Objective:

Design a 143 kVA, three phase, 50 c/s, 11000/433 V, delta / star distribution
transformer. Tapping  2.5%,  5% on high voltage side. Cooling O N (self oil cooled);
temperature rise over oil 500C. No load loss 355 watts; copper and stray load loss not
more than 2000 watts. Percentage impedance 4.5%.
Calculate no load current, efficiency at 750C on full load, 75% load and 50% load at unity
power factor; regulation on full load at 750C at unity power factor and at 0.8 power
factor lagging.

Solution:
Primary Calculation
Voltage per turn : Et
Formers
Et = √(143 1000/3) (1/40)
Et = 5.46 volts / turn.
Specific magnetic loading
Choose Bmax = 1.7 Wb / m2;
material for core is chosen as cold rolled grain oriented (CRGO) steel laminations of 0.35
mm thickness; mitred core construction is used; mitred at 450
Cross Section of the core :
Et = 4.44 Bm f Ai Volt where Bm = flux density in wb/m2 f = 50 c/s
Ai is net cross sectional area of the core in the mm2
Ai =( 5.46 )
=14467.40 mm2
=14467 mm2
Diameter of the circumscribing circle for the core : d
Choose seven step core. The area should be nearly circular. In the case of a 7 step
core, the core space factor = 0.88 and stacking factor for laminations = 0.92. Hence if
d = diameter of the core section,
Ai = (.88 .92 4
d2 = (4 14467)/ (.88 )
= 22751.86 mm2
d = 150.83 mm
=150mm
Choose d =155 mm
then area Ai = (.88 .92 4= 15276.5 mm2
With this area, check Bm
E = 4.44 Bm 501627810-6
5.46=4.44 Bm 5015276.510-6 s
from which Bm = 1.61 Wb/m2
Window area Aw :
S = 3.33 Aw kw Ai Bm 10-3 KVA
Window space factor kw is taken approximately as 0.27
Aw = Window area
 = current density taken as 2.5 A / mm2
S = output in kVA
Aw = (143106103) (3.3315276.5.272.51.6150) mm2
= 51733 mm
Choose window width = 155 mm (about d);
then height of window = 51733 155 =333.76 mm . =334 mm
Choose height of the window = 2  width of window approx
= 155  2
= 310 mm checking clearance to yoke. This is later taken
as 320 mm
Then window area = 310 155
= 48050 mm2
The main dimensions of the core are therefore : diameter d = 155 mm;
D = distance between the centers of the adjacent limbs = 155 +148 mm
= 303 mm
with a 7 step core, the largest width of the core with d = 155 mm is 0.95155 = 147.25
148 mm. Fig 1 shows the core and yoke assembly dimensions.
 FIG1:Core & Assembley

From fig 1
Height of window = 310 mm
total width = (2  303) +148 =754 mm
Total height = 310 +148 =458 mm
Check the window space factor approximately before fixing the core and window
dimensions.
Number of turn in I.v. winding
Voltage per phase = 433 / 3 = 250 V as the winding is star connected
Turns per phase on l.v winding = 250/ 5.38
=46.46
= choose 48 turns.
Number of turns of h.v. winding
Turns per phase on h.v. winding = 11000/ 5.46
= 2015
as the winding is delta connected; tappings of  5% and  2.5% are to be provided on
the h.v. winding.
Turns on h.v. winding for normal connections = 2015
5% more, 2015 1.05 =2116 ; 2.5% more, 2015  1.025 = 2065
5% less, 2016  0.95 = 1914.25 ; 2.5% less, 2016  0.975 = 1965
Thus the turns for h.v. winding are

2116 2065 2015 1965 1914

5% 2.5% normal -2.5% -5% tappings.

