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
Frequency

: 480/240 V (multi-tap)

: 60 Cycle

Efficiency at Unity Power Factor

Full Load

: 98.4 %

Load

: 97.8 %

Temperature rise not to exceed to 55c

CALCULATIONS:
Guaranteed Losses:
Total Loss @ Full Load

10.984
x 50000=813 watts
0.984

Total Loss @ Full Load

10.978 50000
x
=281.186 watts
0.978
4

Full Load Copper Loss

813567.268=245.73 watts

Core Loss

Item 1.
Vt

813281
=567.268 watts
1
1
16

Volts Per Turn

=

5 0000
60

(assume c = 60)

= 3.73 volts

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.
Total Secondary Turns

Turns per Secondary coils

480
3.73
=

= 128.686 (say) 132 turns

132
4

= 33 turn/coil

Total Primary Turns

Turns per Primary coils =

Item 5.

@ Low Tension
50000
I p=
=20.83 amp.
2400

2( 132 x 104.167)
=59.3313 sq .inch
1500 x 0.309

4.11 inch
H=14.41 inch

108 x 480
By formula, the flux in the iron is = 4.44 x 132 x 60 =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
0.9 L x 1.5 L=
L=3.8 inch
70000
M =L=3.8

= 330 turn/coil

H
=3.5 inch
D

=660 turns

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
H x D=

660
2

2400
3.73

Full Load Current

@ High Tension
50000
Is

=104.167 amp .
480

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

0.28 ( SF x L x S ) 2( H+ S+ L+ M )

Weight of iron

0.28 ( 0.9 x 3.8 x 5.7 ) x 2 ( 14.41+5.7+3.8+3.8 )

W iron=302.5 lb.
Total core loss watts per pound of B= 70000 be 0.75 from fig. 154
Total Core Loss=W iron ( 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
=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:

1,553,277.415
=
=
CSA=0.9 x 3.8 x 5.7
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
157.3lbs .
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.
CSA=0.9 x 5 x 5.7

25.65 sq .
sq. In.
We read Watts loss per pound be: 0.57

1,553,277.415
25.65
60,556.62 (say) 61,000 lines per

 2 x 0.28 x 25.65 x (4.11+ (2 x 3.8 ))

Weight of 2 end sections

168.2lbs .

168.2 x 0.57

Core Loss of 2 end sections

149.314+95.874=245.314 watts

Total Core Loss

Loss of

95.874 watts
which is practically the specified

245. 75 watts

Core Dimensions:
L= 3.8 in.
S= 5.7 in.

M= 5 in.

H= 14.41 in.

D= 4.11 in.

Size of Wires And Winding Particulars

Thickness CSA / Width
I s 104.167
=
=0. 6933 sq .inch.

1500
Length of winding space in the Layer = 13.91 (from fig.)
13.91
=0.4797
Width of one Conductor including insulation =
29
Cotton Coverings = 0.02 in (20 mils)
Width of Copper = 0.46 inch
0.06933
Thickness =
= 0.15175 inch
0.46
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
Current Density=

20.83
amp
=1 223.24
0.01635
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

=6.67 7 layer
Total Number of Layers of Wire
87

(for each 2 limbs)

Volts (RMS)

1200 x

2 x 87
=360 volts (rms value)
580

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
Clearance
0.067
Inner L.T. coil (one layer) including cotton on wire
0.190
Parchment paper (0.010) between coils; allow
0.015
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
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
Allowance for bulging (0.02 x 3.05)
0.114
Total
2.012

t = 0.125

s = 0.395

g = 0.188

p = 1.304

Space available to accomodate this total thickness of copper and insulation =

4.11
=2.055 in.
2

CALCULATION OF COPPER LOSS

The mean length per turn (MLT) of the windings

2 ( 3.8+5.7 )+ ( 0.25+ 0.395 )
Secondary MLT =
=1.75 ft
12
Primary MLT =

2 ( 3.8+5.7 ) + (0.25+0.79+0.304)
=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 ,
234.5+75
0.5790 x
= 0.61
234.5+60

Total Resistance
(Primary)
RT = 0.61 x 0.9976 = 0.61
IR = 20.83 x 0.61 = 12.68 volts
I 2 R=20.83 2 x 0.61=264.67 watts
(Secondary)
0.0635
203
RT= 0.61 x 0.0726 x 1000 =0.02789

IR = 104.167 x 0.02789 = 2.9 volts

I 2 R=104.167 2 x 0.02789=302.63 watts
Total Copper Loss = 264.67 + 302.63 = 567.3 watts

Items 24 32.

Items 33.

