Unit 3
Introduction
Constituents of transformer:
i.
Magnetic Circuit
ii. Electric Circuit
iii. Dielectric Circuit
iv. Other accessories
Classification or Types
Constructional Details
Constructional Details
Constructional Details
Constructional Details
Constructional Details
The requirements of magnetic
material are,
High permeability
Low reluctance
High saturation flux density
Smaller area under B-H curve
For
small
transformers,
the
laminations are in the form of E,I,
C and O as shown in figure
The percentage of silicon in the
steel is about 3.5. Above this
value the steel becomes very
brittle and also very hard to cut
Transformer Core
Core type Construction
Shell Type Construction
Transformer Core
Stepped Core Construction
10
Transformer Core
Ww
Hw
Core Type
Shell Type
11
Transformer Winding
Types of transformer windings are,
Concentric
Sandwich
Disc
Cross over
Helical
12
Transformer Winding
Hw
Ww
13
Transformer Winding
14
Insulations
Dry type Transformers:
Varnish
Enamel
Large size Transformers:
Unimpregnated paper
Cloths
Immersed in Transformer oil insulation & coolent
15
Comparison between
Core & Shell Type
Description
Core Type
Shell Type
Construction
Easy to assemble &
Dismantle
Complex
Mechanical
Strength
Low
High
Leakage reactance
Higher
Smaller
Cooling
Better cooling of
Winding
Better cooling of
Core
Repair
Easy
Hard
Applications
High Voltage & Low
output
Low Voltages &
Large Output
16
Classification on Service
Details
Distribution
transformer
Power Transformer
Capacity
Upto 500kVA
Above 500kVA
Voltage rating
11,22,33kV/440V
400/33kV;220/11kV
etc.,
Connection
/Y, 3, 4 Wire
/; /Y, 3, 4 Wire
Flux Density
Upto 1.5 wb/m2
Upto 1.7 wb/m2
Current Density
Upto 2.6 A/mm2
Upto 3.3 A/mm2
Load
100% for few Hrs,
Part loadfor some
time, No-load for
few Hrs
Nearly on Full load
Ratio of Iron Loss to 1:3
Cu loss
1:1
Regulation
4 to 9%
6 to 10%
Cooling
Self oil cooled
Forced Oil Cooled
17
Output Equation of Transformer
It relates the rated kVA output to the area of core & window
The output kVA of a transformer depends on,
Flux Density (B) related to Core area
Ampere Turns (AT) related to Window area
Window Space inside the core to accommodate primary & secondary
winding
Let,
T- No. of turns in transformer winding
f Frequency of supply
Induced EMF/Turn , Et=E/T=4.44fm
18
Output Equation of Transformer
Window in a 1 transformer contains one primary & one secondary
winding.
Conductor area in Window
Window Space factor,K w
Total area of Window
Ac
Window Space factor,K w
Aw
Conductor area in window, A c K w A w (2)
Current Density() is same in both the windings
Ip
Is
(3)
ap a s
19
Output Equation of Transformer
Ip
Is
a p
; as
If we neglect magnetizing MMF, then (AT)primary = (AT)secondary
AT=IpTp=IsTs
(4)
Total Cu. Area in window, Ac=[Link] of pry wdg + [Link] of sec wdg
No. of pry turns X area
No. of sec turns X area
of
X
section
of
pry
conductor
of
X
section
of
sec
conductor
Tp a p Ts a s
Tp a p Ts a s
Ip
Tp
Ts
Is
1
TpIp TsIs
1
2AT
AT AT
(5)
20
Output Equation of Transformer
Therefore, equating (2) & (5),
KwAw
2 AT
1
AT K w A w ( 6)
2
kVA rating of 1 transformer is given by,
Q VpIp 10-3 EpIp 10-3
Ep
Tp
TpIp 10- 3
E t AT 10 3
E
from
(
1
),
E
T
(6)
1
4.44fm . K w A w 10 3
2
2.22 fm K w A w 10 3
21
Output Equation of Transformer
m
and m Bm A i
We know that, Bm
Ai
Q 2.22 f Bm A i A w K w 10 3 kVA
Three phase transformer:
Each window has 2 primary & 2 Secondary
windings.
