International Journal of Scientific Research in Engineering and Management (IJSREM)

Volume: 05 Issue: 06 | June - 2021 ISSN: 2582-3930

Design and Simulation of Temperature Rise in a Distribution Transformer

Nikhil, Priya Nayak, Rahul Kumar, Shravan B.A. 1, T.V. Ramaswamy2, Sreevidya T.R.3
1
B.E. Students, Department of Electrical and Electronics Engineering, DSCE
2
Transformer Designer, Sara Consultants, Bengaluru – 19
3
Assistant Professor, Department of Electrical and Electronics Engineering, DSCE

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Abstract - A Distribution Transformer is a vital component now is overheating. Hence, it is important that we constantly
of a power system setup, providing the final consumer-friendly monitor these parameters to ensure proper functioning of the
voltage to a household/industry, based on the demand of the transformer.
consumer. The fabrication of these distribution transformers
must be performed with intricate care and meticulous attention The major goal to be accomplished with this process is to
to the selection and assembly of each and every component design a satisfactorily rated distribution transformer from
involved. As these transformers are expected to survive for a scratch, which involves a multitude of steps and procedures
duration of at least 20-25 years, monitoring the vital parameters which need to be executed as efficiently as possible. Another
of the transformer is crucial in understanding the health and goal is to simulate the effect of overloading a practically rated
functional capabilities of the transformer. Hence, it is of the transformer, so as to observe the adverse heating effects that can
utmost importance that these parameters are monitored on a originate in each individual component of the transformer,
constant basis and that these values are transmitted to an off-site which acts as a good lead to practically control the heating
moderator as efficiently as possible. This paper focuses on the adversities observed in a real-time transformer.
design of a practically rated distribution transformer from
scratch, which involves the individual design of each and every
component involved within the transformer. Meticulous 2. SPECIFICATION AND DESIGN OF THE
attention is also paid to the actual fabrication of the transformer TRANSFORMER
itself, sufficing the required parameters specified during the
design process and being capable of handling a practical load. A The railway is a large power consumer that can cause
simulation of the temperature rise within the transformer is uneven loading of the phases in the high voltage grid. This
performed to demonstrate the adverse effects and significant uneven loading by the utility may lead to voltage and current
impact of higher values of temperature on a practical distribution imbalance in the system and thereby affect other consumers
transformer. connectedto the same network.
A three-phase power system is said to be balanced or
Key Words: connection, system overloading, PROTEUS symmetrical, if the voltages and currents have the same
amplitude and each phase has a phase difference of 120°.
Otherwise, it is termed an asymmetrical or unbalanced power
1. INTRODUCTION system. A perfectly symmetrical power system does not occur
due to some internal effects such as mutual coupling.
Voltage unbalance occurs mainly due to unbalanced currents
Distribution Transformers are a key part of a Power System at the points of common coupling drawn by unevenly distributed
setup as they help to step down the high voltages transmitted by loads. Due to a significant amount of negative sequence current
the transmission lines to lower voltage values (of about 440V) being injected into the system, the power systemcomponents will
and provide it for domestic/consumer use. Distribution suffer from consequent negative effects such as overheating,
Transformers can be mounted in multiple ways depending on additional losses of lines and transformers, interference with
the site it is being installed at and the use-case for the communication systems etc.
transformer itself (some examples are – pole-mounted, In order to reduce the effects of unbalance, several
underground vaulted, etc.,). With an increase in demand/load, techniques can be applied depending upon the technological
the number of distribution transformers being installed has justification. A basic solution would be to distribute the loads
increased exponentially. Hence, it is important to ensure the evenly between the different phases. However, this method
health/working condition of the transformer itself, as it is of vital alone will not be sufficient due to the different traffic intensity
importance to keep functioning for the power system to be occurring at each substation. The possible solutions can be
operational. [1] categorized into two different types. First one is based on
transformer connections, i.e., passive solutions. There are
There are multiple parameters that influence the working of various types of specially connected transformers being
a distribution transformer (or any transformer) in its lifespan. employed in the railway substation, such as Scott transformer,
However, the three main factors that majorly influence V-V transformer, Leblanc transformers etc., and each
efficient functioning of a transformer are - Voltage, Current and connection has its own influence on treating the imbalance.
Temperature. Other parameters like oil level, oil quality, These transformers are widely used in electrified railway
overloading, etc., although aren’t the major parameters systems as a load balancer.
influencing the functioning of a transformer, do have a Electrification of a railway line implies that the line can be
significant impact on the functioning of the transformer. The operated by electric trains apart from diesel. Electrification
biggest issue/plight that a distribution transformer can face right involves large investments compared to diesel but operating
© 2021, IJSREM | www.ijsrem.com | Page 1
 International Journal of Scientific Research in Engineering and Management (IJSREM)
Volume: 05 Issue: 06 | June - 2021 ISSN: 2582-3930

