Transformer Test Report

Test according standards: SASO IEC 60076-1:2014 REF. NO. AES:AE07:QCA:FR:008:01

S.O.No.: SAP No.: C.Item code: Test date:
R.No: Customer:
Transformer Type: TF s/no: Frequency:
Rated power: kVA Phases: HV rated current:
HV rated Voltage: V Tapping: % LV rated current:
LV rated voltage: V Vector group: Connections:
Cooling type: Winding Material (HV/LV):

Insulation Resistance Measurement in Megaohms

DC Test Voltage 2500 V Temprature

HV / LV HV / E LV / E

Voltage Ratio Measurement Vector Group checked and found 0.000

Tap No. 1 2 3 4 5 6 7 8 9 10 11 Max. Deviation

U Phase

V Phase

W Phase

LV Winding Resistance Measurement in ohms

Temperature 27.5 °C
2U-2V 2V-2W 2W-2U Average Avg. at 75oC

HV Winding Resistance Measurement in ohms

Temperature 27.5 °C
1U-1V 1V-1W 1W-1U Average Avg. at 75oC

Separate Source AC Withstand Voltage Test

AC power frequency voltage KV applied for 60 seconds to HV side of transformer. oK withstood

AC power frequency voltage KV applied for 60 seconds to LV side of transformer. oK withstood

Induce AC Withstand Voltage Test

Twice the rated voltage applied to LV at 158 Hz for the duration of Seconds oK withstood

No Load Current and No load losses measurement Guaranteed No load losses W

Measurement side LV
Applied Voltage (V) Current (A) Losses (W) %age of full load current

Load Losses and Impedance Measurement Guaranteed Load losses W

Guaranteed Impedance ( +/- 10% )%
Tap No. Temperature
Test Frequency Impedance Voltage Measured Corrected Loss
Test Current (A) % Impedance % Impedance at 75oC
(Hz) (V) Losses (W) at 75oC

Instruments & devices used for measurements Q.NO:

Remarks :
The results of all the tests conducted on this transformer found satisfactory and within guaranteed limits.

ISSUE DATE TESTED BY CHECKED BY APPROVED BY

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Abbreviations: C.Item code: Customer Item Code, S.O.No.: Sales Order Number, R.No.: Running Number
 Routine Test
Manual
Oil Immersed
Transformers

Approved By: Gurdeep Singh Parihar

QCA Manager - Alfanar Transformers
Alfanar Electrical Systems

[Test Manual for Routine Tests] Page 1

 TABLE OF CONTENT
SR
NAME OF THE TEST PAGE NO
NO

0 Table of content 2

1 Measurement of voltage ratio and check of phase 3

displacement
2 Measurement of winding resistance 4

3 Check of core and frame insulation 5

4 Separate source voltage withstand test 6

5 Measurement of no-load loss and current. 7

6 Induced over voltage withstand test 8

7 Measurement of short-circuit impedance and load loss 9

8 Leak testing with pressure 10

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 MEASUREMENT OF VOLTAGE RATIO AND CHECK OF
PHASE DISPLACEMENT

PURPOSE:
To check the voltage ratio for each tapping between pairs of winding.

REF. STANDARD: IEC 60076-1

PROCEDURE:
The voltage ratio taking into account the tapping used, is the ratio of the number of turns
of HV to LV windings. Ratio is measured by using a ratio meter. HV and LV leads are
connected to transformer’s HV & LV terminals respectively. Single phase supply will be
given to the instrument. Meter directly indicates the ratio of the connected tap and
phase displacement if any. Similarly ratio is checked at different taps.

EQUIPMENT USED: Digital 3 phase Ratio meter.

ACCEPTANCE CRITERIA: Within +\-0.5 % of calculated ratio.

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 MEASUREMENT OF WINDING RESISTANCE
PURPOSE:
(a) To eliminate the possibility of loose joints.
(b) For load loss calculation at reference temperature.
.
REF. STANDARD: IEC 60076-1.

PROCEDURE:
Direct reading milli ohm meter resistance meter is used for the measurement. Before
the measurement, the transformer is standing for at least 3 hours filled with oil and
without excitation. During this period, the temperature differences of the transformer will
equalize the winding temperature will become equal to the oil temperature. The average
winding temperature is obtained by determining the average oil temp. The average oil
temperature is obtained by measuring the top oil temperature and the bottom oil
temperature and taking the average of these two. In the report the terminal, between
which the resistances are measured, the connection, the tapping position and the
average temperature of the windings during the measurement are stated.

ACCEPTANCE CRITERIA: Measured resistance used to calculate the load losses at

refrence temp. of 75 degree centigrade . The acceptance criteria for resistance that load
losses at refrence temperature should be within the limit guaranteed losses as per GTP.

