Tribhuvan University

Institute of Engineering
Central Campus , Pulchowk

Report On :- Transformer design

Submitted by: Submitted to:

Name:- Brijkishor Pandit Department of Electrical Engineering
Class :- III/I ( Sochindra Kumar Roy )

Roll no.:- 076BEL015

Design a 900 KVA, 66/3.3k v, 50 Hz, 3 phase delta /star core
type oil immersed natural cooled distribution transformer. The
transformer is provided with tapping ±2½, ±5½% on the HV
side. Maximum temperature rise not to exceed 45ºC.

CORE DESIGN
From guideline, the value of K for 3-phase delta/star core
distribution transformer is 0.45.
K= 0.45
Voltage per turn is given by :-

Et=K√Q

=0.45√900
=13.5 V
Flux in core Φm =𝐸𝑡/(4.44 ∗ 𝑓) =13.5/(4.44*50)=0.06081 wb.
Here, hot rolled silicon grade 92 is used .The value of flux density
Bm is assumed as 1.10 wb/m2.
Net area of iron core (Ai)= Φm/Bm = 0.0552 m2
Using Cruciform (two stepped) core ,
Ai= 0.56d2 = 0.0552 m2
d= 313.96 mm2
a= 0.85d = 0.85 * 313.96 = 266.86mm
b= 0.53d = 0.53 * 313.96 = 166.39mm
WINDOW DESIGN
Choice: Hw/Ww =4
Since KVA rating is 900 KVA. So, space factor is given by:-
Kw= 12 +( 30+KV) = 12/(30+66) =0.125
Taking current density as 2.3 A/mm2
Q = 3.33 f Bm Kw 𝛿 Aw Ai *10-3
Aw = 309000 mm2
Width of window( Ww ) = √Aw/4 =277.93 mm
Height of window ( Hw ) = 4* Ww =1111.72 mm
Distance between two adjacent core center (D)= Ww+d =
278+314=592mm.

YOKE DESIGN
Assuming area of yoke as 20 % larger than area of cross section ,
Area of yoke (Ay) = 1.2*55.2*103 =66240 mm2
Gross area of yoke (Agy ) = Ay / stacking factor (Ki) = 66240/0.9=
73600 mm2
Depth of yoke (Dy) = a = 267 mm
Assuming section of yoke as rectangular,
Height of yoke (Hy) = 73600/267 =276 mm
OVERALL DIMENSION OF FRAME
Height of frame (H)= Hw + 2Hy=1664mm
Width of frame (W)=2D+a=1451 mm
Depth of frame (Dy)=a= 267mm

LV WINDING DESIGN
Choice: Helical winding
Secondary line voltage = 3.3 *10 3v
Secondary phase voltage (𝑉𝑠) = 3.3 *103 /√3 = 1905.255𝑉
No. of turn per phase(𝑇𝑠) = 𝑉𝑠/ 𝐸𝑡 = 141.11 = 141
Secondary phase current (𝐼𝑠) = 𝑄 /3𝑉𝑠 = 157.48=157𝐴
Area of secondary coil (𝑎𝑠) = 𝐼𝑠/ 𝛿 = 60.26 𝑚𝑚2
From IS table 23.1 (IS :1897-1962)
Size of bare conductor = 22 mm* 3.2 mm (for A = 69.5mm 2)
Size of insulated conductor = 22.5 mm * 3.7mm
New current density(𝛿𝑠) = 𝐼𝑠/ 𝛿 = 2.257𝐴𝑚𝑚-2
No. of winding layer required = 25.5 ∗ 141/ 𝐻𝑤 = 2.85 = 3
No. of turns per layer = 141/3 = 47
Axial height of winding = (47+1)*25.5 = 1080 mm
Clearance (height) = 𝐻𝑤−𝑎𝑥𝑖𝑎𝑙 ℎ𝑒𝑖𝑔ℎ𝑡/2 = (1111.72-1080)/2 =
15.86 𝑚𝑚
Insulation in between layers is 0.5 mm
Radial depth = 3*3.37+0.5*2 = 12.1 mm
Insulation between core and LV winding be 1.5mm
Inner diameter of LV winding = d + 2*1.5 = 313.96+2*1.5=317 mm
Outer diameter of LV winding = 3317+2*12.1= 341.2=341mm

