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Transformer Design
OUTPUT EQUATION: - It gives the relationship between electrical rating and physical dimensions
of the machines.
Let
V1 = Primary voltage say LV
V2 = Secondary voltage say HV
I1 = Primary current
I2 = Secondary current
N1= Primary no of turns
N2= Secondary no of turns
a1 = Sectional area of LV conductors (m2)
I
= 1
Rating is given by
Q = V1 I 1 10 3
KVA
3
= 4.44 fm N1 I1 10
KVA
3
= 4.44 fAi Bm N 1 I 1 10
KVA
Where
f = frequency
m = Maximum flux in the core
Ai = Sectional area of core
Bm = Maximum flux density in the core
V1
( m Ai Bm )
-----------(1)
H L
V V
4.44 f m N 1
L H
VV
Window
H L
V V
a N a2 N 2
1 1
Aw
( I / ) N1 ( I 2 / ) N 2
1
Aw
I N I2 N2
1 1
Aw
(a1 I /1 & a2 I / 2 )
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L H
VV
2 I1 N 1
Aw
So
K w Aw
N1 I1
( 2)
(2)
KVA
KVA
Window
(3)
Kw
N1I1
LV
LV
HV
HV
LV
LV
HV
HV
LV
LV
( 4)
10
2
Q 2.22 f A i Bm K w Aw 10 3
KVA
KVA (5)
Note it is same as for 1-phase core type transformer i.e. equ (3)
(3)
Window
H L
V V
Rating is given by
Q = 3 V1 I1 10 3
KVA
3
= 3 4.44 fm N1 I1 10
KVA
3
= 3 4.44 fAi Bm N1 I1 10
KVA
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L H
VV
H L
V V
L H
VV
H L
V V
V1
-----------(6)
4.44 f m N 1
( m Ai Bm )
L H
VV
3
Window Space Factor
Kw
2(a1 N1 a2 N 2 )
Aw
2 ( I1 / ) N1 ( I 2 / ) N 2
Aw
2( I1 N1 I 2 N 2 )
Aw
2 2 I1 N1
Aw
So
( a1 I /1 & a2 I / 2 )
Window
K w Aw
(7 )
4
Put equation value of N1I1 form equation (7) to equation (6)
N 1 I1
K w Aw
10 3
4
Q 3.33 f A i Bm K w Aw 10 3
Q 3 4.44 f A i Bm
(3)
KVA
KVA (8)
Kw
N1I1
(a1 I /1 & a2 I / 2 )
3-phase shell type transformer with
sandwich windings
( For Ideal Transforme r I1 N1 I 2 N 2 )
(9)
10
2
Q 6.66 f A i Bm K w Aw 10 3
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KVA
KVA (10)
0.9 to 1.1 T
(2) HRGO
(Hot Rolled Grain Oriented Si Steel)
1.2 to 1.4 T
(3) CRGO
(Cold Rolled Grain Oriented Si Steel)
(0.14---0.28 mm thickness)
1.4 to 1.7 T
1.5---2.3 A/mm2
AN
Air Natural cooling
ON
Oil Natural cooling
OFN Oil Forced circulated with Natural air cooling
2.2---4.0 A/mm2
AB
Air Blast cooling
OB
Oil Blast cooling
OFB Oil Forced circulated with air Blast cooling
CORE CONSTRUCTION:
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(c) U-T type
45o
V1 4.44 fm N1
(1)
So EMF / Turn
Et
V1
4.44 fm ( 2)
N1
and
Q = V1 I 1 10 3
KVA
3
= 4.44 fm N1 I1 10
KVA
Et N1 I1 10 3
KVA (3)
In the design, the ration of total magnetic loading and electric loading may be kept constant
Magnetic loading
= m
Electric loading
= N1 I1
m
Q Et m 10 3
KVA
r
Or
Q Et
Et
10 3
4.44 f r
KVA
Et (4.44 f r 10 3 ) Q
Or
Et K t Q
Volts / Turn
Where K t 4.44 f r 10 3
is a constant and values are
Kt = 0.6 to 0.7
for 3-phase core type power transformer
Kt = 0.45
for 3-phase core type distribution transformer
Kt = 1.3
for 3-phase shell type transformer
Kt = 0.75 to 0.85
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6
Kt = 1.0 to 1.2
(1)
Or
Et 4.44 f m
Et 4.44 f Ai Bm
So
Ai
( 2)
Et
4.44 f Bm
(3)
d/2
2-Step
1-Step
Or
CruciformCore
Or Square- Core
K=
0.45
d = Diameter of circumscribe circle
For Square core
Gross Area
0.56
3-Step Core
4-Step Core
0.60
0.625
d
d
0.5 d 2
2
2
K i 0.9
Ai K d 2
So
Ai
K
Graphical method to calculate dimensions of the core
Consider 2 step core
d
Or
90o
,
n 1
i.e n 2
a
b
n No of Steps
90o
30o
2 1
So a dCos
b dSin
Percentage fill
2-Step
Or Cruciform- Core
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Area of circumcirc le
d 2
4
0.625d 2 / 0.9
2
(d )
4
= 0.885 or 88.5%
No of steps
1
2
% Fill
63.7% 79.2%
3
84.9%
4
88.5%
5
90.8%
6
92.3%
7
93.4%
9
94.8%
11
95.8%
Ww=
(D-d)
Q
3.33 f A i Bm K w 10 3
where
m2
Kw = 0.15 to 0.20
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8
L
Aw
width of window(Ww )
(L Ww Aw )
Generally
L
2 to 4
Ww
Yoke area Ay is generally taken 10% to 15% higher then core section area (A i), it is to reduce the iron loss in
the yoke section. But if we increase the core section area (A i) more copper will be needed in the windings
and so more cost through we are reducing the iron loss in the core. Further length of the winding will
increase resulting higher resistance so more cu loss.
