ELECTRICAL POWER

EQUIPMENT TESTING AND

COMMISSIONING

Prepared by:
Engineer: Elsayed Elamin
 Course Objectives:
This course to understand :
Need for testing electrical equipment.
Types of tests that performed to
electrical equipment.
Testing equipment that used in these
tests.
Need of good records keeping on tests.
The various types of HV and MV
equipment that may encounter you in
industries and networks.
 COURSE INDEX
• Chapter(1): Introduction To Electrical Power
Equipment Testing And Commissioning.
• Chapter(2): Insulation Test
Concept And Considerations.
• Chapter(3): High Voltage Test(Hipot Test).
• Chapter(4): Transformer Testing.
• Chapter (5): CTs and VTs Testing .
• Chapter(6): MV/HV Circuit Breakers and
Bus Bars System Tests.
• Chapter(7): Power Cable Tests.
 CHAPTER (1)

INTRODUCTION TO ELECTRICAL
POWER EQUIPMENT TESTING
AND COMMISSIONING
 Power System Voltage Levels
Common power system Voltage levels are:
(1) Low Voltage (LV).
(2) Medium Voltage (MV).
(3) High Voltage (HV).
Power Generation,Transmission&Distribution
 Electrical power networks consists of generation,
transmission, sub distribution and distribution plants.
 Always generation voltages level be in the medium
voltage range (6.6KV,11KV,13,8KV) to reduce the
size of generators by reducing the insulation
materials .
 By sub distribution we mean the substations in the
level of 33/11KV - 66/33KV - 15/5.5KV .
 COMMON HV/MV EQUIPMENTS :
1. Circuit Breakers – HV and MV .
2. Air break switches (Isolators/
Disconnectors) .
3. Instrument transformers (CTs, PTs) .
4. Cables (limited to around 170 kV) .
5. Transformers .
6. Switchgear (GIS & AIS ) .
7. Lightning arrestors(Surge Arrestors) –
HV and MV.
 NEED FOR TESTING :
Necessity to prove the performance of the
equipment before putting into service .
Do all the tests according to the
international standards for HV/MV electrical
equipments.
Doing all electrical equipment testing
according to the international standards give
a strong basis for the future analysis of
failures (if happened).
To give confidence about performance and
safety to the end user before acceptance .
 PURPOSE OF TESTING :
Finished products includes many
components independently tested and
need final tests once assembled.
Many parts not visible, hence these
parts need a common method to check
capability under actual working
conditions.
Base test results used as basis for
future comparisons of performance.
 TEST CATEGORIES(1)
(1) Routine tests :
• The IEC definition of routine tests is a test to
which each individual equipment is subjected.
• Each equipment may subject to routine test
at least one time .
• Practically we find that a routine test can
done to a certain equipment at the factory
after manufacturing and at the site during
commissioning tests or troubleshooting tests .
• For transformers routine tests are no load,
short circuit, ratio ,winding resistance etc ...
 TEST CATEGORIES(1)
(2)Type tests/Design tests :
• Type Tests are the tests that performed on
single specified equipment, which is
representative of others, to demonstrate that
these equipments comply with specified
requirements not covered by routine tests .
•Type tests are intended to check the design
characteristics of the equipments.
• Type tests are applied when new design or
design changes are introduced.
• For transformers type tests are (1)temperature
rise test. (2) impulseSeetests.
Kima Certificate
 TEST CATEGORIES(1)
(3) Special tests :
• The IEC definition of a special test is a test
done for electrical equipments other than a
type test or a routine test agreed by the
manufacturer and the purchaser .
• Type test and special test are carried out on
the specific requirement of customers .
• For transformers special tests are ability to
withstand sudden short circuit,
measurements of noise level ,measurements
of harmonics in the no load current…etc
 ELECTRICAL EQUIPMENTS TESTS
CATEGORIES(1)

Electrical Power Equipments

Tests

(1) Routine (2) Type Tests/Design (3)Special

Tests Tests Tests
(Performed On (Performed On Single (Carried Out
Each Specified Equipment) On The
Equipment) Specific
requirement
Of Customer)
 TEST CATEGORIES (2)
* Also electric equipments tests can be divided
with regard to the place of doing the test :
(1)Factory Acceptance Tests (FAT):
• These tests are carried out at the
Manufacturer’s Factory .
• FAT tests are combination of routine tests,
special tests and type tests .
• Normally customers choose which tests to do
from the above listed
tests(routine ,special ,type).
• The FAT is Performed according to the
customer requirements at the witness of the
customer or his representative/s.
 TEST CATEGORIES(2)
(2)Site Acceptance Tests (SAT):
• These tests are done at the site and
consists of the following :
(a) Pre-commissioning tests.
(b) Commissioning tests.
(c) Maintenance tests(Troubleshooting
tests).
(d) Tests after replacement /repair.
 (SAT) CATEGORIES
a) Pre-commissioning tests:

• These tests are done to assess the condition of an

equipment after installation and comparing tests results

to the factory test reports.
•Following are some examples for Pre-commissioning tests
:-
1- Visual Check and Inspection of the whole equipments .
2- some of routine tests.
3- Tests on auxiliary equipments and Verification of
correct wiring.
 (SAT) CATEGORIES
b) Commissioning tests :
• Process by which an equipment, facility,
or plant (which is installed, or is complete
or near completion) is tested to verify if it
functions according to its design
objectives or specifications.
 (SAT) CATEGORIES
c) Maintenance tests(Troubleshooting Test):
• These are tests that is performed to:
(1) identify or diagnose equipment problems .
(2) prove that the rest of the system has not
been affected by the maintenance work.
d)Tests after replacement/repair :
• These tests are performed to be sure that
insulation of the whole system is not affected
after changes have been made due to faults
or if the system is extended or because of
some additional features added to it.
Electrical Equipments Tests Classifications

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VARIATIONS TO BE CONSIDERED WHEN TESTING &
DESIGN ELECTRICAL POWER EQUIPMENTS :
The following three items are important in
testing and design of electrical equipments
.
(1)Altitude above sea level (not exceed
1000meter) .
(2)Ambient temperature .
(3)Humidity .
Tests results are to be corrected for the
 1. ALTITUDE
Air is an insulating medium with
separation based on operating
voltages.
Increase in location altitude decreases
the dielectric properties of the air.
Normal test results satisfy equipments
used in altitudes up to 1000 meters
above sea level.
Beyond this level we have to use
equipments rated for slightly higher
voltage.
 2.TEMPERATURE
Ambient temperature generally lays
between -25ºC to +40ºC.
Temperature rise generally measured
based on this ambient temperature.
Losses and some performance details
corrected to 75ºC to reflect the actual
operating temperature.
For example Megger test results affects
directly by the temperature at the time of
testing .
 3. humidity
• In gases and liquids, the presence of
humidity can cause a change in
insulating performances.
• In the case of liquids, it always leads to a
drop in performance.
• Humidity affects directly the electrical
insulation and causes huge failures.
• In hard insulators like porcelain bushings,
the humidity can make a flashover at
normal voltage values . See Video
 TOLERANCES :
Tolerances in test results values is very
important and the global specifications
show us when to accept tolerances.
Generally the equipment shall withstand
the test voltages specified without
tolerance.
Standards allow tolerances for the
values of (Losses, impedance,
resistances etc..)because their design
related and based on many factors .
 CHAPTER(2)

INSULATION TEST
CONCEPT AND CONSIDERATIONS

(1) MEGGER TEST

(2)TAN DELTA TEST
(3) PARTIAL DISCHARGE TEST
 INSULATION TESTING :
Need For Insulation:-
(1)To retain the voltage at the terminals in
order to drive the necessary current.
(2)Prevention of short circuits arc between
phases and between phases to ground.
(3)To avoid electrocution.
(4)To ensure safe distribution of electricity.
Air, oil and SF6 are common
insulation materials.
 Electrical Insulation Concept
• The purpose of insulation around a
conductor is much like that of a pipe
carrying water as shown in the picture
below .
 Electrical Insulation Concept
• Insulation between phases and between
phases to ground in electrical power
equipments is achieved by two ways :
(1) Normal air spacing between phases .
(2) Use insulation materials like XLPE , PVC ,
IMPREGNATED PAPER, SF6 .
• The thickness of the insulation material around
a conductor is proportional to the voltage that
will be applied to the conductor .
• Conductor cross section just affects the current
carrying capacity of the conductor .
 Electrical Insulation Concept

IT
IR IC
R C

* Insulation materials and conductors forms an electrical

circuit of a capacitance in parallel with a resistance
 Electrical Insulation Concept
• Degradation of an insulating system happens
due to :
(1)Cracks in the hard insulators(micro cracks) .
(2)Presence of humidity in the liquid insulators
like oil .
(3)Ionization happened to strange materials that
accumulated in the surface of the hard
insulators due to high voltage ,and this will
make a low resistance path for leakage
currents .
(4)Lack of periodic maintenance .
See Videos
 Electrical Insulation Concept
• Degradation happens to any insulation
system, and this is a natural phenomenon ,but
the unnatural is the high rate of degradation
especially in early period of insulation age .
• Good maintenance engineers do periodic
insulation tests with compared reporting to
see if there is a big amount of degradation
happened from the last time of test till now.
• If there is an unusual degradation, procedures
must be done to see what is the real cause of
this degradation .
(1) INSULATION RESISTANCE TEST(IR)
(MEGGER TEST)
• Insulation Resistance test is achieved by
applying DC voltage across the insulation and
measures the current passing through the
insulation to get R using Ohm’s law R=V / I
Insulation Resistance test is done by applying
DC voltage less than the equipment rated
voltage .
The Insulation Resistance value depends
directly on the equipment life time.
Insulation Resistance is measured at factory
to give basis for future measurements.
Conductor Resistance Measurements(Ohmmeter)

• Here R preferred to be as
DC small as possible.
Ohmmeter • If temperature increased, R
will increase .

Insulation Resistance Measurements(Megger)

• Here R preferred to be as
DC big as possible .
Megger
• If temperature increased, R
will decrease .
 Megger Testers

From FLUKE Company From MEGGER Company

 INSULATION RESISTANCE
MEASUREMENT TECHNIQUE
 Megger technique is to apply a DC
voltage(less than the tested equipment rated
voltage) across the insulation and measures
the leakage current through the insulation
material to give the insulation resistance.
The value of IR depends directly on :
(1) The FAT megger values of equipment.
(2) The equipment life time .
Insulation resistance is high at the time of
manufacturing, but slowly reduces during the
insulation life .
MEGGER RECOMMENDED TEST VOLTAGES

System Voltage Test Voltage

(AC) (DC)
Up to 1KV 500 V

1KV to 3.3KV 500-1000V

3.3KV to 6.6KV 2500-5000V

6.6KV to 12KV 5000 V

> 12KV 10,000 V

CURRENTS FOLLOW THROUGH THE INSULATION DURING
IR TEST

 When a High DC voltage is applied across any

electrical equipment terminals , following currents
flow :-
Charging current (Capacitive current) Ic.
Dielectric absorption current Ida.
Resistive (Leakage current) Ir.
 (1) CHARGING(CAPACITIVE) CURRENT (Ic)

Insulation is basically a resistance in parallel

with a capacitance.
When DC voltage is applied the capacitance
starts drawing more current which stops after
a time.
The charging current (Ic) also called
capacitive current.
(2) DIELECTRIC ABSORPTION CURRENT(Ida)
Molecules get realigned when DC voltage is
applied (and absorb energy from this voltage).
Current dies off quickly once realignment is
completed [termed dielectric absorption
current of insulation (Ida)].
 (3) RESISTIVE (LEAKAGE) CURRANT (Ir)
 It is the actual current that decides the
property of the insulation.
For good insulation, resistance is high,
leakage current is low.
For bad insulation, resistance is low,
leakage current is high.
Property of insulation depend on
leakage current measured after
stoppage of (Ic) and (Ida) .
CURRENTS DURING MEGGER TEST
 EQUIPMENTS TO BE INSULATION TESTED

Transformers
Motors
Switchgear and circuit breakers
Switches and switch boards
Disconnect switches
Insulators and bushings
Cables and bus ducts
 PURPOSE OF INSULATION RESISTANCE TEST

(1)Verify assembled equipment meets

minimum conditions for putting into
service.
(2)To ensure no transit damage during
transportation.
(3)Environmental factors have not affect
the insulation quality (if affected, take
necessary corrective actions).
(4)Monitor quality of insulation over its life
time (to maintain its expected life time).
 WHEN INSULATION RESISTANCE TEST DONE?

