Part 2 – A General Overview

Records

Records of the test results shall include the following:

· Scope of the testing

· Equipment tested and date of test
· Test results
· Interpretation and recommendations based on the
testing

This information should be permanently recorded for each

of the transformers. Records should include all factory tests
as well as factory drawings of the transformers.

Safety

General Precautions

Some tests, like DGA, Oil Screen, and Infrared Thermog-

raphy do not require that the unit be de-energized. This is not
the case for electrical testing. Special attention and training
is needed to ensure protection. Personnel performing such
testing must observe proper safety regulations at all times.
Plant safety rules as well as state and federal regulations
should be consulted when working on and around energized
equipment. Temporary safety barriers may be needed to keep
other personnel a safe distance from the test area.

The testing devices in use today are highly sophisticated.

Restrict the use of this equipment to properly trained
personnel.

The test voltages generated by this equipment represent a

hazard to both the equipment under test and testing personnel.

Electrical Testing 83
 Equipment to be tested must be disconnected from the power
system using established operating procedures. Proper
grounding techniques must be practiced to avoid injury to
personnel or damage to equipment. Personnel should be
trained to treat all ungrounded equipment as energized.
Never take the word of another that something is grounded or
de-energized. Prove that it is for yourself.

Lockout/tagout procedures shall be followed as required

by plant, state, and federal safety procedures. Precautions
must be taken to prevent personnel from contacting any
terminals of the apparatus under test. When possible, an
observer should be stationed to warn approaching personnel
of the potential hazard. This person should be provided with a
means of de-energizing the power source.

Entering Transformers

New transformers are sometimes shipped without oil

to reduce the shipping weight. To prevent the entrance of
moisture during transit, the tank may be filled with dry nitrogen
gas under low pressure, displacing oxygen. On the other
hand, when oil is drained from service-aged transformers prior
to making an internal inspection, carbon monoxide and/or
other combustible gasses may evolve from the cellulose
in concentrations that are also dangerous. Because of
such atmospheric conditions and other potential hazards,
transformers must generally be classified as permit entry
confined spaces and treated accordingly under safety
regulations prior to entry.

Objectives

Electrical tests on transformers will fulfill four distinct

but general functions:

84 Transformer Maintenance Guide

 · Prove the integrity of the piece of equipment at the
time of acceptance
· Verify the continued integrity of the unit at periodic
intervals of time and plot any changes
· Determine the nature or extent of the damage when
a unit has failed
· Validate a successful field repair

The specific tests required to fulfill each function may vary

and will be tailored to meet the equipment’s requirements and
the technician’s recommendations.

Acceptance Tests (Factory and Field)

We recommend running field acceptance tests on a

transformer immediately upon arrival and prior to removing
from the carrier. Damage may occur during transit that may
be detected during field acceptance testing. Test data should
be compared to the factory acceptance testing data. If a
change is apparent, contact the manufacturer.

Manufacturers are capable of producing a properly

dried transformer with a moisture content of 0.5% M/DW or
less. However, experience also tells us they are capable of
producing a unit in excess of the 0.5% M/DW limit (Figure
4.1). We are responsible as consumers for indicating in our
purchase specifications a moisture content of 0.5% M/DW
or less. Running a power factor or dissipation factor test is
a good way of verifying the unit’s moisture content. If field
acceptance testing reveals a power factor in excess of 0.5%,
you should take steps to dry the unit properly.

We recommend that transformer purchase specifications

stipulate that manufacturers’ power factor testing method
conforms to the purchasers’ field-testing practice.

Electrical Testing 85
 Figure 4.1 - Initial power-factor tests on power transformers
manufactured since 1970 (courtesy of Doble Engineering
Co.).

Periodic Tests

All insulation inevitably ages over time. Aging rates

vary and are influenced by oxygen, water, heat, and the
by-products of the oxidation process. The rate of aging is
never static. Sometimes it’s faster, sometimes slower, but
it’s always present. This is true of all transformers, whether
energized or not. It is important to monitor the condition of
the cellulose. Its condition will also indicate remaining life and
signal when maintenance is needed.

Testing Units After Failure

Caution – When a transformer has gone off line, extreme

care needs to be taken to determine the cause of the outage.
Premature re-energizing may result in additional damage or
complete failure. The possibility of serious injury to personnel
also exists. Technical publications by NETA, IEEE, and NFPA

86 Transformer Maintenance Guide

address many troubleshooting problems. The manufacturer’s
assistance may also be procured.

Causes – These outages may be in response to primary

breaker or fuse operation, pressure relay or mechanical relief
operation, differential relay operation, etc., and may have
been preceded by a voltage line problem. The inspection is
intended to expose clues as to what triggered the operation
of the protective device. This cause may range from failure of
the transformer to a faulty protective device.

Clues - The initial visual inspection of the transformer’s

exterior may reveal such things as tank wall bulge, cracked or
leaking seals, oil spills. Visual inspection through the manhole
may reveal burned cellulose, melted metals, darkened oil,
and unusual odor. Be cautious as combustible gases may be
present in the oil and/or in the head space.

Appropriate electrical tests, to be detailed later, include

transformer turns ratio, insulation resistance, winding
resistance, and power factor. High voltage tests should be
avoided as they may excessively stress an already weakened
insulation. Instead, perform a dissolved gas-in-oil analysis
and furan testing.

If determined that the outage was not due to a transformer

fault, it may be re-energized safely.

Standards

Transformers that have been built according to American

National Standard Institute (ANSI)/The Institute of Electrical
and Electronic Engineers Inc. (IEEE) comply with the standards
in the “IEEE Standards Collection for Distribution, Power and
Regulating Transformers, 1998 Edition.” This collection is
also known as the C57 Series. Every attempt should be made
to consult the latest version of the standards.

Electrical Testing 87
 Application

The test requirement for any given repaired transformer

may be unique. This is understandable, considering the
complex variety of failure modes and repairs that may be
involved. Consider the options available when a transformer
fails.

· Repair in kind and risk the possibility of a repeat

failure.
· Repair employing updated materials and design
philosophy, which may void original performance
guarantees.
· Scrap the unit and purchase a new one.

If you choose either of the first two options, you need

to modify the acceptance tests to accommodate the new
specifications.

88 Transformer Maintenance Guide