ABSTRACT Transformer is very important and efficient electrical power equipment.

Its ability to step-up voltages has made huge blocks of electric power transformation over long distances very economical and its ability to step-down voltages to convenient low levels has made electric power utilization safe. Depending upon application for which transformers are put in electric power industry, there are divided into power transformers, distribution transformers, grounding transformers, instrument transformers etc. The ratings and characteristics of these different transformers are therefore different and hence their design considerations, fabrications and testing procedures also different. Hence, a thorough study of above aspects and actual problems that come up at various stages in the manufacture of this important piece of electrical apparatus in a factory before being marketed is considered worth study. Currently many factories are engaged in manufacturing distribution transformers. Three phase 50 Hz distribution transformers up to 100 KVA have been designed for given ratings. This work is mainly divided into four chapters. The first chapter deals with the basics of transformers construction and the theoretical aspects behind this. The second chapter deals with the theoretical aspects in designing of a distribution transformer. The third chapter deals with complete design of a three phase, 50 Hz, 100 KVA distribution transformers. The Fourth chapter deals with the C Program illustrating problem definitions and its results. By giving the input parameters of a distribution transformers we can obtain the design specification of that transformer by using a C program.

CONTENTS CHAPTER 1: TRANSFORMER CONSTRUCTION 1.1 Principal of Transformer Action 1.2 Rating of transformers 1.3 Transformer on Load 1.4 Transformer with Resistance & Leakage Reactance 1.5 Transformer Tests 1.6 All-day efficiency CHAPTER 2: DESIGN THEORY 2.1 Design of Core 2.2 Choice of Flux Density 2.3 Selection of Type of winding 2.4 Design of Insulation CHAPTER 3: OPTIMUM DESIGN PROCEDURE 3.1 Design for minimum cost 3.2 Design for minimum loss (or) maximum efficiency 3.3 Core Design 3.4 Window Design 3.5 Yoke design 3.6 Overall Dimensions 3.7 Windings 3.8 Resistance 3.9 Leakage Reactance 3.10 Regulation 3.11 Losses 3.12 Efficiency
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3.13 All day Efficiency 3.14 No-Load Current 3.15 Tank 3.16 Cooling system CHAPTER 4: RESULTS AND DISCUSSIONS CHAPTER 5: CONCLUSION CHAPTER 6: C-PROGRAM CHAPTER 7: REFERENCES

TRANSFORMER CONSTRUCTION

CHAPTER-1 TRANSFORMER CONSTRUCTION There are two types of general transformers, the core type and the shell type. These two types differ from each other by the manner in which the windings wound around the magnetic core. The magnetic core is a stack to thin silicon-steel laminations about 0.35 mm thick for 5o Hz transformers. In order to reduce the eddy current losses, nearly all transformers have their magnetic core made from cold-rolled grain-oriented sheet-steel (C.R.G.O). This material, when magnetized in the rolling direction, has low core loss and high permeability. In the core-type, the windings around a considerable part of steel core as shown in fig 1.1 (a). In the shell-type, the steel core surrounds a major part of the windings as shown in fig 1.1 (b). For a given output and voltage rating, core-type transformer requires less iron but more conductor material as compared to a shell-type transformer. The vertical portions of the core are usually called limbs or legs and the top and bottom portions are called the yoke. This means that for single- phase transformers, core-type has two-legged core, where as shell-type has three legged core. In iron-core transformers, most of the flux is confined to high permeability core. There is, however, some flux that leaks through the core legs and non-magnetic material surrounding the core. This flux, called leakage flux, links one winding and not he other. A reduction in this
5

leakage flux is desirable as it improves the transformer performance considerably. Consequently, an effort is always made to reduce it. In the core-type transformer, this is achieved by placing half of the low voltage (L.V) winding over one leg and other half over the second leg or limb. For the high voltage winding also, half of the winding is over one leg and the other half over the second leg, fig 1.1(a). L.V winding is placed adjacent to the steel core and H.V winding outside, in order to minimize the mount of insulation required.

In the shell type transformer, the L.V and H.V windings are wound over the central limb and are interleaved or sandwiched as shown in fig 1.1 (b). Note that the bottom and top L.V coils are of half the size of other coils.

In core-type transformer, the flux has a single path around the legs or yokes, fig 1.1 (a). In the shell-type transformer, the flux in the central limb divides equally and returns through the outer two legs as shown in fig 1.1(b)

L.V. Winding

H.V-Winding 1.1 (a) CORE TYPE TRANSFORMER Yoke

Gaps Limb (or)leg 1.1 (b) SHELL TYPE TRANSFORMER

7

One type of laminations for the core and shell type of transformers is illustrated in Fig 1.2 (a) and (b) respectively. The steel core is assembled in such a manner that the butt joints in adjacent layers are staggered as illustrated in fig 1.2 (c). The staggering of the butt joints avoids continuous air gap and, therefore, the reluctance of the magnetic circuit is too increased. At the same time, a continuous air gap would reduce the mechanical strength of the core and, therefore, the staggering of the butt joints is essential BUTT JOINTS

BUTT JOINTS

BUTT JOINTS

1.2 (a)

1.2(b)

Two adjacent layers for:

(a) Core (b) Shell type of transformers and (c) arrangement of Butt Joints in a magnetic core

1.1

Principle of Transformer Action:

A transformer works on the principle of electromagnetic induction. According to this principle, an e.m.f is induced in a coil if it links a changing flux. In core-type transformer, half the L.V and H.V winding is on one limb and the other half is on the second limb. In shell-type transformer, the L.V and H.V windings are sandwiched. However, for both these type transformers, the schematic diagram is as shown in fig 1.3. The primary winding P is connected to an alternating voltage source, therefore, an alternating current I is connected to an alternating voltage, voltage source, therefore, an alternating current I starts flowing through N1 turns. The alternating mmf N1I sets up alternating flux which confined to high permeability iron path as indicated in fig 1.3, the alternating flux induces voltage E1 in the primary P and E2 in the secondary S. If the load is connected across the secondary, a load current starts flowing. In addition to the secondary winding, there may be a third winding on the same iron core. The emf induced in the secondary winding is usually referred to as the emf due to transformer action. Thus the transformer action requires the existence of alternative mutual flux linking the various windings on a common magnetic core. During the transformer construction, first the primary and secondary windings are wound, then the laminations are pushed through The coil openings, layer and the steel core is prepared, the laminations are then tightened by means of clamps and bolts.

10

Low power transformers are air cooled where as large power transformers are immersed in oil for better cooling. In oil cooled transformers, the oil serves as a coolant and also as an insulating medium. For power frequency range of 25 to 400Hz, transformers are constructed with 0.32 mm thick silicon-steel laminations. For audio frequency range of 20 to 20,000Hz, iron core with suitable refinements is used. For high frequencies employed in communication circuits, core is made up of powdered ferromagnetic alloy. In special cases the magnetic circuit of transformer is referred to as an air core transformer is primarily used in radio devices and in certain types of measuring and testing instruments. Cores made of soft ferrates are also used for pulse transformers as well as for high frequency electronic transformers. 1.2 Rating Of Transformers: The manufacturer of transformers fixes a name plate on the transformers, on which are recorded the rated output, the rated voltages, the rated frequency etc. of a particular transformer. A typical name plate rating of a single phase transformer is as follows: 20 KVA, 3300/220V,50Hz. Here 20KVA is the rated output at the secondary terminals. Note that rated output is expressed in Kilo-volt-amperes(KVA) rather than in Kilowatts(KW).This is due to the fact that rated transformer output is limited by heating and hence by the losses in the transformer. These losses depend on transformer voltage (core loss) and current loss and are almost unaffected by the load power factor. Consequently the transformer rated output is expressed in KVA and not in KW. At zero p.f

11

load, a transformer can be made to operate at rated KVA output while delivering zero power For any transformer (Rated input in KVA at the primary terminals)(Cos 1) = (Rated output in KVA at the secondary terminals)(Cos 2)+Losses Since the transformer at a very high efficiency, losses may be ignored. Further, the primary p.f.Cos 2 are nearly equal. Therefore, the rated KVA marked on the name plate of a transformer, refers to both the windings, i.e. the rated KVA of the primary winding and the secondary winding are equal.
1.3

