Unit- IV Testing and trouble shooting of Transformers

4.1 Testing: type, routine and special tests as per IS 2026-1981 for Distribution and Power
transformers.
4.2 Causes of failure: internal and external, types of faults: mechanical, electrical and magnetic
4.3 Trouble-shooting and remedies: trouble shooting charts for single phase and three phase
transformers,
4.4 Foundations: requirements for static machine foundations, factors governing them. Routine Tests
as per IS 2026 & IEC 60076
Routine Tests & Quality Checks for all parameters as per IS & IEC guidelines to meet the highest
quality standards in the industry. 12 types of different Routine Tests as per IS 2026 & IEC 60076.

https://law.resource.org/pub/in/bis/S05/is.2026.1.2011.pdf
https://law.resource.org/pub/in/bis/S05/is.2026.3.2009.pdf

What Is a Transformer?
A transformer is a device used in the power transmission of electric energy. The transmission current
is AC. It is commonly used to increase or decrease the supply voltage without a change in the
frequency of AC between circuits. The transformer works on the basic principles of electromagnetic
induction and mutual induction.

• Step-up Transformer: They are used between the power generator and the power grid. The
secondary output voltage is higher than the input voltage.
• Step-down Transformer: These transformers are used to convert high-voltage primary supply
to low-voltage secondary output.
Core Losses Or Iron Losses
Eddy current loss and hysteresis loss depend on the magnetic properties of the material used for the
construction of the core. So, these losses are also known as core losses or iron losses.
Hysteresis loss in transformer: The reason is the reversal of magnetization in the transformer core.
This loss depends on the volume and grade of the iron, frequency of magnetic reversals and value of
flux density. We have the Steinmetz formula:
Wh= ηBmax1.6fV (watts)
Where, η = Steinmetz hysteresis constant
V = volume of the core in m3

Eddy current loss in transformer: The AC current is supplied to the primary winding which sets
up alternating magnetizing flux in the transformer. When this flux flow to a secondary winding, it
produces induced emf in it. But some part of this flux also gets linked with other conducting parts
such as steel core or iron body or the transformer, which will result in induced emf in those parts,
causing small circulating current in them. This current is called as eddy current. Due to the current,
some energy will be dissipated in the form of heat.

Copper Loss

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The ohmic resistance of the transformer windings creates copper loss. Cu loss is proportional to
square of the current, and current depends on the load. So that copper loss in transformer varies with
the load

Stray Loss: The reason for the types of loss is the occurrence of the leakage field. When compared
with copper and iron losses, the percentage of stray losses are less, so these losses can be neglected.

Dielectric Loss : The oil of the transformer is the reason for this loss. Oil in transformer is an
insulating material. When the oil in the transformer gets deteriorates then the transformer’s efficiency
will be affected.

An electrical transformer is tested at the transformer manufacturer premises and at the consumer’s
site and also periodically in regular and emergency basis during its service life to confirm its
specifications and performance.
Types of Transformer Tests
Tests of transformer done at the manufacturer’s premises −
➢ Type tests
➢ Routine tests
➢ Special tests
Tests of transformer done at the consumer’s site −
➢ Pre-commissioning tests
➢ Periodic tests
➢ Emergency tests
List the tests to be carried out on transformer as per IS-2026. Also state the objective of heat
run
1) Routine Tests of Transformer : The routine tests of a transformer are performed to confirm the
operational performance of the transformer and being performed on every units manufactured.
1. Polarity test
2. Phasing out test
3. Winding resistance test
4. Voltage ratio test
5. Magnetizing current & core loss test (O.C test)( No-load losses and current)
6. Measurement of impedance voltage, S/C impedance & copper loss.(S.C test)
7. Transformer vector group test
8. Dielectric tests (H.V. Test)
a)Separate source AC voltage b)Induced overvoltage c) Lightning impulse tests
9. Oil pressure test on transformer to check against leakages past joints & gasket
10. Test on ON-load tap-changer, where appropriate
11. Measurement of Insulation resistance test

