Chapter - 3

Design of Transformers
3.1 Introduction.
A transformer is static electrical machine in which energy is transferred from
one electrical circuit to another through magnetic field. The transformer is not an energy
convesion device but it transforms electrical energy between primary and secondary
circuits with changed values of voltage and current.
It is used to match source and load impedance for maximum power transfer in
electric and control circuits. The transformer is also used to provide electric isolation
between the circuits.
Transformer Construction:
Main parts of the transformer are primary and secondary windings made up of
/copper or aluminum conductors and iron core.
The expression for emf induced E = 4.44 f Фm T
Where f = frequency, Фm =mutual flux and T=number of turns in the primary/ secondary
winding
Usually the winding connected to supply is called primary winding and the
other winding connected to load is called secondary winding.
Depending upon the type of construction used, the transforms are classified into
two categories as : (i) core type, and (ii) shell type
Core type transformers: The magnetic core is built of laminations to form rectangular
frame and the windings are arranged concentrically with each other around t legs or
limbs of the core as shown in Fig 2.1
Shell type transformers: In shell type transformers the windings are put the central limb
and the flux path is completed through two side limbs as shown in Fig2.2 The central
limb carries total mutual flux while the side limbs forming a part parallel magnetic circuit
carry half the total flux. Consequently, the cross-sectional area (and width) of the central
limb is twice that of each of the side limbs.
Comparison of core and shell types of transformers:
S.No Core type Shell type
1 Easy in design and construction. Comparatively complex.
2 Has low mechanical strength due to non- High mechanical strength.
bracing of windings. Reduction of leakage reactance
3 Reduction of leakage reactance. is not easily is highly possible.
possible. It cannot be easily dismantled
4 The assembly can be easily dismantled for for repair work.
repair work. Heat is not easily dissipated
5 Better heat dissipation from windings. from windings since it is
6 Has longer mean length of core and shorter surrounded by core.
mean length of coil turn. Hence best suited for It is not suitable for EHV (Extra
EHV (Extra High Voltage) requirements. High Voltage) requirements.

3.2 Output equation of a Single Phase transformer:

The transformer output is rated in kilo volt ampere (KVA). It depends
on flux density (i.e. core area) and ampere turns (AT) (i.e. winding area).
The voltage induced in a transformer winding with T turns
 Emf E = 4.44 f Фm T volts --- 1
E
Emf per turn Et = = 4.44 f Фm volts --- 2
T

Figure 3.1- core and shell types of transformers

The window space factor Kw is defined as ·the ratio of copper area in window to total
area of the window. .
conductor area in. window Ac
Kw = = -------- 3
Total area in. window Aw
Conductor area in window = Ac = Kw * Aw -------- 4

Taking the current density δ is same in both the windings

Ip Is
Therefore, Current density, δ = = -------- 5
ap as
Area of a cross – section of primary conductor = ap = Ip / δ ----- 6

Area of a cross – section of secondary conductor= as = Is / δ ----- 7

If we neglect magnetizing mmf then primary ampere turns is equal to secondary ampere
turns.
Therefore, Ampere turns = AT = Ip * Tp + Is * Ts ------ 8
The window in a single phase transformer contains one primary and one secondary
winding.
Total copper area in window Ac
 = copper area of primary + copper area of secondary
=primary turns * area of primary conductor + secondary turns * area of
secondary conductor
Ac =Tp * ap+ Ts * as ------ 9

Substituting for ap and as from 6 and .7 in 9 we get

Ac = Tp * (Ip / δ ) + Ts * (Is / δ ) --------- 10
Ac = 1/ δ (Tp * Ip + Ts * Is ) --------- 11
From 8 we have
Ac = 1/ δ ( AT + AT ) --------- 12
Ac = 2 AT / δ --------- 13
Equating 4 and 13 we get,
Kw * Aw = 2 AT / δ --------- 14
1
Now AT = ( Kw * Aw *δ) --------- 15
2
KVA output of the transformer = Q = Vp * Ip * 10 -3 --------- 16
Since Ep ≈ Vp we have
= Ep * Ip * 10 -3 --------- 17
Dividing 17 by Tp and multiplying by Tp we get,
= (Ep / Tp )* Tp Ip * 10 -3 --------- 18
= Et * AT* 10 -3 --------- 19
Substituting for Et from 2 and AT from15 we get,
1
Q = 4.44 f Фm * ( Kw * Aw *δ) * 10 -3 --------- 20
2
= 2.22 f Фm * ( Kw * Aw *δ) * 10 -3 --------- 21
But Bm = Фm / Ai --------- 22
Фm = Bm * Ai --------- 23
Substituting 23 in 21 we get,
Q = 2.22 f Bm * Ai * ( Kw * Aw *δ) * 10 -3 --------- 24
Equation 24 is output equation of single phase transformer.
EXAMPLE3.1:
Calculate the core and window areas required for a 1000 kV A, 6600/400 V, 50Hz,
single phase core type transformer. Assume a maximum flux density of 1.25Wb/m2 and a
current density of 2.5 A/mm2. Voltage per turn = 30 V. Window space factor = 0.32.
Given data:
kVA = 1000 . f = 5Q Hz B = 1.25 Wb/m2
Vp = 6600V Vs =400V δ = = 2.5 A/mm2
Et = 30 V Kw =0.32 Core type
Solution
Emf per turn Et = 4.44 f Фm volts
Фm = Et / 4.44 f = 30/4.44*50 = 0.1351 Wb
Flux density Bm = Фm / Ai
The net area of core = Ai = Фm / Bm = 0.1351 / 1.25 = 0.108 m2

