Transformer Testing

Engr.Md. Fardouse Alam , MIEB- 40075

Essential Elements

• Copper or coli
• Core
• X-F oil
• Board.
• Heavy metal
• Insulation material
Inner Part of X-F
Transformer core

CORE
Transformer Test

2 types. There are

• Pre Manufacturing Test.
• Pre Commissioning Test.
Pre Manufacturing Test

• Copper test
• Core test
• Oil test
Pre Commissioning Test.

2 Types. There are,

▪ Routine Test
▪ Type Test
Routine Test

• Turns Ratio / Voltage ratio Test.

• Polarity / Vector group Test.
• Open-circuit Test or No-load losses.
• Short-circuit impedance and load loss Test.
• % Impedance Test.
• High Voltage Test.
• Insulation Resistance Test.
Copper Test or copper
Resistance Test

• Why need Core in transformer?

▪ The core helps to shape the magnetic field. Without a core, a lot of the field
would not pass through the secondary windings. With the magnetic core, 99%
of the field is guided to pass through the secondary windings.
▪ Reduce the transformer vibration and extra noise
▪ A good laminated core reduces the no load current that’s why temperature of
transformer will be maintained.
▪ Increase the life time of transformer
▪ Reduce no load power P and ampere I at same voltage.
Copper Test or copper
Resistance Test

Test Purpose
To identify purity of copper
1.Mathematical Result:
Low,
R= pL/A
• Using screw gage (h x w) in mm
• h= Height of copper
• w= Width of copper
2.Practical Result:
• Using resistance Meter
Resistance Tester
Core Test

Test Purpose
To identify power loss of core
Testing Equipment
• Iron Loss Tester
Testing Procedure
• Using screw gage measure only w in mm
• Iron Loss Must less then 1.0 watt/Kg
Core testing procedure
▪ Sample collection from importer.
▪ Measure iron loss in Watt using Iron Loss Tester machine
▪ If loss in watt per Kg is less than 1.00 watt, the performance of
tested laminated core is good for using in transformer.
▪ If loss in watt per Kg is more than 1.00 watt, the core loss will be
high. For this reason no load loss or open circuit loss will be
high.
Iron Loss Tester
Oil Test

Test Purpose
• To ensure good Brake Down Voltage of Oil.
• Must need >35KV
Testing Equipment
• X-F Oil Tester
Insulation resistance test

Purpose
To ensure the insulation of Tx-F is OK or Not
Testing Procedure
Standard 2000+ Mega ohm
• LT to Ground
• HT to Ground
• LT to HT
Testing Equipment
• Megger Meter
Top View
Turns Ratio Test

Purpose
• Tx-F Taping position is ok or not.
Procedure
• +1 x 2.5, 0, -3 x 2.5
• 11000/415 V
• 415 to HT
Testing Equipment
• AV meter/clamp meter
NO Load Test/ Open Circuit Test

Test Purpose
• To ensure the core loss in transformer.
Testing Procedure
• Core loss
• LT side 415V supply
• NO Load Current a and b
• Power p1 and p2
Testing Equipment
• Power Meter
• AV Meter/clamp meter
Tx-F Connection (No Load Test)
Load Test/ Short Circuit Test

Test Purpose
• To ensure over all Tx-F losses
Testing Procedure
• Supply rated Ampere to HT side
• Short LT side with N
Testing Equipment
• Power Meter
Tx-F Connection (Load Test or
Short Circuit Test)
 Vector Group Test

Test Purpose
To identify the winding configuration of a
transformer
Testing Procedure
Supply 415V to HT
• HT-A and LT- a (A and a) short
• Bb=Bc
• Cb>Cc
Testing Equipment
AV meter/clamp meter
Tx-F Connection (Vector Group Test)
High Voltage Test

Test Purpose
• To ensure the Tx-F will be run at station or
not with safely.
Testing Purpose
• 11000V connect to HT
• Short LT with N
• LT to Ground
Testing Equipment
• HV Panel
Voltage Supplier (VARIAC)
Thank You
 FACTORY TEST REPORT OF TRANSFORMER DATE :
GENERAL INFORMATION JOB: TEMPERATURE: 32°C
CLIENTS:
Transformer Serial No:150-
CAPACITY: 150 KVA INPUT VOLTAGE : 11000 V OUTPUT VOLTAGE : 415 V
IN PUT CURRENT : 7.87 A OUTPUT CURRENT : 208.68 A
INSULATION RESISTANCE TEST:
HT TO EARTH(MΩ) HT TO LT(MΩ) LT TO EARTH(MΩ) STANDARD REMARKS
4000+ 4000+ 4000+ 2000 + OK
TURNS RATIO TEST:
TAP TURNS (%) Supply voltage (v) Measured voltage (v) RATIO STANDARD STD.
AB BC CA ab bc ca Ratio TOLERANCE

