TESTING OF POWER

TRANSFORMERS

NAGARAJA.M.C
Executive Engineer (E), R.T South Division, KPTCL,
Rajajinagar, K.P.T.C.L, Bangalore :560010
The History of the
Transformer
 Ottó Bláthy Lucien Gaulard Sebstian Ferranti

It all started in 1883 with one of the first implementations to the

transmission line a single-phase 15 kVA, 1500/300 V transformer, by K.
Zipernowski, M. Deri, O. Blathy (Ganz, Budapest) and others.
Ottó Bláthy, Miksa Déri, Károly Zipernowsky of the
Austro-Hungarian Empire First designed and used the transformer in
both experimental, and commercial systems. Later on Lucien Gaulard,
Sebstian Ferranti, and William Stanley perfected the design.
 Transformers
"the heart of the alternating current
system“
William Stanley Jr.
William Stanley's First Transformer built in
1885
Stanley's first transformer which was used in
the electrification of Great Barrington,
Massachusetts in 1886
 When was the transformer invented?
The property of induction was discovered in the
1830's but it wasn't until 1886 that William Stanley, working
for Westinghouse built the first refined, commercially used
transformer. His work was built upon some rudimentary
designs by the Ganz Company in Hungary (ZBD Transformer
1878), and Lucien Gaulard and John Dixon Gibbs in England.
Nikola Tesla did not invent the transformer as some dubious
sources have claimed. The Europeans mentioned above did the
first work in the field, George Westinghouse and Stanley made
the transformer cheap to produce, and easy to adjust for final
use.
 Where were the
first transformers used?
The first AC power system that used the modern transformer
was in Great Barrington, Massachusetts in 1886. Earlier forms
of the transformer were used in Austro-Hungary 1878-1880s
and 1882 onward in England. Lucien Gaulard (Frenchman) used
his AC system for the revolutionary Lanzo to Turin electrical
exposition in 1884 (Northern Italy). In 1891 mastermind Mikhail
Dobrovsky designed and demonstrated his 3 phase transformers
in the Electro-Technical Exposition at Frankfurt, Germany.
 Transformer development timeline:
1830s - Joseph Henry and Michael Faraday work with electromagnets
and discover the property of induction independently on separate
continents.

1836 - Rev. Nicholas Callan of Maynooth College, Ireland invents the

induction coil

1876 - Pavel Yablochkov uses induction coils in his lighting system

1878 -1883 - The Ganz Company (Budapest, Hungary) uses

induction coils in their lighting systems with AC incandescent systems.
This is the first appearance and use of the toroidal shaped transformer.

1881 - Charles F. Brush of the Brush Electric Company in

Cleveland, Ohio develops his own design of transformer
(source: Brush Transformers Inc.)
1880-1882 - Sebastian Ziani de Ferranti (English born with an
Italian parent) designs one of the earliest AC power systems with
William Thomson (Lord Kelvin). He creates an early transformer.
Gaulard and Gibbs later design a similar transformer and loose the
patent suit in English court to Ferranti.

1882 - Lucien Gaulard and John Dixon Gibbs first built a

"secondary generator" or in today's terminology a step down
transformer which they designed with open iron core, the invention was
not very efficient to produce. It had a linear shape which did not work
efficiently. It was first used in a public exhibition in Italy in 1884 where
the transformer brought down high voltage for use to light incandescent
and arc lights. Later they designed a step up transformer. Gaulard
(French) was the engineer and Gibbs (English) was the businessman
behind the initiative. They sold the patents to Westinghouse. Later they
lost rights to the patent when Ferranti (also from England) took them to
court.
1883 - In Hungary Ottó Bláthy had suggested the use of closed-cores,
Károly Zipernowsky the use of shunt connections, and Miksa Déri had
performed the experiments. They found the major flaw of the Gaulard-
Gibbs system were successful in making a high voltage circuit work using
transformers in parallel. There design was a toroidal shape which made it
expensive to make. Wires could not be easily wrapped around it by machine
during the manufacturing process.

1884 - Use of Lucien Gaulard's transformer system (a series system) in

the first large exposition of AC power in Turin, Italy... This event caught the
eye of George Westinghouse who bought Gaulard and Gibbs Transformer
design. The 25 mile long transmission line illuminated arc lights,
incandescent lights, and powered a railway. Gaulard won an award from the
Italian government of 10,000 francs.

1885 - George Westinghouse orders a Siemens alternator (AC generator)

and a Gaulard and Gibbs transformer. Stanley begin experimenting with
this system.
1885 - makes the transformer more practical due
to some design changes: "Stanley's first patented design was for
induction coils with single cores of soft iron and adjustable gaps to
regulate the EMF present in the secondary winding. (See drawing
at left.) This design was first used commercially in the USA in
1886". William Stanley explains to Franklin L. Pope (advisor to
Westinghouse and patent lawyer.) that is design was salable and a great
improvement. Pope disagrees but Westinghouse decides to trust Stanley
anyway.

George Westinghouse and William Stanley create a transformer that is

practical to produce (easy to machine and wind in a square shape, making
a core of E shaped plates) and comes in both step up and step down
variations. George Westinghouse understood that to make AC power
systems successful the Gaulard design had to be changed. The toroidal
transformer used by the Ganz Company in Hungary and Gibbs in
England were very expensive to produce (there was no easy way to wind
wire around an iron ring without hand labor).
1886 - William Stanley uses his transformers in the electrification of
downtown Great Barrington, MA.This was the first demonstration of
a full AC power distribution system using step and step down
transformers.

