Dry-Type Transformer

Basic Analysis and Design of 1600 KVA ,18/0.4 KV Dry-

type Transformer
This section describes :-
The transformer design methodology
Three phase core type transformer
The winding material
The core material
The performance of transformer
Table3.1 Proposed design specific

Design specification
NO. Specification Value
1 Method of cooling AN
2 Connection of HV/LV Delta/Star
3 Number of Phases 3
4 Frequency , Hz 50
5 Rated continuous power ,KVA 400
6 Nominal Voltage KV,(HV side / LV side) 18/0.4
7 Connection (Vector group) Dyn11
8 No load loss, W (max) 2300
9 Load loss, W (max) 11000
10 Temperature rise of winding 80 c

11 HV/LV winding material Copper
Off load tap changer with 5 position + 5% to -5% in steps of 2.5 % with 6
12
range taps
 Active Part Design
High voltage winding Design

1) Voltage per phase (VP) = line voltage 18000 V (being delta

connected)
2) Current per phase (Ip) =
3) Current density (Cd) =2.9 A/mm2
4) Conductor area (Aw)= mm2
)In this case, the current is generally high, rectangular
conductor is commonly used.
)Therefore 1.7 x6 mm rectangular bare conductor is
selected from wire standard.
cont.
Calculation of primary turns
To calculate the number of turns Et= , Where
Et=Voltage per turn
Q = Rated KVA of the transformer (1600 KVA)
where K= constant
The value of K for copper wound transformer may be
taken between 0.37 to 0.45.
Et =17.6
 Cont.
No. of secondary turns=13.12 T

This we can round off it to 13 T

No. of primary turns @ normal=1013.249 turns
which is rounded to 1013 Turns
Additional turns towards 5 tapping voltage=
Which is rounded-off to the nearest even number =51 Turns
So the total primary turns per phase= 51 + 1013= 1064
Turns
HV parameters
The HV winding design can be proceed as shown in the table below.

Voltage per phase ,Vp 18000 V

Current per phase , Ip 29.63A

Bare Wire diameter 1.7x 6 mm

Conductor Area 10.2 mm2

Current density 2.9 A/mm2

 Cont.
We're going to concluded that, there is a HV coil per phase which is
having 86turns per layer , the winding Axial length of the coil being
520 mm. The Radial build of coil being 26 mm and the inter layer
insulations are 0.2 mm thick
Estimating the core window height:

Total axial length of the coil =520 mm

End packing insulation = 2 x 20 = 40 mm
560mm
Upper yoke insulations = 70mm
Bottom yoke insulations = 30mm
Window Height (W/H) of core =560 + 100 = 660
mm
End insulation of HV winding

H1=20mm
H2=14mm
Cont.
End insulation of primary winding for the three
coils Item 1
Level number
L Number

1-2 1.5 1180 12

2-4 1.5 1210 12

5-6 1.5 1240 12

7-8 1.5 1270 12

9-10 1.5 1300 12

11-13 1.5 1330 18

Layer Insulation of HV
winding
The thickness of the insulation between the layers of
the HV winding
Cont.
Item 1 Item 2
Level number
L H Number

1-2 0.2 1180 18

560

2-4 0.2 1230 18

560

5-6 0.2 1280 18

560

7-8 0.2 1330 18

560

9-10 0.2 1380 18

560

11-13 0.2 1430 18

560
 Cont..
No. layer 1 2 3 4 5 6 7 8 9

Turn per

layer 86 86 86 86 86 86 86 86 86
Turn used 86 172 258 344 430 516 602 688 774

No. layer
10 11 12 13
Turn per

layer 86 86 86 32
Turn used 86 103

0 946 2 1064
Particulars Particular Particulars Value Particulars Value
Value s Valu

e
Rated Power 1600 Rated 18k No. 3 Type of connection

KVA voltage V Phases

No. of layers 13 Total no. 106 Phase 29.63A Conductor arrangement

of Turns 4 current
Conductor Parallel 1 Conductor 6 x1.7(Bare) HV weight=415 kg

specification wound length in m

conductor
s
 Technical Requirements
1) Winding multi-layer coil Cylindrical Winding left wound
2) Winding terminal end is 300mm; Starting, End terminals and
Tapping terminals use Shrinkable tape at the end
3) The outer most layer of the coil wound with cloth tape.
4) Break on the dissatisfaction of turn layer
5) Taped Line is at center of the axial length of the coil
6) HV and LV winging is separately wound
7) Winding Terminal of each side of the Insulation is 4mm
Low voltage winding Design

1) Voltage per phase (VP) = 231V (being star connected)

2) Current per phase (Ip) =2310
3) Current density (Cd) =2.96 A/mm2
4) Conductor area (Aw)= 770 mm2
5) In this case, the current is generally high, foil sheet conductor is commonly
used.
6) Therefore 520 x1.5 mm bare foil sheet conductor is selected from wire
standard.

Rated Rated voltage Rated phase No Phase Vector

power=1600kVA =18kV current=771 =3phase group=Yn
connection
Total no. of No. of layers=13 Conductor Layer Insulation Starting terminal
turns=13T specification(bare) =0.2mm =500mm
End insulation of lV winding

H=20mm
L=500mm
Core design

1600 KVA, 18/0.4 V CORE CHARACTERSTIC DRESIGN OUT PUTS

Material = CRGO C/L= 500 mm
Core dia. = 255 mm Grade = M4 W/H
= 660 mm No of step with =10
Thickness =0.27mm Stack = 248 mm
Total Weight of steps =571.64 Kg
Stag Thickne No.
NO. B L L1 L2 Silicon steel shape
e ss plates
116
1 1
250 0 100
114
2 2
235 5 98
113
3 3
220 0 60
111
4 4
 Cont.
1600 KVA, 18/0.4 V CORE CHARACTERSTIC DRESIGN OUT PUTS
Material = CRGO C/L= 500 mm
Core dia. = 255 mm Grade = M4 W/H
= 660 mm No of step with =10
Thickness =0.27mm Stack = 248 mm
Total Weight of steps =571.64 Kg
Stag Thickne No.
NO. B L L1 L2 Silicon steel shape
e ss plates
145
1 1
250 0 100
143
2 2
235 5 98
142
3 3
220 0 60
140
4 4
205 5 46
Cont.
Cont.