TRANSFORMER DESIGN

NATIONAL COLLEGE
OF ENGINEERING
TALCHIKHEL, LALITPUR, NEPAL

BY
AKASH MAN SHAKYA

2075 Batch

Date: 10TH SHRAWAN 2078

TO
DEPARTMENT OF ELECTRICAL
ENGINEERING
 INSTRUCTIONS

Design a 1.25 MVA, 66/11 kV, 50

Hz, three phase star/delta core
type oil immersed natural cooled
distribution transformer. The
transformer is provided with
tapping ±212 , ±522 % on the HV
side. Maximum temperature rises
not to exceed 450C
 Table of Contents

1. Given
2. Overall dimension of transformer
• Output equation
• Maximum flux
• Area of iron core
• Window’s space factor
• Area of window
• Height to width ratio of window
• Stacking factor
• Yoke design
• Height and width of the window
• Overall height and width of the frame
3. Winding design of the transformer
• Low voltage winding
- No of turns
- Current through winding
- Area of conductor
• High voltage winding
- No of turns
- Current through winding
- Area of conductor
4. Operational characterstics of transformer
• Resistance
• Leakage reactance
• Pu regulation
• Losses
• efficiency
5. Cooling and tank design
• Height of tank
• Width of tank
• Area of tank
• No of tubes
1. Given:
Rating of transformer (Q)=1.25 MVA =1250 KVA
Type: 3 phase core type distribution transformer
Frequency: 50 HZ
Material : Cold Rolled Grain Oriented (CRGO)
Voltage ratio : 66/11 kv
Connection type: star/delta
Core type: Two stepped core (cruciform)
Tapping: ±212 , ±522% on HV side
Temperature shouldn’t exceed 450C

2. Overall dimension of transformer

• Et= k√𝐐

= 0.45 x √1250
=15.909903 Volts
𝐄
• Φm=𝟒.𝟒𝟒𝐟
𝐭

15.909903
= 4.44 x 50
=0.0716662 wb
Assuming Bm=1.55 wb/m2
𝚽
• Ai= 𝐁 𝐦
𝐦
0.0716662
= 1.55
=0.04624m2
𝟏𝟎
• Kw=𝟑𝟎+𝐇𝐕(𝐤𝐯)
10
=30+66
=0.1041667
Assuming δ=2.3 A/mm2

𝐐( 𝐊𝐕𝐀)
• Aw=𝟑.𝟑𝟑𝐟𝛅𝐁 −𝟑
𝐦 𝐀 𝐢 𝐊 𝐰 𝐱𝟏𝟎
1250
=3.33x50x2.3x0.04624x0.1041x1.55x103
=0.43161 m2

𝐇𝐰
• Let,𝐫𝐚𝐭𝐢𝐨 𝐨𝐟 𝐡𝐞𝐢𝐠𝐡𝐭 𝐭𝐨 𝐰𝐢𝐝𝐭𝐡 𝐨𝐟 𝐰𝐢𝐧𝐝𝐨𝐰 =3
𝐖𝐰
And, HwxWw= Aw
A
Therefore, Ww=√Hw
w

0.43161
=√ 3
Ww=0.3793m( width of the window)
And Hw=1.137m ( Height of the window)
• Let Stacking factor (Ks)=0.9
We know,
𝐀
Ks=𝐀 𝐢
𝐠𝐢
0.04264
0.9= Agi

Gross area Agi=0.0416126m2

Since material is CRGO, Area of yoke is given by,

Ay=Agi=0.0416126 m2
• Yoke design:

Considering two stepped core(crucifrom)

Ai=0.56d2

So, d=0.28734m

a=0.85d
=0.85 x 0.28734
=0.24424m

b=0.53d
=0.53 x 0.28734
=0.15229m

We know,
Ay=Hy x Dy(Depth of yoke)
=Hy x a
Ay
Hy= a =0.17038 m

• D=d+Ww
=0.28734+0.3793
=0.6665m

Height of the frame (H)= Hw+2Hy

=1.137+ 2 x 0.17038
=1.4786 m
Width of the frame (W)=2D+a
=2 x 0.6665 + 0.24424
=1.5775m
3. Winding design of the transformer

• Low voltage winding(delta connection)

Secondary phase voltage = 11kv
V
- No of turns (Ts)= Es
t
11000
=15.9099
=691.39
=691 turns
Q x 1000
- Current (Is) =
3 x kv
1250 𝑥1000
= 3 𝑥 11000
=37.879 A
As δ=2.3 A/mm2
I
- Area of secondary conductor(as)= s
𝛅
37.879
=
2.3
=16.46 mm2

From table 23.1 (I.S.: 1897-1962), using bare conductor of one strip having thickness
2.6mm and width 6.0mm.
Where, as=16.3 mm2

Hence the current density δ = 37.879/16.3 =2.324 A/ mm2

Again,
0.5mm paper is used to insulate conductor.

