1

Transformer Design
OUTPUT EQUATION: - It gives the relationship between electrical rating and physical dimensions
of the machines.
Let
V1 = Primary voltage say LV
V2 = Secondary voltage say HV
I1 = Primary current
I2 = Secondary current
N1= Primary no of turns
N2= Secondary no of turns
a1 = Sectional area of LV conductors (m2)
I
= 1

a1 = Sectional area of HV conductors (m2)

I
= 2

= Permissible current density (A/m2)

Q = Rating in KVA
We place first half of LV on one limb and rest half of LV on other limb to reduce leakage flux.
So arrangement is LV insulation then half LV turns then HV insulation and then half HV turns.
(1)

For 1-phase core type transformer

Rating is given by
Q = V1 I 1 10 3
KVA
3
= 4.44 fm N1 I1 10
KVA
3
= 4.44 fAi Bm N 1 I 1 10
KVA
Where
f = frequency
m = Maximum flux in the core
Ai = Sectional area of core
Bm = Maximum flux density in the core

V1

( m Ai Bm )

-----------(1)

H L
V V

4.44 f m N 1

L H
VV

Window

H L
V V

Window Space Factor

Kw

Actual Cu Section Area of Windings in Window

Window Area ( Aw )

a N a2 N 2
1 1
Aw
( I / ) N1 ( I 2 / ) N 2
1
Aw
I N I2 N2
1 1
Aw

1-phase core type transformer with

concentric windings

(a1 I /1 & a2 I / 2 )

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L H
VV

2 I1 N 1
Aw

( For Ideal Transforme r I1 N1 I 2 N 2 )

So

K w Aw
N1 I1

( 2)

Put equation value of N1I1 form equation (2) to equation (1)

K w Aw
10 3
2
Q 2.22 f A i Bm K w Aw 10 3
Q 4.44 f A i Bm

(2)

KVA
KVA

Window

(3)

For 1- phase shell type transformer

Window Space Factor

a1 N1 a2 N 2
Aw
( I / ) N1 ( I 2 / ) N 2
1
(a1 I /1 & a2 I / 2 )
Aw
I N I2 N2
1 1
Aw
2I N
1 1
( For Ideal Transforme r I1 N1 I 2 N 2 )
Aw
So
K w Aw

Kw

N1I1

LV

LV

HV

HV

LV

LV

HV

HV

LV

LV

1-phase shell type transformer with

sandwich windings

( 4)

Put equation value of N1I1 form equation (4) to equation (1)

K w Aw
3
Q 4.44 f A i Bm

10
2
Q 2.22 f A i Bm K w Aw 10 3

KVA

KVA (5)

Note it is same as for 1-phase core type transformer i.e. equ (3)
(3)

Window

For 3-phase core type transformer

H L
V V

Rating is given by
Q = 3 V1 I1 10 3
KVA
3
= 3 4.44 fm N1 I1 10
KVA
3
= 3 4.44 fAi Bm N1 I1 10
KVA

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L H
VV

H L
V V

L H
VV

H L
V V

3-phase core type transformer with

concentric windings

V1
-----------(6)

4.44 f m N 1

( m Ai Bm )

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L H
VV

3
Window Space Factor
Kw

Actual Cu Section Area of Windings in Window

Window Area ( Aw )

2(a1 N1 a2 N 2 )
Aw

2 ( I1 / ) N1 ( I 2 / ) N 2
Aw
2( I1 N1 I 2 N 2 )

Aw
2 2 I1 N1

Aw
So

( a1 I /1 & a2 I / 2 )

( For Ideal Transforme r I1 N1 I 2 N 2 )

Window

K w Aw
(7 )
4
Put equation value of N1I1 form equation (7) to equation (6)
N 1 I1

K w Aw
10 3
4
Q 3.33 f A i Bm K w Aw 10 3
Q 3 4.44 f A i Bm

(3)

KVA
KVA (8)

For 3- phase shell type transformer

Window Space Factor

a1 N1 a2 N 2
Aw
( I / ) N1 ( I 2 / ) N 2
1
Aw
I N I2 N2
1 1
Aw
2I N
1 1
Aw
So
K w Aw

Kw

N1I1

(a1 I /1 & a2 I / 2 )
3-phase shell type transformer with
sandwich windings
( For Ideal Transforme r I1 N1 I 2 N 2 )

(9)

Put equation value of N1I1 form equation (9) to equation (6)

K w Aw
3
Q 3 4.44 f A i Bm

10
2
Q 6.66 f A i Bm K w Aw 10 3

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KVA

KVA (10)

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CHOICE OF MAGNETIC LOADING (Bm)

