roduct Scope: Substation

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: 300 12,000 kva Single Phase: 167 6,667 kva Primary Voltage 2400 46,000 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

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

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

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 2400 46,000 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

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

Padmount Product Scope

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

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

External Gauges and Sampling Valve

External Gauges enclosure

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

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

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

he Ruling The Ruling (10 CFR Part 431) A level between TSL 4 and TSL 5 was established for Single phase transformers 10 833 kva Three phase 45 2500 kva units must meet a level between TSL 2 and TSL 3 The Ruling applies to all units manufactured 01 01 2010 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

OE Ruling Single and Three-phase

Efficiency Standard Comparison kva NEMA TP-1 Efficiency (%) DOE 10 CFR Part 431 Efficiency (%) 15 98.1 98.36 30 98.4 98.62 45 98.6 98.76 75 98.7 98.91 112.5 98.8 99.01 150 98.9 99.08 225 99 99.17 300 99 99.23 500 99.1 99.25 750 99.2 99.32 1000 99.2 99.36 1500 99.3 99.42 2000 99.4 99.46 2500 99.4 99.49 All efficiency values are at 50 percent of nameplate-rated load

OE Ruling Dry Type

Liquid vs. Dry DOE 10 CFR Part 431 Efficiency (%) Comparison kva Liquid-Filled Transformers Dry Transformers 45-95 kv BIL 15 98.36 97.18 30 98.62 97.63 45 98.76 97.86 75 98.91 98.12 112.5 99.01 98.30 150 99.08 98.42 225 99.17 98.57 300 99.23 98.67 500 99.25 98.83 750 99.32 98.95 1000 99.36 99.03 1500 99.42 99.12 2000 99.46 99.18 2500 99.49 99.23

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

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% efficient @ 50% load per DOE Total losses ~ 4375 watts (@50% load) Present value of cost of losses $16,922 Annual cost of losses $2300 @ 50% Load ~ $3548 @ 75% Load

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% efficient @ 50% load per DOE Total losses ~ 4375 watts (@50% load) Present value of cost of losses $16,922 Annual cost of losses $2300 @ 50% load ~ $3548 @ 75% load $1200 1750 savings per y Dry transformer 99.12% efficient @ 50% load per DOE Total Losses ~ 6659 watts (@50% load) Present value of cost of losses $25,757 Annual cost of losses $3500 @ 50% load ~ $5322 @ 75% load

DOE Efficiency Requirements 2010 vs. 2016

DOE Liquid Filled 2010 vs. 2016 Efficiencies kva 2010 2016 15 98.36 98.65 30 98.62 98.83 45 98.76 98.92 75 98.91 99.03 112.5 99.01 99.11 150 99.08 99.16 225 99.17 99.23 300 99.23 99.27 500 99.25 99.35 750 99.32 99.4 1000 99.36 99.43 1500 99.42 99.48 2000 99.46 99.51 2500 99.49 99.53

016 DOE Manufacturer Implications Manufacturers will need to revise most of their active catalog numbers before 1 1 2016 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.

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.

NEC Compliance Indoors Liquid Filled Transformers Less flammable fluid filled NEC 450 23 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

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

UL Classification of Envirotemp FR3

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.

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

Fire point Mineral oil: 155 C Less flammable: min. 300 C (Required by NEC 450 23) Envirotemp FR3 : 360 C FR3 and Envirotemp are licensed trademarks of Cargill, Incorporated.

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

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

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

ational Electric Code 450.23 450.23 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 450.23(A) or 450.23(B).

FPA 70 450.23(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 450.27 (2) In accordance with 450.27.

