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DESIGN AND DEVELOPMENT OF NANO PARTICLES TRANSFORMER TESTER, Part
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2nd Integrated Design Project Conference (IDPC) 2015
Faculty of Mechanical Engineering, Universiti Malaysia Pahang, 11 Dec 2015
DESIGN AND DEVELOPMENT OF NANO PARTICLES TRANSFORMER TESTER,
Part 1
C.X. Lee, M. Johani, V.L. Goh, N.S.M. Najib, S.A.M.A.B.S.M A. Alkaff
Faculty of Mechanical Engineering, University of Malaysia Pahang,
26600 Pekan, Pahang Darul Makmur, Malaysia.
E-mail: steveleecx@gmail.com
ABSTRACT
Electrical power transformer is a static devise which transforms electrical energy from one
circuit to another without any direct electrical connection and with the help of mutual induction
between two windings. It transforms power from one circuit to another without changing its
frequency but may be in different voltage level. This project is to design and develop a cooling
system test rig for the transformer. This cooling system is expected to reduce the temperature of
the transformer within 10 minutes period. This cooling test rig is built according to power rating
of transformer, windings size, dimension of plate for coolant flow, diameter of holes and
rotational speed of cooling fan and most importantly with low cost. In term of the temperature
drop of the transformer, the data obtained by recording the reading displayed by the universal
monitoring thermometer. Compare to the conventional method that used fan in air cooling
system, our design has higher efficiency in term of rate of heat transfer due to the combination of
air and coolant. This could serve for further improvement in the future in order to contribute in
this industry.
Keywords: Transformer, cooling system, test-rig
INTRODUCTION
A transformer is a device that transfers electrical power from one voltage level to another level
without energy conversion. The transfer of energy takes place through the magnetic field.
ANSI/IEEE defines a transformer as a static electrical device, involving no continuously moving
parts, used in electric power systems to transfer power between circuits through the use of
electromagnetic induction[1, 2]. Transformer is the most important and critical equipment in
Transmission Line Grid [3]. Transformers are designed according to its operation environment
Transformer design optimization is mainly determined by minimizing the overall
transformer cost which consist of materials cost, labor cost and system losses cost that
were taken into consideration constraints connected to international technical specifications
and transformer user needs [4, 5]. In recent years, the modernization and globalization takes
place rapidly especially in big cities and urban area. Along with this, the electric power
consumption has also increasing strongly. The traditional transformer cooling technologies
mainly involve natural air cooling, forced air cooling and water cooling [6-9]. Forced air and
water cooling methods are more widely used due to the larger and larger capacity of transformers
need in urban grid nowadays [9].
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2nd Integrated Design Project Conference (IDPC) 2015
Faculty of Mechanical Engineering, Universiti Malaysia Pahang, 11 Dec 2015
The only advantage of natural air cooling is that its cooler is cheap and no need for
maintenance. Forced air cooling with fans blowing the air is adopted to get better cooling effect.
Meanwhile, the heat transfer coefficient of water achieving more than 1000W/m2K which is
having a much better cooling effect than air cooling where water is the coolant medium. In real
life application, temperature give a really big impact on the life of a transformer [9]. During the
long hours of transformers operation, heat losses will arise which are necessary to take away
from the transformer to the surrounding using of different types of cooling [10]. One of the main
sources of losses and reasons for temperature rise in various parts of a transformer are magnetic
circuit and windings [11]. Large transformers thus need more intense cooling to remove thermal
losses[12]. The basic purpose a cooling system is to limit the temperature of a transformer. The
main two parameters of cooling optimization of a transformer are the temperature and losses of
the cooling system of a transformer. The ageing of a transformer can be slowed down by
lowering the temperature and at the same time increases losses of the cooling system [13]. The
way of the transformer cooling system control has a direct effect on its thermal performance.
Therefore the transformer operating conditions can also be optimized by effective cooling system
control [14]. Natural convection cooling by air or oil and forced convection cooling by air and
oil can be adopted to prevent the transformer from adverse effects [15].
