Transformer Design

Dr. Puneet Chawla

1
 Transformer Design

 Specifications Known kVA, L.V and H.V ratings,1 phase

or 3 phase

Design the

 Core
 Windings
 Insulation
 Cooling Systems
 Tank
 Accessories
 Mechanical components

2
 Output Equation of Transformer
 It relates the rated kVA output to the area of core & window
 The output kVA of a transformer depends on,
 Flux Density (B) – related to Core area
 Ampere Turns (AT) – related to Window area
 Window – Space inside the core – to accommodate primary &
secondary winding
Let,
T- No. of turns in transformer winding
f – Frequency of supply
Induced EMF/Turn , Et = E / T=4.44 f φm

3
1- Phase core type Transformer

4
Output Equation of Transformer

 Window in a 1φ transformer contains one primary & one

secondary winding.
Conductor area in Window
Window Space factor, K w 
Total area of Window
A
Window Space factor, K w  c
Aw
 Conductor area in window, A c  K w A w  (2)
Current Density(δe is same in both the windings
I p Is
δ   (3)
ap as

5
 Core and Shell Transformers

• Shell type
• Core type
 Half coils

1-Phase Core Type 1-Phase Shell Type

Output Equation of Transformer
Ip Is
a p  ; as 
 

If we neglect magnetizing MMF, then (AT)primary = (AT)secondary

AT=IpTp=IsTs  (4)
Total Cu. Area in window, Ac = Cu.area of pry wdg + Cu.area of sec wdg
 No. of pry turns X area   No. of sec turns X area 
  
 of X - section of pry conductor  of X - section of sec conductor 
 Tp a p  Ts a s
 Tp a p  Ts a s
Ip Is
 Tp  Ts
δ δ
1

δ

Tp I p  Ts I s 
1 2AT
 AT  AT    (5)
δ δ 8
 Output Equation of Transformer
Therefore, equating (2) & (5),
2 AT
KwAw 

1
AT  K w A w   ( 6)
2

kVA rating of 1φ transformer is given by,

Q  Vp I p  10-3  E p I p  10 -3
Ep -3  E
 Tp I p  10 from (1), E t  T 
Tp  
 E t  AT 10 3  (6)
1
 4.44fφ m . K w A w δ  10 3
2
 2.22  fφ m  K w A w δ  10 3
9
 Output Equation of Transformer
φm
We know that, Bm  and φ m  Bm A i
Ai
 Q  2.22  f Bm Ai Aw K w 10 3 kVA

Three phase transformer:

 Each window has 2 primary & 2

Secondary windings.
Hw
 Total Cu. Area in the window is given by,
A c  2Tp a p  2Ts a s Ww

4AT
Ac   (7)
δ
4AT
Compare (2) & (7),   KwAw
δ
K A δ
AT  w w 10
4
Output Equation of Transformer
kVA rating of 3φ transformer,

Q  3 E p I p  10 3
Ep
3 Tp I p  10-3
Tp
 E t  AT  10 3
1
 3  4.44  fφ m .  K w A w δ  10 3
4
 3.33 f Bm A i A w K w δ  10 3 kVA

11
 1. EMF per Turn
Design of Transformer starts with EMF/turn.
Let,

Ratio of Specific magnetic loading  φm

 r
to Electric loading  AT
Q  Vp I p 10 3 r is constant for a given type,
service condition & method
3
 4.44 f φ m Tp I p 10 of construction of
transformer.
 4.44 f φ m (AT)  10 3
φm
 4.44 f φ m  10 3
r
2 Qr Q  r  103
φm  3

4.44 f  10 4.44 f
Q  r  103
φm 
4.44 f
12
 EMF per Turn
w.k.t, E t  4.44 f φ m
Q  r 103 3 Q
 4.44 f  4.44 f  4.44 f  r  10 .
4.44 f 4.44 f
 4.44 f  r 103  Q

Et  K  Q

where, K  4.44 f  r 103

 K depends on the type, service condition & method of

construction of transformer.

13
 EMF per Turn

Transformer Type Value of K

1φ Shell Type 1.0 to 1.2
1φ Core Type 0.75 to 0.85
3φ Shell Type 1.2 to 1.3
3φ Core Type Distribution 0.45 to 0.5
Transformer

3φ Core Type Power 0.6 to 0.7

transformer

14
 Optimum Design
 Transformer may be designed to make one of the
following quantities as minimum.
 Total Volume
 Total Weight
 Total Cost
 Total Losses
 In general, these requirements are contradictory & it is
normally possible to satisfy only one of them.
 All these quantities vary with φm
r 
AT

