DISTRIBUTION TRANSFORMER MANUFACTURING PROCESS MANUAL

Transformer Design
The Transformer manufacturing plant shall have processes in place to aid transformer
designing. Client’s specifications and the relevant IEC standards shall be the main input to the
design process, any necessary requirement not specified but necessary for fitness purpose
shall be identified and communicated in writing to the client for clarification at design
stage. system should be in place at design stage to establish and record clients’ technical
requirements, statutory and regulatory requirements, clarifications, delivery, quality and
maintenance requirements. Product information, outline drawing, design report and fully filled
and signed Guaranteed technical parameters shall be submitted
Material Acquisition
The transformer manufacturing plant shall have an established purchasing process, which
guides suppliers. Based on the design output, materials specification customized for transformers
shall be development for the supplier. This shall address technical requirements for; copper
winding wires, core materials, bushings, tank, insulating oil, Surge arrestors, arcing horns and
Insulating paper. The specifications shall also address the appropriate quality, safety and
environmental management requirement. All purchased and outsourced service shall be
inspected, verified and tested at receipt according to a documented procedure. Both parties shall
sign acceptance test reports and copies shall be submitted to the client for verification. All
materials purchased for transformers shall be used and where production is not yet started, such
materials shall be quarantined.

Production
The production process shall be carried out under controlled conditions, the information
that describes the characteristics of the product shall be provided to the responsible staff
in form of detailed drawings, charts, instructions, etc. These shall be made available at
point of use. A production quality plan shall be established and this shall highlight process
specific quality checks, equipment required, resources requirement, suitable monitoring and
measuring devices. At every stage in the transformer manufacturing, quality & technical
compliance checks shall be performed by a qualified engineer before part is progressed to the
next stage in the production line. There shall be adequate equipment required for each production
activity and these shall be properly maintained Traceability shall be established and maintained
in the production process right from materials acquisition, part assembly and product testing.
Information regarding; material supplier, staff name responsible for each activity, approvals at
each stage, test done and testing personnel among other shall be recorded using a transformer
assembly form/card. In the production process, items shall be identified by either labels, rating
plates, stickers, hang-on cards, hard stamping or marking with ink to indicate rating, drawing
numbered. wherever standards are available for identification purposes such standards shall be
followed.
Core Construction
The core shall be of high grade cold rolled grain oriented silicon sheet steel and securely
clamped. The core material shall be as per material specification and the materials
test report shall be submitted upon request. The transformer core shall be of three limbs, step lap
stacked at joints to minimize losses and sound levels Core sheets should be cut using a semi –
auto or automated cutter. In a semi-auto arrangements, the controls shall be the one manually
operated but the cutting shall be of automated. Samples of core sheet shall be measured for
correct dimensions and recorded on the transformer inspection board. The core flux density shall
be as per the specifications and required loss values
Primary & Secondary Winding Assembly
The primary and secondary windings shall be constructed from high conductivity E.C grade
copper. All turns of the windings shall be adequately supported to prevent movement. The High
voltage winding shall be of layered winding and the Low voltage winding shall be of either
layered or foil winding using copper sheets. The Primary and secondary winding shall be wound
using appropriate winding machines with turns counter. The name of the staff winding a
particular transformer shall be noted on the transformer inspection board together with the
personnel who checked and approved. An appropriate insulating barrier shall separate the
primary and secondary windings; Inter winding insulation shall be of Diamond Dotted Paper
with cooling ducts
Core & Winding Assembly
The windings shall be inserted on the core leg using appropriate tools (Crane, lifting
bracket with a belt), Insulation strips shall be carefully inserted between core and
windings Insulation resistance between core and LV coil shall be checked using an insulation
resistance meter and result recorded on the transformer assembly inspection cards.
Insulation boards shall be placed between the top of the coil and the yoke and no gap
shall be left between strips of the core leg to complete the core. The yoke shall be clamped with
wooden frame and earthing strips shall be inserted into the core closer to the LV side-lifting
traverse Stay rods shall be inserted and earthing strip inserted on the stay rod, the upper wooden
frame must be tightened & the frame foot shall be fixed to stay rods. Correct lifting traverses
shall be fixed to stay rods and tightened properly, LV copper bus bars shall be fixed using
appropriate tool & LV flexible leads shall be fixed properly using correct bolts with spring
washers. Insulating paper tubes shall be inserted to tapping leads & the timber used must we
properly impregnated for 24hrs
Core & Winding Assembly Drying
The core and winding assembly shall be dried in an oven to drive away all moisture in optimum
time (minimum of 24hrs) Minimum time shall be taken between drying, tanking and filling with
oil (maximum 30 minutes) to avoid re-absorption of moisture in the active parts. After drying,
tank, cover plate with accessories and oil should be ready.
Core & Winding Assembly Tanking
Cover plate, Rating, surge arrestors, bushing and bushing accessories shall be prepared
and appropriate tools shall be used. Transformer tank shall be kept clean all the time & all
required components to the cover shall be fixed using appropriate tools. Appropriate clearances
and seal shall be insured using wooden blocks and silicon sealant & cork gaskets. The
transformers shall be hermetically sealed. The cover plate with all accessories shall be first
mounted to the core & winding assembly before tanking, all connections must be checked for
strength.
