TRANSFORMER DESIGN

Er. T.K.RAMACHANDRAN , B.E., M.B.A

TRANSFORMER DESIGN
TOPICS COVERED Aim Of Design .. Magnetic Circuit .. Magnetic Materials .. Magnetization Characteristics .. Silicon Steel Types Operating Flux Density Heating and Cooling ... Ventilation .

TRANSFORMER DESIGN
TOPICS COVERED Types of Transformer . Stepped core and yoke . Tank and accessories .. Buchholz Relay . Bushings

Aim of Design :
Should be carried out based on the given specification Using available materials economically To achieve * LOWER COST * LOWER WEIGHT * REDUCED SIZE * BETTER OPERATING PERFORMANCE

Aim of Design :
The Magnetic circuit design for various electrical machines, to achieve a reasonable high flux in various parts of the magnetic circuit without any increased losses. The Magnetic circuit calculations largely depends on the relationship between magneto motive force and flux in various magnetic parts of the circuit.

Magnetic circuit of a Transformer

Single Phase Core Type

Three Phase Core Type

Should be quite familiar with

Various electrical materials , magnetic, conductors , insulators and their properties. Properties of magnetic and electrical fields. Laws of governing electrical circuits. Laws of governing electromagnetic induction. Calculation of magnetic circuits. Construction and behavior under working condition.

Magnetic materials
Design of electrical circuit ( winding ) and dielectric circuit ( insulation ) is mainly dependent upon limitations imposed by the magnetic materials. Size of the magnetic frame will depend upon the flux density at which the magnetic material can be worked. Best magnetic materials for electrical machines are those, worked at higher flux densities.

Magnetic materials Qualities

HIGH MAGNETIC PERMEABILITY so that even a weak current flowing in the electromagnet can set up large fluxes in its core. HIGH ELECTRICAL RESISTIVITY to reduce the eddy current losses occuring in the magnetic material, achieved by core with laminations, insulated from each other by varnish. At higher frequencies thickness of lamination must be reduced. HYSTERESIS LOOP It should be narrow and must have small area to reduce the hysteresis loss.

Magnetic materials Characteristics

Magnetization curves Plotted in terms of Magnetic flux density in Tesla and the magnetizing force per unit length in ampere turns per metre. Most essential one for the calculation of ampere turns needed for the magnetic circuit.

Magnetization Curves of Different Magnetic Materials

Magnetic materials Characteristics

Iron Loss curves Curves for the total iron losses per kg of the magnetic material Vs flux density are needed during calculations of an electrical machine to find out the total iron losses occuring in a particular part of the machine, corresponding to the operating flux density of that part.

Silicon Steel ( Sheet steel )

The Magnetic properties of steel are greatly improved by adding a certain percentage of silicon. Addition of silicon increases the electrical resistivity of steel , it reduces eddy current losses. Addition of silicon above 1.8% increases magnetic permeability of the material.

Silicon Steel ( Sheet steel )

Addition of large percentage deteriorates the mechanical properties. Silicon content in the order from 0.3% to 4.0%, Depends up on type of the machines. Maximum silicon steel lamination thickness from 0.35 mm to 0.5 mm.

Silicon Steel ( Sheet steel )

HOT ROLLED SILICON STEEL DYNAMO GRADE Rotating Machines silicon content level . Lohys..0.3 %, ( Iron Loss 3.57 w/kg ) Special Lohys.0.85%, ( Iron Loss 2.84 w/kg ) and 42Quality..2.5 % ( Iron Loss 2.25 w/kg )

Silicon Steel ( Sheet steel )

HOT ROLLED SILICON STEEL , TRANSFORMER GRADE Small Transformers silicon content level . Grade 92 4.0 %, ( Iron Loss 2.02 w/kg ) Grade 86 4.0 %, ( Iron Loss 1.89 w/kg ) Grade 80 4.0 %, ( Iron Loss 1.76 w/kg ) Grade 74 4.0 %. ( Iron Loss 1.63 w/kg )

Silicon Steel ( Sheet steel )

COLD ROLLED GRAIN ORIENTED SILICON STEEL , TRANSFORMER GRADE Medium and Large Transformers silicon content level . Grade 51 .. 3.1 %, ( Iron Loss 1.11 w/kg ) Grade 46 3.1 %, ( Iron Loss 0.97 w/kg ) Grade 41 3.1 %, ( Iron Loss 0.89 w/kg )

Magnetic circuit of a Transformer

Operating Flux Density

CORE AREA.. Hot Rolled Silicon Steel 1.1 to 1.4 Tesla Cold Rolled Grain Oriented Silicon Steel 1.5 to 1.7 Tesla YOKE AREA.. Hot Rolled Silicon Steel 1.0 to 1.2 Tesla Cold Rolled Grain Oriented Silicon Steel 1.3 to 1.5 Tesla

Heating and Cooling

Conducting Material Magnetic Material

Insulating Material . Most Sensitive to temperature rise. Because 10C rise in temperature in an electrical machine reduces the life of insulation used there in, by 50%.

