Contents:

 Construction of core
 Design of core
 Window design
 Window in single phase transformer
 Window in three phase transformer
 Choice of flux density in the core
 EMF per turn
 Winding design
 Windings for Shell Type Transformer
 Windings for core Type Transformer
CONSTRUCTION OF CORE:
 Core is constructed from of a highly permeable material
made from thin silicon steel laminations.
 The core is laminated to prevent circulating eddy currents
within the iron core itself.
 These thin laminations are assembled together to provide
the required magnetic path with the minimum of magnetic
losses.
 The thickness of the laminations vary from 0.25mm to
0.5mm .
 The laminations , any fixing studs, rivets or bolts are
electrically insulated by a very thin coating of insulating
varnish or by the use of an oxide layer on the surface.
 In a shell-type transformer, laminations are cut in the form of long
strips of E and I

 In a Core Type Transformer, The laminations are cut in the form of L-

shape or U-I shape .
 In order to avoid high reluctance at the joints where laminations are
butted against each other, the alternate layers are placed differently to
eliminate the continuous joints.
DESIGN OF CORE:
 For core type transformer the cross-section may be
rectangular, square or stepped.
 When circular coils are required for distribution and power
transformers, the square and stepped cores are used.
 For shell type transformer the cross-section may be
rectangular.
 When rectangular cores are used the coils are also
rectangular in shape.
 The rectangular core is suitable for small and low voltage
transformers. In core type transformer with rectangular
cores, the ratio of depth to width of the core is 1.4 to 2.
 In shell type transformers with rectangular cores the width
of the central limb is 2 to 3 times the depth of the core.
 In square cores the diameter of the circumscribing circle is larger than
the diameter of stepped cores of same area of cross-section.
 Thus when stepped cores are used the length of mean turn of winding
is reduced with consequent reduction in both cost of copper and
copper loss.
 However with larger number of steps a large number of different sizes
of laminations have to be used.
 This results in higher labour charges for shearing and assembling
different types of laminations.
Window design:
 Total area of the window depend upon total conductor area in window
and window space factor .
 The window space factor (Kw) is the ratio of conductor area in window to
total area of window.

 Area of window (Aw) = total conductor area in window/ window space

factor

 Area of window(Aw) = Height of window x Width of window

= Hw x Ww
 The ratio of height to width of window, Hw /Ww is between 2 to 4
Window in single phase transformer :
 The window in single phase transformer contains one
primary and one secondary winding.
 Total copper area in window(Ac )= Copper area of primary
winding + Copper area of secondary winding = (Number of
primary turns x area of cross-section of primary conductor)
+ (Number of secondary turns x area of cross - section of
secondary conductor)
Window in three phase transformer :
 In case of three phase transformer, each window has two
primary and two secondary windings.
 Total copper area in window, Ac = (2 x Number of primary
turns x area of cross-section of primary conductor) + ( 2 x
Number of secondary turns x area of cross - section of
secondary conductor)
CHOICE OF FLUX DENSITY IN THE CORE:
 The flux density decides
 Area of cross-section of the core and
 Core loss.
 Higher values of flux density results in
 Smaller core area, lesser cost, reduction in length of mean
turn of winding,
 Higher iron loss and large magnetizing current.
 The choice of flux density depends on the service condition
(i.e., distribution or transmission) and the material used
for laminations of the core.
 The laminations made with cold rolled silicon steel can
work with higher flux densities than the laminations made
with hot rolled silicon steel.
 Usually the distribution transformers will have low flux
density to achieve lesser iron loss.
 When hot routed silicon steel is used for laminations the
following values can be used for maximum flux density
(Bm)
 Bm = 1.1 to, 1.35 Wb/m2 - For distribution transformers
 Bm = 1.25 to 1.45 Wb/m2 - For power transformers ·
 When cold rolled silicon steel is used for laminations, the
following values can be used for maximum flux density
(Bm)
 Bm = 1.55 Wb/m2 - For transformers with voltage rating upto
132 kV
 Bm= 1.6 Wb/m2 - For transformers with voltage rating 132 kV
to 275 Kv
 Bm = 1.7 Wb/m2 - For transformers with voltage rating 275
kV to 400 Kv
EMF PER TURN :
 The transformer design starts with selection of an
appropriate value for emf per turn(Et).