Dimension of insulated conductor=(2.6+0.5)*(6.0+0.5)=20.15 mm2

Using 4 layers of each having 158 turns and one 159 turns.

Axial depth of one turn =6.0 + 1 = 7.0mm

Radial depth of one turn = 2.6 + 1 = 3.6mm

Helical winding is used. Therefore, space has to be provided for (159+1) = 160 turns along
the axial depth.

Axial depth of l.v. winding Lcs =160*7 = 1120mm

The height of window is 1137 mm. This leaves a clearance of (1137 -1120)/2 =8.5mm

Using 0.5mm pressboard between layers,

Radial depth of L.V winding bs = no of layers*radial depth of one conductor +

insulation between layers
=4*3.6 + 4*0.5 = 16.4 mm
 Diameter of limb d= 287.34 mm

Insulation=5+0.9*KV=5+0.9*11= 14.9mm

Inside diameter of L.V. winding = 287.34 + 14.9 = 302.24mm

Outside diameter of L.V. winding = 302.24 + 2*16.4 = 335.04mm

• High voltage winding

Primary line voltage (Vl) = 66000V (connection – Star)
Primary phase voltage (Vp) = 38105.12V
Vs
- No of turns (TP)=
Et
38105.12
= 15.9099
=2395.057
=2395 turns
Q x 1000
- Current (IP) = 3 x kv
1250 𝑥1000
=
3 𝑥 38105.12
=10.935 A
As δ=2.3 A/mm2
I
- Area of secondary conductor(aP)= 𝛅s
10.935
= 2.3
=4.754 mm2
Then, diameter=2.46mm

From the table,

Nominal diameter=2.360 mm
Dcoat=2.710mm

Hence the current density δ = 10.395/4.374 =2.376 A/ mm2

800
Maximum possible layers ≤2∗E =25.143
t

38105.12
Minimum coil number = =47.6314
800

Choosing 50 coils then,

Number of turns per layer=2395/50=47.9

Assuming 7 layers of winding per turns

47.9/7=6.84mm

Axial depth of one coil=6.879*2.710=19.19mm

The spacers used are 0.5mm in height

Axial depth of H.V winding,

Lcp=no of coils*axial depth of each coil+ depth of spacers= 50*19.19+49*0.5=984mm

Which is less than Height of window.
 The insulation used between layers is 0.3mm thick paper

Radial depth of HV winding,bp=7*2.710+6*0.3=20.77mm

The thickness of insulation between HV and LV =5+0.9*KV=64.4mm

Inside diameter of H.V. winding = outside diameter of L.V. winding +2* thickness of
insulation
= 335.04 + 2*64.4
= 463.84mm

Outside diameter of h.v. winding = 463.84 + 2*20.77

= 505.38mm

Clearance between windings of two adjacent limbs = D – outside diameter of h.v.

winding

= 666.5 – 505.38 = 161.12mm

4. Operatonal characterstics of transformer

• Resistance

Outer diameter of H.V+Inner diamter of H.V

Mean diameter of H.V winding= 2
0.463+0.505
= =0.484 m
2

Length mean turn of H.V winding, LMTP=π*0.484=1.521m

Outer diameter of L.V+Inner diamter f L.V

Mean diameter of L.V winding= 2
0.302+0.335
= =0.3185 m
2

Length mean turn of L.V winding, LMTS=π*0.3185=1 m

Outer diameter of H.V+Inner diamter L.V

Length mean turn , LMT = π( )
2
0.302+0.505
= π( )=1.267 m
2

taking ρ = 0.021 Ωmm2

Now,
ρ x LMTP x Tp
Resistance of primary winding (rp)= a p
0.021∗1.521∗2395
= =17.489Ω
4.374

