Transformer testing – Learn about all types of tests and variations

Routine tests
Visual Inspection
Winding Resistance Test
Ratio Test
Insulation Resistance Test
Dielectric Tests
Polarity and Phase Relation Test
Excitation Current Test
Leakage Reactance Test
Type tests
Temperature Rise Test
Lightning Impulse Test
Short Circuit Test
Special Tests
Frequency Response Analysis (FRA)
Partial Discharge Test
Vibration Analysis
 Commissioning Tests
Voltage Ratio Test
Magnetic Balance Test
Load Test
Importance of Transformer Testing
Safety
Reliability
Efficiency
Longevity
Preventive Maintenance
Compliance with Standards
Conclusion

Transformer testing is essential for ensuring the safety, reliability, and efficiency of transformers in electrical power systems. By
identifying and addressing potential issues early, these tests help prevent severe consequences and maintain a stable power supply.
This comprehensive process includes various testing stages, each designed to assess specific aspects of transformer performance and
integrity, thereby guaranteeing optimal operation under specified conditions.

Routine tests
Routine tests are essential for ensuring that transformers function correctly and safely under normal operating conditions. These tests
are typically conducted on each transformer unit before it leaves the factory and are also performed periodically during the
transformer’s operational life. Here’s a more detailed look at some of the key routine tests:

Visual Inspection

The objective of the visual inspection is to identify any physical damage, manufacturing defects, or irregularities in the transformer.
During this procedure, the transformer is inspected for dents, cracks, oil leaks, and proper assembly of components. The nameplate is
also checked for accuracy. This inspection can also involve verifying the correct installation of accessories and components, such as
bushings, conservators, and cooling systems, to ensure they meet design specifications.

Winding Resistance Test

The objective of the winding resistance test is to measure the resistance of the transformer windings to detect issues like loose
connections, broken strands, or short circuits. In this procedure, a direct current (DC) is passed through the windings, and the voltage
drop is measured. The resistance is then calculated using Ohm’s Law (R = V/I). Variations in resistance measurements between phases
can indicate issues like uneven winding or improper connections, which can affect transformer performance and efficiency.

Ratio Test

The objective of the ratio test is to verify that the ratio of the number of turns in the primary winding to the secondary winding is
correct. During this procedure, a known voltage is applied to the primary winding and the resulting voltage on the secondary winding is
measured. The ratio of these voltages should match the specified turns ratio. This test also helps to identify issues such as shorted turns
or incorrect winding connections, which can impact the transformer’s ability to step voltage up or down correctly.
Insulation Resistance Test

The objective of the insulation resistance test is to ensure that the insulation between the windings and between windings and the
transformer core or ground is adequate. In this procedure, a high-voltage DC is applied and the resistance is measured using an
insulation resistance tester (megger). The resistance should be high, indicating good insulation. This test helps in detecting insulation
deterioration due to moisture, dirt, or aging, which can lead to insulation failure and transformer breakdown.

Dielectric Tests

The objective of dielectric tests is to verify the dielectric strength of the transformer’s insulation system. There are two types of
dielectric tests: the Dielectric Withstand Test (Hi-pot Test), where a high AC or DC voltage is applied to the windings to check for
breakdown, and the Induced Overvoltage Test, where the secondary winding is excited with a higher frequency voltage to induce a
higher voltage in the primary winding, testing the insulation’s ability to handle overvoltage conditions. These tests are crucial for
ensuring that the transformer can withstand operational and transient voltages without insulation failure.

Polarity and Phase Relation Test

The objective of the polarity and phase relation test is to determine the correct polarity and phase relationship of the transformer
windings. During this procedure, the polarity test ensures that the transformer connections are correct and that it will properly
integrate into the electrical system without causing phase issues. Incorrect polarity or phase relationships can lead to issues such as
circulating currents or phase imbalances, which can cause overheating and damage to the transformer or connected equipment.

