Advanced Diagnostic Testing Series

Live Virtual Event | August 17 - November 2, 2023

1:00 PM – 3:00 PM, Central Time
Advanced Transformer Diagnostics
1:00 PM - 3:00 PM Central Time

Brandon Dupuis, OMICRON Fawaz Iqbal, OMICRON

Advanced Transformer Diagnostics Key Topics
1. Live testing from the OMICRON Academy in Houston, TX
2. Overview of each test – the why and the how
3. Best testing practices and test fundamentals
4. Tips and tricks, common challenges, common mistakes made in the field
5. “Advanced” tests and topics (this doesn’t mean they’re complicated)
6. TESTRANO 600 and CP TD12 hardware introduction
7. Primary Test Manager (PTM) software introduction
8. Assessment, Analysis, and Trending tools
9. Future training resources
Advanced Transformer Diagnostics Roadmap
1. Introduction to Power Factor, Performing Frequency and Voltage sweeps
2. Introduction to the TESTRANO 600 and CP TD12 hardware for live testing
3. Overall Power Factor live testing
4. Testing bushings 101
5. Bushings live testing
6. Introduction to Turns-Ratio (TTR), DC Winding Resistance, DRM, and Demag
7. TESTRANO 600 live testing setup using one-time test-connection concept
8. Turns-Ratio (TTR), DC Winding Resistance, and Demag live testing
9. Rapid fire quiz questions – 10 questions in 10 minutes
10.Q&A/FAQ
 Power Factor Overview

 The Power Factor Test is used to test the integrity of an insulation system
 The Power Factor Test can identify the following issues:

 Naturally aged, deteriorated, and/or contaminated insulation (both the main winding insulation and fluid)

 Moisture ingress, which is one of the main “transformer killers” (both the main winding insulation and fluid)

 Localized insulation failures, such as a partial or full short-circuit to ground, or between the windings
Power Factor Overview
1. Overall Power Factor – Main winding insulation and fluid (CH, CL, and CHL)
2. The C1 Power Factor Test (bushing tap required)
3. The C2 Power Factor Test (bushing tap required)

C1 Insulation C2 Insulation
The Value of Performing Power Factor Sweep Tests

 The voltage sweep test involves performing Power Factor measurements at different test voltages
(e.g., 2kV, 4kV, 6kV, 8kV, and 10kV)
 The frequency sweep test involves performing Power Factor measurements at different test
frequencies (e.g., at 15Hz, 30Hz, 60Hz, 200Hz, and 400Hz)

 In its simplest terms, the Power Factor voltage sweep and frequency sweep tests can be used to:
1. Better identify “bad” Power Factor measurements

2. Better assess the condition of an insulation system

 These tests provide significant value with no additional effort or test-connections

The Power Factor Voltage Sweep Test (aka the Voltage Tip-Up Test)

 The voltage sweep test involves performing Power Factor measurements at different test voltages
(e.g., 2kV, 4kV, 6kV, 8kV, and 10kV)
 At a minimum, a fluid-filled insulation system should always be tested at two different test
voltages (e.g., at 2kV and at 10kV)
Quiz Question

Should a Power Factor measurement at two different test-voltages be reasonably similar?

Example of abbreviated Overall Power Factor Voltage Sweep
Example of abbreviated Bushing C1 Voltage Sweep Test
Quiz Question

If a Power Factor measurement is voltage-sensitive, then what does this typically indicate?
The Power Factor Frequency Sweep Test

