Transformer Testing - DV Power Products

Smart test devices for reliable electric power systems
Transformer Testing
Using DV Power Devices
Maid Dzambic, Application Engineer
2 | 2016 DV Power All Rights Reserved.
DV Power Devices Transformer Group
Winding resistance measurement

Turns ratio test AC voltage
and OLTC analysis DC current
RMO-T series TRT series

RMO-TW TRT03
RMO-TD TRT30
RMO-TT TRT33
TWA series TRT4x
TWA25A TRT63
TWA40D

Transformer Tests using DV Power Devices
TYPES OF MEASUREMENTS
Winding resistance measurement (IEC 60076-1) RMO-T, TWA
Analysis of On-Load Tap changers (IEC 60214-1) RMO-T, TWA
Heat run test (IEC 60076-2) RMO-T
Demagnetization process RMO-T, TWA, DEM
Turns ratio measurement of power transformers (IEC 60076-1) TRT
Turns ratio verification of instrument transformers (IEC 60076-1) TRT
Excitation current measurement TRT
Phase angle measurement TRT
Vector group detection TRT
Demagnetization status verification TRT
Magnetic balance test TRT

RMO-T and TWA Family of Devices
TYPES OF TESTS (RMO-T and TWA family)
Winding resistance measurement RMO-T, TWA

Analysis of On-Load Tap changers RMO-T, TWA
Heat run test RMO-T
Demagnetization process RMO-T, TWA, DEM

Device Series Development Evolution
RMO-TW series
winding resistance measurement The most advanced on the market
TWA40D
RMO-TD series
+ connection of all 8 (or 6) bushings at once
+ tap changer analysis (DVtest)
+ OLTC synchronization measurement
+ OLTC motor current measurement
+ simultaneous three-phase measurement
+ demagnetization process
+ fast measurement
RMO-TT series
+ temperature measurement channels

Winding Resistance Measurement
Why is it important?
Winding and connection damages
OLTC contact malfunctions
Defined by standard
How is it performed?
Injecting DC current, measuring voltage drop,
calculating resistance R = U / I
Should be done for all phases and every tap position
Compared to reference measurement, across phases

How difficult it can be?
Time to inject DC current to a winding (charging)
Stabilization time

Charging time
Volt-seconds needed
100 kV winding at 50 Hz needs 450 Vs
100 kV winding at 60 Hz needs 375 Vs
Thus, 50 Hz winding needs 75 s at 6 V
Or, 8 s at 60 V
Residual flux makes time 0.25 1.7 times longer
All our devices have charging voltage up to 55 V DC!

Stabilization time
Depends on time constant L/R
Eliminate inductance influence
By saturating the core

How to saturate the core
Use high current

Low current may not saturate the core in a reasonable time
High current may heat up the winding
Higher current => better saturation => lower L => shorter time

How to saturate the core
To get saturation 1.2 x Iex = 1.2 x 2-5% In

To avoid heating of the wire <10% In
10% of nominal current
Current cannot be reached? Winding resistance too high Device
power limit reached, lower the current value
Our instruments can generate up to 100 A DC!

Measuring at LV side may take very long time
LV side may have very low resistance

Therefore large time constant L/R
On large units stabilization may take 15-60 minutes
Sometimes even 100 A might not be enough to significantly shorten
the time
Use HV winding as an additional help for faster saturation!

Saturation by one or two windings?

Measuring at LV side by saturating core from HV side
Less current required

Need more cables on top of the transformer (if using single-phase
devices)
Need a little more thinking prior to the test (if using single-phase
devices)
On a large GSU transformers this can speed up the

measurement 10 to 20 times!

