CATEGORY 1:

TRANSFORMERS:
a) EFFECTIVE COOLING
TECHNIQUES OF POWER
TRANSFORMERS:
INTRODUCTION:
It is broadly accepted that the life of a power
transformer is the life of the oil/ paper insulating
system, also the fact that most failures in their final
on electro-mechanical base such as a short
temperature increment or a mechanical failure.
During the natural ageing of transformers, the
insulation of winding, which is cellulose paper,
deteriorates. Cellulose insulation degrades due to
heating or electrical Breakdown, resulting in the
production of furfural derivatives, which dissolve in
oil. Hence, the chemical analysis of the

MODES OF EFFECTIVE COOLING

TECHNIQUES OF POWER
TRANSFORMERS:
Most of the reason of failure of a transformer or
degrade electric power transformer age is failing of
transformer insulation. The effects of temperature on
insulation life are being investigated continuously,
and new data may affect future revisions of this
guide.

1) AGING ACCELERATION
FACTOR:For a given hottest-spot temperature, the
rate at which transformer insulation aging is
accelerated compared with the aging rate at a
reference hottest-spot temperature.For hottest-spot
temperatures lower than the reference hottest-spot
temperature, the aging acceleration factor is less than
1.

2) SUPPLEMENTAL OF EXISTING
SELF COOLED TRANSFORMERS :The
load that can be carried on existing self-cooled
transformers can usually be increased by adding
auxiliary cooling equipment such as fans, external
forced-oil coolers, or water spray equipment. The

amount of additional loading varies widely,

depending upon the following:
a) Design characteristics of the transformer
b) Type of cooling equipment
c) Limitations in associated equipment

3) WATER COOLANT WITH

WATER:The water cooling method, with the heat
transfer coefficient of water achieving more than
1000W/m2K, has much better cooling effect than air
cooling. This system is used when water coolant with
water is as a coolant medium.

PROPER SIZING : Transformers are

sometimes placed into a speculative setting in
advance of occupancy, so the engineer does not
necessarily know the load that will be placed on the
unit. As the installer is often not the party paying the
electric bill, there can be a tendency to oversize the
transformer capacity relative to the load it will
actually see. Since the no-load loss is a function of
the kVA capacity of the transformer, careful selection
of the transformer capacity closer to the intended task
will ensure lowest core loss.

SPECIFYING TO MINIMIZE OWING

COST: Whenever possible, always compare
competing transformer models by asking for the load
and no-load losses, in watts, and look at the total cost
of ownership. If possible, perform life cycle cost
analysis (discussed elsewhere on this Web site).
Remember that no-load losses are constant whenever
the transformer is energized. Specifying copper
windings can minimize both the load loss and the noload loss, by allowing for a smaller core. If the load is
known or can be predicted, choose a transformer that
will be loaded to about 75% of its nameplate rating.
Oversizing the unit increases the no-load losses, as
well as the purchase price, unnecessarily.

MEDIA:
Cooling system parts and working:
The cooling of a transformer depends on several
factors. Transformer oil must have low viscosity as
possible throughout the entire working temperature
interval; here we are using fresh transformer oil. A
tank as shown in fig filled with transformer oil up to
a limited volume. An electrical coil connected to the
tank that increases temperature of oil. Inside the tank
three sensing devices are connected at differentdifferent height to measure the temperature of oil.

These devices measure the temperature of bottom oil

and top oil level and these sensing devices directly
connected to electronics circuit, the circuit show the
temperature of top oil and bottom oil of transformer
tank, and temperature also measured by software.
The electronic circuit connected with computer to
USB port, the software show the temperature of
every minute of transformer tank, and reading
recoded by software of every second.

