1 Transformer
1 Transformer
1 Transformer
1
Layout of a Typical Transmission system
showing the importance of
TRANSFORMERS at various stages.
Introduction
Constituents of transformer:
i. Magnetic Circuit
ii. Electric Circuit
iii. Dielectric Circuit
iv. Other accessories
3
Classification or Types
Transformers
Based on
Based on
Based on Core transformer
Service
Ratio
4
Constructional Details
5
Constructional Details
6
Constructional Details
7
Basic parts of transformer
Core Type
• Shell type
• Core type
Transformer Core
16
The low voltage windings are placed
nearer to the core as it is the easiest to
insulate.
to cut
• In laminated cores, thin layers of steel
laminations are stacked over one another to make
the core.
•These layers stay insulated from one-another by
thin non-conducting layer of insulation.
• One common design of laminated core is made
from interleaved stacks of E-shaped steel sheets
capped with I-shaped pieces,leading to its name of
"E-I transformer".
• It exhibits more losses, but
is very economical to
manufacture.
TOROIDAL CORE
• They are built around a ring-shaped core made from a
long strip of silicon steel wound into a coil, powdered
iron, or ferrite.
• Grain boundaries are optimally aligned,
• Improved efficiency
• Reduced core reluctance.
• Closed ring shape eliminates
air gaps inherent in the
construction of an E-I core.
Toroidal Core
.
Concentric
Lower voltage winding closest
to Iron
Winding types
Sandwich or Pancake
35
CRGO Material
• Grain oriented Electrical Steels are iron-silicon alloys that
provide low core loss and high permeability needed for more
efficient and economical electrical transformers.
• CRGO Grain oriented grades of electrical steel are typically
used in Transformer and large generators.
• Important physical properties of Electrical steels
(CRGO) include resistivity, saturation induction, magneto-
crystalline anisotropy.
• Resistivity, which is quite low in iron, increases markedly
with the addition of silicon.
• Higher resistivity lessens the core loss by reducing the eddy
current component. Raising the silicon content reduces the
aging of the material.
Mitred Joint
• A miter joint, sometimes shortened to miter, is a joint
made by beveling each of two parts to be joined,
usually at a 45°/ 45°angle or 35°/55° to form a
corner, usually a 90° angle.
• In square core when bending of conductor takes
place its mechanical strength decreases.
40
Cooling of Cores
42
Transformer Core
Hw
Ww
Core Type
Shell Type
43
CONSERVATOR AND BREATHER
• It is required to keep the oil clean and dry. With the
rise of temperature, the oil level increases.
• Rise of temperature depends on the load of the
transformer. If load increases, oil expands. If load
decreases, contraction of oil occurs.
• Smaller transformers are not totally filled by oils,
some space is left between tank walls and oil, which
is occupied by air.
• The tank is connected to the atmosphere through a
vent pipe. Air is expelled out if oil expands. Air is
drawn from the atmosphere if oil contracts.
• When air enters the transformer, it is required to
extract moisture from the air.
• An apparatus known as breather is used to
extract moisture from the air.
• It is a small container connected to the vent
pipe containing a dehydrating material such
as silica gel crystal impregnated with cobalt
chloride.
• The color of the material is blue when it is
dry. It becomes whitish pink when it is
damp.
• In front of the container, a glass window is
provided to observe the color of the
material.
• If the transformer becomes overloaded, it
overheats the oil and sludge formation occurs in
the presence of air.
• If transformer suffers short circuit, temperature rise
becomes very high and this causes vaporization of
a part of the oil, which forms an explosive mixture
with air. This explosive mixture can ignite and
cause considerable damage.
• To prevent the air coming in contact with air as well
as moisture, conservators are used.
• It takes the responsibility of expansion and
contraction of oil without allowing it to come into
contact with air.
• The conservator is an air-tight cylindrical drum
mounted on or near the cover of the transformer. It
is connected to the transformer through a small
pipe. In fig, breather and conservator are shown.
Conservator
57
Classification Based On Cooling
• Dry Transformer – Air Cooled
• Oil immersed Transformer – Oil Cooled
• Oil is filled in tank and transformer inside it.