When insulation resistance test is done

on equipment?
Before dispatch from a factory.
Before putting equipment into service.
At periodic intervals during the life of the
equipment (generally once in a year).
Before putting equipment back into
service after a shutdown (maintenance
or after a repair or after a prolonged
shutdown).
 CAUTIONS DURING IR TEST
 Never test in an explosive area.
Use hand gloves during test.
Use good quality leads.
Take care of ambient temperature(affects
test values).
All far ends of equipment under test must be
identified and sign with alarm strips.
Use guard wires when necessary.
Equipment under test must be dry and clean.
 (1) IR TEST FOR TRANSFORMERS :
Introduction To Transformer Internal Construction

See Pictures for TR Construction See a Video for TR Construction

 IR TEST FOR TRANSFORMERS :
HV to LV HV to E
A a A a

B b B b

C c C c
n n

A a

B b

C c
n
LV to E

See Pictures for internal TR faults

 IR TEST FOR TRANSFORMERS :
Why We Short Transformer Terminals When
Meggering

Without Short With Short

• Transformer terminals shorted before meggering to:
(1)detect insulation failures in case of open conductor.
(2)Distribute test voltage equally to the winding .
(Shorting TR terminals reducing the time of testing)
 (2) IR TEST FOR POWER CABLES :
For power cables IR test is normally
done across phases, phase-to-ground,
phase-to-neutral and neutral-to-ground.
Phase-to-ground Test Phase-to-phase Test

See Video For Cable Meggering

 (3) IR TEST FOR MOTORS :
See Motor Coils Connection
Motor Stator Phases to Earth Test

Motor Stator Phase to Phase Test

Repeat This Test For Other Phases

 (4) IR TEST FOR SWITCHGEAR
(Phases To Earth Test)

See Video for AIS Switchgear

See Video1 for GIS Switchgear
Test each Phase alone if See Video2 for GIS Switchgear
See Video3 for GIS Switchgear
the 3 phase test fail .
See Video4 for GIS Switchgear
Megger Test For MV & HV Switchgear (GIS)

3 Phases to Earth Switchgear Meggering

 (5)IR TEST FOR SWITCHGEAR
(Phase To Phase Test)

Repeat The Test

For Other Phases
Megger Test For MV & HV Switchgear (GIS)

Phases to Phase Switchgear Meggering

 WHAT IS THE GUARD WIRE IN MEGGER SET
• By guard wire we mean the third terminal that we
found in MEGGER set.

Guard Terminal

• The purpose of guard terminal is to eliminate the

effect of leakage current through paths in parallel
with the insulation you are testing(accurate values).
• The surface leakage is essentially a resistance in
parallel with the true insulation resistance of the
material being tested.
USE GUARD WIRES TO BYPASS STRAY CURRENTS
 USE GUARD WIRES TO BYPASS STRAY CURRENTS

See a video
See additional Pictures
 GUARD WIRE IN MEGGER SET
• The guard path intercepts currents caused by
the unwanted parallel paths on the surface of
the insulation and connect them to ground by
passing the current as on the above diagram.
• Guard wire is not necessary in application with
lower insulation resistance values less than
100MΩ such as in wiring of low voltage building
application.
• The use of the guard terminal is often
important with a value of insulation above
100MΩ as found in HV insulation application .
 INSULATION TEST /COMMON PRACTICES
 Before doing IR test notice to:
(1)Remove components that reduces
resistance across phases like VTs connected
to earth, indication lamps, surge arrester etc.
(2)Clean the surface of the equipment that to
be tested.
 Megger uses DC for testing, and the primary
windings of VTs are connected directly to
earth so test will fail due to the very low
impedance that will appears in VTs primary
windings (XL= 0 because f = 0).
See VTs Connection
 Why VTs affects The Megger Test?

Fuses

a n da dn a n da dn a n da dn
Z = R+jXL
N N N
Z = R+j*2 π f L
f =0 in case of DC
Z = R (While R is
very low in coils
compared to X)
Insulation Resistance Value With Respect To
Time

R10min is greater a
little than R1min
because the leakage
current decreases
with the time .
 POLARIZATION INDEX (PI) AND ABSORBATION
FACTOR
Polarization Index (PI) (R10/R1):
Apply the voltage with the a MEGGER
and take the IR value after one minute
(R1) .
Continue with the test voltage for 9
more minutes .
Take the IR reading again at the end of
10th minute (R10) .
Calculate the polarization Index (PI) by
the formula R10/R1
PI VALUES GUIDE
 POLARIZATION INDEX (PI) AND ABSORBATION
FACTOR

Absorption Factor (R60/R15) :

Apply the voltage with a MEGGER and
take the IR value after 15 second
(R15) .
Continue with the test voltage for 45
more second .
Take the IR reading again at the end of
sixty second (R60)
Calculate the absorption factor by the
formula R60/R15
POLARIZATION INDEX (PI) AND ABSORBATION
FACTOR
Q- What is the difference between
polarization index and absorption factor
techniques in Megger test :
A- Polarization index is performed in fields or
you can say on used TR or in that TR which
remains idle(not in use for long time with oil
present in it) where there is a chance of
moisture presence due to condensation , in PI
technique the molecules of water are polarized
and it takes almost 10 minutes to polarize the
water molecules by using Megger , while the
POLARIZATION INDEX (PI) AND ABSORBATION
FACTOR
absorption factor technique is used for routine
tests at the factory and here the TR is new
and moisture is just remove ,but PI technique
is always preferred for good and reliable
results.
Absorption factor Polarization Index

15 Second 60 Second 10 Minute

• The ratio R60/R30 is called DAR(Dielectric

Absorption Ratio) and its general concept is
same like PI and absorption factor.
 INSULATION RESISTANCE TEST(IR)
Factors affects the values of Megger test :
1- Temperature During Test:
 When the temperature is high the
resistance of the insulation materials will
degrade and this will affect the
measurement of the Megger (degrade
the value).
 The standard temperature is 20˚C and
we make the correction as in the tables
shown on the next slides :
TEMP.CORRECTION FACTORS IN MEGGER TEST
TEMP.CORRECTION FACTORS IN MEGGER TEST
TEMP.CORRECTION FACTORS IN MEGGER TEST
 INSULATION RESISTANCE TEST(IR)
2- insulation surface cleaning :
• Sometimes when the surface of the insulation is dirty
or polluted by dust, oil leakage or other materials , we
find that the values of the Megger test affects a little
and we need to clean up the insulators with a clean
piece of cloth to reduce the value of the leakage
currents through the dirt on the insulators and also
use the guard wire.
3- Using Wrong Wires of Megger(not original one) :
• The Megger wires are insulated enough to be used
with the Megger, and you can not use AVO meter
leads because the insulation values will not be
accurate .
 INSULATION RESISTANCE TEST(IR)
Megger test results Analysis :
i. The results are good, if the absorption factor
or polarization index lays between 1.25 and
2.5.
ii. The results are bad, if the absorption factor or
polarization index is less than 1.25 and all the
values is low with respect to the life time of
the equipment.
iii. Comparison must be done with previous
measurements(if exist) and in the case of
cables, the comparison between phases IR
values will be helpful.
 (2) TAN DELTA TEST :
• Insulation test can be done by another
technique called tan delta test .
• The general concept of TAN DELTA TEST is
that the equipment under test being as a
capacitor, (and in a perfect capacitor the
voltage and current are phase shifted 90
degrees) this makes the current through an
insulation capacitive . If there are impurities in
the insulation, the resistance decreases,
resulting in an increase in resistive current
through the insulation and an angle ᵟ is exist .
 Power Factor, Dissipation Factor, Tan Delta
P Power Factor
Ɵ • The power factor in a circuit is
defined as the ratio of active
Q power to apparent power (P/S) .
S
• The power factor also defined as
cos Ɵ .
Dissipation Factor(Tan Delta)
• The dissipation factor in a circuit
P is defined as the ratio of active
power to reactive power (P/Q) .
Ɵ
• The dissipation factor is equal to
ᵟ S
Q tan δ ,where δ = (90 - Ɵ).
• For practical insulation circuits
where Ɵ is larger than 85, the
power factor and DF are
numerically the same .
Tan Delta Test Theory
In ideal insulation the current
is 90 degree shift from
voltage.
Tan Delta Test Theory
Dielectric Loss Angle/Dissipation factor (tanᵟ)
Comparison between MEGGER TEST and TAN
DELTA TEST :
• Tan delta test is more accurate than Megger test ,
because it takes into account not only surface
conditions of the insulators but also the internal
voids,deterioration,moisture absorption and changes
in dielectric constant due to ageing of insulation.
Tanᵟ test Megger Test
Comparison Between tanᵟ & Megger Temperature Correction
Factor Table

Correction Temperature (C)

Factor

1.56 0
1.46 5
1.38 10
1.2 15
1 20
0.79 25
0.63 30
0.51 35
0.42 40
0.34 45
0.28 50

Megger Table Tan Delta Table

• UST stands for Ungrounded Specimen Test

• CHL is measured in
nano-farads and it will
give an indicator for
insulation problems .

• GST stands for Grounded Specimen

Test

• CH is measured in nano-
farads and it will give an
indicator for insulation
problems .
Tan Delta Test Values

See a picture for Tan delta equipment

Factory Test (IR & Tanδ) Results For
20MVA-33/11KV TR
 (3) PARTIAL DISCHARGE TEST(PD) :
• Partial Discharge(PD) is a localized dielectric
breakdown with a small portion in a solid or fluid
electrical insulation system under high voltage
stress, and this dielectric breakdown does not reach
the level to bridge the space between the
conductors to cause a fault.
• PD occurs in a gaseous, liquid or solid insulating
medium and it often starts within cracks, gas voids
such as voids in solid insulation or bubbles in
transformer oil.
• Corona is a form of PD that occurs in gaseous
media around conductor which are remote from
solid or liquid insulation .
See Video for PD test
 PARTIAL DISCHARGE TEST (PD) :
• PD can also occur along the surface of solid
insulating materials if the surface electric field
is high enough to cause the PD, and this
phenomenon happens on contaminated
insulators surface during days of high humidity.
• PD can erode solid insulation and eventually
lead to breakdown of insulation.
• PD within solid insulation system is not visible
and it dissipates energy in the form of heat,
sound and light,
• The localized heating from PD may cause
thermal degradation for the insulation.
 PARTIAL DISCHARGE TEST (PD) :
• When partial discharge is initiated high frequency
transient current pulses will appear and continue
for nanoseconds to microseconds then disappear
and reappear repeatedly as the voltage sine wave
goes through the zero crossing .
• Once PD begun, it causes progressive deterioration
of insulating materials ultimately leading to
electrical breakdown.
• The Partial Discharge is a modern test used in
early detecting insulation deteriorations problems,
and it is used in many electrical equipments like
transformers ,switchgear and cables etc….
See Picture for TR Under PD Test
 PARTIAL DISCHARGE TEST (PD) :
• Generally there are two ways for measuring the level
of PD :
(1) Electrical Method (off line method):
Here the equipment (transformer, cable, motor..etc)
is de-energized ,and we supply the voltage
gradually(about 1.8Ur) to see if there is PD started.
(2) Sound Method (On line method):
Here the tested equipment is in service and we put
special sensors on the surface of the equipment at
the place where we suspect the PD is existing, these
sensors send signals to electric analyzer for filtering
the noise emitted from the place of sensors.
See a Video for PD test
 CHAPTER(3)

HIGH VOLTAGE TEST

OR
HI-POT TEST
 HIGH VOLTAGE TEST
: What is the High Voltage Test
• It is an electrical test performed on a component
or product to determine the effectiveness of its
insulation by applying a voltage above the rated
voltage (either AC or DC according the
application) .
: When High Voltage Test is Done

(1) During Factory Acceptance Test for

equipments .
(2) During commissioning tests at the site .
(3) After equipment repairs or switchgear system
 HIGH VOLTAGE TEST
:Why High Voltage Test is Done
(1)To determine that the equipment insulation
system is in a proper condition to put in service
after installation.
(2)To be sure about the whole insulation status of
the equipment under test,checking insulation
dimension and insulation material quality.
• International standards show you the test
voltage values according to the equipment
rated voltage .
• Always High Voltage testers are single phase
and the test voltage can be AC or DC
 PICTURE SHOWS SINGLE PHASE AC HI-POT TESTER

CONTROL UNIT

HV SINGLE PHASE TRANSFORMER

 High Voltage Test Procedure
• The required test voltage shall be raised
gradually and maintained for one minute
between one phase and the other phases
connected to the ground, and then the test
voltage reduced slowly to zero .
• Test shall be repeated for other phases as
mentioned above and leakage current shall be
recorded during each test.
• The test passed if there is no interruption in the
HV tester till the one minute finished .
• HV test is done for transformers inside factories
and it is called Separate Source Withstand
Voltage Test .
Some High Voltage AC Test Values as Per IEC 60076-3 Table (2) Page(15)
 HIGH VOLTAGE TEST
.

