TESTING

OF
HIGH VOLTAGE
POWER TRANSFORMERS

NECESSITY OF TESTS ON TRANSFORMER

WHEN ALL MANUFACTURING PROCESSES HAVE BEEN
COMPLETED, TESTS ARE PERFORMED ON TRANSFORMER AT THE
MANUFACTURERS WORKS TO ENSURE THE FOLLOWING
PURPOSES:

TO PROVE THAT THE DESIGN MEETS THE SPECIFIED JOB

REQUIREMENTS AND TO OBTAIN TRANSFORMER CHARACTERISTICS.

TO CHECK THAT THE QUALITY REQUIREMENTS HAVE BEEN MET AND

THAT PERFORMANCE IS WITHIN THE TOLERANCE GUARANTEED.

TESTS PERFORMED FOR THE FORMER PURPOSE ARE REFERRED TO AS

TYPE TESTS AND THAT FOR THE LATTER PURPOSE ARE REFERRED TO AS
ROUTINE TESTS (CARRIED OUT ON EVERY UNIT MANUFACTURED). IN
ADDITION TO THE AFORESAID TWO CATEGORY OF TESTS, SPECIAL TESTS
MAY ALSO BE PERFORMED TO OBTAIN INFORMATION USEFUL TO THE
USER DURING OPERATION OR MAINTENANCE OF THE TRANSFORMER.

TESTS
THE FOLLOWING TESTS ARE GENERALLY PERFORMED ON THE
TRANSFORMER REFERENCE STANDARD : IEC 60076
ROUTINE TESTS
MEASUREMENT OF WINDING RESISTANCE
MEASUREMENT OF VOLTAGE RATIO, POLARITY AND CHECK OF VOLTAGE
VECTOR RELATIONSHIP
MEASUREMENT OF NO-LOAD LOSS AND EXCITATION CURRENT
MEASUREMENT OF SHORT-CIRCUIT IMPEDANCE AND LOAD LOSS
MEASUREMENT OF INSULATION RESISTANCE
SWITCHING IMPULSE VOLTAGE WITHSTAND TEST
LIGHTNING IMPULSE VOLTAGE WITHSTAND TEST
SEPARATE-SOURCE VOLTAGE WITHSTAND TEST
INDUCED AC OVER VOLTAGE WITHSTAND TEST WITH PARTIAL DISCHARGE
MEASUREMENT
MAGNETIC CIRCUIT (ISOLATION) TEST

TYPE TESTS
TEMPERATURE RISE TEST
MEAUREMENT OF POWER TAKEN BY WATER PUMPS
DISSOLVED GAS ANALYSIS ( DGA ) OF OIL FILLED IN THE TRANSFORMER

SPECIAL TESTS
MEASUREMENT OF ACOUSTIC SOUND LEVEL
DETERMINATION OF CAPACITANCES AND TAN DELTA BETWEEN
WINDING-TO-EARTH AND BETWEEN WINDINGS

MECHANICAL TESTS
VACUUM TEST ON TRANSFORMER TANK
OIL PRESSURE TEST ON COMPLETELY ASSEMBLED TRANSFORMER

MEASUREMENT OF WINDING RESISTANCE

RESISTANCE MEASUREMENT HELPS TO DETERMINE THE FOLLOWING

CALCULATION OF THE I2R LOSSES.

CALCULATION OF WINDING TEMPERATURE AT THE END OF A

TEMPERATURE RISE TEST.

AS A BASE FOR ASSESSING POSSIBLE DAMAGE IN THE FIELD.

