National Conference on Recent Trends in Engineering & Technology

Pre-Commissioning Tests on Dry Type Transformer

Hardik V Rupareliya1, Nidhish G. Mishra2
1
PG Student, Dept of Electrical Engineering, Gujarat Technological University, Gujarat, India
2
Associate Professor, BVM Engg. College, Gujarat, India
1
[email protected]
2
[email protected]

Abstract— The purpose of commissioning tests on whether they are carrying any load or not. 2). Power
transformer is to satisfy, to pre-determined standards, that all the transformer is used in generating stations and sub stations at
equipment erection is correct and that all the equipment each of a power transmission line for stepping up or stepping
connections / cables have been installed in accordance with the down the voltage. Above size 500KVA transformer is called
approved erection drawings and diagrams. Furthermore to
Power transformer. This transformer is disconnected during
demonstrate to the satisfaction of the client that the foregoing
work has been done and that the equipment functions as light load period.
designed. This paper discussed procedures and testing results of
transformer. A Dry type transformer is defined as a transformer in
which the core and windings are not immersed in an
Index Terms— Commissioning, ACSD, CRT. insulating liquid. A Dry-type transformer having one or more
windings encapsulated in solid insulation is called an
I. INTRODUCTION encapsulated winding dry-type transformer.
Transformer is a device that transfers electric energy
from one circuit to another, usually with a change in voltage.
Transformers work only with a varying electric current, such
as alternating current. Transformers are important in the
distribution of electric power. They raise the voltage of the
electricity generated at a power plant to the high levels
needed to transmit the electricity efficiently. Other
transformers reduce the voltage at the locations where the
electricity is used. Many household devices contain
transformers to raise or lower house-current voltage as
needed. For example, Television sets and stereo equipment
require high voltage where the doorbells and thermostats
require low voltages.
Fig. 1. Cast Resin type Transformer
A simple transformer consists essentially of two coils of
insulated wire. In most transformers, the wires are wound Pre-Commissioning Test: Prior to energizing the
around an iron-containing structure called the core. One coil, transformer, several pre-commissioning tests are done. The
called the primary, is connected to a source of alternating objective of these tests is to confirm that the transformer has
current that produces an alternating current in the other coil. not suffered damage during transit and also to check any
This coil, called the secondary, is connected to a separate inadvertent slips in the factory tests, or supply.
electric circuit.

Transformers are classified into mainly two categories. 1). II. PRE-COMMISIONING TESTS
Distribution transformers are used to step down the Following tests are done on the transformer to pre-
distribution voltage to a standard service voltage or from determined standards.
transmission voltage to distribution voltage. Up to size
500KVA transformer is called Distribution transformer. We A) Turn Ratio Test: Ratio between all the three
can keep this transformer in operation all the 24 hours a day corresponding H.V. & L.V. phases is to be measured on all

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 National Conference on Recent Trends in Engineering & Technology

taps. It is desirable to do this test by a Ratio-meter. But if it In case one of the phases has shorted turns, it will draw a
is not available, a simple test of measuring voltages can also comparatively large current when it is energized. When other
serve the purpose. phases are energized, flux and hence voltage in the shorted
phase will be significantly reduced. Hence all three
observations will indicate the shorted phase. Note the
observations in the “Commissioning Report”.

