Testing of Transformers

Preliminary Tests

• Following tests are carried out in the works at different

stages, before the core and the coil assembly is placed
in its tank
(1) Core insulation: After the core is assembled, 2kV test
is done to ensure that the insulation between clamp
plates, core bolts and core is adequate
(2) Core loss test:
Some turns are wound over the core and it is energised
at normal flux density. Core loss and magnetising
current are noted and compared with design values.
 (c)Check of Ratio,Polarity, Vector relationship and winding resistance of
Transformer Assembly

• Ratio test is conducted to ensure the correctness of

voltage ratio between different windings on each
tapping
• The tolerance for ratio is ±0.5% of the declared
ratio or ±10% of the percentage impedance voltage,
whichever is smaller
• In order to get accurate ratio, a ratiometer is
employed
• It also indicates the polarity of transformer
windings
• For a three phase transformer, it is more usual
to carry out a vector relationship test
• In this test, one of the high-voltage and low-
voltage line terminals are joined together as
shown in fig
• Three-phase 400V supply is connected across
high voltage line terminals
• Voltage between terminals 2U-1N, 2V-1N,2W-
1N,2V-1V,2W-1W and 2V-1W are measured
• For YN, d11 vector relationship
• 2U-1N > 2V-1N > 1U-1N
• And 2V-1W > 2V-1V or 2W-1W
• The vector relationship for any other group
can be checked in a similar manner
• The dc resistance of each winding is measured
by Kelvin’s double bridge to check that there is
no faulty joint
2U-1N > 2V-1N > 1U-1N
And 2V-1W > 2V-1V or 2W-1W
 Final Tests

• The completely assembled transformer is tested in accordance

with the International standards.
Routine tests:
1. Measurement of winding resistance
2. Measurement of voltage ratio and check of voltage vector
relationship
3. Measurement of impedance voltage (principal tapping), short
circuit impedance and load loss
4. Measurement of no load loss and current
5. Measurement of insulation resistance
6. Dielectric tests
7. Tests on-load tap changers
 Type tests:

• All the tests listed as above and the

temperature rise test and Dielectric type tests
 Special tests
1. Dielectric special tests
2. Measurement of zero-sequence impedance
of three phase transformers
3. Short-circuit test
4. Measurement of acoustic noise level
5. Measurement of harmonics of the no load
current
 Special tests
6. Measurement of power taken by the fans and
oil pumps
7. Measurement of capacitances between
windings to earth and between windings
8. Measurement of transferred surge voltage on
low voltage windings
9. Measurement of insulation resistance to earth
of the windings, or measurement of dissipation
factor of the insulation system capacitances
 1. Measurement of winding resistance:

• For calculation of I2R losses in the winding, it is

necessary to measure dc resistance of each
winding
• The resistance measurement should be done
after the direct current circulating in the
winding has reached a steady state
• In some cases, it may take some minutes
depending upon the winding inductance
• Temperature of the winding must be stable
and for this reason, this test is usually carried
out before load loss measurement
• The average oil temperature is determined as
the mean of top and bottom oil temperatures
and is taken as average winding temperature
2. Measurement of voltage ratio and check of voltage group

• These tests are conducted to check that all

connections to the bushings, tap changers etc.
have been made correctly during final
assembly.
 3. Measurement of impedance voltage and load loss:

• Load loss = I2R losses in the winding + stray losses

due to eddy currents in conductors, clamps and tank
• Stray losses vary with frequency
• Hence in this test, supply is given to the transformer
at rated frequency
• The load loss and impedance voltage are guaranteed
at 75oC but are measured at the ambient
temperature of the test room
• Measured load loss is corrected to reference
temperature (75oC)
• I2R losses are directly proportional to resistance,
which varies with temperature
• Stray losses vary inversely with temperature
• The test is carried out by short circuiting, usually the
LV winding and by supplying the impedance voltage
to HV winding
• The measured power will also include small core-
loss.
• Since the supply voltage during the test is a small
fraction of normal voltage, this loss can be ignored
• For a high impedance transformer ( Z > 15%) the
core loss may become appreciable and can be
deducted after separately measuring it at
impedance voltage
• As per IS: 2026(Part I) -1977, the measurements
can be made at any current between 25% to 100%,
but preferably not less than 50% of the rated
current
• Load loss and impedance voltage can be corrected
for rated MVA as below
• Computed loss at rated current =
• measured loss at rated current x ( rated current/test current)2

•
• %Z = (test voltage/rated voltage) x (rated current/test current)x100
• While measuring load loss and impedance at
different tap positions, readings should be taken
quickly, and the interval between measurements
at different taps should be adequate to avoid
significant errors due to momentary temperature
rise of windings
• The difference in temperature between the top oil
and bottom oil should preferably be small to
enable the average temperature to be determined
accurately
• Three wattmeter method should be used
instead of two wattmeter method to avoid
large value of wattmeter multiplier constant
• The power factor during load loss test can be
less than 0.1 and wattmeters suitable for such
low power factors should be used
• Tolerances
 4. Measurement of no load loss and current

• To assess the efficiency of transformer

• Also as a check that high voltage tests have not caused
any damage to the winding insulation
• For large transformers, no-load loss measurement is
carried out before and after completion of dielectric tests
• Test is carried out rated frequency feeding usually LV
winding
• I2R will be negligible
• p.f for medium power transformers - around 0.3
• p.f for large power transformers - around 0.1
• Core losses = hysteresis losses + eddy current
losses
• Hysteresis losses dependent on average value of
voltage
• Eddy current losses dependent on rms value of
voltage
• In this test, two voltmeters are used
• (1) bridge rectifier type to indicate average voltage
• (2) dynamometer type to indicate rms voltage
• Supply is set such that specified value is
indicated on the average voltmeter
• Hysteresis component of no load loss is
measured correctly
• Eddy current component will be either lower or
higher than the true value, depending upon the
form factor of the supply voltage
• Ratio between two components is known for
any particular quality of core steel
 Pm
P
P1  KP2
• Where, P = no-load loss for sinusoidal voltage
• Pm = the measured no-load loss
• P1 = ratio of hysteresis losses to total iron losses
• P2 = ratio of eddy current losses to total iron losses
• K= ( rms voltage / ( 1.11*average voltage) )2

• For normal flux densities and frequencies of 50Hz and 60Hz, P 1 and
P2 are each 0.5 for grain oriented steel
• P1 and P2 are 0.7 and 0.3 , respectively, for no-grain oriented steel
 5. Measurement of Insulation Resistance

• IR is measured between all windings and tank

with a megger
• IR varies inversely with temperature
• Thus, oil temperature is also recorded
• IR at 15th second and 60th second are noted for
determining Polarization Index