HITACHI 

Test Procedure Division: PGHV

ABB Contracting Company Ltd.

Description: Power Transformer Testing Procedure PGHV

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A. SCOPE
This Method statement covers the procedures and instructions for transformer testing
Upon arrival at site, the requirement and instructions for executing the activities listed
Under this section including.

1. Ratio Measurement Test (All Taps)

2. Magnetic balance Measurement Test of both side
3. Magnetizing Current Measurement Test
(1Phase No-load current Test)
4. 2KV Isolation Measurement Test
5. Vector Group Measurement Test
6. Insulation Resistance Measurement Test
7. SFRA Test
8. Winding Resistance Measurement Test
9. Bushing C.T. Ratio Measurement Test
10. Capacitance and Tan-delta Measurement Test
11. DFR
Mechanical Functional Test
12. Oil temperature indicator
& Winding temperature indicator Testing
13. Tap Changer Operation
14. Cooling System Operation
15. Buchholz Relay Alarm and Trip Contact Test
16. Oil Break Down Voltage Test
17. Oil DGA test (Dissolved Gas Analysis)
18. Final Site Test Report.
19.

B. PURPOSE
The purpose of this Method Statement is to describe step by step the Procedure for
-testing of Transformers in accordance with Quality and HSE Requirements as per
Scope of work & standard.

C. QUALITY DOCUMENT
1. Approved General Arrangement and Equipment Layout Drawings.
2. Approved Drawing of transformer and Marshalling Box.
3. Transformer GA Drawings.
4. Approved the Rating Plate and Connection Diagram Drawings.
5. Final factory Testing Report and Quality Report.
6. List of Accessories sent from the factory.

D. SAFETY
1. All work forces involved in testing of transformers shall undergo safety induction
-training before starting the testing activities.
2. Ensure earthing of transformers as per approved drawings.
3. All testing equipment shall be grounded prior to use.
4. Transformer terminals shall be discharged prior to changing connections.
5. No access shall be kept for person other than testing crew in transformer testing area.
6. Before commencement of test, release air from transformer. (Mainly, air-release plug,
HV-LV bushing, buchholz relay etc.)

Prepared By: Issued By: Approved By:

Rizwan Vadnagerwala Rizwan Vadnagerwala. Munir Abdulaziz
HITACHI 
Test Procedure Division: PGHV
ABB Contracting Company Ltd.

Description: Power Transformer Testing Procedure PGHV

E. Tools / Equipment’s
1. Hand Tools.
2. Testing Equipment.
3. Special Tools supplied with Transformer.

F. Mechanical Check & Visual Inspection

1. Check the damage of any part of equipment’s of transformers.
2. Ensure the there is no leakage in transformers.
3. Check all joints gasket or “o” ring.
4. Check all protection device like buchholz, PRV, OTI, WTI, etc.
5. All wires are installed and tightened properly at terminals.
6. Ensure that earthing bolt or anchoring is done correctly.
7. Verify the bushings are clean and not damage.
8. Verify all breathers are filled with silica gel & condition.
9. Verify proper liquid level in all tanks (tank oil level, OLTC Oil Level, Bushing If available)
10. Verify that all incoming and outgoing labeling of phases.
11. Check tightness of all bolt connections.

G. Testing- Procedure
Following details should be collected from name plate of transformer for reference
before testing.
1. Transformer Sr. No
2. Work orders No:
3. Name of Manufacture
4. Customer Name:
5. MVA/kVA Rating
6. Voltage Ratio:
7. Year of Manufacturing:
Prior to start the test workforce shall be educated about hazards during task, quality
control requirements and testing method

Prepared By: Issued By: Approved By:

Rizwan Vadnagerwala Rizwan Vadnagerwala. Munir Abdulaziz
HITACHI 
Test Procedure Division: PGHV
ABB Contracting Company Ltd.

Description: Power Transformer Testing Procedure PGHV

Activity 1: Testing Preparations: -

• PPEs should be worn by work force.
• Work Permit arranged before start the work.
• Ensure stable power supply is available at site (3ph/380-415-430V/60Hz)
• Bare copper wire or shorting link arrange before starting the test (Used for IR and
Capacitance and Tan-Delta Measurement)
• Transformer testing area shall be clean and safe.
• Ensure there is no leakage of oil in transformer.
• Temporary Earthing for transformer testing shall be arranged.
• Final factory testing report shall be available at site.
• Thermometer shall be available at site to measure the ambient temperature.
• Proper housekeeping of transformer shall be done prior to start tests.

Activity 2: Earthing Arrangement

• PPEs should be worn by work force.

• Transformer tank earthing shall be connected as per approved drawings.
• Check earthing of neutral bushings as per approved drawings.

