4 ELECT; RICAL wy 1 DESIGN PROBLEMS MACHINE Desig, em I. Design a 25 BVA, 11000/433 V, 50 He, 3 ibutic . The tre is ‘ " core - ed distribution transformer. ransformer is ore tpe, oil i Minding. Maxtnum temperature rise not to exceed 45°C th tings «ype ty mean temperature rise Phase, delta/star, 11 c00 hv. °C. . ; serston. Core Design. The value of K is taken from Table 6.2 sorry for three phase core type distribution transformers, Voltage per turn E,=K JQ = 0.45 /25 = 2.25 v. 1 E 225 tg rluvin the core ©, = Fag 7" Gaqy gp = 0-000135 Wo. sot rolled silicon steel grade 92 is used. The value of ux density B. is assumed | . eee in ed as : 010135 Net iron area A, 01035 m? = 10.135 x 10° mm? Using a cruciform core, A; = 0.56 @ Diameter of circumscribing circle d = 10135 x 107/056 = 134.5 mm. Reference Figs. 5.52 and 5.53(a), widths of laminations : a= 85, d = 0.85 x 135.8 = 114.8 mm, 6 = 0.53 d = 0.53 x 135.8 = 71.6 mm. The laminations are punched from 750 mm wide plates and the nearest standard dimensions i = 114 mm and b = 73 mm. Window Dimensions. The window space factor for a small rating transformer is K,, = 8(30 + kV). K,, = 8(30 + 71) = 0.195. The value assumed is K,, = 0.18 ‘The current density in the windings is taken as 2.3 A/mm?, Output of transformer Q = 3.33 /B,, K, 6A, A; x 10% 25 = 3.88 x 50 x 1x 0.18 x 2.3 x 10% x A, x 0,010195 x 10% or window area A,, = 0.0358 m? = 35.8 x 103 mm?. ‘Taking the ratio height to width of window as 2.5, H, x W,, = 35.8 x 108 or 2.5 W,,? = 3.8 x 10°. “: Width of window W,, = 120 mm and height of window = 300 mm. Area of window provided A,, = 300 x 120 = 36 x 10° mm? = 0.036 m, Distaned between adjacent core centres D = W,, + d = 120 + 196 = 265 mm. Yoke Design. The area of yoke is taken as 1.2 times that of limb. * Flux density in yoke = 1/1.2 = 0.0833 Wb/m?. t area of yoke .2 x 10.135 x 103 = 12.16 x 10° mm’, ic area of yoke 2.16 x 109/0.9 = 13.5 x 10° mm’. ng the section of the yoke as rectangular. Deoth of yoke D,=a=1l4mm * Height of yoke H, = 13.5 x 10/114 = 114 mm Yerall Dimensions of Frame. Reference Fig. 5.70. wie of frame H =H, + 2H, = 300 + 2x 114 = 628 mm. > th of frame = W= 2D +a = 2x 255 + 114 = 624 mm. “pth of frame Dy 114 mm. — aie Scanned with CamScannerDESIGN OF TRANSFORMERS 5.113 LY. Winding : Secondary line voltage 33 V ; Connection = star. Secondary phase voltage V, = 439/48 = 250-V. : Number of turns per phase T, = V/E, = 250/2.25 = 111. Secondary phase current aoe 7 3 x 250 = 33,3 A. ‘Acurrent density of 2.3 A/mm? is used. ‘area of secondary conductor a, = $3.9/2.8 = 14.48 mm. From Table 23.1 (IS : 1897-1962), using a bare eonduetor of 7.7 x 2.2 mm, ‘Area of bare conductor a, = 14.9 nim’. Current density in secondary windings 8, = 83.4/14: ‘The conductors are paper covered. The increase in di is 0.5 mm. Dimensions of insulated conductor = 7.5 x 2.7 mm. Using three layers for the winding. Helical winding is used. ‘Therefore spa axial depth. ‘Axial depth of L.v. winding L,, = 38 * axial depth of conductor ‘ize height of window is 300 mm, This leaves a ciearem