2021

SCHOOL OF ELECTRICAL, ELECTRONIC AND COMPUTER

ENGINEERING

ENEL4EA TRANSFORMER DESIGN REPORT

Group : 02
Group Members : Likhabiso Lempe (219012258)
: Amanda Ngwenya (217037822)
: Sabelo Shezi (218002588)
: Siphesihle Nkosi (217012929)

Course : Electrical Design 3

Code : ENEL3EA
Title : Transformer Design

Due Date: Friday, 04 June 2021

DECLARATION
Group 2 members of Electrical Design 3, hereby declare that the provided information in the
report has not being plagiarized or copied with citation
Student Name Student Number Signature Date
Siphesihle Nkosi 217012929 S.I Nkosi 4 June 2021
Amanda Ngwenya 217037822 A.P Ngwenya 4 June 2021
Likhabiso Lempe 219012258 L.L Lempe 4 June 2021
Sabelo Shezi 218002588 S. Shezi 4 June 2021

Abstract
This report discus the design of a three-phase core type distribution transformer rate 11kV/400V,
25kVA plane tank, 50Hz star-delta connected. The type of a transformer to be designed is a step-
down transformer whereby the amount by which the voltage is stepped down depends on the turn’s
ratio. The relevant theoretical background and the design of the transformer is discussed.

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Contents
Abstract .......................................................................................................................................................... i
Nomenclature ............................................................................................................................................... v
1. Introduction .............................................................................................................................................. 1
2. Literature review ....................................................................................................................................... 2
2.1. Background history of transformer ................................................................................................... 2
3. Principle of operation ............................................................................................................................... 3
3.1. What is an Electric Transformer? ....................................................................................................... 3
3.2. Main part constructing a transformer ............................................................................................... 4
3.3. Classification of Transformers ........................................................................................................... 6
4. Construction of a transformer .................................................................................................................. 7
5. Types of transformers ............................................................................................................................... 9
6. Three phase transformer connections...................................................................................................... 9
7. Losses in Transformer ............................................................................................................................. 10
7.1. Core Losses or Iron Losses ............................................................................................................... 10
7.2. Copper Loss in Transformer ............................................................................................................. 11
8. Efficiency of Transformer ........................................................................................................................ 11
9. Transformer protection and maintenance ............................................................................................. 11
10. Design of the Transformer .................................................................................................................... 12
Design Specification ................................................................................................................................ 12
Core design ............................................................................................................................................. 12
Yoke Section ............................................................................................................................................ 14
Overall dimensions ................................................................................................................................. 15
Design of windings (star-delta connection) ............................................................................................ 15
Selection of conductor for LV winding (Secondary)................................................................................ 16
HV Winding ............................................................................................................................................. 16
Resistance of HV and LV.......................................................................................................................... 18
Reactance and Impudence...................................................................................................................... 19
Voltage regulation................................................................................................................................... 20
Copper and core Losses .......................................................................................................................... 22
Efficiency ................................................................................................................................................. 22
Equivalent circuit of a transformer ......................................................................................................... 22
Phasor diagram of a transformer............................................................................................................ 23

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11. Conclusion ............................................................................................................................................. 25
References .................................................................................................................................................. 26
Appendix 1 (Siphesihle Nkosi 217012929).................................................................................................. 28
Three phase core type distribution Transformer Calculations ................................................................... 28
Core design ............................................................................................................................................. 28
Yoke design ............................................................................................................................................. 30
Overall dimension ................................................................................................................................... 31
Design of windings .................................................................................................................................. 31
Selection of conductor for LV winding (Secondary)................................................................................ 32
HV Winding ............................................................................................................................................. 33
Appendix 2 (Amanda Ngwenya 217037822) .............................................................................................. 35
Methodology............................................................................................................................................... 35
Core Design ............................................................................................................................................ 35
3-phase core type transformer ............................................................................................................... 35
Calculating the diameter of the circumscribing circle ............................................................................ 39
Window Dimensions: .............................................................................................................................. 40
The current density ............................................................................................................................. 40
Window factor .................................................................................................................................... 40
Calculating Window Dimensions deign :................................................................................................. 40
Yoke Design ............................................................................................................................................. 41
Overall Dimension ................................................................................................................................... 42
Design of the winding ............................................................................................................................. 43
Voltage calculation: ............................................................................................................................ 43
Current calculation.................................................................................................................................. 44
Primary winding.................................................................................................................................. 44
Conductor calculation ......................................................................................................................... 44
Space between HV windings and yoke ................................................................................................... 45
Appendix 3 (Lempe Likhabiso 219012258) ................................................................................................. 46
Design calculations.................................................................................................................................. 46
Core Design: ............................................................................................................................................ 46
Flux in the core:....................................................................................................................................... 46
Calculating Core Area:............................................................................................................................. 47
For two stepped core: ............................................................................................................................. 47

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 Design of windings (star-delta connection): ........................................................................................... 50
High Voltage calculations: ....................................................................................................................... 53
Appendix A .................................................................................................................................................. 56
APPENDIX C PROOF ..................................................................................................................................... 59

iv
Nomenclature
SYMBOL DESCRIPTION

𝐸𝑡 Voltage per turn

∅𝑚 Maximum flux

𝐴𝑖 Net core area

𝐵𝑚 Maximum flux Density

𝐴𝑔𝑖 Gross Core Area

𝑑 Inner Diameter

𝐷 Outer Diameter

𝐾𝑊 Window Space Factor

𝐴𝑤 Area of Window

𝐻𝑊 Height of Window

𝑊𝑊 Width of Window

𝑉𝐿 Line Voltage

𝐼𝐿 Line Current

𝐼𝑝ℎ𝑎𝑠𝑒 Phase Current

𝐾𝑖 Stacking factor

𝑉𝑝ℎ𝑎𝑠𝑒 Phase Voltage

𝑉𝑃 Voltage at Primary Winding

𝑉𝑆 Voltage at Secondary Winding

𝐼𝑃 Current at Primary Winding

𝐼𝑆 Current at Secondary Winding

𝑁𝑆 Number of turns in Secondary Winding

𝑁𝑃 Number of turns in Primary Winding

𝑡 Insulation Thickness

𝑅0 Initial Resistance

𝑅 Final Resistance

𝑙 Length of windings

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 𝜌 Resistivity

𝛿 Current Density

𝛼 Temperature Coefficient

𝑇0 Initial Temperature

𝑇𝐹 Final Temperature

𝑅𝐿𝑉 Resistance at the low voltage side

RHV Resistance at the high voltage side

PHV Copper Loss at high voltage winding

𝑃𝐿𝑉 Copper loss at low voltage winding

𝑋𝑚 Magnetizing Inductance

𝑋1 Primary Inductance

𝑋2 Secondary Inductance

𝑋𝑒𝑞 Equivalent Inductance

𝑅𝐶 Core Resistance

𝑅1 Primary Resistance

𝑅2 Secondary Resistance

𝑅𝑒𝑞 Equivalent Resistance

𝑋′𝑚 Magnetizing resistance referred to primary

𝑅𝐶′ Core Resistance referred to primary

𝑍𝑒𝑞 Equivalent Impedance

𝐼𝑆′ Secondary Current Referred to primary

𝑉𝑆′ Secondary Voltage Referred to primary

𝑉𝑅 Voltage Regulation

𝑃𝐹 Power Factor

𝑃𝑜𝑢𝑡 Power Output

𝜂 Efficiency

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1. Introduction
A transformer is a static electric device that uses the phenomenon of Faraday’s law of electro-
magnetic induction to change the values of alternating current and voltage for transmission and
distribution of electricity. An asymmetrical current in one coil of the transformer produces a
varying magnetic flux, which, in turn, induces a varying electromotive force (emf) or "voltage"
across a second coil wound around the same core. Electric power can be shifted between the two
coils, except a metallic connection within the two circuits. Faraday’s law of induction discovered
in 1831 stated the induced voltage upshot in any secondary coil due to changing magnetic flux
laceration it. Three phase transformers are used to step-up or step-down the high voltages in
different stages of power transmission system. Transformers are used to increment or decrements
the alternating voltages in electric power applications. Since the discovery of the first constant
potential transformer in 1885, transformers have become requisite for the transmission,
distribution, and utilisation of alternating current electrical energy (Wang, et al., 2007).
It is possible either to decrease or increase the voltage and currents by the use of transformer in
AC circuits based on the requirements of the electrical equipment or device or load. Various
applications use wide variety of transformers including power, instrumentation and pulse
transformers. Transformers are categorized into two types, namely, electronic transformers and
power transformers. Electronic transformers operating voltages are very low and are rated at low
power levels. The term power transformer is referred to the transformers with high power and
voltage ratings. These are extensively used in power generation, transmission, distribution and
utility systems to increase or decrease the voltage levels. However, the operation involved in these
two types of transformers is same (Electrical 4U, 2020).
A wide range of transformer designs come together in electronic and electrical power applications.
Transformers range in province form RF transformers less than a cubic centimetre in volume to
units interconnecting the power grid weighing hundreds of tons. Three phase transformers are used
to step-up or step-down the high voltages in different stages of power transmission systems. The
power generated at different generating stations is in three phase nature and the voltages are in the
range of 13,2kv or 22kv. In order to minimise the power loss to the distribution end, the power is
transmitted at any higher voltages like 132 0r 400KV. Hence, for transmission of the power at high
voltages, three phase step-up transformers are used to rise the voltage. Also, at the end of the
transmission or distribution, these high voltages are step-down to levels 0f 6600, 400 ,230 volts.
For this, three phase step-down transformers are used. Three phase transformers can be constructed
in two ways: a bank of three single phase transformer or single unit of three phase transformer.

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2. Literature review
2.1. Background history of transformer
Electromagnetic induction, the principle of the operation of the transformer, was discovered
independently by Michael Faraday in 1831 and Joseph Henry in 1832 [1]. Only Faraday
furthered his experiments to the point of working out the equation describing the relationship
𝑑𝜙𝐵
between EMF and magnetic flux now known as Faraday's law of induction:|𝜀| = | 𝑑𝑡 |
where |𝜀| is the magnitude of the EMF in volts and ΦB is the magnetic flux through the circuit
in Weber’s. Faraday performed early experiments on induction between coils of wire, including
winding a pair of coils around an iron ring, thus creating the first toroidal closed-core transformer.
However, he only applied individual pulses of current to his transformer, and never discovered the
relation between the turn’s ratio and EMF in the windings. The first type of transformer to see
wide use was the induction coil, invented by Rev. Nicholas Callan of Maynooth College, Ireland
in 1836. He was one of the first researchers to realize the more turns the secondary winding has
in relation to the primary winding, the larger the induced secondary EMF will be.
Induction coils evolved from scientists' and inventors' efforts to get higher voltages from batteries.
Since batteries produce direct current (DC) rather than AC, induction coils relied upon
vibrating electrical contacts that regularly interrupted the current in the primary to create the flux
changes necessary for induction. Between the 1830s and the 1870s, efforts to build better induction
coils, mostly by trial and error, slowly revealed the basic principles of transformers.
By the 1870s, efficient generators producing alternating current (AC) were available, and it was
found AC could power an induction coil directly, without an interrupter. In 1876, Russian
engineer Pavel Yablochkov invented a lighting system based on a set of induction coils where the
primary windings were connected to a source of AC. The secondary windings could be connected
to several 'electric candles' (arc lamps) of his own design. The coils Yablochkov employed
functioned essentially as transformers (Daware, n.d.).
In 1878, the Ganz factory, Budapest, Hungary, began producing equipment for electric lighting
and, by 1883, had installed over fifty systems in Austria-Hungary. Their AC systems used arc and
incandescent lamps, generators, and other equipment. Lucien Gaulard and John Dixon Gibbs first
exhibited a device with an open iron core called a 'secondary generator' in London in 1882, then
sold the idea to the Westinghouse company in the United States. They also exhibited the invention
in Turin, Italy in 1884, where it was adopted for an electric lighting system (Anon., ).
Induction coils with open magnetic circuits are inefficient at transferring power to loads. Until
about 1880, the paradigm for AC power transmission from a high voltage supply to a low voltage
load was a series circuit. Open-core transformers with a ratio near 1:1 were connected with their
primaries in series to allow use of a high voltage for transmission while presenting a low voltage
to the lamps. The inherent flaw in this method was that turning off a single lamp (or other electric
device) affected the voltage supplied to all others on the same circuit. Many adjustable transformer
designs were introduced to compensate for this problematic characteristic of the series circuit,

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including those employing methods of adjusting the core or bypassing the magnetic flux around
part of a coil. Efficient, practical transformer designs did not appear until the 1880s, but within a
decade, the transformer would be instrumental in the war of the currents, and in seeing AC
distribution systems triumph over their DC counterparts, a position in which they have remained
dominant ever since.
In 1886, George Westinghouse built the first long-distance ac (alternating current) electric lighting
system in Great Barrington, Massachusetts. The power source was a 25 hp steam engine driving
an alternator with an output of 500 V and 12 A. Westinghouse realized that electric power could
only be delivered over distances by transmitting at a higher voltage and then reducing the voltage
at the location of the load. He purchased U.S. patent rights to the transformer developed by Gaulard
and Gibbs. William Stanley, Westinghouse's electrical expert, designed and built the transformers
to reduce the voltage from 500 to 100 V on the Great Barrington system [2].

