Sunday 22 July 2012

Miniature Circuit Breaker

Miniature Circuit Breaker or MCB

What is MCB ?

Nowadays we use more commonly Miniature Circuit Breaker or MCB in low voltage electrical network instead of fuse.

The MCB has some advantages compared to fuse.
1. It automatically switches off the electrical circuit during abnormal condition of the network means in over load condition as well as faulty condition. The fuse does not sense but Miniature Circuit Breaker does it in more reliable way. MCB is much more sensitive to over current than fuse.
2. Another advantage is, as the switch operating knob comes at its off position during tripping, the faulty zone of the electrical circuit can easily be identified. But in case of fuse, fuse wire should be checked by opening fuse grip or cutout from fuse base, for confirming the blow of fuse wire.
3. Quick restoration of supply can not be possible in case of fuse as because fuses have to be rewirable or replaced for restoring the supply. But in the case of MCB, quick restoration is possible by just switching on operation.
4. Handling MCB is more electrically safe than fuse.
Because of to many advantages of MCB over fuse units, in modern low voltage electrical network, Miniature Circuit Breaker is mostly used instead of backdated fuse unit.
Only one disadvantage of MCB over fuse is that this system is more costlier than fuse unit system.
miniature circuit breaker

Miniature Circuit Breaker Working Principle

There are two arrangement of operation of miniature circuit breaker. One due to thermal effect of over current and other due to electromagnetic effect of over current. The thermal operation of miniature circuit breaker is achieved with a bimetallic strip whenever continuous over current flows through MCB, the bimetallic strip is heated and deflects by bending. This deflection of bimetallic strip releases mechanical latch. As this mechanical latch is attached with operating mechanism, it causes to open the miniature circuit breaker contacts. But during short circuit condition, sudden rising of current, causes electromechanical displacement of plunger associated with tripping coil or solenoid of MCB. The plunger strikes the trip lever causing immediate release of latch mechanism consequently open the circuit breaker contacts. This was a simple explanation of miniature circuit breaker working principle.

Miniature Circuit Breaker Construction

Miniature circuit breaker construction is very simple, robust and maintenance free. Generally an MCB is not repaired or maintained, it just replaced by new one when required. A miniature circuit breaker has normally three main constructional parts. These are:

Frame of Miniature Circuit Breaker

The Frame of Miniature Circuit Breaker is a molded case. This is a rigid, strong, insulated housing in which the other components are mounted.

Operating Mechanism of Miniature Circuit Breaker

The Operating Mechanism of Miniature Circuit Breaker provides the means of manual opening and closing operation of miniature circuit breaker. It has three-positions "ON," "OFF," and "TRIPPED". The external switching latch can be in the "TRIPPED" position, if the MCB is tripped due to over-current. When manually switch off the MCB, the switching latch will be in "OFF" position. In close condition of MCB, the switch is positioned at "ON". By observing the positions of the switching latch one can determine the condition of MCB whether it is closed, tripped or manually switched off.

Trip Unit of Miniature Circuit Breaker

The Trip Unit is the main part, responsible for proper working of miniature circuit breaker. Two main types of trip mechanism are provided in MCB. A bimetal provides protection against over load current and an electromagnet provides protection against short-circuit current.

Practice for power system protection

Code of practice for power system protection

01 The entire wiring of circuitry for indications, alarms, metering and protection should be permanent wiring.
02 The leads should be marked and identified by ferrules near terminals.
03 Every lead should end at a terminal point and no junction by twisting is allowed.
04 The wiring should be by copper leads for C.T secondary for all cores i.e. metering cores as well as protection cores and for PT secondary for protection core.
05 The wiring should be by copper leads 1.07 The copper lead for 1.05 & 1.06 above should be stranded but not single lead type.
06 Aluminum leads can be used for indication, alarms and PT secondary for metering but stranded wires only are to be used. But copper leads are always preferable for these said purposes.
07 The terminations should be lugged by ring shape ‘O’ lugs. ‘U’ shape lugs should be avoided since ‘U’ shape lugs may slip if terminal is loosen.
08 For CT Secondary terminations, two nuts with one spring washer and two flat washers to be compulsorily used.
09 The CT terminal strips should be stud type with nuts and not screw-in-type.
10 Wherever two sets of batteries are available, the primary protection and back-up protection should be from different batteries.
11 Where there is only one battery at an Electrical Power Substation, the primary and back-up protections should be given D.C supply through two individual circuits with independent fuses run from D.C bus.
12 When CBs have two trip coils, both main protection and backup protection will energize both the trip coils.
13 D.C and A.C supplies should not be taken through different cores of the same cable. Totally different cables should be used for DC and AC supplies.
14 Independent D.C cables should be run to each equipment in the yard and looping of D.C supply from one equipment to other is not permitted.
15 The D.C emergency lighting in substation should be through independent cables and not mixed up with protection and other circuitry.
16 Standard color codes for wires in control circuit of different sizes should be as follows,
PURPOSESIZECOLOR
Indication, Alarm, trip, close etc 1.5 mm2 Gray
Red Phase Metering PT Circuit 1.5 mm2Red
Yellow Phase Metering PT Circuit 1.5 mm2Yellow
Blue Phase Metering PT Circuit 1.5 mm2Blue
Red Phase Protection PT Circuit 2.5 mm2Red
Yellow Phase Protection PT Circuit 2.5 mm2Yellow
Blue Phase Protection PT Circuit 2.5 mm2Blue
Red Phase Metering and Protection CT Circuit 2.5 mm2Red
Yellow Phase Metering and Protection CT Circuit 2.5 mm2Yellow
Blue Phase Metering and Protection CT Circuit 2.5 mm2Blue
Phase for auxiliary AC supply2.5 mm2Red
Neutral for auxiliary AC supply2.5 mm2Black
Common star point of CTs 2.5 mm2Black
Common star point of Protection PTs 2.5 mm2Black
Common star point of Metering PTs 1.5 mm2Black
Earthing Connection 2.5 mm2Green
17 The lead numbers are also standardized as follows so that anyone can easily identify the purpose for which the lead is connected
Alphabet SeriesPurposeExample
J Series D.C Incoming J1, J2, etc.
K Series Control - Closing, Tripping, etc.K1, K2, K3 etc.
L Series Alarms, indications and annunciations L1, L2, L3, etc.
M Series Motor Circuit M1, M2, etc.
E Series Potential transformer secondaries E1, E2, E3, etc.
H Series LT A.C Supply H1, H2, H3, etc..
A Series C.T secondary for special protection A1, A2, A3, etc.
B Series Bus bar protection B1, B2, B3, etc..
C Series Protection Circuits C1, C2, C3, etc.
D Series Metering Circuit D1, D2, D3, etc.
18 The CT ratios available and adopted with number of cores shall be displayed on each panel as follows: (with underlined position as adopted). 400 - 200 - 100 / 1-1-1
19 Wherever CT cores are not used “SHORTING LOOPS” should be provided in CT secondary terminals and not in marshaling boxes or at panels.
20 The Cable entries in the equipment, marshaling boxes and panels should be through appropriate size of cable glands. No other means are allowed.
21 PT secondaries should have group MOCBs with D.C alarm.
22 Few cells from a battery set should not be used for separate low voltage D.C circuits. Here D.C - D.C converters may be employed for utilizing full D.C voltage of the entire battery as input.

Standard lead numbers used in control circuit of protection of power system

Certain lead numbers are standardized as follows and should be compulsorily adopted with ferrules at terminations of leads.
Main DC Positive supply – J1
Main DC Negative supply – J2
DC Positive bus inside panel – K1
DC Nagetive bus inside panel – K2
Remote Close - K15R
Remote Trip - K5R
Local Close - K15L
Local Trip - K5L
Metering CT secondaries – D11, D31, D51, D71 etc.
Protection CT secondaries – C11, C31, C51, C71 etc.
Special Protection CT secondaries – A11, A31, A51, A71 etc.
PT scondaries - E11, E31, E51, E71 etc.

