Power Transformer Testing Proceduer Update

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Power Transformer
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Index sheet
This Photo by Unknown Author is licensed under CC BY
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Commissioning Services Department
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Why do we need Transformers in electrical Network ???
Why electrical power not transfer direct from generation to distribution ???
What is the important type of transformer ??
How Transformer Work ???
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step-up transformer is used to increase the voltage

and reduce the current. ...
Less current means less energy is lost through
heating the wire. Less Voltage Drop-less cost
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Type of insulation :
1. Oil transformer 2. dry transformer
Type of using :
1. Power transformer 2. measurement transformer 3. testing transformer 4. welding transformer
Winding number :
1- 3-phase transformer (3-winding) 2. 1-phase transformer (1-winging)
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It is important to remember that transformers do not generate electrical power; they

transfer electrical power from one AC circuit to another using magnetic coupling. The core of
the transformer is used to provide a controlled path for the magnetic flux generated in the
transformer by the current flowing through the windings, which are also known as coils.
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When an input voltage is applied to the primary winding, alternating current starts to flow in
the primary winding. As the current flows, a changing magnetic field is set up in the
transformer core. As this magnetic field cuts across the secondary winding, alternating voltage
is produced in the secondary winding.
The ratio between the number of actual turns of wire in each coil is the key in determining the
type of transformer and what the output voltage will be. The ratio between output voltage
and input voltage is the same as the ratio of the number of turns between the two windings.
A transformers output voltage is greater than the input voltage if the secondary winding has
more turns of wire than the primary winding. The output voltage is stepped up, and
considered to be a "step-up transformer". If the secondary winding has fewer turns than the
primary winding, the output voltage is lower. This is a "step-down transformer."
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Data Shell be filled in format as per details from Nameplate

,valve schedule plate, factory acceptance test report, approved
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Check list for Commissioning of Oil-Immersed Power Transformer Index Number:CL-NG-6460-002-018
1- Winding Insulation Resistance and Polarization Index test
2- Core and frame insulation
3-Measurement of winding resistance (DC) (at all taps)
4-Measurement of no load current (Excitation Current- MAGENTISING CURRENT)
5-Percentage impedance (Short circuit impedance) PART-1
6-Magnetic balance test.
7-Measurement of zero-sequence impedance(s)
8-Measurement of turns ratio (for all taps)
9-Vector group at normal tap.
10-Measurement of dissipation factor (tan δ)
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Check list for Commissioning of Oil-Immersed Power Transformer Index Number:CL-NG-6460-002-018
11- Frequency test.
12- Calibration of Oil and Winding Temperature Sensors Test
13- Oil Test

PART-2
14- Cooling Fan Motor Test
15- Tests on on-load tap-changers ─ Operation test
16- Functional Check of the following
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Winding Insulation Resistance and
Polarization Index test transformer testing
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1- Winding Insulation Resistance and Polarization Index test
Objective
To measure the condition of a major insulation system (the insulating system between a
winding and the ground (core) or between two windings
Test Equipment's :- (mega ohm meters)(Megger)
Test preparation:-
I. Isolate the area by safety warring tape
II. Safety tagging shall be implemented
III. Tester having valid calibration
IV. Clean all Bushing of the transformer
V. May be taken to see that test leads do not touch among themselves and with
Transformer bod
VI. Confirm the tightness of all connections made
VII. Factory test
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Test procedure:-
I. Terminals of all HV &LV bushings are shorted together.
II. Connect testing as per connection above with Apply 5 KV DC
III. Measurement insulation resistance and record from 1 minuet to
10 minuets as per test formats
IV. Obtain the Polarization Index= IR at 10Minuet /IR at 1 minuet
V. Acceptable Value IR value > 2M Ω Polarization Index>1.5
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INSULATION INSULATION RESISTANCE WITH 5000 VOLTS TESTER (GΩ)