• The table below shows that HV test at field

during commissioning is reduced to 80%
compared to the first testing value at the
factory .
 HIGH VOLTAGE TEST
• HiPOT test is a short name of high potential test,
and it is also known as high voltage test or
dielectric withstand test.
• The HiPOT test is a nondestructive test that
determines the adequacy of electric insulation for
the normally occurring over voltage transients.
• HiPOT test is done for transformers just at FAT
and not during commissioning, while it is done
for switchgear at FAT and SAT because we do
assembling for switchgear cells at site so we have
to check our site assembling if a minor problems
 HIGH VOLTAGE TEST
• HiPOT test is helpful in detecting the following :
(1) Nicked or crushed insulation.
(2) Stray wire strands.
(3) Conductive or corrosive contaminants around the
conductors.
(4) Terminal spacing problem.
(5) Inadequate creepage and clearance distances
introduced during the manufacturing process.
• High voltage test can done using AC or DC according
to application, and normally switchgear and
transformers are tested by AC while cables are
tested by DC .
 AC & DC High Voltage Test
• The majority of standards allow to use either AC or
DC voltage for a HiPOT test and when using AC the
insulation under test is being stressed most when
the voltage is at its peak either at the positive or
negative peak of the sine waves.
• Therefore, if we use DC test voltage we ensure
that the DC test voltage is under √2 or (1.414
times the AC test voltage) so the value of the DC
voltage is equal to the AC voltage peak.
• For example for 1500V-AC , the equivalent DC
voltage to produce the same amount of stress on
the insulation would be (1500*1.414) or
 LEAKAGE CURRENT DURING HIPOT TEST
• Most modern HiPOT testers allow the
user to set the leakage current limit.
• The best way to identify the leakage
current trip level is to test some product
samples and establish an average for the
leakage current.
• The leakage current trip level should be
set high enough to avoid nuisance failure
related to leakage current and at same
time low enough not to overlook a true
break down in the insulation.
 HIGH VOLTAGE TEST
Let us discuss high Voltage Test Procedures for
: different electrical power equipments

 Switchgear includes panel enclosure, bus bars,

CTs, VTs and circuit breakers.
 Switchgear high voltage test is done for the first
time inside the factory and must be done for
the next time after assembling in site(reducing
voltage to 80%) .
 VTs and surge arrestors must be isolated
before switchgear high voltage testing .
High Voltage Test For MV & HV Switchgear(GIS)

HV Unit
Control Unit
SWITCHGEAR HIGH VOLTAGE TEST
• Before starting switchgear HV test, precautions
should be taken:
1. A visual inspection will be made to ensure dust
and moisture on the surface has been removed
from the component under test.
2. Ensure the component under test is isolated from
other connected system which may feed back to
the other components or circuits not under test.
3. VTs and surge arrestors shall be isolated from
the equipment under test.
4. Insulation resistance test should be performed
before and after HV test.
See wrong Switchgear HV connection See pictures of Surge Arrestor
SWITCHGEAR HIGH VOLTAGE TEST
 There will be no flashover or discharge
during switchgear high voltage test and
corona discharge noise may be heard.
 For old switchgear the test voltage shall be
reduced according to the age .
 The normal leakage current will be in the
MICRO AMPER range(ɥA) .
 Practically For one switchgear cell the
leakage current will be about 5 to 8 micro
amper .
See a video of HV test at a factory
See Picture of Test Holes
 HIGH VOLTAGE TEST
2- Power Cables:
• High voltage DC test is used mainly to do
pressure test on power cables, although the
cables operate with AC.
• AC testing is not practical in cables because
The high capacitance of the cables
necessitates AC test sets with a high KVA
rating to be able to supply the
capacitive current. In the case of DC, once the
cable is charged, only the insulation losses
have to be supplied.
 POWER CABLE HIGH VOLTAGE TEST
• Following precautions should be made before starting
HV test for cables;
1. Cable under test should be clean and free of dust
especially at the insulators.
2. Shields of all cables should be grounded and tied
together at the near end of the cable and at far end
bare conductor should be taped with some insulation.
3. Cable under test should be disconnected at both
ends, this will assure that the cable under test will not
feed back to circuits/components not under test.
4. instructions of testing equipment being used should
be followed .
 POWER CABLE HIGH VOLTAGE TEST
:Cables High Voltage DC Test Procedures
 DC voltage shall be raised slowly up to 4*U˳(Rated
voltage between conductor and earth or metallic
screen)and maintained for 15 minutes between one
phase and earth while the other two phases and the
metallic screen connected to earth .
 After elapse of test time voltage shall be reduced
slowly to zero and the cable shall be discharged.
 Test shall be repeated for other phases and there
will be no flashover or discharge during test.
 Acceptance Limits that during the test no flashover
or disruptive discharge happened .
 POWER CABLE HIGH VOLTAGE DC TEST
• Table below shows the cable high voltage DC
test values as in the IEC specifications :
 POWER CABLE HIGH VOLTAGE TEST
Cables High Voltage AC Test:
 As in the IEC the cable AC VOLTAGE TEST can be
done as in (a) or (b) below;
a. Test for 5 minutes with phase-to-phase voltage of
the system (U) applied between the conductor and
the metallic screen.
b. Test for 24 hours with the normal operating voltage
(U) of the system.
: NOTE
Normally cables have three voltages U˳/U/Um where
U˳= rated phase to (earth/screen) voltage
U = rated phase-to-phase voltage(Operating Voltage)
Um = rated maximum phase to phase voltage
 HIGH VOLTAGE TEST
Factory AC Test Voltage Value will be according to the
specifications .
AC test Voltage value before commissioning =
0.8 × Factory AC test value
AC test voltage value in maintenance =
0.6 × Factory AC test value
* Sometimes the high voltage test is used as
troubleshooting test for detecting marginal insulation
problems in the electrical equipments like
transformers ,cables etc …..
 Famous Insulation Tests
Objectives Test
(1)Measures the insulation resistance in MΩ or GΩ. Megger
(2)Use DC test voltage less than the rated voltage of the
equipment under test(Megger not affect the life time) .
(1)Explain general status of an insulation . Tan delta
(2)Use AC test voltage less than the rated voltage of the
equipment under test(Tan delta not affect life time) .
(3)More accurate than Megger but the set is heavy and
more expensive than Megger set .

Test the insulation by checking the existence of PD)1( Partial

.phenomenon Discharge
. Use AC voltage raised gradually till about (1.8Ur))2(
.Detects minor problems in insulation systems)1( High
Use AC/DC voltage higher than tested equipment rated)2( Voltage
voltage according to specification tables(affect life time)
 Comparison Between Famous Insulation Tests
High Voltage
Test Partial Tan Delta Megger
Discharge Factors
AC or DC AC AC DC Test Voltage
affect Not affect Not affect Equipment Life
Affect a little
Time
Expensive Very Expensive Expensive Cheap Set Price

Very Heavy Heavy Heavy Light Set Weight

Not Sometimes Done Done Is it Done in
Done(affects Done to predict Periodic
the life time) insulation ? Maintenance
problems
Routine According to Routine Routine Test Category
)for 1 time( application
 CHAPTER(4)
TESTING
of
TRANSFORMERS
 Introduction For Transformer Testing
Brief Information about Transformer
Construction
• Before starting transformer testing in details
it is important to explain the internal parts of
the transformers and its physical place inside
the transformer tank .
• The pictures on the next slides shows an
important details inside transformer tank
that can help you well understanding
transformer testing . See Some Pictures for Transformers
See Video for TR Construction with OLTC
 Classification Of Transformer tests
Method (1) :-
We can divide transformer tests with regards to the time
of doing it to:
1- Periodic tests:
• It is important for early detecting faults, like the test of
insulation resistance, and if the value of the insulation
resistance is degraded, this may be an indicator for
beginning of some problems inside the transformer.
2- Tests for trying to analysis a problem happened :
• For example if the transformer windings temperature is
high although the fans are well doing ,we can do the
winding resistance tests or the oil analysis tests to look
up for the reason of rising the transformer temperature .
 Classification Transformer tests
3- Tests for measuring transformer parameters:
• These parameters are ratio, impedance, Vector
group,etc...
• Tests for measuring TR parameters are done in
FAT and SAT .
• In case of need to parallel two transformers
together some tests for measuring parameters are
required to be sure about right parallel condition .
•Transformer parameters tests are very important
when troubleshooting a problem inside the
transformer .
 Classification of Transformer tests
Method (2) :
• In addition to the way of doing the tests,
the specifications determined for us the
sequence which the tests must be done :
a. TESTS BEFORE TANKING:
1. Preliminary ratio test, vector group and
windings resistance.
2. Core insulation tests.
3. Ratio and polarity tests for bushing
current transformers if fitted.
 Classification of Transformer tests
b. TESTS AFTER TANKING (FINAL TESTS):
1. Final ratio and winding resistance.
2. Insulation capacitance and dissipation
factor (tan delta test).
3. Insulation resistance (Megger Test).
4. Control-wiring checking(for large
transformers).
5. Other routine tests (in the witness of the
customer or his representative).
 Classification of Transformer tests
C. TESTS BEFORE SHIPMENT:
1. Core to ground Megger test :
• This test is done to be sure about the
good fixing of the core before shipment of
a transformer , because the TR exposes
to moving and handling with cranes and
vehicles during travelling from a factory to
its destination and an internal core
problem may happen.
2. Insulation resistance (Megger Test).
 Classification Of Transformer Tests
Method(3):
Also we can divide transformer tests as below:
1- Routine tests :
 The IEC definition of routine test is a test to
which each individual transformer is subjected.
 These tests are necessary to be performed on
all transformers and can divided to dielectric
tests and parameters calculation tests .
 Some example of these tests are insulation
resistance test, oil tests, separate source test,
winding resistance test etc….
 Classifications Of Transformer Tests
2- Type tests :
• The IEC definition of type test is a test made on a
transformer which is representative of other
transformers, to demonstrate that these transformers
comply with the specified requirements not covered by
routine tests .
• Transformer type tests are :
(1) temperature rise test. (2) impulse tests .
3- Special tests :
• The IEC definition of a special test is a test other than
a type test or a routine test agreed by the manufacturer
and the purchaser .
• Example for special tests are measurement of noise
 Classifications Of Transformer tests

• Type tests and special tests are carried out

on the specific requirement of customer. In
case, these tests have already been carried
out in the past on a transformer and the
available tests certificates are not older than
5 years, the buyer may not insist in repetition
of such tests .
• On the next slide you find a diagram
illustrates distribution transformers test
classifications as in method(3).
Method(3) for classifications Of TR tests
IEC 60076-3 Table (1)

See Old Table

 Classification of Transformer Tests
• Transformers tests classifications :
1. Dielectric Tests group. (Routine Tests)
(Megger Test – tanᵟ Test - Partial Discharge)
2. Withstand Voltage Tests group. (Routine Tests)
(Induced Voltage - Separate Source Withstand Voltage)
3. Transformer Oil Tests group. (Routine Tests)
(Dielectric Strength - Dissolved Gas Analysis - Rate of Humidity
in the Oil - Power factor (tan) - Oil Acidity )
4. Transformer Type Tests group. (Impulse test - Temperature
Rise Test)
5. Transformer Parameters Calculations Tests group.(Routine
Tests)
(Turn Ratio - Winding Resistance - Open Circuit - Short Circuit –
Vector Group )
6. Transformer Special tests
1- Transformer Dielectric Tests
group(Routine Tests)

(1) Megger Test

(2) Dielectric Loss Angle (tan)
(3) Partial Discharge Tests(PD)
 1- Dielectric Tests group(Routine Test)

Megger Test, Dielectric Loss Angle (tan) Partial

Discharge Tests(PD)
 We do the dielectric tests to check the
insulation which is very important in
transformer theory, and we immediately lose
the transformer when there is an insulation
problem.
 60% of transformer failure caused by
weakness in the insulation, and with the
absence of the periodical insulation test
there will be a problem that may lead to lose
the transformer itself.
 Dielectric Tests group
A- MEGGER TEST FOR TRANSFORMERS: -
 This test is called Megger Test because it is
done by the Megger device.
 The Megger gives DC Volt from 500V till
1000V for the low voltage equipment's, and
from 2500V till 15000V for high voltage
equipments.
 The expected insulation resistance depends
directly on the equipment life time, and
practically it will be in the GΩ range, in new
transformers IR value may reach (30GΩ).
Connections Of TR Under IR Test
HV to LV HV to E a
• A• a A

B b
• B• b
C c
• C• c n
• n

A a

B b

C c
n

LV to E
 Dielectric Tests group

Steps of Meggering a Transformer :

1. Put the transformer to be tested out of service
and earth the tank.
2. Discharge any electrostatic in the transformer
by a discharging rod or by using a Megger
equipped with automatic discharge.
3. Make a short in the terminals of high and low
voltage independently without earthing and
start to measure the insulation resistance
between:
HV and LV , HV and E , LV and E.
 Absorption Factor & Polarization Index
• First we do the test for 15 second and get
the value (R15) , after that we do the test for
60 seconds and register (R60),finally we get
what is called the ABSORPSION FACTOR
by this formula: R60/R15.
• Another test is done for 1 minute and get the
value (R1) , after that we do the test for 10
minutes and register (R10),finally we get
what is called the POLARIZATION INDEX by
this formula: R10/R1
Absorption factor Polarization Index

15 Second 60 Second 10 Minute

 Dielectric Tests group
B- Dielectric Loss Angle/Dissipation factor/
(tanᵟ):
Connection diagram of the transformer under
this test looks like the connection of the
Megger test (HV/LV - HV/LV.E - LV/HV.E) .
UST mode in tan delta tester means
Ungrounded Specimen Test and it looks like
the position (HV/LV) in megger test .
GST mode in tan delta tester means
Grounded Specimen Test and it looks like the
positions (HV/LV.E) & (LV/HV.E) .
 Dielectric Loss Angle/Dissipation factor/ (tanᵟ)

• This test is done by special instrument

as you see on the pictures attached and
this instrument measures the value and
the angle of the currents that follow
through the insulation during the test.
• Tan delta tester also measures a
capacitance value (C) in the range of
PICO FARAD or NANO FARAD
according to TR size, which also can
give an indication of insulation state .
Tan Delta Test Values
 Dielectric Tests group
C- Partial Discharge Tests: -
A partial discharge (PD) is an electric discharge that
partially bridges the insulation between conductors or
through solid insulator surface .
When there is an insulation problem inside a TR , a
discharge may happen at that area accompanied by
emission of sound, heat and chemical reactions .
 PD will diagnose insulation faults before they happen
and help us to take appropriate decision at right time.
The main reasons for the PD in TRs are :
1. Moisture in the liquid insulation.
2. Cavity in the hard insulation because of
manufacturing problems.
 TR Partial Discharge Test
The PD sometimes happens in the oil and there
will be hydrogen dissolved in the oil, in this case
it is very difficult to discover the PD in the oil by
oil test because the sample maybe took from a
place which there is no PD .

