(AN UNDERTAKING OF BHAKTAPUR MUNICIPALITY)
KHWOPA COLLEGE OF ENGINEERING
AFFILIATED TO TRIBHUVAN UNIVERSITY
A
Progress Report on
Electric Machine Design
Submitted By:
Sushant Acharya KCE079BEL031
Submitted To:
DEPARTMENT OF ELECTRICAL ENGINEERING
KHWOPA COLLEGE OF ENGINEERING
LIBALI-08, BHAKTAPUR
20 July, 2025
Design a 150 KVA, 11/0.4 KV, Delta/Star, core type, oil immersed natural
cooled distribution transformer. The transformer is provided with tapping
±2.5%, ±5.5% on H.V. side. Maximum temperature rise not exceeding 48◦ C.
SOLUTION:-
0.1 CORE DESIGN
GIVEN,
Q= 150 KVA
frequency(f)= 50Hz
constant for o/p voltage per turn (k) = 0.45
So,
√
Voltage per turn Et =k ∗ Q
√
=0.45 ∗ 150
= 5.5113 V/turns
We know that,
Et =4.44fϕm
5.5113
ϕm = 4.44∗50
ϕm =0.02482567 Wb
ϕm =24.82567 mWb
Now,
Taking Bm = 1.2W b/m2
ϕm
Area of iron core (Ai ) = Bm
0.2482567
= 1.2
=0.020688m2
=20688.05833mm2
i
Taking two stepped core
(Ai ) = 0.56d2
q
Ai
Diameter of iron core (d) = 0.56
q
−6
= 20688.05833∗10
0.56
= 192.2055184 mm
Length of long strip (a) = 0.85d
= 0.85*192.2055184
= 163.37469 mm
Length of short strip (b) = 0.53d
= 0.53*192.2055184
= 101.86892 mm
ii
0.2 Design of window
Q = 3.33f ϕm Aw kw δ ∗ 10−3 (1)
For distribution transformer,
10
Window space factor (kw ) = 30+kV
12
= 30+150
= 0.243902
Taking , Current density (δ) = 3 A/mm2
From equation 1
Q
Area of window (Aw ) Aw = 3.33f ϕm kw δ∗10−3
150∗103
= 3.33∗50∗0.02482567∗0.243902∗3∗10−3
= 49595.17497mm2
= 0.0495951175m2
Hw
The ratio of height of window to width of window ( Ww
) is
Hw
Ww
= 3.1
Hw = 3.1Ww
Area of window (Aw ) = Hw ∗ Ww
74392.76246 = 3.1Ww2
Width of Window (Ww ) = 126.4849538 mm
Height of Window (Hw )= 3.1 ∗ Ww
Hw = 3.1*126.4849538 mm
Hw = 392.1033568 mm
iii
0.3 Design of Yoke
As we are using Hot Rolled Silicon Steel.
So, taking Area of Yoke (Ay ) = 1.15Agi
Taking stacking factor (Ki ) = 0.9
1.15∗Agi
Ay = Ki
1.15∗20688.05833
= 0.9
Ay = 26434.7412 mm2
Ay = 0.0264347412 m2
Depth of Yoke (Dy ) = Width of largest stamping (a)
(Dy ) = 163.37469 mm
Ay = Dy ∗ Hy
Ay
Height of Yoke (Hy ) = Dy
26434.7412
= 163.37469
Hy = 161.8043848 mm
0.4 Overall Dimension of Frame
• Distance between adjcent core centers (D) =Ww + d
= 126.4849538 + 192.2055184
= 318.6904722 mm
• Height of Frame (H) = Hw + 2Hy
= 392.1033568 + 2*161.8043848
= 715.7121264 mm
• Width of Frame(W) = 2D + a
= 2*318.904722 + 163.37469
= 800.7556344 mm
iv
• Depth of the Frame (DF ) = Dy = a = 163.37469mm
v
0.5 Design of L.V winding
Secondary line voltage(Vs,L ) = 0.4KV (star connected)
0.4 ∗ 103
Secondary phase voltage(Vph,s ) = √
3
= 230.94V ≈ 231V
Vph,s
No. of turns per phase(Ts ) =
Et
11 ∗ 103
=
5.5113
= 41.903turns ≈ 42turns
Q
secondary phase current(Iph,s ) =
3Vp,ph
150 × 103
=√
3 × 11 ∗ 103
= 216.506A
Iph,s
Area of secondary side(as ) =
δs
216.506
=
3
= 72.16866667mm2 ≈ 72mm2
From Table.??
