DESIGN PROBLEMS

core type, oil mmersesl

Problem I. Designa 25 kVA, 11000/433 V, 50 Hz, 3 phase, delta/stur,
tappings t 2%
natural cooled distribution transformer. The transformer is provuded wuhm e u n
57
to exceed 45"C
wilh temperature rine
on the h.u. winding. Maximum temperature rise not

of oil 35°C.
from Table 6.2.
Solution. Core Design. The value of K is taken
transtormers,
A = 0.45 for three phase core type distribution

25 2.25 V.
Voltage per turn E, =KJQ =0.45 =

2.25
Flux in the core
E = 0.010135 Wb.
4.44xf 4.44 x 50
flux density B,, is assumed
92 is used. The value of
as
Hot rolled silicon steel grade
1.0 Wb/m2.
0.010135 103 mm2
Net iron area A = 0.01035 m2 = 10.135x
1.0
tteo stepped
Using a cruciform) core, A; 0.56 d2 =

Diameter of circumscribing circle d =

10.135 x 10/0.56 =
134.5 mm.

56
5.56 Reference Figs. 5.52 and 5.53(a), widths of laminations
b 0.53 d 0.53 x 135.8 71.6 mm. =
85, d= 0.85 x 135.8 114.8 mm,
=

a = =
=
4
standard dimensions
The laminations are púnched from 750 m m wide plates and the nearest
32

are a = 114 mm and b = 78 mm.

Window Dimensions. The window space factor for a small rating transformer is
K = 8/(30 + kV),2J1

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

3.33 fB K 8A A, x 10-3
25 3.33 x 50 x 1 x G.l8 x
2.3x10 xA *0.010135 x 10
or window area A. =0,0368 m = 35.8 x 10 mm.
Taking the ratio height to width of window as 2.5, Taktrg -2.S
31
x Wu =35.8'x 10 or 2.5 W2 =3.8-x103. 35.g
Width of window W = 120 mm and height of window = 300 mm.
Area of window provided A, = 300 x 120 3 6 x 103 mm2 = 0.036 m
Distance between adjacent core centres D = W +d = 120 +135 255 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/m2
Net area of yoke = 1.2 x 10.135 x 103 =12.16 x 103 mm2.
Gross area
of yoke
12.16 x 10/0.9 = 13.5 x 10 mm2.
Taking the section of the yoke as rectangular. Ay Hy xD
Depth of yoke D, = a = 114 mm Height ofyoke H, 13.5 x 10/114 = = 114 mm
Overall Dimensions of Frame. Reference
Fig. 5.70.
Height of frame H = H + 2H, = 300+ 2 x 114 = 528 mm.
Width of frame W 2D+a =2 x 255 114 624 mm.
Depth of frame D, =a 114 mmn.
 LV. Winding:
Secondary line voltage = 433 V: Connection =star.
Secondary phase voltage V, 433/13 =250 V. =
22 14

Number of turns per

phase T, VJE, 250/2.25 111.
= =

25 x 1000
= 33.3 A.
Secondary phase current, 3 x 250
of 2.3 A/mm* is used.
A current density
conductor a, = 33.3/2.3 14.48 mm2
Area of secondary
From Table 23.1
(IS 1897-1962), using a bare conductor
: 2.2 mm. of 7.x
14.9 mm2. =

Area of bare conductor a,

in secondary windings 8, 33.4/14.9 2.23 A/m2 = =

Current density
covered. The increase in dimensions on account of paper covering
The conductors are paper
is 0.5 mm.
conductor 7.5 x 2.7 mm2.
of insulated
=
Dimensions

Using layers for the winding.

three
has to be provided for (37+ 1) =
38 turns along the
Helical winding is used. Therefore space
axial depth.
Axial depth of l.v. winding
285
axial depth of conductor 38 7.5
= x = mm.
L 38 x
7.5 each side
The height of window is 300 mm. This leaves élearance
a of (300 285/2 on
below
clearance should be 6 for mm windings having voltages
of the winding. (The minimum
500 V.)
Using 0.5 pressboard cylinders
mm between layers,
Radial depth of l.v. winding
radial depth of conductor + insulation between layers
b, = number of layers x

3 x 2.7 +2x 0.5 = 9.1 mm.

