1

Transformer Design
OUTPUT EQUATION: - It gives the relationship between electrical rating and physical dimensions
of the machines.

Let
V1 = Primary voltage say LV
V2 = Secondary voltage say HV
I1 = Primary current
I2 = Secondary current
N1= Primary no of turns
N2= Secondary no of turns
a1 = Sectional area of LV conductors (m2)
I
= 1

a1 = Sectional area of HV conductors (m2)
I
= 2

 = Permissible current density (A/m2)
Q = Rating in KVA
We place first half of LV on one limb and rest half of LV on other limb to reduce leakage flux.
So arrangement is LV insulation then half LV turns then HV insulation and then half HV turns.

(1) For 1-phase core type transformer

Rating is given by
Q = V1 I 1  10 3 KVA
=  4.44 fm N1  I1  10
3
KVA  V1  4.44 f m N 1 
=  4.44 fAi Bm N 1  I 1  10 (  m  Ai Bm )
3
KVA -----------(1)
Where
f = frequency
m = Maximum flux in the core
Ai = Sectional area of core
H L L H H L L H
Bm = Maximum flux density in the core Window
V V VV V V VV
Window Space Factor

Actual Cu Section Area of Windings in Window

Kw 
Window Area ( Aw )
1-phase core type transformer with
a1 N1  a2 N 2
 concentric windings
Aw
( I /  ) N1  ( I 2 /  ) N 2
 1 (a1  I /1  & a2  I / 2  )
Aw
I N  I2 N2
 1 1
Aw

2 I1 N 1
 ( For Ideal Transforme r I1 N1  I 2 N 2 )
Aw So

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 K w Aw 
 N1 I1                ( 2)
 2 
Put equation value of N1I1 form equation (2) to equation (1)

 K w Aw
Q  4.44 f A i Bm  10 3 KVA
2
Q  2.22 f A i Bm  K w Aw  103 KVA          (3) Window

(2) For 1- phase shell type transformer

LV LV
Window Space Factor
HV HV
a1 N1  a2 N 2 LV LV
Kw 
Aw
HV HV
( I /  ) N1  ( I 2 /  ) N 2
 1 (a1  I /1  & a2  I / 2  ) LV LV
Aw
I N  I2 N2
 1 1
Aw 1-phase shell type transformer with
2I N sandwich windings
 1 1 ( For Ideal Transformer I1 N1  I 2 N 2 )
Aw
So
K w Aw
N1I1               ( 4)
2
Put equation value of N1I1 form equation (4) to equation (1)
 K w Aw 3
Q  4.44 f A i Bm  10 KVA
2
Q  2.22 f A i Bm  K w Aw  103 KVA          (5)
Note it is same as for 1-phase core type transformer i.e. equ (3) Window

(3) For 3-phase core type transformer

H L L H H L L H H L L H
V V VV V V VV V V VV

3-phase core type transformer with

Rating is given by concentric windings
Q = 3 V1 I1  10 3 KVA
= 3   4.44 fm N1  I1  10
3
KVA  V1  4.44 f m N 1 

= 3   4.44 fAi Bm N1  I1  103 KVA -----------(6) (  m  Ai Bm )

Window Space Factor

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Actual Cu Section Area of Windings in Window
Kw 
Window Area ( Aw )

2(a1 N1  a2 N 2 )

Aw
2   ( I1 /  ) N1  ( I 2 /  ) N 2 
 (a1  I /1  & a2  I / 2  )
Aw
2( I1 N1  I 2 N 2 )

Aw
2  2 I1 N1
 ( For Ideal Transforme r I1 N1  I 2 N 2 )
Aw Window
So
 K w Aw
N1I1               (7 )
4
Put equation value of N1I1 form equation (7) to equation (6)

 K w Aw
Q  3  4.44 f A i Bm  10 3 KVA
4
Q  3.33 f A i Bm  K w Aw  10 3 KVA      (8)

(3) For 3- phase shell type transformer

Window Space Factor

a1 N1  a2 N 2
Kw 
Aw
( I /  ) N1  ( I 2 /  ) N 2
 1 (a1  I /1  & a2  I / 2  )
Aw
3-phase shell type transformer with
I N  I2 N2 sandwich windings
 1 1
Aw
2I N
 1 1 ( For Ideal Transforme r I1 N1  I 2 N 2 )
Aw
So
K w Aw
N1I1               (9)
2
Put equation value of N1I1 form equation (9) to equation (6)
 K w Aw 3
Q  3  4.44 f A i Bm  10 KVA
2
Q  6.66 f A i Bm  K w Aw  10 3 KVA          (10)

CHOICE OF MAGNETIC LOADING (Bm)

