Transformer Testing - Analysis of The Test Results, Real-Case Studies

Smart test devices for reliable electric power systems
Test Results Analysis

Maid Dzambic, Application Engineer
2 | 2016 DV Power All Rights Reserved.

TAP-CHANGER & WINDING ANALYZER

Numerical results
Graphs
Static resistance graph
Dynamic resistance graph (DRM graph)
THREE PHASE TRANSFORMER TURNS-RATIO TESTER

Numerical results
Graphs

TWA40D Test Results
Numerical results
Resistance value for all tap positions
Ripple (measured current ripple in percents) value for all
transitions
Transition times

TWA40D Test Results
Graphs
Static Resistance Graph (Winding resistance value (in Ohms)
for all tap positions)
Dynamic Resistance Graph (current values recorded durnig
tap chages)

TWA40D Test Results
Static Resistance Graph

TWA40D Test Results
DRM graph and motor current

Resistor-Type On-Load Tap Changer

Some Problems Diagnosed Using
TWA40D
Winding defects / continuity (high resistance of connections)
On Load Tap Changer (OLTC)
OLTC contact defects
High resistance contact in tap selector
Loose contact in tap selector
Burned, loose contacts in diverter switch
Broken resistors in diverter switch
Abnormal arcing
Misaligned contacts
Contact bounce
Phase synchronization problems
Mechanical and motor problems
Some Problems Diagnosed Using Static
Resistance Graph
How to analyze?
Comparing static resistance graph with reference graph
Comparing static resistance graph across different phases
Indicators of potential problem

Static resistance graph shape irregularities
Abnormal resistance value on all even (or odd) tap positions

Resistance Graph
Static resistance graph standard shapes
Linear Fine/coarse
Plus/minus (reversing change over-selector)

Resistance Graph
High resistance values of phase W

Resistance Graph
Static resistance graph shape irregularity indicate potential
problems (bad contact in some position, bad connections...)

Resistance Graph
Abnormal resistance values on all even (or odd) tap positions
indicate potential problem with diverter switch, selector switch.

Some Problems Diagnosed with DRM
How to analyse?
Comparing DRM graph with reference graph
Comparing DRM graph across different phases
Analysis of DRM graph shape

DRM resistance graph problem indicators

DRM graph shape
Linearity
Abnormalities on all even (or odd) tap positions
DRM graph linearity on stable region of DRM graph
Transition shape
Transition times
Abnormalities at all tap positions, at every second position or at
individual position (contact bouncing)

DRM resistance graph problem indicators

Ripple shape
Linearity
Ripple 100% (open circuit during tap change)
Three phase synchronisation
Desynchronisation at all tap positions, at every second position or at
individual position
Tap changer motor current
Magnitude and duration
Shape abnormalities
Compare across tap positions

DRM graph shape linearity bad contact in some position

Abnormalities on all even (or odd) tap positions - indicate
potential problem with diverter switch, selector switch

female diverter coupling contact

male diverter coupling contacts
Before service After service

problem with OLTC contact


Erosion on OLTC contact


Transition shape - transition time
Transition resistor shorted Second resistor open

Transition shape - transition time
Even = 76 mSec Odd =112 mSec

Ripple shape linearity

Ripple shape irregularity

Three phase synchronization
Synchronized Desynchronized

Tap changer motor current (duration)
2.5 sec vs. 5.5 sec

Tap changer motor current (shape abnormalities)

Case Studies

Testing in Ardnacrusha, Ireland
ESBI transformer workshop located in Ardnacrusha

Various problems could be simulated on an open OLTC
Valuable information about appearance of different faults
on DVtest graph
Short-circuited secondary side provided clearer results
ACEC (Ireland) Limited Waterford 1969, 5000 kVA, 37500 /
10480 V, 11 tap positions
Special thanks to Mr. Brendan Diggin from ESBI, Ireland
and Dr. Raka Levi from DV Power, Sweden

