Transformer Design

PAGE 4

Transformer DesignOutput Equation: - It gives the relationship between electrical rating and physical dimensions of the machines.Let

V1 = Primary voltage say LVV2 = Secondary voltage say HV

I1 = Primary current

I2 = Secondary current

N1= Primary no of turns

N2= Secondary no of turns

a1 = Sectional area of LV conductors (m2)

=

a1 = Sectional area of HV conductors (m2)

=

= Permissible current density (A/m2)

Q = Rating in KVA

We place first half of LV on one limb and rest half of LV on other limb to reduce leakage flux. So arrangement is LV insulation then half LV turns then HV insulation and then half HV turns.

(1)For 1-phase core type transformer Rating is given by Q =

KVA =

KVA

= KVA-----------(1)

Where

f = frequency

= Maximum flux in the core

= Sectional area of core

= Maximum flux density in the core

Window Space Factor

So

Put equation value of N1I1 form equation (2) to equation (1)

(2)For 1- phase shell type transformer Window Space Factor

Kw

So

Put equation value of N1I1 form equation (4) to equation (1)

Note it is same as for 1-phase core type transformer i.e. equ (3)

(3)For 3-phase core type transformer Rating is given by Q =

KVA =

KVA

= KVA-----------(6)

Window Space Factor

So

Put equation value of N1I1 form equation (7) to equation (6)

(3)For 3- phase shell type transformer Window Space Factor

Kw

So

Put equation value of N1I1 form equation (9) to equation (6)

Choice of magnetic loading (Bm)(1) Normal Si-Steel

0.9 to 1.1 T

(0.35 mm thickness, 1.5%3.5% Si)

(2) HRGO

1.2 to 1.4 T

(Hot Rolled Grain Oriented Si Steel)

(3) CRGO

1.4 to 1.7 T

(Cold Rolled Grain Oriented Si Steel)

(0.14---0.28 mm thickness)

Choice of Electric Loading

This depends upon cooling method employed

(1) Natural Cooling:

1.5---2.3 A/mm2

ANAir Natural cooling

ONOil Natural cooling

OFNOil Forced circulated with Natural air cooling (2) Forced Cooling :

2.2---4.0 A/mm2

ABAir Blast cooling

OBOil Blast cooling

OFBOil Forced circulated with air Blast cooling

(3) Water Cooling:

5.0 ---6.0 A/mm2

OWOil immersed with circulated Water cooling

OFWOil Forced with circulated Water cooling

Core Construction:

EMF per turn:We know

and

Q =

KVA

(Note: Take Q as per phase rating in KVA) =

KVA

In the design, the ration of total magnetic loading and electric loading may be kept constant

Magnetic loading =

Electric loading =

So

Or

using equation (2)

Or

Where is a constant and values are Kt = 0.6 to 0.7

for 3-phase core type power transformer

Kt = 0.45

for 3-phase core type distribution transformer

Kt = 1.3 for 3-phase shell type transformer

Kt = 0.75 to 0.85for 1-phase core type transformer

Kt = 1.0 to 1.2

for 1-phase shell type transformer

Estimation of Core X-sectional area AiWe know

Or

So

Now the core may be following types

d = Diameter of circumscribe circle For Square core

Gross Area

Let stacking factor

Actual Iron Area

(0.45 for square core and take K as a general case)

So

Or

Graphical method to calculate dimensions of the core

Consider 2 step core

Percentage fill

= 0.885 or 88.5%

No of steps1234567911

% Fill63.7%79.2%84.9%88.5%90.8%92.3%93.4%94.8%95.8%

Estimation of Main dimensions:Consider a 3-phase core type transformer

We know output equation

So, Window area

where

Kw =Window space factor

For higher rating Kw = 0.15 to 0.20Assume some suitable range for

D = (1.7 to 2) d

Width of the window Ww = D-d

Height of the window

Generally

Yoke area Ay is generally taken 10% to 15% higher then core section area (Ai), it is to reduce the iron loss in the yoke section. But if we increase the core section area (Ai) more copper will be needed in the windings and so more cost through we are reducing the iron loss in the core. Further length of the winding will increase resulting higher resistance so more cu loss.

Ay = (1.10 to 1.15) AiDepth of yoke

Dy = aHeight of the yoke hy = Ay/Dy

Width of the core

W = 2*D + d

Height of the core

H = L + 2*hyFlux density in yoke

Estimation of core loss and core loss componet of No load current Ic:Volume of iron in core = 3*L*Ai

m3

Weight of iron in core = density * volume

= * 3*L*Ai

Kg

= density of iron (kg/m3)

=7600 Kg/m3 for normal Iron/steel

= 6500 Kg/m3 for M-4 steel

From the graph we can find out specific iron loss, pi (Watt/Kg ) corresponding to flux density Bm in core.

So

Iron loss in core

=pi** 3*L*AiWatt

Similarly

Iron loss in yoke

= py** 2*W*AyWatt

Where

py = specific iron loss corresponding to flux density By in yoke

Total Iron loss Pi =Iron loss in core + Iron loss in yoke

Core loss component of no load current

Ic= Core loss per phase/ Primary Voltage

Ic

Estimation of magnetizing current of no load current Im:Find out magnetizing force H (atcore, at/m) corresponding to flux density Bm in the core and atyoke corresponding to flux density in the yoke from B-H curve

So

MMF required for the core

= 3*L*atcoreMMF required for the yoke

= 2*W*atyokeWe account 5% at for joints etc

So total MMF required

= 1.05[MMF for core + MMF for yoke]Peak value of the magnetizing current

RMS value of the magnetizing current

Estitmation of No load current and phasor diagram:

No load current Io

No load power factor

The no load current should not exceed 5% of the full the load current.Estimation of no of turns on LV and hv winding

Primary no of turns

Secondary no of turns

Estimation of sectional area of primary and secondary windings

Primary current

Secondary current

Sectional area of primary winding

Sectional area of secondary winging

Where is current the density.

