Selection of no of turns Et=K√Q, Et voltage per turn, Q rated kvA, K is decided, for

aluminium k=0.32-0.35,for copper k=0.37-0.45. Selection of Core Diameter

Et=phase voltage/turns=4.44*f*Bm*Ag*0.97*10-4, Bm is flux density in tesla, Ag
gross core area sqcm,0.97 stacking factor, Ag=K1π*d2/4, K1is factor to select basic of
no of core step & d is diameter. For 6 step core K1=0.92, 7 step core K1=0.925, 8 step
core K1=0.93, 9 step core K1=0.935, 10 step core K1=0.94, 11 step core K1=0.945.
Selection of Winding Wires & Strips Current density for aluminium= 1.5A/Sqm m,
For copper=3A/Sqmm.KVA=√3 *V*I. conductor area=current per phase/current
density For 100kva t/f has voltage ratio 11000/433v delta/star connection find
current Secondary current=100k/433*√3, line current=133.34A. Primary current=
100k/11000*√3=5.25A,Primary in delta so 5.25/√3=3.03A.Conductor area=current
per phase/current density. Calculation of size of high voltage conductor For
distribution t/f of medium capacity conductor chose for primary winding in round
shape. Conductor area=πd2/4. If diameter of conductor more than 3.5mm rectangular
strips used. equivalent rectangular strip has good result than thick round conductor..
thick round conductor has poor surface area as well be as a poor space factor.
Comparison of space factor of round and rectangular conductor
Round conductor of dia=3.6m m Equivalent strip 6*1.7mm
Cross sectional area πd2/4=1.018sq m m 10.2sqm m
Surface length π d=11.3m m (L*B)*2=15.4mm
Space factor 1.27 1.0
Calculation of size of low voltage conductor Low voltage conductor current is high.
Rectangular conductor used. Multiple strips in parallel select for high rating t/f.
current has tendency to flow through surface of conductor is skin effect.
Max depth of strip It should not be more than
half of strip width. If width is 9mm, its depth not
more than 4.5mm in any case. Width/depth >2.
Minimum depth of strip Min depth of strip1:6. For practical ratio is 1:4 means min
depth 9/4=2.25mm. width/depth <4. Transposition In case of a non-transposed coil
strip place as a lower mean length than that of upper strip. In such case When two
strips of unequal resistance placed in parallel, strip placed below will greater share of
current because of Its low resistance, while strip placed above will share less current
owing to Its high resistance. purpose of transposing strips is to make length of
strips almost similar, there by making resistances of both strips equal, transposition is
done to minimize leakage reactance. A non-transposed coil is one of reasons to yield
more reactance than calculated design value. Design of 100 kVA t/f(delta/star):
working current density of Primary side HV side (11000/433)v Voltage
per phase=vp=11000v. current per phase Ip=100/√3*11= 5.248/√3=3.03A Current
density=1.5A/sqmm. Conductor area=3.03/1.5=2.02sqmm. equivalent conductor dia=
πd2/4=2.02sqmm, d=1.603mm, let d=1.7mm. area after propose conductor= πd2/4=
π(1.7)2/4=2.27sqmm, working current density=3.03/2.27= 1.335A/sqmm.
Number of turns per coil Et=K√Q for aluminum k=0.32-0.35 let k=0.33Qis rating
value Et=0.33√100=3.3, no of sec turn=secondary phase voltage/Et= 433/√3/3.3=76T
no of primary turn at normal= Primary phase voltage*secondary turn /sec phase
voltage=11000*76/433/√3=3344T. additional turn toward 5% tapping
voltage3344*5/100=1687turn, total primary turn=3344+168=3512turn. No of coil per
phase=4m, so turn per coil=3512/4= 878 turn. The HV winding design Process
Description Length Radial
Bare conductor(wire size) 1.7mm 1.7mm
Covering thickness +0.2 +0.2
Cover conductor 1.9mm 0.8mm
Gap b/t 2 consecutive conductor +0.05 WorkTol(5% +0.05 working tolerance
Insulate size of conductor with 1.95mm 1.95mm
working tolerance (size of 1 conductor) +0.1(4mil inter paper
layer insulation)
Turn per layer (878/17+1)=53 *53 2.05mm
17 is the layer must in odd no *17(no of layer in odd)
Axial length of HV coil rounded 103.35 34.85mm (radial build
off to =104mm 35mm of HV coil)
Estimating core Window height Total axial length of 4 coils=4*104mm=416mm
Gap b/t yoke to top& bottom coil=2*25mm=50mm, Gap b/t 2 tap coil at center=
1*10mm=10mm, Gap b/t plain coil= 2*7mm= 14mm, all values add=490mm
Window height ki HVside limits ma rahty hovy LV seide ko design karna ha
Working current density of LV side
Secondary coil Voltage per phase Vs=433/√3=250v. current per phase
Is=100k/433*√3=133.7A, Current density Cd=1.5A/sqmm, conductor area=
133.34/1.5=89sqm m. so conductor dia= πd2/4=89. D=10.6>3.5mm , so we use strips.
