On-site Testing of Power Transformers

Using TDS146
Transformer Diagnostic System
A diagnostic tool for on-site diagnosis of power transformers with on-load tap changer

 The Transformer Diagnostic System is developed by Seitz Instruments AG in Switzerland

for testing power transformers with on-load tap changer.

 The transformer diagnostic system is suitable for pre-failure detection of major

degradation mechanisms and defects of different types of on-load tap changers. Winding
defects can also be found with this Diagnostic System.

Applicability

On-site testing of power transformers with on-load tap changer, typically in transport and
distribution networks above 25kV. The transformer diagnostic system is suitable to test high-
speed resistor type tap changers, both in-tank and compartment type on-load tap changer,
installed in:

 Delta connected windings

 Star connected windings
 Zigzag connected windings
 Autotransformers
 Phase shifters
 Step-up transformers

The TDS146 is used to:

 Monitor the contact condition: condition

based maintenance requires diagnostic
measurements to determine when and
what kind of maintenance is necessary

 Diagnose the power transformer windings

and OLTC in case protective devices
switched off the transformer

 After tap changer maintenance or repair:

 pre-failure detection of
maintenance errors
 find defects that remained
undiscovered during inspection (for
example contact misalignment).
 measure OLTC contact degradation
and winding defects inside the
transformer tank, which are not
visible during inspection.

Onsite application of the Transformer Diagnostic System

 Detection of defects

The TDS146 checks the main functionality of the

tap changer and is able to find defects like:
 Contact deterioration of:
 Selector switch contacts
 Diverter switch contacts
 Tap-selector contacts
 Change-over selector contacts
 Reversing switch contacts
 Coarse change-over selector contacts
 Fixed connections contacts, e.g. due to coking
or overheating.
 Interrupted or damaged transition resistors
 Mechanical friction in the motor drive and
transmission
 Broken or weakened springs
 Winding damage
 Maintenance errors
 Safety contactor for switching time protection
 Weak or damaged drive axis
 Synchronization problems between phases

Visual inspection after DRM measurement of a tap-selector contact which confirms

degradation

Main functionality of the TDS146

1. Tap Changer:
a. Dynamic resistance measurement (DRM)
 Find degradation and defects in the on-load tap changer (contact coking, oil
film layer deposition, arcing contact wear, longer switch times, contact timing
problems, maintenance errors, defect transition resistors, synchronization
problems between phases, etc).
 Find problems in the transformer windings that affect the resistance (due to
internal and external faults or vibrations, open circuits, shipping damage,
insulation defects,
defects defect tap changer positions,
positions incorrect connections)
b. Check contactor for switching time control (if equipped)
c. Position measurement on the OLTC drive axis (for rotor-type OLTC’s with
accessible drive axis)
d. Motor power measurement on the OLTC drive mechanism
 Detect mechanical friction in the drive mechanism, contact binding, longer
motor operation times.
2. Transformer Windings:
a. Transformer turn ratio measurement
I. Find problems in the transformer windings and magnetic core (due to
internal and external faults or vibrations, open circuits, shipping damage,
insulation defects and incorrect connections)
II. Results should be within 0.5%
b. DC winding resistance measurement
I. Find problems in the transformer windings (due to internal and external
faults or vibrations, open circuits, shipping damage, insulation defects,
defect tap changer positions, incorrect connections)
II. Calculate I2R conductor losses
III. Results should be within 1%
Important standards and recommendations

 ANSI/IEEE C57.12.90-1987: American national standard / IEEE Standard Test Code for
Liquid-Immersed Distribution, Power, and Regulating Transformers.
 IEEE Std 62-1995: IEEE Guide for Diagnostic Field Testing of Electric Power Apparatus. Part
1: Oil Filled Power Transformers, Regulators, and Reactors.
 IEEE Std C57.12.37-2006: IEEE Standard for the Electronic Reporting of Distribution
Transformer Test Data.
 IEEE Std C57.140-2006: IEEE Guide for the Evaluation and Reconditioning of Liquid
Immersed Power Transformers.
 IEC 60214: Tap-changers - Performance requirements, test methods and application
guide.
 IEC 60076-1: Power Transformers - Part 1: General

Typical connection of the TDS146 instrument including the optional hardware features to a
power transformer in case the dynamic resistance of the OLTC is recorded, using additional
sensors to diagnose
di the
h drive
d i system. Kelvin
K l i clamps
l are connectedd to the
h transformer
f
bushings. Drive motor voltage and current are recorded at the motor connections, OLTC
control is performed by bridging OLTC control contacts used for manual OLTC control. A
rotation sensor can be placed at the remote end of the drive axis and an OLTC-in-operation-
contact can be measured to check the excessive switch time protection.

Dynamic resistance measurements configuration: a stable test voltage is applied to the

transformer during the charge phase and the tap changer is switched through its cycle of
operation during the measurement
Typical procedure for measurements with the TDS146

Take transformer out of service

Connect TDS146

Connection of cables

Object Definition

Charging

Measurement

Analysis / Reporting

Take transformer back in operation

Flow chart with the measurement procedure of diagnosing tap changers with the TDS146 and
connection of a Kelvin clamp to the transformer bushing

The TDS146 diagnostic instrument connected to the primary and secondary terminals of a
power transformer and remotely controlled by the notebook
User interface for measurements with the TDS146

Firstly,
Fi tl the
th windings
i di are charged
h d with
ith a DC Secondly, the voltage and current are
Secondly
current. recorded while the tap changer is switched
through its cycle of operation

Dynamic resistance results are

standard presented as current
graphs. Results from all three
transformer phases are showed
and a table with switch times is
presented.

Detailed close-up DRM graphs are shown of
each OLTC operation (left) and switch times
are calculated (centre). Average values of
current and resistance are shown in graphs
to make small changes visible (right).
Impedance graphs are calculated based on
the measured current and voltage
difference.
Drive analysis option for the TDS146

Examples of results from mechanical OLTC diagnosis as presented by the transformer

diagnostic system. Close-up graphs of the active drive motor power (left) and remote-end
drive axis rotation (right) during OLTC operation are presented

Typical example of TDS146 application with Drive Analysis option

The transformer diagnostic system connected to a power transformer. Right: example of a

connection for motor voltage and current measurement, using clamps and a clamp-on current
probe (top) and an example of a rotation sensor connection (bottom).
Typical measurement results

Typical example of dynamic resistance results of clean tap changer contacts (top) and service-
aged tap changer contacts (bottom) as measured with the TDS146.

Know the status of the

tap changer and
prevent tap changer failures
Technical data TDS146

Current: max 10ADC

Resistance tests

(winding resistance and dynamic OLTC) Range: 100mΩ-100Ω

Accuracy: ±1mΩ static

±5m Ω dynamic
Measurement of the transformer turn ratio Test voltage: 20V

Range: 1:1 to 1:100

Accuracy: 0.1%
Magnetizing current:
Range: 0-300mA, 50/60Hz
Accuracy:1mA
Phase angle: ±0.5°
Timing of switch time contact Accuracy: 1ms
Auxiliary Voltage available

Drive motor power Voltage range: 0-400VAC, 50/60Hz

Current: Input for current clamp, 10V

Accuracy: ±1W
Driver axis rotation Accuracy: 0.5°
Transformer connection Auto-configuration by relays
OLTC control 2x NO contact, 16A 400V
Operating temperature range 0ºC to 50ºC
Communication with laptop Wireless
Supply voltage 100-250VAC, 50/60Hz
Weight 9.7 kg

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