Transformer Testing

Test Methods and Testing Purposes

 Bangladesh University of Engineering and Technology
Department of Electrical and Electronic Engineering
Course No: EEE 206

Course Title: Energy Conversion Laboratory

Report Title
Transformer Testing:
Testing Methods and Testing Purposes

Submitted to

Dr. Md. Farhad Hossain Department of Electrical and Electronic

& Engineering,
Nurun Nahar Erina Bangladesh University of Engineering and
Technology

Submitted By

Shakil Ahammad Department of Electrical and Electronic

ID:1806052 Engineering,
Section:A2 Bangladesh University of Engineering
Level 2 Term 2
and Technology
Date of Submission:23 -02 -2022
Abstract
This report consist of the specification of a transformer and procedure of various testing of the
transformer

Specification of Transformer

• Type : Out door, Oil cooled

• KVA rating : 250KVA
• Rated voltage H.V. (Volts) : 11000
L.V. (Vol : 430
• Rated current H.V. (Amp.) : 0.84
L.V. (Amp.) : 21.33
• Number of phases : 3
• Connection H.V./L.V. : Delta/Star
• Frequency (Hz.) : 50
• Type of cooling : ONAN
• Temperature rise of oil : 45oC
• Vector group : Dyn-11
• Insulation level H.V. : 28 kVrms
• Insulation level L.V. : 3 kVrms
 1

Introduction
Transformer
A transformer is a stationary machine which facilitates in the transformation of electric power
from one circuit to another circuit of same frequency. The objective of a transformer is to convert
power from one system voltage to another. For a distribution transformer, this voltage
relationship, or voltage ratio, is determined by the ratio of the number of turns on the high
voltage winding to the number of turns on the low voltage
winding. As the alternating current in the high voltage
winding changes polarity 50 or 60 times a second (50Hz or
60Hz ac voltage), it induces a current in the low voltage
winding that is proportional to the voltage of the high
voltage winding divided by the ratio of the number of turns.
As the transformer works, it incurs power (and thus energy)
losses in the high voltage winding, the low voltage winding,
the core steel and in the surrounding transformer tank /
housing and fittings (called stray losses). The magnitude of
these losses relative to the power throughput determines
the efficiency of the transformer.
Various tests are done on a transformer to know its
efficiency and condition. The primary incentive of these tests
is to make sure the transformer meets manufacturing
specifications. Type test of transformer confirms basic
criteria of production lot. For confirming operational Fig. 1:A Distribution Transformer
performance of individual unit in a production lot routine test
is done. In this paper we have discussed in detail about some important test of a distribution
transformer.

Parts and Purpose

A transformer is made of several different parts that function in their own different ways to
enhance the overall functioning of a transformer. These include core, windings, insulating
materials, transformer oil, tap changer, conservator, breather, cooling tubes, Buchholz Relay, and
explosion vent. The core, windings, insulating materials and transformer oil are seen in almost
every transformer, while the other components are seen in transformers that are more than 50
KVA.
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Core
The core of the transformer is used to support the windings. It is
made of soft iron to reduce eddy current loss and Hysteresis loss
and provides low reluctance path to the flow of magnetic flux. The
diameter of a transformer’s core is directly proportional to copper
loss and inversely proportional to iron loss.

Windings
Fig. 2: Transformer Core
Windings consist of several copper coil turns bundled
together; each bundle connected to form a complete winding.
Windings can be based either on the input-output supply or
on the voltage range. Windings that are based on supply are
classified into primary and secondary windings, meaning the
windings to which the input and output voltage is applied
respectively. On the other hand, windings based on voltage
range can be classified into high voltage and low voltage Fig. 3: Transformer Windings
windings.

Insulating materials
Insulating materials like papers and card boards are used to isolate primary and secondary
windings from each other as well as the transformer core. These windings are made of copper
due to high conductivity and ductility. High conductivity minimizes the amount of copper needed
and minimizes losses. Moreover, high ductility results in easy bending of conductors into tight
winding around the core that also minimizes the amount of copper and volume of winding.

