NOPR Rulemaking StageFrameworkDocumentPreliminaryAnalysisNOPRFinalRuleDateComplianceDateDocumenta ys sRuleDateScreeningEngineeringAnalysisMarkups forEquipment PriceDeterminationMarket &TechnologyAssessmentAnalysisEnergy Use andEndUse LoadNationalImpactLife-CycleCost andPaybackPeriod AnalysisEnd-UseLoadCharacterizationShipmentsAnalysisImpactAnalysisManufacturerImpact Analysis1 | Building Technologies Programeere.energy.govGoals of the Engineering Analysis• To evaluate design options that improve efficiency.• To characterize manufacturer selling price (MSP) versusefficiency for higher-efficiency distribution transformers.Downstream AnalysesManufacturer Selling Price –Efficiency Relationship•Life-Cycle Cost andPayback Period Analysis

c turer Price•National Impact Analysis

Manufa c Selling2 | Building Technologies Programeere.energy.govEfficiency LevelEngineering Analysis:MethodologySubdivide 10 equipment class groupings into 14 design linesbased on similar principles of design. Identify rep units.Choose Rep.Design Lines andUnitsIdentify design option combinations to characterize thespectrum of possible efficiencies.Select HigherEfficiencyDesign OptionsIdentify materials prices, markups, labor requirements, andother cost components for each design option combination.U O ti i d P S i (OPS) ft t d lDevelop CostInputsUseOptimizedProgramService(OPS)softwareto modeloptimized designs based on several hundred A and B values.Develop efficiency levels (ELs) that span the range ofModel OptimizedDesigns Basedon A’s and B’sDevelopefficiencylevels(ELs)thatspantherangeofefficiency from the baseline to the maximum technologicallyfeasible.Develop ELsScale to3 | Building Technologies Programeere.energy.govScale results to other equipment classes not analyzed.EquipmentClasses NotAnalyzedEngineering Design Lines andRepresentative Units• Subdivide equipment classes into 14 engineeringdesign lines based on similar principles of designd t tiChoose Rep.Design Lines andUnitsandconstruction.– Five liquid-immersed,– Three LVDT, andSelect HigherEfficiencyDesign Options–Six MVDT.• Span a range of kVA ratings for which the 0.75Develop CostInputsscaling rule would provide accurate results.• Select one representative unit from each engineeringModel OptimizedDesigns Basedon A’s and B’sp ggdesign line.Develop ELsScale to4 | Building Technologies Programeere.energy.govEquipmentClasses NotAnalyzedLiquid-Immersed Equipment Class toDesign Line MappingChoose Rep.Design Lines andUnitsEquipment Class Group 1Liquid-Immersed,Equipment Class Group 2Liquid-Immersed,Select HigherEfficiencyDesign OptionsRectangular RoundTank Tank10Single-PhasekVADesignLines15Three-PhasekVADevelop CostInputs10152537.5 L 1 L 2Rep Unit15304575112 5 L 4Model OptimizedDesigns Basedon A’s and B’s5075100167 D L

D LRep Unit112.5150225300500 D LRep UnitDevelop ELsScale to167250333500667 DL 3Rep Unit500750100015002000 DL 5Rep Unit5 | Building Technologies Programeere.energy.govEquipmentClasses NotAnalyzed66783320002500Liquid-Immersed Design Lines andRepresentative Units

u ipment C lass e sign L ineType of DistributionTransformerkVARangeRepresentative Unit