2) Type Test:- Type tests are tests made on a transformer which is representative of other transformers
to demonstrate that they comply with specified requirements not covered by routine tests.
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The type tests of a transformer are performed at the manufacturer’s premises to prove the design
expectations and consumer’s specifications. The type tests are performed in a prototype unit, not in
all manufactured units and these tests confirm the basic and main design criteria of the transformer.
In Type test all Routine tests of transformer are again conducted in addition with following tests.
1. Temperature Rise Test
2. Impulse Voltage Test
3. Noise Level test
4. Vacuum test on Tank & radiator
5. Winding resistance test
6. Voltage ratio test
7. Magnetizing current & core loss (O.C test)( No-load losses and current)
8. Measurement of impedance voltage, S/C impedance & copper loss test on transformer.
9. Vector group test
10. Dielectric tests (H.V. Test)a) Separate source AC volt b)Induce over voltage
c)Lightning impulse test
11. Test on ON-Load tap-changer
12. Measurement of Insulation test
3) Supplementary Tests:-
1. Efficiency test
2. Back to Back test

4) Special Tests: Special tests are tests, other than routine or type tests, agreed between
manufacturer and purchaser, for example
1. Noise Level
2. Harmonics on the no-load current
3. Vibration test
4. Short –circuit with stand test
5. Measurement of zero phase sequence impedance of the 3-ph transformer
6. Dielectric test(H.V. test)( Test with lightning impulse chopped on the tail)
7. Measurement of the power taken by the fans & oil pump motor

Objective of heat run test on transformer:

This test is used to find maximum temperature rise of transformer. See whether the rise in temperature
is as per designed value or not. If not check whether it is within permissible limits or not. And if the
temperature rise is much more in comparison to designed value, the reasons for it is temperature rise
should be determined, necessary modification in design made to obtain results within permissible
limits.
OR To check the with stand capacity of insulation of winding against temperature.
OR If the equipment remains idle for long time the heat run test is carried out before commissioning
of equipment. It is also carried out when the equipment is re-commissioning after maintenance. And

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for machines kept in damp/flooded condition. Heat run test is necessary particularly for high voltage
machines (above 1000V rating)

List out internal and external causes of failure of transformer.

List of Internal causes of Failure of Transformers:
1. Insulation breakdown between winding and earth.
2. Insulation breakdown between different phases.
3. During normal working shot - circuit may occur due to some reasons (e.g. short circuit between
H.V. & L.V.).
4. Some live terminal touches the metallic part hence developing phase to ground fault.
5. Fault between winding and core leads to failure of machine.
6. Failure of magnetic circuit.
7. Some turns of phase windings get shorted.
8. Insulation breaks down between adjacent turns i.e. inter-turn fault.
9. In some unavoidable situation the transformer may have to be run "over loaded" for a longer
period which causes temperature rise beyond the permissible limit. Resulting abnormal operation of
transformer.
10. Single phasing means one of the three phases become open circuited and the load is shared by
only two phases instead of 3 - phases. Hence over loading on phases and behaviour becomes
abnormal.
11. Phase winding may electrically touch each other may create problem.
12. Unbalance loading causes abnormal behaviour of the transformer.
13. Presence of moisture, air bubbles in the transformer oil.
14. Open circuit (either in H.V or L.V).
15. Short circuit (between in H.V and L.V).
16. Ground fault (between H.V and core).
17. Ground fault (between H.V and supporting structure).
18. Shorted turns (either in H.V or L.V).
19. Transformer core fault.

List of External causes of Failure of Transformers:

1. Sometimes in the generating station receiving station / substation there occurs over voltage or
under voltage which affect the normal working of the transformer.
2. High voltage disturbances.
3. Sustained power frequency over voltage disturbances.
4. Lightning surges.
5. Switching surges (there may be always chances of system over voltages due to sudden
disconnection of the large / bulk loads).
6. Travelling waves.
7. Arcing grounds.
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8. Resonance conditions.
9. External short circuit – the short circuit may occur in two or three phases of feeder/ distributor
lines.
10. Sometimes due to wind, rains, birds etc. short circuit occurs in the supply system which affects
working of machine / equipment instantly.
11. If supply system generator working in generating station is subjected change in the speed of prime
mover, then supply frequency changes which affects the working of transformer.
12. Under frequency effect in power transformers i.e. if frequency reduces in a system, flux in the
core changes and causes abnormal operation for the machine / equipment which are supplied by such
transformers.
13. If external load on the transformer is sustained for a length of period, the insulation may start
burning due to excessive temperature rise.
14. A 3- phase machine is supplied with 3 - line wires L.L.L. These are called as lines. If fault is
developed in the feeder / distributor line only two lines will supply the
equipment. The two lines supply power to three phases of transformer & two phases become
excessive of load & over heating take place and transformers condition becomes abnormal.
15. External damage to transformer supply cable, Fault in MCCB, Fault in MCB, damage happened
by mechanical means as accidental breakage of cable etc.

