MEE Unit 4

UNIT 4:Testing and trouble
shooting of transformers
Wednesday, May 19, 2021 EE5962 MRS.A.V.THAKARE LEE GP AMRAVATI 1/70

• Testing: type, routine and special tests as per IS 2026-1981 for Distribution and
Power transformers. Procedure for conducting following tests:
1) Measurement of winding resistance,
2) no load losses & no load current,
3) Impedance voltage, load losses,
4) Insulation resistance,
5) Induced over voltage withstand test,
6) separate source voltage withstand test,
7) Impulse voltage withstand test,
8) Temperature rise test of oil & winding,
9) Different methods of determining temp rise- back to back test,
10) short circuit test,
11) open delta test.
12) dissolved gas analysis.
• Causes of failure: internal and external, types of faults: mechanical. electrical and
magnetic
• Trouble-shooting and remedies: trouble shooting charts for single phase and three
phase transformers,
EE5962 MRS.A.V.THAKARE LEE GP
Wednesday, May 19, 2021 2
AMRAVATI
TRANSFORMER
• TRANSFORMER IS A STATIC
DEVICE WHICH TRANSFORMS
A.C. ELECTRICAL POWER
FROM ONE VOLTAGE level TO
ANOTHER VOLTAGE level
KEEPING THE FREQUENCY
SAME BY ELECTROMAGNETIC
INDUCTION.

AMRAVATI
TYPES OF TRANSFORMER BY APPLICATION
• 1. DISTRIBUTION TRANSFORMER
• 2.POWER TRANSFORMER
• 3.CURRENT TRANSFORMER
• 4.POTENTIAL TRANSFORMER
• 5.FURNACE TRANSFORMER
• 6.BOOSTER TRANSFORMER
• 7.RECTIFIER TRANSFORMER
• 8.LOCOMOTIVE TRANSFORMER
• 9.MINING TRANSFORMER
• 10.PHASE SHIFTING TRANSFORMER
• 11.WELDING TRANSFORMER
• 12.HIGH VOLTAGE TESTING/SC TESTING TRF.
• 13.GROUNDING TRANSFORMERS
• 14.CONVERTER
Wednesday, May 19, 2021
TRANSFORMER
4
AMRAVATI
DISTRIBUTION TRANSFORMER
• TRANSFORMER WHICH IS USED FOR THE
PURPOSE OF DISTRIBUTION OF POWER.
• 11KV/433V is the standard voltage rating.
• STANDARD KVA ratings are

25,63,100,160,200,250,315,400,500,630,750
, 1000 , 1250,1500,2000,2500 KVA.
IS-2026 is the NATIONAL I S STANDARD.
AMRAVATI
MAIN FEATURES
• OUTDOOR,OIL COOLED, 3 PHASE,50HZ
• PRIMARY IS DELTA CONNECTED AND
SECONDARY IS STAR CONNECTED.
• NATURALY COOLED (ONAN TYPE).
• AMONGST ALL THE TYPES OF TRANSFORMERS
THIS IS THE MOST REQUIRED AND MOST USED
TYPE.

AMRAVATI
PARTS OF TRANSFORMER
• MAIN TANK
• RADIATORS
• CONSERVATOR
• EXPLOSION VENT
• LIFTING LUGS
• AIR RELEASE PLUG
• OIL LEVEL INDICATOR
• TAP CHANGER
• WHEELS
• HV/LV BUSHINGS
• FILTER VALVES
• OIL FILLING PLUG
• DRAIN PLUG
• CABLE BOX

AMRAVATI
AMRAVATI
TESTING of TRANSFORMER
• Routine test –carried out each and every
transformer
• Type test - carried out on few transformer
from a lot of same design
• Special test - carried out on transformer for
specified purpose only
• Supplementary test- carried out if additional
information is required about a particular
transformer .
AMRAVATI
Routine tests of transformer include :-
1.Transformer winding resistance measurement.
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
AMRAVATI
Type tests of transformer includes :-
1.Transformer winding resistance measurement
2.Transformer ratio test.
3.Transformer vector group test.
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.

AMRAVATI
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
buchholz relay, temperature indicators, pressure relief
devices, oil preservation system etc.
.
AMRAVATI
Supplementary test-
carried out if additional information is required
about a particular transformer .
1.Back to back test
2.Efficiency test

AMRAVATI
1.Transformer winding resistance
measurement
This test measures the resistance of
the HV & LV winding. The values of
resistance should be balance for all
three phases and should match the
designed values.
Equipment used : Digital resistance
meter. Or using voltmeter ammeter
method
AMRAVATI
14
Transformer winding resistance measurement

