will be the
loaddivision between the several transformers.
Voltage Ratio: An equal voltageratio is necessary to avoid noload circulating current, other wise it
will lead to unnecessary losses. The impedance of transformers is small, so that a small percentage
voltage difference may be sufficient to circulate a considerable current and cause additional I
2
R loss.
When the secondaries are loaded, the circulating current will tend to produce unequal loading
conditions and it may be impossible to take the combined fullload output from the parallelconnected
group without one of the transformers becoming excessive hot.
Impedance: The impedances of two transformers may differ in magnitude and in quality (i.e. ratio of
resistance to reactance) and it is necessary to distinguish between perunit and numerical
impedance. Consider two transformers of ratings in the ratio 2:1. To carry double the current, the
former must have half the impedance of the latter for the same regulation. The regulation must,
however, be the same for parallel operation, this condition being enforced by the parallel connection.
Hence the currents carried by two transformers are proportional to their ratings, if their numerical or
ohmic impedances are inversely proportional to those ratings, and their perunit impedances are
identical.
A difference in quality of the perunit impedance results in a divergence of phase angle of the two
currents, so that one transformer will be working with a higher, and the other with a lower, power
factor than that of the combined output.
Polarity: This can be either right or wrong. If wrong it results in a dead short circuit.
PhaseSequence: This condition is associated only with polyphase transformers. Two transformers
giving secondary voltages with a phasedisplacement cannot be used for transformers intended for
paralleloperation. The phase sequence or the order, in which the phases reach their maximum
positive voltages, must be identical for two paralleling transformers; otherwise during the cycle each
pair of phases will be shortcircuited.
The two power transformers shall be paralleled only for a short duration, because they may be risking
a higher fault level during this short period. The system impedance reduces when the two or more
transformers are paralleled and hence increases the fault level of the system.
2.5. Losses in Transformers
The losses in a transformer are as under.
1. Dielectric Loss
2. Hysteresis Losses in the Core
3. Eddy current losses in the Core
4. Resistive Losses in the winding conductors
5. Increased resistive losses due to Eddy Current Losses in conductors.
6. For oil immersed transformers, extra eddy current losses in the tank structure.
9
Basic description of the factors affecting these losses is given below.
2.5.1. Dielectric Losses
This loss occurs due to electrostatic stress reversals in the insulation. It is roughly proportional to
developed high voltage and the type and thickness of insulation. It varies with frequency. It is
negligibly small and is roughly constant. (Generally ignored in medium voltage transformers while
computing efficiency).
2.5.2. Hysteresis Loss
A sizeable contribution to noload losses comes from hysteresis losses. Hysteresis losses originate
from the molecular magnetic domains in the core laminations, resisting being magnetized and
demagnetized by the alternating magnetic field.
Each time the magnetising force produced by the primary of a transformer changes because of the
applied ac voltage, the domains realign them in the direction of the force. The energy to accomplish
this realignment of the magnetic domains comes from the input power and is not transferred to the
secondary winding. It is therefore a loss. Because various types of core materials have different
magnetizing abilities, the selection of core material is an important factor in reducing core losses.
Hysteresis is a part of core loss. This depends upon the area of the magnetising BH loop and
frequency. Refer Fig 2.4 for a typical BH Loop.
Figure 24: BH Loop
Energy input and retrieval while increasing and decreasing current. Loss per half cycle equals half of
the area of Hysteresis Loop. The BH loop area depends upon the type of core material and
maximum flux density. It is thus dependent upon the maximum limits of flux excursions i.e. B
max
, the
type of material and frequency. Typically, this accounts for 50% of the constant core losses for
CRGO (Cold Rolled Grain Oriented) sheet steel with normal design practice.
Hysteresis Losses,
1.6
m h h B f K W × × = Watts/Kg.
Where Kh = the hysteresis constant
f = Frequency in Hertz
B
m
= Maximum flux density in Tesla
10
2.5.3. Eddy Current Losses in the Core
The alternating flux induces an EMF in the bulk of the core proportional to flux density and frequency.
The resulting circulating current depends inversely upon the resistivity of the material and directly
upon the thickness of the core. The losses per unit mass of core material, thus vary with square of
the flux density, frequency and thickness of the core laminations.
By using a laminated core, (thin sheets of silicon steel instead of a solid core) the path of the eddy
current is broken up without increasing the reluctance of the magnetic circuit. Refer fig 2.5 below for a
comparison of solid iron core and a laminated iron core.
Fig. 2.5B shows a solid core, which is split up by laminations of thickness ‘
d1’
and depth d
2
as shown
in C. This is shown pictorially in 2.5 A.
Figure 25 Core lamination to reduce eddy current losses
Eddy Losses,
2 2
m e e t f B K W
2
× × × = Watts/Kg.
Where Ke = the eddy current constant
f = Frequency in Hertz.
B
m
= Maximum flux density in Tesla
t = Thickness of lamination strips.
For reducing eddy losses, higher resistivity core material and thinner (Typical thickness of
laminations is 0.35 mm) lamination of core are employed. This loss decreases very slightly with
increase in temperature. This variation is very small and is neglected for all practical purposes. Eddy
losses contribute to about 50% of the core losses.
2.5.4. Resistive losses in the windings
These represent the main component of the load dependent or the variable losses, designated as I
2
R
or copper losses. They vary as square of the r.m.s current in the windings and directly with D.C.
resistance of winding. The resistance in turn varies with the resistivity, the conductor dimensions; and
the temperature.
A
l ρ
R
×
=
Where R = Winding resistance, Ω
ρ = Resistivity in Ohms  mm
2
/m.
l = Length of conductor in metres
A = Area of cross section of the conductor, mm
2
In addition, these losses vary with winding temperature and thus will vary with the extent of loading
and method of cooling. The winding resistance at a temperature T
L
is given by the following equation.
11

¹

\

+
+
× =
235 T
235 T
R R
0
L
0 L The constant 235 is for Copper. For Aluminium, use 225 or 227
for Alloyed Aluminium.
Where R
0
= Winding resistance at temperature T
0
, Ω
R
L
= Winding resistance at temperature, T
L,
Ω
The r.m.s value of current will depend upon the load level and also the harmonic distortion of the
current.
2.5.5. Eddy Current Losses in conductors:
Conductors in transformer windings are subjected to alternating leakage fluxes created by winding currents.
Leakage flux paths, which pass through the cross section of the conductor, induce voltages, which vary
over the cross section. These varying linkages are due to selflinkage as also due to proximity of adjacent
current carrying conductors. These induced voltages, create circulating currents within the conductor
causing additional losses. These losses are varying as the square of the frequency.
For an isolated conductor in space, the varying selflinkage over the section, leads to clustering of the
current near the conductor periphery. This is known as Skin Effect. The same effect, with the addition of
flux from surrounding conductors, (Proximity effect) leads to extra losses in thick conductors for transformer
windings. These losses are termed as Eddy Current Losses in conductors.
The Test Certificate mentions the load losses, which include these eddy losses in conductors at supply
frequency (50 Hertz) as also the eddy losses in tank structure in general at the same frequency in the case
of oil cooled transformers. For dry type transformers, tank losses are absent.
The contribution of eddy losses including tank losses, over the basic copper losses for an equivalent D.C.
current, can be estimated from the difference in measured load losses and expected copper losses at the
test current at the test temperature. For normal designs it ranges from 5% to 15%. Detailed subdivision is
available only from design data. It can be taken as 10% of load losses in the absence of specific design
data. These extra losses vary with square of frequency and square of per unit harmonic current.
The eddy losses in the tank structure are equivalent to the dissipation in a loaded secondary with leakage
reactance. The variation is not as the square of frequency, and it is customary to take a value of 0.8 for the
exponent.
The Eddy losses in a thick conductor can be reduced by decreasing the radial thickness by sectionalising
the conductors (multistranded) and increasing the axial dimension. The sectionalised conductor has to be
transposed to make it occupy all possible positions to equalise the e.m.fs to the extent possible.
A simplified expression for eddy current losses in conductors is given below.
Figure 26: Sectionalised transformer winding  Schematic
1
2
N1
N
w
L L
C
W/N
12
The total radial thickness of conductor of W cm is subdivided into N parts of W/N thickness each. Ke is the
ratio of the total losses including eddy loss, to the loss due to D.C. current.
Ke = ( )
2
4
9
N
αW/N 1 × +
Where α =
( )
L ρ
Lc f 10 4π π
7
×
× × × ×
−
where 4π X 10
–7
is permeability of space.
Where Lc = Axial length of coil.
L = Window Height
W = Radial total conductor width in metres
W’= Width per subdivision W/N in centimeters.
ρ = Resistivity, in Ohmmetres
For Copper at 60 °C,
L
Lc
100 α × ≈ . ρ= 2 X 10
–8
Ohmmetres
If W’ is in cm, W = W’/100
Hence αW/N
L
Lc
w'× ≈ , α
4
is thus proportional to f
2
.
As the number of subdivisions increase, W’ becomes smaller and Ke comes nearer to 1; but always above
1. For a given geometry, eddy losses increase as square of frequency.
It is important to transpose each layer so that each layer is connected in series with a path in each one of
the possible N positions before being paralleled. Thus circulating current is forced to flow in a relatively very
thin conductor.
2.3.6 Extra Eddy Losses in Structural Parts
Some leakage flux invariably goes in air paths away from the transformer. Strength of this stray flux
diminishes and varies inversely with distance. If it links with any conducting material, it will produce eddy
losses in that material. For oil immersed transformers, some stray flux links with some parts of the tank and
causes extra eddy current losses in the structure. These losses are absent in dry type transformers.
Similarly, extra flux due to outgoing L.T. conductors carrying large currents cause extra eddy current losses
in the structural portion surrounding the leads.
Both these losses vary with frequency
0.8
, as stated earlier.
The above discussion on transformer losses is given only to gain familiarity with the fundamental principles.
The most important losses are core loss and copper loss. The other losses are described mainly to give a
complete picture on losses.
13
3. TRANSFORMER OPERATIONS
3.1 Variation of losses during operation
The losses vary during the operation of a transformer due to loading, voltage changes, harmonics and
operating temperature.
3.1.1. Variation of losses with loading level
% Efficiency =
Losses Output
100 Output
+
×
=
T p L.L. N.L 1000 p.f. rating kVA P
100 1000 p.f. rating kVA P
2
× × + + × × ×
× × × ×
Where,
p = per unit loading
N.L. = No load losses in Watts
L.L. = Load losses in Watts at full load, at 75 °C
T = Temperature correction factor
p.f. = Load power factor
The basic D.C. resistance copper losses are assumed to be 90% of the load losses. Eddy current losses
(in conductors) are assumed to be 10% of the load losses. Basic I
2
R losses increase with temperature,
while eddy losses decreases with increase in temperature. Thus, 90% of the load losses vary directly with
rise in temperature and 10% of the load losses vary inversely with temperature. Calculations are usually
done for an assumed temperature rise, and the rise in temperature is dependant on the total losses to be
dissipated.
Operating temperature = Ambient temperature + Temperature rise
To estimate the variation in resistance with temperature, which in turn depends on the loading of the
transformer, the following relationship is used.
ref
rise amb
re T
op T
T F
T T F
f R
R
+
+ +
=
−
−
Where F= 234.5 for Copper,
= 225 for Aluminium
= 227 for alloyed Aluminium
R
Top
= Resistance at operating temperature
T
ref =
Standard reference temperature, 75 C
Temperature correction factor, T =
e temperatur reference at losses Load
e temperatur operating at losses Load
= 
¹

\

× + 
¹

\

×
−
−
−
−
op T
ref T
ref T
op T
R
R
0.1
R
R
0.9
If a more realistic subdivision of load losses is known from design data, the above expression can be
modified accordingly.
If operating temperature is 100 C,
75 234.5
100 234.5
f R
R
re T
op T
+
+
=
−
−
= 1.0808
Hence T = 0.9 x 1.0808 +0.1/1.0808 = 1.06523
14
3.1.2. Variation in Constant losses
The iron loss measured by no load test is constant for a given applied voltage. These losses vary as
the square of the voltage.
Variation in iron losses due to system voltage harmonics: The system input voltage may contain
voltage harmonics due to aggregate system pollution in the grid. The current harmonics of the local
harmonic load adds to this by causing additional harmonic voltage drop depending upon magnitude of a
particular harmonic and the system short circuit impedance at the point of supply, and the transformer
impedance for that specific harmonic frequency. The combined total harmonics affect the flux waveform
and give added iron losses. The increase in constant loss is quite small, due to this voltage distortion.
3.1.3. Variation in Load Losses
About 90%of the load losses as measured by short circuit test are due to I
2
R losses in the windings.
They vary with the square of the current and also with winding temperature.
Load Losses =
( ) 
¹

\

+
+
× ×
ref
op
2
T F
T F
Load Full at Losses Load Loading Unit Per
F = Temperature coefficient = 234.5 for Copper and 227 for Aluminium.
T
ref
= 75 °C usually, or as prescribed in the test certificate
Variation in load losses due to load power factor: Any reduction in current for the same kW load by
improvement in p.f. reduces load losses.
Variation in losses due to current harmonics: The system current harmonics increase the r.m.s current
and thus increase the basic I
2
R losses. In addition, the major increase comes from the variation in eddy
current losses in the windings (Usually 5 to 10% of the total load losses), which vary with the square of the
frequency.
3.2. Loss Minimisation in Application & Operation
Transformers have a long life and do not generally suffer from technical obsolescence. The application
details are not clearly known during selection and the load and the type of load also changes with time.
Hence transformer rating is likely to be overspecified. However, this is generally not a disadvantage from
the view point of energy consumption. The usual best efficiency point is near 50% load.
3.2.1. Selection of Rating and Number of Transformers
In general, selection of only one transformer of large rating gives maximum efficiency and simpler
installation. For large plants with long in plant distances, two or more transformers of equal rating may be
selected. Moreover for critical continuous operation plants, power may be had from two independent
feeders at similar or different voltage levels. In all such cases, each transformer may be sufficient to run the
plant. Thus normal operation may be at 50% load. Such a situation can lead to lower than 25% load at
times. For noncontinuous operation of plants with holidays or seasonal industries, switching off one
transformer to save part load losses is generally considered.
Planning for growth of loads and addition of non linear loads is becoming increasingly important. The
factors to be considered are:
• Expected growth of load over around five to ten years
• Margin for minimum 15 to 20% growth
• 10 to 15% margin for nonlinear loads
• Availability of standard rating
Generally, 30 to 50% excess capacity reduces load losses, but the extra first cost is rarely justified by
energy saving alone. On the contrary, a close realistic estimate permits extra first cost on a smaller
15
transformer designed on the basis of Least Total Ownership Cost ( TOC) basis. Economic evaluation of
transformers is discussed in chapter 5.
For nonlinear loads, transformers with minimum eddy losses in total load loss are preferred. Transformer
losses may be specified at a standard reference temperature of 75 C. They have to be corrected to
expected site operating temperature. Basic I
2
R losses increase with temperature, while eddy losses
decrease with increase in temperature.
For nonlinear loads, the derating factor may be worked out taking a Kfactor of 20. Details of K factor
evaluation are given in section 3.4 of this chapter. This will need derating of 12% for 10% nonlinear load to
about 27% for 40% nonlinear load.
The load factor affects the load losses materially and an estimate of annual r.m.s. load current value is
useful. Transformers with relatively low no load losses( Amorphous Core Type) will maintain good
efficiency at very low loads and will help in cases where high growth is expected, but risk of slow growth is
to be minimised.
3.2.2. Energy Saving by Underutilisation of transformers
Table 3.1 summarises the variation in losses and efficiency for a 1000 kVA transformer and also shows the
difference in losses by using a 1600 kVA transformer for the same. The 1000 kVA transformer has a no
load loss of 1700 watts and load loss of 10500 Watts at 100% load. The corresponding figures for 1600
kVA transformer are 2600 Watts and 17000 Watts respectively. Loading is by linear loads. Temperatures
assumed equal.
Table 31: Comparison of transformer losses
1000 kVA,
No load losses = 1700 W
1600 kVA.
No load losses =
2600 W
Difference in
losses, W
Per
unit
load
Load
losses,
W
Total
losses,
W
Output,
kW
Efficiency,
%
Load
losses,
W
Total
losses,
W
0.1 105 1805 100 98.23 60 2660 861
0.2 420 2120 200 98.95 265 2865 745
0.3 945 2645 300 99.13 597 3197 552
0.4 1680 3380 400 99.16 1062 3662 282
0.5 2625 4325 500 99.14 1660 4267 58
0.6 3780 5480 600 99.09 2390 4990 490
0.7 5145 6845 700 99.03 3258 5853 992
0.8 6720 8420 800 98.96 4250 6850 1570
0.9 8505 10205 900 98.88 5379 7979 2226
1.0 10500 12200 1000 98.78 6640 9240 2960
The efficiency of 1000 kVA transformer is maximum at about 40% load. Using 1600 kVA transformer
causes under loading for 1000 kW load. The last column shows the extra power loss due to oversized
transformer. As expected, at light loads, there is extra loss due to dominance of no load losses. Beyond
50% load, there is saving which is 2.96 kW at 1000 kW load.
The saving by using a 1600 kVA transformer in place of a 1000 kVA transformer at 1000 kW load for 8760
hours/annum is 25960 kWh/year. @Rs 5.0 /kWh, this is worth Rs 1.29 lakhs. The extra first cost would be
around Rs 10.0 lakhs. Hence deliberate over sizing is not economically viable.
3.2.3. Reduction of losses due to improvement of power factor
Transformer load losses vary as square of current. Industrial power factor vary from 0.6 to 0.8. Thus the
loads tend to draw 60% to 25% excess current due to poor power factor. For the same kW load, current
drawn is proportional to KW/pf. If p.f. is improved to unity at load end or transformer secondary, the saving
in load losses is as under.
16
Saving in load losses = (Per unit loading as per kW)
2
X Load losses at full load X


¹

\

−
(
¸
(
¸
1
pf
1
2
Thus, if p.f is 0.8 and it is improved to unity, the saving will be 56.25% over existing level of load losses.
This is a relatively simple opportunity to make the most of the existing transformer and it should not be
missed. It should also be kept in mind that correction of p.f downstream saves on cable losses, which may
be almost twice in value compared to transformer losses.
3.3. Segregation of non linear loads
In new installations, nonlinear loads should be segregated from linear loads. Apart from ease of separation
and monitoring of harmonics, it can be supplied from a transformer which is specially designed for handling
harmonics. The propagation of harmonics can be controlled much more easily and problems can be
confined to known network. Perhaps a smaller than usual transformer will help in coordinating short circuit
protection for network as well as active devices. The only disadvantage apart from additional cost is the
increased interdependence of sensitive loads.
3.4. Effect of operating temperature
The losses have to be dissipated through the surface area. When the transformer volume increases, the
ratio of surface area to volume reduces. Thus, larger transformers are difficult to cool. Oil cooling uses a
liquid insulating medium for heat transfer. In cold countries the ambient temperature is lower, giving a lower
operating temperature. In tropical countries, ambient temperature is higher giving a higher operating
temperature.
Oil cooled transformers operate at lower temperatures compared to dry type transformers. Every 1°C rise in
operating temperature gives about 0.4% rise in load losses. A reference temperature of 75 °C is selected
for expressing the losses referred to a standard temperature. The operating temperature limit is decided by
the type of insulation used and the difficulties of cooling. This gives an additional factor for comparing
losses during design. Higher temperature permits reduction in material content and first cost. Operating
temperature beyond the limits prescribed for the insulation, reduces life expectancy materially.
3.5. Assessing the effects of Harmonics
Load loss performance of a design or an installed transformer with known data can be done if the levels of
harmonic current are known or estimated.
IEC 613781 ‘Transformers for Industrial Applications’ gives a general expression for estimating load losses
for loads with harmonics. This standard is specifically meant for transformers and reactors which are an
integral part of converters. It is not meant for power distribution transformers. The method is applicable for
estimation in power distribution transformers. It can be used for oil cooled transformers or dry type
transformers.
The alternative approaches for power distribution transformers using KFactor and FactorK are given later.
As per IEC 613781, the total load losses with current harmonics are given as under
( )
(
(
¸
(
¸
× 
¹

\

× + +
(
(
¸
(
¸
× 
¹

\

× + 
¹

\

× =
∑ ∑
n
1
0.8
2
1
SE1 CE1
n
1
2
2
1
WE1
2
1
L
DC1 T n
I
In
P P n
I
In
P
I
I
P P
Where T P = Total load losses and ‘n’ is the order of the harmonic.
∑
=
=
n
1 n
n
2
L
2
I I
P
DC1
= Basic copper losses for fundamental frequency
P
WE1
= Winding eddy losses for fundamental
P
CE1
= Eddy losses in structural parts due to current leads for fundamental
17
P
SE1
= Eddy losses in structural parts for fundamental
I
n
= Current for harmonic order n
I
1
= Fundamental current
P
CE1
and P
SE1
are not applicable to dry type transformers
3.5.1. U.S. Practice – K Factor
The KFactor rating assigned to a transformer and marked on the transformer case in accordance with the
listing of Underwriters Laboratories, is an index of the transformer's ability to supply harmonic content in its
load current while remaining within its operating temperature limits.
The KFactor is the ratio of eddy current losses when supplying nonlinear loads as compared to losses
while supplying linear loads. In U.S., dry type of transformers are used in majority of applications.
2
2
1 n
n .n I k
2
∑
=
=
I
n
= per unit harmonic current, and n = Order of harmonic.
For specification in general, the U.S. practice is to estimate the K – Factor which gives ready reference ratio
K for eddy losses while supplying nonlinear loads as compared to linear loads.
K = 1 for resistance heating, motors, distribution transformers etc.
K = 4 for welders Induction heaters, Fluorescent lights
K = 13 For Telecommunication equipment.
K = 20 for main frame computers, variable speed drives and desktop computers.
The eddy losses in conductors are assumed to vary as ( )
2
2
n
n
I
I
× where I is the total r.m.s. current
and is assumed to be 100 % i.e. rated value.
( )
2
n
2
2
2
1 I .... I I I + + + = Where I
1
is taken as 1. Now, since I is defined, loss variation is taken as
( )
2
2
n
n
I
I
× including fundamental.
K is ratio of Eddy losses at 100 % current with harmonics and Eddy losses at 100 % current with
fundamental.
K = ( )
( )
2
2
1 1
2
2
n
1 n
n
1
/I I
n
I
I
× ×
∑
=
K = ( )
2
2
n
1 n
n
n
I
I
×
∑
=
The KFactor is used directly to specify transformers for a given duty. The total losses, if needed can
be estimated at any % x loading as under if the contribution of eddy losses in load losses at
fundamental frequency test is known from design; or assumed typically as 10 %. Copper losses are
then assumed to be the balance 90 %.
Total load losses at 100 % load = (0.9 + 0.1 x K)
If K = 11, eddy losses at 100% load with this harmonic pattern are 11 times the eddy losses at
fundamental.
Total load losses at 100% load = 0.9 + 1.1 = 2
Total load losses at % x load = x
2
x 2.
18
If total load losses are assumed to be 100% or 1 for same temperature rise, then x
2
= 1/K =1/2. x =
1/K
0.5
or 70.7%. Thus the transformer can work at 70% of its rated load current specified for linear
loads.
A sample K factor calculation is given for a given set of harmonic measurements, based on the
above relationships.
Table 32: Estimation for K factor
Harmonic
No.
RMS
Current
I
n
/I
1
(I
n
/I
1
)
2
(I
n
/I) (I
n
/I)
2
(I
n
/I)
2
xn
2
1 1 1 1 0.6761 0.4571 0.4571
3 0.82 0.82 0.6724 0.5544 0.3073 2.7663
5 0.58 0.58 0.3364 0.3921 0.1538 3.8444
7 0.38 0.38 0.1444 0.2569 0.0660 3.2344
9 0.18 0.18 0.0324 0.1217 0.0148 1.2000
11 0.045 0.045 0.0020 0.0304 0.0009 0.1120
Total r.m.s 1.479
Sum 2.1876 11.6138
I
r.m.s. = √
2.1876 =1.479 =I. KFactor is given by last column. K factor = 11.618
A K13 rated transformer is recommended for this load.
3.5.2. European Practice ‘Factor K’
The European practice as defined in BS 7821 Part 4 and HD 538.3.S1 defines a derating factor for a
given transformer by a ‘FactorK’.
K =
0.5
N
2 n
2
1
n q
2
1
I
I
n
I
I
e 1
e
1
(
(
¸
(
¸