Eq u C D e LTransformerRange1Liquid-immersed,singlephase,10–16750 kVA, 65°C, single-phase, 60Hz,14400Vprimary,240/120V secondary,1gp ,rectangular tankp y, y,rectangular tank2Liquid-immersed,single-phase, roundtank10–16725 kVA, 65°C, single-phase, 60Hz,14400V primary, 240/120V secondary,round tanktankroundtank3Liquid-immersed,single-phase250–833500 kVA, 65°C, single-phase, 60Hz,14400V primary, 277V secondary6 | Building Technologies Programeere.energy.govIdentify Transformer Design OptionCombinations• Select design option combinations.– Vary core configurations, core steels, and winding materials.Capture most common designs and maximum efficiencyChoose Rep.Design Lines andUnits–Capturemostcommondesignsandmaximumefficiency.Select HigherEfficiencyDesign OptionsDesign Option Designs ConsideredWound core distributedgap;Develop CostInputsCore Configuration(Type)Woundcoredistributedgap;Stacked butt-lap;Stacked full miter;Step-lap miter;Stacked cruciform miterModel OptimizedDesigns Basedon A’s and B’sStackedcruciformmiter.Core Configuration(Construction)1-Phase:Shell and Core type.3-Phase:3-legged, 5-legged and Symmetric Core.Develop ELsCore SteelsSilicon steel:M12, M6, M5, M4, M3, M2.Domain refined silicon steel:H-0 DR (dry-type),ZDMH (liquid-immersed).Amorphous steel:SA1 (Dry-type and Liquid)Scale to7 | Building Technologies Programeere.energy.govWinding materialsCopper;Aluminum.EquipmentClasses NotAnalyzedIdentify Transformer Design OptionCombinations (Continued)DesignCoreConductorConductorCore/Coil DesignChoose Rep.Design Lines andUnitsExample of Design Option Combinations AnalyzedDL7: 75 kVA low-voltage dry-type, three-phase.DesignOptionCoreMaterialConductorPrimaryConductorSecondaryCore/CoilDesignType1 M12 Al Al 3-leg stacked butt-lap2 M12 Cu Al 3-leg stacked butt-lapSelect HigherEfficiencyDesign Options3 M6 Al Al 3-leg stacked butt-lap4 M6 Al Al 3-leg stacked full miter5 M4 Cu Al 3-leg stacked full miterDevelop CostInputs6 M3AlAl 3-leg stacked full miter7 M3 Al Al 3-leg step-lap miter8 M3 Al Al 3-leg distributed gap core9H0DRAlAl3leg stacked full miterModel OptimizedDesigns Basedon A’s and B’s9H-0DRAlAl3-legstackedfullmiter10 H-0 DR Al Al 3-leg step-lap miter11 ZDMH Al Al 3-leg distributed gap core12 H-0 DR Cu Cu 3-legstacked full miterDevelop ELsScale to8 | Building Technologies Programeere.energy.govg13 SA1 Al Al 5-leg distributed gap core14 SA1 Cu Cu 5-leg distributed gap coreEquipmentClasses NotAnalyzedEngineering Analysis:Markups and Labor Rate• DOE determined materials prices and labor requirementsthrough conversations with manufacturers and experts.Choose Rep.Design Lines andUnits• DOE determined markups and labor rates from censusdata, SEC filings, and manufacturer interviews.Select HigherEfficiencyDesign OptionsDevelop CostInputsMarkup / Cost Input Markup NotesScrap and handling2.5 %Standard scrap and handling; applied tomaterials15%P f bi t dhModel OptimizedDesigns Basedon A’s and B’sScrapandhandling1.5%Prefabricatedamorphous cores4.0 % Additional scrap on fully mitered coresFactory overhead 12.5 % Applied to materialsDevelop ELsShipping$ 0.28 /poundAdded prior to profit markup; Approximately4–8% of MSPFully-burdened hourlylabor rate$ 51.52 Applied to total labor hoursScale to9 | Building Technologies Programeere.energy.govlaborrateNon-production 25 %Applied to total cost for SG&A, R&D,warranty/risk provisions, and profit factorEquipmentClasses NotAnalyzedEngineering Analysis:Markups and Labor Rate• For large (1500 kVA or greater) dry-type designs using anamorphous