An ISO:9001 Cerified Company

Transformer

Energypac Engineering Ltd.

10,Jiban Bima Tower,11th Floor
Motijheel Dilkusha
Dhaka-1000, Bangladesh

1
PREFACE

Testing procedures and equipment used for the testing and measurement of power transformer at
Energypac Factory are dealt in the scope of this booklet.

The electrical characteristics and dielectric strength of the transformer are checked by means of
measurements and tests defined by standards (e.g, IEC, ANSI and BS....... etc) and by the
requirements of customer’s specifications.

Summary of the tests and measurement processes are given as follows :

ROUTINE TESTS:

1. Measurement of winding resistance 3

2. Measurement of Insulation Resistance 5
3. Measurement of voltage ratio and check of vector relationship. 6
4. Measurement of impedance voltage and load loss. 10
5. Measurement of no-load loss and current 13
6. Dielectric tests 15
7. Separate source voltage withstand test 17
8. Induced over –voltage withstand test 18
9. Tests on on-load tap changer 20

TYPE TEST AND SPECIAL TESTS (Performed at Independent International Labs)

10. Temperature rise test 21

11. Measurement of Zero sequence impedence 26
12. Lightning impulse test 27
13. Switching impulse test 31
14. Measurement of acoustic sound level 33

List of tests and measuring equipment of the test field.

Prepared by :

2
1. MEASUREMENT OF WINDING RESISTANCE

Although the winding resistance values are not the guaranteed values given to customers, they
are needed in connection with the load loss measurement when the load losses corrected to
correspond to the reference (e. g. 750C) temperature. The resistance measurement will also show
whether the winding joints appropriate and the windings are correctly connected.

The winding resistances that very with the temperature strongly, are the ohmic/ d.c resistance’s of
a winding and the resistance is computed as follows :

235 +t 2 225 +t 2
R 2 =R 2 . ( for copper ) R 2 = R 1 . ( for alu min ium)
235 +t 2 225 +t 1

Where ; R2 = winding resistance at t2 temperature

R1 = winding resistance at t1 temperature

Therefore wherever the winding resistances are stated the temperatures during the measurement
must be given.

The resistance between all pairs of phase terminals at all tapping connections are measured.
During the measurement of the resistance, winding temperature should be correctly measured.

Direct current can be obtained from a constant-current supply or from a battery unit. The value of
the direct current should be high enough to ensure correct measurement and should be low
enough to prevent any effects on the winding temperature. In practices this value should be
greater than 1,2x10 and less than 0,1xIn The time constant of the measurement circuit will depend
on the ratio of L/R.

When the test object is assumed to be composed of a R resistance and L inductance which is
series connected to it, U voltage applied to this circuit will be;

U⎛ − t ⎞
R
i= ⎜1 − e L ⎟ Where time coefficient depends on L/R ratio.
R ⎜⎝ ⎟
⎠

If the measuring current increases it leads to the reduction of inductance due to saturation of the
core these enables the current to reach the steady state condition in a short time.

After switching on the supply voltage to the measurement circuit, it should be waited until the
current becomes stationary, otherwise measurement errors will be occurred.

Measurement Circuit

Winding resistances can be measured by any of the following method, by current voltage method
or by bridge method. Measuring sensitivity can be increased by using the digital measuring
instruments. The circuit of the measurement by current –voltage method is given in figure 1.1.

In the current voltage measuring method, by applying the winding current through the reference
resistance in the system, the voltage drops occurred in both resistances. Thus voltage drop values

3
of reference and winding resistances are compared to determine the value of unknown resistance
(winding resistance) which can be read directly from the bridge instrument.

It is necessary to care in older avoid of very high voltages during the switching on and off the
circuit the voltmeter shall not be kept in the circuit during this time.

Figure 1.1: Winding resistance measurement by Current-Voltage method.

In the method measurement the principle is the comparison of unknown resistance with a known
resistance. This will be accomplished to make the current flowing through Galvanometer to zero by
bringing the arms of the bridge into the equilibrium. The lower resistances with (<1ohm) are
measured by Thomson (Kelvin) Bridge, the resistances with relatively higher (≥1ohm) are
measured by Whitestone Bridge. By this means, the measurement errors are minimized.

Figure 1.2 : Thomson (Kelvin) Bridge Method Figure 1.3: Whetstone Bridge

The resistance measured by Thomson (Kelvin) bridge method.

R1
Rx= RN . (R1 R3 and R2 = R4)
R2

The resistance measured by Whetstone Bridge method.

R1
Rx= RN .
R2
In Energypac for measuring Resistance, Digital winding resistance meter, specially designed for
this purpose in used.

4
2. MEASUREMENT OF INSULATION RESISTANCE

The purpose of the measurement is to determine the leakage current of the insulation
resistance. This current is changing with the moisture, impurity contents and temperature of the
insulation.

Beside the result of the measurements, the comparison of the periodical measurement give
the information about the condition of the insulation. In order to compare they must be at
the same temperature ( for example at 200C reference temperature ).

"Time resistance method" in the insulation resistance measurement is one of the best
methods, that is simple and gives correct results.

The insulation resistance is measured by means of an insulation resistance meter which apply a
voltage 1000 V dc or 5000 V dc. Each winding is measured separately by connecting the
voltage between the winding to be tested and earth. While the other windings are connected
to the guard circuit of the test instrument. The temperature and humidity are recorded during the
test.

The Resistance values R15, Rio, R45 and R60 are taken at 15 s, 30 s, 45 s and 60 s after apply the
voltage. Furthermore, the ratio of the insulation resistance R60 to the insulation resistance R15 (or
R30 ) is stated as absorption ratio in the test report.

