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Machine Design Questions 4

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45 views20 pages

Machine Design Questions 4

machine design

Uploaded by

Sandesh Karki
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Q.4.

Design a 200 KVA, 11000/400 V,50 Hz, 3-phase , Δ/Y, core type, oil immersed natural cooled distribution transformer
with tapping ±2.5 ± 5% on H.V winding. Maximum temperature rise not to exceed 45 ℃ with mean temperature rise of
oil 35 ℃
Solution:-

Design of Transformer:
core design:
for 3- phase core type distribution transformer,
We use K=0.45
Voltage per turn Et =k√Q=0.45√200= 6.36V
Flux in the core ɸm==
Here, cold rolled silicon steel is used and the value of flux density is assumed as 1.6wb/m²

Net iron area (Ai)= = = 0.0179m2 =17.9*10^3 mm2


Using a cruciform core, Ai=0.56d²

or d=√
now, width of laminations :
a=0.85d=0.85*178.89=152.05mm=0.152m
b=053d=0.53*178.89=94.81mm
Window design:
the window space factor for transformer (Kw)=
=
the current density (∂)=2.3A/mm² from standard value for distribution cooled type transformer (2.2 -
3.2) A/mm2
output of transformer :
Q=3.33f*Bm*Kw*∂ *Aw*Ai*10^-3
or Aw= =0.0759m²
We have the relations,
Aw=Hw*Ww
or, Aw=2.5Ww*Ww
or , Ww=√
width of window ,Ww=0.174m
also ,
height of window , Hw=2.5Ww=0.435m
Distance between adjacent core center, D=Ww+d
= 0.174+0.1789=0.3529m
Design of yoke:
the area of yoke is taken as 1.2 times that of limb.
flux density of yoke = 1.6/1.2
=1.34 wb/m²
net area of yoke(Ay)=1.2*0.01792=0.0215m²
gross area of yoke , Agi= Ay since , cold rolled steel is used
=0.0215m²
depth of yoke , Dy=a=0.152m
height of yoke , Hy=

Overall dimension:
height of frame, H=Hw+2Hy= 0.435+2*0.1414=0.7178m
width of frame, W=2D+a=2*0.3529+0.152=0.8578m
Low voltage winding(L.V):star connection;
secondary line voltage=400V
secondary phase voltage , Vs= =231V
secondary phase current , Is=
no . Of turn per phase , Ts turn
a current density of 2.3 A/mm2 is used.
area of conductor ,as= m²
From the table (IS 1897-1962) , using a bare conductor of area = 18×7 mm2 =126mm²
Area of bare conductor ,as = 125mm2
Actual current density, ds = A/mm2
ds =2.3A/mm2
Using paper insulator of 0.5 mm,
Dimension of insulated conductor =18.5*7.5 mm2
Using 2 layers of helical winding.
The no of turns along axial depth =17+1=18
Axial depth of L.V winding,
Lcs=18*axial depth of conductor
=18*18.5=333mm
Height of window= 435.6mm
Clearance on each side of yoke = (435.6-333)/2 = 51.3mm
Radial depth of L.V. Winding :
bs= no. of layers * radial depth of conductor + insulation between layers
= 2*7+0.5 =14.5 mm
insulation = 5+0.9*Kv=5+0.9*11=15mm
Inside diameter of L.V winding, = d+2*insulation = 178.89+ 2*15 = 208.89 mm
Outside diameter of L.V winding = 208.89+ 2*14.5 =237.89 mm
Mean diameter of L.V, Ds ==223.4mm
Lmts = ∏* 223.4 =702mm

Design H.V winding:


