HNC Operations Engineering Noel Jennings

Engineering Design Assignment

Deliverables

Design Specification

Design Report

Example of the use of computer-based technology in the design process

Introduction

My name is Noel Jennings. I am a design engineer who has had

experience in the petrochemical and commercial electrical installation
industries. I have decided to go through the process of provided design
specification, a design report and provide use of computer based
technology in the design of 3 phase power transformer. This would
simulate working for a client as a electrical design engineer focused on
the electrical power industries. It will incorporate some of the electrical
principles theory that I covered during my Btec ONC and HNC in
Operations Engineering.

Design Brief

A client from the power industries in American has contacted me wanting

a transformer designed and built in order to transfer a voltage at a set
rate of 380V to a set amount of 220V. Operating at a frequency of 50Hz
and a load current of 100A. The type of transformer that they are looking
for isn’t specified only the performance characteristics. It is taken that the
design should categories the use of the transformer as a general
purpose transformer as none other use is specified.
Design Specification

As most transformers in use in the power industries are 3 phase

construction it will be taken that this transformer from its specification will
be designed to be a 3 phase general transformer. A single phase
transformer can be designed using these characteristics however is it
isn’t as practical in terms of use of materials and construction method.

An example of a 3 phase general transformer as

designed for an installation in a unit substation. The
high voltage windings are insulated by the low
voltage windings above and to the outer air space in
relation to the core. This is then varnished to
provide good insulation to the windings as a whole
to prevent current loses.

Example of 3 phase that may need to be replaced in a power generator

for a nuclear power station. This was similar to a model that was
specified to be replaced recently.

Transformer Construction:
There are two general types of transformers
1. Core type transformer
2. Shell type transformer

These two differ by the manner in which the windings are wound around
the magnetic core. The magnetic core is a stack of thin silicon-steel
laminations about 0.35 mm thick for 50 Hz transformer. In order to
reduce the eddy current losses, these laminations are insulated from one
another by thin layers of varnish. In order to reduce the core losses,
transformers have their magnetic core made from cold-rolled grain-
oriented sheet steel (C.R.G.O). This material, when magnetized in the
rolling direction, has low core loss and high permeability.

Core Type Transformer:

(a) core-type Transformer

In the core-type, the windings surround a considerable part of steel

core as shown in fig (a). The core type transformers require more
conductor material and less iron when compared to shell-type. The
vertical portions of the core are usually called limbs or legs and the top
and bottom portions are called the yoke. For single phase transformers,
core-type has two legged core. In order to reduce leakage flux, half of
the L.V. winding is placed over one leg and other half over other leg. For
H.V. winding also, half of the winding is placed over one leg and the
other half over the other leg. L.V. winding is placed adjacent to the steel
core and H.V. winding outside, in order to minimize the amount of
insulation required.
Shell Type Transformer:

In the core-type, the steel core surrounds a considerable part of the

windings as shown in fig (b). Shell-type transformer has three legged
core. The L.V. and H.V. windings are wound on the central limb. In order
to reduce leakage flux, the windings are interleaved or sandwiched. The
shell type transformers require more iron and less conductor material
when compared to core-type.

There are two types of windings employed for transformers.

1. concentric coils.
2. Interleaved coils.
3.
The concentric coils are used for core-type transformers and interleaved
coils for shell-type transformers.

(b) Shell type transformer

TRANSFORMER SPECIFICATIONS

GENERAL DESIGN GUIDELINES

1. UK's recommendations on transformer design are listed below in

order of
preference.

1. Indoor transformer, cast coil, unit substation. 1st. choice

2. Indoor transformer, VPI (Epoxy Encapsulated) coil, unit
substation.
2nd. Choice

3. Pad mount indoors, less flammable liquid, switch. 3rd. choice

4. Pad mount outdoors, less flammable liquid, switch. 4th. choice
5. Pad mount outdoors, oil liquid, switch. 5th. Choice

2. Cast coil and VPI coil provided shall be unit substation type mounted
in line with
matching switchgear including high voltage load break switch and fuses
in a
transformer room.

