Problem Statement:

Suppose we are going to Design a Three Phase Distribution Transformer whose KVA Rating is 250 KVA, Turn Ratio is
11000 / 400 having a Vector Group DY-11.

Solution:

As we know that all the Transformers are Based on the Principal of Mutual Induction. There is no Electrical Link
between Primary and Secondary Winding of a Transformer. The Primary and Secondary Windings of a Transformer
are Magnetically Linked and Transformer works on the Phenomenon of Electromagnetic Induction. So, first of all we
need to find out the 𝐸𝑡 (Induced EMF per Turn):

𝐸𝑡 = 𝐾 √𝑄

K is the Constant, it’s Value depends upon the type of Distribution Transformer. For a 3-Phase Distribution
Transformer, it’s value is 0.45. While Q is the KVA rating of the Transformer.

𝐸𝑡 = 0.45 √250
𝑽𝒐𝒍𝒕
𝑬𝒕 = 𝟕. 𝟏𝟏𝟓𝟏𝟐
𝑻𝒖𝒓𝒏
Next Step is to Find out the Number of Turns of the Primary and Secondary Winding. In all Calculations, we use the
Phase Values because we are measuring the value of Single while the other two phases will be similar.

As the Primary Winding is Connected in Delta, So Line Voltage is equals to the Phase Voltage. So, Number of Turns of
the Primary Winding can be obtained by dividing the Phase Voltage of Primary Winding with Induced EMF per turn.
11000
𝑁1 = = 1546 𝑡𝑢𝑟𝑛𝑠.
7.11512
The load which is connected nearest to the Transformer having Voltage Greater than the Rated Voltage, While the
Load Connected at the far end of the Transformer having Voltage Less than the Rated Voltage. So, to Adjust the
Output Voltage on the Secondary Side, we Place a tapping on the Primary Winding. Tapping is used to Change the
Number of turns which changes the Output Voltage on the Secondary Side. If we Place the Tapping on the Low
Voltage Side having a large amount of Current may be damaged due to spark produce during the Adjustment of
Tapping. For this reason, we always place the Tapping on the High Voltage Side. For a 3-Phase Distribution
Transformer, the Tapping is normally 5 %.

So, the Number of Turns of Primary Winding with 5 % Tapping is:

𝑁1 = 1546 𝑥 1.05
𝑵𝟏 = 𝟏𝟔𝟐𝟑 𝑻𝒖𝒓𝒏𝒔.
As the Secondary Winding is Connected in Y, So Line Voltage and Phase Voltage are Related in such a way:
𝑉𝐿𝑖𝑛𝑒
𝑉𝑃ℎ𝑎𝑠𝑒 =
√3
400
𝑉𝑃ℎ𝑎𝑠𝑒 = = 230.94 𝑉
√3
So, Number of Turns of the Secondary Winding can be obtained by dividing the Phase Voltage of Secondary Winding
with Induced EMF per turn.
400
𝑁2 =
7.11512
𝑵𝟐 = 𝟑𝟐. 𝟒𝟓 ≈ 𝟑𝟐 𝒕𝒖𝒓𝒏𝒔.
Next Step is to find out the Core Area. As we know that:

𝐸𝑡 = 4.44 ∗ 𝑓 ∗ 𝜙
 𝐸𝑡 = 4.44 ∗ 𝑓 ∗ (𝐵𝐴)
𝐸𝑡
𝐴=
4.44 ∗ 𝑓 ∗ 𝐵
A is the Core Area, f is the frequency and B is the Magnetic Flux Density. The Sheets of Core are normally Hot Rolled
and Cold Rolled. The Magnetic Domains of Hot Rolled Grain Oriented Silicon Steel are not permanently Aligned,
While the Magnetic Domains of Cold Rolled Grain Oriented Silicon Steel are permanently Aligned. That’s why Cold
Rolled Grain Oriented Silicon Steel is Used for 3-Phase Distribution Transformer. Its Value is Normally (1.3 to 1.7)
Web / m2. Suppose:

B = 1.5 Web / m2

So,
7.11512
𝐴= = 0.021366 𝑚2 = 213.66 𝑐𝑚2
4.44 ∗ 50 ∗ 1.5
To Minimize the Eddy Current Losses, Sheets of the Core Are Laminated. So, the Actual Required Area is:
𝟐𝟏𝟑. 𝟔𝟔
𝑨𝒊 = = 𝟐𝟑𝟕. 𝟒𝟎 𝒄𝒎𝟐
𝟎. 𝟗
Next Step is to find the Core Diameter, As we know that:

𝐴 = 𝐾𝑑2
𝐴
𝑑2 =
𝐾

𝐴
𝑑=√
𝐾

A is the Core Area; K is the Constant. The Value of K depends upon the number of Steps in the Core. As the Core is of
Rectangular Shape and have the Sharp Edges, it may damage the Low Voltage Winding of the Transformer because
Low Voltage Winding is relatively thicker than High Voltage Winding and have less Elasticity. So, to give the Core, a
Circular Shape, we use a Three Step Core. For a Distribution Transformer having 3 Step Core. It’s Value is 0.6.