¹

\

× × 
¹

\

+
+
∑
+
e = Eddy current loss at fundamental frequency divided by loss due to a D.C. current
equal to the R.M.S. value of the sinusoidal current.
I
n
= magnitude of nth harmonic current.
q = Exponential constant dependent on type of winding and frequency
= 1.7 for round / rectangular section
= 1.5 for foil type low voltage winding.
I = R.M.S. value of the current including all harmonics
=
0.5
N n
1 n
2
n
I 
¹

\

∑
=
=
The objective is to estimate the total load losses at 100% current, when that current contains harmonics.
The base current is thus I the r.m.s. current which is 100%. This is equal to the rated current at which the
load losses are measured at fundamental frequency. The basic copper losses vary as the square of the
r.m.s. current and hence are equal to the measured losses at fundamental frequency.
Total load losses at fundamental are taken as unity i.e. 1.
1 = EddyLosses R I
2
+ where as Eddy Losses =( ) R I e
2
×
Hence, 1 = ( ) ( ) e 1 R I
2
+ ×
Eddy Losses as a fraction of total load losses =
( )


¹

\

+
×
e) 1 R I
R I e
2
2
=
( )


¹

\

+ e) 1
e
19
Eddy Losses at I (100%) =
( )
q
n
1 n
n
n
I
I
e 1
e
2
2
× × 
¹

\

+
∑
=
Since harmonics are expressed as fractions of fundamental,
Eddy Losses =
( )
∑
=
× + + × + ×
× 
¹

\

× 
¹

\

+
n
1 n
1
q
n
q
3
q
1
2
1
2
2 2 2
I
n I ... 3 I 1 I
I
I
e 1
e
=
( )


¹

\
 × + + × + ×
+ × 
¹

\

× 
¹

\

+
∑
+ =
n
2 n n
1
q
n
q
3
q
1
2
1
2
2 2 2
I
n I ... 3 I 1 I
1
I
I
e 1
e
I = I
1
2
+ I
H
2
where I
H
2
equals the sum of squares for harmonics, but excluding fundamental.
Total losses =
( ) q
n × 
¹

