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Centre For Industrial Solutions and Advanced Training

(An ISO 9001:2015 Certified)
“A Complete Training Solution (Outsourcing) under One roof”

Training Course Material- Transformer

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1. TRANSFORMER
FUNDAMENTALS

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How does a transformer work?

1. An AC current in the primary coil

creates a changing magnetic field in the
iron core.
2. This changing magnetic field induces a
current in the secondary coil as
described by Faraday’s Law.

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Transformer

• Alternating current in
one circuit induces an
alternating current in a
second circuit
• Transfers power between
the two circuits
• Doesn’t transfer charge
between the two circuits

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Transformer and Faraday's Law

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Current and Voltage

• Power arriving in the primary circuit
must equal power leaving the
secondary circuit
• Power is the product of voltage ·
current
• A transformer can change the voltage
and current while keeping power
unchanged!
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E.M.F equation
Ns – Secondary winding turns.
Np – Primary winding turns.
Φ max – max. flux linking with both windings.
f– Frequency.
1
Flux grows from zero to max in 4cycles i.e in a time
t= 1
second.
4f

Avg. rate of change of flux is max
 4 max f lines / sec .
t
= 4Φ max. f lines/sec.

contd.
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Av. emf induced in each turn = 4Φmax f volts.

r.m.s. value
Form Factor =  1.11
Av .value

R.M.S (emf) = 1.11×Av. Value of emf

= 4.44Φmax f volts.
Hence: Ep = 4.44 Np Φ max. f volts.
Es = 4.44 Ns Φ max. f volts.
( transformer works on the principle of Mutual
Induction)

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2. KNOW YOUR EQUIPMENT

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Construction of Transformer
Magnetizing circuits: Limbs, yoke & clamping structures.
Electric circuits: Windings, insulation & bracings.
Terminals: Tapings & Tapping switches, bushings
& leads.
Tank: Oil, cooling devices, dryers, conservators
& ancillaries.
Core: Made up with laminations from C.R.G.O steel
strip of about 3% silicon content.

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Parts of Power Transformer

• Windings (Copper)
• Core (CRGO Silicon Steel)
• Main Tank and Conservator (Oil Tank)
• Buccholz Relay
• Body or case or Yoke in case of Motor
• Connecting Terminal and Bushing
• Breather (contains Silica Gel)
• Fans/Cooling Fins
• Protective Devices/Relays/CBs
• Cooling Arrangement

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Accessories of Transformers
• Terminals & Bushings.
• Cable Boxes.
• Oil conservator.
• Constant oil pressure system.
• Breather.
• Oil Gauge (oil level indicator).
• Oil Temperature Indicator (OTI).
• Winding Temperature Indicator (WIT).
• Oil temp – Alarm - 70°c, Trip - 80°c.
Contd.
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• WDG temp – Alarm - 80°c, Trip - 90°c.

• Buchholz’s Relay – Float & Bucket type.
• Relief or explosion vent.
• Tapping switch (off load).
• Tapping switch (OLTC).
• Marshalling Box.
• Radiators.
• Other accessories etc.
• Modern trends.
• Hydrogen Monitoring System.
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• Nitrogen Blanketing System.

• OFW cooling.
• Heat Exchangers.
• Pressure Balancing Pipes.
• Float Switches (Mercury).
• Bucket system for signals.
• Oil Pumps (contractor coil D.C, main contacts
carry A.C)

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Transformer construction
configuration

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Construction of core with windings

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Main tank,Conservator tank and

buccholz relay
Buccholz relay scheme Installation scheme

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Surge relay

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WTI and OTI

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Magnetic oil level gauge

Installation scheme Schematic

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HV/LV /Neutral Bushings

Schematic Drawing
Description
 Condensor bushing with oil
impregnated paper core gen
as per IS-3347,Part-5,1979 .

 Wound in specially
condenser graded over
central conductor for field
control .
 Porcelain insulator on top.

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Marshalling panel
Schematic Description
• All control connections from
transformer accessories are
brought out on the terminal
strips in the marshalling
panel.
• Houses all indicators ,
control relays and other
electrical accessories.

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NO LOAD TAP CHANGER

Schematic drawing Description
• For tap changing during
switch OFF condition.
• Externally operated by
manual movement.
• Contact A short circuits the
taps for voltage regulation.
• No movement possible
beyond F .

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On Load Tap Changer

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On Load Tap Changer

Schematic drawing Description
• Switch 3 closes, an off-load operation.
• Rotary switch turns, breaking one connection
and supplying load current through diverter
resistor A.
• Rotary switch continues to turn, connecting
between contacts A and B. Load now supplied
via diverter resistors A and B, winding turns
bridged via A and B.
• Rotary switch continues to turn, breaking
contact with diverter A. Load now supplied via
diverter B alone, winding turns no longer
bridged.
• Rotary switch continues to turn, shorting
diverter B. Load now supplied directly via left
hand connection. Diverter A is unused.
• Switch 2 opens, an off-load operation

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Heat exchangers and cooling

system

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NCT ,BCT and WTI CT

• Neutral Current Transformer is provided at the
neutral cable inside the LV Cable box and is used for
Stand by (1 core) and REF earth fault protection(2ND
core) of transformer.

• Bushing CT (3 nos.) is provided on the HV bushing on

the primary side and is used for Transformer
differential protection .

• WTI CT, 1 no. is used for indirect Winding

temperature monitoring purpose.
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Transformer oil

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Insulation System
Class:
class Y A E B F H C
temp°C 90 105 120 130 155 180 >180

Cooling:
AN, AF, ONAN, ONAF, OFAN, OFAF, ONWF, OFWF.

(Same Tr. Can have different ratings depending

upon different cooling systems)
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Materials of Temperature Class

Class Temp. Materials

Y 90 Cotton, Silk, paper, wood etc.

without impregnation.

