Salient Points for the Inspection of any Transformer (Range b/w 6.

3 - 40kVA)

Firstly, check the full quantity of the offered lot.

Take the S.No. list of the offered transformers.
Choose random transformers from the lot as samples for performing the tests as per the
DISCOM specification.
Note: - No load & load test should be performed on 100% quantity of the allotted
transformers.
No Load Loss Test:
1. Applied 250 V on LT side at 50 Hz frequency.
2. Make HT side opened.
3. As these losses are Iron Losses, therefore independent to temperature.
4. Note down the values of current (i) & power (w) from the 3 phase power analyzer.
5. The values of:
Current: Is Varies;
Always equal or below to 2% of the full rated current value plus 30%
tolerance of that 2% Value. i.e. 13.33A for 10kVA T/F’s, this value is
0.2666+0.08=0.34A (for 100% voltage)
Always equal or below to 4% of the full rated current value. i.e. 13.33A for
10kVA T/F’s this value is 0.5332 (for 112.5% =281.5 voltage)
Voltage : Is Fixed (At 250 V)
Power : Is Varies In Watts (Within the limit as per the GTP)
Frequency : May Varies In Hz (Within the limit as per the Specification (+/- 3%))

6. The value of current is not exceeded to 30% of 2% of the full rated current value (for
100% voltage) & for 112.5% voltage, this current value is not exceeded to 4% of the full
rated current value. For the value of power, it is lies in b/w its rated limit (as per the
GTP).
These all values of losses in GTP are at 75°C. So for the conversion of values of power at
75°C there is a conversion factor used, which is as follows:
For Aluminum Wound T/F’s = (225 + 75)
(225 + T)

For Copper Wound T/F’s = (235 + 75)

(235 + T)
Here, T= Atmospheric Temperature.

Load Loss Test:

1. Apply rated current on HT side at 50 Hz frequency.
2. Make LT side shorted by a metal strip or a thick copper wire.

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 3. Note down the values of voltage (v; Called Impedance Voltage) & power (w) from
the 3 phase power analyzer.
4. Values of:
Current : Is Fixed (50% Test is Applicable only for BEE Rated X’mer)
(For 50% load test, its value is 50% the rated ct value. i.e. For 10 kVA it is
0.26A)
(For 100% load test, its value is 100% the rated ct value. i.e. For 10 kVA it is
0.52A)
Voltage : Is Varies (Called Impedance Voltage) (Within the limit as per the
Specification)
Power : Is Varies (Within the limit as per the GTP)

DVDF or Induced over Voltage test:

1) DVDF test should be performed only on all the sampled transformers.
2) Apply 866 V on LT side at 100 Hz frequency.
3) Make HT side open.
This test should be performing for the seconds, calculated with the method mentioned
below:
Calculation for Second’s= 120 x Rated Freq. ; But it must not less that 15 sec’s.
Modified Freq.

Here, Rated Freq. =50 Hz; & Modified Freq. = 100/125 Hz.
If any transformer fails to withstand these values before the rated time, there is a
sudden decrease in the voltage & increase in the leakage current value. That means its
lamination of wire or Insulation b/w windings or layers of windings is not proper.

Separate source voltage test:

In this we had perform two tests:

(A) High Voltage Test (For HT Side):

1) High Voltage test should be performed on all the sampled transformers.
2) Apply 28 kV, 50 Hz supply on HT side.
3) Make LT side shorted & earthed.
This test should be performing for 1 minute withstand.
If any transformer is fails to withstand these values before 1 minute, there is a
fluctuation/no increment happens in the applied voltage & sudden increase in the leakage
current value. If this condition happens that means, the HT coil or any internal part of the
assembly in the T/F tank is not at proper spacing with the internal T/F body.

(B) Low Voltage test (For LT Side):

1) Low Voltage test should be performed on all the sampled transformers.

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 2) Apply 3 kV, 50 Hz on LT side.
3) Make HT side shorted & earthed.
This test should be performed for 1 minute withstand.
If any transformer is fails to withstand these values before 1 minute, there is a
fluctuation/no increment happens in the applied voltage & sudden increase in the leakage
current value. If this condition happens that means, the LT coil in the T/F limb found have
some damage insulation with the base channels or a tear in the insulation b/w base channel
to foot plate channel.