OPTIMIZATION: To improve the life of

transformer it is necessity to provide efficient cooling
system like in this assignment we are trying to show
the three cooling system simultaneously is working.
Natural oil cooling is not only sufficient cooling for
power and/or large transformer. We need a new
thinks to cooled a transformer here we are using
water forced cooling if temperature reach 58C then
water pump on and if temperature reach at 63C air
forced cooling start . These three cooling work
together to control the transformer winding
temperature and to increase the life of oil-paper
insulation and/or a transformer. With optimizing
cooling it is possible to lower the life cycle costs
(LCC) of a transformer with normal reliability of
operation. The effectiveness of optimizing depends
on the capacity of the cooling system, the average
load factor and the age of a transformer being
optimized.

load conditions and changes in ambient temperatures

make it difficult, if not impossible, to arrive at such
definitive information. To ensure reliable cooling
operation, a large margin of safety must be designed
into a transformer. Design criteria include winding
wire size, insulation material, and core size.
Transformer cooling assists in maintaining the
temperature rise of various parts within permissible
limits. The heat, which comes from the windings and
core depending on load conditions, is dissipated from
the transformer tank and the radiator to the
atmosphere. In particular, tanks, which are assembled
by cold rolled/hot rolled steel plates through welding,
are equipped with radiators or corrugated steel sheets
(panels) in accordance with the capacity of the
transformers.

MODES OF COOLING
TECHNIQUES:
The heat transfer mechanism in a transformer occurs
by three modes, i.e. conduction, convection and
radiation. In oil cooled transformers, convection
plays the most important role and conduction the
least important. The coupled thermal and fluid flow
processes, taking place inside the transformer, are
analyzed by the use of a coupled three-dimensional
computational fluid Manuscript dynamics-thermal
finite element model, developed and for better
representation purposes, the whole transformer
geometry is modeled, consisting of four iron cores,
three primary and three secondary windings of the
active part and finally the oil tank that surrounds
them. The figure shows how to remove the heat from
within the tank effectively, the convection and
radiation area of the tank walls is enhanced by typical
rectangular panels (fins).

b)EFFECTIVE COOLING
TECHNIQUES Of DISTRIBUTION
TRANSFORMERS:
INTRODUCTION:

expectancy
operating
transformers
at
varying
is
accurately
not
Fluctuating
known.
conditions
load
in
ambient
make
temperatures
it
difficult,
ifsuch
not
definitive
arrive
at
ToIFE
information.
ensure
operation,
large
margin
athe
of
be
safety
must
a
transformer.
Design
include
criteria
winding
wire
material,
core
size.
and
cooling
Transformer
maintaining
temperature
rise
parts
of
within
various
limits.
The
heat,
comes
which
from
the
and
windings
depending
on
conditions,
isof
from
dissipated
the
tank
L
and
the
radiator
atmosphere
to
expectancy
transformers
of
operation,
a
large
of
safety
margin
must
be
a
Design
transformer.
criteria
winding
include
wire
material,
and
core
Transformer
size.
cooling
maintaining
rise
temperature
of
various
parts
within
limits.
heat,
which
The
comes
the
windings
from
and
depending
on
conditions,
dissipated
is
from
L
IFE
the
tank
radiator
and
to
the
the
atmosphere
operating
varying
at
is
not
known.
accurately
load
Fluctuating
conditions
in
temperatures
ambient
make
difficult,
it
if
not
arrive
at
such
information.
definitive
To
ensure
expectancy
transformers
operation,
a
large
of
safety
margin
must
be
a
Design
transformer.
criteria
winding
include
wire
material,
and
core
Transformer
size.
cooling
maintaining
rise
temperature
of
various
parts
within
limits.
heat,
which
The
comes
the
windings
from
and
depending
on
conditions,
dissipated
is
from
the
tank
radiator
and
to
the
the
In
atmosphere.
particular,
are
assembled
by
rolled/hot
cold
rolled
plates
steel
welding,
are
equipped
radiators
or
with
steel
corrugated
(panels)
in
with
accordance
the
capacity
of
the
system
Cooling
is
designed
properly
to
have
proper
siphon
which
helps
system
to
minimize
the
between
gradient
oil
[1],
[2].
and
operating
at
varying
is
accurately
not
Fluctuating
known.
conditions
load
in
ambient
make
temperatures
it
difficult,
if
not
arrive
definitive
at
such
To
information.
ensure
transformers
novel
panel
tank
geometries
investigated
design.
design
derived
isThe
by
specifications
means
ofof
Mixed
Programming
Linear
methodology
(MINLP)
[17].
More
16
specifically,
inputs
transformer
power,
primary
secondary
and
winding
voltage,
line-to-line
conductor
type,
current
and
operating
density,
type
of
material,
magnetic
no
guaranteed
load
and
and
shortimpedance)
circuit
are
MINLP
used.
The
the
based
on
the
of
the
overall
cost
function:
life expectancy of transformers operating at varying
temperatures is not accurately known. Fluctuating