core, DOE accounted for additional labor andhardware costs.Choose Rep.Design Lines andUnitsSelect HigherEfficiencyDesign OptionsCost FactorAdditionalAmountper DesignRationaleE t h dli i d fDevelop CostInputsLabor 10 hoursExtrahandling requiredforlarge, fragile amorphous cores.Additional bracing necessary inl d i t t i th ilModel OptimizedDesigns Basedon A’s and B’sHardware $230 to $330largedesignsto containthe coiland prevent short circuitproblems.Develop ELsScale to10 | Building Technologies Programeere.energy.govEquipmentClasses NotAnalyzedEngineering Analysis:Modeling Optimized Designs• Optimized Program Service (OPS) software conductsdesign runs.Choose Rep.Design Lines andUnits• As an input to the OPS software, economic parameters(A and B values) are varied to simulate a range ofSelect HigherEfficiencyDesign Optionscustomer orders, creating a database of transformerdesigns.Develop CostInputs• Approximately 2,500 unique designs for each of thefourteen representative unitswithin each of the fourteendesign lines.Model OptimizedDesigns Basedon A’s and B’sDevelop ELsScale to11 | Building Technologies Programeere.energy.govEquipmentClasses NotAnalyzedEngineering Analysis:Modeling Optimized Designs• OPS design software output includes:– Construction and winding instructions for the core and coilChoose Rep.Design Lines andUnits(e.g., core dimensions, high- and low-voltage windings, taplocations, insulation, cooling ducts, and labor).– Bill of materials and electrical analysis report.Select HigherEfficiencyDesign Options• Material, labor costs and markups are combined todetermine the manufacturer’s selling price (MSP).Develop CostInputs• Temperature-corrected efficiency determined from OPSsoftware electrical analysis report.Model OptimizedDesigns Basedon A’s and B’sDevelop ELsScale to12 | Building Technologies Programeere.energy.govEquipmentClasses NotAnalyzedEngineering Analysis:Symmetric Core Designs• DOE was unable to identify a company that could modelsymmetric core designs.Choose Rep.Design Lines andUnits• DOE gathered information on symmetric cores throughmanufacturer interviews, published literature, and limitedd i id d b f tSelect HigherEfficiencyDesign Optionsdesigns providedby manufacturers.– Using these data sources, DOE roughly estimated the costefficiency relationship of symmetric core designs.Develop CostInputs• DOE did receive limited design data from manufacturers ofsymmetric core transformers, and may issue some analysisto the extent that it is able.Model OptimizedDesigns Basedon A’s and B’stotheextentthatitisable.Develop ELsScale to13 | Building Technologies Programeere.energy.govEquipmentClasses NotAnalyzedEngineering Analysis:Develop efficiency Levels• DOE identified efficiency levels (ELs) that span the range ofdistribution transformer efficiencies from the baseline to themaximum technologically feasible efficiencyChoose Rep.Design Lines andUnitsmaximumtechnologicallyfeasibleefficiency.• Factors DOE considered in setting ELs:Select HigherEfficiencyDesign OptionsDevelop CostInputsHarmonization across single-phase and the per-phasekVA equivalent three-phase design lines.Model OptimizedDesigns Basedon A’s and B’sEqually spaced efficiency incrementsqp gDevelop ELsBenchmark efficiency levels (e.g., NEMA Premium)Scale to14 | Building Technologies Programeere.energy.govEquipmentClasses NotAnalyzedEngineering Analysis:Modeled Designs from DL1Rep Unit from DL1: 50 kVA liquid-immersed, single-phase, pad-mounted$4,000CSL 0CSL 1CSL 2CSL 3CSL 4CSL 5CSL 6$3,500$3,000