A 105 Material of class ‘Y’ impregnated

with natural Resins, cellulose,
insulating oil etc.

E 120 Synthetic resin, Enamels, cotton, paper

laminates with formaldehyde bonding
etc.

contd..

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Class Temp Materials

B 130 Mica, glass, fibre, asbestos etc. with
suitable bonding substance.
F 155 Materials of class ‘B’ with
thermally resistant bonding mat.
H 180 Glass fibre, asbestos mats. & built
up mica with app. silicon resin.
C >180 Mica, ceramic glass, quartz &
without binders or with silicon
resins of superior thermal stability.

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3. TECHNICAL
PARTICULARS

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Transformer technical specifications.

1.NP Details

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Transformer technical specifications.

Other Specifications ( Not provided on name plate)

 Transformer regulation
 Flux density
 Volts per turn ratio
 No Load current
 Transformer losses .
 Insulation class
 Insulation level
 One minute PF Withstand voltage

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TRANSFORMER
A few important standards (out of many)
• IS:2026 (Part III)
– 1977 Power TRS Insulation level and dielectric tests.
• IS:3024 – 1965 Elect. sheets.
• IS:3637 - 1966 Gas operated relays.
• IS:6088 – 1971 Heat exchanger.
• IS:8468 – 1977 O.L.T.C.
• IS:1886 –
– 1967 Code of practice for installation and
maintenance.

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 IS:9434 –
 1979 guide for sampling & analysis of free and dissolved gases
& oil from oil filled equipments.
 IS:335
 1983 New insulating oils for TR. & SW. gears.
 IS:1448 –
 1977 Methods of test for petroleum and its products.
 IS:6855 –
 1973 Methods of sampling for oil dielectrics.
 IS:2071 –
 Part I-1974, Part II-1974, Part III-1976
 High voltage test.
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Transformer Protections

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CAUSES OF FAILURES
• Short circuits.
• O.V, U.V & V.DIPS.
• O.F, U.F & df/dt.
• Switching surge.
• Lightning.
• Improper Selection.
• Wrong layouts.
• Improper load distribution.

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• Equipment failures.
• Protection failures.
• Improper relay co-ordination.
• Tripping of drives, loaded feeders & large
generators.
• Islanding failures.
• Hot spots, high temp.
• Ageing.
• Natural causes.

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• Faults caused by lizards, rats, snakes, birds etc.

• Improper operation and maintenance.
• Lack of training.

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REMEDIES
• Foresee imminent problems.
• Analyze failures.
• Take corrective measures.
• Exchange experience.
• Innovative measures.
• Adopt modern management techniques.
• Periodical training.
and so on…

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• Erection.
• Testing.
• Commissioning.
• Operation
• Maintenance.

Are needed to prevent failures.

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Installation & Commissioning

• Precautions.
• Connection with earth ( as per IS: 3043-1966)
• Generator Trs.: neutral directly earthed.
• S/S transformer.
Resistance earthing preferable to limit fault current.
• DISTR. Tr.: Neutral point is directly earthed.
• Tr. With delta winding.
Artificial star point is achieved by earthing Tr.
contd..

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 Instrument Trs.:
Secondary windings and the bodies are earthed.
 Earthing Tr. Neutral point is either directly or
through a resistance connected to earth as per
requirement.
 Isolation:
A circuit breaker of requisite breaking capacity
should be installed on both sides of Tr.
 Oil soakpit:
It is provided wherever oil exceeds 2000 ltrs.

contd..

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• Site preparation.
Outdoor and indoor
• Filling of Tr. with oil.
• Drying of Tr. & oil purification (filtration).
• Check list: (a few important ones)
• Earth pits→ min. 2 for neutral and min. 2 for
body earthing and E.R. remaining < 1 ohm.
• Breather, bushings, arching horns, Buchholz
relay, cooling, T.C, OLTC etc.
• Marshalling box, explosion-vent, radiators,
oil level etc.

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POWER TRANSFORMER PROTECTIONS

Abnormal Conditions Protection Remarks

-Internal fault, low oil Buchholz relay - Used for Trs. Beyond 500 L
Level KVA generally
-Earth faults -E.F. Relay - Restricted E.F.
-Wdg. faults -Differential Relay -Trs. Above 5MVA
-Through faults -DMT/IDMT O.C. Relay Drop out/HRC fuse upto
500 KVA Trs.
-Faults in Tap changer, Percentage
While Tap change and differential protection For Trs. above 5 MVA
Through fault
Saturation of mag. ckt. Over fluxing relay For large Trs., important
over voltage protection gen., Trs.

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Contd.

-High Temp. (Oil) - Temp. Relay - Warning 700C

Tripping 800C
High temp. (Wdg.) - temp. relay - 900C & 950C respectively
Oil & Water
Circulation failure - Mercury switches- Warning/tripping for
(Preferable) large Trs.
High water Pressure/ - Pressure balancing- For large Trs.
water Surge system
High voltage surge - Horn gap, shielding. - Out door Trs.
due to switching and lightning arresters
lightning

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DIFFERENTIAL PROTECTION FOR GEN.= TRANSFORMER – AUX.TR.IMIT

OP R
R
UNIT

CT CT
CT
CT
OP TR
R R CT

STATION
SERVICE TR.

The zone of combined differential protection includes gen. Wdg., main step up Tr.
And the auxiliary transformer
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PROTECTION FOR A LARGE GEN. - TR. UNIT

Primary & back up protection for gen. Main Tr. & unit aux.
Tr.
Combined protection for gen. & Main Tr.
Differential Protection for Gen., Main Tr. & unit aux. Tr.
Overall differential protection
Generator Protections
Main Transformer Protections.
Unit aux. Tr. Protections.

