EEE-240

Electrical Machine Design

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 Course Objectives

The main objective of this course is to provide

students with a complete overview of electrical
machine design considering the end user requirement.

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 Electrical machines
An electrical machine is a device that can convert either
mechanical energy to electrical energy or electrical energy to
mechanical energy through the action of a magnetic field.

Generator
Transformer
Motors

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 Electrical machines
An electrical machine is a device that can convert either
mechanical energy to electrical energy or electrical energy to
mechanical energy through the action of a magnetic field.

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Power Grid Map

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 Course Outcomes

After the successful completion of this course, the students will be

able to do the following:

➢ Apply principles of the electrical machine and know how to

solve mathematical equations of ac machines based on
practical applications

➢ Design an electrical transformer based on given specification

and real-world constraints

➢ Manage an electrical design project and submit a complete

report as the term paper

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 Reference Book

✓Design & Testing of Electrical Machines

By M. V. Deshpande

***
Every student is required to bring this book from next class. Otherwise, he/she will be noted as “Absent”.
***

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 Introduction

❑ WHAT IS TRANSFORMER ?

➢ A transformer is a static piece of apparatus by means of which an electrical

power is transferred from one alternating current circuit to another
electrical circuit
▪ There is no electrical contact between them
▪ The desire change in voltage or current without any change in
frequency

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 History of Transformer
Who invented the transformer?

Ottó Bláthy, Miksa Déri, Károly Zipernowsky of the Austro-Hungarian Empire First
designed and used the transformer in both experimental, and commercial systems.
Later on Lucien Gaulard, Sebstian Ferranti, and William Stanley perfected the design.

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Historical Evolution of Transformer

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 Introduction

❑ TRANSFORMER CONSTRUCTION

➢ A transformer consists of two windings coupled through a

magnetic medium.
➢ The two windings work at different voltage level.
➢ The two windings of the transformer are called High voltage
winding and Low voltage winding.
➢ Both the windings are wound on a common core.
➢ One of the winding is connected to ac supply and it is called
primary.
➢ The other winding is connected to load and it is called secondary.
➢ The transformer is used to transfer electrical energy from high
voltage winding to low voltage winding or vice-versa through
magnetic field.

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 Introduction
TRANSFORMER CONSTRUCTION
➢ The construction of transformers varies greatly, depending on their
applications, winding voltage and current ratings and operating
frequencies.
➢ The two major types of construction of transformers (used in transmission
and distribution of electrical energy) are core type and shell type.
➢ Depending on the application, these transformers can be classified as
distribution transformers and power transformers.
➢ The transformer is extremely important as a component in many different
types of electric circuits, from small-signal electronic circuits to high
voltage power transmission systems.
➢ The most important function performed by transformers are:
▪ Changing voltage and current level in an electric system.
▪ Matching source and load impedances for maximum power transfer
in electronic and control circuitry.
▪ Electrical isolation.

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 Introduction

❑ CORE TYPE TRANSFORMER

➢ In core type transformer, the magnetic core is built of laminations to
form a rectangular frame and the windings are arranged
concentrically with each other around the legs or limbs.
➢ The top and bottom horizontal portion of the core are called yoke.
➢ The yokes connect the two limbs and have a cross sectional area
equal to or greater than that of limbs.
➢ Each limb carries one half of primary and secondary.
➢ The two windings are closely coupled together to reduce the
leakage reactance.
➢ The low voltage winding is wound near the core and high voltage
winding is wound over low voltage winding away from core in
order to reduce the amount of insulating materials required.

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 Introduction

❑ SHELL TYPE TRANSFORMER

➢ In shell type transformers the windings are put around the central
limb and the flux path is completed through two side limbs.

➢ The central limb carries total mutual flux while the side limbs
forming a part of a parallel magnetic circuit carry half the total
flux.

➢ The cross sectional area of the central limb is twice that of each
side limbs

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Core Type and Shell Type Transformer

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Core Type and Shell Type Transformer

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Core Type and Shell Type Transformer

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 Introduction
❑ DISTRIBUTION TRANSFORMER
➢ Transformers up to 500kVA are used to step down distribution voltage to a
standard service voltage or from transmission voltage to distribution voltage
known as distribution transformers.
➢ They are kept in operation 24 hours a day whether they are carrying any load
or not.
➢ The load on the distribution transformer varies from time to time and the
transformer will be on no-load most of the time.
➢ Hence in the distribution transformer, the copper loss (which depends on load)
will be more when compared to core loss (which occurs as long as the
transformer is in operation).
➢ Hence distribution transformers are designed with less iron loss and designed
to have maximum efficiency at a load much lesser than a full load.
➢ Also, it should have good regulation to maintain the variation of supply
voltage within limits and so it is designed with a small value of leakage
reactance.

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 Introduction
❑ POWER TRANSFORMER
➢ The transformers used in sub-stations and generating stations are
called power transformers.
➢ They have ratings above 500kVA. Usually, a substation will have a
number of transformers working in parallel.
➢ During heavy load periods, all the transformers are put in operation
and during light load periods, some transformers are disconnected.
➢ Therefore the power transformers should be designed to have
maximum efficiency at or near full load.
➢ Power transformers are designed to have considerably greater
leakage reactance than that is permissible in distribution
transformers in order to limit the fault current.
➢ In the case of power transformers, inherent voltage regulation is less
important than the current limiting effect of higher leakage
reactance.

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Power Transformer and Distribution Transformer

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Transformer Specifications & Nameplate

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 Design flow chart

Start Compare with given specification

Given specification
No Satisfactory ?

