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Chiragkumar N Parekh 18
4.Design Methodology of Power Transformer
The difficulty in achieving the optimum balance between the transformer cost
and performance is a complicated task and the techniques that are employed
for its solution must be able to deal with the design considerations. So as to
provide a design optimum while remaining. cost effective and flexible.”
For any chosen optimization.method, there always will be a question for its
effectiveness and how much detail to include in the problem. description.
Although,the ultimate aim is to find out the lowest cost, one might wish to
achieve such solution that should.provide sufficient information. So finally the
actual design can be shaped with little further work.”
However, it would be. impractical to think that the optimum. cost design for a
transformer would certainly satisfy all of the electrical, mechanical and thermal
constraints that require sophisticated design algorithms to evaluate.
So to work for the transformer design optimization techniques. that deal with
the minimization of the manufacturing. as well as operating cost can be well
worth for manufacturer as well as for utility.
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4.Design Methodology of Power Transformer
4.1.1.1 Winding:”
It is known as the heart of transformer. Winding” is made up of costly metal
like copper and”aluminum, it is considered as a costliest component of
”transformer. Transformer windings are designed to” meet three fundamental
requirements viz. mechanical, thermal and electrical. ”They are ”cylindrical in
shape and are assembled concentrically.” Paper insulated conductors of high
conductivity & soft drawn E.C. Grade copper is used which comply with the
latest Indian as well as international standards. According to the application
and rating of the transformer the suitability of winding type is decided by
designer. Cylindrical windings, helical windings, cross over windings,
continuous disc winding, inter leaved winding, Intra shield winding, foil winding
etc are the different types of winding of transformer. For example, the inter
leaved or Intra shield windings are used for EHV or UHV class transformers,
while helical windings are used for high current transformer.”
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4.Design Methodology of Power Transformer
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4.Design Methodology of Power Transformer
4.1.1.4 Bushings:
It is used to connect the active part (CCA) of transformer to the electrical
network.
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4.Design Methodology of Power Transformer
4.1.2.1 Copper:
Copper is most suitable material for power transformer winding construction
due to it’s tensile strength, High electrical conductivity and density. Depending
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4.Design Methodology of Power Transformer
4.1.2.2 CRGO:
CRGO is use to construct the magnetic circuit of power transformer. It is 0.23
to 0.3 mm thickness steel sheets with silicon content of approximate 3%. It is
responsible for No Load loss and Noise in transformer. There are different
grades available for CRGO, which has specific losses at specific flux density.
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4.Design Methodology of Power Transformer
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4.Design Methodology of Power Transformer
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4.Design Methodology of Power Transformer
while working. During the course of fault and failure it plays a vital role to
handle the developed excessive pressure and prevent the chance fire in yard.
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4.Design Methodology of Power Transformer
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4.Design Methodology of Power Transformer
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4.Design Methodology of Power Transformer
Input Parameters
kVA, HV, LV, Tapping etc.
Costing
The Flux density (Bm), Current Density, K factor. are the parameter which
influence. greatly to customer’s requirements viz. No load. Loss, Load Loss,
%Z and cost too. The inter relation between these parameters are as
following.
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4.Design Methodology of Power Transformer
120
100
No Load Loss(kW)
80
60 Impedance
(%Z)
40
Load Loss
20 (kW)
0
0.4 0.410.420.430.440.450.460.470.480.49 0.5
(A)
120
100
80
60 No Load Loss(kW)
40 Cost(INR)
20
0
1.5 1.53 1.56 1.59 1.62 1.65 1.68 1.71 1.74
(B)
150
0
2 2.2 2.4 2.6 2.8 3 3.2 3.4 3.6
(C)
Figure: 4.13 Parametric Impact to the Cost and Losses of the
Transformer (A) NLL, Load Loss and %Z Comparison (B) NLL Vs Cost of
Transformer (C) Load Loss Vs Cost of Transformer.
Apart from the mathematical equations, transformer design process ask for
several standard data.and assumptions factors which also are described
herewith.
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4.Design Methodology of Power Transformer
Based on kVA rating emf per turns is calculated. So, emf per turns is
calculated using equation
Core design includes the calculation of. area, diameter, number of steps of
core. This design is based on frequency, flux density.and emf per turns.
Et×104
Ai = [4]
4.44×Bm×f
the diameter of core is obtained from. eqation [5], take round off to the nearest
value. the number of steps is calculated,
If, Ns=. (d×0.04) > 17 then Ns.= 17 otherwise take Ns= d× 0.04
There are two types of winding designs : (i) HV winding. Design and (ii) LV
winding design. To design a winding,. rated current, cross sectional area,
number of. disc, tapping disc, turns per. disc, radial depth, axially. unshrunk
height and shrunk height, inner and outer. diameter are calculated. some
standard. constant values are require to design winding.”
