Design of Distribution Transformer

Design a Transformer to meet the following Specification:

Type of Distribution : CORE

Output in KVA : 50kVA

Primary (HT) Volts : 2400 V

Secondary (LT) Volts : 480/240 V (multi-tap)

Frequency : 60 Cycle

Efficiency at Unity Power Factor

Full Load : 98.4 %

¼ Load : 97.8 %

Temperature rise not to exceed to 55⁰c

CALCULATIONS:
Guaranteed Losses:
1−0.984
Total Loss @ Full Load = 𝑥50000 = 813 𝑤𝑎𝑡𝑡𝑠
0.984

1−0.978 50000
Total Loss @ ¼ Full Load = 𝑥 = 281.186 𝑤𝑎𝑡𝑡𝑠
0.978 4

813−281
Full Load Copper Loss = = 567.268 𝑤𝑎𝑡𝑡𝑠
1−1⁄16

Core Loss = 813 − 567.268 = 245.73 𝑤𝑎𝑡𝑡𝑠

 Item 1. Volts Per Turn (assume c = 60)

√50000
𝑉𝑡 = = 3.73 volts
60
 Item 2 to 4. Primary and Secondary Turns. It is desirable to use Two coils on the High
Tension Side
and Four coils of the Low Tension Side.

480
Total Secondary Turns = = 128.686 (say) 132 turns
3.73
132
Turns per Secondary coils = = 33 turn/coil
4
2400
Total Primary Turns = =660 turns
3.73
660
Turns per Primary coils = = 330 turn/coil
2
  Item 5. Full Load Current

@ High Tension @ Low Tension

50000 50000
𝐼𝑠 = 480 = 104.167 𝑎𝑚𝑝. 𝐼𝑝 = 2400 = 20.83 𝑎𝑚𝑝.

 Item 6 to 15. Before deciding upon the sizes of wire in the windings, it would be advisable
to
the probable dimensions of the opening or window, which must accommodate both primary
and secondary windings. (assume Current Density = 1500 amp/sq. inch)
10
 Space factor = 30+2.4 = 0.309
2(132𝑥104.167)
 H x D= 1500𝑥0.309 = 59.3313 𝑠𝑞. 𝑖𝑛𝑐ℎ
 𝐻⁄𝐷 = 3.5 inch
 D = 4.11 inch
 𝐻 = 14.41 inch

108 𝑥480
 By formula, the flux in the iron is 𝛷 = 4.44𝑥132𝑥60 = 1365001.365 𝑚𝑎𝑥𝑤𝑒𝑙𝑙𝑠

 From art 130. We select 70000 lines per sq. in as a trial density in the limbs under windings.
Hence the proportion S = 2L and stacking factor of 0.9 assume S = 1.5L.
1365001.365
0.9𝐿 𝑥 1.5𝐿 = 𝑳 = 3.8 inch
70000
𝑴 = 𝑳 = 3.8 inch 𝑺 = 1.5(3.8) = 5.7 inch

 Assuming M=L, the same cross section of iron and the same flux density in the end of the core as
in the limbs under windings M= 3.8 inch
 Weight of iron = 0.28(𝑆𝐹 𝑥 𝐿 𝑥 𝑆) 2( 𝐻 + 𝑆 + 𝐿 + 𝑀)
= 0.28(0.9𝑥3.8𝑥5.7)𝑥2(14.41 + 5.7 + 3.8 + 3.8)
𝑊𝑖𝑟𝑜𝑛 = 302.5 𝑙𝑏.
 Total core loss watts per pound of B= 70000 be 0.75 from fig. 154
𝑻𝒐𝒕𝒂𝒍 𝑪𝒐𝒓𝒆 𝑳𝒐𝒔𝒔 = 𝑊𝑖𝑟𝑜𝑛 (0.75) = 302.5(0.75) = 226.875 𝑤𝑎𝑡𝑡𝑠