 The frequency sweep test involves performing Power Factor measurements at different test
frequencies (e.g., at 15Hz, 30Hz, 60Hz, 200Hz, and 400Hz)
 A Power Factor measurement at a frequency below 60Hz, is more sensitive than a Power
Factor measurement at 60Hz
 The Power Factor measurement is plotted versus the applied test-frequency, and is analyzed based
on the shape of the frequency sweep “trace”
 Limits for Power Factor values at frequencies other than 60Hz are not needed
Power Factor Frequency Sweep - Analysis Guidelines
 In general, if the insulation system under test is healthy, then the Power Factor value will increase
(from left-to-right) versus frequency for the majority of the sweep
 In general, if the insulation system is compromised, then the Power Factor value will decrease (from
left-to-right) versus frequency for the majority of the sweep
 Compromised insulation typically produces a distinctive fish-hook in the low-frequency range (i.e., at
frequencies below 60Hz)
Typical/Healthy Bushing Frequency Sweep Measurements
Questionable Bushing C1 Power Factor Measurements
Questionable Overall Power Factor Test

Serial number Mfg. Year Rated Power Voltage (Prim.) Voltage (Sec.)
Wint.2-502411010 2005 20MVA 115kV 13.2kV

Measurement 2kV PF 10kV PF 10kV PF – 2kV PF

CH 0.40% 0.45% 0.05%
CL 0.42% 0.50% 0.08%
CHL 0.39% 0.48% 0.07%
Power Factor Frequency Sweep – Four Examples of Invalid Measurements
Advanced Transformer Diagnostics Roadmap
1. Introduction to Power Factor, Performing Frequency and Voltage sweeps
2. Introduction to the TESTRANO 600 and CP TD12 hardware for live testing
3. Overall Power Factor live testing
4. Bushings 101
5. Bushings live testing
6. Introduction to Turns-Ratio (TTR), DC Winding Resistance, and DRM
7. TESTRANO 600 live testing setup using one-time test-connection concept
8. Turns-Ratio (TTR), DC Winding Resistance, and Demag live testing
9. Rapid fire quiz questions
10.Q&A/FAQ
Advanced Transformer Diagnostics Roadmap
1. Introduction to Power Factor, Performing Frequency and Voltage sweeps
2. Introduction to the TESTRANO 600 and CP TD12 hardware for live testing
3. Overall Power Factor live testing
4. Bushings 101
5. Bushings live testing
6. Introduction to Turns-Ratio (TTR), DC Winding Resistance, and DRM
7. TESTRANO 600 live testing setup using one-time test-connection concept
8. Turns-Ratio (TTR), DC Winding Resistance, and Demag live testing
9. Rapid fire quiz questions
10.Q&A/FAQ
Bushing Power Factor Testing

 Performing routine Power Factor measurements on bushings is important for extending the life of a
power transformer
 A “bad bushing” is one of the most common issues we identify when testing a transformer
 Bushing insulation problems can be detected by performing periodic electrical tests
 A visual inspection should always be performed to see if there are any cracks, leaks, discolored fluid,
etc.
Bushing Power Factor Testing

1. The C1 Power Factor Test (bushing tap required) - The most-valuable test for assessing the
condition of a bushing’s insulation system, and the test that will identify most bushing issues (95%)
2. The C2 Power Factor Test (bushing tap required) – We DO recommend performing the C2
Power Factor test because it can identify, let’s say, 5% of the total bushing issues
3. The Energized/Hot Collar Test (no bushing tap required) – A limited test, and just because you
“Pass” Hot Collar, it doesn’t necessarily mean the bushing is in good condition
The Bushing C1 Power Factor Test – Test Procedure

1. Place the high-voltage lead on the center-conductor of the bushing under test, or anywhere on the
short-circuited electrode
2. Place the current measurement lead on the tap of the bushing
3. Perform an Ungrounded Specimen Test (UST) to measure the C1 insulation system of the bushing
under test
4. Remove one tap-cap at a time!
Quiz Question

What is the most common mistake made when C1 Power Factor testing bushings?
The Bushing C2 Power Factor Test – Test Procedure

1. Place the high-voltage lead on the tap of the bushing under test
2. Place the current measurement lead on the center conductor of the bushing under test, or
anywhere on the short-circuited electrode
3. Perform a Grounded Specimen Test with Guard (GST-Guard) to measure the C2 insulation