Tap Changer DVtest Method
New method (used and approved by MR and ABB)
Detecting problems within tap changer
No need to extract tap changer from the transformer
Injecting and recording DC current through winding
Changes of current reflect changes of resistance/reactance

Tap Changer DVtest Method
Cooperation with MR tap changers
Maschinenfabrik Reinhausen the one of the
biggest tap changer manufecturer in the world
Link for the brochure

The Result is a Graph

The Result is a Graph

Why bother?
Give me one good reason to test!
I will give you 4

Reason 1
40% of problems in transformers

Reason 2
About one in 20 OLTC failures lead to

transformer main tank failure
- Presentation on OLTC diagnostics, Laurent Allard, ABB Secheron, Euro TechCon

Chester UK 2010

Reason 3
HQ study showed 12% require maintenance

before manufacturers suggested period.
- WECC Substation WG meeting minutes, Vancouver Washington, May 2006

Reason 4
About 33% of OLTC failures are caused by

incorrect maintenance and bad reassembly.
- P.Kang, D. Birthwistle, et al. "Non invasive on line condition monitoring of OLTC",

IEEE proceedings January 2000, Generation, transmission and distribution, Volume 3,
pp.2223-2228

Heat Run Test
Detecting winding hot spot temperature
Performed by transformer manufacturer
Measuring winding resistance during transformer cooling
Measuring ambient temperature, top and bottom oil layer
temperature
Extrapolating resistance curve

Demagnetization
Remanent magnetism can cause various problems:
High amplitude inrush current at start-up of power transformer,
Incorrect operation of protective relays,
Erroneous results during electrical measurements on transformer
(FRA test, excitation current measurement)

Causes of Transformer Magnetization
When disconnecting a transformer from service

Consequence of high fault currents
Test using DC current

Inrush Current
Comparison of maximum inrush current with and without

residual flux

Calculation
It was shown that inrush currents calculated at

the head of the feeder were reduced by about
60% when a power transformer was previously
demagnetized.
- B. Kovan, F. de Leon, D. Czarkowski, Z. Zabar, L. Birnebaum, 2011: "Mitigation of

Inrush Currents in Network Transformers by Reducing the Residual Flux With an
Ultra-Low-Frequency Power Source", IEEE Transactions on Power Delivery, vol. 26
issue 3, 1563-1570.

How?
DV Power has developed a simple and very effective

demagnetization method:
Internally changing the polarity of a controlled DC
current
Current is supplied at decreasing magnitude for each
step
Safely discharges the energy and guarantees the
current magnitude

How?
Every next step, value of current will be 60% of the

previous value
This will continue until 5 mA value is reached

etization process implies reducing the surface of the hysteresis loop
Theory
etization is succesfull if the surface of hysteresis loop is small enough
Alternate direction
Lower the magnitude
Bring flux to 0
36/47

Why demagnetization
Before AC tests to avoid bad results due to remnant

magnetism
Before putting a transformer back in service to avoid high
inrush currents
Requires some additional time for tests, but improves
safety

Winding Ohmmeters
RMO-TW series
RMO10TW
RMO20TW
RMO30TW
RMO50TW

Winding Ohmmeters
RMO-TW series
RMO100TD RMO10TW RMO20TW RMO30TW RMO50TW
Max. current 10 A DC 20 A DC 30 A DC 50 A DC
Max. charging voltage 55 V DC 55 V DC 55 V DC 55 V DC
Typical accuracy 0,1% 0,1% 0,1% 0,1%
Resolution 0,1 0,1 0,1 0,1

Tap Changer Analyzers &
Winding Ohmmeters
RMO-TD series
RMO25TD
RMO40TD
RMO60TD

Winding Ohmmeter
RMO-TD series
O00TD RMO60TT RMO40TD
RMO25TD RMO60TD
Max. current 25 A DC 40 A DC 60 A DC
Max. charging voltage 55 V DC 55 V DC 55 V DC
Typical accuracy 0,1% 0,1% 0,1%
Resolution 0,1 0,1 0,1
Built-in TC control Optional Optional Included

Winding Ohmmeters
RMO-TT series
RMO40TT
RMO60TT
RMO100TT

Winding Ohmmeter
RMO-TT series
RMO60TT RMO60TT
RMO40TT RMO100TT
Max. current 40 A DC 60 A DC 100 A DC
Max. charging voltage 55 V DC 55 V DC 55 V DC
Typical accuracy 0,1% 0,1% 0,1%
Resolution 0,1 0,1 0,1
Temperature channels 3 3 6
Built-in TC control Included Included Included

