CHAPITRE 1: DESIGN OF TRANSFORMERS

1.1- Generalities
Definition: The transformer is a static electrical machine for transferring electrical energy by
adapting the voltage (sinusoidal in nature) and current levels between two networks of the same
frequency.

Applications:

Figure1.1.1- Electric power transmission

Figure1.1.2- Electric power distribution

(a) (b) (c) (d)

Figure1.1.3- (a,b) Power supply for electronic devices (c) Electrical measurements (d)
Radio frequency transformers
1.2- SINGLE-PHASE TRANSFORMER
1.2.1- Constitution

Figure1.2.1.1- Constitution of the single-phase transformer

(a) (b)

Figure1.2.1.2- Single-phase transformers: (a) Core type (b) Shell type

MMF. The core losses should be less.

1.2.2- Physical and geometric parameters for transformer sizing
 Et in V per turns

Volt (Emf) per turns: Et  4.44m f with  m in Wb
 f in Hz


Cross-section of single phase core type transformer:

 Figure1.2.2.1- Cross section of single phase core transformer
KVA rating of single phase transformer:

Q in kVA
3 
Q  E p I p .10 with  E p in V
 I in A
 p

 Tp : number of primary turns

E  T : number of secondary turns
 S
However, Et  p and AT  Tp I p  TS I S with 
Tp  AT : Ampere turns
 I S : secondary current in A

Thus, Q  Et AT .103

 Aw : Window area in m 2
 2

Aw K w  Ai : Iron area in m

In addition Et  4.44m f , m  Bm Ai and AT  with  K w : Window space factor
2  : Current density in [Link] 2

 Bm : Flux density in T

i.e. Q  2.22 fBm Ai Aw K w .103

Ip
Area of cross section of primary conductor: a p 


IS
Area of cross section of secondary conductor, aS 


Conductor area in window: AC  Aw K w  a pTp  aS TS

m
Ratio of magnetic and electric loading:  
AT
Single phase Core type transformer:

 H : Overall height
 W : Overall width

 D : Distance between core centers  H  H w  2HY
  D W d
 d : Distance of circumscribing circle  W
 
WW : Width of the window  W  Da
 HW : Height of the window  DY  a

 H Y : Height of yoke
 D : Depth of yoke
 Y
Note: Generally, we take H Y  a

Single phase Shell type transformer:

 H  H w  2 HY
 W  2W  4a
 W

 H Y  a
 DY  b
1.3- THREE-PHASE TRANSFORMER
1.3.1- Constitution

Figure1.3.1.1- Three-phase core transformer

1.3.2- Physical and geometric parameters for Three-transformer sizing

Cross-section of three-phase core type transformer:

Figure1.3.2.1- Cross section of three-phase core transformer

KVA rating of single phase transformer:

Q in kVA

Q  3 E p I p .10 3 with  E p in V
 I in A
 p
  Tp : number of primary turns
E  T : number of secondary turns
 S
However, Et  p and AT  Tp I p  TS I S with 
Tp  AT : Ampere turns
 I S : secondary current in A

Thus, Q  3Et AT .103

 Aw : Window area in m 2

 Ai : Iron area in m 2
AK  
In addition Et  4.44m f , m  Bm Ai and AT  w w with  K w : Window space factor
4  : Current density in [Link] 2

 Bm : Flux density in T

i.e. Q  3.33 fBm Ai Aw K w .103

Conductor area in window: AC  Aw K w  2a pTp  2aS TS

Three- phase Core type transformer:

Figure1.3.2.2- Three-phase core transformer

 H : Overall height
 W : Overall width

 D : Distance between core centers  H  H w  2HY
  D W  d
 d : Distance of circumscribing circle  w
 
WW : Width of the window  W  2D  a
 HW : Height of the window  DY  a

 H Y : Height of yoke
 D : Depth of yoke
 Y

1.4- TANK AND TUBES

Height, length and width of the tank

 H t :height of the tank in m

 H t  H  clearance(30 to 60)cm  L : length of the tank in m
  t
 Lt  L  clearance(10 to 20)cm with 
W  W  clearance(10 to 20)cm  Wt : width of the tank in m
 t  L : lenght of the transformer in m

