Q.48.

Design a 25 KVA, 50 Hz, 33000/11000 V, three phase

delta/star core type oil immersed, natural cooled power
transformer. The transformer is provided with tapping
±2.5%, ±5.5% on the HV side. The maximum temperature rise
not to exceed 45°C.
 SOLUTION:
Design of Transformer
o Design of Core:
Constant ‘K’ of three phase core type distribution transformer (K) =0.45

Voltage per turn (Et) =K√Q =0.45√25 =2.25 V/turn

φm= 2.25/ (4.44*50) =0.010135 Wb

Hot rolled steel is used.

Assuming Bm=1.0 Wb/m2

Ai=φm/Bm=0.010135/1.0=0. 010135m2

Using cruciform core,

Ai=0.56d2

Or, 0. 010135=0.6d2

... d=0.1345m =134.5 mm

a=0.85d=0.85x134.5=114.3mm
b=0.53d=71.285 mm

o Design of Window:
8
Window space factor (Kw) =( )= 8
=0.1269
30+kV 30+33

Assuming δ=1.1 A/mm2

For three phase transformer,

Q=3.33fBmKwδAwAix10-3
25=3.33x50x1x0.1269x1.1x106xAwx0.010135x10-3

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... Aw=0.106.11m2
Assuming ratio of height to width of window=2.5
Aw
Ww = √ =√0.10611/2.5=203.086mm
2.5

... Hw = 2.5x Ww =507.71mm

Distance between adjacent limbs (D) = d+Ww = 134.5+203.086=337.586mm

o Design of Yoke:

Area of yoke=1.2Ai=1.2x0.010135m2=0.012162m2 =12162mm2

Depth of yoke (Dy) =a=114.3mm

Area of yoke 12162
Height of yoke (Hy) = = =106.4mm
Depth of yoke 114.3

... Dy=114.3mm

Hy=106.4mm
o Dimension of Frame:

Height of frame (H) = Hw+2Hy = 507.71 + 2 x 106.4 = 720.51mm Width

of frame (W) = 2 x D + a = 2 x 337.586 + 114.3 = 789.472mm Depth of

frame = Dy = 114.3mm

o Design of L.V winding:

Secondary line voltage=11,000V

Connection = star

Secondary phase voltage = 11,000/√3 =6350.85V

6350.85
Number of turns in L.V winding =
= 2823
2.25 turns
Current in secondary winding (Is) = 25x103/(√3x11000) = 1.312 A Area of

secondary conductor = Is/δ = 1.312/1.1 = 1.192mm2

From table 23.1 (IS 1897-1962) using a bare conductor of 1.4x0.9 mm2
Current density in secondary winding =1.04A/ mm2
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The conductors are covered with paper of thickness 0.5mm.

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So dimension of insulated conductor=1.9x1.4 mm2 We
use helical windings.
We use 12 layers of windings for the conductors.
Actual area of conductor=1.9x1.4=2.66mm2
Therefore space is to be provided for (235+1=236) turns along the axial depth. Axial
depth of L.V. winding=236x axial depth of conductor=236x1.9=448.4mm Radial
width of each conductor =1.4mm
Clearance on each side = ( Ww - Lcs )/2 = 29.65mm

Radial depth of L.V. winding = 12x1.4+1 = 17.8mm

Using press board wraps 2.5mm thick as insulation between core and L.V. winding
Insulation thickness between L.V winding and core = 5mm
Inside diameter of L.V winding = 135+2x2.5 = 140mm Outside
diameter of L.V winding = 135+2x17.8 = 171 mm

o Design of H.V Winding:

Number of turns in H.V winding = 33000 𝑥2823 = 14669 turns

6350.85

As ±5.5% tapping is provided, no of turns = 1.055x14669 = 15476 turns

Using 15 coils
Voltage per coil = 2200 V
Turns per coil = 1032
Using 14 normal coils of 1050 turns and one reinforced coil of 776 turns

Current in primary winding (Ip) = 25x103/3x3300 = 0.252 A

We use cross-over winding.

Taking δ = 1.2 A/ mm2
Area of primary conductor = Ip/δ = 0.21 mm2

Diameter of bare conductor = 0.517mm

Insulated conductor diameter = 0.767mm (using fine insulation)

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Space between adjacent coils is taken as 1 mm in height.

Axial depth of each coil = 42x0.767 = 32.214mm

Axial height of each coil (Lcp) = 15x32.214+15x1 = 498.21mm

Radial depth of HV coil = bp = 25x0.517+24x0.3 = 20.125mm

Inside diameter = 171 + 2x2.5 = 176mm

Outside diameter = 176 + 2x20.125 = 217mm
Clearance = 337.5 - 217 = 120.5 = 121mm

o Resistance:

Mean diameter of H.V winding = (217+176)/2 = 197mm = 0.197m

Length of mean turn of primary winding (Lmts) = πx0.197 = 0.617m rp =

14669x0.021x0.617/0.21 = 905Ω

Mean diameter of L.V winding = (140+171)/2 = 156mm = 0.156m Length

of mean turn of secondary winding (Lmtp) = πx0.156 = 0.490m rs =

2823x0.021x1.192/0.490 = 144Ω

Rp = 905+(14669/2823)2x144 = 4793Ω

Per unit resistance (εr) = 0.252x4793/33000 = 0.0366 p.u

o Reactance:

Length of mean turn (Lmt) = πx(140+217)/2x10-3 = 0.560m

Mean height of coil (Lc) = (448.4+498.21)/2 = 473.3mm = 0.4733m
Lmt
Xp = 2πfμoTp2 (a+(∑bp+∑bs)/3x10^-3
Lc

=1521.899Ω
Per unit reactance(εx) = 0.252x1521.899/33000=0.0116 p.u

Per unit impedance (εs) = √(0.0116)^2 + (0.0336)^2 =0.0378

o Regulation
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P.U. regulation(ε)= εr=0.0336 (at unity p.f.)

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P.U. regulation(ε) = εs = 0.0116(at zero p.f.)

o Losses:

I2R loss

I2R loss at 75 degree centigrade=3* Ip2Rp = 913.12W

Taking stray load loss as 15% of above

Total I2R loss = 1050W
Core loss
Taking density of laminations = 7.6x1000kg/m3
Wt. of three limbs = 3x0.507x0.010135x7.6x103 = 117.15kg
Specific core loss = 1.2W/kg
Core loss in limb = 1.2x117.15 = 140.5W
Wt. of two yokes = 2x0.789x1.2x0.010135x7.6x103 = 145.8kg Sp.
core loss in yoke = 0.85W/kg
Core loss in yoke = 0.85x145.8 = 123.93W Total
core loss=123.93+140.5=264.43Watts

o Efficiency:

Total loss =264.43+1050=1314.43W

Efficiency at full load and unity power factor
(25x 1000) / (25 x 1000+1314.43) = 95 %
For max. efficiency: x2Pc = Pi

x=√264.43/1050=50.18% .This is good feature of distribution transformer

o Tank

Height of frame H= 721 mm. Width of

frame (W) = 789.472mm Depth of

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frame = 114.3mm

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Clearance height (h) = 450 mm
Height of the transformer tank (Ht) = H + h = 721 + 450 = 1171 mm

Clearance width (b) = 40 mm

External diameter of the HV winding (De) = 217 mm Width

of the transformer tank (Wt) = 2 *D + De + 2* b

= 2 * 337.586 + 217 + 2 * 40
= 972.172 mm
Clearance length (l) = 50 mm
Length of the transformer tank (Lt) = De + 2 * l

= 217 + 2 * 50
= 317 mm

Loss dissipating surface of tank (St) = 2 x (972.172 +317) *1171 = 3.01924 m2 The

mean temperature rise of oil is to be limited to 45 degree centigrade Temperature

rise = 1314.5/ (3.01924x12.5) = 34.83 0C
This is below 450C .So plain tank is sufficient for cooling. No tubes is required.

Design sheet
The design is carried out in 1:5 proportion as follows:
d = 134.5/5 mm = 26.9 mm ≈ 27 mm a =
114.3/5 mm = 22.86 mm ≈ 23 mm
b = 71.285/5 mm = 14.257 mm ≈ 14 mm

Ww = 203.086/5 mm = 40.6172 mm ≈ 41 mm Hw =

507.71/5 mm = 101.452 mm ≈ 101 mm

Distance between adjacent limbs (D) = 337.586/5 mm = 67.5172 mm ≈ 68 mm

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Depth of yoke (Dy) = 114.3/5 mm = 22.86 mm ≈ 23 mm

Height of yoke (Hy) = 106.4/5 mm = 21.28 mm ≈ 21 mm

Height of frame (H) = 720.51/5 mm = 144.102 mm ≈ 145 mm Width

of frame (W) = 789.472/5 mm = 157.8944 mm ≈ 158 mm Depth of
frame = 114.3/5 mm = 22.86 mm ≈ 23 mm

Axial depth of L.V. winding = 448.4/5 mm = 89.68 mm Radial

depth of L.V. winding = 17.8/5 mm = 3.56 mm ≈ 3 mm Inside
diameter of L.V winding = 140/5 mm = 28 mm
Outside diameter of L.V winding = 171/5 mm = 34.2 mm ≈ 34 mm

Axial depth of HV coil = 498.21/5 mm = 99.642 mm ≈ 99 mm

Radial depth of HV coil = 20.125/5 mm = 4.025 mm ≈ 4 mm Inside
diameter = 176/5 mm = 35.2 mm ≈ 36 mm
Outside diameter = 217/5 mm = 43.4 mm ≈ 44 mm Clearance
= 337.5 - 217 = 120.5 ≈ 121/5 mm =24.2 mm ≈

Height of the transformer tank (Ht) = 1171/5 mm = 234.2 mm ≈ 234 mm

Width of the transformer tank (Wt) = 972.172/5 mm = 194.4344 mm ≈ 194 mm Length

of the transformer tank (Lt) = 317/5 mm = 63.4 mm ≈ 63 mm

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 074BEL34
[AN ASSIGNMENT OF ELECTRIC MACHINE DESIGN] 8

fig. design of the transformer

fig. tank design

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