International Journal of Engineering Innovation & Research

Volume 4, Issue 3, ISSN: 2277 – 5668

Pre-Commissioning Tests and Functionality Assessment

of a Bulk Power Transformer
Peter Michael Enyong
Department of Electrical/Electronic Engineering Technology;
Auchi Polytechnic, Auchi, Nigeria;
Email: [email protected]

Abstract – A step-up bulk-power transformer had just been winding transformer installed by MELCO (Nig.)
installed for the Unit 1 of Egbin Thermal Power Plant in the LIMITED in 1985 for Unit 1 of the Egbin Thermal Power
Lagos area, Nigeria. It was required by due practice to Plant, Lagos. Such a transformer is otherwise called
ascertain that it was in good functional condition and that it generator transformer; the name which arises from the
was installed to international standards. In this paper, the
practice that it is always located as close to the associated
author presents details of the physical inspection and thirteen
tests that were carried out. The observations from inspection generator as possible, in order to transfer bulk power from
and the results of the tests were analyzed with a view to the generator to a given transmission line system [1]. After
ascertaining the condition and availability of the equipment it was successfully installed it had to be thoroughly
for service delivery. The analysis indeed proved the power inspected and tested before putting it into service.
transformer to have satisfied international standards in By way of organization of the paper, the next section
virtually all aspects of the transformer tests considered and shall deal with General Physical Inspection Exercise; to
that it did not suffer defects arising from transportation be followed by the third section entitled Actual Pre-
hazards. To that extent the equipment was properly installed Commissioning Test Exercises; whilst the fourth and final
only that it yielded over 50% excess resistance than the
section takes care of Summary and Conclusion.
factory stipulated (reference) resistance on the high voltage
side which was, however, not satisfactory.
II. GENERAL PHYSICAL INSPECTION EXERCISE
Keywords – Bulk Power Transfer, Transformer Tests.
Details of the various aspects of the apparatus inspected
I. INTRODUCTION and the observations made are as given in Table I(a).

The step-up bulk-power transformer in question was a

270MVA, 16/330kV, 50Hz, YNd1 MITSUBISHI two-

Table I(a): Record of observations from general physical inspection/check

S/No. ASPECTS OF INSPECTION/CHECK FINDINGS REMARKS
1 Bushing oil level Bushings filled up to mark Good
2 Transformer oil level Conservator oil level indicator pointer on 35 o Good [2]
3 Fitting of accessories Accessories in their proper positions and due Good
directions
4 Condition of fitted accessories No dents, no caving in, no misalignment Good
5 Tightness of fastenings Torque wrench tightness sound heard when Good
applied [see Table I(b)]
6 Signs of transformer oil leakage No dripping from flanges and corks, no oil Good
marks on tank walls, plinth or ground
7 Positions of valves Valves in their correct operational positions Good
8 Condition of insulators No cracks, no chippings-off, no breakage Good
9 Condition of breather Silica-gel bright blue, oil-seal in place with Good [3]
correct oil level
10 Earthing connections HV neutral point & equipment body all duly Good
connected to earth.
11 Equipment painting Cement Gray oil-paint applied Good [3]
12 Condition of transformer immediate Tidy surrounding Good
surrounding