Width (Ws ) = 16 mm
Thickness (ts ) = 4.5 mm
Standard area (a′s ) = 72 mm2
Thin paper of insulation 0.5mm is used for insulation.
Width (Ws′ ) = 16.5mm
Thickness (t′s ) = 5mm
Dimension of insulated conductors = Ws′ × t′s
= 16.5 × 5
Now,
Iph,s
New current density (δ ′ ) =
a′s
216.506
=
72
= 3.007A/mm2
vi
Hw
Maximum no. of turns in a layer (MT L ) =
Ws′
392.1033568
=
16.5
= 24.5turns ≈ 25turns
Minimum number of layers (mTL ) = Total number
MTL
of turns
42
=
25
= 1.68 ≈ 2layers
Ts
Actual turn per layer =
mT L
42
=
2
= 21turns/layer
Taking Helical Winding
We have to provide some spacing
Actual no. of turns per layer = (21 + 1) = 22turn/layer
Axial depth of L.V winding (Lcs ) = 22 × Ws′
= 22 × 16.5
= 363mm
HW − Lcs
Clearance =
2
392.1033568 − 363
=
2
= 14.5516784mm
Radial depth of L.V winding (bs ) = no. of layers×thickness of conductor+insulation between layers
= 2 × 5 + (2 − 1) × 0.5
= 10.5
Insulation between core and LV winding (y) = 5 + (0.9 × voltageof LV side(kV ))
= 5 + (0.9 × 0.4)
= 5.36mm
Internal diameter of LV winding (Dint,LV ) = d + 2 × y
= 192.2055184 + 2 × 5.36
= 202.9255184mm
External diameter of LV winding (Dext,LV ) = Dint,LV + 2 × bs
= 202.9255184 + 2 × 10.5
= 223.9255184mm
vii
Dext,LV +Dint,LV
Mean diameter of LV windingmts ) 2
223.9255184+202.9255184
= 2
= 213.4255184mm
Length of mean turn of LV side (Lmts ) = π×Dt extmts =
670.4960407 mm
0.6 Design of H.V winding
Primary line voltage(Vp,L ) = 11KV (Delta connected)
Primary phase voltage(Vp,ph ) = 11KV
Vp , ph
No. of turn per phase (Tp ) = × Tp
Vs , ph
11
= × 42
0.4
√
3
= 2000.5186turns ≈ 2001turns
Ts
Primary current per phaseIp , ph = × Is
Tp
42
= × 216.506
2001
= 4.5443A
Ip , ph
Area of HV winding(ap ) =
1.05 × δ
4.5443
=
1.05 × 3
= 1.44265mm2
Taking round conductor for H.V winding
Area of secondary winding (ap )
π×d2p
then,(ap ) = 4
Diameter of bare conductor(dp ) = 1.355300346mm
Taking paper insulation for round conductor,
From Table.??Bare diameter (dp , new) = 1.4mm
Insulated diameter with fine covering(d′p ) = 1.575mm
πd2p
Modified area of HV winding(a′p ) = 4
= 1.948278319mm2
viii
Ip
New current density(δp′ ) = a′p
4.5443
= 1.948278319
= 2.33246A/mm2
Tapping Maximum Minimum
2.5% 1.025 T p 0.975 T p
= 2051.025 = 1950.975
≈ 2052 ≈ 1951
5.8% 1.055 T p 0.945 T p
= 2111.005 = 1890.945
≈ 2112 ≈ 1891
Now, We know that,
The voltage per coil should not exceed 1500V.
U singTp , max = 2122turns
Vp , ph
Voltage in each coil =
numberof coils
Now,
Vp , ph
Minimum no. of coil =
1500
11 × 103
=
1500
= 7.33 ≈ 8
Tp (max)
Maximum turns per coils =
minimumno.of coil
2112
=
8
= 264turns
Using 7 normal coils having 260 turns and 1 reinforced coil having 292 turns.