RESISTANCE
BETWEEN 1 2 3 4 5 6 7 8 9 10
PI
MIN MIN MIN MIN MIN MIN MIN MIN MIN MIN
HV to GROUND 14.8 16.9 18.3 19.3 20.2 20.8 21.6 22.2 22.6 23.0 1.55
LV to GROUND 12.1 14.8 16.5 17.8 18.9 20.2 21.0 22.0 22.8 23.6 1.95
HV to LV 12.2 16.0 19.3 22.0 24.4 26.8 28.6 30.4 32.2 33.8 2.77
Acceptable Value IR value > 2M Ω Polarization Index>1.5

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Core and frame insulation testing
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2- Core and frame insulation
Objective
To Ensure the condition of the Insulation resistance core -frame by of measuring the core-to-ground
insulation –frame-to ground and between them
Test Equipment's :- Meggers (mega ohm meters)
Test preparation:-
V. may be taken to see that test leads do not touch among
themselves and with Transformer bod
VII. Factory test
VIII. Link to Core and Frame must be removed
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I. Test procedure:-
II. Connect testing with applied voltage of 1 KV DC as per test Connection for 1 Min
III. Record the Result insulation resistance on format test
IV. Acceptance Value > 2M Ω
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Measurement of winding resistance (DC)
(at all taps) testing
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3-Measurement of winding resistance (DC) (at all taps)
Object :-
Measuring the resistance of the transformer windings ensures that the connections are correct and
the resistance measurements indicate that there are no severe mismatches or opens
Test Equipment's:-
Low Transformer Ohmmeter (MTO330)/ Transformer Winding Resistance Meter(TRM 40)
Test preparation:-
VI. Factory test
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Test procedure:-
I. Connect test as per above connection HV / LV winding Resistance all taps and Record test Result
II. Acceptance Value= should be within ±5% of measure in factory test
WINDING RESISTANCE ()
Average
@ AMBIENT TEMP. * Res/ph @
Res /Ph @ Amb. Winding
TAP NO. 75  C
Temp Connection
()
X1-X0 X2-X0 X3-X0 ()
----- 0.00755 0.00755 0.00756 0.007553 0.008672 STAR
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Measurement of no load current
(Excitation Current- MAGENTISING CURRENT)
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4-Measurement of no load current (Excitation Current- MAGENTISING CURRENT)
Objective :-
I. To confirm no loose contact or loose connection in winding or core.
II. To ensure that there is no shorting in the core material.
III. To ensure no inter turn shorting of winding
IV. To measure current that maintain the magnetic flux excitation in the core
Test Equipment's:- voltmeters and ammeters & 3 phase variable input supply,
Test preparation:-
V. may be taken to see that test leads do not touch among themselves and with
Transformer bod
VII. Factory test
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Test procedure:-
I. Connect as per connection
II. Three phase voltage applied on HV side, by
keeping LV, TV side open.
III. Current measurement carried at HV terminals.
IV. IO% =Average Current /Average Voltage *rated
Voltage/rated current *100
V. Excitation current should not be higher than the
guaranteed value by more than 30%.
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MAGNETIZING CURRENT AT
APPLIED VOLTAGE AT
secondary
Tap
Rated Rated
Pos Avg. Avg. Current
Tap Tap Io%
PRIMARY Voltage WINDING IN mA (A)
Voltage Current
WINDING(V)
H1-H2 H2-H3 H3-H1 IH1 IH2 IH3
1 418000 693 366.4 383.2 376.8 375.46 1.5 1.9 1.9 0.00176 0.28
9 380000 763 364.5 380.6 375.5 373.53 2.1 2.5 2.2 0.00266 0.354
21 323000 897 368.00 382.1 370.8 373.63 2.8 3.6 4.8 0.00373 0.359
AVERAGE CURRENT RATED TAP VOLTAGE

