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Transformer Design
OUTPUT EQUATION: - It gives the relationship between electrical rating and physical dimensions
of the machines.
Let
V1 = Primary voltage say LV
V2 = Secondary voltage say HV
I1 = Primary current
I2 = Secondary current
N1= Primary no of turns
N2= Secondary no of turns
a1 = Sectional area of LV conductors (m2)
=
a1 = Sectional area of HV conductors (m2)
=
= Permissible current density (A/m2)
Q = Rating in KVA
We place first half of LV on one limb and rest half of LV on other limb to reduce leakage flux.
So arrangement is LV insulation then half LV turns then HV insulation and then half HV turns.
(1) For 1-phase core type transformer
Rating is given by
Q= KVA
= KVA
= KVA -----------(1)
Where
f = frequency
= Maximum flux in the core
= Sectional area of core
H L L H H L L H
= Maximum flux density in the core Window
V V VV V V VV
Window Space Factor
1-phase core type transformer with
concentric windings
So
2
Put equation value of N1I1 form equation (2) to equation (1)
Window
(2) For 1- phase shell type transformer
LV LV
Window Space Factor
HV HV
LV LV
Kw
HV HV
LV LV
1-phase shell type transformer with
sandwich windings
So
Put equation value of N1I1 form equation (4) to equation (1)
Note it is same as for 1-phase core type transformer i.e. equ (3) Window
(3) For 3-phase core type transformer
H L L H H L L H H L L H
V V VV V V VV V V VV
3-phase core type transformer with
Rating is given by concentric windings
Q= KVA
= KVA
= KVA -----------(6)
Window Space Factor
3
Window
So
Put equation value of N1I1 form equation (7) to equation (6)
(3) For 3- phase shell type transformer
Window Space Factor
Kw
3-phase shell type transformer with
sandwich windings
So
Put equation value of N1I1 form equation (9) to equation (6)
CHOICE OF MAGNETIC LOADING (Bm)
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(1) Normal Si-Steel 0.9 to 1.1 T
(0.35 mm thickness, 1.5%3.5% Si)
(2) HRGO 1.2 to 1.4 T
(Hot Rolled Grain Oriented Si Steel)
(3) CRGO 1.4 to 1.7 T
(Cold Rolled Grain Oriented Si Steel)
(0.14---0.28 mm thickness)
CHOICE OF ELECTRIC LOADING
This depends upon cooling method employed
(1) Natural Cooling: 1.5---2.3 A/mm2
AN Air Natural cooling
ON Oil Natural cooling
OFN Oil Forced circulated with Natural air cooling
(2) Forced Cooling : 2.2---4.0 A/mm2
AB Air Blast cooling
OB Oil Blast cooling
OFB Oil Forced circulated with air Blast cooling
(3) Water Cooling: 5.0 ---6.0 A/mm2
OW Oil immersed with circulated Water cooling
OFW Oil Forced with circulated Water cooling
CORE CONSTRUCTION:
(a) U-I type (b) E-I type
(c) U-T type (d) L-L type
45o 5
(e) Mitred Core Construction (Latest)
EMF PER TURN:
We know
and
Q= KVA (Note: Take Q as per phase rating in KVA)
= KVA
In the design, the ration of total magnetic loading and electric loading may be kept constant
Magnetic loading =
Electric loading =
So
Or using equation (2)
Or
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
ESTIMATION OF CORE X-SECTIONAL AREA Ai
We know
6
Or
So
Now the core may be following types
d d/√2
1-Step 2-Step 3-Step Core 4-Step Core
Or Square- Core Or Cruciform- Core
K= 0.45 0.56 0.60 0.625
d = Diameter of circumscribe circle
For Square core
Gross Area
Let stacking factor
Actual Iron Area
(0.45 for square core and take ‘K’ as a general case)
So
a
Or
b
Graphical method to calculate dimensions of the core
Consider 2 step core
Ө
b a
Percentage fill
2-Step
Or Cruciform- Core
7
= 0.885 or 88.5%
No of steps 1 2 3 4 5 6 7 9 11
% Fill 63.7% 79.2% 84.9% 88.5% 90.8% 92.3% 93.4% 94.8% 95.8%
ESTIMATION OF MAIN DIMENSIONS:
Consider a 3-phase core type transformer
W
hy
L H
Ww=
(D-d)
d D
We know output equation 3-phase core type transformer
So, Window area
where Kw =Window space factor
For higher rating Kw = 0.15 to 0.20
Assume some suitable range for
D = (1.7 to 2) d
Width of the window Ww = D-d
Height of the window
Generally
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Yoke area Ay is generally taken 10% to 15% higher then core section area (A i), it is to reduce the iron loss in
the yoke section. But if we increase the core section area (A i) more copper will be needed in the windings
and so more cost through we are reducing the iron loss in the core. Further length of the winding will
increase resulting higher resistance so more cu loss.
Ay = (1.10 to 1.15) Ai a
Depth of yoke Dy = a
Height of the yoke hy = Ay/Dy b
Width of the core
W = 2*D + d
Height of the core
H = L + 2*hy
b a
Flux density in yoke
2-Step
Or Cruciform- Core
ESTIMATION OF CORE LOSS AND CORE LOSS COMPONET OF NO LOAD CURRENT IC:
Volume of iron in core = 3*L*Ai m3
Weight of iron in core = density * volume
= * 3*L*Ai Kg
= density of iron (kg/m3)
=7600 Kg/m3 for normal Iron/steel
= 6500 Kg/m3 for M-4 steel
From the graph we can find out specific iron loss, pi (Watt/Kg ) corresponding to flux density Bm in core.
