Electrical Machine Design (17EE64)

Module 3

Design of Transformer
 Introduction
Classification of transformer
1) Based on type of construction.
2) Based on type of Application.
3) Based on no of phases
4) Based on cooling types
 Construction of transformer
Transformer consists of
• Magnetic Circuits : Core, Yoke, Limbs
• Electric Circuit : Primary and secondary winding
• Insulation: Insulation between the windings,
Insulation between lamination, insulation
between core and windings.
• Cooling circuit : Cooling tank, cooling tubes,
cooling accessories.
• Other accessories such as buchholz relay,breather
etc.
 Aim of transformer design
• To obtain the dimension of the main parts :
Net iron area of the core, Area of the window, diameter
of the conduction, Height of yoke, depth of the yoke,
Area of the window, height of the window, depth of the
window, overall height of the transformer and width of
the transformer.
• Winding details : No of turns in HV winding and No of
turns in LV winding, Primary and secondary rated
currents, Area of cross section of primary and
secondary winding.
• Design of cooling tank and it accessories
 Requirement to initiate transformer design
• Emf Equation of transformer
E1=4.44 𝑓 ∅𝑚 𝑇1 volts
E2=4.44 𝑓 ∅𝑚 𝑇2 volts
• Emf/ turn Equation
E=K 𝐾𝑉𝐴 𝑟𝑎𝑡𝑖𝑛𝑔/𝑃𝑕𝑎𝑠𝑒 volt/turn
• Output Equation
Q= 2.22 f Bm Ai Ki Aw Kw δ x 103 KVA for single phase shell
and core type transformer
Q= 3.33 f Bm Ai Ki Aw Kw δ x 103 KVA for three phase core
type transformer
Q=6.66 f Bm Ai Ki Aw Kw δ x 103 KVA for three phase shell
type transformer
 Steps to design transformer
Step 1: Calculate net iron area by using volt per turn equation.
𝐸
𝐴𝑖 =
4.44 𝑓 𝐵𝑚
𝐸=𝐾 𝑄/𝑝𝑕𝑎𝑠𝑒
K= 4.44 𝑓 𝑟103
∅ 𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑓𝑙𝑢𝑥
r= 𝑚=
𝐼 𝑇 𝐹𝑢𝑙𝑙 𝑙𝑜𝑎𝑑 𝑀𝑀𝐹
Step 2: find the diameter “d” of the circumscribing circle by using net
iron area formulae.
Ai=0.56 𝑑 2 , a= 0.85 d and b=0.53 d for two stepped core
Ai=0.6 𝑑 2 , a= 0.9 d for three stepped core
Ai=b*2a , rectangular core, shell type transformer.
Step 3 : Determine the width of the Window
𝑊𝑤 =D-d , single phase core type transformer.
Step 4: Calculate the area of cross section of the window by using
output equation.
𝑄
Aw=
2.22 𝑓 𝐵𝑚 𝐴𝑖 𝐾𝑖 𝐾𝑤 𝜕103
𝐴𝑤 =𝐻𝑤 𝑊𝑤
Determine the height of the window,
Step 5:Height of the yoke 𝐻𝑦 =a, Depth of the yoke 𝐷𝑦 = a.
Step 6: Determine the over all dimension of the transformer.
For single phase transformer.
Over all Width of the transformer W=𝑊𝑤 + 𝑑 + 𝑎
Or W=D+a,
Over all height of the transformer H= 𝐻𝑤 +2𝐻𝑦
For three phase core type transformer
Over all width of the transformer W=2𝑊𝑤 +2d+a.
For single phase shell type transformer.
Overall width of the transformer W=2𝑊𝑤 +2d+2a or 2𝑊𝑤 +4a
Winding details:
• Since the applied voltage V1 is approximately equal to the voltage induced E1
= 4.44 m f T1 = Et T1
• Number of primary turns (or turns / phase)
T1 = V1 / Et in case of single phase transformers
T1= V1ph / Et in case of 3 phase transformers
• Number of secondary turns (or turns / phase)
T2 = V2/ Et in case of single phase transformers
T2= V2ph / Et in case of 3 phase transformers
• Primary current (or current/phase)
I1 = kVA x 103 / V1 in case of single phase transformers
I1= kVA x 103 / 3V1ph in case of 3 phase transformers
Cross-sectional area of primary winding conductor a1 = I1/ mm2

