Three phase power transformer design of 500kva/15kv/0.

4KV

Proposed specification to be done

Rating 500kva oil cooled
No load voltage ratio 15000/400 v
No of phase 3 phase
Frequency 50 HZ
Winding material electrolyte copper
Tapping on HV +_ 2.5% up to +-5% of circuit
Impedance 4%
No load loss 510 watt
load loss 5500 watt
Flux density 1.7 tesla max
Current density 2.6 ampere / mm2
Connection delta/star, vector group dyn5
Temperature rise 45/55 ℃

Number of turn’s calculation

No of turns and KVA are linked by the formula E/T (voltage per turn) = k√ Q

Where E =voltage per phase

T= turn per phase

Q = rated KVA

K= known constant

The value of K copper conductor range is = 0.37 to 0.45

I can take for k value = 0.45 so E /T = 0.45√ 500 = 10 v¿t

Number of secondary turns per phase (T S) = 230.94/10 = 23 turns

. Secondary phase voltage = 400 /√ 3 = 231 volt

Design of secondary coil

Secondary phase current (assuming connected in star connection) IP = 500/√ 3 *0.40
= 723 ampere
Conductor area of secondary = secondary current/current density

= 723 /2.6

= 278.8mm 2

Design of axial length of secondary coil height (LV)

LV wire size 3.35 * 8.5 2 W * 5D SO the working conductor area is (3.35 *8.5) *10 = 285
2
mm

A L = (((strip wire width +0.45+0.1)*2) +0.1) T/L+3 coil * (Width of strip with in insulation)

= (((8.5+.45+.1)*2) +.1)*23+3*(8.95) =443mm

Assume small size of end insulation =9 mm one side

So coil height =axial length +end insulation both sides

=443mm +18mm =461mm

The largest size of end insulation = 9 + 2w where w is width of strip wire.

So the end insulation of small and large is 9 and 26 mm respectively

LV ID (Internal diameter of low voltage) = core diameter+8mm clearance of core to secondary

coil =192mm+8 mm =200mm

Radial lv = (depth of strip wire + 0.1 insulation tolerance) *5

= (3.8 +0.1) *5 =19.5mm

LV OD = LV Id *2 radial =200+2*(19.5) =239mm

D M (Mean diameter) = (LVID+ LVOD)/2 = (200+239)/2 =219.5mmL

Mean length of turn (MLT) = DM * ¶ = 219.5 *3.14 = 689.23

(Length of lv copper) =MLT *N2T=689.23 *23 = 15852.29mm

Resistance (R) = (L * K *10−3 ) / Area of lv wire where k is resistivity of copper conductor

which is 0.0215 Ω

= (15852.29*0.021* 0.001)/285=0.00116806Ω

Loss = I 2R=(723)2 * 0.00116806 * 3 =1831.74195 watts

As per design convention the cross sectional area of single strip should be limited to 28.5 mm2
Based on this assumption the number of strips wire run in parallel is = 285/28.5=10 strips

Dissipation of 10 strips = 2 w * 5d

The LV winding design can be proceed as shown in the table below.

Table: 1 lv parameters

Voltage per phase ,VP 230.94 V

Current per phase , IP 723 Ampere

Secondary turns per phase 23 turns

Design of
No of layer One layer primary
coil or HV coil
End insulation 18mm
Area of primary
Conductor Area 285 mm2 conductor =
current per
phase/ current
Axial length of secondary coil 443mm
density

Coil height 461mm But primary

current per
LV ID 200mm phase
=500/3*15 =
11.1 Radial LV 19.5mm ampere

Area of
Mean diameter 219.5 mm primary
conductor =
Mean length of turn 689.23mm 11.1/2.4 = 4.4
2
mm
LV OD 239mm
So the diameter
of the conductor
Working Current density 2.53 A/mm2
can be calculated
as AC =¿*
length of conductor 15852.29mm
D ¿/¿4
2

Resistance (R) 0.00116806Ω D = 2.37 mm

LOSS OF LV 1831.74195 watts

No of primary turns per phase (at normal tap) = (primary phase voltage)/ (secondary phase
voltage) * ST

