A

Presentation on

Transformer Designing and Manufacturing

ELECTRICAL ENGINEERING DEPARTMENT

Moradabad Institute of Technology Moradabad
Session: 2016-17
Industrial Training Coordinator:
Mrs. Niyati Gulati
Assistant Professor

Presented By:
Lalit Kumar Verma
1308221018

Training Guide:
Mr. Prem Kumar

Contents

About the Company

Introduction

Designing of transformer

Manufacturing Process of Transformer

Testing of Transformer

About the company

S.J. Transformers Rampur are manufacturer and repairer of distribution

tranformers.

The company is established in 1992.

It is an ISO certified company.

Company is manufacturing the tranformers of rating 25kV to 1MVA.

Introduction of Transformer

A device which transforms the electric energy from one circuit to another
circuit without electrical connection.

It works on principle of Electromagnetic Induction.

It changes the voltage magnitude without changing the frequency.

It is a static device with no moving parts.

There is no friction losses so efficiency is high.

Designing of Distribution Transformer

Winding
Designing

Calculation of Number of Turns

Length of HV and LV Windings
Calculation of Core Window Height
Core
Designing

Core Diameter, Area, Stack

Step Width
Loss
Calculation

Calculation of Core and Winding

Losses
Efficiency

Proposed Specification for 100KVA

Transformer
Rating
No-Load voltage ratio
No. of Phase/Frequency
Connection
Winding Material
Tapping on HV
No-Load and Load Loss(Max.)
Impedance
Maximum flux density
Maximum current density
Temperature Rise

100KVA
11000/ 433 volts
3 Ph/ 50 Hz
Delta/ Star Dyn-11
Aluminum
At + 2.5% + 5% for HV variation
260/1760 W
4.5%
1.6 Tesla
1.5 A/sq mm
40/

Winding Designing

Step
1: Calculation of Number of Turns

Voltage per Turn=

(For Alluminium K=0.33)

= = 3.3

Number of LV Coil Turns = = = 76 Turns

Number of HV Coil Turns =
=
5% Additional turns in HV Coil for tapping, Total HV Coil Turns = 3512 Turns

Contd..
2: Length of HV Coil and HV Wire Size
Step

Current Density = 1.5 Amp/mm2

Wire Area = = 2.02 mm2
Wire Diameter = = 1.7 mm
Number of Turns per Coil per phase =

Contd..
Description

Length

Radial

(1) Bare Conductor

(2) Covering thickness towards DPC

1.7 mm
(+) 0.2 mm

1.7 mm
(+) 0.2 mm

Covered Conductor
(3) Gap between two consecutive conductors

1.9 mm
(+) 0.05 mm

1.9 mm
(+) 0.05 mm

Insulated size of conductor with working

tolerance

1.95 mm

1.95 mm
(+)0.1 mm=2.05 mm

(4) Turns per Layer: & 17 Layer

X 53

X 17

(5) Axial Length of HV Coil

104 mm

35 mm

Contd..
Step 3: Estimation of Core Window Height
(i) Total axial length of 4 coils

: 4 x 104 mm = 416 mm

(ii) Gap Between yoke to top and bottom coil : 2 x 25 mm = 50 mm

(iii) Gap between two tap coils

: 1 x 10 mm = 10 mm

(iv) Gap between plain coils

: 2 x 7 mm

Therefore, Core Window Height

= 14 mm
= 490 mm

Contd..
Step

4: Length of LV Coil and LV Strip Size

Current Density = 1.5 Amp/mm2

Wire Area = =
Number of Strips to be used in parallel = 2
Area of each strip =
Disposition of strips = 1 width x 2 depth
Number of turns = 76 (38turns per strip)
LV Strip Size = 470/(38+2) = 11.75 mm
Width = 44.5/11.75 = 4.5mm (appx.)

Core Designing
Step

1: Core Area and Diameter

Voltage per turn E =

Flux Density(Specified) = 1.6 Tesla
E

Core Area

Core Area

Core Diameter

d = 114mm & Area = 95.5 sq mm

Contd..
Step 2: Step Width
1st Step

110 mm (L1)

2nd Step
3rd Step
4th Step

105 mm (L2)
100 mm (L3)
90 mm (L4)

5th
6th
7th
8th

Step
Step
Step
Step

80 mm (L5)
70 mm (L6)
60 mm (L7)
50 mm (L8)

9th Step

40 mm (L9)

Contd..
Step

3: Calculation of Core Stack

K
1st step(L1=110mm), K1=mm
2nd step K2, and so on..
K= K1+K2+K3+K4+K5+K6+K7+K8+K9 = 106.75mm

Contd..
Step

4: Weight of the Core

Weight of the complete set of core in kg

= 193.6 kg

Estimation of Losses
Transformer
Losses

Load Loss

Load

Loss:

Winding Resistance per phase at ,

For HV Coil

For LV Coil

No Load Loss

Contd..
Total

Load Loss =

Approximate Stray Loss for 100KVA = 100 Watt

Load Loss = 1699 Watt (1760 Watt Maximum)
No Load Loss:
Specific Loss(CRGO Steel) at 1.6 Tesla = 1 Watt/kg
Handling factor = 25%
Effective Loss = 1.25 Watt/kg
Total No Load Loss = 1.25 * Weight of the core = 1.25 * 193.6 =242 Watt (260W Max)

Contd..
Efficiency

Calculations:
Efficiency

Transformer Manufacturing Process

Flowchart
H.V.Winding
Core
Assembly

L.V.Winding
Coil
Assembly

Insulation
Cutting

Process
and Baking
Oil
Tanker

Oil
Centrifuging

Box-Up

Shot
Blasting

Tank
Fabrication

Contd..
Testing

Leakage
Test

Painting &
Finishing

Dispatch

Testing of Transformer
For confirming the specifications and performance of
transformer, various test are performed:
(i) Vector Group Test
(ii) Open Circuit and Short Circuit Test
(iii) Winding Resistance Measurement Test
(iv) DVDF Test
(v) Transformer Oil Test

Vector Group Test

Vector Group of distribution transformers are Dyn11
The polarity references phase by phase are:
UV - un ; VW - vn ; WU wn
For connection Dyn 11 ,the following conditions must
be satisfied:
Vv = Vw
Wv > Ww
Un + Vn = UV
Wn > Vn

DVDF Test
This test is performed to check the withstand capacity of transformer at high voltge.
In this test,double voltage and frequency is applied to lv side while hv side kept
open.

Erms= 4.44mfN volts

Frequency is doubled to reduce unwanted heating of core.

Winding Resistance Measurement Test

DC variable source is connected to star or
delta winding.
Voltmeter and Ammeter reading is tested in
various dc levels.
Resistance is measured by V/I ratio.

Conclusion
In the summer training, I came to know about how the transformers are
manufactured in the industry.

I learnt about the testing and designing of distribution transformers.

Thank You