Different relay device number used in protection of power system

Mark NumberName of the Device
2 Time delay relay
3 Checking or Interlocking relay
21 Distance relay
25 Check synchronizing relay
27 Under voltage relay
30 Annunciator relay
32 Directional power (Reverse power) relay
37 Low forward power relay
40 Field failure (loss of excitation) relay
46 Negative phase sequence relay
49 Machine or Transformer Thermal relay
50 Instantaneous Over current relay
51 A.C IDMT Over current relay
52 Circuit breaker
52a Circuit breaker Auxiliary switch “Normally open” (‘a’ contact)
52b Circuit breaker Auxiliary switch “Normally closed” (‘b’ contact)
55 Power Factor relay
56 Field Application relay
59 Overvoltage relay
60 Voltage or current balance relay
64 Earth fault relay
67 Directional relay
68 Locking relay
74 Alarm relay
76 D.C Over current relay
78 Phase angle measuring or out of step relay
79 AC Auto reclose relay
80 Monitoring loss of DC supply
81 Frequency relay
81U Under frequency relay
81O Over frequency relay
83 Automatic selective control or transfer relay
85 Carrier or pilot wire receive relay
86 Tripping Relay
87 Differential relay
87G Generator differential relay
87GT Overall differential relay
87U UAT differential relay
87NT Restricted earth fault relay
95 Trip circuit supervision relay
99 Over flux relay
186A Auto reclose lockout relay
186B Auto reclose lockout relay


Electrical Isolator in Substation

Electrical Isolator or Electrical Isolation Switch

Definition of Isolator

Circuit breaker always trip the circuit but open contacts of breaker cannot be visible physically from outside of the breaker and that is why it is recommended not to touch any electrical circuit just by switching off the circuit breaker. So for better safety there must be some arrangement so that one can see open condition of the section of the circuit before touching it. Isolator is a mechanical switch which isolates a part of circuit from system as when required. Electrical isolators separate a part of the system from rest for safe maintenance works.
So definition of isolator can be rewritten as Isolator is a manually operated mechanical switch which separates a part of the electrical power system normally at off load condition.

Types of Electrical Isolators

There are different types of isolators available depending upon system requirement such as
Double Break Isolator
Single Break Isolator
Pantograph type Isolator
Depending upon the position in power system, the isolators can be categorized as
Bus side isolator – the isolator is directly connected with main bus
Line side isolator – the isolator is situated at line side of any feeder
Transfer bus side isolator – the isolator is directly connected with transfer bus

Constructional features of Double Break Isolators

Lets have a discussion on constructional features of Double Break Isolators. These have three stacks of post insulators as shown in the figure. The central post insulator carries a tubular or flat male contact which can be rotated horizontally with rotation of central post insulator. This rod type contact is also called moving contact. double break isolator The female type contacts are fixed on the top of the other post insulators which fitted at both sides of the central post insulator. The female contacts are generally in the form of spring loaded figure contacts. The rotational movement of male contact causes to come itself into female contacts and isolators becomes closed. The rotation of male contact in opposite direction make to it out from female contacts and isolators becomes open. Rotation of the central post insulator is done by a driving lever mechanism at the base of the post insulator and it connected to operating handle (in case of hand operation) or motor (in case of motorized operation) of the isolator through a mechanical tie rod.

single break isolator

Constructional features of Single Break Isolators

The contact arm is divided into two parts one carries male contact and other female contact. The contact arm moves due to rotation of the post insulator upon which the contact arms are fitted. Rotation of both post insulators stacks in opposite to each other causes to close the isolator by closing the contact arm. Counter rotation of both post insulators stacks open the contact arm and isolator becomes in off condition. This motorized form of this type of isolators is generally used but emergency hand driven mechanism is also provided.

Earthing Switches

Earthing switches are mounted on the base of mainly line side isolator. Earthing switches are normally vertically break switches. Earthing arms (contact arm of earthing switch) are normally aligned horizontally at off condition. during switching on operation, these earthing arms rotate and move to vertical position and make contact with earth female contacts fitted at the top of the post insulator stack of isolator at its outgoing side. The erarthing arms are so interlocked with main isolator moving contacts that it can be closed only when the main contacts of isolator are in open position. Similarly the main isolator contacts can be closed only when the earthing arms are in open position.

Operation of Electrical Isolator

As no arc quenching technique is provided in isolator it must be operated when there is no chance current flowing through the circuit. No live circuit should be closed or open by isolator operation. A complete live closed circuit must not be opened by isolator operation and also a live circuit must not be closed and completed by isolator operation to avoid huge arcing in between isolator contacts. That is why isolators must be open after circuit breaker is open and these must be closed before circuit breaker is closed. Isolator can be operated by hand locally as well as by motorized mechanism from remote position. Motorized operation arrangement costs more compared to hand operation; hence decision must be taken before choosing an isolator for system whether hand operated or motor operated economically optimum for the system. For voltages up to 145KV system hand operated isolators are used whereas for higher voltage systems like 245 KV or 420 KV and above motorized isolators are used.

Substation Layout

Electrical Bus System & Substation Layout

Electrical Bus System

There are many different electrical bus system schemes available but selection of a particular scheme depends upon the system voltage, position of substation in electrical power system, flexibility needed in system and cost to be expensed.

The main criteria’s to be considered during selection of one particular Bus – Bar Arrangement Scheme among others

(i) Simplicity of system
(ii) Easy maintenance of different equipments.
(iii) Minimizing the outage during maintenance.
(iv) Future provision of extension with growth of demand
(v) Optimizing the selection of bus bar arrangement scheme so that it gives maximum return from the system.
Some very commonly used bus bar arrangement are discussed below

Single Bus System

Single Bus System is simplest and cheapest one. In this scheme all the feeders and transformer bay are connected to only one single bus as shown.


Advantages of single bus system

This is very simple in design
This is very cost effective scheme
This is very convenient to operate

Disadvantages of single bus system

single bus system One but major difficulty of these type of arrangement is that, maintenance of equipment of any bay cannot be possible without interrupting the feeder or transformer connected to that bay.
The indoor 11KV switchboards have quite often single bus bar arrangement.

Single Bus System with Bus Sectionalizer

Some advantages are realized if a single bus bar is sectionalized with circuit breaker. If there are more than one incoming and the incoming sources and outgoing feeders are evenly distributed on the sections as shown in the figure, interruption of system can be reduced to a good extent.

Advantages of single bus system with bus sectionalizer

If any of the sources is out of system, still all loads can be fed by switching on the sectional circuit breaker or bus coupler breaker.
single section bus system If one section of the bus bar system is under maintenance, part load of the substation can be fed by energizing the other section of bus bar.

Disadvantages of single bus system with bus sectionalizer

As in the case of single bus system, maintenance of equipment of any bay cannot be possible without interrupting the feeder or transformer connected to that bay.
The use of isolator for bus sectionalizing does not fulfill the purpose. The isolators have to be operated ‘off circuit’ and which is not possible without total interruption of bus – bar. So investment for bus-coupler breaker is required.

Double Bus System

In double bus bar system two identical bus bars are used in such a way that any outgoing or incoming feeder can be taken from any of the bus. Actually every feeder is connected to both of the buses in parallel through individual isolator as shown in the figure. double bus system By closing any of the isolators one can put the feeder to associated bus. Both of the buses are energized and total feeders are divided into two groups, one group is fed from one bus and other from other bus. But any feeder at any time can be transferred from one bus to other. There is one bus coupler breaker which should be kept close during bus transfer operation. For transfer operation, one should first close the bus coupler circuit breaker then close the isolator associated with the bus to where the feeder would be transferred and then open the isolator associated with the bus from where feeder is transferred. Lastly after this transfer operation he or she should open the bus coupler breaker.


Advantages of Double Bus System

Double Bus Bar Arrangement increases the flexibility of system.

Disadvantages of Double Bus System

The arrangement does not permit breaker maintenance with out interruption.