No of strips Proposed to be use in parallel=2nos. Approx area of each strip= 89/2=
44.5sqmm. Et= 0.33√100=3.3 no of sec turn=secondary phase voltage/Et=
433/√3/3.3=76T .Dispos ition of strip=1w*2D, no of secondary turn=76T. 76/2=38T.
space require to accommodate 38T=38+1=39T. steps place one alone other so,
transposition required= 39+1=40turn. Gap b/t LV coil to yoke at top & bottom
=10mm. Window height = 490mm. axial length available to accomodate 40T=
490-(2*10)=470mm, Approx width of Lv strip winding thickness= 470/40= 11.75 m
m, Air gap b/t two consecutive conductor (assume) =0.1mm, (10% working tolerance)
so,width of bare conductor taking consider of covering thickness 0.4 mm =
11.75-(0.4+0.11) =11.25, Let width=11mm, Area of each strip (calculated before)
=44.5sqmm. approx depth of bare conductor=44.5/11=4.05mm. Let depth(11kay half
say kam ho) =4.5 mm. Area of proposed 1strip= 11*4.5=49.5sqmm. We need to
reduce area by its rounding-off factor 0.21sq mm up to depth of 1.6mm. 0.36 sq mm
up to depth of 2.24mm, 0.55sq mm up to depth of 3.25mm. 0.86sq mm above 3.25m.
Since this case, depth is 4.5 mm. rounding-off factor is 0.86 sq mm. net area of one
strip, after taking into consideration rounding-off factor=49.5-0.86=48.64sq mm.
Total area of two strips =48.64*2=97.25sqmm. Working current density of LV
side=13.34/97.28=137A/sqmm. Radial width of LV side
Length Radial
Bare conductor size 11mm 4.5mm
Covering thickness +0.4 +0.4
Cover strip size 11.5mm 4.9mm
Gap b/t 2 consecutive strips +0.1 +0.1
Insulated size of strip with working 11.5mm 5.0mm
tolerance
Placement of strip(1w*2D) *1w *2D
Effective dimension of each turn 11.5mm 10mm(for 1st layer)
Space required to accommodate *40 (turn) +0.25(inter layer insulation)
38turn(38+2)=40turn +10mm(for 2nd layer)
Length of LV coil 460mm 20.25= 21.0
Use end packing of 5mmon either +10mm
side of coil(5*2=10mm)
Length of LV coil with packing 470mm 21.0mm Radial build of LV side
Core Diameter Approximate core diameter is: Voltage per turn Et=433√3/76=3.289,
Flx densityBm=1.6T, Stacking factor=0.97, Gross core area Ag=?, Et=4.44*f*Bm*Ag
*0.97*10-4 ,Ag=Et/4.44*f*Bm*0.97*10-4= 95.5sqmm, Ag= K1πd2/4, d=√4Ag*/πK1,
=11.403 cm*10=114mm. Step Width 1st step=110mm(L1) 2st step=105mm(L2)3st
step= 100mm(L3) 4st step=90mm(L4) 5st step=80mm(L5) 6st step=70mm(L6) 7st step=
60mm(L7) 8st step=50mm(L8) 9st step=40mm(L9) Core stack K=√d2-L2 , L=step
width,1st step (LI = 110 mm), K1 =√1142 -1102 = 29.93 mm, 2nd step (L2 = 105 mm),
K2 =√1142 - 1002 (-) 29.93=14.46 mm, 3rd step (L3 = 100 mm). K3 √1142 -1002 (-)
44.39 =10.34 mm, up to9 step. K=K1+K2+k3+k4+k5+k6+k7+k8+k9=106.75mm.