Oil Filling
Transformer oil shall be filled in a vacuum chamber to prevent air bubbles
Tank Fabrication
The tank fabrication process shall be parallel to active part assembly. The tanks for
transformers shall be of fin type with a base, radiator, flange and cover plate.
The transformer tank and tank cover shall be made of mild steel, hot dip galvanized and
then powder coated as per the specification The welding shall be done using an appropriate
method suitable not to damage the materials. Preferably Arc & Metal Inactive Gas (MIG)
welding shall be used accordingly Appropriate machines preferably semi-auto or automated shall
perform all the machining processes of shearing, bending, punching & drilling The materials
thickness for the base, cover plate, flange and radiator shall be as per specification The finished
tank and cover plate shall be properly cleaned before dipping and painting processes.
Testing
Test protocols according to IEC standards shall be established and the required equipment put in
place in a testing laboratory. All transformers shall be inspected and tested as per IEC standards
& specifications New design shall be type tested by an internationally recognized testing
laboratory and type test reports shall be submitted to the client

Product Handling & Packing

All products shall be handled properly to prevent damage or deterioration throughout the
production process. Special handling tool should be in place for example cranes and
forklifts, and these should be inspected regularly. Secure storage areas shall be provided to
prevent transformers from getting damaged or deteriorated before dispatch and all finished
transformers shall be suitably marked for clear identification.

PART 2: MATERIAL MANUAL

1.0 Transformer Core
The material for production of the transformer core shall be cold rolled grain orientated
silicon steel sheet (CRGO) with high permeability, low core loss, low magnetostriction,
high inter-laminar resistance and high lamination factor manufactured in accordance with
BS EN 10107:2005, JIS C 2553:2000 standards or any other national and international
standard that can offer equal or higher but not less quality the standards mentioned above.
The core shall be of three limbs stacked core type and shall be securely clamped. The material
shall be free from holes, inclusions, cracks and other imperfections that would make it useless
for manufacture of transformer cores. The material shall also be free of flakes, particles, or other
forms of separable electrically conductive materials. The maximum thickness of CRGO
laminations shall be 0.23mm. Thickness tolerance shall not be more than 3% and edge burr
height when cut shall be within permissible limits (for production 90% below 0.010mm and
100% below 0.02mm). The flatness (waviness) must not exceed 15mm/1000mm. the edge
deviation (Camber) must not exceed 0.3mm over measuring length of 1.5m. The maximum flux
density shall not exceed 1.6 Testa. An inorganic coating shall be applied to both sides of the steel
sheets and it shall have the following properties:
1. Shall offer high inter-laminar properties
2. Shall be thin and bonded to the steel surface so that it never peels off even when
subjected to shearing or bending.
3. Shall not be affected by mineral transformer oil, machine oil owing to its anti-rust
property .
2.0 Transformer Winding
Shall be made of Enameled copper winding wire and copper strips. However, aluminum
may be used if expressly asked for in specifications.
2.1 Enameled copper winding wire
The enameled copper wire used shall conform to the following standards and or the latest
editions thereof:
 IEC 60317-0-1:2013
 IEC 60317-8:2010 Class 180 (Grade 2)
 IEC 60264-3:1999
 IEC 60851:1996
Items conforming to other national or international standards, which give equal or higher,
but not less quality requirements can be accepted. Enameled round copper winding wire shall be
of class 180, with a sole coating based on polyesterimide resin. The film coating shall be
essentially smooth and continuous, free from streaks, blister and foreign material when examined
with normal vision as wound on the original spool. The copper for electrical purposes E-Cu 57
according to DIN 40500 teil 4 with minimum copper content of 99.90% shall be used.The
overall diameter, electrical characteristics and insulating properties of the enamel covering shall
be in accordance with the standards specified. In addition, copper wire shall withstand electrical
break through voltage of at least 450V in a salt solution (Water + 5% NaCl, weight to
weight).The maximum resistance value shall not be greater than the calculated with resistivity of
1/58 Ωmm2/m. the value shall be calculated for the minimum tolerated cross-sectional area of
the conductor. The maximum current density shall not exceed 2.5 – 3.0 A/mm2.
2.2 Enameled aluminum winding wire
The enameled aluminum wire used shall conform to the following standards and or the
latest editions thereof:
 IEC 60317-0-3: 2008 Grade 1 Class 180
 DIN 40501
 IEC 60851
 IEC 60264-3: 1999
 BS 1489: 1972
Items conforming to any other international or national standards, which are equal to
higher but not less, rigid than the specifications stipulated may be offered. Aluminum for
electrical purposes E-Al F7 according to DIN 40501 with a minimum aluminum content of
99.5% shall be used.