Which electrical tests are carried out before commissioning of transformer?

Following tests are required before commissioning of a transformer.
1. Overall inspection of control & relay panels
2. Tests on relays & alarm contacts
3. Voltage ratio test on all phases.
4. Measurement of earth resistance
5. Test on Buchholz relay
6. Testing of cooling system fans, cooling water pump etc
7. Operation of tap-changing arrangement
8. If required Phasing out test
9. Insulation resistance measurement
10. Oil level in conservator
11. Closing of neutral earthing switch
12. Working of meters on both sides, when transformer is loaded.
13. Operation of No-load tap changing arrangement is checked.

Explain routine preventive maintenance of transformer.

1. External inspection: The transformer should be given an external inspection on a semi-annual basis.
The inspection should include checking the tank, radiators, auxiliary equipment, gasket leakage, and
metal parts for corrosion. Also, the electrical connection should be checked for tightness and
overheating.
2. Auxiliary equipment: Auxiliary equipment required for cooling, such as fans. oil pumps, control
devices, and wiring, should be checked on an annual basis. The equipment should be cleaned and
damaged parts replaced.
3. Pressure-relief device: Most sealed transformers are equipped with pressure-relief devices to
relieve excessive pressure in the tank due to the internal arcing. This device is set to open at a pressure
of 10–15 psi. Routine inspection of pressure-relief devices should include checking for leaks around
joints, diaphragm cracking, and the like. This inspection should be done quarterly.
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4. Protective alarms: Transformers come with various types of alarms, such as over temperature,
liquid temperature, and pressure-relief devices. These are usually open-type contacts that can be
connected to either alarm or trip the circuit breaker. The alarm contact and associated wiring should
be inspected on a monthly basis.
5.Ground connections: The transformer tank is always solidly grounded to eliminate electric shock
per the NEC. The frequency of this inspection and test should be annual.
6. Lightning arrester: When transformers are supplied from overhead line, lightning arresters are used
to protect the transformer from lightning and other surges. Lightning arresters should be inspected
for looseness, broken parts, dirt, and other deposits. All dirt and deposit should be cleaned, loose
connections tightened, and broken parts replaced during this check. The inspection of the lightning
arrestor and its grounding system should be done annually.
7. Protective devices: It is important that protective devices are inspected and maintained on a regular
basis to ensure that these devices will operate in case of transformer malfunction or failure.
8. Liquid level: Liquid level is important since it not only supplies the cooling medium but also
insulates the windings. Any liquid lost by the transformer should be replaced promptly.
OR
1. Breather:- In case of plain breather its ends must be kept clean & ventilation holes free from dust
for proper breathing action. When the colour of silica gel crystal changes from blue to pink than it is
necessary to change the silica gel crystal by new blue colour crystal. (Silica gel crystals are baked at
2000C until it restore blue colour. It is preferable to have a spare charge of silica gel, so that the
breather can be replaced immediately.)
2. Bushing: - Porcelain bushing are cleaned & examined for cracks & chips. Any serious damage will
require replacement of bushing by new one.
3. Oil Level: The oil levels vary with temperature. The oil level can be checked accurately only when