Total Cu. Area in the window is given by,
A c 2Tp a p 2Ts a s
4 AT
Ac
Hw
Ww
(7)
4 AT
Compare (2) & (7),
KwAw
K w A w
AT
4
22
Output Equation of Transformer
kVA rating of 3 transformer,
Q 3 EpIp 10 3
Ep
Tp
TpIp 10-3
E t AT 10 3
1
3 4.44 fm . K w A w 10 3
4
3.33 f Bm A i A wK w 10 3 kVA
23
EMF per Turn
Design of Xmer starts with the section of EMF/turn.
Let,
Ratio of Specific magnetic loading
m
r
to
Electric
loading
AT
Q VpIp 10 3
4.44 f m TpIp 10 3
4.44 f m ( AT ) 10 3
m
10 3
r
Q r
Q r 103
2
m
3
4.44 f 10
4.44 f
4.44 f m
Q r 103
4.44 f
24
EMF per Turn
w.k.t , E t 4.44 f m
Q r 103
Q
3
4.44 f
4.44 f 4.44 f r 10 .
4.44 f
4.44 f
4.44 f r 103 Q
Et K Q
where, K 4.44 f r 103
K depends on the type, service condition & method of construction of transformer.
25
EMF per Turn
Transformer Type
Value of K
1 Shell Type
1.0 to 1.2
1 Core Type
0.75 to 0.85
3 Shell Type
1.2 to 1.3
3 Core Type
Distribution Xmer
0.45 to 0.5
3 Core Type Power
Xmer
0.6 to 0.7
26
Optimum Design
Transformer may be designed to make one of the
following quantitites as minimum.
i.
ii.
iii.
iv.
Total
Total
Total
Total
Volume
Weight
Cost
Losses
In general, these requirements are contradictory &
it is normally possible to satisfy only one of them.
All these quantities vary with
r
m
AT
27
Optimum Design
Design for Minimum Cost
Let us consider a single phase transformer.
Q 2.22 f Bm A i A w K w 10 3 kVA
Q 2.22 f Bm A i A c 10 3 kVA
A c K w A w
Assuming that & B are constant, [Link] Constant
Let, Ac Ai M 2 (1)
In optimum design, it aims to determining the minimum value of
total cost. r m
AT
m B m A i
Ac
1
AT K w A w
2
2
28
Optimum Design
Design for Minimum Cost
Bm A i
2 Bm A i
r
A c
Ac
2
A i 2 Bm
r
Ac
Ai
r
Ac
2 Bm
( 2)
is the function of r alone [ & Bm Constant]
From (1) & (2),
M
Ai M & Ac
A A M
2
29
Optimum Design
Design for Minimum Cost
Let, Ct - Total cost of transformer active materials
Ci Cost of iron
Cc Cost of conductor
pi Loss in iron/kg (W)
pc Loss in Copper/kg (W)
li Mean length of flux path in iron(m)
Lmt Mean length of turn of transformer winding (m)
Gi Weight of active iron (kg)
Gc Weight of Copper (kg)
gi Weight/m3 of iron
C t gc C i Weight/m
C c c Gof Copper
c cGc
3
i i
30
Optimum Design
Design for Minimum Cost
C t c i g i li A i c c g c Lmt A c
where, c i & c c specific cos ts of iron and copper respectively.
M
C t c i giliM c c gc Lmt
Differeniating Ct with respect to ,
d
1
1
C t ci g i li M () 1/ 2 c c g c Lmt M 3 / 2
d
2
2
For minimum cost,
d
Ct 0
d
1
1
1/ 2
c i giliM() c c gc Lmt M 3 / 2
2
2
c i gili c c gc Lmt 1
Ac
c i gili c c gc Lmt
Ai
31
Optimum Design
Design for Minimum Cost
c i gili A i c c gc Lmt A c
ci G i cc G c
Ci C c
Hence for minimum cost, the cost of iron must be equal to the cost of
copper.
Similarly,
For minimum volume of transformer,
Volume of iron = Volume of Copper
Gi
gi
Gc
gc
or G i
Gc
gi
gc
For minimum weight of transformer,
Weight of iron = Weight of Conductor Gi Gc
For minimum loss,
Iron loss = I2R loss in conductor
Pi x Pc
2
32
Optimum Design
Design for Minimum Loss and Maximum
Efficiency
Total losses at full load = Pi+Pc
At any fraction x of full load, total losses = Pi+x2Pc
If output at a fraction of x of full load is xQ.
