TESTING OF TRANSFORMER

The objective of testing is

To ensure quality
To ensure that the products manufactured have met
the requirements of Customer Specification/Standard
To prevent accidents which may occur if a failed
product is put into service.
To ensure that the product is fit for its intended use

STANDARDS
IEC Standards
IEC 60076 (Part 1- Part 14)- Specification for Transformers
IEEE / ANSI Standards
ANSI/IEEE: C.57.12.00 -- General requirements for oil filled power &
distribution transformers
ANSI/IEEE: C.57.12.01-- General requirements for Dry type power &
Distribution Transformers
ANSI/IEEE: C.57.12.20 Specification for Overhead type distribution
Transformers 500 kVA and smaller & HVVoltage-67000 V and below, Low
Voltage-15000V and below.
ANSI/IEEE: C.57.12.90 Standard test code for oil immersed power &
Distribution Transformers and short circuit testing of power & distribution
transformers.

SAFETY PRECAUTIONS
Cordoning off the test Area.
Display of Danger boards.
Indication Lamps.
Use of Hand gloves and safety shoes.
Entry of unauthorized personnel to be restricted.
Discharge the transformer after high voltage test.
Earth resistance.

PREPERATION FOR THE TEST

Earthing connection should be rigid to the transformer.
Check for oil level
Release air from the Buchholz Relay and the bushings.
Clean the bushings with non-fibrous dry cloth.
Ensure that all connections are tight
Cables and shorting links should be of sufficient cross section.
Ensure that the ranges of all instruments are correctly chosen.
Ensure that the connections are made as per the circuit diagram.
Ensure that all instruments are properly earthed.

TESTS
Type tests -- For design validation

Sample: Only on Proto type

Routine tests -- Performed to ensure that a product is
manufactured as per the design specification and is free
from manufacturing defects.
Sample: 100 %

TESTS
Special tests -- To check whether the product meets any
special requirements of the customer specification and
also to know the bench mark values for preventive
maintenance and trouble free operation
Sample: Some tests on sample quantity.
Some tests on 100 % quantity.
Acceptance test -- Performed during customer inspection
on samples selected at random.

TESTS ON TRANSFORMERS.
Type Tests.
Measurement of insulation resistance test.
Measurement of winding resistance
Measurement of voltage/Turns ratio
Vector group/polarity check
Measurement of no-load Loss and no load current
Measurement of impedance voltage, short circuit impedance and
Load Loss.
Induced over-voltage withstand test.
Separate source voltage withstand test.
Temperature Rise Test
Lightning Impulse Voltage Withstand Test.
Dynamic and thermal ability to withstand Short circuit test

TESTS ON TRANSFORMERS.
Routine Tests.
Measurement of Insulation Resistance.
Measurement of winding resistance.
Measurement of voltage/Turns ratio.
Vector Group/Polarity check
Measurement of No-load Loss and No load current
Measurement of impedance voltage, short circuit
Impedance and Load Loss.
Induced Over-Voltage Withstand Test.
Separate Source Voltage Withstand Test.

TESTS ON TRANSFORMERS.
Special Tests
Measurement of Capacitance and Tan
Delta.
Measurement of Zero Sequence Impedance
Measurement of Acoustic Noise Level
Measurement of Partial Discharge.
Measurement of Unbalance Current.

ROUTINE TESTS
Measurement of Insulation Resistance.

Purpose:
To ensure proper dry ness of the active parts.
To ensure sufficient clearance between the windings and between
winding and earth.
Instruments
Insulation Tester/Megger (Hand driven/Battery operated)
Connecting Cables.
Procedure
Check the IR Value between HV and LV.
Check the IR Value between HV and earth.
Check the IR Value between LV and earth.

ROUTINE TESTS
Polarization Index
I = Ic + Ia + I lc + I ls
I: Total leakage current seen by the meggar
Ic: Charging Current of the capacitance
Ia : Dielectric absorption current
I lc : Conduction leakage current through the insulation
I ls : Surface leakage current.
IR Value at 600th Second
Polarization Index = ------------------------------IR Value at 60th Second

ROUTINE TESTS
Measurement of Voltage/ Turn Ratio
Purpose: To ensure correct number of turns in different windings.
Instruments:
Single Phase Auto Transformer
Voltmeter/Multimeter
Ratio meter
Connecting cables.
Procedure:
1. Voltage Method:
Apply any convenient A.C Voltage say about 200 V on HV winding and measure the
Voltage at LV winding.
Calculate the Ratio of HV Voltage to LV Voltage and calculate % Error comparing
with the specified value

Specified Ratio Actual Ratio

% Ratio Error = -------------------------------------- X 100

Specified Ratio
2. Ratio Meter method:
Use Turns Ratio meters to get the Ratio / % deviation directly.

ROUTINE TESTS
Polarity test
Purpose:
To check the polarity of single phase transformers
Instruments:
Single phase Auto transformer
Voltmeter / Multi meter.
Connecting Cables
Procedure:
Short H1 of the HV winding to the adjacent terminal X1of the LV
winding.
Apply any convenient A.C Voltage say about 100 V on HV Winding
H1 and H2
Measure Voltage between H2 & X2
Conditions:
If H1 H2 < H2 X2
Additive Polarity.
If H1 H2 > H2 X2
Subtractive Polarity.

