METHOD STATEMENT: TRANSFORMER TESTING AND

COMMISIONING

PURPOSE

THIS METHOD STATEMENT WILL GIVE A BRIEF STEPS TO BE CARRIED OUT FOR TESTING AND PRE-COMMISSIONING OF
TRANSFORMERS.

BELOW IS A STANDARD METHOD STATEMENT FOR TESTING AND COMMISSIONING OF TRANSFORMERS:

1. REQUIRED TOOLS FOR TRANSFORMER TESTING & COMMISSIONING.

 PORTABLE HAND TOOLS/TOOL BOX.

 DIGITAL MULTIMETER.
 EARTH RESISTANCE TESTER.
 MEGGER TESTER.
 SAFETY REQUIREMENTS TOOLS (PPE) SUCH AS SAFETY SHOES, SAFETY HELMET, SAFETY GLASSES, FLUORESCENT
VEST, AND SAFETY GLOVES TO ENSURE MAXIMUM ABILITY OF SAFE WORK AND DUST MASK.

2. PROCEDURE OF TRANSFORMER TESTING & COMMISSIONING.

a) INSPECT TRANSFORMER AND PARTS FOR SHIPPING DAMAGE AND MOISTURE.

b) CHECK NAMEPLATE AND PRINTS FOR PROPER VOLTAGES AND EXTERNAL PHASING CONNECTION TO THE LINE
OR BUS.

c) CHECK CALIBRATION OF ALL THERMAL GAUGES AND HOT-SPOT HEATER , BRIDGE RTDs AND ASSOCIATED
ALARM CONTACTS.CONTACTS SETTINGS SHOULD BE SIMILAR TO BE FOLLOWING :

 ONE STAGE RUNS ALL THE TIME (FORCED COOLING)

 2ND STAGE AT 80°C
 3RD STAGE AT 90°C
 HOT-SPOT ALARM 100°C (TRIP AT 110°C WHEN APPLICABLE)
 TOP-OIL ALARM 80°C AT 55°C RISE AND 75°C AT 65°C RISE
 OA = NO FANS OR PUMPS
 FA = FANS RUNNING
 FOA = FANS AND PUMPS RUNNING

d) CHECK AND MEGGER ALL WIRING POINT TO POINT: FANS, PUMPS, ALARMS, HEATERS, TAP CHARGERS, AND ALL
OTHER DEVICES ON THE TRANSFORMER AND INTERCONNECTING CABLES.

e) ALL BANKS ABOVE 150 MVA SHOULD BE VACUUM DRIED.DO NOT APPLY TEST VOLTAGES TO THE WINDING
DURING THE VACUUM DRYING PROCESS.MAKE CERTAIN THE TERMINALS ARE SHORTED AND GROUNDED
DURING OIL CIRCULATION BECAUSE OF THE LARGE AMOUNT OF STATIC CHARGE THAT CAN BUILD UP ON THE
WINDING.
 f) AFTER THE TANK HAS BEEN FILLED WITH OIL, CONFIRM THAT AN OIL SAMPLE WAS SENT TO THE CHEMICAL LAB
AND THAT ITS RESULTS ARE ENTERED IN THE BANK TEST REPORTS.NOTE THE OIL LEVEL AND TEMPERATURE AT
COMPLETION OF FILLING.

g) POWER OPERATE TO VERIFY PROPER ROTATION OF PUMPS AND FANS AND CORRECT OPERATION OF THE
UNDER LOAD (UL) TAP CHARGER, WHEN PROVIDED. ALSO, CHECK HEATER, ALARM AND ALL OTHER DEVICES
FOR PROPER OPERATION.

3. PREPARATION FOR TESTING.

a) PRIOR TO THE COMMENCEMENT OF ANY PERMANENT WORKS, AREAS AND ACCESS WILL BE INSPECTED TO
CONFIRM THAT THEY ARE IN A CONDITION FOR PERMANENT WORKS TO COMMENCE ENSURING THE
ENVIRONMENT IS CLEAN AND DRY.TESTING WILL COMMENCE ONLY AFTER THE EQUIPMENT IS COMPLETELY
INSTALLED AS PER APPROVED METHOD STATEMENT FOR THE INSTALLATION OF THE TRANSFORMER AND
RELEASED FOR THE TESTING COMMISSIONING.

b) ALL MATERIALS AND RELEVANT DOCUMENTATION TO THIS TESTING WORKS SHALL BE CHECKED BY THE
RESPONSIBLE PERSONNEL PRIOR TO BE COMMENCEMENT OF TESTING ACTIVITIES.

c) BEFORE ANY ITEM OF EQUIPMENT IS ACCEPTED FOR TESTING A VISUAL INSPECTION WILL BE CARRIED OUT ON
THAT EQUIPMENT.WHERE DEFECTIVE EQUIPMENT IS FOUND IT WILL BE REPORTED TO CONSULTANT FOR
FURTHER ACTION.

