Voltage Ratio and Magnetizing Current Tests by Kareem o

TCN
VOLTAGE AND MAGNETIZING

CURRENT TEST
Procedure and Analysis for Power Transformer
KAREEM O.A & UKELA A.G
2/27/2015
A Technical Presentation to PC & M Department of Transmission Company of Nigeria, Egbin

Sub-Region, on Voltage Ratio and Magnetizing Current Test - Procedures and Analysis.
VOLTAGE RATIO AND MAGNETIZING CURRENT TESTS
PART-A : Detailed Description

Introduction
This paper aims to set out the step by step procedures of carrying out voltage ratio
and magnetizing current test on the field thus helping young test
engineers/technicians to gain confidence in doing the test with minimum
supervision and eliminate confusions arising from :
(1) observed differences in the way voltage ratio test is being described in various
textbooks available as well as online resources compare with how it is being carried
out on the field when the transformer is already in service, during installation, or
about to be commissioned;
(2) lack of resources showing physical arrangement of test equipment/tools required
and detailed description.
Also, it will ensure pragmatic approach is adopted in carrying out the test even by
experienced engineers and technicians thereby eliminating error as a result of
oversight.
The reasons for carrying out the voltage ratio/magnetizing current test, observations
and conclusions from various practical field test results shall be examined thus
enabling a test engineer to state without ambiguity whether transformer under test
has pass voltage ratio test or otherwise.
Definitions
Voltage Ratio Test: of a power transformer refers to the test carried out on a
transformer with application of three phase voltage simultaneously at rated
frequency on one side windings (usually an HV side) while the other side windings
(usually an LV side) is left open circuited. The values of voltage is taken on both
sides and ratio of HV winding voltage to LV winding voltage is computed for a
particular tap position. This is repeated for all tap positions and voltage/turn ratio
from measured values are compared with design turn ratio values at corresponding
tap positions of the transformer under test. Therefore, it is common to also refer to
voltage ratio test as transformer turns ratio test(TTR).
Magnetizing Current Test: of a power transformer refers to the test carried out as
described under voltage ratio test above with primary no load(magnetizing) current
value being taken from each phase of the primary windings for every tap changer
position. It is also called no-load excitation current test.
The tests can be done with single phase supply but it will take longer time and can be
a little bit cumbersome especially for power transformers with several tap positions.
2
Voltage and Magnetizing Current Test-Procedure and Analysis for Power Transformer
Designed Turn Ratio: refers to ratio of HV winding voltage to LV winding voltage as

specified on the nameplate by the manufacturer. It is also referred to as expected
turn ratio or desired turn ratio , the ratio changes with movement in tap changer
position as indicated in the nameplate.
Measured Turn Ratio: refers to ratio of measured HV winding voltage to measured
LV winding voltage obtained during voltage ratio test. It can be expressed
mathematically as:
a
Measured Primary Voltage

Measured Secondary Voltage
Recall, from ideal transformer equation, turn ratio

a
Ep
Es
Np
Ns
Percentage Deviation: refers to the difference in measured turn ratio as compared

with designed turn ratio of the transformer expressed as a percentage.
Percentage deviation can be expressed mathematically as follows:
%Deviation
(Measured Turn Ratio) -( Designed Turn Ratio) x 100%

Designed Turn Ratio
Tap Changer: this is a winding ratio changing device installed on a transformer

secondary side and connected internally to them for the purpose of selecting
different ratios as desired. Some can be operated during load conditions and are
referred to as On-Load-Tap-Changer(OLTC) while some can only be operated when
the transformer is de-energized and are referred to as Off-Circuit-TapChanger/Selector(OCTC or OC TS). Tap changer for most big power transformers are
OLTC and for smaller distribution transformers as well as grounding transformers,
they are OCTS.
In all cases, tap changer is used in raising or lowering secondary voltage to the
desired level by altering the amount of turns ratio of transformer windings in
response to voltage change in the primary side. Hence, it can be seen that a test on
voltage ratio can actually gives a reflection of tap changer efficiency.
Aim
(1) The tests shall confirm no load voltage ratio stated on the nameplate of the
transformer under test.
(2) The tests shall determine conditions of both primary and secondary windings.
(3) The effectiveness of Tap Changer is confirm during the tests.
(4) The tests gives insight into condition of core i.e. magnetic circuit path.
(5) It provides basis of analyzing problem if any in the windings at different tap
positions, this is explain further under tolerances.
3
Methods
The ratio test can be carried out using the following methods:
(1) Voltmeter method
(2) Ratio Bridge method(TTR Test Set)
Any of the methods stated above is acceptable but it is preferable to used method-2
above for a newly installed HV Power Transformer because it gives highest degree of
accuracy i.e. 0.1%(source: BEST, SUBST COMM-1) while method-1 is also widely
used due to :
(a) possibility of converting the test arrangement for Short Circuit/Impedance Test
with ease,
(b) it is a very good test for verifying the proper tap changer functionality,
(c ) there is no need for any special test set only a voltmeter and a clamp-on
ammeter are required. (SUBST COMM-1)
At Transmission Company of Nigeria(TCN) whose test procedures this paper is largely
focusing on, voltmeter method is the most often used and shall be the basis of
further discussion as we progress(detailed description of a TTR test set usage is
always attached to the test set and can be accessed easily). Voltmeter method
allows for the two tests to be carried out once i.e. voltage ratio test and magnetizing
current test, hence the description under Test Procedure cover these two tests.
Tolerances
The accepted tolerance according to International Standard IEC 60076-1 for no-load
voltage ratio for principal tappings is 0.5% . This means that absolute value of the
percentage deviations from specified design values should not exceed 0.5% by
standard (we shall later compare the values obtain from field works on how they
conform with the standard or otherwise). While tolerance for no-load
current(magnetizing current) must not exceed +30% of declared value at rated
voltage by the manufacturer.
There is need to remark here that accuracy of the test is a function of accuracy of all
measuring equipment/tools used during the test and human factor.
Fundamentally, the following positions are true for transformer during voltage ratio
and magnetizing current tests:
(1) Percentage deviation with absolute value far higher than 5% accompanied with
high magnetizing current may be due to shorted turns or problem with the tap
changer contact.
(2) Very low magnetizing current with no LV voltage shows there is an open-circuit in
the primary winding.
(3)Normal magnetizing current with fluctuating and very low LV side voltage is an
indication of open circuit in the secondary winding.(source
http://electrical4u.com/voltage-and-turn-ratio-test-of-transformer/)
4
Requirement for Voltage Ratio/Magnetizing Current Test