of the winding, (The minimum clearance should be 6 mm for windings havi 500 V.) Using 0.5 mm pressboard cylinders between layers, Radial depth of Lv. winding 8, = number of layers * radi 23x27+2%05=9.1 mm. Fig. 5.88 shows a cross-section through Ly. coil, 0.5mm Press boord 9 = 2.23 Alm? ‘mensions on account of paper covering ce has to be provided for (37 + 1) = 98 turns along the 38 x 7.5 = 285 mm. ce of (300 ~ 285V2 = 7.5 on each side ing voltages below ial depth of conductor + insulation between layers a 7S. LLLLLLLILILLLLL LLL ELLA Scanned with CamScanner5.114 ELECTRICAL MACHINE DESIGN Diameter of circumscribing circle d = 135 mm, Using pressboard wraps 1.5 mm thick as insulation between l.v. winding and core. Inside diameter of L.v. winding = 195 + 2 x 1.5 = 138 mm. Outside diameter of L.v, winding = 138 + 2 x 9.1 = 156.2 mm, HLV. Winding : Primary line voltage = 11000 V. Connection = Delta Primazy phase voltage V, = 11000 V. = Number of turns per phase 7,, = 11000 x 111/250 = 4884. As 6% tappings are to be provided, therefore, the number of turns is increased to T,, = 1.05 x 4884 = 5128. i voltage per coil is abut 1500 V. _, Using 8 coils, Voltage per coil = 1100/8 = 1375 V. Turns per coil = 5158/8 = 641. Using 7 normal coils of 672 turns and one reinforced coil of 424 turns. Total hwy. turns provided 7, = 7 x 672 + 424 = 5128. ‘Taking 24 layers per coil. Turns per layer = 674/24 = 28, Maximum voltage between layers = 2 x 28 x 2.25 = 126 V, which is below the allowable limit. 25 x 1000 HL. winding phase current I, = 759 = 0.757 A. Taking a current density of 2.4 A/mm, Area of hv. conductor a, = 0.757/2.4 = 0.316 mm?, Diameter of bare conductor= (4/n x 0.316)!” = 0.635 mm. Using paper covered conductors. From Table 23.4 (BIS : 3454 ~ 1966) the nearest standard luctor size has : /- ave diameter = 0,63 nm, insulated diameter = 0.805 mm with fine eovering. Modified area of conductor a, = x/4 x (0.63)? = 0.312 mm. Actual value of current density used 8, = 0.757/0.312 = 2.43 A/mm?. Axial depth of one coil = 28 x 8.05 = 22.6 mm. The spacers used between adjacent coils are 5 mm in height. Axial length of h.v. winding al depth of each coil + depth of spacers L,, = number of evi =8x 226 +8x 5 = 221 mm. ‘The-height of window is 300 mm and therefore, the space left between winding and window is 300-221 = 79 mm. This is occupied by insulation and axial bracing of the coil. The clearance left on each side is 39.5 mm, which is sufficient for 11 kV transformers. ‘The insulation used between layers is 0.3 mm thick paper. ~ 2, Radial depth of hv, coil b,, = 24 x 0.805 + 23 x 0.3 = 26.22 mm. From Eqn. 6.22 the thickness of insulation betwe een hv. and 1. =5+0,9 kV =5 +09 x 11 = 15 mm, This includes the width of oil duct also. ‘The insulation between h.v. and Lv. winding is a 8 mm thi s ck bakelized paper cylinder. Th hv. winding is wound on a former 5 mm thick and the duct is 5 mm wide, aki the total insulation between h.v. and Ly. windings 15 mm, 5 winding As the current is below 20 A, cross-over coils are used for