Io= ____________ × ________________ *100
AVERAGE VOLTAGE RATED TAP CURRENT
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Short circuit impedance measurement
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5-(Short circuit impedance)
Objective:-
1- To determine copper losses at full load –to obtain parameters the equivalent circuit
2-To check the occurrence of any inter-turn shorting or shift of the winding during transportation
Test Equipment's :- Ammeter, Voltmeter and Wattmeter.
Test preparation:-
VII. Factory test
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Test procedure:-
I. Connect test as per above connection (LV shorted)
II. Inject 380 V Power supply at Primary Side (lower tap, normal tap and higher tap.
III. Measured current and Voltage between phases as per above and calculate =
IV. Z=(applied voltage/measured current ×rated current/rated voltage)×100
V. Acceptance Criteria 10 % of specified value
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Acceptance Criteria 10 % of specified value
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Magnetic balance test
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6-Magnetic balance test
Objective:-
The purpose of this test is to check whether the flux path in the core is uniform and
properly distributed in the core limbs
identify inter turn faults and magnetic imbalance
Test Equipment's :- Ammeter, Voltmeter and Wattmeter.
Test preparation:-
V. may be taken to see that test leads do not touch among themselves and
with Transformer bod
VII. Factory test
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Test Procedure
I. Inject 220 V/230 V Single phase as per connection above and reading voltage other phases
II. The Sum of these two voltages should give the applied voltage
III. If there is any inter-turn short circuit that may result in the sum of the two voltages not being equal to the applied
voltage
Injection
H1-H0 H2-H0 H3-H0 X1- X0 X2-X0 X3- X0 Y1-Y2 Y2-Y3 Y3-Y1
(V)
H1-H0 219.2 186 22.48 57.52 49.55 4.94 12.22 10.95 1.39
H2-H0 116.1 219.4 102.5 30.17 57.63 27.63 6.25 12.46 6.57
H3-H0 20.57 218.3 218.3 5.20 49.06 57.80 1.46 10.89 12.20
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Measurement of zero-sequence impedance(s)
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7-Measurement of zero-sequence impedance(s)
Objective
The zero-sequence impedance is usually measured for all star-connected windings of the transformer
measure zero sequence impedance which is necessary for ground fault protection
Test Equipment's:- Ammeter, Voltmeter and Wattmeter..
Test preparation:-
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Test procedure Zero Sequence :-

1- Connect test as per above connection (LV shorted)
2- Inject 380 V single Power supply at Primary Side (lower tap, normal tap and higher tap )
3- Record the measured (I)-(V)
4- Calculate The Zero Sequence impedance Formula as per
5-
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Measurement of turns ratio (for all taps)
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8-Measurement of turns ratio (for all taps)
Objective:-
I. To ensure the Turns ratios of the transformer are designed / manufactured as per the
specifications/ requirements.
II. To ensure the Turns ratio errors are within acceptable limits
Test Equipment's :- TTR 330 (Megger)
Test preparation:-
V. may be taken to see that test leads do not touch among themselves
and with Transformer bod
VII. Factory test
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Test Procedure:-
I. connect the tester as per connection above.
II. Test Ratio at all Taps
Limit :- ± 0.5% of the design
Measured value – Calculated value
* % Error = ------------------------------------------------------- X 100
Calculated value
Compare result with factory report
MEASURED RATIO MEASURED RATIO MEASURED RATIO

