Transformer Testing | Type Tests and Routine Tests of

Transformer
March 2, 2019 by Electrical4U

For confirming the specifications and performances of an electrical power transformer it has to
go through a number of testing procedures. Some tests are done at a transformer manufacturer
premises before delivering the transformer.
Transformer manufacturers perform two main types of transformer testing – type test of
transformer and routine test of transformer.
Some transformer tests are also carried out at the consumer site before commissioning and also
periodically in regular and emergency basis throughout its service life.
Type of Transformer Testing
Tests done at factory
1. Type tests
2. Routine tests
3. Special tests
Tests done at site

1. Pre-commissioning tests
2. Periodic/condition monitoring tests
3. Emergency tests

Type Test of Transformer

To prove that the transformer meets customer’s specifications and design expectations, the
transformer has to go through different testing procedures in manufacturer premises. Some
transformer tests are carried out for confirming the basic design expectation of that transformer.
These tests are done mainly in a prototype unit not in all manufactured units in a lot. Type test of
transformer confirms main and basic design criteria of a production lot.
Routine Tests of Transformer
Routine tests of transformer is mainly for confirming the operational performance of the
individual unit in a production lot. Routine tests are carried out on every unit manufactured.
Special Tests of Transformer
Special tests of transformer is done as per customer requirement to obtain information useful to
the user during operation or maintenance of the transformer.
Pre Commissioning Test of Transformer
In addition to these, the transformer also goes through some other tests, performed on it, before
actual commissioning of the transformer at the site. The transformer testing performed before
commissioning the transformer at the site is called the pre-commissioning test of transformer.
These tests are 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.
Type tests of transformer include:
1. Winding resistance test of transformer
2. Transformer ratio test
3. Transformer vector group test
4. Measurement of impedance voltage/short circuit impedance (principal tap) and load loss (Short
circuit test)
5. Measurement of no-load loss and current (Open circuit test)
6. Measurement of insulation resistance
7. Dielectric tests of transformer
8. Temperature rise test of transformer
9. Tests on on-load tap-changer
10. Vacuum tests on tank and radiators
Routine tests of transformer include
1. Winding resistance test of transformer
2. Transformer ratio test
3. Transformer vector group test
4. Measurement of impedance voltage/short circuit impedance (principal tap) and load loss (Short
circuit test)
5. Measurement of no load loss and current (Open circuit test)
6. Measurement of insulation resistance
7. Dielectric tests of transformer.
8. Tests on on-load tap-changer.
9. Oil pressure test on transformer to check against leakages past joints and gaskets
That means Routine tests of transformer include all the type tests except temperature rise and
vacuum tests. The oil pressure test on transformer to check against leakages past joints and
gaskets is included.

Special Tests of transformer include

1. Dielectric tests.
2. Measurement of zero-sequence impedance of three-phase transformers
3. Short-circuit test
 4. Measurement of acoustic noise level
5. Measurement of the harmonics of the no-load current.
6. Measurement of the power taken by the fans and oil pumps.
7. Tests on bought out components / accessories such as buchhloz relay, temperature indicators,
pressure relief devices, oil preservation system etc.
Transformer Winding Resistance Measurement
Transformer winding resistance measurement is carried out to calculate the I2R losses and to
calculate winding temperature at the end of a temperature rise test. It is carried out as a type test
as well as routine test. It is also done at site to ensure healthiness of a transformer that is to check
loose connections, broken strands of conductor, high contact resistance in tap changers, high
voltage leads and bushings etc.
There are different methods for measuring of the transformer winding, likewise:

 Current-voltage method of measurement of winding resistance.

 Bridge method of measurement of winding resistance.
 Kelvin bridge method of Measuring Winding Resistance.
 Measuring winding resistance by Automatic Winding Resistance Measurement Kit.
Note: Transformer winding resistance measurement shall be carried out at each tap.

Transformer Ratio Test

The performance of a transformer largely depends upon perfection of specific turns or voltage
ratio of transformer. So transformer ratio test is an essential type test of transformer. This test
also performed as a routine test of transformer. So for ensuring proper performance of electrical
power transformer, voltage and turn ratio test of transformer one of the important tests.
The procedure of the transformer ratio test is simple. We just apply three phase 415 V supply to
HV winding, with keeping LV winding open. We measure the induced voltages at HV and LV
terminals of the transformer to find out actual voltage ratio of the transformer. We repeat the test
for all tap position separately.