AMRAVATI
• The meaning of D.C. resistance is that resistance measured between two
terminals of transformer winding when D.C. current is made to flow through
it. It's value will change if A.C. is applied across it's terminals due to skineffect.
• The simplest method of measuring D.C. resistance is by using voltmeter,
ammeter, which gives better results for moderate and high values of
resistances. Very accurate results can be obtained in case of low resistances
using Wheatstone bridge or Kelvin bridge method._
• Resistance R = V/I
• In some cases, the test temperature will not be the same at which the
resistance value is determined during design. Hence, the same is required to
be converted to the desired temperature value.
• In case of copper conductors it can be determined using the following
relation,Rt2= Rt1*(234.5 + t2 )/ (234.5 + t1)
where, Rt1 = Resistance at t1 degree centigrade
Rt2 = Resistance at t2 degree centigrade
t2 = Temperature at which resistance is required
t1 = Temperature at the time of testing
AMRAVATI
2.Measurement of no load loss and current
(Open circuit test) :The aim of the test is to determine the percentage variation
of the magnetising current, no-load current and core losses from the designed values
and to see whether they are within the permissible limits as specified bylSS

AMRAVATI
• In this test, generally the L.V. winding is connected to it's
rated voltage at rated frequency.
• As the H.V. voltage may not be available in the laboratory
for testing purpose, this test can be carried out on
transformers complete with windings and fitted in tank
with oil.
• For normal or low flux densities the reading of the
wattmeter (low p.f.) will represent: (i) Core losses of
transformer, (ii) L.V. copper loss at no-load which is
negligible (iii) Dielectric loss very low for low voltages as it
dependsupon voltage.
• Neglecting other losses which are very small, the
wattmeter reading represents core losses
Sr. Applied No load No load Secondary Transformation
No. Voltage (V1) current (I0) Power (W0) Voltage (V2) 𝐕𝟐
Ratio K=
or (V0)Volts Amp Watt Volts 𝐕𝟏

AMRAVATI
• If W0 = Wattmeter reading on no-load I0 = Ammeter
reading V0 = Rated voltage applied in O.C. test.
• Iron losses= Wo watts.
• No load P.f., Cos Ø = Wo/Vo*I0
• Magnetizing current, Im = Io Sin Ø
• Loss component of no load current, Iw = Io Cos Ø
• Magnetizing reactance, Xo = Vo/Im
• Equivalent resistance of iron losses, Ro = Vo /Iw
• When higher values of flux densities are used the
saturation effect may cause harmonic e.m.fs. or the
voltage applied to the transformer may consist of
harmonic e.m.fs.; the eddy current loss which is a function
of waveform of flux density depending upon induced
e.m.fs.

AMRAVATI
impedance and load loss(Short circuit test).
In this test, the equivalent impedance,-the equivalent
resistance and the' equivalent reactance of the
transformer referred to the measuring side can be;
determined. At the same time if full-load current is
circulated through the transformer windings the full-
load copper loss can also be determined. In this test,
transformer H.V. winding is (generally) connected to
variable voltage supply source and the L.V. winding is
short-circuited by thick low, resistance (negligible)
wire, a wattmeter, voltmeter and ammeter being!
connected on H.V. side as shown in Fig
AMRAVATI
20
The reason for connecting voltage to H.V. side in this test
is that, the voltage! required for conducting the test is
nearly 5% of rated voltage which will be! available in the
laboratory, but the current required for L.V. is much more
in i comparison to full-load H.V. current, which may not
be available or may cause disturbance to the distribution
system at the time of testing. The readings of the
wattmeter, voltmeter and ammeter are recorded.
Generally, current flowing through H.V. winding is
adjusted to its full-load value.
At this time the reading of the wattmeter indicates full-
load copper-loss. Iron losses being negligible

AMRAVATI
Sr. Voltage applied (VSC) Volt Current Circulated Short circuit power
No. (ISC) Amp (WSC)

AMRAVATI
Calculations:
Total resistance referred to H.V side
W SC
R02= = ………………….. Ω
I 2SC
2 2
X02 = √(𝑍02 − 𝑅02 ) = ……………. Ω
% Efficiency at full load
Full load at rated output of transformer in watts = kVA * 1000 * Power factor
x VA rating ×cos ∅
% Efficiency at full load = × 100
x VA rating ×cos ∅+ W 0 + x 2 W SC
= …………………… %
% Efficiency at any load and given p. f
actual load
X= = …………………..
full load
Then output power at actual load = x * (kVA)*1000* p. f =……………watts
Iron losses = Wi = W0 = …………….
Copper losses = Wcu = (x2) WSC = ……………
Total losses = Wi + Wcu = ………………
% Efficiency = (output)/(Output + losses) *100
% Voltage regulation at full load of given p. f
% Regulation at full load = (I2 R02cos ∅0 ±I2X02sin ∅0 )/V2
% Regulation at any(x) load = (x I2 R02cos ∅0 ± x I2 X02sin ∅0 )/V2
‘+’ for lagging power factor EE5962 MRS.A.V.THAKARE LEE GP
‘-’ for leading power factor AMRAVATI
AMRAVATI
4.Methods for measurement of insulation resistance:
1) Megger:-
 A 5000V or 2500V or 1000V or 500V motor driven megger is used to
measure the insulation resistance.
 First disconnect all the line & neutral terminals of the transformer
 To check the IR, megger should be crancked (rotate) at a speed indicated in
its certificate (usually 120 rpm).
 First, Megger leads to connected to HV bushing studs & LV bushing studs.
This measure insulation resistance value in between the HV windings & LV
bushing
 Megger leads to be connected to HV bushing studs & transformer tank earth
point. This measure insulation resistance value in between the HV windings &
earth.
 Megger leads to connected to LV bushing studs & transformer tank earth
point. This measure insulation resistance value in between the LV windings &
earth.
Take Two readings, one after 15 sec. & the other after 60 sec.
 If Wednesday,
the material is sound, TheEE5962
May 19, 2021
value of R60 isLEEhigher
MRS.A.V.THAKARE GP than value of R15 25
AMRAVATI
2) Step Voltage Method:-
 In this test DC voltage in steps of 1KV, or 2 KV is
applied between winding & earth.
 The voltage can be raised up to a test value & a
current flowing through circuit is recorded.
Precaution:-The step voltage is maintained for a
small time interval.
Calculation:-Calculate value of insulation resistance
from V & I reading.
Graph:-Then graph is plotted between calculated
value of resistance & applied test voltage
AMRAVATI
High Voltage Tests
• The insulation resistance measured by megger
does not give clear idea about the strength of
insulation, that is whether it will withstand the
high voltages developed in the network due to
switching surges etc. or not. For determining
this, high voltage tests are conducted as per IS
2026-1981 on the transformers.
• The high voltage tests can be conducted in the
following two ways:
(i) Induced overvoltage with stand test
(ii) Power frequency high voltage test,

