Transformer Tests

Transformer Testing
At
At Factory
Factory and
and In
In Field
Field
Weidmann-ACTI Inc. Fifth Annual Technical Conference
New Diagnostic Concepts for Better Asset Management
November 13 - 15, 2006

Hotel Albuquerque at Old Town Albuquerque, NM
H. Jin Sim
Waukesha Electric Systems
energy solutions WAUKESHA

ELECTRIC
… to power your future SYSTEMS
Transformer Testing
Agenda
General
Dielectric Tests
Performance Characteristics Tests
Temperature Rise Tests
Other Factory Tests
Let’s make this interactive!
Field Testing
Please stop me and ask
questions during the
presentation if you have them.

ELECTRIC
Factory Test
General
Reasons
Reasons for
for Testing
Testing
9
9 COMPLIANCE
COMPLIANCE WITH
WITH CUSTOMER
CUSTOMER SPECIFICATIONS
SPECIFICATIONS
9
9 ASSESSMENT
ASSESSMENT OF
OF QUALITY
QUALITY AND
AND RELIABILITY
RELIABILITY
9
9 VERIFICATION
VERIFICATION OF
OF DESIGN
DESIGN
9
9 COMPLIANCE
COMPLIANCE WITH
WITH INDUSTRY
INDUSTRY STANDARDS
STANDARDS
Test
Test Classification
Classification
¾
¾ Routine
Routine
¾
¾ Design
Design
¾
¾ Other
Other

ELECTRIC
TRANSFORMER
TRANSFORMER TESTS
TESTS
DIE
DIE ELECTRIC
ELECTRIC TESTS
TESTS PERFORMANCE
PERFORMANCE THERMAL
THERMAL TESTS
TESTS OTHER
OTHER TESTS
TESTS
CHARACTERISTICS
CHARACTERISTICS
TRANSIENTS 1)
1) No-Load
No-Load Loss
Loss 1)
1) Winding
Winding Resistance
Resistance *1)
*1) Insulation
Insulation Capacitance
Capacitance
1)
1) Lightning
Lightning Impulse
Impulse 2)
2) %% Exc.
Exc. Current
Current 2)
2) Heat
Heat Run
Run Test
Test and
and dissipation
dissipation factor
factor
ii Full
Full Wave
Wave 3)
3) Load
Load Loss
Loss iOil
iOil Rise
Rise 2)
2) Sound
Sound Level
Level Tests
Tests
ii Chopped
Chopped Wave
Wave 4)
4) %% Impedance
Impedance iWdg.
iWdg. Rise
Rise 3)
3) 10
10 kV
kV Exc.
Exc. Current
Current
ii Steep
Steep Wave
Wave 5)
5) Zero
Zero Sequence
Sequence iHot
iHot spot
spot rise
rise 4)
4) Megger
Megger
Impedances
Impedances 3)
3) Over
Over Load
Load Heat
Heat Run
Run 5)
5) Core
Core Ground
Ground
6)Ratio
6)Ratio Tests
Tests 4)
4) Gas
Gas In
In Oil
Oil *6)
*6) Electrical
Electrical Center
Center
2)
2) Switching
Switching Impulse
Impulse 7)
7) Winding
Winding Resistance
Resistance 5)5) Thermal
Thermal Scan
Scan *7)
*7) Recurrent
Recurrent Surge
Surge
8)
8) Dew
Dew Point
Point
LOW (POWER)
9)
9) Short-Circuit
Short-Circuit Test
Test
FREQUENCY
*10)
*10) Control
Control Circuit
Circuit Test
Test
*11)
*11) Test
Test on
on Series
Series Transformer
Transformer
1)
1) Applied
Applied Voltage
Voltage *12)
*12) LTC
LTC Tests
Tests
2)
2) 1∅
1∅ Induced
Induced *13)
*13) Preliminary
Preliminary Ratio
Ratio Tests
Tests
3)
3) Induced
Induced Voltage
Voltage *14)
*14) Test
Test on
on Bushing
Bushing CTCT
4)
4) Partial
Partial Discharge
Discharge *15)
*15) Oil
Oil Preservation
Preservation System
System
*Quality
*Quality Control
Control Tests
Tests
Factory Test
Dielectric Tests – Background
DIELECTRIC ENVIRONMENT
¾Power Frequency (Normal, Abnormal)
¾Natural (Lightning)
¾Man-made (Switching Impulse)

