APPROVED

SISTEMA DE TRANSMISIN 500 KV

MEJILLONES - CARDONES
NOMBRE DE LA SUBESTACIN

TTULO DEL DOCUMENTO

S/E LOS CHANGOS

FAT (factory acceptance

test) procedures

AUTOR
REVISADO
APROBADO
AUTOR
REVISADO
APROBADO

LOGO
SUBCONTRACTOR

DOCUMENTO SUBCONTRATISTA

RAYS LI
JANAN QU
ZHENB XU

DOCUMENTO ALSTOM

MCT-COM-500-TR-AWT-5515-TD
DOCUMENTO CLIENTE

REVISADO

Revisin
A
B
0

Fecha
2015-8-4
2015-8-12
2015-12-14

SIGATE
TEN

SCHA-500-E-PC-5515

Propsito de la modificacin
First issue
Add the document code
For manufacturing

ALSTOM GRID
Salar Ascotn 1288, Parque Industrial ENEA, Pudahuel, Santiago CHILE

Content
1.
2.
3.
4.
5.

Scope ........................................................................................................................................................................... 3
Applied standards..................................................................................................................................................... 3
Technical Data ........................................................................................................................................................... 3
Test list ........................................................................................................................................................................ 4
TEST PROCEDURE .................................................................................................................................................. 5

AWT 5515 -

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1. Scope
This test items covers shop tests for

250MVA/5253kV

power transformers.

PROJECT NO.
5352PH139

2. Applied standards
The tests will basically comply with the specified standards IEC60076/ IEEE57.12.90 and specification, if some
test items are not required in the standards or specification; they will comply with ALSTOM or manufacturer
standards or practice.

3. Technical Data
Rated Power (MVA)

250/250/51

Rated Voltage (kV)

525/3 / 230/3(-12~+4x1.25%)/ 66

Rated Current (A)

825 / 1883/ 773

Connection Group

Ia0i0(YN,a0+d)

Cooling Type

170MVA(ONAN);210MVA(ONAF1);250MVA(ONAF2)

Frequency (Hz)

50

Insulation Level

HV line terminal
LV line terminal
TV line terminal
HV & MV netrual

SI/LI
LI
LI /AC
LI /AC

1175/1425
950
325/140
145/60

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4. Test list
Apply to
No.

Test item

Page

One
unit

Other
unit

General inspection

Conversion rate and Polarity

Measurement resistance of the winding

Winding insulation resistance

Winding and bushings Isolation capacity and power factor

Exciting current at 10kV

Excitation tests before dielectric test

Level of audible noise test

Positive sequence impedance and load losses

10

Impulse and over-voltage maneuver tests

11

Switching impulse test

10

12

Dielectric tests of low frequency

11

13

Partial discharge tests before dielectric test (DP)

12

14

Partial discharge tests(DP)

12

15

Temperature increase test

13

16

Control Cabinet Wiring dielectric and operational tests.

16

17

Oil Gas Dissolved Analysis before and after dielectric tests &
temperature rise test.

16

18

FRA, Frequency Response Analysis

17

19

OLTC test

17

20

Overpressure test on tank and accessories

18

21

Test for the determination of dew point

18

22

Tank and accessories vacuum test

18

23

Transferred voltage impulse test

19

24

Transfer switching impulse tests

21

25

Fans power measurement

21

26

Excitation tests after dielectric test

21

27

Winding isolation resistance after dielectric test

22

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NO.

5.
1

Test Item

Test Procedure

Applied Spec. or Standards

TEST PROCEDURE
General inspection

Verification of dimensions, location of the bushings, dimensions of the bushings, layout Technical Specification and approved
of the valves and rest of accessories in accordance with the approved drawings

drawings

Verification of the correct cabling of the power, control, protection and signaling devices
in accordance with the electrical diagrams approved
Verification of the correct operation of the protection and monitoring devices

Conversion rate and

The voltage ratio will be measured on all tap positions by comparison method with

IEC 60076-1

Polarity

RATIO METER. The test will be made as follows:

The turns ratio error shall be within

between HV and MV at all tap positions

0.5%

between MV and LV

and the relation is Ia0i0.

