ADDIS ABABA SCIENCE AND TECHNOLOGY UNIVERSITY

College of Electrical and Mechanical Engineering

Electromechanical Engineering

Course: Electrical machine

Transformer design project

Section- B

Group 4
DESTA ELIAS LOMBASO ETS0488/14
EBA MEREBA OLANA ETS0494/14
ELIAS DESSALEGN ENDEG ETS0518/14
ELIZABETH DEBEBE SHAWUL ETS0521/14
ELSAYE MATHEWOS BEYENE ETS0525/14
ELSHADAY ESHETU DEMISSEW ETS0526/14
EMAN EBRAHIM MOHAMMED ETS0527/14
ENIYEW TIBEBU TILAYE ETS0532/14

Submitted To: Tsehaye Aman

Submitted Date: 08/08/23

 Introduction

Transformer design plays a crucial role in the efficient and reliable distribution of electrical
power. This document focuses on the design of three-phase shell type transformers, considering
specific parameters such as rated power, primary and secondary voltages, frequency, and cooling
method.
The given transformer specifications include a rated power of 150 KVA, primary voltage of 15
KV, secondary voltage of 400 V, frequency of 50 Hz, and the utilization of oil natural cooling.
Furthermore, the core material is specified as normal silicon steel, and the type of transformer is
identified as a distribution transformer. The transformer's connection type is delta/star, and the
efficiency is specified as 88% with a power factor of 0.8.
The design process begins with the selection of magnetic loading (Bm), which depends on the
chosen core material. The document provides the acceptable range of magnetic loading for
normal silicon steel. The choice of electric loading (δ) is determined by the cooling method
employed, in this case, oil natural cooling.
The core construction and electromagnetic force per turn (EMF/Turn) are further discussed to
establish the relationship between voltage and turns. The document provides equations to
calculate the electric loading and the total magnetic loading. The constant ratio between these
loadings is maintained throughout the design process.x
Output Equation: The output equation relates the electrical rating (KVA) of the transformer to its
physical dimensions. It involves parameters such as primary and secondary voltages (V1 and
V2), primary and secondary currents (I1 and I2), primary and secondary numbers of turns (N1
and N2), sectional areas of LV (low voltage) and HV (high voltage) conductors (a1 and a2), and
the permissible current density (δ). Here is below the necessary parameters
Three phase shell type transformers
Rated power: 150KVA
Primary voltage: 15KV
Secondary voltage: 400V
Frequency: 50Hz
Cooling: Oil Natural cooling
Type of Core material Normal Si-Steel
Type: Distribution transformer
Type of connection Delta / Star
Efficiency 88%
Power factor 0.8
Design a transformer for the above given data
CHOICE OF MAGNETIC LOADING (Bm)
The choice of magnetic loading (Bm) is an important aspect in transformer design and is
dependent on the core material used. In the specified core material is normal silicon steel, which
has a thickness of 0.35 mm and a silicon content ranging from 1.5% to 3.5%.
For normal silicon steel, the acceptable range of magnetic loading is provided as 0.9 to 1.1 Tesla
(T). Magnetic loading refers to the level of magnetic flux density that the core material can
handle without saturating.
In transformer design, selecting an appropriate magnetic loading is crucial to ensure optimal
performance and efficiency. The magnetic loading affects the size and dimensions of the core, as
well as the number of turns required for the windings. By staying within the specified range of
magnetic loading, the designer ensures that the core material operates within its magnetic limits
and avoids saturation.
In the given case, for the normal silicon steel core material with a thickness of 0.35 mm and a
silicon content of 1.5% to 3.5%, the recommended magnetic loading (Bm) range is 0.9 T to 1.1
T. This range ensures that the core can effectively handle the magnetic flux and operates
efficiently in the designed transformer.
CHOICE OF ELECTRIC LOADING  

