Chapter 4

Transformer types
Depending on the voltage level Depending on the insulation system:

S Power Transformer Distribution Transformer

.
N
o
1 Connections: 3-phase or three 1-phase ∆ − 𝚼, 3-phase, 4-wire
transformers,
∆ − ∆, ∆ − 𝚼, 3-wire
2 Capacity: MVA kVA

3 Voltage Rating: 220kV / 11kV or in high 11/0.440 kV

voltage range
4 Flux density: 1.5 to 1.7 𝐖𝐛/𝐦𝟐 With cold rolled steel upto 1.7 𝐖𝐛/𝐦𝟐

5 Load: Generally on full load Load 100% for part of the day; for sometime on no load and
for sometime on part load.

6 Ratio of iron loss to copper loss 1:1 1:3

7 Percentage impedance 6% to 18% 4% to 5%

8 Cooling: Forced air-cooled forced oil- Self-oil cooled

coold, Forced water cooled, self oil-
cooled
9 Regulation: 6% to 10% 4% to 9%
1. Step up transformer 2. Step down transformer
Depending on the uses:
1.Power T/F 2 Distribution T/F 3.Instrument T/F
Depending on the design criteria:
1.Two winding transformer 2.Auto transformer
1. Oil immersed T/F 2. Dry type T/F
Depending on the operating phase:
1.Single phase T/F 2.Three phase T/F
Depending on construction
1.Core type (low voltages, large 2. Shell
type (high voltages, smaller
Core type & Shell type T/F

Standard ratings
Transformers are built in standard ratings
Ratings for three phase power transformers
250 kVA, 400 kVA, 630 kVA, 1000 kVA In large sizes, 3 MVA, 5 MVA, 10 MVA and then
special sizes as required by the consumers are built Power transformers in large sizes can be
categorized in (i) upto 3150 kVA (ii) 3151 to 40000 kVA and (iii) above 40 MVA sizes
Ratings for distribution transformers
The standard ratings commonly used are 63 kVA and 100 kVA, though in
smaller sizes 25 kVA and 40 kVA sizes are also built The no load voltage ratios for distribution
transformers are 3.3 kV/ 440 V, 6.6 kV/ 440 V or 11 kV/ 440 V The tappings are
generallygenerally±2.5% and±5%on the HV side

Specifications
The transformers specifications give the ratings and performance
expectations of the transformer These are broadly as given below
1. kVA rating 2.Rated Voltage 3.Number of phases ( 1−Φor 3−Φ) 4.Rated frequency, 50Hz
5.Connections: delta/star combinations for HV and LV windings
6.Tappings , if any 7.Reference ambient temperature (generally average 40 ̊C )
8.Type of cooling 9.Temperature rise 10.Total loss at rated voltage
11. No load loss 12. Load loss at rated current 13.Impedance at rated current
14.Reactance at rated current 15. No load current at rated voltage
16.Efficiency at 75℃ at unity power factor at full load, 3/4 th load and ½ load
17.Regulation at full load
The other information required from the manufacturer is
18.Approximate weight of core and windings, tank fittings and accessories, oil and total weight.
19.Approximate overall dimensions: length, breadth, height.

Cooling of Transformers
The considerable variety of possible methods of heat dissipation make necessary a concise
standard designation
The letter symbols employed are
Cooling medium: 1 O: Oil 2 A: Air 3 W:Water
Type of Circulation: 1 N: Natural 2 F: Forced (oil not directed) 3 D: Forced (oil directed)
The combinations of the symbols are used to indicate the type of cooling
Order: Four letter symbols are used for each system for which the transformer is assigned a
rating.
The order is (1) the medium and (2) the circulation of the coolant in contact with the windings
and (3) the medium and (4) the circulation of the of cooling medium in contact with the
external cooling system.

Air Cooling of Transformers

AN: The ambient air is used as coolant, with natural circulation by convection. The
development of high temperature insulating materials (glass and silicone resins) makes the
method suitable for ratings up to 1.5 MVA, and for special conditions such as those in mines
AF With forced air circulation and improved heat dissipation, the specific loadings can be raised

Oil immersed, Oil Cooling of Transformers

ONAN: This method of natural oil circulation and natural air flow over the tank (and tubes) is
very common, and can be applied to transformers rated up to 5 MVA.
ONAF: Air is blown on to the tank surface, so that less surface is required for a given rating.
OFAN: This is uncommon, but can be useful where the coolers have to be well removed from
the transformer. The oil is pumped round the system, and high current densities can be used in
the transformer windings.
OFAF: The forced oil- and air-circulation method is the usual one for transformers of 30
MVA and upward. Mixed cooling may be used, with an ONAN condition up to 0.5 p.u.
rating, temperature-sensing elements initiating oil pumps and air fans for the forced cooling
at upper conditions of load.