01. 102.5 417 415 414 15.28 15.27 15.29 27.15 27.17
02. 100.0 415 415 415 15.65 15.67 15.68 26.49 26.51
03. 97.5 416 415 416 16.05 16.04 16.05 25.86 25.84 ±0.5%
04. 95.0 417 414 415 16.48 16.44 16.47 25.20 25.18
05. 92.5 415 414 415 16.94 16.93 16.92 24.51 24.52
VECTOR GROUP TEST FOR GROUP Dyn11: (A & a SHORTED):
APPLY VOLTAGE (V) MEASURED VOLTAGE(V) REMARKS
AB= 416 BC= 414 Bc= 401 Cc= 401 As Bc=Bb, Cb > Cc
CA= 415 Bb= 401 Cb= 415 Vector Group is Dyn11
HIGH VOLTAGE TEST:
APPLIED VOLTS(KV) for 60 seconds LEAKAGE CURRENT(mA) REMARKS
H.V. 28 18 OK
L.V. 2.5 - OK
NO LOAD TEST:
SUPPLY VOLTS(V) AVG. NO LOAD CURRENT(A) AVERAGE NO LOAD
VOLTS(V) CURRENT LOSS(W)
ab bc ca a b c
415 415 416 415 3.85 3.83 3.86 3.84 Measured Guaranteed
320 350
LOAD TEST:
SUPPLY CURRENT AVG. IMP. VOLTS. AVG. LOSS AT FULL LOAD GUARANTEED
AMB.TEMP LOSS(W) LOSS(W)
A B C AMP. AB BC CA VOLT AT 75°C
Watt
7.88 7.87 7.87 7.87 440 440 439 440 1930 1930x1.17 2400
=2258
PERCENTAGE IMPEDANCE: 4.00%
Oil Test:
SPHERE GAP BREAK DOWN VOLTAGE REMARKS
2.5MM 58 OK

TEST ENGINEER
MAINTENANCE INSTRUCTIONS FOR POWER & DISTRIBUTION TRANSFORMERS
Engr. Md. Fardouse Alam
MIEB- 40075
Phone/whatsapp 01717487346

Maintenance Schedule

Action required if
Sl Inspection Items to be inspection shows
To be checked
No frequency inspected unsatisfactory
conditions

1 Hourly Ambient temperature

2 Hourly Winding
temperature
Ensure that temperature rise is
within specified limits.
3 Hourly Oil temperature

Check against rated figures given

4 Hourly Load (amps)
on the name plate

5 Hourly Voltage

If low, top with dry

Oil level in
6 Daily Check oil level gauge oil find whether there
transformer
is any leak.

7 Daily Oil level in bushing -- --

If silicagel is pink,
change by new
Check that air passages are free. charge. The old
8 Daily Dehydrating breather
Check colour of active agent charge may be
reactivated for using
again.

Oil level in OLTC Check oil sight window or oil If low, top with new
9 Daily
conservator level gauge dry oil
 Action required if
Sl Inspection Items to be inspection shows
To be checked
No frequency inspected unsatisfactory
conditions

Relief diaphragm of
Replace if cracked or
10 Daily OLTC explosion --
broken
vent

Cooler fan, bearing Check the bearings. Examine Lubricate the bearing.
11 Daily motor & operating contacts, check manual control Replace burnt or worn
mechanism and interlock contacts.

Clean the dirt. If

12 Quarterly Examine for cracks and dirt deposit cracked or broken
Bushings
replace the bushing.

Take suitable action

Check for dielectric strength and
13 Quarterly to restore quality of
Oil in transformer water content
oil.

Filter or replace if
BDV is less than
a. Dielectric strength
specified value.
Half yearly or
at the
14 end of 5000 Oil in the diverter Measure the water
switch of OLTC content using KARL
operations
FISHER method.
b. Water content Replace/ recondition
if exceeds that limits
specified

15 Yearly Oil in transformer Check acidity resistivity, tan delta Filter or replace
and sludge

Oil filled condenser

16 Yearly Refer to the maintenance schedule As recommended
bushing for OIP condenser bushings

Tighten the bolts

17 Yearly Gasket joints evenly to avoid
uneven pressure
 Action required if
Sl Inspection Items to be inspection shows
To be checked
No frequency inspected unsatisfactory
conditions

Replace gasket if
18 Yearly Cable boxes Check sealing arrangements and
find out whether there is any leak leaking

Clean the components.

Relays alarm and Examine relay and alarm contacts,
19 Yearly Replace contacts and
other circuits their operation fuses etc. check
relay accuracy. fuse if necessary

20 Yearly Painting Touch up to be done

Rusting/colour

Take suitable action if

21 Yearly Earth resistance earth resistance is
--
high

After 50000
22 operations of Arcing contacts -- Replace if necessary
the OLTC

Lubricating oil in
the gear box of Add or replace with
23 -do- Low oil level
driving lubricating oil
mechanism

1000 kVA to 2000

5 yearly
kVA
Overall inspection including core Wash the core and
24
and coil coils with clean oil
7 – 10
above 3000 kVA
yearly

Note :

In case of abnormal phenomena occurring during service, inform the manufacturer

the exact nature of the phenomena together with the name plate particulars for easy
identification.