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Testing and commissioning of

transformers
1. Factory Tests (Routine, Type, special)
2. Pre commissioning tests
3. Periodic tests
4. Emergency tests

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Routine and type tests:

Routine tests
• Measurement of winding resistance
• Measurement of voltage ratio and check of voltage vector relationship
• Measurement of impedance voltage/short circuit impedance (principal
tap) and load loss
• Measurement of no load loss and current
• Measurement of insulation resistance
• Tests on on-load tap-changer
• Oil pressure test on transformer to check against leakages past joints and
gaskets.
Type tests
• Temperature – rise.
• Vacuum tests on tank and radiators.

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Special Tests:
By mutual agreement between the purchaser and Supplier:

 Dielectric Tests
 Measurement of zero-sequence impedance of three-phase
transformers
 Short-Circuit Test
 Measurement of acoustic noise level
 Measurement of the harmonics of the no-load current and
 Measurement of the power taken by the fans and oil pumps
 Tests on bought out components / accessories such as buchholtz relay,
temperature indicators, tr.oil, pressure relief devices, oil preservation
system etc.

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At Site :

During transport and installation, the transformer may be exposed

to conditions which can adversely affect its reliability and useful life.
Pre commissioning tests to be done to assess the condition of
transformer after installation and compare the test results of all the
low voltage tests with the factory test reports.
Periodical tests to be carried out during service life of the
transformer on a regular basis to assess the behavior and
condition of the transformer during operation.
Emergency tests to be done to ascertain the healthiness of
transformer after it has been isolated from service due to an
internal fault, before taking back the transformer into service.

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Pre-Commissioning Tests
1. Insulation Resistance Test
(use 1000 V Meggar. For EHV class, 2.5 kV Meggar)
a) Continuity
b) I.R Values – Standard values given at 60oc. For every 10oc rise,
I.R values get halved.
2 . Ratio test
3. Vector group Test
4. Excitation current test
5. Core magnetic balance test
6. Short circuit tests
7. Oil dielectric strength and acidity

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1. Insulation resistance test

Winding temperature (0C) and
Insulation resistance in Mohm.
TR. Voltage class (kv)

10 20 30 40 50 60 70

Upto 35 kv 450 300 200 130 90 60* 40

> 35 kv to 110 kV 900 600 400 260 180 120* 80

* THE MINIMUM PERMISSIBLE I.R. AT 600 C IN MEG. OHM FOR OIL –

IMMERSED TRANSFORMER WINDINGS ARE TABULATED ABOVE
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2. Ratio Test:
Apply 3Φ, 415 VAC on H.V side.

Tap HV side LV side

1 UV VW UW 2U-2V 2V-2W 2W-2U 2UN 2VN 2WN

2
3
4
5
6

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3. Excitation Current Test:

Apply 3Φ, 415VAC to HV side & measure the current in
all 3 phases (note tap position).

Applied Voltage Measured Current

UV U

VW V

UW W

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4. Core Magnetic Balance Test:

• Apply single ph.(reduced voltage to LV side) and measure the
voltage as follows. (note the tap position)

Applied ‘V’ Measured voltage

at LV side
rn - rn - yn - bn - Ry - yb - Br -

yn - rn - yn - bn - Ry - yB - BR-

bn - rn - yn - bn - Ry - yB - BR-

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5. Short Circuit Test

Short LV terminals and apply 400 V 3-phase to HV throuh a variac .Gradually

increase the voltage till rated current is established. Measure currents
drawn and ensure perfect balance with neutral zero.
6. Oil Tests

a) Dielectric Strength
b) Acidity
7. Vector group test
Refer test procedure
(Contd)

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Idle Charging
• After conducting all
Pre-commissioning Checks
&
Pre-Commissioning Tests
Idle charge the transformer and observe temperature rise of oil and
windings. Then load the transformer and observe temperature rise.

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Power Transformers
Dispatching of Transformers :
When transformer is dispatched filled with oil, sufficient space is
left above the oil to take care of expansion of oil. This space is
filled with pure dry air / nitrogen gas under atmospheric pressure.
When any internal parts like tap changers etc or removed for
transportation, they are dispatched in tanks filled with oil / inert
gas or suitable measures taken so that they do not absorb
moisture.
Large rating power transformers are transported to site without oil
and filled with dry air or nitrogen due to weight limitations. During
transportation, positive pressure of 0.175 kgs / m² is to be
maintained.

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Dispatching of Transformers (Contd) :

 The temperature, pressure and dew point measured at the time

of gas filling shall be painted on the transformer tank.

 For large rating transformer of above 100 MVA, the impact

recorder / indicators may be provided during shipment. In case
the impact recorder indicates some serious shock during
shipment, the core and coil will have to be subjected to thorough
inspection before erection.

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Inspection and Storage :

A thorough external examination shall be made immediately on
arrival of transformer at site.

When the transformer is dispatched filled with oil, a sample of oil

shall be taken from the bottom of the tank and tested to IS 1866. If
the sample of the oil does not meet the requirements, the matter
should be reported to supplier along with IR values of windings to
earth.

Bushings
Oil level should be checked.
The porcelain portion is to be checked for any cracks or chipping.
The terminals should be checked for any bends.

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Storage:
After arrival at site, as far as possible, transformer should be
commissioned with minimum delay. If not possible to commission
immediately, the tank shall be preferably filled with processed oil up
to core and winding level, with dry air / nitrogen filling above the oil.
Gas pressure is to be monitored periodically.
The transformer shall never be stored in polluted areas likely to cause
corrosion.

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Precautions:
 Every precaution shall be taken to avoid moisture absorption,
particularly during rainy season / wet conditions

 Extreme care must be taken to prevent any foreign material from being
dropped into the transformer.