Transformer oil
The transformer oil insulates as well as cools the core and coil assembly. The core and windings
of the transformer must be completely immersed in the oil that normally contains hydrocarbon
mineral oils.
 3

Conservator
The conservator is an airtight metallic cylindrical drum fitted
above the transformer that conserves the transformer oil. It
is vented at the top and is filled only half with the oil to allow
expansion and contraction during temperature variations.
However, the main tank of the transformer with which the
conservator is connected is filled with the oil through a
pipeline.

Breather Fig. 4: Conservator and Breather

The breather is a cylindrical container filled with silica gel, which is used to keep the air that enters
the tank moisture-free. This is because the insulating oil when reacts with moisture can affect
the insulation and cause internal faults, which is why it is a must to keep the air free from
moisture. In the breather, when the air passes through the silica gel, the moisture contents are
absorbed by the silica crystals.

Tap changer
To balance voltage variations within the transformer, tap changers are used. There are two types
of tap changers – on load and off load. In on load tap changers, tapping can be changed without
isolating transformer from the supply, while in off load, the transformer needs to be
disconnected from the supply.

Cooling tubes
As the name suggests, cooling tubes are used to cool the transformer
oil. The circulation of oil within the transformer may be natural or
forced. In the case of natural circulation, when the oil temperature
rises, the hot oil naturally moves to the top and cold oil moves down,
while in case of forced circulation, an eternal pump is used.

Fig. 5: Cooling Tube

 4

Buchholz Relay
Placed over the connecting pipe that runs from the main tank to
conservator tank the Buchholz Relay senses the faults occurring
within the transformer. It operates by the gases emitted due to
decomposition of transformer oil during internal faults. Thus, this
device is used to sense and in turn protect the transformer from
internal faults.

Explosion vent
Fig. 6: Buchholz Relay
The boiling hot oil from the transformer is expelled during internal faults
through the explosion vent to avoid explosion of the transformer. This is generally placed above
the level of the conservatory tank.

Why needs testing

Transformers are one of the most expensive equipment used in distribution and transmission
process of power. So routine testing and maintenance of transformers are obvious.
The transformer must go through different procedures for testing periodically to prove that the
transformer is functioning properly. Below listed are some of the main reasons for transformers
testing:

❖ To check the workings of the whole transformer.

❖ To check if the main components/components of electrical transformers are working
properly.
❖ To reduce risk of a malfunction of working.
❖ To confirm the specification and performance of the transformer.
❖ To avoid future malfunction risks that will happen because of electrical, thermal, or
mechanical problem.

Now, it is necessary to define measurement accuracy (or uncertainty levels) of test methods to make sure
that the manufacturer, the customer, and energy regulator all obtain the same result while testing
distribution transformers.

IEC:
The IEC is a worldwide standardization organization made up of national electrotechnical committees.
Purpose of the IEC is to facilitate international co-operation on all matters concerning standardization in
the electrical and electronic fields. The IEC, therefore, prepare and publishes international testing
standards through technical committees made up of representatives from any IEC National Committees
who are interested. International, governmental, and non-governmental organizations also participate in
this process. The set of international standards published under IEC 60076, Power Transformers, were
 5

prepared by IEC Technical Committee 14. IEC mentioned of how to test transformer and standard of
testing value in their publication.

Type of Transformer Test

a) Type Test
b) Routine Test
a) Type Test of Transformer to prove that the transformer meets customer specifications and design
expectations, the transformer must go through different testing procedures in the manufacturer
premises. Some transformer tests are conducted for confirming the underlying design expectation of that
transformer. These tests are done in the prototype unit not in all manufactured units in a lot. Type test of
transformer confirms main and basic design standards of a production lot. Type tests of transformer
include:

1. Transformer ratio test

2. Measurement of insulation resistance.
3. Open circuit and short circuit test.
4. Transformer oil testing
5. Transformer winding resistance measurement
6. Magnetic balance test

b) Routine Tests of Transformer Routine tests of transformer are to confirm an operating performance
of a separate unit in a production lot. Routine tests are conducted on every unit manufactured. Routine
tests of transformer also include:

1. Open circuit and short circuit test.

2. Measurement of insulation resistance.
3. Transformer ratio test
4. Transformer oil testing
5. No-load tap changer tests.
6. Vacuum tests on tanks and radiators.
7. Transformer winding resistance measurement
8. Magnetic balance test Routine tests of transformer include all the type tests.
9. Testing the temperature rise of the transformer.

