RESIBLOC

Dry Type Distribution Transformer

250 kVA to 40,000 kVA

Quality Control Test Procedures

 Quality Control Test Procedures

In this document a brief description will be made of the quality control procedures that are used for dry type
distribution and small power transformers in the test room.

The detailed test sequence for a product is based on contractual agreements between the customer and the
manufacturer and upon additional engineering decisions taken during the design stage. This usually involves
various national standards of which many are following the international IEC rules.

Extremely important parts of the test specifications are the criteria for acceptable performance.

Test Categories and Sequences

The tests to be described in this document can be grouped into three main categories:

Routine test: A test to which each individual transformer is subjected.

Type test: A test made on a transformer which is representative of other transformers, to demonstrate
that these transformers comply with specified requirements not covered by routine tests.
These deviations should be subject to agreement between the manufacturer and the
purchaser.

Special test: A test other than a type test or a routine test, agreed by the manufacturer and the purchaser.

The routine tests are listed in the order in which they are normally performed in the test room. This document
will describe only the main features of each test.

1. Routine Tests
1.1 Measurement of voltage ratio and check of phase displacement
1.2 Separate-source AC withstand voltage test (applied voltage)
1.3 Induced AC overvoltage withstand test
1.4 Measurement of no load loss and current
1.5 Measurement of winding resistance
1.6 Measurement of impedance voltage, short-circuit impedance and load loss
1.7 Partial discharge measurement
1.8 Function- and insulation test of control wiring, auxiliary operation, tests on on-load tap changers,
where appropriate

2. Type Tests
2.1 Lightning impulse (LI) test
2.2 Temperature-rise test

3. Special Tests
3.1 Determination of sounds levels
3.2 Determination of capacitances windings-to earth, and between windings
3.3 Measurement of zero-sequence impedance(s) on three-phase transformers
3.4 Measurement of the harmonics of the no-load current
3.5 Measurement of insulation resistance to earth of the windings, and between the windings

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1. Routine Tests

The routine tests include the electromagnetic functions such as winding resistance, voltage ratio, no-load
and short-circuit properties as well as several tests of the insulation system and finally the control functions.

The test sequence is the result of thorough industrial development and long practical experience.

1.1 Measurement of voltage ratio and check of phase displacement

IEC 60076-1: 1993 + A1: 1999, clause 10.3 (IEC 60076-11: 2004, clause 16)

These measurements are made to verify the voltage ratio of the windings, their interconnections and phase
displacement, i.e. vector group. For purposes of measurement, the transformer is exited by a low voltage
(some tens of volts) and, using a null method, comparison is made with an accurate, adjustable voltage ratio
standard.

The observed ratios are accepted if they are within the tolerances of the relevant standard.

All standards which are adjusted to IEC permit a tolerance of 0.5 % of the ordered ratio on the principal
tapping or a percentage of deviation which equals 1/10 of the measured impedance on the principal tapping.

The tolerance for other tappings is to be agreed, but not less than the lessest of the values above.

1.2 Separate-source AC withstand, voltage test (applied voltage)

IEC 60076-3: 2000, clause 11 (IEC 60076-11: 2004, clause 19)

This test will demonstrate the capability of the insulation between windings, and between windings and
structural parts, i.e. earth, to withstand the stresses from specified, sinusoidal power frequency test voltages.

The separate source AC voltage test shall be made with single-phase alternating voltage as nearly as
possible on sine-wave from and not less than 80 % of the rated frequency.

The peak value of the voltage shall be measured. The peak value divided by 2 shall be equal to the test
value.

The test shall commence at a voltage not greater than one-third of the specified test value, and the voltage
shall be increased to the test value as rapidly as is consistent with measurement. At the end of the test, the
voltage shall be reduced rapidly to less than one-third of the test value before switching off.

The full test voltage shall be applied for 60 s between all terminals of the winding under test connected
together and all terminals of the remaining windings, core, frame, and tank or casing of the transformer,
connected together to earth. During this time the voltage and current are observated.

The test is passed if no collapse of the test voltage occurs.

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Common practice acc. IEC 60076-11: 2004 table 3 is to apply the following voltages:

system highest voltage Um (kV) Appl. pot. test voltage (kV)

1.1 3
3.6 10
7.2 20
12.0 28
17.5 38
24.0 50
36.0 70

1.3 Induced AC voltage withstand test

IEC 60076-3: 2000, clause 12 (IEC 60076-11: 2004, clause 20)

In order to demonstrate the capability of the interturn and in-winding insulation to withstand stresses from
specified test voltages this test with induced voltage is performed.