d) THE TESTING ELECTRICAL ENGINEER/SUPERVISOR SHOULD CONFIRM THE AVAILABILITY OF NECESSARY THREE
PHASE AC POWER SUPPLY AND SINGLE PHASE FOR TESTING ACTIVITIES.

e) THE TESTING ELECTRICAL ENGINEER/SUPERVISOR SHOULD CONFIRM THE AVAILABILITY OF PROPER ACCESS TO
THE SITE AREA IN WHICH THE EQUIPMENT HAVE TO BE TESTED.

f) WHEN A SATISFACTORY PRE-TESTING INSPECTION HAS BEEN CARRIED OUT, THE TESTING WORK WILL
COMMENCE.

g) THE TESTING ENGINEER WILL INSTRUCT THE SUPERVISOR REGARDING THE TESTING WORKS AND WILL ARRANGE
FOR ALL NECESSARY SCHEMATIC DRAWINGS, DATA SHEETS AND TEST FORMATS TO BE AVAILABLE AT THE
TESTING AREA.

h) THE SUPERVISOR WILL CHECK THAT ALL THE NECESSARY TOOLS AND EQUIPMENT’S TO BE USED FOR TESTING
ARE AVAILABLE IN THE TESTING AREA.

i) AFTER THE TESTING WORK IS COMPLETED THE SUPERVISOR CHECKS ALL THE TESTING EQUIPMENT AND
RETURNS TO THE STORAGE CABIN.

j) WHILE CARRYING OUT THE TESTING WORK THE TESTING ENGINEER WILL FILL ALL THE NECESSARY TEST
FORMATS .AFTER COMPLETION OF TESTING WORK THE TESTING ENGINEER WILL OBTAIN THE SIGNATURE OF
RELEVANT OFFICIALS: CONSULTANT.

3. METHOD OF TESTING OF TRANSFORMERS:

a) VISUAL INSPECTION:
  CORRECTNESS OF INSTALLATION, ASSEMBLY.
 DAMAGE, PAINT, CRACKS CHECKS.
 TIGHTNESS CHECKS.
 EARTHING CONNECTION CHECKS.
 LABELS/MARKINGS RATING PLATE CORRECTNESS CHECKS.
 FERRULES/TERMINAL NUMBERING CHECKS.

b) INSULATION RESISTANCE MEASUREMENT FOR PRIMARY WINDING.

 ISOLATE THE POWER SUPPLY TO THE TRANSFORMER.
 EARTH THE SECONDARY WINDING.
 APPLY VOLTAGE ON THE PRIMARY WINDING.
 OBSERVE READINGS AND RECORD IN THE TEST FORMAT.

c) INSULATION RESISTANCE MEASUREMENT FOR SECONDARY WINDINGS.

 ISOLATE THE POWER SUPPLY TO THE TRANSFORMER.
 EARTH THE PRIMARY WINDINGS.
 APPLY VOLTAGE ON THE SECONDARY WINDINGS.
 OBSERVE READINGS AND RECORD IN THE TEST FORMAT.

d) WINDING RESISTANCE MEASUREMENT

 TO CHECK FOR ANY ABNORMALITIES DUE TO LOOSE CONNECTIONS, BROKEN STRANDS AND HIGH
CONTACT RESISTANCE IN TAP CHANGERS.
 ENSURE THE CONTACTS AT BUSHINGS ARE CLEANS.
 HOLD THE SENSING PROBES ACROSS THE CONDUCT BETWEEN WHICH THE CONTACT RESISTANCE IS TO
MEASURED (TEST CURRENT 10A DC).
 OBSERVE THE READING AND THE RECORD IN THE TEST FORMAT.
 MEGGER AND POWER FACTOR WINDINGS, BUSHING AND ARRESTORS. NOTE: WAIT UNTIL 24 HOURS
AFTER COMPLETION OF OIL FILLING FOR POWER FACTOR TESTING.

e) RATIO MEASUREMENT
 ENSURE THAT BOTH THE PRIMARY AND SECONDARY WINDINGS ARE NOT CONNECTED TO ANY
CABLES/BUS BAR.
 ENSURE THE TAP CHANGER IN THE LOWEST TAP POSITION.
 APPLY THREE PHASE SUPPLY VOLTAGE (415 V AC) ACROSS THE PRIMARY TERMINATION OF THE
TRANSFORMER.
 MEASURE THE SECONDARY (LV) VOLTAGE AT THE LV TERMINATION USING MULTIMETER, FOR EACH
TAP.OBSERVE THE READING AND RECORD IN THE TEST FORMAT.
 IF THE TAP CHANGER IF OFF LOAD TYPE, SWITCH OF THE POWER SUPPLY AND RISE ONE STEP AND
APPLY THE THREE PHASE 415 V AC ACROSS THE SECONDARY TERMINATION AND MEASURE THE
VOLTAGE AT BOTH SECONDARY AND PRIMARY SIDE.
 THE ABOVE STEP TO BE CARRIED OUT UNTIL THE HIGHEST TAP.
 RATIO AND POLARITY (VOLATAGE METHOD OR TTR). THE PREFERENCE IS THAT ALL LARGE POWER
TRANSFORMERS (>1 MVA) BE TESTED WITH TTR TEST SET.

