Maintenance and Testing of Electrical Machines

Week 01 Lecture 01

Introduction to Transformers

Objectives

 To understand the basics of transformers

 To understand the construction of transformers

 To study the type of transformers

Transformer

A transformer can be defined as a static device which helps in the transformation of electric

power in one circuit to electric power of the same frequency in another circuit. The voltage can

be raised or lowered in a circuit, but with a proportional increase or decrease in the current

ratings.

Working Principle

The main principle of operation of a transformer is mutual inductance between two circuits

which is linked by a common magnetic flux. A basic transformer consists of two coils that are

electrically separate and inductive, but are magnetically linked through a path of reluctance. The

working principle of the transformer can be understood from the figure below.
 Figure 1: Transformer

As shown above the electrical transformer has primary and secondary windings. The core

laminations are joined in the form of strips in between the strips you can see that there are some

narrow gaps right through the cross-section of the core. These staggered joints are said to be

overlapped. Both the coils have high mutual inductance. A mutual electro-motive force is

induced in the transformer from the alternating flux that is set up in the laminated core, due to

the coil that is connected to a source of alternating voltage. Most of the alternating flux

developed by this coil is linked with the other coil and thus produces the mutual induced electro-

motive force. The so produced electro-motive force can be explained with the help of Faraday’s

laws of Electromagnetic Induction as

(1)

If the second coil circuit is closed, a current flow in it and thus electrical energy is transferred

magnetically from the first to the second coil. The AC supply is given to the first coil and hence

it can be called as the primary winding. The energy is drawn out from the second coil and thus

can be called as the secondary winding.

For the construction of a transformer, we need two coils having mutual inductance and a

laminated steel core. The two coils are insulated from each other and from the steel core. The

device will also need some suitable container for the assembled core and windings, a medium

with which the core and its windings from its container can be insulated.

In order to insulate and to bring out the terminals of the winding from the tank, apt bushings that

are made from either porcelain or capacitor type must be used. In all transformers that are used

commercially, the core is made out of transformer sheet steel laminations assembled to provide a

continuous magnetic path with minimum of air-gap included. The steel should have high

permeability and low hysteresis loss. The steel should be made of high silicon content and must

also be heat treated. By effectively laminating the core, the eddy-current losses can be reduced.

The lamination can be done with the help of a light coat of core plate varnish or lay an oxide

layer on the surface. For a frequency of 50 Hz, the thickness of the lamination varies from

0.35mm to 0.5mm for a frequency of 25 Hz.

Types of Transformers

Core Type Transformer: In core-type transformer, the windings are given to a considerable part

of the core. The coils used for this transformer are form-wound and are of cylindrical type. Such

a type of transformer can be applicable for small sized and large sized transformers. In the small

sized type, the core will be rectangular in shape and the coils used are cylindrical. The figure

below shows the large sized type. You can see that the round or cylindrical coils are wound in

such a way as to fit over a cruciform core section. In the case of circular cylindrical coils, they

have a fair advantage of having good mechanical strength. The cylindrical coils will have
different layers and each layer will be insulated from the other with the help of materials like

paper, cloth, micarta board and so on. The general arrangement of the core-type transformer with

respect to the core is shown below. Both low-voltage (LV) and high voltage (HV) windings are

shown.

Figure 2: Core type transformer

The low voltage windings are placed nearer to the core as it is the easiest to insulate. The

effective core area of the transformer can be reduced with the use of laminations and insulation.

Shell Type Transformer: In shell-type transformers, the core surrounds a considerable portion of

the windings. The comparison is shown in the figure below.

Figure 3: Shell type transformer

Paper is used to insulate the different layers of the multi-layer discs. The whole winding consists

of discs stacked with insulation spaces between the coils. These insulation spaces form the

horizontal cooling and insulating ducts. Such a transformer may have the shape of a simple

rectangle or may also have a distributed form.

A strong rigid mechanical bracing must be given to the cores and coils of the transformers. This

will help in minimizing the movement of the device and also prevents the device from getting

any insulation damage. A transformer with good bracing will not produce any humming noise

during its working and will also reduce vibration.

A special housing platform must be provided for transformers. Usually, the device is placed in

tightly-fitted sheet-metal tanks filled with special insulating oil. This oil is needed to circulate

through the device and cool the coils. It is also responsible for providing the additional insulation

for the device when it is left in the air. There may be cases when the smooth tank surface will not

be able to provide the needed cooling area. In such cases, the sides of the tank are corrugated or

assembled with radiators on the sides of the device. The oil used for cooling purpose must be

absolutely free from alkalis, sulphur and most importantly moisture. Even a small amount of

moistures in the oil will cause a significant change in the insulating property of the device, as it

lessens the dielectric strength of the oil to a great extent.

The presence of about 8 parts of water in 1 million reduces the insulating quality of the oil to a

value that is not considered standard for use. Thus, the tanks are protected by sealing them air-

tight in smaller units. When large transformers are used, the airtight method is practically
difficult to implement. In such cases, chambers are provided for the oil to expand and contract as

its temperature increases and decreases.

These breathers form a barrier and resist the atmospheric moisture from contact with oil. Special

care must also be taken to avoid sledging. Sledging occurs when oil decomposes due to

overexposure to oxygen during heating. It results in the formation of large deposits of dark and

heavy matter that clogs the cooling ducts in the transformer.

The quality, durability and handling of these insulating materials decide the life of the

transformer. All the transformer leads are brought out of their cases through suitable bushings.

There are many designs of these, their size and construction depending on the voltage of the

leads. Porcelain bushings may be used to insulate the leads, for transformers that are used in

moderate voltages. Oil-filled or capacitive-type bushings are used for high voltage transformers.

The selection between the core and shell type is made by comparing the cost because similar

characteristics can be obtained from both types. Most manufacturers prefer to use shell-type

transformers for high-voltage applications or for multi-winding design. When compared to a core

type, the shell type has a longer mean length of coil turn. Other parameters that are compared for

the selection of transformer type are voltage rating, kilo-volt ampere rating, weight, insulation

stress, heat distribution and so on.

Oil Filled Self Cooled Type: Oil filled self-cooled type uses small and medium-sized distribution

transformers. The assembled windings and core of such transformers are mounted in a welded,

oil-tight steel tanks provided with a steel cover. The tank is filled with purified, high quality

insulating oil as soon as the core is put back at its proper place. The oil helps in transferring the

heat from the core and the windings to the case from where it is radiated out to the surroundings.
Oil Filled Water Cooled Type: This type is used for much more economic construction of large

transformers, as the above-told self-cooled method is very expensive. The same method is used

here as well- the windings and the core are immersed in the oil. The only difference is that a

cooling coil is mounted near the surface of the oil, through which cold water keeps circulating.

This water carries the heat from the device. This design is usually implemented on transformers

that are used in high voltage transmission lines. The biggest advantage of such a design is that

such transformers do not require housing other than their own. This reduces the costs by a huge

amount. Another advantage is that the maintenance and inspection of this type is only needed

once or twice in a year.

Air Blast Type: This type is used for transformers that use voltages below 25,000 volts. The

transformer is housed in a thin sheet metal box open at both ends through which air is blown

from the bottom to the top.

Summary

After the completion of lecture the learners will be able to explain the basic of transformers, its

working principle, construction and types of transformers.