Readings are referred to 200C by multiplying the value at transformer oil temperature 0
(ambient ) by correction factor given in table below :

θ0C Correction factor θ0C Correction factor

-10 0.13 35 2.80
-5 0.18 40 3.95
0 0.25 45 5.60
5 0.36 50 7.85
10 0.50 55 11.20
15 0.75 60 15.85
20 1.0 65 22.40
25 1.40 70 31.75
30 1.98 75 44.70

5
3. MEASUREMENT OF VOLTAGE AND CHECK OF VECTOR RELATIONSHIP

The voltage ratio (i,e turn ratio) of the transformer is the ratio of voltage at no-load.

Purpose of the measurement : verification of no-load voltage ratios specified by the specification
and detection of any problem within the coils or tapping connections.

Measurements are carried out on all taps and on all phases.

Measuring Circuit

Turn ratio measurement is performed by

(Turn ratio test by TTR) Measurement of voltage ratios.

1. Turn ratio measurement is carried out by means of a voltage ratio measuring bridge in one-
phase basis between the winding pairs. measurements are repeated at all phases and all taps.
During measurement only the turn ratio between the windings in which same magnetic flux flows.
In other words the turn ratio can be measured between the winding pairs, which are in parallel in
vector diagrams (figure 3.1,3.2,3.3). The supply voltage is 60/120 Vac

Figure 3.1: Measurement of voltage ratio measuring bridge.

1 Transformer to be measured.
2 The Transformer with adjustable taps.
3 Zero indicator.

U1- The supply voltage of the bridge and H.V winding (60V/120V, 50 Hz)
U1- The inducted voltage of the bridge in L.V winding.

the voltage of HV winding

Theoretical turn ratio :
the voltage of LV winding

The theoretical turn ratio of the transformer is adjustable on the tapped transformer of the bridge %
error indicator knob is adjustable until the balance is reached to the zero indicator. The reading
from the error indication scale shows the difference (deviation) between the actual turn ratio and
turn ratio in %.

(measured turn ratio) − (theoretical turn ratio)

% Deviation = x 100%
theoreticaal turn ratio
% deviation can directly be read from the TTR. The minimum deviation measured by the
TTR±0.01%

6
(connection group) and current measurements can be performed with these method. The method
of comparing the voltages of dual vectors enables the measurements of phase shifting between
the vectors.

The deviation in the turn ratio shall be <±0.5%

Vector Group

In multiphase transformers primary & secondary connections can be either star (Y) delta (D) or
zigzag (Z) depending on the type of the transformer. The phase angle between the primary and
secondary windings changes between O0 and 3600. The vectorial denotation when HV windings
shows 12 (0) the numbers of the other windings in the connection group show the number of the
clock in comparison with real or imaginary neutral point. For example in Dyn11 connection group
HV winding is Delta (D), LV winding is Star (Y) and there is a phase displacement of (1x300)
between the windings. When the vector of H.V shows 12 (0) the vector of L.V shown 11 300 Load)

The connection group is defined only for three-phase transformers. In connection group
denotation, the H.V winding is shown first (as a reference) than the other winding are as followed
up

The vector diagrams are also checked at the same time. The correct connection of the
measurement cables between the transformer and between the bridge verifies the vector
relationship otherwise it is not possible to balance the bridge.

Besides the above mentioned the check of vector relationship and the check of polarity also could
be done using a volt-meter. In this method AC or DC voltages could be applied.

The wiring connections related with the AC method are given in standards as in details. An
example to this method is illustrated in a phase diagram as below :-

Example : Vector Group Dyn11

Measuring Procedure :

1. three phase voltage is applied to ABC phase.

2. he voltage between any two phases is measured ( e. g AB)
3. C & C terminals are short circuit.
4. the voltage between A and a / is measured.
5. the voltage between A and b / is measured.
6. the voltage between B and b / is measured.
7. the voltage between B and a / is measured.

7
 Figure 3.2: measuring of vector group

As it can seen from the phase diagram, to obtain Dyn11 vector group the following condition
should be realized.
Aa ′ = Ab ′ = Bb ′ < Ba ′

The other vector relationship can be checked by using the same principles.

3.2. Measurement of Voltage Ratio

Voltage ratio measurement is generally performed by the 0.5 class........... volt meter.

For 3∅/1∅ transformer 3∅/1∅ AC supply is applied to the HV side of the transformer.

For measuring input & output voltage voltmeter is connected to both HV & LV side. By measuring
applied voltage at HV side and inducted voltage on LV side voltage ratio is measured as below :
VHV
=Voltage Ratio
VLV

MeasuredRatio − Therotrical Ratio

% Deviation = x100
Therotrical Ratio

Measuring CKT

Fig 3.3: Measuring cisrcuit connection diagram.

8
9
4. MEASUREMENT OF IMPEDANCE VOLTAGE AND LOAD LOSSES

Short-circuit (load) losses and short-circuit impedance voltage are guaranteed and reported values
by the manufacturer to customers. Short-circuit impedance voltage is an important parameter
specially for the parallel operation of the transformers, where as short-circuit losses are important
from economical point of view.

This measurement is carried out to determine the load losses of the transformer and the
impedance voltage at the rated frequency and rated current. The measurements are made
separately for each winding (e. g between 1st winding and 2nd winding for a two winding
transformer and between 1st and 2nd between 1st and 3rd and between 2nd and 3rd winding for a
three-winding transformer). If the tapping range is more than 5% the measurements are repeated
on the extreme tapping also.

Measurement Circuit

1. 3∅ balance AC source
2. 0-1000A dimmer stat
3. Loading Transformer
4. Capacitor Bank
5. Transformer current
6. Potential transformer
7. Transformer under test
(A) Ammeter
(W) Watt meter
(V) Volt meter

Rated current is generally applied to the H.V winding while L.V winding is short-circuited. Test
current should be close to the value of IN rated current as mush as possible. And the voltage
waveform should be in sinus-form with rated frequency. The voltage, current and load losses for
each phase should be measured during the test.

In case that the source could not supply the system, the reactive power is encountered by using
the capacitor banks.