Secondary current (or current / phase)

I2 = kVA x 103 / V2 in case of single phase transformers
I2= kVA x 103 / 3V2ph in case of 3 phase transformers

Cross-sectional area of secondary winding conductor a2 = I2/ mm2

 No Load Current
• No load current of transformer is having two
components
1) Core loss component or Active component 𝐼𝑐
2) Magnetizing component or reactive
component 𝐼𝑚
No load current 𝐼0 = (𝐼𝑚 )2 + (𝐼𝑐 )2
 Calculation of Magnetizing current
Total Magnetizing Ampere turns
𝐴𝑇𝐹 = Ampere turns required for iron parts+ total
ampere turns required for joints
Ampere turns required for joints = 8,00,000 𝐵𝑔 𝑙𝑔
𝐵𝑔 =𝐵𝑚 ,𝑙𝑔 = Length of the air gap.

𝐴𝑇 𝑓𝑜𝑟 𝑖𝑟𝑜𝑛 𝑝𝑎𝑟𝑡𝑠+8,00,000 𝐵𝑔 𝑙𝑔

𝐼𝑚 = Amps
2𝑇𝑝
 Calculation of Core loss current
Volume of the iron = Net iron area X Mean length of iron or
mean flux path.
Weight of the iron = Volume of the iron X Density of the iron.
Density of the iron = 7.8 x 103 Kg/𝑚3
Total core loss = Weight of iron X loss/kg

𝑇𝑜𝑡𝑎𝑙 𝑐𝑜𝑟𝑒 𝑙𝑜𝑠𝑠

Core loss current 𝐼𝑐 = Amps
𝑉1
 Resistance and reactance of the transformer.

