Electrical Distribution

System

Confederation of Indian Industry

CII – Godrej Green Business Centre, Hyderabad, India
Transformers

• Second Largest loss making electrical equipment

• 35 billions kWh of energy is lost as loss per year
• 6% of Total generation is lost in transformers
• Life of transformer

© Confederation of Indian Industry

 Transformer

 Transformer
 Heart of Electrical
Distribution

 Category
 Power Transformers
 Distribution Transformers
© Confederation of Indian Industry
 Types Of Transformers

❖ Transformer - Heart of Electrical Distribution

Distribution Transformer Power Transformer

• Normal Efficiency- 98% to 99% • Normal Efficiency- 99% to
• Iron loss is 10% to 15% of full 99.5%
load copper loss • Iron losses is 20% to 25% of
• Fe loss take place throughout full load copper losses
the day and Cu loss depends • Cu and Fe loss take place
on load cycle through out the day
• Optimum efficiency occurs • Optimum efficiency occurs
between 40% to 60% of between 60% to 80% of
loading loading
© Confederation of Indian Industry
 Losses in Transformer
KVA Rating Iron Loss FL copper
Transformer Losses (Watt) Loss (W)

500 1030 6860

Core Loss Copper Loss Dielectric Auxillary
Loss Loss
750 1420 9500
Hysterisis
Loss 1000 1770 11820

Eddy Efficient Transformer only 1 % 1250 1820 12000

Current Loss Loss
2000 3000 20000

© Confederation of Indian Industry

 Transformer Efficiency

❖Optimum efficiency

occurs at Iron losses

Copper losses

 50% load
 75% load
 100% load

© Confederation of Indian Industry

Oil Cooled or Dry Cooled ??????

Oil Cooled Dry Type

❖ Cooling media liquid ❖ Cooling media - Air

❖ Conventional Mineral Oil ❖ Chances of formation of
❖ More Efficient and longer life hotspots in coils
expectancy ❖ Less efficient
❖ Better overload capacity ❖ Normally used for lower
❖ Drawback of fire prevention rating

© Confederation of Indian Industry

 OIL TYPE vs DRY TYPE

kVA Rating Oil Transformer Dry Type

kVA Half Load(W) Full Load(W) Hal Load(W) Full Load(W)
500 2465 4930 5000 10000
750 3950 7900 7500 15000
1000 4360 8720 8200 16400
1500 6940 13880 11250 22500
2000 8155 16310 13200 26400

 Dry Type transformers need

 Bulkierthan oil type – Need more core material and winding
 Additional fins for heat transfer

8 © Confederation of Indian Industry

 Case Study 1 – Parallel Operation of Transformer
11 KV

❖ Background
 Capacity of transformer 2000 CB CB

KVA
2000 KVA 2000 KVA
 Load on the transformer is 80% 11 KV / 415 V 11 KV / 415 V
80% Load
 Iron loss = 3 kW

 F L Copper loss = 20 kW CB CB

415 V
© Confederation of Indian Industry
 Case Study 1 – Parallel Operation of Transformer
❖ Loss calculation 11 KV

 One transformer in operation

(3) + 20 x (0.8) 2 = 15.8 kW CB CB

 Both transformers are in operation

2000 KVA 2000 KVA
[(3) + 20 x (0.4) 2]x 2 = 12.4 kW 11 KV / 415 V 11 KV / 415 V
40% Load 40% Load
 Recommend to operate the both
transformers in parallel
CB CB

Annual Savings : Rs.1.10 lakhs

Investment : NIL
© Confederation of Indian Industry 415 V
Case Study II – Isolate one transformer in Main Substation

110 KV
❖ Background
 Two Transformers (12.5MVA)
are operated parallel

 Actual total effective load is 6 12.5 MVA

12.5 MVA 110 KV / 22KV
MVA 110 KV / 22KV

 % load to the individual

transformers is 24%
22 KV 6 MVA LOAD
© Confederation of Indian Industry
 Case Study II – Isolate one transformer in Main Substation

110 KV
❖ Loss calculation
 Both transformers are in operation

[(25) + 72 x (0.24) 2 ] x 2 = 58.2 kW

 One transformer operation 12.5 MVA

12.5 MVA 110 KV / 22KV
(25) + 72 x (0.48) 2 = 41.5 kW 110 KV / 22KV
 Isolated one transformer

Annual Savings : Rs. 5.10 lakhs

Investment : NIL 22 KV 6 MVA LOAD
© Confederation of Indian Industry
Transformer Life

