Temperature Rise and Transformer Efficiency

This article is excerpted from "Premium-Efficiency Motors and Transformers", a CD-ROM

available from CDA by going to the Publications List.

https://www.copper.org/environment/sustainable-energy/transformers/education/trans_efficiency.html

What Is Temperature Rise of a Transformer?

All devices that use electricity give off waste heat as a byproduct of their operation. Transformers are no exception.
The heat generated in transformer operation causes temperature rise in the internal structures of the transformer.
In general, more efficient transformers tend to have lower temperature rise, while less efficient units tend to have
higher temperature rise.

Transformer temperature rise is defined as the average temperature rise of the windings above the ambient
(surrounding) temperature, when the transformer is loaded at its nameplate rating.

Standard Ratings and Overload Capacity

Dry-type transformers are available in three standard temperature rises:
80 C,
115 C,
150 C

Liquid-filled transformers come in standard rises of

55 C
65 C

These values are based on a maximum ambient temperature of 40 C. That means, for example, that an 80 C
rise dry transformer will operate at an average winding temperature of 120 C when at full-rated load, in a 40 C
ambient environment. (So-called hot spots within the transformer may be at a higher temperature than average.).

Since most dry transformers use the same insulation on their windings (typically rated at 220 C), irrespective of
the design temperature rise, the 80 C rise unit has more room for an occasional overload than a 150 C rise unit,
without damaging the insulation or affecting transformer life.

Transformer Efficiency and Temperature Rise

It is best to obtain the actual load and no-load losses in watts from the transformer manufacturer, but sometimes
those data are not available. In that case, temperature rise is a rough indicator of transformer efficiency. For
example, a transformer with an 80 C temperature rise uses 13-21% less operating energy than a 150 C rise unit.

A more efficient transformer generates less waste heat in the first place, but transformer temperature rise results
from not only how much heat is generated but also how much heat is removed. Be careful that a unit carrying a
low temperature rise figure is not also inefficient, using fans to remove the excess heat.

The examples of 1,500 kVA and 75 kVA transformers in the table below are of high-efficiency, copper-wound
transformers designed to achieve an 80 C rise and high efficiency. These are compared to standard-efficiency
aluminum-wound units, that are designed for a 150 C rise. As can be seen from this table, the higher-efficiency
80 C rise transformers have a first-cost premium, but a shorter payback than the less-efficient 150 C rise
transformers. Not only will a lower-temperature-rise transformer have fewer losses, but also it will have a longer
life expectancy.
 Manufacturer A 1,500 kVA*

Standard High-Efficiency Standard High-Efficiency

(Aluminum) (Copper) (Aluminum) (Copper)

Load Factor** 65% 85%

Efficiency 98.64% 99.02% 98.47% 99.02%

Temp. Rise
150 C 80 C 150 C 80 C
(100% load)

Core Loss 4.3 kW 5.5 kW 4.3 kW 5.5 kW

Conductor
9.1 kW 4.1 kW 15.5 kW 7.1 kW
Loss

Total Loss 13.4 kW 9.6 kW 19.8 kW 12.6 kW

Power Saving 3.8 kW 7.2 kW

First Cost $16,750 $22,650 $16,750 $22,650

Cost
$5,900 $5,900
Premium

Benefits of Using High-Efficiency Copper-Wound Dry-Type Transformers

Electrical Energy
Annual Savings Payback Period Annual Savings Payback Period
Cost

$0.05/kWh $1,660 3.5 y $3,150 1.9 y

$0.07/kWh $2,330 2.5 y $4,420 1.3 y

 Manufacturer A 1,500 kVA*

Standard High-Efficiency Standard High-Efficiency

(Aluminum) (Copper) (Aluminum) (Copper)

$0.09/kWh $3,000 2.0 y $5,680 1.0 y

Manufacturer B 75 kVA*

Standard High-Efficiency Standard High-Efficiency

(Aluminum) (Copper) (Aluminum) (Copper)

Load Factor 50% 75%

Efficiency 97.24% 98.61% 96.61% 98.38%

Temp. Rise
150 C 80 C 150 C 80 C
(100% load)

Core Loss 0.34 kW 0.21 kW 0.34 kW 0.21 kW

Cond. Loss 0.73 kW 0.32 kW 1.64 kW 0.72 kW

Total Loss 1.07 kW 0.53 kW 1.98 kW 0.93 kW

Power Saving 0.54 kW 1.05 kW

First Cost $890 $1,790 $890 $1,790

Cost
$900 $900
Premium
 Manufacturer A 1,500 kVA*

Standard High-Efficiency Standard High-Efficiency

(Aluminum) (Copper) (Aluminum) (Copper)

Benefits of Using High-Efficiency Copper-Wound Dry-Type Transformers

Electrical Energy
Annual Savings Payback Period Annual Savings Payback Period
Cost

$0.05/kWh $240 3.8 y $460 2.0 y

$0.07/kWh $330 2.7 y $640 1.4 y

$0.09/kWh $420 2.1 y $830 1.1 y

* Actual examples of 1,500 kVA, 15 kV 277/480 V, and 75 kVA, 480 V 120/208 transformers.
** A combination of duty cycle and percent of full loading.

How Does Temperature Affect the Life of a Transformer?

Temperature is one of the prime factors that affect a transformer's life. In fact, increased temperature is the major
cause of reduced transformer life. Further, the cause of most transformer failures is a breakdown of the insulation
system, so anything that adversely affects the insulating properties inside the transformer reduces transformer life.
Such things as overloading the transformer, moisture in the transformer, poor quality oil or insulating paper, and
extreme temperatures affect the insulating properties of the transformer. Most transformers are designed to
operate for a minimum of 20-30 years at the nameplate load, if properly sized, installed and maintained.
Transformers loaded above the nameplate rating over an extended period of time may have reduced life
expectancy.

Lower Temperature Rise Means Increased Overload Capability

A lower-temperature-rise transformer results in a transformer with higher overload capability. For example, an 80
C rise dry-type unit using 220 C insulation has 70 C reserve capacity compared to a 150 C unit. This allows
the 80 C unit to operate with an overload capability of 15-30% without affecting the transformer life expectancy.
Also, a cooler running transformer means a more reliable unit and more up-time.

Designing a Transformer with Lower Temperature Rise

Transformers with lower temperature rise often use windings with lower resistance. The low resistance per unit
length of copper allows lower temperature rise transformers to be built without unnecessarily building a bigger
transformer. For example, an aluminum-wound transformer coil requires conductors with approximately 66 per
cent more cross-sectional area than a copper-wound transformer coil to obtain the same current carrying capacity.
High Efficiency and Conditioned Spaces
High-efficiency, low-temperature-rise (80 C rise dry-type or 55 C liquid-filled) transformers are frequently found in
confined spaces, like inside electrical rooms, underground vaults, and air-conditioned spaces in buildings. High
efficiency means less waste heat generated, thus lower ventilation and air conditioning requirements. Selecting
such a transformer, properly sized to the load requirements, assures greatest efficiency, longer life and increased
overload capability