A) MEASUREMENT IS MADE WITH DIRECT CURRENT, AND

SIMULTANEOUS READINGS OF CURRENT AND VOLTAGE ARE TAKEN.
B) TO MINIMIZE ERRORS OF OBSERVATION:
1) THE MEASURING INSTRUMENTS SHALL HAVE SUCH RANGES AS
WILL GIVE REASONABLY LARGE DEFLECTION.
2) THE POLARITY OF THE CORE MAGNETIZATION SHALL BE KEPT
CONSTANT DURING ALL RESISTANCE READINGS.
THE VOLTMETER LEADS SHALL BE INDEPENDENT OF THE CURRENT
LEADS AND SHALL BE CONNECTED AS CLOSELY AS POSSIBLE TO THE
TERMINALS OF THE WINDING TO BE MEASURED. THIS IS TO BE AVOID
INCLUDING IN THE READING THE RESISTANCE OF CURRENTCARRYINGLEADS, THEIR CONTACTS AND EXTRA LENGTH OF LEADS.
READINGS SHALL NOT BE TAKEN UNTIL AFTER THE CURRENT AND VOLTAGE
HAVE REACHED STEADY-STATE VALUES.
READINGS SHALL BE TAKEN WITH NOT LESS THAN FOUR VALUES OF
CURRENT WHEN DEFLECTING INSTRUMENTS ARE USED.
THE CURRENT USED SHALL NOT EXCEED 15% OF THE RATED CURRENT
OF THE WINDING WHOSE RESISTANCE IS TO BE MEASURED. LARGER
VALUES MAY CAUSE INACCURACY BY HEATING THE WINDING AND

POLARITY BY ALTERNATING-VOLTAGE TEST

THE LINE TERMINAL OF HIGH VOLTAGE WINDING (1.1 ) SHALL BE CONNECTED TO
THE ADJACENT LINE TERMINAL LOW-VOLTAGE LWINDING (2.1) AS SHOWN IN
FIGURE BELOW
1.1

2.1

1.2

2.2

(a)

ANY CONVENIENT VALUE OF ALTERNATING VOLTAGE SHALL BE APPLIED TO THE

FULL HIGH-VOLTAGE WINDING AND READINGS SHALL BE TAKEN OF THE APPLIED
VOLTAGE AND THE VOLTAGE BETWEEN THE RIGHT-HAND ADJACENT HIGHVOLTAGE AND LOW-VOLTAGE LEADS.
WHEN THE LATER READING IS GREATER THAN THE FORMER, THE POLARITY IS
ADDITIVE.
WHEN THE LATER READING IS LESS THAN THE FORMER (INDICATING THE
APPROXIMATE DIFFERENCE IN VOLTAGE BETWEEN THAT OF THE HIGH-VOLTAGE
AND LOW-VOLTAGE WINDINGS), THE POLARITY IS SUBTRACTIVE.

Verification of vector group

1U
2U
2W
1W
Dy-I

2V

1V

FIGURE FOR HV-DELTA / LV-STAR

TRANSFORMER
CONNECT 1U TO 2U
MEASURE
1W-2V, 1W-2W, 1U-2W, 1V-2V, 1V-2W
VOLTAGE RELATION
1W-2V= 1W-2W
1W-2V< 1W-1U
1V-2V<1V-2W
1V-2V <1U-1W

CONNECT 1U TO 2U
MEASURE
1W-2V, 1W-2W, 1U-2W, 1V-2V,
1V-2W
VOLTAGE RELATION
1W-2W = 1V-2W
1W-2V > 1V-2V
1U-N = (1U-2W)+(2W-N)

MEASUREMENT OF NO-LOAD LOSS AND EXCITATION

CURRENT
NO-LOAD (EXCITATION) LOSSES ARE THOSE LOSSES THAT ARE
INCIDENT TO THE EXCITATION OF THE TRANSFORMER. NO-LOAD
(EXCITATION) LOSSES INCLUDE CORE LOSS, DIELECTRIC LOSS,
CONDUCTOR LOSS IN THE WINDING DUE TO EXCITATION CURRENT, AND
CONDUCTOR LOSS DUE TO CIRCULATING CURRENT IN PARALLEL
WINDINGS. THESE LOSSES CHANGE WITH THE EXCITATION VOLTAGE.

