Test Manual

Test Manual for Transformers
Page 2 of 65

1. General

Test requirements, procedures and criteria for transformers are defined in national and
international standards, i.e. IS 2026 and IEC Publication 60076 in general.
This manual describes specific requirements for performing tests specified in IEC Publication
60076, IS 2026 and other standards applicable to distribution, power and regulating
transformers. It is intended for use as a guide and reference for testing of transformers. The
manual covers purpose, interpretation and explanation of specific conditions pertaining to the
testing of transformer.
The main objectives of this manual are following:
To ensure system needs are met
To obtain technical uniformity
To provide inputs for proper interpretation of test results
To eliminate unsuccessful practices

2. 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:
1) To prove that the design meets the specified job requirements and to obtain
transformer characteristics.
2) 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.
Transformer is important and vital equipment, it is therefore necessary to ensure its proper
performance throughout its service life. Also during transportation, installation and service
operation, the transformer may be exposed to conditions, which adversely affect its reliability
and useful life. It is therefore necessary to do the field testing to ensure good operating health
of transformers.


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3. Tests

The general requirements and details of the various category of tests (Routine Tests, Type
Tests and Special Tests) are in accordance with IEC Publication 60076-2003. The Indian
standard IS:2026 is being revised in accordance with IEC. The customer specific
requirements are referred here as Additional tests and Mechanical Tests.
The following tests are generally performed on the transformer which may also forms part of
the customer acceptance:

A) Routine Tests

1. Measurement of winding resistance
2. Measurement of voltage ratio, polarity and check of voltage vector relationship
3. Measurement of no-load loss and excitation current
4. Measurement of short-circuit impedance and load loss
5. Measurement of Insulation resistance
6. Tests on on-load tap-changers, where appropriate
7. Switching impulse withstand voltage test, transformer winding U
m
> 170 kV
8. Lightning impulse withstand voltage test, transformer winding U
m
> 72.5 kV
9. Separate-source withstand voltage test
10. Induced AC over voltage withstand test with partial discharge measurement

(The tests at sl. no.7, 8, 9 and 10 above are referred as Dielectric Tests)

Type Tests

11. Lightning impulse voltage withstand test, transformer winding U
m
< 300 kV
12. Temperature rise test


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Special Tests
13. Lightning impulse test on neutral terminal
14. Long-duration induced AC voltage test (ACLD), transformer winding U
m
< 170 kV
15. Short-circuit withstand test
16. Measurement of zero-sequence impedances on three phase transformers
17. Measurement of acoustic sound level
18. Measurement of the harmonics of the no-load current
19. Measurement of the power taken by the fan and oil pump motors
Additional Special Tests
20. Test with lightning impulse chopped on the tail
21. Magnetic circuit (Isolation) test
22. Determination of capacitances and dissipation factor between winding-to-earth and
between windings
23. Magnetic balance test on three-phase transformers
24. Determination of transient voltage transfer characteristics
25. Dissolved gas analysis ( DGA ) of oil filled in the transformer before and after
temperature rise test
26. Radio interference voltage ( RIV ) test, if applicable
27. Recurrent surge oscillographic ( RSO ) test
28. Determination of core hot spot temperature
29. Frequency response analysis ( FRA ) test
30. Measurement of magnetization current at low voltage
31. Functional tests on auxiliary equipments
32. Tests on oil filled in transformer

Mechanical Tests

33. Oil pressure test on completely assembled transformer

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34. Jacking test and Dye-penetration test
35. Pressure relief device test

B)Recommended Field tests

1. Dew point measurement for large transformer filled with dry air or nitrogen filled
2. Winding resistance measurement
3. Vector group and polarity
4. Voltage ratio test
5. Measurement of magnetizing current
6. Magnetic balance test on three phase transformer
7. Magnetic circuit (Isolation) test
8. Measurement of short circuit impedance at low voltage
9. Insulation resistance measurement
10. Measurement of capacitance and dissipation factor
11. Dissolved gas analysis ( DGA ) on transformers above 50 MVA
12. Tests on oil filled in transformer as per IS 1866

The dielectric tests (Test Nos. A.8 to A.12) may be routine, type or special tests depending
upon the voltage rating, specific customer requirements and referred standards.
The purpose, interpretation and explanation for specific test conditions of the tests are briefly
described as below.
The tests and their sequence shall be mutually agreed between manufacturer and user.


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3.1 Measurement of winding resistance

General

Resistance measurement helps to determine the following
a) Calculation of the I
2
R losses.
b) Calculation of winding temperature at the end of a temperature rise test.
c) As a base for assessing possible damage in the field.

3.1.1 Determination of cold temperature

The resistance is measured at ambient (cold) temperature and then converted to resistance
at 75
0
C, for all practical purpose of comparison with specified design values, previous results
and diagnostics. The cold temperature of the winding shall be determined as accurately as
possible when measuring the cold resistance. The following should be observed.

3.1.1.1 Transformer windings immersed in insulating liquid

The temperature of the winding shall be assumed to be the same as the temperature of the
insulating liquid, provided:
a) The windings have been under insulating liquid with no excitation and with no current in
the winding from three hours to eight hours (depending upon the size of the transformer)
before the cold resistance is measured.
b) The temperature of the insulating liquid has stabilized, and the difference between top and
bottom temperature does not exceed 5
0
C.

3.1.1.2 Transformer windings without insulating liquid


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The temperature of the winding shall be recorded as the average of several thermometers or
thermocouples inserted between the coils, with care taken to see that their measuring points
are as nearly as possible in actual contact with the winding conductors. It should not be
assumed that the windings are at the same temperature as the surrounding air.

3.1.2 Resistance measurement methods

The resistance of each winding shall be measured by any one of the following methods. If
winding has tapping, then resistance shall be measured on at least principal, maximum and
minimum taps.

3.1.2.1 Voltmeter-Ammeter method

This method should be employed if the rated current of the transformer winding is one
ampere or more. The following steps are performed to conduct this test.

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.
c) 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 current-carrying leads, their contacts and extra
length of leads.
d) Readings shall not be taken until after the current and voltage have reached steady-state
values.
e) Readings shall be taken with not less than four values of current when deflecting
instruments are used.
f) 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 thereby changing its temperature and resistance.


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3.1.2.2 Bridge method
Bridge methods or high-accuracy digital instrumentation are generally preferred because of
their accuracy and convenience. The current rating of the measuring instrument should not
be very low for large inductive objects. In case of delta connected windings of a large rating
transformer, the resistance meter should have adequate current rating.

For star connected windings with neutral brought out, the resistance shall be measured by
two methods
1) Between line and neutral
2) For small transformer with star connected windings, the resistance shall be measured
between phases (line to line), and then resistance of the individual windings shall be
determined by dividing the value by 2. This will rule out the effect of the resistance of
the neutral lead and bus bars which is significant in comparison to phase resistance of
small transformers. However, for the delta connected windings, measurements shall
be made between pairs of line terminals. In this case the resistance per winding will be
1.5 X measured resistance between the pair of line terminals. In case of open delta
connected winding, the resistance can be measured across all the three windings are
in series and also individual winding resistance can be measured.

Few precautions are to be carried out to minimize errors while performing the test as
follows:

a) Charged battery of sufficient capacity or at least 10 A shall be used with the bridge to
avoid errors due to drop in battery voltage during measurements.
b) To reduce the high inductive effect, it is advisable to use a sufficiently high current to
saturate the core. Therefore the measuring instruments shall have high ranges as well
as large deflection.
c) The polarity of the core magnetization shall be kept same during all resistance
readings. A reversal in magnetization of the core can change the time constant and
result in erroneous readings.
d) 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 avoid
including in the reading the resistances of current-carrying leads and their contacts
and of extra lengths of leads.
e) To protect the voltmeter from injury by off-scale deflections, the voltmeter should be
disconnected from the circuit before switching the current on or off. To protect the
personnel from inductive kick, the current should be switched off by a suitably
insulated switch.
f) Readings shall not be taken until after the current and voltage have reached steady-
state values.
g) 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 due to heating of
the winding and thereby changing its temperature and resistance.


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3.2 Measurement of voltage ratio, polarity and check of voltage vector relationship

3.2.1 Ratio test

General
The turn ratio of a transformer is the ratio of the number of turns in the high-voltage winding
to that in the low-voltage winding.
When the transformer has taps, the turn ratio shall be determined for all taps and for the full
winding.
The ratio tests shall be made at rated or lower voltage and the voltage shall be applied to the
winding with higher voltage rating.
In the case of three-phase transformers, when each phase is independent and accessible,
single-phase supply should be used; although, when convenient, three-phase supply may be
used.

Tolerances for ratio

The tolerances for ratio shall be as specified in IS 2026 Part 1 and IEC 60076-1.

Ratio test methods

Various types of ratio test methods are given in IS: 2026 Part 1 and IEC 60076 -1. Out of
those, Ratio Bridge method is most commonly adopted. In this method, the turn ratio on each
tapping between pairs of winding shall be measured by a direct reading ratio meter. This
method gives more accurate results as compared to other methods described in aforesaid
standards.
The modern ratio bridge can also be used to test polarity, phase relation and phase
sequence. More accurate results can be obtained using a ratio bridge that provides phase-
angle correction.

3.2.2 Polarity and Vector group verification


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(a)
1.1
1.2 2.2
2.1
Polarity and phase-relation tests are of interest primarily because of their bearing on
paralleling or banking two or more transformers. Phase-relation tests are made to determine
angular displacement and relative phase sequence. Phase-relation or vector group
verification test is performed on a three phase transformer or on a bank of three single-phase
transformers.
The details of Additive and Subtractive polarity are given in IS: 2026-Part 1 and IEC 60076-1.
3.2.2.1 Polarity by alternating-voltage test

For a single-phase transformer having a ratio of transformation of 30 to 1 or less, the polarity
test shall be done as follows. 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 1

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 high-voltage 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.

3.2.2.2 Verification of vector group

The phasor diagram of any three-phase transformer that defines the angular displacement
and phase sequence can be verified by connecting the HV and LV leads together to excite
the unit at a suitably low three-phase voltage, taking voltage measurements between the
various pairs of leads and then either plotting these values or comparing them for their
relative order of magnitude with the help of the corresponding phasor diagrams, e.g. as
Fig : 1 - Polarity by Alternating Voltage Test
source
V
1.1
2.1
1.2
2.2

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2V 2W
1W
Dy-I
1V
2U
1U
1W
1V
N
1U+2U
2V
2W
shown in figure 2 and 3. Typical check measurements are to be taken and their relative
magnitudes are then compared.
Example 1 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

Fig 2 : For HV-Delta / LV-Star Transformer
Example 2 Connect 1U to 2U
1V-2W
VOLTAGE RELATION
1W-2W = 1V-2W
1W-2V > 1V-2V
1U-N= (1U-2W)+(2W-N)
Yd11

Fig 3 : For HV-Star / LV-Delta Transformer

3.3 Measurement of no-load loss and excitation current

General
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.
Excitation current (no-load current) is the current that flows in any winding used to excite the
transformer when all other windings are open-circuited. It is generally expressed in percent of
the rated current of the winding in which it is measured.

3.3.1 No-load loss test
The purpose of the no-load loss test is to measure no-load losses at a specified excitation
voltage and a specified frequency. The no-load loss determination shall be based on a sine-
wave voltage. The average-voltage voltmeter method is the most accurate method for
correcting the measured no-load losses to a sine-wave basis and is recommended. This

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method employs two-parallel-connected voltmeters; one is an average-responding (possibly
rms calibrated) voltmeter; the other is a true rms-responding voltmeter. The readings of both
voltmeters are employed to correct the no-load losses to a sine-wave basis, using equation
given in paragraph for waveform correction of no-load losses.
Test voltage will be 90%, 100%, 110% ,guarnteed at 100% and for reference purpose at 90
and 110%

Connection diagrams

Tests for the no-load loss determination of a single-phase transformer are carried out using
the schemes depicted in figure 4 and figure 5. Figure 4 shows the necessary equipment and
connections for the case where instrument transformers are not required. When instrument
transformers are required, which is the general case, the equipment and connections shown
in figure 5 apply. If necessary, correction for losses in connected measuring instruments may
be made by disconnecting the transformer under test and noting the wattmeter reading at the
specified test circuit voltage. These losses represent the losses of the connected instruments
(and voltage transformer, if used). They may be subtracted from the earlier wattmeter reading
to obtain the no-load loss of the transformer under test.
Tests for the no-load loss determination of a three-phase transformer shall be carried out by
using the three wattmeter method. Figure 6 is schematic representation of the equipment and
connections necessary for conducting no-load loss measurements of a three-phase
transformer when instrument transformers are necessary.
Nowadays, digital power analysers or power meters are available for determination of losses
(both no-load and load). Selection of these power analysers shall be based on the desired
accuracy at low power factors
without instrument transformers
Fig : 4 - Connections for no-load loss test of a single-phase transformer
S
o
u
r
c
e
A
V AV W


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with instrument transformers
Fig : 5 - Connections for no-load loss test of a single-phase transformer
S
o
u
r
c
e A
Current
Transformer
Transformer
Voltage
W AV V

B
Fig : 6 - Three phase transformer connections for no-load loss and excitation
for Y-Y connected CT
transformer neutral
present to provide
return path from
transformers when no
delta winding is
A
Note : Source neutral
should be available
A
C
source
Power CT
current tests using three-wattmeter method
delta-connected winding
or Line-to-Line for
for Y-connected winding
be connected Line-to-Neutral
Note : Voltmeters should
A
N
V
W
3
r a
V VT
r a
C
N
V
W
2 V VT
A
A
CT
r
V V
a
1
W
N
B
VT
N
1U
1V
1W
2U
2V
2W

Voltage and frequency for no-load loss test
The operating and performance characteristics of a transformer are based upon rated voltage
and rated frequency, unless otherwise specified. Therefore, the no-load loss test is
conducted with rated voltage impressed across the transformer terminals, using a voltage
source at a frequency equal to the rated frequency of the transformer under test, unless
otherwise specified.