Heating and Cooling

Insulating Material . Most Sensitive to temperature rise. Resistivity of the insulating material decreases. Electric Strength Decreases. Dielectric Loss angle increases. Dielectric losses increases. Tensile strength decreases.

Heating and Cooling

The total losses occurring in an electrical machine is converted into heat and as a result, the various parts of the machine are heated and their temperature rises above the Ambient temperature. The various parts of the machine dissipates heat by radiation, convection and conduction.

Heating and Cooling

In Transformers the heat dissipated by conduction is negligible. the heat dissipated by convection is maximum. the heat dissipated by radiation is medium. NATURAL CONVECTION ARTIFICIAL CONVECTION

Heating and Cooling

NATURAL CONVECTION Liquid or the Gas particles near heated surface of the machine becomes lighter. Lighter liquid is carried away by the circulating current produced by the heavier fluid. Such a continuous processes, by which heat transfer from surface to liquid then to atmosphere is known as natural convection.

Heating and Cooling

ARTIFICIAL CONVECTION Machines of large sizes, heat is removed by forced circulation of cooling medium. Cooling of transformer by blasting air on the external radiators, Cooling of turbo-alternators by Hydrogen under pressure.

Heating and Cooling Curves

Heating and Cooling Curves

Curve A A A Shows the heating and cooling curves when the machine working continuously on full load. Curve B . B B Shows heating and cooling condition of the machine, when it operated on full load for a period of say 20 min. followed by a stationary period sufficiently long so as to cool the machine. Curve C . C C Indicates heating and cooling conditions in case of intermittent load cycle of 15 min. on full load followed by 25 min. on no load, the cycle being repeated indefinitely.

Heating and Cooling Curves

STANDARD RATINGS . Continuous rating
Gives output without exceeding the specified temperature.

Short time rating

Operated for specific period without exceeding the specified temperature.

Intermittent periodic rating

Operated for short period followed by short period of rest or no load and without exceeding the specified temperature.

Ventilation of Static Machines

Transformer being a static machine, cooling is more difficult compared to a rotating machine. Because no relative motion to assist in the circulation of ventilating air. The Iron losses/Kg. of magnetic material and the copper losses/Kg. of the conducting material are nearly equal for pow er transformer. The cooling surface of the tank will not be in a position to dissipate all the heat generated by the losses.

Ventilation in Transformer

*Duct between
core and windings.

*Ducts between windings. *Ducts in the core

and yoke in case of Large Transformers.

*Ducts in the windings for

guided circulation of oil.

Ventilation in Transformer
The transformer attains final temperature depending on the cooling system and the amount of heat generated. Final temperature, when the heat generated is equal to the heat dissipated.

Ventilation in Transformer
Heat transferred from interior of the magnetic core and the windings to the external surface in contact with oil by conduction. Heat transfer by convection from the surface of the core and winding to the oil. Heat transfer by convection from oil to the tank walls and the radiators. Transfer Heat from wall radiators to the atmosphere by convection and radiation.

Types of Transformer
Position of the windings with respect to core CORE TYPE and SHELL TYPE Transformation ratio STEP-UP and Types of service DISTRIBUTION

STEP-DOWN

and

POWER

Types of Transformer
Winding encircle the core .. Core type transformer core encircle the Winding .. Shell type transformer

Types of Transformer
COMPARISON : * Construction : core type assembled and dismantled more easily compared to shell type. * Repair : repairs can be carried out in a better way compared to shell type. Windings is accessable. * Cooling : cooling of winding is better in core type, because windings encloses the core, in shell type cooling of core is better. * Leakage Reactance : shell type is smaller compared to core type, better linkage between L.V. and H.V. side.

Types of Transformer
COMPARISON : * Mechanical forces : shell type transformer are more robust mechanically compared to core type, because of better support to windings against to e.m.fs. * Application : shell type transformers is better for low voltages and large output. In core type for high voltage and comparatively smaller output.

Types of Transformer

Stepped Core and Yoke

Stepped Core and Yoke

Lateral ducts

Oil ducts provide along the lamination ( longitudinal ducts )

Stepped Core and Yoke

In general circular coils are used , for better mechanical strength , theoretically circular core but complicated for production. Stepped core is generally used. Small transformer square core is used.

Tank and Accessories

Conservator Voltage rating of 6 K.V and output rating of 25 K.V.A equipped with it. Breather contains calcum chloride or silica gel. Buchholz Relay Bushings

Buchholz Relay

Bushings

THANK YOU
Er. T. K. RAMACHANDRAN. B.E., M.B.A.