Transformer Testing’s
Annual testing of transformers in substation is most important to check the healthiness of
transformer. Test to be performed are:
1. Insulation resistance (IR)
2. Transformer turn ratio (TTR) or Ratio Test
3. Winding resistance (WR)
4. Capacitance and Dissipation Factor
5. Dielectric strength (DES) of transformer oil
6. Tertiary Busbar testing of 500KV Transformers.
1. Insulation resistance (IR)
Insulation resistance tests, like those performed with a megohmmeter, typically
use DC voltage. The purpose of the IR test is to detect damage to insulation and to assess
the operation of the transformer. For healthy insulation and transformer, a “Ri” resistance
reading of 1 Mega Ohm/1 Kilo Volt at 20oC oil temperature is considered satisfactory.
• Test voltage are mostly 5KV/10KV depending on test set.
• Disconnect transformer cables/connectors, clean terminals, and short all HV
bushing along with neutral bushing with a tight jumper. Repeat the same for the LV
side and tertiary side as well.
• Note oil temperature and record IR readings for H-XG, X-HG, HX-G for 2
winding transformers or record IR readings for H-XTG, X-HTG, T-HXG for 3
winding transformers, where H = HV, X = LV, T = Tertiary, and G = Ground.
Connections are:
For two winding transformer
• After high voltage testing, test terminals should be grounded before any staff
touch them
• Dielectric absorption ratio is ratio of IR value in 60S to IR value in 15 Sec.1 to
1.25 is Good and more than 1.4 is best.
•
2. Transformer turn ratio (TTR) or Ratio Test
It is AC low voltage test.The Transformer Turns Ratio (TTR) test on
a high voltage transformer involves applying a test voltage to the primary winding and
measuring the corresponding voltage on the secondary winding to determine the ratio
between them. The procedure ensures the transformer's windings maintain the correct voltage
transformation. TTR is performed to detect faults in the insulation of the transformer by
measuring the percentage ratio of the transformer. It also tells the status of connections
between the transformer-tapped windings and selector switches of the tap changer. The ratio
meter used to measure the TTR also measures the phase angle ratio of the transformer in
addition to checking the polarity of the single-phase transformer, finding unknown primary
or secondary voltage, and detecting open circuit faults in transformer winding.
• De-energize and isolate the transformer by disconnecting all bushing connections
Connections:
• Both previously mentioned standards specify the tolerance of the turns ratio should be
within ± 0.5 % of the specified nameplate ratio.
3. Winding resistance (WR)
Winding resistance (WR) is measured by a transformer ohmmeter, and it is a DC test
used for DC resistance of all types of magnetic winding. WR shows the condition of the
windings of transformers and provides information about the tap changer connections at a
standard temperature of 75oC.
• Perform the test at each HV and LV winding of the transformer.
• Take readings R-N, T-N, B-N, r-n, y-n, and b-n, if neutral is not provided record the
following readings R-Y- T-B, B-R, r-y, y-b, and b-r.
Connection:
• For star-connected winding, the resistance measurement shall be done between the
neutral terminal and the line.
• For star-connected autotransformers, the resistance measurement of the HV side is
carried out between the IV terminal and the HV terminal, then between the neutral
and IV terminal.
• For delta-connected windings, winding resistance shall be measured between pairs
of line terminals. As in delta connection, the resistance measurement of individual
winding can not be done separately, the resistance per winding shall be calculated
based on the following formula:
Resistance per winding = 1.5 × Measured value
• Current shall be less than 15% of the rated current of the winding. If it is larger, the
heat of winding cause inaccuracy
4. Capacitance and Dissipation Factor
C & DF (Capacitance and Dissipation Factor) test sets generally use AC
(Alternating Current) for the testing voltage .This test is used to detect minor faults of
insulation and to know the quality and condition of insulation to assess the extent of
deterioration of insulation. The capacitance and Dissipation Factor (C&DF) test provides
an alarm for preventive maintenance activity..
• Disconnect all cables from the bushing and clean/dry all bushings thoroughly
• Short all HV bushings along with neutral bushing (if provided) with a tight bare
jumper. Repeat the same for the LV side and tertiary side as well
• The OLTC should be off the neutral tap position
• For 2-winding transformer record six readings, i.e., H-X, H-G, X-G, HX-G, H-XG,
and X-HG. For 3-winding transformer record 12 readings, i.e., H-X, H-T, H-G, X-T,
X-G, T-G, HX-G, HT-G, XT-G, H-XG, and X-TG.
• High C&DF values indicate that the insulation is contaminated and requires
dehydration.
• Only if increased DF is observed it represents chemical deterioration (or aging) of
insulation.
• Increased DF and decreased C represent an open circuit of core ground.
• Only if C is changed a mechanical damage suspected
5. Dielectric strength (DES) of transformer oil
Dielectric oil test sets typically use AC voltage to measure the breakdown voltage
of insulating oils. Transformer oil performs at least four functions namely insulation,
cooling, extinguishing arcs, and dissolving gases generated by oil degradation, moisture,
cellulose insulation, and deterioration. Among different oil tests, the most common and
periodic routine test is the dielectric strength (DES) test of transformer oil. It defines the
ability of transformer oil to withstand electrical stress without breaking down.
• Glass sample syringes are recommended for sample collection and be stored in
stainless steel vacuum bottles to avoid interaction with the atmosphere. These
syringes must be used carefully and be protected from direct sunlight.
• Pour the collected sample into the DES kit and set the right distance of spherical
electrodes.
• Apply voltage as per the recommended data and increase the voltage stepwise
until the oil breakdown is achieved.
• The measurement is taken 3 to 6 times in the same sample of oil, and we take the average
value of these readings
• The industry standard for Good transformer oil is a minimum breakdown voltage of 30
kV (kilovolts) per millimeter.
6. Tertiary Busbar testing of 500KV Transformers.
Bus bar is installed to connect the tertiary windings of a three-unit
transformer in a close delta connection to suppress the triple frequency component.
Maintenance of the tertiary bus bar is essential to ensure the healthiness of the
transformer. Physically inspect the bus bar for any crack, rust, or loose connection.
• Insulation Resistance
i. Method: Use a 5 kV or 10 kV insulation resistance tester (megger).
ii. Scope:
Phase-to-phase.
Phase-to-ground.
• Dielectric (HiPot) Testing (Optional, based on condition & age)
Detect weaknesses in insulation.
Note: Performed only if prior IR readings are suspicious or after repairs.
