Brief Explanation of a Transformer

Consists of:
• Left coil (primary coil) – input
• Right coil (secondary coil) – output
• Magnetic field

How it works:
• changes the voltage level (or current level) on its
input winding to another value on its output winding
using a magnetic field
• operates on Faraday’s principal of “mutual induction”,
in which an EMF is induced in the transformers Source: Google Images
secondary coil by the magnetic flux generated by the
voltages and currents flowing in the primary coil
winding
 Transformer Construction

A power transformer contains 6 key components:

•Core
•Winding
•Bushings
•Load tap changer
•Losses
•Cooling
Core Construction
What’s the purpose of the transformer core?
Mission:
Core supports the induction process by providing a path for the magnetic flux to move from the
primary winding to the secondary [1]
The core must:
– Provide good magnetic permeability
– Minimize flux leakage
Problem:
Eddy current losses in solid iron cores were excessive -> Cores consisting of bundles of insulated iron
wires -> Stacking layers of thin steel laminations to create the core
Effect of laminations:
To confine eddy currents -> reduce their magnitude
Transformer Core Types
Shell Type
Preferred for extra-high voltage and
higher MVA applications
- Labor-intensive and expensive to
manufacture
+ Provides high short-circuit current
withstand capabilities. [1]
Core Type
Preferred for high voltage power
transformer applications at the lower
end of their voltage and power rating
ranges
+ More economical

+ The outside limbs provide extra Source: Google Images

path for the leakage flux to flow.
Transformer Winding Arrangements
How are the transformer windings designed?
• In a single-phase two winding transformer, two windings would be present as
shown. The one which is connected to the voltage source and creates the magnetic
flux called the primary winding, and the second winding called the secondary in
which a voltage is induced as a result of mutual induction. [2]
• The type of wire used as the main current carrying conductor in a transformer
winding is either copper or aluminium. Aluminium is lighter and less expensive, but
copper is considered the best way to ensure high short-circuit withstand
capability in power transformers. [3] Source: Google Images
Concentric Coils Sandwiched Coils
• In core-type transformer construction, • Sandwich coils and windings are more
the windings are usually arranged common with shell type core
concentrically around the core limb construction.
with the higher voltage primary • Consist of flat conductors wound in a
winding being wound over the lower spiral form and are so named due to
voltage secondary winding the arrangement of conductors into
discs.
Winding Design
• Transformer winding turn method: Layer and helical windings commonly used for tertiary
windings. Disc windings commonly used in primary and secondary windings. [1]

• For primary and secondary windings, employing a continuously transposed conductor (CTC)
provides high mechanical stability (because of the way magnetic fields cancel). For tertiary or
stabilizing windings, the flat copper conductor gets used.
• Although windings can be simply spun helically around the core, interleaving the turns creates
mini-capacitors that helps break down the incoming voltage surge and bury it into the windings.
Inserting a shield wire (flat copper) between turns is another method of channeling the surge.
Winding Design (Insulation)
How is insulation applied to the transformer
windings?

• To channel the current, every inch of copper is paper insulated:

turn-to-turn, between LV winding and core, between HV and LV
winding, between HV winding and core. [1]
• The insulation used to prevent the conductors shorting together
in a transformer is usually a thin layer of varnish or enamel in an
air cooled transformer. This thin varnish or enamel paint is
painted onto the wire before it is wound around the core.
• In larger power and distribution type transformer’s, the Source: Google Image

conductors are insulated from each other using oil impregnated

paper or cloth. 
Bushing Design
What’s the purpose of a bushing on the transformer?

• Bushings provide a path for the current to flow from the energized (high
voltage) conductor to the windings inside the tank (without energizing the
tank) [1]
• There are two points of contact:
1. at the top, where the conductor lands. The porcelain insulator maintains the
phase-to-ground clearance Source: Google Images
2. inside the bushing, the mini-capacitors created by paper and foil maintains
the clearance (capacitors break down the voltage). This type of bushing is
called the capacitance or condenser bushing.
Load Tap Changers Design
• Load tap changers (LTC) - designed to change the voltage under load
The Purpose of On-load Tap Changers:
• On-load tap changers are mainly used for power transformers and autotransformers; the change
of tap position is realized without de-energizing the unit. To keep the voltage stable, the number
of winding turns can be added or removed.
• The OLTC windings remain in the main tank (around the core) while the operator and its
accessories mount in a separate compartment. [1]
Reactive type Resistive type

• Reactive LTC uses reactors to limit current during
switching; because reactor can be designed as
permanently loaded with trough-current of LTC,
one may use bridging position to double the
number of steps in LTC
• Reactive-type LTC uses two reactors (two parallel
branches), two by-pass switches, selector switch
with two contacts and vacuum interrupter; also
reversing switch is used to double the number of
steps [4]
• Resistive type LTC performs switching with main
switching contact and two transition contacts with
resistors; typically equipped also with reversing
switch
• During normal operation (at given tap position) the
current is carried by the main switching contact
only
• During changing the tap position, the transition
contact are switched on and carry current through
resistors
Losses
Transformer as energy converter dissipates losses; depending on operation of the unit load
characteristics the losses can have significant economical cost for users.
Losses are divided into:
• no-load loss
• load loss
Transformer also consumes some auxiliary power, resulting in auxiliary losses [4]
No-Load Losses
Losses generated in the core sheets by main flux of a transformer are called no-load losses. They
include the hysteresis loss and the eddy current loss.
No-load losses do not depend on:
• Load
• Core temperature
No-load losses depend on:
• Voltage, these losses increase dramatically with increase in voltage if flux density is approaching the
saturation,
• Frequency
• Core material: its properties, the lamination thickness, mass of the core.
Because most transformers are energized at all times, what results in continuous generation of no-
load losses, these losses have high cost evaluation. [4]
Load Losses
Losses generated in transformer by load currents, both primary and secondary, are called load
losses.

