SYLHET ENGINEERING COLLEGE

EEE 404

TRANSFORMER DESIGN

SUBMITTED BY
SHAHJAHAN
2015338531
SOYABBIR ABU HANIF
SUBMITTED TO
2015338535
JANIBUL ALAM SOEB
FAYZUL ISLAM
LECTURER
2015338540
DEPT. OF EEE
SHAHJALAL ATIK
SYLHET ENGINEERING
2015338545
COLLEGE
MITHUN KANTI PAUL
2015338547
SAYEDA SAMIHA ISLAM
2015338555
TRANSFORMER DESIGN Dept. Of EEE

Contents

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TRANSFORMER DESIGN Dept. Of EEE

1 Introduction
1.1 Transformer
Electrical power transformer is a static device which transforms electrical energy
from one circuit to another without any direct electrical connection and with the
help of mutual induction between two windings. It transforms power from one circuit
to another without changing its frequency but may be in different voltage level.

Figure 1: Basic Circuit of a transformer

1.2 Types of transformer

Depending upon the type of construction used:

Figure 2: Illustrating a Core Type Transformer.

1.Core type

Figure 3: Illustrating a Shell Type Transformer.

2.Shell type

1.3 Cutway views of a three-phase transformer

Cutaway views of a three-phase transformer are shown in Figure 4. These cross-
sectional views show the window and iron areas. The three-legged core is designed
to take advantage of the fact that, with balanced voltages impressed, the flux in
each phase leg, adds up to zero. Therefore, no return leg is needed under normal
conditions. When the transformer is subjected to unbalanced loads, or unbalanced
line voltages, it may be best to use three single-phase transformers, because of the

Figure 4: Cutway view of a three-phase transformer.

high-circulating currents.

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TRANSFORMER DESIGN Dept. Of EEE

1.4 Comparison of core type and shell type transformers

I.Construction:-Core type transformers are much simpler in design and permit
easier assembly and insulation of winding.
II. Mechanical forces:- The forces produced between windings is proportional to
the product of the currents carried by them. Very large electromagnetic forces are
produced when secondary winding is short circuited. Since the windings carry cur-
rents in opposite direction, there exists a force of repulsion between them. Hence,
the inner winding experiences a compressive force and outer winding experiences a
tensile force. In a shell type transformer, windings have greater capability of with-
standing forces produced under short circuit as these windings are surrounded and
supported by the core. But in a core type transformer windings have a poorer me-
chanical strength.
III. Leakage reactance:- In core type transformer large space required between
the high and low voltage winding, it is not possible to subdivided the winding, while,
in shell type transformer the windings can be easily subdivided by using sandwich
coil. So it is possible to reduce the leakage reactance of shell type transformers.
IV. Repairs:- The winding of core type transformer is completely accessible so
coils can be easily inspected. And also core type transformer is easy to dismantle
for repair. In shell type transformer, the coils are surrounded by core, therefore
difficulty in inspection and repair of coils.
V. Cooling:- In core type transformer windings are exposed and therefore the cool-
ing is better in winding than core. In case of shell type transformer core is exposed
therefore cooling is better than winding.

1.5 Classification on the basis of type of service

I. Distribution transformer
II. Power transformer

1.6 Classification on the basis of power utility

I. Single phase transformer
II. Three phase transformer

1.7 Construction of transformer

I. Design of core
II. Design of window
III. Design of yoke

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TRANSFORMER DESIGN Dept. Of EEE

IV. Design of L.V winding

V. Design of H.V winding
VI. Calculation of losses
VII. Tank Design
VIII. Transformer cooling

1.8 Optimum design

Transformer may be designed to make one of the following quantity as minimum
i. Total volume
ii. Total weight
iii. Total cost
iv. Total loss
All these quantities vary with ratio r = φm/AT . If we choose high value of ‘r’ then
flux will be high, so large cross section is required which will increase volume, weight
and cost of iron and also give higher iron loss. Also due to decrease in value of ‘AT’
the volume, weight and cost of copper decreased and also decrease in copper losses.
Thus ‘r’ is a controlling factor for above mention quantities.