Later 1880s - Later on Albert Schmid improved Stanley's design,

extending the E shaped plates to meet a central projection.

1889 - Russian-born engineer

developed the first three-phase transformer in Germany at AEG. He had
developed the first three phase generator one year before. Dobrovolsky
used his transformer in the first powerful complete AC system
(Alternator + Transformer + Transmission + Transformer + Electric
Motors and Lamps) in 1891.
1891
Early three phase transformer (circular core type)
Siemens and Halske company
5.7 kVA 1000/100 V

This transformer was created at the beginning of the modern

electrical grid.
Main parts of Power Transformer
• CORE
• WINDING AND INSULATION SYSTEM
• TANK
• BUSHINGS
• RADIATORS
• TAP CHANGER- OLTC
• PRV
• CONSERVATOR
• BREATHER
• MARSHALLING BOX
• BUCHHOLTZ RELAY
• OSR
• MOG
 CORE
• It is made up of thin laminations of CRGO of thickness
0.28mm to 0.35mm.
• Laminations are insulated from each other by oxide coating.
• Magnetostriction in the core produces a vibration that
causes audible noise called as Humming. (Due to contract
and expansion of core material)
• It is the backbone of the transformer from magnetic and
mechanical aspect.
• It provides a path for Magnetic flux.
• It supports windings.
• Low losses, better heat dissipation, low vibrations,
Higher working flux, specific core losses W/Kg at peak flux
density 1.7 Tesla at 50 Hz, ageing withstand capability.
ASSEMBLY OF TRANSFORMER CORE
 WINDING AND INSULATION SYSTEM
• Winding is made up of Copper material.
• Wound concentrically around the core limbs.
• LV winding with thick cross sectional area is placed near the
core on the press board cylinder.
• HV winding is placed above LV winding and is separated by
press board cylinder and by oil ducts, hence HV winding is
away from the core.
• Superior Craft Paper Insulation is wrapped over conductor.
• Most sensitive part subjected to Thermal, Mechanical and di-
electric Stresses.
• Major Insulations used in Windings are Thermally upgraded
Craft Paper Cylinders, Synthetic Resins bonded press board
cylinder and press board sheets.
• Minor Insulations used in windings are Press Board spacers,
Cellulose tape and synthetic enamel wire.
WINDING OF COILS USING VARIABLE SPEED MOTORS
WINDINGS OF POWER TRANSFORMERS WITH INSULATION
TRANSFORMER CORE AND WINDING ASSEMBLY UNDER OVEN FOR DRYING
 TANK
• It is made from Steel material.
• Fabricated welded construction to obtain a box type
construction.
• Supports and encloses various parts.
• Should be strong sturdy, free from vibrations.
• Should withstand mechanical load, during handling,
lifting and transport.
• Should withstand Vacuum test and Pressure test
• Tank cover supports, tap changers and other
fitments.
• It’s accessories includes lifting legs, manhole for
inspection, valves for filling and draining of oils,
earthing terminals.
TRANSFORMER TANK
 BUSHINGS
• Oil impregnated paper wound condenser bushing
(OIP).
• Provides insulated support to conductor connecting
the external terminal to the Transformer winding.
• Central Copper or Aluminum rod with surrounding
condenser body
• The Bushings are made of porcelain, the leads of HV
and LV windings are brought out and connected to the
terminals of the Bushings.
• Oil filling between condenser and porcelain.
• Bushing mounted vertically or inclined on tank over
on turrets.
TRANSFORMER BUSHINGS
 RADIATOR
• It consists of a bank of tubes through which heat of
oil is dissipated.
• Oil is circulated inside the Radiator tube and air is
circulated around Radiator tubes.
• Both oil and air flow will be forced circulation.
• It could be fitted on the tank.
• For circulating oil, oil pump is provided.
• For circulation of air, fans are provided.
 TAP CHANGER- OLTC
• On Load Tap Changer is mounted vertically
within the Transformer Tank.

• It consists of diverter switch and Tap selector

and separate Driving Mechanism Box.

• Driving Mechanism Box is fitted on the side of

the Transformer Tank.
 OLTC
WINDING

R R
Functional Diagram of M type OLTC
 Transition Sequence of Diverter Switch

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Measuring of Transition Resistance
 Pressure Relief Valve

• Pressure Relief Valve (PRV) is mounted on the tank to

permit venting out of the gases produced by oil.

• It protects Transformer Tank against explosion.

 CONSERVATOR
• It is a large cylinder connected by pipe to the
Transformer.
• Transformer Oil is filled up to certain level in the
conservator.
• Expansion and contraction of transformer oil is
accommodated by air cushion in the conservator.
• Direct contact with external air is avoided.
• It is of two types:
• Air Cushion connected with external atmosphere
through Breather.
• Air cushion contained in Rubber bags called as Air
cell or Bellow installed within the Conservator.
Rubber Bag is filled with air of +ve Pressure
 BREATHER
• It is connected to Conservator.
• It is filled with Dry Silica Gel.
• Colour of the good Silica Gel is dark blue or blue
colour.
• Silica Gel absorbs the moisture and only the Dry Air
to the Conservator.
• Wet Silica gel is in Pink or pale Pink colour.
 BUCHOLTZ RELAY

• It is fitted in the pipe between Tank and Conservator.