Figure 1: First transformer by otto blathy, miksa Deri, & Karoly zipemowsky in 1800s

3. Principle of operation
3.1. What is an Electric Transformer?
A transformer is a static device that consists of one, two or more windings which are magnetically
coupled and electrically separated with or without a magnetic core. It transfers the electrical energy
from one circuit to the other by electromagnetic induction principle. The winding connected to the
AC main supply is called primary winding and the winding connected to the load or from which
energy is drawn out is called as secondary winding. These two windings with proper insulation are
wound on a laminated core which provides a magnetic path between windings. When the primary
winding is energized with alternating voltage source, an alternating magnetic flux or field will be
produced in the transformer core.

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 Figure 2: Electrical transformer

This magnetic flux amplitude depends on the applied voltage magnitude, frequency of the supply
and the number of turns on the primary side. This flux circulates through the core and hence links
with the secondary winding. Based on the principle of electromagnetic induction, this magnetic
linking induces a voltage in the secondary winding. This is called as mutual induction between
two circuits. The secondary voltage depends on the number of turns on the secondary as well as
magnetic flux and frequency. Transformers are extensively used in electrical power systems to
produce the variable values of voltage and currents at the same frequency. Therefore, by an
appropriate primary and secondary turns proportion desired voltage ratio is obtained by the
transformer.

3.2. Main part constructing a transformer

The main parts of a transformer are core, windings, container or tank, bushings and conservator
and radiators.

Core
For high power applications, transformer core is made with high permeability material which
provides the low reluctance path for the magnetic flux. The cross section of the core would be
square or rectangular. Generally, the iron core transformers provide better power transformation
compared with air core transformers. Air core transformers are used for high frequency application
(above 2 KHz) whereas, for low frequency applications (below 2 KHz) iron core transformers are
employed.

In all types of transformers, core is made up of silicon steel or sheet steel laminations which are
assembled to provide a continuous magnetic path for the flux. With this laminated core eddy
current losses are minimized. The thickness of these laminated sheets of steel are 0.35 to 5 mm
and are insulated with a varnish, or oxide, or phosphate and then formed as a core. For a better
magnetic property, hot rolled grain oriented (HRGO) steel, or Cold Rolled Grain Oriented (CRGO)

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steel, or High B (HiB) laminations are used. In case of small transformers, core is constructed with
hot rolled silicon steel laminations in the form of E and I, C and I or O are used.

Windings
Generally, the (two winding) transformer has two windings namely primary and secondary
windings which are made up of high-grade copper. The insulated stranded conductors are used as
windings for carrying high currents. This insulation avoids turns contacting with other turns.

Figure 3: Transformer windings

The voltage connected to the primary winding is called primary voltage whereas the induced
voltage in the secondary is called as secondary voltage. If the secondary voltage is more than the
primary, it is called as step-up transformer and if less, it is called as step-down transformer.
Therefore, the windings are designated as HV and LV windings based on the voltage level.
Compared to the LV winding, HV winding needs more insulation to withstand high voltages, also
needs more clearance to the core and the body. The transformer coils can be concentric or
sandwiched coils. Concentric coils are used in core type transformers whereas sandwiched coils
are used in shell type transformers. In concentric arrangement, LV winding is placed near to the
core and HV winding is placed around the LV winding for low insulation and clearance
requirements.

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 Figure 4: two transformer windings operating

The two transformer windings are on separate parts of the silicon-steel core
The most commonly used coils for the transformer include helical, sandwiched, disc and cross
over coils. Other necessary parts of the transformer are conservator tank which is used to provide
the necessary oil storage such that the pressure of the oil under heavy loads settles down. When
the oil in the transformer subject to the heat, naturally, oil expand and contract. Under this, oil is
subjected to heavy pressure so without a conservator tank, there will be a chance of bursting the
transformer. The bushings provide the insulation to the output terminals to be taken from the
windings of the transformer. These can be porcelain or condenser type bushing and based on the
level of operating voltage these are selected. Because of simple, durable and rugged construction,
transformers require a little maintenance. Because of no moving parts, the efficiency of the
transformer is very high which may vary from 95% to 98%.

3.3. Classification of Transformers

Transformers are classified into several types depends on the various factors including voltage
ratings, construction, type of cooling, number of phases of the AC system, the place where it is
employed, etc. Let us discuss some of these types of transformers.

Based on Function
Transformers are classified into two types based on the conversion of voltage level. These are step-
up and step-down transformers.

Step-up Transformers
In step-up transformer, the secondary voltage is more than the primary voltage. This is due to the
lesser number of coils in the primary compared to the secondary. This type of transformer is used
to raise the voltage to a higher level. These are used in transmission systems and are rated at higher
power levels.

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Step-down Transformers
In step-down transformer, secondary voltage is less than the primary voltage due to the smaller
number of turns in the secondary winding. Hence, this type of transformer is used to reduce the
voltage to specified levels of the circuit. Most of the power supplies use the step-down transformer
to keep the circuit operating range to a specified safer voltage limit. These types of transformers
are used in distribution systems (power transformers) and in electronic circuits (electronic
transformers). It is to be noted that the transformer is a reversible device, so it can be used as both
step-up and step-down transformer. For example, if the circuit needs a high voltage we will connect
the HV terminals to the load whereas the load or circuit needs a low voltage, we will connect the
LV terminals to the load.

Figure 5: Step-down transformer and step-up transformer

The ratio of the voltage of a transformer is determined by the turn’s ratio. With the use of larger
number of turns in the winding, higher will be the voltage produced in it. Hence, a step-down
transformer has lesser number of turns on secondary to produce a low voltage and has more turns
on primary to withstand high voltage levels of the AC supply. Turns Ratio = Primary Voltage/
Secondary Voltage = Primary Turns/ Secondary turns.

The turns ratio: VP /VS = NP /NS

Transformer function is based on the principle that electrical energy is transferred efficiently by
magnetic induction from one circuit to another. When one winding of a transformer is energized
from an alternating current (AC) source, an alternating magnetic field is established in the
transformer core. Alternating magnetic lines of force, called “flux,” circulate through the core.
With a second winding around the same core, a voltage is induced by the alternating flux lines. A
circuit, connected to the terminals of the second winding, results in current flow. The figure below
demonstrates the principle of operation of a transformer.

4. Construction of a transformer
A basic transformer consists of two inductive windings and a laminated steel core. The coils are
insulated from each other as well as from the steel core. A transformer may also consist of a
container for winding and core assembly called tank, suitable bushings to take the terminals, oil

7
conservator to provide oil in the transformer tank for cooling purposes etc. The figure at left
illustrates the basic construction of a transformer. In all types of transformers, core is constructed
by assembling laminated sheets of steel, with minimum airgap between them to achieve continuous
magnetic path. The steel used is having high silicon content and sometimes heat treated, to provide
high permeability and low hysteresis loss. Laminated sheets of steel are used to reduce eddy current
loss. The sheets are cut in the shape as E, I and L. To avoid high reluctance at joints, laminations
are stacked by alternating the sides of joint. That is, if joints of first sheet assembly are at front
face, the joints of following assemble are kept at back face (Daware, n.d.).

Figure 6: Basic construction of a transformer (Daware, n.d.)

There are two types of construction, core type and the shell type as shown in the figure below. The
core type is designed such that the core in the form of a rectangular frame with the coils placed on
two vertical sides. The coils are cylindrical and relatively long. They are divided, part of each
primary and secondary being on each of the two vertical legs. While in the shell type, the core
surrounds the coils, instead of the coils surrounding the core. The coils in the shell type are
generally flat instead of cylindrical, and the primary and secondary coils are alternated. In core
type transformer each limb is occupied with both primary and secondary winding. In shell type
transformer the main frame is constructed with three limbs. Both the primary and secondary
windings are wound around the central limb. In core type transformer no additional limb is used
as flux as flux flow path but in shell type transformer two limbs are used as low reluctance flux
path. Core type is generally more suitable for high voltage whereas shell is suitable for low voltage.

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 Figure 7: Types of construction

5. Types of transformers
Transformers can be designed to be of dry or oil filled transformers. Dry transformers use air for
cooling, while oil filled transformers have oi circulating through the windings to remove the heat.
Oil filled transformers are commonly used for large commercial appliances in electric utility.
There are common typed of transformers, autotransformer and insulating transformers. Insulating
transformers have primary and secondary windings not connected. Control transformers are
special types of insulating transformers. They are used when the line voltage is not equal to control
circuit voltage.
In autotransformers have their windings interconnected for primary and secondary side of
transformers, this means that primary and secondary windings are electrically connected.
Autotransformers have a special type which is a zigzag transformer which is used to ground 480
V three phase system.

6. Three phase transformer connections

Windings of a three-phase transformer can be connected in various configurations as (i) star-star, (ii)
delta-delta, (iii) star-delta, (iv) delta-star, (v) open delta and (vi) Scott connection. These configurations
are explained below. (Daware, n.d.)

i) Star -star connection

 For small, high-voltage transformers, the star-star connection is commonly used.
Because of the star connection, the number of required turns/phase is reduced (the
1
phase voltage in the star connection is only of the line voltage). As a result, the
√3
amount of insulation required is reduced.
 The transformation ratio of the transformers is equal to the ratio of line voltages on
the primary and secondary sides.
 Line voltages on both sides are in phase with each other.
 This connection is only usable if the connected load is balanced.

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 ii) Delta-Delta
 This is a common connection for large, low-voltage transformers. The number of
required phases/turns is higher than for a star-to-star connection.
 The transformation ratio of the transformers is equal to the ratio of line voltages on
the primary and secondary sides.
 This connection can be used even for unbalanced loading.
 Another benefit of this type of connection is that even if one transformer fails, the
system can continue to operate in open delta mode with reduced available capacity.
iii) Star-Delta
 The primary winding is connected to a grounded neutral by a star star (Y), and the
secondary winding is connected by a delta.
 This connection is primarily used in the step down transformer at the transmission
line's substation end.
 The ratio of secondary to primary line voltage is 1/√3 times the transformation ratio.
 There is 30° shift between the primary and secondary line voltage
iv) Delta-Star
 The primary winding is connected in delta, while the secondary winding is
connected in star, with the neutral grounded. As a result, it can provide 3-phase 4-
wire service.
 This type of connection is mainly used in step-up transformer at the beginning of
transmission line.
 The ratio of secondary to primary line voltage is √3 times the transformation ratio.
 There is 30° shift between the primary and secondary line voltages

7. Losses in Transformer
In any electrical machine, loss can be defined as the difference between input power and output
power. There are different kinds of losses that occurs in the transformer such as iron, copper,
hysteresis, eddy, stray and dielectric. Transformer is a static device, hence mechanical losses like
windage or friction losses are absent in it. A transformer only consists of electrical losses iron
losses and copper losses.
7.1. Core Losses or Iron Losses
Iron losses mainly occur through the alternating flux within the transformer’s core. Once this loss
occurs within the core then it is called core loss. This kind of loss mainly depends on the material’s
magnetic properties within the core of the transformer. The core in the transformer can be made
with iron, so these are called iron losses. This type of loss can be categorized into two types like
hysteresis as well as eddy current.
Hysteresis loss in transformer: Hysteresis loss is due to reversal of magnetization in the
transformer core. This loss depends upon the volume and grade of the iron, frequency of magnetic
reversals and value of flux density.
Eddy current loss in transformer: In transformer, AC current is supplied to the primary winding
which sets up alternating magnetizing flux. When this flux links with secondary winding, it
produces induced emf in it. But some part of this flux also gets linked with other conducting parts

10
like steel core or iron body or the transformer, which will result in induced emf in those parts,
causing small circulating current in them. This current is called as eddy current. Due to these eddy
currents, some energy will be dissipated in the form of heat.
7.2. Copper Loss in Transformer
Copper losses occur because of the ohmic resistance in the windings of the transformer. Copper
loss for the primary winding is I12R1 and for secondary winding is I22R2. Where, I1 and I2 are
current in primary and secondary winding respectively, R1 and R2 are the resistances of primary
and secondary winding respectively. It is clear that copper loss is proportional to square of the
current, and current depends on the load. Hence copper loss in transformer varies with the load.

