Design of Distribution Transformer
Design a Transformer to meet the following Specification:
Type of Distribution : CORE
Output in KVA : 50kVA
Primary (HT) Volts : 2400 V
Secondary (LT) Volts : 480/240 V (multi-tap)
Frequency : 60 Cycle
Efficiency at Unity Power Factor
Full Load : 98.4 %
¼ Load : 97.8 %
Temperature rise not to exceed to 55⁰c
CALCULATIONS:
Guaranteed Losses:
1−0.984
Total Loss @ Full Load ¿ x 50000=813 watts
0.984
1−0.978 50000
Total Loss @ ¼ Full Load ¿ x =281.186 watts
0.978 4
813−281
¿ =567.268 watts
Full Load Copper Loss 1
1−
16
Core Loss ¿ 813−567.268=245.73 watts
Item 1. Volts Per Turn (assume c = 60)
V t = √ 5 0000 = 3.73 volts
60
Item 2 to 4. Primary and Secondary Turns. It is desirable to use Two coils on the High
Tension Side
and Four coils of the Low Tension Side.
480
Total Secondary Turns = = 128.686 (say) 132 turns
3.73
132
Turns per Secondary coils = = 33 turn/coil
4
2400
Total Primary Turns = =660 turns
3.73
660
Turns per Primary coils = = 330 turn/coil
2
Item 5. Full Load Current
@ High Tension @ Low Tension
50000 50000
Is ¿ =104.167 amp. I p= =20.83 amp.
480 2400
Item 6 to 15. Before deciding upon the sizes of wire in the windings, it would be advisable
to
the probable dimensions of the opening or window, which must accommodate both primary
and secondary windings. (assume Current Density = 1500 amp/sq. inch)
10
Space factor = =0.309
30+2.4
2(132 x 104.167)
H x D= =59.3313 sq . inch
1500 x 0.309
H
=3.5inch
D
D ¿ 4.11 inch
H=14.41 inch
108 x 480
By formula, the flux in the iron is Φ= =1365001.365maxwells
4.44 x 132 x 60
From art 130. We select 70000 lines per sq. in as a trial density in the limbs under windings.
Hence the proportion S = 2L and stacking factor of 0.9 assume S = 1.5L.
1365001.365
0.9 L x 1.5 L= L=3.8 inch
70000
M =L=3.8 inch S=1.5 ( 3.8 )=5.7inch
Assuming M=L, the same cross section of iron and the same flux density in the end of the core as
in the limbs under windings M= 3.8 inch
Weight of iron ¿ 0.28 ( SF x L x S ) 2( H +S + L+ M )
¿ 0.28 ( 0.9 x 3.8 x 5.7 ) x 2 ( 14.41+5.7+3.8+3.8 )
W iron=302.5 lb .
Total core loss watts per pound of B= 70000 be 0.75 from fig. 154
Total Core Loss=W iron ( 0.75 )=302.5 ( 0.75 )=226.875 watts
The total Core Loss needs to be increased to meet the guaranteed Core Loss of 245.73.
By making slight changes in the design and decreasing the number of turns in the windings, it will
now be possible to proceed with the final calculations and approxiamate the losses required to
give the specified efficiencies.
Recalculation of Core Loss
The total flux is:
132
Φ=1,365,001.365 x
116
= 1,553,277.415 maxwells
Calculating the losses in the limbs under the windings and in the end sections must be calculated
separately.
For the losses of the 2 limbs under windings:
Φ 1,553,277.415
CSA=0.9 x 3.8 x 5.7 β= =
CSA 19.494
¿ 19.494 sq. in ¿ 79679.769 (say) 80,000 lines per sq. In.
We read watts loss per pound be: 0.95
Weight of 2 limbs under windings¿ 0.28 x 19.494 x 14.41 x 2
¿ 157.3 lbs.
Core Loss of 2 limbs under windings ¿ 157.3 x 0.95=149.44 watts
For the losses of the 2 end sections, it will also be calculated in the same manner.
Henc, adjusting M=5.
1,553,277.415
CSA=0.9 x 5 x 5.7 β=
25.65
¿ 25.65 sq .∈¿ ¿ 60 , 556.62(say) 61,000 lines per sq. In.
We read Watts loss per pound be: 0.57
Weight of 2 end sections ¿ 2 x 0.28 x 25.65 x (4.11+ ( 2 x 3.8 ))
¿ 168.2lbs .
Core Loss of 2 end sections ¿ 168.2 x 0.57 ¿ 95.874 watts
Total Core Loss ¿ 149.314+ 95.874=245.314 watts which is practically the specified Loss of 245. 75
watts
Core Dimensions:
L= 3.8 in. M= 5 in. H= 14.41 in.
