Testing of Distribution Transformer

Distribution Transformer
Principle of Transformer
Construction of Transformer
Transformer Name plate details
Routine Test

Factory test
Type Test
Transformer failure and causes

Principle of transformer action

A current flowing through a
coil produces a magnetic field
around the coil. The magnetic
field strength H,
required to produce a
magnetic field of flux density
B, is proportional to the
current flowing in the coil.

Principle of transformer action

A transformer is a static piece of
apparatus used for transferring
power from one circuit to
another at a different voltage,
but without change in frequency.
It can raise or lower the voltage
with a corresponding
decrease or increase of current.

Distribution Transformer
Principle of transformer actions
Construction of Transformer
Transformer Name plate details
Routine Test

Factory test
Type Test
Transformer failure and causes

Construction of Transformer
CONSERVATOR TANK
EXPLOSION VENT

H.T BUSHING

BREATHER
TAP SWITCH

L.T BUSHING
RADIATOR

HV / LV WINDING
OIL

BOTTOM VALVE

Construction of Transformer
DELTA / STAR

HV

LV
.

y
ETH

b
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Distribution Transformer
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Core and Coil Assembly

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Distribution Transformer
Principle of transformer actions
Construction of Transformer
Transformer Name plate details
Routine Test

Factory test
Type Test
Transformer failure and causes

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Transformer Name Plate Details

- Before any testing study of name plate details is must, The HV/LV voltage
,HV/LV current, Size of transformer, Vector group & Impedance volts play
an important roll for calculating test values.
MAKE : ( XYZ )
KVA :

(315)

NO LOAD VOLTS

HV / LV

( 11000 / 415 ) Volts

FULL LOAD AMPS. HV / LV ( 16.5 / 438.2 ) Amps

FREQUENCY : 50 HZ
TAPPING : No. of Taps :- 7
VECTOR GROUP : Dyn11
TYPE OF COOLING : ONAN
IMPEDANCE VOLTS : 5 %
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Name plate of Distribution transformer-Sample

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Distribution Transformer
Principle of transformer actions
Construction of Transformer
Transformer Name plate details
Routine Test

Factory test
Type Test
Transformer failure and causes

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Routine Test
Generally routine test is carried out at stores where we received New /
Recovered transformers from manufacturer and site.
Following Test are perform as routine test.
Insulation Resistance Test
Continuity test
Ratio test (Voltage / Turns ratio)
Short circuit test (Short circuit current)
Open circuit test (Magnetizing current )
Magnetic balance test
Vector Group test
Oil test
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Insulation Resistance Test

(IR VALUE)
Insulation resistance test to be carried out by 1 / 2.5 / 5 KV manual
or motor driven megger, It gives us the status of insulation of HV
winding and LV winding with respect to earth and between the
winding.
HV WDG. TO EARTH = _____

LV WDG. TO EARTH

= _____

HV WDG.TO LV WDG. = _____

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Insulation resistance measurement

between LV winding and earth

Insulation resistance measurement

between HV winding and earth

TR BODY

TR BODY

LV
R
R

HV
Y

0
M
MEGGER

0
M
MEGGER

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Insulation resistance measurement between LV winding and HV

winding
TR BODY
LV
R
R

HV

N
Y

B
B

0
M
MEGGER

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Continuity Test
CONTINUITY TEST CARRIED OUT BY MEGGER OR AVO METER TO
CHECK ANY OPEN CIRCUIT FAULT IN THE HV & LV WINDING OF THE
TRANSFORMER.
HV SIDE

LV SIDE
R

RY = _____
YB = _____
BR = _____

rn = _____
yn = _____

Y
b

bn = _____
B

VALUE = ZERO ( CONTINUITY O.K )

VALUE = INFINITY ( CONTINUITY NOT O.K)
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Continuity test for HV

winding

Continuity test for LV

winding
TR BODY

TR BODY

LV
R
R

HV
Y

B
B

0
M

0
M
MEGGER

MEGGER

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Voltage ratio test

Objective:
To check that the ratio of voltages ( in 3-phase
transformers, line to line voltages) is as per designed
value in all tap position.
The % Error of the voltage ratio is not more that +/- 0.5
% as per the IS 2026 and IEC 60076

Apparatus:
3 phase supply -415V (Applied to HV side)
Clip on meter for measuring voltage at LV side.
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Voltage ratio test

Procedure:

Apply 3 phase 415V supply on HV side and LV side voltage is to be

measured.