ELECTRIC
Factory Test
Dielectric Tests – Background
TRANSFORMER INSULATION SYSTEM
9Major Insulation
9Minor Insulation
9Phase to Phase Insulation

ELECTRIC
Factory Test
Dielectric Tests
•Impulse tests
–Lightning impulse
•full wave, chopped wave, front of wave
–Switching impulse
•Low (power) frequency dielectric tests
–Induced voltage test
–Applied voltage test
–Single phased induced test
•Additional dielectric tests
–Partial discharge monitoring
–1 hour test at 1.5 P.U. voltage

ELECTRIC
Factory Test
Dielectric Tests – Impulse Tests

ELECTRIC
Factory Test

ELECTRIC
Factory Test

ELECTRIC
Factory Test
•LIGHTNING IMPULSE
9Front Time - 1.2 microseconds ± 30% Tolerance
9(1.67 Times the time between 30% and 90% voltage)
9Tail Time - 50 microseconds ± 20%
9(Time to 50% peak voltage)
9Chop Time ≥ 3 microseconds for ≥ 150 KV
≥ 2 microseconds for < 150 KV
9(Time to first zero on tail of the wave)
•TEST CIRCUIT:
9Test one terminal at a time, all other terminals are grounded
9Current is measured at other end of winding through a shunt

ELECTRIC
Factory Test

ELECTRIC
Factory Test

ELECTRIC
Factory Test

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Factory Test

ELECTRIC
Factory Test
Dielectric Tests – Switching Impulse Tests
•SWITCHING IMPULSE TEST

•Time to peak value > 100 microseconds
•Time for 90 % of peak Value > 200 microseconds
•Time to first zero on tail of the wave >1000 microseconds
• TEST CIRCUIT
•Test for each HV Line terminal
•Ground Neutral terminal for all Wye connection, Ground other end of all Delta windings
•All Line terminals to be kept open except test terminal

ELECTRIC
Factory Test

ELECTRIC
Factory Test

ELECTRIC
Factory Test

ELECTRIC
Factory Test

ELECTRIC
Factory Test
Dielectric Tests – Applied Voltage Test
•TEST CIRCUIT:
•All terminals of winding under test are shorted together and connected to the 60 Hz
supply through a High voltage test transformer
•All other winding terminals are shorted together and connected to ground
•Tank is also connected to ground
•Test voltage is raised slowly to the required voltage and held for 1 minute
•The test is considered to be passed if there is no collapse of voltage or no audible
internal sound

ELECTRIC
Factory Test
Dielectric Tests – Applied Voltage Test
•TEST VOLTAGE
¾During this test as both ends of winding are connected,all parts of the
winding and leads attain the same voltage level with respect to ground
and all other windings
¾For Delta connected windings applied test voltage level is the voltage
equivalent to BIL. For example – equivalent applied test voltage for
550 KV BIL is 230 KV
¾For Wye connected windings the applied test voltage is limited to the
BIL of Neutral. For example if Line end BIL is 550 KV and neutral end
BIL is 150 KV then equivalent applied test voltage is limited to 50 KV
(equivalent for 150 BIL)

ELECTRIC
Factory Test
Dielectric Tests – Induced Voltage Test
•TEST CONNECTION
•Three phase voltage is applied to LV terminals at frequency ≥ 2 times
rated frequency
•All other line terminals are left open
•Neutral and Tank is connected to ground

ELECTRIC
Factory Test
•TEST VOLTAGE & DURATION
•For Class I Transformers (≤ 69 KV Class) –
•Test voltage is equivalent to twice the volts/turn and line end is
raised to achieve equivalent power frequency test voltage across
phases
•Test duration is 7200 Hz, if test frequency is 200 Hz then test
duration = 7200/200 = 36 seconds
•The test is considered to be passed if there is no collapse of voltage
or no audible internal sound