MEASUREMENT OF SHORT-CIRCUIT IMPEDANCE AND LOAD

LOSS
THE LOAD LOSSES OF A TRANSFORMER ARE THOSE LOSSES INCIDENT TO
A SPECIFIED LOAD CARRIED BY THE TRANSFORMER. LOAD LOSSES
INCLUDE I2R LOSS IN THE WINDINGS DUE TO LOAD CURRENT AND STRAY
LOSSES DUE TO EDDY CURRENTS INDUCED BY LEAKAGE FLUX IN THE
WINDINGS, CORE CLAMPS, MAGNETIC SHIELD, TANK WALLS AND OTHER
CONDUCTING PARTS. STRAY LOSSES MAY ALSO BE CAUSED BY
CIRCULATING CURRENTS IN PARALLEL WINDINGS OR STRANDS. LOAD
LOSSES ARE MEASURED BY APPLYING A SHORT CIRCUIT ACROSS EITHER
THE HIGH VOLTAGE WINDING OR THE LOW VOLTAGE WINDING AND
APPLYING SUFFICIENT VOLTAGE ACROSS THE OTHER WINDING TO CAUSE
A SPECIFIED CURRENT TO FLOW IN THE WINDINGS. THE POWER LOSS
WITHIN THE TRANSFORMER UNDER THESE CONDITIONS EQUALS THE
LOAD LOSSES OF THE TRANSFORMER AT THE TEMPERATURE OF TEST FOR
THE SPECIFIED LOAD CURRENT.
THE IMPEDANCE VOLTAGE OF A TRANSFORMER BETWEEN A PAIR OF
WINDINGS IS THE VOLTAGE REQUIRED TO CIRCULATE RATED CURRENT
THROUGH ONE OF TWO SPECIFIED WINDINGS WHEN THE OTHER WINDING
IS SHORT CIRCUITED, WITH THE WINDINGS CONNECTED AS FOR RATED
VOLTAGE OPERATION. IMPEDANCE VOLTAGE IS USUALLY EXPRESSED IN
PER UNIT OR PERCENT OF THE RATED VOLTAGE OF THE WINDING ACROSS
WHICH THE VOLTAGE IS APPLIED AND MEASURED.

WATTMETER-VOLTMETER-AMMETER METHOD FOR LOAD

LOSS AND IMPEDANCE VOLTAGE TEST

FOR THREE PHASE TRANSFORMERS, THREE-PHASE POWER

MEASUREMENT UTILIZING TWO WATTMETER IS POSSIBLE BUT CAN
RESULT IN VERY LARGE ERRORS AT LOW POWER FACTORS
ENCOUNTERED IN LOAD LOSS TESTS OF TRANSFORMERS. IT IS
RECOMMENDED THAT THE TWO-WATTMETER METHOD SHOULD NOT BE
USED FOR LOSS TESTS ON THREE-PHASE TRANSFORMERS OF SMALL
RATINGS PREFERABLY BELOW 20 MVA, 66 KV CLASS.

MEASUREMENT OF INSULATION RESISTANCE

INSULATION RESISTANCE TESTS ARE MADE TO DETERMINE THE

INSULATION RESISTANCE FROM INDIVIDUAL WINDING TO GROUND OR
BETWEEN INDIVIDUAL WINDINGS. THE INSULATION RESISTANCE IN
SUCH TESTS IS COMMONLY MEASURED IN MEGA-OHMS, OR MAY BE
CALCULATED FROM MEASUREMENTS OF APPLIED VOLTAGE AND
LEAKAGE CURRENT

NOTE

THE INSULATION RESISTANCE OF ELECTRICAL APPARATUS IS

SUBJECTED TO WIDE VARIATION IN DESIGN, TEMPERATURE, DRYNESS,
AND CLEANLINESS OF THE PARTS. WHEN THE INSULATION
RESISTANCE FALLS BELOW PRESCRIBED VALUES, IT CAN, IN MOST
CASES OF GOOD DESIGN AND WHERE NO DEFECT EXISTS, BE
BROUGHT UP TO THAT REQUIRED STANDARD BY CLEANING AND
DRYING THE APPARATUS. THE INSULATION RESISTANCE, THEREFORE,
MAY OFFER A USEFUL INDICATION AS TO WHETHER THE APPARATUS IS
IN SUITABLE CONDITION FOR APPLICATION OF DIELECTRIC TESTS.