15
 Optimum Design
Design for Minimum Cost
Let us consider a single phase transformer.

 Q  2.22  f Bm A i A w K w   10 3 kVA
Q  2.22  f Bm A i A c   10 3 kVA A c  K w A w 
Assuming that φ & B are constant, Ac.Ai – Constant
Let, Ac Ai  M 2  (1)
In optimum design, it aims to determining the minimum value of
total cost. 
r m
AT
m  B m A i
1 Ac
AT  K w A w  
2 2 16
 Optimum Design
Design for Minimum Cost
Bm A i 2 Bm A i
r 
Ac Ac
2
A i 2 Bm
r
Ac 
Ai 
 r    ( 2)
Ac 2 Bm
β is the function of r alone [δ & Bm – Constant]
From (1) & (2),
M
A A  M 
c i
2

Ai  M  & Ac 


17
 Optimum Design
Design for Minimum Cost
Let, Ct - Total cost of transformer active materials
Ci – Cost of iron
Cc – Cost of conductor
pi – Loss in iron/kg (W)
pc – Loss in Copper/kg (W)
li – Mean length of flux path in iron(m)
Lmt – Mean length of turn of transformer winding (m)
Gi – Weight of active iron (kg)
Gc – Weight of Copper (kg)
gi – Weight/m3 of iron
gc – Weight/m
C t  Ci 3of
C cCopper
 ci G i  c c G c
18
 Optimum Design
Design for Minimum Cost
C t  c i g i li A i  c c g c L mt A c
where, ci & c c  specific costs of iron and copper respective ly.
M
Ct  ci g i li M   cc g c Lmt

Differeniating Ct with respect to β,
d 1 1 / 2 1
C t  c i g i li M ()  c c g c Lmt M 3 / 2
d 2 2
d
For minimum cost, Ct  0
d
1 1
c i giliM() 1/ 2  c c gc Lmt M 3 / 2
2 2
c i gili  c c gc Lmt  1
Ac
c i gili  c c gc Lmt
Ai 19
 Optimum Design
Design for Minimum Cost
c i gili A i  c c gc Lmt A c
ci G i  cc G c
Ci  C c
Hence for minimum cost,
the cost of iron must be equal to the cost of copper.
Similarly,
For minimum volume of transformer,
Gi Gc
Volume of iron = Volume of Copper  or G i  gi
gi gc Gc gc

For minimum weight of transformer,

Weight of iron = Weight of Conductor Gi  Gc

For minimum loss,

Iron loss = I2R loss in conductor Pi  x 2Pc

20
 Optimum Design Design
for Minimum Loss and Maximum Efficiency
Total losses at full load = Pi+Pc
At any fraction x of full load, total losses = Pi+x2Pc
If output at a fraction of x of full load is xQ.
Efficiency, xQ
x 
xQ  Pi  x 2 Pc
d x
Condition for maximum efficiency is, 0
dx
dx

 
xQ  Pi  x 2 Pc Q - Q  2xPc xQ
0
dx 
xQ  Pi  x Pc2
2

xQ  P  x P Q  Q  2xP xQ

i
2
c c

xQ  P  x P   Q  2xP x
i
2
c c

xQ  Pi  x 2 Pc  xQ  x 2 Pc  x 2 Pc
Pi  x 2 Pc
21
 Optimum Design
Design for Minimum Loss and Maximum Efficiency

Variable losses = Constant losses

Pi piG i

Pc pcG c
piG i Gi p
x2  or  x2 c
for maximum efficiency pcG c Gc pi

22
 3
 Q  2.22  f Bm A i A w K w   10 kVA

Et  K  Q

23
DESIGN OF CORE
 2. Design of Core
 Core type transformer :
 Rectangular/Square /Stepped cross section

 Shell type transformer :

 Rectangular cross section

25
 Design of Core
 Core design is governed by rating of transformer, its operating
conditions and transport limitations.

 The core cross section may be square, rectangular or stepped.

 For best economic use of core and conductor material, the core cross
section should be circular.

 Circular cross section requires the use of a large number of

laminations of different sizes

 In stepped cores, the length of mean turn decreases with an increase

in the number of steps, but the number of different sizes of
laminations increases.

 While designing a stepped core a balance has to be struck between the

cost of conductor and labour charges.
 Rectangular Core
 Used for core type distribution transformers and small power
transformers for moderate and low voltage.

 Ratio of depth to width of core varies between 1.4 to 2.

 Shell type transformers also use cores with rectangular cross

section.

 For a shell type transformer width of central limb is 2 to 3 times

the depth of the core.

Rectangular shaped coils are used for rectangular cores.

 Square and Cruciform Cores
 High voltage distribution and power transformers require circular
coils due to their superior mechanical characteristics.

 For large transformers, it becomes wasteful to use rectangular

cores.

 Hence, square cores are used along with circular coils.

 2 stepped or cruciform cores utilize space better than square cores.

 A cruciform core makes use of 2 different sizes of laminations.

Larger transformers make use of cruciform cores to reduce copper

losses and conductor costs.
 Square & Stepped Core
 Dia of Circumscribing circle is larger in Square core than
Stepped core with the same area of cross section.