Reference 10 A Measurement

Problem with Moving Selector Contact

Problem with Moving Selector Contact

Problem with Stationary Selector Contact

Problem with Stationary Selector Contact

Simulated Fault Duct Tape in Path of
Moving Selector Contact
Open circuit was
reported first couple of
times, as expected
Eventually, the 20 A
DC current has burned
through the insulation
Advantage of high test
currents no false
alarms caused by oil
films on the contact
surface

Simulated Fault Duct Tape in Path of
Moving Selector Contact

Case Study
Transformer SIEMENS 20 MVA, 35 kV / 10,5 kV, Ynd11

Case Study
Different slope of DRM graph for different phases

Case Study
Potential problem on reversing
switch contact 3

Case Study
There is no ripple
linearity on DRM graph
Deviation on all even tap

positions

Case Study
Comparison of odd and even tap positions
Abnormalities on even tap positions

Case Study
Potential problem on diverter switch
contact (second transition resistor)

Case Study
Static resistance graph
Static resistance graph shows deviation of phase C winding resistances
compared with other two phases after reversing switch has operated.

Case Study
Winding resistances of phase C deviate approximately 13% compared to other
phases (A, B). It is recommanded winding resistance deviation accros different
phases should not be larger more than 3%.

THREE PHASE TRANSFORMER TURNS-RATIO TESTER
Numerical results
Graphs

Single phase turns ratio

Single phase turns ratio deviation (%)

Some Problems Diagnosed with TRT
Failures simulation
1- one turn shorted
2- shorted one phase (A shorted with LV side neutral n)
3- shorted two phases (phase A shorted with phase B)
Transformer: Minel
Connection: Dyn5
Power: 12,5 MVA
Voltage: 35/10,5 kV
Current: 206/687 A

Transformer: Minel
Connection: Dyn5
Power: 12,5 MVA
Voltage: 35/10,5 kV
Current: 206/687 A

Results in normal state without failures
Test voltage 100 V
Test voltage 40 V

One turn shorted
Test voltage 100 V
Test voltage 40 V

Shorted one phase (A shorted with neutral n)
Test voltage 8 V
For higher values of test voltage (40 V and 100 V)

error message Excitation current too high was showed.

Shorted two phases (phase A shorted with phase B)
For all values of test voltage (1V, 8V, 40 V and 100 V)

error message Excitation current too high was showed.

Case Study
RADE KONAR
YN yn0 d5
Sn = 20 MVA
Un = 110000 / 36750 /6300 V
In = 105 / 314.3 / 550 A

Case Study
Single phase test 100 V vs 250 V (Value of test voltage is important!)
Test voltage 100 V
Test voltage 250 V

Case Study
True three-phase test 100 V vs 250 V (Value of test voltage is important!)
Test voltage 100 V
Test voltage 250 V

Case Study
Importance of Single-phase and True three-phase test
Single-phase test voltage 250 V (indicates which phase has the problem)
True three-phase test voltage 250 V (simulate real transformer state)

Case Study
Demagnetization status verification using TRT device
100 MVA transformer, 110/36,75 kV, YNyn0

Test voltage 100V
By comparing excitation currents before and after demagnetization
Single-phase Iex (mA) Three-phase Iex (mA)
After DC testing 17,2 14,1 14,2 11,3 9,2 9,4
After 40 A 8,0 6,0 8,0 6,0 3,5 6,4

demagnetization

Questions?

Thank you for your attention!

Transformer Testing - Analysis of The Test Results, Real-Case Studies

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Smart test devices for reliable electric power systems

Test Results Analysis

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TAP-CHANGER & WINDING ANALYZER

THREE PHASE TRANSFORMER TURNS-RATIO TESTER

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Indicators of potential problem

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Plus/minus (reversing change over-selector)

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DRM resistance graph problem indicators

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DRM resistance graph problem indicators

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female diverter coupling contact

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2.5 sec vs. 5.5 sec

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ESBI transformer workshop located in Ardnacrusha

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Deviation on all even tap

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