• It is a Gas operated Relay.
• It gives alarm for incipient faults in the Transformer
from the gas.
• Gas pressure operates alarm contacts.
• It also operates due to the loss of oil in Bucholtz Relay
and conservator tank.
BUCHOLTZ RELAY
 OIL SURGE RELAY

• It is connected in-between OLTC chamber and its

conservator.
• It is also a Gas operated Relay.
 Magnetic Oil Gauge

• Magnetic Oil Gauge is fitted on the side of

the conservator tank.
• It shows the level of the oil in the
conservator tank.
• The minimum oil level in the conservator
should be 30˚ level.
 MARSHALLING BOX
• It is placed on the side of the tank, fixed on the
Brackets.

• All instruments for Measurement Monitoring, Control

are placed in this cabinet.

• All Control cables and Power cables between

Transformer, Cooler, Control Room, Auxiliary supply ,
Switch gear etc connected via control cabinet.
TRANSPORTATION OF POWER TRANSFORMER BY
HYDRALLIC TRAILER

ON ROAD ON RAILWAY TRACK

A TRANSPARENT VIEW OF POWER TRANSFORMER
1. Manufacturing Process.

2. Classification of testing.

3. Field Tests of power Transformers.

 • Raw material basically used is CRGO(cold
rolled grained oriented)silicon steel.
Manufacturing Process RAW • The purpose of using CRGO is to reduce
the Hysteresis Losses.
MATERIAL
Of Transformer
• It is in the form of thin sheets & cut to size
as per design.
CORE • Generally three different shapes of core
CUTTING laminations are used in one assembly.

• Coil Winding is of two types:-

• R-S COIL
COIL • HELICAL COIL
WINDING • SPIRAL COIL

• The core assembly is vertically placed with the foot

plate touching the ground. the top yoke of the core
CORE is removed. The limbs of the core are tightly
wrapped with cotton tape and then varnished.
FITTING

• The coils as specified in the design may be

of following types:
• L.V COIL
ASSEMBLY • H.V COIL
 • COIL WINDING
• CONNECTION
TESTING

• Tanking is a procedure of embracement of complete

unit (active unit) in a mild steel tank, the unit being
TANKING enclosed includes (core entrapped with windings).

• ROUTINE TEST
• RATIO METER METHOD
• DIELECTRIC TESTS
TESTING AT • IMPULSE TEST LEVELS
POWER LEVEL • TEMPERATURE RISE TEST

• After testing is completed and before dispatch from the factory

all necessary work, e.g. removal of bushings etc. shall be
performed.
DISMANTLIN • A shipping list is made concerning the General arrangement
G& drawing which list out the external attachments of a power
transformer to be send to customers .
DISPATCH
 RAW MATERIAL USED
 MATERIAL- CRGO SILLICON STEEL

 DIFFERENT GRADES OF CRGO

 CTC-Continuous transposed material

 TYPICAL LOSS VALUE (W/Kg) AT 50 Hz & B

(Tesla)
CRGO
GRADE LOSS VALUE B (Telsa)
 27M-4 0.83 1.22
 MOH 0.72 0.99
 ZH100 0.70 0.96
 ZDKH90 0.60 0.83
CTC (Continuous Transposed
Conductors)
CORE CUTTING

E shape

I shape

V shape
 COIL WINDING

HELICAL WINDING SPIRAL WINDING

CONTINUOUS DISC WINDING INTERLEAVED DISC WINDING

CORE FITTING
 CONSTRUCTION

1.THREE LEG (NORMAL)

2.FIVE LEG (TO REDUCE
HEIGHT)
 CLAMPING ARRANGEMENT

1.END FRAME & INSULATION

2.CLAMPING PLATES
3.YOKE BOLTS
OR
YOKE STEEL BAND
(NO HOLE PUNCHING REQ )
 PROPER TIGHTENING TO REDUCE
NOISE LEVEL
 VARNISH AT EXPOSED SURFACES
The steps are being continued..
ASSEMBLY(BEFORE TERMINAL
GEAR STAGE)
 TOP YOKE REMOVAL

 LEVELING OF BOTTOM SUPPORT BLOCK

 LEG PREPARATION
VISUAL CHECKING OF COIL

 LOWERING OF COIL IN PROPER

ORIENTATION

 TOP INSULATION & CLAMPING RINGS

 MOUNTING OF ENDFRAMES

 SHRINKAGE IN HEATER

 TOP YOKE FITTING

 BTG TEST FOR CHECKING CORRECTNESS

 DESCRIPTION OF TESTS ON TRANSFORMERS
Sl. NAME OF TEST/
PURPOSE OF TEST/ CHECK
No. CHECK POINT
1 Core insulation tests To check the insulation between Core (CC&CL) and Ground
Operational Checks on cooler bank (pumps & Fans),
Operational Checks Breathers (silica gel or drycol), MOG, temperature gauges
2
on protection System (WTI/OTI), gas actuated relays (Buchholz, PRD, SPR etc.)
and simulation test of protection system