The choice of electric loading in natural cooling methods is determined by the transformer's
cooling capabilities. Natural cooling methods, such as Air Natural (AN) and Oil Natural (ON)
cooling, rely on the surrounding air or oil for heat dissipation. The permissible current density
range of 1.5 to 2.3 A/mm² ensures that the conductors carrying the electrical current stay within
their thermal limits. This allows for effective dissipation of the generated heat through natural
convection.
The selection of the specific permissible current density range takes into account various
factors, including the ambient temperature, cooling efficiency, and insulation class of the
transformer. By operating within this range, the transformer maintains a safe temperature level,
preventing excessive heating and potential damage.
Natural Cooling: 1.5---2.3 A/mm2
AN Air Natural cooling
ON Oil Natural cooling
OFN Oil Forced circulated with Natural air cooling

CORE CONSTRUCTION
The core construction is essential in transformer design because it determines the physical
structure and arrangement of the core material, which directly affects the transformer's
performance and efficiency.
Here are the reasons why We choice core construction:
1. Magnetic Flux Path: The core construction defines the path of the magnetic flux within the
transformer. It ensures that the flux generated by the primary winding is efficiently transferred to
the secondary winding. A well-designed core construction minimizes magnetic losses and
ensures optimal energy transfer.
2. Core Material Compatibility: The core construction is chosen based on the type of core
material used. In this case, the core material specified is normal silicon steel. The core
construction is designed to accommodate and utilize the magnetic properties of the core material,
such as high permeability and low hysteresis and eddy current losses.
3. Heat Dissipation: The core construction also plays a role in heat dissipation. Transformers
generate heat during operation, and the core construction helps facilitate the dissipation of heat to
prevent overheating and maintain the transformer's efficiency and reliability.
4. Electromagnetic Force per Turn (EMF/Turn): The core construction determines the
relationship between voltage and turns in the transformer. The EMF/Turn equation provided in
the document helps establish this relationship, allowing for accurate calculations of voltage and
turns required for the desired transformer specifications

EMF PER TURN:

Calculating the EMF per turn in transformer design is crucial for establishing the voltage-turn
relationship in the winding. It helps determine the induced voltage in each turn and has the
following key purposes:
1. Voltage and Turns Relationship: The EMF per turn calculation defines how voltage and
turns in the winding are related, aiding in achieving the desired voltage transformation
ratio.
 2. Power Rating Calculation: Incorporating the EMF per turn in the power rating equation
allows for accurate determination of the transformer's power rating based on voltage,
current, and turns.
3. Design Optimization: Optimizing the transformer design requires considering the EMF
per turn to select the appropriate number of turns, ensuring efficient and reliable operation.

We know

V1  4.44 fm N1              (1)

V1
So EMF / Turn Et   4.44 fm            (2)
N1

and

Q = V1 I1  10 3 KVA (Note: Take Q as per phase rating in KVA)

= 4.44 fm N1 I1  103 KVA

 Et N1 I1 103 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 m
So  cons tan t ( say " r" )  N1I1  put in eqution (3)
N1 I1 r

m
Q  Et  10 3 KVA
r
Et
Or Q  Et  10 3 KVA using equation (2)
4.44 f r

Et  (4.44 f r 103 )  Q
2

Or Et  Kt 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
Kt = 1.0 to 1.2 for 1-phase shell type transformer

ESTIMATION OF CORE X-SECTIONAL AREA Ai

Core Type Transformer - Single Phase: This section provides the rating formula for a single-phase
core type transformer. The formula is given by:Q = (44.4 V1I1) / (10^3 fBAm)where Q is the rating in KVA,
V1 is the primary voltage, I1 is the primary current, f is the frequency, BAm is the maximum flux density in
the core, and m is the sectional area of the core

Q = (44.4 V1I1) / (10^3 fBAm)

In this formula, the variables represent the following:

Q: The rating of the transformer in KVA (kilovolt-amperes). It indicates the transformer's

power capacity.
 V1: The primary voltage of the transformer. It represents the voltage supplied to the primary
winding.

I1: The primary current of the transformer. It refers to the current flowing through the primary
winding.

f: The frequency of the power supply. It represents the rate at which alternating current cycles
occur, typically measured in hertz (Hz).

