Transformer construction

All transformers have the following parts:

A laminated steel core, which provides the path for the magnetic flux.
Two or more coils (also called windings) having mutual inductance and
insulated from each other. Other parts are,
a) A container to hold the assembled core and windings.
b) A medium to insulate core and its windings from its container
c) Bushings for insulating and bringing the terminals of the windings
out of the tank.
Basically the transformers are classified into two types based on their
construction.
Core-type transformers
Here, the windings surround the core as shown in Fig. 1. The core is made of
silicon steel laminations which are either rectangular or L-shaped. To provide
maximum linkage between the two windings they are interleaved to reduce
leakage flux, as shown in Figure a. The coils are form wound and are of
cylindrical type. The coils may be rectangular, oval or circular. The cores may
be of different shapes as shown in Figure b. Basically they are rectangular
with one or more steps. Core stepping gives a high space factor and reduces
the length of the mean turn, thus reducing the I
2
R losses. Three stepped cores
are most popular.


Figure a: core type transformer


Figure b: Types of cores



Shell-type transformers
In the shell-type transformers the core surrounds a considerable part of the
windings. The cross section of the shell-type transformer is shown in figure c.
The low-voltage coils are placed near the core to reduce amount of insulation
required. The cores and coils of transformers must be provided with rigid
mechanical bracing to prevent movement, vibrations and insulation damage.
Transformers are housed in tightly fitted sheet-metal tanks, filled with a
special insulating oil (mineral oil or a special synthetic fluid) which helps to
cool the coils and also provide additional insulation. The oil must be free from
sulphur, alkalies and moisture.


Figure c: shell type transformer

The sides of the transformers are sometimes provided with corrugations or
with vibrators to provide sufficient cooling area. Large transformers are
provided with chambers, called breathers, to permit the oil to expand or
contract as its temperature increases or decreases. Atmospheric moisture is
trapped in the breathers. The life of the transformer unit depends on the
quality of the insulating materials. The leads are brought out of their cases
through suitable bushings. For medium voltages porcelain bushings are used.
For high voltage installations, oil-filled bushings are used.

The choice between core-type and shell-type transformers is based on a
number of factors such as voltage rating, KVA rating, weight, insulation stress,
heat distribution etc.
A few points to be noted are
The core-type in general has a longer mean length of core and shorter
mean length of coil turn.
The core-type has a smaller cross-section of iron and so will need more
number of coil turns to produce required flux.
There is more room for insulation in core type; hence it is preferred for
high-voltage applications.
The shell-type has better mechanical bracing.

Power Transformers:
These transformers normally have rating above 200 kVA. These are used in
generating stations as well as in substations at each end of transmission
line for either stepping up or stepping down the voltage.
The power transformers which are installed near generating stations are
used for stepping up the voltage for the purpose of economical power
transmission. These transformers are used to transmit power over long
distances. These are generally referred as generator step up transformers.
The kVA and kV ratings of the generator step up transformers are
determined by the amount of power produced by the generator and the
distance that this power must be transmitted. These units are manufactured
in very large sizes. The maximum rating is 500 MVA. The reason for this
limit is physical size of one large transformer. Also if only one large
transformer is installed and a malfunction is produced than the entire
system would be without power whereas if there are two smaller unit is not
working then the other unit would continue to supply power at a reduced
value.
The transformers which are used to transform the transmission voltage to
the voltage level of primary feeders are called substation transformers.
They are also nothing but power transformers.
The power transformers are normally available in single phase or in three
phase units. They are not put in service for 24 hrs. as the case with
distribution transformer but are switched on during load periods and
switched off during light loads. Therefore power transformers are normally
designed to have maximum efficiency at or near full load.
Generally power transformers are designed to have greater leakage
reactance than is permissible in distribution transformers because the
voltage regulation in case of power transformer is not much important than
current limiting effect of the higher leakage reactance.

Distribution Transformers:
Distribution transformers change the feeder voltage to the utilization voltage
required by the consumer. They are essentially step down transformers
which changes the voltage to standard service voltage. Normally their rating
is about 200 kVA.
Distribution transformers are operated for 24 hrs. a day even though they
are carrying load or not. So in such transformers there are iron losses
throughout a day whereas the copper losses account for loss in energy only
when transformer is loaded. Therefore as far as possible the iron losses are
kept as small as possible as compared to full load copper losses.
Alternatively the distribution transformers are designed in such a way that
have maximum efficiency at load lower than load, which is about 60 to
70 of full load even less.
Since the distribution transformers are in operation throughout a day, so
they should have good all day efficiency. They should have better voltage
regulation. Hence they should be designed for small value of leakage
reactance.
The construction of the outside metal enclosure of distribution transformers
depends upon the method of mounting and the location of installation. They
may be installed indoors or exposed to weather or may be installed on a
pole or in a special enclosed area or nay other special locations.