UNDERSTANDING

TRANSFORMERS
TUTORIAL MANUAL.2025
THIS DOCUMENT IS DEVELOPED BY ENG’, ALMIRAH ALAN FOR LEARNING PURPOSES ONLY.
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 TABLE OF CONTENTS
CONTENT.
TRANSFORMER CATEGORIES................................................................................................................. 3
TYPES OF TRANSFORMERS; ................................................................................................................ 3
PARTS OF AN ELECTRICAL TRANSFORMER. ....................................................................................... 4
AUXILLIARY DEVICES IN A TRANSFORMER ....................................................................................... 6
1. TRANSFORMER OIL ...................................................................................................................... 6
2. TRANSFORMER MAIN TANK ....................................................................................................... 7
3. CONSERVATOR TANK .................................................................................................................... 7
4. BUCHOLZ RELAY ......................................................................................................................... 7
5. BREATHER UNIT ........................................................................................................................... 8
OIL COOLING SYSTEM ............................................................................................................................. 9
TAP CHANGER ............................................................................................................................................ 9
MEASUREMENT AND CONTROL ACCESSORIES ................................................................................ 10
TRANSFORMER TESTS .............................................................................................................................. 2
1. OIL DIELECTRIC BREAKDOWN TEST ........................................................................................ 2
2. BUSHING TAN DELTA TEST ........................................................................................................ 1
3. MEASUREMENT OFWINDING INSULATION RESISTANCE. .................................................... 2
4. MEASUREMENT OF CORE AND FRAME AND FRAME INSULATION AT 1Kv DC ..................................... 4
Purpose ............................................................................................................................................. 4
5. MEASUREMENT OF WINDING RESISTANCE ............................................................................ 5
6. EXCITATION [No LOAD] TEST FOR POWER TRANSFORMERS............................................... 6
7. SHORT CIRCUIT [%Z] TEST FOR POWER TRANSFORMERS ................................................... 7
8. POWER TRANSFORMER – TURNS RATIO TEST ....................................................................... 8
9. POWER TRANSFORMER – VECTOR GROUP TEST ................................................................................. 11
TRANSFORMER CATEGORIES.
Transformers come in various types based on size, function, shape, and other factors. Electrical
transformers can be classified into multiple categories, such as classification by usage. Here is a list of
some of the most common uses:

TYPES OF TRANSFORMERS;
1. Power Transformers: Used in transmission networks for stepping up
or stepping down the voltage levels.
2. Distribution Transformers: Used to distribute electrical energy to
end-users at lower voltage levels.
Power Transformers:
3. Instrument Transformers: Used in conjunction with measuring
instruments for accurate measurement of voltage, current, and power.
4. Isolation Transformers: Used to isolate different sections of electrical
systems for safety and protection.
5. Autotransformers: Used for voltage regulation and to provide
variable voltage supply.

Distribution Transformers

Instrument Transformers 1Isolation Transformers Autotransformers

PARTS OF AN ELECTRICAL TRANSFORMER.
LEGEND ON THE PARTS OF THE TRANSFORMER
ITEM NUMBER COMPONENT NAME
1 OIL FILTER VALVE
2 CONSERVATOR
3 BUCHOLZ RELAY
4 OIL FILTER VALVE
5 PRESSURE RELIEF DEVICE
6 HIGH VOLTAGE BUSHING
7 LOW VOLTAGE BUSHING
8 SUSPENSION LUG
9 B C T TERMINAL
10 TRANSFORMER MAIN TANK
11 ON-LOAD TAP CHANGER
12 TAP CHANGER HANDLE
13 FASTENER FOR CORE AND COIL
14 LIFTING HOOK FOR CORE AND COIL
15 END FRAME
16 COIL PRESSURE BOLT
17 OIL DRAIN VALVE
18 JACKING BOSS
19 STOPPER
20 FOUNDATION BOLT
21 GROUNDING TERMINAL
22 SKID BASE
23 COIL PRESSURE PLATE
24 CORE
25 TERMINAL BOX FOR PROTECTIVE DEVICES
26 NAME PLATE
27 THERMOMETER
28 RADIATOR
29 MANHOLE
30 LIFTING HOOK FOR CORE AND COIL
31 DIAL TYPE OIL LEVEL GAUGE
AUXILLIARY DEVICES IN A TRANSFORMER
1. TRANSFORMER OIL
The oil in contact with the winding and core is known to transfer heat from the winding to the core and to
the rest of the cooling system (pumps, radiators, pipes, and fans). The elements of the cooling system
(pumps, radiators, pipes, and fans) expel this heat through various methods (conduction, convection, and
radiation) to the external environment
1. Cooling is a vital function in transformers, as unchecked internal
heat can result in significant risks. Oil serves as the most
effective medium for transferring this heat outside the
transformer, as it easily circulates between the windings,
absorbing heat from them. This absorbed heat is then released
either through fans and radiators or through the natural contact
between the oil and the transformer's metal body. To maintain the
oil's ability to dissipate heat efficiently under diverse conditions
and a wide range of temperatures, it must possess essential
properties such as appropriate viscosity, boiling point, flash point, and evaporation rate.