Selling Price ($)$2,500

ManufacturerM5_CuAl_dgw_shM3_AlAl_dgw_shM3_CuAl_dgw_shM2_AlAl_dgw_shM2_CuAl_dgw_sh$2,000ZDMH_AlAl_dgw_shZDMH_CuCu_dgw_shSA1_AlAl_dgw_shSA1_CuCu_dgw_shCSLs15 | Building Technologies Programeere.energy.gov$1,50099.00% 99.10% 99.20% 99.30% 99.40% 99.50% 99.60%Efficiency at 50% Load, Temperature CorrectedDeveloping Trial Standard Levels forthe NOPR• If DOE issues a NOPR, it will select trial standard levels(TSLs) based on groupings of ELs, such as:Ph h i ti i i LCC d i NPVChoose Rep.Design Lines andUnits–Per-phaseharmonization, minimumLCC, andmaximumNPV.• These TSLs may consider any interaction betweenSelect HigherEfficiencyDesign Optionsequipment classes.• DOE will select itsproposed standard level in the NOPRDevelop CostInputsp pfrom the list of TSLs developed.Model OptimizedDesigns Basedon A’s and B’sDevelop ELsScale to16 | Building Technologies Programeere.energy.govEquipmentClasses NotAnalyzedMedium-Voltage Dry-Type EquipmentClass to Design Line MappingMedium-Voltage Dry-Type, Single-Phase• Single-phase MVDT units have low unit shipments and MVAcapacity shipped.Choose Rep.Design Lines andUnitscapacityshipped.• Rather than directly analyzing these units, DOE scaled to theseunits by dividing the kVA rating of three-phase MVDT units bythree.Select HigherEfficiencyDesign OptionsDevelop CostInputsThree-Phase Rep UnitkVASingle-Phase ScaledUnit kVAModel OptimizedDesigns Basedon A’s and B’s300 1001500 500Scales To...Develop ELsScale to2000 66717 | Building Technologies Programeere.energy.govEquipmentClasses NotAnalyzedEngineering Analysis:Scaling Results• DOE scaled the total losses (TL) from a representative unitto other unanalyzed kVA ratings (S) within a design lineusingthe 0.75 ScalingRule:Choose Rep.Design Lines andUnitsg gTL1= TL0x (S1/ S0)0.75Select HigherEfficiencyDesign Options• Costs of construction and losses can be scaled whendesign parameters are held constant, including:frequency magnetic flux density current density andDevelop CostInputs–frequency,magneticfluxdensity,currentdensityandinsulation level.Model OptimizedDesigns Basedon A’s and B’sDesign Line 7 (LVDT, 3-phase, 15 – 150 kVA):75 kVA Representative UnitDevelop ELs75kVARepresentativeUnit15304575112 5150Scale ResultsScale to18 | Building Technologies Programeere.energy.gov15kVA30kVA45kVA75kVA112.5kVA150kVAEquipmentClasses NotAnalyzed19 | Building Technologies Programeere.energy.govBackup SlidesBackup Slides20 | Building Technologies Programeere.energy.govLiquid-Immersed Equipment Class toDesign Line MappingEquipment Class 1Liquid-Immersed,Equipment Class 2Liquid-Immersed,Choose Rep.Design Lines andUnitsRectangular RoundTank Tankq ,Single-PhasekVADesignLines15qThree-PhasekVASelect HigherEfficiencyDesign Options10152537.5 L 1 L 2Rep Unit15304575112 5 4Develop CostInputs37.55075100167 D L D LRep Unit112.5150225300 DLRep UnitModel OptimizedDesigns Basedon A’s and B’s167250333500 D L 3Rep Unit50075010001500 D L 5Rep UnitDevelop ELsScale to21 | Building Technologies Programeere.energy.gov667833 D20002500 DEquipmentClasses NotAnalyzedLow-Voltage Dry-Type EquipmentClass to Design Line MappingEquipment Class 3Dry-Type, Low Voltage,Equipment Class 4Dry-Type, Low Voltage,Choose Rep.Design Lines andUnitskVA Design Line15y yp gSingle-PhasekVA Design Line15Three-PhaseSelect HigherEfficiencyDesign Options152537.5Rep Unit304575 DL 7Rep UnitDevelop CostInputs5075100 DL 6112.5150225Model OptimizedDesigns Basedon A’s and B’s100167250333300500750 DL 8Rep UnitDevelop ELsScale to22 | Building Technologies Programeere.energy.gov3331000EquipmentClasses NotAnalyzedMedium-Voltage Dry-Type EquipmentClass to Design Line MappingChoose Rep.Design Lines andUnitsEC 6 EC 8 EC 1020-45kV 46-95kV >96kVDry-Type, Medium Voltage, Three-PhaseSelect HigherEfficiencyDesign Options15 -30 -45 -Develop CostInputs75 -112.5 -150 -

DL 9 DL 11Model OptimizedDesigns Basedon A’s and B’s225300500750 A & B)Rep UnitRep UnitRep UnitDevelop ELsScale to750100015002000 DL 13 ( A

D L 10 D L 12Rep UnitRep UnitRep Unit23 | Building Technologies Programeere.energy.govEquipmentClasses NotAnalyzed20002500 D DRepUnitLiquid-Immersed Design Lines andRepresentative Units

n t E quipme Class Design LineType of DistributionTransformerkVARangeRepresentative Unit