The above problem is solved by analysis of the

gas collecting inside the buchholz-relay chamber
and this can give an indication of PD in the oil.
 TR Partial Discharge Test
There are two ways for measuring the level of the
PD, the electric method and the sound method :
(a) electric method (off line method):
 We increase the voltage across the tested
transformer gradually till the rated value and see if
the PD starts to happen; we call the value of the
voltage in which the PD starts the inception
voltage and of course we know it by the increase
in the value of the leakage current on the testing
equipment.
 After that we start degrading the voltage until the
PD stops and we call this point the extinction
voltage .
 TR Partial Discharge Test
 Now if the value of the extinction voltage
is low than the operating voltage, this
means that the PD will not stop when we
supply the transformer with its normal
voltage and of course our tested
transformer is facing a real danger.
 If the value of the extinction voltage is
higher than the operating voltage, this
mean that the existing PD is not
dangerous now but in the future may
causeSee aproblem.
picture for a transformer under PD test(off line method)
 TR Partial Discharge Test
(b) Using sound method (On Line Method):
• In this way the tested transformer is in service
and just we put special sensors in the surface of
the transformer at the place where we suspect
the PD is existing, these sensors send signals to
electric analyzer to make filtering for the noise
comes from the place of the sensor to determine
the PD.
• Waveforms are captured from the sensors with
the testing unit and a software is used to
examine the waveform shapes.
See a Picture for a TR under PD test by a sound method(on line method)
2- Transformer Withstand Voltage
Tests group(Routine Tests)

(1) Induced Voltage Test

(Double Voltage Double Frequency Test)

(2) Separate Source Withstand Voltage Test

(Transformer High Voltage Test)
 What is The Transformer Winding Uniform and Non-uniform
Insulation?

• Uniform Insulation of a Transformer Winding :

* It is the insulation of a transformer winding
when all its ends are connected to terminals have
the same rated insulation level.
• Non-uniform Insulation of a Transformer
Winding(Graded Insulation):
* It is the insulation of a transformer winding
when it has a neutral terminal end for direct or
indirect connection to earth and is designed with
a lower insulation level than assigned for the line
terminal. See Picture of HV TR Windings
Comparison Between TR Separate Source Withstand Voltage
Test and Induced Voltage Test
Separate Source Withstand Test For each Winding (1Minute)

Induced Voltage Test

(Double Voltage Double Frequency)
 Withstand Voltage Tests group
(1)Separate Source Withstand Voltage Test or
Applied Voltage(AV):
This test looks like the High Voltage test of
switchgear and cables .
Shorting terminals is made in primary and
secondary to do the test as follow :
1- apply the single High Voltage to the shorted
primary while the secondary winding is shorted
together and connected to earth .
2- apply the single High Voltage to the shorted
secondary while the primary windings are
shorted together and connected to earth .
 Separate Source Withstand Voltage Test

Testing the HV side

One Minute

*The non-testing side must be

connected to the earth .

Testing the LV side

One Minute
 Separate Source Withstand Voltage
Test Values as Per IEC tables
Test Voltage (KV) Transformer Voltage )KV(
Range

3 Any Voltage <= 1.1KV

10 3.6
28 12
50 24
70 36
140 72.5
• Voltage is raised with a frequency similar to the
rated frequency of the equipment under test .
 Withstand Voltage Tests group
(2)Induced voltage test(Double Voltage
Double Frequency Test):
The main purpose of this test is to be sure about
the quality of the insulation both between phases
and between turns of the windings .
Induced voltage test is a factory routine test
normally done inside factories and not in
commissioning at sites.
Induced voltage test is more important than the
separate source withstand test, because it takes
in to account the insulation between the phases.
 Induced voltage test(Double Voltage
Double Frequency)
 Induced voltage test is a hard test for
transformer insulation but it is useful because
the double voltage and double frequency
checks the insulation between the windings
layers by discovering the air gap between
these layers .
 We use high frequency in this test to :
(1) Prevent the core from saturation due to
doubling the test voltage .
(2) Discover air gaps and weak insulation
 Induced voltage test(Double Voltage
Double Frequency)
• The frequency of the transformer induced
test must be at least twice the rated
frequency of the transformer under test,
and this depend on the generator used in
the testing LAB because some generators
have frequency of 150Hz,200Hz,248Hz .
• Time of doing the induced voltage test is
calculated from the formula :
 Induced Voltage Test
• Induced voltage test is done by two ways :
(1)Short Duration Induced Voltage Test(ACSD)
a) Uniform Insulated Windings :
*This test is done by applying a 3ɸ symmetrical
voltage to low voltage side while the high voltage
side is opened .
* Normally the test voltage is twice the rated
voltage .
* As per IEC 60076 part3 the induced voltage test
for Um > 72.5 KV is normally performed with
partial discharge measurements to verify PD free
operation of the TR under operating conditions.
Induced Voltage Test For a Transformer
With Uniform Insulation Windings

• We either supply the LV or HV side ,but

practically LV side is supplied while opening the
HV .
• For non uniform insulation winding this test is
done per phase .
 Induced Voltage Test
b) Non-Uniform Insulated Windings :
* In the case of non-uniform insulation the level of
insulation is different along the winding ,so we
should not apply double voltage directly to the
winding because the insulation will be
stressed .
* This test is done by applying the test voltage to
the phase terminals as single phase and it is
repeated for each phase as explained on the
next slides.
* The values U1 and U2 are given in IEC tables
(attached) for each value of Um.
 Induced Voltage Test
(2)Long Duration Induced Voltage Test (ACLD):
• This test is done for uniform and non-uniform
insulated transformers according to standards
tables design .
• It is applied either single phase or three phase
according to insulation type (uniform or non-
uniform) .
• ACLD is not a design proving test, but a quality
control test intended to cover temporary over
voltages and continuous service stresses.
• ACLD always done with Partial Discharge
measurements .
 Induced Voltage Test With PD

ACSD with PD ACLD with PD

TR with Um > 72.5 KV TR with Um > 72.5 KV
 Induced Voltage Test Result (ACSD) For 20MVA-
33/11KV-50Hz Transformer With Uniform Insulation
IEC 60076-3 Table (1)

See Old Table

IEC 60076-3 Table (D1)
IEC 60076-3 Table (D2)
 3- Transformer Oil Tests group.

(1) Dielectric Strength Test.

(2) Dissolved Gas Analysis(DGA).
(3) Rate of Humidity in the Oil.
(4) Power factor (tan) Test.
(5) TR Oil Acidity Test.
(6) Oil Flash Point Test
 MAIN FUNCTIONS OF OIL IN TR
• Below is the main functions of oil in transformers
(1) Acts as insulation between phases and
between phases-to-ground.
(2) Coolant medium to transfer heat from the coils
to the radiators or surface of a transformer.
(3) Arc quenching medium and hence oil used in
circuit breakers for same purpose
(nowadays becoming obsolete for this purpose in
CB for safety reasons)
 NEED FOR TR OIL TESTING
• Why we need TR oil testing ?
(1)Oxidation happens due to high operating
temperature and faults, causing sludge which
affects oil properties .
(2) Normal deterioration of oil dielectric properties
due to age .
(3) Purifications decreases oil property of cooling,
and transformer life time depends on operating
temperature (every 10ºC rise over maximum
permitted temperature reduces the life by half)
(4) Necessary to avoid transformer failure .
Taking Transformer Oil Sample
 Transformer Oil Tests group
:Oil Dielectric Strength Test(Break Down Voltage) -1
 An oil sample is taken and checked in the oil test
device shown on picture, voltage is increased
gradually (2-5KV/SECOND) till the spark appears
inside the oil sample, we do the test about 5 times
and take the average value.
 These are the latest values that we say the oil is
good or not ;
Not less than 20KV/2.5mm for the voltage level 11KV.
Not less than 25KV/2.5mm for the voltage level 35KV.
Notless than 35KV/2.5mm for the voltage level 220KV.
Notless than 45KV/2.5mm for the voltage level 500KV.
See Pictures for TR oil Tester See a Video for TR oil Tester
 Transformer Oil Tests group
2- Dissolved Gas Analysis (DGA):
 DGA test mainly done to know the
general status of the transformer oil .
 In addition to above this test early
discovers many problems happen inside
the transformer tank and affects the
chemical properties of the oil, for
example, existence of internal spark,
existence of bad contact or hot spot,
existence of partial discharge(PD).
 This test is done in special chemical
laboratories.
 Dissolved Gas Analysis (DGA)

 The international standards advice you

to make analysis for the dissolved gas in
the transformer oil before the first
operation and takes the results which is
called(Benchmark) as a reference for
comparing results in the future analysis .
 On the next slide a table shows the
probable reasons for presence of every
gas in the DGA test.
The Table Below Shows The Probable Reasons For Presence of Every Gas in The (DGA) Test :
 Transformer Oil Tests group
3-Rate of Humidity in the Oil(Water Content):
 This test is very important because an existence of
2000 ppm (part per million) of oxygen dissolved in
oil is enough to damage the transformer.
 The acceptable values of this test are as below;
(1) an existence of humid 35 ppm at 60˚C in the
transformer of voltage above 66KV is acceptable.
(2) an existence of humid 12 ppm at 60˚C in the
transformer of voltage above 220KV is acceptable.

See Picture for water content Tester

 Transformer Oil Tests group
4/ TR Oil Power factor / tan  test :
Measures the oil insulation characteristics and
normally done for bigger size transformers.
 A power factor value of 0.5% is considered
unacceptable for bigger transformers at high
voltages and a value of around 1% is still
accepted for smaller transformers.
 Transformer Oil Tests group
(5) TR Oil Acidity Test(Acid Number Test) :
Acids formed during oxidation of the oil due
to humidity and affects the following:
(1)The oil’s dielectric properties .
(2)The circulation of the oil inside the
transformer tank.
Acids deteriorates cellulose paper used in
the insulation.
0.03 to 0.05 is an acceptable values of
acidity test , but values beyond 0.10 is
unacceptable .
 Transformer Oil Tests group
(6) Oil Flash Point Test :
The oil flash point is the minimum
temperature at which heated oil gives off
sufficient vapor to form a flammable
mixture with air.
 If the transformer oil flash point has
decreased and a heavy fault happened
inside the transformer, a fire will break
out and damage all the transformer
components .
 * TR OIL FILTRATION *
- Transformer oil filtration process must
be at least once every two years in dry
places .
- Every year before annual maintenance
program starts, an oil test must be done
to decide which transformer need oil
filtration .
- Sometimes oil filtration may be
required after prolonged idle time or
prolonged use at higher load.
 OIL FILTRATION UNIT
- There are two types of TR oil filtration units :
(1) On load filters.
(2) Off load filters.
- Mainly TR oil filtration units consists of :
(1) Inlet pump.
(2) Hard Filter.
(3) Heat exchanges .
(4) Edge filter/Fine filter.
(5) Outlet pump .
(6) Vacuum pump.
See Pictures of TR Oil Filter
 OIL FILTRATION UNITS

 High vacuum in the filtration units for

extracting water present in the form of
vapors (then condensed) .
 Some types of filters contains a column
of activated Alumina (for correction of
acidity) .
 On load filters need more supervision
against oil leakage during filtration,
because the transformer is in service .
4-Transformers Type Tests
(1)Impulse Voltage test.
(2)Temperature Rise Test.
 (1)Transformer Impulse voltage test
Transformers impulse tests divided to: (1)
lightning impulse test
*simulates the travelling waves that may hit the
transformers during thunder and lightning storms.

