Application of Computers in Electrical

Machines Design
EPM445

Transformer Design
Lect. 2
Dr. Mohamed Shalaby
Electrical Power Engineering
Faculty of Engineering, Cairo University
Fundamentals and Applications
✓What is a Transformer
A transformer is not an energy conversion device, but it is a device that
transfers electrical energy from one circuit at certain voltage level into
another circuit at another voltage level through the action of magnetic field,
without a change in frequency. It can be either step-up or step down.
✓Applications
▪ Used to convert between high and low voltages
▪ To change impedance
▪ To provide electrical isolation between circuits
▪ Essential for high voltage power transmission (Makes long distance
transmission economically practical)

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Fundamentals and Applications
B.B. B.B.
B.B. L
U.G.C.
U.G.C.
B.B. B.B. L
B.B.
O.H.T.L. U.G.C. L
G U.G.C.
L

U.G.C. U.G.C.
PT 20 / 200:1000 KV L

Gen 20KV
DT 3.3: 66 KV / 380 V

PT 200:1000 / 3.3: 66 KV UT 220 / 110 V

Single Line Diagram of a Simple Power System

PT: Power Transformer DT: Distribution Transformer
UT: Utilization Transformer OHTL: Overhead Transmission Line
UGC: Under-Ground Cable 3
Types and Construction
• Classification based on service:
i. Distribution transformer.
ii. Power/Generator transformer.

• Classification based on core type:

i. Core type transformer.
ii. Shell type transformer.

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Types and Construction
• Power Transformer
• Used in generating stations.
• Usually arranged in parallel, so that they can be put into operation during
load hours and disconnected during light load hours.
• They are designed to have maximum efficiency at full load
• Distribution Transformer
• Used for stepping down voltage and kept near consumer premises.
• They are continuously in the circuit whether they are carrying any load or not.
• They are designed to have maximum all day efficiency

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 Types and Construction
1) Core-type construction
(usually for distribution transformers)
Each core of the transformer is wound with both primary and
secondary windings in order to reduce the magnetic leakage.

1-phase core-type transformer 3-phase core-type transformer

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Types and Construction
2) Shell-type construction
(usually for high voltage power
transformers)
The windings are wound around the
central core of the transformer and
the flux path is being completed
through side cores (limbs).

1-phase core-type transformer 3-phase shell-type transformer

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 Types and Construction
Limb
✓Iron Core
• Transformer cores are made up of thin
sheets of specially annealed and rolled
silicone steel laminations that are insulated
from each other, to reduce eddy currents
losses. Yoke

• Thickness of laminations varies for 0.3 – 0.5

mm for a frequency of 50 Hz.
• The part of the core, that is surrounded by
windings, is called a limb or leg. The other
part, which is not surrounded by windings,
but is essential for completing the path of
flux, is called the yoke.

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 Types and Construction
✓Iron Core
• Joints between limbs and yokes contribute
significantly to the core loss due to cross-
fluxing and crowding of flux lines in them.
• While building a core, the laminations are
placed in such a way that the gaps between
the laminations at joints between limbs and
yokes are overlapped by the laminations in the
next layer. This is done so that there is no
continuous gap at joints when laminations are
stacked one above the other
Overlap at corners
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 Types and Construction
✓Iron Core
• There are two types of joints
• Non-mitered joints, in which the overlap angle is 90°.
Simple in manufacturing but more in losses (flux is not
along the grains orientation direction). Used in small
transformers.
• Mitered joints, with an overlap angle “α” of 30-60°
(usually 45°). For air-gaps of equal length, the excitation
requirement with mitered joints is (sin α) times that
with non-mitered joints.

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 Types and Construction
✓Iron Core
• Advanced type of mitered joints is called Step-lap
joints. A typical step-lap joint consists of a group of
laminations (normally 5 to 7) stacked with a
staggered joint. It improves no-load performance
in terms of current, losses and noise.

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Types and Construction
✓Windings
• The transformer consists of two coils called WINDINGS which are wrapped
around the core.
• The winding that is connected to the source is called the PRIMARY
WINDING. The winding that is connected to the load is called the
SECONDARY WINDING.
• The winding consists of many turns of relatively small wire. The wire is
coated with varnish so that each turn of the winding is insulated from
every other turn.
• Insulation is present between core and inner winding and between
windings. To reduce insulation, low voltage winding is usually placed nearer
to the core.

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 Types and Construction
✓Windings
Primary
Insulation Winding
Wires Holder

LV
C C
L H o
o Secondary
. . HV r Winding
r
V V e
e Insulation
. .

Concentric winding Sandwich winding 13

Types and Construction
✓Cooling Systems
▪ Heat from core losses and copper losses must be dissipated to the
environment.
▪ Transformers come in various cooling classes, such as:
▪ Dry type transformers (Natural or Forced Air),
▪ Oil-Immersed Transformers,
▪ Oil-Immersed transformers with radiator (self-cooled, forced air
and cooled by water),
▪ Gas-Filled transformers

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 Types and Construction
Large Oil-Cooled High Voltage
✓Cooling Systems Transformer

High voltage
bushing

Low voltage
Oil tank bushing

Cooling
Dry type transformer radiators

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Types and Construction
✓Cooling Systems
• For the dry type transformers
• Air Natural (AN) Cooling
• Air Forced (AF) or Air Blast (AB) Cooling
• For oil immersed type transformers
• Oil Natural Air Natural (ONAN) Cooling
• Oil Natural Air Forced (ONAF) Cooling
• Oil Forced Air Forced (OFAF) Cooling
• Oil Forced Water Forced (OFWF) Cooling

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Types and Construction
✓Cooling Systems

OFAF
ONAN

OFWF
ONAF

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Transformer Operation
✓Theory of Operation
▪ If the primary, is connected to an AC voltage source, an AC flux will be
produced whose amplitude will depend on the primary voltage, the
frequency of the applied voltage, and the number of turns. The
mutual flux will link the other winding, the secondary, and will induce
a voltage in it whose value will depend on the number of secondary
turns as well as the magnitude of the mutual flux and the frequency.
If a load is connected to the secondary terminals a current will flow
throw the load.