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(1) Normal Si-Steel 0.9 to 1.1 T
(0.35 mm thickness, 1.5%—3.5% Si)

(2) HRGO 1.2 to 1.4 T

(Hot Rolled Grain Oriented Si Steel)

(3) CRGO 1.4 to 1.7 T

(Cold Rolled Grain Oriented Si Steel)
(0.14---0.28 mm thickness)

CHOICE OF ELECTRIC LOADING   

This depends upon cooling method employed

(1) Natural Cooling: 1.5---2.3 A/mm2

AN Air Natural cooling
ON Oil Natural cooling
OFN Oil Forced circulated with Natural air cooling

(2) Forced Cooling : 2.2---4.0 A/mm2

AB Air Blast cooling
OB Oil Blast cooling
OFB Oil Forced circulated with air Blast cooling

(3) Water Cooling: 5.0 ---6.0 A/mm2

OW Oil immersed with circulated Water cooling
OFW Oil Forced with circulated Water cooling

CORE CONSTRUCTION:

(a) U-I type (b) E-I type

(c) U-T type (d) L-L type

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(e) Mitred Core Construction (Latest)

EMF PER TURN:

We know
V1  4.44 fm N1              (1)
V1
So EMF / Turn Et   4.44 fm            (2)
N1
and

Q = V1 I 1  10 3 KVA (Note: Take Q as per phase rating in KVA)

=  4.44 fm N1  I1  10 3
KVA
 Et N1 I1  103 KVA        (3)
In the design, the ration of total magnetic loading and electric loading may be kept constant
Magnetic loading = m
Electric loading = N1 I1
m 
So  cons tan t ( say " r" )  N1 I1  m put in eqution (3)
N1 I1 r

Q  Et m  10 3 KVA
r
Et
Or Q  Et  10  3 KVA using equation (2)
4.44 f r
2
Et  (4.44 f r  103 )  Q

Or Et  K t Q Volts / Turn

Where K t  4.44 f r  10 3 is a constant and values are

Kt = 0.6 to 0.7 for 3-phase core type power transformer
Kt = 0.45 for 3-phase core type distribution transformer
Kt = 1.3 for 3-phase shell type transformer

Kt = 0.75 to 0.85 for 1-phase core type transformer

Kt = 1.0 to 1.2 for 1-phase shell type transformer

ESTIMATION OF CORE X-SECTIONAL AREA Ai

We know
Et  K t Q           (1)

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Et  4.44 f m
Or Et  4.44 f Ai Bm           ( 2)
Et
So Ai            (3)
4.44 f Bm

Now the core may be following types

d d/√2

1-Step 2-Step 3-Step Core 4-Step Core

Or Square- Core Or Cruciform- Core

K= 0.45 0.56 0.60 0.625

d = Diameter of circumscribe circle
For Square core
d d
Gross Area    0.5 d 2
2 2
Let stacking factor
K i  0 .9
Actual Iron Area
Ai  0.9  0.5d 2
 0.45 d 2 (0.45 for square core and take ‘K’ as a general case)
 K d2
So Ai  K d 2
Ai a
Or d
K b
Graphical method to calculate dimensions of the core
Consider 2 step core

90o
  , n  No of Steps
n 1
i.e n  2 Ө
So a  dCos b a
90o b  dSin
   30o
2 1

Percentage fill
Gross Area of Stepped core Kd 2 K i
  2-Step
Area of circumcirc le d 2 Or Cruciform- Core
4
0.625d 2 / 0.9
 for 4 Step core
 2
(d )
4
= 0.885 or 88.5%
No of steps 1 2 3 4 5 6 7 9 11

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% Fill 63.7% 79.2% 84.9% 88.5% 90.8% 92.3% 93.4% 94.8% 95.8%

ESTIMATION OF MAIN DIMENSIONS:

Consider a 3-phase core type transformer

W

hy

L H
Ww=
(D-d)

d D

We know output equation 3-phase core type transformer

Q  3.33 f A i Bm  K w Aw  10 3 KVA
So, Window area
Q
Aw  m2
3.33 f A i Bm  K w  10 3

where Kw =Window space factor

8
Kw  for upto 10 KVA
30  HigherKV
10
Kw  for upto 200 KVA
30  HigherKV
12
Kw  for upto 1000 KVA
30  HigherKV
For higher rating Kw = 0.15 to 0.20

Assume some suitable range for

D = (1.7 to 2) d
Width of the window Ww = D-d
Height of the window
Aw a
L
width of window(Ww ) b
(L  Ww  Aw )
L
Generally  2 to 4
Ww

Yoke area Ay is generally taken 10% to 15% higher then core section area (A i), it is to reduce the iron loss in
the yoke section. But if we increase the core section area (A i) more copper will be needed in thebwindings
a
and so more cost through we are reducing the iron loss in the core. Further length of the winding will
increase resulting higher resistance so more cu loss.
Ay = (1.10 to 1.15) Ai