• First alphabet defines medium used for cooling which is cooling
winding.
• A-air, O-oil, G-gas, W-water, S-solid insulator.
• Air and Oil are mostly used.
• Second alphabet defines the method of circulation.
• N – Natural, B – Blast, F - Forced.
• Since no transformer is truly an “ideal”
transformer, each will incur a certain amount of
energy loss, mainly that which is converted to
heat.
• Methods of removing this heat can depend on the
application, the size of the unit, and the amount
of heat that needs to be dissipated.
• The insulating medium inside a transformer,
usually oil, serves multiple purposes, first to act
as an insulator, and second to provide a good
medium through which to remove the heat.
• The windings and core are the primary sources of
heat, although internal metallic structures can
act as a heat source as well.
• It is imperative to have proper cooling ducts and
passages in the proximity of the heat sources
through which the cooling medium can flow so
that the heat can be effectively removed from
the transformer.
• The natural circulation of oil through a
transformer through convection has been referred
to as a “thermosiphon” effect.
• The heat is carried by the insulating medium until
it is transferred through the transformer tank wall
to the external environment.
• Radiators, typically detachable, provide an
increase in the surface area available for heat
transfer by convection without increasing the
size of the tank.
• In smaller transformers, integral tubular sides or
fins are used to provide this increase in surface
area.
• Fans can be installed to increase the volume of
air moving across the cooling surfaces, thus
increasing the rate of heat dissipation.
• Larger transformers that cannot be effectively cooled using
radiators and fans rely on pumps that circulate oil through
the transformer and through external heat exchangers, or
coolers, which can use air or water as a secondary cooling
medium.
• Allowing liquid to flow through the transformer windings
by natural convection is identified as “nondirected flow.”
• In cases where pumps are used, and even some instances
where only fans and radiators are being used, the liquid is
often guided into and through some or all of the windings.
• This is called “directed flow” in that there is some degree
of control of the flow of the liquid through the windings.
• The use of auxiliary equipment such as fans and pumps
with coolers, called forced circulation, increases the
cooling and thereby the rating of the transformer without
increasing the unit’s physical size.
• Ratings are determined based on the temperature of the
unit as it coordinates with the cooling equipment that is
operating.
• First alphabet defines medium used for
cooling the windings.
• A-air, O-oil, G-gas, W-water, S-solid insulator.
• Air and Oil are mostly used.
• Second alphabet defines the method of
circulation.
• N – Natural, B – Blast, F - Forced.
• Usually, a transformer will have multiple ratings
corresponding to multiple stages of cooling, as the
supplemental cooling equipment can be set to run only at
increased loads.
• Methods of cooling for liquid-immersed transformers have
been arranged into cooling classes identified by a four-
letter designation as follows:
Table for symbols
• This system of identification has come about through
standardization between different international
standards organizations and represents a change from
what has traditionally been used in the U.S. Where OA
classified a transformer as liquid-immersed self-cooled
in the past, it is now designated by the new system as
ONAN.
• Similarly, the previous FA classification is now identified
as ONAF.
• FOA could be OFAF or ODAF, depending on whether
directed oil flow is employed or not.
• In some cases, there are transformers with directed
flow in windings without forced circulation through
cooling equipment.
• An example of multiple ratings would be
ONAN/ONAF/ONAF, where the transformer has a
base rating where it is cooled by natural
convection and two supplemental ratings where
groups of fans are turned on to provide additional
cooling so that the transformer will be capable of
supplying additional kVA.
• This rating would have been designated
OA/FA/FA per past standards.
Cooling of transformers
Methods of cooling:
1. Air Natural (AN)-upto 1.5MVA
2. Air Blast (AB)
3. Oil natural (ON) – Upto 10 MVA
4. Oil Natural – Air Forced (ONAF)
5. Oil Forced– Air Natural (OFAN) – 30 MVA
6. Oil Forced– Air Forced (OFAF)
7. Oil Natural – Water Forced (ONWF) – Power plants
8. Oil Forced - Water Forced (OFWF) – Power plants
Constructional Details
72
73
74
75
76
77
78
79
80
Constructional Details
81
Constructional Details
82
TRANSFORMER
WINDINGS
INTRODUCTION
• Main purpose of a winding is to convert the energy
on the primary side to a different voltage level on
the secondary side.
