PRESENTATION ON
TRANSFORMER SIZING
Prepared by: Birender Kumar Pal
August 2007
CONTENTS
0.0 GENERAL DEFINITIONS
1.0 PURPOSE
2.0 PROCEDURE
3.0 STEPS FOR TRANSFORMER SIZING
4.0 LIST OF ATTACHMENTS
0.0 GENERAL DEFINITIONS
POWER FACTOR:- The ratio between the Actual power & active power is called power
factor. Or the ratio of resistance to impedance is also called the power factor or The Cosine of
angle between actual power & active power.
DEMAND FACTOR:-Demand factor is the ratio of maximum demand of a system to the
connected load on the system under consideration. Demand factor is always less than one.
Demand Factor=Maximum Demand/ Connected Load
DIVERSITY FACTOR:- Diversity factor is the ratio of sum of individual maximum
demands of the various subdivisions of a system, or part of a system, to the maximum demand of
the whole system, or part of a system under consideration. Diversity factor is usually more than
one.
Diversity Factor=Sum of Individual Maximum Demand of a system/Maximum
Demand of Whole system
LOAD FACTOR:- Load factor is the ratio of Electricity consumption to the peak demand
(expressed as %age) for each billing period. Load
Factor (%)=[Energy used (in kWH)]/[Maximum demand (in kW)*Time(hours)]
1.0 PURPOSE
The purpose of this document is to lay down
the guidelines and design procedure for
performing the distribution transformer sizing
calculation, rather to say verification of kVA
rating and fixing of transformer ‘%Z’ and/or
starting method of big motors as generally kVA
rating of transformer is fixed during conceptual
engineering.
2.0 PROCEDURE
The sizing of the transformer is selected based on the following conditions.
a) Actual Working load calculated from continuous & intermittent
loads
b) 5-10% spare capacity or VFD margin according to project requirement.
c) Actual load requirement with highest rated motor started on DOL/Star-
Delta
3.0 STEPS FOR TRANSFORMER
SIZING
3.1 Step-1 - Calculation of Total Working (Active) Load
3.2 Step-2 – Calculation Of Transformer Capacity
3.3. Step-3 – Determination of allowable % voltage drop at
different section and target transformer regulation
3.1 Step-1 -Calculation of Total Working
(Active) Load
Actual Working load is calculated from continuous & intermittent load as
mentioned below: -
Following factors will govern the transformer load calculation.
1. Diversity Factor:-
i) Continuous Load=1.0
ii) Intermittent Load=1.5
iii) Lighting Load=1.1
2. %Age Loading
i) Motor Load=0.9
ii) Instrumentation Load=1.0
iii) Lighting Load=1.0
3.2 Step-2 – Calculation Of Transformer
Capacity
From the value of Actual Working load obtained in step-1, transformer
capacity is calculated as mentioned below: -
Transformer Capacity = (Actual Working Load) *1.05[considering 5%
spare capacity/VFD Margin]
In case 5% margin does not fulfill the voltage regulation limit then 10 %
margin to be considered.
3.3. Step-3 – Determination of allowable %
voltage drop at different section and target
transformer regulation
3.3.1 Prior to transformer regulation calculation allowable voltage
drops at different section of electrical distribution system are to
be determined and tabulated in a proper tree structure as shown
in the SLD. SLD SHOWING VOLTAGE DROP
Say allowable voltage drop at any consumer end is 6% of
equipment rated voltage.
