TRANSFORMER DESIGN

Here we will establish a working Design of a 1250KVA T/F, the brief Specifications of which are
as Follows

Remembers some important configuration during Design the T/F

 Transformer =T/F
 Voltage per phase on primary side=Vpp
 Voltage per phase on secondary side =Vsp
 Line voltage primary side =Vp
 Line voltage secondary side=vSL
 Line current primary side =Ipl
 Phase current on primary side = Ipp
 Phase current on secondary side=Ips

In delta Connection
 VL=Vp
 Ip=IL/√ 3

In star connection
 IL=Ip
 VP=VL/√ 3
Propose Specification
Rating 1250KVA
No Load voltage Ratio 33Kv/11kv
No of phase 3-phase
Frequency 50Hz
Connection Delta/Delta-Ddn
Winding material Aluminum
No load/Load losses 694W/10912W
Impendence 5.12%
Maximum flux Density 1.6Tesla
Maximum current Density 1.8 A/(mm)2
Temperature 45/50°C
K 0.37
Stacking Factor 0.95

Primary coil Design

Voltage per phase Vp=33Kv
Phase current 1250× 1000
IP= =12.63A
3× 33 ×1000
Current density (assumed) 1.8 A/mm2
Conductor Area 12.63
=7.02mm2
1.8
Equivalent conductor diameter π d2
=7.02
4
d=3.005mm
Let’s us propose to select the next round
figure d=3.1mm
Area of the propose conductor π d2
=7.55 mm2
4
There the working current density is 12.63
=1.672A/mm2
7.55

Numbers of turns
Voltage per turn

Et=k√ Q
 Et= (.37)√ 1250 =13.08

secondary phase voltages 11000

No of secondary turns= = = 841T
Et 13.08

Vpp
No of primary turns at normal side= ×secondary turns
Vsp

33000
= ×841
11000

=2523T

No of coil =4

Turns per coil =631T

Estimating the core Height

Descriptions Length Radial
Bare conductor 3.1mm 3.1mm
Covering thickness toward DPC (+)0.3mm (+)0.3
Covered conductor 3.4mm 3.4mm
Gap B/W two consecutive (+)0.05 (+)0.05
conductor
Insulating Size of conductor with 3.45mm 3.45mm
working tolerance 0.2(4 mil intra layer paper)
Turns per layer 3.65mm
631 ×59 ×11
( +1)
11
Axial length of HV coil Rounded 203.55mm 40.15mm
off to 204mm 41mm(round off)

 Total axial length of four coils =4×204=816mm

 Gap B/W yoke to top and bottom coil =2×25=50mm
 Gap B/W plain coil =03×15=24mm
 TOTAL W/H =911mm
 Round off =915mm

Secondary coil Design

Voltage per phase Vsp =11000v
Current per phase 1250× 1000
Isp= =37.88A
3 ×11000
Current density (assumed) Cd=1.8 A/mm2
Conductor Area 37.88
=21.04 A/mm2
1.8
Here diameter is greater than 3.5 mm so we d=5.175
will us strip
No of strips proposed to be used in parallel 2 no’s
Approximate Area of each strip 21.04
=10.52 mm2
2
Disposition of strip 1 w ×2D
No of turn per phase 121 T
Space required to accommodate (+)1
Since the strip are placed one above the other (+)1
so we will take one turn to Transposition
Gap B/W Lv coil to yoke at the top and the 2×15
bottom =30mm
Axial length available to accommodate 123T 915-30=885mm
Approximate width of Lv strip, including DPC 885/123
covering and with working tolerance =7.195
Air Gap B/W two consecutive conductor 0.1mm
Therefor width of the bare conductor 7.195-(0.1+0.4)=6.695mm
Let us round off 6.5mm
Area of Each strip 10.52mm2
Therefore the approx. depth of bare 1.576mm
conductor
Let’s us round off 2mm
Area of proposed strip with 1 D 6.5×2=13
Reduce the rounding of Factor if depth is 13-0.36
(1.7mm-2.24mm )then we will use Rounding =12.64
off Factor=0.36mm
Both strip having proposed Area 25.28mm2
Working current density 37.88
=1.498 A/mm2
25.28