10
The reading have to be taken as quickly as possible to prevent the temperature changes in the
windings and the applied current should be between 25% .......... to 100% of rated current, So that
the measurement errors are minimized.

If the measuring current is different than the “IN” (rated current) short circuit impedance and load
losses are calculated referring the rated current as follows :

IN IN 2
U k =U km . P k = P km . ( )
Im Im
Ukm = Measured short circuit impedance Im = Measured current

Pkm = Measured load losses Pk= Load losses at rated current

Uk = Short-circuit impedance at rated current

According to the standards, the measured values of the losses are evaluated at a reference
temperature (e.g 750C). The measuring temperature (tm) losses are corrected to the reference
temperature () 750C) according to the standards as follows :

The d.c losses Pdc at the measuring temperature “tm” are calculated using the resistance values
RHV and RLV obtained in the resistance measurements RHV and RLV between line terminals.

DC losses = at tm measuring temperature Pdc = ( I 1 . R HV + I 2 2 . RLV )

2

Additional losses = at tm measuring temperature Pac = Pkm – Pdc

The load losses at reference temperature :

t s + 75 o C t +t
Pk = Pdc + Pac . s m Where, ts :2350C for copper ( acc To IEC)
t s+t m t s + 75
2250C for aluminum (acc To IEC)

The short circuit impedance

At measuring temperature (tm) u km = 100.

U km
[%]
UN

u RM =100.
Pkm
[%] ohmic component u xm = u 2 km − u 2 RM [%] ‘inductive component’
SN

Pk
At reference temperature of 750C : u R = 100. [%], u k = u 2 R + u 2 xm [%]
SN

Load losses and short circuit impedance measurements and corrections must be done at rated
and extreme taps.

If the short-circuit losses and voltage of a transformer measured at frequency which is different
form rated frequency, the following correction must ve applied.

11
 fN fN 2
Short circuit impedance voltage u k = U km . short-circuit Pk = Pdc + Pac . ( )
fm fm

Where,

Ukm = short circuit imp. voltage at fm meas. freq. Uk = short circuit imp. voltage at fm meas. freq.

Pac = additional losses at fm meas. freq. Pk = total short circuit losses at fn rated freq.

12
5. MEASUREMENT OF NO-LOAD LOSSES

The no load test is performed when one of the winding is unconnected to power supply (usually
the H.V winding) while the other winding is supplied with rated voltage at rated frequency. Then
the no-load losses ( P0) and the no-load current ( I0) are measured. the test is usually carried out
between 90%-115% of Un voltage at equal interval and corresponding values to the rated voltages
are determined.

No Load- Losses and No- Load Current

The following losses occur at no-load

Iron losses in the transformer core and other metal parts.

Dielectric losses in the insulation’s
Load losses caused by the no-load current.

Since the last two mentioned losses are relatively very low, they can be ignored. So that the no-
load losses are only the iron losses.

Measurement Circuit

1. 0-100A Dimmer star

2. Loading Transformers
3. Capacitor Bank
4. Current Transformer
5. Potential Transformer
6. Transformer under Test
(A) Ammeter
(W) Watt meter
(V) Volt meter

13
Because the losses are to determined under standard conditions. It is necessary to apply a wave
shape correction by losses are corrected to correspond to test conditions where the supply voltage
is sinusoidal. In case of non-uniform waveform the effective value of voltage (U) is different that the
mean value (U). Three is no need for correction, if the voltmeter readings are the same for all.

The test voltage wave shape is satisfactory if the difference between reading U and U are less
than 3%.

The test voltage (U) is adjustable by the “mean value” voltmeter. Than the hysterics losses can be
measured correctly. But the Eddy- current losses should be corrected.

Pm=Po(P1+k. P2) Pm measured losses

P0 no-load losses at sinusoidal voltage

2
⎡U ⎤
k=⎢ ⎥ P1 ratio ( as a percentage) hysterias is losses to total iron losses.
⎣U ′ ⎦
P2 ratio ( as a percentage) of Eddy current losses to total iron losses.

It is assumed that for cold oriented steel sheets at 50 and 60 Hz, P1 =P1=50% This yields

Pm
P0 = Where : P1 = P2 =0.5
P1 + k . P2

2
⎡U ⎤
According to IEC 60076-1; Pm = P0.(1+d) where k=⎢ ⎥
⎣U ′ ⎦
During the no-load loss measurement the r.m.s value of no-load current is also measured at the
same time. For a three phase transformer, the average of the three phase currents is taken.

During the measurements the connections of the transformer shall be as foreseen in the services.

The transformer could be magnetized by d.c before performing the no-load test. Therefore, the
transformer shall be supplied with a voltage during a suitable duration (a few minutes) for
demagnetization of the core then the measurement shall be made.

Since the no-load currents are not symmetrical and generally not equal in magnitude. they have
also different phase angles in three phases, so that the indications on the watt-meters will not be
equal. The indication on one wattmeter can be zero (0) or even reach to (-) negative value.

If the measurements are being made on delta connected windings, one of the current can be
absolutely greater and the other two can be similar and their magnitude approximately equal to
each other. On star connected windings, the measured current on the middle phase can be
smaller and the outer phase currents can be greater.

When the analysis is made on phase currents, due to non-linear and dissymmetrical structure of
the core, dissymmetrical distortion will be also detected on the currents, which are happened as
currents harmonics. The measurements are made normally at room temperatures.

14
6. DILECTRIC TESTS

The standard dielectric requirements are verified by dielectric tests. They shall where applicable
and otherwise agreed upon be performed in the sequence as given below.

Switching Impulse Test : The test is intended to verify the switching impulse withstand strength
of the line terminals and its connected winding(s) to earth and other windings and along the
winding.

Lightning Impulse Test : The test is intended to verify the impulse withstand strength of the
transformer, when the impulse is applied to its line terminals.

Separate Source Withstands Voltage Test : The test is intended to verify the AC withstands
strength of the line and neutral terminals and their connected windings to earth and other
windings.

