Testing of Transformers

J S Sastry

IF YOU HAVE NO DOUBTS YOU HAVE NOT UNDERSTOOD ANYTHING.

- a Spanish proverb.

Categories of Tests
1. Tests to prove transformer is built correctly Voltage Ratio, Polarity, Vector Group, Winding Resistance and tap change operation. 2. Tests to prove guarantees no-load and load loss, impedance, oil and winding temperatures, noise level 3. Tests to prove satisfactory service life Dielectric tests and Short-circuit test.

Schedule of Tests
Routine Tests
Dielectric Tests Parametric Tests

Type Tests
Temperature Rise Test Impulse Test

Special Tests
Short-circuit Test Magnetic Balance Test Measurement of Zero sequence Test Measurement of Noise Level

Ratio & Polarity Test

Ratio meter (working as potentiometer) having accuracy 0.1% to be used. Tolerance allowed : 0.5%. Ratio also confirms polarity as balance can not be obtained if winding connection is reversed.

Ratio & Polarity Test

Ratio adjustment Transformer under test

LT

HT 250V LAMP GALVANO

Polarity change switch

Ratio Meter

Phase angle adjustment

Polarity Check Test

V2

V1

V2 > V1 for subtractive polarity

HV

LV

Test for Vector Group

1U 2u Supply 440 V 3-phase supply across HV terminals 1U-1V-1W.

2n
2w 2v
Terminal Measured Voltage

1N

1V - 2v 1W 2w

1W

1V

Yy0

1U 2n

Test for Vector Group

1U Supply 440 V 3-phase supply across HV terminals 1U-1V-1W.
Dy1
Terminal Measured Voltage

2u 2w 1W 2u 2v

1V

1W 2w 1V 2w 1V 2u 2v 2n 1W 2n

1U 2n
2w

2v

1V 1W

1W 2u

Measurement of Winding Resistance

Kelvin Double Bridge used 25 30 Amps DC required Ambient/oil temperature to be noted
If oil, average of top & bottom temperatures to be considered.

Conversion to 750C by: R75 = Ra x (234.5 + 75)/(234.5 + Ta) where Ra is resistance at ambient temperature Ta.

Measurement of Winding Resistance

G

P p q

RX

External Resistance

RX = S.Q/P where, RX = Resistance of winding under test S = Standard Resistance (part of measuring Bridge

Measurement of Insulation Resistance

2 KV or 5 KV Insulation Resistance Tester (Megger) is used. IR Value at 1 minute and ambient / average oil temperature to be noted. 15 seconds and 60 seconds or 1 minute and 10 minute readings also are noted sometimes to calculate PI of the insulation system.

Measurement of Insulation Resistance

LV LV LV 2n 2u 1U 2v 1V 2w 1W

2n

2u
1U

2v
1V

2w
1W L HV G E

2n
1U L G E

2u
1V

2v 2w
1W

L G E (a)

HV

(b)

(c)

(a) IR Value between HV and earth (b) IR value between LV and earth (c) IR Value between HV and LV

Power Frequency Test

Also called Separate Source Voltage withstand test. Conducted at 50 Hz for 60 seconds. All windings other than the winding under test are shorted and connected to earth. Checks the Major Insulation of the transformer. Values for uniformly insulated windings are given in the standards. Non-uniformly insulated windings with neutral are tested at 38 KV. The transformer should withstand the specified voltage without any breakdown.

Power Frequency Test

~
LV
2n 2u 1U 2v 1V 2w 1W 2n 2u 2v 2w

LV

1U

1V

1W

HV

HV

N0-Load Loss Test

Usually conducted at 50 Hz from LV side keeping HV open. Core loss consists of Hysteresis and Eddy Current losses. Hysteresis loss depends on average value and eddy current loss on rms value of the supply voltage. Hence two voltmeters (average voltmeter scaled to read 1.11 times the average voltage and rms voltmeter) are used. Generally 3-wattmeter method is used.

N0-Load Loss Test

1U

1V

1W
CT 2u 3 Phase Voltage at Rated Frequency

2w 2v

VT

N0-Load Loss Test

Rated voltage as per average voltmeter (Ua) is applied and readings of rms voltmeter, no-load currents and losses of the three phases are noted. Corrected loss Pm = Pm (1+d) where Pm = sum of the three wattmeter readings, and d = (Ua Urms)/Ua

Load Loss & Impedance Test

Load loss comprises of I2R loss and stray loss where R is the resistance of the winding. I2R loss varies directly with temperature and stray loss varies inversely with temperature. Measured loss is to be corrected to 750C. Test is carried out by short circuiting usually LV windings and feeding rated current to HV windings. The voltage measured is the reactance voltage. 3-wattmeter method is normally used for measurement of losses. Load loss test to be conducted preferably at rated current or at any value between 50 100% rated current.

Load Loss & Impedance Test

1U
CT VT 1V

3 Phase Controlled Voltage at Rated Frequency

1W

2u

2w 2v

Load Loss & Impedance Test

Calculation of Load loss at 750C:
Stray loss Sa at ambient / average oil temperature (Ta) = (Sum of three wattmeter readings sum of HV & LV I2R losses at Ta) Stray loss S75at 750C = Sa x (234.5 + Ta)
(234.5+75) Load loss at T75 = (Sum of HV & LV I2R losses at T75 + S75)

Load Loss & Impedance Test

Calculation of %Impedance Voltage (Iz):
%Iz = (%Ir2 + %Ix2) where, %Ir = (Load loss at 750C)x100/Rated KVA of transformer, and %Ix = (Reactance voltage at rated current)x100/Rated voltage.

