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    Transformer Design

    Uploaded by

    Mahidhar Talapaneni
    The document describes designing a distribution transformer using MATLAB programming. It discusses transformer components, core design considerations including flux density and losses, winding design including materials and insulation, and calculations for parameters like EMF, core area, winding dimensions, resistance, and losses. MATLAB programs are presented to calculate dimensions of LV conductor and coils. The procedure involves calculations for HV coils, efficiency, impedance, and tank dimensions. The conclusion states that computer-aided design saves time over manual design and requires few customer inputs.

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    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd

    Transformer Design

    Uploaded by

    Mahidhar Talapaneni
    3K views42 pages
    The document describes designing a distribution transformer using MATLAB programming. It discusses transformer components, core design considerations including flux density and losses, winding design including materials and insulation, and calculations for parameters like EMF, core area, winding dimensions, resistance, and losses. MATLAB programs are presented to calculate dimensions of LV conductor and coils. The procedure involves calculations for HV coils, efficiency, impedance, and tank dimensions. The conclusion states that computer-aided design saves time over manual design and requires few customer inputs.

    Original Description:

    basic concept in design of transformers

    Original Title

    Transformer Design ppt

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    © © All Rights Reserved

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    The document describes designing a distribution transformer using MATLAB programming. It discusses transformer components, core design considerations including flux density and losses, winding design including materials and insulation, and calculations for parameters like EMF, core area, winding dimensions, resistance, and losses. MATLAB programs are presented to calculate dimensions of LV conductor and coils. The procedure involves calculations for HV coils, efficiency, impedance, and tank dimensions. The conclusion states that computer-aided design saves time over manual design and requires few customer inputs.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    3K views42 pages

    Transformer Design

    Uploaded by

    Mahidhar Talapaneni
    The document describes designing a distribution transformer using MATLAB programming. It discusses transformer components, core design considerations including flux density and losses, winding design including materials and insulation, and calculations for parameters like EMF, core area, winding dimensions, resistance, and losses. MATLAB programs are presented to calculate dimensions of LV conductor and coils. The procedure involves calculations for HV coils, efficiency, impedance, and tank dimensions. The conclusion states that computer-aided design saves time over manual design and requires few customer inputs.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    of 42
    At a glance
    Powered by AI
    The key takeaways are that computer aided design of transformers has advantages over manual design as it is error free, economical and saves time. The document discusses the various components, construction, design process and calculations involved in transformer design using MATLAB.

    The main components of a transformer discussed are the core, windings, insulating materials, insulating oil, tank, fittings and accessories.

    The choice of using copper or aluminum as winding material generally depends on the end-users and rating of the transformer. Copper is preferred for higher ratings due to some limitations in aluminum's properties, while aluminum is used for lower ratings due to its wide availability and lower cost.

    DESIGING OF DISTRIBUTION

    TRANSFORMER
    BY
    MATLAB PROGRAMMING

    ABSTRACT
    The concept of optimization and performance of three phase
    distribution transformer will be achieved by using the computer
    technology.
    The computer aided design eliminates the tedious and time
    consuming hand calculations thereby realizing the designers
    from numerical drudgery to enable the designer time to grapple
    with physical and logical ideas thereby accelerating the design
    process.
    In this project for designing of transformer we are using the
    MATLAB software because MATLAB is using everywhere in
    Electrical fields. MATLAB program facilitates us to make design
    simple and accurate. As our project requires lot of mathematical
    calculations

    we

    implementation.

    have

    chosen

    MATLAB

    for

    programming

    Transformer construction

    Core
    Windings
    Insulting materials
    Insulating oil
    Tank
    Fittings and accessories

    Core

    Different grades of CRGO core and their losses at different Flux densities
    Flux density
    (T)

    M3
    (W/kg)

    M4
    (W/Kg)

    23MOH
    (W/Kg)

    1.5

    0.70

    0.84

    0.67

    1.6

    0.85

    1.00

    0.77

    1.7

    1.09

    1.20

    0.92

    In our design we select the flux density from 1.5 T to 1.7 T (max),
    depending on the rated no load loss.

