Dry Type Transformer Testing Manual
Dry Type Transformer Testing Manual
Steps to disassemble of primary side transformer cable and secondary side transformer
cable /bus bar.
Step1:- earthing the primary side cable/ bus bar terminals in the RMU/ short both the
primary side cable and connect to the earth.
Step2:- earthing the secondary side cable / bus bar terminals in the transformer / short
both secondary side cable/ bus bar terminals and neutral and connect to the earth by
using earhing cable.
The insulation resistance test (meggering) is of value for future comparison and also
for determining if the transformer is to be subjected to the applied voltage test. The
winding insulation resistance test is a DC high voltage test used to determine the
dryness of winding insulation system. The test measures the insulation resistance
from individual windings to ground and/or between individual windings.
1. Isolate the equipment, apply working grounds to all incoming and outgoing cables and
disconnect all incoming and outgoing cables from the transformer bushing terminals
connections. Disconnected cables should have sufficient clearance from the switchgear
terminals greater that the phase spacing distance.
2. Ensure the transformer body/tank and core is grounded.
3. Disconnect all lightning arresters, fan system, meter or low voltage control systems that
are connected to the transformer winding.
4. Short circuit all winding terminals of the same voltage level together.
5. Perform a 1 minute resistance measurements between each winding group to the other
windings and ground.
6. Remove all shorting leads after completion of all tests.
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Insulation Resistance Test Connections for single phase and three phases
winding dry type transformer
Test Single-phase transformer Three-phase transformer
No.
1 High voltage winding to High voltage winding to low voltage winding and
low voltage winding and ground ground
3 High Voltage winding to ground High voltage winding to ground with low voltage
winding to ground
4 Low Voltage winding to Low voltage winding to high voltage winding and
high voltage winding and ground ground
5 Low voltage winding to ground Low voltage winding to ground and high voltage
winding to guard
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Step1: both the HV winding terminals are short and connect to the earth
terminal by using earthing cable
Step2:- both the LV winding terminals and neutral bus bar are short
Step3:- both the LV winding terminals and neutral bus bar are short and connect
to the megger L.
step4:- the megger terminal (E) is connect to the earth of the transformer body
step5:- the megger is set as the 2500VDC
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2. HV insulation resistance testing
Step1: both the secondary winding terminals and neutral bursar are short and
connect to the earth terminal by using earthing cable.
Step2:- both the LV winding terminals and neutral bus bar are short and connect to the earth
terminal by using earthing.
Step4:- both the HV winding terminals bus bar are short and connects to the megger L.
Step4:- the megger terminal (E) is connect to the earth of the transformer body
Step5:- the megger is set as the 5000VDC
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2. DC Winding Resistance Test (Winding resistance testing
Inject DC current into a transformer winding
Measure the DC voltage drop across the same transformer winding
Wait for the calculated resistance (R = V / I) to stabilize or “bottom out”, which ensures
that the core has been saturated
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Winding resistance value:-
1. A to N
2. B to N
3. C to N
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3. Transformer voltage ratio testing
Measures the performance and efficiency of transformers. It involves comparing the
voltage and current ratios of the transformer's primary and secondary windings. The test
helps identify any winding faults, turns ratio errors, or core defects in the transformer.
The transformer turns ratio test (TTR) test, confirms that the transformer has the correct
ratio of primary turns to secondary turns. Using this test correctly can help to identify tap
changer performance, shorted turns, open windings, incorrect winding connections and
other faults inside transformers.
Power transformer turns ratio test is an AC low voltage test which determines the ratio
of the high voltage winding to all other windings at no-load. The turns ratio test is
performed on all taps of every winding.
Transformer transformation ratio refers to the ratio of the line voltage between the
primary and secondary windings during no-load operation.
The purpose of measuring transformer voltage transformation ratio is:
1. Check the correctness of the turn ratio of the transformer winding.
2. Check the condition of the tapping points.
3. When a transformer malfunctions, it is common to measure the transformer ratio to
check for inter turn short circuits in the transformer.