Effective surface area of the tank

St  2 H t ( Lt  Wt ) in m2

Transformer losses
For radiation = 6 W/ m2C and convection = 6.5 W/ m2C
PL  12.5St with  in °C and PL in W

Transformer losses with dissipation from all the tubes of area

PL  12.5St  8.78 At with At the area of tubes in m2

Area of one tubes

at   dt 0.9 H t with dt the diameter of one tube in m

Number of tubes
At
nt 
at
1.4- CORE DESIGN
1.4.1- Rectangular core

Figure1.4.1.1- Rectangular core

 Ai : Iron area in m 2

a: Width of the stamping or leg in m
Core type Transformer : Ai  abKi with 
 b: Width of the transformer in m
 K i : iron factor or stacking factor

Shell type Transformer : Ai  2abK i

1.4.2- Rectangular core

Figure1.4.2.1- Rectangular core

 Ai : Iron area in m 2

2 a: Width of the stamping or leg in m
Core type Transformer : Ai  a Ki with 
 a: Width of the transformer in m
 K i : iron factor or stacking factor

Shell type Transformer : Ai  2a 2 Ki

 1.4.3- Square core (with a circular coil)

Figure1.4.3.1- Square core (with a circular core)

 Ai : Iron area in m 2

2 2 a: Width of the stamping or leg in m
Ai  a K i   0.71d  K i with 
d: diameter of circumscribing circle in m
 K i : iron factor or stacking factor

1.4.4- Cruciform or 2-stepped core

Figure1.4.4.1- Square core (with a circular core)

 a  0.85d
Ai   2ab  b 2  K i  0.62d 2 K i with  and
 b  0.53d
 Ai : Iron area in m 2

a: Width of the largest stamping in m
 b: Width of the smallest stamping in m
 d: diameter of circumscribing circle in m

 K i : iron factor or stacking factor

Note: Generally, we take K i  0.9

1.5- APPLICATION
1.5.1- Single phase transformer

1- Determine the main dimensions of the core and window for a 500 kVA, 6600/400V,
50Hz, single phase core type. The flux density is 1.2T. The current density is [Link]-
 2
. The window space factor is 0.32. The volt/turn is 16.8. The type of core is cruciform.
The height of the window is 3 times its width.
2- Calculate the numbers of turns and cross sectional area of the conductors used for the
primary and secondary windings

Solution

1- Determine the main dimensions of the core and window

Q  500kVA , E p  6600V ES  400V , f  50Hz , single phase core type. Bm  1.2T .
  [Link] 2 . KW  0.32 . Et  16.8 . The type of core is cruciform. HW  3Ww

Flux
Et 16.8
Since Et  4.44m f , we have m    0.076Wb
4.44 f 4.44  50
Net iron area of the leg or limb
 0.076
Ai  m   0.0633m 2
Bm 1.2
Diameter of the circumscribing circle
Ai 0.0633
Since for a cruciform core Ai  0.56d 2 . Thus d    0.34m
0.56 0.56
Width of the largest stamping
a  0.85d  0.85  0.34  0.29m
Width of the smallest stamping
b  0.53d  0.53  0.34  0.18m
Height of the yoke
H y  a  0.29m
Area of the window
Since Q  2.22 fBm Ai Aw K w .103
Q 500
then Aw  3
 6 3
 0.067m2
2.22 fBm Ai K w .10 2.22  50 1.2  0.0633  0.32  2.75 10 10
Width of the window
0.067
In fact, Aw  H wWw  3Ww2 . Thus Ww   0.15m
3
Height of the window
In fact, H w  3Ww  3  0.15  0.45m
Overall height
H  H w  2 H Y  0.45  2  0.29  1.03m
Overall length
W  Ww  d  a  0.15  0.34  0.29  0.78m
Width or depth of the transformer
DY  a  0.29m
Summary
Ai  0.0633m 2 ; d  0.34m ; a  0.29m ; b  0.18m ; Aw  0.067m2 ; Ww  0.15m ;
H w  0.45m ; H  1.03m ; W  0.78m ; DY  0.29m

2- Calculate the numbers of turns and cross sectional area of the conductors used for the
primary and secondary windings

