NATIONAL UNIVERSITY

College of Engineering
ELECTRICAL ENGINEERING DEPARTMENT

DESIGN OF DISTRIBUTION TRANSFORMER

(Design 2)

A Design Report Submitted

In Partial Fulfillment of the Requirements
in
AC APPARATUS

Submitted by

Benjie R. Romano
BSEE
SN: 2019-101694

Submitted to

DR. ROGELIO B. ANIEZ, JR., PEE

PROFESSOR
PROGRAM CHAIR, EE DEPARTMENT

Date Submitted: FEBRUARY 5, 2021

Introduction

           
 PROBLEM
DESIGN NO. 2
DESIGN OF CURRENT TRANSFORMER FOR WATTHOUR METER
(pp 397 -403)
PROBLEM: Design a transformer to meet the following specifications:
Ratio: 150/5
Voltage of primary circuit: 4,800
Frequency = 60 Hz
External Burden: Volt-ampere = 4
Power Factor = 0.85
Possible limits of error over range from 10 to 100 per cent of rated current:
Phase angle = 25 minutes
Ratio = 0.5 per cent

Draw the Cross section through current transformer (Fig. 180, p 401)
 151. Illustrative Example. Design of Current Transformer for
Watthour Meter. The specification for this transformer is given at the top of
the design sheet shown on page 398. It is not possible to calculate the various
items in the order in which they are recorded on the design sheet, but so far
as possible this order will be followed in working out the numerical values.

Items 1 to 5. Within certain limits, a large number of turns in the

windings will tend to reduce the errors because the exciting current
component in the primary will be a small percentage of the total current. We
shell assume the total secondary ampere-turns to be 1,400.

Since I P = 200 and I S = 5, the number of turns are T P = 7 and T S = 280,

but a very slight change in the secondary turns may be made later to
compensate for ration error.

-----figure 179-----

Assuming a core-type transformer as shown in section (Fig.180), there

is no serious objection to winding both primary and secondary on both limbs
as in a distributing or power transformer. We shall, however, assume the
winding to consist of a single coil containing both primary and secondary
turns.

Items 6 to 8. A high current density in the secondary should be avoided

as it tends to increase the IR drop in the winding. This is apart from heating
effects, which are not likely to give trouble on normal loads but may be very
serious on momentary overloads such as occur in the case of short circuits on
the primary system.

Assuming current density of 1,100 and 1,400 amp per sq. in., in
secondary and primary, respectively, we have 5/1,100 = 0.00454 as the cross
section of the secondary wire. From the wire table on page 432, we select No.
13 square wire with a cross section of 0.00465 sq. in. The current density in
the secondary is, therefore, ∆ = 5/0.00465 = 1,075 amp per sq. in.

Before deciding upon the actual dimensions of the primary winding,

which will probably consist of a fairly heavy conductor of rectangular section, it
will be advisable to settle upon the approximate dimensions for the window or
opening to accommodate the windings.

Items 19 to 24. By formula (134) we have sf = 10 / (30 + 6.6) = 0.273,

but this should be reduced to at least 10 per cent because of the small size of
the transformer. We shall try sf = 0.24; whence, for an average current density
of about 1,200, we have for the area of the opening in the core, H × D = (2 ×
1,400) / (1,200 × 0.24) = 9.7 sq. in. If the length H of the window is made

1
equal to about twice the width D, we may try the dimensions H = 4 and D =
4

1
2 in. The width D may be altered later if necessary to accommodate the
4
coils

A rough estimate must be made of the core cross section in order that
the lengths of wire in the winding may be calculated. The total flux in the core
will depend upon the total voltage to be generated in the secondary and not
only the amount of external burden. We shall assume the total burden
(including secondary winding and connecting leads) to be 15 volt-amp which,
with secondary current of 5 amp, means that the flux in the core must develop
3 volts in the 280 turns of secondary winding. Thus,

3× 108
Φ= =4,000 maxwells
4.44 × 60× 280

Very low flux densities must be used in order to avoid exceeding the limits of
error as specified. If we use a good quality of silicon-steel, which is cheaper
material than nickel-steel, we may select a flux density as low as B’’ = 2,000

1 1
lines per sq. in. This leads to a core section about 1 by 1 in. which, with a
2 2
stacking factor of 0.89,, makes the cross section of iron equal to 1.5 × 1.5 ×
0.89 = 2 sq. in.