4. Test-voltage is either 500V or 2kV, depending on the rating of the bushing:

 350kV BIL and below, test at 500V

 Above 350kV BIL, test at 2kV

Quiz Question

What is the name of the test that uses the C2 test connection BUT the UST-A mode?
Advanced Transformer Diagnostics Roadmap
1. Introduction to Power Factor, Performing Frequency and Voltage sweeps
2. Introduction to the TESTRANO 600 and CP TD12 hardware for live testing
3. Overall Power Factor live testing
4. Bushing testing 101
5. Bushings live testing
6. Introduction to Turns-Ratio (TTR), DC Winding Resistance, and DRM
7. TESTRANO 600 live testing setup using one-time test-connection concept
8. Turns-Ratio (TTR), DC Winding Resistance, and Demag live testing
9. Rapid fire quiz questions
10.Q&A/FAQ
Advanced Transformer Diagnostics Roadmap
1. Introduction to Power Factor, Performing Frequency and Voltage sweeps
2. Introduction to the TESTRANO 600 and CP TD12 hardware for live testing
3. Overall Power Factor live testing
4. Bushing testing 101
5. Bushings live testing
6. Introduction to Turns-Ratio (TTR), DC Winding Resistance, and DRM
7. TESTRANO 600 live testing setup using one-time test-connection concept
8. Turns-Ratio (TTR), DC Winding Resistance, and Demag live testing
9. Rapid fire quiz questions
10.Q&A/FAQ
Transformer Turns-Ratio (TTR) Test - Overview

 The Transformer Turns-Ratio (TTR) Test is a functional check of the transformer – it helps determine
whether the transformer can perform its intended function
 If a transformer cannot transform the applied voltage with the correct ratio, then the unit should not be
returned to service until the issue is resolved
 At a minimum, the transformer must “Pass” the TTR Test

Primary Secondary
Winding Winding

Vp
V Vs
q
Transformer Turns-Ratio (TTR) Test – Test Procedure

Step 1: Open circuit the secondary-side bushing terminals

Step 2: Apply an AC voltage across one phase on the primary-side
Step 3: Measure the AC voltage induced across the same phase on the secondary-side
Step 4: Calculate the ratio (Vprimary/Vsecondary) and assess the results by comparing the measured
ratio to the nameplate ratio and amongst the three phases

Primary
Winding Secondary
Winding

Vp

V Vs

q
TTR Test Analysis
 Calculate the measured ratio and the deviation percentage relative to the nominal
(nameplate) value
 Typically, the measured ratio should compare to within ±0.5%, relative to the
nameplate value (starting point)
 The ratio deviation percentage value should be reasonably similar when
comparing the three phases
 If the ratio deviation percentage value is reasonably similar when comparing
the three phases, then the TTR test is typically “passed”

Primary
Winding Secondary
Winding

Vp

V Vs

q
The DC Winding Resistance Test is a “Continuity Check”
 The DC Winding Resistance test is used to identify discontinuities, “bad” connections, and
open-circuits involving the following transformer components:
The windings’ connection points

The bushings’ connection points

The tap-changer connection points (e.g., DETC, barrier board connections, stationary contacts, tap
selectors, the diverter switch, and the reversing switch)
The DC Winding Resistance Test - Test Procedure

Step 1: Inject a DC current into a transformer winding

Step 2: Measure the DC voltage drop across the same transformer winding
Step 3: Wait for the calculated resistance (R = V / I) to stabilize or “bottom out”, which indicates that
the core has been saturated
The DC Winding Resistance Test - Core Saturation

 The transformer core must be saturated before the resistance measurement is recorded
 Incomplete core saturation may result in an incorrect measurement (and possibly a “false positive”)

 Saturation time is dependent on:

Current - In general, the higher the test current, the faster the core will saturate

