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1.0 INTRODUCTION :

Transformer is an important equipment in the electrical system. The transient and steady state behaviour of electrical
system largely depend on the correct selection of transformer rating and specification. The rating of transformer shall
be selected such that:

a) It is suitable to feed present load and have a margin of about 20% future load that can be added on the
transformer

b) The voltage dip on the bus during largest motor starting should be less than 10%

2.0 GENERAL GUIDELINES :

Transformer rating shall be generally 120 to 130% more than the load connected on it. This takes care for @ 20%
future load growth. In addition to cater future load, the transformer when loaded 70 to 80% remains cool and thus its
life is enhanced. Further this kind of rating takes care of peak requirement of the load.

Two transformers of equal rating are required to feed critical continuous process load. Each shall be rated to feed
entire load as and when one of the transformer is taken out for either maintenance or failure. The other transformer
shall feed entire load without causing disturbance to the critical load of the process. Though capital cost is more in
having two transformers but it pays even in one or two failures of process which means loss of production due to
want of electricity. The non-critical load is fed from single transformer as stoppage of non-critical load does not affect
much to process. Hence, cost of two transformers are not justified and loss of production due to above is acceptable
norm in industry.

To arrive at the transformer capacity, the estimated motors rating are collected from process and mechanical
departments and tabulated as a load list document.

Normally motors are not loaded fully. Neither all motors are operating at a particular given time. Suitable factors are
applied to arrive at the actual load on the transformer. These factors are discussed among process and mechanical
engineers.

Lighting load shall be added to the motor load.

3.0 DESIGN CALCULATIONS METHODOLOGY:

Inputs, Basis & Assumptions

Operating KVA
Spare Capacity @ 20%
Loading Condition for Transformer Design @80%
Distribution losses @3%

Transformer Output = [(Operating KVA x 1.2) / 0.8] x 1.03 which shall be approximated to the rating

Suitability of rating of transformer shall also be checked for starting of largest motor. (Largest motor or group of
motors that may be started simultaneously is calculated to determine system withstand capability). The two cases
with & without base load shall be considered. Given below is the methodology without considering the base load. In
case there is a base load, then the base load is added to the starting KVA of the largest motor to be started as the
starting KVA for the consideration.

The minimum symmetrical interrupting duty at the supply point of the plant is the first data required in making the
calculation. Then, compute the system line impedance or reactance between the supply point and the motor.

Between the incoming bus and the motor terminals there are usually several impedances in series or parallel. The
procedure for calculating voltage drop at the motor during motor starting involves the use of the maximum available
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short-circuit current of the primary, the line voltage, the various line, transformer and motor impedances, and motor
characteristics.

Assume that voltage drop occurs in the circuit elements, such as cables, transformers, reactors and transmission
lines, and that the supply voltage is constant.

To obtain voltage Vs at the motor during starting

Z m x V1
(Rm + R) 2 + ( Xm + X) 2
Vs =
Where,

V1 = Initial voltage at starting

Zm = Impedance of the motor being started (ratio of applied voltage to current drawn)

Rm = Zm Cosθm

Xm = Zm Sinθm

Cosθm = Power factor of the current drawn by the motor being started

R = Total resistance of the circuit between the motor and the point in the system where voltage
is assumed to remain constant (i.e. is not affected by starting of motor)

X = Total reactance of the circuit between the motor and the point in the system where voltage is
assumed to remain constant.

All impedances, resistances and reactance are expressed in ohms, in percent or per-unit on a conveniently chosen
base. The voltage drop can be calculated with little error by neglecting resistances and considering only the
reactance of the circuit elements in series with the motor. Simplified formula for calculating the voltage at the motor
when starting:

Zm
Vs = Zm + X x V

The percent voltage drop at starting:

% Zm
% Vs = % Zm + % X x 100

The motor impedance Zm in ohms is:

Vm
Zm =
3 x Is

Where

Vm = Voltage rating of motor in volts

Is = Starting current in amperes at rated motor voltage

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100
Motor percent impedance: % Zm =
Ι S / Ι FL
Where

IFL = Full-load current in amperes

The value of IS / IFL varies from 5 to 10 according to the type and characteristics of the motor.

Following are the steps for calculation:

STEP 1:

Prepare a one-line diagram showing all short-circuit current sources and all impedance elements, include
utility supplies, generators, induction and synchronous motors as well as significant impedance elements
such as transformers, reactors, cables, buses, circuit breakers, etc.

STEP 2:

Select a convenient base kVA, which is a common base for all voltage levels. Separate base voltages are
selected for each nominal voltage level. Usually transformer voltages are selected as base values.

STEP 3:

The reactance values are introduced into the reactance diagram after being converted by the per-unit
method on chosen base kVA.

