Malewski PDF

Advanced Research Workshop
on Modern Transformers
28-30 October 2004, Vigo - Spain
Power Transformer
Acceptance Tests
. Ryszard Malewski, LFIEEE, FCAE
Prof. dr hab. in
Malewski Electric
Warszawa, Poland
malewski@ieee.org
ARWtr 2004
Modern Transformers
28 -30 October. Vigo Spain
http://webs.uvigo.es/arwtr04
ARWtr 2004 Lecture: POWER TRANSFORMER ACCEPTANCE TEST by Prof. Dr. Hab. Inz.Ryszard Malewski
Acceptance tests are described in the technical

specification prepared by the buyer. However, such
specification often refers to international or national
standards.
The American Standard is
often used in Europe and other
continents, either in parts or as
the basic standard
Prof. dr hab. inz.
ARWtr 2004
Modern Transformers
Ryszard Malewski
In principle, the dieletric tests consist in an application of a

higher than rated voltage for a relatively short period of time.
It is assumed that such test shall reveal dielectric faults that
may appear after a long time of service at the rated voltage.
In reality, a transformer failure in service may also be caused
by overheating, excessive mechanical stress, insulating
material contamination and aging, but all these factors result in
the insulation breakdown.
The acceptance tests should also provide reference data for
subsequent diagnostic procedures in service, since most of
such procedures hinge on a comparison to initial records taken
on a new transformer.
ARWtr 2004
Modern Transformers
The acceptance tests shall reveal flaws of

design and manufacturing
Prof. dr hab. inz. Ryszard Malewski Prof. dr hab. inz. Ryszard Malewski
Impulse test
Heat run test
Load and no-load
loss measurement
Induced voltage test

with partial discharge
(PD) measurement
These tests shall provide

initial reference data
for subsequent measurements
Dissolved gas in oil (DGA)
tg = (f) characteristic
Short-circuit impedance
Winding frequency response (FRA)
ARWtr 2004
Modern Transformers
Ryszard Malewski
Prof. dr hab. inz.
Impulse test
Checking the dielectric stress distribution in the winding
ARWtr 2004
Modern Transformers
Applied impulse
Standard impulse forms

have been defined to ensure reproducibility
of the impulse test carried out at different HV laboratories
Standard lightning impulse:

T1= 1.2s30% T2=50s 20%
T=T1/1.67
Chopped lightning impulse:

on the tail
on the front
Tc=2 to 6s
Tc=0.5s
Switching impulse:
T1=1.67*T>100s
Td>200s
Tz>500s (better 1000s) IEC
Tz>1000s IEEE
ARWtr 2004
Modern Transformers
ARWtr 2004
Modern Transformers
Impulse test of the regulation winding

IEC requires testing at two extereme
tapping positions of the regulation
winding, unless the regulation range is
less than 5%. Then the principal tap
only shall be tested
IEEE requires impulse application at the
tap position that corresponds to the
minimum number of turns.
Coarse and fine

regulation winding
connections
ARWtr 2004
Modern Transformers
Dangerous transient overvoltage may

be induced in this part of the
regulation winding that is not
connected at the end. An internal
surge protector is used to limit these
overvoltages by some designers
Impulse test set-up
Impulse
generator
Tested transformer
Voltage divider
is composed of the impulse generator, voltage divider, current

shunt, chopping gap, impulse recorder and an equipotential
ground plane
Impulse
recorder
Chopping gap
Current
shunt
Equipotential ground plane
ARWtr 2004
Modern Transformers
Acceptance criterion: no significant differences between the

impulse records taken at 100% and 50% test voltage level.
This means that the stressed winding insulation shall remain linear,
i.e. do not change with voltage up to the Basic Insulation Level (BIL)
s
MHz
ARWtr 2004
Modern Transformers
Superimposed and scaled