\

× 
¹

\

× 
¹

\

+
+


¹

\

× 
¹

\

+
−
+
× 
¹

\

+
+
∑
+ =
2
n
2 n n
1
n
2
1
2
2
H
2
2
H
2
1 2
I
I
I
I
e 1
e
I
I
e 1
e
I
I I
e 1
e
R I
If the term for I
H
2
is neglected, there is an error on safe side with a total deviation of only 2% to 4%
depending upon I
H
, since e/ 1+ e itself is about 9% to 10% of total losses at fundamental. The addition to
eddy losses may be 10 to 15 times due to harmonics. The first two terms equal the total losses at
fundamental and thus equals 1.The Factor K is taken as the square root of total losses. The expression
thus simplifies to the form stated earlier. The summation term is for n > 1 and thus covers harmonics only.
At % x load, Load Losses = X
2
K
2
and since new load losses should be equal to 1,
X= 1/K .
Typical calculation (taking q as 1.7 and assuming that eddy current loss at fundamental as 10% of
resistive loss i.e. e= 0.1) is given below.
Table 33: Estimation of Factor K
Harmonic No. RMS Current I
n
/I
1
(I
n
/I
1
)
2
n
q
n
q
(I
n
/I)
2
1 1 1 1 1 1
3 0.82 0.82 0.6724 6.473 4.3525
5 0.58 0.58 0.3364 15.426 5.1893
7 0.38 0.38 0.1444 27.332 3.9467
9 0.18 0.18 0.0324 41.900 1.3576
11 0.045 0.045 0.0020 58.934 0.1193
Sum 2.1876 Σ=15.9653
I
r.m.s.
=√ 2.1876 = 1.457.
K
2
= 1 + (0.1/ 1.1) x (1/1.457)
2
x (15.9653 –1) =1.641
K = 1.28
Transformer derating factor = 1/K = 1/1.28 x 100 = 78.06%
20
4. REDUCTION OF LOSSES AT DESIGN STAGE
4.1. Introduction
Design changes to reduce transformer losses, just as in a motor, always involve tradeoffs. For
example, consider varying the crosssectional area of the transformer core. An increase tends to
lower noload loss while raising the winding loss. An increase in volts per turn reduces winding loss
while increasing the core loss. Variation in conductor area and in the electric and magnetic circuit
path lengths will affect efficiency in various ways, always leading the designer to seek a costeffective
balance.
To raise transformer efficiency, core loss has probably drawn the most attention. Core construction
permits two important energysaving features not applicable to industrial motors. First, the inherent
colinearity between lamination orientation and the magnetic field direction allows use of grain
oriented steel for transformer laminations. That greatly reduces hysteresis loss in the corethe energy
required to cyclically realign the "molecular magnets" within the steel, which are randomly positioned
in a nonoriented material.
Second, because laminations are sheared or slit in strips rather than being punched with slots, much
thinner material can be used in a transformer core than in a rotating machine. Whereas motor
laminations are usually 0.014 to 0.025 inch thick, transformer lamination thickness may be as low as
0.006, with 0.009 to 0.012 being common. That lowers eddy current loss.
A further improvement appearing during the 1980's is amorphous core material. Resembling glass
more than steel, this lamination material contains no granular structure at all. Laminations only 0.001
inch thick were used in the first massproduced distribution transformers (25 kVA) manufactured by
Westinghouse in 1986. Many similar units have been put in service since then, along with some large
power transformers. Typical core loss in such a transformer is only onethird of that in a conventional
unit.
The design approaches for reduction of losses are well known and proven. They consists of
1. Using more material
2. Better material
3. New Material
4. Improved distribution of materials
5. Improvement in cooling medium and methods
Each design tries to achieve desired specifications with minimum cost of materials or minimum weight or
volume or minimum overall cost of ownership. Worldwide, more and more consumers are now purchasing
transformers based on the total ownership costs, than just the first cost.
4.2. Minimising Iron Losses
4.2.1. Losses in Core
Choice of metal is critical for transformer cores, and it's important that good quality magnetic steel be
used. There are many grades of steel that can be used for a transformer core. Each grade has an
effect on efficiency on a perkg basis. The choice depends on how you evaluate nonload losses and
total owning costs.
Almost all transformer manufacturers today use steel in their cores that provides low losses due to
the effects of magnetic hysteresis and eddy currents. To achieve these objectives, high permeability,
coldrolled, grainoriented, silicon steel is almost always used. Construction of the core utilizes step
lap mitered joints and the laminations are carefully stacked.
The evolution of materials used in transformer core is summarised below.
21
Table 41: Evolution of core material
Year
(Approx.)
Core Material Thickness
(Mm)
Loss
(W/Kg At 50hz)
1910 Warm rolled FeSi 0.35 2 (1.5T)
1950 Cold rolled CRGO 0.35 1 (1.5T)
1960 Cold rolled CRGO 0.3 0.9 (1.5T)
1965 Cold rolled CRGO 0.27 0.84 (1.5T)
1975 Amorphous metal 0.03 0.2 (1.3T)
1980 Cold rolled CRGO 0.23 0.75 (1.5T)
1985 Cold rolled CRGO 0.18 0.67 (1.5T)
There are two important core materials used in transformer manufacturing. Amorphous metal and CRGO. It
can be seen that losses in amorphous metal core is less than 25% of that in CRGO. This material gives
high permeability and is available in very thin formations (like ribbons) resulting in much less core losses
than CRGO.
The trade off between the both types is interesting. The use of higher flux densities in CRGO (up to 1.5 T)
results in higher core losses; however, less amount of copper winding is required, as the volume of core is
less. This reduces the copper losses.
In amorphous core, the flux density is less and thinner laminations also help in reducing core losses.
However, there is relatively a larger volume to be dealt with, resulting in longer turns of winding, i.e. higher
resistance resulting in more copper losses. Thus iron losses depend upon the material and flux densities
selected, but affect also the copper losses.
It becomes clear that a figure for total losses can be compared while evaluating operating cost of the
transformers. The total operating cost due to losses and total investment cost forms the basis of Total
Ownership Cost of a transformer.
4.2.2. Amorphous cores
A new type of liquidfilled transformer introduced commercially in 1986 uses ultra lowloss cores
made from amorphous metal; the core losses are between 60% to 70% lower than those for
transformers using silicon steel. To date, these transformers have been designed for distribution
operation primarily by electric utilities and use woundcut cores of amorphous metal. Their ratings
range from 10kVA through 2500kVA. The reason utilities purchase them, even though they are more
expensive than silicon steel core transformers, is because of their high efficiency. The use of
amorphous core liquidfilled transformers is now being expanded for use in power applications for
industrial and commercial installations. This is especially true in other countries such as Japan.
Figure 41: Amorphous core ribbons
Amorphous metal is a new class of material having no crystalline formation. Conventional metals
possess crystalline structures in which the atoms form an orderly, repeated, threedimensional array.
Amorphous metals are characterized by a random arrangement of their atoms (because the atomic
structure resembles that of glass, the material is sometimes referred to as glassy metal). This atomic
22
structure, along with the difference in the composition and thickness of the metal, accounts for the
very low hysteresis and eddy current losses in the new material.
Cost and manufacturing technique are the major obstacles for bringing to the market a broad
assortment of amorphous core transformers. The price of these units typically ranges from 15% to
40% higher than that of silicon steel core transformers. To a degree, the price differential is
dependent upon which grade of silicon steel the comparison is being made. (The more energy
efficient the grade of steel used in the transformer core, the higher the price of the steel.)
At present, amorphous cores are not being applied in drytype transformers. However, there is
continuous developmental work being done on amorphous core transformers, and the use of this
special metal in drytype transformers may become a practical reality sometime in the future.
If you're considering the use of an amorphous core transformer, you should determine the economic
trade off; in other words, the price of the unit versus the cost of losses. Losses are especially
important when transformers are lightly loaded, such as during the hours from about 9 p.m. to 6 a.m.
When lightly loaded, the core loss becomes the largest component of a transformer's total losses.
Thus, the cost of electric power at the location where such a transformer is contemplated is a very
important factor in carrying out the economic analyses.
Different manufacturers have different capabilities for producing amorphous cores, and recently,
some have made substantial advances in making these cores for transformers. The technical
difficulties of constructing a core using amorphous steel have restricted the size of transformers using
this material. The metal is not easily workable, being very hard and difficult to cut, thin and flimsy, and
difficult to obtain in large sheets. However, development of these types of transformers continues;
you can expect units larger than 2500kVA being made in the future.
4.3. Minimising Copper losses
The major portion of copper losses is I
2
R losses. Using a thicker section of the conductor i.e. selecting a
lower current density can reduce the basic I
2
R losses. However, an arbitrary increase in thickness can
increase eddy current losses. In general, decreasing radial thickness by sectionalisation leads to reduction
in eddy current losses. A properly configured foil winding is useful in this context. The designer has to take
care of the proper buildup of turns with transposition and also take care of the mechanical strength to
sustain short circuit in addition to needed insulation and surge voltage distribution.
All the same, designers can always try to get minimum basic I
2
R and minimum eddy current losses for a
given design and specified harmonic loading.
4.4. Choice of liquidfilled or dry type
Information on the pros and cons of the available types of transformers frequently varies depending
upon what information is made available by the manufacturer. Nevertheless, there are certain
performance and application characteristics that are almost universally accepted.
Basically, there are two distinct types of transformers: Liquid insulated and cooled (liquidfilled type)
and non liquid insulated, air or air/gas cooled (dry type). Also, there are subcategories of each main
type.
For liquidfilled transformers, the cooling medium can be conventional mineral oil. There are also wet
type transformers using less flammable liquids, such as high fire point hydrocarbons and silicones.
Liquidfilled transformers are normally more efficient than drytypes, and they usually have a longer
life expectancy. Also, liquid is a more efficient cooling medium in reducing hot spot temperatures in
the coils. In addition, liquidfilled units have a better overload capability.
There are some drawbacks, however. For example, fire prevention is more important with liquidtype
units because of the use of a liquid cooling medium that may catch fire. (Drytype transformers can
catch fire, too.) It's even possible for an improperly protected wettype transformer to explode. And,
depending on the application, liquidfilled transformers may require a containment trough for
protection against possible leaks of the fluid.
23
Arguably, when choosing transformers, the changeover point between drytypes and wettypes is
between 500kVA to about 2.5MVA, with drytypes used for the lower ratings and wettypes for the
higher ratings. Important factors when choosing what type to use include where the transformer will
be installed, such as inside an office building or outside, servicing an industrial load. Drytype
transformers with ratings exceeding 5MVA are available, but the vast majority of the highercapacity
transformers are liquidfilled. For outdoor applications, wettype transformers are the predominate
choice. The flowing table 4.2 shows losses in dry type and oil filled type transformers.
Table 42: Comparison of Losses – Oil type and dry type
(Oil Transformer) Losses Dry Type Transformer Losses
KVA Half Load (w) Full Load (w) KVA Half Load (w) Full Load (w)
500 2465 4930 500 5000 10000
750 3950 7900 750 7500 15000
1000 4360 8720 1000 8200 16400
1500 6940 13880 1500 11250 22500
2000 8155 16310 2000 13200 26400
24
5. ECONOMIC ANALYSIS
1.1 Introduction
For any investment decision, the cost of capital has to be weighed against the cost/benefits accrued.
Benefits may be in cash or kind, tangible or intangible and immediate or deferred. The benefits will have to
be converted into their equivalent money value and deferred benefits have to be converted into their
present worth in money value for a proper evaluation. Similarly, future expenses have to be accounted for.
The cost of capital is reckoned as the rate of interest where as the purchasing power of the currency
measured against commodities determines the relative value of money in a given economic domain. The
deferred monetary gains/expenses are expressed in terms of their present worth (PW). If Rs 90.91 is
invested at an annual interest of 10%, it will yield 90.91x (1+10/100) = Rs 100/ at the end of one year.
Hence the present worth of Rs 100 after one year is Rs 90.91/ , if the annual rate of interest is 10%.
PW =
( ) ( )
( )
n
n
i i
i
+
− +
1
1 1
where PW is present worth of future cash flows
i = per unit interest rate
n = number of years
Purchase of a transformer involves first cost and subsequent payment of energy charges during a given
period. The effective first cost or the total ownership cost can be had by adding the present worth of future
energy charges. The TOC
EFC
i.e. Total Ownership Cost Effective First Cost adds an appropriate amount to
account for energy expenses and shows a better measure of comparing an equipment with higher first
cost, but having a higher efficiency and thus lower running charges.
The concept of evaluation can be applied to transformers with the assumptions that the annual losses and
the load level remain steady at an equivalent annual value, the tariff is constant and the rates of inflation
and interest are constant. These assumptions have obvious limitations, but the TOC
EFC
concept is widely
used method for evaluation. The period of ‘n’ years may be 10 to 15 years. The longer the period, greater
the uncertainty. Generally, ‘n’ will be roughly equal to the economic life of the equipment governed by the
technical obsolescence, physical life and perceptions of return of capital of the agency making the
investment decision.
5.2 Total Ownership cost of transformers
TOC
EFC
= Purchase Price + Cost of No load loss + Cost of Load loss
Cost of Core loss
EFC
= A X No load loss in Watts
Cost of Load loss
EFC
= B X Load loss in Watts
Where A = Equivalent first cost of No load losses, Rs/Watt
=
1000
HPY EL PW × ×
PW = Present worth, explained in previous section 5.1
EL = Cost of electricity, Rs/ kWh, to the owner of the transformer
HPY = Hours of operation per year
B = Equivalent first cost of load losses
= T p A × ×
2
p = Per Unit load on transformer
T = Temperature correction factor, details of calculation given in section 3.1.1.
For some typical operating values, let us calculate the TOC
EFC
for a 1000 kVA , 11 kV/433 V transformer
having no load losses of 1500 Watts and load losses of 10000 Watts ( at full load).
25
Purchase price = Rs 8,00,000
Life of equipment, n = 15 years
Inflation rate, a = 4.5%
Interest rate (discounting factor), i = 10%
EL = Cost of Electricity = Rs 4.0 per kWh
HPY = Hours per Year = 8000
Per unit transformer loading (average) = 0.75
Operating temperature = 100 ºC
PW = Present Worth =
( ) ( )
( )
n
n
i i
i
+
− +
1
1 1
=
( ) ( )
( )
15
15
1 . 0 1 1 . 0
1 1 . 0 1
+
− +
= 7.61
Equivalent first cost of No load losses A =
1000
HPY EL PW × ×
=
1000
8000 4 61 . 7 × ×
= 243.52 Rs/Watt
If operating temperature is 100 ºC,
75 234.5
100 234.5
f R
R
re T
op T
+
+
=
−
−
= 1.0808
Hence Temperature correction factor, T = 0.9 x 1.0808 +0.1/1.0808 = 1.06523
Equivalent first cost of load losses
B = T p A × ×
2
= 06523 . 1 75 . 0 52 . 243
2
× ×
= 145. 9152 Rs/Watt
TOC
EFC
= 800000 + 243.52 x 1500 + 145.9152 x 10000
= Rs 2624432/
5.3 Decisions for changeover to new equipment
In this case there is an added cost of the existing working equipment. The value left in a working equipment
can be evaluated either by its technical worth, taking its left over life into consideration or by the economic
evaluation by its depreciated value as per convenience. For transformers, the prediction of life is very
difficult due to varying operating parameters. Moreover, for any equipment, there is a salvage value, which
can be taken as equivalent immediate returns.
Thus TOC
EFC
= (Present depreciated effective cost of old equipment – Salvage value) + A X No load loss +
B X Load loss
5.4 Sample Calculations
Total Owning Cost of a 1000 kVA Transformer Using Noload and Load Losses and present worth is
estimated below. The calculations for a standard transformer are done in previous section 5.2. Let us
now compare a high efficiency 1000 kVA transformer with the standard transformer. Table 5.1
summarises purchase price and losses of two transformers of same rating 1000 kVA.
Table 51: Comparison of transformers
Standard Transformer HighEfficiency Transformer
Purchase price – Rs 8,00,000
Noload losses  1500 W
Load losses at 100%  10000 W
Load loss at 75%  6234 W
Rs 9,50,000
1210 W
7964 W
4215 W
26
Total Owning Cost of Transformer #1 (standard efficiency)
= Rs 2624432/ as estimated in section 5.2.
Total Owning Cost of transformer #2 (high efficiency):
A = Rs 243.52 / year
B = Rs 145.9152 / year
Total Owning Cost of HighEfficiency transformer
= Rs 9,50,000 + Rs 243.52 x 1210 + Rs 145.9152 x 4215
= Rs 18,69,592
Present Value of Savings with Energy Efficient transformer = Rs 2624432  Rs 18,69,592
= Rs 7,54,840/
Note that a high efficiency transformer is having much less Total Owning Cost compared to a standards
efficiency transformer in spite of higher investment.
27
6 CASE STUDIES
6.1 Introduction
There are nine case studies presented in this chapter. Three case studies are from Indian
industries and six case studies from international scenario.
The case studies from KEMA, Netherlands assume full details of No Load Loss and Load Loss as
well as portion of Eddy Losses in Load Loss as being available from transformer manufacturer or
from relevant standard. No tests are conducted at site.
The harmonic content of the load is given for each typical application. The applicability of Low
Loss designs in each rating is analysed and payback period is found out. The case studies also
give the energy saving gains in terms of reduction in carbon dioxide (Co2) emission. The likely
penalty/gain per Ton of Co2 in monetary terms is taken as 0.3 kg/kWh to 0.6 kg/kWh with a cost
ranging from Euro 10 to Euro 33/ ton. This gives a monetary factor of 0.003 Euro/ kWh to 0.02
Euro/kWh. The energy price is taken as 0.04 Euro/kWh. Thus CO
2
cost can be 15 % to 50 % of
Energy cost. This factor however is not applicable for payback and it is thus not considered for
payback in the tables presented.
The payback is considered for extra price to be paid for the low loss transformer and it is around 2
to 3 years. The Load Loss figures given in the tables give the Load Losses considering the
harmonics in the load. In the first case study, the factor for enhanced eddy losses in the first load
loss is shown for illustration only for illustrating rough order of values. All studies are presented in
the year 2002.
6.2 Case Study 1
The case study considers a large company in the Iron and Steel sector. The average loading is
400 MW out of which about 60 MW is through H.T. utilization by H.T. Motors. The remaining 340
MW is through distribution transformers. Load is constant during 24 hours a day, 7 days a week.
Transformer ratings vary from 800 kVA to 4800 kVA. There are about 400 Transformers. About
200 Nos. are of 1250 kVA and about 100 Nos. of 1600 kVA while the remaining 100 Numbers are
of different ratings. Most of the transformers are replaced between 1982 to 1990. Almost all the
transformers are of Dry Type due to problems faced in the earlier oil cooled transformers.
The company follows the total ownership cost (TOC) concept and has used A and B figures of EUR
2.27/W for no load losses and EUR 1.63/W for load losses.
The comparative figures are given for 1250 kVA transformers.
Table 61input data 1250 kV transformer
Transformer load 65% (constant load, 24/24h) with 6 pulse harmonics
Economic lifetime 10 years
Interest rate 7%
Energy price EUR 40/MWh
Harmonic spectrum 1 3 5 7 9 11 13 15 17 19 21 23 25
% 100 0 29 11 0 6 5 0 3 3 0 2 2
A (noload loss
evaluation)
EUR 2,46 /W
B (load loss evaluation) EUR 1,04 /W
Illustrative Calculations
Inflation is not considered and hence the present worth expression is simplified using a = zero.
28
Present worth =
( )
( )
n
n
i 1 i
1 i 1
+
− +
Interest Rate 7 % i.e. 0.07 per unit. Period is 10 years
( )
( )
7.0236
1.07 0.07
1 0.07 1
P
10
10
w
=
− +
=
EL = 0.04 EUR/kWh
tt EUR2.46/Wa
1000
8760 EL Pw
A =
× ×
=
B = A x P
2
x T,
P = 65 %, i.e. 0.65,
T = 1
B = 2.46 x 0.65 x 0.65 = 1.039
= EUR 1.04/watt
6.2.1 Factor for Harmonics
Factor for eddy losses ( )
∑
=
=
× =
n h
h
h
h
I
I
1
2
2
1
If harmonics are absent, this factor is one; the tested load losses have eddy losses at
fundamental. If data from design is available for percentage of eddy loss at fundamental, it should
be used in the calculation. In the absence of specific data, copper losses due to I
2
R can be taken
as 90 % and 10% of the specified Load Losses can be attributed to eddy losses at fundamental
frequency.
Thus Load Losses at fundamental frequency = Load Losses x [p.u. loading]
2
x [0.9 + (0.1) x 1]
The Extra addition is over and above eddy losses due to fundamental frequency and hence extra
harmonic factor
( )
∑
=
=
− × =
n h
h
h
h
I
Ih
K
1
2
2
1
1
Or ( )
∑
=
=
× =
n h
h
h
h
I
Ih
K
3
2
2
1
For the given six pulse harmonics, the fifth has 29% value of the fundamental.
Hence ( ) 5 5 29 0
2
5
× × = . K = 2.1025
( ) ( ) ( ) ( ) ( )
( ) ( ) ( ) 625 02 . 0 529 02 . 0 361 03 . 0
287 03 . 0 169 05 . 0 121 06 . 0 49 11 . 0 25 29 . 0
2 2 2
2 2 2 2 2
× + × + × +
× + × + × + × + × =
h
K
25 . 0 2116 . 0 3249 . 0 2601 . 0 4225 . 0 4356 . 0 5929 . 0 1025 . 2 + + + + + + + = 6001 . 4 =
Total eddy loss factor = 4.6001 + 1 = 5.6
29
6.2.2 Percentage of Eddy Losses in Load Losses:
The next step is to evaluate full load losses with harmonic loading for the given transformer and
also for the relatively low loss transformer of similar rating being considered for replacement. This
requires data on percentage of Eddy Losses in conductors in the total Load Losses for the
existing transformer and the nearest low loss substitute. For 1250 kVA rating, the existing and
new low loss design have following data for the subdivision of eddy losses, the figures are
inferred from the final load loss figures given in the KEMA publication.
Existing 1250 kVA Low Loss 1250 kVA
No Load 2400 W 2200 W
Rated Load Loss 9500 W 8200 W
Assumed % Copper Losses 90.69% 90.69%
Assumed % Eddy Losses 9.31 % 9.31%
6.2.3 Full load losses for Harmonic Loading:
Existing Transformer:
Full load losses on Harmonic Load = Rated load losses on linear loads x [p.u. Copper + K (p.u.
Eddy loss)]
= ( ) 093 . 0 6 . 5 9069 . 0 9500 × + ×
= 42826 . 1 9500×
= 47 . 13568 Or 13568 Watts
For Suggested Low Losses transformer
Full load losses = 8200 x 1.42826 = 11711.73 or 11712 watts.
It can be noted that inferred distribution is very close to assumed distribution of 90% and 10%.
This is not always true as can be seen from tables given in the annexure.
For 1600 kVA transformer, the distribution works out to 88.68% copper losses and 11.32% for
eddy losses. For similar harmonic load factor of 5.6 the multiplier comes to 1.5207. Thus rated full
load loss (Linear) of 10000 w yields a figure of 10000 x 1.5207 = 15207 w. The low loss substitute
has full load loss (linear) = 9500 x 1.5207 = 14447 w
The actual figure stated is 14218 w. Thus a slightly different distribution is considered for the low
loss substitute. The method thus illustrates the steps to calculate full load loss (harmonic loads) if
the distribution is known. If design data is not available, 90% and 10% subdivision can give a
reasonable value.
Incidentally it shows that due to harmonic loads the full load losses have gone up by 42% in 1250
kVA, and 52% in 1600 kVA transformer.
The needed derating would be ( ) 839 . 0
42 . 1
1
= and ( ) 811 . 0
52 . 1
1
=
For 1250 kVA and 1600 kVA respectively for harmonic loading. The actual loading is only 65% and
hence all alternatives considered are safe from the view point of temperature rise.
6.2.4 Relative economics for low loss transformers (All Dry type)
The data worked out for 1250 kVA and 1600 kVA are given in Table 6.2 and Table 6.3.
30
Table 62 1250 kVA transformer
Unit Dry
transformer
Dry transformer,
low losses
Difference
Transformer rating kVA 1250 1250
Rated noload loss W 2400 2200 200
Rated load loss W 13568 11712 1856
Total annual losses kWh/a 71241
62618
8623
CO
2
emission @ 0,4
kg/kWh ton/a
28,5 25,0 3,5
Purchase price EUR 12250 13000 750
Present value noload loss EUR 5907 5414 493
Present value load loss EUR 14108 12178 1930
Capitalised costs EUR 32265 30592 1673
Pay back (years) 2,2
Internal rate of return 45%
Table 63 1600 kVA transformer
Unit Dry
transformer
Dry transformer, low
losses
Difference
Transformer rating kVA 1600 1600
Rated noload loss W 2800 2670 130
Rated load loss W 15207 14218 989
Total annual losses kWh/a 80809
76012
4797
CO
2
emission @ 0,4
kg/kWh ton/a
32,3 30,4 1,9
Purchase price EUR 14451 14990 539
Present value noload
loss
EUR 6891 6571 320
Present value load loss EUR 15812 14784 1028
Capitalised costs EUR 37154 36345 809
Pay Back (years) 2,8
Internal rate of return 34%
Comments:
The figures for 1250 kVA, existing transformer are illustrated first.
Rated No Load Loss = 2400 w = 2.4 kW
Rated load loss = 13568 W = 13.568 kW (full load)
Annual losses for 65% loading for 8760 hours = 2.4 x 8760 + 13.568 x 0.65 x 0.65 x 8760 kWh
= 21024 + 50216.5
= 71240.5 = 71241 kWh/annum.
Carbon Dioxide emission at 0.4 kg/kWh = 71241 x 0.4
= 28496 kg
= 28.5 Tons/annum
Purchase Price is given as EUR 12250 (About Rs.673750)
Present value of no load losses 2.46 x 2400 = 5904
Present value of Load Loss = 13568 x 1.04 = EUR 14110
Total Capitalised Cost = EUR 32265
A similar figure for low loss transformer is EUR 30592
31
This figure favours the low loss type with an initial purchase price of EUR 13000 which is EUR
750 of added investment.
Payback for extra investment of EUR 750:
The low loss transformer consumes 62618 kWh/annum, saving thereby 8623 kWh/annum.
Thus the annual saving = EUR 0.04 x 8623
= EUR 345
Simple payback = 17 . 2
345
750
= or 2.2 years. (For about 6.12 % Extra Investment)
Internal Rate of Return = 45
2 . 2
100
= %about.
A similar calculation for 1600 kVA shows a saving of 4797 kWh and a payback of 2.8 years for an
added investment of EUR 539 (about 3.73 % extra cost). IRR 34 %.
6.2.5 Summary:
1. Due to somewhat higher load loss figures used for TOC during initial purchase, higher
investments have been preferred. Hence it is not very attractive to replace existing
transformers by scrapping.
2. If a transformer is to be replaced for any reason, the low loss substitutes show an attractive
payback of 2.2 to 2.8 years.
The total saving potential of 2939 MWh/year is equivalent to EUR 117564/year and is 0.084% of
the total consumption of 3.5 x 10
6
MWh/year.
6.3 Case Study2: Non ferrous metal sector
In a large company in the non ferrous metal sector, the total loading is about 190 MW. But almost 180
MW are consumed through dedicated high voltage transformers for electrolysis. The scope for
distribution transformers is limited is only to 10 MW. Out of it, the load variation is about 45% during 10
hours, 35% during 14 hours.
Total number of transformers is 25, wherein a good number is at 1000 kVA. Excepting 3 new dry type
installed in 1999, most of the transformers are old (1965 to 1970). The loss pattern is
No load = 1900 Watts
Load loss = 10250 Watts
Calculations for1000 kVA old transformer with the loading pattern and 5 years of life with 7% interest
rate gives the A factor = EUR 1.44/watt
And B factor = EUR 0.24/Watt. Harmonics are not considered.
Since the loading is low, giving a very low B factor, direct replacement is not economically viable. Table
6.4 summarises the data for dry transformers and oil cooled transformers for future replacement.
32
Table 64 : Outcome 1000 kVA transformer
Unit Dry HD 538
transformer
Oil CC’
transformer
Difference
Transformer rating kVA 1000 1000
Rated noload loss W 2000 1100 900
Rated load loss W 8600 9500 900
Total annual losses kWh/a 30336
23793
6543
CO
2
emission @ 0,4
kg/kWh ton/a
12,1 9,5 2,6
Purchase price EUR 10074 8007 2067
Present value noload
loss
EUR 2873 1580 1293
Present value load loss EUR 2102 2322 220
Capitalised costs EUR 15049 11909 3140
Pay back (years) N/A
Internal rate of return N/A
In this case, the oil transformer has a lower first cost and also lower losses. Hence it is the most favored
