Transformer Temperature

Rise Testing Tutorial

Presented By: Bruce L. Broweleit

2007 September Doble Client Conference and
Committee Meetings
Philadelphia, Pennsylvania
The Purpose of
Factory Temperature Rise Tests

• Limits are established by IEC & IEEE

Standards.
• Limits & Tests Specified in requirements of
contract.
• Testing verifies that under maximum kVA
rating on nameplate temperature rise of
windings and oil will not exceed
guaranteed values.
• Has a direct bearing on insulation life.
Transformer Temperature Rise Testing Tutorial – September 2007 2
DEFINITIONS & CONVENTIONS
• Test Classifications:
– Routine: QC tests to verify product meets design
specifications.
– Design: Determine adequacy of type on
representative sample.
– Other: Tests specified by purchaser in addition to
Routine tests.
– Conformance: Tests made to demonstrate
conformity with applicable standards.
• Temperature Rise Tests are usually
considered “Design” or “Other”.
Transformer Temperature Rise Testing Tutorial – September 2007 3
DEFINITIONS & CONVENTIONS

• Ambient Temperature:
– The surrounding air temperature...
Generally assumed to be 30°C for design purposes.
• Average Winding Temperature:
– The measured average temperature of the entire
winding.
• Temperature Rise:
– The difference in temperatures between one part of
transformer (windings, etc.) and ambient.

Transformer Temperature Rise Testing Tutorial – September 2007 4

DEFINITIONS & CONVENTIONS

• Winding Hottest Spot:

– The highest temperature of the winding–elusive...
Hot Spot = Ambient + Ave.Wdg.Temp.Rise + Fudge Factor1, or
Hot Spot = Ambient + TOR + H.S.Factor X Avg.Wdg Gradient
NOTE 1: “Fudge Factor” = “Estimated Hot Spot Allowance”, assumed to be 10°C or 15°C for 55°C or
65°C Rise designs, respectively. Ref: S.D. Myers: “50 Years – A Guide To Transformer Maintenance”.
– “Old Standard”: Hottest Spot limit 105 °C (<1963)
– “New Standard”: Hottest Spot limit 110 °C (1963+)
• Average Winding Temperature Rise:
– Temperature of Winding above ambient with unit operating at
full-load.
– “Old Standard”: 55°C Hottest Spot Rise (<1963)
– “New Standard”: 65°C Hottest Spot Rise (1963+)
– Thermally Upgraded paper allowed 65°C Hottest Spot Rise.

Transformer Temperature Rise Testing Tutorial – September 2007 5

DEFINITIONS & CONVENTIONS
• Top Oil Temperature:
– Temperature of liquid insulation at top of transformer.
• Solid Insulation Life:
– Impossible to predict with certainty.
– Models based on Arrhenius chemical reaction rate law:
Log10 Life (Hours) = A + B/T
Where: A, B = Constants
T = Winding Hottest Spot Temperature in
degrees Kelvin (= WHST + 273°C)
– “8°C Rule”: Life halved for each 8°C increase. (IEEE)
– “6°C Rule”: Life halved for each 6°C increase. (IEC)
Transformer Temperature Rise Testing Tutorial – September 2007 6
Transformer Temperatures
AVERAGE TOP WINDING
WINDING OIL HOTTEST
TEMP. TEMP. SPOT

RADIATORS XFMR TEMPERATURE DISTRIBUTION

Top Oil Temp.

ELEVATION
W.O.G. x H
CORE H = 1.1 Dist.
H = 1.3 Power
Top
Oil
Hottest Spot

ING
L

ND
OI

WI
Average Wdg-Oil
Wdg.Avg.Temp.
Oil Gradient
W.O.G.

