Designing and Constructing Transformer Test System with aid of Labview

A.Emami, Member, IEEE, H. Tabatabaei Yazdi

AbstractThis paper describes the developments, and the practical implementation of on-line real-time testing system for three/single phase Distribution Transformers. To achieve this goal, a GUI (Graphical User Interface) program is developed by means of LabVIEW software. This implementation is also suitable for performance evaluation, efficiency testing, real-time on-line condition monitoring and protection of transformers with any type of design, size and characteristics. The new constructed transformer testing system takes into account the transformer parameter variations due to changes in electric supply, temperature, saturation and load. The described system is based on using a fast real-time computer based data acquisition system to measure, record and analyze the necessary parameter determination data such as current, voltage, power, frequency and temperature accurately and dynamically whilst testing the transformer. This system substantially reduces the testing time and saves energy while at the same time achieves higher accuracy compared with conventional transformers testing methods. Index Terms Medium-voltage transformer, Real time, GUI, LabVIEW

I. INTRODUCTION

istribution transformers are important components in the electric power system. The knowledge of the actual status of transformer e.g. turn ratio, insulation behavior, load tap changer performance, temperature, load loss, etc. is necessary in order to evaluate the service performance concerning reliability, availability and safety. So, the routine tests of transformers have an important role to reach these goals. These tests should be made on a transformer to ensure that it is ready for service, and to provide a basis for comparison with future maintenance tests. Typically, all or any portion of routine tests may be made, depending on the equipment available and importance of particular transformer [1]. In accordance with the requirements of IEC76 or ANSI/IEEE C57, all manufactured transformers are subject to the following seven routine tests in order to ensure that they meet the guarantee performance [2][4]. These are: 1) No-Load loss test and excitation current 2) Impedance voltage and Load loss test

Manuscript received June 14, 2009; revised September 29, 2009. A. Emami is with the Electrical Engineering Department, Ferdowsi University of Mashhad, Mashhad, Iran ( phone:98-9155052090;fax:98-5117611419;e-mail: mami112@hotmail.com). H. Tabatabaei is with the Electrical Engineering Department, Ferdowsi University of Mashhad, Mashhad, Iran. (e-mail: h.tabatabaei@theiet.org).

3) Resistance measurements of all windings on the rated voltage tap and at the tap extremes of the first unit made on a new design 4) Ratio test on the rated voltage connection and on all tap connections 5) Polarity and phase relation tests on the rated voltage connection 6) Induced over voltage withstand test 7) Applied voltage test Using this system all of the above mentioned tests can be carried out, with the help of the GUI program created to simply perform these tests in real-time. The comparison of the experimental results with the results which is obtained using traditional method shows the accuracy and many advantages of the new computerized testing system. The project's main objective was also to create a Microsoft Windows' application for running these tests and also to analyze the results of the tests for both single-phase and threephase transformers. Besides, another objective was also to build a transformer testing prototype, to interface a PC with measuring meters, to build a database for the storage, management and analysis of all testing data. The transformer analysis program is written in LabVIEW (Laboratory Virtual Instrument Engineering Workbench) for windows XP (all versions). Its tasks are to automate the testing of transformers, to perform an analysis based on the test results, to store these results and to generate results report. Test data acquired through PCI-1710HG card made by Advantech Corporation will be displayed on the PC screen. Analysis of the transformer's performance is carried out by means of efficiency curve, voltage regulation and equivalent circuit. The tests are based on either the (IEC76, BS 17 1) or (ANSIC57) standards depending upon the user's preference. The test results are stored in a database for future retrieval. This database is created with LabVIEW. A report on the test results can also be produced on a preferred format such as Microsoft Word. This paper presents development of a prototype with a windows-based graphical user interface (GUI) to facilitate the on-line process of the distribution transformers tests and also to perform an analysis on the test results. The platform is Intel Pentium 4 (or its equivalences) PC, with Windows XP (all versions) II. SYSTEM OVERVIEW Considering the merits of object-oriented programming feature and compatibility with other Microsoft products,

