NAME: QAISER AMIN UD DIN

Black: Manual fixed entries

Pink: Manual variable enteries for program as data input
Brown: formulas
Red:Remarks, explanations and references.
Blue: Unknown parameters to be calculated

STATEMENT: Design of Distribution transformer with following specifications:

Specifications:
Rating 67 KVA
Phase 3
Type Core
Primary Voltage 11000 V
Secondary Voltage 400 V
Winding Type Mesh/Star
Natural Cooled Oil Immersed
Tapping ± 2.5 %
Impedance 4~6 %
Ambient temperature 35 °C
Max. Oil temperature rise 55 °C
Max. Copper temperature rise 65 °C
Oil temperature rise 45 °C
Frequency 50 Hz.

1. CORE DESIGN
(A) Calculation of Voltage per turn
Et = K (Q)0.5, where
K is a constant and for Core type Distribution T/F and is given by, K = (4.44 x
f x 10 -3 ) 0.5 = 0.47
Transformer rating,Q = 67 KVA
So, Et = K (Q)0.5 = 3.839 Volts

(B) Diameter of the Limb

We also know that
Et = 4.44 x f x Bm x Ai
Where, Maximum Flux density, Bm
Iron Area, Ai = Et / (4.44 x f x Bm)
Total Limb cross section or area,A =
of insulation (10% of Ai) = 126.82 cm2
Number of core steps
Cross Sectional Area, A = kdc2 where k =
Diameter of the Limb, dc= (A/k)0.5
Area of circumscribing circle = πr2 = πdc2/4
= 1.5 wb/m2 * For cold rolled steel,Bm is 1.5 to 1.75.Higher values for Power T/F.
= 115.29 cm2
Iron Area, Ai + Area
4 *Select from Table-A (given below) depending upon KVA rating.
0.64 *Select from Table-A (given below) depending upon KVA rating.
= 14.08 cm
= 155.56 cm2

(C) Core stepping and their design

The following "Table-A" will be used to calculate No. of core steps and their design based upon KVA ratings:

LAMINATION DESIGN ( All values in centimeters)

STEP-1 STEP-2 STEP-3 STEP-4

KVA Rating Value of K T

Th T
W hi
ick hic
Width id ck Width Width Thickness
No. of ne kne
th ne
Core ss ss
ss
Steps
1 0.45 0.71 ### 0 0 0 0 0 0
KVA < 25
2 0.56 0.85 ######### 0 0 0 0
KVA = 25 3 0.6 0.9 ######### 0.42 0.2 0 0
25 < KVA < 200 4 0.64 0.95 ######### 0.56 ### 0.36 0.2
200 < KVA < 400 5 0.7 0.94 ######### 0.68 ### 0.54 0.15
400 < KVA < 2000 6 0.77 0.97 0.3###### 0.77 ### 0.65 0.12

(i) Core Step No. 1

Lamination Width = .95dc 13.37 cm
Step Thickness = 0.36 dc 5.07 cm
Thickness of single Lamination sheet = 0.04 cm
No. of Laminations = Step Thickness = . Single
144.79
Lamination thickness
Hence one set of 145 Laminations will be used.
 (ii) Core Step No. 2
Lamination Width = .75dc 10.56 cm
Step Thickness = 0.2 dc 2.82 cm
Thickness of single Lamination sheet = 0.04 cm
No. of Laminations = Step Thickness = . Single
80.44
Lamination thickness
Hence two sets of 40 Laminations will be used.

(iii) Core Step No. 3

Lamination Width = .56dc 7.88 cm
Step Thickness = 0.19 dc 2.67 cm
Thickness of single Lamination sheet = 0.04 cm
No. of Laminations = Step Thickness = . Single
76.42
Lamination thickness
Hence two sets of 38 Laminations will be used.

(iv) Core Step No. 4

Lamination Width = .36dc 5.07 cm
Step Thickness = 0.2 dc 2.82 cm
Thickness of single Lamination sheet = 0.04 cm
No. of Laminations = Step Thickness = . Single
80.44
Lamination thickness
Hence two sets of 40 Laminations will be used.