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Detailed Testing
Procedures

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Recommended Field Tests

Field testing is one of the techniques to ensure good operating
health of power transformers :
1. Dew Point Measurement
Dew point measurement test is carried out for large
transformers filled with dry air or nitrogen.
Insulation of transformer is hygroscopic (it absorbs moisture
from atmosphere) if positive pressure of gas is not maintained.
To ascertain that there is no moisture ingress and to check the
dryness of the insulation, dew point measurement is carried
out at site.
Dew point is the temperature at which the water vapour
present in the gas, filled in the transformer, begins to
condense.
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Recommended Field Tests (Contd)

2. Winding resistance Measurement
It is carried out as a type test, routine test and also as a field
test.
In the factory, it helps in determining the following :
(a) Calculations of the I² R losses
(b) Calculation of winding temperature at the end of
a temperature rise test.
(c) As a benchmark for assessing possible
damages in the field.
It is done at site in order to check for abnormalities due to loose
connections, broken strands of conductor, high contact
resistance in tap changers, high voltage leads and bushings.

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Recommended Field Tests (Contd)

Winding resistance Measurement (Contd)

The resistance is measured at ambient (cold) temperature and

then converted to resistance at 75˚C for all practical purposes
of comparison with specified design values, previous results
and diagnostics. The cold temperature of winding shall be
determined as accurately as possible when measuring the cold
resistance.
Transformer windings immersed in insulation liquid :
(i) Temp of winding = Average temp of insulating
liquid.
(taken 3 to 8 hours after de-energizing transformer.

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Winding resistance Measurement (Contd)

(ii) Difference between top & bottom temp should be less than
5˚C.
(iii) Resistance shall be measured at all taps.
Volt Meter – Ammeter Method
(a) Measurement is done with D.C
(b) To minimize observation errors, polarity of the core
magnetization shall be kept constant during all
resistance readings.
(c) Volt meter leads shall be independent of the current leads.
(d) Reading shall be taken after the current and voltage have
reached steady – state values.

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Winding resistance Measurement (Contd)

Volt Meter – Ammeter Method (Contd)
(e) Current shall not exceed 15% of the rated current
of the winding. Large values may cause
inaccuracy by heating the winding and thereby
changing its temperature and resistance.
Bridge Method
Kelvin Bridge meter or automatic winding resistance measurement
kit. (ohm meter, preferably 25 Amps kit) should be used for
measuring the resistance. Winding resistance shall be measured at
all tap positions. Pre commissioning values are to be compared
with factory values after applying temperature correction factors.
Deviation in results within 5% is accepted

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3. Voltage ratio Test

(a) Apply 3 phase supply on HV terminals.
(b) Measure the voltage ratio of HV & IV as well as HV & LV.
(c) Repeat the steps for each tap position separately.
Results of the transformation turns / voltage ratio are absolute
and may be compared with the specified values measured during
factory testing. The acceptance criteria should be that the
measured values are within 0.5% of the specified values for all
windings. One should also consider the trend of voltage
ratio values with reference to the ratio values measured during
the commissioning tests.
The voltage shall be applied only on the high voltage winding in
order to avoid unsafe voltage.

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4. Vector Group Test

(a) Connect neutral point of star connected winding

with earth.

(b) Join 1U of HV and 2U of LV.

(c) Apply 415V, three phase supply to HV terminals.

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Vector Group Test (Contd)

A a
A a
A a
A a
b b
b c b
c
c
c

C B B
C B C B
C

DY 11 Aa = 0
DY 11 Aa = 0
VAb = VAc Ab = bc = ca
VAb = VAc Ab = bc = ca
VBb = VBc Bb = Cc
VBb = VBc Bb = Cc
VCb > VCc
VCb > VCc
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5. Measurement of Magnetizing current.

This test is performed to locate defects in the magnetic
core structure, shifting of windings, failure in turn to turn
insulation or problem in tap changers. These conditions
change the effective reluctance of the magnetic circuit,
thus affecting the current required to establish flux in the
core.
(a) First of all keep the tap position in the lowest
position and IV & LV terminals open.
(b) Apply three phase 415V supply on the line
terminals for three phase transformers and single phase
230V supply on single phase transformers.
(c) Measure the voltage applied on each phase
(Phase to phase) on line terminals and current in each
phase of the line terminal.
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Measurement of Magnetizing current (Contd)

(d) Repeat the steps (a) to (c) after keeping the tap at
normal position.
(e) Repeat the steps (a) to (c) after keeping the tap at
highest position.
(f) Repeat the test with tap position in normal position.

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 Acceptance criteria for the results of exciting current measured

should be based on the comparison with the previous site test
results or factory test results.

 The general pattern is two similar high readings on the outer phases
and one lower reading on the centre phase, in case of three phase
transformers.

 An agreement to within 30 % of the measured exciting current with

the previous test is usually considered satisfactory.

 If the measured exciting current value is 50 times higher than the

value measured during factory test, there is likelihood of a fault in
the winding which needs further analysis.

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Measurement of Magnetizing current (Contd)

Care should be taken during exciting current measurement to avoid the
effect of residual magnetism in the transformer core. The residual
magnetism results in the measurement of higher than the normal
exciting current.
This test is to be carried out before DC resistance measurement.

6. Magnetic Balance test on three phase transformers

This test is conducted only on three phase transformers to check the
imbalance in the magnetic circuit.
(a) Keep the tap in normal position
(b) Disconnect the transformer neutral from ground.
(c) Apply single phase 230V across one of the HV winding
terminals and neutral and then measure voltage in two
HV terminals across neutral. Repeat the test for each of the
three phases.

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Magnetic Balance test on three phase transformers

(Contd)
(d) Repeat the above test for IV winding also.
The test shall be conducted with 230V single phase
supply and volt meter.
The voltage induced in the center phase may be 50 to
90% of the applied voltage. However, when the centre
phase is excited, then the voltage induced in the other
phases may be 30 to 70% of the applied voltage.
Zero voltage or very negligible voltage induced in the
other two windings should be investigated.
Disconnect the transformer neutral from ground and
no wing terminal should be grounded. Otherwise
results would be erratic and confusing.

