PRE-COMMISSIONING TESTS OF A TRANSFORMER

CONDUCTED IN
APTRANSCO

By
D.SHALINI (08W91A0245)
N.AMALASRI (08W91A0202)
T.AVINASH (08W91A0206)
DEPARTMENT OF EEE

MALLAREDDY INSTITUTE OF ENGINEERING AND TECHNOLOGY

UNDER THE GUIDANCE OF SRI.Y.RAMA MOHAN, ASSISTANT DIVISIONAL
ENGINEER/
MRT/TL&SS/ METRO CIRCLE, HYDERABAD
DURING 2011-2012 FROM

TO

ACKNOWLEDGMENT

Through this acknowledgment, we express our sincere gratitude to all those people who have
been associated with this assignment and helped us and made it worth wile experience. Firstly
we extend our thanks to various people who have shared their opinion and experience through
which we received the required information crucial for our report. Finally we express our sincere
thanks to Sri.Y.Rama Mohan, Assistant Divisional Engineer/MRT and Sri G.Naga Potha
Rao.Assistant Engineer/MRT who constantly guided us through this project sparing their
valuable time in spite of their busy schedule and gave us the opportunity to learn the subject in
practical approach and also we thank Sri.G.Sivaiah, Divisionl Engineer/MRT/TL&SS, Metro
Circle, APTRANSCO, Hyd, who gave us valuable suggestions in completing this project report.

ABSTRACT
A transformer is a static device consisting of a winding, or two or more coupled
windings, with, for inducing mutual coupling between circuits. Transformers are exclusively
used in electric power systems to transfer power by electromagnetic induction between circuits
of different voltage levels, at the same frequency. There are numerous types of transformers used
in various applications including audio, radio, instrument, and power. Now we deal exclusively
with power transformer involving the protection and the pre commissioning tests conducted on
power transformers.
The Pre Commissioning Tests were essential to the start up of any electrical system for
the first time, regardless of its size, type or industry.
An electrical installation work is complete only when the prescribed pre-commission
tests are conducted on different components and the test results are found satisfactory. By
carrying out the pre-commission tests, it is ensured that different components of the system have
their declared specifications/characteristics and also the system is fit for safe and reliable
operation. The pre-commission tests are broadly classified into pre-commission checks meant for
initial inspection covering visual inspection for damages, quality of workmanship, mechanical
operation etc. and the pre-commission tests meant for measurement or testing of various safety
parameters like insulation resistance, breakdown voltage of insulation, relay characteristics etc.
In addition to describing the procedure for pre commissioning checks and tests, attempt is also
made to give essential information about the specifications and characteristics of different parts
and components. Detailed description of the test procedures and interpretation of the test results
were given on Transformers. The test results obtained at commissioning stage of transformer will
be used as reference values /signatures for diagnosing the transformer during any internal faults
in its life time. Before carrying out the pre-commission tests it is always advisable to refer to the
manufacturers instructions. Products of different manufactures may have special features and
characteristics and it is necessary to have a good knowledge of these special features before
carrying out the tests.

CHAPTER I
INTRODUCTION:
The transformer works on the principle of electromagnetic induction. As the
name suggest it transfers electrical energy from one circuit to another at constant frequency and
power, at different voltage levels. Depending on upon the requirement, the voltage levels can be
stepped up (or) stepped down. This makes it possible to use very high voltages for transmission
lines resulting in a lower current. Higher voltage and lower current reduce the conductor size,
transmission line losses and improves the voltage regulation as well. Transformers have made
possible economic delivery of electric power over long distances.
In our country the electrical energy is usually generated at 6.6 or 11 or 33 kv,
stepped upto 132,220,400 or 765 kv with the help of step up transformers for transmission and
then stepped down the voltage to 11 kv for feeding distributing transformers stepping down the
voltage further to 400/230 volts for the consumer uses.

PRINCIPLE OF TRANSFORMER:
The physical basis of the transformer involves the Faradays laws of electro magnetism in
which an alternating flux induces voltage in the coil and Lenz Law which states that the effect
produced will oppose the cause. Combining the two laws stated above, the emf (back emf)
induced in a coil, with an alternating flux is given by:
(1.1)
The transformer consists of two inductive coils which are electrically separated but
magnetically linked through a path of low reluctance by mutual induction.
If one coil is connected to the source of alternating voltage an alternating flux is set up in
the laminated core most of which is linked with the other coil produces mutually induced emf. If
the second coil circuit is closed, a current flow in it and so electric energy is transferred from the
primary to secondary coil.

Figure 1.1: principle of a transformer

CHAPTER II
CONSTRUCTION AND PARTS OF TRANSFORMER
2(a) Transformer construction:
The transformer is simple in construction and consists of magnetic circuit linking
with two windings known as primary and secondary windings. Besides magnetic circuit and
windings it consists of a suitable tank for the assembled core and windings such as a tank, a
suitable medium for insulating the core and the windings from its container such as transformer
oil, suitable bushings (either of porcelain , oil filled or condenser type) for insulating and
bringing out terminals of the windings from the transformer tank, temperature

gauge for

measurement of temperature of hot oil or hottest spot temperature, and oil gauge to indicate the
oil level inside the tank. Transformers are also provided with the conservator tank in order to
slow down deterioration of oil and keep the main tank full of oil.

Figure 2.1: Cut view of a transformer

2(b) Parts of a transformer:

6

2.1 Transformer tank:

Small capacity tanks are fabricated from welded sheet steel, while larger ones are
assembled from plain boiler plates or cast aluminum parts, usually mounted on a shallow
fabricated steel base. The lids of these transformer tanks can be of cast iron, a water proof gasket
being used at the joints. For cooling purpose, cooling tubes are welded with the tank, but in case
of radiators, separate radiators are individually welded and then bolted-on to the transformer. A
tank must withstand the stresses developed by jacking and lifting and shall be not larger than
necessary to accommodate the core, windings and internal connections with appropriate
electrical clearance.

2.2 Core Assembly:

Core Assembly forms the magnetic circuit linking the two windings of the transformer.
Those parts of the magnetic circuit, which carry the transformer windings, are called the limbs or
legs, and those parts which connect the legs and serve for closing the magnetic circuit are termed
yokes.
The core material used in its construction should satisfy
Maximum flux is created with minimum magnetizing current
Minimum core loss.
The use of steel in magnetic circuit introduces iron or core loss but ensures a high
permeability of the magnetic circuit. High permeability of core limits the magnitude of exciting
current necessary to create the required flux .The presence of steel core causes 100% of the
magnetic flux created by the primary to be linked with the secondary. The magnetic frame of the
transformer is built up of laminated hot rolled or cold rolled grain oriented steel consisting of
3.5% silicon. The higher content of silicon increases the resistivity of the core, thereby reducing
the eddy current core loss.
As the flux in the core is pulsating one ,it becomes necessary that the transformer cores
are laminated and the laminations should be insulated and made as thin as possible in order to
minimize the eddy current loss .