2. Insulator, oil serves both as an insulator and a cooling medium. It enhances insulation between
windings, the core, and the tank, offering better dielectric strength compared to air. Oil's dielectric
constant (2.2) and breakdown voltage (up to 80 kV/cm) significantly reduce electrical stress,
allowing for a more compact transformer design. In comparison, air has a lower dielectric strength
(30 kV/cm), requiring larger spacing between components. For even smaller transformer sizes, SF6
gas can be used, offering superior insulation (100 kV/cm). This explains why air-insulated
transformers are larger than oil or SF6-insulated ones.
 2. TRANSFORMER MAIN TANK
Transformer tanks are made of non-magnetic iron and come in different
designs based on capacity. Small transformers (below 50 kVA) use plain tanks
with flat surfaces for heat dissipation. Medium-capacity transformers have
tubed tanks with welded pipes to increase the cooling surface. Large
transformers use radiators on all sides, with pumps circulating oil through
them for efficient cooling. The tanks are mounted on wheels for easy
transport, and hooks are added for lifting.

3. CONSERVATOR TANK
In large transformers, a reserve oil tank is used to keep the main tank fully submerged in oil without an
air gap. This expansion tank accommodates changes in oil volume due to thermal expansion or
contraction, compensates for any oil loss, and includes an oil level gauge to monitor levels. The
expansion tank is typically about one-tenth the size of the main tank. When operating at full load, the
oil can expand by approximately 8% at maximum temperatures, so the main tank is filled to only about
30% of the expansion tank's height to allow for this expansion.

4. BUCHOLZ RELAY
The Buchholz relay is a protective device installed in the connecting tube between the main and reserve oil
tanks of a transformer. It triggers an alarm when the oil level drops and can disconnect the transformer
during serious faults. The relay features a chamber with two floats, and gas accumulation due to faults
displaces the oil. It also has a valve for excess oil discharge and a vapor release valve that allows operators
to identify faults by observing the color of the oil vapor.

 When there is an excessive load, the oil temperature rises and boils, causing vapor to accumulate
and trigger the alarm circuit.
  In the event of a short circuit, the increased oil pressure activates the main transformer breaker and
causes a trip. If there is a loss of transformer oil, it disturbs the position of both floats, mimicking a
fault condition.

5. BREATHER UNIT
When the oil level in the main tank drops, it is automatically replenished from the
reserve tank. This causes the oil level in the reserve tank to drop, increasing the air
gap. Air is drawn in from the outside through the Dehydrated Breathing Unit,
which contains Silicone gel. This material can absorb any moisture that leaks into
the oil. The color of the gel changes from blue to pink when it loses its ability to
absorb moisture. Silica gel is a crystalline salt that absorbs moisture from the air
as it enters the transformer, thus preventing moisture from reaching the
transformer oil.

Silica Gel Colors:

 Blue: Indicates the active material.