Transformer on Load: When the secondary is loaded, the secondary current I2

with respect to V2 is determined by the characteristics of the load. Current I2 is in phase with V2 if load is non-inductive, it lags if load is inductive and it leads if load is capacitive. The secondary current set up its own m.m.f (=N 2 I2) and hence its own flux 2 which is in opposition to the main primary flux which is due to I0. The secondary flux 2 weakens the primary flux momentarily, hence primary back e.m.f. E to flow in primary. Let the additional primary current be I2.It is know as load Component of primary current. This current is antiphase with I2.The additional primary m.m.f N1I2 sets up its own flux 2 which is in opposition to 2 (but is in the same direction as ) and is equal to it magnitude. Hence, the two cancel each other out. So, we find that the magnetic effects of secondary current I2 are immediately neutralized by the additional
12
1

tends to be reduced. For a

moment V1 gains the upper hand over E1 and hence causes more current

primary current I2 which is brought into existence exactly at the same instant as I2. Hence, wherever the load conditions, the net flux passing thought the core is approximately the same at no-load. An impartment deduction is that due to the constancy of core flux at all loads, the core loss is also practically the same under all load conditions. As 2= 2 I2=(N2/N1)I2 N2I2=N1I2 = KI2

13

Hence, when transformer is on load, the primary winding has two currents in it; one is I0 and the other is I2 which is anti-phase with I2 and K time in magnitude. The total primary current is the vector sum of I 0 and I2. In fig1.3(a) are show the vector diagrams for a load transformer when load is non-inductive and when it is inductive (a similar diagram could be drawn for capacitive load).Voltage transformation ratio of unity is assumed so that primary vectors are equal to the secondary vectors. With reference to fig 1.3(a), I2 is secondary current in phase with E2 (strictly speaking it should be V2). It causes primary current I2 which is anti-phase with it and equal to it in magnitude (k=1). Total primary current I1 is the vector sum of I0 and I2 and lags behind v1 by an angle 1.

In fig 1.3 (b) vectors are drawn for an inductive load. Here, I2 lags E2 (actually V2) by 2. Current I2 is again anti phase with I2 and equal
14

to it in magnitude. As before I1 is the vector sum of I2 and I0 and lags behind V1by 1.

It will be observed that 1 is slightly greater than 2 But if we neglect I0as compared to I2 as in fig 1.3(c) then 1= 2 more over, under this assumption. N1I2=N2I1=N1I2; I2/I1=I1/I2=N2/N1=K. It shows that under full-load conditions, the ratio of primary and secondary current is constant. This impartment relationship is made the basis of current transformer. A transformer which is used with a low15

range ammeter for measuring currents in circuits where the direct connection of the ammeter is impracticable.

1.4

Transformer with Resistance and Leakage Reactance:

16

The above figure 1.4 shows the primary and secondary windings of a transformer with reactance taken out of the windings. The primary impedance is given by Z1= (R12+X12) Similarly second impedance is given by Z2= (R22+X22) The resistance and leakage reluctance of each winding is responsible for some voltage drop in each winding. In primary, the leakage reactance drop is I1X1(usually 1 or 2%) Hence V1 = E1 + I1(R1 +j X1) = E1 + I1 Z1

Similarly, there are I2 R2 and I2 X2 drops in secondary which combine with V2 to give E2. E2= V2+ I2(R2 +j X2)= V2+ I2 Z2 It may be noted that leakage reactances can also transferred from one winding to the other in the same way as resistance. X2= X2/K2 and X1= K2 X1 and X02= X2+ X1= X2+ K2 X1 And X01= X1+ X2= X1+ X2/K2 given by Z01 = (R012+X012) Z02 = (R022+X022)

It is obvious that total impedance of the transformer as referred primary is

17

1.5 Transformer Tests The transformer constants or parameters can be easily determined by two tests (i) pen-circuit test and (ii) the short-circuit test. These tests are very economical and convenient, because they furnish the required information without actually loading the transformer. In fact, the testing of every large a.c.machinary consists of running two tests similar to the open and short circuit test of a transformer. Open circuit or No-load Test The main purpose of this test is to determine on-load losses. One winding of the transformer whichever is convenient but usually high voltage winding is kept open the other is connected to a supply of normal voltage and frequency (Fig.21-29). A wattmeter W, voltmeter V and ammeter A are connected in the low-voltage winding i.e. primary winding in the present case. Fig.21-29.

Shows the simplified diagram whereas, Fig.21-30 shows actual connections. With normal voltage applied to the primary, normal flux will be set up in the core, hence normal iron losses will occur which are recorded by the wattmeter. As the primary no load current Io (as measured by ammeter) is small (usually 2 to 10% of rated load current) Cu loss is negligibly small in primary and nil in secondary (being open). 18

Hence, the wattmeter reading represents practically the core-loss under no-load conditions (and which is the same for all loads as pointed out in Art.21-8). Sometimes a high resistance voltmeter is connected across the secondary. The reading of the voltmeter gives the induced e.m.f. in the secondary winding. This helps in finding the transformation ration K. Short-circuit or Impedance Test This is an economical method for determining the following: (i) Equivalent impedance (Zo1 or Zo2), leakage reactance (Xo1 or Xo2) and resistance (Rol or Ro2) of the transformer as referred to the winding in which the measuring instruments are placed. (ii) Cu loss at full-load (and at any desired load). This loss is used in calculating the efficiency of the transformer. (iii) Knowing Zo1 or Z02, the total voltage drop in the transformer as referred to primary or secondary can be calculated and hence regulation of the determined. In this test, one winding usually the low- voltage winding, is solidly shortcircuited by a thick conductor ( or through an ammeter which may serve the additional purpose of indicating rated load current) as shown in Fig. 21-31. A low voltage (usually 5 to 10% of normal primary voltage) at correct frequency (though for Cu losses it is not essential) is applied to the primary and is cautiously increased till full-load currents are flowing both in primary and secondary (as indicated by the respective ammeters). Since, in this test, the applied voltage is a small percentage of the normal voltage, the mutual flux produced in the core is also a small percentage of its normal value (because flux is proportional to the voltage as shown in the e.m.f. equation of the transformer in Art.21-6). Hence, core losses are very small with the result that the 19

wattmeter reading represents the full-load Cu loss or I2 R loss for the whole transformer i.e. both primary Cu loss and secondary Cu loss. If Vsc is the voltage required to calculate rated load current on short circuit, then

Also

1.6

All day Efficiency: The ordinary or commercial efficiency of transformer is given by

the ratio of output in watts and input in watts. But there are certain types of transformers whose performance cannot be judged by this efficiency. Transformers used for supplying lighting and general network i.e. distribution transformers have their primaries energized all twenty-four hours, although their secondarys supply little or no load much of the time during the day except during the house lighting period. It means that where as core loss occurs throughout the day, the copper loss occurs only when the transformer is loaded. Hence, it is considered a good practice to design such transformers so that core losses are very low. The copper losses are relatively less important, because they depend on the load. The performance of such transformer should be judged by all-day efficiency which is computed on the basis of energy consume during a certain time period, usually a day of 24 hours. Output in KWH All day efficiency= ----------------------------Input in KWH (for 24 hours)

20

This efficiency is always less than the commercial efficiency of a transformer. To find this all day efficiency, we have to know the load cycle on the transformer i.e. how much and how long the transformer is loaded during 24 hours. Practical calculations are facilitated by making use of load factor

21

DESIGN THEORY

22

CHAPTER-2 DESIGN THEORY

2.1 Design of core: The cross section for core type of transformers may be rectangular, square or stepped. Shell type transformers use cores with rectangular cross section. 2.1.1 Rectangular core: For core type distribution transformers and small power transformers for moderate and low voltage, the rectangular stepped core section may be used. The ratio of depth to width of core varies between 1.4 to 2. Rectangular shaped coils are used for rectangular cores. For shell type transformer width of central limb is 2 to 3 times the depth of the core. 2.1.2 Square and stepped cores: When circular coils are required for high voltage distribution and power transformers square and stepped cores are used. Circular coils are preferred because of the superior mechanical characteristics. A transformer coil, under mechanical stresses produced by excessive leakage flux due to short circuit, tend to assume a circular from . On circular coils, these forces are radial there is no tendency for the coil to change its shape; on

23

rectangular coils the forces are perpendicular to the conductors and tend to give the coils a circular form, thus deforming it.

With core type transformers of small sizes, simple rectangular core can be used with either square or rectangular coils. For this purpose the cores are squares shaped. This circle is know as the circumscribing circle being large in comparison giving rise to higher copper loss and conductor cost.

With larger transformer cruciform cores which utilize the space better are used. As space utilization is better with cruciform cores. The diameter of circumscribing circle is smaller than with square cores of the same area. Thus the length of mean turn of copper is reduced with consequent reduction in cost of copper. It should be kept in mind that two different sizes of laminations are used in cruciform cores, the large transformers further steps are introduced to utilize the core space which reduces the length of mean turn with consequent reduction in both cost of copper and copper loss. It would seen that we can go on introducing steps with resultant reduction in cost of winding . However with larger number of steps a large numbers of sizes

24

of laminations have to be used. This results in higher labour charges for shearing and assembling different types of laminations. Thus the reduction in winding costs with a certain numbers of steps has to be balanced with the extra labour cost. The numbers of steps to be used for particular transformers have to be decided by the about considerations.

