ENERGY SAVINGS OPPORTUNITIES ON TRANSFORMERS IN THERMAL POWER PLANT- CASE STUDY

ABSTARCT- A Study on Transformers to find out the losses due to loading on transformers.
Out of 69 L.T. transformers based on loading record of few Months, 30 nos. heavily loaded transformers were selected for study .And calculation has been done for Transformers Losses and the results are as follows:Total Losses in Transformers of one unit of 210 MW are = 687KW or 0.33% of 210MW Contribution of Power Transformers in Losses per unit 210 MW = 659 KW Contribution of Service (L.T.) Transformers in Losses per 210 Mw = 29 KW Total Transformer Losses in Plant of 1240 MW = 4040 KW Annual Amount Loss due to Transformer Losses which could have been sent out = Rs.6.7 crores /year Overall Auxiliary Consumption of 1240 MW is 9.72 % and Excluding Power Transformer losses it is 9.39 %. (A)Savings for 1240 MW due to reduced Station Transformer Losses by P.F. Improvement = RS. 4.20 Lac/year (B)Savings for 1240 MW due to reduced Distribution Losses by P.F. Improvement = Rs.5.9 crores /year By Station Transformers Loading Adjustment one no. of Station Transformer can be put-off that will reduce the Total Losses of 44.50KW plus Service Transformers of EPT, WT, and DMT can also be put-off which will also reduce 16KW Losses. And by selecting G.T. of 350 MVA its Loading will reduce to 60% .Thus Total Losses reduction will be up to 136 KW. (C)Overall by Optimization strategy Annual saving @Rs.2.13/-will is (2.13*325*24*136) Rs.23 lacs. Expected Total yearly saving on Improving Power Factor and Transformer optimisation for 1240 Mw Power Plant (A+B+C) = Rs.6.17 crore Expected Total Saving by improving power factor for 1240 mw Power Plant = RS. 5.95 crores Expected Total Investment including the installation = Rs. 1.19 crores Simple Pay back Period = 65 days Expected Total saving by improving power factor from .83 to .99 and loading optimization on transformers by distribution companies on 1240 Mw = Rs. 13 crores/year Key Words: Overall Transformer Losses, Reduction in Transformer Losses by Optimisation, Savings by improving power factor

1.0 Introduction
1.1 General Plant details
Kota Thermal Power Station is first major coal power station of Rajasthan. Its present installed capacity is 1240 MW. It is located on the left bank of Chambal River at Kota. KTPS has established a record of excellence and has earned meritorious productivity awards from the Ministry of Power, Govt. of India during 1984,1987,1989,1991 and every year since 1992-93 onwards. In 2008-09 its Gross Generation was 8874 MU at 94.76% PLF with Auxiliary Power consumption 9.37% and Sp. Oil consumption 0.43 ml/kWh.

1.2 TRANSFORMERS
Types of Transformers:Transformers are classified as two categories: power transformers and distribution transformers. Power transformers are used for transmission of power at high voltage i.e. 400 kV, 200 kV, 110 kV, 66 kV, 33 kV deployed for step-up and step down the power as per requirement. Distribution transformers are used for distribution of power at low voltage as a means of end user connectivity i.e. 11 kV, 6.6 kV, 3.3 kV, 440 V, 230 V.

2.0 Methods and Materials

2.1 Transformer losses and Efficiency
The efficiency varies anywhere between 96 to 99 percent. The efficiency of the transformers not only depends on the design, but also, on the effective operating load. Transformer losses consist of two parts: No-load loss and On-Load loss 1. No-load loss (also called core loss) is the power consumed to sustain the magnetic field in the transformers steel core. Core loss occurs whenever the transformer is energized; core loss does not vary with load. Core losses are caused by two factors: hysteresis and eddy current losses. Hysteresis losses occur due to the energy loss by reversing the magnetic field in the core as the magnetizing AC rises and falls and reverses directions. 2. On-Load loss (also called copper loss) is associated with full-load current flow in the transformer windings. Cooper loss is power loss in the primary and secondary windings of a transformer due to the resistance of the windings. Cooper loss varies with the square of the load current. (P = I2R) For a given transformer, the manufacturer, supply values for no-load loss, PNO-LOAD, and On-load loss, PLOAD. The total transformer loss, PTOTAL, at any load level can then be calculated from: PTOTAL = PNO-LOAD + (% Load/100)2 x PLOAD , Where transformer loading is known, the actual transformers loss at given load can be computed as: No load loss + kVA Load Rated kVA Transformer Efficiency at Unity Power factor = {1-(Total Losses/%Loading*Rated KVA)*100
2