Tap Changer & Winding Analyzer
TWA40D
Three-phase instrument
One-time connection of all 6-8 bushingss
All 6 resistances measured in one test
Max. 25 A per phase in step by step test
Max. 40 A, 13 A per phase in OLTC
synchronization test

Tap Changer & Winding Analyzer
TWA series
TWA25A TRT03C
TWA40D
Max. current 25 A DC 40 A DC
Max. charging voltage 55 V DC 55 V DC
Typical accuracy 0,1% 0,1%
Resolution 0,1 0,1
Motor current mes. No Yes
Quick YN test No Yes
TPC Analysis Verification (4 ms) DVtest (0.1 ms)

Summarized TWA40D Features
Three tests in one device

One time connection system
Unique transformer saturation method
Quick YN test (TWA40D)
Synchronization test (TWA40D)
Tap changer motor current measurement (TWA40D)
Three-phase demagnetization
Combined transformer testing with TWA and TRT
3 years warranty

Three-Phase Transformer
Demagnetizer DEM60C
Basic technical data:

Demagnetization current :
5 mA - 60 A DC
Weight: 13,5 kg
Demagnetization graph
recording
A, B, C, N connectors
One- time cable setup

TRT series

TYPES OF TESTS (TRT):

Power transformers turns ratio measurement
Excitation current measurement
Phase angle measurement
Vector group detection
Instrument transformers turns ratio verification
Instrument transformers polarity check
Demagnetization status verification

Development Evolution
TRT03 series
Single phase voltage
TRT4x series
+ 125 V max. voltage
TRT30 series
(Together with CVT40 it can
+ true three phase voltage
output 5 kV AC for testing CVTs)
TRT33 series
+ test voltage 1 V Most advanced
(instrument transformers testing) TRT63 series
+ 250 V test voltage

Turns Ratio Measurement
Detecting winding defects
Voltage ratio between primary and
secondary windings is measured for
each transformer leg, applying voltage
at HV side and measuring on LV side
Phase by phase with single-phase
voltage
All phases at once with true three-
phase

Single-phase vs. true three-phase voltage
What the international standards say?
IEC doesnt stipulate which of these to use

ANSI stipulates single-phase voltage, but allows true three-
phase where single-phase is not applicable (In the case of
three-phase transformers, when each phase is independent
and accessible, single-phase power should be used;
although, when convenient, three-phase power may be
used., ANSI C57.12.90-1999)

Single-phase vs. true three-phase voltage
What is the right choice?
The best is to have both options

Exactly what we offer both options in the same unit
No additional modules, no additional cables needed
User can perform single-phase only, true three-phase only,
or both tests

Excitation Current Measurement
Detecting short-circuited turns
Core lamination shorts
Core de-laminations
Verification of demagnetization process
Excitation current is transformer primary no load current, or
magnetizing current (with open secondary) tested at reduced
voltage
Results are compared to values obtained under same test voltage
values
Results should follow specific pattern based on transformer
construction type

Phase Angle Measurement
Can indicate problems in windings and/or magnetic core
Measuring displacement of transformers with specific vector groups
(phase shifting, rectifier, arc furnace and traction transformers)
Verifying polarity of instrument transformers
Comparing sine waves of AC voltage(s) on HV side and AC voltage(s)
induced on LV side

Vector Group Detection
Verification of transformer vector group
During/after manufacturing
During/after reparation
Looking for incorrect connections
Using proprietary algorithm & software solution loaded in TRT
Completely automatic

Demagnetization Status Verification
Confirmation that transformer has been successfully
demagnetized
By comparing excitation currents before and after
demagnetization

Combined Measurement System
TRT
TWA

One measuring system TRT & TWA
Interchangeable test leads only one cable set
needed
One time connection saves time
7 tests at once:
Turns ratio in all tap positions
Excitation current
Phase angle
Magnetic balance test
Winding resistances in all tap positions
On load tap changer dynamic resistance
Demagnetization