Test reveals the condition of insulation (i.e. degree of

dryness of paper insulation), presence of any foreign
Insulation
contaminants in oil and also any gross defect inside the
3 Resistance (IR)
transformer (e.g. Failure to remove the temporary
measurement
transportation bracket on the live portion of tap-changer
part)
Measurement of C1 & C2 Capacitance and Tanδ in UST
Capacitance and Tan mode. Changes in the normal capacitance of an insulator
4 δ measurement of indicate abnormal conditions such as the presence of
bushings moisture layer, short -circuits or open circuits in the
capacitance network.
 DESCRIPTION OF TESTS ON TRANSFORMERS
Sl. Name of Test/
Purpose of test/ check
No. Check point
Capacitance & Tan Dissipation factor /Loss factor and capacitance
δ measurement of measurement of winding is carried out to ascertain the
5
windings general condition of the ground and inter-winding
insulation
Turns ratio (Voltage To determine the turns ratio of transformers to identify any
6 ratio) measurement abnormality in tap changers/ shorted or open turns etc
Vector Group & To determine the phase relationship and polarity of
7 Polarity transformers
Winding resistance To check for any abnormalities due to loose connections,
8 measurement broken strands and high contact resistance in tap changers
Magnetic Balance This test is conducted only in three phase transformers to
9 test check the imbalance in the magnetic circuit
Floating Neutral This test is conducted to ascertain possibility of short
10 point measurement circuit in a winding.
 DESCRIPTION OF TESTS ON TRANSFORMERS
Sl. Name of Test/
Purpose of test/ check
No. Check point
This test is used to detect winding movement that usually occurs
Measurement of Short due to heavy fault current or mechanical damage during
11
Circuit Impedance
transportation or installation since dispatch from the factory.
To locate defect in magnetic core structure, shifting of windings,
failures in turn to turn insulation or problems in tap changers.
Exciting/ Magnetising
12 These conditions change the effective reluctance of the magnetic
current measurement
circuit thus affecting the current required to establish flux in the
core
To measure the vibrations of core /coil assembly in the tank of the
reactor. Movement of the core-coil assembly and shielding
Vibration measurement structure caused by the time–varying magnetic forces results in
13 of Oil immersed vibration of the tank and ancillary equipment. These vibrations
Reactor have detrimental effects such as excessive stress on the core-coil
assembly
Operational checks on To ensure smooth & trouble free operation of OLTC during
14 operation.
OLTCs
 DESCRIPTION OF TESTS ON TRANSFORMERS
Sl. Name of Test/
Purpose of test/ check
No. Check point
This test is performed to check the proper operation of
Stability of
Differential & REF protection of Transformer & Reactor by
15 Differential, REF of
simulating actual conditions. Any problem in CT connection,
Transformer/ Reactor
wrong cabling, relay setting can be detected by this test.
Tests/ Checks on
To ascertain the healthiness of bushing current transformer at the
16 Bushing Current
time of erection
Transformers (BCTs)
To assess the mechanical integrity of the transformer.
Transformers while experiencing severity of short circuit current
Frequency Response
losses its mechanical property by way of deformation of the
17 Analysis (FRA)
winding or core. During pre-commissioning this test is required to
measurement
ascertain that Transformer active part has not suffered any severe
impact/ jerk during transportation.
Oil sample for DGA to be drawn from transformer main tank
before commissioning for having a base data and after 24 hrs. of
Dissolved Gas
charging subsequently to ensure no fault gas developed after first
18 Analysis (DGA) of
charging. DGA analysis helps the user to identify the reason for
oil sample
gas formation & materials involved and indicate urgency of
corrective action to be taken
 DESCRIPTION OF TESTS ON TRANSFORMERS

Sl. Name of Test/

Purpose of test/ check
No. Check point
A thermo vision Camera determines the temperature
distribution on the surface of the tank as well as in
the vicinity of the Jumper connection to the
Thermo vision
bushing. The information obtained is useful in
Infrared scanning
19 predicting the temperature profile within the inner
(IR
surface of tank and is likely to provide approximate
thermography)
details of heating mechanism. Thermo vision
scanning of transformer to be done at least after 24
hrs of loading and repeated after one week.
 CLASSIFICATION OF TESTS

• ROUTINE TESTS

• TYPE TESTS

• SPECIAL TESTS
 (A) ROUTINE TESTS:

1. Measurement of winding resistance for each tap position

(As per IS 2026 PI Clause 16.2)

2. Measurement of voltage ratio, verification of polarity and

vector group
(As per IS 2026 PI Clause 16.3)

3. Measurement of No load losses & Magnetizing current

(As per IS 2026 PI Clause 16.5)

4. Measurement of impedance Voltage/Short Circuit impedance

and full load loss at principal tap
(As per IS 2026 PI Clause 16.4)

5. Measurement of insulation resistance

(As per IS 2026 PI( Clause 16.6)
6. DIELECTRIC TESTS

a) Power frequency/separate source AC voltage withstand

(As per IS 2026 PIII Clause 16.7)

b) Induced over voltage test

(As per IS 2026 PI Clause 16.7)

7. Testing of transformer oil (as per IS 335: 1992)

8. Tests on ON LOAD tap changer

(As per IS 2026 PI Clause 16.9)

9. Pressure test for oil leakage an a completely assembled

transformers (as per Cl.No. 17.32 (b) of CBIP specifications)
 (B) TYPE TESTS:
Following type tests shall be conducted on transformer:

1. Measurement of winding resistance

(Cl.No. 16.2 of IS 2026 Part I - 1977)
2. Measurement of voltage ratio and check of voltage vector relationship
(Cl.No. 16.3 of IS 2026 Part I - 1977)
3. Measurement of impedance voltage/short-circuit impedance (principal tapping) and load loss
(Cl.No. 16.4 of IS 2026 Part I - 1977)
4. Measurement of no load loss and current
(Cl.No. 16.5 of IS 2026 Part I - 1977)
5. Measurement of insulation resistance
(Cl.No. 16.6 of IS 2026 Part I - 1977)
6. Dielectric tests
(Cl.No. 16.7 of IS 2026 Part I - 1977)
7. Temperature – rise
(Cl.No. 16.8 of IS 2026 Part I - 1977) and
8. Tests on on-load tap-changers, where appropriate
(Cl.No. 16.9 of IS 2026 Part I - 1977)
 (C) SPECIAL TESTS:
Following special tests shall be conducted on Transformer:
1. Measurement of acoustic Noise level (at no load, at normal voltage and at normal frequency)

2. Measurement of Zero phase sequence impedance.

3. Magnetic Balance Test

4. Measurement of auxiliary losses like losses of cooling fans.

5. Measurement of Tan delta & capacitance of winding.

6. Measurement of harmonics at No load current.

7. Jacking test

NOTE:-The above stated tests has to be agreed between the purchase and
supplier. Hence purchaser should clearly specify conducting above tests in the
P.O.
 FIELD TESTS
1. I.IR Measurement
measurementsof Impedance voltage/short
circuit
2. Ratio test current
3. II. Testsgroup
Vector on OLTC
test and Cooler controls
4. III. Alarm and trip
Magnetization teststest
current
5. IV. Core Isolation
Magnetic balance test
test ( for 3 phase unit )
6. V.
C &Testing of oil
Tan delta for DGA & of
measurement other parameters
bushings and windings.
7. VI. Oil filling
Winding , oil circulation
resistance and air venting.
measurement
 (1) MEASUREMENT OF INSULATION RESISTANCE:

Reference Standard : IS 2026-Cl.No. 16.6

Equipment required : 5 KV / 10kV Insulation Tester.

TEST METHOD/PROCEDURE:

The mean temperature of transformer oil and air temperature (ambient)

will be measured & will be recorded immediately prior to the test. The insulation
resistance of each winding, in turn to all the other windings, core & frame or tank
together & to earth shall be measured & recorded as follows.
a) High voltage winding to low voltage winding.
b) High voltage winding to low voltage windings, tank & earth
c) Low voltage winding to high voltage winding, tank & earth

However, insulation resistance is highly temperature dependent and thus

the results should be corrected to a standard temperature, usually 40°C.
A good thumb rule is that for every 10°C increase in temperature, the
current doubles while resistance halves.

Most modern insulation testers offer displays that provide the operator
with both a digital readout of the result and some form of analog readout.

When an insulation tester is “hooked up” to the item to be tested, and

when the test is started several things occur.

The three different currents ---Capacitive charging

Dielectric absorption
Conduction/leakage are following.
 `The sum of these three currents will cause instrument display to
vary with the reading increasing, initially quickly and then more slowly
with time.

With an analogue display, the movement of the pointer may

provide information to an experienced operator. The movement of pointer-
traveling smoothly or stuttering?, rising steadily or intermittently dropping
back.

When doing insulation testing, more the operator knows about the results
(during and after test) it is better on how to correct the problem.

Condition of Test results What to do

No cause for concern

Fairly higher values and well maintained

Condition is probably all right

Low but well maintained may simply be the type of
insulation is poor.
Locate and remedy the cause
Fairly high values but showing a
and check the down award
constant tendency towards lower values
trend
 INSULATION RESISTANCE OF 3-WINDING TRANSFORMER IS MEASURED AS
FOLLOWS:
[TEST VOLTAGE TO BE APPLIED: 5 KV]

TERMINALS INSULATION RESISTANCE IN MEGA Polarization index =

OHMS 4/3
1 2 3 4 5
LINE [-] LINE[+] At 60 seconds At 600 seconds

HV LV+TV+Tank
Earthed
LV HV+TV+Tank
Earthed
TV HV+LV+Tank
Earthed
HV LV
LV TV
TV HV
 PURPOSE:
The insulation resistance test is one that can be easily performed in the field.
Many manufacturers require that this test be made prior to energizing a transformer, to
preclude start up failure caused by the entry of moisture into the transformer during
shipment or storage.

The insulation resistance test can detect other ground circuit that may exist in
the transformer caused by shipping damage. This test checks the complete circuit,
bushing, leads and coils.

Acceptance Criteria For megger results -At 30° C of temperature.

As per CBIP specifications the acceptable values are 2 Mega ohms

per KV but minimum values which are considered at present in KPTCL are
as follows
 As per CBIP specifications the acceptable values are 2 Mega
ohms per KV but minimum values which are considered at
present in KPTCL are as follows
: a) i) Minimum 200 M ohms, for below 6.6 KV class
ii) Minimum 400 M ohms between 6.6KV &11KV class Parameters
iii) Minimum 500 M ohms upto 33KV class
iv) Minimum 600 M ohms upto 132KV class
v) Minimum 650 M ohms upto 220KV class

(b) Polarization Index test

The measurement of insulation resistance will be done and

expressed in mega-ohms at the end of 60 seconds, & 600 seconds.
The ratio of second reading to the first reading is called
“POLARISATION INDEX”.
 The simplest implementation of the time resistance test for
solid insulation is represented by the popular polarization index
(PI) test, which requires only two readings followed by a simple
division: the one minute reading is divided into the ten-minute
reading to provide a ratio. The result is a pure number and can
normally be considered independent of temperature since the
thermal mass of the equipment being tested is usually so great that
the overall cooling which takes place during the 10 minutes of the
test is negligible.