The kV A rating of transformer Q = 2.22 f Bm * Ai * ( Kw * Aw *δ) * 10 -3

:. Window area Aw = Q / 2.22 f Bm * Ai * ( Kw *δ) * 10 -3
= 1000 / 2.22*50*1.25*0.108*0.32*2.5*106* 103
= 0.0834 m2
Result
Net core area, Ai = 0.108 m2 = 0.108 x 106 mm2
Window area, Aw = 0.0834 m2 = 0.0834 x 106 mm2
3.3Output equation of Three phase transformer:
The voltage induced in a transformer winding with T turns
The induced Emf per phase E = 4.44 f Фm T volts - 1
E
Emf per turn Et = = 4.44 f Фm volts --- 2
T
Three Phase Transformers, In the case of three window contains two primary and two
secondary windings,
The window space factor Kw is defined as ·the ratio of copper area in window to total
area of the window. .
conductor area in. window Ac
Kw = = -------- 3
Total area in. window Aw
Conductor area in window = Ac = Kw * Aw -------- 4
Taking the current density δ is same in both the windings
Ip Is
Therefore, Current density, δ = = -------- 5
ap as
Area of a cross – section of primary conductor = ap = Ip / δ ----- 6

Area of a cross – section of secondary conductor= as = Is / δ ----- 7

If we neglect magnetizing mmf then primary ampere turns is equal to secondary ampere
turns.
Therefore, Ampere turns = AT = Ip * Tp + Is * Ts ------ 8
Three Phase Transformers, In the case of three window contains two primary and two
secondary windings,
Total copper area in window Ac
= copper area of primary + copper area of secondary
=2*primary turns * area of primary conductor + 2*secondary turns * area of
secondary conductor
Ac = 2*Tp * ap+ 2*Ts * as ------ 9
Substituting for ap and as from 6 and 7 in 9 we get,
Ac =2*Tp * (Ip / δ ) + 2*Ts * (Is / δ ) --------- 10
Ac = 2/ δ (Tp * Ip + Ts * Is ) --------- 11
From 8 we have
Ac = 2/ δ ( AT + AT ) --------- 12
Ac = 4 AT / δ --------- 13
Equating 4 and 13 we get,
Kw * Aw = 4 AT / δ --------- 14
1
Now Ampere-turn AT = ( Kw * Aw *δ) --------- 15
4
KVA output of the three phase transformer = Q =3* Vp * Ip * 10 -3 ----- 16
 Since Ep ≈ Vp we have
=3* Ep * Ip * 10 -3 --------- 17
Dividing 17 by Tp and multiplying by Tp we get,
= 3*(Ep / Tp )* Tp Ip * 10 -3 --------- 18

= 3*Et * AT* 10 -3 --------- 19

Substituting for Et from 2 and AT from 15 we get,
1
Q =3* 4.44 f Фm * ( Kw * Aw *δ) * 10 -3 --------- 20
4
= 3.33 f Фm * ( Kw * Aw *δ) * 10 -3 --------- 21
But Bm = Фm / Ai --------- 23
Фm = Bm * Ai --------- 24
Substituting 24in 21 we get,
Q = 3.33 f Bm * Ai * ( Kw * Aw *δ) * 10 -3 --------- 25
Equation 2.48 is output equation of three phase transformer.
3.4 Equation for Emf per turn:
Selection of an appropriate value for emf per turn is most important step in transformer
design .
Hence an equation for emf per turn can be developed by relating output k V A,
magnetic and electric loading. In transformers the ratio of specific magnetic and electric
loading is specified rather than actual value of specific loadings.

Let the ratio of specific magnetic and electric loading = r = Фm / AT ----- 1

AT = Фm / r ----- 2
The volt-ampere per phase of a transformer is given by the product of voltage and current
per phase. Considering the primary voltage and current per phase we can write,

kV A per phase, Q = Vp Ip x 10-3 ------3

Since Ep ≈ Vp we have
= Ep * Ip * 10 -3 --------- 4
But Ep = 4.44 f Фm Tp ------ 5
Substituting 4 in 3 we get,
Q = 4.44 f Фm Tp Ip* 10 -3 ------ 6

Q = 4.44 f Фm AT* 10 -3 ------ 7

From 2 we can write 7 as
Q = 4.44 f Фm * (Фm / r) *10 -3
Q = 4.44 f (Фm2 / r) * 10 -3 ------ 8
Q*r
Фm2 = ------- 9
4.44 f * 10 − 3

Фm = √ Q*r * 103/ 4.44 f ------ 10

E
We knew that Emf per turn Et = = 4.44 f Фm volts --- 11
T
Substituting for Фm in eqn11 from eqn10 we get,
Et = 4.44 f * √ Q*r * 103/ 4.44 f ---- 12
 Et =√4.44 f *r* 103 * √ Q ---- 13
Et = K * √ Q ---- 14
Where K =√4.44 f *r* 103 ---- 15
K =√4.44 f *( Фm / AT )* 103 ---- 16
14 is Equation for Emf per turn
In equation 14 , Q is kVA rating for single phase transformer and Q is kVA per
phase for three phase transformer.
Values of K for different types of transformer:
The value of K depends on the type, service condition and method 'of
construction of transformer. value of K for Single phase shell type 1.0 to 1.2 Single phase
core type 0.75 to 0.85 , Three phase shell type 1.3 . Three phase core type, distribution
transformer 0.45 Three phase core type, power transformer 0.6 to 0.7
3.5 Design of cores:
Different types of cores: 1.Rectangular core 2. Square core 3. Stepped core.
• For core type transformer the cross-section may be rectangular, square or stepped.
• For shell type transformer the cross-section may be rectangular. When rectangular
cores are used the coils ate also rectangular in shape.
• The excessive leakage fluxes are produced during short circuit and over loads.
This develops severe mechanical stresses on the coils.
• On circular coils these forces are radial and there is no tendency for the coil to
change its shape.
• But on rectangular and square coils the forces are perpendicular to the conductors
and tend to deform the shape of coil.
• Hence circular coils are employed in high voltage and high capacity transformers.
• When circular coils are employed the square and stepped cores are used.

Figure 3.2- Square core and stepped core.