xQ
Efficiency, x xQ P x 2 P
i
c
Condition for maximum efficiency is,
dx
0
dx
xQ Pi x 2 Pc Q - Q 2xPc xQ
dx
0
2
2
dx
xQ Pi x Pc
xQ P x P Q Q 2xP xQ
xQ P x P Q 2xP x
2
xQ Pi x 2 Pc xQ x 2 Pc x 2 Pc
Pi x 2 Pc
33
Optimum Design
Design for Minimum Loss and Maximum
Efficiency
Variable losses = Constant losses
Pi
Pc
pi G i
pcG c
piG i
x
pcG c
2
or
Gi
2 pc
x
Gc
pi
for maximum efficiency
34
Design of Core
Core type transformer :
Rectangular/Square /Stepped cross
section
Shell type transformer : Rectangular
cross section
35
Design of Core
Rectangular Core
For core type distribution transformer
& small power transformer for
moderateDepth
& low
1.4 tovoltages
2
Width
Rectangular coils are used.
of Central limb
For shellWidth
2 to 3
type,
Depth of Core
36
Design of Core
Square & Stepped Core
Used when circular coils are required for high
voltage distribution and power transformer.
Circular coils are preferred for their better
mechanical strength.
Circle representing the
inner surface of the tubular
form carrying the windings (Circumscribing Circle)
37
Design of Core
Square & Stepped Core
Dia of Circumscribing circle is larger in Square
core than Stepped core with the same area of
cross section.
Thus the length of mean turn(Lmt) is reduced in
stepped core and reduces the cost of copper
and copper loss.
However, with large number of steps, a large
number of different sizes of laminations are
used.
38
Design of Core
Square Core
Let, d - diameter of circumscribing circle
a side of square
Diameter,
d a 2 a 2 2a 2 2 a
d
a
Gross core area,
2
d
Agi Area of square a
Let the stacking factor, Sf=0.9.
2
Net core area,
Agi 0.5d 2
39
Ai 0.9 0.5d 2 0.45d 2
Design of Core
Square Core
Gross core area includes insulation area
Net core area excludes insulation area
Area of Circumscribing circle is
Ratio of net core area to Area of Circumscribing circle is
Ratio of gross core area to Area of Circumscribing circle is
2
d
4
0.45d 2
0.58
2
d
4
0.5d 2
0.64
2
d
4
40
Design of Core
Square Core
Useful ratio in design Core area factor,
KC
Net Core area
Square of Circumscri bing Circle
A i 0.45d 2
2
0.45
2
d
d
41
Design of Core
Stepped Core or Cruciform Core
Let,a Length of the rectangle
b breadth of the rectangle
d diameter of the circumscribing circle and diagonal of the rectangle.
Angle b/w the diagonal and length of the rectangle.
The max. core area for a given d is
obtained by the max value of
For max value of ,
(a-b)/2
d
(a-b)/2
dA gi
d
From the figure,
a
cos a d cos
d
b
sin b d sin
d
42
Design of Core
Stepped Core or Cruciform Core
b
Two stepped core can be divided in to 3 rectangles.
Referring to the fig shown,
ab
ab
Gross core area, Agi ab
b
b
2
2
2( a b )
ab
b
2
ab ab b 2 2ab b 2
(a-b)/2
d
(a-b)/2
On substituting a and b in the above equations,
A gi 2(d cos )(d sin ) (d sin ) 2
A gi 2d 2 cos sin d 2 sin 2
A gi d 2 sin 2 d 2 sin 2
For max value of ,
dA gi
d
43
Design of Core
Stepped Core or Cruciform Core
i.e.,
dA gi
d 2 2 cos 2 d 2 2 sin cos 0
d
d 2 2 cos 2 d 2 2 sin cos
2 cos 2 sin 2
sin 2
2
cos 2
tan 2 2
2 tan 1 2
1
1
0
tan
31
.
72
0
Therefore, if the =31.72 , the dimensions a & b will give maximum area of
2
core for a specified d.