Choice of materials
Modify yes
assumption
Assumption of basic Print Design Sheet
quantities

Design Process
Stop

Performance Calculation

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 Design flow chart

1. Generator
2. Motor
Start 3. Transformer

Performance requirements as needed by the customer’s and

BDS, ASA, BSI, IEC, IEEE
Given (Bangladesh Standards and Testing Institution,
specification American Standards Association, British Standards Institution,
International Electrotechnical Commission,
Institute of Electrical and Electronics Engineers)

Choice of 1. Magnetic (HRS, CRS, CRGOS, etc)

2. Conducting ( Cu, Al, etc)
materials 3. Insulating Material

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 Choice of materials

Electrical Materials:

Materials used in Electrical machines are classified into three types:

I. Conducting; 2. Insulating and 3. Magnetic

Conducting Materials

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Insulating Materials

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Insulation for Conductor Covering

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 Magnetic Materials
A good magnetic material should possess the following qualities
1. High magnetic permeability, so that for required flux density it draws
minimum no. of amp turns
2. High electrical resistivity to reduce the eddy current losses
3. Hysteresis loop should be narrow to reduce hysteresis loss

Silicon Steel:
Magnetic properties of permeability and resistivity of steel are greatly
improved by adding a certain percentage of silicon. But, if the percentage of
silicon increases 4%, steel becomes brittle. These silicon steels are made into
laminations of normal thickness of 0.35 mm and 0.5 mm either by cold working
or hard working.

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 Magnetic Materials
A good magnetic material should possess the following
qualities
(a) High magnetic permeability, so that for required flux
density it draws minimum no. of amp turns
(b) High electrical resistivity to reduce the eddy current
losses
(c) Hysteresis loop should be narrow to
reduce hysteresis loss.

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Magnetic Materials

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 Magnetic Materials
Silicon Steel:
Magnetic properties of permeability and resistivity
of steel are greatly improved by adding a
certain percentage of silicon. But, if the percentage
of silicon increases 4%, steel becomes
brittle. These silicon steels are made into
laminations of normal thickness of 0.35mm and
0.5 mm either by cold working or hard working.

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 Eddy current

• In a transformer, alternating current (AC) in the primary winding

generates a time-varying magnetic field. This magnetic field
induces a voltage not only in the secondary winding (as intended)
but also in the transformer's iron core. As a result, circulating
currents known as eddy currents are produced within the core.

• These eddy currents flow in closed loops perpendicular to the

magnetic flux. Since the iron core is conductive, the changing
magnetic field causes these currents to flow in the bulk of the core
material.

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 Effects of Eddy Currents in Transformer

Power Loss (Eddy Current Loss): Energy is wasted as heat in the

core material, reducing the efficiency of the transformer.

Core Heating: Excessive heating can damage the insulation or other

components.

Vibration and Noise: In high-power transformers, eddy currents

can cause localized heating and mechanical stress, producing
vibration or noise.

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How to Minimize Eddy Currents in Transformers

Laminated Core Construction:

The transformer core is made of thin sheets (laminations) of electrical steel.
Each lamination is insulated from the others by a thin layer of paper, varnish
or oxide. This restricts the eddy current paths to each thin layer, greatly
reducing their magnitude.

Use of High-Resistivity Core Materials:

Materials such as silicon steel are commonly used, as they have higher
electrical resistance and lower eddy current loss.

Orienting Laminations Properly:

Laminations are stacked such that they are parallel to the magnetic field,
minimizing the loop area available for eddy current flow.

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 Design flow chart

1. Specific magnetic loading

Assumption 2. Specific electrical loading
of basic 3. Space factor
4. Staking factor/ Lamination factor
quantities
Choice of Electric Loading (Δ)

Choice of Magnetic Loading (Bm) Natural 1.5---2.5 A/mm2

Cooling: AN Air Natural cooling
Normal Si-Steel 0.9 to 1.1 T ON Oil Natural cooling
(0.35 mm thickness, 1.5%—3.5% Si) OFAN Oil Forced circulated with
Natural air cooling
HRGO 1.2 to 1.4 T Forced 2.2---4.0 A/mm2
(Hot Rolled Grain Oriented Si Steel) Cooling : AB Air Blast cooling
OB Oil Blast cooling
CRGO 1.4 to 1.7 T
OFAB Oil Forced circulated with air
(Cold Rolled Grain Oriented Si Steel) Blast cooling
(0.14---0.28 mm thickness)
Water 5.0 ---6.0 A/mm2
Cooling: OW Oil immersed with circulated
Water cooling
OFW Oil Forced with circulated
Water cooling

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 Design flow chart

1. Predetermination of performance of the

machine is then made based on the calculated
Performance dimensions.
Calculation 2. Performance are calculated [ No-load, On-Load
conditions and temperature rise etc.]

1. Compare with customer’s requirement.

Compare with 2. If not, designer has to modify the basic
assumption so as to bring the final design
given specification closer to the objective.

Print Design
Sheet

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 STANDARDIZATION AND STANDARDS
Standardization and standards play an important part in the choice, design,
manufacturer and operation of any apparatus.

1) To the manufacturer it means reduction in cost ( a number of

objects are built at the same time)
2) To the user, it means interchangeability of equipment's
3) To the designer, it means rigidity.

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 Design procedure of distribution transformer
1) Specification of the transformer to be design
2) Assumption of basic quantities ( Et, Bm, δ)
3) Design of Main dimension (Ai, D, Aw, kw)
4) Design of winding ( T1, T2, a1, a2)
5) Design winding layout ( no. of turn per layer, no of coils,
clearance between core & LV, LV & HV, HV & tank etc.)
6) Design core frame, core dia, widow, yoke, overall core size
7) Calculate % R, %X, %Z
8) Calculate magnetizing VA, No-load loss, Cu loss, stray loss and
load loss at 750C
9) Calculation of performance
10) Thermal design ( Design of Tank, Radiator)

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 Objective of this Class
➢ To Design a distribution transformer
Design Example:

“Design a 100 kVA, 3 phase, 50 Hz, 11 KV/415 V, delta/star

distribution transformer. Tapping  2.5%,  5% on high voltage
side. Cooling ON (self oil cooled); Temperature rise over oil
500C. No load loss not more than 250 watts; copper and stray load
loss not more than 2000 watts. Percentage impedance between
3.5% to 4.5%. Calculate: No load current, efficiency at 750C on
full load, 75% load and 50% load at unity power factor; Voltage
regulation on full load at 750C at unity power factor and at 0.8
power factor lagging”.