An objective comparative measure of hot and cold that measured by thermometer is called
temperature [16]. It may work through the bulk behavior of a thermometric material, detection
of thermal radiation, or particle kinetic energy [17]. For experimental physics, hotness means
that, when comparing any two given bodies in their respective separate thermodynamic
equilibrium, any two suitably given empirical thermometers with numerical scale readings will
agree as to which is the hotter of the two given bodies, or that they have the same temperature
[18]. This does not require the two thermometers to have a linear relation between their
numerical scale readings, but it does require that the relation between their numerical readings
shall be strictly monotonic [19]. Therefore, this project was done to design and develop a new
cooling system for the transformer by using water and air form fan.
METHODOLOGY
The design and development of Nano particles transformer tester is divided into 4 stages. It
begins with gathering of information, then concept generation, followed by fabrication and
testing. In the first stage, we gather all the related information we search and study from internet,
journals and articles such as the mechanism of transformer, how it’s work, heat distribution of
the winding of transformer, how to capture the heat loss from the transformer, medium of
cooling and etc. The design parameters for our tester are then being discussed briefly and the
fabrication methods to be used as described in literature review.
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2nd Integrated Design Project Conference (IDPC) 2015
Faculty of Mechanical Engineering, Universiti Malaysia Pahang, 11 Dec 2015
Concept Design
The first design of the Nano particles transformer tester is made by using computer aided
design software (CAD) named SolidWorks 2012. The design consists of an industrial type
transformer, a 10 x 10mm Aluminium plate with 18 holes for the flow of the coolant and a
cooling fan attached on the plate. Parameters such as the power rating of the transformer, size of
the winding for the cooling system, dimension of the plate, diameter of the holes and rotational
speed of the cooling fan. The measurement and instrumentation equipment is determined after
the design is done.
In this project, we simulate the transformer with two 60W light bulb connecting in series
configuration and a tank that made up of galvanized iron. Figure 1 shows the interior circuit and
design of the simulated transformer. Figure 3 on the other hand shows the design of the cooling
system with a 10 x 10mm Aluminium plate for coolant flow and heat sink. The design concept is
to test how much the cooling system is able to reduce the temperature of the cover of the tank.
This experiment is carried out in a few times in order to observe the capability of each
component of the cooling system to act as the priority in the tester. Table 1 highlights the name
and purpose of each important parts of this tester as labeled in the Figure 1 and Figure 2.
1
2
Figure 1: Interior design of the simulated transformer
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2nd Integrated Design Project Conference (IDPC) 2015
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3
4
Figure 2: Design of the cooling system with a 10 x 10mm Aluminium plate for coolant flow and
heat sink
Table 1: Important parts of the nano particles transformer tester
Parts
No.
1
2
3
4
Parts Name
GI Tank
Light Bulb
Heat Sink
Aluminium Plate
Function
Simulated as the casing of the transformer
Simulated as the heat source of the transformer
One of the component of cooling system tester using air as medium.
One of the component of cooling system tester using liquid as
medium.
Temperature Distribution Analysis
The designed cooling system was analyzed for its steady-state temperature distribution at
the tank cover area by using Autodesk 2015 to perform the Finite Element Analysis (FEA) [2024]. The heat source supplied by the bulbs is 4.2781 x 10−4 W/mm2 . Heat transfer coefficient
for galvanized iron is given by 5.7 W/m2 K. The initial temperature taken is 30.5 °C and tested
for 10 minutes. From the analysis illustrated in Figure 4 below, at 5 minute interval the
maximum temperature is 41.3333 °C and the minimum temperature is 41.3332°C. Thus, it can be
conclude that the distribution of temperature is even across the horizontal plate of the tank cover.
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2nd Integrated Design Project Conference (IDPC) 2015
Faculty of Mechanical Engineering, Universiti Malaysia Pahang, 11 Dec 2015
Figure 3: Temperature distribution of tank cover
Heat Transfer
Heat transfer has emerged as a central discipline in contemporary engineering science
[25]. Theoretically, heat is transferred from a high temperature object to a lower temperature
object. It changes the internal energy of both system and obey the First Law of Thermodynamics.
