Transformer

1
 Basic assembly

[Link] showing basic

assembly of a three phase
transformer (3 mts)

[Link]

Lets list various parts which you can recognize

2
 Transformer construction

The basic parts of a power transformer

 Core ( Laminated )
 Windings of the Transformer
 Insulating Material
 Tap Changer
 Transformer Tank
 Oil Conservator Tank
 Bushings
 Cooling Tube and Radiator
 Breather
 Buchholz Relay
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 Classification or Types

Transformers

Based on Based on transformer Based on

Core Ratio Service

Distributio
Power
Core Shell Step n
Step up Transform
Type Type Down Transform
er
er

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Constructional Details

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Constructional Details

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Constructional Details

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 Classification of Transformer

• Shell type
• Core type
 Core & Shell Type Transformer
• In core type transformer, each and every limb is occupied
with both primary and secondary winding. In single phase,
half part of the primary winding and half part of the
secondary winding are placed successively around each
limb.
• On the other hand in shell type transformer, the main
frame is constructed with three limbs. Both the primary and
secondary winding are wound around the central limb.
• In core type transformer no additional limb is used as flux
flow path but in shell type transformer two limbs are used as
low-reluctance flux path.
• The core type transformer is generally more suitable for
high voltage whereas the shell-type is generally more
suitable for low voltage.
 1. Core Type Transformer
 In core-type transformer, the windings are given to a
considerable part of the core.

 The coils used for this transformer are form-wound and

are of cylindrical type.

 The low voltage windings are placed nearer to the

core as it is the easiest to insulate.

 The effective core area of the transformer can be

reduced with the use of laminations and insulation.

 The general arrangement of the core-type transformer

with respect to the core is shown below.
1- Phase Core- Type Transformer
3- phase Transformer core type
3-Phase core Type Transformer

Fig.(2): construction of core type three phase transformer

 2. Shell-Type Transformer
 In shell-type transformers the core surrounds a
considerable portion of the windings.

Schematic diagram of 1 Phase Core andshell-type transformer

 [Link]-Type Transformer
 The coils are form-wound but are multi layer disc type
usually wound in the form of pancakes.

 Paper is used to insulate the different layers of the multi-

layer discs.

 The whole winding consists of discs stacked with insulation

spaces between the coils.

 These insulation spaces form the horizontal cooling and

insulating ducts.

 Such a transformer may have the shape of a simple

rectangle or may also have a distributed form.
 Half coils

1-Phase Core Type 1-Phase Shell Type

2. 1-Phase Shell-Type
Transformer
3- phase Shell typeTransformer
 Comparison between
Core & Shell Type
Description Core Type Shell Type
Construction Easy to assemble & Complex
Dismantle

Mechanical Strength Low High

Leakage reactance Higher Smaller

Cooling Better cooling of Better cooling of Core

Winding

Repair Easy Hard

Applications High Voltage & Low Low Voltages & Large

output Output
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 Transformer core

Review of Transformer core Types

(1.45 mts)
[Link]

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 Constructional Details
Core is constructed by
assembling (stacking) laminated
sheets of steel (0.33-0.5mm),
with minimum air-gap between
them (to achieve continuous
magnetic path)
For transformers, the laminations
are in the form of E,I,L, C and O
Laminated sheets of steel are
used to reduce eddy current loss.
The steel used is having high
silicon content and sometimes
heat treated, to provide high
permeability and low hysteresis
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loss.
 CRGO Material
• Grain oriented Electrical Steels are iron-silicon alloys that provide low
core loss and high permeability which reduces magnetizing current.
• CRGO Grain oriented grades of electrical steel are typically used in
Transformer and large generators.
• Important physical properties of Electrical steels (CRGO) include
resistivity, saturation induction, magneto-crystalline anisotropy.
• Resistivity, which is quite low in iron, increases markedly with the addition
of silicon (3-5% si).
• Higher resistivity reduces the core loss by reducing the eddy current
component.
• Raising the silicon content reduces the aging of the material.
• Maximum flux density - 1.4Wb/m2 in hot rolled steels
• 1.8 Wb/m2 in cold rolled steels
 Mitred Joint
• A miter joint, is a joint made by beveling each of two parts to be
joined, usually at a 45°/ 45°angle or 35°/55° to form a corner, usually
a 90° angle.
• The limbs and yoke lamination edges are placed face to face at
the Mitred joints in transformer core.
• Flux enters and leaves the lamination, gets smooth path in the
direction of its flow
• Involves extra manufacturing cost but it is preferable where loss
minimization is the main criteria in designing of transformer
core.
Mitred Joint

