Electrical Distribution

Electrical Distribution System
© Confederation of Indian Industry

Transformer
 Transformer
 Heart of Electrical Distribution
 Category
 Power Transformers
 Distribution Transformers

Types Of Transformers
Distribution Transformer
 Normal Efficiency- 98% to 99%
 Iron loss is 10% to 15% of full load copper

loss
 Optimum efficiency occurs between 40% to

60% of loading

Types Of Transformers
Power Transformer
 Normal Efficiency- 99% to 99.5%
 Iron losses is 20% to 25% of full load
copper losses
 Optimum efficiency occurs between 60% to
80% of loading

Issues of transformers
 Second Largest loss making electrical

equipment
 35 billions kWh of energy is lost as
loss per year
 6% of Total generation is lost in
transformers
 Life of transformer
 Life cycle cost

Loss in Transformer
 Efficient Transformer – 1% loss

 Substantial at higher ratings
 Losses contributed by
 Core loss – No load loss
 Copper Loss – Depends on load

Core losses-No load losses
 Hysterisis losses
 Due to magnetization
and demagnetization
 Eddy current losses
 Due to circulating
currents in core

Load losses
 Resistive losses
 Copper loss in windings
 Minor losses
 Dielectric losses
 Due to electrostatic stress
 Auxiliary losses
 Due to cooling fans and pumps

Transformer Efficiency
 Transformer efficiency - 98-99%

 Optimum efficiency occurs at
 50% load
 75% load
100% load

Transformer Efficiency
 Optimum efficiency occurs, where
Iron losses Copper losses

Three Phase Transformer-Typical
Loss Chart
KVA Rating Iron Loss FL copper
(Watt) Loss (W)
500 1030 6860
750 1420 9500
1000 1770 11820
1250 1820 12000
2000 •Loss3000
in watts 20000
Case Study
11 KV
CB CB
2000 KVA 2000 KVA

11 KV / 415 V 11 KV / 415 V
80% Load
CB CB
415 V
Case Study
Background
 Capacity of transformer 2000 KVA
 Load on the transformer is 80%
 Iron loss = 3 kW
 F L Copper loss = 20 kW

Operate Both The Transformers In
Parallel
Loss calculation
 One transformer in operation
(3) + 20 x (0.8) 2 = 15.8 kW
 Both transformers are in operation
[(3) + 20 x (0.4) 2]x 2 = 12.4 kW
Annual Savings = Rs 1.1 Lakhs

Case Study
110 KV
12.5 MVA 12.5 MVA

110 KV / 22KV 110 KV / 22KV
22 KV 6 MVA LOAD
Case Study
Background
 Two Transformers (12.5MVA) are operated
parallel
 Actual total effective load is 6 MVA
 % load to the individual transformers is
24%
 Losses
Iron loss = 25 kW
FL. Copper losses = 72 kW

Isolate One Transformer In Main
Substation
Loss calculation
 Both transformers are in operation
[(25) + 72 x (0.24) 2 ] x 2 = 58.2 kW
 One transformer operation
(25) + 72 x (0.48) 2 = 41.5 kW
 Isolated one transformer
Savings in kW = 16.7 kW
Annual savings = Rs 5.1 Lakhs

Case Study
11 KV
CB CB
2000 KVA 2000 KVA

11 KV / 433 V 11 KV / 433 V
CB CB
415 V

Isolate Primary Of The Idle
Transformer
 Idle transformer consumes power for

its inherent magnetization losses
 No load loss = 3 kW
Annual Savings = Rs 0.8 Lakhs

Transformer Life
 Life of the transformer is 40 years

 Possible if the temperature of windings is
less than 80°C
 Depends up on the insulation of the core
 For every 10K decrease in winding
temperature, copper losses fall by
3.9%
 Lowering of winding temperature
slows down ageing of a transformer
Transformers Cooling
 Insulating oil acts as cooling medium

 Oil flow is through
 Natural thermo siphon flow (no pumps)
 Forced flow (pumps)
 Heat exchangers or radiators transfer
heat from oil to environment
 Fans may be used to increase forced
convection over radiator fins

Transformers Cooling

Case Study-Radiators Enhancement
 20 MVA Power transformer is

operating at 65-70% loading
 8 Cooling fans (1.5 kW) are running
 Fans are interlocked with
temperature
 Transformer is tripping because of
high temperature
 Insufficient cooling

Case Study-Radiators Enhancement
 Redesigned (increased) the size of

transformer radiators
 In all 4 directions by conducting a
separate study
 Still cooling fans are interlocked
with winding temperature to avoid
the problems