4. Check if the transformer tap is soldered incorrectly.
5. Inspect the transformer for damage or changes during transportation.
6. Determine whether the transformers can operate in parallel.
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Test Leads: Connect the probes to the appropriate terminals of the transformer primary and
secondary voltage pressure for measuring voltage and current.
Before beginning the test, ensure all necessary safety precautions are in place, including proper
grounding and personal protective equipment.
Connect the primary winding of the transformer to the AC power source, ensuring proper phase
and polarity.
Voltage Measurement: Measure the voltage across the primary winding using the ratio tester
and record the value as VP (primary voltage).
Current Measurement: Measure the current flowing through the primary winding using the
ratio tester and record the value as Ip (primary current).
Secondary Voltage Measurement: Measure the voltage across the secondary winding using the
multimeter and record the value as Vs (secondary voltage).
Secondary Current Measurement: Measure the current flowing through the secondary winding
using the multimeter and record the value as Is (secondary current).
Calculate Ratios: Calculate the primary and secondary voltage ratios (Vp/Vs) and the primary and
secondary current ratios (Ip/Is).
Compare Ratios: Compare the measured ratios with the expected values specified by the
transformer's design or nameplate data.
Voltage ratio: If the measured voltage ratio deviates significantly from the expected value, it
indicates a potential winding or turn ratio problem.
Current ratio: If the measured current ratio deviates significantly from the expected value, it
suggests issues with the winding or core losses.
Finally Based on the comparison of measured ratios with expected values, draw conclusions
regarding the transformer's performance.
Acceptable Ratios: If the measured ratios closely match the expected values, the transformer is
functioning properly.
Deviations: Significant deviations in the ratios may indicate faults or issues that require further
investigation or repairs.
Safety Considerations: Work with transformers and electrical equipment only if you are a trained
professional with adequate knowledge and experience. Ensure that the transformer is completely
disconnected from any power source during the test setup. Follow appropriate safety procedures,
such as wearing insulated gloves and using proper grounding techniques. Exercise caution when
working with high voltages and currents, and avoid touching exposed conductors.
Conclusion: The Ratio Test of a transformer is an effective method to evaluate its performance and
detect any abnormalities in the winding or core. By comparing the measured voltage and current
ratios with the expected values, you can identify potential faults and make informed decisions
regarding maintenance or repairs.
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Remember to prioritize safety at all times when working with electrical
equipment!!!
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Steps to measure the voltage ratio tester
Step 1:- Short the LV terminals and the neutral bus bar and connect to the ratio tester in LV voltage
(low pressure terminals).
Step 2:- Short the HV terminals bus bar and connect to the ratio tester in HV voltage (High pressure
terminals).
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4. HV Voltage Withstand Test
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Transformer testing classification
Transformer Tests are done by Manufacturer
(A) Routine Tests
(B)Type Tests
(C) Special Tests
Transformer Tests were done at the Site
(D) Pre-Commissioning Tests
(E) Periodic/Condition Monitoring Tests
(F) Emergency Tests
(A) Routine tests:
A Routine test of a transformer is mainly for confirming the operational
performance of the individual unit in a production lot. Routine tests are
carried out on every unit manufactured.
All transformers are subjected to the following Routine tests:
Insulation resistance Test.
Winding resistance Test.
Turns Ration / Voltage Ratio Test
Polarity / Vector Group Test.
No-load losses and current Test.
Short-circuit impedance and load loss Test.
Continuity Test
Magnetizing Current Test
Magnetic Balance Test
High Voltage Test.
Dielectric tests
Separate source AC voltage.
Induced overvoltage.
Lightning impulse tests.
Test on On-load tap changers, where appropriate.
(B) Type tests
Type tests are tests made on a transformer that is representative of other
transformers to demonstrate that they comply with specified requirements not
covered by routine tests:
Temperature rise test (IEC 60076-2).
Dielectric type tests (IEC 60076-3).
(C) Special tests
Special tests are tests, other than routine or type tests, agreed upon between
the manufacturer and purchaser.