WINDINGS
Bottom
Oil

CORE OIL
AMBIENT Ambient Temp.
TEMP.
(30° C)
TEMP

Transformer Temperature Rise Testing Tutorial – September 2007 7

Temperature Test Requirements

• Why and when is the temperature test

required?
– Tests are made by Mfr on a representative
sample to verify ratings for similar apparatus.
– Tests are made by Mfr on a specific unit
because purchaser required in specifications.
– May be used to establish possible hot-spots.
– Ave. Temp. Rise is usually a guaranteed
value and sometimes tied to penalties.

Transformer Temperature Rise Testing Tutorial – September 2007 8

Temperature Test Requirements

• Test Sequence:
– Resistance, No-Load & Load Losses (BEFORE)
– Temperature Rise
– Dielectric (AFTER)
– Note: This list is NOT complete–other tests are
typically involved (Design, Routine, Other, etc.)

Transformer Temperature Rise Testing Tutorial – September 2007 9

Temperature Test Requirements
• Rationale:
– Resistance test results are used later to calculate
winding temperatures. Accurate cold resistance
temperature measurements are important to
determine the Ave.Wdg.Temp.Rise.
– No-Load & Load Losses are used to determine:
tap settings, winding temp. correction calculation
method & loading for the test.
– Dielectric tests have greater risk to insulation and
so are usually done last1. NOTE 1: Per C57.12.90-1987, Sec. 4.4

Transformer Temperature Rise Testing Tutorial – September 2007 10

Temperature Test Requirements

• Standard Conditions for Temperature Test:

(Best Simulation)
– Depending on factory limitations or multiple
transformer connections, specifically three winding
auto-transformers, the perfect test may not be
achievable.
– In those cases, other methods must be used to
ascertain the capability of unit under test.
– These techniques may include multiple tests at
different connections & calculated corrections, etc.

Transformer Temperature Rise Testing Tutorial – September 2007 11

Temperature Test Requirements

• Transformer Conditions and Preparation

– Completely assembled & oil-filled at proper level.
– Thermal indicators, BCTs, etc. installed.
– Tested with connections & taps resulting in highest
wdg. temp. rise–usually those of highest losses.
• Ambient Temperature Considerations:
– Conducted in a draft-free room.

Transformer Temperature Rise Testing Tutorial – September 2007 12

How NOT To Do A
Temperature Rise Test...

Transformer Temperature Rise Testing Tutorial – September 2007

Test Methods

• There are two basic methods used to

conduct test, depending upon size of the
transformer:
– “Actual Loading” (Smaller Units)
– “Simulated Loading” (Larger Units)
– With “Simulated Loading” there are two ways:
• Short-circuit Method
• Loading Back Method

Transformer Temperature Rise Testing Tutorial – September 2007 14

Actual Loading

• The actual loading method is the most

accurate of all methods, but its energy
requirements are excessive for large
transformers.
• Transformers of small output may be
tested under actual load conditions by
loading them on a rheostat, bank of lamps,
water box, and so forth.

Transformer Temperature Rise Testing Tutorial – September 2007 15

Simulated Loading

• Short-Circuit Method:
– One or more windings are shorted and
sufficient current is circulated at rated
frequency to produce “total losses” for the
connection and loading used.
– “Total Losses” are those measured during the
No-Load Loss and Load Loss Tests.
– Losses are converted to a temperature equal
to rated Average Temp. Rise plus 20°C.

Transformer Temperature Rise Testing Tutorial – September 2007 16

Simulated Loading
• Short-Circuit Method – Three Phase, 3-Wdg:

SHORT CIRCUIT
Rated
V&f
Source

L3

~ L2
XV
YV

SHORT CIRCUIT
L1 HV
DISC.

MEASUREMENT
A, V, W XFMR UNDER TEST

Transformer Temperature Rise Testing Tutorial – September 2007 17

Simulated Loading
Short-Circuit Method
Hook-up Example:

240 MVA, 3-Winding GSU

LV Shorting Bars

XFMR UNDER TEST

Test Power Xfmr

Instrument Xfmrs in Foreground

Transformer Temperature Rise Testing Tutorial – September 2007 18

Liquid Rise Measurement

• Liquid Temp. Rise is the difference

between liquid temp. and ambient temp.
• “Ultimate” Liquid Temp. Rise is considered
to be reached when temp. rise does not
vary more than the greater of 2.5% or 1°C
during a consecutive 3 hour period.
• Permissible to shorten test time by use of
initial overloads or temporarily restricted
cooling.
Transformer Temperature Rise Testing Tutorial – September 2007 19
Liquid Rise Measurement, Cont.