a
cos a d cos a d cos(31.720 ) 0.85d
d
b
sin b d sin b d sin(31.72 0 ) 0.53d
d
44
Design of Core
Stepped Core or Cruciform Core
Gross core area,
A gi 2ab b 2
A gi 2(0.85d )(0.53d) (0.53d ) 2
A gi 0.618d 2
Let stacking factor, S f 0.9,
Net core area, Ai Stacking factor X Gross Core area
Ai 0.9 0.618d 2 0.56d 2
The ratios,
Net core area
0.56d 2
0.71
Area of Circumscri bing circle
d2
4
Gross core area
0.618d 2
0.79
2
Area of Circumscri bing circle
d
4
45
Design of Core
Stepped Core or Cruciform Core
Core area factor,
KC
Net Core area
Square of Circumscri bing Circle
A i 0.56d 2
2
0.56
2
d
d
Ratios of Multi-stepped Cores,
Ratio
Net core area
Area of Circumscri bing circle
Gross core area
Area of Circumscri bing circle
Core area
factor,KC
Square
Core
Cruciform
Core
3-Stepped
Core
4-Stepped
Core
0.64
0.79
0.84
0.87
0.58
0.71
0.75
0.78
46
0.45
0.56
0.6
0.62
Design of Core
Choice of Flux Density in Core
Flux density decides,
Area of cross section of the core
Core loss
Choice of flux density depends on,
Service condition (DT/PT)
Material used
Cold rolled Silicon Steel-Work with higher flux density
Upto 132 kV : 1.55 wb/m2
132 to 275kV: 1.6 wb/m2
275 to 400kV: 1.7 wb/m2
Hot rolled Silicon Steel Work with lower flux density
Distribution transformer : 1.1 to 1.4 wb/m2
Power Transformer : 1.2 to 1.5 wb/m2
47
Overall Dimensions
Single phase Core Type
Hy
Hw
Hy
a
W
Dy
Ww
D
48
Overall Dimensions
Single phase Shell Type
Hw
2a
Ww
Depth
Over
winding
49
Overall Dimensions
Thee phase Core Type
Hy
Hy
Hw
Hw
Hy
Hy
Dy
Dy
a
W
Ww
D
Ww
D
50
Design of Winding
Transformer windings: HV winding & LV winding
Winding Design involves:
Determination of no. of turns: based on kVA rating & EMF per turn
Area of cross section of conductor used: Based on rated current and
Current density
No. of turns of LV winding is estimated first using given data.
Then, no. of turns of HV winding is calculated to the voltage
rating.
No. of turns in LV winding, TLV
VLV
AT
(or )
Et
I LV
where, VLV Rated voltage of LV winding
I LV Rated Current of LV winding
51
Design of Winding
No. of turns in HV winding, THV TLV
VHV
VLV
where, VHV Rated voltage of HV winding
52
Cooling of transformers
Losses in transformer-Converted in heat energy.
Heat developed is transmitted by,
Conduction
Convection
Radiation
The paths of heat flow are,
From
From
From
From
internal hot spot to the outer surface(in contact with oil)
outer surface to the oil
the oil to the tank
tank to the cooling medium-Air or water.
Cooling of transformers
Methods of cooling:
1.
2.
3.
4.
5.
6.
7.
8.
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
Cooling of transformers
Transformer Oil as Cooling Medium
Specific heat dissipation due to convection is,
1
4
2 0
conv 40.3
W /m . C
H
where, - Temperatur e difference of the surface relative to oil,0C
H Height of dissipating surface, m
The average working temperature of oil is 50600C. 20 0C & H 0.5 to 1m,
For
conv 80 to 100 W/m 2 .0 C.
The value of the dissipation in air is 8 W/m2.0C. i.e,
10 times less than oil.
Cooling of transformers
Temperature rise in plain walled tanks
Transformer wall dissipates heat in radiation & convection.
For a temperature rise of 400C above the ambient
temperature of 200C, the heat dissipations are as follows:
Specific heat dissipation by radiation,rad=6 W/m2.0C
Specific heat dissipation by convection, conv=6.5 W/m2.0C
Total heat dissipation in plain wall 12.5 W/m 2.0C
The temperature rise,
P Pc
Total losses
i
12.5 S t
Specific heat Heat dissipating
Dissipatio
n
surface
of
tank
St Heat dissipating surface
Heat dissipating surface of tank : Total area of vertical
sides+ One half area of top cover(Air cooled) (Full area of
top cover for oil cooled)
Design of tanks with cooling tubes
Cooling tubes increases the heat dissipation
Cooling tubes mounted on vertical sides of the
transformer would not proportional to increase in
area. Because, the tubes prevents the radiation
from the tank in screened surfaces.
But the cooling tubes increase circulation of oil
and hence improve the convection
Circulation is due to effective pressure heads
Dissipation by convection is equal to that of 35%
of tube surface area. i.e., 35% tube area is added
to actual tube area.