BAm: The maximum flux density in the core. It indicates the maximum magnetic field strength
in the core material.

m: The sectional area of the core. It represents the cross-sectional area of the core material.

The rating formula calculates the rating (Q) of the single-phase core type transformer based on these
variables. It is derived from the fundamental principles of transformer operation.

To use the formula, you would substitute the specific values for each variable based on the given
transformer specifications. For example, if the primary voltage (V1) is 15KV, the primary current (I1) is
known, the frequency (f) is 50Hz, the maximum flux density (BAm) is determined, and the sectional area of
the core (m) is calculated, you can plug in these values and calculate the transformer's rating in KVA (Q).

za

We know

Et  Kt Q           (1)

Et  4.44 f m

Or Et  4.44 f Ai Bm           (2)

Et
So Ai            (3)
4.44 f Bm

σ= 1.9 A/𝑚𝑚2 Use Bm = 1.1tesla

Et = 𝐾𝑡 √𝑄

=1.3√150𝑘𝑉𝐴
 =15.921KVA

Then
𝐸𝑡
Ai= 4.44𝑓𝐵𝑚 Use f = 50 Hz

15.921
= 4.44 ∗ 1.1 ∗ 50

Ai=0.065𝑚2
So, based on the provided values, the estimated core cross-sectional area (Ai) is approximately
0.0653 m20.0653m2
In this transformer design we prefer Core,
We Use Bm = 1
The diameter of the circumscribing
in a shell type transformer it is more common to use a relatively rectangular shape core but for
this specific transformer we selected a circular shaped core.

c 𝐴𝑖 = 0.56𝑑 2
𝐴𝑖 =0.065 𝑚2

0.065
d=√ 0.56

d=0.340m
d = Diameter of circumscribe circle
For Square core
d d
Gross Area    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 (0.45 for square core and take ‘K’ as a general case)

 K d2

Ai  K d 2

Ai
d
K

Gross Area of Stepped core Kd 2 K i

%fail  
Area of circumcirc le d 2
4
𝑂. 56 ∗ 𝑑2/𝑜. 9
%fail = ⁄𝜋𝑑2/4

%fail = 0.792 or 79.2%

For three(3) phase shell type transformer

Three-Phase Core Type Transformer: The formula Q =6.66 f𝐴𝑖 𝐵𝑚 S 𝐾𝑤 𝐴𝑤 *10−3 is specifically
associated with three-phase core type transformers.Focus on Core Dimensions: The formula
primarily involves parameters related to the transformer core's dimensions and magnetic
properties:
 Q: Core cross-sectional area (square meters)
 f: Frequency (Hz)
 ABS: Absolute permeability of the core material (Henries per meter)
 KA: Core window area (square meters)
For the equation we going to Calclaute Aw

Q =6.66 f𝐴𝑖 𝐵𝑚 𝛿 𝐾𝑤 𝐴𝑤 *10−3

But we going to derive the formula for Kw

Kw=Window space factor

Kw = 10/(30+15) = 0.22
For this equation Aw

Aw = Q/6.66 f𝐴𝑖 𝐵𝑚 𝛿𝐾𝑤 *10−3 where Q = 150kVA

150𝐾𝑉𝐴
Aw = 6.66x0.065𝑚 2𝑥1.1𝑇𝑥1.9𝐴/𝑚𝑚^2𝑥0.17

= 980.39mm2 = 0.00980 m2
Assume some suitable range for:
D = (1.7 to 2)d
Ww = D – d = Width of the window
𝐴𝑤
Height of the window: L 𝑊𝑤 , Aw = L × Ww
𝐿
= 2 to 4 (prefer 3)
𝑊𝑤
𝐴𝑤
L = 𝐿⁄ , L2 = 3Aw , L=√3𝐴𝑤= √3(0.00980)= 0.5422m =hw
3
Since the width, Ww =L/3 = 0.5422/2 = 0.271m

(Aw is already calculated above)

