Test Procedure- Transformer:

As per the contract the following tests need to be performed for the Transformers:

Test Procedure for measurement of Insulation Resistance Test & Polarization

Index
SL No. Issue No. Issue date Rev No. Rev Date
1

Utility of the test:

Fault in an electrical system is generally due to failure of the insulation. It is extremely
important to know the insulation resistance of the equipment. Insulation resistance test is a spot
test to measure the dielectric strength of the insulation at a given point of time.
Device used: Insulation resistance tester/ Meggar
References
IS-2026 Part-1
Test Range
2.5kV Insulation Resistance tester

Safety Precautions
1. The testing area should cover with the barricades/barricading tape to prevent entry of
unauthorized persons.
2. Ensure that danger boards are displayed around the test area, before starting the test.
3. Ensure that Danger/Red lamps were glowing to give indication that testing is under progress.
4. Availability of discharge rod near the testing area.
5. Check that one end of the discharging rod is connected to the earth.
6. Ensure that all testing personnel are wearing safety shoes and hand gloves.
7. Prevent entry of unauthorized personnel into the testing area.
8. Only trained and authorized testing personnel shall carry out the tests as per the approved test
procedure.
9. Never assume that the circuit is dead, check the circuit before working.
10. Discharge after completion of tests with discharging rod every time.
11. During testing of all kinds of transformers, ensure that two or more persons available for
executing the test and helping each other in case of any shock or any other accident. The above
persons shall have the knowledge of de energizing the circuit

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Test procedure:
Connection

1. Shutdown of the transformer is required for performing the IR (Insulation resistance test).
2. Isolating the transformer is required i.e disconnecting the cables/ jumpers & LA for OH
lines.
3. IR testing of the transformer winding shall be performed between
i. HV-Earth
ii. LV- Earth
iii. HV-LV
4. In case of star connected winding, disconnection of the solidly earthed neutral is required.
5. The IR test shall run for 1 minute & the value shall be noted in the below table.
6. The PI (Polarization Index) shall be calculated from the IR test run for 10 mins & 1 min
(PI= IR_10 mins/ IR_1 min)

Table of Readings:
Test type Rating Injected DC MΩ for 1 MΩ for 10 Polarization
Volts min mins Index
HV- Earth

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 LV- Earth
HV- LV

Test Procedure for Winding Resistance Measurement

SL No. Issue No. Issue date Rev No. Rev Date
3

Utility of the test

Winding resistance measurements in transformers are of fundamental importance for the
following purposes: Calculations of the I2R component of conductor losses. Calculation
of winding temperature at the end of a temperature test cycle as a diagnostic tool for assessing
possible damage in the field. It is done at site in order to check for abnormalities due to lose
connections, broken strands of conductor, high contact resistance in tap changers, high voltage
leads and bushings.
References
IS-2026 Part-1
Device used: Transformer winding resistance measurement kit.
Safety Precautions
1. The testing area should cover with the barricades/barricading tape to prevent entry of
unauthorized persons.
2. Ensure that danger boards are displayed around the test area, before starting the test.
3. Ensure that Danger/Red lamps were glowing to give indication that testing is under progress.
4. Availability of discharge rod near the testing area.
5. Check that one end of the discharging rod is connected to the earth.
6. Ensure that all testing personnel are wearing safety shoes and hand gloves.
7. Prevent entry of unauthorized personnel into the testing area.
8. Only trained and authorized testing personnel shall carry out the tests as per the approved test
procedure.
9. Never assume that the circuit is dead, check the circuit before working.
10. Discharge after completion of tests with discharging rod every time.
11. During testing of all kinds of transformers, ensure that two or more persons available for
executing the test and helping each other in case of any shock or any other accident. The above
persons shall have the knowledge of de energizing the circuit.

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Connection
Test procedure

1. The transformer shutdown shall be required & complete isolation of the transformer along
with disconnecting the neutral in case of star connected winding.
2. The transformer shall be kept idle for about 3-4 hrs after taking shutdown unless the top oil
& the bottom oil temperature difference is not more than 50C.
3. For star connected winding the resistance shall be measured between the line and the neutral
terminal.
4. For delta connected windings, measurement of winding resistance shall be done between
pairs of line terminals. As in delta connection the resistance of individual winding cannot be
measured separately, the resistance per winding shall be calculated as per the following
formula:
Resistance per winding = 1.5 × Measured value
5. Resistance shall be measured at ambient temperature & converted to equivalent resistance at
750C.
Table of Readings:
Delta Transformer Rating Test current <15% of the Resistance value (Ω)
connected rated current
winding
R-Y
Y-B
R-B

Resistance of winding thus calculated:

R-Phase-
Y-Phase-
B-Phase-
Wye Transformer Rating Test current <15% of the Resistance value (Ω)
connected rated current
winding

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 R-N
Y-N
B-N

Acceptance Criteria:
The readings thus obtained shall be matched with the readings of the manufacturer data sheet/
previous test results. Any value with a deviation of +/- 2% shall be reported to the concerned
authorities.