2.2 Choice of Flux Density: The value of flux density in the core determines the core area. Higher values of flux density give smaller core area and therefore there is a saving in cost of iron. Also with the reduction in core area the length of mean turn of windings is also reduced. Thus there is saving in conductor costs also. But with higher flux densities the iron loss become high, resulting in considerable temperature gradient across the core. High flux density necessitates a large magnetizing current which contains objectionable harmonics. The value of flux density to be chosen also depends upon the service conditions of the transformers. As a distribution transformer has to e designed for a high all day efficiency, and there fore the value of flux density should be low in order to keep down the iron loss.

25

The usual values of maximum flux density BM for transformers using hot rolled silicon steel are: Distribution transformer-----------1.1to1.35 wb/m2 Power transformer------------------1.25to1.45 wb/m2 Lower values should be used for small rating transformers.

2.3 Selection of Type of Winding: It is first necessary it select proper types of windings to be used in the transformer. The design of the winding chosen must be such that the desired electrical characteristics and adequate mechanical strength is obtained. The high voltage winding are usually of the following types; 1) Cylindrical winding with circular conductor 2) Cross over winding with either circular or small rectangular conductors 3) Continuous disc type winding with rectangular conductors The cylindrical and the cross-over winding are used for transformers of ratings upto 1000 KVA and 33 KV. The disc type winding is used for transformers of higher rating ranging from 200K VA to tens of MVA and Voltages from 11KV upwards.

26

The low voltage are usually of the following two types: 1) cylindrical winding 2) Helical winding(usually double helical) But these windings employ rectangular conductors. Cylindrical windings are used for KVA rating up to 800 and voltages up to 15KV and sometimes up to 33KV. 2.4 Design of Insulation: During the processes of power transfer from one circuit to another; electrical, mechanical and thermal phenomenon take place in a transformer., the winding voltage produce an electrostatic field in the dielectric and therefore stress the insulation, the current in the windings and to mechanical stressing of insulation, finally the losses. In the transformer produce temperature rise which produce thermal stresses.

Hence, the fundamental considerations in the design of insulation of transformers may be described as those of arranging core, windings and insulation to obtain satisfactory electrical and thermal characteristics during the steady state as well as transient conditions. The three basic considerations in the design of insulation are various conditions. 2.4.1 Electrical considerations: The basic insulation structure is primarily determined from consideration of the magnitude and nature of voltage which appears between different parts of the transformer i.e., voltages between individual
27

turns, between coil or layers, between windings and from winding to core and tank. The electrical design should also take care of the eddy current losses in conductors and leakage reactance of windings. a) Eddy current losses: The winding should be designed that the stray load losses small. The stray load loss includes eddy current loss in conductor and also in tank walls and clamping structure. The conductor should be split into small strips to reduce eddy current losses in conductor. b) Leakage Reactance: A given arrangement of core and winding determines the leakage reactance of the windings. The leakage reactance is adjusted by changing the winding configuration and brought within desired limits. 2.4.2 Mechanical Considerations: The basic mechanical considerations in the design of insulation are of two types: a) The insulation must be capable of withstanding the mechanical stresses imposed on it during manufacturing processes. b) The insulation must be able to withstand the mechanical stresses which are developed in the winding due to electromagnetic forces and mechanical stresses produced
28

under normal conditions of operation are quite small and ordinarily are of minor importance .However, under fault conditions, times. 2.4.3 Thermal considerations: The thermal aspects of design of insulation are determine from the consideration of insulating materials used, selection of maximum operating temperatures and types of cooling method employed. The transformer structures should be such that the losses developed in the core and winding produce temperature rises in the various parts which no where exceed the permissible limit both under normal over load/fault conditions and which, in the interest of economy, approved those limits as early as possible. The insulation of a transformer is divided into four types: a) Major insulation b) Minor insulation c) Insulation relative to tank d) Insulation between the phases a) Major Insulation: The insulation between windings and grounded core and insulation between the windings of the same phase is called major insulation. b) Minor insulation: Insulation between different parts of one winding i.e. insulation between turns, coils and layers etc is called Minor insulation. c) Insulation relative to tank:
29

particularly

dead

short

circuit,

the

electromagnetic forces may be increased several hundred

The insulation relative to the tank is called oil barrier insulator in oil immersed transformers. This insulation consists of oils ducts, barriers and coverings. Partitions of solid insulating materials placed inside oil ducts are called barriers d) Insulation between the phases: There must be provided relative insulation between the phases to avoid the short circuit between the phases

30

DESIGN PROCEDURE

31

CHAPTER 3 DESIGN PROCEDURE OPTIMUM DESIGN: Transformers may be designed to make of following qualities as minimum. 1) Total volume 2) Total weight 3) Total cost 4) Total losses m All these qualities vary with r= -------AT Thus we say r is a controlling factor for all these qualities. 3.1 Design for minimum cost: Let us consider a single transformer, whose KVA output is, Q = 2.22fBmAiKwAw X 10-3 =2.22fBmAiAc X 10-3 Assuming flux and current densities are constant, the product Ac Ai is constant for a given transformer. Let, Ac Ai = M2 m Now r = -------AT

32

m = BmAi AT = KwAw / 2 r = 2 BmAi / Ac => Ai = * r / 2 Bm = (say) = /2

Where is a function of only as Bm and are constants. From above Ai = M , A c = M / Let Ct = Total cost of transformer active materials Ci = Total cost of Iron Ct = Cc+ Ci Cc = Total cost of conductor Ct = CI gi li Ai + Cc gc lmt Ac Where Ci & Cc are specific costs of iron & copper. Now, Ct = CI gi li Ai M + Cc gc lmt M / Differentiate Ct with respect to d Ct -------d For minimum cost = CI gi li Ai M ()-1/2 ----------------------2 d Ct ------ = 0 d Cc gc lmt M ()-3/2 ------------------------2

33

CI gi li = Cc Gc Imt ()-1 = Cc Gc Imt Ac / AI CI gi Ii Ai = Cc Gc Imt Ac conductor. Now, Gi == Gc == Cc CI or Ci = Cc Hence for minimum total cost, cost of iron must equal to the cost of the

Knowing the value of iron and conductor ratio of weight of iron to conductor can be determined. This can be substituted in equation, to determine core area which gives minimum cost of transformer 1) 2) 3) 4) For minimum cost, Gi / Gc= Cc / CI

For minimum volume, Gi / Gc = gi / gc For minimum weight, Gi = Gc For minimum losses (or) maximum efficiency, Iron loss = I2 R loss PI = X2 P c

3.2 Design for minimum loss or maximum efficiency: Total losses at full load = Pi + Pc At any fraction `X of full load, total losses are, = Pi + X2 Pc If Q is out put at full load, out put at fraction X is XQ XQ Efficiency at output xQ, nx =-----------------XQ+Pi + X2 Pc

34

dnx This maximum if, ----------------------- = 0 dx

Differentiating with respect to `X dnx -----dx (XQ + Pi + X2 Pc)Q XP (Q + 2XPc) -------------------------------------------------(XQ + Pi + Pc) 2

For maximum n Nr = 0

(XQ + Pi + X2 Pc)Q - XP (Q + 2XPc) = 0 Pi = X2 Pc

So, maximum efficiency is obtained when variable losses are equal to constant losses.

35

DESIGN Design of 100 KVA-3-Phase, 50 Hz, Distribution transformer: The transformer of above rating is designed, which is based on the theoretical assumptions. But the transformer of the same rating which is manufactured in the factory is having different values of dimensions and other things. The errors are due to the practical considerations and assumptions.