8. Efficiency of Transformer
Just like any other electrical machine, efficiency can be defined as the output power divided by the
input power. Transformer’s efficiency directly affects its performance and aging. Most of the
transformers have full load efficiency between 95% to 98.5%. For large power transformer with
very low losses, the efficiency can be as high as 99.7% (Daware, n.d.). The input and output
measurements of a transformer are not done under loaded conditions as the wattmeter readings
inevitably suffer errors of 1 – 2%. So, for the purpose of efficiency calculations, OC and SC tests
are used to calculate rated core and winding losses in the transformer. The core losses depend on
the transformer rated voltage, and the copper losses depend on the current through the transformer
primary and secondary windings. Hence transformer efficiency is of prime importance to operate
it under constant voltage and frequency conditions. The rise in the temperature of the transformer
due to heat generated affects the life of transformer oil properties and decides the type of cooling
method adopted. The temperature rise limits the rating of the equipmentInvalid source specified..
As a transformer being highly efficient, output and input are having nearly same value, and hence
it is impractical to measure the efficiency of transformer by using output / input. A better method
to find efficiency of a transformer is using,
Input − Losses Losses
efficiency = = 1 −
Input Input

9. Transformer protection and maintenance

External faults and internal faults are the two types of faults that can occur on a transformer. To
avoid any danger to the transformer, an external fault is cleared as quickly as possible by a complex
relay system. Internal flaws are primarily caused by sensors and measurement systems. There are
six types of internal protection which are Overheating protection, Overcurrent protection,
Differential Protection of Transformer, Earth Fault Protection (Restricted), Buchholz (Gas
Detection) Relay, and Over-fluxing protection.
A dedicated protection, commonly referred to as a thermal overload relay, protects a transformer
from overloads. The temperature of the transformer's windings is simulated by this type of
protection. The simulation is based on the current measurement and the transformer's thermal time
constant.

11
Transformer oil must be tested twice a year, or once every six months, for dielectric strength, water
content, acidity, sludge content, flash point, DDA, IFT, and resistivity.
The auto, remote, and manual cooling system functions, which include oil pumps, air fans, and
other items involved in the transformer's cooling system, as well as their control circuit, must be
checked once a year. In the event of a problem, look into the control circuit as well as the physical
condition of the pumps and fans. (Electrical 4U, 2020)

10. Design of the Transformer

Design Specification
Design of a 3-phase core-type distribution transformer rated 11kV/400V, 25 KVA, plane tank, 50
Hz, star-delta. Design its core dimensions and its primary and secondary windings. Ensure that the
necessary clearance between adjacent HV windings and also between HV windings and core are
met for the transformer. Given that the resistivity of copper at 20°C is 0.17241x10-7 Ωm and the
temperature coefficient α is 0.0039 1/°C, determine the resistance of the both the HV and LV
windings per phase given that the operating temperature of the transformer is 40°C. Finally draw
the approximate equivalent circuit of the transformer referred to primary and determine the
efficiency and voltage regulation of the transformer when it is operating at full load, at an operating
temperature of 40°C with a power factor of 0.8 lagging

Core design
Magnetic flux in the core:

𝐸𝑡 = 𝑘√𝑄 , Where k=0.45

𝐸𝑡 = 0.45√25
𝐸𝑡 = 2.25 𝑉

𝐸𝑡
∅𝑚 =
4.44𝑓
2.25
∅𝑚 =
4.44 × 50
∅𝑚 = 0.010135 𝑊𝑏

Net core area:

Take the magnetic flux density to be 𝐵𝑚 = 1.25 𝑤𝑏/𝑚2

∅𝑚
𝐴𝑖 =
𝐵𝑚
0.010135
𝐴𝑖 =
1.25
𝐴𝑖 = 8.108 × 10−3 𝑚2

12
Gross core area:
𝐴
𝐴𝑔𝑖 = 𝐾𝑖 , where 𝐾𝑖 = 0.9
𝑖

8.108 × 10−3
𝐴𝑔𝑖 =
0.9
𝐴𝑔𝑖 = 9.009 × 10−3 𝑚2

Circumscribing circle diameter:

𝐴𝑔𝑖
𝜋 = 0.79
× 𝑑 2
4

9.009 × 10−3 × 4
𝑑=√
𝜋 × 0.79
∴ 𝑑 = 0.12050 𝑚 = 120.50𝑚𝑚

Dimensions of cruciform:

𝑎 = 0.85𝑑
𝑎 = 0.85 × 0.12050
𝑎 = 0.12043𝑚

𝑏 = 0.53𝑑
𝑏 = 0.53 × 0.12050
𝑏 = 0.0636 𝑚
Take 𝑎 = 102𝑚𝑚 and 𝑏 = 65 𝑚𝑚
The circumscribing circle diameter is also recalculated as follows:
𝑑 = √𝑎 2 + 𝑏 2
𝑑 = √1022 + 652
𝑑 = 120.95 𝑚𝑚

Gross core area using the values of 𝑎 and 𝑏:

𝐴𝑔𝑖 = 2𝑎𝑏 − 𝑏 2
𝐴𝑔𝑖 = 2 × 0.102 × 0.065 − 0.0652
𝐴𝑔𝑖 = 9.035 × 10−3 𝑚2

Net core area is also recalculated:

𝐴𝑖 = 0.9 × 𝐴𝑔𝑖
𝐴𝑖 = 0.9 × 9.035 × 10−3
𝐴𝑖 = 8.132 × 10−3 𝑚2

Window spacing factor:

13
 8.5
𝐾𝑤 =
30 + 𝑘𝑉
8.5
𝐾𝑤 =
30 + 11
𝐾𝑤 = 0.207

Take the current density to be 𝛿 = 1.8 𝐴/𝑚𝑚2 = 1.8 × 106 𝐴/𝑚2

The area of the window is calculated as shown:
𝑄 × 103
𝐴𝑤 =
3.33 × 𝑓 × 𝐵𝑚 × 𝛿 × 𝐾𝑤 × 𝐴𝑖
25 × 103
𝐴𝑤 =
3.33 × 50 × 1.25 × 1.8 × 106 × 0.207 × 8.132 × 10−3
𝐴𝑤 = 0.39 𝑚2

𝐻𝑤
The ratio of the height and the width of the window: 2 < 𝑊𝑤
<4

𝐻
Assume 𝑊𝑤 = 2
𝑤

The width of the window:

𝐴𝑤 = 𝐻𝑤 × 𝑊𝑤
𝐴
𝑇ℎ𝑒𝑟𝑒𝑓𝑜𝑟𝑒 𝑊𝑤 = √ 2𝑤

0.039
𝑊𝑤 = √
2
𝑊𝑤 = 0.141067 𝑚 𝑜𝑟 141.067 𝑚𝑚
The height of the window:
𝐻𝑤 = 2 𝑊𝑤
𝐻𝑤 = 2 × 141.067
𝐻𝑤 = 282.134 𝑚𝑚

Yoke Section
The area of the yoke is 15% to 25% greater than the gross core area when using hot rolled silicon
steel:
𝐴𝑦 = 1.2 × 𝐴𝑔𝑖
𝐴𝑦 = 1.2 × 9.009 × 10−3
𝐴𝑦 = 0.0108108𝑚2

The depth of the yoke:

𝐷𝑦 = 𝑎
𝐷𝑦 = 102𝑚𝑚

The height of the yoke:

14
 𝐴𝑦
𝐻𝑦 =
𝐷𝑦
0.0108108
𝐻𝑦 =
0.102

𝐻𝑦 = 0.105988𝑚 𝑜𝑟 105.988 𝑚𝑚

Overall dimensions
The overall distance between two adjacent limbs:
𝐷 = 𝑑 + 𝑊𝑤
𝐷 = 120.95 + 141.067
𝐷 = 262.017 𝑚𝑚
The overall height of the transformer frame:
𝐻 = 𝐻𝑤 + 2𝐻𝑦
𝐻 = 282.134 + 2 × 105.988
𝐻 = 494.11 𝑚𝑚
The overall length of the transformer frame:
𝑊 = 𝑎 + 2𝐷
𝑊 = 102 + 2 × 262.017
𝑊 = 626.034 𝑚𝑚

Design of windings (star-delta connection)

Primary and secondary voltages:
𝑉𝑝(𝑙𝑖𝑛𝑒) = 11 𝑘𝑉
𝑉𝑠(𝑙𝑖𝑛𝑒) = 400 𝑉
𝑉𝐿 11𝑘
𝑉𝑝(𝑝ℎ𝑎𝑠𝑒) = = = 6,35 𝑘𝑉
√3 √3
𝑉𝑠(𝑝ℎ𝑎𝑠𝑒) = 400 𝑉

Primary and secondary currents:

𝑄 25 × 103
𝐼𝑠(𝑝ℎ𝑎𝑠𝑒) = 3 = 3 = 20,833 𝐴
𝑉𝑠(𝑝ℎ𝑎𝑠𝑒) 400

𝑄 25 × 103
𝐼𝑝(𝑝ℎ𝑎𝑠𝑒) = 3 = 3 = 1.312 𝐴
𝑉𝑝(𝑝ℎ𝑎𝑠𝑒) 6.35 × 103

Primary and secondary number of turns:

𝐸𝑠 400
𝑁𝑠 = = = 177.78 ≈ 178 𝑡𝑢𝑟𝑛𝑠
4.44𝑓𝐵𝑚 𝐴𝑖 4.44 × 50 × 1.25 × 8.108 × 10−3

15
 𝐸𝑝 6.36 × 103
𝑁𝑝 = × 𝑁𝑠 = × 178 = 2810 𝑡𝑢𝑟𝑛𝑠
𝐸𝑠 400

Area of primary and secondary conductors:

𝛿𝑝 = 𝛿𝑠 = 1.8 𝐴⁄𝑚𝑚2
𝐼𝑝 1.312
𝑎𝑝 = = = 0.729 𝑚𝑚2
𝛿𝑝 1.8
𝐼𝑠 20.833
𝑎𝑠 = = = 11.574 𝑚𝑚2
𝛿𝑠 1.8

Selection of conductor for LV winding (Secondary)

Using table 17.1
𝑎𝑠 = 11. 574 mm: 5.5 × 2.2

Insulation conductor: 6 × 2.7

Insulation thickness = 5 + (0.9 × 0.4) = 5.36mm
Outer diameter of Insulation = d + 2 × 5.36
= 120.95 + 2 × 5.36 = 131.67 mm

Available length of LV winding = HW- (Insulation thickness)

= 282.134 − 2 × 5.36 = 271.414mm

N for 1 layer of windings:

Available length of LV winding 271.414
= = = 45.23 ≈ 45
6 6
No. of layers:
𝑁𝑆 178
= = = 3.956 ≈ 4
𝑁 for 1 layer of windings 45