ρ x LMTS x Ts
Resistance of Secondary winding (rs)= as
0.021∗1∗ 691
= =0.89Ω
16.3
 Resistance of the transformer referred to primary side,
Tp
Rp=rp+( T )2 x rs
s
2395
=17.489+( 691 )2 X 0.89 =28.180Ω

I p Rp
Per unit resistance drop, Er= Vp
10.935∗28.180
= =0.008087
38105.12

• Leakage reactance

(Lcp +Lcs )
Height of winding, Lc = 2
0.984+1.120
= =1.052m
2

Leakage reactance of transformer referred to primary side:

LMT bp +bs
Xp=2 x π x f x µo x (Tp)2 (a + )
Lc 3

1.267 0.0207+0.0164
=2*π*50*µ0*(29352)* * (0.064 + )
1.052 3
=208.274 Ω

P.U leakage reactance drop:

Ip x Xp
Ex=
Vp
10.935 x 208.74
= =0.0599
38105.12

• PU regulation

for ø=00,

PU regulation, E=ErCosø+ExSinø
= 0.008087Cosø+0.0599Sinø
=0.8087%

for ø=900,

PU regulation, E=ErCosø+ExSinø
= 0.008087Cosø+0.0599Sinø
=5.99%

for ø=cos-1(0.8)

PU regulation, E=ErCosø+ExSinø
= 0.008087Cosø+0.0599Sinø =4.24%
• Losses
Taking the density of laminated steel=7.6*103 kg/m3

Weight of a limb=Area of the core*Height of the window*density

=0.0462*1.137*7.6*103
=399.22 kg

Total weight of limb(WL)=3*399.22

=1197.67 kg
Similarly,
Weight of yoke=Area of yoke*width of frame*density
= 0.0416126*1.5775*7.6*103
=498.893 kg

Total weight of yoke(WY)=2*498.893

=997.786 kg

Total weight of core (W)=WL+WY

=1197.67+997.786
=2195.45 kg

Total core loss = specific core loss* W

=1.2 * 2195.45
=2634.54 W
Where, specific core loss=1.2 W/kg is taken from core loss vs Flux density graph

Copper loss in the core =3 Ip2 Rp

=3*10.9352*28.180
=10108.805 W

Total loss=Total core loss + Total copper loss

=10108.805+2637.54
=12743.345 W

• Efficiency:
(KVA output)∗p.f
Efficiency =(KVA
output)∗p.f+total losses

1250∗1000∗1
Efficiency at full load and unity p.f= x100%
1250∗1000∗1+12743.345
=98.99%

1250∗1000∗0.8
Efficiency at full load and 0.8 p.f= x100%
1250∗1000∗0.8+12743.345
=98.742%
• No load current:
Considering flux densities of 1.3wb/m2 and 1.0833wb/m2 in core and yoke respectively
atc = 800 A/m and aty = 200 A/m.
Total magnetizing mmf = 3*atc*height of window + 2*aty*width
= 3*800*1.137 + 2*200*0.3793
= 2880.52AT

Magnetizing mmf per phase AT0 = 2880.52/3 = 960.173 AT

AT0
Magnetizing current Im =
√2Tp
960.173
= = 0.2834A
√2∗2395

P
Loss component of no load current Ic= 3Vi
p
2634.54
=3∗38105.12=0.02304

No load current I0 = √Im

2 + I2
c
=√0.28342 + 0.023042 =0.2844 A
I
No load current as a percentage of full load current = I 0
p
0.2844
= 10.935 =2.60%

5. Cooling and Tank design

Height of frame (H)=1.4786m=1478.6 mm

From table:

Clearance between H.V winding and tank (b) =85mm

Clearance on each side between winding and tank along width (l) = 125mm
Clearance the height between the assembled transformer and the tank (h) = 550mm

Height of tank Ht = H + h
= 1478.6 +550
= 2028.6mm
= 2.0286m

Width of tank Wt = 2*D + outer diameter of h.v. winding (De) +2*b

= 2*666.5 +505.38 + 2*85
= 2008.38mm
=2m

Length of tank Lt = outisde diameter of HV winding + 2*l

= 505.38 + 2*125
= 755.38mm
Total loss dissipating surface of tank, St = 2*[(Lt * Ht) + (Ht* Wt)]; neglecting top and
bottom surface
= 2*[(755.38*2028.6) + (2028.6*2008.38)]
=11213127.07mm2
= 11.21m2
P +P
Temperature rise without tubes = 12.5∗S
i c
t
12743.345
= 12.5∗11.21
=90.940C
Let area of tube = x*St
1 𝑃𝑖 +𝑃𝑐
Where x =8.8 [ 𝛳∗𝑆 − 12.5]
𝑡
1 12743.345
=8.8 [ 45∗11.21 − 12.5]=1.215