True three-phase transformer
turns ratio testers
TRT63 series
Additional 250 V test voltage
Important for comparing
excitation currents obtained with
mains voltage
Improved ratio accuracy, up to
0,03%
Higher ratio range, up to 50 000

Summarized TRT63 Features
High test voltage 250 V Better accuracy
True three-phase test Testing transformer with non-standard vector group

(phase-shifting, rectifier, furnace...)
Test plan Preparation the test in office
Automated test mode Automatic measurement and tap position changing
Combined operation with TWA Saving the time and money
3 years warranty

Questions?

Thank you for your attention!

Transformer Testing - DV Power Products

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Smart test devices for reliable electric power systems

Winding resistance measurement

RMO-T series TRT series

3 | 2016 DV Power All Rights Reserved.

4 | 2016 DV Power All Rights Reserved.

Winding resistance measurement RMO-T, TWA

6 | 2016 DV Power All Rights Reserved.

7 | 2016 DV Power All Rights Reserved.

8 | 2016 DV Power All Rights Reserved.

9 | 2016 DV Power All Rights Reserved.

All our devices have charging voltage up to 55 V DC!

10 | 2016 DV Power All Rights Reserved.

11 | 2016 DV Power All Rights Reserved.

Use high current

12 | 2016 DV Power All Rights Reserved.

To get saturation 1.2 x Iex = 1.2 x 2-5% In

Our instruments can generate up to 100 A DC!

13 | 2016 DV Power All Rights Reserved.

LV side may have very low resistance

Use HV winding as an additional help for faster saturation!

14 | 2016 DV Power All Rights Reserved.

15 | 2016 DV Power All Rights Reserved.

Less current required

On a large GSU transformers this can speed up the

16 | 2016 DV Power All Rights Reserved.

17 | 2016 DV Power All Rights Reserved.

Link for the brochure

18 | 2016 DV Power All Rights Reserved.

19 | 2016 DV Power All Rights Reserved.

20 | 2016 DV Power All Rights Reserved.

Give me one good reason to test!

I will give you 4

21 | 2016 DV Power All Rights Reserved.

40% of problems in transformers

22 | 2016 DV Power All Rights Reserved.

About one in 20 OLTC failures lead to

- Presentation on OLTC diagnostics, Laurent Allard, ABB Secheron, Euro TechCon

23 | 2016 DV Power All Rights Reserved.

HQ study showed 12% require maintenance

- WECC Substation WG meeting minutes, Vancouver Washington, May 2006

24 | 2016 DV Power All Rights Reserved.

About 33% of OLTC failures are caused by

- P.Kang, D. Birthwistle, et al. "Non invasive on line condition monitoring of OLTC",

25 | 2016 DV Power All Rights Reserved.

26 | 2016 DV Power All Rights Reserved.

27 | 2016 DV Power All Rights Reserved.

When disconnecting a transformer from service

28 | 2016 DV Power All Rights Reserved.

Comparison of maximum inrush current with and without

29 | 2016 DV Power All Rights Reserved.

It was shown that inrush currents calculated at

- B. Kovan, F. de Leon, D. Czarkowski, Z. Zabar, L. Birnebaum, 2011: "Mitigation of

30 | 2016 DV Power All Rights Reserved.

DV Power has developed a simple and very effective

31 | 2016 DV Power All Rights Reserved.

Every next step, value of current will be 60% of the

32 | 2016 DV Power All Rights Reserved.

33 | 2016 DV Power All Rights Reserved.

Before AC tests to avoid bad results due to remnant

34 | 2016 DV Power All Rights Reserved.

35 | 2016 DV Power All Rights Reserved.

RMO100TD RMO10TW RMO20TW RMO30TW RMO50TW

Max. charging voltage 55 V DC 55 V DC 55 V DC 55 V DC

Typical accuracy 0,1% 0,1% 0,1% 0,1%