Power transformers testing and commissioning at the

site (instructions and precautions)

electrical-engineering-portal.com/power-transformers-testing-commissioning-at-site

By Omar Salah May 31, 2021

Commissioning of Power Transformers

Since I started the commissioning work 30 years back, transformer commissioning
consisted of more tests, but nowadays, the number of tests has been reduced due to
costs and time-saving. This article will go through complete testing that needs to be done
at the site during the commissioning process of the transformer.

Power transformers testing and commissioning at the site (on photo: Transformer dynamic resistance
measurements with the Omicron's CPC 100)

Table of contents:

Power transformers testing and commissioning at the site.

1. Power Transformer Tests

These tests include winding insulation resistance test, winding resistance test, vector
group test, tan delta test, no-load test or iron losses, load test or copper losses,
temperature rise test, partial discharge test, frequency response analysis test, and

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transformer oil breakdown test.

These tests are detailed as follows:

1.1 Measurement of Winding Insulation Resistance

The purpose of this test is to determine the insulation resistance of the high-voltage
winding to the ground, low-voltage winding to the ground, and the high-voltage winding to
the low voltage winding, also to assess the amount of moisture in transformer insulation.

This test is done using a DC Meger, 5000 V by applying this voltage -5000-volts DC for a
period of one 30 Sec and if there is no failure in insulation, we extend the test to one
minute. If the reading is not stable then we should extend the test to 5 minutes.
This test should be done between the windings as follows:

1. High Voltage winding to the Earth as shown in the figure given below.
2. Low Voltage winding to the Earth same as HV-Earth but the connection will be
between LV-Earth.
3. The high voltage winding to the low Voltage Windings as shown in the figure given
below.

Figure 1 – Insulation resistance testing: HV-Earth and HV-LV

Figure 1 – Insulation resistance testing: HV – Earth and HV – LV

We take the reading after 15 sec and after 60 sec the result will give the polarization
index of transformer insulation, which indicates the transformer insulation condition.

Polarization Index (PI) =R60/R15 should be as follows:

More than 1.3 for the transformer with voltage up to 35kV

Between 1.5 to 1.7 for transformers with voltage range from 66 kV up to 500 kV

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 If PI reading is more than 3.1 this means the transformer insulation is in good
condition.
As a guide for practical reading:
LV-Earth 1 G-Ohm.
HV-Earth 2.5 G-Ohm.
L.V to H.V 2.5 G-Ohm.

Conclusion:

Do not choose the megger test voltage as standard 5000 volts as some transformer’s
manufacture has low insulation for big transformer neutral points, for example, 500MVA,
500kV Transformers and if you apply 5000 D.C voltage in the winding you will lose the
transformer windings, so please refer to the specified D.C voltage to test the transformer
windings as per manufacture manual instruction.

After the test, do not energize the transformer before earthing the windings to be
sure that the windings are discharged.
If you find the insulation resistance is not satisfied, further investigation should be done in
the transformer before energization.

For Megger, discharge the current to avoid shock. Switch off the power supply when
connecting the circuit to avoid a spark.

Watch Video At:

https://youtu.be/yOfbz2QL1z4

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1.2 Winding Resistance Test
The purpose of this test is to measure the D.C. resistance of the transformer
windings, this test can be done by a voltmeter and ammeter method. For low reading
values, we connect the voltmeter after the ammeter, but for high resistance values, we
connect the voltmeter before the ammeter. A sensitive voltmeter and ammeter will be
used with a 100 DC Amp. This test will give accurate results as shown below:

Figure 2 – DC winding resistance test (current-voltage method)

Figure 2 – DC winding resistance test (current-voltage method)

This test can be done when a transformer is hot or cold, but the temperature of the
winding and oil should be recorded during the test. If a transformer for example delta/star
windings, then check the resistance as follows:

1. HV winding resistance between phase R and phase S

2. HV winding resistance between phase S and phase T
3. HV winding resistance between phase T and phase R
4. LV winding resistance between phase R and neutral N at Tap 9
5. LV winding resistance between phase S and neutral N at Tap 9
6. LV winding resistance between phase T and neutral N at Tap 9

As a practical guide for a power transformer 66/33 kV, 20 MVA we have the
following values measured at the site:

H.V Side, Tap Changer on Tap Number 9:

1. The resistance between windings R and winding S is 824 mOhm

2. The resistance between windings S and winding T is 832 mOhm
3. The resistance between windings T and winding R is 763 mOhm

L.V Side, Tap Changer on Tap Number 9:

1. The resistance between windings R and neutral N is 78 mOhm

2. The resistance between windings R and neutral N is 79 mOhm

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 3. The resistance between windings R and neutral N is 79.5 mOhm

Conclusion:

If the values of the winding resistance are low do not energize the transformer there a
possibility of winding damage.

