- 1. Paci c Crest Transformers: On Going GreenExecutive Summary
The United States, like many other countries worldwide, is
experiencing a growing concern about the environment. Currently
more the domain of activists and environmental organizations, it is
only a matter of time before these concerns grip consumers as well
maybe even to the point when they get discerning enough to question
the source of their electricity. In such a scenario, industries
will be faced with some pretty tough questions and it is best that
they begin the process of re-looking at their energy infrastructure
from an e ciency and environmentally protective point of view, now.
This white paper looks at the electricity need of the United
States, its aging energy infrastructure, and explores the
advantages of introducing green components something as simple as
the humble transformer - into the power distribution network. It
also makes a case for the switch over to energy- and cost-e cient
technology, and how legislation is pushing ahead those who are
resistant. We then take an in-depth look at the contributions of
Paci c Crest Transformers (PCT), a company that has paved a path
towards energy-e cient transformers with sound, long-term
initiatives. PCT introduced fundamental changes in the production
of transformers and began manufacturing custom, energy e cient and
environmentally friendly transformers even before legislative
compulsions made it mandatory for its competitors to do so. The
whitepaper concludes on a positive note; encouraging industries to
switch over to technologically modern and thus e cient transformers
thus realizing economic gains from the process as well. With over
90 years of collective experience, PCT may be one of the few
companies with the seasoned vision to advise clients on energy
requirements and provide transformers that are custom designed to
meet diverse needs for the next three decades or more.Copyright
Paci c Crest Transformers Inc. 2007-2009 www.paci ccresttrans.comOn
Going Green01
2. Introduction The electric power system in the United States
is the largest in the world. It has over 800,000 Megawatts Electric
(MWe) of installed capacity and growing. According to the Energy
Information Administration (EIA), electricity generated in America
in 2006 came from the following sources: Coal 49.7% Nuclear 19.3%
Natural Gas 18.7% Hydroelectric Conventional - 6.6% Petroleum -
3.0% Others - 2.7%Source:
http://commons.wikimedia.org/wiki/File:Sources_of_electricity_in_the_USA_2006.pngFig.
1.1: Sources of Electricity in the US, 2006The North American
Electric Reliability Corporation (NERC) claims the demand for
electricity in the US will continue to grow, even while long term
reliability of supply concerns persist.The EIA predicts the
countrys electricity demand will continue to grow at the rate of
1.8% to 1.9% percent per year till 2025. To keep pace with this
increasing demand the US must therefore add approximately 300,000
MWe of new capacity over the next 16 years. Copyright Paci c Crest
Transformers Inc. 2007-2009 www.paci ccresttrans.com On Going Green
02 3. While demand needs to be met, the electricity infrastructure
in the country is aging. A signi cant amount of equipment in the
public utility grid is over 40 years old and needs to be replaced
in the near future. According to the Department of Energy,
distribution transformers which are 30 years old or more, can waste
60-80 billion kWh annually. A better design could yield annual
energy savings of up to $1 billion. An integral issue needing to be
addressed along with the growing demand for electricity and its
aging infrastructure is its impact on the environment. In a
situation where governments are searching for ways to reduce their
greenhouse emissions in a cost-e ective method, reducing
electricity losses from distribution transformers represents a
productive avenue. For example, research shows that the global
electric savings potential from e cient distribution transformers
is well over 100 TWh/year (this doesnt correspond to the number
below). In fact, investing in energy e cient technology is said to
be the cheapest form of energy we can get and an excellent move
towards sustainability and environmental protection. E cient and
clean technology is now increasingly available and needs to be
adequately leveraged. The use of energy-e cient technology in
electricity transformers is thus becoming more important because
energy resources are becoming both scarce and expensive. Investing
in the right technology can help your company ensure electricity
needs are met without interruption or shortfall. Responding to this
thrust towards more e cient transformers and green technology, some
companies, such as Paci c Crest Transformers, have led the way even
before the presence of Department of Energy (DOE) guidelines.Energy
E cient Transformers Electric transformer loss in a typical grid
can be 40-50% of the total transmission and distribution (T&D)
loss. An energy e cient transformer is therefore an important means
to reduce T&D loss. Energy saving transformers can save upto
120 TWh / year, equivalent to more than 70 million tons of CO2
emissions. Some reasons for considering a switch over to more
energy-e cient transformers: All electricity generated worldwide
constantly passes through distribution transformers. Even a minor
improvement in e ciency, therefore, can result in substantial
energy savings, and lower emissions of greenhouse gases.