Here, in this paper we will broadly discuss about

1. Measurement of turns ratio test

2. Vector group test
3. Measurement of winding resistance
4. Measurement of insulation resistance
5. Measurement of no-load loss and no-load current
6. Measurement of impedance voltage and load loss at 75o C
7. Dielectrics withstand test/ High voltage test
8. Dielectric test of transformer oil
9. Temperature rise test
 6

1. Measurement of Turn Ratio Test

The transformer turns ratio test is used to specify the number of turns in one winding of a
transformer in relation to the number of turns in the other windings of the same phase of the
transformer. The transformer turns ratio test is one of the most fundamental transformer routine
tests declared by both IEC 60076-1 and IEEE C57.12.90. standards. When the transformer has an
on-load tap changer (OLTC), this test should be carried out on each tapping.

Why do we need to test turn ratio of transformer?

The transformer turn ratio is one of the most important parameters of the transformer, and the
change of the transformer turn ratio is closely associated with the change of the transformer
winding. Simultaneously, the transformer winding is the main component of the transformer to
transmit and convert electrical energy, which makes up the electrical circuit of the transformer
to input and output electrical energy. in a power system, two or more transformers are usually
operated in parallel, and these transformers are required to have the same phase, and the phase
difference between the two transformers cannot
overdo 0.5%, otherwise, a large circulation will arise
between the two transformers, and the loss of the
transformer will increase, which will certainly lead to
faults, such as winding short circuit or open circuit,
winding breakdown, or burning, and winding
deformation. These faults will affect the reliability of
the transformer windings. Transformer turn ratio
test is able to detect winding interturn turn-to-turn Fig 7: Vanguard ATRT 03 Three Phase Transformer
short circuit, winding open circuit, winding Turns-Ratio Tester
breakdown and burn and any other faults.

Equipment used: voltmeter, Vanguard ATRT 3 Phase

Transformer Turn-Ratio Tester .

Method:
IEC 60076-1 and IEEE C57.12.90 standards state that turns
ratio test will be carried out on a rated or lower test voltage
and rated frequency, by applying voltage on the HV side and
measuring the induced voltage. The turns ratio test is
conducted by applying a lowered test voltage to HV terminals Fig 8: Reading from turn ratio tester
and measuring an induced voltage at LV terminals, under no-
load transformer conditions. The ratio of those measured voltages is roughly equal to
transformer turns ratio. The turns ratio should be checked on each tap position. In the case of three-
phase transformers, when each phase is independent and easily accessible, single-phase power needs to
be used, although, when it is convenient, three-phase power can be used.
 7

Our transformer is Dyn11. We are using Vanguard ATRT-03 S2 transformer turn ratio tester. This test
device produces and applies a true three-phase excitation test voltage to the three transformer primary
windings(H). The induced three-phase voltages across the unloaded transformer windings(X) is measured
and the transformer turns ratio is calculated for all three phases. In the display it shows the turn ratio of
every winding, excitation current and percentage difference of the measured ratio and calculated ratio.

2. Vector Group Test

The vector group of transformers is an important property for a successful parallel operation of
transformers. Therefore every electrical power transformer must pass through vector group test
of transformer at factory site for ensuring that the customer specified vector group of
transformers. The phase sequence or the order in which the phases reach their maximum
positive voltages, must be the same for two paralleled transformers. Otherwise, during the cycle,
each pair of phases will be short circuited.
The several secondary connections are available in relation to of various primary three phase
connection in a three-phase transformer. So, for same primary applied three phase voltage there
may be different three phase secondary voltages with various magnitudes and phases for
different internal connection of the transformer.
Interconnections of the phase windings to give a three-phase, three-wire or three-phase, four
wire supply provides three alternative modes of connection (i) delta or mesh (ii) star and (iii) zig-
zag. Each of these can be accomplished in two ways. For Instance a star-connection may be had
by joining together U1 , V1 and W1 , to form the neutral and using U2, V2 and W2 as line
terminals. On the other hand U2, V2, and W2 may be put together to provide neutral and U1 ,
V1 and W1 may be used as line terminals. Since primary and secondary can be dealt with in either
of these ways, at least twelve combinations of connection are feasible. According to the phase
displacement which exists between the line voltages on the two sides of the transformer these
combinations can be organized into various groups. Among these our given transformer is Dyn11.