Core and Copper Losses 245.31 + 567.3= 812.61 watts

Efficiency at unity power factor

1
4

Full Load

50,000
4
1
=98.77
567.3
50,000
120+
16
4
@ Full load
245.31+567.3
1
=98.4
50000+812.61

@ Half Full load

245.31+141.825
=98.5
25000+203.1525

@ Three quarter full load :

0.75
( 2 x 567)+120+( 0.75 x 50,000)=98.42
0.75 x 50,000

@ 25% over load

1.25
( 2 x 567.3)+ 120+(1.25 x 50,000)=98.42
1.25 x 50,000

Maximum Efficiency:
245.31
50000
=32.88 KVA
567.3

Items 34.

245.31+245.31
= 94.5%
8439.3+490.62
Basis of 4 hour full load and 20 hour no load.

All Day Efficiency:

50000 x 4
=96.7
( 50000 x 4 ) + ( 145.31 x 24 )+(812.4 x 4)

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

2
Np
total I x T
Ic=

197.55
=0.2408
580 ( 2)

Energy Component=I w =

core loss
245.31
=
=0.1022 amp .
H . T . volts 2400

I = I c 2 + I w2 =(0.1022)2+(0.2408)2=0.2616 amp .

Item 36 to 39.
IR Drop=

Regulation

812.61
x 100=1.7087
50000

length=12 x

%IX Drop=

1.75+1.72
=18.06
2

2 f T s Isl
n h E s 10

x g+
5

p+ s 2 x 60 x 116 2 x 104.167 x 18.06

1.304+0.395
=
x 0.188+
=1.656
5
3
3
2 x 14.41 x 480 x 10

Equivalent Reactive Drop=2400 x 0.01656=43.24 volts

% Regulation @ 0.80 power factor

%IR cos+%IX sin
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

S=

245.48
=861 sq . inch
50 x 0.0057

Dimension are 15 x 12 x 24 in high

1
20 [ (15 x 2 )+(12 x 2) ] + ( 24 x 15 )=1440 sq . inch.
2

Cooling Effective Surface

For Watts

861
=0.6
1070

For temperature

Item
No.
1

245.48
=42
0.0041 x 1440

SUMMARY OF CALCULATIONS
Volts per turn : From formula = 3.73 v

Windings

; actual = 4.138 v

High
Tension

Low
Tensi
on

2
3
4
5
6

Total numbers of turns

Numbers of coils
Turns per coil
Full Load Current (Amp)
2
Current Density( amp ./inch )

580
2
290
20.83
1223.24

116
4
29
104.167
1500

7
8
9
10
11
12
13
14

Cross Section of Conductor

Dimension of Conductors
# of Turns per Layer per Coil
# of Layer per Coil
# of Taps
Volts per Coil
Volts Between Layers
Length of Winding Layers

0.01635
No. 7
87
7
None
1200
360
13.68

0.07245
0.46 x 0.1575
29
1
2
120

15

Length of Layer Including Insulation

16
17
18
19
20
21
22

Insulation Between Layers

Insulation on Wire
Length per Turn
Total Length, all Turn in series, ft
Weight in Copper(lbs)
Resistance a 75 c All Coils
IR Drop Volts

14.41

0.02
dcc
1.72
997.6
62.85
0.61
12.68

13.91
14.41

dcc
1.75
203
54.145
0.02789
2.9

23

Full Load Copper Loss(Compare to

Guaranteed)

246.67

302.63

THE MAGNETIC CIRCUIT

24
25
26
27
28
29
30
31
32

Dimension of Windows
Total Flux, Maxwells
Flux Density in Core Under Windings
Cross Section of Iron in Core Under Windings
Width of Stampings in Core Under Windings
Gross Thickness of Core
Total Weight or Iron in Core, lbs.
Watts Loss in Iron (compare to guaranteed)
Total Full Load Losses, watts

14.41 x 4.11
1553277.415
80000
19.494
3.8
5.7
325.5
245.31
812.61

EFFICIENCY AND EXCITING CURRENT

33

34
35

Efficiency at Unity Power Factor

At Full Load
At Load
At Load
At Load
At 25% Over Load
All Day Efficiency (4Hr Full Load)
Primary Exciting Current, Amp.

98.4%
98.5%
98.77%
98.84%
98.42%
96.7%
0.2408

REGULATION
36
37
38
39

Total Equivalent IR Drop Percent

Total Reactive Drop Percent
Regulation on Unity Power Factor
Regulation on 0.80 Power Factor

1.6252
1.656
1.6252
2.29376

DESIGN OF TANK TEMPERATURE RISE

40
41

Effective Cooling Surface of Tank, sq. inch.

Watts per square inch of Tank

3020
0.269

42

Approximate Temperature Rise,

47.2