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National Instrument's LabVIEW is chosen as the programming Language. In order to explain the advantages of LabVIEW it is worth noting these points. At first, National Instruments LabVIEW software development package provides both the flexibility of high-level textual languages and the simplicity of graphical programming. Indeed, Products such as Visual C++ and Visual Basic have general purpose functionality, but they are not truly graphical languages. Secondly, automatic memory management is also one of the most valuable built-in features of LabVlEW. The developer is freed from the tedious task of allocating, managing, and deallocating system memory. LabVIEWs sophisticated memory management algorithms determine when resources should be surrendered and when allocated memory buffers can be reused by other portions of the program [3]. Finally, LabVlEW has excellent execution speed. Though a LabVlEW front panel and diagram may appear complex, the LabVlEW code generator can produce highly efficient machine executable code. On some platforms like the Intel processor family, the target microprocessor is well evolved and well-understood -- so much so that LabVlEWs code generator is hand-tuned to exploit certain machine-specific features. The resulting machine code is optimized and it can out-perform conventional C-based compilers in some situations [3]. The data acquisition card used to convert the signals from the sensors and meters is PCI-1710HG. This data acquisition board has 16 single ended or 8 differential analogue inputs multiplexed to a 12-bit A/D converter with maximum throughput of 100 kHz. It also has 16+16 lines of TTL level digital I/O that are useful for automated controlling and monitoring of the transformer test system [5]. Fig.1 illustrates the simplified block diagram of the test system used for on-line transformer test and analysis prototype, which is created for both semi-automatic and automatic testing.

Then the user will be able to view and print data of the tested transformers through the browse and search features available from developed program pull-down menu. Here, all the routine tests of transformer can be computerized, that is, when one of the routine test is started, computer take the control of the test ,and in this way, it does not require any one to control the operation of the test and save the data and process it. In this paper all of the tests that were mentioned in introduction section are classified into five main steps. This classification is done with regard to capability of new system test and some similarities in circuit test among several tests: Step 1) In this step resistance winding test is performed on each transformer winding and the values of voltage and current of the test are sensed with sensors and are sent to computer for obtaining the final results. Step2) In this step the transformer is connected to the nominal voltage, and then the computer program acquire the voltage and current values of primary and secondary of transformer through the meters and sensors in about several seconds. Consequently, the program calculates and processes all the acquired data to give the required test results for three tests. Namely: no-load loss, turn ratio, polarity and phase relation (vector groups). Step 3) In this step applied voltage test is performed on the transformer and the values of voltage and current are sensed, monitored and saved easily with computer. Step 4) In this step induced voltage test is performed on the transformer and the values of voltage and current are sensed, monitored and saved easily by computer. In addition, because of using computer and data acquisition card, here, it is not necessary to utilize frequency meter to obtain the frequency. Step 5) In this step load loss test is performed on the transformer and the values of voltage and current are sensed and sent to computer for final calculation. III. GUI DESIGN A. Windows programming using LabVIEW Selecting a software development environment can be the most crucial decision made during the design phase of a new project. Many things must be considered in the selection process. The language should be flexible enough to develop general-purpose applications and, simultaneously, powerful enough that developers working at the application level can quickly and simply assemble software components, rather than drudge through tedious low-level functions and data. The National Instruments LabVlEW software is an ideal tool for rapid development of graphical user interfaces in the test area. Once the basic capability to acquire data through the PCI1710HG system was established through a virtual control panel, the remaining application software could be developed independently of hardware installation and check-out. Preliminary versions of the LabVlEW code were installed at the customers site in order to review the status of the effort and to gather user feedback. Simple changes to the placement of buttons, colors, text strings, etc. could be rapidly implemented at the customers site according to user requests.

Fig. 1. Block diagram of on-line transformer test system

After the completion of each test, TEMWIN, the name of GUI program, will start analytical computation. The user can view efficiency curve, the voltage regulation curve and the equivalent circuit of the transformer as well as results obtained from each test mentioned above. The program will also store all transformer specifications and test results in a database, which is created using LabVIEW report generation functions.

