SCHOOL OF ELECTRICAL, ELECTRONIC AND COMPUTER

ENGINEERING

ELECTRICAL DESIGN 3 (ENEL3EA)

TRANSFORMER DESIGN

FINITE ELEMENT METHOD MAGNETICS

GROUP 6
Names Student Number
Lungelo zindela 217028993
Simphiwe Dubazana 217019340
Ayanda Sibiya 217002611
Noksinathi Majozi 217050166
Declaration
We the undersigned Group 6 members declare that this design project report “TRANSFOMER DESIGN”
is based on our own work carried out during the course of this semester. We assert the statement made and
conclusion drawn are as outcome of our research work and feather certify that:

1. The work contained in this report is original and has not been taken in any other sources available
anywhere either in similar design projects or in the internet.

2. We have followed the guidelines in writing a report provided by the University.

3. In cases where we have used relevant information from various sources, we have given due credit
to them in the text of the report and giving their full details in the reference list.

4. This report has not been submitted for any other degree or examination at any other University.

5. This report does not contain other previous reports data, pictures, graphs or any other information,
unless acknowledged as being sourced from other reports or persons.

Full Name Student Number Signature Date

Lungleo Zindela 217028993
Ayanda Sibiya 217002611
Nkosinathi Majozi 217050166
Simphiwe Dubazana 217019340

i
Abstract
This report presents results obtained in the design of a three phase core-type delta-star distribution
transformer using Finite Element Method Magnetics (FEMM) software tool. The design is broken into four
sub-sections which includes the Magnetic design section, Thermal design section, Short circuit design
section and Electrical Insulation design section. In the magnetic design section, a confirmation of the
transformer design dimensions against theoretical calculations is presented, the short circuit design section
presents findings based on the radial and axial forces experienced by the transformer windings, the thermal
design section confirms the current density and losses of the transformer at full load and lastly the electrical
insulation design section confirms that under the influence of an electric field, different type of materials
have different insulation capabilities to prevent charges flowing freely between the high voltage (HV) side
and the low voltage (LV) side of a transformer. A brief summary is presented at the end of the report on
how to improve the design in order to meet the transformer design specification.

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Table of Contents
Declaration……………………………………………………………………………………………………………………………………..i

Abstract…………………………………………………………………………………………………………………………………………ii

List of symbols………………………………………………………………………………………………………………………………..v

1. Introduction ........................................................................................................................................... 1
2. Magnetic Circuit Design Section (Lungelo Zindela) ............................................................................ 2
2.1 The core design procedure .................................................................................................................. 2
2.2 The winding design procedure............................................................................................................ 3
2.3 Results and comparison to theoretical design.................................................................................... 4
2.3.1 Magnetic flux density ................................................................................................................... 5
2.3.2 Magnetizing Current .................................................................................................................... 6
2.4 Correlation to Other sub-project ........................................................................................................ 7
2.5 Discussion and recommendations ...................................................................................................... 7
3. Thermal Design (Ayanda Sibiya) ................................................................................................... 8
3.1 Design procedure ...................................................................................................................... 8
3.2 Results and comparison to theoretical design .......................................................................... 9
3.2.1 Result under heat generation ............................................................................................... 9
3.2.2 Result of transformer under cooling effect ........................................................................ 10
3.3 Correlation to Other sub-project ............................................................................................ 11
3.4 Discussion and recommendations .......................................................................................... 11
3.5 Calculations ............................................................................................................................. 12
3.6 Improvements ......................................................................................................................... 12
4 Insulation design(Simphiwe Dubazana) ......................................................................................... 13
4.1 Design procedure ........................................................................................................................ 13
4.2 Material description .................................................................................................................... 14
4.3 Discussion of results ................................................................................................................... 15
4.4 Improvements ............................................................................................................................. 17
5 Short circuit Design (Nkosinathi Majozi) ....................................................................................... 17
5.1 Design procedure ........................................................................................................................ 17
5.1.1 Currents in the primary limbs. ............................................................................................ 18
5.1.2 Currents in the secondary limbs. ......................................................................................... 18
5.2.1 Forces .................................................................................................................................. 19
5.2.2 Radial force ............................................................................................................................. 19

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5.2.3 AXIAL FORCE ...................................................................................................................... 20
6.conclusion……………………………………………………………………………….22
7.references………………………………………………………………………………………………………………….23

