(a) Design steps for L.V.

Winding Design
Step-1 Calculate number of turns/phase using the equation
V
Ts  s
Et
The number of turns calculated may be a fraction which should be rounded of suitably.

Step-2 Find Secondary phase current Is

kVA 103
Is  (for 3-phase transformer)
3  Vs
kVA 103
Is  (for 1-phase transformer)
Vs

Step-3 Obtain the cross sectional area (in mm2) of the secondary conductor given by
I
as  s
s
Where δs is the assumed current density in Amp/mm2.

Step-4 Find out suitable dimensions of the conductor. If the cross sectional area of the
secondary conductor exceeds 50 mm2, it is better to take standard parallel conductors. Also
calculate the secondary current density again with the selected conductor area.

Step-5 The Conductors are paper insulated. This increases the thickness of the conductor.
Allow 0.5 mm for increase in thickness of the conductor for single covering

Step- 6 Select suitable type of winding from Table 5.4. If it is helical winding keep 1 turn more
along the axial depth.

Step-7 Determine axial depth Lcs of l.v. winding;

Lcs  number of secondary turns  axial depth of conductor
Obtain window clearance as below:
Window clearance =(height of the window - Lcs )/2

Step-8 Find radial depth bs of l.v. winding as follow:

bs  number of layers  radial depth of conductor + insulation between layers

Step-9 Find the inside and outside diameter of the l.v. winding can be found as follow:

inside dia. = dia. of circumscribing circle +2  pressboard thickness for insulation between l.v. and core.

outside dia. = inside dia. + b s

(b) Design Steps for H.V. Winding Design
Step-1 Calculate number of turns/phase using the equation
HT side phase voltage
Tp 
Voltage per turn
Voltage rating of HV side
Tp  number of LT side turns 
Voltage rating of LV side

Step-2 If 5% tapping are to be provided, the number of turns to be increased to

Tp (new)  1.05  Tp

Step-3 HT side current is calculated from

kVA 103
Ip 
3  HT side voltage rating

Step-4 Select the Conductor. In HT winding cross over type, cylindrical type with circular and
continuous disc type are generally used. The conductor section is then selected depending upon
the type of winding. It may be circular or rectangular. For small transformer due to lesser
conductor section, circular conductors are selected, while for large transformer, due to high
current ratings, rectangular conductors are preferred.
Actual current density is recalculated on the basis of new or modified cross-sectional area.

HT side phase current

Actual current density=
Modified area of the conductor

In case of selection of rectangular conductor, the winding height may be assumed to be 70%
of the window height.
hw  0.7 H w

axial length for one coil

Number of turns/coil =
diameter of the insulated conductor

Assume 30 mm end insulation, we are to add 60 mm axial end insulation for two ends. We add
a little slackness factor and add these axial lengths to find net axial length. To get the net radial
length, we are to add with outside dia of lv winding the depth of oil ducts between lv and hv
winding and between hv winding and hv insulating cylinder.