3.3.2 Depending on electrical distribution configuration, target
distribution transformer regulation % to be fixed say 4 %
according to clause 3.3.1
TRANSFORMER SIZING CALCULATION
%age ACTUAL
UNIT PF at Full EFFICIENCY % Age Diversity Working
S. RATING QTY. TOTAL Load AT FULL Loading Factor LOAD
NO. DESCRIPTION (in kW) (Nos.) LOAD (Cos ø) LOAD (η) (LF) (D) (IN kVA)
1 MAIN PUMP 160 2 320 0.89 93.5 0.9 1 346.09
2 SUCTION & DELIVERY VALVE ACTUATOR 1.1 1 1.1 0.8 74 0.9 1 1.67
3 INLET & HEADER VALVE ACTUATOR 2.2 1 2.2 0.8 78 0.9 1 3.17
4 WINDOW AC FOR CONTROL ROOM 1.5 2 3 0.8 76 0.9 1 4.44
5 DRY WELL DRAIN PUMP 2.2 1 2.2 0.8 78 0.9 1 3.17
6 EXHAUST FANS FOR PUMP HOUSE 0.37 8 2.96 0.7 63 0.9 1 6.04
7 EXHAUST FANS FOR DG ROOM 0.37 2 0.74 0.7 63 0.9 1 1.51
8 AUXILIARY PUMP 45 1 45 0.87 90 0.9 1 51.72
9 EOT CRANE 4 1 4 0.8 83 0.9 1 5.42
10 INSTRUMENTATION 1 1 1 0.9 _ 1 1.5 0.74
11 LIGHTING 20 1 20 0.9 - 1 1.1 20.20
SUB TOTAL 444.19
CONTIGENCY@10% 488.61
INPUT PARAMETERS:-
Diversity Factor (D) = (Considered as per Process Mechanical) Attached Data Sheets:-
Motor Rating (kW) = (As per the Load list issued by Process Mechanical)
PF of Motor(Cosø) = (As per Motor Manufacturer's Data Sheet)
Efficiency of Motor (η) = (As per Motor Manufacturer's Data Sheet) 1. 4 Pole Motor
%AGE Loading(LF) = (For Motor=0.9, For Instrumentation & Lighting=1.0) Data Sheet
of ABB
P kW LF
P kVA k VA
cos D
HENCE THE REQUIREMENT OF 488.61 kVA ~ 500.00 kVA
Considering the nearest standard 2. TRANSFORMER
rating as per Trf. Data sheet from 500 kVA SIZE & %AGE
IMPEDANCE
IS:2026, Part 1, 1996
Voltage drop on Transformer due to Motor Starting
Voltage drop on Transformer due to Motor Starting
k VAst sin st
%age Voltage drop is given by the formula:
k VAopsin
VD % X
Where:-
k VArated
max running load in kVA on the transformer
except the motor to be started.
kVAop =
(If not known this is equal to transformer rating less
motor rating in kVA)
Sine of average PF angle of max. running load
Sinø =
(If not known Cos(operating angle)=0.8)
Starting kVA of the motor to be started
kVAst = (Normally 6 times the rated kVA for DOL starting and
2 times for Star-Delta Starting)
Sine of starting PF angle of the motor
Sinθst =
(Normally Cos(θst)=0.2)
kVArated = Transformer rating
%X = Transformer %age impedance
Input/Calculated Parameters:-
Power Factor of system (Cosø) = 0.85 (assumed)
Starting PF of Largest motor (Cosθst) = 0.20 (assumed)
Maximum Load on Transformer including margin = 488.61 kVA (As per Transformer Sizing)
Largest Motor Size = 160.00 kW (As per Load List)
PF of Largest Motor (Cosθ) = 0.89 (As per Motor Data Sheet)
Efficiency of Largest Motor (η) = 93.50 (As per Motor Data Sheet)
kVA of Largest Motor = 192.27 kVA
Input/Calculated Parameters:-
Transformer kVA (kVArated) = 500.00 kVA
(Transformer kVA selected as per STD rating in IS, considering the Contigency of 10% in the actual working load.)
kVAop = 296.34 kVA
[Maximum Load-Largest Motor rating (kVA)]
Sine of PF angle of system (Sinø) = 0.53
Sine of Avg PF of max running load (Sinθst) = 0.98
kVAst = 384.55 kVA
[Motor kVAx2(For Star-Delta Starting)]
Impedance X% = 4%
Voltage Drop is Given by:- k VAst sin
k VAopsin st
VD % X
k VArated
VD = 4.36 %
Conclusion:-
Total Voltage drop
Voltage drop due to Transformer Impedance = VD 4.36 (From Above)
Voltage drop from Transformer to PCC = X<=0.5 0.30 (From Cable Sizing Calculation)
Voltage drop from Main MCC to Package MCC = Y<=2.5 2.50 (From Cable Sizing Calculation)
Voltage drop of motor cable of 415V switchgear = Z<=3 3.00 (From Cable Sizing Calculation)
Nett Voltage drop due to Motor Starting = 10.16 <15%, Hence OK)
(%age VD at Starting of Largest motor should not normally exceed 15% and in worst cases, 20%)
Conclusion:-
VD is within limits of 15% max.
Hence the selection of 500kVA Power Transformer is appropriate based on VD calculation.
QUESTIONS??
Thank You
