Transformer Testing Report

PES/DMSRN/RPT-RM/ 31-12-2017

20140005801217

GUL AHMED ENERGY LIMITED

PRESCON ENGINEERING PRIVATE LIMITED.

Ground Floor, 184-Air l i ne society, Near UCP La hore
PH: 0092 423 5229371-2 FAX: 0092 42 3 5229373
http://www.theprescon.com
20140005801217 Transformer Testing Report
Contents
Preface .................................................................................................................................................2
TESTING REPORT DETAILS......................................................................................................................3
Introduction to Transformer Testing Theory ...........................................................................................4
Disclaimer.........................................................................................................................................6
Referred Standards: ..............................................................................................................................6
Test Equipment Details..........................................................................................................................7
Test Methodology Details......................................................................................................................7
Testing Object Details of T0-3 Transformer.............................................................................................8
Test Results ..........................................................................................................................................9
Insulation Resistance Winding ...............................................................................................................9
Winding Capacitance & Dissipation Factor December 2017........................................... 10
Tansformer Turns Ratio (TTR) .............................................................................................................. 11
Winding Resistance Test/ DC Resistance at Ambient Temperature ......................................................... 13

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20140005801217 Transformer Testing Report
Preface
This report describes the results of Condition Assesment tests on the following transformer at Gul Ahmed
Energy Limited, Korangi, Karachi :

Sr. Objects Tested Make YOM Rating Serial No.

1 Main Transformer T-03 ABB ELTA 1996 63MVA 1132812

The following tests were carried out:

Test No Test Name Purpose
1 Insulation Resistance To check contamination content in the insulation.

2 Winding Resistance Test To check loose connections in winding.

3 Transformer Turns Ratio (TTR) To determine shorted turns in the windings.

4 Power Factor test /Capacitance &
Dissipation Factor (for Windings)
5 Power Factor test /Capacitance &
Dissipation Factor (for HV Bushings)
To check the bulk insulation condition for HV & LV
windings.
To check the insulation condition for HV bushings

Further included in details are:

 Reading charts
 Our Conclusion and recommendation.

We have taken all the necessary care and have used the best available expertise to analyze the data. The
results are compared with general standards and Doble recommendations. We sincerely hope that you will
find this report beneficial.

Testing Department
PRESCON

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20140005801217 Transformer Testing Report

GUL AHMED ENERGY LIMITED

TRANSFORMER TESTING REPORT
HIGH VOLTAGE INSULATION CONDITION ASSESMENT REPORT

TESTING REPORT DETAILS

JOB NUMBER
CUSTOMER ABB
SITE GAEL Power Plant
JOB DESCRIPTION HV TESTING OF TRANSFORMER
WORK ORDER NO.
JOB START DATE 29-12-2017
JOB FINISH DATE 29-12-2017
OUR REPORT REF. 20140005801217
REPORT ISSUE DATE 31-12-2017
ISSUE NO. 1

Report Submitted To:

Mr. Shabir Ahmed

Regional Manager South
ABB Pakistan Pvt Ltd

Job Supervised & Report Written by:

Shahid Iqbal Ali Arshad

Sr. Services Engineer Services Engineer
shahid.iqbal@theprescon.com ali.jaswal@theprescon.com
Shahid.Iqbal@theprescon.com

Report Vetted By:

Mr. Irfan Akhtar
Director Technical/CEO
Prescon Engineering Pvt Ltd.

PRESCON CONFIDENTIAL Page 3 of 16

20140005801217 Transformer Testing Report
Introduction to Transformer Testing Theory
Insulation Resistance / Dielectric Absorption Ratio test

The purpose of the measurement is to determine the contamination/moisture content in the Insulation.
The insulation resistance can be measured between HV-G, LV-G and between HV-LV. Dielectric Absorption
Ratio should be calculated from values at 30 sec & 60 sec. The minimum acceptable range of DAR is greater
than 1.25 for transformers.

Winding Capacitance & Dissipation Factor

The purpose of this test is to determine the state of contamination/dryness of the windings and insulation
System and to determine a power factor for the overall insulation, including bushings, oil, and windings. It
is a measure of the ratio of the power (I²R) losses to the Volt-amperes applied during the test.

