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Design of Electrical Machines

Professor Akhtar Hussain

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Design of Electrical Machines

Course No. EE 4210

Credit Hours 3+1

Teacher:
Akhtar Hussain
Assistant Professor
Electrical Engineering Department
College of Engineering & Emerging Technologies
University of the Punjab, Lahore

Professor Akhtar Hussain

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Course contents

Professor Akhtar Hussain

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Teaching Schedule
Design of Electrical Machines

Week Topics to be covered CLO PLO

1 Magnetic materials, si steel 1 1
2 grain oriented, hot rolled, cold rolled, B-H curves 1 1
3 Copper/aluminium wires, round /rectangular conductors 1 1
4 Enameled, d.c.c., paper insulation, swg tables 1 1
5 Details of 3-phase transformer, Calculation of area of iron of 2 1
transformer
6 Et , turns of LV, HV 2 1
7 Dmt, Lmt of HV/LV, copper losses, iron losses, % impedance 2 1
8 Tank, tubes, conservator, efficiency, voltage drop 2 1
calculations, cost of transformer
9 Mid Term Exam
10 Theory and performance of 3-phase induction motor 3 2
11 Design of slots, windings of stator 3 2
12 Design of rotor bars, rings, rotor core 3 2
13 Calculation of slip, efficiency, cost of ind. motor 3 2
14 Over current, ov/uv breakers, magnetic contactors 4 2
15 ELCB, magnetic relay 4 2
16 Equipment used in electrical system 4 3

17 Final Term Exam

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Topic Page
Teaching schedule
Materials used in Electrical Machines
Magnetic materials and their properties
Applications of magnetic materials
Insulating materials and their properties
Dielectric strength of different insulating materials
Insulation classes and their temperature range

Part- I Design of Transformer

Core construction
Core type, shell type transformer
Core shapes
Core sections
Relation between core area and circumscribing dia
Relation between KVA rating and K (constant)
Range of flux density for different core materials
Types of transformer winding
Leads, terminals and bushings
Cooling Classes for transformers
Types of tanks
Transformer oil and its properties
Transformer winding connections
Vector groups of transformer

Design specifications
Design calculations
No. of turns of low voltage and high voltage winding
Core area and circumscribing circle dia
Design of LV
Design of HV
Dmt (mean dia), and Lmt (mean length of turn) of windings
Percentage reactance of winding

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Percentage resistance of windings

Percentage impedance of windings
Copper losses
Design of yoke and iron losses
Magnetizing current
Weight of Copper
Weight of iron
Efficiency of transformer
Variation of efficiency with power factor
Variation of efficiency with load
Voltage regulation
Variation of voltage regulation with power factor
Design of tank, tubes and conservator
Oil temperature and winding temperature
Cost estimate

Part 2, Design of induction Motor

Design specifications
D,L
Design of stator
Arrangement of conductors in the slot
Slot dimensions
Stator resistance and looses
Depth pf stator core
Length of flux path in stator core
Design of rotor
Current in rotor bars
Rotor resistance and losses
Losses in rings
Rotor resistance referred to the stator
Rotor tooth design
Design of rotor core

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Length of flux path in rotor core

Effective thickness of air gap
Total Amp. Turns
Magnetizing current
Core losses
No load current
Reactances of motor
Short circuit current
Efficiency
Slip
Max. output
Starting torque

Data Sheets
SWG table for round copper conductors
SWG table for round aluminum conductors
Data of rectangular conductors
B-H curves
Iron loss curves
m and c for temperature calculation
Carter Coefficient

https://www.youtube.com/watch?v=unQr9SN2mUM

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Materials used in the manufacture of Electrical Machines

Following materials are used in the manufacture of electrical machines
Magnetic materials
Electrical materials
Insulating materials
Cooling materials
A detailed description of these materials is given below

Magnetic materials
(a). Soft magnetic materials

Fig.1 B—H curve

These have following properties
If current is passed through a coil put on such material, it will gain magnetic energy. After removal
of current, most of the magnetic energy is lost. These materials have low coercive force and are
used for the cores of transformers, armatures and electromagnets of DC machines.