50% & 100% BIL impulses.
Magnified (8x) difference
between these impulses.
Superimposed and scaled
neutral terminal currents.
Magnified (8x) difference
between these currents.
Winding transfer function
derived from 50% and
100% BIL records.
The minor difference
observed between the
current records shows up
clearly as a winding fault
at the transfer function
graph
T(f) =
| I(f) |
| U(f) |
Analysis of the recorded HV impulse

and the neutral terminal current
A local insulation breakdown

disqualifies
transformer
under
test.
A partial discharge is acceptable
during the impulse test
ARWtr 2004
Modern Transformers
A breakdown in the winding (say

turn to turn) changes the local
inductance and capacitance of the
affected coil. This results in a
change of the resonant frequency of
this coil.
A partial discharge is a flow of
charge to ground that by passes the
current measuring shunt. On the
equivalent circuit it shows as a
inserted resistor that dissipates
energy. This resistor contributes to
damping of the local resonant pole
but does not affect its frequency
Digital impulse recorder and analyser

An analog signal is
converted
to
high
resolution (>12 bit) digital
record
sampled
at
Fs>100
MHz.
This
conversion results in the
quantization error that
shows up on the
frequency spectrum of
recorded impulses at the
higher frequency range.
The winding transfer
function is corrupted in
this range.
A low value of coherence function reveals the frequency

range where the transfer function is corrupted
ARWtr 2004
Modern Transformers
Digital impulse recorder and analyser
TF2
Coherence
TF1
ARWtr 2004
Modern Transformers
Superimposed
TF
transfer functions
derived from the full
100% and reduced
50% level impulse
tests,
and
their
coherence.
Transient Electromagnetic Interference

induced in the impulse measuring circuit
by firing the generator and by impulse chopping
A transient current Ignd is

induced in the ground
plane by a discharge of
the impulse genertor IG
capacitance to ground..
Moreover, the chopping
gap CG discharges stage
capacitors and injects a
heavy current pulse in the
ground plane. A transient
potential difference U
appears between the
grounding points of the
divider VD, shunt SH and
recorder DR.This imposes
an oscillatory interference
on the voltage and
current records.
ARWtr 2004
Modern Transformers
Equipotential ground plane of the impulse test bay

High frequency oscillatory current Ic induced in the coax. cable sheath results
in an interference Uc imposed on the impulse voltage and current records
Voltage
divider
Impulse
recorder
Expanded
copper mesh
used as the
ground plane
Measuring
coaxial
cable
Expanded
copper mesh
ARWtr 2004
Modern Transformers
Induced voltage test with Partial Discharge Measurement

This test verifies AC withstand of line terminal and winding insulation.
It is performed at the test voltage Ut higher than the rated voltage U,
and applied for a time period tt.
An absence of significant partial discharges (PD) recorded during this test
demonstrates that the transformer will operate for its technical life (of t 30
years). This assumption is based on probability P of the PD onset depending
on the applied test voltage Ut and the voltage application time tt.
U m t a
P(U, t) = 1
Ut t t
Weibull probability distribution of the uniform-field
oil-gap breakdown voltage, with the voltage
application-time as parameter. The distribution shape
coefficient m8 was determined experimentally for
uniform-field oil gaps of the spacing used in HV
transformer insulation
ARWtr 2004
Modern Transformers
The oil-gap breakdown probability was determined as a

function of the test voltage application time t. The slope
of this characteristic 1/n decreases for longer time t.
At the constant breakdown probability,

e.g. P(U,t)=const. the breakdown
voltage U will depend on the time t:
Where: a = 1
k
k
and k
m n U= a =
n

t
depends on
m
t
the oil-gap
Basis for determination of

the induced voltage value
60
ARWtr 2004
Modern Transformers
IEC and IEEE induced voltage test procedure