So
Iron loss in core =pi* * 3*L*Ai Watt
Similarly
Iron loss in yoke = py* * 2*W*Ay Watt
Where py = specific iron loss corresponding to flux density By in yoke
Total Iron loss Pi =Iron loss in core + Iron loss in yoke
Core loss component of no load current
Ic = Core loss per phase/ Primary Voltage
Ic
ESTIMATION OF MAGNETIZING CURRENT OF NO LOAD CURRENT Im:
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Find out magnetizing force H (atcore, at/m) corresponding to flux density Bm in the core and atyoke
corresponding to flux density in the yoke from B-H curve
So
MMF required for the core = 3*L*atcore
MMF required for the yoke = 2*W*atyoke
We account 5% at for joints etc
So total MMF required = 1.05[MMF for core + MMF for yoke]
Peak value of the magnetizing current
RMS value of the magnetizing current
ESTITMATION OF NO LOAD CURRENT AND PHASOR DIAGRAM:
No load current Io V1=-E1
Io
No load power factor Ic
Ф0
Im
The no load current should not exceed 5% of the full load current.
E2
ESTIMATION OF NO OF TURNS ON LV AND HV WINDING No load phasor diagram
Primary no of turns
Secondary no of turns
ESTIMATION OF SECTIONAL AREA OF PRIMARY AND SECONDARY WINDINGS
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Primary current
Secondary current
Sectional area of primary winding
Sectional area of secondary winging
Where is the current density.
Now we can use round conductors or strip conductors for this see the IS codes and ICC (Indian Cable
Company) table.
DETERMINATION OF R1 & R2 AND CU LOSSES:
Let Lmt = Length of mean turn
Resistance of primary winding
Resistance of secondary winding
Copper loss in primary winding
Copper loss in secondary winding
Total copper loss
Where
Note: On No load, there is magnetic field around connecting leads etc which causes additional stray losses
in the transformer tanks and other metallic parts. These losses may be taken as 7% to 10% of total cu losses.
DETERMINATION OF EFFICIENCY:
Efficiency
ESTIMATION OF LEAKAGE REACTANCE:
Assumptions
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1. Consider permeability of iron as infinity that is MMF is needed only for leakage flux path in the
window.
2. The leakage flux lines are parallel to the axis of the core.
Consider an elementary cylinder of leakage flux lines of thickness dx at a distance x as shown in following
figure.
MMF at distance x
a b2
b1
dx
Permeance of this elementary cylinder Lc x
(Lc =Length of winding)
Leakage flux lines associated with elementary cylinder
N1I1=N2I2
x
MMF Distribution
Flux linkage due to this leakage flux
Flux linkages (or associated) with primary winding
Flux linkages (or associated) with the space a between primary and secondary windings
We consider half of this flux linkage with primary and rest half with the secondary winding. So total flux
linkages with primary winding
Similarly total flux linkages with secondary winding
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Primary & Secondary leakage inductance
Primary & Secondary leakage reactance
Total Leakage reactance referred to primary side
Total Leakage reactance referred to secondary side
It must be 5% to 8% or maximum 10%
Note:- How to control XP?
If increasing the window height (L), Lc will increase and following will decrease b1, b2
& Lmt and so we can reduce the value of XP.
CALCULATION OF VOLTAGE REGULATION OF TRANSFORMER:
TRANSFORMER TANK DESIGN:
Width of the transformer (Tank)
Wt=2D + De + 2b
Where De= External diameter of HV winding
b = Clearance width wise between HV and tank
Depth of transformer (Tank)
lt= De + 2a
Where a= Clearance depth wise between HV and tank
Height of transformer (Tank)
Ht= H + h
Where h=h1 + h2= Clearance height wise of top and bottom
W 13
hy
L H
Ww
(D-d)
D D
a
lt
De
b a b
Wt
h1
W
Ht
H
h2
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Tank of a 3-Phase transformer
CALCULATION OF TEMPERATURE RISE:
Surface area of 4 vertical side of the tank (Heat is considered to be dissipated from 4 vertical sides of the
tank)
St= 2(Wt + lt) Ht m2 (Excluding area of top and bottom of tank)
Let
= Temp rise of oil (35o C to 50o C)
12.5St =Total full load losses ( Iron loss + Cu loss)
So temp rise in o C
If the temp rise so calculated exceeds the limiting value, the suitable no of cooling tubes or radiators must be
provided
Specific Heat dissipation
CALCULATION OF NO OF COOLING TUBES: 6 Watt/m2-0C by Radiation
6.5 Watt/m2-0C by Convection
Let xSt= Surface area of all cooling tubes
Then
Losses to be dissipated by the transformer walls and cooling tube
= Total losses
6 W-Raditon+6.5 W=12.5 Convection 6.5*1.35 W ( 35% more) Convection only
So from above equation we can find out total surface are of cooling tubes (xSt)
Normally we use 5 cm diameter tubes and keep them 7.5 cm apart
At= Surface area of one cooling tube
Hence
No of cooling tubes
7.5 Cm
d= 5 Cm
Tank and Arrangement of Cooling tubes
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WEIGHT OF TRANFORMER:
Let
Wi = Weight of Iron in core and yoke (core volume* density + yoke volume* density) Kg
Wc= Weight of copper in winding (volume* density) Kg
(density of cu = 8900 Kg/m3)
Weight of Oil
= Volume of oil * 880 Kg
Add 20% of (Wi+Wc) for fittings, tank etc.
Total weight is equal to weight of above all parts.