 Thus the length of mean turn(Lmt) is reduced in stepped

core and reduces the cost of copper and copper loss.

 However, with large number of steps, a large number of

different sizes of laminations are used.

29
 Square Core

d a

d : Dia of circumscribing circle

a : side of square
Cruciform Core

d : circumscribing Dia
a  d cos 
b  d sin 

b
a
d
Cruciform Core

d : circumscribing dia
a  d cos 
b  d sin 

b
a
d
Cruciform Core

d : circumscribing dia
a  d cos 
b  d sin 

What should be the dimensions

to maximize the area for a given
b diameter?

a
d
 Multi Stepped Cores
 With an increase in the number of steps core space is utilized more
effectively.

 Multi stepped cores also reduce the length of mean turn with
consequent reduction in both cost of copper and copper loss.

 With an increase in the number of steps a large number of laminations

have to be used, which leads to higher labour charges.

 The reduction in winding costs with a certain number of steps has to be

balanced with the extra labour costs.

Stacking Factor- the net cross sectional area is obtained from the
dimensions of various packets and an allowance is made for the space
lost between lamination ; this allowance is known as stacking factor.

Utilization factor – Ratio of net cross sectional area to the gross area of
the core circle.
 Design of Core
Square Core
Let, d - diameter of circumscribing circle
d a
a – side of square
2 2 2
Diameter, d  a  a  2 a  2 a
d
a
2
Let the stacking factor, Sf=0.9.
2
 d 
2
Gross core area, Agi  Area of square  a   
 2
Agi  0.5d 2
Net core area,
35
 Design of Core
Square Core
 Gross core area includes insulation area
 Net core area excludes insulation area
d a
Area of Circumscribing circle is 
d2
4

 Ratio of net core area to 0.45d 2

 0.58
Area of Circumscribing circle is  2
d
4
 Ratio of gross core area to 0.5d 2
 0.64
Area of Circumscribing circle is  2
d
4

36
 Design of Core
Stepped Core or Cruciform Core
Let , a – Length of the rectangle
b – breadth of the rectangle
d – diameter of the circumscribing circle and diagonal of the
rectangle.
θ – Angle b/w the diagonal and length of the rectangle.

 The max. core area for a given ‘d’ is

b
obtained by finding the max value of ‘θ’
 For max value of ‘θ’,
(a-b)/2
dA gi
0
d
d
b a
θ
 From the figure,
a
(a-b)/2 cos     a  d cos 
d
b
a sin    b  d sin 
d 37
 Design of Core
Stepped Core or Cruciform Core
Two stepped core can be divided in to 3 b

rectangles.
(a-b)/2
Referring to the fig shown,
ab ab d b a
Gross core area, Agi  ab   b   b
 2   2  θ

2( a  b ) (a-b)/2
 ab  b
2
 ab  ab  b 2  2ab  b 2 a

On substituting ‘a’ and ‘b’ in the above equations,

A gi  2(d cos )(d sin )  (d sin ) 2
A gi  2d 2 cos  sin   d 2 sin 2 
A gi  d 2 sin 2  d 2 sin 2 
For max value of ‘θ’,
dA gi
0
d 38
 Design of Core
Stepped Core or Cruciform Core
dA gi
i.e.,  d 2 2 cos 2  d 2 2 sin  cos   0
d
d 2 2 cos 2  d 2 2 sin  cos 
2 cos 2  sin 2
sin 2
2
cos 2
tan 2  2
2  tan 1 2
1
  tan 1 2   31.72 0
2
Therefore, if the θ=31.72 , the dimensions ‘a’ & ‘b’ will give maximum
0

area of core for a specified ‘d’.

a
cos     a  d cos   a  d cos(31.720 )  0.85d
d
b
sin    b  d sin   b  d sin( 31.72 0 )  0.53d
d 39
Design of Cruciform Core

d : circumscribing dia
a  d cos 
b  d sin 
To maximize area for a given
diameter:
  31‘45
a = 0.85 d
b = 0.53 d
b
a
d
 Design of Core
Stepped Core or Cruciform Core
Gross core area, b

A gi  2ab  b 2
(a-b)/2

d b a
2
A gi  2(0.85d)(0 .53d)  (0.53d) θ
(a-b)/2

A gi  0.618d 2
a

Let stacking factor, Sf  0.9,

The ratios, Net core area, A i  Stacking factor X Gross Core area
A i  0.9  0.618d 2  0.56d 2
Net core area 0.56d 2
  0.71
Area of Circumscri bing circle  2
d
4
Gross core area 0.618d 2
  0.79
Area of Circumscri bing circle  2
d 41
4
 Most Economical Dimensions for
Multi Stepped Cores
Area as a percentage Square Cruciform Three stepped Four stepped
of area of
circumscribing
circle