Appendix A ......................................................................................................................... 24
A.1Process of group work and version control ................................................................... 24
Meeting 1 ............................................................................................................................ 25
Meeting 2 ............................................................................................................................ 26
Meeting 3 ............................................................................................................................ 27
Meeting 4(final)................................................................................................................... 28

iv
List of symbols

SYMBOL DESCRIPTION UNIT

A Area (cross-section) m2
Ai Net core area mm2
Agi Gross core area mm2
Aw Window area mm2
B Flux density T
Br Radial flux density T
d Diameter of circumscribing circle m
D Overall width of the core mm
E Electric field V/m
Et Voltage per turn V
Ei Field intensity V/m
f frequency Hz
F Force N
Fr Radial force N
Fa Axial force N
H Magnetizing field (H-field) A/m
Hw Height of Window mm
I Current A
Im Magnetizing current A
J Current density A/m
K Stacking factor
Kw Window space factor
L Length of conductor mm
N Number of turns
Q Power rating KVA
𝜇 Permeability H/m
Ww Width of Window mm
𝝓 Magnetic flux wb

v
 1. Introduction
Almost all of our modern conveniences are electrically powered, thus the need for electricity has become
one of the most essential tool for living. The question that most of us ask ourselves today is that how does
the electricity that we consume distributed across the country? And the answer to that is simply based on
transformers. Transformers are generally devices with no internal moving parts referred to as being static,
these electric devices transfers energy from one circuit to another by means of electromagnetic induction
[1]. They are typically used because a change in voltage is needed and there are two main types of
transformers namely the power transformer and distribution transformer. Power transformers are used in
transmission networks with higher voltages for step-up and step-down applications, they are generally rated
above 200MVA whereas in the other hand distribution transformers are used for lower voltage distribution
networks for residential and small business consumption which are generally rated below 200MVA [2].
Our design problem was to design a three phase core-type distribution transformer using FEMM software
tool to understand the basic operation of a transformer under different internal and external loading effects
as described in the main body of this report. FEMM is an application which consist of several types of
programs to assist a user in solving electromagnetic problems of low frequency on two dimensional planer
and axisymmetric domains, this application also facilitates in solving problems which include linear and
nonlinear magneto-static, linear and nonlinear time harmonic, liner electromagnetic problems and steady
state heat flow problems [3].
FEMM software tool is suitable for obtaining measures such as magnetic field energy, hysteresis losses,
resistive losses, total current of the transformer, forces and other quantities. Obtaining these measurements
will help measure the transformers performance capability in meeting specifications and in being
competitive in today’s market environment. Our transformer was designed to be 11kV/400V step down
with a 30KVA power rating and is plane tank, the transformer’s frequency is 50Hz and is delta-star
configured with a clearance of not less than 14mm between adjacent windings. The operating temperature
of the transformer is 40° with a coefficient of 𝛼 = 0.00392/°𝐶 and a power factor of 0.8 lagging.

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 2. Magnetic Circuit Design Section (Lungelo Zindela)

2.1 The core design procedure

In designing the magnetic circuit, the following steps/procedure was followed:

i. Calculated the voltage turn from the given rated voltage via this formula:

𝐸𝑡 = 𝐾 × √𝑄 (1)

ii. From the above result maximum flux was determined via the following formula

𝐸𝑡
𝜙= (2)
4.44𝑓

iii. We chose a value in a given range for magnetic flux which was then used in determining the area
of the core section.

iv. The grass core area was then determined and then from the ratio of the gross core area to that of
the net area the diameter of the circumscribing circle was then obtained via the equation.

𝐴𝑔𝑖
𝑟𝑎𝑡𝑖𝑜 = 𝑑2
(3)
𝜋×
4

v. Then we chose a suitable value of the current density to calculate the area of the window.

103
𝐴𝑤 = 𝑄 × 3.33𝑓.𝐵.𝜌.𝐾𝑤.𝐴𝑖 (4)

vi. From the above value we determined the height and width of the window of the magnetic core

𝐻𝑤
𝑊𝑤
=2 (5)

vii. We then proceeded to the yoke section of the core by determining the area of yoke, yoke depth and
its height.

viii. And then we completed the core by calculating its overall dimensions using the previous values
calculated with the two following formula where (H) is the overall height and (D) overall width.

𝐷 = 𝑑 + 𝑊𝑤 (6)

𝐻 = 𝐻𝑤 + 2𝐻𝑦 (7)

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2.2 The winding design procedure
This section presents steps taken in the design for the low voltage (LV) and High Voltage(HV) windings
of the transformer.

i. Firstly, we determined the phase and line voltages on the primary and secondary side of the
transformer taking note of the given transformer configuration.

ii. Currents in the LV and HV sides where determined

iii. Following the current was the number of turns

iv. Then we selected the conductor for the LV winding in the table given.

v. The inner diameter of insulation was then determined

vi. Followed by Insulation thickness

vii. And the Overall diameter of insulation

viii. Hence the Available length of the LV winding was determined by

𝐻𝑤 − 2(𝑖𝑛𝑠𝑢𝑙𝑎𝑡𝑖𝑜𝑛 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠) (8)

ix. Worked out how many conductors can fit in the LV side from the length available

x. And the Radial depth of the LV winding (Thickness of the LV winding)

xi. Proceeded to the HV winding

xii. We determined its diameter via the formula

𝑑𝑖𝑎(𝐻𝑉) = 𝑜𝑢𝑡𝑒𝑟 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 + 2 × 𝑖𝑛𝑠𝑢𝑙𝑎𝑡𝑖𝑜𝑛 (9)

xiii. We then used table 7.4 for paper coved conductors to get ordinary covering and fine covering

xiv. The findings from the table facilitated in finding the length of the HV winding

xv. Hence clearance was determined which is suitable and above 30mm

xvi. Radial depth of the (HV) winding was then determined

xvii. Followed by the outer diameter of the HV winding

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xviii. Hence final clearance was obtained which was above the minimum value 19𝑚𝑚 > 14𝑚𝑚

Hence, using the above calculated values which are the overall dimension of the core and winding we
constructed our circuit model using FEMM software.

