Electrical Machine Design

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 PRINCIPLES OF ELECTRICAL MACHINE DESIGN

Introduction

 The magnetic flux in all electrical machines (generators, motors and transformers) plays an
important role in converting or transferring the energy.
 Field or magnetizing winding of rotating machines produces the flux while armature winding
supplies either electrical power or mechanical power.
The basic design of an electrical machine involves the dimensioning of the magnetic circuit,
electrical circuit, insulation system etc., and is carried out by applying analytical equations.
 A design should ensure that the products perform in accordance with the requirements at
higher efficiency, lower weight of material for the desired output, lower temperature rise and
lower cost. Also they are to be reliable and durable.
 As the design involves a number of assumptions and constraints, final design values can be
obtained only by iterative methods.

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A electrical designer must be familiar with the,

a. National and International standards

Indian Standard (IS),
Bureau of Indian Standard (BIS), India
British Standard (BS), England
International Electrotechnical Commission (IEC)
NEMA (The National Electrical Manufacturers Association).

b. Specifications (that deals with machine ratings, performance requirements etc., of the
consumer)

c. Cost of material and labour

d. Manufacturing constraints etc.

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Factors for consideration in electrical machine design
 The basic components of all electromagnetic apparatus are the field and armature windings
supported by dielectric or insulation, cooling system and mechanical parts. Therefore, the factors
for consideration in the design are,

1. Magnetic circuit or the flux path: Should establish required amount of flux using minimum
m.m.f. The core losses should be less.
2. Electric circuit or windings: Should ensure required emf is induced with no complexity in
winding arrangement. The copper losses should be less.
3. Insulation: Should ensure trouble free separation of machine parts operating at different
potential and confine the current in the prescribed paths.
4. Cooling system or ventilation: Should ensure that the machine operates at the specified
temperature.
5. Machine parts: Should be robust.

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The factors, apart from the above, that requires consideration are
a. Limitation in design ( saturation, current density, insulation, temperature rise etc.,)
b. Customer’s needs
c. National and international standards
d. Convenience in production line and transportation
e. Maintenance and repairs
f. Environmental conditions etc.

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Limitations in design
The materials used for the machine and others such as cooling etc., imposes a limitation in
design. The limitations, from saturation of iron, current density in conductors, temperature,
insulation, mechanical properties, efficiency, power factor etc.

a. Saturation: Higher flux density reduces the volume of iron but drives the iron to operate
beyond knee of the magnetization curve or in the region of saturation. Saturation of iron poses a
limitation on account of increased core loss and excessive excitation required to establish a
desired value of flux. It also introduces harmonics.
b. Current density: Higher current density reduces the volume of copper but increases the losses
and temperature.
c. Temperature: poses a limitation on account of possible damage to insulation and other
materials.
d. Insulation (which is both mechanically and electrically weak): poses a limitation on
account of breakdown by excessive voltage gradient, mechanical forces or heat.

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e. Mechanical strength of the materials poses a limitation particularly in case of large and
high speed machines.
f. High efficiency and high power factor poses a limitation on account of higher capital cost. (A
low value of efficiency and power factor on the other hand results in a high maintenance cost).
g. Mechanical Commutation in dc motors or generators leads to poor commutation.
Apart from the above factors Consumer, manufacturer or standard specifications may pose a
limitation.

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Materials for Electrical Machines:
The main material characteristics of relevance to electrical machines are those associated with
conductors for electric circuit, the insulation system necessary to isolate the circuits, and with
the specialized steels and permanent magnets used for the magnetic circuit.
Conducting materials: Commonly used conducting materials are copper and aluminum. Some
of the desirable properties a good conductor should possess are listed below.
1. Low value of resistivity or high conductivity
2. Low value of temperature coefficient of resistance
3. High tensile strength
4. High melting point
5. High resistance to corrosion
6. Allow brazing, soldering or welding so that the joints are reliable
7. Highly malleable and ductile
8. Durable and cheap by cost

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 Some of the properties of copper and aluminum are shown in the table-1

Sl.No No Particulars Copper Copper Aluminum

1 Resistivity at 200C 0.0172 ohm / m/ mm2 0.0269 ohm / m/ mm2

2 Conductivity at 200C 58.14 x 106 S/m 37.2 x 106 S/m

3 Density at 200C 8933kg/m3 2689.9Kg/m3

4 Tensile strength 25 to 40 kg / mm2 10 to 18 kg / mm2

5 Mechanical property highly malleable and Not highly malleable and

ductile ductile

6 Melting point 10830C 6600C

7 Jointing can be easily soldered cannot be soldered easily

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MAGNETIC MATERIALS:

 The magnetic properties of a magnetic material depend on the orientation of the crystals of the
material and decide the size of the machine or equipment for a given rating, excitation required,
efficiency of operation etc.
The some of the properties that a good magnetic material should possess are listed below.