= (15000/230.94)* 23 = 1493.9 turns

Add 5% of additional turns for taping voltage = 0.05*1493.9=74.695 turns

N1 total = 1493.9 +74.695= 1569 turns

Turn per layer of HV= (CH - end insulation)/ (wire size+ tolerance)

(461-18)/2.43=182.3 turns

Number of layers = number of HV turns / turn per layer

=1569/182.3=8.606 round of to 9 layers

Radial building of HV= [(wire size + tolerance) * number of layers] + (insulation size * number
of insulation per layer * number of layers) + HV oil duct [Thermos flow]

Radial building of HV= [(2.43+0.03)*9] + (0.075 * 6 * 7) + (2.5 + 4) / 2

= 26.965 rounded to =27mm

HV OD= HV ID+ (radial HV*2)

HVID =LVOD + (gap b/n LV and HV) * 2

= 239 +18 = 257mm

= (LV OD + (gap b/n LV and HV * 2) + (Radial HV * 2)

= 239+ (9*2) + (27*2)

= 311mm

Table: 2 insulation b/n lv and HV

NO Strip Multiple of Thickness Width Height Numbers of
3 items quantities in
pcs
1 Oil duct 8 *10 *450 8mm 10mm 450mm 54 pcs
2 Hard 1* 900 * 450 1mm 900mm 450mm 6 pcs
paper
3 Wood 4 * 10 * 450 4mm 10mm 450mm 54 pcs
stick

DM = [HVID + HV OD] / 2 = [257+311] / 2 = 284mm

MLT=DM * ¶ =284* 3.14 = 891.76 mm
Length of primary conductor = (MLT *NTP) =891.76 *1569=1,399, 171.44 mm
R= [L * k *10−3 ] / a = [1,399, 171.44 * 0.012 *10−3 ] / 4.4 = 3.815Ω
Copper loss on HV = I 2r * 3 = (11.11)2 *3.815 * 3 = 1,412.6803 watt
Total loss of copper on LV and HV= 1831.74195 +1,412.6803 =3,244.422 watt
DMT = [dm1+ dm2] / 2 = [284 + 219.5] / 2 =251.75 mm
R% =total copper loss in watt /VA * 100 = [3,244.422 / 500000] * 100 = 0.64888 Ω
X1% = (7.91* f*i2 *(n2)2 * ¶ *DMT *(β+ (b1 +b2) / 3) VS*AL = (7.91*50 * 723 *23 * 23 * 3.14
*251.75 * (15 + ((19.5+3.2)/3¿ 10−6 ) /230.94) *230.94* 440.5)
= 3.2515
X% =x1% *.95 = 3.0889
Therefore the impedance [Z%] is equal to square root of resistance in percentage square
plus reactance in percentage square.
Then Z% [impedance] =3.156

Table: 3 HV parameters
NO Name of parameters Results with their units
1 Primary current[ IP] 11.1 ampere
2 Area of primary conductor 4.4mm 2
3 Diameter of primary wire 2.3mm
4 Primary Turns at normal 1493.9T
condition [NO]
5 5% additional turns for tapping 74.695 T
voltage
6 Total primary turns [NT] 1569 T
7 turn per layer 182.3 T
8 No of layer 9 layer
HV Coil height 456mm
9 HV radial building 32mm
10 HV OD 311mm
11 Oil duct 8* 10 *450 54 pcs
12 Hard paper 1* 900 *450 6 pcs
13 Wood stick 4* 10 *450 54 pcs
14 DM [mean diameter] 284mm
15 MLT[ mean length of turn] 891.76mm
16 L[length of the conductor] 1,399, 171.44 mm
17 R[winding resistance at 75℃ ] 3.815Ω
18 Loss= [ I 2R * 3] / A 1,412.6803 watt
19 DMT [total mean diameter of 251.75 mm
LV and HV]
20 Total loss of copper 3,244.422 watt

21 R% [winding resistance in 0.64888 Ω

percentage]
22 X1% 3.2515
23 X% =X1% * reactance factor 3.0889
which is 0.95
24 Z%[impedance in percentage] 3.156