• They are broadly classified as circular &
rectangular.
• Generally circular windings are used for all
the types of transformers invariably.
• Rectangular windings involve wastage of space &
under short current conditions it gets deformed.
Hence is used for very small capacity
transformers.
Type & arrangement of
windings depends on some
factors
1.Current rating
2.Short circuit strength
3.Temperature rise
4.Impedance
5.Surge voltage
6.Transport facilities.
Types Of Windings
1.Cylindrical Windings
2.Helical Windings (Single and Multiple)
3.Cross-over Windings
4.Disc & Continuous Disc Windings
5.Aluminium Foil Windings
Cylindrical windings
• Cylindrical windings are layered type and use
either rectangular or round conductors.
• Conductors are wound on the flat side with their longer
sides parallel to the core axis.
• The layered winding may have conductors wound
in one, two or more layers and is, therefore,
accordingly called the one, two or multi-layered
winding.
• Cylindrical windings employing rectangular conductors
are used mainly as low voltage windings upto 6.6 kV
for kVA ratings up to 600-750.
• They are wound on a solid paper bakelite
cylinder.
• In order to improve cooling conditions of the inner
layer, these are often wound on vertical strips
forming an oil duct, between winding &insulating
cylinder.
Helical Windings
MOG LV Bushing
PRV
Radiator
Main
Tank
Cooling
Fan
OLTC
V1/ V2 = N1/ N2 = I2 / I1
Copper leads
Main contact
Auxiliary contact
Driving shaft
Collector ring
Transition resistance
Fixed contact
Tungsten part
Copper part
Moving contacts
DSS switch
HAND INTERLOCK
SWITCH
Main Testing on OLTC:
• Generally these
bushings are used for
72.5 kV & above.
• These bushings
contain their own oil
and are sealed to
retain the same.
Oil communicating type bushings:
FUNCTIONS OF TRANSFORMER OIL
•INSULATION
•COOLING MEDIUM
•TO QUENCH ARCS
•DISSOLVE GASES GENERATED /EXPOSED TO
2.22 fm K w A w 10 3
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
120
K A
AT w w
4
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 fm . K w A w 10 3
4
3.33 f Bm A i A wK w 10 3 kVA
121
EMF per Turn
Design of Transformer starts with EMF/turn.
Let, Ratio of Specific magnetic loading r m
to Electric loading AT
Q VpIp 10 3
4.44 f m TpIp 10 3
4.44 f m ( AT) 10 3
m
4.44 f m 10 3
r
Q r Q r 10 3
m
2
3
4.44 f 10 4.44 f
Q r 10 3 122
m
4.44 f
EMF per Turn
w.k.t , E t 4.44 f m
Q r 10 3 Q
4.44 f 4.44 f 4.44 f r 10 .
3
4.44 f 4.44 f
4.44 f r 10 3 Q
Et K Q
where, K 4.44 f r 10 3
124
Optimum Design
Ai M & Ac
127
Optimum Design
Design for Minimum Cost
Let, Ct - Total cost of transformer active materials
Ci – Cost of iron
Cc – Cost of conductor
pi – Loss in iron/kg (W)
pc – Loss in Copper/kg (W)
li – Mean length of flux path in iron(m)
Lmt – Mean length of turn of transformer winding (m)
Gi – Weight of active iron (kg)
Gc – Weight of Copper (kg)
gi – Weight/m3 of iron
gc – Weight/m3 of Copper
C t Ci Cc c iGi c c Gc
128
Optimum Design
Design for Minimum Cost
C t ci g ili A i cc g c Lmt A c
where , ci & cc specific cos ts of iron and copper respective ly .
M
C t c i giliM c c gc Lmt
Differeniating Ct with respect to β,
d 1 1
C t ci g ili M() 1/ 2 c c g c Lmt M3 / 2
d 2 2
d
For minimum cost, Ct 0
d
1 1
c i giliM() 1/ 2 c c gc LmtM 3 / 2
2 2
c i gili c c gc Lmt 1
Ac 129
c i gili c c gc Lmt
Ai
Optimum Design
Design for Minimum Cost
c i gili A i c c gc Lmt A c
ci G i c c G c
Ci C c
Hence for minimum cost, the cost of iron must be equal to the
cost of copper.