2.3 Copper strip or foil
Copper strip (rectangular) and copper foil shall be used for low voltage winding. The
copper strip used shall comply with or latest editions of EN 1652 or any other standard
that offers a higher performance. The foil or strip shall be free of short, sharp
deformations and edge wrappings. The foil or strip shall also be free of holes, bubbles,
dragon’s teeth, bumps, edge cracks, notches and other deformations which may be
defined as manufacturing defects. The foil or strip surface shall be shiny and free of
grease and other impurities. Grease test according to DIN 53364: Testing of plastic films,
which can also be applied for copper foils or strips can be conducted if required. The
edges shall be without any blurr. In accordance with DIN 40500 Teil 1, material E-Cu57 F20.
The minimum copper content shall be 99.90%. Current density shall not exceed 3.5A/mm2.
Thickness and
width of the copper strip shall be within the range of 0.1 – 2.5mm and 350 – 1250mm
respectively. Thickness and width tolerances shall be kept within reasonable limits.
2.4 Aluminum strip or foil
The items used shall be in accordance with standards specified below or latest editions
and amendments thereof;
 DIN 1783
 DIN 1784
 DIN 40501
 DIN 53364
 BS EN 13599: 2002
Items conforming to any other international or national standards, which are equal to or
higher but not less rigid, the standards and specifications stipulated may be offered.
The foil or strip shall be free of short, sharp deformations and edge wrappings. The foil or
strip shall also be free of holes, bubbles, dragon’s teeth, bumps, edge cracks, notches and
other deformations, which may be defined as manufacturing defects. The foil or strip
surface shall be shiny and free of grease and other impurities. Grease test according to
DIN 53364: Testing of plastic films, which can also be applied for copper foils or strips
can be conducted if required. The edges shall be without any blurr.
Aluminum for electrical purposes E-Al F7 according to DIN 40501 teil 4 with a
minimum aluminum content of 99.5% shall be used.
Transformer oil shall be used dissipate heat generated in the windings and to also provide
electrical insulation. The raw material for production of transformer oil shall be low viscosity
transformer oil base stock (TOBS) obtained by fractional distillation and subsequent treatment of
crude petroleum which is further refined by acid treatment process to yield transformer oil. Any
other transformer oil shall be accepted as long as it’s demonstrated that such oil offers superior
performance. The oil shall be produced in accordance with standards specified below or later
editions and or amendments thereof;
 BS 148: 2009 Class 1
 IEC 60296: 2003
Any other national or international standard that offers higher but not less quality
requirements can be used with prior approval from REA.
The transformer oil shall have the minimum characteristics of given in table below
Minimum characteristics of transformer oil
Test Test Method Value

Relative density ISO 3675:1998 0.871

Viscosity 40 deg. C.Cs ISO 3014:1993 12.0 (max)
Viscosity 20 deg. C.Cs ISO 3014:1993 31.0
Viscosity 0 deg. C.Cs ISO 3014:1993
Viscosity -15 deg. C.Cs ISO 3014:1993 350
Viscosity -30 deg. C.Cs ISO 3014:1993 1800 (max)
Flash point deg. C ISO 2719: 2002 154
Pour point deg. C ISO 3016: 1994 -40
Neutralization value
IEC 60296: 2003 < 0.03
mg.KOH/g
Corrosive sulphur BS 2000-315:1998 Non corrosive
Water content mg/kg IEC 60814: 1997 1.5
Breakdown Voltage kV IEC 60156: 1995 70
Resistively Ωm 20 deg. C IEC 60247: 2004 20
Dielectric dissipation factor
IEC 60247: 2004 0.001
90 deg. C
Gassing tendency mm/min IEC 60628: 1985 -1
Antioxidant additive IEC 60666: 1979 None
Oxidation Test:
Acidity mg.KOH/g IEC 61125: 1992 0.4
Sludge value % IEC 61125: 1992 0.1
PCB IEC 61619: 1997 None
4.0 Insulating Paper
Insulating paper shall be used to offer inter turn winding insulation as well as insulation
between MV and LV windings.
4.1 Corrugated Boards
Corrugated boards shall be used provide insulation between MV and LV windings. The
corrugated board shall be manufactured in accordance with;
 IEC 60641-1: 2007
 DIN EN 60641-3-1: 2009
The board shall be of Class A insulation in transformer oil, shall not affect the properties
of the transformer oil and shall have a minimum dielectric strength of 60 kV/mm in oil.
Cutting edge of the corrugated board must be free from burrs, any deformations and
thickness shall not be increased. The designed thickness and curvature of the corrugation
shall ensure adequate insulation and circulation of transformer oil.
4.2 Transformer Board
The transformer board shall be used to provide insulation between core and LV windings,
between MV phase to phase winding and between the end of windings of every phase
and the core. The board shall be manufactured in accordance with standards specified below or
latest editions and or amendments thereof; IEC 60641-1: 2007 The transformer board shall be of
class A insulation in transformer oil, shall not affect the properties of the transformer oil and
shall have a minimum dielectric strength of 60kV/mm in oil.
4.3 Diamond Dotted Paper
Diamond dotted paper shall be used to provide inter-turn winding insulation for both
primary and secondary winding.
