Design

of
100KVA,
15KV/40
0V
Distribu
tion
Transfor
mer
Specifications of the transformer

S.N Specifications Requirements

1 Power Rating 100KVA
2 Primary Voltage 15KV
 3 Secondary Voltage 0.4KV
4 Number of phases 3
5 Frequency 50HZ
6 Vector group DYn5
7 Transformer type Oil immersed, ONAN
8 Winding material Copper
9 Tapping on HV ±2.5% & ±5%
10 No load loss 145W
11 Load loss 1700W
12 Frequency withstand voltage 50KV
13 Impedance 4%
14 Flux density 1.7 Tesla (maximum)
15 Temperature rise 30°C - 50°C
16 Current density 2.3 A/mm2

Design of Primary coil

From specification,

Rated KVA = 100KVA

Primary line to line voltage, VL = 15KV
 Secondary line to line voltage, VS = 0.4KV

Primary phase voltage, Vpp = VL = 15KV (Since the connection is Delta)

Rated KVA 100 KVA

Primary Line current, IL = = = 3.849A
√ 3V L √3 x 15 KV
IL 3.849 A
Primary phase current, Ip = = = 2.222A
√3 √3
0.4 KV
Secondary phase voltage, Vsp= induced EMF per turn = = 230V
√3
1. Size of primary conductor
Current density (δ) of a conductor is given by,

Ip
Current density, δ = , where A – cross sectional area of the conductor
A
Ip 2.222 A
A= = = 0.966 mm2
δ 2.3 A /mm2
2. Number of primary turns
Rated voltage per phase per turn, Et is calculated as,

Et = K√ Q

Where Q – rated power in KVA

K – Transformer constant which depends on the type, service condition and method of
construction of transformer, and its value is 0.45 for three phase core type distribution transformer.

Et = 0.45x√ 100 = 0.45x10 = 4.5V (this is induced EMF per turn)

400V
Secondary phase voltage
Number of secondary turns per phase, Ns =
Induced EMF per turn
= √3 = 51.32 = 52 turns
4.5
Number of primary turns per phase, Np = turns ratio x Number of secondary turns per phase

Primary phase voltage

= x Ns
Secondary phase voltage
15000V
= 400 V x 52 turns
√3
= 3377.49

Therefore, number of turns in the primary side without tapping is 3377 turns.
 3. Number of turns with tap changer
To calculate number of turns with tapping, we use ±2.5% and ±5% based on the specification

Number of turns @ tap 1 = Np+ 5% Np = 3377 + 0.05 x 3377 = 3546 turns

Number of turns @ tap 2 = Np+ 2.5% Np = 3377 + 0.025 x 3377 = 3461 turns

Number of turns @ tap 3 = Np+ 2.5% Np = 3377 + 0.025 x 3377 = 3461 turns

Number of turns @ tap 4 = Np- 2.5% Np = 3377 - 0.025 x 3377 = 3293 turns

Number of turns @ tap 5 = Np- 5% Np = 3377 - 0.05 x 3377 = 3208 turns

Total number of turns in primary winding with tapping is 3546 turns.

 Type of conductor and Types of transformer winding

1. Type of conductor
The choice of conductor winding depends on various factors such as the application, operating
conditions, cost considerations, and performance requirements. Both copper and aluminum are
commonly used conductor materials in transformer windings, each with its own set of
advantages and disadvantages.
Copper conductors are known for their excellent electrical conductivity, high thermal
conductivity, and superior mechanical properties. Copper has lower resistivity compared to
aluminum, which results in lower resistive losses and higher efficiency in transformers. Copper
conductors also have better mechanical strength and durability, making them suitable for high
temperature applications and environments.
On the other hand, aluminum conductors are lighter in weight and less expensive than copper
conductors. Aluminum has a high resistivity compared to copper, leading to high resistive losses
in transformers. However, aluminum conductors can be larger in size to compensate for the
higher resistivity, making them suitable for high-voltage applications where weight is a critical
factor.
In general, copper conductors are often preferred for high-efficiency transformers and
applications where size and weight are not significant concerns. Aluminum conductors are
commonly used in medium to high-voltage transformers where cost considerations and weight
savings are important factors.
The choice between round and rectangular conductors for transformer windings also depends on
various factors such as the application, space constraints, current-carrying capacity, and
manufacturing considerations.
Round conductors are commonly used in transformer windings due to their ease of winding and
good current carrying capacity. They have a uniform cross-section, which helps distribute the
current evenly throughout the winding, reducing hot spots and improving efficiency. They also
have good mechanical strength and flexibility, making them suitable for various winding
configurations.
Rectangular conductors, on the other hand, have relatively larger surface area, which can help
improve heat dissipation and reduce hots pots in the winding. They are often used in high-current
applications where heat dissipation is a critical factor. They can also be stacked more efficiently
in the winding, allowing for better space utilization in compact transformer designs.
If the conductor area is more than 7 mm2, we should use rectangular conductors.
 2. Types of transformer winding