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Transformer Operation
✓Ideal Transformer
Assumptions of ideal transformer:
▪ No windings resistance.
▪ No leakage flux.
▪ No iron losses.
▪ Permeability of the iron core is ∞

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 Transformer Operation
✓Ideal Transformer
d
Assuming sinusoidal flux: e1 = − N1
dt
 =  m sin t =  m  N1 sin(t −  / 2)
 m = Bm A e2 = − N 2
d
dt
 = 2 f =  m  N 2 sin(t −  / 2)
Applying Faraday’s law:  m 2fN1
E1 = = 4.44 f  m N1
d
e =− N 2
dt  m 2fN 2
E2 = = 4.44 f  m N 2
2 20
 Transformer Operation
✓Ideal Transformer
➢ Impedance Transformation

V1 E1 N1 N2 N1
= =
V2 E2 N 2
= Turns Ratio V2 = Z L I 2 V1 = Z L I1
N1 N2
2
For ideal transformer No Losses  N1 
V1 = Z L   I1
 N2 
S1 = S2 V1 = Z L I1
I1 V2 N 2  N1 
2

V1 I1 = V2 I2 = = Z L = Z L  
I 2 V1 N1  N2 

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Transformer Operation
✓ Practical Transformer
✓ Equivalent Circuit Xm

r1&x1 r2&x2

Iron Losses (Rc)

Transformers

Schematic diagram of practical transformer 22

 Transformer Operation
✓ Practical Transformer
Ideal Transformer
r1 r2 x2
I1 I/ I2
E2 =V2 + I 2 (r2 + J x2 ) 2

x1 Io
N N
E1 2 =V2 + I 2 1 (r2 + J x2 )
N1 N2
V1 Xm Rc E1 E2 V2 ZL
N N
E1 =V2 1 + I 2 ( 1 )2 (r2 + J x2 )
N2 N2
E1 =V2 + I 2 (r2 + J x2 )
N1 N2
N2
N2 N
r2 = r2 ( 1 ) 2 I 2 = I 2
I 2 = I 2 N2 N1
N1
N1 2
N x2 = x2 ( ) Equivalent Circuit of practical transformer
V2 = V2 1 N2
N2
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Transformer Operation
✓ Practical Transformer
✓ Equivalent Circuit
x1 r1 r /2 x /2
I1 I /2

Io

V1 Xm Rc E1 V /2 Z/L

Exact Equivalent Circuit Referred to Primary

Io = no-load current ≈ 5% Ir I1 = I o + I 2
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Transformer Operation
✓ Practical Transformer
✓ Equivalent Circuit Req1 Xeq1
I1 I /2

Io

V1 Xm Rc V /2 Z/L

Approximate Equivalent Circuit Referred to Primary

Req1 = r1+ r/2 Xeq1 = x1+ x/2

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Transformer Operation
✓Transformer Efficiency Output Power
=  100%
▪ To check the performance of Input Power
the transformer, we calculate Pout
its efficiency(η). =  100%
Pout + Plosses
▪ The higher the efficiency, the
better the transformer. V2 I 2 cos
=  100%
V2 I 2 cos + Piron + Pcu

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 Transformer Operation
✓Transformer Efficiency
I2 S
K = Load Factor = = Pcu = I 22 Req 2 = K 2 I 22r Req 2
I 2r Sr
V2 I 2 cos = K V2 I 2r cos = K 2 Pcufl
= K Sr cos

Piron ≡ Fixed losses Pcu ≡ Variable losses

K Sr cos 
=  100 %
K Sr cos  + Piron + K Pcufl 2
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 Transformer Operation
✓Transformer Efficiency
To get maximum efficiency: Assume constant power factor
 2 η
=0  Km Pcufl = Piron ηmax
K
Piron
Km =
Pcufl

For max. Eff.: Fixed losses = Variable losses

K
K m Sr cos Km
max =  100%
K m Sr cos + 2 Piron 28
 Transformer Operation
✓ Voltage Regulation
▪ The purpose of voltage regulation is basically to determine the percentage of voltage
drop between no load and load conditions. Req1 Xeq1
/
I2
I1
V2 NL − V2 L
V .R. =  =  100% Io
V2 NL
Z/L
V1 − V2
V1 Xm Rc V /2
=  100%
V1

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 Transformer Operation
✓ Voltage Regulation I/2 Zeq1

Neglect the vertical component of V1 V1

V1 =V2 + I 2 Z eq1 cos( sc − ) φ V/2 I/2 Xeq1

I 2 Zeq1 I/ 2
= cos( sc − )  100% Referred to Primary I/2 Req1
V1
I 2 Z eq2
= cos( sc − )  100% Referred to Secondary (θsc – φ)
V2
I 2 = K I 2r K I 2r Zeq2
= cos( sc − )  100%
V2
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Useful videos
• Transformer Winding types:
https://www.youtube.com/watch?v=_yRu-a9HjXI

• Transformer Parts and Functions:

https://www.youtube.com/watch?v=3osmO4FQ2Yg

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