the transformer has been off for some hrs. And if found low top up oil, when oil topped up shall be
of the same make.
4. Gaskets: Gaskets may be replaced if necessary. It is preferable to have in stock a set of spare gaskets
obtained from manufacture.
5. Cooling System: Check the cooling system fans etc, Lubricate the fan bearings and if worn out,
replace it.
6. Oil Sampling: Samples of oil taken from the bottom of the tank through the sampling value or
drain value. The samples of oil should be taken when the transformer is warm & under dry weather
about three litre oil is collected for sample. After taking sample the value is tightly closed. After
taking of sample of oil.
following test of oil should be conducted
i. Crackle Test
ii. Dielectric Strength
iii. Flash point Test
iv. Acidity Test
v. Sludge Test
vi. And oil should be Filter or replace if needed.
7. Oil which is unsatisfactory can be treated; Sludge, dust, dirt, moisture can be removed by filtration.
Or by drying out test.
8. Oil condition of OLTC to be examined in every year. For that, oil sample to be taken from drain
valve of diverter tank, and this collected oil sample to be tested for dielectric strength (BDV) and
moisture content (PPM). If BDV is low and PPM for moisture is found high compared to recommend
values, the oil inside the OLTC to be replaced or filtered.
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9. All connections (of HV & LV side) must be tight. If any dirt dust is accumulated on connection
clean it by metal polish paper.
10. Insulation Resistance: The insulations resistance is measured. Compare with values at the time of
commissioning and processes if required. (It should not be less than 2000 mega ohm for each 1000V
of operating voltage)
11. Move taps changer through all positions a few times; Examine contacts of ON-load tap changers
replace all worn-out & burnt contacts.
12. Set the limit switch in position.
13. Clean glasses on gas relay, thermometer and liquid level indicator,
14. Conservator to be cleaned from inside after every three years.
15. See that the conservator is filled up to the filling oil level marked
16. Check alarm and trip contacts replace all worn-out & burnt contacts.
17. Check the earth resistance. Take suitable action if it is high.
18. Check Condition of relief vent diaphragm, replace if cracked or broken
19. Check Condition of Pressure relief devices
20. All the relays, alarms and control switches along with their circuit, in R&C panel (Relay and
Control Panel) and RTCC (Remote Tap Changer Control Panel) to be cleaned by appropriate cleaning
agent.
21. The pockets for OTI, WTI (Oil Temperature Indicator & Winding Temperature Indicator) on the
transformer top cover to be checked.
22. The calibration of OTI and WTI must be carried once in two years.
23. Tan & delta; measurement of bushings of transformer also to be done once in two years.
24. Internal Inspection:- This inspection involves the internal investigation of the tank and core.
For internal inspection it includes lifting of core & winding from the tank for complete examination
& inspection e.g.
➢ Sludge at the bottom of the tank can be removed.
➢ The megger tests are carried out on the core & coils out of tank.
➢ Tapping switch should be examined.
➢ All bolts used in general assemble should be checked.
➢ Replace gasket by new one.
25. Welding: - Leaking joints can be repaired only by welding.
26. When welding is completed the core & winding are brought back to the tank & refit back as it
was carefully.
27. Paint work: It should be paint at least one time in twice year.
28. Cleanliness in the Substation yard should be done.
29. Lock the rollers for accidental movement on rails.

