CHAPTER 4

DESIGN CALCULATION OF CURRENT TRANSFORMER AND

VOLTAGE TRANSFORMER

4.1. Selection of CT Rating for 33 kV Line

In this thesis, 50 MVA transformers is used for 33 kV line. Then the line
current is calculated in the following equation.

S = √3 VI

I =S/ √3 V

I = (50 × 106) /( √3 × 33 ×103)

I = 874.77 A
Therefore, 1000:1 CT is selected. Thus, the primary rating of CT is 1000 A
and secondary rating is 1 A.

4.2. Specifications to Design

A design based on the following typical specifications.
Rated Output 50 VA
CT rating 1000:1
Rated secondary current 1A
Frequency 50 Hz
Percentage tapping 10%
Design Tank type
Isolation Oil -paper
Insulation Level 17~70 kV
Ambient temperature -10°C to +50°C
Location Outdoor

4.3. Design of Magnetic Frame of Current Transformer

 38

50 VA rating of Current Transformer is designed, S = 50 VA

 27

Net cross section area of iron core,

√s
Ai = 5.58

√ 50
Ai = 5.58
= 1.267 sq-in
= 1.267 × (2.54)2
= 8.174 cm2
Stacking factor, ks = 0.9
Gross cross section area of iron core,
Agi = A i / ks
Agi = 8.174 / 0.9
= 9.082 cm2
The form of magnetic frame of CT is toroidal type (circular ring). So, the
circumference condition (the inner diameter, the outer diameter, the height of the
core, and the width take place by the winding) will be calculated.
Width of the ring face,

A = √ A gi
A = √ 9.082
A = 3.014 cm
Then, Agi = A × B
And A = B (It is assumed as the square core)
So A = B = 3.014 cm
The ratio B/A must have 1.5~ 2.0
Choice the value of A within the ratio B/A = 1.5~2.0
If A = 2.4 cm, the height of core B = 9.082/2.4
B = 3.784 cm
Where;OD - outer diameter of core
ID - inner diameter of core
B - height of core
A - width of core
These dimensions are shown in Figure 4.1.
 28

Inner radius IR = 5.5 cm

Outer radius, OR = IR + A
= 5.5 cm + 2.4 cm
= 7.9 cm
Outer diameter, OD = 2 × OR
= 2 × 7.9
= 15.8 cm

ID

OD

Figure 4.1. Magnetic Ring of Current Transformer

4.4. Winding Design of CT

The winding design of CT differs from that of power transformer. While the
power transformer is considered with turns per volts, the current transformer is
considered with ampere-turn.
In this thesis, the design may be based on the winding developing typically
1000 ampere-turn at rated current so that a CT of 1000:1 ampere rating might have
1 primary turns and 1000 secondary turns (neglecting turns compensation).
The primary winding = 1000 A-T / 1000 A
= 1 turn
The secondary winding = 1000 A-T / 1 A
= 1000 turns
4.4.1. Turns Compensation
A reduction of the secondary winding by one or two turns is often to
compensate for the small current error introduced by component I e. The prospective
secondary current is then slightly high, but is reduced by the current error due to the
 29

exciting component with the result that the actual error may be very small. For lower
value burden or other power factor, the error would change in the positive direction to
a maximum of +70% at zero burdens; the leakage reactance of the secondary winding
is assumed to be negligible.

4.4.2. Detail Design of Secondary Winding

Number of turn per phase, Ns = 1000 turns
Current density, δ2 = 2.0 A/mm2 (assumed)
Current per phase, I2 =1A
Cross sectional area, a2 = I2 / δ 2
= 1 /2.0
= 0.5 mm2
According to the above value, the rectangular copper conductors are selected.
Thus 1000 turns will be arranged, 50 axially and 4 radically.
Length of the core = Length of the ring (Because it is toroidal core)
= 2 × π × IR
= 2 × π × 5.5
= 34.56 cm
Axial space for secondary winding = length of the core - (length of the core × 1/4)
= 34.56 - (34.56 × 1/4) cm
= 25.92 cm
Axial space available for one turn = 25.92 /50
= 0.5184 cm
Axial space for one strand = 0.5184 /1 cm
= 0.5184 cm = 5.814 mm
Therefore, size of rectangular strand = 5.5 mm × 0.8 mm
Modified sectional area of rectangular strand = 4.26 mm2 (from Table)
Size of strand with double cotton covering (fine) = 5.55 mm × 0.85 mm
Thus, the above selection of conductor size shows that the axial arrangement
is right and the winding will be well accommodated.