Hw
Maximum no. of turns in a layer = ′
dp
392.1033568
=
1.575
= 248.95
≈ 249turns
Tp (max
Minimum no. of layer =
maximumno.of turnsinalayer
2112
=
249
= 8.48
≈ 9layer
ix
For Normal Coil
260
No. of turn per layer per coil =
9
= 28.888 ≈ 29turns/layer/coil
Maximum voltage between layer = 2 × Et × No. of turn per layer per coils
= 2 × 5.5113 × 29
= 308.65V
Here,308.65V > 300V
260
Hence minimum number of layer is increased to 11.No. of turn per layer per coil =
11
= 23.63 ≈ 24turns/layer/coil
Maximum voltage between layer = 2 × Et × No. of turn per layer per coils
= 2 × 5.5113 × 24
= 264.542V
Here,264.542V < 300V
For Reinforced Coil
292
No. of turn per layer per coils =
11
= 26.54 ≈ 27turns/layer/coil
Maximum voltage between layer = 2 × Et × No. of turn per layer per coils
= 2 × 5.5113 × 27
= 297.6102V
Here,297.6102V < 300V
Axial depth for normal coil (lcpnormal ) = No. of turns per layer per coil×insulated diameter (d′p )×
no. of coil
= 7 × 1.575 × 24
= 264.6mm
Axial depth for reinforced coil (lcpreinf orced ) = No. of turns per layer per coil×insulated diameter (d′p )×
no. of coil
= 1 × 1.575 × 27
= 42.525mm
A spacer is used in between 2 adjcent coils
Let us assume,5mm in height of spacer.
New axial depth of H.V. winding (lcp ) = Axial depth for normal coil (lcpnormal +Axial depth for reinforc
x
depth of reinforced coil spacers
= 264.6 + 42.525 + 7 × 5
= 342.125mm
Hw − Lcp
Clearance on each side =
2
392.1033568 − 342.125
=
2
= 24.9891784mm
The isulation thickness between layer = 0.3mm(say)
Taking paper insulation then,
Radial depth of HV winding (bp ) = No. of layers × d′p + total insulation between layers
= 11 × 1.575 + (11 − 1) × 0.3
= 20.325mm
Insulation between L.V and H.V(z) = 5 + 0.9KV
= 5 + 0.9 × 11mm
= 14.9mm
Internal diameter of HV winding(Dint,HV ) = Dext,LV + 2z
= 223.4255184 + 2 × 14.9
= 253.7255184mm
External diameter of HV winding(Dext,HV ) = Dint,HV + 2bp
= 253.7255184 + 2 × 20.325
= 294.3755184mm
Dint,HV + Dext,HV
Mean diameter of HV winding(Dmtp ) =
2
294.3755184 + 253.7255184
=
2
= 274.0505184mm
Length of mean turn of HV winding (Lmtp ) = π × Dmtp
= π × 274.0505184
= 860.9550953mm
Dint,LV + Dext,HV
Mean diameter of winding(Dmt ) =
2
202.9255184 + 294.3755184
=
2
= 248.6505184mm
Length of mean turn of winding (Lmt ) = π × Dmt
= π × 248.6505184
= 781.1586419mm
xi
Lcs + Lcp
Height of winding(Lc ) =
2
363 + 342.125
=
2
= 352.5625mm
xii
0.7 Operating Characteristics
P.U Resistance Drop
resistivity of copper(ρ) = 0.021Ωmm2 /m
ρ×L
mtp×Tp
Resistance of primary winding(rp ) = a′p
0.021 × 10−3 × 860.9550953 × 2001
=
1.948278319
= 18.569Ω
ρ×L mts×Ts
Resistance of secondary winding(rs ) = a′s
0.021 × 10−3 × 670.4960407 × 42
=
72
= 8.213 × 10−3 Ω
Tp
Total resistance referred to primary side(Rp ) = rp + ( )2 × rs
Ts
2001 2
= 18.569 + ( ) × 8.213 × 10−3
42
= 37.21121101Ω
IP × RP
P.U resistance of transformer(ER ) =
VP
4.5443 × 37.21121101
=
11 × 103
= 0.01537p.u
P.U Reactance
Lmt bs + bp
Leakage reactance referred to primary side(Xp ) = 2πf µ0 Tp 2 (z + ) × 10−3
Lc 3
781.1586419
= 2π×50×y7π×10−7 ×20012 × ×
352.5625
10.5 + 20.325
(14.9 + ) ∗ 10−3
3
= 154.299517Ω
IP × Xp
p.u leakage reactance(EX ) =
Vp
4.5443 × 154.299517
=
11 × 103
= 0.063744p.u
V oltage Regulation
For 0.8 p.f lagging
cosϕ = 0.8
ϕ = 36.87◦
sinϕ = 0.6
xiii
Voltage Regulation = E R cosϕ + E X sinϕ
= 0.01537 × 0.8 + 0.063744 × 0.6
= 0.0505424p.u
= 5.05424%
0.8 LOSSES And Effciency
Copper loss
Bm
Flux density in yoke(Bym ) =
the ratio of area of yoke and gross iron area
1.2
= = 1.043478W b/m2
1.15
Copper loss(pc1 ) = 3IP2 RP
= 3 × 4.54432 × 37.21121101
= 2305.308478W
Taking stray loss 15% of copper loss.