Dyn11 Connection:
Dyn11 is vector group representation of transformer means
LV winding, which is star connected (written in small
letters means LV side) is 30 degrees lagging by HV(capital
letters) winding which is delta connected.

Fig 9: Connection of Dyn11

 8

Test Purposes: This test verifies the Dyn-11 vector group of a

distribution transformer.

Equipment used: voltmeter.

Test Method for Dyn11:
Step 01:
Connect 1U and 2u
Keep the neutral floating
Apply 3Φ voltage to the HV side
Fig 10: Connection for step 02
Step 02:
Measure Voltage between
1.1U and 2n (V1U2n)
2.2n and 1V (V2n1V)
3.1U and 1V (V1U1V)
V1U1V= V1U2n+ V2n1V

Step 03:
Measure Voltage between
1.1W and 2v (V1W2v)
2.1W and 2w (V1W2w) Fig 11: Connection for step 03
V1W2v > V1W2w

Step 04:
Measure Voltage between
1.1V and 2v (V1V2v)
2.1V and 2w (V1V2w)
V1V2v > V1V2w

Note:
1.Ensure only one terminal of HV and one terminal of LV is connected.
Fig 12: Connection for step 04
2.Ensure the additive voltage does not exceed the safe limit.
 9

3. Measurement of Winding Resistance

This test is used to measure the resistance of the HV & LV winding.
This helps in determining the copper loss(I2R) of the transformer.
Equipment used: Voltmeter, Ammeter.
Current Voltage Method of measurement of winding
resistance: In this method of measurement of winding resistance,
Fig 13: Measuring winding
a test current is given to a winding and corresponding voltage drop across
resistance for star connected
the other winding is measured by applying simple Ohm’s law Rx = V ⁄ I, one side
can easily determine the value of resistance.
01. For star connected three phase winding, the resistance per
phase would be half of measured resistance between two-line
terminals of the transformer.
02. For delta connected three phase winding, the resistance
per phase would be 0.67 times of measured resistance between
two-line terminals of the transformer.
Fig 14: Measuring winding
Note: resistance for Delta connected
• This current voltage method of measurement of winding resistance side
of transformer should be repeated for each pair of line terminals of
winding
• Before measurement, the transformer should be stored in OFF condition without excitation
at least for 3 to 4 hours. During this time the winding temperature will eventually become
equal to its oil temperature.
• In order to reduce examination errors, polarity of the core magnetization shall be kept
constant throughout all the resistance readings.
• The readings must be taken after the electric current and voltage have reached steady state
values. In some instances, it could take a few minutes depending upon the winding
impedance.
• The test current shall not exceed 15% of the rated current of the winding. Large values may
cause inaccuracy by heating the winding and thereby changing its resistance.
 10

4. Measurement of Insulation Resistance:

Insulation resistance is the resistance between HV & LV windings with respect to earth (body) and
between LV & HV winding. Direct voltages are being used to measure the insulation resistance
values. Insulation resistance test of transformer is an essential type test. This test is conducted
to ensure the wellbeing of overall insulation system of an electrical power transformer. The
insulation resistance (IR) test (also commonly known as a Megger test) is a spot insulation test
which uses an applied DC voltage (typically 250Vdc, 500Vdc or 1,000Vdc for low voltage
equipment <600V and 2,500Vdc and 5,000Vdc for high voltage equipment) to measure insulation
resistance in either kΩ, MΩ or GΩ.
The measured resistance is meant to indicate the condition of the insulation or dielectric
between two conductive parts, where the higher the resistance, the better the condition of the
insulation. Ideally, the insulation resistance is going to be infinite, but as no insulators are ideal,
leakage currents through the dielectric will ensure that a finite (though high) resistance value is
measured.

Equipment used: Insulation Resistance Tester.