AMRAVATI
5.Methods for measurement of insulation resistance/dielectric test:
Induced Over voltage Withstand test (DVDF test flash test)
The aim of the test is to test the insulation between turns, insulation
between] coils and terminals.
• In this test, a voltage equal to twice the rated voltage of any one
winding: i.e. either H.V. or LV. (preferably L.V.) is applied. It will cause
high voltage to be induced in the other winding.
• To avoid the excessive magnetizing or no-load current, the voltage is
applied from a separate alternator so that frequency of the test voltage
can be adjusted to twice the normal frequency.
• the voltage applied at start is not more than l/3rd test value then it is
brought to the test value; maintained for 60 seconds for test frequencies
up to twice the normal then reduced to less than l/3rd test value before
switching off.

AMRAVATI
• If the test frequency is other than, up to twice the normal
frequency the duration of test is given by the following
relation, Duration of the test in sec. = 60 x Twice the rated
frequency /test frequency
• For induced type transformers, the test voltage is equal to
twice the highest system voltage + 1000 volts; subjected to a
minimum of 2000 volts. For example, in case of a 11 kV
transformer the highest system voltage is 12 kV, therefore the
test voltage will be 12 x 2 + 1= 25 kV. This test is also called as
flash test.
• For a 11KV/433V transformer,866 Volts are applied at the
433V winding with the help of a Generator for 1 minute. This
induces 22KV on 11KV side. The frequency of the 866V supply
is also increased to 100HZ.
Equipment used : MOTOR GENERATOR SET
AMRAVATI
AMRAVATI
AMRAVATI
6 Methods for measurement of
insulation resistance/dielectric test:
• Separate source voltage withstand test ( power frequency High Voltage
tests on HV & LV )
• This dielectric test is intended to check the the ability of main insulation to
earth and between winding.
• Procedure
• All three line terminals of the winding to be tested are connected together.
• Other winding terminals which are not under test and also tank of the
transformer should be connected to earth.
• single-phase A.C. voltage of sinusoidal waveform is applied at rated frequency.
The highest value of the test voltage is as given in the table below. At the time
of conducting the test a voltage less than l/3rd of the test value is applied at
the beginning. It is then increased gradually to full-test value and maintained
for 60 seconds, then it is reduced to less than l/3rd test value and then the
supply is switched off.
•
The test is successful if no break down in the dielectric of the insulation occurs
during test.

AMRAVATI
In this transformer testing, the peak value of voltage is measured, that is why the
capacitor voltage divider with digital peak voltmeter is employed as shown in the diagram
above. The peal value multiplied by 0.707 (1/√2) is the test voltage.
AMRAVATI
AMRAVATI
The values of test voltage for different fully insulated
winding are furnished below in the table.
Voltage of Transformer Test Voltage

3.3 kV 16 kV
6.6 kV 22 kV
11 kV 28 kV
33 kV 70 kV
66 kV 140 kV
110 kV 230 kV
132 kV 275 kV
220 kV 460 kV