It will be manufactured according to the following standards;
 IEC 60641-1:2007
 DIN EN 60641-3-1:2009
The diamond dotted paper shall be diamond patterned epoxy papers and have shall the
following minimum properties;
 Paper shall contain both sulphate wood pulp and cotton in a 50/50 mixture to
impart a combination of both favorable stiff and tensile properties.
 The resin shall be on both sides of the paper and shall result in partial adhesion of
the electrical conductors to the layer insulation at a temperature between 100 0C –
130 0C.
 Approximately 36% of the total area on each side should be printed with epoxy
resin of 9.5×9.5mm2
 The thickness of the partial coating of resin shall be 0.01mm on each side.
 The epoxy resin must not affect the properties of mineral oil used in the transformer.
 Single layer diamond dotted paper shall generally have a nominal thickness of 0.13mm and
0.25mm.
 When the insulation is specified as double layer diamond dotted paper (DDP), it shall have two
layers of DDP glued under dry conditions. Double layer DDP shall generally have a nominal
thickness of 0.15mm, comprising of two 0.075mm thick insulation paper.
5.0 Offload Tap Changer
Offload tap changer shall be manufactured in accordance with the following standards;
 IEC 60893-1: 2004
 EN 12420: 1999
 EN 13599: 2002
The tap selector shall be suitable for off load operation and immersing in transformer oil
and to be used in hermetically sealed transformers. These shall be operated generally at
nominal voltages of 36kV and 12kV with different current ratings. The number of tap
positions shall be as per REA specifications. The materials to be used in different parts of the tap
selector are shown in table below
6.0 Pressure Relief Valve
Pressure relief valve shall be manufactured in accordance with IEEE Std C57.12.22-1993
or any other national and international standard that offers equal or higher but not less
quality requirements. The pressure valve shall operate at 0.35 bars and shall reseal at the same
pressure.
7.0 Transformer Tank
Mild steel shall be used to manufacture transformer lifting traverse, lifting hook, lifting
lug, and tank, base, top cover and the flange. This shall be in the form of;
 Mild steel sheets
 Mild steel angles
 Mild steel channels
 Mild steel flat bars
 Mild steel rods
Items supplied shall be in accordance with the standards specified below or later editions
and or amendments thereof
 BS EN 10029: 1991
 BS 7668: 2004
 BS EN 10025-1:2004
 BS EN 10025-3:2004
 BS EN 10025-4:2004
 BS EN 10210-1:2006
Items conforming to any other international or national standards, which are equal to or
higher but not less, rigid than the standards and specifications stipulated may be offered.
The mild steel components shall be free from corrosion, oil/grease and burrs. The minimum
thickness of the mild steel for up to 400kVA transformer shall be between 4mm to 6mm and for
500 – 600kVA shall be 6mm to 10mm.
8.0 Radiator
The radiator shall be used convectional cooling of the transformer so that designed
temperature rise in the inside transformer is with desired limits. The items used shall be
formed out of steel in compliance with standards specified below or later editions and or
amendments thereof;
 DIN EN 10131: 1992
 DIN 1623: 2009
The (items formed out of) steel conforming to any other international or national standards which
are equal to or higher but not less rigid than the standards and specification stipulated may be
offered. All radiator surfaces should be free from oil and the minimum thickness shall be 0.2mm.
PART 3: TESTING PROTOCOLS
1.0 Introduction
The Client in accordance with the relevant IEC and ISO standards shall inspect the
manufacturing plant, its process and products. The tests on the products shall include:
2.0 Transformer Tests
2.1 Transformer Routine Tests
1. Transformer insulation resistance test
2. Vector group test
3. Voltage ratio test
4. DC resistance test/winding resistance test
5. Oil dielectric strength test
6. Separate source voltage withstand test
7. Induced overvoltage withstand test at high frequency.
8. No load test
9. Full load test/ short circuit test
2.2 Transformer Type Tests
1. Impulse voltage withstand test (Dry power frequency voltage withstand test)
2. Electrical break through voltage of copper wire
3. Transformer pressure testing
4. Sound level test
The following information about the transformer test equipment shall be provided by all
transformer manufacturers as it may be required from time to time to ensure acquisition
of result with minimal errors; Equipment name, Manufacturer, Date of purchase and Last
date of calibration
3.0 TRANSFORMER TEST PROTOCOLS
3.1 Transformer Insulation Resistance Test
Purpose:
This test is intended to assess the condition of insulation of all insulated parts of a
transformer.
Apparatus:
Megger Insulation Tester
Preparation of Sample
Isolate the transformer.
Clean all bushings with a clean piece of cloth.
Procedure
 Set a scale indicator to the discharge position before each test.
 Connect the probes of the tester (P1 & P2) to the points between which insulation
is measured (e.g. In the case of H/E, connect probes to the winding terminal and Earth).
 Select the proper scale:
 Select 1000V scale for winding voltages below 1.0KV.
 Select 5000V scale for winding voltages above 2.5kV.
Acceptance Criteria
Measurements taken
Minimum acceptable value
between
HV & LV 600 Mega Ohms
HV & E 600 Mega Ohms
LV & E 600 Mega Ohms
Safety
 Make sure the test leads are not damaged
 Do not touch the leads while the meter is switched ON
 Always follow general safety instruction of the area
3.2 Transformer Vector Group Test
Purpose
To confirm the vector group is provided. Test should be performed as per IEC – 60076 test
standards.
