BEE - CODE DEVELOPMENT PROJECT

DRAFT CODE
ON
TRANSFORMERS

Prepared by

Devki Energy Consultancy Pvt. Ltd.,

Vadodara
 OBJECTIVE & SCOPE
1. The objective of this BEE Code is to establish rules
and guidelines for conducting tests on electrical
distribution transformers used in industrial,
commercial and such other load centers at site
conditions.

2. This Code covers Electrical power distribution

transformers of single phase/three phase and oil
cooled or dry type but restricted to those having
secondary voltages in the L.T distribution range of
415 V/240 V. The ratings covered are 25 kVA and
upwards.
 TESTS DESCRIBED IN THIS CODE ARE:

1. Measurement of winding resistance

2. Measurement of no load losses
3. Measurement of load losses
4. Measurement of operating load and winding
temperature
 GUIDING PRINCIPLES
SOME SIMPLE MINIMUM STEPS FOR ENSURING SAFETY ARE AS FOLLOWS.

1. Before conducting the tests, the HT area should be clearly demarcated to set
up a suitable physical barrier to prevent inadvertent entry /proximity of
personnel in the HT zone.

2. The HT supply should be switched off by the primary breaker visibly and then
disconnected by the isolater; followed by disconnection on the LT side.

3. The HT side terminals should be discharged by a proper grounding rod, which

is compatible with the voltage level on the HT side. The primary terminals
should then be physically disconnected and left open.

4. It should be remembered that application of even 4 volts on the secondary LT

side can induce more than 100 volts on the 11 kV HT side, as per transformer
ratio. Similarly abrupt breaking of relatively small D.C. currents can give large
voltage spikes on the HT side.
 GUIDING PRINCIPLES
Estimation of transformer efficiency

Efficiency at Full Load

Rated Output
 x 100%
Rated Output  Total Losses at full Load

Efficiency at Actual Load

Output Power at actual Load
 x 100%
Output Power at actual Load  Total Losses at Actual Load
INSTRUMENTS AND METHODS OF MEASUERENMENTS
Power input

A wattmeter or a suitable electronic 3-phase 4-wire energy meter

calibrated for 0.1 p.f can be used for measurement of power in no load
test and short circuit test. It also gives a power reading or for improved
resolution, energy reading over a period of measured time is possible.
Modern digital energy meters have indications of voltage, current,
power and frequency; hence more convenient for site measurements.

1. No load losses can be measured from the L.V. side using an adjustable
three phase voltage source with neutral. It can be derived from mains or
a D.G. set.

2. The L.V. side is energised at the rated tap at rated voltage and power is
measured by three watt meters or 3 phase, 4 wire single
wattmeter/energy meter. Due to energisation on L.V. side, PT’s are
avoided.
Connection diagram using 3-phase 4 wire
energy meter
 Load loss Test

This test is done by energizing on the H.V. side at a

suitable low voltage, while shorting the L.V. side
(secondary). The applied voltage is adjusted to pass
the needed current in the primary/secondary.
For example, for a 11 kV/433 V, 1000 kVA transformer with 5%
impedance, the voltage to be applied on H.V. side during load
test is estimated below.

H.V. side full load current, I 1 = Full load kVA x 1000

√3 x H.V. line voltage
= 1000 x 1000
√3 x 11000
= 52.5 A

Line to line voltage to be applied on H.V side for getting 5 A

on H.V. side,

V l-SC =Line voltage in kV x 1000 x Z x 5

0.866 x I1 x 100
= 11 x 1000 x 5x 5
0.866 x 52.5 x 100
= 60.5 volts
 Operating load measurements

This measurement is to be carried out after a

sustained load level for 3 to 4 hours. The
Frequency, Voltage, Current and Power should be
measured at L.T side using calibrated 0.5 class
meters of suitable range. Note that p.f. at actual
load conditions may vary from 0.7 to 1.0 and
power meters should be calibrated in this range.
The power measured at the L.T side will give the
output power of the transformer.
 Voltage

Two types of voltmeters are used in the

measurements.

1. Average reading type voltmeters with scale

calibrated assuming the normal form factor of
1.11 for sine wave. The usual digital voltmeters
are of this variety.