5.88 shows cross-section through l.v. coil,

Fig. a

0.5mm
Press board

2.7 2.7-
-2.7

2.2
7.5
7.0

0.25mm
Paper tape
91

dimensions in mm).
Fig. 5.88. L.V. winding(All
 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 135 + 2 x 1.5 = 138 mm.
Outside diameter of l.v. winding = 138 +2 x 9.1 = 156.2 mm.

H.V. Winding:
Primary line voltage 11000 V. Connection
= = Delta
Primary phase voltage V, = 11000 V.

'As Number of turns per phase T, 11000 x111/250 4884.

=

5% tappings are to be provided, therefore, the number of turns is increased

to
T = 1.05 x 4884 = 5128.
The voltage per coil is about 1500 V. . Using 8 coils,
1375 V. Turns per coil = 5128/8
= 641.
Voltage per coil = 11000/8 =

normal coils of 672 turns and one reinforced coil of 424 turns.
Using
Total h.v. turns provided T, =7x 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.
1

25x 1000
H.V. winding phase currentp
3x 11000 =0.757 A.
As the current is below 20 A, cross-over coils are used for h.v. winding.
Taking a current density of 2.4 A/mm2.
Area of h.v. conductor a=0.757/2.4 = 0.316 mm2.
Diameter of bare conductor= (4/T x 0.316)2 = 0.635 mm.
Using paper covered conductors. From Table 23.4 (BIS 3454 1966) the nearest standard
conductor size has
bare diameter = 0.63 mm, insulated diameter = 0.805 mm with fine covering.
Modified area of conductor a, = n/4 x (0.63)? =0.312 mm2.
Actual value of current density used 6, = 0.757/0.312 = 2.43 A/mm?
Axial depth of one coil = 28 x 8.05 22.6 mm.22
The spacers used betweenladjacent coils are 5 mm in height.
Axial length of h.v. winding:
L = number of coils x axial depth of each coil + depth of spacers
8 x 226 +8 x 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
=

left on each side is 39.5 mm, which is sufficient for 11 kV

bracing of the coil. The clearanee
transformers.
The insulation used between layers is 0.3 mm thick paper
.

Radial depth of h.v. coil

b, 24 0.805 + 23 0.3 26.22 mm.
= x
x =

From Eqn. 5.22 the thickness of

= 5 + 0.9 kV 5 +(0.9 x 11)
= insulationbetween h. and l.v. winding
15 mm. This includes the width of oil
=
duct also.
The insulation betwéen h.v. and l.v.
h.v. winding is wound on a former 5
winding is a 5 mm thick bakelized paper
cylinder. The
mm thick and the duct is 5 mm wide, making the
insulation between h.v/and l.v. windings 15 mm. tola
. Inside diameter of h.v. winding
2 thickness of insulation
outside diameter 1.v. winding
+ x
=

156.2+2x 15 186.2 mm.

186.2 +2 26.22 238.64 mm 239 mm.
Outside diameter of h.v. winding = x

of two'adjacent limbs =
255 -

239 16 mm.
Clearance between windings

Resistance
186.2+239
Mean diameter of primary winding =
212 mm.
2
turn of primary winding Lmt T x 212 x 10-3 = 0.666 m.
Length of mean

Resistance of primary winding at 75°C r, = TP Lmtp

ap
4884 0.021 x 0.666
219.2
0.312

Mean diameter of secondary winding = 138+156.2 149 mm.

2

of turn of secondary winding = T x 149 x 10- =0.468 m.

Length mean mts

Resistance of secondary winding at 75°C, r, =

111x 0.021 x0468 = 0.0732 Q
14.9
Total resistance referred to primary side R, = 219.2 + 4884 x0.0732 = 364 .
111
0.757 x 364
P.U. resistance of transformer e, =
11000
0.025 -

Leakage Reactance :
Mean diameter of windings = (138 + 239)/2 = 188.5 mm.