Figure 1. Magnetic model using FEMM design

2.3 Results and comparison to theoretical design

This section deals with the comparison between the result obtained in analyzing the magnetic model using
FEMM with our theoretical calculations for the transformer. The comparison will be done based on the
magnetic flux density obtained in FEMM and the one calculated, the conductor and winding size, the
magnetizing current and the transformer’s rated voltage of the LV and HV sides.

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2.3.1 Magnetic flux density
The magnetic flux density is the amount of magnetic flux in a given area taken perpendicular to the field
direction. In the theoretical calculation a range between 1.1 𝑡𝑜 1.35𝑤𝑏/𝑚2 for flux density was given
in the design specifications and in our design we chose a value of

𝐵 = 1.1𝑤𝑏/𝑚2 (10)
This value is approximately equal to the flux density in the middle limb of the which ranges between 1.181
to 1.272𝑤𝑏/𝑚2 which confirms the expected value for our design and this is depicted in Figure 2. Since
the area of the core is constant the magnetic field is proportional to the flux density according to the
following equation
𝐵 = 𝜙𝐴 (11)
Hence an increase in the flux density causes an increase in the magnetic field, and the reason why the
magnetic flux density is concentrated in the middle limb is due to the fact that the field converges at the
center limb and diverges when it leaves the center limb creating a field imbalance in each limb as a result
the flux density will also vary as shown in the figure below.

Figure 2. The magnetic circuit showing the variation of the magnetic flux density in the core

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2.3.2 Magnetizing Current
Magnetizing current is a current that flows in the primary winding when the primary voltage is
applied with the secondary unloaded [4]. When we unloaded the secondary we applied no current
(open circuit) to the LV side and introduced a phase shift of 120° in each currents in the limb and
adjusted the current in each limb in order to match with our chosen theoretical flux density of
1.1𝑤𝑏/𝑚2 in the center limb. We also alternated the signs of the current according to the right
hand rule where the currents entering the page are considered to be positive and negative when it
leaves the page, the calculation for each current in the limb is as follows

Since the magnetizing current is approximately equal to the current in HV side at no load then it
follows that
|𝐼𝑚 | = 𝐼𝐻𝑉 (12)
For HV: 1&2
𝐼𝐻𝑉 = ±0.0546𝐴
∴ 𝐼𝑚 = 0.0546𝐴

For HV:3&4
𝐼𝐻𝑉 = ±0.0546∠120°

For HV:5&6
𝐼𝐻𝑉 = ±0.0546∠ − 120°

The flow of current in the winding generates a magnetic field around a coil, thus an increase in the
field increases the magnetic flux density and the relationship between current and the flux density
if given by the following formula which shows that the current and flux density are directly
proportional.
𝐵𝐿
𝐼= (13)
𝑁×𝜇

the graph on the next side shows the variation of flux density across the core with the center of the it being
the highest which confirms where the flux density should be heights and with each core on the sides from
the center being approximately half of the center limb.

6
 Figure 3. The graph showing the variation of the magnetic flux density across the core

2.4 Correlation to Other sub-project

The geometry of the magnetic design is the foundation of all the design sub-section in this report, for
insulation design its plays a vital role in determining the size and length available for the insulating material
to be placed between the windings, thus the results obtained in the insulation design is affected by both the
space available and the type of material used for insulation.
The short circuit design entirely depends on the magnetic design since the exact circuit is used to determine
the short circuit forces of the transformer which are the axial and radial forces experienced by the winding,
hence the design of the number of turns, current in the winding, flux density in the core and volume of the
winding all play a vital role in the short circuit design analysis.
For the thermal section only the geometry as mentioned and the block volume of the high voltage side play
an important role in determining the overall heat generation of the transformer.

2.5 Discussion and recommendations

The magnetic circuit is designed to provide a path for the magnetic field which induces voltage in the
windings, hence the type of material chosen for the core determines whether the path for the field will be
of low reluctance and this implies that it is important when designing the core to select the optimal material
of low reluctance to provide optimal magnetic field in the core. In addition to providing low reluctance we
must make shore that also the core is designed to prevent circulating currents within the core which causes
heating and energy losses. There is also another loss that is generated in the winding (HV) due to its
resistance of the magnetizing current, even when there is no load in the secondary side, thus to feather
reduce these losses the transformer should be immersed into oil to remove the excess heat generated.