Double Breaker Bus System

double breaker bus system In double breaker bus bar system two identical bus bars are used in such a way that any outgoing or incoming feeder can be taken from any of the bus similar to double bus bar system. Only difference is that here every feeder is connected to both of the buses in parallel through individual breaker instead only isolator as shown in the figure. By closing any of the breakers and its associated isolators, one can put the feeder to respective bus. Both of the buses are energized and total feeders are divided into two groups, one group is fed from one bus and other from other bus similar to previous case. But any feeder at any time can be transferred from one bus to other. There is no need of bus coupler as because the operation is done by breakers instead of isolator. For transfer operation, one should first close the isolators and then the breaker associated with the bus to where the feeder would be transferred and then he or she opens the breaker and then isolators associated with the bus from where feeder is transferred.

One and a half Breaker Bus System

one and half breaker bus system This is an improvement on the double breaker scheme to effect saving in the number of circuit breakers. For every two circuits only one spare breaker is provided. The protection is however complicated since it must associate the central breaker with the feeder whose own breaker is taken out for maintenance. For the reasons given under double breaker scheme and because of the prohibitory costs of equipment even this scheme is not much popular. As shown in the figure that it is a simple design, two feeders are fed from two different buses through their associated breakers and these two feeders are coupled by a third breaker which is called tie breaker. Normally all the three breakers are closed and power is fed to both the circuits from two buses which are operated in parallel. The tie breaker acts as coupler for the two feeder circuits.
During failure of any feeder breaker, the power is fed through the breaker of the second feeder and tie breaker, therefore each feeder breaker has to be rated to feed both the feeders, coupled by tie breaker.

Advantages of One and a half Breaker Bus System

During any fault on any one of the buses, that faulty bus will be cleared instantly without interrupting any feeders in the system since all feeders will continue to feed from other healthy bus.

Disadvantages of One and a half Breaker Bus System

This scheme is much expensive due to investment for third breaker.

Main and Transfer Bus System

main and transfer bus system This is an alternative of double bus system. The main conception of Main and Transfer Bus System is, here every feeder line is directly connected through an isolator to a second bus called transfer bus. The said isolator in between transfer bus and feeder line is generally called bypass isolator. The main bus is as usual connected to each feeder through a bay consists of circuit breaker and associated isolators at both side of the breaker. There is one bus coupler bay which couples transfer bus and main bus through a circuit breaker and associated isolators at both sides of the breaker. If necessary the transfer bus can be energized by main bus power by closing the transfer bus coupler isolators and then breaker. Then the power in transfer bus can directly be fed to the feeder line by closing the bypass isolator. If the main circuit breaker associated with feeder is switched off or isolated from system, the feeder can still be fed in this way by transferring it to transfer bus.

Switching operation for transferring a feeder to transfer bus from main bus without interruption of power

(i) First close the isolators at both side of the bus coupler breaker.
(ii) Then close the bypass isolator of the feeder which is to be transferred to transfer bus.
(iii) Now energized the transfer bus by closing the bus coupler circuit breaker from remote.
(iv) After bus coupler breaker is closed, now the power from main bus flows to the feeder line through its main breaker as well as bus coupler breaker via transfer bus.
(v) Now if main breaker of the feeder is switched off, total power flow will instantaneously shift to the bus coupler breaker and hence this breaker will serve the purpose of protection for the feeder.
(vi) At last the operating personnel open the isolators at both sides of the main circuit breaker to make it isolated from rest of the live system.
So it can be concluded that in Main & Transfer Bus System the maintenance of circuit breaker is possible without any interruption of power. Because of this advantage the scheme is very popular for 33KV and 13KV system.

Double Bus System with Bypass Isolators

double bus with bypass isolator system This is combination of the double bus system and main and transfer bus system. In Double Bus System with Bypass Isolators either bus can act as main bus and second bus as transfer bus. It permits breaker maintenance without interruption of power which is not possible in double bus system but it provides all the advantages of double bus system. It however requires one additional isolator (bypass isolator) for each feeder circuit and introduces slight complication in system layout. Still this scheme is best for optimum economy of system and it is best optimum choice for 220KV system.

Ring Bus System

ring bus system The schematic diagram of the system is given in the figure. It provides a double feed to each feeder circuit, opening one breaker under maintenance or otherwise does not affect supply to any feeder. But this system has two major disadvantages. One as it is closed circuit system it is next to impossible to extend in future and hence it is unsuitable for developing system. Secondly, during maintenance or any other reason if any one of the circuit breaker in ring loop is switch of reliability of system becomes very poor as because closed loop becomes opened. Since, at that moment for any tripping of any breaker in the open loop causes interruption in all the feeders between tripped breaker and open end of the loop.



Electrical Substation

Electrical Power Substation Engineering


Electrical Substation

Now days the electrical power demand is increasing very rapidly. For fulfilling these huge power demands the modern time requires creation of bigger and bigger power generating stations. These power generating stations may be hydro – electric, thermal or atomic. Depending upon the availability of resources these stations are constructed different places. These places may not be nearer to load centers where the actual consumption of power takes place. So it is necessary to transmit these huge power blocks from generating station to their load centers. Long and high voltage transmission networks are needed for this purpose. Power is generated comparatively in low voltage level. It is economical to transmit power at high voltage level. Distribution of electrical power is done at lower voltage levels as specified by consumers. For maintaining these voltage levels and for providing greater stability a number of transformation and switching stations have to be created in between generating station and consumer ends. These transformation and switching stations are generally known as electrical substations. Depending upon the purposes, the substations may be classified as

Step up Substation

Step up substations are associated with generating stations. Generation of power is limited to low voltage levels due to limitations of the rotating alternators. These generating voltages must be stepped up for economical transmission of power over long distance. So there must be a step up substation associated with generating station.
primary step down substation

Step down Substation

The stepped up voltages must be stepped down at load centers, to different voltage levels for different purposes. Depending upon these purposes the step down substation are further categorized in different sub categories.

Primary Step down Substation

The primary step down sub stations are created nearer to load center along the primary transmission lines. Here primary transmission voltages are stepped down to different suitable voltages for secondary transmission purpose.

Secondary Step down Substation

secondary step down substation Along the secondary transmission lines, at load center, the secondary transmission voltages are further stepped down for primary distribution purpose. The stepping down of secondary transmission voltages to primary distribution levels are done at secondary step down substation.

Distribution Substation

Distribution Substation are situated where the primary distribution voltages are stepped down to supply voltages for feeding the actual consumers through a distribution network.

Bulk Supply or Industrial Substation

Bulk Supply or Industrial Substation are generally a distribution sub – station but they are dedicated for one consumer only. An industrial consumer of large or medium supply group may be designated as bulk supply consumer. Individual step down substation is dedicated to these consumers.

Mining Substation

The mining substation are very special type of substation and they need special design construction because of extra precautions for safety needed in the operation of electric supply.

Mobile Substation

The mobile Substations are also very special purpose sub – station temporarily required for construction purpose. For big construction purpose this Substation fulfils the temporary power requirement during construction work.
Depending upon the constructional feature categories of sub – station may be divided into following manner

Outdoor type sub – station

outdoor substation Outdoor type Substation are constructed in open air. Nearly all 132KV, 220KV, 400KV substation are outdoor type substation. Although now days special GIS (Gas Insulated Sub – Station) are constructed for Extra High Voltage system which are generally situated under roof.

Indoor Substation

The substations are constructed under roof is called indoor type substation. Generally 11KV and sometime 33KV substation are of this type.

Underground Substation

The substation are situated at underground is called underground substation. In congested places where place for constructing distribution substation is difficult to find out, one can go for underground sub – station scheme.

Pole mounted Substation

Pole mounted substation are mainly distribution substation constructed on two pole, four pole and sometime six or more poles structures. In these type of substation fuse protected distribution transformer are mounted on poles along with isolator switches.

Losses in Transformer

Losses in Transformer

As the electrical transformer is a static device, mechanical loss in transformer normally does not come into picture. We generally consider only electrical losses in transformer. Loss in any machine is broadly defined as difference between input power and output power.