2. R.M.S. reading voltmeter, preferably digital true

r.m.s meters are the second type.
 Waveform errors
Ideally, the no load loss is to be measured at the rated maximum flux
density and sinusoidal flux variation, at rated frequency. This means
that during no load test, an adjustable voltage supply would be
required to vary the applied voltage to get the rated flux density.

Rated Voltage
Applied Voltage  x Actual Frequency
Rated in
To account for the distortion Frequency
waveforms, which is usually seen in
waveforms, which may be present during measurements, the values
of average and r.m.s voltages are to be measured across the
transformer phase windings. The r.m.s. voltage U may slightly higher
than average voltage U’.
The measured core losses need to be corrected to sinusoidal excitation, by using the
following expression.
No load losses corrected for sinusoidal excitation,

Wnl =
W nl _ m
Where k =(form  kC
Ch factor e)
correction
Ch = Ratio of hysteresis loss to total iron losses
Ce = Ratio of eddy current losses to total iron losses
For usual flux densities, the following data can be used.

For oriented steel, Ch = Ce = 0.5

For non-oriented steel , Ch = 0.7, Ce = 0.3
For amorphous core materials, Wnl = Wnl-m
 Frequency

A digital frequency-measuring instrument for 50

Hz range with 600v range and having a resolution
of 0.1hz is preferred.
 Winding temperature
The transformer should be de-energised with continued
cooling for at least 8 hours. Alternatively, if the winding
temperature does not vary by more than 1ºC over a period
of 30 minutes, the transformer can be assumed to have
reached a cold stage. For oil cooled transformers, the
temperature can be measured either at the top of the oil
surface or in an oil filled thermo-well if it is provided.

For dry type transformers, the temperature sensor should

be kept in close contact with coil surface. The sensor
should be covered and protected from direct draft. When a
stable temperature is reached in the indicator, within 1ºC,
this temperature is taken as temperature of the windings,
Tm, at the time of measuring the winding resistance.
For oil temperature measurements calibrated
mercury in glass thermometer can be used with a
resolution of 1ºC .in general, electronic instruments
with suitable probes are preferred. They include
probes using thermo couple resistance or
Thermisters with the resolution of 1ºC.

For surface temperature measurements the probe

of the instrument should be mounted and covered
suitably. Due care should be taken to isolate the
instrument for reliable reading and safety
 Cold winding resistance
The winding resistance can be measured using a Kelvin
bridge for low resistances or a wheat-stone bridge for
resistances above 10 Ω.

It is preferable to use modern direct reading digital

resistance measuring instruments with a resolution of 10
micro Ω or better for L.V. windings.

If resistance is measured across line terminals, the per

phase resistance can be calculated as follows:

1. If winding is connected in delta, Rph = 1.5 x Rll

2. If winding is connected in Star, Rph = 0.5 x Rll
 Settling time for readings
Due to circuit time constant, for the current driving circuit
used, final reading will take some time for reaching a
stable value. This time should be measured and noted.
This time is useful for taking a valid reading when taking
hot winding resistance. If hot resistance is measured after
de-energising the transformer, a valid reading can only be
considered after the lapse of settling time as measured
above.

Polarity of D.C. current with respect to winding terminals

should be consistently same. The above comment is
applicable to all resistance measurements including
those taken by bridge method or using a direct indicating
digital meter.
 COMPUTATION OF RESULTS
Sequence of Tests
Any convenient sequence can be followed, but preferably
after a sufficiently long OFF period, the test for cold
winding resistance should be taken first to minimise minor
temperature rise errors.

This should be followed by no load loss test and then

followed by short circuit test, if needed.

Indirect or direct measurement of operating winding

temperature can be planned and taken after a proper
stabilization period under any chosen load condition.
Measurement of actual operating parameters also need to
be done during normal load condition.
 Chronological order of measurements and
calculations
1. Obtain nameplate specifications of the transformer.
2.Switch off the transformer for at least 8 hours with
continued cooling to attain steady state. Alternatively,
measure winding temperature at every 15 minutes and if
temperature drop is not more than 1ºC, the transformer can
be considered to have attained steady state.
3.Measure resistances of primary and secondary windings. If
resistance is measured across line terminals, the per phase
resistance can be calculated as follows:

If winding is connected in delta, Rph = 1.5 x Rll

If winding is connected in Star, Rph = 0.5 x Rll
 4. Conduct no load test, by energizing on the L.V. side.
For this, first connect instruments as in figure 4.3 for
single phase transformers or as in figure 4.1 for three
phase transformers.