ONAN and ONAF

OFAF

Oil immersed Water Cooling of Transformers

ONWF: Copper cooling coils are mounted in the tank above the level of the transformer core,
but below the oil surface.
OFWF: Oil / water heat-exchangers are external to the transformer. The advantages over
the ONWF system are that the transformer is smaller and the tank does not have to contain
cooling coils; there are no condensation troubles; leakage of water into the oil is
improbable if the oil pressure is greater than that of the water.
Where the cooling water has considerable 'head', it is usual to employ cascaded heat-
exchangers (oil/water and water/water), with the intermediate water circuit at low
pressure.
The use of water as a coolant is common in generating stations, particularly hydro stations,
where an abundant supply is available

Output Equation of Transformer + problem

Design of transformer
The design of transformer consists of
1. designing the cross section of the core fixing up the frame size of the core
2. design of windings and 3. design of tank

Design Criterion
The criterion can be one of the following
(a) Design the transformer for maximum efficiency or minimum total losses
The efficiency of transformer is maximum when the iron loss (or rather constant loss) is equal
to I 2 R loss. If the transformer is to work on full load for most of the time, and the efficiency is to
be maximum at this load, copper loss on full load is made equal to iron loss
weight of iron ¿
=Copper loss ¿
weight of Copper (iron loss)

This equation gives the ratio of weights of active materials for the criterion of maximum
efficiency at the mean working load
(b) The minimum first cost of the transformer, i.e., the cheapest transformer
Find the ratio of weight of iron to weight of copper for this condition
c) Minimum annual cost, i e capital charge on cost depreciation cost of energy losses
minimum
This criterion needs a lot of information regarding the load curve of the system
where the transformer is to be used, the cost of energy at different load factors, the load
factor of the system, etc in addition to the normal cost of transformer material, etc
This is a complicated problem and can be solved only with the help of a computer
The usual practice is to design a transformer for the best efficiency or the minimum losses This
is to be done consistent with the costs involved The aim of the designer will be to keep the
losses within the permissible limit given by the specifications.

Design of Core Section

For design of the core, relation is used as
Voltage per turn = K √ S V Where S is the kVA output of transformer, K is constant that depends
on the material and labor cost etc and on the type of transformer such as shell or core type and
 single phase or three phase The approximate mean values for criterion of load for maximum
efficiency are given in

Table: Approximate mean values for criterion of load for maximum efficiency

Type Single- Three-phase Three-phase distribution

phase

Core type 0.75 to 0.85 0.60 to 0.90 0.45 to 0.75

Shell type 1.00 to 1.20 1.00 to 1.50 0.80 to 1.25

following table

The net x sectional area of the core can be determined by choosing K and 𝐸𝑡 and the flux
density 𝐵𝑚
Choosing 𝐵𝑚 and 𝛿, 𝐴i ,AW can be found. The core design is done to conform to a standard
frame.

d = diameter of the core,

D = distance between the centers of the limbs,
W = width of the core frame
L = length of the window
Aw = area of each window

The core is built of 0.35 mm thin strips arranged in a

number of steps so as to obtain near round cross
sectional area so that a better space factor for
accommodating iron in the most useful way can be
achieved.
The number of steps usually chosen is 3,4 5,6,7 or 9
For a large size transformer, more steps may be used
if this is found to be feasible.
The area of the iron section in the steps in terms of the
π D2 2
circumscribing diameter is given by Ai̇=k k s m
4
Figure shows a standard frame giving
the main dimensions of a three phase
core type transformer.
𝑘 is the iron space factor given in the Table
This is due to three being steps instead of one solid round section of the core. K 𝑠 is
the staking factor due to paper or varnish insulation between the laminations of the core.
This may be taken as approximately 0.92.
Figures show the typical sections of 3 steps and 6 steps cores with the approximate widths
of the lamination pieces used

Design of Windings Main dimensions of Frame

The output equation of a three phase transformer is given by
 When the net area of the core has been determined, and the current density 𝛿
chosen depending on the type of cooling of the transformer, 𝑘𝑤𝐴𝑤 can be found out from
the kVA rating from above equation.
For higher voltages, the window space factor is smaller as more clearance space is
required to give the necessary insulation levels.
Approximate space factors for window 𝑘𝑤 for various voltage ranges are given in Table

kVA 3kV 10kV 30kV 100kV

100 0.28 0.20 0.14 ---

800 0.37 0.27 0.20 0.15

2000 0.40 0.31 0.23 0.16

10000 0.45 0.37 0.28 0.21

Table:Window
Space Factor
Choosing a suitable value of 𝑘𝑤, the window area 𝐴𝑤 is determined.
The height and width of the window can be adjusted to accommodate the windings
in the required arrangement and to give the desired leakage reactance.
The normal ratio of height/width of window is 2 to 4.