Design Notations : Let, m Bm Agi Ai = = = = = = Main flux, wb Maximum flux density, wb/m2 Current density, A/m2 Gross area,m2 Net core area,m2 Stacking factor * Gross core area

36

Ac Aw D d Kw f Et Tp,Ts

= = = = = = = =

Area of copper in window, m2 Window area, m2 Distance between core centers, m Diameter of circumscribing circle, m Window space factor Frequency, Hz E.M.F. per turn, V Number of turns in primary and Secondary windings respectively

Ip,Is

Current in primary and secondary Windings respectively, A

Vp,Vs

Terminal voltage of primary and secondary Windings respectively, V

ap,as

Area of conductor of primary and Secondary windings respectively, m2

37

Ii Lmt Gi gc gi Gc Pi Pc

= = = = = = = =

Mean length of flux path in iron, m Length of mean turn of transformer windings, m Weight of active iron, Kg Weight of copper, Kg Weight per m3 of iron, Kg Weight per m3 of copper, Kg Loss of iron per Kg, W Loss of copper per Kg, W

Output Equation-VOLT PER TURN: Considering the output of one phase KVA rating of 1-phase: Q = = VpIp 10 -3 = (4.44).f. m.Tp.Ip.10 -3

(4.44).f. m.AT. 10 -3

The ratio of m /AT is a constant for a transformer of a given type, service and 4.44 method of construction. Let m /AT = r, where `r is a constant.
38

But we have individual voltage E = (4.44).f. m.T Voltage per turn Et Q = E/T = (4.44).f. m

= (4.44).pim.f.AT.10-3 = 4.44 f. m.( m /r).10-3 = 4.44. m 2. {f/r}. 10-3 m = [r.103/4.44]1/2 = Q Voltage per turn Et = 4.44 f m = 4.44f [r.103 / 4.44f]1/2. Q = k. Q where k = (4.44f r.10) = [4.44f. m 103 / AT]

3.3

Core Design:

Taking the value of k = 0.35 Voltage per term Et = 4.44m

39

Et = 0.35 100 =3.5V

Flux (m) Taking Bm Net iron area

= Et/4.44f = 3.5/(4.44x50) = 0.01576 wb = 1.2 wb/m = Ai = 0.01576 / 1.2 = 0.01313 = 131.2 cm = d = 0.56 d2 (131.3 / 0.56)

Using a cruciform core Ai

BUTT JOINTS

Fig. 1.2 a = 0.85 d b = 3.4 Winding design: Window space factor Kw =10/ (30 + kV) = 10 / (30+11) = 0.243 Rating of a 3-Phase transformer in KVA, Q Taking = 3.3f.Bm. Kw.Aw.Ai.10-3 0.53 d = = 13.0 cm 8.1 cm

del () = 2.3 Amps/mm2

100 = 3.33 x 50x1.2x2.3x106x0.24xAw x 0.013 x 10-3

40

Aw =

0.0679 M2 = 679 cm2

Taking the ratio of height to window as 2.5 Width of window, Ww Window area = 16.56 cm = 41 x 16.56 = 679 cm2

Height of window, Hw= 2.5 x 16.5 = 41 cm Distance between adjacent core centres: D= Ww + d = 16.5 + 15.3 = 31.8 cm 3.5 Yoke Design:

The area of yoke is taken as 1.3 times that of limb. Flux density in yoke Net area of yoke Gross area of yoke Depth of yoke, Height of yoke 3.6 = = = 1.2/1.3 = 0.92 Wb/m2 1.2 x 131.3 = 157.5 cm2 157.5 / 0.9 = 175 cm2

Taking the section of yoke as rectangular Dy = a = 13 cm Hy = 174/13 = 13.5 cm

Overall dimensions: = 41 + 2 x 13.5 = 67.5 cm = 2 x 32 + 13.5 = 76.6 cm

Height of frame H = Hw + 2 Hy Length of frame W = 2D+a

41

Depth of frame

a = 13.0 cm

Fig 3.1 gives the various dimensions 3.7 Windings: Secondary line voltage = 433 v Secondary phase voltage = 433 / 3 = 250 v Number of turns Ts=Vs /Es = 250 / 3.5 = 71.426 z 72 Secondary phase current = Is = 100x x 1000 / 3 x 250
42

L.V. Winding:

= 133.3 A using a current density of 2.3 Amps/ mm2 area of secondary conductor = as = 133.3 / 2.3 = 58 mm2 using bare conductor of 9.5 x 6 mm area of bare conductor = 57 mm2 current density in secondary windings, dels = 133.3 / 57 = 2.33 Amps/ mm2 using paper tape of 0.25 mm over bare conductor dimensions of insulated conductor = 10 x 6.5 mm 2 using two layers for the winding, turns per layer = 72 / 2 = 36 Maximum voltage between layers = 2 x turns per layer x Et = 2x 36 x 3.5 = 252 volts this is below the limit of 300v since the helical winding is used space has to be provided for 36 + 1 = 37 turns along the axial depth Axial depth of LV winding les = 37 x axial depth of conductor = 37 x 10 = 370 mm = 37 cm The height of window is 41 cm. This leaves a clearance of ( 41 -37) / 2 = cm On each of winding conductor 37 x 10.5 = 38.85 Insulation bracing etc. = 2.15 -------= 41.00 cm -----------using 0.5 mm pressboard cylinders between layers radial depth of LV winding bs = (No. of layers x Radial depth of conductor) + insulation
43

between layers = (2 x 6) + 0.5 = 12.5 mm = 1.25 cm diameter of circumscribing circle, d = 15.3 cm using pressboard wraps of 1.5 mm thick as insulation between L.V. winding and core. Inside dia of L.V. winding = 15.3 + 0.15 = 15.5 cm Outside dia of L.V. winding = 15.5 + 12.5 = 16.75 cm H.V. winding: Primary voltage = 11000v Primary voltage = 11000v No. of turns per phase = 11000 x 71.426 / 250 = 3143 Taking 17 layers Turns per layer = 3143 / 17 = 185 HV winding phase current Ip = 100 x 1000 / (3 x 110000) = 3.03 Amps Taking current density = 2.4 Amps / mm2 Area of HV conductor = 3.03 / 2.4 = 1.26 mm 2 Dia of conductor d = [1.26 x 4 / (22/7)] = 1.3 mm Using cotton covered conductors Insulated dia = 1.70 mm Modified area of HV conductor = (3.142 / 4) (1.300)2 = 1.32 mm2 Axia dept = No of turns per layer x dia of insulated conductor = 186 x 1.70 = 316.2 mm =n 31.62 cm = = 31.62 9.38 -----------41.00 cm ------------44

Axial depth of HV winding Insulation basing etc.

the clearance of 9.38 cm with 4.69 cm on each side sufficient of 11 KV transformer. This is utilized for insulation and supporting coolers This insulation between layers is 0.3 mm thick paper Radial depth of HV coil bp == 17 x 1.70 + 16 x 0.3 = 3.4 cm the thickness of insulation between HV and LV winding is = 5 + 0.9 Kv = 5 + 0.9 x 11 = 15 mm This includes width of the oil duct. The insulation between HV and LV winding is a 5 mm thick bakelized paper cylinder. The HV winding is wound on a former 5 mm thick and the duct is 5 mm wide, making the total insulation between HV and LV winding as 15 mm Inside of diameter of HV winding = outside dia of LV winding + 2 x thickness of insulation = 16.75 x 2 x 1.5 = 19.75 cm

Outside dia of HV winding = 19.75 + 2 x 3.40 = 27 cm Clearance between windings of two adjacent limbs = 32 - 26.55 = 5.45 cm

45

3.8

Resistance;

Mean dia of primary winding = (19.75 + 26.55) / 2 = 23.15 cm Length of mean turn of primary winding = Lmpt = (22/7) x 0.2315 = 0.7272 cm Resistance of primary winding at 75 c Rp = (Tp.p.Lmpt) / ap = 3168 x 0.021 x 0.7272 / 1.32 = 36.65 ohms Mean dia of secondary winding = ( 15.5 + 16.75) / 2 = 16.125 cm Length of mean turn of secondary winding = Lmpt = (22/7) x 0.16125 = 0.506 mm Resistance of secondary winding at 75c Rs= 72 x 0.021 x 0.506/ 58 = 0.013 ohms Total resistance referred to primary Rp = 36.65 + (3168 / 72)2 x 0.013 = 61.8 ohms Per unit resistance of transformer er - IpRp /Vp = 3.03 x 61.8 / 11000 = 0.01728 3.9 Leakage reactance : Length of mean turn = Lmt = Lmpt+Lmts) / 2 = (0.7272 + 0.506) / 2 = 0.6166 m Height of winding Lc= Lcp + Lcs) / 2

46

= (0.034+ 0.37) / 2 =0.202 m Leakage reactance referred to primary = Xp = 2( 22/7) f 0 Tp2 (Lmt) /LC (Ith + [(bp +bs) /3] Xp = 2 (22/7) x 50 x 4(2217) X 10-7 x (3143)2 x 0.6166 0.202 = {0.0149 +[0.0125 + 0.0340]/3} = 360.56 ohms per unit leakage reactance ex = 3.03 x 360.56 / 11000 = 0.0993 per unit impedance ez = 0.1 00079 3.10 Regulation: per unit regulation e = er cos + ex sin At unity power factor e = er = 0.01728 At zero power factor lagging e = ex = 0.0993 = (0.01702)2 + (0.0993)2