In square cores the diameter of the circumscribing circle is larger than the.
diameter of stepped cores of same area of cross-section.
• Thus when stepped cores are used the length of mean turn of winding is reduced
with consequent reduction in both cost of copper and copper loss. However with
 larger number of steps a large number of different sizes of laminations have to be
used: This result in higher labour charges for shearing and assembling different
types of laminations.
Square core:
Let d = diameter of circumscribing circle
Also, d = diagonal of the square core
a= side of square core
Diameter of circumscribing circle, d = √ a 2 + a 2 = √2 a
Side of square, a = d / √2

Gross core area, Agi = area of square = a2 = (d /√2)2 = 0.5 d2

Let stacking factor, Sf =0.9
The gross core area is the area including insulation area and net core area is e area of iron
alone excluding insulation area. Hence
Net core area, Ai = Stacking factor x Gross core area
= 0.9 x 0.5 d2 = 0.45 d2
Area of circumscribing circle = ( Π/4) * d2
Netcorearea
The ratio, = 0.45 d2 / ( Π/4) * d2 = 0.58
Areaofcircumscribingcircle
Grosscorearea
The ratio, = 0.5 d2 / ( Π/4) * d2 = 0.64
Areaofcircumscribingcircle
Another useful ratio for the design of transformer core is core area factor. It is the ratio of
net core area and square of the circumscribing circle
Netcorearea
Core area factor, Kc =
Squareofcircumscribingcircle
= Ai / d2 = 0.45 d2 / d2 = 0.45
Two stepped core or cruciform core:
• In stepped cores the dimensions of the steps should be chosen, such as to a occupy
maximum area within a circle. The dimensions of the two step to give maximum
area for the core in the given area of circle are determined as follows [Also for
given diameter of circle].
Let, a = Length of the rectangle
b = Breadth of the rectangle
d = Diameter of the circumscribing circle
Also d = Diagonal of the rectangle
θ = Angle between the diagonal and length of the rectangle.
 Figure 3.3- Two stepped core.
The cross· section of two stepped core is shown in above figure. The maximum
core area for a given d is obtained when θ is maximum value. Hence differentiate Agi
with respect to θ and equate to zero to solve for maximum value of θ.
a
From above figure we get, Cos θ = ; a = d*Cos θ ---- 1
d
b
Sin θ = ; b = d*Sin θ ---- 2
d
The two stepped core can be divided into three rectangles. The area of three
rectangles gives the gross core area. With reference to above figure we can write,
a−b a−b a−b
Gross core area, Agi = ab + ( )*b + ( )*b = ab + 2* ( )*b
2 2 2
Agi = ab+ab-b2 = 2ab-b2 ----- 3
On substituting for a and b from equations 1 & 2 in equation 3 we get,
Agi = 2(d cos θ)(d sin θ)-(d sin θ)2 = 2d2 cos θ sin θ - d2 sin2 θ
= d 2 (2 sin θ cos θ - sin 2 θ ) = d 2 (sin2 θ - sin 2 θ ) = d2 sin2 θ -d2sin2 θ -4
To get maximum value of θ, differentiate Agi with respect to θ, and equate to zero,
d/d θ Agi = 0
On differentiating equation 4 with respect to θ we get,
d/d θ Agi = d2 cos 2 θ x 2- d2 2 sin θ cos θ
. put d/d θ Agi = 0
d2 cos2 θ x 2 - d2 2 sin θ cos θ = 0
d 2 sin θ cos θ = d2 cos2 θ x 2
2

d2 2 sin 2θ = d2 cos2 θ x 2
sin 2 θ / cos2 θ = 2
2 θ = tan-12
θ = ½ tan-12 = 31.72°
When θ = 31.72°, the dimensions of the core (a & b) will give the maximum area for core
for a specified d.
When θ = 31.72°, a = d cos θ = d cos 31.720 = 0.85d
b = d sin θ = d sin 31.720 = 0.53d
On substituting the above values of a & b in equation 3 we get,
Gross core- area, Agi = 2ab- b2 = 2(O.85d)(O.53d)- (O.53d)2 = 0.618 d2
. Let stacking factor, Sf = 0.9 Net core-area, Ai = Stacking factor x Gross core area
 = 0.9 x 0.618 d2 = 0.56 d2 ---- 4
Netcorearea
The ratio, = 0.56 d2 / ( Π/4) * d2 = 0.71
Areaofcircumscribingcircle
Grosscorearea
The ratio, = 0.618 d2 / ( Π/4) * d2 = 0.79
Areaofcircumscribingcircle
Netcorearea
Core area factor, Kc =
Squareofcircumscribingcircle
= Ai / d2 = 0.56 d2 / d2 = 0.56 --- 5
3.6 Choice of flux density in the core:
• The flux density decides the area of cross-section of core and core loss.
• Advantages of higher values of flux density: It results in smaller core area, lesser
cost, reduction in length of mean turn of winding
• Advantages of higher values of flux density : It results in higher iron loss and
large magnetizing current.
• The choice of flux density depends on the service condition (i.edistribution or
transmission) and the material used for laminations of the core.
• The laminations made with cold rolled silicon steel can work with higher flux
densities than the laminations made with hot rolled silicon steel.
• Usually the distribution transformers will have low flux density to achieve lesser
iron loss.
• Bm = 1.1 to 1.4 Wb/m2 For distribution transformers
• Bm = 1.2 to 1.5 Wb/m2 For power transformers
3.7 Overall dimensions of the transformer:
• The main dimensions of the transformer are Height of window (Hw) and Width of
window Ww
• The other important dimensions of the transformer are
• width of largest stamping (a),
• diameter of circumscribing circle (d),
• distance between core centers (D),
• height of yoke (Hy), depth of yoke (Dy)
• Overall height of transformer frame (H) and overall width of transformer frame
(W).
• These dimensions. for various types of transformers are shown in figure (4.7),
(4.8) and (4.9). '
• The figure 4.7 shows a vertical and horizontal cross-section of the core and
winding assembly of a core type single phase transformer.
• The fig 4.8 shows a vertical and horizontal cross-section of the core and winding
assembly of a core type three phase transformer.
• The fig 4.9 shows a vertical and horizontal cross-section of a shell type single
phase transformer.
 Figure 3.4- Overall dimensions of the 1Ф transformer

