Testing Program
Factory tests are performed on a transformer to confirm that it is properly designed and constructed to carry rated load and that it will withstand the conditions it will be exposed to in service.
Each transformer manufactured by Power Partners must undergo a series of tests.
- Polarity, Phase-Relation, and Ratio
- Applied Voltage Test of the HV
- Applied Voltage Test of the LV
- Induced Voltage Test
- No-Load (Excitation) Loss and Excitation Current
- Circuit Breaker Test (for CSP transformers only)
- Impedance Voltage and Load Loss
- Full Wave Impulse
- Continuity Check
Test Facilities
The multi-station, automated test facilities are operated by process control computers. Required interaction with test floor personnel is minimal with the computers initiating and monitoring each test, and then analyzing the test results feedback. The computers are programmed to conduct tests according to ANSI standards, and according to the ratings of each transformer style, the test floor computers will initiate appropriate test setups, compare results with established ANSI standard limits, and determine acceptance for each tested unit.
The test results for each unit are recorded and stored on computer files for access and analysis.
Polarity, Phase-Relation, and Ratio Tests
These tests verify proper phase-relation (three phase), ratio, and polarity (single phase) of the transformer under test. To pass, a unit must demonstrate the proper polarity or phase-relation and have a turns ratio within one-half of one percent of the nominal voltage ratio.
Applied Voltage Test of the HV
This test checks the dielectric integrity of insulation structures between the high voltage and low voltage, and between the high voltage and ground. A pass/fail decision is made by monitoring the test current intensity. If the resulting current is larger than specified normal leakage and capacitive currents, the unit is rejected. This test is omitted for transformers with a permanently grounded high voltage winding.
Applied Voltage Test of the HV
This test checks the dielectric integrity of insulation structures between the high voltage and low voltage, and between the high voltage and ground. A pass/fail decision is made by monitoring the test current intensity. If the resulting current is larger than specified normal leakage and capacitive currents, the unit is rejected. This test is omitted for transformers with a permanently grounded high voltage winding.
Applied Voltage Test of LV
This dielectric test is similar to the Applied Voltage test of the high voltage circuitry except that the integrity of insulation structures between the low voltage and the high voltage, and between the low voltage and ground is checked. A pass-fail decision is made by monitoring the test current intensity. If the resulting current is larger than specified normal leakage and capacitive current, the unit is rejected.
Induced Voltage Test
The principal purpose of this test is to verify the dielectric strength of turn to turn, layer to layer, phase to phase, and other insulation structures within the transformer windings by inducing an overvoltage condition (at higher than normal frequency to avoid saturation of the core). The test current is monitored, and if it exceeds limits specified for each transformer, the unit is rejected.
No-Load Loss and Excitation Current
This test measures the no-load (excitation) loss and the transformer exciting current with rated voltage applied. If the exciting current and/or the no-load loss exceed the limits specified, the transformer is rejected. Circuit Breaker Test (for CSP transformers only) This test verifies the proper operation of the low voltage circuit breaker under fault conditions. The breaker is required to operate within a specified time under a simulated fault.
Impedance Voltage and Load Loss
This test measures the load loss and the impedance voltage at rated current. The load loss and the impedance voltage must be within specified limits.
Full Wave Impulse
The impulse test is one of several tests designed to verify the dielectric strength of the many insulation structures within the distribution transformer against line voltage surges. It is performed to comply with ANSI standards and for quality assurance. The change in the ANSI standard in 1993 required all manufacturers to install fault detection sensitive enough to detect a single turn short.
Continuity Check
This test is performed on all transformers to verify transformer circuit and component integrity. This test is performed with an ohmmeter to verify that the internal wiring is correct.
The transformer's nameplate is compared to manufacturing information for style, serial number, kVA, HV rating, LV rating, tap voltages, impedance, conductor materials and coil BIL rating. The bushings, electrical accessories, and fuses are verified.