Test Procedure for Capacitance & Tan Delta Test

SL No. Issue No. Issue date Rev No. Rev Date
4

Utility of the test

The condition of the insulation is essential for secure and reliable operation of the transformer.
Measuring capacitance and dissipation/power factor helps you to determine insulation condition in
bushings or between windings.

Changes in capacitance can, for example, indicate mechanical displacements of windings or partial
breakdown in bushings. Aging and degradation of the insulation, coupled with the ingress of water,
increase the amount of energy that is converted to heat in the insulation. The rate of these losses is
measured as dissipation factor.

References
IEC-60076:2000 Part-I, Clause 10.1.3

Safety Precaution
1. All bushing terminals and the bushing shall be thoroughly cleaned with dry cloth to avoid
surface leakages currents.
2. Service Engineer shall use proper PPEs.
3. During the measurements the test area shall be demarked with warning tape.
4. Sagging of the connection lead shall be avoided.
5. Measurement at higher voltage shall not be done while the transformer under vacuum.
6. Electrostatic interference; especially due to nearby EHV lines may lead to unreliable results.
Interference suppressor circuits along with shielded cable may be used to avoid this.

Device used: Capacitance & Tan-Delta measuring kit

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 Test procedure
Connection

1. The transformer shutdown shall be required & complete isolation of the transformer.
2. Disconnection of the transformer neutral in case of star connected winding required.
3. Capacitance & Tan-Delta shall be measured among HV-LV, HV-Tank, and LV to Tank.
4. Results thus obtained shall be matched with the earlier results for trend analysis.
5. Capacitance and Tan Delta test shall be conducted at the Transformer windings as well as
the transformer bushings (air type) in three modes as follows:
6. GST-g mode- Grounded specimen test with guard- This mode of test measures the total
current leaking to the ground only.
7. UST mode- Ungrounded specimen test- This mode of test measures the current leakage
other than the ground.
8. GST mode- Grounded specimen test- This test measures the total leakage current to the
ground as well as to the system.
9. The test voltage shall be injected at steps of 2kV, 5kV & 10kV depending upon the rating
of the transformer and test shall be repeated (GST-g/ UST/ GST) for all the voltage levels

Table of Readings:
Transformer Rating Capacitance (nF) Tan Delta
HV-LV
HV- Tank
LV- Tank

Acceptance Criteria:

1. Dielectric factor for oil filled transformers and reactors in good condition should be not exceed 0.5%
at 20˚C
2. Periodic tests done in service will indicate whether the aging of insulation is normal or rapid.
3. Test results on the new equipment provide a benchmark for future comparison.
4. Obtained test results shall be matched with the previous results & manufacturer datasheet.

PAGE 6 OF 21
 Test Procedure for Sweep Frequency Response Analysis

SL No. Issue No. Issue date Rev No. Rev Date

6

Utility of the test

SFRA is a powerful & sensitive method to evaluate the mechanical integrity of the core, windings
& clamping structures of the transformer. It gives a complete reflection of any mechanical damages
or loose connections inside the transformer.
References
IEC-60076-18
Device used: Sweep Frequency Response Analyzer
Test Range: 10Hz to 20 MHz
Safety Precautions

1. Service Engineer shall ensure the use of proper PPEs.

2. SFRA measurement is sensitive to DC magnetization of the core and hence it has to be
carried out before application of any DC voltage, if any DC measurement was carried out
before FRA measurement, it should be properly demagnetized.
3. The resultant plot may distort from the actual one in case of a loose

Test procedure
1. The transformer shutdown shall be required & complete isolation of the transformer.
2. Disconnection of the transformer neutral in case of star connected winding required.
3. The excitation & reference clips shall be connected to one end of the winding ( Example
Neutral of the star connected Transformer winding)
4. The response clip shall be connected to the other end of the winding ( Example Red phase)

PAGE 7 OF 21
 5. Transformer tank to be grounded.
6. The instrument sends excitation signals & measures the response signal across a broad
frequency range.
7. The results will be shown in graph dB vs frequency.
8. The test shall be repeated for every tap position.
9. Results thus obtained shall be matched with the earlier results and also the from other
phases to identify any mechanical damages inside the transformer.

