SITE TESTS MANUAL OF THE POWER TRANSFORMERS

AREVA T&D Enerji Endstrisi A . . Bar Mah. E 5 Alt, 1801 Sok. No 104 41410 Gebze- Kocaeli / TRKYE Tel. : + 90 262 648 33 00 Fax : + 90 262 641 20 36

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INTRODUCTION:

Site Test procedures and test equipment of The Power Transformers are dealt in the scope of this manual. CONTENTS:

Pages 2-3 3-4 5-8 8-9 9-11 11-13 13-14 14

1. Measurement of voltage ratio 2. Measurement of capacitance and power factor 2.1 Bushing capacitance and power factor measurements 2.2 Transformer capacitance and power factor measurements 3. Transformer exciting current measurements 4. Measurement of winding DC resistance 5. Measurement of insulation resistance and polarization index 6. Quality analysis of insulation oil 7. Total combustible gas test

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1. MEASUREMENT OF VOLTAGE RATIO The voltage ratio (i.e. turn ratio) of the transformer is the ratio of voltages at no-load. Purpose of the measurement: verification of no-load voltage ratios specified by the specification and detection of any problem within the coils or tapping connections. Measurements are carried out on all taps and on all phases. Measuring Circuit Turn ratio measurement is performed by measurement of voltage ratios
the voltage of HV winding the voltage of LV winding

Theoretical turn ratio =

Deviation =

( measured

turn ratio ) ( theoretical turn ratio ) %100 theoretical turn ratio

Voltage ratio measurements are generally performed by the digital instruments produced for this purpose. In addition to voltage ratio measurement, the determination of the vector group (connection group) and current measurements can be performed with these instruments, it is necessary that the instrument must have 3-phase system for vector group determination. The method of comparing the voltages of dual vectors enables the measurement of phase shifting between the vectors.

The deviation in the turn ratio shall be < 0,5 %.

The characteristics of measurement devices used in AREVA Gebze Laboratory indicated as follows: Ratio measuring instrument : Type : 2791 and 2793 Accuracy : 0,1% Measuring range : 0,18...1999,9 Measuring voltage : 2791 150 V ac 2793 100 V ac Manufacturer : TETTEX

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Figure 1.1

2. MEASUREMENT OF CAPACITANCE AND POWER FACTOR 2.1 Bushing capacitance and power factor measurement Prior to taking a condenser bushing into service, and on a suspected fault, the capacitance and dissipation factor can be measured and compared with the values given on the rating plate or in the routine test report. Measuring procedure When tetsing a bushing having a capacitive test tap, i.e. practically all our bushings, it is not necessary to disconnect the top of the bushing. It is enough to open the disconnecting switch. For the sake of safety and for reduction of the influence from the winding inductance, all transformer windings shall be short-circuited. Windings not connected to the tested bushing shall be grounded. See Figure 2.1.1 The bridge shall be placed on a vibration-free base. If the reference capacitor is separate, it shall be placed on a dry, insulating base. Depending on which insulation is to be tested, the voltage source (test voltage) shall be connected via separate leads to the bushing top or the capacitive test tap. Leads for test voltage or grounding must not be common with leads for measuring. Measuring lead shall be as short as possible and must not touch grounded objects. Bands or strings used for spacing must be dry and clean. This also applies to the test object. If the bushings is in its transport case, it must not be surrounded by wet filling material. The test tap shall be clean and dry.

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At humid conditions drying of the test tap may be required in order to get representative readings for tan over C2. An air dryer may be used for drying. Cleaning of the air side insulator housing is indispensable for correct measuremnet of tan over C1.

Power factor test It is assumed that the bushing to be tested is equipped with a capacitive test tap. It is further assumed that the bridge in use can measure ungrounded, according to the UST-metod (Ungrounded Specimen Test). This way, the influence from the transformer on the test result (power factor) is minimized. To make it possible to compare the test resultwith the value on the rating plate or with the routine test report supplied with each bushing, the power factor shall be measured at 10 kV. The measurement procedure shall begin with low sensitivity on the bridge. The sensitivity is then increased gradually to the highest possible. In rare cases, external interferences can make it difficult to set the detector to zero. If the interference cannot be eliminated, the sensitivity must be lowered. Table 2.1.1 shows the connections to be made, when measuring the dissipation factor of the different insulations. It is to be noted that most bridges give capacitance and dissipation factor in the same measuring operation. Table 2.1.1
Test Sequence 1 2 Test Level 10 kV Note A Voltage to CL Tap HV test lead to CL Tap LV test lead to Tap CL Switch position UST Guard Measure power factor and capacitance C1 C2

Figure 2.1.1

CL = Center conductor Tap = Capacitive test tap C1 = Main insulation C2 = Tap insulation UST = Ungrounded measurement (Ungrounded Specimen Test) Guard = In this position C1 by-passed and only C2 is measured. This method is not available on all bridges.

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Note A = Test 2 shall be carried out at no higher voltage than 1kV if the test tap insulation is delivery tested with 2 kV. If the test tap is tested with 20 kV, 2.5 or 5 kV may be used.