(1) Normal Si-Steel
(0.35 mm thickness, 1.5%3.5% Si)

0.9 to 1.1 T

(2) HRGO
(Hot Rolled Grain Oriented Si Steel)

1.2 to 1.4 T

(3) CRGO
(Cold Rolled Grain Oriented Si Steel)
(0.14---0.28 mm thickness)

1.4 to 1.7 T

CHOICE OF ELECTRIC LOADING

This depends upon cooling method employed
(1) Natural Cooling:

1.5---2.3 A/mm2
AN
Air Natural cooling
ON
Oil Natural cooling
OFN Oil Forced circulated with Natural air cooling

(2) Forced Cooling :

2.2---4.0 A/mm2
AB
Air Blast cooling
OB
Oil Blast cooling
OFB Oil Forced circulated with air Blast cooling

(3) Water Cooling:

5.0 ---6.0 A/mm2

OW Oil immersed with circulated Water cooling
OFW Oil Forced with circulated Water cooling

CORE CONSTRUCTION:

(a) U-I type

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(c) U-T type

(b) E-I type

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(d) L-L type

45o

(e) Mitred Core Construction (Latest)

EMF PER TURN:

We know

V1 4.44 fm N1

(1)

So EMF / Turn

Et

V1
4.44 fm ( 2)
N1

and
Q = V1 I 1 10 3
KVA
3
= 4.44 fm N1 I1 10
KVA
Et N1 I1 10 3

(Note: Take Q as per phase rating in KVA)

KVA (3)

In the design, the ration of total magnetic loading and electric loading may be kept constant
Magnetic loading
= m
Electric loading
= N1 I1
m

cons tan t ( say " r" ) N1 I1 m put in eqution (3)

So
N1 I1
r

Q Et m 10 3
KVA
r
Or

Q Et

Et
10 3
4.44 f r

KVA

using equation (2)

Et (4.44 f r 10 3 ) Q
Or

Et K t Q

Volts / Turn

Where K t 4.44 f r 10 3
is a constant and values are
Kt = 0.6 to 0.7
for 3-phase core type power transformer
Kt = 0.45
for 3-phase core type distribution transformer
Kt = 1.3
for 3-phase shell type transformer
Kt = 0.75 to 0.85

for 1-phase core type transformer

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6
Kt = 1.0 to 1.2

for 1-phase shell type transformer

ESTIMATION OF CORE X-SECTIONAL AREA Ai

We know
Et K t Q

(1)

Or

Et 4.44 f m
Et 4.44 f Ai Bm

So

Ai

( 2)

Et
4.44 f Bm

(3)

Now the core may be following types

d/2

2-Step
1-Step
Or
CruciformCore
Or Square- Core
K=
0.45
d = Diameter of circumscribe circle
For Square core
Gross Area

0.56

3-Step Core

4-Step Core

0.60

0.625

d
d

0.5 d 2
2
2

Let stacking factor

K i 0.9

Actual Iron Area

Ai 0.9 0.5d 2
0.45 d 2
K d2

(0.45 for square core and take K as a general case)

Ai K d 2

So

Ai
K
Graphical method to calculate dimensions of the core
Consider 2 step core
d

Or

90o
,
n 1
i.e n 2

a
b

n No of Steps

90o

30o
2 1

So a dCos
b dSin

Percentage fill
2-Step
Or Cruciform- Core
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Gross Area of Stepped core Kd 2 K i

Area of circumcirc le
d 2
4

0.625d 2 / 0.9
2
(d )
4

for 4 Step core

= 0.885 or 88.5%
No of steps
1
2
% Fill
63.7% 79.2%

3
84.9%

4
88.5%

5
90.8%

6
92.3%

7
93.4%

9
94.8%

11
95.8%

ESTIMATION OF MAIN DIMENSIONS:

Consider a 3-phase core type transformer
W
hy

Ww=

(D-d)

We know output equation

Q 3.33 f A i Bm K w Aw 10 3

3-phase core type transformer

KVA

So, Window area

Aw

Q
3.33 f A i Bm K w 10 3

where

m2

Kw =Window space factor

8
30 HigherKV
10
Kw
30 HigherKV
12
Kw
30 HigherKV
Kw

For higher rating

for upto 10 KVA

for upto 200 KVA
for upto 1000 KVA

Kw = 0.15 to 0.20

Assume some suitable range for

D = (1.7 to 2) d
Width of the window
Ww = D-d
Height of the window

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8
L

Aw
width of window(Ww )

(L Ww Aw )