The total Core Loss needs to be increased to meet the guaranteed Core Loss of 245.73.
By making slight changes in the design and decreasing the number of turns in the windings, it will
now be possible to proceed with the final calculations and approxiamate the losses required to
give the specified efficiencies.
 Recalculation of Core Loss
The total flux is:
132
Φ = 1,365,001.365 𝑥
116
= 1,553,277.415 maxwells
 Calculating the losses in the limbs under the windings and in the end sections must be calculated
separately.
 For the losses of the 2 limbs under windings:
Φ 1,553,277.415
𝐶𝑆𝐴 = 0.9 𝑥 3.8 𝑥 5.7 𝛽 = 𝐶𝑆𝐴 = 19.494
= 19.494 sq. in = 79679.769 (say) 80,000 lines per sq. In.
 We read watts loss per pound be: 0.95

Weight of 2 limbs under windings = 0.28 𝑥 19.494 𝑥 14.41 𝑥 2

= 157.3 𝑙𝑏𝑠.
Core Loss of 2 limbs under windings = 157.3 𝑥 0.95 = 𝟏𝟒𝟗. 𝟒𝟒 𝒘𝒂𝒕𝒕𝒔

 For the losses of the 2 end sections, it will also be calculated in the same manner.
Henc, adjusting M=5.

1,553,277.415
𝐶𝑆𝐴 = 0.9 𝑥 5 𝑥 5.7 𝛽= 25.65
= 25.65 𝑠𝑞. 𝑖𝑛 = 60, 556.62 (say) 61,000 lines per sq. In.

We read Watts loss per pound be: 0.57

Weight of 2 end sections = 2 𝑥 0.28 𝑥 25.65 𝑥 (4.11 + (2 𝑥 3.8))

= 168.2 𝑙𝑏𝑠.

Core Loss of 2 end sections = 168.2 𝑥 0.57 = 𝟗𝟓. 𝟖𝟕𝟒 𝒘𝒂𝒕𝒕𝒔

Total Core Loss = 149.314 + 95.874 = 𝟐𝟒𝟓. 𝟑𝟏𝟒 𝒘𝒂𝒕𝒕𝒔 which is practically the specified Loss of
245. 75 watts

Core Dimensions:

L= 3.8 in. M= 5 in. H= 14.41 in.

S= 5.7 in. D= 4.11 in.

Size of Wires And Winding Particulars

 Thickness CSA / Width

𝐼𝑠 104.167
= = 0. 6933 𝑠𝑞. 𝑖𝑛𝑐ℎ.
∆ 1500

Length of winding space in the Layer = 13.91 (from fig.)

13.91
Width of one Conductor including insulation = 29 = 0.4797 𝑖𝑛
Cotton Coverings = 0.02 in (20 mils)
Width of Copper = 0.46 inch
0.06933
Thickness = 0.46 = 0.15175 inch
 For rectangular conductor = 0.46 𝑏𝑦 0.1575 = 0.07245 𝑠𝑞. 𝑖𝑛𝑐ℎ.

 For high tension side select the size of wire at the table n page 431 use size #7 DCC wire
20.83 𝑎𝑚𝑝
𝐶𝑢𝑟𝑟𝑒𝑛𝑡 𝐷𝑒𝑛𝑠𝑖𝑡𝑦 = 0.01635
= 1𝟐𝟐𝟑.𝟐𝟒
𝑠𝑞.𝑖𝑛𝑐ℎ

Length of winding Layer = 13.66 (assumption)

Number of Wires per Layer = 13.66 x 6.35 = 86.74 (say) 87

where 6.35 is obtained from the wire table on page 431.

580
 Total Number of Layers of Wire = 87 = 6.67 ≅ 7 𝑙𝑎𝑦𝑒𝑟
(for each 2 limbs)
2𝑥87
 Volts (RMS) = 1200𝑥 580 = 360 𝑣𝑜𝑙𝑡𝑠 (𝑟𝑚𝑠 𝑣𝑎𝑙𝑢𝑒)

 It is usual to limit the potential

difference between layers which can
generally be accomplish the number
of windings in the sufficient number
of separate coils providing adequate
insulation between coils with core
dimension.
Thickness of copper and insulation
is computed as follows.