Transformers have high average e ciency (98 99%), but 2nd standby
losses (post standby power loss in electrical equipment) can still
cause considerable environmental impact. Copyright Paci c Crest
Transformers Inc. 2007-2009 www.paci ccresttrans.comOn Going Green
03 4. The energy losses in electric transformers fall into two
components:No-load losses or iron losses: A result of core
energizing, this is a phenomenon thatoccurs 24/7, throughout the
transformers lifetime.Load losses: Providing power to users result
in load losses, both from the coil resistancewhen the transformer
is in use; and stray ux that causes eddy currents. Electricity
grids typically lose 2% of total generation in distribution
transformers, which is nearly one-third of total system losses .
Distribution transformers are typically in use for 30 or even 50
years; enough time to build up signi cant losses. Toxic emissions
and global warming are now growing concerns, and power generation
is clearly one of the largest contributors to carbon and greenhouse
gas emissions. Energy e cient transformers can provide considerable
environmental bene ts. For example, a typical urban distribution
transformer rated at 400 kW has lifetime losses equivalent to 125
184 tons of CO2 emissions; a more energy-e cient design could
reduce these emissions to 56 tons.Enhancing Transformer Energy E
ciency New technology provides solutions to reduce energy losses in
electricity transformers by a good margin when 30-year-old
transformers are replaced with new ones.Energy-e ciency can be
improved with:Better, lower core-loss steels, such as
high-permeability grain-oriented steels (HiB)Larger core sizes to
reduce ux density in a speci c coreReducing current density with
increased conductor cross-sectionsA better balance between iron and
copper in the core and coils Distribution transformers built with
amorphous iron cores have also demonstrated a reduction in no-load
losses, when compared with existing designs. These cores are wound
with amorphous ribbon made from a ferric metal alloy produced with
very rapid quenching to eliminate crystallization. This technology
however, has only been proven for transformer ratings up to 10MVA;
this is expected to change soon. Higher-e ciency transformers are
available and already used by the utility industry: the issue is
about the choice individual companies must make.Copyright Paci c
Crest Transformers Inc. 2007-2009 www.paci ccresttrans.com On Going
Green04 5. What the Legislation Says The Energy Star Transformer
Program is a voluntary energy e ciency program designed to
encourage utilities to purchase and install higher-e ciency, cost e
ective transformers in their distribution systems. Consideration is
being given to setting minimum standards for distribution
transformer losses. This program includes: Information and software
dissemination Technical assistance to partners to ensure that
transformers are not oversized The Distribution Transformer Cost
Evaluation Model (DTCEM) is available and provides a standard
methodology for evaluating multiple transformer bids The US
Department of Energy (DOE) Federal Energy Management Program also
encourages government procurement of energy-e cient distribution
transformers Starting in 1998, the DOE began a process of research
and consultation on the merits and potential levels for a minimum
energy performance standard (MEPS) but companies are yet to adopt
the Energy Star Transformer Program in a big way. Besides the
Energy Star Transformer Program numerous other laws and regulations
like the Environmental Health and Safety Laws and Regulation, the
Department of Environmental Quality Laws and Rules, Environmental
Protection Agency and the Occupational Safety and Health
Administration require that electricity transformers watch their
emissions and adopt energy saving technology.Paci c Crest
Transformers: Leading the Way While the thrust towards more energy
e cient electrical transformers may be a relatively new phenomenon
in the US, environmentally conscious companies like Paci c Crest
Transformers (PCT) have displayed deep foresight; beginning their
environmentally friendly initiatives years earlier. Way back in the
1980s, Paci c Crest Transformers committed to designing and
manufacturing superior quality, custom and specialty transformers
in the most cost-e ective and responsive manner possible. The
company has 90 years of experience in building Pad mount, Station
and Secondary Unit Sub transformers and today specializes in the
environmentally friendly and e cient liquid- lled distribution
transformers. Copyright Paci c Crest Transformers Inc. 2007-2009
www.paci ccresttrans.comOn Going Green05 6. During the 1990s, the
Department of Environmental Quality began issuing guidelines on
materials in common usage which could possibly be carcinogens.