1. Pad mount transformers installed outside of buildings shall be

liquid filled, concrete pad mounted and completely enclosed with
high voltage switching and fusing (removable oil fusing) and shall
be dead front type with bushing wells and inserts, not one piece
bushing. Transformers shall conform to the requirements of the
State Fire Marshall's office for distance from the building.

2. SPECIFICATIONS FOR ALL TRANSFORMERS

1. Built to ANSI Standard C57.12.00 - 1968. ANSI short circuit test

(Sample Unit)
data, ANSI impulse test - full and chopped wave (Sample Unit) data and
certified
test data (ANSI) (Actual Unit) shall be provided to the University.

2. Current limiting fuses shall protect all transformers.

KVA size as specified.

4. Primary voltage - 12,470 volts delta connected, 95 kV BIL.

5. Secondary voltage - 120/208 Y volts or 277/480 Y volts, 30 kV BIL.
The low
voltage neutral shall be brought out through a fully insulated bushing in
the
secondary compartment and grounded externally.
6. Three phases.

7. 60 Hertz frequency.

8. Temperature Rise above ambient shall not exceed 65 C.

9. 98% conductivity copper coil.

10. Two winding transformer - 3 coils.

11. +2 2-1/2% taps - external handle for de-energized operation.

12. Impedance - not less than 4% and not more than 7%.

13. Noise level - not to exceed NEMA Standard levels.

14. Shall be supplied with lightning arrestors on the high voltage side, if
not protected
by switch equipped with lightning arrestors.

15. Bolted connection will be acceptable only from lead to bushing. All
other
connections shall be welded or adequately crimped.
THE DESIGN PROCESS
Step-by-step transformer design procedure

The following quantities are specified, using the units noted:

Wire effective resistivity 􀀄(􀀁-cm)

Total rms winding current, ref to pri Itot (A)

Desired turns ratios n2/n1, n3/n1, etc.

Applied pri volt-sec 􀀃1 (V-sec)

Allowed total power dissipation Ptot (W)

Winding fill factor Ku

Core loss exponent 􀀂

Core loss coefficient Kfe (W/cm3T􀀂)

Other quantities and their dimensions:

Core cross-sectional area Ac (cm2)

Core window area WA (cm2)

Mean length per turn MLT (cm)

Magnetic path length l

e (cm)
Wire areas Aw1, … (cm2)

Peak ac flux density 􀀁B (T

Core or shell type construction?

Back ground of transformer

Core and shell type constructions and efficiency

Basic Transformer Components

3 phase transformer

Three-phase transformer with four

wire output for 208Y/120 volt
service: one wire for neutral, others
for A, B, and C phases.
Delta and Wye Connections
In a three-phase transformer, there is a three-legged iron core as
shown below. Each leg has a respective primary and secondary
winding.

-Phase Transformer Connections:

There are only 4 possible transformer combinations:

Delta to Delta - use: industrial applications

Delta to Wye - use : most common; commercial and industrial

Wye to Delta - use : high voltage transmissions

Wye to Wye - use : rare, don't use causes harmonics and balancing problems
Shell type transformer

It has a double magnetic circuit where the core has three limbs. Both the windings are
placed on the central limb. The core encircles most part of the windings. The coils used are
generally multi-layer disc type or sandwich coils. Each high voltage coil is in between two
low voltage coils. The low voltage coils are nearest top to bottom of the yokes. The core is
laminated where care is taken to ensure that all joints at alternate layers are staggered. This
is done to avoid a narrow air gap at the joint, right through the cross section of the core.
Generally for very high voltage transformers the shell type is preferred.

