CONTENTS

1.

INTRODUCTION.............................................................................................................................................................4
1.1 BACKGROUND....................................................................................................................................................................4
1.2 A GUIDE TO THIS GUIDE .......................................................................................................................................................4

2.

FUNDAMENTALS ..........................................................................................................................................................5
2.1.
2.2.
2.4
2.5.
2.5.1.
2.5.2.
2.5.3.
2.5.4.
2.5.5.
2.3.6

3.

TRANSFORMER OPERATIONS ..................................................................................................................................13

3.1
3.1.1.
3.1.2.
3.1.3.
3.2.
3.2.1.
3.2.2.
3.2.3.
3.3.
3.4.
3.5.
3.5.1.
3.5.2.

4.

VARIATION OF LOSSES DURING OPERATION................................................................................................................13

Variation of losses with loading level ...............................................................................................................13
Variation in Constant losses ............................................................................................................................14
Variation in Load Losses .................................................................................................................................14
LOSS MINIMISATION IN APPLICATION & OPERATION ...................................................................................................14
Selection of Rating and Number of Transformers ............................................................................................14
Energy Saving by Under-utilisation of transformers .........................................................................................15
Reduction of losses due to improvement of power factor.................................................................................15
SEGREGATION OF NON LINEAR LOADS .......................................................................................................................16
EFFECT OF OPERATING TEMPERATURE ......................................................................................................................16
ASSESSING THE EFFECTS OF HARMONICS..................................................................................................................16
U.S. Practice K- Factor.................................................................................................................................17
European Practice- Factor K..........................................................................................................................18

REDUCTION OF LOSSES AT DESIGN STAGE...........................................................................................................20

4.1.
4.2.
4.2.1.
4.2.2.
4.3.
4.4.

5.

PRINCIPLE OF TRANSFORMER ACTION..........................................................................................................................5

SAMPLE CALCULATION ...............................................................................................................................................7
PARALLEL OPERATION OF TRANSFORMERS..................................................................................................................8
LOSSES IN TRANSFORMERS ........................................................................................................................................8
Dielectric Losses ...............................................................................................................................................9
Hysteresis Loss.................................................................................................................................................9
Eddy Current Losses in the Core.....................................................................................................................10
Resistive losses in the windings ......................................................................................................................10
Eddy Current Losses in conductors: ................................................................................................................11
Extra Eddy Losses in Structural Parts .............................................................................................................12

INTRODUCTION.........................................................................................................................................................20
MINIMISING IRON LOSSES .........................................................................................................................................20
Losses in Core ................................................................................................................................................20
Amorphous cores ............................................................................................................................................21
MINIMISING COPPER LOSSES ....................................................................................................................................22
CHOICE OF LIQUID-FILLED OR DRY TYPE.....................................................................................................................22

ECONOMIC ANALYSIS................................................................................................................................................24
1.1 INTRODUCTION .................................................................................................................................................................24
5.2
TOTAL OWNERSHIP COST OF TRANSFORMERS ...........................................................................................................24
5.3
DECISIONS FOR CHANGEOVER TO NEW EQUIPMENT ....................................................................................................25
5.4
SAMPLE CALCULATIONS...........................................................................................................................................25

CASE STUDIES............................................................................................................................................................27
6.1
INTRODUCTION.........................................................................................................................................................27
6.2
CASE STUDY 1.........................................................................................................................................................27
Illustrative Calculations .....................................................................................................................................................27
6.2.1
Factor for Harmonics.......................................................................................................................................28
6.2.2
Percentage of Eddy Losses in Load Losses: ...................................................................................................29
6.2.3
Full load losses for Harmonic Loading:............................................................................................................29
6.2.4
Relative economics for low loss transformers (All Dry type).............................................................................29
6.2.5
Summary:........................................................................................................................................................31
6.3
CASE STUDY-2: NON FERROUS METAL SECTOR .........................................................................................................31
6.4
CASE STUDY-3: PAPER & PULP COMPANY ................................................................................................................32
6.5
CASE STUDY-4 CHEMICAL INDUSTRY .....................................................................................................................33
6.6
CASE STUDY 5 CASE OF A LARGE DATA HOTEL START UP .......................................................................................33
6.7
SUMMARY OF EUROPEAN CASE STUDIES: .................................................................................................................34
6.8
CASE STUDY 6: TEA INDUSTRY (INDIA) ......................................................................................................................34
6.9
CASE STUDY 7: STEEL MILL (INDIA) ..........................................................................................................................35
6.10
CASE STUDY-8: AUTOMOBILE PLANT (INDIA).............................................................................................................36
6.11
CASE STUDY -9: IMPROVING RELIABILITY AND AVAILABILITY .......................................................................................37
6.12
CASE STUDY-10: USE OF AMORPHOUS CORE TRANSFORMERS ...................................................................................38

ANNEXURE-1: GUIDELINES FOR INSTALLING TRANSFORMERS.....................................................................................39

ANNEXURE-2: MAINTENANCE GUIDELINES.......................................................................................................................42
REFERENCES ........................................................................................................................................................................46