Ay > Ai , Ay = 1.10 to 1.15)Ai ,
Ay = 1.12 Ai = 1.12* 0.065 = 0.072
𝐴𝑦
Dy = a – Depth hy = ⁄𝐷𝑦 – Height
Graphical method to calculate dimensions of the core
a
Consider 2 step core
b
90o
 , n  No of Steps
n 1
i.e n  2
So a  dCos
90o b  dSin 
  30o Ө
2 1 b a

a =0.5422m *cos30 b = 0.5422m *sin30

=0.469m =0.271

2-Step
Width: W = 2D + d
Or Cruciform- Core
Height : H = L + 2hy
𝐴𝑖 0.065
Flux density in yoke, By = 𝐴𝑦 Bm =0.072 1.1 = 0.993 T
To find the yoke parameters:
 Depth of yoke Dy = a = 0.469m
0.072m2
 Height of the yoke Hy = Ay/Dy = 0.153𝑚
0.469m
 To find the Volume of the Yoke = 4* Hy * Kf*2a
But first calculate that: 2a = 2Hy = 2*0.153m=0.306m
Then we will get Volume of Yoke=4* 0.153𝑚 × 1.12 ∗ 0.306𝑚 = 0.209𝑚3
 Width of the core W = 2*D + d
W = 2*0.47605+0.340 =1.292m
 Height of the core H = L + 2*hy
H =0.5422+2*0.153=0.848m

 Flux density in yoke m

Volume of Limb = 3* Hw* Ag* Kf = 3× 0.5422𝑚 × 0.074m2 × 1.12 =0.134𝑚3

 Density of Si-steel 𝜎𝐹𝑒 =7600 kg/𝑚3

Net area of yoke𝐴 0.0742m2
Gross area of yoke = Stacking factor Ki𝑦 = = 0.066m2
1.12

ESTIMATION OF CORE LOSS AND CORE LOSS COMPONET OF NO LOAD

CURRENT IC:
Volume of iron in core = 3*L*Ai m3 = 3(0.5422)(0.065)= 0.105m3
Weight of iron in core = density * volume = i * 3*L*Ai Kg

i = density of iron (kg/m3)

=7600 Kg/m3 for normal Iron/steel

w= 7600(0.105)= 803.5 N
From the graph we can find out specific iron loss, p i (Watt/Kg ) corresponding to flux density B m
in core.
From this graph Pi=0.9 and Py= 0.78
So

Iron loss in core =pi* i * 3*L*Ai Watt= 0.9*803.5= 723.15

Similarly Iron loss in yoke = py* i * 2*W*Ay Watt = 0.78*803.5= 626.73

Where py = specific iron loss corresponding to flux density B y in yoke

Total Iron loss Pi =Iron loss in core + Iron loss in yoke
Core loss component of no load current
Ic = Core loss per phase/ Primary Voltage

Pi 0.9
Ic  =  =0.02A
3V1 3 (15kv)

ESTIMATION OF MAGNETIZING CURRENT OF NO LOAD CURRENT Im:

First we need to find out magnetizing force H (at core, at/m) corresponding to flux density B m in
the core and atyoke corresponding to flux density in the yoke from B-H curve
Bm  atcore / m, Bc  at yoke / m  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
Bm  atcore / m, Bc  at yoke / m  (Magnetizing force)

H(atcore, at/m) IINl/Hc (height of core)

H(atcore, at/m) 3,699.1Aturn/m
H(atyoke, at/m) = IINI/ Dy (Depth of yoke)
H(atyoke, at/m) - 3.34*1630/0.24 = 22684.17 Aturn/m

So
MMF required for the core= 3*L*atcore= 3x0.5422x3699.1= 6,016.9
MMF required for the yoke =2*w*at yoke=2X1.292x22684.17= 58,615.89528
We account 5% at for joints etc. So total MMF required = 1.05[MMF for core + MME for
yoke)= 1.05(6016.9 + 58615) = 67,864.435044
Peak value of the magnetizmg current

Im, Peak = 67864.4/3x942= 24

RMS value of the magnetizing current

=16.98

We account 5% at for joints etc. So total MMF required = 1.05[MMF for core + MMF for yoke]