 Item 16 to 23.

Materials Radial Thickness

Cotton tape binding assembled laminations 0.018
Varnished cambric 0.010
Pressboard 0.030 t = 0.125
Clearance 0.067
Inner L.T. coil (one layer) including cotton on wire 0.190
Parchment paper (0.010) between coils; allow 0.015 s = 0.395
Outer L.T. coil (one layer) 0.190
Pressboard around outer L.T. coil 0.020
Spacers of treated wood to form oil ducts 0.125
Pressboard 0.020 g = 0.188
Two layers cotton tape 0.018
Parchment paper w/ crimped edges on w/c primary and
secondary coil will be wound 0.005
18 layers of No. 13 dcc round wire 1.092
Two thickness of 0.005 papers between layers 0.080
Cotton tape, half lapped 0.018 p = 1.304
Allowance for bulging (0.02 x 3.05) 0.114
Total 2.012

Space available to accomodate this total thickness of copper and

4.11
insulation = 2 =2.055 in.
CALCULATION OF COPPER LOSS

 The mean length per turn (MLT) of the windings

2(3.8 + 5.7) + 𝜋(0.25 + 0.395)
𝑆𝑒𝑐𝑜𝑛𝑑𝑎𝑟𝑦 𝑀𝐿𝑇 = = 1.75 𝑓𝑡
12
2(3.8 + 5.7) + 𝜋(0.25 + 0.79 + 0.304)
𝑃𝑟𝑖𝑚𝑎𝑟𝑦 𝑀𝐿𝑇 = = 1.72 𝑓𝑡
12
 Total Length of Wire
Primary Winding = 580 x 1.72 = 997.6 ft
Secondary Winding = 116 x 1.75 = 203 ft
 Weight of Copper Loss
Primary Coils (No.7), 63 x 0.9976 = 62.85 lb
Secondary Coils = 0.32(0.46 x 0.151) x 203 x 12 = 54.145 lb
Since the resistance of No.7 DCC wire is 0.5790 Ω,
234.5+75
0.5790 𝑥 [234.5+60] = 0.61 𝛺

