Inspection Test Procedure

Site Installation & Pre-commissioning test of 150 kV Transformer

Purpose: To draw up site installation and testing of transformer at site and to ensure that
transformer ready for operation.

A. Arrival inspection

Arrival inspection is recommended to be conducted after transformer has sat down on the final
foundation.

1. Inspection of damage

This inspection aims to cover any damage that may occur during shipment. The inspection
takes place as soon as possible. If damage is found an immediate internal inspection of the
transformer is recommended.

2. Inspection of the impact recorder and Dry air or N2 inert gas pressure system

Check for positive pressure in the main tank by means of the gauge, the minimum positive
pressure should be 0.04 bars. Also the reading of shocklog recorder and or paper chart
impact recorder

3. Core grounding insulation resistance test

The core grounding megger test is used to determine the state of the core clamping structure,
core to ground or clamp to ground insulation.
The test is conducted by using a megger voltage 1000 VDC with the values should exceed
200 M-Ohms.

4. Transport gas moisture (dew point) test

The transport gas moisture (dew point) test is used to determine the moisture of active part
insulation for transformer shipped without oil. The dew point test is conducted if the Dry Air
pressure is below 0.04 bars. The value should not exceed than 0.5%.

B. Assembling and Installation

Transformer was delivered with oil and pressurised with dry air.

1. General Installation

- Preparation for Installation of the transformer tank

- Inspection of availability of all parts as per packing list, tool and equipments needed
- Oil stream line in the storage tank before filled into main tank
- Dry air supply or machine with regulator and fittings for flushing main tank during installation
to prevent exposure ambient air.
 - Installation of main accessories:
 Metal parts : radiators, conservator, turrets, pipes, and etc
 Tertiery, LVN, LV and HVN Bushing
- Wiring the accessories
- Oil treatment
- Air Venting
- Leak test (pressure test)
- General Check

2. Preparation for Installation

Provide work permit, all document and drawing required for installation and pre-commissioning
purpose

3. Inspection of availability of all parts, tool and equipment

- Check and inspect the availability of all parts, accessories of transformer as per packing list
- Inform to manufacturer immediately if any missing or damage part found
- Check and inspect of tool and equipment required for transformer installation. Tool and
equipment required at least as below:
 Crane of ± 10 ton capacity and suitable slings for radiators, conservator and condenser
bushings
 High capacity vacuum pump and fittings minimum 200-300 m3/h
 High vacuum stream line filter, minimum of 6000 litters per hour, including moisture content
meter installed, which can read moisture content below 5 ppm.
 Oil storage tank available on site, 1 x 8,000 litters for oil treatment, prior to filling into the
transformer)
 Dry air supply or machine with regulator and fittings for flushing main tank during bushing
installation to prevent exposure ambient air.
 Generator set or Power supply which suitable for all machine power consumption
requirement
 Oil test apparatus (at least 80 kV/2.5 mm )
 Dew point measuring instrument (optional, in case Nitrogen pressure in main tank is found
below 0.04 bar during arrival inspection)
 Megger test equipment, 500 – 10 kV
 Multi-Ratio meter
 Winding resistance meter
 Capacitance & Tangent Delta test set
 SFRA set test
 Multi meter/general purpose meter
 Hand tools for assembly purposes
 Torque wrenches and socket for external nuts and bolts
 Painting tool for touch up
 Ladders and safety harnesses
 Cleaning item (acetone and clean rag)
4. Oil stream line in the storage tank

New oil which coming from oil supplier has to be streamed line firstly at least one cycle until oil
pass the oil quality standard at least 60 kV/2.5 mm before oil is filled into main tank.

5. Installation of accessories:
During installation, flush the main tank with dry air to prevent active part exposure with the
ambient air.
Install main accessories of transformer as per General Arrangement drawing,
 Metal parts : radiators, conservator, turrets, pipes, and etc
 Tertiery, LVN, LV and HVN Bushing

6. Vacuum Process & Oil filling of transformer
The purpose of vacuum is to remove all gas from the insulation. The presence of gas in the
insulation may cause the failures and/or develop partial discharges that can develop into an
internal failure.
Apply vacuum to the main tank conservator and OLTC conservator simultaneously via the top
oil filling valve. The vacuum should be applied for a period not less than 16 hours and reading
of 1 tor is achieved. Oil filling then can be processed up to conservator at ambient
temperature level. Make sure that oil have been streamed line in the storage tank and oil has
passed the oil quality standard before filled in the main tank

7. Wiring the accessories:

Wire the accessories as per schematic circuit diagram drawing

8. Oil Treatment

Once the oil filling process has been completed, then continued with oil purification at least 3
(three) cycle until oil pass the oil quality standard with BDV oil at least 60 kV/2.5 mm IEC
standard and moisture content below 5 ppm

9. Air venting

Once the oil purification process has been completed, all vents plugs should be opened until all
air bubbles have been evacuated. The most appropriate venting sequence is first opening the
lower vent plugs and then the higher ones.
After completion of the venting procedure close all vents plugs and clean all spilled oil around
the vent plugs so that it cannot be mistaken for oil leaks.

