 windings can create a mutual capacitance between the windings. Where transformers are intended for high electrical isolation between primary and secondary circuits, an electrostatic shield can be placed between windings to minimize this effect.
Transformers may also be enclosed by magnetic shields, electrostatic shields, or both to prevent outside interference from affecting the operation of the transformer or to prevent the transformer from affecting the operation of other devices (such as CRTs in close proximity to the transformer). Transformers may also be enclosed for reasons of safety, both to prevent contact with the transformer during normal operation and to contain possible fires that occur as a result of abnormal operation. The enclosure may also be part of the transformer's cooling system.
Small transformers up to a few kilowatts in size usually are adequately cooled by air circulation. Larger "dry" type transformers may have cooling fans.
High-power or high-voltage transformers are bathed in transformer oil - a highly-refined mineral oil that is stable at high temperatures. Large transformers to be used indoors must use a non-flammable liquid. Formerly, polychlorinated biphenyl (PCB) was used as it was not a fire hazard in indoor power transformers and it is highly stable. Due to the stability of PCB and its environmental accumulation, it is no longer permitted in new equipment. Today, nontoxic, stable silicone-based oils or fluorinated hydrocarbons may be used, where the expense of a fire-resistant liquid offsets additional building cost for a transformer vault. Other less-flammable fluids such as canola oil may be used but all fire resistant fluids have some drawbacks in performance, cost, or toxicity compared with mineral oil.
The oil cools the transformer, and provides part of the electrical insulation between internal live parts. It has to be stable at high temperatures so that a small short or arc will not cause a breakdown or fire. To improve cooling of large power transformers, the oil-filled tank may have radiators through which the oil circulates by natural convection. Very large or high-power transformers (with capacities of millions of watts) may have cooling fans, oil pumps and even oil to water heat exchangers. Large and high-voltage transformers undergo prolonged drying processes, using electrical self-heating, the application of a vacuum, or both to ensure that the transformer is completely free of water vapor before the cooling oil is introduced. This helps prevent electrical breakdown under load.
Oil transformers tend to be equipped with Buchholz relays - safety devices sensing gas buildup inside the transformer (a side effect of an electric arc inside the windings) and switching off the transformer.
Experimental power transformers in the 2 MVA range have been built with superconducting windings which eliminates the copper losses, but not the core steel loss. These are cooled by liquid nitrogen or helium.
Very small transformers will have wire leads connected directly to the ends of the coils, and brought out to the base of the unit for circuit connections. Larger transformers may have heavy bolted terminals, bus bars or high-voltage insulated bushings made of polymers or porcelain. A large bushing can be a complex structure since it must both provide electrical insulation, and contain oil within the transformer tank.
Transformer designs Edit
An autotransformer has only a single winding, which is tapped at some point along the winding. AC or pulsed DC power is applied across a portion of the winding, and a higher (or lower) voltage is produced across another portion of the same winding. Autotransformers are used to compensate for voltage drop in a distribution system or for matching two transmission voltages, for example 115 kV and 138 kV. For voltage ratios not exceeding about 3:1, an autotransformer is less costly, lighter, smaller and more efficient than a two-winding transformer of a similar rating.
Variable autotransformers Edit
Variac is a trademark of General Radio (mid-20th century) 