Induced AC withstand Voltage Test : The Test is intended to verify the AC withstand strength of
the each line terminal and its connected winding (s) to earth and other windings, the withstand
strength between phases and along the winding(s) under test.

Partial Discharge measurement : It verifies partial discharges free operation of the phases and
along the winding(s) under test.

Transformer windings are identified by their maximum operating voltage Um and their
corresponding insulation levels, and applicable dielectric tests are given in the below.

Category of Highest Tests

winding voltage for Lightning Switching Long Short Separate
equipment impulse (LI) impulse duration duration source AC
Um KV AC ( AC (
ACLD) ACSD)
Uniform Um ≤ 72.5 type (note-1) N/A N/A routine routine
insulation (note-1)
72.5<Um≤ routine N/A special routine routine
170
170<Um <300 routine routine routine special routine
(note-2) ( note-2)
≥300 routine routine routine special routine

Note –1 : In some country for transformer with Um ≤ 72.5 kV, LI tests are required as routine tests
and ACLD tests are required as routine or type tests.

Note –2 : If the ACSD test is specified the SI test is not required.

The transformer which have one or more non-uniformly insulated windings, the test voltage for
induced voltage test and for the switching impulse test if used are determined by the winding with
the highest. Um value and the windings with lower Um values may not receive their appropriate test
voltages. This discrepancy should normally be accepted. It the ratio.

Between the windings is variable by tapping this should be used to bring the test voltage for the
winding with lower Um voltage as close as possible to the appropriate value.

15
If LI is requested to include the chopped wave in this case the peak value of the chopped impulse
shall be 10 % higher than for the full impulse (i.e 10 % more ).

For transformers with a high-voltage winding having U m > 72,5 kV, lightning impulse tests are
routine tests for all windings of the transformer.

Repeated dielectric tests:

For transformers which have already been in service and have been refurbished or serviced,
dielectric tests shall be repeated at test levels of 80 % of the original values, unless otherwise
agreed upon, and provided that the internal insulation has not been modified. Long duration
AC induced test (ACLD) shall always be repeated at 100 % test level. Repetition of tests
required to prove that new transformer, having been factory tested, is always performed at
100% of test level.

16
7. SEPARATE SOURCE VOLTAGE WITHSTAND TEST

The purpose of the test is testing the insulation between the windings and the insulation
between windings and earth parts (tank press iron, etc) under the temporary and switching
over-voltages conditions which may be occurred during the service.

Test Circuit

The test which are made with separate source voltage shall be made at rated frequency or at a
frequency nor less than the 80 percent of the rated frequency. This allows the testing of 60 Hz
transformers at 50 Hz. The waveform of voltage must be sinusoidal as much as possible and
must be single phase.

The voltage is measured by using tapping from the HV winding (Measuring winding) in
conjunction with voltmeter response to r.m.s values. The test duration is one minute. The test
voltage is applied to the winding which is going to be tested (all terminals of this windings that
are not under test voltage tank and core also should be grounded. Secondary winding terminals
of the bushing type CT’s shall be connected to each other’s and grounded in order to prevent
unwanted sparkling.

The current should remain constant during the test.

The test is successful if no collapse of the test voltage occurs.

This test is applied to the uniformly insulated windings and to the star point (neutral point) of the
graded insulated (non-uniform) windings. Every point of the windings to which the voltage
applied is tested with the test voltage.

The line terminals of non-uniform insulated windings are tested by induced over voltage
withstand test.

17
8. INDUCED OVERVOLTAGE WITHSTAND TEST

The purpose of the test is testing the insulation between the phase windings, turns, coils,
tapping leads and terminals, for non-uniformly insulated windings also the insulation between
these parts and earth, under the temporary and switching over-voltages conditions to which the
transformer may be subjected during its life time.
Normally, the excitation voltage is applied to the terminals of the low voltage winding while the
terminals of the other windings are left open or grounded in one point.
Since the test voltage is much higher than the rated voltage, the frequency of the test voltage is
chosen at least two times greater than the rated frequency without causing the over saturation in the
core.
The test voltage is measured with voltage transformer connected to H.V. terminal or the test
voltage can be read from the voltmeter through voltage transformer in the low voltage side,
which is calibrated with the voltage transformer. Another method is to measure the test voltage
from the peak value voltmeter, which is connected to the test tap of H.V. condenser bushings.
The peak voltmeter indicates the peak value divided by √2.

The test duration not being less than 15 seconds is determined by the following formula;

Rated frequncy
120 sec ond ×
Test frequency
If no flashover voltage collapse and abnormal increase in the current occurs during the test,
then the test said to be satisfactory.

Short duration induced AC voltage test ( ACSD )

a) Uniformly insulated windings

Test connection is essentially the same as in service, a three phase symmetrical voltage is
supplied. The test voltage is generally twice as the rated voltage. However, the voltage
between line terminals of any winding shall not exceed the rated short duration power frequency
withstand voltage. The tapping of the transformer should be accordingly.

The voltage is measured from terminals to earth or between terminals of the low voltage
winding using precision voltage transformers.

Test Circuit

Figure 8.1: Test circuit for induced over-voltage withstands test on uniformly insulated winding

18
1. synchronous supply gen.
2. test transformer
3. current transformer and ammeter
4. voltage transformer and voltmeter
5. transformer under test

Transformers with Um < 72.5 kV normally, no partial discharge measurements are performed
during this test. Test duration and voltage are explained above.
Transformers with Un > 72,5 kV this transformers shall all, if not otherwise agreed, be tested
with partial discharge measurement. The partial discharge performance shall be controlled
according to the time sequence for the application of the voltage as shown in figure 8.2 :
U2 = 1,3 Um /√3 phase - earth and U2 = l, 3 . U2 phase – phase
A : 5 min
B : 5 min
C :test duration
D :≥5 min
E: 5 min

Um Highest voltage for

equipment

Figure : 8.2 Test duration voltage –time curve

b) non-uniformly insulated windings

For three phase transformers, two test sets are required ;

1. A phase-to-earth test with rated withstand voltages between phase and earth with
partial discharge measurement.
2. A phase-to-phase test with earthed neutral and with rated withstand voltages between
phases with partial discharge measurement. The test shall be carried out in accordance with
uniformly windings (sub clause a ).

