G.A.Narayana Swamy B.E.

Ph :( 080) 23490692,
(M)9448351455,
Retd. Engineer No..1240, 12th ‘B’ cross, 10th main, 2nd
stage,
Mahalakshmipuram, Bangalore 86. Date: Sunday, March 01,
2009

TESTING OF REPAIRED-GOOD DISTRIBUTION TRANSFORMERS.

Here it should be noted that the innovations can only be brought out after proper
assimilation of the existing technologies. Actually in field activities no proper understanding of
the technology is available and a lot of handling of equipment is done mechanically.
Electrical technology is a very abstract subject compared to say civil or mechanical
engineering. In the latter fields grasping is easy. Besides visual models can be easily set up. In
electricals a detailed explanations often starting from fundamentals is required. This all the more
necessary for supervisory staff coming up from non-engineering cadres ie. who are not
engineering diploma \ degree holders.

The number of distribution transformers in India is supposed to exceed 2.5 million. More
than 50% of them are reported to be failing earlier than their lifetime period.
I headed for a period of 8 years (from 1989-1996); transformer sub division in the then
M. T. Division, Bangalore of the erstwhile KEB, now unbundled into several companies.
In view of large numbers, the repair works were outsourced a few months earlier. One of
the assignments of the transformer subdivision was evolving and later actually adopting a
procedure for testing the repaired good distribution transformers & certification, based on which
the repaired good transformers were later accepted .All the transformer repairs of entire KEB
were handled here only.
Before drawing up the standards for testing we contemplated on the existing procedures
and observed a number of failed transformers after de-tanking the active parts (core &coil
assembly). About 60% of the parts were reusable. The replacement by new ones was to the
extent of transil oil & H.V. windings & L.V. windings (Many a time the LV windings were re-
insulated only) and giving a new coat of metallic paint. The transil oil was also not new oil but
filtered good oil. The cost of repairs was about 25% of the cost of a new transformer of similar
KVA capacity.
We also examined the various tests conducted by transformer manufacturers on new
transformers. In view of usage of a large number of old parts, the costs involved, the years
through which they have served already, the balance years of their expected service & opinions
of the repairers, we evolved tests and standards which were different from those for newly
manufactured transformers. The same were proposed to the then Chief Engineer MM &P
(Material Management & Purchase) & approval obtained. At the chief engineer’s office I
explained at length to the connected engineers etc the reasoning behind the tests. In certain tests
there was a dilution of standards. The logic behind the same was also explained. Later a format
was got printed. Subsequently, all the details of the tests like nature of tests, purpose of tests,
electrical theory behind each test, expected standards etc. were explained by me to my
subordinate assistant engineers and junior engineers who were the actual engineers deputed for
testing.
 But over a period all the testing engineers stand transferred and found that the knowledge
was not transferred from one to the other. A sort of mechanical handling of events had come to
stay. For the purpose of giving knowledge to the present testing engineers & to create a
permanent record of all the details of testing procedures, the tests on repaired good distribution
transformers are narrated as below.

ACCEPTANCE TESTS FOR REPAIRED GOOD DISTRIBUTION TRANSFORMERS.

At the outset for the purpose of identifying each transformer & to differentiate one from the other
the name plate details of each transformer shall be noted. In cases where name plates are missing
suitable name plates may be provided with his own serial number etc.
1. Megger or Insulation Resistance test: Megger is an acronym for mega-ohm meter. Mega is
for a million and ohms stand for resistance in ohms. In other words megger test is to meter
the millions of ohms of insulation resistance offered for the electricity or electrons to escape
from its metal route to ground. It is the ability to prevent the electrons from leaking out. It is
the first & foremost test of an electrical engineer to ascertain the healthiness of an electrical
gadget from the point of confining electricity to its metallic parts. The quality & strength of
the insulation provided decides the mega ohms.
The strength of a chain lies in its weakest link. This proverb hold good here. The insulation
provided at the weakest point decides the strength of the insulation & hence the mega ohms.
The megger values of a winding are actually much more at its dried condition. ie.
immediately after ovening (A process for driving out all the moisture). After adequate
ovening, the winding is put into transil oil which occupies the vacuum points created while
drying out the moisture. At this stage the megger values actually decreases but the values
remains sustained at constant values for a long period. The values of course get affected due
to age & other factors like over & impulse voltages.
While actually measuring the megger values it is necessary to involve all the
independent metallic items into consideration. In a distribution transformer the metallic items
available are HV winding, LV winding and tank ( magnetic core is bolted to the tank and
hence can be taken as part of tank). Since tank is going to be earthed when the transformer is
put to service, HV winding megger results can be between HV winding and tank. When
actually measuring it is important to interconnect LV winding and tank as shown in the
sketch below. Similarly LV winding megger results is between LV winding and tank inter
connected with HV winding.
 TANK
HV LV