The polarity and phase relation will be checked automatically by RATIO METER when
voltage ratio test.
Test circuit: for example HV to LV
A
X

Y1
a
x

T u r n r a tio te s te r
TTR 2795

X1

H0

Y2

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NO.
3

Test Item

Test Procedure

Applied Spec. or Standards

measurement resistance The winding resistance will be measured with a special DC resistance bridge on all
of the winding

IEC 60076-1

windings at all tap positions.

Performed

twice

(from tap 1 to tap 17 and then from tap 17 to tap 1)

Test circuit: for example HV winding

H1

V1
I1

Y1
V2
I2

X1

D C r e s is t a n c e t e s t e r
JY R 40D

H0

Y2

Winding insulation

The insulation resistance will be measured between winding to ground and winding to IEC 60076-1

resistance

winding by 1000 V insulation tester (MEGGER).

Insulation resistance(20):

(1) R1: HV+MV ~LV and ground

Winding to ground, winding to

(2) R2: LV ~ HV+MV and ground

winding

(3) R3: HV, MV, LV ~ ground

>=500Mohm@1min

(4) R4: HV+MV~LV

Core frame to

1. Insulation resistance curve of each winding based on superior temperature of the ground >=200Mohm@1min
oil of the autotransformer submitted to heating test.

Duration of the measurement on

each spot, one minute.

2. The measurement will be made in ten minutes, the value in 15th second the first
minute, the fifth minute and the tenth minute will be record.
3. The insulation resistance measurement at environmental temperature shall be
performed before starting and after finishing the dielectric tests.
-

This test shall be performed at a minimum voltage of stable 1,000 VDC

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NO.

Test Item

Test Procedure
-

Applied Spec. or Standards

The insulation resistance of core frame and between them will be measured for 1
minute with 2500 V DC MEGGER.

Test circuit : for example

HV+MV ~LV and ground

H1

HV

Y1
G ro u n d

X1

in s u la tio n re s is ta n c e te s te r
M e g g e r M IT 5 2 0 /2

H0

Y2

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NO.
5

Test Item

Test Procedure

Applied Spec. or Standards

Winding and bushings

The dielectric loss angle and capacitance will be measured at 10kV by MIDAS2880 as IEC 60076-1 & technical specification

Isolation capacity and

follows.

power factor

tg& <0.5% (20)

(1) HV +MV~ LV and ground

(2) LV ~ HV+MV and ground
(3) HV+MV+LV ~ ground
(4) HV+MV ~LV
Test circuit: for example

windings HV +MV~ LV and ground

H1

HV

Y1
G ro u n d

X1

T e tte x d ie le c tric d is s a p a tio n

te s te r M ID A S 2 8 8 0

H0

Y2

The bushings will be tested.

6

Exciting current at 10kV

Supply 10kV from H1 terminal and measured from H0 terminal. Test circuit is below

Technical specification
Record the current at 10kV

H1

HV

Y1
A

X1

T e tte x d ie le c tric d is s a p a tio n

te s te r M ID A S 2 8 8 0

H0

Y2

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NO.
7

Test Item
Excitation tests before
dielectric test

Test Procedure
a)

Applied Spec. or Standards

No-load loss and no-load current will be measured on the LV winding at 50Hz at,

IEC 60076-1

95%,100%,105%, 110% rated voltage.

At rated voltage and frequency

Test circuit:

Guaranteed value:

MV will be nominal tap position.

95%
P0
(kW)
I0

CT

HV

Y1

100%

105%

85

96

120

0.3

0.4

0.6

H0

PT

a
b
Ge
1

Y2

The voltage will be recorded in average voltage and RMS voltage.

The no-load current will be measured with RMS ammeter.
No-load loss will be corrected according to the sinusoidal waveform factor.
The harmonics of exciting current will be measured.
Excitation test will be performed twice, before and after dielectric tests
8

Determination of sound

The sound level will be measured with no-load at 100% rated voltage and frequency .for IEC 60076-10,

level

following condition:
At 0.3m away from the principal radiating surface with forced air
cooling auxiliaries are out-off service.
At 2.0m away from the principal radiating surface with forced air

IEEE 57.12.00-2006
1.0 UN 0.3m -ONAN
1.0 UN 2m

-ONAF

LPA<70 dB(A)

cooling auxiliaries put into service.