4.5. Design of Current Transformer Tank

 30

To design the dimension of tank, the following values must be assumed. Since
the tank is cylinder shape, only the clearance of diameter and clearance of height must
be known.
Winding thickness for width = 2 × {(wire thickness × number of layer) +
(insulation thickness ×numbers of insulation layer)}
= 2 × {(0.85 × 4) + (0.26 × 3)}
= 8.36 mm = 0.836 cm
Winding thickness for height = 2 × {(wire thickness × numbers of layer) +
(insulation thickness × numbers of insulation layer)}
= 2 × {(0.85 × 4) + (0.26 × 3)}
= 8.36 mm = 0.836 cm
Total clearance diameter, Δd = 1.67 cm (assumed)
Total clearance height, ∆h = 1.67 cm (assumed)
The diameter of the tank, Dt = OD + wire thickness for width + ∆d
= 15.8 + 0.836 + 1.67 = 18.306 cm
The height of the tank, Ht = B + wire thickness for height + Δh
= 3.784 + 0.836 + 1.67 = 6.29 cm

Insulation Thickness 0.26 mm

0.8 mm

IR = 5.5 cm
B = 3.784 cm

OR = 7.9 cm
A = 2.4 cm

Figure.4.2. Winding Design of Current Transformer

 31

1.25 cm

1.25 cm
1.25 cm
1.25 cm

Figure.4.3. Tank Design of Current Transformer

4.6. Cooling
The mineral oil can be used as a transformer cooling and insulation medium.
Mineral oil surrounding a transformer core-coil assembly enhances the dielectric
strength of the winding and prevents oxidation of the core. Dielectric improvement
occurs because oil has a greater electrical withstand than air and because the dielectric
constant of oil is closer to that of the insulation. Oil also picks up heat while it is in
contact with the conductors and carries the heat out to the tank surface by self-
convection. Thus a transformer immersed in oil can have smaller electrical clearances.

4.7. Performance Calculation of Designed CT

The performance for the designed current transformer can be calculated. To
get the efficiency, iron losses of the core and copper losses in the winding must be
calculated.
4.7.1. Iron Losses of CT
Volume of the cores, V= {π(OR)2 × h} – { π(IR)2 × h}
= πh{(OR)2 - (IR)2}
= π × 3.784 {7.92 – 5.52}
= 382.31 cm3
Weight of the cores = volume of the cores × density of the transformer steel
= 382.31 cm3 × 7.5 × 103 × 10-6 kg /cm3
= 2.867 kg
Flux density in core = 1.5 Tesla
Thus, Specific loss = 1.5 W/kg
Iron losses in the cores = 1.5 × 2.867
 32

= 4.3 W
4.7.2. Core Losses of CT
Width of the core, A = 2.4 cm
Height of the core, B = 3.784 cm
Core corner thickness, c = 0.8 mm (assumed)
Inner layer insulating paper thickness = 0.26 mm
Wire thickness for first layer = 0.85 mm
Inner layer insulating paper thickness for four layers = 3 × 0.26 mm
= 0.78 mm
Final layer insulation thickness = 0.4 mm
Wire thickness for four layer = 4 × 0.85 mm
= 3.4 mm
Thus, d = 3.4 + 0.4 + 0.78 mm
= 4.58 mm
= 0.458 cm
The mean length per turn, Lm = 2A + 2B + 4c + πd
= 2(2.4 + 3.784) + (4 × 0.08) + π(0.458)
= 14.127 cm
Total length for 50 turns = 14.127 × 50
= 706.35 cm
= 7.06 m
Resistance per phase of secondary winding,
R2 = ρLm/ a2
where, ρ - specific resistance
ρ = 0.0216 Ω-mm2/m (+75°C)
R2 = (0.0216 Ω-mm2/m × 7.06 m) / 2.5 mm2
= 0.061 Ω
Total copper losses in secondary winding = 3 × I2 × R2
= 3 × (1)2 × 0.061
= 0.183 W
Total losses = 4.3 + 0.183
= 4.483 W
4.7.3. Efficiency of CT
 33