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Magnetic Balance Test

Volts

AN BN CN Applied Voltage

230 180 50
Induced

115 230 115

50 180 230

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7. Magnetic Circuit (Isolation) Test

This test should be performed prior to a unit being
placed in service or modifications to the transformer
which could affect the integrity of its core insulation.
Adequate oxide/ silicate coating to be given on the
core steel.
The frame work and clamping arrangements shall be
earthed as follows :
The top main core clamping structure shall be
connected to the tank body by a copper strap.
When insulation is provided for the core to core bolts
and core to clamp plates, the same should withstand
a voltage of 2 KV for 1 minute.
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Magnetic Circuit (Isolation) Test (Contd)

Earthing of Magnetic Circuit

The magnetic circuit shall be earthed to the clamping
structure at one point only through a link placed in an
accessible position beneath an inspection opening in the
tank cover.
The connection to the tank shall be on the same side of
core as the main earth connection. The link should be
brought out using bushing / terminal board on all
transformers above 31.5 MVA.

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8. Measurement of short circuit impedance at low

voltage
 Measurement is performed in single phase mode. This test is
performed for the combination of two winding. One of the
winding is short circuited and the voltage is applied to the other
winding. The voltage and current readings are noted.

 The test shall be conducted with Variac of 0 – 280V, 10A,

precision RMS voltmeter and ammeter.

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8. Measurement of short circuit impedance at low

voltage (Contd)
The acceptable criteria should be the measured impedance
voltage having agreement to within 3% of impedance
specified in rating and diagram name plate of the
transformer.
Variation in impedance voltage of more than 3% should be
considered significant and further investigated.
The conductors used for short circuiting one of the
transformer windings should have low impedance (less than
1 milli ohm) and short length. The contacts should be clean
and tight.

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Insulation resistance measurement

 Insulation resistance is proportional to the leakage current

through / over the insulation after capacitive charging and
absorption currents become negligible. application of DC
Voltage.

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Insulation resistance measurement (Contd)

Insulation Resistance values are to be taken at 15
seconds, 60 seconds and 600 seconds.
IR Values at 60 Secs
Dielectric absorption = ------------------------
IR Values at 15 Secs

IR Values at 600 Secs

Polarization Index (PI) = ---------------------------
IR Values at 60 Secs
Usually 5KV DC meggar is used.

Polarization index is independent of temperature

and gives more reliable data for large power transformers.

Dielectric absorption factor should be more than 1.25.

Polarization Index should be more than 1.3
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Insulation resistance measurement (Contd)

Polarization Index of <1 calls for immediate corrective
action.
For bushings, an IR Value of above 10,000 Mega Ohms
is considered satisfactory.
It may be noted that no national / international standards
specify minimum IR values for transformers.
The value of IR may be very low under heavy fog or
humid condition.
During IR measurement, we must ensure the following
conditions :
(i) Transformer is disconnected from other associated
equipment.
(ii) Bushings are cleaned and free of moisture.
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Insulation resistance measurement (Contd)

(iii) Transformer tank and core are properly grounded.
(iv) Both ends of winding under test are short circuited.

10. Measurement of Capacitance and Dissipation

Factor
Capacitance values are relatively independent of temp and
prevailing atmospheric conditions.
The voltage to be applied shall not exceed half of the power
frequency test voltage or 10KV, whichever is lower.
The test is conducted with high voltage supply and Schering
bridge.
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Other Precommissioning tests

1. Tap Changer
The sequence of operation of the tap changer shall be
checked. Check should be made for :
(a) Manual operation (b) Local electrical operation
(c) Remote Electrical operation (d) Group operation, if
applicable.
2. Buchholtz relay test
Check whether the Buchholtz relay is mounted at an angle
by placing sprit level on the top of the relay. Confirm that the
relay does not operate when pumps are switched on in
forced oil cooled transformers. Buchholtz relay operation for
alarm and trip are checked by injecting air through the test
petcock.
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3. Magnetic oil level gauge.

The float level of the oil level indicator is moved up and down
between the end positions to check that the mechanism does
not stick at any point. The low oil level alarm of the oil gauge
shall be checked. This can only be checked before installation.
4. Temperature Indicators
The contacts of WTI & OTI for alarm and trip are checked and set
at required temp depending upon ambient temp and loading
conditions.
5. Fans and Pumps
It should be checked that the specified number of fans are
mounted on radiators as per general arrangement drawing. IR
values and setting for operation of fan motors and oil pumps are
checked. Check also that the direction of rotation of fans and
pumps is correct.
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6. Marshalling Box
The wiring from various accessories to marshalling box shall be
checked.
7. Oil
Oil samples from top and bottom of main tank are tested as per IS
1866. DGA tests are to be done to obtain bench mark before
charging, one month after charging, three months after charging,
and thereafter every year.
Oil of diverter switch should be checked for BDV at the time of
commissioning and subsequently yearly or 5000 operations,
whichever is earlier.

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General Checks
(i) All oil valves are in correct position : closed or open
as required.
(ii) All air pockets are cleared.
(iii) Thermo meter pockets are filled with oil
(iv) Oil is at correct level in the bushings, conservator,
diverter switch and tank etc.
(v) Earthing connections are done.
(vi) The colour of silica gel and oil in the breather cup.
(vii) Arcing horn gaps on bushings (where provided) are
properly adjusted.
(viii) Heaters in cubicles, marshalling boxes etc where
provided shall be checked.
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General Checks (Contd)

(ix) To check alarm / trip contacts of all accessories,
instruments, flow meters, pressure gauges etc.
(x) In case of water cooled transformers, the pressure gauge
readings on both water and oil sides to confirm that the
water pressure is less than the oil pressure. The oil and
water flow should not be less than that specified.
If all the above tests / checks are found satisfactory, allow
a settling time of at least 24 hours for oil and release air
from all venting points.