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Table I(b): Recommended Torque for various Sizes of 100Megohms; whereas, IR values of 10 to 100Megohms
Spanner, Bolt and Nut [4] are indicative of deteriorating insulation between the core
S/ SPANNER BOLT/NUT TORQUE and ground. For the windings generally IR values of
No. SIZE SIZE (Nm) 600Megohms and above are acceptable for transformers
i M08 M05 5.7 rated 10MVA and above [6]. Hence, the transformer of
ii M10 M06 7.9 this work did possess good IR property.
iii M13 M08 17 B. Core & Winding Polarization Index (PI) Test.
iv M17 M10 28 This test was effected under the same condition as in (a)
v M19 M12 45 above. The same apparatus and method was used, only
vi M22 M14 61 that the 5kV(d.c.) was applied for 10 minutes in each case
vii M24 M16 91 here.
viii M30 M20 136 Test Results:
ix M32 M22 170 (i) Core-to-Earth = 1628Megohms
x M36 M24 125 (ii) HV-to-Earth = 2090Megohms
(iii) LV-to-Earth = 1700Megohms
(iv) HV-to-LV = 2566Megohms
III. ACTUAL PRE-COMMISSIONING TEST
Analysis:
EXERCISES Polarization Index (PI) = {10 min IR value}/{1 min IR
value}. Very good PI values are usually above 2.0 [7].
The actual pre-commissioning exercises involving But, the limit of acceptable values is 1.6 as in [8]. The
various tests carried out on the generator transformer Egbin Station generator transformer gave PI values of not
yielded results as detailed in the subsections that follow. less than 1.6 which is good enough.
A. Core & Winding Insulation Resistance (IR) Test. C. Turns Ratio Test Exercise.
The test was carried out at an Oil Temperature of 28 oC This involved the use of Transformer Turns Ratio Test
by applying 5kV(d.c.) for 1 minute in each case using a Set (Make – KEIHIN DENSOKKI, Type – TR 10).
5kV Megger Insulation Tester (Make – Yew, Type –
Test Results:
3213).
Results of the exercise were as presented in Table II
Test Results:
(i) Core-to-Earth = 1005Megohms
Analysis:
(ii) HV-to-Earth = 1254Megohms The percentage deviation from the rated turn ratio, Trated,
(iii) LV-to-Earth = 1030Megohms should be within ± 0.5% [9].
(iv) HV-to-LV = 1510Megohms However, acceptable values of %deviation extend up to
±1.0% according to [10]. It is therefore clear from Table II
Analysis:
that the transformer turns were produced to standard
As in [5], a new transformer should give Core-to-Earth
judging from the maximum %deviation from tap to tap.
IR value greater than 1000Megohms; a service-aged
transformer should give a value greater than

Table II: Results of the Turns Ratio Test Exercise

Turns Ratio as Measured Rated Turns Max ± (%)
Tap Tap Voltage (H1-H0)/ (H2-H0)/ (H3-H0)/ Ratio (Trate) Deviation
Pos. (x1-x2) (x2-x3) (x3-x1) from Trate
1 (346.50/√3)/16.0 12.523 12.535 12.535 12.504 + 0.248
2 (338.25/√3)/16.0 12.235 12.236 12.236 12.206 + 0.246
3 (330.00/√3)/16.0 11.961 11.955 11.957 11.908 + 0.445
4 (321.75/√3)/16.0 11.660 11.663 11.668 11.610 + 0.500
5 (313.50/√3)/16.0 11.381 11.383 11.383 11.312 + 0.628

D. Voltage Vector Relationship Test Exercise. Table III: Results of the Voltage Vector Test Exercise
AVO Multi-meter Model 8MK.V was use in conducting Test Voltage Terminals
this test. Winding Applied Linked
Test Results: H.V. 420V H1-to-x1
Results of the exercise were as presented in Table III. (a.c.)
Measured Voltage
Between Between Between Between
H2 & x2 H2 & x3 H3 & x2 H3 & x3
405V 435V 405V 405V
(a.c.) (a.c.) (a.c.) (a.c.)

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Analysis: Table IV: Results of the Dissipation Factor Test Exercise

The magnitude of measured voltages between the WINDING VALUES OBTAINED
stipulated terminals in Table III should show the S/ CONNECTIONS
relationship given in [11] as No. DURING TEST tan δ Capacitance
(H2-x3) > TEST VOLT > (H2-x2) = (H3-x2) = (H3-x3) (%) (uF)
Consider the arbitrary Yd transformer winding 1 HV-to-(LV&E) 0.70 0.041
configuration in Fig.1(a) where H1 and x1 terminals are 2 LV-to-(HV&E) 0.48 0.059
short-circuited. The condition or equation stated above can 3 HV-to-LV 0.70 0.036
only be realized when the equilateral triangle representing (NB: HV=High voltage Winding; LV=Low voltage
the LV winding rotates clockwise through 30 o in order to Winding; E=Earth or ground).
assume the position in Fig.1(b).
Table V: DF Correction Factor for Various Temperatures
[15]
TEST CORR. TEST CORR.
TEMP. FACTOR TEMP. FACTOR
(oC) (K2) (oC) (K2)
10 0.80 45 1.75
15 0.90 50 1.95
20 1.00 55 2.18
25 1.12 60 2.42
30 1.25 65 2.70
Fig.1. (a): Arbitrary Yd Configuration 35 1.40 70 3.00
40 1.55

