Design of Transformer

Details of Transformer

Types of Transformers

Comparison between core & shell type Transformers

Principle of Transformers

Phasor diagram of Transformers

Design of Transformers
Details of Transformer
Classification of Transformer
Single phase core type Transformer
Single phase shell type Transformer
Core Type 1 phase Transformer Cruciform section
Types of Core
Schematic diagram of Transformer
Principle of Transformer
Transformer on No load
Transformer on load
 Specification of transformer

Input design data:

• Rated output (KVA or MVA);

• Voltage ratio (Primary volts/secondary volts on no load);
• number of phases (1-phase or 3-phase);
• frequency;
• type of transformer (core or shell);
• class (power or distribution);
• connections of LV and HV windings:
• percentage tappings
• type of cooling:
• maximum temperature rise.
 Standard Ratings of transformer

Transformers of small, medium and large sizes are normally built as per
the standard ratings.

Standard KVA Ratings

 Magnetic circuit of Transformer

Transformer has magnetic circuit in following parts:

Yoke
• Core
• Yoke
• Window

Core

Magnetic circuit of 1-phase Transformer

 DESIGN EQUATIONS

For magnetic circuit following equations are needed.

1. e.m.f. equation.

2. [Link]. per turn in terms of output

3. output equation

3-phase core type transformer

 E.M.F. EQUATION
The flux, established in the core is alternating in nature.
Hence an e.m.f. is induced in the primary winding due to the change of main flux,
which is given by,
𝑑𝜙
𝑒1 = −𝑇1
𝑑𝑡
Since
𝜙 = 𝜙𝑚 co s 𝜔 𝑡
𝑑
𝑒1 = −𝑇1 𝜙 co s 𝜔 𝑡 = 𝑇1 𝜔𝜙𝑚 si n 𝜔 𝑡
𝑑𝑡 𝑚
Hence,
𝐸1max = 𝑇1 𝜔𝜙𝑚

𝑇1 (2𝜋𝑓)𝜙𝑚
or, rms. value of induced emf , 𝐸1 =
2

𝐸1 = 4.44𝑓𝑇1 𝜙𝑚 volts
𝐸1 = 4.44𝑓𝑇1 𝐵𝑚 𝐴𝑖 volts
Similarly, induced emf. in secondary winding, 𝐸2 = 4.44𝑓𝑇2 𝐵𝑚 𝐴𝑖 Volts
 Hence, emf per turn,
𝐸𝑡 = 4.44𝑓𝐵𝑚 𝐴𝑖

𝑇1 -Number of turns in the primary winding.

𝑇2 -Number of turns in the secondary winding
𝜙𝑚 -Maximum value of main flux, weber
𝐵𝑚 -Maximum value of flux density in the core, Tesla
𝑓-Frequency of supply, Hz
𝐴𝑖 -Net cross-sectional area of the core, 𝑚2

the cross-sectional area of the core can be determined, provide the e.m.f. per turn is known.
 E.M.F. PER TURN

e.m.f. per turn, 𝐸𝑡 = 4.44𝑓𝜙𝑚

KVA rating /phase = 𝑉 × 𝐼 × 10−3
= 𝑉 Τ𝑇 × 𝐼𝑇 × 10−3
= 𝐸𝑡 × 𝐼𝑇 × 10−3

Cross sectional area of core, 𝐴𝑖 = 𝜙𝑚 /𝐵𝑚 𝐼

Since 𝛿 =
𝑎
I
Copper area of the windings, 𝐴𝑐 = 𝑎𝑇 = 𝛿 × 𝑇

𝜙𝑚 𝛿
𝐴𝑖 /𝐴𝑐 = × = constant
𝐼𝑇 𝐵𝑚
The ratio of cross-sectional area of the core and the copper area of the windings will be constant for a
particular transformer i.e.
𝐴𝑖 /𝐴𝑐 = constant
As current density, 𝛿 and flux density, 𝐵𝑚 is nearly constant
𝜙𝑚
= 𝑟 = Constant
𝐼𝑇
Contd..

substituting for IT
𝜙𝑚
KVA/phase = 𝐸𝑡 × × 10−3
𝑟

( KVA/phase ) × 𝑟
𝜙𝑚 = × 103
𝐸𝑡

(KVA/ phase )×𝑟

Substituting for 𝜙𝑚 𝐸𝑡 = 4.44𝑓 × × 103
𝐸𝑡

𝐸𝑡2 = 4.44𝑓𝑟 × 103 × 𝐾𝑉𝐴ൗ𝑝ℎ𝑎𝑠𝑒

𝐸𝑡 = 𝐾 (KVA/ phase )

K = 4.44𝑓𝑟 × 103
 Factor K
cross sectional area of core
Factor, 𝐾 = = 𝐴𝑖 /𝐴𝑐
copper section of the windings

For the identical transformers,

• The factor, K will be higher for shell type compared to core type of transformers.