X (full load loss)

3.0 Observations and Measurements

3.1 Transformer Losses Calculation
A Study was done on transformers to find out the losses due to loading on transformers. Out of 69 transformers based on loading record of few Months, 30 heavily loaded transformers were selected for study. UNTI 7 LOAD CALCULATIONS AT 7.15PM S.No 1 2 3 4 5 6 7 SERVICES AHT7A CTT7A CTT7B EPT7A EPT7B UST7B UST7A Load KVA 296 547 649 65 160 333 353 RATED KVA 1600 2000 2000 2500 2500 2000 2000 %age Loading 18.50 27.35 32.45 2.60 6.40 16.65 17.65 NO-LOAD LOSS KW 1.60 1.90 1.90 2.20 2.20 1.90 1.90 LOAD LOSS 13.50 15.00 15.00 20.00 20.00 15.00 15.00 TOTAL LOSS* KW 2.06 3.02 3.48 2.21 2.28 2.32 2.37 Transform er Eff. 99.30 99.45 99.46 96.59 98.57 99.30 99.33

8 9 10 11 12 13

SSIVA/IVB SST 5A SST 5B UAT7A UAT7B G.T.7 SUB-TOTAL CHP TOTAL LOSSES

11564 490 319 3904 8228 219640 246548 338

50000 2500 2500 15000 15000 250000

23.13 19.60 12.76 26.03 54.85 87.86

34.60 2.20 2.20 8.17 8.17 119.34

185.00 20.00 20.00 50.34 50.34 599.10

44.50 2.97 2.53 11.58 23.32 581.77 684.39 2.42 686.81

99.62 99.39 99.21 99.70 99.72 99.74

UNIT 7 LOAD CALCULATIONS S. No 1 1 2 3 4 2 SSIVA/IVB UAT7A UAT7B GEN.TRANS. SUB-TOTAL CHP TOTAL SERVICES Load KVA AT 2.30PM 3 9136.00 7884.00 6630.00 218000.0 23650.0 338.00 23988.0 Load KVA AT 7.15PM 4 11564.00 3904.00 8228.00 219640.00 23696.00 338.00 24034.00 Load KW AT 7.15PM 5 9621.25 3162.24 6664.68 210000.00 19448.17 287.30 19735.47 6 50000.00 15000.00 15000.00 250000.00 RATED KVA % Loadi ng 7=3/6 18.27 52.56 44.20 87.20 No-Load LOSS KW 8 34.60 8.17 8.17 119.34 9 185.00 50.34 50.34 599.10 TOTAL LOSS LOAD LOSS TOTAL LOSSE S KW 10 40.78 22.08 18.00 574.89 655.74

STATION TRANSFORMERS S. No. 1 2 3 4 Unit No. Unit #1 Unit #2 Unit #3 Unit #4 Unit Cap. 110 MW 110 MW 210 MW 210 MW Unit Transf. Cap. 50 MVA 50 MVA 50 MVA 50 MVA Input/Output Volt. 220/7/7 KV 220/7/7 KV 220/7/7 KV 220/7/7 KV Make Crompton Bombay Crompton Bombay BHEL Bhopal TELK Kerala

UNIT AUXILIARY TRANSFORMERS S. No. 1 2 3 4 5 6 7 S. No. Unit No. Unit #1 Unit #2 Unit #3 Unit #4 Unit #5 Unit #6 Unit #7 Unit No. Unit Cap. 110 MW 110 MW 210 MW 210 MW 210 MW 195 MW 195 MW Unit Cap. Unit Transform Cap. 15 MVA 15 MVA 2*15 MVA 2*15 MVA 2*15 MVA 2*15 MVA 2*15 MVA Unit Transform Cap. Input/Output Voltage 11/7 KV 15.75/7 KV 15.75/7 KV 15.75/7 KV 15.75/7 KV 15.75/7 KV 15.75/7 KV Input/Output Voltage Make BHEL Jhansi BHEL Jhansi BHEL Jhansi BHEL Jhansi Bharat Bijlee Mumbai BHEL Jhansi BHEL Jhansi Make

