roduct Scope: Substation

Transcription

1

2 roduct Scope: Substation Three Phase or Single Phase, 50 or 60 Hz, 55ºC, 65ºC, 75ºC, 55ºC/65ºC, 55ºC/75ºC, 65ºC/75ºC Envirotemp FR3 fluid or Mineral Oil Three Phase: ,000 kva Single Phase: 167 6,667 kva Primary Voltage ,000 V Secondary Voltage 208Y/120 V 24,940 V Wye Specialty Designs Inverter/Rectifier Bridge K Factor Hazardous Location (Class 1 Div 2) Internal Circuit Breaker (VFI) and/or Visual Break Fans UL Listed & Labeled/ Classified Factory Mutual (FM) Approved Differential Protection 6 or 12 Pulse Designs Grounding Transformers

3 ubstation Product Scope Substation Types Primary Open Secondary Open Definition Open Cover mounted Bushings Primary Above 2500 kva, Secondary voltage above 1000 Volts Secondary 2500 kva and below with less than 1000 Volt secondary

4 ubstation Product Scope Substation Types Primary Unit Secondary Unit Definitions Unit Sidewall mounted bushings typically in a lineup Primary/Secondary same as previous slide

5 roduct Scope: Padmount Three Phase 50 or 60 Hz, 55ºC, 65ºC, 75ºC, 55ºC/65ºC, 55ºC/75ºC, 65ºC/75ºC Envirotemp FR3 fluid or Mineral Oil Three Phase: 45 10,000 kva Primary Voltage ,000 V Secondary Voltage 208Y/120 V 24,940/14,400 V Wye Specialty Designs K Factor UL Listed & Labeled/ Classified Factory Mutual (FM) Approved Solar/Wind Designs Differential Protection 6 or 12 Pulse Designs Grounding Transformers Internal Circuit Breaker (VFI) and/or Visual Break Fans

6 Transformer Design Winding Material Aluminum or Copper Dead Front or Live Front Secondary under 600 Vac must be Live Front Arresters Color Loop Feed or Radial Feed Special Impedance requirements Special bushing heights/spacing

7 Padmount Product Scope

8 Transformer Design Losses other than DOE requirements Overcurrent protection inside transformer VFI, fuses or none Switching inside transformer T blade, V blade, On/Off or none Visual Break with VFI or switches Containment pans for indoor transformers Contacts added to gauges UL, c UL Listing, UL Classified, FM Approval

9 Transformer Design Arc Flash Arc Flash Issues Not able to shut down transformers for maintenance due to critical loads and/or system design. Padmount move items external to cable termination compartment Nameplate Liquid sample valve Gauges Switch operating handle Add IR windows

10 External Gauges and Sampling Valve

11 External Gauges enclosure

12 DOE Efficiency Requirements Indoor Liquid-filled Transformers IEEE Power & Energy Society December 09, 2009

13 DOE 10 Code of Federal Regulations (CFR) Part 431 Minimum Efficiency The Ruling and its effects

14 ackground DOE Minimum Efficiency: History The Department of Energy (DOE) studied raising distribution transformer efficiency; Technologically Feasible, Economically Justifiable, and Produce Significant Energy Savings FINAL RULING PUBLISHED OCTOBER 12, 2007 The Driver is to Reduce CO 2 Emissions

15 he Ruling The Ruling (10 CFR Part 431) A level between TSL 4 and TSL 5 was established for Single phase transformers kva Three phase kva units must meet a level between TSL 2 and TSL 3 The Ruling applies to all units manufactured and beyond Does not affect distributor stock, only manufacturers All transformers produced and imported to the U.S. Does not apply to rebuilt transformers Enforcement mechanisms are not fully defined

16 OE Ruling Single and Three-phase

17 Efficiency Standard Comparison kva NEMA TP-1 Efficiency (%) DOE 10 CFR Part 431 Efficiency (%) All efficiency values are at 50 percent of nameplate-rated load

18 OE Ruling Dry Type

19 Liquid vs. Dry DOE 10 CFR Part 431 Efficiency (%) Comparison kva Liquid-Filled Transformers Dry Transformers kv BIL

20 fficiency Levels So, Does 0.3% Difference in Efficiency Matter? Efficiency = Rated output Rated output + Total losses Example If Performing a Loss Evaluation on 1500 kva Transformers Based on $.06/kW Hr Present Value Factor based on 6% interest over 10 years Overall conservative evaluation

21 fficiency Levels So, Does 0.3% Difference in Efficiency Matter? Efficiency = Rated output Rated output + Total losses Example If Performing a Loss Evaluation on Transformers Based on $.06/kW Hr Present Value Factor based on 6% interest over 10 years Overall conservative evaluation Example for Efficiency Difference for 1500 kva Liquid filled transformer 99.42% 50% load per DOE Total losses ~ 4375 watts (@50% load) Present value of cost of losses $16,922 Annual cost of losses 50% Load ~ 75% Load