• The factor, K will be higher for single phase core type transformers compared to
3-phase core type transformers.

• K will be lesser for distribution transformer compared to power transformers.

Value of factor, K
 OUTPUT EQUATION
Cross sectional area of the core can be calculated based on the given specification by using
the equation for emf per turn.

output equation is used to find out the dimensions of the window

Output of single-phase transformer,

𝑄 = 𝑉2 𝐼2 = 𝑉1 𝐼1
𝑄 = 4.44𝑓𝐵𝑚 𝐴𝑖 𝑇1 × 𝐼1

window space available in the magnetic frame is occupied by both the windings on the core
and insulation
Thus, total copper area in the window

𝐴𝑐𝑢 = 𝑎1 𝑇1 + 𝑎2 𝑇2
= 𝐾𝑤 𝐴𝑤

Total copper area in the window 𝐴𝑐𝑢

𝐾𝑤 = = 𝐾𝑤 -window space factor i.e. 𝑎1 𝑇1 + 𝑎2 𝑇2 /𝐴𝑤
Total window area 𝐴𝑤
 𝐾𝑤 𝐴𝑤 = 𝑎1 𝑇1 + 𝑎2 𝑇2
𝐼1 𝐼2
𝐾𝑤 𝐴𝑤 = 𝑇1 + 𝑇2 (As 𝐼1 𝑇1 = 𝐼2 𝑇2 ; 𝛿1 ≈ 𝛿2 = 𝛿 for a transformer)
𝛿1 𝛿2
= 2𝐼1 𝑇1 Τ𝛿
1
= 𝑚𝑚𝑓 𝑜𝑓 𝐻𝑉 𝑤𝑖𝑛𝑑𝑖𝑛𝑔 + 𝑚𝑚𝑓 𝑜𝑓 𝐿𝑉 𝑤𝑖𝑛𝑑𝑖𝑛𝑔
𝛿
1 2
= 𝐴𝑇 + 𝐴𝑇 = 𝐴𝑇
𝛿 𝛿
After substituting for, 𝐼1 𝑇1 , we get
Output of 1-phase transformer,
𝐾𝑤 𝐴𝑤 × 𝛿
= 𝐼1 𝑇1
2

𝐼1 , 𝐼2 - currents in primary and secondary winding respectively

𝑎1 , 𝑎2 - cross section of conductor for primary and secondary winding
𝛿1 , 𝛿2 - current density in primary and secondary winding
𝛿 -average value of current density, 𝐴/m2
( 𝛿1 and 𝛿2 will differ slightly, because of difference in the cooling conditions of the windings)
𝐴𝑤 - window area, 𝑚2
Contd..

Output of 3 phase transformer,

𝑄 = 3𝑉1 𝐼1
= 3 × 4.44𝑓𝐵𝑚 𝐴𝑖 𝑇1 × 𝐼1

Here, each window space is occupied by both the windings of two phases i.e.

𝐴𝑤 𝐾𝑤 = 2 𝑎1 𝑇1 + 𝑎2 𝑇2 = 4𝐼1 𝑇1 Τ𝛿

substituting for I1 T1

Output of 3-phase transformer,

𝑄 = 3.33𝑓𝐵𝑚 𝛿𝐾𝑤 𝐴𝑤 𝐴𝑖 , Volt Amp.
= 3.33𝑓𝐵𝑚 𝛿𝑘𝑤 𝐴𝑤 𝐴𝑖 × 10−3 KVA
3-phase core type
transformer
The above equations will hold good for both types of transformers i.e. core and shell.
 CHOICE OF DESIGN PARAMETERS

1. Window space factor

It is the ratio of total area occupied by copper material of the windings in the
window to the window area i.e.
Total copper area in the window 𝐴𝑐𝑢
𝒌𝒘 =
window area
=
𝐴𝑤

Its value depends upon the following:

• Voltage rating of the windings, mainly the highest voltage:

The window space factor decreases as the voltage of the HV winding
increases for same KVA rating.
• KVA rating of the transformer.
An increased value of the window space factor has to be taken as the rating of
the transformer increases for same voltage of HV winding.
Contd..