C) Measurement of Insulation Resistance: Measure

Insulation Resistance (IR) between windings and between
windings and earth with a 2500/1000V Megger, preferably
motor driven, otherwise hand- driven. Before measuring I.R.
thoroughly clean all the bushings with clean cotton cloth, if
required using Carbon Tetrachloride. Also, there should be
no external connections to the transformer terminals. Check
and adjust, if required, the infinity setting of the Megger.
Lead wires from the Megger to the transformer should run
independently and be permanently clamped. They should not
have any joints. It is known that the I.R. reading continues to
increase initially and for comparison purpose, reading is to
be taken at 1 minute of energizing. It is also known that I.R.
Fig. 2 : Megger value is dependent on temperature. Hence temperature at the
Referring to name plate find out which terminals of H.V. & time of measurement should be noted. Compare the I.R.
L.V. correspond to one phase e.g. for a vector Group of Dyn- values measured, with the Factory results keeping in view
11, H.V. Terminals 1U, 1V, & L.V. terminals 2U, 2N the temperature at the time of measurements. Note the
correspond to U phase. Apply single phase, 415V or 240V, observations in “commissioning Report”. Also measure and
AC, 50 Hz to H.V. side and measure voltage on the L.V. side. note the I.R. values of the Power Cables.
Measure these voltages on all taps and note them in
“Commissioning Report”. Repeat for the other two phases. D) Measurement of Winding Resistance: To measure the
These observations should indicate a consistent trend of calculation of I2R losses, to Calculate winding temperature at
variation in line with the details given in name plates. the end of Temperature rise test and as a bench mark for
Numerical values should approximately check with the assessing possible damage in the field.
voltage ratio. If the winding has tapping, then resistance shall be measured
at all taps otherwise the resistance of each winding shall be
B) Magnetic Balance Test: This is a simple test to detect measured by following methods:
shorted turns in a winding. Its principle is that shorted turns (i) Voltmeter-Ammeter Method.
oppose establishments of flux in that limb because of the (ii) Bridge Method.
current that circulates through the shorted turns.
Apply single phase, 415 or 240V. AC. To such H.V. line
terminals which would energies U phase (Outer limb). Use
an averaging instrument like a Multimeter. Measure the
voltage induced in the V phase (Center limb) and W phase
(other outer limb). Measure also the current drawn by the
energized phase. This test can, then, be carried out on
L.V.Side Centre limb being nearer to the energized limb,
more flux passes through it and less flux in the outer limb.
The division is around 70-30% & hence the measured
voltages will be having approx this proportion.
Next, energize W phase and measure the other two voltages
as before. Results should be similar to previous ones. Then
energize V phase (Centre limb). As both the outer limbs are
symmetrically located w.r.t. centre limb, flux will divide
equally between them. Hence the voltages measured on outer
phases will be equal. Also, for reasons explained earlier,
currents drawn when outer phases are excited will be equal,
Fig. 3: Measurement of Winding Resistance
that for centre phase will be less (approx 70%). Thus these
observations will confirm the healthiness of the windings.
The resistance is measured at ambient temperature and then
converted to resistance at 75 °C.

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 National Conference on Recent Trends in Engineering & Technology

