TRANSFORMERS

• A transformer is a device that transfers electrical energy

from one circuit to another through inductively coupled
conductors ,the transformer's coils or windings.
• A varying current in the first or "primary" winding
creates a varying magnetic field in the core (or cores) of
the transformer. This varying magnetic field induces a
varying electromotive force (EMF) or "voltage" in the
"secondary" winding. This effect is called mutual
induction
 Basic Principle
• The transformer is based on two principles: firstly, that an
electric current can produce a magnetic field (
electromagnetism) and secondly that a changing
magnetic field within a coil of wire induces a voltage
across the ends of the coil (electromagnetic induction).

Fig:- An ideal step-down transformer showing magnetic flux in the core

Making of a Transformer of 100kVA
Things required for the making of a transformer :

• Core laminations
• HT coils
• Lt coils
• Insulation sheets and Bakelite tube
• Insulation material press board
• Transformer oil
• Lt bushing
• Ht bushing
• Wooden sticks,channel,nut and bolts,
 Preparation of Core

• It is the most important and the first step in the preparation of transformer making, it is
consider as the most important part of transformer making because most of the transformer
losses i.e. copper and iron losses such as hysteresis and eddy current losses are due to the core
lamination.

• For less losses thinner core laminations of silicon steel material with high permeability should
be used.

• It takes about 50 such laminations to make a core an inch thick.

fig :- Preparation of core fig:- Assembling of core with channels

 Low Tension Coils

• The size of the LT wire is about 8mm,the LT coil is prepared on the LT coil
machine.
• The LT coil consists of 73 turns, i.e. 36 turns overlapped by another 37 turns.
• An insulation sheet is placed in between the overlapped LT wire, the type of
winding used is spiral and the inner diameter of the LT coil is just few more
than than the diameter of the core.

Fig:- making of an LT coil

 High Tension Coils
• It is known as the primary coil of the transformer, it is prepared on the HT machine

• The wire used in HT winding is about 1mm thick and this wire is either covered with insulated paper or polished so that
while operating of the transformer,these wires may not come in contact with each other and cause short circuit in the
transformer.

• After one layer is completed an insulating paper is placed on the completed layer and then next layer is formed on the
insulating paper.

• There are 803 turns per coil and 6 spacers are used per circumference

• For per phase 4 coils are prepared i.e a total of 12 coils are prepared for the 3 phases,the type of winding done in
preparing HT coils is cross-over.

• 1 turn of LT coil= 44 turns of HT coil.

• Wooden sticks are used to separate the LT coil and HT coil,these wooden sticks are 2mm thick
 Assembly of Core , LT and HT
• After the Assembling of the transformer is done, now the assembled part
i.e.core,LT,HT is placed in a heat furnance so that there may be no moisture
present in the assembled part may get removed as the presence of moisture
plays a very important part in the functioning of the transformer.
• Presence of moisture in transformer may affect its working and functioning.
 Transformer Tank

• Dimensions of the tank are made

according to the customer’s choice,
the tank with big size will consume
more oil and tank with small size
may short circuit with the tank, so a
medium type tank with intermediate
capacity should be used.

• The tank should be properly painted

to prevent it from corrosion and
leakages in the transformer should
be checked so that oil may not leak
out of the tank.
 Conections of a Transformer
• Delta connection is done on the HT side
winding and Star connection is done in the LT
side
 Transformer Oil
• First oil is checked for the quality to see whether oil is
free of moisture and other material.

• We use mineral oil.

• Oil is filtered several times before

pouring it into the tank.

• Quality of oil is tested by using

insulating oil tester.