1.9 Design of core

Rectangular core: It is used for core type distribution transformer and small
power transformer for moderate and low voltages and shell type transformers. In
core type transformer the ratio of depth to width of core varies between 1.4 to 2. In
shell type transformer width of central limb is 2 to 3 times the depth of core.

Figure 5: Square and Stepped core

Figure 6: Cross-section and dimensions of Stepped cores

Square and stepped cores: For high voltage transformers, where circular coils
are required, square and stepped cores are used.

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TRANSFORMER DESIGN Dept. Of EEE

1.10 Choice of flux density

The value of flux density in the core determines the core area.
High value of flux density give smaller core area, so saving in iron cost. Also small
core area provides reduced mean turn of winding which gives reduction in copper
cost. But higher flux density increase iron losses resulting high temperature rise.
The value of flux density also depends upon service conditions of transformer. A
distribution transformer design with low value of flux density to keep down the iron
losses and increase in all day efficiency.
The values of maximum flux density for transformers

i. For hot rolled silicon steel

Distribution Transformer 1.1 to 1.35 wb/m2
Power transformer: 1.25 to 1.45 wb/m2

ii. For CRGO core Upto 132 kV 1.55 wb/m2

For 275 kV 1.6 wb/m2
For 400 kV and Generation Transformer 1.7 to 1.75 wb/m2

1.11 Window Space Factor

It is the ratio of copper area in the window to the total window area.
Kw = 10/(30+kV) for transformer rating 50 to 200kVA
Kw = 12/(30+kV) for rating about 1000 kVA
Kw = 8/(30+kV) for rating about 20 kVA

1.12 Window dimensions

The area of window depend upon total conductor area and window space factor.
Area of window Aw = total conductor area/ window space factor
= 2.ap Tp/Kw for 1-ph transformer
= 4.ap Tp/Kw for 3-ph transformer
Aw = height of window x width of window = Hw x Ww
The ratio of height to width of window, Hw /Ww is b/w 2 to 4.

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TRANSFORMER DESIGN Dept. Of EEE

1.13 Design of Yoke

The section of yoke can either be taken as rectangular or it may be stepped. In
rectangular section yokes,
depth of the yoke = depth of core area of yoke,
Ay = Dy x Hy
Dy = depth of yoke= width of largest core stamping = a

1.14 Overall dimensions

Single Phase Transformer
d= diameter of circumscribing circle
D= distance b/w centers of adjacent limbs
H= overall height
W= length of yoke
D = d + Ww,
Dy = a
H = Hw + 2Hy
W=D+a

Figure 7: Overall dimensions of single phase transformer

Width over two limbs = D + outer diameter of hv winding

Width over one limb = outer diameter of hv winding

Three Phase Transformer

D = d + Ww, Dy = a
H = Hw + 2Hy W = 2D + a

Figure 8: Overall dimensions of three-phase transformer

Width over two limbs = D + outer diameter of hv winding Width over one limb =
outer diameter of hv winding

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TRANSFORMER DESIGN Dept. Of EEE

1.15 Types of Losses in a Transformer

There are various types of losses in the transformer such as iron losses, copper
losses, hysteresis losses, eddy current losses, stray loss, and dielectric losses. The
hysteresis losses occur because of the variation of the magnetisation in the core
of the transformer and the copper loss occur because of the transformer winding
resistance.These are-
Iron Losses
Hysteresis Loss
Eddy Current Loss
Copper Loss Or Ohmic Loss
Stray Loss
Dielectric Loss

1.16 Tank
Because of the losses in the transformer core and coil, the temperature of the core
and coil increases. In small capacity transformers the surrounding air will cool the
transformer effectively and keeps the temperature rise well with in the permissible
limits. As the capacity of the transformer increases, the losses and the temperature
rise increases. In order to keep the temperature rise with in limits, air may have to be
blown over the transformer. This is not advisable as the atmospheric air containing
moisture, oil particles etc., may affect the insulation. To overcome the problem of
atmospheric hazards, the transformer is placed in a steel tank filled with oil. The
oil conducts the heat from core and coil to the tank walls. From the tank walls the
heat goes dissipated to surrounding atmosphere due to radiation and convection.