The following are required to carried out voltage ratio/magnetizing current test of a
transformer:
(1) A three phase (415V, L-L) voltage source.
(2) 2 no Moulded Case Circuit Breaker(at least 1 is mandatory)
(3) 2 no voltmeter( 1 no can be managed if the test is properly set out)
(4) A set of screwdrivers
(5) A set of spanners
(6) 6 no of 8m long 6mm2 cable or 2 no of 8m long 6mm2 x 3core armoured cable
(7) 2 sets of grounding leads and sticks
(8)Low Range Clamp-on AC Ammeter(that can measure current in mA)
(9) Personal protective equipment(at minimum safety boots and helmet)
(10) Ladder especially if the transformer does not have any
(11) A pen and a notebook(not a sheet of paper that can get lost easily)
Precautions
(1) Ensure you have the necessary Permit To Work document(s) especially in an
existing substation that is already in service.
(2) Ensure that the transformer is de-energised, with isolation confirmed and
secured.
(3) Ensure you have all the tools/materials required before commencing to avoid
running around when the test has started.
(4) Ensure that both HV incomer conductors and LV outgoing cables/conductors as
well as transformer bushings are discharged before disconnecting any
conductor/cable.
(5) Put on your Safety Boot and Helmet before climbing the transformer.
(6) There must be effective communication among persons involved in the test with
each person understanding the role to play to avoid error in sequence of test and
recording (at minimum 2 personnel must be involved in carrying out the test).
(7) All cables and tools used for test MUST be removed immediately after the
test(easy way to ensure this is to assign somebody as tool man/housekeeper that
will take inventory of tools/equipment brought to the test location and he should
confirm the list after test)
Test Procedure
The step by step procedure of getting the test done correctly is as follows:
5
(1) The transformer to be tested is confirm switch off and isolated. The isolation
should be secured.
(2) The nameplate data from the transformer is neatly copied with date, time as well
as winding/oil temperature recorded. A sample of typical nameplate data is shown in
figure-1. The table for recording of test result is also drawn below the nameplate
data, typical sample of voltage ratio test table format is shown in table-1.
(3) The grounding lead is tied to earth first with its clamp and the other end with aid
of grounding stick is use to discharge conductors and connectors on all phases of the
LV side .
(4) Step (3) above is repeated for the HV side.
(5) Disconnection of conductors/cables from all the bushings across phases for both
HV and LV
sides(if the transformer has earthed neutral connection, earth cable
must be disconnected too).The transformer bushing terminals must be free of all
connections before the test commence.
(6) One end of first test cable RED, YELLOW, BLUE is connected to corresponding
bushing terminals of the transformer on HV side and the other end is connected to
corresponding terminals of mccb marked HV
(7) One end of second test cables RED, YELLOW, BLUE is connected to corresponding
bushing terminals of the transformer on LV side and the other end is connected to
corresponding terminals of mccb marked LV(it is possible to do without LV mccb but
it is safer to use it).
(8) The connections are checked and confirmed alright by other person and all tools
on top of the transformer is removed .
(9) Three-phase supply is connected appropriately to HV mccb in OFF position.
(10) The transformer tap changer is tapped down to tap-1, that is minimum tap
position while noting the original tap position.
(11) HV mccb is switched on, voltmeter is used to check the applied phase-phase
voltage to the HV winding via HV mccb terminals in the sequence red-yellow, yellowblue and blue-red respectively. The readings are to be recorded immediately.
(12) Voltmeter is used to check corresponding phase-phase voltage on LV winding
via LV mccb winding via LV mccb terminals in the sequence red-yellow, yellow-blue
and blue-red respectively. The readings are to be recorded immediately.
(13) Clamp-on Ammeter is used to check the magnetising current on all phases in the
primary windings starting from red phase, followed by yellow phase and then blue
phase. The readings are to be recorded immediately. It is expected that the currents
should be in few milliamps, high current is an indication of a problem and if it is
observed, the supply should be switch off and connections should be checked. If the
connection is alright, the test should be continued with caution because the
observation might be due to shorted turns. The general arrangement drawings for
voltage ratio/magnetizing current test are as shown in figures 2 to 4.
6
(14) Tap changer is moved to tap 2, and steps-11 to 13 are repeated. These continue
until the last tap is reached.
(15) All readings are recorded immediately and final computation of the ratios can
be done.
(16) The AC supply for test and HV mccb is switched off, all test cables disconnected
and removed.
(17) All disconnected conductors/cables are terminated as-met, all tools/equipment
removed and the tap changer is return to as-met tap which is usually the nominal
tap.
(18) The permit to work is surrender and normal procedure is followed for
restoration of transformer if the test is satisfactory .
Figure-1
7
Table-1
Figure-2
8
Figure-3
Figure-4
9
Analyzing Test Result