Similarly,
For minimum volume of transformer,
Gi Gc
Volume of iron = Volume of Copper or G i gi
gi gc Gc gc
xQ P x P Q 2xP x
i
2
c c
xQ Pi x 2 Pc xQ x 2 Pc x 2 Pc 131
Pi x 2 Pc
Optimum Design
Design for Minimum Loss and Maximum Efficiency
132
DESIGN OF CORE
Design of Core
• Core type transformer : Rectangular/Square /Stepped cross section
• Shell type transformer : Rectangular cross section
• Stacking Factor- the net cross sectional area is obtained
from the dimensions of various packets and an allowance is
made for the space lost between lamination ; this allowance
is known as stacking factor.
• Utilisation factor – Ratio of net cross sectional area to the
gross area of the core circle.
134
DESIGN OF CORE
• Core design is governed by rating of transformer, its operating
conditions and transport limitations.
SQUARE CORE
d : circumscribing radius
a : side of square
d : circumscribing radius
a d cos
b d sin
To maximize area for a given diameter:
3145‘
b a = 0.85 d
b = 0.53 d
a
d
CRUCIFORM CORE
MULTI STEPPED CORES
• With
an increase in the number of steps core space is utilized
more effectively.
• Multi stepped cores also reduce the length of mean turn with
consequent reduction in both cost of copper and copper loss.
Depth
1.4 to 2
Width
Rectangular coils are used.
For shell type,
143
Design of Core
Square Core
2
Agi 0.5d 2
Let the stacking factor, Sf=0.9. 144
tan 1 2 31.720
1
2
Therefore, if the θ=31.720, the dimensions ‘a’ & ‘b’ will give
maximum area of core for a specified ‘d’.
a 149
cos a d cos a d cos(31.720 ) 0.85d
d
b
sin b d sin b d sin( 31.720 ) 0.53d
d
Design of Core
Stepped Core or Cruciform Core
Gross core area,
A gi 2ab b 2
A gi 2(0.85d)(0.53d) (0.53d) 2
A gi 0.618d 2
Let stacking factor, S f 0.9,
Net core area, Ai Stacking factor X Gross Core area
Ai 0.9 0.618d 2 0.56d 2
The ratios,
Net core area 0.56d 2
0.71
Area of Circumscri bing circle
d2
4 150
Gross core area 0.618d 2
0.79
Area of Circumscri bing circle 2
d
4
151
Design of Core
Stepped Core or Cruciform Core
Core area factor,
Net Core area
KC
Square of Circumscri bing Circle
A i 0.56d 2
2 2
0.56
d d
Ratios of Multi-stepped Cores,
Ratio Square Core Cruciform Core 3-Stepped Core 4-Stepped Core
Vh.v.
Th.v. Tl .v.
Vl .v.
Tappings on h.v. side:-
• Total loss
Pc U p U t U p
2
p
2
s
• Differentiating Pc wrt Up
dPc
dU p
p2 s2
• For minimum loss
dPc
0
dU p
p s
Therefore, for minimum loss, the value of current density in
each of the two winding should be equal.
Practically, however, current density in the relatively better cooled
outer winding is made 5% greater than the inner winding.
CHOICE OF CURRENT DENSITY
• Copper losses depend on the choice of current density.
• Different values of current density are chosen for distribution
and power transformers as the level of iron and copper
losses required is different .
• The following values of current density for different types of
transformers maybe used:
• Cylindrical windings are used for ratings upto 800 kVA and
voltages upto 433 V.
• Helical winding can be used for ratings upto tens of MVA and
voltages upto 33 kV.
• Electrical Considerations.
• Mechanical Considerations.
• Thermal Considerations.
Electrical considerations in insulation
design
• Basic insulation structure is primarily determined from
consideration of voltage which appear between different parts
of transformer.
• Sustained frequency high voltage tests and impulse test are
done to check strength of winding.
