DESIGN OF SINGLEPHASE TRANSFORMER

BY: KUNTAL MONDAL. Co-worker:

MANAS KUMAR MANDAL.

Dept. of Electrical Engg, 3rd Year, Jadavpur University.

# SPECIFICATION:
1.5 KVA, 230/110 V, Sinewave 50 Hz, air-cooled, plain tank, ambient 40C, temperature rise 50C.

#STEP-1: (Calculation of primary and secondary

KVA) VPIP=VSIS=KVA. IS=1.510/110 A=13.16 A. IP= VsIs/VP=(11013.6)/220 A=6.18 A. Actual value of primary current, IP=1.02 IP ; for the noload current =1.026.18 A =6.93 A. Primary KVA= VP IP= 1.526KVA. Secondary KVA=1.5 KVA.

#STEP-2: (Calculation of volts per

turn)
Volts per turn, Et=KQ. Where, Q=average of total KVA of secondary & primary =(1.5+1.526)/2 KVA =1.513 KVA. K=emperical constant=1.1 for shell type =0.8 for core type. We choose core type construction. Et=0.81.513 =0.98

#STEP-3: (Net iron area)

Net iron area, Ai=m/Bm=(Et10)/(4.44fBm) cm. Factor 4.44sinewave. 4.0squarewave. The value of Bm depends on core material.We choose fresh CRGO as core material. Bm =1.5 Wb/m. Ai =(0.9810)/(4.44501.5) cm

=29.43 cm.

#STEP-4: (Gross-iron area)

Gross-iron area, Agi = Ai/Ki cm. Where, Ki iron space factor =actual area of iron in core/mechanical area of core =0.95 for CRGO. Agi =29.43/0.95 cm =31cm.

#STEP-5: (Type of core)

Normally,we prefer circular winding. So,we select step core for getting circular winding.

#STEP-6: (Calculation of actual core

dimension)
If d=diameter of the circumscribing circle of core, then, d> (4Agi / ) =(431/ ) =6.28 cm. From table,we select minimum diameter d in cm =7.5 cm. So, corresponding maximum number of steps=4. (b) Now, if Agi be the gross core area given as per unit value of the area of circumscribing circle, then corresponding to each Agi we calculate the numerical value of diameter of circumscribing circle d, using d=(4Agi / Agi ). From table, corresponding to 4 steps Agi =0.886. d={(431/( 0.886)}=6.674 cm. (c) The dimensions a1,a2,a3,a4(thickness of steps) are the width of the laminations per step size, are given as per unit value of diameter d of circumscribing circle in the table. So, multiplying with d we get actual dimensions as,

(a)

a1=6.22cm. a3=4.04 cm.

a2=5.33 cm. a4=2.39 cm.

#STEP-7:
From the new sectional dimensions of core, we calculate the resulting gross-core area Agi using geometry as shown:

K1 =(d-a1)=2.42 cm. K2 =(d-a2) =4.056 cm. K3 =(d-a3) =5.31 cm. K4 =(d-a4) =6.231 cm. . Agi (new)= [a1K1+a2(K2-K1)+a3(K3-K2)+ a4(K4-K3)] =[6.222.24+5.31.636+4.041.254+2.390.92 1] cm = 31cm.

This Agi (new) is almost equal to Agi obtained in step-4. Ai (new)= KiAgi (new) = 0.9531cm = 29.43 cm. New flux density, Bm (new)=Ai (old)Bm (old)/ Ai (new) =(29.431.5)/29.43 Wb/m =1.5 Wb/m. New value of d=(4Agi / Agi ) ={(431)/(0.934)} cm d(new)=6.674cm.

#STEP-8: (Window Space Factor)

Window space factor, Kw =8/(30+KV) ;where,KVis the highest kilo =8/(30+0.220) volts rating in transformer. =0.264 .

#STEP-9: (Current Density)

The value of current density depends on the type of cooling,the permitted temperature rise,the maximum ambient temperature,the class of insulation and the size of the transformer. For air natutal cooled without radiators, =100 to 300 A/cm. We take, =200 A/cm.