*ALTERNATIVELY, TEST IS PERFORMED WITH A DIGITAL RATIO METER WHICH MEASURES THE RATIO VALUE OF THE
TRANSFORMER AND SIMULTANEOUSLY CHECKS THE VECTOR GROUP AND THE POLARITY.
 f) VECTOR GROUP CHECKS
 THIS TEST IS USED TO DETERMINE THE PHASE RELATIONSHIP AND POLARITY OF TRANSFORMERS.
 ENSURE THAT BOTH PRIMARY AND SECONDARY WINDINGS ARE NOT CONNECTED TO ANY CABLES/BUS
BARS.
 CONNECT THE “R” PHASE OF THE PRIMARY WINDING AND “R” PHASE OF THE SECONDARY WINDING
(SHORT R PHASE OF PRIMARY AND SECONDARY TERMINATION).
 APPLY 3 PHASE SUPPLY VOLTAGE (415 V AC) ACROSS THE PRIMARY TERMINATION OF THE
TRANSFORMER .MESURE THE VOLTAGE AT THE BOTH PRIMARY AND SECONDARY TERMINATION AT ALL
THE PHASES.OBSERVE THE READING AND RECORD IN THES TEST FORMAT.
 APPLY THE FORMULA OR PLOT THE VALUES IN THE GRAPH TO GET THE VECTOR GROUP.

g) MAGNETIC BALANCE TEST

 THIS TEST IS CONDUCTED ONLY IN THREE PHASE TRANSFORMERS TO CHECK THE IMBALANCE IN THE
MAGNETIC CIRCUIT.
 THIS TEST SHALL BE PERFORMED BEFORE WINDING RESISTANCE MEASUREMENT.
 ENSURE THAT BOTH THE PRIMARY AND SECONDARY WINDINGS ARE NOT CONNECTED TO ANY
CABLES/BUS BARS.
 APPLY 3 PHASE SUPPLY VOLTAGE (415 V AC) ACROSS THE 1U & 1V AND MEASURE THE CORRESPONDING
VOLTAGE FOR 1U – 1V, 1V1W & 1U1W.
 SWITCH OFF THE SUPPLY AND REPEAT THE TEST AGAIN BY APPLYING THE VOLTAGE IN 1V & 1W AND
MEASURE THE CORRESPONDING VOLTAGE FOR 1U -1V, 1V1W & 1U1W.
 AGAIN, SWITCH OFF THE SUPPLY AND REPEAT THE TEST AGAIN BY APPLYING THE VOLTAGE IN 1U & 1W
AND MEASURE THE CORRESPONDING VOLTAGE FOR 1U – 1V, 1V1W & 1U1W.
 OBSERVE THE READING AND RECORD IN THE TEST FORMAT.

h) BREAK DOWN VOLTAGE TEST

 BREAK DOWN VALUE FOR TRANSFORMER OIL IS MEASURED WITH 2.5 MM ELECTRODE GAP USING BDV
TESTER FOR BOTH TRANSFORMER AND HV CABLE BOX.
 THE RESULTS ARE RECORDED IN THE TEST REPORT ENCLOSED.

5. PRE COMMISSIONING CHECKS FOR TRANSFORMERS

a) OIL TEMPERATURE INDICATOR

 THE ABOVE CHECK IS PERFORMED BY STIMULATING A VALUE AND CHECKING THE CONTINUITY FOR
PERFORMANCE.
 THE ABOVE CHECK IS PERFORMED FOR THE ALARM AND TRIP SET VALUES FOR ALL TRANSFORMERS.

b) WINDING TEMPERATURE INDICATOR

 THE ABOVE CHECK IS PERFORMED BY STIMULATING A VALUE AND CHECKING THE CONTINUITY FOR
PERFORMANCE.
 THE ABOVE CHECK IS PERFORMED FOR THE ALARM AND TRIP SET VALUES FOR ALL TRANSFORMERS.

c) ELECTRICAL PRESSURE RELIEF VALVE

 THE ABOVE CHECK IS PERFORMED BY MANUALLY LIFTING THE PLUNGER OF THE VALVE AND CHECK FOR
THE CONTINUITY FOR PERFORMANCE.
d) COOLING GEAR
 THE IR VALUES AND SETTING FOR OPERATION OF OIL PUMPS AND FANS MOTOR SHOULD BE CHECKED.
 ALARM TRIP CONTACT SETTINGS OF DIFFERENTIAL PRESSURE, OIL AND WATER FLOW INDICATORS,
WHERE PROVIDED SHOULD BE CHECKED.

e) MARSHALLING BOX
 THE WIRING FROM VARIOUS ACCESSORIES TO THE MARSHALLING KIOSK SHOULD BE CHECKED.