during test. The test voltage is the peak value of voltage

E) Polarity & Vector group Verification: Polarity and phase divided by root √2. The test time at full voltage shall be 60
relation tests are of interest primarily because of their seconds for test frequency up to and including twice the
bearing on paralleling two or more transformers. Phase rated frequency. For frequency above twice the rated
relation tests are made to determined angular displacement frequency the time duration of test shall be:
and relative phase sequence. Phase relation or vector group
verification test is performed on a three phase transformer. 120 X Rated frequency / Test frequency.
The phasor diagram of any three phase transformer that
defines the angular displacement and phase sequence can be H) Open circuit test: No-load losses are those losses that
verified by connecting the HV & LV leads together to excite are incident to the excitation of the transformer. No-load
the unit at a suitably low three phase voltage, taking voltage losses include core losses, dielectric losses and conductor
measurements between the various pairs of leads and then losses in the winding due to excitation current. These losses
either plotting these values or comparing them for their change with change in excitation voltage. No-load current is
relative order of magnitude. the current that flows in any winding used to excite the
transformer when all other windings are open-circuited.
F) Separate Source Withstand Voltage Test: A normal
power frequency, such as 50Hz, shall be used and the
duration of shall be one minute. The winding being tested
shall have all its parts joined together and connected to the
ground and to the other terminal of the testing transformer.
The test shall be commenced at a voltage not greater than
one-third of the full value and be brought up gradually to full
value in not more than 15 s. After being held for the
specified time of 60 seconds, it should be reduced to one
third or less of the maximum value and the circuit open.
Fig. 4 Open Circuit Test
This test is successful if no collapse of the voltage occurs.
Careful attention should be given for evidence of possible
The purpose of the No-load test is to measure no-
failure that could include an audible sound such as a thump,
load losses at a specified excitation voltage and a specified
or a sudden increase in test circuit current. Any such
frequency. The no-load loss determination shall be based on
indication should be carefully investigated by observations,
a sine wave voltage. The average voltage voltmeter method
by repeating the test, or by other test or determine if a failure
is the most accurate method for correcting the measured no-
has occurred.
load losses to a sine wave basis and is recommended. This
method employs two parallel-connected voltmeters; one is
G) Induced AC over voltage withstand test:
an average-responding voltmeter; the other is a true rms-
In this test, twice of the primary voltage and frequency given
responding voltmeter. The readings of both voltmeters are
on LV side to verify the AC withstand strength of each line
employed to correct the no-load losses to sine-wave basis.
terminal and its connected windings to earth and other
For the determination of the no-load losses of a single phase
windings, the withstand strength between phases and along
transformer or a three phase transformer, the frequency of
the windings under test.
the test source should be within +-0.5 % of the rated
AC Short duration (ACSD) test is intended to verify the AC
frequency of the transformer under test. If the excitation
withstand strength of each line terminal and its connected
frequency is beyond the specified tolerance, then the test
windings to earth and other windings, the withstands
voltage shall be adjusted to maintain the V/F ratio
strength between phase and along the windings under test.
corresponding to the ratio of rated voltage and rated
For Um < 72.5 KV, ASCD test is carried out without partial
frequency. The voltage is adjusted to the specified value as
discharge measurements for 60 secs. For Um > 72.5 KV, the
indicated by voltmeter. Simultaneous values of rms voltage,
test is normally performed with partial discharge free
rms current, power and the average voltmeter reading shall
operation of the transformer under operating condition.
be recorded.
However the requirements for partial discharge measurement
during the ACSD test may be omitted. ACSD test is always
(I) Short circuit test: For the H.V. side voltage and the %
performed with the measurement of partial discharge during
impedance, it would be possible to calculate the current
the whole application of test. This test is not a design
which would flow in the H.V. side, with 415V applied to it,
proving test, but a quality control test and is intended to
while keeping L.V. side shorted. If the 415V source can feed
cover temporary over voltages and continuous service stress.
that current, a short-circuit test can be carried out.
It verifies PD free operation of the transformers under
This test would confirm proper contact engagement at all tap
operating conditions. Applied AC voltage shall be as nearly
positions. Apply 3 Ph. 415V, 50 Hz to H.V. side, keeping
as possible sinusoidal and its frequency is sufficiently above
L.V. side shorted. Measure the 3 line currents at all tap
the rated frequency to avoid excessive magnetizing current
positions. If the switch is an OFF-CIRCUIT switch, supply

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 National Conference on Recent Trends in Engineering & Technology

has to be disconnected before changing tap. Note the

observations in the “Commissioning Report”. (C) Measurement of Insulation Resistance at 28 °C:

(i) H.V. winding to Earth: 38.8 GΩ

(ii) L.V. winding to Earth: 680 MΩ
(iii) H.V. winding to LV winding: 59.4 GΩ

(D) Measurement of Winding Resistance:

a) HV winding Resistance: (in mΩ)

TABLE III
MEASUREMENT OF HV WINDING RESISTANCE
Tap No. 1U1V 1V1W 1W1U
1 226.8 226.8 227.0
2 221.6 221.17 221.7
3 215.9 215.1 215.5
Fig. 5 Short Circuit Test 4 209.9 209.9 209.9
5 204.1 204.1 204.1
A Consistent trend indicates healthiness. If short circuit test
is not possible due to limitation of source carry out one tap b) LV winding Resistance: (in mΩ)
changing operation over the entire range increasing as well
TABLE IV
as decreasing. MEASUREMENT OF LV WINDING RESISTANCE
2U2n 1.404
III. CASE STUDY 2V2n 1.406
This is the study of tests conducted on 11th Oct 2W2N 1.408
2010 of 500 KVA Cast Resin Transformer (CRT) at
VOLTAMP TRANSFOMERS LTD. Under guidance of Mr.
Rajendra Chaudhri and Mr. Pankit patel. (E) Polarity & Vector group Verification:
The specifications of the CRT are as follows:
Job No. : 18530/1 TABLE V
POLARITY & VECTOR GROUP CHECK
KVA : 500
1U1V 425 V
Voltage ratio: 3300 / 433
Vector Group: Dyn1 1V1W 423 V
Type of tap changer: Off load tap changer 1W1U 422 V