Table of Readings:
Transformer Tap Excitation Response R Response Y Response B
Rating Position frequency phase Phase Phase
range

Test Procedure for Transformer Turns Ratio (TTR Measurement)

SL No. Issue No. Issue date Rev No. Rev Date

7

Utility of the test

The transformer turns ratio test is used to determine the number of turns in one winding of a
transformer in relation to the number of turns in the other windings of the same phase of the
transformer
References
IS-2026 Part-1
Device used: Turns Ratio Tester
Safety Precautions
.1. The testing area should cover with the barricades/barricading tape to prevent entry of
unauthorized persons.
2. Ensure that danger boards are displayed around the test area, before starting the test.
3. Ensure that Danger/Red lamps were glowing to give indication that testing is under progress.
4. Availability of discharge rod near the testing area.
PAGE 8 OF 21
5. Check that one end of the discharging rod is connected to the earth.
6. Ensure that all testing personnel are wearing safety shoes and hand gloves.
7. Prevent entry of unauthorized personnel into the testing area.
8. Only trained and authorized testing personnel shall carry out the tests as per the approved test
procedure.
9. Never assume that the circuit is dead, check the circuit before working.
10. Discharge after completion of tests with discharging rod every time.
11. During testing of all kinds of transformers, ensure that two or more persons available for
executing the test and helping each other in case of any shock or any other accident. The above
persons shall have the knowledge of de energizing the circuit

Test procedure
Connection

1. The transformer shutdown shall be required & complete isolation of the transformer.
2. Disconnection of the transformer neutral in case of star connected winding required.
3. The 3-phase turns ratio tester shall be employed.
4. High voltage test lead cables shall be connected to the HV windings (H0, H1, H2, and H3).
For delta connected windings, H0 shall not be connected.
5. Low voltage test lead cables shall be connected to the LV windings (X0, X1, X2, and X3).
For delta connected windings, H0 shall not be connected.
6. Test readings will be taken in the form of turns ratio.

Table of Readings:
Measured Turns Ratio Turns Ratio as per Name Plate
Red Phase
Yellow Phase
Blue Phase

PAGE 9 OF 21
Magnetic balance test of transformer is conducted only on three-phase transformers to check the
imbalance in the magnetic circuit.This test can determine the following:

Distribution of magnetic flux

Core Assembly Condition
Incorrect winding connection

Magnetic Balance Test Of Transformer

SL No. Issue No. Issue date Rev No. Rev Date

8

Utility of the test

Magnetic balance test of transformer is conducted only on three-phase transformers to check the
imbalance in the magnetic circuit.This test can determine the following:

Distribution of magnetic flux

Core Assembly Condition
Incorrect winding connection

Test Procedure
Single phase supply is to be applied to any phase terminal on HV side of Power transformer and
voltages in other two phase in combinations are to be measured with LT open.
Sum of the voltage induced in the other two phases shall be equal to the applied voltage.
The test shall be repeated for all the HV winding phase.

Applicable Standards
IS2026-Part-1

Test Procedure- VCBs:

As per the contract the following tests need to be performed for the VCBs:

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 Test Procedure for Coil Resistance Measurement

SL No. Issue No. Issue date Rev No. Rev Date

3

Utility of the test:

Two coils are used in a circuit breaker, one is closing coil and another is tripping coil. To check
the healthiness of both the coils, coil resistance measurement test is performed .
Device used: Coil Resistance Measurement Kit.

Standards:
IS- 13118
Safety Precautions:
1. Proper PPEs shall be ensured.
2. Loose connections shall be avoided.
Test procedure:
Resistance of both closing and tripping coils is measured by a digital multimeter. The original
ohmic value of both the coils marked in both the coils will be compared with the present
reading of digital multimeter. If both the readings are almost same, then we can conclude that
both the coils are in good working condition.

