the need to take transformers beyond epact 2005
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The Need toTake
Transformersbeyond
EPACT 2005
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The Value of Ultra Efficient Transformers
as an Effective Energy Conservation Measure
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Environmental Management
Quality Management
Certified Efficiency Test Lab
Founded 1996
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High Efficiency/Performance Transformers & PDU’s
Measurement & Verification
Integrated Power Distribution (PDUs)
Sustainability Management Platform
Our Technology Platforms
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FACTS: Transformer vs. Life Cycle Cost
• Few Products, if any, will remain functional longer than transformers, 35 - 40+ years
• Lighting Comparison 2 - 3 Upgrades• HVAC Comparison 1 - 2 Upgrades• Plug Loads – Numerous Upgrades
While originally installed transformers remain functional
TransformerChallenge
Installed then
forgotten
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Dry-type transformer efficiency– A race to the bottom
Utility Life Cyclepurchaseshave driven up utility transformer efficiency
Commercial First Costpurchaseshave driven down efficiency of low voltage transformers
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Context• Estimated 40 million Transformers in U.S.A.
Why are Low Voltage Dry-type Transformers so Important
• Significant Energy losses – last 32+ years• Generic New Construction spec focused on
low first cost = minimum efficiency• Retrofit
– 40 Million across country (Est. 10% California)– 50% are nearing end of life– If not replaced with higher efficiency driven by
energy savings, will be replaced with low first cost product with minimum efficiency - losses will be embedded for another 32+ years
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Impact on Losses and the EnvironmentBased on Dept. Of Energy Study
• Approx. 40 million dry-type transformers
– 60-80 Billion kWh losses– 9 days generating capacity– Annual Cost $3-4 Billion/year
• Environmental Impact– Requires burning 145 Million tons of coal– Resulting in CO2 & Pollution:
• 45 million tons of CO2 emissions• Acid Rain, Smog• 387,000 tons Sox, 166,000 tons NOx emissions
Losses and Pollution embedded for 32 + years
Initial ResponseEnergy Star Transformers
• Started in 1998
• Voluntary Program
• Adopted NEMA TP-1 Transformer Efficiency as Standard
• Efficiency Target @ 35% load levelDrawbacks
– Not UL Listed to feed Electronic Equipment– Exemption for K-rated and HMT
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EPACT 2005Effective Date: JAN 1, 2007
• Sets Minimum legal allowable efficiency• References NEMA TP-1 Transformer Efficiency
Levels• Much Broader dry-type transformer definition
– – no exception for K-rated, low temp rise • Replaces Energy Star for transformers
-- Gen Purpose EPACT not UL listed to feed electronicsGen Purpose EPACT not UL listed to feed electronics-- Meeting EPACT does not contribute to LEED creditMeeting EPACT does not contribute to LEED credit
NEMA TP-1
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DOE analysis highlights benefits of moving from low
first cost to Low Life Cycle Cost
• EPACT 2005/NEMA TP1 is minimum efficiency –to rid market of worst offenders
• Significant losses remain
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Moving to Life Cycle Assessment
DOE Proposed Efficiency Classes (example: 75kVA 480/208-120V dry type)
98.00%
98.20%
98.40%
98.60%
98.80%
99.00%
99.20%
Class 1 Class 2 Class 3 Class 4 Class 5
15% less losses
30% less
losses
45% less
losses
54.5% less
losses
EPACT/TP1min. legal
DOE Analysis Low lifecycle is CLASS 3DOE Analysis Low lifecycle is CLASS 3
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Proven Savings => 3rd party Adoption
“High Efficiency Transformers have the greatest opportunity to save money on electrical distribution of anything that we
as engineers specify”.
Doug Garrison, P.E.Senior Principal, Shah Smith & Associates
Houston, TX
MD Anderson Cancer Research Center, University of Texas projects
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• 2008
• Specification of Energy-Efficient Transformers. Energy-efficient transformers
• Should be specified using DOE’s CSL-3 Standard as the basis.
• Specifications must include maximum no-load losses for specified transformers sizes and percent efficiency at 16.7% loading.
• A statement should be included in the specification that requires the Bid submission to include test data for the transformers being provided.
ASBO INTERNATIONAL ANNUAL EVENT IN THE MILE HIGH CITYReaching New Summits
How Much Energy is Wasted Behind Closed Doors
Fall 2008
Benefits from requiring installation of energy efficient C-3 Transformers?
• Reduced electricity usage in schools - continuous – no action required by personnel either in behavior or maintenance;
• Reduced energy costs (no control on unit costs); More funding available for educational programs and positions;
• Funding available for facility needs.
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GRID NEUTRAL: Electrical Independence for California Schools and Community Colleges
California Division of State Architect: DGS, February 2009
Electrical Transformers• Transformers operate 24 hrs a day/7 days a week for the life of a building. Even
at night when buildings are not in use, transformers have electrical losses (called no-load losses).
• CSL-3 Transformers reduce the no-load electrical losses by 50 percent or more compared to the regularly installed TP-1 transformer.