On single -phase transformers, only a phase-to-earth test is required.

The test sequence for three phase transformer consist of three single-phase applications of
test voltage to the individual phases with different points of the winding connected to earth at
each time.

At this type of windings, induced over voltage test and separate source voltage withstand test (
at the phase terminals) are performed in the same time.
For the three single-phase tests for the phase-to-earth insulation ; U2 =1,5 • U m / √ 3
For the partial discharge performance evaluation, during the phase-to-phase test,
measurements should be taken at U2 = 1.3 . Um. For U2 = 420 kV and 550 kV transformers with
test values of 460 kV and 510 kV, the PD evaluation level should be reduced to U 2 = 1.2. Um
during the phase-
to-phase test and U2 =1.2 • Um/√3 - during the phase-to-earth test.

19
1. synchronous supply gen.
2. test transformer
3. current transformer and ammeter
4. voltage transformer and voltmeter
5. transformer under test

Fig 8.3: Test circuit for induced over-voltage withstands test on non-uniformly insulated winding of a three-
phase transformer.

9. OPERATION TESTS ON ON-LOAD TAP CHANGER

After the tap-changer is fully assembled on the transformer, the following tests are performed
at (with the exception of clause b) 100% of the rated auxiliary supply voltage;
a) 8 complete operating cycles with the transformer not energized.

b) 1 complete operating cycle with the transformer not energized, with 85% of the rated
auxiliary supply voltage.

c) 1 complete operating cycle with the transformer energized at rated voltage and frequency
at no-load.

d) 10 times tap-changer operations with ±2 steps on either side of the principal tapping with
as for as possible, the rated current of the transformer, with one winding short-circuited.

20
10. TEMPERATURE RISE TEST

The purpose is, to check that the temperature rises of the oil and windings do not exceed the limits
agreed on or specified by the standards.

The supply and measuring facilities as well as the measuring circuits are the same as in the load
loss measurement (section 3) and in the measurement of windings resistance (section 2).

Simplified temperature distribution diagram is given in figure 10.1.

Figure 10.1 A simplified temperature distribution for a transformer.

θ0 = maximum oil temperature (under cover)

Ìθ0 = maximum oil temperature rise Ìθ0=θ0-θa
θ0 = ambient temperature
θw = the average winding temperature
Ìθ0 =the average winding temperature rise Ìθw=θw-θa= Ìθwo-Ìθoawg
θg =temperature of oil going into the cooler
θc = temperature of oil coming from the cooler
θ0max = maximum winding temperature
R = cooler
θoavg = the average oil temperature rise
Ìθ0w =the temperature difference between winding and oil
Ìθ0oavg= the average oil temperature
θhe = hot-spot temperature

a) The measurement procedure

The necessary precautions should be taken for the effects (i.e. warm or cool air circulation) which
would affect the transformer under temperature-rise test.
The current and voltage measuring principles, during this test, are the same as in the load loss
measurement. The temperature rise test will, unless otherwise specified, be carried out on the
maximum current tapping.

21
Since, it is necessary to record the temperature rises and the ambient temperature through the test,
thermometers are placed in a thermometer pocket in the cover, going out of the cooler and 1 to 2
meter away from the transformers. The temperatures in these thermometers are measured and
recorded when the transformer is in cold position before starting the test. Before starting the test,
the winding temperature (cold resistance measurement) is measured and recorded.

The transformer is supplied with a voltage and current which constitutes the sum of short-circuit
losses at the maximum loss tap and no-load losses in order to achieve to the service
conditions. For a multi winding transformer, the temperature rise requirement refer to rated power in
all windings simultaneously if the rated power of one winding is equal to the sum of the rated powers
of other windings.

In certain cases, if it suits, first part of the test can be a few hours shortened by switching of the
cooling system.

The maximum values of the current and the voltage during the supply are as follows;

Po + Pk Po + Pk
Supply current I d = I N . Supply voltage U d = U k .
Pk Pk

in which;

IN = Rated current (the current of the tap in which the test is performed)
Po = No-load losses, Pk = Load losses
The test is performed separately in two parts:

Total loss injection (1. Part of the test) : Supplied with total losses. The test is continued until a
steady-state oil temperature rise is established (i.e. the difference between top oil temperature and
ambient temperature is less than 1 ° C for 3 hour ). This period is called as first part of the test.
The supply values and the temperatures of different points are recorded at suitable time intervals.

b) Rated current injection ( 2. Part of the test) : When the top oil temperature rise has been
established, the test shall immediately continue with rated current supply one hour. This period is
called as second part of the test. The supply values and the temperatures are recorded as above. At
the end of one hour, supply is disconnected and the hot-resistance of windings are measured. The
test connection is changed for carrying out the resistance measurement and after the inductive
effects have disappeared the resistance time-curves are measured for a suitable period of time than
by extrapolation method the resistance value of the winding at the instant of switching off the supply
is determined.

After disconnection of the test current, the pump circulation and fan ventilation are continued.

b) Measurement of ambient temperature (Temperature of cooling air or water)

The cooling ambient temperature is measured by means of at least three thermometers or
thermocouples. Measurement is done by placing the thermometer or thermocouple in a container filled
with oil which has 2 hour time-constant. Containers should be protected against any air circulation
and thermal ray. They should be replaced I and 2 m away from the three sides of the transformer
at a height of half way up the transformer coolers.

For forced-air cooled transformers the temperature of the in going air is measured. If water is used
as cooling medium, the water temperature at the intake of the cooler ( in the thermometer pocket)
is the reference temperature.