Area of tube = 1.215*11.21 = 13.621m2

Length of each tube = 1.75m (< height of the tank)

Let, Diameter of each tube, dt = 0.05m

Surface area of each tube = π * dt*length of each tube

= π *0.05*1.75 = 0.274m2

No of tubes = 13.621/0.274 = 49.55 = 50

Fig: Overall dimension of 1.25 MVA 6/11 KV distribution transformer
 Design sheet
Rating: 1.25 MVA
Line voltage ratio: 66/11 kV
Frequency: 50 Hz
Phase: Three phase
Connection: Star/delta core type
Type: Oil immersed natural cooled distribution transformer.
Tapping: ±212 , ±522 % on the HV side. Maximum temperature rises not to exceed 450C

Overall dimension Symbol Value

1. Output constant k 0.45
2. Voltage constant Et 15.909903 V
3. Maximum flux Φm 0.0716662 wb
4. Flux density B 1.55 wb/m2
5. Area of core Ai 0.04624 m2
6. Window’s space factor Kw 0.1041667
7. Area of window Aw 0.43161 m2
8. Height to width ratio of window (Hw/Ww) 3
9. Width of window Ww 0.3793m
10. Height of window Hw 1.137m
11. Staking factor Ks 0.9
12. Gross area Agi 0.0416126m2
13. Material CRGO Cold Rolled Grain Oriented
14. Area of yoke Ay 0.0416126m2
15. Diameter of circumscibing circle d 0.28734m
16. Height of yoke Hy 0.17038m
17. Distance between adjacent limbs D 0.6665m
18. Height of frame H 1.4786m
19. Width of frame W 1.5775m

Winding design L.V. H.V.

1. Type of winding Helical Crossover
2. Connection Star Delta
3. Conductor Copper Copper
4. Area of conductor 16.3 mm2 4.374 mm2
5. Current density 2.324 A/mm2 2.376 A/mm2
6. Radial depth 16.4mm 20.77mm
7. Axial depth 1120mm 984mm
8. Insulation 14.9mm 64.4mm
9. Outer diameter 335.04mm 505.38mm
10. Inner diameter 302.24mm 463.84mm

For resistance L.V H.V

1. Mean diameter 0.3185m 0.484m
2. Length mean turn 1m 1.512m
3. Resistance 0.89Ω 17.489Ω
1. Length mean turn 1.267m
2. Resistance of transformer referred to primary side 28.180
3. Per unit resistance drop 0.008087

For Leakage reactance Value

1. Height of the winding 1.052m
2. Leakage reactance of transformer referred to primary side 208.274Ω
3. Per unit leakage reactance drop 0.0599

Power factor Per unit regulation value in percentage

1. Unity 0.8087%
2. Zero 5.99%
3. 0.8 4.24%

For Losses Value

1. Density of laminated steel 7.6*103 kg/m3
2. Total weight of limb 1197.67 kg
3. Total weight of yoke 997.786 kg
4. Total weight of core 2195.45 kg
5. Total core loss 2634.54 W
6. Total copper loss 10108.805 W
7. Specific core loss 1.2 W/kg
8. Total loss 12743.345 W

Efficiency Value
1. For full load and unity p.f 98.99%
2. For full load and 0.8 p.f 98.74%

For no load current Value

1. Total magnetising mmf 2880.52 AT
2. Magnetising mmf per phase 960.173 AT
3. Magnetising current 0.2894 A
4. Loss component of no load current 0.02304 A
5. No load current 0.2844 A
6. No load current of full load current 2.60%

Tank design Value

1. Clearance between H.V winding and tank 85mm
2. Clearance on each side between winding and tank along width 125mm
3. Clearance the height between the transformer and the tank 550mm
4. Height of tank 2.0286m
5. Width of tank 2m
6. Length of tank 755.38mm
7. Temperature without tubes 90.940C
8. Area of tube 13.621 m2
9. Diameter of each tube 0.05m
10. Lengh of each tube 1.75m
11. Surface area of each tube 0.274 m2
12. No of tube 50
Tables and graphs used for ease of calculation:
© Akash Man Shakya , 2021 A.D