Bob Ruzensky Regional Sales Director Gulf Region - WMEA Papers/1115_Transformer_Design_Eaton_Nov... · 5 5 Transformer Customer Challenges 5 Electrical Consumption and Demand are

© 2012 Eaton Corporation. All rights reserved.

Bob Ruzensky

Regional Sales Director – Gulf Region

2© 2013 Eaton, All Rights Reserved.

Agenda

• Peak Transformers

• VFI Protected Transformers

• Addressing Arc Flash when doing preventive

maintenance on transformers

3© 2013 Eaton, All Rights Reserved.

A NEW ERA IN TRANSFORMER DESIGN

44

• High Fire-Point

• Mineral Oil: 155°C

• EnvirotempTM FR3TM: ≈360°C

• Non-Toxic

• Renewable

4

Envirotemp™ FR3™ Fluid

PEAK Transformers Include all the Benefits of Envirotemp™ FR3™ Fluid

Envirotemp™ and FR3™ are licensed trademarks of Cargill, Incorporated.

55

Transformer Customer Challenges

5

Electrical Consumption and Demand are Growing

Load Growth and Future Demand May Stress Transformers Beyond Nameplate Ratings− Some Loads are Variable

− Some Load are Predictable

Some Projects Have Size and Weight Constraints for Transformers

Customers Prefer Flexibility in Loading Transformers

PEAKTM Transformers May Be Part of the Solution

66

PEAK Transformer Family

6Envirotemp™ and FR3™ are licensed trademarks of Cargill, Incorporated.

PEAK transformers from Cooper Power Systems are designed to:

Provide enhanced capability compared to traditional transformers in

today’s market

Utilizes an advanced high temperature insulation system

Thermally upgraded kraft paper

EnvirotempTM FR3TM dielectric fluid

Optimized core and coil design.

77

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%


88





load



• More precisely size transformers based on periods

of peak demand—without accelerated reduction of

insulation life


99





load





insulation life

• Continuous overload capabilities to

75⁰ C AWR

• Maintains IEEE® per unit life requirements at

75 ⁰ C AWR

• 65 °C AWR and 75 °C AWR kVA ratings

on the nameplate


1010





load





insulation life

• Continuous overload capabilities to 75⁰ C AWR

• Maintains IEEE® per unit life requirements at 75 ⁰C AWR


on the nameplate

• Complies with IEEE Std C57.154™-2012

standard


1111





load




insulation life

• Continuous overload capabilities to 75⁰ C AWR

• Maintains IEEE® per unit life requirements at 75 ⁰C AWR


on the nameplate


standard


1212


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


standard

• All PEAK Transformers are filled with

EnvirotempTM FR3TM Fluid


1313

Ideal for Expectation of Increasing Demand and for Withstand of Peak or Prolonged Overload Conditions

− Application: serve building with expectation of growth in tenants over time

• Eliminates need to replace transformer with larger kVA unit

Why Increased Overload Capacity?

13

1414


− Application: Serve building with expectation of growth in tenants over time


− Application: Double-ended substation with shared load on each end capable of serving full load on one side for periods of time


14

1515


− Application: serve building with expectation of growth in tenants over time


− Application: double-ended substation with shared load on each end capable of serving full load on one side for periods of time

− Application: for critical loads where overload is a concern, 65/75 °C AWR provides an alternative, or complementary, solution to forced air (fans) and transformer oversizing


15

1616

Increased Reliability

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.

Longer Insulation System Life Than Conventional Mineral Oil-Filled Transformers

1717

FR3™ Fluid & Moisture

• Higher Moisture Content in Insulation than Fluid

FR3™ and Envirotemp™ are licensed trademarks of Cargill, Incorporated

1818


• Higher Moisture Content in Insulation

• FR3™ - Higher Affinity for and Tolerance of Moisture

• 25 C Saturation Levels• Mineral Oil: 70 ppm

• EFR3™ : 1200 ppm


1919


• Higher Moisture Content in Insulation

• FR3™ - Higher affinity for and tolerance of moisture

• 25 C Saturation Levels• Mineral Oil: 70 ppm

• FR3™ : 1200 ppm

• Maintains Dielectric Strength Similarly to Mineral Oil in Terms of Relative Saturation