Output power = Rating of CT × power factor

= 50 VA × 0.9
= 45 W
Input power = Output power + Total losses
= 45 W + 4.483 W
= 49.483 W
Efficiency = (Output power / Input power) × 100%
= (45 /49.483) × 100%
= 90.9 %
4.8. Calculation of Oil Weight for Current Transformer
To obtain oil mass, weight of the core, weight of the winding and weight of
the tank must be calculated.
Volume of the cores, Vc = {π(OR)2 × B} - { π(IR)2 ×B}
= π × {(OR)2 - (IR)2} × B
= π{7.92 - 5.52} × 3.784
= 382.31 cm3
Weight of the cores, Wc = volume of the cores × density of the transformer steel
= 382.31 cm3 × 7.5 × 103 × 10-6 kg /cm3
= 2.867 kg
Volume of the tank, Vt = π(Rt)2 × h
= π(Dt/2)2 × h
where, h = B + winding thickness + ∆h
= π × (18.306/2)2 × (3.784 + 0.836 + 1.67)
= 1655.5 cm
Weight of the tank, Wt = Volume of the tank × density of the steel
= 1655.5 × 7.93 × 103 × 10-6 kg/cm3
= 13.128 kg
Volume of the winding, Vw = {π(R)2 × h} - { π(r)2 × h}
= πh{(R)2 - (r)2}
where, R = r + winding thickness,
= 7.9 + 0.836
= 8.74
Vw = π × 3.784 {8.742 - 7.92}
 34

= 166.16 cm3
Weight of the winding, Wc = volume of the winding × density of the iron wire
= 166.16 cm3 × 7.86 × 103 × 10-6 kg /cm3
= 1.31 kg
Weight of the oil = Weight of tank - (weight of core + weight of winding)
= 13.128 – (2.867 + 1.31) = 8.95 kg

4.9. Selection of VT Rating for 33 kV Line

In this thesis, 33 kV line is used. Then the suitable VT rating is selected for

this line. Therefore, 33000/ √3 :110/ √3 VT are selected for this line.
4.10. Specification of VT
Rated Output 50VA

VT rating 33000/ √3 :110/ √3

Rated secondary voltage 110/ √3 V
Frequency 50 Hz
Percentage Tapping 10 %
Location Outdoor
Design Tank type
Isolation Oil-paper
Ambient temperature -10°C to +50°C

4.11. Design of Magnetic Frame of Voltage Transformer

By using these design equations, main dimension of magnetic frame are
calculated.
The e.m.f per turn,
Et = 4.44 f Bm Ai
The e.m.f per turn,

KVA
Et =K √ phase
For single phase core type, factor, K = 0.75 ~ 0.85
From this equations,
Net cross section area of core,
 35

Et
Ai = 4. 44 f B m

Gross cross section area of core,

Agi = Ai / ks
The suitable assumption of various design parameters have been given below.
Maximum flux density in the core,
Bm = 1.5 tesla
Stacking factor,
ks = 0.9 (assumed)
Average current density,
∂ = 2.0 A/ mm2
Window proportion,
L/ D- d (or) Hw/ Ww = 2.5 (suitable assume)
The gross cross section area of yoke,
Agy = 1.15 × gross cross section area of iron core, Agi
Main Dimension of Magnetic Frame of VT;
Design for 50 VA voltage transformer;
The e.m.f per turn;
Et = 4.44 f Bm Ai
The e.m.f per turn,

kVA
Et = K √ phase
0.05
Et = 0.85 √ 1
= 0.19 V
Net cross section area of iron core,
Et
Ai = 4. 44 f B m