IEC
Um highest voltage
phase-to-phase for
three-phase, and phase
to ground for singlephase transformers
D=60min for Um>300kV,
or 30min for Um<300kV;
Transformers with Um<170 kV have to pass AC Short Duration test that requires
1.3Um/3 instead of 1.5Um/3, induced for 5min rather than for 60min. The short
duration (<60 s) voltage shall be close to 2Um, but no more than given in the Standard.
For higher voltage transformers (Group II) the IEEE requires 1.5Un to be induced first
for a time needed to measure PD, then a higher enhancement voltage of 1.7Un is
induced for 60 s (or less). Then 1.5Un is induced again for 60 min and PDs are
recorded. After that the test voltage is decreased and shut down.
ARWtr 2004
Modern Transformers
IEC and IEEE induced voltage test procedure

Induced voltage level and
duration specified by the IEC
for transformers of a different
rated voltage class.
Routine ACSD and ACLD
tests are indicated with and
without PD measurements.
The American standard

requirements are indicated
below.
ARWtr 2004
Modern Transformers
IEEE allows PD and RIV

measurements
using a
narrow-band
instrument,
whereas IEC prefers PD
broadband measurements.
Measurement of PDs during the induced voltage test

Partial discharges (PD)

develop in gas cavities
inside stressed transformer
insulation,
at
metallic
protrusions,
floating
potential screens, inside
cellulose with an excessive
water content ...
PDs are measured by an
impedance Zm attached to
the transformer bushing
tap. A PD detector displays
their onset-voltage Uo,
charge Q, phase of the
test voltage and polarity.
Test transformer and test voltage source shall be free

from PDs, and the HV laboratory shall be protected by
electromagnetic shield that attenuates external
interferences from radio station, and other sources.
ARWtr 2004
Modern Transformers
Electromagnetic shield of the HV laboratory enables

measurement of PD with a wide-band instrument
Shielded HV laboratory prevents
interference radiated by radio
stations and other sources from
inducing disturbing signals in
the PD measuring circuit
Shielding efficiency map plotted

on a HV laboratory floor plane
ARWtr 2004
Modern Transformers
Measurement of PDs with narrow and wide-band meter

Narrow-
fo=100kHz;band
f=10kHz
fo=250kHz; f=10kHz
fo=1.0MHz; f=5kHz
100pC calibration pulse was injected at each

Narrow and wide-band disc of transformer coil, and measured by
narrow, as well as wide-band instrument.
fo=100kHz; f=10kHz
The latter introduced a uniform attenuation of
fo=100kHz; f=50kHz
pulses coming from discs deep inside the
winding.
The narrow-band instrument introduced an
Wide-band
irregular attenuation, and pulses coming from
discs deep in the winding were completely
eliminated when fo has reached 1MHz.
ARWtr 2004
Modern Transformers
Instrument for simultaneous measurement of PDs and RIV

Radio Influence Voltage (RIV) meter has a low (50) input impedance and a narrow
band, whereas PD detector needs a high (2.5k) input impedance and frequency
bandwidth from ~20 to 300 kHz. Some US Customers insist on RIV measurements,
and a special instrument was developed to measure simultaneously PDs and RIV.
PD
monitor
ARWtr 2004
Modern Transformers
Comparative measurement of PDs and RIV

PDs (in pC) and RIV (in V) have been simultaneously measured on a few hundred
large power transformers. A ratio of pC to V was calculated for these transformers
and plotted on PD against RIV graph.
It was concluded that a lower reading V was This is caused by a higher input
obtained for the same pC, on large transformers capacitance of large transformers
that was not accounted for by the
voltage signal (100 V ) calibration
according to NEMA 107 Standard.
500
The charge pulse calibration (100

pC) was independent of the
transformer
capacitance,
and
reflected the actual charge of PDs
inside the windings insulation.
Apparently the National Electrical
Manufacturers Association Standard
107 makes the RIV test easier to pass
for large and expensive transformers
ARWtr 2004
Modern Transformers
Digital PD measuring instrument