• Top Liquid Temperature is measured by

thermocouple or thermometer ~2” (50 mm)
below top of liquid surface.
• Average Liquid Temperature is taken to be
Top Liquid Temperature minus half the
temperature difference of moving liquid at top
and bottom of radiators, coolers, etc. If can’t
measure liquid directly, surface temps of
inlet/outlet are used.
• Thermocouples are the preferred method to
measure surface temperatures.

Transformer Temperature Rise Testing Tutorial – September 2007 20

Liquid Rise Measurement, Cont.
Ambient Temp:
Thermocouple 1 of 3 or More T-C’s
Examples
Bottom Cooler T-C

Transformer Temperature Rise Testing Tutorial – September 2007 21

Simulated Loading

• Short-Circuit Method, Continued:

– After Liquid Temp. Rises are determined,
immediately reduce winding current to rated
value for connection and loading used.
– Hold current constant for 1 hour, then measure
liquid temperature, shutdown, and measure
Average Winding Temperature corrected to the
instant of shutdown using one method as follows:
• Empirical Method
• Cooling Curve Method

Transformer Temperature Rise Testing Tutorial – September 2007 22

Average Winding Temperature Rise
Measurement
Temperature Correction to Instant of Shutdown:
• Either of two correction factor procedures shall be
used depending upon the Winding Load Loss
Density.
• For these determinations, the Winding Load Loss
Density for the winding connection shall be taken
as:
= Calculated I2R Losses + Eddy Losses or,
= (Winding Rated Temperature Rise + 20 °C) ÷
Connected Winding Calculated Conductor Weight
Transformer Temperature Rise Testing Tutorial – September 2007 23
Average Winding Temperature Rise
Measurement
Temperature Correction to Instant of Shutdown:
• Corrected Average Winding Temperature measurement
using Empirical Method:
– Use for xfmrs with wdg Load Loss < 30W/lb Cu., or
60W/lb Al.
– Take 1 hot resistance reading on each winding.
– Record time after shutdown when reading taken.
– Calculate temperature from resistance:
Where: T = Hot Resistance Temp in °C
T0 = Cold Resistance Temp in °C
R0 = Cold Resistance in

R = Hot Resistance in

Tk = 234.5 °C (Copper)
225.0 °C (Aluminum)

Transformer Temperature Rise Testing Tutorial – September 2007 24

Average Winding Temperature Rise
Measurement
Temperature Correction to Instant of Shutdown:
• Corrected Average Winding Temperature
measurement using Empirical Method, Continued:
– All winding hot resistance readings must be made
within 4 minutes after shutdown. If not completed
in time, resume Temperature Rise Test for 1 hour,
then take readings again.
– Temperature correction to shutdown instant
requires adding degrees equal to factor from Table
2 multiplied by Winding Load Loss Density (W/lb).
– If Winding Load Loss Density <= 7 W/lb (Cu.) or 14
W/lb (Al.), a correction of 1 °C/min may be used.