Radial depth of LV winding = (2.2 × 4) + (0.5 × 3) = 10.3 mm

Outer diameter for LV winding = 2 × radial depth + inner diameter
= 2 × 10.3 + 131.67 = 152.27 mm

HV Winding
Inner diameter of HV winding = Outer diameter of LV winding +2 × Insulation thickness
= 152.27 + 2 (5 + (0.9 x 6.35)) = 173.7 mm
𝐼𝑝 = 1.312 𝐴 < 20 𝐴

16
Cross-Over winding type is selected to reduce voltage between adjacent layers. Spacers are used
in between coils.
For 11 kV, 8 Coils and 24 Layers per coil is used
Turns per layer:
𝑁 𝑝𝑒𝑟 𝑐𝑜𝑖𝑙 2810
= = = 117.083 𝑚𝑚
24 24
Diameter of the conductor:

4
= √ × 0.729 = 0.463 𝑚𝑚
𝜋

Using table 7.4 for paper covered conductors = 0.950 mm

Insulation conductor with fine covering = 1.125 mm
Axial length of one coil = 12 × 1.125 = 13.5 mm
Axial length of HV winding = No. of coils x axial length of one coil + depth of spacers
= 8 × 13.5 + 7 × 5 = 143 mm

Space between the HV winding and the yoke = Hw – Axial length

= 282.134 − 143 = 139.134 mm
139.134
Clearance on each side of HV winding = 2
= 69.57 mm

From table 7.5 minimum clearance is 30 mm for 11 kV

Clearance = 69.57𝑚𝑚 > 30𝑚𝑚, Hence clearance is satisfactory.
Insulation between layers is 0.3 𝑚𝑚 thick paper standard for 6.6 kV/11 kV
Radial depth of HV winding = 0.3 × 23 + 24 × 1.125 = 33.9 mm
Out diameter of HV windings = inner diameter + 2 × radial depth
= 173.7 + 2 × 33.9 = 241.50 mm
D = 262.107 mm

Clearance between the winding of the adjacent limbs = 262.017– 214.50 = 20.517 mm
Using table 7.5 minimum clearance for HV winding = 14 mm
Clearance = 20.517𝑚𝑚 > 14𝑚𝑚, Hence clearance is satisfactory

17
Resistance of HV and LV
Given that the resistivity of copper at 20°C is 0.17241 × 10−7 Ωm and the temperature
coefficient α is 0.0039 1/°C, operating temperature of the transformer is 40°C.

𝜌𝑐𝑢 = 𝜌𝑜 (1 + 𝛼 (𝑇 − 𝑇𝑜 ))
𝜌𝑐𝑢
𝜌𝑜 =
(1 + 𝛼 (𝑇 − 𝑇𝑜 ))
0.17241 × 10−7
𝜌𝑜 =
(1 + 0.0039 × (20℃ − 0℃))
𝜌𝑜 = 1.599 × 10−8 Ω𝑚
The resistance of the HV windings per phase:
𝜌𝐿𝑝
𝑅𝑝 = × 𝑁𝑝
𝐴𝑝

Where, 𝐿𝑝 is the mean length of the HV winding, the mean length of the HV can be determined
using the following equation,
𝐿𝑝 = 𝜋 × 𝑚𝑒𝑎𝑛 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟

Mean diameter:
𝑜𝑢𝑡𝑒𝑟 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 + 𝑖𝑛𝑛𝑒𝑟 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟
𝑚𝑒𝑎𝑛 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 =
2
241.50 + 152.27
𝑚𝑒𝑎𝑛 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 =
2
𝑚𝑒𝑎𝑛 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 = 196.885 𝑚𝑚
Therefore,

𝐿𝑝 = 𝜋 × 196.885

𝐿𝑝 = 618.532 𝑚𝑚

Hence,

1.8796 × 10−8 × 618.532 × 10−3

𝑅𝑝 = × 2810
0.729 × 10−6
𝑅𝑝 = 44.813Ω

The resistance of the LV windings per phase:

𝜌𝐿𝑠
𝑅𝑠 = × 𝑁𝑠
𝐴𝑠

18
Where, 𝐿𝑠 is the mean length of the low-voltage winding, the mean length of the LV winding can
be determined using the following equation,
𝐿𝑠 = 𝜋 × 𝑚𝑒𝑎𝑛 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟

Mean diameter:
𝑜𝑢𝑡𝑒𝑟 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 + 𝑖𝑛𝑛𝑒𝑟 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟
𝑚𝑒𝑎𝑛 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 =
2
173.7 + 131.67
𝑚𝑒𝑎𝑛 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 =
2
𝑚𝑒𝑎𝑛 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 = 152.685 𝑚𝑚

Therefore,
𝐿𝑠 = 𝜋 × 152.685
𝐿𝑠 = 479.674 𝑚𝑚

Hence,
1.8796 × 10−8 × 479.674 × 10−3
𝑅𝑠 = × 178
11.574 × 10−6
𝑅𝑠 = 0.0138 Ω

Reactance and Impudence

𝑋1 = 2𝑅1 𝑝𝑒𝑟 𝑝ℎ𝑎𝑠𝑒
𝑋1 = 2(44.813) = 89.626 𝛺
𝑋𝑀 = 3000𝑋1 per phase
𝑋𝑀 = 3000(89.626) = 268878 𝛺
𝑋2 = 2𝑅2 per phase
𝑋2 = 2(0.0138) = 0.0276 𝛺
𝑅𝐶 = 2000𝑅1 per phase
𝑅𝐶 = 2000(44.813) = 89626 𝛺

Referring all values to the primary side

𝑉1
𝑎=
𝑉2

𝑉1 2
𝑋2′ = ( ) × 𝑋2
𝑉2

11000 2
𝑋2′ =( ) × 0.0276 = 𝑗20.873 𝛺
400

19
 𝑉1 2
𝑅2′ = ( ) × 𝑅2
𝑉2

11000 2
𝑅2′ =( ) × 0.0138 = 10.436 𝛺
400

Similarly, voltage and current are as follows:

𝑉1
𝑉2′ = × 𝑉2
𝑉2
11000
𝑉2′ = × 6350.853 = 174648.458 𝑉
400

𝑉2
𝐼2′ = × 𝐼2
𝑉1
400
𝐼2′ = × 20.833 = 7.576 𝐴
11000

Equivalent parameters
𝑅𝑒𝑞 = 𝑅1 + 𝑅′2

𝑅𝑒𝑞 = 44.813 + 10.436 = 55.249 𝛺

𝑋𝑒𝑞 = 𝑋1 + 𝑋′2

𝑋𝑒𝑞 = 89.626 + 20.873 = 𝑗110.499 𝛺

𝑍𝑒𝑞 = 𝑅𝑒𝑞 + 𝑋𝑒𝑞

𝑍𝑒𝑞 = 55.249 + 𝑗110.499 𝛺

Voltage regulation
Referring to the secondary side:
𝑉2 2
𝑋1′ = ( ) × 𝑋1
𝑉1

400 2
𝑋1′ = ( ) × 89.626 = 𝑗0.119 𝛺
11000

20
 𝑉2 2
𝑅1′ = ( ) × 𝑅1
𝑉1

400 2
𝑅1′ = ( ) × 44.813 = 0.059 𝛺
11000

Similarly, voltage and current are as follows:

𝑉2
𝑉1′ = × 𝑉1
𝑉1
400
𝑉1′ = × 6350.853 = 230.94 𝑉
11000

𝑉1
𝐼1′ = ×𝐼
𝑉2 1
11000
𝐼1′ = × 1.312 = 36.08 𝐴
400

Equivalent
𝑅𝑒𝑞 = 𝑅2 + 𝑅′1

𝑅𝑒𝑞 = 0.0138 + 0.059 = 0.0728 𝛺

𝑋𝑒𝑞 = 𝑋2 + 𝑋′1

𝑋𝑒𝑞 = 0.0276 + 0.119 = 𝑗0.147 𝛺

𝑍𝑒𝑞 = 𝑅𝑒𝑞 + 𝑋𝑒𝑞

𝑍𝑒𝑞 = 0.0728 + 𝑗0.147 𝛺

𝑉2𝑓𝑙 = 𝑉′1 − 𝐼′1 × 𝑍𝑒𝑞

𝑉2𝑓𝑙 = 230.94 − (36.08 < −𝑐𝑜𝑠 −1 (0.8))(0.0728 + 𝑗0.147) = 228.282 < −1.320

𝑉2(𝑛𝑜 𝑙𝑜𝑎𝑑) − 𝑉2(𝑓𝑢𝑙𝑙 𝑙𝑜𝑎𝑑)

𝑉𝑜𝑙𝑡𝑎𝑔𝑒 𝑅𝑒𝑔𝑢𝑙𝑎𝑡𝑖𝑜𝑛 = × 100
𝑉2(𝑛𝑜 𝑙𝑜𝑎𝑑)
230.94 − 228.282
𝑉𝑜𝑙𝑡𝑎𝑔𝑒 𝑅𝑒𝑔𝑢𝑙𝑎𝑡𝑖𝑜𝑛 = × 100
228.282
𝑉𝑜𝑙𝑡𝑎𝑔𝑒 𝑅𝑒𝑔𝑢𝑙𝑎𝑡𝑖𝑜𝑛 = 1.16%

21
Copper and core Losses
𝑃𝑐𝑢 = 𝐼2 2 × 𝑅𝑒𝑞

𝑃𝑐𝑢 = 36.082 × 0.0728 = 94.769 𝑊

𝑉1 2
𝑃𝑐𝑜𝑟𝑒 =
𝑅𝑐
6350.852
𝑃𝑐𝑜𝑟𝑒 = = 450.018 𝑊
89626
𝑃𝑙𝑜𝑠𝑠 = 𝑃𝑐𝑢 + 𝑃𝑐𝑜𝑟𝑒
𝑃𝑙𝑜𝑠𝑠 = 94.769 + 450.018 = 544.787 𝑊

Efficiency
𝐼𝑛𝑝𝑢𝑡 𝑝𝑜𝑤𝑒𝑟 = 𝑜𝑢𝑡𝑝𝑢𝑡 𝑝𝑜𝑤𝑒𝑟 + 𝑝𝑜𝑤𝑒𝑟 𝑙𝑜𝑠𝑠𝑒𝑠
𝐼𝑛𝑝𝑢𝑡 𝑝𝑜𝑤𝑒𝑟 = 25000 + 544.787 = 25544.787 𝑊
𝐼𝑛𝑝𝑢𝑡 − 𝐿𝑜𝑠𝑠𝑒𝑠 𝐿𝑜𝑠𝑠𝑒𝑠
𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 = × 100 = ( 1 − ) × 100
𝐼𝑛𝑝𝑢𝑡 𝐼𝑛𝑝𝑢𝑡
544.787
𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 = (1 − ) × 100 = 97.87%
25544.787

Equivalent circuit of a transformer

The simplified equivalent circuit of a transformer is drawn by representing all the parameters of
the transformer either on the secondary side or on the primary side. The equivalent circuit
diagram of the transformer is shown below:

Figure 8: Equivalent circuit of the transformer

22
The secondary resistance and reactance can be referred from the primary side as follows:
𝑁1 2
𝑋2′ = ( ) × 𝑋2
𝑁2

𝑁1 2
𝑅2′ = ( ) × 𝑅2
𝑁2

Similarly, voltage and current are as follows:

𝑁1
𝑉2′ = × 𝑉2
𝑁2
𝑁1
𝐼2′ = × 𝐼2
𝑁2

After referring the impedances, voltage and current to primary side the representation of core is no
more necessary.

Figure 9: Equivalent circuit of the transformer referring to the primary side

Phasor diagram of a transformer

By reference to the equivalent circuit of the transformer, the phasor diagram of a transformer can
be drawn. Applying KVL on the figure 1 (Equivalent circuit) 𝑉1 and 𝑉1 are as follows:
𝑉1 = 𝐸1 + 𝐼1 × 𝑅1 + 𝐼1 × 𝑋1
𝑉2 = 𝐸2 − 𝐼2 × 𝑅2 + 𝐼2 × 𝑋2

23
 Figure 10: Phase diagram of the transformer

Similarly, by reference to the equivalent circuit of the transformer referred to primary side, the
phasor diagram can be drawn

Figure 11: Phase diagram of the transformer referred to primary side

24
11. Conclusion
The satisfactory clearance of the transformer at 11KV was achieved since the calculated clearance was
equal to 62,5 mm which was greater than the minimum clearance of 30 mm. the clearance between the
winding of the adjacent limbs was calculated to be 20.527 mm, using table 17.5 the minimum clearance of
the high voltage winding was found to be 14mm, therefore the clearance is satisfactory.