Digital instruments can record each PD pulse, and store its charge, phase of
appearance (point-on-the-wave) and polarity. The PDs recorded during a fixed time
period (i.e. 10 s) can be plotted on three-dimensional graph. Then a specific pattern
reveals the origin of PDs.
A characteristic form of their distribution indicates whether they come from a metallic
protrusion, gas cavity inside paper wrap or transformer-board layers, excessive
amount of moisture in the cellulose insulation or a floating potential screen.
ARWtr 2004
Modern Transformers
Computer-assisted PD analysis
Distributions of identified origin PDs has been stored in memory and can be
compared to the test records. Probability of finding the same PD origin is evaluated.
A computer-assisted interpretation of PD measurements indicates possible source of
PDs and assists the test personnel in their diagnose of the problem.
PD ORIGIN PROBABILITY %
ARWtr 2004
Modern Transformers
Acoustic location of PDs inside the tank

and UHF detection of PDs in transformers in service
Acoustic detectors
attached to the tank
wall by magnets
reveal the time of
arrival of the sonic
wave emitted by PD
Simultaneous arrival
of sonic signals from
a
few
sensors
indicates that they
The PS source can be located by are equidistant to the
triangulation between to position PD source.
of acoustic sensors. To locate the
PD source the test voltage shall
be controlled in such a way to
find the PD source onset voltage
110 kV transformer with three UHF sensors
installed inside the tank near HV bushings
ARWtr 2004
Modern Transformers
UHF signals
Measurement of transformer load loss

The transformer buyer penalizes the
manufacturer for the loss that exceeds the
guaranteed value, and the penalty for each
kW of cumulative loss ranges between
$3,000.- and $6,000.Measuring uncertainty of transformer loss
is directly related to the loss of
manufacturer revenue. However, a precise
measurement of the load loss is difficult
since large transformers with shortcircuited winding represent almost purely
reactive impedance.
This impedance power factor cos equals
approximately to the ratio of active loss
power P and reactive power S drawn by
transformer, and may be as low as 1%.
ARWtr 2004
Modern Transformers
Accuracy of the loss measuring system

The load loss measuring uncertainty is dominated
by the angular uncertainty of the voltage and
current transducers, as well as of the wattmeter:
= U + I +
2
and
P
tg
Assuming the short-circuited transformer powerfactor cos=0.01, 1.560796 Rad, and tg

1
99.995.
Then P / tg 100 Rad 0.343 min
It is rather difficult to achieve so small angular uncertainty in a loss measuring circuit
composed of magnetic voltage and current transformers, and an electro-dynamic
wattmeter.
To comply to the requirement of the overall angular uncertainty smaller than 100 Rad
the compressed-gas capacitor with an active low-voltage part, and zero-flux current
transformer are employed to reduce the measured high-voltage and heavy-current to
the wattmeter input level, and a time-division-multiplier wattmeter is used.
ARWtr 2004
Modern Transformers
Loss measuring system of high accuracy

Three-phase loss measuring system

contains a zero-flux current transformer
with the angular uncertainty reduced by
power-amplifier feeding the secondary
winding. Voltage divider is composed of a
virtually loss-less standard HV capacitor,
and of the low-voltage capacitor with a solid
dielectric. Its loss factor is compensated by
a tuned phase-shifting network in order to
reduce the divider angular uncertainty.
ARWtr 2004
Modern Transformers
Measurement of transformer no-load loss