Primary voltage , Vp =11kv
No.of turn per phase , Tp = 11000=1715 turn
as ± 5% tapping to be provided, Tp =1.05*1715=1800
the voltage per coil is about 1500V ,using 8 coils
Voltage per coil = 11000/8=1375V
Using 7 normal coils of 225 turns and one reinforced coil of 140 turn
turn per coil=
Taking 12 layers per coil, we have
Turns per layer = 225/12=19
Max. voltage between layers = 2 * 19* 6.363=242V , which is less than 300V
Primary phase current , Ip ===6.06A
As current is below 20A. So, cross over coils are used for H.V. winding .
area H.V winding, ap=Ip /δ= 6.06/2.4=2.525mm2
diameter of bare conductor=√(4/∏*2.525)= 1.8mm
Using paper covered conductor from table (IS: 1954 -1966),
he nearest standard conductor size…………
Bare diameter = 1.8mm
Insulated diameter =1.97mm
Modified area of conductor = ∏/4 *1.8²= 2.544mm2
Actual value of current density = 6.06/2.544=2.38A/mm2
Axial depth of one coil =19*1.97 mm =37.43 mm
Axial length of H.V winding = no of coils* axial depth of each coil + depth of spacers
= 8*37.43+8*5=339.5mm The spacers used between adjacent
coils are 5mm in height.
The height of window(Hw)= 435mm
Clearance on each side of yoke= (435- 339.5)/2 = 47.75 mm
Radial depth of H.V winding:
Radial depth of H.V winding ,bs = no of layers* radial depth of conductor +insulation between layers
=12*1.97 +11*0.5= 29.14mm
The thickness of insulation between H.V and L.V , a = 5+ 0.9KV = 5+0.9*11= 15mm
Inside diameter of H.V winding=outer diam. of L.V+2 thickness of insulation between L.V and H.V
= 237.89+ 2*15 = 267.9 mm
Outside diameter of H.V winding=Inside diameter+2*Radial depth of HV winding
=267.9+2*29.14= 326.2 mm
mean diameter of H.V ,Dp=
Lmtp = ∏* 297 =933.2mm
RESISTANCE :
mean diameter of H.V ,Dp=
Lmtp = ∏* 297 =933.2mm=0.9332m
Resistance of primary winding, rp==Ω
Mean diameter of L.V, Ds ==223.4mm
Lmts = ∏* 223.4 =702mm=0.702m
Resistance of primary winding, rp==Ω
Total resistance referred to primary side ,Rp= rp+rs*(Tp/Ts)
= 13.3+0.004229*(1715/36)² = 22.9 Ω
P.U resistance of transformer , Er = =0.0126 p.u
LEAKAGE REACTANCE:
Mean diameter of windings= =
Length of mean turn ,Lmt = ∏*0.2675 m = 0.84 m
Height of windings, Lc= =
Width of H.V winding , bp= =0.0294m
Width of L.V winding , bs= =0.0145m
width of duct, a = =0.014755m
Thus,
Xp=2∏*µ0 *Tp²*
= 2∏*µ0 *1715²* Ω

P.U leakage reactance of transformer ,Ex = =0.0009398 p.u


REGULATION:
We have, cosɸ =0.8 , sinɸ=0.6
P.U regulation = Er. cosɸ + Ex. sinɸ =0.0126*0.8+0.0009398*0.6
=0.01065 p.u
Losses:
copper loss :
At 75◦ C,
3I²Rp = 3*6.06²*22.9 = 2523watt
Taking 15% stray loss , Pc= 1.15*2523 = 2901.5 watt
Core loss/Iron loss:
Taking the density of laminations= 7.6*10³kg/m
Weight of 3 limbs = 3* Hw *Ai * 7.6*10³
=3*0.435*0.0179* 7.6*10³ =177.53 Kg
The flux density in the limbs = 1.6Wb/mm2
From the specific core/iron loss = 1.55 W/kg
Therefore, core loss in limbs = 177.53*1.55 = 275.2 Watt
Weight of two yoke = 2* length of yoke *area of the cross section *density of laminations
=2*0.857*0.0179* 7.6*10³
=233.2 Kg
Corresponding to flux density in yoke 1.25 Wb/m2, specific iron loss =1.55 W/kg
Therefore core loss in yoke =1.55* 233.2= 361.41Watt
Total core loss Pi = Core loss in 3-limbs + Core loss in 2-yokes
=275.2+361.41
= 636.61 Watt

Efficiency:
Total loss at full load= Pc+ Pi=2901.5+ 636.61=3538.11Watt
Efficiency at unity power factor :
%ɳ =
=98.26%
For maximum efficiency,
x² Pc = Pi
x =

hence maximum efficiency occurs at 46.85%of full load.


No load current , I=

Corresponding to flux density of 1.6 wb/m2 in core and yoke ;


ATc = ATy =
Total magnetising mmf = no . Of limb * ATc * Hw +no .of yoke *ATy *W
=3*5000*0.432+2*5000*0.868
=
magnetizing mmf per phase ,ATo =
magnetizing current Rms ,Iw= =
No load current , Io = (Iw²+ I²)=(Iw²+ I²)=
Tank Design:
height of frame , H=
allowing 50mm at base and about 150mm at top of frame for oil level;
Height of oil level=50+748.31+150=
allowing another 200mm height leads, etc
Height of tank=200+948.31=
Assuming , the clearance of 40mm along the width on each side,
Length of tank , Lt=2* distance between adjacent limb center + outside diameter of H.V winding +2*
clearance
a= 0.152m

Hy=0.1414m
H=0.7178m
Hw=0.435m

W=0.8578m

Dy=0.152m

d= 178.89mm D= 0.3529m
Figure 1: Overall dimensions, core type, oil immersed
Fig: Overall dimension of distribution transformer.
H.V winding

Insulation between
LV winding and core insulation

L.V winding

Cruciform core

Figure 2: A cross section of a core and windings


b=94.81mm

(a-b)/2

d=178.89mm
b=94.81mm

(a-b)/2

a=152.05mm

Fig 3: Cross section of core without winding


Width of tank=f
Length of tank=

Figure 4 : Tubes details of 200 KVA, 11000/400 V,50 Hz, 3-phase , distribution transformer

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