List the mechanical, magnetic and electrical faults in the electrical equipment
1. Mechanical fault:- A fault which occurs due to mechanical failure in the electrical machines are
called as mechanical fault.
Following are the reasons of mechanical faults:-
1. Warn out bearings
2. Misalignment
3. Rotor unbalance
4. Bent shaft
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 5. Excessive belt pull.
6. Failure of lubricating system
7. Loose foundation
8. Overloaded bearings
9. Out of roundness in a Commutator
2. Magnetic faults: It is internal fault caused by unbalance in magnetic condition.
Following are the reasons of magnetic faults:-
a) Non-uniformity of air gap
b) Short circuit between armature laminations
c) Failure of insulation between core clamping bolts and core
d) Misalignment of poles
e) Non-uniform distribution of magnetic flux
f) Bad contacts of contactor
3. Electrical:
1. Internal Short circuit fault (turn to turn fault)
2. Open circuit fault
3. Ground fault
4. Poor contact in armature winding.
5. Wrong setting of brushes.
6. Overheating of Commutator due to sparking
7. Overvoltage
8. Over frequency
9. Under frequency
10. Single phasing faults:-
Explain the trouble shooting chart of 3 transformers.
Transformers Trouble shooting: ( Any Four Point Expected)
1. Incorrect secondary voltage: This condition can be due to improper turns ratio, abnormal primary
voltage, and/or shorted turns in the transformer.
2. Bushing failure Bushing failure can be caused by flash over due to dirt accumulation and/or
lightning strikes.
3. Internal arcing: Internal arcing can be caused by low liquid level exposing live parts of the
transformer, loose connections, or failure of the transformer dielectric. Usually, internal arcing can
become audible and cause radio interference.
4. Core failure: This condition is due to the failure of core laminations, core, bolts, clamps, and so
on.
5. Over temperature: Over temperature can be caused by an over current, over voltage, I insufficient
cooling, low liquid level, sludge in the transformer liquid, high ambient, or short-circuited core. In
dry-type transformers, this condition can be due to clogged ducts.
6. Winding insulation failure: This is an electrical fault in the transformer winding insulation where
it can involve phase-to-ground, phase-to-phase, three-phase and/or ground, or turn-to-turn-type short
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circuit. The causes for this type of failure may be due to a short-circuit fault, lightning, overload or
over current condition, or transformer liquid containing moisture and contaminants.
7. Pressure-relief diaphragm broken: This is due to an internal fault causing excessive internal
pressures or the transformer liquid level being too high or excessive internal pressure due to loading
of transformer.
8. High exciting current: Usually, high exciting currents are due to short circuited core and/or open
core joints.
9. Low dielectric strength: This condition can be caused by condensation and penetration of moisture
due to improper ventilation, broken relief diaphragm, leaks around transformer accessories, or
cooling coil leakage.
10. Oxidation of oil: Oxidation usually results in the formation of acids and sludge in the transformer
liquid. It is mainly due to exposure to air and high operating temperatures.
11. Discoloration of transformer liquid: Discoloration is mainly caused by carbonization of the liquid
due to switching, core failure, or contaminations.
12. Leakage of transformer liquid: Leakage can occur through screw joints, around gaskets, welds,
casting, pressure relief device, and so on. The main causes are improper assembly of mechanical
parts, improper filters, poor joints, improper finishing of surfaces, defects in the material used, or
insufficient tightness of mechanical parts.
13. Moisture condensation: The main causes for moisture condensation are improper ventilation in
open-type transformers and a cracked diaphragm or leaking gaskets in sealed-type transformer.
14. Gas-sealed transformer troubles: In gas-sealed transformers, additional problems can be the loss
of gas, oxygen content above 5%, or gas regulator malfunctions. These problems are caused by gas
leaks above the oil, leaky valve seats, insufficient gas space, and/or insufficient flushing of gas space
with nitrogen.
15. Transformer switching equipment troubles: Many transformers are equipped with tap chargers
and other switching equipment. The problems associated with these transformers may be excessive
wearing of contacts, mechanism Over travel, moisture condensation in mechanism liquid, and others.
Excessive contact wear is due to loss of contact pressure from weakened springs or contact making
voltmeter set at too narrow a bandwidth or
16. Insufficient time delay. Mechanism over travel usually is due to defective or improper adjustment
of controller contacts. Moisture condensation is due to improper ventilation, and carbonization is due
to excessive operation and lack of filtering. Other problems such as control fuse blowing and
mechanism motor stalling are due to short circuits in the control circuit, mechanical binding, or low-
voltage conditions in the control circuitry.

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MEE 22625 Unit 4 SKBPP EE 17.2.2024
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Prepare the trouble shooting chart for the following troubles in transformer.
i) Zero output voltage ii) Low output voltage iii) Oil temperature is very high iv) Overheating of
transformer winding

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iii) Oil temperature is very high

