Application of Computers in Electrical

Machines Design
EPM445

Transformer Design
Lecture 4

Dr. Mohamed Shalaby

Electrical Power Engineering
Faculty of Engineering, Cairo University
Window Space Factor (Kw)
• Area of window should be larger than Copper area, to allow for insulation, cooling ducts,
prevent flashover, etc.
• Usually, Kw ≈ 0.33. However, For accurate calculation of Kw
• For small transformers up to 10 kVA
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𝐾𝑤 =
30 + 𝑘𝑉
• For transformers up to 250 kVA
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𝐾𝑤 =
30 + 𝑘𝑉
• For transformers above 250 kVA
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𝐾𝑤 =
30 + 𝑘𝑉
Where, kV is the phase voltage of the H.V. winding

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Windings Current Density
• Better cooling circuit enables higher current densities to be utilized

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Flux Density
• Flux density (Bm) = 0.9 to 1.1 T, for distribution transformer,
= 1.1 to 1.4 T, for power transformer,
= 1.2 to 1.4 T, for hot rolled Si steel,
= 1.4 to 1.7 T, for cold rolled grain oriented (CRGO) Si steel.
For CRGO transformer up to 132 kV = 1.55 T
For CRGO transformer up to 275 kV = 1.6 T
For CRGO transformer up to 400 kV = 1.7 T

• Note: The distribution transformer has to be designed for high all day efficiency,
so Bm should be low to keep low iron losses

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 Emf Per Turn (Et)
𝑉1 = 𝐸1 = 4.44 𝑓 𝜑1 𝑁1 (For ideal transformer: V1 = E1)

𝐸𝑡 = 𝐸1 /𝑁1 = 4.44 𝑓 𝜑1

For a given transformer, the ratio of magnetic loading (𝜑1 ) to current loading (NI) is constant.
𝜑1
𝛾 = 𝑐𝑜𝑛𝑠𝑡𝑎𝑛𝑡 =
𝑁𝐼
𝜑1
𝑄 = 𝑉1 𝐼1 × 10−3 = 4.44 𝑓 𝜑1 𝑁1 𝐼1 × 10−3 = 𝐸𝑡 𝑁1 𝐼1 × 10−3 = 𝐸𝑡 × 10−3
𝛾
𝐸𝑡
= 𝐸𝑡 × 10−3
4.44 𝑓 𝛾

𝐸𝑡 = 𝐾𝑡 𝑄 = 𝐾𝑡 𝑘𝑉𝐴 𝑅𝑎𝑡𝑖𝑛𝑔

Where 𝐾𝑡 = 4.44 𝑓 𝛾 × 103

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Emf Per Turn (Et)
• The value of Kt depends upon:
i. Type of transformer (core or shell type). It is more for shell type than the core type for same
rating since shell type transformer require more magnetic material.
ii. Material employed in construction.
iii. Choice of electric and magnetic cooling.

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 Different Dimensions Of Transformer
• Main Dimensions of
Transformer
i. Inner diameter of
circumscribing circle
ii. Width of window
iii. Height of window
iv. Overall width of transformer
v. Overall height of transformer

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Different Dimensions Of Transformer
• Different dimensions of a 1-phase core type transformer

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Different Dimensions Of Transformer
• Different dimensions of a 3-phase core type transformer

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Different Dimensions Of Transformer
• Different dimensions of a 1-phase shell type transformer

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Different Dimensions Of Transformer
• Different dimensions of a 3-phase shell type transformer

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Steps to Design a Transformer
1. Select Kt for a particular transformer. Estimate e.m.f. per turn (Et) for a
given kVA rating.

2. Estimate iron cross-section (Ai) by selecting suitable value of Bm.

3. Calculate inner diameter

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of circle enclosing the winding (d) using the
equation “𝐴𝑖 = 𝑘𝑑 ”. Estimate the width of largest step (Wc).

4. Estimate window area (Aw) from output equation by selecting suitable

value of current density (σ) and suitable value of window space factor
(Kw)
• Select suitable value of window space factor (Kw)
• Window area, Aw = hw × Ww
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Steps to Design a Transformer
5. The ratio of height of windows to width of window is taken from 2 to 3 (i.e. hw/Ww = 2
– 3).

6. Select suitable value of (hw/Ww) ratio and calculate height (hy) and width (Ww) of core
from steps (4) and (5).

7. Overall width of transformer can be calculated.

8. Width of yoke is calculated, as width of yoke Wy

• Wy= 0.9d, for 3-stepped core.
= 0.85d, for cruciform section (2-stepped core).
= 0.71d, for square section.
“Generally, rectangular section is considered for making small and medium
transformers” 13
Steps to Design a Transformer
9. Sectional area of yoke, Ay is taken 15% more than Ai (Ay=1.15 Ai, and for CRGO
is used then Ay=Ai)

10. Height of the yoke (hy) is calculated from Ay = hy× Wy

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Example 1:
Estimate the main core dimensions, of a 25 kVA, 3-phase, 6600/440 volts, delta/star.
50 Hz, core type transformer with the following data:
• Stepped core for which area factor = 0.56
• Spaces factor for window = 0.25
• Voltage per turn = 21.0 V
• Current density = 2.36 A/mm2
• Flux density = 1.1 tesla

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Solution

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Example 2:
Estimate the main dimensions of a 500 kVA, 6600/400 V, 3-phase, 50Hz core type oil immersed self
cooled distribution transformer. Assume suitable data if needed.
• Let voltage per turn, Et = 20 V
• Area factor for stepped core = 0.56
• Window space factor = 0.3
• Current density = 3.0 A/mm2
• Flux density, Bm = 1.2 Wb/m2
• Width of largest step, Wc = 0.85 * d
• Ratio height of window to width of window = 2.1
• Distance between two adjacent limbs = 1.85 × d
• Use Ay = Ai

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Solution

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