When input power is supplied to the primary of transformer, some portion of that power is used to compensate core losses in transformer i.e. Hysteresis loss in transformer and Eddy Current loss in transformer core and some portion of the input power is lost as I2R loss and dissipated as heat in the primary and secondary winding, as because these windings have some internal resistance in them. The first one is called core loss or iron loss in transformer and later is known as ohmic loss or copper loss in transformer. Another loss occurs in transformer, known as Stray Loss, due to Stray fluxes link with the mechanical structure and winding conductors.

Copper loss in transformer

Copper loss is I2R loss, in primary side it is I12R1 and in secondary side it is I22R2 loss, where I1 & I2 are primary & secondary current of transformer and R1 & R2 are resistances of primary & secondary winding. As the both primary & secondary currents depend upon load of transformer, so copper loss in transformer vary with load.

Core losses in transformer

Hysteresis loss and eddy current loss, both depend upon magnetic properties of the materials used to construct the core of transformer and its design. So these losses in transformer are fixed and do not depend upon the load current. So core losses in transformer which is alternatively known as iron loss in transformer and can be considered as constant for all range of load.
Hysteresis loss in transformer is denoted as,
Wh = KhfBm1.6     watts
Eddy Current loss in transformer is denoted as,
We = Kef2Kf2Bm2     watts
Where, Kh = Hysteresis Constant.
Ke = Eddy Current Constant.
Kf = form Constant.
Copper loss can simply be denoted as,
IL2R2′ + Stray loss
Where, IL = I2 = load of transformer, and R2′ is the resistance of transformer referred to secondary.
Now we will discuss Hysteresis loss and Eddy Current loss in little bit more details for better understanding the topic of losses in transformer

Hysteresis loss in transformer

Hysteresis loss in transformer can be explained in different ways. We will discuss two of them, one is physical explanation other is mathematical explanation.

Physical explanation of Hysteresis loss

The magnetic core of transformer is made of ′Cold Rolled Grain Oriented Silicon Steel′. Steel is very good ferromagnetic material. This kind of materials are very sensitive to be magnetized. That means whenever magnetic flux passes through,it will behave like magnet. Ferromagnetic substances have numbers of domains in their structure. Domain are very small region in the material structure, where all the dipoles are paralleled to same direction. In other words, the domains are like small small permanent magnet situated randomly in the structure of substance. These domains are arranged inside the material structure in such a random manner, that net resultant magnetic field of the said material is zero. Whenever external magnetic field or mmf is is applied to that substance, these randomly directed domains are arranged themselves in parallel to the axis of applied mmf. After removing this external mmf, maximum numbers of domains again come to random positions, but some few of them still remain in their changed position. Because of these unchanged domains the substance becomes slightly magnetized permanently. This magnetism is called " Spontaneous Magnetism". To neutralize this magnetism some opposite mmf is required to be applied. The magneto motive force or mmf applied in the transformer core is alternating. For every cycle, due to this domain reversal there will be extra work done. For this reason, there will be a consumption of electrical energy which is known as Hysteresis loss of transformer.

Mathematical explanation of Hysteresis loss in transformer

Determination of Hysteresis loss

hysteresis loss in transformer Consider a ring of ferromagnetic specimen of circumference L meter, cross - sectional area a m2 and N turns of insulated wire as shown in the picture beside,
Let us consider, the current flowing through the coil is I amp,
Magnetizing force,






Let, the flux density at this instant is B,
Therefore, total flux through the ring, Φ = BXa   Wb
As the current flowing through the solenoid is alternating, the flux produced in the iron ring is also alternating in nature, so the emf (e′) induced will be expressed as,
saturation curve of b - h curve










According to Lenz,s law this induced emf will oppose the flow of current, therefore, in order to maintain the current I in the coil, the source must supply an equal and opposite emf. Hence applied emf ,






Energy consumed in short time dt, during which the flux density has changed,










Thus, total work done or energy consumed during one complete cycle of magnetism,










Now aL is the volume of the ring and H.dB is the area of elementary strip of B - H curve shown in the figure above,


= total area enclosed by Hysteresis Loop.





Therefore, Energy consumed per cycle = volume of the ring X area of hysteresis loop.
In the case of transformer, this ring can be considered as magnetic core of transformer. Hence this work done is nothing but electrical energy loss in transformer core and this is known as hysteresis loss in transformer.

What is Eddy Current loss ?

In transformer we supply alternating current in the primary, this alternating current produces alternating magnetizing flux in the core and as this flux links with secondary winding there will be induced voltage in secondary, resulting current to flow through the load connected with it. Some of the alternating fluxes of transformer may also link with other conducting parts like steel core or iron body of transformer etc. As alternating flux links with these parts of transformer, there would be an locally induced emf. Due to these emfs there would be currents which will circulate locally at that parts of the transformer. These circulating current will not contribute in output of the transformer and dissipated as heat. This type of energy loss is called eddy current loss of transformer. This was a broad and simple explanation of eddy current loss. The detail explanation of this loss is not in the scope of discussion in that chapter.

Open Circuit Test and Short Circuit Test in Transformer

Open Circuit Test and Short Circuit Test on Transformer

These two tests are performed on a transformer to determine (i) equivalent circuit of transformer (ii) voltage regulation of transformer (iii) efficiency of transformer. The power required for these Open Circuit test and Short Circuit test on transformer is equal to the power loss occurring in the transformer.


Open Circuit Test on Transformer

The connection diagram for open circuit test on transformer is shown in the figure. A voltmeter, wattmeter, and an ammeter are connected in LV side of the transformer as shown. The voltage at rated frequency is applied to that LV side with the help of a variac of variable ratio auto transformer. The HV side of the transformer is kept open. Now with help of variac applied voltage is slowly increase until the voltmeter gives reading equal to the rated voltage of the LV side. After reaching at rated LV side voltage, all three instruments reading (Voltmeter, Ammeter and Wattmeter readings) are recorded. The ammeter reading gives the no load current Ie. As no load current Ie is quite small compared to rated current of the transformer, the voltage drops due to this current then can be taken as negligible. Since, voltmeter reading V1 can be considered equal to secondary induced voltage of the transformer. The input power during test is indicated by wattmeter reading. As the transformer is open circuited, there is no output hence the input power here consists of core losses in transformer and copper loss in transformer during no load condition. But as said earlier, the no load current in the transformer is quite small compared to full load current so copper loss due to the small no load current can be neglected. Hence the wattmeter reading can be taken as equal to core losses in transformer. Let us consider wattmeter reading is Po.
Po = V1 2/Rm
Where Rm is shunt branch resistance of transformer.
If, Zm is shunt branch impedance of transformer.
Then, Zm = V1/ Ie.
Therefore, if shunt branch reactance of transformer is Xm
Then, (1/ Xm)2 = (1/ Zm)2 - (1/ Rm)2
These values are referred to the LV side of transformer as because the test is conduced on LV side of transformer. These values could easily be referred to HV side by multiplying these values with square of transformation ratio.
Therefore it is seen that the open circuit test on transformer is used to determine core losses in transformer and parameters of shunt branch of the equivalent circuit of transformer.
open circuit test on transformer

Short Circuit Test on Transformer

The connection diagram for short circuit test on transformer is shown in the figure. A voltmeter, wattmeter, and an ammeter are connected in HV side of the transformer as shown. The voltage at rated frequency is applied to that HV side with the help of a variac of variable ratio auto transformer. short circuit test on transformer The LV side of the transformer is short circuited . Now with help of variac applied voltage is slowly increase until the ammeter gives reading equal to the rated current of the HV side. After reaching at rated current of HV side, all three instruments reading (Voltmeter, Ammeter and Wattmeter readings) are recorded. The ammeter reading gives the primary equivalent of full load current IL. As the voltage, applied for full load current in short circuit test on transformer, is quite small compared to rated primary voltage of the transformer, the core losses in transformer can be taken as negligible here. Let’s, voltmeter reading is Vsc. The input power during test is indicated by wattmeter reading. As the transformer is short circuited, there is no output hence the input power here consists of copper losses in transformer. Since, the applied voltage Vsc is short circuit voltage in the transformer and hence it is quite small compared to rated voltage so core loss due to the small applied volate can be neglected. Hence the wattmeter reading can be taken as equal to copper losses in transformer. Let us consider wattmeter reading is Psc.
Psc = Re.IL2
Where Re is equivalent resistance of transformer.
If, Ze is equivalent impedance of transformer.
Then, Ze = Vsc/ IL.
Therefore, if equivalent reactance of transformer is Xe
Then, Xe2 = Ze2 - Re2
These values are referred to the HV side of transformer as because the test is conduced on HV side of transformer. These values could easily be referred to LV side by dividing these values with square of transformation ratio.
Therefore it is seen that the Short Circuit test on transformer is used to determine copper loss in transformer at full load and parameters of approximate equivalent circuit of transformer.