Dielectric special tests.
Zero-sequence impedance on three-phase transformers.
Short-circuit test.
Harmonics on the no-load current.
Power was taken by the fan and oil pump motors.
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Determination of sound levels.
Determination of capacitances between windings and earth, and between
windings.
Determination of transient voltage transfer between windings.
Tests intended to be repeated in the field to confirm no damage during
shipment, for example, frequency response analysis (FRA).
(D) Pre-commissioning Tests
The Test performed before commissioning the transformer at the site is called
the pre-commissioning test of the transformer. These tests are done to assess
the condition of the transformer after installation and compare the test results
of all the low voltage tests with the factory test reports.
All transformers are subjected to the following Pre-commissioning tests:
IR value of transformer and cables
Winding Resistance
Transformer Turns Ratio
Polarity Test
Magnetizing Current
Vector Group
Magnetic Balance
Bushing & Winding Tan Delta (HV )
Protective relay testing
Transformer oil testing
Hipot test
(A) Routine tests of the Transformer
(1) Insulation Resistance Test:
Test Purpose:
The insulation resistance test of a transformer is essential to ensure the
healthiness of the overall insulation of an electrical power transformer.
Test Instruments:
For LT System: Use 500V or 1000V Megger.
For MV / HV System: Use 2500V or 5000V Megger.
Test Procedure:
First, disconnect all the line and neutral terminals of the transformer.
Megger leads to be connected to LV and HV bushing studs to measure
Insulation Resistance (IR) value in between the LV and HV windings.
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.
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 an insulation resistance test of the
transformer per phase wise in a three-phase transformer. IR values are taken
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between the windings collectively because all the windings on HV side are
internally connected together to form either star or delta and also all the
windings on the LV side are internally connected together to form either star
or delta.
Measurements are to be taken as follows:
Type of Transformer Testing-1 Testing-2 Testing-3
Two Winding HV to LV HV to E LV to E
Transformer
Oil temperature should be noted at the time of the insulation resistance test of
the transformer. Since the IR value of transformer insulating oil may vary
with temperature.
IR values are to be recorded at intervals of 15 seconds, 1 minute, and 10
minutes.
With the duration of the application of voltage, the IR value increases. The
increase in IR is an indication of the dryness of the insulation.
Absorption Coefficient = 1-minute value/15-second value.
Polarization Index = 10 minutes value / 1-minute value
Tests can detect:
Weakness of Insulation.
(2) D.C. Resistance or Winding Resistance Test
Test Purpose:
Transformer winding resistance is measured
To check any abnormalities like Loose connections, broken strands, and High
contact resistance in tap changers
To Calculation of the I2R losses in the transformer.
To Calculation of winding temperature at the end of the temperature rise test
of the transformer.
Test Instrument:
The Resistance of HV winding and LV winding between their terminals are
to be measured with
Precision milliohm meter/ micro ohm meter / Transformer Ohmmeter. OR
Wheatstone bridge or DC resistance meter.
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Method No: 1 (Kelvin Bridge Method for measurement of winding
resistance)
Test Procedure:
The main principle of the bridge method is based on comparing an unknown
resistance with a known resistance.
When electric currents flowing through the arms of the bridge circuit become
balanced, the reading of the galvanometer shows zero deflection that means
at a balanced condition no electric current will flow through the
galvanometer.
A very small value of resistance (in the milliohms range) can be accurately
measured by the Kelvin Bridge method whereas for higher values
Wheatstone bridge method of resistance measurement is applied. In the
bridge method of measurement of winding resistance, the error is minimized.
All other steps to be taken during transformer winding resistance
measurement in these methods are similar to that of current-voltage method
of measurement of winding resistance of transformer
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For Dry-type transformers: the transformer shall be at rest at a constant
ambient temperature for at least three hours.
For Oil immersed transformers: the transformers should be under oil and
without excitation for at least three hours. In the case of tapped windings, the
above readings are recorded at each tap. In addition, it is important to ensure
that the average oil temperature (average of the top and bottom oil
temperatures) is approximately the same as the winding temperature.