47

At 0.8 power factor lagging e = 0.01728 x 0.8 + 0.0993 x 0.6 = 0.0676 3.11 Losses: Copper losses at 75 c = Wc = 3. Ip2. Rp = 3 X (3.03)2 x 61.8 = 1.702 Kw

Core losses Volume of 3 limbs = 3 x 0.41 x 0.01313 = 0.0161499 Taking density of stampings as 7.6 x 103 Kg / m3 Weight of limbs = 7.6 x 103 xO.0161499 = 123 Kg Flux density in limbs = 1.2 Wb / m 2 Corresponding to this flux density core loss per Kg = 1.2 w Core loss in limbs = 123 x 1.2 z148 watts Volume of two yokes = 2x 0.775 x 0.01575 = 0.02441 m Weight of yokes = 7.6 x 103x 0.02441 = 182.4 Kg

48

Flux density in the yoke = 1.0 wb / m2 Loss per Kg = 1.0 watts Core loss in yokes = 1 x 182.4 = 182.4 watts Total core loss = 147 + 182.4 = 330.4 watts

3.12 Efficiency: For maximum efficiency X2 WC = Wi X2 x 1702 = 332 x= (332 /1702) = 0.4410 Thus maximum efficiency occurs at 44.10 % of fun load This is a good fig. for distribution transformers Efficiency at full load and at unity power factor = 100000/ (100000 + 1702 +330.4) = 98.00% Total losses at full load = 1702 + 330.4= 2032.4 watts 3.13 All day efficiency :

49

Let us assume full load 12 hours at 0.8 p.f Half load 6 hours at 0.8 p.f No load 6 hours The total cu losses at full load = 1702 watts The total core losses =330.4 watts Total core losses for 24 hours Wco =330.4x 24 =7.93 kw Cu losses at full load for 12hours WC1 =1702 x12 =20.424kw Cu losses at 1/2, load for 6 hours Wc2 = 1702/4 x6 =2.553kw Total losses = Wc0 +Wcl+Wc2 =7.93 +20.424+2.553=30.907 kw Total olp in kwh at 0.8 p.f=(100xO.8xlx120 +112 *100 xO.8 x6 =1200kw Total I/p in kwh =total_o/p +losses All day efficiency = Out put in kwh/Input in kwh
50

1200 = ----------------1200+30.907

= 97.489% 3.14 No Load Current: Corresponding to flux density of 1.2 wb I m2 in limbs mmf per meter atc = 240 Amps Total mmf for limbs = 3 x 0.41 x 240 = 295 Corresponding to flux density of 1 wb I m2 in yokes Aty = 120 Amps Total mmf for yokes = 2 x 0.766 x 120 = 184Amps Total magnetizing mmf= 295 + 184 = 479 Magnetizing mmf per phase = 480/3 = 160 Magnetizing current per phase = Im = AT0 / ( 2 x Tp) = 160 I ( 2 x 343) = 0.03579Amps
51

Loss component of no-load current

Ii = Wi I (3Vp) = 330.41 (3 x 11000) = 0.01006 Amps No-load current per phase I0 = (0.0359)2 + (0.01006)2 = 0.0370 Amps No-load current as percentage of full load current = (0.0370 / 3.03) x 100 = 1.22 % Allowing for joints etc. No load current will be about 2.5 percent of full load current 3.15 Tank: Height over yoke, H = 67.S3cm Width over 3 limbs = 2D + outer dia of HV winding = 2 x 31.79 +27 =90.58 cm Width over 1 limb = outer dia of HV winding = 27 cm Allowing 5 cm at the base and about 15 cm for oil.

52

Height of oil level = 67.S3 + 5 +15 = 87.53cm Allowing another 20 cm height for leads etc. Height of transformer tank = 87.53 + 20 = 107.53 cm Allowing 5 cm each side along the length Length of transformer tank = 90.58 + (2 x 5) = 100.58 cm In width allowing 10 cm Width of transformer tank = 27 + 10 = 37 cm Total heat dissipating area of tank, considering 4 walls only. St = 2(lOO.58+37)x107.53x 10-4=2.695 m2 Total specific heat dissipation = 12.5 W/m2/ C Temperature rise q =2032.4/ (2.69Sx 12.5) =60.32C This is greater than 35C so it is necessary to provide cooling system in order to dissipate the heat. 3.16 Cooling System: Area of the plain tank St = 2(100.58+ 37)x 1O7.53x 10-4=2.695 m2
53

Let tubular cooling be provided Let the tube area be = xSt Total dissipating surface = (1 +x) St = 2.7 (1+x) m2 Total loss to be dissipated = 2032.4 watts Assume the convection is improved by 35% due to provision of tubes Specific heat dissipation = 2032.41 {2.695(1 +x) x 35} =21.546/(1 +x) w/m 2 - c Loss dissipated per m per c = {(12.5+8.8) x} / (x+ 1) =21.521(1+x) x = 1.027 Area of tubes= x st = 1.027 x 2.695 = 2.77 m2 Wall area of each tube = (22/7) dtlt =(22/7)x 0.05 xO.8 =0. 12566m2 Dia of each tube =O.05m Length of each tube =0.8m = (22/7) x 5 x 80 = 1256 cm2 Total no. of tubes to be provided = 2.695 / 0.12566= 21.446z22 The tubes are spaced 7.5 cm apart. Therefore in 101 cm we will be able to accommodate 11 tubes leaving 9 cm on each side.

54

C- Program & Results

55

CHAPTER - 4 C-Program & Results DESIGN NOTATIONS F Bm m Agi Ai 0 Aw Hw Ww Kw = = = = = = = = = = = = Frequency of the generating system = 50 Hz Maximum flux density inside the core. Let assume Bm = 1.2 Wb/m (or)Tesla. Maximum flux inside the core in Wb Gross iron area of the core Net iron area of the core Current density inside the transformer Let = 2.3 Amps/mm Resistivity of copper conductor 1.72 x 10 Ohm-meter Absolute permeability = Area of the window in M Height of the window in meters width of the window in meters. window space factor Let Kw = 0.25 Tp Ts = = Number of primary turns Number of secondary beams

56

Ip Is Vp Vs ap a b Ay Dy Hy as w H D Lp

= = = = = = = = = = = = = = =

Current in primary winding in amps. Current in secondary winding in Amps. Terminal Voltage of Primary winding in volts Terminal Voltage of Secondary winding in volts Area of conductor of primary in m2 Larger length of the cruci-form in meters. Smaller length of the cruci-form in meters. Cross sectional area of the yoke in m2 Depth of yoke in meters. Height of the yoke in meters. Cross sectional area of the primary conductor in m2 Total horizontal length of the core in meters. Total height of the transformer core in meters. Distance between the centers of adjacent lims in meters. Length of conductor in primary winding in meters.
57

Ls Rp Rs R01 er Lmt Xp ex ez R C Cp Cs Vi

= = = = = = = = = = = = = =

Length of conductor in secondary winding in meters. Resistance of primary winding in ohms. Resistance of secondary winding in ohms Total resistance referred to primary in ohms. Per unit resistance of transformer. Length of meom turn in meters. Leakage resistance refer to primary in ohms. Per unit resistance. Per unit in pedance. Regulation of transformer. Total copper losses of the transformer in watts. Primary copper losses in watts. Secondary copper losses in watts. Volume of the core in transformer in m3

58

Vy V Wi E L Th TL Tw St T N At Wco Wc1 Wc2

= = = = = = = = = = = = = = =

Volume of the yoke in transformer in m3 Volume of the iron in transformer in m3 Total iron losses in watts. Efficiency of transformer. Total losses of transformer in watts. Total weight of the tank in meters. Total length of the tank in meters. Total width of the tank in meters. Area of plain tank in m2 Temperature rise of the transformer in C Total No. of tubes. Area of tube in m2 Total core losses in 24 hours in watts. Total copper losses at full load for 12 hours. Total copper losses at half full load for 6 hours in watts.
59

Wt Qo Ae Dmp Dms Dip Dop Dis Dos Ith Lcs Lc bp bs =

= = = = = = = = = = = = =

Total copper losses in 24 hours in kwh total output of the transformer for 24 hours in kwh All day efficiency of distribution from transformer. Mean dia. of primary winding in meters. Mean dia. of secondary winding in meters. Inside dia. of primary winding in meters. Outside dia. of primary winding in meters Inside dia. of secondary winding in meters Outside dia. of secondary winding in meters Thickness of insulation between H V and L V winding Arial depth of L.V winding in meters. Height of winding in meters. Axial depth of H V coil in meters let assume bp = 0.034m Radial depth of L V coil in meters let assume bs = 0.0125m