The test circuit is same with item 6-excitation test
9

Positive sequence

The measurement will be made at rated current on as follows.

IEEE C57.12.00 and technical

impedance and load

Test frequency: 50 Hz

specification
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NO.

Test Item
losses

Test Procedure

Applied Spec. or Standards

Guaranteed value (at 85) based on

Test circuit: for example between HV and LV

ONAN capacity:
CT

HV

Y1

H0

PT

a
b
Ge
1

Y2

Tap

Group

Impedance (%)

HV-MV

9.20( 10%)

HV-MV

9.50( 10%)

17

HV-MV

12.40( 10%)

MV-LV

3.17( 10%)@35

MV-LV

3.0(10%)@35MVA

17

MV-LV

2.99( 10%)@35

HV-LV

5.5(10%)@35

Total load loss:

based on ONAF2 capacity

For ONAF2 cooling stage, impedance and load loss will be measured at 1/5/17 taps,

Tap

Group

Loss(kW)

PK+ P0

<646

Load losses in each ATR single

phase with rated power simultaneous
maximum in all its windings
250/250/50MVA (capacitive) and
rated voltage in the tap of rated
voltage, the load losses refer to 85C,
based on ONAF2
10

Lightning impulse test

1) Test connection
HV terminal test, the test voltage will be applied on the terminal under test, MV will be
connected to neutral through a resistance (Max is 400 ), other terminals will be
grounded. The voltage will be measured at the terminal under test by a divider and
current will be measured the shunt connected between neutral and ground in series.
Test circuit: for example HV:

IEC 60076-3
No significant difference between
voltage and current transients
recorded at reduced voltage and
those recorded at full test voltage.

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NO.

Test Item

Test Procedure

Applied Spec. or Standards

MV terminal test, the test voltage will be applied on the terminal under test, other
terminals will be grounded. The voltage and current measurement is same to HV.
Neutral terminal test, the test voltage will be applied on the terminal under test, other
terminals will be grounded. The voltage will be measured at the terminal under test by a
divider and current will be measured the shunt connected between HV&MV to ground in
series.
LV winding test, the test voltage will be applied on the terminal under test, other
terminals will be grounded. The voltage will be measured at the terminal under test by a
divider and current will be measured the shunt connected between not tested terminal
of LV winding to ground in series.
Test tap position:
In unit 1 tap will be maximum tap.
In unit 2 tap will be minimum tap.
In unit 3 tap will be nominal tap.

Unit 4 will be tap Nr 9

Note:
Wider tolerance may be accepted, if the capacitance of the winding to earth is very
high and / or the inductance is very low, and if the standard wave shape cannot be
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NO.

Test Item

Test Procedure

Applied Spec. or Standards

achieved by installation of additional resistors (Max. 400 ) in the non-tested

windings.
2)Test voltage(negative polarity)
erminal

HV

MV

LV

Neutral

W.(kV)

1425

950

350

150

3) Wave shape (for line terminal)

Standard impulse voltage wave shape
time of wave front 1.2 30 % S
time of wave tail 50 20 % S
A longer duration of the front time is allowed, up to 13S for test on neutral terminal.
4)Test sequence
1) one 50% reduced full wave
2) three 100% full wave
11

Switching impulse test

The switch impulse test will be made only on HV line terminals .The impulse voltage will IEC 60076-3
be applied to HV winding so that the test voltage is inductively transferred to LV line
terminals.

A voltage oscillogram shall be taken

of each applied or induced transient.

test voltage
HV line terminal ~ ground

The test is successful if there is no

1175 kV

sudden collapse of voltage indicated

Wave shape
The virtual front time
The time above 90%:

on the oscillograms. Successive

100 S

oscillograms may differ, however,

200 S

The duration from virtual origin to the first zero passage :

1000 S

Test tap position :tap 1

because of the influence of magnetic

saturation on impulse duration

Test sequence type test

a).

one 50% reduced full wave

b).

three 100% full wave

Test circuit

(the resistance in neutral is very low to get the current )

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NO.

