3 Phase Transformer Design

Rating Q KVA 100

Type of transformer P or D D
HV Line voltage VL1 Volts 11000
LV Line voltage VL2 Volts 433
Frequency Hz 50
HV connection D D
LV connection Y Y
HV Tappings + % 5
No of core steps 2
Lemination Stack factor Ks 0.97
Hw / Ww 3.5
Window factor=12/(30+Kv) Kw 0.244
Assumed 0.18
Constant for Et C 0.45
Flux density Bm Wb/m² 1.45
Et=C*Sqrt(Q) 4.500
Core assembly
Ai=Et/(4.44*Bm*F) Ai m² 0.014
Gross Lemination area=Ai/Ks Ag m² 0.014
Step dimension a=0.9d 0.85
b =0.7d 0.53
c=0.42d 0
Step core to circular core factor Kc 0.56
=(a*c)+b*(b-c)+c*(a-b)
Core diameter= Sqrt(Ag/Kc) d' m 0.160
Rounded of core diameter d mm 160
Rounded of Step dimension a=0.9d mm 136
b =0.7d mm 85
c=0.42d mm 0
Actual gross core area
=(a*c)+b*(b-c)+c*(a-b) m² 0.016
Revised core area Ai m² 0.015
Revised flux density Bm Wb/m² 1.315
Aw=Q/(3.33*f*Bm*Kw*δ*Ai/1000) 0.065
Window width Ww=SQRT(Aw/Kw) Ww mm 136.163
Rounded of Ww mm 135
window height Hw mm 472.5
 Rounded of Hw mm 473
%Increase Yoke area % 15
Gross yoke area Ayg m² 0.018
Yoke depth Dy=a Dy mm 136
Yoke height Hy =Ayg/Dy Hy mm 134.406
Rounded of Yoke height Hy Hy mm 134
Core Center to center D=Ww+a D mm 271
Window width=2*D+a W mm 678
Height of core assembly H mm 741
H=Hw+2*Hy

Coil design
HV Phase voltage Vp1 11000
LV Phase voltage Vp2 250
No of LV turns / phase N2 55.556
Rounded No of LV turns / phase N2 56
No of HV turns / phase N1 2464.000
No of HV turns / phase with 10 % tap N1 2587.200
Rounded No of HV turns / phase N1m 2587
with tapping

HV voltage /section coil 1500

No of HV coils 7.333
Rounded No of HV coils 8
No of HV turn/coil 323.375
Rounded No of HV turn/coil 323
Phase power KVA/Ph 33.333
LV phase current Ip2 Amp 133.333
HV phase current Ip1 Amp 3.030
Current density A/mm² 2.3
LV conductor CS area Bare mm² 57.971
HV conductor CS area Bare mm² 1.318
LV Coil design
Coil to yoke clearence mm 25
Coil height mm 423
Conductor width with insulation mm 21.508
No of LV layers 3
 No of turns /LV layer 18.666666667
No of conductor parallel 1
Conductor width with insulation 21.508
Conductor insulation mm 0.5
Conductor width bare 21.008
selected mm 21
Parallel conductors 3
Conductor width 7
Conductor Thickness bare 2.761
selected 3
Conductor thickness with insulation 3.5
core diameter 160
LV cylinder thickness mm 2.5
Laye 1 ID 165
Layer 1 OD 172
Gap between LV layers 0.5
Layer 2 ID 173
Layer 2 OD 180
Gap between LV layers 0.5
Layer 3 ID 181
Layer 3OD 188
Mean length of conductor LV coil 554.704
Lenth of LV conductor / phase mm 31063.435
CS area of LV conductor mm² 63
Resistivity of copper conductor ohms mm²/m 0.021 0.010
I²R losses Secondary / Phase 184.080

HV Coil design
Coil to yoke clearence mm 25
Coil height mm 423
HV Conductor dia bare mm 1.295
Insulation thickness 0.2
HV Conductor dia with insulation 1.495
Gap between each HV coils 5
HV section coil height 51.57
Axial conductor /layer 34.5
Inter 34
Radial layers 9.50
 assumed 10
Paper covering between layers 0.3
total HV Insulation spacing 3
radial width of HV coil 17.95
Assumed 18
Gap Between LV & HV coil= 5+0.9*KV 14.9
Rounded 15
HV coil ID 218
HV coil OD 254
Mean length of conductor HV coil 742
Lenth of HV conductor / phase mm 1918780
CS area of HV conductor mm² 1.32
Resistivity of copper conductor ohms mm²/m 0.021 30.58
I²R losses Secondary / Phase 280.84

