DESIGN OF ELECTRICAL MACHINES UNIT - III D. RAJASEKARAN ASSOC. PROF.

/EEE

UNIT III

TRANSFORMERS
Output Equations – Main Dimensions - KVA output for single and three phase transformers –
Window space factor – Overall dimensions – Operating characteristics – Regulation – No load
current – Temperature rise in Transformers – Design of Tank - Methods of cooling of Transformers.

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DESIGN OF ELECTRICAL MACHINES UNIT - III D. RAJASEKARAN ASSOC. PROF./EEE

OUTPUT EQUATIONS

1. OUTPUT EQUATION OF SINGLE PHASETRANSFORMER

-------------- (1)

-------------- (2)

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------------ (3)
Equating equation (2) and (4), we get

------------- (4)

-------------- (5)
Substituting equations (1) and (4) in equation (5), we get

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---------------- (6)

The equation (6) is the output equation of single phase transformer.

2. OUTPUT EQUATION OF THREE PHASETRANSFORMER

-------------- (7)

Hence the area of copper is taken twice that of single phase core type transformer.

-------------- (8)

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DESIGN OF ELECTRICAL MACHINES UNIT - III D. RAJASEKARAN ASSOC. PROF./EEE

----------------- (9)

Equating equation (8) and (9), we get

---------------- (10)

----------------- (11)
Substituting equations (7) and (10) in equation (11), we get

------------------ (12)
The equation (12) is the output equation of three phase transformer.
The equations (6) and (12) hold good for core and shell type transformers.

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OUTPUT EQUATION – VOLT PER TURN

----------------- (13)

----------------- (14)

Substituting equation (13) in equation (14) we get,

------------------ (15)

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RATIO OF IRON LOSS TO COPPER LOSS

Where

RELATION BETWEEN CORE AREA AND WEIGHT OF IRON AND COPPER

Area of core
Q Gi
Ai =
fBmG c

OPTIMUM DESIGN

1. DESIGN FOR MINIMUMCOST

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Where Ac = k w Aw

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2. DESIGN FOR MINIMUM LOSS OR MAXIMUMEFFICIENCY

WINDOW SPACE FACTOR

The window space factor is defined as the ratio of copper area in the window to total window area.

Conductor area in window AC

KW = =
total area of window AW

It depends upon the relative amounts of insulation and copper provided, which in turn depends upon
the voltage rating and output of transformers. The following formulae may be used for estimating the value
of window space factor.

8
KW= for 20 kVA rating
30 +kV
10
KW= for 50 to 200 kVA rating
30 +kV
12
KW= for 1000 kVA rating
30 +kV

Where kV is the voltage of h.v. winding in kilo-volt.

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DESIGN OF ELECTRICAL MACHINES UNIT - III D. RAJASEKARAN ASSOC. PROF./EEE

DESIGN OF CORE

❖ The core section of core type of transformers may be rectangular, square or stepped.

❖ Shell type transformers use cores with rectangular cross section.

The fig. shows the cross section of transformer cores.

❖ With small size transformers, rectangular core can be used with either circular or
rectangular coils.

❖ With medium size transformers, square core can be used.

❖ With large transformers, cruciform (stepped) cores, which utilize the space better are
used.

❖ The circle represents the inner surface of the tubular form carrying the windings. This
circle is known as the circumscribing circle.

❖ Circular coils are preferred over rectangular coils because of their superior mechanical
characteristics. On circular coils the forces are radial and there is no tendency for the
coil to change its shape. On rectangular coils the forces are perpendicular to the
conductors and tend to give the coil a circular form, thus deforming it. Hence circular
coils are employed in high voltage and high capacity transformers.

Note:

Sf = ki=Stacking factor

By increasing the number of steps, the area of circumscribing circle is more effectively utilized. The
most economical dimensions of various steps for a multi-stepped core can be calculated. The results are
tabulated in table.

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SELECTION OF CORE AREA AND TYPE OF CORE

CALCULATION OF CORE AREA

DESIGN OF WINDINGS

Vp
Number of turns in primary winding T p =
Et
Vs
Number of turns in secondary winding T s=
Et
KVA103
Current in primary winding I p =
Vp

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Ip
Area of each primary winding a p =
p
Is
Area of each secondary winding a =s
s
❖ The current densities in the two windings should be taken equal in order to have
minimum copper losses. i.e.  p = s

❖ In practice, however, the current density in the relatively better cooled outer winding
is made 5 percent greater than the inner winding.