Test Item

Test Procedure

Applied Spec. or Standards

HV

Y1
H0

Y2

Dielectric tests of low

The required test voltage will be applied on tested winding with the other windings being IEC 60076-3

frequency

connected to earth. Test frequency:50Hz , MV winding will be rated tap position

The test is successful if no collapse

HV+MV - LV ground

of the test voltage occurs and the test

test voltage

60 kV

test duration 1 minute

supply current does not change

LV - HV+MV and ground

test voltage

significantly.
140kV

test duration 1 minute

Test circuit: for example HV+MV-Neutral,

Y1

R protective TR

HV
X

12

Y2

H0

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NO.
13

Test Item

Test Procedure

Applied Spec. or Standards

Partial discharge tests

200Hz single phase power source will apply to LV winding to perform long-duration

IEC 60076-3 and Technical

before dielectric test

induced voltage test.

Specification

PD will be measured during test.

The background noise during the measurement of partial discharges (PD) shall be 1.3 rated voltage: PD<100pC

10 pC.
MV tap position: nominal tap
Test circuit :

Voltage
HV-earth
MV-earth

1.3Un
413
181

Test sequence:
a)

b)
c)

Before the impulse tests, the PD curve (pC) versus voltage in the winding (kV)
shall be drawn measuring the pC increasing voltage to: 90, 100, 110, 120 and 130
per cent and diminishing from 130, 120, 110, 100 and 90 per cent of the nominal
voltage of the winding.
The duration of the test, at a level of 130% of nominal voltage of the winding, shall
be 30 minutes.
During the induced voltage tests, two PD values will be measured, one at the start
and the other at completion of the period of maximum voltage.

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NO.
14

Test Item
Partial discharge tests

Test Procedure

Applied Spec. or Standards

200Hz single phase power source will apply to LV winding to perform long-duration

IEC 60076-3 and Technical

induced voltage test. PD will be measured during test.

Specification

MV tap position: nominal tap

1.5 rated voltage: PD<400pC

The background noise during the measurement of partial discharges (PD) shall be 1.3 rated voltage: PD<100pC

10 pC.
Test circuit :

Test voltage:
Um=550KV
Voltage

1.3Um

1.4Um

1.5Um

U1=1.7Um

HV-earth

413

445

475

540

MV-earth

181

195

209

236

Test sequence:

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NO.

Test Item

Test Procedure

Applied Spec. or Standards

After dielectric test(LI, Transfer LI,SI transfer SI), the test sequence is shown below,
U1 duration=120x(50/200)=30s
PD will be measured as following sequence:
a)

The duration of the test, at a level of 130% of nominal voltage of the winding, shall
be 30 minutes.

b)

During the induced voltage tests, two PD values will be measured, one at the start
and the other at completion of the period of maximum voltage.

c)

During the induced voltage tests, a curve pC versus kV, shall be drawn measuring
the pC at: 90, 100, 110, 120, 130 per cent during 30 minutes, and 140, 150 per
cent during 1 minute, and after that it will be diminished from 150, 140 and 130 per
cent during 30 minutes, and 120, 110, 100 and 90 per cent of the nominal voltage
of the winding.

d)

The application of the before mentioned voltage cycles, shall be performed

continuously, gently increasing and diminishing the voltage and allowing a clear
determination of the start and extinction voltages of the PD.

e)

During periods in which voltage is maintained (for example: 130% during 30

minutes, 150% during 1 minute and the period of maximum voltage during the
induced potential test), the behavior of the PD shall be observed and the values of
the partial discharges at the start and completion of the period shall be measured.

15

Temperature increase

The test will be performed before the dielectric tests on the unit of greatest

IEC 60076-2

losses.

Temperature rise guaranteed

The test will be made by a short-circuit method at the maximum loss tap position.

Top oil:

<60k
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NO.

Test Item

Test Procedure

Applied Spec. or Standards

Temperature of oil, HV, MV & LV will be measured.

Winding average: <65K

(1) The oil temperature rise

Winding Hot spot <80K

The power will be injected into HV and MV is shorted. The top oil temperature rise
is determined by supplying 100% of maximum total loss under full power, then the
correction to insufficient loss will be made by multiplying correction factor as
follows:
Correction factor = (Max total loss / supplied loss)^0.9
The test will be terminated when the rate of change of top oil temperature
rise has fallen below 1 K per hour and has remained there for a period of 3
hours, then the readings of the last hour is taken as the result of the test.
(2) The average winding temperature rise of HV and MV
After determination of the top oil temperature rise, the rated current is supplied to
HV winding for 1 hour, then the HV winding temperature rise is measured by a
winding resistance method. After then, we will re-inject rated current for an
hour, and measure the regulator winding hot resistance.
The test circuit of HV and regulation winding

CT
A

Y1

HV

PT

a
b
Ge
1

Stage 1-2
Y2

H0

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NO.