HV WINDING DESIGN
Choice: crossover winding
Primary line voltage = 66 *103v
Primary phase voltage (𝑉𝑠) = 66 *103 v (Delta)
No. of turn per phase(𝑇p) = Ts*𝑉p/ Vs = 141*66000 / 1905 =4885
For tapping of ±5½% on HV side , number of turn increased to
Tp=1.055*4885=5153.71=5153
The voltage per coil should be less than 1500V ,so,
Using 45 coils ,
Voltage per coil = 66000/45 = 1466.67 = 1466 <1500V.
No. of turn per coil = 5153/45 =114.51 = 144
Using 45 coil of 114 number of turns and 1 reinforced coil of 58
turns .
Total HV turns provided (Tp) = 45*114 + 58 = 5188
Taking 8 layer per coil ,
Turn per layer = 114 /8 =14.25=14
Maximum voltage between layer = 2NcEt =2*14*13.5=378 < 800 (
which is below the allowable limit)
HV winding phase current (𝐼p) = 𝑄 /3𝑉𝑠 = 4.54A
Since, current in HV winding is below 20A ,so
Using cross over coil.
Current density (𝛿) = 2.3+10% of 2.3 =2.53 Amm-2
But we use , 𝛿= 2.4 Amm-2
Area of HV coil (𝑎p) = 𝐼p/ 𝛿 = 4.54/2.4=1.8916 𝑚𝑚2
π d2/4= 1.8916
d=1.55mm
using power covered round copper conductor
From table 23.4 (IS:3454-1966)
Size of bare conductor = 1.6mm
Size of insulated conductor = 1.775mm (with fine covering)
Modified area of conductor = π*1.6*1.6/4=2.011mm2
Actual value of current density(𝛿𝑠)=𝐼p/ ap = 4.54/2.011=2.26𝐴𝑚𝑚-2
Axial depth of one coil = 14*1.775=24.85=25mm
The space used between adjacent coil are 5mm in height.
Axial length of HV winding =no. of coil * axial depth of each coil +
. depth of spacer
=45*24.85+45*5
=1343.25mm

If insulation is used between layer =0.3 mm thick paper then

Radial depth of HV coil = 45*1.775+44*0.5 = 55.8 mm
Insulation between HV and LV winding is given as
a= 5+0.9*66=64.4=64mm
Inner diameter of LV winding = outside diameter of LV winding +2*
. thickness of insulation
=341+2*64
=469mm
Outer diameter of LV winding = 469+2*55.8=580.6=581mm

RESISTANCE
Mean diameter of primary winding = (469+581) /2=525mm
Length of mean turn of primary winding ,
(Lmtp)= π*d=3.14*525=1648.5mm
Resistance of primary winding(rp)=Tp*ρ* Lmtp / ap
=4885*0.021*1648.5/1.8916
=89.40 Ω
Mean diameter of secondary winding =(317+341)/2=329mm
Length of mean turn of secondary winding ,
(Lmts)= π*329=1034mm
Resistance of secondary winding(rp)=Ts*ρ* Lmts / as
=1034*0.021*141/68
=0.045 Ω
Total resistance referred to primary side
Rp=89.4+(4885/141)2*0.045=143.41 Ω
PU resistance of transformer (Er)=Ip*Rp/Vp=0.00986

LEAKAGE REACTANCE
Mean diameter of winding = (581+317)/2 =417.5 mm
Length of mean turn (Lmt) = π*417.5 =1312.14mm=1.312m
Height of winding (Lc) =1221.25 =1221mm
Leakage reactance of transformer referred to primary side ,
𝑋𝑝 = 2𝜋 ∗ 𝜇𝑜 ∗ 𝑓 ∗ 𝑙𝑚𝑡/𝑙𝑐 ∗ 𝑇𝑝2 ∗ (𝑎 + (𝑏𝑝 + 𝑏𝑠)/ 3 ) = 878𝛺
Pu Leakage reactance (Xp) = Ip*Xp/Vp=0.06pu