Resistance and Leakage Reactance of Transformer or Impedance of Transformer

Resistance and Leakage Reactance of Transformer or Impedance of Transformer

Leakage Reactance of Transformer

All the flux in transformer will not be able to link with both the primary and secondary windings. A small portion of flux will link either winding but not both. This portion of flux is called leakage flux. Due to this leakage flux in transformer there will be a self - reactance in the concerned winding. This self-reactance of transformer is alternatively known as leakage reactance of transformer. This self - reactance associated with resistance of transformer is impedance. Due to this impedance of transformer there will be voltage drops in both primary and secondary transformer windings.

Resistance of Transformer

Generally both primary and secondary windings of electrical power transformer are made of copper. Copper is very good conductor of current but not a super conductor. Actually super conductor and super conductivity both are conceptual, practically they are not available. So both windings will have some resistance. This internal resistance of both primary and secondary windings are collectively known as resistance of transformer.

Impedance of Transformer

As we said, both primary and secondary windings will have resistance and leakage reactance. These resistance and reactance will be in combination is nothing but impedance of transformer. If R1 & R2 and X1 & X2 are primary & secondary resistance & leakage reactance of transformer respectively, then Z1 & Z2 impedance of primary & secondary windings are respectively ,
Z1 = R1 + jX1
Z2 = R2 + jX2
The Impedance of transformer plays a vital role during parallel operation of transformer

Leakage Flux in transformer

In ideal transformer all the flux will link with both primary and secondary winding but in reality it is impossible to link all the flux in transformer with both primary and secondary windings. Although maximum flux will link with both winding through the core of transformer but still there will be a small amount of flux which will link either winding not both. This flux is called leakage flux which will pass through the winding insulation and transformer insulating oil instead of passing through core. Due to this leakage flux in transformer, both primary and secondary winding have leakage reactance. These reactance of transformer is nothing but leakage reactance of transformer. This phenomena in transformer is known as Magnetic Leakage.
leakage flux in transformer Voltage drops in the windings occur due to impedance of transformer. Impedance is combination of resistance and leakage reactance of transformer. If we apply voltage V1 across primary of transformer, there will be a component I1X1 to balance primary self induced emf due to primary leakage reactance. (Here, X1 is primary leakage reactance). Now if we also consider voltage drop due to primary resistance of transformer, then voltage equation of a transformer can easily be written as,
V1 = E1 + I1(R1 + jX1) ⇒ V1 = E1 + I1R1 + jI1X1
Similarly for secondary leakage reactance, the voltage equation of secondary side is,
V2 = E2 - I2(R2 + jX2) ⇒ V2 = E2 - I2R2 − jI2X2
Here in the figure above, the primary and secondary windings are shown in separate limbs and this arrangement could result a large leakage flux in transformer as because there is a big room for leakage. Leakage in primary and secondary could be eliminated it the windings could be made to occupy the same space. This of course is physically impossible but by placing secondary and primary in concentric manner can solve the problem in good extent.

Three Phase Transformer

Three Phase Transformer

Comparison between single Three Phase transformer and bank of three Single Phase transformers for three phase system


It is found that generation, transmission and distribution of electrical power are more economical in three phase system than single phase system. For three phase system three single phase transformers are required. Three phase transformation can be done in two ways, by using single three phase transformer or by using a bank of three single phase transformers. Both are having some advantages over other. Single 3 phase transformer costs around 15% less than bank of three single phase transformers. Again former occupies less space than later. For very big transformer, it is impossible to transport large three phase transformer to the site and it is easier to transport three single phase transformers which is erected separately to form a three phase unit. Another advantage of using bank of three single phase transformers is that, if one unit of the bank becomes out of order, then the bank can be run as open delta.

Connection of Three Phase Transformer

A Varity of connection of three phase transformer are possible on each side of both a single 3 phase transformer or a bank of three single phase transformers.

Marking or labeling the different terminals of transformer.

Terminals of each phase of HV side should be labeled as capital letters, A, B, C, and those of LV side should be labeled as small letters, a, b, c. Terminal polarities are indicated by suffixes 1 & 2. Suffix 1’s indicate similar polarity ends and so do 2’s.

Star Star Transformer

star star three phase transformer Star Star Transformer is formed in a 3 phase transformer by connecting one terminal of each phase of individual side, together. The common terminal is indicated by suffix 1 in the figure below. If terminal with suffix 1 in both primary and secondary are used as common terminal, voltages of primary and secondary are in same phase. That is why this connection is called zero degree connection or 0o - connection.
If the terminals with suffix 1 is connected together in HV side as common point and the terminals with suffix 2 in LV side are connected together as common point, the voltages in primary and secondary will be in opposite phase. Hence, Star Star Transformer connection is called 180o - Connection, of three phase transformer.

Delta Detla Transformer

In delta delta transformer, 1 suffixed terminals of each phase primary winding will be connected with 2 suffixed terminal of next phase primary winding. delta delta three phase transformer If primary is HV side, then A1 will be connected to B2, B1 will be connected to C2 and C1 will be connected to A2. Similarly in LV side 1 suffixed terminals of each phase winding will be connected with 2 suffixed terminals of next phase winding. That means, a1 will be connected to b2, b1 will be connected to c2 and c1 will be connected to a2. If transformer leads are taken out from primary and secondary 2 suffixed terminals of the winding, then there will be no phase difference between similar line voltages in primary and secondary. This delta delta transformer connection is zero degree connection or 0o - Connection.
But in LV side of transformer, if, a2 is connected to b1, b2 is connected to c1 and c2 is connected to a1. The secondary leads of transformer are taken out from 2 suffixed terminals of LV windings, and then similar line voltages in primary and secondary will be in phase opposition. This connection is called 180o - Connection, of three phase transformer.

Star Delta Transformer

Here in star delta transformer, star connection in HV side is formed by connecting all the 1 suffixed terminals together as common point and transformer primary leads are taken out from 2 suffixed terminals of primary windings. star delta three phase transformer The delta connection in LV side is formed by connecting 1 suffixed terminals of each phase LV winding with 2 suffixed terminal of next phase LV winding. More clearly, a1 is connected to b2, b1 is connected to c2 and c1 is connected to a2. The secondary (here it considered as LV) leads are taken out from 2 suffixed ends of the secondary windings of transformer. The transformer connection diagram is shown in the figure beside. It is seen fron the figure that the sum of the voltages in delta side is zero. This is a must as otherwise closed delta would mean a short circuit. It is also observed from the phasor diagram that, phase to neutral voltage (equivalent star basis) on the delta side lags by − 30o to the phase to neutral voltage on the star side; this is also the phase relationship between the respective line to line voltages. This star delta transformer connection is therefore known as − 30o - Connection.

Star – Delta + 30o connection is also possible by connecting secondary terminals in following sequence. a2 is connected to b1, b2 is connected to c1 and c2 is connected to a1. The secondary leads of transformer are taken out from 2 suffixed terminals of LV windings,
delta star three phase transformer

Delta Star Transformer

Delta star transformer connection of three phase transformer is similar to star – delta connection. If any one interchanges HV side and LV side of star – delta transformer in diagram, it simply becomes delta – star connected 3 phase transformer. That means all small letters of star delta connection should be replaced by capital letters and all small letters by capital in delta star transformer connection.

Delta Zigzag Transformer

The winding of each phase on the star connected side is divided into two equal halves in delta zig zag transformer. Each leg of the core of transformer is wound by half winding from two different secondary phases in addition to its primary winding.