1. Low reluctance or should be highly permeable or should have a high value of relative

permeability µr.

2. High saturation induction (to minimize weight and volume of iron parts)

3. High electrical resistivity so that the eddy emf and the hence eddy current loss is less.

4. Narrow hysteresis loop or low Coercivity so that hysteresis loss is less and efficiency of

operation is high.

5. A high curie point. (Above Curie point or temperature the material loses the magnetic property

or becomes paramagnetic, that is effectively non-magnetic)

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6. Should have a high value of energy product (expressed in joules / m3).
a) Hard or permanent magnetic materials: have large size hysteresis loop (obviously
hysteresis loss is more) and gradually rising magnetization curve.
Ex: carbon steel, tungsten steal, cobalt steel, alnico, hard ferrite etc.

b) Soft magnetic materials: have small size hysteresis loop and a steep magnetization curve.
Ex: i) cast iron, cast steel, rolled steel, forged steel etc., (in the solid form).
-Generally used for yokes poles of dc machines, rotors of turbo alternator etc., where
steady or dc flux is involved.
c) Special purpose Alloys:
Nickel iron alloys have high permeability and addition of molybdenum or chromium
leads to improved magnetic material. Nickel with iron in different proportion leads to
(i) High nickel permalloy (iron +molybdenum +copper or chromium), used in current
transformers, magnetic amplifiers etc.,
(ii) Low nickel Permalloy (iron +silicon +chromium or manganese), used in transformers,
induction coils, chokes etc.
(iii) Perminvor (iron +nickel +cobalt)
(iv) Pemendur (iron +cobalt +vanadium), used for microphones, oscilloscopes, etc.
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(v) Mumetal (Copper + iron)
INSULATING MATERIALS:
To avoid any electrical activity between parts at different potentials, insulation is used. An
ideal insulating material should possess the following properties.
1) Should have high dielectric strength.
2) Should with stand high temperature.
3) Should have good thermal conductivity
4) Should not undergo thermal oxidation
5) Should not deteriorate due to higher temperature and repeated heat cycle
6) Should have high value of resistivity ( like 1018 Ωcm)
7) Should not consume any power or should have a low dielectric loss angle δ
8) Should withstand stresses due to centrifugal forces ( as in rotating machines), electro
dynamic or mechanical forces ( as in transformers).
9) Should withstand vibration, abrasion, bending
10) Should not absorb moisture
11) Should be flexible and cheap
12) Liquid insulators should not evaporate or volatilize
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 Insulating materials can be classified as Solid, Liquid and Gas, and vacuum.

Solid: Used with field, armature, transformer windings etc. The examples are:

1) Fibrous or inorganic animal or plant origin, natural or synthetic paper, wood, card board,

cotton, jute, silk etc.,rayon, nylon, terelane, asbestos, fiber glass etc.,

2) Plastic or resins. Natural resins-lac, amber, shellac etc.,

Synthetic resins-phenol formaldehyde, melamine, polyesters, epoxy, silicon resins, bakelite,

Teflon, PVC etc

3) Rubber : natural rubber, synthetic rubber-butadiene, silicone rubber, hypalon, etc.,

4) Mineral : mica, marble, slate, talc chloride etc.,

5) Ceramic : porcelain, steatite, alumina etc.,

6) Glass : soda lime glass, silica glass, lead glass, borosilicate glass

7) Non-resinous : mineral waxes, asphalt, bitumen, chlorinated naphthalene, enamel etc.,

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Liquid: Used in transformers, circuit breakers, reactors, rheostats, cables, capacitors etc.,

& for impregnation. The examples are:

1) Mineral oil (petroleum by product)

2) Synthetic oil,

3) Varnish, French polish, epoxy resin etc.,

Gaseous: The examples are:

1) Air used in switches, air condensers, transmission and distribution lines etc.,

2) Nitrogen use in capacitors, HV gas pressure cables etc.,

3) Hydrogen though not used as a dielectric, generally used as a coolant

4) Inert gases neon, argon, mercury and sodium vapors generally used for neon sign lamps.