 Where, r= ratio of specific magnetic and electric

loading =øm/AT
 Emf per turn is directly proportional to K.
 The value of K depends on the type, service condition
and method of construction of transformer.
The value of K for different types of transformers is listed in table
below:
Transformer type K

Single phase shell type 1.0 to 1.2

Single phase core type 0.75toO.85

Three phase shell type 1.3

Three phase core type, distribution transformer 0.45

Three phase core type, power transformer

0 .6_to 0. 7
Design of windings:
 No of turns in primary winding (Tp)
= voltage of primary winding/voltage per turn=Vp/Et
 No of turns in secondary winding (Ts)
= voltage of primary winding/voltage per turn=Vs/Et
 No of turns in L V winding is usually determined in a
preliminary design by adjusting voltage per turn to get no
of turns in primary winding a integer value.
 Tlv = Vlv / Et= an integer
 The no of hv winding turns per phase is therefore
(Thv)=(Vhv/Vlv) x Tlv
 Is=(Ip x Vp)/Vs

 Area of conductor in primary and secondary

winding is determined after choosing suitable
current density (ð).
Different types of Windings :
 Mainly there are two types of transformer:
 Core type transformer
 Shell type transformer
 In core type, the primary, and the secondary winding
are wound on the outside limbs and in shell type we
place the primary and secondary windings on the
inner limbs.
 The low voltage winding is placed nearer to the core in
order to reduce the insulation requirement.
Windings for Shell Type
Transformer:
 Sandwich Type Winding
are used.
 The HV and LV windings
are split into a number of
sections where each HV
section lies between two
LV sections.
 In sandwich coils, easily
leakage can be controlled.
Desired value of leakage
reactance can be obtained
by proper division of
windings.
Types of Windings Used in Core Type Transformers:
 Cylindrical Windings
 Helical Windings
 Single Helical Winding
 Double Helical Winding
 Disc-Helical Winding
 Multi- Layer Helical Windings
 Cross- Over Windings
 Disc and Continuous Disk Winding
Cylindrical Windings:
 These windings are layered type and uses rectangular or round
conductor .
 The conductors are wound on flat sides or wound on the rib side.
 Conductors are wound in one, two or more layers, accordingly they are
called one, two or more layer windings.
 Cylindrical windings employing rectangular conductor are mainly
used are low voltage windings used up to 6.6 kV for kVA up to 600-750.
 Cylindrical windings employing circular conductor are mainly used
are high voltage windings used up to 6.6 kV, 11 kv, 33 KV for kVA up to
600-100.
Helical Windings:
 Helical windings are used for low voltage windings,
high and medium capacity transformers, where the
current is higher and at the same time the winding
turns are lesser.
 The output of transformer in this case varies from 150
KVA to 30 MVA at voltages from 400V to 11 kV.
 They are three types:
 Single Helical Winding
 Double Helical Winding
 Disc-Helical Winding
 Single Helical Windings consist of winding in an axial
direction along a screw line with an inclination. There is
only one layer of turns in each winding.
 In double helical winding , Parallel conductors are divided
into two parallel circuits and situated in two layers shifted
in axial direction.
Disc- Helical Windings
 The Disc- Helical
Windings is designed in
a way that the parallel
connected strips are
placed side to side in a
radial direction so as to
occupy the total radial
depth of the winding.
Multi- Layer Helical Windings:
 It is used commonly for high
voltage windings for 110 kV and
above.
 These windings include several
cylindrical layers concentrically
that are wound and connected in
series.
 All layers are wound on paper
cylinder and separated by each
other by vertical strip.
 No of layer depend on voltage.
Cross- Over Windings
 These windings are used for high
voltage windings of the small
transformers.
 The coils are wound over formers with
side cheeks( U pieces) and each coil
consists of no of layer with no of turn
per layer.
 The conductors of these windings are
paper covered strips or round wires.
 The windings help reduce the voltage
between adjacent layers as they are
divided into a number of coils.
 The inside end of the coil is connected
with the output end of the adjacent
one.
Disc and Continuous Disk Winding:
 It is used for high capacity transformers.
 These windings consist of numerous flat coils/
discs in a series or parallel formation.
 The conductors of these windings can be a single
strip or multiple strips in a parallel formation
that are wound on the flat side.
 The discs are separated from each other with the
help of press- board sectors that are attached to
vertical strips.
 The vertical and the horizontal spacers for free
circulation of oil provide radial and axial ducts.
 In case the winding consists of no of disc
connected in series it can be wound
continuously with out breaking the conductor
between separate disc coil.
 The advantage of these windings is that they
provide greater mechanical axial strength and
cheapness.
THE END