Construction of Transformer

Electrical Engg. Department

CKPCET, Surat
Construction of Transformer
 Types of Transformer
 Depending on the arrangement of the core and the
winding there are three types of transformer
• Core Type
• Shell Type
• Berry Type
Construction of Transformer
• Core Type Transformer
• Core is in the form of a rectangular frame made from lamination
• Single magnetic path
• Primary and secondary windings are uniformly distributed on
two limbs of the core
• Core is surrounded by winding
Construction of Transformer
• Shell Type Transformer
• Core is in the form of a rectangular frame made from lamination
• Double magnetic path
• Primary and secondary windings are placed on the central limb of
the core.
• Winding is surrounded by cord
Construction of Transformer

• Berry Type Transformer

• It has distributed magnetic circuit
• The core type is like the spikes of a wheel
• The transformer are generally placed in tightly fitted sheet metal tanks
• Tanks are made up of high quality steel plate, formed and welded into a
rigid structure
• The tanks are filled with special insulating oil
• All the joints are painted with light blue chalk solution disclosing even a
minute leak
Construction of Transformer
• Core Type Transformer
• Shell Type Transformer
Construction of Transformer
• Core Type Transformer
Construction of Transformer
• Core Type Transformer
Construction of Transformer
• Shell Type Transformer
Construction of Transformer
Construction of Transformer
• Difference between core and shell type transformers

Core Type Transformer Shell Type Transformer

Core has two limbs Core has three limbs
The core has one magnetic path The core has two magnetic path
The core is surrounded by winding The winding is surrounded by core
Cylindrical type winding are used Sandwich type winding are used
Easy to repair Not to repair easily
It has better cooling since more surface Cooling is not so effective
is exposed to atmosphere
Natural cooling can provided Natural cooling cannot provided
Coils are easily removed for Coils are not easily removed for
maintenance maintenance
Low voltage transformer High voltage transformer
Construction of Transformer
Construction of Transformer
• Silicon steel material is used for the construction of the transformer core
• Silicon steel has high permeability and low magnetic reluctance
• Magnetic field produced in this core is very strong
• IT has narrow hysteresis loop. So Hysteresis loss is reduced.
• Laminated stampings are assembled to manufacture the core
• There is electrical isolation in stampings from each other
• Lamination size 0.35 to 0.5 mm
• The core is laminated to reduce eddy current from the core material and hence to
reduce eddy current loss
• Iron loss or Core Loss = Hysteresis loss+ Eddy Current Loss
Construction of Transformer
Construction of Transformer
• L-shaped
lamination

• I-shaped lamination
Construction of Transformer
• Different cross-sections for transformer limbs
• The cross-section of the limb of the core of small transformer is
rectangular (a)
• The cross-section of the limb of core of such transformers is
either square or stepped as shown in Fig. (b), (c), (d)
• With increase in the number of steps, the cross-section of the
windings will be more and more close to circular cross-section
and less copper is required to wind these coils.
• The stepped structure of the limb of core the labour charges to
construct the core increase
Construction of Transformer
• Winding of the transformer
• Primary and secondary windings to be on two different limbs
of the core
• The flux produced in the core will not linked to the secondary
windings at all
• The primary and secondary windings are mounted on the same
limb of the core
• Two types o windings
• Concentric cylindrical type of winding
• Sandwiched type winding
Construction of Transformer
• Winding of the transformer
• Concentric cylindrical type of winding
• Here windings are
placed in the
concentric manner
around the same
limb with the low
voltage winding
placed inside and
high voltage
windings is placed
outside
• Windings are
insulate from the
core
Construction of Transformer
• Winding of the transformer
• Sandwiched type winding
• Here the high voltage and
low voltage windings are
divided into number of
small coils and then these
small windings are
interleaved windings are
placed in the concentric
manner around the same
limb with the low voltage
winding placed inside and
high voltage windings is
placed outside
• Windings are insulate from
the core
Construction of Transformer
• Transformer tank
• Assembly of large size
transformer is placed in a
sheet metal tank
• Inside the tank the
assembly of the transformer
is immersed in oil
• The oil acts as insulator as
well as coolant
Construction of Transformer
Purpose of oil in a transformer:
•Cooling
As the current flows through the windings of a transformer heat is
generated due to the resistance of the windings. Also the flux in the core
generates heat. This heat is absorbed by the oil surrounding the
transformer core as well as the windings.
•Insulation
The components in a transformer needs to be insulated from each other
as well as the earth so that smaller clearances can be used in the
transformer, reducing the total size of the transformer. The oil fulfills this
requirement.
•Diagnosis
By analysing the gases developed in a transformer oil the condition of the
transformer can be determined. For example furanic compounds found
in a sample of the oil will tell you the condition of the solid insulation
material.
Construction of Transformer
Conservator
Some empty space is always provided
in transformer above oil level is known
as Conservator
Function of Conservator :
When transformer is loaded
and when ambient temperature rises,
the volume of oil inside
transformer increases.
A conservator tank of
transformer provides adequate space to
this expanded transformer oil. It also
acts as a reservoir
for transformer insulating oil.
when the oil cools, it contracts
and the outside air gets sucked inside
the conservator.
This process is called as the breathing
of the transformer
Construction of Transformer
 Conservator
When the outside air which has being drawn in have moisture in it.
When such an air comes in contact with the oil, the oil will absorb the
moisture content and loses its insulating properties.
This can be prevented by using conservator

The conservator is a cylindrical shaped air tight metal drum placed on the
transformer tank
The conservator is connected to the tank by a pipe
Construction of Transformer
 Breather
Breather are used to absorb the moisture content from the
sucked air, while the transformer oil gets expanded due to
heating. Breathers make use of silica gel coloured with
brown used extensively in power transformers.
when its absorb moisture its colour change and become pink
Construction of Transformer
 Buchholz relay
Buchholz relay is used for the protection of transformers from the
faults occurring inside the transformer. Short circuit faults such as inter
turn faults, incipient winding faults, and core faults may occur due to
the impulse breakdown of the insulating oil or simply the transformer
oil.
During this process different types of gases are liberated.
Buchholz relay get operated by these gases and gives an alarm to the
operator.
If a fault continues, then the relay will trip off the main circuit breaker
to protect the transformer
Construction of Transformer
 Explosion Vent
Explosion Vent. The explosion vent is used to expel boiling oil in
the transformer during heavy internal faults in order to avoid
the explosion of the transformer
Construction of Transformer
Assembling the core
Assembling the core
Assembling the core
Assembling the core
Winding : Concentrated winding – HV & LV
Winding : Sandwich winding – HV & LV
Winding
Winding placement surrounding the core
Winding placement surrounding the core
Winding placement surrounding the core
Winding placement surrounding the core
Drying
Drying
Transformer Oil Tank
Overall view
Overall view
Overall view
Overall view
Bushing: Transformer Terminal
Breather
Construction of Transformer
Construction of Transformer
Construction of Transformer
Construction of Transformer
Construction of Transformer