Equivalent resistance of the transformer

referred to primary
′
𝑅𝑝𝑒 =𝑅𝑝 +𝑅𝑠
Similarly Equivalent resistance of the
transformer referred to secondary
𝑅𝑠𝑒 =𝑅𝑠 +𝑅𝑝 ′
Equivalent Reactance referred to primary
• Assumptions considered for the derivation of
Equivalent reactacne:
a. Effect of magnetizing current is neglected.
b. Reluctance and effect of saturation of iron is
neglected.
c. All the mmf is assumed to be used to over
come the reluctance of coil height
d. Leakage flux distribution in coil and in the
space between the LV and HV coils is assumed
to be parallel to the leg axis.
• Equivalent reactance referred to primary
𝑋𝑝 =𝑥𝑝 +𝑥𝑠 ′
2 𝐿𝑚 𝑏𝑝 +𝑏𝑠 𝑎
𝑋𝑝 =2πf𝑇𝑝 μ𝑜 ( + )
𝐿𝑐 3 2
Equivalent reactance referred to secondary
𝑋𝑠 =𝑥𝑠 +𝑥𝑝 ′
2 𝐿𝑚 𝑏𝑝 +𝑏𝑠 𝑎
𝑋𝑠 =2πf𝑇𝑠 μ𝑜 ( + )
𝐿𝑐 3 2
𝐿𝑚 =𝐿𝑚𝑡𝑝 =𝐿𝑚𝑡𝑠 = meant length of primary and
secondary turns.
𝐿𝑐 =Axial length of the conductor.
 Requirements of cooling system
• In higher rating transformer, due to losses in
transformer , temperature in core and oil
increases.
• In order to keep the temperature rise with in the
limits transformer is placed in a steel tank filled
with the oil.
• The oil conducts heat from the core and coils to
the tank walls.
• From the tank walls heat goes dissipated to
surrounding atmosphere due to convection and
radiation.
• Further increase in capacity of the transformer,
increase in losses and temp raise which demands
large heat dissipating area of the tank, this calls
more space.
• The dissipating area can be increased by artificial
means without increasing the size of the tank.
a) Fitting fins to the tank walls
b) Using corrugated tank
c) Fitting tubes to the tank
d) Using auxiliary radiator tanks.
Tank with tubes is much used in practice.
 Dimension of cooling tank
• The dimension of the tank depends on type,
capacity, voltage rating of the transformer.
• The following clearances can be assumed
between the transformer and tank
a) 30 to 60 cm with respect to height
b) 10 to 20 cm with respect to length
c) 10 to 20 cm with respect to breadth
Height of transformer tank(for single phase)
𝐻𝑡 =𝐻𝑤 + 2𝐻𝑦 + 𝐶𝑙𝑒𝑎𝑟𝑒𝑛𝑐𝑒 30 𝑡𝑜 60𝑐𝑚
Length of transformer tank(for single phase)
𝐿𝑡 =𝑊𝑤 + d + 𝐷𝑒𝑥𝑡 + Clearence 10 to 20 cm
Length of transformer tank (for three phase)
𝐿𝑡 =2𝑊𝑤 + 2d + 𝐷𝑒𝑥𝑡 + Clearence 10 to 20 cm
Length of the transformer tank (for single phase shell type)
𝐿𝑡 =2𝑊𝑤 + 4a + Clearence 10 to 20 cm
Width or breadth of the tank
𝑊𝑡 =𝐷𝑒𝑥𝑡 + 10 to 20 cm clearance (for circular coil)
𝑊𝑡 =𝑊𝑊 + b+ 10 to 20 cm clearance
Effective surface area from which heat is getting
dissipated is assumed as
𝑆𝑡 =2𝐻𝑡 𝐿𝑡 + 𝑊𝑡 𝑚2
Heat goes dissipated to the atmosphere from the tank by
radiation and convection. 6 W per 𝑚2 goes dissipated
from the plain surface per degree centigrade by
convection. 6.5 W per 𝑚2 goes dissipated by radiation.
12.5 W/ 0𝐶 goes dissipated to the surrounding.
If θ is the temperature raise
Then losses dissipated by transformer due to temperature
raise is given by
Transformer losses = 12.5𝑆𝑡 θ Watts
At Equilibrium/steady state condition
Losses responsible for raise in temperature = Heat
dissipated by surface area.
 Expression for Number of cooling tubes
• Permissible temperature raise is 50𝑜 C.
• Including more number of tubes we can limit the
temp raise up to 30 t0 40 % of permissible limit.
• The oil when get heated up ,moves upwards and
cold oil downwards, circulation of oil in the tubes
will be more. Obviously, this circulation of oil
increases the heat dissipation. Because of this
syphoning action, it has been found that the
convection from the tubes increase by about 35 to
40%. Thus if the improvement is by 35%, then the
dissipation in watts from all the tubes of area
At = 1.35 x 6.5At = 8.78 Atθ .
• Thus in case of a tank with tubes, at final steady temperature rise
condition,
Total Losses = 12.5 St + 8.78 Atθ
• Round, rectangular or elliptical shaped tubes can be used. The
mean length or height of the tubes is generally taken as about 90%
of tank height. In case of round tubes, 5 cm diameter tubes spaced
at about 7.5cm (from centre to centre) are used. If dt is the
diameter of the tube, then dissipating area of each tube
at = dt x 0.9Ht.
• Where ‘nt’ is the number of tubes, then total surface area
covered by tubes is given by
At = at X nt.
• Now a days rectangular tubes of different size spaced at
convenient distances are being much used, as it provides a greater
cooling surface for a smaller volume of oil. This is true in case of
elliptical tubes also
• .The tubes can be arranged in any convenient way ensuring
mechanical strength and aesthetic view.
Arrangements of Cooling tubes
Problems on Cooling tubes
 Theory Question
1) Obtain the output equation of single phase and
three phase core type transformer.
2) Derive the expression for No-load current in a
single phase transformer.
3) Obtain the expression for Equivalent reactance
referred to primary for single phase core type
transformer and list the assumption made.
4) Obtain the expression for no of cooling tubes for
single phase transformer
5) Why cooling is needed ? What are the different
methods adopted for cooling ?
 References :
1) Electrical Machine [Link].
2) Design of Electrical Machines –V.N Mittle,
Aravind Mittal.

Thank You