AMRAVATI
Type Tests/Special Test/Dielectric Test
Impulse Voltage Withstand Test/Lightening Impulse Test
• Lighting is a common phenomenon in transmission lines because of
their tall height. This lightning stroke on the line conductor causes
impulse voltage. The terminal equipment of transmission line such
as power transformer then experiences this lightning impulse
voltages. Again during all kind of online switching operation in the
system, there will be switching impulses occur in the network. The
magnitude of the switching impulses may be about 3.5 times the
system voltage.
• Insulation is one of the most important constituents of a
transformer. Any weakness in the insulation may cause failure of
transformer. To ensure the effectiveness of the insulation system of
a transformer, it must confirms the dielectric test. But the power
frequency withstand test alone can not be adequate to demonstrate
the dielectric strength of a transformer. That is why impulse test of
transformer performed on it. Both lightning impulse test and
switching impulse test are included AMRAVATI in this category of testing.
 .The lightning impulse is a pure natural phenomenon. So it is very difficult to predict the
actual wave shape of an lightning disturbance. From the data compiled about natural
lightning, it may be concluded that the system disturbance due to natural lightning
stroke, can be represented by three basic wave shapes .
Full wave, Chopped wave and Front of wave
 Although the actual lightning impulse disturbance may not have exactly these three
shapes but by defining these waves one can establish a minimum impulse dielectric
strength of a transformer.
 If lighting disturbance travels some distance along the transmission line before it reaches
the transformer, its wave shape may approach to full wave. If during traveling, if flash-
over occurs at any insulator of the transmission line, after the peak of the wave has been
reached, the wave may become in form of chopped wave. If the lightning stroke directly
hits the transformer terminals, the impulse voltage rises rapidly until it is relieved by a
flash over. At the instant of flash-over the voltage suddenly collapses and may form the
front of wave shape.
 The effect of these waveforms on the transformer insulation may be different from each
other. whatever may be the shape of lightning disturbance voltage wave, all of them can
cause insulation failure in the transformer. So lighting impulse test of transformer is one
of the most important type test of transformer.
AMRAVATI
• Hence , a impulse test has been developed to determine the ability of a
transformer to withstand the effects of high unidirectional voltages
resembling the lightning surge. For carrying out this test a high voltage
impulse generator is required The simplest basic circuit used for
developing a 1/50 wave and its application to the electrical equipment
under test is shown in Fig. 1. The 1/50 wave is represented in Fig. 2.
•

AMRAVATI
For a three phase transformer, impulse is carried out on all three
phases in succession.
The voltage is applied on each of the line terminal in succession,
keeping the other terminals earthed.
The current and voltage wave shapes are recorded on the
oscilloscope and any distortion in the wave shape is the criteria for
failure.

AMRAVATI
TYPE TEST Temperature rise/ heat run
on test on transformer:
• This test is primary intended to determine the

actual maximum temperature attained on
• different parts of the transformer while
running at full load.
• This test is also used to find regulation,
efficiency

AMRAVATI
In case of transformers the temperature rise
test can be conducted by the following
methods:
(i) By equivalent short circuit test.
(ii) By back to back test using auxiliary
transformer.
iii)By back to back test using one transformer
with suitable tapping on secondary.
iv) By open delta connection on three-phase
Delta/Delta transformer.
v)In case of high frequency transformers equivalent
O.C. test
vi)Direct loading method EE5962 MRS.A.V.THAKARE LEE GP
AMRAVATI
SUPPLEMENTARY TEST- Back to back test on
transformer to determine efficiency and
regulation.(Sumpner’stest/summationtest/regenerat

AMRAVATI
Procedure :
 For this test two identical transformer are required.

 Primary of two transformers are connected in parallel
and secondaries are connected in series opposition.
 Supply is given at rated voltage and rated frequency
generally to LV winding similar to OC test.
 Now supply is given to HV winding with the help of
auto-transformer (Regulating transformer) till full load
current is circulated in HV winding similar to short
circuit test.
 To measure the temperature rise two transformers
are kept under rated load conditions for several hours
till maximum steady state temperature is reached.
AMRAVATI
Observation:-
2. Note down the room temperature.

3. When steady state temperature is reached, take the temperature of oil with
the help of thermometer.
4. Measure the resistance of winding when immediately after steady state
temperature

AMRAVATI
AMRAVATI
Open Delta Method:
 This method is applicable in case of a Delta/Delta connected transformers. When a
balanced three-phase voltage is applied to the primary winding of a Delta/Delta
transformer, it will induce balanced three-phase voltage in the delta-connected
secondary.
Under this condition, the resultant voltage acting in the closed delta is zero
,Hence, no circulating current will flow in the circuit.
To make the current to circulate in the secondary as well as primary, circuit
diagram as shown in Fig 1 is used.
A small voltage js introduced in the secondary by connecting secondary of
auxiliary transformer in series as shown in Fig. 1
. The voltage applied to the primary of auxiliary transformer is adjusted In; a
way that full-load current circulates through three-phase transformer
secondary as recorded by ammeter A.
It will cause full-load current to circulate through transformer primary Hence, a
condition similar to full-load working condition is developed i.e. losses at normal
flux density drawn from mains and full-load copper drawn from auxiliary bus.
This condition is maintained till final steady-state temperature is develop The
temperature rise can be determined in a similar manner by resistances
measurement tests,
AMRAVATI
Main bus bars
Delta/Delta connected
transformers
auxiliary
transformer