UNDER NO CONDITIONS, TEST SHOULD BE MADE WHILE THE

TRANSFORMER IS UNDER VACUUM.

LIGHTNING IMPULSE WITHSTAND VOLTAGE TEST

T1 = 1.2 Micro Seconds 30 %

T2 = 50 Micro Seconds 20 %

SWITCHING IMPULSE WITHSTAND VOLTAGE TEST

VIRTUAL FRONT TIME OF AT LEAST 100 S

TIME ABOVE 90% OF SPECIFIED AMPLITUDE 200 S
TOTAL DURATION OF AT LEAST 500 S

SEPARATE SOURCE VOLTAGE WITHSTAND TEST

A NORMAL POWER FREQUENCY, SUCH AS 50 HZ, SHALL BE USED AND

THE DURATION OF THE TEST SHALL BE ONE MINUTE.
THE WINDING BEING TESTED SHALL HAVE ALL ITS PARTS JOINED
TOGETHER AND CONNECTED TO THE TERMINAL OF THE TESTING
TRANSFORMER.
ALL OTHER TERMINALS AND PARTS (INCLUDING CORE AND TANK)
SHALL BE CONNECTED TO GROUND AND TO THE OTHER TERMINAL
OF THE TESTING TRANSFORMER.

INDUCED AC VOLTAGE WITHSTAND TESTS WITH PARTIAL

DISCHARGE MEASUREMENT

C
B

Ustart

1.1Um/ 3

A = 5 min
B = 5 min
C = test time
D = 5 min
for ACSD
E = 5 min

U2

and

U1

60 min

U2

1.1Um/ 3

<Ustart

PD LEVEL <500 PC

for ACLD

Time sequence for the application of test voltage

with respect to earth

120

RATED FREQUENCY
TEST FREQUENCY

TEMPERATURE RISE TEST

TO ESTABLISH THE TOP OIL TEMPERATURE RISE IN STEADY STATE
CONDITION WITH DISSIPATION OF TOTAL PROCESS.
TO ESTABLISH THE AVERAGE WINDING TEMPERATURE RISE AT
RATED CURRENT AND WITH THE TOP OIL TEMPERATURE RISE

JOB CONDITION
COMPLETED ASSEMBLED WITH COOLERS

TYPE OF COOLING
ONAN, ONAF, ONAF, OFWF
WATER COOLED TRANSFORMER

TEST CONDITION
RATED POWER
ONE WINDING SHORTED ( AS LIKE LOAD LOSS)

TEMPERATURE RISE
OIL RISE AND WINDING RISE

TOTAL LOSS INJECTION FOR DETERMINATION OF

OIL RISE
FIRST THE TOP OIL AND AVERAGE OIL TEMPERATURE RISES ARE
ESTABLISHED WHEN THE TRANSFORMER IS SUBJECTED TO ATEST
VOLTAGE SUCH THAT THE MEASURED ACTIVE POWER IS EQUALS
TO THE TOTAL LOSSES OF THE TRANSFORMER
THE TEST CURRENT WILL BE DONE AT ABOVE RATED CURRENT TO
THE EXTENT NECESSARY FOR PRODUCING AN ADDITIONAL
AMOUNT OF LOSS EQUAL TO THE NO-LOAD LOSS AND THE
WINDING TEMPERATURE RISE WILL BE CORRESPONDINGLY
ELEVATED.
THE OIL TEMPERATURE AND COOLING MEDIUM TEMPERATURE ARE
MONITORED, AND THE TEST IS CONTINUED UNTIL A STEADY STATE
OIL TEMPERATURE RISE ESTABLISHED

