Method Statement

Winding Resistance Testing: To check any abnormalities like Loose

connections, broken strands and High contact resistance in tap changers. To
Calculation of the I 2 R losses in transformer. To Calculation of winding
temperature at the end of temperature rise test of transformer.

Turns Ratio Test / Voltage Ratio Test: Are done in Transformer to find out Open
Circuited turns, Short Circuited turns in Transformer winding.

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Introduction to Winding Resistance:

Winding resistance measurements in transformers are of fundamental importance for the following
purposes:

 Calculations of the I2R component of conductor losses.

 Calculation of winding temperature at the end of a temperature test cycle.
 As a diagnostic tool for assessing possible damage in the field.

Transformers are subject to vibration. Problems or faults occur due to poor design, assembly, handling, poor
environments, overloading or poor maintenance. Measuring the resistance of the windings assures that the
connections are correct and the resistance measurements indicate that there are no severe mismatches or
opens. Many transformers have taps built into them. These taps allow the ratio to be increased or decreased
by fractions of a percent. If any of the ratio changes involve a mechanical movement of a contact from one
position to another, these tap changes should also be checked during a winding resistance test.

Regardless of the configuration, either star or delta, the measurements are normally made phase to phase
and comparisons are made to determine if the readings are comparable. If all readings are within one
percent of each other, then they are acceptable. Keep in mind that the purpose of the test is not to
duplicate the readings of the manufactured device, which was tested in the factory under controlled
conditions and perhaps at other temperatures.

Why Winding Resistance Measurements?

1. At Installation

Risk of damage is significant whenever a transformer is moved. This is inherent to the typical transformer
design and modes of transportation employed. Damage can also occur during unloading and assembly. The
damage will often involve a current carrying component such as the LTC, RA switch or a connector. Damage
to such components may result in a change to the DC resistance measured through them. Hence, it is
recommended that the DC resistance be measured on all on-load and off-load taps prior to energizing.
If the transformer is new, the resistance test also serves as a verification of the manufacturers work.
Installation measurements should be filed for future reference

2. At Routine (scheduled) Transformer Maintenance

Routine maintenance is performed to verify operating integrity and to assure reliability. Tests are performed
to detect incipient problems. What kind of problems will the resistance test detect?

 Ratio Adjusting Switch (ratio adjusting off-load tap changer)

Contact pressure is usually obtained through the use of springs. In time, metal fatigue will result in lower
contact pressure. Oxygen and fault gases (if they exist) will attack the contact surfaces. Additionally,
mechanical damage resulting in poor contact pressure is not uncommon. (E.g. A misaligned switch handle
linkage may result in switch damage when operated). Such problems will affect the DC resistance measured
through the RA switch and may be detected

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  Load Tap Changer

The LTC contains the majority of the contacts and connections in the transformer. It is one of few non static
devices in the transformer and is required to transfer load current several thousand times a year.
Hence, it demands special consideration during routine maintenance. In addition to detecting problems
associated with high resistance contacts and connectors, the Megger winding tester will also detect open
circuits (drop-out test). LTCs transfer load current. An open circuit would likely result in catastrophic failure.
On installation and after maintenance it is certainly prudent to verify operating integrity by checking for
open circuits. LTC maintenance often involves considerable disassembly and the test will provide confidence
in the reassembly.
It is recommended DC resistance measurements be made on all on-load and off-load taps to detect
problems and verify operating integrity of the RA switch and LTC.

3. At Unscheduled Maintenance/Troubleshooting

Unscheduled Maintenance generally occurs following a system event. The objectives of unscheduled
maintenance are:
 To detect damage to the transformer.
 To determine if corrective action is necessary.
 To establish priority of corrective action.
 To determine if it is safe to re-energize.
Many transformer faults or problems will cause a change in the DC resistance measured from the bushings
(shorted turns, open turns, poor joints or contacts). Hence, the information derived from the resistance test
is very useful in analyzing faults or problems complimenting information derived from other diagnostic tests
such as FRA, DFR, power factor and other measurements. The winding resistance test is particularly useful in
isolating the location of a fault or problem and assessing the severity of the damage.

