76 RELIABILITY AND

ROUTINE TESTING

Electrical Testing
of Dry-Type
Transformers
by Mark Pustejovsky

Photo by Shutterstock
Transformer Technology June 2019 77

Issue 2

Mark Pustejovsky graduated with a Bach-

elor of Science in Electronics Engineering
Technology from Texas A&M University in
1993. He has worked in the electrical testing
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tive relaying. In his role as Senior Vice Presi-
dent of Workforce Development at Shermco
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cruit Shermco employees to continue to be
a leader in the most technical workforce in
the industry.

Dry-type transformers are a large part of the electrical infrastructure for many industrial and
commercial sites. Therefore, ensuring the performance of electrical testing and maintenance on
critical transformers is very important to electrical system reliability. This article covers electrical
testing and maintenance items recommended by the InterNational Electrical Testing Association
(NETA) and other industry best practices for transformers above 500 kVA. NETA has two standards,
one for acceptance testing of new units (ANSI/NETA ATS-2017, Standard for Acceptance Testing
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aged units, (ANSI/NETA MTS-2019, 6WDQGDUGIRU0DLQWHQDQFH7HVWLQJ6SHFLͧFDWLRQVIRU(OHFWULFDO
3RZHU(TXLSPHQW 6\VWHPV :HZLOOIRFXVRQPDLQWHQDQFHWHVWLQJVSHFL̨FDWLRQVLQWKLVDUWLFOH
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with a few key differences.
78
For large dry-type transformers (500
kVA and above), ANSI/NETA MTS-2019
recommends visual and mechanical
inspections and electrical tests
similar to the tests recommended for
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determining the health and reliability
of a dry-type transformer can be
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typically makes up a large part of the
insulation system. Being that most
insulating oils have relatively similar
dielectric values, expected insulation
values are very similar in most liquid-
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transformers, however, the primary
insulation is made up of different
types of dry insulation, depending
on the manufacturer and
URGEKƒECVKQPU5KPEGFT[
type transformers do not
have oil to cool them during
operation, they must be
constructed of materials
that can withstand higher
temperatures without
sustaining damage. Dry-
type transformers can be
constructed of Insulation
Class B (130°C), Class C
(220°C), or Class H (180°C)
materials. The typical oil-
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rated temperature rise of
65°C and Insulation Class A
materials are used.
There are various
construction methods for
the manufacturing of dry-
type transformers, and each type
is suited for different environments
and applications. These various
construction methods include
Open Wound, Vacuum Pressure
Impregnated (VPI), Vacuum Pressure
Encapsulated (VPE), and Cast-Coil
Resin.
Insulation Tests
When testing a transformer’s
insulation integrity, there are two
main types of tests recommended:
1) Insulation-resistance tests and
2) insulation power-factor
(or dissipation-factor) tests.
Because of the different types of
materials and methods used, the
test results can vary greatly between
different types of transformers.
Moisture or humidity can also
influence the test results, as the
insulating materials of dry-type
transformers are exposed to the
atmosphere and can be greatly
affected by the surrounding
environment. When the transformer
is energized, it will be elevated in
temperature, and as it cools, it will
absorb moisture. Therefore, it is best
to test soon after it is de-energized.
Per Table 100.5 in ANSI/NETA MTS-
2019, insulation resistance values
for windings of dry-type transformers
(greater than 5,000 V) should
be 25,000 Megohms or greater.
There are various
construction methods
for the manufacturing
of dry-type
transformers, and
each type is suited for
different environments
and applications
Insulation power factor results
vary depending on the material and
construction, and it is recommended
to compare to similar units and
previous base line tests results.
Capacitance should be recorded
whenever a power-factor test is
performed. The capacitance is
dependent on the shape of the
windings, and if the transformer
ever feeds a high-level fault, these
readings can be compared to
previous results to determine if there
was damage to the transformer due
to winding movement during the
fault.
It is also worth noting that it is
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readings to a base temperature on
dry-type transformers.
RELIABILITY AND
ROUTINE TESTING
Temperature may influence the
power-factor results, but there
are too many different types of
insulation to assemble a “standard
temperature correction factor”
chart, and for the most part the
temperature characteristic curve
should be relatively flat. If power-
factor results are questionable at high
temperatures, allow the unit to cool
and retest when the temperature is
closer to 20°C.
When performing power-factor
testing, a “tip-up” test should also
be performed on all windings
greater than 2.5 kV. This will aid
in determining the presence of
partial discharge (PD) anomalies.
In dry insulation, partial
discharges can occur
within voids in the
insulation. Partial discharge
is a localized dielectric
breakdown of a small
portion of the electrical
insulation. Over time,
a series of these small
insulation breakdowns
will eventually lead to an
insulation failure. Therefore,
it is important to detect
when PD is occurring,
before it leads to failure.
A tip-up test is conducted
at two voltages; a lower
voltage (something below
the PD inception point)
typically 2 kV or below, and
then at operating voltage.
If no PD is occurring,
the power-factor values at the two
voltages will be similar. If PD is
occurring, the power factor at the
high voltage will be higher than it
is at the lower voltage. ANSI/NETA
MTS-2019 recommends that this
difference be less than 1.0 % for an
acceptable test. A tip-up test can be
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but it is much more important with
dry insulation.
Visual and Mechanical
Inspection
When performing acceptance
or maintenance testing on dry-
Photo by Shutterstock
type transformers, visual and
mechanical inspections are very
important. Transformers are shipped
with shipping bolts that keep the
Transformer Technology June 2019 79