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 Design of a 100 kVA, 3φ distribution transformer
➢ Voltage per turn: Et
𝑘𝑉𝐴 × 1000
√
𝑛𝑜. 𝑜𝑓 𝑙𝑒𝑔𝑠
𝐸𝑡 =
40
This is an empirical expression which gives 𝐸𝑡 fairly accurate. Here, 𝑛𝑜. 𝑜𝑓 𝑙𝑒𝑔𝑠
for this three phase core type transformer is 3
Hence,
𝐸𝑡 = 4.56 ≅ 4.5 𝑣𝑜𝑙𝑡𝑠/𝑡𝑢𝑟𝑛

➢ Choice of core material: CRGO steel lamination of 0.35mm

➢ Choice of specific magnetic loading, Bmax: 1.7 Wb/m2

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 EMF equation of a transformer

Average rate of change of flux = Φm /(T/4) = Φm /(1/4f)

Therefore, average rate of change of flux = 4f Φm

Induced emf per turn = rate of change of flux per turn

Therefore, average emf per turn = 4f Φm ..........(Volts).

Now, we know, Form factor = RMS value / average value

Therefore, RMS value of emf per turn = Form factor x average emf per turn.

As, the flux Φ varies sinusoidally, form factor of a sine wave is 1.11

Therefore, RMS value of emf per turn = 1.11 x 4f Φm = 4.44f Φm

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 Design of a 100 kVA, 3φ distribution transformer
➢Cross Section area of the core Ai:
We know, E = 4.44 Bm f  A
t i 2
Where, Bm = flux density in wb/𝑚 ; f = 50 Hz and
A = net cross section area of the core
i
Et
A=
i 4.44 f Bm
= 4 .5 = 0.01192 m2
4.44501.7
=11,923mm2

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 Choice of core section

Circular core :
Square core : Rectangular core:
❑ If the area is 10cm2,
❑ for Ai = 10cm2, ❑ for Ai = 10 cm2 ,
❑ then the diameter of the
❑ side of the square = ❑ sides of the rectangle to
core =3.56cm and
3.16 cm be 10cm and 1.0cm
❑ the Circumference
❑ Perimeter = ❑ Perimeter =
= πx3.56=11.2 cm
4x3.16=12.64cm (10+1)2=22cm

➢ Which type of core is preferable for transformer design? And why?

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 Choice of core section

Another reason….
❑ Very high value of mechanical forces tries to deform
the shape of the square or rectangular coil (the
mechanical forces try to deform to a circular shape)
and hence damage the coil and insulation.
❑ Since this is not so in case of circular coils, circular
coils are preferable to square or rectangular coils.

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 Selection of the no of step in core design.

Laminated Square core

circular core Three stepped core
Four stepped core

❑ Thus a circular core and a circular coil is preferable.

❑ Since the core has to be of laminated type, circular core is not practicable as it required more
number of different size laminations and poses the problem of securing them together is in position.
❑ However, a circular core can be approximated to a stepped core having different number of steps.
❑ In practice the core is built of 0.35 mm thin strips arrange in a number of steps.
❑ By increasing the no of steps, the area of the circumscribing circle is more effectively utilized.
❑ Iron space factor for typical number of steps in core is presented table 6.4, Page 147 [Deshpande]

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Standard frame for a three-phase core type transformer

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Typical core section for 3 and 6 steps

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Iron Space factor

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 Design of a 100 kVA, 3φ distribution transformer

A = K Ks  d 2
i i 4
= 0.880.92 d 2
➢ Diameter of the circumscribing 4
circle for the core: d d 2 = 411923
❑ Chosen seven step cores so, the area 0.880.92
should be nearly circular. d 2 =18760 mm2
❑ In the case of a 7 step core, Iron space
factor, Ki= 0.88 d =136.96
❑ Stacking factor for laminations, Ks= 0.92 Choose d 140 mm
then area A = K Ks  d 2
i i 4
=12,456 mm2

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 Stacking Factor
The stacking factor is defined as the ratio of the volume
occupied by the transformer core laminations to the total
volume of the core, including the gaps between the
laminations due to insulation.

✓ Volume of the laminations refers to the actual volume

occupied by the iron laminations of the transformer core.
✓ Total volume of the core includes both the volume of the
laminations and the insulating material between them.

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 Design of a 100 kVA, 3φ distribution transformer
➢ Check Bm:
With this area A =12,456 mm2 Here,
i
Et Kw = Window space factor (kw)
Bm =
4.44 fA Empirical formula is used for kw
i
= 4 .5 =1.63 Wb/ m2
10−6 See, Art 6.6 and Table 6.5 page 149
4.445012463
[Deshpande]
➢ Window area Aw:
S = 3.33 A  Aw  kw   Bm  f 10−3 kVA Kw is taken approximately 0.29
i Aw = Window area ?
Aw =
S mm2
Ai = net cross section area of the core, m2
−3  = current density taken as 2.5 A/ mm2
3.33 A  k   B  f 10 S = output in kVA (100 kVA) ;
i w m
➢ Therefore, Aw = 40,779 mm2
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 Design of a 100 kVA, 3φ distribution transformer
Core and Window Dimensions:
Choose window width =1 x 150= 150 mm (about d)

• then height of window =40779/150=272 mm

• Choose height of the window =2×width of window approx.=150×2=300 mm
• Checking clearance to yoke. This is later taken as 334 mm.
• Then window area =300×150=45000 mm2

The main dimensions of the core are therefore:

• Diameter, d=140 mm;
• with a 7 step core, the largest width of the core with d=140 is 0.95×140=133 mm
• D=distance between the centres of the adjacent limbs=150+133=283

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Design of a 100 kVA, 3φ distribution transformer

Check the window space

factor approximately
before fixing the core
and window dimensions!

