NATIONAL UNIVERSITY

College of Engineering
ELECTRICAL ENGINEERING DEPARTMENT

DESIGN OF DISTRIBUTION TRANSFORMER

(Design 1)

A Design Report Submitted

in Partial Fulfillment of the Requirements
in

AC APPARATUS AND DEVICES

Submitted by

Eric P. Pomar
BSEE
SN: 2017-200951

Submitted to

DR. ROGELIO B. ANIEZ, JR., PEE

PROFESSOR
PROGRAM CHAIR, EE DEPARTMENT

Date Submitted: DECEMBER 7, 2018

 Design a transformer to meet the following specifications:

Output in kilovolt-amperes = 125

Primary (high-tension) = 2,300

Secondary (Low-tension) = 115/230

Frequency = 60 cycles

Fullload=0.985
Efficiency at unity power factor 1
4
{
full load=0.982

Temperature rise not to exceed 55°C

Item1. It is proposed to design a core-type transformer with rectangular

coils. A subsequent design, Article 147, will be devoted to the calculation of a
cruciform-core type of transformer.

Description. This is a distribution transformer of standard type for

maximum output rating. It is oil-immersed and self-cooling, without taps for
voltage adjustment.

Insulation test (in tank with oil); voltage applied for 1 min

H.T. winding to L.T. winding and core, 10,000 volts

L.T. winding to core 4,000 volts

DESIGN SHEET FOR TRANSFORMER

Single-phase Distribution Type (High All-day Efficiency)

Copper ( full load ) … ..1,420

Guaranteed losses, watts {Iron… … … … … … … …. 484

Item
No.
Summary of Calculation

1 Volts per turn; from formula = 8.84

 Windings HT. L.T.

2 Total number of turns 260 26

3 Number of coils 2 4

4 Turns per coil 130 7

5 Full-load current, amp 54.35 543.48

6 Current density, amp per sq in. 1,315 1,600

7 Cross section of each conductor, sq in. 0.04133 0.339

8 Dimension of conductors No.3 1.19x0.28

9 Number of turns per layer per coil 34 7

10 Number of layers per coil 4 1

11 Taps None None

12 Volts per coil 1,150 57.5

13 Volts between layer 602 ---

14 Length of winding layer 1 1

18 18
4 2

15 Length of layer including insulation 1 1

19 19
4 4

16 Insulation between layer, in 0.017 ---

17 Insulation of wire dcc dcc

18 Length per turn, ft. 2.32 1.82

19 Total length, all turns in series, ft. 604 48

20 Weight in copper, lb. 96.22 61.42

21 Resistance at 75°C-all coils in series, 0.12 0.0011
ohms

22 IR drop, volts 6.52 0.6

23 Full-load copper loss (compare with 355 325

guarantee)

The Magnetic Circuit

24 Dimension of “window,” in 12x4

25 Total flux, Maxwells 3,321,000

26 Flux density in core under windings, lines per sq. in 75,000

27 Cross section of iron in core under windings 43.2 sq. in

28 Width of stamping in core under windings 4 in

29 Gross thickness of core 7 in

30 Total weight of iron in core, lb. 258.44

31 Watts lost on iron (compare with guarantee) 386

32 Total full-load losses, watts 1,066

Efficiency and Exciting Current

33 Efficiency at unity power factor:

1 0.9902
At 1 load
4
0.99077
At full load
0.9908
3
At load
4 0.9896

1 0.9834
At load
2

1
At load
4

34 All-day efficiency (4-hr full load) 0.9909

 35 Primary exciting current, amp 1.043

REGULATION

36 Total equivalent IR drop, per cent 0.544

37 Total reactive drop, per cent 1.22

38 Regulation on unity power factor, per cent 0.544

39 Regulation on .80 power factor per cent 1.17

DESIGN OF TANK – TEMPERATURE RISE

40 Effective cooling surface of tank, sq. in 5,154

41 Watts per sq. in of tank surface 0.285

42 Approximate temperature rise of oil °C 55

The specified temperature rise of 55°C means that the temperature of

the windings, as measured by the resistance method, after the transformer
has been operating continuously at full load, will not be more than 55°C above
the temperature of the surrounding air.