D = d + Ww --- 1
H = Hw + 2Hy ---- 2
W=D+a ---- 3
Figure 3.5- Overall dimensions of the 3Ф transformer
 Figure 3.6- Overall dimensions of the 1Ф shell type transformer
3.8 Design of winding:
• The transformer has one high voltage winding and one low voltage winding.
• The design of winding involves the determination of number of turns and area of
cross-section of the conductor used for winding.
• The number of turns is estimated using voltage rating and emf per turn (or by
using ampere-turns and rated current).
• The area of cross-section is estimated using rated current and current density.
• Usually the number of turns of low voltage winding is estimated first using the
given data and it is corrected to nearest integer. Then the numbers of turns of high
voltage winding are chosen to satisfy the voltage rating of the transformer.
• Number of turns in low voltage winding TLV = VLV / Et or AT / ILV ---- 1
where, V LV = Rated voltage of low voltage winding
ILV = Rated current of low voltage winding
• Number of turns in high voltage winding THV = TLV * (VHV / TLV )
 where, V HV = Rated voltage of high voltage winding
• Area of cross - section of primary winding conductor ap = Ip / δ
• In transformers same current density is assumed for primary and secondary.
• Area of cross - section of secondary winding conductor as = Is / δ
• δ = 1.1 to 2.2 A/ mm2 for distribution transformers
• δ = 2.2 to 3.2 A/ mm2 for large power transformers with self oil cooling or air-
blast.
• δ = 5.4 to 6.2 A/ mm2 for large power transformers with forced circulation of oil
or with water cooling coils.
EXAMPLE 3.2:
Estimate the main dimensions including winding conductor area of a 3- phase, ∆- Y
core type transformer rated at 300 kV A, 6600/440 V, 50Hz. A suitable core with 3-steps
having a circumscribing circle of 0.25 m diameter and a leg spacing of 0.4 m is available.
Emf per turn = 8.5V, δ = 2.5A/mm2, Kw= 0.28, Sf= 0.9 (stacking factor).
Solution
Let 440V side be secondary and 6600V be primary. Here the secondary is star
connected and primary is delta connected.
Secondary voltage per phase, Vs = 440/√3 = 254V
Also, Es ≈ Vs we have
Emf per turn, Et = Es /Ts It is given that Et = 8.5 V.
254
Number of secondary turns per phase, Ts = = 29.88 ≈ 30 turns
8 .5
6600
Number of primary turns per phase, Tp = Ts *( Vp / Vs ) = * 30 = 779.5 turns
254
= ≈ 780 turns
kV A rating of transformer =Q = √3* VLP ILP x 10-3 = √3* VLS ILS x 10-3
where, V LP Line voltage on primary side ILP Line current on primary side V LS Line
voltage on secondary side ILS Line current on secondary side
Line current on primary side, ILP = Q / √3* VLP x 10-3 = 300/ √3* 6600 x 10-3
= 26.24 A
Since primary is delta connected,
The phase current on primary I P= ILP = 26.24/ √3 = 15 15 A
The area of cross-section of primary conductor ap = I P /δ = 15.15 / 2.5 =6.06mm2
Line current on secondary side, ILs = Q / √3* VLs x 10-3 = 300/ √3* 440 x 10-3
= 393.65 A
Since secondary is star connected,
The phase current on secondary, I s= ILs = = 393.65 A
The area of cross-section of secondary conductor as = I s /δ = 15.15 / 2.5 =157.5mm2

