ost petrochemical industrial facilities have numerous small (30kVA or 45kVA)

transformers spread throughout the process units serving lighting and power
distribution panelboards. In the U.S., the typical scenario is the transformers are fed on
the primary side with a 480VAC, 3-phase circuit and stepped down to feed
208Y/120VAC, 3-phase at a panelboard. The 480V primary overcurrent protective
device (OCPD) is either a thermal magnetic breaker or a set of fuses. Its also common to
see a main breaker for a secondary OCPD (main circuit breaker) installed in the
panelboard for transformer secondary protection.
The 2014 Edition of the National Electrical Code (NEC), Table 450.3(B), indicates the
maximum rating or setting for primary and secondary OCPDs. For example, a 30kVA
step-down transformer, rated 480V-208/120V, 3-phase with primary and secondary
OCPDs sized per Table 450.3(B), has a maximum rating of 250% of the primary side
current where secondary protection is provided. Therefore, we size the protective device
as follows:
30,000VA (480V x 1.732) = 36A x 2.5 = 90.2A
Based on this result, we know a maximum 90A circuit breaker or set of fuses could be
used for the primary OCPD.
The reason this high current rating is allowed is to compensate for transformer inrush
(winding saturation) currents, which, in some cases, can be more than 20 times the
normal primary current rating of the transformer for a few milliseconds.
Some engineers or electricians use 125% of the normal primary current rating of the
transformer when sizing the primary OCPD, without considering the inrush current. In
this case, it would result in using a primary OCPD rated at 45A.
30,000VA (480V x 1.732) = 36A X 1.25 = 45A
In this case, theres no Code violation if using a 45A breaker or fuse. But, as the Code
states in Sec. 90.1, the provisions of the Code are provided for safety and not intended as
a design specification. One should go a step further when sizing the primary OCPD and
check the time-current curves for the OCPD in coordination with the transformer to
make sure there wont be nuisance tripping of the breaker or an occasional blown fuse
when energizing the transformer when sizing the primary OCPD at 125% of the full
current rating of the transformer. Depending on the transformer and where the primary
OCPD closes in the sinusoidal cycle, its very possible that a 45A breaker or fuse may trip
or blow, respectively.

I dont advocate using the maximum allowable 250% multiplier in every case. Doing so
increases wire and conduit sizes, which in the end drives up costs. But blindly using a
125% multiplier, without checking the inrush currents and the time-current curves for
the OCPD, may result in unsatisfactory performance. Its been my experience that the
ideal rating for the primary OCPD usually lies somewhere between 125% and 250% of
the full load current rating of the transformer.
The bottom line: Sizing the primary OCPD should be looked at closely during the design
phase of a project to reduce a potential nuisance tripping problem during operation of
the system.