Transformer Temperature Rise Testing Tutorial – September 2007 25

Average Winding Temperature Rise
Measurement
Temperature Correction to Instant of Shutdown:
• Corrected Average Winding Temperature measurement
using Empirical Method, Continued:

Table 2 (IEEE C57.12.90)

Winding Temperature Correction Factor
Time After Winding Temperature
Shutdown Correction Factor (W/lb.)
(min.) Copper Aluminum
1 0.19 0.07
1.5 0.26 0.10
2 0.32 0.13
3 0.43 0.17
4 0.50 0.21
Transformer Temperature Rise Testing Tutorial – September 2007 26
Average Winding Temperature Rise
Measurement
Winding Hot
Resistance
Measurement
At Instant Of
Shutdown:

240 MVA,
3-Wdg GSU

Transformer Temperature Rise Testing Tutorial – September 2007 27

Average Winding Temperature Rise
Measurement
Temperature Correction to Instant of Shutdown:
• Corrected Average Winding Temperature
measurement using Cooling Curve Method:
– Make series of at least 4 resistance readings on 1
phase of each winding, along with time taken.
– 1st reading of each series < 4 min after shutdown.
– After reading set taken, Heat Run resumed for 1
hour before taking more readings. Repeat as needed
until all windings measured.
– Plot data and extrapolate curve to obtain resistance
at instant of shutdown. This R used to calculate
Average Winding Temperature at shutdown.

Transformer Temperature Rise Testing Tutorial – September 2007 28

Simulated Loading

• Short-Circuit Method, Continued:

Average Winding Temperature RISE is
Calculated using either
Top Liquid Rise or Average Liquid Rise:
– Top Liquid Rise Method:
Ave.Wdg.Temp.Rise = Top Liquid Rise + (Ave.
Wdg. Temp. @ SD – Top Liquid Temp. @ SD)
– Average Liquid Rise Method:
Ave.Wdg.Temp.Rise = Ave. Liquid Rise + (Ave.
Wdg. Temp. @ SD – Ave. Liquid Temp. @ SD)
Transformer Temperature Rise Testing Tutorial – September 2007 29
Simulated Loading
• Short-Circuit Method, Continued:
Correction For Variation From Rated Current:
– If current in any winding under test differs from rated
current, a correction must be made.
– Differences between Ave.Wdg.Temp. @ SD and
Ave. Liquid Temp. @ SD are corrected to give
Ave.Wdg.Temp.Rise @ Rated Current using:
Where:
Tc = Corr.
of Ave.Wdg.Temp & Ave.Liq.Temp .
T0 = Obs.
of Ave.Wdg.Temp & Ave.Liq.Temp .
m = 0.8 for Class OA, FA & non-dir. FOA, FOW.
= 1.0 for dir.-flow Class FOA, FOW.

– Corrected Ave.Wdg.Rise is Ave.Liquid Rise, plus Tc

Transformer Temperature Rise Testing Tutorial – September 2007 30

Simulated Loading

• Loading Back Method:

– Duplicate xfmrs may be tested by connecting
respective HV and LV windings in parallel.
– Apply rated voltage at rated frequency to one
set of windings.
– Circulate load current by opening connections
of either pair of windings at one point and
impress voltage across break sufficient to
circulate rated current through windings.

Transformer Temperature Rise Testing Tutorial – September 2007 31

Simulated Loading
• Loading Back Method – Single Phase:

HV LV LV HV

XFMR XFMR
Rated V & f UNDER UNDER
Source TEST * TEST *

Imped.
Loss
Source
LOADING
* NOTE: Only 1 Xfmr Needs To Be XFMR
Tested, But Both Must Be Similar.

Transformer Temperature Rise Testing Tutorial – September 2007 32

Simulated Loading
• Loading Back Method – Three Phase:
Rated V & f Source

LV HV

HV LV
LOADING
XFMR UNDER TEST * XFMR XFMR UNDER TEST *

* NOTE: Only 1 Xfmr Needs To Be

Tested, But Both Must Be Similar. Loading Source

Transformer Temperature Rise Testing Tutorial – September 2007 33

Simulated Loading

• Loading Back Method, Continued:

– Obtain Top Liquid Rise in same manner shown
for “Short-Circuit Method” on slides 19-20.
– Shut down and measure Average Winding
Temperature Rise in same manner shown for
“Short-Circuit Method” on slides 23-26.
– If other than rated frequency is used for load
current. It may not differ > 10% and Top Liquid
Rise must be corrected…