Gross core area 64 % 79 % 84 % 87 %

Net core area 58 % 71 % 75 % 78 %

Net core area 0.45 d2 0.56 d2 0.60 d2 0.62 d2

Dimensions of stepped cores

43
Variation of core diameter

b
a
b d
a
d 44
 Variation of core diameter
 Higher core diameter increase cross sectional area of the core,
thereby increasing voltage per turn.
 Higher voltage per turn reduces the number of turns in various
windings.
 The increase in core diameter can result in reduction in core height . In
spite of reduction of core height, due to increase of core diameter ,the
core weight increase thereby increasing the no load loss of the
transformer. Number of winding turns is reduced though length of
mean turn increases.
 The net effect reduces the weight of copper and obviously reduces
copper loss in winding.
 On the other hand reduction of core diameter results in reduced core
weight along with lower no load loss but increased copper weight and
higher copper loss.
 Selection of Core Area and
Type of Core
 Stepped core cross section is preferred to obtain the optimum core
area within the circumscribing circle of the core .
 The core area is determined by the number of steps, grade of steel ,
insulation or laminations and type of clamping.
 Selection of type of core depends upon the rating ,operation duty and
transport limitations .
 For large three phase transformers, five limbed core is recommended
to overcome the problem of higher height of the core .
 For single phase shell transformers, one centre-wound limb with two
return limbs is a common configuration.

Area of core is found out using

Net core area required Ai = φ/B
Gross core area Agi = Ai / Sf
 Design Steps
 1.
 2. Calculate φ
 3 Ai = φ / B
 4.Calculate d, Ai = 0.45d2 (Square core), 0.56d2
(cruciform core)
 5. Agi = Ai / Sf
 6. Calculate a , b , c etc

47
 3. Choice of Flux Density
 Advantages of higher value of flux density :
 Smaller core area
 Reduction in length of mean turn
 Saving of copper in winding
 Reduction in net weight of transformer

 Disadvantages of higher value of flux density :

 Higher leakage reactance
 Increase in core loss
 Lower Efficiency
 Higher temperature rise
 Large magnetizing current which contains objectionable
harmonics
 Choice of Flux Density
 Value of flux density chosen depends on the service conditions of
the transformer.

 Distribution transformer has to be designed for a high all day

efficiency, hence it necessitates a lower value of flux density in order
to keep down the iron losses.

 Power transformers are designed to have maximum efficiency at or

near full load, hence they require a higher value of flux density.

 In case of power transformers inherent voltage regulation is less

important than the current limiting effect of the higher leakage
reactance.
 Values of Flux Density
 The values of maximum flux density using hot rolled silicon steel
are :

 Distribution Transformer : 1.1 to 1.35 Wb/m2

 Power Transformer : 1.25 to 1.45 Wb/m2

 Lower values should be used for small rating transformers.

 For transformers using CRGO steel, the following values may be

used :
1. For transformers upto 132 kV : 1.55 Wb/m2
2. For transformers upto 275 kV : 1.60 Wb/m2
3. For 400 kV and generator transformers : 1.70 to 1.75 Wb/m2
 4.Design of Winding
 Transformer windings: HV winding & LV winding
 Winding Design involves:
 Determination of no. of turns: based on kVA rating & EMF per
turn
 Area of cross section of conductor used: Based on rated current
and Current density
 No. of turns of LV winding is estimated first using given data.
 Then, no. of turns of HV winding is calculated to the voltage rating.

VLV AT
No. of turns in LV winding, TLV  (or)
Et I LV
where, VLV  Rated voltage of LV winding
I LV  Rated Current of LV winding
Cont…
 No. of turns in l.v. winding is determined in preliminary design.

Vl .v.
Tl .v.  An integer
Et
 H.V. winding turns per phase

Vh.v.
Th.v.   Tl .v.
Vl .v.
Tappings on h.v. side:-
 If the tappings are located in the middle part of and h.v.
winding, the number of winding turns must be even to
ensure the symmetry of winding.

 For a winding with tapping, it is necessary to have proper

turn ratio not only on the principal tapping but on the other
taps as well. Therefore, turns should be selected judiously.
 Area of conductor and current density

 Primary and Secondary currents are given by:

kVA 3 Vp
Ip   10 Is  I p
Vp Vs
 Current density is chosen before finding area of the
conductor.
Ip Is
a p  ; as 
 
 High value of current density results in excessive increase
in temperature rise and can cause injury to insulation.
 5.Choice of Current Density
 Copper losses depend on the choice of current density.
 Different values of current density are chosen for distribution and
power transformers as the level of iron and copper losses required is
different .
 The following values of current density for different types of
transformers maybe used:

 Distribution, small / medium power transformers : 1.1 to 2.3 A/mm2

 Large power transformers, self oil cooled type : 2.2 to 3.2 A/mm2
 Large power transformers, forced circulation of oil : 4 to 6.2 A/mm2

 To minimize copper losses the values of current density in both the

windings should be the same.