Excitation Current Test

The objective of the excitation current test is to measure the current drawn by the transformer primary winding when energized at
rated voltage with no load on the secondary side. In this procedure, the current is measured and compared with the manufacturer’s
specified values to detect abnormalities like core saturation or winding issues. Abnormally high excitation current can indicate
problems such as core defects, improper core assembly, or short-circuited laminations, which can affect transformer efficiency and
operation.

Leakage Reactance Test

The objective of the leakage reactance test is to measure the leakage reactance of the transformer, which affects its voltage regulation
and short-circuit impedance. During this procedure, the secondary winding is short-circuited and a voltage is applied to the primary
winding, measuring the current and voltage to calculate the reactance. Accurate measurement of leakage reactance is important for
ensuring proper transformer performance under load and fault conditions, as it influences voltage drop and fault current levels.

Type tests

Type tests are performed on a prototype unit to validate the design and manufacturing process. These tests are crucial for ensuring that
the transformer’s design meets all specified performance and safety standards before mass production begins. By subjecting a prototype
to rigorous testing, manufacturers can identify and address any potential design flaws or weaknesses. This helps in preventing costly
failures and ensuring the reliability and safety of the transformers in actual service.

Temperature Rise Test

The temperature rise test is performed to determine the maximum temperature rise of the transformer during normal operation. This
test involves running the transformer at its rated load conditions and measuring the temperature of the windings and oil. The objective
is to ensure that the temperature rise does not exceed the specified limits, which can impact the lifespan and reliability of the
transformer. Excessive temperatures can degrade the insulation, leading to premature failure. This test also helps in verifying the
efficiency of the cooling system, whether it be natural cooling (ONAN), forced air cooling (ONAF), or oil-directed cooling (ODAF).

Lightning Impulse Test

The lightning impulse test is designed to simulate the effects of lightning strikes on the transformer’s insulation system. During this test,
high-voltage impulses are applied to the transformer windings to replicate lightning conditions. The objective is to ensure that the
insulation can withstand these high-voltage surges without breakdown. This test is crucial for validating the transformer’s ability to
handle real-world overvoltage conditions caused by lightning strikes. It also helps in identifying any weak points in the insulation
system that could lead to catastrophic failures during service.

Short Circuit Test

The short circuit test is performed to ensure that the transformer can withstand short-circuit conditions without sustaining damage. In
this test, the transformer is subjected to high current levels that simulate short-circuit conditions, and its mechanical and thermal
stability is evaluated. The objective is to verify that the windings and core can handle the mechanical forces generated during a short
circuit without deformation or displacement. This test is essential for confirming the structural integrity of the transformer and its
ability to continue operating reliably after experiencing a fault condition. Additionally, it helps in assessing the performance of
protective devices and systems designed to limit the duration and impact of short circuits.

Special Tests
Special tests are conducted based on specific customer requirements or for diagnostic purposes. These tests are not typically part of
standard testing procedures but are performed to address particular concerns or to ensure the transformer’s performance under
specific conditions. They provide detailed insights into the condition and reliability of the transformer, often aiding in preventive
maintenance and failure analysis. These tests include:

Frequency Response Analysis (FRA)

The Frequency Response Analysis (FRA) test is designed to detect mechanical deformations in transformer windings. During this test, a
range of frequencies is applied to the transformer, and the resulting frequency response is measured. The objective is to identify
changes in the winding structure, such as displacements, deformation, or looseness, which can occur due to mechanical stress, short
circuits, or transportation damage. By comparing the frequency response with baseline data or manufacturer specifications, technicians
can detect anomalies that indicate mechanical issues. FRA tests are highly effective in detecting core movement, winding deformation,
and other structural changes that are not easily identified through other testing methods. It provides a signature or fingerprint of the
transformer’s mechanical structure, which can be monitored over time to detect changes. FRA is a non-invasive and highly sensitive
diagnostic tool, providing valuable information about the internal condition of the transformer without needing to disassemble it.