The Calculations of various tests performed on this CRT are 1V2v 1V2w 1W2w 1W2v
as follows: 375 V 423 V 374 V 374 V
\
(A) Turn Ratio Test: Vector Group Checked (Dyn1): O.K.
TABLE I
RATIO OF HV / LV PHASE MEASUREMENT
(F) Separate Source Withstand Voltage Test:
Tap No. U/u V/v W/w a) Applied 10KV between HV winding to Earth for 1
1. 13.859 13.859 13.860 min.
2. 13.526 13.525 13.526 b) Applied 3 KV between L.V. winding & Earth for 1
3. 13.193 13.191 13.193 min.
4. 12.859 12.859 12.858
5. 12.526 12.525 12.526 (G) Induced AC over voltage withstand test:
Applied 2 x 433 Volts at 124.8 Hz for 50 Secs.
(B) Magnetic Balance Test:
(H) Open circuit test:
TABLE II PT ratio P: 660/110 =6
MEASUREMENT IN VOLTAGE
CT ratio C: 20/1 =20
2U2n 2V2n 2W2n
WMSM = 0.2
25.7 V 17.82 V 8.11 V
12.5 V 25.6 V 12.08 V
Total MF= C*P*WMSM = 24
7.99 V 17.14 V 25.34 V

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 National Conference on Recent Trends in Engineering & Technology

TABLE VI
O.C. TEST MEASUREMENT
Load Loss in Watts (Tap 1) =(W1+W2+W3)* Total M.F.
%Voltage 90% 100% 110%
= (50)*96=4800
Vavg 65 72.5 79.5
Vrms 65 72.33 79.33 Load Loss in Watts (Tap 3) = (53)*96=5088
Ir 0.21 0.35 0.71
Iy 0.17 0.28 0.55 Load Loss in Watts (Tap 5) = (55)*96=5280
Ib 0.22 0.37 0.76
W1 20 28 48
W2 12.5 17 26 IV. CONCLUSIONS
W3 9 7 (- 4)
Dry type Resin cast Transformers requires very little
maintenance from time to time. However, inspection should
No Load Loss in Watts (90%) be made at regular intervals & corrective measures shall be
=(W1+W2+W3)* Total M.F.= (41.5)*24=996 taken when necessary to ensure the most satisfactory service
from this equipment. Evidence of rusting, corrosion on
No Load Loss in Watts (100%) = (52)*24=1248 enclosure and deterioration of the insulation and paint should
be checked and corrective measures shall be taken whenever
No Load Loss in Watts (110%) = (70)*24=1680 necessary.

(I) Short circuit test:

PT ratio P : 440/110=4 REFERENCES
CT ratio C: 120/1=120
WMSM = 0.2 (1) “Service Manual for installation, commissioning, operation and
Total MF= C*P*WMSM =96 maintenance of transformers” VOLTAMP TRANSFORMER
Temp. = 28 °C LTD.
(2) “Testing of Three Phase Power transformer” by Brahambhatt
TABLE VII
Sohil H, SVIT-VASAD.
S.C. TEST MEASUREMENT
(3) Operation, Installation, Commissioning & Maintenance
Tap No. 1 3 5 Manual”, by TRANSDELTA TRANSFORMERS PVT LTD.
Ir 0.69 0.73 0.77 (4) “Electrical Testing & Validation”- O’HARA ENGINEERING
Iy 0.695 0.73 077 SERVICES LTD.
Ib 0.695 0.73 0.78 (5) “PRESENTATION ON CAST RESIN DRY TYPE
Vry 45 44 41 TRANSFORMERS” by VIJAI ELECTRICALS LTD.
(6) www.eaton.com
Vyb 46 44 42 (7) Web Source on Dry-type Transformer.
Vbr 45 43 41
W1 16 17 18
W2 17 17.5 18.5
W3 17 18.5 18.5

13-14 May 2011 B.V.M. Engineering College, V.V.Nagar,Gujarat,India