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 DESIGN OF WINDINGS
Number of turn in L.V. winding: (∆-yn)
Voltage per phase = 415 / 3 = 239.6 V [L.V. is Y connected]

Turns per phase on l.v winding = 239.6 ÷ 4.5

=53.24 turns, choose 54 turns.

Number of turns of H.V. winding: (∆-yn)

Voltage per phase = 11 KV [H.V. is ∆ connected]

Turns per phase on h.v. winding = 11 103 ÷ 4.5 = 2444.44

= chosen as 2445 turns.

Tapings of  5% and  2.5% are to be provided on the h.v. winding.

5% Normal 2.5%
More 2568 2445 2383 turn
Less 2506 2322 turn

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 DESIGN OF WINDINGS
LOW VOLTAGE WINDING: (∆-yn)
Current per phase = (100 103) ÷ {(√3) 415} = 139 A

Here, choose helical cylindrical coil.

Current density, δ = 2.5 A / mm2 ; (assumed for ON
cooling)

✓ Area of L.V. conductor, a2 = 139 ÷ 2.5

= 55.6 mm2  56 mm2

Choosing, rectangular copper conductor

from IS:6160:1977 specs.

Let, Cross Section = T  W = 4 mm  7 mm;

2 conductor strips
Therefore,
Forming conductor of L.V. area, a2 = 472 mm2;
= 56 mm2

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 DESIGN OF WINDINGS

High voltage winding: (∆-yn)

Choose disc coils.
current in H.V. winding per phase
= (100 103)÷(3 11 103)
= 3.03 A
Cross section of conductor for H.V.
winding ,
a1 = 3.03 ÷ 2.5 = 1.21 mm2

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 DESIGN OF WINDINGS

Choosing round conductor where,

d = diameter of conductor
a1 = πd2 ÷ 4; d2=1.54;
Therefore, d = 1.212 mm
Now choosing, d = 1.25 mm;
Then area, a1 = 1.23 mm2
Copper area in window = 2 (a1T1 + a2T2) = 2 (1.232568 + 5456)
= 12,365.28 mm2
Now for this dimensions, we get, window space factor,
kw = (12,365.28 ÷ 40,800) = 0.3
which is near about 0.29 (chosen)

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For more: [Link]

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 DESIGN OF WINDINGS
LOW VOLTAGE WINDING: (∆-yn)
Current per phase = (100 103) ÷ {(√3) 415} = 139 A

Here, choose helical cylindrical coil.

Current density, δ = 2.5 A / mm2 ; (assumed)

✓ Area of L.V. conductor, a2 = 139 ÷ 2.5

= 55.6 mm2  56 mm2

Choosing, rectangular copper conductor

from IS:6160:1977 specs.

Let, Cross Section = T  W = 4 mm  7 mm;

2 conductor strips
Therefore,
Forming conductor of L.V. area, a2 = 472 mm2;
= 56 mm2

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 DESIGN AND LAYOUT OF L.V. WINDING

❑ Number of turns in L.V= 54.

❑ Size of conductor : 2 strips of 47 mm ,
❑ Consider paper insulation of conductor is = 0.25 mm;
❑ With paper insulation: 2 strips of conductor (4+ 0.25) mm  (7 + 0.25) mm

❑Choosing 2 layers for L.V. winding, Turns per layer = 54 / 2 = 27

❑ Width of conductor 7.25 mm is taken along the window,
❑ with 2 conductor sides 4.25 + 4.25 = 8.5 mm forming conductor per
layer.
❑ For two layers, the dimension of conductors width wise is 17 mm

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 DESIGN AND LAYOUT OF L.V. WINDING

➢ height of l.v. winding in window= 277.25= 195.75mm; say 196 mm;

➢ thickness of l.v. coil = 8.5 2 = 17 mm
➢ distance between core and l.v. coil = 3.5 mm
➢ inside diameter of l.v. coil = 140+ ( 2  3.5 ) = 147 mm
➢ outside diameter of l.v. winding = 147 + ( 2  17) = 181 mm
➢ mean diameter of l.v. coil = 147 + 17= 164 mm
➢ mean length of turn of l.v. coil =πd= 164 π = 515 mm

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DESIGN AND LAYOUT OF L.V. WINDING

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 DESIGN AND LAYOUT OF H.V. WINDING

❑ The distance between L.V. and H.V. = 12 mm

❑ Inside diameter of h.v. = 181 + ( 12 2 ) = 205 mm
❑ Now, Split h.v. winding in 4 coils each with turns =
2568/4 = 642
❑ The size of conductor = 1.25 mm diameter.
❑ With paper insulation on conductor, the diameter =
(1.25 + 0.25) mm= 1.50 mm

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 DESIGN AND LAYOUT OF H.V. WINDING
❑ Choose 15 layers ; turns per layer = 642/15  43
➢ height of winding in each h.v. coil = 43 1.5 = 64.5 mm
➢ thickness of each coil = 15  1.5 = 22.5 mm
➢ outside diameter of h.v. coil = 205 + ( 222.5 ) = 250 mm
➢ mean diameter of h.v. coil = 205 + 22.5 = 227.5 mm
➢ mean length of turn =πd=227.5 π = 714.35 mm
➢ height of h.v. coils in window = ( 64.5 4 ) +8+8+8 = 282 mm
➢ The space required between coils and core on either side is taken as
26 mm.
➢ The height of window required:= 282 + 26 2 = 334 mm ; Which is
acceptable
196mm
196 + 20 = 216 mm

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 Clearance to Yoke
❑ The clearance to yoke is a critical design parameter in transformer
construction, especially for ensuring proper insulation and cooling.
❑ It refers to the space between the winding and the yoke (the horizontal
part of the transformer core that connects the vertical limbs).