107%
100%
Sub-harmonic
resonance
A large capacitor bank is needed to supply the

current pulses, and to maintain the sine voltage
waveform.
ARWtr 2004
Modern Transformers
Idle transformer supplied with power

frequency voltage above the rated level is
driven to saturation, and the magnetizing
current shows conspicuous pulses around
voltage zero-crossings. The regulated test
voltage source of HV laboratory cannot
deliver such current pulses and the voltage
waveform is distorted. This does not reflect
conditions prevailing in real power system
Harmonic components of the transformer no-load loss
Ideally, the test voltage

waveform should contain
the fundamental harmonic
only.
However, with a relatively
weak, regulated voltage
source,
a
complete
compensation of the nonlinear load by the
capacitor bank was not
possible.
A harmonic analysis
reveals a small difference
between
the
power
frequency loss and the
total measured loss.
ARWtr 2004
Modern Transformers
Reference data
for subsequent diagnostic procedures in service
HV winding
Hydrogen
Methane
Ethane
Ethylene
Acethylene
Autotransformer 160 MVA, 230/115kV,
Common open (Bp-N) and shorted (Ap-N, Cp-N)
Dissolved Gas in Oil

(DGA)
ARWtr 2004
Modern Transformers
Winding frequency response

(FRA)
Transformer leakage impedance

Winding
arrangement
HV2
HV 1
Test
circuit
HV-LV
HV-LV
Phase
Leakage
Impedance,
Ohm
Name
Inplate service
35.3
35.39
Np S
%
0.25
35.08
35.39
0.62
0.25
36.23
2.63
35.08
35.33
0.62
0.08
35.3
LV
In service measurements of leakage impedance reveal a
change with respect to the original measurements and that
indicates a winding displacement
ARWtr 2004
Modern Transformers
Dielectric polarization methods

to assess the transformer insulation condition
Moisture
content in cellulose
3%
Vr(V)
Zawarto wody %
4%
2%
100
1%
0.5%
10
Temperatura=38C
0.2
tg = (f) dielectric loss-factor

frequency characteristc
ARWtr 2004
Modern Transformers
20
200
T(s)
Recovery voltage characteristic

(RVM)
ARWtr 2004
Modern Transformers

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Advanced Research Workshop

28 -30 October. Vigo Spain

Acceptance tests are described in the technical

Prof. dr hab. inz.

28 -30 October. Vigo Spain

In principle, the dieletric tests consist in an application of a

28 -30 October. Vigo Spain

The acceptance tests shall reveal flaws of

Induced voltage test

These tests shall provide

28 -30 October. Vigo Spain

Checking the dielectric stress distribution in the winding

28 -30 October. Vigo Spain

Standard impulse forms

Standard lightning impulse:

Chopped lightning impulse:

28 -30 October. Vigo Spain

28 -30 October. Vigo Spain

Impulse test of the regulation winding

Coarse and fine

Dangerous transient overvoltage may

Impulse test set-up

is composed of the impulse generator, voltage divider, current

28 -30 October. Vigo Spain

Acceptance criterion: no significant differences between the

28 -30 October. Vigo Spain

Superimposed and scaled

Analysis of the recorded HV impulse

A local insulation breakdown

A breakdown in the winding (say

28 -30 October. Vigo Spain

Digital impulse recorder and analyser

A low value of coherence function reveals the frequency

28 -30 October. Vigo Spain

Digital impulse recorder and analyser

28 -30 October. Vigo Spain

Transient Electromagnetic Interference

A transient current Ignd is

28 -30 October. Vigo Spain

Equipotential ground plane of the impulse test bay

28 -30 October. Vigo Spain

Induced voltage test with Partial Discharge Measurement

28 -30 October. Vigo Spain

The oil-gap breakdown probability was determined as a

At the constant breakdown probability,

Basis for determination of

28 -30 October. Vigo Spain

IEC and IEEE induced voltage test procedure

28 -30 October. Vigo Spain

IEC and IEEE induced voltage test procedure

The American standard

28 -30 October. Vigo Spain

IEEE allows PD and RIV

Measurement of PDs during the induced voltage test

Partial discharges (PD)

Test transformer and test voltage source shall be free

28 -30 October. Vigo Spain

Electromagnetic shield of the HV laboratory enables

Shielding efficiency map plotted

28 -30 October. Vigo Spain

Measurement of PDs with narrow and wide-band meter

100pC calibration pulse was injected at each