(b). Hard Magnetic materials

These have following properties If current is passed

through a coil put on such material, it will gain magnetic
energy. After removal of current, most of the magnetic
energy is retained by them. These materials have large
coercive force and are used for permanent magnets
used in telephones, relays, bells, small dynamos and
magnetic chucks Figure - 2
of lathe machines. Other examples are, oldest
permanent magnet known as load stones (Fe3O4 ), hardened carbon steel containing carbon from
1—1.5 %, tungsten steel containing 0.5—1 & carbon and 5—6 % tungsten.
Soft irons are further classified into following categories

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1. Pure iron
It has 0.1 % carbon. It is not possible to pure iron in practice. The flux density of pure iron
is 2.1 web/m2 at saturation point.
2. Silicon Steel
It is made of pig iron by melting and rolling into sheets. The thickness of sheets are
generally 0.006--.014 inch. Their quality depends upon percentage of silicon,
(i). 0.2 % Si Lhoy
(ii). 4 % Si Stalloy
(iii), 5.5 % Al, 9.5 % Si, 85 % Fe Sendust
Their flux density varies from 1.3—1.7 web/m2 in the normal operating range.
3. Ni-Iron alloy
It has following types
(i) Permalloy used in telephones
(ii) Permanerm used in radar equipment
(iii) Supermalloy used in electrical machines
4. Sintered Oxides
It is a mixture of two alloys which are melted are mixed—Fe3O4 and Fe2O4 . It is used in
high frequency applications

Material Application
Dynamo magnet DC dynamos, DC motors
Lhoy Small machines
Superhyperm DC electromagnets
Stalloy Transformers
Crystalloy It is 3—5 % Si, grain oriented, used in high quality low loss transformers
Supermalloy Wide band frequency transformers, magnetic shielding chokes
RHO metal Used in polarized relays
Permalloy High frequency transformer used in radio

Electrical Materials
Good conductors (not super conductors) of electricity having low resistivity, and 99 % purity are
used, so as to have minimum losses. Gold is used for high quality and costly devices such as
mobiles and digital watches. But for general purpose and large scale machines, either copper or
aluminum is used. Nowadays, due to high prices of copper, people have started using aluminum.
Although the conductivity of aluminum is 60 % as compared to copper, yet its weight and cost is
much lower. The conductivity of aluminum can be balanced by increasing the area of the
conductor. The current density of 2—4 amp/mm2 is used for copper conductor

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Insulating Materials
These are used to insulate the electrical parts from each other or from magnetic parts. Following
materials are usually used for this purpose
1. Paper
2. Hydrocarbon oils
3. Chlorinated hydrocarbons Silicon Varnishes
4. Ceramics
5. Mica
6. Glass
Qualities of insulating materials
The insulating materials must have following electrical, mechanical and chemical properties
(i) Electrical properties
(a) Loss angle
There is an analogy between insulator and capacitor. In pure capacitor, the current
in pure capacitor leads the voltage by 900 . But usually, this angle falls short by some
degrees known as loss angle. It should be as small as possible.
(b) Resistivity
It is the resistance between opposite faces of a unit cube of insulation. It is measured
in ohm/cm3 . It should be as high as possible.
© Dielectric strength
It is the voltage at which the insulating material destroys. It is measured in KV/cm.
For air it is 30 KV/cm (rms)
(ii) Mechanical Properties
The insulating material should be tested for tensile, compression, impact and shear qualities. It
should have machineability and ability to be formed into rods and sheets.
(iii) Chemical properties
It should be tested for temperature, combustibility, water absorption, resistance to different
solvents, corrosion, atmospheric tolerance.
Selection of insulating material
Following things should be kept in mind while selecting an insulating material
(i) Cost
(ii) Availability

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(iii) Form/shape
(iv) Size/weight
(v) Stability (long life)

Following is a table showing different parameters of insulators

Material K Dielectric Resistivity Applications

(dielectric strength Ohm/cm3
constant) KV/cm
Paper 2—2.6 40--60 1014 Between layers, coils, and formers of
transformer
Oils 2.2--3 10--20 1010 Impregnating paper, oil ckt breakers
Rubber 2—3.5 15--30 108 Conductor insulation for lift, welding,
house and industrial wiring
Plastic 4.5---5.5 50--70 2x 104 Wide use
Ceramic 5.7—6.8 Very high 7x 103 Pole insulators, transformer bushing,
heaters, furnaces etc
Glass 5,4—9.9 80—150 6x103 Glass tape, x-ray tube ,glass sleeves
etc
2.5—6.6 50--250 8x103 Heater base, commutator segments
Mica
Fibers and 2.5--5 Varies 3x103 Tapings, conductor insulation(DCC)
textiles largely

Insulation Classes

Class Temperature Materials

OC

O 900 Cotton, silk, paper, similar materials when neither impregnated nor
immersed in oil
A 1050 Cotton, silk, paper impregnated or immersed in oil, molded and
laminated material with cellulose filler, phenolic resin, film and
sheets of cellulose acetate, other derivatives of acetate, organic
variables (enamels)
B 1300 Mica, asbestos, fiber glass, etc
H 1800 Mica, asbestos, fiber, glass, etc
C 1800 Mica, glass, porcelain

