ELECTRICAL BOOKS

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OIL TYPE OR OIL INMERSED POWER same for both the windings. The magnetizing flux
TRANSFORMER corresponds to the magnetizing current in the primary
and the number of turns of the primary winding.
Transformer is one of the most vital and important Primary and secondary windings are wound on the
electrical machinery. The development of the present same core; hence the induced voltage per turn is the
day power system is very much attributable to the same for both primary and secondary winding. Also
large number and types of transformer that are in the absolute value of induced voltage in the primary
operation in the system, such as, generator and secondary windings is proportional to the number
transformers, step-up transformers, step-down of turns in the respective windings.
transformers, interlinking transformers, power
transformers & distribution transformers etc. Being a
static machine, it is inherently reliable compared to
other machines. Distribution transformers are an
important link between the power system and millions
of electricity consumers. Any failure of this important
equipment, apart from adversely affecting the
consumers, will also mean considerable financial loss
to the electricity undertaking. It is therefore of
important that utmost care is taken in the design,
manufacture, testing, installation, and maintenance of
transformers.
A transformer consists of a magnetic core made out
of insulated silicon steel laminations. Two distinct
sets of windings, one called primary and other called
secondary winding, are wound on such core. The
transformer helps in converting low voltage into high TRANSFORMER CONSTRUCTION DETAILS:
voltage or visa-versa and accordingly the transformer The main parts of a transformer are;
is termed step-up or step-down. The winding to which 1- Transformer core.
the voltage is applied is called primary winding, 2- Transformer windings.
where as the winding to which the load is connected 3- Transformer tank and radiators.
is called secondary winding. The transformer works
on the principle of electro-magnetic induction. Such Transformer core:
phenomena can take place in a static device, only, if Every transformer has a core, which is surrounded by
the magnetic flux is continually varying. It is therefore windings. The core is made out of special cold rolled
clear that static transformers can only be used with grain oriented silicon sheet steel laminations. The
alternating currents only. When an alternating EMF is special silicon steel ensures low hysteresis’s losses.
applied to the primary winding of a transformer with The silicon steel laminations also ensure high
the secondary winding open circuited, a small current resistively of core material which results in low eddy
flows in the primary winding which serves to currents. In order to reduce eddy current losses, the
magnetize the core and to feed the iron losses of the laminations are kept as thin as possible. The
transformer. As primary and secondary windings are thickness of the laminations is usually around 0.27 to
wound on the same core, the magnetizing flux is the

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0.35 mm. The transformer cores construction are of selecting identical cross-section and shape for core
two types, core type and shell type. and yoke sections and having mitered corners. The
materials used are such as to give low hysteretic
losses, for a particular flux density. These are
dependent on weight of material used and design flux
density. In case a low flux density is employed, the
weight of material increases, which in turn also leads
to increase in length of mean turn of transformer coil.
Both these aspects result in increase in losses.
Similarly, the eddy current loss depends on the
quality of material thickness of laminations and the
flux density employed.
The limb laminations in small transformers are held
together by stout webbing tape or by suitably spaced
In core type transformers, the windings are wound glass fiber bends. The use of insulated bolts passing
around the core, while in shell type transformers, the through the limb laminations has been discontinued
core is constructed around the windings. The shell due to number of instances of core bolt failures. The
type transformers provide a low reactance path for top and bottom mitered yokes are interleaved with
the magnetic flux, while the core type transformer has the limbs and are clamped by steel sections held
a high leakage flux and hence higher reactance. together by insulated yoke bolts. The steel frames
clamping the top and bottom yokes are held together
by vertical tie bolts.

Transformer windings:
1- Cross over Type.
2- Helical Type.
3- Continuous Disc Type.
Cross-over type winding is normally employed where
rated currents are up-to about 20 Amperes or so. In
this type of winding, each coil consists of number of
The ideal shape for the section of the core is a circle,
layers having number of turns per layer. The
as this would mean no wastage of space between the
conductor being a round wire or strip insulated with a
core and windings, except the space taken by the
paper covering. It is normal practice to provide one or
insulation between laminations. A perfectly circular
two extra layers of paper insulation between layers.
section of core would mean varying dimensions for
Further, the insulation between layers is wrapped
each successive lamination, which may not be
round the end turns of the layers there by assisting to
economical. A compromise is therefore struck and a
keep the whole coil compact. The complete winding
stepped core (four or six steps) construction is
consists of a number of coils connected in series.
normally preferred. The net sectional area is
The inside end of a coil is connected to the outside
calculated from the dimensions of the various
end of adjacent coil. Insulation blocks are provided
sections and giving due allowance for the insulation
between adjacent coils to ensure free circulation of
thickness. The yoke section is arranged similar to the
oil.
limb section. To make the best use of the grain
oriented silicon steel it is necessary that the flux run
parallel to the direction of the rolling for as much of
the magnetic path as possible. This is achieved by

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 and provides efficient heat dissipation from windings
to the oil. The whole coil structure is mechanically
sound and capable of resisting the most enormous
short circuit forces.

