Testing Theory

The winding resistance measurement is a standard test performed every time a transformer is tested. Dynamic Resistance
Measurement is a fast-sampling record of the test current in time, while the OLTC changes position. Comparison with
fingerprint results, which were taken when the transformer OLTC was in good condition and to adjacent phases, allows
for an efficient analysis and if no previous test results are present than inter phases comparison is done. Defective selector
contacts could be detected by measuring static resistance in all OLTC positions. Switching problems of a diverter switch
could be detected by recording the dynamic resistance. It is recommended to measure starting from the first position to
final position, and then to compare the measurement results in the same positions. DRM is a new method that is not
widely known around the world. A big advantage of this method is that if there is a problem inside the OLTC, it can often
be identified externally, without opening the OLTC, removing oil from the tank, etc; thus, significantly reducing
maintenance and service costs. The vast variety of OLTC designs, operating methods, regulating winding configurations,
and contact types and materials make analysis very type specific
Detected problems are: burned/coked contacts, bouncing contacts, switchover selector problems, and diverter switch
opening of the circuit, and more.
OLTCs consist mostly of two parts: the diverter switch, which diverts the current during transition (tap change) and
minimizes arcing, and a tap selector that selects the taped winding connection. Switchover selectors or inverter switches
are included in some designs. Figure below shows a schematic of a typical diverter OLTC transition from tap to tap.

Test Results of 1BBT

NAME PLATE DATA
Transformer Type: Step-Down

Serial No: 54LYPT10530

Rated Output 13 MVA

No. of Phases: 3

Std. Spec.:

IEC

Service: Cont.

Position

High Voltage

12420 V

11500 V

11

10580 V

Low Voltage

Frequency 50 Hz

Vector Group : Dd0

H.V. Current

L.V. Current

Impedance Voltage

464.9
6900 V

502.0

8.2%

545.7

Type of Cooling ODAF

Windings

Yr. of Manuf. 2007

Tap-Changer by MR, Germany

2 windings

Manufacturer

Type: On-Load

LEEEC CHINA

Special ID: 1BBT

HV side

1 R (1 U)

1 Y (1 V)

1 B (1 W)

LV side

2 r (2 u)

2 y ( 2 v)

2 b (2 w)

Table 1: Measurements of HV winding

Tap Resistance Current Volts(V)

No
(m) (Amps)
1 84.00 m
20.8 A
1.75 V
2 82.19 m
21.0 A
1.73 V
3 80.43 m
21.3 A
1.71 V
4 78.72 m
21.5 A
1.69 V
5 76.87 m
21.8 A
1.67 V
6 75.20 m
22.0 A
1.65 V
7 73.47 m
22.3 A
1.63 V
8 71.72 m
22.5 A
1.61 V
9 69.84 m
22.8 A
1.59 V

1U-1W
Ripple Transition Resistance Current
Time(ms) (m)
(Amps)
83.97 m 20.7 A
19.40%
82.7 ms 82.13 m 21.0 A
20.10%
83.1 ms 80.35 m 21.3 A
20.30%
81.8 ms 78.65 m 21.5 A
20.80%
82.4 ms 76.81 m 21.8 A
21.30%
82.0 ms 75.15 m 22.0 A
22.10%
83.8 ms 73.41 m 22.2 A
23.10%
86.2 ms 71.66 m 22.5 A
23.70%
85.7 ms 69.78 m 22.8 A

1V-1U
Volts(V) Ripple
1.74 V
1.73 V
1.71 V
1.69 V
1.67 V
1.65 V
1.63 V
1.61 V
1.59 V

25.50%
26.10%
26.30%
26.60%
27.10%
28.00%
29.10%
29.10%

Transition Resistance
Time(ms) (m)
83.97 m
81.3 ms
82.18 m
83.6 ms
80.41 m
80.6 ms
78.7 m
80.8 ms
76.86 m
83.0 ms
75.19 m
84.5 ms
73.47 m
85.0 ms
71.71 m
86.1 ms
69.82 m