ELECTRIC
Factory Test
•TEST VOLTAGE & DURATION
•For Class II Transformers (> 69 KV Class) –
•Test voltage - 150% maximum tap voltage for 1 hour
173% maximum tap voltage for 7200 Hz
•Test voltage is raised slowly to 150% level and is held for few minutes and is
raised to Enhancement level for 7200 Hz and then reduced to 150% (1 hour)
level
•During this 1 hour test RIV (Partial Discharge) is recorded every 5 minutes.
As per ANSI standards guaranteed level is ≤ 100 micro-volts
•The test is considered to be passed if during 1 hour duration of test RIV level
is ≤ 100 micro-volts and if increase in RIV readings during 1 hour period is ≤
30 micro-volts

ELECTRIC
Factory Test

ELECTRIC
Factory Test
Perf. Char. – No-Load Loss and Exciting Current
•Losses of unloaded transformer excited at rated voltage and frequency

•Include Core loss, Dielectric Loss, and I2R Loss
•Core Loss – Hysteresis loss & Eddy Current loss
•Hysteresis Loss – Flux Density & Grade of Steel
•Eddy Current Loss – Frequency & Temperature
•Average Voltage Voltmeter Method to measure the voltage
•Compared to the RMS voltage to make correction to sine wave basis

ELECTRIC
Factory Test
Perf. Char. – No-Load Loss and Exciting Current
Test Circuit –
Transformer is excited from either TV/LV or HV side at 60 Hz.
with a variable voltage sinusoidal source. All other terminals are
left open. Applied voltage is slowly increased to test voltage
90%, 100%, 110% or any other % of the Rated voltage as
required.

ELECTRIC
Factory Test
Performance Characteristics – Load Loss and %
Impedance
•Load loss is the Losses of Transformer caused by Load Current

•Load Loss = I2R loss + Eddy loss + Stray loss
•Eddy losses depend on;
¾conductor thickness and width
¾leakage flux distribution
•Stray loss depends on;
¾% impedance
¾Winding dimensions, and clearance to tank and clamps

ELECTRIC
Factory Test
Perf. Char. – Load Loss and % Impedance
Test Circuit
9Transformer is excited from one side at rated frequency with a variable
voltage source
9The other side is shorted
9Applied voltage is raised to produce rated test currents in windings

ELECTRIC
Factory Test

•Measurements of Winding Resistance
•Temperature Rise Test
•Over Load Heat Run
•Gas In Oil Analysis

ELECTRIC
Factory Test

•Factors Affecting Winding Resistance Measurement
•Transformer Saturation Time
•Transformer Connection
•Characteristics of D.C. Source
•Average Winding Temperature at Cold Resistance Measurement

ELECTRIC
Factory Test
•Performed at Base ONAN and Maximum ONAF Rating
¾If maximum current/loss can not be fed due to test limitations, then
transformer can be loaded to 80% loss levels @ 90% current as per
C57.12.90
•Performed by shorting all 3 LV terminals and applying voltage
from HV winding to circulate sufficient current to produce
maximum total loss
•After reaching steady state oil temp. rise, current is reduced to
rated value and circulated for 1 hour. Hot winding resistance is
measured and curve plotted to arrive value at time of shutdown
(Time zero)
•Temperature correction is applied to steady state Top-oil Rise,
Mean oil Rise for total /test losses if applicable as per clause
11.5.2.2.1/C57.12.90
•Temperature correction is applied to winding gradient to correct
to rated current if applicable as per clause 11.5.2.1/C57.12.90

ELECTRIC
Factory Test
•Measurements during Temperature Rise Test –
Top oil Temperature, 3 Ambient Temperatures, Top and Bottom
Radiator Temperature, & Hot winding resistance at shut down
•Top Oil Rise = Top oil temperature – Average ambient
•Average oil rise = average of top & bottom header temperature
•Average winding rise = (Hot Resistance / Cold
Resistance)*(234.5+ambient temp) – ambient
•Gradient = Average winding rise – Average oil rise
•Hot spot Rise = Top oil rise + Hot spot gradient
•Hot spot gradient = Gradient (1 + k)
•k = hot-spot factor calculated based on maximum eddies due to actual
radial and axial field