60

C-Program # include<stdio.h> # include<conio.h> # include<math.h> # define f 50 # define Bm 1.2 # define del 2300000 # define dels 2300000 # define delp 2400000 # define bp 0.034 # define bs 0.0125 # define rho 0.000000021 # define Abs 0.000001256 # define di 7600 # define S 1.25 # define cospi 0.8 # define sinpi 0.6 void main() { FILE * babu; float Agi,Ai,Pim,Et,Q,Vp,Vs,d,a,b; float Aw,Ww,Hw; float Ay,Dy,Hy; float Tp,Ts,Ip,Is,ap,as; float W,H,D,Lp,Ls,Rp,Rs,R01,er; float Lmt,Xp,ex,ez,R; float C,Cp,Cs; float Vi,Vy,V,Wc,Wi,E,L;
61

float Th,Tl,Tw,St,T; float X,N,At; float Wc0,Wc1,Wc2,Wt,Q0,AE; float Dmp,Dms,Dip,Dop,Dis,Dos; float Ith,Lcs,Lc,Kw; clrscr(); textbackground(GREEN); textcolor(RED); cprintf(\n Enter volt per turn:); cscanf(%f,&Et); cprintf(\n Enter capacity of transformer :); cscanf(%f,&Q); cprintf(\n Enger Primmary voltage : ); cscanf(%f,&Vp); cprintf(\n Enter Secondary Voltage: ); cscanf(%f,&Vs); /*printf(\n Enter volt per turn, capacity of transformer, Primmary voltage and Secondary Voltage); scanf(%f%f%f%f,&Et,&q,&Vp,&vs); */ babu=fopen(result.txt,w+); fprintf(babu,Volt per turn:%f\n,Et); fprintf(babu,Capaicty of Transformaer: %f\n,Q); fprintf(babu,Primary voltage:%f\n,Vp); fprintf(babu,enter secondary Voltage:%f\n,Vs); Pim = Et/(4.44*f); Ai=Pim/Bm; Kw = (10/(30+Vp*0.001));
62

d=sqrt(Ai/056); a=0.85*d; b=0.53*d; Aw=Q/(3.33*f*1.2*dels*Kw*Ai*0.004); Ww=sqrt(Aw/2.5); Hw=2.5*Ww; Ay=1.2*Ai; Agi=Ay/0.92; Dy=a; Hy=Agi/dy; Ts=(Vs/(1.732*Et)); Tp=(Vp/Vs)*Ts*1.732; Ip=(Q*1000)/(3*Vp); Is=(Q*1000*1.732)/(3*Vs); Ap=(Ip/delp) As=(Is/dels); D=Ww+d; W=(2*D+a); H=(2*Hy+Hw); Dis=d+0.0015; Dos=Dis+bs; Dmp=(Dip+Dop)/2; Dms=(Dis+Dos)/2; Ith=((5+(0.9*Vp*0.001))*0.001); Dop=dip+2*bp; Lcs=(((Ts/2)+1)*10)*0.001; Lc-(Lcs+bp)/2; Dip=Dos+(2*Ith); Lp=Tp*3.14*Dmp;
63

Ls=Ts*3.14*Dmms; Rp=(rho*Lp)/ap; Rs=(rho*Ls)/as; R01=Rp+(Rs*(Vp/Vs)*(Vp/Vs)*3); Er=(Ip*Rp)/Vp; Lmt=((Lp/Tp)+(Ls/Ts))/2; Xp=(2*3.14*f*Abs*Tp*Tp)*(Lmt/Lc)*(Ith+(bp+bs)/3; Ex=(3.03*Xp)/Vp; Ez=sqrt(er*er+ex*ex); R=er*cospi+ex*sinpi; Cp=Ip*Ip*Rp; Cs=Is*is*Rs; C=3*Ip*Ip*R01; Vi=3*Ai*Hw; Vy=2*Ay*W; V=Vi+Vy; Wc=(Vi+Vy)*di; Wi=(Vi*1.2+Vy)*di; L=C+Wi; E=(Q*1000)/((Q*1000)+L); E=E*10; Th=H+4; T1=(2*D+dop)+0.1; Tw=Dop; St=2*(Tw+T1)*Th; T=L/(st*12.5); X=(((L/(St*35))-12.5)/8.8); At=3.14*0.05*0.8; N=X*St/At;
64

Wc0=wi*24; Wc1=C*12; Wc2=C*0.25*6; Wt=(Wc0+Wc1+/wc2)/1000; Q0=(Q*cospi*12)+(0.5*Q*cospi*6); AE=(Q0*100)/(Wt+Q0); textbackground(MAGENTA); textcolor(YELLO); printf(\n CORE DESIGN); printf(\n ~~~~~~~~~~~~~~~~~~~~~~); cpintf(n\ Net iron area of the core %f m2,Ai); cpintf(n\ Gross iron area of the core %f m2,Agi); cpintf(n\ Larger length of the cruci-form %f m,a); cpintf(n\ Smaller length of the cruci-form %f m,b); getch(); printf(\n\n DESIGN OF WINDOW); printf(\n~~~~~~~~~~~~~~~~~~~~~); printf(n\ Area of window %of m2,Aw); printf(n\ Width Area of window %of m,Ww); printf(\n Height of window %fm,Hw); getch(); printf(\n\n DESIGN OF YOKE); printf(\n~~~~~~~~~~~~~~~~~); printf(\n Cross sectional Area of the yoke %f m2,Ay); printf(\n Depth of the yoke %f m,Dy); printf(\n Height of the yoke%f m,Hyderabad); getch(); printf(\n\n WINDING DESIGN); printf(\n~~~~~~~~~~~~~~~~~~~~);
65

printf(\n No. of turns on primary %f,Tp); printf(\n No. of turns on secondary %f,Ts); printf(\n Current in primary winding %f amps, Ip); printf(\n Current in secondary winding %f amps, Is); printf(\n Cross Sectional area of primary conductor %f m2, ap); printf(\n Cross Sectional area of secondary conductor %f m2,as); getch(); printf(\n \n OVERALL DESIGNING OF TRANSFORMER); printf(\n ~~~~~~~~~~~~~~~~~~~~~~~~~); printf(\n The total horizontal length of the core%fm,W); printf(\n total height of the transformer core %fm,H); printf(\n distance between the centers of adjacent limbs %f m,D); getch(); printf(\n\n RESISTANCE OF WINDINGS); printf(\n Length of conductor in primary winding %f m,Lp); printf(\n Length of conductor in Secondary winding %f m,Ls); printf(\n Resistance of Primary winding %f ohms,Rp); printf(\n Resistance of secondary winding %f ohms,Rs); printf(\n per Unit resistance of transformer %f ,er); getch(); printf(\n\n LEAKAGE REACTANCE OF TRANSFORMER); printf(\n~~~~~~~~~~~~~~~~~~~); printf(\n Length of mean turn %f m,Lmt); printf(\n Height of the winding %f m,Hw); printf(\n Leakage reactance refer to primary %f ohms,Xp); printf(\n Per Unit reactance %f,ex); printf(\n Per unit impedance %f,ez); getch(); printf(\n\n REGULATION OF THE TRANSFORMER);
66

printf(\n ~~~~~~~~~~~~~~~~~); printf(\n Regulation at.8 power factor %f,R); printf(\n COPPER LOSSES OF THE TRANSFORMER \n); printf(\n ~~~~~~~~~~~~~~~~~~~~~\n); printf(\n total copper losses of the transformer %f watts, C); getch(); printf(\n\n IRON LOSSES OF TRANSFORMER); printf(\n~~~~~~~~~~~~~~~~~~~~~~~~); printf(\n Volume of the core in transformer %f m3,Vi); printf(\n Volume of the yoke %f m3,Vy); printf(\n Volume of the Iron in transformer %f m3,V); printf(\n total iron losses %f watts,Wi); getch(); printf(\n\n THE EFFICIENCY OF THE TRANSFORMER); printf(\n~~~~~~~~~~~~~~~~~~~~~~~~); printf(\n Total losses of transformer %f watts,L); printf(\n Efficiency of transformer %f ,E); getch(); printf(\n\n THE ALLDAY EFFICIENCY OF TRANSFORMER); printf(\n~~~~~~~~~~~~~~~~~~~~~~~~); printf(\n\n taking full load for 12 hrs at 0.8pf lag); printf(\n Taking no load for 6 hrs); printf(\n Copper loss at full load %f watts, Wc1); printf(\n Copper loss at half full load %f watts, Wc2); printf(\n iron losses for 24 hrs %f watts, Wc0); printf(\n total loss for 24 hrs %f kwh, Wt); printf(\n total output for 24 hrs %f kwh, Q0); printf(\n ALLDAY EFFICIENCY %f , AE); getch();
67

printf(\n\n TRANSFORMER TANK DESIGN); printf(\n~~~~~~~~~~~~~~~~~~~~~~~~); printf(\n Total height of the tank %f m,Th); printf(\n Total length of the tank %f m,T1); printf(\n Total width of the tank %f m,Tw); getch(); printf(\n Temperature rise of the transformer %f m,T); getch(); if(T>35) { printf(\n since temperature rise is>35 cooling is required\n); printf(\n\n COOLING SYSTEM); printf(\n~~~~~~~~~~~~~~~~~~~~~~~~); printf(\n Area of plain tank %f m2,St); printf(\n Area of tube %f m2,At); printf(\n Number of tubes required %f ,N); getch(); } else printf(\n since temperature rise is <35 cooling system is not required\n); getch(); fprintf(babu,\n\t\t CORE DESIGN); fprintf(babu,\n\t\t ~~~~~~~~~~~~); fprintf(babu,\n Net iron area of the core %m2, Ai); fprintf(babu,\n Gross iron area of the core %m2, Agi); fprintf(babu,\n Larger length of the cruci-form %f m, a); fprintf(babu,\n smaller length of the cruci-form %f m, b);

