Overhead to Underground System

Underground Distribution System

An electrical supply system employing underground structures, cables, and other
equipment located under designated areas along public ways or utility encasements

Patrick Joseph U. Munoz, REE

Market Development Manager
1
© 2015 Eaton, All Rights Reserved.
“Wireless na ang some part ng
Davao! Tingnan nyo yung mga
poste, ang linis tingnan, just like in
JAPAN!”

Source: https://twitter.com/digongquotes/status/730668548847079425
https://twitter.com/digongquotes/status/730668548847079425
© 2015 Eaton, All Rights Reserved.
Underground Distribution - Why?

• Aesthetics
• Property Value
• Health Impact
• Public Safety
• Technological Advances

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© 2016 Eaton Corporation. All rights reserved. 3
Aesthetics

• Trend to keep unsightly poles and wires out

of new residential subdivisions started in the
1960’s
• Many communities enacted laws restricting
overhead distribution lines.

4
© 2016 Eaton Corporation. All rights reserved. 4
 “Wireless na ang some part ng Davao! Tingnan
nyo yung mga poste, ang linis tingnan, just like
in JAPAN!”

Source: https://aboitizpower.com/article/davao-light-completes-first-
underground-distribution-system-makes-araw-ng-davao-celebration-festive/ 5
© 2015 Eaton, All Rights Reserved.
Technological Advances

• Cable Construction
• Deadfront Elbows
• Pad-Mounted Transformers

6
© 2016 Eaton Corporation. All rights reserved. 6
Public Safety
Florida Safety Data
(Over a seven year period)
Overhead Underground
Line Miles 57,000 17,810
Injuries 269 20
Injuries per 100 miles 0.471 0.112
Deaths 118 1

7
© 2016 Eaton Corporation. All rights reserved. 7
 Cost Effectiveness

How much is the public willing to pay for the

benefits?

- Consider Initial and Life Cycle Costs

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Cost Factors to Consider

Initial:
Labor
Material
Right-of-Way
Disposal
Salvage

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© 2016 Eaton Corporation. All rights reserved. 9
Cost Factors to Consider
Life-Cycle:
Operation Technology
Maintenance Reliability
Safety Quality
Public Safety Overhead Expenses
Storm Damage Training
Aesthetics Competition
Bird Migration Standardization
Health Impacts Logistics
Environmental Volume Purchase
Toxicity of Poles
10

© 2016 Eaton Corporation. All rights reserved. 10

Reliability

• Reduced exposure to storm damage

• Improved cable/connector technology
• Equipment Protection
• Installation and maintenance methods

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© 2016 Eaton Corporation. All rights reserved. 12
“Aside from the aesthetics, the UDS program makes he
VECO distribution system more reliable because
electricity trip offs caused by trees, strong winds and
lightning will no longer be a problem, said the
company's Power Systems Design Department
manager, Armil Logarta.”

Source: https://www.Cebu+city+electrical+underground+distribution+system
© 2015 Eaton, All Rights Reserved. http://www.philstar.com/cebu-business/2017/09/20/1740841/veco-city-identify-priority
 EATON Company Profile

Underground Distribution System Design

Fernando Vasquez Jr. PEE
Regional Technical Manager

© 2016 Eaton Corporation. All rights reserved. 14

 Underground Distribution Design

BASIS OF DESIGN
• Philippine Electrical Code
• ANSI / IEC Std codes.
• .

15
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Standard Nominal System Voltages
according to
ANSI and IEC Standards

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Common Configuration in
Underground Design

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© 2016 Eaton Corporation. All rights reserved. 17
System Configuration
FUSED
CUTOUT
(CLOSED)

ARRESTER

LOADBREAK BUSHING AND ELBOW

UNDERGROUND
CABLE

PADMOUNT TRANSFORMER
Typical Radial System RADIAL FEED WITH INTERNAL FUSING
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© 2016 Eaton Corporation. All rights reserved. 18
System Configuration
FUSED
CUTOUT
(CLOSED)

ARRESTER

LOADBREAK BUSHING AND ELBOW

ARRESTER
UNDERGROUND
CABLE

PADMOUNT TRANSFORMER
LOOP FEED WITH INTERNAL FUSING AN
Typical Radial System
19
© 2016 Eaton Corporation. All rights reserved. 19
Riser pole application from an overhead to an
underground system.
20
© 2016 Eaton Corporation. All rights reserved. 20
System Configuration
FUSED
CUTOUT
(CLOSED)

ARRESTER

PADMOUNT TRANSFORMER
WITH INTERNAL FUSING

LOADBREAK BUSHING AND ELBOW

UNDERGROUND
CABLE

Typical Radial System

21
© 2016 Eaton Corporation. All rights reserved. 21
System Configuration
FUSED FUSED
CUTOUT CUTOUT
(CLOSED) (OPEN)

POLE TOP
ARRESTER TERMINATOR

PADMOUNT TRANSFORMER
WITH INTERNAL FUSING

LOADBREAK BUSHING AND ELBOW

UNDERGROUND
CABLE

Typical Loop System

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© 2016 Eaton Corporation. All rights reserved. 22
Application

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Different types of MV Supply

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Medium voltage loop

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© 2016 Eaton Corporation. All rights reserved. 25
 Medium voltage loop