Efficiency
Total 3 phase LV losses w2 watts 552.2
Total 3 phase HV losses w1 watts 842.5
Iron loasses w0 watts 458.0
Total Losses wt=w1+w2+w0 watts 1852.7
Efficiency ηQ*1000*100/(Q*1000+wt) 98.18

Leakage reactance
Mean dia of windings( LVID+HVOD)/2 mm 209.5
Mean length of turn m 0.6581652
Height of winding m 0.423
µ0 0.00000125712
HV turns / phase normal 2464
HV to LV gap a mm 15
Radial width of LV coil bs mm 11.5
Radial width of HV coil bp mm 18
Le=2*3.1416*f*µ0*N1^2*(Lmt/Hw)*(a+(bs+bp)/3)/1000
Leakage reactance ohms 92.65
HV phase current 3.030
PU leakage reactance Le*Ip/VL1 ex 0.026

LV resistance 0.010
LV resistance reffered to HV 20.05
HV resistance 30.58
 Total reflected resistence on HV 50.63
PU resistsnce of transformer er 0.0139

PU impedance ez 0.0291

PU regulation, e =er*cosϴ+exsinϴ cosϴ 1 0.0139

sinϴ 0

PU regulation, e =er*cosϴ+exsinϴ cosϴ 0.8 0.0265

sinϴ 0.6
Iron losses
Length of mean height of core=Ww + Hy 607
Length of mean length of yoke= 2*D 542
Core weight 214.8
Yoke weight 151.6
Total weight 366.4
Watt loss Watt / Kg 1.25
Iron losses watt 458
Tank Design
Height of core asembly 741
Overall width= 2x c to C core + HV coil OD 678
Overall depth =HV coil OD 254
Peripharal oil clearence between tank & coil 50
Tank bottom clearence 50
Top oil clearence 150
Top lead & tap switch clearence 200
Tank height 1141
tank width 778
tank depth 354
surface area of 4 walls of tank m² St 2.58
Heat loss descipation factor W/m² ⁰C 12.5
Total losses= Ironlasses + winding losses Watts 2310.7
Temp rise ⁰C 71.56
Temp rise permitted for plain tank ⁰C 35
additiodal cooling surface required Yes / No Yes
Factor= Losses/(Tank area*35) 25.56
additional surface factor X 1.484
additional surface required X * St m² 3.833
Tube dia 50
tube spacing 75
average of tube average 1141
each tube discipating area m² 0.1793
No of tubes required 21.377
rounded off 22
Maximum No of tubes along length 10
Maximum No of tubes along width 4
No of raws 0.7857
rounded off 1
 100 300 300 400 400 500 500
P D P D P D P
11000 11000 11000 11000 11000 11000 11000
433 433 433 433 433 433 433
50 50 50 50 50 50 50
D D D D D D D
D Y D Y D Y D
5 5 5 5 5 5 5
3 3 3 3 3 3 3
0.97 0.97 0.97 0.97 0.97 0.97 0.97
3.5 3.5 3.5 3.5 3.5 3.5 3.5
0.244 0.293 0.293 0.293 0.293 0.293 0.293
0.18 0.3 0.3 0.3 0.3 0.3 0.3
0.65 0.45 0.65 0.45 0.65 0.45 0.65
1.65 1.45 1.65 1.45 1.65 1.45 1.65
6.500 7.794 11.258 9.000 13.000 10.062 14.534