2.3 Winding Assembly:

The most important features that the windings of a transformer should possess are:
a) The winding should be economical regarding initial cost of copper.
b) The efficiency of the transformer in service
c) The heating conditions of the windings should meet standard requirements
7

d) The winding should be mechanically stable in respect to the forces appearing when sudden
short circuit of the transformer occurs.
e) The winding should have the necessary electrical strength in respect to the over voltages.

Fig: 2.3.1Winding construction

Fig.2.3.2 continuously Transposed conductor

Usually LV winding is placed near the core and HV &LV windings are assembled
alternately around the core with insulating paper between the two windings.
Transformer windings are made of solid or stranded copper or aluminum strip
conductors. Heavy current capacity needs conductors of large cross section .to reduce eddy
current losses in the conductors, several small wires or parallel straps are preferred to one large
strap. This gives rise to unequal reactance components of the conductor which can be eliminated
by transposition of conductors.

2.4 Bushings:
Bushings are incorporated to bring the Extra High voltage winding terminations through
the cover of the transformer tank. Variety of bushings used for various voltage classes were
mentioned below:
Table:2.4.1:various voltage classes
Voltage
Class
<33KV
<132KV
>132KV

Type of bushing
Porcelain bushing
Oil filled bushings
Oil impregnated
paper(OIP) Condenser
bushing

The oil filled bushing consists of a hollow porcelain cylinder with a conductor through its
centre. The space between the conductor and the porcelain is filled with oil, the dielectric
strength of which is greater than that of air.
The OIP Condenser bushing is constructed of thick layers of bakelized paper alternating
with thin graded layer of tin foil. The result is a series of capacitors formed by the conductor and
the first tin-foil layer, the first and second tin foil layers ...and so on. The bakelized paper and
the tin foil are arranged in such a way that the capacitances of the capacitors and hence dielectric
stress across each capacitor are uniform through out the radial depth of the insulator.
Table:2.4.2:parts of oip
Description of
Part
Oil impregnated
core
Center
metal
tube
Fixing flange

S.
No
10

Description
of
Part
Air releasing screw

11

Test tap

12

Top terminal

13

Oil filling plug

14

Oil sight glass

Porcelain

upper
Porcelain lower

15

Gaskets

16

Base plate/stress
shield
Upper arcing horn

Springs

17

Lower arcing horn

Expansion bowl

18

Cable bolt

Nitrogen
plug

S.
No
1
2
3
4

filling

Fig2.4: OIP Bushing of Power Transformer

The last tin foil of the insulating medium of bushing is terminated to Voltage tap called as
Tan tap of bushing used to measure the Capacitance and dissipation factor of the bushing.
NOTE: The Tan tap must always be earthed by the screwed on cap and should never
be removed during operation.

2.5 Transformer oil:

Oil in the transformer construction serves the double purpose of cooling and insulating
.The heat is produced from the metal of the transformer ,passes through the insulation and raises
the temperature of oil and is then conducted either through the radiators of the tank to the
surrounding air by means of cooler fans.
Transformer oil has to fulfill certain specifications:
1. High dielectric strength :
As per IS Standard, the breakdown strength of new transformer oil when treated
must be at least 50 kV RMS when measured with the help of 2 spherical electrodes of
12.5mm dia. and with a gap spacing of 2.5 mm.
2. Low viscosity:
It is to provide the good heat transfer. A high viscosity is an obvious disadvantage
because of the sluggish flow through the many small orifices in the windings.
3. Purity:
The oil must not contain impurities such as acid, alkali and sulphur or its
compounds to prevent the corrosion of the metal parts and insulation.
10

4. High flash point:

The temperature at which oil vapor ignites spontaneously is called the flash point.
The flash point of transformer oil should not be less than 135 degrees.
5. Free from sludge under normal operating conditions:
Sludging means slow formation of semi solid hydrocarbon owing to heating and
oxidation. The sludge deposits itself on the windings, tank walls and in cooling ducts.
Sludge being bad conductor of heat greatly reduces the heat transfer from the
windings to the oil and so increases the temperature of windings. Sometimes for
preventing sludging certain chemicals called the inhibitors are added to the
transformer oil.

2.6 Radiators and cooler fans:

Radiators are incorporated to cool the low density hot oil at top of the transformer to
lower temperatures on its way to the bottom of the tank by means of Natural air
cooling(AN)/Forced Air cooling(AF) through cooler fans.
Depending on the quantity of oil used in the transformer tank, the number of radiators
required and the type of cooling required were decided by the manufacturer.
The various types of cooling techniques used in a transformer were mentioned below:
Table:2.6:types of cooling techniques
Type of Cooling
ON
AN
ONAN
ONAF
OFAF

Description
Natural Oil cooling
Natural Air Cooling
Oil Natural with Natural air cooling
Oil Natural with Forced air cooling
by Cooling Fans/Blowers.
Forced Oil cooling by Oil pump
accompanied by cooler fans.

Fig 2.6.Radiators and Cooler Fans

2.7 Conservator:
The oil level of a transformer changes with the changes in the temperature of the oil
which in turn depends upon the load on the transformer. The oil expands with the increase in
load and contracts when the load decreases. Large transformers are also liable to overloads which
may overheat the oil and consequently there is a sludge formation if air is present. This causes
the vaporization of a part of the oil. The oil vapors forms explosive mixture with air that ignites
and may cause a considerable damage. For these reasons it is necessary to prevent the oil from
having contact with air as well as the moisture. For this purpose some conservators are employed

11

with Air cell-a balloon like structure in the conservator tank to prevent mixture of air with
insulating oil.

Figure:2.7 conservator tank with Air Cell

Conservator is a small auxiliary oil tank that may be mounted above the transformer and
connected to the main tank by a pipe. Its function is to keep the main tank of the transformer
completely filled with oil in all circumstances despite expansion or contraction of oil with the
changes in the temperature. Conservator is partly filled with oil and absorbs the expansion and
contraction of oil and keeps the main tank full of oil. It also reduces the rate of oxidation of oil,
partly because less oil surface is exposed to air and partly because of the reduced temperature of
the oil exposed to air. Thus the sludge formation is considerably reduced.
Normally the capacity of conservator should be approximately 10-12% of the oil volume
of the main tank. The conservator tank is usually installed on the low voltage side of the
transformer tank above the level of the transformer cover on a supporting frame. A small pipe
connection between the gas space in the expansion tank and the cover of the transformer tank
permits the gas above the oil in the transformer to pass into the expansion tank so that the
transformer main tank will be completely filled with the oil.

2.8 Silica gel breather:

Whenever there is a change in the ambient temperature or in the load on oil
immersed transformers there is a change in the volume of oil in tank and conservator. This
change forces the air above the oil level in the conservator to be either pushed out or breathe in
from outside atmosphere. Whenever the air is breathed in there is a possibility of moisture and
dust from the atmosphere to be sucked in. This is dangerous to the insulating properties of oil.
Silica gel breathers are provided to prevent this and to ensure that dry and clean air is breathed in
and out through the breather.
12

Construction & Operation:

Conventional silica gel breather

consists of casing, silica gel crystals, and an oil seal

arrangement at the lower end of the casing.