The approximate values of the window space factor can also be calculated by empirical
formula based upon the voltage of HV winding in KV,
Range of Window space factor
 Specific magnetic loading, Bm

Choice of flux density in the core basically depends upon the steel grades used for

• Core
• Yoke
As a guide line, the values of flux density considering the economics and
performance are given below:

Using hot rolled silicon steel

Power transformers = 1.2 to 1.4 Tesla

Distribution transformers = 1.1 to 1.3 Tesla

Using cold rolled grain-oriented silicon steel

Power transformers = 1.5 to 1.7 Tesla

Distribution transformers = 1.4 to 1.5 Tesla

Lower values should be used for small rating transformers

 Current density

As guide line, following values may be used for the average current density.
(average of LV and HV winding current density)

Distribution transformers = 2.0 to 2.5 𝐴/𝑚𝑚2

Power transformers = 2.3 to 3.5 𝐴/𝑚𝑚2

Large transformers with forced circulation of oil = 3.0 to 4.5 𝐴/𝑚𝑚2

 MAIN DIMENSIONS OF MAGNETIC CIRCUIT

ℎ𝑤 =
𝑏𝑤 =

ℎ𝑦 =
𝑏𝑦 =Width of the yoke,
 MAIN DIMENSIONS OF MAGNETIC CIRCUIT

(1) Main dimension for core

i) Diameter of the circumscribed circle, d round the stepped core.

ii) Length of the core, L, which is equal to the height of the window.

iii) Centre to center distance, D between the cores

Choice of number of steps in the core

Gross core section

<𝟑 3-5 5-7 7-15 15-45 45-80 80-200
𝒎 𝟐 ; × 𝟏𝟎−𝟑
No. of steps 1 2 3 4 5 6 7
Steps for calculating the diameter of the circumscribed phaseover
(KV/circle ) × the
𝑟 stepped
3 core d:
𝐸𝑡 = 4.44𝑓 × × 10
𝐸𝑡
𝐸𝑡2 = (4.44𝑓𝑟 × 103 ) × KVA2 phase
A. Calculate e.m.f. per turn i.e. 𝐸𝑡 = 𝐾 (KVA/ phase )
𝐾= 4.44𝑓𝑟 × 103

Value of factor, K
B. Net cross-sectional area of the core 𝑨𝒊

can be calculated by using the emf per turn

𝐸𝑡 = 4.44𝑓𝐵𝑚 𝐴𝑖

C. Diameter of the circumscribed circle round the stepped core

can be calculated by
𝐴𝑖 = 𝑘 × 𝑑 2

Value of factor, k

Quantity Square Cruciform Three stepped Four stepped

Factor 𝑘 0.45 0.56 0.6 0.62
𝐴𝑖 = 𝑘 × 𝑑 2
 Shell type transformer

• Normally cores of shell type transformer is rectangular in shape.

• A narrow, long core gives better cooling for the iron portion.

• Normally a ratio between 2 to 3 : 1 is suitable for the proportion of the core

i.e.

length of the core is 2 to 3 times the width of the core.

 2. Main dimensions of window
Main dimension of the window consists of the height and the width of the window.

A). Window area

By using the output equations

(for single phase)

𝑄 = 3.33𝑓𝐵𝑚 𝛿𝐾𝑤 𝐴𝑤 𝐴𝑖 , Volt Amp. (for 3 phase)

= 3.33𝑓𝐵𝑚 𝛿𝑘𝑤 𝐴𝑤 𝐴𝑖 × 10−3 KVA
 Window space factor

Average current density (average of 1.v. and HV winding current density)

Distribution transformers = 2.00 to 2.5 𝐴/𝑚𝑚2

Power transformers = 2.3 to 3.5 𝐴/𝑚𝑚2

Large transformers with forced circulation of oil = 3 to 4.5 𝐴/𝑚𝑚2

 B). width of the window

𝑏𝑤 = 𝐷 − 0.9𝑑 for 3 stepped core

For design purposes, width of the window can be

approximately taken as
𝑏𝑤 = 𝐷 − 𝑑 for various stepped core.