VIDEO: – Measuring DC winding resistance and checking the tap changer

Watch Video At:

https://youtu.be/GijrrUbfIXQ

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1.3 Transformer Voltage Ratio Test

The simple method is to inject 380 Volts at the site on high-voltage winding and to
take the readings of the injected on a high-voltage and low-voltage at each tap. This can
also be done by a small portable transformer with a fixed primary winding and a
secondary with large numbers of taps connected to selector switches for coarse and fine
adjustment of the reading or an autotransformer.

After injecting a voltage of 220 volts on the HV side of the transformer under test
(connected to the primary winding of the ratio meter), the voltage induced in the voltage
winding of the power transformer will be compared to the secondary voltage of the ratio
meter.

Any deviation between the two readings will be detected by an ammeter connected in the
circuit that detects the circulated current between the two windings due to the difference

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in voltages.
Also, this test can be done more easily by using modern devices to measure the ratio by
different manufacturers such as Megger and Omicron CPC100, etc. as shown below. The
error should be within ± 5% of the transformer nameplate ratio.

VIDEO: – Explaining transformer turns ratio test

VIDEO: – How to perform a transformer turns ratio test

VIDEO: – Measuring ratio and winding resistance of all taps/phases

Conclusion:

Do not do this test if the transformer is under a vacuum process or there is any
doubt for any short circuit in transformer windings, this vacuum can cause flashover
or fire, or explosion.
If the error exceeds ± 2% from nameplate values, different causes should be
investigated to rectify.
Wrong connections in tap changer.
Short circuit in transformer windings.
By the end of the test earth the transformer windings to discharge it.

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1.4 Transformer Polarity Test

The purpose of this test is to identify the beginning and end of the primary winding to the
beginning and end of the secondary windings of the power transformer. Defining polarity
is important to identify the direction of the induced voltage in the transformer winding.

Polarity can be tested using the AC or the DC circuit as shown below.

Figure 3 – Transformer polarity test scheme

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 Figure 3 – Transformer polarity test scheme

In the A.C circuit test method shown above in Figure 3(a), we use an AC voltage source
and three voltmeters. If the reading of V3 is the sum of V1-V2, then we have the correct
polarity shown in the circuit. In the DC circuit test method, we use a suitable battery,
switch, and a sensitive moving-coil galvanometer. Closing the switch instantaneously
causes the moving of the pointer in the galvanometer, and if it is in the positive direction
then the polarity is ok.

In the new testing devices from different manufacturers, there is a feature to detect the
correct polarity of the transformer automatically.

The importance of power transformer polarity is clear when we want to connect two
transformers in parallel the same polarity in the primary winding of the two transformers
will be connected also the same in the secondary windings of the two transformers.
As shown in the figure given below:

Figure 4 – Paralleling of two transformers connection diagrams

Figure 4 – Paralleling of two transformers connection diagrams

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1.5 Transformer No-Load Losses Test
This test determines the no-load losses that include the hysteresis losses and eddy
current losses. During the no-load condition, the high-voltage side of the transformer
draws a no-load magnetizing current. The input power is measured by three-watt meters,
three ammeters, and three voltmeters as shown in the figure below.

The power supply should be a diesel generator with suitable power to supply the
transformer The input power will give the value of the no-load losses (iron-losses). The
input current will give transformer-magnetizing current.

Figure 5 – Connection diagram for measuring no-load losses

Figure 5 – Connection diagram for measuring no-load losses

Any problem in the transformer magnetic circuit will cause excessive heating that will
reduce transformer life. This problem in the magnetic circuit will be noticed in the rising
iron losses of the transformer in this test. This value of iron losses will be used in
transformer efficiency calculations; a rise in these losses will reduce the transformer
efficiency.

This test was done at the site in the past, but nowadays this is not the practice. Due
to the cost of providing a diesel unit and huge time-consumed, it is performed only at the
factory.

By the end of the test earth the transformer windings to discharge it.

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Go back to the Contents Table ↑

1.6 Transformer Load Losses (Short Circuit) Test

Load loss is important in the transformer efficiency calculation, which affects the cost
of the transformer operation in service. In this test, the low-voltage winding of the
transformer is short-circuited and the input power is supplied on the transformer’s high
voltage side. Measured is done by three wattmeters, three voltmeters, and three
ammeters, and the supply will be a suitable diesel generator unit.

The measured input power will represent R×I² for primary and secondary windings
losses, where I is the current of the corresponding winding and R is the resistance of the
corresponding winding.
In this regard, we measure the transformer impedance voltage, which is a critical
parameter in short-circuit calculations of the power transformer. We measure the voltage
that circulates the rated current in the short-circuited low voltage winding as shown in the
figure given below.