Dry silica gel crystals which are dark blue in color have a very good capacity to absorb
moisture. When the air from outside is breathed in conservator it passes through the crystals and
moisture in the air is absorbed. Thus the air that reaches the conservator is dry. Dust particles are
partly trapped in the oil seal and partly tapped by the crystals of the silica gel.
Silica gel crystals change their color from dark blue to pink depending upon absorption of
certain quantity of moisture. On turning pink, the efficiency of absorption of moisture becomes
very low. The crystals can be reactivated by heating them. The moisture absorbed then gets
evaporated and the crystals again turn dark blue and are ready for re-use.

Fig: 2.8.1: Arrangement of silica Breather

Figure 2.8 .2: silica gel breather

2.9. Magnetic oil Gauge:

A float is used as sensor of liquid level inside the conservator tank. Swing of hinged
float due to change in liquid level is utilized to indicate level in a calibrated dial and to operate
the switches for external alarm units.
Use of magnetic coupling in the indicator achieves complete sealing off the liquid
inside the conservator from surroundings atmosphere. This result in avoiding any leakage of
costly oil and avoiding contamination of insulating oil due to the seepage of surrounding air in
the conservator.
The details of the subassembly parts are as below:
(1)Gear Assembly
(2) Magnetic Couple
13

(3) Float with arm

(4) Cam assembly with Mercury Switch
(5) Dial with pointer.
The float is hinged and swings up or down when oil level rises or falls. This rise or fall
rotates the bevel gear and thus the pinion of the gear assembly. The pinion in turn rotates the
driving magnet inside the conservator. The follower magnet positioned outside carries a pointer
and a cam. The pointer reads oil level and the cam set operate the mercury switch at a
predetermined low level.

Figure 2.9: Magnetic oil gauge

2.10 ON LOAD Tap Changer (OLTC):

This arrangement is employed for changing the turn ratio of the transformer to
regulate the system voltage while the transformer is delivering load. It is invariable practice to
provide the tapping at the neutral end of the HV windings of a transformer.
Construction:
The On load Tap changer consists of a high speed resistor transition diverter switch,
Tap selector switch, driving mechanism and external driving shaft.
Diverter Switch:
The diverter switch consists of contact compartment, transition resistors, and spring
acting mechanism. A perfect oil tight structure is employed between diverter switch and the
transformer tank, to prevent mixing of oil outside the diverter switch chamber with the oil inside,
which will be contaminated due to switching operations.

14

The tips of arcing contacts are made of copper-tungsten alloy which has got excellent arc
resisting characteristics. Current limiting resistors consist of nickel chromium wire wound on
heat resisting bobbins held at both ends by insulating plates.
Oil in the diverter switch is maintained under a separate conservator head. The pipe
leading to the conservator from the diverter switch chamber is filled with a gas and oil operated
relay, the normally open, Velocity actuated contact of which is connected to trip circuit of the
transformer.
Selector switch:
The tap selector operates under no load condition and therefore, there need not be any
fear of arc generation, damage of contacts or deterioration of main transformer oil.
The tap lead wires from the winding of the transformer are brought and terminated at the
fixed contacts of the tap selector. Tap Change operation requires two rotary switches per phase.
The odd numbered tapings are connected to one switch and even numbered tapings to the other
in such a way that the two switches come into use alternately.
The selected odd and even numbered contacts are fitted on either insulating bars mounted
vertically to diverter switch chamber.
Principle of Operation:
The tap operation in a transformer is explained referring to fig .2.9.1. The odd moving
contact is on tap 7 and even side contact on tap 8 of the tap selector. The odd and even collector
contacts are connected to the diverter switch contacts O&E respectively. Since Diverter switch is
making contacts at O (odd) flow of current will be through tap 7.When a signal is given to the
driving mechanism for changing the tap from 07 to 06, it will first operate the even contact of tap
selector from tap 08 to 06 without changing the position of odd contact.
Simultaneously with the Operation of the tap selector, the spring mechanism, which is the energy
accumulator mounted on the top of the diverter switch will be charged.
On completion of tap selector operation, energy accumulated in the spring will be
released for instantaneous Transfer of the diverter switch moving contacts from tap O to E
through the resistor contacts OR and ER thus changing the flow current from tap 07 to 06.
For reverse operation i.e. for changing tap 6 to 7, the tap selector shaft

15

will not operate as its contacts is already on tap 07.But the transfer of the diverter switch moving
contacts from E to O via- ER-OR-O will take place
completing the tap changing operation.

Figure 2.10.1: Tap Changer with

Transfer switch

R1-R2 : Bridging resistors

S1-S2 : Selector Switches
M1-M2: Diverter Switch Main
arcing contacts
T1-T2 : Diverter Switch
Transient arcing Contacts
01-19 : fixed Selector contacts
IL : Load Current flowing in
winding
Ic : Circulating current
when Tap section is
bridged

16

Running position No: 1 Series transition Bridging Transition

Series transition
Running position No: 2
IL via S1, T1. IL via R1, T1 R1 R2, across tap section IL via R2 IL via2, S2, M2

Fig: 2.10.2: Tap Changeover process in a Diversion Switch of On Load Tap Changer
The Tap changeover from odd to even contacts in diversion switch can be observed from
fig 2.10.2(a) to Fig 2.9.2(e). At the time of transition Bridging resistors R1 &R2 Will come
across Tap section as in fig 2.10.2 (c). Load current IL splits S1, R1.T1 & S2, R2, and T2, thus
causing circulating current IC adding in R2 & subtracting in R1.

CHAPTER III
PROTECTION OF POWER TRANSFORMERS
A power transformer is subjected to various faults throughout its life time. The
protection of power transformer should be effective enough to isolate the power transformer
from internal and external faults of the transformer minimizing the fault clearing time as well as
increasing the life time of transformer. The protection incorporated for an oil immersed type
power transformer can be classified as shown in fig 3.1

Protection of
transformer

Against Internal
Faults

17

Against Through
Faults

Differential

Gas and Surge Operated

Relays
Buchholz relay
Oil Surge Relay
Pressure Relief
Valve

Over current and

Earth Fault
Protection

Fig: 3.1 Protection employed for an Oil immersed power Transformer

3.1 Gas operated relays:

3.1.1 Buchholz relay:
The gas actuated Buchholz relay is a protective device designed to give indication of
faults occurring in oil field conservator type transformers, on load tap changers. All types of
faults occurring within an oil field transformers are accompanied by gas generation. This
phenomenon has been effectively utilized by buchholz relays to provide the best known
protection arrangement for transformers.
The high sensitivity and capability of the relay has been successfully proved to detect
faults stated below.

Defective core laminations.

Breakdown of core insulations.
Local overheating of windings.
Phase to phase, phase to earth or internal short circuits.
Insulation breakdown of major nature.

Construction:
The relay comprises of flanged housing detachable front cover, terminal, box,
toughened glass windows, alarm and tripping device with mercury switches and valves for
venting and relay setting.

