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)
Single Phase Single Phase Single Phase Three Phase Three Phase Three Phase
KVA DOE NEMA TP-1 KVA DOE NEMA TP-1
15 98.36 98.1
10 98.62 98.4 30 98.62 98.4
15 98.76 98.6 45 98.76 98.6
25 98.91 98.7 75 98.91 98.7
37.5 99.01 98.8 112.5 99.01 98.8
50 99.08 98.9 150 99.08 98.9
75 99.17 99.0 225 99.17 99.0
100 99.23 99.0 300 99.23 99.0
167 99.25 99.1 500 99.25 99.1
250 99.32 99.2 750 99.32 99.2
333 99.36 99.2 1000 99.36 99.2
500 99.42 99.3 1500 99.42 99.3
667 99.46 99.4 2000 99.46 99.4
833 99.49 99.4 2500 99.49 99.4
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Liquid-Filled Efficiency Levels
Single Phase Single Phase Single Phase Three Phase Three Phase Three Phase
KVA Efficiency TSL KVA Efficiency TSL
15 98.36 TSL2
10 98.62 ltTSL5 30 98.62 TSL2
15 98.76 ltTSL5 45 98.76 TSL2
25 98.91 ltTSL5 75 98.91 TSL2
37.5 99.01 ltTSL5 112.5 99.01 TSL2
50 99.08 ltTSL5 150 99.08 TSL2
75 99.17 ltTSL5 225 99.17 TSL2
100 99.23 ltTSL5 300 99.23 TSL2
167 99.25 TSL4 500 99.25 ltTSL2
250 99.32 ltTSL3 750 99.32 gtTSL3
333 99.36 ltTSL3 1000 99.36 TSL3
500 99.42 ltTSL3 1500 99.42 TSL3
667 99.46 ltTSL3 2000 99.46 TSL3
833 99.49 ltTSL3 2500 99.49 TSL3
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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
Core Type Thickness (Mils) Efficiency Cost
Amorphous 1.0 Most Efficient Most Costly
M2 7.0
M3 9.0
M4 11.0
M5 12.0
M6 14.0 Least Efficient Least Costly
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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
Date Design / Manufacturing Status
Jan 1, 2008 Re-design process begins
Apr 1, 2009 Start building DOE designs (with existing non-DOE)
Jun 30, 2009 Re-design process completed
Sep 1, 2009 New production started is DOE compliant
Sep 30, 2009 All production completed is DOE compliant
Jan 1, 2010 DOE mandated compliance
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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