choice and the rate of return is not applicable; since the low loss transformer also happens to have a
lower first cost.
Table 6.5 summarise the overall potential for the saving. This is equal to EUR 6560 and 0.0099% of the
total electricity charges because only a small fraction of the total load is qualifying for calculation of
savings.
Table 65: Annual savings potential
Transformer
size
Total
number
Energy saving
[MWh]
CO
2
emission saving
[tonnes]
1000 kVA 12 78,5 31,2
Other 13 85,1 33,8
Total 25 164 65
6.4 Case Study3: Paper & Pulp Company
A paper mill started functioning since 1978 and was expanded in 1986, the peak electrical loading is
about 110 MW, out of which 72 MW are used at high voltage for HT motors. The remaining is
distributed with 52 transformers with ratings of 1000 kVA and 3150 kVA. The dominant number (28) is
3150 kVA transformers with LV of 690 Volts. Average loading is 65%. The highlight of the case study is
that in 1986, the company took special care to select transformers with low losses for long term gains.
These transformers are better compared to the low loss transformers available today.
The case is presented for 3150 kVA transformer for which the input data is given in table 6.6
Table 66: Input data of 3150 kVA transformer
Transformer size 3150 kVA oiltype
Transformer load 65% during 24/24 hours with 6
pulse harmonics
Economic lifetime 20 years
Interest rate 7%
Energy price EUR 40/MWh
Harmonic spectrum
6 pulse according to IEC 14611
A (noload loss evaluation) EUR 3,71 /W
B (load loss evaluation) EUR 1,57 /W
33
The comparison of the 1986 low loss transformer is made with the original supply of 1978 based on the
likely prices as prevalent in 2002.
The results are shown in table 6.7. It is seen that even though 1986 transformer is about 30% more
expensive, it still gives large savings with an internal rate of return of 33 % and a payback period for
extra investment of 3 years.
Table 67 Outcome of 3150 kVA transformer
Unit Oil 1978
transformer
Oil 1986
Transformer
Difference
Transformer rating kVA 3150 3150
Rated noload loss W 2870 3150 280
Rated load loss W 24500 16800 7700
Total annual losses kWh/a 181908
135092
46816
CO
2
emission @ 0,4 kg/kWh
ton/a
72,8 54,0 18,8
Purchase price EUR 19329 24987 5658
Present value noload loss EUR 10654 11693 1039
Present value load loss EUR 66432 45553 20879
Capitalised costs EUR 96415 82233 14182
Pay back (years) 3,0
Internal rate of return 33%
It is estimated that the company is already saving 46816 kWh/year due to these transformers.
6.5 Case Study4 Chemical Industry
In the KEMA studies, it is observed that; despite variations in the processes, common trends are
observed regarding electrical installations. High reliability requirements lead to redundancy in
transformer installations and a low average loading of about 40%. Based on the general observations, a
fictitious but representative case study is prepared.
Average loading is 110 MW, out of which 40 MW are for electrolysis or H.V. motors and thus out of the
purview. Loading is continuous round the clock and loads are nonlinear. A typical rating is 1250 KVA
(60 out of 71 transformers). The remaining transformers are 630, 1000 and 1600 KVA.
The study compares 1250 KVA HD538 transformer and 1250 KVA low loss transformer. Life time is
considered 5 years and harmonics are not considered. Interest rate is taken as 7%. Energy price EUR
50/MWH. A= EUR 1.8/W and B= EUR 0.29/W (40% loading ).
Highlights: For the chosen parameters, the differences are marginal. The extra cost of Low Loss type is
EUR 750 over EUR 12250, and payback is 4.2 years with a rate of return of 6%. This is a case where
the chosen parameters of lifetime, harmonics etc. can significantly affect the decision. If the Low Loss
type is chosen, the potential savings can be 214.4 MWH/yr. Which can also mean savings in CO
2
emission of 85.8 Ton.
6.6 Case Study 5 Case of a Large Data Hotel Start Up
This is a high growth rate business with computers as a major load. The startup load connection is
typically 100 MW in the growth expectation of 200% to 300% rise per year for a few years. The
economic life time is considered as only one year and interest 7%. Figures assumed are 25% initial 24
Hrs. loading which reaches 70% at the end of one year. Energy at EUR 60/MWH, high harmonic
loading, A = EUR 0.52/W initial and also the same value for no load losses. B = EUR 0.03/W initial and
0.24/W at the end of the year.
Highlights: The study shows that due to selection of one year as economic life, the preference is clearly
in favour of lowest first cost. It is revealed that compared to 1600 KVA Dry type normal and 1600 KVA
34
low loss Dry type, the cheapest would be an oil cooled CC’ type transformer. The capitalised costs with
harmonics are EUR 16714, and 17132 (low loss) respectively initially. At the end of one year the figures
are EUR 22311 and 22366. Thus the low loss transformer is still not attractive. There is a net saving of
8222 KWH/year after one year which equals about EUR 411. The extra price of EUR 539 can not be
recovered in the economic life prescribed. The oil cooled transformer is a winner in the short run, with a
capitalised cost for initial period as EUR 12951 including harmonics.
Even for this transformer, higher operating temperature due to harmonics suggests a drastic decrease
in operating life from 30 years to 6 years. Even then the selected short economic life span makes this
choice viable, provided the hot spot temperature is acceptable. By the same consideration a smaller
rating 1000 KVA transformer gives a capital saving of 25% even though it has an energy penalty.
It is important to note that the payback period is not affected by the choice of economic life span, but the
relatively longer payback loses its significance due to short time investment perception. In such a case,
enforcing minimum loss norms only can help. Alternatively the investment in the transformer can be
made by the utility with a long term perception to make energy saving possible. The utility can shift the
transformer later to a suitable load as needed.
6.7 Summary of European Case Studies:
There is an interesting summary of the sensitivity of the payback period to input parameters. Table 6.8
gives a summary of effect of Low, Medium and High values of parameters on the payback period.
Loading and electricity price are two most important factors. Loading should be carefully evaluated for a
proper choice.
Table 68: Parameter sensitivity on the payback period
Parameter Parameter variation Payback time (years)
Unit L M H L M H
Harmonic spectrum None 12 pulse 6 pulse 3,3 3,1 2,7
Electricity price EUR/MWh 40 60 80 4,5 3,1 2,4
CO2 emissions kg/kWh 0,3 0,4 0,6 3,2 3,1 3,0
CO2 costs EUR/tonne 0 10 33 3,3 3,1 2,7
Loading profile % 20 40 60 5,2 3,1 1,9
Economic lifetime years 1 5 10 3,1 3,1 3,1
Interest % 5 7 9 3,1 3,1 3,1
Purchase price % 80 100 120 2,5 3,1 3,7
6.8 Case Study 6: Tea Industry (India)
Energy Audit for Tea Factories making C.T.C. Tea, managed by H/S C.W.S (India) Ltd., District
Coimbatore. Audit was conducted in May 1990 for Mayura and Parlai Tea factories. Power is
received at 22 kV and 11 kV by separate lines. This is stepped down by two 500 kVA
Transformer o 22 kV/433 V an 11 kV/433 V which fee segregated loads.
The typical loss figures for 500 kVA transformers are 1660 W for no load and 6900 W as load
losses for 100% load.
Recommendation: Parallel both transformers for a total 500 kVA load on secondary side and in
lean season and holidays when the load is 5% to below 25%, cut off one transformer on H.V. and
H.V. sides.
Brief Analysis:
For total load of 500 kVA, there are three options.
a) Only one transformer takes full 500 KVA LOAD.
Losses = 1.66 (No Load) + (500/500)
2
x 6.9 kW (load losses)
35
b) One transformer takes segregated 300 kVA while second takes 200 kVA segregated load.
Loss = 1.66 + (300/500)
2
x6.9 +1.66 + (200/500)
2
x 6.9 kW
c) Both are paralleled to take 250 kVA each.
Loss = 2 (1.66 + (250/500)
2
x 6.9) kW = 6.77 kW.
Thus on major load, the losses are minimum by paralleling both transformers.
Operation at higher loads during lean season:
a) Two paralleled transformers
Losses = 2 [1. 66 + (0.25/2)
2
x 6.9} kW = 3.54 kW at 25% load
Losses = 2 {(1.66) + (0.05/2)
2
x 6.9} kW = 3.33 kW at 5% load
b) Only one transformer is energized
Losses = 1.66 x (0.25)
2
x 6.9 = 2.09 kW at 25% load
Losses = 1.66 x (0.05)
2
x 6.9 = 1.68 kW at 5% load
Thus losses are minimum at low loads using only one transformer. The tariff was kVA of M.D. x
Rs. 60 + Rs. 0.89 x kWh + Rs. 150 meter rent.
The total annual consumption for the factory was 1856479 kWh per year and the electricity bill
was Rs. 2038694 giving Rs. 1.0094/kWh as average cost.
The saving by paralleling and switching off one transformer were conservatively estimated at a
minimum of 10000 kWh/year with no investment giving a little over Rs. 10000/year as a saving.
Power factor improvement was already made but some scope for further improvement was
suggested. This would reduce M.D. and save on M.D. charges and also give savings on
transformer and cable losses.
6.9 Case Study 7: Steel Mill (India)
INTESCOBhoruka has implemented an energy efficiency project at Bhoruka Steel's Karnataka
minimill. The project is designed to reduce energy costs, and increase plant productivity. The
company's energy costs have increased due to power shortages and low voltage levels causing
inefficient operation of its melting and casting operations. The $265,000 project involves the
installation of a highlyefficient 25 MVA transformer to replace two older and smaller transformers.
Energy consumption profile:
Energy use at the plant is comprised of consumption at the steel melting shop, the wire rod mill,
and inherent transformer losses. The steel melting shop has a 30ton GEC electric arc furnace.
When power quality is good, specific energy consumption averages between 550 kWh and 650
kWh per ton. With poor power quality, consumption can increase up to 700 kWh for the same
product mix. By improving the voltage quality under this project, it was expected that specific
consumption would be reduced by 3035 kWh per ton.
The wire rod mill produces wire rods from 5 mm to 16 mm in diameter. The average specific
energy consumption during good voltage conditions is about 200 kWh per ton. As the drive
systems at the mill already have inbuilt automatic voltage regulators, there was not expected to
be any substantial reduction in energy usage as a result of the project.
Energy saving measure
Prior to the energy efficiency project, the power from the grid was being tapped through two12.5
MVA, 66/11KV transformers. Each transformer had a load loss factor of 1012 kWh per ton, for a
36
total of 2025 kWh per ton. Installation of the new transformer was expected to slash load loss by
half (to a total of 1012 kWh per ton).
In sum, the total savings per ton of steel produced was expected to reach 40 units per ton, with
the majority coming from the savings in the steel melting shop (75% of the savings).
Project Savings (in kWh per Ton of Steel Produced)
Steel Melting Shop 30
Wire Rod Mill 0
Transformer Losses 10
Total 40
Project Implementation
In order to solve the voltage problem, it was proposed to replace the two 12.5 MVA transformers
with a single 66/11 KV 25 MVA transformer fitted with an onload tap changer. The new 25 MVA
transformer can handle large fluctuations in incoming voltage, resulting in energy savings.
These changes would reduce load losses and reduce energy consumption during production.
The new 25 MVA transformer installed by INTESCO Bhoruka was expected to reduce energy
consumption per unit of steel produced by as much as 8%. Construction of the project began in
May 1994, and was completed in September. Commissioned in October 1994, the upgraded plant
is already running eight "heats" per day, up from five per day previously. (A heat is the process of
melting steel in an arc furnace in preparation for casting.) The annual energy savings is
estimated at 1.8 million KWh.
The total cost of the project is about $265,000 (Rs. 82.6 lakhs) and the combination of improved
energy efficiency and productivity is expected to save Bhoruka Steel about $115,000 per year
(Rs. 36 lakhs). The project has a simple payback on investment of 2.3 years
6.10 Case Study8: Automobile Plant (India)
A leading automobile manufacturer has main incomer at 132 kV. This voltage is stepped down to
11 kV. From 11 kV to 433 V, plant has several transformers located in eight substations. During
an energy audit, loading on transformers located at various substations was analyzed. In few of
the cases it was observed that some transformers are grossly under loaded (around 1020%) and
the scope exists to shift or distribute this load to other transformer in the substation. This would
also ensure optimum level of loading. While achieving optimum loading, the standby transformers
at various substations were suggested to be kept open on H.T side to save noload losses. Also
an operating schedule was proposed to alternate the transformer operation weekly so as to keep
them in good health. In sub station # 1, one transformer was kept as stand by. This hot standby
transformer can be kept open (Energy savings 0.45 lakh per annum)
In sub station # 3, transformers #1 and #2 were drastically under loaded (i.e, 20% and 15%
respectively). Loads of transformer # 2 was transferred to Transformer # 1 and Transformer # 2
was switched off (Energy savings 0.37 lakh kWh/year) In sub station # 7, transformers # 2 and # 3
were drastically under loaded (i.e, 10% and 25% respectively). Loads of transformer # 2 was
transferred to Transformer # 2 and Transformer # 2 was switched off (Energy savings 0.42 lakh
kWh/year) In substation # 8, keeping hot standby transformer open, resulted in energy saving of
0.45 lakh kWh per year.
Annual Total energy savings, 1.69 lakh KWh
Annual Cost savings, Rs. 5.9 lakh
Cost of Implementation Nil
Simple payback period, Immediate
37
6.11 Case Study 9: Improving Reliability and availability
A lot of industries (e.g. chemical) are interested in a reliable power supply, as an unforeseen
interruption of the power supply may have severe consequences. First there is the economical
damage if there is a shutdown, which leads to loss of production until the process has restarted.
But also there can be damage of the installation. Next to the direct damage, long outages may
cause pollution and human safety problems.
To reduce the risks of an outage, it is possible to have two transformers in redundancy. This
means if one transformer fails, the other transformer will carry the full load, and there will be no
interruption of the power and/or shutdown of the factory.
For this case study, the economical cost when an unforeseen outage occurs is a necessary input
figure. The costs of outages are very hard to determine, for this given situation it is presumed that
outage of the electricity will cause a shutdown of the factory, whereby each hour outage is equal
to Euro 10.000,=.
The MTBF (mean time between failures) for a transformer is presumed to be 40 years. The MTTR
(mean time to repair) or time to replace a failed transformer is 8 hours. This means that the
average outage frequency equals 0,025 per year and the average outage duration equals 12
minutes per year. If there is redundancy the average outage frequency equals 1,14x10
6
per year,
while the average outage duration equals 2,7x10
4
minutes per year. This means the chance that
both parallel transformers having a failure at the same time is very small compared to the outage
of one transformer.
The choice for the designer to use one transformer (2500 kVA) or two transformers (1600 kVA)
can now be quantified. Presuming the load is 1500 kVA; the 2500 kVA transformer loading is
60%, while the loading of the 1600 kVA transformer is 47% when both transformers are in
parallel. The total annual losses for both options are given in table 6.9
Table 69: electricity losses over a year
2500 kVA Transformer Oil CC’ Oil DD’ Dry HD 538 Dry Low loss
No load kWh/yr.
21900 18615 37668 36179
Load kWh/yr. 69379 58972 56765 47083
Total kWh/yr. 91279 77587 94433 83262
2x 1600 kVA Transformer Oil CC’ Oil DD’ Dry HD 538 Dry Low loss
No load kWh/yr. 29784 25316 49056 46778
Load kWh/yr. 54182 46054 38702 36186
Total kWh/yr. 83966 71370 87758 82964
If the economic life time is estimated at 10 years, and the electricity price Euro 70,= per MWh, the
following costs are expected in these 10 years (see table 6.10).
Table 610: Costs over 10 years.
2500 kVA Transformer Oil CC’ Oil DD’ Dry HD 538 Dry Low loss
Purchase price [Euro] 24897 29402 25527 27494
Cost of no load [Euro] 15330 13030 26368 25325
Cost of load [Euro] 48565 41280 39736 32958
Cost of outage [Euro] 20000 20000 20000 20000
Total cost [Euro] 108792 103712 111631 105777
2x 1600 kVA Transformer Oil CC’ Oil DD’ Dry HD 538 Dry Low loss
Purchase price [Euro] 27340 35774 35902 38146
Cost of no load [Euro] 20849 17721 34339 32745
Cost of load [Euro] 37927 32238 27091 25330
Cost of outage [Euro] <1 <1 <1 <1
Total cost [Euro] 86117 85734 97333 96222
38
From table 6.10, it can be seen that the costs of outage are having influence on the total costs
over 10 years. If the costs of outage are neglected, the designer would probably have chosen for
a single 2500 kVA oiltransformer type DD’ or a dry transformer with lower losses than given in
the HD 428.
However if the average costs of an outage are taken in account, the designer will probably order
two 1600 kVA transformers. However, the two 1600 kVA transformers will also need an
installation more than the 2500 kVA transformer, which is not taken in account in this case study.
Nevertheless, it is clear that redundancy of transformers is preferred anyway for situations were
shutdown of a process causes pollution or safety risks.
6.12 Case study10: Use of Amorphous Core Transformers
This case study describes the choice of amorphous core distribution transformers in place of
conventional silicon steel core transformers.
A very large amorphous iron threephase distribution transformer has been built and installed in
the European Union at an engine plant at Waterford in Ireland in 1998. The 1.6MVA transformer
is the first to be designed specifically for the European industrial market. The load losses are
18.2kW, the noload losses are as low as 384W, compared to 1,700W for a HD 428 CC’
transformer. With noload losses up to 80% lower than a conventional silicon core transformer,
and the payback period is 3 years. The transformer has increased the site’s power capacity by
40%, while providing dramatically lower losses than a conventional transformer.’
At an average loading of 70%, the AMDT will use 13.3GWh less energy a year than a
conventional transformer. With a price premium of £2,500 over a standard transformer, the AMDT
should pay for itself in about three years at current Irish power prices  and continue to make
savings over its 2030year life.
The 20kV/400V transformer, completed by Pauwels International, is the first AMDT to target
European industrial customers.
39
ANNEXURE1: GUIDELINES FOR INSTALLING TRANSFORMERS
When your transformer arrives on site, various procedures should be carried out to assure
successful operation.
The successful operation of a transformer is dependent on proper installation as well as on good
design and manufacture. The instructions mentioned in the manufacturer manual or in Standards
shall be followed to ensure adequate safety to personnel and equipment.
This section will provide general guidelines for installing and testing both drytype and liquidfilled
transformers for placement into service.
Standard transformer tests performed for each unit include the following:
• Ratio, for voltage relationship;
• Polarity for single and 3phase units (because singlephase transformers are sometimes
connected in parallel and sometimes in a 3phase bank);
• Phase relationship for 3phase units (important when two or more transformers are
operated in parallel);
• Excitation current, which relates to efficiency and verifies that core design is correct;
• Noload core loss, which also relates to efficiency and correct core design;
• Resistance, for calculating winding temperature
• Impedance (via short circuit testing), which provides information needed for breaker
and/or fuse sizing and interrupting rating and for coordinating relaying schemes;
• Load loss, which again directly relates to the transformer's efficiency;
• Regulation, which determines voltage drop when load is applied; and
• Applied and induced potentials, which verify dielectric strength.
There are additional tests that may be applicable, depending upon how and where the
transformer will be used. The additional tests that can be conducted include the following:
• Impulse (where lightning and switching surges are prevalent);
• Sound (important for applications in residential and office areas and that can be used as
comparison with future sound tests to reveal any core problems);
• Temperature rise of the coils, which helps ensure that design limits will not be exceeded;
• Corona for medium voltage (MV) and highvoltage (HV) units, which helps determine if
the insulation system is functioning properly;
• Insulation resistance (megohmmeter testing), which determines dryness of insulation and
is often done after delivery to serve as a benchmark for comparison against future
readings; and
• Insulation power factor, which is done at initial installation and every few years thereafter
to help determine the aging process of the insulation.
40
Site considerations
When planning the installation, the location is selected, that complies with all safety codes yet
does not interfere with the normal movement of personnel, equipment, and material. The location
should not expose the transformer to possible damage from cranes, trucks, or moving equipment.
Preliminary inspection upon receipt of transformer
When received, a transformer should be inspected for damage during shipment. Examination
should be made before removing it from the railroad car or truck, and, if any damage is evident or
any indication of rough handling is visible, a claim should be filed with the carrier at once and the
manufacturer notified. Subsequently, covers or panels should be removed and an internal
inspection should be made for damage or displacement of parts, loose or broken connections, dirt
or foreign material, and for the presence of water or moisture. If the transformer is moved or if it is
stored before installation, this inspection should be repeated before placing the transformer in
service.
Plan for the prevention of contaminants
Develop a procedure for inventory of all tools, hardware, and any other objects used in the
inspection, assembly, and testing of the transformer. A check sheet should be used to record all
items, and verification should be made that these items have been properly accounted for upon
completion of work.
Making connections that work
The connections shall be made, between the transformer's terminals and the incoming and
outgoing conductors, carefully following the instructions given on the nameplate or on the
connection diagram. Check all of the tap jumpers for proper location and for tightness. Retighten
all cable retaining bolts after the first 30 days of service. Before working on the connections make
sure all safety precautions have been taken. Arrangements shall be made to adequately support
the incoming/outgoing connecting cables, so that there is no mechanical stress imposed on
transformer bushings and connections. Such stress could cause a bushing to crack or a
connection to fail.
Controlling sound level
All transformers, when energized, produce an audible noise. Although there are no moving parts
in a transformer, the core does generate sound. In the presence of a magnetic field, the core
laminations elongate and contract. These periodic mechanical movements create sound
vibrations with a fundamental frequency of 120 Hz and harmonics derivatives of this fundamental.
The location of a transformer relates directly to how noticeable its sound level appears. For
example, if the transformer is installed in a quiet hallway, a definite hum will be noticed. If the unit
is installed in a location it shares with other equipment such as motors, pumps, or compressors,
the transformer hum will go unnoticed. Some applications require a reduced sound level, such as
a large unit in a commercial building with people working close to it. Occasionally, the installation
of some method of sound abatement will be called for.
Make sure the transformer is grounded
Grounding is necessary to remove static charges that may accumulate and also is needed as a
protection should the transformer windings accidentally come in contact with the core or
enclosure (or tank for wet types).
Note that for MV transformers, the secondary neutral is sometimes grounded through an
impedance.
Ensure that all grounding or bonding systems meet NEC and local codes.
41
Final inspection and testing
Once the transformer has been located on its permanent site, a thorough final inspection should
be made before any assembly is accomplished and the unit is energized. Before energizing the
unit, it's very important that all personnel installing the transformer are alerted, that lethal voltages
will be present inside the transformer enclosure as well as at all connection points. The
installation of conductors should be performed only by personnel qualified and experienced in
highvoltage equipment. Personnel should be instructed that should any service work be required
to the unit, the lines that power the transformer must be opened and appropriate safety locks and
tags applied.
A careful examination should be made to ensure that all electrical connections have been
properly carried out and that the correct ratio exists between the low and highvoltage windings.
For this test, apply a lowvoltage (240V or 480V) to the highvoltage winding and measure the
output at the lowvoltage winding. However, for lowvoltage (600V and below) transformers, this is
not practical. Here, a transformer turns ratio indicator should be used to measure the ratio.
Any control circuits, if any, should be checked to make sure they function correctly. These include
the operation of fans, motors, thermal relays, and other auxiliary devices. Correct fan rotation
should be visually verified as well as by checking indicator lights if they are installed. Also, a one
minute, 1200V insulation resistance test of the control circuits shall be done. (If the power
transformer has CT circuits, they should be closed.)
All windings should be checked for continuity. An insulation resistance test shall be carried out to
make certain that no windings are grounded.
Applying the load
Before energizing a 3phase transformer, arrangement for monitoring the voltages and currents
on the lowvoltage side shall be done. Then, without connecting the load, energize the
transformer. The magnitude of the voltages shown (linetoground and linetoline) should be very
similar. If this is not the case, deenergize the transformer and contact the manufacturer before
proceeding further.
Next, connect the load and energize the transformer. While monitoring the voltages and currents,
gradually increase the load in a stepped or gradual application until full load is reached. Both the
voltages and currents should change in a similar fashion. If this does not happen, deenergize the
transformer and contact the manufacturer.
The maximum continuous load a transformer can handle is indicated on its nameplate.
Adjustment for correct tap setting
After installation, check the output voltage of the transformer. This should be done at some safe
access point near or at the load. Never attempt to check the output voltage at the transformer.
Dangerous high voltage will be present within the transformer enclosure.
When changing taps, the same changes must be made for all phases. Consult the transformer
diagrammatic nameplate for information on what tap must be used to correct for extra high or
extra low incoming line voltage. The same adjustment should be made to compensate for voltage
drop in the output due to long cable runs. When the loadside voltage is low, tap connections
below 100% of line voltage must be used to raise the load voltage. If the loadside voltage is high,
tap connections above 100% of line voltage must be used to lower the load voltage.
42
ANNEXURE2: MAINTENANCE GUIDELINES
Following specific checking and maintenance guidelines as well as conducting routine inspections will
help ensure the prolonged life and increased reliability of a drytype transformer.
The frequency of periodic checks will depend on the degree of atmospheric contamination and
the type of load applied to the transformer.
Routine checks and resultant maintenance
Sl
No
Inspection
Frequency
Items to be inspected Inspection Notes Action required if
inspection shows
unsatisfactory
conditions
1.01 Hourly Ambient Temperature  
1.02 Hourly Oil & Winding
Temperature
Check that
temperature rise is
reasonable
Shutdown the
transformer and
investigate if either is
persistently higher than
normal
1.03 Hourly Load (Amperes) and
Voltage
Check against rated
figures
Shutdown the
transformer and
investigate if either is
persistently higher than
normal
2.01 Daily Oil level in transformer Check against
transformer oil level
If low, top up with dry
oil examine
transformer for leaks
2.02 Daily Oil level in bushing  
2.03 Daily Leakage of water into
cooler
 