22
The values of cooling ambient temperature ( cooling air or water temperature) taken at every 1/2
hour in the last quarter of the test are used for temperature rise calculations.
c) Determination of the temperature rise of oil
The top oil temperature is measured by a thermometer placed in an oil filled thermometer pocket on
the cover. The difference between the maximum measured temperature and ambient temperature is

1
θavg =θ0 – . θ g -θ c the average oil temperature
2
∆t oavg = θ oavg − θ a the average oil temperature rise

The temperature of oil coming in and going out of the cooler is measured by means of
thermometers which are fitted to the pipes of the cooler. When the transformer has separate cooler,
oil inlet and outlet temperatures are measured on the inlet and outlet pipes near to the transformer
tank.
If the test object during the test can not be supplied by the current which encounter the total losses
of the insufficient power, in this case test losses (ensuring that not less than the 80 percent of the
total losses) are computed as follows:
X
⎛P ⎞
∆θ ON = ∆θ OM .⎜⎜ N ⎟⎟ ÌθON : total losses temperature rise at PN rated value
⎝ PM ⎠
ÌθOM : test losses temperature rise at PM test
X : for distribution tr. (natural cooling rated power <
2500 KVA) = 0.8 ON-cooling =0.9 OF and Water
cooling =1.0

d) Determination of the temperature rise of the winding :

The transformer under test is continuously supplied by IN rated current the oil temperature is
reached to the equilibrium. This is necessary to adapt the equilibrium between the winding and
the oil into the conditions when the transformer is in service, At the end of this time, the circuit
is switched off and the winding cooling curve is obtained by the method of winding resistance
measurement.
The winding temperature rise is calculated as follows :

R2
θ2 = (235 + θ1 ) − 235 Where
R1
θ2 : Winding temperature of the instant of switching off
θ1 : Winding (cold) temperature at the beginning of the test
(average oil temperature)
R2 : The resistance at θ2 temperature
R1 : The resistance at θ1 temperature
P.S For aluminum windings 225 K should be taken instead of 235 K

When the supply of IN rated current for 1 hour is the second part of the test, the temperature of
oil decreases during this time. The relation between the temperature of the winding and the
average temperature of the oil shall be calculated with this decreases temperature.

23
Then :

Ìθwo=θ2=θwoavg (IN)
Where
Ìθwo = the temperature difference between winding and oil
θ2 = winding temperature
θoavg (in)= the average oil temperature at the end of 1 hour In supply

The temperature θoavg oil temperature rise is determined as in clause (c)

The Difference between the winding temperature and the average oil temperature in the second
part of the test is as follows :

θw +the average winding temperature is calculated when the Ìθw is added with the Ìθoavg from the
clause c) in the first part of the test (the supply of transformer with Ia)

Ìθw-Ìθwo +Ìθoavg

If the In rated current can not reached because of insufficient supply system the difference
between the temperature of the winding and the temperature of the oil is corrected as
follows :

y
⎛I ⎞
∆θ woN = ∆θ woM .⎜⎜ N ⎟⎟ Where
⎝ IM ⎠
ÌθwoN = the temperature difference at the rated Incurrent
ÌθwoM = the temperature difference at the test current IM
Y = exponent ON and OF cooling = 1.6
OD cooling = 2.0

The maximum temperature occurring in any part of the winding insulation system is called the “hot-
spot temperature”. This parameter represent the thermal limitation of loading of the transformer.
the winding hot-spot temperature rise versus ambient is computed as follows :

θhs=θwoM=+Chf+Ìwf Chf hot-spot factor

Hot-spot factor is 1.1 in distribution transformers and 1.3 in medium size power transformer

When the transformer is supplied with total losses in the first of the test, there is no need to make
any correction if the test frequency is different than the rated frequency but for the loading with
rated current for one hour in the second part of the test, the correction must be made in
accordance with the below equation :

2
Pdc + ⎛⎜ N ⎞ .P
f
⎝ f M ⎟⎠ ac
I M= IN .
Pdc + Pac

IM=Test current IN rated current

24
fM =test frequency fN rated frequency

Pdc dc losses Pac additional losses

25
11. MEASUREMENT OF ZERO-SEQUENCE IMPEDANCE

The zero-sequence impedance is usually measured for all star or zig-zag -connected windings
of the transformer. The measurement is carried out by supplying with rated frequency
between the parallel connected phase terminals and the neutral terminal. The zero-sequence
impedance per phase is three times the impedance measured in this way.
Uo
Zo = 3 . Ω / phase
I

Figure 11.1: Circuit for zero-sequence impedance measurement

Zero-sequence impedance is related with connection group and manufacturing properties.

Zero-sequence impedance consists of two parts as Ro ( real) and Xo ( imaginary), due to
Ro<< X0, Ro can be neglected. This yields the zero sequence impedance equals to zero-
sequence reactance.

Zero-Sequence impedance, only winding which star point is brought out can be measured.
Measurement is done at principal tapping when the active part of the transformer is installed in
the tank.

The value of zero-sequence impedance is infinity for the windings which are delta connected or
the star point is not brought out.

When the other winding of the transformer is delta connected or a delta connected tertiary
winding exists, in the measurement of zero-sequence impedance, the star point of the
transformer can be loaded up to max. rated current. At this instant, the U0 test voltage will be
between 15 % and 27 % of the phase-neutral voltage of the transformer. In cases where
counter magnetic flux does not exists e.g. in star -connected transformers which do not have
tertiary windings, this test current shall be max. 0,3 x IN to avoid excessive temperature of
metallic constructional parts.

It can be said that for the transformers which both windings are star connected and which
star points are brought out, there are two different zero-sequence impedance's.
a- No-load zero-sequence impedance ZOO
When one of the star-connected windings is measured, the terminals of the other winding is
left open.
b- Short-circuit zero sequence impedance ZOK
When one of the star-connected windings is measured, the terminals of the other winding and
the star point terminals are short circuited.