The alarm and the tripping device consist of 2 counter balanced

aluminum buckets which are hinged and the tilting of these buckets operates the mercury
switches.

18

Air release valve is provided at the top of the housing for releasing the trapped air and
for taking out the gas samples. One more valve is provided for introducing air inside the relay to
carry out the gas volume and surge tests
The front inspection glass is provided with scale to allow reading the accumulated
volume of the gas and observe color of the gas for fault analysis.IN Service/Test lock can be
selected in the form of movement of red indicator on the reading scale.

Fig 3.1.1: Buchholz relay

Operation:
When any fault occurs the gas formation takes place in the transformer and
accumulates in the Buchholz relay on its way to conservator .In consequence, oil level in the
relay drops and the upper counter balanced and hinged bucket moves down tilting the mercury
switch to activate alarm circuit. If the oil level drops further lower bucket also operates and
closes the contact for tip circuit.
Commissioning:
While mounting the relay care should be taken to see that the arrow on the relay is
pointing towards the conservator and the air vent valve at top. Ensure that pipe ascends to
conservator at angle between 10 -90 as per specification of manufacturer & the relay is kept in
service position.
After installation of the relay and when the transformer has been filled with oil up to
the oil conservator the air trapped in the gas chamber must be allowed to escape through the air
vent valve at top.

19

Gas Analysis:
Depending on the nature of fault i.e., with winding, paper insulation, oil flashover in the
transformer the nature of gases formed will vary. The type of fault formed in the transformer can
be detected by diagnosing the gases collected in the Buchholz relay.
Gases collected in the Buchholz relay is allowed to pass through a test tube filled with
Silver Nitrate (AgNO3) solution by releasing the Air release plug .The precipitate formed on the
walls of the test tube is observed for diagnosing the fault in the transformer as stated below.
Table3.1.1:Diagnosing the fault of transformer by precipitate
formed
Nature of gas
Colorless and odorless
Grayish white with pungent smell, non
flammable
Yellowish inflammable
Dark grey inflammable

Probable fault
Air trapped in oil or insulation.
over heating of insulation, press board
Decomposing of wood insulation
Flash over in oil or due to excessive
overheating of oil caused by a fault in
the winding or core.

3.1.2 Oil surge relay:

This relay is sensitive to both low oil level and oil surge conditions. It is usually
installed for protection against faults in the One Load Tap Changer.
The housing is provided with two flanges for connecting pipes leading to the tap
changer head and to the oil conservator. The flap valve position can be checked through the
inspection glass on front of the housing
For checking the tripping function of the relays well as subsequently resting the flap
valve, two push buttons are installed in the terminal box .One pushbutton for actuating the trip
contact manually and the other pushbutton for resetting the trip contact.

20

Fig 3.1.2: Oil Surge Relay

Operation:
The protective relay is energized by an oil surges from the tap changer to the oil
conservator only. The oil flow operates the flap valve being trapped in to the OFF position. At
that moment the contact is actuated, the circuit breakers are operated and the transformer is
switched OFF the line. It is not energized by the tap changer being subject to nominal load or
permissible overload.
Commissioning:
The protective relay has to be mounted in the pipe leading from the tap changer head to
the oil conservator. The relay must be located as near as possible to the tap changer head. Pipe
work rising to the conservator should be arranged at an angle of 5 0 above the horizontal to ensure
the effective operation of the protective relay with the test push buttons in the top of the housing.
The arrow on the terminal box cover must point towards the oil conservator.
3.1.3 Pressure relief valve:
The pressure relief valve is a protective device for oil filled transformers. It is
designed to relieve the excessive pressures which may build up by a fault or an arcing inside the
transformer tank.
Table3.1.1:Parts of preesure relief valve

21

S.N
o
1
2
3
4
5
6
7
8
9
10
11
12

Description
Base
Gasket
O Ring
Diaphragm
Cover
Springs
Rod retaining spring
Lock nut
Switch operating rod
Visual indicator
Stopper
Visual indicator

Fig3.1.3: Pressure Relief Valve

22

When the pressure inside the tank exceeds a preset limit, acts on the diaphragm inside
which in turn causes the diaphragm to lift up 4m from its seat. A movable rod attached to this
diaphragm operates a micro switch and makes the transformer to switch OFF. This lifting is
instantaneous and allows venting off the excess pressures inside the tank
It also gives a visual indication of the valve operation by raising a flag.
The diaphragm resets to its original position as soon as the pressure inside the tank drops
below the set limit.

3.2 Oil and Winding Temperature Indicators:

The temperature indicator is used as an Oil temperature Indicator (OTI) or as a Winding
Temperature Indicator (WTI) for the protection of liquid immersed power transformers.
Construction:
A sensing bulb (20), a measuring bellow (2) and a small bore capillary tube (19)
connecting the two form the measuring system. A second bellow called as compensating bellows
connected with a second capillary (19) running parallel to the first capillary and terminated at the
head of the bulb form the temperature compensation system. The bellows are linked to a
compensating lever (17) in such a manner that the effect of ambient temperature changes on the
capillary line and measuring bellows is compensated. The movement of measuring bellows is
related only to the temperature being measured by the sensing bulb. This movement is amplified
by the link and lever mechanism (4) which directly drives the rotating disc (13) carrying the
control switches and pointer indicating the temperature.

23

Figure 3.2 winding and oil temperature indicator

A heater coil (3-Bellows heater) is fitted around the measuring bellows (2) and
supplied from a current transformer mounted in the bushing of the transformer. The heater coil
indicates the hot spot temperature of the windings over top oil temperature for a given load. The
measuring bellows reacts to this simulated temperature rise in addition to the top oil temperature
measured by the sensing bulb and the instrument functions as WTI indicating the temperature of
the winding. An adjustable shunt resistor is provided for shunting a portion of current through
the heater coil to obtain precise thermal image.
All internal electrical contacts of mercury switches are wired to terminal blocks. Switches are
identified by marking s S1, S2, S3, S4 on them.
Terminal nos wired to each circuit are detailed below:
Table3.2:Mercury switches
Terminal Nos
1,2
3,4
5,6
7,8

Switch Nos
S1
S2
S3
S4
24

Wired to
Alarm
Tip
Cooler Control-1
Cooler Control-2

9,10,11

Bellows heater & adjustable

shunt

3.4 Differential Protection:

Differential protection also called as unit protection, is the Main Protection of Power
Transformer as it only operates for faults on the unit it is protecting, which is situated between
the CTs. The relay therefore can be instantaneous in operation, as it does not have to coordinate
with any other relay on the network. This Differential protection, as its name implies, compares
currents entering and leaving the protected zone and operates when the differential current
between these currents exceed a pre-determined level.
The type of differential scheme normally applied to a transformer is called the current
balance or circulating current scheme as shown in Figure 3.4.1 below:

Fig 3.4.1: Circulating current scheme in the case of through faults

The CTs and relay were connected in such a way that the relay is operated by circulating
current between secondary of CT. Differential current does not arise and hence the relay does
not operate for external faults as shown in the fig.3.4 .1
Under internal fault conditions (i.e. faults between the CTs) the relay operates since both
the CT secondary currents add up and pass through the relay as seen in Fig: 3.4.2

Fig 3.4.2: Circulating current scheme in the case of internal faults

25

Unfortunately the circulating current protection mentioned above may operate even for
through faults due to the following factors which need careful consideration:
(a) Transformer vector group (i.e. phase shift between HV and LV)
(b) The possibility of zero sequence current entering the relay may destabilize the
differential for an External earth fault.
(c) Magnetizing in-rush currents (from one side only)
(d) Mismatch of HV and LV CTs
(e) Varying currents due to on-load tap changer (OLTC).
Factor (a) can be overcome by connecting the HV and LV CTs in star/delta respectively
(Or vice versa) opposite to the vector group connections of the primary windings, so
counteracting the effect of the phase shift through the transformer.
The delta connection of CTs provides a path for circulating zero sequence current,
thereby stabilizing the protection for an external earth fault as required by factor (b).
NOTE: To counter factors (a) & (b), the Thumb rule for differential protection is that the
CTs are to be connected in star for delta connected winding, and vice versa.
As the magnetizing current in-rush is predominantly 2nd, harmonic filters are utilized to
stabilize the protection for this condition (c).
And Finally, It is necessary to bias the differential relay to overcome the current
unbalances caused by factor (d) & (e) i.e. mismatch of CTs and taps of OLTC respectively. And
Hence a Percentage Biased Differential relay is preferred instead of a circulating current
principle.
The Percentage Bias Differential Protection applied for an YNyn0 Power Transformer is
mentioned in fig 3.4.3 below:

Figure 3.4.3 differential protection of a transformer

Under-load or through-fault conditions, the CT secondary currents circulate, passing
through the bias windings to stabilize the relay, whilst only small out-of-balance spill currents
will flow through the operate coil, not enough to cause operation. In fact the higher the
26

circulating current the higher will be the spill current required for tripping the realy as shown in
the relar charecteristics fig 3.4.4 .

Fig:3.4.4 .Differential Realy opearting chareceristcs

Most transformer differential relays have a bias slope setting of 20%, 30% and 40% as
shown in fig 3.4.4. The desired setting is dictated by the operating range of the OLTC, which is
responsible for the biggest current unbalance under healthy conditions;

3.5 Over Current and Earth Fault Protection:

Over current and Earth Fault protection is the Back Up protection for power transformer.
Unlike Differential Protection which operates for internal faults (between CTs), Over current
protection will operate even for through faults, above the pickup current setting, thus isolating
the transformer from feeding the fault.
Over current and earth fault protection is provided on both HV and LV Side of the winding
and hence proper time gradation is to be provided for relay operation starting from the feeders
connected to LV side of transformer to the Over Current protection on HV Side, to avoid
complete black out for an fault on feeder connected to LV Side of transformer.
To achieve selectivity and coordination by time grading two philosophies are available,
namely:
1. Definite time lag (DTL), or
2. Inverse definite minimum time (IDMT).
(1).Definite Time Characteristic:
The relays are graded using a definite time interval of approximately 0.5 s. The relay R3
at the extremity of the network is set to operate in the fastest possible time, whilst its upstream
relay R2 is set 0.5 s higher. Relay operating times increase sequentially at 0.5 s intervals on each
section moving back towards the source as shown in Fig.3.5.1
27

Fig 3.5.1: Definite Time Relay protection

Draw Back:
The problem with this philosophy is, the closer the fault to the source the higher the Fault
current, the slower the clearing time exactly the opposite to what we should be Trying to
achieve.
(2)Inverse Time Characteristic:
A relay having IDMT Characteristic will incorporate lower operating time for higher fault
currents. Various inverse characteristic curves can be selected among Normal Inverse, Very
Normal Inverse, and Extreme inverse curves. For a radial feeder, time grading by means of
relays having IDMT characteristics is shown in fig: 3.5.2 below.

Fig 3.5.2: IDMT relay protection

IEC Standard Normal Inverse 3.0 sec curve is used for the Over current and Earth Fault
protection of power transformer and the characteristic curve can be expressed as:
Relay Operating time (in secs) = (0.14*TL) / (PSM0.02-1)
Where TL=Time Setting Multiplier adopted.
PSM=Plug Setting Multiplier =
Fault current on CT Primary
(CT Ratio Adopted) *(Current Setting Adopted on
relay)
28

Example: For a feeder having CT Ratio adopted=400/1, and Relay settings adopted for a relay
having nominal current of 1A as Pick up=100% and Time Lever=0.1, the relay
operating time for a fault current of 800Amps on feeder can be obtained as below:
Plug Setting Multiplier=800/ (400*100% of 1A) =2 & TL=0.1
Then, relay operating time (in secs) = (0.14*0.1)/ (20.02-1) =1sec.
Thus, for a fault current of 800Amps, the relay will operate in 1sec.
For protection of power transformer proper time gradation is to be provided for HV and
LV side IDMT relays. The CT connections on HV and LV side of transformer for over current
and Earth fault protection is shown fig 3.5.3:

Fig: 3.5.3.OverCurrent & Earth Fault protection for a transformer

For an HV winding fault the HV breaker is tripped but the fault can continue to be fed
via the Low voltage side, the back-feed coming from the adjacent transformer(s) as shown in Fig
3.5.4,where the LV Protection is set high to coordinate with downstream requirements. Thus, the
Transformer Protection should always trip both HV and LV circuit breakers for operation of HV
Side IDMT Relay.

Fig3.5.5: Protection should trip HV and LV breakers

29

CHAPTER IV
PRE COMISSIONING TESTS OF A POWER TRANSFORMER

Introduction:
Various tests are performed on power transformer at various stages starting from the first
stage of transformer construction to the commissioning stage at the site. The tests conducted can
be classified as Type Tests, Routine Tests, etc. The test results obtained for various tests at the
time of commissioning will be used as reference values for diagnosing the transformer during
any faults in the life time of transformer. Among various tests, Routine tests performed on power
transformer were mentioned in detail.
Routine Test performed on Power Transformer at site at the time of commissioning
includes:
(1)
(2)
(3)
(4)
(5)
(6)
(7)

Insulation Resistance Test(Megger)

Ratio Test
Magnetizing Current test.
Magnetic Balance test.
Short Circuit test.
Winding Resistance.
Tan delta test of windings & bushings.