Transil oil

MEGGE
R

Item meggered Mega ohms Temperature

HV to Ground
LV to ground
HV to LV

Below are the megger results of a typical repaired good 63 and 100 kva ,1100 \ 433
transformers.

Item meggered Megger used Mega ohms

HV to Ground 2.5 KV 5000
HV to LV 2.5 KV 5000
LV to ground 500 volts 5000

Tests on transformer efficiency: These tests decide how effectively the repairs have been
carried out & to what extent the transformer could be used after the repairs. For the purpose
one will have to measure the losses, both when the transformer is on No-load condition as
well as Full-load condition. Hence the losses are termed as No load loss & load loss
respectively.
Fortunately the losses can be easily measured by subjecting the transformer to what are
called open circuit test & short circuit tests.
2. Open Circuit test: Here the test consists of applying the No-load rated voltage of a
distribution transformer ie. 3 x 433 volts to the L.V. winding of the transformer, leaving the
H.V. winding open. Here one must note that the voltage applied must be 433 volts and not
400 volts since all distribution transformers are designed for 400 volts at full load and 433
volts at no load. The circuitry is setup to measure the currents as well as watts.
w1 1U 1V
1W
A 2U 2V
1
Supply
A
from 3
phase 2
Dimmersta 2
t A
W
3

Ammete Wattmete Leave HV open

r w2 r

The LV currents are normally measured as above. Some times tong tester can also be used.
The watts are measured by two wattmeter method. The results, including the applied volts are
entered into a table as shown below. Below are the open circuit test results of a typical
repaired good 63 and 100 kva ,1100 \ 433 transformers

Particula L.V. Voltage Current in No Load Losses

rs of in Volts amperes
Transfor between
mer
2U- 2V- 2W- 2U 2V 2W W1 W2 W1 – W2
2V 2W 2U
Transfor 433 433 433 0. 0. 0.8 80 40 40 watts.
mer 8 9
63KVA
Transfor 433 433 433 1. 1. 1.5 32 16 160 watts.
mer 100 6 6 0 0
Transfor 433 433 433
mer No.3

The watts measured here pertain to what occurs when the transformer is in idle service ie
without any load. These losses occur always ie 24hrs a day & 365 days of the year. They are
called iron losses. The iron losses measured should not exceed a pre-determined value
(standard set by CEE MM&P) for a given KVA of the transformer.
3. Short circuit test: Here the test consist of applying the same 3 x 433
(or 400) volts to L.V winding of the transformer with H.V. winding short
circuited. Here current in amperes is more important than the applied
volts.
 w1
A
Supply 1
from 3
A
phase
Dimmer 2
stat
A
3
Ammet L.V. short circuited.
er w2 Wattmeter