For the determination of the no-load losses of a single-phase transformer or a three-phase
transformer, the frequency of the test source should be within 0.5% of the rated frequency
of the transformer under test. If the excitation frequency is beyond the specified tolerance,
then the test voltage shall be adjusted to maintain the V/f ratio corresponding to the ratio of
rated voltage and rated frequency. The voltage shall be adjusted to the specified value as
indicated by the average-voltage voltmeter. Simultaneous values of rms voltage, rms current,
electrical power and the average voltmeter readings shall be recorded. For a three-phase

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transformer the average of the three voltmeter readings shall be the desired nominal value of
the voltage.

The most difficult cases, both with regard to voltage wave shape distortion and power
measurements usually arise when testing large single-phase transformers.

Instrument error at low power factor
At low power factors, such as those encountered while measuring the load losses and
impedance voltage of power transformers, judicious selection of measurement method and
test system components is essential for accurate and repeatable test results. The phase-
angle errors in the instrument transformers, measuring instruments, bridge networks and
accessories affect the load loss test results. Procedures for correcting the load losses for
meeting phase-angle errors are described in IEC Publication 60076-8

Correction of no-load losses
The eddy current component of the no-load loss varies with the square of the rms value of
excitation voltage and is substantially independent of the voltage waveform. When the test
voltage is held at the specified value as read on the average-voltage voltmeter, the actual
rms value of the test voltage may not be equal to the specified value. The no-load losses of
the transformer corrected to a sine-wave basis shall be determined from the measured value
by means of the following equation:

2 1
kP P
P
P
m
c
+
=

Where
P
c
is the no-load losses, corrected for waveform
P
m
is measured no-load losses
P
1
is per unit hysteresis loss
P
2
is per unit eddy-current loss
2
|
|
\
|
=
a
r
E
E
k

E
r
is the test voltage measured by rms voltmeter.
E
a
is the test voltage measured by average-voltage voltmeter.

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The actual per unit values of hysteresis and eddy-current losses should be used if available.
If actual values are not available, it is suggested that the two loss components be assumed
equal in value, assigning each a value of 0.5 per unit for CRGO.
The above equation is valid only for voltage with moderate waveform distortion. If waveform
distortion in the test voltage causes the magnitude of the correction to be greater than 5%,
then the test voltage waveform must be improved for an adequate determination of the no-
load losses and currents. For large single phase transformers, it is expected that the
difference between rms voltages and average voltage will be greater than 5%, which should
be accepted in view of test voltage source limitation.
The new generation of power analysers are equipped with software for automatic calculation
of corrected losses based on the input data of voltages and power.

3.3.2 Measurement of excitation (no-load) current

The excitation (no-load) current of a transformer is the current that maintains the rated
magnetic flux excitation in the core of the transformer. The excitation current is usually
expressed in per unit or in percent of the rated line current of the winding in which it is
measured. Measurement of excitation current is usually carried out in conjunction with the
tests for no-load losses. RMS current is recorded simultaneously during the test for no-load
losses using the average-voltage voltmeter method. This value is used in calculating the per
unit or percent excitation current. For a three-phase transformer, the excitation current is
calculated by taking the average of the magnitude of the three line currents. The tolerance for
no-load current should be as per IS 2026 Part -1

3.4 Measurement of short-circuit impedance and load loss

3.4.1 General

The load losses of a transformer are those losses incident to a specified load carried by the
transformer. Load losses include I
2
R 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.


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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.
The impedance voltage is measured during the load loss test by measuring the voltage
required to circulate test current in the windings. The measured voltage is the impedance
voltage at the test frequency and the power loss dissipated within the transformer is equal to
the load losses at the temperature of test and at rated load. The impedance voltage is
corrected to the rated frequency and the load losses are corrected to a reference temperature
using the formulas specified in this standard.

3.4.2 Factors affecting the values of load losses and impedance voltage
The magnitude of the load losses and the impedance voltage will vary depending on the
positions of tap changers, if any in various windings. These changes are due to the changes
in the magnitudes of load currents and associated leakage-flux linkages as well as being due
to changes in stray flux and accompanying stray losses.

3.4.2.1 Temperature
Load losses are also a function of temperature. The I
2
R component of the load losses
increases with temperature, while the stray loss component decreases with temperature.
Procedures for correcting the load losses to the standard reference temperature are
described in 3.5.5.

3.4.2.2 Instrument error at low power factor
At low power factors, such as those encountered while measuring the load losses and
impedance voltage of power transformers, judicious selection of measurement method and
test system components is essential for accurate and repeatable test results. The phase-
angle errors in the instrument transformers, measuring instruments, bridge networks and
accessories affect the load loss test results. Procedures for correcting the load losses for
meeting phase-angle errors are described in IEC Publication 60076-8

3.4.3 Methods for measuring load losses and impedance voltage
Test Conditions
To determine the load losses and impedance voltage with sufficient accuracy, the following
conditions shall be met.

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1. The temperature of the insulating liquid has stabilized and the difference between top
and bottom oil temperatures does not exceed 5
0
C.
2. The temperature of the windings shall be taken immediately either before or after the
load losses and impedance voltage test in a manner similar to that described in 3.1.1.
The average shall be taken as the winding temperature for computation of losses.
3. The conductors used to short-circuit the low voltage, high current winding of a
transformer shall have a cross-sectional area equal to or greater than the
corresponding transformer winding leads.
4. The test current shall be at least 50 % of the rated current of the winding across which
the voltage is applied.
5. The measurement of losses shall be done at the earliest after excitation of the
transformer to the test current to avoid heating of the winding resulting in increase in
resistance.
3.4.3.1. Wattmeter-voltmeter-ammeter method for load loss and impedance voltage test

The connection and apparatus needed for the determination of the load losses and
impedance voltage of a single-phase transformer are shown in figure 7 and 8. Figure 8
applies when the instrument transformers are required, which is the general case.

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 ratings preferably above 20 MVA, 66 kV class.

For three phase transformers, figure 9 shows the apparatus and connections using the three-
wattmeter method.
S
o
u
r
c
e
A
W V
Fig : 7 - Basic circuit for load loss and impedance measurement
impedance tests with instrument transformers
Source
AC
V
A
HV LV
CT VT
W
Fig : 8 - Single-phase transformer connections for load loss and


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N
impedance voltage tests using three-wattmeter method
Fig : 9 - Three phase transformer connections for load loss and
CT
AB, BC, CA
A
AN, BN, CN
Volts can
be read
C
A
Power
source
CT
B
(For any delta or Y
Transformer under test
A
N
V
W
3
r a
V VT
combination)
VT V 2
W
V
a r
C
N
B
3U 3V
2U 2V
A
A
CT
V
W
1 V
a r
VT
1U 1V
Short

3.4.3.2 Measurement with Power analyser
Nowadays, digital power analysers or power meters are available for determination of load
losses. Selection of these power analysers shall be based on the desired accuracy at low
power factors.
The new generation of power analysers are equipped with software for automatic calculation
of corrected losses based on the input data of voltage, current, power, frequency and
temperature.

3.4.4 Test procedure

3.4.4.1 Two-winding transformers and auto transformers

Load loss and impedance voltage tests are carried out using the connections and apparatus
shown in figure 8 for single-phase transformers and figure 9 for three-phase transformers.
With one winding short-circuited, a voltage of sufficient magnitude is applied to the other
winding and adjusted to circulate test current in the excited winding. Simultaneous readings
of wattmeter, voltmeter and ammeter are taken. If necessary, the corrections for the losses in
external connections and connected measuring instruments should be made.
The procedure for testing three-phase transformers is very similar, except that all connections
and measurements are three-phase instead of single-phase and a balanced three-phase
source of power is used for the test. If the three line currents cannot be balanced, their
average rms value should correspond to the desired value, at which time simultaneous
reading of wattmeters, voltmeters and ammeters should be recorded.


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Single phase and three-phase auto transformers may be tested with internal connections
unchanged. The test is made using the auto transformer connection. The input (or output)
terminals are shorted and voltage is applied to the other terminals. The voltage is adjusted to
cause test current to flow in the test circuit as shown in figure10. Simultaneous readings of
wattmeters, voltmeters and ammeters are recorded for determination of load losses and
impedance voltage.
Fig : 10 - Connections for impedance loss and impedance-voltage
S
o
u
r
c
e
V W
A
tests of an auto-transformer

For the purpose of measuring load losses and impedance voltage, the series and common
windings of auto transformers may be treated as separate windings, one short circuited, the
other excited. In this situation, where the transformer is connected in the two-winding
connection for the test, the current held must be the test current of the excited winding, which
may or may not be the same as rated line current. The load loss watts and applied volt-
amperes will be same, whether series and common windings are treated as separate
windings in the two-winding connection or are connected in the auto-transformer connection,
so long as rated winding current atleast 50 percent is held in the first case and rated line
current atleast 50 percent in the second case.

3.4.4.2 Three winding transformers

For a three winding transformer, which may be either single phase or three phase, three sets
of impedance measurements are made between pairs of windings, following the same
procedure as for two winding transformers. Measurement of the impedances Z
12
, Z
23
and Z
31

are obtained between windings 1, 2 & 3.

If the kVA capacities of the different windings are not alike, the current held for the
impedance test should correspond to the capacity of the lower rated winding of the pair of the
windings under test. However, all of these data when converted into percentage form should
be based on the same output kVA, preferably that of the primary winding. An equivalent
three-winding impedance network as shown in figure 11 can be derived from the following
equations:

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Fig : 11 - Equivalent three-winding impedance network
1
3
Z
3
Z
1
Z
2
2

1 23
23 12 31
3
1 12
12 31 23
2
31 23 12
1
2
2
2
Z Z
Z Z Z
Z
Z Z
Z Z Z
Z
Z Z Z
Z
=
+
=
=
+
=
+
=

Where
Z
12
, Z
23
and Z
31
are the measured impedance values between pairs of windings, as indicated
all expressed on the same kVA base.

These equations involve complex numbers, but they may be used for the resistance (in-
phase) component or the reactance (quadrature) component of the impedance voltage or of
the impedance volt-amperes.

The treatment of the individual load losses for temperature corrections, etc., is the same as
for two-winding, single phase transformers.

The total load losses of the three winding transformer is the sum of the losses in the
branches of the equivalent circuit of figure 11 for any specific terminal load conditions.

3.4.5 Calculation of load losses and impedance voltage for test data

Load loss measurements vary with temperature and in general must be corrected to a
reference temperature. In addition, load loss measurement values must be corrected for
metering phase angle error. Impedance voltage measurement to vary with frequency and the
values must be corrected for rated frequency.