Position of winding relative to the core

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EXAMPLE: 01

Solution

EXAMPLE: 02

Given data

Solution

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EXAMPLE: 03

Given data

Q=400 KVA f=50 Hz φm/AT=2.4 x 10-6 Bm=1.3 wb/m2 δ=2.7 A/mm2

Kw=0.26 single phase core type

Solution

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WINDOW DIMENSIONS

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DESIGN OF YOKE

The entire core is divided into two portions. The vertical portion is called core or limb or leg. The
horizontal portion is called yoke.

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OVERALL DIMENSIONS

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EXAMPLE: 01

Solution

EXAMPLE: 02

Given Data:
Hw/D=2.8 d/D=0.56 Ai/Acc=0.7 δ=2.3 A/mm2
Kw=0.27 f=50 Hz Bm=1.2 wb/m2 D=0.4 m

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DESIGN OF ELECTRICAL MACHINES UNIT - III D. RAJASEKARAN ASSOC. PROF./EEE

Solution

EXAMPLE: 03

Given Data:

Q=200 KVA f=50 Hz D=1.6 a Et=14 V Bm=1.1 wb/m2

Kw=0.32 δ=3 A/mm2 ki=0.9 Ai=0.56 d2 a=0.85 d

Solution

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DESIGN OF ELECTRICAL MACHINES UNIT - III D. RAJASEKARAN ASSOC. PROF./EEE

EXAMPLE: 04

Given Data:

Q=200 KVA Vp=6600 V Vs=440 V f=50 Hz Et=10 V Bm=1.3 wb/m2

δ=2.5 A/mm2 Kw=0.3 H=W ki=0.9 a=0.9 d Ai=0.6 d2

Solution

EXAMPLE: 05

Given Data:
Q=400 KVA f=50 Hz φm/AT=2.4 x 10-6
Bm=1.3 wb/m2 δ=2.7 A/mm2 Kw=0.26 single phase core type
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DESIGN OF ELECTRICAL MACHINES UNIT - III D. RAJASEKARAN ASSOC. PROF./EEE

Solution

EXAMPLE: 06

Given Data:

Q=5 KVA Vp=11000 V Vs=400 V f=50 Hz Ac=KwAw=0.6 Ai

Bm=1 wb/m2 δ=1.4 A/mm2 Kw=0.2 Hw=3 Ww

Solution

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DESIGN OF ELECTRICAL MACHINES UNIT - III D. RAJASEKARAN ASSOC. PROF./EEE

EXAMPLE: 07

Given data
Q=100 KVA Vp=2000 V Vs=400 V f=50 Hz Et=10 V ki=0.9
Bm=1.1 wb/m2 δ=2 A/mm2 Kw=0.33 Hw/Ww=3 b/2a = 2.5
Solution

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EXAMPLE: 08

Given data

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Solution

EXAMPLE: 09

Given data

Solution

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EXAMPLE: 10

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EXAMPLE: 11

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DESIGN OF ELECTRICAL MACHINES UNIT - III D. RAJASEKARAN ASSOC. PROF./EEE

OPERATING CHARACTERISTICS

REGULATION

EXAMPLE: 01

Solution

outside diameter + inside diameter

Mean diameter of l.v winding =
2

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DESIGN OF ELECTRICAL MACHINES UNIT - III D. RAJASEKARAN ASSOC. PROF./EEE

Length of mean turn of l.v. winding = π x mean diameter

Resistance of l.v. winding =

 LmtsTs
as

outside diameter + inside diameter

Mean diameter of h.v. winding =
2

Length of mean turn of h.v. winding = π x mean diameter

L T
mtp p
Resistance of h.v. winding =
ap

 Tp 
2

Resistance of transformer referred to primary = R p= r +p r  s 

Ts

kVA1000
H.V. winding current per phase I p =
3V p

I R
p.u. resistance = p p
Vp

outside diameter of h.v+ inside diameter of l.v.