Star Zigzag Transformer

The winding of each phase on the secondary star in a star zigzag transformer is divided into two equal halves. Each leg of the core of transformer is wound by half winding from two different secondary phases in addition to its primary winding.

Choice between Star connection and Delta connection of Three Phase Transformer

In star connection with earthed neutral, phase voltage i.e. phase to neutral voltage, is 1/√3 times of line voltage i.e. line to line voltage. But in the case of delta connection phase voltage is equal to line voltage. Star connected high voltage side electrical power transformer is about 10% cheaper than that of delta connected high voltage side transformer.
Let’s explain,
Let, the voltage ratio of transformer between HV & LV is K, voltage across HV winding is VH and voltage across LV winding is VL and voltage across transformer leads in HV side say Vp and in LV say Vs.

In Star Star Transformer

VH = Vp/√3 and VL = Vs/√3
⇒ Vp / Vs = VH / VL = K
⇒ VH = K. VL
Voltage difference between HV & LV winding,
VH − VL = Vp − Vs = (K − 1).Vs

In Star Delta Transformer

VH = Vp/√3 and VL = Vs
Voltage difference between HV & LV winding,
VH − VL = Vp/√3 − Vs = (K/√3 − 1).Vs

In Delta Star Transformer

VH = Vp and VL = Vs/√3
Voltage difference between HV & LV winding,
VH − VL = Vp − Vs/√3 = (K − 1/√3) .Vs

For 132/33KV transformer K = 4

Therefore, case 1,
Voltage difference between HV & LV winding,
(4 − 1) Vs = 3. Vs
case 2,
Voltage difference between HV & LV winding,
(4/√3 − 1) Vs = 1.3 Vs
and case 3,
Voltage difference between HV & LV winding,
(4 − 1/√3) Vs = 3.42 Vs
In case 2 voltage difference between HV and LV winding is minimum therefore potential stresses between them is minimum, implies insulation cost in between these windings is also less. Hence for step down purpose Star – Delta transformer connection is most economical, design for transformer. Similarly it can be proved that for Step up purpose Delta - Star three phase transformer connection is most economical.

Testing of Transformer

Transformer Testing

For confirming the specifications and performances of an electrical transformer it has to go through numbers of testing procedures. Some tests are done at manufacturer premises before delivering the transformer. Mainly two types of transformer testing are done at manufacturer premises - type test of transformer and routine test of transformer. In addition to that some transformer tests are also carried out at the consumer site before commissioning and also periodically in regular & emergency basis through out its service life.

Type of transformer testing

Tests done at Factory

Type Tests
Routine Tests
Special Tests
Tests done at Site

Pre Commissioning Tests
Periodic/Condition Monitoring Tests
Emergency Tests

Type test of transformer

To prove that the transformer meets customer’s specifications and design expectations, the transformer has to go through different testing procedures in manufacturer premises. Some transformer tests are carried out for confirming the basic design expectation of that transformer. These tests are done mainly in a prototype unit not in all manufactured units in a lot. Type test of transformer confirms main and basic design criteria of a production lot.

Routine tests of transformer

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

Special tests of transformer

Special tests of transformer is done as per customer requirement to obtain information useful to the user during operation or maintenance of the transformer.

Pre commissioning test of transformer

In addition to these, the transformer also goes through some other tests, performed on it, before actual commissioning of the transformer at site. The transformer testing performed before commissioning the transformer at site is called pre commissioning test of transformer. These tests are done to assess the condition of transformer after installation and compare the test results of all the low voltage tests with the factory test reports.
Type tests of transformer includes

Transformer winding resistance measurement
Transformer ratio test
Transformer vector group test
Measurement of impedance voltage/short circuit impedance (principal tap) and load loss (Short circuit test)
Measurement of no load loss and current (Open circuit test)
Measurement of insulation resistance
Dielectric tests of transformer
Temperature rise test of Transformer
Tests on on-load tap-changer
Vacuum tests on tank and radiators
Routine tests of transformer include

Transformer winding resistance measurement
Transformer ratio test
Transformer vector group test
Measurement of impedance voltage/short circuit impedance (principal tap) and load loss (Short circuit test)
Measurement of no load loss and current (Open circuit test)
Measurement of insulation resistance
Dielectric tests of transformer
Tests on on-load tap-changer
Oil pressure test on transformer to check against leakages past joints and gaskets.

That means Routine tests of transformer include all the type tests except temperature rise and vacuum tests. The oil pressure test on transformer to check against leakages past joints and gaskets is included.
Special Tests of transformer include

Dielectric Tests
Measurement of zero-sequence impedance of three-phase transformers
Short-Circuit Test
Measurement of acoustic noise level
Measurement of the harmonics of the no-load current
Measurement of the power taken by the fans and oil pumps
Tests on bought out components / accessories such as buchhloz relay, temperature indicators, pressure relief devices, oil preservation system etc.

Transformer winding resistance measurement

Transformer winding resistance measurement is carried out to calculate the I2R losses and to calculate winding temperature at the end of a temperature rise test. It is carried out as a type test as well as routine test. It is also done at site to ensure healthiness of a transformer that is to check loose connections, broken strands of conductor, high contact resistance in tap changers, high voltage leads and bushings etc.
There are different methods for measuring of transformer winding, likewise

♣ Current voltage method of measurement of winding resistance.
♣ Bridge method of measurement of winding resistance.
        ♠ Kelvin bridge method of Measuring Winding Resistance.
        ♠ Measuring winding resistance by Automatic Winding Resistance Measurement Kit.
NB: - Transformer winding resistance measurement shall be carried out at each tap.

Transformer Ratio Test

The performance of a transformer largely depends upon perfection of specific turns or voltage ratio of transformer. So transformer ratio test is an essential type test of transformer. This test also performed as routine test of transformer. So for ensuring proper performance of electrical power transformer, voltage and turn ratio test of transformer one of the vital tests.
The procedure of transformer ratio test is simple. We just apply three phase 415 V supply to HV winding, with keeping LV winding open. The we measure the induced voltages at HV and LV terminals of transformer to find out actual voltage ratio of transformer. We repeat the test for all tap position separately.

Magnetic balance test of transformer

Magnetic balance test of transformer is conducted only on three phase transformers to check the imbalance in the magnetic circuit.

Procedure of Magnetic balance test of transformer

1) First keep the tap changer of transformer in normal position.
2) Now disconnect the transformer neutral from ground.
3) Then apply single phase 230V AC supply across one of the HV winding terminals and neutral terminal.
4) Measure the voltage in two other HV terminals in respect of neutral terminal.
5) Repeat the test for each of the three phases.
In case of auto transformer, magnetic balance test of transformer should be repeated for IV winding also.
There are three limbs side by side in a core of transformer. One phase winding is wound in one limb. The voltage induced in different phases depends upon the respective position of the limb in the core. The voltage induced in different phases of transformer in respect to neutral terminals given in the table below.
 Left side phaseCentral phaseRight side phase
 ANBNCN
Voltage applied at left side phase 230 V180 V50 V
Voltage applied at central phase 115 V230 V115 V
Voltage applied at right side phase 50 V180 V230 V

Magnetizing Current Test of Transformer

Magnetizing current test of transformer is performed to locate defects in the magnetic core structure, shifting of windings, failure in turn to turn insulation or problem in tap changers. These conditions change the effective reluctance of the magnetic circuit, thus affecting the current required to establish flux in the core.
1) First of all keep the tap changer in the lowest position and open all IV & LV terminals.
2) Then apply three phase 415V supply on the line terminals for three phase transformers and single phase 230V supply on single phase transformers.
3) Measure the supply voltage and current in each phase.
4) Now repeat the magnetizing current test of transformertest with keeping tap changer in normal position.
5) And repeat the test with keeping the tap at highest position.
Generally there are two similar higher readings on two outer limb phases on transformer core and one lower reading on the centre limb phase, in case of three phase transformers. An agreement to within 30 % of the measured exciting current with the previous test is usually considered satisfactory. If the measured exciting current value is 50 times higher than the value measured during factory test, there is likelihood of a fault in the winding which needs further analysis.
Caution: This magnetizing current test of transformer is to be carried out before DC resistance measurement.