Transformer Temperature Rise Testing Tutorial – September 2007 34

Simulated Loading

• Loading Back Method, Continued:

Top Liquid Rise non-rated frequency correction:
Calculation Method:
(May be used when actual loss within 20% of required loss)

Where: Td = Liquid Rise Correction, °C

Tb = Observed Liquid Rise, °C
W = Required Loss, W
w = Actual Loss, W
n = 0.8 for Class OA
= 0.9 for Class FA
= 1.0 for Classes FOA, FOW
– Corrected Liquid Rise = Observed Liquid Rise + Td
– Corrected Winding Rise = Observed Winding Rise + Td

Transformer Temperature Rise Testing Tutorial – September 2007 35

Simulated Loading

• Loading Back Method, Continued:

Top Liquid Rise non-rated frequency correction:
Adjust the Losses Method:
– When Top Liquid Rise approaches constant,
adjust excitation voltage until sum of excitation
loss & load loss as measured during
temperature test equals the required loss.
– Obtain Top Liquid Rise as described earlier.
– Shut down and measure Average Winding
Temperature Rise as descried earlier.

Transformer Temperature Rise Testing Tutorial – September 2007 36

Temperature Rise Correction for
Differences in Altitude

• Altitude correction is required when tests

made at an altitude
3,300 feet and will be
operated > 3,300 feet.
• In this case, it is assumed that Temperature
Rises will increase as follows:
Where: TA = Increase in Temp. Rise @ Altitude A meters, °C
Te = Observed Temp. Rise , °C
A = Altitude, m
F = 4 • 10-5 self-cooled mode
= 6 • 10-5 forced-air cooled mode

Transformer Temperature Rise Testing Tutorial – September 2007 37

Hottest Spot Temperature
Additional Factors To Consider:
• Winding Hottest Spot Calculation, review:
Hot Spot = Ambient + Ave.Temp.Rise + 15 °C
• Metallic Hottest Spot Temperature Rise:
– For other than windings. See coming slide…
• The need for Thermography scans:
– Visually show temperature distribution over
transformer during heat run.
– Can reveal unexpected hot spots. See examples...

Transformer Temperature Rise Testing Tutorial – September 2007 38

Hottest Spot Temperature, Cont.

Winding Hottest-spot Simulation

and Calibration:
• If transformer equipped with Winding
Hottest-spot Simulator, it should be
calibrated after Temperature Rise Test to
give accurate readings in service.

Transformer Temperature Rise Testing Tutorial – September 2007 39

Hottest Spot Temperature, Cont.
Direct Measurement With Fiber Optics:
• Not considered in the Standards.
• A practical alternative or supplement to Simulated
Hottest Spot equipment.
• Has advantages in that it measures the actual
temperatures rather than simulating them.
• In recent years, technology is more cost-effective,
reliable, and with good installation success.
• Caveat: Might have some difficulty in positioning
probes in actual hottest spots.
Transformer Temperature Rise Testing Tutorial – September 2007 40
Hottest Spot Temperature, Cont.
Direct Measurement With Fiber Optics:
Probe Location Nameplate

F.O.
Feed-
thru
Inside
Tank

Monitor In
Term. Cab.

F.O. Feed-
thru J-box

Monitors In Test
Monitor Panel Datalog Lash-up

Transformer Temperature Rise Testing Tutorial – September 2007 41

Hottest Spot Temperature, Cont.
Direct Measurement With Fiber Optics, Example, Cont.:

Probes Entering HV Wdg

Probe Mounting Details

Probe In LV Spacer

Transformer Temperature Rise Testing Tutorial – September 2007 42

 Hottest Spot Temperature, Cont.
Direct Measurement With Fiber Optics, Example, Cont.:
GCPUD #4 ONAN Heat Run - All F.O. Probes & Oil RTDs

90

1:H2 Core Leg

2:H3 Core Leg
80 3:H2 Winding
4:H2 Winding
5:H3 Winding

70 6:H3 Winding
7:X3 Winding
8:X3 Winding
1:Y3 Winding
60
2:Y3 Winding
3:H1 Core Leg
Temp, deg.C