 In Practice, the current density in outer winding is made 5 % greater

than the inner winding on account of better cooling in outer winding.
 Area of conductor
 Area of each primary and secondary conductor is ap and as
respectively:
Ip Is
ap  as 
p s

 p s Current densities of secondary and primary respectively

 For minimum loss, the value of current density in each of the two
winding should be equal.
 A current density of 2.3 A/mm2 may be used for Cu conductor
BIS

57
 Selection of Windings
 Winding should be selected such that the desired electrical
characteristics and adequate mechanical strength is obtained.

 In case more than one winding is suitable, the winding with simple
constructional features should be selected.
 High voltage windings are usually of the following types :
 Cylindrical winding with circular conductors.
 Cross-over winding with either circular or small rectangular
conductors.
 Continuous disc type winding with rectangular conductors.

 The disc type winding is used for transformers of higher ratings

ranging from 200 kVA and voltages from 11kV upwards.

The cylindrical and cross-over windings are used for transformers of

ratings upto 1000 kVA and 33 kV.
 Selection of windings
 The low voltage windings are usually of the following types :
 Cylindrical Winding
 Helical winding

 Both these windings employ rectangular conductors.

 Cylindrical windings are used for ratings upto 800 kVA and voltages
upto 433 V.

 Helical winding can be used for ratings upto tens of MVA and
voltages upto 33 kV.

 Sandwich windings are used in shell type transformers.

Ranges of different winding types
Type Of Rating Voltage Maximum Conductor cross-
Winding kVA kV current/conductor section
A mm2

Cylindrical 5000 -10000 Upto 33 Upto 80 Upto 30

[circular
conductors]
Cylindrical 5000 -8000 Upto 0.6 10 – 600 5- 200
[rectangular
conductors]

Cross over Upto 1000 Upto 33 Upto 40 Upto 15

Helical Above 160 Upto 33 From 300 and 75 to 100 and

above above
Continuous Above 200 3.3 - 220 12 and above From 4 to 200 and
disc above
 Design Steps
 1.
 2. Calculate φ (Et = 4.44 f φm )
 3. Choose Bm
 4. Calculate Ai = φ / B
 5. Calculate d, Ai = 0.45d2 (Square core), 0.56d2 (cruciform core)
 Agi = Ai / Sf
 6. Calculate a , b , c etc
 7. Choose Current density of conductors
 8. No of Turns of L.V and H.V. Winding T L.V ,T H.V.
 9. Area of cross section of L.V and H.V. Winding a L.V. , a H.V.

61
 Design Example
Q. Design a 25kVA, 11000 / 433V, 50Hz, 3phase, delta /star core
type distribution transformer. The transformer is provided with
tappings at ± 2.5%,and ± 5% on H.V. winding.
Max. temperature rise not to exceed 450C with mean temperature
rise of oil 350C

62
 EMF per Turn

Transformer Type Value of K

1φ Shell Type 1.0 to 1.2
1φ Core Type 0.75 to 0.85
3φ Shell Type 1.2 to 1.3
3φ Core Type Distribution 0.45 to 0.5
Transformer

3φ Core Type Power 0.6 to 0.7

transformer

63
 Design Steps
1. , k = 0.45, E = 0.45√25
t = 2.25V

2. Calculate φ = 0.010135Wb (Et = 4.44 f φm )

3. Choose Bm =1.0 Wb/m2
4. Calculate Ai = φ / B = 0.010135 m2

5.. Calculate d ; Ai = 0.45d2 (Square core), for Cruciform core = 0.56d2

d =134.5 mm : Agi = Ai / Sf
6. Calculate a , b , c etc
a= 0.85d = 114.8 mm , b = 0.53d = 71.6mm

7. No of Turns of L.V and H.V. Winding T L.V ,T H.V.

Vl.v.= 433/√3 = 250V,
Tl.v = Vl.v / Et

64
 Design Steps
7. No of Turns of L.V and H.V. Winding T L.V ,T H.V.
Vl.v.= 433/√3 =250V,
Tl.v = Vl.v / Et

T L.V = 250/2.25 =111

Vh.v.
Th.v. x 111/ T250
= 11000 l .v . =4884
Vl .v.