1.17 Cooling of transformer

The coolant used in transformers are air and oil. Transformers using air as coolant
are called Dry type transformers while transformers which use oil as coolant are
called Oil immersed transformers.
Methods of Cooling of Transformers: The choice of cooling method depends
upon the size, type of application and the type of conditions of installation sites.
The symbols designated these methods depend upon medium of cooling used and
type of circulation employed.
Circulation:- Natural-N, Forced-F

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TRANSFORMER DESIGN Dept. Of EEE

Cooling of Dry-type transformer Air Natural (AN), Air Blast (AB)

Cooling medium
•A - air cooling
•O - oil cooling
•K, L - cooling with synthetic fluid
•W - water cooling

Methods of cooling:
Air Natural (AN)-upto 1.5MVA
Air Blast (AB)
Oil natural (ON) – Upto 10 MVA
Oil Natural – Air Forced (ONAF)
Oil Forced– Air Natural (OFAN) – 30 MVA
Oil Forced– Air Forced (OFAF)
Oil Natural – Water Forced (ONWF) – Power plants
Oil Forced - Water Forced (OFWF) – Power plants

2 Calculation Of Design Parameters

2.1 Design Parameters
Rating 100KVA
Primary Voltage 11KV
Secondary Voltage 132KV
Phase 3
Primary Connection Delta
Secondary Connection Star
Frequency 50Hz
Cooling Type Oil immersed natural cooled
Max. Temp Rise 40◦

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TRANSFORMER DESIGN Dept. Of EEE

2.2 Parameters That is Used Throughout The Entire Design

Let,
φm main flux,Wb
Bm maximum flux density,W b/m2
δ current density, A/m2
Agi gross core area,m2
Ai net core area, 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
Tp , Ts number of turns in primary and secondary windings respectively
Ip , Is current in primary and secondary windings respectively, A
Vp , Vs terminal voltage of primary and secondary windings respectively, V
ap , as area of conductors of primary and secondary windings respectively, m2
Hy height of yoke
Lmtp , Lmts length of primary and secondary windings respectively, m
rp , rs resistance of primary and secondary windings respectively, Ω

2.3 Calculation Of Core

Here, k = 0.6 √ √
∴ Voltage per turn Et = k Q = 0.6 100 = 6v
Et 6V
∴ Flux in the core, φm = = = 0.027wb
4.44 × f 4.44 × 50Hz
Hot rolled silicon steel grade 92 is used.The value of flux density Bm is assumed
as 1.0 wb/m2
φm 0.027
Net iron area, Ai = = = 0.027m2 = 27 × 103 mm2
Bm 1.0
Using a cruciform core, Ai = 0.56d2
r
27 × 103
∴ diameter of circumscribing circle, d = = 219.58mm
0.56
Width of laminations:

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TRANSFORMER DESIGN Dept. Of EEE

a = 0.85d = 0.85 × 219.58 = 186.643mm

b = 0.53d = 0.53 × 219.58 = 116.38mm

The laminations are punched from 750mm wide plates and the nearest standard
dimensions are a = 186mm and b = 116mm

2.4 Calculation Of Window Dimensions

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The window space factor for a small 100KVA transformer is kw = = 0.06,
30 + Kv
Here Kv = High voltage side

The current density in the winding is taken as 2.3A/mm2

Output of transformer:

Q = 3.33f Bm kw δAw Ai × 10−3

100 = 3.33 × 50 × 1 × 0.06 × 2.3 × 106 × Aw × 0.027 × 10−3

Aw = 0.161m2 = 161.19 × 103 mm2

Taking the ratio height to width of window as 2.5,

Hw × Ww = 161.19 × 103

2.5 × Ww2 = 161.19 × 103

Ww = 253.92mm ' 254mm

Hw = 634.80mm ' 63mm

Area of window provided:

Aw = 635 × 254 = 161290mm2

= 161.29 × 103 mm2

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TRANSFORMER DESIGN Dept. Of EEE

= 0.16129m2

∴distance between adjacent core centers:

D = Ww + d = 254 + 219.58 = 473.58mm

2.5 Yoke Design

The area of yoke is taken as 1.2 times that of limb.
1
∴ Flux density in yoke= = = 0.833W b/m2
1.2
Net area of yoke = 1.2 × 27 × 103 = 32.4 × 103 mm2

32.4 × 103
Gross area of yoke= = 36 × 103 mm2
0.9

Taking the section of the yoke as rectangular

Depth of yoke,Dy = a = 186.64mm

36 × 103
∴ Height of yoke,Hy = = 192.88mm ' 193mm
186.64

2.6 Overall Dimension of Frame

Height of frame:

H = Hw + 2Hy

H = 635 + 2 × 193

H = 1021mm

Width of frame, W = 2D + a = 2 × 474 + 187 = 1135mm

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TRANSFORMER DESIGN Dept. Of EEE

2.7 Design Of Low Voltage Winding

Primary line voltage = 11000V, connection = Delta.

