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NATIONAL UNIVERSITY OF SCIENCE & TECHNOLOGY

PNEC, KARACHI

ELECTRICAL MACHINES
TRANSFORMER PROJECT REPORT

NAME ROLL # CMS ID

SYED SHUJAT ALI EE-1474 00000340021

MUHAMMAD EE-1492 00000350997
WAHAB ZAFAR
ALI ANWAR EE-1482 00000336783
SAAD ALI EE-1463 00000339425
BILAL AHMED EE-1490 00000345552

Submitted to: CAPT DR SAJJAD ZAIDI

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Abstract

The objective of this project is to design three transformers using three different cores so we choose, one with
an iron core, one with silicon steel core and third with wooden core.
The turn’s ratio ‘a’
(a = Np/Ns)
Of iron, silicon steel and wooden transformers are 420/84, 420/84 and 600/120 respectively: i.e. an Iron = a
Silicon Steel = a Wood = 5. Here Np is the number of turns of primary or input winding and Ns is the number
of turns of secondary or output winding. 21 gauge copper wire is used for primary/input winding and 18
gauge copper wire is used for secondary/output winding.
The iron and silicon steel cores of the transformers consist of three-legged laminated core made of several
laminated iron and silicon steel sheets and the wooden core is a 31.5 cm long rectangular piece of weed. This
complete transformer report covers construction, working, principle, disadvantages, types, etc. of
transformers.

Introduction:
A power transformer is a static machine used to convert electricity from one circuit to another without
changing the frequency. Since there are no rotating or moving parts, a transformer is classified as a static
device. Transformer works on AC supply. Transformers work on the principle of mutual induction.

The transformer, which is frequently used in the distribution and transmission of alternating current power,
is essentially a voltage control device. In 1831, Michael Faraday introduced the concept of a transformer,
which was further developed by a number of other eminent scientists. The fundamental goal of utilizing
transformers, however, was to maintain equilibrium between electricity produced at very high voltages and
consumed at very low voltages.
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Use of power transformers:

Power generation at low voltage levels is very cost effective. Theoretically, this low voltage level of power
can be transmitted to the receiving end. This lower voltage power if transmitted results in higher line current
which actually causes higher line losses.
But if the voltage level of a power is increased, the power current is reduced which leads to reduction in ohmic
or I2R losses in the system, reduction in the cross-sectional area of the conductor i.e. reduction in capital cost
of the system and this too Improves system voltage regulation. Because of these, low-level power amplification
is essential for efficient electrical power transmission.

This is done by a step-up transformer in the sending part of the power system network. Since this high voltage
power cannot be distributed directly to consumers, it must be stepped down to the required level at the
receiving end with the help of a step-down transformer. An electrical power transformer thus plays an
important role in the transmission of electricity.
Two winding transformers are generally used where the ratio of high voltage to low voltage is greater than
2. Using an auto transformer is cost effective where the ratio between high voltage and low voltage is less
than 2.
Again a single unit three-phase transformer is more cost effective than a bank of three single-phase
transformer units in a three-phase system. But a single three-phase transformer unit is a little difficult to
transport and if one of the phase windings breaks, it has to be completely taken out of service.
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Types of Transformers:
Transformers can be classified in different ways depending on their purpose, use, construction etc. Note that
sometimes these classifications overlap - ex: a transformer can be both a three-phase transformer and a step-
up transformer at the same time. For more information, some of the best books on electrical engineering
describe the operation of a transformer in more detail.

Following are the types of transformers.

Step-up transformer and step-down transformer:

Step-up transformers convert low voltage (LV) and high current to high voltage (HV) on the primary side of
the transformer and to a low current value on the secondary side of the transformer.
A step-down transformer converts high voltage (HV) and low current at the primary side of the transformer
to low voltage (LV) and high current values at the secondary side of the transformer.
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Three phase transformer and single phase transformer:

A three-phase transformer is commonly used in three-phase power systems because it is more cost-effective
than single-phase transformers. But when size matters, it is better to use a bank of three single-phase
transformers versus three-phase transformers, as it is more convenient than a single three-phase transformer
unit.

Electrical Power Transformers, Distribution Transformers and

Instrument Transformers:
Power transformers are commonly used to step up or step down voltage levels in a transmission network. It
operates primarily during high or peak loads and has maximum efficiency at or near full load.
A distribution transformer steps down the voltage for
the purpose of distribution to domestic or commercial
consumers. It has good voltage regulation and operates
24 hours a day with maximum efficiency at 50% of full
load .Instrument transformers include C.T and P.T
which are used to step down high voltages and currents
which can be measured by conventional instruments.
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Two winding transformer and auto transformer:

A two-winding transformer is generally used where the ratio between the high voltage and low voltage side
is greater than 2.
It is more cost effective for autotransformers in situations where the ratio between high voltage and low
voltage sides is less than 2.

Outdoor transformer and indoor transformer:

As the name suggests: outdoor transformers are designed to be installed outdoors.
Whereas indoor transformers are designed to be installed indoors (who would have guessed it!).

Oil cooled and dry type transformer:

This classification is related to the transformer cooling system used inside the transformer.
In oil cooled transformers, the cooling medium is transformer oil. Whereas in dry type transformer air cooling
is used instead.