    Three phase core type and shell type construction

    Stepped core

    Window

    Core structure

    MS

    W/H = Window height


    W/W = window width
    C/L = Center limb distance
    MS = maximum step

    Winding materials
    Copper
    Aluminum

    Maximum
    Current density
    for Aluminum

    1.5 A/sq mm

    Current density
    for copper
    winding

    3.0 A/Sq mm

    Choice of using copper or aluminum as winding material generally


    depends upon the end-users. Most of our power utilities in India
    desire transformers up to 250 KVA/11 KV with aluminum windings,
    because of its wide availability and economy in cost. But owing to
    some limitation in its inherent properties, higher rating
    transformers are made with copper winding.

    Why we use Rectangular Strip for LV conductor ?

    10

    10 mm

    Area of LV conductor = 80 sq mm
    Diameter for round conductor = 10 mm

    10 mm

    8 mm

    Length for rectangular conductor = 10 mm


    Width for rectangular conductor = 8mm

    8 mm

    Reduced Winding space factor

    Why parallel conductor in LV ?


    10 mm
    8mm

    RL
    Surface length = 2x (10+8) = 36 mm

    10 mm
    4mm

    Surface length = 2 x 2 x (10+4) = 56 m


    4mm

    Skin effect is reduced as surface resistance is inc

    Windings Insulation
    Major insulation
    It is well known to the transformer designer that the main
    and most important insulation consists of the insulation between
    the high voltage coil and the low voltage coil in the same phase and
    from the LV coil to ground. In Medium and Low Voltage transformers,
    the insulation material used between High and low voltage coils are
    pressboard and cooling ducts, which are also used for cooling.
    Minor Insulation
    This category is normally for the insulation between the
    adjacent turns in a coil and between different sections in the same
    coil. Synthetic enamel covered and DPC wires are normally used in
    Medium and Low voltage transformers.
    A Pressboard represents a thick insulation paper made of
    extremely pure cellulose fiber, suitably treated at the wet stage of
    manufacturing process and then compacted at very high pressure.

    coi
    l

    Transformer insulation construction

    Limits for Winding clearances


    Clearance
    between

    Minimum
    (mm)

    Maximum
    (mm)

    Limb to LV coil (CLLV )

    2.5

    3.0

    LV coil to HV coil
    (CLVHV )

    11

    Limb to Limb (CLL )

    10

    Yoke to LV coil (CYLV )

    10

    Yoke to HV coil (CYHV


    )

    16

    25

    Spacer between HV
    coil

    10

    HV winding to Tank
    Side walls

    30

    LV Winding Assembly

    LV coil

    CYLV
    CLLV

    Front view
    Top view

    HV winding Assembly

    Spacer between HV coil to Coil

    CYHV

    Front view
    Top view

    CLVHV

    BASIC STRUCTURE OF DESIGN PROCEDURE


    START
    ENTER THE SPECIFICATIONS OF
    DTR WITH ALL NECESSARY
    LIMITATIONS
    PERFORM THE
    CALCULATION S
    IS THE
    CALCULATED
    RESULTS ARE
    MATCHED WITH
    SPECIFICATIONS
    YES
    PRINT THE REQUIRED OUTPUT
    DATA
    STOP

    MAKE NECESSARY
    CHANGES WITH IN
    LIMITS
    NO

    PROCEDURE FOR DESIGNING


    Step 1: start the design by calculating Et .
    Step 2: Calculate the core area and core diameter.
    Step 3: Calculate the LV winding details.
    Step 4: Calculate the HV winding details.
    Step 5: Calculate the dimensions of core.
    Step 6: Calculate the main dimensions of tank.

