SITE TESTING PROCEDURE -ET 1

INDEX SHEET

Sl. No. Description of test Page Test Format Ref. no:

no:
01 Index Data 01 DEWA/TP/TCD/ET/ST/01
02 Transformer general data 02 DEWA/TP/TCD/ET/ST/02
03 Final checks (To be carried out after & prior to 02 DEWA/TP/TCD/ET/ST/03A-03B
energisation)
04a Initial check (To be carried out prior to starting 02~05 DEWA/TP/TCD/ET/ST/04
test)
04b MOLG alarm checks DEWA/TP/TCD/ET/ST/04
05 Site processing details 06 DEWA/TP/TCD/ET /ST/04
06 Visual Inspection 07 DEWA/TP/TCD/ET /ST/05
07 Measurement Insulation Resistance (winding and 07~09 DEWA/TP/TCD/ET/ST/06
core & clamp)
08 2 kV test on core and clamp structure 10 DEWA/TP/TCD/ET/ST/06
09 Ratio and vector group check 11~13 DEWA/TP/TCD/ ET/ST/07
10 Measurement of magnetizing current 13~15 DEWA/TP/TCD/ET/ST/08
11 Measurement of winding resistance 15~18 DEWA/TP/TCD/ET/ST/08
12 Measurement of short circuit impedance 19~20 DEWA/TP/TCD/ET/ST/09
13 Measurement of tan delta and capacitance of 21~23 DEWA/TP/TCD/ET/ST/09
Winding
14 Calibration of temperature Indicators 24~26 DEWA/TP/TCD/ET/ST/10
15 Hot spot gradient check of winding temperature 27 DEWA/TP/TCD/ET/ST/10
indicator
16 Ratio check of CTs for winding temperature 28~29 DEWA/TP/TCD/ET/ST/10
indicator
17 Insulation resistance check of device 29~30 DEWA/TP/TCD/ET/ST/11
18 Protective device wiring/ operation check 30~31 DEWA/TP/TCD/ET/ST/11
19 Oil leakage test 31~32 DEWA/TP/TCD/ET/ST/12
20 Break Down Voltage test on Transformer oil 32~33 DEWA/TP/TCD/ET/ST/13
21 Cable box inspection 33 DEWA/TP/TCD/ET/ST/13
22 Test on transformer oil (Oil Characteristics) 34~37 DEWA/TP/TCD/ET /ST/14
23 Test on Transformer oil after complete processing 38 DEWA/TP/TCD/ET/ST/15
24 Dissolved gas Analysis (DGA) on Transformer Oil 39~41 DEWA/TP/TCD/ET/ST/16
25 Check on small power wiring 41~42 DEWA/TP/TCD/ET/ST/17
26 Check during Fire deluge operation 42 DEWA/TP/TCD/ET/ST/17
27 Frequency Response Analysis (FRA) 42~47 DEWA/TP/TCD/ET/ST/18
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2.0 TRANSFORMER GENERAL DATA

Format no: DEWA/TP/TCD/ET/ST/02

This format contains the general technical data of the Transformer. Data shall be filled in the format
as per details from Nameplate, valve schedule plate, factory acceptance test report, approved
drawings, standards etc.

3.0 FINAL CHECKS

Format no: DEWA/TP/TCD/ET/ST/ 03-A/03-B

These documents contain the items to be checked and reconfirmed after & prior to energisation of
the transformer. These checks are conducted after completion of all tests as a reconfirmation. All
items specified in these formats are verified and comments, if any shall be reported. Healthiness of
the WTI CT circuit shall be ensured before energization by opening any one link in the CT circuit
and measuring the loop resistance across it with the link in open condition and in closed condition.
Care shall be taken to ensure that the link is closed and tightened after the measurements. The CT
circuit healthiness shall be again reconfirmed after energization during the IDT load test by
checking all the points as in the test format 03-A.

4.a. INITIAL CHECK

Format no: DEWA/TP/TCD/ET/ST/ 04

These are the checks that to be verified prior to start of any site acceptance tests. These are for
ensuring the fitness of the transformer to be tested at site. The checks include ensuring that the
Transformer was received safely at site on the basis of safe receipt report and shock recorder data.
With the available details, verification is to be done on perfect completion of site processing
(erection, assembling, oil processing etc). Also the availability of records including specifications,
approved drawings, instruction manual, factory test report, test reports of accessories including
technical their catalogues, site note file etc. is to be checked.
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4.b. MOLG ALARMS CHECK

Format no: DEWA/TP/TCD/ET/ST/ 04

Aim

To ensure correct operation of contacts for MIN/MAX alarms of MT MOLG.

Test preparation
Check the availability of approved scheme drawings with terminal details along with factory
tested data’s for MOLG graph. Availability of the filtering machine and a digital multi meter
shall also be ensured.

Test procedure

 Oil filling/draining into/from the transformer shall be carried out through inlet or outlet
valves as suitably recommended by the manufacturer.
 Connect digital multimeter into the TB alarm terminals of MOLG MIN/MAX contacts
inside the MK.
 Start oil filling gradually into the conservator of MT until the pointer reached to MAX
alarm position marked on the dial.
 Confirm the initiation of the MAX alarm while making sure that the PRD is not operated.
 Start oil draining gradually from the MAX position until reached the MIN position marking
on dial and confirm the alarm operation at MIN position.
 Ensure that the oil level position at MIN/MAX and 35Deg in the MOLG dial guage shall
be comparable with the corresponding markings in the prismatic guage.
Precautions
Ensure the oil to be filled shall be filtered and the test results are meeting the DEWA
requirement.

Interpretation

1. The quantity of oil at which the minimum oil level alarm is initiated shall be not less than 5% of
the total conservator volume and maximum oil level alarm shall be initiated below 90% of the
conservator volume.
2. MIN/MAX alarms of MT MOLG’s shall operate exactly at the positions as marked in the gauge
 SITE TESTING PROCEDURE -ET 4

PREPARING TRANSFORMER GENERAL DATA

FACTORY ACCEPTANCE TEST REPORTS

TRANSFORMER GENERAL DATA

NAME PLATE
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INITIAL CHECK

CHECK AVAILABILTY OF DOCUMENTS IN DEWA OFFICE AT SITE

FACORY ACCEPTANCE TEST REPORTS

SAFE RECEIPT REPORTS

SAFE TRANSIT REPORTS

APPROVED DRAWINGS WITH LETTER OF APPROVAL

OIL TEST CERTIFICATE & SITE PROCESSING PROCEDURE

TECHNICAL SPECIFICATION AND GTP

SITE NOTE COPY FILE

SITE TEST REPORT COPY FILE

APPROVED EQUIPMENT LAY OUT OF SUBSTATION

SAFETY CLEARANCE FOR TESTING

APPROVED TESTING ENGINEER

READINESS FOR TESTING

 SITE TESTING PROCEDURE -ET 6

5.0. SITE PROCESSING DETAILS

Format no: DEWA/TP/TCD/ET/ST/ 04

These are checks to ensure whether the oil processing at site was completed either as per the
procedure furnished by manufacturer or based on any relevant documents/ standards. The safe and
healthy conditions of oil purifier, vacuum pump, pressure gauges etc. used during oil processing are
to be ensured. The record of the insulation resistance values taken at regular intervals during oil
filtration at site has to be verified. Also the degree of vacuum maintained during processing and the
condition of hot oil circulation are verified. The ppm, BDV and tan delta capacitance values of the
oil as per test report are verified.

SITE PROCESSING OF TRANSFORMER OIL

Storage tank for oil

Oil Filtration Machine

 SITE TESTING PROCEDURE -ET 7

6.0. VISUAL INSPECTION

Format no: DEWA/TP/TCD/ET/ST/05

These checks include physical verification of the components and accessories fixed on the
transformer & marshalling kiosk etc. This is a general check for compliance of the different parts of
the transformer with the approved list and specifications. All the items listed in the parts list and
given in the general outline arrangement drawings are verified.

7.0. MEASUREMENT OF INSULATION RESISTANCE

Standard : IEC 60076-2000(part 1), IEEE 62

Format no : DEWA/TP/TCD/ET/ST/06

General

Insulation resistance measurements are performed to verify that the state of dryness of the
insulation of the various windings and the core are of acceptable values. Insulation resistance
testing may also reveal important information about concealed damage of bushings.

Insulation resistance is the volume and surface resistivity of the insulation involved. Insulation
resistance of transformers and reactors are measured using Insulation Tester and the values
expressed in Mega Ohms. The output voltage from the insulation tester is DC. The value of
insulation resistance (IR value) depends on the design (voltage class, type etc.), temperature of oil,
dryness of internal parts, cleanliness of parts (especially bushing porcelains, terminals), condition
of oil, atmospheric conditions (humidity) etc. IR value varies with voltage applied for measurement
and hence comparison may always be done with measurements carried out at same voltages. IR
value is inversely proportional to the temperature.

Before starting the measurement, the temperature of the oil in Transformer must be noted; which
shall be almost the same as the reference ambient temperature. Measurements are made at 15th, 60th
and 600th seconds. Ensure that the measured value at 60th seconds is not less than 2000 Meg.Ohm.
Polarization Index (PI) value, which is the ratio of 600th to 60th seconds IR value is determined. PI
value gives a rough guide to the condition of the insulation properties; especially the dryness of the
windings and internal parts of the Transformer. PI value ≤1.0 indicates bad/ unsatisfactory, ≥ 1 .3
satisfactory, ≥ 1.5 good and ≥ 2.0 very good conditions of the dryness / insulation properties inside
the transformer.