STEP 4:

Make a reactance diagram by converting the one-line diagram to per-unit values on a chosen base. Usually
the resistance of most parts of the system is a small percentage of the corresponding reactance, and a
negligible error on the safe side is made by ignoring resistance. This is the rule above 600 V; at 600 V and
below, the resistance of feeders and branch circuits may become significant.

Reactance diagram is obtained by drawing a zero-reactance bus (source bus) and connecting all short-
circuit current sources to this bus.

STEP 5:

Combine reactance into a single equivalent reactance including all reactance between the zero-reactance
bus and the fault point. The resulting total equivalent reactance in per-unit on a chosen base is used to
determine the short-circuit current and kVA at the fault point.

STEP 6:

Find percent of system voltage at starting using formula

% Zm
% Vs = % Zm + % X x 100

STEP 7:

Obtain percent of motor rated voltage at starting by multiplying percent of Vs by the ratio between system
voltage and motor voltage.

STEP 8:
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Check for starting torque required, by multiplying the percent full-voltage starting torque by the square of the
percent voltage drop at starting. (Torque varies with the square of the voltage.)

Generally if the calculated voltage drop is 20% or above, it is not acceptable except for a dedicated single
motor connected to a dedicated transformer then voltage drop upto 30% is acceptable on case-to-case basis

4.0 Typical Examples :

a. Simple calculation without Motor Staring Verification

The transformer rating calculations are carried out as mentioned below :

Total Operating Load as per Load List = 1248.90 kVA

(Including critical, semi-critical, non critical and lighting load)

Consider 20% spare capacity = 1248.90 x 0.2 kVA

= 249.78 kVA

Total kVA = 1498.68 kVA

Loading condition for Design of transformer = 80%

Rated kVA at given loading condition = kVA with 20% spare

0.8

= 1873.35 kVA

Assuming @ 3% distribution losses,

Transformer output = 1.03 x 1874.35 kVA

= 1930.58 kVA

SAY 1930 kVA

Assuming the above load is distributed among two nos. 2000 KVA rated transformer.

Each transformer shall be loaded to 965 KVA, which is 48.25% of its rated capacity.

b. Calculation with Motor Staring Verification without considering Base load

Step 1. The single line diagram for a 3500-hp induction motor supply is shown in fig. 1. The utility incoming
line supplies a main switchyard bus at 12 kV. An overhead 4000-ft line of two 3-1/2C 750-MCM, 15 kV,
shielded aerial triplexed cable connects the main switchyard bus to a remote 12-kV switchgear. Latter
supplies a 3500 hp, 2.3 kV induction motor via a 1000-ft line of two 3-1/2C 500 MCM, 15-kV shielded
armored cable, a 10,000-kVA 12-kV / 2.4-kV transformer and a 2.4 kV switchgear.

Since the length of cable connecting the 2.4-kV switchgear to the motor is less than 500 ft, its effect is
negligible.

Step 2. The minimum available symmetrical interrupting duty, obtained from the utility supply company, is
400 MVA.

Step 3. A value of 10,000 kVA is selected as base (same rating as the stepdown transformer).
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Step 4. Converting the source Impedance and the impedances of cables, transformer and motor into terms
of percent impedance on the chosen base, the following values are obtained:

10000 kVA base

• Source Impedance = 400000 kVA x 100 = 2.5%

• Cable percent reactances:

For the 4,000-ft, two 3-1/2C 750 MCM, 15kV, shielded aerial triplexed cable (from tables), X =
0.0396 ohms / 1,000 ft L-N. Reactance of 4,000 ft, two cables in parallel:

4 x 0.0396
X = 2 = 0.0792 ohm

ohms x kVA base

% X Cables = 10 x (kV)
2

0.0792 ohms x 10000 kVA base

= 10 x (12)2 = 0.55%

For the 1,000-ft, two 3-1/2C 500 MCM, 15-kV, shielded armoured cable, from reactance tables
obtain the value X = 0.0351 ohms / 1,000 ft L-N. Then, the reactance of 1,000 ft, two cables in
parallel, is

0.0351
X = 2 = 0.01755 ohm

0.01755 ohms x 10000 kVA

% X Cables = 10 x (12)
2 = 0.12%
• Motor impedance:

Convert motor horsepower into kVA by using motor data characteristics:

3500hp × 0.746
= 2,956kVA ,
0.96eff × 0.92pf

Motor full load current = 2956 = 742 A

1.732 x 2.3

Motor starting current = 6.7 x Full load current = 6.7 x 742 = 4971 A

100 100
%Zm = = = 14.92%
4971A 6.7
742A

As the kVA drawn by a motor varies with the square of the voltage, the percent motor impedance is :

2
 2300 
% Zm @ 2.4 kV = 14.92% ×   = 14.92% × 0.92 = 13.72%
 2400 
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10000 kVA base
% Zm on base = × 13.72% = 46.41%
2956 kVA

• Transformer impedance is 6.6% maximum on the chosen base of 10,000 kVA (base and rated MVA
of transformer are same)

Step 5. The reactance diagram reflecting the values of step 4 is shown in fig. 2.