PADMOUNTED SWITCHGEAR WITH 6 UNITS LOOP FEED PADMOUNTED

TRANSFORMERS

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Typical Design of Meralco for
Underground Distribution

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© 2016 Eaton Corporation. All rights reserved. 27
Typical Design of Meralco for
Underground Distribution

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© 2016 Eaton Corporation. All rights reserved. 28
Typical Transformer Vault for U/G
installation

Common Design in
Underground Installation

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© 2016 Eaton Corporation. All rights reserved. 29
 30
© 2016 Eaton Corporation. All rights reserved. 30
 31
© 2016 Eaton Corporation. All rights reserved. 31
 32
© 2016 Eaton Corporation. All rights reserved. 32
 33
© 2016 Eaton Corporation. All rights reserved. 33
 Major Equipment

Padmounted Transformer Padmounted Switchgear

Connectors (Molded Rubber Products) Power Cable

© 2013 Eaton. All Rights Reserved. 34

Padmount Transformer
Standards, Specification and Technological Advancement

Patrick Joseph Munoz, REE

Market Development Manager

©2018 Eaton. All Rights Reserved

 Function of Transformers
POWER IN POWER OUT

(FROM SOURCE) (TO LOAD)

TRANSFORMER

13,800 VOLTS 120/240 VOLTS

• To change the voltage of electrical energy so it can be most

efficiently delivered to the customer

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© 2016 Eaton Corporation. All rights reserved.
6 36
History of transformer

Who invented the transformer?

© 2018 Eaton. All rights reserved.. 37 37

History of transformers

When it was invented?

© 2018 Eaton. All rights reserved.. 38 38

History of transformers

What is a transformer?

© 2018 Eaton. All rights reserved.. 39 39

 Transformer Development Timeline
1830s - Joseph “Henry” and Michael “Faraday” work with
electromagnets and discover the property of induction
independently on separate continents.

1836 - Rev. Nicholas Callan (priest) of Maynooth College,

Ireland invents the induction coil
1876 - Pavel Yablochkov uses induction coils in his lighting
system
1878 -1883 - The Ganz Company (Budapest, Hungary) uses
induction coils in their lighting systems with AC incandescent
systems. This is the first appearance and use of the toroidal
shaped
transformer.

© 2018 Eaton. All rights reserved.. 40 40

 Transformer Development Timeline
1881 - Charles F. Brush of the Brush Electric Company in
Cleveland, Ohio develops his own design of the earliest AC power
systems with William Thomson (Lord Kelvin). He creates an early
transformer. Gaulard and Gibbs later design a similar transformer
and loose the patent suit in English court to Ferrranti.

1882 - Lucien Gaulard and John Dixon Gibbs first built a

"secondary generator" or in today's terminology a step down
transformer which they designed with open iron core, the
invention was not very efficient to produce. It had a linear shape
which did not work efficiently.

© 2018 Eaton. All rights reserved.. 41 41

 Transformer Development Timeline
1884 - In Hungary Ottó Bláthy had suggested the use of closed-
cores, Károly Zipernowsky the use of shunt connections, and
Miksa Déri had performed the experiments. They found the major
flaw of the Gaulard-Gibbs system were successful in making a
high voltage circuit work using transformers in parallel. Their
design was a toroidal shape which made it expensive to make.
Wires could not be easily wrapped around it by machine during
the manufacturing process.

© 2018 Eaton. All rights reserved.. 42 42

 Transformer Development Timeline

1884 - Use of Lucien Gaulard's transformer system (a series

system) in the first large exposition of AC power in Turin, Italy.
This event caught the eye of William Stanley, working for
Westinghouse. Westinghouse bought rights to the Gaulard and
Gibbs Transformer design. The 25 mile long transmission line
illuminated arc lights, incandescent lights, and powered a railway.
Gaulard won an award from the Italian government of 10,000
francs.

© 2018 Eaton. All rights reserved.. 43 43

 Transformer Development Timeline

1885 - George Westinghouse orders a Siemens alternator (AC

generator) and a Gaulard and Gibbs transformer. Stanley begin
experimenting with this system.

1885 - William Stanley working with Westinghouse, modify

the design of transformer in a more practical way."Stanley's
first patented design was for induction coils with single cores
of soft iron and adjustable gaps to regulate the EMF present
in the secondary winding. This design was first used
commercially in the USA in 1886".

© 2018 Eaton. All rights reserved.. 44 44

 Transformer Development Timeline

George Westinghouse and William Stanley create a transformer

that is practical to produce (easy to machine and wind in a square
shape, making a core of E shaped plates) and comes in both step
up and step down variations. George Westinghouse understood
that to make AC power systems successful the Gaulard design
had to be changed. The toroidal transformer used by the Ganz
Company in Hungary and Gibbs in England were very expensive
to produce (there was no easy way to wind wire around an iron
ring without hand labor).

© 2018 Eaton. All rights reserved.. 45 45

 Transformer Development Timeline

1886 - William Stanley uses his transformers in the electrification

of downtown Great Barrington, MA.This was the first
demonstration of a full AC power distribution system using
step up and step down transformers.