Area of the window,

𝐴𝑤 = 𝐿 𝐷 − 𝑑
3-phase core type transformer
C). height of the window

Range of height of the window ℎ𝑤 = from 2.5 to 4.0 times 𝑏𝑤

𝐿
i.e. = 2.5 to 4.0
𝐷 −𝑑

It gives the following advantages:

• Proper accommodation of the windings.

• Increased heat dissipation.

• Reduced leakage reactance.

So, Centre to centre distance between the cores,

D = 𝑏𝑤 +𝑑
 3. Main Dimensions of Yoke

Main dimensions of the yoke consists of:

I. Over all length W,

II. Width of the yoke, 𝑏𝑦
III. Height of the yoke, ℎ𝑦
(I) Overall length of the yoke,

W = 2D + 0.9 d (for 3-φ, 3 stepped)

= D+ 0.9 d (for 1- φ, 3 steeped)

(II) Sectional area of the yoke,

sectional area of yoke, 𝐴𝑦 = (1.1 𝑡𝑜 1.15) 𝐴𝑖

(III) Width of the yoke, 𝑏𝑦

= 0.9 d (for 3 stepped core)

= 0.85 d (for cruciform section)
= 0.71 d (for square section)

(IV) Height of the yoke

𝐴𝑦
ℎ𝑦 =
𝑏𝑦

𝐴𝑦 = sectional area of yoke

𝑏𝑦 = Width of the yoke
 General procedure for Main
(KV/dimensions
phase ) × 𝑟
𝐸𝑡 = 4.44𝑓 × × 103
𝐸𝑡
Procedure for calculating the main dimensions is 2given below:
𝐸𝑡 = (4.44𝑓𝑟 × 103 ) × KVA2 phase
1. The emf per turn, 𝐸𝑡 is calculated 𝐸𝑡 = 𝐾 (KVA/ phase )
𝐾= 4.44𝑓𝑟 × 103

2. Net cross-sectional area of the core, 𝐴𝑖 is determined 𝐸𝑡 = 4.44𝑓𝐵𝑚 𝐴𝑖

3. The diameter of the circumscribed circle, d over the stepped core is calculated i.e.
𝐴𝑖 = 𝑘 × 𝑑 2

4. Window area is determined, using the output equation

(for single phase)

𝑄 = 3.33𝑓𝐵𝑚 𝛿𝐾𝑤 𝐴𝑤 𝐴𝑖 , Volt Amp.

(for 3 phase)
= 3.33𝑓𝐵𝑚 𝛿𝑘𝑤 𝐴𝑤 𝐴𝑖 × 10−3 KVA
5. Window area Aw = L D − d

𝐿
6. = 2.5 to 4.0 (assume suitable ratio)
𝐷 −𝑑

7. Height and width of the window is then calculated

8. Overall length of the yoke is found out.

9. Sectional area of yoke 𝐴𝑦 , is determined i.e.

𝐴𝑦 = (1.1 𝑡𝑜 1.15) 𝐴𝑖
[Link] of the yoke, 𝑏𝑦 is calculated. = 0.9 d (for 3 stepped core)
= 0.85 d (for cruciform section)
= 0.71 d (for square section)
11. Height of the yoke, ℎ𝑦 is found out
𝐴𝑦
i.e. ℎ𝑦 =
𝑏𝑦
Q. Determine the main dimensions of the core and window for a 1250 KVA, 33/6.6
KV, 50 Hz, 3 phase, core type, power transformer, based on the following
information of design parameters.

Maximum flux density in the core, Bm = 1.5 Tesla

Average current density, δ = 2.5 𝐴/𝑚𝑚2
window space factor, kw = 0.21
Net area of 3 stepped core, 𝐴𝑖 = 0.6 d2
window proportions =3:1
full load magnetic loading to m.m.f. ratio 1.687 x 10-6
 Position of LV & HV windings

The LV winding is placed nearer the core, whereas HV winding over the LV winding

Arrangements of windings
Windings are normally arranged, in two ways:

• Concentric winding:
Concentrically in relation to one another (used for core type)
• Interleaved or sandwich winding
In groups of LV & HV coils stacked alternately one over the other,
along the height of the limb (used for shell type)