costs are lower, as propulsion and maintenance are cheaper. The ● Primary Turns:
second one is based on controllable high voltage power The primary turns are given as the ratio of primary voltage
electronic equipment, i.e., active solutions such as Conventional to volts per turn i.e.,
( )
which here are ≈
.
Static Var Compensators (SVC) or Voltage Source Converters
(this part is not within the scope of this paper. 489 Turns

● Volts/Turn (Actual) Actual volts per turn is given by the

Table -1: Specifications of the designed transformer
formula: = = 0.84867 V
Transformer
Sl. No. Description/Value ● Secondary Turns:
Parameter
Similarly, the secondary turns are given as the ratio of
1 Input Voltage 415V secondary voltage to volts per turn
( )
, which
2 Output Voltage 230V here will be ≈ 272 Turns
.

Number of ● Core Area: We know that the emf generated in the core is
3 Single-Phase given by the formula e = 4.44×B×A×N×f×10⁻⁶(Where A is
Phases
in 𝑚𝑚 and B is in T)
4 Vector Group Ii0
= 4.44×B×A×f×10⁻⁶
Core-Type
construction with 2
0.84867 = 4.44×1× A×50×10⁻⁶
Type of limbs/ Each limb
5
Construction carries 50% of .
A= x 10⁻⁶ = 3828.84𝑚𝑚 ≈ 3828𝒎𝒎𝟐
primary and . × ×
secondary windings
6 Capacity 2KVA
● Gross Area: Here the gross area which will be available is
Conductor Used Aluminium with given by
7
for Windings super-enamel coating = = 4253.3𝒎𝒎𝟐
. .

Cold-Rolled Non-
 Stacks used: 40×100
8 Core Material Grain Oriented
Silicon Steel
2.1 Primary Design -
9 Total Weight 25 kg The design process of the primary windings of the transformer
involves the calculation of the primary current, the inner and
These parameters are chosen in order to design a transformer outer dimensions, along with the total weight of conductors
capable enough to replicate the characteristics of a practically and insulators used for the primary winding. Here, we use
utilized transformer [2] while being small enough to perform aluminum with a super-enamel coating as the conductor and
various tests on it to determine the adverse heating and insulator material respectively.
overloading effects that occur during a transformer’s lifespan. To design the primary side or the LV side of the transformer
we have the following data:
Once the specifications are finalized, the design process is
Rating = 2KVA = 2000VA
commenced. The designing of the Transformer involves the
calculation of multiple parameters of the transformer. It is of Voltage = 415V
utmost importance that it is carried out as accurately as
possible so that it doesn’t affect the manufacturing process and Current = = 4.82A
the transformer fabricated can meet the desired specifications.
Turns/phase = 488

Conductor size:
 Volts/Turn
To determine the volts per turn required for each winding, Choose a current density of 1.5A/𝑚𝑚 for oil cooled
we use the formula which is given by –
Diameter is calculated by the formula given below
Volts/turn = k√𝑲𝑽𝑨 (where, k = 0.3 - 0.7 for oil cooled
transformer) A=

Choosing k = 0.6, we get . ×

d2 =
Volts/turn = 0.6√2
d = 2mm (bare) = 2.1mm (insulated)
= 0.8485 ≈ 0.849 Volts/turn
© 2021, IJSREM | www.ijsrem.com | Page 2
 International Journal of Scientific Research in Engineering and Management (IJSREM)
Volume: 05 Issue: 06 | June - 2021 ISSN: 2582-3930