The transformer is not guaranteed against overloading.

CALCULATIONS

Guaranteed Losses. Before proceeding with the design, it is well to

determine the amount of the iron and copper losses corresponding to the
specified efficiencies.

By formula (144),

1−0.985
Total loss at full load = x 125,000 = 1,904 watts
0.985

By formula (145)
 1 1−0.982 125,000
Total loss at load = x = 573 watts
4 0.982 4

By formula (146)

1904−573
Full-load copper loss = 1 = 1,420 watts
1−
16

And the guaranteed core loss is 1,904 – 1,420 = 484 watts.

The copper loss will be a maximum when the transformer is hot. In the
calculating the resistance of the windings to determine the full-load copper
loss, a temperature of 75°C will be assumed.

In making the calculations, it is not possible to follow the exact

sequence of the items as recorded in the design sheet shown on page 371,
but the items covered by the calculations are referred to in the margin to
facilitate reference

Assuming c = 40 in formula (129) of Article 129, we have

Vt =
√125,000 = 8.84 volts
40

Items 2 to 5. Since the high-tension winding is the primary and the low-
tension winding the secondary, the number of secondary turns is 230/8.84 =
26.02, or (say) 26 turns in 4 coils of 7 turns each. It is usual to have not less
than four coils on the low-tension side in both large and small transformer.
The number of primary will be 260. Before proceeding further, it should be
pointed out that the numbers of primary and secondary turns here calculated
are preliminary values and may require modification should the copper and
iron losses differ greatly from the guaranteed losses; this is, in fact, -actually
the situation, as the result of items 6 to 15 indicate. This winding may consist
of two coils (one on each limb) in a small transformer for as low a voltage as
2,300, but the winding on each limb may consist of two or more coils
connected in series. Refer to Article 134 for discussion of coil arrangements in
both core and shell-type transformers.
 The full-load secondary current is 125,000/230 = 543.48 amp, and,
since the ratio of transformation is 10 to 1, the primary current (neglecting the
current component) is 54.35 amp.

Items 6 to 15. Before deciding upon the size of wire in the windings, it
will be advisable to determine the probable dimension of the openings, or
window, which must accommodate both primary and secondary windings. By
formula (134) on page 348 the winding factor is sf = 10 / (30+2.3) = 0.309, or
(say) 0.3 for an approximate winding space factor. The current density (Article
130) will be assumed at 900 amps per sq. in.; whence the area of the window
opening (Fig. 156) is,

2(26 x 543.48)
HXD= = 104.67 sq. in
900 x 0.3

Using the ratio (H/D) 3.5, as suggested in Article 133, we may try D = 5

1 3
and H = 19 in. for the length of the limbs upon which the coils will be
2 4
placed. Before proceeding further, it will be advisable to make a rough
estimate of the core dimensions and iron loss.

By formula (125a) on page 340, the flux in the iron is

108 x 230
Φ= = 3,321,000
4.44 x 60 x 26

From Article 130 we select 85,000 lines per sq. in. as a trial density in
the limbs under the windings. Whence, with the proportion S =3L (see article
133) and a stacking factor of 0.9 we have

3,321,000
0.9L X 3L = = 39 sq. in
85,000

Whence the width of the stampings under the windings is L=3.8 or (say) 4 in,
and the total thickness of the stack of laminations is S=12 in.

For preliminary calculations we shall assume M=L in Fig. 156. In other

words, assume the same across section of iron and the same flux f density in
the end portions of the core as in the limbs under the windings. Changes can
be made later if the core losses are too high. The dimensions of the core will
be as shown in Fig. 170. And the weight of iron is 0.28(0.9 x 5.5 x 4) x
2(19.25+4+5.5+4) = 364 lb. From Fig. 154 we find the watts per pound for B”
= 85,000 to be 1.06; whence the total core loss is 386 watts, which does not
exceed the required loss of 484 watts. Before correcting the iron loss it is
usually advisable to calculate the approximate copper loss because changes
in the design can then be made to correct the iron and copper losses
simultaneously.