Types of windings

• Cylindrical winding with rectangular conductor

• Cylindrical winding with circular conductor
• Cross over winding
• Continuous disc coil type winding
• Disc type section winding
• Helical winding
• Sandwich winding (for shell type transformers)
 Input data for winding design

• KVA rating of the transformer

• Voltage rating
• The e.m.f. per turn
• Connection of the winding (star or delta)
• Main dimensions of core and window
• Standard sizes of circular and rectangular conductors
• Details regarding choice of current density
Range of different types of windings
Choice of windings based on the voltage rating of transformer
Design of Low Voltage winding

(1) Number of turns per phase

(2) Cross section of conductor

(3) Dimensions of conductor

(4) Arrangements of LV turns

(5) Mean length of turn

(6) Resistance of LV winding

Single layer with two strands in parallel Stacked/ sandwich type
(1) Number of turns per phase

The number of turns per phase is calculated based on its per phase voltage
rating and the e.m.f. per turn.
𝑉2
Turns per phase, 𝑇2 =
𝐸𝑡

𝑇2 -Number of turns in LV winding per phase

𝑉2 -Voltage rating of LV winding per phase.
(2) Cross section of conductor
𝐼2 𝐾𝑉𝐴 × 103
𝑎2 = 𝐼2 = For 1-φ transformer
𝛿2 𝑉2
𝐼2 =current rating of LV winding
𝛿2 = current density in LV winding
𝐾𝑉𝐴 × 103
𝐼2 = For 3-φ transformer
3𝑉2𝑝ℎ

As a guide line,

Distribution transformers = 1.8 to 2.3 𝐴/𝑚𝑚2

Power transformers =2.1 to 3.3 𝐴/𝑚𝑚2

 (3) Dimensions of conductor

• The dimension of the rectangular conductor in a direction perpendicular to the leakage flux
lines should not exceed 3.5 mm.

• Winding height can be approximately taken 80 % of the window height, leaving

20% for insulation axially.
Radial & axial dimensions of LV windings
• The axial space available for both the windings depends upon the height of the window.

• Radially LV and HV windings on the two adjacent

limbs are to be accommodated in the width of the
window

• Radial space is also occupied by the insulating

materials and oil ducts provided at various places
other than copper.
 (4) Arrangements of LV turns
• Normally LV turns are arranged radially in two layers in case of cylindrical
winding with rectangular conductor. This fixes the number of turns to be
accommodated axially.

• For proper insulation and cooling, there must be a clearance of 1 to 1.5 cm in the
window between the HV windings on the two adjacent limbs.
(5) Mean length of turn

Mean diameter of LV, winding,

𝐷𝑖2 + 𝐷𝑜2
𝐷𝑚2 =
2

So, mean length of LV turn,

𝑙𝑚𝑡2 = 𝜋𝐷𝑚2

(6) Resistance of 𝑳𝐕 winding

Hot resistance per phase of LVwinding,

𝜌 𝑙𝑚𝑡2 𝑇2
𝑟2 =
𝑎2

Where, 𝜌-specific resistance, value at 750 C being 0.02Ω. mm2 /m

3 phase, 300 KVA, 11000 / 400V, 50 Hz, delta / star, core type transformer;
with e.m.f. per turn, 6.0 V; diameter of circumscribing circle round the core,
19 cm; height of window, 54 cm; width of the window, 18.5 cm, Design LV
winding. Assume suitable data required if any.
Recommended
Sizes of
rectangular
copper
conductor
Design of High Voltage winding

(1) Number of turns per phase

(2) Cross section of conductor

(3) Dimensions of conductor

(4) Arrangements of HV turns

(5) Mean length of turn

(6) Resistance of HV winding

 (1) Number of turns per phase

𝑉1
𝑇1 = 𝑇2 ×
𝑉2

𝑉1 =Voltage rating per phase of HV winding

𝑉2 = Voltage rating per phase of LV winding
𝑇2 = number of turns per phase finally selected in the LV winding

• These turns will be split up into a number of coils in order to create oil ducts between
them for better cooling of winding

• For small and medium size transformer, maximum number of turns may
be taken upto 100.
(2) Cross-sectional area of conductor

Cross section of HV winding, 𝑎1 = 𝐼1 Τ𝛿1

Range of current density

Distribution transformers 2.0 to 2.5 𝐴/𝑚𝑚2

Power transformers 2.3 to 3.5 𝐴/𝑚𝑚2
(3) Choice of conductor

• Cross over type, cylindrical type with circular conductor and

continuous disc type are generally used for HV winding.
(4) Dimensions of conductor

(i) Circular conductor

• Diameter of the conductor can be found out from the cross-sectional

area, 𝑎1 as per the table.