The new generation Insulation testers have inbuilt provisions for discharging the voltages through
the testing equipment itself, which takes place within a few seconds after switching off. However,
as the voltage generated for measurement is of the tune of 500V ~ 5000V, earthing may be done
externally before removing the connections as a safety precaution.
 SITE TESTING PROCEDURE -ET 8

7.1 Insulation Resistance of Winding

Aim

a) To determine the insulation resistance of individual winding to Earth and between windings.
b) To evaluate the condition of the Transformer insulation.

Test preparation

Insulation Tester (Megger) must be of 500V range having valid calibration. The earthing of the
main body / tank, core /clamp etc., cleanliness & dryness of the bushing porcelains/ terminals and
tightness of the connection are checked. The temperature of the oil inside the transformer (OTI
reading) is noted. Check the leveling of the megger; if required and access of the supply input. Care
may be taken to see that test leads do not touch among themselves and with Transformer body.

Test procedure

Terminals of all HV bushings and HVN bushing are shorted together as shown in the figure.
Similarly all terminals of LV bushings and LVN bushing are shorted together. The test voltage is
selected as 500V in the megger. IR values of individual winding to Earth and between windings are
measured at 15th, 60th and 600th seconds. Compare the measured IR values with the factory results.
Also evaluate PI values.

Connection diagram for a two winding Transformer is shown below.

Megger Megger Megger

HV-LV & Earth HV-LV LV-HV& Earth

Precautions/ Safety

a) Transformer and the bushings under test shall be thoroughly cleaned with dry cloth.
b) During the measurement the test area shall be demarked with warning tape.
c) Megger shall be placed on a leveled platform.
 SITE TESTING PROCEDURE -ET 9
d) Sagging of the connection leads shall be avoided.

e) Infinity and zero of the megger shall be checked prior to test.

f) Sufficient time shall be given for discharge of megger before taking the next measurement. The
test circuit must be discharged by short-circuiting for a period which shall be at least four times
the voltage application time; if the connection is made by bare hands. However in practice at
least a discharge time equal to the voltage application time shall be given.
g) Measurement at higher voltage shall not be done while the transformer is under vacuum.

Interpretation

a) A high value of polarization index indicates the insulation is very good. PI value <1 indicates
immediate corrective action is required.
b) There are no specific absolute values of acceptable insulation resistance; however reference
should be made to previous test history to establish a trend.

7.2 Insulation Resistance of Core and clamp

Aim

To determined the insulation resistances of core, core clamp and between core & clamp.

Test preparation

Identify the core and core clamp bushings. Insulation Tester (Megger) shall be of 500V range
having valid calibration. Ensure proper earthing of the transformer main body. Disconnect the
earthing from core and core clamp bushings. Check the cleanliness & dryness of the core and core
clamp bushing porcelains/ terminals and tightness of the connection. Note the temperature of the oil
inside the transformer (OTI reading). Check that the megger is placed on a leveled surface and
access of the supply input. Care has to be taken to see that test leads do not touch among
themselves and with Transformer body.

Test procedure

The test is conducted at 500V. IR values are measured at 60th second for core to earth, clamp to
earth and core to clamp. The measurements are repeated after the application of 2kV.

Interpretation

a) Single point earthing of the core is ensured by good IR value between core System and earth.
b) Typical IR value for a new transformer shall be > 1000MΩ.
c) For a transformer in service, IR value of core to earth > 100 MΩ indicates normal condition of
insulation. IR value is between 10 & 100MΩ indicates core insulation deterioration. IR value
<10MΩ indicates generation of inadvertent destructive circulating currents which shall be
investigated.
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8.0 2 kV TEST ON CORE AND CLAMPING STRUCTURE

Format no: DEWA/TP/TCD/ET/ST/06

Standard : IEC 60076-2000, clause-11

Aim

To ensure that the insulation is capable to withstand the specified test voltage of 2kV.

Test preparation

The test set up consists of a source transformer of sufficient capacity in order to provide test voltage
of 2kV AC, single phase slide arc, voltage transformer, multi-meters etc. Ensure the input supply,
connecting leads, tightness of the connection etc before application of test voltage. Test duration is
60 seconds.

Test procedure

The voltage is varied from minimum to the specified test voltage of 2 kV rms and maintained for
60 seconds. During this period, there should not be any collapse in voltage or sudden increase in
leakage current. The leakage current is also noted with a clamp meter.

2 kV test is conducted between core & core clamp together to tank (earth) and between core and
core clamp for one minute each.

A typical circuit is shown below.

Test condition

Core to Tank (Clamp connected to Tank Earth)

Clamp to Tank (Core connected to Tank Earth)
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9.0. RATIO AND VECTOR GROUP OR PHASE DISPLACEMENT CHECK

Standard : IEC 60076-2000, Part 1

Format no : DEWA/TP/TCD/ET/ST/07

9.1 Voltage Ratio measurement

General

The turns ratio of a transformer is the ratio of the number of turns in a higher voltage winding to
that in a lower voltage winding. The voltage ratio of a transformer is the ratio of the rms terminal
voltage of a higher voltage winding to the rms terminal voltage of a lower voltage winding under
specified conditions of load. When the transformer is on open circuit, for all practical purposes its
voltage and turns ratio may be considered equal.

Ratio error is the ratio of the difference between ratios of the measured value and the actual
(design/declared) value to the actual ratio. The maximum allowable ratio error for principle tap is
±0.5% or ± 1/10 of the actual percentage impedance; whichever is less. For the other taps the
desired maximum ratio error is ±0.5%; even though it is not purely binding.

Aim

a) To ensure the voltage ratios of the transformer are designed / manufactured as per the
specifications/ requirements.
b) To ensure the voltage ratio errors are within acceptable limits.

Test preparation

Ensure proper earthing of main tank, core and clamp, availability of stable variable 3 phase or
single phase input supply, voltmeters and/or Ratio Bridge meter etc. Also ensure that the neutral is
not connected to Earth.

Test Procedure for voltage ratio measurement

The voltage ratio shall be determined by two methods.

a) Direct measurement of the voltages using voltmeter
b) Measurement using Ratio Bridge

a) Direct measurement of the voltages using voltmeter

The 3 phase or single phase voltage is applied to the high voltage side and induced voltage across
the low voltage side is measured. The result is determined from the two measured voltmeter
readings. In a star windings transformer the applied and measured voltage shall be checked
between line and neutral. Measurements are made for all phases at all taps positions. Percentage
ratio error is determine as ﴾measured ratio- declared ratio﴿ x 100
Declared ratio

Arrangement for the measurement of ratio error of a two winding Transformer with HV star and
LV delta is as shown.
 SITE TESTING PROCEDURE -ET 12

b) Ratio measurement using Ratio Bridge.

The applied and measured voltages are compared in a bridge by the null indication method. This is
a direct measurement of the ratio error and hence do not require any calculation. This can be done
either with 3 phase or single phase Bridge. Measurements are made for all phases at all taps
positions.

9.2 Polarity / Vector group check

General

The individual winding of poly phase transformer can be connected in star, delta or zig zag as per
design requirements. The phase displacement between windings may be 0 0~3600 according to the
connection method.

The vector diagram of the high voltage winding is placed on a clock face so that the tip of vector
1U is at 12 0' clock and vector diagram of the low voltage winding is placed on top with the same
phase orientation; then the direction of vector 2U identifies the clock number of the vector group.

For a three phase transformer, the phase angle of the intermediate and low voltage winding is
referred to the high voltage winding for the vector group. For zigzag connection the winding half
closest to the terminals determine the terminal markings.

Aim

To ensure the phase displacement or vector group of the Transformer is designed/ manufactured as
per the specification.

Test Procedure for polarity / Vector group checking

For three phase transformer, the polarity / phase displacement shall be verified by checking vector
group. The vector diagram for a three phase, two winding transformer with Zig Zag connection on
HV (ZN) and Star 11'0 clock connection on LV (yn11) is shown below.
 SITE TESTING PROCEDURE -ET 13

Terminals 1U (HV) and 2U (LV) are shorted. Thus HV U phase and LV U phase are brought
together in phase. A balanced three phase 400V shall be applied across the HV winding and
induced voltages across the terminals for the following combinations are measured.

a) 1V-2V
b) 1V-2W
c) 1W-2W
d) 1W- 2V
e) 1U/2U - 1N

The vector is confirmed as ZNyn11, if the measured voltages as per the above combinations satisfy
the following.

i. a = c = d
ii. b > a, c, d
iii. e = Applied voltage / √3
HV / LV ratio

10.0. MEASUREMENT OF MAGENTISING CURRENT

Standard : IEC 60076 - 2000
Format : DEWA/TP/TCD/ET/ST/08

General

The exciting current test is very useful in locating problems like the magnetic core structure,
shifting of windings, failures in the turn-to-turn insulation or problems in the tap changer. These
conditions result in a change in the effective reluctance of the magnetic circuit, which affects the
current required to force a flux through the core.

Low voltage exciting current is measured by this test. The pattern and value of the magnetizing
current gives an idea of the magnetic circuit of the built-up core and winding interconnection.
These values are considered as reference for all future measurements and said to be the base of
transformer diagnostic tool. The measured values at site shall be compared with previous test
 SITE TESTING PROCEDURE -ET 14

results at factory. As the value varies according to the applied voltage, comparison may be done
with the same applied voltage. Usually 400V, 3 phase balanced supply is applied on the HV
terminals and the corresponding magnetizing currents are noted. For LV, the voltage is suitably
reduced in order to limit the induced voltage on HV terminals. The repeatability of the magnetizing
current readings is an indication of the healthy magnetic circuit in the transformer.

