SIZING TRANSFORMERS
WITH LARGE MOTOR LOADS
(PART II)
By Doods A. Amora, PEE
(December, 2006)
EXAMPLE:
Now, supposing a lone 2,000 hp, 4.16 kV, Code Letter J motor (Starting kVA = 7.6 times its rated hp) is
connected to the 7,500 kVA transformer described above, would it not be that the transformer is too
large for the motor load? Probably yes, probably not! Let us see why.
A) IF THE MOTOR CONTROLLER IS ACROSS-THE-LINE (FULL-VOLTAGE CONTROLLER):
Starting kVA of 2,000 hp Motor (SkVA = 7.6):
Starting kVA of 2,000 hp motor = 2,000 kVA x 7.6 or 15,200 kVA
Three-Phase Short Circuit Capacity of the Transformer:
3 SC kVA of 7,500 kVA Trafo = 7,500 kVA/0.08 or 93,750 kVA
Note: In this case, the 7.5 MVA transformer has a maximum of 93.75 MVA
short circuit capability.
The voltage drop on motor inrush will be:
VD at Trafo Terminals = 15,200/(15,200 + 93,750) = 0.1395 or, 13.95%
VD at Trafo Terminals = 580 v
Trafo Terminal Volts During Motor Start-Up = 3,580 v
The transformer output voltage will drop from 4,160v to 3,580v (4,160 x 0.8605 = 3,580 v) as against a
minimum requirement of 3,600v for a 4,000v motor. Thus, we can see that the transformer even at 7.5
MVA is small for a 2,000 hp motor!
Therefore, the transformer must be sized to a short circuit capability equal to or greater than 15,200
kVA times 10, or, 152,000 SC kVA in order to have a voltage drop of 10% or less.
The next higher standard size transformer at 10,000 kVA 8.0% impedance would have a short circuit
output capability of 125,000 kVA which is still not sufficient. Or a 12.5 MVA transformer could be the
choice!
In this particular application, the ratio of the selected standard size transformer kVA to motor kVA is
12,500 kVA/2,000 kVA = 6.25. Thus the transformer rating is 625% larger than the rating of the motor!
Fantastic!
Note that the voltage sag in reality will even be bigger (actual voltage smaller) because the source can
never be infinite in fault duty plus in addition, the voltage drop at the distribution cables from the
transformer to the motor end. The total voltage sag is the sum of the sag in the secondary unit
substation transformer and the secondary circuit. In the case of very large motors of several hundred to
a few thousand horsepower, the impedance of the supply system (or the available fault duty) should be
considered.
NOTE: In addition to methods listed above, users should consider solid-state soft-start motor controllers
and/or adjustable speed drives.
In this example:
Motor Starting kVA = 46% of 2,000 kVA x 4.8 or 4,416 kVA
Motor Starting kVA can therefore be placed at 4,416 kVA.
The voltage drop at transformer terminals on motor inrush will be:
VD at Trafo Terminals = 4,416/(4,416 + 93,750) = 0.045 or, 4.5%
VD at Trafo Terminals = 187.2 v
Trafo Terminal Volts During Motor Start-Up = 3,972.8 v
The transformer output voltage will drop from 4,160v to 3,972.8 (4,160 x 0.955 = 3,972 v) against a
minimum requirement of 3,600v for a 4,000v motor.
Thus, we can see that the 7.5 MVA transformer now becomes sufficient for a 2,000 hp motor with a
different code letter and with the use of an RVS. Note also that if the auto-transformer RVS is at 80%
tap, the voltage drop as seen by the motor would still satisfy the 10% VD requirements.
source?
EXAMPLE:
Assume that in the 7.5 MVA Substation transformer described above, there are 2,150 kVA smaller 460 v
motors in the system through a number of transformers downstream the 4,160 v bus of the substation.
Other load, load growth included is 750 kVA. Assume also that there are 800 hp 4.16 kV Code Letter E
motors directly connected at the 4.16 kv bus. How many 800 hp motors can be energized into the
system complying with the 10% voltage sag requirements? Assume that RVSs for the 800 hp motors
are at 65% tap and the motors shall not be started at one time.
If there are several motors on one transformer:
TRAFO KVA = (Maximum Demand kVA of Small Group Motors) + (Maximum Demand kVA of Other Loads Including
Load Growth) + (kVA Ratings of all Large Motors) + (Additional Trafo kVA capacity necessary to accommodate
the inrush current of the largest motor)
Thus:
TRAFO KVA = 7,500 kVA
Max Demand of Small Group Motors = 2,150 kVA
Other Loads Including Load Growth = 750 kVA
kVA of Large Motors = KVA of LM (Unknown)
Additional Trafo kVA for 800 hp Start-Up = Unknown
Solving for the Starting kVA for 800 hp Code Letter E motor
with RVS at 65% tap:
800 hp Starting kVA = (0.46 x 800 x 4.8)
800 hp Starting kVA = 1766 kVA
Solving for the Additional Trafo kVA Needed for 800 hp Start-Up:
Trafo SC kVA Needed for one 800 hp Start-Up to maintain a 10% VD = 1,766 x10
Trafo SC kVA for one 800 hp Start-Up to maintain a 10% VD = 17,660 kVA
Additional Trafo kVA Needed for one 800 hp Start-Up = SC kVA x %IZ of Trafo
Additional Trafo kVA for one 800 hp Start-Up = 17,660 x 0.08 = 1,413 kVA
Solving for the Number of 800 hp Motors
that can be placed into the system:
Recalling: TRAFO KVA = (Max Demand kVA of Small Group Motors) + (Max Demand kVA of Other Loads Including
Load Growth) + (kVA Ratings of all Large Motors) + (Additional Trafo kVA capacity necessary to accommodate
the inrush current of the largest motor)