Anand Jain, Hod EE

Govt. Polytechnic College, Hanumangarh

Transformer
Construction
Transformer
Construction
Core-Shell
 Transformer
Construction
Core-Shell Anand Jain,Hod EE
Govt. Polytechnic College, Hanumangarh
A transformer consists of two electrical isolated windings coupled through a magnetic
medium. When one of the winding is connected to ac supply of one voltage level, it can
produce alternating supply of the same frequency but different voltage depending upon
the turns ration. The two major types of construction of transformers (used in
transmission and distribution of electrical energy) are core type and shell type.
Depending on the application, these transformers can be classified as distribution
transformers and power transformers.
The most important function performed by transformers are,
ü Changing voltage and current level in an electric system.
ü Matching source and load impedances for maximum power transfer in
electronic and control circuitry.
ü Electrical isolation.
The standard ratings of oil immersed, naturally cooled 3 phase 11
kV/433 - 250 V distribution transformers shall be 10, 16, 25, 63,
100, 160, 200, 250, 315, 400, 500, 630, 1000, 1250, 1600, 2000 and
2500 kVA
 The transformer either single or 3-phase, usually consists of the following elements:
a) Magnetic circuit, consisting of limbs (core), yokes and clamping structures
The core support the winding and it offers a low reluctance path to the magnetic flux. The core is a
stack of cold rolled grain oriented annealed silicon steel insulated lamination. Both sides of 0.3 to 0.5
mm thick laminations are coated with hot oil proof insulation to reduce eddy loss. 3 to 4% Si content in
steel increases its resistivity to eddy currents and reduce hysteresis losses.

CRGO laminations are cut at an

angle and core leg and core yoke
laminations are interleaved in
mitred joints. This reduces No
load losses, No load current &
Noise level. The permissible no
load current is only 3-5% of full
load current.

Core is bolted together and to the frames firmly to

prevent vibration or noise.
b) Electric Circuit: A standard transformer will have two
winding sets which are insulated from one another. In the
winding construction single HV coil is wound over LV coil.
In high voltage winding, large number of turns of thinner
cross section is used. Low voltage winding has thicker
conductors and has fewer turns than its high voltage
counterpart.
HV and LV windings are wound from Super Enamel
covered /Double Paper covered, aluminium /copper
conductor/ foil 100 kVA and below and only copper
conductor/foil above 100KVA. Current density for HV and LV
winding should not be more than 2.8 Ampere per sq mm for
copper and 1.6 Ampere per sq mm for Aluminium Conductor.
LV winding shall be such that neutral formation will be at top.
c) dielectric circuit, consisting of
insulation in different form and used at
different places in the transformer, namely:
core to LV, LV to HV, etc.
Transformers normally use cardboard
and insulating paper as a means of
isolating both primary and secondary
winding from each other as well as the
transformer core. Inter layer insulation
is epoxy dotted Kraft Paper/Nomex and
pressboard. All spacers, axial wedges /
runners used in windings are made of
pre-compressed Pressboard-solid. In
cross-over coil winding of HV all
spacers and all axial wedges / runners
are dovetail in shape.
Heavy cellulose sheets are used as
insulation between two phases.
Another insulating material comes in the form of
transformer oil. Axial & Radial cooling ducts in and
between sections of the windings allow the free flow
of oil around the conductors.
In addition to dissipate heat due to losses in a
transformer, insulating oil provides a medium with
high dielectric strength in which the coils and core
are submerged. This allows the transformers to be
more compact, which reduces costs. Oil cannot retain
high dielectric strength when exposed to air or
moisture. Dielectric strength declines with absorption
of moisture and oxygen. These contaminants also
deteriorate the paper insulation. For this reason,
insulating oil is prevented from contacting air. A
conservator with breather is used to pressure
variations resulting from thermal expansion and
contraction of insulating oil.
The two major construction of transformers are
core type and shell type.
CORE TYPE TRANSFORMER
In core type transformer, the magnetic core is
built of laminations to form a rectangular frame
and the windings are arranged concentrically
with each other around the legs or limbs. The
low voltage winding is wound near the core and
high voltage winding is wound over low voltage
winding away from core in order to reduce the
amount of insulation and increase life of it.
SHELL TYPE TRANSFORMER
In shell type transformers the windings are put
around the central limb and the flux path is
completed through two side limbs. The central
limb carries total mutual flux while the side
limbs forming a part of a parallel magnetic
circuit carry half flux.
CORE TYPE
The top and bottom horizontal
portion of the core are called yoke.
The yokes connect the two limbs and
have a cross sectional area equal to or
greater than that of limbs. In a core-
type transformer, half of the primary
winding and half of the secondary
winding are placed round each limb
to reduce the leakage flux.
.
SHELL TYPE
In shell type transformers the cross
sectional area of the central limb is
twice that of each side limbs.
 CORE TYPE SHELL TYPE

1. Easy in design and construction. Comparatively complex.

2. Low mechanical strength due to non-bracing of windings. High mechanical strength.

3. Reduction of leakage reactance is not easily possible. Reduction of leakage reactance is possible.

4. The assembly can be easily dismantled for repair work. It cannot be easily dismantled for repair work.

5. Better heat dissipation from windings. Heat is not easily dissipated from windings since it is
surrounded by core.

6. Best suited for EHV (Extra High Voltage) requirements. Not suitable for Extra High Voltage requirements.

7. Economic and popular in use. Used in welding or high current transformer where more
bracing support to winding is required.
 Our electric power transmission and distribution systems can deliver generated a.c.
energy over long distances economically and efficiently only because of extensive use of
transformers. As the transformers are such vital links in the network they must be very
reliable especially in conditions of lightning and overload including occasional short
circuits and switching surges.
Transformer design is optimized to minimize
manufacturing and operating cost of losses for utility.
The two important design part of transformer are
magnetic core frame and windings.
Core is built with Cold Rolled Grain Oriented low loss
silicon steel laminations.
Winding is made up of high conductivity & soft drawn
E.C. Grade copper or aluminum. Enamel conductors are
double paper insulated. Windings are designed to fulfill
mechanical, thermal and electrical requirements.
Insulation is required in a transformer, wherever a difference in potential exists between two points.

Solid cellulose insulating materials and

transformer oil are mostly used in distribution
transformers. Main and most important
insulation between High and low voltage coils
are pressboard, separator or cooling ducts. A
Pressboard represents a thick insulation paper
made of extremely pure cellulose fiber, suitably
treated in the manufacturing process and then
compacted at very high pressure. All spacers,
axial wedges / runners used in windings are
made of pre-compressed Pressboard-solid.
Diamond Dotted Press-paper (DDP) with epoxy
resin layer being used to insulate adjacent layers
of conductors or foils. Heavy cellulose sheets
are used as insulation between two phases.
d=diameter of circumscribing circle

D=distance b/w centers of adjacent limbs

H=over all height

W=length of yoke =D+a

Hw=height of window

Ww=width of window

a=width of largest stamping

Hy=height of yoke

D=d+Ww

H=Hw+2Hy

Width over two limbs = D+ outer dia of hv

Width over one limb = outer dia of hv

d=diameter of circumscribing circle
D=distance b/w centers of adjacent limbs
H=over all height
W=length of yoke = 2*D + a
Hw=height of window
Ww=width of window
a=width of largest stamping
Hy=height of yoke
D=d + Ww
H=Hw + 2Hy
Width over two limbs = 2*D + outer dia of hv
Width over one limb = outer dia of hv
Width of core = Dy= b
height of yoke Hy= a
length of yoke = W = 2Ww+ 4a
over all height =H = Hw+ 2a