The power factor obtained is a measure of watt loss in the total transformer insulation system including the
bushings. The power factor for new transformers is generally in the range of 0.01 – 0.30%, less than 0.5 –
0.75% for transformer in service for more than 3 to 5 years. A value of power factor greater than 1.0 is
generally questionable for many of the transformers but it depends on manufacturer, materials used and
design parameters. The values obtained at each test are compared to previous tests and baseline factory
tests, and a trend can be established as the insulation system ages.

Winding Resistance

Winding resistances are tested in the field to check for loose connections on bushings or tap changers,
broken strands, and high contact resistance in tap changers. Results are compared to other phases in WYE
connected transformers or between pairs of terminals on a delta resistance is too high. Resistances can also
be compared to the original factory measurements or to sister transformers. Agreement within ±5% for any
of the above will be satisfactory. If generation of ethylene, ethane, and perhaps methane in the DGAs
indicates poor connections, winding resistances should be checked.

Transformer Turns Ratio test

The turn’s ratio test detects shorted turns which indicate insulation failure by determining if the in -correct
turn’s ratio exists. Shorted turns may result from short circuits or dielectric (insulation) failures.

Measurements are made by applying a known low voltage across one winding and measuring the induced
voltage on the corresponding winding. The low voltage is normally applied across a high voltage winding so
that the induced voltage is lower, reducing hazards while performing the test. The voltage ratio
obtained by the test is compared to the name plate voltage ratio. The ratio obtained from the field test
should agree with the factory results within ± 0.5%.

For three-phase delta/wye or wye/delta connected transformers a three phase equivalancy test should be
performed. The test is performed and calculated across corresponding single windings. Look at the name
plate phasor diagram what winding on the primary corresponds to a particular winding on the
secondary.Calculate the ratio of each three phase winding based on the line to neutral voltage of the
Delta/Wye winding. Multiply/Divide line-to-line winding voltage by 1.732 to obtain correct line to neutral
voltage. Check the tap changer position to make sure it is set at the position on which the nameplate voltage
is based. Otherwise, the turn’s ratio test information can not be compared with the nameplate.

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20140005801217 Transformer Testing Report

Results Interpretation:

Good Condition:

Fair:

Alarm:

Dangerous:

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20140005801217 Transformer Testing Report
Disclaimer

The limits and values mentioned in theory are for generic reference only as different standards mention
different limits. Our report section choses the limit/alarm values based on our experience, depending on
make/model/OEM related data, etc.
Theory section will be updated from time to time.
Theory section of report is our Intellectual property. It is never to be shared with other service providers
in parts or full under any circumstances.
As the company itself does not value limits etc. as extremely important for condition assessment, we do
not take any liability on the results of / misinterpretation of applying these limits on any other equipment
by the client.

Referred Standards:

1. IEC 60076 : International Standard for Transformers

2. IEEE Std C57

IEEE Standard General Requirements for Liquid-Immersed Distribution, Power, and
Regulating Transformers

3. FIST 3-31, Transformer Diagnostics

Facilities Instructions, Standards, and Techniques – Volume 3-31
United Stated Department of the Interior Bureau of Reclamation

4. Doble Test Data Reference Book

Doble Engineering Company – Watertown; Edition no.: 500-0351 / 72

5. IEEE C57.149 and C57.150

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20140005801217 Transformer Testing Report
Test Equipment Details
Description

i) Insulation Resistance test set – Chauvin Arnoux

Rating: 5 kV CA-6549
ii) Transformer Turns Ratio (DV Power TRT 63)
iii) Winding Resistance Test (Wanguard)
iv) Capacitance & Dissipation Factor test set – Doble M4100
Rating: 12 kV (fully automatic)

Test Methodology Details

 The Insulation resistance test is a check of Contamination/Moisture Content in insulation. We have

taken values between HV-G, LV-G & HV-LV. For HV-G, short all phases of HV side & take value with
respect to ground. For LV-G, short all phases & take value with respect to ground.

 The Tan Delta / capacitance test for winding is a check of the bulk insulation. While measuring CH
& CHL, Short all 3 phases of HV & LV Individually. Apply rated voltage of on HV Winding & take
values of Power factor and Capacitance in all 3 modes-UST, GST, GST-GUARD. While measuring CL
& CHL connection will remain same with the difference is that now we will inject rated voltage on
LV and take values in three modes.