Benefits
 Power reliability is increased

 Cooling fans power will be saved
 Cushion for more capacity
 Temperature of the winding will
be reduced
 Resistance of the winding will be
reduced
 Load losses will also come down

Energy Efficient transformer
 Core of the transformer is made of

amorphous material
 Electrical resistivity of amorphous
material is 2-3 times higher than silicon
steel
 70-80 % less core losses than normal
transformers under linear loads
 More savings under non linear loads

Amorphous Vs Conventional

Comparison of Core Geometry
 Crystalline structures have

hard directions for
magnetization
 Requires grain orientation
processing for best
properties
 Random Arrangement of
atoms offers High electrical
resistance for eddy current.
 Easy to magnetize and
Demagnetize
Transformer Core Losses

Comparison of Efficiency
No Load Loss (W) Efficiency (%)
Rating (kVA)
Amorphous CRGO Amorphous CRGO
250 180 570 98.7 98.2
500 250 900 99 98.53

630 200 1000 99.1 98.54
730 365 1250 99.2 98.65

1000 450 1500 99.2 98.68
Cold-Rolled Grain Oriented silicon steel (CRGO).

Transformer efficiency

Harmonics Losses (250 KVA)

Advantages
 No Need for Added Devices such as
Isolation Transformers, Harmonic
Filters
 Lesser heat generation due to lower
losses
 Slower ageing of insulation
 Longer Life
 Superior electrical performance under
harmonics condition
 Lesser Magnetizing current

Power Factor

Terminology
 Active Power (kW)
 Power that actually powers the equipment
and performs useful work
 Reactive Power (KVAr)
 Power that magnetic equipment
(transformer, motor and relay) needs to
produce the magnetizing flux
 Apparent Power
 Vector sum of kW and KVAr

Analogy
Power factor= kW = kW = Beer
KVA kW +KVAr Beer + Foam

Effect of Power Factor

PF Compensation methods
 3 methods
 Centralized compensation
 Distributed compensation
 Mixed compensation

Power Factor Compensation
Centralized compensation
SS PANEL
REACTIVE CURRENT
PCC FLOW
CAPACITOR
BANK
MCC
MOTOR
 Advantages
 Easy P.F maintenance
 Capacitor maintenance easy
 Disadvantages
 More voltage drop in distribution
 Over heating of cable resulting in
failure
 Suitable if distance between PCC
and MCC is less
Distributed Compensation
SS PANEL
PCC
MCC
MOTOR MOTOR
 Advantages
 Minimum voltage drop
 Low distribution losses
 Disadvantages
 Maintenance is difficult
 Applicable where distribution is
remote

Mixed Compensation
SS PANEL
REACTIVE CURRENT
FLOW
PCC
CAPACITOR
BANK
MCC
MOTOR
 Advantages
 Good P.F control
 Easy maintenance
 Low distribution losses
 Common in Continuous Process

industry

Capacitor Selection
 Chart Method
 Formula Method
 Capacitor required (KVAr)
= kW x {Tan cos-11 – Tan cos-12 }
Cos 1 – Present power factor
Cos 2 – Desired power factor

Improve Overall PF and Reduce MD
 Case Study
 Monthly Avg PF maintained at 0.96
 Sanctioned MD : 7300 kVA
 Min demand charges : 75% (5475 kVA)
 Recorded monthly MD
 6800 kVA
 High demand charges

 Action taken
 Installed additional capacitor banks &
APFC to improve PF
 PF improved to 0.99
 kVA demand reduced by 240 kVA
 Additional benefits
 Reduced voltage drop in feeders
 Feeder loss reduction
 Cushion for capacity expansion

Annual Saving - Rs 10.3 Lakhs

Investment - Rs 15.0 Lakhs
Payback period - 18 Months

Benefits of Power factor
Improvement
 Lower utility fees
 Increased system capacity
 Reduced system losses
% Reduction in Power losses
= 100-100 x (Present Pf)^2

New Pf

Improve Power Factor Of Generator
 10 MW turbo generator
 Rated PF : 0.8
 Operating PF: 0.9
 Generator delivers active power &
reactive power
 Efficiency of TG depends on operating
PF
 Higher the PF, higher is the efficiency

 TG Test data
Efficiency @ P.F 0.8 0.99

100 % Load 98.08 98.56
75% Load 97.98 98.5
50% Load 97.59 98.18
25% Load 96.03 96.91

 Improving PF from 0.9 to 0.96

resulted in improvement in efficiency
 Reduced loss due to reduction in current
Annual Savings : Rs 14.8 Lakhs