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Construction of core of transformer

(i) Core type transformer

The flux path does not divide—only one loop

Figure - 3

(ii) Shell type transformer

The flux of a coil is divided into two paths

(iii) EI section (single phase shell type) Figure - 4

Figure-6

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(iv) Three phase core type

Figure-7
Stepped Core Sections

(i) Single step core (ii) Two step core (iii) Three step core
section section section

K= 0.4 K= 0.56 K= 0.6

Figure - 8 Figure - 9 Figure - 10

Front view of the core section of a 3-phase core type transformer

Figure - 11

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Types of Windings of 3-phase transformer

(i) Cylindrical Helix winding

Figure 12

(ii) Sectionalized winding

In case of high voltage winding, the total turns are divided into a certain
No. of packets to improve insulating capacity.

Figure 13

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(iii) Sandwich winding

Both, the high voltage and low voltage windings are divided into certain no. of
packets. Go on placing these packets one upon the other, starting with LV packet
from the top, then HV packet and continue placing upon the limbs alternately one
LV packet, then one HV packet.

Figure- 14

(iv) Disc winding

Oil ducts
These are used to provide
space or distance between the winding layers or sections to allow the cooling oil to
reach the hot area of the windings, so as to provide cooling and insulation. These are
made of Bakelite or ebonite and placed either axially or horizontally. These are
required in transformers of more than 100 KVA.

Leads and terminals

For big 3-phase transformers, the transformer assembly is placed in a tank which is
filled with oil. No hole or vent is provided on the tank. But holes are provided at the
top of the tank which are completely covered with water proof insulators known as
bushings, so that no moisture can enter the tank. Bushings are made of porcelain.
These are either hollow from inside or filled with oil for big transformers. The
terminals of windings are taken out through the inner holes of the bushings to be
connected with the outside power and load lines

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Transformer oil and its properties

Mineral/synthetic transformer oi is used which is meant for higher temperature. It
is diphenyl chloride. It should be free from moisture, should have flash point more
than 1600 C and fire point 2000C . Flash point is the temperature at which the oil
starts burning at the surface, and at fire point, the whole body of oil catches fire.

Transformer Winding connections

3-phase transformer may possibly has following connections on HV and LV side.
HV side LV side
Delta Delta
Delta Star
Star Star
Star Delta

In addition to these, there are other special connection. Moreover, the above connections
may , further, be grouped into 12 different configurations known as transformer groups,
explained as following.

Transformer Cooling Classes

Following types of cooling is used in the transformer, depending upon the heat taken away to
maintain safe temperature.

Cooling Description
class
AN Natural air cooling
ON Natural oil cooling
OW Oil cooling inside the tank and water cooling outside the tank
OB Oil cooling inside the tank and air blast cooling with fans or blowers outside the
tank
AB Natural air cooling with air blast outside
OFN Oil cooling inside the tank , the oil being circulated with a pump
OFB Oil circulation inside the tank, the hot oil taken outside and cooled with an air
compressor
OFW Oil circulation inside the tank, the hot oil taken outside and cooled with water in
another tank
OFWF Oil circulation inside the tank, the hot oil taken outside and cooled with water
pump in another tank

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Types of tanks
Following types of tanks are used in oil cooled transformers
(i) Tank with plain walls
These tanks are used for small transformers less than 25 KVA. No tubes or special
arrangements are used.
(ii) Tank with fins
These tanks are used for 25—50 KVA transformers. Nowadays this method is not
much used because of manufacturing complications
(iii) Tank with corrugations
It is used for 25---50 KVA, but has become obsolete because of manufacturing
complications.
(iv) Tank with tubes at the outer surface
This method is almost universal nowadays. It provides better cooling as compared to
above types. The no. of tubes may be easily adjusted in one or more layers
depending upon the requirement.

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Design Specifications
Design of a 400 KVA, 3-phase, core type, oil immersed, distribution transformer
with Dy-11 connections
Primary=11000 V, secondary=440 V
Voltage adjustment by taps in 4 steps= +/- 2.5 %
Percentage impedance=4 %
Max. oil temperature=600C
Max. copper temp.=650C Ambient temp.= 400C
Video of core cutting and transformer assembly, following link
https://youtu.be/unQr9SN2mUM

Transformer Rating
Transformer rating is expressed in KVA
KVA=V1I1/1000=V2I2/1000
The induced EMF is given by
E=4.44*f*N* ϕ
E/N=Et =Volt/turn=4.44*f* ϕ
V1N1=V1/N1*N1*I1=Et*N1*I1=4.44*f* ϕ *N1*I1
N1I1=Electrical loading
ϕ =Magnetic loading
There is a fixed ratio between electric and magnetic loading
Let Magnetic loading/Electric loading=r
ϕ /N1I1=r
KVA=4.44*f*O*N1I1*1000-3 =Q
ϕ = Q*r*1000/(4.44*f)
Et=4.44*f* ϕ =4.44*f* r*Q*1000/(4.44*f)= 4.44*f*r*1000 * Q
But 4.44*f*r*1000=constant=K hence
Et = K √ Q

