Transformer design aspects

 Design is a creative physical realization of theoretical

concepts
 Engineering design is application of science, technology and
invention to produce a machine which can perform a specific
task with optimum economy and efficiency.
 The major considerations to develop a good design are
1) Cost
2) Durability
3) Compliance with performance criteria as per the specification.
 These requirements are conflicting and usually it is difficult to
meet all of them.
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 Con’t

 It is impossible to design a machine which is cheap

and is also durable at the same time.
 A machine which is expected to have long life span
must use high quality materials which are expensive.
 The basic structural parts of a transformer which
engineers should design carefully are;
- Magnetic parts (iron core)
- Conductor parts (windings)
- Insulating parts (dielectrics)
- Ventilation and cooling parts(thermal)
- Mechanical parts 2
 1. Specifications

 In order to design a transformer, a designer needs to know

the following important specifications;
1. Capacity ( power rating) of the transformer, in KVA;
2. Voltage ratings of primary and secondary windings, in KV;
3. Number of phases, 1 - phase or 3 – phase;
4. Working Frequency, in Hz;
5. Type of connections in 3ϕ-transformers , STAR or DELTA;
6. Tapping, if any
7. Type of iron assembly, Core or Shell type;
8. Type of transformer, Power or Distribution;
9. Operating average ambient temperature, in oC; (generally
40oC)
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 Con’t
10. Type of cooling to be used;
a) Cooling medium; air, Oil, water
b) Circulation type; Natural, forced
c) Simple cooling, mixed cooling
11. Temperature rise above ambient, depending on insulation class;
12. Voltage regulation;
a) % or P.U. at full load at 75oC unity P.F. or 0.8 P.F. lag
b) impedance, % or P.U.
c) reactance, % or P.U.
13. No – load current;
a) Amperes
b) % 0f rated current at rated voltage and rated frequency;
14. Efficiency, in % or P.U. at full load, ½ load, ¾ load at unity P.F.
and 0.8 P.F 4
 2. Basic principles

• The design of di-electrical, thermal and mechanical parts

is based upon knowledge of decades experience and
practice.
• However, the design of both electric and magnetic
circuits is based upon well established basic laws.
Induction, interaction and alignment laws.
• Transformer action is based on induction laws where the
coil is stationary and the flux is varying.
d
e , volts Faraday ' s law
dt
d
e  N , volts for N number of turns
dt
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 Single phase transformer components

Single phase transformer Assembled single phase transformer iron core

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 a. Single phase transformer

Let the basic quantities required for transformer design are designated as follows;
S – output , KVA
φm - main flux, wb
Bm – max. flux density, wb/m2
δ – current density, A/m2
Agi – gross core area, m2
Ai – net core area = staking factor x gross core area, m2
Ac – area of copper in the window, m2
Aw – window area, m2
D – distance between core centers, m
d – diameter of circumscribing circle, m
Kw – window space factor
f – frequency, Hz
Et – emf per turn, v 7
 Con’t
• Np, Ns – number of turns in prim. & second. windings respectively.
• Ip, Is – current in prim. & second. windings respectively, A
• Vp, Vs – terminal voltage of prim. &second. windings, V
• ap, as – area of conductors of prim. & second. windings, m2
• li – mean length of flux path in iron, m
• Lmi – length of mean turn of transformer windings, m
• Gi – weight of active iron, kg
• Gc – weight of copper, kg
• Pi – loss in iron per kg, w (specific iron loss)
• Pc – loss in copper per kg, w (specific copper loss)

Then; 8
 Con’t
• Voltage induced per turn in a single phase transformer with N
number of turns is:
= = 4.44f, Volts
 Total copper area in single phase transformer window (one
primary & one secondary)
= Copper area of prim. + Copper area of second. Winding
= Prim. turns x Area of prim. Conductor + Second. turns x

Area of Second. Conductor

= +
 Taking the current density δ to be the same in prim. And
second winding: = , =
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Con’t

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a) Rating of single phase transformers in KVA

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b . Three phase transformers

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Assembled iron core of a 3-phase transformer

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3. Output equation – EMF per turn of a winding
• The out put in KVA of a transformer can be related to emf
per turn, there by we will get starting point for the design of
a transformer.
Emf per turn
• We know 4.44f
• So emf/turn = = = 4.44f--------------- (2)
• Consider the out put of a single phase transformer:
• S= x = (4.44fx KVA
= x KVA ------------------------- (3)
 In the design, the ratio of total magnetic loading and
electric loading may be kept constant
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 Cont…
• Thus, the designer has to relate the dimensions and the
material in such a way so as to obtain the desired output
and performance at the lowest cost
• Magnetic loading =
• Electric loading =
So = constant (say r) ,a= put in eq. (3)
S= x KVA
Or S= x KVA using equation (2)
= (4.44fr x ) x S
Or = Volt/Turn

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 Cont…

Where is a constant and 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

• As = r is a constant and K is also a constant depending on type,

service condition and method of construction etc. It can be
taken from catalogue tables