The following equation, DF(20) = DF(θ)/K2,

demonstrates the application of the correction factor;
where DF(20) and DF(θ) are DF values at 20oC and Test
Temperature in oC, respectively. Thus, for our test
temperature of 30oC the DF values corresponding to the
reference temperature of 20oC are: 0.384 for the LV-to-
(HV&E) test and 0.56 for both HV-to-(LV&E) and HV-to-
LV tests. Obviously, the second DF value of 0.56 is not
satisfactory.
F. Transformer Winding Resistance Test Exercise.
The ammeter-voltmeter method was adopted as in [16],
Fig.1. (b): Actual Yd1 Configuration being reflected in Fig. 2(a) for the HV winding resistance
test exercise; whilst Fig. 2(b) summarizes that of the LV
Consequently, the chief criterion is that the LV voltage winding.
(and current) vectors must lag those of the HV by 30 o [12,
13]. As the readings in Table III actually satisfy the given
equation, the transformer has proved itself truly a Yd1
power transformer.
E. Dissipation Factor Test Exercise.
The dissipation factor is also referred to as insulation
power factor or tangent delta all of which point to material
dielectric loss [14]. Schering Bridge (Make – HISSIN
DENKI, Type – SH/M) was used; the Oil Temperature
Fig.2. (a): Ammeter-Voltmeter Method of DC Resistance
during test being 30oC.
Measurement for the HV Winding
Test Results:
Results of the exercise were as presented in Table IV.
Analysis:
Dissipation factor, DF, is very sensitive to temperature;
its value not changing with applied voltage. Thus, the
average oil temperature at the time of testing must be
recorded. However, the reference temperature commonly
used is 20oC and correction factors need to be applied
when testing at different temperatures [9]. Table V
Fig.2. (b): Connections for DC Resistance Measurement of
provides the applicable correction factors at various
the LV Winding
temperatures.
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Directly, R = Vo/Io for the HV winding. But, by Rm(HV) = Rr(HV){(Tm+234.5)/(Tr+234.5)}

inspection, it can be seen that Vo/Io = 2R/3 in the case of = 0.35272{(28+234.5)/(10.2+234.5)
the LV winding. Hence, R = 1.5(Vo/Io). = 0.37838
For each measurement the steady-state resistance value
where Tm is the test temperature, whilst Tr is the factory
was obtained by leaving the set-up for 5 – 10 minutes
reference temperature. This is to be compared with the
before taking readings of Vo and Io. The transformer oil
average resistance of all the three phases for each tap
temperature was 28oC on the average. D.C. ammeter and
position which has been computed and presented in Table
voltmeter; rheostat; toggle switch; D.C. source were chief
VII (short Table).
among the apparatus used.
It is clear that the average measured winding resistance
Test Results: per tap position is over 1.5times the factory reference
Results of the exercise were as presented in Table VI. resistance. This realization is really not satisfactory. But,
Analysis: the actual standard criterion for judgment which matters
The factory test results available (as reference data in most is that the measured resistance for a phase winding
this perspective) were should not deviate more than ±2% from the average
(1) Rr(HV) = 0.35272 ohm @ 10.2oC (oil temp.) for H1-H0 resistance of all the three phases on a given tap position,
on Tap Position No.1. for a good enough result [6]. However, the very maximum
(2) Rr(LV) = 0.002553 ohm @ 10.2oC (oil temp.) for x1-x2. acceptable deviation is ±5% [5, 7]. In all these the
For the purpose of comparison the corresponding transformer measured phase winding dc resistance values
value of Rr(HV) for 28oC which may be designated as were quite unsatisfactory.
Rm(HV), shall be computed using a formula obtainable
from [5] and given here as

Table VI: Results of the HV Winding Resistance Test Exercise

Tap Pos
Winding 1 2 3 4 5
Vo = 0.420 Vo = 0.415 Vo = 0.408 Vo = 0.409 Vo = 0.391
H1-H0 Io = 0.727 Io = 0.730 Io = 0.730 Io = 0.749 Io = 0.735
R = 0.578 R = 0.568 R = 0.559 R = 0.546 R = 0.531
Vo = 0.421 Vo = 0.413 Vo = 0.409 Vo = 0.442 Vo = 0.399
H2-H0 Io = 0.726 Io = 0.727 Io = 0.731 Io = 0.799 Io = 0.735
R = 0.580 R = 0.568 R = 0.560 R = 0.553 R = 0.543
Vo = 0.421 Vo = 0.414 Vo = 0.437 Vo = 0.434 Vo = 0.397
H3-H0 Io = 0.726 Io = 0.728 Io = 0.780 Io = 0.790 Io = 0.735
R = 0.580 R = 0.569 R = 0.560 R = 0.549 R = 0.540
Oil Temp. 26oC 26oC 28oC 28oC 30oC

(NB: Values of R include the d.c. resistance of the connecting leads. The LV d.c. winding resistance was, however, not
measured during the exercise).