Items 8 to 14. For the primary winding we need a copper cross section
of about 200/1,400 = 0.143 sq. in. and, since we have to insulate for 6,000

1 1
volts, we shall assume a winding layer 3 in long, leaving in. at each end
4 2
between high-tension winding and core. Two strips in parallel, each of 0.44 by
0.16 in,. wound one on top of the other to make one layer seven turns will
probably satisfactory. The current density in primary is therefore 200/[2(0.44 ×
0.16)] = 1,420 amp per sq. in. For the secondary, the length of layer may be 3

3
in. There will be 7 layers of No. 13 square dcc wire with 0.005-in. paper
4
between layers.

As a check on width of window opening in order to calculate length of

wire, we have the total
Insulation on core, and clearance t = 0.125
Secondary coil consisting of 7 layers of wire with 0.005-in.
paper between layers, and a small allowance for s = 0.75
“bulging”
Insulation between primary and secondary, built up of
press- g = 0.15
board, varnished cambric, or flexible mica, and cotton
tape p = 0.45
0.15
(no oil ducts)
= 1.625
Primary coil, two layers of dcc copper strip 0.16 in. thick,
in.
with
allowance for bulging
Insulation, primary to core (same as g)
Total

5
With a window opening D = 1 in., there should be plenty of room to
8
accommodate the windings. The reason why this dimension is appreciably

1
less than the estimated 2 in. is that the windings are all on one limb instead
4
of on both limbs as in power transformers, and also that solid insulation has
been used and there are no ducts for oil circulation.

The mean length per turn of primary is 0.95 ft., and of the secondary,
0.76 ft. The weight of primary is 3.6 lb., and of secondary, 4.23 lb.
 Items 15 to 18. From the wire table on page 431, the resistance per
1,000 ft. of square No. 13 wire is found to be 1.846 ohms at 60°C. Whence
the secondary resistance at 75°C is 1.846 × 0.213 × [(235 + 75)/(235 + 60)] =
0.413 ohm, and the IR drop is 0.413 X 5 = 2.065 volts. Including connections
between transformer and instrument, this drop might be 2.2 volts. In order to
calculate the total burden (internal plus external), we have for the instrument
burden, IZ = 3.5/5 = 0.7 volt; IR = 0.7 × 0.85 = 0.595 volt, and IX = 0.7 ×
0.527 = 0.369 volt. If we assume the reactance of the secondary winding and
leads to be negligible, the total IR is 2.795 and the total IX is 0.369.

Tan θ = 369/2,795 = 0.132; whence (from trigonometric tables) cos θ =

0.991 and sin θ = 0.131. The total emf to be developed in the secondary
winding is 2.795/0.991 = 2.82 volts, and the total secondary burden is 2.82 ×
5 = 14.1 volt-amp.

1 5
Items 19 to 27. The corrected window dimensions are 4 by 1 in. The
4 8
total flux is Φ = (2.82 × 108/(4.44 × 60 × 280) = 3,780 maxwells; whence B" =
3,780/2 = 1,890 lines per sq. in. when the secondary current has its full rated
value of 5 amp.

1 5 3
The mean length of flux path in the core is 2(4 + 1 + 3) = 17 in.
4 8 4
The weight of iron is 17.75 × 2 × 0.28 = 10 lb.

Figure 180 shows a section through core and windings of the

transformer as designed.

