CONCEPT OF TRANSFORMER TESTING

TYPE OF TRANSFORMER TESTING

Test done at factory:

 Type tests
 Routine tests
 Special tests

Test done on site:

 Pre-commissioning tests
 Periodic/Conditional monitoring tests
 Emergency test

ROUTINE TESTS OF TRANSFORMER

 Routine tests of transformer is mainly for confirming operational performance of individual

unit in a production lot. Routine tests are carried out on every unit manufactured.

SPECIAL TESTS OF TRANSFORMER

 Special tests of transformer is done as per customer requirement to obtain information useful
to the user during operation or maintenance of the transformer.

PRE COMMISSIONING TEST OF TRANSFORMER

 The transformer testing performed before commissioning the transformer at site is called pre-
commissioning test of transformer. These tests are done to assess the condition of
transformer after installation and compare the test results of all the low voltage tests with the
factory test reports.

TYPE TESTS OF TRANSFORMER INCLUDES

 Transformer winding resistance measurement.

 Transformer ratio test.
 Transformer vector group test.
 Measurement of impedance voltage/short circuit impedance (principal tap) and load loss
(Short circuit test).
 Measurement of no-load loss and current (Open circuit test).
 Measurement of insulation resistance.
 Dielectric tests of transformer.
 Temperature rise test of transformer.
 Tests on on-load tap-changer.
 Vacuum tests on tank and radiators

ROUTINE TESTS OF TRANSFORMER INCLUDES

 Transformer winding resistance measurement.

 Transformer ratio test.
 Transformer vector group test.
 Measurement of impedance voltage/short circuit impedance (principal tap) and load loss
(Short circuit test).
 Measurement of no-load loss and current (Open circuit test)
 Measurement of insulation resistance.
 Dielectric tests of transformer.
 Tests on on-load tap-changer.
 Oil pressure test on transformer to check against leakages past joints and gaskets.

That means Routine tests of transformer include all the type tests except
temperature rise and vacuum tests. The oil pressure test on transformer to check
against leakages past joints and gaskets is included

SPECIAL TESTS OF TRANSFORMER INCLUDES

 Dielectric tests.
 Measurement of zero-sequence impedance of three phase transformers
 Short-circuit test.
 Measurement of acoustic noise level.
 Measurement of the harmonics of the no-load current.
 Measurement of the power taken by the fans and oil pumps.
 Tests on bought out components/accessories such as Buchholz relay, temperature indicators,
pressure relief devices, oil preservation system etc
 Transformer winding resistance measurement is carried out to calculate the I2R looses
and to calculate winding temperature at the end of a temperature rise test. It is carried out as a
type test as well as routine test. It is also done at site to ensure healthiness of a transformer that is
to check loose connections, broken strands of conductor, high contact resistance in tap changers,
high voltage leads and bushing etc. There are different methods for measuring of transformer
winding, likewise:

 Current voltage method of measurement of winding resistance.

 Bridge method of measurement of winding resistance.
 Kelvin bridge method of Measuring Winding Resistance.
 Measuring winding resistance by Automatic Winding Resistance Measuring Kit.

TRANSFORMER RATIO TEST

The performance of a transformer largely depends upon perfection of specific turns or

voltage ratio of transformer. So, transformer ratio test is an essential type test of transformer.
This test also performed as routine test of transformer. So, for ensuring proper performance of
electrical power transformer, voltage and turn ratio test of transformer one of the vital tests. The
procedure of transformer ratio test is simple. We just apply three phase 415 V supply to HV
winding, with keeping LV winding open. We measure the induced voltages at HV and LV
terminals of the transformer to find out actual voltage ratio of the transformer. We repeat the test
for all tap position separately.

MAGNETIC BALANCE TEST OF TRANSFOMER

Magnetic balance test of transformer is conducted only on three phase transformer to

check the imbalance in the magnetic circuit. Procedure of magnetic balance test of transformer:

 First, keep the tap changer of transformer in normal position. q Now, disconnect the
transformer neutral from ground.
 Then apply single phase 230 V AC supply across one of the HV winding terminals and
neutral terminal. q Measure the voltage in two other HV terminals in respect of neutral
terminal.
 Repeat the test for each of the three phase.
MAGNETIC BALANCE TEST OF TRANSFOMER

In case of auto transformer, magnetic balance test of transformer should be repeated for
LV winding also. There are three limbs side by side in a core of transformer. One phase winding
is wound in one limb. The voltage induced in different phases depends upon the respective
position of the limb in the core. The voltage induced in different phases of transformer in respect
to neutral terminals given in the table below

Caution: This magnetizing current test of a transformer is to be carried out before DC resistance
measurement

VECTOR GROUP TEST OF TRANSFORMER

In three phase transformer, it is essential to carry out a vector group test of transformer.
Proper vector grouping in a transformer is an essential criteria for parallel operation of
transformers. There are several internal connection of three phase transformer are available in
market. These several connections gives various magnitudes and phase of the secondary voltage;
the magnitude can be adjusted for parallel operation by suitable choice of turn ratio, but the
phase divergence cannot be compensated

So, we have to chose those transformer for parallel operation whose phase sequence and
phase divergence are same. All the transformers with same vector ground have same phase
sequence and phase divergence between primary and secondary. So, before procuring one
electrical power transformer, one should ensure the vector group of the transformer, whether it
will be matched with his or her existing system or not. The vector group test of transformer
confirms his or her requirements.