2.2 Transformers capacitance and power factor measurement All insulating materials used in practice have slightly small dielectric losses at rated voltage and at rated frequency. These losses are fairly low for good insulating materials. This loss changes proportionally with the square of the applied voltage. Insulation, in terms of basic circuits elements, is shown in Figure 2.2.1
V1 = U I I C U I Ic

IC
V2 = 0 a) b)

IR

1 R= G

IR

c)

a) Insulation diagram

b) Equivalent circuit Figure 2.2.1

c) Vector

As it can be seen from Figure 2.2.1 the angle between the total current I and capacitive current Ic is a basic value. Insulation angle is dependent on the thickness, the surface and the properties of the insulation material ( the pores, impurities and humidity which cause the ionization in the insulation material ). Generally, the conditions and the reasons will cause a decrease in the dielectric withstand of the insulation. For this reason, the power factor measurement of the insulation at certain frequency gives a basic idea about the insulation. The measurements to be made during the service are one of the most important indications, showing the ageing of the insulation and the contimination of the oil. The active losses of the circuit is as follows; P= UICos = U . C. . tan Capacitance, tan , active losses and Cos can be measured by bridge methods or power factor ( Cos ) measuring instrument at definite voltages. Measurement is performed between the windings and the tank, and the test temperature is recorded; then according to desired reference value the necessary corrections are done.
2

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2.2.1 Two-winding transformers: The insulations involved in two-winding transformers are shown schematically in Figure 2.2.1.1 The insulations indicated as C H, CL and CHL are, respectively, the insulation between the high side and ground, the insulation between the low side and ground, and the insulation between the high and low windings. These insulations, although actually distributed along the windings, are shown as single capacitors in the drawing for the sake of simplicity. These insulations are not made up of a single dielectric: for instance, CH, the insulation between the high side and ground, includes the bushings, the insulation between the high winding and ground, and the oil between the winding and ground.
Transformer Tank

Fig.2.2.1.1

Readings are made on CH and CL directly. When the high winding is energized and the low winding is guarded, the insulation CH is measured. When the low winding is energized and the high winding is guarded, the insulation CL is measured. By making additional tests (shown in the tabulation below) and a simple computation, the insulation CHL is obtained. In general, transformer windings connected to the guard circuit will have no appreciable effect on the accuracy of the test results. The test procedure is as follows: Isolate transformer from the live bus. Disconnect all external leads from the bushing terminals. Disconnect the neutrals of each winding from ground. Short circuit each winding at its bushing terminals. Ground the tank. Make the series of tests as outlined below:

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2.2.2 Three-winding transformers: The insulations involved in three-winding transformers are shown schematically in Figure 2.2.2.1. The insulations indicated as C H, CL and CT are respectively the insulation between the high side and ground, the insulation between the low side and ground and the insulation between the tertiary and ground. These insulations indicated, CHL, CHT and CLT are respectively the insulation between the high and low windings, the insulation between the high and tertiary windings and the insulation between the low and tertiary windings. These insulations although actually distributed along the windings, are shown as single capacitors in the drawing for the sake of simplicity. These insulations may not not be made up of a single dielectric; for instance CH, the insulation between the high side and ground, includes the bushings, the insulation between the high winding and ground and the oil between the high winding and the tank.
Transformer Tank

Figure 2.2.2.1

Readings are made directly on CH, CL and CT. When the high winding is energized and the low and tertiary windings are guarded, the insulation C H is measured. When the low winding is energized and the high and tertiary windings are guarded, the insulation CL is measured. When the tertiary winding is energized and the low and high windings are guarded, the insulation CT is measured. By making additional tests volving both guarded and guarded windings the interwinding insulations CHL , CHT and CLT can be determined by simple computation. In general, transformer windings connected to the guard circuit will have no appreciable effect on the accuracy of the test results. The test procedure is as follows: Isolate transformer from the live bus. Disconnect all external leads from the bushing terminals. Disconnect the neutrals of each winding from ground. Short circuit each winding at its bushing terminals. Ground the tank.

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Make the series of tests as outlined below:

In the case of new oil-filled transformers and reactors, the power factor shoul not exceed 0,5% (20C); power factor between 0,5% and 1,0%(20C) may be acceptable; however, power factor >1,0% (20C) shall be investigated.
The characteristics of measurement devices used in AREVA Gebze Laboratory indicated as follows: Test equipment Measuring bridge: Manufacturer Model Serial Nr. Meas. range

: Doble Engineering Company : M2H : 905 : 0 12 kV, ac

3.TRANSFORMER EXCITING CURRENT MEASUREMENT TEST CONNECTIONS: Figure 3.1 though 3.3 illustrate test procedures for measurement of exciting currents in transformer windings.