ESTIMATION OF NO OF TURNS ON LV AND HV WINDING

V1
Primary no of turns N1  = 15*103 / 15.921 = 942 TURNS
Et

V2
Secondary no of turns N2  = 400/15.921*103 = 25 TURNS
Et

ESTIMATION OF SECTIONAL AREA OF PRIMARY AND SECONDARY WINDINGS

Q  103
Primary current I1  = 150*10-3/ 3(15) = 3.33
3V1
 Q  103 N
Secondary current I2  OR 1 I1 = 150*10-3/ 3(400)= 125
3V2 N2

I1
Sectional area of primary winding a1  = 3.33/1.9 = 1.75

I2
Sectional area of secondary winging a2  = 125/1.9= 13.15

Where  is the current density.
DETERMINATION OF R1 & R2 AND CU LOSSES:
Now we can use round conductors or strip conductors for this see the IS codes and ICC (Indian
Cable Company) table.
Let Lmt = Length of mean turn =0.0369m
Resistance of primary winding
Lmt N1 (m)
R1, dc, 75o  0.021  10 6 = 0.021x106 (0.0369)(942)/1.75= 0.417
a1 (m 2 )

R1, ac, 75o  (1.15 to 1.20) R1, dc, 75o

Resistance of secondary winding

Lmt N 2 (m)
R2, dc, 75o  0.021  10 6 = 0.021x106 (0.0369)(25)= 1.9
a2 ( m 2 )

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

Copper loss in primary winding  3I12 R1 Watt = 3(1252)(0.417)= 19.54

Copper loss in secondary winding  3I 22 R2 Watt

Total copper loss  3I12 R1  3I 22 R2

 3I12 ( R1  R2' )

 3I12 Rp

R01  Rp  R1  R2'
Where =0.417 +1.9 = 2.317
 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.
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)
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

D D
a

lt
De

b a b

Wt

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)
St= 2(Wt + lt) Ht m2 (Excluding area of top and bottom of tank)
Let
 = Temp rise of oil (35o C to 50o C)
 12.5St  =Total full load losses ( Iron loss + Cu loss)
Total full load losses
So temp rise in o C 
12.5 St

If the temp rise so calculated exceeds the limiting value, the suitable no of cooling tubes or
radiators must be provided

Specific Heat dissipation

CALCULATION OF NO OF COOLING TUBES:
6 Watt/m2-0C by Radiation
Let xSt= Surface area of all cooling tubes
6.5 Watt/m2-0C by Convection
Then
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 (xS t)
Normally we use 5 cm diameter tubes and keep them 7.5 cm apart
At= Surface area of one cooling tube
 d tubeltube, mean

xSt
Hence, No of cooling tubes 
At

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

In the process of designing a transformer, several critical factors must be considered, such as the
dimensions of the transformer tank, including its width, depth, and height, in relation to the
various clearances between windings and the tank. Subsequently, the calculation of the
temperature rise becomes pivotal, as it directly impacts the cooling requirements and determines
if additional cooling elements, such as cooling tubes or radiators, are necessary to maintain safe
operating temperatures.

Moreover, the number of cooling tubes is determined based on the surface area required to
dissipate the total losses from the transformer walls and the cooling tubes. This necessitates a
keen understanding of the surface area of the cooling tubes, considering their size and
arrangement, and their collective capacity to manage heat dissipation effectively.

In conclusion, the design of a transformer is a meticulous and multi-faceted process that

encompasses precise calculations, material considerations, and an acute understanding of
temperature management. It underscores the crucial balance between structural design, thermal
regulation, and operational efficiency, all of which are essential for ensuring the safe and
effective function of the transformer.

Based on the information, it's evident that the selection of electric loading in natural cooling
methods is crucial and determined by the transformer's cooling capabilities and the permissible
current density range. These considerations ensure the safe and effective operation of the
transformer, preventing excessive heating and potential damage.

Finally, the overall weight of the transformer involves comprehensive considerations, including
the weight of the iron in the core and yoke, the weight of copper in the winding, and the weight
of the oil, along with an additional percentage to account for various fittings and the transformer
tank itself.