S= 5.7 in. D= 4.11 in.
Size of Wires And Winding Particulars
Thickness CSA / Width
I s 104.167
= =0. 6933 sq .inch .
∆ 1500
Length of winding space in the Layer = 13.91 (from fig.)
13.91
Width of one Conductor including insulation = =0.4797∈¿
29
Cotton Coverings = 0.02 in (20 mils)
Width of Copper = 0.46 inch
0.06933
Thickness = = 0.15175 inch
0.46
For rectangular conductor ¿ 0.46 by 0.1575=0.07245 sq . inch.
For high tension side select the size of wire at the table n page 431 use size #7 DCC wire
20.83 amp
Current Density= =1 223.24
0.01635 sq .inch
Length of winding Layer = 13.66 (assumption)
Number of Wires per Layer = 13.66 x 6.35 = 86.74 (say) 87
where 6.35 is obtained from the wire table on page 431.
580
Total Number of Layers of Wire ¿ =6.67 ≅ 7 layer
87
(for each 2 limbs)
2 x 87
Volts (RMS) ¿ 1200 x =360 volts (rms value)
580
It is usual to limit the potential
difference between layers which can
generally be accomplish the number
of windings in the sufficient number
of separate coils providing adequate
insulation between coils with core
dimension.
Thickness of copper and insulation
is computed as follows.
Item 16 to 23.
Materials Radial Thickness
Cotton tape binding assembled laminations 0.018
Varnished cambric 0.010
Pressboard 0.030 t = 0.125
Clearance 0.067
Inner L.T. coil (one layer) including cotton on wire 0.190
Parchment paper (0.010) between coils; allow 0.015 s = 0.395
Outer L.T. coil (one layer) 0.190
Pressboard around outer L.T. coil 0.020
Spacers of treated wood to form oil ducts 0.125
Pressboard 0.020 g = 0.188
Two layers cotton tape 0.018
Parchment paper w/ crimped edges on w/c primary and
secondary coil will be wound 0.005
18 layers of No. 13 dcc round wire 1.092
Two thickness of 0.005 papers between layers 0.080
Cotton tape, half lapped 0.018 p = 1.304
Allowance for bulging (0.02 x 3.05) 0.114
Total 2.012
4.11
Space available to accomodate this total thickness of copper and insulation = =2.055 in.
2
CALCULATION OF COPPER LOSS
The mean length per turn (MLT) of the windings
2 (3.8+ 5.7 ) + π ( 0.25+ 0.395 )
Secondary MLT = =1.75 ft
12
2 (3.8+ 5.7 ) + π (0.25+0.79+ 0.304)
Primary MLT = =1.72 ft
12
Total Length of Wire
Primary Winding = 580 x 1.72 = 997.6 ft
Secondary Winding = 116 x 1.75 = 203 ft
Weight of Copper Loss
Primary Coils (No.7), 63 x 0.9976 = 62.85 lb
Secondary Coils = 0.32(0.46 x 0.151) x 203 x 12 = 54.145 lb
Since the resistance of No.7 DCC wire is 0.5790 Ω,
234.5+75
0.5790 x [
234.5+60 ]
=0.61 Ω
Total Resistance
(Primary)
RT = 0.61 x 0.9976 = 0.61 Ω
IR = 20.83 x 0.61 = 12.68 volts
I 2 R=20.832 x 0.61=264.67 watts
(Secondary)
0.0635 203
RT= 0.61 x [ x]
0.0726 1000
=0.02789 Ω
IR = 104.167 x 0.02789 = 2.9 volts
I 2 R=104.1672 x 0.02789=302.63 watts
Total Copper Loss = 264.67 + 302.63 = 567.3 watts
Items 24 – 32. Core and Copper Losses 245.31 + 567.3= 812.61 watts
Items 33. Efficiency at unity power factor
50,000
1 4
@ Full Load : 1− =98.77 %
4 567.3 50,000
120+
16 4
245.31+567.3
@ Full load : 1− =98.4 %
50000+812.61
245.31+141.825
@ Half Full load : 1− =98.5 %
25000+203.1525
@ Three quarter full load :
0.75 x 50,000
(0.75¿¿ 2 x 567)+120+(0.75 x 50,000)=98.42 % ¿
@ 25% over load :
1.25 x 50,000
(1.25¿¿ 2 x 567.3)+120+(1.25 x 50,000)=98.42% ¿
Maximum Efficiency:
245.31
¿ 50000
√
567.3
=32.88 KVA
245.31+245.31
¿ 1− =¿94.5%
8439.3+ 490.62
Items 34. Basis of 4 hour full load and 20 hour no load.