Test Item

Test Procedure

Applied Spec. or Standards

(3) The average winding temperature rise of LV

The rated current is supplied to HV~LV winding for 1 hour, then the LV winding
temperature rise is measured by a winding resistance method.
The test circuit of HV-LV

CT
A

Y1

HV

PT

a
b
Ge
1

S tage 3
Y2

H0

Test sequence

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NO.

Test Item

Test Procedure

Applied Spec. or Standards

Above test sequence will be performed separately when the cooling method of
transformer is ONAN,ONAF1,ONAF2.
The hot spot will calculated according to IEC 60076-2, the hot spot factor is 1.3
An Infrared thermal detector will be used to measure the temperature of tank
during all stages.
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NO.

Test Item

Test Procedure

Applied Spec. or Standards

The test will be performed on the greater losses unit with a fan and radiator out of
service during ONAF1 and ONAF2 stages
16

Control Cabinet Wiring

Continuity and megger test on all control, current and protective wiring.

IEC 60076-1

dielectric and operational Operating test to establish that control circuits function properly.

and technical Specification

tests.

No breakdown

Simulation of operating and trouble conditions to establish that all relays and meters
function properly.
Withstand DC voltage 2kV for 1 minute

17

Oil Gas Dissolved

Oil test for transformer oil sample will be made as following items:

IEC 60296 , ASTM D3487 and

Analysis before and after

Water content

technical Specification

dielectric tests &

Dielectric strength

Combustible gases level shall meet

temperature

tan

AWT internal control standard:

Gas analysis

The gas chromatography analysis will be performed 4 times as follows.

18

At the start of the test schedule

After dielectric test

after temperature rise test

after all test

Before

After

test

test

H2

CH4

0.2

0.4

C2H4

0.1

C2H6

C2H2

C+H

0.2

0.5

Item

FRA, Frequency

This test shall be performed in all alternatives allowed by the winding, considering as

According to the technical

Response Analysis

minimum the following. The sweep frequency shall be between 10 Hz and 2.0 MHz.

specification

Test will be performed at maximum voltage tap position.

No.

Measurement

Open

Short-circuit

H1-X1

X1-H0X0 / Y1-Y2

X1-H0X0

H1-X1 / Y1-Y2

Y1-Y2

H1-X1 / X1-H0X0

The test will be performed two times, one is the transformer fully assembled with oil and
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NO.

Test Item

Test Procedure

Applied Spec. or Standards

bushings, the other is the transformer fully assembled with bushing without oil.

19

OLTC test

OLTC full cycle operation at full voltage no load and full current same as load losses

If the OLTC perform above tests

test.

without any failure, the test is passed.

Two complete cycles of operations being the autotransformer de-energized.

A complete operation cycle being the autotransformer energized with rated voltage and
frequency and without load.
Four operation cycles with 2 steps on each side of the rated tap, being the
autotransformer with short-circuited winding with the rated current.
A complete cycle of operations shall be performed with 85% of rated voltage in the ac
and cc auxiliary circuits, and local operation, being the autotransformer de-energized.
A complete cycle of operations shall be performed with 100% of the rated voltage of ac
and dc auxiliary circuits and normal operation (crank), being the autotransformer
de-energized.
A complete cycle of operations shall be performed with 100% of rated voltage of ac and
dc auxiliary circuits and with automatic operation, being the autotransformer
de-energized.
20

Overpressure test on tank This test shall be performed on each of the autotransformers entirely assembled with

According to the technical

and accessories

specification

oil, with the conservator tank valve opened.

The radiators shall have their valves

opened.
Overpressure tests at 0.7 daN/cm2 during 24 hours, measuring the pressure in the
cover of each autotransformer filled with oil shall be performed. Test sequence:

At 0.7 daN/cm2 during 24 hours,

there shall be no signs of filtrations or
permanent distortions

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NO.