In general, a low ratio indicates little change, hence poor

insulation, while a high ratio indicates the opposite. References to
typical PI values are common in the literature, which make this test
very easy and readily employed.
A test like the Polarization Index is particularly useful because it can be performed
on even the largest equipment, and yields a self-contained evaluation based on
relative readings rather than absolute values. But no P.I. can be calculated with
a tester of limited range, because “infinity” is not a number ! Advanced
testers reach the teraohm range, and therefore, do not run off the graph. The
largest and newest capital equipment can be readily tested to yield repeatable data
for recording and subsequent trend evaluation. The following charge highlights
selected PI values and what they mean to the operator.

Polorization Insulation
Index Condition.
<1 Poor
1-2 Questionable
2-4 Okay
>4 Good

Values above 4 indicate excellent equipment for which no action is likely to be

necessary within the immediate maintenance schedule. The operator may be
called upon to make critical judgments, however. Some high values of PI above
5.0 could indicate brittle or cracked insulation: this should be fairly obvious.
(2) MEASUREMENT OF VOLTAGE RATIO AND POLARITY:

Reference Standard : IS 2026-Part 1 : 1977 Cl.No. 16.3/IEC-76

Equipment required : Transformer turns ratio meter
TEST METHOD/PROCEDURE:

This test will be carried out with the help of direct reading turns-ratio meter.
This test will be done on all taps & all phases. The ratio meter uses the principle of
comparison of voltage fed to H.V. winding and voltage induced in the LV winding.
The ratio meter is used in a bridge circuit where the voltages of windings of the
transformer under test are balanced against the voltages developed across the fixed
and variable resistance of the ratio meter, By selecting correct ratio on ratio meter,
null will be obtained on the null detector usually galvanometer is incorporated along
with ratio meter. This method also confirms the polarity of the windings since a zero
reading would notbe obtained if one of the windings connections are reversed. Ratio
readings on each tap will be recorded. This procedure will be repeated for all 3 phases
in turn. In the case of double ratio transformers, the tests should be carried out for
both ratios.
 PURPOSE:
The purpose of this test is to find out ratio of HV to LV which is
Generally 6:1 for Power transformers at normal Tap.

per phase voltage on HV side

Turns ratio=
per phase voltage on LV side

No. of HV turns
Turns ratio=
No. of LV turns

For example, per phase HV voltage = 66000 V, per phase LV Voltage = 11000 V

66000
Turns ratio=
11000

Therefore Turns ratio= 6.

 Further, this test is to ensure that all windings have the correct
number of turns according to design and should be connected properly. If a
transformer is equipped with either off load tap changer or on load tap
changer then the ratio tests are also carried out at the various positions of
the tap changer.

The object of ratio tests at different tap positions is to ensure that all the
winding taps are made at the correct turns and that the tap connections are
properly made to the tap changer.

Acceptance Critera/
Tolerance on test : Tolerance permissible is +/-0.5% of
Parameter declared ratio on all the taps.
 (3) VERIFICATION OF VECTOR GROUP:

TEST METHOD/PROCEDURE:
Reference : IS 2026-Cl.No. 16.3
Equipment required : Refer figure No. 3

The LV vector will be superimposed on HV by connecting 1U and 2U

terminals 2u
1U
2n
2v

2w

1W 1V

The three phase voltage will be applied to the line terminals of HV winding &
voltage measurement will be done across.
1U-1V 1V-2V 1V-2W

1V-1W 1W-2V 1W-2W

1W-1U 1U-2N 1V-2N

Checks : voltage measured across, must satisfy following conditions

1V-2V = 1V-2W
1W-2V > 1W-2W
1U-2N + 1V-2N = 1U - 1V

PURPOSE: The purpose of this test is to find out whether the winding
connection is as per customer’s specifications. That is, this test
is to ensure that all the windings are assembled in correct
physical orientation and they are connected properly to provide
the desired phase relationship.

Acceptance Criteria : Should confirm the vector group required

 (4) MEASUREMENT OF MAGNETISING CURRENT

Reference Standard : IS 2026-Cl.No. 16.5

• The test is conducted by injecting 3-phase or

two-phase voltages on L.V or H.V windings
keeping the other side open.

• Precautions
This test should be done before DC
measurements of winding resistance to reduce
the effect of residual magnetism. The
transformer may be demagnetized before
commencement of magnetizing current test.
 (5) MAGNETIC BALANCE & MEASUREMENT OF MAGNETISING
CURRENT TEST:
Reference Standard : IS 2026
Equipment : Multi meter

TEST METHOD / PROCEDURE:

This test is carried out preferable from LV side of the transformer

provided the voltage class of the LV winding is more than 6.6 KV. The
voltage available at mains shall be applied across the winding terminals
pertaining to ‘U’ phase and the corresponding transferred voltages
across ‘V’ & ‘W’ phases shall be measured. Then similarly the mains
voltage shall be applied to ‘V’ & ‘W’ phase in turn and measured across
each of the remaining two phases.
In all the three cases the voltage distribution shall be checked.