Generally

L
2 to 4
Ww

Yoke area Ay is generally taken 10% to 15% higher then core section area (A i), it is to reduce the iron loss in
the yoke section. But if we increase the core section area (A i) more copper will be needed in the windings
and so more cost through we are reducing the iron loss in the core. Further length of the winding will
increase resulting higher resistance so more cu loss.
Ay = (1.10 to 1.15) Ai
a
Depth of yoke
Dy = a
b
Height of the yoke
hy = Ay/Dy
Width of the core
W = 2*D + d
Height of the core
H = L + 2*hy
b

Flux density in yoke

By

Ai
Bm
Ay

2-Step
Or Cruciform- Core

ESTIMATION OF CORE LOSS AND CORE LOSS COMPONET OF NO LOAD CURRENT I C:

Volume of iron in core
Weight of iron in core

= 3*L*Ai
m3
= density * volume
= i * 3*L*Ai
Kg
i = density of iron (kg/m3)
=7600 Kg/m3 for normal Iron/steel
= 6500 Kg/m3 for M-4 steel
From the graph we can find out specific iron loss, pi (Watt/Kg ) corresponding to flux density Bm in core.
So
Iron loss in core
Similarly
Iron loss in yoke
Where

= py* i * 2*W*Ay Watt

py = specific iron loss corresponding to flux density By in yoke

Total Iron loss

Pi =Iron loss in core + Iron loss in yoke

=pi* i * 3*L*Ai

Watt

Core loss component of no load current

Ic = Core loss per phase/ Primary Voltage

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9
Ic

Pi
3V1

ESTIMATION OF MAGNETIZING CURRENT OF NO LOAD CURRENT Im:

Find out magnetizing force H (atcore, at/m) corresponding to flux density Bm in the core and atyoke
corresponding to flux density in the yoke from B-H curve

atcore / m,

So
MMF required for the core
MMF required for the yoke

= 3*L*atcore
= 2*W*atyoke

We account 5% at for joints etc

So total MMF required

= 1.05[MMF for core + MMF for yoke]

Bc at yoke / m

Peak value of the magnetizing current

I m , peak

Total MMF required

3N1

RMS value of the magnetizing current

I m , RMS
I m , RMS

I m, peak

2
Total MMF required

3 2 N1

ESTITMATION OF NO LOAD CURRENT AND PHASOR DIAGRAM:

No load current Io
Io

Ic Im

V1=-E1

Io

Ic

No load power factor

Coso

Ic
Io

Im

The no load current should not exceed 5% of the full the load current.

E2
ESTIMATION OF NO OF TURNS ON LV AND HV WINDING

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No load phasor diagram

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10
V1
Et
V
N2 2
Et
N1

Primary no of turns
Secondary no of turns

ESTIMATION OF SECTIONAL AREA OF PRIMARY AND SECONDARY WINDINGS

Primary current

I1

Q 103
3V1

Secondary current

I2

Q 103
3V2

OR

N1
I1
N2

I1

I2
Sectional area of secondary winging a2

Where is current the density.

Now we can use round conductors or strip conductors for this see the IS codes and ICC (Indian Cable
Company) table.
Sectional area of primary winding

a1

DETERMINATION OF R1 & R2 AND CU LOSSES:

Let
Lmt = Length of mean turn
Resistance of primary winding
L N ( m)
R1, dc , 75 o 0.021 10 6 mt 1 2
a1 (m )
R1, ac , 75 o (1.15 to 1.20) R1, dc , 75 o

Resistance of secondary winding

R2, dc , 75 o 0.021 10 6

Lmt N 2 (m)
a2 ( m 2 )

R2 , ac , 75 o (1.15 to 1.20) R2 , dc , 75 o

Copper loss in primary winding

Copper loss in secondary winding
Total copper loss

3I12 R1
Watt
2
3I 2 R2
Watt
2
3I1 R1 3I 22 R2
3I12 ( R1 R2' )
3I12 R p

Where

R01 R p R1 R2'
Total resis tan ce referred to primary side

Note: On No load, there is magnetic field around connecting leads etc which causes additional stray losses
in the transformer tanks and other metallic parts. These losses may be taken as 7% to 10% of total cu losses.
DETERMINATION OF EFFICIENCY:

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11

Efficiency

Output Power
Input Power

Output Power
Output Power Losses
Output Power

100
Output Power Iron Loss Cu loss

ESTIMATION OF LEAKAGE REACTANCE:

Assumptions
1. Consider permeability of iron as infinity that is MMF is needed only for leakage flux path in the
window.
2. The leakage flux lines are parallel to the axis of the core.
Consider an elementary cylinder of leakage flux lines of thickness dx at a distance x as shown in following
figure.
MMF at distance x
NI
Mx 1 1 x
b1
Permeance of this elementary cylinder

b1
Lc

a
dx

b2

A
o
L

Lmt dx
Lc

1 L
o A

(Lc =Length of winding)