Winding Resistance Test:

1) Winding Resistance test should be performed on all the sampled transformers.
2) In this test we have to check the winding resistance of both the HT & LT winding.
3) The value of both the windings is always lies within its specified value. (As mentioned
in the GTP).
In this we measure the values in b/w each Phase to Phase in HT side (i.e. R-Y, Y-B &
B-R) by Wheat Stone’s Bridge instrument & in LT side we had measured the values in b/w
each Neutral to Phase (i.e. N-R, N-Y & N-B) by Micro Ohm Meter or Kelvin’s Double Bridge
measuring instrument.

Insulation Resistance Test:

Insulation Resistance test should be performed on all the sampled transformers.
In this test we had measure the values in between:
1) HT phase - LT phase
2) HT phase - T/F body (Earth) &
3) LT phase - T/F body (Earth) by Megger.
These all values are temperature dependent & be found as per the observation
mentioned below:

Temperature
B/W 20°C 30°C 40°C 50°C 60°C

HV-LV (11000-433 V) 1600 MΩ 800 MΩ 400 MΩ 200 MΩ 100 MΩ

HV-E (11000 V) 800 MΩ 400 MΩ 200 MΩ 100 MΩ 50 MΩ

LV-E (433 V) 400 MΩ 200 MΩ 100 MΩ 50 MΩ 25 MΩ

These all values are in Mega Ohm (MΩ).

Turn Ratio Test (Voltage Ratio):

1) Turn Ratio test should be performed on all the sampled transformers.

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 2) Measure the turn ratio for the HT to LT winding.
3) By this, we had checked that whether the HT winding to LT winding voltage ratio is
proper or not.
4) This test should be measured by a Ratio Meter.
5) The value of this turn ratio is always lies in b/w 43.78 to 44.22 (Ratio Value: 44 +/-
0.5% tolerance).[(11000/250)=44]

Vector Group Test:

1) This test should be performed only on 1 no. of transformer from each lot.
2) In this, we had applied a voltage equal to 400 V on HT side (i.e. 1U-1V, 1V-1W
and 1W-1U) & it is measured by a Multimeter.
3) By this, we had observe that, whether the voltage is distributed in the winding
as per the design or not. If the voltage is distributed as per the standard, than
it is prove that the winding is in at proper design.
4) Hence also proved, Dyn-11 Configuration.

Terminal Design for the T/F’s:

HT Side = 1W 1V 1U
LT Side = 2w 2v 2u 2n
Some calculations done for this test:
1) 1U – 1V = 1V – 1W = 1W – 1U = 400 Volts
2) 1V – 2v = 1V – 2w = 1W – 2w & 1W – 2v > 1W – 2w

Magnetic Balance Test:

1) This test should be performed only on 1 no. of transformer from each lot.
2) In this test we had applied a voltage equal to 250 V on the centre terminal at
LT side. (i.e. 2n – 2v of LT side).
3) Make HT side open.
4) Then measure the values in b/w the terminal (2n – 2u) & (2n – 2w).
5) Resultant values, (2n – 2u) + (2n – 2w) ≈ (2n – 2v).
6) Tolerance: +/- 2% of the applied voltage (middle full & side half).

Physical Verification Test:

1) This test should be performed only on 1 no. of transformer from each lot.
2) At first select any transformer (either from sample or non-samples) from the
lot for the physical verification.

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 3) Measure all the external dimensions before open the top cover of the T/F.
4) Open the top cover completely.
5) Than measure all the internal dimensions (l*w*h) & weights of the coil wire,
coil winding, core, T/F tank, Oil & etc. as per the GTP values.
Note: No negative tolerance should be considered in dimensions & weight of T/F.

Flux Density Test:

1) This test is performed on the transformer after opening for the physical
verification.
2) Count down all the steps of the core.
3) Collect all the steps of core from any one limb for the area measurement.
4) Take the measurement of width & thickness of each core step individually.
5) Note that the wider step of core had a large area & width covered with
respect to all the other steps.
6) Now for the measurement of Flux Density of core, we have to put all the
values in a particular formula. Which is as follows:

Ф= (Applied Vg. X 106 )

(4.44 X Applied Freq. X No. of turns in LT X 0.97 X Area of Core)
Here,
Applied Vg. = 250 V; Applied Freq. = 50 Hz.
7) The measured value of Flux Density of core has to be always less than or equal
to 1.6 Tesla.