#STEP-10: (Window area required)

Aw =(1.51310)/ (2.22501.50.26420029.43) cm =58.47cm. = HwWw. Where, Hw =Height of window.

The window area required, Aw =(Q10)/(2.22fBm KwAi )

Ww =Width of window.

#STEP-11: (Finding Hw and Ww)

Assuming, the ratio Hw/Ww =4. Hw =4Ww Ww =3.82 cm. Hw =15.29 cm.

#STEP-12: (Number of turns on LV winding)

low

NLV =(ELv 10)/(4.44Bm fAi );where, ELv is the

volt

age rating.

=(11010)/(4.441.55029.43) = 113.

#STEP-13: (Number of turns on HV winding)

NHV =NLVEHv/ELv =must be integer. NHV =601.510/110 =226.

#STEP-14: (Area of primary & secondary

conductor)
Primary current= IP. Secondary current= IS. Cross-sectional area of primary conductor, mm

aP = IP10/
=6.931

0/200 mm =3.465 mm. Cross-sectional area of secondary conductor, aS = IS10/ mm =13.63 10/200 mm

mm.

=6.815

#STEP-15: (Selection of conductor)

We use round enamel coated copper conductor. SWG (mm) for Enamel Bare copper area(mm) Bare copper Dia.(mm) Overall Dia. syn.

14 2.152 11 3.086

3.243 6.818

2.032 2.94

#STEP-16: (Coil ratings)

The transformer is core type.then there will be two identical coils. one on each limb. hence, each coil will consist of half the primary and half the secondary winding. the two half primary winding on each coil are connected in series. hence each is rated half the voltage and current.

#STEP-17: (Which winding is to be started

first)
We place the HV (primary) windings on the outside per limb to reduce insulation cost.

former)

#STEP-18: (calculation of dimensions of

The inner windings are to be supported on a former or bobbin when being wound. #length or height of the former or bobbin = (Hw - 0.5) cm = (15.29 0.5) cm = 14.79 cm. #the thickness tb of the former or bobbin= (2+0.5 KV) mm. Where, KV is the numerical value of the kilo-volts rating of the inner winding with respect to earth. tb = (2+0.50.110) mm =2.055 mm. # c/s dimensions of the former or bobbin: In case of circular winding: Inner diameter of the former: Di = (d+0.5) cm ; ddia. of core circumscribing circle. = (6.674 + 0.5) cm = 7.174cm.

Outer diameter of the former: Do =[Di +(2tb)] cm =[7.174+(20.2055)] cm =7.585 cm.

winding) The winding can not be spread over the entire length of the bobbin or former since there must be adequate clearance from the two ends to prevent flash-over from winding to the yoke (which is earthed). The clearance on each side is given by an empirical formula: l= (5+ 0.9KV) mm ; where,KV is the kilo-volts rating of the inner winding w.r.to earth. = (5+ 0.90.110) mm =5.099 mm. It is desirable that the heights of both the primary and secondary windings be equal in order to minimize the leakage reactance between them and also to minimize the mechanical forces between them at the time of short-circuit current flow. Therefore, the LV winding must have a clearance more than what its voltage alone demands. Hence, the available length of the winding is: L=length or height of former or bobbin- twice end clarance =14.79 cm (25.099) mm =13.77 cm.

#STEP-19: (Calculation of available length of

# STEP-20: (First or inner winding of a coil is LV

type)

(a) (b)

This implies a cylindrical or helical type of winding. Dimension of insulated conductor:For round enamelled copper conductor: SWG=11,14. Bare copper diameter=2.946,2.032 mm.

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Overall dia. for synthetic enamel coated conductor=3.086,2.152 mm. This is the axial space taken by the conductor per turn. (c) Calculation of number of turns that can be fitted in one layer:For primary Turns per layer=(Available length of winding/Axial space of Conductor per turn) 1 =(13.77/0.215) 1 =63(smaller integer). For secondary Turn per layer=43

(d)

turns per coil for LV winding=113.

