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DOE Final Rule Transformer Efficiency

DOE Final Rule Transformer Efficiency. 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

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DOE Final Rule Transformer Efficiency

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  1. DOE Final RuleTransformer Efficiency

  2. 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

  3. 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)

  4. 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

  5. Liquid-Filled Efficiency Levels (DOE vs NEMA)

  6. Liquid-Filled Efficiency Levels

  7. Major Concerns—Raw Materials Most distribution transformers sold today do not meet DOE mandate. Additional demand on scarce resources…will 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)

  8. Cost/Efficiency Relationship Cost 100% Transformer Efficiency

  9. Major Concerns—Core Steel

  10. Core Grade Distribution, Non-DOE Designs M4 M3 M5 Production Volume M2 M6 Core Steel Grades

  11. Major Concerns—Core 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

  12. Major Concerns—Core 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.)

  13. 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

  14. 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?

  15. 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

  16. 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

  17. Implementation Schedule

  18. DOE Contact • Antonio Bousa: Project Manager for Distribution Transformer Energy Conservation Standards, (202) 586-4563 • DOE Web: http://www.eere.energy.gov/buildings/appliance_standards/commercial/distribution_transformers.html • Howard Web: www.howard.com

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