8. Choose Current density of conductors 2.3 A/mm2

9. Area of cross section of L.V and H.V. Winding a L.V. , a H.V.

 IL.V = 25x 1000/3 x 250 = 33.3A

 a L.V. = 33.3/2.3 =14.48mm2
 IH.V = 25x 1000/3 x 11000 = 0.757A
 a H.V. = 0.757/2.4 = 0.316 mm2 65
Position of winding related
to the core
 Insulation Design
 Winding voltages produce an electrostatic field in the
dielectric and therefore stresses the insulation.
 Currents in winding set up magnetic fields which give rise
to magnetic forces on the winding and mechanical stresses
on insulation.
 Losses in transformer causes thermal stressing of
insulation.
 Thus basic consideration in Insulation design:
 Electrical Considerations.
 Mechanical Considerations.
 Thermal Considerations.
 Electrical considerations in
insulation design
 Basic insulation structure is primarily determined from
consideration of voltage which appear between different parts
of transformer.
 Sustained frequency high voltage tests and impulse test are
done to check strength of winding.
 Electrical design of winding should also consider
 Eddy current loss – The winding should be so designed that stray
load losses is small. The radial width of strips should be small and
they should be transposed.
 Leakage reactance – The leakage reactance is adjusted by changing
the winding configuration and brought within desirable limits.
 Mechanical considerations in
insulation design
 Insulation must be capable of withstanding mechanical
stresses during manufacturing processes.
 Insulation must be able to withstand mechanical stress
developed due to electromagnetic phenomenon.
 Under normal operation these are quite small. But during fault
condition these forces may increase several hundred times.
Insulation must be designed to withstand these forces for a
specified period of time.
 The mechanical design of insulation should be such that hoop,
bursting and compressive stresses are minimized.
Thermal considerations in insulation
design
 Determined from consideration of
 Insulating material
 Maximum operating temperature
 Types of cooling methods

 Transformer structure should be such that losses developed in core

and windings such that temperature rise in various parts does not
exceed permissible limits.
 Types of Insulation
 1.Major insulation: the insulation between windings and
grounded core and the insulation between the windings of the same
phase(L.V &H.V). Partition of solid insulation materials placed
inside oil ducts are called barriers. for example pressboard, s.r.b.p
or cylinders placed between l.v and h.v windings and between
windings and core are called barriers.
 2.Minor insulation: insulation between different parts of one
winding i.e. insulation between turns, coils and layers etc.
 3.Insulation relative to tank: is called oil barrier insulation in
oil immersed transformers. It consists of oil ducts, barriers and
coverings.
 The major insulation between the low and high voltage windings is
provided by another pressboard or s.r.b.p cylinder and the bars are
arranged around it.
 Thumb rule for thickness of insulation between a winding earth and
between l.v and h.v windings is : insulation thickness =( 5+0.9kV) mm

This thickness includes width of any oil duct provided in between.

Thickness of oil duct is 6mm in small capacity transformers and is 7.5 to
12mm in large cap. transformers.
Insulation design

73
Insulation design

74
Insulation design

75
Insulation design

76
 Major Insulation Of Transformers

C1, C2, C3  thickness of insulating cylinders.

w  thickness of horizontal solid insulation between winding and yoke 77
Major Insulation Of Transformers

C1, C2, C3  thickness of insulating cylinders.

w  thickness of horizontal solid insulation between winding and yoke
Thickness of Major Insulation of H.V. winding upto 33 kV
From Winding end to
Rating Volatge Between h.v. and l.v. yoke Between phases
(kVA) (kV) a2 (mm) C2 (mm) h (mm) w (mm) a3 (mm) C3 (mm)

25-100 8.5 2.5 20 - 10 2

125-630 3.3 and 6.6 12 2.5 20 to 30 10 2
800 and above 17 5 30-50 10 2

25-630 12 3 30 - 14 2
800 and above 11 17 5 30 to 50 14 2

25-630 15 3.5 40 - 17 2
800 and above 15 17 5 40-50 17 2

10-800 27 5 60 2 30 3
1000 and above 33 27 5 75 2 30 3
 Window Space Factor
 Defined as ratio of copper area in the window to the total
window area.
 Estimate value of Window space factor (Kw) can be found
using the following empirical formulae:
 Kw = 8/(30+kV) transformers of rating about 20kVA
 Kw = 10/(30+kV) transformers of rating 50 to 200kVA
 Kw = 12/(30+kV) transformers of rating about 1000kVA
 Here kV is h.v. winding voltage in kilo-volts.
 Value of Kw can be increased or decreased during later stages of
design to decrease or increase window area.
Window Space Factor

Hw

Ww

82
Why window space factor decrease
when the voltage rating of transformer
increase?
For a given power, high voltage transformer requires more
insulation in window from phase to phase and phase to core.