The magnetizing currents will be in the tune of milli amperes. For a star connected winding the
magnetizing currents in the middle phase (V phase) will be less than the other two phases and the
magnetizing currents on U & W phase will be almost equal and >V phase. For D1 delta connected
transformer, the magnetizing current in the W phase will be < U & V phases and magnetizing
currents of V phase will be <U phase, but slightly >W phase. For D11 delta connected transformer,
the magnetizing current in the U phase will be <V & W phases and magnetizing currents of V
phase <W phase, but slightly >U phase.

The test results may be non-confirming as a result of residual magnetism in the core due to DC
applied. Hence this test has to be carried out before applying any DC on the transformer; ie., before
the winding resistance measurement. The core will be demagnetized once the high voltage AC is
fed to the transformer.

Aim

a) To ensure that there is no shorting in the core material.

b) To ensure no inter turn shorting of winding.
c) To confirm no loose contact or loose connection in winding or core.

Test preparation

Stabilized 3 phase variable input supply, voltmeters and ammeters with valid calibration must be
available. The neutral of the Transformer must be open. For comparison of the test results, ensure
that the test voltage at factory is same as that at site. Confirm the tightness of all connections made.

Test procedure

The 3 phase supply is fed to the transformer with milli ammeters in series to each phase. With LV
winding open circuited, voltage on HV is varied from minimum to the applied voltage of 400V and
magnetizing currents are measured at all taps. While applying on LV, care has to be taken to
restrict the voltage in safe limits; if required, as the HV/LV ratio is high and induced voltage on HV
is more. Also the phase sequence of applied voltage shall be maintained.

A test circuit of two winding Transformer (zigzag) for measurement of magnetizing current is
shown below.
 SITE TESTING PROCEDURE -ET 15

Precautions/ Safety

a) The tests shall be performed at the highest possible test voltage without exceeding the
voltage rating of the excited winding.
b) The instrumentation shall exclude to the possible extent exclude from the measurement the
capacitive currents between the excited winding and other windings, the core or the tank.
c) For the purpose of comparison, the subsequent tests shall be performed at the same test
voltage and similar test connections.

Interpretation

a) The residual magnetism results in the measurement of higher than normal exciting current.
b) There is no widely accepted field method for distinguishing between the effect of residual
magnetism and effect of a problem present in the transformer.
c) The measured values are compared with the previous test results and if the values fall with
in +150%, it is usually considered as normal.

11.0 MEASUREMENT OF WINDING RESISTANCE

Standard : IEC 60076- 2000, part 1, Clause - 10.2

Format no: DEWA/TP/TCD/ET/ST/08

General

Winding resistance is defined as the DC resistance of the winding and its value is applied voltage
divided by delivered current expressed in ohms. Measurement is made by applying a DC current to
the specified winding. In order to compensate the resistance of the lead wires, a four wire system is
established as two wires each for potential and current connections.

Winding resistance provides the base value to establish the load losses. It forms an indirect base to
establish the winding temperature and winding temperature rise from the hot resistance
measurements made during heat run test on the transformer.

For preventing core saturation and rise of temperature in the winding during the measurement, the
test current should be limited to a maximum of 10% of the rated current of the specified winding.
Also this current should be at least 1.2 times of the crest value of the magnetizing current.

Winding resistance is proportional to the temperature and reference is at 75ºC. Resistance measured
at a temperature t1ºC (R1) may be converted to R75, resistance at 75 ºC as;

R75 = (K+75ºC) x R1 , where K = Temperature coefficient of material of winding;

( K+ t1ºC) (Copper = 235 & Aluminum =225)
Aim

a) To determine the winding resistances of HV winding for all phases at all taps and that of LV
windings for all phases.
b) To confirm that the FAT report values are matching with the site tested values within the
tolerance limits.
 SITE TESTING PROCEDURE -ET 16

c) For verifying the electrical continuity in a winding and to ensure absence of loose contact of
leads connection at OLTC, Bushing terminals, etc.

Test preparation
A constant current DC source, switch and leads with sufficient cross-sectional area, DC ammeter
and voltmeter or measuring bridge with suitable current rating and leads with sufficient cross
sectional area.

Test Procedure

Winding resistance can be measured either as phase to phase or as phase to neutral. The winding
for which the resistance is to be measured must be connected in the circuit and other phases and
windings shall be kept open circuited. After switching on the DC voltage source, reading shall be
taken only after the current reaches a steady state condition as other wise the switching may cause
induced voltage which in turn influences resistance value. Measurements of winding resistance for

HV winding at all phases & all tap positions and that of LV windings for all phases are to be
carried out. Also the oil temperature shall be noted.
Two methods basically used for this measurement are,
a) Voltmeter-Ammeter method
a) Bridge or micro-ohmmeter method

11.a Voltmeter – Ammeter method

This method is also known as VI method and the measured resistance is determined by Ohm's law
as the voltage drop in the winding (Voltmeter reading) divided by the DC current flowing through
the winding (Ammeter reading). Connections shall be as shown in figure.

The voltmeter leads must be independent from the current leads and shall be connected as close as
possible to the winding terminal in order to prevent possible voltage drop. After the applied DC
current has reached its steady state, the voltmeter and ammeter readings are simultaneously noted.
The voltmeter has to be disconnected from the circuit before switching on and switching off the DC
supply as the sudden off scale damping may damage it.
 SITE TESTING PROCEDURE -ET 17

11.b Bridge or Micro-ohmmeter method

This measurement is based on the comparison of two voltage drops in the bridge, namely the
voltage drop across the unknown resistance RX compared to the voltage drop across a known
resistance RN.
DC current is injected through RX and RN. Corresponding voltage drops are measured and
compared. Varying the values of resistances Rdec and RV, the bridge shall be balanced showing
null deflection in the galvanometer. Then the resistance will be RN x Rdec .
RV

RX = Winding under test.

RN = Standard resistor.
Rdec = Decade resistor.
RV = Variable resistor.
G = Galvanometer.
B = DC source.

A Wheatstone bridge is preferred for resistance values ≥1 Ω and a Kelvin bridge or a micro-
ohmmeter for resistance values <1Ω.

While using a micro-ohmmeter, only a range selection is to be made and the measured reading is
displayed directly on the instrument.

The average value of the winding resistance of three phases at each tap is corrected to 75ºC.

Precautions/ Safety

a) The voltage and current leads shall be independent and shall be connected as closely as
possible to the winding terminals in order to avoid lead resistance.
b) Readings shall be taken only after the current and voltage values have become stable.
c) If the current is suddenly switched off, a high voltage is generated in the winding. The
current should be switched off by a suitable isolated switch before any personnel contact the
circuit.
 SITE TESTING PROCEDURE -ET 18

Interpretation

a) A tolerance of ±3% is generally acceptable for the measured values at site over the factory
test report values.
b) Similarly the measured values between phases of a transformer and between transformers of
identical design also may vary within ±3%.

WINDING RESISTANCE MEASUREMENT

 SITE TESTING PROCEDURE -ET 19

12.0. MEASUREMENT OF SHORT CIRCUIT IMPEDANCE

Standard : IEC 60076 - 2000, Part 1, Clause 10.1 and 10.4

Format no: DEWA/TP/TCD/ET/ST/09

General

Short circuit impedance is the voltage required to drive rated current under short circuit condition.
For a pair of windings, it is the equivalent series impedance (Z=R + jX) in ohms across the
terminals of one winding pair at rated voltage and reference temperature, while the terminals of the
other windings are short circuited. Further excited windings if any, shall be open circuited. It is the
vector sum of resistance and reactance voltages and is also called short circuit voltage. For a
transformer with tapped windings, short circuit impedance is referred to the particular tapping.

Short circuit impedance is normally expressed as percentage of rated voltage at a reference

temperature of 75ºC. It is the impedance voltage measured by short circuiting any one of the
winding; preferably the low voltage winding and passing rated current through the high voltage
winding. Measurements can be made either as single phase or as three phase.

The short circuit impedance measurement is normally done at site at low voltage /current and the
results are extrapolated to the rated current. The calculated percentage impedance at a particular tap
is the product of the ratio of the rated current at measured tap to the measured current and ratio of
the measured voltage to the rated voltage at the measured tap expressed as a percentage.

Short circuit impedance measurement at site is useful to detect any winding movement which may
have occurred after factory tests due to heavy fault current or mechanical damage during
transportation / installation.

Aim

a) To ensure the guaranteed values of the short circuit impedance at rated and extreme taps.
b) To compare the short circuit impedance values at all taps with the factory measured values.
c) To check the occurrence of any inter-turn shorting or shift of the winding during
transportation.

Test preparation

The connecting leads across the shorted terminals must have sufficient cross-sectional area to avoid
over heating of the leads during test due to the short circuit current flowing through them. This is
required to get a stable reading. Earthing of main tank & accessories, shorting of CT secondaries,
availability of steady 3 phase /single phase variable input supply, tightness of connections, validity
of calibration status of Voltmeters and Ammeters etc have to be ensured. The tap position and the
temperature of oil also have to be noted.