 Life of the transformer is 40 years

 Possible if the temperature of windings is less than 80°C
 Depends up on the insulation of the core

 Also on the velocity of ageing

◼ Tensile strength of insulation decreases with ageing
 For every 10K decrease in winding temperature, copper
losses fall by 3.9%
 Lowering of winding temperature slows down ageing of

a transformer
© Confederation of Indian Industry
 Transformers Cooling
 Insulating oil acts as cooling medium

 Oil flow is through

 Natural flow (no pumps)
 Forced flow (pumps)

 Heat exchangers or radiators transfer

heat from oil to environment
 Fans may be used to increase forced
convection over radiator fins
© Confederation of Indian Industry
Case Study-Radiators Enhancement
 20 MVA Power transformer is operating at 65-70% loading
8 Cooling fans (1.5 kW) are running
 Fans are interlocked with temperature
 Transformer is tripping because of high temperature
 Insufficient cooling

 Redesigned (increased) the size of transformer radiators

 In all 4 directions by conducting a separate study
 Still cooling fans are interlocked with winding temperature to avoid
the problems
© Confederation of Indian Industry
Benefits

 Power reliability is increased

 Cooling fans power will be saved

 Cushion for more capacity

 Temperature of the winding will be reduced

Resistance of the winding will be reduced

◼Load losses will also come down
© Confederation of Indian Industry
 Energy Efficient transformer
 Core of the transformer is  Crystalline structures
made of amorphous material have hard directions
for magnetization
 Can be cut into thinner  Requires grain
laminations(0.001 inch thick) orientation processing
 Electrical resistivity of for best properties
amorphous material is 2-3
times higher than silicon steel
 In Amorphous random
 70-80 % less core losses than Arrangement of atoms
normal transformers under offers High electrical
linear loads resistance for eddy
current.
 More savings under non linear
loads  Easy to magnetize and
Demagnetize
© Confederation of Indian Industry
Transformer Losses & Efficiency
 Recommended to install
in the project stage
 Made up of amorphous

metal core
 Available up to 2000 KVA

in India
 50% reduction in energy
loss over iron core
transformer

© Confederation of Indian Industry

Transformer Losses & Efficiency

No Load Loss (W) Efficiency (%)

Rating (kVA)
Amorphous CRGO Amorphous CRGO
250 180 570 98.7 98.2

500 250 900 99 98.53

630 200 1000 99.1 98.54
730 365 1250 99.2 98.65
1000 450 1500 99.2 98.68

© Confederation of Indian Industry

Transformer efficiency

© Confederation of Indian Industry

Example – Harmonics Losses (250 KVA)

© Confederation of Indian Industry

What is K Factor?
 Weighting of the harmonic load currents according to their effects
on transformer heating
 A K-factor of 1.0 indicates a linear load (no harmonics).
 The higher the K-factor, the greater the harmonic heating effects.

Basic Transformer K
Factor –
4,9,13,20,30,40,50

22 © Confederation of Indian Industry

 TRANSFROMER EE CLASS AS PER BIS

23 © Confederation of Indian Industry

 Power Factor Analogy
Power factor= kW = kW = Beer
KVA kW +KVAr Beer + Foam

© Confederation of Indian Industry

 Power Factor Compensation
Centralized compensation
 Advantages
SS PANEL  Easy P.F maintenance

 Capacitor maintenance
REACTIVE CURRENT easy
PCC FLOW
 Disadvantages
CAPACITOR  More voltage drop in
BANK
distribution
MCC  Over heating of cable
resulting in failure
 Suitable if distance between
MOTOR PCC and MCC is less
© Confederation of Indian Industry
 Power Factor Compensation
Distributed Compensation
 Advantages
 Minimum voltage drop
SS PANEL
 Low distribution losses

 Disadvantages
PCC  Maintenance is difficult
 Applicable where
distribution is remote
MCC

MOTOR MOTOR
© Confederation of Indian Industry
 Power Factor Compensation
Mixed Compensation
 Advantages
SS PANEL  Good P.F control
REACTIVE CURRENT  Easy maintenance
FLOW
PCC  Low distribution losses
CAPACITOR
BANK  Common in Continuous
MCC Process industry

