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 I
2R
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 phase | Central phase | Right side phase |
| AN | BN | CN |
Voltage applied at left side phase | 230 V | 180 V | 50 V |
Voltage applied at central phase | 115 V | 230 V | 115 V |
Voltage applied at right side phase | 50 V | 180 V | 230 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.