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Locations
Hammond Power Solutions is North America’s largest and
broadest manufacturer of dry-type transformers:
DOE 2016 Efficiency Levels
The DOE will raise the efficiency requirements of transformers
on January 1st, 2016.
• The major impact will be 3-Phase 600 volt class dry-type
– Losses will be reduced about 30%.
• Single phase 600 volt class will remain at TP1 levels.
• Medium voltage 3-Phase will increase by 2% to 24%.
DOE 2016 Efficiency Levels
Market Impacts:
• Estimated price increases are still difficult to
determine as designs and productions lines are
updated and material prices adjusted.
– Prices will be reduced from similar NEMA
Premium units which are currently 80%-110%
higher than TP1.
• Manufacturers must revise manufacturing,
designs and invest significant capital.
Efficiency Timeline
1992: DOE starts studies for efficiency.
1996: DOE publishes
Distribution Transformer -
efficiency standard for voluntary use.
2002: NEMA developed NEMA TP-1-2002: At this
point, NEMA’s work was only a guideline.
2005: The Energy Policy Act of 2005
(EPACT 2005) specified that all
low-voltage dry-type transformers
manufactured on or after Jan. 1, 2007 must be Class I
Efficiency Level as defined by NEMA in
TP-1-2002 a law.
2006: The EPA suspended the
Energy Star program for distribution
transformers because the
mandated TP1 models met the current criteria.
2007: DOE established TP1
values for most dry type, 600 volt class
distribution transformers
through 1000 kVA in its 10 CFR 431 Subpart K on Jan. 1, 2007. Canada
has similar C802.2 requirements.
Efficiency Timeline
2009: Environmental
groups filed lawsuit that EPACT
required the DOE to implement more efficient designs than TP1. The
Court required the DOE assess TP1 and increased if
needed.
2010: DOE established
efficiency for most oil and dry
transformers through 2500 kVA in its 10 CFR 431 Subpart K on Jan. 1, 2007. Canada
has similar SOR/94-651 requirements.
2011: NEMA announced the
Premium Efficiency mark on
transformers which were 30% more
efficient than NEMA TP-1
2011: The DOE proposed
rulemaking to review and amend
the current standards in effect
for distribution transformers.
2012: The DOE must provide a final rule by Dec. 1, 2012
on the 600 volt class efficiencies.
2016: U.S. DOE efficiency for 3-
phase 600V class increase by about 30% over current TP1. Smaller but
significant increases for
medium voltage dry and oil M.V. units
DOE 2016 Efficiencies
DOE Efficiencies for all Low-Voltage Dry-Type Distribution
Transformer Equipment Classes
Regulations.gov - Rule Document Page 10 of 191
http://www.regulations.gov/ 7/8/2013
Equip. Class 3 Equip. Class 4
Single Phase (No Change) Three Phase (28-34% less losses)
kVA TP1 Eff.
DOE 2016
Eff. kVA TP1 Eff.
DOE 2016
Eff.
15 97.7 97.7 15 97.0 97.89
25 98.0 98.0 30 97.5 98.23
37.5 98.2 98.2 45 97.7 98.4
50 98.3 98.3 75 98.0 98.6
75 98.5 98.5 112.5 98.2 98.74
100 98.6 98.6 150 98.3 98.83
167 98.7 98.7 225 98.5 98.94
250 98.8 98.8 300 98.6 99.02
333 98.9 98.9 500 98.7 99.14
750 98.8 99.23
1,000 98.9 99.28
DOE 2016 Efficiencies
30% 29%
30% 30% 30%
31%
29% 30%
34%
36%
35%
15 30 45 75 112.5 150 225 300 500 750 1,000
Change in Efficiency Change in Efficiency
kVA
While the changes look small, it’s like improving a car’s mileage by about 30%.
Low Voltage NEMA Premium
vs. DOE 2016
Cost/KW: $.12 35% load average per year
KVA TP1 Efficiency DOE 2016 Efficiency
TP1 Cost of Operation
DOE 2016 Cost of Operation
TP1- DOE 2016 Savings
15 97.00 97.89 $166 $116 $50
30 97.50 98.23 $276 $195 $81
45 97.70 98.40 $381 $265 $116
75 98.00 98.60 $552 $386 $166
112.5 98.20 98.74 $745 $522 $223
150 98.30 98.83 $938 $646 $292
225 98.50 98.94 $1,242 $877 $365
300 98.60 99.02 $1,545 $1,082 $463
500 98.70 99.14 $2,391 $1,582 $809
Medium Voltage Regulations
Medium-Voltage Dry-Type Distribution Transformers will also increase in efficiency by about 10-15%
Efficiency for Medium Voltage transformers are assigned by BIL and kVA, not by voltage.