Design Considerations

Frequency

The transformer cannot change the frequency

of the supply. If the supply is 60 hertz, the
output will also be 60 hertz.
Impedance

The impedance (or resistance to current flow)

is important and used to calculate the
maximum short circuit current which is needed
for sizing, circuit breakers and fuses.
Impedance is expressed as a percent. This
percentage represents the amount of normal
rated primary voltage which must be applied to
the transformer to produce full rated load
current when the secondary winding is short
circuited. The maximum short circuit current
that can be obtained from the output of the
transformer is limited by the impedance of the
transformer and is determined by the
multiplying the reciprocal of the impedance
timed the full load current . Thus, if a
transformer has 5% impedance, the reciprocal
of .05 is 20 and maximum short circuit current
is 20 times the full load current.
Insulation System and Temperature
Rise
All Federal Pacific FH class transformers are
designed with 220 oC insulation systems. The
standard units are rated X0 oC rise. The
insulation system classification represents the
maximum temperature permitted in the hottest
spot in the winding when operated in a 40 oC
maximum ambient. The hotspot temperature is
determined by adding the maximum value for
each of the following:
40 oC maximum ambient
150 oC maximum average
winding rise
30 oC maximum hot spot in
winding
220 oC ultimate temperature at
hot spot
The temperature rise commonly associated
with transformers is the temperature of the
conductor inside the coil and does not apply to
the outside surface. The wiring compartment is
ventilated and cooled enough to permit the
use of 60 oC cable for connections. Some
customers will specify 220 oC insulation with
80 oC or 115 oC rise to get overloaded
capability, better efficiency, and longer life.
These transformers are designed to operate
with a lower rise per the following example at
80 oC rise
40 oC maximum ambient
80 oC maximum average winding
rise
30 oC maximum hot spot in
winding
30 oC thermal overload 30%
 220 oC ultimate temperature at
hot spot
There may be differences between the voltage
ratings of transformers and the rated voltage
of some utilization equipment. Some
equipment may be rated 230, 460, or 575 volts
to allow drop due to impedance of wire, circuit
breakers, ect. The respective transformer
secondary voltages would be rated 240, 480,
and 600 volts which are the system or source
voltage . If you are asked to quote on a
transfer rated 460V primary, 115/230V
secondary would be proper to quote a
transformer rated 480V primary, 120/240V
secondary
Basic Impulse Insulation Levels (BIL)

Outdoor electrical distribution systems are

subject to lightning surges. Even if the
lightning strikes the line some distance from
the transformer, voltage surges can travel
down the line and into the transformer. High
voltage switches and circuit breakers can also
create similar voltage surges when they are
opened and closed. Both types of surges have
steep wave fronts and can be very damaging
to electrical equipment . To minimize the
effects of these surges, the electrical system is
protected by lighting arresters but they do not
completely eliminate the surge from reaching
the transformer. The basic impulse level (BIL)
of the transformer measures its ability to
withstand these surges. All 600 volt and below
transformers are related 10 KV BIL. The 2400
and 4160 volt transformers are rated 25 KV
BIL.
Transformer Sound/Noise

A Humming is an inherent characteristic of

transformers due to the vibration caused by
alternating flux in the magnetic core. Sound
levels will vary according to transformers due
to the vibration caused by alternating flux in
the magnetic core. Sound levels will vary
according to transformer size.Attention to
installation methods can help reduce any
objectionable noise. When possible ,locate the
transformer in an area where the ambient
sound will be equal or greater than the noise
of the transformer sound level. Avoid locating
units in corners. Make connections with
flexible conduits and couplings to prevent
transmitting vibration to other equipment.
Larger units should be installed on flexible
mountings to isolate the transformer from the
building structure.
Sound Level In
Decibles
KVA
Nema ST-20
150 Degrees Celcius Rise K-
Average
1
0-9 40
10-50 45
51-150 850
151-300 55
301-500 60
501-700 62
701-1000 64
We know that the air is thinner at higher
altitudes which, in turn, reduces its ability to
cool the transformer. Therefore, standard dry-
type self cooled transformers are designed to
operate with normal temperature rise at
heights through 3300 feet above sea level. If
the operation is at higher altitudes, the rating
should be reduced 0.3% for each 330 feet
above 3300 feet.