2.04 Daily Relief diaphragm  Replace if cracked or
broken
2.05 Daily Dehydrating breather Check that air
passages are free.
Check colour of
active agent
If silica gel is pink,
change by spare
charge. The old charge
may be reactivated for
use again.
3.01 Quarterly Bushing Examine for cracks
and dirt deposits
Clean or replace
3.02 Quarterly Oil in transformer Check for dielectric
strength & water
content
Take suitable action
3.03 Quarterly Cooler fan bearings,
motors and operating
mechanisms
Lubricate bearings,
check gear boxes,
examine contacts,
Replace burnt or worn
contact or other parts
43
check manual
control and
interlocks
3.04 Quarterly OLTC Check oil in OLTC
driving mechanism

4.01 Yearly Oil in transformer Check for acidity and
sludge
Filter or replace
4.02 Yearly Oil filled bushing Test oil Filter or replace
4.03 Yearly Gasket Joints  Tighten the bolts
evenly to avoib uneven
pressure
4.04 Yearly Cable boxes Check for sealing
arrangements for
filling holes.
Replace gasket, if
leaking
4.05 Yearly Surge Diverter and gaps Examine for cracks
and dirt deposits
Clean or replace
4.06 Yearly Relays, alarms & control
circuits
Examine relays and
alarm contacts, their
operation, fuses etc.
Test relays
Clean the components
and replace contacts &
fuses, if required.
4.07 Yearly Earth resistance  Take suitable action, if
earth resistance is high
IR testing:
The transformer should be deenergized and electrically isolated with all terminals of each
winding shorted together. The windings not being tested should be grounded. The megohmmeter
should be applied between each winding and ground (high voltage to ground and low voltage to
ground) and between each set of windings (high voltage to low voltage). The megohm values
along with the description of the instrument, voltage level, humidity, and temperature should be
recorded for future reference.
The minimum megaohm value for a winding should be 200 times the rated voltage of the winding
divided by 1000. For example, a winding rated at 13.2kV would have a minimum acceptable value
of 2640 megaohms ([13,200V x 200] / 1000). If previously recorded readings taken under similar
conditions are more than 50% higher, the transformer should be thoroughly inspected, with
acceptance tests performed before reenergizing.
Turns ratio testing:
The transformer turn ratio is the number of turns in the high voltage winding divided by the
number of turns in the low voltage winding. This ratio is also equal to the rated phase voltage of
the high voltage winding being measured divided by the rated phase voltage of the low voltage
winding being measured.
Transformer turns ratio measurements are best made with specialized instruments that include
detailed connection and operating instructions. The measured turns ratio should be within 0.5% of
the calculated turns ratio. Ratios outside this limit may be the result of winding damage, which has
shorted or opened some winding turns.
Insulation PF testing:
Insulation PF is the ratio of the power dissipated in the resistive component of the insulation
system, when tested under an applied AC voltage, divided by the total AC power dissipated. A
44
perfect insulation would have no resistive current and the PF would be zero. As insulation PF
increases, the concern for the integrity of the insulation does also. The PF of insulation systems of
different vintages and manufacturers of transformers varies over a wide range (from under 1% to
as high as 20%). As such, it's important that you establish a historic record for each transformer
and use good judgment in analyzing the data for significant variations.
Acceptance testing
Acceptance tests are those tests made at the time of installation of the unit or following a service
interruption to demonstrate the serviceability of the transformer. This testing also applies to dry
type units. The acceptance tests should include IR testing, insulation PF measurement, and turns
ratio testing, all as described under periodic tests. In addition, winding resistance measurements
should be made and excitation current testing done.
Winding resistance measurement:
Accurate measurement of the resistance between winding terminals can give an indication of
winding damage, which can cause changes to some or all of the winding conductors. Such
damage might result from a transient winding fault that cleared; localized overheating that opened
some of the strands of a multistrand winding conductor; or short circuiting of some of the winding
conductors.
Sometimes, conductor strands will burn open like a fuse, decreasing the conductor cross section
and resulting in an increase in resistance. Occasionally, there may be turntoturn shorts causing
a current bypass in part of the winding; this usually results in a decrease of resistance.
To conduct this test, the transformer is deenergized and disconnected from all external circuit
connections. A sensitive bridge or microohmmeter capable of measuring in the microohm range
(for the secondary winding) and up to 20 ohms (for the primary winding) must be used. These
values may be compared with original test data corrected for temperature variations between the
factory values and the field measurement or they may be compared with prior maintenance
measurements. On any single test, the measured values for each phase on a 3phase
transformer should be within 5% of the other phases.
Excitation current measurement:
The excitation current is the amperage drawn by each primary coil, with a voltage applied to the
input terminals of the primary and the secondary or output terminals opencircuited. For this test,
the transformer is disconnected from all external circuit connections. With most transformers, the
reduced voltage applied to the primary winding coils may be from a singlephase 120V supply.
The voltage should be applied to each phase in succession, with the applied voltage and current
measured and recorded.
If there is a defect in the winding, or in the magnetic circuit that is circulating a fault current, there
will be a noticeable increase in the excitation current. There is normally a difference between the
excitation current in the primary coil on the center leg compared to that in the primary coils on the
other legs; thus, it's preferable to have established benchmark readings for comparison.
Variation in current versus prior readings should not exceed 5%. On any single test, the current
and voltage readings of the primary windings for each of the phases should be within 15% of each
other.
Applied voltage testing:
The applied voltage test is more commonly referred to as the "hipot test." This test is performed
by connecting all terminals of each individual winding together and applying a voltage between
windings as well as from each winding to ground, in separate tests. Untested windings are
grounded during each application of voltage.
This test should be used with caution as it can cause insulation failure. It should be regarded as a
proof test to be conducted when there has been an event or pattern in the transformer's operating
history that makes its insulation integrity suspect.
45
DC applied voltage tests are often conducted in the field because DC test sets are smaller and
more readily available than AC applied voltage sets. With DC tests, the leakage current can be
measured and is often taken as a quantitative measure. However, DC leakage current can vary
considerably from test to test because of creepage across the complex surfaces between
windings and between windings and ground.
The use of AC voltage is preferable since the transformer insulation structures were designed,
constructed, and tested with the application of AC voltage intended.
Impedance testing:
An impedance test may be useful in evaluating the condition of transformer windings, specifically
for detecting mechanical damage following rough shipment or a service fault on the output side
that caused high fault currents to flow through the transformer windings. Mechanical distortion of
the windings will cause a change in their impedance. To maximize the effectiveness of this test, a
measurement should be taken during the transformer's initial installation to establish a benchmark
value.
An impedance test is performed by electrically connecting the secondary terminals together with a
conductor capable of carrying at least 10% of the line current and applying a reduced voltage to
the primary windings. This is easily accomplished by applying a singlephase voltage to each
phase in succession. The applied voltage is measured at the primary terminals and the current
measured in each line.
These values shall be recorded and then calculate the ratio of voltage to current for each phase.
This ratio should be within 2% for each phase and should not vary more than 2% between tests.
A variation of more than 2% indicates the possibility of mechanical distortion of the winding
conductors, which should be investigated as soon as possible.
46
REFERENCES
1. Energy Saving In Industrial Distribution Transformers May 2002 Authors: W.T.J.
Hulshorst, J.F. Groeman KemaNetherlands
2. The Scope For Energy Saving In The Eu Through The Use Of EnergyEfficient Electricity
Distribution Transformers, European Copper Institute, December 1999.
3. Harmonics, Transformers And KFactors, Copper Development Association, Cda
Publication 144, September 2000.
4. J & P Transformer Book, Twelfth Edition 1998, Martin J. Heathcote.
5. Websites of Copper Development Associiation, UK (www.copper.co.uk)
Bureau of Energy Efficiency (www.energymanagetraining.com)
CONTENTS
1. INTRODUCTION.............................................................................................................................................................4 1.1 BACKGROUND....................................................................................................................................................................4 1.2 A GUIDE TO THIS GUIDE .......................................................................................................................................................4 2. FUNDAMENTALS ..........................................................................................................................................................5 2.1. 2.2. 2.4 2.5. 2.5.1. 2.5.2. 2.5.3. 2.5.4. 2.5.5. 2.3.6 3. PRINCIPLE OF TRANSFORMER ACTION..........................................................................................................................5 SAMPLE CALCULATION ...............................................................................................................................................7 PARALLEL OPERATION OF TRANSFORMERS..................................................................................................................8 LOSSES IN TRANSFORMERS ........................................................................................................................................8 Dielectric Losses ...............................................................................................................................................9 Hysteresis Loss.................................................................................................................................................9 Eddy Current Losses in the Core.....................................................................................................................10 Resistive losses in the windings ......................................................................................................................10 Eddy Current Losses in conductors: ................................................................................................................11 Extra Eddy Losses in Structural Parts .............................................................................................................12
TRANSFORMER OPERATIONS ..................................................................................................................................13 3.1 3.1.1. 3.1.2. 3.1.3. 3.2. 3.2.1. 3.2.2. 3.2.3. 3.3. 3.4. 3.5. 3.5.1. 3.5.2. VARIATION OF LOSSES DURING OPERATION................................................................................................................13 Variation of losses with loading level ...............................................................................................................13 Variation in Constant losses ............................................................................................................................14 Variation in Load Losses .................................................................................................................................14 LOSS MINIMISATION IN APPLICATION & OPERATION ...................................................................................................14 Selection of Rating and Number of Transformers ............................................................................................14 Energy Saving by Underutilisation of transformers .........................................................................................15 Reduction of losses due to improvement of power factor.................................................................................15 SEGREGATION OF NON LINEAR LOADS .......................................................................................................................16 EFFECT OF OPERATING TEMPERATURE ......................................................................................................................16 ASSESSING THE EFFECTS OF HARMONICS..................................................................................................................16 U.S. Practice – K Factor.................................................................................................................................17 European Practice ‘Factor K’..........................................................................................................................18
4.
REDUCTION OF LOSSES AT DESIGN STAGE...........................................................................................................20 4.1. 4.2. 4.2.1. 4.2.2. 4.3. 4.4. INTRODUCTION.........................................................................................................................................................20 MINIMISING IRON LOSSES .........................................................................................................................................20 Losses in Core ................................................................................................................................................20 Amorphous cores ............................................................................................................................................21 MINIMISING COPPER LOSSES ....................................................................................................................................22 CHOICE OF LIQUIDFILLED OR DRY TYPE.....................................................................................................................22
5.
ECONOMIC ANALYSIS................................................................................................................................................24 1.1 INTRODUCTION .................................................................................................................................................................24 5.2 TOTAL OWNERSHIP COST OF TRANSFORMERS ...........................................................................................................24 5.3 DECISIONS FOR CHANGEOVER TO NEW EQUIPMENT ....................................................................................................25 5.4 SAMPLE CALCULATIONS...........................................................................................................................................25
6
CASE STUDIES............................................................................................................................................................27 6.1 INTRODUCTION.........................................................................................................................................................27 6.2 CASE STUDY 1.........................................................................................................................................................27 Illustrative Calculations .....................................................................................................................................................27 6.2.1 Factor for Harmonics.......................................................................................................................................28 6.2.2 Percentage of Eddy Losses in Load Losses: ...................................................................................................29 6.2.3 Full load losses for Harmonic Loading:............................................................................................................29 6.2.4 Relative economics for low loss transformers (All Dry type).............................................................................29 6.2.5 Summary:........................................................................................................................................................31 6.3 CASE STUDY2: NON FERROUS METAL SECTOR .........................................................................................................31 6.4 CASE STUDY3: PAPER & PULP COMPANY ................................................................................................................32 6.5 CASE STUDY4 CHEMICAL INDUSTRY .....................................................................................................................33 6.6 CASE STUDY 5 CASE OF A LARGE DATA HOTEL START UP .......................................................................................33 6.7 SUMMARY OF EUROPEAN CASE STUDIES: .................................................................................................................34 6.8 CASE STUDY 6: TEA INDUSTRY (INDIA) ......................................................................................................................34 6.9 CASE STUDY 7: STEEL MILL (INDIA) ..........................................................................................................................35 6.10 CASE STUDY8: AUTOMOBILE PLANT (INDIA).............................................................................................................36 6.11 CASE STUDY 9: IMPROVING RELIABILITY AND AVAILABILITY .......................................................................................37 6.12 CASE STUDY10: USE OF AMORPHOUS CORE TRANSFORMERS ...................................................................................38
ANNEXURE1: GUIDELINES FOR INSTALLING TRANSFORMERS.....................................................................................39 ANNEXURE2: MAINTENANCE GUIDELINES.......................................................................................................................42 REFERENCES ........................................................................................................................................................................46
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List of figures
Figure 21: Relationship between current, magnetic field strength and flux ............................................................................................ 5 Figure 22: Transformer schematic ........................................................................................................................................................................ 5 Figure 23: Transformer construction .................................................................................................................................................................... 6 Figure 24: BH Loop ................................................................................................................................................................................................... 9 Figure 25 Core lamination to reduce eddy current losses .......................................................................................................................... 10 Figure 26: Sectionalised transformer winding  Schematic ........................................................................................................................ 11 Figure 41: Amorphous core ribbons.................................................................................................................................................................. 21
List of Tables
Table 31: Comparison of transformer losses................................................................................................................................................... 15 Table 32: Estimation for K factor.......................................................................................................................................................................... 18 Table 33: Estimation of Factor K.......................................................................................................................................................................... 19 Table 41: Evolution of core material ................................................................................................................................................................... 21 Table 42: Comparison of Losses – Oil type and dry type ........................................................................................................................... 23 Table 51: Comparison of transformers .............................................................................................................................................................. 25 Table 61input data 1250 kV transformer........................................................................................................................................................... 27 Table 62 1250 kVA transformer ........................................................................................................................................................................... 30 Table 63 1600 kVA transformer ........................................................................................................................................................................... 30 Table 64 : Outcome 1000 kVA transformer...................................................................................................................................................... 32 Table 65: Annual savings potential.................................................................................................................................................................... 32 Table 66: Input data of 3150 kVA transformer ................................................................................................................................................ 32 Table 67 Outcome of 3150 kVA transformer ................................................................................................................................................... 33 Table 68: Parameter sensitivity on the payback period ............................................................................................................................... 34 Table 69: electricity losses over a year.............................................................................................................................................................. 37 Table 610: Costs over 10 years. .......................................................................................................................................................................... 37
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1. 1.1 Background
INTRODUCTION
Distribution transformers are very efficient, with losses of less than 0.5% in large units. Smaller units have efficiencies of 97% or above. It is estimated that transformer losses in power distribution networks can exceed 3% of the total electrical power generated. In India, for an annual electricity consumption of about 500 billion kWh, this would come to around 15 billion kWh. Reducing losses can increase transformer efficiency. There are two components that make up transformer losses. The first is "core" loss (also called noload loss), which is the result of the magnetizing and demagnetizing of the core during normal operation. Core loss occurs whenever the transformer is energized; core loss does not vary with load. The second component of loss is called coil or load loss, because the efficiency losses occur in the primary and secondary coils of the transformer. Coil loss is a function of the resistance of the winding materials and varies with the load on the transformer. In selecting equipments, one often conveniently avoids the concept of life cycle costing. But the truth is that even the most efficient energy transfer equipment like a transformer, concept of life cycle cost is very much relevant. The total cost of owning and operating a transformer must be evaluated, since the unit will be in service for decades. The only proper method to evaluate alternatives is to request the manufacturer or bidder to supply the load and noload losses, in watts. Then, simple calculations can reveal anticipated losses at planned loading levels. Frequently, a small increase in purchase price will secure a unit with lower operating costs. The load profile of electronic equipment—from the computer in the office to the variable speed drive in the factory—drives both additional losses and unwanted distortion. Since transformer manufacturers test only under ideal (linear) conditions, a substantial gap exists between published loss data and actual losses incurred after installation. In fact, test results published in a 1996 IEEE Transaction paper documented an almost tripling of transformer losses when feeding 60kW of computer load rather than linear load. Slightly different practices are followed in USA and UK to account for harmonics while selecting transformers. 1.2 A guide to this guide This Best Practice Manual for Electric Transformers summarise the approach for energy conservation measures pertaining to selection, application and operation of electric distribution transformers. The details of design methodology and the varied approaches for materials, construction are not in the scope of this manual. However, some theoretical aspects are discussed where ever deemed fit. Chapter2 discusses principles of transformer action, description of losses and effect of non linear loads on transformer efficiency. Chapter3 discusses design aspects of transformers to improve efficiency Chapter4 discusses loss Minimisation in application and operation Chapter5 discusses principles of economic evaluation of transformers Chapter6 discusses case studies from Indian and International scenario Annexures are given to familiarize the users with the installation and maintenance of transformers
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the back e. required to produce a magnetic field of flux density B. Vp = − NpA ∆B ∆t Magnetic field Ip Is Vs Np Ns Vs = − NsA R ∆B ∆t Vp Vs Ns = Vp Np Figure 22: Transformer schematic When a changing voltage is applied to the primary winding. Principle of transformer action A current flowing through a coil produces a magnetic field around the coil. Figure 2. EMF = Vp = − NpA ∆B . but without change in frequency. magnetic field strength and flux The above principle is used in all transformers. The magnetic field strength H.fs generated by the primary is given by Faraday’s law. The magnetic field is almost totally confined in the iron core and couples around through the secondary coil.2. It can raise or lower the voltage with a corresponding decrease or increase of current. A transformer is a static piece of apparatus used for transferring power from one circuit to another at a different voltage.(1) ∆t A Current in the primary winding produces a magnetic field in the core. is proportional to the current flowing in the coil. FUNDAMENTALS 2.m.1.1 shown below explains the above principle Figure 21: Relationship between current. The induced voltage in the secondary winding is also given by Faraday’s law 5 .
mm).Vs = − NsA ∆B .(2) ∆t The rate of change of flux is the same as that in primary winding. The following figure shows actual construction of a single phase transformer. and Acore. will operate at a greatly reduced effectiveness due to the magnetic leakage. 6 . Acore and f are as defined above. the primary and secondary coils are shown on separate legs of the magnetic circuit so that we can easily understand how the transformer works. A transformer wound. the longer the magnetic circuit and the greater the leakage. Actually. = crosssectional area of the core material in Sq. J depends upon heat dissipation and cooling.44 × f × N × Bmax × Acore Where E = rated coil voltage (volts). Magnetic leakage is the part of the magnetic flux that passes through either one of the coils. but not through both. f = operating frequency (hertz). The larger the distance between the primary and secondary windings. Dividing equation (2) by (1) gives Vs Ns = Vp Np In Figure 2.2. Figure 23: Transformer construction The voltage developed by transformer action is given by E = 4. Bmax. J is the current density (A/ sq. a power equation expressing the voltampere rating in terms of the other input parameters is also used in transformer design. Bmax = maximum flux density in the core (tesla).2.44 × f × N × Bmax × Acore × J × Acond Where. such as in Figure 2. In addition to the voltage equation. the form of the equation is VA = 4. with sufficient insulation between the two coils and the core to properly insulate the windings from one another and the core. N. of the conducting material for primary winding. Specifically. half of the primary and secondary coils are wound on each of the two legs. N = number of turns in the winding. and Acond is the 2 coil crosssectional area (mm ) in the core window. metres.
Thus 1 = 30° 2 = 60°. Because there are 12 hours on a clock.2. Winding connection designations The winding connections in a transformer are designated as follows.001 = 200 kVA approximately. Use the hour indicator as the indicating phase displacement angle. maximum flux density 2 2 of 1.44 x f x Np x Bmax x Acore.44 X 50 X 100 X 1. 1 = 30° lagging (LV lags HV with 30° and 11 = 330° lagging or 30° leading (LV leads HV with 30° ) ) To summarise: Dd0:Delta connected HV winding. J is taken as 2 Amps/Sq. = 4.5 X 0.5 X 0.3.001 KVA. . delta connected LV winding. LV is leading HV with 30° 7 . star connected LV winding with neutral brought out.5 Tesla and core area of 0. X 0.01 = 333 Volts Voltampere capability is given by the following relationship: Power rating = 4. The minute hand is set on 12 o'clock and replaces the line to neutral voltage (sometimes imaginary) of the HV winding. mm and Acond as 30 mm for this illustration.01 X 2 X 30 X 0. Because rotation is anticlockwise.44 x f x Ns x Bmax x Acore. = 4. .44 X 50 X 1000 X 1. 3 = 90° 6 = 180° and 12 = 0° or 360°.44 X 50 X 1000 X 1. 3 Rated KVA = V 3 X Rated Line Voltage X Rated Line Current X 10 for three phase transformers.01 m .2. (International adopted convention). Dyn11:Delta connected HV winding.44 x f x Np x Bmax x Acore x J x Acond. .5 X 0.01 = 3330 Volts In secondary winding Esecondary = 4. 2. This position is always the reference point. Sample calculation A 50 Hz transformer with 1000 turns on primary and 100 turns on secondary. High Voltage Always capital letters Delta D Star S Interconnected star Z Neutral brought out N Low voltage Always small letters Delta d Star s interconnected star z Neutral brought out n Phase displacement: Phase rotation is always anticlockwise. Eprimary = 4. no phase shift between HV and LV. Voltage developed is given by In primary winding. = 4. and a circle consists out of 360° each hour represents 30° . 3 Actual Rated KVA = Rated Voltage X Rated Current X 10  for single phase transformers.