Ay = (1.10 to 1.15) Ai
a
Depth of yoke
Dy = a
b
Height of the yoke
hy = Ay/Dy
Width of the core
W = 2*D + d
Height of the core
H = L + 2*hy
b
Ai
Bm
Ay
2-Step
Or Cruciform- Core
= 3*L*Ai
m3
= density * volume
= i * 3*L*Ai
Kg
i = density of iron (kg/m3)
=7600 Kg/m3 for normal Iron/steel
= 6500 Kg/m3 for M-4 steel
From the graph we can find out specific iron loss, pi (Watt/Kg ) corresponding to flux density Bm in core.
So
Iron loss in core
Similarly
Iron loss in yoke
Where
=pi* i * 3*L*Ai
Watt
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9
Ic
Pi
3V1
atcore / m,
So
MMF required for the core
MMF required for the yoke
= 3*L*atcore
= 2*W*atyoke
Bc at yoke / m
I m, peak
2
Total MMF required
3 2 N1
Ic Im
V1=-E1
Io
Ic
Ic
Io
Im
The no load current should not exceed 5% of the full the load current.
E2
ESTIMATION OF NO OF TURNS ON LV AND HV WINDING
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10
V1
Et
V
N2 2
Et
N1
Primary no of turns
Secondary no of turns
I1
Q 103
3V1
Secondary current
I2
Q 103
3V2
OR
N1
I1
N2
I1
I2
Sectional area of secondary winging a2
a1
Lmt N 2 (m)
a2 ( m 2 )
R2 , ac , 75 o (1.15 to 1.20) R2 , dc , 75 o
3I12 R1
Watt
2
3I 2 R2
Watt
2
3I1 R1 3I 22 R2
3I12 ( R1 R2' )
3I12 R p
Where
R01 R p R1 R2'
Total resis tan ce referred to primary side
Note: On No load, there is magnetic field around connecting leads etc which causes additional stray losses
in the transformer tanks and other metallic parts. These losses may be taken as 7% to 10% of total cu losses.
DETERMINATION OF EFFICIENCY:
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11
Efficiency
Output Power
Input Power
Output Power
Output Power Losses
Output Power
100
Output Power Iron Loss Cu loss
b1
Lc
a
dx
b2
A
o
L
Lmt dx
Lc
1 L
o A
& Permeance
N1I1=N2I2
dx M x Permeance
N1 I 1
L dx
x o mt
b1
Lc
N1 I1 N1 I1
L dx
x o mt
b1
b1
Lc
x
MMF Distribution
Lmt x
dx
o N
I1
Lc b1
2
1
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12
o
2
L
b a
1 o N 12 mt I 1 1
Lc 3 2
Similarly total flux linkages with secondary winding
2 2' o
2
L
b a
2 o N 22 mt I 2 2
Lc 3 2
Primary & Secondary leakage inductance
L b a
L1 1 o N 12 mt 1
1 1'
I1
Lc 3
L b a
2
o N 22 mt 2
I2
Lc 3 2
Primary & Secondary leakage reactance
L2
Lmt b1 a
Lc 3 2
Lmt b2 a
Lc 3 2
Total Leakage reactance referred to primary side
X 2 2fL2 2fo N 22
X 01 X P X 1 X 2' 2f o N 12
Lmt b1 b2
Lc
3
Lmt b1 b2
Lc
3
V .R.
% Ro 2Cos2 % X o 2 Sin2
13
lt= De + 2a
Where
a= Clearance depth wise between HV and tank
Height of transformer (Tank)
Ht= H + h
Where
h=h1 + h2= Clearance height wise of top and bottom
W
hy
Ww
(D-d)
a
lt
De
b
a
Wt
h1
W
Ht
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h2
14
So temp rise in o C
If the temp rise so calculated exceeds the limiting value, the suitable no of cooling tubes or radiators must be
provided
CALCULATION OF NO OF COOLING TUBES:
Let
Then
So from above equation we can find out total surface are of cooling tubes (xSt)
Normally we use 5 cm diameter tubes and keep them 7.5 cm apart
At= Surface area of one cooling tube
d tube l tube , mean
Hence
No of cooling tubes
xSt
At
7.5 Cm
d= 5 Cm
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Tank and Arrangement of Cooling tubes
15
WEIGHT OF TRANFORMER:
Let
Wi = Weight of Iron in core and yoke (core volume* density + yoke volume* density)
Wc= Weight of copper in winding (volume* density)
(density of cu = 8900 Kg/m3)
Weight of Oil
= Volume of oil * 880
Add 20% of (Wi+Wc) for fittings, tank etc.
Total weight is equal to weight of above all parts.
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Kg
Kg
Kg