Testing of Transformer: Vijai Electricals LTD

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
Vijai Electricals Ltd
Redefining the Quality
Reference Standards on transformers

Indian Standards
IS: 2026: Part 1- Part 5 -- Specification for power Transformers
IS: 1180: Part 1&2 -- Specification for out door type, 3 phase, sealed & non sealed
distribution transformers up to & including 100 kVA, 11 kV
IS: 11171 -- Specification for Dry Type transformers
IS: 6209 -- Method for Partial Discharge Measurement
IS: 2071: Part 1 - Part 3 -- Methods of High Voltage test
IS: 13964 -- Method of Sound level measurement.
Reference Standards on transformers

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 %
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
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.
Special Tests
Measurement
Measurement
Measurement
Measurement
Measurement
of Capacitance and Tan Delta.

of Zero Sequence Impedance
of Acoustic Noise Level
of Partial Discharge.
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 = 1U1V
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:
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:
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 Oil filled transformers
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
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
SShort Circuit method:
Measure cold Resistance
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.
TYPE TEST
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.
TYPE TEST
TEMPERATURE RISE TEST -DRY-TYPE TRANSFORMERS:
a1) No load run test:

Apply Rated voltage on one of the winding preferably LV winding while the
other winding is kept open
Continue till the temperature rise attains steady state
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.
Ccalculate the temperature rise e of the of individual winding
TYPE TEST
b2) Load run test:
Short Circuit one of the winding preferably LV winding and pass rated current on
the other.
Continue till the temperature rise reaches steady state
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 windings
at the time of switch off.
Calculate the temperature rise c of the individual windings.
TYPE TEST
The total winding rise 'c is calculated as below.

'c = c {1+ (e / c) 1.25 }0.8
If Test current is less than the rated current, then temperature rise at n at rated
current is
n = 'c x ( Rated Current/Test Current) q
Where q = 1.6 for AN transformers and
1.8 for AF transformers.
TYPE TEST
IMPULSE VOLTAGE WITHSTAND TEST
P Purpose:
To check the adequacy of the insulation to withstand lightning impulse voltage.
I Instruments:
Impulse generator
Potential divider for voltage measurement
Current measuring shunts.
C Control and measurement system.
P Procedure:
C connect impulse generator output toH1 terminal while earthing H2 terminal through current
measuring shunt and all other windings either directly or through resistor
TYPE TEST
Apply impulse in the following sequence
One reduced full level Impulse

One full level full Impulse
One or more reduced level chopped Impulse
Two full level chopped Impulse
Two full level full Impulse
H The test voltage for 11kV is 75kV peak for full level Impulse and the peak value of the
chopped Impulse shall be 1.1 times the amplitude of full impulse.
TYPE TEST
The oscillographic or digital records obtained during calibration and tests shall clearly
show the applied voltage impulse shape (front time, time to half value and amplitude)
AAcceptance criteria.
The absence of significant differences between voltage and current transients recorded at
reduced voltage and those recorded at full voltage and the full wave impulse before and after
chopped wave impulse constitutes that the insulation has withstood the test.
SPECIAL TESTS
ZERO SEQUENCE IMPEDANCE
Ppurpose:
To determine the current which flows in the event of a line to earth fault.
Iinstruments:
Auto Transformer.
Voltmeter.
Ammeter.
pprocedure:
Short circuit the line terminals of star connected winding
Keep the Delta winding open
AApply Voltage at rated frequency between shorted line terminals and the neutral such
that a current equal to one third of the rated value of that winding flows.
SPECIAL TESTS
Record the applied voltage and the current.

ZERO SEQUENCE IMPEDANCE
Zero Sequence Impedance in percent on kVA base of excited winding is,
(
E
Ir )
Z0 (0/0) = 300
(---------- X ----------) Where,
( Er
I
)
EE = measured excitation Voltage
EEr = Rated phase to neutral voltage of the excited winding
II = Measured current
IIr = Rated current per phase of the excited winding.
SPECIAL TESTS
P Purpose:
SHORT CIRCUIT TEST
T To evaluate the dynamic and thermal ability of the transformer to withstand

short circuit.
I Instruments:
Short circuit generator
Transformer routine test set up
Current measuring shunts.
Connecting cables.
P Procedure:
CCarryout all routine tests as specified by the standard including dielectric tests.
SPECIAL TESTS
SHORT CIRCUIT TEST
Measure base short circuit reactance of the transformer

Calculate short circuit current using the formula as below
U
I I = ----------------- kA. Where,
3 (Zt + Zs)
UU is the rated Voltage of the winding under consideration in kV.
ZZt is the short Circuit impedance of the Transformer referred to the winding under
consideration in Ohms per phase.
Zs is the short circuit impedance of the system in Ohms per phase.
SPECIAL TESTS
SHORT CIRCUIT TEST
The amplitude of the first peak of the asymmetrical test current is calculated as follows
i = I k2
Where,
The factor k2 depends on the ratio X/R where,

X is the sum of the reactances of the transformer and the system (X t + Xs) in ohms
And R is the sum of resistances of the transformer and the system (Rt + Rs)
The values of factor k2 shall be used for different values of X/R is given clause no
16.11.2 of IS: 2026 / 1977.
SPECIAL TESTS
SHORT CIRCUIT TEST
Short circuit the LV terminal through current measuring shunts.