233.40
𝑑=√
0.6

𝒅 = 𝟏𝟗. 𝟖𝟗 ≅ 𝟐𝟎 𝒄𝒎.
Next Step is to Design the Low Voltage Winding. The Formula of Three Phase KVA is:

KVA = √3 𝑉𝐿 𝐼𝐿

250 x 1000 VA = √3 (400) 𝐼𝐿

𝐼𝐿 = 360.84 𝐴
As the Secondary is Connected in Y, So Line Current and Phase Current is Same:

𝑰𝑷𝒉𝒂𝒔𝒆 = 𝟑𝟔𝟎. 𝟖𝟒 𝑨
Now, we have to Find out the Area of Low Voltage Winding. For this Purpose, we need to Select Current Density of
the Conductor. It’s Value depends upon the Nature of Cooling. For a three Phase Distribution Transformer, it’s Value
is 3 Amp / mm2. To find out the Area of the Low Voltage Winding, we need to Divide Current of Low Voltage Winding
with Current Density:
360.84
Area of Low Voltage Conductor = 3
= 120.28 mm2
We Consider that Low Voltage Conductor is of Rectangular Shape, but their Edges are Round, So the Actual Required
Area is:
𝟏𝟐𝟎.𝟖𝟖
Area of Low Voltage Conductor = 𝟎.𝟗
= 133.644 mm2

Low Voltage Design is of 2 Types. When the Current is greater than 100 A, then we cannot use the Single Conductor,
we use Multiple Conductors in Bundled Form. While, when the Current is less than 100 A, then single Conductor is
Used. So, here we use Multiple Conductor whose Combined area will be 133.64 mm2. Let us take two Conductors of
(10 x 5) and 2 Conductors of (4.5 x 5), these four Conductors are Collectively making an area of 136 mm 2 which is
nearest to the Calculated Value.

Height of the Low Voltage Conductor: (10 + 4.5) = 14.5 mm

To Isolate the Conductors, we place a Paper Insulation between them.

Height of the Low Voltage Conductor with Paper Insulation: (10 + 4.5) + 2*0.6 = 15.7 mm = 1.57 cm

Width of the Low Voltage Conductor: (5 + 5) = 10 mm

To Isolate the Conductors, we place a Paper Insulation between them.

Width of the Low Voltage Conductor with Paper Insulation: (5 + 5) + 2*0.6 = 11.2 mm = 1.12 cm

Number of turns on the Secondary Side are 32 but due to Spiral Effect, it will look like 33 Turns.

Height of the Low Voltage Winding:

= No of Turns * Height of Low Voltage Conductor with Paper Insulation:

= 33 * 1.57 cm

= 51.81 cm

Taking 1 Percent Mechanical Allowance = 51.81 * 1.01 = 52.8462 cm

Packing of 1cm at the Top and 1 cm at the Bottom: 52.8462 + 2cm = 54.8462

So,

Height of the Limb = 56 cm

Next Step is to Design the High Voltage Winding. The Formula of Three Phase KVA is:

KVA = √3 𝑉𝐿 𝐼𝐿

250 x 1000 VA = √3 (11000) 𝐼𝐿

𝐼𝐿 = 13.12 𝐴
As the Primary is Connected in Delta, So Line Current and Phase Current are Related in Such a way:
𝐼𝐿𝑖𝑛𝑒
𝐼𝑃ℎ𝑎𝑠𝑒 =
√3
𝟏𝟑. 𝟏𝟐
𝑰𝑷𝒉𝒂𝒔𝒆 = = 𝟕. 𝟓𝟕 𝑨
√𝟑
Now, we have to Find out the Area of High Voltage Winding. For this Purpose, we need to Select Current Density of
the Conductor. It’s Value depends upon the Nature of Cooling. For a three Phase Distribution Transformer, it’s Value
is 3.73 Amp / mm2. To find out the Area of the High Voltage Winding, we need to Divide Current of High Voltage
Winding with Current Density:
𝟕.𝟓𝟕
Area of Low Voltage Conductor = 𝟑.𝟕𝟑 = 2.029 mm2
Let us take SWG No 16 Conductor whose Bare Area is 2.076 mm2 which is nearest to the Calculated Value.

Bare Diameter of the Conductor = 1.63 mm

Diameter of the Conductor with Enamel Coating = 1.63 + 0.2 = 1.83 mm = 0.183 cm.