E1Liquid-immersed,single-phase,rectangular tank10–16750 kVA, 65°C, single-phase, 60Hz,14400V primary, 240/120V secondary,rectangular tank12Liquid-immersed,single-phase, roundtank10–16725 kVA, 65°C, single-phase, 60Hz,14400V primary, 120/240V secondary,round tankLiquid-immersed500kVA65°C single-phase 60Hz3Liquidimmersed,single-phase250–833500kVA,65C,singlephase,60Hz,14400V primary, 277V secondary24 | Building Technologies Programeere.energy.govLiquid-Immersed Design Lines andRepresentative Units

pment l ass e sign L ineType of DistributionTransformerkVARangeRepresentative Unit

Equi C l

D e LTransformerRangep4Liquid-immersed,15–500150 kVA, 65°C, three-phase, 60Hz,12470Y/7200V primary 208Y/120V24three-phase1550012470Y/7200Vprimary,208Y/120Vsecondary5Liquid-immersed,three-phase750–25001500 kVA, 65°C, three-phase, 60Hz,24940GrdY/14400V primary,480Y/277V dthreephase480Y/277Vsecondary25 | Building Technologies Programeere.energy.govLow-Voltage Dry-Type Design Linesand Representative Units

nt Equipme Class Design LineType of DistributionTransformerkVARangeRepresentative Unit3 6Dry-type, low-voltage,single-phase15–33325 kVA, 150°C, single-phase, 60Hz,480V primary, 120/240V secondary,10kV BIL75kVA150°C threephase 60Hz47Dry-type, low-voltage,three-phase15–15075kVA,150C,three-phase,60Hz,480V primary, 208Y/120V secondary,10kV BIL300kVA150°C three-phase 60Hz8Dry-type, low-voltage,three-phase225–1000300kVA,150C,threephase,60Hz,480V Delta primary, 208Y/120Vsecondary, 10kV BIL26 | Building Technologies Programeere.energy.govMedium-Voltage Dry-Type DesignLines and Representative Units

q uipment Class D esign LineType of DistributionTransformerkVARangeRepresentative Unit