Length of mean turn L, = T x 188.5 x 10 = 0.592 m.

(221 285/2 253
Height of winding L, =
(L, + L/2 = + mm.

Leakage reactance of transformer referred to primary side

X,2fHo T: a 3

27 x 50 x 47 x 10-7 x (4884)2 x 0.235* 15+2622+91 1 0 - 3 = 590 Q.

3
P.U. leakage reactance e, = 0.757 x 590/11000 = 0.0406.

P.U. impedance E, 0.025)* +(0.0406) = 0.0477.

Regulation. P.U. regulation e =

E, cOos +E, sin
P e r unit regulation at unity power factor t = E, = 0.025, at zero p.f. lagging e = e,2 0.406,
at 0.8 p.f. 1agging c = 0.025 x 0.8 x 0.0406 x 0.6 = 0.0444.

Losses:
PR Loss
FR loss at 75°C, = 3/,2 R, = 3 x 0.7572 x 364 = 626 W.
 Taking stray load loss 15% of above.
Total R loss including stray load loss P, = 1.15 x 626 720 W.
Core Loss
Taking the density of laminations as 7.6 x 103 kg/m*)
weight of 3 limbs = 3 x0.3/ x(0.010135) x 7.6 x 103 = 69.3 kg.
The flux density in the limbs is 1 Wb/m? and corresponding to this density, specific core
lOss is 1.2
W/kg (See Fig. 4.29). X1-2

Core loss in limbs = 69.3 x

1.2 83.2 W
Weight of two yokes = 2 x0.624)x 0.01216x 7.6 x 103 = 115.3 kg
Corresponding to a flux density
o f o.833 Wb/m? in the yoke, the specific core loss = 0.85 W.
Core loss in yoke = 115.3 x 0.85 98 W.
Total core losses
P, = 33.2 + 98.0 181 W.
Efficiency. Total losses at full load = 181 + 720 = 901 WN.
25000
Efficiency at full load and unity p.f. = x 100 = 96.5 per cent
25000+ 9001
For maximum efficiency x = yPIP V181/720 0.0501
P, =
P; x = =

Thus maximum efficiency occurs at 50.1 perçent of full load. This is a good figure for
distribution transformers.
No load current. Corresponding to flux densities of 1 Wb/m2 and 0.833 Wb/m2 in core and
yoke respectively at, = 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. P-VI I- L
Magnetizing mmf per phase AT% = 207/3 = 69 A. V
Magnetizing current I = AT/(V2 T,) = 62/(V2 x 4884) = 5.5 x 10-3 A. &1/3 11
Loss component
of no
load current I, =(181/301009
5.5 x 10-3 A. =

ooo 3x ilooo
No load current y(10x 103+(6.5x10-32 = 11.4 x 103 A.

No load current as a percentage of full load current = 11.4 x 10-3 x 100 = 1.5%.
0.757
Allowing for joints etc. the no load current will be about 2.5% of full load current.
Tank. Height over yoke H =628 mm.
oil. Height of oil level 528 + 50 + 150 728 mm.
Allowing 50 mm at the. base and about 150 mm for
=
= Allowing another 200 mm for leads etc.,
height of tank H, 728 + 200 928 mm. The height of tank is taken as 0.95height
=
=
m or H, 0.95 m. =

Assuming a clearance of 40 mm along the width on each side

Width of tank W, 2D +D, =
+2 =2 x 255 239 + 2 x 40 =829 mm.
The width of tank
W, is taken as 0.84 m.
The clearance
along the length of the transformer is greater than that
This is because additional along the width.
space is needed along the length to accommodate
clearance used is
approximately 50 mm on each side. tappings etc. The
Length of tank L, D, + 26,= 239 +
=
2 x 50 =
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) x 0.95
=
=
2.26 m.
Total specific loss
dissipation due to radiation and convection is 12.5 W/m2 -