Apparatus
 Transformer Ratio meter (PWR 3A)
 Manual of Transformer Ratio Meter.
Preparation of samples
 Keep the transformer open circuited
 Make sure that the insulation resistance (Megger) values are sufficient.
Procedure
 Before the test, the following information about the transformer must be obtained and checked
 Primary and secondary voltage
 Voltage ratio values.
 Connect the HV and LV leads of the meter to the HV and LV terminals of the transformer.
 Switch ON the meter
 Press “Group” button on Measurement column.
Acceptance criteria
On the top of the display screen, the vector group of the transformer will be displayed.
Work instructions for safety.
 Do not touch the leads while the meter is switched ON.
 Switch OFF the meter before remove of the leads.
 Always follow general safety instructions of the area.
3.3 Transformer Voltage Ratio Test
Purpose:
To ensure that the turns ratio of the windings is correct and that the tapping on any of the
windings have been made at correct position. Tests should be performed as per IEC – 60076 test
standards.
Apparatus
 Transformer turns ratio meter
 Manual for transformer ratio meter
Preparation of sample
 Keep the transformer open circuited.
 Make sure the insulation resistances (Megger values) are sufficient.
Procedure
 Before testing, the following information about the transformer must be obtained and checked.
 Primary and secondary voltage.
 Voltage ratio values.
 Select the tapping. Connect HV & LV leads of the meter to the HV and LV bushing terminals
of the transformer respectively.
 Switch on the meter.
 Press “Ratio” button on Measurement column.
 Enter the vector group of the transformer.
 Enter the required phase or A/N (To get ratio of all phases at selected position)
 Record the readings.
 Perform the test for all tap positions.
Note: The Transformer turns ratio meter has an inbuilt power supply with voltage used being low
such as 8 -10 Volts, 50HZ.
Acceptable criteria
In the event that the voltage ratio does not match the ±0.5% tolerance is allowed from
specified values. (As per IEC 60076).
Measured values should be in the following range.
11kV/415V (2.5% to -7.5% of 33kV/415V (2.5% to -7.5% of
Rated Voltage) Rated Voltage)
Tap 1: 46.82 ≤Measured Value ≤ Tap 1: 140.46 ≤Measured Value ≤
47.29 141.88
Tap 2: 45.68 ≤Measured Value ≤ Tap 2: 137.04 ≤Measured Value ≤
46.14 138.42
Tap 3: 44.54 ≤Measured Value ≤ Tap 3: 133.61 ≤Measured Value ≤
44.99 134.96
Tap 4: 43.39 ≤Measured Value ≤ Tap 4: 130.18 ≤Measured Value ≤
43.83 131.50
Tap 5: 42.25 ≤Measured Value ≤ Tap 5: 126.76 ≤Measured Value ≤
42.68 128.04
Work instructions for safety:
 Do not touch the leads while the meter is switched ON.
 Switch OFF the meter before removal of leads.
 Always follow general safety instructions on the area
3.4 Transformer DC Winding Resistance Test
Purpose:
To measure the DC resistance between lines of all windings and to detect faulty or poorly
made connections. Test should be performed as per IEC – 60076 test standard. Test results are
important in full load loss measurement.
Apparatus
 Transformer winding resistance meter.
 Manual for the meter.
Preparation of the sample
 Isolate the transformer.
Procedure
 Connect the potential 1 output to the HV winding and potential 2 to the LV winding of the
transformer to be tested.
 Test current output terminals should be connected to the upper point of the HV terminals in
which the resistance has to be measured. In the case of Dyn vector connected transformers
connection sequence for HV is A&B, B&C, C&A.
Connection sequence for LV is a&b, b&c, c&a.
 Select appropriate ranges of resistance.
 Then switch on the power switch.
 Then press the start switch.
 The meter will inject current and start measuring.
 Do not touch the leads while the danger sign appears.
 Record the resistance values when safe sign appears.
 Winding temperature at the time of measuring the transformer winding has to be recorded.
Work Instructions for safety
 Always make sure the instrument body is earthed before switch ON.
 Do not disconnect the leads until the RED warning light disappears
 Always follow general safety instructions of the area.
NB: The winding resistance test results obtained above are used in calculating the Full load loss
3.5 Transformer Oil Dielectric Test
Purpose
To confirm the electrical strength of the transformer oil.
Apparatus
Oil Dielectric Strength test se
Preparation of sample
 The sample should be collected from the bottom of the container or transformer.
 Sample should be collected to a clean, dry container.
 Before collecting the sample, allow slug to drain off.
Procedure
 Fill the oil sample to the test vessel up to a level about 10mm above the electrodes level. Put
the magnetic stir in to the test vessel.
 The electrodes are set at 2.5mm/±0.1mm gap. If there is any suspicion, check the gap.
 Select the mode of operation as Automatic or Manual. In manual operation, the rate of rise of
applied voltage should be 2kV/second ± 0.2kV/second.
