Evaluation of Transformer Loading and Energy Loss
For Increasing Energy Efficiency in Distribution System
Suresh Krishnamoorthy, Dr. Devishree Jayabal
Faculty of Electrical and Electronics Engineering
Coimbatore Institute of Technology-CIT, Coimbatore, Tamil Nadu - 641014, India
e-mail: sureshdhaya@rediffmail.com
.
Abstract – Estimating loading per cent of a distribution
transformer and energy loss during power transformation for
a continuous process industry having High Tension (HT) to
Low Tension (LT) power conversion in its distribution is an
imperative for the betterment of energy efficiency. This is done
by measuring and analysing active and apparent power at
utilization and compensated reactive power at transformer
end at standard industry operating condition. Thereby
transformer loading level and operating efficiency is derived
with the help of actual load test results. Transformer loading
level estimation with transformer secondary current
(conventional method) and estimation by power flow
(proposed method) are compared with standard and energy
loss of the transformer is expressed as percent of total energy.
A case study in an industry is also given as an implementation
of suggested the methodology for the scope of increasing
energy efficiency.
Keywords: Power Control Centre (PCC), Distribution
Transformer, Active power (kW), Apparent power (kVA),
Reactive power (kVAr), power factor (pf) , Energy Losses, Energy
Efficiency.
1. INTRODUCTION
1.1 Need of the Study
In industries electrical power transportation from
supply to load is done through a transformer with level
change from High Tension (HT-11/22kV) to Low Tension
(LT- 440V) voltage at 50 Hz. Aim of the energy
management technique is to utilise the input power more
effectively as active power with decreasing energy
wastages. For an industry, transformer is main power
handling service equipment in the LT distribution. Avoiding
excess line losses in distribution is one of the important
areas to increase the energy efficiency. Computing the
loading of transformer and estimating the losses of
transformer are the main objective of the paper to express
the industry energy efficiency.
1.2. Literature Survey
LT distribution transformer losses are calculated based
on fixed core loss (no load loss) for the period of energizing
and copper loss (load loss) as a factor of ratio of minimum
and maximum load [1]. As a case study it is evaluated that
transformer operation is at efficient level at 50 percent
loading with good voltage profile and over loading leads to
power factor (pf) reduction, voltage sag and more losses [2].
Energy losses of LT distribution system is having direct
proportional relation with increase in load with no load
978-1-4799-7961-5/15/$31.00 ©2015 IEEE
(core) loss is predominant and the losses are estimated via loss
factor and working hours for the loss estimation is suggested
[3]. Errors in energy consumption and loss calculation are
happened with the instantaneous measured data if operational
conditions or standard utilization of industry is not ensured
[4]. Energy wastage identification through energy and power
audit for energy conservation and loss reduction after
implementation leads to demand reduction [5]. Designing an
industrial power system with energy efficiency through load
estimation and selection of rating of service equipment during
planning and commissioning stages is a challenging task and
is extended to expansion [6]. Energy losses are calculated
using generalized models of transformer considering the
voltage variation that influences no load and load losses with
limitation of minimum loss present with actual loading [7].
Computing the energy consumption and line losses with the
standard industry production is important to reduce the cost of
the energy contribution to decrease individual energy
consumption without decreasing individual welfare and
productivity. It is obvious that it also contributes to increase
the overall energy efficiency of the national economy.
In all the above references, loss calculation and/or,
improvement of energy efficiency is analyzed with
transformer secondary current. Reactive power compensated
at transformer end, reactive power inductive and reactive
power capacitive is not taken into account for evaluation. In
this method a step by step procedure is suggested to
calculating the transformer loading level based on the power
flow to the loads and the reactive power compensated at
transformer end.
2. METHODOLOGY
A new procedure is suggested to estimate the transformer
loading level, comparing with the standards for loss,
estimating the loss as a percent of total industry energy and
suggestion to increase the energy efficiency of the transformer
and industry.
2.1 Estimation of Transformer loading and loss
a) Measurement of apparent power, active power and
reactive power compensated at load end feeder cables
connected to a particular transformer
b) Calculation of total reactive power (inductive) at
transformer to be compensated.
c) Measurement of reactive power compensated at
transformer end.
d) Calculate the remaining reactive power at transformer end
after compensation
e) Compute the apparent power of the trransformer which
is actual load and express as per centc of its rated
capacity.
f) Calculate the losses from actual loadd test results and
derive its operating efficiency and enerrgy wastage as a
percent of total energy consumption of the
t industry.

