PRINCIPLES OF

TRANSFORMER DESIGN
& MANUFACTURING.

1
TRANSFORMER :DEFINITION
• A transformer is a static piece of apparatus
used for the transferring power from one
circuit to the other without change in
frequency. It can raise or lower the voltage
with a corresponding decrease or increase
in current.

2
• Primary winding
• Secondary winding
• Linkage of the two by Mutual Inductance

3
 Voltage transformation ratio
• E1 = 4.44* f *N1* Øm
E2= 4.44* f *N2* Øm

E2 / E 1 = N1/N2

4
 LOW VOLTAGE WINDING
DESIGN
• Since voltage is less ,hence turns will also
be less.
• Phase Current = MVA/(√3*line voltage in
kV) if winding is star connected.
Phase Current = MVA/(3*line voltage in
kV) if winding is Delta connected.
This indicates current in Low voltage
winding shall be high.
5
 HELICAL WINDING
• To carry high current the area of cross
section of the conductors should be
high.This is accomplished by adopting
more no. of conductors per turn.
• Helical winding which is spring like,suits
most for the LV windings.

6
 HIGH VOLTAGE WINDING
• Large no. of turns
• Less current.
• Disc coils are the best choice for the HV
windings where a single disc can have
turns as high as 25 nos.

7
 Type of Windings

Spiral winding Helical winding

(No radial duct)
8
(a) cross-section (b) connections
SINGLE LAYER DISC 9

COIL
INTERLEAVED DISC
WINDING 10
INTERLEAVED DISC WINDING
11
(4 discs per group)
 L.T
. H.T.
Line

Shields

Connection Diagram of a High Voltage Multi

Layer Winding (Parallel Layer)
12
 Arrangement of Multi Layer Winding
(a) Layer of H.T. Winding (b) Insulation Cylinder
( c) Pressboard Strip (d) Shield 13
Multi Layer H.T. Winding
(Taper Layer)

14
 Transposition

Transposition at each cross-over in

Continuous Disc Winding
15
 Transposition in Spiral/Helical
Winding
(a) Complete Transposition
16
(b) Partial Transposition
Directed Oil Flow
Arrangement

17
 Insulating Area

18
A: Vertical Area B: Horizontal Area C: Area between
Leakage Flux

19
Flux entering the tank
 20
Flux enters the Shunt
Insulation

21
 MATERIAL USED FOR
WINDING
• P.I.C.C.
• C.T.C.
• Bunched P.I.C.C.
• Glued C.T.C.

22
 MAGNETIC CIRCUIT
• Magnetic circuit is formed by ‘CORE’
• CORE is a three or five legged
construction providing the .
• Coils which are of cylindrical shape are
assembled over the legs.

23
 OTHER CONSIDERATIONS
• After designing the windings they are
suitably placed over the core legs keeping
in mind the electrical stresses.
• Windings are designed for impulse
withstand and short circuit forces also.
• This is followed by the cooling design.

24
 WHAT IS A CORE?
• ANY TRFR. CONSISTS OF CORE AND
WINDING. CORE IS THE MAGNETIC CIRCUIT
THROUGH WHICH FLUX FLOWS.

25
 MATERIAL USED IN CORE
• The material used for core making is low
reluctance magnetic steel containing silicon.This
is called “CRGO” i.e cold rolled grain oriented
steel.
• The grain orientation is technology which
ensures that the flux flow through the
laminations with minimum resistance,resulting in
low core loss.

26
 TYPE AND CONSTRUCTION OF
CORE
• THERE ARE FOLLOWING TYPES OF CORE
AVAILABLE:-
– A. THREE LIMB CORE
– B. TWO LIMB CORE
– C. FIVE LIMB CORE
– D. CORE WITH ELLIPTICAL YOKE SECTION
– E. CORE WITH FLAT YOKE
THERE CAN BE SOME MORE VARIATION
KEEPING THE BASICS SAME.

27
 Core Nomenclature

TOP YOKE

• L= Leg
Length
• C= Distance L A A W
between leg
centres
• W=Main leg
width BOTTOM YOKE

C C AUXILIARY
LIMB
C
28
 Section through
Section through 'A-A'‘A-A’
Cooling Duct
Cooling
C
Duct
L

D= Max. core diameter

29
 Type of core forms
SC
W

W
L

C
30
Single Phase, Core type 2 legs
 W/2 SM

W/2
W/2
W

INSIDE YOKE
LENGTH

Single Phase, core type middle leg

31
wound
 SMC
W/2

W/2

W W

INSIDE YOKE LENGTH

Single Phase, core type 2 middle legs 32

 TC

W W
W

Three Phase, core type 33

 TCF

W W W
W

0.43W

0.57 W

INSIDE YOKE LENGTH

Three phase, core type, 5 limb 34

 DESCRIBING SOME TERMS IN
CORE CONSTRUCTION
• CORE DIAMETER: DIAMETER OF THE
CIRCLE ENCLOSING THE STEPS OF A CORE
CROS SECTION .ALL THE STEPS ARE
ACCOMODATED WITHIN THIS CIRCLE.