(D) Iron Factor

Iron Area = Σsn=1(Thickness x width)
where "s" stands for no. of core steps
So, Iron Area = 132.85 cm2
Iron Factor = Actual Iron Area = . Area of
circumscribing circle 0.854

(E) Yoke Area

For cold rolled steel sheets used for laminations,
Area of cross section of limb = Area of cross section of Yoke
Thus, Area of cross section of Yoke = 126.82 cm2

(F) Weight of Core

Weight of iron/core = Volume of Core x Weight density of steel sheet
or Weight of iron/core = Weight of Yoke + Weight of Limb
178.26 Kg
=

(G) Cooling Arrangement of Core

In our case of 59KVA Distribution Transformer, the diameter of circumscribing circle (13.64cm) is less than 0.35 meters, so temperature gradient in the core is sufficient for cooling. In case o
must be augumented by dividing the core into different stacks with oil ducts running through laminations.

(H) Length of Yoke and Limb

Length of yoke = 63.8 cm
Height of Limb = 18.73 cm

2. WINDING DESIGN
(A) Choice of Winding Type
SPIRAL WINDING

(B) Number of turns

(i) Low Voltage winding
V2 (phase) = 400/√3 = 231 V
I2 (phase) = (59x1000)/(3x231) = 96.71 Amp
No. of turns per phase,T2 = Vph/Et = 60 Nos.
Hence turns/layer of LVW for 2 layers = 30 turns

(ii) High Voltage winding

V1 (phase) = 11000 11000 V
I1 (phase) = (59x1000)/(3x11000) = 2.03 Amp
No. of turns per phase, Ti = Vph/Et = 2865.13 Nos.
No. of turns with ±2.5% tapping,T1=1.025xTi = 2937 Nos.
Hence turns/layer of HVW for 2 layers = 1468 turns

(C) Size of Conductor for windings

(i) Low Voltage winding
Current density, δ2 = 3.85 A/mm2 * Manually entered first (See Section 3.4) and adjusted by iteration later.
Area of conductor, a2 = I2/δ2 = 25.1185 mm2
Diameter of conductor, d2 = √(4a2/π) = 5.66 mm
Comparing this diameter with round conductor sizes as per SWG, we will get the approximation
SWG 5 with diameter = 5.38 mm * Get from the standard for SWG table (Section 3.5).
0.11 mm
Thickness of Insulation of round conductors for both sides =
Area of SWG 5 conductor, a = πd2/4 = 22.762 mm2
Conductor dia with insulation or height of each turn = 5.495 mm

(ii) High Voltage winding

Current density, δ1 = 3.45 A/mm2 * Manually entered first (See Section 3.4) and adjusted by iteration later.
Area of conductor, a1 = I1/δ1 = 0.5885 mm2
Diameter of conductor, d1 = √(4a1/π) = 0.87 mm
Comparing this diameter with round conductor sizes as per SWG, we will get the approximation
SWG 21 with diameter 0.81 mm * Get from the standard for SWG table (Section 3.5).
0.11 mm
Thickness of Insulation of round conductors for both sides =
Area of SWG 21 conductor, a = πd2/4 = 0.519 mm2
Conductor dia with insulation or height of each turn = 0.923 mm

(D) Calculation of Coil length , Effective coil length, Limb Height, Radial Thickness and Diameters (inner & outer)
(i) Low Voltage winding
Coil length = factor for winding allowance x (turns/layer + 1) x covered width of each turn
Where Factor of allowance for spiral winding = 1.02
Covered width of each turn = dia of insulated conductor
Thus coil length of LVW = 17.33 cm
Effective coil length = factor for winding allowance x (turns/layer) x covered width of each turn
Thus effective coil length of LVW = 16.77 cm
Insulation of each end packet = 1.2 cm
Backalite ring at each end = 0.2 cm
Limb Height = Coil length + Insulation of each end packet + Backalite ring at each end
Thus Limb Height = 18.73 cm
Radial thickness = (height of each turn x Nos. of layers) + (Total thickness of inter layer wraps) + (Total thickness of Ducts) + winding Allowance
Conductor dia with insulation or height of each turn = 5.495 mm
No. of layers = 2
Total thickness of inter layer wraps = 0
Total thickness of Ducts = 8 mm
Winding allowance = 0.75 mm
Thus the Radial thickness = 1.974 cm
Inner dia of LVW = Dia of core + (2 x thickness of paper or cloth on core)
Outer dia of LVW = Inner dia of LVW + (2x radial thickness of LVW)
Thickness of paper = 0.5 cm
Inner dia of LVW = 15.08 cm
Outer dia of LVW = 19.02 cm