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User input was effectively integrated into the development of the application, thus allowing final acceptance testing of the system to proceed more quickly. B. Database management system in TEMWIN With its built-in data storage and retrieval routines, LabVIEW makes database management simpler. It enables a user to manipulate databases and to build applications that serve as front-ends to many of the popular database formats. LabVIEW implements data access by incorporating the database engine of Microsoft Access. As a result, it gives user access to many standard database formats. Any existing database created in one of these supported formats like Microsoft word and Excell, can be manipulated by LabVIEW. It is obvious that creating such reports allows a user to browse entirely through all records to look at the transformer data. Each transformer has an order number. When a database file is opened, the window will display all the transformer order numbers from that file in a vertical column. The user will thus know how many records exist in the file. The user can view whatever transformer information by clicking the appropriate checkboxes at the top of the window. Subsequently, the program retrieves all the corresponding information from the database and displays them in a spreadsheet-like form. A 'nil' displayed in any cell indicates that the particular data is not available from the database. C. Software implementation The software is divided into six main taps (windows), namely step1 (resistance test), step2 (noload, phase relation and turn ratio test), step3 (applied voltage test), step4 (Induced voltage test), step5 (short circuit test) and setting. Each of the first five taps in the program is responsible for performing and displaying one part of the three phase routine tests. In the last tap user should enter primary information and initial values of the transformer is due to be tested. In fig.2 this window has been shown. Operator determines whether program works automatically or semi-automatically. This action can be done via buttons on the control console. In the automatic version of the program, five mentioned steps are automated. That is, when user push the start button in each step window, program set one bit of PCI-1710 HG digital output port and ,as a result connect one of the corresponding feeding keys of transformer is to be tested. To protect PCI-1710HG digital port from over current an I/O interface card has been built in the project to activate the control console remotely from the PC. All the meter readings are retrieved via the analogue input of PCI-1710HG card. The testing voltage/current is adjusted through a window button. In the semi-automatic version, the testing voltage is adjusted through the control console. Therefore, the developed program just stores and analyses the readings and does not have any role in connecting, disconnecting and adjusting testing voltage. Both versions use the same graphical interface for all the routine tests, computation and analysis of results and data management such as saving and sorting of test results.

It is worth noting that for the routine tests of a single phase transformer the same functions as the three phase routine tests program is performed except for it is applicable only to single phase transformer. The setting window in Fig. 2 is an interface for user to enter transformer's specifications, such as current limits, voltage limits, rated power and rated voltage. It also provides an option of IEC76, or ANSI C57 standard that the routine tests will be based on. Fig. 3 is the window of step1 test consists of DC resistance measurement test for rated tap 1. In this windows operator can witness voltage and current and temperature in real-time. There are also two options for determining winding connection of primary and secondary windings of transformer and their voltage levels (high voltage or low voltage). The resistance value of each transformer winding is measured and displayed immediately after operator chooses each of them. One of the unique features of this program is, for each defined step, a schematic of test circuit and a quick manual (help) is provided. This feature has a noticeable effect on dominance of user to work with program.

Fig. 3. Step1 test window

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The commencement of the automatic Step2 test begins when the 'Connect' button in Fig. 4 is clicked. After checking the devices which are connected, the program will turn on 3 lamps showing program is ready to test, and then the user should click the Start button to begin the measuring process. This test just takes 3 seconds. The results of this step cover the results of several test results as it is expressed in the previous sections. With respect to high speed sampling, vector group of a transformer can be calculated and depicted easily. Fig. 8(section IV) illustrates a vector group diagram for a transformer which has been under test.

transformer windings.

Fig. 6. Step4(Induced voltage test)window

Fig. 4. Step2(no-load, turn ratio& Vector group) test window

Similarly, Fig. 5 gives a snapshot of the step3 test, where the elapsed time, injecting voltage and current supply are monitored. In addition, it is provided a control volume by which user can control the input voltage value.

Fig. 7. Step5(load loss test)window

Fig. 5. Step3(Applied voltage test)window

Fig. 6 and fig. 7 are step4 (Induced voltage test) and Step5 (load loss test) windows, respectively. According to what is stated for Step2 test these windows also have several buttons for starting the process of tests, circuit diagram and quick manual. In step 4 test measuring the values of elapsed time, frequency and RMS of input voltage and current are crucial. So, there are displayed in real-time on the described windows. In step 5 like step 3 there is volume for adjusting input voltage and consequently the currents flowing through

Fig. 8. Vector group diagram for 160KVA transformer

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TABLE III HV SIDE MEASUREMENT

D. Test reports The printing of hardcopies of all test results is done through a utility program called NI LabVIEW Report Generation, available in the LabVIEW. To create a report in this established program, an existing database is required to provide all the necessary data to the report. Once the report is created, it can then be incorporated in the program. The printing destination can either be a printer, a file or a window. Moreover, LabVIEW also has some toolkits (special package programs) that bring facilities for programmer to create report in a desired format such as Microsoft Word and Excel. While printing to a printer, a user should select a driver that suit the hardware configuration. While printing to a window, a user could have a preview of the test report before it is send to the printer. IV. A CASE STUDY

Phase UV VW WU

Voltage 12.25V 12.04V 12.08V

Current 1.11A 1.10A 1.10A

R(@ 15C) 11.036 () 10.98 () 10.94 ()

TABLE IV HV SIDE CALCULATION Phase U V W R (@ 15C) 16.63() 16.46() 16.34() R (@ 75C) 20.62() 20.41() 20.26()

