Design Steps of Transformers

Prof. T. H. Panchal

Department of Electrical Engineering

Institute of Technology
Nirma University, Ahmedabad
 Design Problem
• Design a 25 kVA, 11000/433 V, 50 Hz, 3 phase, delta/star, core type, oil
immersed natural cooled distribution transformer. The transformer is
provided with tappings  2 1 2  5% on the h.v. winding. Maximum
temperature rise not to exceed 45 °C with mean temperature rise of oil
35 °C.
 Solution
• For three phase core type distribution transformer the value of K = 0.45
according to Table 5.2 given in A. K. Sawhney.

Type K
Single phase shell type 1 to 1.2
Single phase core type 0.75 to 0.85
Three phase shell type 1.3
Three phase core type(distribution) 0.45
Three phase core type(power) 0.6 to 0.7
 Solution

• Voltage per turn, Et  K Q  0.45 25  2.25 V

Et 2.25
• Flux in core, m    0.010135 Wb
4.44  f 4.44  50

• Assume max. flux density, Bm = 1 Wb/m2

m 0.010135
• Net core area = Ai    10.135 103 mm 2
Bm 1
 Solution
• Assume 2-stepped core, i
A  0.56  d 2

Ai
• Diameter of circumscribing circle, d 
0.56

• For 2-stepped core, width of laminations are, a = 0.85*d, b = 0.53*d

• a = 114.8 mm, b = 71.6 mm

8 8
• Window space factor, K w    0.195 [rating is small]
30  kv 30  11

• For small rating[25 kVA] transformer, assume current density = 2.3

A/mm2
 Solution
• Output of transformer, Q  3.33 f Bm  K w Aw Ai  10 3

• Calculate window area Aw .

Hw
• Assume ratio of height of window to width of window  2.5
Ww

• Range of this ratio is between 3 to 6.

• As you have value of Aw calculate Hw and Ww .
 Solution
• Design of Yoke:
• Yoke area Ay = Net core area Ai for transformer using hot rolled silicon
steel

• Yoke area Ay = 1.2*Net core area Ai for transformer using hot rolled
silicon steel

• Depth of yoke Dy = width of largest stamping, a

• Dy = a, for yoke having rectangular cross section

• Height of yoke, Hy = Ay/Dy

 Solution
• Overall Dimensions of Frame:
• Calculate,

• Height of magnetic frame = H = Hw + 2Hy

• Width of frame = W = 2D + a

• Depth of frame = Dy = a
 Solution
• Design steps for L.V. Winding Design
Vs
• Step-1 Calculate number of turns/phase using the equation Ts 
Et
• The number of turns calculated may be a fraction which should be rounded of suitably.
• Step-2 Find Secondary phase current Is

kVA 103
Is  (for 3-phase transformer)
3  Vs
kVA 103
Is  (for 1-phase transformer)
Vs

• Step-3 Obtain the cross sectional area (in mm2) of the secondary conductor given by
 Solution
• Step-3 Obtain the cross sectional area (in mm2) of the secondary conductor by
assuming suitable value of current density(in Amp/mm2)
Is
as 
s

• For distribution, small and medium power transformer, self oil cooled type upto 50
kVA, δ = 1.1 to 2.3 A/mm2
• For large power transformer, self oil cooled type or air blast, δ = 2.2 to 3.2 A/mm2
• For large power transformer with forced circulation of oil or water cooling tubes,
• δ = 5.4 to 6.2 A/mm2
 Solution
• Step-4 Find out suitable dimensions of the conductor. If the cross sectional area of the
secondary conductor exceeds 50 mm2, it is better to take standard parallel conductors.
Also calculate the secondary current density again with the selected conductor area.

• Step-5 The Conductors are paper insulated. This increases the thickness of the
conductor. Allow 0.5 mm for increase in thickness of the conductor for single covering

• Step- 6 Select suitable type of winding from Table 5.4. If it is helical winding keep 1
turn more along the axial depth.

• Step-7 Determine axial depth Lcs of l.v. winding;

Lcs  number of secondary turns  axial depth of conductor
Obtain window clearance as below:
Window clearance =(height of the window - Lcs )/2
 Solution
• Step-8 Find radial depth bs of l.v. winding as follow:
bs  number of layers  radial depth of conductor + insulation between layers

• Step-9 Find the inside and outside diameter of the l.v. winding can be found as follow:

• inside dia. = dia. of circumscribing circle +2  pressboard thickness for insulation between l.v. and core.

outside dia. = inside dia. + b s

 Solution
• Design Steps for H.V. Winding Design
• Step-1 Calculate number of turns/phase using the equation
VHV I LV
THV 
VLV
• Step-2 If 5% tapping are to be provided, the number of turns to be increased to
Tp (new)  1.05  Tp

• Step-3 HV winding current is calculated from

kVA 103
Ip 
3  HV side voltage rating
 Solution
• Step-4 Select the Conductor. In HT winding cross over type, cylindrical type with
circular and continuous disc type are generally used. The conductor section is then
selected depending upon the type of winding. It may be circular or rectangular. For
small transformer due to lesser conductor section, circular conductors are selected,
while for large transformer, due to high current ratings, rectangular conductors are
preferred.

• Assuming suitable current density, calculate cross sectional area of conductor

Ip
ap 
p

• Calculate axial length of h.v. winding , Lcp as per the type of winding(refer classnote).
• Calculate radial depth of h.v. winding, bp as per the type of winding(refer classnote).
 Solution
• Inside diameter of h.v. winding = outside diameter of l.v. winding + 2*thickness of
insulation

• Outside diameter of h.v. winding = inside diameter of h.v. winding + 2*bp

• Calculate mean diameter of l.v. winding.

• Calculate length of mean turn of l.v. winding, Lmtlv

 Lmtlv Tlv
• Calculate resistance of l.v. winding, rlv 
a
 Solution
• Calculate mean diameter of h.v. winding.

• Calculate length of mean turn of h.v. winding, Lmthv

 Lmthv Thv
• Calculate resistance of h.v. winding, rhv 
a
• Calculate total Cu losses.
 Solution
• Assume specific iron loss at maximum flux density.

• Calculate weight of core and yoke. Add them to calculate total weight of magnetic
frame.

• Multiply total weight of magnetic frame with specific iron loss. This gives total iron
loss in magnetic frame.

• Calculate Iw.

• Calculate total length of magnetic flux path, 2Hw + 2W.

• Assume ampere turn per meter of magnetic circuit.

 Solution
• Multiply ampere turns per meter with the total length of magnetic flux path. This gives
total ampere turn (AT).

• Calculate magnetizing current, Im.

• Calculate no load current I0.

• Calculate efficiency of transformer.

• Refer numerical solved in theory class to design transformer tank. Assume necessary
data required to design the tank.