Approximate Copper Losses. The approximate mean length per turn of

winding on rectangular lines of core-type transformers, as illustrated in Fig.
170 is 2(L+S+D) which includes an allowance for insulation and clearances
around the iron core. Thus, mean length per turn (m.l.t.) = 2(4+12+5.5) = 43
in. The cross section of copper in both winding is [2(26 x 543.48)/900] = 31.5
sq. in. and the weight of the copper is 0.32 x 43 x 31.5 = 434.44 lb. The watts
lost per pound at 75°C are given by formula (131) on page 345, whence total
copper loss = (434.44 x 2.57 x 9002)/106 = 904.37 watts. This is also not in
excess of the required loss, which is 1,420 watts.

Sizes of Wire and Winding Particulars. It is desirable to make a sketch

such as Fig. 172 showing a cross section through the windings in the window

1 1
opening of dimensions H = 19 in and D = 5 in.
4 2

Two coils of the secondary or low-tension winding will be wound next to

the core on each limb. Each coil may consist of 7 turns in a single layer. The
size of a suitable conductor of rectangular section may be calculated as
follows. The cross section for a current density of (say) 1,600 amp per sq. in.

1
is 543.48/1,600 = 0.339 sq. in. Allowing in. at each end of the layer for
2
clearance and insulation, the available length of winding space in the layer is

1 8.5
18 in., and = 1.21 in., which is the width of one conductor including
2 7
insulation. The cotton covering will account for 20 mils, leaving 1.19 for the
width of copper. The thickness must be 0.339/1.19 = 0.285 or (say) 0.28 in.,
so that a rectangular conductor 1.19 by 0.28 in. wound on edge will be
suitable.

For the high-tension side we may select from the wire table on page
431, No. 3 dcc wire in which the current density will be 54.35/0.04133 = 1,315
amp per sq. in.

1
Assuming the length of the winding layer to be 8 in., the number or
4

1
wires per layer will be about 8 x 4.12 = 34 where the figure 4.12 is obtained
4
from the wire table on page 431. A total of nine layers of wire will be required
for a single coil of 130 turns on each of the two limbs.

The greatest difference of potential between layers will be (1,150 x 2 x

34)/130 = 602 volts (rms value) which is permissible if ample insulation is
provided between layers. It is usual to limit the potential difference between
layers to about 200 to 300 volts which can generally be accomplished without
difficulty by subdividing the winding into a sufficient number of separate coils
and providing adequate insulation between the coils.

Items 16 to 23. (The student should review Art. 131, which treats of
insulation problems; but the formula there given for clearances in oil has
reference to apparatus for considerably higher pressure than the transformer

1
with which this problem is concerned.) With the core dimension 4 x 5 in., the
2

1 9
winding former would be about 4 by 5 in, with slightly rounded corners. As
2 16

1
a check on the space D = 5 in. Provided for the windings (Fig.172) the total
2
thickness of copper and insulation is computed as follows:

Material Radial thickness, in.

Cotton tape binding assembled laminations 0.03

Varnished cambric 0.017

Pressboard 0.05
 Clearance 0.113

t = 0.21

Inner L.T. coil (one layer) including cotton on 0.317

wire

Parchment paper (0.010) between coils; allow 0.025

Outer L.T. coil (one layer) 0.317

s = 0.66

Pressboard around outer L.T. coil 0.034

Spacers of treated wood to form oil ducts* 0.212

Pressboard 0.034

Two layers cotton tape 0.03

Parchment paper with crimped edges on 0.009

which primary coil will be wound

g = 0.318

Nine layers of No. 10 dcc round wire 1.604

Two thickness of 0.005 paper between layers 0.139

Cotton tape, half lapped 0.031

1 0.113
Allowance for bulging+ (0.02 x 3 )
4

p = 1.347

Total………………………………………………………………2.535
1
* For proper circulation of oil, these spacers should be thicker than ; but in small transformer, there will
3
be no danger of high internal temperatures and the insulation is more than sufficient. It would be quite
permissible to omit the oil channels nd simply provide solid insulation of a total thickness as given in Art.
130. In large transformers, and even in small transformers for the higher voltages, the oil duct should be