Charging procedure
(i) Set the protective relays to the minimum extent possible.
(ii) Wherever possible, the voltage should be built up in steps.
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(iii) Observe for any abnormalities such as vibration of

radiator parts, unusual hum, excessive temp etc.
(iv) After a few hours of energization at no load, the
transformer shall be switched off.
(v) Check the Buchholtz relay for air/gas.
(vi) Abnormalities noticed should be attended.
(vii) All protective relays should be reset to normal values.
(viii) Energize the transformer and load it gradually.

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Principle of Measurement

• Short all HV and IV leads

• Short all LV leads
• Open Neutral connection

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Capacitance and Tan Delta Measurement

of Transformer windings and Bushings
(a)For transformer windings, measurements shall be
done after opening the jumpers and isolating the
transformer from the equipment and the ground.

(b)The test kit should be suitable to work in charged

switchyard environment i.e induction suppression
unit should be provided along with double – shielded
leads.

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(C) Test modes shall be selected as below :

(i) Windings :
(a) Between two windings – UST (ungrounded specimen test)
Mode
(b) Between winding to earth – GSTg (grounded specimen
test) mode with other winding guarded. While carrying out
measurement for HV winding, LV winding shall be guarded,
whereas for LV winding, HV winding shall be guarded.
Procedure:
(i) While carrying out the test, all three phases of the same
winding are to be shorted to compensate / nullify the
effect of winding reactance.
(ii) The bushing porcelain and test tap are to be properly
cleaned before the commencement of tests.
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UST (ungrounded specimen test) Mode of Measurement

• Earth will be connected to N Point

10/13/2018 • Hence only CHL will be measured
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GST (grounded specimen test) Mode of Measurement

• Here measurement is made for the

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GSTg Mode of Measurement

• Here measurement is done for CH as L is guarded

• Reverse Connections to measure CL
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(ii)Bushings : UST mode between HV & Test Tap

Tan delta and Capacitance measurement of Bushings

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C1 and C2 Tan delta measurement

For C1: Apply 10kV between HV and test tap on UST

mode.
For C2: Apply 500 V between Test tap and Ground with
HV Guarded on GSTg mode
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Certain Guide Lines for Capacitance and Tan Delta

Values

(i) Comparative values of tests taken at periodic intervals are

useful in identifying potential problems rather than absolute
value of tan delta.
(ii) The initial reference can be drawn from the tan delta
values measured during factory testing.
(iii) However, the tan delta values measured in the field are not
very accurate and deviation up to 30% from the values
measured at the works shall be accepted.
(iv) The acceptance criteria is that no substantial variation in
the measured value of tan delta at periodical intervals when
compared with previous references.

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Certain Guide Lines for Capacitance and Tan Delta Values

(v) The main capacitance of the bushing i.e. the capacitance between
high voltage terminal and test tap is not affected by the
surrounding conditions and the accepted deviation from the
values measured at factory tests should be less than 10%.

iv) The capacitance between bushing test tap and ground is largely
influenced by the stray capacitances in the ground parts in the
transformer and hence large deviation in the measured value
shall be accepted when compared with the factory test value

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Certain Guide Lines for Capacitance and Tan Delta Values (Cont’d)

vii) Environmental factors like variation in temp, relative

humidity, surrounding charged object etc have great
influence on measurement of dissipation factor. Care
should be taken to control the above factors during the
measurement.
viii) Try to take measurements at 20˚C.
xi) Rate of change of tan delta and capacitance is very
important.
x) Tan delta value of bushings and windings at 20˚C should be
less than 0.007.

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Certain Guide Lines for Capacitance and Tan Delta Values (Contd)

(xi) Capacitance value can be within +10% or

-5% of previous value.

(xi) Rate of rise of tan delta value for bushings and windings
should not be more than 0.001 per year. The rate of change of
tan delta more than 0.001 per year needs further investigation

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CAUSES OF FAILURES
• Short circuits.
• O.V, U.V & V.DIPS.
• O.F, U.F & df/dt.
• Switching surge.
• Lightning.
• Improper Selection.
• Wrong layouts.
• Improper load distribution.

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• Equipment failures.
• Protection failures.
• Improper relay co-ordination.
• Tripping of drives, loaded feeders & large
generators.
• Islanding failures.
• Hot spots, high temp.
• Ageing.
• Natural causes.
• Faults caused by lizards, rats, snakes, birds etc.
• Improper operation and maintenance.
• Lack of training.

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REMEDIES
• Foresee imminent problems.
• Analyze failures.
• Take corrective measures.
• Exchange experience.
• Innovative measures.
• Adopt modern management techniques.
• Periodical training.
and so on…

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• Erection.
• Testing.
• Commissioning.
• Operation
• Maintenance.

Are needed to prevent failures.

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TRANSFORMER
A few important standards (out of many)

• IS:2026 (Part III) – 1977 Power TRS.

Insulation level and dielectric tests.

• IS:3024 – 1965 Elect. sheets.

• IS:3637 - 1966 Gas operated relays.

• IS:6088 – 1971 Heat exchanger.

• IS:8468 – 1977 O.L.T.C.

• IS:1886 – 1967 Code of practice for installation and maintenance.

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 IS:9434 – 1979 guide for sampling & analysis of free and

dissolved gases & oil from oil filled equipments.

 IS:335 – 1983 New insulating oils for TR. & SW. gears.

 IS:1448 – 1977 Methods of test for petroleum and its

products.

 IS:6855 – 1973 Methods of sampling for oil dielectrics.

 IS:2071 – Part I-1974, Part II-1974, Part III- 1976-High

voltage test.

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Types of Transformers
• Ordinary transformer.
• Core type Tr.
• Shell type Tr.
• Power Tr.
• Distribution Tr.
• Auto Tr.
• Block Tr.
• Furnace Tr.
contd.