0.018 0.024 0.031 0.028 0.035 0.031 0.040

0.018 0.025 0.032 0.029 0.037 0.032 0.041
0.9 0.9 0.9 0.9 0.9 0.9 0.9
0.7 0.7 0.7 0.7 0.7 0.7 0.7
0.42 0.42 0.42 0.42 0.42 0.42 0.42
0.56 0.56 0.56 0.56 0.56 0.56 0.56
0.181 0.211 0.238 0.227 0.256 0.240 0.270
181 211 238 227 256 240 270
163 190 214 204 230 216 243
127 148 167 159 179 168 189
76 89 100 95 108 101 113
0.022 0.029 0.037 0.034 0.043 0.038 0.048
0.021 0.028 0.036 0.033 0.042 0.037 0.046
1.397 1.232 1.402 1.235 1.402 1.232 1.408
0.030 0.045 0.031 0.053 0.036 0.059 0.041
92.829 113.917 94.791 122.582 101.860 129.451 107.944
95 115 95 125 100 130 110
332.5 402.5 332.5 437.5 350 455 385
 333 403 333 438 350 455 385
15 15 15 15 15 15 15
0.025 0.034 0.043 0.039 0.050 0.044 0.055
163 190 214 204 230 216 243
152.400 177.826 200.385 190.714 215.285 201.889 226.806
152 178 200 191 215 202 227
258 305 309 329 330 346 353
679 800 832 862 890 908 949
637 759 733 820 780 859 839

11000 11000 11000 11000 11000 11000 11000

433 250 433 250 433 250 433
66.615 32.075 38.460 27.778 33.308 24.845 29.791
67 32 38 28 33 25 30
1702.079 1408.000 965.358 1232.000 838.337 1100.000 762.125
1787.182 1478.400 1013.626 1293.600 880.254 1155.000 800.231

1787 1478 1014 1294 880 1155 800

1500 1500 1500 1500 1500 1500 1500

7.333 7.333 7.333 7.333 7.333 7.333 7.333
8 8 8 8 8 8 8
223.375 184.75 126.75 161.75 110 144.375 100
223 185 127 162 110 144 100
33.333 100.000 100.000 133.333 133.333 166.667 166.667
76.982 400.000 230.947 533.333 307.929 666.667 384.911
3.030 9.091 9.091 12.121 12.121 15.152 15.152
3.2 3.2 3.2 3.2 3.2 3.2 3.2
24.057 125.000 72.171 166.667 96.228 208.333 120.285
0.947 2.841 2.841 3.788 3.788 4.735 4.735

25 25 25 25 25 25 25
283 353 283 388 300 405 335
12.129 20.765 14.150 25.867 17.143 30.000 20.938
3 2 2 2 2 2 2
22.33333333 16 19 14 16.5 12.5 15
1 1 1 1 1 1 1
12.129 20.765 14.150 25.867 17.143 30.000 20.938
0.5 0.5 0.5 0.5 0.5 0.5 0.5
11.629 20.265 13.650 25.367 16.643 29.500 20.438
12 20 14 25 17 30 20
2 3 2 3 2 4 3
6 6.6666666667 7.00 8.3333333333 8.50 7.50 6.66666666667
2.005 6.250 5.155 6.667 5.660 6.944 6.014
2 6.5 5 6.5 5.5 7 6
2.5 7 5.5 7 6 7.5 6.5
181 211 238 227 256 240 270
2.5 2.5 2.5 2.5 2.5 2.5 2.5
186 216 243 232 261 245 275
191 230 254 246 273 260 288
5 5 5 5 5 5 5
201 240 264 256 283 270 298
206 254 275 270 295 285 311
5 5 5 5 5 5 5
216 264 285 280 305 295 321
221 278 296 294 317 310 334
639.560 776.272 846.985 826.556 908.269 872.127 956.983
42850.507 24840.691 32185.415 23143.579 29972.884 21803.175 28709.478
24 130 70 162.5 93.5 210 120
0.037 0.004 0.010 0.003 0.007 0.002 0.005
222.201 642.036 514.997 850.734 638.319 969.030 744.363

25 25 25 25 25 25 25
283 353 283 388 300 405 335
1.098 1.902 1.902 2.196 2.196 2.455 2.455
0.2 0.2 0.2 0.2 0.2 0.2 0.2
1.298 2.102 2.102 2.396 2.396 2.655 2.655
5 5 5 5 5 5 5
34.24 42.29 33.54 46.40 35.40 48.30 39.55
26.4 20.1 16.0 19.4 14.8 18.2 14.9
26 20 15 19 14 18 14
8.58 9.25 8.47 8.53 7.86 8.00 7.14
 9 10 9 9 8 9 8
0.3 0.3 0.3 0.3 0.3 0.3 0.3
2.7 3 2.7 2.7 2.4 2.7 2.4
14.38 24.02 21.62 24.26 21.57 26.60 23.64
15 25 22 25 22 27 24
14.9 14.9 14.9 14.9 14.9 14.9 14.9
15 15 15 15 15 15 15
251 308 326 324 347 340 364
281 358 370 374 391 394 412
836 1047 1094 1097 1160 1153 1219
1493905 1546804 1109006 1419307 1020530 1332186 975525
0.95 2.84 2.84 3.79 3.79 4.73 4.73
33.13 11.43 8.20 7.87 5.66 5.91 4.33
304.21 944.96 677.50 1156.09 831.27 1356.41 993.26