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 3. Thermal Design (Ayanda Sibiya)

3.1 Design procedure

During operation of the transformer, the temperature of a transformer increases, meaning heat is generated
within the transformer due to losses experienced by the transformer. Core and copper losses are mainly
responsible for the heat generated within the transformer. The heat generated due to losses might course
damage to the insulation as a result decreases the life span of the transformer.
Thermal design of the three-phase transformer was completed using finite element methods magnetic
(FEMM) package software. It allowed us to analyse the heat distribution of the windings, the core and
surrounding areas of the transformer. Dimensions form the magnetic circuit which were previously
calculated were used in setting the dimensions on FEMM using heat flow problem. Heat flow problem
addressed by FEMM are essentially steady-state heat conduction problem, the represented by temperature
gradient(G) and heat flux density(F). Material as well as the boundary for the transformer were defined:
Boundary Condition- Convection boundary condition was used, meaning the boundary is cooled by fluid
flow. The heat transfer coefficient from the winding to the oil is 60 𝑊/(𝑚^2𝐾) and from the enclosure to
air is 12 𝑊/(𝑚^2𝐾). Convection boundary defined by the following equation.
𝑘𝑑𝑇
𝑑𝑛
+ ℎ(𝑇 − 𝑇𝑜) = 0 (14)

Materials- Figure 1 below shows material used.

Figure 1: Thermal design model

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Steel, 1% Carbon- Volumetric heat capacity of 3 was used. Steel, 1% Carbon has good thermal properties.
Oil - Used to fill the windows and boundary space of the transformer. Thermal conductivities, 𝐾𝑥= 𝐾𝑦 =
0.12 was used.
Windings (HV and LV)- Thermal conductivity kx and ky of 0.12 were used. Heat Volume generation was
calculated using the losses and block volume from the magnetic circuit.
Winding to oil–This boundary was used for the heat transfer coefficient from winding to oil. The boundary
was labelled Winding to oil and given the following properties:
BC Type: Convection
h (heat transfer) W/m2K = 60
T0 (ambient air temperature) = 293k

3.2 Results and comparison to theoretical design

Two result were obtained, transformer under heat generation and under cooling effect. Transformer under
cooling is when the transformer is inserted inside oil which has pump and heat convector to reduce heat
generated.

3.2.1 Result under heat generation

The following heat flow distribution diagram that was obtained. The visible intensities of colour per the
density plot the maximum value of the temperature was found to be 293.1K, this value was within the 65°C
(338.5K) threshold set in the design specification sheet.

Figure 2: Thermal field distribution obtained using FEMM

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 Figure 3: Graph of Temperature Vs Length across transformer

3.2.2 Result of transformer under cooling effect

The following heat flow distribution diagram was obtained. As you can see the heat generated by the
transformer has decreased, as the result this method can be used to reduce losses in the transformer.

Figure 4: Thermal distribution after cooling

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 Figure 5: Graph of Temperature Vs Length across transformer after cooling

3.3 Correlation to Other sub-project

The thermal circuit correlates with all designs as it relies on the heavily on the short circuit and magnetic
design to obtain it results and lends its results to that of the insulation. It much dependent on the magnetic
circuit for calculation of volume heat generation. This heat generation is in turn used to confirm the
loading of the transformer and identify the power that is lost.
The results of the short circuit played a minimal role, however the design of using an increased low
voltage winding height was valuable, as these improvements which were applied to the thermal, helped
decrease the heat lost in the windings and improve heat transfer.
However, the thermal design largely correlated with the design of insulation as it is known that heat
generated can affect the insulations and thermal deterioration occurs under the overload characteristics.
The sharp peaks of temperature on the windings are mainly responsible for this deterioration because of
the stress induced by the changes accompanied with these peak values.

3.4 Discussion and recommendations

The excessive heat generated by losses here are the main source of temperature rise in the transformer.
However, the core and copper losses seen from the structural parts are the main factors of heat generation
within the transformer. The thermal energy produced by the windings is transferred to the winding
insulation and consequently to the oil and transformer walls. Because of the increased temperature in the
windings it was necessary to increase the lengths of the low voltage windings. By doing this the
interacting forces, as discussed in the short circuit, were decreased and less heat was generated thus
reducing the overall temperature. Adding the boundary conditions called winding oil mentioned above to
walls of the windings, act as the method of cooling transformer, as a result reducing the core and copper
losses and increasing life span of the transformer.

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 3.5 Calculations
For low voltage windings, from the magnetic design total losses are 0.000150322W and the block volume
is 0.00325586𝑚3.Volume heat generation of low voltage windings is given by:

𝑇𝑜𝑡𝑎𝑙 𝑙𝑜𝑠𝑠𝑒𝑠
𝑉𝑜𝑙𝑢𝑚𝑒 ℎ𝑒𝑎𝑡 𝑔𝑒𝑛𝑒𝑟𝑎𝑡𝑖𝑜𝑛 =
𝐵𝑙𝑜𝑐𝑘 𝑣𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑙𝑣 𝑤𝑖𝑛𝑑𝑖𝑛𝑔𝑠
0.000150322 0.0462𝑊
= 0.00325586
= 𝑚3

For High voltage windings, total losses are 0.00872078 𝑊 and the block volume is 0.00555818𝑚3.
Volume heat generation of high voltage windings is given by:

𝑇𝑎𝑡𝑎𝑙 𝑙𝑜𝑠𝑠𝑒𝑠
𝑉𝑜𝑙𝑢𝑚𝑒 ℎ𝑒𝑎𝑡 𝑔𝑒𝑛𝑒𝑟𝑎𝑡𝑖𝑜𝑛 =
𝐵𝑙𝑜𝑐𝑘 𝑣𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 ℎ𝑣 𝑤𝑖𝑛𝑑𝑖𝑛𝑔𝑠

0.00872078 1.569𝑊
= =
0.00555818 𝑚3

3.6 Improvements
• In the core use laminated material to decrease Eddy current losses

• Use Soft material to reduce hysteresis losses

• Use a suitable material for cooling down the heat generated of a transformer

• Proper insulation is need also in the windings to prevent core losses which also contributes
to the overall heat generated in the transformer

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4 Insulation design (Simphiwe Dubazana)
The insulation design of a three-phase transformer consists of paper, pressboard and insulating oil.
Insulating oil is one of the most important components within a transformer that acts as both an electrical
insulator and coolant to dissipate heat losses. This oil is seen in 11KV or higher voltage transformer core is
placed. It is not required in low voltage transformers because the heat dissipation in such transformers is
very low. Insulating oil is obtained by fractional distillation and subsequent treatment of crude petroleum
[5]. The insulator design prevents the short circuiting which may occur between the High Voltage and Low
Voltage winding in the transformer. It also decreases the heat transfer between the layers of insulator is
increased to prevent those heat losses during the operation of the transformer. Insulating also have the
important role on protecting short circuiting design by counter acting the axial and radial forces that are
produced from the high current flowing on the windings. At higher voltage and power ratings, shell form
transformers tend to be more prevalent the insulator can be used to prevent these effect [6].

4.1 Design procedure

The insulation design was designed to prevent the failure of the transformer by reducing the losses in the
Thermal design and preventing the short circuiting in the transformer. The geometry that was taken in the
magnetic design. The size of the fine covering insulator of 5.21mm was placed between the High voltage
and the Low voltage winding. The winding has the different voltages which is high and low voltage, they
we defined under the conductor to assign different voltages.
In the insulation design different material or components of different permittivity were used to perform as
an insulation on the three-phase transformer design. The different permittivity of the material is shown in
the table.
Table 1: the permittivity of the material

materials Paper Pressboard Core Transformer HV and LV

oil windings
Relative 2.2 4.2 1 1 1
permittivity
(ε)

• A magnetic design geometry was exported and imported to the new file which under electrostatic
problem to deal with the effect of insulation.
• To complete the design geometry, a paper and the pressboard with an insulation thickness of
5.21mm was placed between the High voltage and Low voltage windings.
• Under the conductor the Low voltage and High voltage windings were defined with different
voltages.
• The conversion of the line voltage that was given in the design specification to phase voltage before
it was loaded in the transformer winding thickness which is defined under conductor. The
transformer design was a three-phase star-delta and the voltage phase change is 120 degrees apart
from each other.

13
 𝑉𝑙𝑖𝑛𝑒
𝑉𝑝ℎ𝑎𝑠𝑒 = 𝑓𝑜𝑟 𝑎 𝑠𝑡𝑎𝑟 𝑐𝑜𝑛𝑛𝑒𝑐𝑡𝑖𝑜𝑛 (15)
√3

𝑉𝑝ℎ𝑎𝑠𝑒 = 𝑉𝑙𝑖𝑛𝑒 𝑓𝑜𝑟 𝑎 𝑑𝑒𝑙𝑡𝑎 𝑐𝑜𝑛𝑛𝑒𝑐𝑡𝑖𝑜𝑛 (16)

The High voltage (line voltage) was given of the magnitude 11KV and the Low voltage (line voltage) of
the magnitude 400V and the phase voltages were calculated.

HV (high voltage)
LV (low voltage)
Phase 1
For HV 𝑉𝑝ℎ𝑎𝑠𝑒1 = 11000𝑉
400
For LV 𝑉𝑝ℎ𝑎𝑠𝑒1 = = 230.94𝑉
√3

Phase 2
For HV 𝑉𝑝ℎ𝑎𝑠𝑒2 = −5500 + 𝑖9526.28𝑉
For LV 𝑉𝑝ℎ𝑎𝑠𝑒2 = −115.47 + 𝑖200𝑉
Phase 3
For HV 𝑉𝑝ℎ𝑎𝑠𝑒3 = −5500 − 𝑖9526.28𝑉
For LV 𝑉𝑝ℎ𝑎𝑠𝑒3 = −115.49 − 𝑖200𝑉

• The nodes were defined in all the windings of the transformer and material of the transformer, so
the problem will be solved.
• The transformer oil was placed inside the window and outside the transformer core.
• The outer boundary was defined to solve the problem inside the boundary.
• The nodes for the paper and pressboard insulation was also placed.
• A mesh was generated to check if all the nodes were labelled and running using mirror to analyze
the circuit.
The circuit was simulated to obtain the result and check the difference in the intensity field if the paper was
placed between the High voltage and Low voltage windings and if the pressboard was placed. To meet the
electric field strength of 5.5KV/mm as it per design specifications.