Basic type transformer:

There are two main types of transformer windings - the core type, and the shell type. There are also Barry
type transformers.
A basic type of transformer has two vertical legs or limbs with two horizontal legs called yokes. The core is
rectangular in shape with a typical magnetic circuit. Cylindrical coils (HV and LV) are placed on both limbs.

Shell type transformer:

A shell type transformer has a central limb and two outer limbs. Both HV,
LV coils are placed on the central limb. There is a double magnetic circuit.
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Berry type transformer:

In a Barry type transformer, the core looks like the spoke
of a wheel. To house this type of transformer, tightly fitted
metal sheet tanks are used, inside which the transformer oil
is filled.

History of Power Transformers:

If we want to know the history of the transformer, we have
to go back to the 1880s. The property of induction was discovered about 50 years ago in 1830, and it is the
working principle of the transformer.
Later the transformer design was improved resulting in higher efficiency and smaller size. Gradually larger
capacity transformers in the range of several kVA, MVA came into existence.
In the year 1950, 400KV electrical power transformer was introduced in high voltage power system. In the
early 1970s, the unit was rated up to 1100 MVA. Various manufacturers produced 800KV and higher KV
class transformers in the 1980s.

Principle:
The principle governing the operation of a transformer is mutual inductance.
Basically Faraday's law of electromagnetic induction.

Statement:
If a flux passes through a turn of a coil of wire, a voltage will be induced in the turn of wire that is directly
proportional to the rate of change in flux with respect to time.
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The minus sign in the formula is an expression of Lenz's law which

states that the induced voltage opposes the change that causes it.
Basically, if a different current is set up in a circuit then excitation
is done. e.m.f is generated in the neighboring circuit. Different currents in a circuit produce different
magnetic flux which is the e.m.f. in the neighboring circuit

Designing Methodology:
The typical construction of a transformer consists of an iron core surrounded by steel bands or sheets, which
are well insulated from each other. These are separated and wound around the lim using a lamination coat or
sheet of parchment. Winding consists of two types, primary and secondary winding. These windings are
isolated from each other and are formed by an electric coil.
A source of alternating e.m.f is connected across the ends of the primary coil. The main feature of the core
is to wind up the magnetic flux and provide less lagging direction with the useful flux. For an ideal
transformer, we assume that the resistance of the primary and secondary windings and iron losses are
negligible.
However, in our case (practically) we have to consider and calculate all the losses.

As mentioned, we made three transformers with three different cores (iron, silicon steel & wood). For the
iron core, we simply wrapped 420 turns of 21-gauge copper wire (primary) on the middle leg of the three-
legged laminated core and then 84 turns of 18-gauge copper wire (secondary) windings on the primary
windings. For the silicon steel core, we wrapped 420 turns of 21-gauge copper wire (primary) on the middle
leg of the three-legged laminated core and then 84 turns of 18-gauge copper wire (secondary) windings on
the primary windings.
Similarly for a 31.5 cm of wooden core, 200 primary turns were made on one side and 40 turns on the other
side as secondary in the same manner. The copper wire used in both of them is also 21 gauge for
primary/input side and 18 gauge for secondary/output side.
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Iron Core Transformer

 E’s and I’s made up of iron material.

Silicon Steel Core transformer

 E’s and I’s made up of silicon

steel material.

Wooden Core Transformer

 E’s and I’s made up of wood
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Efficiency and Power Losses:

The following calculations and formulas are for steel sheet transformers as the specific constants required for
these formulas are not obtainable and hereafter the word "transformer" shall refer to steel sheet core
transformers.
The efficiency of a transformer is given by the formula:

It can be calculated either by the following formulas.

Where the losses include hysteresis losses due to the core and heat losses due to the copper wire.
These losses can be reduced by:
Use of thicker wire to reduce coil losses
Separating sheets with higher quality laminations to further reduce eddy currents or use thinner sheets.
Listed below are further calculations regarding the transformer
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Core:
The core used in the made is most similar to the standard M-85a transformer core hence its specifications
were used:
Apparent power rating S= 70VA Voltage per winding = 232 mV/wdg Current density J= 2.9 A/mm^2
Ip = S/220V= 0.31A P = 68.2W
Is = P/24V = 2.8A
So, according to these current values suitable copper wires were chosen as mentioned 21 gauge for the
secondary rated for 6.2amps and 18 gauge which can handle 0.31A comfortably hence windings don’t heat up.

Results:
The results obtained from the three transformers are transcribed

Silicon Steel Core transformer:

Primary Secondary
Voltage Voltage
220V 22V
60V 6.5V

Silicon Steel Core Testing

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Iron Core Transformer Testing:

Primary Secondary
Voltage Voltage
220V 45.2V
60V 12.8V

Wood Core Transformer:

Primary Voltage Secondary Voltage
220V 3V
60V 0V

Conclusion:
In this project we have designed and tested three transformers having different cores with turn ratio ‘a’ equal
to 5. Observing from the above results, a very interesting and practical approach is used which develop a good
concept regarding the transformer working and their efficiency control using different types of cores, which
also increase our understanding the role which a core plays in a transformer, we see for satisfaction, mutual
induction a core with high magnetic permeability is a crucial requirement.
As we expected that there are no heat losses, unfortunately there are some losses. But not very much. Since
this is a normal problem in any winding thing, we can control this heating issue by lubrication of using
Coolant (Oil etc.).