666.6 1926.1 1545.0 2552.2 1915.0 2907.1 2233.1

912.6 2834.9 2032.5 3468.3 2493.8 4069.2 2979.8
536.7 869.2 1059.9 1081.7 1302.0 1270.4 1560.3
2115.9 5630.1 4637.4 7102.2 5710.7 8246.7 6773.2
97.93 98.16 98.48 98.26 98.59 98.38 98.66

233.5 287 306.5 303 326 319.5 343.5

0.7335636 0.9016392 0.9629004 0.9519048 1.0241616 1.0037412 1.0791396
0.283 0.353 0.283 0.388 0.3 0.405 0.335
1.25712E-06 1.25712E-06 1.25712E-06 1.25712E-06 1.25712E-06 1.25712E-06 0.00000125712
1702 1408 965 1232 838 1100 762
15 15 15 15 15 15 15
17.5 31 26.5 31 28 32.5 29.5
15 25 22 25 22 27 24
76.62 67.33 39.03 49.51 30.01 41.25 24.26
3.030 9.091 9.091 12.121 12.121 15.152 15.152
0.021 0.056 0.032 0.055 0.033 0.057 0.033

0.037 0.004 0.010 0.003 0.007 0.002 0.005

24.20 7.77 6.23 5.79 4.34 4.22 3.24
33.13 11.43 8.20 7.87 5.66 5.91 4.33
57.33 19.20 14.43 13.66 10.00 10.13 7.57
0.0158 0.0159 0.0119 0.0151 0.0110 0.0140 0.0104

0.0264 0.0579 0.0344 0.0566 0.0349 0.0585 0.0350

0.0158 0.0159 0.0119 0.0151 0.0110 0.0140 0.0104

0.0253 0.0461 0.0289 0.0448 0.0287 0.0453 0.0284

485 581 533 629 565 657 612

516 610 618 658 660 692 706
233.2 380.0 442.4 473.7 541.6 554.6 652.9
196.1 315.3 405.5 391.7 500.0 461.7 595.3
429.3 695.3 847.9 865.4 1041.6 1016.3 1248.3
1.25 1.25 1.25 1.25 1.25 1.25 1.25
537 869 1060 1082 1302 1270 1560

637 759 733 820 780 859 839

679 800 832 862 890 908 949
281 358 370 374 391 394 412
50 50 50 50 50 50 50
50 50 50 50 50 50 50
150 150 150 150 150 150 150
200 200 200 200 200 200 200
1037 1159 1133 1220 1180 1259 1239
779 900 932 962 990 1008 1049
381 458 470 474 491 494 512
2.41 3.15 3.18 3.50 3.50 3.78 3.87
12.5 12.5 12.5 12.5 12.5 12.5 12.5
2652.6 6499.3 5697.3 8184.0 7012.7 9517.1 8333.5
88.20 165.17 143.47 186.86 160.51 201.31 172.35
35 35 35 35 35 35 35
Yes Yes Yes Yes Yes Yes Yes
31.50 58.99 51.24 66.73 57.33 71.90 61.55
2.159 5.283 4.402 6.163 5.094 6.750 5.574
5.195 16.630 13.985 21.594 17.804 25.527 21.562
 50 50 50 50 50 50 50
75 75 75 75 75 75 75
1037 1159 1133 1220 1180 1259 1239
0.1630 0.1821 0.1780 0.1917 0.1854 0.1978 0.1947
31.880 91.312 78.550 112.640 96.016 129.031 110.749
32 92 79 113 97 130 111
10 12 12 12 13 13 13
5 6 6 6 6 6 6
1.0667 2.5556 2.1944 3.1389 2.5526 3.4211 2.9211
2 3 3 4 3 4 3
 c b a
a
b
c