TRANSFORMER DESIGN
NOORNABI SHAIKH
DEPARTMENT OF ELECTRICAL ENGINEERING
MUET
TRANSFORMER DESIGN
Design of a transformer depends on its ratings, voltage, number of
phases and frequency. Other factors are type, service conditions, and
relative cost of copper, iron, insulation, labour, machinery and
organization.
In modern electrical manufacturer a line of transformers with a definite
number of frame sizes is developed for standardization.
In 3 – phase core type, the dimensions W, D, and d are fixed for given
frame, while l is varied between limits to given a range of outputs from
the one frame.
Thermal Rating:
Transformer rating has almost exclusively thermal basis. The most
important factor is temperature. Insulating material in oil maintained
continuously at a temperature not exceeding 75oC might be serviceable
for 50 years. But if it is placed at 110 oC might be serviceable for 5
years and become uneconomical.
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The basis of transformer design is the choice of net core section Ai and
net window area Aw, suitable flux density Bm wb/m2, current density J
A/m2 and window space factor Kw. Essential sections are shown in
figure below.
W
Ai = active
ferromagnetic area of
the core. d
ll H
D = limb spacing AW
between centers
l = window length
d = core – circle D D
diameter
Aw = window area Ai d
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1. FRAME STANDARDIZATION
As per British Standards (BS 171) for frame no.4
d = 0.21 m
D = 0.34 m
Frame
1 11 11 1V
No.
Output
10 – 40 40 – 100 100 – 300 300 – 500
limit KVA
Most 1 – phase and 3 – phase transformers are of the core type.
The basic parameters of 3 – phase core (figure) are the core – circle
diameter d, the limb spacing between centers D, and the window
length l. Form these the net core area Ai and the overall core width W
give the available window are Aw. The overall height H and width W
are of importance in tank design and transport.
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For a given type and shape there is a relation between the core –
circle diameter and the rating S.
d S
For economic design it is essential to restrict d by using as much as
possible of the core – circle area. The shape of the core – packet
assembly must therefore approximate to a circle.
Typical optimum proportions are shown below:
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Area (%) 64 79 84 87
Ai (%) 58 71 75 78
Ai/d2 0.45 0.56 0.60 0.62
Seven or more steps may be used for larger sections, but if too
massive to allow adequate cooling, ducts are arranged between
sections of the core packets.
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2. FOR 3 – STEEPED CORE
1. Gross area of the core (iron and insulation) is 84% of the core circle
area.
2. Net iron area (Ai) (excluding insulation) is 75% of the core circle
area.
3. The ratio Ai/d2 = 0.6
3. PEAK FLUX DENSITY
For Bm = 1.3 to 1.6 T (even up to 2 on 20% over voltage)
In order to utilize the core perfectly the flux density should be kept
maximum. But considering the problems of
a. Core – loss
b. Saturation [It results in production of harmonics]
NOTE:
The core area of the transformer is determined by the proper selection of flux
density. A high volume of selected density will give lower cross – section of
the core and hence the volume – weight and cost of iron will be greatly
reduced.
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4. VOLTAGE PER TURN
Vt = 4.44 f m
Vt = 4.44 f Bm Ai
5. RELATION BETWEEN PRIMARY AND SECONDARY
VOLTAGES AND NUMBER OF TURNS
N1 V
1
N2 V2
6. CURRENT DENSITY
For transformer, average current density J = 3.0 A/mm2.
= 3.0 MA/m2
Current density in inner (L.V) winding J2 = 2.85 A/mm2.
Current density in outer (H.V) winding J1 = 3.1 A/mm2.
[Inner winding current density is kept little lower than the outer
winding to improve inner cooling]
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7. WINDOW SPACE FACTOR (KW)
Considering insulation, packing and clearance the available area for
actual conductor cross – section
KW AW
Where
Actual conductor cross sec tion area
KW
total window area
Kw depends on KVA and KV ratings of transformer and it may be very
small if working voltage is high.
WINDOW SPACE FACTOR
KVA / KV 3 KV 10 KV 30 KV 100 KV
100 KVA 0.28 0.20 0.14 --------------
800 KVA 0.37 0.27 0.20 0.15
2000 KVA 0.40 0.31 0.23 0.16
10,000 KVA 0.45 0.37 0.28 0.21
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8. RELATIONS BETWEEN TRANSFORMER RATINGS, S &
WINDOW AREA AW
With the overall dimensions defining its “frame size” the total rating is
S 3.33 f Bm J Ai K w Aw
9. YOKE AREA
Same as limb area
10. STEEL DENSITY
= 7500 kg/m3
11. SPECIFIC CORE LOSS, Pi
The magnetic core is to be c.r.o.s 0.35 mm thick. For 0.35 mm thick
c.r.o.s laminations
Pi = 1.5 W/kg
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12. AMPERE TURNS (AT) FOR JOINTS
The AT are to be raised by about 20% for greater reluctance of the
joints.
