Tribhuvan University

Institute of Engineering
Pulchowk Campus

100kVA, 6.6k/400V, Single Phase, Core Type

Transformer Design
An Assignment for Electric Machine Design

Submitted by:
Bharat Tamang Ghising
078BEL024

Submitted to:
Sochindra Kumar Roy
Department of Electrical Engineering
 CONTENTS

Contents 1
List of Figures 2
1 Design Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Winding Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Primary Winding Preliminary Design . . . . . . . . . . . . . . . . . . 3
2.2 Secondary Winding Preliminary Design . . . . . . . . . . . . . . . . . 4
2.3 Secondary Winding Detail Design . . . . . . . . . . . . . . . . . . . . 5
2.4 Primary Winding Detail Design . . . . . . . . . . . . . . . . . . . . . 5
3 Core Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1 Limb Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2 Yoke Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.3 Window Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.4 Overall Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4 Duct and Insulation Design . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.1 Duct Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5 Coil Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.1 Physical Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.2 Electrical Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6 Mass of Iron and Copper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.1 Iron Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.2 Copper Winding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7 Performance Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
7.1 Voltage Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
7.2 Losses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
7.3 Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7.4 No-Load Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
8 Cooling System Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
8.1 Tank Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
8.2 Tube Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

1
 LIST OF FIGURES

0.1 Windings Section Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

0.2 Limb Cross Section Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
0.3 Tube Arrangement and Clearance . . . . . . . . . . . . . . . . . . . . . . . . 20
0.4 Orthographic Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2
Bharat Tamang Ghising Transformer Design 3

1 Design Specs
Design specification for Transformer to be design is as follow:

Number of Phase 1
Type Core
Apparent Power Rating S 100 kVA
Frequency f 50 Hz
No Load Voltage Vp /Vs 66000/400 V
Temperature Rise θm 35 ◦
C
Winding Material Copper
Core Material CRGO Steel

2 Winding Design

Assumption 2.1
• Constant for voltage per turn: K = 0.8164

• Current density on both windings: δm = 2.5 A/mm2

• Stamping factor: ks = 0.9

Voltage per turn

√
Et = K S
√
= 0.8164 150
= 10 V /turm

2.1 Primary Winding Preliminary Design

Number of Turns

Vp
Tp =
Et
6.6k
=
10
= 660 T urns
Bharat Tamang Ghising Transformer Design 4

Current

S
Ip =
Vp
150k
=
6.6k
= 22.7272 A

Conductor Area

Ip
ap =
δ
22.7272
=
2.5
= 9.0909 mm2

2.2 Secondary Winding Preliminary Design

Number of Turns

Vs
Ts =
Et
400
=
10
= 40 T urns

Current

S
Is =
Vs
150k
=
400
= 375 A

Conductor Area

Is
as =
δ
375
=
2.5
= 150 mm2
Bharat Tamang Ghising Transformer Design 5

2.3 Secondary Winding Detail Design

Assumption 2.2
• Type of Winding: Continuous Disc
∵ High Current Is = 375A

• Chosen Conductor Type: Rectangular Strip

∵ As as (= 150mm2 ) > 50mm2 , single circular conductor can’t be use.

• Chosen Conductor Dimension: 24.5 × 3.5 mm2

• Chosen Conductor Dimension with insulation: 25 × 4 mm2

Design

Disposition of Strip 1W×2D

Number of discs 20
Number of turns in each disc 2
Number of strips in each turn 2
Transposition After each disc
Space between each disc 10 mm
Axial depth of coil Lc 25 × 10 + 10 × 9 = 340 mm
Radial depth of coil bs Radial depth of a disc = 2 × (4 + 4) = 16 mm

2.4 Primary Winding Detail Design

Assumption 2.3
• Type of Winding: Crossover
∵ Single conductor and high number of turns

• Chosen Conductor Type: Circular

∵ As ap (= 9.0909 mm2 ) < 50 mm2 , single circular conductor can be used.