1546 Turns cannot be arranged in a Single Packet; suppose we have to arrange above turns in 8 Packets.

Turns per Packet = Turns / No of Packets = 1623 / 8 = 202.875≅ 203 turns Per Packet.

Let us Suppose 30 Conductor in a Single Layer and 6 Layers of 30 Conductors will complete the Turns per Packet.

Height of the Single Packet = 30 * 0.183 = 5.49 cm

Height of Eight Packets = 5.49 * 8 = 43.92 cm.

Height of the Packets with Insulation = 43.92 + (8*0.6) = 48.72 cm

For the Purpose the Cooling, we use 2 Oil Ducts 0.5 cm wide.

Height of the Packets with Oil Ducts and Insulation = 43.92 + (8*0.6) + 0.5 + 0.5 = 49.72 cm.

Taking 1 Percent Mechanical Allowance = 49.72 * 1.01 = 50.2172 cm.

Packing of 1cm at the Top and 1 cm at the Bottom: 50.2172 + 2 = 52.2172 cm.

So, the height of High Voltage Winding is less than the Low Voltage Winding. So, the Design is Satisfactory.

In Order to find out the efficiency of the System, we have to find out the losses. So, next Step is to Find out the Iron
Losses and Copper Losses. For this Purpose, we need to find out the lmt (Mean Length) and dmt (Mean Diameter)
for both low Voltage and high Voltage Winding.

Mean Length and Mean Diameter for Low Voltage Winding:

Core Diameter (Bare) = 20 cm.

To Isolate the Core with Winding we place a paper of 0.25 cm thick over the Core.

Core Diameter with Paper Insulation = 20 + 0.25 + 0.25 = 20.5 cm.

Core Diameter with Mechanical Allowance of 0.1 cm = 20.6 cm (Inside Diameter of Low Voltage Winding).

Thickness of Low Voltage Winding = 11.2 mm

Thickness of Low Voltage Winding with Paper Insulation = 11.2 + 0.3 = 11.5 mm = 1.15 cm

Outside Diameter of Low Voltage Winding = 20.6 + 1.15 + 1.15 = 22.9 cm

Mean Diameter (dmt2) = 20.6 + 22.9 / 2 = 21. 75 cm.

Mean Length of One Turn (lmt2) = π * dmt2 = (22 / 7) * 21.75 = 68.35 cm.

Mean Length and Mean Diameter for High Voltage Winding:

With an Axial Oil Duct of 0.5 cm = 22.9 cm + 0.5 cm + 0.5 cm = 23.9 cm

Thickness of the former = 0.3 cm

Inside Diameter of High Voltage Winding = 23.9 + 0.3 + 0.3 = 24.5 cm

Thickness of High Voltage Conductor = 1.83 mm

Thickness of High Voltage Winding = 1.83 * 6 = 10.98 mm = 1.098 cm

Outside Diameter of High Voltage Winding = 24.5 + 1.098 + 1.098 = 26.696 cm

Mean Diameter (dmt1) = 24.5 + 26.696 / 2 = 25. 598 cm.

Mean Length of One Turn (lmt1) = π * dmt1 = (22 / 7) * 25.598 = 80.45 cm.

Now, we have to Find out the Copper Losses:

Copper Losses = 3 * 𝐼 2 * R

Copper Losses of Primary Winding:

As we know that R is the Resistance of the Primary Winding.

𝐿
R=𝜌𝐴

𝜌 is the Resistivity of the conductor. It’s value for Copper is 2.1 x 10-6 Ohm-cm.
(68.35 𝑐𝑚 𝑥 33)
R = (2.1 𝑥 10−6 𝑂ℎ𝑚 𝑐𝑚) (0.02029 𝑐𝑚2 )

R = 13.51 Ohm.

Copper Losses of Primary Winding = 3 * (7.57)2 * (13.51) = 2322.567 Watt.

As the Resistance and losses increases with the Increase in Temperature, So 7 % Allowance for Sudden Rise in
Temperature = 2322.567 * 1.07 = 2485.146 W

Copper Losses of Secondary Winding:

As we know that R is the Resistance of the Primary Winding.

𝐿
R=𝜌𝐴

𝜌 is the Resistivity of the conductor. It’s value for Copper is 2.1 x 10-6 Ohm-cm.
(80.45 𝑐𝑚 𝑥 33)
R = (2.1 𝑥 10−6 𝑂ℎ𝑚 𝑐𝑚)
(1.2028 𝑐𝑚2 )

R = 4.635 x 10-3 Ohm.

Copper Losses of Primary Winding = 3 * (360.84)2 * (4.635 x 10-3) = 1810.5747 Watt.

As the Resistance and losses increases with the Increase in Temperature, So 7 % Allowance for Sudden Rise in
Temperature = 1810.5747 * 1.07 = 1937.314 W

Total Copper Losses = 1937.314 + 2485.146 W = 4422.4609 Watt.