1W-1V
Current Volts(V) Ripple
(Amps)
20.8 A
1.74 V
21.0 A
1.72 V
19.20%
21.2 A
1.71 V
19.90%
21.5 A
1.69 V
20.40%
21.7 A
1.67 V
20.70%
22.0 A
1.65 V
21.40%
22.2 A
1.63 V
21.80%
22.5 A
1.61 V
22.90%
22.7 A
1.59 V
23.30%

Transition
Time(ms)
81.5 ms
80.2 ms
80.5 ms
80.2 ms
81.8 ms
83.0 ms
84.9 ms
82.1 ms

Table 2: Measurement of LV winding

Resistance Current
22.89 m 20.4 A

2U-2W
Volts(V)
Resistance
467mV
22.82 m

2V-2U
Current
20.6 A

Volts(V)
469 mV

Resistance
22.81 m

2W-2V
Current
20.1 A

Volts(V)
456 mV

Winding Resistance Graph

90
80
70
60
50

1U-1W
1V-1U

40

1W-1V
30
20
10
0
0

10

Percentage Ripple Chart

0.35
0.3
0.25
0.2

1U-1W
1V-1U

0.15

1W-1V
0.1
0.05
0
0

10

OLTC DYNAMIC RESISTANCE PLOT (Average Motor Current)

U Phase

OLTC DYNAMIC RESISTANCE PLOT (Instantaneous Motor Current)

U Phase

OLTC DYNAMIC RESISTANCE PLOT (Average Motor Current)

V Phase

OLTC DYNAMIC RESISTANCE PLOT (Instantaneous Motor Current)

V Phase

OLTC DYNAMIC RESISTANCE PLOT (Average Motor Current)

W Phase

OLTC DYNAMIC RESISTANCE PLOT (Instantaneous Motor Current)

W Phase

Tap no 4-5 measured again

Observation and Conclusion

When the transformer was handed over to us it was completely isolated from the system. The winding resistance graph of all three
phases shows typical decreasing trend for all three phases, as no factory or commissioning test results were provided to us therefore
these results will be taken as benchmark values and will be trended over time. However these results show characteristics of healthy
tap changer connections. No loose contacts or open circuit were found during testing. All three phases shows resistance within
acceptable range of 5%. It is pertinent to note that during tap changer operation no deformity in ripple wave form was seen. Motor
current was also measured at each tap change and shows no increase in current than normal.. For LV winding all three phases show
comparable results. A increase in motor current can be seen on w phase, this was tested few times to check if there was any
problem in tap changer but it was not seen again when repeated, this was due to switching on then motor current measuring CT
right before changing the tap and is of no concern. The tap changer has completed 43,000 operations and it is still in healthy
condition. Older tap changers tend to develop faults more quickly than new ones hence it should be tested after 10,000 operations or
one year. Tap changer oil DGA should be done every six months to check if there is any heating or arcing inside the transformer.

Test Results of 2BBT

NAME PLATE DATA

Transformer Type: Step-Down

Serial No: 54LYPT10670

Rated Output 13 MVA

No. of Phases: 3

Std. Spec.:

IEC

Service: Cont.

Position

High Voltage

12420 V

11500 V

11

10580 V

Low Voltage

Frequency 50 Hz

Vector Group : Dd0

H.V. Current

L.V. Current

Impedance Voltage

464.9
6900 V

502.0
545.7

Type of Cooling ODAF

Windings

Yr. of Manuf. 2007

Tap-Changer by MR, Germany

2 windings

Manufacturer

Type: On-Load

LEEEC CHINA

Special ID: 2BBT

HV side

1 R (1 U)

1 Y (1 V)

1 B (1 W)

LV side

2 r (2 u)

2 y ( 2 v)

2 b (2 w)