ELECTRIC
Factory Test
For 65 °C Rise Transformers, the guaranteed temperature limits for
normal loss of life as per clause 5.11.1 of Std. C57.12.00 are;
9Top oil Rise - 65 °C

9Average Winding Rise - 65 °C
9Hot Spot winding Rise - 80 °C

ELECTRIC
Factory Test
Overload Testing Of Transformers
•As per the user requirements, overload test is performed at 125% ,
130% , 140% load or 150% load for specified duration or until steady
state condition
•If overload test is not specified, then expected temperature
rise/design values for required overload with calculated “m” and “n”
exponents are provided
•When specified, Heat Run Test is conducted at 3 different load levels
to calculate “m” and “n” exponents which are used to calculate
winding gradients and top oil rise at specified overload rating
•Top oil Rise from 3 heat-run tests is plotted for different loads to
calculate Top oil exponent “n” as per clause 9.8.4 of IEEE Std.
C57.119-2001
•Winding gradient from 3 heat-run tests is plotted for different currents
to calculate winding exponent “m” as per clause 9.8.5 of IEEE Std.
C57.119-2001

ELECTRIC
Factory Test

Dissolved gas in oil Analysis
•Oil sample is taken from the tank Before and After test
•Oil sampled are tested for various dissolved gasses
¾H2, CH4, C2H6, C2H4, C2H2, CO, CO2
•The change in gas levels must be within permissible limits set by
customer or manufacturer’s standards
•This test is also used as a diagnostic test to monitor condition of
transformer in service as per IEEE Guide C57.104-1991
•PC57.130 IEEE Trial-Use Guide for the Use of DGA during Factory
Temperature Rise Tests…. Will be used when it is approved and
published

ELECTRIC
Factory Test
Other Factory Tests
•Front of Wave Impulse Tests
•Sound Level Tests
•Zero Sequence Impedance Measurements
•Infrared Scan during Temperature Rise Tests
•Any other Special Tests

ELECTRIC
Factory Test
Witnessing
¾Majority of users do NOT witness factory tests
¾Many users will witness at least Dielectric tests for:
9New supplier
9New, special application design
¾Many users use independent consultants for this

ELECTRIC
Questions?

ELECTRIC
Field Testing
Field Acceptance Tests
•• Depends on Product and Manufacturer
•• Typical Manufacturer’s Instruction Manual will have….
To
To assure
assure full
full warranty
warranty protection,
protection, the
the following
following tests
tests
must
must be
be performed
performed before
before the
the transformer
transformer isis energized:
energized:
1.
1. Ratio
Ratio Test
Test
2.
2. Oil
Oil Dielectric
Dielectric Strength*
Strength*
3.
3. Oil
Oil Power
Power Factor
Factor
4.
4. Water
Water in
in Oil
Oil Content*
Content*
5.
5. Insulation
Insulation Power
Power Factor
Factor
6.
6. Dew
Dew Point
Point -- as
as received
received or
or when
when removed
removed from
from storage
storage
*On
*On oil
oil samples
samples taken
taken from
from the
the bottom
bottom of
of the
the unit
unit after
after final
final vacuum
vacuum oil
oil fill
fill and
and standtime
standtime

ELECTRIC
Field Diagnostic Testing
Windings
9 Resistance
9 Ratio/Polarity/Phase Relationship
9 Excitation Current
9 Short Circuit Impedance
9 Insulation Resistance
9 Capacitance
9 Power Factor/Dissipation Factor
9 Induced Voltage/Partial Discharge/RIV

ELECTRIC
Bushings
9 Capacitance
9 Dielectric Loss
9 Partial Discharge
9 Temperature (Infrared)
9 Oil Level
9 Visual Inspection