RATED CURRENT INJECTIONS

WHEN THE TOP OIL TEMPERATURE RISE HAS BEEN ESTABLISHED,
THE TEST SHALL BE IMMEDIATELY CONTINUE WITH THE TEST
CURRENT TO RATED CURRENT FOR THE WINDING COMBINATION
CONNECTED. THIS CONDITION IS MAINTAINED FOR ONE HOUR WITH
CONTINUOUS OBSERVATION OF OIL AND COOLING MEDIUM
TEMPERATURE

STEADY STATE CONDITION

SHUT DOWN

MEASUREMENT OF ACOUSTIC SOUND LEVEL

THIS TEST SHALL BE DONE IN ACCORDANCE WITH THE CLAUSES

GIVEN IN NEMA TR1 AND IEC-60076-10. THE DETAILED TEST
PROCEDURE IS GIVEN IN THE ANSI/IEEE STANDARD, WHICH HAS BEEN
APPROVED BY NEMA.

Microphone
Location
Fan cooled surface
2m

TANK
Box

Drain Plug

Reference sound
producing source

Measurement
surface
1m

0.3 m

2/3 Height
1/3 Height

Height

Microphone location for measuring audible sound from transformers

DETERMINATION OF CAPACITANCE AND DISSIPATION FACTOR BETWEEN WINDING

TO EARTH AND BETWEEN WINDINGS
CAPACITANCE AND TAN DELTA ARE USUALLY DETERMINED FOR WINDING TO EARTH AND
BETWEEN WINDINGS BY BRIDGE MEASURING TECHNIQUE, SUCH AS SCHERING BRIDGE.

METHOD I
TEST WITHOUT GUARD

METHOD II
TEST WITH GUARD

TWO WINDING
HV TO LV AND GROUND
LV TO HV AND GROUND
HV TO LV TO GROUND

TWO WINDING
HV TO LV AND GROUND
LV TO HV AND GROUND
HV TO LV TO GROUND
LV TO GROUND, GUARD TO HV

THREE WINDING
HV TO IV ,LV AND GROUND
IV TO HV ,LV AND GROUND
LV TO IV ,HV AND GROUND
HV AND IV TO LV AND GROUND
HV AND LV TO IV AND GROUND
IV AND LV TO HV AND GROUND
HV, IV AND LV TO GROUND

THREE WINDING
HV TO LV AND GROUND, GUARD ON IV
HV TO GROUND, GUARD ON LV & IV
LV TO IV & GROUND, GUARD ON HV
LV TO GROUND, GUARD ON HV & IV
IV TO HV & GROUND, GUARD ON LV
IV TO GROUND, GUARD ON HV & LV
HV & LV TO IV & GROUND
HV & IV TO LV & GROUND

DISSOLVED GAS ANALYSIS (DGA) OF OIL FILLED IN THE

TRANSFORMER
DGA HAS BEEN USED AS A TOOL IN TRANSFORMER DIAGNOSTICS IN
ORDER TO DETECT INCIPIENT FAULTS, TO SUPERVISE SUSPECT
TRANSFORMERS, TO TEST A HYPOTHESIS OR EXPLANATION FOR THE
PROBABLE REASONS OF FAILURES OR DISTURBANCES WHICH HAVE
ALREADY OCCURRED AND TO ENSURE THAT NEW TRANSFORMERS ARE
HEALTHY.
THE GASSES THAT ARE OF INTEREST FOR THE DGA ANALYSIS ARE THE
FOLLOWING;
H2 HYDROGEN
CH4 METHANE
C2 H4 ETHYLENE
C2H6 ETHANE
C2H2 ACETYLENE
(C3H6 PROPENE ) NOT ALWAYS MEASURE
(C3H8 PROPANE ) NOT ALWAYS MEASURE
CO CARBON MONOXIDE
CO2 CARBON DIOXIDE
O2 OXYGEN
N2 NITROGEN
TCG TOTAL COMBUSTIBLE GAS CONTENT (= H2 + CH4 + C2H4 + C2H6 +
C2H2 + CO)

