TRANSFORMER DESIGN : CALCULATIONS SHEET: SPECIFICATIONS AND DESIGN DATA: KVA= Vp(line)= Vs(line)= frequency= phases= 1000 11000

430 50 3 connection= Type: Tappings: Temperature rise: %impedance= CALCULATIONS: Taking value of k, for distribution transformers as: Voltage per turn : therefore flux in core is: Taking the flux density as: Thus the iron area required is: Take stacking factor (for cold rolled grain oriented steel) Gross iron Area available is: k= 0.45 Delta-Star Core type, Distribution 2.5% - 5% <=40 deg < 5%

KV V Hz

Et= fm= Bm= Ai= ks=

14.2302495 V 0.06410022 Wb 1.6 Wb/m^2

0.04006264 m^2 0.97

Ag=

0.04130169 m^2

CORE DESIGN: Per phase primary: Per phasesecondary: Voltage: Current: Voltage: Current: V(H.V)ph= I(H.V)ph= V(L.V)ph= I(L.V)ph= k1= 11000 30.3030303 248.260616 1342.67504 0.92 Actual 0.23908072 m 0.22951749 0.21158643 0.18528756 0.15085993 0.11117253 0.05977018 m m m m m m Taken 240 230 212 186 151 112 60 KV A KV A

Taking a 6 step core :

Diameter of circumscribing circle:

d= a= b= c= d= e= f=

mm mm mm mm mm mm mm

Modified values of

iron area: Ai '= flux density: Bm'=

0.04037132 m^2 1.58776636

WINDOW AND YOKE DESIGN:

Take Window space Factor as: Selecting Current Density: Window area required by Output Equation: Selecting Height to Width Ratio as: Window Height: Window Width: Distance Between Limbs; Taking the Yoke also to be 6 stepped: Height of yoke: Depth Of Yoke:

Kw= d= Aw= Hw/Ww= Hw= Ww= D=

0.3 2.75 A/mm^2 0.11357226 m^2 2.5 0.53285144 m @ 0.21314057 m @ 455 mm 530 215 mm mm

Hy= Dpth=

230 230

mm mm

Overall Height: Overall Width

H= W=

990 1150

mm mm

WINDING DESIGN: Actual 5% tap Integral value Taken 773.001206 811.6513 819 17.4459778 18

Total Primary turns Required= Total Secondary turns Required=

T(H.V)= T(L.V)=

Area of conductors:

H.V: L.V:

ah= al=

11.0192837 mm^2 488.245471 mm^2

L.V WINDING DESIGN: Taking Stranded Conductors: Area per Strand is: Strands= a= 15 32.5496981 mm^2

Selecting a Double Helical Winding , Taking the distribution of each L.V Conductor as: 5 Vertical and 3 horizontal,(Rectangular Conductor) From the Conductor Size data sheet: Dimensions of each Strand is the per strand area is 32.1mm^2,thus modified value of current density: h= w= d'= 6 5.5 mm mm

2.78852553 A/mm^2

Taking 0.25mm insulation all over Dimension of each strand is: Therefore Conductor Size is:

h'= w'= Hc= Wc=

6.5 6 32.5 18

mm mm mm mm

Thus the L.V Winding comprises of 2 Layers Helicaly Positioned and,

9 conductors per layer for a total of 18 conductors, taking 2mm for duct between the 2 layers: Taking space between conductors for cooling as: sp= Total Winding Height:= Total Winding Width:= H= W= 20 452.5 38 mm mm mm

Taking 5mm clearance for bakelite former between lv and the core: inner diameter of L.V Winding: outer diameter of L.V Winding: Length of mean turn is din= 250 dout= 326 Lmt(h.v)= 904.7808 H.V WINDING DESIGN: The H.V Winding design is done using the cross over winding using rectangular conductors. A total of 819 turns are accomodated using 13 coils and 7 coils per layer. Each coil consists of 9 horizontal winding turns.Thus total turns=7*13*9=819. voltage per coil is: the area of each conductor is 10.9mm^2 thus, modified value of current density: Dimensions for each conductor V/coil= d'= h= w= h'= w'= hc= wc= 846.153846 V mm mm mm

2.78009452 A/mm^2 3.8 3 4.3 3.5 30.1 31.5 mm mm mm mm mm mm

including the 0.25mm insulation all over:

Thus,

Coil Height coil width ;

using inter coil spacing of 5.5mm and inter layer(horizontal)spacing of 1mm Winding Height= H= W= 457.3 39.5 12 350 429 mm mm mm mm mm mm