Page 21 of 65

Temperature correction of load losses
Both I
2
R losses and stray losses of transformer vary with temperature. The I
2
R losses, P
r
(T
m
),
of a transformer are calculated from the ohmic resistance measurements (connected to the
temperature, T
m
, at which the measurement of the load losses and impedance voltage was
done) and the current that were used in the impedance measurement. These I
2
r losses
subtracted from the measured load loss watts P(T
m
), give the stray losses, P
s
(T
m
), of the
transformer at the temperature at which the load loss test was made.
P
s
(T
m
) = P(T
m
) P
r
(T
m
)
Where
P
s
(T
m
) is the calculated stray losses (watts) at temperature T
m
.
P(T
m
) is the transformer load losses (watts), corrected in accordance with phase angle errors
in wattmeter at temperature T
m
.
P
r
(T
m
) is the calculated I
2
R loss (watts) at temperature T
m

The I
2
R component of load losses increases with temperature. The stray loss component
diminishes with temperature. Therefore, when it is desirable to convert the load losses from
the temperature at which it is measured, T
m
, to another temperature, T, the two components
of the load losses are corrected separately.
Thus,
( )
( )
(
+
+
=
(
+
+
=
T T
T T
T P P
T T
T T
T P P
k
m k
m s s
m k
k
m r r

Then
P (T) = P
r
(T) + P
s
(T)
Where
P
r
(T) = I
2
R loss (watts) at temperature T,
0
C
P
s
(T) = stray losses (watts) at temperature T,
0
C
P (T) = Transformer load losses (watts) corrected to temperature T,
0
C
T
k
= 234.5
0
C (copper) 235
0
C
T
k
= 225
0
C (aluminium)
.
Calculation for impedance
The impedance shall be measured at rated frequency by applying an approximately
sinusoidal supply to one winding, with the terminal of other winding short circuited, and with
possible other winding open circuited. The supplied current should be equal to the relevant
rated current. However, in case of limitation in the rating of supply source the current should

Page 22 of 65

not be less than the 50% of the rated current. Due to fluctuation in load the supply frequency
may not be always be the rated frequency. Then frequency correction should be applied to
calculate the actual impedance at rated frequency as following.
The formula for calculating the percentage impedance with current and frequency correction
is
( ) 100 % =
t
r
test
rated
rated
test
f
f
I
I
V
V
Z

Where
V
test
=Test voltage
V
rated
=Rated voltage
I
test
= Test current
I
rated
= Rated current
f
t
= Test frequency
f
r
= Rated frequency

3.5 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
1) 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.
2) Under no conditions, test should be made while the transformer is under vacuum.
Instrumentation

Insulation resistance may be measured using the following equipment:

Page 23 of 65

a) A variable-voltage dc power supply with means to measure voltage and current
(generally in micro-amperes or milli-amperes)
b) A mega-ohmmeter
Mega-ohmmeters are commonly available with nominal voltages of 500V, 1000V, 2500V, and
5000V; dc or in multiples of 1000 V upto 10,000 V.

Voltage to be applied

The dc voltage applied for measuring insulation resistance to ground shall not exceed a value
equal to the half of the rated voltage of the winding or 5 kV whichever is lower.
Procedure
Insulation resistance tests shall be made with all circuits of equal voltage above ground
connected together. Circuits or groups of circuits of different voltages above ground shall be
tested separately. All external insulating parts of the transformer shall be cleaned thoroughly
to remove dust, moisture etc. before the test.
Examples:
a) High voltage to low voltage and ground, low voltage to high voltage and ground.
b) Voltage should be increased in increments of usually one kilovolt and held for one
minute while the current is read.
c) The test should be disconnected immediately in the event the current begin to
increase without stabilizing.
d) After the test has been completed, all terminals should be grounded for a period of
time sufficient to allow any trapped charges to decay to a negligible value.

Polarisation Index (PI)
The purpose of polarisation index test is to determine if equipment is suitable for operation or
even for an overvoltage test. The polarisation index is a ratio of insulation resistance value at
the end of 10 min test to that at the end of 1 min test at a constant voltage.
The total current that is developed when applying a steady state dc voltage is composed of
three components:
1) Charging current due to the capacitance of the insulation being measured. This
current falls off from maximum to zero very rapidly.
2) Absorption current due to molecular charge shifting in the insulation. The transient
current decays to zero more slowly.

Page 24 of 65

3) Leakage current which is the true conduction current of the insulation. It has a
component due to the surface leakage because of the surface contamination.
The advantage of PI is that all of the variables that can affect a single IR reading, such as
temperature and humidity, are essentially the same for both the 1 min and 10 min readings.
Since leakage current increases at a faster rate with moisture present than does absorption
current, the IR readings will not increase as fast with insulation in poor condition as with
insulation in good condition. After 10 min the leakage current becomes constant and effects
of charging current and absorption current die down.

Acceptable PI value for power transformer shall be better than 1.5. For distribution
transformer it should be at least 1.3 .

Interpretation of results
Insulation resistance may vary with applied voltage and temperature any comparison must be
made with measurements at the same voltage.
The significance of values of insulation resistance tests generally requires some
interpretation, depending on the design and the dryness and cleanliness of the insulation
involved. When a user decides to make insulation resistance test, it is recommended that
insulation resistance values be measured periodically (during maintenance shutdown) and
that these periodic values be plotted. Substantial variations in the plotted values of insulation
resistance should be investigated for cause.

3.6 Tests on On-load Tap-changers
3.6.1 Operation test
With the tap-changer fully assembled on the transformer the following sequence of
operations shall be performed without failure:
a. With the transformer un-energised, eight complete cycles of operations (a cycle of
operation goes from one end of the tapping range to the other, and back again).
b. With the transformer un-energised, and with the auxiliary voltage reduced to 85% of its
rated value, one complete cycle of operation.
c. With the transformer energized at rated voltage and frequency at no load, one
complete cycle of operation

Page 25 of 65

d. With one winding short circuited and, as far as practicable, two rated current in the
winding, 10 tap-change operations across the range of two steps on each side from
where a coarse or reversing changeover selector operates, or otherwise from the
middle tapping.

3.6.2 Auxiliary circuits insulation test

After the tap changer is assembled on the transformer, a power frequency tests shall be
applied to the auxiliary circuits as specified in IEC 60076-3.

DIELECTRIC TESTS

The purpose of dielectric tests is to demonstrate that the transformer has been designed and
constructed to withstand the specified insulation levels. The insulation requirements for the
transformers and the corresponding dielectric tests are given in IS 2026 Part-3 and IEC
Publication 60076-3 with reference to specific windings and their terminals. For oil immersed
transformers, the requirements apply to the internal insulation only.
The dielectric tests shall generally be made at the manufacturer premises with the
transformers approximately at ambient temperature.

Transformers, including bushings and terminal compartments when necessary to verify air
clearances, shall be assembled prior to making dielectric tests, but assembly of items, such
as radiators and cabinets, which do not affect dielectric tests is not necessary. Bushing shall,
unless otherwise authorised by the purchaser, be those to be supplied with the transformer.

If a transformer fails to meet its test requirements and the fault is in a bushing, it is
permissible to replace this bushing temporarily with another bushing and continue the tests
on the transformer to completion without delay. A particular case arises for tests with partial
discharge measurements, where certain types of commonly used high-voltage bushings
create difficulty because of their relatively high level of partial discharge in the dielectric.
When such bushings are specified for the transformer, it is permitted to exchange them for
bushings of a partial discharge free type during the testing of transformer.

Test levels and other test parameters shall be as per IEC Publication 60076-3 and the
corresponding IS 2026 Part-3.


Page 26 of 65

It is recommended to measure voltage at the high voltage terminal of its transformer. The
measuring system shall be in accordance with IEC Publication 60071-2.

In conducting low frequency tests for transformers of 100 kVA and less to be tested at 50 kV
or less, it is permissible to depend on the ratio of testing transformer to indicate the proper
test voltage.

Rules for some particular transformers

In transformers where uniformly insulated windings having different U
m
values are connected
together within the transformer, the separate source AC withstand test voltages shall be
determined by the insulation of the common neutral and its assigned U
m
.
In transformers which have one or more non uniformly insulated windings, the test voltages
for the induced withstand voltage test, and for the switching impulse test, are determined by
the winding with highest U
m
value, and the windings with lower U
m
values may not receive
their appropriate test voltages.
During switching impulse tests, the voltages developed across different windings are
approximately proportional to the ratio of turns. Rated switching impulse withstand voltages
shall only be assigned to the winding with the highest U
m
. Test stresses in other windings are
also proportional to the ratio of numbers of turns and are adjusted by selecting appropriate
tappings to come as close as possible to the assigned value.

Insulation requirements and dielectric tests

The basic rules for insulation requirements and dielectric tests for different categories of
windings are described in Table 1(Refer IEC Publication 60076-3)
TABLE 1
Tests Category
of
winding
Highest voltage
for equipment
U
m

kV
Lightning
impulse
(LI)
Switching
impulse
(SI)
Long
duration
AC(ACLD)
Short
duration
AC(ACSD)
Separate
source
AC
Uniform U
m
72.5 Type Not
applicable
Not
applicable
Routine Routine
Uniform
and non-
72.5 < U
m
170 Routine Not
applicable
Special Routine Routine

Page 27 of 65

170 < U
m
< 300 Routine Routine* Routine Special* Routine
uniform
insulation
U
m
300 Routine Routine Routine Special Routine
* If ACSD test is specified, the SI test is not required.

The standard dielectric requirements are verified by dielectric tests. They shall, where
applicable and not otherwise agreed upon, be performed in the sequence as given below.
1) Switching impulse test (SI) for the line terminal
2) Lightning impulse test (LI) for the line terminals
3) Lightning impulse test (LI) for neutral terminal
4) Separate source AC withstand voltage test (applied potential test)
5) Short-duration induced AC withstand voltage test (ACSD)
6) Long-duration induced AC voltage test (ACLD)

3.7 Switching impulse withstand voltage test, transformer winding U
m
> 220 kV

This test is intended to verify the switching impulse withstand strength of the line terminals
and its connected windings to earth and other windings, the withstand strength between
phases and along the winding under test.
The impulses are applied either directly from the impulse voltage source to a line terminal of
the winding under test, or to a lower voltage winding so that the test voltage is inductively
transferred to the winding under test.
The detailed test procedures and specific test requirements are addressed in IEC Publication
60076-3.
Switching impulse waves
Polarity
The polarity of test voltage shall be negative because this reduces the risk of erratic external
flashovers in the test circuit.

Wave shape


Page 28 of 65

The voltage impulse shall have a virtual front time of at least 100 s, a time above 90% of the
specified amplitude of at least 200 s, and a total duration from the virtual origin to the first
zero passage of at least 500 s but preferably 1000 s.

Test sequence and records

The test sequence shall consists of one impulse of a voltage between 50% and 75 % of the
full test voltage and three subsequent impulses of full voltage. If the oscillographic or digital
recording should fail, that application shall be disregarded and a further application made.
Oscillographic or digital records shall be obtained of at least the impulse wave-shape on the
line terminal under test and preferably the neutral current.

Test connections

During the test the transformer shall be in a no-load condition. Windings not used for the test
shall be solidly earthed at one point but not short-circuited. For a single phase transformer,
the neutral terminal of the tested winding shall be solidly earthed.
A three-phase winding shall be tested phase by phase with the neutral terminal earthed and
with the transformer so connected that a voltage of opposite polarity and about half amplitude
appears on the two remaining line terminals which may be connected together.
To limit the voltage of opposite polarity to approximately 50% of the applied level, it is
recommended to connect high ohmic damping resistors (10 k to 20 k) to earth at the non
tested phase terminals.

Failure detection
The test is successful if there is no sudden collapse of voltage or discontinuity of the neutral
current if recorded on the oscillographic or digital records.
Additional observation during the test (abnormal sound effect etc.) may be used to confirm
the oscillographic records, but they do not constitute evidence in themselves.

3.8 Lightning Impulse withstand voltage test


Page 29 of 65

This test is intended to verify the impulse withstand strength of the transformer under test.
This test shall only be made on windings that have terminals brought out through the
transformer tank or cover.
When non-linear elements or surge diverters are installed for the limitation of transferred over
voltage transients, the evaluation of test records may be different compared to the normal
impulse test. These non-linear protective devices connected across the windings may cause
difference between the reduced full wave and the full-wave impulse oscillograms. To prove
that these differences are indeed caused by operation of these devices, this should be
demonstrated by making two or more reduced full-wave tests at different voltage levels to
show the trend in their operation.
The detailed test procedure and specific test requirements are addressed in IEC 60076-3.
Impulse wave
The test impulse shall be a full standard lightning impulse: 1.2 s 30% / 50 s 20 %.
But in some cases this standard impulse shape cannot reasonably be obtained, because of
low winding inductance or high capacitance to earth. In such cases wider tolerance may be
accepted by the agreement between purchaser and customer. It is recommended to use IEC
Publication 60722 as a guide for non-standard wave shapes.
Test sequence
The test sequence shall consists of one impulse of a voltage between 50% to 75% of full test
voltage, and three subsequent impulses at full voltage. If, during any of these applications, an
external flashover in the circuit or across a bushing spark gap should occur, or if the
oscillographic recording should fail on any of the specified measuring channels, that
application shall be disregarded and a further application made.