 Pink: Indicates the silica gel is saturated with moisture and needs to be replaced or dried in an
open oven at a temperature of 150-200°C until it turns blue again.
 White: Indicates the silica gel is saturated with moisture and has been dried multiple times,
making it unsuitable for further drying and requiring replacement.
 Black: Indicates the silica gel is saturated with oil, which clogs its pores. If it turns black, it is no
longer suitable for drying and must be replaced.
OIL COOLING SYSTEM
In small transformers, oil heat is dissipated through contact with the tank body. Larger transformers use
radiators to increase cooling efficiency by expanding the surface area exposed to air. Some systems rely on
natural air and oil cooling, while others use forced air cooling with fans, known as FA systems. For even
more effective cooling, FAFO systems use both forced air and forced oil circulation with pumps. These
cooling mechanisms are controlled automatically to optimize efficiency and only operate when necessary.

TAP CHANGER
The Tap Changer is one of the main components in transformer construction, directly related to
the windings. It is responsible for changing the ratio between the number of turns in the primary
winding to the number of turns in the secondary winding, known as ( N1 / N2 ). This device is
only present in large transformers, while in small transformers, the ( N1 / N2 ) ratio is fixed.The
transformation ratio can be changed either during operation (on-load) or when the transformer is
off (off-load), and both types are in service.

The important of it:

Maintaining a fixed transformation ratio in large transformers can cause performance issues due to
variations in input voltage. To address this, a Tap Changer
is used. It adjusts the ratio between the primary and
secondary windings, allowing for small increases or
decreases in the transformation ratio (typically within ±5%
of the nominal voltage). This adjustment helps maintain the
desired output voltage despite fluctuations in the input
voltage. For example, if the input voltage drops from 132
kV to 130 kV, the Tap Changer can increase the transformation ratio to ensure the output voltage
remains at 11 kV.
MEASUREMENT AND CONTROL ACCESSORIES
 TRANSFORMER TEST
1. OIL DIELECTRIC BREAKDOWN TEST

Transformer oils are refined mineral oils obtained through the fractional distillation of crude petroleum.
Afterward, the oil is treated to remove impurities and achieve the desired properties, making it suitable as an
insulating and cooling fluid. Its advantages include:
 High dielectric strength.  Free from sludge deposits under normal
operating conditions.
 Low viscosity.
 Rapid stabilization of by-products from
 Free from inorganic acids, alkalis, and electrical arcing.
corrosive sulfur.
 Low pour point.
 Good resistance
 High flash point.
The breakdown voltage of new or used oil is measured using spherical electrodes with a diameter of 12.5
mm and a specified gap of 2.5 mm between the electrodes. The voltage increase during the test should be at
a rate of 1 kV/s. The apparatus consists of a transformer, a circuit breaker, a voltage regulator, and a
resistor. During the experiment, the temperature conditions should be maintained between 15-35°C. The
measurement steps are as follows:
1. Pour the oil into the designated container in the measuring device, ensuring the oil level is at least 20
mm above the height of the electrodes. Allow the oil to settle and ensure all bubbles are removed before
conducting the test.
2. Begin increasing the voltage at a rate of 3 kV/s until electrical discharge occurs. Record the breakdown
voltage reading, then reset the voltage regulator.
3. Repeat the experiment several times, recording 5-6
breakdown voltage readings. Calculate the average value
of the results. If carbon particles are present on the
electrode surfaces, stir the oil to homogenize it before
taking the next reading.
4. After completing the experiment, discharge the
electrodes to remove accumulated charges, then calculate
the breakdown voltages.
Note: The reference value for the breakdown voltage
should be as recommended by the transformer manufacturer.

2. BUSHING TAN DELTA TEST

The Tan Delta Test, also known as the Dielectric Dissipation Factor (DDF) test, is a diagnostic
technique used to assess the condition of insulation in electrical equipment, particularly
transformers. Here’s a detailed explanation of the test:

Purpose

The primary goal of the Tan Delta Test is to measure the insulation quality and ensure there are no
internal defects. It helps in identifying aging, contamination, and other issues that could
compromise the insulation’s effectiveness.

Principle

The test measures the phase angle difference between the applied voltage and the resulting current
in the insulation system. Ideally, a perfect insulator would only allow capacitive current, but real-
world insulators have impurities that introduce a resistive component. The ratio of the resistive
current to the capacitive current is known as the tan delta (tan δ).