Low voltage winding

Current per phase = 1431000 / 3433 = 190.67 A
Choose helical cylindrical coil.
Current density & assumed = 2.5 A / mm2
area of l.v. conductor aa = 190.67/2.5= 76.268 mm 2
Choose rectangular copper conductor from IS : 6160:1977 spec, for rectangular copper
conductors for electrical machines, giving area near about the required one.
Choose section 4.5 thickness  6.5 width
2 conductor strips forming conductor of l.v. area a 1 = 2 29.25 =58.5 mm2
High voltage winding
Choose disc coils.
Current in h.v. winding per phase = 143 1000/3 11000
= 4.33 A
being delta connected.
Cross section of conductor for h.v. winding : a2 =4.33/2.5
= 1.732 mm2
Choose round conductor
a2 = 4 = 1.732 mm2 ; where d = diameter of conductor in mm .
d2 = 2.2052 or d =1.48 mm ; Choose diameter of conductor 1.5 mm .
Then area == /4 (1.5) 2 =1.767 mm2
Copper area in window = 2 (a1T1 + a2T2)
= 2 (58.548 + 1.7672015)
=12737 mm2
Window space factor kw =12737/ 48050
= .265 = .27
The next test for finalization of the window area and the final dimensions of core and
yoke assembly is to choose the layout of the l.v. and h.v. windings with correct required
clearances and insulation between parts of l.v. and h.v. windings and core and tank and
check whether the windings can be conveniently accommodated in the window area.
Also check % reactance X before further calculations
Design the layout of l.v. winding
Number of turns = 48 .
Size of conductor : 2 strops of 4.56.5 mm copper rectangular conductor.
With paper insulation for conductors,
the size of each conductor will be (4.5+0.25) mm(6.5+ 0.25) mm = 32.0625 mm2
choose 2 layers for l.v. winding.
Turns per layer = 48/ 2 = 24 .
Conductor layout is shown in Fig. 2 Width of conductor 6.75 mm is taken along the
winding
with 2 conductor sides 4.5+4.5 = 9 mm forming conductor per layer.
For two layers, the dimension of conductors width wise is 18 mm
and height of window wise 6.75 mm for each conductor.
height of l.v. winding in window = 24  6.75 = 162 mm
thickness of l.v. coil = 9 2 = 18mm
distance between core and l.v. coil = 3.5 mm
inside diameter of l.v. coil = 155 + ( 2  3.5) = 162 mm
outside diameter of l.v. winding = 162+ (2 18)
= 198 mm
=198mm
mean diameter of l.v. coil = 162+18 = 180 mm
mean length of turn of l.v. coil =  180 = 565 mm
Scale:mm
Design and layout of h.v. winding :
Layout of h.v. winding is shown in Fig. 6.10
The distance between l.v. and h.v. = 12mm
inside diameter of h.v. = 205+ ( 12  2) = 229 mm
Split h.v. winding in 4 coils each with turns = 2015/4 = 504 turns
The size of conductor = 1.5 mm diameter.
With paper insulation on conductor, the diameter =1.5+ 0.25 =1.75 mm
Choose 15 layers; turns per layer = 504/15 = 34 turns
height of winding in each h.v. coil = 34 1.75 = 59.5 mm
thickness of each coil = 15  1.75 = 26.25 mm
outside diameter of h.v. coil = 229+(226.25) =281 mm
mean diameter of h.v. coil = 229+ 26.25 = 255 mm
mean length of turn =  255 mm = 800 mm
height of h.v. coils in window = (59.54) +15+15+15= 283 mm
where 59.5 mm is the height of each h.v. coil,15 mm is the distance between each of the
4 h.v. coils.
The space required between coils and core on either side is taken as 13.5 mm. The
height of window required.
= 283+13.52 =310 mm
If is acceptable for height for L.V & H.V winding
Here, Layout of H.V winding is shown in figure 3
Fig:Layout of High Voltage winding
Percentage Reactance
l.v. mean length of turn = 190  =565 mm
h.v. mean length of turn = 272mm=800 mm
average Lmt = (565+800)/2 =682.5 mm
AT = 190.6747 =8962
mean height of coils = (162+283)/2=222.5 mm
a = 12 mm ; b1 = width of h.v. =26.25 mm ; b2 = width of l.v. =18 mm
a + (b1+ b2)/3 = 12+(26.25+18)/3 =26 mm
% reactance X = (2  50 4 10-7 0.682  190.6  48  .026) / (0.235.45)
X = .05 p.u. or 5 %