Later 1880s - Later on Albert Schmid improved Stanley's

design, extending the E shaped plates to meet a central
projection.

© 2018 Eaton. All rights reserved.. 46 46

 Transformer Development Timeline

1889 - Russian-born engineer Mikhail Dolivo-Dobrovolsky

developed the first three-phase transformer in Germany at AEG.
He had developed the first three phase generator one year
before. Dobrovolsky used his transformer in the first powerful
complete AC system (Alternator + Transformer + Transmission +
Transformer + Electric Motors and Lamps) in 1891.

© 2018 Eaton. All rights reserved.. 47 47

 Transformer Development Timeline

First Transformer
Ever built:

Single Phase
Dry Type,1886

© 2018 Eaton. All rights reserved.. 48 48

 Transformer Development Timeline

Later 1891

Three Phase
Dry Type

© 2018 Eaton. All rights reserved.. 49 49

 Transformer history
(1890-present) High temperature
Diagnostics put into practice materials standards

Thermally
Free Breathing Sealed Natural
Upgraded
Designs Designs Esters
Kraft

1880 1900 1930 1960 1990 2010 2020

Common failure mode: mineral oil
(sludge, a bi-product of oxidation)
impacted heat transfer/dissipation
Common failure mode: shifted
to solid insulation; constrained
by operating temperature
Common failure mode:
solid insulation; operating
temperature increased Common failure mode:
solid insulation; operating
temperature increased

55oC AWR, 95oC HST 65oC AWR, 110oC HST 85oC AWR, 130oC HST

© 2016 Eaton Corporation. All rights reserved. 50

3Ph Padmount Transformer

Houses cable
termination, switching
and sectionalizing
equipment,overcurrent
and overvoltage
protection devices.

51
© 2016 Eaton Corporation. All rights reserved. 51
 3Ø pad-mounted transformers where used
Utility/Residential &
Commercial/Industrial:
Renewables
– Solar farms
– Wind farms
Data centers
Commercial businesses
– Stores / malls
Educational institutions
– High schools / universities
Military bases
Health care facilities
Small industrial facilities
– Machine shops
– Dairies
– Electronics
Large industrial facilities
– Automotive
– Steel
– Heavy power users
Padmount Transformer
Technological Advancements

Became “dead-front” with the introduction of

separable cable connectors in 1963.
Other developments:
• Loadbreak elbow and bushing
• Bay-O-Net primary side fusing
• External tap-changer switch
• Three-phase under-oil switch
• High Temperature Rise Transformers (PEAK)
• Special Transformer Designs (Solar,Data Center,
VFI Transformer, etc)
53
© 2016 Eaton Corporation. All rights reserved. 53
Transformers

Requirements:
• Tamper-proof cabinet
• Lifting provisions
• Standoff brackets
• No-load tap-changers
• Switches (on/off or multi-position)

54
© 2016 Eaton Corporation. All rights reserved. 54
Transformer Standard

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© 2016 Eaton Corporation. All rights reserved. 55
 Transformer Standard
IEEE Std C57.12.00™-2010 standard – IEEE Standard for Standard General Requirements for
Liquid-Immersed Distribution, Power, and Regulating Transformers.

IEEE Std C57.12.28™-2005 standard – Pad-Mounted Equipment - Enclosure Integrity.

IEEE Std C57.12.34™-2009 – IEEE Standard Requirements for Pad-Mounted, Compartmental-

Type, Self-Cooled, Three-Phase Distribution Transformers (2500 kVA and Smaller) - High
Voltage: 34500GrdY/19920 Volts and Below; Low-Voltage: 480 Volt 2500 kVA and Smaller
(issued in March 2005 - combines C57.12.22 and C57.12.26 standards).

IEEE Std C57.12.90™-2010 standard – IEEE Standard Test Code for Liquid-Immersed
Distribution, Power, and Regulating Transformers and IEEE Guide for Short-Circuit Testing of
Distribution and Power Transformers.

IEEE Std C57.12.91™-2011 standard – Guide for Loading Mineral-Oil-Immersed Transformers.

56
© 2016 Eaton Corporation. All rights reserved. 56
 Transformer Standard
IEEE Std C57.154™-2012 standard – IEEE Standard for the Design, Testing, and Application
of Liquid-Immersed Distribution, Power, and Regulating Transformers Using High-Temperature
Insulation Systems and Operating at Elevated Temperatures

NEMA TR 1-1993 (R2000) – Transformers, Regulators and Reactors, Table 0-2 Audible Sound
Levels for Liquid-Immersed Power Transformers.

NEMA 260-1996 (2004) – Safety Labels for Pad-Mounted Switchgear and Transformers Sited in
Public Areas.

10 CFR Part 431 – Department of Energy (US) – Energy Conservation Program for
Commercial Equipment: Distribution Transformers Energy Conservation Standards; Final Rule.