ROUTINE TESTS
Vector Group Verification
Purpose:
To check the Vector Group of three phase transformers
Instruments:
Three phase Auto transformer
Voltmeter / Multi meter.
Connecting Cables.
Procedure:
Short 1U of HV winding to the terminal 2u of LV winding.
Apply any convenient 3 phase A.C Voltage say about 400 V on HV winding.
Voltages 1U-2n, 1V-2n, 1W-2w, 1W-2v, 1V-2w and 1V-2v are measured
Check whether the Voltages measured are satisfying the conditions for respective
vector group.
Conditions for Dyn 11:
1V-2w = 1V-2v
1W-2w < 1W-2v
1U-2n + 1V-2n

ROUTINE TESTS
Measurement of Winding Resistance
Purpose:
To calculate I2 R loss of the winding.
Proper crimping, brazing and other connections can be ensured.
Whether conductors used in winding are as per the designed cross section or
not can be verified.
Instruments:
Transformer Winding Resistance meter / Ohm meter.
Kelvin Bridge / Wheatstone Bridge
Connecting Cables
Procedure:
Record the top oil temperature of the transformer.
Connect current cable and potential cable of the instrument to the winding
under test.
Switch on the instrument and record the reading displayed by the instrument.
Convert the Resistance value to the reference temperature
Compare with the design value.

ROUTINE TESTS
Measurement of No load loss and No Load Current
Purpose:
To assess the efficiency of the transformer.
To estimate energy loss in the transformer.
High no load current is an indicative of inter turn/inter layer insulation
failure
Instruments:
Auto Transformer
Voltmeters, Ammeters, Watt meters and Frequency meter / Digital Power
Analyzer.
Connecting cables.
Procedure:
Make the connections as per the circuit diagram.
Keep the HV winding open circuited
The LV is supplied with a single/three phase, reasonably sinusoidal
voltage equal to rated voltage and rated frequency.
Record the no load current and no load loss.
Compare with the guaranteed values.

ROUTINE TESTS
Measurement of Load Loss and Impedance.
Purpose:
To assess the efficiency and regulation of the transformer
To estimate the energy loss in the transformer
Instruments:
Auto Transformer
Voltmeters, Ammeters, Watt meters / Frequency meter Thermometer /
Digital Power Analyzer.
Connecting cables/ Shorting links
Procedure:
Make the connections as per the circuit diagram.
Keep the LV winding short circuited
Inject rated current on the HV winding.
Record the Load loss and Impedance Voltage.
Record the top oil temperature.
Convert the load loss and impedance to reference temperature.
Compare with the guaranteed values.
Calculate efficiency and regulation for various load and power factor.

ROUTINE TESTS
DIELECTRIC TESTS
These tests are to be conducted only after all other tests are conducted
successfully.
High Voltage Power Frequency Withstand test.
Purpose:
To ensure sufficient clearance between the windings and between
winding and earth.
To check the adequacy of main insulation to earth and between
winding
Instruments:
High Voltage Test set

Procedure:
Short all line terminals of winding under test.
The line terminals of the other winding and the tank are connected
together to earth.

ROUTINE TESTS
DIELECTRIC TESTS
Appropriate test voltage as required by the applicable standard is
applied to the winding under test for 60 seconds.
After completion of the test, the transformer is discharged.

ROUTINE TESTS
DIELECTRIC TESTS
Induced Over Voltage Withstand Test
Purpose:
To check adequacy of inter turn/inter layer insulation
Instrument:
High frequency Motor-Generator Set.
Connecting Cables.
Procedure:
Make the connections as per the circuit diagram.
Keep the HV winding open circuited
The LV is supplied with a single/three phase, reasonably sinusoidal
voltage equal to twice the rated voltage at twice the rated frequency
for 60 seconds.

ROUTINE TESTS
DIELECTRIC TESTS
If the frequency is more than the double the rated
frequency, the duration is reduced as per the formula
given below.
120 X Rated Frequency
Duration = -----------------------------Test frequency
After completion of the test, the transformer is
discharged.

TYPE TEST
Temperature Rise Test
Purpose:
To confirm that the temperature rise of the windings and oil does not
exceed the specified limits under normal service conditions.
Instruments:
Auto Transformer
Voltmeters, Ammeters, Watt meters, Thermometers, Current
Transformers and Potential Transformers.
Connecting cables/ Shorting links
Procedure:
Direct loading method
One winding of the transformer is excited at rated voltage while the
other is connected to a suitable load such that the rated currents flow
in both the winding.

TYPE TEST
Temperature Rise Test

Back to back method

Two Transformers, one of which is the transformer under
test, shall be connected in parallel and excited at the rated
voltage of the transformer under test. By means of
injected voltage, rated current shall be made to flow in
the transformer under test.

TYPE TEST
Temperature Rise Test
Short Circuit method:

Measure cold Resistance

Make the connections as per the circuit diagram.
Keep the LV winding short circuited
The HV is excited such that the total losses are fed to the transformer
Maintain hourly record of ambient temperature, top oil temperature, and
readings of all ammeters, Voltmeters and Watt meters and observe increase in
top oil temperature rise.
Maintain this condition till the top oil temperature rise stabilizes.
Once the stability is reached, reduce the supply to make the current equal to
rated current and maintain for one hour.
Switch off the power supply and measure the hot resistance.
Extrapolate the hot resistance back to zero so as to get the resistance of the
winding at the time of switch off.
Calculate the temperature rise of the winding and compare with the guaranteed
values.