Output voltage will be measure between phase & neutral (VRN, VYN,
VBN). Ratio will be changed in respect to tap positions.
Tap position

Vrn

Vyn

Vbn

Vry

Vyb

Vbr

1
2
3
4
5
6
7

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TR BODY

LV
R
R

N
HV
Y

VOLT-METER
ICTP

Voltage ratio test

400v AC
supply

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Voltage ratio test

HV side 415V
applied

LV side voltage
measurement

Tap switch
position
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Short circuit test

Objective:
To determine the Short Circuit impedance voltage.
To determine the Load losses of the transformer
Short circuit loss = I2R Loss + stray loss
Apparatus:
Voltage injection set (Applied on HV side)
Clip on meter (Measuring current at LV side).
Shorting Link (For passing full load current).

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Short circuit test

Procedure:
LV side will be shorted through
shorting link.
Applied the 3 phase voltage on
HV side and increased the voltage
till the full load current passed
through the transformer.
Unbalance current and phase to phase current measure with the help of
Clip on meter.
Unbalance current should not be more than 2% of full load current.
Load loss and impedance voltage measured on power analyser. This
Load loss measured at Room temperature Converted this loss into 75
Degree C and it should be within the specified limit.

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Short circuit test

TR BODY
LV

HV
Y
B

ICTP

400v AC
supply

N
Y
B

Load loss at 75 Degree C = Load loss at RT (A+75) / (A+RT)

Here RT= Room Temperature
A= 235 for CU wound
A= 225 for Al wound

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Open circuit test

Objective:
To know the Excitation losses and currents of Transformer when
excited at rated kV at rated Hz
To determine the No load losses(Core loss) of the transformer
To check healthiness of winding and stampings.
No load loss = hysteresis loss + eddy current loss
Apparatus:
Voltage injection set (Applied on LV side)
Clip on meter for measuring no load current at LV side.

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Hysteresis Loss
when a magnetic field is applied all the
grains of the magnetic material will
orient in the direction of magnetizing
force. In another cycle this grains will
orient in opposite direction in the
direction of magnetizing force. The
energy required to change the
orientation of the magnetic grains in the
direction of the magnetic field is lost in
the form of heat. This loss is called
hysteresis loss.

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Eddy current Loss

Eddy Current Loss:
When an alternating magnetic flux is applied to the iron
core small emf will be induced due to change in flux
linkage. This induced emf will cause small circulating
current s called eddy currents. Eddy current flowing
through the material causes I2R losses in the material.
In order to reduce the Eddy Current loss:
Use of Material having high electrical resistivity:
By using superior grain orientation CRGO steel will have
higher electrical resistivity. Thus eddy current loss can
be reduced.
Lamination Cores are used:
By using thin laminations the core thickness is reduced
so eddy current losses are reduced. So CRGO steel
laminations are used as a core material.
Insulation between laminations:
Oxide coating is provided for CRGO laminations to
reduce eddy current losses.