ELECTRIC
Insulating Oil
9
9 Water Content
9
9 Dissolved Gas
9
9 Dielectric Strength
9
9 Particle Count
9
9 Dielectric Loss
9
9
9 Interfacial Tension
9
9 Acidity
9
9 Visual
9
9 Color
9
9 Oxidation Stability
9
9 Now…. Corrosive Sulfur per MODIFIED ASTM D 1275

ELECTRIC
Tap Changers
LTC
9
9 Contact Continuity
9
9
9 Ratio
9
9 Timing
9
9 Motor Current
9
9 Limit Switch
DETC
9
9 Contact Pressure
9
9 Centering
9
9 Ratio
9
9 Visual Inspection

ELECTRIC
Core
9 Insulation Resistance
9 Ground Test

ELECTRIC
Tanks and Associated Devices
9 Conservator
9 Inert Air System
9 Gauges
9 Relays
9 Cooling System
9 Pressure
9 Visual Inspection

ELECTRIC
• Electrical Testing – Insulation Power Factor
Typical Values of
V ≅ 0.1 – 12.0 kV
Good insulation
PF ≅ DF ≤ 0.5%
Temperature
Sensitive
Testing “Major”
Insulation

ELECTRIC
• Electrical Testing – Turns Ratio
Can detect problems in:

•Turn to Turn
•Section to Section
•DETC Alignment
•Loose Connection
•Grounded Conductor
Easy to perform in Field

ELECTRIC
• Electrical Testing – Insulation Resistance
• Use megger for test

• All windings immersed in insulating
liquid
• All windings short-circuited
• All bushings in place
• Measure between windings and to
ground

ELECTRIC
Minimum values for Transformers

ELECTRIC
PI Comment
Less than 1 Dangerous

Polarization Index = R10 / R1
1.0 –1.1 Poor
R10 = 10th minute reading
1.1 – 1.25 Questionable
R1 = 1st minute reading
1.25 – 2.0 Fair
Above 2.0 Good

ELECTRIC
• Electrical Testing – Winding Resistance
Can detect defects such as;

•Poor bolted joints
•Corrosion
•Fractures of conductors
“Drop of Potential” method
Highly accurate Kelvin Bridge or Micro-ohmmeter can

also be used successfully in field.
ELECTRIC
• Electrical Testing – Winding Resistance
Transformer Test reports show all winding resistances as they are all
in “Series” connection
Compare the results for each phase to the other phases and to the
earlier readings. More than 2% variance from expected should be
investigated.

ELECTRIC
• Electrical Testing – Calibration and testing of
Protective Relays
Visual Checks
Electrical Testing
Relay Testing / Setting
Operational Testing
Relay Replacement
Thermo-graphic Survey / Inspection
Battery Testing and Maintenance
A stitch in time saves nine……

(Benjamin Franklin)

ELECTRIC
• Electrical Testing – “Hi-Pot” and DC Leakage
Terminals are shorted together

Tests between windings (H to L)
Tests between windings and ground
Voltage applied can be either DC or AC
Leakage current can be measured and used
to determine the integrity of insulation system
It is a Pass/Fail test that can be destructive

(If fails, it must be repaired before returning to service)

ELECTRIC
Electrical Testing - Frequency Response Analysis (FRA)
FRA is a diagnostic tool for modeling
the transfer function of a test specimen
Sweep Frequency Response Analysis (SFRA)

and Impulse method being used today

ELECTRIC
• Electrical Testing –
Frequency Response Analysis
0
Measures the “transfer function”
-10
of RLC network
-20
-30 Initial set of measurements are

-40 called “Finger Prints”
Later measurements are
dB
-50
-60 compared to the finger prints to

-70 see if anything changed
-80
-90
Comparisons can also be made
-100
10
4
10
5
10
6 between “Similar” units or
Fre que nc y - Hz
different phases of the same unit

ELECTRIC
• Electrical Testing –
Frequency Response Analysis
List of FRA application:

9Determine loose windings to perform re-tightening
9Determine core/coil deformations and movements
9Other internal faults after shipments or through-fault events
IEEE Transformers Committee FRA Working Group

What to measure, How to measure, & Acceptance Criteria (PC
57.149)