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4.Design Methodology of Power Transformer
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4.Design Methodology of Power Transformer
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4.Design Methodology of Power Transformer
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4.Design Methodology of Power Transformer
HV LV
Winding Winding
Portion Ht D3 Portion Ht d3
Phase
Phase current A3 current a3
Nos of disc B3 Ht3 ht3
Nos of disc b3
Nos of turns C3 Nos of turns c3
AT 3 A 3* C3 at3 a 3* c3
AT3/MM (A3 *C3)/D3 at3/MM (a3 *c3)/d3
Total(HT(hv)) (Ht1+Ht2+Ht3) Total (HT(lv)) (ht1+ht2+ht3)
***Winding portion Ht =
(Nos of disc x Condustor ht x Nos od axially condust) + (0.8 x Nos of disc x
Nos of axially cond x 0.85) +
((Nos of disc-1) x spacer thickness x 0.95)
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4.Design Methodology of Power Transformer
Csn= (D/36/M)*(A+B+C) PF
A=3.2*(h+(2*t))*(m-d-1)/m^2/t
B=(h+t+g')*d/m^2/((ga/2.7)+(t/3.2))
C=4/3*(R+gr)/((t/3.2)+(gr/2.8))
Where,
t=Conductor covering
n=no of layer
M=No. of Turns
g’=smaller of ga/gr
r=Radial Depth
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4.Design Methodology of Power Transformer
𝐿∗𝑋∗𝑛
𝛼=√ [36]
𝑑∗𝑠
Where,
Hw= wdg ht
Ai= Core area
Bm= flux density
Br= Remnant flux density(Approx. 60% of Bm)
N= NO.Of Wdg Turns
Ac= Mean Area enclosed by winding
µ0=Air Permeability (4 Π x 10 -7)
Isc=k*Sqrt(2)*Iph / Iz [38]
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4.Design Methodology of Power Transformer
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4.Design Methodology of Power Transformer
4.5.6 Calculation of Axial Imbalance Force Due to Tapping within the Winding
Fa = ( a / 2 ) * ( N * Isc )2 * 10 - 7 [43]
Where a= per unit turns out of circuit in the winding = 0.05
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4.Design Methodology of Power Transformer
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4.Design Methodology of Power Transformer
1) Tank Height in cm
2) Tank to Conservator 1/2 Level in cm.
Total (T) = 1) + 2) = cm.
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4.Design Methodology of Power Transformer
B (Oil rise/(A*5+30)
W/Section Q*B.VF.HF.SF
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4.Design Methodology of Power Transformer
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4.Design Methodology of Power Transformer
No-load
9.92 9.79 9.91 10.01 9.88 9.73
losses (kW)
Load losses
66.79 66.85 67.91 68.14 67.66 67.42
(kW)
%Z 8.81 8.72 8.95 9.43 9.07 8.90
Total cost
6305692 6330566 6405511 6290520 6414953 6348652
(Rs.)
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4.Design Methodology of Power Transformer
Sr.
Variable Range
No.
1. K-factor 0.35 to 0.55
2. Flux density (Bm) 1.45 to 1.75 Wb/ m2
3. Current Density of LV winding 1.9 to 3.5 A/mm2
4. Current Density of HV winding 1.9 to 3.5 A/mm2
5. No. of Stiffener 2 to 8
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4.Design Methodology of Power Transformer
START
SELECT THE RUN PROGRAM WITH MAX. & MIN. VALUE OF K, Bm, DELTA
SUITABLE VALUES OF HV & LV WINDING, No. of STIFFENER
FOR CALCULATION
OF DESIGN
PARMETERS FROM
STANDARD TABLES
ON EXCELSHEET DESIGN OF LAMINATION (CORE)
DESIGN OF HV WINDING
DESIGN OF LV WINDING
TANK DESIGN
ARE SPECIFIED
CONSTRAITS
SATISFIED?
GO FOR NEXT
ITERATION
OBJECTIVE
FUNCTION
ACHIEVED?
END
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4.Design Methodology of Power Transformer
(A)
(B)
Figure 4.16 Programming for Design of Power Transformer Using MATLAB
(A) and Respective Result Using Iterative Method(B)
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4.Design Methodology of Power Transformer
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4.Design Methodology of Power Transformer
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4.Design Methodology of Power Transformer
In this method the above results are saved in excel sheet. So from that we
can pick any suitable design as per customer requirement and design the
transformer.
4.14 Conclusion
With the use of National-International standards and Industrial code of
practice, The computer program was developed which was put on experiment
related to the prevailing design methodology. The MATLAB software was
used to get the optimized. design solution, which really will be. the ready
reckoner for designer as it is presenting the.analytical and graphical
comparison between. various parameters.
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