2020

VFI Transformer

2121

Vacuum Fault Interrupter (VFI) Transformer

Switchgear Protection Inside a Transformer• Internal under-oil vacuum fault interrupter

• Three-phase gang operated

• Trip function through Tri-Phase Ground control w/ SCADA

- Gauge contacts wired into SCADA control

- Trip/open function only, won’t automatically reclose

• Optional Trip Function and Protection with Cooper IDEA Relays

• Optional Motor Operator for Remote Closure

• Optional contact switches are wired for alarm or control

functions outside transformer

• User defined schematic based on system requirements

Optional Motor Operator

Available on Pads & Substations

2222

VFI Transformer

• 3Ø Primary over-current

protection and switching

(Vacuum Fault Interrupter)

installed integral to

transformer.

• Resettable medium voltage

breaker with electronic

control

• Over 100 minimum trip

settings

Guentert, J. (2012). Protection, Arc Flash Mitigation Using VFI [Photograph]. CSE Magazine.

2323

VFI transformer

• Up to 35 kV rating

• 600 or 900 A continuous rating

• 12 kA & 16 kA interrupting rating

• Optional secondary relay

• Used to trip VFI on secondary

fault

• Helps mitigate secondary arc

flash hazards

Guentert, J. (2012). Protection, Arc Flash Mitigation Using VFI [Photograph]. CSE Magazine.

2424

TPG w/SCADA

Tri-Phase TPG (Tri-Phase w/Ground)

Standard VFI Controls

2525

VFI switchgear can be customized to be Smart-Grid Ready

• Equipped with iDEA Platform

Controls

• Remote open/close option

• Internal PTs/CTs for voltage

sensing

• Wide range of communication

options available with the

iDEA controls (Ethernet, Fiber

Optic, RS 485)

Smart-Grid ready VFI

2626

Improved System Coordination

• Improved Coordination with Other System Protective Equipment Eliminates Unnecessary Outages

• Tri-Phase Control Improves Coordination for Maximum Up-time

• Selectable TCC Curves

• Pickup Settings from 10-1290 A

• Instantaneous

• Ground Element

• Min Response Time Accessory

• Cold Load Pickup Capable

• SCADA Capable for Automation

Solves complex coordination problems

2727

• Switchgear-type over-

current protection for

large pad-mounted or

substation transformers

• Provides smallest

footprint for primary

switching and over-

current protection

VFI transformer

HV Duplex Load-break

Air Switches

Dry Transformer

Dual Feed Bushings

Selector Switch

VFI

Handle

2828

Visible break

VFI transformer w/ visible break

2929

• Available in pad-mounted

design eliminating pad-

mounted switchgear

• VFI control in HV

termination compartment

Pad-mounted VFI transformer

3030

Complete 35kV Connector System

• Bushing

• Tee body

• Junctions

• 200 A tap plugs

• Insulating plugs

• Connector plugs

• Bushing extender

• 200 A caps

• 600 A caps

“200 kV BIL”

Product markings match 200 kV BIL

bushing color

3131

Voltage Ratings and Characteristics

3232

Addressing Arc Flash

3333


IEEE C57.12.34 requires opening LV compartment door before accessing HV.

3434


• Essential Monitoring

Equipment Accessible

Outside Termination

Compartments

• Drain Valve & Sampler

• Gages

• Load-break switches

3535


• Externally operable visible

break switching

• Reduces unnecessary arc

flash exposure

• Improved visibility and safety

compared to standard load-

break switch mounting

• Ability to ground transformer

windings with on/off/ground

• Reduce maintenance costs

• Maintains tamper resistance

3636

Externally operated visible load-break switch

Visible break windowGages Load-break

switch handle

3737

Externally operated visible load-break switch

3838

Seismic

• OSHPD Certified.