• Insulated diameter with proper insulation can also be found out from the
same table.
(4) Dimensions of conductor
(ii) Rectangular Conductor

• The winding height = space occupied by coils + certain percentage space for the
end insulation + insulating spacers between the coils +metal ring at the top of the
winding+ slackness.

• End insulation can be found as per the voltage rating of HV winding and KVA
rating of the transformer.
Contd..

Insulation thickness & oil ducts

Contd..

• Thickness for the space in between the coils may be taken 4 to 8 mm depending
upon the rating of the transformer.

• Thickness of the metal ring provided at the top of the winding for uniform pressure
may be taken from 2.0 to 3 cm.

The winding height may be assumed approximately 70 percent of the window height i.e.

winding height, ℎ𝑤 = 0.7 𝐿

ℎ𝑤
Axial length available for one coil =
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑐𝑜𝑖𝑙𝑠
Recommended
Sizes of
rectangular
copper
conductor
(5) Arrangement of turns

(i) Number of turns for +5% tapping

𝑉1
= 𝑇2 ×
1.05 × 𝑉2
(ii) Number of turns for +212 % tapping

𝑉1
= 𝑇2 ×
1.025 × 𝑉2

(iii) Number of turns for −212 % tapping

𝑉1
= 𝑇2 ×
0.975 × 𝑉2

(iv) Number of turns for - 5% tapping

𝑉1
= 𝑇2 ×
0.95 × 𝑉2
Performance characteristics of the designed transformer

Performance regarding magnetic frame

Performance regarding windings

Performance regarding the magnetic frame and windings

Transformer on No load
 No load current

No load current = Magnetizing current +active component of no-load current

Calculation of magnetization current from design data,

Two methods are used:

• Based upon the Ampere turns

• Based upon the Magnetizing Volt-ampere

(i) Based upon the Ampere turns

Magnetization Curve
 Total ampere turns for the magnetic circuit,
𝐴𝑇 = 𝐴𝑇𝑐 + 𝐴𝑇𝑦

The RMS value of magnetizing current per phase in terms of HV

Total ampere turns per phase

𝐼𝑚 =
2 × Number of turns in HV winding
(ii) Based upon the Magnetizing Volt-ampere

Magnetizing Volt-ampere Curve

The RMS value of active component of no-load current, 𝐼𝑤 in terms of HV

𝑇𝑜𝑡𝑎𝑙 𝑖𝑟𝑜𝑛 𝑙𝑜𝑠𝑠𝑒𝑠 𝑝𝑒𝑟 𝑝ℎ𝑎𝑠𝑒

𝐼𝑤 =
𝑃ℎ𝑎𝑠𝑒 𝑣𝑜𝑙𝑡𝑎𝑔𝑒 𝑜𝑓 𝐻𝑉 𝑤𝑖𝑛𝑑𝑖𝑛𝑔

no load current

2 2
𝐼𝑜 = 𝐼𝑚 + 𝐼𝑤

Performance limitation

For small transformer 𝐼𝑜 = 3 to 5 percent of the rated current,

For medium transformers 𝐼𝑜 = 1 to 3 percent of the rated current
For large transformers, 𝐼𝑜 = 0.5 to 2 percent of the rated current.

𝐼𝑜 > 𝑡ℎ𝑒 𝑙𝑖𝑚𝑖𝑡𝑖𝑛𝑔 𝑣𝑎𝑙𝑢𝑒

The design of the magnetic frame may be changed

No load losses

Iron losses can be sub-divided into the following two components:

• Hysteresis loss
• Eddy current loss
Determination from design data

Core loss
Performance limitation

For small transformer 𝑊𝑖 = 0.5 to 1 percent of the rated output,

For medium & large transformers 𝑊𝑖 = 0.2 to 0.5 percent of the rated output
 Copper losses

Performance limitation

For small transformer 𝑊𝑐 = 1 to 1.5 percent of the rated output,

For medium & large transformers 𝑊𝑖 = 0.3 to 1 percent of the rated output
 Efficiency