Table VII: Average Resistance of all the Three Phases for each Tap Position
Tap Pos
Winding 1 2 3 4 5
HV 0.628Ω 0.621Ω 0.633Ω 0.630Ω 0.603Ω

G. Auxiliary-Circuit Insulation Resistance Test Analysis:

Exercise. For electrical equipment or circuit rated below 1000V
Auxiliary circuits on a bulk power transformer are the insulation resistance (IR) value should be above
circuits associated with the equipment local protection, 5Megohm when measured with a 500V tester for 1 minute
metering and control devices. They often involve intricate [7]. The prevailing temperature here should be within
cabling works and meant for no more than 440V 3-phase room temperature, which is roughly 28 oC on the average
or 240V single-phase supply as the case may be. Oil in Nigeria. Thus, as reflected in Table VIII where the least
Temperature was 28oC and the duration of injection of d.c. IR value is 10 MΩ, it can be seen that the auxiliary circuits
was 1 minute in each case. A 500V Megger Insulation gave very good readings.
Tester (Make – Yew) was used.
Test Results:
Results of the exercise were as detailed in Table VIII.

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Table VIII: Record of Insulation Resistance (IR) Readings of Auxiliary Circuits

S/ DESCRIPTION OF READINGS
No. AUXILIARY CIRCUIT Phase-to-Earth Phase-to-Phase
1 Main Power Supply Circuit 100 MΩ 200 MΩ
2 Cooling Fan Circuits
i) Groups 1 & 2 fan circuits 10 MΩ each --
ii) Two-fan circuit 200 MΩ --
iii) One-fan circuit 950 MΩ --
3 Winding Temperature Thermometer
i) Alarm system circuit 100 MΩ --
ii) Trip system circuit 30 MΩ --
4 Oil Temperature Thermometer
i) Alarm system circuit 45 MΩ --
ii) Trip system circuit 50 MΩ --
5 Oil Level Indicators
i) Conservator oil level indicator circuit 100 MΩ --
ii) On-load tap-changer oil level indicator circuit 30 MΩ
6 Sudden Pressure Relay Circuit Pressure Relay not
connected --
7 Buchholz Relay
i) Alarm system circuit 1000 MΩ --
ii) Trip system circuit 1000 MΩ --
8 Pressure Relief Device Circuit 1000 MΩ --

H. Bushing Current Transformer (BCT) Insulation I. Bushing Current Transformer Polarity Test
Resistance Test Exercise: Exercise:
The same test equipment and method as applicable to The induction-kick method with d. c. voltage was used
the auxiliary-circuit insulation resistance test exercise as shown in the apparatus arrangement of Fig. 3(a); whilst
above were used here. Fig.3(b) shows details of the BCT winding per phase (the
Test Results: 1st in this case).
Results of the exercise were as presented in Table IX.
Analysis:
A table of insulation resistance values and the associated
voltages is given in [17] which is tailored here to suit the
purpose of this test as it is acceptable generally for all
electrical equipment (see Table X); the applicable test
temperatures of 25oC through 30oC ( or a rough average of
28oC) having been considered appropriate to that effect .
Table X: Acceptable Values of Insulation Resistance
obtained during Tests [7]
EQUIPMENT TEST ACCEPTABL Fig. 3(a): Apparatus setup for the Polarity Test Exercise
S/ RATED VOLTAGE E READING
No. VOLTAGE (Vdc) (MΩ)
1 <1000Vac 500Vdc >5
2 1000 to 2500Vac 1000Vdc >100
3 2501 to 5000Vac 2500Vdc >100
4 >5000Vac 5000Vdc >100

Since the test voltage in this case was 500Vdc it follows

that the generator transformer gave an excellent value of
insulation resistance. Fig. 3(b): Details of the 1st B.C.T per Phase