(ii) High Voltage winding

No. of HVW packets = 4
Insulation of each end packet = 1 mm
Inter packet insulation = 1.2 mm
Oil ducts b/w two groups (each of 2 packets) = 8 mm
End clearance = 12.5 mm
End rings of Bakelite = 1 mm
Total insulation along the height of winding = 2(insulation of each end packet
+ interpacket insulation + end clearance + end ring Bakelite) + oil ducts b/w 3.94 cm
two groups =
Axial space for each packet on the limb = (Height of Limb - Total 3.70 cm
Insulation) / No.of packets
No. of conductors in each packet axially = 45
No.of turns in each packet = 734
No. of conductors / layer in each packet = 16 Coil length/packets
Length per packet = factor for winding allowance x {No. of turns in each packet/(No.of conductors/ layer + 1)} x dia. covered with each turn
So, length per packet = 40.13 mm
Total length of Coil = Length per packet x No. of packets + oil ducts b/w two groups
Total length of Coil = 168.51 mm
Effective coil length = factor for winding allowance x (No. of turns/No.of conductor layers in each packet) x insulated dia of conductor
Thus effective coil length of HVW = 17.05 cm

Radial thichness or depth = (dia of each conductor x No. of cond. Layers in each packet) + (total thickness of interlayer wrap) + (total thickness of the duct) + (winding allowance)
So the Radial thickness will be = 1.39 cm
Inner dia of HVW = Outer dia of LVW + (2 x dia of cooling ducts)
Outer dia of HVW = Inner dia of HVW + (2x radial thickness of HVW)
Outer dia of HVW with insulation = Outer dia of HVW + (2x thickness of insulating covering)
So,
Inner dia of HVW = 20.62
= cm
Outer dia of HVW = 23.40 cm
Thickness of insulating covering = 0.2 cm
Outer dia of HVW with insulation = 23.80 cm

(E) Clearance between two windings and winding & core (T/F rating:25~630KVA, 11KV, Insulator Class "A" type)
(i) Thickness of major insulator of LV winding
 The winding to core insulation thickness = 18 mm *From Table 7.2

(ii) Thickness of major insulator of HV winding

The HV to LV winding insulation thickness = 12 mm *From Table 7.1
The winding end to yoke insulation thickness = 30 mm *From Table 7.1
The insulation thickness between phases = 14 mm *From Table 7.1

3. LOSSES
(A) Copper losses
(i) Low Voltage winding
Resistance=ρL2/a2=ρLmt2xT2 /a2=(resistivity of copper)x(length of mean turn of LVWxNo.of LVW turns)/cross sectional area of LVW conductor
ρ = (resistivity of copper) = 2.23x 10-6 ohm-m
Lmt2 = π/2(LVW innner dia. + LVW outer dia.) = 53.54 cm
Resistance, R2 = 0.0316 ohm
LVW Copper losses at full load = 3I22R2(1.1) = 973.7 Watt *where "1.1" is for 10% stray losses