Step 6. Percentage of system voltage at motor starting:

%Zm 46.41
% Vs = × 100 = × 100 = 82.61%
%Zm + %X 46.41 + 9.77

The voltage dip at the 2.4 kV bus is 100% - 82.61% = 17.39% of 2,400 V.

Step 7. Percent of motor rated voltage at starting is :

2400
% Vm = × 82.61% = 86.2%
2300

The voltage dip at the motor is :

100% - 86.2% = 13.8% of 2,300 V.

Step 8. Since full voltage starting torque is 60% of full load torque, the available starting torque at the 86.2%
2
reduced voltage is 60% x (86.2) = 44.58%. Be sure to verify that this value satisfies the driven load starting
torque requirements.

CONCLUSION :

Since the voltage drop & starting torque required are within limits, system remains stable.
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c. Calculation with Motor Staring Verification considering Base load

110 kW, 415V, 3 phase, 50 Hz is the largest motor in the system. The worst case of starting i.e starting of
the standby motor when all other loads are in service and one transformer is feeding all the loads is
considered. Motor cable rating is 3C x 185 sq mm, XLPE Al cable of 100 m length.

Total load on the transformer = 1248.90 kVA

Adding 20% spare, Total kVA (Base load) = 1248.90 x 1.2

= 1498.68 kVA

The 110 KW motor has an efficiency (η) of = 0.94 and power factor p.f. = 0.908
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KW 110
∴ Motor kVA = =
η x p.f 0.94 x 0.908

= 128.878 kVA

As per standard specification, motor starting current shall be 550% of full load current subject to tolerance.
Considering 10 percent tolerance,

Starting motor kVA = 6.05 times motor kVA

= 6.05 x 128.878 = 779.712 kVA

∴ Total kVA at starting = Base load + Starting kVA of motor

= 1498.68 + 779.712

= 2278.39 kVA at 415V

433 2
Adjusted starting kVA (on 433V base) = 2278.39 x 415
 
= 2480.32 kVA

Starting power factor of motor = 0.4

Per unit voltage drop = I X sin φ = Starting MVA X sin φ

 Rated MVA 

Cos φ = 0.4

∴ Sin φ = Sin (Cos-1 (0.4)) = 0.9165

Impedance considered is source Impedance & transformer Impedance for voltage drop.

Source fault MVA = 750 MVA at 11 KV (as a basis)

Transformer Impedance = 6.25 + 10% variation (6.25 x 1.1 =

6.875%)

Base MVA = 2 MVA

Base MVA 2
Per unit source Impedance ZS = Rated MVA = 750 = 0.0027 p.u.
% Impedence Base MVA
Per unit transformer Impedance Ztr = 100 × Rated MVA

6.875 2
= 100 × 2

= 0.0688 p.u.

∴ Total Impedance (Zs + Ztr) = 0.0027 + 0.0688 = 0.0715 p.u.

a) Voltage drop at bus during Motor Starting:

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Percentage voltage drop at bus = Starting MVA x p.u. impedance x Sin φ x 100%
Rated MVA

Percentage voltage drop = 2480.32 x 0.0715 x 0.9165 x 100

 2000 
= 0.0813 x 100

= 8.13% on 433 V base.

415 2
= 8.13 x 433 on 415V base
 
= 7.47% on 415 V base

The percentage voltage drop of 7.47% on 415 V base is within the maximum permissible voltage drop of
10% at the busbars of the LV switchboard during start up of large LV motor with other loads on the bus.

b) Voltage drop at Motor terminal during Starting:

Motor Cable: 3C x 185 sq mm, Al

Length: 100 m
Cable Resistance: 0.210 ohms/km
Cable Reactance: 0.0932 ohms/km

Istart = 6.05 x IFLC = 6.05x 179.3 = 1084.76 A

3 × I start × Length × ( R cos θ + X sin θ )

% Vdrop Cable = × 100
415

3 × 1084.76 × 0.1 × (0.210 × 0.4 + 0.0932 × 0.92)

% Vdrop Cable = × 100
415

= 7.67%

Hence Voltage drop at motor terminal:

= Voltage drop at bus + voltage drop at cable
= 7.47 + 7.67
= 15.14 %

The percentage drop at motor terminal during staring is less than maximum permissible voltage drop at 20%
hence it is acceptable.