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ELECTRICAL ENGINEERING DEPARTMENT
UNIVERSITY OF ENGINEERING AND TECHNOLOGY
LAHORE
Design of Core
2Design of LT windings
3Design of HT windings
4Losses CaIcuIations
5Percentage Impedance
6VoItage ReguIation
7Efficiency Of Transformer
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IMPORTANT PARTS IMPORTANT PARTS
E
t
= k bS k = 0305
T
2
=V
2
/ E
t
T
2
(Rounded )
E
t
(actuaI) = V
2
/ T
2
A
i
= E
ta
/ (444 L f L B
m
)
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DESIGN OF CORE DESIGN OF CORE
1
2
3
4
Bm= 3
(For Power and Distribution Transformer )
A
g
= ( A
i
/ K
s
) L0^6 (mm
2
)
d = b(4 L Ag) /(kL6) (Core diameter)mm
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6
5
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SHAPE OF 5 STEP CORE: SHAPE OF 5 STEP CORE:
f
,1 ,1
,2 ,2
,3 ,3
,4 ,4
,5 ,5
b5 b5 b4 b4 b3 b3 b2 b2 b1 b1
For five step core 7 = 90/6 = 5
)a=b5 = d L cos (7 )
2)a2=b4 = d L cos (27 )
3)a3=b3 = d L cos (37 )
4)a4=b2 = d L cos (47 )
5)a5=b = d L cos (57 )
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CALCULATIONS: CALCULATIONS:
a = width , b= thickness
No of Laminations = thickness / 03
Ag

= width L 03 L No of Laminations
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FOR STEP A FOR STEP A
FOR STEP B FOR STEP B
a2 = width , b= thickness , b2 = thickness
No of Laminations = (b2 - b) / 03
Ag
2

= a2 L 03 L No of Laminations
a3 = width , b2= thickness , b3 = thickness
no of Iaminations = (b3 - b2) / 03
Ag
3

= a3 L 03 L no of Iaminations
a4 = width , b3= thickness , b4 = thickness
No of Laminations = (b4 - b3) / 03
Ag
4

= a4 L 03 L No of Laminations
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FOR STEP C FOR STEP C
FOR STEP D FOR STEP D
a5 = width , b4= thickness , b5 = thickness
no of Iaminations = (b5 - b4) / 03
Ag
5

= a5 L 03 L no of Iaminations
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FOR STEP E FOR STEP E
Ag

= Ag

Ag
2

Ag
3

Ag
4

Ag
5

Check the difference

If
Ag

- Ag A 0 then Design is OK otherwise

If
Ag

- Ag > 0 then
Remove the Laminations randomIy from
each step
And then proceed further
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TOTAL AREA TOTAL AREA
7
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DESIGN OF LT
WINDING
DESIGN OF LT
WINDING
As T
2
=V
2
/ E
t
No of Iayers mostIy used = 2
the turns per Iayer = T
2
/ 2
The current per phase = I
2
= KVA/ (b3 LV
2
/1000)
current density = 0 A 4 a /mm
2
X-sectionaI area of LT winding Conductor = a
2
a
2
= I
2
/ 0
2
(mm
2
)
If a
2
< 0mm
2
then round conductor wiII be used
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1
2
3
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If a
2
> 0mm
2
then we wiII use the rectanguIar or strip
conductor instead of round
SeIect a conductor from conductor tabIe.
(WLL)
If W < 5
Then subtract (W LL) - 0mm
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If W < 45
then subtract (W LL) - 03mm
eIse
subtract (W LL) -0 9mm
We subtract this because of making the
conductor edges somehow round shape to
avoid the damage of insuIation paper
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SHAPE OF CONDUCTOR SHAPE OF CONDUCTOR
1
2
3
5 6
7 8
9 10
4
Length of one bar / turn = (L06 ) L 5
Here 06mm is due to 3 Iayers of craft paper
insuIation
each of 0mm thickness
and 5 are the conductor in one bar
Iength of LT windings = Lc
2
Lc
2
= (Iength of one bar/turn)L(turns/Iayer )
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4
5
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RadiaI width of LT windings = b
2
b
2
= (2L(W06)) L2 4mm
4mm oiI duct
b
2
oiI duct
6
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DESIGN OF HT
WINDING
DESIGN OF HT
WINDING
HT side has voItage = V

= kv
T

= V

/ E
t
Tapings = N, I 25%, I 5% , 7%
Current per phase = I

= KVA / (3 LKV

) (A)
SeIection for the vaIue of deIta = 0

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b)X-sectionaI area of HT windings conductor
= a

= I

/ 0

If a

< 0mm round conductor

If a

>0mm strip conductor

1
2
3
! = p,ckets , S = sp,cers
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GENERAL SHAPE: GENERAL SHAPE:
!
!
!
!
S
S
S
d