In the cases of conduction and convection, energy transfer between two objects depend
approximately on the temperature difference between them [26]. Convective heat transfer is the
study of heat transport processes effected by the flow of the fluids [25]. In early days,
Tuckermann and Pease [27] studied the fluid flow and heat transfer characteristic in microchannels, with the means of convective flow of water through micro-channel.
In our experiments, we used two incandescent light bulb to obtain heat. According to
Wikipedia online encyclopedia, a 60 watt bulb is only 2.1% efficient, which means that it
produces about 1.26 watts of light and 58.74 watts of heat. Although they are extremely
inefficient, yet appropriate for our tester since we required heat energy more than light.
Conduction occur when a 60W filament is heated by passing an electric current through it. The
wire filament glows with visible light, but most of the energy is given off as heat. Then the heat
is transferred from the filament throughout the bulb via the motion of fluids (Argon gas). This is
called convection process. Last but not least, there are surface-to-surface and surface-to-ambient
radiation. The tungsten filament of an incandescent light bulb emits electromagnetic radiation in
the visible (and beyond) range. This radiation not only allows us to see, it also warms the glass
bulb that contains the filament. Put your hand near the bulb (without touching it) and you will
feel the radiation from the bulb as well.
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2nd Integrated Design Project Conference (IDPC) 2015
Faculty of Mechanical Engineering, Universiti Malaysia Pahang, 11 Dec 2015
Heat transferred by conduction:
𝑄
𝑡
=
𝑘𝐴(𝑇ℎ𝑜𝑡 −𝑇𝑐𝑜𝑙𝑑 )
𝑑
Heat transferred by convection:
𝑞 = ℎ𝐴(𝑇𝑎 − 𝑇𝑏 )
Heat transferred by radiation:
4
4
𝑞 = 𝜎𝐴(𝑇𝑤𝑎𝑙𝑙
− 𝑇𝑠𝑢𝑟𝑟
)
where σ = 5.67 x 10-8 W/m2K4
Figure 4: Dimension of the tank with two 60W light bulb
The heat absorbed by the cover of the tank can be obtained by applying convection
formula to the heat released by the two incandescent light bulb followed by the heat conduction
principle that influenced by the thickness, surface area and roughness of the tank cover.
Figure 5: Arrangement of the components of the cooling system
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2nd Integrated Design Project Conference (IDPC) 2015
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Fabrication Process
In the second stage which is the fabrication stage, we began with the selection of the
material for the tank that simulated as the casing of the transformer. We chose Galvanized Iron
as the material for the tank because it is several times more durable than mild steel and
Aluminium [28]. Then we use shear and bending machine in sheet metal laboratory to form the
shape of tank that we designed using SolidWork 2012. The quality of the product of bending
machine is influenced by the thickness and the die gap [29]. We also use spot welding to join the
contacting surface of the tank after bending. Resistance spot welding is a complicated process,
which involves the interaction of electrical, thermal, mechanical, and metallurgical phenomena
[30]. Last but not least, hand drill is use to drill four holes for the installation of the tank holder.
The final product is as shown in the figure below.
Figure 6: The final product of the tank as simulation of transformer
The important electrical components been purchased for the use in the tester are as shown
in Table 2.
Table 2: Electrical component purchased
Electrical Components
Units
Light Bulb
2
Cooling fan
2
Battery
1
Features
Philips 60W
Softone frosted
240V
Cooler Master
12 V DC
2200 rpm
9V Direct Current
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2nd Integrated Design Project Conference (IDPC) 2015
Faculty of Mechanical Engineering, Universiti Malaysia Pahang, 11 Dec 2015
The electrical circuits for the tester are designed. The electrical systems consist of two
incandescent light bulbs connecting in series to an AC power supply. Same goes to the four
thermocouples for the measurement of heat distribution on the cover of the tank [31]. The
thermocouples are placed on different location on the tank cover in order to observe the
distribution of the heat. On the other hand, the two cooling fan are not using AC power supply,
but 9V motorbike’s battery that supply direct current instead.