 In the case of automatic operation, machine allows a pause of 2 minutes after each breakdown
before re-application of the voltage. The machine conducts the test for six times on the same cell
filling and the mean value of the tests will be automatically printed on the attached printer.
 Acceptance criteria
 Average breakdown voltage of the oil must be > 50kV for transformers.
Work instructions
 Always make sure that the instrument body is earthed before the meter is switched ON.
 Do not try to open the instrument while testing oil.
 Always follow general safety instructions of the area
3.6 Transformer Separate Source Voltage Withstand Test Purpose:
To determine the integrity of the insulation between windings and earth. Tests should be
performed as per IEC – 60076 test standards.
Apparatus
 AC Dielectric test set. (6T CD 100-10)
 Manual of the AC Dielectric Test Set
Preparation of sample
 Transformer should be isolated
 Clean the bushings thoroughly with a clean piece of cloth.
 Make sure the oil level of the transformer is at the top level.
Procedure
 Bushing terminals of the windings under test are connected together using a conducting wire.
The rest of the windings of the transformer are also connected together as above and connected
to the tank and then tank is earthed. Then the appropriate test voltage is applied as per given
under acceptance criteria below. Select the rate of voltage rise and apply the voltage.
 This is performed on both HV and LV sides at power frequency.
 The voltage is gradually increased up to the value below. Holding at the above voltage up to
recommended duration. Reduce the voltage gradually before switching off.
Note: Insulation failure during the test is indicated by sudden increase of leakage current
indicated on the test set. This would trip-off the test supply voltage.
Acceptance Criteria
 For 33kV – When the HV side is subjected to 70kV, it should withstand for 1 minute.
 For 33kV/415V – when the LV side is subjected to 3kV, it should withstand for 1 minute.
 For 11kV – when the HV side is subjected to 28kV, it should withstand for 1 minute.
 For 11kV/415V – When the LV side is subjected to 3kV, is should withstand for 1 minute.
Work instructions for safety
 Never switch ON the HV Tester when someone is inside the testing area.
 Switch off the output voltage before change the HV connections.
 Do not operate other electrical instruments while HV Tester is switched ON.
 Always follow general safety instructions of the area
3.7 Transformer Induced Over Voltage Test At High Frequency
Purpose
To verify voltage withstand strength between the windings and Earth, the withstand strength
between the phases, and between turns of a phase under test. The test should be performed as per
IEC – 60076 test standards.
Apparatus
 High frequency tester
 Manual of the High frequency tester.
Preparation of sample
 Transformer should be isolated
 Clean the bushings thoroughly with a clean piece of cloth.
 Make sure that the oil level of the transformer is at top level.
 Make sure that the transformer tap selector is at rated tap position.
Procedure
 Connect the high frequency generator output to the low voltage winding of the transformer
while high voltage windings are open circuited. Make sure that the same output terminal
sequence of the generator is connected.
 Increase the voltage slowly by rotating the control switch on the control panel until double the
rated voltage of low voltage winding is applied. A gradual increase of the brightness of the set of
bulbs could be observed. Note: If the transformer is faulty, the circuit is tripped off in the test set.
 Since the frequency of the test supply is 120 HZ (This value is fixed for newest High
Frequency Generator), the test duration is 50seconds.
Acceptance Criteria
Sustaining the brightness at peak level for 50 seconds indicates the successful voltage
withstanding strength.
Work instructions for safety
 Switch ON the HF panel only after connecting the test leads to the transformer.
 Switch OFF the output voltage before remove the leads from the transformer.
 Always follow general safety instruction of the area.
3.8 Transformer No Load Test (Core Loss- Hysteresis Loss and Eddy current loss
Purpose
To determine the No Load losses of a transformer. It also checks whether any damages have
been caused to windings and insulation from prior tests. The test should be performed as per IEC
– 60076 test standards.
Apparatus
AC Analyser.
Preparation
 Transformer should be isolated.
 Clean the bushings thoroughly with a clean piece of cloth.
 Make sure that the oil level of the transformer is at top level.
 Make sure that the transformer tap selector is at rated tap position.
Procedure
 Connect n,a,b,c bushing leads to the respective test leads.
 Maintain HV side open circuited.
 Adjust current transformer tappings to get an appropriate current according to the transformer
to be tested. Generally, 5% of the rated current could be considered as a guide.
 Apply the desired CT, PT ratio values and guaranteed loss value.
 Apply the rated voltage by use of Air Circuit Breaker.
 Measure the parameters by pressing the start/stop button of instrument.
 By pressing the start/stop button again the measured values will be stored.
 Switch off the air circuit breaker.
Acceptance Criteria
 No load current shall be less than 5% of the rated current.
 The deviation of the No load loss value should be less than 15% of the specified value.
Work instructions
 Make sure the meter body is connected to the Earth before switch ON the meter.
 Always short circuit the secondary terminals of the current transformers before switch off the
voltage to the transformer.
 Always follow general safety instructions of the area
3.9 Transformer Full Load Loss Test (Copper Losses)
Purpose
To assess the Full Load Loss (copper loss) and the impedance voltage of a transformer. Tests
should be performed as per IEC – 60076 test standards.