Percentage Resistance
Resistance of low voltage winding : (per phase)
ρ 20 =0.01724 ohm/ mm2 /m ; α20 = 0.00393
At 75’ C
ρ 75 = 0.01724 ( 1 + 0.00393  55)
= 0.021 ohm / mm2 / m
Resistance of l.v. winding = (0.02156548)/ (58.51000) =.0097 ohm
Resistance of h.v. winding (per phase)
= (0.0218002015)/ (1.767151000) ohms = 19.15 ohms /phase
Ratio of transformation = T1 /T2 =(11000/433) = 25
Equivalent resistance referred to h.v. winding (per phase)
R = 19.15 + .0097 252 = 25.2 ohms
percentage resistance : (4.3325.2/11000) 100% = 0.010 p.u =0.99%
Percentage impedance : % X = 5%; % R = 0.99 %
%Z = (52 +0.992) =5.09%
Weight of iron in core and yoke assembly
From Fig 1 the volume of the core and yoke is given by
Ai (7542+3103)= 15276.5 2015 =30782147 mm
Weight of iron = 7.85  1000 kg /m3
Weight of core and yoke = (15276.520157.85)/(10001000)
=241.63 kg
=242 kg
Core loss at Bmax = 1.61wb / m is 1.4 watt / kg
Core less in transformer = 242  1.4
= 338.8 watts.
= 339 watts.

Magnetising volt amperes

For Bmax = 1.61 wb / m2, VA / kg from the curve is 9VA /kg .
Magnetising volt amperes = 2429 =2178 VA

Weight of l.v. winding :

Weight of l.v. winding : density of copper 8.89 g / cm2
number of turns = 48
2 conductor strips forming conductor of l.v. area a1 =58.5 mm2
mean length of turn = 565 mm;
weight of l.v. winding (per limb) =(8.8958.556548)/(10001000)
=14.65 kg
Weight of h.v. winding (per limb)
number of turns(5% more tapping ) = 2116
normal = 2015
Cross section of conductor for h.v. winding : a2 = 1.732mm2
mean length of turn = 800 mm
Weight of h.v coils (one limb) =(8.891.7328002116)/(10001000) kg
= 28.24 kg for all turns .
For normal turns,
weight of the h.v coils (one limb) =(8.891.7328002015)/(10001000)
=24.82 kg
Total weight of copper in transformer
3(l.v. + h.v. ) = 3 (14.65 +24.82) = 118.41 kg
=119 Kg
Copper loss and load loss at 750C :
h.v. current per phase = 4.33 A
Copper loss for 3 phases = 3  I2  r
= 3  (4.33)225.4
= 1428.66 watts
=1429 watts (for 3 phase)
stray load loss about 7% of Cu loss = 1429  0.07
= 100.03 watts
total loss = Iron loss +Cu loss +Stray loss
=339+1429+100.03
=1868 watts
Calculation of performance
Efficiency on full load at unity power factor :
ή =(Output /Output+ loss) 100%
=(1431000)/(1431000+1868 100%
= 98.7%
Efficiency on 3/4 th full load at unity power factor
Core loss = 339 watts;
Load loss on 3/4 load = 1529  (3/4)2 =860 W
Total loss = 339 + 860
= 1199watts
ή(3/4) =(.751431000)/(107250+1199)100% ;
=98.9%