but the more nearly it is true. must be identical for two paralleling transformers. their satisfactory performance requires that they have: 1. This mode of operation is frequently required. if their numerical or ohmic impedances are inversely proportional to those ratings. To carry double the current. 4. Polarity: This can be either right or wrong. 2. The two power transformers shall be paralleled only for a short duration. this condition being enforced by the parallel connection. 4.e. There is more latitude with condition 2. Voltage Ratio: An equal voltageratio is necessary to avoid noload circulating current. 6. other wise it will lead to unnecessary losses. the better will be the loaddivision between the several transformers. When operating two or more transformers in parallel. Losses in Transformers The losses in a transformer are as under. The system impedance reduces when the two or more transformers are paralleled and hence increases the fault level of the system. so that a small percentage 2 voltage difference may be sufficient to circulate a considerable current and cause additional I R loss. however. Dielectric Loss Hysteresis Losses in the Core Eddy current losses in the Core Resistive Losses in the winding conductors Increased resistive losses due to Eddy Current Losses in conductors. 5. in which the phases reach their maximum positive voltages. Two transformers giving secondary voltages with a phasedisplacement cannot be used for transformers intended for paralleloperation. the former must have half the impedance of the latter for the same regulation. Consider two transformers of ratings in the ratio 2:1. be the same for parallel operation. The same voltageratio The same perunit (or percentage) impedance The same polarity The same phasesequence and zero relative phasedisplacement Out of these conditions 3 and 4 are absolutely essential and condition 1 must be satisfied to a close degree. ratio of resistance to reactance) and it is necessary to distinguish between perunit and numerical impedance. extra eddy current losses in the tank structure. delta connected LV winding.5. the circulating current will tend to produce unequal loading conditions and it may be impossible to take the combined fullload output from the parallelconnected group without one of the transformers becoming excessive hot. and the other with a lower. 8 . When the secondaries are loaded. If wrong it results in a dead short circuit. 3. Impedance: The impedances of two transformers may differ in magnitude and in quality (i. A difference in quality of the perunit impedance results in a divergence of phase angle of the two currents. 1. 2. power factor than that of the combined output. The regulation must. 2. The impedance of transformers is small. LV lags HV with 150° 2. For oil immersed transformers. otherwise during the cycle each pair of phases will be shortcircuited. so that one transformer will be working with a higher.4 Parallel operation of transformers The parallel operation of transformers is common in any industry.YNd5: Star connected HV winding with neutral brought out. and their perunit impedances are identical. Hence the currents carried by two transformers are proportional to their ratings. 3. The phase sequence or the order. PhaseSequence: This condition is associated only with polyphase transformers. because they may be risking a higher fault level during this short period.
Figure 24: BH Loop Energy input and retrieval while increasing and decreasing current. (Generally ignored in medium voltage transformers while computing efficiency). Each time the magnetising force produced by the primary of a transformer changes because of the applied ac voltage. 2. the selection of core material is an important factor in reducing core losses.4 for a typical BH Loop.Basic description of the factors affecting these losses is given below. It is therefore a loss. Bmax.e. Refer Fig 2.5. Hysteresis is a part of core loss. Loss per half cycle equals half of the area of Hysteresis Loop. It is negligibly small and is roughly constant. Hysteresis Losses.1. resisting being magnetized and demagnetized by the alternating magnetic field. Where Kh f Bm Wh = Kh × f × Bm1. It is thus dependent upon the maximum limits of flux excursions i. It varies with frequency. = the hysteresis constant = Frequency in Hertz = Maximum flux density in Tesla 9 . It is roughly proportional to developed high voltage and the type and thickness of insulation. The BH loop area depends upon the type of core material and maximum flux density. Hysteresis losses originate from the molecular magnetic domains in the core laminations. The energy to accomplish this realignment of the magnetic domains comes from the input power and is not transferred to the secondary winding.6 Watts/Kg. Because various types of core materials have different magnetizing abilities. Dielectric Losses This loss occurs due to electrostatic stress reversals in the insulation. Typically.5. This depends upon the area of the magnetising BH loop and frequency.2. 2. Hysteresis Loss A sizeable contribution to noload losses comes from hysteresis losses. the type of material and frequency. this accounts for 50% of the constant core losses for CRGO (Cold Rolled Grain Oriented) sheet steel with normal design practice. the domains realign them in the direction of the force.
By using a laminated core.s current in the windings and directly with D.5.m. This is shown pictorially in 2. these losses vary with winding temperature and thus will vary with the extent of loading and method of cooling. This variation is very small and is neglected for all practical purposes. 10 . The winding resistance at a temperature TL is given by the following equation. Eddy losses contribute to about 50% of the core losses.C.3. resistance of winding. = the eddy current constant = Frequency in Hertz. The resistance in turn varies with the resistivity. For reducing eddy losses.5 below for a comparison of solid iron core and a laminated iron core. Ω 2 = Resistivity in Ohms .5.4.mm /m. = Length of conductor in metres 2 = Area of cross section of the conductor. mm Where R ρ l A In addition. They vary as square of the r. The resulting circulating current depends inversely upon the resistivity of the material and directly upon the thickness of the core. the conductor dimensions. = Maximum flux density in Tesla = Thickness of lamination strips. which is split up by laminations of thickness ‘d1’ and depth d2 as shown in C.2. Where Ke f Bm t We = Ke × Bm 2 × f 2 × t 2 Watts/Kg.5B shows a solid core. (thin sheets of silicon steel instead of a solid core) the path of the eddy current is broken up without increasing the reluctance of the magnetic circuit. higher resistivity core material and thinner (Typical thickness of laminations is 0. 2. Resistive losses in the windings These represent the main component of the load dependent or the variable losses. Refer fig 2. thus vary with square of the flux density. 2. frequency and thickness of the core laminations. 2 R= ρ×l A = Winding resistance. Eddy Current Losses in the Core The alternating flux induces an EMF in the bulk of the core proportional to flux density and frequency. designated as I R or copper losses. Figure 25 Core lamination to reduce eddy current losses Eddy Losses. and the temperature.5 A. The losses per unit mass of core material. Fig.35 mm) lamination of core are employed. This loss decreases very slightly with increase in temperature.
Where R0 RL The constant 235 is for Copper. The contribution of eddy losses including tank losses. The sectionalised conductor has to be transposed to make it occupy all possible positions to equalise the e. For dry type transformers. For an isolated conductor in space. These extra losses vary with square of frequency and square of per unit harmonic current. Detailed subdivision is available only from design data. The variation is not as the square of frequency. over the basic copper losses for an equivalent D. use 225 or 227 = Winding resistance at temperature T0. These losses are termed as Eddy Current Losses in conductors. tank losses are absent.Schematic 11 .m.5. This is known as Skin Effect. leads to clustering of the current near the conductor periphery. Ω = Winding resistance at temperature. These varying linkages are due to selflinkage as also due to proximity of adjacent current carrying conductors. which vary over the cross section.s value of current will depend upon the load level and also the harmonic distortion of the current.m. can be estimated from the difference in measured load losses and expected copper losses at the test current at the test temperature. the varying selflinkage over the section. TL. which pass through the cross section of the conductor.8 for the exponent. with the addition of flux from surrounding conductors. Eddy Current Losses in conductors: Conductors in transformer windings are subjected to alternating leakage fluxes created by winding currents. Leakage flux paths. These induced voltages. 2.fs to the extent possible. The eddy losses in the tank structure are equivalent to the dissipation in a loaded secondary with leakage reactance.5. A simplified expression for eddy current losses in conductors is given below. create circulating currents within the conductor causing additional losses. The same effect. current. which include these eddy losses in conductors at supply frequency (50 Hertz) as also the eddy losses in tank structure in general at the same frequency in the case of oil cooled transformers. Ω The r. TL + 235 RL = R0 × T0 + 235 for Alloyed Aluminium. These losses are varying as the square of the frequency. (Proximity effect) leads to extra losses in thick conductors for transformer windings. For Aluminium.C. It can be taken as 10% of load losses in the absence of specific design data. induce voltages. w 1 2 N1 N LC L W/N Figure 26: Sectionalised transformer winding . The Eddy losses in a thick conductor can be reduced by decreasing the radial thickness by sectionalising the conductors (multistranded) and increasing the axial dimension. and it is customary to take a value of 0. For normal designs it ranges from 5% to 15%. The Test Certificate mentions the load losses.
L = Window Height W = Radial total conductor width in metres W’= Width per subdivision W/N in centimeters. it will produce eddy losses in that material.8 . Both these losses vary with frequency 0. as stated earlier. ≈ 100 × Lc –8 . Thus circulating current is forced to flow in a relatively very thin conductor. ρ= 2 X 10 Ohmmetres L If W’ is in cm. Where Lc = Axial length of coil. some stray flux links with some parts of the tank and causes extra eddy current losses in the structure. N Ke = 1 + (αW/N ) × 9 4 2 Where α = (π × 4π × 10 −7 × f × Lc ) ρ×L where 4π X 10 –7 is permeability of space. Similarly. 12 . Strength of this stray flux diminishes and varies inversely with distance. α is thus proportional to f . eddy losses increase as square of frequency. For oil immersed transformers. These losses are absent in dry type transformers.The total radial thickness of conductor of W cm is subdivided into N parts of W/N thickness each. It is important to transpose each layer so that each layer is connected in series with a path in each one of the possible N positions before being paralleled. For a given geometry. Ke is the ratio of the total losses including eddy loss.6 Extra Eddy Losses in Structural Parts Some leakage flux invariably goes in air paths away from the transformer. 2. to the loss due to D. conductors carrying large currents cause extra eddy current losses in the structural portion surrounding the leads.3. If it links with any conducting material. The other losses are described mainly to give a complete picture on losses. L As the number of subdivisions increase. in Ohmmetres For Copper at 60 ° α C.C. ρ = Resistivity. W = W’/100 Hence αW/N ≈ w'× Lc 4 2 . current. but always above 1. The above discussion on transformer losses is given only to gain familiarity with the fundamental principles. W’ becomes smaller and Ke comes nearer to 1.T. extra flux due to outgoing L. The most important losses are core loss and copper loss.
Basic I R losses increase with temperature.0808 = 1.0808 +0. and the rise in temperature is dependant on the total losses to be dissipated.06523 13 . 75 C Temperature correction factor. TRANSFORMER OPERATIONS 3. 3.1.9 x 1.C.1 × RT − ref RT − op If a more realistic subdivision of load losses is known from design data.5 for Copper. Variation of losses with loading level % Efficiency = Output ×100 Output + Losses = Where.f.f.5 + 75 Hence T = 0. voltage changes.5 + 100 = 1. × 1000 + N. harmonics and operating temperature.0808 = RT − ref 234. × p 2 × T The basic D.f.L. the following relationship is used. 90% of the load losses vary directly with rise in temperature and 10% of the load losses vary inversely with temperature. T p.L. = 225 for Aluminium = 227 for alloyed Aluminium RTop = Resistance at operating temperature Tref = Standard reference temperature.3.9 × RT − ref RT − op + 0. = per unit loading = No load losses in Watts = Load losses in Watts at full load. × 1000 × 100 P × kVA rating × p. Calculations are usually done for an assumed temperature rise. at 75 °C = Temperature correction factor = Load power factor P × kVA rating × p. resistance copper losses are assumed to be 90% of the load losses. T = Load losses at operating temperatur e Load losses at reference temperatur e = 0. Eddy current losses 2 (in conductors) are assumed to be 10% of the load losses.1 Variation of losses during operation The losses vary during the operation of a transformer due to loading. Operating temperature = Ambient temperature + Temperature rise To estimate the variation in resistance with temperature. while eddy losses decreases with increase in temperature. RT − op 234.L.L + L. Thus. If operating temperature is 100 C. L.1/1. p N. which in turn depends on the loading of the transformer. the above expression can be modified accordingly.1. RT − op F + Tamb + Trise = RT − ref F + Tref Where F= 234.
2. Hence transformer rating is likely to be overspecified. each transformer may be sufficient to run the plant. switching off one transformer to save part load losses is generally considered.2. Variation in Load Losses About 90%of the load losses as measured by short circuit test are due to I R losses in the windings. a close realistic estimate permits extra first cost on a smaller 14 .1. The current harmonics of the local harmonic load adds to this by causing additional harmonic voltage drop depending upon magnitude of a particular harmonic and the system short circuit impedance at the point of supply. Selection of Rating and Number of Transformers In general. For noncontinuous operation of plants with holidays or seasonal industries. Variation in iron losses due to system voltage harmonics: The system input voltage may contain voltage harmonics due to aggregate system pollution in the grid. In all such cases. the major increase comes from the variation in eddy current losses in the windings (Usually 5 to 10% of the total load losses). These losses vary as the square of the voltage.1. 3.s current 2 and thus increase the basic I R losses. but the extra first cost is rarely justified by energy saving alone.3.3. The combined total harmonics affect the flux waveform and give added iron losses. However. In addition. due to this voltage distortion.f. 3. The factors to be considered are: • • • • Expected growth of load over around five to ten years Margin for minimum 15 to 20% growth 10 to 15% margin for nonlinear loads Availability of standard rating Generally. The application details are not clearly known during selection and the load and the type of load also changes with time. Loss Minimisation in Application & Operation 2 Transformers have a long life and do not generally suffer from technical obsolescence.1. The usual best efficiency point is near 50% load. For large plants with long in plant distances. The increase in constant loss is quite small. power may be had from two independent feeders at similar or different voltage levels. Thus normal operation may be at 50% load.2. Moreover for critical continuous operation plants.m. 30 to 50% excess capacity reduces load losses. two or more transformers of equal rating may be selected.5 for Copper and 227 for Aluminium. this is generally not a disadvantage from the view point of energy consumption. and the transformer impedance for that specific harmonic frequency. which vary with the square of the frequency. Variation in losses due to current harmonics: The system current harmonics increase the r. or as prescribed in the test certificate Variation in load losses due to load power factor: Any reduction in current for the same kW load by improvement in p. Planning for growth of loads and addition of non linear loads is becoming increasingly important. On the contrary. Tref = 75 °C usually. 3. Such a situation can lead to lower than 25% load at times. They vary with the square of the current and also with winding temperature. reduces load losses. Variation in Constant losses The iron loss measured by no load test is constant for a given applied voltage. selection of only one transformer of large rating gives maximum efficiency and simpler installation. Load Losses = (Per Unit Loading)2 × Load Losses at Full Load × F + Top F + Tref F = Temperature coefficient = 234.
Thus the loads tend to draw 60% to 25% excess current due to poor power factor. Industrial power factor vary from 0. As expected. Basic I R losses increase with temperature.95 99.16 99.03 98. at light loads. Table 31: Comparison of transformer losses 1000 kVA.4 0. The saving by using a 1600 kVA transformer in place of a 1000 kVA transformer at 1000 kW load for 8760 hours/annum is 25960 kWh/year.29 lakhs.7 0. The corresponding figures for 1600 kVA transformer are 2600 Watts and 17000 Watts respectively. They have to be corrected to 2 expected site operating temperature.6 to 0. this is worth Rs 1. the saving in load losses is as under.2. If p. The 1000 kVA transformer has a no load loss of 1700 watts and load loss of 10500 Watts at 100% load.0 Load losses. current drawn is proportional to KW/pf. Details of K factor evaluation are given in section 3. losses. transformers with minimum eddy losses in total load loss are preferred.2.23 98. 15 . there is extra loss due to dominance of no load losses. Transformers with relatively low no load losses( Amorphous Core Type) will maintain good efficiency at very low loads and will help in cases where high growth is expected.1 0.m. This will need derating of 12% for 10% nonlinear load to about 27% for 40% nonlinear load. Transformer losses may be specified at a standard reference temperature of 75 C. For nonlinear loads.5 0.2. The load factor affects the load losses materially and an estimate of annual r.3.14 99.1 summarises the variation in losses and efficiency for a 1000 kVA transformer and also shows the difference in losses by using a 1600 kVA transformer for the same. For nonlinear loads.8 0. Using 1600 kVA transformer causes under loading for 1000 kW load. there is saving which is 2. the derating factor may be worked out taking a Kfactor of 20.transformer designed on the basis of Least Total Ownership Cost ( TOC) basis. The extra first cost would be around Rs 10. W 861 745 552 282 58 490 992 1570 2226 2960 The efficiency of 1000 kVA transformer is maximum at about 40% load.6 0. is improved to unity at load end or transformer secondary.2 0.f. but risk of slow growth is to be minimised. W W 60 2660 265 2865 597 3197 1062 3662 1660 4267 2390 4990 3258 5853 4250 6850 5379 7979 6640 9240 Difference in losses.96 kW at 1000 kW load. while eddy losses decrease with increase in temperature.13 99. Loading is by linear loads.s. Energy Saving by Underutilisation of transformers Table 3.4 of this chapter.0 /kWh. The last column shows the extra power loss due to oversized transformer. kW Efficiency. W 1805 2120 2645 3380 4325 5480 6845 8420 10205 12200 Output. No load losses = 2600 W Load Total losses. No load losses = 1700 W Per unit load 0. 3.9 1. 3. Hence deliberate over sizing is not economically viable. W 105 420 945 1680 2625 3780 5145 6720 8505 10500 Total losses. Temperatures assumed equal. Reduction of losses due to improvement of power factor Transformer load losses vary as square of current. Beyond 50% load. % 100 200 300 400 500 600 700 800 900 1000 98.88 98.3 0. Economic evaluation of transformers is discussed in chapter 5.09 99. @Rs 5. For the same kW load.96 98.78 1600 kVA.8.0 lakhs. load current value is useful.
It should also be kept in mind that correction of p. 3. it can be supplied from a transformer which is specially designed for handling harmonics. 3. Thus. The propagation of harmonics can be controlled much more easily and problems can be confined to known network. This is a relatively simple opportunity to make the most of the existing transformer and it should not be missed. the ratio of surface area to volume reduces.5. This gives an additional factor for comparing losses during design. Oil cooled transformers operate at lower temperatures compared to dry type transformers. larger transformers are difficult to cool.25% over existing level of load losses.3. The method is applicable for estimation in power distribution transformers.4. Apart from ease of separation and monitoring of harmonics. A reference temperature of 75 °C is selected for expressing the losses referred to a standard temperature. Operating temperature beyond the limits prescribed for the insulation. Segregation of non linear loads In new installations. the total load losses with current harmonics are given as under 2 n In 2 n In 2 IL PT = PDC1 × + PWE1 × ∑ × n 2 + (PCE1 + PSE1) × ∑ × n 0. the saving will be 56. if p. nonlinear loads should be segregated from linear loads. This standard is specifically meant for transformers and reactors which are an integral part of converters.f downstream saves on cable losses. giving a lower operating temperature. Oil cooling uses a liquid insulating medium for heat transfer. 3. The alternative approaches for power distribution transformers using KFactor and FactorK are given later. As per IEC 613781. It can be used for oil cooled transformers or dry type transformers. Perhaps a smaller than usual transformer will help in coordinating short circuit protection for network as well as active devices. Assessing the effects of Harmonics Load loss performance of a design or an installed transformer with known data can be done if the levels of harmonic current are known or estimated. IL2 = ∑ In 2 n =1 n PDC1= Basic copper losses for fundamental frequency PWE1= Winding eddy losses for fundamental PCE1 = Eddy losses in structural parts due to current leads for fundamental 16 . ambient temperature is higher giving a higher operating temperature.f is 0. which may be almost twice in value compared to transformer losses. reduces life expectancy materially. In cold countries the ambient temperature is lower. When the transformer volume increases. 1 2 Saving in load losses = (Per unit loading as per kW) X Load losses at full load X − 1 pf 2 Thus.4% rise in load losses. The only disadvantage apart from additional cost is the increased interdependence of sensitive loads. Higher temperature permits reduction in material content and first cost. The operating temperature limit is decided by the type of insulation used and the difficulties of cooling. Every 1°C rise in operating temperature gives about 0. In tropical countries.8 I1 1 I1 1 I1 Where PT = Total load losses and ‘n’ is the order of the harmonic. It is not meant for power distribution transformers. Effect of operating temperature The losses have to be dissipated through the surface area.8 and it is improved to unity. IEC 613781 ‘Transformers for Industrial Applications’ gives a general expression for estimating load losses for loads with harmonics.
K = 1 for resistance heating.1. K= ∑( I ) × n 2 In 2 2 n =1 (I1/I1) 2 × 12 K= ∑( n n =1 In I ) ×n 2 The KFactor is used directly to specify transformers for a given duty. 17 ..m. Total load losses at 100% load = 0. since I is defined. motors. k = ∑ In 2 . if needed can be estimated at any x % loading as under if the contribution of eddy losses in load losses at fundamental frequency test is known from design.. For specification in general. K is ratio of Eddy losses at 100 % current with harmonics and Eddy losses at 100 % current with fundamental.s. current (I I ) × n n 2 n I= (I 1 2 + I2 2 + . In U.S.1 = 2 2 Total load losses at x % load = x x 2. Fluorescent lights K = 13 For Telecommunication equipment.e.. Copper losses are then assumed to be the balance 90 %.PSE1 = Eddy losses in structural parts for fundamental In I1 = Current for harmonic order n = Fundamental current PCE1 and PSE1 are not applicable to dry type transformers 3. eddy losses at 100% load with this harmonic pattern are 11 times the eddy losses at fundamental.S. practice is to estimate the K – Factor which gives ready reference ratio K for eddy losses while supplying nonlinear loads as compared to linear loads. dry type of transformers are used in majority of applications.Factor The KFactor rating assigned to a transformer and marked on the transformer case in accordance with the listing of Underwriters Laboratories. distribution transformers etc. the U. The total losses.1 x K) If K = 11.9 + 0. Practice – K. + In 2 2 ) Where I1 is taken as 1.5. (I I ) × n n 2 2 where I is the total r. or assumed typically as 10 %. The KFactor is the ratio of eddy current losses when supplying nonlinear loads as compared to losses while supplying linear loads. The eddy losses in conductors are assumed to vary as and is assumed to be 100 % i.n 2 n =1 2 In= per unit harmonic current. U. variable speed drives and desktop computers. rated value. loss variation is taken as including fundamental.. and n = Order of harmonic. Now. is an index of the transformer's ability to supply harmonic content in its load current while remaining within its operating temperature limits.9 + 1. K = 4 for welders Induction heaters. K = 20 for main frame computers. Total load losses at 100 % load = (0.S.
factor calculation is given for a given set of harmonic measurements.1444 0.18 0.7 for round / rectangular section = 1.C. current and hence are equal to the measured losses at fundamental frequency. K factor = 11. = Exponential constant dependent on type of winding and frequency = 1. Thus the transformer can work at 70% of its rated load current specified for linear loads.If total load losses are assumed to be 100% or 1 for same temperature rise.s.s.6138 =1.1217 0.8444 3.58 0. = magnitude of nth harmonic current.s Sum Ir.4571 0.38 0.m.s.0660 0. A sample K. value of the current including all harmonics n=N 2 = ∑ In n =1 0.7663 3.3073 0.7%.5 1/K or 70.2. then x = 1/K =1/2.m.58 0. European Practice.82 0. I 2 R + EddyLosses where as Eddy Losses = (e × I 2 R ) 2 Hence.6724 0. 1 = (I R × (1 + e )) 1= Eddy Losses as a fraction of total load losses = e × I2R e 2 I R (1 + e) ) = (1 + e) ) 18 . 1 3 5 7 9 11 Total r.S. The basic copper losses vary as the square of the r.2344 1.0009 2.4571 2.m. The base current is thus I the r. value of the sinusoidal current.6761 0.m.1876 RMS Current 1 0.045 1. when that current contains harmonics.1120 2 2 1 0. current equal to the R.38 0.5 The objective is to estimate the total load losses at 100% current.2569 0.479 In/I1 1 0.0020 0.‘Factor K’ The European practice as defined in BS 7821 Part 4 and HD 538.5 for foil type low voltage winding. based on the above relationships.M.3.1876 11. KFactor is given by last column.5 e In q I = Eddy current loss at fundamental frequency divided by loss due to a D. 1.e.S. x = 0.M. This is equal to the rated current at which the load losses are measured at fundamental frequency.618 A K13 rated transformer is recommended for this load.5544 0.0324 0.479 =I. 2 2 N In e I1 q K = 1 + ×∑n × I 1+ e I n+2 1 0. = √ 2.3921 0.1538 0. = R.2000 0. 3.S1 defines a derating factor for a given transformer by a ‘FactorK’.5. current which is 100%.0304 (In/I) 2 (In/I) xn 0.0148 0.18 0.045 (In/I1) 2 (In/I) 0.82 0.3364 0. Table 32: Estimation for K factor 2 Harmonic No. Total load losses at fundamental are taken as unity i.
since e/ 1+ e itself is about 9% to 10% of total losses at fundamental.0020 2.1876 = 1..1) x (1/1.0324 0.7 and assuming that eddy current loss at fundamental as 10% of resistive loss i.06% 19 . + In 2 × n q e I1 × ×∑ I1 2 1 + e I n =1 2 n (I1 2 × 1q + I3 2 × 3q + . + In 2 × n q ) e I1 = × × 1 + ∑ I1 2 1 + e I n =n +2 2 ( ) I = I1 + IH 2 where IH equals the sum of squares for harmonics.900 58.3576 0.18 0.1193 q 2 Σ=15. The first two terms equal the total losses at fundamental and thus equals 1.s.1876 2 n 1 6. 2 2 K = 1 + (0.38 0.The Factor K is taken as the square root of total losses.82 0.6724 0.. there is an error on safe side with a total deviation of only 2% to 4% depending upon IH.. The expression thus simplifies to the form stated earlier.045 (In/I1) 1 0.18 0. The summation term is for n > 1 and thus covers harmonics only.58 0. Typical calculation (taking q as 1.473 15.1/ 1.426 27.9653 –1) =1.82 0.38 0.9653 I r. 2 2 2 e I1 2 + IH 2 e IH Total losses = I R + × × 2 2 − I 1 + e I 1 + e 2 ( ) n e I1 In q + × × ∑ × n 1+ e I n = n + 2 I1 2 2 If the term for IH is neglected. At x % load.1) is given below.1444 0.m.045 In/I1 1 0.28 x 100 = 78. Table 33: Estimation of Factor K 2 2 Harmonic No.641 K = 1. but excluding fundamental..3364 0. X= 1/K .1893 3.58 0. The addition to eddy losses may be 10 to 15 times due to harmonics. =√ 2.332 41. 1 3 5 7 9 11 Sum RMS Current 1 0.9467 1.934 q n (In/I) 1 4. Load Losses = X K and since new load losses should be equal to 1. e= 0.28 Transformer derating factor = 1/K = 1/1.457) x (15.Eddy Losses at I (100%) = 2 e n (In ) q ×∑ 2 ×n 1 + e n =1 I Since harmonics are expressed as fractions of fundamental.457. 2 Eddy Losses = n I1 2 × 1q + I3 2 × 3 q + .e.3525 5.
012 being common. more and more consumers are now purchasing transformers based on the total ownership costs. Worldwide. the inherent colinearity between lamination orientation and the magnetic field direction allows use of grain oriented steel for transformer laminations. Minimising Iron Losses 4. just as in a motor. always involve tradeoffs. with 0. To raise transformer efficiency.025 inch thick. That lowers eddy current loss. than just the first cost. Many similar units have been put in service since then.1. The design approaches for reduction of losses are well known and proven. consider varying the crosssectional area of the transformer core. There are many grades of steel that can be used for a transformer core. 4. They consists of 1. An increase tends to lower noload loss while raising the winding loss. Introduction Design changes to reduce transformer losses. REDUCTION OF LOSSES AT DESIGN STAGE 4. 3. Using more material Better material New Material Improved distribution of materials Improvement in cooling medium and methods Each design tries to achieve desired specifications with minimum cost of materials or minimum weight or volume or minimum overall cost of ownership. Whereas motor laminations are usually 0.009 to 0. The evolution of materials used in transformer core is summarised below. To achieve these objectives. The choice depends on how you evaluate nonload losses and total owning costs. A further improvement appearing during the 1980's is amorphous core material. Second. Laminations only 0. An increase in volts per turn reduces winding loss while increasing the core loss. Losses in Core Choice of metal is critical for transformer cores. Core construction permits two important energysaving features not applicable to industrial motors. Resembling glass more than steel. because laminations are sheared or slit in strips rather than being punched with slots. which are randomly positioned in a nonoriented material. always leading the designer to seek a costeffective balance.1. this lamination material contains no granular structure at all. grainoriented.2. high permeability. Construction of the core utilizes step lap mitered joints and the laminations are carefully stacked. Typical core loss in such a transformer is only onethird of that in a conventional unit. 2. coldrolled. Variation in conductor area and in the electric and magnetic circuit path lengths will affect efficiency in various ways. For example. Almost all transformer manufacturers today use steel in their cores that provides low losses due to the effects of magnetic hysteresis and eddy currents. First. core loss has probably drawn the most attention.2. transformer lamination thickness may be as low as 0. That greatly reduces hysteresis loss in the corethe energy required to cyclically realign the "molecular magnets" within the steel. and it's important that good quality magnetic steel be used. 20 .001 inch thick were used in the first massproduced distribution transformers (25 kVA) manufactured by Westinghouse in 1986. silicon steel is almost always used. 5.4. along with some large power transformers.014 to 0. 4.006. Each grade has an effect on efficiency on a perkg basis. much thinner material can be used in a transformer core than in a rotating machine.
