Electrical Machine Design

Lab Report
EE3706

Design of 1-Φ Transformer

Name: Kinjal Bhat-

tacharyya
Roll: 122EE0146

Aim: To design a 300kVA, 50Hz, 6600V/440V 1-

Φ core type, oil immersed, naturally cooled
transformer whose mean temperature rise of
oil shouldn’t exceed 45°C.

• Design of Core:

Emf per turn for the core is given by:

Et =k √ Q

ϕm
where K= √ 4.44 . f . r .10 and r = A T . 3

Plugging k = 0.78 (kV/A)^0.58 and Q = 300

kVA,
Et =13.50 V

Choosing the core to be 2 stepped & selecting

magnetic flux density : Bm =1.3 Wb/m^2.
Et ϕm Ai
From ϕ m =
4.44 . f , Ai=
Bm , A g i=
Ki ( Ki = 0.9 for cruciform
core )

The following values are obtained:

ϕ =0.060Wb , Ai = 0.046 m^2 and Agi = 0.052m^2
m

A
Now we know that d= 0.618 , a = 0.85.d and b = √ gi

0.53.d
Using these we obtain:
d=290 mm, a = 246 mm and
b=154 mm.
Window Dimensions:
Empirical relation for window
space factor(Kw) is given by :
10
30+ k V for 50 <
K = w

kVA < 1000

Where kV is the voltage rat-
ing of the transformer in kV.

Also Aw = (Total Conductor

Area)/(Window Space factor)
2 ap N 1
= Kw = H w .W w =
Q
−3
2.22 f B m Ai δ 10
Also Hw/Ww ranges from 2 to 4.

Assuming Hw/Ww = 3 and δ=2.7A/mm^2 , We obtain:

Kw = 0.27, Aw = 62000 mm^2
Ww = 143.7 mm & Hw = 431.3 mm
D = d + Ww = 433.7 mm
Area of yoke is 15-20% larger than core for hot-
rolled steel
Area of yoke Ay = Dy*Hy where
Dy = a ( Width of largest core stamping)
Ay = 1.15 to 1.25 Agi for Hot Rolled Steel
= Agi for Cold Rolled Steel

H = 2.Hy + Hw ( overall height of the transformer)

W = D+a
Choosing Ay = 1.2.Agi, we obtain that Hy = 253.65
mm
H = 941 mm
W = 670.6mm
• Design of Windings:
V1
I 2= .I
V2 1
Selection of Current Density:
1. Local heating
2. Efficiency
3. Requirement of Cooling and Losses ( Greater
variations seen in Distribution Transformer )

For minimal losses, current density in both primary

and secondary sides must be equal.
i.e. δ =δ 1 2

Secondary Side:
kV A
I 2= , on plugging the values , I2 = 681 A and us-
V2
ing current density δ=2.7A/mm^2, we obtain a =252.52 2

mm^2

Now, to design the conductor, using the following

configuration:
With each strand having area of a =4.5 × 4.5 mm
ss

a =256mm^2 which gives δ =2.65A/mm^2

s sn ew ne w

Assuming 0.5 mm of insulation thickness,

Axial depth = 4.5x5mm + 1 =23.5 mm
Radial Thickness = 4.5x3mm +1 =14.5 mm

Number of turns for secondary = V / E = 32 now on 2 t

each leg half the windings are given with 1 turn ex-
tra to take care of series winding.
i.e. Turns per leg for secondary = 17 turns
From this,
Axial Depth = 23.5x17 =399.5mm
Radial Width/Thickness = 14.5mm

Inner diameter diameter of core = d + 5mm = 295

mm
Using radial thickness = 14.5mm,
Outer Diameter of core = 295mm + 14.5mm =
309.5mm
Mean Diameter (m ) = 302.25mmd

Thus, Mean length of secondary turns = π .m = d

949.06mm

Primary Side:
Using similar analysis, it’s obtained that I1 = 45.4 A
and using current density δ=2.7A/mm^2, we obtain
a =16.81mm^2
2

Number of Turns in primary = V / E = 480 turns.