 Turn to turn ratio test is a check of shorted turns. TTR values were taken on all taps. TTR connections
are always dependent on VECTOR GROUP. TTR values were taken on all taps. We use three phase
TTR tester for this test. If the transformer is YNd11 than we will connect H1, H2, H3, H0 leads on
the HV side and X1, X2, X3 leads on the LV side. Then we apply voltage by the instrument.

 Winding resistance is a check if there are any severe mismatches, loose or open connection in the
transformer winding and tap changer. The measurement is made by injecting a current of suitable
range in transformer winding. The test current must not exceed 10% of rated current of transformer
winding. Two cables are used to inject current in a single winding and voltage drop is measured.
The resistance is calculated by using ohms law. If the winding is star connected, the one single phase
is selected by connecting one testing lead to the phase terminal i.e. H1, H2, H3 and the second wire
is connected to the neutral terminal. The connections are made i.e. (H1-H0, H2-H0, and H3-H0). By
doing this only one phase winding is selected at a time. If the winding is delta connected then
connections are made on two phase terminals, the winding selection can be seen on the name plate
of transformer. The delta winding connection differ with vector group and are shown on nameplate
i.e. for a YNd11 transformer connection for delta winding are x1-x2, x2-x3, x3-x1.In General
Agreement within ±5% for any of the above will be satisfactory.

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20140005801217 Transformer Testing Report
GUL AHMED ENERGY LIMITED
TRANSFORMER TESTING
HIGH VOLTAGE INSULATION CONDITION ASSESMENT

Testing Object Details of T0-3 Transformer

Transformer Type: TNARD 63000/132 PT Serial No: 1132812 Yr. of Manuf. 1996
Rated Output: 63 MVA No. of Phases: 3

Std. Spec.: IEC 76/1993 Service: Cont. Frequency 50 Hz Vector Group: YNd11

Position High Voltage Low Voltage H.V. Current L.V. Current Impedance Voltage

1 149160 243.9 A 15.68

14 132000 11000 V 275.6 A 3306.6 14.53

27 114840 316.7 A 13.60

Type of Cooling: ONAN/ONAF Tap-Changer by: ABB Type: On-Load

Windings: 2 windings Manufacturer: ABB ELTA Sp.

Special ID: TO-3

HV side 1 R (1 U) 1 Y (1 V) 1 B (1 W)

LV side 2 r (2 u) 2 y ( 2 v) 2 b (2 w)

HV side Neutral – 1N

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20140005801217 Transformer Testing Report
Test Results

Insulation Resistance Winding

TIME HV-G at LV-G at HV-LV at

5KV (GΩ) 5KV (GΩ) 5KV (GΩ)
30sec 2.482 1.695 1.987
60sec 2.754 2.029 2.112

2min 3.048 2.238 2.477

3min 3.201 2.321 2.622

4min 3.301 2.374 2.719

5min 3.366 2.408 2.783

6min 3.415 2.432 2.829

7min 3.454 2.458 2.867

8min 3.480 2.477 2.900

9min 3.504 2.488 2.924

10min 3.539 2.506 2.946

DAR 60/30 1.11 1.20 1.11

PI 600/60 1.29 1.24 1.34

Winding Temp. = 32 0 C
Ambient Temp. = 25 0C
Humidity = 16 %

Comments:
Comparison with factory results or previous field results is more significant than the absolute v alue of
megaohms. According to the NETA MTS Insulation Resistance value at 1 min is above the minimum
acceptable limit.

According to IEEE C57.152 PI is less than the acceptable limit of 2 for all test configurations (i.e HV-G, LV-G
and HV-LV) but now these values are in Giga ohms.

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20140005801217 Transformer Testing Report
Winding Capacitance & Dissipation Factor December 2017

TEST
MODE
Test kV mA Watts % PF meas. Corr. Fact. % PF Cap (pF) Measured
Corr.

