Design Sheet

Inputs:-

1. Customer Name:-
2. TQ No:-
3. KVA Rating:-
4. HV:-
5. LV:-
6. Phases:-
7. Basic Insulation Level:-
8. Frequency:-
9. Winding Connections:-
i) HV Connection
ii) LV Connection
10. Vector Group:-
11. Type of Cooling:-
12. Tapings on HV winding for HV voltage Variation
i) Range:- ± _____ % to _____ %
ii) In steps of:-______%
iii) Type of Tap Changer:- Off Circuit/On Load
Calculations:-

Core Calculations:-

1. Step Voltage = [HV X Step %]/100 _______(For Delta Connection)

= [(HV / √3) X Step %]/100 ____(For Star Connection)

2. Volt / turn (et(trial)) = 0.8 X √(KVA/No. of limbs)

3. Turns/Step = Step Voltage/ et(trial)

4. Assume round value of Turns/Step.

5. Volt / turn (new) = Step Voltage/(Assumed Turns/ Step)

6. HV Turns = HV / (Volt / turn (new)) ______(For Delta Connection)

= (HV / √3) / (Volt / turn (new)) ___ (For Star Connection)

7. Final Volt/Turn = HV/HV Turns

8. Core cross-section Area (A) = (Final Vol/Turn) X 10^4 / (4.44 X f x B m)____cm2

9. Core Diameter = √(Core Area(A)/0.715) X 10_____mm

10. LV Turns = LV / (Volt / turn (new)) ______(For Delta Connection)

= (LV / √3) / (Volt / turn (new)) ___ (For Star Connection)

Calculations for HV Windings:-

1. HV Turns = HV / (Volt / turn (new)) ______(For Delta Connection)

= (HV / √3) / (Volt / turn (new)) ___ (For Star Connection)

2. HV Turn for +Ve Step = [ HV Turns X (1 + (%+Ve Step)/100)] - 1

3. HV Turn for -Ve Step = [ HV Turns X (1 + (%+Ve Step)/100)]

4. HV No. of Coil:-
(a) For HV Cross Over Winding
(i) 11 KV – 4 Nos
(ii) 22 KV – 6 Nos
(iii) 33 KV – 8 Nos

5. Coil No. / Type :-

(a) For High Voltage Low Current Winding below 33 KV –Cross Over Winding
(b) For Very High Current in LV below 0.433 KV – Double Layer Spiral Winding
(c) For Very High Current in LV below 11,22,33 KV – Double Layer Helical Winding or
Single Layer Helical Winding
(d) High Voltage Winding above 132 KV – Partial Interleaved Winding
(e) High Voltage Winding for 220 KV – Fully Interleaved Winding

6. Turns / Coil = HV Turns / HV No. of Coil

7. No. Of Layers :- No. of Discs

8. Turns / Layer = (Turn/Coil)/(Turns / Layer)

9. Clearance between Layers: - This is applicable only for Double Layer Helical or Double
Layer Spiral Windings.

10. Clearance Between Coil/Turns:-

i. 11 KV – 2.8 or 1.8 mm
ii. 22 KV – 2.8 mm
iii. 33 KV – 2.8 mm
iv. 66 KV – 3.6 mm
v. 132 KV – 4.2 & 3.6 mm
vi. 220 KV – 4.6 mm

11. Paper Covering:-

i. 11 KV – 0.45 or 0.5 mm
ii. 22 KV – 0.6 mm
iii. 33 KV – 0.6 mm
iv. 66 KV – 0.8 mm
v. 132 KV – 1 mm
vi. 220 KV – 1.2 mm
12. Clearances:-
i. 11 KV – 12 to 15 mm
ii. 22 KV – 15 to 16 mm
iii. 33 KV – 18 mm
iv. 132 KV – 44 to 45 mm
v. 220 KV – 70 mm for 950 BIL; 75 to 80 mm for 1050 BIL

13. Current = (KVA X 1000)/ ( HV X 3)_____(For Delta Connection)

= (KVA X 1000)/ (HV X √3) ____ (For Star Connection)

14. Radial Thickness

= [(No. of Layers X Diameter of Covered Conductor) + Total Clearance between Layers]

15. Area Of HV Bare Conductor = (π/4) X (HV Bare Conductor Diameter) 2

16. Current Density = Current in HV Winding/Area of HV Bare Conductor___ Amp/mm 2

17. Mean Turn (MT Mtr.) = π X Diameter of HV Winding / 1000

18. Length of HV Winding (Mtr.) = [Mean Turn X HV Turn (on +Ve Step) X 3 ] + 5 to 12 tolerance

19. Weight of Bare Conductor(kg)=(Length of HV winding X Area of HV Bare Cond. X 8.9)

1000

20. Weight of Covered Cond.(kg) :-

= [{((π/4 X (Dia of Covered Conductor) 2)/Area of HV Bare Cond.) – 1} X 9.1 + 1] X Weight of

100 bare cond.