Process:
1. First unplug all the line and neutral terminals of the
transformer.
2. Megger is plugged into the LV and HV bushing studs
to calculate the insulation resistance between LV and
HV windings.
3. Megger plugged into HV bushing studs and earth
point transformer tanks for calculating resistance
between HV windings and earth.
4. Megger is attached to the LV bushing studs and the transformer Fig 15: Insulation Tester
tank earth point for calculating the strength of insulation
resistance between the LV windings and ground.
Note:
The oil/air temperatures shall be measured and recorded immediately prior to the ‘test.

5. Measurement of No-load loss and No-load Current

This test is conducted at rated voltage to identify no-load loss or core loss or iron loss. It can also
be used to determine no-load current I0 which is useful in finding the no-load parameters i.e.,
exciting resistance R0 and exciting reactance X0 of the transformer.

Equipment used: Wattmeter or power analyzer, Voltmeter, Ammeter.

 11

Method:
Normally, this test is conducted on low
voltage side of the transformer, i.e., all
measuring devices such as voltage (V),
wattmeter (W) and ammeter (A) are
connected in low-voltage side (say
primary). The primary winding is then
plugged into normal rated voltage V1, and Fig 16: Open circuit test connection
frequency as given on the name plate of the
transformer. The secondary side is being held open or is connected to a voltmeter V’. Since the
secondary (high voltage winding) is open circuited, the current drawn by the primary is called no-
load current I0 measured by the ammeter A. The value of no-load current I0 is very small usually
2 to 10% of the rated full-load current. Thus, the copper loss in the primary is negligible and no
copper loss takes place in the secondary as it is open. Thus, wattmeter reading W0 only
represents the core or iron losses for all practical purposes. These core losses are constant at all
loads. The Iron losses measured by this test is used to determine the transformer efficiency and
parameters of exciting circuit of a transformer
For Dyn11,
❖ Open the high voltage side (11kV side)
❖ Connect Voltmeter, Ammeter and Wattmeter as showing in the figure.
❖ Measure the volage, current and power.

Result:
No-load loss=Power consumed by the transformer(W1+W2).
No-load current=Ammeter reading.

6. Measurement of Impedance Voltage and Load Loss at 75C

The voltage needed to circulate the rated current under short-circuit conditions, is the
impedance voltage. Rated current circulates through the windings with the secondary
short-circuited. The impedance voltage and load loss are measured and they are
corrected to rise +20°C reference temperature.
 12

This test is used to measure the power

consumption by the transformer when
the 433V winding is short circuited and
the rated current is passed through the
11KV winding.
Equipment used: Wattmeter or power
analyzer.
Fig 17: Short circuit connection
Method: For Dyn11,
❖ Short all the Y connected terminal(430V)
❖ Connect Voltmeter, Ammeter and Wattmeter as showing in the figure.
❖ Measure the volage, current and power.

Result:
Load loss=Power consumed by the transformer(W1+W2).
Impedance voltage =Voltmeter reading.

7. Dielectric Withstand Test or High Voltage Test

This test verifies the insulation property
between Primary to earth, Secondary to earth
and between Primary & Secondary. The test is a
means to qualify the transformer ability to work
safely during rated electrical conditions.

HV high voltage test: LV winding connected

and earthed. HV winding connected together
and given 28 KV (for 11KV transformer) for 1
minute. Connection is showing in the figure 18. Fig 18: High voltage test circuit diagram

LV high Voltage test : HV winding connected

together and earthed. LV winding connected
together and given 3 KV(for 415V LV winding) for
1 minute. Connection is showing in the figure:19.

Equipment used: High Voltage tester ( 100KV

& 3KV)
Fig 19: Low voltage test circuit diagram.
 13

Acceptance Criteria:
The test is successful if no break down takes place at full test voltage during the test.

8. Dielectric Test of Transformer Oil

Transformer oil testing is made up of measuring breakdown voltage and
other physical and chemical properties of the specimens of the transformer oil, either in a
laboratory or using portable test equipment on-site.

Why need transformer oil testing: Transformer oil, a type of insulating and cooling oil used
in transformers. Thus, the dielectric quality of transformer oil is essential for the secure operation
of a transformer. That’s why transformer oil needs to
be tested periodically to ensure that it is still fit for purpose.
Reason for this is transformer oil deteriorates through aging
and moisture entry, transformer oil should, depending on
economics, transformer duty and other factors, be tested
on a regular basis. Through such testing, transformers' lives
can be significantly increased, thus delaying new
investment of replacement transformer assets.