(ii) High Voltage winding

Resistance=ρL1/a1=ρLmt1xT1 /a1=(resistivity of copper)x(length of mean turn of HVWxNo.of HVW turns)/cross sectional area of HVW conductor
ρ = (resistivity of copper) = 2.23x 10-6 ohm-m
Lmt1 = π/2(HVW innner dia. + HVW outer dia.) = 69.74 cm
Resistance, R1 = 47.39 ohm
HVW Copper losses at full load = 3I12R1(1.1) = 644.7 Watt *where "1.1" is for 10% stray losses
Total Copper Losses = Sum of HVW copper losses & LVW copper Losses 1.6 KW
=
Weight of Copper = 3(T1xLmt1xa1 + T2xLmt2x8.9)/1000 = 89.6 Kg
Weight Ratio = Iron weight / copper weight = 2.0

(B) Iron losses

(i) Yoke
Length of yoke = 2De + a1dc = 63.8 cm
De=outer dia. Of HVW + clearance b/w 2 HVW = 25.20 cm
a1 is lamination width of step No.1 of core = 0.95 cm
dc is dia of core = 14.08 cm
Area of yoke and limb are same in cold rolled steel, A = 126.82 cm2
Flux density is same in yoke and limb = 1.5 tesla
Losses at this flux density in the grain-oriented sheet steel of grade 46 are
= 0.83 W/Kg
Weight density of cold rolled sheet steel = 7.65 gm/cm3
Yoke width = Lamination width of step 1 x core dia = 13.37 cm
Yoke depth = yoke Area / Width = 9.48 cm
Volume of the yoke = Area x length x 2 = ### cm3
Weight of yoke = Volume x weight density = 123.74 Kg
Losses in yoke = weight x losses of steel = 102.08 Watts
Including 10% allowance for yoke losses = 112.29 Watts

(ii) Limb
Volume of the Limb = Area x limb height x 3 = 7126.85 cm3
Weight of Limb = Volume x weight density = 54.52 Kg
Losses in Limb = weight x losses of steel = 44.98 Watts
Including 10% allowance for Limb losses = 49.48 Watts
Total weight of iron = yoke wt. + limb wt. = 178.26 Kg
Total Iron loss in core = yoke loss + limb loss = 161.77 Watts

4. PERCENTAGE RESISTANCE
%age Resistance = Total Copper Losses(KW)x100 = .
2.42 %
Transformer Rating (KVA)

5. PERCENTAGE REACTANCE
%age Reactance=KVA per phase x (MT/L) x (m/Et2) x (F/50) x K1
where, MT = mean circumferential turn of HV and LV winding = (Lmt1+
61.64 cm
Lmt2)/2 =
L = (L1+L2)/2 + (a+b+c)/3 = 18.48 cm
L1= Length of HV winding = 16.85 cm
L2= Length of LV winding = 17.33 cm
a = Thickness of HV winding = 1.39 cm
c = Thickness of LV winding = 1.974 cm
b = Space between LV and HV winding = 0.8 cm
m = (a/3) + b + (c/3) = 1.92 cm
K1 = 1/2.54 for cm= 1/25.4 for mm= 1 for inches = 0.39 cm
Thus, %age Reactance = 3.8 %
6. PERCENTAGE IMPEDANCE
%age Impedance = √{(%ageR)2 + (%ageX)2} = 4.0 %

7. NO LOAD CURRENT
No load current (I0) = Iron loss current (Ie) + Magnatising current (Im)
Iron loss current (Ie) = (Iron losses) / (V1/3) = 0 Amp.
Magnatising current (Im)=Ampere turn/(√2x3xTi) = 0.04
Ampere turn per meter of yoke and limb at flux density 1.5 tesla
= 290 AT
Total AT for limb=No. of limbsxAT/mxlimb height(m) = 162.967
Total AT for yoke=No. of yokesxAT/mxyoke length(m) = 369.863
Total AT for Core = Total limb AT+Total yoke AT = 532.829
No load current (I0) = Ie + Im = 0.049 Amp.
%age Ratio of no load to full load current = 2.40 %

8. EFFICIENCY AND MAXIMUM EFFICIENCY

Total losses = Total copper loss + total Iron Loss = 1.8 KW
Input = output + losses = 68.8 KW
Efficiency = (Output/Input) x 100 = 97.41 %
Max. Efficiency = (Outputx100)/(Ouput+ 2xIron losses) = 99.52 %