4:H1 Winding
50 5:H1 Winding
6:X1 Winding
7:X1 Winding

40 8:Y1 Winding
2:Y1 Winding
3:X2 Winding
4:X2 Winding
30
5:Y2 Winding
6:Y2 Winding
Top O il
20 Cooler O utlet
Ambient Ch 7
Cooler Inlet

10
39137.6667 39137.8334 39138.0001 39138.1668 39138.3335
T imestamp

Transformer Temperature Rise Testing Tutorial – September 2007 43

 Hottest Spot Temperature, Cont.
Direct Measurement With Fiber Optics, Example, Cont.:
GCPUD #4 ONAF Heat Run - All F.O. Probes & Oil RTDs

FANS ON
100

1:H2 Core Leg

2:H3 Core Leg
90
3:H2 Winding
4:H2 Winding
5:H3 Winding
80
6:H3 Winding
7:X3 Winding
8:X3 Winding
70
1:Y3 Winding
2:Y3 Winding
3:H1 Core Leg
60
Temp, deg.C

4:H1 Winding
5:H1 Winding
6:X1 Winding
50
7:X1 Winding
8:Y1 Winding
2:Y1 Winding
40
3:X2 Winding
4:X2 Winding
5:Y2 Winding
30
6:Y2 Winding
Top O il
Cooler Inlet
20
Cooler O utlet
Ambient

10
39138.3542 39138.5209
T imestamp

Transformer Temperature Rise Testing Tutorial – September 2007 44

Hottest Spot Temperature, Cont.
Metallic Hottest Spot Temperature Rise
Other Than Windings:
• When measured, the Temp. Rise of metal parts shall
be determined by use of thermocouple or suitable
thermometer.
• Thermocouple is preferred; soldered directly to
surface. If not possible, solder to thin metal plate ~1
in2, secure firmly to surface, and thermally insulate
from surrounding medium.
• Surface temps of metal parts near leads or terminals
carrying heavy current may be measured at intervals
or immediately after shutdown.

Transformer Temperature Rise Testing Tutorial – September 2007 45

Hottest Spot Temperature, Cont.

Thermography
Scans
Examples:

240 MVA, 230/13.2kV

3-Winding
ONAN/ONAF GSU

IR Scan After ONAN Test

Transformer Temperature Rise Testing Tutorial – September 2007 46

Hottest Spot Temperature, Cont.

Thermography
Scans
Examples:

240 MVA, 230/13.2kV

3-Winding
ONAN/ONAF GSU

IR Scan After ONAF Test

Transformer Temperature Rise Testing Tutorial – September 2007 47

DGA during
Factory Temperature Testing

• Oil-dissolved Gas Analysis is important to

determine if faults have developed during
testing.
• Usually conducted in coordination with other
Factory Tests, like the Dielectrics.
• Recommend a minimum of 1 sample prior and 1
after Temperature Rise test.
• Consider taking 1 during test (between ONAN &
ONAF)?
• Observe that sample(s) are taken properly.

Transformer Temperature Rise Testing Tutorial – September 2007 48

Conclusion

• The end result of Factory Testing should be a

Certified Factory Test Report.
• If a Temperature Rise Test is performed, the
Report will provide results of the Test, probably
with multiple Base MVAs if multi-stage cooling is
used.
• The most important results are the temperature
rises for the various windings, which should be
at or below guaranteed values.
• Examples…

Transformer Temperature Rise Testing Tutorial – September 2007 49

Factory Test Report Examples

Transformer Temperature Rise Testing Tutorial – September 2007

 END

Helpful Resources:
•Testing of Power Transformers:
Routine Tests, Type Tests, and Special Tests
Published by Pro Print for ABB
•A Guide To Transformer Maintenance
Published by TMI, S.D. Myers

Transformer Temperature Rise Testing Tutorial – September 2007