Equipment used: Oil BDV Test Set.

Procedure:
Evaluating the insulating property of dielectric transformer
oil, a sample of the transformer oil is taken up and
its breakdown voltage are measured. Lower its resulting Fig 20: Transformer Oil tester
breakdown voltage, the poorer the overall quality of the
transformer oil. Oil breakdown voltage is being checked as per
IS-335.
100 mm L X 70 mm B X 80 mm Ht. glass pot.500ml Oil sample.
Spherical electrodes with gap of 2.5 mm.

❖ The transformer oil fills in the vessel of the testing device

(Typically 100 mm Length X 70 mm Base X 80 mm Hight).
Two standard-compliant test electrodes (Spherical
electrodes) with a typical clearance of 2.5 mm surround
the dielectric oil.
❖ A test voltage is applied to the electrodes and constantly Fig 21: Transformer oil and electrode
increased up to the breakdown voltage with a constant, placement
standard-compliant slew rate of e.g., 2 kV/s.
 14

❖ At certain voltage level breakdown occurs in an electric arc, leading to a collapse of the
test voltage.
❖ An instant after ignition of the arc, the test voltage is off automatically by the testing
device. Ultra-fast switch off is desirable, as the carbonization due to the electric arc must
be limited to keep the additional pollution as low as possible.
❖ The transformer oil testing device measures and reports the root mean square value of
the breakdown voltage.
❖ After the transformer oil test is completed, the insulation oil is stirred automatically and
the test sequence is performed repeatedly: typically, 5 repetitions, depending on the
standard.
❖ As a result, the breakdown voltage is calculated as mean value of the individual
measurements.

Recommended value: 60KV

9. Temperature Rise Test

The transformer temperature rise test is one of the type tests. In this type test of the transformer,
we must check oil temperature rise as well as winding temperature rise limits of an electrical
transformer. This test is mainly to check the structural performance of the transformer,
specifically to check whether the transformer can be cooled quickly, that is, to check whether the
heat generated by the total loss can be dissipated quickly during the operation of the
transformer, And whether it meets the top oil temperature rise of the transformer and the
limited value of winding temperature rise specified in IEC standards.

Why need Temperature rise test

Temperature rise tests are used to ensure that a product does not get overheated during
operation. The mean objective of this test is to check whether the oil and winding temperatures
of the transformer satisfy the values specified in the standard and technical projects.

Equipment used: Transformer winding resistance tester, Thermometer

Procedure:
 15

How to determine Top oil temperature rise

i)To applying Transformer HV winding
voltage, making power input capacity is
equal to no load losses plus load losses
corrected to reference temperature 75℃,
and holding it.
ii) During a test, hourly readings of top oil
temperature are taken from the
thermometer already placed in the pocket
of the top cover.
iii)Temperature rise test for top oil of
transformer should be continued until the top oil Fig 22: Temperature vs time plot during testing
temperature has reached an approximate steady
value that means testing would be continued until the temperature increment of the top oil
becomes less than 1℃ in one hour or for 3 consecutive hours (It depends on different criteria).
This steady value of the top oil is determined as the final temperature rise of transformer
insulating oil.

How to determine transformer windings

temperature rise
i) After the completion of temperature rise test for
top oil of transformer the current has been reduced
to its rated value for transformer and is maintained
for one hour.
ii) After one hour the supply is shut down and LV
winding short circuit is removed also. The next is
measure the LV &HV winding resistances quickly
through TO712W
iii) We want to see the winding temperature at the
Fig 23: Wingding resistance and temperature tester
instant of power shut down. However, we need take
several minutes to switch off the transformer and
power input. There is a time gap between the first measurement of resistance and the instant of
switching off the transformer.
We can get the instant resistances of switching off the transformer by the following formula.
△t=(R2-R1)/R1*(K+t1) -(t2-t1)
 16

△t=the winding temperature rise,

R1=The winding resistance at the test beginning.
R2= The winding resistance at the test finished.
L=234.5 for copper winding and L=234.5 for aluminum winding
t1= the ambient temperature at the test beginning.
t2= the ambient temperature at the test finished.