The AC-test voltage from a suitable power source is supplied to one of the winding sets, so that the core is
excited. Consequently, voltages corresponding to the turns ratio are induced in all the windings of the
transformer.

The form of the voltage shall be nearly as possible sinusoidal and its frequency shall be sufficiently above
the rated frequency to avoid excessive magnetizing current during the test. The test shall be commenced at
a voltage not greater than one-third of the test value and the voltage shall be increased to the test value as
rapidly as is consistent with measurement. At the end of the test, the voltage shall be reduced rapidly to less
than one-third of the test value before switching off.

Normal practice (based on IEC) is to apply twice the nominal voltage for 60 sec. In order to avoid
overexcitation of the core, a correspondingly higher frequency is needed for the test voltage.

The test is monitored by observation of voltages and currents. The test is passed if no collapse of the test
voltage occurs.

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1.4 Measurement of no load loss and current
IEC 60076-1: 1993 + A1: 1999, clause 10.5 (IEC 60076-11: 2004, clause 18)

The transformer performance in no load operation is observed to determine the properties of the transformer
core.

The no-load loss and the no-load current shall be measured on one of the windings at rated frequency and at
a voltage corresponding to rated voltage if the test is performed on the principal tapping, or to the
appropriate tapping voltage if the test is performed on another tapping. The remaining winding or windings
shall be left open-circuited and any windings which can be connected in open delta shall have the delta
closed.

Tolerance: + 15 % of the no load losses, provided that the tolerance for total losses (+ 10 %) is not exceeded
(to IEC 60076-1: 1993 + A1: 1999, table 1).

1.5 Measurement of winding resistance

IEC 60076-1: 1993 + A1: 1999, clause 10.2 (IEC 60076-11: 2004, clause 15)

Winding resistances are measured between the phase terminals, in order to verify the continuity of windings,
their correct connections and to create a basis for load-loss.

An important parameter for resistance measurement is the winding temperature. Therefore, it is prerequisite
for good measurement that the winding temperature is stable and known.

The winding resistances are no values, which are guaranteed from the manufacturer to the customer. The
knowledge of the resistance is necessary for calculation of load losses to the reference temperature. And for
determination of winding-temperature during the temperature rise test.

Resistance is determined by DC measurement, either using a voltmeter/amperemeter method or a

resistance bridge method (Wheatstone or Thomson bridge, as applicable) or a digital ohmmeter.

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1.6 Measurement of impedance voltage, short-circuit impedance and load loss
IEC 60076-1: 1993 + A1: 1999, clause 10.4 (IEC 60076-11: 2004, clause 17)

This test serves to determine the transformer impedance and the losses created by currents in the windings
at rated frequency. The short-circuit impedance and load for pair of windings shall be measured at rated
frequency with approximately sinusoidal voltage applied to the terminals of one winding, with the terminals of
the other winding short-circuited, and with possible other windings open-circuited. The supplied current
should be equal to the relevant rated current but shall not be less than 50 % thereof. The measurements
shall be performed quickly so that temperature rises do not cause significant errors.

An important parameter during this test is the temperature of the windings. Therefore, this has to be
stabilized before the test and the test has to be terminated before any noticeable temperature change
occurs.

The measured load–losses and impedance are calculated to the reference temperature at which it is
guaranteed.

Tolerance: + 15 % of the load losses, provided that the tolerance for total losses (+ 10 %) is not exceeded.
For impedance value < 10 %: ± 10 % of the declared value; for impedance > 10 %: ± 7,5 % of the declared
value.

1.7 Partial discharge measurement

IEC 270 (IEC 60076-11, clause 22.4.1.1)

This is a refined, non-destructive technique of tests of the insulation of dry-type transformers. It permits a
more detailed supervision of the insulation than is possible by a simple observation of the complete
breakdown during the induced voltage test. The procedure during this test is similar to that previously
described in clause 1.3 for in-winding insulation with induced voltage. Additional measuring equipment for
observation of high frequency phenomena created by local, non-catastrophic insulation breakdown is
necessary.

Partial discharge measurements are performed at transformers with Um > 3.6 kV.

The partial discharge measurement is the final test of the dielectric tests.

The low voltage winding will be induced by a three or single phase voltage. The form of the voltage shall be
as nearly as possible sinusoidal and its frequency shall be sufficiently above the rated frequency to avoid
excessive magnetizing current during the test.