Estimating the coil length

Descriptions Length Radial
Bare strip size 6.5mm 2mm
Covering thickness strip size (+)0.4mm (+)0.4mm
 with DPC
GAP B/W consecutive (+)0.1mm (+)0.1mm
conductor
Insulated size of strip 7mm 2.5mm
Placement of strip(1W×2D) 1W 2D=5mm
Effective dimension of each 7mm 5mm
turn
No of turns (×)123 (×)7+(0.25×6)
Length of coil 861mm 36.5
End packing each 12mm 37(round off)
With End packing 12×2=24mm
Total length of Lv coil with 885mm 37 (Radial build of LV)
packing

CORE DIAMETER
11000
Voltage per turn (Et) = = 13.079
841

Flux density =1.6Tesla

Frequency =50Hz

Stacking factor =0.95

Gross core Area (to be calculated in) =Ag in cm

Et=4.44×f×Bm×Ag×0.97×10-4

13.079 ×10000
Ag=
4.44 × 50× 1.6 ×0.95

=387.59cm2

=387.6cm2

Let us conceive a core stack of 11th steps having rounding off factor 0.945

π d2
×0.945=387.6
4

D=22.852 cm

D=228.52mm
D=229(round off)

Step width
L1 225mm
L2 220mm
L3 215mm
L4 210mm
L5 200mm
L6 190mm
L7 180mm
L8 170mm
L9 160mm
L10 150mm
L11 140mm

Core stack
Calculation of core stack (k)

K =√ d 2−L2

D= is the diameter of the core

L=is the length of the core stack

L1 =√ 2292−2252 =42.61mm =42.61mm

L2=√ 2292−2202 =63.568-42.61 =20.95mm

L3=√ 2292−2152 =78.84-63.568= 15.2816mm

L4=√ 2292−2102 =¿91.329-78.84 =12.489mm

L5=√ 2292−2002 =111.539-91.329 =20.210mm

L6=√ 2292−1902 =127.83-111.539 =16.292mm

L7=√ 2292−1802 =141.56-127.83 =13.736mm

L8=√ 2292−1702 =153.430-141.56=11.870mm

L9 =√ 2292−1602 =163.832-153.430 =10.402mm

L10=√ 2292−1502 =173.034-163.832 =9.2026mm

L11=√ 2292−1402=181.220-173.034=8.186mm

Kt =181.2292mm

CORE AREA
Gross Core Area =387.6 cm2

Net Core Area =387.6×0.95

=368.22cm2

Flux Density
13.07 ×10000
Bm=
4.44 × 50× 0.95 ×387.6

Working Flux Density= 1.599Tesla

Coil Diameter and Core Limb Center

Coil diameter and core limb center can be determined as under

Core diameter =229mm

Radial build of Lv =37mm

Radial build of Hv =41mm

Radial clearance B/W

Core to Lv coil =3mm

Radial clearance B/W

Lv and Hv =10m

Description Radius Diameter

Core diameter 114.5×2 229mm
Radial Gap 3mm 6mm
LV coil inside diameter 117.5mm 235mm
Radial of Lv 37×2 74mm
Outside diameter of Lv 154.5mm 309
Gap B/W Lv and Hv 10mm 20mm
Inside diameter Of Hv 164.5 329
Radial of Hv 41mm 82mm
Outside diameter 205.5 411mm
Gap B/W Hv limb B/W phases 13mm
Core limb center 424mm

Core frame size and other core details:

Core diameter =114mm

Window height (W/H) =915mm

Limb center (C/L) =424mm

Grade of Core =27-M-4

Gross core Area =387.6cm2

No of core step =11th

Core step width =225/220/215/210/200/190/180/170/160/150/140

Core stack =42.61/20.95/15.2816/12.489/20.210/16.292/13.736/11.870/10.402/9.202/8.186

Total core stack =181.2292mm

Approximate of core Weight

Weight of complete set of core in Kg

= [(3xW/H+4xC/L) + (2xwidth of 1 st stepx0.86)] x gross core area x density of core material