A B C
Tap No. HV LV Calc. Ratio
Iexc. Dev. Iexc. Iexc.
Ratio Dev. (%) Ratio Ratio Dev. (%)
(mA) (%) (mA) (mA)
1 79500 13800 9.5263 9.5374 0.12 0.61 9.5347 0.09 0.42 9.5352 0.09 0.68
2 75038 13800 9.4180 9.4295 0.12 0.61 9.4264 0.09 0.48 9.4278 0.10 0.69
3 74175 13800 9.3098 9.3218 0.13 0.63 9.3207 0.12 0.50 9.3212 0.12 0.70
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Vector Group
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9-Vector Group
Objective:-
To ensure the vector group of the Transformer is designed/ manufactured as
per the specification.
Test Equipment's :- Multimeter,380 VAC supply
Test preparation:-
VII. Factory test
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Test Procedure:- DY1
I. Apply 380 V 3 phase Voltage to the High
voltage Winding terminal and short
between H1-X1the induced voltages across
the terminals for the following above are
measured.
II. The vector is confirmed as DY1, if the
measured voltages as per the above satisfy
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Measurement of dissipation factor (tan δ)
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The Objective
I. Capacitance and power factor/dissipation factor (PF/DF) measurements are performed to
investigate the condition of the insulation of power transformers and bushings. Both insulation
systems are essential for the reliable operation of the transform
II. To measure the power loss due to leakage current through the transformer insulation
III. To determine material quality of the insulation
IV. The purpose of the measurement is to determine the capacitances between the windings and the
earthed parts and between the different windings of the transformer
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Test Equipments :-
The Double power factor insulation test equipment measures the charging current and watts-loss from which the
power factor, capacitance
Test preparation:-
V. may be taken to see that test leads do not touch among themselves and with
Transformer bod
VII. Factory test
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Test Procedure
For Doble equipment, measurement may be done in the following modes.
1CH refers to all insulation between the high voltage winding and grounded parts
CL refers to the same parts and materials between the low voltage windings and grounded parts
CHL refers to all winding insulation, barriers, and oil between high- and low-voltage windings
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Frequency Test
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11- Frequency Response Analysis
Objective:-
detecting damage arising due to dislocation/ movement of core and winding during transportation
or after occurrence any fault
Test Equipment's :- FRA Analyzer
Test preparation:-
VII. Factory test
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Calibration of Oil and Winding Temperature
Sensors Test
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12- Calibration of Oil and Winding Temperature Sensors Test
Objective:-
This is to ensure proper working of temperature indicators within the acceptable tolerance
according to the actual sensing of temperature.
Test Equipment's :-Heating Calibrator (BROMAN- MODEL 861A /Drywell-Hart Scientific………)
Test preparation:-
V. May be taken to see that test leads do not touch among
VII. Factory test
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A- Calibration of Sensors By Heating
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Test Procedure
1-Temperature calibration test is to be done (of thermometer) Bulb of the temperature relays is
to be taken out from pocket and exposed through some liquid medium to slow temperature
rising. By means of thermometer, temperature of medium is to be check and compared to
temperature relays measuring.
Reference Temp. Oil Temp. Indicator HV Winding LV Winding WTI-The dial marking
in ̊ C in ̊ C Temp. Indicator in ̊ C Temp. Indicator in ̊ C
shall be 20 to 160°C
with ±0.5% accuracy.
starting 31 30 31
40 41 40 41
60 60 60 61 OTI -The dial marking

shall be 20 to 160°C
80 80 80 80
with ±0.5% accuracy.
100 98 99 100
120 119 119 120
140 139 140 140
157 156 157 158
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Function Test for OTI/WTI
DEVICE FUNCTION SETTING OPERATION REMARKS
Cooling Fan Start Spare N/A N/A

Oil Temperature Indicator Alarm 95 95 OK
26Q
Trip 105 105 OK
Cooling Fan Start 75 75 OK
High Voltage Winding Alarm - 115 115 OK

Temperature indicator 49W1
Trip 125 125 OK
Cooling Fan Start 75 75 OK

Low Voltage Winding
Temperature indicator Alarm - 115 115 OK
49W2
Trip 125 125 OK
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WINDING TEMPERATURE CALIBRATION BY SECONDARY CURRENT INJECTION
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B-CALIBRATION BY SECONDARY CURRENT INJECTION
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WINDING TEMPERATURE CALIBRATION BY SECONDARY CURRENT INJECTION
HIGH VOLTAGE WINDING TEMPERATURE INDICATOR:

CT RATIO : 500 / 2 A
HIGH LOAD TAP CURRENT : 420 AMPS
CURRENT INJECTION TO HEATING COIL : 1.68 AMPS
READING
Oil Temp. at start (A) 22
TIME (MIN.) TEMP. READING (° C )
0 22
Oil Temp. at end (B) 23
5 30
10 38
Winding Temp. Before current injection (C) 22
15 40
20 44
Winding Temp. After 45 mins (D) 46
25 45
30 46 Simulated Temp. Rise Measured: [(D-C)-(B-A)] 23
35 46
40 46
45 46
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Oil Test-Dielectric strength
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13- Oil Test-Dielectric strength
Objective:-
This is one of the points to the ensure condition of oil
Test Equipment's :- Calibrated Oil Tester
Test preparation:-
1- Isolate the area by safety warring tape
2- Safety tagging shall be implemented
3- Tester having valid calibration
4- Position the test equipment on a safe location where possibility
of falling objects is remote to happen..
5- Make sure the bottle is clean and dry
6- Factory test
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Test Procedure:-
This test is performed by applying an AC voltage between two
electrodes immersed in an oil sample. When the current arcs
across the gap between the electrodes, the voltage at that instant
is the dielectric breakdown strength
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ASTM D 877 ASTM D 1816

This test method uses This method uses
thin flat-faced cylindrical spherically shaped
electrodes with a 2.5 electrodes with a 1 mm
mm gap.), gap.
Tap Changer, LPOF (Low Applied for Power
Pressure Oil Filled) Transformer
Applied Voltage = 3 K Applied Voltage = 0.5 KV
Minimum Strength : 50 KV
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Other tested in an independent lab.

Color-Moisture Content-Dissipation Factor Test-Dissolved Gas in
Oil Analysis………….
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Cooling Fan Motor Test
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13- Fan Test
Objective:-
To ensure the performance of the fan motor
Test Equipment's :-Digital Multimeter with Clamp Meter and megger for IR test
Test preparation:-
5- Make sure the bottle is clean and dry
6- Factory test
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Test Procedures:-
1- Perform insulation Resistance testing through terminal block
2-Measure the Motor starting Current for each cooling fan’s 3phases
3-Measure the running Current for each cooling fan’s 3phases
4-Calculate the total starting and Running current of each group
5- Check the Rotation direction of fan’s
6-Operate the fan separately to ensure that each switch is of the same fan
7-The separation of the fan is ensured by its respective switches by a failure representation
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Tests on on-load tap-changers ─ Operation test
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15- on-load tap-changers Test
Objective:-
To ensure the proper operation / performance of On Load Tap Changer and its compliance with the
requirements.
Test Equipment's :-Digital Multimeter with Clamp
Test preparation:-
5- Factory test
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Test Procedures
ITEM DESCRIPTION REMARKS
1 Heater, light OK
.2 One complete operation by motor OK
3 One complete operation by hand crank OK
4 Mechanical lock (lower and upper ) limit. OK
5 Electrical lock (lower and upper) limit. OK
6 Interlocking with hand switch. OK
7 Check local OK
8 Tap position indicator. OK
9 Counter operation. OK
10 Check Control switch local/remote/off OK
11 Check voltage and phase sequence OK
I R (A) IY (A) IB (A)
12 OLTC Motor staring current
4.60 4.71 4.65
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Functional Check
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16-Functional Check
Objective:-
To ensure the proper operation / performance of of these devices
And to fully perform it
Test Equipment's :-Digital Multimeter with Clamp
Test preparation:-
5- Factory test
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Test Procedures:-
1-Check all circuits as per schematic drawing of MK panel and highlight
with yellow if its ok
2- All functions shall be checked as per scheme, checklist, test forms
and settings and all should be recorded in
3- Alarms & trips shall be checked in HMI’s, work stations and
gateways. Trip commands shall be checked actually
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DESCRIPTION DEVICE NO. SIGNAL TYPE REMARKS
OIL LEVEL MAIN TANK HIGH LEVEL 71Q1 ALARM OK