21. Resistance at 75°C = 21.1 X Mean Turn X HV Turns X 3 (R = ρ x l / A)

Area of HV Bare Cond. X 1000 where ρ=21.1 gm/cm

22. I2 R at 75°C =( Current in HV Winding)2 X Resistance at 75°C

23. Eddy Loss = (I2 R at 75°C) X 15 %

Note:-For Distribution Transformers Eddy losses are generally 15% of I 2R Losses.
Calculations for LV Windings:-

1. LV Turns = LV / (Volt / turn (new)) ______(For Delta Connection)

= (LV / √3) / (Volt / turn (new)) ___ (For Star Connection)

2. LV No. of Coil:-
a) For HV Cross Over Winding
(iv) 11 KV – 4 Nos
(v) 22 KV – 6 Nos
(vi) 33 KV – 8 Nos

3. Coil No. / Type :-

(a) For Very High Current in LV below 0.433 KV – Double Layer Spiral Winding
(b) For Very High Current in LV below 11,22,33 KV – Double Layer Helical Winding or
Single Layer Helical Winding

4. Turns / Coil = LV Turns / LV No. of Coil

5. No. Of Layers :- No. of Discs

6. Turns / Layer = (Turn/Coil)/(Turns / Layer)

7. Clearance between Layers: - This is applicable only for Double Layer Helical or Double Layer
Spiral Windings.

8. Paper Covering:-
i. 0.415,0.433,11 KV – 0.45 or 0.5 mm
ii. 22 KV – 0.6 mm
iii. 33 KV – 0.6 mm
iv. 66 KV – 0.18 mm
v. 132 KV – 1 mm
vi. 220 KV – 1.2 mm

9. Current = (KVA X 1000)/ ( LV X 3)_____(For Delta Connection)

= (KVA X 1000)/ (LV X √3) ____ (For Star Connection)

10. Radial Thickness

= [(No. of Layers X No. of Radial Conductor X Axial Length of covered cond.)] +
[Total Clearance between Layers]
11. Axial Length of LV Covered Conductor =

[Leg Length – Top Clearance–Bottom Clearance–End Strip Thickness–Centre Strip Thickness]

[LV Turns/Layer+1] X [No. of Axial Conductor]

12. Area of LV Bare Conductor :-

i. If Axial Length of bare conductor ≤ 2, then
Area= [(Radial length of bare cond. X Axial length of bare cond.) – 0.35]
ii. If Axial Length of bare conductor < 3, then
Area= [(Radial length of bare cond. X Axial length of bare cond.) – 0.55]
iii. If Axial Length of bare conductor ≥ 3, then
Area= [(Radial length of bare cond. X Axial length of bare cond.) – 0.86]

Note: - The above formula is for 1 Radial & 1 Axial Conductor. If there will be m radial & n axial
conductor, then the formula will be;

= Area of LV Bare Conductor X m X n

13. Current Density = Current in LV Winding/Area of LV Bare Conductor___ Amp/mm 2

14. Mean Turn (MT Mtr.) = π X Diameter of LV Winding / 1000

15. Length of LV Winding (Mtr.) = [Mean Turn X LV Turn X 3 ] + 5 to 12 tolerance

16. Weight of Bare Conductor(kg)=(Length of LV winding X Area of LV Bare Cond. X 8.9)

1000

17. Weight of Covered Cond.(kg) :-

= [{((π/4 X (Dia of Covered Conductor) 2)/Area of LV Bare Cond.) – 1} X 9.1 + 1] X Weight of

100 Bare cond.

18. Resistance at 75°C = 21.1 X Mean Turn X LV Turns X 3 (R = ρ x l / A)

Area of LV Bare Cond. X 1000 where ρ=21.1 gm/cm

19. I2 R at 75°C =( Current in LV Winding) 2 X Resistance at 75°C

20. Eddy Loss = (I2 R at 75°C) X 15 %

Note:-For Distribution Transformers Eddy losses are generally 15% of I 2R Losses.
Calculations of Total Axial Length:-

1. Total HV Axial Length:-

=[HV No. of Coil X (HV Turns/Layer+1) X Dia. Of Covered Conductor]

+
[(HV No. of Coil – 2) X (Clearance between Coil/Turn)
+
[Thickness of insulation At Break of tapping]

2. Total LV Axial Length:-

= [(LV Turns/Layer + 1) X (No. of Axial Conductor X Axial Length of covered conductor)]

+
[2 X (End Strip Thickness/2) ]
+

[Pkg X {Total HV Axl Length-(LV Turns/Layer+1) X (Axl Length of coverd cond)-(2XEnd Strip thk/2)}]

Calculation of Losses:-

1) I2R Losses = HV I2R Losses + LV I2R Losses

2) Eddy Losses = HV Eddy Losses + LV Eddy Losses

3) Stray Losses = [ 5.67 – (1.77 X log (MVA) X MVA) X % Z] / 10

4) Eddy +Stray Losses = I2R Losses X 15 %

5) Total Load Losses = I2R Losses + Eddy Losses +Stray Losses

6) No Load Losses = Total Weight X Watt/Kg1 X Watt/Kg2 X Watt/Kg3

Calculation of % Z:-

1) %X = [ € Dm X LV No. of Turns X LV Winding Current X π]

[2.54 X Final Volt/ Turn X R L X 1000]

2) Total Load Loss X 100 / KVA X 1000

3) %Z = √(%X2 + % R2)
Calculation of Total Weight:-

1) Total Weight of Copper:-

= [Weight of LV Covered Cond. X Weight of HV Covered Cond. X 1.01]

2) Total Weight of Leg:-

= [3 X 7.65 X Core Area X Leg Height]/ (10X 1000)

3) Total Weight of Yoke:-

= [Centre Clearance /10 – Max. Blade Width (W max)/10] X [7.65 X Core Area/1000]

4) Total Weight of Corners:-

=6.14 X (Max. Blade Width/10) X 7.65 X (Core Area/1000)

5) Total Weight = Weight of Leg + Weight of Yoke + Weight of Corners

Calculation of Reactive Length (RL):-

RL = [(LV Radial Depth/10 + Clearance between HV & LV/10 + HV Radial Depth)/3]

+
[Total HV Axial Length/10]

Calculation of € Dm:-

€ Dm= [LV Radial Depth/10 X Mean Dia. of LV/10]/3

[Clearance between HV & LV/10 X Mean Dia. Of high-low gap/10]

[HV Radial Depth/10 X Mean Dia. of HV/10]/3