22 fficiency Levels So, Does 0.3% Difference in Efficiency Matter? Efficiency = Rated output Rated output + Total losses Example If Performing a Loss Evaluation on Transformers Based on $.06/kW Hr Present Value Factor based on 6% interest over 10 years Overall conservative evaluation Example for Efficiency Difference for 1500 kva Liquid filled transformer 99.42% 50% load per DOE Total losses ~ 4375 watts (@50% load) Present value of cost of losses $16,922 Annual cost of losses 50% load ~ 75% load $ savings per y Dry transformer 99.12% 50% load per DOE Total Losses ~ 6659 watts (@50% load) Present value of cost of losses $25,757 Annual cost of losses 50% load ~ 75% load

23 DOE Efficiency Requirements 2010 vs. 2016

24

25

26

27 DOE Liquid Filled 2010 vs Efficiencies kva

28 016 DOE Manufacturer Implications Manufacturers will need to revise most of their active catalog numbers before to meet requirements The new efficiency levels will shift some raw material usage to amorphous cores. There may be new manufacturing challenges for many manufacturers in terms of design, manufacturing, or material procurement.

29 2016 DOE Consumer Implications Transformer weights will change Depends greatly on specific customer designs & specific product designs, but in general Increase in core/coil weight Decrease in fluid volume (core/coil displacement) Overall weight increases slightly Dimensions don t appear to change dramatically Transformer costs and prices will increase Estimates of a 5 15% price increase over the previous efficiency standard for qualifying 3 phase transformers Actual price increases are a function of what customers are paying today, movements in the materials markets, and are design specific.

30 NEC Compliance Indoors Liquid Filled Transformers Less flammable fluid filled NEC Minimum 300 C fire point In Type I or Type II non combustible building No combustible materials around transformer Liquid containment Installation to comply with all fluid listing restrictions. UL Classification FM Approval

31 UL Classification of Envirotemp FR3 Listed less flammable fluids 45 10,000 kva 3Ø transformers Substation Pad mounted 12 psig internal pressure tank withstand rating Minimum pressure relief device ratings* Either current limiting fusing or other over current protection* Other over current protection may include: Externally mounted expulsion fusing Primary breakers Only natural ester based fluid is permitted to use either CL fusing or other over current protection. *In accordance with UL Classification Marking

32 UL Classification of Envirotemp FR3

33 FM Approved transformer requirements Developed Approval Standard 3990 FM Approved transformer 1998 Restrictions based on transformer protection very similar to the UL Classification except in addition to fusing, pressure relief and tank withstand ratings: Alarm contacts on pressure relief devices for indoor installations >500 kva Rapid rise relays >2500 kva Temperature, level and pressure vacuum gages Ground fault CT on neutral Installation limitations, i.e. clearances to walls, etc.

34

35 Envirotemp FR3 fluid Benefits Fire safety characteristics Environmental characteristics Performance characteristics / enhanced life FR3 and Envirotemp are licensed trademarks of Cargill, Incorporated.

36 Fire point Mineral oil: 155 C Less flammable: min. 300 C (Required by NEC ) Envirotemp FR3 : 360 C FR3 and Envirotemp are licensed trademarks of Cargill, Incorporated.

37 Fire Safety Why Choose a Less-Flammable Fluid-Filled Transformer

38 Fire safety Envirotemp FR3 17 Years of service >450,000 installations No reported fires NFPA R Temp fluid Predecessor to FR3 35 Years of service >250,000 installations No reported fires NFPA FR3 and Envirotemp are licensed trademarks of Cargill, Incorporated

39 M Approved Transformer 1994 FM Changes Approval Restrictions Revised Less Flammable Fluid Approval Developed New Transformer Approval Standard 3990

40 ational Electric Code Less Flammable Liquid Insulated Transformers. Transformers insulated with less flammable liquids that have a fire point of not less than 300 C shall be permitted to be installed in accordance with (A) or (B).

41 FPA (B) (B) Outdoor Installations. Less flammable liquid filled transformers shall be permitted to be installed outdoors, attached to, adjacent to, or on the roof of buildings where installed in accordance with (1) or (2): (1) For Type I or Type II buildings, the installation shall comply with all listing restrictions provided for in the listing of the liquid. FPN: Installations adjacent to combustible material, fire escapes, or door or window openings may require additional safeguards such as those listed in (2) In accordance with