OPTIMIZATION: Transformer cooling system

improvement involves minimization of the size of
transformer panels and cooling ducts while retaining
high efficiency in the dissipation of transformer
losses. Thermal performance of power transformers

has been extensively studied through analytical or

advanced numerical techniques
The proposed novel tank panel geometries are
investigated for a given transformer design. The
design is derived according to transformer
specifications by means of Mixed Integer Non-Linear
Programming (MINLP) methodology. More
specifically, 16 transformer inputs (i.e. nominal
power, primary and secondary winding material,
primary and secondary line-to-line voltage, winding
connection type, conductor type and current density,
operating frequency,type of magnetic
material,guaranteed no load and load losses and short
circuit impedances) are used.
for optimizing the transformer design is based on the
minimization of the overall transformer cost function:

where cj and fj are the unit cost (/kg) and the weight
(kg) of each component j (active and mechanical part,
from above figure, and x is the vector of the four
design variables, i.e. the
number of low voltage turns, the magnetic induction
magnitude (B), the width of core leg (D) and the core
window height (G).
MEDIA: Transformer cooling assists in maintaining
the temperature rise of various parts within
permissible limits. The heat, which comes from the
windings and core depending on load conditions, is
dissipated from the transformer tank and the radiator
to the atmosphere. In particular tanks, which are
assembled by cold rolled/hot rolled steel plates
through welding, are equipped with radiators or
corrugated steel sheets (panels) in accordance with
the capacity of the
transformers. Cooling system is properly designed to
have proper self thermo siphon system which helps to
minimize the temperature gradient between winding
and oil. In case of oil-immersed transformer, cooling
is provided by the circulation of the oil. Transformer
oil acts as both insulating material and cooling
medium in the transformer. As a result, a number of
different cooling methods exist.

The distribution transformer is used for the

distribution of electrical energy at low voltage as
less than 33KV in industrial purpose and 440v-220v
in domestic purpose. It work at low efficiency at 5070%, small size, easy in installation, having low
magnetic losses & it is not always fully loaded.

SIZE : Distribution transformers normally have

ratings less than 200 kVA, [2] although some national
standards can describe units up to 5000 kVA as
distribution transformers. Since distribution
transformers are energized for 24 hours a day (even
when they don't carry any load), reducing iron
losses has an important role in their design.

COST:
The price / rating characteristics can be roughly
described as:

where:
C1 is cost of transformer 1
C0 is cost of transformer 0
S1n is rated power of transformer 1
S0n is rated power of transformer 0
x exponent (cost factor)
The X factor is about 0.4 to 0.5. For more efficient
units this factor has a tendency to increase up to 0.6
or even higher. Dry type transformers representing
rated losses specified by HD 538 standard are
usually a few percent lighter than oil transformers
(as they do not contain oil) but, because of the more

COMPARISON:
Power transformer is used for the transmission
purpose at heavy load, high voltage greater than 33
KV & 100% efficiency. It also having a big in size
as compare to distribution transformer, it used in
generating station and Transmission substation .high
insulation level.

costly manufacturing process, they are about 10% to

30% more expensive than CC oil-filled machines.