❑ Key Factors Affecting Clearance to Yoke:

➢ Voltage Level: Higher voltages require larger clearances to prevent

electrical breakdown.
➢ Cooling Requirements: Adequate clearance ensures better oil flow

for cooling in oil-immersed transformers.

➢ Insulation Material: If higher-grade insulation is used, slightly

reduced clearances may be permissible.

➢ Regulatory Standards: Clearances must comply with standards such as

IEC, IEEE, or local codes.

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 Clearance to Yoke
Typical Standard Clearances to Yoke:
The recommended clearance to yoke can vary based on the transformer's voltage
rating and application.
❑ For Low Voltage Transformers (< 1 kV):

10 mm to 15 mm clearance is typical.
❑ For Medium Voltage Transformers (1 kV to 36 kV):

20 mm to 30 mm clearance is common.
❑ For High Voltage Transformers (above 36 kV):

30 mm to 50 mm clearance is often required, depending on the insulation system

and cooling requirements.

In our case,
for the Oil-Immersed Distribution Transformers of rating 100 kVA, 11 kV/415V,
typically, a clearance of 20 mm to 30 mm is used to allow sufficient space for
insulation and oil circulation.

69 Department of EEE, CUET

DESIGN AND LAYOUT OF H.V. WINDING

70 Department of EEE, CUET

 PERCENTAGE REACTANCE
L.V. mean length of turn= 164 π = 515 mm
H.V. mean length of turn = 227.5 π = 714.35 mm
Average, Lmt = 515 + 714.35 = 614.67 mm
2
AT =13954 ;(L.V . Amp & L.V .Turn) = 7506
mean height of coils, hc = 196 + 282 = 239 mm
2
a =12mm, b = width of h.v. = 22.5; b = width of l.v. =17mm
1 2
b +b
a + 1 2 =12 + 22.5 +17 = 25.16 mm
3 3
2f Lmt ( AT )  b + b 
%X = 0 a + 1 2
hc Et 
 3 
 

−7
= 2 50 4 10  0.6146 7506 0.02516 = 0.04256 p.u.
0.239 4.5
or; % X = 4.256%

71 Department of EEE, CUET

 PERCENTAGE RESISTANCE
We Know,
ρ20 = 0.01724 Ω/mm2/m and α20 =0.00393

❑ At 75°C, ρ75 = ρ20{1+ α20(75-20)}

= 0.01724(1+0.0039355);
=0.021 Ω/ mm2/m
❑ Resistance of low voltage (l.v.) winding: (per phase) (R=ρL/A)
= (0.021  51554) ÷ (56 1000) Ω
= 0.01043 Ω (per phase)
❑ Resistance of high voltage (h.v.) winding: (per phase) (R=ρL/A)
= (0.021 714.352568)÷(1.23 1000) Ω
= 33.32 Ω (per phase) (check calculation)

72 Department of EEE, CUET

 PERCENTAGE RESISTANCE
Here, Ratio of transformation = (11 103) ÷ (239) = 46

And, L.V. winding: 0.01043 Ω (per phase)

Resistance of H.V. winding: 33.32 Ω (per phase)

Now,
Equivalent resistance referred to h.v. winding (per phase)
R = 33.32 + 0.0104 (46)2 Ω
= 33.32 +21.92 Ω
= 55.32 Ω

73 Department of EEE, CUET

 Percentage of Impedance
❖ Percentage resistance
❑ % R =(Eq. Resistance / Base Resistance) ; [Base R= h.v. Voltage/h.v. Current]

= (55.32) ÷ (11 103/3.03)  100%

= 1.65%
Here,
❑ % X = 4.25 %

❑ % R = 1.65%

Therefore,
Percentage impedance, %Z = √(4.252 +1.652 ) 100%
= 4.6 %
N.B: % Z is beyond expectable limit (3.5-4.5%)!!!
So change your dimension

74 Department of EEE, CUET

 Change window dimensions for improving % Z
❑ Choose window width =0.7 x d= 0.7 x 140 = 102 mm
❑ then height of window =40779/102≈400 mm
❑ Assume, clearance to yoke =28 mm
❑ Considering clearance to yoke,
This height of window is taken as 400 + 28  2=456 mm

❑ The main dimensions of the core are therefore:

❑ Diameter, d=140 mm;
❑ with a 7 step core, the largest width of the core with d=140 is 0.95×140=133 mm
❑ D=distance between the centres of the adjacent limbs=102+133=235

❑ Total width = (2  235) + 133=603 mm

(total width = 133+102+133+102+133 =603 mm)
❑ Total height = 456 + 133+133 = 722 mm;

75 Department of EEE, CUET

 Change Design layout of L.V. winding
❑ Number of turns in L.V= 54.
❑ Size of conductor : 2 strips of 47 mm , If, paper insulation of conductor=0.25 mm;
❑ With paper insulation for conductors,
= (4+ 0.25) mm  (7 + 0.25) mm; =(4.25  7.25) mm
= 30.81 mm2
❑ Choosing single layers for l.v. winding,
❑ Turns per layer = 54
❑ Width of conductor 7.25 mm is taken along the winding,
❑ with 2 conductor sides 4.25 + 4.25 = 8.5 mm forming conductor per layer.
❑ For single layers, the dimension of conductors,
❑ width wise is 8.5 mm and