42 Making Your Medium Voltage Transformer Installations NEC Compliant 10,000(38) >10,000(38)

43 FPA (A) (A) Indoor Installations. Indoor installations shall be permitted in accordance with the following: (1) In Type I or Type II buildings, in areas where all of the following requirements are met: a. The transformer is rated 35,000 volts or less. b. No combustible materials are stored. c. A liquid confinement area is provided. d. The installation complies with all the restrictions provided for in the listing of the liquid. (2) With an automatic fire extinguishing system and a liquid confinement area, provided that the transformer is rated 35,000 volts or less. (3) In accordance with

44 Why Choose a Less-Flammable Fluid-Filled Transformer What Happened to the Indoor Liquid Filled Transformer? PCB insulated transformers were the indoor transformer of choice until the mid 1970 s. Fears developed regarding replacement fluids Environmental concerns What was the EPA going to ban next? Some transformer manufacturers leaped from the frying pan into the fire Introduced non flammable alternatives Freon Tetrachloroethylene (dry cleaning fluid) Fire Safety Concerns Operational Concerns

45 Why Choose a Less-Flammable FR3 Fluid-Filled Transformer What Did You Give Up? Higher efficiency / lower losses Greater overload capability Greater contamination resistance Higher BIL s Smaller footprint Lower temperature operation Lower noise levels Full diagnostic capabilities Longer life Dramatic cost savings

46 Transformer Ratings 55ºC Rise KNAN 65ºC Rise KNAN (+12%) Envirotran PLUS kva Ratings FR3 - Filled 75ºC Rise KNAN (+9%) 55ºC Rise KNAF (+15% or 25%) 65ºC Rise KNAF (+12%) 75ºC Rise KNAF (+9%) Fan Cooled

47 5/65/75 C Rise Base 55 C Available Ampacity 65 C Available Ampacity KVA '@ 75 C Available Ampacity With Forced Air Cooling Fans FA 55 C Available Ampacity FA 65 C Available Ampacity FA 75 C Available Ampacity

48 Why Choose a Less-Flammable Fluid-Filled Transformer Greater Overload Capability

49 Why Choose a Less-Flammable Fluid-Filled Transformer Full Diagnostic Capabilities Dry type Megger Power Factor Infra Red Scan Liquid filled Color Acidity Dielectric Breakdown Voltage Dissolved Gas Analysis Metals Analysis Inhibitor Content Interfacial Tension Infra Red Scan Power Factor Furan Analysis Water Content Specific Gravity

50 Lower sound level kva Liquid filled transformers operate at 5 6 db less than dry transformers* 3db doubles sound power to your ear *NEMA TR 1

51 ess-flammable Fluid-Filled Transformer Lower Sound Levels kva Liquid filled will be 5 6 db less than dry type 3db doubles sound power Dry Type Liquid Filled

52 Why Choose a Less-Flammable Fluid-Filled Transformer Higher Basic Impulse Level (BIL) 15kV Liquid 95kV Standard Dry 60kV Standard 35kV Liquid 200kV Standard Dry 150kV Standard 480V Liquid 30kV Standard Dry 10kV Standard

53 Why Choose a Less-Flammable Fluid-Filled Transformer Ease of Installation

54 Why Choose a Less-Flammable Fluid-Filled Transformer Smaller footprint Transformer Primary switchgear Lower Cost for lineup Overall benefit: Fit same equipment into smaller electrical rooms Reduced cost

55 Liquid vs. Dry Dimension Comparison

56 lose Coupled Liquid-filled

57 Foot print comparison Based upon published standard sizes for CPS Liquid Filled Transformers Cast Coil Dry Type Transformers

58 Higher Efficiency = Reduced Losses Efficiency Liquid kva Liquid Dry Liquid Efficiency Advantage Losses (Watts) D.O.E. Liquid Losses (Watts) D.O.E. Dry Liquid Savings % 98.83% 35.9% 3,750 $ 16,425 5,850 $ 25,623 $ 9, % 98.95% 35.2% 5,100 $ 22,338 7,875 $ 34,492 $ 12, % 99.03% 34.0% 6,400 $ 28,032 9,700 $ 42,486 $ 14, % 99.12% 34.1% 8,700 $ 38,106 13,200 $ 57,816 $ 19, % 99.18% 34.1% 10,800 $ 47,304 16,400 $ 71,832 $ 24, % 99.23% 33.8% 12,750 $ 55,845 19,250 $ 84,315 $ 28,470 Higher Efficiency = Reduced Losses Save nearly $30,000 in Energy Costs Directly tied to Losses Savings based upon D.O.E. Efficiency for 2500kVA Liquid vs Dry Per D.O.E. Ruling; Liquid Filled Transformers up to 2500kVA are approximately 35% more efficient than their Dry Type counterparts. Dry * Liquid Savings Evaluated over 5 years, based upon $.10kW Energy Rate, Load + No Load Losses