INSULATION RESISTANCE TEST/MEGGER TEST

Insulation resistance test of transformer is essential type test. This test is carried out to
ensure the healthiness of overall insulation system of an electrical power transformer. Procedure
of Insulation Resistance Test of Transformer

 First, disconnect all the line and neutral terminals of the transformer.
 Megger leads to be connected to LV and HV bushing studs to measure insulation
resistance, IR, value in between the LV and HV windings.
 Megger leads to be connected to HV bushing studs and transformer tank earth point to
measure insulation resistance, IR, value in between the HV windings and earth.
 Megger leads to be connected to LV bushing studs and transformer tank earth point to
measure insulation resistance, IR, value in between the LV windings and earth.
INSULATION RESISTANCE TEST/MEGGER TEST

Measurements are to be taken as follows:

 For autotransformer: HV-IV to LV, HV-IV to E, LV to E. q For two winding

transformer: HV to LV, HV to E, LV to E.
 Three winding transformers: HV to IV, HV to LV, IV to LV, HV to E, IV to E, LV to E.
 Oil temperature should be noted at the time of insulation resistance test of the
transformer, since the IR value of transformer insulating oil may vary with temperature. q
IR values to be recorded at intervals of 15 seconds, 1 minute and 10 minutes.
 With the duration of application of voltage, IR value increases. The increase in IR is an
indication of dryness of insulation.
 Absorption coefficient = 1 minute value/15 secs. value.
 Polarization index = 10 minutes value/1 minute value.

DIELECTRIC TESTS OF TRANSFORMER

Dielectric test of a transformer is one kind of insulation test. This test is performed to
ensure the expected overall insulation strength of the transformer. There are several tests
performed to ensure the required quality of transformer insulation; the dielectric test is one of
them. Dielectric test of the transformer is performed in two different steps.

 First one is called Separate Source Voltage Withstand Test of transformer, where a
single-phase power frequency voltage of prescribed level, is applied on transformer
winding under test for 60 seconds while the other windings and tank are connected to the
earth, and it is observed that whether any failure of insulation occurs or not during the
test.
 The second one is the induced voltage test of Transformer where, three- phase voltage,
twice of rated secondary voltage is applied to the secondary winding for 60 seconds by
keeping the primary of the transformer open circuited.

DIELECTRIC TESTS OF TRANSFORMER

The frequency of the applied voltage should be double of power frequency too. Here also
if no failure of insulation, the test is successful. In addition to dielectric tests of transformers,
there are other types of test for checking insulation of transformer, such as lightning impulse test,
switching impulse test and partial discharge test.
INDUCED VOLTAGE TEST OF TRANSFORMER

The induced voltage test of the transformer is intended to check the inter-turn and line end
insulation as well as main insulation to earth and between windings-

 Keep the primary winding of transformer open circuited.

 Apply three-phase voltage to the secondary winding. The applied voltage should be twice
of the rated voltage of secondary winding in magnitude and frequency.
 The duration of the test shall be 60 seconds.
 The test shall start with a voltage lower than 1/3 the full test voltage, and it shall be
quickly increased up to the desired value.
 The test is successful if no breakdown occurs at full test voltage during the test

TEMPERATURE RISE TEST OF TRANSFORMER

Temperature rise test of transformer is included in type test of transformer. In this test,
we check whether the temperature-rising limit of the transformer winding and oil as per
specification or not. In this type test of the transformer, we have to check oil temperature rise as
well as winding temperature rise limits of an electrical transformer.

WHAT IS AN AUTOTRANSFORMER?

An autotransformer (or auto transformer) is a type of electrical transformer with only one
winding. The “auto” prefix refers to the single coil acting alone (Greek for “self”) – not to any
automatic mechanism. An auto transformer is similar to a two winding transformer but varies in
the way the primary and secondary winding of the transformer are interrelated.

AUTOTRANSFORMER THEORY

In an auto transformer, one single winding is used as primary winding as well as

secondary winding. But in two windings transformer two different windings are used for primary
and secondary purpose. A circuit diagram of auto transformer is shown below
COPPER SAVINGS IN AUTO TRANSFORMER

Now we will discuss the savings of copper in auto transformer compared to conventional
two winding transformer. We know that weight of copper of any winding depends upon its
length and cross-sectional area. Again, length of conductor in winding is proportional to its
number of turns and cross-sectional area varies with rated current.