Design of Windings
Given the voltage per phase on the high voltage side and low voltage side of a
transformer, the number of turns in the high voltage and low voltage side can be found out
when the voltage per unit is chosen.

𝑇1 = 𝑉1/𝐸𝑡 and 𝑇2 = 𝑉2/𝐸𝑡 where 𝑇1 and 𝑇2 are turns per-phase on the HV and LV
sides respectively and 𝑉1 ,𝑉2 are the corresponding voltages per phase.
Check the weight of iron and copper and their ratio before proceeding to the
detailed design of the windings.
The windings of transformers must be designed to give the best possible performance and
electrical characteristics with proper mechanical strength to withstand the stresses due to
short circuit and with proper ventilation keeping them within the permissible temperature
rise for the windings.
The windings of transformers may be arranged concentrically in relation to one another or
they may be in groups of LV, HV coils stacked alternately one over the other.
The windings are thus concentric or interleaved.

Design of tanks with tubes

The temperature rise of windings measured by resistance should not exceed 55℃
for natural cooling, 60℃ for forced cooling and 65℃ for forced water cooling and 45℃
for oil cooling.
Tank walls, tubes and radiators dissipated heat by radiation and convection. By natural
cooling, 6W by radiation and 6.5W by convection are dissipated per m² of plain tank
surface per ℃.
Thus if the cooling surface of a transformer tank (neglecting top and bottom) is S t m², it
will dissipate,

If this surface is not enough to limit the temperature rise, then the
surface of the tank is increased 𝑥 times by addition of tubes.

The height of the transformer will be the net height over the yoke plus an
allowance for space for the base (about 50 to 70 mm), and about 250 mm height for
oil above the yoke. Space is also required for leads, etc. about 200 to 250 mm.
The loss to be dissipated is the full load loss.
The volume o foil required is the volume of the tank up to oil level minus the volume of the
transformer, viz. that of copper, iron and insulating materials.
Procedure for the Design of T/F
The points to be noted in designing the transformers
1. Specifications of the transformer to be designed. 2. Choose the voltage per turn, E t
Volts. 3. Choose BmWb/m² 4. Choose the net cross-sectional area of the core, A i
5. Find the diameter of the circumscribing circle for the core, D. 6. Choose the window
area Aw from kw 7. Find the turns in the low voltage winding, T2 8. Find the turns in
the high voltage winding, T1. 9. Choose the current density 𝛿 A/mm². 10. Find the
conductor size of LV winding, 𝑎2. 11. Find the conductor size of HV winding, 𝑎1. 12. Find
the ratio of cross-section of copper of LV and HV windings in window to window area Aw,
Check kw. 13. Choose the layout of LV and HV windings
The number of turns per layer, number of layers, number of coils etc.
Choose distance between the core and LV , between LV and HV , between HV and tanks., for
insulation requirements-and check whether windings can be accommodated in the window
area.
14. Choose the core frame; the core diameter, window , yoke overall core size. 15. Design
the low voltage winding
θ Number of turns per phase, Number of turns layer, Number of layers; size of
conductor ,Inside and outside diameters of the coil ,Thickness and mean diameter of the
coil ,Mean length of the turn , Height of the coil in window
16. Design the high voltage winding
Number of turns per phase , Number of coil, Number of turns per coil, size of conductor,
Inside and outside diameters of the coil, Thickness and mean diameter of the coil, Mean
length of the turn,Height of coils in window
17. Calculate the % reactance 18. Calculate the % resistance 19. Calculate the %
impedance 20. Find the weight of iron in core and yoke. 21. Find the core or iron loss
22. Find the magnetizing VA. 23. Find the weight of LV winding. 24. Calculate the
resistance of LV winding 25. Find the weight of HV winding. 26. Find the weight of copper
in transformer 27. Calculate the resistance of HV winding 28. Find the turns ratio of
HV/LV i.e., 𝑇1 Τ𝑇2. 29. Calculate equivalent resistance referred to HV. 30. Calculate the
copper loss 3𝐼²𝑅 allowing 7% to 10% for stray load loss; find the load loss at 75℃.
Calculate the performance
31. calculate the efficiency on full load, 3/4th load and ½ load at unity p.f. and at 0.8 p.f.
Lagging if required. 32. Calculate regulation at unity p.f. and 0.8 p.f. lagging. 33. Calculate
the core loss current, the magnetizing current and the no-load current.
Design of Tanks
34. Choose the inner dimensions of the tank to accommodate transformer with
necessary clearances. 35. Find the volume and weight of oil required. Find the
temperature rise. 36. Find the number of radiator or tubes required as extension of the
cooling surface so as to be within the required temperature limits. 37. Find the weight of
transformer (and radiators if any). 38. Find the total weight if transformer.
Summary
39. Specifications. 40. Dimensions of core assembly, coils, tank 41. Performance of
transformer: efficiency, regulation, no-load current, % impedance. 42. Diagram
connections.