Higher flux density Bm produces the lower window area and gross area of the core. Increasing the flux
would increase the diameter, therefore increase in the diameter would yield in the increased values of a and
b. current density is inversely proportional to the window area, increasing current density, would result in
less window area value.

Voltage regulation was discovered to be 1.16 percent. The lower the value, the better, since the closer the
transformer is to being perfect. The value achieved shows that the regulation is satisfactory although it
could be improved by getting smaller resistance values. This might be accomplished by increasing the
current density, so lowering the areas of each winding, and therefore lowering the mean length of the
winding.

The transformer design's efficiency was determined to be 97.81 percent. This figure is more than adequate
since the higher the efficiency, the better the transformer because there are fewer power losses. To make
the transformer more efficient, the Rc and Req values must be reduced, which may be accomplished by
reducing the current density and hence the size of the windings.

25
References
[1] Gouda, O. E., Amer, G. M. & Salem, W. A. A., 2012. Predicting transformer temperature rise and loss
of life in the presence of harmonic load currents. Ain Shams Engineering Journal, , 3(2), pp. 113-121.

[2] Brown, C. W., 1949. Three-phase transformer construction. [Online]

Available at: https://patents.google.com/patent/us2458112a/en
[Accessed 23 5 2021].

[3] Chen, T.-H.et al., 1991. Three-phase cogenerator and transformer models for distribution system
analysis. IEEE Transactions on Power Delivery, , 6(4), pp. 1671-1681.

[4] Daware, K., n.d. Electrical Easy. [Online]

Available at: https://www.electricaleasy.com/2014/05/three-phase-transformer-connections.html
[Accessed June 2021].

[5] Electrical 4U, 2020. Electrical 4U. [Online]

Available at: https://www.electrical4u.com/maintenance-of-transformer/
[Accessed June 2021].

[6] Fu, W., McCalley, J. D. & Vittal, V., 2001. Risk Assessment for Transformer Loading. IEEE Transactions
on Power Systems, , 16(3), pp. 346-353.

[7] Georgilakis, P. S., 2011. Environmental cost of distribution transformer losses. Applied Energy, , 88(9),
pp. 3146-3155.

[8] Anon., . Power Transformers. [Online]

Available at: http://www.learnabout-electronics.org/ac_theory/transformers03.php
[Accessed 23 5 2021].

[9] Jahromi, A. N., Faiz, J. & Mohseni, H., 2003. A Fast Method for Calculation of Transformers Leakage
Reactance Using Energy Technique. International Journal of Engineering, Transactions B: Applications, ,
16(1), pp. 41-48.

[10] Li, D. et al., 2012. Reducing the core loss of amorphous cores for distribution transformers. Progress
in Natural Science: Materials International, , 22(3), pp. 244-249.

[11] Olivares-Galvan, J. C., Escarela-Perez, R., Georgilakis, P. S. & Fofana, I., 2013. Evaluation of
distribution transformer banks in electric power systems. International Transactions on Electrical Energy
Systems, , 23(3), pp. 364-379.

[12] Olivares-Galvan, J. C., Georgilakis, P. S., Campero-Littlewood, E. & Escarela-Perez, R., 2013. Core
lamination selection for distribution transformers based on sensitivity analysis. Electrical Engineering, ,
95(1), pp. 33-42.

[13] Olivares, J. C. et al., 2002. Reducing losses in distribution transformers. IEEE Power & Energy
Magazine, , 18(3), pp. 821-826.

[14] Parfomak, P. W., 2014. Physical Security of the U.S. Power Grid: High-Voltage Transformer
Substations. Current Politics and Economics of the United States, Canada, and Mexico, , 19(2), p. 247.

26
[15] Paul, D., 2000. Failure analysis of dry type power transformer. IEEE Transactions on Industry
Applications, , 5(3), pp. 3232-3239.

[16] Paul, D., 2000. Failure analysis of dry type power transformer. IEEE Transactions on Industry
Applications, , 5(3), pp. 3232-3239.

[17] Wang, D. et al., 2007. Theory and application of distribution electronic power transformer. Electric
Power Systems Research, , 77(3), pp. 219-226.

[18] Yazdani-Asrami, M., Mirzaie, M. & Akmal, A. A. S., 2013. No-load loss calculation of distribution
transformers supplied by nonsinusoidal voltage using three-dimensional finite element analysis. Energy,
, 50(), pp. 205-219.

27
Appendix 1 (Siphesihle Nkosi 217012929)
Three phase core type distribution Transformer Calculations
Core design
Voltage per turn: 𝐸𝑡 = 𝑘√𝑄 , where k = 0.45, Q = 25kVA

∴ 𝐸𝑡 = 0.45√25
𝐸𝑡 = 2.25𝑉

𝐸𝑡
The flux in the core: ∅𝑚 = , f = 50Hz
4.44𝑓

2.25
∴ ∅𝑚 =
4.44(50)
∅𝑚 = 0.010135𝑊𝑏

∅𝑚
The Net core area: 𝐴𝑖 = ,taking 𝐵𝑚 = 1.20𝑊𝑏/𝑚2
𝐵𝑚

0.010135𝑊𝑏
𝐴𝑖 =
1.20𝑊𝑏/𝑚2
𝐴𝑖 = 8.45 × 10−3 𝑚2

𝐴𝑖
The Gross area: 𝐴𝑔𝑖 = ,where 𝑘𝑖 = 0.9
𝑘𝑖

8.45 × 10−3 𝑚2
𝐴𝑔𝑖 =
0.9
𝐴𝑔𝑖 = 9.388 × 10−3 𝑚2

For 2 step cruciform core

𝐴𝑔𝑖
𝜋 2 = 0.79
4𝑑

28
 9.388 × 10−3 𝑚2
𝜋 = 𝑑2
× 0.79
4
∴ 𝑑 = 120𝑚𝑚

𝑎 = 0.85(𝑑)
𝑎 = 0.85(120𝑚𝑚)
𝑎 = 100𝑚𝑚

𝑏 = 0.53(𝑑)
𝑏 = 0.53(120𝑚𝑚)
𝑏 = 65𝑚𝑚

𝐴𝑔𝑖 = 2𝑎𝑏 − 𝑏 2

𝐴𝑔𝑖 = 2(100𝑚𝑚)(65𝑚𝑚) − (65𝑚𝑚)2

𝐴𝑔𝑖 = 8775𝑚𝑚2

𝐴𝑖 = 𝐴𝑔𝑖 × 0.9

𝐴𝑖 = 8775𝑚𝑚2 × 0.9
𝐴𝑖 = 7897.5𝑚𝑚2

9
𝐾𝑤 =
30 + 𝑘𝑉
9
𝐾𝑤 =
30 + 11
𝐾𝑤 = 0.21951

29
Taking the current density to be 𝛿 = 2.2𝐴/𝑚𝑚2
𝑄 × 103
𝐴𝑤 =
3.33 × 𝑓 × 𝐵𝑚 × 𝛿 × 𝐾𝑤 × 𝐴𝑖
25 × 103
𝐴𝑤 =
3.33 × 50 × 1.20 × 2.2 × 106 × 0.21951 × 7.8975 × 10−3

𝐴𝑤 = 0.03280785974𝑚2
𝐴𝑤 = 32.81 × 10−3 𝑚2

𝐻𝑤
Assuming = 2.5
𝑊𝑤

𝐻𝑤 = 2.5 × 𝑊𝑤
𝐴𝑤 = 𝐻𝑤 × 𝑊𝑤
𝐴𝑤 = 2.5 × 𝑊𝑤2
32.81 × 10−3 𝑚2 = 2.5 × 𝑊𝑤2
𝑊𝑤 = 115𝑚𝑚
𝐻𝑤 = 2.5 × 115𝑚𝑚
𝐻𝑤 = 288𝑚𝑚
Yoke design

𝐴𝑦 = 1.2𝐴𝑔𝑖

𝐴𝑦 = 1.2 × 8775𝑚𝑚2

𝐴𝑦 = 10530𝑚𝑚2

𝐷𝑦 = 𝑎 = 100𝑚𝑚

𝐴𝑦 = 𝐷𝑦 × 𝐻𝑦

10530𝑚𝑚2 = 100𝑚𝑚 × 𝐻𝑦

𝐻𝑦 = 105.3𝑚𝑚 = 105𝑚𝑚

30
Overall dimension

𝐷 = 𝑑 + 𝑊𝑤
𝐷 = 120𝑚𝑚 + 115𝑚𝑚
𝐷 = 235𝑚𝑚

𝐻 = 𝐻𝑤 + 2𝐻𝑦

𝐻 = 288𝑚𝑚 + 2(105𝑚𝑚)
𝐻 = 498𝑚𝑚

𝑊 = 2𝐷 + 𝑎
𝑊 = 2(235𝑚𝑚) + 100𝑚𝑚
𝑊 = 570𝑚𝑚

Design of windings

Star-delta connection

𝑉𝑝(𝑙𝑖𝑛𝑒) = 11𝑘𝑉

𝑉𝑠(𝑙𝑖𝑛𝑒) = 400𝑉

𝑉𝑝(𝑙𝑖𝑛𝑒) = √3 × 𝑉𝑝(𝑝ℎ𝑎𝑠𝑒)

𝑉𝑝(𝑝ℎ𝑎𝑠𝑒) = 6350.85𝑉

𝑉𝑠(𝑝ℎ𝑎𝑠𝑒) = 𝑉𝑠(𝑙𝑖𝑛𝑒) = 400𝑉

𝑄 = 3𝐼𝑝(𝑝ℎ𝑎𝑠𝑒) 𝑉𝑝(𝑝ℎ𝑎𝑠𝑒)

25 × 103 = 3𝐼𝑝(𝑝ℎ𝑎𝑠𝑒) 6350.85

∴ 𝐼𝑝(𝑝ℎ𝑎𝑠𝑒) = 1.312𝐴

31
 𝑄 = 3𝐼𝑠(𝑝ℎ𝑎𝑠𝑒) 𝑉𝑠(𝑝ℎ𝑎𝑠𝑒)

25 × 103 = 3𝐼𝑠(𝑝ℎ𝑎𝑠𝑒) 400

∴ 𝐼𝑠(𝑝ℎ𝑎𝑠𝑒) = 20.83𝐴

Number of turns in Secondary winding:

𝑉𝑠(𝑝ℎ𝑎𝑠𝑒)
𝑁𝑠 =
4.44 × 𝑓 × 𝐵𝑚 × 𝐴𝑖
400
𝑁𝑠 =
4.44 × 50 × 1.20 × 7.8975 × 10−3

𝑁𝑠 = 190𝑡𝑢𝑟𝑛𝑠
Number of turns is Primary winding:
𝑉𝑝(𝑝ℎ𝑎𝑠𝑒)
𝑁𝑝 = × 𝑁𝑠
𝑉𝑠(𝑝ℎ𝑎𝑠𝑒)
6350.85
𝑁𝑝 = × 190
400
𝑁𝑝 = 3019𝑡𝑢𝑟𝑛𝑠

Area of primary and secondary conductors:

𝛿𝑝 = 𝛿𝑠 = 2.2 𝐴⁄𝑚𝑚2
𝐼𝑝 1.312
𝑎𝑝 = = = 0.5964 𝑚𝑚2
𝛿𝑝 2.2
𝐼𝑠 20.833
𝑎𝑠 = = = 9.46 𝑚𝑚2
𝛿𝑠 2.2

Selection of conductor for LV winding (Secondary)