E q D69Dry-type, mediumvoltage, three-phase, 20-45kV BIL15–500300 kVA, 150°C, three-phase, 60Hz, 4160VDelta primary, 480Y/277V secondary, 45kV BIL610Dry-type, mediumvoltage, three-phase, 20-45kV BIL750–25001500 kVA, 150°C, three-phase, 60Hz, 4160Vprimary, 480Y/277V secondary, 45kV BILDry-type, medium-300kVA150°C three-phase 60Hz 12470V811 voltage, three-phase, 46-95kV BIL15–500300kVA,150C,threephase,60Hz,12470Vprimary, 480Y/277V secondary, 95kV BIL12Dry-type, mediumvoltage, three-phase, 46-95kV BIL750–25001500 kVA, 150°C, three-phase, 60Hz, 12470Vprimary, 480Y/277V secondary, 95kV BIL95kVBILpy y1013 (A& B)Dry-type, medium-voltage, three-phase, 96-150kV BIL225–2500300 kVA, 150°C, three-phase, 60Hz, 24940Vprimary, 480Y/277V secondary, 125kV BIL2000 kVA, 150°C, three-phase, 60Hz, 24940Vi 480Y/277V d 125kV BIL27 | Building Technologies Programeere.energy.gov150kVBILprimary,480Y/277Vsecondary,125kVBILEngineering Analysis: MaterialsPrices for Core SteelsMaterial Units2010 Price[2010$]2006 Price[2010$]2008 Price[2010$]M12 core steel$/lb1.03 0.85 1.60M6 core steel$/lb1.46 0.94 2.19M5 core steel$/lb1.51 0.99 2.24M4 core steel$/lb1.59 1.03 2.30M3 core steel$/lb1.88 1.06 2.60M3 core steel (LiteCarlite)M3coresteel(Carlite$/lb1.95 1.47 2.44M2 core steel$/lb2.00 1.32 2.79M2 core steel (LiteCarlite)$/lb2 101 582 63M2coresteel(LiteCarlite)$/lb2.101.582.63ZDMH (mechanically-scribed core steel)$/lb2.05 1.41 3.22H-0 DR core steel (laser scribed)$/lb2 061 413 2328 | Building Technologies Programeere.energy.gov$/lb2.061.413.23SA1 (amorphous) finished core, volumeproduction$/lb2.38 1.72 3.64Engineering Analysis: Materials Prices forLiquid-Immersed Design LinesMaterial Units2010 Price[2010$]2006 Price[2010$]2008 Price[2010$]Conductor and Miscellaneous PricesCopper wire, formvar, round #10-20$/lb4.87 3.33 5.97Copper wire, enameled, round #7-10$/lb4.84 3.31 5.93Copper wire,enameled,rectangular sizes$/lb4 973 416 09pp , , g4.973.416.09Aluminum wire, formvar, round #9-17$/lb3.07 2.30 3.91Aluminum wire, formvar, round #7-10$/lb2.57 1.93 3.28Copper strip, thickness range 0.02-0.045$/lb4.97 3.41 6.09Copper strip, thickness range 0.030-0.060$/lb4.97 3.41 6.09Aluminum strip, thickness range 0.02-0.045$/lb2.08 1.56 2.67Aluminum strip, thickness range 0.045-0.080$/lb2.08 1.56 2.67Kraft insulating paper with diamond adhesive$/lb1.52 1.17 1.93Mineral oil$/gal3 351 943 8429 | Building Technologies Programeere.energy.govMineraloil$/gal3.351.943.84Tank Steel$/lb0.38 0.32 0.60Engineering Analysis: MaterialsPrices for Dry-Type Design LinesMaterialUnits2010 Price 2006 Price 2008 PriceConductor and Miscellaneous Prices[2010$][2010$][2010$]Copper wire, rectangular 0.1 x 0.2, Nomexwrapped$/lb4.52 3.07 5.53Aluminum wire, rectangular 0.1 x 0.2,Nomex$/lb2 972 233 78Aluminumwire,rectangular0.1x0.2,Nomexwrapped$/lb2.972.233.78Copper strip, thickness range 0.02-0.045$/lb4.97 3.41 6.09Aluminum strip, thickness range 0.02-0.045$/lb2.08 1.56 2.67Nomex insulation$/lb24.50 13.72 29.03Cequin insulation$/lb5.53 3.84 6.09Impregnation$/ l22 5517 1627 31ga...Winding combs$/lb12.34 6.08 15.41Enclosure Steel$/lb0.38 0.32 0.6030 | Building Technologies Programeere.energy.govDeveloping Trial Standard Levels forthe NOPRChoose Rep.Design Lines andUnits• Illustration of how TSLs are selected based on groupings ofELs:C bi li idi d d i li i i ELSelect HigherEfficiencyDesign Options–Combineliquid-immerseddesignlines using maximumELavailable that does not use amorphous metal.Develop CostInputsDesign Line ELModel OptimizedDesigns Basedon A’s and B’s1 22 233TSL 1Develop ELsScale to4 25231 | Building Technologies Programeere.energy.govEquipmentClasses NotAnalyzed52NOPR Rulemaking StageFrameworkDocumentPreliminaryAnalysisNOPRFinalRuleDateComplianceDateDocumenta ys sRuleDateScreeningEngineeringAnalysisMarkups forEquipment PriceDeterminationMarket &TechnologyAssessmentAnalysisEnergy Use andEndUse LoadNationalImpactLife-CycleCost andPaybackPeriod AnalysisEnd-UseLoadCharacterizationShipmentsAnalysisImpactAnalysisPreliminaryManufacturerImpact Analysis32 | Building Technologies Programeere.energy.govPurpose• Market and Technology AssessmentCharacterize the distribution transformer market and industry–Characterizethedistributiontransformermarketandindustry.– Identify the technology options to improve distribution transformerefficiency.