• FRAME SIZE :THE DIMENSIONS REQUIRED

TO DESCRIBE A CORE IS CALLED FRAME
SIZE. IT COMPRISES DESCRIPTIONS LIKE
CORE TYPE,CORE DIAMETER,LEG
CENTRES AND LEG LENGTH.

35
 DESCRIPTIONS CONTINUED….
• LEG CENTRES: THIS IS THE DISTANCE
BETWEEN THE CENTRELINES OF MAIN
LEGS OF A CORE.

• LEG LENGTH :DISTANCE BETWEEN TOP

YOKE LEVEL AND BOTTOM YOKE LEVEL
IN A WINDOW IS CALLED LEG LENGTH.

• WINDOW:AREA ENCLOSED BY TOP AND

BOTTOM YOKE AND THE MAIN LIMBS.
36
DESCRIPTIONS (CORE) CONTD..
• YOKE BOLT:BOLTS USED IN YOKES TO
CLAMP THE LAMINATIONS TOGETHER.

• TOP YOKE LEVEL(TYL)/BOTTOM YOKE

LEVEL(BYL): EDGE OF THE TOP OR BOTTOM
YOKE IN THE WINDOW.

• PIN PAD ASSEMBLY: THE ARRGMT. TO TO

JOIN CLAMP PLATE WITH END FRAME IS
CALLED PIN PAD ASSY.

37
 PURPOSE OF TRFR.TANK

• TRANSFORMER TANK IS AN ENCLOSURE

WHICH CONTAINS INSIDE IT THE LIVE
PARTS SUCH AS CORE AND WINDING
ASSEMBLY, ELECTRICAL CONNECTIONS
AND INSULATING OIL.

38
MOST BASIC CLASSIFICATION
A. CONVENTIONAL
B. BELL TYPE
• CONVENTIONAL TANK:
A TANK IN WHICH THE COVER IS FLAT AND
TANK TO COVER JUNCTION IS AT THE TOP
OF THE TANK.

39
 • BELL TYPE TANK
• A TANK IN WHICH THE COVER IS NOT
FLAT IN SHAPE AND THE TANK AND
COVER JUNCTION IS NEAR THE
BOTTOM OF THE TANK .
• THUS THE TANK HAS GOT TWO PARTS
– ‘TOP TANK’ AND ‘BOTTOM TANK’

40
 TRANSFORMER FITTINGS
• COOLING EQUIPMENTS
• TERMINAL ARRANGEMENT
• CONSERVATOR
• O.L.T.C.
• INSTRUMENTS
• BREATHERS ETC.

41
 TRANSFORMER COOLING
• WHEN THE TRANSFORMER IS IN SERVICE
THE WINDINGS GET HEATED UP. IN OIL
FILLED POWER TRANSFORMERS OIL IS THE
COOLING MEDIUM FOR WINDINGS. OIL IS IN
TURN COOLED BY MEANS OF RADIATORS
/INTEGRAL COOLERS WITH WATER/AIR AS
COOLING MEDIUM.

42
 TYPE OF COOLING

• ONAN COOLING
• ONAF COOLING
• OFAF COOLING

43
 ONAN COOLING
• OIL FLOW IS THROUGH NATURAL
CONVECTION
• AIR FLOW IS ALSO NATURAL(NOT FORCED)
• COOLING EQUIPMENT USED:
– RADIATORS

44
 ONAF COOLING
• OIL FLOW IS THROUGH NATURAL
CONVECTION
• AIR FLOW IS NOT NATURAL BUT FORCED
• COOLING EQUIPMENT USED:
– RADIATORS AND FANS
– ONAF COOLERS

45
 OFAF COOLING
• OIL FLOW IS FORCED BY MEANS OF INLINE
OIL PUMPS.
• AIR FLOW IS FORCED BY MEANS OF FANS
/BLOWERS
• COOLING EQUIPMENTS USED:
– RADIATORS,FANS AND PUMPS.
OR
– INTEGRAL OFAF COOLERS.

