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http://electrical-engineering-portal.com/price-of-a-transformer
Price Of A Transformer
Today the production of t ransf ormers is characterised by a large variety of designs, manufactured in relatively short batches to meet the demands of a variety of customers with everchanging expectations. Of course, fluctuations in commodity prices have a significant effect. The designer has a certain choice of solutions which can be applied in order to build a transformer with expected rated losses. It is possible to use, for instance, different magnetic materials or change the proportions between the level of magnetic induction Oil transf ormer and current density. It is, however, important from the point of view of the manufacturer that the t ransf ormer with expected parameters will be designed in an optimum way. It is also possible to vary the ratio of copper to steel quantities. According to an old rule of thumb within the transformer industry, the production cost optimum lies somewhere around a ratio of steel to copper usage of 2:1. However, it is a fairly flat optimum and, of course, varies with the price ratio of steel to copper. Independently of this, it should be taken into consideration that the operating properties of the transformer also vary when the shares are varied, especially with respect to losses: Holding the current densities in the windings and the magnetic flux density in the core constant, the loss per kilogram of copper or steel, respectively, will be more or less constant. Thereby a transformer designed according to this philosophy, but with more iron and less copper, tends to have higher iron losses, and one with more copper and less iron will have higher copper losses. But this does not mean that skimping on copper and steel pays off! Rather, enhancing the core cross-section while keeping the number of turns constant will reduce core losses, and enhancing the copper cross section while keeping the core cross section constant will reduce copper losses. IN SHORT: the bulkier transformer will always be more efficient, and metal prices will always be an obstacle against its implementation. The progress in the scope of calculation techniques allows for optimisation to get a precise model of the transformer geometry, taking into account the actual core cross-section and the location
of windings. It allows precise calculation of the transformer parameters. Manufacturers have many methods of design optimisation at their disposal which may be used in solving the issues in question. At todays commodity prices (low loss magnetic steel 2 500 3 000 / tonne, copper 6 000 7 000 / tonne) the indicative transformer price for AC class 100 kVA typical distribution transformer is around 3 000 , 400 kVA is around 7 000 and 1 000 kVA around 12 000 . The price / rating characteristics can be roughly described as:
where: C1 is cost of transformer 1 C0 is cost of transformer 0 S1n is rated power of transformer 1 S0n is rated power of transformer 0 x exponent (cost factor) The X factor is about 0.4 to 0.5. For more efficient units this factor has a tendency to increase up to 0.6 or even higher. Dry type transformers representing rated losses specified by HD 538 standard are usually a few percent lighter than oil transformers (as they do not contain oil) but, because of the more costly manufacturing process, they are about 10% to 30% more expensive than CC oil-filled machines. Because of some differences in design, particularly of magnetic circuit, no-load losses of dry transformers are substantially higher than in oil transformers. Thanks to optimisation efforts and technology improvements, there is an area for transformer manufacturing cost reduction. Commodity prices have gone up for the last few years and have outweighed the cost-reducing effect of optimisation and technological improvements. The cost of active materials in typical transformers increased by more than 50% between the years 2003 and 2007. In these conditions transformer design optimisation can bring around 5% savings in manufacturing cost. This effect is better in less efficient machines. Please note that, when the price of both active materials (magnetic steel and winding material) increases in similar proportion, the optimisation brings only marginal savings in manufacturing cost, when the same loss levels are specified. So manufacturers rather prefer to agree certain capitalisation based formula when optimisation of transformer may bring some savings in
manufacturing cost. Today, the cost active materials in an average distribution transformer represents about 50% of the transformer total price; taking all materials into account increases this to 70% of the total price.