The use of higher flux densities in CRGO (up to 1. To date.3 0.5 T) results in higher core losses. This material gives high permeability and is available in very thin formations (like ribbons) resulting in much less core losses than CRGO. resulting in longer turns of winding. the flux density is less and thinner laminations also help in reducing core losses. less amount of copper winding is required. This atomic 21 . Thus iron losses depend upon the material and flux densities selected. but affect also the copper losses. Amorphous metals are characterized by a random arrangement of their atoms (because the atomic structure resembles that of glass.) 1910 1950 1960 1965 1975 1980 1985 Core Material Thickness (Mm) 0. however. threedimensional array. there is relatively a larger volume to be dealt with.e.84 (1. is because of their high efficiency. This is especially true in other countries such as Japan. It becomes clear that a figure for total losses can be compared while evaluating operating cost of the transformers.Table 41: Evolution of core material Year (Approx. The use of amorphous core liquidfilled transformers is now being expanded for use in power applications for industrial and commercial installations. Conventional metals possess crystalline structures in which the atoms form an orderly.03 0. Amorphous metal and CRGO. higher resistance resulting in more copper losses. Figure 41: Amorphous core ribbons Amorphous metal is a new class of material having no crystalline formation.5T) Warm rolled FeSi Cold rolled CRGO Cold rolled CRGO Cold rolled CRGO Amorphous metal Cold rolled CRGO Cold rolled CRGO There are two important core materials used in transformer manufacturing.9 (1.5T) 0. However.3T) 0. In amorphous core.5T) 0. It can be seen that losses in amorphous metal core is less than 25% of that in CRGO. This reduces the copper losses. The reason utilities purchase them.35 0. as the volume of core is less. repeated.5T) 0.2.75 (1.35 0. The trade off between the both types is interesting.2 (1. i. these transformers have been designed for distribution operation primarily by electric utilities and use woundcut cores of amorphous metal. the material is sometimes referred to as glassy metal). 4.67 (1. The total operating cost due to losses and total investment cost forms the basis of Total Ownership Cost of a transformer. even though they are more expensive than silicon steel core transformers.5T) 0.2. Their ratings range from 10kVA through 2500kVA.5T) 1 (1.27 0. the core losses are between 60% to 70% lower than those for transformers using silicon steel. Amorphous cores A new type of liquidfilled transformer introduced commercially in 1986 uses ultra lowloss cores made from amorphous metal.18 Loss (W/Kg At 50hz) 2 (1.23 0.
and they usually have a longer life expectancy. thin and flimsy.structure. A properly configured foil winding is useful in this context. the higher the price of the steel. In addition.m. Losses are especially important when transformers are lightly loaded. However. 4. All the same. The metal is not easily workable. along with the difference in the composition and thickness of the metal. (Drytype transformers can catch fire. too. there are certain performance and application characteristics that are almost universally accepted. amorphous cores are not being applied in drytype transformers. The designer has to take care of the proper buildup of turns with transposition and also take care of the mechanical strength to sustain short circuit in addition to needed insulation and surge voltage distribution. Different manufacturers have different capabilities for producing amorphous cores. the price differential is dependent upon which grade of silicon steel the comparison is being made. designers can always try to get minimum basic I R and minimum eddy current losses for a given design and specified harmonic loading. the cost of electric power at the location where such a transformer is contemplated is a very important factor in carrying out the economic analyses. the cooling medium can be conventional mineral oil. decreasing radial thickness by sectionalisation leads to reduction in eddy current losses. Also.4. and difficult to obtain in large sheets. such as during the hours from about 9 p. liquidfilled transformers may require a containment trough for protection against possible leaks of the fluid. being very hard and difficult to cut. such as high fire point hydrocarbons and silicones. To a degree.) At present. the core loss becomes the largest component of a transformer's total losses. depending on the application. There are some drawbacks. there are two distinct types of transformers: Liquid insulated and cooled (liquidfilled type) and non liquid insulated. in other words. There are also wettype transformers using less flammable liquids. liquid is a more efficient cooling medium in reducing hot spot temperatures in the coils. an arbitrary increase in thickness can increase eddy current losses. If you're considering the use of an amorphous core transformer. The price of these units typically ranges from 15% to 40% higher than that of silicon steel core transformers. to 6 a. Choice of liquidfilled or dry type 2 2 Information on the pros and cons of the available types of transformers frequently varies depending upon what information is made available by the manufacturer. selecting a 2 lower current density can reduce the basic I R losses. When lightly loaded. However. In general. air or air/gas cooled (dry type). Minimising Copper losses The major portion of copper losses is I R losses. and the use of this special metal in drytype transformers may become a practical reality sometime in the future. you can expect units larger than 2500kVA being made in the future. liquidfilled units have a better overload capability. (The more energy efficient the grade of steel used in the transformer core. Basically.) It's even possible for an improperly protected wettype transformer to explode. Liquidfilled transformers are normally more efficient than drytypes.m. you should determine the economic trade off. For example. there is continuous developmental work being done on amorphous core transformers. Nevertheless. Also. there are subcategories of each main type. And. fire prevention is more important with liquidtype units because of the use of a liquid cooling medium that may catch fire. 22 .e. The technical difficulties of constructing a core using amorphous steel have restricted the size of transformers using this material. some have made substantial advances in making these cores for transformers. development of these types of transformers continues. However. For liquidfilled transformers. and recently. the price of the unit versus the cost of losses. however. Thus.3. Cost and manufacturing technique are the major obstacles for bringing to the market a broad assortment of amorphous core transformers. accounts for the very low hysteresis and eddy current losses in the new material. 4. Using a thicker section of the conductor i.
Arguably.5MVA. such as inside an office building or outside. Important factors when choosing what type to use include where the transformer will be installed. the changeover point between drytypes and wettypes is between 500kVA to about 2. Table 42: Comparison of Losses – Oil type and dry type KVA 500 750 1000 1500 2000 (Oil Transformer) Losses Half Load (w) Full Load (w) 2465 4930 3950 7900 4360 8720 6940 13880 8155 16310 KVA 500 750 1000 1500 2000 Dry Type Transformer Losses Half Load (w) Full Load (w) 5000 10000 7500 15000 8200 16400 11250 22500 13200 26400 23 .2 shows losses in dry type and oil filled type transformers. but the vast majority of the highercapacity transformers are liquidfilled. servicing an industrial load. For outdoor applications. The flowing table 4. Drytype transformers with ratings exceeding 5MVA are available. wettype transformers are the predominate choice. when choosing transformers. with drytypes used for the lower ratings and wettypes for the higher ratings.
91 is invested at an annual interest of 10%. 2 A PW EL HPY B p T For some typical operating values. PW = ((1 + i ) − 1) n i (1 + i ) n where PW is present worth of future cash flows i = per unit interest rate n = number of years Purchase of a transformer involves first cost and subsequent payment of energy charges during a given period.5.1 = Cost of electricity. The period of ‘n’ years may be 10 to 15 years. but having a higher efficiency and thus lower running charges. explained in previous section 5.2 Total Ownership cost of transformers TOC EFC = Purchase Price + Cost of No load loss + Cost of Load loss Cost of Core loss EFC = A X No load loss in Watts Cost of Load loss EFC = B X Load loss in Watts Where = Equivalent first cost of No load losses.91x (1+10/100) = Rs 100/. The benefits will have to be converted into their equivalent money value and deferred benefits have to be converted into their present worth in money value for a proper evaluation.at the end of one year. tangible or intangible and immediate or deferred. 5. Similarly. ECONOMIC ANALYSIS 1. if the annual rate of interest is 10%. details of calculation given in section 3. The effective first cost or the total ownership cost can be had by adding the present worth of future energy charges. The cost of capital is reckoned as the rate of interest where as the purchasing power of the currency measured against commodities determines the relative value of money in a given economic domain. Total Ownership Cost.91/. The concept of evaluation can be applied to transformers with the assumptions that the annual losses and the load level remain steady at an equivalent annual value. let us calculate the TOC EFC for a 1000 kVA .e. The deferred monetary gains/expenses are expressed in terms of their present worth (PW). Hence the present worth of Rs 100 after one year is Rs 90. The longer the period. Rs/ kWh. the tariff is constant and the rates of inflation and interest are constant. physical life and perceptions of return of capital of the agency making the investment decision. Rs/Watt = PW × EL × HPY 1000 = Present worth. Benefits may be in cash or kind.1 Introduction For any investment decision. future expenses have to be accounted for. 11 kV/433 V transformer having no load losses of 1500 Watts and load losses of 10000 Watts ( at full load). the cost of capital has to be weighed against the cost/benefits accrued. but the TOCEFC concept is widely used method for evaluation.. ‘n’ will be roughly equal to the economic life of the equipment governed by the technical obsolescence. The TOCEFC i. Generally. greater the uncertainty. 24 . If Rs 90.Effective First Cost adds an appropriate amount to account for energy expenses and shows a better measure of comparing an equipment with higher first cost. to the owner of the transformer = Hours of operation per year = Equivalent first cost of load losses = A ×p ×T = Per Unit load on transformer = Temperature correction factor.1. it will yield 90. These assumptions have obvious limitations.1.
The calculations for a standard transformer are done in previous section 5. which can be taken as equivalent immediate returns.52 Rs/Watt If operating temperature is 100 ºC.9 x 1. Moreover.06523 Equivalent first cost of load losses B = A × p 2 × T = 243.5 + 100 = = 1. Thus TOCEFC = (Present depreciated effective cost of old equipment – Salvage value) + A X No load loss + B X Load loss 5.1 summarises purchase price and losses of two transformers of same rating 1000 kVA.2.000 1210 W 7964 W 4215 W 25 . Let us now compare a high efficiency 1000 kVA transformer with the standard transformer.10000 W Load loss at 75% .Purchase price Life of equipment. RT − op 234.000 Noload losses .1(1 + 0. T = 0.0 per kWh = 8000 = 0. a Interest rate (discounting factor).0808 +0. The value left in a working equipment can be evaluated either by its technical worth.06523 = 145.1) ) = 7.75 = 100 ºC 15 Per unit transformer loading (average) Operating temperature n ((1 + i ) − 1) = ((1 + 0.1500 W Load losses at 100% .000 = 15 years = 4.3 = 800000 + 243. taking its left over life into consideration or by the economic evaluation by its depreciated value as per convenience.52 x 1500 + 145.9152 x 10000 = Rs 2624432/ Decisions for changeover to new equipment In this case there is an added cost of the existing working equipment.00.1) PW = Present Worth = i (1 + i ) n −1 15 0. Table 51: Comparison of transformers Standard Transformer Purchase price – Rs 8.0808 RT − ref 234.4 Sample Calculations Total Owning Cost of a 1000 kVA Transformer Using Noload and Load Losses and present worth is estimated below. the prediction of life is very difficult due to varying operating parameters.5% = 10% = Rs 4. n Inflation rate. 9152 Rs/Watt TOC EFC 5.00. i EL = Cost of Electricity HPY = Hours per Year = Rs 8.50.5 + 75 Hence Temperature correction factor.6234 W HighEfficiency Transformer Rs 9. Table 5. 61 × 4 × 8000 Equivalent first cost of No load losses A = PW × EL × HPY = 1000 1000 = 243.0808 = 1.52 × 0. there is a salvage value.1/1.75 2 × 1.61 7 . For transformers. for any equipment.
54.840/Note that a high efficiency transformer is having much less Total Owning Cost compared to a standards efficiency transformer in spite of higher investment.52 x 1210 + Rs 145.52 / year = Rs 145.9152 x 4215 = Rs 18.Total Owning Cost of Transformer #1 (standard efficiency) = Rs 2624432/. Total Owning Cost of transformer #2 (high efficiency): A B = Rs 243.69.69.592 Present Value of Savings with Energy Efficient transformer = Rs 2624432 . 26 .Rs 18.592 = Rs 7.000 + Rs 243.as estimated in section 5.9152 / year Total Owning Cost of HighEfficiency transformer = Rs 9.2.50.
04 Euro/kWh. Three case studies are from Indian industries and six case studies from international scenario.63/W for load losses. The company follows the total ownership cost (TOC) concept and has used A and B figures of EUR 2.6 kg/kWh with a cost ranging from Euro 10 to Euro 33/ ton. The payback is considered for extra price to be paid for the low loss transformer and it is around 2 to 3 years. The applicability of Low Loss designs in each rating is analysed and payback period is found out. The likely penalty/gain per Ton of Co2 in monetary terms is taken as 0. 27 . Thus CO2 cost can be 15 % to 50 % of Energy cost. 6. Table 61input data 1250 kV transformer Transformer load Economic lifetime Interest rate Energy price Harmonic spectrum % A (noload loss evaluation) B (load loss evaluation) 65% (constant load. 24/24h) with 6 pulse harmonics 10 years 7% EUR 40/MWh 1 3 5 7 9 11 13 15 17 19 100 0 29 11 0 6 5 0 3 3 EUR 2.02 Euro/kWh. Load is constant during 24 hours a day. Netherlands assume full details of No Load Loss and Load Loss as well as portion of Eddy Losses in Load Loss as being available from transformer manufacturer or from relevant standard.1 Introduction CASE STUDIES There are nine case studies presented in this chapter.46 /W EUR 1. Transformer ratings vary from 800 kVA to 4800 kVA. All studies are presented in the year 2002. 7 days a week. The Load Loss figures given in the tables give the Load Losses considering the harmonics in the load.04 /W 21 0 23 2 25 2 Illustrative Calculations Inflation is not considered and hence the present worth expression is simplified using a = zero. Motors. In the first case study. The energy price is taken as 0. This factor however is not applicable for payback and it is thus not considered for payback in the tables presented. There are about 400 Transformers.2 Case Study 1 The case study considers a large company in the Iron and Steel sector. The comparative figures are given for 1250 kVA transformers. No tests are conducted at site. About 200 Nos. The remaining 340 MW is through distribution transformers.3 kg/kWh to 0. The case studies also give the energy saving gains in terms of reduction in carbon dioxide (Co2) emission.27/W for no load losses and EUR 1. This gives a monetary factor of 0.T. Almost all the transformers are of Dry Type due to problems faced in the earlier oil cooled transformers. The average loading is 400 MW out of which about 60 MW is through H.6 6. are of 1250 kVA and about 100 Nos. The harmonic content of the load is given for each typical application. Most of the transformers are replaced between 1982 to 1990.003 Euro/ kWh to 0.T. The case studies from KEMA. the factor for enhanced eddy losses in the first load loss is shown for illustration only for illustrating rough order of values. of 1600 kVA while the remaining 100 Numbers are of different ratings. utilization by H.
i.05 ) × 169 + (0 .65 = 1. the fifth has 29% value of the fundamental.2116 + 0.07 per unit.e. it should 2 be used in the calculation. If data from design is available for percentage of eddy loss at fundamental.02 ) × 625 2 2 2 = 2. 0.4356 + 0.65.07 )10 − 1 = 7.039 = EUR 1.06 ) × 121 + (0 .04/watt 6.65 x 0.07 ) Pw × EL × 8760 = EUR2.u.1) x 1] The Extra addition is over and above eddy losses due to fundamental frequency and hence extra harmonic factor 2 K h = ∑ Ih h=1 h =n ( I1) × h 2 2 − 1 Or K h = ∑ Ih h =3 h =n ( I1) × h 2 2 For the given six pulse harmonics.1 Factor for Harmonics Factor for eddy losses = ∑ (I I ) × h h =n h=1 h 2 1 2 If harmonics are absent. loading] x [0.1025 2 2 2 2 2 2 K h = (0 .6 28 .Present worth = (1 + i )n − 1 n i(1 + i ) Interest Rate 7 % i.2601 + 0. copper losses due to I R can be taken as 90 % and 10% of the specified Load Losses can be attributed to eddy losses at fundamental frequency.0236 = 10 0.6001 Total eddy loss factor = 4.02 ) × 529 + (0 .5929 + 0. Period is 10 years Pw (1 + 0.29) × 5 × 5 = 2.29 ) × 25 + (0 . 0. the tested load losses have eddy losses at fundamental.11 ) × 49 + (0 . Thus Load Losses at fundamental frequency = Load Losses x [p.46 x 0.6001 + 1 = 5. P = 65 %.4225 + 0.25 = 4. T=1 B = 2.07(1. 03 ) × 287 + (0 .2.04 EUR/kWh A= B = A x P x T.e.3249 + 0. Hence K 5 = (0. In the absence of specific data. 03 ) × 361 + (0 .9 + (0.46/Watt 1000 2 EL = 0. this factor is one.1025 + 0.
42826 = 13568. the distribution works out to 88.73 or 11712 watts.42826 = 11711.2. and 52% in 1600 kVA transformer. The method thus illustrates the steps to calculate full load loss (harmonic loads) if the distribution is known. The needed derating would be (11. For 1250 kVA rating.3.2 Percentage of Eddy Losses in Load Losses: The next step is to evaluate full load losses with harmonic loading for the given transformer and also for the relatively low loss transformer of similar rating being considered for replacement. For similar harmonic load factor of 5.u.2.2 and Table 6. the existing and new low loss design have following data for the subdivision of eddy losses.31% Existing Transformer: Full load losses on Harmonic Load = Rated load losses on linear loads x [p. Eddy loss)] = 9500 × (0.2.47 Or 13568 Watts For Suggested Low Losses transformer Full load losses = 8200 x 1. 90% and 10% subdivision can give a reasonable value.31 % 6.42) = 0.5207 = 15207 w. Copper + K (p. Thus rated full load loss (Linear) of 10000 w yields a figure of 10000 x 1. Existing 1250 kVA No Load 2400 W Rated Load Loss 9500 W Assumed % Copper Losses 90.5207 = 14447 w The actual figure stated is 14218 w. If design data is not available.68% copper losses and 11. The actual loading is only 65% and hence all alternatives considered are safe from the view point of temperature rise. the figures are inferred from the final load loss figures given in the KEMA publication.3 Full load losses for Harmonic Loading: Low Loss 1250 kVA 2200 W 8200 W 90.093) = 9500 × 1.69% 9.6. This is not always true as can be seen from tables given in the annexure.69% Assumed % Eddy Losses 9.5207.839 and (11. Incidentally it shows that due to harmonic loads the full load losses have gone up by 42% in 1250 kVA. 6.6 × 0.9069 + 5. It can be noted that inferred distribution is very close to assumed distribution of 90% and 10%.u.32% for eddy losses. This requires data on percentage of Eddy Losses in conductors in the total Load Losses for the existing transformer and the nearest low loss substitute.6 the multiplier comes to 1. 29 . For 1600 kVA transformer.811 For 1250 kVA and 1600 kVA respectively for harmonic loading.4 Relative economics for low loss transformers (All Dry type) The data worked out for 1250 kVA and 1600 kVA are given in Table 6.52) = 0. The low loss substitute has full load loss (linear) = 9500 x 1. Thus a slightly different distribution is considered for the low loss substitute.
0 13000 5414 12178 30592 Difference 200 1856 8623 3. Carbon Dioxide emission at 0.5 = 71240.65 x 8760 kWh = 21024 + 50216. low losses 1600 2670 14218 76012 30.8 34% ton/a EUR EUR EUR EUR 14451 6891 15812 37154 Comments: The figures for 1250 kVA.04 = EUR 14110 Total Capitalised Cost = EUR 32265 A similar figure for low loss transformer is EUR 30592 30 .5 = 71241 kWh/annum.4 kg/kWh = 71241 x 0.4 kW Rated load loss = 13568 W = 13. existing transformer are illustrated first.Table 62 1250 kVA transformer Unit Transformer rating Rated noload loss Rated load loss Total annual losses CO2 emission @ 0. low losses 1250 2200 11712 62618 25.2 45% ton/a EUR EUR EUR EUR 12250 5907 14108 32265 Table 63 1600 kVA transformer Unit Transformer rating Rated noload loss Rated load loss Total annual losses CO2 emission @ 0.3 Dry transformer.4 14990 6571 14784 36345 Difference 130 989 4797 1.568 kW (full load) Annual losses for 65% loading for 8760 hours = 2.568 x 0.9 539 320 1028 809 2.5 750 493 1930 1673 2.4 x 8760 + 13.4 kg/kWh Purchase price Present value noload loss Present value load loss Capitalised costs Pay Back (years) Internal rate of return kVA W W kWh/a Dry transformer 1600 2800 15207 80809 32. Rated No Load Loss = 2400 w = 2.4 kg/kWh Purchase price Present value noload loss Present value load loss Capitalised costs Pay back (years) Internal rate of return kVA W W kWh/a Dry transformer 1250 2400 13568 71241 28.5 Tons/annum Purchase Price is given as EUR 12250 (About Rs.673750) Present value of no load losses 2.65 x 0.5 Dry transformer.4 = 28496 kg = 28.46 x 2400 = 5904 Present value of Load Loss = 13568 x 1.
But almost 180 MW are consumed through dedicated high voltage transformers for electrolysis. Excepting 3 new dry type installed in 1999. most of the transformers are old (1965 to 1970).3 Case Study2: Non ferrous metal sector In a large company in the non ferrous metal sector.04 x 8623 = EUR 345 = Simple payback 750 = 2.8 years. 6. IRR 34 %.12 % Extra Investment) 345 Internal Rate of Return = 100 = 45 %about. giving a very low B factor. Due to somewhat higher load loss figures used for TOC during initial purchase. 2. The total saving potential of 2939 MWh/year is equivalent to EUR 117564/year and is 0. (For about 6.73 % extra cost).2.2 to 2.084% of 6 the total consumption of 3. 35% during 14 hours.8 years for an added investment of EUR 539 (about 3.2 years. Since the loading is low. Total number of transformers is 25.4 summarises the data for dry transformers and oil cooled transformers for future replacement. 2 . Hence it is not very attractive to replace existing transformers by scrapping. 6. wherein a good number is at 1000 kVA. The scope for distribution transformers is limited is only to 10 MW. saving thereby 8623 kWh/annum.2 A similar calculation for 1600 kVA shows a saving of 4797 kWh and a payback of 2.5 x 10 MWh/year.44/watt And B factor = EUR 0. Payback for extra investment of EUR 750: The low loss transformer consumes 62618 kWh/annum. 31 . Table 6. Harmonics are not considered. the total loading is about 190 MW. the load variation is about 45% during 10 hours. Thus the annual saving = EUR 0. The loss pattern is No load Load loss = 1900 Watts = 10250 Watts Calculations for1000 kVA old transformer with the loading pattern and 5 years of life with 7% interest rate gives the A factor = EUR 1.5 Summary: 1.This figure favours the low loss type with an initial purchase price of EUR 13000 which is EUR 750 of added investment.24/Watt.17 or 2. the low loss substitutes show an attractive payback of 2. higher investments have been preferred. Out of it. If a transformer is to be replaced for any reason. direct replacement is not economically viable.
Average loading is 65%.5 8007 1580 2322 11909 Difference 900 900 6543 2.2 33.0099% of the total electricity charges because only a small fraction of the total load is qualifying for calculation of savings. The remaining is distributed with 52 transformers with ratings of 1000 kVA and 3150 kVA. The highlight of the case study is that in 1986. The case is presented for 3150 kVA transformer for which the input data is given in table 6. out of which 72 MW are used at high voltage for HT motors. The dominant number (28) is 3150 kVA transformers with LV of 690 Volts.1 Oil CC’ transformer 1000 1100 9500 23793 9. the peak electrical loading is about 110 MW.71 /W EUR 1. Table 65: Annual savings potential Transformer size 1000 kVA Other Total 6. This is equal to EUR 6560 and 0. the company took special care to select transformers with low losses for long term gains.6 2067 1293 220 3140 N/A N/A ton/a EUR EUR EUR EUR 10074 2873 2102 15049 In this case.8 65 Case Study3: Paper & Pulp Company A paper mill started functioning since 1978 and was expanded in 1986. since the low loss transformer also happens to have a lower first cost. Table 6.57 /W 32 .Table 64 : Outcome 1000 kVA transformer Unit Transformer rating Rated noload loss Rated load loss Total annual losses CO2 emission @ 0. the oil transformer has a lower first cost and also lower losses.5 summarise the overall potential for the saving. Hence it is the most favored choice and the rate of return is not applicable.4 kg/kWh Purchase price Present value noload loss Present value load loss Capitalised costs Pay back (years) Internal rate of return kVA W W kWh/a Dry HD 538 transformer 1000 2000 8600 30336 12.4 Total number 12 13 25 Energy saving [MWh] 78. These transformers are better compared to the low loss transformers available today.1 164 CO2 emission saving [tonnes] 31.6 Table 66: Input data of 3150 kVA transformer Transformer size Transformer load Economic lifetime Interest rate Energy price Harmonic spectrum A (noload loss evaluation) B (load loss evaluation) 3150 kVA oiltype 65% during 24/24 hours with 6 pulse harmonics 20 years 7% EUR 40/MWh 6 pulse according to IEC 14611 EUR 3.5 85.
If the Low Loss type is chosen. the preference is clearly in favour of lowest first cost.29/W (40% loading ). The economic life time is considered as only one year and interest 7%.52/W initial and also the same value for no load losses. Highlights: The study shows that due to selection of one year as economic life. The remaining transformers are 630. it still gives large savings with an internal rate of return of 33 % and a payback period for extra investment of 3 years. Interest rate is taken as 7%. Energy price EUR 50/MWH. Loading is continuous round the clock and loads are nonlinear. despite variations in the processes.7. The startup load connection is typically 100 MW in the growth expectation of 200% to 300% rise per year for a few years.4 kg/kWh ton/a Purchase price Present value noload loss Present value load loss Capitalised costs Pay back (years) Internal rate of return EUR EUR EUR EUR kVA W W kWh/a Oil 1978 transformer 3150 2870 24500 181908 72. B = EUR 0.8 Ton. harmonics etc. the potential savings can be 214.6 Case Study 5 Case of a Large Data Hotel Start Up This is a high growth rate business with computers as a major load. a fictitious but representative case study is prepared.4 MWH/yr. common trends are observed regarding electrical installations. It is seen that even though 1986 transformer is about 30% more expensive. A= EUR 1. motors and thus out of the purview. It is revealed that compared to 1600 KVA Dry type normal and 1600 KVA 33 .0 24987 11693 45553 82233 Difference 280 7700 46816 18. A = EUR 0. Highlights: For the chosen parameters.8/W and B= EUR 0. 6. High reliability requirements lead to redundancy in transformer installations and a low average loading of about 40%. Energy at EUR 60/MWH. 1000 and 1600 KVA.The comparison of the 1986 low loss transformer is made with the original supply of 1978 based on the likely prices as prevalent in 2002.2 years with a rate of return of 6%. the differences are marginal.8 19329 10654 66432 96415 Oil 1986 Transformer 3150 3150 16800 135092 54. The study compares 1250 KVA HD538 transformer and 1250 KVA low loss transformer. Life time is considered 5 years and harmonics are not considered. and payback is 4. high harmonic loading.V. This is a case where the chosen parameters of lifetime. Based on the general observations. The results are shown in table 6.5 Case Study4 Chemical Industry In the KEMA studies. The extra cost of Low Loss type is EUR 750 over EUR 12250. A typical rating is 1250 KVA (60 out of 71 transformers). out of which 40 MW are for electrolysis or H.24/W at the end of the year.03/W initial and 0. loading which reaches 70% at the end of one year. Which can also mean savings in CO 2 emission of 85. can significantly affect the decision. it is observed that.8 5658 1039 20879 14182 3.0 33% It is estimated that the company is already saving 46816 kWh/year due to these transformers. Figures assumed are 25% initial 24 Hrs. Table 67 Outcome of 3150 kVA transformer Unit Transformer rating Rated noload loss Rated load loss Total annual losses CO2 emission @ 0. Average loading is 110 MW. 6.
District Coimbatore.7 6. In such a case. and 17132 (low loss) respectively initially.2 3.9 3.8 Case Study 6: Tea Industry (India) Energy Audit for Tea Factories making C.7 5. 2 Losses = 1. Alternatively the investment in the transformer can be made by the utility with a long term perception to make energy saving possible. a) Only one transformer takes full 500 KVA LOAD.1 2.1 1.S (India) Ltd. 6. Power is received at 22 kV and 11 kV by separate lines. It is important to note that the payback period is not affected by the choice of economic life span. the cheapest would be an oil cooled CC’ type transformer. with a capitalised cost for initial period as EUR 12951 including harmonics. The typical loss figures for 500 kVA transformers are 1660 W for no load and 6900 W as losses for 100% load.T. Tea.. Audit was conducted in May 1990 for Mayura and Parlai Tea factories. Loading and electricity price are two most important factors.1 2.low loss Dry type. Brief Analysis: For total load of 500 kVA. load Recommendation: Parallel both transformers for a total 500 kVA load on secondary side and in lean season and holidays when the load is 5% to below 25%.1 2. The extra price of EUR 539 can not be recovered in the economic life prescribed. At the end of one year the figures are EUR 22311 and 22366.6 0 10 33 20 40 60 1 5 10 5 7 9 80 100 120 Payback time (years) L M H 3. and H.5 3.3 3.1 3.4 0. Loading should be carefully evaluated for a proper choice.1 2.1 3.66 (No Load) + (500/500) x 6.V. cut off one transformer on H. there are three options.1 3.5 3.1 3.0 3. Table 6.W.3 3. provided the hot spot temperature is acceptable. The capitalised costs with harmonics are EUR 16714. Table 68: Parameter sensitivity on the payback period Parameter Unit Harmonic spectrum Electricity price CO2 emissions CO2 costs Loading profile Economic lifetime Interest Purchase price EUR/MWh kg/kWh EUR/tonne % years % % Parameter variation L M H None 12 pulse 6 pulse 40 60 80 0.1 3. Thus the low loss transformer is still not attractive. higher operating temperature due to harmonics suggests a drastic decrease in operating life from 30 years to 6 years.7 4. Even then the selected short economic life span makes this choice viable.C.1 3. The utility can shift the transformer later to a suitable load as needed.2 3. By the same consideration a smaller rating 1000 KVA transformer gives a capital saving of 25% even though it has an energy penalty.9 kW (load losses) 34 .8 gives a summary of effect of Low. but the relatively longer payback loses its significance due to short time investment perception. Even for this transformer. The oil cooled transformer is a winner in the short run.1 3.4 3. Medium and High values of parameters on the payback period.3 0. This is stepped down by two 500 kVA Transformer o 22 kV/433 V an 11 kV/433 V which fee segregated loads. There is a net saving of 8222 KWH/year after one year which equals about EUR 411.7 Summary of European Case Studies: There is an interesting summary of the sensitivity of the payback period to input parameters. enforcing minimum loss norms only can help. sides. managed by H/S C.V.