Test Connections
During test on line terminals
The impulse test sequence is applied to each of the line terminals of the tested winding in
succession. In the case of a three phase transformer, the other line terminals of the winding
shall be earthed directly or through a low impedance, not exceeding the surge impedance of
the connected line. If the winding has neutral terminal, it shall be earthed directly or through
a low impedance such as a current measuring shunt.
In the case of separate-winding transformer, terminals of windings not under test are earthed
directly or through impedances, so that in all circumstances, the voltage appearing at the
terminals is limited to not more than 75% of their rated lightning impulse withstand voltage for
star connected windings, and 50% for delta- connected windings.

Page 30 of 65

In case of auto transformer, when testing the line terminal of the high voltage winding the
non-tested line terminal shall be earthed through resistors not exceeding 400 to get the
impulse waveform as needed.

Impulse test on a neutral terminal
Impulse withstand capability of neutral may be verified by :
a) Indirect application:
Test impulses are applied to any one of line terminals or to all three line terminals
connected together. The neutral is connected to earth through an impedance or is left
open. Then standard lightning impulse is applied to the line terminal which shall not
exceed 75% of the rated LI withstand voltage of the line terminal.
b) Direct application:
Test impulse corresponding to the rated withstand voltage of the neutral is applied
directly to the neutral with all line terminals earthed. In this case, however a longer
duration of front time is allowed, upto 13 s.

Records of test
The oscillographic or digital records obtained during calibrations and tests shall clearly show
the applied voltage impulse shape (front time, time to half value and amplitude). The
oscillograms of the current flowing to earth from the tested winding shall also be recorded.
Test sequence
The test sequence shall consist of one impulse of a voltage between 50% to 75% of full test
voltage, and three subsequent impulses at full voltage. If, during any of these applications, an
external flashover in the circuit or across a bushing spark gap should occur, or if the
oscillographic recording should fail on any of the specified measuring channels, that
application shall be disregarded and a further application made.

Failure detection
Grounded current oscillograms
In this method of failure detection, the impulse current in the grounded end of the winding
tested is measured by means of an oscilloscope or by a suitable digital transient recorder
connected across a suitable shunt inserted between the normally grounded end of the
winding and ground. Any differences in the wave shape between the reduced full-wave and
final full-wave detected by comparison of the two current oscillograms, may be indication of
failure or deviations due to no injurious causes. They should be fully investigated and

Page 31 of 65

explained by a new reduced wave and full-wave test. Examples of probable causes of
different wave shapes are operation of protective devices, core saturation, conditions in the
test circuit external to the transformer.
The ground current method of detection is not suitable for use with chopped-wave tests.
Other methods of failure detection
Voltage Oscillograms: Any unexplained difference between the reduced full-wave and final
full-wave detected by comparison of the two voltage oscillograms, or any such differences
observed by comparing the chopped-waves to each other and to the full-wave up to the time
of flashover, are indications of failure.
Noise: Unusual noise within the transformer at the instant of applying impulse is an indication
of trouble. Such noise should be investigated.
Measurement: Measurement of voltage and current induced in another winding may also be
used for failure detection.
3.9 Separate source voltage withstand test
Duration, frequency, and connections
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.
Application of voltage for Separate Source Withstand test
The test shall be commenced at a voltage not greater than one-third of the full value and be
brought up gradually to full value in not more than 15 s. After being held for the specified time
of 60 seconds, it should be reduced (in not more than 5s) to one thirdor less of the maximum
value and the circuit opened.
Failure detection
Careful attention should be started given for evidence of possible failure that could include
items, such as an indication of smoke and bubbles rising in the oil, an audible sound such as
a thump, or a sudden increase in test circuit current. Any such indication should be carefully
investigated by observation, by repeating the test, or by other test to determine if a failure has
occurred.
3.10 Induced AC voltage withstand tests with partial discharge measurement

Page 32 of 65

This test is intended to verify the AC withstand strength of each line terminal and its
connected winding(s) to earth and other windings, the withstand strength between phases
and along the winding(s) under test.
As per IS 2026 Part 3-1981 and IEC Pub. 60076-3 of 1981, the test is normally performed
with partial discharge measurement (Method 2) for transformers with highest voltage winding
of 300 kV. For transformer with highest voltage winding of < 300 kV, the test is performed
without partial discharge measurement (Method 1). However, with the latest reversion of IEC
60076-3 in 2000, the methods for induced over-voltage withstand test are reformed as AC
short duration test (ACSD) and AC long duration test (ACLD).
For U
m
>72.5 kV, the test is normally performed with partial discharge measurements to verify
partial discharge free operation of the transformer under operating condition,?? the
requirements for partial discharge measurement during the ACSD test may be omitted. This
shall be clearly stated at the enquiry and order stages. However, ACLD test is always
performed with the measurement of partial discharge during the whole application of test.
An alternating voltage shall be applied to the terminals of one winding of the transformer. The
voltage shall be as nearly as possible sinusoidal and its frequency is sufficiently above the
rated frequency to avoid excessive magnetizing current during the test.
The test voltage is the peak value of voltage divided by 2 .The test time at full test voltage
shall be 60 sec for test frequency up to and including twice the rated frequency. For
frequency above twice the rated frequency the time duration of test shall be:
frequency Test
frequency Rated
120 , but not less than 15 sec
Table below shows the different conditions of induced AC voltage test as defined in IEC
publication 60076-3. The time duration for the application of test voltage with respect to earth
is shown in figure 12
Induced AC voltage test

Type of
test
Type of winding Highest
voltage of
equipment
Um
Test voltage level Test
Duration
(Refer Fig
12)
Remarks
72.5 kV

As per Table2 of
IEC 60076-3
60 sec

No PD
measurement

Uniformly insulated

> 72.5 kV U
1
=from Table
D.1 of IEC 60076-
3
U
2
= 1.3 U
m
/3
C= 120x
Rated Frq.
Test freq.
PD level
should be
300 pC at
level U
2


Page 33 of 65

Phase
to
earth
test
U
1
=from
Table
D.2 of IEC
60076-3
U
2
=
1.5U
m
/3
PD level
should be
500 pC at
level U
2

AC
Short
duration
Non-uniformly
insulated
>72.5 kV
Phase
to
phase
test
U
1
=from
table
D.2 of IEC
60076-3
U
2
= 1.3
U
m
/3

C= 120x
Rated Frq.
Test freq.
With PD
measurement
It should be
300 pC at
level U
2

Delta
connected
HV
245 kV U
1
= 1.7 U
m
/3
U
2
= 1.5 U
m
/3
D=30 min
C= 120x
Rated Frq.
Test freq.
PD level
should be
500 pC at
level U
2

AC
Long
Duration

Uniformly
and non-
uniformly
insulated
Star
connected
HV
< 300 kV

300 kV
U
1
= 1.7 U
m
/3
U
2
= 1.5 U
m
/3
U
1
= 1.7 U
m
/3
U
2
= 1.5 U
m
/3
D=30 min
C= 120x
Rated Frq.
Test freq.
D=60 min
C= 120x
Rated Frq.
Test freq.
PD level
should be
500 pC at
level U
2

Here
U
m
=Highest voltage for equipment
U
1
= Test voltage
Fig. 12 Time sequence for the application of test voltage with respect to earth
A = 5 min
B = 5 min
C = test time
D = 5 min for ACSD and 30/60 min for
ACLD
E = 5 min
A
B
C
D
E
U
start
U
2
U
1
U
2
U
m
U
start
<
/ 3 1.1 / 3 U
m
1.1

Page 34 of 65

U
2
= Partial discharge evaluation level

3.10.1 Short-duration induced AC withstand voltage test (ACSD)
3.10.1.1 ACSD for transformers with uniformly insulated high-voltage windings
A three-phase winding shall preferably be tested with symmetrical three-phase voltages
induced in the three winding phases. If the winding has a neutral terminal, this may be
earthed during the test.

Transformers with U
m
72.5 kV
The phase-to-phase test voltage shall not exceed the rated induced AC withstand voltages as
specified in IEC 60073-3. The test voltage across an untapped winding of the transformer
shall be as close as possible to twice the rated voltage. Normally, no partial discharge
measurements are performed during this test.
The test shall commence at a voltage not greater than one-third of the test value and the
voltage shall be increased to the test value as rapidly as is consistent with the measurement.
At the end of the test, the voltage shall be reduced rapidly to less than one-third of the test
value before switching off.
The test is successful if no collapse of the test voltage occurs.

Transformers with U
m
> 72.5 kV
The test is performed at two voltage levels U
1
and U
2
(U
1
as in table D.1 of IEC-60076-3
and U
2
= 1.3 U
m
/3) levels associated with partial discharge measurements.
The phase-to-phase voltage is same as described earlier. The partial discharge performance
shall be according to the time sequence for the application of the test voltage as shown in fig
12 :
The voltage with respect to earth shall be:
- Switched on at a level not higher than one-third of U
2
.
- Raised to 1.1 U
m
/3 and held there for a duration of 5 min.
- Raised to U
2
and held there for a duration of 5 min
- Raised to U
1
, held there for the test time calculated earlier
- Immediately after the test time, reduced without interruption to U
2
and held there for a
duration of at least 5 min to measure partial discharges

Page 35 of 65

- Reduced to 1.1 U
m
/3 and held there for a duration of 5 min
- Reduced to a value below one-third of U
2
before switching off
The test is successful if
- no collapse of test voltage occurs
- the continuous level of apparent charge at U
2
during 5 min does not exceed
300 pC on all measuring channels
- the partial discharge behaviour does not show a continuing rising tendency
- the continuous level of apparent charges does not exceed 100 pC at 1.1 U
m
/3
A failure to meet the partial discharge criteria shall lead to consultation between purchaser
and supplier about further investigations.
3.10.1.2 ACSD for transformers with non-uniformly insulated high-voltage windings
For three phase transformers, two sets of tests are required as per IEC60076-3.
a) A phase-to-earth test with rated withstand voltage between phase and earth
b) A phase-to-phase test with earthed neutral and with rated withstand voltage between
phases
The test sequence for a three-phase transformer consists of three single phase applications
of test voltage with different points of the winding connected to earth at each time.
Other separate windings shall generally be earthed at the neutral if they are star-connected
and at one of the terminals if they are delta-connected.
The test time and test sequence for the application of voltage shall be as given in figure12.
For the partial discharge performance evaluation, during the phase-to-phase test
U
1
= From Table D.2 of IEC-60076-3 U
2
=1.3 U
m

For the three single-phase tests for the phase-to-earth insulation,
U
1
= From Table D.2 of IEC-60076-3 U
2
=1.5 U
m
/3
The test is successful if no collapse of the test voltage occurs and if the partial discharge
measurements fulfil the requirement as in 600076-3 with the following alteration:
The continuous level of apparent charge at U
2
during the 5 min does not exceed 500 pC on
all measuring terminals for single-phase tests at U
2
= 1.5 U
m
/3 line to earth, or 300 pC for
phase to phase tests at U
2
= 1.3 U
m
/3 or as may be required at extremely low a.c.
coordination values at 1.2 U
m
.

Page 36 of 65

The detailed test procedure and specific test requirements are addressed in IEC-60076-3.

3.11 Lightning impulse voltage withstand test, transformer winding U
m
< 300 kV
Refer to the clause no 3.8 of this manual

3.12 Temperature Rise Test

Temperature rise test
To prove that temperature rise comply to limits specified in standards and to derive
thermal characteristics for the transformer,
A heat run is carried out supplying full load losses for sufficient time to ensure that the
temperature rise of the winding and oil reach steady state values.
The transformer shall be assembled completely with its cooling equipment. It is desirable to
put the specified conservator with the transformers, if available. Alternatively, temporary
conservator of approximately same capacity can be used for the purpose of the test.
The top oil temperature is measured by a thermometer in a pocket at the top of the
transformer tank, and this is used to verify that steady conditions have been reached. Final
winding temperatures cannot be measured directly.
The transformers shall be tested in the combination of connections and taps that give the
highest winding temperature rises as determined by the manufacturer and reviewed by the
purchasers representative when available. This will generally involve those connections and
taps resulting in the highest losses.
All temperature rise test shall be made under normal (or equivalent to normal) conditions of
the means of cooling.
The temperaturerise test shall be made in a room that is free from drafts as practicable and
equipped with its protective device.
Cooling air temperature
Precautions should be taken to minimise variations of cooling air temperature specially when
the steady state is approached. Rapid variation of reading should be prevented by providing
at least three sensors, and average of their readings shall be used for evaluation. The
sensors shall be distributed around the tank 1m to 2m away from the tank or cooling surface
and protected from direct radiation.
Cooling water temperature
The temperature is measured at the intake of the cooler. Readings of temperature and rate of
water flow should be taken at regular interval.