4.2 Material description

The operation of the transformer increases the temperature in the transformer, the paper and the pressboard
are used to reduce and prevent the heat loses and the short circuiting in the transformer. The transformer
oil is used as a coolant and prevent dissipation of heat in the transformer. When the transformer is

14
being cooled using transformer oil there will always be a formation of moisture inside and it is
when the paper and the pressboard is needed to absorb that vapor and reduces failure.

4.3 Discussion of results

The following results will be based on the electric intensity. The graph of the paper and the pressboard will
be discussed here on the effect they cause in the transformer, that will influence the field intensity. The
insulation field should have a highest strength of 5.5KV/mm of the power frequency withstand voltage
between the windings. The is a relationship between the voltage and the distance defined by the formula.
The field intensity is directly proportional to the voltage and inversely proportional to the distance.
𝑉
𝐸𝑖 = 𝑑 (17)

V is the voltage
d is the distance between windings
The figure below that shows the field intensity field in the circuit

Figure 6: field intensity results

At first the circuit design was tested when the was no insulator between the windings to observe the changes
in the circuit if the paper or the pressboard has been used. This diagram shows the field intensity when the
is an insulator between the windings. The field intensity in the circuit when the was no insulator was
1.35e+005 V/mm. This value was obtained using a FEM and reading the results in the box with different
intensities. The field intensity is concentrated near the poles of the high voltage and low voltage winding
indicated with a green color in the diagram.
There are also graphs that shows the field intensity in the circuit under different conditions of insulation

15
 Figure 7: the graph of the paper as an insulator

Figure 8: the graph of the pressboard as an insulator

The is a noticeable difference between the two graphs. In the first graph the is the slightly decrease in the
field intensity of 2e V/mm because the paper was used as an insulator. In the second graph the pressboard

16
was used as an insulator, the is a noticeable decrease in the field intensity compared to that of the paper.
The pressboard is the most suitable insulator for a transformer to function well as seen on the two graphs.
Although the paper is not expensive as the pressboard, but the pressboard is expensive due to its properties
which are better than for a paper.

4.4 Improvements

Insulation design can be improved by increasing the layers of the insulator in the transformer. This will
help to reduce the heat loss in the Thermal design and prevent furthermore in the short circuit design.
Although oil is important in the transformer, but it help to realize the heats faster in the transformer, so the
will be no pressure of heat in the transformer. This will decrease the field intensity to became smaller
because there will be an increase in the permittivity of the material.

5 Short circuit Design (Nkosinathi Majozi)

Three dimensional finite element methods are to find and compering short circuit forces in the
transformer. Short circuit consist of two components radial components and axial components.
The distance of phase winding from one another were investigated parameters, of the company of
other phase windings of transformer, and it core configuration.
Short circuit test was done to generate the radial and axial force of the transformer. Designers need
to be very careful when they chose properties of the transformer because of the short circuit
strength and the transformer can resist both thermal and mechanical effect of the short circuit.

5.1 Design procedure

In this section, the co-ordinates and dimensions used are the same as that of the magnetization part
so. Changes made was lowering the height of low voltage winding to equal the height of the high
voltage winding.
This is done because the change in displacement of the winding affect the field. The inner winding
will experience both pulling up and down force.
This short circuit test was performed in an 11KVA 11000/400 V distribution transformer using
FEMM, a magnetizing current (Im=0.0455A) was obtained in the magnetizing design. The
magnetizing calculates the current of the winding in the first limb of the primary side (HV0). The
current of the windings in the primary side (HV) and secondary side (LV) were calculated in the
following procedure using theoretical values of the current in the primary side and secondary side,
from the transformer design calculations.

17
 5.1.1 Currents in the primary limbs.
Theoretical calculated primary current is 𝐼𝑝𝑟𝑖𝑚𝑎𝑟𝑦 = 0.91 𝐴

𝐶𝑖𝑟𝑐𝑢𝑖𝑡1 = 𝐼𝑝𝑟𝑖𝑚𝑎𝑟𝑦 × 5𝑝𝑢 + 𝐼𝑚 = 0.785 × 5𝑝𝑢 + 0.03 = 4.5955 𝐴

𝐶𝑖𝑟𝑐𝑢𝑖𝑡2 = 𝐼𝑝𝑟𝑎𝑚𝑖𝑟𝑦 × 5𝑝𝑢 + 𝐼𝑚 ∠Ɵ = 4.5955∠120° = −2.29775 + 𝐼 ∗ 3.979819743 (𝐴)

𝐶𝑖𝑟𝑐𝑢𝑖𝑡2 = 𝐼𝑝𝑟𝑎𝑚𝑖𝑟𝑦 × 5𝑝𝑢 + 𝐼𝑚 ∠ − Ɵ = 4.5955∠ − 120° = −2.298 − 𝐼 ∗ 3.979819743 (𝐴)