• Chosen Conductor Diameter: 1.7 mm

• Chosen Conductor Diameter with insulation: 2 mm

• Axial Height of Primary Coil = Axial Height of Secondary Coil Lc

Bharat Tamang Ghising Transformer Design 6

Design

Number of cross-over coils ncoc 20

Number of cross-over coils in 1 limb ncoc1 10
Number of turns in each cross-over coil 33
Axial depth of cross-over coils Lcoc 11 conductor = 22 mm
Radial depth of cross-over coils 3 conductor = 6 mm
Space between cross-over coils 13.33 mm
Axial depth of coil Lc 25 × 10 + 10 × 9 = 340 mm
Radial depth of coil bp Radial depth of a cross-over coil = 6 mm

Space between cross-over coils is calculated as

Lc − ncoc1 × Lcoc
Space =
ncoc1 − 1
340 − 10 × 22
=
10 − 1
= 13.33 mm

Figure 0.1: Windings Section Layout

(Unit:mm)
Bharat Tamang Ghising Transformer Design 7

3 Core Design
3.1 Limb Design

Assumption 3.1
• Core type : Cruciform

• Maximum flux density Bm = 1.2W b/m2

• Stamping factor ks = 0.9

Maximum flux
Et
ϕm =
4.44f
10
=
4.44 × 50
= 0.45045 W b

Core Iron Cross Section Area

ϕm
Ai =
Bm
0.45045
=
1.2
= 0.0375375 m2

Gross Core (Iron and Varnish) Cross Section Area

Ai
Agi =
Ks
0.0375375
=
0.9
= 0.041708 m2

Diameter of Circumscribing Circle

πd2
Agi = × 0.79
r4
4 × Agi
d=
π × 0.79
p
= 0.50633 × Agi
√
= 0.50633 × 0.041708
= 0.25927 m
Bharat Tamang Ghising Transformer Design 8

Dimension of Cruciform Core

a = dcos(31.71◦ )
= 0.22056 m
b = dsin(31.71◦ )
= 0.13627 m

Figure 0.2: Limb Cross Section Layout

(Unit:m)

3.2 Yoke Design

Assumption 3.2
• Shape of Cross Section and Area of Yoke is kept same as those of Limb.

Area of Yoke
Ay = Agi
= 0.041708 m2

Depth of Yoke
Dy = a
= .22056 m

3.3 Window Design

Assumption 3.3
• Ratio of window width to height is Hw
Ww
=3
Bharat Tamang Ghising Transformer Design 9

Window Space Factor

10
Kw =
30 + Vp (kV )
10
=
30 + 6.6

= 0.273234

Copper Area
Ac = ap Tp + as Ts
= 9.07 × 660 + 150 × 40
= 11986.20 mm2

Window Area
Aw = Ac × Kw
= 11986.20 × 0.273234
= 43869.49 mm2

Window Width and Height

r
Aw
Ww =
r 3
43869.49
=
3
= 120.92 mm

Hw = 3 × Ww
= 3 × 120.92
= 362.77 mm

3.4 Overall Dimensions

Distance between Limbs
D = Ww + a
= 120.92 + 220.56
= 341.48 mm
Bharat Tamang Ghising Transformer Design 10

Height of Frame
H = Hw + 2a
= 362.77 + 2 × 220.56
= 803.89 mm

Width of Frame
W = Ww + 2a
= 120.92 + 2 × 220.56
= 562.04 mm

4 Duct and Insulation Design

4.1 Duct Width
Width of duct between Core and LV coil
y = 5 + 0.9Vs (kV )
= 5 + 0.9 × 0.4
= 5.36 mm

Width of duct between HV and LV coil

α = 5 + 0.9Vp (kV )
= 5 + 0.9 × 6.6
= 10.94 mm

5 Coil Parameters
5.1 Physical Parameters
Inside and Outside Diameter of Coils
Secondary Coil

Dsi = d + 2y
= 259.27 + 2 × 5.36
= 269.99 mm
Bharat Tamang Ghising Transformer Design 11