MOTOR © Confederation of Indian Industry

 Capacitor Selection
 Thumb rule KVA of the capacitor– 1/3 rd of HP
Rating of the motor
 Chart Method

 Formula Method
 Capacitor required (kVAr) = kW x Tan ( cos-11 – cos-1 2 )
Cos 1 - Present power factor
- Cos 2 – Desired power factor

© Confederation of Indian Industry

 Power factor – Individual compensation
 Motor end compensation
 Below 15 HP not economical
Above 30 Hp kVAr of capacitor bank – appx 25%
of motor HP
 Capacitor current Ic at rated voltage < 90% of
no-load current of motor
◼capacitor current exceeds the no load magnetizing current of
the motor, excessive voltage surges can occur
© Confederation of Indian Industry
Installation of kVAR compensator at Load End

© Confederation of Indian Industry

 Installation of kVAR compensator at Load End

 Sizing Kit is used to fix the kVAR

requirement of motor
 After Sizing fixed kVAR bank is
installed at load end
 Reactive pushed and pulled locally
at load end
 Reduction
in electrical demand and
improvement in PF, thus reducing line
losses

© Confederation of Indian Industry

 Installation of kVAR compensator at Load End

❖Benefits

 Reduce demand charge the motor draws

 Reduce the line losses
 Reduce the motor heating
 Improve voltage regulation due to reduced voltage drop
 Improved power factor

© Confederation of Indian Industry

 Installation of kVAR compensator at Load End

❖Present Status
 Loading of Compressors studied in detail
 Voltage,
PF and Active and Reactive power delivered are
measured
 It was observed some motors are operating at PF in the
range 0.85
Sl NO Name Rated kW Power PF Loading
1 Compressor 1 132 137.33 0.85 72.8
2 Compressor 2 132 130.84 0.83 69.4

© Confederation of Indian Industry

 Installation of kVAR compensator at Load End

❖Savings
 Power Savings – 5.3 kW

Annual Saving - Rs 1.90 Lakhs

Investment - Rs 3.50 Lakhs
Payback - 22 months

© Confederation of Indian Industry

 WHAT IS STACOM??
 Power electronics device to control reactive power flow through
a circuit
 Increases network power stability
 Improves the PF of system
 Connected in shunt with the network

35 © Confederation of Indian Industry

 STATCOM

36 © Confederation of Indian Industry

 CASE STUDY - STATCOM

37 © Confederation of Indian Industry

 CASE STUDY - STATCOM

38 © Confederation of Indian Industry

 PF Improvement
 Planthas installed HT capacitor banks at 33 kV switchyards and
also LT capacitor banks at most of the load centers
 33 kV Switch Yard – 10 MVaR – Manual
 33 kV SAF Switch Yard – 10.5 MVaR - Manual
 1000 kVAr LT Capacitor Banks at load centers
 Plant is operating continuously in export and import mode
 Mainly due to operation of all induction furnace
 PF is varying from 0.80 to 0.90 momentarily as a result avg PF
maintained at Grid Incomer side is 0.927
 TG N1 to TG N4 are operating at a PF of 0.92 to0.95
 TG 6 operating PF (0.88), TG 7 operating PF (0.89), TG operating PF (0.91)
© Confederation of Indian Industry
 PF Improvement
N1-N4 ~ ~ G7, 8, 9

11 KV bus
4 X 11/132KV

132 KV bus
11KV/433V

4 X 11/33 KV
132/33KV Kiln-1,2,3

33 KV bus

33/11KV
33/85-160V

SAF © Confederation
IFD of Indian Industry Kiln-4
PF Improvement

© Confederation of Indian Industry

 PF Improvement

PF Variation during last one year

0.96
kVAh Billing
0.95

Avg PF maintained – 0.927

0.94
Total No of kVAh units -28588800
0.93 Peak Charges – Rs 6.825/kVAh
0.92
Off Peak Charges – Rs 3.93/kVAh
Normal Charges – Rs 5.25/ kVAh
0.91 Electricity Duty Charges – Rs 0.1 for total units
0.9
Concessional EC – Rs 1.4 for total units