• Replacing existing transformers with CSL-3 transformers can realize more energy savings.
• CSL-3 Transformers can significantly reduce the number of PV arrays required to achieve grid neutrality
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PDU’s that include transformers that meet or exceed Department of Energy Candidate Standard 3 Efficiency (CSL-3) have 60 to 70 percent lower
operating losses than other PDU’s measured.
Laurie Minas Senior Strategic Server PlannerIntel Corporation
“Energy Efficiency for Information Technology”
Because distribution systems are generally the third largest component of house load, they are a key factor in determining
Power Utilization Effectiveness (PUE) of a data center.
Laurie Minas Senior Strategic Server PlannerIntel Corporation “Energy Efficiency for Information Technology”
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Improving transformer efficiency among your Data Center PDU’s by just a few percent adds up to significant cost
and energy savings over time.
PDU models with even greater electrical efficiency than mandatedby US and Canadian law are available on the marketplace
and are certainly worth employing”
Douglas AlderIT Architect for Physical InfrastructureCisco Systems
Measurements are the only way to know
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Losses for 75 kVA Transformers ($0.10/kWh)
Transformer Losses (Watts)
584.2531.0531.3
149.4 146.0
674.3
392.1
559.6
916.5
1063.6
784.6
1040.0
1133.7
962.8
652.3
136.0
143.2
964.9
980.5949.7
809.7
592.3
0.0
100.0
200.0
300.0
400.0
500.0
600.0
700.0
800.0
900.0
1000.0
1100.0
1200.0
0% 5% 10% 15% 20% 25% 30% 35%
% Loading
Loss
es (W
atts
)
Powersmiths eSaver-C3L DOE Class CSL 3
Transformers
NEMA TP-1 EPACT 2005 performance
Standard Transformers
(pre-EPACT 2005)
$ 1,142/yr
$ 619/yr
$ 170/yr
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First Cost transformer purchase doesn'tmake sense – energy & carbon footprint
4%
96%
First Cost
Life Cycle OperatingCost
Why does it happen ?: Why does it happen ?: –– Low Bid encourages substitution with cheaper less efficientLow Bid encourages substitution with cheaper less efficient–– Lack of knowledge Lack of knowledge –– designer, userdesigner, user–– Buyer is not one who pays for energy bill, Buyer is not one who pays for energy bill,
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Transformer Construction
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Origin of Transformer Losses
COIL LOSSESCOIL LOSSESVary with loadVary with load
CORE LOSSESCORE LOSSES24hrs/day 24hrs/day
Operating cost:Operating cost:1kW ~ $1,000/yr @$0.10/kWh 1kW ~ $1,000/yr @$0.10/kWh
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So What’s Out There??Transformer Lifecycle 32 yr. per US DOE
Average age of California buildings?
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Cadmus Study documents lightly loaded transformers in many appliCadmus Study documents lightly loaded transformers in many applicationscations
Metered Load Factors for LowMetered Load Factors for Low--Voltage, DryVoltage, Dry--Type Transformers in Commercial, Type Transformers in Commercial, Industrial and Public BuildingsIndustrial and Public BuildingsThe Cadmus Group Inc. 12/7/99, Prepared for Northeast Energy EfThe Cadmus Group Inc. 12/7/99, Prepared for Northeast Energy Efficiency Partnershipficiency Partnership
Figure ES-4 RMS Average Transformer Loads by Building Type
0%5%
10%15%20%25%30%
Offfice
Manufa
cturin
gReta
il
Schoo
ls
Health
careR
MS
Ave
rage
Loa
d Fa
ctor
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Cyberhawk Field Verification of Losses and Efficiency Power Meter
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Transformers are typically much less loaded than 35% reference point
Loading (46 transformers)
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
% L
oadi
ng
35% Load35% LoadEPACTEPACTTP1, NEMA TP1, NEMA PremiumPremiumEfficiencyEfficiencyreference reference pointpoint
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Savings are only there if transformer performance is optimized for load
EPACT & TP1 have same single 35% performance pointEPACT & TP1 have same single 35% performance point
45kVA Efficiency Comparisons vs. Field Data & TP-1
95%
96%
97%
98%
99%
0
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
% loading
% E
ffici
ency
0
10
20
30
40
50
60
# tran
sfor
mer
s
Field Load Data
TP1
Powersmiths ESAVER-C3
TP-1, 35%
XXTP1
C3L
C3H
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Things to remember about transformers part 3 - electronics are everywhere
Electrical systems deliver optimum performance when feeding continuous “linear” loads:• motors• incandescent lighting• resistive heating
Electronics are everywhere- computers, lab, diagnostic & operating
equipment, & patient care
Variable Speed Drives run Ventilation System
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Engineering Liability: General purpose transformers are not UL Listed to feed today’s loads
• Current THD as measured vs. C57.12.01 limit
Load Current Distortion (46 transformers)
0.0
10.0
20.0
30.0
40.0
50.0
60.0
70.0
80.0
90.0
100.0
% It
hd ITHD
5% limit C57.12.01 for general purpose transformer
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Double
Neutral
The Anatomy of a Powersmiths Transformer
Core - Higher grade steel, Mitered and Wound
• 2 - 3 x less losses
Advanced Insulation System:NOMEX / Low VOC Epoxy co-
polymer
LONG LIFE & LOW IMPACT & VERIFIED EFFICIENCY
Coils: Lower current densities
Match footprint & terminal layout:
• Lowest installation cost
ISO 14001 Environment, ISO 9001 Quality,ISO 17025 CSA Certified Efficiency Test LabAll independently Audited - annually
ESSENTIAL: UL 1561,
K-Rated for electronic loading
Easy Skid – simple to move into place
75kVA Case Study – Loss reduction - typical
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75% Reduction in Operating cost
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75kVA Case Study – Physical Room Temperature reduction 1050 to 750 = associated loss reduction
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Adobe Case Study - Before 300-kVA: 70% loading 7kW losses
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Cooing Unit
Exhaust & Fans
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Adobe Case Study - After300kVA, 70% load, 1.5kW losses
79% Reductionin direct losses
PLUSAssociatedCooling SavingsNO MORE FANS!NO MORE MOVE-N-COOL!