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2-Step
Or Cruciform- Core
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Depth of yoke Dy = a
Height of the yoke hy = Ay/Dy

Width of the core

W = 2*D + d
Height of the core
H = L + 2*hy

Flux density in yoke

Ai
By  Bm
Ay

ESTIMATION OF CORE LOSS AND CORE LOSS COMPONET OF NO LOAD CURRENT I C:

Volume of iron in core = 3*L*Ai m3

Weight of iron in core = density * volume
=  i * 3*L*Ai Kg
 i = density of iron (kg/m3)
=7600 Kg/m3 for normal Iron/steel
= 6500 Kg/m3 for M-4 steel
From the graph we can find out specific iron loss, pi (Watt/Kg ) corresponding to flux density Bm in core.

So
Iron loss in core =pi*  i * 3*L*Ai Watt
Similarly
Iron loss in yoke = py*  i * 2*W*Ay Watt
Where py = specific iron loss corresponding to flux density By in yoke

Total Iron loss Pi =Iron loss in core + Iron loss in yoke

Core loss component of no load current

Ic = Core loss per phase/ Primary Voltage
Pi
Ic 
3V1

ESTIMATION OF MAGNETIZING CURRENT OF NO LOAD CURRENT Im:

Find out magnetizing force H (atcore, at/m) corresponding to flux density Bm in the core and atyoke
corresponding to flux density in the yoke from B-H curve
Bm  atcore / m, Bc  at yoke / m 
So

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MMF required for the core = 3*L*atcore
MMF required for the yoke = 2*W*atyoke

We account 5% at for joints etc

So total MMF required = 1.05[MMF for core + MMF for yoke]

Peak value of the magnetizing current

Total MMF required
I m , peak 
3N1
RMS value of the magnetizing current
I m , peak
I m , RMS 
2
Total MMF required
I m, RMS 
3 2 N1

ESTITMATION OF NO LOAD CURRENT AND PHASOR DIAGRAM:

No load current Io V1=-E1

2 2
Io  Ic  Im
Io
No load power factor Ic
Ic Ф0
Coso 
Io

Im
The no load current should not exceed 5% of the full the load current.

E2

ESTIMATION OF NO OF TURNS ON LV AND HV WINDING No load phasor diagram

V
Primary no of turns N1  1
Et
V
Secondary no of turns N2  2
Et

ESTIMATION OF SECTIONAL AREA OF PRIMARY AND SECONDARY WINDINGS

Q  10 3
Primary current I1 
3V1
Q  103 N1
Secondary current I2  OR I1
3V2 N2

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I1
Sectional area of primary winding a1 

I
Sectional area of secondary winging a2  2

Where  is current the density.
Now we can use round conductors or strip conductors for this see the IS codes and ICC (Indian Cable
Company) table.

DETERMINATION OF R1 & R2 AND CU LOSSES:

Let Lmt = Length of mean turn

Resistance of primary winding
L N ( m)
R1, dc , 75 o  0.021  10  6 mt 1 2
a1 ( m )
R1, ac , 75 o  (1.15 to 1.20) R1, dc , 75 o
Resistance of secondary winding
Lmt N 2 (m)
R2, dc , 75 o  0.021  10 6
a2 ( m 2 )
R2 , ac , 75 o  (1.15 to 1.20) R2, dc , 75 o

Copper loss in primary winding  3I12 R1 Watt

Copper loss in secondary winding  3I 22 R2 Watt
Total copper loss  3I12 R1  3I 22 R2
 3I12 ( R1  R2' )
 3I12 R p
R01  R p  R1  R2'
Where
 Total resis tan ce referred to primary side
Note: On No load, there is magnetic field around connecting leads etc which causes additional stray losses
in the transformer tanks and other metallic parts. These losses may be taken as 7% to 10% of total cu losses.

DETERMINATION OF EFFICIENCY:

Output Power
Efficiency  
Input Power

Output Power

Output Power  Losses a b
b1 2
Output Power
  dx  100 %
Output Power  Iron Loss  Cu loss
Lc x
ESTIMATION OF LEAKAGE REACTANCE:

Assumptions
1. Consider permeability of iron as infinity that is MMF is needed only for leakage flux path in the
window.
2. The leakage flux lines are parallel to the axis of the core.