    FORMULAE FOR DESIGNING


    To calculate of EMF per turn (Et ):

    KVA

    Where
    KVA = Rating of the Transformer
    K is a constant and varies from
    0.31 0.39 for Aluminum winding transformer
    0.41 0.45 for copper winding transformer
    To calculate number of LV turns

    Where
    VLV = LV phase voltage
    Et = EMF per turn

    Calculation of gross core area (Ag ) and core diameter (Do ) :

    2.22 X

    X 100

    XCUF

    sqcm

    Where
    Bm = maximum flux density (1.5 T 1.7 T)
    CUF = core utilization factor (0.95 0.97)

    X4

    X K1

    X 10mm

    Where
    K1 = constant and depends on number of steps used in core.
    Number of steps varies from 6 14 depending on core diameter
    K1 varies from 0.92 0.96 with an increment of 0.005.

    LV coil Design
    Calculation of LV current :

    LV

    KVAX 1000

    A
    3 X V LV

    Where
    VLV = LV phase Voltage

    Calculation of Area of LV Conductor :

    ALV

    I
    CD

    LV

    Sqmm
    LV

    Design of LV conductor
    Selection of number of parallel conductors
    Step 1: Fix boundary area of each parallel conductor.
    (aepc)
    Step2: Calculate number of parallel conductors.(NPC)

    Step3: Round off to next integer


    NPC= Fix(npc)
    (for ex: 3.41 to 4)
    Step4: Calculate new area of each parallel conductor,

    Calculation of dimensions of conductor


    Step1: Specify maximum limit of conductor thickness.
    Setp2: Select starting range of Conductor length.
    Step4: By using conductor area calculate the actual
    dimensions of conductor.(LEC and WEC)

    Flow chart for calculation of dimensions of LV conductor


    AEPC
    Limits
    of
    wec=x
    lec= y
    WEC=AEPC/y
    Is
    WEC
    <x
    Yes
    LEC= y
    Display LEC
    & WEC

    No

    y=
    y+0.1

    MATLAB Program
    AEPC=40
    LEC=5;
    WEC=AEPC/LEC;
    while (WEC>3.25)
    LEC=LEC+0.1;
    WEC=AEPC/LEC;
    End;
    fprintf (Length of Lv conductor= %3.2f mm \n\n, LEC);
    fprintf (Width of Lv conductor= %3.2f mm \n\n, WEC);
    Out put
    length of Lv conductor=12.40 mm
    width of Lv conductor=3.23 mm

    Calculation of dimensions of LV coil


    Axial Height (HLV ):
    HLV = (TPL+1) x (nA x (LECI +0.1)) mm
    Inner diameter of LV coil(IDLV):
    IDLV = Do + 2 CLLV mm
    Outer diameter of LV coil (ODLV):
    ODLV = IDLV+ 2x ((2x nR x WECI) + Layer insulation) mm
    Mean diameter(MDLV):
    MDLV = (IDLV + ODLV )/2 mm
    Mean length of Conductor (MLc ):
    MLc = MDLV x 3.14 x NLV x 10-3 M
    Resistance (RLV ):
    RLV =( X MLc)/ ALV
    LV winding loss (PLV ):

    Ohms

    MATLAB program for LV coil Design


    NL=2;
    TLP=NLV/NL;
    %enter 1 for transposition and 0 for no transposition%
    TRANS=1;
    IDLV=DO+2*CLLV;
    if (TRANS==1)
    HLV=((TLP+2)*(LECI+0.1))*a;
    end;
    if (TRANS==0)
    HLV=(TLP+1)*a*(LECI+0.1);
    ODLV=IDLV+2*((2*b*WECI)+LI);
    MLV=mean([IDLV,ODLV]);
    %calculation of LV winding Resistance%
    if WM==1
    R=0.021;
    else R=0.034;
    end;
    RLV=(MLV*pi*0.001*TLP*2*R)/ALVN;

    Why HV coils Are more than One?