= (4La

)/(6) mm
f) d

( insuIated) from standard conductor

tabIe with fine enameI insuIations
g) No of packets = 4 (mostIy )
h) No of spacers = No of packets -
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f) Height of spacer = No of spacer L 4mm
g) Turns per packet = T

/ No of packets
As Lc

= Lc
2
4P 3S = Lc

find out P
where P = height of packet
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No of turns per Iayer = (P /d

) -
(-) due to spiraI effect
No of Iayers in each packet
= turns per packet / no of turns per Iayer
RadiaI width of HT windings = b

No of Iayer in packet = n
b

= d

Ln (n-)L 0
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HT WINDING
DESIGN
(POWER )
(TRANSFORMER)
HT WINDING
DESIGN
(POWER )
(TRANSFORMER)
Taking 5% Taps
T

= V

/ E
t
Current Per Phase = I

= KVA / (3LKV

)
SeIect 0

(0

> 0
2
)
a

= I

/ 0

(mm)
Check for a

< 0mm
or a

> 0mm
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AXIAL LENGTH OF WINDING
AxiaI Length of winding Lc

(To maximize the fIux Iinkage Lc

= Lc
2
)
The insuIating ring of wood or cIipboard at
bottom and top = 2L20mm
Lc

= axiaI Iength (active part)Ring

AxiaI Length = Lc

- 2L20
Here we wiII use Disc Windings
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Lc

- 40 = DLL (D-3)L25 2L5

D = No of Discs ,
D-3 = No of insuIations of size 25
2L5mm = InsuIation
Turns per Disc = T

/ D
Turns AvaiIabIe=Turns/disc L No of discs
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SHAPE SHAPE
D
D
D
D
Oil duct
Oil duct
nsul,tion ring
Disc
Lc1
Some discs wiII have different no of turns
and other wiII have different
so Let x ,y are no of discs having
different turns
x y = D
ax by = T , where a , b are
different no of turns then find out x and y.
b

= (W06)LTurns/Disc
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RADIAL
CALCULATIONS
RADIAL
CALCULATIONS
d = diameter of the core in (mm)
D
2i
= d 2. (. = 5mm)
D
2o
= D
2i
2b
2
D
i
= D
2o
2-
D
o
= D
i
2b

(-= 40mm , Distance b/w LT and HT)

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CALCULATION
OF LOSSES
CALCULATION
OF LOSSES
Mean diameter of LT windings = D
2
m
D
2
m = (D
2i
D
2o
) / 2
Mean Iength of LT winding per turn= Lmt
2
Lmt
2
= 6 D
2
m
TotaI Iength of LT winding conductor = L
2
L
2 =
Lmt
2
L T
2
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LT ( Cu ) LOSSES LT ( Cu ) LOSSES
1
2
3
Resistance of LT windings per phase = R
2
R
2
= (8 L
2
) / a
2
L
2
(m) ; a
2
(m
2
) ; R
2
()
Cu Loss = (I
2
)
2
R (Per Phase)
TotaI Cu Loss = 3(I
2
)
2
R (Three Phase)
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4
Weight of LT winding = W2
W2 = L
2
La
2
LS Kg
where S = specific gravity
S = 9 g/cm
3
(L
2
= mm, a
2
= mm
2
)
W2 = 3 L (L
2
La
2
LS )
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WEIGHT OF LT WINDING WEIGHT OF LT WINDING
5
Mean diameter of LT windings = D
2
m
D

m = (D
i
D
o
) / 2
Mean Iength of LT winding per turn = Lmt

Lmt
2
= 6 D

m
TotaI Iength of LT winding conductor = L

L
=
Lmt

L T

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1
2
3
HT (Cu) LOSSES HT (Cu) LOSSES
Resistance of LT windings per phase = R

= (8 L

) / a

(m) ; a

(m
2
) ; R

()
Cu Loss = (I

)
2
R (Per Phase)
TotaI Cu Loss = 3(I

)
2
R (Three Phase)
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Weight of HT Winding = W
W = L

La

LS (SingIe Phase)
W = 3(L

La

LS) (Three Phase)

4
TotaI Cu Losses = LT Losses HT Losses
Stray Losses = 0%
Net Cu Losses = LTotaI Cu Losses
ToIerance = I0%
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NET (CU) LOSSES NET (CU) LOSSES
Weight of Core = We
We = (3WH 4CL2S

w ) LA
i
L765 L0
-6
WH = Window Height , CL = CIearance
765 = Density of SteeI , a

= S

w
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CORE LOSSES CORE LOSSES
1
WH
CL S

w
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SHAPE SHAPE
Lc
WH = Lc

0(mm) 0(mm) ( For DT)

WH = Lc

40(mm) 40(mm) (For PT )