Vector Group Test of Transformer

In three phase transformer, it is essential to carry out a vector group test of transformer. Proper vector grouping in a transformer is an essential criteria for parallel operation of transformers.

There are several internal connection of three phase transformer are available in market. These several connections gives various magnitudes and phase of the secondary voltage; the magnitude can be adjusted for parallel operation by suitable choice of turn ratio, but the phase divergence can not be compensated. So we have to choose those transformer for parallel operation whose phase sequence and phase divergence are same. All the transformers with same vector ground have same phase sequence and phase divergence between primary and secondary. So before procuring one electrical power transformer, one should ensure the vector group of the transformer, whether it will be matched with his or her existing system or not. The vector group test of transformer confirms his or her requirements.

Insulation Resistance Test or Megger Test of transformer

Insulation resistance test of transformer is essential type test. This test is carried out to ensure the healthiness of over all insulation system of an electrical power transformer.

Procedure of Insulation Resistance test of transformer

1) First disconnect all the line and neutral terminals of the transformer.
2) Megger leads to be connected to LV and HV bushing studs to measure Insulation Resistance IR value in between the LV and HV windings.
3) Megger leads to be connected to HV bushing studs and transformer tank earth point to measure Insulation Resistance IR value in between the HV windings and earth.
4) Megger leads to be connected to LV bushing studs and transformer tank earth point to measure Insulation Resistance IR value in between the LV windings and earth.
NB : It is unnecessary to perform insulation resistance test of transformer per phase wise in three phase transformer. IR values are taken between the windings collectively as because all the windings on HV side are internally connected together to form either star or delta and also all the windings on LV side are internally connected together to form either star or delta.
Measurements are to be taken as follows:
For Auto Transformer: HV-IV to LV, HV-IV to E, LV to E
For Two Winding Transformer: HV to LV, HV to E, LV to E
Three Winding Transformer: HV to IV, HV to LV, IV to LV, HV to E, IV to E, LV to E

Oil temperature should be noted at the time of insulation resistance test of transformer. Since the IR value of transformer insulating oil may vary with temperature.
IR values to be recorded at intervals of 15 seconds, 1 minute and 10 minutes.
.
With the duration of application of voltage, IR value increases. The increase in IR is an indication of dryness of insulation. .
Absorption Coefficient = 1 minute value/ 15 secs. value.
Polarization Index = 10 minutes value / 1 minute value

Dielectric Tests of Transformer

Dielectric tests of transformer is one kind of insulation test. This test is performed to ensure the expected over all insulation strength of transformer. There are several test performed to ensure the required quality of transformer insulation, dielectric test is one of them. Dielectric tests of transformer is performed in two different steps, first one called Separate source voltage withstand test of transformer, where a single phase power frequency voltage of prescribed level, is applied on transformer winding under test for 60 seconds while the other windings and tank are connected to the earth and it is observed that whether any failure of insulation occurs or not during the test. Second one is induced voltage test of Transformer where, three phase voltage, twice of rated secondary voltage is applied to the secondary winding for 60 second by keeping the primary of the transformer open circuited. The frequency of the applied voltage should be double of power frequency too. Here also if no failure of insulation, the test is successful.
In addition to Dielectric tests of transformer there are other type test for checking insulation of transformer, such as lightning impulse test, switching impulse test and partial discharge test.

Induced voltage test of Transformer

The induced voltage test of transformer is intended to check the inter turn and line end insulation as well as main insulation to earth and between windings
1) Keep the primary winding of transformer open circuited.
2) Apply three phase voltage to the secondary winding. The applied voltage should be twice of rated voltage of secondary winding in magnitude and frequency.
3) The duration of the test shall be 60 second.
4) The test shall start with a voltage lower than 1/3 the full test voltage, and it shall be quickly increased up to desired value.
The test is successful if no break down occurs at full test voltage during test.

Temperature Rise Test of Transformer

Temperature rise test of Transformer is included in type test of transformer. In this test we check whether the temperature rising limit of the transformer winding and oil as per specification or not.
In this type test of transformer, we have to check oil temperature rise as well as winding temperature rise limits of an electrical transformer.

Restricted Earth Fault Protection

Restricted Earth Fault Protection

Restricted Earth Fault Protection of Transformer

An external fault in the star side will result in current flowing in the line current transformer of the affected phase and at the same time a balancing current flows in the neutral current transformer, hence the resultant current in the relay is therefore zero. So this REF relay will not be actuated for external earth fault. But during internal fault the neutral current transformer only carries the unbalance fault current and operation of Restricted Earth Fault Relay takes place. This scheme of restricted earth fault protection is very sensitive for internal earth fault of electrical power transformer. The protection scheme is comparatively cheaper than differential protection scheme.
Restricted earth fault protection is provided in electrical power transformer for sensing internal earth fault of the transformer. In this scheme the CT secondary of each phase of electrical power transformer are connected together as shown in the figure. Then common terminals are connected to the secondary of a Neutral Current Transformer or NCT. The CT or Current Transformer connected to the neutral of power transformer is called Neutral Current Transformer or Neutral CT or simply NCT. Whenever there is an unbalancing in between three phases of the power transformer, a resultant unbalance current flow through the close path connected to the common terminals of the CT secondaries. An unbalance current will also flow through the neutral of power transformer and hence there will be a secondary current in Neutral CT because of this unbalance neutral current. In Restricted Earth Fault scheme the common terminals of phase CTs are connected to the secondary of Neutral CT in such a manner that secondary unbalance current of phase CTs and the secondary current of Neutral CT will oppose each other. If these both currents are equal in amplitude there will not be any resultant current circulate through the said close path. The Restricted Earth Fault Relay is connected in this close path. Hence the relay will not response even there is an unbalancing in phase current of the power transformer.
restricted earth fault protection REF protection of transformers restricted earth fault protection of power transformer

Faults in Power Transformer

External and Internal Faults in Power Transformer

This is essential to protect high value transformer against external and internal electrical faults.

External Faults in Power Transformer

External Short - Circuit of Power Transformer

The short - circuit may occurs in two or three phases of electrical power system. The level of fault current is always high enough. It depends upon the voltage which has been short - circuited and upon the impedance of the circuit up to the fault point. The copper loss of the fault feeding transformer is adraptly increased. This increasing copper loss causes internal heating in the transformer. Large fault current also produces severe mechanical stresses in the transformer. The maximum mechanical stresses occurs during first cycle of symmetrical fault current.

High Voltage Disturbance in Power Transformer

High Voltage Disturbance in Power Transformer are of two kinds,
(1) Transient Surge Voltage
(2) Power Frequency Over Voltage

Transient Surge Voltage

High voltage and high frequency surge may arise in the power system due to any of the following causes,
(a) Arcing ground if neutral point is isolated.
(b) Switching operation of different electrical equipment.
(c) Atmospheric Lightening Impulse.
Whatever may be the causes of surge voltage, it is after all a travelling wave having high and steep wave form and also having high frequency. This wave travels in the electrical power system network, upon reaching in the power transformer, it causes breakdown the insulation between turns adjacent to line terminal, which may create short circuit between turns.

Power Frequency Over Voltage

There may be always a chance of system over voltage due to sudden disconnection of large load. Although the amplitude of this voltage is higher than its normal level but frequency is same as it was in normal condition. Over voltage in the system causes an increase in stress on the insulation of transformer. As we know that, voltage V = 4.44Φ.f.T ⇒ V ∝ Φ, increased voltage causes proportionate increase in the working flux. This therefore causes, increased in iron loss and dis - proportionately large increase in magnetizing current. The increase flux is diverted from the transformer core to other steel structural parts of the transformer. Core bolts which normally carry little flux, may be subjected to a large component of flux diverted from saturated region of the core alongside. Under such condition, the bolt may be rapidly heated up and destroys their own insulation as well as winding insulation.