Mean diameter =
2

Length of mean turn = π x mean diameter

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DESIGN OF ELECTRICAL MACHINES UNIT - III D. RAJASEKARAN ASSOC. PROF./EEE

I R
p.u. leakage reactance = p p
Vp

NO LOAD CURRENT

1. No load current of single phase transformer

KPK = Amplitude factor  2

No load current I0 = I m + I2 2
l

2. No load current of three phase transformer

No load current I0 = I2m + I 2

l

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DESIGN OF ELECTRICAL MACHINES UNIT - III D. RAJASEKARAN ASSOC. PROF./EEE

EXAMPLE: 01

Given Data:

Ep=400 V f=50 Hz μr=1000 li=2.5 m Agi=2.5x10-3 Tp=800

Pi=2.6 W/kg Density of iron=7.8x103 kg/m3 Ki=0.9

EXAMPLE: 02

Given Data:

Ep=6600 f=60Hz Ai=22.6x10-3 m2 lap joint = 4 Specific gravity =7.5x10-3 Kg/m3 li=2.23 m
mmf for joint=1/4 x mmf /m of core mmf / m of core =232 specific loss=1.76 W/kg

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DESIGN OF ELECTRICAL MACHINES UNIT - III D. RAJASEKARAN ASSOC. PROF./EEE

EXAMPLE: 03

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TEMPERATURE RISE IN TRANSFORMERS

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DESIGN OF TANK AND COOLING TUBES OF TRANSFORMER

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Let b = 70 mm

Let l = 90 mm

Where H = Height of transformer frame and

h = clearance (height) between the assembled transformer and thetank
= clearance at base + oil height above the assembled transformer + space for terminals and tap
changing gear
Let h = 50 mm + 300 mm + 300 mm =650 mm
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EXAMPLE: 01

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DESIGN OF ELECTRICAL MACHINES UNIT - III D. RAJASEKARAN ASSOC. PROF./EEE

EXAMPLE: 02

Specific heat dissipation due to radiation and convection is respectively 6 and

6.5 W/m2-0c. Assume that convection is improved by 35 percent due to provision of
tubes.

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DESIGN OF ELECTRICAL MACHINES UNIT - III D. RAJASEKARAN ASSOC. PROF./EEE

EXAMPLE: 03

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DESIGN OF ELECTRICAL MACHINES UNIT - III D. RAJASEKARAN ASSOC. PROF./EEE

Given data:

kVA=1000 Vp=6600 V Vs=440 V f=50 Hz 3 phase λcon=6.5 W/m2 - 0C

De=0.44 m H=1.24 m Pi=3.7 kW Pc=10.5 kW θ=350 C λrad=6 W/m2 - 0C
D=0.47 m Improvement in cooling =35 %

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DESIGN OF ELECTRICAL MACHINES UNIT - III D. RAJASEKARAN ASSOC. PROF./EEE

Total number of cooling tubes provided =160

They are arranged as 3 rows on widthwise with each row consisting of 20, 19 and 20 tubes and 3
rows on lengthwise with each row consisting of 8, 7 and 6 tubes.

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COOLING OF TRANSFORMERS

METHODS OF COOLING OF TRANSFORMERS

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DESIGN OF ELECTRICAL MACHINES UNIT - III D. RAJASEKARAN ASSOC. PROF./EEE

TWO MARKS QUESTION AND ANSWERS

01

02

03

04

05

06

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07

08

8a

09

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10

11

12

13

14

15 What are the advantages of using higher flux density in the core?
1. Reduction in core and yoke section for same output.
2. Reduction in mean length of LV and HV turns, resulting in saving of copper
material, reduced over all size and weight of transformer.

16 List various disadvantages of using higher flux density in design of core

1. Increased magnetizing current and iron losses,
2. Saturation of magnetic material,
3. Lower efficiency, because of higher no load losses, higher temperature rise of
transformer.

17 Name a few insulating materials that are used in transformers.

Press board, cable paper, varnished silk, transformer oil, porcelain, insulating
varnish

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DESIGN OF ELECTRICAL MACHINES UNIT - III D. RAJASEKARAN ASSOC. PROF./EEE

18 State the disadvantages of 3 phase transformers over single phase transforemer.

1. It is more difficult to transport a 3 phase transformer as the weight per

unit is more.
2. In the event of a fault in any phase of a 3 phase transformer, the fault is
transferred to the other two phases. Therefore, the whole unit needs
replacement.

