DOE Final Rule Transformer Efficiency

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DOE Final RuleTransformer Efficiency
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Scope of Final Rule

• Liquid-filled distribution transformers
• HV ratings through 35 kV
• LV ratings 600 Volts and below
• Single-phase capacities 10-833 kVA
• Three-phase capacities 15-2500 kVA
• Dry-type medium-voltage transformer
• Approximately same ratings as for liquid-filled

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Changes NOPR vs Final Rule

• 10-100 kVA single-phase mandated efficiency
  slightly less thanTSL5 (was TSL2)
• 167 kVA single-phase mandated efficiency at TSL4
  (was TSL2)
• 250-833 kVA single phase mandated efficiency
  between TSL2 and TSL3 (was TSL2)

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Changes NOPR vs Final Rule

• 15-300 kVA three phase, efficiency levels are
  TSL2 (unchanged)
• 500-2500 kVA three phase mandated efficiency
  levels at TSL3 or slightly above TSL3

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Liquid-Filled Efficiency Levels (DOE vs NEMA)
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Liquid-Filled Efficiency Levels
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Major ConcernsRaw Materials

• Most distribution transformers sold today do not
  meet DOE mandate.
• Additional demand on scarce resourceswill impact
  transformer cost and availability
• Magnet wire 55 increased consumption
• Strip aluminum 55 increased consumption
• Transformer oil 3 reduced consumption
• Core steel 25 increased consumption (and 20
  decreased core steel vendor capacity)

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Cost/Efficiency Relationship
Cost
100
Transformer Efficiency
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Major ConcernsCore Steel
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Core Grade Distribution, Non-DOE Designs
M4
M5
M3
Production Volume
M2
M6
Core Steel Grades
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Major ConcernsCore Steel

• DOE mandate will
• force a shift to M2, M3 and M4 grades
• will eliminate usage of M5 and M6 grades for
  liquid-filled designs

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Major ConcernsCore Steel

• Core steel in global short supply
• Domestic suppliers plan no significant capacity
  increases
• Core steel suppliers unable to supply enough M2
  and M3 steel
• Globally, few core steel suppliers offer M2 and
  M3 grades
• Dry-type transformer producers will consume M5
  and M6 grades
• Rare and exotic core materials may be required
  (amorphous metal, laser scribed, high-B, etc.)

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Transformer Cost

• Transformer prices will increase an average
  15-30 for aluminum primary designs (depending on
  product line)
• Transformer prices will increase an average
  25-40 for non optimum designs (depending on
  product line)
• Increases for individual utilities will vary
  widely, based on present efficiency levels

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Other Issues

• How will increased pole-type transformer size and
  weight of 20-25 impact utility retrofits and
  service reliability?
• How will manufacturers handle redesign
  requirements (most transformer designs do not
  meet the DOE mandate)?
• Will waivers be available for emergencies?

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Howard Action Plan

• Improve process capacities to compensate for
  increased size and weight
• Increase core winding, annealing and lacing
  capacities
• Increase coil winding capacities
• Increase coil oven capacities
• Increase core/coil oven capacities
• Increase crane and conveyor capacities
• Expand Laurel Facility size by 525,000 ft2
• Increase unit production capacities
• Small pole-type from 3,000 to 6,000 units per
  week
• Padmounted capacity by 15
• Modify factory test stations

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Buy the Lowest TOC That Meets DOE
TOC
DESIGN 1 Equal Efficiency Lower TOC
DESIGN 2 Equal Efficiency Higher TOC
TOC
Eff
Eff
Cond
Cond
Core
Core
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Implementation Schedule
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DOE Contact

• Antonio Bousa Project Manager for Distribution
  Transformer Energy Conservation Standards, (202)
  586-4563
• DOE Web http//www.eere.energy.gov/buildings/appl
  iance_standards/commercial/distribution_transforme
  rs.html
• Howard Web www.howard.com