The insulation used for this conductor is super enamel - 5.8𝒎𝒎𝟐 =

polyimide amide, dual coating. The inner coating expands and
contracts with the conductor itself, while the outer coating
d = 2.717mm (Bare) ≈ 2.8mm (Insulated)
provides the necessary insulation to the conductor.
.
No. of limbs here are 2, Turns per limb are = 244 Cross section = = 5.725
Number of layers = 5 .
i.e., Turns per layer 49×4 and 48 turns in last layer Current density x 1.519 ≈ 1.52A/mm
.
Winding length = (49 + 1) × 2.1 = 105mm
End clearance will be 2 × 10mm The winding length of the secondary winding should be equal
Window height = 105 + (2 × 10) = 125mm to or less than the inner winding, so we get Secondary turns as
Inter layer insulation = 2mil of mylar = 0.0508mm 272.
Radical thickness of primary=(2.1×5) + (5× 0.0508) = 11mm
Core inner dimension = 40×100 And, Turns per limb as = 136 turns
Core to primary clearance = 3.5 + 3 = 6.5mm
Inner dimension of primary is (40 + (6.5×2)) + (100 + (6.5×2)) Therefore, Turns per layer = =1
= 53×113 mm²
Outer dimension of primary is (53 + (11×2)) + (113 + (11×2))
= + 1 ≈ 36
= 75×115 mm² .

Length of one turn (LMT) = [ + ] × 2 = 376mm =

Number of turns = ≈ 4 turns
0.376m
Wire length = LMT × turns/limb × 2 + tolerance (1%) = To make the windings uniform, we take 34×4 turns
0.376 × 244 × 2 × 1.01 (tolerance) = 186m
Resistance /phase at 75° (𝑹𝟕𝟓° ) is given by the formula Winding length = 100mm (35×2.8)
⍴×
(⍴= 0.0346 for Al at 75°)
. × × × End clearance = 12.5mm
𝑹𝟕𝟓° = (here A = = 3.14𝑚𝑚 )
𝑹𝟕𝟓° =
. × . ×
= 1.01Ω Radial thickness = (2.8×4) + (3×0.0508) = 11.352mm ≈
. 12mm
𝑹𝟐𝟖° = 𝑹𝟕𝟓° x
= 1.01 x Outer dimension = (87 + (12 × 2)) × (147 +(12×2)) =
111×171 mm²
= 0.8517Ω ≈ 0.852Ω
Bare weight of the conductor is given as the product of volume
Length of one turn (LMT) = [ + ]×2 = 516mm =
and density i.e., Volume ×Density
= L×A×Density 0.516m
= LMT×224×2×3.14×2.703×10⁻³ Kg
Wire length = LMT×turns/limb×2 + tolerance (1%) =
= 1.56Kg
0.516×136×2×1.01 (tolerance) = 142m
( . ) ( ) .
Insulated weight = ( )
× + 1 x 1.56 Resistance /phase at 75° (𝑹𝟕𝟓° ) =
⍴×
(⍴= 0.0346 for Al at 75°)
.
= 1.66Kg ≈1.7Kg ×1.1(Tolerance) ≈ 1.8Kg
The density of the core used is= 7.65g/cc. =
. × ×

These are the various parameters required to be calculated for

the primary/LV region of the distribution transformer. . × . ×
= = 0.43Ω
.
2.2 Secondary Design -
𝑹𝟑𝟎° = 𝑹𝟕𝟓° ×
The secondary/HV design follows the same procedure as the
primary design, wherein the inner dimensions of the entire = 0.43× = 0.3655Ω
winding, the diameter of the windings used and the length of
the wire used is determined.
Bare weight as we know is the product of volume and density
To design the secondary side or the HV side of the transformer i.e., volume ×Density
we have the following data:
= L×A×Density
Inner dimension of secondary (75+(6×2))×(135+(6×2)) =
= LMT×136×2×5.725×2.703×10⁻³ Kg
87×147
= 2.18Kg
Secondary current = ≈ 8.7A
( . ) ( . ) .
. Insulated weight = ( . )
× + 1 ×2.18
.
Cross section = ≈ 5.8 mm²
.