HV-G 10.036 31.216 1.573 0.504 0.94 0.474 9936.1 CH + CHL

HV-LV 10.001 10.324 0.635 0.615 0.94 0.578 3286.2 CH

GUARD
HV-LV 10.002 20.871 0.928 0.445 0.94 0.418 6643.4 CHL (UST)
UST
Test kV mA Watts % PF meas. % PF Cap (pF) Measured
Corr.

LV-G 5.018 66.662 3.171 0.476 0.94 0.448 21218.4 CL + CHL

LV-HV 5.002 45.746 2.172 0.475 0.94 0.447 14561.3 CL

GUARD
LV-HV 5.002 20.879 0.981 0.470 0.94 0.442 6645.9 CHL (UST)
UST
Winding Temp. = 32 C°
Ambient Temp. =25 C°
Humidity = 16 %
Comments:
Power Factor Results for this transformer are very much within acceptable limits of 0.5%. This shows that
the bulk winding Insulation is in good condition. These results are much better than previous testing results
due to oil replacement.

Bushings Capacitance & Dissipation Factor December 2017

Bushing Bushing Test kV mA Watts % PF Corr. % PF Cap (pF)

Capacitance meas. Fact. Corr.

H1 C1 10.017 0.678 0.034 0.502 1.00 0.502 215.8

H2 C1 10.017 0.719 0.032 0.445 1.00 0.445 228.7
H3 C1 10.017 0.721 0.031 0.428 1.00 0.428 229.4
H0 C1 10.017 0.717 0.031 0.433 1.00 0.433 228.1
H1 C2 0.199 0.852 0.151 0.481 1.00 0.481 271.2
H2 C2 0.201 1.113 0.027 0.243 1.00 0.243 354.1
H3 C2 0.200 1.127 0.036 0.318 1.00 0.318 358.6
H0 C2 0.200 1.134 0.027 0.242 1.00 0.242 360.9

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20140005801217 Transformer Testing Report

Comments:
C1 power factor for all the bushing are within acceptable limit of 0.5%. The test results are comparable with
previous year‘s testing results, which shows that no significant deterioration has occured and the bushings
are in healthy condition.

Tansformer Turns Ratio (TTR)

Secondary Winding: 11000 V
Oil Temp. = 31 0C
Winding Temp. = 30 0 C
Ambient Temp. = 29 0C
Humidity = 45 %
U-N V-N W-N

u-w v-u w-v

Tap Np. Np. Ratio % Error Ratio % Error Ratio % Error

no. Voltage Ratio

1 149160 7.829 7.839 -0.125 7.834 -0.066 7.842 -0.170

2 147840 7.760 7.764 -0.060 7.759 0.015 7.769 -0.119
3 146520 7.691 7.700 -0.128 7.693 -0.038 7.706 -0.203
4 145200 7.621 7.626 -0.061 7.618 0.038 7.632 -0.136
5 143880 7.552 7.562 -0.130 7.554 -0.023 7.568 -0.214
6 142560 7.483 7.487 -0.062 7.479 0.054 7.494 -0.147
7 141240 7.413 7.423 -0.132 7.414 -0.008 7.430 -0.226
8 139920 7.344 7.338 0.079 7.338 0.079 7.356 -0.165
9 138600 7.275 7.285 -0.143 7.275 0.000 7.292 -0.238
10 137280 7.206 7.210 -0.064 7.200 0.080 7.218 -0.168
11 135960 7.136 7.146 -0.138 7.136 0.008 7.154 -0.243
12 134640 7.067 7.072 -0.065 7.061 0.082 7.079 -0.172
13 133320 6.998 7.008 -0.149 6.997 0.008 7.016 -0.256
14 132000 6.928 6.933 -0.067 6.923 0.083 6.941 -0.183
15 130680 6.859 6.877 -0.261 6.859 0.008 6.878 -0.269
16 129360 6.790 6.794 -0.060 6.784 0.085 6.803 -0.187
17 128040 6.721 6.730 -0.137 6.722 -0.017 6.738 -0.258
18 126720 6.651 6.655 -0.061 6.647 0.069 6.663 -0.182

