Example: Design the core cross-sectional area of a single-phase 1 kVA, 230/115 V, 50 Hz transformer.
1 kVA, 50 Hz,
Find:
1. Core cross-sectional area
2. Voltage per turn
3. Number of turns in primary and secondary
Solution
Transformer EMF equation:
Where:
Thus:
Voltage per turn:
Step 1 Estimate core area
For 1 kVA transformers:
Convert:
Step 2 Voltage per turn
Step 3 Primary turns
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Step 4 Secondary turns
Problem 2: For the transformer in Problem 1, determine the conductor cross-sectional
area of primary and secondary windings. Given:
Current density
Step 1 Secondary current
Step 2 Primary current
Step 3 Conductor area
Primary conductor area
Secondary conductor area
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Problem 4: Design a 100 W, 50 kHz flyback transformer.
Input: , , Frequency = 50 kHz, , Core area
Find:
1. Primary turns
2. Secondary turns
Step 1 — Primary turns
High Frequency transformer formula:
Convert:
Step 2 — Turns ratio
Choose:
Problem 5 : A transformer core has: Mass = 6 kg, Core loss = 1.4 W/kg
Find total core loss.
Solution
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Problem 6 : A transformer delivers: Output power = 4 kW, Copper loss = 120 W, Core
loss = 80 W
Find efficiency.
Solution
Total loss:
Input power
Efficiency , ,
Problem 7: Explain why ferrite cores are preferred in high-frequency transformers
instead of laminated steel cores.
Solution
1. Low eddy current loss
o Ferrite has very high electrical resistivity.
2. Low hysteresis loss at high frequency
3. Small core size
Core flux equation:
Higher frequency → smaller flux → smaller core.
4. Higher efficiency in kHz–MHz range
5. Reduced weight and size
Problem 6: Design a high-frequency transformer for a forward converter power supply with the
following specifications:
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Parameter Value
Input voltage 48 V DC
Output voltage 12 V DC
Output power 120 W
Switching frequency 50 kHz
Maximum flux density 0.2 T
Core effective area
Efficiency 90 %
Find:
1. Primary turns
2. Secondary turns
3. Primary current
4. Secondary current
5. Conductor cross-section area
Step 1 : Calculate Input Power
Step 2 — Calculate Input Current
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Step 3 — Convert Core Area
Step 4 — Calculate Primary Turns
High-frequency transformer equation:
Substitute values:
Step 5 — Determine Turns Ratio
Voltage ratio:
Step 6 — Secondary Current
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Step 7 :Select Current Density
For high-frequency transformers
Step 8 : Conductor Area
Primary conductor:
Secondary conductor:
Step 9 — Skin Depth Check (Important in High Frequency Design)
Skin depth formula:
Approximate practical rule for copper:
For 50 kHz:
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Thus, litz wire or multi-strand wire must be used.
Q1: Design a single-phase core-type transformer with the following specifications:
Rated power = 10 kVA
Primary voltage = 2200 V
Secondary voltage = 220 V
Frequency = 50 Hz
Power factor = 0.8
Maximum flux density = 1.2 T
Current density = 2.5 A/mm²
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Efficiency ≈ 0.9
Utilization factor
Solution:
Step 1 — Apparent Power
Step 2 — Maximum Flux
Step 3 — Core Area
Step 4 — Voltage per Turn
Step 5 — Number of Turns
Primary turns
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Secondary turns
Step 6 — Currents
Primary current
Secondary current
Step 7 — Conductor Cross-Section
Primary conductor
Secondary conductor
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Q2: Design a 3-phase distribution transformer has the followings:
Power rating = 500 kVA
Primary voltage = 11 kV
Secondary voltage = 400 V
Frequency = 50 Hz
Core type
Flux density
Current density
Connection: Δ–Y
Solution:
Step 1 Power per Phase
Step 2 — Phase Voltage
Primary (Delta)
Secondary (Star)
Step 3 — Flux Estimation
Using design empirical relation:
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Step 4 — Voltage per Turn
Step 5 — Turns
Primary:
Secondary:
Step 6 — Line Currents
Primary:
Secondary:
Step 7 — Conductor Area
Primary:
Secondary:
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Q3: Design a single – phase autotransformer: Input voltage = 240 V
Output voltage = 120 V
Load power = 5 kVA
Frequency = 50 Hz
Flux density = 1.2 T
Solution:
Step 1 — Equivalent Power
Step 2 — Flux
Assume
Step 3 — Voltage per Turn
Step 4 — Turns
Primary turns
Secondary tap
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Step 5 — Currents
Q4: Design a single-phase toroidal power transformer with the following
specifications:
Rated apparent power
Primary voltage
Secondary voltage
Frequency
Maximum flux density
Current density
Efficiency ≈
Solution: Step 1 — Output Current
Secondary current
Primary current
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Step 2 — Core Cross-Sectional Area
Typical toroidal core design formula:
where in VA and in .