(2) Switching impulse test

*simulates the transient waves that appears in the
network due to normal switching of circuit
breakers, capacitors and reactors.
The voltage impulse test device is called
IMPULSE GENERATOR consists of capacitors
charged from
See low voltage
Picture supply.
For Impulse Generator
IEC 60076-3 Table (1) Edition 3.0/ 2013-07

See Old Table

 Lightning & Switching Impulse Waveform

Impulse Wave Switching Wave

T1 range between 1.56ɥS and 0.84ɥS

T2 range between 60ɥS and 40ɥS
 Full Lightning Impulse Wave(220KV Side)
(220/33/11KV ) (YNyn0d11) Transformer

As per IEC 60076-3

table2 lightning
impulse test voltage
for 220KV side is
1050KV , so the
accepted voltage limit
is (1050KV±3%)

T1 (From 0.84ɥS to 1.56ɥS)

T2 (From 40ɥS to 60ɥS)
 Transformer Lightning Impulse Test Connection
(220/33KV) (YNd11)
id e
V S
K
220
Rm Rm

R Y B N R Y B N

R Y B R Y B

Testing R Phase Testing Y Phase

Rm Rm

R Y B N R Y B N

R Y B R Y B

Testing B Phase Testing Neutral

 Transformer Lightning Impulse Test Connection
(220/33KV) (YNd11)
Side
V
33K

R Y B N R Y B N

R Y B R Y B

Rm Rm

Testing R Phase Testing Y Phase

R Y B N
Impulse Generator
(Lightning & Switching)
R Y B

Rm
Testing B Phase
 Transformer Switching Impulse Test Connection
(220/33KV) (YNd11)
id e
V S
K
220
Rm Rm

R Y B N R Y B N

R Y B R Y B

R R

Rm

R Y B N Impulse Generator
(Lightning & Switching)

R Y B

R
(LI) (SI) Test Values as Per IEC 60076-3 Table (2) Page(15)
Insulation level As in Nameplate Of 20MVA-
33/11KV-50Hz TR
 (2) Temperature Rise Test
• If the transformer is well designed, it must
operate with its full rated power without any
significant temperature increase.
• Temperature rise test is done to be sure about
the cooling system design of the transformer.
• In this test we load the transformer with its full
rated power and measure the temperature
every hour till we find that the top oil
temperature rise does not vary more than 1˚C
per hour during four consecutive hourly
readings.
 Temperature Rise Test
• Depending on the choice of the manufacturer
loading is achieved by :
(1)Direct Loading Method: connect the transformer
under test to a suitable load such that rated
currents flow in both windings.
(2)Short Circuit Method: this method is commonly
employed by most of the manufacturers, and
here we just do the short circuit test with the
rated current to obtain the full load copper losses
and hence over load the transformer to add the
no load losses to the transformer under test.
5- Transformer Parameters
Calculations Tests.
(1)Transformer Turn Ratio (TTR)
(2)Winding Resistance Test
(3)Open Circuit Test(no load loss)
(4)Short Circuit Test(load loss)
(5)Polarity and Vector Group Test
 Transformer Parameters Calculations Tests
1- Transformer Turn Ratio Test (TTR):
• Below is a transformer general formula :
N1 = V1 = I2 N2 = V2 = I1
or
N2 V2 I1 N1 V1 I2
• We change the transformer ratio to regulate
the output voltage using tap changer device.
• Tap changer is located in the high voltage
winding of a transformer whether it is a
primary or a secondary.
• When moving tap changer we change N1 or
N2
See TR according
nameplates See Offto
loadthe tapped
Tap changer winding.
Design See Off load Tap operation
 Transformer Turn Ratio Test(TTR)
• TTR test can be done by two ways as below :
(1) At one time for the three phases together
(3ɸ TTR).
(2) For each separate phase (1ɸ TTR) .
• From the formula we can use
either the voltage or the current for TTR
testing, and practically voltage is used.
• We supply voltage at one side of a
transformer and measure the output
voltage then calculate the ratio V1/V2 .
See On load Tap changer Operation1 See On load Tap changer Operation2
 3 Phase TTR Test
• This test is done by connecting one side of
the tested transformer (always the high
voltage side) to a small voltage and measure
the voltage at the other side to give the ratio
at each TAP.
• For example a TTR test can done to a
(11KV/433V) transformer by applying 415V
to the 11KV side and measure the output
voltage at the 433V side as shown on the
next slide .
 TTR Test for(11KV/433V) Transformer
TR Under Test NO MV LV
A a 1 11550 433V
2 11275 433V
3ɸ 415V B b L-L = 16.338V 3 11000 433V
L-L L-N = 9.44V 4 10725 433V
C c 5 10450 433V
1
5 2 n
4 3

* Calculated 3ɸ Ratio at Tap 3 = V1/V2 = 11000/433 = 25.4

* Supplying 3ɸ 415V L-L to 11KV Side induces 16.33V L-L in
the LV Side (If the ratio of the transformer is good)

11000V 433V
X = 433*415/11000 = 16.338 V
415V X
 3 Phase TTR Test
• In the above case it is preferable to apply the test
voltage at the HV side to be sure that the output
voltage at the other side will not exceed the
measurable values .
• This method is easy to check transformer ratio
when we have no modern ratio tester and it just
need 3ɸ supply and AVOMETER .
• We measure line to line and line to neutral values
and see if it is balance and same as the declared
ratio on the name plate .
• 3ɸ and 1ɸ TTR tests can be done using modern sets
that can help us printing reports
 Transformer (TTR) modern Tester
 Now there is a modern computerized set to
do TTR test, it has six terminals and each
three terminals go to one side of the tested
transformer, the set injects voltage in one side
and measure the output voltage to give the
ratio of the transformer in each tap and the
error.
 This set measures
the vector group also .
3ɸ TTR Test Connection Using a TTR Tester
TR Under Test
A a

B b

C c

TTR Tester
 Transformer TTR Test Using Modern Set
• For example if you choose to do a TTR test for a
transformer (110KV±8*1.25/10.5KV) connected
YNd11 using the Chinese set (JYT-A) that shown in
the previous slide, 4 steps are done
(1) Connect the set wires as below :
 Transformer TTR Test Using Modern Set

(2) Start up the set and choose the option (Three-

phase testing) as below:
 Transformer TTR Test Using Modern Set
(3) Using the set keypad insert the calculated ratio,
total number of taps, load pitch and the HV
combines using the terms
(110KV±8*1.25/10.5KV)(YNd11) as below:
Rated ratio = 110KV/10.5KV = 10.476
 Transformer TTR Test Using Modern Set

(4) Start the test and after 7 seconds the results

will display on the screen ( ratio + ratio error +
excitation current) ,also the set shows the vector
group and the recent tap position to help in taking
a right decision that the tested transformer is ok.
 1 Phase TTR Test
• In 1ɸ TTR we test every phase alone by
connecting 1ɸ supply to one side and
measure the voltage at the other side as on
the next slide.
• 1ɸ TTR test can be done after 3ɸ TTR test is
failed, to know how many and which coils
are faulty inside the transformer under test.
• When doing 1ɸ TTR test For 11/0.433KV
transformer with a vector group Dyn11 the
measured 1ɸ ratio will be 11000/(433/1.73)
= 43.95
 1 Phase TTR Test Connection

Testing Phase 1 Testing Phase 2

Testing Phase 3 Helping Diagram

 1 Phase Ratio Calculation
VL VL
1ɸ Ratio = (VL /√3) / (VL /√3)
= VL / VL

VL VL 1ɸ Ratio = VL / VL

VL
VL
1ɸ Ratio = VL / (VL /√3)
 Transformer turn ratio test (TTR)
- TTR test is done:
(1) In the FAT and commissioning tests to ensure that
the ratio at each tap of the tested transformer is
typical to the name plate fixed in the transformer
tank.
(2)When we need to parallel two transformers
together.
(3) At the Transformer Maintenance Workshops and it
is done two times:
(A) To be sure that the transformer has an internal
fault before opening the tank, because the
procedure of opening the tank takes a lot of time
and effort.
 Transformer turn ratio test (TTR)
(B) After the faulted transformer has repaired, the
ratio test is done as a one of the known tests that
done to release a test certificate for the transformer
before leaving the workshop.

 As per (IEC 60076-1) Page 57 tolerance for the

TTR test is ±0.5% of the declared value of the
ratio.
 TTR test error =
measured turn ratio - expected turn ratio *100
expected turn ratio
TTR Test Sheet For 20MVA-33/11KV TR
 Transformer Parameters Calculations Tests
2-Transformer Winding DC Resistance:
- In this test we measure the resistance for
each winding per OHM and see if it is the
same as in the transformer FAT sheets.
- Just we connect DC supply to the tested
winding and measure the resistance using
ohm law (R=V/I ).
- This test is very useful to determine if there
is a loose connection, for example around
the TAP or in the bushings, because bad
connection makes high contact resistance.
TR Winding Resistance Test Connection
 Transformer Windings DC Resistance
 For more accurate test values the winding
resistance tester uses two pairs of test
wires, one to supply the test current and the
other to measure directly the voltage applied
to the tested transformer .
DC Winding Resistance Test Sheet(20MVA-33/11KV)TR
 Transformer Windings DC Resistance
 This test also shows whether the windings
joints are in order and the windings are
correctly connected, so transformer winding
resistance test is done in defect analysis and
in identification and tests before maintenance
to detect internal faults .
 The TR winding resistance test can be done
by any sensitive OHMMETER , but recently
there is a modern instrument to do the test
accurately as in the picture on the next slide .
See Picture For TR Winding Resistance
 Transformer Windings DC Resistance
 The measuring current value should be high
enough to obtain a correct and precise
measurement, and small enough not to change the
winding temperature .
 In practice the value of measuring current should be
larger than 1.2*I˳ and smaller than 0.1*IN where :
I˳ = no load current .
IN = rated current .
 So the AVOMETER can not give accurate values
because the current is not enough, but we can use
it as indication for problem existence .
 Transformer Windings DC Resistance

 When transformer winding resistance test is

done ?
(1) Factory test .
(2) Installation / commissioning .
(3) Routine (Scheduled) transformer
maintenance .
(4) Unscheduled maintenance and
Troubleshooting .
(5) Internal transformer inspections .
 Transformer Windings DC Resistance

 What are the famous faults

that to be identified by
winding resistance test ?

(1) poor connections .

(2) short turns .
(3) open turns .
(4) defective tap changers .
• Operation Curve for 200KVA 11/0.433KV
Transformer with: no load losses = 500 W
Load losses = 3000 W
Losses

3000W Load
Losses

No Load
500W Losses

1 3 4 6 7 Hours
 No Load Losses Test (Open Circuit)

A a A a
Supplying the Supplying the
Vrated Vrated
B b B b
To get true To get true
losses losses
C c C c
n n

Load Losses Test (Short Circuit)

A a A a
Supplying
B b B b Supplying
Vsc
Vsc
C c C c
Vsc = Vrated*Z% n n Vsc = Vrated*Z%
Transformer Parameters Calculations Tests
3/ Open Circuit Test (No Load Losses Test):
• In this test we connect one side of the transformer
to a supply with its rated voltage value and let the
other side open as shown on the next slide.
• The Wattmeter measures the no load losses or
(core losses) ,while the ammeter measures the no
load current (I˳) .
• No load losses has a direct relationship with
(1)Iron Core material .
(2)Iron Core construction .
Open Circuit Test (No Load Losses Test)
We can supply either the high side or the low side with Vrated

A a A W

B b A W V
V
C c A W

No load No load Rated

Current Losses Voltage

See Real Picture for TR Under Open Circuit Test

See Diagram for TR Under Open Circuit Test
 No load losses & No load current
• The no load losses and no load current in details are as
following:
No load losses

iron losses(core losses) CU loss in primary

Hysteresis loss eddy current loss

----------------------------------------------------------------------------------------
No load current (I0)

Active or working or magnetizing component(Iɥ)

iron loss component(Iw)

Supplies the iron losses + Supplies the alternating

small quantity of CU loss flux in the core
 Transformer Equivalent Circuit
• Below is a diagram for the equivalent circuit
of the transformer :
 Transformer Open Circuit Test
 Normally LV side is supplied and the high voltage
side is let open because the low voltage supply is
easy and available, for example if the tested
transformer is 11KV/415V, we find that it is easy to
prepare 415V supply than prepare 11KV supply for
testing.
This test helps to find the value of the no load
losses because I˳ is very small due to CU losses is
negligibly small in primary and nil in secondary(it
being opened).
The no load losses or (core losses) are the same for
all loads.
 Transformer Open Circuit Test
• Also the transformer open circuit test helps
to obtain the value of the parameters R˳, X˳
as in the equations below:

• In the open circuit test the current (I˳)

not exceed 1% of the rated current
value at the injected side and it
represents just the exciting current.
 Transformer Open Circuit Test
 Ifthere is a different between the measured
values and nameplate values for the no load
losses and no load current, the core may
have a problem like a short between the
laminations or gaps between the layers of the
core.
 If the no load current is different or
unbalance this mean that there is an
unsymmetrical structure in the core.
 As per (IEC 60076-1) Page 57 the tolerance
for no load current is +30% of the declared
 Transformer Parameters Calculations Tests
4/ Short Circuit Test (Load Losses Test)
(percentage impedance test)(Voltage
impedance test):
• In this test we supply one side (usually the
HV) and short the other side (LV) to measure
W, Vsc, Isc as in the figure below:

Rated No load No load

Voltage Losses Current

See Picture for TR Under Short Circuit Test

 Transformer Parameters Calculations Tests
- In the short circuit test the Wattmeter
measures the full load losses, while the
voltmeter measures the short circuit voltage
Vsc needed to circulate the rated current at
both sides of the transformer when one side
is shorted .
- The Ammeter measures the rated current of
the transformer if the voltage applied is the
short circuit voltage Vsc .
- The short circuit voltage value (Vsc)is
calculated directly from the formula :
Vsc = Vrated * Z%
 Short Circuit Test (Load Losses Test) (percentage
impedance test)
 As the shorted side load is zero impedance, a
very small value of voltage may circulate the
rated current in the other side and this
voltage is named impedance voltage or short
circuit voltage(Vsc).
 Now the HV side is supplied with 5% of the
rated voltage value, the exciting current not
exceed 2% of its value when the voltage is
complete and this makes the shunt circuit
energy negligible and the measuring
power(Wsc) is the power consumed in the
series impedance (R1&R2).
 Short Circuit Test (Load Losses Test)
(percentage impedance test)
• The following formulas are used with the
short circuit test :