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 Optimum Design
- A transformer may be designed to make one of the following
quantities as minimum;
i) Total volume ii) Total weight
iii) Total cost iV) Total losses
- In general these requirements are contradictory and normally it is
possible to satisfy only one of them.
- All these quantities vary with the ratio of Φm/NI = r
- To Design for minimum cost, the cost of iron must be equal to the
cost of conductors.
- To design for minimum loss or maximum efficiency, variable losses
(I2R loss) must be equal to constant losses ( Iron loss).
Design work can now be started by suitably choosing values of B m,
δ, and Kw and determining Ai and Aw. 17
 4. Design of core section (limb and yoke)

• For small size transformers simple rectangular core section can be used
having circular or rectangular coils.
• As the size of the transformer increases, usually circular coils are used
because of its superior mechanical stability during short circuit
situations.
• For circular coils, the shape of the core section has to be selected so that
no useful space is wasted and the amount of copper used is minimum
( minimum permeter). This could be achieved if the core section is a circle.
• Since transformer iron cores are assembled from large number of
laminations, the approximate circular shape of the core is achieved by
using stepped core sections. (square, two stepped, three stepped, …. many
stepped)

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 Estimation of core x-sectional area Ai

• We know
=
= 4.44f
Or = 4.44f ----------------------------(2)
So = ------------------------------(3)
• Now the core may be following types

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Transformer core is prepared by staking together thin
sheets of laminations giving the required core section.
These laminations are insulated on both sides by varnish
and the assembled area includes the insulation as well.

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 Cont….

• Thus the gross area is related with the net area by a factor
(0.85- 0.9) called stacking Factor.
• Yoke area Ay is generally taken 10% to 15% higher than
core section area (Ai), it is to reduce the iron loss in the
yoke section.
• But if we increase the core section area (Ai) more copper
will be needed in the windings and so more cost.
• Further length of the winding will increase winding
resistance so more cu loss
• Therefore, Ay = (1.10 to 1.15) Ai
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Assembled magnetic core

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 5. Selection of design constants

• Designing work depends on proper selection of design

constants; Bm, δ, Kw and Aw.
 Choice of flux density (Bm) – depends on
1) type of iron;
 hot rolled silicon steel 1.1 – 1.5 T,
 cold rolled silicon steel 1.5-1.7 T,
2) power rating of the transformer ;
 Higher values for higher ratings,
 lower value for lower ratings.
3) service condition;
for power transformers higher values of Bm are selected
for distribution transformers, lower values are selected
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 Cont…
• Note: - If we choose higher values of Bm, the net
core area Ai reduces, which helps to reduce the
diameter of the core and the length of the mean
turnThis results in saving of cost of iron and
copper.
• However, the max value of Bm is limited by the
saturation character of the selected iron type.
• Higher values of Bm causes increased iron losses
which may require intensive cooling.
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 Choice of current density (δ)

 Higher values of current density helps to design a

transformer with lower dimensions.
 However, it is mainly limited by
- heat produced during nominal operation and
efficiency of the transformer.
 Type of transformer ( Power or distribution) because
of different requirement of i2r and iron losses.
 Permissible values can be taken from catalogues
considering cooling system to be employed.
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 Choice of window space factor (Kw)

 It is the ratio of copper area in the window to the total

window area. Kw =Ac/A w
 The total window area includes the copper area, the
insulation and open areas for air or oil.
 The amount of copper and insulation used depends on
the KVA and voltage rating respectively and there
fore, the choice of Kw
• . For higher rating Kw = 0.15 to 0.20

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 Choice of window dimensions (Aw)
 Too a narrow window results in increased height of
window where distance between adjacent limbs/winding
is less.
 This reduces leakage reactance.
 If lower height is chosen, the window width increases
resulting increased distance between adjacent
limbs/windings and increased leakage reactance.
 Thus, height and width of the window is taken
considering desirability of leakage reactance.
 Usually, Hw/W w is taken as 2 – 4. Aw = Hw x Ww

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 6. Design of windings

• The number of turns of the LV and HV windings can be

found out of from the voltage per turn Et
(approximated to nearest integer )

• Turns of HV side is calculated using the nearest integer

value of
Tapping is provided to the HV side. Therefore is to be
increased according to the percentage of tapping required

 We place first half of LV on one limb and rest half of LV

on other limb to reduce leakage flux.
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 Cont…

 So, arrangement is LV insulation then half LV turns

then HV insulation and then half HV turns.

• Current in LV and HV winding is given by

• The cross sectional area for LV and HV winding are:

,,
Nearest size is to be selected from the standard table of
conductors.

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 Choice of type of winding

There are different types of windings employed in

transformers such as cylindrical, helical, cross
over, and continuous disc type.
• Choice of type of winding depends on voltage and
current ratings.
Once the type is properly selected, the winding is
designed to fit to the window dimension with
proper provision for cooling ducts, insulation and
clearances.
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 7. Design of insulation
 The fundamental considerations in the design of
transformer insulation are that of voltages between
different parts. i.e. insulation
- between core and LV winding
- between LV and HV windings
- between HV windings on two consecutive limbs
- between yoke and LV as well as HV windings.
 Different types of insulators like pressboard, paper, oil
immersed paper, oil, Bakelite, etc can be used
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 8. Design of cooling systems

• For large power transformers, tubes and radiators

are employed to circulate natural or forced cooling
medium. ( air, oil, water etc.)
• In addition to the above main parts, tank and other
mechanical parts are designed as required
depending on the power and type of the
transformer

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 OU
K Y
A N
T H
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