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• Variable Tr.
• Tee – Tee (T – T) or Scott connection.
• Open delta Tr.
• Control Tr.
• Instrument Tr. :
Current Tr. (C.T)
Potential Tr. (P.T)
Capacitor Voltage Tr. (C.V.T)

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Acceptance Tests for TRS:

• Type Tests:
a) Measurement of winding resistance.
b) Measurement of voltage ratio and check of voltage vector
relation.
c) Measurement of impedance voltage/short ckt., impedance
(principal tapping) & load loss.
d) Measurement of no load loss & current.
e) Measurement of Insulation – Resistance.
f) Dielectric Tests.
g) Test On-load Tap changers.
h) Temp. rise test.
• Routine Test:
All the above tests from ‘a’ to ‘g’.
10/13/2018
contd..
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Special Tests:
As agreed by the manufacturer & the customer.
For example:
• High voltage test.
• Measurement of acoustic noise level.
• Measurement of power taken by fans & oil pumps.
• Measurement of harmonics of no load current etc.

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Installation & Commissioning:

Precautions.
• Connection with earth ( as per IS: 3043-1966)

• Generator Transformer: neutral directly earthed.

• S/S transformer.

Resistance earthing preferable to limit fault current.

• DISTR. Transformer: Neutral point is directly earthed.

• Transformer With delta winding.

Artificial star point is achieved by earthing Transformer.

contd..
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• Instrument Trs.:

Secondary windings and the bodies are earthed.

• Earthing Transformer Neutral point is either directly or through a resistance

connected to earth as per requirement.

• Isolation:
A circuit breaker of requisite breaking capacity should be

installed on both sides of Transformer.

• Oil soak pit:

It is provided wherever oil exceeds 2000 ltrs.

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• Site preparation.

Outdoor and indoor

• Filling of Transformer with oil.

• Drying of Transformer & oil purification (filtration).

• Check list: (a few important ones)

• Earth pits→ min. 2 for neutral and min. 2 for body earthing and E.R.
remaining < 1 ohm.

• Breather, bushings, arching horns, Buchholz relay, cooling, T.C, OLTC etc.

• Marshalling box, explosion-vent, radiators, oil level etc.

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Tests:
• Oil:

• Dielectric-strength.

• Tanδ.

• Acidity.

• Resistivity.

• Dissolved-gas analysis.

• Other tests as per IS. (details follow).

• I.R.

• P.I.
Contd.
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• Voltage/turn.

• Voltage Ratio at all taps.

• polarity,.

• Sequence.

• Vector Group.

• Winding resistance.

• Magnetizing current .

• Open ckt. Test & Short ckt. test

• Efficiency.

• Buchholz’s Relay.

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C.T:
• Continuity Test.

• Polarity Test.

• I.R Test.

• Magnetization characteristics.

• Rough Ratio Tests.

• Sec. winding resistance.

P.T.
• Voltage Ratio.

• Protective Devices.

• O/C on H.V. side.

Contd.
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• O/C on L.V side.

• E/F on H.V side.
• E/F on L.V side.
• Restricted earth fault.
• Differential Relay (biased).
• WDG. temp.
• Oil temp.
• Cooling system.
• Heat Exchanger:
• Pressure balancing.
• Any other test/Relay.

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Loss angle:
(measured by schering bridge)
cosΦ= cos(90-δ)
= sinδ
δ being small, sinδ=tanδ ic=Vcω
δ
tanδ= V/Ri
Vcω
tanδ= 1/RiCω Φ
iL=V/Ri
Where ω=2πf, RI= insulation resistance,
IL= leakage current, Ic = Charging Current
V= Voltage, C= Capacitance in farads.

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SCHERING BRIGDE
(FOR MEASURING DIELECTRIC LOSS AND P.F.)

C1 is the capacitor whose P.F. is to be measured.

C2 is the Standard air capacitor
Bridge is balanced by varying non-inductive R3 and C4
At balance, C1=C2 R4
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Why testing ?

(a) To prove that the transformer meets the customer’s

specifications and design expectations. (TYPE TESTS)
(b) To check that the quality requirements have been met
and the performance is within the tolerances
guaranteed. (ROUTINE TESTS)
Routine tests are carried out on every unit manufactured.
(c) To obtain information useful to the user during
operation or maintenance of the transformer. (SPECIAL
TESTS)

Transformers type and routine tests are according to IS

2026 & IEC Publication 60076. (Latest Edition)
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Transformer Maintenance.

Inspt. Items Inspection Action

Fr.

Hrly. Amb.Temp. Temp. Rise : Take necessary,

Wdg. Temp. Is it ok ? Action.
Oil Temp.

Load (Amps.) Check against rated

Voltage’ values. -do-

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Contd.

Daily. Oil level in Tr. Check, whether as If low, top up with

& in O.L.T.C per level ? treated oil.

Relief diaphragm Inspect. Replace

if damaged.

Breather. Check If pink, reactivate

Silicagel. or
Replace.

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Quarterly Bushings Check for dirt & Clean/replace

cracks

Oil in Tr. Check for D.E & Restore quality

moisture.

Oil in OLTC - do - - do -

Contd.

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Half yearly All the above As above As above

- do- OLTC Check cont. Take n.a.

- do- OLTC Operating Check conts. Take n.a.

mechanism , Check parts Lubricate,
Fans, Pumps, Replace worn
Bearings etc. parts.

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Yearly Oil in Check tan δ Filter/replace.

Transformer Moisture, Process if reqd.
I.R Acidity etc.

*Gaskets,
Cable box, Check all
Relays, & Take n.a .
Alarms and Test.
Their ckts.
Temp. , oil-
Level Indicator,
painting,
E. R.

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Contd.

Two years Non conservator Internal insp. Filter oil

Transformer Oil Regardless
conservator Of condition.
Buchholz- - do- •Clean
relay •Test, adjust

Conduct all •If, reqd.