AMRAVATI
Sn V1 I1 W1 W2 WI=W+W2 VSC IFL W3=W
CU

AMRAVATI
3.Phasing out test on transformer.
Circuit diagram:-
This test is carried out only on 3 phase transformer to idenitify primary and secondary
winding belonging to same phase .
Procedure:-
 Short primary & secondary winding of other phases expect the one under test.
 Connect voltmeter to secondary winding. A small DC current is circulated through the primary
winding through switch.
 Now with the help of switch interrupt the DC supply instantly & repeatedly.
 If voltmeter indicator deflects than it indicates the two windings concerned belong to the
same phase. If not deflect then two windings are not belong to same phase.
 Repeat the procedure by connecting voltmeter to secondary side to next secondary
winding tillMay
voltmeter EE5962 MRS.A.V.THAKARE LEE GP
Wednesday, 19, 2021 gives deflection. 49
AMRAVATI
In this way we can search the phasing out.
DISSOLVED GAS ANALYSIS OF TRANSFORMER OIL
 In dissolved gas analysis of transformer oil (or DGA of transformer oil) the gases in
oil are extracted from oil and analyze the quantity of gasses in a specific amount of
oil. By observing percentages of different gasses present in the oil, one can predict
the internal condition of transformer.
 Generally the gasses found in the oil in service are hydrogen (H 2), methane(CH4),
Ethane (C2H6), ethylene(C2H4), acetylene (C2H3), carbon monoxide (CO), carbon
dioxide (CO2), nitrogen(N2) and oxygen(O2).
 Most commonly used method of determining the content of these gases in
oil, is using a Vacuum Gas Extraction Apparatus and Gas Chronographs.
By this apparatus first gasses are extracted from oil by stirring it under vacuum.
These extracted gasses are then introduced in gas Chronographs for measurement of
each component.
conclusion:
 Generally it is found that hydrogen and methane are produced in large quantity
if internal temperature of power transformer rises up to 150°C to 300°C due to
abnormal thermal stresses.
 If temperature goes above 300°C, ethylene(C2H4) are produced in large quantity.
 At the temperature is higher than 700°C large amount of hydrogen(H2) and ethylene
(C2H4) are produced. Ethylene(C2H4) is indication of very high temperature hot spot
inside transformer .
 If during DGA test of transformer oil,MRS.A.V.THAKARE
EE5962 CO and COLEE2 GPare found in large quantity it is
predicted that there is decomposition of AMRAVATI
paper insulation.
Furfural Test or Furfuraldehyde Analysis of Transformer Oil:
Transformer core and winding have mainly paper insulation. Base of paper is
cellulose. The Cellulose has a structure of long chain of molecules. As the paper
becomes aged, these long chains are broken into number of shorter parts.
.In transformer, the aging affect of paper insulation is accelerated due to oxidation
occurs in oil. When insulating paper becomes mechanically weak, it can not withstand
the mechanical stresses applied during electrical short circuit and leads to electrical
breakdown.
It is therefore necessary to monitor the condition of paper insulation inside a power
transformer. It is not possible to bring out a piece of paper insulation from a transformer
in service for testing purpose. But ,there is a testing technique developed, where we
can examine the condition of paper insulation without touching it. The method is called
Furfuradehyde analysis of in short Furfural test.
Although by dissolved gas analysis one can predict the condition of the paper
insulation primarily, but it is not very sensitive method.
There is a guide line in IEC-599, where it is said that if the ratio of CO2 and CO in
DGA results is more than 11, it is predicted that the condition of paper insulation inside
the transformer is not good.
A healthy cellulose insulation gives that ratio in a range of 4 to 11. But still it is not a
very sensitive way of monitoring the condition of paper insulation. Because CO 2 and
CO gases also produced during oil breakdown
EE5962 and
MRS.A.V.THAKARE LEEsometimes
GP the ratio may misleads
the prediction. AMRAVATI
Causes of failure: internal and external, types of faults:
mechanical. electrical and magnetic
• Over heating ,overloading

• Winding faults,winding short-circuits,Phase-to-phase faults.
Phase-to-ground faults, Inter turn faults
• Open circuits
• External faults
• Core faults, Saturation of magnetic core,Over fluxing
• Tank faults and cooling failure
• Tap changer faultsEarth-faults,
• Through faults
• High voltages surges
• Incipient faults.