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20140005801217 Transformer Testing Report
19 125400 6.582 6.592 -0.149 6.582 0.000 6.600 -0.272
20 124080 6.513 6.517 -0.062 6.509 0.062 6.524 -0.177
21 122760 6.443 6.453 -0.143 6.444 -0.009 6.461 -0.278
22 121440 6.374 6.378 -0.063 6.369 0.082 6.387 -0.199
23 120120 6.305 6.315 -0.156 6.305 0.000 6.323 -0.284
24 118800 6.236 6.240 -0.074 6.230 0.083 6.248 -0.204
25 117480 6.166 6.176 -0.159 6.166 0.000 6.184 -0.290
26 116160 6.097 6.101 -0.066 6.091 0.095 6.110 -0.208
27 114840 6.028 6.038 -0.125 6.028 -0.066 6.046 -0.170

Comments:
All the values are within the acceptable limit of having %age difference less than 0.5 and also comparable
to the previous testing results. No shorted turns detected.

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20140005801217 Transformer Testing Report
Winding Resistance Test/ DC Resistance at Ambient Temperature
LV side u-w(mΩ) Percentage v-u(mΩ) Percentage w-v(mΩ) Percentage
(Sec.) Variation Variation Variation
3.279 -0.030 3.285 -0.091 3.288 0.273
HV side U-N(mΩ) Percentage V-N(mΩ) Percentage W-N(mΩ) Percentage
Tap no. Variation Variation Variation

1 408.4 -0.367 409.9 2.293 400.5 -1.973

2 402.0 -0.299 2.108 -1.850
403.2 394.7
3 398.9 -0.501 400.9 2.918 389.2 -2.492
4 390.7 -0.537 392.8 2.673 382.3 -2.197
5 385.7 -0.519 387.7 2.760 377.0 -2.308
6 378.1 -0.582 380.3 2.735 369.9 -2.217
7 372.2 -0.215 373.0 2.118 365.1 -1.945
8 367.4 0.299 366.3 2.321 357.8 -2.683
9 359.7 -0.278 360.7 2.246 352.6 -2.014
10 354.9 0.310 353.8 2.176 346.1 -2.543
11 347.2 -0.778 349.9 2.429 341.4 -1.699
12 348.7 -1.921 355.4 5.937 334.3 -4.308
13 335.9 -0.268 336.8 2.286 329.1 -2.066
14 310.0 -1.742 315.4 0.856 312.7 0.863
15 336.0 -0.893 339.0 1.652 333.4 -0.780
16 326.8 -1.346 331.2 1.178 327.3 0.153
17 321.4 -1.089 324.9 1.662 319.5 -0.595
18 315.2 -1.459 319.8 1.814 314.0 -0.382
19 309.9 -1.065 313.2 1.788 307.6 -0.748
20 304.0 -1.809 309.5 2.682 301.2 -0.930
21 297.2 -1.682 302.2 2.151 295.7 -0.507
22 294.0 -1.259 297.7 2.889 289.1 -1.695
23 285.2 -1.823 290.4 2.307 283.7 -0.529
24 285.2 0.000 285.2 2.735 277.4 -2.812
25 273.3 -1.610 277.7 1.981 272.2 -0.404
26 267.5 -1.047 270.3 1.480 266.3 -0.451
27 261.8 -0.993 264.4 1.740 259.8 -0.770
0
Oil Temp. = 32 C
Winding Temp. = 32 0 C
Ambient Temp. = 27 0C
Humidity = 8 %

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20140005801217 Transformer Testing Report
Comments:

Winding resistance at some taps of HV side showing the maximum deviation greater than the acceptable
limits of ±2% (IEEE-C57) between the phases. It points out Loose connections.

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20140005801217 Transformer Testing Report

DISCLAIMER
All rights reserved. No part of this publication may be produced, stored in a retrieval system, or transmitted
in any form by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior
written permission of Prescon Engineering Pvt Ltd.

INDEMNITY
This document may not be distributed or used outside the client for whom it is prepared, except with
written authorization from Prescon Engineering Pvt Ltd. We disclaims all liability for any loss, damage, injury
or other consequence whatsoever arising from any unauthorized use howsoever caused, including any such
resulting from error, omission or negligence in its application.

Document Circulation:

Mr. Shabir Ahmed

Regional Manager South
ABB Pakistan Pvt Ltd

Master Report File (PRESCON):

Mr. Irfan Akhtar
CEO

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