Apparatus
 AC Analyser
 Manual for the AC analyser.
Preparation of sample
 Transformer should be isolated
 Clean the bushings thoroughly with a clean piece of cloth
 Make sure the oil level of the transformer is at the top level.
 Make sure that the transformer tap selector is at the rated tap position.
Procedure
 Short circuit the low voltage winding bushing terminals using a thick flat copper bar which is
sufficient to carry rated low voltage current.
 Connect A.B.C bushing leads to the respective test leads.
 Calculate the rated current of the high voltage winding and select the CT tap position
according to it.
 Apply the CT & PT ratio values to the meter.
 Switch on the air circuit breaker.
 Measure the parameters after injecting the desired rated current by pressing the start/stop
button of the instrument. Pressing the start/stop button again, the measured values can be stored
on the display of the meter.
 Switch off the air circuit breaker.
 Care should be taken to avoid supplying current for longer durations during the test in order to
prevent heating of the windings, which eventually introduce additional losses.
 Record the room temperature
Acceptance criteria
 Deviation of full load losses corrected to 750 C shall be within 15% of the specified value.
 Total losses – deviation of the component losses should be within 15% while maintaining the
deviation of the total losses within10% of the specified value.
Work instructions for safety
 Make sure that the meter body is switched to earth before switch ON the meter.
 Always short circuit the secondary terminals of the current transformers before switch off the
voltage to the transformer.
 Always follow general safety instruction of the area.
3.10 Zero Sequence Impedance Test
Purpose
To determine the zero sequence impedance of the transformer. Test should be done as per
IEC – 76 test standards.
Apparatus
 AC Analyzer
 Voltmeter
Preparation of sample
 Transformer should be isolated
 Clean the bushings thoroughly with a clean piece of cloth.
 Make sure that the oil level of the transformer is at the top level.
 Make sure that the transformer tap selector is at rated tap position.
Procedure
 Short-circuit High Voltage bushing terminals of the three phases.
 Connect the circuit as shown in the circuit arrangement.
 Apply a single phase voltage of about 200V with the same frequency as the operating
frequency of the transformer across the neutral and the short circuited point.
 Measure the voltage (V) and current (I).
 Calculate the zero sequence impedance (Z0) using the formula Z0 = 3V/I
Acceptance Criteria.
 The zero sequence impedance should be within a 10% deviation from the
designed value.
Work instructions for safety
 After completion of the circuit wiring, apply a lower voltage and gradually
increase the voltage up to the required value.
 Switch off the circuit before disconnection.
 Always follow general safety instruction of the area
3.11 Sound Level Test (Type Test).
Purpose
To determine the sound level of the transformer. Test should be performed as per IEC –
60076 test standards.
Apparatus
Integrating sound level meter (NL-05)
Procedure
 Transformer should be placed and mark points (at least 6 points) 0.3 meters away
from its boundary. Energize the transformer under rated condition. Measure the noise level at the
marked points holding the meter at the mid-point of the height of the transformer.
 Measure the noise level after shutdown the transformer on the same points, to get the
surrounding noise level.
 Average value of difference of these two sets of readings give the noise level of the
transformer.
Expression of results
Noise level should be ≤ 52dB.
Work instructions for safety
 Always stay away from the energized transformer.
 For any reason, do not get closer or touch the transformer before switch it OFF.
 Always follow general safety instruction of the area.
3.12 Temperature Rise Test (Type Test)
Purpose
To determine the temperature rise of the transformer. Test should be performed as per
IEC – 60076 test standards.
Apparatus
 AC Analyser
 Manual of AC Analyser
 Thermometer
Preparation of sample
 Transformer should be isolated
 Clean the bushings thoroughly with a clean piece of cloth
 Make sure the oil level of the transformer is at the top level.
 Make sure that the transformer tap selector is at rated tap position.
Procedure
 Connect the A,B,C terminals to the respective test leads.
 Insert a thermometer into the thermometer pocket.
 Sum of the guaranteed of the transformer to be injected during the test. When the steady state
condition is achieved, the difference between the top oil temperature and then room temperature
is recorded at three consecutive readings. Reduce the current to full load rated current and
maintain it for another one hour. Again record the top oil temperature and room temperature.
 Maintain the lose figure by varying the current until steady temperature rise is obtained.
Record the thermometer for every thirty minutes. If constant temperature appears at three
consecutive readings, it will be considered as the steady condition
 Top oil temperature rise can be obtained from the difference between top oil temperature
reading and the room temperature.
 Stop the supplying of the current and get the resistance values of both HV and LV windings.
This should be performed until at least six different readings at regular intervals are recorded.
 Plot a graph using the above data and obtain the resistance value at the time of switching off
the current by extrapolating the graph. Using this value, temperature rise of the winding can be
calculated using the following formula.
Θ2 = (235+θ1)xR2/R1 – 235
Θ1= Room temperature 0C
R1 = Resistance at room temperature (Ohms)
Temperature rise = θ2 – Room temperature
R2 = Resistance at the time of switching off (Ohms)
 Plot the graph for both HV and LV windings.