Dry-Type, Medium Voltage, Single-Phase Dry-Type, Medium Voltage, Three-Phase
kVA
EC 5
Low BIL
EC 7
Med BIL
EC 9
High BIL
kVA
EC 6
Low BIL
EC 8
Med BIL
EC 10
High BIL
20-45kV 46-95kV >96kV 20-45kV 46-95kV >96kV
15 - 15 -
25 - 30 -
37.5 - 45 -
50 - 75 -
75 112.5 -
100 Virtual RU Virtual RU 150 -
167 225
250 300 Rep Unit Rep Unit
333 500
500 Virtual RU Virtual RU 750
667 Virtual RU 1000
833 1500 Rep Unit Rep Unit
2000 Rep Unit
2500
DL9 / 3
DL11 / 3
DL10 / 3
DL12 / 3
DL13 / 3
DL 9
D
L 1
0
DL 1
1
DL 1
2 D
L 1
3
Medium Voltage Regulations
20-45 kV BIL 46-95 kV BIL 96-150 kV BIL
kVA
DOE 2010
DOE 2016
Yearly Savings
DOE 2010
DOE 2016
Yearly Savings
DOE 2010
DOE 2016
Yearly Savings
15 97.50 97.50 $0 97.18 97.18 $0 - - -
30 97.90 97.90 $0 97.63 97.63 $0 - - -
45 98.10 98.10 $0 97.86 97.86 $0 - - -
75 98.33 98.33 $0 98.12 98.13 $0 - - -
112.5 98.49 98.52 $18 98.30 98.36 $6 - - -
150 98.60 98.65 $39 98.42 98.51 $19 - - -
225 98.73 98.82 $106 98.57 98.69 $67 98.53 98.57 $14
300 98.82 98.93 $173 98.67 98.81 $128 98.63 98.69 $40
500 98.96 99.09 $342 98.83 98.99 $287 98.80 98.89 $136
750 99.07 99.21 $552 98.95 99.12 $493 98.91 99.02 $285
1000 99.14 99.26 $631 99.03 99.20 $564 98.99 99.11 $355
1500 99.22 99.37 $1,183 99.12 99.30 $1,119 99.09 99.21 $706
2000 99.27 99.43 $1,682 99.18 99.36 $1,591 99.15 99.28 $1,087
2500 99.31 99.47 $2,102 99.23 99.41 $1,989 99.20 99.33 $1,359
DOE 10 CFR Part 431 Exceptions
• Drive Isolation Transformers (must meet C802.2 in Canada)
• Auto-Transformers
• Rectifier Transformers
• Sealed Transformers (Potted, type 4, 4X and 12)
• Tap range greater than 20%.
• Ferro-Resonant
• Impedance less than 1% or greater than 8%
• UPS transformers
• Welding Transformers
• Marine applications not connected to the Power Grid.
• Transformers exported outside of the U.S. or Canada.
• Installed as a component on machinery.
• Testing Transformer
• Not connected to the U.S. or Canadian power grid.
Common DOE 10
CFR Part 431
exceptions include:
DOE 2016 Questions
• What are the most common efficiency
exemptions?
– Non-Ventilated transformers including potted.
• Potted 15 kVA three phase transformers may be less than
ventilated DOE 2016 units although they won’t offer the same
efficiencies.
– Transformers being power solely from generator power, not from the
national power grid such as mobile equipment and plants.
– Drive isolation and rectifier applications.
Types of Losses
Load is important to determine efficiency and calculating losses. 600
Volt Class units are tested using a resistive 35% load with a sinusoidal
input at unity power factor. Medium voltage is tested at a 50% load.
No-load Losses (Core): Occur in
the core, are mainly caused by hysteresis
and eddy currents and are independent of
the load.
Load losses (Coil & I2R):
Occur in the coils from wire resist
vary by the load.
Transformer Core Losses
Efficiency standards are measured at
35% load for 600 volt class and 50% load
for medium voltage transformers, the
majority of the losses are in the core.
Core losses are more economical to
reduce than resistance losses in the
coils.
No-Load Loss and Load Loss tables
don’t exist within US or Canadian
standards to show compliance with a
particular CSL/TSL level; only minimum
efficiency level matters.
Transformer Core Losses
Like a wire conducting electricity, the core
conducts magnetic flux. Transformer cores are
constructed from low carbon silicon steels.
A steel laminated core carries magnetic flux
1500 times better than air.