–Establish equipment classesEstablishequipmentclasses.S i Ali•ScreeningAnalysis– Screen out technology options that DOE will not consider in theengineering analysis for distribution transformers based on several criteria.33 | Building Technologies Programeere.energy.govRelationship of Market and TechnologyAssessment to Other AnalysesMarket and TechnologyAssessmentEquipment ClassesTh ltit i ffi iechnology oponstoimprove efficiencyScreening AnalysisDesign options to improve efficiencyEngineering Analysis34 | Building Technologies Programeere.energy.govEquipment Classes• DOE divides covered equipment into classes by:– The Type of energy used,– The Capacity, or– Any performance-related features that affect consumer utility orefficiency.• DOE considered 10 equipment class groupings by dividing thel i f di ib i f b dpopulation ofdistribution transformersbasedupon:– Type of transformer insulation:liquid-immersed or dry-type,–Number ofphases:single or three,– Voltage class:low or medium (for dry-type units only), and– Basic impulse insulation level (BIL):(for MVDT units only).35 | Building Technologies Programeere.energy.govDistribution TransformersEquipment Class GroupingsThere are 115 discrete kVA ratings acrossthe ten equipment class groupings (ECG)ECGIns lationPhasesVoltageBILkVARangeInsulationVoltage1 Liquid-Immersed Single Medium --- 10-833 kVA2 Liquid-Immersed Three Medium --- 15-2500 kVA3 Dry-Type Single Low --- 15-333 kVA4 Dry-Type Three Low --- 15-1000 kVA5DTSi lM di2045 kV BIL15833 kVAryypengeeum-45kVBIL-833kVA6 Dry-Type Three Medium 20-45 kV BIL 15-2500 kVA7 Dry-Type Single Medium 46-95 kV BIL 15-833 kVA8 Dry-Type Three Medium 46-95 kV BIL 15-2500 kVA9 Dry-Type Single Medium >96 kV BIL 75-833 kVA10Dry-TypeThreeMedium >96kV BIL 225-2500kVA36 | Building Technologies Programeere.energy.gov0yypeeeed u965500Distribution Transformers2009 Industry ShipmentsEquipment Class GroupingUnitsShippedMVACapacityShipped1. Liquid-immersed, medium-voltage, single-phase 683,726 21,9942. Liquid-immersed, medium-voltage, three-phase 49,739 32,2663 Drytype lowvoltage singlephase17 740647.Dry-type,low-voltage,single-,4. Dry-type, low-voltage, three-phase 206,929 15,7785. Dry-type, medium-voltage, single-phase, 20-45 kV BIL 709 236. Dry-type, medium-voltage, three-phase, 20-45 kV BIL 522 2577. Dry-type, medium-voltage, single-phase, 46-95 kV BIL 546 238Dry-type medium-voltage three-phase 46-95 kV BIL2 0743 655.type,mediumvoltage,threephase,4695kVBIL,,9. Dry-type, medium-voltage, single-phase,≥96 kV BIL 202 910. Dry-type, medium-voltage, three-phase,≥96 kV BIL 1,286 2,20637 | Building Technologies Programeere.energy.govTOTAL 963,473 76,858Technology OptionsTechnology Option Material / ConceptAluminum(wire and sheet)Conductor Materials for Coils(wireandsheet)Copper (wire and sheet)Core MaterialsCold-Rolled High Silicon (CRHiSi) SteelCRHiSi Domain-Refined SteelsAmorphous Materials in Wound CoreGeometry ModificationsAdjust the cross-sectional area of the/ dtdj t lt tGeometryModificationscore/conductor, or adjustvolts perturnSymmetric Core DesignsContinuously wound cores with 120 degreeradial symmetry for three-phase designsA transformer is replaced by threesmaller38 | Building Technologies Programeere.energy.govCore Deactivation TechnologyAtransformerisreplacedbythreesmallertransformers that are (de)activated inresponse to changes in load demand.Technology Assessment:Symmetric Core Designs• “Symmetric Core” designs are three-phasedesigns that use a continuously woundith 120°di l tcore with120raasymmetry.• Advantages include lowered: weight,volume, no-load losses, noise, vibration,stray magnetic fields, inrush current, andpower in the third harmonic.• Best suited for delta-delta or delta-wyeconnections, though zero-sequence fluxesassociated with wye-wye connections canbe mitigated by a delta-connected tertiarywinding.S L d k S j “C t M d l f39 | Building Technologies Programeere.energy.govSource:Lundmark,Sonja.“ComputerModelofElectromagnetic Phenomena in Hexaformer.” 2007.http://www.hexaformer.com/ExternaDokument/chalmers_report1.pdf.Technology Assessment:Core Deactivation Technology• Reduces core losses by using a system of smaller transformers toreplace a single larger transformerreplaceasingle,largertransformer.– Example: Three 25 kVA transformers in parallel replace a 75 kVAtransformer.• Control unit can activate and deactivate component transformersdepending on the loading demands.– Optimizes combination of transformers at given load.• DOE is only aware of this technology in LVDT distributiontransformers.– Medium-voltage core deactivation systems have not been producedcommercially, and pose difficulties for switching within the primary andsecondary connections.40 | Building Technologies Programeere.energy.gov• Best suited for applications with low loading demands.Core Deactivation TechnologyLoad vs. Efficiency989997