In the Next Step, we are Interested to Calculate the Iron Loses. Iron Losses depends upon weight of the Iron and
Magnetic Flux Density of the Iron.

Iron Losses for Limb:

Volume of the limb = 3 * Area * Height = 3 * 213.66 𝑐𝑚2 * 56 cm = 35894.88 cm3.

Specific Weight of Iron = 7.55 gm / cm3

So, Weight of the Limbs = 35894.88 * 7.55 = 271006.344 g = 271.006 Kg

For B = 1.5 Web / m2, Iron losses are 1.6 W per Kg.

So Total Iron Losses in limbs = 1.6 * 271.006 = 433.610 W

With 7 % Allowance in Iron Losses of Limb = 433.610 * 1.07 = 463.96 W

Iron Losses for Yoke:

Area of Yoke is 10 to 15 % more than the area of the limb, in Order to decrease the flux Density which will decrease
the Iron Losses. In Limb, we cannot increase the Area because mean length will increase and more Copper will be
used and this will increase the Cost of Transformer.

Area of the Yoke = 213.66 cm2 x 1.15 = 245.709 cm2.

Length of the Yoke = 2D + 0.9d + 2 = 2 (26.696) + 0.9 (20) + 2 = 73.392 cm

Volume of 2 Yokes = 2 * Area * Length = 2 * 245.709 cm2 * 73.392 cm = 36066.149 cm3

Specific Weight of Iron = 7.55 gm / cm3

So, Weight of the Yokes = 36066.149 * 7.55 = 272299.424 g = 272.229 Kg

Flux in Limbs = Flux in Yokes

BA=BA

(1.5) (213.66) = B (245.709)

B = 1.3043 Web / m2.

For B = 1.3043 Web / m2, Iron losses are 1.15 W per Kg.

So Total Iron Losses in limbs = 1.15 * 272.229 = 313.063 W

With 7 % Allowance in Iron Losses of Limb = 313.063 * 1.07 = 334.97 W

Total Iron losses = 334.97 + 463.96 = 798.93 W

Total Iron and Copper Losses = 798.93 + 4422.4609 = 5521.3909 W

Tank Dimensions:

Tank Height = Transformer Height + (20-40) cm

Tank Height = 56 + 30 cm

Height of the Tank = 86 cm

Outside Diameter of High Voltage Winding = 24.5 + 1.098 + 1.098 = 26.696 cm

Width of the Tank = Outside Diameter of HV + (2x5) cm

Width of the Tank = 26.696 + 10 cm

Width of the Tank = 36.696 cm

Length of the Yoke = 2D + 0.9d + 2 = 2 (26.696) + 0.9 (20) + 2 = 73.392 cm

Length of the transformer = 2D + 0.9d + 2 + D - 0.9d = 3D + 2 = 3 (26.696) + 2 = 82.088 cm

Length of the Tank = Length of the Transformer + (2x5) cm

Length of the Tank = 82.088 + 10 cm

Length of the Tank = 92.088 cm

Surface Area of the Tank = 2 (H x w) + 2 (H x L) = 2Hw + 2HL = 2H (w + L)

Surface Area of the Tank = 2 (86) (36.696 + 92.088) = 22150.848 cm2

Surface Area of the Tank = 2.2150848 m2

3.7
Total Losses = 3.4 𝑥 (8.8 + 𝑥
)55

We need to find out the value of x, so:

5521.3909 W = = 3.4 (8.8 𝑥 + 3.7) 55

5521.3909
- 3.7 = 8.8 𝑥
(55)(3.4)

25.8261 = 8.8 𝑥

𝑥 = 2.93
Actual Surface Required For Cooling = 𝑥 (Surface Area of the Tank) = (2.93) (2.21508) = 6.4901 m2

Excessive Area Required = Actual Surface Required for Cooling - Surface Area of the Tank

Excessive Area Required = 6.4901 m2 – 2.21508 m2

Excessive Area Required = 4.2750 m2

Let Mean length of the Tube = 80 cm and diameter of the tube = 5 cm:

Surface Area of One Tube = 𝜋 𝐷 𝐿 = (3.14) (5) (80) = 1256 cm2 = 0.1256 m2

No of Tubes = Excessive Area Required / Surface Area of one Tube = 4.2750 / 0.1256 = 34.036

34 Tubes are Required for Sufficient Colling.

The tubes are placed sufficiently apart so that the distance between them should be at least equal to the dia of the
tube, so that the tank may not have excessive holes.

92.088 / 36.696 = 3 / 1

8 tubes widthwise and 26 tubes lengthwise.

Conservator Design:

It contains oil which can be fed back to the tank when required. It should contain 1 / 10 of the oil in the tank.