Measure frequency (f), r.m.s voltage (U), average

voltage (U’), current (Inl), energy consumption ( Enl in
Watt-hours) during a period (t) seconds. No load
power input ( Wnl) is calculated from Enl and ‘t’ as
follows.
Average Energy Consumed
Average no load power consumptio n 
Time
Enl x 3600

t the wattmeter
Alternatively, if watt meters are used,
reading is taken as Average no load power
consumption, Wnl-m

·
 The measured core losses need to be corrected to sinusoidal excitation, by using the
following expression.
No load losses corrected for sinusoidal excitation,

Wnl =

W nl _ m
Where k = form factor correction

Ch
(Ch  kCe )
= Ratio of hysteresis loss to total iron losses
Ce = Ratio of eddy current losses to total iron losses
U 2
For usual flux densities, the following data can be used.
For oriented steel, Ch = Ce = 0.5 ( )
For non-oriented steel , Ch = 0.7, Ce = 0.3 U'
For amorphous core materials, W nl = Wnl-m
This value of form factor corrected core loss is then corrected to
normal operating voltage and frequency, to be measured when the
transformer is on load.

The core losses are roughly proportional to square of actual voltage

and frequency, as explained below.

kv =

Corrected value of no load loss to site voltage

and frequency
Unl
Kf =
Ur

Fnl
Fr
Pcore = Wnl x [(Ch x kv 1.6 x kf )+ Ce x kv 2 x kf 2)]

Where,
Unl = Measured voltage during no load test, volts
Ur = Actual site voltage, volts
fnl = Measured frequency during no load test, Hz
fr = Actual site frequency, Hz
5. Conduct short circuit test. Short circuit the L.V. terminals
and apply a reduced voltage on each phase on H.V. side,
so that about 5 A current is maintained on H.V. side.

Line to line voltage to be applied on H.V side for getting

5 A on H.V. side

V l-SC = Line voltage in kV x 1000 x Z x 5

0.866 x I1 x 100
Since the current drawn on HV side is only about 5A in
this test, CT’s can be avoided.
The test is repeated thrice, taking terminals HR and HY by
applying voltage ERY , HY and HB with EYB and then HR and HB
applying voltage ERB. The power readings are Psc-RY, Psc-YB and
Psc-RB respectively. Currents drawn on H.V. side Is1-ph is also
noted. For STAR primary, only the corresponding L.V. side is
shorted. I.e. L1&L2, L2 & L3 and L1& L3 sequencially.

Alternatively, use of energy meter reading and time taken

PRYP - Petc.
YB  PRB
Measured sc 1.5 x
between Load
readings can Loss
also ,
be W
used to calculate sc RB
in
place of direct power measurements. This is similar to3the
calculation procedure explained in point no.4 above for no
load test.
6. Calculate total copper losses in windings based on short
circuit current, Is1 and measured cold phase winding
resistances.

P cu = 3 x I s1-ph2 x R m1-ph + 3 x [I s1-phx (V1/V2 )] 2 x Rm 2-ph

Where I s1-ph = Measured current on H.V. side during

load loss test for STAR primary
= 0.577 times measured current for delta
primary
V1 = Rated H.V. side line to line voltage
V2 = Rated L.V. side line to line voltage
R m1-ph = Cold winding resistance per phase on H.V.
side
Rm2-ph = Cold winding resistance per phase on L.V.
side

7. Calculate stray loss

Stray loss, Ps-m = Wsc - Pcu
8. Convert the copper losses and stray losses to base
kVA and reference temperature.

Copper losses can be converted to base kVA level

and reference temperature as follows.
P cu-base = Pcu x 2 x ---(1)
Where Tm = Measured cold winding temperature of
windings.
I1 = Rated primary current
Stray losses are also converted to base kVA level
and reference temperature as follows.
P s = Ps-mx 2 x -----(2)
Where P s = Stray loss at base kVA and at Tm
TR is usually specified as 75º C.
Total load losses at full load = (1) + (2)
9. Operate the transformer on actual load
conditions for at least 2 hours. Measure actual
load parameters of frequency (fL), site voltage
(UL), current (I L) and power consumption (PL).