13. CORE BUILDING FACTOR
Core building factor = 1.3
14. TREANFORMER STEEL
High resistance steel (h.r.s) 4 to 5% silicon
For c.r.o.s phosphate base coating is used for insulation.
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PROBLEM:
A 50 Hz, 1 – phase transformer has a core of net section Ai = 0.032 m 2,
and a window area Aw = 0.07 m2. the density loadings are Bm = 1.5 T,
and J = 2.7 MA/m2. Insulating and clearance take up 0.7 of the window
area (i.e., kw = 0.3). Find the rating of the transformer.
SOLUTION
From equation
S 2.22 f Bm J Ai kw Aw
S 2.22 50 1.5 2.7 10 6 0.032 0.3 0.07
S 300 000 VA
S 300 kVA
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PROBLEM:
A 3 – phase, 3 – limbed core type transformer to BS 171 rated 400
kVA, 6.6 / 0.41 to 0.45 kV in 2.5% steps, delta/ star, oil immersed,
natural cooled.
Frame size has stepped core of net area Ai = 0.027 m2 contained in an
overall limb diameter d = 0.21 m, with the limb centers spaced D =
0.37 m. The yoke area is the same as that of a limb. With Bm = 1.45 T.
Calculate main dimensions of core, primary and secondary number of
turns, cross – section of primary and secondary windings.
SOLUTION
The voltage per turn from equation:
V1
Vt 4.44 f Bm Ai
N1
4.44 50 1.45 0.027
8. 7 V
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Given primary phase voltage is ;
V1 6600 V
The secondary phase voltage at maximum flux density is
450
V2 260 V
3
The turns per phase
V2 260 V1
N2 30 As Vt
Vt 8. 7 N1
AND
V1 6600 V1 N
N1 N 2 30 760 From 1
V2 260 V2 N2
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FOR TAP CHANGER
The line voltage can be varied from 410 V to 450 V. Tap – changer is
connected to H.V side.
V1 N1
Therefore, to increase the primary number of turns:
V2 N2
V
N1 N 2 1
V2
6600
30 836 turns
410 / 3
N 1 836 Turns
That means , Pr imary turns are increased by : 836 760 76 turns
PRIMARY CURRENT PER PHASE, I1
400
kVA / Phase 133 kVA
3
Therefore , primary current I 1 per phase
kVA / Phase 133
I1
kV 6.6
I1 20.15 A or say 20 A
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CURRENT DENSITY (J) IN THE WINDINGS
It is limited by I2R loss and heat dissipation.
For transformer, average current density J = 3.0 MA/m2.
Current density in inner (L.V) winding J2 = 2.85 A/mm2.
Current density in outer (H.V) winding J1 = 3.1 A/mm2.
[Inner winding current density is kept little lower than the outer winding
to improve inner cooling]
WINDOW SPACE FACTOR KW
Actual conductor cross sec tion area
KW
total window area
Kw depends on KVA and KV ratings of transformer and it may be very
small if working voltage is high.
Lets say it is given as 0.29 for 6.6 kV and 400 kVA.
KW 0.29
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Relationship between Transformer Ratings, S and Window Area, Aw
S 3.33 f Bm J Ai K w Aw
S
AW
3.33 f Bm J Ai Kw
400 1000
3.33 50 1.45 3 106 0.027 0.29
AW 0.0705 m 2
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CALCULATION OF MAIN DIMENSIONS
Width of Transformer (W) W
Where D 0.37 m
W 2 Dm 0.9 d m d 0.21 m
2 0.37 0.9 0.21 d
l H
W 0.929 m AW
Window depth of Transformer (l)
D D
Referring figure
AW l w w (D d ) Ai d
AW l ( D d )
AW 0.071 m 2 0.071 m 2
l
(D d ) (0.37 0.21) m 0.16 m
l 0.443 m
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Height of the Transformer (H)
W
Considering the Yoke area same as limb
H l 2 ( 0 .9 d )
d
0.443 2 (0.9 0.21) l H
AW
H 0.821 m
Summary of the main dimensions
D D
d 0.21 m
Ai d
D 0.37 m
l 0.443 m
W 0.929 m
H 0.821 m
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