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The value of K for different configuration is as under

Transformer 3-phase shell 3-phase core 3-phase Single phase Single phase
Type type type distribution shell core
distribution distribution
K 1.3 0.6—0.7 0.45 1—1.2 0.75—0.85

Tapings can be provided on LV or HV, better to provide them on HV because

HV has large No. of turns with low current.
Design calculations are performed for one phase only, because all three phase are identical.

No. of turns
Et =K √ Q K=0.45 from the table
Et =0.45 √400=9
Primary is delta connected, for which Vp=VL =11000 V
N1 =1000/9=1223, with 5 % taps=1285
Secondary is Y-connected, for which VP=VL/1.732=440/1.732=254 V

N2
=254/9=28

Figure 15

Core Area =Ai

Et =4.44*f* ϕ =4.44*f*B*Ai
The range of B=1.1----1.5 web/m2 (for hot rolled grain oriented silicon Steel)
=1.3----1.7 web/m2 (for cold rolled grain oriented silicon Steel)
Let us take B=1.5
Ai =9/(4.44*f*50*1.5)=0.027 m2 =270 cm2 (Area of pure iron)
Core lamination are coated with insulation, hence
Actual core area=270/0.9=300 cm2
For large transformers, multi step core is used, for which,
Ai =Kd2, where d=dia of circumscribing circle, for which the table is

Core type Square 2-step 3-step 4-step Circular

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K 0.4 0.56 0.6 0.62 0.75

Let us select a 3-step core, for which K=0.6

d= √ 300/0.6=22.5 cm

LV winding design
KVA=400 , VA=400000=1.732VLIL
IL =400000/(1.732*440) IL =525A

Range for 𝛿 (Current density)

for natural cooling = 2—4 amp/mm2

for special cooling = =4—6 amp/mm2

K= 0.6
Let 𝛿 = 3 amp/mm2 Figure- 15
Area of LV conductor=525/3=175 mm2
Such big conductor is not available in round shape; it is
available in rectangular shape.

From the data sheet, any value of “a” can be combined

with any other value of “b” to make up the total area.
Moreover, one set of a, b may not be sufficient.
Therefore, a No. of sets of a, b are used. The corners of
rectangular conductors are usually rounded. Using
rounding factor,
Actual area required= 175/0.9=184 mm2 Figure - 16
Let us select two conductors of 4,7 and four conductors
of 8,4 mm
These six conductors will behave as one big rope of conductor

Figure 17: LV Conductor Rope

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Figure - 17

Figure - 18

On rectangular conductors, there is a paper layer of 0.3 mm thick,

Height of conductor rope with paper insulation=(7+8+8)+3*0.6=24.8 mm
Width =4+4+2*0.6=9.2 mm
Total 28 LV conductors are not arranged in one layer, because this will increase the height of the
winding. Let us select two layers, 14 conductors per layer. But due to spiral effect, 14+1=15
conductors in each layer. Again, the conductors can be arranged in following two fashions,
selecting (ii) fashion

Height of LV winding=15*24.8=372.6 mm=37.2 cm

Taking 1% mechanical allowance, height=37.2*1.01=37.7 c=38 ≈cm
1 cm at the top and 1 cm at the bottom, total height=38+1+1=40 cm
Height of the limb=40 cm

Professor Akhtar Hussain

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Figure - 19

HV winding design
N1 =1285 IL =400000/(1.732*11000)=21 A
Iphase =21/1.732=12.12 A
Taking 𝛿=3.73, area of conductor=12.12/3.73=3.243 mm2 14 SWG copper
HV winding is done in sections, such that max. v/section=6000 V
Let us take 9 sections
Turns section=1287/9=143
Each section will have 143 turns, all of which cannot be done in one layer.
We have following two choices
(i) 11 layers, 13 conductors/layer
(ii) 13 layers, 11 conductors/layer
Selecting (i) to reduce the dia of winding, which may increase the impedance
Bare dia of 14 SWG conductor=2.03 mm
With enamel layer of 0.1 mm thick, dia=2.03+0.2=2.23 mm
Height of one packet=13*2.23=29 mm
Height of 9 packets=9*29=260.9 mm =26.1 cm
HV winding is done on ABS former, the
shape of which is shown below

Height of HV with former

insulation=26.1+9*0.6=31.5 cm
With 2 %
allowance=31.5*1.02=32.1cm≈33 cm
With two radial oil ducts each of 0.5
cm, height=33+1=34 cm
Figure-20
Height of limb=40 cm, a clearance of
3cm at top and 3 cm at bottom is
available. So the design is satisfactory.