Table 3: Measurements of HV winding

1U-1W
Tap Resistance Current Volts(V) Ripple Transition Resistance Current
No
(m) (Amps)
Time(ms) (m)
(Amps)
1 82.07 m 1.72 V
1.72 V
82.54 m 21.0 A
2 80.35 m 1.71 V
1.71 V
17.30% 75.9 ms
80.77 m 21.3 A
3 78.59 m 1.69 V
1.69 V
18.10% 76.6 ms
79.01 m 21.5 A
4 76.91 m 1.67 V
1.67 V
18.40% 77.5 ms
77.34 m 21.7 A
5 75.09 m 1.65 V
1.65 V
18.70% 76.5 ms
75.52 m 22.0 A
6 73.46 m 1.64 V
1.64 V
19.10% 77.7 ms
73.89 m 22.2 A
7 71.76 m 1.62 V
1.62 V
19.60% 78.0 ms
72.17 m 22.4 A
8 70.03 m 1.59 V
1.59 V
20.20% 78.6 ms
70.44 m 22.7 A
9 68.14 m 1.57 V
1.57 V
20.60% 78.5 ms
68.54 m 23.0 A

1V-1U
Volts(V) Ripple
1.73 V
1.72 V
1.70 V
1.68 V
1.66 V
1.64 V
1.62 V
1.60 V
1.57 V

1W-1V
Transition Resistance Current Volts(V) Ripple
Time(ms) (m)
(Amps)
82.61 m 21.0 A
25.70% 77.4 ms
80.84 m 21.2 A
17.50% 17.50%
26.50% 77.7 ms
79.08 m 21.4 A
18.10% 18.10%
26.90% 79.2 ms
77.39 m 21.6 A
18.60% 18.60%
27.00% 78.5 ms
75.56 m 21.9 A
18.80% 18.80%
27.30% 78.8 ms
73.91 m 22.1 A
19.10% 19.10%
27.90% 79.3 ms
72.19 m 22.4 A
19.70% 19.70%
28.70% 83.5 ms
70.45 m 22.6 A
20.40% 20.40%
28.70% 79.6 ms
68.56 m 22.9 A
20.60% 20.60%

Transition
Time(ms)
75.1 ms
75.0 ms
77.0 ms
76.6 ms
76.9 ms
76.8 ms
78.3 ms
78.4 ms

Table 4: Measurements of LV winding

Resistance
22.10 m

2U-2W
Current
20.1 A

Volts(V)
444 mV

Resistance
22.03 m

2V-2U
Current
20.5 A

Volts(V)
452 mV

Resistance
22.00 m

2W-2V
Current
20.0 A

Volts(V)
440 mV

Winding Resistance Graph

90
80
70
60
50

1U-1W
1V-1U

40

1W-1V
30
20

10
0
0

10

Percentage Ripple Chart

0.35
0.3
0.25
0.2

1U-1W
1V-1U

0.15

1W-1V

0.1
0.05
0
0

10

OLTC DYNAMIC RESISTANCE PLOT (Average Motor Current)

U Phase

OLTC DYNAMIC RESISTANCE PLOT (Instantaneous Motor Current)

U Phase

OLTC DYNAMIC RESISTANCE PLOT (Average Motor Current)

V Phase

OLTC DYNAMIC RESISTANCE PLOT (Instantaneous Motor Current)

V Phase

OLTC DYNAMIC RESISTANCE PLOT (Average Motor Current)

W Phase

OLTC DYNAMIC RESISTANCE PLOT (Instantaneous Motor Current)

W Phase

Observation and Conclusion

When the transformer was handed over to us it was completely isolated from the system. The winding resistance graph of all three
phases shows typical decreasing trend for all three phases, as no factory or commissioning test results were provided to us therefore
these results will be taken as benchmark values and will be trended over time. However these results show characteristics of healthy
tap changer connections. No loose contacts or open circuit were found during testing. All three phases shows resistance within
acceptable range of 5%. It is pertinent to note that during tap changer operation no deformity in ripple wave form was seen. Motor
current was also measured at each tap change and shows no increase in current than normal. For LV winding all three phases show
comparable results. The tap changer has completed 50,000 operations and it is still in healthy condition. Older tap changers tend to
develop faults more quickly than new ones hence it should be tested after 10,000 operations or one year. Tap changer oil DGA should
be done every six months to check if there is any heating or arcing inside the transformer.

20340005041213

Prescon Confidential

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