°C.
Temperature rise =(901A2.26 x 12.5)
=31.9°C
This is below 35°C and therefore
plain tank is sufficient for cooling and tubes
Fig. 5.89 shows core and winding details
of the transformer.
no are required.
 DESIGN SHEET
Phase 3 Frequency-50 Hz Delta/Star
kVA 25
h.v. 11000 V. h.v. 11000 V.
Line voltage I.v. 433 V. Phase voltagev. 250 V.
h.v. 1.31 A. h.v. 0.757 A
Line c u r r e n t Phase currentl.v. 36 A
1.v. 36 A.
Type-core Type of coolingON

Core
0.35 mm thick 92 Grade
1. Material

2. Output constant K 0.25

3. Voltage per
turm E 2.25 V

circle diameter d 135 mm

4. Circumscribing
2
5. Number of steps
6. Dimensions
114 mn
b 73 mm

7. Net iron area

10.135x 10 mm
B 1.0 Wb/m
8. Flux density
10.13 5 m Wb
9. Flux
69.3 kg
10. Weight
1.2 Wkg
11. Specific iron loss
83.2 W
12. Iron loss
Yoke
114 mm
1. Depth of yoke D
H 114 mm
2. Height of yoke
12.16x 10'mm*
3. Net yoke area
0.833 Wb/m2
4. Flux density
10.135m Wb
5. Flux
115.3 kg
6 Weight 0.8 Wkg
7. Specific iron loss
98
8. Iron loss
Windows
2
1. Number
0.18
2. Window space factor
300 mm
3. Height of window H
4. Width of window W 120 mm
36x 10 mm*
5. Window area A
Frame
D 255 mm
.Distance between adjacent limbs
2 H 536 mm
Height of frame
3. Width of frame W 624 mm

4. Depth of frame 114 mm

Pressure release valve

Lifting hook
Connector

Tapping leads

Support

Hy

HV wdg

LV wdg

Hw

Limb

Oil drain valve D

-- D
W

LL

Fig. 5.89. 25 kVA, 3 Phase, 1100/433 Volt, 50 Hz, Core Type Distribution Transformer
 Windings LV. HV

helical Cross-over
1. Type of winding
2. Connections Star Delta
3. Conductor
Dimensions-bare 7.0 x 2.2 mm2 Diameter = 0.63 mm
insulated 7.5 x 2.7 mm2 Diameter = 0.814 mm

Area 14.9 mm2 0.312 mmn2

Number in parallel None None
4. Current density 2.23 A/mm2 2.43 A/mm2
5. Turns per phase 111 4884 (5128 at -5% tap)
6. Coils total umber 3 3x8
per core leg 8
7. Turns per coil 111 7 of 672 turns, 1 of 424 turns
per layer 34 28
8. Number of layers 3 24
9. Height of winding 285 mma 221 mmn
10. Depth of winding 9.1 mm 26 mm
11. Insulation Between layers 0.5 mm press board 0.3 mmpaper
Between coils 5.0 mm spacers
12. Coil Diameters Inside 138 mm 186.2 mmn
Outside 156.2 mm 239 mm
13. Length of mean turn 0.468 m 0.666 m
14. Resistance at 75°C 0.0732 219.22

Insulation
1. Between l.v. winding and core press board wraps1.5 mm
bakelized paper 5.0 mm
2 Betweenlv. winding and h.v.winding =

3. Width ofduct between lv. and h.v. 5 mm

Tank
1. Dimensions: height H 0.95 m

length L 0.35 m
0.84 m
width W
2. Oil Level 0.728 m
3. Tubes Nil
4 Temperaturerise 31.9C

Impedance
1. P.U. Resistance 0.025

2. P.U. Reactance 0.0406

3. P.U. Impedance 0.444

Losses
1. Total core loss 181 W
2. Total copper loss 720 W
3. Total losses at full load 901 W
96.5%
4 Bficiency at full load and .p.f. u