Magnetic Balance Test of Transformer

Magnetic balance test of transformer is conducted only on three-phase transformers to check the
imbalance in the magnetic circuit.
Procedure of Magnetic Balance Test of Transformer
1. Keep the tap changer of transformer in normal position.
2. Now disconnect the transformer neutral from ground.
3. Then apply single phase 230 V AC supply across one of the HV winding terminals
and neutral terminal.
4. Measure the voltage in two other HV terminals in respect of neutral terminal.
5. Repeat the test for each of the three phases.
In case of an autotransformer, a magnetic balance test of transformer should be repeated for LV
winding also.
There are three limbs placed side by side in a core of the transformer. One phase winding is
wound in one limb. The voltage induced in different phases depends upon the respective position
of the limb in the core. The voltage induced in different phases of a transformer in respect to
neutral terminals given in the table below.

Magnetizing Current Test of Transformer

Magnetizing current test of transformer is performed to locate defects in the magnetic core
structure, shifting of windings, failure in between 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.
1. Keep the tap changer in the lowest position and open all IV and LV terminals
2. Then apply three phase 415 V supply on the line terminals for three-phase transformers and
single phase 230 V supply on single phase transformers
3. Measure the supply voltage and current in each phase
4. Now repeat the magnetizing current test of transformer test with keeping tap changer
in normal position
5. Repeat the test while keeping the tap at highest position
Normally, there are two similar higher readings on two outer limb phases on transformer core
and one lower reading on the center limb phase, in the 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 a likelihood of a fault in the winding which needs further
analysis.

Caution: This magnetizing current test of a transformer is to be carried out before DC resistance
measurement.
Vector Group Test of Transformer
In a 3 phase transformer, it is essential to carry out a vector group test of transformer. Proper
vector grouping in a transformer is an essential criteria for parallel operation of transformers.
There are several internal connections of three-phase transformer are available on the market.
These several connections give various magnitudes and phase of the secondary voltage; the
magnitude can be adjusted for parallel operation by suitable choice of turn ratio, but the phase
divergence cannot be compensated.

So we have to choose a transformer suitable for parallel operation whose phase sequence and
phase divergence are same. All the transformers with the same vector ground have same phase
sequence and phase divergence between primary and secondary.
Before procuring an electrical power transformer, you should ensure the vector group of the
transformer, whether it will be matched with his or her existing system or not. The vector group
test of transformer confirms his or her requirements.

Insulation Resistance Test or Megger Test of Transformer

Insulation resistance test of transformer is essential type test. This test is carried out to ensure
the healthiness of the overall insulation system of an electrical power transformer.
Procedure of Insulation Resistance Test of Transformer
1. Disconnect all the line and neutral terminals of the transformer
2. Megger leads to be connected to LV and HV bushing studs to measure insulation resistance IR
value in between the LV and HV windings
3. Megger leads to be connected to HV bushing studs and transformer tank earth point to measure
insulation resistance IR value in between the HV windings and earth
4. Megger leads to be connected to LV bushing studs and transformer tank earth point to measure
insulation resistance IR value in between the LV windings and earth
NB: It is unnecessary to perform insulation resistance test of transformer per phase wise in
three-phase transformer. IR values are taken between the windings collectively as because all the
windings on HV side are internally connected together to form either star or delta and also all the
windings on LV side are internally connected together to form either star or delta.
Measurements are to be taken as follows:

 For autotransformer: HV-IV to LV, HV-IV to E, LV to E.

 For two winding transformer: HV to LV, HV to E, LV to E.
 Three winding transformers: HV to IV, HV to LV, IV to LV, HV to E, IV to E, LV to E.
 Oil temperature should be noted at the time of insulation resistance test of the transformer,
since the IR value of transformer insulating oil may vary with temperature.
 IR values to be recorded at intervals of 15 seconds, 1 minute and 10 minutes.
 With the duration of application of voltage, IR value increases. The increase in IR is an indication
of dryness of insulation.
 Absorption coefficient = 1 minute value/15 secs. value.
 Polarization index = 10 minutes value/1 minute value.
Dielectric Tests of Transformer
Dielectric test of a transformer is one kind of insulation test. This test is performed to ensure the
expected overall insulation strength of the transformer. There are several tests performed to
ensure the required quality of transformer insulation; the dielectric test is one of them. Dielectric
test of the transformer is performed in two different steps.

First one is called Separate Source Voltage Withstand Test of transformer, where a single phase
power frequency voltage of prescribed level, is applied on transformer winding under test for 60
seconds while the other windings and tank are connected to the earth, and it is observed that
whether any failure of insulation occurs or not during the test.

The second one is the induced voltage test of Transformer where, three-phase voltage, twice of
rated secondary voltage is applied to the secondary winding for 60 seconds by keeping the
primary of the transformer open circuited.

The frequency of the applied voltage should be double of power frequency too. Here also if no
failure of insulation, the test is successful.

In addition to dielectric tests of transformers, there are other types of test for checking insulation
of transformer, such as lightning impulse test, switching impulse test and partial discharge test.