AMRAVATI
Causes of Troubles and Failures in Power Transformers and Preventive Actions
Trouble Cause Remarks
1. Overheating Overloads Failure of cooling Check cooling system, whether fans are operating whether
system High ambient oil/water is circulating. Reduce the load on the transformer. If
temperature temperature of coii high, switch-off the transformer till safe
temperature is reached. If overload problem is occurring for long
durations, install another transforme' in parallel. If ambient
temperature is higher than that considered in specifications of
transformer derate the transformer
2. Sustained higher Poor voltage control of power Transformer fail due to sustained over voltage. Provide overfluxing
voftage on primary system use of shunt reactance protection and over-voltage protection for bus-bar. Flux density
resulting in and tap changing transformer depends upon V/f ratio. Generator transformers, get overfluxed
overheating of core to control busbar voltage within during low frequency operation.
due to over fluxing. specified limit.
3. Frequent external Insufficient clearances on Transformer windings should be capable of withstanding repeated
short-circuits. overhead lines, accumulation of external short-circuits without failure. Transformer should be
dust on insulation. provided with over current protection.
4. Short-circuit .Sharp corners on conductors Buchholtz relay should operate and sound alarm. Over-current and
between adjacent cutting into insulation. differential protection should operate and open the circuit breaker.
turns, usually high External short circuit (1:3).
voltage winding. Moisture in oil. Fluctuating
loads. Transient over voltage. AMRAVATI
Trouble Cause Remarks
5. Internal Sustained overload and insulation failure Overcurrent protection Earth fault
short-circuit Fault in tap changer protection Differential protection
Failure of end turns of coil due to over voltage
surges
Bad solder joint causing local overheating and
open circuit Ageing of insulation, abrasion of
insulation resulting in internal shod: circuits
6. Moisture • Moisture in the oil while filling Oil should be filtered. Silica jel should be
in oil • Breother saturated replaced, gaskets should be replaced.
• Defective seal;; Transformer should be dried out.
7. Rapid • Excessive overloading Cause should be determined and

deterioration • Pressure of moisture corrective action to be taken
of oil • Poor quality of oil
8. Carbon Sparking in oil, excessive temperature of oil Conducting particles line up on

and other insulation surface causing reduction in
conducting insulation resistance and failure by
particles in tracking. Transformer needs overhauling.
oil
AMRAVATI
ouble Cause Remarks
Failure of insulation of bolts Failure of insulation bolts used for clamping the core
used for clamping core and and yoke cause! heavy circulating short circuit
yoke currents resulting in core heating.
Vibrations in core The loose core clamping bolts and bolts between
core and structure results in vibration of core. This
results in weak core insulation.
Excessive core heating, high Excessive heating of core result ir temperature rise of
magnetizing currents, high in winding.
rush current.
Failure of core, bolt insulation. Moisture absorption and dielectric failure.
Overfluxing of power Flux density depends on V/f ratio The generator

transformer. Melting of core transformer fail b> overfluxing if excitation is
bolts, burning of core both maintained during starting or stopping the unit,
insulation, burning of Overfluxing rel should be provided for protectior
Wednesday,
insulation May 19, 2021
between generator transformer. 55
AMRAVATI
Silica Gel Breather of Transformer
 Whenever electrical power transformer is loaded, the temperature
of the transformer insulating oil increases, consequently the volume
of the oil is increased. As the volume of the oil is increased, the air
above the oil level in conservator will come out. Again at low oil
temperature; the volume of the oil is decreased, which causes the
volume of the oil to be decreased which again causes air to enter
into conservator tank.
 The natural air always consists of more or less moisture in it and this
moisture can be mixed up with oil if it is allowed to enter into the
transformer. The air moisture should be resisted during entering of
the air into the transformer, because moisture is very harmful for
transformer insulation.
 A silica gel breather is the most commonly used way of filtering air
from moisture. Silica gel breather for transformer is connected with
conservator tank by means of AMRAVATI
breathing pipe. 56
Working Principle of Silica Gel Breather
Silica gel crystal has tremendous capacity of absorbing moisture.
When air passes through these crystals in the breather; the
moisture of the air is absorbed by them. Therefore, the air reaches
to the conservator is quite dry, the dust particles in the air get
trapped by the oil in the oil seal cup. The oil in the oil sealing cup
acts as barrier between silica gel crystal and air when there is no
flow of air through silica gel breather.
The color of silica gel crystal is dark blue but, when it absorbs
moisture; it becomes pink. When there is sufficient difference
between the air inside the conservator and the outside air, the oil
level in two components of the oil seal changes until the lower oil
level just reaches the rim of the inverted cup, the air then moves
from high pressure compartment to the low pressure compartment
of the oil seal . Both of these happen when the oil acts as core filter
and removes the dust from the outside
air. Wednesday, May 19, 2021
AMRAVATI
57
AMRAVATI
SPECIAL TEST
• Short circuit withstand ability test.
This tests measures the ability of the transformer to withstand the
mechanical and thermal stresses caused by the external short circuit.
HV terminals are connected to the supply bus of the testing plant. The LV is
short circuited. The testing plant parameters are such adjusted to give the
rated short circuit current.
Supply is made on and closed after specified duration of short circuit. The
record of current wave form is noted.
There should not be any mechanical distortion, fire to the transformer during
this test. Similarly no wave form distortion. The transformer should also
withstand the routine tests after the short circuit test.
The reactance of the winding measured before and after the S.C. test should
not vary beyond the limits stated in the IS2026.