Primary phase voltage = 110000V

110000
∴ No. of turns per phase, Tp = 6
= 1833 turns
100 × 1000
Primary phase current, Ip = = 3.03A
3 × 11000
A current density of 2.3A/mm2 is used.
3.03
Area of primary conductor,ap = = 1.31mm2
2.3
From IS:1897-1962 table using a bare conductor of 7.7 × 2.2mm,

area of bare conductor = 14.9 mm2

3.03
Current density in primary winding, δp = = 0.20 A/mm2
14.9
The conductors are paper covered.The increase in dimensions on account of pa-
per covering is 0.5mm using three layers for winding.Helical winding is used.

Therefore space has to be provided for (83 +1) = 84 turn along the axial depth.

axial depth for L.V winding, Lcs = 84× axial depth of conductor = 84×7.5 = 630mm

The Height of window is 635mm.This leaves a clearance of (635-630)/2 = 2.5 on

each side of the winding.

Using 0.5mm pressboard cylinders between layers,

Radial depth of L.V,

bp =number of layers × radial depth of conductor + insulation between layers

bp = 22 × 2.7 + 2 × 0.5 = 60.4mm

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TRANSFORMER DESIGN Dept. Of EEE

diameter of circumscribing circle d = 219.59mm

Using pressboard warps 1.5mm thick as insulation between 1V winding and core.

Inside diameter of 1V winding = 219.59 + 2 × 1.5 = 222.59mm

Outside diameter of 1V winding = 222.59 + 2 × 60.4 = 343.39mm

2.8 Calculation of HV winding

Secondary line voltage = 132000V; (Star Connection)

132000V
∴ Secondary phase voltage = √
3
= 76210.23V

76210.23V
No. of turns per phase Ts = 6
= 12701.7

100×1000
Secondary phase current Is = 3×132000
= 0.25Amps.

A current density of 2.3A/mm2 is used.

.25
∴ Area of secondary conductor as = 2.3 = .108mm2
q
Diameter of bare conductor = π4 × .108 = .37mm

Using paper covered conductors. From Table (IS : 3454-1966) the nearest stan-
dard conductor size has :

bare diameter = .40mm, insulated diameter = .575mm with fine covering.

π
Modified area of conductor as = 4
× .402 = .126mm2

.25
Actual value of current density used δp = .126
= 1.984A/mm2

The spacers used between adjacent coils are 5mm in height.

Axial depth of high voltage winding :

Lcp = numberof turn × axialdepthof eachconductor

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TRANSFORMER DESIGN Dept. Of EEE

= 1059 × .575
= 608.95mm

The height of window is 635mm and therefore the space left between winding and
window is (635 − 608.95)mm = 26.05mm. This is occupied by insulation and axial
bracing of the coil. The clearance left on each side is 13.125mm. Which is sufficient
for 11kV Transformer.

The insulation used between layers is 0.3mm thick paper.

∴ Radial depth of h.v coil, bs = 12 × .575 = 6.9mm

From reference book eq.:7.22 the thickness of insulation between HV and LV wind-
ing is = 5 + .9kV = 5 + .9 × 132 = 123.8mm
This includes the width of oil duct

∴ Inside diameter of HV winding = outside diameter of lv winding + 2× thickness

of insulation
= 343.39 + (2 × 123.8)
= 590.99mm

Outside diameter of HV winding = 3590.99 + 2 × 6.9 = 604.479mm

Clearance between winding and two adjacent limbs = 604.479 − 473.58 = 130.89mm

2.9 Resistance Calculation

590.99 + 604.79
Mean diameter of secondary winding = = 597.79
2
Length of secondary winding, Lmts = π × 597.79 × 10−3 = 1.87m
Ts ρLmts 12701 × 0.021 × 1.87
Resistance of secondary winding at 75◦ C rs = =
as .108
= 4398.30Ω
222.59 + 343.39
Mean diameter of primary winding = = 282.99mm
2
Length of primary winding Lmtp = π × 282.99 × 10−3 = .889m
1833 × .02 × .889
Resistance of primary winding at 75◦ C rp = = 24.87Ω
131