When a magnetic flux flows in a transformer’s
steel core, two major types of losses occur in
the steel core.
• Eddy current losses
• Hysteresis losses
Transformer Core Losses
The efficiency of the magnetic core is affected
by:
• The shape and geometry
• The air gap in the magnetic circuit.
• The properties of the core material
(especially permeability and hysteresis).
• The operating temperature of the core.
• Whether the core is laminated and how thin
the laminations are to reduce eddy currents.
Hysteresis Losses
• Caused by the magnetization and demagnetization of the core from
sinusoidal voltage. Each time the magnetic field is reversed, a small amount of
energy is lost to hysteresis in the magnetic core.
– The smaller the core volume, the less losses.
– Hysteresis losses vary by unit volume of the core.
• Transformers are designed to operate at a particular supply frequency.
Lowering the frequency will result in increased hysteresis losses.
– 50 Hz Transformers are exempt from DOE regulations but cost more because of
larger cores.
– Hysteresis losses vary by the Volts/Frequency.
Eddy Current Losses
• Eddy Current Losses are caused by the flow of circulating currents
induced into the steel caused by the flow of the magnetic flux around the
core.
– The flux induces currents into the laminations.
– The core laminations are acting like a single loop of wire.
– Since the iron core is a good conductor, the eddy currents induced by a solid
iron core will be large.
• The thinner the lamination, the lower the eddy currents and the lower the
losses.
Core Design Techniques
High efficiency designs using better core designs require: • Extensive engineering knowledge and new manufacturing techniques.
• Expensive and sophisticated core cutting machines.
• Better grades of steel = Thinner and/or Grain Oriented.
• Modern and more complex core designs
Mitered Gapped Step Lap
Interleaved Wound Torroidal
Core Design Techniques
Thinner insulated
laminations reduce eddy
current losses.
The effect of laminations is to
confine eddy currents to highly elliptical paths that enclose little flux, and so reduce their
magnitude)
Core Design Techniques
Welding can disrupt the electro-magnetic properties of steel so cores are clamped with bolts, bands
and plates.
Cold rolled grain oriented steel arranges the
orientation of grain in ferromagnetic steel in the
direction of rolling to reduce iron losses.
Core Design Techniques
Larges losses occur in the transformer corners and center span.
• Flux flows along the direction of the grain orientation
• Interleaved laminations reduce flux leakage and iron losses.
• Mitered Corners reduce losses
Core Design Photos
Corners are mitered at
45 degrees.
Step-Lap laminations reduce in size to
simulate a round core
Core Design Photos
The following is an example of a fully mitered,
interleaved step-lapped core design using
grain oriented steel. This type of construction
is typical for large power transformers and
premium efficiency units.
Core Design Photos
• Wound, Mitered and Gapped cores provide efficiency gains.
Wound Core Designs Gapped Core
Design
Core Design Techniques
Mitered laminations are cut at 45o in the corners.
• Flux gets a smoother path in the direction of its flow; hence
• Wound cores provide similar benefits as mitered cores.
Core Design Concerns
Changing core design, materials, shape and their relation to the coil can affect other design parameters:
•Impedance
•Inrush upon energization
Knowledgeable engineering and
manufacturing will maintain parameters
such as NEMA ST-20.
Similar NEMA Premium units have
been utilized for several years without
issues.
DOE 2016 Questions
• Can I install current TP1 transformers after
January 1st, 2016?
– As long as manufactured to the current U.S.
DOE specifications
– Manufactured by December 31st, 2015.
– In the U.S. by December 31st, 2015.
It is “Grand Fathered” and can be installed after
January 1st, 2016.
DOE 2016 Questions
• Will weights and dimensions change with the
DOE 2016 designs?
– The units will weigh more, typically +10-20%.
– The units will be larger, typically 10-15% more
physical volume. How this affects the individual
dimensions of height, width and depth will vary
from manufacturer to manufacturer.
DOE 2016 Questions
• Should transformer efficiency be checked after
the transformer is installed?
– There is little or no benefit to measure efficiency in the field other
than to add cost to a project.
– Efficiency is measured per DOE at 35% load for 600V class and 50%
load for medium voltage using a sinusoidal load at unity power
factor.
– Efficiency levels in the field will be difficult to accurately compare to
the DOE levels.
DOE 2016 Questions
• Will impedance change? – Probably. On average it will go down slightly for 600 volt class units
due to the new construction techniques. The levels will still be in the
typical NEMA and ANSI ranges. There will be little change in
medium voltage units.
• Will Inrush change?