Test procedure

A 3 phase 400V supply is applied from HV terminals and LV terminals are short circuited. The
voltages and currents on the HV are measured simultaneously and percentage impedances on all 3
phases at all the taps are calculated as below.
 SITE TESTING PROCEDURE -ET 20

Measured impedance voltage(%) = Rated current at measured tap x Measured voltage x 100
Measured current Rated voltage at measured tap

The average value of 3 phases at each tap is taken as the measured percentage impedance. The
factory test report values and measured values at site should be comparable.

A typical circuit for a two winding transformer having HV as star and LV delta is shown below. As
per the above circuit, the current as well as the voltage shall be applied from HV and LV short
circuited.

Precautions/ Safety

a) Conductors used for short circuiting the transformer windings should be low impedance
conductors having a cross section equal to or greater than AWG 1.
b) The short circuiting conductors should be as short as possible and kept away from magnetic
masses.
c) Contacts should be clean and tight.

Interpretation

a) A change in the short circuit impedance of the transformer indicates a possible winding
movement within the transformer.
b) Since the overall measurement accuracy is around 1%, changes of ±2% of the short circuit
impedance with the factory measured values is usually considered insignificant.
c) Changes of more than ± 3% of the short circuit impedance should be considered as
significant and hence not acceptable.
 SITE TESTING PROCEDURE -ET 21

13.0. MEASUREMENT OF TAN DELTA & CAPACITANCE OF WINDING

Standards : IEC 60076-2000, Part 1 , Clause - 10.1.3, IEEE 62.

Format no : DEWA/TP/TCD/ET/ST/09

General

Tan delta

Dielectric loss is the power dissipated by the insulation when subjected to an alternating voltage.
Tan delta or dissipation factor is the ratio of absorbed active power to the absolute value of the
reactive power expressed in percentage. It is the ratio of resistive current to capacitive current
flowing through the insulation.

Low value of dielectric loss indicates good condition of insulation. Aging of dielectric media,
deterioration / contamination of insulation, physical damage due to electrical stress / outside forces
etc. results in the increase of dielectric loss and thereby increase dissipation factor.

Dissipation factor varies with environmental conditions like temperature, relative humidity and
precipitation etc at the time of testing. It is also dependent on dryness of the Transformer insulation
(oil and insulation materials), external cleanness of the Bushing porcelain, applied voltage and
influence of stray parameters during measurement. Tan delta is reported at a reference temperature
of 20ºC.

Capacitance

Capacitance is defined as charge per unit current, i.e. C = Q/ V. It is usually expressed in Pico
Farad. It is dependent on the characteristics of the dielectric material, conductor configuration etc.
It does not vary considerably with the voltage and temperature.

Tan delta and capacitance shall be measured simultaneously using a tan delta and capacitance
measuring Bridge or Volt- ampere watt method Bridge(Doble Insulation Analyzer).

Aim

a) To ensure the condition of transformer insulation.

b) To check any physical damage /shifting of the Transformer windings/ internal parts during
transportation.

Test preparation

All windings shall be shorted separately with proper shorting leads and tightness checked. Proper
Earthing of core / clamp and main tank are checked. Common earthing for the testing equipment
and transformer is ensured. Arrangements for the measurement of oil and ambient temperatures and
humidity are made.
 SITE TESTING PROCEDURE -ET 22

Test Procedure

For Doble equipment, measurement may be done in the following modes.

1. Ground mode(GND / GST)

Measures the insulation between the HV probe and ground (earth) as well as between HV
probe and LV leads.
2. Guard mode (GRD)
Measures the insulation between the HV and ground (earth); leakage through the insulation
between HV probe and LV leads bypasses the meter.
3. Ungrounded specimen test (UST)
Measures the insulation between the HV probe and LV leads; leakage through the insulation
between HV probe and ground (earth) lead bypasses the meter.

If n is the number of independent windings ,the number of possible measurement in GST

(Grounded Specimen Test ) mode is given by :

(n+1 )!
2!(n–1)! for n >1

Hence for a two winding transformer, there shall be 3 measurements possible.

Before the test, bushing terminals of the same windings shall be shorted together and connection
given accordingly as per the test circuit shown below. Tan delta and Capacitance between the
following combinations are measured. Test voltages at site are limited to 10kV for HV and 5kV for
LV windings.

1) HV-Earth
2) LV-Earth and
3) HV+LV -Earth

After verifying the connection and setup supply is switched on. Initially around 20% of the test
voltage is applied and tan delta and capacitance are measured. This is to reduce the time delay for
stabilizing the final test results and to reduce the extent of damage incase of a fault. Then the actual
test voltage is applied and measurement repeated for the different combinations. Ambient
 SITE TESTING PROCEDURE -ET 23
temperature, oil temperature and humidity are noted. The conversion factor for 20ºC is applied for
tan delta value and compared with factory tested values. The site test results must be comparable
with the factory test values.

Between each pair of winding and each winding to earth constitute discrete capacitances . A typical
transformer having two independent winding has capacitances as shown below .

HV CHL LV

CH CL

E E

Equivalent circuit of capacitance a two winding transformer

Measurement by shunting CL ( shorting LV and E ) gives ( CH + CHL ) .Shorting of HV to E

gives ( CHL + CL ) . By shorting HV to LV gives ( CH + CL ) .Solving three simultaneous equation
CH,CL,CHV can be obtained .Corresponding tan  in combination is also obtained .

Precautions/ Safety

a) All bushing terminals and the bushings shall be thoroughly cleaned with dry cloth to avoid
surface leakage currents.
b) During the measurement the test area shall be demarked with warning tape.
c) Sagging of the connection leads shall be avoided.
d) Measurement at higher voltage shall not be done while the transformer is under vacuum.
e) Electrostatic interference; especially due to near by EHV lines may lead to unreliable results.
Interference suppressor circuits along with shielded cable may be used to avoid this.

Interpretation

a) Dielectric factor for oil filled transformers and reactors in good condition should not exceed
0.5% at 20º C.
b) Periodic tests done in service will indicate whether the aging of insulation is normal or rapid.
c) Diagnostic tests on suspect or failed equipment may be helpful in locating fault or reason for
failure.
d) Test results on the new equipment provide a benchmark for future comparison.
 SITE TESTING PROCEDURE -ET 24

14.0 CALIBRATION OF TEMPERATURE INDICATORS

Standard : IEC 60076-1, 2000

Format no: DEWA/TP/TCD/ET/ST/10

Aim
This is to ensure proper working of temperature indicators within the acceptable tolerance
according to the actual sensing of temperature.
General
The temperature indicators are used to measure the Transformer oil and winding temperatures
accurately. The indicator used for measuring oil is called Oil Temperature Indicator (OTI) and for
winding is called Winding Temperature Indicator (WTI). Separate contacts are provided for alarm
and trip functions. These indicators contribute as protective devices for Transformer giving timely
warnings and action against possible faults arising due to rise of temperature of oil/ winding.

Following formula are generally adopted for alarm and trip contact setting, but some manufacturers
are using thereon formulas

a. Oil Temperature Indicator

Alarm setting : Maximum design ambient temperature + Measured top oil temperature rise
during factory test, whichever is higher (Rounded off to the nearest
higher multiple of 5)
Trip setting : Alarm setting + 10ºC

Trip setting shall be at least 10ºC above alarm setting.

b. Winding temperature Indicator

Alarm setting: Maximum design ambient temperature + Measured winding hot spot temperature
during factory test (Rounded off to the nearest higher multiple of 5)

Hot spot temp.: Top oil temp. rise + 1.1 x measured winding gradient

Trip setting : Alarm setting+ 10 ºC

Trip setting shall be at least 10ºC above alarm setting.

Test preparation
A standard oil bath with valid calibration status and sufficient dimensions for fully immersing the
sensing bulb of OTIs & WTI shall be selected for the test. Insulating oil at ambient temperature is
filled in the bath up to required level. The test is started from minimum temperature onwards and
reading taken at multiples of 10ºC up to 110ºC for OTI and 140ºC for WTI . If the alarm and trip
setting are set at multiples of 10 then next higher 5ºC shall be considered for reference temperature.
This is required to avoid error due to contact friction. Calibration of indicators shall be done
simultaneously. Do not disturb any factory settings already made in the meters by the manufacturer
at factory. A calibrated mercury type thermometer shall be used with oil bath to confirm the
temperature reading.
 SITE TESTING PROCEDURE -ET 25
Temperature readings between standard bath and indicators shall be ≤ 2ºC at all calibration steps.
Temperature difference between two indicators on the same reactor shall maximum of 2ºC.

Test procedure

The oil bath is set at the required temperature. Minimum 30 minutes shall be given for stabilization
of each set temperature and temperature reading of the indicators and standard bath are noted down.
Close monitoring is required during the test to check whether any indicator needle goes abnormal
fast/ slow or is getting struck. Compare the measured and standard temperature reading and verify
that it is acceptable or not as per the tolerance limits. Factory set alarm and trip contact shall be
checked with the same setup. The bath temperature is brought to the required level and contact
operations are checked with the help of multi meter.

Precautions/ Safety

a) Ensure the capillary tubes of indicators are not damaged while making preparations for the test.
b) Ensure the sensing bulb of indicators does not have any contact with the walls of the bath and is free
in oil.
c) Care shall be taken against possible fire while the bath temperature rises since the flash point of
transformer oil is about 140ºC.
d) The bath shall be kept at the same height at which the indicators are located to avoid effects due to
head variation.