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Test Results: J. Bushing Current Transformer Winding Resistance

Results of the exercise were as presented in Table XI. Test Exercise.
Table XI: Results of the Polarity D. C. Test The resistance bridge method was adopted. The average
GALVANOMETER (G) DEFLECTION oil temperature was 30oC. In each case the apparatus setup
B.C.T was allowed to stabilize before reading was taken. A
Secondary 1x1‒1x5 2x1‒2x5 3x1‒3x5 Wheatstone Bridge Set (Make ‒ YEW, Type ‒ 2755) was
Transformer used.
Phase Test Results:
RED PHASE (+) (+) (+) Results of the exercise were as presented in Table XII.
YELLOW (+) (+) (+)
Analysis:
The measured secondary winding resistance of a B.C.T
PHASE
may be considered good if it does not deviate more than
BLUE PHASE (+) (+) (+)
±2% from the average secondary winding resistance of all
No 3rd
the three related phase B.C.T’s.
NEUTRAL (+) (+) Neutral
The same assessment yardstick applies to a neutral
B.C.T
B.C.T. This follows the general standard in [6] for the
winding resistance of 3-phase transformers which
Analysis: stipulates that the measured resistance for a phase
The transformer as reflected in Fig.5 is of subtractive winding should not deviate more than ±2% from the
polarity [16]. With the switch, S, in the ON position, the average resistance of all the three phases on a given tap
galvanometer did give a (+) deflection. This was indicative position.
of the fact that the B.C.T in question was of the right
polarity marks [16].

Table XII: Results of the B.C.T Secondary Winding Resistance Test

B.C.T ASPECT OF B.C.T SECONDARY WINDING RESISTANCE (Ω)
SERIAL SECONDARY RED YELLOW BLUE THE
NUM-BER WINDING TESTED PHASE PHASE PHASE NEUTRAL
1x1‒1x5 6.454 6.513 6.527 6.566
1 1x2‒1x5 5.314 5.375 5.386 5.417
1x3‒1x5 2.867 2.902 2.919 2.919
1x4‒1x5 1.863 1.892 1.913 1.900
2x1‒1x5 6.504 6.540 6.532 6.552
2 2x2‒1x5 5.366 5.411 5.392 5.402
2x3‒1x5 2.904 2.936 2.910 2.912
2x4‒1x5 1.888 1.917 1.904 1.897
3x1‒1x5 4.828 4.890 4.906 No 3rd Neutral
3 3x2‒1x5 4.009 4.066 4.095 Bushing Current
3x3‒1x5 2.201 2.252 2.287 Transformer
3x4‒1x5 1.455 1.501 1.530 (B.C.T)
NB: Results include the inevitable resistance of the control cables between the control
cabinet and the transformer bushings.

K. Bushing Current Transformer Magnetization Test rated 1Amp, it was mandatory to use a step-up interposing
Exercise. transformer in order to obtain the necessary voltage for
A variable voltage supply was connected across the proper assessment of the magnetizing curve [18].
terminals of the full length of a given B.C.T secondary Moreover, the average oil temperature at the time of
winding and the current measured at different voltage testing was 30oC. Among the apparatus used were: 0 –
values using a suitable ammeter. It is important to note 260V variable auto-transformer; 220/6600V 1-phase step-
that the ammeter was connected absolutely in series with up transformer; 6600/110V single-phase potential
the B.C.T winding to avoid reading the voltmeter branch transformer; 0 – 1A moving-iron ammeter; 0 – 200V
current, which in some cases could be of the same order of voltmeter.
the B.C.T magnetizing current [17]. As the magnetizing Test Results:
current was not going to be sinusoidal, an ammeter of the Results of the exercise were as presented in Table XIII.
moving-iron type was used [18]. And it is often found that Analysis:
current transformers with secondary ratings of 1Amp or It can be observed from Table XIII that the magnetizing
less do have a knee-point voltage higher than the local currents for the same input voltages are close to one
mains supply [18]. Hence, the B.C.T secondary being another in respect of the No.1 and No.2 sets of B.C.Ts on
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all the phases and neutral. Taking average current of both phases, an average value can be taken in each case (see
sets of B.C.Ts, values of current are obtained applicable to Table XV) for the purpose of plotting one magnetizing
both sets as given in Table XIV for the purpose of curve for this set. Figure 4 shows the curves for the Nos.1
generating magnetizing curves (i.e. 4 in number) common & 2 B.C.T sets; whilst Fig. 5 reflects the one curve for
to both B.C.T sets. Also, as the currents for No.3 set of No.3 B.C.T set. MATLAB was used in accomplishing the
B.C.Ts are not too different from one another on all the plots.