The total annual consumption for the factory was 1856479 kWh per year and the electricity bill was Rs.66 + (250/500) x 6.D.05/2) x 6.9} kW = 3.b) One transformer takes segregated 300 kVA while second takes 200 kVA segregated load.89 x kWh + Rs.25/2) x 6.D. charges and also give savings on transformer and cable losses.000 project involves the installation of a highlyefficient 25 MVA transformer to replace two older and smaller transformers. Energy saving measure Prior to the energy efficiency project.66 + (300/500) x6. the losses are minimum by paralleling both transformers.9 = 1. 1. x Rs.9 kW c) Both are paralleled to take 250 kVA each. and inherent transformer losses.05) x 6.9) kW = 6. Energy consumption profile: Energy use at the plant is comprised of consumption at the steel melting shop.66 x (0. Loss = 1. 2038694 giving Rs. Loss = 2 (1.25) x 6. This would reduce M. 66 + (0. the wire rod mill. The project is designed to reduce energy costs.09 kW at 25% load 2 Losses = 1. for a 35 . 66/11KV transformers. the power from the grid was being tapped through two12. Thus on major load.5 MVA. 10000/year as a saving. When power quality is good. The average specific energy consumption during good voltage conditions is about 200 kWh per ton. it was expected that specific consumption would be reduced by 3035 kWh per ton.9 +1.9 Case Study 7: Steel Mill (India) 2 2 2 2 2 INTESCOBhoruka has implemented an energy efficiency project at Bhoruka Steel's Karnataka minimill. The tariff was kVA of M. consumption can increase up to 700 kWh for the same product mix. By improving the voltage quality under this project. The saving by paralleling and switching off one transformer were conservatively estimated at a minimum of 10000 kWh/year with no investment giving a little over Rs.68 kW at 5% load Thus losses are minimum at low loads using only one transformer.54 kW at 25% load 2 Losses = 2 {(1. 60 + Rs.66) + (0. and increase plant productivity. specific energy consumption averages between 550 kWh and 650 kWh per ton. Operation at higher loads during lean season: a) Two paralleled transformers Losses = 2 [1. 0. The wire rod mill produces wire rods from 5 mm to 16 mm in diameter. Power factor improvement was already made but some scope for further improvement was suggested. there was not expected to be any substantial reduction in energy usage as a result of the project. Each transformer had a load loss factor of 1012 kWh per ton. With poor power quality. 6. The $265. and save on M.66 + (200/500) x 6.33 kW at 5% load b) Only one transformer is energized Losses = 1.77 kW.9} kW = 3.D. 150 meter rent.66 x (0. As the drive systems at the mill already have inbuilt automatic voltage regulators.9 = 2.0094/kWh as average cost. The company's energy costs have increased due to power shortages and low voltage levels causing inefficient operation of its melting and casting operations. The steel melting shop has a 30ton GEC electric arc furnace.
(A heat is the process of melting steel in an arc furnace in preparation for casting. it was proposed to replace the two 12.37 lakh kWh/year) In sub station # 7. 10% and 25% respectively).000 (Rs. with the majority coming from the savings in the steel melting shop (75% of the savings). The new 25 MVA transformer can handle large fluctuations in incoming voltage.9 lakh Cost of Implementation Nil Simple payback period.45 lakh per annum) In sub station # 3. and was completed in September.) The annual energy savings is estimated at 1. 5.total of 2025 kWh per ton.T side to save noload losses. resulting in energy savings. Commissioned in October 1994. While achieving optimum loading.45 lakh kWh per year. 82. Project Savings (in kWh per Ton of Steel Produced) Steel Melting Shop Wire Rod Mill Transformer Losses Total Project Implementation 30 0 10 40 In order to solve the voltage problem. In sum. up from five per day previously. one transformer was kept as stand by. In few of the cases it was observed that some transformers are grossly under loaded (around 1020%) and the scope exists to shift or distribute this load to other transformer in the substation. Immediate 36 . Loads of transformer # 2 was transferred to Transformer # 2 and Transformer # 2 was switched off (Energy savings 0. 20% and 15% respectively). transformers # 2 and # 3 were drastically under loaded (i. Rs.8 million KWh. This hot standby transformer can be kept open (Energy savings 0.10 Case Study8: Automobile Plant (India) A leading automobile manufacturer has main incomer at 132 kV. Loads of transformer # 2 was transferred to Transformer # 1 and Transformer # 2 was switched off (Energy savings 0. loading on transformers located at various substations was analyzed.e. transformers #1 and #2 were drastically under loaded (i. resulted in energy saving of 0. 36 lakhs). plant has several transformers located in eight substations.Bhoruka was expected to reduce energy consumption per unit of steel produced by as much as 8%. During an energy audit. the standby transformers at various substations were suggested to be kept open on H.e. Annual Total energy savings. The new 25 MVA transformer installed by INTESCO.5 MVA transformers with a single 66/11 KV 25 MVA transformer fitted with an onload tap changer. This voltage is stepped down to 11 kV. This would also ensure optimum level of loading.000 per year (Rs.69 lakh KWh Annual Cost savings. Also an operating schedule was proposed to alternate the transformer operation weekly so as to keep them in good health. In sub station # 1.3 years 6. Installation of the new transformer was expected to slash load loss by half (to a total of 1012 kWh per ton).42 lakh kWh/year) In substation # 8. From 11 kV to 433 V. the total savings per ton of steel produced was expected to reach 40 units per ton. The project has a simple payback on investment of 2. 1. keeping hot standby transformer open. The total cost of the project is about $265. the upgraded plant is already running eight "heats" per day. Construction of the project began in May 1994.6 lakhs) and the combination of improved energy efficiency and productivity is expected to save Bhoruka Steel about $115. These changes would reduce load losses and reduce energy consumption during production.
2500 kVA Transformer Purchase price [Euro] Cost of no load [Euro] Cost of load [Euro] Cost of outage [Euro] Total cost [Euro] 2x 1600 kVA Transformer Purchase price [Euro] Cost of no load [Euro] Cost of load [Euro] Cost of outage [Euro] Total cost [Euro] Oil CC’ 24897 15330 48565 20000 108792 Oil CC’ 27340 20849 37927 <1 86117 Oil DD’ 29402 13030 41280 20000 103712 Oil DD’ 35774 17721 32238 <1 85734 Dry HD 538 25527 26368 39736 20000 111631 Dry HD 538 35902 34339 27091 <1 97333 Dry Low loss 27494 25325 32958 20000 105777 Dry Low loss 38146 32745 25330 <1 96222 37 .=. First there is the economical damage if there is a shutdown. and there will be no interruption of the power and/or shutdown of the factory.000. 4 while the average outage duration equals 2. The MTTR (mean time to repair) or time to replace a failed transformer is 8 hours. The MTBF (mean time between failures) for a transformer is presumed to be 40 years. the economical cost when an unforeseen outage occurs is a necessary input figure. Load kWh/yr. To reduce the risks of an outage. The costs of outages are very hard to determine. Load kWh/yr. the 2500 kVA transformer loading is 60%. chemical) are interested in a reliable power supply. This means the chance that both parallel transformers having a failure at the same time is very small compared to the outage of one transformer. The choice for the designer to use one transformer (2500 kVA) or two transformers (1600 kVA) can now be quantified. Total kWh/yr. which leads to loss of production until the process has restarted.= per MWh. the following costs are expected in these 10 years (see table 6. Next to the direct damage. For this case study. while the loading of the 1600 kVA transformer is 47% when both transformers are in parallel.10).6. Presuming the load is 1500 kVA. the other transformer will carry the full load. Table 610: Costs over 10 years.g. as an unforeseen interruption of the power supply may have severe consequences. whereby each hour outage is equal to Euro 10. and the electricity price Euro 70. it is possible to have two transformers in redundancy. The total annual losses for both options are given in table 6. This means that the average outage frequency equals 0.9 Table 69: electricity losses over a year 2500 kVA Transformer No load kWh/yr.025 per year and the average outage duration equals 12 6 minutes per year.11 Case Study 9: Improving Reliability and availability A lot of industries (e.14x10 per year. 2x 1600 kVA Transformer No load kWh/yr. If there is redundancy the average outage frequency equals 1. Oil CC’ 21900 Oil DD’ 18615 Dry HD 538 37668 Dry Low loss 36179 69379 91279 Oil CC’ 29784 54182 83966 58972 77587 Oil DD’ 25316 46054 71370 56765 94433 Dry HD 538 49056 38702 87758 47083 83262 Dry Low loss 46778 36186 82964 If the economic life time is estimated at 10 years. This means if one transformer fails. for this given situation it is presumed that outage of the electricity will cause a shutdown of the factory. Total kWh/yr.7x10 minutes per year. long outages may cause pollution and human safety problems. But also there can be damage of the installation.
the noload losses are as low as 384W. which is not taken in account in this case study.’ At an average loading of 70%. while providing dramatically lower losses than a conventional transformer.3GWh less energy a year than a conventional transformer. it can be seen that the costs of outage are having influence on the total costs over 10 years. The load losses are 18. and the payback period is 3 years.500 over a standard transformer. completed by Pauwels International. the designer will probably order two 1600 kVA transformers. The 1. the AMDT should pay for itself in about three years at current Irish power prices . compared to 1. it is clear that redundancy of transformers is preferred anyway for situations were shutdown of a process causes pollution or safety risks. the AMDT will use 13. The transformer has increased the site’s power capacity by 40%. However if the average costs of an outage are taken in account.and continue to make savings over its 2030year life. the designer would probably have chosen for a single 2500 kVA oiltransformer type DD’ or a dry transformer with lower losses than given in the HD 428.6MVA transformer is the first to be designed specifically for the European industrial market.10. 38 .From table 6.12 Case study10: Use of Amorphous Core Transformers This case study describes the choice of amorphous core distribution transformers in place of conventional silicon steel core transformers.700W for a HD 428 CC’ transformer. A very large amorphous iron threephase distribution transformer has been built and installed in the European Union at an engine plant at Waterford in Ireland in 1998. is the first AMDT to target European industrial customers. 6. With a price premium of £2.2kW. If the costs of outage are neglected. the two 1600 kVA transformers will also need an installation more than the 2500 kVA transformer. Nevertheless. The 20kV/400V transformer. With noload losses up to 80% lower than a conventional silicon core transformer. However.
Noload core loss. which relates to efficiency and verifies that core design is correct. which also relates to efficiency and correct core design. Insulation resistance (megohmmeter testing). The instructions mentioned in the manufacturer manual or in Standards shall be followed to ensure adequate safety to personnel and equipment. which again directly relates to the transformer's efficiency. which determines voltage drop when load is applied. The additional tests that can be conducted include the following: • • • • • Impulse (where lightning and switching surges are prevalent). which helps determine if the insulation system is functioning properly. various procedures should be carried out to assure successful operation. Sound (important for applications in residential and office areas and that can be used as comparison with future sound tests to reveal any core problems). which is done at initial installation and every few years thereafter to help determine the aging process of the insulation. Temperature rise of the coils. Phase relationship for 3phase units (important when two or more transformers are operated in parallel). depending upon how and where the transformer will be used. Regulation. The successful operation of a transformer is dependent on proper installation as well as on good design and manufacture. and Applied and induced potentials. which determines dryness of insulation and is often done after delivery to serve as a benchmark for comparison against future readings.ANNEXURE1: GUIDELINES FOR INSTALLING TRANSFORMERS When your transformer arrives on site. There are additional tests that may be applicable.and 3phase units (because singlephase transformers are sometimes connected in parallel and sometimes in a 3phase bank). which helps ensure that design limits will not be exceeded. Resistance. This section will provide general guidelines for installing and testing both drytype and liquidfilled transformers for placement into service. Polarity for single. Standard transformer tests performed for each unit include the following: • • • • • • • • • • Ratio. which verify dielectric strength. and Insulation power factor. Excitation current. for voltage relationship. Load loss. • 39 . Corona for medium voltage (MV) and highvoltage (HV) units. for calculating winding temperature Impedance (via short circuit testing). which provides information needed for breaker and/or fuse sizing and interrupting rating and for coordinating relaying schemes.
a definite hum will be noticed. Check all of the tap jumpers for proper location and for tightness. the core laminations elongate and contract. a claim should be filed with the carrier at once and the manufacturer notified. or compressors. or moving equipment. and testing of the transformer. the transformer hum will go unnoticed. The location of a transformer relates directly to how noticeable its sound level appears. pumps. Ensure that all grounding or bonding systems meet NEC and local codes. Although there are no moving parts in a transformer. Occasionally. In the presence of a magnetic field. 40 . Before working on the connections make sure all safety precautions have been taken. and any other objects used in the inspection. and. a transformer should be inspected for damage during shipment. These periodic mechanical movements create sound vibrations with a fundamental frequency of 120 Hz and harmonics derivatives of this fundamental. loose or broken connections. trucks. and for the presence of water or moisture. assembly. when energized. the secondary neutral is sometimes grounded through an impedance. Note that for MV transformers. the installation of some method of sound abatement will be called for. Arrangements shall be made to adequately support the incoming/outgoing connecting cables. produce an audible noise. dirt or foreign material. equipment. and material. so that there is no mechanical stress imposed on transformer bushings and connections. hardware. Preliminary inspection upon receipt of transformer When received. that complies with all safety codes yet does not interfere with the normal movement of personnel. For example. covers or panels should be removed and an internal inspection should be made for damage or displacement of parts. if any damage is evident or any indication of rough handling is visible. the location is selected. Such stress could cause a bushing to crack or a connection to fail. if the transformer is installed in a quiet hallway. between the transformer's terminals and the incoming and outgoing conductors.Site considerations When planning the installation. such as a large unit in a commercial building with people working close to it. Subsequently. the core does generate sound. Retighten all cable retaining bolts after the first 30 days of service. The location should not expose the transformer to possible damage from cranes. carefully following the instructions given on the nameplate or on the connection diagram. Plan for the prevention of contaminants Develop a procedure for inventory of all tools. Some applications require a reduced sound level. Make sure the transformer is grounded Grounding is necessary to remove static charges that may accumulate and also is needed as a protection should the transformer windings accidentally come in contact with the core or enclosure (or tank for wet types). Making connections that work The connections shall be made. A check sheet should be used to record all items. this inspection should be repeated before placing the transformer in service. Examination should be made before removing it from the railroad car or truck. and verification should be made that these items have been properly accounted for upon completion of work. If the transformer is moved or if it is stored before installation. Controlling sound level All transformers. If the unit is installed in a location it shares with other equipment such as motors.
Adjustment for correct tap setting After installation. energize the transformer. Both the voltages and currents should change in a similar fashion. Also. A careful examination should be made to ensure that all electrical connections have been properly carried out and that the correct ratio exists between the low and highvoltage windings. deenergize the transformer and contact the manufacturer before proceeding further. For this test. While monitoring the voltages and currents. apply a lowvoltage (240V or 480V) to the highvoltage winding and measure the output at the lowvoltage winding. should be checked to make sure they function correctly. Any control circuits. arrangement for monitoring the voltages and currents on the lowvoltage side shall be done. if any. If this does not happen. gradually increase the load in a stepped or gradual application until full load is reached. Personnel should be instructed that should any service work be required to the unit. tap connections below 100% of line voltage must be used to raise the load voltage. a transformer turns ratio indicator should be used to measure the ratio. the lines that power the transformer must be opened and appropriate safety locks and tags applied. Next. the same changes must be made for all phases. deenergize the transformer and contact the manufacturer. check the output voltage of the transformer. tap connections above 100% of line voltage must be used to lower the load voltage. without connecting the load. motors. Consult the transformer diagrammatic nameplate for information on what tap must be used to correct for extra high or extra low incoming line voltage. and other auxiliary devices. If this is not the case. An insulation resistance test shall be carried out to make certain that no windings are grounded. for lowvoltage (600V and below) transformers. Here. When the loadside voltage is low. The magnitude of the voltages shown (linetoground and linetoline) should be very similar. Dangerous high voltage will be present within the transformer enclosure. a oneminute. However. These include the operation of fans. The same adjustment should be made to compensate for voltage drop in the output due to long cable runs. connect the load and energize the transformer. The installation of conductors should be performed only by personnel qualified and experienced in highvoltage equipment. Applying the load Before energizing a 3phase transformer. they should be closed. Then. This should be done at some safe access point near or at the load. (If the power transformer has CT circuits. that lethal voltages will be present inside the transformer enclosure as well as at all connection points.) All windings should be checked for continuity. this is not practical. If the loadside voltage is high.Final inspection and testing Once the transformer has been located on its permanent site. it's very important that all personnel installing the transformer are alerted. thermal relays. The maximum continuous load a transformer can handle is indicated on its nameplate. Before energizing the unit. a thorough final inspection should be made before any assembly is accomplished and the unit is energized. 1200V insulation resistance test of the control circuits shall be done. Correct fan rotation should be visually verified as well as by checking indicator lights if they are installed. When changing taps. 41 . Never attempt to check the output voltage at the transformer.
change by spare charge.02 Hourly Hourly Ambient Temperature Oil & Winding Temperature Check that temperature rise is reasonable Shutdown the transformer and investigate if either is persistently higher than normal Shutdown the transformer and investigate if either is persistently higher than normal If low.01 1. Check colour of active agent Examine for cracks and dirt deposits Check for dielectric strength & water content Lubricate bearings. 2.05 Daily Daily Daily Daily Oil level in bushing Leakage of water into cooler Relief diaphragm Dehydrating breather 3.02 2. The old charge may be reactivated for use again.01 Daily Oil level in transformer Check against transformer oil level Check that air passages are free.02 Quarterly Quarterly Bushing Oil in transformer 3.04 2. examine contacts.03 Hourly Load (Amperes) and Voltage Check against rated figures 2.ANNEXURE2: MAINTENANCE GUIDELINES Following specific checking and maintenance guidelines as well as conducting routine inspections will help ensure the prolonged life and increased reliability of a drytype transformer. Routine checks and resultant maintenance Sl No Inspection Frequency Items to be inspected Inspection Notes Action required if inspection shows unsatisfactory conditions 1. check gear boxes.01 3. The frequency of periodic checks will depend on the degree of atmospheric contamination and the type of load applied to the transformer. Clean or replace Take suitable action 1.03 2.03 Quarterly Cooler fan bearings. motors and operating mechanisms Replace burnt or worn contact or other parts 42 . top up with dry oil examine transformer for leaks Replace if cracked or brokenIf silica gel is pink.
06 Yearly Yearly Surge Diverter and gaps Relays. Take suitable action. which has shorted or opened some winding turns.01 4. with acceptance tests performed before reenergizing. and temperature should be recorded for future reference. Test relays  4. fuses etc.04 4. Examine for cracks and dirt deposits Examine relays and alarm contacts.2kV would have a minimum acceptable value of 2640 megaohms ([13. The minimum megaohm value for a winding should be 200 times the rated voltage of the winding divided by 1000. if leaking Clean or replace Clean the components and replace contacts & fuses.02 4. the transformer should be thoroughly inspected. The measured turns ratio should be within 0. a winding rated at 13. alarms & control circuits 4. humidity. Transformer turns ratio measurements are best made with specialized instruments that include detailed connection and operating instructions. voltage level.03 Quarterly Yearly Yearly Yearly OLTC Oil in transformer Oil filled bushing Gasket Joints Check oil in OLTC driving mechanism Check for acidity and sludge Test oil Filter or replace Filter or replace Tighten the bolts evenly to avoib uneven pressure Replace gasket.05 4. The megohmmeter should be applied between each winding and ground (high voltage to ground and low voltage to ground) and between each set of windings (high voltage to low voltage). The windings not being tested should be grounded. if earth resistance is high 4.check manual control and interlocks 3. The megohm values along with the description of the instrument. when tested under an applied AC voltage. If previously recorded readings taken under similar conditions are more than 50% higher.04 Yearly Cable boxes Check for sealing arrangements for filling holes. This ratio is also equal to the rated phase voltage of the high voltage winding being measured divided by the rated phase voltage of the low voltage winding being measured. Turns ratio testing: The transformer turn ratio is the number of turns in the high voltage winding divided by the number of turns in the low voltage winding.5% of the calculated turns ratio. Insulation PF testing: Insulation PF is the ratio of the power dissipated in the resistive component of the insulation system. Ratios outside this limit may be the result of winding damage.200V x 200] / 1000). their operation. A 43 .07 Yearly Earth resistance IR testing: The transformer should be deenergized and electrically isolated with all terminals of each winding shorted together. divided by the total AC power dissipated. For example. if required.
the transformer is disconnected from all external circuit connections. This testing also applies to drytype units. Applied voltage testing: The applied voltage test is more commonly referred to as the "hipot test. the reduced voltage applied to the primary winding coils may be from a singlephase 120V supply. Acceptance testing Acceptance tests are those tests made at the time of installation of the unit or following a service interruption to demonstrate the serviceability of the transformer. decreasing the conductor cross section and resulting in an increase in resistance. winding resistance measurements should be made and excitation current testing done. it's important that you establish a historic record for each transformer and use good judgment in analyzing the data for significant variations. This test should be used with caution as it can cause insulation failure. If there is a defect in the winding. in separate tests. it's preferable to have established benchmark readings for comparison. the concern for the integrity of the insulation does also. On any single test. localized overheating that opened some of the strands of a multistrand winding conductor. With most transformers. There is normally a difference between the excitation current in the primary coil on the center leg compared to that in the primary coils on the other legs. The voltage should be applied to each phase in succession. The PF of insulation systems of different vintages and manufacturers of transformers varies over a wide range (from under 1% to as high as 20%). thus. Occasionally. which can cause changes to some or all of the winding conductors. Winding resistance measurement: Accurate measurement of the resistance between winding terminals can give an indication of winding damage. To conduct this test.perfect insulation would have no resistive current and the PF would be zero. with a voltage applied to the input terminals of the primary and the secondary or output terminals opencircuited. Untested windings are grounded during each application of voltage. Sometimes. 44 . In addition. It should be regarded as a proof test to be conducted when there has been an event or pattern in the transformer's operating history that makes its insulation integrity suspect. the transformer is deenergized and disconnected from all external circuit connections. with the applied voltage and current measured and recorded. As such. Variation in current versus prior readings should not exceed 5%. or in the magnetic circuit that is circulating a fault current. the measured values for each phase on a 3phase transformer should be within 5% of the other phases. As insulation PF increases. These values may be compared with original test data corrected for temperature variations between the factory values and the field measurement or they may be compared with prior maintenance measurements. all as described under periodic tests. the current and voltage readings of the primary windings for each of the phases should be within 15% of each other." This test is performed by connecting all terminals of each individual winding together and applying a voltage between windings as well as from each winding to ground. or short circuiting of some of the winding conductors. and turns ratio testing. there may be turntoturn shorts causing a current bypass in part of the winding. On any single test. The acceptance tests should include IR testing. For this test. Such damage might result from a transient winding fault that cleared. A sensitive bridge or microohmmeter capable of measuring in the microohm range (for the secondary winding) and up to 20 ohms (for the primary winding) must be used. this usually results in a decrease of resistance. Excitation current measurement: The excitation current is the amperage drawn by each primary coil. conductor strands will burn open like a fuse. there will be a noticeable increase in the excitation current. insulation PF measurement.
The applied voltage is measured at the primary terminals and the current measured in each line. A variation of more than 2% indicates the possibility of mechanical distortion of the winding conductors. specifically for detecting mechanical damage following rough shipment or a service fault on the output side that caused high fault currents to flow through the transformer windings. which should be investigated as soon as possible. However. the leakage current can be measured and is often taken as a quantitative measure. This is easily accomplished by applying a singlephase voltage to each phase in succession. To maximize the effectiveness of this test. DC leakage current can vary considerably from test to test because of creepage across the complex surfaces between windings and between windings and ground.DC applied voltage tests are often conducted in the field because DC test sets are smaller and more readily available than AC applied voltage sets. An impedance test is performed by electrically connecting the secondary terminals together with a conductor capable of carrying at least 10% of the line current and applying a reduced voltage to the primary windings. Impedance testing: An impedance test may be useful in evaluating the condition of transformer windings. The use of AC voltage is preferable since the transformer insulation structures were designed. Mechanical distortion of the windings will cause a change in their impedance. 45 . These values shall be recorded and then calculate the ratio of voltage to current for each phase. a measurement should be taken during the transformer's initial installation to establish a benchmark value. and tested with the application of AC voltage intended. With DC tests. This ratio should be within 2% for each phase and should not vary more than 2% between tests. constructed.
The Scope For Energy Saving In The Eu Through The Use Of EnergyEfficient Electricity Distribution Transformers. Websites of Copper Development Associiation. UK (www. Heathcote. Copper Development Association. Energy Saving In Industrial Distribution Transformers. Martin J. Cda Publication 144. 3.copper. J.May 2002 Authors: W. Twelfth Edition 1998.energymanagetraining. 4.KemaNetherlands 2. Groeman. September 2000.REFERENCES 1.F.com) 46 . European Copper Institute. December 1999. Transformers And KFactors. 5.uk) Bureau of Energy Efficiency (www.co.T. Hulshorst. Harmonics.J. J & P Transformer Book.
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