The fabrication process is continued with the machining of two Aluminium plates for the
flow of the coolant. Based on the design of the plate in SolidWorks 2012, we determined that the
material should have high conductivity of heat in order to achieve the cooling objective.
Improvement in the thermal conductivity of aluminum can be realized by additives that have a
high thermodynamic affinity toward alumina (Al2O3) [32]. Mettawee and Assassa (2007)
conclude that by embedding aluminum in the paraffin wax enhances its thermal conductivity
[33]. Thus, we decide to use Aluminium for the machining of the plate. Firstly, we cut the
Aluminium block according to the dimension required. Then we went to do the squaring process
to obtain the exact dimension and good finishing of the plates. Last but not least, we use
computer numerically controlled (CNC) machine to drill the holes of 7 mm diameter on the
Aluminium plates for the flow of the coolant [34, 35].
Figure 7: The top view of the cover tank consist of heat sink, Aluminum plates and
plastic tube
After the Aluminium plate is machined, the plastic tubes are used to connect the holes of
the plates with super glue. When this is done, the heat sink is then joined together by using epoxy
adhesive on top of the Aluminium plates. Failure of adhesive joint usually involves considerable
geometrical and material non-linearity [36]. Thermal paste is applied on the surface of the
Aluminium plates before they are pasted on the tank cover to enhance the heat conduction or
heat transfer between the cover and aluminum plates [37-40]. Epoxy adhesive is applied on the
edges of the plates to increase the strength of the joints between the plates and the cover tank. A
biscuit tin is machined to act as the tank for the coolant. A pump is connected to one end of the
plastic tubes of the Aluminium plates, while the other end is placed in the coolant tank.
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2nd Integrated Design Project Conference (IDPC) 2015
Faculty of Mechanical Engineering, Universiti Malaysia Pahang, 11 Dec 2015
The last stage is to test the fabricated test rig for its performance. Any potential
improvement can be made will be noted and the improvement will be done according to the time
available and skills possessed.
Figure 8: The final set up of the Nano particle transformer tester
RESULT AND DISCUSSION
The experiment has been carried out a few times in order to obtain accurate data. First testing is
conducted without the cooling system to observe the maximum temperature achieved by the tank
cover within 10 minutes in ambient condition. Temperature readings from the thermocouples
LCD display are collected every one minute to produce patterns in graph. The experiment is
repeated with cooling system. We began with the cooling system using water only, followed by
both water and air cooling system. Tables and figures below show the result of the tests carried
out to determine the effect of the cooling system on the hot tank cover after absorbing the heat
released from the light bulbs in the tank.
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2nd Integrated Design Project Conference (IDPC) 2015
Faculty of Mechanical Engineering, Universiti Malaysia Pahang, 11 Dec 2015
Table 3: Result of comparison between three different conditions: (a) without cooling (b) water
(c) water and fan
Time (Min)
Temperature (°C)
without cooling
Temperature (°C)
cooling water only
Temperature (°C) with
cooling (water and fan)
0
1
2
3
4
5
6
7
8
9
10
30.5
36.6
40.4
43.6
45.8
49.2
49.6
52.7
54.1
57.6
59.2
30.5
34.7
36.9
39.7
42.2
44.8
46.1
47.4
48.0
48.9
49.6
30.5
34.1
36.0
37.3
38.2
39.0
39.7
40.1
39.3
40.0
39.7
Figure 9: Graph of temperature in three different condition vs time
In the beginning, the temperature of the tank cover is same as the ambient temperature,
which is 30.5oC. As the light bulbs are switched on, the countdown started. From Table 3, it is
obvious that the temperature of the tank cover showed an increasing pattern, despite of the
presence of cooling system. However, compare among the 3 experiments, within the period of 10
minutes, the experiment without cooling system has gradually increased to 59.2oC. Meanwhile,
the implementation of cooling system on the tank cover has successfully reduce the rate of
temperature rising. This is showed by the temperature reading of the second and third testing that
only achieved 49.6oC and 39.7oC respectively.