Table XIII: Results of the B.C.T Magnetization Tests

B.C.T FULL RED YELLOW BLUE THE
SECONDRAY PHASE PHASE PHASE NEUTRAL
WINDING V mA V mA V mA V mA
0 0 0 0 0 0 0 0
400 11 400 11 400 11 400 5
1x1‒1x5 600 13 600 13 600 14 600 10
For No.1 700 15 700 15 700 15 700 12
B.C.Ts 800 16.5 800 17 800 17 800 15
900 21.5 900 24 900 21 900 22
1000 47 1000 55 1000 52 1000 36
1100 288 1100 290 1100 290 1100 230
0 0 0 0 0 0 0 0
400 11 400 11 400 11 400 6
2x1‒2x5 600 13 600 13 600 14 600 8
For No.2 700 15 700 15 700 15 700 10
B.C.Ts 800 17 800 17 800 19 800 13
900 26 900 24 900 30 900 18
1000 65 1000 53 1000 71 1000 33
1100 450 1100 300 1100 410 1100 230
0 0 0 0 0 0 No 3rd Neutral
3x1‒3x5 200 10 200 11 200 10 Bushing
For No.3 300 15 300 14 300 13 Current
B.C.Ts 400 23 400 23 400 19 Transformer
500 65 500 65 500 52 (B.C.T)
600 657 600 690 600 680

Table XIV: Average Magnetizing Currents relative to Nos.1&2 BCT Sets

B.C.T FULL RED YELLOW (Y) BLUE THE
SECONDRAY (R) PHASE PHASE (B) PHASE NEUTRAL
WINDING V mA V mA V mA V mA
0 0 0 0 0 0 0 0
(x1‒x5) 400 11 400 11 400 11 400 5.5
For both 600 13 600 13 600 14 600 9
No.1 and No.2 700 15 700 15 700 15 700 11
B.C.Ts 800 16.75 800 17 800 18 800 14
900 23.75 900 24 900 25.5 900 20
1000 56 1000 54 1000 61.5 1000 34.5
1100 369 1100 295 1100 350 1100 230

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Fig.4(a) Magnetizing Curve For B.C.Ts Nos.1&2 on the