10. Leak test

The test is applied by injecting N2 gas 0.25 bar into atmoseal bag and keep for 24 hour. Put
clamp on top of pressure relief device to prevent the device work.

11. General Check

Check all transformer assembly and installation as per Electrical and Mechanical Check list
C. Pre-Commissioning Test

During pre-commissioning test, at least some testing should be performed as below.

1. Oil Test

After oil filling and purification, test which is required:

 Dielectric strength min. 60 KV / 2.5 mm – IEC 60156
 Moisture or water content < 5 ppm

2. SFRA Test (result refer to FAT)

3. Winding Insulation Resistance Test

Purpose to detect internal movement of parts that may have shorted out some of the insulation
on the core and on the winding and leads, as well as to check for excessive moisture
contamination.

* Winding insulation test should be performed

 HV to LV winding
 HV to Tertiary winding
 LV to Tertiary winding
 HV winding to ground
 LV winding to ground
 Tertiary winding to ground

* Required value : minimum 10 M ohm/kV with minimum of 400 M Ohm

Voltage test 5 kV DC

* Polarization Index

Polarization index is a ratio of the mega ohm resistance at the end of 10 minutes test to the
mega ohm at 1 minute test constant voltage. The criteria for PI refer to ANSI standard :

PI Insulation condition

<1 Dangerous
1.0 – 1.1 Poor
1.1 – 1.25 Questionable
1.25 – 2.0 Fair
>2.0 Good
 Measurement of insulation resistance to earth
of the windings (Megger test)

HV

VDC N

M
CORE

HV / LV + CORE + Earth

LV / HV + CORE + Earth

HV + LV / CORE + Earth N
LV
CORE / HV + LV + Earth

TANK

Connection diagram

4. Voltage ratio & vector group test

The voltage ratio test is used to ensure the internal connection have been made correctly.
The test can be performed with transformer turn ratio test or by using voltage ratio check
This test will detect primarily inner winding short circuit or tap changer alignment problem.

The turn ratio between the transformer winding can be obtained from the transformer
name plate. The measured ratio must be within the tolerance as specified in the
standards (0.5%) compare with ratio calculated from name plate voltage.
 Measurement of voltage ratio and phase displacement

HV

LV
k = U prim . c
U sec N

c = f (Phase displacement)

Connection diagram

5. Winding Resistance Test

Purpose to check for proper connections and determines if an open circuit condition or high
resistance connection exist in parallel conductor winding.

Since the resistance of copper varies with temperature all test reading must be converted to a
common temperature to give meaning full result, most factory test data is converted to 75 C
this has become the most commonly used temperature.
 Measurement of winding resistance

SHUNT
1A = 1 mV

I
V2
U
D.C.-source V1
V1
N

S HV

Current limiter
LV

R= U N
I

Connection diagram

6. Capacitance and Dissipation Factor (tangent delta) test

Capacitance and Dissipation factor test purpose to evaluate the nature and quality of electrical
insulation material system. By measuring dissipation factor losses in electrical insulation the unit can
indicate the presence of contaminations, fracture, punctures and undesirable conditions caused by
moisture on or in the insulation, shorts or opens in winding or insulation and conductive contaminants
in insulating oil, gas or solid materials.
The test results are used to determine the dryness of the insulation system in the main tank and the
bushings.
The test can use high voltage electrical insulation system at power frequency by applying test voltage
up to 12 KV.

Normal values for transformers in service have to be below 1% (50HZ and corrected to 20  C) and
for new transformer below 0.5%.
Connection diagram
7. Insulation Resistance Test Wiring of Auxiliary Circuit ( 500 VDC)

8. Functional test of protection device

Purpose to ensure equipment functionality both mechanical and electrical test on the transformer.

 Buchholz relay
 Temperature indicator
 Pressure relieve device
 Oil level indicator
 RS 2001
 OLTC
 Calibration check of temperature indicator
 Test run cooling fan
 etc