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Open circuit test

Procedure:
Rated voltage applied on LT side
of distribution transformer for
energizing transformer.
No load current measured by
clip on meter and no load loss
measured by power analyzer.
No load current should not be
more than 3% of full load current.
Note: Nobody can go closer to HV side
because it is subject to 11KV.
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TR BODY
LV
R
R

N
HV
Y

Open circuit test

ICTP

400v AC
supply

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Star Rating of Transformer(BEE)

Rating
KVA

1 star

2 star

Max
Max Losses Max Losses
Losses at
at 50%
at 100%
50%
(Watts)
(Watts)
(Watts)

3 star

4 star

5 star

Max
Losses at
100%
(Watts)

Max
Losses at
50%
(Watts)

Max
Losses at
100%
(Watts)

Max
Losses at
50%
(Watts)

Max
Losses at
100%
(Watts)

Max
Losses at
50%
(Watts)

Max
Losses at
100%
(Watts)

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200

555

165

520

150

480

135

440

120

400

25

290

785

235

740

210

695

190

635

175

595

63

490

1415

430

1335

380

1250

340

1140

300

1050

100

700

2020

610

1910

520

1800

475

1650

435

1500

160

1000

2800

880

2550

770

2200

670

1950

570

1700

200

1130

3300

1010

3000

890

2700

780

2300

670

2100

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BEE Star Labeling

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Full load current and loss of different rating

transformers

KVA

HV
(Amp)

LV
(Amp)

NO LOADLOSS
( Watts)

LOAD LOSS
(Watts)

160

8.4

222.6

300

1600

315

16.5

438.2

515

2750

630

33.1

876.5

800

4700

990

52

1377

1250

6200

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Magnetic Balance Test:

Applied 240V on LV side and voltage measured on respective LV terminals
as under.
Division should 65:35 between central and the other extreme limb if one
of the extreme limbs is excited and is 50:50 for central limb excitation

rn

yn

bn

rn= 240

240

156

84

yn= 240

120

240

120

bn =240

84

156

240

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Break down voltage test of Oil

Transformer
oil
is
used
insulation as well as cooling
purpose.
BDV tester ranging from 0100KV used for test.
Gap between two electrodes
must be maintain 2.5mm.
BDV of new insulating oil
Should be more than 60KV.

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Acidity test of Oil

In this test we will measure the value of free carbonic
and non-carbonic acid in oil and this will be measured
with the help of acidity testing kit.(mgKOH/gm)
Acidity must be less than 0.03 for new insulating oil.

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Distribution Transformer
Principle of transformer actions
Construction of Transformer
Transformer Name plate details
Routine Test

Factory test
Type Test
Transformer failure and causes

39

Factory Test
In addition to routine test some more test are carryout at factory, This
type of test required some specific testing instruments and testing
facilities, even through some of the test carryout at site also.

Winding resistance test

Vector group test

Separate source voltage test

Temperature rise test

Induced overvoltage test

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Distribution Transformer
Principle of transformer actions
Construction of Transformer
Transformer Name plate details
Routine Test

Factory test
Type Test
Transformer failure and causes

41

Type Test
Over and above routine test some important test are carried out at
factory or laboratory like ERDA & CPRI, this type of test required
some special testing instrument and testing facility.

Impulse Voltage Test - 95KVp

Short circuit withstand test - 18.4 KA for 3 sec

Partial discharge test

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Distribution Transformer
Principle of transformer actions
Construction of Transformer
Transformer Name plate details
Routine Test

Factory test
Type Test
Transformer failure and causes

43

Failure & Causes

Insufficient Oil level.

Seepage of water in oil.

Prolonged Over loading.

Single Phase loading.

Unbalanced loading.

Faulty Termination (Improper sized lugs etc)

Power Theft.

Prolonged Short Circuit.

Faulty operation of tap changer switch.

Lack of installation checks.

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Failure & Causes

Faulty design

Poor Workmanship

Improper formation of core.

Improper core bolt insulation.
Burr to the lamination blades
Improper brazing of joints.
Burr /sharp edges to the winding conductor.
Incomplete drying.
Bad insulation covering.
Insufficient cooling ducts in the winding.

Bad Quality of raw material.

Transit damaged transformers.
After failure , transformer is removed and replaced with
new/repaired one without removing the cause of failure which results
in immediate or short time failure.
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Thank You