46
 RADIATORS

• RADIATORS USED IN TRFR. COOLING ARE

OF STANDARD PROFILE.
• THEY ARE NORMALLY DESCRIBED IN THE
FOLLOWING FASHION:(EXAMPLE)
10-5 OR 9 - 34 - 3000
10 => NO. OF RADIATORS
5 OR 9 => NO. OF FLUTES IN A RADIATOR
ELEMENT .
32 => NO. OF ELEMENTS IN A RADIATOR
3000 => DISTANCE BETWEEN VALVE
CENTRES.
47
 FANS
• COOLING FANS ARE NORMALLY
CLASSIFIED ON THE BASIS OF THEIR
SIZE LIKE 15,18,24 OR 36 INCHES.

48
 PUMPS
• PUMPS ARE NORMALLY INLINE TYPE.
• PURPOSE IS TO PUMP OIL THROUGH THE
TRANSFORMER TO CREATE FORCED FLOW
OF OIL.

49
 MOUNTING OF RADIATORS
• RADIATORS CAN BE DIRECTLY MOUNTED
ON THE TANK WALL, IF THE NO. OF
RADIATORS IS NOT LARGE.
• RADIATORS CAN BE MOUNTED IN A BANK
FORMATION I.e. GROUP OF RADIATORS ARE
MOUNTED ON HEADERS AND ARE PLACED
SEPARATELY FROM TANK.

50
 HEADER
• HEADERS ARE PIPES OF SQUARE
CROSS SECTION.
• THERE SHALL BE ONE TOP HEADER
AND ONE BOTTOM HEADER FOR A
GROUP OF RADIATORS.
• THE HEADER AND RADIATOR ASSY. IS
SUPPORTED OVER “A”
FRAMES(NAMED SO BECAUSE OF
RESEMBLANCE WITH ALPHABET “A”)
51
 HEADER PIPE WORK

• THE HEADERS ARE IN TURN JOINED WITH

THE TANK WHERE SUITABLE VALVES FOR
CONNECTING PIPE WORK ARE
PROVIDED.
• THESE PIPES REQUIRE PIPE SUPPORTS
WITH SUITABLE FOUNDATION

52
• ARRRNGEMENT OF FANS / INLINE PUMPS
ALONG WITH THEIR SUPPORTS ARE ALSO
SHOWN IN THE HEADER PIPE WORK
DRAWING.

53
 CONSERVATOR PIPE WORK

• A. MAIN CONSERVATOR PIPE WORK

• B. AUXILIARY OR OLTC CONSERVATOR
PIPE WORK

54
 CONSERVATOR
• A CONSERVATOR IS A CYLIDERICAL VESSEL
WHICH PROVIDES SPACE FOR EXPANSION
OF OIL INSIDE THE TRANSFORMER OR
SUPPLIES OIL TO THE TRANSFORMER
WHEN THE TRANSFORMER OIL COOLS AND
CONTRACTS IN VOLUME.
• A CONSERVATOR IS ALWAYS PLACED
ABOVE THE TRANSFORMER.

55
 CONSERVATOR CONTD...
• WHEN THE CONSERVATOR IS USED
FOR THE MAIN TRANSFORMER IT IS
CALLED MAIN CONSERVATOR AND
WHEN IT IS USED FOR THE OLTC IT IS
CALLED AUXILIARY OR OLTC
CONSERVATOR.

56
 TERMINATION
• TRANSFORMERS ARE CONNECTED IN THE
SYSTEM BY ANY OF THE THESE METHODS
AS DEMANDED BY OUR CUSTOMERS.
• OVER HEAD BUSHINGS
• CABLE BOXES
• BUS DUCT
• A COMBINATION OF ABOVE

57
OVERHEAD BUSHINGS
• HIGH VOLTAGE, LOW VOLTAGE AND IN
SOME CASES THIRD WINDING
“TERTIARY” OR “STABILISING” LEADS
ARE BROUGHT OUT THROUGH
BUSHINGS. THEY ARE CALLED HV
BUSHING, LV BUSHING AND TERTIARY
BUSHING.
• THESE BUSHINGS CAN BE MOUNTED
ON THE TANK COVER(OR TOPMOST
HORIZONTAL PLANE IN THE TANK) OR IN
SOME CASES SOME BUSHINGS ARE
MOUNTED ON VERTICAL END WALLS. 58
CABLE BOXES
• IN SITES WHERE CUSTOMER HAS LAID CABLES
INSTEAD OF OVERHEAD CONDUCTORS THE
TERMINATION (CONNECTION) IS THROUGH CABLE
BOXES.
• CABLE BOXES ARE ENCLOSURES ATTACHED
EXTERNALLY TO THE TRANSFORMER TANKS.
• THEY CAN BE ON THE LV WALL,HV WALL OR ON
BOTH LV AND HV WALLS. SIMILARLY INSTEAD OF
WALLS THEY CAN BE ATTACHED ON THE COVER
ALSO.