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 Mitred Joint
45°/ 45°angle or 35°/55°

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Mitred Joint

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 Transformer Core cross-section
• In square core when bending of conductor being wound
takes place, its mechanical strength decreases.
• For higher area of core, a circular cross section is required
so that we can have minimum length of mean turn.
• Practically, the circular core involves assembling of large
number of laminations of different sizes.
• Hence we use stepped cores – arranging core section in
steps such that corners lie on the circle called
circumscribing circle .
• Stepped cores reduces length of mean turn- conductor
material
Core assembly

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Core cut section – Shell type

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Transformer Core cross-section

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Transformer Core cross-section

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Transformer Core cross-section

Stepped Core
Stepped core

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35
Transformer Core cross-section
Stepped Core Construction

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Yoke cross section

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 Transformer Core

Hw
Ww

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Core Type
 Cooling of Cores

• In small sized cores:- no special arrangement for cooling is

required.
• If Diameter of Core > 0.35m, longitudinal ducts for cooling
are provided where width of duct is 6mm(approx).
• If Diameter > 0.8m, ducts have to be provided on both
sides, longitudinal as well as transverse ducts.
Cooling of Cores

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[Link] does a transformer work (5.4 mts)

Animation showing basic working and

assembly of core

[Link]

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 Watch them later

[Link] parts and their functions

(27mts)
Model of transformer
[Link]

[Link] transformer manufacturing and

assembly (13 mts)
[Link]
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Power Transformer and Distribution
Transformer

Difference-between-power-transformer-
and-distribution-transformer

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 Classification on Service
Details Power Transformer Distribution
transformer
Voltage rating 400/33kV;220/11kV…etc., 11,22,33kV/440V

Connection Δ/Δ; Δ/Y, 3φ, 4 Wire Δ/Y, 3φ, 4 Wire

Flux Density Upto 1.7 wb/m2 Upto 1.5 wb/m2

Current Density Upto 3.3 A/mm2 Upto 2.6 A/mm2

Load Nearly on Full load 100% for few Hrs, Part

load for some time,
No-load for few Hrs

Cooling Forced Oil Cooled Self oil cooled

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Power Transformer and Distribution Transformer
Basis of difference Power-transformer Distribution-transformer

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Power Transformer and Distribution Transformer
Basis of difference Power-transformer Distribution-transformer

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CONSERVATOR

AND

BREATHER
 CONSERVATOR and BREATHER

• With the rise of temperature, the oil level in the transformer

increases.
• Rise of temperature depends on the load of the transformer.
If load increases, oil expands and when load decreases,
contraction of oil occurs.
• Smaller transformers are not totally filled by oil, some space
is left between tank walls and oil, which is occupied by air.
• The tank is connected to the atmosphere through a vent
pipe. Air is expelled out if oil expands. Air is drawn from the
atmosphere if oil contracts.
• When air enters the transformer, it is required to extract
moisture from the air.
 CONSERVATOR
• If the transformer becomes overloaded, it overheats the oil and
sludge formation occurs in the presence of air.
• If transformer suffers short circuit, temperature rise becomes
very high and this causes vaporization of a part of the oil, which
forms an explosive mixture with air which can ignite and cause
considerable damage.
• To prevent the oil coming in contact with air as well as moisture,
conservators are used.
• It takes the responsibility of expansion and contraction of oil
without allowing it to come into contact with air.
• The conservator is an air-tight cylindrical drum mounted on or
near the cover of the transformer.
• It is connected to the transformer through a small pipe.
 CONSERVATOR and BREATHER

• Breather is used to extract moisture from the air.

• It is a small container connected to the vent pipe
containing a dehydrating material such as silica gel
crystal impregnated with cobalt chloride.
• Breathers filled with silica gels are provided to separate
moisture from the aspirated air.
• The color of the material is blue when it is dry.
• It becomes whitish pink when it is damp.
• In front of the container, a glass window is provided to
observe the color of the material .
 Buchholz relay

• [Link] relay and its working 3mts

• [Link]

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Buchholz relay

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TRANSFORMER WINDINGS
 INTRODUCTION
• Low voltage winding
• High voltage winding
• Circular & rectangular coductors.
• Generally circular windings are used for all the types
of transformers invariably.
• Rectangular windings involve wastage of space &
under short current conditions it gets deformed.
• Rectangular windings is used for very small capacity
transformers.
Round Conductor

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Rectangular coductors.