© 2021, IJSREM | www.ijsrem.com | Page 3

 International Journal of Scientific Research in Engineering and Management (IJSREM)
Volume: 05 Issue: 06 | June - 2021 ISSN: 2582-3930

= 2.29Kg ×1.01(Tolerance) ≈ 2.32Kg Core clamp = 40×40 L-angle clamps for core
Length = 275×4 = 1100mm = 1.1m
2.3 Core Design - Weight with additional 1% tolerance factor=1.1×2.4=2.64 Kg
For the core of the transformer, Cold-Rolled Non-Grain
Oriented (CRNO) silicon steel is utilized, as it helps
minimizing core losses. In the design process of the core, the
core weight along with the losses observed in the transformer
are evaluated.

Cross-section of core will be 4 ×100 with 95% reduction

= 4 ×100×0.95 = 3800𝒎𝒎𝟐

Weight of the core is given as the product of length, area, and

density = 570 ×3800 ×765×10⁻⁶ = 16.6Kg
Core loss = Core Weight×Specific Loss×Build Factor
= 16.6×3×1.3
= 65W
Primary Load Loss as we know is denoted by 𝑃 and given by
𝑃 = 3×I² R = 3×4.82²×1.01 = 71W Fig 2- Illustration of the designed tank, along with the core.
Secondary load loss: 𝑃 = 3×I² R = 3×8.7²×0.43 = 98W
Once all the calculations for all the parts of the transformer are
Total loss is given by the sum of primary and secondary load concluded, the design sheet is provided to the manufacturer to
loss, core loss, and stray or tank loss(2W/KVA), which will be fabricate the transformer. These parameters are vital to a
- PL(Total) = 71 + 98 + 65 + 6 = 240W manufacturer to efficiently manufacture the transformer to the
required specifications of the designer.

The fabricated transformer has a fiberglass nameplate with

multiple sensors connected internally to the primary,
secondary windings and the core.

Fig 1- 2-Dimensional view of the designed core.

2.4 Tank Design -

The entire transformer must be placed in a tank capable enough

Fig. 3 - Front view of the fabricated transformer
to occupy the entire construction, along with some headroom
for any additional accessories or oil that might be poured into
it to cool the transformer unit. 3. SIMULATION OF TEMPERATURE RISE IN A

To design the tank, certain parameters like depth, capacity, and TRANSFORMER
oil in the tank are to be formulated which is done as shown In a practical temperature rise test of the distribution
below - transformer, the transformer would be connected to a
sinusoidal 415V source, with a variable load of 8A, capable of
Depth of tank: 171 + (2×20) = 211mm ≈ 215mm reaching 10A connected to it. This setup would help us
practically observe the hotspots that might be created within
Capacity of tank: l×b×h (dm³) = 2.75×2.75×2.15=16.2 Litres
the core as well as in the windings of the transformer. This
. ( ) . . . phenomenon can also be simulated to an extent to provide
Displacement: + + = 3.89 ≈ 4 Litres satisfactory details regarding the temperature rise in the
. ( ) . .
distribution transformer.
Oil in tank = Capacity - Displacement =16.2-4=12.2≈13 Litres

© 2021, IJSREM | www.ijsrem.com | Page 4

 International Journal of Scientific Research in Engineering and Management (IJSREM)
Volume: 05 Issue: 06 | June - 2021 ISSN: 2582-3930

To simulate a highly rated distribution transformer

environment, the Proteus Design Studio software was utilized
[3], which provides the essential tools needed to simulate the
temperature rise that can occur in the fabricated distribution
transformer. The Proteus Suite is available in multiple
configurations, depending on the design and simulation that
one wishes to achieve. For our test case, we utilized the
Schematic Capture and Microcontroller Simulation libraries to
get the necessary components for the test.

Fig. 5 - Circuit diagram of the simulation setup in Proteus

Once the circuit diagram is completed, the following steps

are followed to simulate the transformer setup -
1. First, the ideal transformer is connected to the
sinusoidal AC source on the primary side, while the
voltage and current sensors are connected on the
Fig. 4 - The Proteus Design Studio Environment
secondary side.