• SDS

• Design spectral response acceleration

• Japanese earthquake SDS =1.0

• Cooper transformers certified to SDS = 1.93

• Manufacturers vary greatly in terms of kVA ratings being

OSHPD certified

• Transformers Will Also Comply With IBC Seismic

Requirements

3939

DOE defined benefits of 2016 standard

• Increased efficiency standards provide the following perceived national benefits over 30 year period• 3.63 quadrillion (1015) Btu of energy

• Roughly equivalent to the energy consumed by 40 million American households in one year

• 264.7 million metric tons (Mt) of carbon dioxide (CO2)• Average passenger car emits 4.75 metric tons

CO2E/vehicle/year• http://www.epa.gov/cleanenergy/energy-

resources/refs.html

• Roughly equivalent to removing over 55 million light duty passenger cars for one year

• 203.0 thousand metric tons of nitrogen oxides (NOX)

• 182.9 thousand metric tons of sulfur dioxide (SO2)

• 1,200 pounds of mercury (Hg)

Source: “Energy Efficiency Program For Certain Commercial And Industrial Equipment” 10 “CFR” 431.2

4040

0

2

4

6

8

10

12

14

16

18

20

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

Ineff

icie

ncy r

ed

ucti

on

(%

)

3-Ph kVA at DOE (50%) load

3-Phase liquid-filled: DOE 2010 vs. DOE 2016

4141

Impact of DOE 2016

• Transformer sizes, weights, and prices likely to

change

• Changes dependent upon specific customer

requirements and transformer type and rating

• General observations

• Core/coil weight increases are likely

• Footprint may change

• Eaton can design to meet dimensional constraints

The redesign process must be completed in order to provide firm size, weight,

and price changes

4242

Weight change example: 3-phase pad-mounted

Graph is representative of a subset of designs transitioning from DOE 2010 to DOE 2016.

Individual designs may have increases above or below averages presented above.

Transformers with high-current secondary's (i.e. 750kVA+, 208Y/120) will have weight increases well above average

0%

2%

4%

6%

8%

10%

12%

14%

16%

18%

20%

75 112.5 150 225 300 500 750 1000 1500 2000 2500

Av

era

ge W

eig

ht

Ch

an

ge

kVA

4343

kVA DOE 2010

Efficiency (%)

DOE 2016

Efficiency (%)

DOE 2010 Base

Losses (W)

DOE 2016 Base

Losses (W)

Change In

Base Losses

15 98.36 98.65 123 101 -18%

30 98.62 98.83 207 176 -15%

45 98.76 98.92 279 243 -13%

75 98.91 99.03 409 364 -11%

112.5 99.01 99.11 557 501 -10%

150 99.08 99.16 690 630 -9%

225 99.17 99.23 934 866 -7%

300 99.23 99.27 1155 1095 -5%

500 99.25 99.35 1875 1625 -13%

750 99.32 99.4 2550 2250 -12%

1000 99.36 99.43 3200 2850 -11%

1500 99.42 99.48 4350 3900 -10%

2000 99.46 99.51 5400 4900 -9%

2500 99.49 99.53 6375 5875 -8%

3-Phase liquid-immersed efficiency and base losses

4444

Think “MITS” for convenience

MITS – Modular Integrated Transportable

• Fully Integrated

• Factory-assembled, wired, and

tested to minimize on-site labor

costs, quality issues, and time

• Modular

• Flexible, and expandable design

allows a variety of equipment

configurations

• Transportable

• Structural base allows for

assembled units to be lifted and

transported, and relocated.

4545

Voltage Regulators

Single-phase or three-phase

Self contained

+/- 10% regulation

32 Steps, 5/8% increments

55/65 °C average winding rise

(12% more capacity)

25 to 2000 A

2400 V to 34500 V (60-200 BIL)

FR3 or Mineral Oil

Fan cooling option (33% more

capacity)

Substation, pole and pad-mounted

designs

4646

Success Story: Overhead Regulators

• Arizona mining customer having

power quality issues on their shovels

• Eaton CPS and EESS reps sold

benefit of Voltage Regulators over

Substation Load Tap Changers

(LTC’s) for power factor correction

• Minimum outage required for maintenance

• Regulation separate from main

transformer

• Lower Cost

• Designs optimized for the application

• Full 3 phase power quality monitoring

• Readily available replacements

• Communications integration and

automation

4747

Documents

Bob Ruzensky Regional Sales Director Gulf Region - WMEA Papers/1115_Transformer_Design_Eaton_Nov... · 5 5 Transformer Customer Challenges 5 Electrical Consumption and Demand are