Transformer Design

General considerations, output equation,

emf per turn, choice of flux density and
current density, main dimensions , leakage
reactance and conductor size
 Introduction
Considerations of transformer:

i. Magnetic Circuit
ii. Electric Circuit
iii. Dielectric Circuit
iv. Other accessories

2
Classification of Transformers

Transforme
rs

Based on
Based on Based on
transform
Core Service
er Ratio

Distributi
Power
Core Shell Step on
Step up Transfor
Type Type Down Transfor
mer
mer

3
 The Transformer

i1(t) S1 i1(t) i2(t) S2 i2(t)

M V2

e1(t) e2(t)

Coil 2
Coil 1

(Primary has N1 turns) (Secondary has N2 turns)

Transformer 4
 The Transformer
• The source side is called Primary

• The load side is called Secondary

• Ideally

The resistance of the coils are zero.

The relative permeability of the core in infinite.

Zero core or iron loss.

Zero leakage flux

Transformer 5
 Power Distribution Transformers
Transformers
•Load on the transformer will •Load on the transformer does
be at or near the full load not remain constant but varies
through out the period of instant to instant over 24 hours
operation. a day
•Generally designed for •Generally designed for
maximum efficiency at or near maximum efficiency at about
the full load. half the load

• Necessity of voltage •The distributed transformers

regulation does not arise. are located in the vicinity of the
load, so voltage regulation is
an important factor.
 Constructional Details of transformer

Core type Transformer Shell Type Transformer

Transformer Construction

Transformer 8
Transformer Construction

Transformer 9
3- Transformer Construction

Transformer 10
 SIZE OF THE TRANSFORMER
• As the iron area of the leg Ai and the window area
Aw = (height of the window Hw x Width of the
window Ww) increases the size of the transformer
also increases. The size of the transformer increases
as the output of the transformer increases.

Aw Hw

Ai Ww
 Nomenclature
Vp – Applied primary voltage
Vs – Secondary terminal voltage
Ep, Es – EMF induced in the primary and secondary
windings per phase in case of 3 phase
Tp, Ts – Number of primary and secondary turns per
phase in case of 3 phase
Ip, Is – Primary and Secondary currents per phase in case
of 3 phase
ap, as – Cross-sectional area of the primary and
secondary winding conductors
δ - Current density in the transformer conductor.
Assumed to be same for both LV and HV winding.
φm – Maximum value of the (mutual or useful) flux in
weber = AiBm
Bm – Maximum value of the flux density = φm / Ai tesla
Ai – Net iron area of the core or leg or limb = KiAg
Ki – Iron or stacking factor = 0.9 approximately
Ag – Gross area of the core
 Note:
• It is clear that VpIp = VsIs or volt-ampere
input is equal to volt-ampere output or
kVA rating of both primary and
secondary windings is same.
• It is clear that IpTp = IsTs or primary mmf
is equal to secondary mmf.
• It is clear that Ep/Tp = Es/Ts or volt/turn of
both primary and secondary is same.
 Window space factor Kw
• Window space factor is defined as the ratio of
copper area in the window to the area of the
window. That is:

Kw= Area of copper in the window Ac

Area of the window Aw
• For a given window area, as the voltage rating of the
transformer increases, quantity of insulation in the
window increases, area of copper reduces. Thus the
window space factor reduces as the voltage increases.
 Winding arrangement
• Unless otherwise specified, LV winding
is always placed next to the core and HV
winding over the LV winding in order to
reduce the quantity of insulation used.
• However in case of transformers where
the voltage rating is less, LV and HV
windings can be arranged in any manner.
 OUTPUT EQUATIONS
Single phase core type transformer

• Rating of the transformer in kVA

=VpIp x 10-3
=EpIp x 10-3
= 4.44 φm f Tp x Ip x 10-3

• Each leg carries half of the LV and HV turns

• Area of copper in the window

Ac = apTp + apTp
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
T- No. of turns in transformer winding
f – Frequency of supply
Induced EMF/Turn , Et=E/T=4.44fφm (1)

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Output Equation of Transformer
 Window in a 1φ transformer contains one primary &
one secondary winding.

Conductor area in Window

Window Space factor,K w 
Total area of Window
A
Window Space factor,K w  c
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

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Output Equation of Transformer
Ip
Is
ap  ; as 
 
If we neglect magnetizing MMF, then (AT)primary = (AT)secondary

AT=IpTp=IsTs  (4)
Total Cu. Area in window, Ac=Cu.area of pry wdg + Cu.area 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 Is
 Tp  Ts
 

1


TpIp  TsIs 
1 2 AT
  AT  AT   (5)
 
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Output Equation of Transformer
Therefore, equating (2) & (5), 2 AT
K w A w 

1
AT  K w A w   (6)
2
kVA rating of 1φ transformer is given by,

Q  VpIp  10 -3  E pIp  10 -3
Ep  E
 TpIp  10 - 3  from (1), E 
T 
t
Tp
 E t  AT  10  3  ( 6)
1
 4 . 44 f  m . K w A w   10  3
2
 2 . 22  f  m  K w A w   10  3
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Output Equation of Transformer
m
We know that, Bm  and m  Bm A i
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,
Hw

A c  2Tp a p  2Ts a s Ww

4 AT
Ac   (7)

4 AT
Compare (2) & (7),  KwAw

K A 
AT  w w
4 22
Output Equation of Transformer
kVA rating of 3φ transformer,

Q  3 EpIp  103
Ep
3 TpIp  10- 3
Tp
 E t  AT  103
1
 3  4.44  fm .  K w A w   103
4
 3.33 f Bm A i A wK w   103 kVA

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 EMF per Turn
 Design of Transformer starts with the section of EMF/turn.
Let,

 Ratio of Specific magnetic loading  m

  r 
 to Electric loading  AT
Q  V p I p  10  3
 4 . 44 f  m T p I p  10 3

3
 4 . 44 f  m ( AT )  10
 3
 4 . 44 f  m
m
 10
r
Q r Q  r  10 3
 2
m  3

4 . 44 f  10 4 . 44 f
Q  r  10 3
 m 
4 . 44 f
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 EMF per Turn
Et  4.44 f m
Q  r 103 Q
 4.44 f  4.44 f  4.44 f  r 103.
4.44 f 4.44 f
 4.44 f  r  103  Q
Et  K  Q

where , K  4.44 f  r  10 3
 K is another constant depends on the type,
service condition & method of construction of
transformer.

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 EMF per Turn

Transformer Type Value of K

1φ Shell Type 1.0 to 1.2
1φ Core Type 0.75 to 0.85
3φ Shell Type 1.2 to 1.3
3φ Core Type 0.45 to 0.5
Distribution Xmer
3φ Core Type Power 0.6 to 0.7
Xmer

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