Initially in the Proteus environment, the design sheet is set up 2. The LM35 temperature sensor is also connected on
by specifying the libraries needed for the simulation. Once the the secondary winding, which receives its 5V supply
design sheet is initialized, the required components can be from the Arduino board.
picked up from the Component Mode menu on the left-hand
side of the design sheet. 3. A 30 ohms variable load, drawing a current between
8-10A is finally connected to the transformer. On
The components used for the simulation were as follows - completion of the circuit, the design is saved and is
ready to be simulated.
● The transformer used was a 415/230V, single-phase, ideal
transformer with 1.75 turns ratio. 4. As the temperature rise within the transformer is
gradual and takes some time to be reflected on the
● A sinusoidal AC input source of 415V. sensor, the simulation is run for a duration of 15-20
minutes
● A typical voltage sensor and current sensor were
connected in parallel and series respectively. 5. Now, the simulation is made to run, and the
temperature values from the sensor are obtained at
● An LM35 Sensor was connected to the secondary winding an interval of 30 seconds per reading. This interval
of the transformer, which received its supply from an is specified so as to get accurate readings from the
Arduino Uno board, powered by a 5V source. sensor and not overload it constantly, which might
tamper the readings delivered by it.
● A 30-ohm resistor was used as the load, which drew a
current between 8-10A on varying it. This is crucial to 6. Finally, the obtained temperature values are noted
simulate the practical temperature rise occurring on the down and compared with the corresponding
transformer. variation in load which led to its rise.
● A virtual terminal was also connected to visualize the 7. The temperature results obtained after the
temperature values obtained from the LM35 current completion of the simulation were as follows -
sensor. [4]. After the completion of the selection and
configuration of the components needed for the
simulation, all the components are connected as per the
circuit diagram represented below. The LM35 sensor gets
its input from the Arduino board itself, which has a neat
provision of an in-built power source to boot it up during
the simulation. The virtual terminal is also interfaced with
the Arduino itself to get the necessary temperature
readings.

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 International Journal of Scientific Research in Engineering and Management (IJSREM)
Volume: 05 Issue: 06 | June - 2021 ISSN: 2582-3930

3. CONCLUSIONS
The preservation of the health of distribution transformers
is a necessary action that needs to be looked into way more
than the current-day scenario [6]. The ultimate denouement
we hope to present through this paper is to provide a
practically designed transformer, to demonstrate the
overloading and heating effects observed within the
transformer using modern-day software tools.

The simulation of the temperature rise occurring within the

transformer provides us significant information on the
impact of temperature hotspots forming within the
transformer, which in turn inhibits the performance of the
transformer and deteriorates the components within,
thereby reducing the life span of the transformer. Overall,
we aim to present a practically designed transformer
capable of handling practical loads and to provide a picture
on the adverse effects that heat has on the health of a
distribution transformer.

ACKNOWLEDGEMENT
Fig. 6- The temperature readings obtained after the
completion of the simulation The success and final outcome of this paper required the
guidance and assistance of many people. we would like to
use this opportunity to express a few words of appreciation
to everyone who have been a part of this paper right from
Table -2: Specifications of the designed transformer
its inception. Without their support, patience and guidance,
Load Secondary this task would not have been completed. It is to them we
Temperature (℃) owe our deepest gratitude.
Current (A) Voltage (V)

8.0 27.34 230 We express our gratitude to T.V Ramaswamy, Transformer

Designer, Sara Consultants for providing valuable insights,
8.2 33.20 230 making the resources available at right time and all the
encouragement for the completion of our paper.
8.8 39.06 230

9.1 45.90 224 We owe our profound gratitude to Sreevidya T.R, Assistant
Professor, Department of Electrical and Electronics
9.5 52.25 220 Engineering, Dayananda Sagar College of Engineering,
who took keen interest in our work and guided us all along,
9.7 59.08 214
providing all the necessary information and references.
10.0 64.45 210
REFERENCES
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Distribution-Transformers-
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transformer even as much as 40% more than its rated value Industry.html?utm_source=GNW
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on the impact of temperature on a practical distribution Technologies (ICECCT)
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 International Journal of Scientific Research in Engineering and Management (IJSREM)
Volume: 05 Issue: 06 | June - 2021 ISSN: 2582-3930

5. “Short-Term Overloading of Power Transformers” -

Nawzad Rashid, Royal Institute of Technology, June
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nsformer+Market%2c+2020-
2026&utm_exec=joca220gnomd

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