Among those materials was the family of dielectric uids with
chlorine based compounds, namely polychlorinated biphenyls (PCBs).
PCT, then known by a di erent name, acted to stop usage of the
targeted materials and clean their facility to limit employee
exposure and contamination of future products. The clean-up
procedure virtually resulted in the reconstruction of the factory
along environmentally friendly lines. Later, when the government
mandated replacement of all PCB products in use and a country-wide
replacement program started that lasted well into the 1980s, PCT
was already ahead of its time - with a completely PCB-free
facility. In an e ort to introduce energy e ciency in every aspect
of its functioning, PCT established an internal Directorate of
Environmental Quality. This commitment produced a number of
results, including: By 1990 PCT was ahead of its competitors as it
had eliminated the use of solvents like trichloroethylene, the
popular degreaser, from its fabrication facility. In 1994 PCT
completed a construction of a new PCB-free/solvent-free facility
with the goal to be environmentally friendly and energy e cient.
PCT designed special light-gathering skylights that when coupled
with an on-demand lighting system in the fabrication area reduced
power consumption and saved $100 per day in lighting costs. PCT
built high-security oil storage facilities protected by permanent
containment facilities which do not drain into the storm water runo
of the property, and meet the EPA Spill Prevention and Counter
Control standards. A special no-drain lling valve system was
installed to prevent any spillage during the transfer of oil into
the storage tanks. PCT introduced a storm water sampling procedure
which is continues till date, 15 years later, to guarantee that no
contaminants from our manufacturing and storage process are
introduced into the site runo . In 1994 PCT published an
environmental impact sensitivity study to address 6 major areas of
concern:1. Air quality2. Noise pollution3. Storm Water Run-o
quality4. Industrial Waste Discharge5. Greenhouse Gas
contribution6. Groundwater and Soil contaminationCopyright Paci c
Crest Transformers Inc. 2007-2009 www.paci ccresttrans.comOn Going
Green06 7. This was the basis for PCTs present day environmental
policy. In 2002 PCT changed welding materials to reduce exhaust
vapors from their metal fabrication facility. In 2003, PCT obtained
the ISO 1400 environmental certi cate. With its deep commitment to
develop environmentally friendly and energy e cient technologies,
PCT has stringent policies on company functioning. PCT trusts that
since these procedures are tested on the premise of the company, it
helps the company act as a model and adviser to other companies
wishing to follow suit. Secondly, PCTs hands-on experience allows
it to continue on the path of R&D for more energy e cient
transformers.The Paci c Crest Energy E ciency Policy PCTs energy e
cient policy has four main thrusts: 1) Conservation to minimize
utility consumption of electric power, natural gas, and water.PCT
uses natural gas year round to dry the transformer elements.
Re-tooling dryingovens to be more e cient has reduced PCTs gas
consumption. 2) Minimize the potential for insulating uid spills
and soil or groundwater contamination.PCT has recently increased
the containment berm height to provide added security, andcontinued
waste water sampling to monitor runo year round. 3) Deny access to
hazardous materials into the factory. 4) Reduce, reuse, and recycle
whenever possible. PCT generates metals and othermaterials that are
recycled o site. Included in this list are steel, copper, aluminum,
andpaper. Waste oil is pumped and sent to an oil recycler where it
is generally burned forheat. Wood waste is burnt at an electricity
go generation facility. Solid waste is hauledto a certi ed land ll.
The occasional hazardous, or otherwise unidenti ed, materials
aredisposed of using Phillips Environmental.Conclusion Undoubtedly,
energy is an important component of economic growth, both at a
micro and macro level. While the demand for energy increases year
on year, ensuring a steady supply can be a constant challenge, not
just at a national level but at a company level as well. Copyright
Paci c Crest Transformers Inc. 2007-2009 www.paci ccresttrans.com
On Going Green07 8. One of the ways industries can address their
energy demand is by re-evaluating the e ciency of their
distribution transformers. A change in technology will not only
introduce sizable economic bene ts and conserve the current wastage
of scare electricity; it can also help the industry stay in tune
with national commitments on carbon emission. Paci c Crest
Transformers continues to identify its environmental impact as its
responsibility to employees, contractors, suppliers, customers, and
the communities in which it works, and those where its products are
used. Copyright Paci c Crest Transformers Inc. 2007-2009 www.paci
ccresttrans.com On Going Green 08