6 6.

1 Introduction

CASE STUDIES

There are nine case studies presented in this chapter. Three case studies are from Indian industries and six case studies from international scenario. The case studies from KEMA, Netherlands assume full details of No Load Loss and Load Loss as well as portion of Eddy Losses in Load Loss as being available from transformer manufacturer or from relevant standard. No tests are conducted at site. The harmonic content of the load is given for each typical application. The applicability of Low Loss designs in each rating is analysed and payback period is found out. The case studies also give the energy saving gains in terms of reduction in carbon dioxide (Co2) emission. The likely penalty/gain per Ton of Co2 in monetary terms is taken as 0.3 kg/kWh to 0.6 kg/kWh with a cost ranging from Euro 10 to Euro 33/ ton. This gives a monetary factor of 0.003 Euro/ kWh to 0.02 Euro/kWh. The energy price is taken as 0.04 Euro/kWh. Thus CO2 cost can be 15 % to 50 % of Energy cost. This factor however is not applicable for payback and it is thus not considered for payback in the tables presented. The payback is considered for extra price to be paid for the low loss transformer and it is around 2 to 3 years. The Load Loss figures given in the tables give the Load Losses considering the harmonics in the load. In the first case study, the factor for enhanced eddy losses in the first load loss is shown for illustration only for illustrating rough order of values. All studies are presented in the year 2002.
6.2 Case Study 1

The case study considers a large company in the Iron and Steel sector. The average loading is 400 MW out of which about 60 MW is through H.T. utilization by H.T. Motors. The remaining 340 MW is through distribution transformers. Load is constant during 24 hours a day, 7 days a week. Transformer ratings vary from 800 kVA to 4800 kVA. There are about 400 Transformers. About 200 Nos. are of 1250 kVA and about 100 Nos. of 1600 kVA while the remaining 100 Numbers are of different ratings. Most of the transformers are replaced between 1982 to 1990. Almost all the transformers are of Dry Type due to problems faced in the earlier oil cooled transformers. The company follows the total ownership cost (TOC) concept and has used A and B figures of EUR 2.27/W for no load losses and EUR 1.63/W for load losses. The comparative figures are given for 1250 kVA transformers.
Table 6-1input data 1250 kV transformer

Transformer load Economic lifetime Interest rate Energy price Harmonic spectrum % A (no-load loss evaluation) B (load loss evaluation)

65% (constant load, 24/24h) with 6 pulse harmonics 10 years 7% EUR 40/MWh 1 3 5 7 9 11 13 15 17 19 100 0 29 11 0 6 5 0 3 3 EUR 2,46 /W EUR 1,04 /W

21 0

23 2

25 2

Illustrative Calculations

Inflation is not considered and hence the present worth expression is simplified using a = zero.

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