9. %AGE REGULATION
%Age Regulation = {(%R + 100Cosφ)2 + (%X ± 100Sinφ)2}1/2 - 100

%Age Regulation at Lagging Pf %Age Regulation at Leading Pf Power Factor

4.06 -3.52 0.1
4.24 -3.21 0.2
4.38 -2.86 0.3
4.47 -2.46 0.4
4.52 -2.02 0.5
4.51 -1.52 0.6
4.42 -0.94 0.7
4.24 -0.26 0.8
3.87 0.61 0.9
2.49 2.49 1.0

10. %COPPER TEMPERATURE RISE

(i) Low Voltage winding
Surface Area of low voltage winding = π x outer dia x Length/2 + 2T2Lmt2 x
thickness = 1.32 m2
Total copper loss in LVW = 973.7 Watt
Copper loss (watt/m2) = 735.9 Watt/m2
Copper temperature rise = 8 °C *See from graph for winding temp. rise for spiral winding

(ii) High Voltage winding

Surface Area of high voltage winding = 2xno. Packets x thicknessxmean length
of turn + πxouter diaxlength + 0.5xinner diaxlength = 1.49 m2
Total copper loss in HVW = 644.7 Watt
Copper loss (watt/m2) = 432.9 Watt/m2
Copper temperature rise = 5 °C *See from graph for winding temp. rise for spiral winding

11. DESIGN OF TANK

(i) DIMENSIONS OF TANK
Consider Oval Tank,
Clearance b/w HVW and the tank,b = 0.4 cm * Taken from table 4.2.1
Clearance b/w HVW and the tank along the width,l = 0.5 cm * Taken from table 4.2.1
Clearance b/w HVW and the tank along the height,h = 45 cm * Taken from table 4.2.1
Width of the tank = 2xdistance b/w adjacent limbs + outer dia of HVW +
74.19 cm
2xclearance b/w HVW & tank =
Length of the tank = Outer dia of HVW + 2xclearance b/w HVW & the tank
along the width = 24.40 cm
Height of the tank = Limb height + 2(yoke depth) + clearance b/w HVW and
the tank along the height = 82.70 cm

(ii) TANK SURFACE AREA

Only four sides are heat dissipating while top and bottom donot contribute in heat dissipating
Surface Area of round faces = 2(0.5πxlengthxheight)= 6335.56 cm2
Surface Area of plain faces = 2 (width x height) = ### cm2
Total Surface area = SA of round + SA of plain = 1.86 m2
12. COOLING ARRANGEMENT
(i) TEMPERATURE RISE OF TANK WALLS
Heat dissipated by radiation/m2 = 6 W/m2/°C
Heat dissipated by convection/m 2 = 6.5 W/m2/°C
Total heat dissipated = 12.5 W/m2/°C
Temperature rise =Total losses/(Total heat dissipated x Surface Area)
76.5 °C
=

As the tank temperature rise is more than the permissible temperature range i.e, 35°C so we need more cooling area in the form of tubes taking temperature to 35°C.Then the total area (tank+
"X" times so to find the value of "X", we proceed as follows:

Total Losses (Watts) = St x X(8.8+3.7/X) x 35 *where St is total surface area including tank and tubes.
The area to be added in the form of tubes is given by (X-1) x St
So, X = (Total losses - 129.5St) / 308St = 2.686
Hence the area to be added in form of tubes=(X-1)xSt= 5.960 m2

(ii) DESIGN OF TUBES

Top and Bottom clearance for cooling tubes = 5 cm
Length of tube=tank height-top & Bottom clearance,l= 72.7 cm