Using table 17.1
𝑎𝑠 = 9.46 𝑚𝑚2 = 12𝑚𝑚 × 0.8𝑚𝑚

32
Insulation conductor: 6 × 2.7
Insulation thickness = 5 + (0.9 × 0.4) = 5.36𝑚𝑚
Outer diameter of Insulation = d + 2 × 5.36𝑚𝑚
= 120𝑚𝑚 + 2 × 5.36 = 130.72𝑚𝑚

Available length of LV winding = 𝐻𝑤 − (Insulation thickness)

= 288𝑚𝑚 − 2 × 5.36 = 277.28𝑚𝑚

N for 1 layer of windings:

Available length of LV winding 277.28
= = = 46.21 ≈ 46
6 6
No. of layers:
𝑁𝑆 190
= = = 4.130 ≈ 4
𝑁 for 1 layer of windings 46
Radial depth of LV winding = (2.2 × 4) + (0.5 × 3) = 10.3 mm
Outer diameter for LV winding = 2 × radial depth + inner diameter
= 2 × 10.3 + 130.72 = 151.32 mm

HV Winding
Inner diameter of HV winding = Outer diameter of LV winding +2 × Insulation thickness
= 151.32 + 2 (5.36) = 172.75 𝑚𝑚
𝐼𝑝 = 1.32 𝐴 < 20 𝐴

Cross-Over winding type is selected to reduce voltage between adjacent layer. Spacers are used
in between coils.
For 11 kV, 8 Coils and 24 Layers per coil is used
Diameter of the conductor:

4
= √ × 0.5964 = 0.8714 𝑚𝑚
𝜋

Using table 7.4 for paper covered conductors 0.8714 𝑚𝑚

33
Insulation conductor with fine covering = 1.125 𝑚𝑚
Axial length of one coil = 12 × 1.125 = 13.5 𝑚𝑚

Axial length of HV winding = No. of coils x axial length of one coil + depth of spacers
= 8 × 13.5 + 7 × 5 = 143𝑚𝑚
Space between the HV winding and the yoke = 𝐻𝑤 – Axial length
= 288𝑚𝑚 − 143𝑚𝑚 = 145𝑚𝑚
145𝑚𝑚
Clearance on each side of HV winding = = 72.5𝑚𝑚
2

From table 7.5 minimum clearance is 30 mm for 11 kV

Clearance = 72.5𝑚𝑚 > 30𝑚𝑚, Hence clearance is satisfactory.
Insulation between layers is 0.3 𝑚𝑚 thick paper standard for 6.6 kV/11 kV
Radial depth of HV winding = 0.3 × 23 + 24 × 1.125 = 33.9 𝑚𝑚
Out diameter of HV windings = inner diameter + 2 × radial depth
= 172.75 𝑚𝑚 + 2 × 33.9𝑚𝑚 = 240.55 𝑚𝑚
𝐷 = 235𝑚𝑚
Clearance between the winding of the adjacent limbs = 240.55 𝑚𝑚 − 235𝑚𝑚 = 5 𝑚𝑚
Using table 7.5 minimum clearance for HV winding = 5 𝑚𝑚
Clearance = 5𝑚𝑚 < 14𝑚𝑚, Hence clearance is not satisfactory

34
 Appendix 2 (Amanda Ngwenya 217037822)
Methodology
Given parameters:
 3-Phase Core-Type Transformer:
 11 KV/400 V
 Q = 25 KVA
 Plane tank
 F=50 Hz
 Star-Delta connection
 Resistivity of copper at T=20 ̊ C = 0.1724x10^-7 Ωm
 Temperature Coefficient α = 0.00391/ ̊ C
 T = 40 ̊C
 Pf = 0.8

Core Design
3-phase core type transformer

(4) For 3-phase core type transformer

Window

L H
H L V V H L L H H L L H
V V V V V V V V V V

3-phase core type transformer with concentric windings

Q = 3 × V1 I1 × 10−3 KVA

= 3 × (4.44fφm N1 )I1 × 10−3 KVA (∵ V1 = 4.44fφm N1 )

= 3 × (4.44fAi Bm N1 )I1 × 10−3 KVA---------(6) (∵ φm = Ai Bm )

35
Window Space Factor
ActualCuSectionAreaofWindingsinWindow
Kw =
WindowArea ⥂ (Aw )
2(a1 N1 + a2 N2 )
=
Aw
2 × [(I1 /δ)N1 + (I2 /δ)N2 ]
= (∵ a1 = I/1 δ & a2 = I/2 δ)
Aw
2(I1 N1 + I2 N2 )
=
δAw
2 × 2I1 N1
= (ForIdealTransformer I1 N1 = I2 N2 )
δAw
So
δKw Aw
N1 I1 = − − − − − − − − − − − − − (7)
4

Put equation value of N1I1 form equation (7) to equation (6)

δKw Aw
Q = 3 × 4.44fAi Bm × 10−3 KVA.
4

Q = 3.33fAi Bm δK w Aw × 10−3 KVA − − − − − (80)

EMF per turn:

We know:

𝑉1 = 4.44𝑓𝜑𝑚 𝑁1 − − − − − − − − − − − − − (1).
𝑉
𝑆𝑜𝐸𝑀𝐹/𝑇𝑢𝑟𝑛𝐸𝑡 = 𝑁1 = 4.44𝑓𝜑𝑚 − − − − − − − − − − − −(2).
1

And

Q = 𝑉1 𝐼1 × 10−3 KVA (Take Q as per phase rating in KVA)

= (4.44𝑓𝜑𝑚 𝑁1 )𝐼1 × 10−3 KVA

= 𝐸𝑡 𝑁1 𝐼1 × 10−3 𝐾𝑉𝐴 − − − − − − − (3)

In the design, the ratio of total magnetic loading and electric loading may be kept constant.

Magnetic loading = 𝜑𝑚

Electric loading = 𝑁1 𝐼1

36
 𝜑𝑚 𝜑𝑚
So: = 𝑐𝑜𝑛𝑠 𝑡𝑎𝑛 𝑡 (𝑠𝑎𝑦"𝑟") ⇒ 𝑁1 𝐼1 = 𝑝𝑢𝑡𝑖𝑛 ⥂ 𝑒𝑞𝑢𝑡𝑖𝑜𝑛(3)
𝑁1 𝐼1 𝑟
𝜑𝑚
𝑄 = 𝐸𝑡 × 10−3 𝐾𝑉𝐴
𝑟
𝐸
Or 𝑡
𝑄 = 𝐸𝑡 4.44𝑓𝑟 × 10−3 𝐾𝑉𝐴

using equation (2)

𝐸𝑡 2 = (4.44𝑓𝑟 × 10−3 ) × 𝑄

Or 𝐸𝑡 = 𝐾𝑡 √𝑄 𝑉𝑜𝑙𝑡𝑠/𝑇𝑢𝑟𝑛

Where 𝐾𝑡 = √4.44𝑓𝑟 × 10−3 is a constant.

Values are:
Kt = 0.6 to 0.7 for 3-phase core type power transformer
Kt = 0.45 for 3-phase core type distribution transformer
Kt = 1.3 for 3-phase shell type transformer
Kt = 0.75 to 0.85 for 1-phase core type transformer
Kt = 1.0 to 1.2 for 1-phase shell type transformer

Estimation of Core X-sectional area Ai

Figure 12:

D D/√2

1-Step or Square- Core 2-Step or Cruciform- Core 3-Step Core 4-Step Core
Figure 13:
K= 0.45 0.56 0.60 0.625
𝐸𝑡 = 𝐾√𝑄 .

𝐸𝑡 = (0.45)(√25 ).

= 𝟐. 𝟐𝟓 𝑽 .
𝐄𝐭 𝟐.𝟐𝟓
Flux in the Core 𝐐𝐦 = = 𝟒.𝟒𝟒𝒙𝟓𝟎 = 𝟎. 𝟎𝟏𝟎𝟏𝟑𝟓𝟓𝝎𝒃
𝟒.𝟒𝟒𝐟

37
Calculating the core area:
Table 1: FLUX DENSITY TABLE FOR DISTRIBUTION AND POWER TRANSFORMER
Type Bm(Wb/m2)
Distribution transformer 1,1 to 1,35
Power transformer 1,25 to 1,45

𝑄𝑚
Net Core Area Ai =
𝐵𝑚
Where Bm is the maximum flux density. If Ai decrease → saving in cost of iron length of mean
turn of windings is reduced. However, high Bm → high iron losses across the core. Also, high
Bm necessitates a large magnetising current which contains objectionable harmonics.
Choosing Bm = 1.35 ωb/m2
𝟎.𝟎𝟏𝟎𝟏𝟑𝟓𝟏
Ai = = 𝟕. 𝟓𝟎𝟕𝒙𝟏𝟎−𝟑 m2
𝟏.𝟑𝟓

Let stacking factor.

𝑲𝒊 = 𝟎. 𝟗
𝑨𝒊 𝟕.𝟓𝟎𝟕𝒙𝟏𝟎−𝟑
Gross Core Area = 𝑲𝒊 = = 0.008342 m2
𝟎.𝟗

d = Diameter of circumscribe circle

For Square core
𝑑 𝑑
Gross Area = × = 0.5𝑑 2
√2 √2

Let stacking factor.

 𝐾𝑖 = 0.9
Actual Iron Area
𝐴𝑖 = 0.9 × 0.5𝑑2 = 0.45𝑑2 .
(0.45 for square core and take ‘K’ as a general case) = 𝐾𝑑 2
So 𝐴𝑖 = 𝐾𝑑2

𝐴
Or 𝑑 = √ 𝐾𝑖

Graphical method to calculate dimensions of the core. a

b
Consider 2 step core:

38

Ө
b a
 𝟗𝟎𝒐
𝜽 = 𝒏+𝟏 , 𝒏 = 𝑵𝒐 𝒐𝒇𝑺𝒕𝒆𝒑𝒔.

𝒊. 𝒆𝒏 = 𝟐.
90o
θ = 2+1 = 30o .

So a = dCosθ.
b = dSinθ.
Percentage fill
GrossAreaofSteppedcore Kd2 ⁄Ki
%𝐹𝑖𝑙𝑙 = = πd2⁄
Areaofcircumcircle
4

Net Core Area to Area of Circumscribing Circle of (i) Square Core (ii) Cruciform Core
Square Core
0.9𝑥0.5𝑑2
Ratio: 𝜋 2 = 0.58
𝑑
4

𝐺𝑟𝑜𝑠𝑠 𝐶𝑜𝑟𝑒 𝐴𝑟𝑒𝑎 0.5 𝑑2

Ratio: 𝐴𝑟𝑒𝑎 𝑜𝑓 = 𝜋 = 0.64
𝐶𝑖𝑟𝑐𝑢𝑚𝑠𝑐𝑟𝑖𝑏𝑖𝑛𝑔 𝐶𝑖𝑟𝑐𝑙𝑒 𝑑2
4

Cruciform Core:
𝑁𝑒𝑡 𝐶𝑜𝑟𝑒 𝐴𝑟𝑒𝑎 0.9𝑥0.618𝑑2
Ratio: 𝐴𝑟𝑒𝑎 𝑜𝑓 𝑐𝑖𝑟𝑐𝑢𝑚𝑠𝑐𝑟𝑖𝑏𝑖𝑛𝑔 𝑐𝑖𝑟𝑐𝑙𝑒 = 𝜋 2 = 0.71
𝑑
4

0.618 𝑑2
Ratio: 𝜋 = 0.79
𝑑2
4

Calculating the diameter of the circumscribing circle

Using the ratio for the gross core area to area of circumscribing circle

Equation 1: diameter
diameter d = √0.008342 × 4⁄π × 0,79.

∴ d = 0,11595m.

𝑎 = 0.85𝑑.
𝑏 = 0.53𝑑.
a = (0.85)(0.11595) = 0.0985588 m.
𝑏 = (0.53)(0.11595) = 0.0614543 𝑚.
using approximation: ±5 mm
𝒂 = 𝟏𝟎𝟎 𝒎𝒎.

39
𝒃 = 𝟔𝟎 𝒎𝒎.

d= √𝒂𝟐 + 𝒃𝟐 = √𝟏𝟎𝟎𝟐 + 𝟔𝟎𝟐 = 𝟏𝟏𝟔. 𝟔𝟏𝟗 𝒎𝒎

𝐴𝑔𝑖 = 2(100)(60) − (60)2 .