0.19
A i = 4.44 × 50 × 1.1
= 7.78 × 10-4 m2
= 7.78 cm2
 36

Ai = kid2
For square core, the value of ki = 0.45;
Thus, Ai = 0.45 d2

Ai
d = √ 0. 45

7.78
= √ 0.45
= 4.16 cm
The form of magnetic frame of VT is core type (square shape). So, the
circumference condition (the length of core (or) height of window, the width of
window, the height of core and yoke, and the width take place by the winding) will be
calculated.
Window area is determined using the output equation,
Q = 2.22 f Bm δ Kw Ai Aw × 10-3 KVA (for single phase)
Q
−3
Aw = 2 . 22 f Bm δ K w A i×10
50
-3
= 2.22 × 50 × 1.1 × 2 × 0.32 × 7.78 × 10
= 82.24 cm2
If Hw = height of the window, Ww = width of the window,
From Equation 3.29, Aw = Hw Ww
In order to limit the leakage reactance of the transformer, Hw is made more
than Ww . In practice Hw /Ww lies between 2.5 and 4.0.
So, the value of the ratio Hw /Ww = 3.2 is assumed.
Aw = Hw Ww = 82.24 cm2
Hw /Ww = 3.2
From these above two equations the value of Hw and Ww can be calculated.
Height of the window (or) length of the core;

Hw = √ 82.24 ×3.2
= 16.22 cm
Width of the window,
Ww = Aw / Hw
 37

= 82.24 cm2 / 16.22 cm

= 5.07 cm
Center to center distance between cores,
D = Ww + d
= 5.07 + 4.16
= 9.23 cm
Stacking factor, ks = 0.9
Gross cross section area of iron core,
Agi = Ai / ks
Agi = 7.78 / 0.9 = 8.64 cm2
Gross yoke section,
Agy = 1.15 × Agi
= 1.15 × 8.64 = 9.94 cm2
Width of the yoke,
by = 0.71 d (for square core)
= 0.71 × 4.16 = 2.95 cm
Height of the yoke (or) core depth,
hy = Agy / by
= 9.94 / 2.95 = 3.37 cm
Overall length;
L = D + d (for single phase, square core)
= 9.23 + 4.16 = 13.39 cm
Overall height;
H = H w + 2 hy
= 16.22 + 2 (3.37) = 22.96 cm

by = 2.95 cm

hy = 3.37 cm
d = 4.16 cm

d = 4.16 cm

hy = 3.37cm
 38

Figure.4.4. Cross Sectional View of Magnetic Frame

Aw

Ai
H
Hw
Ww
D
L

Figure.4.5. Magnetic Frame of Voltage Transformer

4.12. Winding Design of Voltage Transformer

The winding design of VT is similar to the winding design of the power
transformer. The power transformer is considered with turns per volts and so is the
voltage transformer. In this thesis, the design may be based on the winding
developing typically 0.06 turns per volts at rated voltage.

The primary winding = 0.06 × 33000/ √3

= 1143.15 turns ~ 1143 turns

The secondary winding = 0.06 × 110/ √3

= 3.81 turn ~ 4 turns
4.12.1. Detail Design of Primary Winding
Number of turn per phase, Np = 1143 turns
Current density, ∂1 = 2.0 A/mm2
Current per phase, I1 = 50 VA/ 33000/√ 3
= 0.0026 A
Cross sectional area, a1 = I1 / ∂ 1
= 0.0026 / 2.0
= 0.0013 mm2
According to the above value, the rectangular copper conductors are selected.
Thus, 1143 turns will be arranged, 153 axially and 15 radically.
Length of the core, Hw = 16.22 cm
Axial space for primary winding = 16.22 - (0.2 + 0.2)
= 15.82 cm
Axial space for one turn = 15.82 / 153
 39

= 0.1034 cm
Axial space for one strand = 0.1034 cm
= 1.034 mm
Therefore, size of rectangular strand = 1.0 mm ×1.0 mm
Modified sectional area of rectangular strand = 0.86 mm2 (from Table)
Size of strand with double cotton covering (fine) = 1.03 mm × 1.03 mm
4.12.2. Detail Design of Secondary Winding
Number of turn per phase, Ns = 4 turns
Current density, ∂2 = 2.0 A/mm2 (assumed)