So, turns per layer < turns per coil. We accommodate turns per coil in multiple layers

# STEP-21: The inner winding is not #STEP-22: (Calculation of the radial

thicknessordepth of

HV type.

each layer of the inner winding) The radial thickness or depth of each layer is due to the overall dimension of the insulated conductor in the radial direction i.e. for circular conductors, it is the overall dimension added with the thickness of inter-layer insulation, whose typical values are 5 to 10 mil. This is necessary to prevent interlayer short-circuit, since insulation is often damaged during winding due to bending and hitting with mallet. We havent used any inter-layer insulation. Thus, overall radial depth of winding=Number of layers[radial dimension of insulated conductor+thickness of inter-layer insulation] For lv =33.086 mm=9.258 mm. For hv =42.152mm=8.688mm.

#STEP-23: (cooling duct before start of outer winding)

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Duct radial width= 10 to18 mm ; for oil cooling = 15 mm ; we choose to provide suitable cooling at the same time not much increase in leakage reactance between the windings.

# STEP-24: (For outer or second winding)

# length or height of the former or bobbin= (Hw - 0.5) cm = (15.29 0.5) cm = 14.79 cm. #the thickness tb of the former or bobbin= (2+0.5 KV) mm = (2+0.51.5) mm = 2.11 mm. # c/s dimensions of the former or bobbin: In case of circular winding: Inner diameter of the former: Di = (7.585+4.215+0.5) cm Di=8.445cm Outer diameter of the former:

=[8.445+(20.211)] cm Do=8.867 cm

# STEP-25: (Design of outer winding)

(a) The HV rating = .220KV < 3 KV. This implies a cylindrical or helical type of winding. (b) Dimension of insulated conductor:As before, axial space taken by the conductor per turn = 2.152mm. (c) of turns that can be fitted in one layer =(13.77/0.215) 1 =63(smaller integer (d) Turns per coil for HV winding = 226. So, turns per layer < turns per coil. We accommodate turns per coil in multiple layer.

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The vacant space available per layer is left at the two ends to reduce the possibbility of flash-over due to high voltage. (e) Calculation of the radial thickness or depth of each layer of The outer winding:Similarly, as obtained for inner winding, overall radial depth of windin =42.152mm=8.688mm

#STEP-26:
The clearance required is given by:Clearance = (5+0.9 KV)0.1 cm ; where,KV is the numerical value = of the kilo-volts difference between two outer winding voltages.

#STEP-27: (Yoke dimensions)

Assuming identical c/s as in limb, the yoke may have identical steps as the limb. For CRGO material, to obtain low loss in the core structure, it is essential that the laminations are to be assembled using mitred joints.

#STEP-28: (Calculation of resistance and copper loss

of each winding) For inner(primary) winding:Winding resistance=[Mean turn length(cm) of turns in winding Resistivity] /Area of conductor(cm) A mean turn is one hypothetically placed in the radial midposition. Mean turn length = (7.585 + 0.925/2) cm = 25.28cm. Number of turns in winding = 113.

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Ambient temperature, Ta = 40C. Temperature rise, Tr = 50C. Resistivity of copper:at 20 C,

= 0.017593 -mm/m.

area of bare conductor = 6.818 mm. winding resistance at 20 C = (0.25281130.017593) / 6.818 = 0.074 . winding resistance at (Ta+Tr)C,i.e.,90 C=.074[1+0.003929(90-20)] =0.094 . copper loss in secondary winding = (Is 1.95) watt = (13.63 .094) watt = 17.46 W. For outer(primary) winding:Mean turn length = (8.445 + 0.868/2) cm = 27.9 cm. Number of turns = 226.

winding resistance at 20 C = (0.2792260.017593) / 3.243 = 0.34 . winding resistance at (Ta+Tr)C,i.e.,90 C=0.34[1+0.003929(90-20)] = 0.43 . Copper loss in secondary winding = (Ip 0.43) watt = (6.93 0.43) watt = 20.81W.

Total copper loss =Cu loss in two windings

= (17.46 + 20.81) KW =38.29W.

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