Philippine Green Building Code (June 2015) - A Referral Code of the NATIONAL BUILDING
CODE OF THE PHILIPPINES (P.D. 1096)

57
© 2016 Eaton Corporation. All rights reserved. 57
 Transformer Efficiency & DOE 2016 scope
• Ruling applies to the • Ruling does not apply to the
following transformers: following transformers:
– Manufactured (or – Autotransformers
imported) for sale in – Drive (Isolation)
United States after January – Grounding
01, 2016 – Machine-tool (control)
– Low voltage dry-type – Non-ventilated
– Rectifier
transformers – Regulating
– Medium voltage dry-type – Sealed
transformers – Special impedance
– Liquid-filled distribution – Testing
transformers – Transformers with tap ranges
– Single-phase: 10 – 833 kVA of 20% or more
– Three-phase: 15-2500 kVA – Underground mining (medium
– Input voltage of 34.5 kV or voltage dry type only)
less – Uninterruptible power supply
– Output voltage of 600 V or – Used, rebuilt, refurbished
– Welding
less
 Liquid vs. dry efficiency comparison
99.6
500
500 Watts
99.5 450 Watts 1500
1500
Watts
Watts Watts
350 1350
99.4 300 Watts Watts
250 Watts 2250
Watts Watts
99.3 1050
1150
Watts 1800
Watts Watts Liquid DOE 2010
Efficiency (%)

1350
99.2 900 Watts Liquid DOE 2016
Watts 850
Watts 15kV Dry DOE 2010
99.1
638 15kV Dry DOE 2016
Watts
99
400
98.9 Watts

98.8
98.7
500 750 1000 1500 2000 2500
kVA
• Liquid filled transformers remain more efficient than dry-type transformers
• Significant efficiency increase for dry types = significant purchase price increase
Philippine Green Bldg Code
Padmount Transformers
• KVA - 45 TO 10000
• CONFIGURATION - Loop or Radial Feed
• HIGH VOLTAGE - 2400-43800V, Wye or Delta
• LOW VOLTAGE - 208Y/120 V to 24,940 V
• HV TAPS - 2-2.5% fcan/fcbn, 4-2.5%
fcbn
• BIL - 30 to 200 kV
• PHASE - Single or Three Phase
• TEMP. RISE - 65 , 55/65, 65/75 , 75 other
• TERMINATION - Livefront or Deadfront
• Winding Material - Copper or Aluminum

61
© 2016 Eaton Corporation. All rights reserved. 61
Padmounted Transformers
• COOLANT - Mineral Oil or FR3 Fluid
• SWITCHING - 2 or 4 Position
• PRI. FUSING - Bayonet, ELSP,Cartridge,
Vacuum Fault Interrupter (VFI)
Magnex
• ACCESSORIES - Tapchanger
Pressure Relief Device
Oil Level Gage
Thermometer
Drain Valve w/ sampler

© 2016 Eaton Corporation. All rights reserved. 62

 Transformer

Radial Feed - 3 HV Bushings Loop Feed - 6 HV Bushings

© 2016 Eaton Corporation. All rights reserved. 63

 Transformer

HV Compartment (Deadfront) LV Compartment (Livefront)

© 2016 Eaton Corporation. All rights reserved. 64

Transformer
MERALCO
TRANSFORMER
STANDARD

© 2016 Eaton Corporation. All rights reserved. 65

 Transformer

BUSHINGS

200A,15 & 25 kV Bushing Well 200A,15 & 25 kV Bushing Insert

200A,35kv One Piece Bushing 600A Deadbreak Bushing

© 2016 Eaton Corporation. All rights reserved. 66
 Transformer

SWITCHING

Two Position (On/Off) Four Position T-Blade Switch with

Make before break feature
© 2016 Eaton Corporation. All rights reserved. 67
Loop Circuit
FUSED FUSED
CUTOUT CUTOUT
(CLOSED) (OPEN)

POLE TOP
ARRESTER TERMINATOR

PADMOUNT TRANSFORMER
WITH INTERNAL FUSING

LOADBREAK BUSHING AND ELBOW

UNDERGROUND
CABLE

68
© 2016 Eaton Corporation. All rights reserved. 68
Loop Circuit
FUSED FUSED
CUTOUT CUTOUT
(CLOSED) (CLOSED

POLE TOP
ARRESTER TERMINATOR

ISOLATED FAULTED
CABLE SECTION

FAULT

LOADBREAD ELBOWS

UNDERGROUND
CABLE

Isolated Faulted Cable Section on Loop Underground Circuit.

69
© 2016 Eaton Corporation. All rights reserved. 69
 Transformer – Primary Protection

Bayonet Fuse in series with Current

Limiting Fuse

Transformer with Vacuum Fault

Interrupter (VFI)
Cartridge Fuse in series with Current
Limiting Fuse © 2016 Eaton Corporation. All rights reserved. 70
 Overcurrent protection

• Expulsion fuse in series with partial- range back-up

current-limiting fusing
Fusing – Expulsion (Bay-O-Net mounted) & partial range current-limiting

Bayonets reduce down time and lower cost

© 2016 Eaton Corporation. All rights reserved. 71

 Transformer

Bay-O-Net mounted Cartridge Fuse Current Limiting Fuse

fuse link Shall be mounted Minimizes the effects
Protect distribution under oil and clear of high fault current
apparatus from overload currents, equipment and the
damaging currents secondary faults, and distribution system.
and to protect primary faults through It is coordinated with
distribution systems its maximum that of a low current
from failed apparatus. interrupting rating. Fuse to avoid
Applicable for 4.14- Applicable up to 35kV undesirable low
35kV © 2016 Eaton Corporation. All rights reserved. current operation 72
Transformer - Accessories