CATEGORY 2:
GENERATORS

COOLING OF TURBOALTERNATORS:
Closed circuit ventilation Long core length, small
diameter Methods
Air cooled (One side axial, two side axial, multiple
inlet system
Hydrogen cooled
Direct cooled

a) AIR COOLED TURBO-

ALTERNATORS
For small units used as auxiliaries in large power
stations
1 side axial ventilation: Up to 3MW
Air supply by propeller fan -> Air enters at an end,
leaves by the other
In long machines, temperature rise is high along the
length

b)AIR COOLED TURBOALTERNATORS

2 Sided Axial Ventilation:
Air forced from both sides, both windings have same
temperature rise
Used for machine rating up to 12MWmultiple inlet
system: Larger machines
Outer stator ->many chambers -> Alternate inlets and
outlets ->Up to rating 60MW

1. HYDROGEN COOLING SYSTEM

Hydrogen (4-76%) +Air -> Explosive mixture
Frame strong enough, all joints gas tight
Hydrogen above atmospheric pressure, so leakage is
from machine to atmosphere
Gas pressure maintained
Explosive mix avoided
Purity of hydrogen checked by measuring its thermal
conductivity

2. HYDROGEN COOLING OF TURBO

ALTERNATORS
For machines > 50MW, air cooling unsuitableNo
requisite amount of air, higher fan power
Advantages of hydrogen cooling:
Increased efficiency
Increase in rating
Increase in life span
Elimination of fire hazard
Smaller size of cooler
Less noise

3. DIRECT COOLING OF TURBO

ALTERNATOR
Conventional cooling
Direct cooling: Losses dissipated to medium
circulating in windings Called
supercharged/Conductor cooled/Inner cooled
machines
Advantages: Hydrogen, Water, Oil
Coolants in direct cooling
Hydrogen: Oil: Stator, rotor made hollow
High grade transformer
Hydrogen pumped from oil one end to other
Used in US-direct cooling
Used for machines with of stator conductors rating up
to 300MW
Flash point, can be reached in fault conditions,
damages insulation
4.

WATER AS COOLANT IN DIRECT

COOLING:
Higher rating -> Mechanical limitations for hydrogen
cooling
Water: Superior heat transfer property, Low viscosity,
No high pressure heads required for circulations
Advantages:
1) Higher load is possible as no temperature
difference between conductors and water
2) For rating up to 600MW

CATEGORY 3:
MOTORS:
Dc motors
- The need of cooling arrangement for DC motor is
very important to reduce the frame size of the motor.
It required to select the effective cooling arrangement
of the DC motor based on the application,
surrounding of the motor installation and power
consumption.
The quantity and quality of the cooling air can have
major impact on the DC motor performance,
operation, maintenance and life between overhauls.
Energy consumption in the cooling system depend on
which type of cooling used and what is the nature of
load in that application.

Methods of cooling:Method of cooling is

defined by NEMA with descriptive phrases, i.e.,
Non-ventilated - no cooling by means external to

the enclosure. IEC designates method of cooling by

letter IC (index of cooling) followed by two digits
with the first digit giving the cooling arrangement
and the second digit indicating the method of power
to circulate the coolant. For example, IC 40 - 4 frame surface (exterior) cooling. O - free
convection. In NEMA designation this would be NV.
Although the terminology for both motor enclosures
and method of cooling varies with NEMA and IEC, a
correspondence between the two terminologies can
be obtained for specific application conditions. Large
number of papers have been written on dust
disposition on the commutator. Careful attention is
made to the design of air pressure control to reduce
dust affecting commutator. Adequate air press will
not allow the carbon dust to deposit on the
commutator. The primary source of this dust is the
wear and tear of the brushes due to friction. This can
be blow out and filter by the filter before entering to
the heat exchanger.

Totally Enclosed Fan Cooled - Exterior

surface cooled by external fan on motor shaft.
Available in ratings Motor cooling is dependent on
motor speed.

Totally Enclosed Pipe-Ventilated (TEPV)

or Totally Enclosed Separately-Ventilated
(TESV) - Motor is cooled by customer supplied air
which is piped into the machine and ducted out of the
machine by customer

TYPEs OF COOLING SYSTEM USED

FOR DC MOTOR: Cooling air through a selfventilated or forced-ventilated motor must be clean
and have relative humidity between 30% and 100%
with no free water in the air. Use of damp, cool
outside air with high humidity and free water may
cause the motor to flash over. Use of excessively dry
air may cause excessive brush and commutator wear.
Cooling air temperature must not exceed the
maximum ambient temperature indicated on the
motor nameplate (Standard 40 Deg C).