Amount of insulation in window increases and net copper

area will decrease, hence window space factor decreases.
3-Phase core Type Transformer

Fig.(2): construction of core type three phase transformer

 Window Dimensions
 Leakage reactance is affected by distance between adjacent limbs.
 Width and height of winding are interrelated, if one is decreased other has to
increase.
 Short and wide coils give rise to high leakage reactance.
 Long and thin winding gives low leakage reactance.
 Height and width of window can be adjusted to give suitable arrangement of
winding and desired leakage reactance.
 The ratio of height to width of window is between 2 to 4.
 Area of window Aw =

= 2apTp/Kw for single phase transformer

= 4apTp/Kw for three phase transformer
 Area of window Aw = height of window * width of window
 Aw = Hw * Ww
 Different coil shapes

Hw

Hw
Ww

Ww

Long and thin winding Short and wide windings 86

 Design Of Yoke

• Area of yoke (A Y) is taken as 15 to 25% larger than core of

transformers using hot rolled silicon steel.
– This reduces the flux density and thus iron losses and magnetizing
current decreases.
• For transformers using cold rolled grain oriented steel area of
yoke is same as area of core.
• Yoke can be taken either rectangular or stepped.
– In case of rectangular yoke , depth of yoke is same as depth of core.
– For stepped core depth of yoke is equal to width of largest stamping.
• For rectangular section yokes
– AY = DY * HY
D Y  Depth of yoke
H Y  Height of yoke
Stepped yoke

88
3-Phase core Type Transformer

Fig.(2): construction of core type three phase transformer

Width of window for optimum output
D = Distance between adjacent limbs

D= Width of iron + Width of bare conductors +

Width of insulation and clearance

D = 1.7d

The width of window which gives maximum

output is Ww = D – d = 0.7 d
 Overall Dimensions
Single phase Core Type
Hy

 D = d + Ww
 DY = a Hw H

 H = Hw + 2HY
Hy

W = D + a a
W

Dy

d Ww d

91
 Overall Dimensions
Single phase Shell Type
a

2a Hw

 DY = b
 HY = a a

 H = Hw + 2a Ww

 W = 2Ww + 4a
Depth
b Over
winding

92
 Overall Dimensions
Thee phase Core Type

Hy Hy
a

Hw H Hw H

 H = Hw + 2HY Hy Hy
 W = 2D + a
a
W

Dy Dy

d Ww dd Ww d

 D = d + Ww
D D
 H = Hw + 2HY
 DY = a  W = 2D + a 93
 TRANSFORMER DESIGN
Assignment
1.Design a 200 kVA, 50 Hz, 6.6kV/400V single phase core type, oil immersed
natural cooled power transformer. Temperature rise not to exceed 45℃,
with mean temperature rise of oil 35℃.
2. Design a 75 kVA, 11kV/400V, 50 Hz 3 phase ∆ / Y core type oil immersed
natural cooled distribution transformer. The transformer is provided with
tappings ±2.5 %, ±5 % on the HV winding. Maximum
temperature rise not to exceed 45℃, with mean temperature rise of
oil 35℃.
3. Design a 150 kVA, 6.6kV/440 V, 50 Hz single phase core type, oil immersed,
self-cooled power transformer. Average temperature rise of oil not to
exceed 35℃.
4. Design a 200 kVA, 50 Hz 11kV/400V single phase core type, oil immersed
natural cooled power transformer. The mean temperature rise not to
exceed 35℃. Maximum temperature rise not to exceed 45℃.
 TRANSFORMER DESIGN
Assignment
5. Design a 100 kVA, 6.6kV/400V, 50 Hz 3 phase ∆/Y core type oil immersed natural
cooled distribution transformer. The transformer is provided with tapping±
2.5%, ± 5% on HV side. Mean temperature rise of oil should not exceed
35℃. Maximum temperature rise not to exceed 45℃.
6. Design a 150 kVA, 6.6kV/440V, 50 Hz single phase core type oil immersed, self-
cooled distribution transformer. Average temperature rise of oil not to
exceed 35℃. Maximum temperature rise not to exceed 45℃.

7. Design a 125 kVA, 11kV/400 V, 50 Hz 3 phase, ∆/Y core type oil immersed
natural cooled power transformer. Temperature rise not to exceed 35℃.
Maximum temperature rise not to exceed 45℃.

8. Design a 60 kVA 6600/440 V 3 phase 50 Hz delta star core, naturally cooled

type distribution transformer. The mean temperature rise not to exceed 35℃.
Maximum temperature rise not to exceed 45℃.
 TRANSFORMER DESIGN
Assignment
9.Design a 300 kVA, 11V/400V, ∆/Y oil immersed natural cooled type
power transformer. Mean Temperature rise not to exceed 35℃.
Maximum temperature rise not to exceed 45℃.

10. Design a 125 kVA, 6.6 kV/400V, 3 phase ∆/Y core type distribution
transformer. The mean Temperature rise not to exceed 35℃.
Maximum temperature rise not to exceed 45℃.
 Cooling of transformers
 Losses in transformer-Converted in heat energy.
 Heat developed is transmitted by,
 Conduction
 Convection
 Radiation
The paths of heat flow are,
 From internal hot spot to the outer surface(in
contact with oil)
 From outer surface to the oil
 From the oil to the tank
 From tank to the cooling medium-Air or water.
Increasing Surface area of tanks

98
Cooling of transformers

99
100
 Cooling of transformers
Transformer Oil as Cooling Medium

 Specific heat dissipation

1
due to convection is,
  4
conv  40.3  W / m 2 .0 C
H
where,  - Temperatur e difference of the surface relative to oil, 0C
H  Height of dissipatin g surface, m
 The average working temperature of oil is 50-600C.
 For   200 C & H  0.5 to 1m,

conv  80 to 100 W/m 2 .0 C.