The copper area in window, Ac = 2*Tp * ap+ 2*Ts * as

=2 (6.06 x 780 +157.5 x30) = 18903.6 mm2
Window Area,
Aw = Ac / Kw = 18903.6 / 0.28 = 67512.86 mm2
= 67512.86 x 1O-6m2 = 0.0675 m2
Area of circumscribing circle = ( Π/4) * d2
 Grosscorearea
For 3 stepped core, The ratio, = 0.84
Areaofcircumscribingcircle
Gross core area, Agi = 0.84 x area of circumscribing circle = 0.84 x 0.049 = 0.041 m2
Net core area, A I = Sf x A gi = 0.9 x 0.041 = 0.0369 m2= 0.37 x 106 mm2
Given that, leg spacing = 0.45 m
Width of window, W w = leg spacing = 0.45 m
Height of window, H w = A w / Ww = 0.0675 / 0.45 = 0.15 m
Result:
Number of primary turns per phase T p = 780
Area of cross-section of primary conductor a p = 6.06 mm2
Number of secondary turns per phase T s = 30
Area of cross-section of secondary conductor a s = 157.5 mm2
Net core area, A i = 0.0369 m2
Window area A w =0.0675 m2
Height of window H w = 0.15 m
Width of window, W w =0.45 m
Example3.3:
Determine the dimensions of core and yoke for a 200 KVA, 50 Hz single phase
core type transformer. A cruciform core is to be used with distance between adjacent
limbs equal to 1.6 times the width of core laminations. Assume voltage per turn is 14
volts, Bmax = 1.1 Tesla,Window space factor is 0.32. Current density is 3 A/mm2 and
stacking factor is 0.9. Net iron area is 0.56 m2 where d is the diameter of the
circumscribing circle of cruciform core. Width of largest stamping is 0.85d.
(AnnaUni – Nov/Dec 2003)
Solution:
Emf per turn Et = 4.44 f Bm * Ai volts
Given that Et = 14 V f = 50 Hz Bm = 1.1 Wb/m2
Substituting we get Net iron area = Ai = 14 / 4.44*50*1.1 = 0.573 m2
Netcorearea
We know that, Core area factor, Kc =
Squareofcircumscribingcircle
= Ai / d2 = 0.56 d2 / d2 = 0.56
So, diameter of the circumscribing circle = d = √ Ai / 0.56 = 0.32m
Width of the largest stamping = a = 0.85d = 0.85 * 0.32 = 0.272m
It is given that, distance between adjacent limbs equal to 1.6 times the width of core
laminations.
Distance between core centers = 1.6 a = 1.6 * 0.272 = 0.435m
Width of window, W w = D-d = 0.45 -0.32 = 0.115m
For a single phase transformer, the output KVA is
Q = 2.22 f Bm * Ai * ( Kw * Aw *δ) * 10 -3
Substituting,200 = 2.22*50*1.1*0.32*3*106 * Aw * 10 -3
Window area A w = 0.0293m2
Height of window H w = A w/ W w = 0.0298/0.115 = 0.26m
Using the same stepped section for the yoke as for core,
Depth of yoke = Dy = a = 0.272m
Height of yoke = Hy = 0.272m
Referring to figure 4.7, we have H = Hw + 2Hy =0.26 +2*272 = 0.804m
 W = D + a = 0.435 + 0.272 = 0.737m
Example3.4:
Compute the main dimensions of the core of a 5 KVA, 11000/400 volts 50 Hz
single phase core type transformer. Window space factor = 0.2. The height of the
window is 3 times its width. Current density = 1.4 A/mm2. Bmax = 1.0 Tesla. stacking
factor = 0.9. Net conductor area in the window = 0.6 times the net cross sectional area
of iron in the core. Also find no. of primary and secondary turns.
Given that Net conductor area = 0.6* Net iron area
Or Kw * Aw = 0.6 Ai
Window area = Aw = (0.6 / Kw )* Ai = (0.6/0.2 )*Ai = 3 Ai
For a single phase transformer, the output KVA is
Q = 2.22 f Bm * Ai * ( Kw * Aw *δ) * 10 -3
Substituting, 5 = 2.22*50*1.0*0.2*1.4*106 * 3Ai * Ai 10 -3
We get net iron area Ai = 0.00732m2
Gross iron area Agi = Ai/Sf = 0.00732m2 / 0.9 = 0.00814m2 = a2
Width of the core = √ 0.0814 = 0.09 m, Gross iron area provided Agi = 0.0081m2
Net iron area provided Ai = 0.00729m2
Window area A w = 3 * 0.00729= 0.02187m2
Height of window H w = 3 W w
But Aw = H w * W w So 3 W w2 = 0.02187
Hence Width of window, W w = 0.085m
Height of window H w = 3* 0.085 = 0.255m
The yoke has same gross area as the core, Gross area of yoke = Ay = 0.0081m2
Depth of yoke = Dy = a = 0.09m
Height of yoke = Hy = 0.0081/ 0.09 = 0.09m
Overall dimensions of core:
Referring to figure 4.7, we have
Distance between core centers D = a +Ww = 0.09 + 0.085 = 0.175m
Length of the frame W = D + a = 0.175 + 0.09 = 0.265m
Height of the frame H = Hw + 2Hy =0.255 +2*0.09 = 0.435m
Flux Фm = Bm * Ai = 1.0 * 72.9*10-3 = 7.29* 10-3 wb
Emf per turn, Et = 4.44 f Фm = 4.44*50*7.29* 10-3 =1.625V
400
Number of secondary turns per phase, Ts = = 246 turns
1.625
11000
Number of primary turns per phase, Tp = Ts *( Vp / Vs ) = * 246 = 6765 turns
400
Primary current = Q/KV = 5000/11000 = 0.455A
The area of cross-section of primary conductor ap = I P /δ = 0.455 / 1.4 =0.384mm2
Using circular conductors, diameter of primary conductor = √0.324*4/Π = 0.642m
secondary current = Q/KV = 5000/400 = 12.5A
The area of cross-section of secondary conductor as = I s /δ = 12.5 / 1.4 =8.93mm2
Using square conductors, 3*3 mm2
The area of of secondary conductor as = 9 mm2
3.10 Cooling of transformers:
• The losses developed in the transformer cores and windings = Pi + Pc
• Pi = Iron loss, Pc = Copper loss
 • The losses developed in the transformer cores and windings are converted into
thermal energy and cause heating of corresponding transformer parts.
• The heat dissipation in transformer occurs by Conduction, Convection and
Radiation.
• The paths of heat flow in transformer are the following
• From the internal most heated spots of a given part (of core or winding) to their
outer surface in contact with the oil.
• From the outer surface of a transformer part to the oil that cools it.
• From the oil to the walls of a cooler, eg. Wall of tank.
• From the walls of the cooler to the cooling medium air or water.
The various methods of cooling transformers are Air natural, Air blast, Oil natural, Oil
natural-air forced , Oil natural-water forced, Forced circulation of oil , Oil forced-air
natural , Oil forced-air forced , Oil forced-water forced
• The choice of cooling method depends upon the size, type of application and type
of conditions obtaining at the site where the transformer in installed.
• Air natural is used for transformers up to 1.5 MV A. Since cooling by air is not so
effective and proves insufficient for transformers of medium sizes, oil is used as a
coolant. Oil is used for almost all transformers except for the transformers used
for special applications. Both plain walled and corrugated walled tanks are used in
oil cooled transformer.
3.11Transformer oil as a cooling medium:
For the transformer oil, the specific heat dissipation due to convection of oil is
given by
λ convection = 4.03*( θ/ H )1/4
where θ = Temperature difference of the surface relative to oil,
H = Height of dissipating surface in meters
3.12 Temperature rise in plain walled tanks:
• The transformer core and winding assembly is placed inside a container called
tank. The walls of the tank dissipate heat by both radiation and convection.
• For a temperature rise of 40°C above the ambient temperature of 20 °C, the
specific heat dissipation are as follows,
1. Specific heat dissipating due to radiation, λ rad = 6 W/m2 0C
2. Specific heat dissipation due to convection, λ con = 6.5 W/m2 0C
. The total specific heat dissipation in plain walled tanks is 12.5 W/ W/m2 0C