68

fprintf(babu,\n\n DESIGN OF WINDOW); fprintf(babu,\n ~~~~~~~~~~~~); fprintf(babu,\n Area of window %f m2, Aw); fprintf(babu,\n width of window %f m, Ww); fprintf(babu,\n Height of window %f m, Hw); fprintf(babu,\n\n DESIGN OF YOKE); fprintf(babu,\n ~~~~~~~~~~~~); fprintf(babu,\n Cross sectional area of the yoke %f m2, Ay); fprintf(babu,\n depth of the yoke %f m, Dy); fprintf(babu,\n Height of the yoke %f m, Hy);

fprintf(babu,\n\n WINDING DESIGN); fprintf(babu,\n ~~~~~~~~~~~~); fprintf(babu,\n No. of turns on primary %f , Tp); fprintf(babu,\n No. of turns on secondary %f, Ts); fprintf(babu,\n Current in primary winding %f amps,Ip); fprintf(babu,\n Current in secondary winding %f amps,Is); fprintf(babu,\n Cross sectional area of primary conductor %f m2,ap); fprintf(babu,\n Cross sectional area of Secondary conductor %f m2,as); fprintf(babu,\n\n OVERALL DESIGNING OF TRANSFORMER); fprintf(babu,\n ~~~~~~~~~~~~); fprintf(babu,\n The total horizontal length of the core %f m , w); fprintf(babu,\n The total height of the transformer 0 core %f m , H); fprintf(babu,\n Distance between the centers of adjacent limbs %f m ,D); fprintf(babu,\n\n RESISTANCE OF WINDINGS);
69

fprintf(babu,\n Length of conductor in primary winding %f m,Lp); fprintf(babu,\n Length of conductor in Secondary winding %f m,Ls); fprintf(babu,\n Resistance of Primary winding %f ohms,Rp); fprintf(babu,\n Resistance of secondary winding %f ohms,Rs); fprintf(babu,\n per Unit resistance of transformer %f ,er); fprintf(babu,\n\n LEAKAGE REACTANCE OF TRANSFORMER); fprintf(babu,\n~~~~~~~~~~~~~~~~~~~); fprintf(babu,\n Length of mean turn %f m,Lmt); fprintf(babu,\n Height of the winding %f m,Hw); fprintf(babu,\n Leakage reactance refer to primary %f ohms,Xp); fprintf(babu,\n Per Unit reactance %f,ex); fprintf(babu,\n Per unit impedance %f,ez); fprintf(babu, \n\n REGULATION OF THE TRANSFORMER); fprintf(babu, \n ~~~~~~~~~~~~~~~~~); fprintf(babu,\n Regulation at.8 power factor %f,R); fprintf(babu,\n COPPER LOSSES OF THE TRANSFORMER \n); fprintf(babu, \n ~~~~~~~~~~~~~~~~~~~~~\n); fprintf(babu, \n total copper losses of the transformer %f watts, C); fprintf(babu, \n\n IRON LOSSES OF TRANSFORMER); fprintf(babu, \n~~~~~~~~~~~~~~~~~~~~~~~~); fprintf(babu, \n Volume of the core in transformer %f m3,Vi); fprintf(babu, \n Volume of the yoke %f m3,Vy); fprintf(babu, \n Volume of the Iron in transformer %f m3,V); fprintf(babu, \n total iron losses %f watts,Wi);

70

fprintf(babu, \n\n THE EFFICIENCY OF THE TRANSFORMER); fprintf(babu, \n~~~~~~~~~~~~~~~~~~~~~~~~); fprintf(babu, \n Total losses of transformer %f watts,L); fprintf(babu, \n Efficiency of transformer %f ,E); fprintf(babu, \n\n THE ALLDAY EFFICIENCY OF TRANSFORMER); fprintf(babu,\n~~~~~~~~~~~~~~~~~~~~~~~~); fprintf(babu, \n\n taking full load for 12 hrs at 0.8pf lag); fprintf(babu, \n\n taking half full load for 6 hrs at 0.8pf lag); fprintf(babu, \n\n Taking no load for 6 hrs); fprintf(babu, \n Copper loss at full load %f watts, Wc1); fprintf(babu, \n Copper loss at half full load %f watts, Wc2); fprintf(babu, \n iron losses for 24 hrs %f watts, Wc0); fprintf(babu, \n total loss for 24 hrs %f kwh, Wt); fprintf(babu, \n total output for 24 hrs %f kwh, Q0); fprintf(babu,\n ALLDAY EFFICIENCY %f , AE); fprintf(babu, \n\n TRANSFORMER TANK DESIGN); fprintf(babu, \n~~~~~~~~~~~~~~~~~~~~~~~~); fprintf(babu, \n Total height of the tank %f m,Th); fprintf(babu, \n Total length of the tank %f m,T1); fprintf(babu, \n Total width of the tank %f m,Tw); fprintf(babu,\n Temperature rise of the transformer %f ,T); if(T>35) { fprintf(babu, \n since temperature rise is>35 cooling is required\n);
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fprintf(babu, \n COOLING SYSTEM); fprintf(babu,\n~~~~~~~~~~~~~~~~~~~~~~~~); fprintf(babu,\n Area of plain tank %f m2,St); fprintf(babu, \n Area of tube %f m2,At); fprintf(babu, \n Number of tubes required %f ,N); fclose(babu); } else fprintf(babu,\n since temperature rise is <35 cooling system is not required\n); printf(\n the file is generated for the Out Put as result.txt file\n); printf(*********************************************\n); printf(\t\t\t CLOSE WINDOW NOW \n); printf(\t\t\t*************\n); }

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RESULTS Volt per turn :3.500000 Capacity of Transformer :100.000000 Primary Voltage : 11000.000000 Enter Secondary Voltage : 433.000000 CORE DESIGN Net iron area of the core :0.013138 m 2 Gross iron area of the core :0.017137 m 2 Larger length of the cruci-form :0.130194 m Smaller length of the cruci-form :0.081180 m

DESIGN OF WINDOW Area of window :0.0067909 m 2 Width of window :0.164814 m Height of window :0.412034 m

DESIGN OF YOKE Cross sectional area of the yoke :0.15766 m 2 Depth of the yoke :0.130194 m Height of the yoke :0.131624 m