Prepared By: Issued By: Approved By:

Rizwan Vadnagerwala Rizwan Vadnagerwala. Munir Abdulaziz
HITACHI 
Test Procedure Division: PGHV
ABB Contracting Company Ltd.

Description: Power Transformer Testing Procedure PGHV

Ratio Measurement Test

OBJECTIVE:
This test will be performed to determine the voltage ratio and polarity (HV/LV) on each tap
and in each phase of the transformer.
PROCEDURE:
• Connect the terminal of the measuring bridge to the transformer terminals in the
correct order. Ensure that no part of the transformer winding is connected to ground,
to prevent short-circuit. If the bridge is connected properly, the winding polarity is
determined at the same time.
Basic Circuit of Ratio Meter

Equipment’s: following equipment’s to be use for conduct this test or as per availabilities at store
1) Megger TTR 330
2) SCHUETZ TTR PWR3A
3) TINSLEY 4167F
4) Omicron CPC 100.

Criteria: ± 0.5 % tolerance in principal tap as per IEC 60076-1 (ed.3.0) Sub CL.11.3

Prepared By: Issued By: Approved By:

Rizwan Vadnagerwala Rizwan Vadnagerwala. Munir Abdulaziz
HITACHI 
Test Procedure Division: PGHV
ABB Contracting Company Ltd.

Description: Power Transformer Testing Procedure PGHV

Magnetic Balance and Magnetizing Current Test of (HV and LV)

OBJECTIVE:

• This test is conducted only in three-phase transformers to check the unbalance in the
magnetic circuit. In this test, no winding terminal should be grounded otherwise
results would be erratic and confusing. The test shall be performed before winding
resistance measurement. The test voltage shall be limited to maximum power supply
voltage available at site.

PROCEDURE:

• The test shall be conducted with three-phase supply and voltmeters. Voltage applied
in one phase of the winding and other phase voltages are measured.
Equipment’s: following equipment’s to be use for conducting this test.

1. Multimeter fluke 187, 179, 87.

2. Clamp meter HIOKI, Megger, Fluke.

Prepared By: Issued By: Approved By:

Rizwan Vadnagerwala Rizwan Vadnagerwala. Munir Abdulaziz
HITACHI 
Test Procedure Division: PGHV
ABB Contracting Company Ltd.

Description: Power Transformer Testing Procedure PGHV

Core -Frame Isolation Test:

OBJECTIVE:

This test is performed to determine single point earthing withstand of transformers.

PROCEDURE:

1. Connect H.V Terminal of H.V Tester to yoke bolt & L.V Terminal of H.V Tester to
earth part.

2. Select proper tripping range depending upon rating of transformer.

3. Check the connections.

4. Apply 2 KV using H.V test set for 1 Min. The tester should not trip, in case the tester
trips repeat the test to confirm the results.

5. This test can be performed using megger as well.

CONFIGURATION:

CORE TO EARTH:

FRAME TO EARTH:

CORE- FRAME:

Equipment’s: following equipment’s to be use for conducting this test.

1. Insulation Resistance Meter or HV tester (2.5 kV)

Criteria: - As per IEC 60076-1 (ed.3.0) Sub CL.11.12

Prepared By: Issued By: Approved By:

Rizwan Vadnagerwala Rizwan Vadnagerwala. Munir Abdulaziz
HITACHI 
Test Procedure Division: PGHV
ABB Contracting Company Ltd.

Description: Power Transformer Testing Procedure PGHV

Vector Group Test:

OBJECTIVE:

This test is performed to determine the vector group and phase displacement of
transformers.

PROCEDURE:

• The individual windings of poly phase transformers can be connected in star, delta, or
zigzag depending on the application. The phase displacement between the windings is
between 0° and 360° depending on the connection method. The vector diagram of the
high voltage winding is actually placed on a clock face so that the tip of Vector I (1U)
is at 12 o'clock. When the vector diagram of the low voltage winding is placed on top
with the same phase orientation, the direction of vector I (2u) identifies the clock
number of the vector group. The test shall be conducted with three-phase supply and
voltmeters. By the measured voltage data it should ensure that the desired conditions
of vector group and polarity are fulfilled.

Equipment’s: Following equipment’s to be use for conducting this test.

1. Either confirm from ratio meter or by voltage method.
2. Multimeter fluke 187, 179, 87.
3. Clamp meter HIOKI, Megger, Fluke.
Criteria: Verify the Vector condition by voltage method or direct meter
as per IEC 60076-1 (ed.3.0) Sub CL.11.3

Prepared By: Issued By: Approved By:

Rizwan Vadnagerwala Rizwan Vadnagerwala. Munir Abdulaziz
HITACHI 
Test Procedure Division: PGHV
ABB Contracting Company Ltd.