5.1.2 Currents in the secondary limbs.

Theoretical calculated secondary current is 𝐼𝑠𝑒𝑐𝑜𝑛𝑑𝑎𝑟𝑦 = 43.43 𝐴

𝐿𝑉1 = 𝐼𝑠𝑒𝑐𝑜𝑛𝑑𝑎𝑟𝑦 × 5𝑝𝑢 = −(43.43 × 5𝑝𝑢) = −216.71 𝐴

𝐿𝑉2 − (𝐼𝑠𝑒𝑐𝑜𝑛𝑑𝑎𝑟𝑦 × 5𝑝𝑢∠120° ) = −(216.71∠120° ) = 108.36 − 𝐼 ∗ 187.68(𝐴)

𝐿𝑉3 = −(𝐼𝑠𝑒𝑐𝑜𝑛𝑑𝑎𝑟𝑦 × 5𝑝𝑢∠ − 120° ) = −(216.71∠ − 120° )𝐴 = 108.36 + 𝐼 ∗ 187.68(𝐴)

The current in primary side is left positive and current in the secondary side is multiplied by a
negative sign because HV currents and LV currents must propagate in the same direction. After
calculating the currents, they were then inserted in the primary and secondary limbs using FEMM.
The reason of doing these calculations is to make a short circuit which results in creating a
mechanical stress.
5.2 RESULTS

Figure 9: FEMM Short circuit design

18
in this paper electromagnetic force density is calculate based on the Lorentz force
𝑁 𝐹𝑟𝑎𝑑𝑖𝑎𝑙 = 𝐽 × 𝐵𝑎𝑥𝑖𝑎𝑙
𝐹 = 𝐽 × 𝐵 (𝑚3 ) ⇒ { (𝑁) (18)
𝐹𝑎𝑥𝑖𝑎𝑙 = 𝐽 × 𝐵𝑟𝑎𝑑𝑖𝑎𝑙
The theoretical radial forces and axial forces. Full calculations on appendix A
𝝁𝑵𝑰𝟐
𝑭𝒓 = × 𝝅𝑫𝒎 (𝑵) = 0.195N
𝑯𝒘

𝑭𝒂 (𝒙) = 𝑩𝒓 × 𝑰𝒙 = 𝟎. 𝟎𝟖𝟓 𝑵
The graph of the flux density and the graph of the force is the same this is because force is directly
proportional to the flux density and also directly proportional to the current squared, Flemings left
hand rule is used to determine the direction of the force.

5.2.1 Forces

Short circuit events generate high current conditions in transformer windings. These currents in turn
induce excessive forces in a transformer. Electromagnetic forces are important considerations in the
design, manufacturing and operation of transformers. These forces can be subdivided into axial and radial
forces each with unique considerations and mitigating measures.

The generation of an electromagnetic field inside the transformer is therefore intrinsic to transformer
operation. This electromagnetic field will however lead to the generation of forces inside the transformer
windings stipulated by the laws of magnetism, Faradays law of induction and Lenz's law of
electromagnetic force

5.2.2 Radial force

The flux at mid winding height is for the most part parallel to the winding height. According to the left
hand rule, the resulting force therefore acts perpendicular to the winding height. For windings on the
inside of the main flux field (situated between primary and secondary windings) the force acts inward,
and for outside windings, outward. Forces acting on the inside windings result in a compressive stress
whereas on the outer winding this force leads to a tensil

19
 Figure 10: Flemings Left hand rule

Figure 11: Graph of Bt which shows the components of the flux density

5.2.3 AXIAL FORCE

Axial forces are generated parallel with the winding height. Due to the pattern of the magnetic leakage
field, the windings experience opposing forces at the winding ends, leading to compressive forces. Axial
force is generated when the transformer's magnetic field lines are radially orientated. The local force
generation accumulates toward the middle of the windings resulting in a maximum occurring force at

20
mid-winding height. This force is compressive towards the winding center as the circulation direction of
the magnetic field leads to opposing forces at each end of the winding.

Winding displacement from the center line result in excessive axial forces. This is due to the difference in
the ampere-turns (i.e. mmf) distribution along the winding heights resulting in more pronounced bending
of the field lines at the point of missing ampere-turns or where the displacement occurs.

Figure 12: Graph of Bn which shows the components of the flux density

5.3 Discussion and improvements

Short circuit currents in the transformer induces mechanical forces in the transformer windings, the
electromagnetic force is induced in the transformer windings which is due to the interaction of the magnetic
field of the transformer and the current density in the transformers windings. If the withstand capability of
a transformer is exceeded, the transformer could result in radial and axial modes of failure thus when
designing a transformer, it is highly important to reduce the magnitude of these forces by manipulating the
magnetic field in the core and by changing the transformers design geometry.