Figure 5 – Circuit for the impedance and load-loss measurement

Figure 5 – Circuit for the impedance and load-loss measurement

This test is usually performed at the factory, and not at the site due to the time-consuming
and the cost of providing a diesel unit.

By the end of the test earth the transformer windings to discharge it.

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1.7 Transformer Vector Group Test

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The purpose of this test is to check the vector group indicated on the transformer
nameplate. Consider a three-phase power transformer with star/delta connections in
primary and secondary windings, respectively. This test can be done by shorting the (R)
phase of the transformer’s high voltage side with the (r).

A phase of the transformer low-voltage side (see figure 6), with the high-voltage side
supplied by 380 voltage three-phase supply, and then we measure the voltage between
the following phases in high voltage side and low voltage side as follows:

Between (S) and (s)

Between (T) and (t)
Between (S) and (t)
Between (T) and(s)

Then we draw the vector diagram as shown in the figure below. The intersection of these
vectors will decide the position of phase s and t, vectors with their displacement angle,
considering that the phases R, r coincide as it is shorted together. After measurements,
we draw the clock diagram of the S phase at 0° at the 12-o’clock position. Then the s
phase will be displaced from S by 1×30°=30°, and it can be seen that it is 1 o’clock on the
diagram and that the vector group Yd1 is certified.

By the end of the test earth the transformer windings to discharge it.

Figure 6 – Test of Yd1 transformer vector group

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 Figure 6 – Test of Yd1 transformer vector group

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1.8 Transformer Capacitance and tan δ Test

This test is called the loss angle of the dielectric dissipation factor or power factor
test, which determines the transformer insulation condition and its oil contaminations.
The transformer insulation and oil can be represented as capacitance and the current
passing through this capacitance has two components one is a resistive component IR
as shown in the figure below also the capacitance component IC.

The angle between the pure capacitance current IC and total current IL, which passing
through transformer insulation is called delta (δ°).

The value of the tangent of this angle-tan (δ°) is an indication of the condition of the
transformer insulation and the transformer’ oil contaminations, in ideal case

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theoretically, it is zero if δ°=0.
However, when the value of tan (δ°) increased, this means less age of transformer
insulation and its oil contamination is increased.

This test is done normally at 10-12 kV voltage between:

Transformer high-voltage winding and transformer tank (earth),

Transformer low-voltage winding and transformer tank (earth), and
Transformer high-voltage winding and transformer low-voltage winding.

As a practical guide tan (δ°) for new transformers should be less than 0.2%. Different
manufacturers have simple use and friendly devices to measure tan (δ°) directly as
Megger and Omicron, etc.

VIDEO: – Measuring capacitance and power factor or dissipation factor

VIDEO: – Procedure for AC insulation testing

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1.9 Transformer oil breakdown Test

Good and pure transformer oil is a clear yellow color. If transformer oil contains
suspended particles, water-soluble acids and bases, active sulfur, its dielectric properties,
and insulating properties will deteriorate and internal flashover will occur. Therefore, oil
should be pure and not contains these substances.

Moisture also reduces oil quality for electrical insulation. Transformer drying and oil
filtration unit remove these particles and moisture by circulating the heated oil and filters
the oil until the measuring of transformer insulation resistance reaches the required value.
Refer to Section 1.1 in this article.
Good oil should have a higher flash point of 145°C.

For a sample to be truly useful, it must be representative of the oil in the transformer. This
means that cleanliness is extremely important.

Samples are normally drawn from a drain valve or sampling cock. This must be
cleaned both inside and out before the sample is taken to ensure that dirt does not
fall into the sampling container.
The drain valve is at the bottom of the equipment, where all of the sludge, water,
and contaminant particles collect. It is important, therefore, to flush the system
thoroughly to ensure that the sample is drawn from the main bulk of the oil. This
may involve removing two liters of oil, and even more, if the equipment has been
out of service for some time.
Do not be tempted to use old engine oil bottles, even for a few p.p.m. of engine oil
will cause the sample to fail a breakdown test.

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 Do let the oil flow down the side of the sample bottle, or use a clean tube run to the
bottom of the bottle; it will prevent air from being mixed with the oil.
Do store the oil samples in glass or clear plastic bottles in the dark, mineral oil will
deteriorate if exposed to UV light.

Refer to the video for the transformer oil tester.

VIDEO: – How to test transformer oil? how to use MEGGER oil tester?

DOWNLOAD: – Guide to insulating oil dielectric breakdown testing (PDF).

Download Guide [.pdf]

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1.10 Transformer Temperature Rise Test

This test is also called a back-to-back test. The main purpose of this test is to monitor
the transformer oil and winding temperature over 24 h at full load current and
compare the results to the temperature-time curve given by the manufacture for the
transformer.