4.1Insulation Resistance Test (Megger):

Purpose of IR test is to check over all insulation of transformer .Insulation resistance is a
relative measure of the insulation structure. The test equipment used is a DC Insulation tester
(Megger).The IR test results are correlated with transformer insulation quality by parameters like
Absorption Ratio, Polarization Index.
Test Arrangement:
Ensure that the neutral of the power transformer is disconnected from earth and the Oil
temperature of the transformer under test is to be noted as the temperature is also one of the
deciding factors of IR values obtained by this test.
Table4.1:Insulation resistance test
Insulation resistance Value

30

Temperature(in oC): ---IR Value in Mega Ohms

15 sec
60 sec
P.I=60 sec/15 sec

Voltage Applied: ---S.No

Configuration

1
2
3

HV-LV
HV-Body
LV-Body

4.2 Ratio Test:

Transformer ratio test is conducted to ensure that the turns ratio tally with the name plate
details and also that tap changer connections are done correctly. Ratio test is done using a
transformer turns ratio tester or with voltmeters. With the turns ratio tester, the turns ratio is
directly read on the tester for each tap and for each phase of the winding. The turns ratio can also
be tested by applying a single phase ac voltage (approximately 230V) on the HV side and
measuring the voltage on the low voltage side at all tap positions.

Test arrangement:
This test is carried out to verify the voltage ratio between different windings on each
tapping which certifies correct no. of turns in the windings. For conducting the test, the
transformer neutrals are to be isolated from earthing and 3Ph, 4 wire 415 volts AC supply is
applied to the HV winding and corresponding phase and line voltages are measured at the LV
winding of power transformer.
Table4.2:Voltage ratio test
Voltage Ratio Test
Applied Voltage(volts)

TAP

Measured Voltage

NO
UN

VN

WN

UV

VW
31

WU

(volts)
w uv v

wu

1-25

240

240

240

415

415

415

n
--

n
--

n
---

---

w
---

---

4.3 Magnetizing current test:

The exciting current test at low voltage is very useful in location of problem such as
defects in magnetic core balance in magnetic core structure, shifting of winding, failures in turn
to 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 results .The general pattern of Magnetizing current test would have two similar higher
reading of magnetizing current on outer phases and lower reading of magnetizing current on the
centre phase in case of YNyn0 three phase transformers.
Test Arrangement:
Apply 3 Phase, 4 wire 415 volts AC from HV side & keep LV, neutral isolated.
Measure magnetizing current in U, V&W phases of HV winding.
Table4.3.1:Magnetizing currents at HV windings
Voltage applied
1U-IV Phase
415Volts
1V-1W phase
415 Volts
1W-1U phase
415 Volts

Current measured (mA)

1U Phase
---1V phase
---1W Phase
----

Similarly apply 3 Phase, 4 wire 415 volts AC from LV side & keep HV, neutral isolated.
Measure magnetizing current in u, v &w phases of LV winding.
Table4.3.2:Magnetizing currents at

4.4 Magnetic Balance Test:

LV windings

Voltage applied
2u-2v Phase
415Volts
2v-2w phase
415 Volts
2w-2u phase
415 Volts

Current measured (mA)

2u Phase
---2v phase
---2w Phase
----

Magnetic Balance Test is conducted to check healthiness of windings, core assembly

condition and flux distribution in the transformer. When the supply is fed to outer phase of a
transformer, the voltage induced in the center phase shall be 50 to 90% of the applied voltage.
However when the centre phase is excited then the voltage induced in the either of the outer
phases will be nearly 50% of the applied voltage.
Test Arrangement:
32

Ensure that primary and secondary windings are kept open. Apply 230Volt AC, on
primary/secondary winding in one phase and measure the voltages in remaining phases. Sum of
the measured voltages in two phases should be equal to the applied voltage.
Table4.4:Magnetic balance test
UN
Supply
Measured vltg
Measured vltg

VN
Measured vltg
Supply
Measured vltg

WN
Measured vltg
Measured vltg
Supply

4.5 Short Circuit Test:

Short Circuit test is performed to check the measured Percentage impedance of the
transformer in agreement with name plate details on the power transformer. During internal fault,
any damage to the winding of the transformer may result change in the per unit impedance of
transformer and hence can be reflected in the test results of short circuit test.
Test Arrangement

Table4.5:Short circuit test

Short Circuit Test

HV Winding currents (Amps)
LV Winding Currents (Amps)
U
V
W
N
u
V
w
n
------------------------Short circuit test is conducted by shorting the LV windings and applying the 3Ph supply
to HV winding. Ensure that the LV Winding phase terminals are shorted to its corresponding
neutral and apply 3ph, 4 wire 440V AC supplies to the HV winding and measure the HV & LV
winding line currents.
The measured currents in HV and LV windings should be in agreement with calculated
values for a particular applied voltage.
HV Current at Applied voltage= (Rated HV Current/Impedance in volts)* Applied
Voltage
Where Impedance volts= (% Impedance* HV Volts)/100.
NOTE: (1) Conducting the short circuit test by shorting the HV winding and applying the
3ph supply to LV winding may result in heavy currents on LV side which cannot
be supplied by the LT 3ph Source.

33

(2) Measurement of currents during short circuit test should be done quickly as the
magnitude of currents produced would be of large value.

4.6 Vector Group Test:

Vector group test is conducted to check the HV and LV windings arrangement was in
agreement with the vector group specified by the manufacturer. Various test patterns are to be
followed for various vector groups. The following test arrangement is to be followed for testing a
power transformer having YNyn0 vector group.
Test Arrangement:

Connect the primary and secondary of one phase together and then apply 3Ph, 4wire 440Volts
AC supply to the HV winding of power transformer and measure the voltages as specified below.

Voltage applied on HV Side:

1U1V:
34

IV1W:
1W1U:
Table4.6:vector group test
S.No
1
2
3

Verifying conditions
1U2n+1N2n=1U1N
1W2w=1V2v
1W2w<1W2v

Measured Values

4.7 Winding Resistance Test:

Transformer winding resistance is to be measured at site in order the check for
abnormalities due to loose connection broken strands of conductor, high contact resistance in tap
changers, high voltage leads and bushings.
Test Arrangement:
Ensure that HV and LV windings are kept open and neutrals disconnected. This test is to
be conducted at all taps of the transformer. DC current of approximately 10Amps is injected and
the voltage developed across the test terminals is used to measure the resistance of the winding
which will be of order of m.
Table4.7:Winding resistance test

Winding
HV
LV

Tap No
1 to 25

Winding Resistance
Phase U
Phase V
m
m
m
m

Phase W
m
m

The test results obtained from this test should be in agreement with the factory test results.
NOTE: Winding resistance test is to be conducted after conducting all the above mentioned
tests failing which the test results occurred would be erratic due to core magnetization in a
particular direction with the injected DC Current during this test.

4.8 Tan delta test:

Tan test is conducted to observe the healthiness of insulating material i.e. insulation
between windings,
Winding insulation with respect to body, bushing insulation, etc.