Current per phase, I2 = 50 VA/ (110/ √3 ) = 0.79 A

Cross sectional area, a2 = I2 / ∂ 2
= 0.79 / 2.0
= 0.40 mm2
According to the above value, the rectangular copper conductors are selected.
Thus, 4 turns will be arranged, 4 axially and 1 radically.
Length of the core, Hw = 16.22 cm
Axial space for secondary winding = 16.22 - (2.0 + 2.0)
= 12.22 cm
Axial space available for one turn = 12.22 /4
= 3.055 cm
= 3.1 cm
Axial space for one strand = 3.1 cm = 31 mm
Therefore, size of rectangular strand = 22 mm × 1.4 mm
Modified sectional area of rectangular strand = 30.6 mm2 (from Table)
Size of strand with double cotton covering = 22.5 mm × 1.9 mm
Thus, the above selection of conductor size shows that the axial arrangement
is right and the winding will be well accommodated.

4.13. Design of Voltage Transformer Tank

To design the dimension of tank, the following values must be assumed.
Total clearance length, ∆l = 2.68 cm (assumed)
Total clearance width,∆b = 1.35 cm (assumed)
 40

Total clearance height, ∆h = 4.59 cm (assumed)

The length of the tank, Lt = D + d + ∆l
= 9.22 + 4.16 + 2.68
= 16.06 cm
The width of the tank, Bt = by + winding thickness +∆b
Winding Thickness = 2{(wire thickness + insulation thickness)}
= 2{(1.03 × 15)/10 + (0.26 × 14)/10}
= 3.82 cm
Bt = 2.95 + 3.82 + 1.35
= 8.12 cm
The height of the tank, Ht = Hw + 2hy +∆h
= 16.22 + (2 × 3.37) + 4.59
= 27.55 cm

Δh
hy
Hw = 16.22 cm

Ht
d
Δl

Lt

Figure.4.6. Tank Design of VT from Front View

Bt
by

1.03 mm

Δb
 41

Figure.4.7. Tank Design of VT from Side View

4.14. Performance Calculation of Designed VT

The performance for the designed voltage transformer can be calculated. Iron
losses, core losses for primary winding and secondary winding of voltage transformer
are calculated.
4.14.1. Iron Losses of Voltage Transformer
Volume of the cores = length of core × height of core × breadth of the core
= L × H × by
= 13.39 × 22.96 × 2.95
= 906.93 cm3
Weight of the cores = volume of the cores × density of the transformer steel
= 906.93 × 7.5 × 103 × 10-6
= 6.8 kg
Flux density in cores = 1.5 Tesla
Thus, specific losses in the cores = 1.5 W/kg (from Figure)
Iron losses in the cores = specific losses × weight of the cores
= 1.5 W/kg × 6.8 kg
= 10.2 W
Volume of the yokes = 2 × cross sectional area of the yokes × overall length
of the yokes
= 2 × Agy × L
= 2 × 9.94 × 13.37
= 265.8 cm3
Weight of the yokes = Volume of the yokes × density of transformer steel
= 265.8 × 7.5 × 103 × 10-6
= 1.99 kg
Flux density in the yokes = 1.5 Tesla
Thus, specific loss = 1.5 W /kg
Iron losses in the yokes = specific loss × weight of the yokes
= 1.5 W/kg × 1.99 kg
= 2.985 W
Total iron losses = Iron losses in the cores + Iron losses in the yokes
 42

= 10.2 W + 2.985 W
= 13.19 W
4.14.2. Core Losses of Voltage Transformer
For the primary winding,
Width of the core, d = 4.16 cm
Stack of the core = width of the yoke, by = 2.95 cm
Core corner thickness, c = 0.8 mm
Inner paper insulating paper thickness = 0.26 mm
Wire thickness for first layer = 1.03 mm
Inner layer insulating paper thickness for 15 layers = 14 × 0.26
= 3.64 mm
Final layer insulation thickness = 0.4 mm
Wire thickness for 15 layers = 15 × 1.03 mm
= 15.45 mm
Thus, d1 = 15.45 + 0.4 + 3.64
= 19.49 mm
= 1.949 cm
The mean length per turn, Lm1 = 2d + 2 by + 4c + πd1
= 2(4.16 + 2.95) + (4 × 0.08) + (π × 1.949)
= 20.66 cm
Total length for 153 turns = 20.66 × 153
= 3161.43 cm
= 31.61 m
Resistance per phase of primary winding, R1 = ρLm1 / a1
where; ρ - specific resistance,
ρ = 0.0216 Ω-mm2 /m (+75°C)
R1 = (0.0216 Ω-mm2 /m × 31.61 m)/ 0.00066 mm2
= 1034.5 Ω
Total copper losses in primary winding = 3 × I12 × R1
= 3 × 0.00132 × 1034.5
= 0.0052 W
For the secondary winding,
Width of the core, d = 4.16 cm
 43