10. Measure operating winding resistance and

estimate winding temperature as explained in
section 4.6.
R
TL = 235  Tm   235
Rm
11. Extrapolate the load losses at the actual load and operating
temperature.

Copper losses at actual load,

P cu-L = Pcu x 2
x
 IL1   TL  235 
Where  
 I s1   Tm  235 
T = Measured temperature of windings under actual
L
load.
IL = Primary current at actual load

IL1 can also be estimated from secondary current at actual load, I 2 by

using transformer voltage ratio.
IL1 = IL2 x (V2/ V1)
IL2 = Secondary current at actual load

Stray losses at actual load,

 IL1   Tm  235 
   
P sL = Ps-mx  Is1  2 x -----(2)
 TL  235 

Where P sL = Stray loss at actual load

12. Estimation of transformer efficiency

The above steps calculates total losses in a transformer at base

kVA as well as at the actual load.

Efficiency at Full Load

Rated Output
 x 100%
Rated Output  Total Losses at full Load
Efficiency at Actual Load
A sample calculation is given in section 6, with a format of data
collection Output
and calculations in Power at spreadsheet.
MS Excel actual Load
 x 100%
Output Power at actual Load  Total Losses at Actual Load
Sl. A D E
No.

Description Quantity Unit

1 Output 1000 kVA

2 Primary voltage 11000 V

3 Secondary voltage 433 V

4 Primary current 52.5 A

5 Secondary current 1333.7 A

6 Percentage impedance 5 %

7 Rated temperature 75 ºC
8 Cold temperature 30 ºC

9 Primary winding resistance per phase 0.678 Ω

10 Secondary winding resistance per 1.05 mΩ

phase
11 R.M.S. Voltage applied on L.V. side 460.3 V

12 Average Voltage applied on L.V. side 433 V

13 Frequency 49.5 Hz

14 Phase Current on L.V. side 70 A

15 Power on L.V. side 1100 Watts

 Short circuit test

16 Applied voltage on H.V side (Average of 60.5 V

three voltages measured)

17 Phase Current on H.V. side (Average of 5 A

three currents measured)

18 Power meter reading on H.V. side ( Avg of 86.2 Watts

three power measurements on each line)

19 Power consumed on H.V. side 129.3 Watts

Operating load measurements

20 L.V. side voltage 433 V

21 Frequency 50.2 Hz

22 Current on L.V. side 1187 A

23 Power measured on L.V. side 890.2 KW

24 Calculations Quantity Unit
25 Form factor correction 1.13
26 Ratio of hysteresis loss to total iron losses 0.5
27 Ratio of eddy current losses to total iron losses 0.5
28 No load losses corrected for sinusoidal excitation 1032.9 Watts
29 Ratio of actual voltage to rated voltage 1.0
30 Ratio of actual frequency to rated frequency 1.004
31 Corrected value of no load loss to rated volt. and freq. 1041.2 Watts
32 Total Copper losses at test current 101.67 Watts

33 Stray losses at test current 27.67 Watts

34 Copper losses at base primary current I 1 13106.14 Watts
35 Stray losses at full load at rated temperature 2606.62 Watts
36 Total losses at base primary level 15712.76 Watts
37 Efficiency at full load 98.35%
38 Operating temperature at load 80 C
39 H.V. Side current on load 46.7 A
40 Copper losses at actual load 12346.33 Watts
41 Stray losses at actual load at operating temperature 1737.85 Watts
42 Total losses at actual load
43 Efficiency at actual load 98.33%
 GUIDELINES FOR ENERGY CONSERVATION
OPPORTUNITIES
The following points have to be considered.

1. Power factor correction for reducing copper losses.

2. System operating voltages to be observed for maintaining near rated voltages and
unbalanced to be minimized.
3. Augmented cooling and relative benefits to be seen where applicable.
4. Possibility of switching off paralleled transformers at any low loads.
5. Working out existing realistic losses and cost thereof. This follows study of annual
r.m.s. loading and operating losses at operating temperature, covering harmonic
loading. This is a prerequisite for finding replacement alternatives.
6. Replacement by a low loss transformer with economic justification, considering
present and future harmonic loading and load pattern.
7. When replacement is not justified, collection of invited/standard low loss design data
for optimum cost/rating of transformer for future replacement or for new installation.