 Total Resistance
(Primary)
RT = 0.61 x 0.9976 = 0.61 Ω

IR = 20.83 x 0.61 = 12.68 volts

𝐼 2 𝑅 = 20.832 𝑥 0.61 = 264.67 𝑤𝑎𝑡𝑡𝑠

(Secondary)
0.0635 203
RT= 0.61𝑥 [ ]𝑥 = 0.02789 𝛺
0.0726 1000

IR = 104.167 x 0.02789 = 2.9 volts

𝐼 2 𝑅 = 104.1672 𝑥 0.02789 = 302.63 𝑤𝑎𝑡𝑡𝑠

Total Copper Loss = 264.67 + 302.63 = 567.3 watts

 Items 24 – 32. Core and Copper Losses 245.31 + 567.3= 812.61 watts

 Items 33. Efficiency at unity power factor

𝟓𝟎,𝟎𝟎𝟎
𝟏 𝟒
@ 𝟒 Full Load : 𝟏− 𝟓𝟔𝟕.𝟑 𝟓𝟎,𝟎𝟎𝟎 = 𝟗𝟖. 𝟕𝟕%
𝟏𝟐𝟎+
𝟏𝟔 𝟒

𝟐𝟒𝟓.𝟑𝟏+𝟓𝟔𝟕.𝟑
@ Full load : 𝟏 − 𝟓𝟎𝟎𝟎𝟎+𝟖𝟏𝟐.𝟔𝟏 = 𝟗𝟖. 𝟒%

𝟐𝟒𝟓.𝟑𝟏+𝟏𝟒𝟏.𝟖𝟐𝟓
@ Half Full load : 𝟏 − 𝟐𝟓𝟎𝟎𝟎+𝟐𝟎𝟑.𝟏𝟓𝟐𝟓 = 𝟗𝟖. 𝟓%

𝟎.𝟕𝟓 𝒙 𝟓𝟎,𝟎𝟎𝟎
@ Three quarter full load : = 𝟗𝟖. 𝟒𝟐%
(𝟎.𝟕𝟓𝟐 𝒙 𝟓𝟔𝟕)+𝟏𝟐𝟎+(𝟎.𝟕𝟓 𝒙 𝟓𝟎,𝟎𝟎𝟎)
 𝟏.𝟐𝟓 𝒙 𝟓𝟎,𝟎𝟎𝟎
@ 25% over load : = 𝟗𝟖. 𝟒𝟐%
(𝟏.𝟐𝟓𝟐 𝒙 𝟓𝟔𝟕.𝟑)+𝟏𝟐𝟎+(𝟏.𝟐𝟓 𝒙 𝟓𝟎,𝟎𝟎𝟎)
Maximum Efficiency:
𝟐𝟒𝟓.𝟑𝟏
= 𝟓𝟎𝟎𝟎𝟎√ 𝟓𝟔𝟕.𝟑 = 𝟑𝟐. 𝟖𝟖 𝑲𝑽𝑨

𝟐𝟒𝟓.𝟑𝟏+𝟐𝟒𝟓.𝟑𝟏
= 𝟏 − 𝟖𝟒𝟑𝟗.𝟑+𝟒𝟗𝟎.𝟔𝟐 = 94.5%

 Items 34. Basis of 4 hour full load and 20 hour no load.

All Day Efficiency:

50000 𝑥 4
= (50000 𝑥 4)+ (145.31 𝑥24)+ (812.4 𝑥4) = 𝟗𝟔. 𝟕%

 Item 35. For the two limbs under the winding with mean length
B = 80,000
Mean Length = 2 x (3.8 + 5.7 + 4.11) = 27.22

𝑇 𝑥 𝐼 = [27.22 ]𝑥 [0.8] = 𝟐𝟏. 𝟕𝟖

𝑀𝑒𝑎𝑛 𝐿𝑒𝑛𝑔𝑡ℎ = 2 𝑥(5 + 5.7 + 4.11) = 50.22

𝑇 𝑥 𝐼 = 50.22 x 3.5 = 𝟏𝟕𝟓. 𝟕𝟕

Total (T x I) = 21.78 + 175.77 = 197.55 amp. turns

𝑡𝑜𝑡𝑎𝑙 𝐼 𝑥 𝑇 197.55
𝑰𝒄 = = 580( = 0.2408
𝑁𝑝 ( √2 √2)

𝑐𝑜𝑟𝑒 𝑙𝑜𝑠𝑠 245.31

𝐸𝑛𝑒𝑟𝑔𝑦 𝐶𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡 = 𝐼𝑤 = = = 0.1022 𝑎𝑚𝑝.
𝐻.𝑇. 𝑣𝑜𝑙𝑡𝑠 2400

𝑰 = √𝐼𝑐 2 + 𝐼𝑤 2 = √(0.1022)2 + (0.2408)2 = 0.2616 𝑎𝑚𝑝.

 Item 36 to 39. Regulation

812.61
%IR Drop = 𝑥100 = 1.7087
50000

1.75+1.72
𝑙𝑒𝑛𝑔𝑡ℎ = 12 𝑥 = 18.06
2

2𝑓𝑇 𝐼 𝑝+𝑠 2 𝑥 60 𝑥 1162 𝑥 104.167 𝑥 18.06 1.304+0.395

%𝐼𝑋 𝐷𝑟𝑜𝑝 = 𝑛 ℎ 𝐸𝑠 10
𝑠𝑙
5 𝑥 [𝑔 +
]= 𝑥 [0.188 + ] = 𝟏. 𝟔𝟓𝟔
𝑠 3 2 𝑥 14.41 𝑥 480 𝑥 105 3