ELECTRIC
• Electrical Testing – Partial Discharge Detection
During the normal operation or induced potential tests, PD

can be detected using RIV, Electrical PD measurements, or
Acoustic PD measurements
RIV PD
ELECTRIC
• Electrical Testing – Partial Discharge Detection
PD activity inside the unit could mean the beginning

of an eventual flash-over and arcing
PD activity inside can also be indirectly detected

with DGA
Depending on how severe the PD activity, prepare

for major repair or replacement

ELECTRIC
• Other Testing – Degree of Polymerization (DP)
Degree of polymerization = measurement of ‘n’

New material DP ≅ 1000 – 1400
Near the end of life DP ≅ 150 – 200
Requires very little quantity to test

Correlates well with mechanical strength of cellulose

ELECTRIC
• Electrical Testing – Excitation Test
Testing is done with single phase AC
Results are compared to previous readings and between

phases (For three phase three legged unit, the middle
phase reads lower current than outer legs. Currents on
the outer legs should be within 15% of each other.)
Can detect defects in windings and the core structure,

turn to turn insulation, tap changing devices, etc.

ELECTRIC
• Electrical Testing – Others
•Impedance measurements
•Core Megger
•Series of Bushing tests (Capacitance, Dielectric Loss,
PF/DF, PD, Visual Inspection)
•Cooling System (Fans, Pumps, Cooling Control Circuits)

ELECTRIC
• Others – Infrared

ELECTRIC
Start-up Considerations
Testing AFTER all preparations BEFORE energization
• Insulation resistance (winding to ground and between
windings)
• Insulation power factor or dissipation factor test on each
winding to ground and between windings
• Core insulation
• PF/DF on Bushings
• Winding Ratio on all taps
• Winding resistance of all windings

ELECTRIC
Testing AFTER all preparations BEFORE energization
• Dielectric liquid (Screen tests and DGA)
• Exciting Current
• Check operation of auxiliary equipment
•• LTCs, liquid-circulating pumps, fans, or liquid or water flow meters in
accordance with manufacturer's instructions
• Frequency Response measurement compared to factory results

All these tests should be within acceptable limits prior to energization

ELECTRIC
Energization
9 Set cooling controls to automatic
9 Energize the transformer
9 Hold at rated voltage and no-load for at least 8 h or at the
manufacturers recommended time
9 Test gas blanket for oxygen and combustible gas
9 Check operation of LTC mechanism and auxiliary
equipment during this time
9 Note excessive audible noise and vibration
9 Observe the transformer carefully for the first few hours
after load is applied

ELECTRIC
Critical Transformers:
9 Always follow the Manufacturer’s recommendations
9 It is a good idea to have qualified engineers/technicians from the
manufacturer to perform the installation, testing, and commissioning
work or as a minimum, have them on-site for
consultation/supervision

ELECTRIC
Questions?
Thank You

ELECTRIC

Transformer Tests

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Transformer Testing

Weidmann-ACTI Inc. Fifth Annual Technical Conference

New Diagnostic Concepts for Better Asset Management

November 13 - 15, 2006

energy solutions WAUKESHA

energy solutions WAUKESHA

energy solutions WAUKESHA

Dielectric Tests – Background

energy solutions WAUKESHA

energy solutions WAUKESHA

energy solutions WAUKESHA

energy solutions WAUKESHA

energy solutions WAUKESHA

energy solutions WAUKESHA

energy solutions WAUKESHA

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•SWITCHING IMPULSE TEST

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•Neutral and Tank is connected to ground

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•Losses of unloaded transformer excited at rated voltage and frequency

energy solutions WAUKESHA

energy solutions WAUKESHA

•Load loss is the Losses of Transformer caused by Load Current

energy solutions WAUKESHA

energy solutions WAUKESHA

Temperature Rise Tests

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Temperature Rise Tests

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energy solutions WAUKESHA

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9Top oil Rise - 65 °C

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energy solutions WAUKESHA

Temperature Rise Tests

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•Sound Level Tests

•Zero Sequence Impedance Measurements

•Infrared Scan during Temperature Rise Tests

•Any other Special Tests

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