h.v. winding. | canne Te ncd win CamOCanner amScannerSCS Se Sena SO ER DESIGN OF TRANSFOI RMI ERS 5.115 ++ Inside diameter of h.v, winding = outside diameter Lv. winding + 2 x thickness of insulation 156.2 +2 16 = 186.2 mm, eC of hv. winding = 186.2 + 2 x 26.22 = 238.64 mm = 289 mm een windings of two adjacent limbs = 255 — 239 = 16 mm. Resistance : Mean diameter of primary winding = 28824259 = 212 mm. 2 Length of mean turn of primary winding L,,, = % x 212 x 10° = 0.666 m. Ty PLintp Resistance of primary winding at 75°C r, = 7 ay = 4884 «0021 x 0658 o9.90 0312 1981562 aoe Length of mean turn of secondary winding L,,., 111 x 0021 x 0468 _ 9.9739 0 149 Mean diameter of secondary winding = xx 149 x 10° = 0.468 m. Resistance of secondary winding at 75°C, r, 2 Total resistance referred to primary side R, = 219.2 + (2%) x 0.0732 = 364.2. 1, Ry x (Ry _ 0757 x 364 _ 9 o95. P.U, resistance of transformer ¢, ano Leakage Reactance : Mean diameter of windings = (138 + 239)/2 = 188.5 mm. = x x 188.5 x 10° = 0.592 m. Length of mean turn L,,, (Dy + Lpl2 = (221 + 2852 = 253 mm. Height of winding L, = referred to primary side Leakage reactance of transformer Ln {bv . 2 Lm {g , bo X, = xf wT? [a | wT) 0592) (,, , 2622+ 91) 2 Dn x 50 x 4x x 10°7 x (4884)? x (22) x (18+ ) x 10% = 590 2. P.U. leakage reactance ©, 757 x 590/11000 = 0.0406. 0.0477. (0.025)? + (0.040 Regulation. P.U. regulation « = ¢, cos @ +6, sin Por unit regulation at unity power factor ¢ = ¢, = 0.026, at zero p.t lagging © at 0.8 pil lagging © = 0.025 x 0.8 x 0.0406 x 0.6 = 0.0444, P.U. impedance 0.406, Losses + PR Loss "PR loss at 75°C, = 31,2 R, = 3 * 0.757 x 364 = 626 W. Scanned wih neemrr a 5.116 ELECTRICAL Macuis aking stray Toad Toss 15% of above. MACHINE Deston 8 oss including steny Toad Toss P, = 1.16 x 626 = 720 w ‘Total pre Loss , oo Taking the density of laminations as 7.6 x 10° kg/m, weight of 3 Himbs = 9 * 0.3 x 0.010136 « 7.6 « 103 = 69.3 kg naity in the limbs is 1 Wh/m? and i a Ng (Gee Fig, 429) Corresponding to this density, specie core iss is 12 Loe in firs = 69.3 x 1.2 = 83.2 W. | Weight of two Yokes = Ee 0.624 ; 0.01216 « 7.6 x 10° = 116.3 kg to a flux density of 0.833 Wh/m? in th = Core los ve yoke = 115.3 x 0,85 = 98 W. e yoke, the specific core loss = 0.85 W. yal eore loses: P, = 83.2 + 980 = 181 W. Efficiency- ‘Total losses at full load = 181 + 720 = 901 W, Correspondin 25000 Efficiency at full load and unity P-L = 555594 gor * 100 = 96.5 per cent For maximum efficiency x? P, = P; x= (RIP. = fieis7a = 9.9501 Thus maximum efficiency occurs at 50.1 percent of full load. This is a good figure for gistribution transformers. No load current. Corresponding to flux densities of 1 Wb/m? and 0.833 ‘Whim? in core and yoke respectively af, = 120 A/m and at, = 80 A/m. (See Fig. 3.3) "Total magnetizing mmf = 3 x 120 x 0.3 + 2 x 80 x 0.624 = 207 A. Magnetizing mmf per phase AT, = 207/3 = 69 A. Magnetizing current I, = ATY(V2 T,) = 62/12 x 4884) = 5.5 x 107 A. Loss component of no load current J, = 18/3 x 11000 = 5.5 * 107A. = (10x 1079)? +65 «1 114x 103A. a MAXIO™ «190 = 15%. No ioad current as a percentage of full load current = —T757 | | Allowing for joints ete. the no load current will be about 2.5% of full load current. | the base and about 150 mm for | Tank. Height over yoke H = 328 mm. Allowing 60 mm at «il, Height of oil level = 528 + 50 + 150 = 728 mm. Allowing another 200 mm height for leads ete.. height of tank H, = 728 + 200 = 928 mm. ‘The height of tank is taken as 0.95 m or H, = 0.95 m. Assuming a clearance of 40 mm along the width on each side | Width of tank W, = 2D + D, + 21 = 2 x 255 +290 + 2x40 = 829 mm. “Phe width of tank W, is taken as 0.84 m. Te be clearance along the length of the transformer is greal fo additivnal space is needed along the length to accom sed is approximately 50 mm on each side. Length of tank L, = D, + 2b = 239 + 2 x 60 = 339 mm ‘The length of tank L, is taken as 0.35 m Total loss dissipating surfae of tank S, = 2(0.84 + 0.35) Total specific loss dissipation due to radiation and convection & = ‘Temperature rise = 9012.26 x 12.5) = 31.9°C a is below 35°C and therefure plain tank is sufficien ig. 5.89 shows core and winding details of the transformer 73mm 7. Netiron area A, 10.135 10 mm? 8, Flucdensity B, 10Wbin? 9. Flux on 10.135 Wb 10. Weight 693ke 11, Specific iron loss 12 Wag 12, Iron loss s32W Yoke 1. Depth of yoke d, 14mm 2. Height of yoke 4, 14mm 3. Net yoke area 12.16 « 10% mim? 4. Fluxdensity 0.833 Wein? 5. Flax 10.135 n Wo 6. Weight Us. akg 1. Specific iron loss 08 Wiis 8. Iron loss Ww Windows 1. Number 2 2. Window space factor K, 018 3. Height of window 4, 300 mm 4. Width of window W, 120 mm 5. Window area A, 36 10! mint Frame 1. Distance between adjacent limbs Dp 255 mm 2. Height of frame H 536mm - 3. Widthof frame Ww 4. Depth of frame 2B, ee Scanned with CamScanner| | | DESIGN OF TRANSFORMERS 5.119 Windings Ly. HY 1. Type of winding holical Cross-over 2 Connections Star Delta 3. Conductor Dimensions-bare 7.0% 2.2 mm? Diameter = 0.63 mm insulated 7.6% 2.7 mm? Diameter = 0.814 mm Area 4.9mm? 0.312 mm? ‘Number in parallel None None 4. Currentdensity 2.23 Nim? 2.43 An? 8. Tumsper phase m1 4884 (5128 at -5% tap) 6. Coils total number 3 3x8 per core leg 1 8 ‘Turns per coil m1 7 of 672 turns, 1 of 424 turns perlayer 4 8 8, Number of layers 3 u 9, Height of winding 285mm 221mm 10. Depth of winding 9.1mm 26mm 11. Insulation Between layers 0.5 mm press board 0.3 mm paper Between coils 5.0mm spacers 12, Coil Diameters Inside 138mm 186.2mm Outside 156.2mm 239mm 13, Length of mean turn 0.468m 0.666m 14. Resistance at 75°C 0.07320 21929 Insulation 1. Between Lv. winding and core ress board wraps 1.5 mm 2 Betweenlv. windingandh.v. winding =bakelized paper 6.0 mn 3, WidthofductbetweenLv.andhy. =5 mm Tonk 1, Dimensions : height H, 095m length L, 035m width W, 084m % OilLevel 0.728 m 3. Tubes Nil 4, Temperature rise 31.9C Impedance 1. PLU. Resistan 2 PLU Reactance a 3. PU. Impedance o0406 Losses oad 1, Total core loss 2 Total copper loss nny) 8. Total losses at full oad poo 4, Efficiency at fll oad and w pf on 6.5% Scanned with Camecanner