First of all the selection has to be made in type of tubes, we will go for elliptical tube as these require less oil than the round tubes.
Major Axis, M = 7.5 cm
Minor axis, m = 1.5 cm
Dissipating surface = πDl = π x l x √(M2+ m2) = 1745.96 cm2
Volume of Oil contained (neglecting thickness) in each tube = πxM/2xm/2xl
642.02 cm3
=
Thus, volume of Oil contained (neglecting thickness) in all tubes =
πxM/2xm/2xl = ### cm3
No.of tubes=Area of tubes/surface area of each tube= 34
Distance between two consecutive eliptical tubes = 4.5 cm
No. of tube accomodated layers = 2(tank width+ tank Length) / Distance
44
between two consecutive tube =
So number of tube layers = 1
Twice Outer dia of HVW with insulation, Dt = 47.60 cm
Length of the tank = 24.40 cm
Total pheripheral length available = 143.99 cm
Each tube has distance available = 4.23 cm
Tubes accomodated at each long face = 12
Tubes accomodated at each smaller face = 5
The distance between two consecutive elliptical tubes from center to center
2.73 cm
=

13. CONSERVATOR DESIGN

The conservator is not required in our particular 59KVA transformer, however it is being given here for the program be comprehensive:

Cross Sectional area of transformer =0.5πDtxlength = 1823.18 cm2

Volume of tank = X-section area x height = ### cm3
Transformer length = Dt + outer dia of HVW = 71.39 cm
Transformer Width = outer dia of HVW = 23.80 cm
Transformer height = limb height + 2(yoke depth) = 37.70 cm
Transformer volume = Length x width x height = ### cm3
Volume of Oil in tank= volume of tank - T/F volume = ### cm3
Total oil volume = oil in tank + oil in tubes = ### cm3
Conservator volume = 1% of total oil volume = 1085.51 cm3
Let the diameter of the conservator = 8 cm *Manual entry of your choice
Then cross sectional area = 0.25πd2 = 50.24 cm2
Length of the conservator = Volume/area = 21.61 cm

14. TEMPERATURE OF DIFFERENT TRANSFORMER PARTS

(i) OIL TEMPERATURE RISE
Total area of the tank = tank area + tube area = 7.82 m2
Oil temperature rise =Total losses/(Total heat dissipated x Surface Area)
= 18.2 °C
Maximum Oil Temperature rise= Oil temperature rise= .
21.32 °C
Iron factor

(ii) TEMPERATURES
Given Ambient temperature = 35 °C
Oil temperature = 53.2 °C
Maximum Oil Temperature = 56.32 °C
Copper Temp. of HVW = Oil temp.+Cu Temp. rise = 58.2 °C
Max. Copper Temperature = max. oil+Cu temp. rise = 61.32 °C
Copper Temp. of LVW = Oil temp.+Cu Temp. rise = 61.2 °C
15. WEIGHT OF TRANSFORMER
Thickness of sheet = 0.3 cm
Total area of tank=4 sides area+top & bottom area = ### cm2
Volume of tank material used = total area x thickness of sheet = 6129.09 cm3
Total area of conservator material = πxconservator dia.xconservator length +
2π(conservator dia)2/4 = 643.24 cm2
Volume of Conservator = area x thickness of sheet = 192.97 cm3
Volume of Tubes=area of tubesxthickness of sheet = ### cm3
Thus total volume of material = tank volume + conservator volume + tubes
volume = ### cm3
Weight density of material per cm3 = 7.65 grams
Total weight of material = total volume x wt. density = 185.15 Kg
Weight density of oil per cm3 = 0.98 grams
Weight of oil used = (Oil in tank + oil in tubes + oil in conservator) x oil
weight density = 107.44 Kg
Total weight of Transformer = Weight of iron core + weight of copper +
560.45 Kg
weight of oil + weight of material =
Higher values for Power T/F.

pending upon KVA rating.

pending upon KVA rating.

ATION DESIGN ( All values in centimeters)

STEP-5 STEP-6

Width Thickness Width Thickness

0 0 0 0
0 0 0 0
0 0 0 0
0 0 0 0
0.35 0.11 0 0
0.5 0.11 0.3 0.09
ient in the core is sufficient for cooling. In case of higher capacity cooling

4) and adjusted by iteration later.

4) and adjusted by iteration later.

s of the duct) + (winding allowance)

for spiral winding

for spiral winding

g temperature to 35°C.Then the total area (tank+tube) must be increased by