Volume of tank = Length of the tank * width of the Tank * Height of the Tank

Volume of tank = 92.088 * 36.696 * 86 = 290616.467 cm2

Volume of tubes = (𝛑 / 4 * d2* L) * 34

Volume of tubes = (3.14 / 4 * 52* 80) * 34

Volume of tubes = 53380 cm2

Volume of Transformer = Length of the Transformer * width of the Transformer * Height of the Transformer

Volume of tank = 82.088 * 26.696 * 56 = 122719.589 cm2

Volume of oil in the tank = Total Volume of Tank + Total Volume of Tubes – Total Volume of Transformer

Volume of oil in the tank = 290616.467 + 53380 – 122719.589

Volume of Oil in the tank = 221276.878 cm2

Volume of Oil in the Conservator = 10 % of Volume of Oil in the Tank = (10 / 100) * 221276.878

Volume of Oil in the Conservator = 22127.68 cm2

Volume of conservator should be 50 % greater than this Volume.

Size of Conservator = 1.5 * Volume of Oil in the Conservator

Size of Conservator = 22127.68 * 1.5

Size of Conservator = 33191.52 cm3

The conservator is in cylindrical form. It is placed along the width, at the top of the tank.

Problem Statement:

Suppose we are going to Design a Three Phase Distribution Transformer whose KVA Rating is 30 KVA, Turn Ratio is
11000 / 230 having a Vector Group DY-11.

Solution:

First of all we need to find out the 𝐸𝑡 (Induced EMF per Turn):

𝐸𝑡 = 𝐾 √𝑄

K is the Constant, it’s Value depends upon the type of Distribution Transformer. For a 3-Phase Distribution
Transformer, it’s value is 0.45. While Q is the KVA rating of the Transformer.

𝐸𝑡 = 0.45 √25
𝑽𝒐𝒍𝒕
𝑬𝒕 = 𝟐. 𝟐𝟓
𝑻𝒖𝒓𝒏
Next Step is to Find out the Number of Turns of the Primary and Secondary Winding. In all Calculations, we use the
Phase Values because we are measuring the value of Single while the other two phases will be similar.

As the Primary Winding is Connected in Delta, So Line Voltage is equals to the Phase Voltage. So, Number of Turns of
the Primary Winding can be obtained by dividing the Phase Voltage of Primary Winding with Induced EMF per turn.
11000
𝑁1 = = 4888 𝑡𝑢𝑟𝑛𝑠.
2.25
The load which is connected nearest to the Transformer having Voltage Greater than the Rated Voltage, While the
Load Connected at the far end of the Transformer having Voltage Less than the Rated Voltage. So, to Adjust the
Output Voltage on the Secondary Side, we Place a tapping on the Primary Winding. Tapping is used to Change the
Number of turns which changes the Output Voltage on the Secondary Side. If we Place the Tapping on the Low
Voltage Side having a large amount of Current may be damaged due to spark produce during the Adjustment of
Tapping. For this reason, we always place the Tapping on the High Voltage Side. For a 3-Phase Distribution
Transformer, the Tapping is normally 5 %.

So, the Number of Turns of Primary Winding with 5 % Tapping is:

𝑁1 = 4888 𝑥 1.05
𝑵𝟏 = 𝟓𝟏𝟑𝟐 𝑻𝒖𝒓𝒏𝒔.
As the Secondary Winding is Connected in Y, So Line Voltage and Phase Voltage are Related in such a way:
𝑉𝐿𝑖𝑛𝑒
𝑉𝑃ℎ𝑎𝑠𝑒 =
√3
230
𝑉𝑃ℎ𝑎𝑠𝑒 = = 132.79 𝑉
√3
So, Number of Turns of the Secondary Winding can be obtained by dividing the Phase Voltage of Secondary Winding
with Induced EMF per turn.
132.79
𝑁2 =
2.25
𝑵𝟐 = 𝟓𝟗. 𝟎𝟏 ≈ 𝟓𝟗 𝒕𝒖𝒓𝒏𝒔.
Next Step is to find out the Core Area. As we know that:

𝐸𝑡 = 4.44 ∗ 𝑓 ∗ 𝜙
𝐸𝑡 = 4.44 ∗ 𝑓 ∗ (𝐵𝐴)
𝐸𝑡
𝐴=
4.44 ∗ 𝑓 ∗ 𝐵
A is the Core Area, f is the frequency and B is the Magnetic Flux Density. The Sheets of Core are normally Hot Rolled
and Cold Rolled. The Magnetic Domains of Hot Rolled Grain Oriented Silicon Steel are not permanently Aligned,
While the Magnetic Domains of Cold Rolled Grain Oriented Silicon Steel are permanently Aligned. That’s why Cold
Rolled Grain Oriented Silicon Steel is Used for 3-Phase Distribution Transformer. Its Value is Normally (1.3 to 1.7)
Web / m2. Suppose:

B = 1.5 Web / m2

So,
2.25
𝐴= = 0.006756 𝑚2 = 67.56 𝑐𝑚2
4.44 ∗ 50 ∗ 1.5
To Minimize the Eddy Current Losses, Sheets of the Core Are Laminated. So, the Actual Required Area is:
𝟔𝟕. 𝟓𝟔
𝑨𝒊 = = 𝟕𝟓. 𝟎𝟕𝟓 𝒄𝒎𝟐
𝟎. 𝟗
Next Step is to find the Core Diameter, As we know that:

𝐴 = 𝐾𝑑2
𝐴
𝑑2 =
𝐾

𝐴
𝑑=√
𝐾

A is the Core Area; K is the Constant. The Value of K depends upon the number of Steps in the Core. As the Core is of
Rectangular Shape and have the Sharp Edges, it may damage the Low Voltage Winding of the Transformer because
Low Voltage Winding is relatively thicker than High Voltage Winding and have less Elasticity. So, to give the Core, a
Circular Shape, we use a Three Step Core. For a Distribution Transformer having 3 Step Core. It’s Value is 0.6.

75.075
𝑑=√
0.6

𝒅 = 𝟏𝟏. 𝟏𝟖𝟓 ≅ 𝟏𝟏. 𝟐 𝒄𝒎.

Next Step is to Design the Low Voltage Winding. The Formula of Three Phase KVA is:

KVA = √3 𝑉𝐿 𝐼𝐿

25 x 1000 VA = √3 (230) 𝐼𝐿

𝐼𝐿 = 62.755 𝐴
As the Secondary is Connected in Y, So Line Current and Phase Current is Same:
 𝑰𝑷𝒉𝒂𝒔𝒆 = 𝟔𝟐. 𝟕𝟓𝟓 𝑨
Now, we have to Find out the Area of Low Voltage Winding. For this Purpose, we need to Select Current Density of
the Conductor. It’s Value depends upon the Nature of Cooling. For a three Phase Distribution Transformer, it’s Value
is 3 Amp / mm2. To find out the Area of the Low Voltage Winding, we need to Divide Current of Low Voltage Winding
with Current Density:
𝟔𝟐.𝟕𝟓𝟓
Area of Low Voltage Conductor = 𝟑
= 20.918 mm2

Low Voltage Design is of 2 Types. When the Current is greater than 100 A, then we cannot use the Single Conductor,
we use Multiple Conductors in Bundled Form. While, when the Current is less than 100 A, then single Conductor is
Used. So, here we use Multiple Conductor whose Combined area will be 133.64 mm2. Let us take SWG No 5
Conductor whose Bare Area is 22.77 mm2 which is nearest to the Calculated Value.

Bare Diameter of the Conductor = 5.38 mm

Diameter of the Conductor with Enamel Coating = 5.38 + 0.2 = 5.53 mm = 0.553 cm.

Number of turns on the Secondary Side are 32 but due to Spiral Effect, it will look like 33 Turns.

Height of the Low Voltage Winding:

= No of Turns * Diameter of Low Voltage Conductor with Enamel Coating:

= 59 * 0.553 cm

= 32.627 cm

Taking 2 Percent Mechanical Allowance = 33.627 * 1.02 = 33.279 cm

Packing of 1cm at the Top and 1 cm at the Bottom: 33.279 + 2 = 35.279 cm

So,

Height of the Limb = 37 cm

Next Step is to Design the High Voltage Winding. The Formula of Three Phase KVA is:

KVA = √3 𝑉𝐿 𝐼𝐿

25 x 1000 VA = √3 (11000) 𝐼𝐿

𝐼𝐿 = 1.312 𝐴
As the Primary is Connected in Delta, So Line Current and Phase Current are Related in Such a way:
𝐼𝐿𝑖𝑛𝑒
𝐼𝑃ℎ𝑎𝑠𝑒 =
√3
𝟏. 𝟑𝟏𝟐
𝑰𝑷𝒉𝒂𝒔𝒆 = = 𝟎. 𝟕𝟓𝟕𝟓 𝑨
√𝟑
Now, we have to Find out the Area of High Voltage Winding. For this Purpose, we need to Select Current Density of
the Conductor. It’s Value depends upon the Nature of Cooling. For a three Phase Distribution Transformer, it’s Value
is 3.73 Amp / mm2. To find out the Area of the High Voltage Winding, we need to Divide Current of High Voltage
Winding with Current Density:
𝟎.𝟕𝟓𝟕𝟓
Area of High Voltage Conductor = 𝟑.𝟕𝟑
= 0.2030 mm2

Let us take SWG No 25 Conductor whose Bare Area is 0.2027 mm2 which is nearest to the Calculated Value.

