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Design Engineering

Noel Jennings, a design engineer, is creating a design brief for a 3 phase power transformer to simulate working for a client in the electrical power industries. The design brief specifies a 30-2500 kVA dry type transformer or 315-2500 kVA on-load tap changer transformer that meets the following specifications: 10kV, ANSI standards, current limiting fuses, delta connected primary voltage of 12,470V, secondary voltages of 120/208Y or 277/480Y, 60Hz, 98% copper coil, impedance between 4-7%, NEMA noise levels, and lightning arrestors if not protected by switch. The transformer would be designed following standard procedures considering parameters like resistivity, current,

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50 views6 pages

Design Engineering

Noel Jennings, a design engineer, is creating a design brief for a 3 phase power transformer to simulate working for a client in the electrical power industries. The design brief specifies a 30-2500 kVA dry type transformer or 315-2500 kVA on-load tap changer transformer that meets the following specifications: 10kV, ANSI standards, current limiting fuses, delta connected primary voltage of 12,470V, secondary voltages of 120/208Y or 277/480Y, 60Hz, 98% copper coil, impedance between 4-7%, NEMA noise levels, and lightning arrestors if not protected by switch. The transformer would be designed following standard procedures considering parameters like resistivity, current,

Uploaded by

Noel Jennings
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as DOCX, PDF, TXT or read online on Scribd
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Express transformers

Noel Jennings

Operations Engineering

Engineering Design

Design Brief

My name is Noel Jennings. I am a design engineer who has experience in the petrochemical, and the
commercial electrical installation industries. I have decided to design a 3 phase power transformer
for my design brief. This would simulate working for a client as a electrical design engineer focused
on the electrical power industries. A sector which I could develop in after I attain the qualification.

A design brief specified by a customer would be for a 3 phase transformer for use in the power
industries.

Example of 3 phase that may need to be replaced in a power generator for a


nuclear power station. This was similar to a model that was specified to be replaced recently.

The design specification is as follows:

30 ~ 2500 kVA Dry type transformer


SCZB9, SCZB10, SC(H)ZB10-Z Series 10kV
315 ~ 2500 kVA On-load tap changer transformer
16320S01 - TRANSFORMER SPECIFICATIONS
1. GENERAL DESIGN GUIDELINES
1. UK's recommendations on transformer design are listed below in order of
preference.
1. Indoor transformer, cast coil, unit substation. 1st. choice
2. Indoor transformer, VPI (Epoxy Encapsulated) coil, unit
substation.
2nd. choice
3. Pad mount indoors, less flammable liquid, switch. 3rd. choice
4. Pad mount outdoors, less flammable liquid, switch. 4th. choice
5. Pad mount outdoors, oil liquid, switch. 5th. choice
2. Cast coil and VPI coil provided shall be unit substation type mounted in line with
matching switchgear including high voltage load break switch and fuses in a
transformer room.
3. Pad mount transformers installed outside of buildings shall be liquid filled,
concrete
pad mounted and completely enclosed with high voltage switching and fusing
(removable oil fusing) and shall be dead front type with bushing wells and inserts,
not one piece bushing. Transformers shall conform to the requirements of the
State Fire Marshall's office for distance from the building.
2. SPECIFICATIONS FOR ALL TRANSFORMERS

1. Built to ANSI Standard C57.12.00 - 1968. ANSI short circuit test (Sample Unit)
data, ANSI impulse test - full and chopped wave (Sample Unit) data and certified
test data (ANSI) (Actual Unit) shall be provided to the University.
2. Current limiting fuses shall protect all transformers.
3. KVA size as specified.
4. Primary voltage - 12,470 volts delta connected, 95 kV BIL.
5. Secondary voltage - 120/208 Y volts or 277/480 Y volts, 30 kV BIL. The low
voltage neutral shall be brought out through a fully insulated bushing in the
secondary compartment and grounded externally.
6. Three phases.
7. 60 Hertz frequency.
8. Temperature Rise above ambient shall not exceed 65 C.
9. 98% conductivity copper coil.
10. Two winding transformer - 3 coils.
11. +2 2-1/2% taps - external handle for de-energized operation.
12. Impedance - not less than 4% and not more than 7%.
13. Noise level - not to exceed NEMA Standard levels.
14. Shall be supplied with lightning arrestors on the high voltage side, if not protected
by switch equipped with lightning arrestors.
15. Bolted connection will be acceptable only from lead to bushing. All other
connections shall be welded or adequately crimped.
15.2 Step-by-step
transformer design procedure
The following quantities are specified, using the units noted:

Wire effective resistivity 􀀄(􀀁-cm)


Total rms winding current, ref to pri Itot (A)
Desired turns ratios n2/n1, n3/n1, etc.
Applied pri volt-sec 􀀃1 (V-sec)
Allowed total power dissipation Ptot (W)
Winding fill factor Ku
Core loss exponent 􀀂
Core loss coefficient Kfe (W/cm3T􀀂)
Other quantities and their dimensions:
Core cross-sectional area Ac (cm2)
Core window area WA (cm2)
Mean length per turn MLT (cm)
Magnetic path length l
e (cm)
Wire areas Aw1, … (cm2)
Peak ac flux density 􀀁B (T

Core or shell type construction?