Page 37 of 65

Test method
Short circuit method
During this test the transformer is subjected to the calculated total losses, previously
obtained by two separate determination of losses, namely load loss at reference temperature
and no load loss.
The purpose of this test is
- to establish the top oil temperature rise in steady-state condition with dissipation of total
losses
- to establish the average winding temperature rise at rated current and with the top oil
temperature rise as determined above.
This is achieved in two steps:
a) Total loss injection
First the top oil and average oil temperature rises are established when the transformer is
subjected to a test voltage such that the measured power is equal to the total losses of the
transformer. The test current will be above rated current to the extent necessary for
producing an additional amount of loss equal to the no-load losses, and 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 is established.
The test may be terminated when the rate of change of top oil temperature rise has fallen
below 1C per hour and has remained there for a period of 3 hour.
b) Rated current injection
When the top oil temperature rise has been established, the test shall immediately continued
with the test current reduced to the rated current for the winding combination connected. This
condition is maintained for 1 h, with continuous observation of oil and cooling medium
temperatures.

At the end of one hour, the resistance of windings are measured with suitable method.
During the hour with rated current the oil temperature falls. The measured values of winding
temperature shall therefore be raised by the same amount as the average oil temperature
rise has fallen from the correct value. The corrected winding temperature value minus the
cooling medium temperature at the end of the total losses injection period is the average
temperature rise.
By the agreement, the two steps of the test may be combined in one single application of the
power at a level between load loss and the total loss. The temperaturerise figures for the top
oil and for the windings shall then be determined using the correction rules. The power
injected during the test shall however be at least 80% of the total loss figure.

Determination of average winding temperature

Page 38 of 65

The average winding temperature is determined via measurement of winding resistance. A
reference measurement (R
1
,
1
) of all winding resistances is made with the transformer at
ambient temperature, in a steady condition. When the resistance R
2
at different temperature
(2) is measured this yields the temperature value
( )
( ) 235 225 : min
235 235 : Copper
1
1
2
2
1
1
2
2
+ =
+ =

R
R
ium Alu
R
R

The external cooling medium temperature at the time of shutdown is a
The winding temp. rise is then, finally :
w =
2
-
a

Determination of winding temperature before shutdown
Immediately after disconnection of test power supply and removal of short circuit connection
the resistance of winding is measured with a suitable measuring circuit. The winding has
large electrical time constant therefore accurate reading obtained only after a certain time
delay. The resistance of the winding varies with time as the winding cools down. It shall be
measured for a sufficient time to permit the extrapolation back to instant of shutdown.
The detailed procedure to determine the resistance at the instance of shutdown is
accordance with IEC-60076-2.
Corrections :
If the specified values of power or current have not been obtained during the test, the result
shall be corrected according to the following relation. They are valid within a range of 20%
from target value of power and 10% from target value of current.
The oil temperature rise above ambient during the test is multiplied by :
X
losses Test
losses Total
|
|
\
|

X= 0.8 for distribution transformers
X= 0.9 for larger transformers with ON cooling
X= 1.0 for transformers with OF or OD cooling
The average winding temperature rise above average oil temperature during the test is
multiplied by:

Page 39 of 65

Y
Current Test
Current Rated
|
|
\
|

Y=1.6 for ON and OF cooled transformers
Y= 2.0 for OD cooled transformers
3.13 Lightning impulse test on neutral terminal
Details of this test covered in the clause3.8 of this manual
3.14 Long-duration induced AC voltage test (ACLD), transformer winding U
m
< 170 kV
ACLD with non-uniformly and/or uniformly insulated high-voltage windings
This test is not a design proving test, but a quality control test and is intended to cover
temporary over voltages and continuous service stress. It verifies partial discharge-free
operation of the transformer under operating conditions.
This test is not recommended for three phase transformers supplied from low voltage side
with a delta connected high voltage winding
The time sequence and application of voltage is as follows:
- Switched on at a level not higher than one-third of U
2
.
- Raised to 1.1 U
m
/3 and held there for a duration of 5 min.
- Raised to U
2
and held there for a duration of 5 min
- Raised to U
1
, held there for the test time calculated earlier
- Immediately after the test time, reduced without interruption to U
2
and held there for a
duration of at least 60 min when U
m
300 kV or 30 min for U
m
< 300 kV to measure
partial discharges
- Reduced to 1.1 U
m
/3 and held there for a duration of 5 min
- Reduced to a value below one-third of U
2
before switching off
During the whole application of the test voltage, partial discharges shall be monitored.
The voltage to earth shall be:
U
1
=1.7 U
m
/3
U
2
=1.5 U
m
/3
The partial discharges shall be observed and evaluated as follows.
- Measurements shall be carried out at the line terminals of all non-uniformly insulated
winding.

Page 40 of 65

- The measuring channel from each terminal used shall be calibrated with repetitive
impulses between the terminal and earth, and this calibration is used for the evaluation
of readings during the test.
- Before and after the application of test voltage, the background noise level shall be
recorded on all measuring channel.
- During the raising of voltage upto level U
2
and reduction from U
2
down again, possible
inception and extinction voltages should be noted. Measurement of apparent charge
shall be taken at 1.1 U
m
/3.
- No values of apparent charge are assigned to the application of U
1
.
- During the whole of the second period at voltage of U
2
, the partial discharge level shall
be continuously observed and readings shall be recorded every 5 min.
The test is successful if
- no collapse of the test voltage occurs
- the continuous level of partial discharges does not exceed 500 pC during the long
duration test at U
2
.
- the partial discharge behaviour shows no continuously rising tendency at U
2
. Occasional
high bursts of non-sustained nature should be disregarded
- the continuous level of apparent charges does not exceed 100 pC at 1.1 U
m
/3.
A failure to meet the partial discharge acceptance criteria shall therefore not immediate
rejection, but lead to consultation between purchaser and supplier about further
investigations.

3.15 Short circuit withstand test
General
This test identifies the requirement for power transformer to sustain without damage the
effects of over current originated by external short-circuit. The test demonstrates the thermal
ability and dynamic effects of power transformer to withstand the rated short-circuit forces.
The detailed procedures describing the magnitude of current, test duration, no. of tests and
evaluation criteria shall be as per IEC 60076-5.

3.16 Measurement of zerophasesequence impedances on 3-phase transformers
Zerophasesequence impedance tests of threephase transformers

Page 41 of 65

The zerophasesequence impedance characteristics of threephase transformers depend
upon the winding connections, and in some cases, upon the core construction. Zerophase
sequence impedance tests apply only to transformers having one or more windings with a
physical neutral brought out for external connection. In all tests, one such winding shall be
excited at rated frequency between the neutral and the three line terminals connected
together. External connection of other windings shall be as described in succeeding
paragraphs for various transformer connections. Transformers with connections other than as
described in succeeding paragraphs shall be tested as determined by those responsible for
design and application.
The excitation voltage and current shall be established as follows:
If no delta connection is present on the transformer, the applied voltage should not exceed
30% of the rated linetoneutral voltage of the winding being energized, nor should the
phase current exceed its rated value. If a delta connection is present, the applied voltage
should be such that the rated phase current of any delta winding is not exceeded. The
percent excitation voltage at which the tests are made shall be shown on the test report. The
time duration of the test shall be such that the thermal limits of any of the transformer parts
are not exceeded.
Singlephase measurements of excitation voltage, total current, and power shall be similar to
those described in for load loss measurements. The zerosequence impedance in percent on
kVA base of excited winding for the test connection is:
( )
|
|
\
|
=
I
I
E
E
Z
r
r
. 300 %
Where
E = measured excitation voltage
E
r
= rated phasetoneutral voltage of excited winding
I = measured total input current flowing in the three parallelconnected phases
I
r
= rated current per phase of the excited winding
A zero-sequence test shall be made on the winding with the available neutral. A singlephase
voltage shall be applied between the three shorted line terminal and neutral. The external
terminals of all other windings may be opencircuited or shorted and grounded.

The zero-sequence impedance is dependent upon the physical disposition of the windings
and the magnetic parts and measurement of different windings may not therefore agree.

3.17 Measurement of acoustic sound level

Page 42 of 65

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.
Audible sound from transformer originates principally in the transformer core and is
transmitted, either through the dielectric fluid or the structural support, to other solid surfaces
from which it is radiated as airborne sound. The audible sound also contains the noise
emitted by any dielectric fluid mechanical cooling system.
Measurement should be made in an environment having an ambient sound pressure level at
least five decibels below the combined sound pressure level of the transformer and the
ambient sound pressure level.
The transformer shall be located so that no acoustically reflecting surface is within 3 m of the
measuring microphone, other than the floor or ground.
The transformer shall be connected and energised at rated voltage and rated frequency, and
shall be at no load with the tap changer on principal tap. Pumps and fans shall be operated
as appropriate for the rating being tested. Sound measurements shall begin after the
transformer being tested is energised and steady- state sound level conditions are
established. Measurements may be made immediately on the transformers that have been in
continuous operation.
The rated voltage shall be measured line-line for connected windings and line-neutral for Y
connected windings. The voltage shall be measured with a voltmeter responsive to the
average value of the voltage but scaled to read the rms value of a sinusoidal wave having the
same average value. The voltmeter should be connected between the terminals of the
energized windings.
The reference sound-producing surface is a vertical surface that follows the contour of a taut
string stretched around periphery of the transformer or integral enclosure (Fig 12). The
contour shall include radiators, coolers, tubes, switch compartments, and terminal chambers,
but exclude bushing and minor extensions.
The measurement shall be done with the microphone, which shall be calibrated as
recommended by the sound level meter manufacturer before and after measurement. The
first microphone locations shall coincide with the main drain valve. The number of
microphone position is not less than 4. The microphone shall be located on the measurement
surface spaced 0.3 m from the reference sound- producing surface. When fans are in
operation, the microphone shall be located 2 m from any portion of radiators and coolers. For
transformers having an overall tank or enclosure height of les than 2.4 m, measurements
shall be made at half height. For transformers having an overall tank height of 2.4 m or more,
measurements shall be made at one-third and at two-thirds height.
The sound power rating of the transformer is determined using the following five steps:
a) Measure ambient sound pressure level

Page 43 of 65

Microphone location for measuring audible sound from transformers
Reference sound
Fan cooled surface
TANK
Drain Plug
Box
producing source
surface
Measurement
Location
Microphone
2/3 Height
1/3 Height
Height
2 m
0.3 m
1 m
b) Measure combined ambient and transformer sound pressure levels
c) Compute ambient corrected sound pressure levels
d) Compute average sound pressure levels
e) Calculate sound power levels
The detailed calculation is done in accordance with the ANSI/IEEEC57.12.90-1993.
The average sound level of transformers should not exceed the values given in table 0-2
through 0-4 of NEMA TR1 when measured at the factory in accordance with the conditions
outlined in ANSI/IEEEC57.12.90-1993.

3.18 Measurement of the harmonics of the no-load current

The harmonics of the noload current in all the phases are measured by means of harmonic
analyzer and the magnitude of the harmonics is expressed as a percentage of the
fundamental component.

3.19 Measurement of power taken by the fans and oil pump motors
The measurement shall be done by suitable instruments at rated voltage.

3.20 Test with lightning impulse chopped on tail


Page 44 of 65

This test is a special test and should be used for special applications on the line terminals of
a winding. When this test is performed it shall be combined with the full lightning impulse test.
The peak value of the chopped impulse shall be 1.1 times the amplitude of the full impulse.
Usually the same settings of the impulse generator and measuring equipment are used, and
only the chopping gap instrument is added. The standard chopped lightning impulse shall
have a time to chopping between 2 s and 6 s.
The triggered type chopping gap should be used with adjustable timing, although a plain rod-
rod gap is allowed. The chopping circuit should be so arranged that the amount of over swing
to opposite polarity of the recorded impulse will be limited to not more than 30% of the
amplitude of the chopped impulse. For this purpose, it is permitted to put a resistance in
service with the chopping gap.

The test is combined with the full impulse test in a single sequence. The order of application
is :

one reduced level impulse
one full level impulse
one or more reduced level chopped impulse(s)
two full level chopped impulses
two full level impulses

The same type of measuring channels and oscillographic or digital records are specified as
for the full-wave impulse test.
The detection of faults during chopped impulse test depends essentially on a comparison of
the oscillographic or digital records of full level and reduced level chopped impulses. The
neutral current record presents a superposition of transient phenomena due to the front of the
original impulse and from the chopping. Account should therefore be taken of the possible
variations, of the chopping time delay.
The recordings of successive full impulse tests at full level constitute a supplementary
criterion of a fault, but they do not constitute in themselves a quality criterion for the chopped
impulse test.