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Powersmiths provides Right-Sizing Choices
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• Code calculations already force oversized infrastructure
• Big gaps in standard kVA choices more over-sizing (code says “use next size up”)
• Moves loading up towards peak efficiency• Right-sizing AVOIDS:
– More expensive transformer– Larger primary breaker ($$)– Large cables and conduit (primary and
secondary) ($$)– Likely larger capacity secondary
Switchgear or panel-board ($$$$)– More expensive breakers in larger
gear/panel-boards ($$$)– Larger footprint of infrastructure
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Match Footprint & Wiring as Required
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Ensure transformers are recycled
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Integrated Options
Metering
Hinged DoorsRotatable IR Port Input and/or Output Breakers
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Compare Products- Savings- Payback
- Life Cycle Cost - Environmental
impact
The ESP Calculator TM
Toll Free : 1-800-747-9627 or (905) 791-1493 Energy Savings Payback CalculatorBlack box indicates data entry fieldProject Description New ProjectDate 13-Sep-02Data Entry% Load during normal operating hours 35% QTY kVA% Load outside operating hours 20% Full Load kW 15equipment operating hrs/ day 10 1283 15 30equipment operating days/yr 260 15 45kWh rate 0.080$ Load kW 4 75demand rate ($/kW/mo) ex. $10.00 $10.00 449 112.5Load Power Factor 0.90 257 150% additional cooling losses 0% 225
Nonlin Loss Mult 300Other Transformer Linear Efficiency & Loss Multiplier* 95.0% 2.0 500Powersmiths Nonlinear Efficiency 98.0% 1425 Other kVA
Energy Cost Analysis (calc) Annual kW Losses inOperating Cost Normal operation
Traditional Transformers * $30,404 49.9Powersmiths Transformers $5,584 9.2ANNUAL Energy Savings with Powersmiths $24,819 40.7
16359 14,044.80 Estimated Annual Power Quality Savings $0 3004.714286 2579.657143
0 0 00 0 0
2732 2140 1768
Life Cycle Savings and Payback First Cost Operating Total OwnershipTraditional Transformers $52,000 $760,095 $812,095Powersmiths Transformers $80,000 $139,609 $219,609Total Life Cycle Savings -$28,000 $620,486 $592,486Payback on Incremental Cost 1.13 years
Leasing Option 60 Month Term 48 Month Term 36 Month TermTotal Annual Leasing Payments $21,216 $25,680 $32,784Net Annual Cost with savings ($3,603) $861 $7,965
Summary of Environmental BenefitsAnnual Reduction in Greenhouse Gases 184 tons of CO2 1,442 kgs of SO2(Per EPA) 596 tons of Coal 621 kgs of NOxEquivalence 34 Acres trees planted 25 homes heated
25 Car Emissions
IMPORTANT: By using the ESP Calculator™, you are agreeing the TERMS OF USE section on page 2
Powersmiths International Corp. is a licensed user. Content subject to change without noticePage 1 of 2 © Power Quality Institute 1998-2002, All rights reserved
23.3
Transformers on Project
kW Losses outside
V02.10.30
5.2
operating hours28.5
Life Cycle Cost
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Transformer Market
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NEW CONSTRUCTION
Driven by First CostMinimum Legal Efficiency (EPACT2005)
Higher EfficiencyOptionNeeds to justifyIncremental Cost
RETROFITDriven by Payback on Energy Savings
Savings need to offsetEntire Transformer Cost& Installation
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$586k labor & materialsROI: 3.84 years (before rebate)
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Ultra Efficient Transformer Benefits
• kWh & Demand Savings• Embedded for 32+ years• Passive – no controls or user behavior change• No efficiency degradation over installed life• Key piece of electrical infrastructure – feeds all plug
power• Compatibility with electronic equipment load profile • Impact beyond Energy Savings (CO2, kWh, net zero..)
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5858
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Questions...
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