PROCEDURE
THE DGA PROCEDURE CONSISTS OF ESSENTIAL FOUR STEPS:
SAMPLING OF OIL FROM THE TRANSFORMER
ANALYSIS OF THESE GASES FROM OIL
ANALYSIS OF THE EXTRACTED GAS MIXTURE IN A GAS
CHROMATOGRAPHY, GC.
INTERPRETATION OF THE ANALYSIS ACCORDING TO AN EVALUATION
SCHEME.
OVERHEATING OF CELLULOSE
CO, CO2
OVERHEATING OF OIL
INCREASING TEMPERATURE
C2H6
C2H4
C2H4
CH4
CH4
CH4
C2H2
PARTIAL DISCHARGES (PD)
INCREASING TEMPERATURE
H2
H2
C2H2
DISCHARGES
C2H2
H2

 MEASUREMENT OF POWER TAKEN BY THE WATER PUMP

MOTORS
- THE MEASUREMENT SHALL BE DONE BY SUITABLE INSTRUMENTS AT
RATED VOLTAGE

TESTS
THE FOLLOWING TESTS ARE GENERALLY PERFORMED ON THE
TRANSFORMER REFERENCE STANDARD : IEC 60076
ROUTINE TESTS
MEASUREMENT OF WINDING RESISTANCE
MEASUREMENT OF VOLTAGE RATIO, POLARITY AND CHECK OF VOLTAGE VECTOR
RELATIONSHIP
MEASUREMENT OF NO-LOAD LOSS AND EXCITATION CURRENT
MEASUREMENT OF SHORT-CIRCUIT IMPEDANCE AND LOAD LOSS
MEASUREMENT OF INSULATION RESISTANCE
SWITCHING IMPULSE WITHSTAND VOLTAGE TEST
LIGHTNING IMPULSE WITHSTAND VOLTAGE TEST
SEPARATE-SOURCE WITHSTAND VOLTAGE TEST
INDUCED AC OVER VOLTAGE WITHSTAND TEST WITH PARTIAL DISCHARGE MEASUREMENT

TYPE TESTS
TEMPERATURE RISE TEST
MEAUREMENT OF POWER TAKEN BY WATER PUMPS

SPECIAL TESTS
MEASUREMENT OF ACOUSTIC SOUND LEVEL
DETERMINATION OF CAPACITANCES AND TAN DELTA BETWEEN WINDINGTO-EARTH AND BETWEEN WINDINGS

ADDITIONAL TESTS
TEST WITH LIGHTNING IMPULSE CHOPPED ON THE TAIL
MAGNETIC CIRCUIT (ISOLATION) TEST
MAGNETIC BALANCE TEST ON THREE-PHASE TRANSFORMERS
DETERMINATION OF TRANSIENT VOLTAGE TRANSFER CHARACTERISTICS
DISSOLVED GAS ANALYSIS ( DGA ) OF OIL FILLED IN THE TRANSFORMER

MECHANICAL TESTS
MEASUREMENT OF VIBRATION ON TRANSFORMER TANK
VACUUM TEST ON TRANSFORMER TANK
OIL PRESSURE TEST ON COMPLETELY ASSEMBLED TRANSFORMER
JACKING TEST AND DYE-PENETRATION TEST
PRESSURE RELIEF DEVICE TEST

FIELD TESTS
DEW POINT MEASUREMENT FOR LARGE TRANSFORMER FILLED WITH
DRY AIR OR NITROGEN FILLED
WINDING RESISTANCE MEASUREMENT
VECTOR GROUP AND POLARITY
VOLTAGE RATIO TEST
MEASUREMENT OF MAGNETIZING CURRENT
MAGNETIC BALANCE TEST ON THREE PHASE TRANSFORMER
MAGNETIC CIRCUIT (ISOLATION) TEST
MEASUREMENT OF SHORT CIRCUIT IMPEDANCE AT LOW VOLTAGE
INSULATION RESISTANCE MEASUREMENT
MEASUREMENT OF CAPACITANCE AND DISSIPATION FACTOR

DISSOLVED GAS ANALYSIS ( DGA )

TESTS ON OIL FILLED IN TRANSFORMER AS PER IS 1866