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 CHECK OF CORE TO FRAME INSULATION
PURPOSE:
This test is to measure the insulation resistance between core and frame.

REF. STANDARD: IEC 60076-1.

PROCEDURE:
Standard motorized or electronic megger set is used for measurement at 2500V dc
between core and frame. The readings for IR value shall be taken at 60 seconds. Top
and bottom oil temperature shall be recorded.

ACCEPTANCE CRITERIA: Minimum 1000 Mega ohm at ambient temperature.

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 SEPARATE SOURCE VOLTAGE WITHSTAND TEST
PURPOSE:
This test is intended to verify the power frequency withstand strength of the winding
under test to earth and other windings.

REF. STANDARD: IEC 60076-3.

PROCEDURE:
All HV terminals are shorted together and all LV terminals are shorted together. The
separate source power frequency voltage is applied for one minute to one winding and
other earthed. The figure shows when separate source voltage is applied to LV terminal
with HV winding earthed. Next, voltage is applied to HV winding respectively with LV
winding earthed.
Duration of the test - 60 seconds

ACCEPTANCE CRITERIA: The above test is successful if no collapse of the test

voltage occurs.

CONNECTION DIAGRAM:

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 MEASUREMENT OF NO LOAD LOSS AND CURRENT
PURPOSE:
a. To check guaranteed losses and percentage of excitation current.
b. Any shorted turn can be noticed in this test.
c. Performance of core material.

REF. STANDARD: IEC 60076-1.

PROCEDURE:
No load loss is the active power absorbed when rated power frequency voltage is
applied to one of the winding, the other winding is kept open. No load current is the
current flowing through line terminals at rated power frequency applied voltage, when
the other windings being open.
To measure losses power analyser based on 3 wattmeter method is used. The no load
loss includes
a. Core loss including stray loss due to excitation current
b. Dielectric loss (negligible)
c. I2R loss due to excitation current.
Frequency shall be noted at the time of testing.

ACCEPTANCE CRITERIA: No load loss should be within limit of guarantee.

CONNECTION DIAGRAM:

CT1
R

CT2
Y
3 phase
Supply Transformer under
test will be connected
CT3
B
PT
To panel

PT

To panel

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 INDUCED OVER VOLTAGE TEST

PURPOSE:
This test is intended to verify the power frequency voltage withstand strength of the line
terminals to earth and other windings and withstand strength between phases and along
the winding under test.

REF. STANDARD: IEC 60076-3

PROCEDURE:
Twice the rated Voltage is applied to the LV winding
HV winding terminals are kept open. The test frequency is sufficiently above the rated
frequency to avoid excessive magnetizing current.

The duration of the test shall be 120 * rated frequency seconds.

---------------------
Test frequency

ACCEPTANCE CRITERIA: The test is successful if no collapse of voltage occurs.

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 MEASUREMENT OF SHORT CIRCUIT IMPEDANCE AND LOAD LOSS
PURPOSE:
To measure the load loss and impedance voltage.

REF. STANDARD: Test will be as per clause no. 10.4 of IEC 60076-1.

PROCEDURE:
Load loss is the active power absorbed at power frequency when the rated current is
flowing through the line terminals of the windings. The measurement of load loss is
done with the help of Power Analyser. The load loss includes
a).I2R loss in the winding and
b).Stray losses in the transformer
Measurement is done by injecting approximately rated current to HV winding at power
frequency and LV terminals is being short-circuited. The impedance voltage applied
and the rated current passed is measured on Power Analyser by using appropriate
P.T.s and C.T.s. as per need. The test will be performed on principal and extreme taps,
if applicable. Top & bottom oil temperatures shall be noted.

ACCEPTANCE CRITERIA: Measured load loss and percentage impedance

value should be within limit of guarantee.
CONNECTION DIAGRAM:
CT1

CT2

3 phase supply Y
Transformer under
test will be connected
CT3

PT

To panel

PT

To panel

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 LEAKAGE TESTING WITH PRESSURE

PURPOSE :
To check the oil tightness and to verify no leakage for complete assembled transformer.

REF. STANDARD :
As per IEC 60076-1

PROCEDURE :
The complete assembled transformer shall be tested for oil tightness by completely
filling with oil and applying a pressure 150 mbar for corrugated tank and 300 mbar for
transformer’ tank with radiator at the top of the tank. This pressure shall be maintained
for a period of 8 hours , during which no leakage shall be occur.