The LV currents are normally measured as above and the HV currents by a tong tester. Some
times tong tester can be used for measuring both the currents.
The watts are measured by two wattmeter method. The results are entered into a table as shown
below. Below are the short circuit test results of a typical repaired good 63 and 100 kva ,1100 \
433 transformers
Perticulars Applied volts. Current in amperes Watts Load losses
Of Trans recorded.
. 1U 1V 1W 2U 2V 2W W1 W2 W1-W2
Trans-100KVA 430 5 5.1 5 128 127 128 1520 240 1280 watts
Trans-63 KVA 430 3 3.1 2.9 79 80 80 800 160 640 watts.
Trans-3
The watts measured here are called load losses, (at 433 volts in lieu of 11000 volts) because the
test circuitry resembles the full load condition of a transformer. Here one should understand what
is meant by loading a transformer & what is meant by No load & full load. No load of course is a
status when the transformer is put on the rated voltage but no supplies are extracted from the
other winding.
What is meant by loading? Suppose the transformer is 50KVA distribution transformer. The full
load current would be 66 amperes.
Then what is meant by fully loading a transformer? Decreasing the resistance R to values so that
I = 66 amps. By short circuiting the secondary & applying the rated L.V. volts ie 3 x 433 volts
to the primary we are providing for maximum current flow at 433 volts. Since the winding is
designed for 11000, shot circuiting will not result in any damages. The watts obtained is
extrapolated to the full load temperatures of transformer when the transformer is heated to
around 75ºC which is room temperature plus designed allowable temperature rise in transil oi ie
45ºC. So watt loss at 30 + 45 = 75ºC is more than watt loss at 30ºC (normal room temperature
assumed).
In other words, the load loss at 75ºC is arrived by adding figures (empirical ie based on
experience) depending upon the total KVA capacity of transformers. Please note that this
extrapolation is only for short circuit test & not to open circuit test or No load test, since the
temperature almost remains the room temperature in the latter case. The watts measured as in the
case of iron loss should not exceed predetermined or standard value for a given KVA of the
transformer. The losses can be computed to losses at full load currents by employing a formula
given in part-1 of I.S. 2026 of 77. Computed loss at rated current = measured loss at test current
x (rated current)² ÷ (test current)²
3. Winding resistance measurement: The total winding resistance is a
measure of total number of turns provided & cross section of the wires
used in the construction of the full winding. Why DC in lieu of AC? When
AC is used the winding reactance also comes into play. Hence the same is
eliminated by applying only direct current volts to the winding. Nowadays
there are meters which show the resistance readings directly & the same
are recorded as below.

Below are the results of a typical repaired good 63 and 100 kva ,1100 \ 433 transformers

Particulars D.C. resistance in ohms Remar

of ks
Transformer
1U-1V 1V- 1W-1U 2U-2V 2V-2W 2W-2U
1W
Transforme 18.9 18.9 18.9 24.2 24.2 24.1
r 100 kva ohms ohms ohms. Mili- Mili- Mili-
ohms ohms ohms
Transforme 20.1 20.1 20.1 25.1 25.1 25.2
r 100 kva ohms ohms ohms Mili- Mili- Mili-
ohms ohms ohms
Transforme 34.6 34.6 34.6 25.7 25.7 25.6
r 63 kva ohms ohms ohms Mili Mili Mili
ohms ohms ohms

4. Dielectric tests
4 a)separate source voltage withstand test. This is to
check the adequacy of the insulations to earth and
between windings. Here the HV & LV windings are treated
separately since each is insulated to different voltage
levels. A little concession in the case of repaired
transformers is made here compared to newly
manufactured transformers. So, the HV & LV windings are
subjected 21 KV & 2.25 (in lieu of 28 and 3 KV as per IS)
respectively for a duration of 60 seconds and observe for
any irregularities.. Here one should understand what is
meant by say 21KV. It means applying a potential
difference between the metal part of winding & earth at
21,000 volts.
 TANK
HV LV

Transil oil

Earthing bolt
Apply 21 KV
for 60
seconds

TANK
HV LV

Transil oil

Earthing bolt
Apply 2.25 KV
for 60
seconds
5. Induced over voltage test :
This test is popularly called double voltage double frequency test
This is actually a high voltage test on the transformer as in test 5. Here the LV winding of the
transformer is applied with twice the rated voltage 3 x 866 volts for a duration of 60 seconds &
observing for any irregularities in transformer functioning. But the core which provides paths for
the magnetic lines created is designed for 433 volts of LV & 11000 volts of H.V ( plus with a
small safety as per I.S ). When the voltage is increased to twice, the number of lines also
increases by two fold & the core designed for 11000/433 volts will not accommodate or provide
a path to the increased magnetic lines. So the core gets saturated at a voltage less than 22KV. In
other words we will not impress the 22 KV to core and LV winding.
Here one phenomenon of the magnetic lines created with reference to frequency of voltage is
used. The magnetic density in a core is inversely proportional to the frequency of voltage
applied. Namely the number of lines created is directly proportional to the frequency. In other
words a core designed for say 10,000 lines at 11,000/433 volts at 50 cycles can accommodate or
provide a path to 20,000 lines of 22,000/866 volts at 100 cycles frequency & 30,000 lines of
33,000/1299 volts at 150 cycles frequency.
Thus the frequency of double voltage test is raised to double frequency namely 100
cycles / second so that all the three elements namely the HV & LV windings and core are
subjected to twice their normal voltages