n cy %Core Deactivation System9596

Efficie nCoreDeactivationSystemTraditional Transformer DesignT P d L di9394TestProcedureLoadingThis figure is for illustrative purposes only and is not based on actual5 15 25 35 45 55 65 75 85 95Percentage of Full Rated Load41 | Building Technologies Programeere.energy.govThisfigureisforillustrativepurposesonly,andisnotbasedonactualDOE researchTechnology Assessment:Core Deactivation Technology• While core deactivation technology could save energy over a loadcycle, these energy savings may notbe captured by the current testprocedure specifyinga single load factor.p yg g• A weighted-average loss calculation using various loadings couldbetter capture this technology’s energysavingspotential.gy gy g pExample:Loading(%)Losses( )Single Loading Point,(%)Weighted Average,(%)(%)(W)Load Frequency(%)Load Frequency0 200.0 0 3115 222.5 0 2235 322.5 100 2050 450.0 0 1875762 50942 | Building Technologies Programeere.energy.gov75762.509Average Losses 322.5 322.5Technology Assessment:Core Deactivation Technology• DOE is not considering core deactivation technology in the context ofsetting standards, but may explore doing so in the future.Scale each design to 1/3 its kVA and group them in sets of three–Scaleeachdesignto1/3itskVAandgrouptheminsetsofthree.– Account for additional cost and weight of the core deactivation technology.– Analyze each core deactivation system using various loading scenarios.• Core deactivation systems using non-identical component transformers.– Each component transformer requires a similar winding design to maintaini d t h l diimpedance ateachloading.• Based on conversations with manufacturers, core deactivation withMVDT has additional challenges.43 | Building Technologies Programeere.energy.govScreening AnalysisPurpose• Screen out technology options that DOE will not consider in theengineering analysis for distribution transformers.ApproachTechnological feasibility• DOE will evaluate each technology option based on the following criteria:Practicability to manufacture, install, and serviceTechnologicalfeasibilityImpacts on health or safetyAdverse impacts on equipment utility or availability toconsumers44 | Building Technologies Programeere.energy.govImpactsonhealthorsafetyTechnology Options ScreenedOut of the AnalysisTechnology Option Excluded Screening CriteriaSilver as a Conductor Material Practicabilityto manufacture,install,and service,,High-TemperatureSuperconductorsTechnological feasibility;Practicability to manufacture, install, and serviceAmorphous Core Material inStacked Core ConfigurationTechnological feasibility;Practicability to manufacture, install, and serviceCarbon Composite MaterialsCarbonCompositeMaterialsfor Heat RemovalTechnological feasibilityHigh-Temperature InsulatingMaterialTechnological feasibilitySolid-State (Power Electronics)TechnologyTechnological feasibility;Practicability to manufacture, install, andservice.45 | Building Technologies Programeere.energy.govNanotechnology Composites Technological feasibilityEngineering Validation• DOE maymake available detailed design information forgcertain design lines and efficiency levels to allowmanufacturers to compare with designs of their own.• DOE may invite manufacturers to submit similar designinformation for their own designs. Such information, ifsubmitted to a Department contractor would be kept insubmittedtoaDepartmentcontractor,wouldbekeptinconfidence.46 | Building Technologies Programeere.energy.gov