3.21 Magnetic circuit (Isolation ) test

This test is done to detect the presence of inadvertent ground if exists.
This test is done with help of megger or by AC supply. During this test other terminals should
be in open circuit position. This test is done by applying the voltage alternate between the
core clamp to end frame, core clamp to tank and between end frame to tank. The value of
test voltage is varying according the customer requirement and electrical specification. The
duration of test voltage application is 60 seconds.
Alternatively the test is performed with the help of megger. In which the value of insulation
resistance is measured between two terminals. This test shall be conducted in accordance
with IS-2026 Part 1.

Page 45 of 65

The tests will be successful if the terminals withstand the required AC voltage for test
duration. The values of the insulation resistance in mega-ohm (M) should as follows;
Test voltage : 2 kV
New equipment : > 10 M
Service aged equipment : > 1 M
Insulation deterioration : < 1 M
Destructive circulating current : < 100 K

3.22 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.

The test specimen shall have the following requirements:
All windings immersed in insulating liquid.
All winding short-circuited.
All bushings are in place.
The applied voltage for measuring capacitance and tan delta shall not exceed half of the low
frequency test voltage, for any part of the winding or 10 kV whichever is lower.
This test may be performed with or without guard for the circuit combination as shown below.

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

Page 46 of 65

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

Temperature correction factors

The temperature correction factors for the insulation power factor depend upon the insulating
material, their structure, moisture, etc. Values of correction factor K listed in the below table
are typical and satisfactory for practical purpose for use as given in equation

Test temperature T,
0
C Correction Factor K
10 0.80
15 0.90
20 1.00
25 1.12
30 1.25
35 1.40
40 1.55
45 1.75
50 1.95
55 2.18
60 2.42
65 2.70
70 3.00

F
P20
= F
pt
/K

Where,
F
P20
is the power factor corrected to 20
0
C
F
pt
is the power factor measured at T
T is the test temperature
0
C
K is the correction factor


Page 47 of 65

Insulation temperature may be considered to be that of the average liquid temperature. When
insulation power factor is measured at a relatively high temperature and the corrected values
are unusually high, the transformer should be allowed to cool and the measurements should
be repeated at or near 20
0
C

3.23 Magnetic balance test on 3-phase transformers

This test is conducted only in three phase transformer to check the imbalance in the magnetic
circuit. In this test, no winding terminal should be grounded; otherwise results would be
erratic and confusing.

Evaluation criteria
The voltage induced in the center phase shall be 50 to 90% of the applied voltage on the
outer phases. However, when the center phase is excited then the voltage induced in the
outer phases shall be 30 to 70% of the applied voltage.

Zero voltage or very negligible voltage induced in the other two windings should be
investigated.

3.24 Determination of transient voltage transfer characteristics

When the low - voltage winding cannot be subjected to lightning over voltage from the low
voltage system, this winding may, by agreement between supplier and purchaser, be impulse
tested with surges transferred from high voltage winding.

This method is also used when the design is such that an impulse directly applied to the low
voltage winding could result in unrealistic stressing of higher voltage windings, particularly
when there is a large tapping winding physically adjacent to the low voltage winding.

With the transferred surge method, the tests on the low voltage winding are carried out by
applying the impulse to the adjacent high voltage winding. The line terminals of the low
voltage winding is connected to earth through resistance of such value that the amplitude of
the transferred impulse voltage between line terminals and earth, or between different line
terminal or across a phase winding, will be as high as possible but not exceeding the rated
impulse withstand voltage. The magnitude of the applied impulses shall not exceed the
impulse level of the winding to which the impulses are applied.

The details of the procedure shall be same as the test on line terminal of HV winding.

3.25 Dissolved Gas Analysis (DGA) of oil filled in the transformer


Page 48 of 65

Introduction

For many years the method of analyzing gasses dissolved in the oil 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.
Finally, DGA could be used to give scored in a strategic ranking of a transformer population.

In this respect the dissolve gas analysis (DGA) is regarded as a fairly mature technique and it
is employed by several transformer companies around the world either in own plant or in
cooperation with an affiliated or independent laboratory.

The idea with dissolve gas analysis is based on the fact that during its lifetime the transformer
generates decomposition gassesessential from the organic insulation under the influence
of various stresses both normal and abnormal.
The gasses that are of interest for the DGA analysis are the following;
H
2
Hydrogen
CH
4
Methane
C
2
H
4
ethylene
C
2
H
6
Ethane
C
2
H
2
acetylene
(C
3
H
6
propene ) not always measure
(C
3
H
8
propane ) not always measure
CO carbon monoxide
CO
2
carbon dioxide
O
2
oxygen
N
2
Nitrogen
TCG total combustible gas content (= H2 + CH4 + C2H4 + C2H6 + C2H2 + CO)

All these gases except oxygen and nitrogen may be formed during the degradation of the
insulation. The amount and the relative distribution of these depend on the type and severity
of the degradation and stress.

Around the world and during the years several different schemes have been proposed as
evaluation scheme for the DGA. The most commonly known schemes are the one proposed
by Rogers and the scheme laid down in IEC publication 60599

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.
Sampling, extraction and analysis.


Page 49 of 65

The oil samples should preferable be taken in the moving oil so that the gas generated
somewhere easily and rapidly is transported from the point of generation to the sampling
point. Suitable locations are valves in the cooler/radiator circuit. To take samples from these
locations is not always possible because of design limitations. Other places from which to
draw samples are the cover, bottom valve, the conservator and from the buchholz relay.

In addition, it is very important that the sampling is made in such a way that the
contamination of the sampling vessel is held at a minimum and that gas are not lost during
sampling or transpiration to the laboratory.

The removal of the gasses from the oil can be accomplished by various methods:
Partial degassing (singlecycle vacuum extraction)
Total degassing (multi cycle vacuum extraction)
Stripping by flushing the oil with another gas
By the headspace technique in which gases are equalized between a free gas
volume and the oil volume.

After extraction in the extracted gas mixture is fed into adsorption columns in a GC where the
different gases are absorbed to various degrees and reach the detector after different periods
of time. In this way the gas mixture is separated into individual chemical compounds,
identified and their concentration in volume gas STP/volume oils is calculated and expresses
in ppm (STP = standard temperature and pressure).
It should be emphasized that this extraction and analysis may involve analytical errors which
mean that it may be difficult to directly compare the results from two different laboratories.
One should not jump from one lab to another but try to stick to one well-reputed lab.

Interpretation

There are several different approaches how to explain and interpret the analyzed gas
composition and to diagnose the condition of the transformer. Essentially the following
methods are at had;
Identification of the key gas , The key gas identify a particular problem, e.g., H2
indicates a PD
Determination of rations between gasses, normally between gas levels.
Determination of rates of increase (production rates), in ppm / day or ml gas/day

Around the world and during the years several different schemes have been proposed as
evaluation schemes for the DGA. The most common known schemes are the one proposed
by Rogers forming the basis for the ANSI method and the scheme laid down in IEC
Publication 60599. Both these methods are using ratios gas concentrations.
In order to get a feeling for DGA the key-gas method is appropriate.

Overheating of cellulose
CO, CO
2


Page 50 of 65

Overheating of oil
increasing temperature
C
2
H
6
C
2
H
4
C
2
H
4

CH
4
CH
4
CH
4
C
2
H
2

Partial Discharges (PD)
increasing temperature
H
2
H
2

C
2
H
2

Discharges
C
2
H
2
H
2

Chrematistics key gases principal lay-out

One looks for the most prominent gas the one which differs most from a tacitly expected
normal level (or change). For instance, at overheating of cellulose the main decomposition
gases are CO and CO
2
. At a partial discharge of corona H
2
is formed. (PD in cellulose
involves the formation of carbon oxides). At a partial discharge of corona H
2
is formed. (Pd in
cellulose involves the formation of carbon oxides). At a more sever electric discharge such as
arching C
2
H
2
is formed. (Normally also H
2
is formed with smaller amounts of methane and
ethane. If CO is present cellulose is involved). Finally, at overheated oil it is the hydrocarbons
that are formed normally the saturated hydrocarbons such as C
2
H
6
at lower temperatures
and unsaturated such as C
2
H
4
at higher temperature. Acetylene points to very high
temperature.

This scheme can also be used to understand the evaluation scheme based on ratios.
For instance, the IEC method uses 3 ratios, C
2
H
2
/ C
2
H
4
, CH
4
/ H
2
, C
2
H
4
/ C
2
H
6

CH
4
/H
2
is used to discriminate between a thermal fault and an electric fault. C
2
H
2
/C
2
H
4

indicates the presence of a strong discharge of very severe electric problem and C
2
H
4
/ C
2
H
6

is an indication of the oil temperature.

3.26 Radio interference voltage (RIV) test, if applicable

The radio interference level to be permitted at the specified test voltage depends on many
factors, such as the importance and vulnerability of the radio communications which are to be
protected against interference and the distance of the receiver from the source of
interference. For all reasons, agreement between the manufacturer and purchaser may be
necessary to decide the followings:
The value of test voltage,
Details of the arrangement of the job
The level of radio interference to be accepted

This test is a type test and shall be made only in a special case when agreed by purchaser
and manufacturer.
The detailed test procedure should be in accordance with the IS 8263.

Page 51 of 65

3.27 Recurrent surge oscillographic (RSO) test

The insulation of a transformer must be proportioned to the surge voltages, which will appear
at the various points throughout the windings. The surge voltage distribution in the winding is
independent of the magnitude of the applied voltage and that the same results may be
obtained by applying a reduced surge voltage, of the order of a few hundred volts.
In order to obtain the maximum possible amount of information it is desirable to have
electrical contact with the maximum number of points on the winding. Hence this test is
generally performed at pre-stage of transformer manufacturing after completion of terminal
gear. High voltage impulse tests on a complete transformer are costly and take a great deal
of time
Furthermore, for high-voltage transformers the core and windings must be immersed in oil
and mounted in the tank. This condition does not facilitate the collection of data. This test is
conducted with a recurrent surge generator, which consists of a capacitor charged to a
suitable voltage and discharged by means of a thyratron into a circuit which is designed to
generate the required low-voltage surge of the standard wave shape. The charge and
discharge sequence is repeated fifty times per second. The output voltage from the recurrent
surge generator is applied to the terminal of the transformer being tested, in a similar manner
to that in which a high voltage impulse test would be conducted. The surge voltage appearing
at any point of the winding can be measured and displayed on the screen of the cathode-ray
oscilloscope. The time base is arranged so that it is synchronized with the recurrent
discharge of the capacitor. By this means it is possible to obtain a standing picture on the
screen of the applied voltage and of the voltage appearing at the points along the winding,
together with a time calibration wave.

3.28 Determination of core hot spot temperature

This test is done to check uniform distribution of flux on every point on the core & to
determine the core hot spot temperature.

This test is done by exciting the core with suitable voltage, which is the voltage per turn is
multiplied with the wound turn around the core.
The required voltage is applied to transformer and note down the reading of temperature at
the different point on the core using thermo vision camera or laser temperature scanner. The
reading of the temperature should not vary too much from point to point.
If the temperature is varying from one point to other then the flux is not distributed uniformly
around the core. Scan the point around the core where the highest temperature occurs. This
is the hot spot temperature of the core.

3.29 Frequency Response Analysis (FRA)

Frequency response analysis (FRA) test is conducted on transformers & reactors to
determine the frequency response of windings. The reference frequency responses obtained

Page 52 of 65

during laboratory testing serve as fingerprints to monitor the condition of the transformer or
reactor during service.

The frequency response of an electrical winding is obtained by application of sweep
frequency (sinusoidal). The winding will have a characteristic frequency response for the
applied signal at different frequencies. The response is uniquely determined by the winding
arrangement involved and any winding movement or other fault will modify the frequency
response due to changes in inductances and capacitances. The sweep frequency voltage is
applied through network analyzers. The frequency response of the winding is determined
between the frequency range of 10 Hz to 2 MHz.

The FRA test is performed on one winding of the electrical equipment at a time. The
transformer / reactor shall be electrically isolated from any other electrical connections or
systems, including earth connections during FRA test. The two end terminals of each winding
shall be made available for measuring the frequency response across the winding.

# For star connected winding, the response shall be measured across the terminal &
neutral.
# For delta connected winding, the response shall be measured across two line
terminals & in case of open-delta, across individual winding.
# For auto connected winding, the response of series & common windings shall be
measured separately.