1 t

Selecting a =2.6 × 6 m m, a =16.3mm^2 which results in

ss s sn e w

δ =2.78A/mm^2.
pn e w

Axial Depth = 120x3.1 mm + 9.5mm =381.5 mm

Radial Thickness = 6.5 mm

Thickness of former + duct = 11mm

With this we get the following set of values:
1. d =309.5+22 m m=331.5 mm
h v i n n er

2. Inner dia of HV side former = 309.5 + 2x6 =

321.5mm
3. Outer dia of HV former = 321.5 + 2x5 =
331.5mm
4. Outer dia of 1st HV winding layer = 6.5x2 +
331.5 = 344.5 mm
5. Inner dia of 2nd HV winding = 344.5 + 2x8 =
360.5mm
6. Outer dia of 2nd HV winding = 360.5 + 2x6.5 =
373.5mm
Mean diameter of primary winding =
(Inner dia of 1st HV wdg + Outer dia of 2nd HV
wdg)*0.5
= (373.5+331.5)*0.5 = 352.5mm
Mean length of turn of primary = π ×352.5 =
1107.41mm
Window space = Ww - ( D −d ) = 60.2 mm o u t er

• Resistance and Leakage Reactance of Windings:

We know that ρ = −8
1.68 ×10 Ω−m for copper
N 1 . L mt p
Resistance of Primary (r ) = p ρ.
ap = 0.547 Ω
N .L
Resistance of Secondary(r ) s = ρ . 2 a s m t s = 0.00204 Ω
Leakage reactance of Secondary Winding is given
by:
Lmt bs a
X s=2 π f μ 0 N 2
2
( + )× 2
Lc 3 2
= 0.0046 Ω where
Where bs is the radial thickness of Secondary wind-
ing, a is the width of radial duct, μ =4 π ×10 H /m 0
−7

Similarly, leakage reactance of Primary Winding is

given by: ′ ′′
❑ ❑
L b +b a
X =2 π f μ N
p 0 ( 2
1 + )× 4 = 0.684 Ω
mt p p
L 3 4 c

Now, to calculate Voltage Regulation, Z b a s e =V b a s e / I b a s e=

64.61 Ω for primary side

%VR = (ϵ c o s θ+ϵ s in θ)x100%

r x

where c o s θ=0.8 & from calculation,

ϵ =0.0266 p u, ϵ =0.0155 pu
x r
Using these values, voltage regulation is obtained
as:

%VR = 2.835%

• Calculation of Losses:
Ohmic Losses:
Assuming stray load losses = 10% of ohmic losses
2 2
PC u=1.1(I 1 r p + I 2 r s )
Plugging the values of respective parameters, loss is
obtained as: P =3.831 k W Cu

Core Losses:
Core losses are due to hysteresis and eddy current
losses and the empirical formula for core loss is
given by:
Pc =1.2 × Pi ×W t

Where Pi is specific iron loss, and Wt is Weight of

Iron in core. (20% extra losses are present in joints)
The mean length of flux path is given by:
L =2 ×(H +b+ a) = 2.221m
i w

Volume of iron = V = A × L and density of iron is:

i i i

3 3
gi=7.6 × 10 k g /m

Thus total Wt of iron = 777.69 kg

From the empirical relationship, for B =1.3 W b /m , m
2

Pi = 2.5 W/kg
Total Core loss = 1.2x(2.5x777.69) kW=2,333 kW

From this data, efficiency is calculated using the fol-

lowing formula:
3
k V A ×10
E f f ic ie n c y= 3
× 100 %
k V A ×10 + Pi + PC u
= 97.9%
• Design of Tank:
Temperature Rise:
Total loss due to dissipation = 12.5 W/m^2/°C
P +P
And temperature rise is given by: θ= 12.5 S C Cu

where St is the dissipating surface area.

To increase surface area, tubes are added which in-

crease surface area by 55%

Given area of each tube as = π . d .l ,

t t

1 P +P
Number of tubes (n ) = 8.8 π d l ( θ −12.5 S )
t
t t
C Cu
t

Where dt is the diameter of the tubes and lt is the

length of the tubes.

Width of Tank(Wt) = D + De + 2b ( De: Dia of wdgs,

b: clearance)
Height of Tank(Ht) = H+h ( h : Clearance between
assembled transformer and tank)
Length of Tank(Lt) = De + 2×l (l: clearance on each
side)

Choosing l = 80mm, h = 600mm,

b = 100mm.
Wt = 1.007m
Lt = 0.533m
Ht = 1.591m

To find the number of tubes, first

calculating St,
St = 2*(Lt+Wt)*Ht, which comes out
to be:
St = 2*(0.533+1.007)*1.591 m^2 = 4.9 m²
For the dimensions of the tube :
dt = 50mm = 0.05m and lt = 1 m(Let)
Taking θ=20 C since ambient temperature is assumed
∘

to be 25 C .
∘

Hence, number of tubes is given by:

n = 178.65 = 179 tubes
t

MATLAB Programme:
To draw top view of the transformer:>
Diagram Obtained:
————————————————————
Thank You