Step 3 — Maximum Flux
Step 4 — Voltage per Turn
Step 5 — Number of Turns
Primary turns
Secondary turns
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Step 6 — Conductor Area
Primary winding
Secondary winding
Q5: Design a ferrite toroidal transformer for a switch-mode power supply.
Power = 500 W
Input voltage = 325 V DC
Output voltage = 48 V
Switching frequency
Maximum flux density
Core area
Solution: Step 1 — Flux
Step 2 — Voltage per Turn
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Step 3 — Primary Turns
Step 4 — Secondary Turns
Step 5 — Output Current
Step 6 — Conductor Area
Assume
Q6: Design a toroidal transformer for high-end audio amplifier. Specifications:
Power = 800 VA
Primary voltage = 230 V
Secondary voltage = ±35 V
Frequency = 50 Hz
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Flux density
Current density
Solution: Step 1 — Core Area
Empirical toroidal formula
Step 2 — Flux
Step 3 — Voltage per Turn
Step 4 — Turns
Primary
Secondary
(two identical windings)
Step 5 — Current
Total current
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Each secondary ≈ 5.7 A
Step 6 — Conductor Section
Summary of the Three Toroidal Designs
Transformer Power Primary Turns Secondary Turns
Toroidal power transformer 2 kVA 148 16
SMPS toroidal 500 W 49 7
Audio toroidal 800 VA 291 44
Q7: Design a 3-phase core-type power transformer with the following
specifications:
Rated apparent power
Primary voltage
Secondary voltage
Frequency
Connection: Δ–Y
Maximum flux density
Window utilization factor
Current density
Solution: Step 1 — Power per Phase
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Step 2 — Phase Voltages
Primary (Delta)
Secondary (Star)
Step 3 — Core Flux
Assume typical design coefficient for large transformers:
Step 4 — Core Area
Equivalent circular diameter:
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(This large value indicates scaling assumptions and normally optimization follows in real
design.)
Step 5 — Voltage per Turn
Step 6 — Turns
Primary turns
Secondary turns
(Large power transformers often use few turns with large conductors.)
Step 7 — Line Currents
Primary current
Secondary current
Step 8 — Conductor Area
Primary conductor
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Secondary conductor
Q8: For the 50 MVA transformer, determine leakage reactance required to obtain:
Short-circuit impedance and System voltage
Solution: Step 1 — Base Impedance
Step 2 — Required Leakage Reactance
Step 3 — Leakage Inductance
Q9: Given Loss components: Copper loss = 220 kW, Core loss = 90 kW. Total loss:
and Cooling method: ONAF (Oil Natural Air Forced)
Solution:Step 1 — Heat Dissipation Requirement
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Heat to be removed:
Step 2 — Oil Temperature Rise
Assume allowable rise:
Heat transfer coefficient for radiators:
Step 3 — Required Cooling Surface Area
Step 4 — Number of Radiator Panels
If one radiator panel area = 8 m²
Final Cooling Design
Parameter Value
Total loss 310 kW
Cooling method ONAF
Required cooling area 704 m²
Radiator panels 88
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Q10: Design a protection current transformer (CT) for a 132 kV transmission line with
the following specifications:
Rated primary current
Rated secondary current
Accuracy class: 5P20
Knee-point voltage required
Frequency
Maximum flux density
Core mean magnetic path length
Determine the number of turns and core cross-sectional area.
Solution: Step 1 — CT Turns Ratio
For a CT:
Primary turns normally
Step 2 — Knee-Point Voltage Equation
Knee point voltage relation:
Solve for flux:
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Step 3 — Core Cross-Sectional Area
Step 4 — Magnetizing Current Estimation
Magnetic field strength:
Assume magnetizing current ≈ 0.05 A
This ensures operation before saturation for protection relays.
Q11: Given A protection CT has: Ratio = 1000/1
Secondary burden = 10 Ω
System fault current = 20 kA
DC offset factor = 1.8
Secondary resistance = 1 Ω
Determine whether CT saturation occurs?
Step 1 — Secondary Fault Current
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Step 2 — Secondary Voltage
Total resistance:
Voltage required:
Step 3 — Including DC Offset
Step 4 — Saturation Check, If
CT saturates.
If CT knee point = 350 V
Therefore:
CT will saturate during the fault transient.
Engineering Interpretation
Protection relay may experience:
• waveform distortion
• incorrect differential protection operation
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Solution:
increase core size
increase knee point voltage
Q12: Given Two CTs are used for transformer differential protection.
Transformer rating: 50 MVA, 132 / 33 kV
CT ratios selected:
HV side: 600/1
LV side: 2000/1
Connection: Transformer: Δ–Y
CT compensation required.
Step 1 — Line Currents
HV current
LV current
Step 2 — Secondary Currents
HV CT secondary
LV CT secondary
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Step 3 — Compensation
Because transformer is Δ–Y, CTs must be connected: HV side CT → star
, LV side CT → delta. Delta connection multiplies current by
Adjusted LV current
Step 4 — Matching Error
This is unacceptable.
Correct Design
Choose CT ratios:
HV side:
LV side
Then differential currents match within ±5% protection tolerance.
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