TESTING & COMMISSIONING

OF
POWER TRANSFORMER

By
ROMIL KUMAR
 Type of Transformer Testing

 Tests done at factory

 Type tests
 Routine tests
 Special tests

 Tests done at site

 Pre-commissioning tests
 Periodic/condition monitoring tests
 Emergency tests

2
 Type Tests of Transformer
 To prove that transformer meets
-- customer’s specifications
-- design expectations
transformer has to go through different testing
procedures in manufacturer premises.
 These tests are done mainly in a prototype unit not in all
manufactured units in a lot.
 Type test of transformer confirms main and basic design
criteria of a production lot.

3
 Routine Tests of Transformer
 Routine tests of transformer is mainly for confirming
--- operational performance of individual unit in a
production lot.
 Routine tests are carried out on every unit manufactured.

4
 Special Tests of Transformer
 Special tests of transformer are done
---as per customer requirement to obtain information
useful to user during operation or maintenance of
transformer.

5
 TESTING OF TRANSFORMER

 TYPE TESTS:
 Temperature rise test
 Impulse voltage test
 Noise level test

6
 TESTING OF TRANSFORMER
 TESTING IS CARRIED OUT AS PER IS-2026.

 ROUTINE TESTS ( TO BE CARRIED OUT ON EACH )

 1. Measurement of winding resistance
 2. Measurement of insulation resistance
 3. Separate source voltage withstand test (High Voltage
tests on HV & LV)
 4. Induced over voltage withstand test
 5. Measurement of voltage ratio and polarity
 6. Measurement of NO LOAD LOSSES & CUIRRENT.
 7. Measurement of LOAD LOSS & IMPEDENCE.
(efficiency & regulation)
 8. Vector Group Verification
 9. Oil BDV test.
 10. Tests on OLTC (if Attached) 7
 SPECIAL TESTS
 Partial discharge test
 Radio interference test
 Vibration test
 Short-circuit withstand test
 Tan delta test

8
 Pre Commissioning Test of Transformer
 Testing performed before commissioning of transformer
at site is called pre-commissioning tests .
 These tests are done to assess condition of transformer
after installation and compare test results of all
low voltage tests with factory test reports.

9
 Transformer Commissioning Procedure
 Pre -commissioning
 prior to commissioning work, refer to manufacturer’s
instruction booklet / product catalogue etc. Furnished
with handing-over documents

10
 PRE-COMMISSIONING TESTS

After satisfactory completion of installation, following pre-

commissioning checks and tests on transformer are
performed before putting it into service

 Insulation Resistance (IR) test

 Break-Down Voltage (BDV) test
 Voltage Ratio Test
 Winding Resistance Measurement test

11
 Measurement of insulation resistance

 Measures the insulation resistance of HV & LV windings

with respect to earth (body) and between LV & HV
winding.
INSULATION TESTER OR MEGGER IS USED.
Recommended Values are
2000Mohms for HV & 500 Mohms for LV.

12
 Insulation Resistance (IR) Test

 All power terminal bushings are thoroughly cleaned with a dry clean
cloth.
 During IR test, no external power lines / cables, lightning arresters,
neutral earthing, etc., should be in circuit and transformer is
completely isolated at HV & LV sides and all non-current carrying
conductors are earthed
 IR values of windings to earth & between windings are measured at
all tap positions with insulation tester of suitable ratings .
 Between HV Winding and Earth use 5000V or 2500V Insulation
Tester
Between HV and LV Winding use 5000V or 2500V Insulation
Tester
Between LV Winding and Earth use 1000V or 500V Insulation
Tester
 13
 IR TESTING OF TRANSFORMER

use following test voltages for determining IR:

 10/5 kV megger for EHV transformers.

 2.5 kV Megger for windings of 10.5 kV and above.

 1000 V Megger for windings of 3.3 kV and above.

 500 V Megger for windings of LT Voltages.

 250 V for thermocouples embedded in winding.

 The general thumb rule for insulation resistance with a 2.5

kV megger is 2 Meg-ohm/kV at 60oC temperature.