A back-to-back test can be done easily by connecting the two identical transformers at
the same busbar in parallel through empty busbars coupled through the bus coupler in
the substation with these conditions are confirmed for the two transformers:

1. Typical voltage ratio.

2. Same polarity and the same vector group.
3. Typical percentage impedance (Z %).
4. Same phase rotation of the power supplied at the busbar to which the two
transformers are connected.

A back-to-back test can be easily confirmed in the substation. You should put the tap-
changer of the first transformer in the highest tap and put the second transformer tap-
changer tap in the lowest tap to circulate the full load current between the two
transformers. The voltage difference between the two transformers will drive the full load
current between the two transformers.
We draw the temperature readings of the transformer’s oil and windings (taken from the
gages of oil temperature and winding temperature at the local transformer cubicle or the
control room) on the Y-axis and time in the X-axis for a time of 24 h.

Compare the results with the curves supplied by the power transformer manufacture.

VIDEO: – Temperature rise test

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1.11-Transformer Frequency Response Analysis (FRA Test)

This test is called also Sweep Frequency Response Analysis (SFR test) and can be
done by generating a sweep frequency on the high voltage-winding of a power
transformer and detecting the output signal on the low-voltage winding of the transformer
to produce a picture of the transformer-winding ability to transfer the generated
frequencies in the secondary side.

This test is done at the factory and the response is plotted in a file. After transportation of
the power transformer to the site, the test is repeated at the site and if there is any
mechanical shift in transformer windings or any electrical problem in the transformer
windings – the picture of the generated frequencies at the site will differ from that
one generated at the factory.
The response of transformer windings will be as figure print of that transformer. For
comparison purposes, the test can be performed at the factory for identical power
transformers. It is useful to perform the test if a short-circuit occurs inside or outside the
operational transformer, to investigate the response of transformer windings after this
fault.

Many manufacturers provide an SFR device kit.

VIDEO: – Transformer frequency response analysis (FRA)

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1.12 Transformer Partial Discharge Test

This test is used to determine an approximate lifetime of the insulating material of the
transformer. These partial discharges happened at a cretin area in the insulating
material in gaps or the surface of the material with small energy. Partial discharges do not
cause a breakdown or flashover but by the time the thermal energy of these discharges
causes deterioration, aging in the insulating material of the transformer.

This test can be performed at the site or we can provide the transformers with online
devices that measure the discharges instantaneously and can forecast the lifetime of the
transformer. This can be especially critical in power stations as the failure of the unit
transformer can lead to unit shutdown.

It’s worth mentioning that an order of a the new transformer usually takes months.

Suggested reading – Measurements of bad impulsive noise in HV substation caused by

partial discharge (PD) sources

Measurements of bad impulsive noise in HV substation caused by partial discharge

(PD) sources

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Go back to the Contents Table ↑

2. Transformer General Tests

These tests include testing of relay and control panel of power transformer, transformer
Local Control Cubicle (LCC) , fans, motor or pumps, and control and tap changer. control
box.

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3. Transformer Primary Tests

In this test, a stability test of transformer differential protection is performed by injecting
380 volts on the transformer HV side, and shorting the LV side. Measurements are
taken in the current transformer of the differential protection in HV and LV sides.
Readings of the operating current and the restraining current in the differential relay are
taken.

Also, the primary injection test in transformer bay to check the circuit continuity in
secondary circuits.

Suggested reading – Secondary injection testing for transformer differential protection

relay

Secondary injection testing for transformer differential protection relay

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4. Transformer Secondary Tests

Secondary tests include secondary injection tests of transformer protective relays, voltage
regulation relay test with tap changer, and checking of all alarm circuits.

Suggested reading – 6 alarms coming from a substation transformer you MUST take
seriously

6 alarms coming from a substation transformer you MUST take very seriously

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5. Transformer Tripping Tests

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All tripping issued from protective relays to the high-voltage circuit breaker and low
voltage the circuit breaker of the transformer should be checked also intercropping from
high-voltage side to low voltage side should be checked, Buchholz relay, transformer-
winding device, transformer oil device tripping should be checked.

Suggested reading – The mystery of nuisance tripping incidents in transformer protection

that worry engineers

The mystery of nuisance tripping incidents in transformer protection that worry

engineers

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6. Transformer Load Tests

A new transformer should be connected to an empty busbar to accelerate the overcurrent
protection by reducing its time to have fast tripping for any fault.

It’s advisable to check phase rotation and phasing of transformer voltages in the three
phases on HV and LV sides. Loading the transformer and taking the reading of currents in
secondary circuits of the transformer on the HV and LV sides should be performed as
well.

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