Items 28 to 31. From Fig. 178 we read the ampere-turns per inch for
the iron (silicon-steel), about 0.35 for B" = 1,890, and 0.05 for B" 189. From
Fig.179 we read watts per pound = 0.0015 for B” = 1,890. It is practically
impossible to read the losses at one-tenth rated burden, from this curve, but
by assuming the iron loss to vary as B1.6, we have, for B” = 189, watts per

1 1.6
pound = 0.0015 × ( ) = 0.000037.
10
 In calculating the magnetizing current component, we shall make an
allowance for joints in the magnetic circuit because the reluctance of the

-----fig180-----

Joints is negligible at very low flux densities. Then, by formula (153), at full
load,

17.75× 0.35
Io = √ 2×7
=0.628 amp

and at one-tenth load, Io = 0.09 amp.

By formula (154), at full load,

10 × 0.0015
Io = 40 × 2.82
=0.213 amp

and at one-tenth load,

10 × 0.000037
Io = 40 × 0.282
=0.0525 amp

Item 32. By formula (151) the tangent of the phase angle with 100 per
rent rated current is

0.628× 0.991−0.213× 0.131

tan α = = 0.00298
40× 5

whence α = +10’.

Similarly, with one-tenth rated current, we have tan α = 0.0041 and α =

+14'.

These results are well within the specified limit of 20 min.

Item 33. If we leave the secondary winding unchanged with 280 turns,
the ratio with full-rated current, by formula (152), is

Ip 0.213 × 0.991+ 0.628× 0.131

= 40 + = 40 +0.059
Is 5

and with one-tenth rated current,

 Ip 0. 0525× 0.991+ 0.09 ×0.131
= 40 + = 40 +0.128
Is 0. 5

the maximum percentage ratio error being 100 × (0.128/40) = 0.32 which is
well within the specified limit of 0.5 per cent. If desired, this error can be
reduced by altering the number of secondary turns. Thus, if we remove one

9
turn of the secondary, the compensation for ratio error is 27 - 40= -0.143,
7
which makes the actual ratio at full load equal to 39.916 and at one-tenth
load, 39.985, the percentage errors being 0.21 and 0.037 respectively.

Since the calculated performance of this transformer is somewhat

better than that called for in the specification, it is possible that some saving of
material might be effected (1) by reducing the number of primary turns from 7
to 6 without decreasing the core section, or (2) by leaving the number of turns
unchanged and slightly decreasing the core section. The greatest saving in
weight would be obtained by using nickel-steel instead of silicon-steel for the
transformer core.

Effect of Overload on Temperature of Windings. A short. circuit may

cause the current through the primary windings of current transformers to be
from fifty to one hundred times the rated full-load value; and, unless the circuit
breakers interrupt, this current in a very short interval of time, the instrument
transformer may burn up. This is apart from possible mechanical injury which
will be considered in the following chapter.

In order to calculate the maximum length of time during which such a

condition may exist without damage from overheating, it is usual to neglect
the very small amount of heat which will be dissipated by surface radiation
and consider merely the thermal capacity of the coils.

Assuming that a temperature above 180°C would be injurious to the

insulation, and that the copper temperature is 75°C under normal operating
conditions with 200 amp in primary, the permissible rise of temperatures 180
-75 = 105°C.
 The primary copper loss when the current is 200 amp at a density of
1,420 amp per sq. in may be calculated by formula (131) in Art. 130. Thus, at
75°C, the loss in the primary coils is 3.6 × [2.57(1,420)2/106 ] = 18.6 watts. The
permissible watt-seconds per pound of copper are calculated as explained in
Art.64, and since 177 watts will raise the temperature of 1 lb. of copper 1°C in
1 sec, the permissible amount of heat which can be stored in the primary coil
before temperature becomes excessive is 177 × 3.6 × 105 = 66,800 watt-sec.

Suppose that, under short-circuit conditions, the current through

transformer primary may be fifty times normal, or 200 × 50 = 10,000 amp. The
rate at which energy in the form of heat is being stored in the copper will be
18.6 × (50)2 = 46,500 watts, and since 66,800/46,500 = 1.435 sec, this is the
maximum time during which the short-circuit current may pass through the coil
without damage to the transformer.

DRAWINGS

Fig. 179 Losses in transformer iron for low values of flux density.
Fig. 168. Porcelain Bushings for transformer leads

VECTOR DIAGRAMS