All Day Efficiency:
50000 x 4
¿ =96.7 %
(50000 x 4 )+ (145.31 x 24 ) +(812.4 x 4 )
Item 35. For the two limbs under the winding with mean length
B = 80,000
Mean Length = 2 x (3.8 + 5.7 + 4.11) = 27.22
T x I =[ 27.22 ] x [ 0.8 ] =21.78
Mean Length=2 x ( 5+5.7+ 4.11 )=50.22
T x I =50.22 x 3.5=175.77
Total (T x I) = 21.78 + 175.77 = 197.55 amp. turns
total I x T 197.55
Ic= = =0.2408
Np¿¿ 580( √ 2)
core loss 245.31
Energy Component =I w = = =0.1022 amp .
H . T . volts 2400
I =√ I c2 + I w 2=√ (0.1022)2+(0.2408)2=0.2616 amp .
Item 36 to 39. Regulation
812.61
% IR Drop= x 100=1.7087
50000
1.75+1.72
length=12 x =18.06
2
2 f T s I sl p+ s 2 x 60 x 116 2 x 104.167 x 18.06 1.304+ 0.395
%IX Drop=
n h Es 10 5 [
x g+
3 ]
=
2 x 14.41 x 480 x 10 5 [
x 0.188+
3 ] =1.656
Equivalent Reactive Drop=2400 x 0.01656=43.24 volts
% Regulation @ 0.80 power factor
¿ %IR cosθ+%IX sinθ
¿ 1.6252 ( 0.80 )+ 1.656 ( 0.60 )=2.49 %
Item 40 to 42. The temperature rise of the windings as measured by the resistance method
must not exceed the specified 55℃.
For the dimension of tank total area
245.48
S= =861 sq . inch
50 x 0.0057
Dimension are 15’ x 12’ x 24’ in high
1
Cooling Effective Surface ¿ 20 [ ( 15 x 2 ) +(12 x 2)] + ( 24 x 15 ) =1440 sq . inch.
2
861
For Watts ¿ =0.6
1070
245.48
For temperature ¿ =42 ℃
0.0041 x 1440
Item No. SUMMARY OF CALCULATIONS
1 Volts per turn : From formula = 3.73 v ; actual = 4.138 v
Windings High Tension Low Tension
2 Total numbers of turns 580 116
3 Numbers of coils 2 4
4 Turns per coil 290 29
5 Full Load Current (Amp) 20.83 104.167
6 Current Density(amp ./inch2) 1223.24 1500
7 Cross Section of Conductor 0.01635 0.07245
8 Dimension of Conductors No. 7 0.46 x 0.1575
9 # of Turns per Layer per Coil 87 29
10 # of Layer per Coil 7 1
11 # of Taps None 2
12 Volts per Coil 1200 120
13 Volts Between Layers 360
14 Length of Winding Layers 13.68 13.91
15 Length of Layer Including Insulation 14.41 14.41
16 Insulation Between Layers 0.02
17 Insulation on Wire dcc dcc
18 Length per Turn 1.72 1.75
19 Total Length, all Turn in series, ft 997.6 203
20 Weight in Copper(lbs) 62.85 54.145
21 Resistance a 75 ⁰c All Coils 0.61 0.02789
22 IR Drop Volts 12.68 2.9
23 Full Load Copper Loss(Compare to Guaranteed) 246.67 302.63
THE MAGNETIC CIRCUIT
24 Dimension of ”Windows” 14.41 x 4.11
25 Total Flux, Maxwell’s 1553277.415
26 Flux Density in Core Under Windings 80000
27 Cross Section of Iron in Core Under Windings 19.494
28 Width of Stampings in Core Under Windings 3.8
29 Gross Thickness of Core 5.7
30 Total Weight or Iron in Core, lbs. 325.5
31 245.31
Watts Loss in Iron (compare to guaranteed)
32 Total Full Load Losses, watts 812.61
EFFICIENCY AND EXCITING CURRENT
33 Efficiency at Unity Power Factor
At Full Load 98.4%
At ½ Load 98.5%
At ¼ Load 98.77%
At ¾ Load 98.84%
At 25% Over Load 98.42%
34 All Day Efficiency (4Hr Full Load) 96.7%
35 Primary Exciting Current, Amp. 0.2408
REGULATION
36 Total Equivalent IR Drop Percent 1.6252
37 Total Reactive Drop Percent 1.656
38 Regulation on Unity Power Factor 1.6252
39 Regulation on 0.80 Power Factor 2.29376
DESIGN OF TANK – TEMPERATURE RISE
40 Effective Cooling Surface of Tank, sq. inch. 3020
41 Watts per square inch of Tank 0.269
42 Approximate Temperature Rise, ℃ 47.2℃