External Tap Changer Pressure Relief Device

Liquid Level Gauge Liquid Temperature Gauge

© 2016 Eaton Corporation. All rights reserved. 73
Transformer - Accessories

Pressure Vacuum Gauge Pressure Relief Device

Sampling Drain valve

© 2016 Eaton Corporation. All rights reserved. VFI Switch 74
Transformer - Accessories

200A,15kV Standoff Bushing

600A,15kV Standoff Bushing

Nameplate
© 2016 Eaton Corporation. All rights reserved. 75
Cooling types

• Radiator panel style

• Welded
• Bolted (Removable)
• With fan(s) (not shown)
• Corrugate style
• Made in-house
• With fan(s) (below)

© 2016 Eaton Corporation. All rights reserved. 76

Building a Greener Grid…. One
Transformer at a Time

© 2013 Eaton. All Rights Reserved. 77

 EF2
• Envirotemp FR3 fluid
– Soy Beans
• Domestically grown renewable resource
• Reduces drilling for new crude oil

© 2013 Eaton. All Rights Reserved. 78

 EF2
Soy-based Dielectric Fluid:
➢ Ultimately biodegradable: Readily, completely, quickly
➢ Non-toxic: Per standard oral and aquatic testing
➢ Essentially non-oxygen depleting in pond water (per
UofC)
➢ >95% Biobased and Renewable: 100% USA Crop &
Processing Sourced

© 2013 Eaton. All Rights Reserved. 79

 100
EF2
Aerobic Aquatic Biodegradation

CO2 Evolution (% of theoretical max)

80
Envirotem p FR3 fluid
conventional transform er oil
sodium citrate reference m aterial
(EPA "ultim ate biodegradability")
60

40

20
test perform ed per EPA OPPTS 835.3100 by
Thomas A. Edison Technical Center
Franksville, W I 53126 USA
W isconsin DNR Laboratory #252021770
report issued April 23, 1999
0
0 5 10 15 20 25 30 35 40 45
Elapsed Time (days)

100
Biodegradation Rate (%)
21-Day CEC-L-33

75

50

25

0
Silicone Oil Mineral Oil R-Temp Envirotemp
© 2013 Eaton. All Rights Reserved. Fluid FR3 Fluid 80
• Fire Safety—Improved EF2
Environmental Safety:
– Flawless fire history of soy-based dielectric fluid filled
transformer
• Eliminates need for asset replacement due to fire damage
• Meets NEC, UL, FM requirements for indoor installations
• Typically eliminates need for resources for deluge systems, fire
walls, lengthy clearances (1/10)

400
Flash Point 360
Degree Centigrade ( °C)

343
350 Fire Point
312 324
300
300 276
250

200 165
147
150
Mineral Oil R-Temp Silicone Oil Envirotemp
Fluid
© 2013 Eaton. All Rights Reserved.
FR3 Fluid 81
* Listed Less-Flammable Fluids must have a minimum Fire Point of 300°C
 EF2
• Reducing Utility Costs—Extended Insulation Life
– FR3 fluid enables longer transformer insulation life, which
results in lower life cycle costs and delayed asset
replacement
• Offsets raw material needs for replacement transformers

Envirotemp FR3 Mineral Oil Envirotemp FR3 Mineral Oil Envirotemp FR3 Mineral Oil

Upgraded Paper Upgraded Paper Upgraded Paper

500 hours @ 2000 hours @ 4000 hours @ 170°C
170°C 170°C
per Sealed Tube Test – MIL 152-2000

© 2013 Eaton. All Rights Reserved. 82

Transformer

FR3 INSULATING FLUID

 Exceptionally high fire
point @ 360C & flash
point @ 330C)
 Less-flammable dielectric
coolant by Factory Mutual
& Underwriters
Laboratories
 Indoor, submersible &
outdoor application

© 2016 Eaton Corporation. All rights reserved. 83

Copper vs. aluminum

• Misconception today that all copper wound

transformers are:
• More efficient
• More reliable
• Greater short circuit strength

© 2016 Eaton Corporation. All rights reserved. 84

 Copper vs. aluminum

• Truth:
• Copper wound not necessarily more efficient

Aluminum design Copper design

No-load losses 2607 2599
Load losses 13,261 13,194
Total losses 15,868 15,793
Efficiency @ 100% load 99.40% 99.40%
Price 13% Higher

Price differential varies widely depending on the price for copper.