GENERATOR TRANSFORMERS

1 2 3 4 5 6 7

Unit #1 Unit #2 Unit #3 Unit #4 Unit #5 Unit #6 Unit #7

110 MW 110 MW 210 MW 210 MW 210 MW 195 MW 195 MW

125 MVA 125 MVA 230 MVA 250 MVA 250 MVA 250 MVA 250 MVA

11KV/240 KV 15.75KV/240 KV 15.75KV/240 KV 15.75KV/240 KV 15.75KV/240 KV 15.75KV/240 KV 15.75KV/240 KV

BHEL Jhansi BHEL Jhansi BHEL Jhansi BHEL Jhansi Bharat Bijlee Mumbai BHEL Jhansi BHEL Jhansi

TABLE OF SELECTED TRANSFORMERS FOR ANALYSIS S. No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 SST- 1A SST- 1B BCW-1 SST II A Compressor IIA EPT3C EPT3A EPT4C Compressor IIA SST II B AHT II B UST5A SSTIIIB Const. Supply SST4A SST4B EPT 6B CT-6A CHP-IIA CHP-IIIA WT-IIA AHT7A CTT7A CTT7B EPT7A EPT7B UST7B UST7A SST 5A SST 5B SERVICES AV. LOAD AMP. 60.00 65.00 45.00 55.00 35.00 50.00 25.00 25.00 20.00 55.00 40.00 25.00 25.00 20.00 25.00 30.00 45.00 40.00 20.00 40.00 40.00 21.00 47.00 56.00 6.00 9.00 56.00 53.00 39.00 38.00 686.00 743.00 514.00 629.00 400.00 572.00 286.00 286.00 229.00 629.00 457.00 286.00 286.00 229.00 286.00 343.00 514.00 457.00 229.00 457.00 457.00 247.00 547.00 649.00 73.00 108.00 650.00 602.00 455.00 427.00 1600.00 1600.00 1600.00 2000.00 1600.00 1600.00 1600.00 1600.00 1600.00 2000.00 1600.00 1600.00 2000.00 1600.00 2000.00 2000.00 1600.00 1600.00 2000.00 2000.00 2000.00 1600.00 2000.00 2000.00 2500.00 2500.00 2000.00 2000.00 2500.00 2500.00 TOTAL LOSSES 42.88 46.44 32.13 31.45 25.00 35.75 17.88 17.88 14.31 31.45 28.56 17.88 14.30 14.31 14.30 17.15 32.13 28.56 11.45 22.85 22.85 15.44 27.35 32.45 2.92 4.32 32.50 30.10 18.20 17.08 1.60 1.60 1.60 1.90 1.60 1.60 1.60 1.60 1.60 1.90 1.60 1.60 1.90 1.60 1.90 1.90 1.60 1.60 1.90 1.90 1.90 1.60 1.90 1.90 2.20 2.20 1.90 1.90 2.20 2.20 13.50 13.50 13.50 15.00 13.50 13.50 13.50 13.50 13.50 15.00 13.50 13.50 15.00 13.50 15.00 15.00 13.50 13.50 15.00 15.00 15.00 13.50 15.00 15.00 20.00 20.00 15.00 15.00 20.00 20.00 Load KVA RATED KVA %age Loading NO-LOAD LOSS KW LOAD LOSS TOTAL LOSS* KW 4.08 4.51 2.99 3.38 2.44 3.33 2.03 2.03 1.88 3.38 2.70 2.03 2.21 1.88 2.21 2.34 2.99 2.70 2.10 2.68 2.68 1.92 3.02 3.48 2.22 2.24 3.48 3.26 2.86 2.78 81.85 99.41 99.39 99.42 99.46 99.39 99.42 99.29 99.29 99.18 99.46 99.41 99.29 99.23 99.18 99.23 99.32 99.42 99.41 99.08 99.41 99.41 99.22 99.45 99.46 96.96 97.93 99.46 99.46 99.37 99.35 Transfor mer Eff.