For a transformer, it is normal practice to earth one end of every winding that is not being
tested, leave the other open end. Alternatively, all other windings may be left unconnected
from each other and from earth. In every case, the termination of each winding for each test
should be recorded.

The frequency response of the winding is determined by plotting the ratio of the output from
the winding to the input at atleast following frequency ranges.

* 10 Hz to 2 KHz
* 100 Hz to 20 KHz
* 1 KHz to 200 KHz
* 10 KHz to 2 MHz

Alternatively frequency ranges specified by the customer can be selected. The test is
normally conducted at maximum, mean and minimum taps, in case of windings having
tappings. While making measurements at mean tap, care should taken to move the tap from
higher voltage taps, for proper comparison of FRA results of different phases of same
transformer or different transformers.

The FRA results is analyzed for

Changes in response of the winding
Difference between the FRA records of different phases of the same transformer.

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FRA test is primarily a condition assessment test and can be used in conjunction with other
diagnostic tests for detailed analysis and interpretation of the transformer.

3.30 Measurement of magnetization current at low voltage

This test is performed at 415 V 3-phase(neutral un-grounded) for three phase transformer
and 230 V 1-phase for single phase transformer. This test is performed to locate defect in
magnetic core structure, shifting of windings, failures in turn insulation or problem in tap
changers.

The acceptance criteria for the results of exciting current measurement should be based on
the comparison with the previous site test results or factory test results. The general pattern
is two similar high readings on the outer phases and one lower reading on the center phase,
in case of three phase transformers. An agreement to within 25% of the measured exciting
current with the previous test is usually considered satisfactory. If the measured exciting
current value is 50% higher than the value measured during pre-commissioning checks, then
the winding needs further analysis.

3.31 Functional tests on auxiliary equipments
Acceptance test for Oil (OTI) and winding (WTI) temperature indicator

A. Routine test
1. OTI (Range 20-140 C)
i) Each completely assembled instrument shall be tested for accuracy over the
complete range i.e. at 40, 60, 80, 100 & 120 C by keeping the bulb in
the hot oil bath continuously stirred. The accuracy of indication shall be 1.5
% full scale deflection (FSD).

2. WTI ( Range 30 - 150 C)
i) Each completely assembled instrument shall be tested by injecting the
current to its heater coil. Oil bath shall be maintained at 60
0
C, Total
temperature and temperature rise shall be recorded for 0, 2, 3 and 4
amperes current. The accuracy of the indication i.e. oil bath temperature
measured by standard. Thermometer plus rise in temperature due to
injection of current in heating coil i.e. total temperature indicated by WTI
shall be within 1.5 % FSD. Error allowed shall be 1.5 / 100 x 150 = 2.25
0
C Max.
ii) In case of repeater, both WTI and repeater shall be tested together by
injecting the current as mentioned in 2(I). Accuracy of the repeater readings
shall be within 1.5 FSD i.e. 1.5
0
C considering WTI readings as the
reference temperature.

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High Voltage Test on Insulation test of auxiliary wiring

Unless otherwise specified the wiring for auxiliary power and control circuitry shall be
subjected to a one minute power frequency withstand test of 2 kV r.m.s. to earth. Motors and
other apparatus for auxiliary equipment shall fulfill insulation requirements according to the
relevant IEC standard (which are generally lower than the value specified for the wiring alone,
and which may sometimes make it necessary to disconnect them in order to test the circuits)

B Type tests (one instrument of each lot / batch)

Switch setting and operations: Switches shall be able to set between 50140
0
C and their
operation shall be within 2.5% of pointer indication unless otherwise specified on purchase
order. Switch setting will be done as below:
OTI: Alarm (S
1
) 95
0
C
Trip (S
2
) 100
0
C
WTI: Alarm (S
1
) 115
0
C
Trip (S
2
) 125
0
C
Fan start (S
3
) 85
0
C
Pump start (S
4
) 95
0
C
Switch differential
Each switch shall have adjustable differential (difference between make and break
temperature) of 6
0
C to 90
0
C and will be set for 6 1
0
c differential.
Switch Rating
5 Ampere, continuous 250 V, AC or DC for make or break.

3.32 Tests on oil filled in transformer

3.32.1 Dielectric strength

The voltage at which the oil breaks down when subjected to an AC electric field with
continuously increasing voltage contained in the specified apparatus is called dielectric
strength. The voltage is expressed in kV.

This test is performed to determine the dielectric breakdown voltage of service-aged oil. It is
important to measure the oils ability to withstand electrical stress without failure.

The dielectric strength of oil is determined by the two methods. First method utilizes spherical
capped electrode in the test cell, which is recommended primarily for filtered, degassed and
dehydrated oil prior to and during filling of electrical power equipment rated above 230 kV
and above. The second method utilizes flat electrodes and recommended for all other
apparatus.

The detailed test procedure is in accordance with IS 6792.

The acceptance value of oil for the different test voltage of transformer in general is
recommended as per the table given below.
System voltage of transformer
kV
Electric strength
kV

Page 55 of 65

Above Upto and including
- 72.5 60
72.5 145 65
145 245 65
245 420 70

High dielectric strengths do not indicate the absence of oil contaminants. There should not be
direct correlation between a certain breakdown voltage and failure, except in extreme cases.

3.32.2 Water content

There is always some moisture present in any practical transformer. In addition, since the
paper in the insulation system has a great affinity for water, most of the moisture present will
be in the paper. The dielectric strength of the paper is very sensitive to the presence of
moisture as is the oil, it is therefore important that the moisture content be known and its
concentration controlled. An estimate of the moisture content of the paper is determined by
measuring the moisture content of the oil.
Dissolved water may or may not affect the electrical properties of the oil. The solubility of
water in transformer oil increases with increasing temperature. Above a certain water content
level which is called saturation water content, all the water cannot remain in solution and free
water may be seen in the form of cloudiness or water droplets. Free water invariably results
in decreased dielectric strength and resistivity and increased dielectric dissipation factor.
The concentration of water-in-oil expressed in ppm. Concentration in ppm does not provide
sufficient information to obtain an adequate evaluation of the insulation system dryness.
Relative saturation provides a better evaluation under a wide range of operating condition
and temperatures.
The detailed test procedure, equipment and test condition for measurement of water content
is in accordance with the IS 13567.
In a transformer the total water content is distributed between the paper and the oil in a ratio
that is predominantly in the favor of paper. Small changes in the temperature significantly
modify the water content of the oil but only slightly that of paper.
Using the graphs as given in the IS 13567, it is possible to obtain at a given temperature the
water content of the paper from the measured water content of the oil assuming equilibrium
conditions. The limiting value of water content are given in table below

System voltage of transformer
kV
Above Upto and including
Water content
ppm, max.
- 72.5 20
72.5 145 20
145 245 15
245 420 15

High water content accelerates the chemical deterioration of the insulating paper and is
indicative of the undesirable operating conditions or maintenance requiring correction.

Page 56 of 65

3.32.3 Dielectric dissipation factor

This test covers the determination of the power factor of new and service aged oil. This test is
used to indicate the dielectric losses in the oil when used in an alternating electric field and of
the energy dissipated as heat. A low power factor indicates low dielectric losses. It is useful
as a means to ensure that sample integrity is maintained, and as an indication of changes in
quality resulting from contamination and deterioration in service or as a result of handling.
This test is satisfactorily performed in the field, as well as in a laboratory environment.
The detailed test procedure and test equipment may be in accordance with IS 6262.
Acceptable limit for the dielectric dissipation factor largely upon the type of apparatus and
application. The power factor limits given for oil are based upon the understanding that this is
an indicator test for contamination by excessive water or polar or ionic materials in the oil.
High level of dissipation factor (.0.5 % at 25 C) is because of contaminants may collect in the
areas of high electrical stress and concentrate in the winding. Very high dissipation factor ( >
1.0% ) in oil may be caused by the presence of free water which could be hazardous to the
operation of a transformer.

3.32.4 Resistivity

The resistivity ( specific resistance) in ohm-centimeters of a liquid is the ratio of the dc
potential gradient in volts per centimeter paralleling the current flow within the specimen, to
the current density in amperes per square centimeter at a given instant of time and under
prescribed conditions. This is numerically equal to the resistance between opposite faces of a
centimetre cube of liquid.

Resistivity measurements are made at many different temperatures. But for acceptance test,
it is generally done at a temperature of 90 C, while for routine testing, it is usually made at
room temperature or 90 C. The average electrical stress to which specimen is subjected to
shall not be less than 200 V/mm nor more than 1200 V/mm. the upper limit is set with the
purpose of avoiding possible ionization if higher stresses are permitted.
The detailed test procedure is as accordance with IS 6103.
Useful information can be obtained by measuring resistivity at both ambient and at higher
temperature such as 90 C. A satisfactory result at 90 C coupled with an unsatisfactory value
at lower temperature is an indication of the presence of water or degradation products
precipitated.

3.33 Oil pressure test on completely assembled transformer

This test is done after completion of all electrical and temperature rise test. Transformer
with cooling bank, bushing and other accessories shall be tested for any oil leakage at
high pressure (normal pressure plus 35 kN per Sq.m measured at the base of tank) and
at room temperature as specified by customer.
The procedure for conducting this test is as follows:

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1. Conservator along with the protective relay shall be disconnected.
2. Calibrated pressure gauge shall be mounted at the bottom of the tank.
3. Bushings will remain mounted however conservator along with buchholz relay
shall be isolated.
4. In welded cover type construction cooler bank, bushings shall be removed but all
turrets and cover pipe work shall remain.
5. Fill the oil completely and release all trapped air.
6. The specified pressure shall be maintained for the specified test duration as
specified in the test schedule or quality plan.
7. The test duration should be at least one hour unless otherwise specified.

Criteria for oil pressure test

During the pressure test, there shall not be any leakage. If there is pressure drop during
the test either because of some trapped air inside the transformer or due to ambient
temperature variation, the pressure shall be raised to the specified level. The unit will be
considered to pass the test only if there is no visual oil leakage. Pressure drop shall be
considered as failure of the unit in the test.

3.34 Jacking test and Dye-penetration test

This test is done to check out the mechanical capability of jacking pads on bottom tank
of transformer.
The procedure for conducting the above test is as follows:
1. Bring the transformer on to rail track
2. The transformer should be filled with oil.
3. Place jack under jacking pads such that the C.L. of the jack ram coincides with
the jack points on jacking pads at appropriate height.
4. connect the jacks to hydraulic pump unit
5. Raise pressure of oil slowly so that the transformer is lifted gradually.
6. Continue lifting till, the flanges of the rollers are above the R/L and its possible
to turn the wheel.
7. The transformer must be held in the raised condition for 15 minutes.
8. Lower the transformer gradually after the expiry of time period by releasing oil
pressure in stages till the wheel again rest on the rails.

The transformer jacking pads should withstand this test without any deformation or any
cracks.
The dye-penetration test is done simultaneously with jacking test to check out any
welding cracks in jacking pads. This is done by applying the dye paint to the welded
joints of jacking pads. If there is no leakage of dye at welding joints, then the welded
joint is perfect.


Page 58 of 65

3.35 Pressure relief device test

The pressure relief device shall be subjected to rising pressure (pneumatically). The
pressure at which the device operates shall be noted. The operating pressure should be
less than normal pressure plus 35 kN/m
2
.

B) FIELD TEST

INTRODUCTION

Transformer is important and vital equipment between generation station and the utility and
therefore necessary to ensure its proper performance through out its service life. During
transportation, installation and service operation, the transformer may be exposed to
conditions, which adversely affect its reliability and useful life.
Field-testing and condition monitoring are the techniques to ensure good operating health of
power transformers. Interpretations are also included to provide additional information on the
particular test and to provide guidance on acceptable criteria. There is not necessary any
direct relationship between field tests and factory tests.

Interpretation of measured results is usually based on a comparison with data obtained
previously on the same unit under similar condition. It should be noted that some times the
results of several types of tests should be interpreted together to diagnose a problem.
Manufactures acceptance criteria shall also be consulted.

B.1 Dew point measurement for large transformers filled with dry air or nitrogen filled

Large rating transformers are transported to site from manufacturing works, without oil and
filled with dry air or nitrogen due to weight limitations. Positive gas pressure is generally
maintained at 0.175 kg/m
2
during transportation and storage. As the insulation of transformer
is hygroscopic, it absorbs moisture from atmosphere if positive pressure of gas is not
maintained.

After arrival of transformer at site it is necessary to check the gas pressure and if it is not
positive there is every possibility that moisture must have gone inside the transformer during
transportation. To ascertain this factor and to check the dryness of the insulation, dew point
measurement is carried out at site.