An ideal Dielectric material

draws a capacitive component of current, which leads the applied voltage by 90 0.But due to
absorption of moisture in the insulation; the dielectric material

draws resistive and capacitive

components of currents and hence, the current flowing through the insulation leads the voltage

35

by some angle which is slightly less than 90 degrees. This small angle between pure capacitive
current and actual current represented by d (delta) is known as Loss angle.
Thus, the comparison of Resistive to Capacitive component of current is termed as Tan
is
Indicative of the Dielectric loss, ageing of insulation in a Lossy Dielectric material.
Tan =IR/IC.
Tan testing can be conducted in two modes:
(1).Ungrounded Specimen test (UST):- In this mode of testing, the Tan tap of test object is
isolated from the grounding and Capacitance, Tan is obtained for insulation with respect to
Tan tap of test object.
(2). Grounded specimen test (GST)

:- For test objects which do not have Tan test tap,

Capacitance ,Tan is obtained for insulation of test object with respect to ground.
Test Arrangement:
A 5KV Tan delta testing kit consists of a Standard Capacitor, HV cable, Induction
suppression circuit and a LV Cable (to conduct test in UST Mode).Tan testing is conducted for
transformer winding ,Transformer Bushings, Capacitive Voltage Transformers, Current
Transformers, Potential transformers insulation, etc.
(4.8.1) Testing of Transformer winding insulation:
For conducting Transformer Winding Insulation Tan test, the neutrals of the
transformer are to be isolated from grounding, and the following test procedure is to be followed:
(1)Before starting the test, the HV & LV bushings are to be shorted to their corresponding
neutrals to eliminate the inductance effect of the winding and create symmetrical balance of
voltage gradient on the HV &LV windings of transformer
(2).For testing insulation between HV and LV windings in UST mode, Connect 5KV HV cable
and LV cable of Tan testing kit to the HV winding and LV windings of power transformer.
(3). For testing insulation between winding and body in GST mode, Connect 5KV HV cable
of Tan testing kit to the winding of power transformer.
(4 Capacitance and Tan values are to be noted in each step.
36

Table4.8.1:Testing of transformer winding insulation

Winding

Transformer winding insulation Tan

HV-LV (UST) HV-Body
LV-Body
(GST)

(GST)

Capacitanc
e
Tan
(4.8.2)Testing of Bushing Insulation:
Tan test is conducted for OIP Bushings for 132KV and above voltage class .For
Insulation Tan test, the neutrals of the transformer are to be isolated from grounding, and the
following test procedure is to be followed:
(1).The Tan tap of the bushing should be isolated from the ground.
(2). For testing bushing insulation in UST mode, apply 5KV HV Cable & LV cable of Tan
testing kit to Bushing lead and Tan tap respectively and measure Capcitance, Tan of
bushing .
NOTE: After completion of Tan test, the bushing Tan tap must be tightened to earth
.

Table4.8.2:Testing of bushing insulation

Bushing

Bushing insulation Tan

R-ph
Y-ph (UST)
(UST)

Capacitanc
e
Tan

37

B-ph (UST)

CHAPTER V (APPENDIX)
Type of cooling
Rating HV SLV(MVA)
No load voltage HV(KV)
No load voltage LV(KV)
Line current HV(Amps)
Line current LV(Amps)
Oil Temperature rise (0C)
Winding Temperature rise
(0C)
Phase
Frequency
Connection symbol
Ref ambient temperature
% Impedance

OFAF/ONAN
50/25
132
33
218.70/109.35
874.77/437.39
50
55
3
50HZ
YNyn0
500C max
12.58

5.1 NAME PLATE DETAILS OF

THE POWER TRANSFORMER
UNDER TEST
BHARAT HEAVY ELECTRICALS
LIMITED 50MVA, 132/33KV POWER
TRANSFORMER

Table5.1.1:Name plate details of

transformer 50MVA,132/33KV

Insulation level
HV
230KV RMS/550KVp
LV
70 KV RMS/170KVp
HV(winding)
38 KV RMS/95KVp
LV(winding)
70 KV RMS/170KVp

38

(3-4),(1N-16)
(3-4),(1N-15)
(3-4),(1N-14)
(3-4),(1N-13)

No load HV
line voltage
(KV)
138.60
136.95
135.30
133.65

Rated HV
line current
(Amps)
208.28
210.79
213.36
216.06

(3-4),(1N-12)

132.00

218.70

(3-4),(1N-11)
(3-4),(1N-10)
(3-4),(1N-9)
(3-4),(1N-8)
(3-4),(1N-7)
(3-4),(1N-6)
(3-4),(1N-5)
(3-4),(1N-4)
(3u-16),(3-4),(1N-3)
(3-16),(1N-16)
(3-16),(1N-15)
(3-16),(1N-14)
(3-16),(1N-13)
(3-16),(1N-12)

130.35
128.70
127.05
125.40
123.75
122.10
120.45
118.80
118.80
118.80
117.15
115.50
113.85
112.20

221.47
224.30
227.22
230.20
233.28
236.43
239.67
243.00
243.00
243.00
246.42
249.94
253.56
257.29

(3-16),(1N-11)
(3-16),(1N-10)
(3-16),(1N-9)
(3-16),(1N-8)
(3-16),(1N-7)
(3-16),(1N-6)
(3-16),(1N-5)
(3-16),(1N-4)

110.55
108.90
107.25
105.60
103.95
102.30
100.65
99.00

261.13
265.09
269.17
273.37
277.71
282.19
286.82
291.60

Switch
position

Leads joined on
HV Winding

1
2
3
4
5
(Nr. tap)
6
7
8
9
10
11
12
13(A)
13(B)
13(C)
14
15
16
17
18
19
20
21
22
23
24
25

Table5.1.2:Switch positions with their voltages and current

39

LV Winding
Line
Voltage(KV)

LV Winding
Rated
(Amps)

874.79
33

5.2 TEST RESULTS:

Insulation resistance test:
Table5.2.1:practical values of insulation resistance test
Insulation resistance Value
Voltage Applied:
D.C
S.No
1
2
3

5KV

Configuration
HV-LV
HV-Body
LV-Body

Voltage ratio test:

TAP
NO
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25

UN

Temperature(in oC): 480C

IR Value in Mega Ohms
60 sec
P.I=60 sec/15 sec
1800M
1.8
2200M
1.1
1000M
1

15 sec
1000M
2000M
1000M

Table5.2.2:practical values of voltage ratio test

VN

W
N

UV

V
W

W
U

255

255

254

445

442

443

255

255

253

445

442

443

257

256

255

448

445

445

259

257

255

447

443

445

40

un

vn

wn

uv

vw

Wu

60
60
61
62
63
64
65
66
67
68
69
70
71
73
74
75
76
77
78
80
81
82
83
84
85

60
60
61
62
63
63
64
66
66
67
68
69
71
73
74
75
76
77
78
79
80
81
82
83
84

60
60
61
61
62
62
64
65
66
67
68
69
70
73
73
75
76
77
78
79
80
81
82
83
83

105
106
107
108
110
111
112
114
116
117
119
121
123
127
128
131
133
134
136
138
139
141
143
145
147

104
105
106
108
109
110
111
113
115
116
118
120
122
126
128
130
131
133
135
136
138
140
142
143
145

104
105
106
109
109
111
111
113
115
117
118
120
123
126
128
130
132
134
135
137
138
140
142
144
146

Magnetizing current test:

Table5.2.3:practical values of magnetizing current test
Voltage applied
1U-IV Phase
415Volts
1V-1W phase
415 Volts
1W-1U phase
415 Volts
TAP
1U
01
2.6
05
2.6
13b
3.5
25
4.9