AMRAVATI
Tests Before Commissioning a Transformer
The tests to be carried out on a transformer before connecting it to supply, depend upon the kVA
rating, voltage rating and also the facilities available at the site at the time of switching on. Also it
may depend upon the conditions laid down by the purchaser. The tests are carried out as per ISS
1886-1967. Generally the following tests can be carried out at site:
1. A overall inspection of the control and relay panels, cable junction boxes is carried out and
observed if any connection is left open.
2. Tests on relays such as over current, earth fault, reverse power etc. is carried out for their
operation.
3. Voltage ratio with equal tappings on all phases can be checked.
4. Measurement of earth resistance and necessary steps for bringing it within suitable value.
5. Tests carried out on Buchholz relay for its contact operation.
6. Test can be carried out, on cooling fans, cooling water pumps about their direction of rotation,
speed and troubles in starting etc.
7. If on loading tap changing arrangement is there, its operation can be checked with the
indication of tap number on panel and buzzer etc. at the time of change.
8. If required phasing out test is carried out.
9. Insulation resistance measurement with megger between H.V. and between LV. and core, H.V.
and core etc. at the same time on C.T. and P.T. used in measurement and protection systems.
10. Oil in conservator should be upto the indication mark on glass plate.
11. If neutral earthing switch is provided, it should be closed before switching on supply.
12.Transformer can then be loaded and the meters both on H.V. and L.V. sides be checked for their
readings on all the phases. It should be equal for same loading.
13. Operation of on-foad tap changing arrangement can then be checked.
14. If possible transformers above 1000 kVA rating should be connected to variable supply and the
voltage then be
Wednesday, Mayincreased
19, 2021 to rated value gradually
AMRAVATI
60
MAINTENANCE OF TRANSFORMER
• Transformer is the heart of any power
system. Hence preventive maintenance is
always cost effective and time saving. Any
failure to the transformer can extremely
affect the whole functioning of the
organization.

AMRAVATI
Routine Preventive Maintenance
Routine preventive maintenance is that type of
maintenance work which does not require opening of
transformer tank cover for inspection. It mainly includes
visual inspection.
• It may consist of checking of fitments, checking of oil level
in the conservator or tank, cooling system fastenings.
Operation of control circuits, any leakage of oil from tank,
bushing, conservator etc.
• Measurement of insulation resistance values, between
windings, between winding and core, measurement of
break-down voltage of transformer oil , analysis of gas
sample obtained from Buchholz relay.

AMRAVATI
In addition to the above, following mechanical
maintenance can also be carried out.
• Tightening of nut-bolts,
• Any layers of dust and oily-skum on the surface of
bushings etc. Should be removed.
• If the colour of the silica gel changes to pink from
blue it should be replaced.
• Oil level is brought up to required mark by adding
transformer oil of good quality, and good
dielectric strength, and if required it should be
filtered.

AMRAVATI
All these repairs should be carried out at fixed
interval of time, if they are so carried out major
faults will not develop i.e. routine maintenance
reduces development of major faults.
During periodic maintenance following tests are

carried out on transformer oil
(i) Crackle test,
(ii) Dielectric test,
(iii) Acidity test,
(iv) Moisture containment.
AMRAVATI
Factors Affecting Life of the Transformer
1. Temperature: Mostly the life of the transformer depends upon its working temperature. If the
working temperature exceeds by 1()C, the life of the transformer is reduced by nearly 10%. Hence,
it should be observed that its working temperature should not exceed above the fixed limit.
2. Moisture: If there is present, moisture in the transformer oil, it will come in contact with
transformer windings and will be absorbed by insulation, which reduces insulation strength of
conductor, at the same time the dielectric strength of conductor insulation and oil also reduces
due to presence of moisture. For avoiding this effect no free passage for air should be provided in
transformer tank, it should find its path through breather only and the silica gel should be
replaced from time to time.
3. Oxygen: If precaution is not taken at the time of oil filling, to remove all air from tank, there
may remain small air bubbles in the windings and also may be present in transformer oil. The
oxygen from air is responsible for forming sludge when it comes in contact with oil. This sludge
blocks the passage of free circulation of oil, increasing the temperature of transformer oil and windings.
4. Solid impurities: If solid impurities are present in the tank at the time of oil filling, it will reduce
the dielectric strength of transformer oil. For this reason before filling of oil the tank should be
clean. And also the transformer oil should be filtered after a very short period of operation so
that impurities can be removed.
5. Varnishes: Varnishes having property of entering in reaction with transformer oil form the
sludge at very fast rate. Hence, use of such varnishes should be avoided.
6. Slackness of winding: The slackness of winding may be due to alternate heating and cooling of
coils, electromagnetic forces, between the coils, defective construction of coils. At short circuit
condition, the coils may get displaced due to electrostatic forces. It is therefore necessary to lift
the core and May
windings EE5962 MRS.A.V.THAKARE LEE GP
Wednesday, 19, 2021 and remove any slackness by tightening tie rods etc. In all other cases,65
AMRAVATI
instructions given by manufacturer should be followed.
PROTECTION OF TRANSFORMERS
• The best way of protecting a transformer is to
have good preventive maintenance schedule.
• Oil Temperature Indicators.
• Winding Temperature indicators.
• Buchholz Relay.
• Magnetic Oil level Gauge.
• Explosion Vent.