Average oil temperature is to be recorded. Measured values are to be
corrected to the required temperatures.
As the measurement current increases, the core will be saturated and
inductance will decrease. In this way, the current will reach the saturation
value in a shorter time.
After the current is applied to the circuit, it should wait until the current
becomes stationary (complete saturation) before taking measurements,
otherwise, there will be measurement errors.
The values shall be compared with the original test and result which varies
with the transformer ratings.
Test Acceptance criteria:
DC Resistance Should be<=2% Factory Test.
Test Current <10% Rated Current
The test can detect:
Short Turns
Loose Connection of bushing
Loose Connection or High Contact Resistance on Tap Changer.
Broken winding stands
(3) Turns Ratio / Voltage Ratio Test:
Test Purpose:
Turns Ratio Test / Voltage Ratio Test is done in Transformer to find out
Open Circuited turns, Short Circuited turns in Transformer winding.
The voltage ratio is equal to the turn ratio in a transformer (V1/V2=N1/N2).
Using this principle, the turn ratio is measured with the help of a turn ratio
meter. If it is correct, then the voltage ratio is assumed to be correct
This test should be made for any new high-voltage power transformer at the
time it is being installed.
With the use of a Turns Ratio meter (TTR), the turns Ratio between HV &
LV windings at various taps is to be measured & recorded.
The turn ratio is a measure of the RMS voltage applied to the primary
terminals to the RMS Voltage measured at the secondary terminals.
R= Np / Ns
Where,
R=Voltage ratio
Np=Number of turns at primary winding.
Ns= Number of turns at secondary Winding.
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The voltage ratio shall be measured on each tapping in the no-load condition.
Test Instruments:
Turns Ratio meter (TTR) to energy the transformer from a low-voltage
supply and measure the HV and LV voltages.
Wheatstone Bridge Circuit
Method No1 Turns Ratio Testing:
Test Procedure:
Transformer Turns Ratio Meter (TTR):
The transformer ratio test can be done by Transformer Turns Ratio (TTR)
Meter. It has in built power supply, with the voltages commonly used is very
low, such as 8, 10 V, and 50 Hz.
The HV and LV windings of one phase of a transformer (i.e. R-Y & r-n) are
connected to the instrument, and the internal bridge elements are varied to
produce a null indication on the detector.
Values are recorded at each tap in case of tapped windings and then
compared to the calculated ratio at the same tap.
The ratio meter gives an accuracy of 0.1 percent over a ratio range up to
1110:1. The ratio meter is used in a ‘bridge’ circuit where the voltages of the
windings of the transformer under test are balanced against the voltages
developed across the fixed and variable resistors of the ratio meter.
Adjustment of the calibrated variable resistor until zero deflection is obtained
on the galvanometer then gives the ratio to the unity of the transformer
windings from the ratio of the resistors.
Bridge Circuit:
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implies the deviation of the measured turn ratio from the expected turn ratio
in percentage.
Theoretical Turns Ratio = HV winding Voltage / LV Winding Voltage
% Deviation = (Measured Turn Ratio – Expected Turns Ration) /
Expected Turns Ration
Out-of-tolerance, ratio test of the transformer can be due to shorted turns,
especially if there is an associated high excitation current.
Open turns in HV winding will indicate a very low exciting current and no
output voltage since open turns in HV winding cause no excitation current in
the winding means no flux and hence no induced voltage.
But open turn in LV winding causes, low fluctuating LV voltage but normal
excitation current in HV winding. Hence open turns in LV winding will be
indicated by normal levels of exciting current, but very low levels of unstable
output voltage.
The turn ratio test of the transformer also detects high resistance connections
in the lead circuitry or high contact resistance in tap changers by higher
excitation current and difficulty in balancing the bridge.
Test Caution:
Disconnect all transformer terminals from the line or load.
Neutrals directly grounded to the grid can remain connected
Method No 2 Voltage Ratio Testing:
This test is done to check both the transformer voltage ratio and the tap
changer.