A pre-stress voltage of 1.8 Un shall be induced for 30 s (Un being the rated voltage for the transformer),
followed without interruption by a voltage of 1.3 Un for 3 min, during which the partial discharge shall be
measured.

The maximum level of partial discharges shall be 10 pC.

The insulation is considered to has successfully passed the test if the partial discharge level was below
specified values. The sensitivity of this test method necessitates very high quality in the high voltage
equipment.

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1.8 Control wiring, auxiliary operation test on on-load tap-changers, where appropriate
IEC 60076-1: 1995 + A1: 1999, clause 10.8.1+2

This test verifies the proper function and the integrity of insulation of the control and auxiliary system.

For the test, the control system insulation is exposed to a specified test voltage (IEC 60076-3: 2000, clause
10). During the test, ordinary operation of the control system is executed as weIl as applicable sequence
checks.

If the transformer is equipped with an on-load tap changer the tap changer is operated over its full range and
the performance of its control gear, including voltage measuring equipment if any, is verified. (IEC 60076-1:
1993 + A1: 1999, clause 10.8.1)

The performance is considered acceptable if the insulation withstands the test voltage and the equipment
operates properly.

2. Type Tests

These are tests that are performed only when agreed upon as part of the contract between customer and the
manufacturer. Each of the tests can be agreed upon separately.

2.1 Lightning impulse (LI) test

IEC 60076-3: 2000, clause 13 (IEC 60076-11: 2004, clause 21)

This test serves to verify the capability of the insulation to withstand the stresses from a standardized voltage
impulse applied at the winding terminal. The standardized lightning impulse insulation test is the result of
considerable industrial experience and research. It is a good, practical representation of stressness on the
insulation, created by atmospheric overvoltages induced in power line systems.

The voltage impulse is created by the discharge of a capacitor bank into a suitable network connected to the
transformer terminal.

Refer to clause 12 of IEC Publication 76-3.

The test voltage shall be in accordance with List 1 or List 2 of Table V, for the specified insulation level of the
transformer.

The test impulse shall be a full standard lightning impulse:

Typical 1.2 µs ± 30 % front time and 50 µs ± 20 % time to half value.

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The test voltage shall normally be of negative polarity. The test sequence per line terminal shall be one
calibration impulse at a voltage between 50 % and 75 % of the full voltage followed by three impulses at full
voltage.

In dry-type transformers, the lightning impulse test can give rise to capacitive partial discharges in the air
which do not endanger the insulation. These partial discharges lead to changes in the current waveform,
whilst the voltage waveform varies only slightly or not at all.

The shape of the full amplitude impulse is carefully compared with the shape of the reduced amplitude
pretest. Good similarity in the shapes indicates that the insulation has successfully withstood the test.
Additional information regarding the insulation can be obtained by analysis of oscillograms of the current in
one of the windings.

Common practice acc. IEC 60076-11: 2004, table 3

System highest voltage Impulse voltage BIL (LI) KV

Um (kV) List 1 List 2
1.1 - -
3.6 20 40
7.2 40 60
12.0 60 75
17.5 75 95
24.0 95 125
36.0 145 170

2.2 Temperature-rise test

IEC 60076-2: 1993 (IEC 60076-11: 2004, clause 23.2.1)

This test is made to verify the thermal design of the transformer including the capability of its cooling
equipment. The temperature rise test for dry type transformers is made according to the simulated load
method, which consists of two tests.

During the first one the transformer is connected as described in clause 1.4 for the no-load test until the
transformer core has reached a steady state or is in the direct vicinity. The winding temperature rises ( No
Load) are then measured. The windings are heated by a thermal flow coming from the core.

The second test ( Load Loss) is carried out in short circuit operation like the impedance and load loss test
described in clause 1.6 with the rated current circulating in both windings.

The ultimate temperature rise is reached when the temperature rise becomes constant; this is considered to
be achieved when the temperature rise does not vary by more than 2 % of the permissible temperature rise
per hour or 2 K per hour, whichever is the smaller one. After disconnection, the winding resistance is quickly
and repeatedly measured in time sequences.

The results are then extrapolated backwards in time to the disconnection moment and serve as a
thermometer for determination of the winding temperatures.

If there are more than two windings the test procedure has to be agreed.