5) Halogens like fluorine, used under high pressure in cables

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 CLASSIFICATION OF INSULATING MATERIALS BASED ON
THERMAL CONSIDERATION :

Insulation Maximum Typical materials

class operating
Temperature in ℃
Y 90 Cotton, silk, paper, wood, cellulose, fiber etc., without
impregnation or oil immersed
A 105 The material of class Y impregnated with natural resins,
cellulose esters, insulating oils etc., and also laminated wood,
varnished paper etc.
E 120 Synthetic resin enamels of vinyl acetate or nylon tapes,cotton
and paper laminates with formaldehyde bonding etc.,
B 130 Mica, glass fiber, asbestos etc., with suitable bonding
substances, built up mica, glass fiber and asbestos laminates.
F 155 The materials of Class B with more thermal resistance
bonding materials
H 180 Glass fiber and asbestos materials and built up mica with
appropriate silicone resins
C >180 Mica, ceramics, glass, quartz and asbestos with binders or
resins of super thermal stability.
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 Transformer is the Heart of the Conventional & Non-Conventional Power Plants, To decide
the Required Transformer Rating & Specification,
 We need to Check first, Whether offered Transformer Specification from the Vendor was
Compliance with IEC Standards or Not ? Suddenly Question in Our Mind that, for the
Transformer we need to refer IEC 60076 only, Is it Correct ? No...Each Power &
Distribution Transformer needs to Compliance Various IEC Standards.
 Let we See, in Detailed Manner:

IEC 60076 : This Standard Elaborates 'General Conditions of Power Transformer'

also it gives detailed Technical Information on Each part of Transformer

IEC 60034 : This Standard Elaborate 'Efficiency & Architecture of Rotating Electrical
Machines'
IEC 60038 : This Standard Elaborate 'Standard AC Voltage Levels, DC Traction
Voltage Levels

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IEC 60071 : This Standard Elaborate 'Co-ordinate of Insulation Strength'. Each
Transmission Voltage Level is having 2 Insulations, One is Lightning Impulse Withstand
Voltage kV (Peak) , Second One is Power Frequency Withstand Voltage kV (rms).

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IEC 60156 : This Standard Elaborate Method for Determination of the Electric Strength
for Insulating Oils, Also this Standard details the Required Standard Procedures for
Testing the Oils, Conditions which are needs to be Check before Oil filling to the
Transformer Tank and Procedures for the Testing of Oil at Factory and Site ..

IEC 60214 : This Standard Elaborate 'General Technical Requirements of ON-Load Tap
Changer'.

IEC 60185 : This Standard Elaborate 'General Technical Requirements of Current

Transformers.

IEC 60947 : This Standard Elaborate 'General Technical Requirements of Low Voltage
Switch gear & Control Gear'.

IEC 60551 : This Standard Elaborate 'Determination of Transformer and Reactor Sound
Levels, Normally for the Distribution Transformers, the Advisable Sound limit is <=75 dB,
If Offered Transformer Sounds More than Standard decibel level then Quality of the
Transformer needs to be investigate. To have a Proper Guidelines of Advisable Sound
Limit of Power Transformer Designer needs to refer this Standard.

IEC 60616 : This Standard Elaborate 'Terminal & Tapping Markings for Power
Transformer'.
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IEC 60606 : This Standard Elaborate ' Application Guide for Power Transformer '
Required Technical Guidelines for different Transformer like Auto Transformer, Booster
Transformer, Interconnecting Transformer, Arc Furnace Duty Transformer, Traction
Transformer - Need to refer this Standard to have more clarity on the Application of the
Transformer.
IEC 60529 : This Standard Elaborate 'Degrees of Protection Provided by Enclosures' (IP
Code), This Standard Gives General Technical Requirements for the Indoor & Outdoor
Protection Code Guidelines for the Electrical Equipments.
IEC 60542 : This Standard Elaborate 'Application Guide for ON-Load Tap Changers. Tap
Changer Architecture may differ Subjected to the Application of the Transformer. So to get
better idea on the Tap Changer, Designer needs to refer this Standard.
IEC 60242 : This Standard Elaborate 'Standard Frequencies for Centralized Network
Control Installations'. This Code will help us, While Initiating Synchronization of EHV /
HV Substations, also it will be more helpful in Generating Station also.

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