2.2. Standards for Transformer losses

Losses and efficiency of the transfoormers not only

depend on the design, but also, on the efffective operating
load. Transformer losses consist of two paarts: No-load loss
and Load loss. Fig.1. Transformer loading vs Looss.
2.2.1. No-load loss (core loss)
2.4. Power Flow in Industry LT Distribution.
It is the self power consumed to keep up the magnetic
field in the transformer's core. Core loosses are caused Electrical distribution of HT
T/LT conversion in an industry
mainly by two factors: hysteresis and edddy current losses. having conventional method off reactive power compensation
Hysteresis loss is that energy loss consumption
c by and the power flow from HT souurce to load is shown in Fig.2.
magnetic field reversal in the core duringg the positive and
negative o the alternating current or vooltage. Also self
induced current at core is the reason for the eddy current
loss. Also as a third factor, negligible am
mount of no load
copper loss compared to core loss is accouunted.

2.2.2. Load loss (copper- I2R loss)

It is associated with full load currrent flow in the
transformer windings. Copper loss is poower lost in the
primary and secondary windings of a traansformer due to
the ohm resistance of the windings. Coopper loss varies
with the square of the load current. Hence
H efficiency
varies for an industrial distribution trransformer with
different level of loading. Efficiency decrease with
increase in load for a distribution transfoormer (500 kVA
capacity) is tabulated in Table.1 [10].