21

Test Item

Test Procedure

Applied Spec. or Standards

Test for the determination The autotransformers shall be without oil, with nitrogen gas or dry air (approximately 0.2 IEEE C57.12.12-1980
of dew point

bars) during 24 hours.

The dew point shall be measured at the start and completion of According to the technical

this period in order to determine the contents of water in the isolation.

Dew point

specification:

measurement will be performed using flow control dew point measurement instrument. The content of humidity after the 24
hours shall be lower or equal to 0.5%
in weight of the dry isolation
22

Tank and accessories

Provide the test report from supplier

vacuum test

This test shall be performed on the autotransformer entirely assembled without oil, and specification
the tank conservation tank valve closed.

According to the technical

The radiators shall have their valves opened. Two hours after the disconnection of

The vacuum test shall be performed at absolute pressure not higher to 1 mmHg during the vacuum pump the pressure of the
two hours, with the autotransformer without oil.

autotransformer shall not have

Test sequence:

increased in more than 1.5 mm Hg.

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NO.

23

Test Item

Test Procedure

Applied Spec. or Standards

Transferred voltage

On each primary terminal atmospheric impulse waves shall be applied in levels 30%

impulse test

and 60% of full wave (100% = BIL of the winding) and the results shall be recorded in
the terminals of the secondary.

After that, the process shall be reverse that is,

atmospheric impulse waves of 30% and 60% level shall be applied on the terminals of
the secondary, and the results shall be recorded in the terminals of the primary.

Then

the process shall be inverse that is atmospheric impulse waves and switching of levels
30% and 60%, shall be applied on the opposite terminals to the previous pair and the
results shall be recorded on the other terminals.
The following shall be considered as pair of winding:
High voltage-Medium voltage
High voltage-Low voltage
Medium voltage-Low voltage
The results of these tests shall coincide and the calculation sheet delivered by the
factory shall be validated with regards of transferred voltages.
Tap position:

No 17 (minimum voltage)

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NO.

Test Item

Test Procedure

Applied Spec. or Standards

Test circuit:

Test sequence:

Transferred atmospheric impulse

Applied on

Measured on

HV

XV

HV

YV1

HV

YV2

XV

HV

XV

YV1

XV

TV2

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NO.

24

Test Item

Test Procedure

Transferred switching

Like above process and sequence tap will be at

impulse test

Test sequence:

Applied Spec. or Standards

No 1 (maximum voltage)

In accordance with technical

specification

Tra sferr d atmospheric impulse

Applid on

Measured on

HV

XV

HV

YV1

HV

YV2

XV

HV

XV

YV1

XV

TV2

25

Fans power
measurement

Taken power and current will be measured at rated voltage and frequency.

26

Excitation tests after

No-load loss and no-load current will be measured on the LV winding at 50Hz at 90%, IEC 60076-1

dielectric test

95%,100%,105%,110%, rated voltage.

At rated voltage and frequency

Test circuit:

Guaranteed value:

technical specification

MV will be nominal tap position.

95%
P0
(kW)

CT

HV

Y1

105%

85

96

120

0.3

0.4

0.6

H0

100%

I0

PT

a
b
Ge
1

Y2

The voltage will be recorded in average voltage and RMS voltage.

The no-load current will be measured with RMS ammeter.
No-load loss will be corrected according to the sinusoidal waveform factor.
The harmonics of exciting current will be measured.
Excitation test will be performed twice, before and after dielectric tests
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NO.

27

Test Item
Winding insulation

Test Procedure

Applied Spec. or Standards

The insulation resistance will be measured between winding to ground and winding to IEC 60076-1

resistance after dielectric winding by 5000 V insulation tester (MEGGER).

Insulation resistance:

test

(1) R1: HV+MV ~LV and ground

Winding to ground, winding to

(2) R2: LV ~ HV+MV and ground

winding

(3) R3: HV, MV, LV ~ ground

>=500Mohm@1min

(4) R4: HV+MV~LV

Core frame to

The measurement will be made in ten minutes, the value in 15th second the first

ground >=200Mohm@1min

minute, the fifth minute and the tenth minute will be record.
Test circuit is same as item 4

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