© 2016 Eaton Corporation. All rights reserved. 85

Copper vs. aluminum

• In lieu of copper or aluminum -

What should you specify?
• Functionality
• Efficiency
• Wiser spend?
• Better dielectric fluid

© 2016 Eaton Corporation. All rights reserved. 86

 75 Deg C Design,
PEAK Transformers

• PEAK transformers from Eaton’s Cooper Power Systems are designed to:
• Provide enhanced capability compared to traditional transformers in today’s market
• Utilizes an advanced high temperature insulation system
• Thermally upgraded kraft paper
• EnvirotempTM FR3TM dielectric fluid
• Optimized core and coil design

© 2016 Eaton Corporation. All rights reserved. 87

Envirotemp™ and FR3™ are licensed trademarks of Cargill, Incorporated.
 IEEE C57.154™-2012
IEEE Standard for the Design, Testing, and Application of Liquid
Immersed Distribution, Power, and Regulating Transformers
Using High-Temperature Insulation Systems and Operating at
Elevated Temperatures

All liquid-immersed distribution, power, and regulating transformers

that are designed to operate at temperatures that exceed the normal
thermal limits of IEEE C57.12.00TM under continuous load, in the
designed average ambient, and at rated conditions are covered by
this standard. Specific requirements and guidance in the design,
testing, and application of the transformers covered within the scope
of this standard are provided. High-temperature insulation systems or
systems that use a combination of high-temperature and conventional
insulation are incorporated by these transformers

© 2013 Eaton. All Rights Reserved.. 88

 PEAK Transformers – TWO Options
1. Increased Overload Capacity

• PEAK 65/75 ⁰C Average Winding Rise (AWR)

• Operate PEAK transformers beyond full rated base load

• Single-phase at least 9%

• Three-phase at least 12%

• More precisely size transformers based on periods of peak demand—without accelerated reduction
of insulation life

• Continuous overload capabilities to 75⁰ C AWR

• Maintains IEEE® per unit life requirements at 75 ⁰C AWR

• 65 °C AWR and 75 °C AWR kVA ratings on the nameplate

• Complies with IEEE Std C57.154™-2012 standard

2. Smaller, Lighter Transformers

• PEAK 75 ⁰C Average Winding Rise

• Smaller and lighter than traditional 65 °C AWR transformers of the same kVA rating

• Typically use less material and fewer gallons of dielectric fluid

─resulting in better value

• Complies with IEEE Std C57.154™-2012 standard

All PEAK Transformers are filled with EnvirotempTM FR3TM Fluid © 2013 Eaton. All Rights Reserved.. 89 89
Envirotemp™ and FR3™ are licensed trademarks of Cargill, Incorporated.
 Increased Overload Capacity
➢ Accommodates Overloading While Maintaining IEEE ® Per
Unit Life Requirements
➢ 9% Continuous Overload – 1 Phase
➢ 12% Continuous Overload – 3 Phase

Continuous Overload With No Loss of IEEE® Per Unit

Life Requirements
© 2013 Eaton. All Rights Reserved.. 90 90
 Why Increased Overload Capacity?
➢ Ideal for Expectation of Increasing
Demand and for Withstand of Peak or
Prolonged Overload Conditions
− Application: serve building with
expectation of growth in tenants over time
• Eliminates need to replace transformer
with larger kVA unit
− Application: for critical loads where
overload is a concern, 65/75 °C AWR
provides an alternative, or complementary,
solution to forced air (fans) and
transformer oversizing

Ideal for Withstand of Peak or Prolonged Overload Conditions

© 2013 Eaton. All Rights Reserved.. 91 91
 Smaller, Lighter Transformers

➢ Less Materials for Better Value

(Fluid, Steel)
➢ Easier to Handle and Install
➢ Reduced Shipping Costs
➢ Reduction in Required Storage Space
➢ Overload Capacity per ANSI/IEEE Loading
Guide

Optimized for Smaller Size and Weight

© 2013 Eaton. All Rights Reserved.. 92 92
 Why Smaller, Lighter Transformers?
➢ Ideal For Customers with Size or Weight
Constraints
− Retrofit applications
− Indoor installation - accommodates
smaller doorway, elevator and transformer
room constraints
− Replacement of Non-DOE compliant
pad-mounted transformer with DOE
compliant unit, PEAK allows for use of
existing concrete pad
− Replacement of Non-DOE compliant
Single-Phase Pole-mounted transformer
with DOE compliant unit, PEAK may
eliminate need to replace utility pole
− Lifting/Loading constraints
− Reduces need to rent or upgrade to
heavier duty lifting/loading equipment

Smaller, Lighter Transformers With Increased Asset Life

© 2013 Eaton. All Rights Reserved.. 93 93
 PEAK Optimized Transformer
• Optimized Core and Coil Design
• Thermally Upgraded Kraft Paper
• Filled with Envirotemp™ FR3™ Fluid

Lower Lifetime Cost of Ownership

Source: US Dept of Interior, Bureau of Reclamation, FIST Vol.3-32 © 2013 Eaton. All Rights Reserved.. 94 94
Envirotemp™ and FR3™ are licensed trademarks of Cargill, Incorporated.
Specialty Transformers

© 2016 Eaton. All Rights Reserved.

 Critical Load Transformer (CLT)
A more robust transformer design for the highest degree of
reliability in the most demanding power applications
• Eaton published white paper WP202001
in 2016 with laboratory testing and system
analysis to prove design concept
• Superior overload capability and insulation
life
Applications:
• C&I (Data Centers, hospitals, waste water
treatment plants, manufacturing, mining
operations, process industry)
• Indoor and outdoor installations

© 2016 Eaton Corporation. All rights reserved. 96

©2018 Eaton. All Rights
 Critical Load Transformer (CLT)
• Advanced impulse protection
• Unmatched BIL ratings compared to
dry transformers

• FR3™ fluid-filled
• More than triple the dielectric
strength of air
• Additional insulation & conductor
support

© 2016 Eaton Corporation. All rights reserved.