Totalloss
The temperature rise,θ =
Specificheat * Heatdissipationsurfaceof tan k
= (Pi + Pc )/ 12.5 Si

where, Pi = Iron loss Pc = Copper loss Si = Heat dissipating surface of the tank
3.13 Design of tank with cooling tubes:
• The transformers are provided with cooling tubes to increase the heat dissipating
area.
• The tubes are mounted on the vertical sides of the 'transformer tank. '
 • But the increase in dissipation of heat is not proportional to increase in area,
because the tubes would screen (conceals) some of the tank surface preventing
radiations from the screened surface.
• On the other-hand the tubes will improve the circulation of oil. This
improves the dissipation of loss by convection. The circulation of oil is due to
more effective pressure heads produced by columns of oil in tubes.
• The improvement in loss dissipation by convection is equivalent to loss
dissipated by 35% of tube surface area. Hence to account for this
improvement in dissipation of loss by convection an additional 35 % tube
area is added to actual tube surface area or the specific heat dissipation due
to convection is taken as 35% more than that without tubes.
Let, the dissipating surface of the tank = Si
The dissipating surface of the tubes = x * Si
Loss dissipated by surface of the tank by radiation and convection
= (6 + 6.5) St = 12.5 St
135
Loss dissipated by tubes by convection = 6.5 * *X*St
100

Total loss dissipated by walls and tubes = 12.5 St + 8.8*X*St = (12.5 + 8.8 X)* St
---- 1
Actual total area of tank walls and tubes = St + X* St = (1+X) * St
Total loss dissipated
Loss dissipated per m2 of dissipating surface =
Total area
= St(12.5 + 8.8X) / St (1 + X)
= (12.5 + 8.8X) / (1 + X) ---- 2
Total loss
Temperature rise in transformer with cooling tubes θ =
Loss dissipated
Total loss, Ploss = Pi + Pc ---- 3
Where Pi = Iron loss Pc = Copper loss
From equation 1 & 2 we get θ = (Pi + Pc)/ (12.5 + 8.8 X)* St
Or (12.5 + 8.8 X) = (Pi + Pc)/ θ * St ----- 4
1
X = ((Pi + Pc)/ θ * St - 12.5 ) * ---- 4
8 .8
Total area of cooling tubes = X*St
On substituting for X from equation 4 we get,
1
Total area of cooling tubes = [(Pi + Pc)/ θ - 12.5 )] *St --- 5
8 .8
Calculation of number of tubes:
Let, lt = Length of the tube
dt = Diameter of the tube
Surface area of each tube = Π dt lt
( surface area of a cylinder)
Total area of tubes
Total number of tubes =
Area of each tube
 1
= (1/ Π dt lt ) * [(Pi + Pc)/ θ - 12.5 )] *St ---- 6
8 .8
• The standard diameter of the cooling tubes is 50 mm and the length of the tube
depends on the height of the tank.
• The tubes are arranged with a centre to centre spacing of75 mm.
• The dimensions of the tank are decided by the dimensions of the transformer
frame and clearance required on all the sides.
• The dimensions of the tank are shown in following figure.

Figure 3.7 Dimensions of the tank

With reference to above figure it can be written,
Width of the tank, WT = 2D + Doc + 2 C1 (for 3-phase) --- 7
= D + Doc + 2C1 (for I-phase) --- 8
Length of the tank, LT = Doc + 2 C2 ---- 9
Height of the tank, HT = H + C3 + C4 ---- 10
Where,
 C1 - Clearance between winding and tank along the width.
C2 - Clearance between the winding and tank along the length.
C3 - Clearance between the transformer frame and the tank at the bottom.
C4 - Clearance between the transformer frame and the tank at the top.
Doc - Outer diameter of coil
EXAMPLE3.5:
A 250 KVA, 6600V/400V, 3-phase core type transformer has a total loss of
4800W at full load. The transformer tank is 1.25m in height and 1m * 0.5m in plan.
Design suitable scheme of tubes if the average temperature rise is limited to 350 C. The
diameter of tube is 50mm and is spaced 75mm from each other. The avarege height of the
tubes is 1.05m. Specific heat dissipation due to radiation and convection is respectively 6
and 6.5 W/m2 0 C. Assume that the convection is improved by 35% due to provision of
tubes. (AnnaUni – Ap/May 2005)
Solution:
Step 1: Calculation of Heat dissipating surface of the tank:
Given that Tank dimension = 0.5 x 1 x 1.25 m

Figure 3.8 Dimensions of the tank

So it is given that LT = Length = 0.5 m, HT = Height = 1.25 m
WT = Width = 1 m
Now the heat dissipating surface of the tank = St = Total area of vertical sides
= 2(LT HT + WT HT) = 2 HT (LT + WT)
St = 2 x 1.25 x (0.5 + I) =3.75 m2
Loss dissipated by surface of the tank by radiation and convection
= (6 + 6.5) St = 12.5 St
Let the dissipating surface of the tubes = x * Si
135
Loss dissipated by tubes by convection = 6.5 * *X*St
100

Total loss dissipated by walls and tubes = 12.5 St + 8.8*X*St = (12.5 + 8.8 X)* St
 Total loss
Temperature rise in transformer with cooling tubes θ =
Loss dissipated
Given that, Total loss, P loss = 4800 W
θ = 4800 / (12.5 + 8.8 X)* St
1
X = (4800/ θ * St - 12.5) *
8 .8
1
= ( 4800/ 35 * 3.75 - 12.5 ) *
8 .8
= 2.7354
Total area of cooling tubes = X*St = =2.7354 x 3.75 = 10.2578 m2
Area of each cooling tube = Π dt lt = Π X 50 x 10-3 x 1.05 = 0.1649 m2
Total area of tubes
Total number of tubes = n i =
Area of each tube
10.2578
= = 62.206 = 62 tubes
0.1649
• The width of the tank is 1000 mm. If we leave an edge spacing of 87.5 mm on
either sides, then we can arrange 12 tubes widthwise with a spacing of 75mm
between the centres of tubes.
• The length of the tank is 500 mm. If we leave an edge spacing of 100mm on
either sides, then we can arrange 5 tubes lengthwise with a spacing of75mm
between the centres of tubes.
• But one row is not sufficient to accommodate the required 62 cooling tubes.
Hence 2 rows of cooling tubes are provided on both lengthwise and widthwise.
The plan of the cooling tubes is shown the following figure