When the “Turns Ratio meter” is not available, the Voltage Ratio Test is
done at various tap positions by applying 3 phases of LT (415V) supply on
the HT side of the Power transformer. In order to obtain the required
accuracy it is usual to use a ratio meter rather than to energy the transformer
from a low-voltage supply and measure the HV and LV voltages.
At Various taps applied voltage and Resultant voltages LV side between
various Phases and phases& neutral measured with a precision voltmeter &
noted.
Test Procedure:
With 415 V applied on the high voltage side, measure the voltage between all
phases on the low voltage side for every tap position.
First, the tap changer of the transformer is kept in the lowest position and LV
terminals are kept open.
Then apply 3-phase 415 V supply on HV terminals. Measure the voltages
applied on each phase (Phase-Phase) on HV and induced voltages at LV
terminals simultaneously.
After measuring the voltages at HV and LV terminals, the tap changer of the
transformer should be raised by one position and repeat the test.
Repeat the same for each of the tap positions separately.
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At other taps values will be as per the percentage raise or lower at the
respective tap positions.
In the case of Delta/Star transformers the ratio measure between RY-rn, YB-
yn, and BR-bn.
Being Delta/Star transformers the voltage ratio between HV winding and LV
winding in each phase limb at the normal tap is 33 KV OR 33x√3 = 5.196,11
KV / √3 11
At higher taps (i-e high voltage steps) less number of turns are in the circuit
than normal. Hence ratio values increase by a value equal to.5.196 + {5.196 x
(no. of steps above normal) x (% rise per each tap)} 100
Similarly for lower taps than normal, the ratio is equal to 5.196 – {5.196 x
(no. of steps above normal) x (% rise per each tap)}100
Test Acceptance Criteria:
The range of measured ratio shall be equal to the calculated ratio ±0.5%.
Phase displacement is identical to the approved arrangement and
transformer’s nameplate.
The IEEE standard (IEEE Standard 62) states that when rated voltage is
applied to one winding of the transformer, all other rated voltages at no load
shall be correct within one-half of one percent of the nameplate readings. It
also states that all tap voltages shall be correct to the nearest turn if the volts
per turn exceed one-half of one percent desired voltage. The ratio test verifies
that these conditions are met.
The IEC60076-1 standard defines the permissible deviation of the actual to
the declared ratio
Principal tapping for a specified first winding pair: the lesser ±0.5% of the
declared voltage ratio
Or 0.1 times the actual short circuit impedance. Other taps on the first
winding pair and other winding pairs must be agreed upon and must be lower
than the smaller of the two values stated above.
Measurements are typically made by applying a known low voltage across
the high voltage winding so that the induced voltage on the secondary is
lower, thereby reducing hazards while performing the test. For three phase
delta/wye or wye/delta transformer, a three-phase equivalency test is
performed, i.e. the test is performed across the corresponding single winding.
The test can detect:
Shorted turns or open circuits in the windings.
Incorrect winding connections, and other internal faults or defects in the tap
changer
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(4) Polarity / Vector Group Test
Purpose of Test:
The vector group of transformers is an essential property for the successful
parallel operation of transformers. Hence every electrical power transformer
must undergo through vector group test at the transformer at factory site for
ensuring the customer-specified vector group of the transformer.
Test Instruments:
Ratio meter.
Volt Meter. A Ratio meter may not always be available and this is usually the
case on-site so that the polarity may be checked by a voltmeter.
Test Circuit Diagram:
Test Procedure:
The primary and secondary windings are connected together at one point.
Connect the neutral point of the star connected winding with the earth.
A low-voltage three-phase supply (415 V) is then applied to the HV
terminals.
Voltage measurements are then taken between various pairs of terminals as
indicated in the diagram and the readings obtained should be the phasor sum
of the separate voltages of each winding under consideration.
Condition :( HV side R-Y-B-N and LV Side r-y-b-n)
R and r should be shorted.
Apply 415 Volt to R-Y-B
Measure Voltage between Following Phase and Satisfy Following Condition
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