Acceptance Criteria
 Top oil temperature rise should be less than 550 C
 Winding temperature rise should be less that 600 C
Work instructions for safety
 Make sure the meter body is connected to the earth, before switching ON the meter.
 Always short the secondary terminals of the current transformers before switching off the
voltage to the transformer.
 Use hand gloves to remove the leads from heated terminals of the transformer.
 Always follow general safety instruction of the area.
3.13 Measurement Of Electrical Break Through Voltage Of Copper Wire Purpose
This test is carried out to assess the insulation of copper wire.
Apparatus
 Voltage regulator (Variable between 0 – 440V)
 Salt solution (Water +5% NaCl, weight to weight)
 Plastic rod (for forming the copper thread according to the table below)
Safety
All safety procedures outlined in test method for dielectric voltage withstand test shall be
followed during this test
Procedure
 Get a copper sampling with a length of at least 6m.
 Wind the copper sample or the rod in spiral.
 Prepare salt solution (water + salt in 1:5% weight ratio). Note: 1 g of water = 1ml of water.
 Place the prepared copper spiral in the salt solution with terminals at least 20mm over the
surface of the liquid.
 Touch one set probe of voltage regulator to the salt solution and one end of copper wire should
be isolated and kept 20mm over the liquid level.
 Start with 0V and then increase the voltage up to 440V and maintain it for 30secs and check
the break through voltage.
Acceptance Criteria
There should not be any flash over point throughout the selected length
Diameter of thread Diameter of rod
0.100mm – 0.315mm 3.0mm
0.315mm – 1.000mm 18.0mm
1.000mm – 2.240mm 18.0mm
Work Instructions for safety
 Connect the copper wire to the terminals and immerse in salt water prior to switch ON.
 Do not touch the test leads, sample or salt solution while switch ON.
 Always follow general safety instruction of the area.
3.14 Dry Power Frequency Voltage Withstand Test
Purpose
To identify any flashover or punch of the bushings
Apparatus
High voltage test set
Procedure
Clamp the bushing as its intended use and apply the power frequency voltage as in given
table
Acceptance Criteria
The bushing should be considered to have passed the test if no flashover or puncture
occurs. If there is a puncture, the bushing shall be considered to have failed the test. If a
flashover occurs the test shall be repeated once only. If during the repetition of the test no
flashover or puncture occurs the bushing shall be considered to have passed the test.
Dry lightning impulse
Power frequency withstand
Nominal Voltage kV (rms) withstand voltage
voltage dry & wet kV (rms)
1.2/50micro sec kV (peak)
3.6 40 10
7.2 60 20
12 75 28
17.5 95 38
24 125 50
36 170 70

Routine Test
≥ 1000 MΩ when
5000V is applied for
60 seconds for
Insulation resistance 5000V Insulation
1 HV & E, HV & LV
measurement resistance meter
and 1000V applied
for 60 seconds for
LV&E
Test set should not
trip when 70kV is
Separate source applied for 60 AC Dielectric Test
2
voltage withstands. seconds for 33kV set
transformer, 28kV
for 11kV
 transformer, and 3kV for
LV windings.

Transformer ratio with ±5%

Transformer turns
3 Transformer ratio tolerance for the respective
ratio meter
tap positions
Vector group displayed Transformer Ratio
4 Vector Group Test
should Dyn11 Meter
DC Transformer
Winding resistance at All phase resistance values
5 winding resistance
rated tap should be similar.
meter
 The deviation of no load
loss value should be
6 No load loss ≤15% of specified value AC analyzer
 No load current shall be
less than 5% of rated
 Deviation of full load
losses corrected to 750 C
7 Load Loss shall be within 15% of AC analyzer
the specified value.
 Total losses – deviation

Induced over voltage
8
at High frequency
of the component losses
should be within 15%
while maintaining the
deviation of the total
losses within10% of the
specified value
Should withstand double the
rated voltage at 120 HZ High frequency test
applied to LV windings for set
50 seconds.

Measure the electrical

strength of Transformer oil
when a layer of oil is placed Oil
Testing the electrical
between two electrodes, dielectric
9 strength of transformer
which are placed at 2.5mm strength
oil
apart. Average breakdown test set
voltage of the oil must be >
50kV.
Sound
Noise level should be less
10 Sound level test level
than specified
meter
 The zero sequence AC
Zero sequence impedance should be within Analyzer
11
impedance a 10% deviation from the And
designed value. Voltmeter
Dry lightning impulse No flashover or puncture
withstand voltage occurs to the bushing at
HV test
12 1.2/50micro sec kV 75kV for 11kV transformer,
set
(peak): 170kV for 33kV
Voltage withstand transformer and 6kV for LV
No flashover or puncture
Power frequency occurs to the bushing at
HV test
13 withstand voltage dry 28kV for 11kV transformer,
set
& wet kV (rms): 70kV for 33kV transformer
and 3kV for LV.
Pressure
Transformer should be free
14 Pressure testing testing
from leaks
device