Professor Akhtar Hussain

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Dmt (mean dia), Lmt (mean length of

turn)
Core dia (bare)=22.5 cm
With a paper insulation of 0.25 cm thick
around the limb, dia=22.5+0.5=23 cm

Figure - 21

Core dia with mech. allowance of 0.1

cm=23.1 cm
Thickness of one layer of LV=9.2 mm
Thickness of two layers=18.4 mm

Thickness of LV with
insulation=18.4+0.6=19 mm=1.9 cm
Outside dia of LV=23.1+2*1.9=26.9 cm
With one axial oil duct of 0.5 cm, Inside
dia of former of HV=26.9+1=27.9 cm
Thickness of HV former=0.3 cm
Outside dia of former of
HV=27.9+0.6=28.5 cm Figure -22
Thickness of HV=11*2.23=24.54 mm,
with 1% allowance=25.8 mm=2.58 cm
Outside dia of HV=28.5+2*2.58=33.66 cm
Dia with insulation of 0.1 cm=33.66+2*0.1=33.86 ≈34 cm
Mean dia of LV, dmt2=(26.9+23.1)/2=25 cm
Mean length of one turn=Lmt2 = 𝛑*dmt2=79 cm
Mean dia of HV, dmt1=(28.5+34)/2=31.7 cm
Lmt1= 𝛑*dmt1=97 cm

Percentage Reactance
It is given by
% X=2* 𝛑 µo *f *Lmt *AT*100 *(α+(b1+b2))/(Et *Lc) , where
µo=4* 𝛑 *10-7 , Lmt=(Lmt1+Lmt2)/2 =(79+97)/2=88 cm=0.88m
AT=Amp. turn=N1I1=N2I2=1285 *12.12=15574.2 Et=9
Lc =(height of LV +height of HV)/2=(38+34)/2=36 cm=0.36 m
α =(inside dia of HV +outside of LV)/2=(28.5+26.9)/2=27.7cm=0.277m
b1 =thickness of HV=2.58 cm=0.0258 m, b2=thickness of LV=1.9 cm= 0.019 m
putting these values in the %X formula, we get

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% X=3.83

Copper losses
LV
It is given by Copper losses =3 (I2)2r2, where r2= ρ l2/a2
-6
ρ for copper=2.1 * 10 ohm-cm, l2=Lmt2 * N2=79*28=2212

a2=area of LV conductor=1.79 cm2 , putting values in r2

-6 -3
r2=2.1 * 10 *2212/1.79=2.59 * 10 ohm
Copper losses for 3-phases=3 *(525)2 * 2.59 * 10-3=2145.8 W
With 7 % allowance (resistance changes with temp.)=215.8 *1.07=2296 W
HV
Similarly, copper losses for HV=3810 W
Total copper losses=2296+3810=6106 W
Percentage resistance
It is given by, % R=(R/Z) * 100=copper losses * 100/KVA=6.1/400 * 100=1.52 %

Percentage Impedance
% Z= √(%R)2+(%X)2= √(1.52)2+(3.83)2 =4.1% It is within the range

Iron losses
Iron losses depend upon weight of iron and flux density
Iron losses for limbs
Volume of limbs=3 * Ai *L=3*270*40=32400 cm3
Specific weight of iron=7.55gm/cm3
Weight of iron=32400*7.55=247 kg
From the graph on page 176 (M.G. Say book) , iron loss =1.6 W/kg (for B=1.5)
Iron loss for limbs=1.6*247=395 W
With 7 % allowance=395*1.07=422 W
Iron losses for yoke
Iron area of limbs may be increased to reduce iron losses. But it should not be increased,
because that will increase the weight of copper. Instead, iron area of yoke is usually increased
to 15—20 %.
Let it be 15 % greater than limb area

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Area of yoke=270*1.15=310 cm2

The cross-sectional view of yoke is as under

Figure-23

Figure-24

Outside dia of HV= 34 cm =D

Length of yoke=2D+0.9d +2=2*34+0.9*22.5+2=90 cm

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Volume of 2 yokes=2*90*310=55800 cm3

Weight of yokes=7.55*55800/1000=422 kg
Flux in limbs=flux in yokes=Ai*B=270*1.5/10000=0.0405 web
B in yokes= 0.0405/(310/10000) =1.31 web/m2
From the graph on page 176, Iron loss for B=1.31 1.2 W/kg
Iron loss in yoke=1.2*422=506 w
With 7 % allowance=1.07*506=542 W
Total iron loss in( limbs + yokes)= 542+422=964 w=0.964 KW
Total iron weight=247+422=669 kg