 The IR Values at site should not be less than 75% of the

original test value. Normally the absorption factor values

are measured at ambient condition. The insulation
resistance will increase with the decrease in temperature.
 POWER TRANSFORMER

MEASUREMENT OF INSULATION:
1. PI Measurement for solid insulation:
This test is done to adjudge the insulation level between
various windings and winding to earth with the help of a
‘Motorised Insulation Tester’ by measurement of :-
A) Absorption coefficient = R60sec/ R15sec
= 1.3 to 3.0
B) Polarisation Index = R10min/ R1min
Bad insulation PI < 1
Good insulation PI > 2
POWER TRANSFORMER

PI Measurement for solid insulation:

Checking of insulation resistance between each winding to ground.
For finding out polarisation index, note the readings at the end of 1
minute and at 10 minute. The ratio R10min/ R1min is called
polarisation index . It is an indication of the deterioration or ageing
of the insulation.
PI = IR10min/ IR1min
= 1.0 to 1.1 suspicious
= 1.1 to 1.3 good
= 1.3 to 1.5 very good
 Insulation Resistance (IR) Test

 IR values obtained should be similar to those indicated in

manufacturers’ test report. In humid weather, IR values
obtained may be lower due to condensation on terminal
bushings
 If IR values are very low and unacceptable, then it may
be necessary to filter the oil / dry-out the winding till
insulation reaches satisfactory values

17
 Procedure of Insulation Resistance Test
of Transformer

 First disconnect all line and neutral terminals of

transformer.
 Megger leads to be connected to LV and HV bushing
studs to measure IR value in between LV and HV
windings.
 Megger leads to be connected to HV bushing studs and
transformer tank earth point to measure IR value in
between HV windings and earth.
 Megger leads to be connected to LV bushing studs and
transformer tank earth point to measure IR value in
between LV windings and earth.

18
 Measurements are to be taken as follows:
For two winding transformer: HV to LV , HV to E, LV to E.
Three winding transformer: HV to IV, HV to LV, IV to LV,
HV to E, IV to E, LV to E.
 Note oil temperature at the time of IR test of
transformer since IR value of transformer insulating oil
may vary with temperature.
 IR values to be recorded at intervals of 15 seconds, 1
minute and 10 minutes.
 With duration of application of voltage,IR value
increases. Increase in IR is an indication of dryness of
insulation.
 Absorption coefficient = 1 minute value/ 15 secs. value.
 Polarization index = 10 minutes value / 1 minute value. 19
 Voltage Ratio Test / Turns Ratio Test
of Transformer

 Procedure of Transformer Ratio Test

 First, tap changer of transformer is kept in lowest position
and LV terminals are kept open.
 Apply 3-phase 415 V supply on HV terminals.
--- measure voltages applied on each phase (Phase-
phase) on HV
--- measure induced voltages at LV terminals
simultaneously.
 After measuring voltages at HV and LV terminals, tap
changer of transformer should be raised by one position
and repeat test.
 Repeat same for each of tap position separately. 20
 Voltage and Turn Ratio Test of
Transformer
 Transformer ratio test can also be performed by portable
transformer turns ratio (TTR) meter.
 There is built up power supply, with voltages commonly
used being very low, such as 8-10 V and 50 Hz.
 HV and LV windings of one phase of a transformer are
connected to instrument, and internal bridge elements
are varied to produce a null indication on detector.
 Phase voltage is applied to one of windings by means of
a bridge circuit and ratio of induced voltage is measured
at bridge.
 Accuracy of measuring instrument is < 0.1 %.
21
22


23
 Break-Down Voltage (BDV) Test:

 Oil samples from tank bottom, tank top, radiator, etc. shall
be carefully taken and tested for BDV value.
 BDV value of oil should be more than 60kV (rms) for 1
minute .
 If BDV value is very low and unacceptable (30kV(rms) or
less for 1 minute, then it may be necessary to dry-out &
clean oil till insulation reaches satisfactory values.

24
 Winding Resistance Measurement Test

 Winding Resistance of every phase of each winding

should be measured using suitable DC Resistive Bridge
or similar.
 Winding Resistance values obtained should be similar to
those indicated in the manufacturers’ test report.