CL = D
o
0 (mm)
TotaI Core Losses = Sp Loss L We
SpeIas Take it for Bum graph
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HandIing factor = 20%
Net Core Loss = 2LTotaI Core Loss (W)
ToIerance = 0%
3
2
4
5
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PERCENTAGE
INPEDANCE
PERCENTAGE
INPEDANCE
%R = (Net Cu Losses / KVA) L00
%X = 026fL3
o
LL
mt
T
2
I
2
L ( - (b
2
b

)/ 3 )
E
t
L Lc
Mean Length of LT and HT Winding = L
mt
L
mt
= 6 D
mt
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%Z %Z
2
1
D
mt
= (D
2i
D
o
) / 2
%X = ____
%Z = (%R)
2
(%X)
2
ToIerance =I5%
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3
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VOLTAGE
REGULATION
VOLTAGE
REGULATION
VR = VoItage ReguIation
= (n%Rcosn%Xsin)(n%Xcos -n%Rsin )
2
200
n = Percentage Loading
cos = Power factor
0% Loading means n = 0
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PERCENTAGE
EFFICIENCY
PERCENTAGE
EFFICIENCY
% = Percentage Efficiency
% = (P
o
/ P
in
) L00
=(P
o
/ P
in
Losses) L 00
% = KVA(cos)
KVA (cos) Core Loss Cu Loss
This is for NormaI Loading Condition
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FOR OTHER LOADING CONDITIONS
% = KVA(cos)Ln
KVA(cos)Ln Core Loss Cu LossLn
2
n = Percentage Loading
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DESIGN OF
SMALL POWER
TRANSFORMER
DESIGN OF
SMALL POWER
TRANSFORMER

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VoItage Rating 0VA000VA
A
i
= E
t
/ (444Lf LB
m
) ( B
m
= 02 )
E
t
= 444Lf LB
m
L A
i
T
e
= / E
t
T
e
= /(444 Lf L B
m
L A
i
) turn/voIt
A
g
= A
i
/ K
s
( K
s
= 09 )
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DESIGN OF CORE DESIGN OF CORE
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VA Rating vs Te VA Rating vs Te
When the
rating is in between then
use the interpoIation
VA Te
0 203
20 4
50 70
75 56
00 46
50 40
200 35
300 2
400 23
500 20
750 7
000 6
Py winding turns = T

= V

LT
e
Ps winding turns = T
2
= V
2
L T
e
I

= VA / (V

L ) (A) = 090%
0 = 22 25
a

= I

/ 0

Specific No for conductor wire

SWG No =
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DESIGN OF WINDINGS DESIGN OF WINDINGS
Area occupied by py winding = A
p
A
p
= (T

L a

) / space factor
Space factor = 07 (d / d
i
)
2
Area occupied by Ps winding = A
s
A
s
= (T
2
L a
2
) / space factor
space factor = 07 (d / d
i
)
2
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WINDOW AREA WINDOW AREA
TotaI area required = A
T
A
T
= 5 L( A
p
A
s
)
If area required > AvaiIabIe area
then use the next standard
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WINDOW AREA WINDOW AREA
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DESIGN OF
COOLING
SYSTEM
DESIGN OF
COOLING
SYSTEM

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TANK TANK
Height
Width
Length
Width = 2CL D
0
2Cw
Length = D
0
2C
L
Height = WH 2SWBasebeam C
H
C
W
= width wise cIearance (2070mm)
C
L
= Length wise cIearance (2070mm)
C
H
= Height wise cIearance (70200mm)
Basebeam = 50mm
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MAIN DIMENSIONS OF TANK MAIN DIMENSIONS OF TANK
Heat Iost by the process of conduction is
negIigibIe
Heat Iost by the process of convection
=65W/m/C
Heat Iost by the process of radiation
= 6W/m/C
TotaI heat dissipation = (656)LSt L 7
St = Surface area of the Tank
7 = Temperature rise of tank
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St = 2(width L Height) 2(Height L Length)
7 = Net Losses L 5 / (25 L St )
If 7 < oiI average temperature ,CooIing
tubes are not required
and if 7K oiI avg temp then cooIing tubes
are required
OiI avrg temp = 40LK (CH)
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By the provision of cooIing tubes the totaI
surface area = xSt
Surface area of cooIing tubes = xSt-St
Net IossesL5 = (7372/x)LxLStL7
Find out x = ???
TotaI surface area of cooIing tubes = (x-)St
for one cooIing tube = P L L
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NO OF COOLING TUBES NO OF COOLING TUBES
P = perimeter (P=02mm)
Length of the tube = Height - 75 - 5 - 50
Basebeam = 50mm
Top Iid to top oiI IeveI = 75mm
No of cooIing tubes = N_C_T
N_C_T = TotaI surface area of cooIing tubes
Surface area of one cooIing tube
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No of cooIing tubes No of cooIing tubes
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