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Explain any four factors that govern the foundation of transformer.
Ans: Factors that Govern the Foundation of Transformer:
1. Drawings of transformer from foundation design point of view
➢ Dimension of the transformer
➢ Plan dimension transformer base
➢ Its length & width
2. Height of transformer.
3. Information about condition of soil as
➢ Bearing capacity of soil
➢ Soil density
➢ Ground water table location
4. Weight of transformer as
➢ Erection weight
➢ Operating weight
➢ Imposed weight
➢ Accessories weight
5. Transformers centre of gravity location in empty condition and operating condition.
6. Vibration level of transformer.
7. Level of plinth ( it should be above the maximum flood level of the site).
8. Ground water level.
9. Surrounding atmospheric conditions.
List out basic requirements of foundation. (Any four).
Ans: Basic Requirements for the Foundation:
1. The foundation should be strong / rigid preferably of concrete which should be able to
carry the superimposed loads without causing shear or crushing failure.
2. The foundation should be able to withstand against the Weight of machine, Erection weight,
Operating weight, Super imposed load weight and Accessories weight.
3. The foundation should be made of concrete with concrete ratio of 1:2:4.
4. The foundation should be of well cure before installing the machine on it.
5. Depth of foundation should be proportional to the bearing capacity of soil.
6. The surface of foundation must be well protected from the machine etc. by means of
suitable chemical coating or suitable chemical treatment.
7. Level of plinth of foundation should be above the maximum flood level of the site.
8. The location of foundation is such that there should be sufficient space all around the machine.
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9. The combined centre of gravity of machine and foundation should be as far as possible in the same
vertical line as the centre of gravity of the base plane.
10. All amplitudes / settlements / limits should be within permissible limits which are prescribed by
the machine manufacturers.
11. The dimension of foundation should be somewhat more than actual requirements and proportional
to safe bearing capacity of soil.
12. The foundation should be sufficiently rigid to withstand possible horizontal thrust caused
by machine while in operation.
13. The surface of foundation should be perfectly plane to avoid misalignments.
14. The depth of the foundation should be as given in the following table for better operation of
machine.
With the help of neat circuit diagram explain back to back / sumpners test on transformer to
determine efficiency and regulation.
Sumpner's test or Back to back test is a method to find out transformer efficiency, voltage
regulation and temperature rise under loaded conditions. It is regenerative test and hence economical
and very useful.
This test can be employed only when two identical transformers are available. Back to back test, the
two primary windings of the identical transformers are connected in parallel across the supply and
the two secondaries are connected in series with their polarities in opposition.
Wattmeter, voltmeter and ammeter are connected at primary side and at secondary side. If primaries
are energized then the voltage across the two secondaries will be zero since the emfs in them will
cancel each other due to being in phase opposition.
The power input to the two transformers at no-load is indicated by the wattmeter on the primary side.
This power is, equal-to the iron losses of the two transformers as their secondary currents are absent.
An auto-transformer is connected in series with the two secondaries. A small voltage is injected in
the secondary circuit from a separate ac source. It will circulate a current in the secondary side since
the secondary’s are in opposition, the secondary current will cause by transformer action primary
side currents in opposite directions. Thus the total current in the primary local circuit of the windings
is zero.
The reading of wattmeter on primary is not affected and it will indicate only the iron losses of the
two transformers. The auto-transformer is adjusted till the full load current flows in the secondary
side of the transformer. At full load current the wattmeter on the secondary side indicates the full load
copper losses of the two transformers as their winding resistances are in series.

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Procedure :-
1. For this test two identical transformer are required.
2. Primary of two transformers are connected in parallel and secondaries are connected in
series opposition.
3. Supply is given at rated voltage and rated frequency generally to LV winding similar to OC
test.
4. Now supply is given to HV winding with the help of auto-transformer (Regulating
transformer) till full load current is circulated in HV winding similar to short circuit test.
5. To measure the temperature rise two transformers are kept under rated load conditions for
several hours till maximum steady state temperature is reached.

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With the help of neat diagram explain phasing out test to be carried out on transformer.

1. Short primary & secondary winding of

other phases expect the one under test.
2. Connect voltmeter to secondary
winding.
3. A small DC current is circulated
through the primary winding through switch.
4. A small DC current is circulated
through the primary winding through switch.
5. Now with the help of switch interrupt
the DC supply instantly & repeatedly. If
voltmeter indicator deflects than it indicates
the two windings concerned belong to the
same phase. If not deflect then two windings
are not belong to same phase.
6. Repeat the procedure by connecting voltmeter to secondary side to next secondary winding
till voltmeter gives deflection. In this way we can search the phasing out.