𝐸𝑞𝑢𝑖𝑣𝑎𝑙𝑒𝑛𝑡 𝑅𝑒𝑎𝑐𝑡𝑖𝑣𝑒 𝐷𝑟𝑜𝑝 = 2400 𝑥 0.01656 = 43.24 𝑣𝑜𝑙𝑡𝑠

% Regulation @ 0.80 power factor

= %𝐼𝑅 𝑐𝑜𝑠𝜃 + %𝐼𝑋 𝑠𝑖𝑛𝜃

= 1.6252(0.80) + 1.656(0.60) = 𝟐. 𝟒𝟗%

 Item 40 to 42. The temperature rise of the windings as measured by the resistance method
must not exceed the specified 55℃.

 For the dimension of tank total area

245.48
𝑆 = 50 𝑥 0.0057 = 861 𝑠𝑞. 𝑖𝑛𝑐ℎ

 Dimension are 15’ x 12’ x 24’ in high

1
Cooling Effective Surface = 20[(15𝑥2) + (12𝑥2)] + 2 (24𝑥15) = 1440 𝑠𝑞. 𝑖𝑛𝑐ℎ.
861
 For Watts = 1070 = 0.6
245.48
 For temperature = 0.0041 𝑥 1440 = 42℃

Item No. SUMMARY OF CALCULATIONS

1 Volts per turn : From formula = 3.73 v ; actual = 4.138 v

Windings High Tension Low Tension
2 Total numbers of turns 580 116
3 Numbers of coils 2 4
4 Turns per coil 290 29
5 Full Load Current (Amp) 20.83 104.167
2
6 Current Density(𝑎𝑚𝑝./𝑖𝑛𝑐ℎ ) 1223.24 1500
7 Cross Section of Conductor 0.01635 0.07245
8 Dimension of Conductors No. 7 0.46 x 0.1575
9 # of Turns per Layer per Coil 87 29
10 # of Layer per Coil 7 1
11 # of Taps None 2
12 Volts per Coil 1200 120
13 Volts Between Layers 360
14 Length of Winding Layers 13.68 13.91
15 Length of Layer Including Insulation 14.41 14.41
16 Insulation Between Layers 0.02
17 Insulation on Wire dcc dcc
18 Length per Turn 1.72 1.75
19 Total Length, all Turn in series, ft 997.6 203
20 Weight in Copper(lbs) 62.85 54.145
21 Resistance a 75 ⁰c All Coils 0.61 0.02789
22 IR Drop Volts 12.68 2.9
23 Full Load Copper Loss(Compare to Guaranteed) 246.67 302.63
 THE MAGNETIC CIRCUIT

24 Dimension of ”Windows” 14.41 x 4.11

25 Total Flux, Maxwell’s 1553277.415
26 Flux Density in Core Under Windings 80000
27 Cross Section of Iron in Core Under Windings 19.494
28 Width of Stampings in Core Under Windings 3.8
29 Gross Thickness of Core 5.7
30 Total Weight or Iron in Core, lbs. 325.5
31 Watts Loss in Iron (compare to guaranteed) 245.31
32 Total Full Load Losses, watts 812.61

EFFICIENCY AND EXCITING CURRENT

33 Efficiency at Unity Power Factor

At Full Load 98.4%
At ½ Load 98.5%
At ¼ Load 98.77%
At ¾ Load 98.84%
At 25% Over Load 98.42%
34 All Day Efficiency (4Hr Full Load) 96.7%
35 Primary Exciting Current, Amp. 0.2408

REGULATION

36 Total Equivalent IR Drop Percent 1.6252

37 Total Reactive Drop Percent 1.656
38 Regulation on Unity Power Factor 1.6252
39 Regulation on 0.80 Power Factor 2.29376

DESIGN OF TANK – TEMPERATURE RISE

40 Effective Cooling Surface of Tank, sq. inch. 3020

41 Watts per square inch of Tank 0.269
42 Approximate Temperature Rise, ℃ 47.2℃