A. Air Blowers on the Top and side (CA)In this arrangement side motor is forcing the air in
motor while the top motor extracting the air from the
motor.

Totally Enclosed Air-Over In-line - External

fan driven by constant speed AC motor flange
mounted to motor fan shroud. Provides cooling
independent of motor speeds.
Totally Enclosed Air-Over Piggyback - Has
top mounted AC motor driven blower shroud to
direct ventilating air over motor frame. Available thru
C400ATZ frame.

B. Air Blowers on the Top (FA) - In this

arrangement Blower is forcing the air in motor and
this air coming out from the ventilation grills.

Totally Enclosed Dual-Cooled with Airto-Air Heat Exchanger - Cooled by circulating

motor internal air through the heat exchanger by an
AC motor driven blower.

Totally Enclosed Dual-Cooled with Airto-Water Heat Exchanger - Similar to TEDC

A/A except external circulating air flow is replaced
by customer supplied water to remove heat from heat
exchanger. Available in ratings through 3000 HP.

D.

Circulating air Circulating water

( CACW) In this arrangement air blower used to
circulate the air in the motor and heat exchanger.
Water circulate through the heat exchanger and cool
the hot air. In this system no external air added hence

the contamination of air not occurred. Only the

carbon dust disposition is there in the motor.

COOLONG METHODS
TOTALLY ENCLOSED WATER TO AIR
COOLED
DEGREE OF PROTECTION: IP55
Cooling method :IC81W

INDUCTION MOTOR
COOLING TECHNIQUES
AC MOTOR COOLING SYSTEM:
The cooling system for the AC induction motors
consider for stator and rotor. AC motor can be
ventilated from driving or non driving end.
Unregulated motors cant be self ventilated or by
providing emperor on the shaft.Bigger size motor can
be externally ventilated It is better to blow out the
carbon dust from the slip ring to reduce tracking
when mixed with humid air and other contaminations
hence separate blower used for slip ring. In the steel
rolling mill, load on the rolling stand motors,
conveyor motors. Roller table motors not fixed and
this is the main cause of variable heat generation in
the motor. Cooling Blowers are operated at rated
RPM and consume rated power. The load on the
motor is varying as per the section requirement.
Cooling system is, however, not optimized
accordingly.

Utilities required: cooling water

Cooling path: Cooling air circulates in a path closed
off to the outside through the heat source inside the
motor and the water-cooled heat exchanger
Features: Good cooling performance; environmental
resistance; most compact and cost-effective solution
for large-capacity motors for sites with supply of
cooling water; noise can be restricted to low levels.
Totally enclosed water-to-air-cooled with fan
Degree of protection: IP55
COOLING MEYHOD: IC86W

SYNCHRONOUS COOLING
The motors can be supplied with forced ventilation,
air inlet and outlet by ducts, and other cooling
systems, meeting the requirements of the application
and environment where they are installed in the most
efficient way.
Motors are specially designed for high performance,
which requires that they be efficiently and effectively
cooled during operation. Depending on the type of
motor, there are three cooling methods to choose
from: weather-protected, air-to-air or water-to-air. We
will help you to choose the one that best matches
your needs.

Utility required: Cooling water, power-supply for

fan
COOLING PATH: Cooling path is the same as
above but the fan creates a forced airflow
FEATURES: Fan further enhances cooling
performance; accommodates wide range of operating
speeds in variable-speed system.
TOTALLY ENCLOSED PIPE VENTILATED

Degree of protection: IP55

Cooling method: IC97

Utility required: COOLING AIR

Cooling path: Cooling air supplied from the outside
circulates in a path closed off to the outside through
the heat source inside the motor and the heat
exchanger, located at a distance, through a duct
Features: Most compact, cost-effective solution for
sites with a supply of cooling air but without a supply
of cooling water.

Conclusion:
Cooling is very much essential for modern output
machines
Makes the output of machine stable
Increases efficiency, rating of machine
Increases longevity of machines, maintains safe
operation

Protects the inner parts of machine from thermal

damages