– Energization inrush will increase slightly for 600 volt class u nits due
to the new construction techniques. Properly applied, the levels will
still be within the range of typical circuit breakers and time delay
fuses. There will be little change in medium voltage units.
DOE 2016 Questions
Will current TP1 efficiency units be
available into Q4/2015 and Q1/2016?
• The supply will be hard to predict.
Many manufacturers will stop
production of these units well before
January 1st.
– Supply channel may be hesitant to stock
the current TP1 units if specifications are
largely updated to support the new
regulations.
– Manufacturers will establish cut-offs for
stock replenishment and custom orders
2-5 months before January 1st.
DOE 2016 Questions
When should specifications be updated?
• Caution for 600V class transformers on site
up to 1000 kVA after Nov. 1st, 2015
– Typical lead times* after release is 4-6 weeks.
• Caution for medium voltage oil or dry type
transformers up to 2500 kVA on site after
Nov. 1st, 2015.
– Typical lead times* after release is 6-20 weeks.
*Typical Lead Times may increase in Q4/2015 as a larger than
average number of projects are released to get units manufactured
before January 1st, 2016.
DOE 2016 Questions
What effect will the new efficiency levels have on
transformer cost?
• Demand for higher core steel grades may increase cost.
• Estimated price increases are still difficult to determine as
designs and productions lines are updated and material
prices adjust.
DOE 2016 Questions
How can I update my specification?
Remove efficiency references to TP1, TP2, TP3, NEMA Premium or CSL.
• TP1, TP2 and TP3 will be discontinued by NEMA
Replace these efficiency
requirements with:
Efficiency levels must meet the
new DOE 10 CFR Part 429 and 431
levels as of January 1st, 2016.
Additional Specification
Considerations
• IEEE 519 increasing from 5% to 8% Total Harmonic Distortion measured at the utility service entrance.
• This will increase the overall system THD.
• Local circuit’s THD may be significantly higher than 8%.
• More THD means more transformer heating.
Specify K-Rated
transformers (K=4 or 13).
Additional Specification
Considerations
• 2014 NEC Code Updates
• Inrush Concerns
• Voltage Regulation Concerns
Do not allow back feeding
or reverse feeding.
• 2014 NEC Code Updates
• Specify factory installed ground lugs.
Wires and grounding lugs cannot block
ventilation openings.
DOE 2016 Questions
Where can I go for more information on the DOE 2016
Regulations?
HPS has established information at:
www.hammondpowersolutions.com/our-products/doe-2016
This will be updated periodically throughout the year as
information becomes available.
Contact Information
Contact your HPS Regional Sales Manager or local
representative which can be found at:
Http://www.hammondpowersolutions.com/rep-locator/
Presenter’s Contact Information
Mike Van Gheem [email protected]
Important Dates
The following page highlights some key dates related to the
DOE 2016 Transition that we want you to use when planning
our joint business in the coming months.
We appreciate your support during this time of exciting
industry change!
Important Dates
• September 2015 Release of selected DOE 2016 product information
• September 30th, 2015 Final date to request a Stock Rotation/Return of TP1 Product (per HPS Policy)
• September 30th, 2015 Final date to release approval orders for TP1 MV (power) products that are engineered-to-order
• October 5th, 2015 DOE 2016 Product Launch
• October 14th, 2015 Final date for HPS to receive a previously approved Stock Rotation of TP1 Product (standard items only, and must be returned to a U.S. warehouse)
• October 16th, 2015 Final date to release approval orders for TP1 LV products that are engineered-to-order
• October 16th, 2015 Final date to cancel an order for any TP1 products (U.S. customers only)
• November 1st, 2015 All orders for TP1 products after are for immediate shipment only (no releases)
• November 2015 Initial shipment of DOE 2016 standard products
• December 11th, 2015 Final date to release factory shipment of all TP1 orders
DOE 2016 Efficiency Levels
HPS Impacts:
• Rather than using existing NEMA Premium style designs,
HPS is investing millions in new equipment, plants and
engineering to provide mutual success with our partners.
• Product lines will undergo a complete redesign:
– Updated enclosures
– Updated and new features and options
– Necessary supporting information
– Q3/2015 product availability
Strategy and Development
Marketing Excellence
Business and product
innovation
Sales Excellence
DOE 2016 Efficiency Levels
• Hammond Power Solutions Inc. announced that it has
entered into a joint venture with National Material to
manufacture transformer cores for the electrical transformer
industry.
• Under the joint venture agreement, HPS and NMLP will
share financial and technological resources with the intent to
construct and operate a world-class core manufacturing
facility.