Description: Power Transformer Testing Procedure PGHV

Insulation Resistance Measurement Test:

OBJECTIVE:
Insulation resistance tests are made to determine the insulation resistance from individual
Winding to ground or between individual windings.

PROCEDURE:
• Insulation resistance tests shall be made with all circuits of equal voltage above
ground connected. It is standard practice to take the reading after the
voltage has been applied for one minute and calculate the 1min/15 sec. reading it
called AI (absorption index) for new transformer value will be more than 1.3. At the
time of test temperature shall be recorded. Insulation resistance may be measured
using DC power supply, range of 500 - 5000V.

• Insulation reading is vary with the temperature.

• Measure the Polarization Index,
• Insulation resistance value will vary with applied voltage, any measurement will
compare with same voltage (as per IEEE guideline)
• PI = 600 sec / 60 sec. more than 1.3 is good for new transformer.

Equipment’s: following equipment’s to be use for conducting this test.

1) Megger MIT‐510
2) Megger BM‐21.

Criteria: 1.0 unsatisfactory, >1.3 Good. (Manufacturer criteria)

Prepared By: Issued By: Approved By:

Rizwan Vadnagerwala Rizwan Vadnagerwala. Munir Abdulaziz
HITACHI 
Test Procedure Division: PGHV
ABB Contracting Company Ltd.

Description: Power Transformer Testing Procedure PGHV

Sweep Frequency Response Analysis Test:

• The Sweep Frequency Response Analysis (SFRA) test diagnoses the condition of the
transformer windings and magnetic core. It is performed by injecting a variable
frequency AC voltage to each winding and plotting the responding current as a curve.
Typically, these “fingerprint” reference curves are captured either when the
transformer is new or when it is known to be in good condition
• SFRA test should be perform first or must perform before DC test like Winding
Resistance & Insulation resistance test.
• They can be used as a baseline reference during maintenance tests or when there is a
reason to suspect a problem.
• Establish a list of FRA measurements as per below table, where:
• High Voltage terminals: H1, H2, H3, and H0 for neutral
• Low Voltage terminals: X1, X2, X3, and X0 for neutral
• Prepare the equipment to perform the test
• Install the connections for the first FRA measurement
• Check grounding connections of the transformer
• Check cabling installations, and the testing equipment
• the first FRA measurement
• Record measurement
• Proceed to the next connection

Configuration check as below.

1. 1U – 1N HV (LV open)
2. 1V – 1N HV (LV open)
3. 1W - 1N HV (LV open)
4. 1U – 1N HV (LV short)
5. 1V – 1N HV (LV short)
6. 1W - 1N HV (LV short)
7. 2U – 2V LV (HV Open)
8. 2V– 2W LV (HV Open)
9. 2W – 2U LV (HV Open)

Criteria: - As per IEC 60076-18 (ed.1.0)

Prepared By: Issued By: Approved By:

Rizwan Vadnagerwala Rizwan Vadnagerwala. Munir Abdulaziz
HITACHI 
Test Procedure Division: PGHV
ABB Contracting Company Ltd.

Description: Power Transformer Testing Procedure PGHV

Winding Resistance Measurement Test:

OBJECTIVE:
• Winding resistance serves a number of important functions like providing a base value
to establish load loss providing a basis for an indirect method to establish winding
temperature and temperature rise within a winding Inclusion as part of an in-house
quality assurance program, like verifying electric continuity within a winding

Procedure:
• Apply the Dc current to the winding but current not more than 15 % of the rated
current of that winding.
• Note down the temperature of the winding during the test.
• Ensure that the oil is available in the OTI port.
• Compare the resistance with the factory result, without the temperature not possible
to compare the reading.
• After switching on the DC voltage source reading must not be taken until the current
has reached At Steady State.
• Step resistance of each tap must be verifying, and it should be within ±5 % tolerance.
Also check the phase to phase resistance difference.
Equipment’s: following equipment’s to be use for conducting this test.

1) Raytech WR-50.
2) Megger MTO-330
3) Omicron-CPC 100.

Criteria: ± 5 % tolerance from the factory results as per IEC 60076-1 (ed.3.0) Sub CL.11.2

Prepared By: Issued By: Approved By:

Rizwan Vadnagerwala Rizwan Vadnagerwala. Munir Abdulaziz
HITACHI 
Test Procedure Division: PGHV
ABB Contracting Company Ltd.

Description: Power Transformer Testing Procedure PGHV

Current transformer Testing (Bushing CT or Winding CT):

OBJECTIVE:

This test is performed to ensure bushing CT Ratio and Polarity.

PROCEDURE:

1. Check the Polarity of CT.

2. CT analyzer measure the CT resistance, ratio, knee point curve, CT burden etc.
3. Apply 100V AC supply through a ratio meter OR CT analyzer & verify CT ratio.
4. Check the CT FAT report result to verify the SAT result as well.
5. Verify the CT ferrule Number as per the approved drawing.
6. Check the CT Shorting link available or not.