Stray loss(Pc2 ) = 15%of Pc1
= 345.7962717W
Total copper loss(Pc ) = Pc1 + Pc2
= 2305.308478 + 345.7962717
= 2651.10475W
Iron loss
Taking density of laminations as 7.6 × 103 kg/m3
Weight of 3 limbs = 3 × Hw × Ai × density of laminations
= 3 × 392.1033568 × 10−3 × 20688.05833 × 10−6 × 7.6 × 103
= 184.95kg
Weight of 2 yokes = 2 × W × Ay × density of laminations
= 2 × 800.7556344 × 10−3 × 26434.7412 × 10−6 × 7.6 × 103
= 321.75kg
xiv
From fig?? Taking the specific core loss accordingly:
F or limb at Bm = 1.2 W b/m2 , specif ic iron loss in limb = 2W/kg
F or yoke at By m = 1.043478 W b/m2 , specif ic iron loss in limb = 1.3889W/kg
Core loss (Pi1 ) = Weight of 3 limbs × sp. core loss in limbs
= 184.95 × 2
= 369.9W
Core loss (Pi2 ) = Weight of 2 yokes × sp. core loss in limbs
= 321.75 × 1.3889
= 446.878W
Total core losses(Pi ) = 369.9 + 446.878
= 816.778W
Total losses(PT ) = 3467.88275W
EFFICIENCY
Pout
Efficiency at unity p.f = × 100%
Pout + losses
150 × 103 × 1
= × 100%
150 × 103 × 1 + 3467.88275
= 97.74%
Pout × p.f
Efficiency at 0.8 p.f = × 100%
Pout × p.f + losses
150 × 103 × 0.8
= × 100%
150 × 103 × 0.8 + 3467.88275
= 97.19%
For maximum efficiency
x2 Pcr
= Pi
Pi
x=
r Pc
816.778
=
2651.10475
= 0.555058
= 55.5058%
xv
NO LOAD CURRENT
From fig??
Corresponding to a flux density of 1.2 Wb/m2 and 1.04378 Wb/m2 in the limb and yoke respectively,
atc = 400 A/mt and aty = 233.333 A/mt respectively.
Total magnetizing mmf = 3 × atc × Hw + 2 × aty × W
= (3 × 400 × 392.1033568 + 2 × 233.333 × 800.7556344) × 10−3
= 844.209457AT
totalmagnetizingmmf
magnetizing mmf per phase(AT0 ) =
3
844.209457
=
3
= 281.4031523AT /phase
AT0
Magnetizing current (Im ) = √
2Tp
281.4031523
= √ = 0.9944A
2 × 2001
= 99.4413mA
Pi
Loss component of no load current (Il ) =
3 × Vp
816.778
=
3 × 11 × 103
= 0.02475A
= 24.7508mA
p
2 + I2
No-load current(I0 ) = Im l
= 102.47523mA
= 0.10247523A
I0
% of no load current as of full load current = × 100%
Ip
0.10247523
= × 100%
4.5443
= 2.255%
xvi
0.9 DESIGN OF TANK
for 11KV, 150KVA transformer clearance for tank are as follows:h = 450mm l = 50mm b =
40mm
Height of tank(HT ) = H + h
= 715.7121264 + 450
= 1165.712126mm
Width of tank(WT ) = 2D + Dext,HV + 2b
= 2 × 318.6904722 + 294.3755184 + 2 × 40
= 1011.756463mm
Length of tank(LT ) = Dext,HV + 2l
= 294.3755184 + 2 × 50
= 394.3755184mm
Now,
Surface Area of tank (St ) = [2 × (Lt + Wt )] × Ht
= [2 × (394.3755184 + 1011.756463)] × 1165.712126
= 3278290.203mm2
= 3.27829m2
Total loss
Temperature Rise(θ) =
12.5 × St
3467.88275
=
12.5 × 3.27829
= 84.6266◦ C
Here, 84.6266◦ C > 48◦ C, hence we need a cooling system.