Figure 3.9 The plan of the cooling tubes

Result: Total number of cooling tubes provided = 64
They are arranged as 2 rows on widthwise with each row consisting of 12 & 11 tubes and
2 rows on lengthwise with each row consisting of 5 & 4 tubes.
3.14 Estimation of no load current of transformer:
• The no-load current of a transformer has two components. They are magnetizing
component and loss component.
• The magnetizing current depends on the mmf required to establish the desired
flux.
• The loss component of no-load current depends on the iron loss.
3.15 No-Load current of single phase transformer:

Figure 3.10 Dimension of core - 1Ф transformer

No-load current, I0 = √ Im2 + Il2 --- 1
I m = magnetizing current
I l = loss component of no-load current
Magnetizing current:
In above figure, Total length of core = 2 l c Total length of yoke = 2 l y
Here, l c = H w = Height of window, l y = Ww = Width of window

Mmf for core = mmf per meter for maximum flux density in core * Total length of core
= at c * 2 l c = 2 at c l c

Mmf for yoke = mmf per meter for maximum flux density in yoke * Total length of yoke
 = = at y * 2 l y = 2 at y l y

Total magnetizing mmf, AT 0 = mmf for core + mmf for yoke + mmf for joints
= 2 at c l c + 2 at y l y + mmf for joints ---- 2

Maximum value of magnetizing current = ATo / Tp ---- 3

If the magnetizing current is sinusoidal then,
rms value of magnetizing current = Im = ATo / √2 Tp ---- 4
The values of at c and at y are taken from B-H curves for transformer steel.
Loss component of no-load current:
• The iron losses are calculated by finding the weight of cores and yokes.
• The loss per kg of iron is taken from the loss curves given by the manufacturer
of transformer laminations.
The loss component of no-load current, I0 = Pi / Vp ----- 5
Pi - Iron loss in watts Vp =Terminal voltage of primary winding
3.16 No-Load current of three phase transformer:
No-load current/ phase I0 = √ Im2 + Il2 --- 6
I m = magnetizing current
I l = loss component of no-load current
Magnetizing current:

Figure 3.11 Dimension of core - 3Ф transformer

In above figure, Total length of core = 3 l c Total length of yoke = 2 l y
Here, l c = H w = Height of window, l y = 2Ww + d
Where Ww = = Width of window d = diameter of circumscribing circle
Mmf for core = mmf per meter for maximum flux density in core * Total length of core
= at c * 3 l c = 3 at c l c