Dso = d + 2(y + bs )
= 259.27 + 2 × (5.36 + 16)
= 301.99 mm

Primary Coil

Dpi = d + 2(y + bs + α)
= 259.27 + 2 × (5.36 + 16 + 10.94)
= 323.87 mm

Dpo = d + 2(y + bs + α + bp )
= 259.27 + 2 × (5.36 + 16 + 10.94 + 6)
= 335.87 mm

Length of Mean Turn

Secondary Coil

Dso + Dsi
Lmts = π ×
2
301.99 + 269.99
=π×
2
= 898.46 mm

Primary Coil

Dpo + Dpi
Lmtp = π ×
2
335.87 + 323.87
=π×
2
= 1036.31 mm
Bharat Tamang Ghising Transformer Design 12

5.2 Electrical Parameters

Leakage Reactance
Secondary Coil


Lmtp
α bp
xp = 2πf µ0 Tp2 +
Lc2 3
 
2 1036.31 10.94 6
= 2π50µ0 × 660 + mΩ
340 2 3
= 4.4396 Ω

Primary Coil
 
Lmts α bs
xs =2πf µ0 Ts2 +
Lc 2 3
 
2 898 10.94 16
= 2π50µ0 × 40 + mΩ
340 2 3
= 0.018032 Ω

Referred to Primary Side

Tp2
X p = xp + 2 xs
Ts
6602
= 4.4396 + 0.018032mΩ
402
= 9.3489 Ω

Per Unit Value

Ip Xp
ϵx =
Vp
22.7272 × 9.3489
=
6600
= 0.032193 pu

Resistance
Secondary Coil
Lmts Ts
rs = ρ
as
898.46 × 40
= 1.7757 × 10−5 mΩ
150
= 4.2545 × 10−3 Ω
Bharat Tamang Ghising Transformer Design 13

Primary Coil

Lmtp Tp
rp = ρ
ap
1036.31 × 660
= 1.7757 × 10−5 mΩ
9.0909
= 1.3360 Ω

Referred to Primary Side

Tp2
Rp = rp + rs
Ts2
6602
= 1.3360 + 4.2545 × 10−3
402
= 2.4943 ohm

Per Unit Value

Ip Rp
ϵr =
Vp
22.7272 × 2.4943
=
6600
= 8.5892 × 10−3 pu

6 Mass of Iron and Copper

6.1 Iron Core

Assumption 6.1
• Density of Lamination σlam = 7.6 × 103 kg/m3
Bharat Tamang Ghising Transformer Design 14

Area of core cross section Agi = 0.04170 m2

Volume of a core vcore = Agi × Hw

= 0.04170 × 0.36277
= 0.015098 m3

Volume of a yoke vyoke = Agi × W

= 0.04170 × 0.56204
= 0.023440 m3

Mass of Iron Core = 2σlam (vcore + vyoke )

= 2 × 7.6 × 103 (0.015098 + 0.023440)
= 585.79 kg

6.2 Copper Winding

Assumption 6.2
• Density of Copper σCu = 8.96 × 103 kg/m3

Volume of windings vwind = ap Tp Llmpt + as Ts Llmps

= 9.09 × 660 × 1036.31 + 150 × 40 × 898.46
= 0.011607 m3

Mass of Copper Winding = σCu vwind

= 8.96 × 103 (0.015098 + 0.023440)
= 104 kg
Bharat Tamang Ghising Transformer Design 15

7 Performance Characteristics

7.1 Voltage Regulation

Per unit regulation at unity power factor is

pu regu = ϵr cos(ϕ) + ϵx sin(ϕ)

= 8.5892 × 10−3 × 1 + 0.032193 × 0
= 0.0085892 pu

7.2 Losses

Assumption 7.1
• Specific core loss of 0.27mm CRGO lamination at 50 Hz and Flux density of
1.3 W b/mm2 is 1 W/kg.

• Stray load loss is 7 12 % of I 2 R loss.

Copper Loss

Copper loss without stray load loss = Ip2 Rp

= 22.72722 × 2.4943
= 1288.36 W

Total copper loss under load, Pc = I 2 R Loss + Stray Loss

= 1288.36 × 1.075
= 1384.99 W

Core loss

Core Loss, Pi = M ass of Core × Specif ic Core Loss

= 585.79 × 1
= 585.79 W
Bharat Tamang Ghising Transformer Design 16

7.3 Efficiency

Total Loss at Full Load, Ploss = Pi + Pc

= 1384.99 + 585.79
= 1970.78 W

Real Output at full load and unity power factor, Pout = 150 kW
Pout
Efficiency at full load and unity power factor, η = × 100%
Pout + Ploss
150k
= × 100%
150k + 1970.78
= 98.70%

7.4 No-Load Current

Assumption 7.2
• Because of the same cross section of yoke and limb, MMF required for joints is
negligible.