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Figure 3.1

Figure 3.2

Fig.7 Figure 3.3

The characteristics of measurement devices used in AREVA Gebze Laboratory indicated as follows: Test equipment Measuring bridge: Manufacturer Model Serial Nr. Meas. range

: Doble Engineering Company : M2H : 905 : 0 12 kV, ac

4. MEASUREMENT OF WINDING DC RESISTANCE The resistance measurement will show whether the winding joints are appropriate and the windings are correctly connected. The winding resistances that vary with the temperature strongly, are the ohmic/d.c. resistances of a winding and the resistance is computed as follows:

R2 = R1
aluminium ) where;

235 + t 2 235 + t 1

( for copper )

R2 = R1

225 + t 2 225 + t 1

for

R2 = winding resistance at t2 temperature R1 = winding resistance at t1 temperature

Therefore, wherever the winding resistances are stated, the temperatures during the measurement must be given.

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The resistances between all pairs of phase terminals at all tapping connections are measured. Direct current can be obtained from a constant-current supply unit. The value of the direct current should be high enough to ensure correct measurement and should be low enough to prevent any effects on the winding temperature. In practise this value should be greater than 1,2 x I0 and less than 0,1x In. The time constant of the measurement circuit will depend on the ratio of L/R. When the test object is assumed to be composed of a R resistance and L inductance which is series connected to it, U voltage applied to this circuit will be;
R t U i = (1 e L ) R

where time coefficient depends on L/R ratio.

If the measuring current increases, it leads to the reduction of inductance due to saturation of the core, these enables the current to reach the steady state condition in a short time. After switching on the supply voltage to the measurement circuit, it should be waited until the current becomes stationary, otherwise measurement errors will be occurred.
Measurement Circuit Winding resistances can be measured by the following current-voltage method. Measuring sensitivity can be increased by using the digital measuring instruments. The circuit of the measurement by current-voltage method is given in Figure 4.1. In the current-voltage measuring method, by applying the winding current through the reference resistance in the system, the voltage drops occurred in both resistances. This voltage drop values of reference and winding resistances are compared to determine the value of unknown resistance (winding resistance) which can be read directly from the digital measuring instrument. It is necessary to care, in order avoid of very high voltages during the switching on and off the circuit.
a A Power supply unit A B C V N n b c

Figure 4.1: Winding resistance measurement by Current-Voltage method

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Comparison of readings with other phases or previous measurements under field conditions are recommended. Variations under field conditions should not exceed 5%.
The characteristics of measurement devices used in AREVA Gebze Laboratory indicated as follows: Test equipments Measuring instruments: Manufacturer : TETTEX Model : 2292 and 2285c/100/3 Meas. current : 50A and 100A 5.MEASUREMENT OF INSULATION RESISTANCE The purpose of the measurement is to determine the leakage current of the insulation resistance. This current is changing with the moisture, impurity contents and temperature of the insulation. Beside the result of the measurements, the comparison of the periodical measurement give the information about the condition of the insulation. In order to compare they must be at the same temperature ( for example at 20C reference temperature ). Time resistance method in the insulation resistance measurement is one of the best methods, that is simple and gives correct results. The insulation resistance is measured by means of an insulation resistance meter which apply a voltage between 1kV dc and 5kV dc. Each winding is measured separately by connecting the voltage between the winding to be tested and earth. While the other windings are connected to the guard circuit of the test instrument. The temperature and humidity are recorded during the test. The Resistance values R15 , R30, R45, R60 and R600 are taken at 15 sec , 30 sec, 45 sec, 60 sec and 600 sec after apply the voltage. Furthermore, the ratio of the insulation resistance R600 to the insulation resistance R60 is stated as polarization index (PI) in the test report. Readings are referred to 20 C by multiplying the value at transformer oil temperature by correction factor given in table below:

C -10 -5 0 5 10 15 20 25 30

Correction factor 0,13 0,18 0,25 0,36 0,50 0,75 1,0 1,40 1,98

C 35 40 45 50 55 60 65 70 75

Correction factor 2,80 3,95 5,60 7,85 11,20 15,85 22,40 31,75 44,70

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5.1 Two-windings measurement

Transformer Tank

Figure 5.1.1

5.2 Three-windings measurement

Transformer Tank

Figure 5.2.1

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For small transformers the polarization index will be equal to 1 or slightly higher. Larger transformers may exhibit a polarization index of 1,1 1,3. In general, a high value of polarization index indicates that the insulation system is good condition. A polarization index of <1 indicates that immediate corrective action is required.
The characteristics of measurement devices used in AREVA Gebze Laboratory indicated as follows: Test equipment Measuring bridge: Manufacturer : MEGGER Model : BM25 Meas. range : 0,5 5 kV, dc

6. QUALITY ANALYSIS OF INSULATION OIL TAKEN FROM BOTTOM VALVE

6.1 Dielectric strength

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6.2 Acidity,Neutralization number

In the case of new oil as received from refinery the acid number should not ecxeed 0,03 mg KOH/g.
6.3 Interfacial tension

6.4 Power factor measurement

The maximum suggested power factor for new oil after filling and standing, prior to energizing, should not exceed 0,10% (at 25C).
6.5 Water content

Moisture content in oil for new transformer should not exceed 10 ppm.

7. TOTAL COMBUSTIBLE GAS TEST OF INSULATION OIL TAKEN FROM TOP VALVE
Total dissolved gas for new transformers shall not exceed 0,5% (if units are equipped with nitrogen blankets, total dissolved gas should not exceed 1,0%).