AMRAVATI
PROTECTION OF TRANSFORMERS
• HT fuse & D.O. fuse.
• LT circuit breaker.
• HT Circuit breaker with Over load, Earth
Fault relay tripping.
• Oil Surge Relay for OLTC.
• HORN GAPS & Lightening Arrestor.
• Breather.

AMRAVATI
FAILURES & CAUSES
• Insufficient Oil level.
• Seepage of water in oil.
• Prolonged Over loading.
• Single Phase loading.
• Unbalanced loading.
• Faulty Termination (Improper sized lugs etc)
• Power Theft.
• Prolonged Short Circuit.
• Faulty operation of tap changer switch.
• Lack of installation checks.

AMRAVATI
Maintenance schedule of distribution transformer
as per IS 10028 (Part III) - 1981.
1. Hourly:-
1. Check & measure Voltage & current.
2. Check & measure ambient temperature.
3. Check & measure Oil & winding temperature.
2. Daily:-
1. Check Oil level in transformer.
2. Check the air passage of breather is clear.
3. Check Condition of relief diaphragm.
4. Check the colour of Silica gel in breather.
5. Checks tap changer.
6. Check tank and radiator against oil leakage.
7. Check the cooling system.
8. Check the ground connection (earthing).
. Monthly:-
1. Check Oil level in transformer.
2. Check the temperature indicators
3. Breathing
Wednesday, May 19,holes
2021 in silica gelEE5962
breather shouldLEEalso
MRS.A.V.THAKARE GP be checked monthly and
69
AMRAVATI
properly cleaned if required, for proper breathing action.
4. Quarterly:-.
1. Bushing is checked.
2. Oil strength (dielectric) is checked.
3. Cooling arrangement.
4. Operating mechanism.
5. Half Yearly:-
1. Check conservator.
2. Check the acidity of oil in transformer.
3. Test oil filled in bushing.
4. Check the gasket joints.
5. Check the terminals and connections in the boxes.
6. Examine the lighting arrestor.
7. Examine relay and alarm contacts there operations, fuses etc.
8. Check the earth resistance.
9. Check the insulation resistance.
6.Yearly:-
1. Check Oil in transformer.
2. Check Oil filled bushings.
3. Check Gasket joints.
4. Check Cable boxes.
5. Check Surge diverter & gap.
6. Check Relay alarm & their circuits.
7. Check Earth resistance.
7. Two Yearly:-
Check oil conservator, Buchholz relay & transformer oil.
EE5962 MRS.A.V.THAKARE LEE GP AMRAVATI

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UNIT 4:Testing and trouble

Wednesday, May 19, 2021 EE5962 MRS.A.V.THAKARE LEE GP AMRAVATI 1/70

EE5962 MRS.A.V.THAKARE LEE GP

• 11KV/433V is the standard voltage rating.

• STANDARD KVA ratings are

EE5962 MRS.A.V.THAKARE LEE GP

EE5962 MRS.A.V.THAKARE LEE GP

EE5962 MRS.A.V.THAKARE LEE GP

1.Back to back test

EE5962 MRS.A.V.THAKARE LEE GP

EE5962 MRS.A.V.THAKARE LEE GP

EE5962 MRS.A.V.THAKARE LEE GP

EE5962 MRS.A.V.THAKARE LEE GP

EE5962 MRS.A.V.THAKARE LEE GP

EE5962 MRS.A.V.THAKARE LEE GP

EE5962 MRS.A.V.THAKARE LEE GP

EE5962 MRS.A.V.THAKARE LEE GP

EE5962 MRS.A.V.THAKARE LEE GP

EE5962 MRS.A.V.THAKARE LEE GP

Voltage of Transformer Test Voltage

EE5962 MRS.A.V.THAKARE LEE GP

EE5962 MRS.A.V.THAKARE LEE GP

EE5962 MRS.A.V.THAKARE LEE GP

• This test is primary intended to determine the

EE5962 MRS.A.V.THAKARE LEE GP

EE5962 MRS.A.V.THAKARE LEE GP

 For this test two identical transformer are required.

2. Note down the room temperature.

EE5962 MRS.A.V.THAKARE LEE GP

EE5962 MRS.A.V.THAKARE LEE GP

EE5962 MRS.A.V.THAKARE LEE GP

• Over heating ,overloading

EE5962 MRS.A.V.THAKARE LEE GP

7. Rapid • Excessive overloading Cause should be determined and

8. Carbon Sparking in oil, excessive temperature of oil Conducting particles line up on

Failure of core, bolt insulation. Moisture absorption and dielectric failure.

Overfluxing of power Flux density depends on V/f ratio The generator

EE5962 MRS.A.V.THAKARE LEE GP

EE5962 MRS.A.V.THAKARE LEE GP

EE5962 MRS.A.V.THAKARE LEE GP

EE5962 MRS.A.V.THAKARE LEE GP

During periodic maintenance following tests are

EE5962 MRS.A.V.THAKARE LEE GP

EE5962 MRS.A.V.THAKARE LEE GP

EE5962 MRS.A.V.THAKARE LEE GP

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