Partial Discharge Test

The Partial Discharge (PD) test is used to identify localized insulation defects within the transformer. Partial discharges are small
electrical discharges that occur within voids, cracks, or inclusions in the insulation material. During this test, high voltage is applied to
the transformer, and sensitive instruments detect and measure the partial discharges. The objective is to locate and quantify these
discharges, which can be indicative of insulation deterioration or manufacturing defects. Identifying and addressing partial discharges
early can prevent complete insulation failure, which can lead to catastrophic transformer breakdowns. This test is crucial for ensuring
the long-term reliability and safety of the transformer’s insulation system. PD testing is essential for high-voltage transformers, where
insulation integrity is critical. It helps in maintaining the dielectric health of the transformer, ensuring it can withstand operational
stresses without failure. The data from PD tests can be used to predict the remaining life of the insulation and plan maintenance
activities accordingly.

Vibration Analysis

The Vibration Analysis test checks for the mechanical integrity and balance of the transformer. During this test, sensors are placed on
the transformer to measure vibrations while it is operating under normal or simulated conditions. The objective is to detect
abnormalities such as loose components, misaligned parts, or imbalanced forces within the transformer. Excessive or unusual vibrations
can indicate mechanical problems that may lead to further damage if not addressed promptly. Vibration analysis helps in identifying
issues that might not be apparent through electrical testing alone and can be critical in preventing mechanical failures. This test is also
useful in ensuring that the transformer installation meets vibration standards and that it will operate smoothly and quietly in its
intended environment. Vibration analysis can also help in identifying issues related to the transformer’s cooling system, such as
imbalanced fans or pumps, which can affect the overall performance and longevity of the transformer. This test is often conducted both
during the commissioning phase and as part of regular maintenance to ensure ongoing mechanical stability.

Commissioning Tests

Commissioning tests are conducted on-site before the transformer is put into service. These tests ensure that the transformer is
installed correctly and is functioning as expected under actual operating conditions. They provide a final verification of the
transformer’s readiness and performance, ensuring it will operate reliably and safely when energized. Commissioning tests include:

Voltage Ratio Test

The voltage ratio test is performed to verify the transformer’s voltage ratio at different taps. During this test, a known voltage is applied
to the primary winding, and the voltage on the secondary winding is measured at various tap positions. The objective is to ensure that
the transformer provides the correct voltage ratios as specified by the manufacturer. This test confirms that the tap changer operates
correctly and that the transformer can deliver the required voltage levels for different load conditions. Accurate voltage ratio testing
ensures that the transformer can maintain proper voltage regulation, which is crucial for the stability and efficiency of the electrical
system.

Magnetic Balance Test

The magnetic balance test ensures that the magnetic circuit of the transformer is balanced. During this test, voltages are applied to the
primary windings, and the voltages induced in the secondary windings are measured to detect any imbalances in the magnetic circuit.
The objective is to identify any core faults or winding issues that could affect the transformer’s performance. This test is important for
detecting problems such as core defects, shorted turns, or incorrect assembly that might not be evident through other tests. Ensuring a
balanced magnetic circuit helps in maintaining the efficiency and stability of the transformer, reducing the risk of overheating and other
operational issues.

Load Test

The load test involves testing the transformer under actual load conditions to ensure proper performance. During this test, the
transformer is connected to a load, and various parameters such as voltage, current, and temperature are monitored to assess its
performance. The objective is to confirm that the transformer operates efficiently and reliably under its rated load conditions. This test
helps in identifying issues such as overheating, improper load sharing, and voltage drops that can affect the transformer’s performance
in real-world conditions. Conducting a load test ensures that the transformer can handle the expected operational demands and
provides an opportunity to verify the proper functioning of protective devices and cooling systems.