Table: 1 Transformer Load and effficiency

Percent Load 125 100 75 50 25
Efficiency at
98.52 98.76 98.97 9
99.14 99.10
unity pf
Efficiency at
98.15 98.45 98.72 9
98.93 98.87
0.8 pf
Fig.2. Power flow and loss distriibution in LT network
2.3. Optimum loading and energy wastagee
2.5 Energy Efficiency:
Efficient loading of a distribution transformer is
As the distribution traansformer gives maximum
between 50 percent – 60 percent at 0.95 – 0.99 PF where
efficiency between 50 percent – 60 percent load levels, for
core loss and copper loss are equal. Maxim mum efficiency of
an industry to be energy efficient, the losses at transformer
the transformer is 98.5 percent to have a standard loss of
during power transportation shhould be less than 1.5 percent
1.5 percent of total energy [9]. If the trannsformer is fully
of total energy [9].
loaded additional energy loss varies betweeen 0.4 percent –
1.9 percent. This results the total loss off the transformer
will be 1.9 percent – 2.4 percent dependinng on the layout 3. ESTIMATION OF TRANSFOR
RMER LOADING AND LOSSES.
and complexity of the distribution system m which turns the
system inefficiency. The relation between the
t losses and the 3.1 Conventional method
loading of a distribution transformer is show
wn in Fig.1. Secondary current of the transformer = A1 Amps
Rated secondary current of the trransformer = A2 Amps
Transformer loading level (in peercent)
A1
Percent load = x 100 (1)
A2
3.2 Proposed method 4.1.2 Field Study and data analysis
Measurements Secondary current of transformer at PCC and power flow
Transformer rated Capacity = kVA1 to each feeder is measured through recording of voltage,
Existing Reactive Power at PCC = kVAr1 active (kW) , apparent power (kVA) at feeder end and the
(in general, it is inductive) reactive power compensated at both feeder and transformer
Reactive power compensated with = kVAr2 end. The electrical parameters of each feeder are measured at
capacitors at PCC actual industry standard running condition during power study
Reactive power at PCC = kVAr3 is given in Table.3 and Table.4.
after compensation
Measured full load Active power = kW Table: 3 Feeder end active and apparent power
(Adding active power of all feeder values)
Measured full load Apparent power = kVA2 Full
(Adding apparent of all feeder values) Stopped Load Full Active Apparent
Apparent Power at PCC = kVA3 Feeder Load in HP Factor Power kW Power kW
after reactive power compensation Feeder 1 101.3 0.54 103 184
Feeder 2 0.0 0.56 120 136
3.3 Transformer loading (Proposed Method) Feeder 3 130.0 0.76 193 272
Feeder 4 0.0 0.73 71 96
kVAr 1(inductive ) = ( kVA 2 ) 2 − ( kW ) 2 (2) Total 487 688
kVAr3 = kVAr1 – kVAr2 (3)
Table:4 Reactive Power Compensation
(Negative value of kVAr3 indicates excess reactive power
Compensation Effective
compensated at PCC panel) At Rated kVAr kVAr ** Voltage
2 2
kVA 3 = (kVAr3 ) + (kW ) (4) Transformer 300 284
Feeder 1 0 0 415 V
Transformer loading level (in percent) Feeder 2 0 0
kVA3 Feeder 3 0 0
Percent load = x 100 (5) Feeder 4 0 0
kVA1
** Effective value of the capacitor bank is calculated
4. RESULTS AND DISCUSSIONS WITH A CASE STUDY from the percent reduction from the ratio of measured
4.1 Details of the Industry Considered: capacitor current to the rated current.
A continuous yarn manufacturing industry has been
4.2 Results
selected for the energy study. The industry considered is
high tension (HT) power consumer from the utility With the data obtained from study and interpretation,
supplier having HT /LT electrical distribution network. analysis is done with conventional method (secondary current)
4.1.1 Transformer Details and proposed method (power flow analysis) to estimate the
loading percent of transformer and the result is given in
The industry is having a distribution transformer for its
Table.5.
power consuming loads. It is without on-load tap correction
Table: 5 Transformer loading comparison
(OLTC) facility for voltage correction. The rating of
transformer and the connected load details identified and Percent
recorded during the field study are given in Table.2. Loading estimation by Measured Rated Loading
Conventional Method
Table: 2 Transformer rating and connected load 733.5 A 722 A 101.6 %
Secondary current
Transformer Capacity 500 kVA Proposed Method 527.2 500
105.4 % *
Primary. Voltage Rating 11000 V Apparent Power kVA kVA
Secondary Voltage Rating. 400 V * Excess loading level indentified = 4%
Primary current rating. 26 A
4.2.2 Interpretation
Secondary current rating.. 722 A
No of Feeders Connected 4 From the analysis and interpretation, it is clear that
Connected Load in feeders in Horse Power (HP) loading analysis through power flow shows a significance
difference at higher side than the secondary current analysis
Feeder 1 255 method. Loading comparison of a distribution transformer
Feeder 2 285 with two methods in percent is shown in Figure.3.
Feeder 3 341
Feeder 4 131
 107 105.4
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Loadin g in percent

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loading of industrial distribution transformer should be
avoided.
As the Transformer loss is one of the major portions of
line losses in LT distribution, it is derived for the industry
as the percent of total input energy. Result of this approach
gives raise to increase the energy efficiency for the better
energy management of the industry. Industries in India
coming under HT tariff structure having high energy cost
for the product. Facing acute power crisis and high energy
cost, energy conservation and reducing energy wastage is
imperative and can be attained through periodic power and
energy studies and adopting better energy management
techniques at correct instant [8].Hence improvement in
industry energy efficiency of the industry with the
advantage of above suggested approach can be quantified
with a complete study of entire distribution system starting
from transformer, feeder and till utility.