Magnetizing
Current measured
IV
1.9
1.8
2.5
3.6

(mA)
1W
2.5
2.5
3.3
4.7

Magnetizing balance test:

At TAP NO: 01

Table5.2.4.1:practical values of magnetic balance test at tap 1

UN
255
120
46

VN
204
255
205

WN
51
133
254

AT TAP NO: 05 (Normal TAP)

Table5.2.4.1:practical values of magnetic balance test at tap 5
UN
255
120
48

VN
201
253
204

WN
53
132
252

AT TAP NO: 13b (Middle tap)

Table5.2.4.1:practical values of magnetic balance test at tap 13b
UN
257
120
50

VN
201
257
205

41

WN
56
133
256

AT TAP NO: 25
Table5.2.4.1:practical values of magnetic balance test at tap 25
UN
255
120
55

VN
194
255
195

WN
60
132
252

Short circuit test:

AT TAP NO: 05 (Normal TAP)
Table5.2.5:practical values of short circuit test at tap5
Short Circuit Test
HV Winding currents (Amps)
LV Winding Currents (Amps)
U
V
W
N
u
V
w
n
6.13
5.8
5.8
0.4
25
24
24
1.4

Vector group test:

Voltage applied on HV Side:

1U1V:412V
IV1W:407V
1W1U:409V

S.No
1
2
3

Verifying
conditions
1U2n+1N2n=1U
1N
1W2w=1V2v
1W2w<1W2v

Measured
Values
59+178=237

Table5.2.6:practical values of vector

group test

307308
305<365

42

Winding resistance test:

Table5.2.7:practical values of winding resistance test

Winding Resistance
Winding

Tap No

UN (m)

VN (m)

WN (m)

Winding

un (m)

vn(m)

wn(m)

HV

617

611

617

LV

25.7

25.7

25.6

609

608

609

602

597

602

594

593

594

587

582

588

579

578

580

572

568

573

565

563

565

43

558

553

558

10

550

550

550

11

543

539

544

12

535

535

535

13

527

526

527

14

535

536

535

15

543

539

544

16

549

550

550

17

557

554

558

18

564

565

565

19

571

569

572

20

578

580

578

21

586

583

586

22

592

594

593

23

600

597

601

24

607

609

607

25

615

612

615

44

Insulation Tan test:

Table5.2.8.1:practical values of transformer winding insulation
Transformer winding insulation Tan
Winding
HV-LV
HV-Body
LV-Body
(UST)
(GST)
(GST)
Capacitanc
1000pF
4890pF
14040 pF
e
Tan
0.384
0.648
0.575

Table5.2.8.2:practical values of bushing insulation

HV
Bushing
Capacitance
Tan

HV OIP Bushing insulation Tan

R-ph (UST)
Y-ph (UST)
B-ph (UST)
1000pF
0.384

4890pF
0.648

14040 pF
0.575

5.3 INTERPRETATION OF TEST RESULTS

5.3.1 Insulation resistance test:
It is used to find out the overall insulation of a transformer. The values from the test
results are proved to be correct by observing the polarization index values obtained must be
similar to the values got at initial tests and they must be >1.5 for a new transformer and >1.3 for
a used transformer.

5.3.2 Turns ratio test:

The ratio test is conducted to ensure that the turns ratio tally with the name plate
details and also that tap changing is done correctly. From the obtained ratio test values it is clear
that the turns ratio satisfies with the name plate details.

5.3.3 Magnetizing current test:

This test is used in locating the problems such as defects in magnetic core balance in
magnetic core structure, shifting of winding, problem in tap changers. From the obtained test
results of magnetizing current test, it is shown that the value of magnetizing current on the outer
phases is higher when compared to the magnetizing current on the inner phase at all taps.

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5.3.4 Magnetizing balance:

The values from the test results are said to be correct if and only if the applied supply
voltage for a phase must be equal to the sum of the other two phase voltages measured.

5.3.5 Short circuit test:

It is used to find out the percentage impedance of the transformer to satisfy the
percentage impedance given in the name plate details and also to find out the full load losses in a
transformer. The values from the test results are true for which agrees with the theoretical values
from the name plate details.
The theoretical calculations for short circuit test are as follows:

Given data:
p=50MVA
Rated HV voltage=132KV
Rated LV voltage =33KV
Rated HV current =218.70 Amps
Rated LV current =874.77
% impedance =12.58
Applied voltage=440 volts
No. of turns=4
HV Current at Applied voltage= (Rated HV Current/Impedance in volts)* Applied
Voltage

Where, Impedance volts= (% Impedance* HV Volts)/100.

Impedance volts= (%impedance*HV volts)/100

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= (12.58*132KV)/100
=16.60KV
HV Current at Applied voltage= (Rated HV Current/Impedance in volts)* Applied Voltage
= (218.70/16.60KV)*440
= (218.70/16.60*103)*440
= (0.01317)*440
= 5.79 Amps
LV Current at Applied voltage=HV current at applied voltage*no. of turns
=5.79*4
=23.16 Amps

Practical values from test results:

At tap no. 5

Table5.3.1:short circuit test results

Short Circuit Test

HV Winding currents (Amps)
LV Winding Currents (Amps)
U
V
W
N
u
v
w
n
6.13
5.8
5.8
0.4
25
24
24
1.4

Hence the theoretical and practical values are similarly equal therefore the % impedance is
agreement with the name plate details on the power transformer. This test result indicates that
impedance of winding that is no fault with the winding.

5.3.6 Vector group test:

This test is conducted to check whether the HV and LV windings arrangement was in
agreement with the vector group specified by the manufacturer. From the obtained test results of
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vector group test it is clear that it satisfies the connection of YNyn0 as represented in the name
plate details of the transformer.

5.3.7 Winding resistance test:

The obtained test results of winding resistance test are in decreasing manner in
corresponding to the leads joined on the winding transformer from (3-4),(1N-16) to (3-4),(1N-4)
and again from the leads (3-16,)(1N-16) to (3-16),(1N-4) and winding resistance in phase is
identical with respect to other phases at all taps of HV winding.

5.3.8 Tan test:

This test is used to find out the healthiness of the insulation in a transformer. In this the
healthiness of the insulation for both windings and bushings can be obtained. And the values of
Tan test must be less than 1 for UST and GST modes and they must be similar to that of the
previous values of initial testing.

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Chapter VI
BIBLIOGRAPHY

1. A practical technology of power transformer by Martin J.Heath Cote,CEng,FEE.

2. Transformer engineering design & practice by S.V.Kulakarni,S.A.Khaparde. Indian
3.
4.
5.
6.

Institute of Technology, Mumbai.

Power system relaying; third edition by Stanley H.Horwitz and Arun G; Phadke.
Performance and Design of AC Machines by MG. Say, CBS publishers.
Electrical Machines by P.S.Bimbra, Khanna publishers.
Electrical Power Systems by C.L.Wadhwa, New age international (P) limited, Publishers,
3rd edition.

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