Oil Break Down Voltage Test:

1). This Oil BDV test is performing on the fresh sample oil taken from any of the
allotted T/F or from the physical verification T/F.
2). Before starting this test, check proper spacing b/w the arcing terminals by a
metal strip of 2.5mm & then clean the oil flask with the fresh T/F oil.
3). Now take 6 reading for the Oil BDV Test.
4). Before starting, give a start interval of 4 mins. for the first reading.
5). After that, take another 5 readings with an interval of 1 mins in each.
6). The average of all the readings must be above 50 kV.
7). If the avg. reading is not satisfying that value, the oil should be considered as
of poor breakdown value.

Temperature Rise Test:

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 1). This test should be done on 1 nos. of T/F taken from the samples which had
found maximum total losses in the loss test.
2). Selected T/F should be surrounded with any other three oil filled T/F’s or
bottles for the ambient temperature reference.
3). Take four thermometers & put these it in the T/F thermometer pocket or in
bottles.
4). Main T/F should be marked by T & others by T1, T2 & T3 resp.
5). Now take the winding resistances of both the HT & LT winding & note down
the ambient tempr of the main T/F before start the Tempr Rise test. These
readings should be considered as cold winding resistance values & cold
winding temperature respectively.
6). Now apply full load losses at the main T/F (T) calculated at 100⁰C as
mentioned in GTP & note down the values of V, I, W, T, T1, T2 & T3 at every 1
Hr by 3-phase watt-meter method.
7). Top oil temperature rise which is {T-(T1+T2+T3)/3} should be observed, which
must be stable in 10 – 12 Hrs & must be less than 35°C.
8). Now put down the main T/F at rated current & note down the value of V, I, W,
T, T1, T2 & T3.
9). After 1 hr, shut down the main T/F & take these readings again.
10). Now measure the winding resistance of that phase of HT & LT side which had
showed the lower value at the time of Cold Measurement without any
interval.
11). Take 4 – 5 readings from both the side (1 LT & 1 HT) at their corresponding
decreasing points.
12). Decrease the value of LT Resistance by 0.4 mili-ohms & 0.2 ohm of HT
Resistance.
13). These both the readings of HVR & LVR should be taken in within 10 minutes
from time after taking shutdown.
14). Now plot the graph from these both the values of HT & LT on a graph paper
with respect to Time (X-Axis) & Resistance (Y-Axis).
15). Extend the curve from top such that it can cut on Y-axis at t=0. These values of
resistance of HV & LV winding are called as Hot Winding Resistance by Graph
& temperature is called as Ambient Hot Winding Temperature.
16). The difference in temperature of main T/F and in the ambient T/F’s before put
at rated current is called Rise in Oil Temperature. This value should be maxm
35OC.

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 17). The difference in temperature of main T/F (T’), & it’s at shut down (T’’)
multiply by 0.8 will be the degree correction factor. *i.e. (T’- T’’) X 0.8 = T’’’+
which is further add in the winding resistances for the final rise of windings.
18). Final value of winding can be given by the formula:

[{(Hot Wndng Resist.) X [(235 + Cold Wndng Temp.)} - (235 + Hot Wndng Temp.)] + Correction
Fact.
(Cold Wndng Resist.) 1

18). The value of rise in winding resistance should be maxm 40OC.

Oil Leakage Test:

1) This test should be performing on 10% of the offered lot. Maybe it ought to be
Samples or Non Samples.
2) Apply a pressure of 0.8 kg/cm2 for 10 Minutes on the T/F withstand.
3) Observe it; whether it leaks from any tighten part of the T/F tank body or from
any of the welding joints.
4) And note it down, if any observation occurs.
Peel Off Test:
1) This test should be done for the painting quality done on Transformers.
2) Select any T/f for the peel off test. Make cuts on top part of the body of T/f
with the help of cutter at a proper space of 1cm2 (Horizontally &
Vertically(30°))
3) Now put a cello-tape paste over the surface of body tightly & remove it fast,
as you can.
4) Observe the surface, whether paint is tear or not, If not, then it passes the
Peel Off-Test.

- Report Prepared by Er. Amit Mittal

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