Magnetizing Current
This is the current to produce flux
Magnetizing current=magnetizing Amp. turns/turns
From the graph of magnetizing amp. turns against B,
Amp. turns=2000 At/m=20 At/cm for B=1.5
AT for limbs=3*40*20=2400
AT=4 At/cm for B=1.31
AT for yokes=2*90*4=720 Total AT=2400+720=3120 for 3-phases
=3120/3=1040 AT/phase
Imag (rms)=1040/(1285*1.41)=0.57 A
% Imag=0.57*100/12.12=4.5 % (it should not be more than 5 %)

Iron/copper weight ratio

Volume of windings=a*Lmt*turns
Total weight of both windings for 3-phases=3*(a1*Lmt1*T1+a2*Lmt2*T2)
=3*(0.0324*97*1285+1.75*79*28)=23728.5 gm
Specific weight of copper=8.9 gm/cm3
Weight of copper=8.9*23728.5/1000=211 kg
Weight of iron=669 kg
Weight of iron/weight of copper=669/211=3.17
This ratio should be 3—6. But nowadays copper has become more costly, therefore the ratio
should be higher.
Efficiency
The efficiency of transformer is very high, more than 90 %, because there are no moving parts
and no mech. Losses
At full load
Copper losses =6.1 KW Iron losses=0.964 KW KVA=400
Efficiency at full load and unity p.f.=400*100/(400+6.1+0.964)=98.4 %
KVA for max. efficiency= rated KVA *√ (iron loss/f.l. copper loss) =400* √ 0.964/6.1 =164.4 KVA
Other values of efficiency at full load and different p.f. are as under.
It should be noted that copper and iron losses don’t change with p.f.
P.f. Losses Output=KVA*(p.f.) Input Efficiency
0.1 6.37 KW 40 KW 46.37 KW 86.4 %

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0.2 6.37 80 KW 86.37 92.7

0.3 6.37 120 KW 126,37 95
0.4 6.37 160 KW 166.37 96.1
0.5 6.37 200 KW 206.37 96.8
0.6 6.37 240 KW 246.37 97.4
0.7 6.37 280 KW 286.37 97.8
0.8 6.37 320 KW 326.37 98
0.9 6.37 360 KW 366.37 98.1
1.0 6.37 400 KW 406.37 98.4

Percentage Voltage Regulation

The approximate formula for % regulation=% R*cos ϕ +% X*sin ϕ for lagging p.f.
==% R*cos ϕ -% X*sin ϕ for leading p.f.
% R=1.43 % X=3.83
Following is a table 0f % reg. at lagging p.f.
p.f. 1.0 0.9 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0
Sin ϕ 0 0.437 0.6 0.707 0.8 0.866 0.916 0.95 0.98 0.98 1
Cos ϕ 1 0.9 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0
R cos ϕ 1.43 1.287 1.14 1.001 0.85 0.76 0.57 0.42 0.286 0.14 0
X sin ϕ 0 1.67 2.3 2.79 3.06 3.32 3.51 3.65 3.75 3.8 3.8
% reg. 1,43 2.95 3.44 3.74 3.91 4.03 4.08 4.079 4.036 3.9 3.8

Tank Dimensions

There should be a clearance of at least 5 cm

on all sides between the transformer and
the tank, except at the top, where 30-50 cm
clearance is required.
Length of the transformer =90+D-
0.9d=90+34-0.9*22.5=104 cm
Length of tank=104+10=114 cm
Width of the transformer=34 cm
Width of the tank=34+10=44 cm
Area of yoke=310 cm2 =kd2 where k=0.6
from here d=24 cm
Height of transformer=40+0.9d+0.9d=83.2
cm
Height of tank=83+10+20=113 cm
Cooling of tank takes place from all four
walls
Surface area of tank for cooling=2* (114+44) Figure-25
*113=35708 cm2 =3.57 m2 =Stank
Ambient temp.=400C

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A temperature gradient of 100C is sufficient for heat transfer

Let us assume a temp. gradient of 150C
Actual surface area required for cooling is given by S=Stank*X
Where X is a multiplying factor which can be obtained from the following empirical formula
Total losses (copper +iron)=3.4*x* (8.8+3.7/x) *temp. of walls
Putting values, 6370=3.4*x* (8.8+3.7/x) * 55 x=3.68
Actual surface area required for cooling =3.68 * 3.57=13.13 m2
Excess area required=13.13-3.57=9.56
m2 to be obtained by using tubes on
the walls of the tank.
Area of tubes=9.56 m2 =at

