Engineering Analysis Validation Form - 04 October 2011

This form serves as a source of feedback for DOE's Engineering The information shared should allow DOE and 

manufacturers to verify which design configurations can achieve optional efficiency levels.

The "Design Details" tab gives the design specifications for each design line. Please enter data in only 

the blue cells. The "Design Options" column has dropdown menus limiting combinations of design 

features to those DOE selected for modeling. Not every buildable combination is represented. For each 

efficiency within a design line, please enter the design details of your lowest first-cost design that can 

meet that efficiency, ideally, optimizing with respect to the same material costs that DOE uses. If you 

do not produce designs meeting those specifications (e.g., optimized with respect to different prices), 

please describe your modifications in the "Notes" column.

Additional information is requested that can be described as a summary Bill of Materials. With this 

BOM a first order price estimate can be prepared using the same material cost estimates (ex. $/lb) as 

used by DOE. This will provide an apples-to-apples comparison that avoids grouping design cost drivers 

from differences in material costs. The potentially large impact of material costs differences can be 

analyzed separately.
Material for Liquid-Immersed

M6 core steel $/lb $ 1.46

M5 core steel $/lb $ 1.51

M4 core steel $/lb $ 1.59

M3 core steel $/lb $ 1.88

M3 Lite Carlite core steel $/lb $ 1.95

M2 core steel $/lb $ 2.00

M2 Lite Carlite core steel $/lb $ 2.10

ZDMH (mechanically-scribed core steel) $/lb $ 2.05

SA1 (amorphous) - finished core, volume production $/lb $ 2.38

Copper wire, formvar, round #10-20 $/lb $ 4.87

Copper wire, enameled, round #7-10 $/lb $ 4.84

Copper wire, enameled, rectangular sizes $/lb $ 4.97

Aluminum wire, formvar, round #9-17 $/lb $ 3.07

Aluminum wire, formvar, round #7-10 $/lb $ 2.57

Copper strip, thickness range 0.02-0.045 $/lb $ 4.97

Copper strip, thickness range 0.030-0.060 $/lb $ 4.97

Aluminum strip, thickness range 0.02-0.045 $/lb $ 2.08

Aluminum strip, thickness range 0.045-0.080 $/lb $ 2.08

Kraft insulating paper with diamond adhesive $/lb $ 1.52

Mineral oil $/gal $ 3.35

Tank Steel $/lb $ 0.38
Material for Dry-type

M36 core steel (26 gauge) $/lb $ 0.66

M19 core steel (26 gauge) $/lb $ 0.91

M12 core steel $/lb $ 1.03

M6 core steel $/lb $ 1.46

M5 core steel $/lb $ 1.51

M4 core steel $/lb $ 1.59

M3 core steel $/lb $ 1.88

M2 core steel $/lb $ 2.00

H-0 DR core steel (laser-scribed) $/lb $ 2.06

SA1 (amorphous) - finished core, volume production $/lb $ 2.38

Copper wire, rectangular 0.1 x 0.2, Nomex wrapped $/lb $ 4.52

Aluminum wire, rectangular 0.1 x 0.2, Nomex wrapped $/lb $ 2.97

Copper strip, thickness range 0.02-0.045 $/lb $ 4.97

Aluminum strip, thickness range 0.02-0.045 $/lb $ 2.08

Nomex insulation (per pound) $/lb $ 24.50

Cequin insulation (per pound) $/lb $ 5.53

Impregnation (per gallon) $/gal $ 22.55

Winding Combs (per pound) $/lb $ 12.34

Enclosure Steel (per pound) $/lb $ 0.38
Efficiency

Design 

Line Type Phases kVA P Voltage S Voltage Temp. Rise (C) BIL

1 Liquid 1 50 14400 240/120 65 - 99.08%

option 1

option 2

option 3

option 4

option 5

option 6

2 Liquid 1 25 14400 120/240 65 - 98.91%

option 1

option 2

option 3

option 4

option 5

option 6

3 Liquid 1 500 14400 277 65 - 99.42%

option 1

option 2

option 3

option 4

option 5

option 6

4 Liquid 3 150 12470Y/7200 480Y/277 65 - 99.08%

option 1

option 2

option 3

option 4

option 5

option 6

5 Liquid 3 1500 24940GrdY/14400 480Y/277 65 - 99.42%

option 1

option 2

option 3

option 4

option 5

option 6

6 LVDT 1 25 480 120/240 150 10 98.00%

option 1

option 2

option 3

option 4

option 5

option 6

7 LVDT 3 75 480 208Y/120 150 10 98.00%

option 1

option 2

option 3

option 4

Design Line Specifications
option 5

option 6

8 LVDT3 300 480 208Y/120 150 10 98.60%

option 1

option 2

option 3

option 4

option 5

option 6

9 MVDT3 300 4160 480Y/277 150 45 98.82%

option 1

option 2

option 3

option 4

option 5

option 6

10 MVDT3 1500 4160 480Y/277 150 45 99.22%

option 1

option 2

option 3

option 4

option 5

option 6

11 MVDT3 300 12470 480Y/277 150 95 98.67%

option 1

option 2

option 3

option 4

option 5

option 6

12 MVDT3 1500 12470 480Y/277 150 95 99.12%

option 1

option 2

option 3

option 4

option 5

option 6

13a MVDT3 300 24940 480Y/277 150 150 98.63%

option 1

option 2

option 3

option 4

option 5

option 6

13b MVDT3 2000 24940 480Y/277 150 150 99.15%

option 1

option 2

option 3

option 4

option 5

option 6
Design Options

Steel 

(lbs)

Primary 

(lbs)

Primary 

(material)

Secondary 

(lbs)

Secondary 

(material)

Oil 

(lbs)

Tank 

(lbs)

Overall 

(lbs)

Height 

(in)

Width 

(in)

Depth 

(in) Notes

Flux 

Density (T)

Impedance 

(%)

Primary 

Volts/Turn

Secondary 

Volts/Turn

Primary Current 

Density (A/in^2)

Design Details

Secondary Current 

Density (A/in^2) Comments