𝐴𝑔𝑖 = 0.0084 𝑚2 .

𝐴𝑖 = 0,9 × 0.0084.

∴ 𝐴𝑖 = 0.00756 𝑚2.

Window Dimensions:
The current density
The limitations to the choice of current density is due to the local heating and efficiency. High
values of current density cause excessive temperature rising in the windings and this can damage
the insulation. The range of values used for a distribution transformer, self-oiled cool type up to
50KVA, is: Current density(δ) = 1,1 to 2,3 A/mm2.
For this case, the value was assumed to be 1.4 A/mm2.

Window factor
Window Space factor is the ratio of copper area in the window of the total area. This ratio depends on the
relative amount of insulation and copper provided, which in turn depends on voltage rating and output.

Ratings Window Factor

For ratings approximately 20KVA 8
𝐾𝑤 =
30 + 𝐾𝑉
For ratings between 50 to 200KVA 10
𝐾𝑤 =
30 + 𝐾𝑉
For ratings approximately 1000KVA 12
𝐾𝑤 =
30 + 𝐾𝑉
Table 2: Window Factor Equations based on KVA rating
In this case the KVA rating is 25KVA so we use the first window factor for approximately 20KVA. The
KV value is the voltage of the high voltage (HV) winding in kilovolt. Therefore, from Table 2: Window
Factor Equations based on KVA rating

Calculating Window Dimensions deign :

The window space factor:
𝟖 𝟖
Kw = 𝟑𝟎 + 𝑲𝑽 = = 𝟎. 𝟏𝟗𝟓𝟏𝟐𝟏
𝟑𝟎 + 𝟏𝟏

The current density in the winding:

40
We know output equation:

𝑄 = 3.33𝑓𝐴𝑖 𝐵𝑚 𝛿𝐾𝑤 𝐴𝑤 × 10−3 𝐾𝑉𝐴

𝑸
So, Window area : 𝑨𝒘 = 𝟑.𝟑𝟑𝒇𝑨 𝑩 −𝟑
𝒎𝟐
𝒊 𝒎 𝜹𝑲𝒘 ×𝟏𝟎

25 000
𝐴𝑤 = = 0.0538565 𝑚2
(3.33)(50)(1.35)(0.195121)(1.4𝑥106 )(7.56𝑥10−3 )
The area of the window (Aw) depends on the total conductor area and Kw :
𝑡𝑜𝑡𝑎𝑙 𝑐𝑜𝑛𝑑𝑢𝑐𝑡𝑜𝑟 𝑎𝑟𝑒𝑎
Aw =
𝐾𝑤

Taking the ratio high to width of window

Hw
: the ratio between 2 to 4.
Ww
𝐻𝑤
=2
𝑊𝑤

Equation 2: Area of window

0.05385650
Ww = √ = 0.164098 = 164.09829 mm
2

Hw = 𝑊𝑤 𝑥 2 = 164.09829𝑥2 = 328.1966 mm
Yoke Design
The area of the yoke is usually between 15 to 25 percent larger than that of the core for a
transformer using hot rolled silicon steel. This reduces the flux density in the yoke therefore fewer
iron losses and magnetising current.
The rectangular section yokes have the same depth of the yoke as the depth of the core. This depth
of core is equal to the width of the largest stamping when the square or stepped core is used. This
means that the dimension a is equal to the depth of the yoke.
Ay =( 1.15 to 1.25 )Agi
The area of yoke is taken as 1.2 times that of the limb:
Ay = 1.2xAgi
𝟏
So, flux density in yoke = = 𝟎. 𝟖𝟑𝟑 𝑾𝒃𝒎𝟐
𝟏.𝟐

Ay = 1.2xAgi = 1.2x0.0084 = 0.01008 𝒎𝟐

41
Dy = a = 0.100 m
𝐀𝐲 𝟎.𝟎𝟏𝟎𝟎𝟖 𝐦𝟐
Hy = = = 𝟎. 𝟏𝟎𝟎𝟖 𝐦 = 𝟏𝟎𝟎. 𝟖 𝐦𝐦
𝐃𝐲 𝟎.𝟏𝟎𝟎 𝐦

Overall Dimension
The definitions of the variables all in millimetres(mm)
 a: The width of the largest stamping
 d: The diameter of circumscribing circle
 D: The distance between centres of adjacent limbs
Ww: The width of the window

Figure
Figure14:
15: THREE PHASE CORE TYPE TRANSFORMER
 Hw: The height of window= Length of limb
 Hy: Height of yoke
 H: Overall height of transformer over yokes or overall height of frame.
 W: Length of yoke= overall length of frame

Distance between centres of adjacent limbs

D = d + Ww = 116.619 + 164.09829 = 280.7173 mm
Depth of the yoke
Dy = a = 100 mm
Overall height of the frame
H= 𝐻𝑤 + 2𝐻𝑦 = 328.1966 + (2)(100.8) = 529.7966𝑚𝑚

42
Overall width of the frame:
W = 2𝐷 + 𝑎 = ((2)(280.7173)) + (100) = 661.4346 𝑚𝑚
Design of the winding
The transformer is connected in Star-Delta connection
 Primary winding is connected in star connection while the secondary winding is connected in
delta connection.
Table 3: three phase transformer connection

Primary-Secondary Line Voltage Line Current

Configuration Primary or Secondary Primary or Secondary

Delta – Delta

Delta – Star

Star – Delta

Star – Star

Equation 3: turns ratio

Number of turns in secondary windings→ star-Delta connection, which means that the primary
winding is connected in star connection and secondary winding is connected in delta connection.
Voltage calculation:
Table 4: voltage calculation
For primary winding(Star connected) For Secondary winding(Delta
connected)

VP(line) = 11000 V VS(line) = 400 V

43
 𝑽𝒑(𝒍𝒊𝒏𝒆) 𝟏𝟏𝟎𝟎𝟎 VS(phase) = VS(line) = 400V
VP(phase)= = = 𝟔𝟑𝟓𝟎. 𝟖𝟓𝟐𝟗𝟔𝟏 𝑽
√𝟑 √𝟑
Current calculation
Primary winding
 Q= 25 KVA
𝑸 𝟐𝟓𝟎𝟎𝟎
𝟑 𝟑
I P= = = 𝟏. 𝟑𝟏𝟐𝟓𝟗𝟕𝟎𝟑 𝑨
𝑽𝒑(𝒑𝒉𝒂𝒔𝒆) 𝟔𝟑𝟓𝟎.𝟖𝟓𝟐𝟗𝟔𝟏

Secondary winding
𝑸 𝟐𝟓𝟎𝟎𝟎
𝟑 𝟑
IS= = = 𝟐𝟎. 𝟖𝟑𝟑 𝑨
𝑽𝒔(𝒑𝒉𝒂𝒔𝒆) 𝟒𝟎𝟎

Number of turns in secondary winding

𝑽𝒔(𝒑𝒉𝒂𝒔𝒆) 𝟒𝟎𝟎
TS= 𝟒.𝟒𝟒∗𝟓𝟎∗𝜷𝒎∗𝑨𝒊 = 𝟒.𝟒𝟒∗𝟓𝟎∗𝟏.𝟑𝟓∗𝟎.𝟎𝟎𝟕𝟓𝟔 = 𝟏𝟕𝟔 𝒕𝒖𝒓𝒏𝒔

Number of turns for primary windings

𝑽𝒑(𝒑𝒉𝒂𝒔𝒆) 𝟔𝟑𝟓𝟎.𝟖𝟓𝟐𝟗𝟔𝟏
Tp = ∗ 𝑻𝒔 = ( ) (𝟏𝟕𝟔) = 𝟐𝟕𝟗𝟒 𝒕𝒖𝒓𝒏𝒔
𝑽𝒔(𝒑𝒉𝒂𝒔𝒆) 𝟒𝟎𝟎

Conductor calculation
The range of values used for a distribution transformer, self-oiled cool type up to 50KVA, is:
Current density(δ) = 1,1 to 2,3 A/mm2.
For this case, the value was assumed to be δ =1.4 A/mm2.
Conductor for LV winding(Secondary side):
δP = δS=1.4 A/ mm2
𝑰𝒔 𝟐𝟎.𝟖𝟑𝟑𝟑
αS = 𝜹𝒔 = = 𝟏𝟒. 𝟖𝟖𝟎𝟗 𝒎𝒎𝟐
𝟏.𝟒

conductor for primary side HV winding

𝑰𝒔 𝟏.𝟑𝟏𝟐𝟓𝟗𝟕𝟎𝟑
αp = 𝜹𝑷 = = 𝟎. 𝟗𝟑𝟕𝟓𝟔𝟗𝟑 𝒎𝒎𝟐
𝟏.𝟒

selection of conductor for LV winding

αs=14.8809 𝒎𝒎𝟐
using table 17.1- double paper Tape cover shown in the appendix
5.5x2.8 : 14.9
𝟐𝟎.𝟖𝟑
Current density in secondary winding = = 𝟏. 𝟑𝟗𝟖𝟐 𝑨/𝒎𝒎𝟐 ≈ 𝟏. 𝟒 𝑨/𝒎𝒎𝟐
𝟏𝟒.𝟗

∴ the clearance of current density in secondary winding is satisfastory , the conducter is paper covered

44
Thickness =5.5 + (2 ∗ 0.25) = 6𝑚𝑚
Width = 2.8 + (2*0.25) = 3.3mm
Insulation thickness = 𝟓 + (𝟎. 𝟗 ∗ 𝑲𝑽) = 𝟓 + (𝟎. 𝟗 ∗ 𝟎. 𝟒) = 𝟓. 𝟑𝟔 𝒎𝒎
Outer diameter of the insulation=d + 2 ∗ insulation thickness = 116.619 + 10.72 = 127.339mm
The outer diameter of the lower voltage winding
Available length of LV winding =𝐇𝐰 − 𝟐(𝐢𝐧𝐬𝐮𝐥𝐚𝐭𝐢𝐨𝐧𝐭𝐡𝐢𝐜𝐤𝐧𝐞𝐬𝐬) = 𝟑𝟐𝟖. 𝟏𝟗𝟔𝟔 − 𝟐 ∗ 𝟓. 𝟑𝟔 = 𝟑𝟏𝟕. 𝟒𝟕𝟔𝟔 𝐦𝐦

N for 1 layer of winding

𝟑𝟏𝟕.𝟒𝟕𝟔𝟔
Nt= = 𝟓𝟐 𝐭𝐮𝐫𝐧𝐬
𝟔

The number of layers is given as:

𝑻𝒔 𝟏𝟕𝟔
No. of layers = 𝑵 = = 𝟒 𝒍𝒂𝒚𝒆𝒓𝒔
𝒕 𝟓𝟐

Radial Depth of LV winding = 𝑵𝒐. 𝒐𝒇𝒍𝒂𝒚𝒆𝒓𝒔 ∗ 𝟑. 𝟑 + (𝟐 ∗. 𝟎𝟐𝟓) = (𝟒)(𝟑. 𝟑) + (𝟎. 𝟓) = 𝟏𝟑. 𝟕𝒎𝒎

Outer Diameter of LV winding = 𝟐 ∗ 𝟏𝟑. 𝟕 + 𝟏𝟐𝟕. 𝟑𝟑𝟗 = 𝟏𝟓𝟒. 𝟕𝟑𝟗 𝒎𝒎

Space between HV windings and yoke
inner Diameter of HV winding = outerDiameterofwinding + 2 ∗ insulationthickness(HV)
Insulation Diameter of HV winding =𝟓 + (𝟎. 𝟗 ∗ 𝐊𝐕) = 𝟓 + (𝟎. 𝟗 ∗ 𝟔. 𝟑𝟓𝟎𝟖𝟓𝟐𝟗𝟔𝟏) =
𝟏𝟎. 𝟕𝟏𝟓𝟕𝟔𝟕𝟔𝟔 𝐦𝐦
Inner Diameter of HV winding = 𝟏𝟓𝟒. 𝟕𝟑𝟗 + (𝟐 ∗ (𝟏𝟎. 𝟕𝟏𝟓𝟕𝟔𝟕𝟔𝟔)) = 𝟏𝟕𝟔. 𝟏𝟕𝟎𝟓𝟑𝟓𝟑 𝐦𝐦

Since: Ip=1.312 < 20 𝐴

Cross over winding type is selected to reduce voltage between adjacent. Spacer is between the
coils.