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Winding with Rectangular coductors

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 Factors affecting type of winding

Type & arrangement of windings depends on some

factors
[Link] rating
[Link] circuit strength
[Link] rise
[Link]
[Link] voltage
[Link] facilities.
 Transformer Winding
 Types of transformer windings are,
 Concentric - used in core type
 Sandwich – used in shell type
The windings used in core type of transformers are
1. Cylindrical Windings
2. Helical Windings (Single,Double and Multiple)
3. Cross-over Windings
4. Disc & Continuous Disc Windings
5. Aluminium Foil Windings

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 Transformer winding

• 6. Transformer windings 3mts

• [Link]

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Transformer winding

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Transformer winding

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 Cylindrical windings
• Cylindrical windings are layered type and use
either rectangular or round conductors.
• Conductors are wound on the flat side with their longer
sides parallel to the core axis.
• The layered winding may have conductors wound in one,
two or more layers and is, therefore, accordingly called
the one, two or multi-layered winding.
• Cylindrical windings employing rectangular conductors
are used mainly as low voltage windings upto 6.6 kV for
kVA ratings up to 600-750.
 Cylindrical windings

• They are wound on a solid paper bakelite cylinder.

• In order to improve cooling conditions of the inner layer,
these are often wound on vertical strips forming an oil
duct, between winding & insulating cylinder.
67
68
69
70
71
 Helical Windings

• Helical windings are mostly used for LV coils of medium &

high capacity transformers with currents as high as say
2000 A.
• Here, axial spacing strips are provided for duct
formation to improve oil circulation for better cooling.
• The ducts are formed by spacers placed all the way
round the periphery of the cylinder at regular intervals.
 Transposition of helical winding
• For uniform division of current between the parallel
conductors, they are transposed so that each
conductor may take each possible position.
 Cross-over windings
• Suitable for current rating not exceeding about 25 A.
• Mostly used for HV windings of low rating
transformers where number of turns may be large
but conductors are of small cross sections with
double cotton covering or paper covering.
• The whole cross-over winding is divided into a
number of coils depending upon the voltage rating.
• Each coil is wound over a former with several
number of layers & many number of turns per layer.
• The coil ends, one from inside and other from
outside are joined to other similar coils in series.
 Cross over winding
• Various coils are separated by blocks of insulating
material to allow free oil circulation.
Continuous Disc Windings
77
 Continuous Disc Windings
• A Continuous disc winding consists of several discs & in each
disc there are radially wound strip conductors so that there may
be several layers in each disc.
• Layers are wound spirally from inside outwards.
• The discs are separated from each other by press board
sectors.
• The winding is named “Continuous Disc” as it is wound with a
continuous conductor without a single joint.
• These are reliable & strong and therefore are widely used both
as LV& HV coils in large capacity transformers.
Transformer Winding

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 Aluminium foil Windings

• Aluminium in place of copper can be used as a material for

conductors in any of the windings.
• Aluminium, when used as a single section has many
disadvantages compared to copper.
• Hence are employed in foil windings, because it can be
rolled to thinner &more flexible sheets than copper.
Aluminium foil Windings

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Aluminium foil Windings

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 Transformer Windings

• 7. 3 D Animation of Distribution Transformer assembly.

Watch how insulation ,spacers and wooden
strips are placed for making ducts.(3 mts)
• [Link]

• 8. 40 KVA Distribution Transformer Manual assembly

specially windings and insulation process 7mts
(Explained in Hindi)
• [Link]

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Winding arranged in window

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Core Building
CORE WITH UPPER YOKE REMOVED
CORE COIL ASSEMBLY
COIL CLAMPING FOR ADJUSTING IT’S AXIAL HEIGHT
Disc Type Winding
Disc Type Winding with Tappings
FOIL TYPE WINDING
Cross Over Windings
Cylinder Pasting on Former
Bobbins on which copper coils are loaded
Winding arranged in window

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Winding arranged in window

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Winding arranged in window

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Transformer Winding

Hw

Ww

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Windings used in core type
transformer
Selection of windings
 Tappings and Tap changers
• The transformer voltage at the load side desired to be
constant or as close to the design value. But the load voltage
may vary according to current drawn by the load or supply
voltage.
• Secondary voltage = (supply voltage or primary

voltage)/Turnsratio.