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Polarity Test
1. Make the connections as per circuit diagram.
2. Primary terminals are marked A1 and A2.
3. Short A2 and a2 by low resistance wire.
4. Keep terminals B1, B2, C1, C2 remains open.
5. Apply suitable voltage across primary.
6. Measure primary voltage E1,secondary voltage E2 and
voltmeter reading
7. If voltmeter reading is equal to difference of primary
voltageE1 and secondary
voltage E2, then the connected (shorted) terminals are of
same polarity.
8. If voltmeter reading is equal to sum of primary voltage E1
and secondary voltage E2 then the connected terminals are of
opposite polarity.
9. Switch OFF the supply.
10. Repeat the same procedure for other phases of the
transformer.

State the maintenance to be carried out on breather used in transformer.

1. The oil level in oil cap under silica gel breather must be checked in a one-month interval. If it is
found the transformer oil inside the cup comes below the specified level, oil to be top up as per
specified level.
2. Breathing holes in silica gel breather should also be checked monthly and properly cleaned if
required, for proper breathing action.
3. Check whether the air passage of breather is clear and check / clean the dirt, dust accumulated in
the air passage.
4. Daily dehydrate the breather.
5. Daily check the color of silica gel crystal it should be dark blue (dry / healthy condition) but when
it absorbs moisture it becomes pink then replace it.
11. Presence of sludge which is mainly an oxidation product, whose formation is accelerated by
temperature and contact with air.
12. Presence of solid particles.

Explain any four factors that govern the foundation of transformer.

Factors that Govern the Foundation of Transformer:
1. Drawings of transformer from foundation design point of view
➢ Dimension of the transformer
➢ Plan dimension transformer base
➢ Its length & width
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2. Height of transformer.
3. Information about condition of soil as
➢ Bearing capacity of soil
➢ Soil density
➢ Ground water table location
4. Weight of transformer as
➢ Erection weight
➢ Operating weight
➢ Imposed weight
➢ Accessories weight
5. Transformer center of gravity location in empty condition and operating condition.
6. Vibration level of transformer.
7. Level of plinth ( it should be above the maximum flood level of the site).
8. Ground water level.
9. Surrounding atmospheric conditions.
Describe desirable properties of transformer oil (any eight).
1. Dielectric strength or breakdown voltage (BDV):The transformer oil should have high
dielectric strength not less than 40kV (rms) in drums and 30kV (rms) in the tank for gap of
4mm of electrodes.
2. Water Content: Moisture or water content in transformer oil is highly undesirable as it affects
the dielectric properties of the oil adversely. Water content is expressed as Particles Per
Million (PPM) and its permissible value is 50PPM.
3. Acidity Content: The acidity content value should be equal to or less than 0.4mg of KOH /
gm. The oil should be reconditioned if the value of acidity is 0.5 to 1 mg of KOH / gm.
4. Flash Point: It is desirable to have high flash point of transformer oil. In general, it is more
than 160 c.
5. Fire Point: The temperature at which an oil will ignite and continues for burning is the fire
point. This should be about 25% above the flash point so it should be at least of 200 c
6. Chemical Stability: The oil should be chemically stable i. e. should not be affected by
chemicals.
7. Purity: The oil must not contain impurities such as sulphur and its compounds. Sulphur when
present, causes corrosion of metal parts.
8. Viscosity: Good transformer oil should have a low viscosity so that it offers less resistance to
the conventional flow of oil thereby not affecting the cooling of a transformer.
9. Sludging: The remedy is use oil which will not contain Sulphur & which remains without
sludge formation for long period.
10. Density: This indicates the mass of substance per unit volume. As per IS, this should be 0.89
gm / cm
3 maximum.
11. Appearance: The oil should be perfectly clear and has pale clear yellow colour, transparent
and free from suspended matter of sediments.
MEE 22625 Unit 4 SKBPP EE 17.2.2024
 12. Pour Point: It is the lowest temperature expressed on a multiple of 3o at which the oil is
observed to flow when cooled. The oil should have high pour point at least 9c