Interpretation

a) If the difference in temperature readings between standard bath and indicator is greater than 2ºC at
any of calibration steps except at alarm and trip setting temperature, that indicator is rejected.
b) If temperature reading between indicators is more than 2ºC, the indicators are rejected.

CALIBRATION OF TEMPERATURE INDICATORS

 SITE TESTING PROCEDURE -ET 26

STANDARD OIL TEMPERATURE BATH

Calibration of temperature indicator using oil bath kit

 SITE TESTING PROCEDURE -ET 27

15.0. HOT SPOT GRADIENT CHECKING OF WINDING TEMPERATURE

INDICATOR

Format no: DEWA/TP/TCD/ET/ST/10

Aim
To ensure the set gradients in the WTIs are either as per the factory temperature rise test results or
as per the values given in the factory acceptance test report.

General

Winding gradient is the difference between winding temperature and average oil temperature.
Hot spot winding gradient is the hot spot developed in the winding and is 1.1 times the winding
gradient.
Winding temperature is depending upon the load current. Hence that secondary current of WTI
BCT is taken into account for gradient checking. While passing the BCT secondary current through
the heater coil of WTI, heat and gas will be produced in the capillary tube of the indicators. This
will expand further due to heat conveyed and push the needle to indicate the winding temperature at
that particular load current.

Test preparation

The same setup used for calibration of indicators shall be used for this test. Set hot spot gradient
shall be checked at 80ºC of oil temperature. Hot spot gradient shall be checked full load condition.
Calculate the BCT current required. Put the sensing bulb of local WTI in the oil bath.
Test procedure

Switch on the bath and set the reading at 80ºC and is kept for minimum 45 minutes for stabilization
of the temperature. Check and note down the readings of oil bath, indicators and milli ampere out
put of the remote WTI. The current corresponding to full load is injected to the heater coil of the
indicator and kept for minimum 45 minutes. The difference of WTI reading after injecting BCT
current and bath temperature gives the hot spot gradient in the local WTI.

Compare the measured hot spot gradient with factory test results and set values in the indicators
The factory set values and the measured values must be more or less the same and the difference
should be 2 ºC in any case for acceptance of test.

GRADIENT CHECK OF WTI &RWTI

 SITE TESTING PROCEDURE -ET 28

16.0 RATIO CHECK OF BCTS FOR WINDING TEMPERATURE INDICATOR

Format no: DEWA/TP/TCD/ET/ST/10

Aim

To ensure that the ratios of BCTs for WTI are correct and manufactured as per the specifications.

General

This test is done to verify the primary to secondary current ratio of WTI BCTs with out connecting
a burden and hence this is only a rough ratio check. The principle is that primary ampere turns and
secondary ampere turns in the BCT is the same. A separate winding called the test winding
provided in addition to the secondary winding, is used for the measurement and easy checking of
ratio. If test windings are not available, the test can be done during short circuit impedance
measurement.
.
Test preparation

This test can be done either during short circuit impedance measurement or with test winding and
the test setup can be decided accordingly. For test with test winding, single phase dimmer stat and it
accessories are required. When measured through test winding, HV and LV are kept open.

Test procedure

16.a Measurement during short circuit impedance test of the Transformer

BCT secondary is connected to ammeter. The BCTs secondary current and primary applied current
shall be measured as shown below. Tap position shall be noted during the measurement.

Data and calculation for checking the BCT ratio as an example is given below.

Design ratio says Voltage Vector Accuracy class

HV --- 10.45kV at tap 5 ZN 3.0

LV --- 800 / 2 12 kV yn11 3.0

From the above data, HV / LV ratio (tap position of BCT) is 10.45 / 0.4 = 26.125
Applied HV current = 7.64A
Corresponding current in LV = 7.64 x HV/LV ratio = 7.64 x 26.125 = 199.595A.
Measured LV BCT secondary current when LV current is 199.595A is 495 mA. (0.495A), then the
BCT secondary current, when LV is at 800A = 800 x 0.495 = 1.984A
199.595
i.e. Percentage error for HV BCT = (1.984 - 2.0) x 100 = 0.8 %, ok.
2.0
Thus the measured ratio is 800/1.984 against design ratio of 800/2.
 SITE TESTING PROCEDURE -ET 29

16.b Measurement with test winding.

Since the transformer lead conductor serves as the primary of BCT, the primary turn of the BCT is
normally designed with a single turn.

Data and calculations to check the BCT ratio as an example is given below.

Let LV BCT design ratio is 800/2 and test winding current is 10A.
Assume LV turns = 1, BCT secondary turns = 400 and test winding turns = 80
Primary ampere turns = Secondary ampere turns
Primary ampere turns = 800 x 1 = 800
Secondary ampere turns = 2 x 400 = 800.
Test winding ampere turns = 10 x 80 = 800
This means Primary ampere turns= Secondary ampere turns= Test wind ampere turns.

If 10A is applied to the test winding, the secondary winding will read 2A. Keeping the HV and LV
windings open apply 10A to the test winding and measure the secondary current. If the measured
secondary current is 1.985A, then the BCT measured ratio can be taken as 800/1.985.

17.0 INSULATION RESISTANCE CHECK OF DEVICES / CONTACTS

Format no: DEWA/TP/TCD/ET/ST/11

Aim
To check the insulation resistance of devices with individual wiring and between wiring of devices
and contacts.

Test preparation

Ensure the availability of 500V megger and thermometer for ambient temperature, completion of
all wiring and cable gland earthing
 SITE TESTING PROCEDURE -ET 30

Test Procedure
Check the insulation resistance of individual wiring to Earth and between wirings with 500V
megger at one minute. The make and serial number of devices are noted down. Also the terminal
numbers at MK are checked with Drawings.

18.0. PROTECTIVE DEVICE WIRING CHECK

Format no: DEWA/TP/TCD/ET/ST/11

Aim
a) To ensure correct operation of protective devices at DCS/SCADA before energisation of the sub
station.
b) To check the wring and terminals identification at MK/LCC etc are as per the approved
drawings.

Test preparation

Check the availably of approved wiring drawings with terminal details and digital multi meter.

Test Procedure

Alarm and trip contacts of each protective device shall be checked at MK/ LCC/DCS/ SCS/
SCADA etc by operating the respective devices. Buchhloz relay shall be checked by applying
nitrogen (N2) with pressure.

PROTECTIVE DEVICE WIRING CHECK

MOLG BUCHHOLZ RELAY

CT TERMINALS CORE & CLAMP EARTHING

 SITE TESTING PROCEDURE -ET 31

PRD

19.0. OIL LEAKAGE TEST (PRESSURE TEST)

Format: DEWA/TP/TCD/ET/ST/12

Aim

To ensure that the Transformer is fully leak proof.

General
Oil leakage test is done to ensure any oil leakage through welds, gasket joints, devices and at any
point of the transformer. During the continuous full load operation, the temperature of oil goes up,
so the oil viscosity will be reduced and oil level increased in the conservator and hence there are
more chances for the oil leak. This condition is simulated by constantly applying additional
pressure over the normal oil head for a particular period. During this keeping time if there is no oil
leakage, it is presumed that oil leakage will not occur during continuous normal loading. Dry
nitrogen (N2) is normally used for the applying pressure.
A test pressure of normal static pressure plus 34 KN/m2 (0.34 bar) shall be applied in the
conservator for 48 hours. During this period, no oil leakage or ingress into normal oil free spaces
shall occur. It is suggested to apply the pressure at maximum ambient temperature so that we can
reduce the applied pressure during the whole keeping period to avoid creating excess pressure,
which may cause the PRD operation.

Test preparation.
 Ensure proper cleaning of the reactor / surroundings and no oil trace at anywhere on the transformer.
 Check availability of N2 cylinder with regulator and pressure gauge valid calibration.
 Ensure the availability of thermometer for ambient temperature.
 Ensure statuses of all valves are as per service condition (check with valve schedule plate).
 Ensure oil filling and topping up of oil are done as per O & M manual
 Ensure all blanking covers shall be in place.
 SITE TESTING PROCEDURE -ET 32

Test procedure
 Remove silica breather and connect the output of the nitrogen cylinder to the main tank breather line
to apply the pressure inside the tank.
 Pressure gauges shall be connected at bottom and top of the main tank. Also one gauge to measure
the applied pressure to be connected.
 Note down the pressure due to normal oil head at bottom and top of the tank.
 Note down the ambient and oil temperature.
 Slightly open the N2 cylinder valve and regulate N2 over the normal oil head. When the pressure
has reached required value, pressure test is started and the pressure gauges are monitored and
pressure maintained for 48 hours.
 While applying pressure, ensure the pressure at tank top is less than the operating pressure of PRD.
 Check for any leak from the input line to the conservator by applying soap water on the weld joints
and flanges.
 Hourly readings of the ambient temperature, oil temperature, top, bottom and applied pressure shall
be noted down for the full duration of the test.

Interpretation

The complete system shall be leak proof during the whole duration of test.

20.0. BREAK DOWN VOLTAGE (BDV) TEST ON TRANSFORMER OIL

Standard : IEC 60156

Format no: DEWA/TP/TCD/ET/ST/13

Aim

To ensure the electrical strength of the insulating oil and BDV of the oil at each stage meet the
requirements/ specifications.

General

This is one of the points to ascertain the condition of oil. Sphere gap method with a gap of 2.5 mm
in oil is normally used. The BDV of oil at the above test condition shall be greater than 70 kV.