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TRANSFORMER DESIGN Dept. Of EEE

1833
∴ Total resistance referred to primary = 24.87 + × 4398.3 = 659.62Ω
12701

Ip Rp 3.03 × 659.62
P.U resistance of transformer r = = = .181Ω
Vp 11000

2.10 Leakage Reactance Calculation

604.79 + 222.59
Mean diameter of winding = = 413.69mm
2
Length of mean turn Lmt = π × 413.69 × 10−3 = 1.29mm

(Lcp + Lcs ) 630 + 608.95

Height of winding Lc = = = 619.47mm
2 2
∴ Leakage reactance of transformer referred to primary side
Lmt bp + bs
Xp = 2πf µ0 Tp2 × (a + )
Lc 3
1.29 60.4 + 6.9
Xp = 2 × π × 50 × 4π × 10−7 × 18332 × × (123.8 + ) × 10−3
.619 3
Xp = 404.23Ω
3.03 × 404.23
P.U leakage reactance x = = 0.11
11000
√
P.U Impedance s = .1812 + .112 = .213

2.11 Regulation Calculation

P.U regulation  = r cosφ + x sinφ

∴ Per unit regulation at unity power factor  = r = .181

At zero p.f lagging  = 2x = 0.112 = 0.121

at 0.8 p.f lagging  = .181 × .8 + .1100 × .6 = .2108

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TRANSFORMER DESIGN Dept. Of EEE

2.12 Calculation Of Losses

I 2 R loss:
I 2 R loss at 75◦ C = 3Ip2 Rp = 3 × 3.032 × 24.87 = 684.98W

Taking stray loss 15% above,

Total I 2 R loss including stray loss pc = 1.15 × 684.98 = 787.727W

Core loss
Taking the density of laminations as 7.6 × 103 kg/m3

weight of 3 limbs = 3 × .3 × 0.027 × 7.6 × 103 = 184.68 kg

The flux density in the limbs is 1wb/m2 and corresponding to this density,specific
core loss is 1.2w/kg.

∴ core limbs = 184.68 × 1.2 = 121.616W

weight of two yokes = 2 × 1.135 × 0.0324 × 7.6 × 103 = 558.96kg, Correspond-

ing to a flux density of .833wb/m2 in the yoke.The specific core loss = 0.85w

∴ core loss in yoke = 558.96 × .85 = 475.11w

Total core loss Pi = 121.616 + 475.11 = 596.726W

2.13 Efficiency Calculation

Total losses at full load = 787.727 + 596.726 = 1384.446W
100000
Efficiency at full load at unity p.f, η = × 100% = 98.63%
100000 + 1384.446
For maximum efficiency X 2 Po = Pi
r r
Pi 596.726
∴X= = = 0.87
Po 787.727
Thus maximum efficiency occurs at 87 percent of full load,this is good figure for
power transformer.

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TRANSFORMER DESIGN Dept. Of EEE

2.14 Tank Design

Height over yoke H = 1021mm alowing 50mm at the base and about 1500mm for
oil.
Height of oil level = 1021 + 50 + 150 = 1221mm Allowing another 200mm height of
tank is taken as 1.45m on Ht = 1.45m

Assuming a clearance of 50mm along the width on each side.

Width of tank Wt = (2 × 474) + 604.79 + (2 × 50) = 1652.73mm
∴ Width of tank is taken Wt = 1.65m

The clearance along the length of transformer is grater along the width. This is
because additional space is needed along the length to accommodate tapping etc.
The clearance used is approximately 50mm on each side.

∴ Length of tank Lt = 604.79 + (2 × 50) = 704.79mm

∴ Lt , is taken as 0.704m

Total specific loss dissipation surface of tank St = 2 × (1.65 + .704) × 1.45 = 6.82m2
Total specific loss due to radiation and convection is 12.5W/m2 − ◦ C
1384.446
∴ temperature rise = = 16.23◦ C
6.82 × 12.5
This is below 35◦ C and therefore plain tank is sufficient for cooling and no tubes
are required .