Figure-26

Let mean length of tube=90 cm dia of tube=5 cm

Surface area of one tube= 𝛑 *d*l=1413 cm2=0.1413 m2
N0. Of tubes=9.56/0.1413=68 double layer will be provided on four walls of the tank
The tubes are placed sufficiently apart so that the distance between them should be at least
equal to the dia of the tube, so that the tank may not have excessive holes.
112/44=3/1 3+1=4 68/4=17 17 tubes widthwise and 51 tubes lengthwise
Conservator
It contains oil which can be fed back to the tank when required. It should contain 1/10
Of the oil in the tank.
Volume of tank=113*44*114=566808 cm3
Volume of tubes=( 𝛑/4*d2*Lt) *68= 𝛑/4*(5)2*90*68=120165.9 cm3
Volume of (tank +tubes)=566808+120165.9=686973.9 cm3
Volume of transformer= 34*72*100=247000 cm3
Volume of oil in the tank=686974-247000=439974
Volume of oil in the conservator=439974/10=43997
Volume of conservator should be 50 % greater than this
Volume of conservator=43977*1.5=659961 cm3
The conservator is in cylindrical form. Its volume is given by 𝛑/4(d)2L let d=40 cm then
L=48 cm. it is placed along the width , at the top of the tank

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Oil temperature rise

Empirical formula for m=12.5 *(tank +tube area in m2)*wall temp/(1.05* total losses)
=12.5*12.5*55/(1.05*6730)=1.27
Following is a table of m Vs average temp. rise
m 2.2 2.1 2 1.9 1.8 1.73 1.65 1.58 1.515 1.46 1.41 1.365 1.325
Av. 25 26 27 28 29 30 31 32 33 34 35 36 37
Temp
Rise

m 1.285 1.25 1.217 1.185 1.155 1.13 1.1 1.07 1.05 1.025 1 0.9 0.8
Av. 38 39 40 41 42 43 44 45 46 47 48 53 58
Temp
rise

From this table, av. Temp. rise=38.50C against m=1.27

But av. Temp.=0.85* max. temp
Max. temp.=38.5/0.85 =45.2 which is within the range of the spec.

Winding temperature
(i) HV winding
Surface area of HV winding (inner +outer)=3*2* 𝛑*34*34=22000 cm2
Watts/m2 =HV copper losses/surface area=3450/2.2=1570 =v
Temp=v/c where c is a constant, which can be obtained from the following table

Trans. Types of winding c

rating
Upto LV single layer 75
200 LV multilayer+ oil duct 55
KVA HV over a cylinder +radial duct 75
HV over a cylinder +axial duct 65

From LV single layer 75

200 to LV multi layer +oil duct 80
600KVA HV radial duct 65
HV axial duct 60
HV axial + radial duct 65

From the table, c=65

Temp.=c/v=1570/65=24.200C
Max. temp. for copper=650C (given) Ambient temp=40
Temp. rise=65-40=250C , in our design 24.20C , hence the design is safe for HV winding

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(ii) LV winding
Surface area=3*2*25* 𝛑*38=17900cm2 =1.79 m2 v=2250/1.79=1260
Temp.=v/c=1260/55=22.90C (safe design)

Insulation Class
Total temperature of transformer=(40+46+24.2)=110.2
From the table, we see that B class insulation is required

Vector Group of Transformer

When two 3-phase transformers are connected in parallel, their phase shift must be identical;
i.e they must have the same vector group. The question is, what a vector group is and how it is
determined. This experiment is designed to find the answers of these questions.
Three phase transformer consists of three sets of primary windings, one for each phase and three
sets of secondary windings wound on the same iron core. The primary and secondary windings
are connected in several ways. The two most common configurations are
(i). Delta: In which the polarity end of one winding is connected to non-
polarity end of the next.
(ii).Y or Star: In which all three non polarity (or Polarity) ends are connected
together.
The secondary windings are connected similarly. This means that a 3-phase transformer
can have its primary and secondary connections as under

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Primary Secondary
Star Star
Star Delta
Delta Delta
Delta Star

It is important to remember that secondary voltage waveforms are in phase with the
primary waveforms when the primary and secondary are connected the same way. This is called
“ no phase shift”. But when the primary and secondary are connected differently, the secondary
voltage waveforms will differ from the corresponding primary voltage waveforms by 30 0
electrical degrees. This is called a 300 phase shift. When two transformers are connected in
parallel, their phase shifts must be identical; if not so, a short circuit will occur when the
transformers are energized.
Winding connection designations:

• First symbol for high voltage, always capital letter.

