Transformer Testing

Matz Ohlen M.Sc.EE

Life of a transformer
with and without diagnostics and maintenance actions
(Mechanical/dielectrical strength)

Diagnostic testing

(due to increased loading etc)

(Transformer) Modeling
Make it as simple as possible; but not simpler than that, Albert Einstein Generally in science
Observe and measure Create a model Verify model by experiments Extend model (only) if necessary

Transformer The electric gear box

Fixed ratio, e.g. 100 kV / 10 kV LTC (Load Tap Changer)
1009x1.67% / 10 kV

DETC (De-Energized Tap Changer)

Tuning voltage level Change configuration, e.g. from Dzn10 to Yzn11

Basic transformer model (impedance)

Primary side:
Winding resistance, Leakage Inductance (X1+(N1/N2)2*X2) Magnetization current (excitation current)

Secondary side
Winding resistance Inductance

Primary to secondary
Turn ratio (E1/E2)

Measuring the parameters

Excitation/magnetization current (field) and no-load loss (factory) measurements Winding resistance measurements (factory and field) Load-loss measurements (factory) Short-circuit impedance (voltage) measurements (factory and field) Turn ratio (factory and field)

R+jX = R1+jX1 + (N1/N2)2 x (R2+jX2)

Summary - Impedance modeling

The ideal transformer combined with the simple equivalent circuit describes the physics of the transformer well. The important measurement parameters are: Magnetization/Excitation current (voltage dependent) Winding resistance (temperature dependent) Short-circuit impedance/Leakage reactance Turns ratio

Insulation modeling and measurement

Hi
Measure with: DC AC (single freq) AC (multi freq) High or low voltage

V Lo A

Ground
Use Ohms law to calculate: Insulation resistance Tan delta/Dissipation factor Power factor Capacitance Permittivity Etc

CHL

CL

CH

It is always a capacitor!

Oil modeling and measurement (electrical)

Hi

V Lo A

Ground

CHL

Dielectric test:
Measure voltage and current (test cell) Calculate conductivity (mS/m) or dissipation factor at power frequency

CL

CH

Dielectric strenght:
Measure the breakdown voltage (test cell)

Transformer designs: Shell form and core form transformers

Source: ABB Transformer Service Handbook

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Shell form and core form transformers

Advantages of Shell Form Transformers (from www.meppi.com )
High short-circuit withstand capability High mechanical strength High dielectric strength Excellent control of leakage magnetic flux Efficient cooling capability Flexible design Compact size Highly Reliable Design

Disadvantages of Shell Form Transformers

Complicated manufacturing process, i.e. more expensive

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Types of transformers
Power Transformers Distribution Transformers Phase-Shifting Transformers Rectifier Transformers (Dry-Type Transformers) (Instrument Transformers) (Step-Voltage Regulators) (Constant-Voltage Transformers) (Reactors)

Electric Power Transformer Engineering, CRC Press, 2004, ISBN 0-8493-1704-5

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Type of transformers
Power Transformers
One-phase Three-phase

Distribution Transformers
Three-phase Two-phase (mainly in the U.S)

Phase-Shifting Transformers
Three-phase

Rectifier Transformers
Six-phase, twelve-phase

Why three-phase? The sum of the power in the three phases is constant, i.e. the torque is constant.

Electric Power Transformer Engineering, CRC Press, 2004, ISBN 0-8493-1704-5

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Configurations
One phase, two windings or three windings Three phase, two windings or three windings. e.g. YNyn0yn6 Auto transformers with or without tertiary, e.g. YNa0 Rectifier transformers: Six-phase, twelve phase Phase-shifting (uses LTC on a different core leg)

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Transformer stress factors

Thermal Stress
Develops across all assembly components. It ages the dielectric material (even at rated temperatures). Stress to insulation worsened by high temperature and repeated changes in temperature. Temperature is one of the most important factors affecting transformer life! Cellulose decomposes and create water in the solid insulation Oil additives may have a deteriorating effect on insulation components. Develops within the insulation material separating conductors at different potentials. It ages the dielectric materiel (even at rated voltages) Deforms/displaces assembly components. High shock events during shipping displaces components. High current events (short-circuit faults) creates high impact forces and may cause winding deformation. Water may enter the transformer through leaking gaskets Salt and other corrosive substances in the environment may deteriorate tanks and peripheral equipment.

Chemical Stress

Electrical Stress

Mechanical Stress

Environmental Stress

High temperature and water/moisture will finally kill every transformer!

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Transformer fault statistics - Fault reasons

Poor worksmanship Sabotage Overload Moisture Contacts Joints etc Electric reasons in the net

Maintenance reasons Insulation reasons

What was the reason for the transformer fault?

Source: Cigr, IEEE, Hartford S&B Univ of Queensland, ZTZService Canadian El Assosiation, Doble mfl

Lightning

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Different methods for fault detection

Insulation testing Reenergizing Protectionrelay s TTR Internal inspection Winding resistance

Exitation current

How was the fault found?