26
Zero sequence impedance may be given as percentage of the rated phase impedance. In this
case.

IN
zo = Z o .
UN
zo = relative zero-sequence impedance (%)

IN = rated phase current (A)

VN = rated phase-neutral voltage (V)

ZO = Zero-sequence impedance (Ω/phase)

12. LIGHTNING IMPULSE TEST

The purpose of impulse Voltage test is to confirm that the transformer insulation’s
withstand the lightning overvoltages which may occur in service.

The Power Transformers used in high voltage systems at any time may be affected
by the atmospheric discharges.The magnitudes of the lightning over voltages
always depend on the impulse current and impulse impedance where the lightning
impulse occurs. This value is several timesof operating voltage.
Impulse voltage is produced by a “impulse voltage generator” I laboratory. For oil
type transformers, this impulse voltage is stated as with (-) negative polarity and
the waveform at the line terminal shall be T f r o n t /T t a i l = 1.2+30%/50+20%µS. Besides
the full wave (fig12.1) in chopped wave at the tail, the chopping time shall be
between 2….6µS.(Fig12.2).

T 1 = 1.2+30%µS
T 2 = 50+20%µS

Fig 12.1: Full wave lightning impulse

27
 Figure 12.2: Chopped wave at the tail

Lightning impulse voltages are applied to the line terminals successively. The number and
application method of the lightning impulse voltages are stated in the standards. The other line
terminals and the neutral line terminal shall be grounded directly or through a small resistance (fig.
12.3 and 12.4).

In three-phase transformers, unless it has been agreed on a particular tapping, impulse

test are performed at he two extreme tapping and the principal tapping. Each phase tests
are performed at min., max. and principal tapping.

Sometimes in the LV windings of the higher rated transformers, it might not be possible to
reach half time-value on tail as it is defined in the standards. In such cases, suitable
resistances may be connected between the windings which are not under the test and the
ground. The resistance's must be so selected, according to /EC 60076-3, that the voltage of
these terminals of the windings against the ground must not be greater than the 75 % of the
test voltages of the winding terminals and the value of the resistance must be maximum 500 Ω

Figure 12.3 Connection diagram for the lightning impulse test

28
Some connection diagram used for lightning impulse test are given in figure 12-4

Figure 12-4 : One and three phase transformer impulse test

The voltage dividers used for measuring of impulse voltages generally are made of three types.

1- Ohmic voltage divider

2- Capacitive voltage divider
3- Mixed (ohmic capacitive) voltage divider

Although the types are changing according to the aim and place of using the most widely used
voltage divider is R damped capacitive voltage divider.

To measure the impulse currents, non-inductive, ohmic resistances are used. Usually its
value varies from 0, 1Ω to 20 Ω.

Coaxial cables are used to transmit the measurement signals to peak-value voltmeter and

29
to the oscilloscope.

If the application of chopped-wave is foreseen; a system which chopped the wave is added
to the impulse circuit. In modern impulse voltage circuits, this is usually a " Multiple chopping
device ".

In beginning impulse voltage test is started with a value of 50 percent of the test voltage which
wave form is determined by the oscillogram. After obtaining the form which is acceptable
according to the standards, first a "Reference Impulse" which has the magnitude of 50% percent
of the test voltage, is applied, then "Full Impulse" which has a value of 100% are applied at
certain times which the standards are stated.
The magnitudes of applied voltages are determined numerically on the peak-value voltmeter
through a voltage divider. Besides, the time-change of the applied voltage, and the changes of
the current leaking from the winding under test to the earth or the capacitive current leaking
from the windings which are under test, to the earth; are detected with photographs by means of
an oscilloscope.

For the evaluation of the impulse voltage tests, the evaluation of oscillographic records is a most
widely and most used method that is stated in the standard. For evaluation purposes, the
oscillographic record « the reference waveform which has small magnitude (50%
...................75%) should completely coincide with WO oscillographic record of the wave form
which has full magnitude (100%).

In some cases, there might be inconsistencies in the oscillogrammes due to the effects caused
by the arrangement of the test circuit, external disturbances and / or earthing circuit. Such
deviation should not be considered is indication of a failure.
Differences in the instant of firing of the stages in the impulse generator may give rise to initial high
frequency oscillations in the front part of the voltage vaweform.

Small differences in the wave pattern because of the chopping time may cause deviations
after chopping. These should not be considered as symptom for any failure.

If the impulse voltage to the neutral points is requested in technical specifications; the method of
impulse voltage application on this point are stated by two ways in the standards.

a) The application of a voltage, which will produce a determined impulse voltage magnitude
in the neutral point, to the parallel connected line terminals.

b) The direct application of determined impulse voltage to the neutral point.

When an impulse is applied to the neutral terminal "stated in b", a voltage waveform which
has longer front duration ( up to 13,uS) is permissible according to the standards.

30
13. SWITCHING IMPULSE TEST

The purpose of the switching impulse test is to secure that the insulation between windings,
between windings and earth, between line terminals and earth and between different terminals
withstand the switching over voltages which may occur in service.

The switching impulse voltage is simply produced by conventional impulse voltage generator. The
polarity of the voltage is negative, and form of the voltage shall he T 1 /Td / T2 >_ 200/200/500,uS
according to IEC 60076.3 (fig. 13.2).

Test conditions determine the choice of transformers tapping, see clause 5.

Because of the high saturation of core ( increasing of the flux density) during the switching impulse
test, after each test impulse, to bring the transformer core to the normal beginning condition
(demagnetized), a few impulse tests which have small magnitude and positive polarity, are applied
to provide the duration needed for the next impulse voltage .

The switching impulse test is carried out on each line terminal of a three-phase winding in
sequence. During the application, neutral terminal is grounded, the windings which are not under test
are left open (grounded from one point). This connection type is like the one in the induced over
voltage withstand test. The voltage distribution on the winding is linear like in the induced over
voltage withstand test and the voltage magnitudes of the windings, which are not under test, are
induced according to the turn ratio. It must be noticed that at this instance the voltage between the
phases will be 1,5 times of the phase-to neutral voltage.