𝑂𝑢𝑡𝑝𝑢𝑡 𝑝𝑜𝑤𝑒𝑟
𝜂=
𝐼𝑛𝑝𝑢𝑡 𝑝𝑜𝑤𝑒𝑟
𝑂𝑢𝑡𝑝𝑢𝑡 𝑝𝑜𝑤𝑒𝑟
𝜂=
𝑂𝑢𝑡𝑝𝑢𝑡 𝑝𝑜𝑤𝑒𝑟 + 𝑖𝑟𝑜𝑛 𝑙𝑜𝑠𝑠𝑒𝑠 + 𝑐𝑜𝑝𝑝𝑒𝑟 𝑙𝑜𝑠𝑠𝑒𝑠

𝑂𝑢𝑡𝑝𝑢𝑡 𝑖𝑛 𝐾𝑊𝐻 𝑑𝑢𝑟𝑖𝑛𝑔 𝑡ℎ𝑒 𝑑𝑎𝑦

𝐴𝑙𝑙 𝑑𝑎𝑦 𝜂 =
𝐼𝑛𝑝𝑢𝑡 𝑖𝑛 𝐾𝑊𝐻 𝑑𝑢𝑟𝑖𝑛𝑔 𝑡ℎ𝑒 𝑑𝑎𝑦

𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝜂

𝑊𝑐 = 𝑊𝑖

Performance limitation

For small transformer 𝜂 = 98 percent,

For medium & large transformers 𝜂= 98 to 99.2 percent
 Leakage Reactance

The effect of leakage reactance is to cause a voltage drop in the respective windings.

leakage flux in windings

 Leakage reactance for concentric windings

LV & HV windings

𝑏1 -radial width of the HV winding.

𝑏2 -radial width of the LV winding
𝐿𝑐 - Axial length of the HV winding.
𝑎 - radial width of the duct between LV and HV winding.
b = inner surface of LV winding
a = outer surface of LV winding
c = inner surface of HV winding
d = outer surface of HV winding

leakage flux in windings

 following simplifying assumptions have been made.

(i) Leakage flux lines are parallel to core

(ii) The leakage mmf distribution is trapezoidal across any winding cross section
(iii) The flux density distribution curve has the shape similar to mmf

(iv) Half of the leakage flux in duct links with each winding.

(v) 𝑙𝑚𝑡1 = 𝑙𝑚𝑡2 = 𝐿𝑚𝑡 = 𝜋 × 𝐷𝑚𝑡 mean of (𝐷𝑚𝑡1 & 𝐷𝑚𝑡2 )

(vi) Magnetizing current is zero.

(vii) The reluctance of flux path through yokes in negligible.

(viii) The windings are uniformly distributed and hence the winding mmf. varies
linearly from one end to the other.

The total flux linkages of the HV winding consists of the following two parts:
(a) HV winding flux linking the HV turns.
(b) Duct (between LV and HV) flux linking the HV turns
Total flux linkage of HV winding

𝜇𝑜 𝐴𝑇 𝑇1 𝑙𝑚𝑡1 𝑏1 𝑎
Ψ1 = +
𝐿𝑐 3 2

Ψ1
Leakage inductance of HV winding 𝐿1 =
𝐼1
𝜇0 𝐼1 𝑇1 𝑇1 𝑙𝑚𝑡1 𝑏1 𝑎
= +
𝐿𝑐 × 𝐼1 3 2

leakage reactance of HV winding,

2𝜋𝑓𝜇0 𝑇 2 lm𝑡1 𝑏1 𝑎
𝑥1 = +
𝐿𝑐 3 2
 leakage reactance of LV winding,

2𝜋𝑓𝜇0 𝑇22 𝑙𝑚𝑡2 𝑏2 𝑎

𝑥2 = +
𝐿𝑐 3 2

Total equivalent reactance in referred to HV

2
𝑇1
𝑋1 = 𝑥1 + 𝑥2
𝑇2
2𝜋𝑓𝜇0 lm𝑡 𝑇12 𝑏1 + 𝑏2
= 𝑎+
𝐿𝑐 3
per unit reactance,
𝐼1 𝑋1
𝜀𝑥 =
𝑉1
2𝜋𝑓𝜇𝑜 lm𝑡 𝐼1 𝑇12 𝑏1 + 𝑏2
𝜀𝑥 = 𝑎+
𝐿𝑐 𝑉1 3