Design of tanks with cooling tubes
Let, Dissipating surface of tank S t
Dissipating surface of tubes XSt
Loss dissipated by surface of the tank by radiation and
6 6.5 St 12.5St
convection =
Loss dissipated by
135
XSt 8.8XSt
6.5
tubes by convection
100
Total loss dissipated
12.5St 8.8XSt 12.5 8.8X St (1)
by walls and tubes
Actual total area of tank walls and tubes St XSt St (1 X )
Design of tanks with cooling tubes
Total losses dissipated
Loss dissipated per m of dissipating surface
Total area
St (12.5 8.8 X ) (12.5 8.8 X )
2
Loss dissipated per m of dissipating surface
( 2)
St (1 X )
(1 X )
2
Temperatur e rise in
Total loss
Transformer with cooling tubes
Loss Dissipated
Total losses, Ploss Pi Pc
(3)
Pi Pc
From (1) and (3), we have,
St (12.5 8.8 X )
Pi Pc
(12.5 8.8 X )
St
Pi Pc
8.8 X
12.5
St
1 Pi Pc
X
12.5
8.8 St
Design of tanks with cooling tubes
1 Pi Pc
1 Pi Pc
Total area of cooling tubes
12.5 St
12.5St (5)
8.8 St
8.8
Let , lt Length of tubes
d t Diameter of tubes
Surface area of tubes d t lt
Total area of tubes
Area of each tube
1
Pi Pc
nt
12.5St (6)
8.8 d t lt
Total number of tubes, nt
Standard diameter of cooling tube is 50mm
& length depends on the height of the tank.
Centre to centre spacing is 75mm.
C4
HT
C3
WT
LT
C2
Doc
C1
Design of tanks with cooling tubes
Dimensions of the tank:
Let, C1 Clearance b/w winding and tank along width
C2 - Clearance b/w winding and tank along length
C3 Clearance b/w the transformer frame and tank at the bottom
C4 - Clearance b/w the transformer frame and tank at the top
Doc Outer diameter of the coil.
Width of the tank, WT=2D+ Doc +2 C1 (For 3 Transformer)
= D+ Doc +2 C1 (For 1 Transformer)
Length of the tank, LT= Doc +2 C2
Height of the tank, HT=H+C3+ C4
Design of tanks with cooling tubes
Clearance on the sides depends on the voltage &
power ratings.
Clearance at the top depends on the oil height above
the assembled transformer & space for mounting the
terminals and tap changer.
Clearance at the bottom depends on the space
required for mounting the frame.
Design of tanks with cooling tubes
Clearance in mm
Voltage
kVA Rating
C1
C2
C3
C4
Up to 11kV
<1000kVA
40
50
75
375
Upto 11 kV
1000-5000kVA
70
90
100
400
11kV 33kV
<1000kVA
75
100
75
450
85
125
100
475
11kV 33kV 1000-5000kVA
Estimation of No-load Current
No-load Current of Transformer:
Magnetizing Component
Depends on MMF required to establish required flux
Loss Component
Depends on iron loss
65
Estimation of No-load Current
No-load current of Single phase Transformer
ly
Total Length of the core = 2lc
Total Length of the yoke = 2ly
lC
lC
Here, lc=Hw=Height of Window
ly= Ww=Width of Window
ly
MMF for core=MMF per metre for max. flux density in core X Total length of Core
= atc X 2lc= 2 atc lc
MMF for yoke=MMF per metre for max. flux density in yoke X Total length of yoke
= aty X 2ly= 2 aty ly
Total Magnetizing MMF,AT0=MMF for Core+MMF for Yoke+MMF for joints
= 2 atc lc +2 aty ly +MMF for joints
The values of atc & aty are taken from B-H curve of transformer steel.
66
Estimation of No-load Current
No-load current of Single phase Transformer
Max. value of magnetizing current=AT 0/Tp
If the magnetizing current is sinusoidal then,
RMS value of magnetising current, Im=AT0/2Tp
If the magnetizing current is not sinusoidal,
RMS value of magnetising current, Im=AT0/KpkTp
The loss component of no-load current, I l=Pi/Vp
Where, Pi Iron loss in Watts
Vp Primary terminal voltage
Iron losses are calculated by finding the weight of cores and yokes. Loss per kg is
given by the manufacturer.
No-load current,
67
I 0 I 2m Il2
Estimation of No-load Current
No-load current of Three phase Transformer
ly
lC
lC
lC
ly
68