• Electrical design should also consider
– Eddy current loss – The winding should be so designed that
stray load losses is small. The radial width of strips should
be small and they should be transposed.
– Leakage reactance – The leakage reactance is adjusted by
changing the winding configuration and brought within
desirable limits.
Mechanical considerations in insulation
design
• Insulation must be capable of withstanding mechanical stresses
during manufacturing processes.
• Insulation must be able to withstand mechanical stress
developed due to electromagnetic phenomenon.
– Under normal operation these are quite small. But during fault
condition these forces may increase several hundred times.
Insulation must be designed to withstand these forces for a
specified period of time.
• The mechanical design of insulation should be such that hoop,
bursting and compressive stresses are minimized.
Thermal considerations in insulation design
1. Major insulation: the insulation between windings and grounded core and the
insulation between the windings of the same phase.
2. Minor insulation: insulation between different parts of one winding i.e. insulation
between turns, coils and layers etc.
3.Insulation relative to tank: is called oil barrier insulation in oil immersed transformers.
this insulation consists of oil ducts, barriers and coverings. Partition of solid insulation
materials placed inside an oil ducts are called barriers. for example pressboard, s.r.b.p or
cylinders placed between l.v and h.v windings and between windings and core are called
barriers. The barriers and coverings increase the electrical strength of an oil duct.
The major insulation between the low and high voltage windings is
provided by another pressboard or s.r.b.p cylinder and the bars are
arranged around it.
Thickness of insulation between a winding earth and between l.v and h.v
windings is :
25-630 12 3 30 - 14 2
800 and 11 17 5 30 to 50 14 2
above
25-630 15 3.5 40 - 17 2
800 and 15 17 5 40-50 17 2
above
10-800 27 5 60 2 30 3
1000 and 33 27 5 75 2 30 3
above
Thickness of Major Insulation of L.V. winding upto 33 kV
• D = d + Ww
• DY = a
• H = Hw + 2HY
• W=D+a
Single phase shell type transformer
• DY = b
• HY = a
• H = Hw + 2a
• W = 2Ww + 4a
Three phase core type transformer
• D = d + Ww
• DY = a
• H = Hw + 2HY
• W = 2D + a
Overall Dimensions
Single phase Core Type
Hy
Hw H
Hy
Dy
196
d Ww d
D
Overall Dimensions
Single phase Shell Type
a
2a Hw
Ww
Depth
b Over
winding
197
Overall Dimensions
Thee phase Core Type
Hy Hy
a
Hw H Hw H
Hy Hy
a
W
Dy Dy
d Ww d Ww d
D D
198
OPERATING
CHARACTERISTICS
Estimation of No-load Current
No-load Current of Transformer:
Magnetizing Component
Depends on MMF required to establish required flux
Loss Component
Depends on iron loss
200
No load Current in transformer design:
Io
Im
No-load current,
I0 I 2m Il2
• Now to calculate the loss component. First calculate
2 the
iron losses with the use of loss per weight vs flux density
curve.
• IL = Pi/Vp
Calculation of no load current of Three Phase
transformer:
HT
D D
C3
WT
LT
Doc C1
C2
Design of tanks with cooling tubes
Dimensions of the tank:
Let, C1 – Clearance b/w winding and tank along width
C2 - Clearance b/w winding and tank along length
C3 – Clearance b/w the transformer frame and tank at the bottom
C4 - Clearance b/w the transformer frame and tank at the top
Doc – Outer diameter of the coil.
Width of the tank, WT=2D+ Doc +2 C1 (For 3 Transformer)
= D+ Doc +2 C1 (For 1 Transformer)
Length of the tank, LT= Doc +2 C2
Height of the tank, HT=H+C3+ C4
Design of tanks with cooling tubes
Clearance on the sides depends on the voltage &
power ratings.
Clearance at the top depends on the oil height above
the assembled transformer & space for mounting the
terminals and tap changer.
Clearance at the bottom depends on the space
required for mounting the frame.
Design of tanks with cooling tubes
Clearance in mm
Voltage kVA Rating
C1 C2 C3 C4
7.5 Cm
d= 5 Cm
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