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TRANSFORMER DESIGN Dept. Of EEE

2.15 Design Sheet

1.Material .35mm thick 92 grade
2.Output constant K 0.6
3.Voltage per turn Et 6V
4.Circumscribing circle diameter d 219.58mm
5.Dimensions
a 186.643mm
b 116.38mm
6.Net iron area Ai 27 × 103 mm2
7.Flux density Bm 1.0wb/m2
8.Flux in the core φm 0.027wb
9.Specific iron loss 1.2 W/kg
10.Iron loss in limb 121.616W
Yoke
1.Depth of yoke Dy 186.64mm
2.Height of yoke Hy 193mm
3.Net yoke area 32.4 × 103 mm2
4.Flux density 0.833W b/mm2
5.Specific iron loss 0.85W
6.Iron loss 475.11 W
Window
1.Number 2
2.Window space factor kw 0.06
3.Height of window Hw 635 mm
4.Width of window Ww 120 mm
5.Window area Aw 161.29 × 103 mm2
Frame
1.Distance between adjacent limbs D 473.58 mm
2.Height of frame H 1021 mm
3.Width of frame W 1135 mm
4.Depth of frame Dy 186.64 mm

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TRANSFORMER DESIGN Dept. Of EEE

Windings L.V H.V

1.Types of windings Helical Cross-over
2.Connection Delta Star
3.Dimensions-bare insulated 7.7 × 2.2 mm2 Diameter = 0.63 mm
7.5 × 2.7 mm2 Diameter = 0.814 mm
4.Area 14.9 mm2 .108 mm2
5.Current density 2.3 A/mm2 2.3 A/mm2
6.Turns per phase 1833 12702
7.Turns per layer 84 1059
8.Number of layers 22 12
9.Height of winding 630 mm 608.95 mm
10.Depth of winding 60.4 mm 6.9 mm
11.Insulation
Between layers 0.5 mm press board 0.3 mm paper
Between coils 5.0 mm spacers
12.Coil Diameters
Inside 222.59 mm 590.99 mm
Outside 343.39 mm 604.479 mm
13.Resistance at 75◦ C 24.87Ω 4398.30Ω

Insulation Between L.V. Winding and core press board wraps 1.5 mm
Between L.V. winding and H.V. winding bakelized paper 5.0 mm
Width of duct between L.V. and H.V. 5 mm
Tank
1.Dimensions
Height Ht 1.45 m
Length Lt 704.79 mm
Width Wt 1.65 m
2.Oil Level 1221 mm
3.Tubes Nill
4.Temperature rise 16.23◦ C
Impedance
1.P.U. resistance r .181Ω
2.P.U. reactance x .11Ω
3.P.U. impedance s .213Ω

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TRANSFORMER DESIGN Dept. Of EEE

Losses
1.Total core loss 596.726 W
2.Total copper loss 787.727 W
3.Total losses at full load 1384.44 W
4.Efficiency at full load and u.p.f 98.63%

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TRANSFORMER DESIGN Dept. Of EEE

3 References
1.A k Shawhney, A Course In Electrical Machine Design,Second Edition
2.Colonel Wm. T. McLyman,Transformer and Inductor Design Handbook, Fourth
Edition
3.Transformer Design and Design Parameters,Ronnie Minhaz, P.Eng.
4. https://www.electrical4u.com/what-is-transformer-definition-working-principle-of-
5. http://www.ymcaust.ac.in/electrical/images/transformer_design.pdf
6. https://circuitglobe.com/types-of-losses-in-transformer.html
7. http://allaboutmetallurgy.com/wp/wp-content/uploads/2016/10/is.1897.
2008.pdf
8. http://www.questin.org/sites/default/files/standards/is.7404.1.1991_
0.pdf

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TRANSFORMER DESIGN Dept. Of EEE

4 Appendix
4.1 IS 1897-1962:Recomended sizes of copper strip

Figure 9: IS:1897-1962

4.2 Diameter of paper-covered round copper conductors

Figure 10: IS:3454-1966

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