Following precautions shall be taken during oil sampling.

It is suggested to take the oil sample directly to the BDV kit set. Special tools, gloves etc shall be
used. Dry, clean and good atmospheric condition is better for taking sample. Avoid talking during
sampling. Do not allow air bubbles in the sampling oil. Care shall be taken to avoid entry of
moisture, dust metal parts etc to the sampling oil. Required quantity of oil shall be taken in the kit
at a time for each test. After sampling, immediately cover it properly, to avoid entry of air/ moisture
through the sampling portion of the Transformer as well as the sampling oil.

Test preparation

The BDV kit with valid calibration status placed in a clean and closed room. Ensure the availability
of supply in put.
 SITE TESTING PROCEDURE -ET 33

Test procedure

Precautions shall be taken during sampling as stated in general. The cleaned BDV kit vessel shall
be washed two to three times with the oil to be tested. Check any air bubbles in the sampling oil.
The oil sample shall be kept carefully inside the kit and covered. Minimum 15 minutes shall be
given as settling time. Six set of reading shall be taken at appropriate intervals and reported average
value. The measured average value will be greater than 70 kV. Ensure that none of the six readings
is less than 60kV. If the test values are not satisfactory, decision shall be taken for taking oil sample
again for re-test or further oil processing is required to improve the values. After test the kit shall be
switched off and clean the oil vessel.

Following oil samples shall be tested.

 Processed oil before filling into the Transformer.

 After hot oil circulation of the oil--- Main take top and bottom.

21.0. CABLE BOX INSPECTION

Format no: DEWA/TP/TCD/ET/ST/13

Aim

To ensure the entire requirement are met as per the documents/drawings before and after
conducting cable high voltage test at HV and LV cables inside respective cable boxes.

General

HV, HVN and LV cable boxes after cable terminations and high voltage test are not oil filled; but
have to be air tight with silica gel breather.

Test preparation

Ensure the cleanliness inside the cable the cable boxes. Tightness of the HV, HVN, LV and LVN
bushing terminal connectors and cable end connections are checked. Check availability sufficient
clearance to the nearest earth point from live parts and absence of any floating objects inside the
cable boxes. Cable box inside shall be cleaned and ensure that there is on floating object inside the
cable box. Ensure that the connections are as per the documents / drawings and all the connections
are locked after torque checking.

Test Procedure

If the preparations are found satisfactory, the checks shall be done as per format. The settings for
hydrostat and thermostat inside the cable boxed are checked. The tightness of the cable box covers
is checked.
 SITE TESTING PROCEDURE -ET 34

22.0 TESTS ON TRANSFORMER OIL

(OIL CHARACTRISTICS-UNUSED OIL)

Standard : IEC 60296 - 2003

Format no: DEWA/TP/TCD/ET/ST/14

Aim

To ensure the properties and characteristics of Transformer oil

General

This is purely an oil manufacturer’s test report which contain data to met our requirements/
specifications. If oil manufacturer’s test report is incomplete, test shall be done at independent
laboratory before conducting any oil processing.

Following are the properties and characteristics of oil.

1. Kinetic viscosity
2. Flash point.
3. Pour point.
4. Dielectric Dissipation Factor
5. Resistivity
6. Appearance.
7. Density.
8. Interfacial tension
9. Neutralization value
10. Corrosive sulphur
11. Potentially corrosive sulfur
12. Total sulphur content.
13. Water content.
14. Anti oxidant additives.
15. Oxidation stability (shall be done in case manufacturer’s oxidation stability report not
available).
a) Total acidity.
b) Sludge
c) Dissipation factor@ 90C
d) Total sulphur content.
16. Break Down Voltage (BDV).
17. 2- Furfural content.
18. PCA content
19. PCB content.
20. DBDS

Kinetic viscosity

Measurement is done in accordance with ISO 3104. Viscosity is an important controlling factor in
the dissipation of heat. Ageing and oxidation of the oil tends to increase viscosity. Viscosity is also
 SITE TESTING PROCEDURE -ET 35
2 2
affected by temperature. As per standard it’s value must be  8mm / s at 40C and  800mm / s at
-30C.

Flash point.

Measurement is in accordance with ISO 2719. A low flash point is an indication of the presence of
volatile combustible products in the oil. Breakdown of the oil caused by electrical discharge or
prolonged exposure to very high temperature may produce sufficient quantities of low molecular
weight hydrocarbon to cause a lowering of the flash point. As per standard it’s value must be 
140C

Pour point

Measurement is in accordance with ISO 3016. Pour point is measure of the ability of the oil to flow
at low temperature. There is no evidence to suggest that this property is affected by the normal oil
deterioration. Changes in pour point can normally be interpreted as the result of mixing with
different type of oil. As per standard it’s value must be  - 40C

Dielectric Dissipation Factor (DDF) and or Resistivity

Measurement is in accordance with IEC 60247 / 61620. It is a measure for the dielectric losses
caused by the oil. High DDF can indicate the contamination of the oil by moisture, particles or
soluble polar contaminants or poor refining quality. There is generally a relation ship between DDF
and resistivity. At elevated temperatures resistivity decreases as DDF increases. As per standard it’s
value must be  0.005 at 90C for DDF and is  60 Gm at 90C

Appearance

Measurement is in accordance with IEC 60296. Visual inspection of insulating oil indicate the
presence of visible contaminants, free water or suspended matters. As per standard, oil must be free
from sediments and suspended matters.

Density

Measurement is in accordance with ISO 12185. Density of oil must be low enough to avoid the
freezing of free water in cold climate which may arise due to floating on the oil surface and
possibly leading to fault conditions developing in flash over of conductors. As per standard it’s
value must be  0.895g / ml at 20C

Interfacial Tension (IFT)

Measurement is in accordance with ISO 6295. Low IFT some times indicate the presence of
undesirable contaminants. As per standard it’s value must be at 25C, unit is N/ m.

Neutralization Value

Measurement is in accordance with IEC 62021. The neutralization value of oil is a measure of the
acidic constituents or contaminants in the oil. Its value is negligible in an unused oil, increase as a
results of oxidative ageing and is used as a general guide for conformation is received from other
tests. As per standard it’s value must be  0.01mgkoH/g
 SITE TESTING PROCEDURE -ET 36

Corrosive sulphur

Measurement is in accordance with DIN51353. Some sulphur compounds, e.g. mercaptans, are
very corrosive to metal surface, steel, copper and silver and may be present in new oil. As per
standard, oil must be non-corrosive.

Total sulphur content

Measurement is in accordance with ISO 14596. Organo- sulphur compounds are presence in oil,
dependent on the crude oil degree and type of refining. As some sulphur compounds have an
affinity to metals, they may act as copper passivators or they may promote corrosion. As per
standard it’s value must be ≤ 0.15%

Water Content

Measurement is in accordance with IEC 60814. Low water content oil is necessary to achieve
adequate electrical strength and low dissipation losses. To avoid separation of free water, unused
oil should have limited water content, before filling the electrical equipments, the oil should be
treated to meet the requirements as per IEC 60422. The supplier of oil shall demonstrate that after
treatment to remove solid particles, humidity and dissolved air by vacuum procedure. As per
standard it’s value must be ≤ 30mg / kg.

Anti Oxidant additives

Measurement is in accordance with IEC 60666. Anti oxidant additives (inhibitor) slows down the
oxidation of oil and there fore the formation of oil sludge and acidity. It is important to know
whether and in what proportion anti oxidant additives has been added in order to monitor additive
depletion during service. 2,6-di-tert- butyl p- cresol (DBPC) is the most commonly used anti
oxidant. As per standard it’s value must be 0.08-0.40 %

Oxidation Stability

Measurement is in accordance with IEC 61125. Oxidation of oil gives to rise to acidity and sludge
formation and can be minimizing as a result of high oxidation stability leading to longer service
time by minimizing sludge deposition, electrical losses, metal corrosion, electrical faults and
maximizing insulation life. There is an option for stricter limits for special applications. In some
countries more stringent limits and additional requirements and test may be requested

As per standard it’s value must be

a) Total acidity : ≤ 0.3 mg KOH / gm
b) Sludge : ≤ 0.05 %
c) Dissipation factor : ≤ 0.050 @ 90C
d) Total sulphur content : ≤ 0.15 %
 SITE TESTING PROCEDURE -ET 37

Break Down Voltage (BDV)

Measurement is in accordance with IEC 60156. Break down voltage of Transformer oil indicates its
ability to resist electrical stress in electrical equipments. As per standard it’s value must be ≥ 70/ 30
kV (treated / delivered)

2- Furfural Content

Measurement is in accordance with IEC 1198. 2- furfural and related compound in unused oil can
result either from improper re-distillation after solvent extraction during refining or from
contamination with used oil.As per standard it’s value must be ≤ 0.1mg /kg.

Furans are a family of organic compound which are formed by the degradation of paper nsulation.
Over heating, oxidation, acids and decay caused by high moisture with oxygen accelerate the
destruction of insulation and form furanic compound. The most important one for our purpose is 2-
furfural dehyde.

Poly Cyclic Aromatics (PCA) content

Measurement is in accordance with BS 2000. Some PCA are classified to be carcinogens and there
fore need to be controlled to an acceptable level in oil. PCA are defined so as to be detectable by
extraction with (DMSO) Dimethylsulfoxide. As per standard it’s value must be ≤ 3 %

Poly Chlorinated Biphenyls (PCB)

Measurement is in accordance with IEC 61619. Unused oil shall be free from PCB content
Requirement is not detectable.