21
6 Conclusion
The implementation of transformer design was done successfully using FEMM software tool, the analysis
of the result played a vital role in understanding the operation of a real transformer which is also governed
by the electromagnetic induction effect observed that when designing a transformer several factors are taken
into account such as the geometry, winding size, insulation material used, depth of core, insulation material
size, thermal stress, mechanical stresses etc.
All these aspects of a transformer mentioned above were critical in considering when designing a
transformer and these measurements are all driven by theoretical design calculations, however the results
obtained in our theoretical calculations are not exactly the same as the one analyzed using FEMM due to
many assumptions done during our calculations and the fact that practical measurements will always have
some slight different to some extent when compared to theoretical measurements and FEMM software is
consider to be one of the best tool in simulating real life electrical or mechanical devices.

22
References

1.Mack, J. E., 2006. Distribution Transformer. In: T. Shoemaker, ed. Lineman's and Cableman's
Handbook. New York: McGraw-Hill, pp. 15-22.

2.Meeker, D., 2015. infor Archives. [Online]

Available at: http://www.femm.info/Archives/doc/manual42.pdf
[Accessed 11 May 2019].

3.Parma, J., 2011. Electrical Engineering Portal. [Online]

Available at: https://electrical-engineering-portal.com/difference-between-power-transformer-and-
distribution-transformer
[Accessed 11 May 2019].

4.Carrander, C., 2017. Magnetizing Currents in Power Transformers – Measurements, Simulations,and

Diagnostic Methods, Sweden: Stockholm.

5.H.J.Macbride, 2005. Transformers,Basics, Maintenance and Diagnostics, New York: U.S. Department of
the Interior.

6.John W, K. G., 2012. Hydroelectric Reserch and Technical Services. Interior, Bureau of Reclamation,
II(10), p. 12.

23
Appendix A

A.1 Process of group work and version control

The following schematics depicts steps following during the entire design

Identify Problem Analyze the problem

Make individual
Deliver work on time contribution to the group

Generate
solution
Execute optimal solution

Enhance work of group members

Benefit from their support
Appendix B

Effective
communication
between group
members

24
Meeting 1

Date: 08/03/19
Time: 19:30 -23:00
Place: Main Library

Matters Discussed: The agenda for this meeting is as follows:

• Review on what are transformers

• Task allocated for each member in the design calculation

A summary of meeting highlights is below:

• Review on what are transformers and discussed about the basic principles governing it.
• Each member was allocated a section in the design calculation
• Lungelo & Nkosinathi were allocated to do the core design section
• Ayanda & Simphiwe were allocated to do the winding and insulation design section.

Attendee Sheet

By signing this attendee sheet, you affirm that you have participated in the stated meeting and received and
reviewed the materials presented to you. Meeting minutes will be captured, acted upon and then reviewed
as part of the next review meeting.

Group Members

Print Name Signature

Simphiwe Dubazana
Ayanda Sibiya
Nkosinathi Majozi
Lungelo Zindela

25
Meeting 2

Date: 29/03/19
Time: 19:30-23:30
Place: Main Library

Matters Discussed: The agenda for this meeting is as follows:

• Review on our last meeting

• Discussion of complete design calculation
• Next step taken for our design

A summary of meeting highlights is below:

• Combined our calculations core, winding and insulation design

• Made adjustments and improvements on our calculations
• Divided subsections to be done by each member in the FEMM design.

Attendee Sheet

By signing this attendee sheet, you affirm that you have participated in the stated meeting and received and
reviewed the materials presented to you. Meeting minutes will be captured, acted upon and then reviewed
as part of the next review meeting.

Group Members

Print Name Signature

NKosinathi Majozi
Lungelo Zindela
Ayanda Sibiya
Simphiwe Dubazana

26
Meeting 3

Date: 06/05/18
Time: 08:30 – 12:30
Place: Main Library

Matters Discussed: The agenda for this meeting is as follows:

• Address problems encountered in in FEMM design section

• Prepare for interim presentation for firm design section

A summary of meeting highlights is below:

• Review on our last meeting discussion

• Address individual problems encounter in FEMM
• Prepare for interim presentation on FEMM design

Attendee Sheet

By signing this attendee sheet, you affirm that you have participated in the stated meeting and received and
reviewed the materials presented to you. Meeting minutes will be captured, acted upon and then reviewed
as part of the next review meeting.

Group Members

Print Name Signature

Lungelo zindela
Simphiwe Dubazana
Ayanda Sibiya
Nkosinathi Majozi

27
Meeting 4(final)

Date: 04/05/19
Time: 08:30 – 13:00
Place: Main Library

Matters Discussed: The agenda for this meeting is as follows:

• Review on our last meeting and discuss on improvements based on the presentation
• Finalize our FEMM design for final presentation
• Allocate task to be done on the next presentation

A summary of meeting highlights is below:

• Review on our last meeting discussion

• Discuss improvements based on our presentation and present our final design to group members
• Allocate task to be done on report writing.

Attendee Sheet

By signing this attendee sheet, you affirm that you have participated in the stated meeting and received and
reviewed the materials presented to you. Meeting minutes will be captured, acted upon and then reviewed
as part of the next review meeting.

Group Members

Print Name Signature

Lungelo zindela
Simphiwe Dubazana
Nkozinathi Majozi
Ayanda Sibiya

28