2
 Short Circuit Impedance (Voltage Impedance)
(percentage impedance)(Per Unit Impedance)(Z%)
• The Z% value is written on the nameplates of the
transformers as below, and it is calculated directly
from the short circuit test .
 Short Circuit Test (Load Losses Test)
(percentage impedance test)
 The transformer which have Z% equal to 5%
means that 5% of the rated voltage for each side is
sufficient to circulate the rated current in the other
side.
 For example a transformer 1000KVA (11KV/433V)
with an impedance of 5% need 550V in the high
side to circulate the rated current in the low side
and 21.65V in the low voltage side to circulate the
rated current in the high side.
 The direct formula of the Percentage Impedance is
Z% = Vsc / Vrated *100
 Short Circuit Test For TRs With Same Data But Different Z%
1000KVA - 11/0.433KV - Z%=6% 1000KVA - 11/0.433KV - Z%=6.5%

11KV 433V 11KV 433V

Irate = 52A Irate = 52A
A a A a
Irate = Irate =
VSC = 660V B b 1333A VSC = 715V B b 1333A
C c C c
n n
1 2
1000KVA - 11/0.433KV - Z%=5.7% 1000KVA - 11/0.433KV - Z%=7%

11KV 433V 11KV 433V

Irate = 52A Irate = 52A
A a A a
Irate = Irate =
VSC = 627V B b 1333A VSC = 770V B b 1333A
C c C c
3 n 4 n
 Short Circuit Test (Load Losses Test)
(percentage impedance test)
• Z% is called per unit impedance
because its value nearly equal whether it
is calculated at high or low side .
• When we transfer the transformer
impedance from one side to the other,
we obtain Z01 & Z02 as in the next
example ,and they are different in value,
but Z% is equal at both sides because it
is a per unit impedance .
EXAMPLE FOR CALCULATING Z01 & Z02 & Z%
The Relation Between Z01,Z02 and Z%
Z% (Z per unit) = Z actual / Z base
Z base = KV²/MVA
Z actual = impedance referred to one side of a transformer (Z01
or Z02)

for the previous example (30KVA, 2400/120V)

Calculating Z% Using primary side referred Z01 :
Z actual = Z01 = 15 Ω
Z% = Z actual / Z base = 15/(2.4²/0.03)*100 = 7.8%
Calculating Z% Using secondary side referred Z02 :
Z actual = Z02 = 0.0374 Ω
Z% = Z actual / Z base = 0.0374/(0.12²/0.03)*100 = 7.8%
 Transformer Impedance Z%

A a
B b
C c
n

= = =

If Vapplied = the Vsc , formula will be

=
 Short Circuit Test (Load Losses Test)
(percentage impedance test)
• An important point to mention is that you can use any
available test voltage to do the short circuit test for
calculating transformer impedance Z% as below;

• Below formula is derived from the above formula

Z% = Vsc / Vrated *100

How To Apply Z% Formula When We Have Test Voltage Less Than
Vsc

W A A a W A A a
V V
V W A B b V W A B b
V V
W A C c W A C c
n n
 Short Circuit Test (Load Losses Test)
(percentage impedance test)
• There are modern sets used especially to
calculate the short circuit impedance from
the formula :

• Here the set injects voltage not exceed 216V

and measures the current to calculate Z% .
Transformer Short Circuit Impedance
Tester(Z% Tester)
 Z% Design Formula

The calculations below for a TR 1250KVA,

11/0.433KV
 Z% Design Formula

=
 Short Circuit Test Table To Fill At The TR
Factory Visit
• In our practical visit to the TR factory you
have to fill the following table by your self
during SHORT CIRCUIT TEST :
Relation Between Z% and The Terminal Voltage Of a Transformer

• If we have a transformer with the following data

1000KVA (11KV/433V) with an impedance of 5%
Vsc1 = 11000*5/100 = 550 V
Vsc2 = 433*5/100 = 21.65 V
• Now if we full load the transformer above, the
terminal voltage will decrease from 433V to a
value of 433 - 21.65 = 411.35 V
• If we load the transformer with 50% ,the terminal
voltage will decrease to 433-(21.65*50/100) =
422.175 V
 Transformer Short Circuit Test Calculations
20MVA - 66/11KV - Z%=7.4% 1000KVA - 33/6.3KV - Z%=6.5%

66KV 11KV 33KV 6.3KV

Irate = 175A A a Irate = Irate = 17.5A A a Irate =
1050A 91.7A
B b B b
VSC1 = VSC2 = VSC1= 2145V VSC2 =
4884V C c 814V C c 409.5V
n n
1 2
VSC1 = 66000*7.4/100 = 4884V VSC1 = 33000*6.5/100 = 2145V
VSC2 = 11000*7.4/100 = 814V VSC2 = 6300*6.5/100 = 409.5V
If we supply the high side with If we supply the high side with
415V and short the low side, 415V and short the low side,
the current at high side will be the current at high side will be
415*175/4884 =14.9A 415*17.5/2145 =3.4A
The current at low shorted side The current at low shorted side
14.9*6 = 89.4 A 3.4*5.2 = 17.8 A
 Short Circuit Test (Load Losses Test)
(percentage impedance test)
• In addition to identifying the parameters
mentioned above, short circuit test is helpful :
1. to discover any deformation in the winding
due to shipping and transportation, internal
short circuit, wrong connection for the
winding after maintenance etc.
2. to calculate the short circuit level for a
transformer according to percentage
impedance and choose the right
specifications of the CB to protect the
transformer.
 TR Maximum Short Circuit Current
• It is the maximum current that will flow at each
side of a transformer in case of a 3ɸ symmetric
fault at the secondary terminal of this
transformer .
Isc/max = Irate / Z%
 TR Maximum Short Circuit Current
• We must distinguish between the transformer
maximum short circuit current and the
transformer rated current by using the calculation
below for 100KVA TR – (11KV/433V) with an
impedance of 3.7% :
Irate = 100*10ˆ3/1.73*11*10ˆ3 = 5.25A ( HV Side )
Irate = 100*10ˆ3/1.73*433 = 133.5A ( LV Side )
Irate Irate Isc referred 100KVA Isc
100KVA
5.25A 133.5A to primary 11/433KV 3608.1A
11/433KV
141.8A Z%=3.7%

Isc = 5.25/0.037 = 141.8A (referred to HV Side )

Isc = 133.5/0.037 = 3608.1A ( LV Side )
See practical slide
 TR Maximum Short Circuit Current
• Transformer maximum short circuit current
values are used to :
(1) calculate the rating of circuit breakers
that installed in the upstream and
downstream of the transformer .
(2) choose the right protection scheme and
settings for the relays .
• On the next slides you find a practical case
for using transformer short circuit values to
choose the right protection scheme .
 TR Maximum Short Circuit Current
Practical Case Study
• A transformer with the following data :
(33KV/433V) -(1000KVA)- (Z% = 6%) connected to
33KV busbar directly via 33KV cable and MV 33KV
circuit breaker with MICOM relay P122 as shown in
the single line diagram on the next slide .
• When the operator came to energize the
transformer for the first time by closing the 33KV
Circuit Breaker a great sound heard around the
transformer, but the 33KV Circuit Breaker not
tripped until the operator ran quickly and opened it
manually .
 TR Maximum Short Circuit Current
Single Line Diagram For The Case Under Study

110KV
Y
Y
35MVA
33KV

O/C Setting O/C Setting O/C Setting

100m Cable
350A 350A 350A
33KV
1000KVA
Outgoing 3 Outgoing 2 Outgoing 1
Y
433V
MCCB

Package Transformer Without RMU

 TR Maximum Short Circuit Current
Practical Case Study
• A fault occurred in the LV side due to a copper bar
forgotten up the main MCCB during
manufacturing .
Now the question is why the 33KV C.B not tripped?
• Let us calculate the maximum short circuit
current for the two sides of the transformer :
Isc = 17.5/0.06 = 291.7A ( HV Side )
Isc = 1333/0.06 = 22216.6A ( LV Side )
 TR Maximum Short Circuit Current
Practical Case Study
• The setting of the relay on the 33KV Bus Bar was
350A for the over current and the maximum
short circuit current of the transformer not
reach the pick up value so no trip occurred until
the operator open the circuit breaker manually .
• Now the relay setting for the over current is
0.1(This is the minimum setting value in the
MICOM P122), and the CT ratio at the 33KV
circuit breaker is 400/1 so the over current pick
up value is 40A .
 TR Maximum Short Circuit Current
Practical Case Study
• The minimum 40A setting at the primary side
appears when there is 3048 A in the LV side,
and this large current will exists for at least
110ms affecting the insulation of the
transformer .
 TR Maximum Short Circuit Current
Practical Case Study
• Now in your opinion what is the proper
protection scheme for this case???
• The answer is : fuse is the proper device to use
at the 33KV side because its time of blowing will
be in the range of 20ms compared to 110ms in
the circuit breaker and relay scheme .
• For the above reason we found that protection
by fuses is preferred in the high voltage side of
substations auxiliary transformers .

See Picture For The Nameplate of The TR Under study

Values of Z% As In IEC Standard
 Tolerances For Transformer Losses and
percentage impedance
• Each manufacture has what is called declare value of
his transformer losses and impedance.
TR LOSSES TOLERANCES :
• As per (IEC 60076-1) Page 57 the tolerances of transformer
losses are as below :
Total Losses: +10% of the total declared losses.
Component losses: +15% of each component loss
IMPEDANCE (Z%)TOLERANCES :
• As per (IEC 60076-1) page 57 the tolerances of Z%
When Z% is 10% : ±7.5% of the declared value
 Short Circuit Test for(11KV/433V) Transformer
TR Under Test TR Data
274A 11/0.433KV
10.7A
A A a A 200KVA
10.7A 274A Z% = 4%
3ɸ 430V A B b A
L-L 274A
10.7A
A C c A

= 430 * 10.4
*100 = 3.8%
10.7 * 11000

= 430 * 266.6 *100 = 3.8%

274 * 11000

Full Load Losses (Copper Loss) PL = PLm (Ir /Im)²

= 3742 (10.4/10.7)² = 3535 W
 Transformer Parameters Calculations Tests
5/ Transformer Vector Group Test:
• The following pictures illustrate the real
meaning of the polarity term in general;

180˚ Phase Shift 0˚ Phase Shift

See Video
Transformer Polarity And Vector Group Test:
• There are two common method for testing the
polarity of transformers :
(1) Polarity Test By DC Flashing Method :
• In this test we use a dry battery cell (1.5V to 6 V)
and a voltmeter with central zero or you can use
any digital multimeter :
DC DC DC

H1 H2 H1 H2 H1 H2

h1 h2 h1 h2 h1 h2

- + - + Voltmeters - + See Video

 Transformer Polarity And Vector Group Test
(2) Polarity Test By The AC Method :
• In this method a voltage may be applied to the high
voltage winding (H1,H2) and the two adjacent
bushing of the high and low voltage winding(H2,B)
are jumpered together as below :
Transformer Polarity And Vector Group Test:
(3)Polarity Test Using TTR Tester :
• The AC polarity test method nowadays is done by
the modern TTR sets at the same time during the
single TTR test .
Transformer Polarity And Vector Group Test:
(4)Polarity Test Using Polarity Check Tester :
• The transformer polarity can be checked by the
following device called polarity check tester :
Transformer Polarity And Vector Group Test:
From the previous slides we notice that
polarity defines the instantaneous direction of
the voltage or current of the primary with
respect to secondary.
Transformer Vector Group
The vector group symbol of a transformer
illustrates:
(1)The way of connecting windings in each
side- delta or star.
(2)The phase shift between primary and
secondary windings.
 Vector Group Symbol For 2 Winding TR

H.V Winding L.V Winding

Connection in Connection in
Capital letter Small letter
D or Y or Z d or y or z

Capital N is written If a Small n is written If a Write here a

neutral Exist and neutral Exist and number from 0 to
Brought Out, and do Brought Out, and do not 11 illustrates the
write any thing if there Shift Between
not write thing if there
Primary and
is no neutral brought is no neutral brought
Secondary in
out out

Dyn11
YNd7
ZNd11
 Vector Group Symbol For 3 Winding TR
H.V Winding Sec1 Winding Sec2 Winding
Connection in N Connection in n Connection in n
Capital letter Small letter Small letter
D or Y d or y d or y

a number from 0 a number from 0

to 11 illustrates to 11 illustrates
the Shift Between the Shift Between
Primary and Primary and
Secondary 1 Secondary 2

YNyn0d11
YNyn6d1
Dyn11d0
 Transformer Vector Group:

b2

B2 C1
a2 a1
b1
c1

B1 C2
A2
A1 c2

D y n 5
 Transformer Vector Group:

C1 c1 b2 b2 c1 b2
c1
c1

b1 b1
b1 a2 a2
B2 C2 c2
A2 c2 c2 a1 c2 a1
A1
B1
Y N d 1
See more
Transformer Polarity And Vector Group Test:
The testing of the vector group for a
transformer is achieved by supplying a
voltage across one side and measure
the voltage and angle at the other side
for each phase, as you can shown on
the next slide.
Transformer turn ratio tester measures
the vector group by applying a voltage
wave and receive it at the secondary
side to see the shift angle. .
 Q. Explain How To Test The Vector Group Of a Dyn11
Transformer ?
1) Connect R-r then supply (2) Draw the following diagram and
he HV side with available notice that if the vector group is
oltage (415V) Dyn11, three equations must be
Realized :
HV LV
RY = Rn + Yn
Yy = Yb
R R r
By > Bb R
r
Y Y y

B b n
B y
n
b

Dyn11
B Y
Transformer Polarity And Vector Group Test:
Q- What is the problem that will happen if we
parallel two transformers with different vector group
together ?