Gassing (H2)

Measurement is in accordance with IEC 60628. Gassing tendency of mineral insulating oil, i.e. the
gas absorbing property of an oil under electrical stress, is only necessary and important for special
Transformer like HV Transformers and is a measure of the rate of absorption or evolution of
hydrogen into oil under prescribed laboratory condition.

DBDS

Measurement is in accordance with IEC 62535.Corrosive Sulfur can be found in the transformer oil
and it’s presence can cause transformers to prematurely fail. Specifically, Dibenzyl Disulfide
(DBDS) is a sulfur compound known to react with the copper (such as windings), creating
byproducts that degrade the insulation.
 SITE TESTING PROCEDURE -ET 38

23.0. TESTS OF TRANSFORMER OIL AFTER COMPLETE PROCESSING

Standard : IEC 60422- 2005

Format no: DEWA/TP/TCD/ET/ST/15
Aim
To ensure the properties and characteristics of processed oil filling into the Transformer, i.e. used
oil in Transformer.
General
After treatment and filling oil inside the transformer, sample shall be taken for test. Test certificate
from independent laboratory is be required.
Following are the properties and characteristics
1. Colour : ≤ 2.0 (number)
2. Appearance : Clean from sediments and suspended matters
3. Break down voltage : ≥ 70 kV
4. Water content : ≤ 15 mg / kg at 20 C
5. Dissipation factor : 0.015 at 90 C
6. Resistivity : ≥ 60 GΩm at 90C
7. Neutralization value : ≤ 0.03mgKOH / gm
8. Interfacial tension : ≥ 35 mN / m
9. Oxidation stability : To be done if manufacturer’s oil test
certificate not available
10. Flash point : ≥ 140 C
11. Sulphur content : ≤ 0.05 %
12. Anti oxidant additives (DBPC) : 0.08-0.40 %
13. Total PCB content : < 2 (total) mg/kg
14. DBDS ` : Not detectable
15. Corrosive sulphur : Non Corrosive
16. Potentially Corrosive Sulfur : Non Corrosive

Following precautions and preparation shall be taken during oil sampling.

 It is suggested to take the oil sample directly to the sampling bottle

 Special tools, gloves etc shall be used
 Dry, clean and good atmospheric condition is better for taking sample.
 Do not speak during sampling.
 Do not allow air bubbles in the sampling oil.
 Care shall be taken to avoid entry of moisture, dust metal parts etc to the sampling oil.
 Required quantity of oil shall be taken in the bottle at a time for each test.
 The cleaned sampling bottle shall be washed two to three times with the oil to be tested.
 Check any air bubbles in the sampling oil.
 Sealed and identification mark shall be given to each sample.
 After sampling, immediately covered properly, to avoid entry of air / moisture through
the sampling portion of the Transformer as well as the sampling
 Test shall be conducted by independent laboratory
 Laboratory test report shall be verified
 If the values are not satisfied decision shall be taken, again oil sample is taken for re-
testing, or further oil processing required for improving the values.
 Test results shall be reported and recorded.
 SITE TESTING PROCEDURE -ET 39

24.0. DISSOLVED GAS ANALYSIS (DGA)

Standard : IEC 60599, IEC 60567

Format no: DEWA/TP/TCD/ET/ST/16

Aim

To identify the presence and quantity of gasses dissolved in the Transformer oil.

Chemical names and symbols of gas

 Nitrogen : N2
 Oxygen : O2
 Hydrogen : H2
 Carbon monoxide : CO
 Carbon dioxide : CO2
 Methane : CH4
 Ethane : C2H6
 Ethylene : C2H4
 Acetylene : C2H2

General

This the most important tool to determine the condition of a transformer. It is the primary indication
of a problem inside transformer and can identify the deterioration of insulating oil, over heating, hot
spot, partial discharge and arcing. The healthy transformer oil reflects a healthy transformer.

Mineral insulating oil are made of a blend of different hydrocarbon molecules containing CH3, CH2
and CH chemical groups linked together by carbon – carbon molecules bonds. Session of some of
the C-H and C-C bonds may occur as a results of electrical and thermal faults. These with the
formation of small unstable fragments in radical or ionic form, such as H, CH3, CH2, CH or C
(among many other more complex forms), and recombine rapidly through complex reactions into
gas molecules such as hydrogen (H-H), methane (CH3_H), ethane (CH3-CH), ethylene (CH2=CH2)
or acetylene (CH=CH). C3 and C4 hydrocarbons gasses, as well as solid particles of carbon and
hydrogen polymers (X-wax), are other possible recombination products. The gasses formed
dissolved in oil or accumulate as free gasses if produce rapidly in large quantities, and may be
analyzed by DGA according to IEC 60567.

Low energy faults, such as partial discharges of the cold plasma type (corona discharges), favor the
scission of the weakest C-H bonds (338kJ / mole) through ionization reactions and the
accumulation of hydrogen as the main recombination gas. More and more energy and/or higher
temperatures are needed for the scission of the C-C bonds and their recombination into gasses with
a C-C single bond (607kJ / mole), C=C double bond (720kJ / mole) or C=C triple bond (960kJ /
mole), following processes bearing some similarities with those observed in the petroleum oil
cracking industry.
 SITE TESTING PROCEDURE -ET 40

Ethylene is thus favoured ethane and methane above temperatures of approximately 500˚C
(although still present in lower quantities below), Acetylene requires temperatures of at least 800˚C
to 1200˚C, and a rapid quenching to lower temperature, in order to accumulate as a stable
recombination product. Acetylene is thus formed in significant quantities mainly in arcs, where the
conductive ionized channel is at several thousand of degrees Celsius, and the inter face with the
surrounding liquid oil necessarily below 400˚C (above which oil vaporized completely) with the
layer of oil vapour/ de composition gasses in between. Acetylene may still be formed at lower
temperature (less than 800˚C), but in very minor quantities. Carbon particles form at 500˚C to
800˚C and are indeed observed after arcing in oil or around very hot spots.

Oil may oxidize with the formation of small quantities of CO and CO2, which can accumulate over
long periods of time into more substantial amounts. The polymeric chains of solid cellulosic
insulation (paper, press board, wood blocks) contain a large number of anhydroglucose rings, and
weak C-O molecular bond and glycosidic bonds which are thermally less stable than the
hydrocarbon bonds in oil, and which decompose at lower temperatures. Significant rates of polymer
chain scission occur at temperature higher than 105˚C, with complete decomposition and
carbonization above 300˚C. Mostly carbon monoxide and dioxide, as well as water, are formed, in
much larger quantities than by oxidation of oil at the same temperature, together with minor
amount of hydrocarbon gasses and furanic compounds. The latter can be analyzed according to IEC
61198, and used to complement DGA interpretation and confirm whether or not cellulosic
insulation is involved in a fault. CO and CO2 formation increases not only with temperature but
also with oxygen content of oil and the moisture content of paper.

Gasses may be generated in some cases not as results of faults in the equipments but through
rusting or other chemical reaction involving steel, uncoated surfaces or protective paints.

Hydrogen may be produced by reaction of steel with water, as long as oxygen is available from the
oil nearby. Large quantities of hydrogen have thus been reported in some Transformer that had
never been energized. Hydrogen may also be formed by the reaction of free water with special
coating on metal surfaces, or by catalytic reaction of some type of stainless steel with oil, in
particular oil containing dissolved oxygen at elevated temperature. Hydrogen may also be formed
in new stainless steel, absorbed during its manufacturing stages, or produced by welding, and
released slowly in to the oil.

Hydrogen may also be formed by the decomposition of the thin oil film between overheated core
laminates at temperature of 140˚C and above. Gasses may also be produced by exposure of oil to
sunlight or may be formed during repair of the equipments. Internal Transformer paints, such as
alkyd resins and modified polyurethane containing fatty acids in their formulation, may also form
gasses. These occurrences, however, are very unusual, and can be detected by performing DGA
analyses on new equipment, which has never been energized, and by material compatibility tests.
The presence of hydrogen with the total absence of other hydrocarbon gasses, for example, may be
an indication of such a problem. Although the formation some gasses is favoured, depending on the
temperature reached or the energy contained in a fault, in practices mixture of gasses are almost
always obtained. One reason is thermodynamic, secondary gasses are still formed, albeit in minor
quantities. Existing thermodynamic models derived from the petroleum
 SITE TESTING PROCEDURE -ET 41

Type of faults

Partial discharge (Pd) of the cold plasma (corona) type, resulting in possible X- wax deposition
on paper insulation, or of the sparking type, inducing pinhole, carbonized perforations (punctures)
in paper, which, however, may not be easy to find.

Discharge of low energy in oil or paper, evidenced by large carbonized perforations through paper
(puncture), carbonization of the paper surface (tracking) or carbon particle in oil as in tap changer
diverter operation

Discharge of high energy in oil or and paper, with power follow-through, evidenced by extensive
destruction and carbonization of paper, metal fusion at the discharge extremities, extensive
carbonization in oil and, in some cases, tripping of the equipment, confirming the large current
follow-through.

Thermal faults in oil and paper, below 300˚C, if the paper has turned brownish and above 300˚C if
it has carbonized.

Thermal faults of temperature above 700˚C if there is strong evidence of carbonization of the
oil, metal coloration at 800˚C or metal fusion at greater than 1000˚C.