 Efficiency on ½ of full load at unity power factor

Total loss =339+(1/21/21529)=721.25 watts .
efficiency on ½ of full load at unity ή(1/2) p.f, = (71.51000/71500+721.25) 100%
=98.94%
Regulation on full load at unity power factor
% R = 0.99%, % X =5.1%
(V + IR)2 + (IX)2 = E2
(1.0 + 0.0099)2 +(0.051)2= E2
E =1.01 .
regulation = 1.01 – 1.0 =0.01 p.u. or 1%
Regulation on full load at 0.8 power factor lagging
= IR cosΦ + IX sinΦ
= 0.99  0.8 + 5.1  0.6 =3.852%
Core loss current, magnetising current, no load current :
Core loss = 342 watts.
core loss current Ic = 342/(311000) = 0.010 A
Magnetising VA = 2178 VA
magnetising current , Im = (2178/311000)=0.066 A
No load current per phase = Io = (0.012 + 0.0662)
=0.067 A
Current per phase = 4.33 A
No load current = (0.067/4.33) 100 %
= 1.55 % of full load current
Design of tank
Fig.4 shows the spacing of outside diameters of h.v. coils on the cores.
Outside diameter of h.v. = 281 mm;
the distance between coils on adjacent limbs = 22 mm;
clearance at each end is 31.5mm.
Thus the length of the tank = 281  3 + 22  2 +2 31.5 =950 mm;
breadth of the tank= 281 + (222) = 325 ;
Height = 458 + 50 for base + 300mm for oil level above core+250 for leads
=1058 mm
Inside dimensions of the tank of the transformer = (length  breadth  height)
= (950 325  1058) mm3

FIG:Tank Dimension
Temperature rise
For dissipation of heat only 4 surfaces of a tank are taken into consideration. The top
and the bottom are not considered.
Surface of tank =(325/1000)(1058/1000)2+(950/1000)(1058/1000)2
= 0.6877 +2.01 m2
=2.7 m2
Full load loss to be dissipated = 1871 watts
If 12.5 per m2 per 0C temperature rise is taken as dissipation due to convention and
radiation, temperature rise = (1871/12.52.7) = 55.430C
If the temperature of transformer walls may be limited to 350C instead of 360C & the oil
temperature is to be limited to 500C & that of coils 550C. Hence it is necessary to extend
the cooling surface.
If the total surface area is considered, ‘x’ times the tank surface area, we get:
( 2.7 )  (x)  (8.8 + 3.7/ x )  35 = 1871
Or,
from which, x = 1.8
Where,total surface area = x times of tank surface area
Additional area = 2.70.8 = 2.16 m2
As, 808 mm is height up to oil level;
Height of tube is taken as 760 mm
Surface of 1 tube of 85 mm diameter = π x 85 x 760 x l0-6
=0.202 m2
Number of tubes required =(2.16/0.202) =11
Volume and weight of oil
Volume of tank upto oil level of 808 mm =(950/1000) (325/1000) (808/1000)
=0.25 m3
Volume of transformer core and copper =(242/7.851000)+(119/8.891000)
= 0.0442 m3
Volume of oil=(Volume of tank upto oil level - volume of core and windings) = (0.25-
0.0442)
= 0.2058 m3
Oil required in transformer=0.2058 x 1000 litres = 205.8 litres
weight of oil required=-205.8  0.89 =183.16 kg
Weight of tank
If the thickness of the tank walls is taken as = 5 mm.,
Weight of tank=
.005(9503252/10001000)+(95010582/10001000+32510582/10001000)1
0007.85
=130.12 kg.
Volume and weight of oil in tubes
11 tube each of 85 mm diameter and 0.70 m length.
Therefore, Volume = π x (85/1000)2 x 0.70 x11 ÷ 4
= 0.043 m3,
Volume of oil in tubes = 0.043 x 1000
= 43 liters.
Weight of oil in tubes = 43 x 0.89
=38.27 kg
Weight of tube = π x (85/1000) x 0.70 x 0.005 x 11 x 7.85 x 1000 kg
= 75.92 kg
Total weight of transformer
Weight of core and yoke assembly = 242 kg
Weight of copper in windings = 119 kg
Weight of tank =130.12 kg
Weight of tube =75.92 kg
Weight of oil in tank = 183.16 kg
Weight of oil in tubes = 38.27kg
Total weight = 788.47 kg
Say 790 kg
Summary
Specifications
Transformer designed as per IS : 1180
kVA 143 ; Volts H.V. 11000 volts; Volts L.V. (no load) 433 volts;
Amperes H.V 7.5 ; L.V. 190.67 (line values); 3 phase, delta/star 50 c/s;
temperature rise of oil 500C ; type of cooling O N ;
Vector group D Y 11 ; percentage impedance 5.1%
2.5% and ±5% tappings on h.v. side.
Core and yoke
Material : CRGO (cold rolled grain oriented) steel laminations 0.35 mm thick; mitred
core construction 45° cut.
Voltage per turn, 5.46 volts ; Flux density Bmax=1.61 Wb/m2; Net area of cross section of
core, 15276.5 mm2; circumscribing circle diameter 155 mm.
Size of core, yoke and frame : yoke made of the same section as the core, 3 limb core
construction. Distance between centers of adjacent limbs, 303mm; width of the
window, 155 mm; height of window, 310 mm; width of limb 148 mm; overall height of
frame 458 mm; overall width of core frame 754 mm.
Weight of core and yoke assembly 321 kg;
core loss at Bmax = 1.61 wb / m2, 1.4 watts per kg ;
magnetizing VA = 2178 VA, 9 VA / kg