Test Procedure
The resistance of each transformer winding is measured using DC current and recorded at an ambient temp.
In this test resistance of winding is measurement by applying a small DC voltage to the winding and
measuring the current through the same. The measured resistance should be corrected to a common
temperature such as 75OC or 85OC using the formula:

Where RC is the corrected resistance, RM is the measured resistance. CF is the correction factor for copper
(234.5) or aluminum (225) windings. CT is the corrected temperature (75 OC or 85OC) WT is the winding
temperature (OC) at time of test. Before measurement the transformer should be kept in OFF condition at
least for 3 to 4 hours so in this time the winding temperature will become equal to its oil temperature. To
minimize observation errors, polarity of the core magnetization shall be kept constant during all resistance
readings.
Voltmeter leads shall be independent of the current leads to protect it from high voltages which may occur
during switching on and off the current circuit. The readings shall be taken after the electric current and
voltage have reached steady state values. In some cases this may take several minutes depending upon the
winding impedance.

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'The test current shall not exceed 10% of the rated current of the winding'. Large values may cause
inaccuracy by heating the winding and thereby changing its resistance. For Calculating resistance, the
corresponding temperature of the winding at the time of measurement must be taken along with resistance
value.

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Introduction to Transformer Turn Ratio:

Ratio measurements in transformers are of fundamental importance for the following purposes:

 To validate design specifications

 To verify quality of manufacturing process
 To establish present condition and condition trend
 To determine if damage has occurred

Deviation of ratio from expected calculated target values may indicate the following:

 Manufacturing defect in winding

 Improper turns
 Incorrect polarity
 Incorrect winding configuration
 Insulation failure
 Damaged turn-to-turn insulation resulting in shorted windings
 Major insulation failure: inter-winding or winding-to-ground
 Defective tap-changer
 Incorrect assembly of winding connections
 High resistance connections
 Incorrect tap-changer setting

Transformers are subject to mechanical impact and vibration. Problems or faults occur due to poor design,
assembly, handling, poor environments, overloading or poor maintenance. Measuring the polarity and turn
ratio of a transformer winding assures that the connections are correct and there are no severe mismatches
or opens.

Test Procedure:

The test set outputs an excitation test voltage to the transformer’s primary windings and measures the
expected target ratio. The target ratio, i.e. the expected measured voltage ratio, is calculated from the
transformer nameplate ratio and the actual configuration of the transformer. The recalculation factor is
pending transformer vector configuration and when applicable also the actual TTR test setup including
eventual shorts to create a virtual neutral terminal.

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Testing Equipment details:

MTO300/330

The MTO300/330 delivers full eight-terminal/six-winding resistance measurement capability. It is designed

to save time by testing all six windings without having to disconnect and reconnect leads. Also, the
simultaneous winding magnetization (SWM) method gives fast and reliable measurements even on large
transformers with delta configuration on the low voltage side.

MWA300/330A
The Megger MWA300/330A Transformer Winding Analyzer is an advanced 3-phase transformer test system
delivering portability, reduced set-up time, increased job-site safety, and effortless productivity. The
MWA3xx provides complete ratio, phase and winding resistance measurements for a 3-phase transformer.
All ratio and winding resistance tests are performed in one instrument, with only one 3-phase lead-set
connection. The MWA3xx utilizes PowerDB as a single software platform saving the user additional time with
only one set-up and one easy-to-use test form.

The MWA300/300A effectively tests:

 Power transformers
 Distribution transformers
 CTs and VTs (PTs)
 Motors/Generators

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TRAX280
TRAX is a multi-function test system for transformer substation testing. The test system replaces numerous
individual testing devices which makes testing with TRAX a time saving and cost-effective alternative to
conventional measurements using separate instruments.

Test capability

 Winding resistance measurements

 Adaptive algorithm for optimized transformer demagnetization
 True dynamic resistance measurements on load tap changers
 250 V transformer turns ratio measurements
 12 kV dissipation factor and capacitance testing features

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