Under Frequency effect in Power Transformer

As, voltage V = 4.44Φ.f.T ⇒ V ∝ Φ.f as the number of turns in the winding is fixed.
Therefore, Φ ∝ V/f
From, this equation it is clear that if frequency reduces in a system, the flux in the core increases, the ffect are more or less similar to that of the over voltage.

Internal Faults in Power Transformer

The principle faults which occurs inside a power transformer are categorized as,
(1) Insulation breakdown between winding and earth
(2) Insulation breakdown in between different phases
(3) Insulation breakdown in between adjacent turns i.e. inter - turn fault
(4) Transformer core fault

Internal Earth Faults in Power Transformer

Internal Earth Faults in a Star connected winding with neutral point earthed through an impedance

In this case the fault current is dependent on the value of earthing impedance and is also proportional to the distance of the fault point from neutral point as the voltage at the point depends upon, the number of winding turns come under across neutral and fault point. If the distance between fault point and neutral point is more, the number of turns come under this distance is also more, hence voltage across the neutral point and fault point is high which causes higher fault current. So, in few words it can be said that, the value of fault current depends on the value of earthing impedance as well as the distance between the faulty point and neutral point. The fault current also depends up on leakage reactance of the portion of the winding across the fault point and neutral. But compared to the earthing impedance,it is very low and it is obviously ignored as it comes in series with comparatively much higher earthing impedance.

Internal Earth Faults in a Star connected winding with neutral point solidly earthed

In this case, earthing impedance is ideally zero. The fault current is dependent up on leakage reactance of the portion of winding comes across faulty point and neutral point of transformer. The fault current is also dependent on the distance between neutral point and fault point in the transformer. As said in previous case the voltage across these two points depends upon the number of winding turn comes across faulty point and neutral point. So in star connected winding with neutral point solidly earthed, the fault current depends upon two main factors, first the leakage reactance of the winding comes across faulty point and neutral point and secondly the distance between faulty point and neutral point. But the leakage reactance of the winding varies in complex manner with position of the fault in the winding. It is seen that the reactance decreases very rapidly for fault point approaching the neutral and hence the fault current is highest for the fault near the neutral end. So at this point, the voltage available for fault current is low and at the same time the reactance opposes the fault current is also low, hence the value of fault current is high enough. Again at fault point away from the neutral point, the voltage available for fault current is high but at the same time reactance offered by the winding portion between fault point and neutral point is high. It can be noticed that the fault current stays a very high level throughout the winding. In other word, the fault current maintain a very high magnitude irrelevant to the position of the fault on winding.

Internal Phase to Phase Faults in Power Transformer

Phase to phase fault in the transformer are rare. If such a fault does occur, it will give rise to substantial current to operate instantaneous over current relay on the primary side as well as the differential relay.

Inter turns fault in Power Transformer

Power Transformer connected with electrical extra high voltage transmission system, is very likely to be subjected to high magnitude, steep fronted and high frequency impulse voltage due to lightening surge on the transmission line. The voltage stresses between winding turns become so large, it can not sustain the stress and causing insulation failure between inter - turns in some points. Also LV winding is stressed because of the transferred surge voltage. Very large number of Power Transformer failure arise from fault between turns. Inter turn fault may also be occured due to mechanical forces between turns originated by external short circuit.

Core fault in Power Transformer

In any portion of the core lamination is damaged, or lamination of the core is bridged by any conducting material causes sufficient eddy current to flow, hence, this part of the core becomes over heated. Some times, insulation of bolts (Used for tightening the core lamination together) fails which also permits sufficient eddy current to flow through the bolt and causing over heating. These insulation failure in lamination and core bolts causes severe local heating. Although these local heating, causes additional core loss but can not create any noticeable change in input and output current in the transformer, hence these faults can not be detected by normal electrical protection scheme. This is desirable to detect the local over heating condition of the transformer core before any major fault occurs. Excessive over heating leads to breakdown of transformer insulating oil with evolution of gases. These gases are accumulated in Buchholz relay and actuating Buchholz Alarm.

Transformer Cooling System

Transformer Cooling System

The main source of heat generation in transformer is its copper loss or I2R loss. Although there are other factors contribute heat in transformer such as hysteresis & eddy current losses but contribution of I2R loss dominate them. If this heat is not dissipated properly, the temperature of the transformer will rise continually which may cause damages in paper insulation and liquid insulation medium of transformer. So it is essential to control the temperature within permissible limit to ensure the long life of transformer by reducing thermal degradation of its insulation system. In Electrical Power transformer we use external transformer cooling system to accelerate the dissipation rate of heat of transformer.There are different transformer cooling methods available for trans former, we will now explain one by one.

Different Transformer Cooling Methods

For accelerating cooling different transformer cooling methods are used depending upon their size and ratings. We will discuss these one by one below,

ONAN Cooling of Transformer

This is the simplest transformer cooling system. The full form of ONAN is "Oil Natural Air Natural". Here natural convectional flow of hot oil is utilized for cooling. In convectional circulation of oil, the hot oil flows to the upper portion of the transformer tank and the vacant place is occupied by cold oil. This hot oil which comes to upper side, will dissipate heat in the atmosphere by natural conduction, convection & radiation in air and will become cold. In this way the oil in the transformer tank continually circulate when the transformer put into load. As the rate of dissipation of heat in air depends upon dissipating surface of the oil tank, it is essential to increase the effective surface area of the tank. So additional dissipating surface in the form of tubes or radiators connected to the transformer tank. This is known as radiator of transformer or radiator bank of transformer. We have shown below a simplest form on Natural Cooling or ONAN Cooling arrangement of an earthing transformer below.
onan cooling of transformer earthing  transformer


forced air or onaf cooling of transformer

ONAF Cooling of Transformer

Heat dissipation can obviously be increased, if dissipating surface is increased but it can be make further faster by applying forced air flow on that dissipating surface. Fans blowing air on cooling surface is employed. Forced air takes away the heat from the surface of radiator and provides better cooling than natural air. The full form of ONAF is "Oil Natural Air Forced". As the heat dissipation rate is faster and more in ONAF transformer cooling method than ONAN cooling system, electrical power transformer can be put into more load without crossing the permissible temperature limits.

OFAF Cooling of Transformer

In Oil Forced Air Natural cooling system of transformer, the heat dissipation is accelerated by using forced air on the dissipating surface but circulation of the hot oil in transformer tank is natural convectional flow. forced oil or ofaf cooling in transformer The heat dissipation rate can be still increased further if this oil circulation is accelerated by applying some force. In OFAF cooling system the oil is forced to circulate within the closed loop of transformer tank by means of oil pumps. OFAF means "Oil Forced Air Forced" cooling methods of transformer. The main advantage of this system is that it is compact system and for same cooling capacity OFAF occupies much less space than farmer two systems of transformer cooling. Actually in Oil Natural cooling system, the heat comes out from conducting part of the transformer is displaced from its position, in slower rate due to convectional flow of oil but in forced oil cooling system the heat is displaced from its origin as soon as it comes out in the oil, hence rate of cooling becomes faster.

OFWF Cooling of Transformer

We know that ambient temperature of water is much less than the atmospheric air in same weather condition. So water may be used as better heat exchanger media than air. In OFWF cooling system of transformer, the hot oil is sent to a oil to water heat exchanger by means of oil pump and there the oil is cooled by applying sowers of cold water on the heat exchanger's oil pipes. OFWF means "Oil Forced Water Forced" cooling in transformer.

ODAF Cooling of Transformer

ODAF or Oil Directed Air Forced Cooling of Transformer can be considered as the improved version of OFAF. Here forced circulation of oil directed to flow through predetermined paths in transformer winding. The cool oil entering the transformer tank from cooler or radiator is passed through the winding where gaps for oil flow or pre-decided oil flowing paths between insulated conductor are provided for ensuring faster rate of heat transfer. ODAF or Oil Directed Air Forced Cooling of Transformer is generally used in very high rating transformer.

ODWF Cooling of Transformer

ODAF or Oil Directed Water Forced Cooling of Transformer is just like ODAF only difference is that here the hot oil is cooled in cooler by means of forced water instead of air. Both of these transformer cooling methods are called Forced Directed Oil Cooling of transformer