Load losses consist of:

• fundamental (ohmic) losses in each phase, while resistance is measured at DC voltage;

• additional (eddy) losses, generated by the eddy currents induced by the stray flux in all metallic
elements (leads, windings, constructional parts, tank, shields) penetrated by this flux

• Ohmic losses increase with resistance which increases with the temperature [4]
Auxiliary Losses
Auxiliary losses are generated by cooling equipment:
• Fans
• Pumps

Typically, these losses are not significant when compared to no-load and load losses.
The auxiliary losses depend on the cooling stage of the unit, reaching maximum for top power
rating [4]
Cooling
• Both no-load and load losses are converted into heat which increases the temperature of active
parts (core and windings), constructional parts (clamps, tank), as well as of the oil.

• Next, the heat has to be dissipated by cooling system (tank, radiators, etc.) to cooling medium,
e.g. to surrounding air. The temperature rises of all components are limited by appropriate
standards. These criteria have to be satisfied during the temperature rise test.

• Intensity of cooling has to be increased together with increase in rated power, in order to sustain
allowable temperature rises. In power transformers one may utilize: radiators, or coolers, forced
air flow, forced oil flow, water cooling [4]
Transformer Cooling Methods
For the dry type transformers:
• Air Natural (AN) Cooling
• Air Forced (AF) or Air Blast (AB) Cooling
For oil immersed type transformers:
• Oil Natural Air Natural (ONAN) Cooling
• Oil Natural Air Forced (ONAF) Cooling
• Oil Forced Air Forced (OFAF) Cooling
• Oil Forced Water Forced (OFWF) Cooling
Dry Type Transformer
• Air Natural (AN) Cooling
The air natural (AN) cooling is used in dry type, self-cooled transformers. In this method, the natural
circulation of surrounding air is used for cooling of the transformer. The windings of the transformer
are protected against the mechanical damages by a sheet metal enclosure. The air natural cooling is
used for low voltage small transformers up to a few kVA.

• Air Forced (AF) or Air Blast (AB) Cooling

The air forced (AF) cooling is used in the dry type, forced-air cooled transformers. In this method, a
continuous blast of filtered cool air is forced with the help of a fan through the core and windings of
the transformer for cooling. This method is used for cooling of the transformers up to 15 MVA [5]
Oil Immersed Type Transformers
• Oil Natural Air Natural (ONAN) Cooling
The oil natural air natural cooling is used in oil immerged type transformers. The most of the
transformers of the medium and large ratings have their core and windings immerged in dielectric
oil, which acts both as cooling medium and insulating medium.
The oil immerged transformers are enclosed in a sheet steel tank. The heat generated in the core
and windings being transferred to the oil. The heated oil becomes lighter and rises to the top and
the cool oil takes its place from the bottom of the transformer tank.
The heat of the oil is transferred to the walls of the tank by natural circulation of the oil and the
heat is then transferred to the surrounding air through the natural radiation and convection. Hence,
the oil gets cooler and falls to the bottom. Therefore, a natural circulation of oil takes place for the
cooling of the transformer. [5]
Oil Immersed Type Transformers
• Oil Natural Air Forced (ONAF) Cooling
In oil natural air forced cooling of the transformer, the heat generated by the core and windings of the
transformer is transferred to the walls of the tank and to the radiator through the natural circulation of
the oil. Now, the forced air is directed over cooling elements (tank, radiator, tubes, fins etc.) of the
transformer. Hence, the transformer is cooled by the natural circulation of oil and blast of air.
This method of cooling is suitable for the large transformers up to 60 MVA.

• Oil Forced Air Forced (OFAF) Cooling

In this method of cooling, the heated oil is circulated from the top of the transformer tank to a heat
exchanger and the blast of air is forced through the heat exchanger by turning on a fan. Then, the cool
oil is returned to the bottom of the transformer tank.
This method of cooling is used for higher rating transformers like transformers which are used in
substations and generating stations. [5]
Oil Immersed Type Transformers
• Oil Forced Water Forced (OFWF) Cooling
In the oil forced water forced cooling method, the heated oil is circulated from the top of the
transformer tank to a heat exchanger where the pressurised water is used to separate the heat from
the oil. The cool oil is then returned to the bottom of the transformer tank.
This type of cooling is mainly used for very large transformers with a 100 MVA ratings like at
generating stations. [5]
References
[1] Power Transformers – Design and Application, Peguru, 2021. Link
[2] Transformer Construction, Electronics Tutorials, 2015. Link
[3] Copper in Transformer, Leonardo Energy, 2021. Link
[4] Transformer Design and Design Parameters, R. Minhaz, P.Eng., 2014
Link
[5] Cooling Methods of a Transformer, M. K. Saini, 2021. Link