Back ground of transformer

Core and shell type constructions and efficiency


Basic Transformer Components

Frequency

The transformer cannot change the frequency of the supply. If the


supply is 60 hertz, the output will also be 60 hertz.

Impedance

The impedance (or resistance to current flow) is important and


used to calculate the maximum short circuit current which is
needed for sizing, circuit breakers and fuses. Impedance is
expressed as a percent. This percentage represents the amount
of normal rated primary voltage which must be applied to the
transformer to produce full rated load current when the secondary
winding is short circuited. The maximum short circuit current that
can be obtained from the output of the transformer is limited by
the impedance of the transformer and is determined by the
multiplying the reciprocal of the impedance timed the full load
current . Thus, if a transformer has 5% impedance, the reciprocal
of .05 is 20 and maximum short circuit current is 20 times the full
load current.

Insulation System and Temperature Rise


All Federal Pacific FH class transformers are designed with 220
o
C insulation systems. The standard units are rated X0 oC rise.
The insulation system classification represents the maximum
temperature permitted in the hottest spot in the winding when
operated in a 40 oC maximum ambient. The hotspot temperature
is determined by adding the maximum value for each of the
following:

40 oC maximum ambient
150 oC maximum average winding rise
30 oC maximum hot spot in winding
220 oC ultimate temperature at hot spot

The temperature rise commonly associated with transformers is


the temperature of the conductor inside the coil and does not
apply to the outside surface. The wiring compartment is
ventilated and cooled enough to permit the use of 60 oC cable for
connections. Some customers will specify 220 oC insulation with
80 oC or 115 oC rise to get overloaded capability, better
efficiency, and longer life. These transformers are designed to
operate with a lower rise per the following example at 80 oC rise

40 oC maximum ambient
80 oC maximum average winding rise
30 oC maximum hot spot in winding
30 oC thermal overload 30%
220 oC ultimate temperature at hot spot

There may be differences between the voltage ratings of


transformers and the rated voltage of some utilization equipment.
Some equipment may be rated 230, 460, or 575 volts to allow
drop due to impedance of wire, circuit breakers, ect. The
respective transformer secondary voltages would be rated 240,
480, and 600 volts which are the system or source voltage . If
you are asked to quote on a transfer rated 460V primary,
115/230V secondary would be proper to quote a transformer
rated 480V primary, 120/240V secondary

Basic Impulse Insulation Levels (BIL)

Outdoor electrical distribution systems are subject to lightning


surges. Even if the lightning strikes the line some distance from
the transformer, voltage surges can travel down the line and into
the transformer. High voltage switches and circuit breakers can
also create similar voltage surges when they are opened and
closed. Both types of surges have steep wave fronts and can be
very damaging to electrical equipment . To minimize the effects of
these surges, the electrical system is protected by lighting
arresters but they do not completely eliminate the surge from
reaching the transformer. The basic impulse level (BIL) of the
transformer measures its ability to withstand these surges. All
600 volt and below transformers are related 10 KV BIL. The 2400
and 4160 volt transformers are rated 25 KV BIL.
Transformer Sound/Noise

A Humming is an inherent characteristic of transformers due to


the vibration caused by alternating flux in the magnetic core.
Sound levels will vary according to transformers due to the
vibration caused by alternating flux in the magnetic core. Sound
levels will vary according to transformer size.Attention to
installation methods can help reduce any objectionable noise.
When possible ,locate the transformer in an area where the
ambient sound will be equal or greater than the noise of the
transformer sound level. Avoid locating units in corners. Make
connections with flexible conduits and couplings to prevent
transmitting vibration to other equipment. Larger units should be
installed on flexible mountings to isolate the transformer from the
building structure.
Sound Level In Decibles

KVA Nema ST-20


150 Degrees Celcius Rise K-1 Average
0-9 40
10-50 45
51-150 850
151-300 55
301-500 60
501-700 62
701-1000 64

We know that the air is thinner at higher altitudes which, in turn,


reduces its ability to cool the transformer. Therefore, standard
dry-type self cooled transformers are designed to operate with
normal temperature rise at heights through 3300 feet above sea
level. If the operation is at higher altitudes, the rating should be
reduced 0.3% for each 330 feet above 3300 feet.

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