D=Delta Y=Y or Star Z=Zig Zag N=Neutral
• Second symbol for low voltage, always small letter
D=delta y=y or star z=zig zag n=neutral
• Third symbol, phase displacement expressed as the clock hour number (0,1,2----
-----------11)
Example: Dy 11 : This transformer has a delta connected primary winding (D), a y-
connected secondary winding and a phase shift of 300 leading (11 O’ clock).
The 3-phase windings can be connected several ways. Based on the winding’s
connections, the vector group is determined. The transformer vector group is indicated on the
name plate by the manufacturer. The vector group indicates the phase difference between the
primary and secondary sides, introduced due to that particular configuration of transformer
connections.
The vector group is very important before connecting transformers In parallel. If two
transformers of different vector groups are connected in parallel, then phase difference exists
between the secondary of the transformers and large circulating current flows between the
two transformers, which is detrimental.
Phase displacement between HV and LV windings:
The vector for the high voltage is taken as reference. Displacement of the vectors of
other windings from the reference vector , with anticlockwise rotation, is represented by the
use of clock hour figure. Although there are a large number of connections, hardly any power

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system adopts such a large variety of connections. Some of the commonly used connections
with phase displacement of 0,-300, -180 and 330 (clock –hour 0,1,6 and 11). The digits (0,1,11
etc) relate to the phase displacement between the Hv and LV windings using a clock face
notation. The phasor representing the HV winding is taken as reference and set at 12 o’clock.
Phase notation is always anti-clockwise. (International adopted).
Use the hour indicator as the indicating phase displacement angle. Because there are 12
hours on a clock, and a circle consists out of 3600 , each hour represents 300 . Thus 1=300,
2=600, 3=900, 6=1800, and 12=3600 . The minute hand is set at 12 o’clock and represents the
line to neutral voltage of the HV winding. This position is always the reference point.
Example

• Digit 0=00 The LV phasor is in phase with the HV phasor

• Digit 1=300 LV lags HV with 300 ,Because rotation is anti-clockwise
• Digit 11=3300 LV lags HV by 3300 or LV leads HV by 300
• Digit 5=1500 LV lags HV by 1500
• Digit 6=1800 LV lags HV by 1800

Some of the commonly used notations are as under

Clock Notation “0” (Phase shift 0)

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Clock Notation “1” (Phase shift 30)

Clock Notation “2” (Phase shift 60)

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Clock Notation “5” (Phase shift 150)

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Clock Notation “6” (Phase shift 180)

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Clock Notation “7” (Phase shift 210)

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Clock Notation “11” (Phase shift 330)

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B (Weber/meter2)

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B (Weber/meter2)
Data of Rectangular conductors

b (mm) 4 4.5 5 6 7 8 9 10 11 12

A 1.2— 1.6---2 2.2--- 3 3.5 4 4.5 5 5.5 6

(mm) 1.4 2.5

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Data sheet of Aluminum conductors

For current density of 2.5 A/mm2

SWG Dia (mm) Area (mm2 ) Current SWG Dia Area Current
1 7.62 45.6 71.8 23 0.61 0.291 0.459
2 7.01 38.599 60.46 24 0.559 0.2452 0.377
3 6.4 32.18 50.7 25 0.508 0.2027 0.3149
4 5.89 27.27 40.9 26 0.457 0.1641 0.251
5 5.38 22.77 35.9 27 0.417 0.1382 0.2
6 4.88 18.68 29.4 28 0.376 0.11 0.17
7 4.52 16.06 25.19 29 0.345 0.093 0.144
8 4.22 13.96 22.04 30 0.305 0.0799 0.125
9 3.86 11.71 18.43 31 0.295 0.0688 0.107
10 3.45 9.372 14.5 32 0.274 0.0591 0.0944
11 2.95 6.818 10.7 33 0.254 0.05067 0.0818
12 2.64 5.48 8.629 34 0.234 0.0428 0.0629
13 2.34 4.289 6.739 35 0.213 0.0357 0.0566
14 2.03 3.243 5.1 36 0.193 0.02927 0.044
15 1.83 2.627 4.094 37 0.172 0.02323 0.0377
16 1.63 2.076 3.21 38 0.152 0.01814 0.0314
17 1.42 1.589 2.519 39 132 0.01379 0.0188
18 1.22 1.168 1.889 40 0.121 0.01199 0.0188
19 1.02 0.8109 1.259 41 0.111 0.0096 0.0125
20 0.914 0.656 1 42 0.101 0.008 0.0125
21 0.813 0.518 0.818 43 0.091 0.0065 0.0125
22 0.711 0.397 0.629 44 0.081 0.0051 0.0062

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Professor Akhtar Hussain