➢ height of l.v. winding in window = 547.25 = 391.5 mm; say 392 mm;
➢ thickness of l.v. coil = 8.5 1 = 8.5 mm
➢ distance between core and l.v. coil = 3.5 mm
➢ inside diameter of l.v. coil = 140+ ( 2  3.5 ) = 147 mm
➢ outside diameter of l.v. winding = 147 + ( 2  8.5) = 164 mm
➢ mean diameter of l.v. coil = 147 + 8.5= 155.5 mm
➢ mean length of turn of l.v. coil =πd= 155.5 π = 488.27 mm

76 Department of EEE, CUET

 Change Design and layout of H.V. winding
❑ The distance between L.V. and H.V. = 12 mm
❑ Inside diameter of h.v. = 164 + ( 12 2 ) = 188 mm
❑ Now, Split h.v. winding in 4 coils each with turns = 2568/4 = 634
❑ The size of conductor = 1.25 mm diameter.
❑ With paper insulation on conductor, the diameter = (1.25 + 0.25) mm= 1.50 mm

➢ Choose 10 layers ; turns per layer = 634/10 = 64

➢ height of winding in each h.v. coil = 64 1.5 =96 mm
➢ thickness of each coil = 10  1.5 = 15 mm
➢ outside diameter of h.v. coil = 188 + ( 215 ) = 218 mm
➢ mean diameter of h.v. coil = 188 + 15 = 203 mm
➢ mean length of turn =πd=203 π = 637.42 mm
➢ height of h.v. coils in window = ( 96 4 ) +8+8+8 =408 mm
➢ The space required between coils and core on either side is taken as 24 mm.
➢ The height of window required:= 408 + 24 2 = 456 mm ; Which is acceptable
As it lies under the assumed values of window height and window width.
[N:B: window width=102 mm, height = 456 mm;]***

77 Department of EEE, CUET

 Percentage Reactance
L.V. mean length of turn= 155.5 π = 488.27 mm
H.V. mean length of turn = 206 π = 646.84 mm

Lmt = 488.27 + 637.42 = 562.84mm

2
AT =13954
mean height of coils = 392 + 408 = 400mm
2
a =12mm, b1= width of h, v = 22.5; b2 = width of l.v =17mm
b +b
a + 1 2 =12 + 22.5 +17 = 25.16 mm
3 3
2fLmt ( AT )  b1 + b2 
%X = a + 
hc Et 
 3 
 

2  50  4 10−7  0.56284 7506 0.02516

= = 0.04256 p.u.
0 .4  4 .5
or; % X = 2.32%

78 Department of EEE, CUET

 PERCENTAGE OF IMPEDANCE
❖ percentage resistance
❑ % R =(Eq. Resistance / Base Resistance)

= (55.24) ÷ (11 103/3.03)  100% = 1.52%

Here,
❑ % X = 2.32 %;

❑ % R = 1.52%

Therefore,
❑ Percentage impedance, %Z = √(2.322 +1.522 ) 100%

= 2.77 %
N.B: % Z is too low expectable limit, So change your dimension
again
79 Department of EEE, CUET
Change window dimensions again for modifying % Z
❑ Choose window width =0.78 x d= 0.78 x 140 = 110 mm
❑ then height of window =40779/110≈370 mm
❑ Assume, clearance to yoke =30 mm
❑ Considering clearance to yoke,
This height of window is taken as 370 + 30  2=430 mm

❑ The main dimensions of the core are therefore:

❑ Diameter, d=140 mm;
❑ with a 7 step core, the largest width of the core with d=140 is 0.95×140=133 mm
❑ D=distance between the centres of the adjacent limbs=110+133=243

❑ Total width = (2  243) + 133=619mm

❑ Total height = 430 + 133+133 = 696 mm;

80 Department of EEE, CUET

 Design the layout of l.v. winding
❑ Number of turns in L.V= 54.
❑ Size of conductor : 2 strips of 47 mm , If, paper insulation of conductor=0.25 mm;
❑ With paper insulation for conductors,
= (4+ 0.25) mm  (7 + 0.25) mm; =(4.25  7.25) mm
= 30.81 mm2
❑ Choosing 2 layers for l.v. winding,
❑ Turns per layer = 54 / 2 = 27
❑ Width of conductor 7.25 mm is taken along the winding,
❑ with 2 conductor sides 4.25 + 4.25 = 8.5 mm forming conductor per layer.
❑ For two layers, the dimension of conductors,
❑ width wise is 17mm and

➢ height of l.v. winding in window = 277.25 = 195.75 mm; say 196 mm;
➢ thickness of l.v. coil = 8.5 2 = 17 mm
➢ distance between core and l.v. coil = 3.5 mm
➢ inside diameter of l.v. coil = 140+ ( 2  3.5 ) = 147 mm
➢ outside diameter of l.v. winding = 147 + ( 2  17) = 181 mm
➢ mean diameter of l.v. coil = 147 + 17= 164 mm
➢ mean length of turn of l.v. coil =πd= 164 π = 515 mm

81 Department of EEE, CUET

 DESIGN AND LAYOUT OF H.V. WINDING
❑ The distance between L.V. and H.V. = 12 mm
❑ Inside diameter of h.v. = 181 + ( 12 2 ) = 205 mm
❑ Now, Split h.v. winding in 4 coils each with turns = 2568/4 = 634
❑ The size of conductor = 1.25 mm diameter.
❑ With paper insulation on conductor, the diameter = (1.25 + 0.25) mm= 1.50 mm

➢ Choose 12 layers ; turns per layer = 634/12 = 54

➢ height of winding in each h.v. coil = 54 1.5 =81 mm
➢ thickness of each coil = 12 1.5 = 18 mm
➢ outside diameter of h.v. coil = 205 + ( 218 ) = 241 mm
➢ mean diameter of h.v. coil = 205 + 18 = 223 mm
➢ mean length of turn =πd=223 π = 700.22 mm
➢ height of h.v. coils in window = ( 81 4 ) +8+8+8 =348 mm
➢ The space required between coils and core on either side is taken as 30 mm.
➢ The height of window required:= 348 + 30 2 = 408 mm ; Which is acceptable
As it lies under the assumed values of window height and window width.
➢ [N:B: window height = 430 mm; width=110 mm, ]***