59 Higher Efficiency = Reduced Losses Cost of Losses $90,000 $85,000 $80,000 $75,000 $70,000 $65,000 $60,000 $55,000 $50,000 $45,000 $40,000 $35,000 $30,000 $25,000 $20,000 $15,000 $10,000 $5,000 $- $9,200 Savings $12,150 Savings 5 Year Cost of Losses $14,450 Savings kva $19,700 Savings $24,500 Savings For all kva Ratings; Liquid Filled Transformers = Lowest Cost of Losses $28,500 Savings D.O.E. Liquid D.O.E. Dry

60 fficiencies Considerably Less Total Losses than Cast Resin or VPI Dry Type Transformers

61 ound Levels Significantly Reduced Sound Levels and Vibration

62 perating Temperatures Cooler Operating Temperatures than Cast Resin and VPI Dry

63 EED Accreditation LEEDS Accredidation Points for Distribution Transformers Criteria DOE Transformer Energy & Atmosphere up to 19 points Material & Resources Indoor Environmental Quality Innovation & Design Description Up to 24% more efficient than equivalent non-doe design Liquid Filled vs. Dry Type % less HVAC required FR3 Envirotemp Fluid point 1 point 5 points Positive carbon footprint Total Possible Points 19 Points 1 point 1 point 5 points 26 points Obtain up to 26 LEED Points towards building installations

64 Operation at Higher Base Temperature Introduction of the 75 C rise transformer

65 Lockie Test Series (ANSI/IEEE C57.100)

66 Insulation life extension Aging of paper depends primarily on temperature and water content. Paper aged in seed oil based fluid took 5 8 times longer to reach end of life parameters than paper aged in mineral oil. FR3 and Envirotemp are licensed trademarks of Cargill, Incorporated

67 PEAK Transformer family IEEE Std C lists 75 C rise transformers PEAK transformers from Cooper Power Systems are designed to: Utilizes an advanced high temperature insulation system Thermally upgraded Kraft paper Envirotemp TM FR3 TM dielectric fluid Optimized core and coil design. Envirotemp and FR3 are licensed trademarks of Cargill, Incorporated. 67

68 PEAK Transformers Three Options 1. Increased Overload Capacity PEAK 65/75 ⁰C Average Winding Rise (AWR) Operate PEAK transformers beyond full rated base load Single phase at least 9% Three phase at least 12% Envirotemp and FR3 are licensed trademarks of Cargill, Incorporated.

69 PEAK Transformers Three Options 1. Increased Overload Capacity PEAK 65/75 ⁰C Average Winding Rise (AWR) Operate PEAK transformers beyond full rated base load Single phase at least 9% Three phase at least 12% More precisely size transformers based on periods of peak demand without accelerated reduction of insulation life Continuous overload capabilities to 75⁰ C AWR Maintains IEEE per unit life requirements at 75 ⁰C AWR Envirotemp and FR3 are licensed trademarks of Cargill, Incorporated.

70 PEAK Transformers Three Options 1. Increased Overload Capacity PEAK 65/75 ⁰C Average Winding Rise (AWR) Operate PEAK transformers beyond full rated base load Single phase at least 9% Three phase at least 12% More precisely size transformers based on periods of peak demand without accelerated reduction of insulation life Continuous overload capabilities to 75⁰ C AWR Maintains IEEE per unit life requirements at 75 ⁰C AWR 65 C AWR and 75 C AWR kva ratings on the nameplate Complies with IEEE Std C standard UL Listed Envirotemp and FR3 are licensed trademarks of Cargill, Incorporated.

71 PEAK Transformers Three Options 2. Increased Overload Capacity PEAK 55/75 ⁰C Average Winding Rise (AWR) Operate PEAK transformers beyond full rated base load Three phase at least 22% More precisely size transformers based on periods of peak demand without accelerated reduction of insulation life Continuous overload capabilities to 75⁰ C AWR Maintains IEEE per unit life requirements at 75 ⁰C AWR 55 C AWR and 75 C AWR kva ratings on the nameplate Complies with IEEE Std C standard UL Listed Envirotemp and FR3 are licensed trademarks of Cargill, Incorporated.

72 PEAK Transformers Three Options 3. Smaller, Lighter Transformers PEAK 75 ⁰C Average Winding Rise Smaller and lighter than traditional 65 C AWR transformers of the same kva rating Typically use less material and fewer gallons of dielectric fluid resulting in better value Complies with IEEE Std C standard UL Listed Envirotemp and FR3 are licensed trademarks of Cargill, Incorporated.

73 PEAK transformer PEAK Transformer kva Ratings Temp Rise (55 to 65-12%, 65 to 75-9%, 55 to 75-22%) Fans (500 to %, 2500 to %) 55ºC Rise KNAN 65ºC Rise KNAN 75ºC Rise KNAN 55ºC Rise KNAF 65ºC Rise KNAF 75ºC Rise KNAF

74 Questions? Thank You For Your Time