Bare Diameter of the Conductor = 0.508 mm

Diameter of the Conductor with Enamel Coating = 0.508 + 0.2 = 0.708 mm = 0.0708 cm.

5132 Turns cannot be arranged in a Single Packet; suppose we have to arrange above turns in 8 Packets.

Turns per Packet = Turns / No of Packets = 5132 / 8 = 641.5≅ 642 turns Per Packet.

Let us Suppose 46 Conductor in a Single Layer and 14 Layers of 46 Conductors will complete the Turns per Packet.

Height of the Single Packet = 46 * 0.0708 = 3.2568 cm

Height of Eight Packets = 3.2568 * 8 = 26.0544 cm.

Height of the Packets with Insulation = 26.0544 + (8*0.6) = 30.8544 cm

Taking 1 Percent Mechanical Allowance = 30.8544 * 1.01 = 31.1629 cm.

Packing of 1cm at the Top and 1 cm at the Bottom: 31.1629 + 2 = 33.162 cm.

So, the height of High Voltage Winding is less than the Low Voltage Winding. So, the Design is Satisfactory.

In Order to find out the efficiency of the System, we have to find out the losses. So, next Step is to Find out the Iron
Losses and Copper Losses. For this Purpose, we need to find out the lmt (Mean Length) and dmt (Mean Diameter)
for both low Voltage and high Voltage Winding.

Mean Length and Mean Diameter for Low Voltage Winding:

Core Diameter (Bare) = 11.2 cm.

To Isolate the Core with Winding we place a paper of 0.25 cm thick over the Core.

Core Diameter with Paper Insulation = 11.2 + 0.25 + 0.25 = 11.7 cm.

Core Diameter with Mechanical Allowance of 0.1 cm = 11.8 cm (Inside Diameter of Low Voltage Winding).

Thickness of Low Voltage Winding = 5.53 mm

Thickness of Low Voltage Winding with Paper Insulation = 5.53 + 0.30 = 5.83 mm = 0.583 cm

Outside Diameter of Low Voltage Winding = 11.8 + 0.583 + 0.583 = 12.966 cm

Mean Diameter (dmt2) = 11.8 + 12.966 / 2 = 12. 383 cm.

Mean Length of One Turn (lmt2) = π * dmt2 = (22 / 7) * 12.383 = 38.918 cm.

Mean Length and Mean Diameter for High Voltage Winding:

Thickness of the former = 0.3 cm

Inside Diameter of High Voltage Winding = 12.966 + 0.3 + 0.3 = 13.566 cm

Thickness of High Voltage Conductor = 0.708 mm

Thickness of High Voltage Winding = 0.708 * 14 = 9.912 mm = 0.9912 cm

Outside Diameter of High Voltage Winding = 13.566 + 0.9912 + 0.9912 = 15.5484 cm

Mean Diameter (dmt1) = 15.5484 + 13.566 / 2 = 14.5572 cm.

Mean Length of One Turn (lmt1) = π * dmt1 = (22 / 7) * 14.5572 = 45.7512 cm.

Now, we have to Find out the Copper Losses:

 Copper Losses = 3 * 𝐼 2 * R

Copper Losses of Primary Winding:

As we know that R is the Resistance of the Primary Winding.

𝐿
R=𝜌𝐴

𝜌 is the Resistivity of the Conductor. It’s value for Copper is 2.1 x 10-6 Ohm-cm.
(45.712 𝑐𝑚 𝑥 5132)
R = (2.1 𝑥 10−6 𝑂ℎ𝑚 𝑐𝑚) (0.02030 𝑐𝑚2 )

R = 24.26 Ohm.

Copper Losses of Primary Winding = 3 * (0.7575)2 * (24.26) = 41.77 Watt.

As the Resistance and losses increases with the Increase in Temperature, So 7 % Allowance for Sudden Rise in
Temperature = 41.77 * 1.07 = 44.70 W

Copper Losses of Secondary Winding:

As we know that R is the Resistance of the Primary Winding.

𝐿
R=𝜌𝐴

𝜌 is the Resistivity of the conductor. It’s value for Copper is 2.1 x 10-6 Ohm-cm.
(38.918 𝑐𝑚 𝑥 59)
R = (2.1 𝑥 10−6 𝑂ℎ𝑚 𝑐𝑚) (2.277 𝑐𝑚2 )

R = 2.117 x 10-3 Ohm.

Copper Losses of Primary Winding = 3 * (62.755)2 * (2.117 x 10-3) = 25.01 Watt.

As the Resistance and losses increases with the Increase in Temperature, So 7 % Allowance for Sudden Rise in
Temperature = 25.01 * 1.07 = 26.7707 W

Total Copper Losses = 44.70 + 26.7707 W = 71.47047 Watt.

In the Next Step, we are Interested to Calculate the Iron Loses. Iron Losses depends upon weight of the Iron and
Magnetic Flux Density of the Iron.