OIL LEVEL MAIN TANK LOW LEVEL 71Q1 ALARM OK
OIL LEVEL OLTC HIGH LEVEL 71Q2 ALARM OK
OIL LEVEL OLTC LOW LEVEL 71Q2 ALARM OK
ALARM OK
BUCHHOLZ RELAY MAIN 96B
TRIP
ALARM
PROTECTED RELAY OLTC 96 OK
TRIP
ALARM
PRESSURE RELIEF DEVICE -1 MAIN TANK 63P1 OK
TRIP
ALARM
PRESSURE RELIEF DEVICE -2 MAIN TANK (OLTC) 63P2 OK
TRIP
PRESSURE RELIEF DEVICE - 3 ALARM
63P3 OK
OLTC TRIP
GAS DETECTOR RELAY 63 D ALARM OK
ALARM
PROTECTED RELAY OLTC 96P1 OK
TRIP
ALARM
PROTECTED RELAY OLTC 96P2 OK
TRIP
SUDDEN PRESSURE RELAY 63S TRIP OK
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1

Why do we need Transformers in electrical Network ???

What is the important type of transformer ??

How Transformer Work ???

step-up transformer is used to increase the voltage

It is important to remember that transformers do not generate electrical power; they

Data Shell be filled in format as per details from Nameplate

Check list for Commissioning of Oil-Immersed Power Transformer Index Number:CL-NG-6460-002-018

1- Winding Insulation Resistance and Polarization Index test

2- Core and frame insulation

3-Measurement of winding resistance (DC) (at all taps)

4-Measurement of no load current (Excitation Current- MAGENTISING CURRENT)

5-Percentage impedance (Short circuit impedance) PART-1

6-Magnetic balance test.

7-Measurement of zero-sequence impedance(s)

8-Measurement of turns ratio (for all taps)

9-Vector group at normal tap.

10-Measurement of dissipation factor (tan δ)

Check list for Commissioning of Oil-Immersed Power Transformer Index Number:CL-NG-6460-002-018

11- Frequency test.

12- Calibration of Oil and Winding Temperature Sensors Test

13- Oil Test

15- Tests on on-load tap-changers ─ Operation test

16- Functional Check of the following

Winding Insulation Resistance and

Polarization Index test transformer testing

1- Winding Insulation Resistance and Polarization Index test

Test Equipment's :- (mega ohm meters)(Megger)

INSULATION INSULATION RESISTANCE WITH 5000 VOLTS TESTER (GΩ)

Acceptable Value IR value > 2M Ω Polarization Index>1.5

Core and frame insulation testing

2- Core and frame insulation

Test Equipment's :- Meggers (mega ohm meters)

Measurement of winding resistance (DC)

(at all taps) testing

3-Measurement of winding resistance (DC) (at all taps)

----- 0.00755 0.00755 0.00756 0.007553 0.008672 STAR

Measurement of no load current

(Excitation Current- MAGENTISING CURRENT)

4-Measurement of no load current (Excitation Current- MAGENTISING CURRENT)

H1-H2 H2-H3 H3-H1 IH1 IH2 IH3

AVERAGE CURRENT RATED TAP VOLTAGE

Short circuit impedance measurement

5-(Short circuit impedance)

Test Equipment's :- Ammeter, Voltmeter and Wattmeter.

Acceptance Criteria 10 % of specified value

Magnetic balance test

6-Magnetic balance test

Test Equipment's :- Ammeter, Voltmeter and Wattmeter.

Measurement of zero-sequence impedance(s)

7-Measurement of zero-sequence impedance(s)

Test Equipment's:- Ammeter, Voltmeter and Wattmeter..

Test procedure Zero Sequence :-

Measurement of turns ratio (for all taps)

8-Measurement of turns ratio (for all taps)

Test Equipment's :- TTR 330 (Megger)

MEASURED RATIO MEASURED RATIO MEASURED RATIO

Test Equipment's :- Multimeter,380 VAC supply

Test Procedure:- DY1

I. Apply 380 V 3 phase Voltage to the High

voltage Winding terminal and short

between H1-X1the induced voltages across