& Permeance

Leakage flux lines associated with elementary cylinder

N1I1=N2I2

dx M x Permeance

N1 I 1
L dx
x o mt
b1
Lc

Flux linkage due to this leakage flux

d x No of truns with which it is associated d x

N1 I1 N1 I1
L dx

x o mt
b1
b1
Lc

x
MMF Distribution

Lmt x
dx
o N
I1
Lc b1
2
1

Flux linkages (or associated) with primary winding

2
b1
x
b
2 L
'
2 Lmt
dx o N1 mt I1 1
1 o N1
I 1
Lc 3
Lc 0 b1
Flux linkages (or associated) with the space a between primary and secondary windings
L
o o N 12 mt I 1 a
Lc
We consider half of this flux linkage with primary and rest half with the secondary winding. So total flux
linkages with primary winding

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12
o
2
L
b a
1 o N 12 mt I 1 1
Lc 3 2
Similarly total flux linkages with secondary winding

2 2' o
2
L
b a
2 o N 22 mt I 2 2
Lc 3 2
Primary & Secondary leakage inductance
L b a

L1 1 o N 12 mt 1
1 1'

I1

Lc 3

L b a
2
o N 22 mt 2
I2
Lc 3 2
Primary & Secondary leakage reactance
L2

Lmt b1 a

Lc 3 2

X 1 2fL1 2fo N12

Lmt b2 a

Lc 3 2
Total Leakage reactance referred to primary side
X 2 2fL2 2fo N 22

X 01 X P X 1 X 2' 2f o N 12

Lmt b1 b2

Lc
3

Total Leakage reactance referred to secondary side

X 02 X S X 1' X 2 2f o N 22

Lmt b1 b2

Lc
3

It must be 5% to 8% or maximum 10%

Note:- How to control XP?
If increasing the window height (L), Lc will increase and following will decrease b1, b2
& Lmt and so we can reduce the value of XP.
CALCULATION OF VOLTAGE REGULATION OF TRANSFORMER:
I 2 Ro 2Cos2 I 2 X o 2 Sin2
100
E2
R Cos2
X Sin2
o2
100 o 2
100
E2 / I 2
E2 / I 2

V .R.

% Ro 2Cos2 % X o 2 Sin2

TRANSFORMER TANK DESIGN:

Width of the transformer (Tank)
Wt=2D + De + 2b
Where
De= External diameter of HV winding
b = Clearance width wise between HV and tank
Depth of transformer (Tank)
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13
lt= De + 2a
Where
a= Clearance depth wise between HV and tank
Height of transformer (Tank)
Ht= H + h
Where
h=h1 + h2= Clearance height wise of top and bottom
W
hy

Ww
(D-d)

a
lt

De
b

a
Wt

h1
W

Ht

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h2

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14

Tank of a 3-Phase transformer

CALCULATION OF TEMPERATURE RISE:
Surface area of 4 vertical side of the tank (Heat is considered to be dissipated from 4 vertical sides of the
tank)
m2

St= 2(Wt + lt) Ht

Let

(Excluding area of top and bottom of tank)

= Temp rise of oil (35o C to 50o C)

12.5St =Total full load losses ( Iron loss + Cu loss)

So temp rise in o C

Total full load losses

12.5 St

If the temp rise so calculated exceeds the limiting value, the suitable no of cooling tubes or radiators must be
provided
CALCULATION OF NO OF COOLING TUBES:
Let
Then

xSt= Surface area of all cooling tubes

Specific Heat dissipation

6 Watt/m2-0C by Radiation
6.5 Watt/m2-0C by Convection

Losses to be dissipated by the transformer walls and cooling tube

= Total losses
12.5 St 8.5 xSt Total losses
6 W-Raditon+6.5 W=12.5 Convection

6.5*1.35 W 8.5 ( 35% more) Convection only

So from above equation we can find out total surface are of cooling tubes (xSt)
Normally we use 5 cm diameter tubes and keep them 7.5 cm apart
At= Surface area of one cooling tube
d tube l tube , mean

Hence
No of cooling tubes

xSt
At

7.5 Cm

d= 5 Cm
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Tank and Arrangement of Cooling tubes

15

WEIGHT OF TRANFORMER:
Let
Wi = Weight of Iron in core and yoke (core volume* density + yoke volume* density)
Wc= Weight of copper in winding (volume* density)
(density of cu = 8900 Kg/m3)
Weight of Oil
= Volume of oil * 880
Add 20% of (Wi+Wc) for fittings, tank etc.
Total weight is equal to weight of above all parts.

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Kg
Kg
Kg