Number of primary turns

E 6600
T1  p   393
Et 16.8
Number of secondary turns
E 400
T2  S   24
Et 16.8

Cross-sectional area of the primary winding conductor

I p Q.103 500.103
ap     27.55mm 2
  Ep 2.75  6600
Cross-sectional area of the secondary winding conductor
I Q.103 500.103
ap  S    454.5mm 2
  Es 2.75  400
1.6- TUTORIALS
Exercise 1:
Determine the dimensions for core and yoke for a 5KVA, 50Hz single phase core type
transformer. A rectangular core is used with long side twice as long side twice as long as short
side. The window height is 3 times the width. Voltage per turn is 1.8 V. Space factor 0.2, current
density 1.8 A/mm2 flux density 1wb/ m2

Exercise 2:
Calculate the dimension of the core, the number of turns and cross- sectional area of conductors
in the primary and secondary windings of a 100 KVA, 2300/400 V, 50 Hz, 1 phase, shell type
transformer. Ratio of magnetic and electric loading = 480 x 10-8 (i.e. flux and secondary mmf
at full load) Bm = 1.1 Wb/ m2, δ = 2.2 A/mm2, KW = 0.3; Stacking factor = 0.9,
Depth of stacked core H
 2.6 and W  2.5
Width of central limb Ww

Exercise 3:
Determine the main dimensions of the core of a 5 KVA, 11000/1400 volts, 50 Hz, single phase
core type distribution transformer having the following data: The net conductor area in the
window is 0.6 times the net cross- sectional area of iron in the core. The core is of square cross
section, maximum flux density is 1 wb/ m2. Current density is 1.4 A/mm2. Window space' factor
is 0.2. Height of the window is 3 times its width.

Exercise 4:
Determine the main dimensions for the core and the yoke for a 250 KVA, 50 Hz, single phase
core type transformer having the following data: Emf per turn is 15v, window space factor is
0.33, current density is 3A/mm2 and Bmax is 1.1 T. The distance between the centre of the square
section core is twice the width of the core.

Exercise 5:
The tank of a 1250 KVA natural oil cooled transformer has the dimensions of length, width and
height as 1.55m x 0.65m x 1.85m respectively. The full load loss is 13.1 kw. Find the number
of tubes for this transformer assuming: W/ m2C due to radiation = 6 and due to convection =
6.5. Improvement in convection due to provision of tubes = 40% temperature rise = 40C.
Length of each tube = 1m and diameter of tubes. Neglect the top and bottom surfaces of the
tank as regards cooling.

Exercise 6:
A 250 kVA, 6600/400V, 3 phase core type transformer has a total loss of 4800W at full load.
The transformer tank is 1.25m in height and 1 m X 0.5 m in plan. Design a suitable scheme for
tubes if the average temperature rise is to be limited to 35C. The diameter of tubes is 50mm
and are spaced 75mm from each other. The average height of tubes is 1.05m. Specific heat
dissipation due to radiation and convection is respectively 6 and 6.5 W/m2 -C. Assume that
convection is improved by 35% due to provision of tubes.

Exercise 7:
Calculate the approximate overall dimensions for a 200KVA,6600/440V,50HZ,3Ф core type
transformer. The following data may be assumed: emf per turn = 10v, Max. flux density = 1.3
Web/ m2, current density =2.5 A/mm2,window space factor=0.3,overall height = overall width,
slacking factor = 0.9. use a 3 stepped core. For a three stepped core, width of largest stamping
= 0.9d and net iron area = 0.6 d2 where d is the diameter of circumscribing circle.

Exercise 8:
Estimate the main dimensions including winding conductor area of a 3-phase, delta to star core
type transformer rated at 300 KVA, 6600/440 V, 50 Hz. A suitable core with three steps having
a circumscribing circle of 0.25 m diameter and a leg spacing of 0.4 m is available. δ =
2.5A/mm2, EMF per turn = 8.5 V, Kw = 0.28, Sf =0.9 (Stacking factor)

Exercise 9:
Calculate approximate overall dimensions for a 200KVA, 6600/440V, 50Hz, 3 phase core type
transformers. The following data may be assumed: emf per turn = 10V, maximum flux density
= 1.3 Wb/ m2, current density = 2.5 A/mm2, window space factor = 0.3, overall height = overall
width, staking factor = 0.9. use a 3 stepped core for which net iron area is 0.6 m2, width of the
largest stamping is 0.9d.