• To maintain constant secondary voltage/load voltage or as

close to the desired value it is needed to change the turn’s
ratio.
• The tap changer of the transformer performs this task to
change the turn’s ratio.
• Basically the tap changer removes or connects some portion
of the winding to the load side or source side.
• Tap changer can be located on primary side or secondary
side. However it will be placed on high voltage winding side.
 Tappings
• Principal Tapping: This is the point where we obtain rated
secondary voltage when rated primary voltage is applied.
• Negative tapping -The number of turns is less with respect
to the principal tap. Means as the tap changer moved to
negative portion - the number of turns from which output is
taken will decrease.
• Positive tapping : The number of turns is more with
respect to the principal tapping i.e as the tap changer is
moved to positive portion - the number of turns from which
output is taken will increase.

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Why tap changer is placed on high
voltage side?

• The tap changer is placed on high voltage side because:

1) The HV winding generally wound over LV winding hence it
is easier to access the HV winding turns instead of LV
winding.
2) The current through the HV winding is less compared to
LV windings, hence there is less “wear” on the tap changer
contacts. Due to this low current, tapping on load tap changer
during change over, spark will be less.
3) Providing tapping on low voltage side may not get exact
voltage regulation.
106
 Why tap changer is placed on high
voltage side?
• For Example consider a transformer tap changer is designed
to get ± 2.5 % voltage regulation in a 3 phase 6.6
kV/400 Delta/Star transformer designed for 11.55 Voltage per
turn on secondary. The voltage per phase on low voltage side
is 230 V. The number of turns are 20 (230/11.55).
• It is possible to tap a whole number of turns. Here, the
minimum number of turns possible is one.
• Therefore, the minimum voltage regulation we get from the
transformer tap changers on l.v. side is ± 5% (440V /20
=11.55 V) => regulation in % = 11.55
• It is not possible to obtain a regulation of± 2.5% with tappings
on l.v. side 107
 Necessity of tapchangers

• To compensate the variation of applied voltage on bulk

supply system and other system transformers.
• To compensate for regulation within transformer and
maintain the output voltage constant.
• Control of reactive power flow in system.
• Compensate the factors that not accurately known at the
time of planning of system.
• To allow future changes in existing system conditions.
 Types of tap changers

• Off load: The change in tap position done with when

transformer is in off load condition. Mainly distribution
transformers having such tapchangers.

• On load: A selector switch device, which may include

current interrupting contactors, used to change transformer
taps with the transformer energized and carrying full load.
• Load current must not be interrupted during tap change
operation.
• No section of the transformer winding may be short-
circuited during a tapchange
 How inside tank OLTC look like

Mild steel tank

Phase board

Copper leads
Main contact
Auxiliary contact

Selector switch arm

Fixed contact (cu & tungsten)

Driving shaft
Collector ring

Transition resistance
 Fixed contact

Tungsten part

Copper part
 Insulations

Dry type Transformers:

 Varnish
 Enamel
Large size Transformers:
 Unimpregnated paper
 Cloths
Immersed in Transformer oil – insulation & coolant

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 Cooling of transformers

• Since no transformer is truly an “ideal” transformer, each will incur

a certain amount of energy loss, mainly that which is converted to
heat.
• The windings and core are the primary sources of heat, although
internal metallic structures can act as a heat source as well.

• Methods of removing this heat can depend on the application, the

size of the unit, and the amount of heat that needs to be
dissipated.
• The insulating medium inside a transformer, usually oil, serves
multiple purposes, first to act as an insulator, and second to
provide a good medium through which to remove the heat.
 Cooling of transformers
• It is imperative to have proper cooling ducts and passages in
the proximity of the heat sources through which the cooling
medium can flow so that the heat can be effectively removed
from the transformer.
• The natural circulation of oil through a transformer through
convection where the heat is carried by the insulating medium
until it is transferred through the transformer tank wall to the
external environment.
• Larger transformers that cannot be effectively cooled using
radiators and fans rely on pumps that circulate oil through the
transformer and through external heat exchangers, or coolers,
which can use air or water as a secondary cooling medium.
 Cooling of transformers
• Radiators, typically detachable, provide an
increase in the surface area available for heat
transfer by convection without increasing the size
of the tank.
 Cooling of transformers
• In smaller transformers, integral tubular sides or
fins are used to provide this increase in surface
area.
 Cooling of transformers
• Fans can be installed to increase the volume of
air moving across the cooling surfaces, thus
increasing the rate of heat dissipation.
 Temperature Rise Of Transformers

• The problem of temperature rise and cooling of

transformers is essentially the same as that of rotating
machines.
• The losses developed in the transformer cores and
windings during conversion are converted into thermal
energy and cause heating of corresponding transformer
parts.
 TEMPERATURE
TRansformer OIL AS ARISE OF
COOLING
TRANSFORMER
MEDIUM Oil
• Tests have shown that an average working temperature of
the oil is θ0=50-600C.
• Oil viscosity corresponding to above temperature, the
specific heat dissipation due to convection of oil is
λconv=40.3(θ/H)1/4
θ=temperature difference of the surface relative to oil
H=height of dissipating surface, m.
 Temperature Rise Of Transformer

• The walls of tank dissipate heat by both radiation and convection.