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

FPA 70 450.23(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 450.26

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

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

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%) 500 560 610 575 644 702 750 840 916 863 966 1053 1000 1120 1221 1150 1288 1404 Fan Cooled 1500 1680 1831 1725 1932 2106 2000 2240 2442 2300 2576 2808 2500 2800 3052 3125 3500 3815 3750 4200 4578 4688 5250 5722 5000 5600 6104 6250 7000 7630 7500 8400 9156 9375 10500 11445 10000 11200 12208 12500 14000 15260

5/65/75 C Rise Base KVA @ 55 C Available Ampacity KVA @ 65 C Available Ampacity KVA '@ 75 C Available Ampacity With Forced Air Cooling Fans FA KVA @ 55 C Available Ampacity FA KVA @ 65 C Available Ampacity FA KVA @ 75 C Available Ampacity 500 601 560 674 610 734 575 692 644 775 702 844 750 902 840 1010 916 1102 863 1038 966 1162 1053 1267 1000 1203 1120 1347 1221 1469 1150 1383 1288 1549 1404 1689 1500 1804 1680 2021 1831 2202 1725 2075 1932 2324 2106 2533 2000 2406 2240 2694 2442 2937 2300 2766 2576 3098 2808 3378 2500 3007 2800 3368 3052 3671 3125 3759 3500 4210 3815 4589 3000 3608 3360 4041 3662 4405 3750 4511 4200 5052 4577 5505

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

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

Lower sound level 750 2500 kva Liquid filled transformers operate at 5 6 db less than dry transformers* 3db doubles sound power to your ear *NEMA TR 1

ess-flammable Fluid-Filled Transformer Lower Sound Levels 750 2500 kva Liquid filled will be 5 6 db less than dry type 3db doubles sound power Dry Type Liquid Filled

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

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

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

Liquid vs. Dry Dimension Comparison

lose Coupled Liquid-filled

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

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 500 99.25% 98.83% 35.9% 3,750 $ 16,425 5,850 $ 25,623 $ 9,198 750 99.32% 98.95% 35.2% 5,100 $ 22,338 7,875 $ 34,492 $ 12,154 1000 99.36% 99.03% 34.0% 6,400 $ 28,032 9,700 $ 42,486 $ 14,454 1500 99.42% 99.12% 34.1% 8,700 $ 38,106 13,200 $ 57,816 $ 19,710 2000 99.46% 99.18% 34.1% 10,800 $ 47,304 16,400 $ 71,832 $ 24,528 2500 99.49% 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

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 500 750 1000 1500 2000 2500 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

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

ound Levels Significantly Reduced Sound Levels and Vibration

perating Temperatures Cooler Operating Temperatures than Cast Resin and VPI Dry

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 -------- -------- -------- -------- 20% less HVAC required FR3 Envirotemp Fluid -------- 1 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

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

Lockie Test Series (ANSI/IEEE C57.100)

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

PEAK Transformer family IEEE Std C57.154-2012 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

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.

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.

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 C57.154 2012 standard UL Listed Envirotemp and FR3 are licensed trademarks of Cargill, Incorporated.

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 C57.154 2012 standard UL Listed Envirotemp and FR3 are licensed trademarks of Cargill, Incorporated.

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 C57.154 2012 standard UL Listed Envirotemp and FR3 are licensed trademarks of Cargill, Incorporated.

PEAK transformer PEAK Transformer kva Ratings Temp Rise (55 to 65-12%, 65 to 75-9%, 55 to 75-22%) Fans (500 to 2000-15%, 2500 to 10000-25%) 55ºC Rise KNAN 65ºC Rise KNAN 75ºC Rise KNAN 55ºC Rise KNAF 65ºC Rise KNAF 75ºC Rise KNAF 500 560 610 575 644 702 750 840 916 863 966 1053 1000 1120 1221 1150 1288 1404 1500 1680 1831 1725 1932 2106 2000 2240 2442 2300 2576 2808 2500 2800 3052 3125 3500 3815 3750 4200 4578 4688 5250 5722 5000 5600 6104 6250 7000 7630 7500 8400 9156 9375 10500 11445 10000 11200 12208 12500 14000 15260

Questions? Thank You For Your Time