Procedure

1. Setup: Connect the test instrument (e.g., MEGGER Delta 4000) as shown in the provided
diagram. Ensure the transformer bushings are clean and the connections are made
correctly.
2. Short Circuiting: Short circuit each winding of the transformer at its bushing terminals
and connect all windings to ground except the one being measured.
3. Voltage Application: Apply a test voltage, starting at 500 V. If the test is successful,
increase the voltage to 10 kV.
4. Measurement: The test device measures the charging current and the power loss, from
which the power factor, capacitance, and AC resistance are computed.
5. Evaluation: Compare the results with the manufacturer’s recommendations and previous
factory test results to determine the insulation’s condition.
Modes

 UST (Ungrounded Specimen Test) Mode: Used when the specimen is not grounded.
 GST (Grounded Specimen Test) Mode: Used when the specimen is grounded.

3. MEASUREMENT OFWINDING INSULATION RESISTANCE.

Purpose
The purpose of this test is to measure the insulation quality of the transformer windings and ensure there
are no internal defects.
Tools Used
 Insulation Resistance Tester (like MEGGER Delta 4000)
 Test Leads to connect the tester to the transformer
Steps
1. Setup: Place the tester on a stable, dry surface. Clean the transformer bushings.
2. Identify Parameters: Determine the test parameters and connection points.
3. Connect: Connect the tester as shown in the diagram. Ensure correct connections.
 4. Test: Apply a test voltage of 5 kV DC as per the connections shown.
5. Measure: Measure the insulation resistance from 1 minute to 10 minutes and record the readings.
6. Calculate Polarization Index: Use the formula

7. Record Results: Write down the test results in the appropriate form.

Importance
This test helps detect insulation problems early, allowing for preventive maintenance and avoiding major
failures. It ensures the reliability and safety of transformers.
 4. MEASUREMENT OF CORE AND FRAME AND FRAME INSULATION
AT 1Kv DC

Purpose
 Measure the insulation resistance of the core and frame of a power transformer.
 Ensure there are no internal defects.

Tools Used

 Calibrated insulation resistance tester (e.g., MEGGER Delta 4000).

 Test leads.

Steps

1. Setup: Place the calibrated test instrument on a stable, dry surface.

2. Clean: Thoroughly clean all bushings of the transformer.
3. Identify Parameters: Determine the test parameters and the terminals for proper connections.
4. Connect:
o Remove the link between the core and frame.
o Remove the earth link to the transformer.
o Connect the test leads as shown in the diagram.
5. Test: Apply a test voltage of 1kV DC and measure the insulation resistance for the following
connections:
o Core to Earth.
o Frame to Earth.
o Core to Frame.
6. Measure: Record the insulation resistance readings for each connection.
7. Evaluate: Compare the results with the standards or criteria (typically >10 MΩ).

Importance

 Detect insulation issues early.  Ensure the reliability and safety of the
transformer
 5. MEASUREMENT OF WINDING RESISTANCE
Purpose
 Measure the winding resistance of a power transformer to check the health of the windings and
connections.
 Identify potential damage or abnormalities.
Tools Used
 Calibrated test instrument (e.g., Digital Low Resistance Ohmmeter).
 Test leads.
Steps
1. Setup: Place the calibrated test instrument on a stable, dry surface.
2. Clean: Thoroughly clean all bushings of the transformer.
3. Identify Parameters: Determine the test parameters and the terminals for proper connections.
4. Connect:
o Connect the test leads to the appropriate terminals for the HV, LV, and tertiary windings as
shown in the diagram.
5. Test: Apply the test current and measure the voltage drop across the winding. Use Ohm’s law to
calculate the resistance.
6. Measure: Record the resistance readings for each winding.
7. Evaluate: Compare the results with the standards or criteria (typically at 75°C).
Importance
 Detect winding issues early.
 Ensure the reliability and safety of the transformer
 6. EXCITATION [No LOAD] TEST FOR POWER TRANSFORMERS
Purpose
 Measure the core losses (iron losses) of the transformer.
 Determine the no-load current and losses at rated voltage and frequency.
Tools Used
 Calibrated high voltage test instrument.
 Measuring instruments (ammeter, voltmeter, wattmeter).
Steps
1. Setup: Place the calibrated test instrument on a stable, dry surface.
2. Clean: Thoroughly clean all bushings of the transformer.
3. Identify Parameters: Determine the test parameters and the terminals for proper connections.
4. Connect:
o Inject High Voltage (10 KV) at the High Voltage (HV) side.
o Inject Low Voltage (220 V or 380 V) at the Low Voltage (LV) side.
 5. Test: Measure the no-load current at the first tap, middle tap, and last tap.
6. Measure: Record the no-load current values for HV and LV test connections.
7. Evaluate: Compare the results with the standards or criteria.
Importance
 Detect core issues early.
 Ensure the reliability and efficiency of the transformer.