Iron Losses for Limb:

Volume of the limb = 3 * Area * Height = 3 * 67.56 𝑐𝑚2 * 37 cm = 7499.16 cm3.

Specific Weight of Iron = 7.55 gm / cm3

So, Weight of the Limbs = 7499.16 * 7.55 = 56618.658 g =56.618 Kg

For B = 1.5 Web / m2, Iron losses are 1.6 W per Kg.

So Total Iron Losses in limbs = 1.6 * 56.618 = 90.58 W

With 7 % Allowance in Iron Losses of Limb = 90.58 * 1.07 = 96.93 W

Iron Losses for Yoke:

Area of Yoke is 10 to 15 % more than the area of the limb, in Order to decrease the flux Density which will decrease
the Iron Losses. In Limb, we cannot increase the Area because mean length will increase and more Copper will be
used and this will increase the Cost of Transformer.

Area of the Yoke = 67.56 𝑐𝑚2 x 1.15 = 77.694 cm2.

Length of the Yoke = 2D + 0.9d + 2 = 2 (15.5484) + 0.9 (11.2) + 2 = 43.1768 cm

Volume of 2 Yokes = 2 * Area * Length = 2 * 77.694 cm2 * 43.1768 cm = 6709.156 cm3

Specific Weight of Iron = 7.55 gm / cm3

So, Weight of the Yokes = 6709.156 * 7.55 = 50654.132 g = 50.654 Kg

Flux in Limbs = Flux in Yokes

BA=BA

(1.5) (67.56) = B (77.694)

B = 1.3043 Web / m2.

For B = 1.3043 Web / m2, Iron losses are 1.15 W per Kg.

So Total Iron Losses in limbs = 1.15 * 50.654 = 58.2521 W

With 7 % Allowance in Iron Losses of Limb = 58.2521 * 1.07 = 62.329 W

Total Iron losses = 96.93 + 62.329 = 159.25 W

Total Iron and Copper Losses = 159.25 + 71.4707 = 230.7304 W.

Tank Dimensions:

Tank Height = Transformer Height + (20-40) cm

Tank Height = 37 + 30 cm

Height of the Tank = 67 cm

Outside Diameter of High Voltage Winding = 13.566 + 0.9912 + 0.9912 = 15.5484 cm

Width of the Tank = Outside Diameter of HV + (2x5) cm

Width of the Tank = 15.5484 + 10 cm

Width of the Tank = 25.5484 cm

Length of the Yoke = 2D + 0.9d + 2 = 2 (15.5484) + 0.9 (11.2) + 2 = 43.1768 cm

Length of the transformer = 2D + 0.9d + 2 + D - 0.9d = 3D + 2 = 3 (15.5484) + 2 = 48.6452 cm

Length of the Tank = Length of the Transformer + (2x5) cm

Length of the Tank = 48.6452 + 10 cm

Length of the Tank = 58.6452 cm

Surface Area of the Tank = 2 (H x w) + 2 (H x L) = 2Hw + 2HL = 2H (w + L)

Surface Area of the Tank = 2 (67) (25.5484 + 58.6452) = 11281.9424 cm2

Surface Area of the Tank = 1.12819 m2

 3.7
Total Losses = 3.4 𝑥 (8.8 + 𝑥
)55

We need to find out the value of x, so:

230.7304 W = = 3.4 (8.8 𝑥 + 3.7) 55

230.7304
(55)(3.4)
- 3.7 = 8.8 𝑥

- 2.46614 = 8.8 𝑥

𝑥 = −0.2802
As the value of x is less than 1, so the Available Area is sufficient for better Cooling.

Conservator Design:

It contains oil which can be fed back to the tank when required. It should contain 1 / 10 of the oil in the tank.

Volume of tank = Length of the tank * width of the Tank * Height of the Tank

Volume of tank = 58.5484 * 25.5484 * 67 = 100219.802 cm2

Volume of Transformer = Length of the Transformer * width of the Transformer * Height of the Transformer

Volume of tank = 48.5484 * 15.5484 * 37 = 27929.4478 cm2

Volume of oil in the tank = Total Volume of Tank – Total Volume of Transformer

Volume of oil in the tank = 100219.802 – 27929.4478

Volume of Oil in the tank = 72290.3542 cm2

Volume of Oil in the Conservator = 10 % of Volume of Oil in the Tank = (10 / 100) * 72290.3452

Volume of Oil in the Conservator = 7229.03 cm2

Volume of conservator should be 50 % greater than this Volume.

Size of Conservator = 1.5 * Volume of Oil in the Conservator

Size of Conservator = 7229.03 * 1.5

Size of Conservator = 10843.545 cm3

The conservator is in cylindrical form. It is placed along the width, at the top of the tank.