Dew point is the temperature at which the water vapours present in the gas filled in the
transformer begin to condense.


Page 59 of 65

It will not be possible to define a limit of dew point of nitrogen gas as dew point depends on
the ambient temperature, pressure of the gas, moisture level of cellulose insulation etc.
The procedure and acceptance limits are given in section K of this manual.

ELECTRICAL TESTS

B.2 Winding resistance measurement

Transformer winding resistances are measured at site in order to check for abnormalities due
to loose connections, broken strands of conductor, high contact resistance in tap changers,
high voltage leads and bushings.

The resistance is measured by two methods
a) Voltmeter Ammeter method
b) Bridge method

The detailed test procedure of above methods is same as factory testing and is covered in
section A.3.1.2 of this manual. Precautions shall be taken during field testing as given below.
The test shall be conducted at all taps of the transformer winding and the measured value
shall be converted to 75
0
C.
The acceptance criterion is usually agreement to within 5% of resistance measurements
made separately on different phases, under field condition. But, for large transformers it is
recommended to compare the resistance values with original data measured in the factory
and in case of large variation, connection tightness to be checked.

The current used for these measurements should not exceed 15% of the rated current in
order to avoid heating the winding thereby changing its resistance. However, the current
should not be too small, which may not be sufficient to avoid inductive effect, due to core
magnetization
The winding resistance shall be preferably done when the difference in the top and bottom
temperature of the winding (temperature of oil in steady-state condition) is equal to or less
than 5C.

Winding resistance measurement shall be done only after measurement of magnetization
current (excitation current). The polarity of the core magnetization shall be kept constant
during all resistance measurement. A reversal in magnetization of the core can change the
time constant and result in erroneous readings.

B.3 Vector group and polarity

To determine the phase relationship and polarity of transformers

Page 60 of 65

2V 2W
1W
Dy-I
1V
2U
1U
1W
1V
N
1U+2U
2V
2W

The procedure to find out vector group shall be general be same as defined in section
A3.2.2.2.
a) Connect neutral point of star connected winding with earth
b) Join 1U of HV and 2U of LV
c) Apply 415V, 3 phase supply to HV terminals
d) Measure voltage across following terminals
1W-2V,1W-2W,1U-2W,1V-2V,1V-2W
Example 1 For HV-Delta/LV-Star Transformer
Connect 1U to 2U
1V-2W
VOLTAGE RELATION
1W-2V= 1W-2W
1W-2V< 1U-1W
1V-2V<1V-2W
1V-2V <1U-1W

Fig 1 : Connection for HV-Delta / LV-Star Transformer
Example 2 For HV-Star/LV-Delta Transformer
Connect 1U to 2U
1V-2W
VOLTAGE RELATION
1W-2W = 1V-2W
1W-2U > 1V-2U
1U-N=(1U-2W)+(2W-N)

Yd11
Fig 2: Connection diagram for HV-Star / LV-Delta Transformer


Page 61 of 65

The test shall be conducted with three phase supply and voltmeters.

By the measured voltage data it should ensure that the desired conditions of vector group
and polarity are fulfilled.

Ensure the isolation of transformer from high voltage and low voltage side with physical
inspection of open condition of the concerned isolators. In case tertiary is also connected,
ensure the isolation of the same prior to commencement of testing.

B.4 Voltage ratio Test

To determine the turns ratio of transformers during commissioning and periodic interval
decided by the customer for preventive maintenance

The procedure shall be following

a) Keep the terminals of IV and LV open.
b) Apply 3 phase or single phase supply according to the transformer type on HV terminals.
c) Measure the voltage ratio of HV and IV.
d) Repeat the steps for each tap position separately.

The test shall be conducted with three phase supply and voltmeters.

Results of the transformation turns/voltage ratio are absolute, and may be compared with the
specified values measured during factory testing. The acceptance criteria should be that the
measured values are within 0.5% of the specified values for all windings. One should also
consider the trend of voltage ratio values with reference to the ratio values measured during
the commissioning tests.

The voltage should be applied only in the high voltage winding in order to avoid unsafe
voltage.

B.5 Measurement of magnetizing current

This test is performed to locate defect in the magnetic core structure, shifting of windings,
failure in turn to turn insulation or problems in tap changers. These conditions change the
effective reluctance of the magnetic circuit thus affecting the current required to establish flux
in the core.

The procedure is as follows:

a) First of all keep the tap position in the lowest position and IV and LV terminals open.
b) Apply 3 phase 415V supply on HV

Page 62 of 65

c) Measure the voltage applied on each phase (Phase-Phase) on HV terminals and
current in each phase of HV terminal.
d) After completion of the above steps keep the tap positioning Normal position and
repeat the steps a to c.
e) After completion of the above steps keep the tap positioning Highest position and
repeat the steps a to c.
f) Keep the tap position in normal position and keep HV and LV terminals open.
g) Apply 3 phase 415V supply on IV
h) Measure the voltage applied on each phase (Phase-Phase) on IV terminals and
current in each phase of HV terminal.

The test shall be conducted with single phase or three phase supply according to test
requirement, voltmeter and multimeter.

The acceptance criteria for the results of exciting current measurement should be based on
the comparison with the previous site test results or factory test results. The general pattern
is two similar high readings on the outer phases and one lower reading on the center phase,
in case of three phase transformers. An agreement to within 25% 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 pre-commissioning checks,
then there is likelihood of a fault in the winding which needs further analysis.

Care should be taken during exciting current measurement to avoid the effect of residual
magnetism in the transformer core. The residual magnetism results in the measurement of
higher than normal exciting current.

B.6 Magnetic balance test on 3-phase transformer

This test is conducted only in three phase transformer to check the imbalance in the magnetic
circuit.

The procedure for conducting test is as follows

a) Keep the tap in nominal tap position
b) Disconnect the transformer neutral from ground
c) Apply single phase 230 V across one of the HV winding terminal and neutral then
measure voltage in other two HV terminals across neutral. Repeat the test for each of
the three phases.
d) Repeat the above test for IV winding also

The test shall be conducted with 230 V single phase supply and voltmeter


Page 63 of 65

The voltage induced in the center phase shall be 50 to 90% of the applied voltage. However,
when the center phase is excited then the voltage induced in the outer phases shall be 30 to
70% of the applied voltage.

Zero voltage or very negligible voltage induced in the other two windings should be
investigated.

Disconnect transformer neutral from ground and no winding terminal should be grounded,
otherwise results would be erratic and confusing.

B.7 Magnetic circuit (Isolation) test

This test should be performed prior to a unit being placed in-service or following modifications
to the transformer which could affect the integrity of its core insulation.

Refer clause 3.21 part A of this manual for test procedures and acceptance criterion.

B.8 Measurement of short circuit impedance at low voltage

To find out the short circuit impedance of transformer.

The measurement is performed in single phase mode. This test is performed for the
combination of two winding. The one of the winding is short circuited and voltage is applied to
other winding. The voltage and current reading are noted.

The test shall be conducted with variac of 0-280 V, 10 A, precision RMS voltmeter and
ammeter.

The acceptable criteria should be the measured impedance voltage having agreement to
within 3 percent of impedance specified in rating and diagram nameplate of the transformer.
Variation in impedance voltage of more than 3% should be considered significant and further
investigated.

The conductors used for short-circuiting one of the transformer windings should have low
impedance (less than 1m-ohm) and short length. The contacts should be clean and tight.

B.9 Insulation resistance measurement

Insulation resistance test 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.
The test is conducted with the help of Mega-ohmmeter. IR is proportional to the leakage
current through/over the insulation after capacitive charging and absorption currents become

Page 64 of 65

negligible on application of DC voltage. Insulation resistance shall be measured after the
intervals of 15 sec, 60 sec and 600 sec. The polarization index (PI) is defined as the ratio of
IR values measured at the intervals of 600 and 60 seconds respectively. Whereas, the
dielectric absorption is the ratio of IR values measured after 60 sec and 15 sec. IR is normally
measured at 5 kV DC or lower test voltage, but the test voltage should not exceed the rated
power-frequency test voltage of transformer windings.

Polarization Index (PI) is useful parameters for logistic interpretation of IR test results. This
ratio is independent of temperature and gives more reliable data for large power
transformers. A PI of more than 1.25 and dielectric absorption factor of more than 1.3 are
considered satisfactory for a transformer when the results of other low voltage tests are found
in order. PI of less than 1 calls for immediate corrective action. For bushings, an IR value of
above 10000 M-ohms is considered satisfactory.
The IR value of transformer is dependent on various factors such as configuration of winding
insulation structures, transformer oil, atmosphere condition etc. therefore, present trend is to
monitor oil characteristics for judging the condition of dryness of the transformer and not to
rely solely on absolute values of IR. It may be note that no national/international standards
specify minimum insulation resistance values of transformers. The value of IR could be even
zero under heavy fog or humid conditions.
During IR measurement, we must ensure following conditions.

- Transformer is disconnected from other associated equipment
- Bushings are cleaned and free of moisture
- Transformer tank and core are properly grounded
- Both ends of winding under test are short-circuited.

B.10 Measurement of capacitance and dissipation factor

The insulation dissipation factor (tan delta) is the ratio of the resistance current to the
capacitor current flowing through the insulation on application of sinusoidal voltage under
prescribed condition. The capacitance values are relatively independent of temperature and
prevailing atmospheric conditions. Normally low dissipation factor is indicative of problem in
insulation structure and predictive aging of insulation.

The voltage to be applied shall not exceed half of the power frequency test voltage or 10 kV
whichever is lower. Detailed test procedure is concerned under this manual earlier.

The test is conducted with high voltage supply and Schering bridge

Low dissipation factor is indicative of problem in insulation structure and predictive aging of
insulation. But, the comparative values of tests taken at periodic intervals are useful in
identifying potential problems rather than an absolute value of tan delta. The initial reference
can be drawn from the tan delta values measured during factory testing. However, the tan
delta values measured in the field are not very accurate and deviation up to 30% from the
values measured at the works should be accepted.


Page 65 of 65

The acceptance criterion to assess the probable condition of the insulation of the transformer
is no substantial variation in the measured values of tan delta (dissipation factor) at periodic
interval when compared with previous references. For bushings, the tan delta value shall not
exceed 0.7%.

The main capacitance of the bushing i.e., the capacitance between high voltage terminal and
test tap is not affected by the surrounding conditions and the accepted deviation from the
values measured at factory tests should be less than 10%. The capacitance between bushing
test tap and ground is largely influence by the stray capacitances to ground parts in the
transformer and hence large deviation in the measured value shall be accepted when
compared with the factory test value.

Environmental factors like variation in temperature, relative humidity, surrounding charged
objects etc. have great influence on measurement of dissipation factor. Care shall be taken to
control the above factors during measurements.

B.11 Dissolved gas analysis (DGA)

Dissolved gas analysis is a well-established condition-monitoring tool for power transformers.
The method is based on analyzing the types of gases dissolved in the transformer oil and
their production rates. The relative concentration of these gases depends upon the type and
severity (energy density) of fault.

The test procedure to conduct DGA test is accordance with the IS 9434.

The main gases formed as result of thermal and electrical faults in a transformer are
Hydrogen (H
2
), Methane (CH
4
), Ethane (C
2
H
6
), Ethylene (C
2
H
4
), Acetylene (C
2
H
2
), Carbon
Monoxide (CO) and Carbon dioxide (CO
2
). Whereas Acetylene is mainly associated with
arcing at very high temperature ranges, Ethylene is related with hot spots and medium
temperature ranges. Hydrogen is mainly result of cold gas plasma of corona discharges.
Carbon monoxide and carbon dioxide are the result of thermal decomposition of cellulose
material.
For proper interpretation of DGA results, it is essential to collect data at periodic intervals
during the service life of the transformer and the additional information regarding age of the
transformer, past history of failures, loading pattern, history of filtration etc.

B12. Tests on oil filled in transformer as per IS 1866

Refer clause 3.32 part A of this manual

CONDITION MONITORING

In addition to the well established low voltage routine tests, additional checks have been
developed in order to increase reliability of the transformer by condition monitoring. These
tools or checks conducted first time, determine the initial condition of the transformer at the
beginning of its service life.

Page 66 of 65

These initial references are considered as 'benchmark' or 'fingerprints' to demonstrate
subsequent changes in the dielectric, mechanical and thermal properties of the transformer,
which are indicative for reliability. These tools provide useful data for predictive life and
maintenance management of transformer, better known today as condition-based
management (CBM).

The detailed procedure and interpretation of the test results is concerned under different
chapter in this manual.

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