REGULATION
PU regulation (ε)= εrcosΦ + εxsinΦ
At unity power factor ,ε=0.025
At zero power factor , ε=0.0406
At power factor (0.8), ε=0.0444
LOSSES
Cu loss at 75.c = 3*Ip2 *Rp = 8867.72 watts
Taking stray load 15% above,
Full load Cu loss = 3*Ip2 *Rp*1.15 = 10197.878 watts
Taking density of lamination as 7.6*10 3 kgm-3
Weight of 3 limbs = 3*Hw*Ai *density=1399.16 kg
Core loss in limb =specific core loss * weight . ..
=1.5*1399.16 (Bcore =1.5w/kg for HRS )
=2097.39 watts
Weight of 2 yokes = 2*W*Ay*density= 1460.93Kg
Crossponding to flux density in yoke ,specific core loss =0.7 W/kg
Core loss in 2 yokes = specific core loss in yoke*weight
= 0.7*1460.93
= 1022.651 watts
Hence, total iron loss = 2097.39+1022.65 = 3120.041 watts
Total losses = 8867072+3120.041= 11987.761watt=11.987KW
EFFICIENCY
Efficiency at full load and unity power factor,
η=(output power)/(output power+loss)*100%
=98.68%
For maximum efficiency,
X2Pc=Pi
X=0.593
Since, maximum efficiency occurs at 59.3% of full load which is
good figure for distribution transformer ,
Maximum efficiency=98.8%

CALCULATION OF NO LOAD CURRENT

Specific AT of core = 280AT/m
Specific AT of yoke = 85AT/m
AT of core = 3*specific AT*Hw = 933.84 AT
AT of yoke = 2*specific AT*W = 246.67 AT
Total AT = 933.84+246.67=1180.51 AT
Total AT per phase = 1180.51/3=393.50 AT
𝐼𝑢 = 393.5/(√2*4885) = 0.056 𝐴
𝐼𝑤 = ( 𝑃𝑖𝑟𝑜𝑛 𝑝𝑒𝑟 𝑝ℎ𝑎𝑠𝑒/3* 𝑉𝑝ℎ𝑎𝑠𝑒 ) = 3120.041/(3*66000) = 0.015A
No load current (Io) = √(0.0562+ 0.0152)=0.0579 A
Io as %of full load current = 0.0579/4.54*100% = 1.275%

TANK DESIGN
Height of tank, Ht = H + 60mm = 1664 + 60 = 1724 mm
Length of tank, Lt = 2D + (HV)out + 20 = 2*592 + 581+20 = 1696.14mm
Width of tank, Wt = (HV)out + 20 = 581 + 20 = 601 mm

COOLING SYSTEM DESIGN

Take surrounding temperature of 20.C
Maximum temperature rise (Ɵ) = 𝑡𝑜𝑡𝑎𝑙 𝑙𝑜𝑠𝑠𝑒𝑠/ (𝑠𝑝𝑒𝑐𝑖𝑓𝑖𝑐 ℎ𝑒𝑎𝑡
𝑑𝑖𝑠𝑠𝑖𝑝𝑎𝑡𝑖𝑜𝑛∗𝑠𝑢𝑟𝑓𝑎𝑐𝑒 𝑎𝑟𝑒𝑎 𝑜𝑓 𝑡𝑎𝑛𝑘)

Where,
Total losses = 11.987Kwatts
Specific heat dissipation = 12.5 watts m -2.c-1
Surface area of tank, St = 2 * ( Lt + Wt ) * Ht
=2(1785+601)*1724
=8.226m 2
Therefore,
Ɵ = 116.560C
i.e. final temperature = 116.56+20=136.56 0C
Hence, cooling system is required
Allowable rise in temperature, Ɵ = 45-20 = 250C
Using total area of tube = 1 8.8 ( 𝑡𝑜𝑡𝑎𝑙 𝑙𝑜𝑠𝑠/ Ɵ − 12.5𝑆𝑡)
= 42.80m 2
Let the diameter of tube be 5cm and height be 172cm
Area of each tube = π*d*h = 0.27m2
No. of tubes required = 42.80/0.27 = 159
I.e. n= 160
They are spaced 70mm apart.
No. of tubes that can be accommodated on length = 1785/70
= 25.5
=26
No. of tubes that can be accommodated on width = 601/70
= 8.58
=9
They are arranged in four layers each of 20, 16, 14, 12 tubes on
length and four layers each of 6, 5, 4, 3 tubes on width of the tank.
Check: (20 + 16 + 14 + 12)*2 + (6+5+4+3)*2 = 160
Total area of tube = 160*π*0.05*1.7
= 42.704m2
Rise in temperature = 𝑡𝑜𝑡𝑎𝑙 𝑙𝑜𝑠𝑠 /(St∗8.8+12.5∗st)
=11987.761/(42.704*8.8+12.5*8.226)
 =24.690C
Therefore maximum temperature attained = 20+24.69 = 44.67 0C
< 450C.