Induced Voltage Test of Transformer

The induced voltage test of the transformer is intended to check the inter-turn and line end
insulation as well as main insulation to earth and between windings-

1. Keep the primary winding of transformer open circuited.

2. Apply three-phase voltage to the secondary winding. The applied voltage should be twice of the
rated voltage of secondary winding in magnitude and frequency.
3. The duration of the test shall be 60 seconds.
4. The test shall start with a voltage lower than 1/3 the full test voltage, and it shall be quickly
increased up to the desired value.
The test is successful if no breakdown occurs at full test voltage during the test.

Temperature Rise Test of Transformer

Temperature rise test of transformer is included in type test of transformer. In this test, we
check whether the temperature-rising limit of the transformer winding and oil as per
specification or not. In this type test of the transformer, we have to check oil temperature rise as
well as winding temperature rise limits of an electrical transformer.
The power transformer testing (FAT Test) is performed after completion of the assembly
at the manufacturing shop.  You may also review power transfer inspection article for
step by step inspection guideline or review power transformer inspection and test plan.

Measurement of Winding Resistance 

The resistance of each winding shall be measured at ambient temperature.
Measurement shall be carried out with direct current (DC) by the voltage drop method or
the bridge method as specified in the manufacturer approved power transformer testing
procedure. 

Measurement of Voltage Ratio

The voltage ratio shall be measured on each tapping and verified aginst manufacturer
approved power transformer testing procedure. 

Check of Phase Displacement

The polarity of single-phase transformers and connection symbol of three-phase
transformers shall be checked in each winding.
Measurement of No-Load Loss and Current in
Power Transformer Testing

The no-load loss and no-load current shall be measured at the rated voltage and the
rated frequency. The wave-form of the test voltage shall be an approximately sinusoidal
wave.

Measurement of Short Circuit and Impedance and

Load Loss
The short-circuit impedance and load loss shall be measured at the rated frequency and
the rated current.  When the measurement of the rated current is difficult, the test may
be performed at reduced current to 50 % and above of the rated current.  In this case,
above measured value shall be converted into rated current.

Short-circuit impedance shall be measured with the windings connected on the principal
tappings. Furthermore, the short-circuit impedance shall be measured with the winding
connected on the maximum and minimum tappings.

Temperature Rise Test

The test shall be carried out by any one of the following methods.Direct loading method

Direct loading method

Rated load is applied to the transformer windings.

Back-to-back method

Rated current is applied to the transformer windings at rated voltage.

Equivalent loading method (short-circuit method)

To determine the temperature rise of oil, the input power corresponding to the sum of
no-load and load losses shall be supplied to the transformer, one of its windings being
excited and another short-circuited.

When the rate of change of top oil temperature rise has fallen below 1 K per hour, the
input is reduced to a value which results in the flowing of rated current at rated
frequency in the windings, and this value shall be maintained for three(3) hours.  The
temperature of the windings is then determined by resistance method.

When the winding is provided with taps, the temperature rise tests shall be carried out
at the tap which makes the total losses maximum.

The temperature rise test shall be carried out on the following items:

 Maximum temperature rise of oil

 Temperature rise of windings
 Temperature rise of core and other metallic parts when specified.

Insulation Resistance Test

The insulation resistance between all windings or other live parts of the transformers
and ground (or casing) shall be measured, and the insulation resistance tester and
allowable insulation resistance value for each part shall be as follows, or specified
values in the manufacturer approved power transformer testing procedure.
Induced Overvoltage Withstand Test

The test shall be carried out by applying an alternating voltage as nearly of sinusoidal
wave form as possible and a frequency higher than the rated frequency, to the terminals
of one winding of the transformer.
Separate-Source Voltage Withstand Test
The separate-source voltage test shall be carried out with single-phase alternating
voltage as nearly of sinusoidal wave form as possible and of any convenient frequency
not loss than 80 % of the rated frequency.

For live parts of accessories (except on-load tap changer), test voltage (2E+1 000 V)
shall be applied for 1 minute, and no electrical or mechanical defects shall be found.
(Where E means the rated voltage.)

Lightning Impulse Test

Impulse test voltage specified in applicable standard shall be applied to the windings of
high voltage side of transformers designed for lightning impulse test.

Calculation For Losses And Characteristic Value

The following losses and characteristic values shall be calculated from the results of
"Winding Resistance Test", "No-Load Loss and Current Test" and "Short Circuit
Impedance and Load Loss Test" and shall be compared with manufacturer approved
test procedure acceptance criteria.

1- Losses

 No-load loss
 Load loss

2- Characteristic Values

 Short circuit impedance

 Voltage regulation
 Conventional efficiency

Measurement Of Noise
Measurement of the sound level of transformers shall be carried out when specially
specified as for large size transformers.  Measuring method shall be by the relevant IEC
standards