19 State the advantages of colled rolled grain oriendted (CRGO) stell used for magnetic
circuits of transformer.

1. Magnetic induction is maximum and the loop of BH curve is large.

2. Core loss during no load operation of transformer is low.
3. Reactive power input at no-load operation of the transformer is low.
4. Magnetostriction is low.
5. Good mechanical properties.

20 Write the relation between core area and weight of iron and copper for a single phase
transformer.
Q Gi
Area of core Ai =
fBm G c
21 Why is the core of a transformer laminated?

Eddy current loss can be reduced by core of thin laminations. Hence the core
of transformer core is laminated.
22 Explain the concern while doing the design of distribution transformer.

(i) The distribution transformers are designed to have low iron loss and
higher copper loss.
(ii) The distribution transformers are designed to have the maximum
efficiency at a load much lower than full load (about 50 percent).
(iii) The distribution transformers should have a good voltage regulation
and therefore they should be designed for a small value of leakage
reactance.

23 m
Explain the significance of the ratio r = in the design of transformer.
AT

Transformers may be designed to make one of the following quantities as

minimum. (i) Total volume (ii) Total weight (iii) Total cost (iv) Total losses.

All these quantities vary with the ratio r = m . If we choose a high value of r, the flux
AT
becomes larger and consequently a large core cross-section is needed which results in
higher volume, weight and cost of iron and also gives a higher iron loss. On the other hand,
owing to decrease in the value of AT the volume, weight and cost of copper required
decrease and also the copper losses decreases. Thus we conclude that the value of r is
controlling factor for the above mentioned quantities at the time of design of transformer.
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DESIGN OF ELECTRICAL MACHINES UNIT - III D. RAJASEKARAN ASSOC. PROF./EEE

24 List out the advantages and disadvantages of stepped cores.

Advantages:
For same area of cross-section the stepped cores will have lesser diameter of
circumscribing circle than square cores. This results in reduction in length of mean turn of
the winding with consequent reduction in both cost of copper and copper loss.

Disadvantages:
With large number of steps a large number of different sizes of laminations
have to be used. This results in higher labour chargers for shearing and assembling
different types of laminations.

25 What an empirical relation which is normally used for the estimation of window space
factor in the design of transformer.

8
K = for transformer of about 20kVA rating

30 +kV
10
K = for transformer of rating between 50 to 200 kVA rating

30 +kV
12
K = for transformer of about 1000 kVA rating

30 +kV

where kV is the voltage of h.v winding in kilo-volt.

26 State the reason for preferring circular coils in comparison to rectangular coil in
transformer windings.

The excessive leakage fluxes produced during short circuit and over loads
develop severe mechanical stresses on the coils. On circular coils these forces are radial
and there is no tendency for the coil to change its shape. But on rectangular coils the force
are perpendicular to the conductors and tends to deform the coil in circular form.

27 Top and bottom surfaces of the transformer tank are not considered for the design of
cooling tubes for transformer. Why?

The area of top and bottom surfaces of the transformer tank are not
considered for the design of cooling tubes, as it has very little cooling effect.

28 Define window space factor used in the design of a transformer.

The window space factor is defined as the ratio of copper area in the window
to total window area.
Conductor area in window Ac
K = =
total area of window A

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DESIGN OF ELECTRICAL MACHINES UNIT - III D. RAJASEKARAN ASSOC. PROF./EEE

29 What are the advantages of three phase transformers over single phase transformers.

1. A 3 phase transformer is lighter, occupies lesser space, cheaper and more efficient
than a bank of single phase transformers.
2. The installation and operational costs are smaller for 3 phase units.

30 The voltage/ turn of a 500 kVA, 11 kV/415 V, Delta/Star, 3 phase transformer is 8.7 V.
Calculate the number of turns per phase of LV and HV windings.

31 Draw the cruciform section of the transformer core and give the optimum dimensions in
terms of circumscribing circle diameter ‘d’.

32 Distinguish between shell type and core type transformer.

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DESIGN OF ELECTRICAL MACHINES UNIT - III D. RAJASEKARAN ASSOC. PROF./EEE

33 State different losses in a transformer.

The losses in a transformer are of two types namely

(i) Core or iron losses
The core losses consist of hysteresis and eddy current losses and occur in the
transformer core due to the alternating flux.

(ii) Copper losses

These losses occur in both the primary and secondary windings due to their
ohmic resistance.

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