DESIGN SHEET

KVA : 900KVA Phase 3delta/star Frequency 50 Hz

Voltage HV: 66KV Type:Core,distribution

LV: 3.3KV Cooling: Oil immersed
natural

Current
HV: 4.54A

LV: 157A

CORE
1. Material HRS
2. Output constant K 0.45Z
3. Voltage per turn Et 13.5 V
4. Circumscribing d 313.96 mm
diameter
5. Number of steps 2
6. Dimension a 266.86 mm
b 166.39 mm
7. Net iron area Ai 55.0*103 mm2
8. Flux density Bm 1.1 Wb/m2
9. Flux Φm 0.06081 Wb
10.Weight 1399.16 kg
11.Specific iron loss 1.5 W/kg
12.Iron loss 2097.37 watts

YOKE
1.Material CROS
2.Depth of yoke Dy 267 mm
3.Height of yoke Hy 276 mm
4.Net yoke area Ay 66240 mm2
5.Flux density 1.1 Wb/m2
6.Flux 0.0625 Wb
7.Weight 1460.93 kg
8.Specific iron loss 0.7 W/kg
9.Iron loss 1022.651 watts

WINDOW
1.Number 2
2.Window space factor Kw 0.125
3.Height of window Hw 1111.72 mm
4.Width of window Ww 277.93 mm
5.Area of window Aw 309000 mm2
FRAME
1.Distance between D 592 mm
adjacent limb
2.Height of frame H 1664 mm
3.Width of frame W 1451 mm

WINDING
LV HV
1.Type of winding Helical Crossover
2.Conductor Dimension rectangular Circular
Bare 22mm*3.2mm 1.6mm
Insulated 22.5mm*3.7mm 1.775mm
3.current density 2.3 A/mm2 2.26 A/mm2
4.Number of turns 141 4885
5.Number of coils - 45
6.Number of layers 3 8
7.Turns per layer 47 14.25
8.Turns per coil - 114
9.Axial height of winding 1080mm 1343.25mm
10.Radial depth of winding 12.1mm 55.8mm
11.Insulation of layer 0.5mm 0.3mm
12.Coil diameter
Inside 317mm 469mm
Outside 341mm 581mm
13.Length of mean turns 1034mm 1648.5mm
14.Resistance 0.045 Ω 89.40 Ω
INSULATION
1. Insulation between LV winding and core = 1.5 mm pressboard
2. Insulation between LV winding and HV winding = 64.4 mm
3. Insulation in between layers of LV winding = 0.5 mm
4. Insulation in between layers of HV winding = 0.3 mm (thick paper)

TANK
1. Dimensions
Height Ht 1724 mm
Width Wt 601 mm
Length Lt 1785 mm
2. No. of tubes 160
3. Maximum Temperature rise 24.69 0C
4. Maximum temperature attained 44.69 0C

IMPEDANCE
1. P.U. Resistance 0.00986pu
2. P.U. Reactance 0.06pu
LOSSES
1. Total iron loss 3120.041watts
2. Total copper loss 8867.72watts
3. Total loss at full load 11987.761 watts
4. Efficiency at full load and unity pf 98.68%
5. Maximum efficiency 98.8% at 59.3% of full

load

NO LOAD CURRENT 0.0579A

1.27% of full load
Current
 1664 mm
WW = 277.93mm

D = 592mm D= 592mm

Figure :- 3 phase star / delta transformer

 1785 mm

1724mm
601mm

Figure :- Tank