2𝜋𝑓𝜇𝑜 l 𝑚 𝑡 𝐴𝑇 𝑏1 + 𝑏2
= 𝑎+
𝐿𝑐 𝐸𝑡 3
𝐴𝑇 = Ampere turns for the HV winding.
𝑙𝑚𝑡1 = Mean circumferential length of the annular duct,
which is approximately taken as mean length of the HV turns.
𝐵𝜎 = flux density in the duct
lm𝑡 = mean length of the turns, i.e. mean of l𝑚𝑡1 and l𝑚𝑡2
𝐷𝑚𝑡 = mean of 𝐷𝑚𝑡1 & 𝐷𝑚𝑡2
 Weight of transformer

Weight of copper in transformer = 8900 × 𝐿𝑚𝑡1 × 𝑇1 𝑎1 × 10−6 + 𝐿𝑚𝑡2 × 𝑇2 𝑎2 × 10−6

𝐿𝑚𝑡1 =length of mean turn of HV winding

𝑇1 = number of turns in HV winding
𝑎1 =cross-sectional area of HV winding conductor
𝐿𝑚𝑡2 , 𝑇2 and 𝑎2 are denoted for LV winding

Weight of iron in transformer = Weight of core + Weight of yoke

Weight of oil in transformer = 330 × Volume of oil in transformer.

Weight of transformer = Weight of copper in windings + Weight of iron + Weight of oil

+ Weight of different fittings and fixtures etc
Design of transformer tank

The design of the tank includes:

1. Main dimensions of the tank

2. Calculation of temperature rise

3. Numbers of cooling tubes

1. Calculation of main Dimensions of tank

The main dimensions of the tank are

(i) Length of the tank

(ii) Width of the tank

(iii) Height of the tank

(i) Length of the tank

The length of the tank for 3-phase transformer

𝑙𝑡 = 2𝐷 + 𝑑𝑜1 + ∆𝑙

The length of the tank for 1-phase transformer,

𝑙𝑡 = 𝐷 + 𝑑𝑜1 + ∆𝑙

D = Centre to centre distance between the cores

𝑑𝑜1 = Outer diameter of the HV winding.
∆𝑙 = Total clearance length wise on both the sides between the HV winding and the tank.

∆𝑙 will depend upon

• The KVA rating

• The voltage of h.v. winding.
 (ii) Width of the tank

𝑏𝑡 = 𝑑𝑜1 + ∆𝑏

∆𝑏 = Total clearance width wise on both the sides between the HV windings and the tank.

(iii) Height of the tank

ℎ𝑡 = 𝐿 + 2ℎ𝑦 + ∆ℎ

L = height of the window

ℎ𝑦 = height of the yoke
∆ℎ = total clearance height wise between the assembled transformer and the tank.

∆ℎ includes
• the clearance at the base,
• oil height above the assembled transformer,
• clearance for the leads etc.
Clearance for the tank
2. Calculation of temperature-rise

(i) Calculate the cooling area of the plain tank, neglecting top and bottom surfaces.

𝑆t = 2 𝑏𝑡 × ℎ𝑡 + 2 𝑙t × ℎ𝑡
= 2 𝑏𝑡 + 𝑙t ℎ𝑡 𝑚2

(ii) Find out the total losses to be dissipated

Total losses = iron losses + copper losses in LV and HV windings

(iii) Calculate the temperature rise, 𝜃 with the plain tank

12.5 𝑆t 𝜃 = Total losses to be dissipated

or, temperature rise. 𝜃 = Total losses to be dissipated

12.5 × tank area
3. Number of cooling tubes

(i) Calculate the total area of the cooling tubes, required for limiting the temperature rise to a
particular value, 𝜃1 i.e.

12.5 𝑆𝑡 𝜃1 + 6.5 𝐴𝑡 𝜃1 1.35 = Total losses to be dissipated.

𝐴𝑡 = Area of cooling tubes

(ii) Select the size of the cooling tube i.e. diameter and length of the cooling tubes.

(iii) Calculate the area of one cooling tube i.e.

Area of one cooling tube = 𝜋 × diameter of the tube × length of the tube

(iv) Calculate the number of cooling tubes required,

Total area of the cooting tubes
=
Area of one cooling tube