59
BUS DUCT

• GENERATOR TRANSFORMER PRIMARY IS

CONNECTED TO THE GENERATOR THROUGH
BUS DUCTS.
• FOR BUS DUCT CONNECTIONS BUSHINGS ARE
BROUGHT OUT THROUGH COVER OR THROUGH
INDEPENDENT/COMMON TURRETS.
• THESE BUSHINGS ARE ENCLOSED
CIRCUMFERENTIALLY BY HOODS WHICH IN
TURN RECEIVE THE BUSDUCT FLANGE.

60
 COMBINATION OF
TERMINATION METHODS
• TERMINATION OF DIFFERENT WINDINGS
CAN BE THROUGH DIFFERENT
COMBINATIONS. FOR EX.
• HV-BUSHING, LV-CABLE BOX
• HV-BUSHING, LV-BUS DUCT
ETC.

61
 TANK BASE
• BASE CAN BE WTH OR WITHOUT
ROLLERS
• ROLLERS OF 4 TYPES AND ARE OF
STANDARD DESIGN
• SKID BASE
• BASE SUITABLE FOR PLACEMENT ON THE
PLINTH

62
 OLTC

• OLTC => ON LOAD TAP CHANGER.

• IT’S PURPOSE IS TO ADD OR SUBTRACT
TURNS FROM THE MAIN COIL.
• IT IS HOUSED INSIDE THE
TRANSFORMER TANK (EXCEPT CTR
OLTC). THESE ARE THE STANDARD
PRODUCTS AND BASED ON THE VARIANT
IN USE THEIR DIMENSIONS ARE KNOWN
IN ADVANCE.

63
 BUCHHOLZ RELAY

• When oil in the transformer tank expands some

room for this expansion is required. This is
provided by the conservator ,which is a
cylindrical vessel placed above the transformer
tank.
• Because of any internal fault heat is generated
which decomposes oil and insulation material
resulting in the formation of gases.
• These gases rise up and while approaching the
conservator passes through the buchholz relay.

64
 BUCHHOLZ RELAY contd….
• Buchholz relay is a protective relay .When
the accumulation of the gases rise above
a certain level then the float in the
buchholz relay rises activating a mercury
switch which gives the alarm
• When the gas accumulation is still higher
then another float activates the trip switch
disconnecting the transformer from the
circuit.

65
 M.O.G . WITH LOLA
• Magnetic Oil Gauge with low oil level
alarm.
• This is used with conservator
• It's purpose is to indicate the oil level in the
conservator vessel and to give alarm when
the oil level falls below a threshold limit.

66
 OIL SURGE RELAY
• This is similar to MOG but used in On load
tap changer oil compartment.

67
 PRV
• Pressure Relief Valve
• When transformer experiences excessive
pressure due to extreme heating on
account of faulty operation or conditions
then this valve saves the transformer by
releasing the excessive pressure and
simultaneously disconnecting the
transformer from the lines.
• This equipment is of spring loaded type.
68
 OTI
• OTI: Oil Temp. Indicator: This consists of a
bulb dipped in a oil cup on the cover of the
transformer tank cover. This bulb is
connected to the meter placed in the
marshalling box meant for housing the
equipment electrical controls by means of
a capillary. This indicates the temperature
of the top part of the transformer oil which
is the hottest part.
69
 WTI
• Similar in construction to the OTI.
• This reads the temperature of the winding
in an indirect way.
• A current transformer injects current into
the heating coil of the equipment giving
the extra temperature gradient over the
top oil temp. which normally a winding is
expected to have.
70
 SILICA GEL BREATHERS
• Moisture is an enemy of transformer insulation
system
• Whenever oil contracts transformer breaths in
through breathers.
• With air lot of moisture which is present in the air
also go inside.
• The silica gel present in the breathers absorb
moisture and only dry air goes inside.
• After a certain level of absorption the color of
silica gel crystals change from blue to pink when
these particles should be recharged or replaced.
71
 AIR CELL
• When transformer breathes in air oxygen also
gets in touch with the oil.Oxygen oxides the
insulating oil and contaminate it in terms of the
electrical properties.
• Air cell is rubber bag compatible with the
transformer oil and is fitted inside the
transformer conservator.When oil in transformer
contracts ,it sucks air into the this bag and when
oil expands it expels air. Thus Air Cell prevents
atmospheric oxygen to come in contact with the
oil.
72
 PRINCIPLES OF
TRANSFORMER TESTING,
ERECTION &
COMMISSIONING.