Red Phase Fig.4(d) Magnetizing Curve For B.C.Ts Nos.1&2 on the
Neutral

Table XV: Average Magnetizing Currents relative to No.3

BCT Set
No.3 FULL SECONDARY WINDINGS
B.C.Ts (x1‒x5)
V 0 200 300 400 500 600
mA 0 10.5 14 21 58.5 675.7

Fig.4(b) Magnetizing Curve For B.C.Ts Nos.1&2 on the

Yellow Phase

Fig.5. Magnetizing Curve for No.3 B.C.Ts on all the

Phases

It is to be realized that the performance requirements of

a B.C.T, like any other current transformer, are often
specified in terms of the knee-point voltage [19]. The
knee-point voltage of the excitation or magnetization
characteristics or curves is the point at which 10% further
increase in the voltage applied to the current transformer
secondary will produce a 50% increase in the exciting or
magnetizing current flow [17]—[19]. Thus, beyond the
knee-point the current transformer becomes saturated.
By inspection of the magnetizing curves in Fig.4 (a, b, c
Fig.4(c) Magnetizing Curve For B.C.Ts Nos.1&2 on the & d), the knee-point voltage of each curve is being
Blue Phase stipulated as 1000V, with a reasonable degree of accuracy.
Similarly, the knee-point voltage of the magnetizing curve
in Fig. 5 has been specified as 500V.
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L. Buchholtz Relay Function Test Exercise. sufficiently capable of withstanding the expected stresses
The ALARM CONTACTS were tested by supplying of the transformer rated voltages.
nitrogen gas through the gas sampling valve into the top N. Dial Oil & Winding Temperature Thermometer
chamber and the TRIP CONTACTS were tested by Test Exercise
releasing the pressure (of about 0.15Kg/cm2) from the top The indicator bulb of the dial thermometer was
of the transformer, thus causing a pressure surge. A hand suspended in an oil bath together with an accurate mercury
pump was used. thermometer; care being taken to avoid their touching the
Test Results: side or bottom of the container.
Alarm contacts made at the right level of oil fall in the Hotplate was used to heat the oil while stirring and the
upper chamber with 450cm3 of gas. Trip contacts made in readings of the two thermometers were taken as the
the lower chamber following the pressure surge created. temperature increased. Oil bath test kit (Qualitrol),
Analysis: hotplate, mercury thermometer were thus chief amongst
Buchholz alarm and trip systems observed to be the apparatus used.
functional judging from the test results. Test Results:
M. Transformer Oil Dielectric Strength Test Results of the exercise were as presented in Table XVII.
Exercise. Analysis:
For this exercise, five samples of the oil were taken with The error temperature for any of the dial thermometers
oil-sampling bottles that were rinsed many times with the should be within ±5oC [5]. Thus, both dial thermometers
same transformer oil and a small amount of the oil was were in good working condition.
first made to flow out of the tap and run to waste before
samples were then taken. The electrode gap was set to IV. SUMMARY & CONCLUSION
2.5mm. The SANMI Oil Tester, No.JIS C2101, Range 0 –
60kVdc was used. The test voltage (dc) was applied A. Summary
gradually each time within 1 minute. From the physical inspection report as detailed in Table
Test Results: I(a), the transformer was satisfactory in terms of external
Results of the exercise were as presented in Table XVI. facility and surrounding conditions. The thirteen test
Table XVI: Results of the Oil Dielectric Strength (DS) exercises covered in this paper include: (1) core &
Tests winding dielectric property test (2) turns ratio test (3)
SAMPLES 1 2 3 4 5 voltage vector relationship test (4) dissipation factor test
B.D.V (kV) 55 55 58 58 58 (5) transformer winding resistance test (6) auxiliary-
AVERAGE B.D.V(kV) 56.8kV circuit insulation resistance test (7) bushing current
56.8/2.5 = 22.72kV/mm transformer insulation resistance test (8) bushing current
D.S.
transformer polarity test (9) bushing current transformer
(NB: B.D.V – Breakdown Voltage; D.S. – Dielectric Strength) resistance test (10) bushing current transformer
magnetization test (11) buchholz relay functional test (12)
Analysis: transformer oil dielectric strength test and (13) dial
The breakdown voltage (B.D.V) should not be less than temperature thermometer test.
30kV for transformers rated 287.5kV and above, and B. Conclusion
25kV for those rated below 287.5kV [5]. If the B.D.V falls From the test results as provided in this work and the
below these values, the oil should be reclaimed. It follows analysis as presented, the generator transformer yielded
that a transformer oil D.S should not be lower than acceptable pre-commissioning test results, excepting (of
10kV/mm at an electrode gap of 2.5mm or 6.25kV/mm at course) the HV winding resistance test results which were
a gap of 4mm. Here, only the B.D.V test was carried out. over 1.5times the factory reference resistance on each tap.
Although a significant test, this was grossly inadequate for The apparatus was, however, commissioned; but not
the transformer oil property evaluation, because moisture without the strong recommendation for an effective
in combination with oxygen and heat will have cellulose cooling measure to avoid over-heating due to substantial
insulation destroyed in a transformer long before the additional copper losses (of over 50%). Effective use of
B.D.V or D.S of the oil gives a clue that anything was the transformer cooling fans was thus the near solution.
going wrong [20]. However, with average B.D.V of
56.8kV and D.S of 22.72kV/mm the oil proved

Table XVII: Results of the Dial Temperature Thermometers

o
TEST TEMP. ( C) 120 100 90 80 70 60 50 40
O.T.T READING (oC) 119 100 89.5 79.5 70 60.5 50.5 40.5
ERROR (oC) -1 0 - 0.5 - 0.5 0 +0.5 +0.5 +0.5
o
W.T.T READING ( C) 120.5 100.5 90.5 80.5 70.5 60 50 40
o
ERROR ( C) +0.5 +0.5 +0.5 +0.5 +0.5 0 0 0
(NB: O.T.T – Oil Temp. Thermometer; W.T.T – Winding emp. Thermometer)
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 International Journal of Engineering Innovation & Research
Volume 4, Issue 3, ISSN: 2277 – 5668

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