Investment : Rs 15.0 Lakhs
Payback : 13 Months

Voltage Drop
 Voltage drop is an indication of distribution
loss
 Causes of voltage drop
 Poor power factor
 Inadequate cable size laid
 Poor contact surface at
 Cable Termination
 Cable joints
 Contactors/Switches
Voltage Drop
 In a large complex distribution system,

voltage drops are very common
 Acceptable limit in a 3 Ph. System is

4-5 Volts / Phase
 More than 5 V/Phase indicates energy

loss in the distribution

Voltage Drop Measuring
Procedure
 Measuring instruments should be calibrated

 Simultaneous measurement of voltage in the
feeding and receiving end of the feeder
 Measure P.F & Current
 Note down the cable size

Case Study-Voltage Drop
33 kV
CB CB
2500 KVA 2000 KVA

33 kV / 433 V 33 kV / 433 V
37% Load
PCC-I
PCC-II
434 V 419 V
 Observations
 Currently the PCC-I is supplied from PCC-II
Measurements
 Voltage at PCC-II = 434 V
 Voltage at PCC-I = 419 V
 Drop in Voltage = 15 Volts (avg)
 Load current = 740 A
 Power factor = 0.99
 Cable size = 4 x 400 x 3.5 Sq.mm

 Cable loss- 19kW

 Causes of voltage drop
 Poor contact surface at
 Cable Termination
 Cable joints
 Contactors/Switches

 Operated both the transformers
33 kV
CB CB
2500 KVA 2000 KVA

33 kV / 433 V 33 kV / 433 V
13% Load 29% Load
PCC-II PCC-I

 Operation of both transformers resulted in
reduced % loading
 Increase in transformer losses by 2kW
No load loss Full Load Cu loss Operating kVA Rated kVA % Load Total Loss
PCC-II 2.5MVA 3.3 25.4 926 2500 0.3704 6.78
PCC-I 2MVA 2.95 23.63 596 2000 0.298 5.04
PCC-II 2.5MVA 3.3 25.4 330 2500 0.132 3.74
 Subsequent reduction in cable losses and

net saving potential was 17kW
Annual Saving - Rs 6.85 Lakhs

Investment - Nil

Other opportunities
 Integrated online energy

management system
 Avoids the difficulties
 Better monitoring
 Drives where to focus
 Easy to compare with other plants

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Technical Specifications

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 Advantages
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Electrical Distribution System

© Confederation of Indian Industry

© Confederation of Indian Industry

 Normal Efficiency- 98% to 99%

 Iron loss is 10% to 15% of full load copper

 Optimum efficiency occurs between 40% to

© Confederation of Indian Industry

© Confederation of Indian Industry

 Second Largest loss making electrical

© Confederation of Indian Industry

 Efficient Transformer – 1% loss

© Confederation of Indian Industry

© Confederation of Indian Industry

© Confederation of Indian Industry

 Transformer efficiency - 98-99%

© Confederation of Indian Industry

 Optimum efficiency occurs, where

Iron losses Copper losses

© Confederation of Indian Industry

750 1420 9500

1000 1770 11820

1250 1820 12000

2000 KVA 2000 KVA

 Capacity of transformer 2000 KVA

 Load on the transformer is 80%

© Confederation of Indian Industry

Annual Savings = Rs 1.1 Lakhs

© Confederation of Indian Industry

12.5 MVA 12.5 MVA

© Confederation of Indian Industry

© Confederation of Indian Industry

2000 KVA 2000 KVA

© Confederation of Indian Industry

 Idle transformer consumes power for

Annual Savings = Rs 0.8 Lakhs

© Confederation of Indian Industry

 Life of the transformer is 40 years

 Insulating oil acts as cooling medium

© Confederation of Indian Industry

© Confederation of Indian Industry

 20 MVA Power transformer is

© Confederation of Indian Industry

 Redesigned (increased) the size of

© Confederation of Indian Industry

 Power reliability is increased

© Confederation of Indian Industry

 Core of the transformer is made of

© Confederation of Indian Industry

© Confederation of Indian Industry

 Crystalline structures have

© Confederation of Indian Industry

500 250 900 99 98.53

730 365 1250 99.2 98.65

© Confederation of Indian Industry

© Confederation of Indian Industry

© Confederation of Indian Industry

© Confederation of Indian Industry

© Confederation of Indian Industry

© Confederation of Indian Industry

© Confederation of Indian Industry

© Confederation of Indian Industry

© Confederation of Indian Industry

© Confederation of Indian Industry