Consider an elementary cylinder of leakage flux lines of thickness dx at a distance x as shown in following
figure.
N1I1=N2I2

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x
MMF Distribution
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MMF at distance x

N1I1
Mx  x
b1
Permeance of this elementary cylinder
A
 o
L
Lmt dx
 o (Lc =Length of winding)
Lc
 1 L 1
 S  & Permeance  
 o A S 
Leakage flux lines associated with elementary cylinder
dx  M x  Permeance
N1 I1 L dx
 x   o mt Flux linkage due to this leakage flux
b1 Lc
d x  No of truns with which it is associated  d x
N1 I1 N1 I1 L dx
  x  o mt
b1 b1 Lc
2
Lmt  x 
 o N12 I1   dx
Lc  b1 
Flux linkages (or associated) with primary winding
b1 2
2 Lmt x 2 Lmt b 
 1   o N1
'
I 1    dx  o N1 I1  1 
Lc 0  b1  Lc  3 
Flux linkages (or associated) with the space ‘a’ between primary and secondary windings
L
 o   o N 12 mt I 1a
Lc
We consider half of this flux linkage with primary and rest half with the secondary winding. So total flux
linkages with primary winding

 1   1'  o
2
L b a
 1   o N 12 mt I 1  1  
Lc  3 2 
Similarly total flux linkages with secondary winding

 2   2'  o
2
L b a
 2   o N 22 mt I 2  2  
Lc  3 2 
Primary & Secondary leakage inductance
 L b a
L1  1   o N 12 mt  1  
I1 Lc  3 2
2 L b a
L2    o N 22 mt  2  
I2 Lc  3 2 
Primary & Secondary leakage reactance

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Lmt  b1 a 
X 1  2fL1  2fo N12   
Lc  3 2 
Lmt  b2 a 
X 2  2fL2  2fo N 22   
Lc  3 2 
Total Leakage reactance referred to primary side
Lmt  b1  b2 
X 01 X P  X 1  X 2'  2f o N 12   a
Lc  3 
Total Leakage reactance referred to secondary side
Lmt  b1  b2 
X 02  X S  X 1'  X 2  2f o N 22   a
Lc  3 
It must be 5% to 8% or maximum 10%
Note:- How to control XP?
If increasing the window height (L), Lc will increase and following will decrease b1, b2
& Lmt and so we can reduce the value of XP.

CALCULATION OF VOLTAGE REGULATION OF TRANSFORMER:

I 2 Ro 2Cos2  I 2 X o 2 Sin2
V .R.   100
E2
R Cos2 X Sin2
 o2  100  o 2  100
E2 / I 2 E2 / I 2
 % Ro 2Cos2  % X o 2 Sin2

TRANSFORMER TANK DESIGN:

Width of the transformer (Tank)

Wt=2D + De + 2b
Where De= External diameter of HV winding
b = Clearance width wise between HV and tank
Depth of transformer (Tank)
lt= De + 2a
Where a= Clearance depth wise between HV and tank
Height of transformer (Tank)
Ht= H + h
Where h=h1 + h2= Clearance height wise of top and bottom

hy

L DW D H
w
a(D-d)

lt
De

b
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Wt
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h1
W

Ht
H

h2

Tank of a 3-Phase transformer

CALCULATION OF TEMPERATURE RISE:

Surface area of 4 vertical side of the tank (Heat is considered to be dissipated from 4 vertical sides of the
tank)

St= 2(Wt + lt) Ht m2 (Excluding area of top and bottom of tank)

Let
 = Temp rise of oil (35o C to 50o C)
12.5St  =Total full load losses ( Iron loss + Cu loss)

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Total full load losses
So temp rise in o C  
12.5 St
If the temp rise so calculated exceeds the limiting value, the suitable no of cooling tubes or radiators must be
provided

CALCULATION OF NO OF COOLING TUBES: Specific Heat dissipation

6 Watt/m2-0C by Radiation
Let xSt= Surface area of all cooling tubes 6.5 Watt/m2-0C by Convection
Then
Losses to be dissipated by the transformer walls and cooling tube
= Total losses
12.5 St  8.5 xSt   Total losses
6 W-Raditon+6.5 W=12.5 Convection 6.5*1.35 W  8.5 (  35% more) Convection only

So from above equation we can find out total surface are of cooling tubes (xSt)
Normally we use 5 cm diameter tubes and keep them 7.5 cm apart
At= Surface area of one cooling tube
 d tube l tube , mean
Hence
xSt
No of cooling tubes 
At

7.5 Cm

d= 5 Cm

Tank and Arrangement of Cooling tubes

WEIGHT OF TRANFORMER:

Let

Wi = Weight of Iron in core and yoke (core volume* density + yoke volume* density) Kg
Wc= Weight of copper in winding (volume* density) Kg
(density of cu = 8900 Kg/m3)
Weight of Oil
= Volume of oil * 880 Kg
Add 20% of (Wi+Wc) for fittings, tank etc.
Total weight is equal to weight of above all parts.

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