 The value of specific heat dissipation in air is 8 W/m2/0C.
i.e, 10 times less than oil.
 Cooling of transformers
Temperature rise in plain walled tanks
 Transformer wall dissipates heat in radiation & convection.
 For a temperature rise of 400C above the ambient temperature of
200C, the heat dissipations are as follows:
 Specific heat dissipation by radiation , rad=6 W/m2.0C
 Specific heat dissipation by convection, conv=6.5 W/m2/0C
 Total heat dissipation in plain wall 12.5 W/m2.0C
 The temperature rise,
Total losses P  Pc
  i
Specific heat  Heat dissipatin g  12.5 St
    
 Dissipatio n   surface of tank 
 St – Heat dissipating surface
 Heat dissipating surface of tank : Total area of vertical sides+ One
half area of top cover(Air cooled)/ (Full area of top cover for oil
cooled)
Design of tanks with cooling tubes

 Cooling tubes increases the heat dissipation

 Cooling by tubes mounted on vertical sides of the
transformer not proportional to increase in area. Because,
the tubes prevents the radiation from the tank in screened
surfaces.
 But the cooling tubes increase circulation of oil and hence
improve the convection
 Circulation is due to effective pressure heads
 Dissipation by convection is equal to that of 35% of tube
surface area. i.e., 35% tube area is added to actual tube area.
 Design of tank with cooling tubes
Let, Dissipating surface of tank – S t
Dissipating surface of tubes – X S t
Loss dissipated by surface of the tank by radiation and
convection = 6  6.5St  12.5St

Loss dissipated by  135

  6 . 5   XSt  8.8XSt
tubes by convection  100

Total loss dissipated 

  12.5St  8.8XSt  12.5  8.8X St  (1)
by walls and tubes 
Actual total area of tank walls and tubes  St  XSt  St (1  X )
 Design of tanks with cooling tubes
2 Total losses dissipated
Loss dissipated per m of dissipatin g surface 
Total area
S (12.5  8.8 X ) (12.5  8.8 X )
Loss dissipated per m 2 of dissipatin g surface  t   (2)
St (1  X ) (1  X )

Temperatur e rise in  Total loss

 
Transforme r with cooling tubes  Loss Dissipated
Total losses, Ploss  Pi  Pc  (3)
Pi  Pc
From (1) and (3), we have,  
S t (12.5  8.8 X )
Pi  Pc
(12.5  8.8 X ) 
 St
P  Pc 1  Pi  Pc 
8 .8 X  i  12.5  X    12.5 
 St 8.8   St 
 Number of cooling tubes
1  Pi  Pc  1  Pi  Pc 
Total area of cooling tubes    12.5  St    12. 5 S t   (5)
8.8   St  8.8   
Let , lt  Length of tubes
d t  Diameter of tubes
 Surface area of tubes   d t lt
Total area of tubes
Total number of tubes, nt 
Area of each tube
1  Pi  Pc 
nt    12.5 S t   (6)
8.8 d t lt   
 Standard diameter of cooling tube is 50mm & length depends
on the height of the tank.
 Centre to centre spacing is 75mm.
Tank with cooling tubes

107
 Design of tanks with cooling tubes

C4

HT

D D
C3

WT

LT

C2 Doc C1
 Design of tanks with cooling tubes
 Dimensions of the tank:
Let
C1 – Clearance b/w winding and tank along width
C2 - Clearance b/w winding and tank along length
C3 – Clearance b/w the transformer frame and tank at the bottom
C4 - Clearance b/w the transformer frame and tank at the top
Doc – Outer diameter of the coil.
Width of the tank, WT = 2D + Doc + 2 C1 (For 3 Transformer)
= D + Doc + 2 C1 (For 1 Transformer)
Length of the tank, LT = Doc +2 C2
Height of the tank, HT = H + C3 + C4
 Design of tanks with cooling tubes
 Clearance on the sides depends on the voltage & power
ratings.
 Clearance at the top depends on the oil height above the
assembled transformer & space for mounting the terminals
and tap changer.
 Clearance at the bottom depends on the space required for
mounting the frame.
 Design of tanks with cooling tubes
Clearance in mm
Voltage kVA Rating
C1 C2 C3 C4

Up to 11kV <1000kVA 40 50 75 375

Upto 11 kV 1000-5000kVA 70 90 100 400

11kV – 33kV <1000kVA 75 100 75 450

11kV – 33kV 1000-5000kVA 85 125 100 475

112