Now we can use round conductors or strip conductors for this see the IS codes and ICC (Indian Cable Company) table.Determination of R1 & R2 and Cu losses:

Let

Lmt = Length of mean turn

Resistance of primary winding

Resistance of secondary winding

Copper loss in primary winding

Copper loss in secondary winding

Total copper loss

Where

Note: On No load, there is magnetic field around connecting leads etc which causes additional stray losses in the transformer tanks and other metallic parts. These losses may be taken as 7% to 10% of total cu losses. Determination of EFFICIENCY: Efficiency

%Estimation of leakage REACTANCE:Assumptions

1. Consider permeability of iron as infinity that is MMF is needed only for leakage flux path in the window.

2. The leakage flux lines are parallel to the axis of the core.

Consider an elementary cylinder of leakage flux lines of thickness dx at a distance x as shown in following figure.

MMF at distance x

Permeance of this elementary cylinder

(Lc =Length of winding)

Leakage flux lines associated with elementary cylinder

Flux linkage due to this leakage flux

Flux linkages (or associated) with primary winding

Flux linkages (or associated) with the space a between primary and secondary windings

We consider half of this flux linkage with primary and rest half with the secondary winding. So total flux linkages with primary winding

Similarly total flux linkages with secondary winding

Primary & Secondary leakage inductance

Primary & Secondary leakage reactance

Total Leakage reactance referred to primary side

Total Leakage reactance referred to secondary side

It must be 5% to 8% or maximum 10%

Note:- How to control XP?

If increasing the window height (L), Lc will increase and following will decrease b1, b2 & Lmt and so we can reduce the value of XP.

Calculation of VolTage Regulation of transformer:

Transformer Tank Design:Width of the transformer (Tank)

Wt=2D + De + 2b

Where

De= External diameter of HV winding

b = Clearance width wise between HV and tankDepth of transformer (Tank)

lt= De + 2a

Where

a= Clearance depth wise between HV and tank

Height of transformer (Tank)

Ht= H + h

Where

h=h1 + h2= Clearance height wise of top and bottom

Tank of a 3-Phase transformerCalculation of temperature rise:

Surface area of 4 vertical side of the tank (Heat is considered to be dissipated from 4 vertical sides of the tank)

St= 2(Wt + lt) Ht m2

(Excluding area of top and bottom of tank)Let

= Temp rise of oil(35o C to 50o C)

12.5St=Total full load losses ( Iron loss + Cu loss)

So temp rise in o C

If the temp rise so calculated exceeds the limiting value, the suitable no of cooling tubes or radiators must be provided

Calculation of no of cooling tubes:Let

xSt= Surface area of all cooling tubes

Then

Losses to be dissipated by the transformer walls and cooling tube

= Total losses

So from above equation we can find out total surface are of cooling tubes (xSt)

Normally we use 5 cm diameter tubes and keep them 7.5 cm apart

At= Surface area of one cooling tube

Hence

No of cooling tubes

Weight of TRANFORMER:LetWi = Weight of Iron in core and yoke (core volume* density + yoke volume* density)Kg

Wc= Weight of copper in winding (volume* density)

Kg

(density of cu = 8900 Kg/m3)

Weight of Oil

= Volume of oil * 880

KgAdd 20% of (Wi+Wc) for fittings, tank etc.

Total weight is equal to weight of above all parts.

L

V

L

V

L

V

L

V

H

V

H

V

H

V

H

V

H

V

1-phase core type transformer with concentric windings

Window

H

V

L

V

L

V

L

V

H

V

L

V

1-phase shell type transformer with sandwich windings

Window

LV

LV

HV

HV

LV

LV

HV

LV

HV

LV

H

V

3-phase core type transformer with concentric windings

H

V

H

V

L

V

L

V

Window

3-phase shell type transformer with sandwich windings

Window

(a) U-I type

(b) E-I type

(c) U-T type

(d) L-L type

(e) Mitred Core Construction (Latest)

45o

d

d/2

1-Step

Or Square- Core

2-Step

Or Cruciform- Core

3-Step Core

4-Step Core

K= 0.45 0.56 0.600.625

3-phase core type transformer

a

2-Step

Or Cruciform- Core

hy

H

d

W

a

b

a

b

Ww=

(D-d)

D

L

b

a

b

Ic

2-Step

Or Cruciform- Core

Im

Io

V1=-E1

E2

0

No load phasor diagram

b1

b2

a

x

dx

N1I1=N2I2

x

Lc

MMF Distribution

EMBED Equation.3

d= 5 Cm

hy

H

Ww

(D-d)

Wt

De

D

D

H

Ht

W

L

lt

a

a

b

b

Tank and Arrangement of Cooling tubes

7.5 Cm

h1

W

h2

EMBED Equation.3

Specific Heat dissipation

6 Watt/m2-0C by Radiation

6.5 Watt/m2-0C by Convection

6 W-Raditon+6.5 W=12.5 Convection

6.5*1.35 W EMBED Equation.3 ( EMBED Equation.3 35% more) Convection only

PAGE http://eed.dit.googlepages.com,

Prepared by: Nafees Ahmed

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