Envirotemp™ and FR3™ are licensed trademarks 97
of Cargill, Incorporated.
VFI transformers

• Vacuum Fault Interrupter VFI

installed integral to the
transformer
• Switchgear-type over-current
protection for pad-mounted or
substation transformers
• Control box in HV termination
compartment (pad-mounted)
• Resettable fault protection up
to 35 kV with no fuses to
replace

© 2016 Eaton Corporation. All rights reserved. 98

VFI transformer scope

• 100 - 12,000 kVA

• Primary: thru
34500GY/19920 V
150 kV BIL
• VFI ratings:
• 600 A or 900A cont.
• 12.5 kA RMS
interrupting (16 kA
available @ 15 kV)

© 2016 Eaton Corporation. All rights reserved. 99

Smart VFI transformers

• Arc-flash: Reduce incident energy from an arc fault,

PPE category ‘dangerous’ down to a level 1 or 2.
• Factory installed and tested relay with VFI xfmr in
one complete package.
• Simplifies installation and reduced installed
footprint.
• Option to remotely control and monitor VFI and
pertinent transformer alarms.
Applications:
• Situations that require Arc-
flash safety
• Installations with limited space
• Systems that could benefit
from relay to relay
communication

© 2016 Eaton Corporation. All rights reserved. 100

 Solar Transformer
PV Array
PV String

DC Section
 Combiner Boxes 

 Inverters 

AC Section
Two Winding Three Winding
CPS Product
 Padmount  Padmount  Scope
Transformers Transformer

Utility-Scale PV
AC Electrical
Products
Padmount Switchgear

Connection to Distribution Grid 101

© 2016 Eaton Corporation. All rights reserved. 101
New Design Considerations :
External gauges, valves, nameplates

External gages
External control box

External sampling valve

External nameplate

© 2016 Eaton Corporation. All rights reserved. 102

©2018 Eaton. All Rights
New Design Considerations :
External gauges, valves, nameplates
• Transformer with external load-
break switch eliminates need to
access the HV compartment
• Addition of visible break enhances
ability to verify open contacts
• IR windows allows inspection of
connections externally

Above: External load-break

(no window)
Right: IR camera and
window
© 2016 Eaton Corporation. All rights reserved. 103
©2018 Eaton. All Rights
New Design Considerations : Integral fluid
containment

NEC® compliant Fluid containment –

required for indoor applications

© 2016 Eaton Corporation. All rights reserved. 104

©2018 Eaton. All Rights
Modular integrated transportable
substation (MITS)

© 2016 Eaton Corporation. All rights reserved. 105

MITS

© 2016 Eaton Corporation. All rights reserved. 106

MITS

© 2016 Eaton Corporation. All rights reserved. 107

Triplex design

© 2016 Eaton Corporation. All rights reserved. 108

Modular design

© 2016 Eaton Corporation. All rights reserved. 109

Triplex Transformer

© 2016 Eaton Corporation. All rights reserved. 110

Eaton Manufacturing Experience
• Eaton’s Cooper Power series transformers
• Serving over 25,000 MW of critical load
• Well over 6,000,000+ hours without any
reported downtime caused by a thermal or
short-circuit coil failure
• Installed in world’s most efficient data centers
 Single-phase pad-mounted transformers
product scope
Conventional FR3 PEAK Ranch Runner Shrubline VFI

• 10-167 kVA • 10-167 kVA • FR3 fluid • 10-50 kVA • 10-167 kVA
• 2.4 kV–19.9/34.5Y kV • 2.4 kV–19.9/34.5Y • Average winding rise • 2.4 kV – 14.4 kV • 2.4 kV–19.9/34.5Y
Primary kV Primary of 75°C Primary kV primary
• 120 V-600 V Secondary • 120 V-600 V • Overload capacity of • Compact design • 120 V-600 V
• Up to 150 kV BIL Secondary at least 109% ideal for secondary
• ANSI Type-2/Shurbline • High fire point FR3 • Smaller, lighter design residential • Vacuum fault
& Type-1/MaxiShurb fluid for increased applications interrupter in low
fire safety profile enclosure for
• Average Winding resettable fault
Rise of 65°C protection through
25 kV

© 2016 Eaton Corporation. All rights reserved. 112

 Three-phase pad-mounted transformers
product scope

• 45 – 10,000 kVA
• Primary voltage 2,400 – 46,000V
• Secondary voltage 208Y/120V –
24,940/14,400 V wye

© 2016 Eaton Corporation. All rights reserved. 113

 Substation product scope

• 3Ø kVA: 500 - 12000

• 1Ø kVA: 167 - 6667
• Primary voltage - 2400 - 46000 delta, through 250 kV BIL
• Secondary voltage - 208Y/120 - 14400, through 110 kV BIL