82 Department of EEE, CUET

 Percentage Reactance
L.V. mean length of turn= 164 π = 515 mm
H.V. mean length of turn = 223 π = 700.22 mm

Lmt = 515 + 700.22 = 607.61mm

2
AT =13954
mean height of coils = 196 + 348 = 272mm
2
a =12mm, b1= width of h, v = 22.5; b2 = width of l.v =17mm
b +b
a + 1 2 =12 + 22.5 +17 = 25.16 mm
3 3
2fLmt ( AT )  b1 + b2 
%X = a + 
hc Et 
 3 
 

2  50  4 10−7  0.607 7506 0.02516

= = 0.04256 p.u.
0.272 4.5
or; % X = 3.69%

83 Department of EEE, CUET

 Percentage of IMPEDANCE
❖ percentage resistance
❑ % R =(Eq. Resistance / Base Resistance)

= (55.24) ÷ (11 103/3.03)  100% = 1.52%

Here,
❑ % X = 3.69 %;

❑ % R = 1.52%

Therefore,
❑ Percentage impedance, %Z = √(3.692 +1.522 ) 100%

= 3.99 %
N.B: This %Z is within expectable limit (3.5-4.5%)

84 Department of EEE, CUET

 WEIGHT OF IRON IN CORE AND YOKE ASSEMBLY:

From Fig 6.8 the volume of the core and yoke is given by:
❑ = Ai { (619 2) + (430 3) } mm3
❑ = 12456 2528 mm3 ;
= 31488768 mm3;
Density of iron = 7.85  1000 kg /m3.
Weight of core and yoke
= (31488768  7.85 ) ÷ ( 1000  1000 ) = 247 kg

85 Department of EEE, CUET

Iron loss Vs Bmax

86 Department of EEE, CUET

 Core loss
Core (iron) loss at Bmax = 1.63 wb/m is 1.2 watts/kg
(see previous slide)
Core less in transformer = 247 1.2 = 296 watts ;
approximate

87 Department of EEE, CUET

Magnetizing VA vs Bmax

88 Department of EEE, CUET

 MAGNETIZING VOLT AMPERES
❑ Magnetizing volt amperes:
For Bmax = 1.63 wb/m2,
VA / kg from the curve is 10 VA/kg
Magnetizing volt amperes = 247 10 = 2470 VA

89 Department of EEE, CUET

 Weight of Windings
❑ Weight of l.v. winding :
We know, density of copper 8.89 g/cm3
Number of turns = 54 & a2 = 56 mm2
Mean length of turn = 515 mm
Weight of l.v. winding (per limb)
= ( 8.89 56  515 54 ) ÷ ( 1000 1000 ) = 13.84 kg

90 Department of EEE, CUET

 Weight of Windings

❑ Weight of h.v. winding (per limb):

2
❑ Number of turns = 2568; normal 2445 ; a1 = 1.21 mm ;

Mean length of turn = 700.22 mm

Weight of 4 coils (one limb)
= ( 8.89 1.21700.222568 ) ÷ ( 1000 1000 ) kg
= 19.34 kg ; for all turns
For normal turns,
weight of the coils (one limb)
= (8.89 1.29700.222445) ÷ ( 1000  1000 ) kg
= 18.41 kg

91 Department of EEE, CUET

TOTAL WEIGHT OF COPPER IN TRANSFORMER
❑ Total weight of copper in transformer:
We can write:
= 3( l.v. + h.v. ) = 3 ( 13.84 + 18.41) = 96.75 kg ;

92 Department of EEE, CUET

 Copper loss
❑ Copper loss and load loss at 750C :
❑ h.v. current per phase = 3.03 A

Copper loss for 3 phases = 3  I2 r

= 3 3.03255.24
=1521.76 W
Let, stray load loss about 7%,
➢ Then, load loss (at 75 C) = 1521.76 1 .07 = 1628 watts
0

Iron loss = 296 watts

93 Department of EEE, CUET

 Total loss
Therefore, total loss = Iron loss + Copper loss
= ( 296 + 1628)
= 1924 watts

94 Department of EEE, CUET

 CALCULATION OF PERFORMANCE
❑ Calculation of performance:
Efficiency on full load at unity power factor :
Output = 100 1000 watts.
Efficiency = 100 1000/(100  1000+1924)  100%
= 98.11%

95 Department of EEE, CUET

 CALCULATION OF PERFORMANCE
❑ Efficiency on 3/4th full load at unity power factor:
❑ Core loss = 296 watts;
❑ Load loss on 3/4 load = 1628 (3/4)2 = 916 Watt;
❑ Total loss = 296 + 916
❑ = 1212 watts
❑ Efficiency on 3/4th of full load
=75000/(75000+1212)  100%
= 98.4%

96 Department of EEE, CUET

 CALCULATION OF PERFORMANCE

❑ Efficiency on ½ of full load at unity power factor:

❑ Core loss = 296 watts;
❑ Load loss on 1/2 load = 1628 (1/2)2 = 407 W
❑ Total loss = (296 + 407 )
❑ = 703 watts
❑ Efficiency on 1/2 of full load
= 50000/(50000+703) 100%
= 98.61 %

97 Department of EEE, CUET

 VOLTAGE REGULATION
❑ Regulation on full load at unity power factor:
❑ % R = 1.52%,
❑ % X = 3.69%
❑ Now,
❑ ( V + IR )2 + ( IX )2 = E2
❑ Or, ( 1.0 + 0.0152 )2 + (0.0369)2 = 1.031=E2
❑ Or, E = 1.015
❑ Regulation = 1.015 – 1.0
❑ = 0.015 p.u.
❑ = 1. 5%