Source: Cigr, IEEE, Hartford S&B Univ of Queensland, ZTZService Canadian El Assosiation, Doble mfl

External inspecton

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Testing and Standards

CIGRE
CIGRE Brochure 342 (SFRA-FRAX) CIGRE Brochure 414 (DFR-IDAX) CIGRE Brochure 445 (Guide for Transformer Maintenance)

IEC, TC 14
IEC 60076-1, Power Transformers IEC 60076-2, Temperature rise IEC 60076-3, Insulation levels, dielectric tests and external clearances in air IEC 60076-18, Measurement of frequency response (SFRA)

ANSI, IEEE Transformer Committee

IEEE C57.152 IEEE C57.12.00-2006 IEEE C57.12.90-2006 IEEE PC57.149 (formerly IEEE 62-1995) (under revision) (under revision) (SFRA)

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Transformer diagnostics by test set

STANDARD TEST TYPES
Component Test Resistance Ratio/polarity Excitation current Short-circuit impedance Frequency response analysis Insulation resistance Capacitance Power factor/tan delta Dielectric frequency response Capacitance Power factor/tan delta Dielectric frequency response Water content Dielectric strength Power factor/tan delta Moisture content Resistance Ratio Continuity (make before break) Dynamic resistance (DRM) Resistance Ratio Insulation resistance Frequency response analysis
Ground test

TEST SETS
Delta IDAX MIT FRAX MLR TTR MTO CBA/LTC MoM X X X X X X X X X X X X X X X X X X X X X X X X X X X X X
X

OTS

KF

X X X

Windings

Bushings

Insulating oil Cellulose insulation Load Tap changers De-energized Core/Tank

X X X X

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WRM (winding resistance measurements)

Winding resistance measurements
1, 2 or 6-ch measurement Single winding or SWM current injection (HV and LV simultaneously)

Tap-changer testing
Winding resistance/tap Current change detection (continuity)

Demagnetization of transformer core

Important to perform before excitation current and SFRA measurements Recommended in IEEE as standard procedure before taking the transformer in service (in-rush current risk)

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TTR measurements
Transformer turn-ratio measurement Polarity and phase deviation test Excitation current measurement

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MicroOhmmeters
Low resistance measurements of;
HV/LV leads and connections Core ground connection

Some units can perform winding resistance measurements on small transformers

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Short-circuit impedance/leakage reactance

Short-circuit impedance/leakage reactance measurement @ 50/60 Hz Test method and practice described in e.g. IEEE C57.152 For three-phase transformers, the perphase test results should be within 3% of the average value of all three phases. Some units also provides capacitor bank testing

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SFRA
Sweep frequency response analysis (SFRA) from Hz to MHz Excitation impedance measurement [open] Short-circuit impedance testing [short] Fingerprint

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DC insulation testing
DC insulation testing
Insulation resistance (IR) Polarization index (PI) Dielectric absorption (DAR) Step voltage testing

Note: Polarization index, PI, was introduced to detect moisture in the winding insulation of rotating machines. For the complex oil-cellulose insulation system of transformers the PI results can be misinterpreted and the polarization method should not be used to assess insulation condition in new power transformers. Polarization index for insulation liquid is always close to 1. Therefore, the polarization index for transformers with low conductivity liquids (e.g. new mineral oil) may be low in spite of good insulation condition. DFR/FDS/PDC measurements are preferred for quantitative assessments of the moisture in the insulation. (CIGRE 445 Guide for Transformer Maintenance and IEEE PC57.152 IEEE Guide for Diagnostic Field Testing of Fluid-Filled Power Transformers, Regulators, and Reactors)

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Tan delta/power factor measurements

12 kV insulation testing
Tan delta/power factor and capacitance
Power transformers Bushings CT/VTs Generators and motors Circuit Breakers Oil (with test cell) Etc...

50/60 Hz (power frequency) standard test Some units offer testing over a frequency range Excitation current measurement

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Dielectric response measurements

Measurements
Typically 200 to 2000 V (peak) test voltage DC and/or AC methods
DFR/FDS (AC) PDC (DC) RVM (DC)

Standardized and described in CIGRE reports Moisture in cellulose insulation Some units offer modeling-characterization of tan delta temperature dependence

Automatic analysis of:

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Oil testing Dielectric strength

Two methods - D877 and D1816 A measure of a liquids ability to withstand electric stress without failure Detects presence of contaminants: water, dirt, fibers, conducting particles

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Oil testing Water in oil (Karl-Fischer)

Measures the water content in the oil Standard test performed by most transformer owners Results are traditionally also used to estimate moisture in the cellulose insulation by using equilibrium charts The method tends to overestimate moisture in cellulose

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The doctor is in...

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