Written By: RJS Approved By: STT

DESIGN MANUAL ELECTRICAL DEPARTMENT TRANSFORMER RATING

No. DCB-08-11 Date: Feb. 21, 1996

Rev. : 0

Transformer rating shall be generally 120 to 130% more than the load connected on it. This takes care for @ 20% future load growth. In addition to cater future load, the transformer when loaded 70 to 80% remains cool and thus its life is enhanced. Further this kind of rating takes care of peak requirement of the load. Two transformers of equal rating are required to feed critical continuous process load. Each shall be rated to feed entire load as and when one of the transformer is taken out for either maintenance or failure. The other transformer shall feed entire load without causing disturbance to the critical load of the process. Though capital cost is more in having two transformers but it pays even in one or two failures of process which means loss of production due to want of electricity. The non-critical load is fed from single transformer as stoppage of non-critical load does not affect much to process. Hence cost of two transformers are not justified and loss of production due to above is acceptable norm in industry. Below given is an example for a mixed type of load i.e. critical, semi-critical and noncritical. The example is for a typical 180 Tonne continuous Polymerisation (CP) load. To arrive transformer capacity the estimated motors rating are collected from process and mechanical departments. These are tabulated in attached Appendix-I. Normally motors are not loaded fully. Neither all motors are operating at a particular given time. Suitable factors are applied to arrive the actual load on the transformer. These factors are discussed among process and mechanical engineers. Lighting load shall be overall added to the motor load. The calculations are carried out as mentioned below :

Written By: RJS Approved By: STT

DESIGN MANUAL ELECTRICAL DEPARTMENT TRANSFORMER RATING

No. DCB-08-11 Date: Feb. 21, 1996

Rev. : 0

APPENDIX - I 1. Continuous Operating Load : a) b.1) b.2) c) Critical Load [C1] Semi-Critical Load [C2-A] Semi-Critical Load [C2-B] Non Critical Load [C3] TOTAL LOAD Assuming the motors are loaded @ 75%, the operating load shall be Assuming efficiency of motors @ 86%, Input to the motor For above operating load of 951.60 kw, Input to the motors 2) kw Intermittent Operating Load : 358.95 Assuming the motors are loaded 75% and only 50% of Intermittent motors running at a time the Intermittent operating load shall be Assuming efficiency of motors @ 86%, Input to the motors 3) Lighting Load = = = = = = = = = = 333.95 209.70 198.50 209.45 kw kw kw kw

951.60 kw 951.60 x 0.75 713.7 kw 713.7 0.86 829.90 kw 829.90 kw

= = = = =

358.95 x 0.75 x 0.5 134.60 kw 134.60 0.86 156.5 kw 150 kw

Written By: RJS Approved By: STT

DESIGN MANUAL ELECTRICAL DEPARTMENT TRANSFORMER RATING

No. DCB-08-11 Date: Feb. 21, 1996

Rev. : 0

Total Load Continuous Operating Motors Intermittent Operating Motors Lighting Load = = = 829.90 kw 156.50 kw 150.00 kw 1136.4 kw Assuming @ 3% distribution losses, Transformer output Transformer Output KVA

= = = =

1.03 x 1136.4 1170.49 kw 1170.492 0.8 1463.2 KVA SAY, 1470 KVA

Assuming the above load is distributed among two nos. 1600 KVA rated transformer. Each transformer shall be loaded about 735 KVA only for process load including, intermittent and lighting load. Thus, each transformer is loaded @ 46%. Normally, each transformer may be loaded @ 80% i.e. 0.8 x 1600 = 1280 KVA. Available capacity for buyers power load (under normal operating condition) @ 545 KVA on each transformer. CONCLUSIONS : It is recommended that two transformers each rated for 1600 KVA are adequate for process and lighting load.
(FILENAME : 84928684.doc / FL. NO. 155-43-B)