3 1
at least in and preferably in.; the total thickness of insulation (including oil ducts between high-
16 4
tension and low-tension windings being calculated by formula (132) on page 347.
+ The allowance for bulging is here assumed to be equal to 2% of the core thickness. With cores of
cruciform cross section, the coils are circular, and no allowance for bulging is required.

The space available to accommodate this total thickness of copper and

1
insulation is 5 / 2 = 2.75, so that the space provided as shown in sketch (Fig.
2
172) would seem to be sufficient to allow of a small clearance between the
windings on the two limbs for insulation and oil circulation.

Calculation of Copper Losses. In these calculations we may neglect the

magnetizing component of the total primary current, as this adds very little to
the I2R loss in the primary at full load.

Referring to Fig. 173, the mean length per turn (m.l.t.) of the windings,
as designed, is computed as follows:

2 ( 4+5.5 ) + π (0.25+ 0.66)

Secondary m.l.t. = = 1.82 ft.
12

2 ( 4+5.5 ) + π (0.25+ 1.2+1.347)

Primary m.l.t = = 2.32 ft.
12

The total lengths of wire are:

Secondary winding length = 26 x 1.82 = 48 ft.

Primary winding length = 260 x 2.32 = 604 ft.

The weight of copper is:

In the secondary coils, 0.32(1.19 x 0.28 x 48 x 12) = 61.42 lb.

In the primary coils, (No. 3), 159.3 x 0.604 = 96.22 lb.

Since the resistance per 1,000 ft. of No. 3 wire at 60°C is 0.1816 ohms
(Table I, page 431), at 75°C, it will be

234.5+75
0.1816( ) = 0.19 ohms
234.5+60

The total resistance of the high-voltage winding (hot) is therefore 0.19 x

0.604= 0.12 ohms
 IR = 54.35 x 0.12 = 6.52 volts (i.e., 0.28%) and I2R = 355 watts.

The cross section of the low-tension winding is 0.339 sq. in., as against
0.04133 for the high-tension wire. Therefore, the resistance (hot) of all low-
tension coils in series is

0.04133 48
0.19( )x( ) = 0.0011 ohms
0.339 1000

IR = 543.48 x 0.0011 = 0.6 volts (i.e., 0.26 per cent), and I2R = 325
watts. The total copper loss is 355+325 = 680 watts, which is slightly less than
the guaranteed copper loss as calculated from the specified efficiencies.

Items 24 to 32. The core dimension as given in Fig. 171 are suitable
and may be adapted. The total full-load losses (item 32) are 484+680 = 1,164
watts.

Item 33 (Refer to Art. 140) by formula (141) the efficiencies at unity

power factor are:

680+ 484
At full load, 1 - = 0.99077
125,000+ 1,164

680+121
At half load, 1- = 0.9896
62,500+801

The calculated values for other loads are:

At 25 per cent overload = 0.9902

At three-quarter full load = 0.9908

At one-quarter full load = 0.9834

The maximum efficiency occurs when the total copper losses are equal to the

Core loss
core loss, under which condition the fraction of rated load is
√ F . L . copper loss
.