Core Area Total gross core
Step no Step width Core stack Gross core area area=9594.2sqmm
1 110 (L1) 29.8 (K1) 3292.3 (L1*K1) Net core area=gross
2 105 (L2) 14.46 (K2) 1518.3 (L2*K2) Core area*stacking
3 100 (L3) 10.34 (L3*K3) factor= 9594.2*0.97
4 90 15.24 (L4*K4) 9306.374=sqmm
5 80 11.24 (L5*K5)
6 70 8.76
7 60 6.86
Flux Density Et=4.44*f*Bm*Ag*0.97*10-4, Bm=Et*104/4.44*f*Ag*0.97 (tesla)
Bm=3.28*104/4.44*50*95.942*0.97=1.592 Tesla.
Coil Diameter & Core Limb Center Core diameter=114mm, radial build of LV
coil=21mm, Radial build of Hv coil=35mm, core of LV coil gap=3mm(assume)
Gap b/t LV & HV =10mm(assume),
Radius Diameter
Core diameter 57 *2 114mm Core limb
Radial gap b/t core of LV +3 +(2* 3) centre=265m
Lv coil iside diameter 60 *2 120mm
Radial build of LV coil +21 +(2*21)
LV coil outside dimeter 81*2 162mm
Radial gap b/t LV &HV +10 +(2*10)
HV coil inside diameter 91 182mm
Radial build of hv coil +35 +(2*35)
Hv coil outside diameter 162mm 252mm
Gap b/t HV limb b/t phase +13
Core frame size & core Detail Core dameter=114mm, window
height=490mmLlimb centre(c/L)=265mm, grade of core=27-M4,
gross core area=95.942sqmm, no of steps=9, core step width=
110/105/100/90/80/70/60/50/40mm. core stack=29.93/ 14.46,
10.3/15.24/11.24/8.76/6.96/5.52/4.3mm, total core stack=106.75.
Approximate Weight of Core Weight of core complete in kg=
[(3*w/h-in cm)+(2*0.86*width of 1st step-in cm)*(gross core area)*(density of core
material)*0.97*10-3]= [(3*49+4*26.5)+(2*11*0.86)*95.942*7.65*0.97*10-3]=193kg
Weight of LV &HV Aluminium

Parameter LV Coil HV Coil

Inside diameter of coil-D1 120mm 182mm
Inside diameter of coil-D2 162mm 252mm
Mean diameter=DM=D1+D2/2 141mm 217mm
Mean length of turns L1= π*DM 443mm 682mm
No of turns (T) 75T 3344+168=3512T
Total length of conductor (L=L1*T) 33668mm 2395184mm
Specific quantity of aluminium (S) 2.76g/cm 2.76g/cm
Cross sectional area of conductor- A 97.28sqmm 2.27sqmm
Bare weight of conductor for 1 phase 9Kg 15Kg
(L*A*5*10-6)
For 3 phase 27kg 45kg
Weight of covered conductor (7% of 27*1.07 45*1.14
LV strip & 14% of HV wire ) 29kg 51.5kg
Bare conductor weight
Winding Resistance & Load Losses
parameter LV coil HV coil
Total length of conductor L=L1*T 33668mm 2280mm
Resistivity of electrolyte aluminium-K 0.034 Ω cm at 75c0 0.034 Ω cm at 75c0
Cross sectional area of conductor-A 97.28sqmm 2.27sqmm
Winding resistance per phase at 75c0 0.012Ω 3.4.7Ω
R=L*k*10-3/ A
Current per phase 133.34A 3.03A
I2R* 3 214*3=642w 319*3=957w
Total I2R (LV+HV) 642+957=1599w
Aprox stray loss for 100kvA 100w
Load loss at rated load 1599+100=1699w
Load loss(garanted) 1760w (maximum)
No- Load Loss Core diameter=114mm, core window height=490mm, core
limb=265mm, gross core area=95.942sqcm. net core area=93.06sqcm, working flux
density=1.592T, specific loss(watt/kg)at 1.6T for grade M-4=1.0w/kg, handling factor
=25%, effective core loss per kg=1*1.25=1.25w/kg, total weight of core= 193.6 kg.
calculated no load loss=193.6kg*1.25w/kg=242w. no load loss=260w(max)