Mmf for yoke = mmf per meter for maximum flux density in yoke * Total length of yoke
= = at y * 2 l y = 2 at y l y
Total magnetizing mmf, = mmf for core + mmf for yoke + mmf for joints
= 3 at c l c + 2 at y l y + mmf for joints ---- 7
Total magnetizing mmf, AT 0 per phase = ( 3 at c l c + 2 at y l y + mmf for joints )/3 --8
Maximum value of magnetizing current/ phase = ATo / Tp
If the magnetizing current is sinusoidal then,
rms value of magnetizing current = Im = ATo / √2 Tp ---- 4
The values of at c and at y are taken from B-H curves for transformer steel.
Loss component of no-load current:
• The iron losses are calculated by finding the weight of cores and yokes.
• The loss per kg of iron is taken from the loss curves given by the manufacturer
of transformer laminations.
Let, Pi = Total iron loss for the three phases Pi = 3 3 Vp * Il
Loss component of no-load current, I l = P i /3 Vp
EXAMPLE 3.6:
A 15,000 KVA, 33/6.6KV,star/delta 3-phase core type transformer has the following
data.Net iron area of each limb = 1.5* 10 -3 m2. Net area of yoke = 1.8* 10 -3 m2. mean
length of magnetic flux path in each limb = 2.3 m, mean length of magnetic flux path in
each yoke = 1.6 m, number of turns per phase of HV windings = 450. Calculate the no
load current. Density of core steel =7.8*103 Kg/m3 Use the following data:
Flux density Bm 0.9 1.0 1.2 1.3 1.4
Mmf/m 130 210 420 660 1300
Iron loss/Kg 0.8 1.3 1.9 2.4 2.9
(AnnaUni – Ap/May 2005)
Solution:
H.V winding voltage per phase = 33000/ √3 = 19100 V
E
Emf per turn Et = = 4.44 f Фm volts
T
Фm = 19100/ 4.44*50*450 = 0.191 Wb
Flux density in the limbs = Bm (limb) = 0.191/0.15 = 1.27 Wb/m2
Referring to the given data corresponding to this flux density
At c = 560 A/m P i = 2.25W/Kg
Flux density in the yokes = Bm (yoke)= 0.191/0.18 = 1.06 Wb/m2
Referring to the given data corresponding to this flux density
At y = 260 A/m P i = 1.4W/Kg
Total mmf for three limbs = 3*560*2.3 = 3860A
Total mmf for two yokes = 2*260*1.6 = 832A
Total mmf limbs and yokes = 3860+832 = 4692A
Total magnetizing mmf, AT 0 per phase = 4692/3 = 1564 A
rms value of magnetizing current = Im = ATo / √2 Tp
= 1564 / √2 *450 = 2.6 A
Volume of three limbs = 3*2.3*0.15 = 1.035 m3
weight of three limbs = 1.035*7.8*103 = 8.08*103 Kg
Volume of two yokes = 3*1.6*0.18 = 0.576 m3
weight of two yokes = 0.576*7.8*103 = 4.49*103 Kg
Loss in limbs = 8.08*103 *2.25 = 18.2*103 W
Loss in yokes = 4.49*103 *1.4 = 6.3*103 W
 Total iron loss = 18.2*103 +6.3*103 = 24.5*103 W
Loss per phase = 24.5*103 /3 = 8.16 *103 W
Loss component of no-load current, I l = P i / Vp = 8.16 *103/ 19100 = 0.427A
No-load current/ phase I0 = √ Im2 + Il2 = √ 2.462 + 0.4272 = 2.5A
Questions
Unit – 3 – Design of Transformers
Part –A
1. State various methods of cooling of large power transformers.
2. State the various types of limb sections of core type transformer.
3. The voltage per turn of a 500 KVA, 11 KV/415V, ∆/Υ, 3-phase transformer is
8.7 V. Calculate number of turns per phase of LV and HV windings.
4. What is conservator?
5. Define voltage regulation of a transformer and state its importance.
6. State the factors on which the thermal time constant of a transformer depends.
7. State the reasons for preferring circular coils in comparison to rectangular coil in
transformer winding.
8. Top and bottom surfaces of the transformer tank are not considered for the design
of cooling tubes for transformer. Why?
9. Define window space factor the design of a transformer.
10. What is the functional difference between CT and PT?
11. What are the different losses in a transformer?
12. State the merits of three phase transformers over single phase transformers.
13. What is the significance of the ratio of magnetic loading to electric loading in the
design of transformer.
14. What are the steps followed for the calculation of magnetizing current in a single
phase transformer?
15. Draw the cruciform section of the transformer core and give the optimum
dimensions in terms of circumscribing circle diameter d.
Part –B
1. Derive the voltage per turn equation for a single phase transformer (8)
0
2. A 250 KVA transformer give the temperature rise of 20 C after 1 hour of full
load and 33.50 C after 2 hours.Find out the percentage overload to which the
transformer can be subjected safely for 1 hour if it has maximum efficiency on
full load. (8)
3. Explain the design procedure of cooling tubes for a transformer. (8)
4. Estimate the no load current of a 400 volt, 50 Hz, single phase transformer
With the following particulars: length of the mean magnetic flux path – 200 cm,
gross cross section 100 cm2, joints are equivalent to 0.1mm air gap. Maximum
flux density – 0.7 Wb/m2, magntising force corresponding to 0.7 Wb/m2 is 2.2
AT/cm and specific loss corresponding to0.7 Wb/m2 is 0.5 Watt/kg. Assume a
stacking factor of 0.9. (8)
5. Derive the output equation of a 3-phase transformer. (6)
6. A 250 KVA, 6600V/400V, 3-phase core type transformer has a total loss of
4800W at full load. The transformer tank is 1.25m in height and 1m * 0.5m in
plan. Design suitable scheme of tubes if the average temperature rise is limited to
350 C. The diameter of tube is 50mm and is spaced 75mm from each other. The
 avarege height of the tubes is 1.05m. Specific heat dissipation due to radiation and
convection is respectively 6 and 6.5 W/m2-0 C. Assume that the convection is
improved by 35% due to provision of tubes. (10)
7. How will you estimate no-load current in single and 3-phase transformers. (6)
8. A 15,000 KVA, 33/6.6KV,star/delta 3-phase core type transformer has the
following data.Net iron area of each limb = 1.5* 10 -3 m2. Net area of yoke limb =
1.8* 10 -3 m2. mean length of magnetic flux path in each limb = 2.3 m, mean
length of magnetic flux path in each yoke = 1.6 m, number of turns per phase of
HV windings = 450. Calculate the no load current. Use the following data: (10)
Mmf/m 130 210 420 660 1300
Iron loss/Kg 0.8 1.3 1.9 2.4 2.9
9. Derive the output equation of a single phase transformer and point out salient
features of this equation. (4)
10. Explain different methods of cooling of a transformers with relevant sketches.
State relative merits and limitations of these methods. (4)
11. Compute the main dimensions of the core of a 5 KVA, 11000/400 volts 50 Hz
single phase core type transformer. Window space factor = 0.2. The height of the
window is 3 times its width. Current density = 1.4 A/mm2. Bmax = 1.0 Tesla.
stacking factor = 0.9. Net conductor area in the window = 0.6 times the net cross
sectional area of iron in the core.Also find no. of primary and secondary terms. (8
12. Calculate the approximate overall dimensions for a 200 KVA, 6600/400 volts 50
Hz three phase core type transformer. Data: Emf/turn = 9 volts, Bmax = 1.0 Tesla,
Current density δ = 2.5 A/mm2 Window space factor Kw= 0.3. Overall height =
Overall width. Core is 4 stepped. Assume the stacking factor as 0.91 (16)
13. Determine the dimensions of core and yoke for a 200 KVA, 50 Hz single phase
core type transformer. A cruciform core is to be used with distance between
adjacent limbs equal to 1.6 times the width of core laminations. Assume voltage
per turn is 14 volts, Bmax = 1.1 Tesla,Window space factor is 0.32. Current density
is 3 A/mm2 and stacking factor is 0.9. Net iron area is 0.56 m2 where d is the
diameter of the circumscribing circle of cruciform core. Width of largest stamping
is 0.85d. (16)
14. A 100 kVA,6600/440 volts ,50Hz three phase delta/star core type oil immersed
natural cooled transformer has the following data :Distance between centers of
adjacent limbs =0.47 metre,Outer diameter of high voltage winding =0.44 metre,
Height of frame =1.24 metre, Core loss =3.7 kw and rated coper loss =10.5 kw.
Design a suitable tank with tubes for this transformer.
The average temperature rise of oil should not exceed 350 C. Specific heat
Dissipation from tank walls due to radiation and convection is respectively 6 and
6.5 W/m2-0 C. Assume that the convection is improved by 35% due to provision
of tubes. (16 )
15. Calculate the core and window area and make an estimate of the weights of
copper and iron required for a 125 KVA,2000/400 V,50Hz,single phase shell type
transformer.Data: Bm =1.1 wb/m2 , δ = 2.2 amp/mm2, Voltage/turn =11.2 V
Window area constant =0.33. Core is a rectangular and the stampings are all 7cm
wide. Sketch the core inserting the dimensions. (16)
16. The tank of a 150 KVA transformer has the dimensions 100cm *55cm*120cm
height. Design a suitable arrangement of cooling tubes of mean length
100com,and diameter of 5cm to limit the temperature rise to 350 C if the full load
losses to be dissipated are 5KW.Assume other values suitably. (16)