Figure 16:
𝟐𝟕𝟗𝟒
𝑵𝑷𝒆𝒓 𝒄𝒐𝒊𝒍 𝟖
Turns per layer = 𝟐𝟒
= 𝟐𝟒
= 𝟏𝟒. 𝟓𝟓 ≈ 𝟏𝟓 𝒕𝒖𝒓𝒏𝒔

45
 𝟒
Diameter of bare conductor = √𝝅 ∗ 𝜶𝒑 = 𝟏. 𝟎𝟓𝟕𝟗 𝒎𝒎

Using table 17.4

Insulation conductor width with fine covering= 𝟏. 𝟐𝟔𝟎 𝒎𝒎
Axial length of one coil = 𝟏𝟓 ∗ 𝟏. 𝟐𝟔𝟎 = 𝟏𝟖. 𝟗 𝒎𝒎
Axial length of HV winding = ((𝟏𝟖. 𝟗 ∗ 𝟖 ) + (𝟕 ∗ 𝟓)) = 𝟏𝟖𝟔. 𝟐 𝒎𝒎
Space between HV winding and yoke = 𝑯𝒘 − 𝒂𝒙𝒊𝒂𝒍 𝒍𝒆𝒏𝒈𝒕𝒉 = 𝟑𝟐𝟖. 𝟏𝟗𝟔𝟔 − 𝟏𝟖𝟔. 𝟐 =
𝟏𝟒𝟏. 𝟗𝟗𝟔𝟔𝒎𝒎
𝟏𝟒𝟏. 𝟗𝟗𝟔𝟔
∴ = 𝟕𝟎. 𝟗𝟗𝟖𝟑 𝐦𝐦 > 𝟑𝟎𝐦𝐦 ∴ 𝐜𝐥𝐞𝐚𝐫𝐞𝐧𝐜𝐞 𝐢𝐬 𝐬𝐚𝐭𝐢𝐟𝐚𝐜𝐭𝐨𝐫𝐲
𝟐
Radial Depth of HV winding = 𝟎. 𝟑 ∗ 𝟐𝟑 + 𝟐𝟒 ∗ 𝟏. 𝟐𝟔𝟎 = 𝟑𝟕. 𝟏𝟒 𝒎𝒎
Outer Diameter of HV winding = inner diameter of HV + (2 ∗ Radial Depth of HV winding)
Outer Diameter of HV winding = 𝟏𝟕𝟔. 𝟏𝟕𝟎𝟓𝟑𝟓𝟑 + (𝟐 ∗ 𝟑𝟕. 𝟏𝟒) = 𝟐𝟓𝟎. 𝟒𝟓𝟎𝟓𝟑 𝐦𝐦
Clearance between the HV winding = 𝐃 − 𝐎𝐮𝐭𝐞𝐫 𝐃𝐢𝐚𝐦𝐞𝐭𝐞𝐫 𝐨𝐟 𝐇𝐕 𝐰𝐢𝐧𝐝𝐢𝐧𝐠 = 𝟐𝟖𝟎. 𝟕𝟏𝟕𝟑 −
𝟐𝟓𝟎. 𝟒𝟓𝟎𝟓𝟑 = 𝟑𝟎. 𝟐𝟔𝟔𝟕𝐦𝐦 ≈ 𝟑𝟎 𝐦𝐦 > 𝟏𝟒 𝐦𝐦
∴ 𝐜𝐥𝐞𝐚𝐫𝐚𝐧𝐜𝐞 𝐛𝐞𝐭𝐰𝐞𝐞𝐧 𝐇𝐕 𝐰𝐢𝐧𝐝𝐢𝐧𝐠 𝐢𝐬 𝐬𝐚𝐭𝐢𝐬𝐟𝐚𝐜𝐭𝐨𝐫𝐲

Appendix 3 (Lempe Likhabiso 219012258)

Design calculations
Core Design:
Voltage per turn:

𝐸𝑡 =𝐾√𝑄 (𝐾 𝑓𝑜𝑟 𝑐𝑜𝑟𝑒 𝑡𝑦𝑝𝑒 𝑑𝑖𝑠𝑡𝑟𝑖𝑏𝑢𝑡𝑖𝑜𝑛 = 0.45)

𝐸𝑡 =0.45 × √25

= 2,25 V

Flux in the core:

𝐸𝑡
∅m =
4.44𝑓

2,25
= 4,44(50)

= 0,010135Wb

46
Calculating Core Area:
Taking Bm = 1,34 Wb/m2

Net core Area:

∅m
Ai = 𝐵𝑚
0,010135
=
1,53

= 7,5635 x 10-3 m2

Gross core Area:

Ki = 0,9
𝐴𝑖
Agi = 𝐾𝑖

7,5635 𝑥 10−3
= 0,9

= 8,4039 x 10-3 m2

For two stepped core:

Ratio:
𝐴𝑔𝑖
𝜋 = 0,79
𝑥 𝑑2
4

𝐴𝑔𝑖 𝑥 4
d = √𝜋 𝑥 0,79

8,4039 𝑥 10−3 𝑥 4
d=√ 𝜋 𝑥 0,79

d = 0,11638 m
d = 116,38 mm

To achieve maximum area:

a = 0,85d
a = 0,85(0,11638)
a = 0,098923 m

47
b = 0,53d
b = 0,53(0,11638)
b = 0,061681 m

a = 98,923 mm
b = 61,681 mm

Approximation: +- 5 mm
a = 100 mm
b = 60 mm

d = √𝑎2 + 𝑏 2

d = √(100)2 + (60)2

d = 116,619 mm

Agi = 2ab – b2
= 2(100)(60) – (60)2
= 8400 mm2
Agi = 0,00840 m2

8
Kw = 30+𝑘𝑉
8
= 30+11

= 0,19512

Choosing 𝛿 = 1,5 A/mm2

48
 𝑄 𝑋 103
Aw = 3,33 𝑥 𝑓 𝑥 𝐵𝑚 𝑥 𝛿 𝑥 𝐾𝑤 𝑥 𝐴𝑖

(25 𝑥 103 )
Aw = (3,33)(50)(1.34)(1,5𝑥106 )(0,19512)(7,5635 𝑥 10−3 )

Aw = 0,0506 m2

𝐻𝑤
Choosing𝑊𝑤 = 2,1

Aw = Hw x Ww = 2,1 (Ww)2
0,0506 = 2,1 (Ww)2

0,0506
Ww = √ 2,1

Ww = 0,1553 m
Ww = 155,25 mm

Hw = 2,1 Ww
Hw = 2,1(155,25)
Hw = 326,03 mm
Hw = 0,32603 mm

Area of the yoke:

Ay = 1,2Agi
= 1,2(0,00840)
= 0,01008 m2

Dy = a = 100mm = 0,100m

49
 𝐴𝑦
Hy = 𝐷𝑦

0,01008
= 0,100

= 0,1008 m
= 100.8 m

Overall Dimension:
D = d + Ww
D = 0,1636 + 0,1553
D = 0,37168m
D = 371,68 mm

H = Hw + 2Hy
H = 0,32603 + 2(0.1008)
H = 0,52763m
H = 527,6mm

Overall length of the transformer frame:

W = a + 2D
W = 100 + 2(371,68)
W = 843,36mm

Design of windings (star-delta connection):

Vp(line) = 11 kV
11𝑘𝑉
Vs(phase) = = 6,35kV
√3

Vp(line) = 400 V
Vs(line) = 400kV

Currents in primary and secondary windings:

50
 𝑄𝑝ℎ𝑎𝑠𝑒
Is(phase) = 𝑉𝑠(𝑝ℎ𝑎𝑠𝑒)

25 𝑥 103
3
= 400

= 20,83 A

25 𝑥 103
3
Ip(phase) = 6,35 𝑥 103

= 1,312 A

Number of turns in primary and secondary windings:

𝐸𝑠(𝑝ℎ𝑎𝑠𝑒)
Ns = (4,44)(𝑓)(𝐵𝑚)(𝐴𝑖)

400
= (4,44)(50)(1,35)(7,5635 𝑥 10−3 )

= 177,778
≈ 178 turns

𝐸𝑝(𝑝ℎ𝑎𝑠𝑒)
Np = x Ns
𝐸𝑠

6,35 𝑥 103
Np = x 178
400

Np = 2826 Turns

Area of primary and secondary conductors:

𝛿𝑝 = 𝛿𝑠 1,5 A/mm2
𝐼𝑝
ap = 𝛿𝑝
1,312
= 1,5

= 0,875 mm2
𝐼𝑠
as = 𝛿𝑠

51
 20,83
= 1,5

= 13,98mm2

Using Table 17,1:

as = 13,9 mm2
width = 7,5 mm
thickness = 1,9 mm

approximation +- 0,5 mm
width = 7,5 mm + 0,5 mm
= 8,0 mm

Thickness = 1,9 mm + 0,5 mm

= 2,4 mm

400𝑉
kV phase = 1000 = 0.4 kV

Insulation Thickness(t) = 0,5 + 0,9 x kV phase

= 0,5 +0,9 X 0,4
= 5,36 mm
Outer diameter of insulation = d + 2t
= 116,38 + 2(5,36)
= 127,1 mm
Hw = 326,03 mm
Available length of LV winding:
= Hw – 2t
= 326,03 – 2(5,36)
= 315,31 mm

52
N. for one layer of winding:
𝐴𝑣𝑎𝑖𝑙𝑎𝑏𝑙𝑒 𝑙𝑒𝑛𝑔𝑡ℎ
= 𝑤𝑖𝑑𝑡ℎ
315,31
= 8,0

= 39,41375
≈ 40 turns

𝑁𝑠
Number of layers = 40
178
= 40

= 4,45
≈ 5 layers

Radial depth of LV winding = no. of layers x radial thickness + 0,5 x no. of layers – 1
= 5(2,4) + 0,5(4)
= 10 mm
Outer diameter of LV winding
= 2 x radial depth + outer diameter of insulation
= 2 x 10 +127,1
= 147,1 mm

High Voltage calculations:

Insulation Thickness = 5 + 0,9 x kV phase

= 5 + 0,9 x 6,35
= 10,715 mm
Inner diameter = Outer diameter of LV winding + 2 x insulation thickness

53
 = 147,1 = 2(10,715)
= 168,53 mm

For 11 kV, 8 coils and 24 layers per coil are used

𝑁𝑝
8
Turns per layer = 24
2826
8
= 24

= 14,72
≈ 15 turns

ap = 0,875 mm2

4 𝑥 𝑎𝑝
Diameter of bare conductor = √ 𝜋

4 𝑥 0,875
=√
𝜋

= 1,005 mm

Using table 17.4:

Diameter of bare conductor = 1,06 mm
Fine covering = 1.260 mm
Axial length of one coil = turns per layer x fine covering
= 15 x 1,260
= 18,9 mm

Axial length of HV winding and yoke+

= number of coils x axial length of coils + depth of spacers
= 8 x 18,9 + 7 x 5

54
= 186,2 mm
Spacers between HV and Yoke = Hw – axial length of HV
= 326,03 – 186,3
= 139,83 mm

Clearance on each side of the winding and core

138,82
= 2

= 69,915 mm
Minimum is 30 mm therefore this one is acceptable.

Radial depth of Winding = 0,3 x 23 + 24 x 1,260

= 37,14 mm

Outer diameter = inner diameter of HV winding + 2 x radial depth

= 168,53 + 2(37,14)
= 242,81 mm

Distance between the adjacent core (D) = 271,68 mm

Clearance between HV windings = 271,68 – 242,81
= 28,87 mm

55
Appendix A
Table 5: Table 17.1

56
Table 6: Table 17.4

57
Table 7: Table 17.5 and 17.6

58
APPENDIX C PROOF

59
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