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WINDING DESIGN No.of turns on primary:3142.857178 No.of turns on secondary :71.428574 Current in primary winding :3.030303 amps Current in secondary winding :133.333328 amps Cross sectional area of primary conductor :0.000001 m2 Cross sectional area of secondary conductor :0.000058 m2 OVERALL DESIGNING OF TRANSFORMER The total horizontal length of the core:0.766161 m Total height of the transformer core :0.675282 m Distance between the centers of adjacent limbs :0.317983 m RESISTANCE OF WINDINGS Length of conductor in primary winding :2279.341064 m Length of conductor in secondary winding :36.091991 m Resistance of primary winding :37.910000 ohms Resistance of primary secondary winding :0.013074 ohms Per unit resistance of transformer :0.010444 LEAKAGE REACTANCE OF TRANSFORMER Length of maen turn :0.615266 m Height of the winding :0.412034 m Leakage reactance refer to primary :363.275635 ohms Per unit reactance :0.100066 Per unit impedance :0.1000609
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REGULATION OF THE TRANSFORMER Regulation at 0.8 power factor :0.068394 COPPER LOSSES OF THE TRANSFORMER Total copper losses of the transformer :1741.690674 waatts IRON LOSSES OF TRANSFORMER Volume of the core in transformer :0.016240 m3 Volume of the yoke :0.024158 m 3 Volume of the iron in transformer :0.040398 m3 Total iron losses :331.712158 watts THE EFFICIENCY OF THE TRANSFORMER Total losses of transformer:2073.402832 watts Efficiency of transformer :97.968712 THE ALLDAY EFFICIENCY OF THE TRANSFORMER Taking full load for 12 hrs at 0.8pf lag Taking half full load for 6 hrs at 0.8pf lag Taking no load for 6 hrs. Copper loss at full load :20900.289062 watts Copper loss at half full load :2612.536133 watts Iron losses for 24 hrs:7961.091797 watts Total loss for 24 hrs :31.473917 kwh Total output for 24 hrs :1200.000000 kwh
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ALLDAY EFFICIENCY :97.444206 TRANSFORMER TANK DESIGN Total height of the tank :1.075282 m Total length of the tank :1.000937 m Total width of the tank :0.264970 m Temperature rise of the transformer :60.928371 Since temperature rise is>35 cooling system is required. COOLING SYSTEM Area of plain tank :2.722414 m2 Area of tube :0.125600 m2 Number of tubes required :22.808620 Volt per turn :2.250000 Capacity of Transformer :25.000000 Primary Voltage :11000.000000 Enter Secondary Voltage :433.000000 CORE DESIGN Net iron area of the core:0.008446 m2 Gross iron area of the core :0.011016 m2 Larger length of the cruici-form :0.104388 m Smaller length of the cruci-form :0.065089 m DESIGN OF WINDOW
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Area of window :0.026409 m2 Width of window :0.102779 m Height of window :0.256949 m DESIGN OF YOKE Gross sectional Area of the yoke :0.010135 m2 Depth of the yoke :0.104388 m Height of the yoke :0.105534 m WINDING DESIGN No.of turns on primary :4888.889160 No.of turn on secondary :111.111115 Current in primary winding :0.757576 amps Current in secondary winding :33.333332 amps Cross sectional area of primary conductor :0.000000 m2 Cross sectional area of secondary conductor :0.000014 m2 OVERALL DESIGN OF TRANSFORMER The toal horizontal length of the core :0.555564 m Total height of the transformer core:0.468017 m Distance between the centers of adjacent limbs :0.225588 m RESISTANCE OF WINDINGS Length of conductor in primary winding :3079.570801 m Length of conductor in secondary winding :45.550579 m
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Resistance of primary winding :204.877686 ohms Resistance of secondary winding :0.066003 ohms Per unit resistance of transformer :0.014110 LEAKAGE REACTANCE OF TRANSFORMER Length of maen turn :0.519934 m Height of the winding :0.256949 m Leakage reactance refer to primary :497.006165 ohms Per unit reactance :0.136903 Per unit impedance :0.137628 REGULATION OF THE TRANSFORMER Regulation at 0.8 power factor :0.093430 COPPER LOSSES OF THE TRANSFORMER Total copper losses of the transformer :572.773010 waatts IRON LOSSES OF TRANSFORMER Volume of the core in transformer :0.006511 m3 Volume of the yoke :0.011261 m3 Volume of the iron in transformer :0.017772 m3 Total iron losses :144.962891 watts

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THE EFFICIENCY OF THE TRANSFORMER Total losses of transformer:717.735901 watts Efficiency of transformer :97.209183

THE ALLDAY EFFICIENCY OF THE TRANSFORMER Taking full load for 12 hrs at 0.8pf lag Taking half full load for 6 hrs at 0.8pf lag Taking no load for 6 hrs. Copper loss at full load :6873.276367 watts Copper loss at half full load :859.159546 watts Iron losses for 24 hrs:3479.109375 watts Total loss for 24 hrs :11.211545 kwh Total output for 24 hrs :300.000000 kwh ALLDAY EFFICIENCY :96.397453 TRANSFORMER TANK DESIGN Total height of the tank :0.868017 m Total length of the tank :0.785786 m Total width of the tank :0.234609 m Temperature rise of the transformer :32.413685 Since temperature rise is<35 cooling system is not required. Capacity of transformer :100.000000 Primary Voltage:11000.000000 Enter secondary Voltage :250.000000
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CORE DESIGN Net iron area of the core:0.013138 m2 Gross iron area of the core :0.017137 m2 Larger length of the cruici-form :0.130194 m Smaller length of the cruci-form :0.081180 m DESIGN OF WINDOW Area of window :0.067909 m2 Width of window :0.164814 m Height of window :0.412034 m DESIGN OF YOKE Gross sectional Area of the yoke :0.015766 m2 Depth of the yoke :0.130194 m Height of the yoke :0.131624 m WINDING DESIGN No.of turns on primary :3142.856934 No.of turn on secondary :41.240513 Current in primary winding :3.030303 amps Current in secondary winding :230.933334 amps Cross sectional area of primary conductor :0.000001 m2 Cross sectional area of secondary conductor :0.000100 m2

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OVERALL DESIGN OF TRANSFORMER The toal horizontal length of the core :0.766161 m Total height of the transformer core:0.675282 m Distance between the centers of adjacent limbs :0.317983 m RESISTANCE OF WINDINGS Length of conductor in primary winding :2279.340820 m Length of conductor in secondary winding :20.838328 m Resistance of primary winding :37.909996 ohms Resistance of secondary winding :0.004358 ohms Per unit resistance of transformer :0.010444 LEAKAGE REACTANCE OF TRANSFORMER Length of maen turn :0.615266 m Height of the winding :0.412034 m Leakage reactance refer to primary :582.429626 ohms Per unit reactance :0.160433 Per unit impedance :0.160772 REGULATION OF THE TRANSFORMER Regulation at 0.8 power factor :0.104615 COPPER LOSSES OF THE TRANSFORMER Total copper losses of the transformer :1741.690430 waatts IRON LOSSES OF TRANSFORMER Volume of the core in transformer :0.016240 m 3 Volume of the yoke :0.024158 m 3
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Volume of the iron in transformer :0.040398m 3 Total iron losses :331.712158 watts THE EFFICIENCY OF THE TRANSFORMER Total losses of transformer:2073.402588 watts Efficiency of transformer :97.968712 THE ALLDAY EFFICIENCY OF THE TRANSFORMER Taking full load for 12 hrs at 0.8pf lag Taking half full load for 6 hrs at 0.8pf lag Taking no load for 6 hrs. Copper loss at full load :20900.285156 watts Copper loss at half full load :2612.535645 watts Iron losses for 24 hrs:7961.091797 watts Total loss for 24 hrs :31.473913 kwh Total output for 24 hrs :1200.000000 kwh ALLDAY EFFICIENCY :97.444206 TRANSFORMER TANK DESIGN Total height of the tank :1.075282 m Total length of the tank :1.000937 m Total width of the tank :0.264970 m Temperature rise of the transformer :60.928364 Since temperature rise is>35 cooling system is required.

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COOLING SYSTEM Area of plain tank :2.722414 m2 Area of tube :0.125600 m2 Number of tubes required :22.808615

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CONCLUSIONS The design of distribution transformer is the main objective of this project. In the design process some specifications are taken common to all the distribution transformers for making the design easier. Here, we used C language program for the design of distribution transformer. In design process, by giving volt per turn, capacity of transformer (KVA), primary voltage and secondary voltage as input parameters, we designed core, window, yoke, windings, overall design, resistance of winding, leakage reactance of transformer, regulation of transformer, iron loss, copper loss, efficiency of transformer and cooling system of transformer. For finding regulation of the distribution transformer we assumed power factor as 0.8 lagging, since all distribution transformers are working more or less at this power factor only. Flux density, current density and window space factor are assumed common to all the distribution transformers to make C program easy. Assumed primary and secondary winding coils are made of copper, core and yoke are made of iron. Tubular Oil circulating cooling system is employed. Due to time limitation, we could not study the fabrication methods that are employed in the design of transformer. But, we have gone through design procedures and implemented this in developing the C language program by which we can design any distribution transformer specifications by giving only four input parameters.

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By using the C language program we can design up to 100 KVA transformer due to assumption of specifications and constraints. The same program can be useful to design desired parameter values more than 100 KVA by altering some of assumed specifications and constraints.

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REFERENCES

1.

ELECTRICAL MACHINE DESIGN

By A.K.Sawhney 2. PERFORMANCE AND DESIGN OF AC MACHINES

By MG Say 3. ELECTRICAL MACHINARY

By Dr. B.S. Bimbhra 4. ELECTRICAL MACHINES & D.P. Kothari

By I.J.Nagrath

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