• It has been found experimentally that a plain tank dissipates 6 and
6.5 W/m2/C0 by radiation and convection respectively.
Where St=heat dissipating surface of tank
•
 Temperature Rise Of Transformer
• For the transformers of low output, the plain walled
tank is large enough to accommodate the
transformer and oil and has sufficient surface to keep
the temperature rise within limits.
• But for transformers of large output, the plain walled
tanks are not sufficient to dissipate losses.
• This is because volume and hence losses increase as
cube of linear dimensions.
• Thus an increase in rating results in an increase in loss
to be dissipated per unit area giving a higher
temperature rise.
The path of heat flow:
Internal most heated spots of a given part(core & winding)

Outer surfaces in contact with the oil

Oil that cools the given transformer part

Walls of the cooler, for instance of the tank

Cooling medium –air or water

 Transformer Cooling methods
Transformer Cooling methods

123
 Air Blast Cooling

• For transformers rated more than 10 MVA, cooling by natural air

method is inadequate.
• Air blast cooling is used.
• In this method, air is forced on the core and windings with the
help of fans or blowers mounted on radiators.
• Heat dissipation is 50-60% more than natural cooling.
• Heat dissipation= (1.5 to 1.6)* 12.5= 20W/m2- 0C
 Cooling of transformers

• The use of auxiliary equipment such as fans and pumps with

coolers, called forced circulation, increases the cooling and
thereby the rating of the transformer without increasing the
unit’s physical size.
• Ratings are determined based on the temperature of the unit
as it coordinates with the cooling equipment that is operating.
• An example of multiple ratings would be ONAN/ONAF/ONAF,
where the transformer has a base rating where it is cooled by
natural convection and two supplemental ratings where groups
of fans are turned on to provide additional cooling so that the
transformer will be capable of supplying additional kVA.
 Classification Based On Cooling

• Dry Transformer – Air Cooled

• Oil immersed Transformer – Oil Cooled
• Oil is filled in tank and transformer inside it.
• First alphabet defines medium used for cooling which is
cooling winding.
• A-air, O-oil, G-gas, W-water, S-solid insulator.
• Air and Oil are mostly used.
• Second alphabet defines the method of circulation.
• N – Natural, B – Blast, F - Forced.
• First alphabet defines medium used for
cooling the windings.
• A-air, O-oil, G-gas, W-water, S-solid insulator.
• Air and Oil are mostly used.
• Second alphabet defines the method of
circulation.
• N – Natural, B – Blast, F - Forced.
• Usually, a transformer will have multiple ratings
corresponding to multiple stages of cooling, as
the supplemental cooling equipment can be set to
run only at increased loads.
• Methods of cooling for liquid-immersed
transformers have been arranged into cooling
classes identified by a four-letter designation as
follows:
Table for symbols
 Cooling of transformers

 Methods of cooling:
1. Air Natural (AN)-upto 1.5MVA
2. Air Blast (AB)
3. Oil natural (ON) – Upto 10 MVA
4. Oil Natural – Air Forced (ONAF)
5. Oil Forced– Air Natural (OFAN) – 30 MVA
6. Oil Forced– Air Forced (OFAF)
7. Oil Natural – Water Forced (ONWF) – Power plants
8. Oil Forced - Water Forced (OFWF) – Power plants
Constructional Details

131
Constructional Details

132
Constructional Details

133
 Forced cooling of Transformer
Forced Air Circulation
• By increasing the circulation by m times, output increases by
(m)1/4.
• In oil cooler with natural air cooling, the assembly of core and
windings is immersed in insulating oil and cooling is improved by
forced air over the cooling surfaces.
• In water cooling of circulating oil, the core and windings is
immersed in an insulating oil and cooling is improved by
circulation of water through copper cooling coils mounted above
the transformer core but below oil surface.
• The heated water is cooled in a spray pond or cooling tower.
135
 Transformer cooling methods

• Transformer cooling methods 4-5 min

• [Link]

136
Thank you

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