73
 TRANSFORMER TESTING
• A. Routine tests
• B. Type tests
Routine tests are conducted on each and
every transformer of the lot/order .
Type tests are conducted on one
Transformer of a particular design and on
successful passing of this test the design
of the transformer is said to be validated.
74
 Routine tests
• RATIO TEST
• VECTOR GROUP VERIFICATION
• WINDING RESISTENCE
• CORE LOSS
• LOAD LOSS
• IMPEDANCE MEASUREMENT
• SEPARATE SOURCE VOLTAGE WITHSTAND
TEST
• INDUCED OVER VOLTAGE WITHSTAND TEST

75
 TYPE TEST
• TEMPERATURE RISE TEST
• LIGHTENING IMPULSE TEST
• VACUUM AND PRESSURE TEST

76
 TEST REQUIREMENTS
• IN ORDER TO ENSURE THE SUITABILITY OF TRANSFORMER
FOR VARIOUS POSSIBLE TRANSIENTS/OVERVOLTAGES OF
SYSTEM, VARIOUS NATIONAL STANDARDS LIKE IS 2026
(PART-III) & INTERNATIONAL STANDARD LIKE IEC 60076-3
DEFINE THE TEST LEVELS & TEST METHOD REQUIREMENT
FOR DIFFERENT TESTS.
• THE MAJOR DIELECTRIC TESTS APPLICABLE FOR EHV
CLASS TRANSFORMERS ARE:
1. LIGHTNING IMPULSE WITHSTAND
2. SWITCHING IMPULSE WITHSTAND
3. INDUCED OVERVOLTAGE WITH OR WITHOUT PD
MEASUREMENT
4. SEPARATE SOURCE VOLTAGE WITHSTAND TEST

77
 TEST REQUIREMENTS
• RECENTLY, IEC 60076-3 HAS BEEN REVISED TO
INCORPORATE MORE STRINGENT TESTING
REQUIREMENTS. THE MAJOR CHANGES wrt
EARLIER EDITION OF 1980 ARE:
PARAMETER EARLIER REQT. AS PER IEC-
60076-3(2000)
ACLD NA SPECIAL TEST
FOR Um=72.5-
170kV. ROUTINE
TEST FOR
Um>170kV
LI ROUTINE FOR ROUTINE FOR
Um300kV Um>72.5kV
78
 TEST REQUIREMENTS
PARAMETER EARLIER REQT. AS PER IEC-
60076-3(2000)
SI ROUTINE FOR ROUTINE FOR
Um300kV Um>170kV
ACSD WITHOUT NA ROUTINE FOR
PD Um72.5kV

ACSD WITH PD NA ROUTINE TEST

FOR 72.5<Um 
170kV. SPECIAL
TEST FOR
Um>170kV
INDUCED WITHOUT PD FOR NA
OVERVOLTAGE Um<300kV WITH PD
TEST FOR Um300kV 79
 TEST REQUIREMENTS
PARAMETER EARLIER REQT. AS PER IEC-
60076-3(2000)
CHOPPED WAVE NOT SPECIFIED 10% HIGHER THAN
LI FULL WAVE LEVEL
REPEAT 75% OF ORIGINAL 80% OF ORIGINAL
DIELECTRIC
TESTS
WAVE SHAPE FOR 3 STEPPED MULTISTEPPED
ACSD & ACLD/IND. WITH HIGHER
O/V WITH PD LEVELS & HIGHER
DURATION.

80
 ERECTION AT SITE : INSPECTION

• Make visual inspection for any transit

damage
• Check nitrogen pressure.
• Check various accessories for any type of
transit damage.
• Make internal inspection of the transformer
to the extent possible for any visible
discrepancy.
81
 OIL FILLING
• Before filling the oil into transformer
check the oil carefully for

a. Break down voltage

b. Moisture content
c. Tan delta and capacitance

82
 OIL FILLING CONTINUED…
• If the oil is not having the properties as
recommended by the standards,it must be
filtered with filters with built in heaters and
vacuum pumps for improving the quality of
oil.
• For transformers dispatched gas filled ,oil
filling must always be done under vacuum.

83
PRECAUTIONS DURING OIL FILLING

• Keep the oil free from contamination

• All equipments used for oil filling should be
cleaned and flushed with oil before filling.
• Flexible steel hose or good and known quality
rubber hose alone should be used .
• Transformer must be disconnected from the
electricity supply system before the oil level in
the tank is lowered.
• Oil must not be emptied near naked lights as the
vapour released is inflammable.

84
THANK
YOU !

85