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2nd Integrated Design Project Conference (IDPC) 2015
Faculty of Mechanical Engineering, Universiti Malaysia Pahang, 11 Dec 2015
Table 4: Result of cooling temperature
Time (s)
0
30
60
90
120
150
180
210
240
270
300
Temperature (°C)
62.5
52.6
48.0
46.1
48.0
45.2
45.5
44.3
45.2
45.5
45.2
Cooling Temperature vs Time
70
Temperature (°C)
60
50
40
30
Temperature (°C)
20
10
0
0
30
60
90
120
150
180
210
240
270
300
Time (sec)
Figure 10: Graph of cooling temperature vs time
For the next testing, the tank cover was leave to heat up to 60.2oC. The light bulbs are
remaining switch on in order to obtain continuous heat absorption on the tank cover. Stopwatch
began the countdown when the cooling system is activated. Temperature readings are taken for
every 30 seconds until 300 seconds. The result showed that there is a significant declination of
temperature in the first 90 seconds. When it reached 46.1oC, unstable pattern started to appear in
the range of 44oC - 46oC. Thus, we can conclude that the cooling system can be improved by
replacing the coolant with fluid with higher rate of heat transfer.
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2nd Integrated Design Project Conference (IDPC) 2015
Faculty of Mechanical Engineering, Universiti Malaysia Pahang, 11 Dec 2015
In methodology section, we mentioned that the designed cooling system was analyzed for
its steady-state temperature distribution at the tank cover area by using Autodesk 2015 to
perform the Finite Element Analysis (FEA) [20-24]. Four thermocouples were installed in the
transformer tester to measure the temperature distribution experimentally, on the tank cover
during the heat run tests. The data is tabulated in Table 5 and analyzed graphically in Figure 11.
Result shows that the distribution of temperature is even across the horizontal plate of the tank
cover.
Table 5: Result of temperature distribution at four different points
Time (min)
0
1
2
3
4
5
6
7
8
9
10
T1
28
29
31
32
33
33
34
34
35
35
36
T2
28
29
31
33
33
34
34
35
35
35
36
T3
28
31
32
34
34
35
36
36
37
37
38
T4
28
29
31
32
33
34
35
36
36
37
38
Temperature (˚C)
40
35
30
T1
25
T2
20
T3
T4
15
10
5
0
0
1
2
3
4
5
6
7
8
9
10 Time (min)
Figure 11: Graph of temperature distribution at four different points vs time
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2nd Integrated Design Project Conference (IDPC) 2015
Faculty of Mechanical Engineering, Universiti Malaysia Pahang, 11 Dec 2015
CONCLUSION
This project was an attempt to develop a cooling system of a transformer for future
improvement. The transformer prototype and cooling system were designed by using
SolidWorks 2012 and the temperature distribution analysis was performed by using Autodesk
2015 to perform the Finite Element Analysis (FEA) to determine the heat distribution on the tank
cover. The simulation shows that the distribution of temperature is even across the horizontal
plate of the tank cover. From the experiment, it shows that this cooling system is able to reduce
the temperature absorbed by the tank cover approximate 20oC within 10 minutes testing period.
The project is successful in reducing the temperature of the test rig by using both water as the
cooling medium and fan. Meanwhile, the temperature distribution in different points is almost
the same. The suggested improvement is replacing the coolant with oil or Nano particle that
claimed to have high conductivity of heat. Overall, this project has achieved the objective to
develop Nano particles transformer tester that capable of perform a cooling testing with Nano
fluids. The heat transfer coefficients with Al2O3 nanofluid increased by 12 to 15% with the
increase of volume concentration from 0.02 to 0.5% compared to water. [41]
ACKNOWLEDGEMENTS
Throughout the completion of this project, we would like to express our upmost gratitude toward
our project supervisor, Dr. Kumaran a/l Kadirgama for his ideas, supports and guidance. Other
than that, we would like to thanks Dr. Muhamad bin Mat Noor for providing the financial
assistance under mechanical system design project and for his guidance. Not forgotten to thanks
the lab assistants for providing help throughout this project completion.
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Faculty of Mechanical Engineering, Universiti Malaysia Pahang, 11 Dec 2015
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