The test connections in three-phase transformers vary with the core design ( three of five-legged),
the limit of the voltage between the phases, the position of the delta connected windings whether it is
open or closed.

Figure 13.1 Test circuit for the switching impulse test .

Test is first performed with a decreased voltage which is 50% of the test voltage, then it is carried
out with full value impulse voltages the number of which is stated in the standards. The peak value
of the voltage is measured by an impulse voltmeter. The change of voltage waveform and winding
current are determined by means of an oscilloscope. The faults which may occur during the test are
determined by comparison of current and voltage calligraphic records. The sudden collapses
(flashover) in the voltage and abnormal sound effects show the damage in the insulation of the
transformer. The variation in the voltage waveform and the increase of sound due magnetic
saturation of the core must not be considered as reasons for any fault.

31
 Front time : T 1 ≥20 ...<250µS = 1, 67 T

Ninety - percent time : Td ≥200µS

Time to first voltage zero : T2 ≥500µS

Figure 13.2 : Waveform of switching impulse voltage

32
14. MEASUREMENT OF ACOUSTIC SOUND LEVEL

The purpose of the sound level measurement is to check that, the sound level of the transformer
meets the specification requirements, or guaranteed values given by the transformer manufacturer.

The principal sound sources in transformers are

a) core sound : caused by magnetostriction and inter-laminar magnetic forces.
b) load sound : caused by electromagnetic forces in the windings, tank wall, and magnetic
shields.
c) cooling equipment sound : caused by fans and pumps.

The predominant source of transformer sound is the core. The core sound depends on the flux
density in the laminations and the magnetic properties of the core steel. The low-frequency and tonal
nature. It occurs at twice the power frequency. Magnetic forces within the core will create vibration
and sound.
Load sound is the sound emitted by a loaded transformer in addition to its no-load sound. It
is caused by electromagnetic forces resulting from leakage fields. The load sound is proportional to
the fourth power of the current. The sources of this sound are the vibration of the tank walls,
magnetic shields, and the windings.
The core and winding sound dominates the intermediate freq. range between 100 and 600 Hz.
Sound produced by the cooling fans ( aerodynamic and motor/bearing sound) is usually broad band
in nature. Factors that affect the total fan sound output, include type speed, blade design, number of
fans, and the arrangement of radiators. Pump sound is normally not significant if the fans are
running, although low frequency sound may be present.
The definitions have been given in IEC 60076 - 10.
The transformer must be located at the test site so that the free distance from the transformer to
reflecting objects is sufficiently large. It has to stand on a floor directly on its rollers, so that no vibration
will occur. All the accessories must be fixed tightly on the transformer.
The feeding of the transformer must be in sinus form at rated voltage and frequency.
When the tank height is less than 2.5 m the microphone is located at half of the tank height. When the
height of the tank is greater than 2.5 m the microphone position in the vertical direction shall be at 1/3
and 2/3 of the transformer tank height. The cooling equipments only energized, the microphone shall be
on a horizontal plane at half of the height for cooler structures with an overall height of less than 4m
and for cooler structures with an overall height of more than 4m the microphone positions shall be used
which are horizontal plane at 1/3 and 2/3 of the height. The measurement is carried out alone all the
circumference of the transformer. The max. distance between the measuring points will be not more
than 1 m.
The distance of the microphone from the principal radiation surface will be selected as follows;
1) If the fans of the cooling unit are switched-off, or they are assemble 3 m away from the
transformer, then the microphone must be 0.3 m away from the principal radiation surface.

2) If the cooling unit is switched-on ( the pumps and the fans working) the microphone must
be 2 m away from the principal radiation surface.

The test object shall be energized as follows :

a) transformer energized, cooling equipment and any oil circulating pumps out of service.
b) transformer energized, cooling equipment and any oil circulating pumps in service.
c) transformer energized, cooling equipment out of service, oil circulating pumps in
service.
d) d) transformer unenergized, cooling equipment and any oil circulating pumps in service.

33
Before starting the transformer sound level measurement the background noise level is measured. If
the difference between background noise level and the noise level of the transformer is more than 8
dB (A), no correction at the noise level of the transformer is needed. If the difference is between 3 dB
(A) and 8 dB (A), a correction is needed acc. to the standards. No measurement shall be made, if
the difference between background noise level and the transformer noise level is less than 3 dB. The
correction factor for the effect of background noise level to the transformer noise level is the in the
below table as per IEC 60076 - 10;

The difference between the The difference between Decisions

background and transformer the background noise
noise level levels before and after
LpAO –the higher LbgA Initial LbgA –final LbgA
≥8dB - Accept test
>8dB <3dB Accept test
<8dB >3dB Accept test
<3dB - Accept test

−
The corrected average A- weighted sound pressure level L pA shall be caculated by using
equation as follows :

⎡ o ,1 L o ,1 L ⎤
− − −

L PA = 10 log ⎢10 pAo − 10 bgA ⎥ − K

⎣ ⎦
LpA=10log[100.1 LpAO-101 LbgA]-K
−
L bgA : The lower of calculated average background noise
−
L pAO : Measured average sound level
K : Environment correction factor

The characteristics of the measuring equipment are described at the international standards. The
noise level of the transformer is measured acc to IEC 60076-10, NEMA standards using the
evaluation of the weighting curve A.

The principle of parameters influencing noise are either internal (frequency, flux, mass, quality of
magnetic material and operation) or external (distance). According to the laws of acoustics the
volume of sound decreases with the square of the distance “d” from the assumed point source, i.e.
the center of the equivalent hemisphere;

Lp(d)= Lp(2m) –20 Log (d/2) Where ; d is in meters

Other things the sound volume varies with the square of the frequency ;

Lp(f)= Lp(50hz) –20 Log (f/50Hz) Where ; f is test frequency

34