TESTING, MAINTENANCE &

PROTECTION OF
TRANSFORMERS

S. P. Nanda
 WHAT IS A TRANSFORMER?
• TRANSFORMER IS A STATIC
DEVICE WHICH
TRANSFORMS A.C.
ELECTRICAL POWER FROM
ONE VOLTAGE TO ANOTHER
VOLTAGE KEEPING THE
FREQUENCY SAME BY
ELECTROMAGNETIC
INDUCTION.
 TYPES OF TRANSFORMER
BY APPLICATION
• 1. DISTRIBUTION TRANSFORMER
• 2.POWER TRANSFORMER
• 3.CURRENT TRANSFORMER
• 4.POTENTIAL TRANSFORMER
• 5.FURNACE TRANSFORMER
• 6.BOOSTER TRANSFORMER
• 7.RECTIFIER TRANSFORMER
• 8.LOCOMOTIVE TRANSFORMER
• 9.MINING TRANSFORMER
• 10.PHASE SHIFTING TRANSFORMER
• 11.WELDING TRANSFORMER
• 12.HIGH VOLTAGE TESTING/SC TESTING TRF.
• 13.GROUNDING TRANSFORMERS
• 14.CONVERTER TRANSFORMER
 DISTRIBUTION TRANSFORMER
• TRANSFORMER WHICH IS USED FOR THE
PURPOSE OF DISTRIBUTION OF POWER.
• 11KV/433V is the standard voltage rating.
• STANDARD KVA ratings are

25,63,100,160,200,250,315,400,500,630,750 ,
1000 , 1250,1500,2000,2500 KVA.
IS-2026 is the NATIONAL I S STANDARD.
 MAIN FEATURES
• OUTDOOR,OIL COOLED, 3 PHASE,50HZ
• PRIMARY IS DELTA CONNECTED AND
SECONDARY IS STAR CONNECTED.
• NATURALY COOLED (ONAN TYPE).
• AMONGST ALL THE TYPES OF TRANSFORMERS
THIS IS THE MOST REQUIRED AND MOST USED
TYPE.
PARTS OF TRANSFORMER
• MAIN TANK
• RADIATORS
• CONSERVATOR
• EXPLOSION VENT
• LIFTING LUGS
• AIR RELEASE PLUG
• OIL LEVEL INDICATOR
• TAP CHANGER
• WHEELS
• HV/LV BUSHINGS
• FILTER VALVES
• OIL FILLING PLUG
• DRAIN PLUG
• CABLE BOX
 TESTING OF TRANSFORMER
• TESTING IS CARRIED OUT AS PER IS-2026.
• ROUTINE , TYPE TESTS & SPECIAL TESTS

• ROUTINE TESTS ( TO BE CARRIED OUT ON EACH JOB)

• 1.Measurement of winding resistance
• 2.Measurement of insulation resistance
• 3.Seperate source voltage withstand test (High Voltage tests on HV & LV)
• 4.Induced Over voltage Withstand test (DVDF test)
• 5.Measurement of voltage ratio
• 6.Measurement of NO LOAD LOSS & current.
• 7.Measurement of LOAD LOSS & IMPEDENCE.(EFFICIENCY & REGULATION)
• 8.Vector Group Verification
• 9.Oil BDV test.
• 10.Tests on OLTC (if Attached)
 TYPE TESTS
THESE TESTS ARE CARRIED OUT ONLY ON
ONE TRANSFORMER OF THE LOT.
• All routine tests
• Additionally following tests are included in
type tests
1. Lightening Impulse test.
2. Temperature rise test
 SPECIAL TESTS
• Additional Impulse test
• Short circuit test
• Measurement of zero Phase sequence
Impedance test.
• Measurement of acoustic noise level.
• Measurement of harmonics of the no load
current.
• Magnetic balance test.
 ROUTINE TESTS
• 1.Measurement of winding resistance
This test measures the resistance of the HV & LV
winding. The values of resistance should be
balance for all three phases and should match
the designed values.
Equipment used : Digital resistance meter.
 ROUTINE TESTS
• 2.Measurement of insulation resistance
Measures the insulation resistance of HV & LV
windings with respect to earth (body) and
between LV & HV winding.
INSULATION TESTER OR MEGGER IS USED.
Recommended Values are
≥ 2000Mohms for HV & ≥ 500 Mohms for LV.
 ROUTINE TESTS
• 3.Seperate source voltage withstand test (High Voltage tests
on HV & LV)- This test checks the insulation property
between Primary to earth, Secondary to earth and between
Primary & Secondary.

HV high voltage test : LV winding connected together and

earthed. HV winding connected together and given 28 KV ( for
11KV transformer) for 1 minute.
LV high Voltage test : HV winding connected together and
earthed. LV winding connected together and given 3 KV for 1
minute.
Equipment used : High Voltage tester ( 100KV & 3KV)
 ROUTINE TESTS
• 4.Induced Over voltage Withstand test (DVDF test)- This
test checks the inter turn insulation.