Taking the clearance between H.V and L.V as: a= inner diameter of H.V Winding: outer diameter of H.V Winding: Length of mean turn is din= dout=

Lmt(h.v)= 1223.6532

OPERATING CHARACTERISTICS: RESISTANCE; Resistivity of copper is= r= 0.021 W-mm^2/m

Resistance of: Resistance of:

H.V: L.V:

r(H.V)= r(L.V)= Req= Rp.u=

1.8026211

0.00070048 W 3.17782364 W 0.00875434

Equivalent Resistance refered to H.V: p.u value of resitance=

REACTANCE: Average mean turn is: Average Height of Winding: Ratio of Lmt/Lc is value of reactance is: p.u value of reactance: Net impedance is: p.u value of impedance is: Lmt(avg) Lc= Ratio= X= Xp.u= Z= Z(p.u)= 1064.217 454.9 2.33945263 20.8789598 W 0.0575178 20.9028936 W 0.05758373 mm mm

REGULATION: at 0.8 pf full load regulation is: at upf full load the regulation is: Reg(p.u)= 0.04151415 Reg(p.u)= 0.00875434

LOSSES AND EFFICIENCY: IRON LOSSES: From the loss graph of the crgo grade 56 loss curves, Loss per unit volume is now total fluxpath length is: volume of the iron parts: Taking density of grade 56 crgo is: Total mass of the iron parts is: thus total iron loss is: Loss/vol= 1.42 L= volume= s= M= Pi= W/kg

4120 mm 0.16632984 m^3 7650 kg/m^3

1272.42324 kgs 1806.841 W

Total copper Losses is=

Pc=

8754.3351

thus %full load at max efficiency is and efficiency at 0.8pf is: upf is:

x= h= h=

0.45430591 0.98697054 0.9895492

MAGNETIZATION CHARACTERISTICS: Total iron losses= Pi= 1806.841 0.05475276 110 453.2 AT AT W

Thus the loss component of no load current is: Il= now the mmf/meter for iron is: Total mmf required is taking atotal of 0.05mm air gap per joint Total airgap length is: mmf required for the air gap is: Total mmf Required is the magnetizing current per phase is: thus the no load current is: Ati/m= Ati=

La/g= Ata/g= AT0= Im= I0=

0.3

mm

381.063927 AT 834.263927 AT 0.25438239 0.26020812 0.858687 % of full load current.

OVERALL TANK DIMENSIONS AND VOLUME: Taking the basic clearances of: b= l= h= W= L= H= V= 50 80 300 1439 589 1290 1.131 mm mm mm mm mm mm m^3 1450 600 1300 mm mm mm

Width of the tank is=

thus total volume of tank is: for calculation of copper volume: volume of lv winding: volume of hv winding: Thus total copper volume is total iron volume is thus volume of oil in transformer (including radiators is:)

V(lv)= V(hv)= V= V= V(oil)=

0.01555771 m^3 0.02210328 m^3 0.11298295 m^3 0.16632984 m^3 1.34667402 m^3

CONSERVATOR DESIGN: Volume of conservator is taken . as 10% of oil in tank and radiators thus taking length to diameter ratio as: V(cons)= R= D= L= 0.1346674 m^3

2.5 0.40933341 m 1.02333352 m

DESIGN OF COOLING ARRANGEMENTS (RADIATORS): Value of thermal coefficient at 75 deg c is Temperature rise limits specified: Total Watts dissipating from surface for the requisite temperature rise is: Surface Area of Tank is: Total Watts that are dissipated from the tank walls naturaly is= Thus the total watts required to be dissipated by radiators is Taking height of radiators as: thus the watts per section for this height and temperature is: thus no of section required is now the values of spacing constants are: C= q= W/m^2= 12.5 40 500 W/(m^2-degC) degC W/m^2

St=

5.33

m^2

Diss= Rdwats=

2665 7896.1761

W W

Hrad=

1200

mm

W/sectn= 167 sections= 47.2824916 c= b= d= 0.955 0.93 1

Modified value of no of sections required

sections= 53.2370564 56

Thus we select 56 elliptical Radiator sections in total of 6 Radiators,with 7 sections per radiator. Thus Radiator section dimensions are: h= w= l= 1200 300 25 50 A= V= Vnet= mm mm mm mm

Horizontal distance between each Section is: vertical surface area of each radiator is: Volume of each radiator= Net Volume of all Radiators