Circuit Diagram:-

Test Report Format:-

Breaker Rated Observed Rated Observed Remarks

Nomenclature/Sr. Closing Coil Closing Coil Tripping Coil Tripping Coil
No. Resistance Resistance Resistance Resistance

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 Test Procedure Vacuum Checking

SL No. Issue No. Issue date Rev No. Rev Date

3

Utility of Test:-

The vacuum interrupters in vacuum circuit breakers do not last forever. Leakage starts after
years or decades and the air find its way in the interrupter, making the breaker unreliable. In
most cases, the leakage process is rapid, once it has started. In addition to leakage, dirt on poles
and on the exterior surface of the interrupter can make it unsafe during operation.

Device used: Vacuum integrity test set.

Standards:
IS-13118
Safety Precautions:
1. Proper PPEs shall be ensured.
2. Loose connections shall be avoided.

Test procedure:
Both AC and DC vacuum interrupter testers can be used to check the condition of vacuum in a
vacuum interrupter. The industry guidelines for selecting the test voltage for testing vacuum
voltage are shown in the table below. The test voltage will be applicable for1 minute in open
condition.

Circuit Diagram:-

PAGE 12 OF 21
 Test Report Format:-

Rated Voltage as per Rated power frequency Field test voltage 75% of the
IS13118 withstand voltage rated power frequency
withstand voltage

AC DC
6.6 20 15 21
12 28 21 30

Test Procedure for Integrity Testing(Flashover Threshold Voltage) of Vacuum

Interrupter(VI)

SL No. Issue No. Issue date Rev No. Rev Date

3

Utility of Test:-

Vacuum interrupter contacts are designed so they practically never wire up. The purpose of
vacuum integrity test is to demonstrate that the pressure of the vacuum interrupter is still below
the maximum level required for the acceptable performance of the switching and insulating
functions.

PAGE 13 OF 21
 Device used: Vacuum Interrupter test set.

Standards:
IS-13118.
Safety Precautions:
1. Proper PPEs shall be ensured
2. Loose connections shall be avoided.

Test procedure:
Both AC and DC vacuum interrupter testers can be used to check the condition of vacuum in a
vacuum interrupter. The industry guidelines for selecting the test voltage for testing vacuum
voltage are shown in the table below. The test voltage will be applicable for1 minute in open
condition.

Circuit Diagram:-

Test Report Format:-

Breaker Applied high Withstood or Remarks

Nomenclature Sr. voltage(DC) for 1 not(Y/N)
No. minute

Test Procedure for Contact Resistance Test

PAGE 14 OF 21
SL No. Issue No. Issue date Rev No. Rev Date
3

Utility of Test:-

The main contacts and primary stabs need to be checked periodically to detect abnormal wear,
inadequate lubrication, and loose pivot points inside the circuit breaker. Poorly maintained or
damaged contacts can case arcing, single phasing & electrical fires.

Device used: Milli-volt drop test set.

Standards:
IS-13118 / IEC-56
Safety Precautions:
1. Proper PPEs shall be ensured
2. Loose connections shall be avoided.

Test procedure:
Electrical resistance of the circuit breakers primary circuit is calculated by measuring the
voltage drop across the line and load terminals for each phase. The test will be performed using
a low voltage direct current power supply to pass current from line to load; with the circuit
breaker in the closed position. Test current will be 10A or 100A.

Circuit Diagram:-

Test Report Format:-

Sr. No./ R-Ph Y-Ph B-Ph Remarks

Nomenclature

PAGE 15 OF 21
 Suggestion:-

Measured resistance values should be within the acceptable limit i.e. the value found during
Type Test of the similar breaker as per IS-13118/IEC56.Values of all the three phases should
be almost same. More than 25% variation is not accepted.

Test Procedure for Insulation Resistance Test

SL No. Issue No. Issue date Rev No. Rev Date

3

Utility of Test:-

Circuit Breaker’s insulation system is a critical area that requires testing & evaluation.
Insulation systems can weaken due to the heat created by arc interruption, especially if they are
not routinely maintained. Weak insulation can result in a catastrophic failure, especially during
arc interruption. The insulation testis useful for detecting major defects in the insulation
system, but it can also be used as a final safety check before returning the breaker to service.

Device used: Insulation resistance tester/ Megger

Standards:

IS-13118
Safety Precautions:
1. Proper PPEs shall be ensured
2. Loose connections shall be avoided.

Test procedure:
This test should be performed using a mega-ohmmeter phase to phase & phase to ground with
the breaker in the closed position as well as across the open contacts for each phase.