Following precautions and preparation shall be taken during oil sampling.

It is suggested to take the oil sample directly to the sampling bottle. Special tools, gloves etc shall
be used. Dry, clean and good atmospheric condition is better for taking sample. Do not speak or
allow air bubbles during sampling. Care shall be taken to avoid entry of moisture, dust metal parts
etc to the sampling oil. Sufficient quantity of oil shall be taken in the bottle at a time for each test.
Cleaned sampling bottle shall be washed two to three times with the oil to be tested. Sealed and
identification mark shall be given to each sample. After sampling, immediately seal properly to
avoid any possible entry of air/ moisture through the sampling portion of the transformer as well as
the sample. Test shall be conducted by independent laboratory and test report shall be verified.

If the values are not satisfactory, decision to do oil sampling again for re-testing or to do further oil
processing for improving the values have to be taken. The DGA prior to energisation of the
equipment is the base of next DGA for comparison. Further samples for DGA are taken and
checked after one month, one year and two years after energisation.

25.0. CHECK ON SMALL POWER WIRING

Format no: DEWA/TP/TCD/ET/ST/17

Aim

1) To ensure the items provided are confirming to the specification and drawings.
2) To check that the wiring of the components are in order.

Test Preparation

The wiring are checked in accordance with approved drawings and specifications.
 SITE TESTING PROCEDURE -ET 42

Check Points

1) Ensure the disconnection facilities and identifications of alarm and trip terminals are separately
provided.
2) Ensure the terminations and looping are correct.
3) Check that CT terminals are correctly connected.
4) The following contact operation checks and settings are done.

1. Door switch of MK
2. Heaters
3. Thermostat setting - 30˚C
4. Hygrostat setting - 60 %

26.0. CHECKS DURING FIRE DELUGE OPERATION

Format no: DEWA/TP/TCD/ET/ST/17

Aim

1) To ensure that there is no water ingress in the closed cabinets of LV cable box, MK, CT
terminal boxes, PRD etc. and all other device terminal boxes after fire deluge operation.

Test Preparation

Ensure all the opening of LV cable box, MK, MOLG, CT terminal boxes and PRD are properly
closed. Check the readiness of cooling fan for switch in on position and completion of the inter
connection wiring with the fire deluge system.

Test Procedure

After fire deluge operation, all cabinets including MK and the cable boxesof LV,HV,HV-N shall
be opened immediately and checked for any water entry. All device terminal boxes like the PRD,
MOLG, Protective relays, CT’s etc shall be ensured for water tightness. If any water is traced inside
the cabinets/terminal boxes, repeat the test after rectification.

27.0. FREQUENCY RESPONSE ANALYSIS

Standard : IEC 60076-18
Format no: DEWA/TP/TCD/ET/ST/18

Aim
To ensure any possible damages (physical shifting/ deformation etc) of the transformer winding,
core or internal parts have occurred during transportation or after any failure.

General

Frequency response analysis (FRA) is a valuable tool to verify the geometric and mechanical
integrity of electrical apparatus; especially transformers, providing accurate and repeatable
measurements. This is a proven field diagnostic technique capable of detecting damage arising due
to dislocation/ movement of core and winding during transportation or after occurrence any fault.
 SITE TESTING PROCEDURE -ET 43

FRA is based on the principle of measurement of steady electrical response against a steady
sinusoidal input given to the test object.

The basis of the FRA technique is that the impedance of the transformer is a function of the
resistance, inductance, capacitance and applied signal frequency. The resistance is related to the
physical construction of the winding. Capacitance and inductance are related to the construction
and geometry of the windings. Deformations and movements have an effect on both inductance and
capacitance that may be reflected in the resulting frequency response.

There are two basic methods for conducting FRA test; low voltage impulse method and sweep
response frequency Analysis (SFRA).

Low voltage impulse method relies on indirect measurement of the frequency response. An impulse
or set of impulses with assumed frequencies of interest is applied to the winding that is under test.
These frequencies are disentangled using signal analysis techniques (FFT) to produce a frequency
response plot by converting time domain to frequency domain. The technique is dependent on good
impulse signals, fast signal processing and analysis. However these produce limited or poor
responses at lower frequencies, up to a few hundred Hz, where much information about internal
construction of the transformer in terms of inductance is gained.

SFRA measurement is done with the frequencies being swept in a wide range; usually from 20 Hz
to 2 MHz. This is the simple direct measurement in frequency domain. Also a direct relationship
exists between geometric configurations and RLC network constituted by winding and core
assembly identified by its frequency dependent transfer function. Measuring the frequency response
may be performed by applying a simple varying frequency signal to the transformer that covers the
frequency range of interest. Sweep frequency method has far higher repeatability and consistency
over impulse methods which are prone to variation due to lead arrangement and impulse shape.

Normally a factory FRA measurement is taken as reference (signature) and later on site
measurement (after erection or any failure) is compared with the reference measurement. In
practice measurement after erection at site is taken as reference for the future measurements done at
site during the operational period of the transformer.

Possible damages in the winding are indicated in a relevant range of frequencies by shifting of
resonance points or by the introduction of new resonance, not being present in the reference
measurement.

The comparison of the traces belonging to different phases or different Transformer of same design
(sister unit) may be useful, but with limitations.

A shifting of the resonant point (if any) of the open circuited admittance is noted. The difference
(ie, the shifts of resonant points or the introduction of new resonance not present in the reference
measurement) is evaluated as an indication of normal variation or faults in the winding.

The plots of the admittance (reverse of impedance) verses frequency indicate a series of resonance
with small value and anti resonance with high value. The resonance with low admittance represents
a parallel resonance circuit. The resonance with high admittance represents a series resonance
circuit.
 SITE TESTING PROCEDURE -ET 44

Test Preparation

Measuring the frequency response of a winding within a transformer, or of a transformer transfer

function from winding to winding, gives a fingerprint for that winding or transformer. The process
requires measurement of both input and output signals, which are then ratioed to give the response.
This reduces the effect of the measurement of a three lead system involving input, measured input
and measured response.

Signals are applied and measured with respect to ground. The amplitudes and phases of the two
signals, (S Measurement and R Measurement), are measured to determine the relative amplitude
and phase shift changes between them. The basic measurement is of the attenuation and phase shift
of a signal after having passed through the winding from the input to the output terminal.

The test can also include voltage transfers between windings i.e. applying a signal to one winding
of a transformer and measuring the response at another winding to determine the amplitude change
and phase shift of the signal having been transferred along a winding, or from one winding to the
other.
Transformer under test should be completely de-energized and isolated from the power system.
This shall be solidly earthed which is common to FRA test equipment. FRA is performed as
response to electrical measurement at the terminals connected to the starting and end of any
winding. The test leads must be first connected to the FRA instrument and then to the Transformer
Bushings.

Connect the colour code cable to the instrument

1. Yellow : Excitation source cable.

2. Black : Measurement cable.
3. Red : Reference cable.

The main cable clamps red and black are connected to bushing terminals accordingly. Also connect
the ground clips for each cable, red and black to the corresponding Bushing flanges. Test set up and
actual test shall be done as per the manufacture's manual.

Test Procedure

Transformer tap no., earthing details, ambient temperature etc are noted. Frequency range is
selected as 20Hz to 2MHz. The test connections are verified and measurements done for the
following combinations. The plot names are assigned with reference to terminal markings as given
below.

 1U1N –LV oc, 1V1N - LV oc, 1W1N - LV oc (applied on HV and LV open circuited)
 1U1N –LV sc, 1V1N - LV sc, 1W1N - LV sc (applied on HV and LV short circuited)
 2U2V –HV oc, 2V2W–HV oc, 2W2U –HV oc (applied on LV and HV open circuited)
 SITE TESTING PROCEDURE -ET 45

(Applied on HV & (Applied on HV & (Applied on LV &

LV open circuited) LV short circuited) HV open circuited)

The measured magnitude and phase plots are compared with corresponding reference plots
(signatures). If any abnormalities/ deviations in the measured plot is noticed, tightness and
correctness of connections may be reconfirmed before finalizing the test results.

Precautions/ Safety

a) FRA measurement is sensitive to DC magnetization of the core and hence it has to be carried
out before application of any DC voltage. If any DC measurement was carried out before FRA
measurement, it should be properly demagnetized.
b) The resultant plot may distort from the actual one in case of a loose connection.

Interpretation

a) The exact comparison of the FRA measurement plots at site with the factory measurements can
be made only if the measuring equipments, measuring connection, setup, measuring leads etc
are the same. However identical test equipments with the same connection and setup may give
almost the same results.
b) Frequency response plot provides a fingerprint for a transformer. Fingerprints from similar
transformers have common features.
c) The core condition, in principle, cannot be checked by the FRA method. However
magnetization of core, affects low frequency results.
d) A clear shifting of first resonance, usually below 1000Hz, indicates inter turn connection
failure.
e) Clear shifts of resonance or new resonance of the lower harmonic in the range 1000 Hz to
10kHz indicate the axial movement of bulk winding or radial hoop bucking.
f) Shifts of resonance or new resonance in the range of 10kHz to 100kHz indicate movements of
small winding parts (e.g. tap winding)
 SITE TESTING PROCEDURE -ET 46

SWEEP FREQUENCY RESPONSE ANLYSIS TEST

 SITE TESTING PROCEDURE -ET 47

SFRA TRACES

Test lead

Signal &
Reference Leads

Frequency
Response
Analyser Shield
Ground