ACCEPTANCE CRITERIA : No leakage should be observed

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 Temperature Rise
Test Procedure
Oil Immersed
Transformers

[Test Manual for Temperature Rise Tests] Page 1

 Measurement of Transformer Temperature rise

PURPOSE:
a. To verify the guaranteed temperature rise of Transformer oil & winding.
b. Maximum temperature rise during the Load condition can be determined.

REF. STANDARD: IEC 60076

PROCEDURE:

Transformer temperature rise is a Type test conducted to determine the temperature rise in
Oil & Winding. Transformers under the test will be kept in safe location surrounded by four
sensors to measure the ambient temperature throughout the test and cold resistance of HV
& LV Winding will be measured at an ambient Temp. (Resistance R1) before making the
short circuit & Input connections as per the standard below connection diagram. which will be
used to conduct the Temperature rise test of Transformer.

CONNECTION DIAGRAM:

CT1
R

CT2
Y
3 phase
Supply Transformer under test
will be connected
CT3
B

PT
To panel

PT

To panel

[Test Manual for Temperature Rise Tests] Page 2

 1. For the determination of Top Oil temperature rise.
Total losses to be injected on HV winding side while LV side is kept shorted during the first
part of the test. This part of the test determines the maximum Top-liquid temperature rise.
The top-liquid temperature (θo) is conventionally determined by using sensors immersed in
insulating liquid at the top cover pocket & fixed at bottom of the tank. Each hour sensor
readings will be recorded to determine the steady state of Top oil temperature.

TEMPERATURE RISE OF TOP OIL AT STEADY STATE [∆Qo = Qo-Qa]

TEMP. RISE OF TOP OIL CORRESPONDING TO TOTAL LOSSES [∆Qo CORRECT]

∆Qo CORRECTED = (Pr./Pt)0.8*∆Qo)

2. For the determination of winding temperature rise

Once three consecutive readings recorded less than 1 degree rise, Then it considered as
steady state. Now reduces the total losses to rated current of HV winding for one hour.

At the end of the hour, the resistances of the windings are measured, after a rapid
disconnection of the supply and short circuits by using DC winding resistance meters for both
hot HV & LV winding and conservative readings of resistance against time will be recorded to
plot the graph to get Hot resistance R2

For HV Winding:

TEMP. OF HV WDG. AT SHUTDOWN = [Q2HV=R2HV/R1HV(235+Q1)-235]

TEMP. RISE OF HV WDG. [∆Qw HV= Q'2HV + ∆Qofm - Q'a]

Where R2HV is Hot Resistance of HV Winding, and R1HV is Cold resistance of HV winding, Q'a is
ambient temp. at time of shutdown

Similarly, by using the below mentioned formula winding Temperature rise of LV winding will be
determined.

TEMP. OF LV WDG. AT SHUTDOWN = [Q2LV=R2LV/R1LV(235+Q1)-235]

TEMP. RISE OF LV WDG. [∆Qw LV= Q'2LV + ∆Qofm - Q'a]

ACCEPTANCE CRITERIA: Measured values should be within the limit of

guarantee.

[Test Manual for Temperature Rise Tests] Page 3

 SOUND LEVEL
TEST PROCEDURE
Transformers
(OIL & DRY)

[Test Manual for Routine Tests] Page 1

 MEASUREMENT OF Sound level of Oil & DRY Transformer

PURPOSE:
a. To verify the guaranteed Sound level of Transformer
b. High Noise level can be determined.

REF. STANDARD: IEC 60076-10

PROCEDURE:
The Sound level of Transformer (OIL or DRY) is the Noise absorbed when rated power
frequency voltage is applied to one of the windings, the other winding is kept open.

• Test Object will be kept inside the shielded room to avoid much interference of
surrounding noise during the test.

• Measurement locations should be marked as effective surface for Oil Immersed

Transformer 300 mm from the Tank or Radiators and 1 Meter away for DRY
Transformer.

• Microphones adjusted or fixed at the half height of transformers used to measure

the Sound level.

• Background Sound to be measured and recorded before & after Sound pressure
level test.

• A power analyzer based on 3 wattmeter method is used (as shown below) to

inject the rated power frequency voltage on Low Voltage Side and High Voltage
side is Kept Open.

• To measure Sound pressure level, microphone readings will be recorded at many

points (e.g. 12 points) covering the complete surroundings of test Object as
shown below

ACCEPTANCE CRITERIA: Corrected Average A- weighted sound pressure level

(LpA) should be within the limit of guarantee.

[Test Manual for Routine Tests] Page 2

CONNECTION DIAGRAM:
CT1
R

CT2
Y
3 phase
Supply Connected to
CT3 Transformer Low
B voltage terminals.

To panel PT

PT

To panel

[Test Manual for Routine Tests] Page 3