TABLE OF MAGNETIC BALANCE TEST

TYPICAL VALUES OF A 10MVA POWER TRANSFORMER
 The magnetizing current shall be measured at the time of
application of voltage across individual phases.

1U-1V 1V-1W 1W-1U 2N-2U 2N-2U 2N-2V

401 321 80 402 309 93

202 403 201 201 401 200
70 333 403 99 302 401

Acceptance Criteria/ : The values shall be recorded for

reference Tolerance on Test
Parameters
 (5) TAN DELTA AND CAPACITANCE TEST:
Reference Standard : IS 2026
Equipment : 12KV Capacitance and tan delta bridge

TEST METHOD / PROCEDURE:

Measurement will be done with a direct reading of capacitance in micro/pico farads
and tan delta in percentage under UST and GST mode to measure the capacitance
between the windings and capacitance with respect to ground as follows.
CAPACITANCE & TAN DELTA VALUES OF BUSHING.
Terminals Sr.No. of Test Capacitance in Tan Delta in
Bushing voltage pico farads %
5KV
The capacitance
1U values
10KVare taken for future

reference only. 5KV

10KV
The value
1V
of Tan delta shall be less than 0.5%.
5KV
1W 10KV
5KV
2U 10KV
5KV
2V 10KV
5KV
10KV
2W
 (7) MEASUREMENT OF WINDING RESISTANCE:

Reference Standard : IS 2026-P I/1997 (Clouse No. 16.2)

Equipment required : Kelvin double Bridge/wheat stone
Bridge. High accuracy digital resistance
meters & Thermometers.

TEST METHOD/PROCEDURE:

The resistance of each windings of Principal, maximum and

minimum tap or each taps shall be measured depending on the value
of the resistance using Kelvin Bridge or high accuracy digital
resistance meters.
 PURPOSE:

This is a measure of the resistance of the copper conductor in the transformer

windings.

The resistance measurements taken at known temperatures have two

important functions.

1. Calculation of the temperature of the windings during the temperature

rise-test

2. Calculation of I2 R components of the winding losses and stray losses.

Resistance measurement across the transformer terminals provide an

assessment of the quality of internal connections made to the transformer
windings. Loose or defective connections are indicated by usually high
or unstable resistance windings.

Acceptance criteria
Tolerance on test parameters : +/-3% of designed value of resistance
(8) MEASUREMENT OF IMPEDANCE VOLTAGE/SHORT CIRCUIT CURRENT.
Reference standard : IS 2026-Cl.No. 16.4
Equipment required : Voltmeters, Ammeters, milli-ammeter.
 TEST METHOD/PROCEDURE:

The impedance voltage / short circuit impedance ( on principal

tapping only) and load loss shall be measured at rated frequency by
applying an approximately sinusoidal supply of rated current to HV
winding with the other LV winding short circuited, with the windings
connected on the relevant tapping.
On Field- 3-phase currents is passed to the High voltage winding keeping
the other winding shorted (Two Winding). The Phase currents and neutral
currents are recorded.
IMPEDANCE:

The impedance is normally expressed in terms of percent of rated

voltage. The impedance voltage is that voltage required circulating the rated
current through the primary winding with secondary shorted. The impedance is
composed of two components, the percent reactance voltage (% X) and the
percent resistance voltage (% R). The equation expressing the percent impedance
is as follows:

% Z = √ (% X)2 + (% R)2
 The percent resistance voltage is the ratio of the winding losses over the rated
KVA and can be determined as follows:
% R = winding losses (watts)/10 x KVA
The percent reactance voltage can be determined by substituting for % R and %Z.
The %R and %X components are important in calculating the regulation of the transformer.

PURPOSE :
The purpose of this test is to measure I2R loss in winding and stray losses in the tank
& find out impedance level during short circuit test.

The impedance test is made to verify the design impedance.

The impedance is also important when paralleling two or more transformers.

A transformer dissipates load loss that depends upon the transformer load current .
Load loss is a cost to the user during the life time of transformer. Maximum values of the
load loss of transformers at rated current are specified and often guaranteed by the
manufacturer. Load loss measurements are made to verify that the load loss does not exceed
the specified or guaranteed value.
Acceptance Criteria/ : The losses & impedance shall be within
Tolerance on test guaranteed values mentioned in the purchase
Parameters order or + 10% tolerance on total losses and
+/-10% tolerance on declared impedance
 (9) TESTING OF TRANSFORMER OIL (as per IS 335)

The transformer oil sample of power transformer should have following

characteristics as per IS 335:

Conducting DGA of Transformer oil Portable DGA testing kit

 Schedule of characteristics
Sl.No. Characteristics Required Method of Tests Remarks
-1 -2 -3 -4 -5

i) Appearance The coil shall be clear and A representative sample of the -

transparent and free oil shall be examined in
from suspended a 100 mm thick layer at
0
matter or sediments 27 C
0 3
ii) Density at 29.5 C Max 0.89 g/cm IS 1448 [P:16] 1977 See NOTE 1

iii) Kinematic viscosity. Max, at IS 1448 [P:25] 1976 -

0
a) 27 C
0
b) 40 C 27 Copy Submitted to:

Under consideration
0
iv) Interfacial tension at 27 C, 0.04 N/m IS 6104 : 1971 -
Min
0
v) Flash point pensky-Marten 140 C IS 1448 [P:21] 1970 -
(closed), Min
0
vi) Pour point, Max -6 C IS 1448 [P:10] 1970 -

vii) Neutralization value IS 1448 [P:2] 1967 Alcoholic potassium

hyudroxide solution
a) Total acidity, 0.03 mg KOH/G of 0.02 N should be
Max used in place of 0.1
N indicated in test
b) Inorganic Nil do method
acidity/alkalinity

viii) Corrosive sulphur Non-corrosive Annex B -

ix) Electric strength IS 6792 : 1972 -

(breakdown voltage)

a) New unfiltered oil, Min 30KV (rms)

b) After filtration, Min

If the above value is not See Note 2

attained, the oil shall
be filtered 60KV (rms)
x) Dielectric dissipation factor 0.002 IS 6262 : 1971 See note
0
(tan q) at 90 C, Max
xi) Specific resistance IS 6103 : 1971 See note 2
(resistivity)
0
a) At 90 C, MIn
0 12
b) At 27 C, Min 35 x 10 ohm-cm
12
1500x 10 ohm-cm

xii) Oxidation stability Annex C -

a) Neutralization value after 0.4 mg KOH/g

oxidation, Max

b) Total sludge, after

oxidation Max
0.1 % by weight

xiii) Ageing characteristics after - IS 12177 : 1987 -

accelerated ageing (open
beaker method with copper
catalyst)

a) Specific resistance Method A

(resistivity)
0
1) at 27 C, Min
0
2) at 90 C, Min

b) Dielectric dissipation
0
factor (Tan q) at 90 C, Max
c) Total acidity, Max

d) Total sludge, Max IS 6103 : 1971

12
2.5 x 10 ohm-cm
12
0.2 x 10 ohm-cm

0.2 IS 6262 : 1971

0.05 mg KOH/G IS 1448 [P : 2] : 1967

0.05% by weight Annex A of IS 12177

xiv) Presence of oxidation The oil shall contain anti- IS 13631 : 1992 See Note 3
inhibitor oxidant additives

xv) Water content, Max 50 ppm IS 13567 : 1992 -

xvi) SK value Under consideration Annex D -

 a) BDV of Transformer oil – Testing procedure

Reference standard : IS 6792 : 1992

Equipment : Transformer oil BDV tester
Circuit diagram : Refer Figure No. 9
The oil sample shall be taken out from the bottom sampling valve of the transformer in
an oil cup. The oil cup shall be rinsed with the oil twice or thrice before filling it with the oil
sample. The gap between the two electrodes shall be set to 2.5mm with Go-No Go Guage. The
gap between them shall be set to an accuracy of +/- 0.01 mm by means of thickness gauge. The
axis of electrodes is immersed to a depth of approx 40 mm. Test for breakdown voltage shall be
made at an atmosphere of less than 50% relative humidity. The oil shall be allowed to settle down
for the period of 10 minutes. The voltage shall be gradually raised form zero till the breakdown
occurs.

Six such readings shall be taken at the interval of 1 minute & the average of six
readings shall be taken as the breakdown voltage of the oil sample under test.

Acceptance Criteria : Minimum B.D.V. is 50 for cold oil

Tolerance on test as per KPTCL p.o. specifications
Parameters
 (10) TESTS ON ON - LOAD TAP CHANGER
(AT RATED VOLTAGE & RATED CURRENT)
Test will be carried as per IS 2026 part I – 1997 (Cl. No. 16.9)

Figure: Assembling of EMR OLTCs for 100MVA Transformer at

M/s. EMCO Ltd, Thane.
1) Functional test:

After tap changer and transformer have been fitted together the following tests are
carried out at 100 percent of the rated auxiliary supply voltage. Following
performed without failure.
a) Eight complete operating cycles with the transformer not energised.
b) One complete operating cycle with the transformer not energized, with 85 percent
of the rated auxiliary supply voltage .
c) One complete operating cycle with the transformer energized at rated voltage
and
frequency at no load; and
d) Ten tap-change operations with + 8 steps on either side of the principal tapping
with one winding short-circuited.

PURPOSE:

The correct functioning of all control devices, including limit switches and
mechanical end stops will be demonstrated.
 (11) Inspection of Accessories of Power Transformer
i. Oil conservator and air cell

Oil conservator shall be checked for physical dimensions. Air cell shall be
tested by applying certain pressure for definite time to see air leakage.
 (11) Inspection of Accessories of Power Transformer
ii. Pressure relief device

Pressure relief device shall be tested for designed pressure

 (11) Inspection of Accessories of Power Transformer
iii. Magnetic oil gauge
Magnetic oil gauge shall be tested for its operation as per the manual
 (11) Inspection of Accessories of Power Transformer
iv. Marshalling Box/Cooler cabinet for oil pumps and fans

Marshalling box wiring shall be tested to withstand 2KV for one minute. All
the wiring connections shall be tested in accordance with approved
Drawing. All the operations of cooling fans and oil pumps shall be tested
for its operation as per Technical specifications.
SOME OF THE FAILURES
Failure of 400/220kv/33kv,
315MVA transformer
(BHEL make) at bamnauli
substation of
delhi transco on 11-02-2008
Courtesy : CEA
THANK YOU

9448365077