A- a fault occurred because there will be a phase

shift between each typical phases, although they
may be same in type (R-R / B-B / Y-Y).
TR Parallel operation
 The vector group is a very important issue when
paralleling two transformers together.
 The table on the next slide gives a brief idea
about paralleling transformers .
See Picture For Synchro-check
TR PARELLEL OPERATION CONDITIONS :
 Famous Transformer Tests
Objectives Test
(1)See if the number of turns are equal in each TTR
winding(no human error during winding at factory).
(2)See if there is an open conductor or loose connection
inside the transformer (During troubleshooting tests).
(TTR Not affect transformer life time)
(1)See if the windings resistance are equal and matching Winding
with the manufacturer declared values for each winding . Resistance
(2) See if there is an open conductor or loose connection
inside the transformer (During troubleshooting tests).
(Winding Resistance test not affect transformer life time)

(1)Calculate the no load losses (iron losses) at the factory. Open

(2)See if there is a problem concerning the iron core Circuit
(overlapping or material quality).
(3)Detect ratio problem by comparing the balancing of I0
 Famous Transformer Tests
Objectives Test
(1)Calculates the load losses(copper losses) at the factory. Short
(2)Calculates the percentage impedance Z% . Circuit
(3)Detects ratio problems by comparing the balancing of test
the three phases currents passing during the test.
(4)Detects loose connection or open conductor inside
transformers by comparing the balancing of the three
phases currents passing during the test (backup test for
the winding resistance).
(5)Full loading the transformer during temperature rise
test.
)Short circuit test not affect transformer life time(
(1)Test that windings terminals are connected correctly Vector
together (from polarity aspect). Group
test
6. Transformer Special Tests

(1) Noise level Test.(Special)

 (1) Noise level Test(Special)
• When transformer is energized, noise is
generated due to vibration in the magnetic
circuit and this noise can be minimized by
rigidly binding and clamping the core
laminations, but the noise can not be made
zero.
• Sometimes the transformer generates more
noise because of over excitation or higher
operating flux density.
• Noise level is expressed in decibel (dB ).
 Noise level Test(special)
• The noise level of medium sized power
transformer should be restricted to an
acceptable value of approximately 50 to 55
dB .
• Transformer noise level test is done when
the surrounding of the transformer is
reasonably calm and quiet.
• The measurements is done by a battery
operated meter known as (Noise Level
Meter).
 Noise level Test
• The transformer noise level test steps are :
(1)Record the noise level of the surrounding without
energizing the transformer and take it as reference.
(2)Energize the transformer at its full rated voltage without
load and rerecord the noise level at a distance
approximately one meter away from the transformer .
(3)The difference {step(2) – step(1)} equal the noise level of
the transformer under test
Transformer Noise Level = Noise level measured after
energizing the transformer - Noise level measured before
energizing the transformer

* See a video for Transformer Noise Level Test

 Transformers Commissioning Tests
• Transformer commissioning tests must be
done at the site after installations and before
putting the transformer in service.
• Transformer Commissioning tests are :-
(1) Megger test.
(2) Ratio Test for each tap position.
(3) losses tests, impedance test.
(4) Vector group test.
(5) Oil Dielectric test.
(6)Check the wiring of the mechanical alarms
and trips.
 CHAPTER(5)
CTs AND VTs
TESTING

CTs VTs
 INSTRUMENT TRANSFORMERS
They are two types : –
(1)Voltage transformers (VTs or PTs) .
(2)Current transformers (CTs) .
 VTs and CTs help us to :
(1)Reduces the hundreds and thousands of
amperes/volts to low manageable values.
(2)Ensuring uniformity in the ratings of relays
and meters irrespective of the system
voltages.
(3)Insulate the meters and relays from high
voltage.
 Fuse Fuse Fuse

Vector : YNyn0
IY

IR

IB
Relay or Meter

N a n da dn N a n da dn N a n da dnRelay or Meter
VY

VR
See
VR VY VB VB
 INSTRUMENT TRANSFORMERS- FEATURES

CTs and VTs are similar to standard of

power/distribution transformers but not
for transferring power.

Ratings are in volt-amperes(VA)

compared to MVA ratings of power
transformers.

Theory of operation similar to standard

transformer (comprising of two windings).
 CURRENT TRANSFORMERS (CTs)
 The CT is designed to carry the full
operating current of the system and able to
withstand the system short-circuit currents .

 Standard values of currents in the

secondary is 1 amp / 5 amp referred as 1
amp CTs and 5 amp CTs.

 From the principle of transformer theory the

CT decreases the current, so it increases
the voltage across its terminal to a very
high values so the secondary of a CT must
not be open when current is passing
through primary .
 Current Transformers Construction

S1 S2 S3 S1 S2 S3 S1 S2 S3
 Ring CTs Construction
1000/1 500/1
N L1 L2 L3
L1 L2 L3

XS
1 2 3 4 5 6 7 8 9 10

S2 S2 S2
S3 S1 S3 S1 S3 S1
 Metering & Protection CTs
Changing Ratio Done at
Secondary Terminals .

PROTECTION RELAY
See CT Terminal
 Current Transformers Construction

P1 P2 P1 P2 P1 P2

1S1 1S2 2S1 2S2 1S11S2 2S12S2 1S1 1S2 2S1 2S2
Metering & Protection CTs (Separate Core)
Ratio Changing Tap
CTs SAFETY PRECAUTIONS
NEVER OPEN CT SECONDARY
CIRCUIT WHILE A CURRENT
TRANSFORMER IS ON LOAD!!!
THE ABOVE PRECAUTION IS
IMPORTANT BECAUSE OF THE
HIGH VOLTAGE GENERATING AT
THE CT TERMINAL CAUSING A
LARGE FLASHOVER IF IT
OPENED DURING LOAD .
See real Pictures for CTs
 CT Saturation phenomenon
• What is the CT magnetizing curve ?
It is the curve drawn of CT excitation current(Ie)
in the X axis versus CT secondary voltage Es , and
there is a point in this curve called knee point.
 CT Saturation phenomenon
• As per IEC definition CT knee point is the
point at which 50% increase in Ie current
cause 10% increase in Es value, and we can
say that it is the point after it SATURATION
will happen .
• The CT core here looks like a road with cars
passing through it, and the road has a
design ability to withstand a limit number
of cars and above this limit we say the road
is saturated.
 CT Saturation phenomenon
• Saturation stops flux increasing in the core
and this leads to stop current increasing in
CT secondary winding.
• When CTs Saturation happens ?
(1)In protection CTs when high currents
passing during faults and this produce high
flux induced in CT core .
(2)In measuring CTs when the normal current
exceeds the CT rating current .
 CTs Saturation
P1 1A P1 1A
E E
100/1 S1
100/1 S1
R = 1Ω R = 1Ω
S2 S2
100A 100A 1V
1V
P2 I P2 I
P1 1A P1 10A
E E
100/1 S1 100/1 S1
10V
R = 1Ω 10V
R = 10Ω
S2 S2
100A 1000A
P2 I P2 I
P1 1A P1 100A
E E
100/1 100V 100/1 100V
S1 S1

R = 100Ω R = 1Ω
S2 S2
100A 10000A
P2 I P2 I
Isec is Fixed But Load Burden is Changed Load Burden is Fixed but Isec is Changed
 CURRENT TRANSFORMERS TYPES
(1) Metering CT: will have to carry only full
load current without saturation.
(2) Protection CT: will have to carry the fault
currents which are 10 times the normal full
load current without saturation .
• Core balance CT is an earth fault Protection
CT designed just for earth fault protection
and not for overcurrent protection nor for
metering .
• Metering CTs accuracy is more than
protection CTs,but the knee point voltage of
protection CTs is higher than metering CTs.
 Core Balance CT Basic Concept
• At normal conditions the summation of
currents that follow in the three phases
is balance and no flux appear in the core
.
• When earth fault occurs the summation
of currents have a resultant value that a
flux follow in the core and induce current
in the secondary causing relay operation
.
• Sometimes it is called
Zero Sequence Current
Transformer .
 CT BURDEN
• For CTs and VTs BURDEN is the maximum VA load can
be connected in the secondary winding .

• Ip = Primary current .
• Is = Secondary current .
• Rct = CT secondary winding resistance .
• ZB = measuring or protection device impedance .
• Es = EMF appear in CT secondary terminals due to
magnetic flux from primary.
• Voltage across measuring/protection device is :
IsZB = Es - IsRct
 CT/VT BURDEN
• CT or VT burden is the maximum power that a Ct
or VT can give without saturation .
• Load burden(VA load)is the load for secondary
side of CT or VT and it is the secondary winding
resistance + device resistance.
• The burden of CT or VT is expressed in VA and not
in ohm, although they are the same and we can
get any one from the other as below:
CT with 12.5VA and 5A secondary current can
withstand load impedance (ZB ) as below:
(ZB) = VA/I² = 12.5/25 = 0.5Ω
 CT Knee Point Voltage (Ek)
• The next equation is used to determine the
maximum impedance ZB that can be connected
between CT terminals , as in the example on the
next slide .

Ek = 4.44*N*F*A*B max
where :
Ek = Knee Point Voltage.
N = number of turn. F = frequency.
A = Core cross section in m². Bmax = flux density
Example (1) :-
Calculate maximum impedance of protection device that
can be connected across CT with the following
specifications :
CT ratio = 2000/5 Rct+RLead = 0.13Ω IpriR
max = 40KA B max = 1.6 Tesla
2000/5A
Core CSA = 20cm2
Solution : -
N= 2000/5 = 400 Isec-max = 40000/400=100A
Ek = 4.44*N*F*A*B max
Ek = 4.44*400*50*20*10ˆ-4*1.6 = 284 Volt
Rmax = 284/100 = 2.84Ω
Rct + RLead = 0.13Ω
So maximum impedance of a device connected to this CT
Example (2) :-
Calculate the VA output required for a CT of 5A
rated secondary current when burden consist of
relay requiring 10VA at 5A plus loop lead
resistance 0.1Ω ? Rct +RLead=0.1Ω
5A
R Lead
Rct R Relay
10VA
Solution : -
VA required to compensate the loop lead resistance
= I²R = 5²*0.1 = 2.5VA
The relay requires 10VA
Total VA output required = 10 + 2.5 = 12.5VA
Hence we can choose a CT of rating 15VA/Isec =5A
Accuracy Limit Factor(ALF) (Saturation Factor)
• ALF value gives you an indication for maximum
primary current that follow without affecting the
accuracy of secondary measurements, or we can
say the maximum current that follow in primary
before core saturates and secondary current
distort.
• (CT 1000/1 5P20) means if 20 times nominal
current at the primary side passed (20KA), the
secondary current will equal (20A ± 1A) , ALF=20
20A ± (20A*5/100) 20KA 20KA
20A ± 1A
1000/1 S2 S1
5P20 20A±1A
R
 Accuracy Limit Factor(ALF) or (Saturation
Factor)
• As we learned in the previous slides that we
calculate the knee point voltage Vk from the
formula :
Vk = 4.44*N*F*A*Bmax
and Bmax is difficult to be determined, so we use
the following formula that contains ALF value that
written in the name plate of the CTs:
 CTs Tests
CTs tests are done to confirm the physical
condition and electrical characteristics and to
ensure the CT is connected to system
properly (primary and secondary).After visual
inspection we do the following tests:
:Insulation Resistance test (Megger Test) )1(
;in this test voltage shall be applied between *
.Primary to secondary connected to ground)1(
Secondary core to core (in case of separate)2(
)secondary core type
 Current Transformer Meggering
CT Primary to Secondary Connected to Earth Test
P1 P2
P1 P2

CT Secondary to Secondary Test

1S1 1S2 2S1 2S2
1S1 1S2 2S1 2S2

P1 P2

• Insulation between cores is

low, so we must apply
1S1 1S2 2S1 2S2 minimum DC test voltage
when Meggering core to
CT Secondary to Earth Test
 CT Tests
(2) Polarity test:
 this test is done to confirm the polarity marking on
the CT primary is right and it is giving an idea how
to connect properly the CT secondary for metering
and to apply protections like (differential &
directional & restricted earth fault).
 To test the polarity of a CT you must first isolate the
CT secondary from the load and make the circuit
connection as below :

See Video
 CTs Polarity Test
P1 P1

+ S1 + S1

- S2 - S2

P2 P2

P1
P1
S1 S1
+ +

- S2 - S2

P2 P2

P1 P1

+ S1 + S1

- S2 - S2

P2 P2
Right polarity Wrong polarity in Y phase
 CTs Tests
(3) CT Secondary Winding Resistance Test :
This test is done to :
(1) Measure the value of the CT secondary
resistance and compare it with the factory test
certificate .
(2) Test and confirm that no internal open circuit
in the CT secondary winding.
Rct
 CTs Tests
(4) CT Secondary Loop Resistance Check:
 This test is done to :
(1) ensure that CTs secondary circuits is connected
properly to the meters or relays and the secondary
circuits not left open after CTs commissioning tests.
(2) This test is very important before putting equipments
into service.