0.00736588 m^2 0.00883905 m^3 0.4949868 m^3

TRANSFORMER DESIGN

KVA= 25000 Vp(line)= 33 Vs(line)= 6.9 frequency= 50 phase= 3 transportation height=3.5m load loss= 20 no load loss= 110 load loss capitalization= load loss capitalization= Bmax= 1.7 tesla current density= 3 width of conductor= 17<x<6 ratio= 2>y>7 specific loss= 1.2 copper rate= 425 iron rate= 180

KVA KV KV Hz

connection= type= temp= tappings=

Star-Delta power transformer 75 10.00%

KW KW 1 lakh/KW 5 lakh A/mm2 thickness of conductor= stacking factor= KW/Kg Rs./Kg Rs./Kg CALCULATIONS 4<x<1.5 0.9

HV side voltage: LV side voltage:

Vhv= Vlv=

19.05255888 KV 6.9 KV

Current in HV & LV Current in HV: current in LV: Iph(hv)= Iph(lv)= Core area assuming diameter: core area: D= A= 440 mm 136847.776 mm2 437.3865676 1207.729469

No. of turns in HV & LV HV no. of turns: LV no.of turns N(hv)= N(lv)= 133.6009207 368.9042622 332.1 405.9 134 369 333 406

min.HV turns(90%): N(hv min)= max. HV turns(110%) N(hv max)=

Height of core structure assuming height of core structure 2500 mm. H= 2500 mm height of core window: H(window)= 1620 mm height of winding: H(wdg)= 1470 mm Design of HV winding using Disc winding. assuming No. of turns/disc=

HV no.of turns: No. of discs: actual No. of discs:

T(hv)= Discs=

369 123 128 8.184375 2.5 174.954627 3.47 6.160421642

123

width of HV conductor:w(hv)= assuming current density: area of conductor: a(hv)= assuming thickness: No. of parallel paths: paths=

Design of LV conductor area of conductor: a(lv)= width of LV conuctor: w(lv)= assuming thickness: No. of parallel paths: paths= 483.0917874 7.670149254 2.5 25.19334482 26

Design of Tapping winding winding turns: T(tap)= assuming no. of turns per discs: No. of discs: Discs= actual no. of discs: Discs= ht of tapping winding: ht(tap)= 73 3 24.33333333 28 964.6875

25

Calculation of %Z width of air gap btwn core & LV: width of air gap btwn LV & HV: width of air gap btwn HV & tap: width of LV winding: Inner Dia for LV: mean dia of LV: width of HV winding: Inner Dia of HV: mean dia of HV: T1= ID(lv)= D1= T2= ID(hv)= D2= Tg= Tg1= Tg2= 78 470 587 71.46 656 763.19 23.82 818.92 854.65 626 661.73 798.92 813.92 45516.09745 mm2 455.1609745 15 mm 15 mm 10 mm

width of Tapping wdg T3= Inner Dia of Tapping: ID(tap): mean dia of Tapping: D3= ID for air gap btwn HV-LV: mean diameter Dg1= ID for air gap btwn HV-Tap: mean diameter: Dg2= summation ATD: ATD=

Rogowski Factor:

Kr= Heq=

0.964388269 1524.282332 mm 152.4282332 cm 161395.6434 52.17758139 11.45326084 %

Ampere turns: Volts/turns: % impedance:

AT= V/T= %Z=

Width of core width of transformer: W(core)= Volume of core volume of 3 limbs: volume of 2 yokes: total volume of core: vlm(limb)= 738977990.3 vlm(yoke)= 736777185.3 total= Core loss Weight of core: No load loss: wt= core loss= 11289.52709 18.06324335 KW 1475755176 2536.76

Copper loss mean dia of LV: mean dia of HV: mean dia of Tap: d(lv)= d(hv)= d(tap)= 548 mm 727.46 mm 842.74 mm 1721.592774 2285.382992 2647.545793 483.0917874 mm2 174.954627 mm2 230693.4317 mm2 843306.324 mm2 74131.2822 mm2 0.009550708 0.09640286 0.008474344 41.79228836 KW 56.94720892 KW

mean length turn LV: Lmt(lv)= mean length turn HV: Lmt(hv)= mean length turn Tap: Lmt(tap)= area of conductor LV: a(lv)= area of conductor HV: a(hv)= length of LV: length of HV: length of Tap: resistance LV: resistance HV: resistance Tap: Copper loss in LV: l(lv)= l(hv)= l(tap)= Rlv= Rhv= Rtap= loss(lv)=

Copper loss in HV(normal tap)= Total loss total loss:

116.8027406