4.0 RESULTS AND DISCUSSIONS

4.1 POWER FACTOR CALCULATIONS
KVAr required = P(Kw)(tan 01 tan 02) COS o1 = 0.83 BEFORE CAPACITOR BANK Auxiliary Load = 19740 KW; Power Factor = 0.83; KVAr = SQRT(24034 19740 ) = 13710 KVAr AFTER INSTALLING CAPACITOR BANK Auxiliary Load = 19740 KW; Power Factor = 0.99; KVAr = 13710 KVAr 10462 KVAr (Proposed Bank) = 3248 KVAr KVA Load = SQRT (197402 + 32482 ) = 20005 Reduction in KVA Load = 24034 20005 = 4029 KVA Loading on STATION TANSFORMER after proposed reduction = 9136 -4029 = 5107 KVA % Loading of STATION TRANSFORMER = (5107/50000)*100 = 10.21% Losses of STATION TRANFORMER after Power Factor correction = 34.6 + (5107/50000)2 * 185 = 36.52 KW Reduction in STATION TRANSFORMER Losses after Power factor correction = 40.78 36.52 = 4.26 KW Saving Potential = 4.26 * 24 * 325 * 2.13 = Rs. 71000.00 /year/210MW (A)Saving Potential for 1240 MW = RS. 4.20 Lacs/year Reduced current = 4029/6.6*1.732 = 352 Amp. Reduction in Distribution losses = 352*352*R WATTS Distribution Losses before Power Factor correction= (24034/1.732*6.6)2*R % Reduction in Distribution Losses = (352*352*R / (24034/1.732*6.6)2*R)*100 = 2.8% Saving Potential = .028 * 19740 * 24*325 *2.13 = Rs. 1 crore/year/210MW (B)Saving Potential for 1240 MW = (1/210)*1240=Rs.5.9 crores /year Total Annual Savings for 1240 MW Generation (A+B) = Rs 5.942 crores Expected Annual Saving by Distribution Company @Rs.4.5/unit will be Rs. 1.94 crores/210mw Expected Annual Saving by Distribution Company for 1240 Mw power plant is Rs. 11.46 crores. Expected Total year saving by Improving the Power Factor for 1240 Mw Power Plant (A+B) = Rs.5.94 crore Expected Total Investment including the Capacitor Bank installation = Rs. 1.19 crores Simple Pay back Period = 70 days
2 2

COS o2 = 0.99

KVAr rating = 10462 kvar KVA LOAD = 24034

4.2 Transformers Losses Calculations and the results are as follows:Total Losses in Transformers of one unit of 210 MW are = 687KW or 0.33% of 210MW Contribution of Power Transformers in Losses per unit 210 MW = 659 KW Contribution of Service (L.T.) Transformers in Losses per 210 Mw = 29 KW Total Transformer Losses in Plant of 1240 MW = 4040 KW Annual Amount Loss due to Transformer Losses which could have been sent out = Rs.6.7 crores /year Transformer Losses contributes to share in Auxiliary power Consumption = 3.5 % Overall Availability of Plant has been considered 325 days in a year Overall Auxiliary Consumption of 1240 MW is 9.72 % and Excluding Power Transformer losses it is 9.39 %.

By Station Transformers Loading Adjustment one no. of Station Transformer can be put-off that will reduce the Total Losses of 44.50KW plus Service Transformers of EPT, WT, and DMT can also be put-off which will also reduce 16KW Losses. Thus Total Losses reduction will be up to 60 KW. By selecting G.T. of 350 MVA its Loading will reduce to 60% and 76KW Transformer Losses will also reduce. (C)Overall by Optimization strategy Annual saving @Rs.2.13/-will be (2.13*325*24*136)Rs.23 lacs. Expected Total yearly Saving on Improving Power Factor and Transformer optimisation for 1240 Mw Power Plant(A+B+C) = Rs.6.17 crore Expected Annual Saving by Distribution Company on Improving Power Factor and Transformer optimisation for 1240 Mw power plant is Rs. 13 crores

5.0 CONCLUSION
5.1 RECOMMENDATIONS 1) Equal loading shall be done on Service Transformers shall be done to avoid under loading and overloading 2) The transformers at minimum loading shall be replaced from high rated capacity to low required capacity or shall be switched off by transferring that load on other transformer to avoid losses and maintenance cost. 3) Routine and Preventive maintenance of transformers shall be carried out to avoid tripping. 4) By load analysis - Total losses can be reduced which will reduce the Overall Auxiliary Consumption of KTPS, and more power will be available to fulfil the gap between demand and supply. 5) Two transformers operating in parallel, should be technically identical in all aspects and more important both should have the same impedance level .This will minimize the circulating current between transformers. 6)Where the load is fluctuating in nature, it is preferable to have more than one transformer running in parallel, so that the load can be operated close to the maximum efficiency range by this operation.

6.0 REFERENCES
The following books, Literature and websites were referred in preparing this report:1) Technical Specification Sheets of Transformers 2) Tests Reports of Transformers 3) Website of RRVUNL 4) Guide Books for National Certification Examination on Energy Audit and Energy Management