EE 3220
Electrical Machine Design
Designing of Transformer
Nashrah Afroze
Lecturer
Department of Electrical and Electronic Engineering
Khulna University of Engineering and Technology
Khulna, Bangladesh
Transformer types
• On the basis of core construction:
Core Type
Shell Type
• On the basis of phase:
Single Phase
Three Phase
• On the basis of method of cooling:
Self Cooled
Air forced Cooled
Oil Cooled
Forced oil Cooled
On the basis of ratings and working Principle
On the basis of ratings and working purpose
• Step-up & Step-down Transformer:
If (Vs,Ns>Vp,Np) Step-up Transformer
If (Vs,Ns<Vp,Np) Step-down Transformer
• Power Transformer: Used in the transmission networks of higher
voltages
Rating: 400 KV, 200 KV, 110 KV, 66 KV, 33 KV.
Above 200 MVA
Efficiency: Almost 100%
• Distribution Transformer: Used in the distribution network to provide
voltage transformation in the power system by stepping down the
voltage level where the electrical energy is distributed and utilized at
the consumer end
Rating: 11 KV, 6.6 KV, 3.3 KV, 440 V and 230 V
Less than 200 MVA
On the basis of working purpose
• Instrument Transformer: They are generally known as an isolation transformer.
Instrument transformer is an electrical device used to transform current as well as voltage level.
The most common use of instrument transformer is to safely isolate the secondary winding when
the primary has high voltage and high current supply so that the measuring instrument, energy
meters or relays which are connected to the secondary side of the transformer will not get
damaged.
Current Transformer
2000:5
Voltage/Potential Transformer
500:120
Core and Shell type Transformer
Core Construction
Structure of laminated core
Types of Winding
• Cylindrical
• Helical
• Double helical
• Multi-layer helical
• Cross-over
• Disc and continuous disc
• Aluminum foil
Windings used in core-type transformer
video
Value of K for different type of transformer
Type K
Single phase core type 1.0 to 2.0
Single phase core type 0.75 to 0.85
Three phase shell type 1.3
Three phase core type (distribution) 0.45
Three phase core type (power) 0.6 to 0.7
Area percentage of circumscribing circle
Square Cruciform Three stepped Four stepped
Gross core area Agi 64 79 84 87
Net core area Ai 58 71 75 78
Net core area, 0.45 0.56 0.6 0.62
Ai=kod2kn
Calculation of Core Area
Voltage per turn,
Et K Q
A suitable value of K can be chosen from the table and Et can be determined
Et
Flux,
m
0.44 f
Therefore, the value of flux in the core can be calculated. The area of the core is found out by assuming
a suitable value of maximum flux density Bm.
m
Net core area required, A i
B m
Gross core area, Ai
Agi
Ki
Design of Winding
For distribution and small power transformers, self oil cooled type upto 50 KVA:
δ=1.1 to 2.3 A/mm2
For large power transformers, self oiled type or air blast, δ= 2.2 to 3.2 A/mm2
For large power transformers with forced circulation of oil or with water cooling coils, δ= 5.4 to 6.2
A/mm2
Ranges of different winding types
Type of Rating Voltage KV Max current Conductor No. of
winding KVA /conductor Cross- conductors in
A section parallel
mm2
Cylindrical 5000-10,000 Upto 33 Upto 80 Upto 30 1 to 2
(Circular
conductors)
Cylindrical 5000-8000 Upto 6 10-600 5-200 1 to 4
(Rectangular (usually 0.433)
conductors)
Cross-over Upto 1000 Upto 33 Upto 40 Upto 15 1
Helical From 160 to Upto 15 but From 300 and 75 to 100 and 4 to 16
tens of sometimes above above (sometimes
thousands upto 33 more)
Continuous From 2000 to 3.3-220 12 and above From 4 to 200 1 to 4
disc tens of and above (sometimes
thousands more)
Design of window
Window space factor
The window space factor is defined as the ratio of copper area in the window of the total
window area. It depends on the relative amounts of insulation and copper provided, which in
turn depends upon the voltage rating and output of transformers.
Kw=10/(30+KV) KV= voltage of h.v winding in kilo-volt
Space factor is larger for large outputs and smaller for small outputs.
For a transformer of about 1000 KVA rating, Kw=12/(30+KV)
For transformers of about 20 KVA rating, Kw=8/(30+KV)
Design of window
Area of window
Area of window Aw = (total conductor area)/ (window space factor)
=(2apTp)/ Kw ; for single phase transformer
= (4apTp)/Kw ; for three phase transformer
Area of window Aw=height of window*width of window =Hw*Ww
The ratio of height to width of window, Hw/Ww is between 2 to 4
Assuming a suitable value for ratio Hw/Ww, the height and width of window can be calculated
Design of window
Let D be the distance between adjacent limbs as shown in Fig. Now,
D= width of iron+ width of bar conductors+ width of insulation and clearance
d= diameter of circumscribing circle
d
Ww Hw
Width of the window which gives the maximum output,
Ww=D-d=0.7d
or Ww+d=D
D
Design of Yolk
For hot rolled steel, area of the yolk is 15 to 25% larger than core
For CRGO, area of the yolk is taken equal to that of core
For rectangular section yokes,
Area of the yoke Ay= depth of yolk* height of yolk= Dy*Hy
Where
Dy=width of largest core stamping=a
Ay= (1.15 to 1.25) Agi ; for transformers using hot rolled steel
=Agi ; for transformers using grain oriented steel
Overall Dimensions
H= Overall height of transformer
W= length of yolk= overall length of frame
We have the following relations for single phase core type transformers
D= d+Ww, Dy= a
H= Hw+2Hy
W= D+a
Width over two limbs= D+outer diameter of h.v winding
Width over one limb= outer diameter of h.v winding
For 3 phase core type tranformers
D= d+Ww; Dy=a; H=Hw+2Hy; W=2D+a
Width over 3 limbs= 2D+outer diameter of h.v winding
Width over one limb= Outer diameter of h.v winding
For single phase shell type ,
Dy= b, Hy=a, W=2Ww+4a, H=Hw+2a
Resistance of winding
Design of tank with tubes
The inner dimensions of the transformer tank are fixed by the active dimensions of the
transformer and clearances between windings and grounded parts of the transformer.
Width of the tank Wt=2D+De+2b ; for three phase
=D+De+2b ; for single phase
Where
D=distance between adjacent limbs
De= external diameter of h.v winding
b= clearance between h.v winding of the tank
Length of the tank Lt=De+2l
Simplified steps for transformer design
Simplified steps for transformer design
Simplified steps for transformer design
Simplified steps for transformer design
Simplified steps for transformer design
Simplified steps for transformer design
Problem 1
Table 23.1
That’s All!
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