Explain open circuit and short circuit tests on the single phase transformer and determine its
performance (regulation and efficiency)
Pre-determining the regulation and efficiency of a transformer at any load condition (at any power
factor) is of utmost importance in electrical power system or the relevant industry. Open circuit test
and short circuit test are very economical and convenient methods to predetermine the regulation and
efficiency of high capacity transformer as they are without actually loading of the transformer.
Open Circuit test (O.C. Test): It is used to estimate iron losses, transformation ratio and parameters
of magnetizing branch of equivalent circuit. It is determined by applying rated voltage to the low
voltage winding and keeping the high voltage winding open.
Short Circuit test (S.C. Test): It is to estimate copper losses and parameters of equivalent circuit of a
transformer by applying low voltage to primary winding, just sufficient to circulate rated full load
current or the required load current in the secondary winding, keeping low voltage winding short
circuited.

Open Circuit Test:

1. Make the connection as per the circuit diagram for O.C Test.
2. Set an auto transformer to zero position and switch ON the supply.
MEE 22625 Unit 4 SKBPP EE 17.2.2024
3. Increase the autotransformer output voltage gradually till rated voltage is reached.
4. Note down the readings of voltmeter, ammeter and wattmeter.
5. Bring the autotransformer knob to minimum position and switch OFF the supply.

Short Circuit test:

1. Note down the name plate rating and determine the rated currents for both the windings of given
transformer
2. Make the connection as per the circuit diagram for O.C Test.
3. Set the auto transformer output to zero and switch ON the supply.
4. Increase the autotransformer output voltage very slowly and carefully till rated current
flows through the windings.
5. Note down the readings of voltmeter, ammeter and wattmeter.
6. Bring the autotransformer knob to minimum position and switch OFF the supply.
Routine Tests as per IS 2026 & IEC 60076
Our products go through a regular Routine Tests & Quality Checks for all parameters as per IS &
IEC guidelines to meet the highest quality standards in the industry. We have state-of-the-art Testing
Facilities to carry out 12 types of different Routine Tests as per IS 2026 & IEC 60076.
List of Routine Tests:
1. Measurement of Winding Resistance.
2. Measurement of Voltage Ratio.
3. Measurement of Polarity & Vector Group.
4. Measurement of Short Circuit Impedance.
5. For Measurement of No Load Losses & Current.
6. Measurement of Load Losses.
7. Measurement of Insulation Resistance.
8. Separate Source Ac Voltage Withstand Test.
9. Induce Over Voltage Withstand Test.
10. BDV Of Transformer Oil.
11. Oil Pressure Test.
12. Special Type Tests – We can also test the transformers for Temperature Rise, Noise Level,
Capacitance and Ten Delta, Tank Vacuum & Pressure Test..
MEE 22625 Unit 4 SKBPP EE 17.2.2024
 Some commonly asked question
UNIT 4. Testing and troubleshooting of Transformers Marks 20
1. Describe open circuit test to be carried out on 1KVA, 230/110V transformer with diagram.
2. Prepare the troubleshooting chart (probable reasons and remedies) for single phase transformer
for the following symptoms i) no output voltage, ii) transformer oil overheats,
3. Draw neat diagram of the foundation used for floor mounted transformer
4. Explain the troubleshooting chart for three phase transformer for the following, i) transformer
overheats, ii) excessive humming noise near it, iii) overload relay operated and iv) primary side
fuses blow off
5. Explain separate source voltage withstand test on transformer
6. Explain neat diagrams and expressions open delta method of testing of transformers.
7. Explain with neat diagram the impulse test on a power transformer.
8. List out Electrical and Magnetic faults (each four faults) in transformer.
9. List out internal and external causes of failure of transformer
10. Prepare the trouble shooting chart for the following troubles in transformer. i) Zero output
voltage ii) Low output voltage iii) Oil temperature is very high iv) Overheating of transformer
winding
11. Describe back-to-back test on 1ɸ transformer with neat diagram or Explain the steps to
determine the efficiency and regulation from the results of the back to back test on single phase
transformer with neat diagrams if needed

MEE 22625 Unit 4 SKBPP EE 17.2.2024

MEE 22625 Unit 4 SKBPP EE 17.2.2024