C. Test result for Step2 test

TABLE V TURN RATIO MEASUREMENT UV/un VW/vn 44.40 46.183 48.11 43.98 45.75 47.70

Tap

WU/wn 45.77 47.62 49.56

A. Transformer specifications: ANSI C57 Type N90 Cooling ONAN Winding material Secondary - Copper Vector group Dyz5 Rated power 160KVA Primary rated voltage 11000V Secondary rated voltage 400V No. of Taps 3 Rated Tap2 Primary Copper B. Test result for Step1 test
TABLE I LV SIDE MEASUREMENT Phase uv vw wu Voltage 53mV 45mV 52mV current 2.63A 2.66A 2.63A TABLE II LV SIDE CALCULATION Phase u v w R (@ 15C) 0.01135() 0.00875() 0.00835() R (@ 75C) 0.0141() 0.0108() 0.0103() R(@ 15C) 0.0201 () 0.0171 () 0.0197 ()

1 2 3

Phase uv vw wu

TABLE VI NOLOAD TEST MEASUREMENT Voltage Current 394.70V 394.55V 392.53V 4.58A 5.58A 5.91A

Power 470.1Watt 50.51Watt 52.79 Watt

Tap 2

TABLE VII NOLOAD TEST CALCULATION Average Current Total power Average turn ratio 5.36 A 573Watt 46.52

Current (%) 2.32

D. Test result for Step3 test

TABLE VIII APPLIED VOLTAGE TEST RESULT Applied voltage HV side 25kV

Current 23mA

E. Test result for Step4 test

TABLE IX INDUCED VOLTAGE TEST RESULT Voltage Current 790.54V 790.3V 787.66V 11.47A 13.68A 14.93A

phase uv vw wu

frequency 99.85 Hz 99.9 Hz 99.81 HZ

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F. Test result for Step5 test

TABLE X
LOAD LOSS RESULTS @ 65% RATED CURRENT

Tap 2

Phase UV VW WU

Voltage 280.83 286.56 278.26

Current 5.5 5.66 5.44

power 487.45 506.09 451.42

Tap 2

TABLE XI CALCULATED LOAD LOSS RESULTS FOR 100% RATED CURRENT Average voltage Voltage (%) Current Total Power 427.66V 3.9 8.39A 3325.11Watt

V. HARDWARE DESIGN AND IMPLEMENTATION A testing circuit is built up to perform the routine tests, mainly to perform the DC resistance, no-load ,turn ratio, phase relation(vector group), applied voltage, Induced voltage, load loss tests. The circuit is depicted in Fig. 1, a control console comprising several motor driven auto-variable transformers, meters and sensors. The control console provides an interface between the input supply and the under test transformer. It is equipped with push buttons, indicating lamps, fuses, contactors, voltage meters, current meters and power meters. Various safety features are taken into consideration during designing the final circuit, to provide users a hazard free testing environment. Fig. 9 is a photo of the front panel of control console in transformer laboratory. Figure 10 shows portions of circuits within control console.

Fig. 10 portions of circuits within control console

VI. CONCLUSION In conclusion, transformers are important components in power system and consequently, quality and precision of tests which must be made on them can have a determining role in reliability and stability of them in a power system network. Hence, this transformer test system is designed and implemented. The most momentous and outstanding part of this system is the GUI program. This computer program brings some advantages for the user. For instance, it extremely saves time and energy and decreases the destructive effects causes from a particular test due to prolonging the time of performing the test by speeding up the test. It also provides high accuracy in results of tests by eliminating human mistakes. In addition, the developed GUI interface is really user-friendly and satisfies the specifications and standards set by industry. TEMWIN and its accompanying control console and sensors are now installed at PICHESH-SIM TOOS Company in Mashhad, Iran for implementing routine tests on Distribution Transformers. REFERENCES
[1] American National Standard guide for installation of oil-immersed transformers (10 MVA and larger , 69 287 kV rating), ANSI/IEEE C57.12.11, 1986.. General Requirements for Liquid Immersed Distribution , power , and Regulating transformers, IEEE Std C57.12.00(R2000).. K.Fertitta and B.Meacham, Developing portable test program sets in a graphical design environment, in Proc.IEEE Autotestcon, CA, USA,Sep. 1997, pp. 475-487. Power Transformers-part I: General, IEC Std, 2002. Advantech Technical Staff, PCI-1710 series Users Manual, NJ: Advantech Corp., 2005.

[2] [3]

[4] [5]

Fig. 9 Front of the designed control console for the transformer testing system

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