0.89
Apr-16 May-16 Jun-16 Jul-16 Aug-16 Sep Oct-16 Nov-16 Dec-16 Jan-17 Feb-17 Mar-17

© Confederation of Indian Industry

 Harmonics Mitigation and PF Improvement

kVAh before & after PF Improvement

3500000

3000000

2500000

2000000

1500000
6.3 % reduction in
1000000
consumuption from grid
500000

0
Apr-16 May-16 Jun-16 Jul-16 Aug-16 Sep Oct-16 Nov-16 Dec-16 Jan-17 Feb-17 Mar-17

at avg 0.93 PF at 0.99 PF

© Confederation of Indian Industry

PF Improvement and Harmonic Mitigation

• Can maintain Grid Incomer PF close

to unity
PF Compensation • Super APFC can act as master node
for reactive power compensation
• Rs 113 Lakhs recurring saving

© Confederation of Indian Industry

Improve Power Factor Of Generator

 10 MW turbo generator
 Rated PF : 0.8
 Operating PF: 0.9
 Generator delivers active power & reactive power
 Efficiency of TG depends on operating PF
 Higher the PF, higher is the efficiency

© Confederation of Indian Industry

 Improve Power Factor Of Generator
 TG Test data
Efficiency @ P.F 0.8 0.99
100 % Load 98.08 98.56
75% Load 97.98 98.5
50% Load 97.59 98.18
25% Load 96.03 96.91

© Confederation of Indian Industry

 Improve Power Factor Of Generator
 Improving PF from 0.9 to 0.96 resulted in
improvement in efficiency
Reduced loss due to reduction in current

Annual Savings : Rs 14.8 Lakhs

Investment : Rs 15.0 Lakhs
Payback : 13 Months

© Confederation of Indian Industry

 Voltage Drop Measurement

 In a large complex distribution system, voltage drops

are very common
 Acceptable limit in a 3 Ph. System is 4-5 Volts /
Phase
 More than 5V/Phase indicates energy loss in the
distribution
© Confederation of Indian Industry
 Voltage Drop Measuring Procedure

 Measuring instruments should be calibrated

 Simultaneous measurement of voltage in the

feeding and receiving end of the feeder

 Measure P.F & Current

 Note the capacity of the Power cable used

© Confederation of Indian Industry
 Reasons For Voltage Drop

 Poor power factor

 Inadequate cable size laid
 Poor contact surface at
 Cable Termination
 Cable joints
 Contactors/Switches
© Confederation of Indian Industry
 Case Study-Voltage Drops

 Voltage drop – PCC to MCC

Measurements
❑ Voltage at Sub station = 418 V
❑ Voltage at DB end = 405 V
❑ Drop in Voltage = 13 Volts
❑ Load current = 225 A
❑ Power factor = 0.6 Lag
❑ Cable size = 1R x 3C x 300 Sq.mm
© Confederation of Indian Industry
 Case Study-Voltage Drops

 Present cable loss = 5.1 kW

 Capacitor installed at Load end – 60 kVAr
 Reduction cable loss = 2.5 kW
 Capacitor relocated

Annual savings = Rs. 0.76 Lakhs

© Confederation of Indian Industry

 Solar Mill
❖The SolarMill Generates :
 Daytime energy from the sun and wind.

 Day & Night energy from the wind.

 Standing at about 1 meter height, Solar

Mill meets building code requirements.
 3 Vertical-Axis Wind Turbines coupled to
3 permanent magnet generators
 On-Board “Smart” Electronics include
dynamic Maximum Power Point Tracking
(MPPT) and connectivity
© Confederation of Indian Industry
 Solar Mill
❖ Solar Mill Assembly:
 3 Vertical Axis Turbines mounted
on a single base.
 Cut-in wind speed – 2 m/s & Cut-
out wind speed – 18 m/s.
 Turbines (Savonius) produce energy
by accepting winds coming from
any direction.
 Designed for both On-Grid and Off-
Grid applications.
© Confederation of Indian Industry
 Solar Mill

13kW- Residence, 10kW- Sidvin Plastech,

Shamshabad Shameerpet

5kW- GreenAssets,
5kW- Dexler, Bangalore
Dehradun
© Confederation of Indian Industry
Solar Mill Performance Video

© Confederation of Indian Industry

Bi Facial Panel

© Confederation of Indian Industry

Thank You….
58 © Confederation of Indian Industry