Transformer windings may be classified into two groups viz. concentric winding and sandwiched
winding. Concentric windings are used in core type transformers. Sandwiched windings are
almost exclusively used in shell type transformers. The positioning of the H.V. and L.V.
windings with respect to the core is also very important from the point of view of insulation
requirement. The low-voltage winding is placed nearer to the core in the case of concentric
windings and on the outside positions in the case of sandwiched windings on account of less and
easier insulation facilities.
A. Concentric Windings
The concentric windings may be classified into four major groups, viz.
1. Cylindrical windings
2. Helical winding
3. Crossover winding
4. Continuous disc winding
5. Aluminum foil windings
1. Cylindrical windings
Cylindrical windings are layered type, and use either rectangular or round conductors.
Conductors are wound on the flat side with their longer sides parallel to the core axis. The
layered winding may have conductors wound in one, two or more layers and is, therefore,
accordingly called the one, two or multi-layered winding. Cylindrical windings employing
rectangular conductors are used mainly as low voltage windings up to 6.6 KV and their current
rating ranges from 10 – 600 A.
Cylindrical windings using round conductors are usually multi-layered. They are wound on a
solid paper Bakelite cylinder. In order to improve cooling conditions of the inner layer, these are
often wound on vertical strips forming an oil duct, between winding and insulating cylinder.
These windings are applicable where high voltage ratings are used up to 33 kV, 800 kVA &
current ratings up to 80 A. For a bare conductor, the highest diameter size used is 4 mm.
2. Helical winding
Helical windings are known as spiral windings which are used for low voltage & high capacity-
based transformers, where the flow of current is higher & the turns of winding are smaller. They
are mostly used for LV coils of medium & high capacity transformers with currents as high as
say 2000A. Here axial spacing strips are provided for duct formation to improve oil circulation
for better cooling. The ducts are formed by spacers placed all the way round the periphery of the
cylinder at regular intervals. For uniform division of current between the parallel conductors,
they are transposed so that each conductor may take each possible position. The transformer
output changes from 160 to 1000 kilovolt-ampere & 0.23 to 15 Kilovolt. For protecting sufficient
mechanical power, the cross-sectional area of the strip is not made less than 75mm to 100mm
square. The maximum number of strips that are used to make up the conductor in parallel is 16.

3. Crossover winding
The whole cross-over winding is divided into a number of coils depending upon the voltage
rating. Each coil is wound over a former usually U pieces, with several number of layers & many
number of turns per layer. The coil ends, one from inside and other from outside are joined to
other similar coils in series. Various coils are separated by blocks of insulating material to allow
free oil circulation.
Suitable for current rating not exceeding about 25 A. Mostly used for HV windings of low rating
transformers where number of turns may be large but conductors are of small cross sections with
double cotton covering or paper covering.

4. Continuous disc winding

A Continuous disc winding consists of several discs. In each disc there are radially wound strip
conductors so that there may be several layers in each disc. Layers are wound spirally from
inside outwards. The discs are separated from each other by press board sectors.
The winding is named “Continuous Disc” as it is wound with a continuous conductor without a
single joint.
These are reliable & strong, and therefore are widely used both as LV and HV coils in large
capacity transformers.

5. Aluminum foil windings

Aluminum in place of copper can be used as a material for conductors in any of the windings. When
used as a single section has many disadvantages compared to copper. Hence, they are employed in
foil windings, because it can be rolled to thinner and more flexible sheets than copper.
 Fig 1.1: ranges of different windings types

B. Sandwiched Winding
Sandwiched windings are commonly employed for shell-type transformers. The leakage
reactance of the windings can be easily controlled by employing sandwiched winding. The
nearer are the high voltage and low voltage coils, the less is the leakage flux. Leakage can be
further reduced by subdividing the high voltage and low voltage coils. The high voltage sections
lie between two consecutive low voltage sections. The two end sections are low-voltage sections
and contain half the turns of other low-voltage sections. Each normal section, whether high
voltage or low voltage, has equal number of ampere-turns in order to balance the mmf of
adjacent sections. Lower values of reactance can be obtained by increasing the number of
subdivisions.

In our case, in this transformer, we select round copper conductor using cross-over winding for
HV winding, and rectangular copper conductor for using cylindrical winding for LV winding.