xvii
0.10 DESIGN OF COOLING TUBES
Total loss − 12.5 × θmax 3467.88275 − 12.5 × 48◦ C
Total Area of tubes = =
8.8 × θmax 8.8 × 48◦ C
= 6.789495147mm2
Let,
diameter of tubes = 50mm
length of tubes = 1m
Area of each tubes = π × 0.05 × 1
= 0.1570796327mm2
Total area of tubes
No. of tubes required =
Area of each tubes
6.7895
=
0.1570796327
= 43.22
Taking total number of tubes as 48.
The tubes are 75 mm apart from their centers, 25 mm apart from each other and their diameter are 5
Therefore, the clearance along the width and length can be:
Along width
10 × 50 + 9 × 25 = 725
1011.756463 − 725
Clearance = = 143.3782315mm
2
Along length
5 × 50 = 250
394.3755184 − 250
Clearance = = 72.1877592mm
2
xviii
0.11 Design Sheet
Core
1. Output constant K 0.45
2. Voltage per turn Et 5.5113 V/turn
3. Circumscribing circle diameter d 192.2055184 mm
4. Number of steps 2
5. Dimensions a 163.37469 mm
b 101.86892 mm
6. Net iron area Ai 20688.05833 mm2
7. Flux density Bm 1.2 Wb/m2
8. Flux ϕm 24.82567 mWb
9. Weight of 3 limbs 184.95 Kg
10. Weight of 2 yokes 321.75 Kg
11. Specific iron loss in limb 2W/mm2
in yoke 1.3889 W/mm2
Yoke
1. Depth of yoke Dy 163.37469 mm
2. Height of yoke Hy 161.8043848 mm
3. Net yoke area Ay 26434.7412 mm2
4. Flux density Bm 1.043478 Wb/m2
Window
1. Window space factor Kw 0.243902
2. Height of window Hw 392.1033568 mm
3. width of window Ww 1236.4849538 mm
4. Window area Aw 49595.17497 mm2
Frame
1. Distances between adjacent limbs D 318.6904722 mm
2. Height of frame H 715.7121264 mm
3. Width of frame W 800.7556344 mm
xix
Winding L.V H.V
1. Type of winding Hellical Cylindrical
2. Connection star delta
3. Current density 3 A/mm2 2.33246 A/mm2
4. Turns per phase 42 2001
2112 at +5.5%
5. Coil diameter inside 202.9255184mm 253.7255184mm
6. Coil diameter outside 223.9255184mm 294.3755184mm
7. Length of mean turn 670.4960407mm 781.1586419mm
8. Resistance 0.0082136 Ω 18.569 Ω
Impedance
1. P.U resistance ER 0.01537 p.u
2. P.U reactance EX 0.063744 p.u
Losses
1. Total core loss Pi 816.778 W
2. Total copper loss Pc 2651.10475 W
3. No load current I0 0.10247 A
4. Efficiency at full load and 0.8pf 97.19%
5. Efficiency at unity pf 97.74%
6.All day efficiency 55.0583%
Tank
1. Length Lt 394.3755184 mm
2. Height Ht 1165.712126 mm
3. Width Wt 1011.756463 mm
4. Temperature rise θ 78.1268◦ C
xx
Tubes
1. Length lt 1000 mm
2. Diameter dt 50 mm
3. Separation between center 75 mm
4. Separation between tubes 25 mm
5. Total area of tubes At 6789494.555 mm2
6. Area of each tube at 157079.6327 mm2
7. Number of tubes 48
xxi
Figure 1: Standard Area for round Copper Conductors
xxii
Figure 2: Standard Area for Copper Stripes Conductors
Figure 3: B-H Curve
xxiii
Figure 4: Specific Iron Loss Curve
xxiv