Windings L.V H.V

Type of winding helical Disc

Current density 2.5 2.5 a/mm2

Cross sectional area

of conductor 58.5 1.767 mm2

Conductor : Copper 2 strips of diameter

4.56.5mm

Number Of Layers
per limb 2 15

Number of turns 48 2015

Number of turns per layer 24 34

Height of winding in window 162 59.5

Thickness of coil 18 26.25 mm

Inside diam of coil 162 237 mm

Outside diam of coil 198 281 mm

Mean length of turm 565 800 mm

Resistance at 750c 0.01 19.15 ohms per

phase

Weight of copper for winding per limb 14.65 KG 24.82 KG

Total Weight Of Copper 119 KG

Insulation
Insulation for cooling. : pressboard paper
Insulation for conductors paper
Insulation between layers : Crape paper
Insulation between l.v. and h.v. windings : bakelized paper cylinder; Laminated pressed
wood sticks for spacers for cooling.Class A insulation for O N type transformers
Tank : Temperature rise of oil 500C
Inside dimensions of tank : length 950 mm;
Breadth 325 mm;
height 1058 mm
Oil level 808 mm
Tubes 8, each of 85 mm diam; 760 mm long

Oil in transformer tank 205.8 liters

Oil in tubes 43 liters

Weight in oil in tank 183.16 kg

in tubes 38.27 kg

Weight of tank 130.12 kg

of tubes 75.92 kg

weight of complete transformer 790 kg

Performance :

Percentage resistance 0.99%

Percentage resistance 5%

Percentage impedance 5.09%

Iron loss 339 watts

Copper and stray load loss, i.e. load loss at 750C 1529 watts

Total loss on full load 1868 watts

Efficiency on full load at unity power factor 98.7%

Efficiency on 3/4 th full load at unity power factor 98.9%

Efficiency on 1/2 full load at unity power factor 98.94%

Regulation on full load at unity power factor 1%

Regulation on full load at 0.8 power factor lagging 3.852%

Core loss current per phase 0.01A

Magnetizing current per phase 0.06 A

No load current per phase 0.067 A

1.55% of full load current

Tapping:

2116 2065 2015 1965 1914

5% 2.5% normal -2.5% -5% tappings.