Resistance of the winding under test - In general, the lower the resistance of the winding, the longer it can
take to saturate the core
The DC Winding Resistance Test - Analysis Strategies

 Compare the measured resistance values amongst the three phases

 In general, if the measured resistance is within 2% when comparing the three phases, then the test is
“passed”
 Note, when the measured resistance is relatively low (e.g. below 50mΩ), then a deviation of
more than 2% is often allowed, since a deviation of 2% in this range is often insignificant
Dynamic Resistance Measurement (DRM)
 The Dynamic Resistance Measurement tests the condition, timing, and continuity
(i.e. “make-before-break”) of the following components,
The transition resistors
The diverter switch - Note, not all resistive-type LTCs have a diverter switch
The moving contacts
 DRM is best applied to resistive-type LTCs

Transient Current during Switching Process

5.1 A

Slope

5.0 A
α
Current

4.9 A
Ripple

4.8 A

4.7 A
-0.05 s 0s 0.05 s 0.1 s 0.15 s 0.2 s 0.25 s 0.3 s 0.35 s

Time
Advanced Transformer Diagnostics Roadmap
1. Introduction to Power Factor, Performing Frequency and Voltage sweeps
2. Introduction to the TESTRANO 600 and CP TD12 hardware for live testing
3. Overall Power Factor live testing
4. Bushings 101
5. Bushings live testing
6. Introduction to Turns-Ratio (TTR), DC Winding Resistance, and DRM
7. TESTRANO 600 live testing setup using one-time test-connection concept
8. Turns-Ratio (TTR), DC Winding Resistance, and Demag live testing
9. Rapid fire quiz questions
10.Q&A/FAQ
Advanced Transformer Diagnostics Roadmap
1. Introduction to Power Factor, Performing Frequency and Voltage sweeps
2. Introduction to the TESTRANO 600 and CP TD12 hardware for live testing
3. Overall Power Factor live testing
4. Bushings 101
5. Bushings live testing
6. Introduction to Turns-Ratio (TTR), DC Winding Resistance, and DRM
7. TESTRANO 600 live testing setup using one-time test-connection concept
8. Turns-Ratio (TTR), DC Winding Resistance, and Demag live testing
9. Rapid fire quiz questions
10.Q&A/FAQ and future educational resources
Quiz Question

Do you need to Demag first before performing any electrical tests?

Quiz Question

What’s the most common challenge/mistake made when Power Factor testing?
Quiz Question

What does an “abnormally low” (< 0.1%) or “negative” Power Factor value typically indicate?
What are some exceptions?
Quiz Question

Which Overall Power Factor measurement is NOT influenced by the condition of the bushings?
CH, CL, or CHL?
Quiz Question

Which Overall Power Factor measurement is the best indicator of a moisture problem?
CH, CL, or CHL?
Quiz Question

Which Overall Power Factor measurement is the least affected by user-error and the test-environment?
CH, CL, or CHL?
Quiz Question

For TTR, if the Ratio Deviation % exceeds 0.5%, does that mean that you should Fail the TTR test?
Quiz Question

If your winding resistance under test is 1Ω, approximately which test current should you use: 3A or 30A?
Quiz Question

If your winding resistance under test is 10mΩ, approximately which test current should you use: 3A or 30A?
Quiz Question

Do we always use a 2% limit for DC Winding Resistance phase comparison?

The Transformer Bulletin/Webpage

The mission of the Transformer Bulletin is to provide a collection of unbiased technical documents (i.e.
guides, PowerPoints, and papers), all relating to transformer testing. The Bulletin is always available to
both customers and non-customers.
Keep in mind, the latest issue includes all the content provided in the previous Bulletins, so you only
need the latest issue to stay up-to-date.

omicronenergy.com/transformerbulletin
Come attend an OMICRON Academy class!

https://www.omicronenergy.com/en/training/courses/detail/electrical-diagnostic-testing-of-
power-transformers-circuit-breakers/114/
Thank You for Your Participation!