x0.97x10-3

All values putting in centimeter

=554.60Kg

Core chart specification

Material : CRGO, GRADE –M4

Thickness : 0.27mm

Core diameter: 229mm

Window height: 915mm

Limb center : 424mm

Weight/s : 554.60Kg

Weight of LV and Hv Aluminum

Particulars LV coil HV coil
Inside diameter of coil(D1) 235mm 329
Outside diameter of coil (D2) 309mm 411mm
D1+ D 2 272mm 370mm
Mean diameter of coil [Dm= ]
2
Mean length of Turns ( L1=π×Dm) 855mm 1163mm
No of turns (T) 841T 2523T
Total length of conductor (L=L1×T) 719055mm 2934249mm
Specific gravity of Aluminum(s) 2.76 g/cc 2.76 g/cc
Cross-sectional area of the conductor (A) 25.28mm2 21.04mm2
Bare weight of the conductor being used on one 50.17Kg 170.393kg
phase(L×A×S×10-6)
Bare weight conductor used for 3 phase 150.51kg 511.179kg
Weight of the covered conductor used 161.05kg 582.744kg
(7% for Lv)and (14% for Hv )
Winding Resistance and load loss
Particular LV coil Hv coil
Inside diameter of coil(D1) 235mm 329
Outside diameter of coil (D2) 309mm 411mm
D1+ D 2 272mm 370mm
Mean diameter of coil [Dm= ]
2
Mean length of Turns ( L1=π×Dm) 855mm 1163mm
No of turns (T) 841T 2523T
Total length of conductor (L=L1×T) 719055mm 2934249mm
Resistivity of Electrolyte aluminum (k) 0.0345 ohm/cm at 75°C 0.0345 ohm/cm at 75°C
Cross-sectional area of the conductor(A) 25.28mm2 21.04mm2
winding Resistance per phase at 75℃ 0.981 ohm 4.811ohm
L× K × 0.001
[R= ¿
A
Current per phase 37.88A 12.63
I2×R ×3 phase at 75℃ 4222.89W 2302.30W
Total I2R(LV+HV) 6525.19W
Approx. stray losses 100W
Load loss at rated load end at 75℃ 6625.19W
Load loss (guaranteed) 6700W Maximum

No load losses
Core diameter 229mm
Core window height 915mm
Core limb center 424mm
Gross core Area 387.6 cm2
Net Core Area 368.22cm2
Working flux density 1.599Tesla
Grade of core 27-M4
Specific loss (watts/kg) at1.6tesla 1.0W/kg
Handling factor (25%) 25%
Effective core loss per kg including H.F 1×1.25=1.25w/kg
Total weight of core being used 554.60Kg×1.25
=693.25W
No load losses(guaranteed) 720W
  No load current at 100%

Since the measurement of current is done on the low voltage side, we shall establish the
relation by the taking the reference of secondary phase voltage.

I. The magnetizing component of no-load current:

Magnetizing VA/Kg at 1.6Tesla = 1.6 VA/Kg

Vsp=11000v

Weight of complete set of core =554.60kg

1.6× 554.60
Im= =0.0268A
3 ×11000

Add 200% towards the handling factor for stress.

Im =0.0268+(0.0268×2)=0.0804A

II. Hysteresis and eddy current component is calculated from no-load loss
and rated secondary phase voltage:
No Load loss 693.25
I (h+e)= = = 0.0193A
3× phase voltage 3× 11000

III. No load current at 100% voltage

Io =√ ℑ2+ I (h+ e)2

=√ 0.08042 +0.01932

= 0.0826 A

No load current at 100% voltage as a percentage of full load current

0.0826 ×100
=
37.88

=0.218%

 No load current at 112.5% voltage

 Flux density at 112.5% voltage =1.6×1.125 =1.8tesla

 Magnetizing component of no load current

Magnetizing VA/Kg at 1.8 tesla is = 7VA/kg
V=1.125% of the phase voltages =11000×1.125=12375v

7 ×554.60
I m= =0.1045 A
3× 12375

Adding 200% in magnetizing current

Im=0.1045+0.2091=0.3136 A

 The Hysteresis and Eddy current component at 112.5%

No load loss at 1.8T with 25% handling factor=554.60×1.9×1.25=1317.175W
1317.175
Therefore I (h+e)= =0.0354A
3× 12375

No load current at 112.5% voltage:

Io =√ ℑ2+ I (h+ e)2

=√ 0.31362 +0.0354 2

=0.3155 A

No load current at 112.5% voltage as percentage of full load current:

0.3155× 100
=
37.88

=0.8328%

Percentage Reactance, Resistance and Impedance

Calculation of percentage reactance, percentage resistance and percentage

impedance

 Percentage reactance
2
b 1+ b 2
X (%)= 7.91× f ×VsI s××Alπ ×T ×D -6
(a+ 2 )×10
 = 5.528%

Multiplying the above by 0.95 toward leakage flux

Therefore the calculated value of X(%)=5.528×0.95

=5.252%

 Percentage resistance
calculated load loss∈kw
R (%)= ×100
Rated KVA
Where calculated load loss=6.625Kw
R (%) =0.53%