Importance of Transformer Testing

Safety

Ensuring the transformer operates safely without posing any risk of electrical hazards is paramount. Transformers are critical
components in power systems, and any failure can lead to severe consequences, including electrical fires, explosions, or shocks. By
conducting thorough testing, potential hazards such as insulation breakdown, overheating, or mechanical failures can be identified and
mitigated. Safety testing ensures that all components and materials used in the transformer meet stringent safety standards and
regulations, thus protecting personnel, property, and the environment from electrical accidents.

Reliability

Confirming the transformer performs reliably under specified conditions is essential for the stability of the power system. Reliability
testing helps to verify that the transformer can withstand various operational stresses, such as load changes, voltage fluctuations, and
environmental conditions. Reliable transformers ensure uninterrupted power supply, which is crucial for industrial processes,
commercial operations, and residential services. Regular testing and maintenance also help in predicting and preventing potential
failures, thereby minimizing downtime and maintenance costs.

Efficiency
Ensuring optimal performance and efficiency of the transformer is crucial for reducing energy losses and operational costs. Efficiency
tests evaluate the transformer’s ability to convert electrical energy with minimal losses, which directly impacts the overall efficiency of
the power system. An efficient transformer reduces operational costs by lowering energy losses and improving power quality. Regular
efficiency testing also helps in identifying issues such as core losses, winding resistance, and improper cooling, which can degrade
performance over time. Optimizing transformer efficiency contributes to energy conservation and sustainability efforts.

Longevity

Detecting and addressing potential issues early to extend the lifespan of the transformer is a key benefit of comprehensive testing.
Regular testing allows for the early identification of problems such as insulation degradation, mechanical wear, and thermal issues that
can shorten the transformer’s lifespan. By addressing these issues promptly through maintenance or repairs, the overall lifespan of the
transformer can be significantly extended. This not only ensures a better return on investment but also reduces the frequency of
replacements and associated costs. Proactive testing and maintenance strategies help in maintaining the health and performance of
transformers throughout their operational life.

Preventive Maintenance

Transformer testing forms the backbone of preventive maintenance programs, helping utilities and industries avoid unexpected failures
and costly emergency repairs. By regularly monitoring the condition of transformers, operators can schedule maintenance activities
during planned outages, minimizing disruption to the power supply.

Compliance with Standards

Ensuring transformers comply with national and international standards (like IEC, IEEE, and ANSI) through rigorous testing helps
manufacturers and users meet regulatory requirements. This compliance is essential for certification, market acceptance, and
operational approval in different regions.

Conclusion

The rigorous process of transformer testing is indispensable for maintaining the health and functionality of power systems. Through
detailed assessments, ranging from visual inspections to advanced diagnostic tests, potential issues can be detected and resolved early,
ensuring the transformer operates safely and efficiently. This not only extends the transformer’s lifespan but also enhances the overall
reliability and efficiency of the electrical grid. By investing in thorough testing procedures, the power industry can prevent costly
failures, ensure regulatory compliance, and deliver consistent, high-quality power to consumers.

At TTES, we have over 100 combined years of experience manufacturing, maintaining, and repairing transformers. If you’re looking for
industry-leading lead times of just 20 weeks on average, don’t hesitate to reach out to us for a free quote
Table Assessment of Transformer in Industrial park development corporation

S/n Name of Number of Models Power Total Total Cooling Status Number
parks transformer capacity load load or of DG
in kva delivered consume insulation
1. Adama
2 Bahirdar
3 Bole Lemi
-1
4 Bole Lemi
-2
5 Debrebirh
an
6 DireDawa
7 Hawassa
8 Jimma
9 Kombolch
a
10 Kilinto
11 Semera
12 Mekelle
13 Arerti

- When choosing a transformer, it is important to determine the appropriate capacity based on the load of the
actual power system. This can be done by considering factors such as
the nature of electricity consumption,
 Electric power consumption refers to the amount of electrical energy used over a specific period, as shown by the
plots of average monthly consumption in different regions. It varies seasonally, with peaks in summer months due to
increased demand for cooling, such as air-conditioning.
load conditions,
the number and capacity of electrical equipment.