7. SHORT CIRCUIT [%Z] TEST FOR POWER TRANSFORMERS

Purpose
 Determine the transformer’s impedance voltage (%Z).
 Assess the transformer’s ability to withstand short-circuit conditions.
Tools Used
 Calibrated test instrument.
 AC voltage source.
 Measuring instruments (ammeter, voltmeter).


 

Steps
1. Setup: Place the calibrated test instrument on a stable, dry surface.
2. Clean: Thoroughly clean all bushings of the transformer.
3. Identify Parameters: Determine the test parameters and the terminals for proper connections.
4. Connect:
o Inject 380V 3-phase power supply to the transformer’s primary side.
o Short the secondary side as shown in the diagram.
5. Test: Measure the input voltage and current at each phase for the first tap, middle tap, and last tap.
6. Measure: Record the measured input voltage and current.
7. Calculate:
o Calculate the average value of the recorded input voltage and current.
o Calculate the impedance voltage using the
formula
o Calculate %Z using the formula
8. Evaluate: Compare the results with the acceptance criteria (typically +/- 10%).
Importance
 Detect potential issues with the transformer’s impedance.
 Ensure the reliability and safety of the transformer under short-circuit conditions.

8. POWER TRANSFORMER – TURNS RATIO TEST

Purpose

 Verify the turns ratio between the primary and secondary windings of the transformer.
 Ensures the transformers is function correctly and efficiently.

Tools used

 Calibrated Turns Ratio Tester [TTR]

 Test leads
 Multi meter
 Steps
1. Setup: Place the calibrated test instrument on a stable, dry surface.
2. Clean: Thoroughly clean all bushings of the transformer.
3. Connect:

 Connect the TTR test set to the transformer terminals/bushings as shown in the diagram.

 Refer to the transformer’s nameplate to confirm proper terminals.

4. Test: Apply the test voltage and measure the turns ratio for each tap position.
5. Measure: Record the turns ratio readings for each winding.
6. Evaluate: Compare the results with the acceptance tolerance for ratio deviation (typically +/- 0.5%).
Importance
 Detect winding issues early.
 Ensure the reliability and efficiency of the transformer
 .
9. POWER TRANSFORMER – VECTOR GROUP TEST
Purpose

 Verify the phase displacement and connection of transformer windings.

 Ensure transformers can operate in parallel without issues.

Tools Used

 Calibrated test instrument.

 Voltmeter.

Steps

1. Setup: Place the calibrated test instrument on a stable, dry surface.

2. Clean: Thoroughly clean all bushings of the transformer.
3. Identify Parameters: Determine the test parameters and the terminals for proper connections.
4. Connect:
o For HV Test: Apply 415V between R-Y and note down all voltmeter readings.
o For LV Test: Apply 415V between r-y and note down all voltmeter readings.
5. Test: Measure the voltages for each configuration:
o HV Test (Vector Group Yy0/Yd11): Expected results: ( V_{RY} = V_{YB} = V_{BR} )
and ( V_{RN} = V_{YN} = V_{BN} ).
o LV Test (Vector Group Yy0/Yd11): Expected results: ( V_{ry} = 3 \times V_{yb} = 3
\times V_{br} ) and ( V_{rn} = 3 \times V_{yn} = 3 \times V_{bn} ).
o HV Test (Vector Group Dd0/Dy11): Expected results: ( V_{BY} ) should be zero, and
other voltages as per nameplate details.
o LV Test (Vector Group Dd0/Dy11): Expected results: All measured values using b-y as
reference should be zero volts.
6. Measure: Record all values in a table format.
7. Evaluate: Compare the results with the expected values to confirm the vector group.

Importance

 Detect phase displacement issues early.

 Ensure the reliability and compatibility of transformers for parallel operation.