Apply 866V, 100 c\s supply for 60

seconds

TANK
HV LV

Transil oil

Ratio test: This test is to ensure the correctness of voltage transformation ratio of a transformer
namely 11,000/433 volts. Incase the transformer is provided with off load tap changer one must
carry out this test on all taps. (Please note that the transformation ratio changes from tap to tap).
This test also ensures proper engagement without any loose contactness at all contacts of the off
load tap changer in the interiors because these are several instances of the transformers failing
while in service after one or two days of tap changing because of loose contacts. Ratio bridges or
ratio meters giving a direct reading of the ratios can also be used.

Below are the results of a typical repaired good 63 and 100 kva 1100 \ 433 transformers

Applied 1U – 1V 1V – 1W 1W –1U
voltage
430Volts 430Volts 430Volts
Output 2U – 2V 2V – 2W 2W – 2U 2U – 2n 2V – 2n 2W – 2n
voltage
16.1 Volts 16.1 Volts 16.1 Volts 9.1 Volts 9.1 Volts 9.1 Volts

6. Vector group test: This is to check up polarity and to ensure that all the transformers tested
belong to the same vector group. Almost all the distribution transformers are manufactured to
Dyn11 vector group. In other words, the phase displacement of LV voltage from HV voltage
is as in a clock showing 11’0 clock. At 11’o clock the angle between hour arm & minutes
arm would be 330º ( measured in clock wise direction only) ie the power supply in LV
winding lags behind that of HV winding by 330 electrical degrees. Suppose in the field a
situation arises for putting two or three transformers in parallel. If the transformers do not
belong to the same vector group, parrelling of the transformers would lead to short circuiting
and would be dangerous. Hence we must ensure that all the transformers belong to the same
vector group. This is ensured by carrying out this vector group verification test. The same is
done by short circuiting 1U & 2N ( This is one type; out of three to four types
available).Before such shorting the transformer vectors of a DY11 vector group would be as
below

1
U
2U

2
N 2V

2
1 W
1W
V
The vector diagram after shorting would be as below. Apply 3 phase 400 volts to the three
terminals of primary & measuring the output voltages as shown in the table.

If the polarity between HV and LV is same and vector group is Dy11, then the following
THREE observations should be ensured

2U
.
2
1 N 2V
U

2
W

1W 1V

1. The voltage 1V-2U should be equal to the sum of voltages 1V-1U & 1U-2U.
2. The voltage 1U-1W should be equal to the sum of voltages 1W-2W & 2W-1U.
3. The voltages 1V-2W and 1V-2V should be equal.

Below are the results of a typical repaired good 63 and 100 kva 1100 \ 433 transformers

Applied 1V – 1U 1U – 1W 1W – 1U
voltage
426Volts 426Volts 426Volts
Output 1V – 2U 1V – 1U 1U – 2U 1U – 1W 1W – 2W 2W – 1U
voltage
435 Volts 426Volts 9Volts 426 Volts 418 Volts 8 Volts
Output 1V – 2W 1V – 2U
voltage
405Volts 405Volts
 So the transformer windings are correctly inter connected to correct polarities and DYN
vector group.

Painting :- This is recently introduced measure for identification of different capacities

of transformers. One of the conditions of repairing a transformer is giving a fresh coat of
paint with a red oxide base coat. Instead of retaining the existing colour the transformers
are given new colours so that one can identify the capacity of the transformer by looking
at the body paint alone. The colour codes are sky blue, silver grey and green for 25, 63
and 100 KVA transformers respectively.

In all the above tests standards are to be fixed to serve as a yard stick for passing the transformer
as good. This will have to be decided by a committee of engineers including expert repairers.

-------- G. A. Narayana Swamy.