•. Operations.

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Contd.

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5 Yrs. Transformer Overall insp. Wash by

» Including Dry clean oil
Up to 3 MVA Lifting of Check all.
core & coils

7 to 10 yrs. Above 3MVA - DO- - DO -

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TRANSFORMER DRYING CURVES

D.E. I.R.
strength

Time
Time

Additional Action if Reqd.

1. Cover by Tarpaulin (to be earthed) 2. External Heating
3. Short Circuit Heating (Rise in oil Temperature is < 10 0C/hrs. until 600C)

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TRANSFORMER OIL
 It serves the double purpose of insulating and cooling.
 Characteristics of oil as per IS: 335 - 1983

Sl. No. Characteristics Limit / Requirements

1. Density at 270C max. 0.89g/Cm3

2. Kinematic Viscosity – do- 27 cst
3. Interfacial tension at 270C min 0.04 N/m
4. Flash Point (Min) 1400C
5. Pour Point -90C
6. Neutralization value
(total acidity max) 0.03mg KOH/g
7. Corrosive Sulphur Non-corrosive

Contd.
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Sl. No. Characteristics Limit / Requirements

8. D.E Strength (as received) 30kv (rms)/2.5 mm gap

After Filtration 50 kv-do-
9. Dielectric Dissipation Factor
(Tan  at 900C Max.) 0.005
10. Sp. Resistance (min.) At 270C 500  1012 cm
At 900C 30  1012 cm
11. Oxidation stability
(a) Neutralization value after 0.40 mg KOH/g
oxidation, Max.
(b) Total Sludge – do- 0.10% by wt.
12. Presence of oxidation Inhibitor No oxidant additives.
13. Water content (As recd. Max.) 50 ppm by wt.

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Sl. Test Equipment Permissible Limits

No. voltage

1. Electric strength (BDV) as 145kv & above 60KVrms

per IS:6792 72.5-145kv 50KVrms
Below 72.5kv 40kvrms/2.5 gap

2. Wate Content As per 145kv & above 15 ppm

IS: 2362 - 1973 72.5-145kv 20 ppm
Below 72.5kv 25 ppm

3. Sediment and / or All voltages No sediment and /

perceptible sludge or Sludge

4. Specific Resistance All voltages 0.1  1012 cm (Min)

(Resistively at 900C)

Contd.
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Sl.N Test Equipment Permissible Limits

o. voltage

5. Dielectric Dissipation Factor 145kv & above 60KV rms

(Tan  ) at 900C Below 145 kv 50KV rms
40kvrms/2.5mm gap

6. Neutralization value All Voltages 0.5 mg KOH/gm of

(Total Acidity) oil

7. Flash Point All voltages Min 1250C

8. Interfacial Tention At 270C All voltages 0.018 N/M (Min)

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DGA (Dissolved Gas Analysis)Test.

This Test Ascertains the Healthiness of Transformer,
and not of oil.
Test Set : Gas Chromatograph
Mechanisms of Gas formation:
(a) Natural Ageing.
(b) Heat Flux Generated
(c) Oxidation
(d) Vaporization
(e) Insulation Decomposition
(f) Oil Break down.
(g) Electrolytic Action
Contd.
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GAS DISSOLVED IN TRANSFORMER OIL

Sl. Nitrogen Oxygen Methane Hydrogen Acetylene

No N2 O2 CH4 H2 C2H2
1. Normal 70 to 79% 20 to 30% 0.1 to 0.2% - -
Condition

*2. Minor 85 to 92% 5 to 8% 0.5 to 1% 2 to 5% 0.5 to 2%

faults.
**3 Grave Int. 4 to 8% 3 to 10% 50-70% 10 to 25%
Fault

•Shorted conductors, Poor connection in joint & tap switch and magnetic system
of core
** Arcing (Insulation damage, shorted turns, flash over in tap-changer)

Contd.

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a) Arcing :Presence of Acetylene is the key indicator

a) Partial discharge (Corona) : Presence of Hydrogen is the key indicator

a) Over Heated Oil : Presence of Ethylene is the key indicator

(+Methane+Small Qty. of H2 & Ethane)

d) Over heated Cellulose : Presence of CO/CO2 ratio is the key

indicator

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OIL PURIFICATION (DRYING & FILTRATION)

 Objective :
To remove all contaminants such as Dirt, Sludge, Water,
Carbon deposits, dissolved gases, moisture etc.

Type of oil Purifiers :

a) Centrifugal Purifiers such as “De Laval” type.
b) Filter pack type such as “Streamline” Type
c) Filters using activated earth media.
(streamline filter (vacuum type) is commonly used

Contd.

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Cold –vacuum drying out of Transformer.

 For large Transformer Oil is taken out from drum to drum or

dirty oil tank to clean oil tank, treatment by streamline filter
(vacuum type) OR any other type.

 Then vacuuming is done for the Transformer Tank with core &
winding (without oil) through dry ice (solid CO2 ) which
solidifies. The drawn moisture is weighed.

Failures in Transformers
a. Magnetic Circuit
b. Windings
c. Dielectric circuit
d. Structure

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Fire safety & Modern Developments

a) Mulsy fire system
b) Buffer Wall
c) Nitrogen Injection System
d) Hydrogen Monitoring System
e) Constant oil Pressure system. (Air Cell)
f) Use of cast resin dry type Transformer presently available up to
10 MVA, 33kv class especially in fire areas / environment
using H-class & C-class insulting materials operating at 180-
2000C. (Proper design, installation, testing, commissioning,
operation & maintenance are needed as the rating of
Transformer (one Tank) has risen from 60MVA in 1930 to
about 120 MVA in 1958, to as high as 750 MVA now & the
voltage to 750 KV).
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Thank you
ANY
QUESTIONS
PLEASE
??????
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