    1833.3 V

    Layer insulation

    11000 V

    1833.3 V
    1833.3 V
    1833.3 V
    1833.3 V
    1833.3 V
    Single coil per limb

    Six coils per limb

    Coil
    voltage

    Layer Voltage

    For
    Single
    coil

    11000 V

    42 x 3.5 x 2=
    294 V

    For six

    1833.3 V

    7 x 3.5 x 2 =

    Calculation of window height


    WH = HLV + 2 CYLV mm

    Calculation of HV coil details:


    Number of HV turns ( NHV ) :
    NHV = NLV x 44
    HV Current (IHV ):
    IHV = (KVA x 1000)/(3 x 11000)
    Area of HV conductor (AHV):
    AHV = IHV / CDHV
    where CDHV = Current density on HV side.
    HV conductor Diameter ( DHV ):

    DHV =

    HV

    X4

    mm

    Inner diameter of HV coil (IDHV ):


    IDHV = ODLV + 2x CLVHV mm
    Height of HV coil (HHV ):
    HHV = (WH-2CYHV -(n-1)SCC)/CPL

    Select number HV coils and should be even.


    Calculate turns per coil :
    TPC = N HV /Number of HV coils
    Calculate Turns per Layer (TPL):
    TPL =( H HV / (D HVI +0.05) ) -1
    Calculate number of layers (NL):
    NL = TPC/ TPL
    Outer diameter ( OD HV ):
    OD HV = 2 x ((NL x D HVI )+((NL-1) x Layer insulation)) mm
    Mean diameter(MDHV):
    MDHV = (IDHV + ODHV )/2 mm
    Mean length of Conductor (MLc ):
    MLc = MDHV x 3.14 x NHV x 10-3 M
    Resistance (RHV ):
    RHV =( X MLc)/ AHV

    Ohms

    HV winding loss (PLV ):


    PHV = 3 I2HV RHV Watts

    Full load loss (FLL):


    FLL= P LV + P HV Watts
    Calculation of core dimensions
    center limb distance (CL) = OD
    window width (WW) = CL MS
    Where MS = Maximum step

    HV

    +C

    LL

    mm

    Calculation of weight of core :

    W c 3 XWH 4 XCL 2 XMSX 0.86 X 7.65 X10 X Ag XCUF


    3

    Calculation of no load loss (NLL):

    NLL = W

    x (W/KG) x B.F

    watts

    Where
    W/KG = core loss per kg at specified flux density
    B.F = Building factor (1.20 1.24)

    Efficiency

    KVACOS% L
    2

    KVA COS % L% L FLL NLL

    Where FLL and NLL are in KW

    Percentage resistance (%R) :

    FLL( KW )
    %R
    100
    KVA

    100

    Percentage reactance (%X) :

    RT

    %X

    LV

    RT
    3

    HV

    C LVHV

    7.91 50 10 I LV N LV MD W 0.95

    LV

    MH W

    Where
    RT

    LV

    RT

    HV

    LVHV

    = radial thickness of LV coil in cm


    = radial thickness of HV coil in cm
    = clearance between LV and HV coils cm

    MD

    = mean diameter of windings in mm

    MH

    = mean height of windings in mm

    100

    Percentage Impedance (%Z):

    %Z

    %R

    %X

    For distribution transformer the impedance voltage should be 4.5%


    with 10% tolerance

    % Impedance

    Short circuit current

    5 % impedance

    20 times rated current

    4 % impedance

    25 times rated current

    3 % impedance

    33.5 times rated current

    2 % impedance

    50 times rated current

    Main dimensions of tank


    Length of tank = (2x CL) + OD
    Width of tank = OD

    HV

    HV

    +60 mm

    + 45 (LV connection side) + 50 (HV side) mm

    Height of tank = Overall height of core + bottom clearance 35-50mm)+


    top
    clearance (100 mm)

    MATLAB Program

    Output

    conclusion
    Computer aided design has various advantages over
    manual design. It is error free, economical and saves valuable
    time. In computer aided design programme, very few inputs are
    available from the customer specifications. The rest of the
    inputs are estimated by the designer on the basis of
    performance parameters. Since programme discussed is on
    performance based, we may run the programme with different
    values

    of

    impedance.

    variable

    inputs

    and

    with

    close

    proximity

    of

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