Apply voltage on HV so as to pass the short circuit current as calculated above in LV
winding
Repeat the above step three times on each limb.
After every shot, measure the reactance of the transformer.
Repeat all routine tests including dielectric tests.
Untank the transformer for inspection of the core and winding.
SPECIAL TESTS
A Acceptance criteria:
SHORT CIRCUIT TEST
T The transformer is deemed to have passed the test if the following conditions are
fulfilled.
1)The routine tests are successfully repeated
2)The results of the short circuit tests, measurements during short circuit tests and out
of tank inspection do not reveal any defects (displacements, deformations of windings,
connections or supporting structures, or traces of discharge)
3)The short circuit reactance measured after tests differs from that measured in the
original state by not more than 2 % in case of concentric circular windings and 7.5 % in
case of concentric non-circular winding.
SPECIAL TESTS
MEASUREMENT OF HARMONICS OF NO LOAD CURRENT
P Purpose:
To measure the total harmonic distortion in the no load current
I Instruments:
Three phase auto transformer
Harmonic analyzer
P Procedure:
Connect the harmonic analyzer to the transformer.
Excite the transformer at rated voltage and frequency.
Measure the various harmonic components from the harmonic analyzer.
Magnitude of the harmonic is expressed in terms of the percentage of fundamental
harmonics
Repeat the same for all the phases
SPECIAL TESTS
P Purpose:
AND TAN DELTA
To Measure theMEASUREMENT
Capacitance and OF
TanCAPACITANCE
Delta of the transformer
I Instruments:
Capacitance and Tan delta Bridge
Procedure:
Connect the C & Tan Delta Bridge to the Transformer
Apply the appropriate voltage between HV and LV.
Balance the bridge.
Record the values of capacitance and tan delta.
Repeat the test by applying voltage between HV-Earth and LV - Earth
SPECIAL TESTS
SOUND LEVEL MEASUREMENT
P Purpose:
TTo measure the sound emanating from the transformer
I Instruments:
Sound level meter
P Procedure:
Energize the transformer at rated voltage and rated frequency.
Measure the sound emanating from the transformer using sound level meter at a distance
of about 0.3 meter all around the transformer at least eight point.
SPECIAL TESTS
If the transformer height is more than 2.5 meter then the measurement is made at 1/3
and 2/3 the height of the transformer.
If the height of the transformer is less than 2.5 meter then the measurement is to be
made at half the height of the transformer
Measure the back ground sound without energizing the transformer
TThe background noise should be measured immediately before and after the
measurement of noise of transformer. If the background noise is much lower than the
combined level of Transformer noise + back ground noise (if the difference is more
than 10 dB), measurements are made at only one point and no corrections are needed.
If the difference is less than 10 dB and more than 3 dB, then correction is done
according to the table given below
SPECIAL TESTS
Difference between sound
pressure levels measured
with equipment operating
and background sound
pressure level alone. (dB)
Correction to be subtracted from sound pressure level

measured with equipment operating to obtain sound
pressure level due to equipment alone (dB)
4-5
6-8
9-10
0.5
SPECIAL TESTS
UNBALANCE CURRENT MEASUREMENT
Purpose:
To determine the unbalance current flowing through the neutral.
Instruments:
Three phase auto transformer
Ammeter / Clamp meter
Procedure:
Sufficient voltage to be applied on HV winding while LV winding is shorted.
Current in shorted LV winding (Isc) and in shorted LV to Neutral (In) is to be measured.
% Unbalance current = (In) / (Isc) x 100
SPECIAL TESTS
PARTIAL DISCHARGE MEASUREMENT
Purpose:
To determine the partial discharge currents in the transformer.
Instruments:
PD free MG-set
Partial discharge meter
Coupling capacitors
Voltmeter
Procedure:
Pre-stress voltage of 1.5 Um/ 3 shall be induced for 30 seconds followed without
interruption by a line to earth voltage of 1.1 Um/3 for 3 minutes during which partial
discharge shall be measured.
Where Um = Higher system voltage
CIRCUIT DIAGRAMS
CIRCUIT DIAGRAMS
CIRCUIT DIAGRAMS
CIRCUIT DIAGRAMS
CIRCUIT DIAGRAMS
CIRCUIT DIAGRAMS
short
short
CIRCUIT DIAGRAMS
CIRCUIT DIAGRAMS
CIRCUIT DIAGRAMS
CIRCUIT DIAGRAMS
CIRCUIT DIAGRAMS

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TESTING OF TRANSFORMER

The objective of testing is

Vijai Electricals Ltd

Redefining the Quality

Reference Standards on transformers

Vijai Electricals Ltd

Redefining the Quality

Reference Standards on transformers

Vijai Electricals Ltd

Redefining the Quality

Vijai Electricals Ltd

Redefining the Quality

PREPERATION FOR THE TEST

Vijai Electricals Ltd

Redefining the Quality

-- For design validation

Vijai Electricals Ltd

Redefining the Quality

Special tests -- To check whether the product meets any special

Vijai Electricals Ltd

Redefining the Quality

Vijai Electricals Ltd

Redefining the Quality

Vijai Electricals Ltd

Redefining the Quality

of Capacitance and Tan Delta.

Vijai Electricals Ltd

Redefining the Quality

Vijai Electricals Ltd

Redefining the Quality

Vijai Electricals Ltd

Redefining the Quality

Specified Ratio Actual Ratio

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

Vijai Electricals Ltd

Redefining the Quality

Vijai Electricals Ltd

Redefining the Quality

Vijai Electricals Ltd

Redefining the Quality

Vijai Electricals Ltd

Redefining the Quality

Vijai Electricals Ltd

Redefining the Quality

Vijai Electricals Ltd

Redefining the Quality

Vijai Electricals Ltd

Redefining the Quality

Appropriate test voltage as required by the applicable standard is applied to the

Vijai Electricals Ltd

Redefining the Quality

Vijai Electricals Ltd

Redefining the Quality

Vijai Electricals Ltd

Redefining the Quality

Vijai Electricals Ltd

Redefining the Quality

Back to back method

Vijai Electricals Ltd

Redefining the Quality

Vijai Electricals Ltd

Redefining the Quality