In helical winding, the coil consists of a number of

rectangular strips wound in parallel racially such that
each separate turn occupies the total radial depth of
the winding. Each turn is wound on a number of key
spacers which form the vertical oil duct and each turn
or group of turns is spaced by radial keys sectors.
This ensures free circulation of oil in horizontal and
vertical direction. This type of coil construction is
normally adopted for low voltage windings where the
The windings coils after manufacture are subjected to
magnitude of current is comparatively large.
drying out in an oven by circulation of hot air at
around 80 degree centigrade. The pre drying and
shrinking of coils is achieved in this process. The
coils are further dried until the required insulation
resistance is achieved. In case of larger distribution
and power transformers, the assembled core and
windings are further subjected to drying out at about
100C and 730mm absolute pressure to drive out
water vapor and gas from the windings. Appropriate
clamping arrangements in the form of rings are
provided on the windings to adjust for any shrinkage
of insulation. The clamping rings could be either
metallic with suitable grounding arrangements or of
The continuous disc type of windings consists of insulating material.
number of discs wound from a single wire or number
of strips in parallel. Each disc consists of number of The insulation of the windings comprises of insulating
turns, wound radically, over one another. The cylinders between LV windings and core and
conductor passing uninterruptedly from one disc to between HV winding. Also insulating barriers are
another with multiple-strip conductor. Transpositions provided where necessary, between adjacent limbs,
are made at regular intervals to ensure uniform in some cases and between core yoke and coils.
resistance and length of conductor. The discs are The leads from top and bottom end of windings and
wound on an insulating cylinder spaced from it by from such tapings, as may be provided, are brought
strips running the whole length of the cylinder and out to a few centimeters length only. The electrical
separated from one another by hard pressboard connection from these leads to the terminals or
sectors keyed to the vertical strips. This ensures free bushings consist of either copper rod or strips
circulation of oil in horizontal and vertical direction
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depending on the current to be carried. Copper rods
are insulated with Bakelite tubes and supported by
cleats. Which in turn are supported from the vertical
tie rods passing through the top and bottom yoke
clamps. When copper strips are used for low voltage
leads no insulation need to be provided, except the
cleats, which hold the strip in position. The strips are
however wrapped with linen or varnish cloth at the
point where it passes through the leads. Leads from
tapings are brought out to a point just
below the top oil and so arranged that tapings may
be readily changed by means of off load Tap
changer. In larger tanks, stiffeners are also provided on the
sides of the tank to prevent bulging of the tank under
Transformer tank: oil pressure. The tubes are welded on the inside of
Transformer tanks commonly used are of the the tank, while all other joints are welded both, inside
following types: and outside.
1- Plain sheet steel tank.
Large size transformers, above 5 MVA rating are
2- Sheet steel tank with external cooling tubes.
normally provided with detachable radiator tanks to
3- Radiator banks.
provide required cooling surface. The radiator tank
4- Tanks with corrugated wall panels.
consists of series of elliptical tubes or a pressed steel
Plain sheet steel tanks are used where the size of plate assembly welded into top and bottom headers.
the tank provides adequate cooling surface to The radiator bank is bolted on to the tank wall and
dissipate the heat generated on account of losses two isolating valves are fitted into the oil inlet and
inside the transformer. Normally transformers up-to outlet. In case of very large transformers, even
50KVA could be manufactured without external detachable radiator banks mounted onto the tank
cooling tubes. For transformers of higher rating, tanks walls do not provide adequate cooling surface. In
are constructed with external cooling tubes to such cases, separate self supporting coolers are
provide additional surface for heat dissipation. The provided which are connected to the main
cooling tubes could be circular or elliptical. Elliptical transformer through large detachable pipes. This type
tubes with smaller width are employed where one of of arrangement is good for naturally cooled
the sides of the transformer is fully occupied by on transformers, as well as, for forced cooled
load tap changer. This ensures more tubes on the transformers. Forced air cooling could be provided by
given surface thereby providing more area for heat means of suitable fans located below the cooler
dissipation. banks. Similarly, forced oil cooling could be provided
by installing an oil pump in the return cold oil pipe
connecting the main transformer tank to the cooler
bank. For outdoor transformers, the transformer has
to be water-tight. For this purpose, the cover bolts are
closely spaced and a substantial tank flange of ample
width is provided. Further a neoprene bonded cork
gasket is provided between the tank flange and the
cover.

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The bushing insulators are selected considering the
maximum system voltages encountered in the
system and pollution conditions prevailing at site. The
joints are made water-tight by use of Neoprene
bonded cork gaskets.
Transformers of rating 1 MVA or more are also
normally provided with a conservator tank connected
to the main tank. The conservator tank has a capacity
of about 10% of the oil content of the main tank.

Transformer tanks with corrugated wall panels

Forced cooled power transformer with a conservator oil tank

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