Finally the temperatures of both temperature rise tests are added according to a special formula laid down in
the IEC 60076-11:2004, clause 23.2.1

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If the tapping range is within ± 5 %, and the rated power not above 2500 kVA, temperature rise refer to the
principal tapping only, and the temperature rise test is running on that tapping. If the tapping range exceeds
± 5 % or the rated power is above 2500 kVA, temperature rise refer to the maximum current tapping (which
is usually the tapping with the highest load losses), and the temperature rise test is running on that tapping.

3. Special tests

Special tests are tests other than a type test or a routine test, agreed by the manufacturer and the purchaser.

3.1 Determination of sounds levels

IEC 60076-10: 2001 (E) (IEC 60076-11: 2004, clause 24)

This test will verify the audible sound created by the transformer and its cooling equipment if applicable. As
the audible sound from a transformer is essentially created by magnetostrictive effects in the core, the test is
executed with the transformer excited in no-load operation and with rated frequency as previously described
in clause 1.4.

The test area has to be carefully chosen with respect to surrounding walls, buildings, etc., that may reflect
sound in an unfavourable manner.

For measurements made with forced air cooling auxiliaries (if any) out of service, the prescribed contour
shall be spaced 0.3 m away from the principal radiating surface unless, for safety reasons associated with
dry-type units without enclosures, 1 m is chosen.

For transformers with a height of < 2.5 m, the prescribed contour shall be on a horizontal plane at half the
tank height. For transformers with a tank height > 2.5 m, two prescribed contours shall be used which are on
horizontal planes at one-third and two-thirds of the height unless, for safety reasons, a lower height is
chosen.

The microphone positions shall be on the prescribed contour(s), approximately equally spaced and not more
than 1 m apart. There shall be a minimum of six microphone positions.

As agreed between manufacturer and purchaser at the time of placing the order, the sound level will be
described as sound pressure- or sound power level.

The allowed value of sound pressure- or sound power level is an agreement between manufacturer and
purchaser.

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3.2 Determination of capacitances windings-to-earth and between windings

The purpose of the measurement is to determine the capacitances between the windings and the earthed
parts and between the different windings of the transformer.

The capacitance values are needed when planning transformer overvoltage protection and calculating the
overvoltages affecting the transformer. In addition, the results are used by the manufacturer for design
purposes.

All line terminals of each winding are connected together during the measurement. The winding
capacitances of a two-winding transformer are shown on the following figure.

Core LV HV housing

C1 C2 C3

3.3 Measurement of zero-sequence impedance(s) on three-phase transformers

IEC 60076-1: 1993 + A1: 1999, clause 10.7

The zero-sequence impedance is usually measured for all star-connected windings of the transformer. The
measurement is carried out by supplying a current of rated frequency between the parallel connected phase
terminals and the neutral terminal.

The zero-sequence impedance per phase is three times the impedance measured in this way.
The zero-sequence impedance is needed for earth-fault protection and earth-fault current calculations.

J J/3 J/3 J/3

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3.4 Measurement of the harmonics of the no-load current
IEC 60076-1: 1993 + A1: 1999, clause 10.6

At applied sinusoidal voltage shows the part of magnetization-current of the no-load-current harmonics,
caused of the cured magnetization characteristic. The wave of the resultant no-load-current is distorted.

It is possible that the current-harmonics cause voltage-distortion in the network. Disturbances in electrical-
installation and equipment could be caused by this voltage- and current harmonics.

However in general the harmonics interests are covered to the nominal current of the transformer smaller
than 1 % and therefore, for the transformers operator usually without importance meaning.

The measurement is performed with a special harmonic analyzer during the no-load-measurement.

3.5 Measurement of insulation resistance to earth of the windings and between the windings
IEC 60076-1: 1993 + A1: 1999, clause 10.1.3.i

The purpose of the measurement is to determine the leakage current resistance of the insulation. The
insulation resistance, as measured at a constant voltage difference across the insulation, depend on the
strength of the electric field during the measurement and thus on the size and construction of the
transformer. This measurement gives information about the condition of the insulation and secures that the
leakage current is adequately small.

The insulation resistance is measured by means of an insulation resistance meter at a voltage of 5000 V DC.
Each winding is measured separately by connecting the voltage between the windings to be tested and
earth, while the other windings are earthed. The resistance readings R15 and R60 are taken 15s and 60s after
connecting the voltage.

K (core) US LV OS HV

R R R

LV - K HV - LV HV - K

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 1LDE000018 08/2005

ABB AG
Transformers
An der Bremecke 1
D-59929 Brilon
Telefon: +49 29 61 7 97-0
Telefax: +49 29 61 7 97-2 90 11