Stack of the core = width of the yoke, by = 2.95 cm

Core corner thickness, c = 0.8 mm (assumed)
Wire thickness for first layer = 1.9 mm
Final layer insulation thickness = 0.4 mm
Wire thickness for one layer = 1 × 1.9 mm
= 1.9 mm
Thus, d2 = 1.9 + 0.4 mm
= 2.3 mm
= 0.23 cm
The mean length per turn, Lm2 = 2d + 2by + 4c + πd2
= 2(4.16 + 2.95) + (4 × 0.08) + (π × 0.23)
= 15.26 cm
Total length for 4 turns = 4 × 15.26 cm
= 61.04 cm
= 0.61 m
Resistance per phase of secondary winding;
R2 = ρLm2 / a2
= (0.0216 Ω-mm2/m × 0.61 m) / 0.4 mm2
= 0.033 Ω
Total copper losses in secondary winding = 3 × I22 × R2
= 3 × 0.792 × 0.033
= 0.062 W
Thus, total losses = 13.19 + 0.0052 + 0.062
= 13.26 W
4.14.3. Efficiency of Voltage Transformer
Output power = Rating of VT × power factor
= 50 VA × 0.9
= 45 W
Input power = Output power + total losses
= 45 W + 13.26 W
= 58.26 W
Efficiency = (Output power / Input power) ×100%
= 45 W /58.26 W × 100 %
 44

= 77.2 %

4.15. Calculation of Oil Weight for VT

To obtain oil mass, weight of the core, weight of the yoke, weight of the
winding and weight of the tank must be calculated.
Volume of the cores = length of core × height of core × breadth of the core
= L × H × by
= 13.39 × 22.96 × 2.95 = 906.93 cm3
Weight of the cores = volume of the cores × density of the transformer steel
= 906.93 × 7.5 ×103 × 10-6
= 6.8 kg
Volume of the yokes = 2 × cross sectional area × overall length
of the yokes of the yokes
= 2 × Agy × L
= 2 × 9.94 × 13.39
= 266.19 cm3
Weight of the yokes = Volume of the yokes × density of transformer steel
= 266.19 × 7.5 × 103 × 10-6
= 1.996 kg
Volume of the primary winding = Cross sectional area × length of the
of the wire winding
= 0.86 × 10-2 × 3161.43
= 27.19 cm3
Weight of the primary winding = volume of the winding × density of the copper wire
= 27.19 × 8.9 × 103 × 10-6
= 0.242 kg
Volume of the secondary winding = Cross sectional area × length of the
of the wire winding
= 30.6 × 10-2 × 61.04
= 18.68 cm3
Weight of the secondary winding = volume of the winding× density of the
copper wire
= 18.68 × 8.9 × 103 × 10-6
= 0.17 kg
 45

Total weight of the winding = Weight of the + Weight of

primary winding the secondary winding
= 0.242 + 0. 17
= 0.41 kg
Volume of the tank = Length, Lt × Width, Bt × Height, Ht
= 16.06 × 8.12 × 27.55
= 3592.72 cm3
Weight of the tank = Volume of the tank × density of steel
= 3592.72 cm3 × 7.5 × 103 × 10-6 kg/cm3
= 26.95 kg
Weight of oil = Weight of the tank - (weight of the core + weight of the yoke
+ total weight of the winding)
= 26.95 – (6.8 + 1.996 + 0.41) kg
= 17.74 kg