The Need to Take Transformers beyond EPACT 2005

POWERSMITHS CORP.

GET ON THE GREEN TEAM

The Need toTake

Transformersbeyond

EPACT 2005

POWERSMITHS CORP.


The Value of Ultra Efficient Transformers

as an Effective Energy Conservation Measure

POWERSMITHS CORP.


Environmental Management

Quality Management

Certified Efficiency Test Lab

Founded 1996

66

High Efficiency/Performance Transformers & PDU’s

Measurement & Verification

Integrated Power Distribution (PDUs)

Sustainability Management Platform

Our Technology Platforms

POWERSMITHS CORP.


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

8

POWERSMITHS CORP.


10

POWERSMITHS CORP.


11

12

POWERSMITHS CORP.


13

14

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

POWERSMITHS CORP.


15 6

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

16

POWERSMITHS CORP.


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

POWERSMITHS CORP.


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

POWERSMITHS CORP.


21

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

22

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

POWERSMITHS CORP.


23

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

POWERSMITHS CORP.


• 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.

POWERSMITHS CORP.


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

POWERSMITHS CORP.


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”

POWERSMITHS CORP.


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

32

POWERSMITHS CORP.


33

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

34

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,

POWERSMITHS CORP.


35

Transformer Construction

36

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

POWERSMITHS CORP.


So What’s Out There??Transformer Lifecycle 32 yr. per US DOE

Average age of California buildings?

38

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

POWERSMITHS CORP.


39

Cyberhawk Field Verification of Losses and Efficiency Power Meter

40

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

POWERSMITHS CORP.


41

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

42

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

POWERSMITHS CORP.


43

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

44

POWERSMITHS CORP.


45

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

46

75% Reduction in Operating cost

POWERSMITHS CORP.


75kVA Case Study – Physical Room Temperature reduction 1050 to 750 = associated loss reduction

47

Adobe Case Study - Before 300-kVA: 70% loading 7kW losses

48

Cooing Unit

Exhaust & Fans

POWERSMITHS CORP.


Adobe Case Study - After300kVA, 70% load, 1.5kW losses

79% Reductionin direct losses

PLUSAssociatedCooling SavingsNO MORE FANS!NO MORE MOVE-N-COOL!

49

Powersmiths provides Right-Sizing Choices

50

• 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

POWERSMITHS CORP.


51

Match Footprint & Wiring as Required

52

Ensure transformers are recycled

POWERSMITHS CORP.


53

Integrated Options

Metering

Hinged DoorsRotatable IR Port Input and/or Output Breakers

54

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

POWERSMITHS CORP.


Transformer Market

55

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

56

$586k labor & materialsROI: 3.84 years (before rebate)

56

POWERSMITHS CORP.


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..)

57

5858

POWERSMITHS CORP.


59

Questions...

59

The Need to Take Transformers beyond EPACT 2005

Documents

Transcript of The Need to Take Transformers beyond EPACT 2005