© 2016 Eaton Corporation. All rights reserved. 114

 North Street facility – Waukesha, WI
• All 3-phase transformer and voltage regulator coil winding
• Wound core fabrication
• Thermal and fluid test laboratories
• 450,000 ft2 of manufacturing, office and lab space
 Badger Drive facility – Waukesha, WI
“4 Factories in 1” • 470,000 ft2 of manufacturing and office
• Small 3Ø pad-mounted transformer space (added 116,000 ft2 of fabrication
assembly (<1500 kVA) and assembly in 2015/2016)
• Medium 3Ø pad-mounted transformer • Manufacturing transformers since 1991
assembly (<3750 kVA) • Flexible Manufacturing for individual or
• 1Ø & 3Ø Voltage regulator assembly large quantity orders
• Produces approximately 25
• Tank fabrication (transformers, transformers/day
regulators, pad-mounted switchgear) approx. 6000 transformers/year
Lincoln Avenue facility – Waukesha, WI
• Large 3Ø pad-mounted transformer assembly (>3000 kVA)
• Substation transformer & high complexity transformer assembly
• Stacked core fabrication
– 153,000 ft2 of manufacturing and office space
– Manufacturing transformers since 1969
– Produces approximately 10 transformers/day
– Approx. 3000 transformer/year
Coating system
Advanced multi-stage process exceeds IEEE
C57.12.28 requirements
• Eight-stage pretreatment process
• A high-build electro-deposition applied epoxy primer
• Urethane top coat adds ultraviolet protection
– Munsell Green (7GY 3.29/1.5)
– ANSI 61 Light Gray
– ANSI 70 Sky Gray
– Any special color available upon request
• Touch-up paint available
• Full Corrosion Protection
– (Meet IEEE C57.12.29 w/ 100% stainless steel construction)
• 3 mils standard coverage
• 5 mils available upon request
 Reduced footprint
Liquid-filled VFI
transformer offers:

• Approx. 60%
Dry type with Liquid-filled
reduction in footprint
primary switch VFI xmfr

• Increased electrical
efficiency

• Inherently safe,
deadfront primary
connections

Each line-up performs the same function

©2018 Eaton. All Rights
 Transformer Designs
kVA Rating 45 - 12,000 kVA kVA Rating 45 - 12,000 kVA
Primary Voltage 34500V Primary Voltage 34500V
Secondary Voltage 400/230V Secondary Voltage 400/230V
Temperature Rise 65 Deg C Temperature Rise 65/75 Deg C
Voltage Taps (+/-) 2 - 2.5% taps Voltage Taps (+/-) 2 - 2.5% taps
Fluid FR3 Fluid FR3
Configuration Loop Configuration Loop
Overcurrent Protection Bayonet , CLF Overcurrent Protection None
Loadbreak Switching 4 Position LBS Loadbreak Switching 4 Position LBS
Gauges Standard (Liquid, Gauges Standard (Liquid,
Temperature,Pressure) Temperature,Pressure)
Alarm Contacts Yes Alarm Contacts On Temperature Gauge
Only

Typical Design for Padmount Optimized Design for Padmount

Transformers Transformers

120
© 2016 Eaton Corporation. All rights reserved. 120
Connectors – Molded Rubber Products

© 2013 Eaton. All Rights Reserved. 121

Molded Rubber Products

200 Amp Molded Rubber Products

122
© 2016 Eaton Corporation. All rights reserved. 122
Molded Rubber Products

600 Amp Molded Rubber Products

© 2016 Eaton Corporation. All rights reserved. 123

 Transformer Design : 200 Amps Bushings

15 &
25kV Bushing Insert

Bushing Well
Elbow Connector (15,25 & 35kV)

Feedthru Insert

35kV

One Piece Bushing Elbow Arrester (15,25,35kV)

124
© 2016 Eaton Corporation. All rights reserved. 124
 Transformer Design : 600 Amps Bushings

15 &
25kV

Deadbreak Connector (15,25 & 35

35kV

One Piece Bushing Elbow Arrester (15,25,35kV)

125
© 2016 Eaton Corporation. All rights reserved. 125
 T-OPII System

Integral Bushing
Reducing Tap Plug
LRTP615
Stud-T
T-Body
Threaded Cu-Top DT625 (T)
Connector
Cable Adapter
CC6C—T
CA625-
(Conductor Size
& Type) (Insulation Dia.)
© 2016 Eaton Corporation. All rights reserved. 126
 Separable Splices

• 15/25 35 kV
• Used to splice two,
three or four, etc.
cables.
• Also used to
deadend a single
cable.
• Bol-Ts & Connecting
Plug

© 2016 Eaton Corporation. All rights reserved. 127

 Standoff Bushings

• Available in 15/25 &

35 kV ratings.
• Insulated Standoffs
❖ISB625---
❖ISB635---
• Grounded Standoffs
❖GSB625---
❖GSB635---
• Stud Options
• Parking Cable

© 2016 Eaton Corporation. All rights reserved. 128

 Deadbreak Junctions

• Available in 15/25
and 35kV ratings.
❖DJ625A----
❖DJ625C----
❖DJ635A----
❖DJ635C----
• 2, 3 or 4 Position
• SS Bracket or U-
Straps

© 2016 Eaton Corporation. All rights reserved. 129

 Deadbreak Protective Cap

• Available in15/25 &

35 kV ratings.
❖DPC625
❖DPC635
• Provides insulated,
fully shielded
submersible
protection for
energized interfaces.

© 2016 Eaton Corporation. All rights reserved. 130

© 2016 Eaton Corporation. All rights reserved. 131