25
 Transformer Winding Resistance
Measurement

 Transformer winding resistance measurement is

carried out as a type test, routine test and also as field
test.
 In factory, it helps in determining following :
 Calculation of I2R losses in transformer.
 Calculation of winding temperature at end of temperature
rise test of transformer.
 In field
 As a benchmark for assessing possible damages.
 To check for abnormalities due to loose connections,
broken strands of conductor, high contact resistance in
tap changers, high voltage leads and bushings. 26
 Procedure of Transformer Winding
Resistance Measurement

 For star connected winding, resistance shall be

measured between line and neutral terminal.

 For delta connected windings, measurement of

winding resistance shall be done between pairs of line
terminals. As in delta connection resistance of
individual winding can not be measured separately,
resistance per winding shall be calculated as per
following formula:
Resistance per winding = 1.5 x Measured value

27
 Procedure of Transformer Winding
Resistance Measurement

 Resistance is measured at ambient temperature and

then converted to resistance at 75˚C for all practical
purposes of comparison with specified design values,
previous results and diagnostics.

 Winding Resistance at standard temperature of 75° C

 Rt = Winding resistance at temperature t.

t = Winding temperature.
28
 Procedure of Transformer Winding
Resistance Measurement

 Generally transformer windings are immersed in

insulation liquid and covered with paper insulation, hence
it is impossible to measure actual winding temperature in
a de-energizing transformer at time of transformer
winding resistance measurement.
 An approximation is developed to calculate temperature
of winding at that condition, as follows

Temperature of winding = Average temperature of

insulating oil.

29
 Procedure of Current Voltage Method of
Measurement of Winding Resistance

30
 Procedure of Current Voltage Method of
Measurement of Winding Resistance

31
 Procedure of Current Voltage Method of
Measurement of Winding Resistance

 For star connected three phase winding, resistance per

phase would be half of measured resistance between two
line terminals of transformer.
 For delta connected three phase winding, resistance per
phase would be 0.67 times of measured resistance
between two line terminals of transformer.
 This current - voltage method of measurement of
winding resistance of transformer should be repeated
for each pair of line terminals of winding at every tap
position.

32
 Bridge Method of Measurement of Winding
Resistance

 All other steps to be taken during transformer

winding resistance measurement in these methods are
similar to that of current - voltage method
of measurement of winding resistance of transformer,
except measuring technique of resistance.

33
 Bridge Method of Measurement of
Winding Resistance
 Principle of bridge method is based on comparing an
unknown resistance with a known resistance.
 When currents flowing through arms of bridge circuit
become balanced, reading of galvanometer shows zero
deflection that means at balanced condition no current will
flow through galvanometer.
 Very small value of resistance ( in milli-ohms range) can
be accurately measured by Kelvin bridge method whereas
for higher value Wheatstone bridge method
of resistance measurement is applied.
 In bridge method , error is minimized.

34
 Buchholz Relay Test

 Relay operation for alarm and trip contact shall be

checked by injecting air inside relay through test
petcock.
 Injected air collected inside relay allow alarm float / flap
& trip float / flap to fall thereby operating their respective
switch

35
 After Oil-Filling or Before Commissioning, AT LEAST
12hrs should be allowed for oil to settle-down and air is
released from all points at 2 hourly intervals

36
 ADDITIONAL PRE-COMMISSIONING
CHECKS
 BEFORE SWITHCH ON ENSURE that
 All Oil Shut-off Valves are OPEN and Draw-Off Valves
are CLOSED
 All Thermometer Pockets are near filled (85%) with oil.
 Oil is at correct level in Conservator
 Colour in breather is blue for silica-gel
 Earthing Connection of Main Tank, Neutral Bushing,
Marshalling Box, Control Gear Box, Cable Box, Arcing-
Horn, etc., are correctly made.
 Bushing arcing horn gap is set correctly
 All CT Secondary Circuits are Closed
 All Air-Release Plugs of Main Tank , Radiator,
Conservator , Buchholz Relay, Bushings, etc., are free of
air pocket / bubbles 37
 It is recommended that transformer is initially energised
at NO-LOAD only and checked for any abnormalities for
next 6 to 8 hours
 AFTER SWITCHING on no-load, if Primary side Circuit
Breaker is tripped, investigate cause thoroughly and re-
energise transformer ONLY AFTER ensuring that fault is
properly cleared
 If satisfactory (transformer on No-Load) then apply load
gradually and observe for any abnormalities for next 6 to
8 hours

38
THANKS

39