For a 11KV/433V transformer,866 Volts are applied at

the 433V winding with the help of a Generator for 1
minute. This induces 22KV on 11KV side. The frequency
of the 866V supply is also increased to 100HZ. The
transformer must withstand the voltage applied.
Equipment used : Variable Voltage & frequency
generator.
 ROUTINE TESTS
• 5.Measurement of voltage ratio
This test measures the voltage ratio as per the
customer’s requirement.
V1/V2 = N1/N2
The voltage ratio is equal to the turns ratio in a
transformer. Using this principle, the turns ratio is
measured with the help of a turns ratio meter. If it is
correct , then the voltage ratio is assumed to be
correct.
Equipment used : Turns Ratiometer
 ROUTINE TESTS
• 6.Measurement of NO LOAD LOSS & current.
The iron losses and no load current are measured in
this test. The 433V winding is charged at 433V supply
& the 11KV winding is left open .The power
consumed by the transformer at no load is the no
load loss in the transformer.
Effect of actual frequency must be taken into
account.
Equipment used : Wattmeters or power analyser.
 ROUTINE TESTS
• 7.Measurement of LOAD LOSS & IMPEDENCE.
(EFFICIENCY & REGULATION)
This test measures the power consumed by the
transformer when the 433V winding is short
circuited and The rated current is passed
through the 11KV winding.
Equipment used : Wattmeters or power
analyser.
 ROUTINE TESTS
• 8.Vector Group Verification test
This test verifies the Dyn-11 vector group of a
distribution transformer.

Equipment used : voltmeter.

 ROUTINE TESTS
• Oil BDV TEST.
Oil breakdown voltage is 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
Recommended value : 60KV
Equipment used : OIL BDV TEST SET.
 TYPE TESTS
• LIGHTENING IMPULSE TEST
All the dielectric tests check the insulation level of the job.
Impulse generator is used to produce the specified voltage
impulse wave of 1.2/50 micro seconds wave
One impulse of a reduced voltage between 50 to 75% of the full
test voltage and subsequent three impulses at full voltage.
For a three phase transformer, impulse is carried out on all three
phases in succession.
The voltage is applied on each of the line terminal in succession,
keeping the other terminals earthed.
The current and voltage wave shapes are recorded on the
oscilloscope and any distortion in the wave shape is the
criteria for failure.
 SPECIAL TEST
• Short circuit withstand ability test.
This tests measures the ability of the transformer to withstand the
mechanical and thermal stresses caused by the external short
circuit.
HV terminals are connected to the supply bus of the testing plant.
The LV is short circuited. The testing plant parameters are such
adjusted to give the rated short circuit current.
Supply is made on and closed after specified duration of short circuit.
The record of current wave form is noted.
There should not be any mechanical distortion, fire to the
transformer during this test. Similarly no wave form distortion.
The transformer should also withstand the routine tests after the
short circuit test.
The reactance of the winding measured before and after the S.C. test
should not vary beyond the limits stated in the IS2026.
 MAINTENANCE OF TRANSFORMER
• Transformer is the heart of any power
system. Hence preventive maintenance is
always cost effective and time saving. Any
failure to the transformer can extremely
affect the whole functioning of the
organization.
 MAINTENANCE PROCEDURE
• OIL :
1. Oil level checking. Leakages to be attended.
2. Oil BDV & acidity checking at regular
intervals. If acidity is between 0.5 to 1mg
KOH, oil should be kept under observation.
3. BDV, Color and smell of oil are indicative.
 MAINTENANCE PROCEDURE
1. Sludge, dust, dirt ,moisture can be removed by
filtration.
2. Oil when topped up shall be of the same make. It
may lead to sludge formation and acidic contents.
• Insulation resistance of the transformer should be
checked once in 6 months.
• Megger values along with oil values indicate the
condition of transformer.
• Periodic Dissolved Gas Analysis can be carried out.
 MAINTENANCE
• BUSHINGS
Bushings should be cleaned and inspected for
any cracks.
Dust & dirt deposition, Salt or chemical
deposition, cement or acid fumes depositions
should be carefully noted and rectified.
 MAINTENANCE
• Periodic checking of any loose connections of the
terminations of HV & LV side.
• Breather examination. Dehydration of Silica gel if
necessary.
• Explosion vent diaphragm examination.
• Conservator to be cleaned from inside after every
three years.
• Regular inspection of OIL & WINDING TEMPERATURE
METER readings.
• Cleanliness in the Substation yard with all nets, vines,
shrubs removed.
 PROTECTION OF TRANSFORMERS
• The best way of protecting a transformer is to
have good preventive maintenance schedule.
• Oil Temperature Indicators.
• Winding Temperature indicators.
• Buchholz Relay.
• Magnetic Oil level Gauge.
• Explosion Vent.
 PROTECTION OF TRANSFORMERS
• HT fuse & D.O. fuse.
• LT circuit breaker.
• HT Circuit breaker with Over load, Earth Fault
relay tripping.
• Oil Surge Relay for OLTC.
• PRV for OLTC.
• HORN GAPS & Lightening Arrestor.
• Breather.
 FAILURES & CAUSES
• Insufficient Oil level.
• Seepage of water in oil.
• Prolonged Over loading.
• Single Phase loading.
• Unbalanced loading.
• Faulty Termination (Improper sized lugs etc)
• Prolonged Short Circuit.
• Faulty operation of tap changer switch.
• Lack of installation checks.
 FAILURES & 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.
 FAILURES & CAUSES

• 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.
THANK YOU ALL