Issue 2

transformer core and coil assembly that winding. This test will evaluate
secured to the base frame. During for possible winding damage (such
testing it is often found that the as short circuits between windings
shipping bolts are still in place and or between turns), open circuits, or
secured, which causes high noise connection issues. ANSI/NETA MTS-
and vibration when the transformer 2019 recommends comparing your
is energized. This excessive vibration test results to previous results and
can cause the bracing in the core being within 1.0% of previous readings.
assembly to become loose over time. It may not be possible to locate
Leave the bolts in place but loosen previous results, so another means
them, to allow the transformer to float to evaluate is to compare results
on the isolation pads. This will reduce between phases. Variances between
transformer noise and vibration. The phases should be investigated. Note
noise difference can be dramatic. that for low-voltage windings, the
Also inspect that the transformer winding resistance values are typically
is properly grounded, that the unit in milliohms, and small differences in
is clean, and that all cooling fans the amount of copper or bus length
operate properly. can affect readings between phases.
For medium-voltage windings, the
Winding Resistance Test value is typically in ohms, and small
differences in the amount of bus or
Winding resistance is another test cable connections do not greatly
recommended by ANSI/NETA MTS- affect the readings.
2019. A winding resistance
test injects a DC current
through the winding to be
measured, and then reads
the voltage drop across ,WLVGL̪FXOWWRFRUUHFW
power factor readings to
a base temperature on
dry-type transformers
Transformer Turns Ratio Test
The transformer turns ratio test, or
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has the correct number of primary
and secondary turns. This test can
identify shorted turns, open windings,
and incorrect winding connections.
TTR test sets come in a variety of
styles and test connections; however,
all test sets will have at least two
high-side leads and two low-side
leads. Turns ratio results should
not deviate by more than 0.5 %
from either the adjacent coils or the
nameplate calculated ratio.
Excitation Tests
Excitation testing is performed
by energizing one phase of a
transformer at a time and measuring
the amount of current drawn. A
typical excitation current
test pattern for a three-
legged core is two similar
readings and one lower
reading.
80 RELIABILITY AND
ROUTINE TESTING

6JGCKOQHVJKUVGUVKUVQƒPFRQQT Core Ground Test recognized by the protective system

electrical connections, inter-turn short of the power supply/line (and quickly
circuits, abnormal core faults and The transformer core, which is disconnect the line), the transformer
winding problems. It gives information effectively a conductor that is not core must be grounded to provide
for an electrical and mechanical intended as a current-carrying path, an electrical (fault) path back to the
assessment of transformer may develop potential [voltage] source. A core is typically grounded
conditions. The test is performed due to capacitive coupling with at a single point only, as multiple core
on each phase by exciting the the innermost winding when the grounds may result in circulating
transformer with all other windings transformer is energized, resulting in currents and overheating in the core.
being open-circuited. Excitation partial discharges that may damage The core ground test is performed to
tests must be performed before any the transformer and induced potential ensure that the core is only grounded
other DC tests (such as winding when the transformer is carrying load. at the grounding point. Not all dry-
resistance) are performed, as DC This can occur and be detrimental to type transformers have the ability
testing can magnetize the core and the transformer’s useful life unless to lift the core ground, but when
cause erroneous test results during the core is solidly connected to earth available, the grounding bond to the
the excitation test. If a pattern of two ground. The core ground also assures core should be lifted and an insulation
similar readings and one low reading protective device operation in the test of 500 Vdc should be performed.
is not obtained, one possibility is core event of a winding to core insulation The core insulation-resistance values
magnetization. The core should be failure. For such a fault to be should not be less than one megohm.
demagnetized, and the
test performed again to
see if the results change.
Many manufacturers of
electrical test equipment When performing
offer stand-alone test sets
for this function, or have acceptance or
this function built into the
winding resistance test set.
maintenance testing on
dry-type transformers,
visual and mechanical
inspections are very
important

Photo by Shutterstock
Transformer Technology
Issue 2
Lightning (Surge) Arresters
Many transformers have surge
arresters on the high side to protect
the windings from transients that
might occur from switching or
external sources such as lightning.
The proper voltage rating of the
arrester is critical and should be
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varistor (MOV) type arresters have
two voltage ratings: maximum
continuous operating voltage (MCOV)
and rated voltage. The MCOV rating is
chosen by what type of grounding is
used on the electrical system. When
the system is solidly grounded, the
MCOV rating of the arrestor can be
lower than if the system is a Delta or
ungrounded system. On
an ungrounded system,
the phase voltage on one
phase can become as high
as phase-to-phase voltage
during a fault on anther
phase. Therefore, ensure
the proper MCOV rating
was selected based on the
manufacturer’s recommendations for
the type of grounding system used
at the site. Watts-loss testing (using
an insulation power factor test set)
is commonly performed on surge
arresters to verify insulation integrity.
Compare results between the phases
and similar arresters.
On-line Inspection and Test
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very easy to pull oil samples and get a
very cost-effective analysis of what is
going on inside the transformer. Since
it is not possible to sample the air in
a dry-type transformer in the same
manner, regular off-line maintenance
is important. However, you can
When performing
acceptance or
maintenance testing on
dry-type transformers,
visual and mechanical
inspections are very
important
June 2019 81
perform on-line partial discharge
scans and thermographic (IR) scans
of the electrical connections at regular
intervals as a cost-effective means to
monitor the health of the transformer.
The temperature gauges, cooling fans,
output voltage readings, and loading
should also be monitored regularly.
In Summary
There are many tests that can be
performed routinely on dry-type
transformers to keep the electrical
system at your site safe and reliable.
Since there are many different
transformer construction techniques
and materials used, trending test
data can be very valuable. No one
electrical test can tell
you if a transformer is in
overall good condition, but
performing the battery of
tests outlined in this article
can give you reasonable
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health of the transformer.