So, weight of copper in winding is directly proportional to product of number of turns

and rated current of the winding.

ADVANTAGES OF USING AUTO TRANSFORMERS

The advantages of an auto transformer include:

 For transformation ratio = 2, the size of the autotransformer would be approximately 50%
of the corresponding size of two winding transformer. For transformation ratio say 20
however the size would be 95%. The saving in cost of the material is of course not in the
same proportion. The saving of cost is appreciable when the ratio of transformer is low,
that is lower than 2. Thus, auto transformer is smaller in size and cheaper.
 An auto transformer has higher efficiency than two winding transformer. This is because
of less ohmic loss and core loss due to reduction of transformer material.
 Auto transformer has better voltage regulation as voltage drop in resistance and reactance
of the single winding is less.

DISADVANTAGES OF USING AUTO TRANSFORMERS

The disadvantages of an auto transformer include:

 Because of electrical conductivity of the primary and secondary windings the lower
voltage circuit is liable to be impressed upon by higher voltage. To avoid breakdown in
the lower voltage circuit, it becomes necessary to design the low voltage circuit to
withstand higher voltage.
 The leakage flux between the primary and secondary windings is small and hence the
impedance is low. This results into severer short circuit currents under fault conditions.
 The connections on primary and secondary sides have necessarily needs to be same,
except when using interconnected starring connections. This introduces complications
due to changing primary and secondary phase angle particularly in the case of delta/delta
connection.
DISADVANTAGES OF USING AUTO TRANSFORMERS

The disadvantages of an auto transformer include:

 Because of common neutral in a star/star connected auto transformer it is not possible to

earth neutral of one side only. Both their sides should have their neutrality either earth or
isolated.
 It is more difficult to maintain the electromagnetic balance of the winding when voltage
adjustment tappings are provided. It should be known that the provision of tapping on an
auto transformer increases considerably the frame size of the transformer. If the range of
tapping is very large, the advantages gained in initial cost is lost to a great event.

THE APPLICATIONS OF AN AUTO TRANSFORMER

The applications of an auto transformer include:

 Compensating voltage drops by boosting supply voltage in distribution systems.

 Auto transformers with a number of tapping are used for starting induction and
synchronous motors. Auto transformer is used as variac in laboratory or where
continuous variable over broad ranges are required

CONVERSION OF 2-WINDING TRANSFORMER INTO AUTOTRANSFORMER

Any two winding transformer can be converted into an auto-transformer either step-down
or step up. In the figure shows such a transformer with its polarity marking. Suppose it is a 20-
kVA, 2400/240 V transformer.

If we employ additive polarity between high voltage and low voltage sides, we get a step-up
auto-transformer. The common current flows towards the common terminal.

If, however, we use the subtractive polarity, we get a step-down auto-transformer. The common
current flows away from the common terminal
PARALLEL OPERATION OF SINGLE-PHASE TRANSFORMER

There are certain definite conditions which must be satisfied in order to avoid any local
circulating currents and to ensure that the transformers share the common load in proportion to
their kVA ratings. The conditions are :

 Primary windings of the transformers should be suitable for the supply system voltage
and frequency.
 The transformers should be properly connected with regard to polarity.
 The voltage ratings of both primaries and secondaries should be identical. In other words,
the transformers should have the same turn ratio i.e. transformation ratio.
 The percentage impedances should be equal in magnitude and have the same X/R ratio in
order to avoid circulating currents and operation at different power factors.
 With transformer having different kVA ratings, the equivalent impedances should be
inversely proportional to the individual kVA rating if circulating currents are to be
avoided.

NEED OF PARALLEL OPERATION OF TRANSFORMERS

The parallel operation of the transformer is needed due to following reasons.

 To supply a load of more ratings to the existing transformer, we need to connect the
second transformer in parallel with the existing transformer.
 At the time of maintenance, a second transformer is used to maintain continuity of supply
to the consumer. It increases the reliability of a system.
 When one transformer is in fault condition or fails to operate due to any reason, the
second transformer is used to supply and avoid intrusion of power.
THREE-PHASE TRANSFORMER

A three-phase electrical system in used to generate and transmit electric power over long
distances for use by offices and industry. Three-phase voltages (and currents) are raised or
lowered by means of three phase transformers as the three phase transformer can have its
windings connected in various ways.

A transformer cannot act as a phase changing device and change single-phase into three-
phase or three-phase into single phase. To make the transformer connections compatible with
three-phase supplies we need to connect them together in a particular way to form a Three Phase
Transformer Configuration.