Thus, at the point of maximum efficiency the load is 125,000 √ 484 /680 =
105.46 kva, and the maximum efficiency is
 484 +484
1- = 0.9909
105,458+ 968

Item 34. On the basis of 4-hr full load and 20-hr no load, the all-day
efficiency, as defined in Article 140, is

125,000 x 4
= 0.972
( 125,000 x 4 )+ ( 484 x 24 ) +(680 x 4 )

Item 35. (Refer to Art. 135.) The magnetizing component Io of the total
exciting current is calculated by making use of the BH curve (Fig.161) and
estimating the approximate mean lengths of the flux paths wherein the flux
density is approximately of constant value throughout the length of path
considered (refer to Fig. 171.). Thus, for the two limbs under the windings, we
have B” = 75,000; mean length = 33 in.; whence (TI) = 33 x 6.5 = 214.5

For the two ends of the (outside the winding) B” = 55,000; mean length
= 30 in., whence the (TI) = 30 x 2.5 = 75

In order to estimate the ampere-turns required for the four joints in the
core as shown in Fig. 171, we refer to fig. 16.2

For the two joints with core density B” = 75,000 we have (TI) = 2 x 35 =
70 and, for the two joints with core density B” = 55,000 we have (TI) = 2 x 8 =
16, making a total of 375.7 amp-turns. The magnetizing components of the
primary current is, therefore,

375.7
Io = = 1.0218 amp
260 x √ 2

The “energy” components are Iw = 484/2,300 = 0.210 amp and the total
exciting current components is √ (1.0218)2 +¿ ¿ = 1.043 amp

Items 36 to 39: Regulation. The percentage IR drop in the two windings

is the same as the total copper loss expressed as a percentage of the kilovolt-
ampere output. Whence per cent IR drop = (680 x 100)/125,000 = 0.544,
which checks with the resistance drops previously calculated. Note that this
quantity is also given by the expression (IpR / Ep) x 100, where Ip is the primary
current (54.35 amps), Ep is the primary pressure (2,300 volts), and R is the
equivalent resistance of the two winding as given by formula (136) of Article
139.

The numerical values of the quantities in formula (135) required for the
calculation of the IX drop are as follows: f = 60, Ts = 26, Is= 543.48 Es= 230;
n = 2.
The length l may be taken as 12 x [(1.82+2.32)/2] = 24.84 in., where
the numbers 1.82 and 2.32 are the mean lengths per turns of low and high-
tension windings. Respectively the remaining dimensions are taken from

1
Fig.172, where h = H = 19 , g = 0.318, p = 1.347, and s = 0.66.
4

The calculated IX drop is 1.22%, which is equivalent to reactive drop of

2,300 x 0.0122 = 28.06 volts in the primary winding. This would be the length
of the vector marked (I1x) in Fig. 166, which is used for determining the
voltage regulation.

For calculating items 38 to 39, we may use the approximate formula

(140); whence the regulation on unity power factor is the same as the
percentage IR drop, namely 0.544%. On 80 per cent power factor we have
(0.544 x 0.8) + (1.22 x 0.6) =1.17% (nearly).

Items 40 to 42. The temperature rise of the windings as measured by

the resistance method must not exceed the specified 55°C. The permissible
temperature rise of the oil near the top of tank (Where it is hottest) must be
something less than this. The student is referred to Article 66 and the
illustrative example of article 144, where the manner in which the difference of
temperature between the coil where the heat is generated and the oil on the
outside of the insulation is explained. We shall here assume that if the
temperature rise of the oil does not exceed 50°C. The temperature at the
hottest part will not be excessive. In Article 141 the cooling coefficient for self-
cooling transformers was given as c = 0.0057 watts per sq.in. per °C rise of
the temperature the total outside area of tanks surface should, therefore, not
be less than
 1,164
S= = 4,084.21 sq. in.
50 x 0.0057

The case to accommodate this transformer may be generally of the

type illustrated in Fig. 167; the minimum dimensions would be about 31 by 28
by 40 in. high, and the effective cooling surface, computed as explained in

1
Article 141 is 40(62+56) + (31x 28) = 5,154 sq. in.; whence the maximum
2

1,164
temperature rise of the oil is t = = 55°C.
0.0041 x 5,154