 Percentage Impedance
Percentage impedance is the victoria sum of X(%) and R(%)

Z (%) =√ x (%)2 + R(% )2

=√ 5.2582 +0.532

=5.2846%

Efficiency
Calculation of Efficiency at different load at different power factors

output
Efficiency= × 100
(output +losses)

1. Efficiency at the rated load and at unity power factor

(1250)
= × 100
(1250+0.639+ 6.625)
=99.42%

2. Efficiency at the 75% load and at unity power factor

(1250 × 0.75)
= ×100
(1250 ×0.75)+0.639+(0.752 × 6.625)

=99.53%
 3 Efficiency at the 50% load and at unity power factor

(1250 × 0.50)
= ×100
(1250 ×0.50)+0.639+(0.502 ×6.625)

=99.63%

4 Efficiency at the 25% load and at unity power factor

(1250 × 0.25)
= ×100
(1250 ×0.25)+0.639+(0.252 × 6.625)

=99.66%

4 Efficiency at the any % of load and at unity power factor

(1250 × n)
×100
(1250 ×n)+0.639+(n2 ×6.625)
5 Efficiency at the 75 % of load and at 0.8 power factor
(1250 × 0.75× 0.8)
= ×100
(1250 ×0.75 × 0.8)+ 0.639+(0.752 ×6.625)
=99.42%
6 Efficiency at the 50 % of load and at 0.8 power factor

(1250 × 0.50× 0.8)

= × 100
(1250 ×0.50 × 0.8)+ 0.639+(0.50 2 ×6.625)

=95.54%
7 Efficiency at the 25 % of load and at 0.8 power factor

(1250 × 0.25× 0.8)

¿ ×100
(1250 ×0.25 × 0.8)+0.639+(0.252 ×6.625)

¿ 99.580%

8 Efficiency at the any % of load and at 0.8 power factor

(1250 × n× Pf )
= ×100
(1250 ×n × Pf )+0.639+(n2 × 6.625)

Maximum Efficiency
 Transformer will yield Maximum Efficiency at a load when the no load losses and
load losses are equal and may be represented as
No load losses
K=load at which maximum Efficiency will get:
√
load losses

( KVA × K )
= ×100
( KVA × K )+ No load +(k 2 ×6.625)
No load losses =0.693Kw
Load losses =6.625Kw
0.639
K=
√6.625
K=0.3105
At 31.5% load, maximum Efficiency will occur:

(1250 × 0.3105)
= ×100
(1250 ×0.3105)+0.639+(0.31052 × 6.625)

¿ 99.671%

Regulations
The voltage ratio defined for any transformer is at no load. During loading the load
voltage drops down, based on its percentage reactance and resistance .For any
assumed load other than the rated load and at any power factor, the percentage
regulation is approximately equal to:

Formula
(n . Ex % . cos ( θ )−n . Er % .sin ( θ ) )2
(n.Er%.cos (θ) +n.Ex%.sin (θ))+
200

Regulation at rated load and at unity power factor

(n . Ex % . cos ( θ ))2
(n.Er%.cos (θ))+
200
2
( 5.28 )
=0.53+
200
=0.669%
 Regulation at rated load and at 0.8 power factor
(5.284 × 0.8−0.53 × 0.6)2
(0.53×0.8 +5.284×0.6)+
200
=3.67%

Design of the Tank

I. The following assumptions are made while calculating the tank dimensions:
II. Gap B/W Hv coil to the inside of tank on length side -25mm
III. Gap B/W Hv coil to the inside of tank on width side -40mm
IV. Gap B/W core yoke to tank bottom -40mm
V. Gap B/w core yoke to ratio switch base -20mm
VI. Height of ratio switch -90mm
VII. Gap B/W ratio switch top to the inside of tank cove -40mm
Based on the above internal clearances, let us form the tank dimension as follows
 Length if tanks (inside)
= 2×C/L of core + HV coil O.D + 2×25mm
=2×424mm+411mm+50mm
=1309mm
=1310mm (round off)
 Breadth of tank (inside)

=Hv coil O.D. + 2×40mm

=411mm+80mm
=491mm
=495mm (round off)

 Height of tank (up to tank flange):

=40+ bottom yoke insulation + W/H of core + 2width of 1st core step +20 + R/s height +40mm

=40 + 5 + 915 + 2×225 + 20 + 90 + 40

=1560mm

Therefore the final Dimension of the tank is

 Length = 1310mm

Breadth = 495mm

Height = 1560mm