PAGE 16 OF 21
 Circuit Diagram:-

Test Report Format:-

Nomenclature/ Sr No. Closed Phase to Earth Open Upper & Lower Remarks
Contact

Test Procedure for Stroke Length Measurement

SL No. Issue No. Issue date Rev No. Rev Date

3

PAGE 17 OF 21
 Utility of the test
This test is used to determine and validate the performance characteristics of circuit breakers.
For example, the changing state of main and resistor contacts (open- close, close-open, etc.) and
auxiliary contacts versus time, varying defined distances traveled by the main contacts (e.g.,
total travel, over travel, rebound, stroke, and contact wipe), velocity (average and
instantaneous), dwell-time and dead-time, are primary circuit breaker characteristics measured.
Standards
IS-13118:1991
Safety Precautions:
1. Proper PPEs shall be ensured
2. Loose connections shall be avoided.

Device used: Timing kit / Analyzer

Test procedure
1. Shutdown of the breaker is required for the test.
2. The breaker shall be measured by the CB timing kit/ analyzer.
3. The stroke length shall be measured with the help of designated probes fitted across the
upper contact & lower contact of the breaker.
4. The value of the stroke length is mentioned at the datasheet of the manufacturer.
5. The measured value shall be matched with the value defined in the data sheet/ previous test
result.

Table of Readings:
Breaker serial Measured stroke length Remarks
No.
R-Phase Y-Phase B-Phase

Test Procedure for Coil Pickup Test

SL No. Issue No. Issue date Rev No. Rev Date

3

PAGE 18 OF 21
 Utility of the test
This test is intended to determine the minimum voltage at which the breaker is able to operate.
The objective of this test is to make sure that the breaker can operate at the lowest voltage level
provided by the station battery when the breaker has to operate during a power outage.
Standards
IS-13118
Safety Precautions:
1. Proper PPEs shall be ensured
2. Loose connections shall be avoided.

Device used: Variable DC source & Digital multimeter

Test procedure
1. The VCB shutdown shall be required & complete isolation of the VCB.
2. Testing begins at a low voltage, sending a control pulse to the breaker.
3. The closing coil shall pick-up at 85% of the rated voltage & the tripping coil shall pick-up at
70% of the rated voltage.
4. A Digital multimeter will record the voltage at which the plunger strikes the latch for both
closing & tripping.

Table of Readings:
Breaker Test voltage Whether Test voltage Whether Remarks
Nomenclature on tripping picked up or on closing coil picked up or
coil not not

Test Procedure for Contact Erosion Test

SL No. Issue No. Issue date Rev No. Rev Date

3

PAGE 19 OF 21
Utility of the Test

An electric circuit breaker provides opening & closing of the current carrying contacts. Circuit
breaker remains at its closed position for maximum period of its lifetime. Erosion of contacts can
take place which reduces the contact area & also the spring over travel.

Safety Precautions:
1. Proper PPEs shall be ensured
2. Loose connections shall be avoided.

Test procedure

1. Circuit breaker shutdown is necessary for performing this test with complete isolation of the
same.
2. Contact erosion shall be determined by closing the circuit breaker & measuring the spring
over travel.
3. The measured spring over travel & the original spring over travel measured when the
interrupter was first put into service represent contact erosion.

Equipment to be used: Vernier Caliper

Breaker Sr No. Initial Value Test Value Remarks

Test Procedure for Damper Settings Test & Tripping-Closing Time Test

SL No. Issue No. Issue date Rev No. Rev Date

3

Utility of the test

Damping is an important parameter to monitor as the stored energy of the mechanism for
opening & closing the CB is considerable. The powerful mechanical stress can easily damage/
reduce the breaker’s useful life.

Standards
IS-13118
PAGE 20 OF 21
 Safety Precautions:
1. Proper PPEs shall be ensured
2. Loose connections shall be avoided.

Device used: Timing kit / Analyzer

Test procedure
1. Shutdown of the breaker is required for the test.
2. The test shall be conducted with the CB timing kit/ analyzer.
3. The test shall be carried out to identify that the moving contact has reached far enough
before entering the damping zone.
4. The value thus obtained shall be measured & matched with the initial damper settings,
available with the manufacturer data sheet.
Table of Readings:
Breaker serial Closing Time Remarks
No.
R-Phase Y-Phase B-Phase

Breaker serial Tripping Time Remarks

No.
R-Phase Y-Phase B-Phase

.;.;……………………………………,

PAGE 21 OF 21