Equipment’s:

Following equipment’s to be use for conducting this test or any new equipment will be use as
per availabilities at store, but it must be calibration valid date.

1) CT Analyzer – Omicron.
2) MRCT – Megger.

Prepared By: Issued By: Approved By:

Rizwan Vadnagerwala Rizwan Vadnagerwala. Munir Abdulaziz
HITACHI 
Test Procedure Division: PGHV
ABB Contracting Company Ltd.

Description: Power Transformer Testing Procedure PGHV

Capacitance and Tan delta Measurement:

OBJECTIVE:

• The capacitance value depends on the physical configuration of the winding. The
dielectric loss in Insulation is the power dissipated when subjected to AC Voltage. It is
measured in terms of Tan-delta, which is the ratio of resistive current to capacitive
Current and expressed in percentage.

PROCEDURE:

1. All HV and LV terminals are shorted. Both HV and LV side shorting shall be separate.
2. The tank is kept earthed.
3. Readings are obtained directly from the bridge.
4. Test voltage is 10kV A.C
5. Before injecting the 10kV need to be check at low voltage 2kV.
6. ensure that Bushing are clean & enough space between test lead and ground.
7. Configuration should be change or more as per the transformer design.
8. Verify the all the reading with FAT as well.
9. Condenser Bushing tan delta value will not be converted at 20 Degree.

Following combination are done

• HV to Ground (GST-G) (GST = Grounded specimen Test)
• HV to LV (UST-Y) (UST = Ungrounded Specimen Test)
• LV to Ground (GST-G)
Oil temperature shall be noted. Results shall be calculated for 20’C Temperature.
(20’C is a reference temperature)

Combination should be increase according to the transformer specification.

• Measure the temperature during the capacitance & tan delta measuring time, tan delta
values are varying with temperature and capacitance value will be same at any
temperature.

• Measure value of tan delta are converted on 20 C degree. (As per IEEE- table 5)
Prepared By: Issued By: Approved By:
Rizwan Vadnagerwala Rizwan Vadnagerwala. Munir Abdulaziz
HITACHI 
Test Procedure Division: PGHV
ABB Contracting Company Ltd.

Description: Power Transformer Testing Procedure PGHV

Equipment’s: following equipment’s to be use for conducting this test or Any another
equipment available at Hitachi ABB store but it’s must be valid calibration date.

1) Megger kit (Delta 4000 & Delta 4310)

2) Omicron -CPC 100.
3) Megger TRAX (Transformer and Substation Test System )

Prepared By: Issued By: Approved By:

Rizwan Vadnagerwala Rizwan Vadnagerwala. Munir Abdulaziz
HITACHI 
Test Procedure Division: PGHV
ABB Contracting Company Ltd.

Description: Power Transformer Testing Procedure PGHV

DFR Testing.
• For determining percentage moisture content of transformer by indirect method.
• It is basically a plot of frequency vs. %DF (dissipation factor). Range of the
frequency is 0.1mHz to 1000 Hz. Measurement starts with higher frequency and
cut off frequency on lower side is selected based on temperature of the
transformer. Following is the criteria for selection of cut off frequency as given by
manufacturer.
Temp ⁰ C Cut off frequency (mHz)
0-4.9 0.1
5-9.9 0.2
10-19.9 0.5
20-29.9 1
30-44.9 2
45-59.9 5
>60 10
• All winding terminals for particular winding (e.g. for star connected HV winding: 1U-1V-
1W-1N) are connected together with thin copper conductor as it is done for insulation
resistance measurement. For different types of transformer connection is done as given
in table 1,

Transformer Mode of testing Connect Connect Connect

Type output of input 1 of input 2 of
IDAX to IDAX IDAX
Two winding CHL(UST-R) HV LV NIL
transformers
Three winding CHL(UST-R) HV LV1/ IV LV2/
transformers Tertiary
Auto transformer CHL(UST-R) HV+IV+N Tertiary NIL
with tertiary
Auto transformer CHG(GSTg- HV+IV+N NIL NIL
without tertiary RB)

• After checking proper connection when test is started, insulation diagnostic analyzer
automatically measures the value of dissipation factor at different frequency in selected
range of frequency. It also plots the graph of frequency vs. %DF. The measured curve is
compared with inbuilt modeled curve to get value of moisture content in transformer.
• According to moisture content observed during test, condition of transformer is divided in
four different categories: <1.0% as new; 1.0-2.0% dry; 2.0-3.0% Moderately wet; >3.0%
Wet.

Prepared By: Issued By: Approved By:

Rizwan Vadnagerwala Rizwan Vadnagerwala. Munir Abdulaziz