• Magnetic field intensity of CRGO, corresponding to flux density of 1.2 Wb/mm2

is 150 A/m.

Core Loss Component Ic

Pi
Ic =
Vp
585.79
=
6600
= 88.75 mA
Bharat Tamang Ghising Transformer Design 17

Magnetizing Component Im

Magneto Motive Force of Core, F = Im Tp

F
=⇒ Im =
Tp
F0
=√ ∵ F0 is the peak value of the MMF
2Tp
Flimbs + Fyokes + Fjoints
= √
2Tp
2Hlimb Llimb + 2Hyoke Lyoke + 0
= √ ∵ H is the Magnetic Field Intensity
2Tp
2H(Llimb + Lyoke )
= √
2Tp
HLc
=√ ∵ Lc is the mean flux path of the core Lc = 2(H + W − a)
2Tp
150 × 2.29074
= √
2 × 660
= 404.94 mA

p
∴ No load current, I0 = 2 + I2
Im c
√
= 404.94 + 88.752
2

= 414.56 mA

8 Cooling System Design

8.1 Tank Design

Assumption 8.1
• Only 4 vertical walls contribute to convection and radiation to air.

• Heat dissipation flux per ◦ C of tank by means of convection and radiation

are 6.5 W/m2 ◦ C and 6 W/m2 ◦ C respectively, giving the total flux ϕqT =
12.5 W/m2 ◦ C.

• Clearance for height, width, and length are as follows: Ch = 50 + 350 mm,
Cw = 50 mm, and Cl = 60 mm.
Bharat Tamang Ghising Transformer Design 18

Tank Dimension

Length of tank LT = D + Dpo + 2CL

= 341.48 + 335.87 + 2 × 50
= 797.35 mm

Height of tank HT = H + CH
= 803.89 + 400
= 1203.89 mm

Width of tank WT = Dpo + 2CW

= 335.87 + 2 × 50
= 435.87 mm

Surface area of 4 walls ST = 2HT (LT + WT )

= 2 × 1203.89(797.35 + 435.87)
= 2.969324 m2

Temperature Rise

Ploss
θ= (0.1)
12.5ST
1970.78
= (0.2)
12.5 × 2.969324
= 53.09◦ C (0.3)
(0.4)

Since, the temperature rise is greater than maximum allowed temperature(θm =

35◦ C).There should be tube arrangement for cooling.
Bharat Tamang Ghising Transformer Design 19

8.2 Tube Design

Assumption 8.2
• Heat dissipation flux per ◦ C of tube by means of convection is neg-
ligible and by means of radiation is 35% more than that of the tank,
giving the total flux ϕqo = 6.5 × 1.35 = 8.775 W/m2

• Diameter and length of tube are do = 50 mm and lo = 600 mm, giving

surface area of So = πdo lo = π × 50 × 600 = 0.094247 m2

• Space between 2 tubes from center to center spo = 70 mm.

Temperature rise with tube arrangement

Ploss
θm =
ϕqT ST + ϕqo nSo
Ploss
=⇒ ϕqT ST + ϕqo nSo =
θm
 
1 Ploss
=⇒ no = − ϕqT ST
ϕqo So θm
 
1 1970.78
= − 12.5 × 2.969324
8.775 × 0.094247 35
= 23.40
Number of tubes, no ≈ 24

LT − spo
Number of tube that can be fit along length =
spo
797.35 − 70
=
70
= 10.39
≈ 10

Total number of tube along length = 2 × 10

= 20
Total number of tube along width = 24 − 20
=4
Bharat Tamang Ghising Transformer Design 20

Figure 0.3: Tube Arrangement and Clearance

(Unit:mm)
Bharat Tamang Ghising Transformer Design 21

Figure 0.4: Orthographic Drawing

(Unit:mm)