98 Department of EEE, CUET

 CORE LOSS CURRENT, MAGNETIZING CURRENT

❑ Regulation on full load at 0.8 power factor lagging

❑ = [IR cos φ + IX sin φ] %
❑ = [1.52 0.8 + 3.69 0.6] % = 3.43 %

❖ Core loss current, magnetizing current, no load current :

❑ Core loss = 296 watts.
❑ core loss current, Ic = ( 296 ) ÷ ( 3 11 103 )
❑ = 0.0089A
❑ Magnetizing VA = 2470 ;
❑ magnetizing current, Im = ( 2470 ) ÷ (311  103)
❑ = 0.0748 A
99 Department of EEE, CUET
 NO-LOAD CURRENT
❑ No load current per phase , Io = (0.07482 + 0.00892)
= 0.0753 A
❑ Current per phase = 3.03 A
❑ No load current = ( 0.0753÷ 3.03 )  100 %
= 2.48% ; of full load current

100 Department of EEE, CUET

Transformer tank

101 Department of EEE, CUET

 DESIGN OF TANK:
Outside diameter of h.v. = 241 mm ;
The distance between coils on adjacent limbs = 29 mm;
Clearance at each end is 37 mm.
Thus, the length of the tank = 241 3 + 29 2 + 372 = 818. mm ;
choose 820 mm
Breadth of the tank = 241 + 60 2 mm
= 361 mm ; choose 370 mm
Height = 696 + 50 mm for base + 250 oil level above core
= 996 mm up to oil level + 250 mm for leads etc
= 1,246 mm ;

102 Department of EEE, CUET

 This figure is taken from the book.
The values will not match with that
of slides.

This is just for your understanding.

please use the values that you
have found.

103 Department of EEE, CUET

 DESIGN OF TANK:
➢ Inside dimensions of the tank of the transformer
➢ = (length  breadth  height)

➢ = (820 3701246) mm
3

❑ Temperature rise:

Now, for dissipation of heat only 4 surfaces of a tank are

taken into consideration.
The top and the bottom are not considered.
Surface of tank = (1246/1000 )  ( 370/1000 )  2 = 0.858 m2
(1246/1000 )  (820/1000 )  2 = 2.045 m2

104 Department of EEE, CUET

 Task from book
See the rest of the design task related to following topics
from the book
➢ temperature rise,

➢ Volume and weight of oil,

➢ Volume and weight of oil in tubes,

➢ weight of transformer

105 Department of EEE, CUET

Derivation of the
equations used

106 Department of EEE, CUET

 Single phase transformer
➢ The induced emf in a transformer,
➢ Emf per turn,
➢ The window in single phase transformer contains one primary and
one secondary winding.
➢ The window space factor Kw is the ratio of conductor area in
window to total area of window.

➢ Conductor area in window,

➢ The current density is same in both the windings. Therefore
Current density,

➢ Area of cross - section of primary conductor,

➢ Area of cross - section of secondary conductor,

107 Department of EEE, CUET

 Single phase transformer
➢ If we neglect magnetizing mmf then primary ampere turns is equal
to secondary ampere turns. Therefore ampere turns,

➢ Total copper area in window, Ac = Copper area of primary winding

+ Copper area of secondary winding = (Number of primary turns x
area of cross-section of primary conductor) + (Number of secondary
turns x area of cross - section of secondary conductor)

➢ On equating the above equations, we get,

➢ Therefore Ampere turns,

108 Department of EEE, CUET

 Single phase transformer
The kVA rating of single phase transformer is given by,

On substituting for Et and AT from equations we get,

The above equation is the output equation of single phase transformer.

109 Department of EEE, CUET

 Three-phase transformer
❑ OUTPUT EQUATION OF THREE PHASE TRANSFORMER
➢ The simplified cross-section of core type three phase
transformer is shown in figure.
➢ The cross-section has three limbs and two windows.
➢ Each limb carries the low voltage and high voltage winding of a
phase.

110 Department of EEE, CUET

 Three-phase transformer
➢ The induced emf per phase,
➢ Emf per turn,
➢ In case of three phase transformer, each window has two primary and
two secondary windings.
➢ Total copper area in window, Ac = (2 x Number of primary turns x
area of cross-section of primary conductor) + ( 2 x Number of
secondary turns x area of cross - section of secondary conductor)

111 Department of EEE, CUET

 Three-phase transformer
➢ On equating we get,

➢ Therefore Ampere turns,

➢ The kVA rating of three phase transformer is given by,

➢ On substituting for Et and AT from equations we get,

112 Department of EEE, CUET

 EMF PER TURN
❑ EMF PER TURN
➢ The transformer design starts with selection of an appropriate value
for emf per turn. Hence an equation for emf per turn can be
developed by relating output kVA, magnetic and electric loading.
➢ In transformers, the ratio of specific magnetic and electric loading is
specified rather than actual value of specific loadings.
➢ Let, ratio of specific magnetic and electric loading be,
➢ The volt-ampere per phase of a transformer is given by the product of
voltage and current per phase.
➢ Considering the primary voltage and current per phase we can write,

113 Department of EEE, CUET

 Introduction

➢ We know that Emf per turn,

➢ On substituting for Фm from equation we get,

➢ From the above equation we can say that the emf per turn is directly
proportional to K. The value of K depends on the type, service
condition and method of construction of transformer.

114 Department of EEE, CUET

 Introduction

• The value of K for different types of transformers is listed in table below.

• An empirical expression which gives voltage per turn fairly accurately for transformers
is:
kVA  1000
no. of legs
Et = ;
40
• For 3 phase core type transformers the number of legs =3.

115 Department of EEE, CUET

THANK YOU

116 Department of EEE, CUET