Induced Over Voltage Test

This test is conducted to check the Minor insulation of a transformer. In case of non-uniformly insulated windings it checks total insulation (both major and minor). In case of transformers with uniformly insulated windings, 2 times normal voltage is applied to the LV windings at 2 times normal frequency for 60 seconds duration keeping the HV open. In case of non-uniformly insulated windings, the voltage equal to two times or more is applied to LV terminals in such a way that the specified voltage is induced across the HV terminals. The duration and frequency can be so adjusted that the windings are subjected 6,000 cycles of the required voltage.

Induced Over Voltage Test

(For Uniformly Distributed winding transformers)
1U

1V

1W
CT 2u

2w 2v

VT

3 Phase 2 x Rated Voltage At 2 x Rated Frequency for 1 Minute

Induced Over Voltage Test

(For Non-uniformly Distributed winding transformers)
231.5 KV 1U 1V 1W

154.33 KV

HV 77.17 KV

2u

2v

2w

38.1 KV at 100 Hz

LV

Note: Test circuit shown for a typical 132/33 KV Transformer.

Test for Lightning Impulse

For system voltages < 300 KV, Lightning Impulse Test is a type test. For system voltages 300 KV, it is a routine test. Chopped wave test is a type test in all cases. Wave shape of the impulse voltage: Front: 1.2 s 30% and tail: 50 s 20%. The transformer should withstand the specified voltage with out any breakdown. Breakdown is indicated by voltage collapse or change in the neutral current wave shape. Test sequence: 1 Reduced full wave 1 100% Full wave 1 Reduced chopped wave If required. 2 100% Chopped waves 2 100% Full waves

Test for Lightning Impulse

1U R1 & R2 are external resistors used for obtaining wave shape if required.
R2

1W R1

1V

2u For Neutral Current 2w 2v

Wave shape through

Oscilloscope.

Circuit shown for HV

Rf
Gn Rt Cn Rf

Output

Impulse Generator

Rc

G3 Rt C3 Rf

Rc

G2

Rt

C2

Rf

Rc

G1
Rt C1

C1,C2,Cn : Stage Capacitor G1,G2,Gn : Stage Gaps Rc: Charging Resistance Rf : Series Resistance (Front) Rt : Discharge Resistance (Tail)

Impulse Wave Shapes

V o l t a g e
1.0 0.9

0.5 0.3 0 T1

Time
T2

V o l t a g e

1.0 0.9
0.5 0.3 0

T1 Tc

Time

Switching Impulse test

Switching over voltages due to switching-on or switching-off of transformer. For system voltages > 300 KV, it is routine test. Switching impulse wave shape to have specified amplitude of at least 200 s and a total duration of at least 500 s, but preferably 1000 s. Sequence of impulse voltage application: 1 Reduced full wave 2 Full waves Voltage and neutral current wave shapes are recorded and examined for fault detection.

Switching Impulse Wave Shape

V o l t a g e

1.0 0.9 0.5 0.3 0 200 s 100 s

1000 s (at least 500 s )

Time

Partial Discharge Measurement

Causes of Partial Discharges:
Insufficient processing High stress zones Sharp points Cavities in insulation Bad contacts Foreign objects inside tank.

Basically a quality control check

Partial Discharge Measurement

Circuit similar to Open Circuit test (Noload loss test). Supply 1.5 times rated voltage at higher frequency for 30 minutes. Check electrical signals generated by discharges produced with a partial discharge detector. Discharges measured should be less than 500 pc.

Zero-Phase Sequence Test

Zero-phase sequence impedance is measured on star connected windings with neutral earthed. This determines the amplitude of current that will flow in the event of a line to earth fault. Reluctance path for zero sequence flux is different in 3-limb core and 5-limb core. Hence value of ZPS Impedance depends upon type of core construction. %Z0 = 3 x voltage measured x rated current Vph x rated current

Zero-Phase Sequence Test

~
1U
1N 2u 2v 2w LV 2n 3u 3v 3w 1. Short 1U 1V 1W and supply 1U1V1W 1N, with 2u-2v-2w open and tertiary closed. Measure Z (H T). HV

1V

1W

2. Short 1U 1V 1W and supply 1U1V1W 1N, with 2u 2v 2w shorted and tertiary closed. Measure Z (H /L T). 3. Open 1U 1V 1W and supply 2u-2v-2w 2n, with 2u 2v 2w shorted and tertiary closed. Measure Z (L T). 4. Short 1U 1V 1W and supply 1U1V1W 1N, with 2u 2v 2w shorted and tertiary open. Measure Z (H -L). 5. Short 2u-2v-2w and supply 2u-2v-2w 2n, with 1U-1V-1W shorted and tertiary closed. Measure Z (L/H T).

SV

Short-Circuit Test
SC current is calculated by using measured SC impedance of the transformer plus the system impedance. Two types of SC Test procedures can be followed:
Pre-set method: LV winding is shorted prior to application of power to HV winding. Post-set method: Here one of the windings

Short-Circuit Test
Test calls for 3 shots per phase one each at maximum tap, normal tap and minimum tap. Impedance measured after the SC Test should not be more than 2% of the value measured before the test.

Measurement of Acoustic Noise Level

Acoustic noise due to core vibrations (magnetostriction). Measured under open circuit test conditions with all the oil pumps, fans etc. running. Test to be conducted as per NEMA TRI 1971 and noise levels should not exceed the values specified.