Burden

Measured Value = Rct + R wiring + R burden

 CTs Turn Ratio test :
(5) Turn Ratio test:
this test can be done by primary injection
technique, and the circuit connection shall be
made as below :

hortS
orary
50A

Temp
Primary Injection Set

50 0

50 180

Relay or Meter 0 0
See CT Polarity Test
 CTs Magnetizing Curve test :
(6) Magnetizing Curve test:
this test is done to confirm the magnetization
characteristics of CT with nameplate
specification, and the circuit connection shall
be made as below :
 CTs High Voltage Testing

(7) High Voltage test:

• No flux is produced
during the high voltage
test because no current
P1 P2
passing through CT
primary .

1S1 1S2 2S1 2S2

 CT Testing Using CT Analyzer
• Recently the big companies that producing testing
equipments like (OMICRON COMPANY) have one
equipment to do all the CT tests at one time.
 CT Testing Using OMICRON Analyzer

To CT Secondary
 VOLTAGE TRANSFORMERS (VTs or PTs)

General Concepts for Voltage Transformers :

 Voltage transformer is a step-down
transformer, normally with rates (33KV/110V)
or (11KV/110V) .
 With compare to CTs the secondary windings
voltage is low and there is no hazard to open
the secondary as in CTs .
 An MCB or FUSES are protect the secondary
windings of voltage transformers against short
circuits .
 Voltage Transformers (VTs or PTs)

Secondary Terminals
Primary Terminals
Capacitor Type Voltage Transformers(CVT) :

 In extra high voltage applications(110KV /

220KV /380KV /500KV) a capacitor type
voltage transformer is used(CVT) .

 It is similar to the electro magnetic type

except for the additional capacitor units to
step down the voltage before measure it .

 The next slide shows diagram for this type .

Capacitor Type Voltage Transformers(CVT) :
 Voltage Transformer Tests
 VTs testing is done to confirm the physical
condition and electrical characteristics and to
ensure it is connected properly in all respect
(primary and secondary).
:Insulation Resistance Test (Megger Test) )1(
The insulation resistance test for VTs can be -
;done as below
).Primary to earth test )1
.Secondary to earth test )2(
. Primary to secondary test )3(
Secondary core to core test. (4)
 Voltage Transformer Meggering

Primary to Secondary to N a n da dn
N a n da dn
Earth Test Earth Test
Primary to Secondary Core to
Secondary Test Core Test

N a n

N a n da dn da dn
 Voltage Transformer Test
: Polarity Test )2(
 This test is done to confirm the polarity
marking on the VT primary and secondary
and verify if it is matching with the drawings.
Connect the VT under test as below:
 Voltage Transformer Tests
: Winding Resistance Test )3(
 This test is done to verify the VT primary
and secondary windings have no
discontinuity or abnormal in the wiring.
 VT primary winding resistance can be
measured by multimeter as it will be a
higher resistance, the secondary winding
resistance can be measured with low
ohmmeter for each winding.
 Voltage Transformer Winding Resistance
Primary Winding Secondary 1
Resistance Test Winding Resistance
Test

N a n da dn
N a n da dn

Secondary 2
Winding Resistance
Test

N a n da dn
 VTs High Voltage Testing

(4) High Voltage test:

• No flux is produced
during the high
voltage test because
the primary winding
has no voltage
difference due to the
external artificial
short .
N a n da dn
 Wrong VTs High Voltage Testing

N a n da dn • If the tested VTs rate is 11KV/110V,

this means that the primary rated
voltage per phase is 11KV/√3 = 6.3KV .
• 28KV is the HV value for testing the
6.3KV 110V 11KV system as per IEC standard .
28KV X • If we apply 28KV as in the diagram
above, a secondary voltage equal to
X = (28000*110)/6300 489V will appear across secondary
= 489V terminals (a,n) & (da,dn) .
 Do not do HiPOT Test for a busbar with connected VTs
Because a high voltage will appear across secondary terminals

Fuses

N a n da dn N a n da dn N a n da dn
(6)MV/HV CIRCUIT BREAKERS
&
BUS BARS SYSTEM TESTS
 MV/HV CIRCUIT BREAKERS & BUS BARS TESTS

MV/HV CBs Main Components

(1) The Main Contacts with a technique to
extinct the spark .
(2) The Trip Coil and Close Coil which
release the mechanism to operate the
CB .
(3) A DC Motor to charge the spring of the
mechanism .
 MV/HV CIRCUIT BREAKERS TESTS
 The common tests for MV/HV Circuit
Breakers are :
(1) Contact Resistance Test.
* measures the ohmic resistance of the CB contacts .
(2) Opening Closing Time Test.
* measures the time from sending the open/close
signal till the CB operates.
(3) High Voltage Test.
* Check the CB insulation strength.
(4) Insulation Resistance Test (megger test).
* Measures the insulation resistance between phases
and phase to earth.
 MV/HV Circuit Breaker Tests :
1/ Contact Resistance Test:
This test is done using the Micro Ohmmeter
device to check the value of the of the circuit
breaker main contacts resistance, because
sometimes one pole or more of a circuit breaker
not close well or exposes internal corrosion on
the contacts, and this may produce heat during
the normal operation.
This test is done in the FAT and at site as a
precommissioning test and also as a routine test
of the circuit breaker according to the times of
operation.
 Circuit Breaker Contact Resistance Test :
 The Micro Ohmmeter injects current and
voltage to get the resistance from ohm law
R = V/I

 Normally The values of the contact

resistance in this test is in the range of
(50 – 60 micro.ohm) .

 On the next slide you see pictures

illustrates how to test using a MICRO-
OHMMETER .
 Circuit Breaker Contact Resistance Test :
 Below is a picture of a Micro Ohmmeter set
from MEGGER company :

See Video
See Video
Contact Resistance Test For Medium Voltage Circuit Breaker
(SF6 For Internal Arc Extinguish & Air For Poles Insulation)

*Contact resistance test

is done in the two
position of the CB (open
and close) to detect CB
close or open failure .

Repeat test for other phases

Contact Resistance
Tester
 Contact Resistance Test For MV Outdoor Circuit Breaker

* The thick wires for

carrying the test current
and the thin wires is for
measuring voltage direct
across CB terminals .

Repeat test for other phases

Contact Resistance
Tester
Contact Resistance Test For GIS Circuit Breakers

See Video

Contact Resistance Tester

 MV/HV Circuit Breakers Tests :
2/ Opening-Closing Time Test:
this test is done to:
(1) Be sure that the mechanical operation of the CB is
good and the three poles close and open at the
same time.
(2) Get the exact CB tripping time in millisecond to
substitute the value in the famous formula:
fault clearing time = relay time + CB tripping time
 CB Opening-Closing Time Test :
 A set called circuit breaker analyzer is
used to test the opening and closing
time of a circuit breaker.
 Circuit breaker analyzer energizes the
closing and tripping coils of a CB then
calculate the time from sending the
command(close or open) till the CB
mechanism completes its operation.
See Picture For CB Analyzer
See Video For Testing with CB Analyzer
 CB Opening-Closing Time Test :
 In this test we use (100% DC voltage
first, 80% DC voltage second) and
operate the CB to measure the closing
and tripping time and compare the
results with the FAT values.
 decrease the DC voltage gradually to
see the minimum DC voltage that
operates the trip coil and this must be in
the rate of 60% DC.
CB Analyzer Connection
 MV/HV Circuit Breaker Tests :
3/ High voltage test or (Hi-Pot Test) :
 High voltage test is a routine test done for
each CB to be sure about :
(1) Insulation material strength.
(2) Insulation spacing between phases.
 In this test we apply single phase AC voltage
to each pole of the CB using a single phase
HIGH-POT equipment as explained in the
third chapter.
 Test voltage values are obtained from the
standards tables . (refer to chapter three)
MV/HV Circuit Breaker Hi-Pot Test :
 Each CB is tested with its full test
voltage for (1 minute) in the factory, then
after assembling at sites high voltage
test is repeated with a value equals 80%
of the original value that applied inside
the factory for (1 minute).
 High voltage test for CBs is repeated at
site after assembling to be sure about
the right assembling of the switchgear
cells .
 MV/HV Circuit Breaker Tests :
4/ Insulation Resistance (Megger Test) :
 Insulation resistance test is done for
circuit breakers as a routine test in the
factories and as a commissioning test at
sites .
 Insulation resistance test is a quick test to
discover and locating the fault in a
defective switchgear system.
 Insulation resistance is done as periodic
test in the maintenance programs.
 The Group Of CBs & Bus-bars tests
• In the new substations after assembling
the bus-bars and installing the panels,
the following tests are done for the
whole system :

1. Insulation Resistance Test (megger)

2. Contact Resistance Test
3. High voltage test
 The Group Of CBs & Bus-bars tests
: Contact Resistance Test )1(
 This test is done by the contact resistance
equipment for the whole system to detect major
problems while assembling ,like bad tighten of
screws or some parts of a busbar .(see next slide)
High voltage test )2( :
 This test is done after contact resistance test to
discover minor problem in the insulation like micro
cracks in porcelain or small partial discharge(PD)
around the whole system .
 In this test we examine the insulators that carry
the bus-bars, circuit breakers,CTs and VTs and
also the good tighten of bus bars joints.
 Contact Resistance Test For Medium Voltage Busbars(GIS)

Contact Resistance
Tester
 High Voltage Test For The Group Of CBs & Bus-bars

 For safety and right test results the following

procedures must be done before starting a
high voltage test for the group of bus bars
and circuit breakers :

(1)Put all earthing switches in off position.

(2)Put all circuit breakers in CLOSE position.
(3)Short all the secondary circuits of the CTs
and connect it to earth.
(4)Put all the safety signs before starting tests.
High Voltage Test For MV or HV Switchgear(GIS)

HV Unit
Control Unit
 CHAPTER(7)

POWER CABLE TESTS

 INTRODUCTION TO POWER CABLE
CONSTRUCTION
• Power cables are designed in different cross
section according to the current carrying
capacity.
• The following chemical materials are used
as insulating layers in power cable :
(1) Polyvinyl Chloride – PVC .
(2) Cross Linked Polyethylene – XLPE .
(3) Impregnated Paper - PILC .
 LV Cable Construction
notice that there is no semi-conductor screens
MV Cable Construction
MV Cable Construction
MV Cables Termination
MV Cables Termination

See Video
 POWER CABLE TESTS
 Cables with different voltage level
have many tests such as :-
(1) Phase checking (SAT).
(2) DC Conductor Resistance(FAT&SAT).
(3) Insulation Resistance (FAT&SAT).
(4) High Voltage Test (FAT&SAT).
(5) Tan Delta Test (FAT&SAT).
 POWER CABLE TESTS

(1) Phase Checking (Site Test):-

This test is done by connecting one of the
faces in the far side to earth while the other
faces is not earthed, then we use the
Megger to know this face.
We do the above test two times to identify
two faces and the third face is known
without testing .
Normally this test is done for cables
connect two generation bus bars to avoid
wrong synchronization.
 POWER CABLE TESTS
2/ DC Conductor Resistance (FAT&SAT ):-
It is important to measure the resistance of
the cable conductor to be sure that it is not
above the guarantee value.
If the value of the resistance is high, there will
be some losses produce heat which affects
the current carrying capacity of the cable.
In this test we use a Micro Ohmmeter to
measure the resistance value, we also
measure the temperature at the moment of
testing.
 POWER CABLE TESTS
(3)Insulation Resistance(Megger Test):-
• Value of the cable insulation resistance
depends on:
1. the humidity content in the insulation material.
2. the type of the insulation material.
3. the temperature.
4. the age of the cable.
• The insulation resistance test is done before
and after the high voltage test to be sure that
high voltage not affect the insulation .
• For more details refer to CHAPTER(2) .
 POWER CABLE TESTS

-:Cable High Voltage Test (SAT&FAT) /4

• Refer to CHAPTER (3) HiPOT tests for details .

5/ Cable Tan Delta Test :-

• Cable insulation can be checked by a
TAN DELTA tester, that uses same theory
of TAN DELTA test.
 Power Cable Testing Van
 This van is used to :
1. Be sure about existing of a fault in a piece of
cable and determines the fault location.
2. Testing new cables as commissioning before
putting it in service.
 The pictures below show us the equipments
inside the Van and the procedure of the
test .
See Pictures For Cable Test Van

See a Video Of Cable Testing