The following conditions have to be fulfilled for the test to be accepted as
satisfactory.
(1) The magnetizing current has to be in few milliamps(experience shows this is
usually less than 20mA for most power transformer).
(2) The deviation calculated from measured ratio and design ratio values must fall
within the range: 0.5%(International standard IEC 60076-1). Quick way to
determine this is to know the expected ratio for each transformer e.g. for 132/33kV
transformer, expected ratio is 4:1. It implies that if test voltage at HV side is 400V,
100V is the expected value at the LV side.
(3) There should be gradual increment in the magnetizing current and measured LV
winding voltage as tap changer is from tap-1 to higher tap(there may as well be
gradual decrease depending on how the tap-changer is configured)
(4) The impedance ratio (Vm/Im ) (Vr/Ir) must be greater than 10 ( TCN standard).
Measured value is m and r is rated or design value.
It must be emphasized that quite a number of times, we have slight departure from
conditions above largely due to variation in test voltage within the time the test is
being conducted, test instrument error and on few occasions human error. Hence,
there is need to be a little conservative in pronouncing the test result until previous
values from earlier tests on the same transformer is checked and discussing with
experienced colleague(s) is usually necessary for conclusion to be arrived at
especially If the results appears inconsistent.
Recommendations
(1) There should be conscious effort to spend little more time in copying full
transformer details from nameplate and possibly compute the design ratio prior to
starting the tests. Test has little or no meaning without data to compare values
obtained with.
(2) Report of any transformer tests should be documented in a hard copy with oil
and winding temperature taken, the older document will serve as basis of evaluating
any fresh test perform on same transformer and trend of any deterioration in
condition can be tracked with ease.
(3) There is need for every member of the test team to understand what is to be
done and the role they have to play to avoid accident and unnecessary lapse usually
resulting from a member thinking another member will carry out an activity without
actually communicating effectively.
Voltage ratio and magnetizing current test give some information concerning state
of a transformer as described above, but practical experience has revealed there is
usually a need for other diagnostic tests before final conclusion could be drawn. In
part-b, practical test results from field shall be analyzed using criteria described
above.
10
PART-B: FIELD RESULTS ANALYSIS

Samples From Field Test Results and Observations
To be discussed below are practical test results obtained from substations that are
within coverage of Egbin Sub-Region of Transmission Company of Nigeria.
Field Sample-1:
The first transformer to be analyzed is T1-Grounding transformer at Ikorodu
substation which was brought to replace the faulty one, the nameplate and test
results conducted before commissioning are as detailed in Figure-5 and Table-2:
Figure-5
Table-2
Observations:
11
(1) The date, location and complete nameplate data are copied except voltages at
different taps except nominal(this was later reflected on Table-2 , it shows that test
shall be inconclusive without the complete data because test report cannot be
prepared if there is no adequate information on a transformer) .
(2) The measured magnetizing current has maximum value of 0.94mA which is far
less than limit of 20mA(this value is purely based on several site results observed).
(3) The design ratio at nominal tap(tap-3) for the above transformer is 33000V415V
= 79.51807, this means expected voltage on LV side if line voltage of 415V is applied
on primary winding, expected voltage on corresponding secondary winding should
be 415 79.51807 = 5.21, comparing this value with above table shows correlation
with the measured value at the nominal tap.
(4) Absolute value of deviation in percentage apart from first value on tap-1 are
within the range 0.5%.
(5) Measured LV winding voltage shows gradual increment from tap-1 to tap-5,
magnetizing current is also expected to follow same order but inconsistence value is
obtained-this may be due to winding configuration and further investigation is
necessary.
(6) The impedance ratio at tap-3 is (414/0.00066) (33000/8.7). The value is very far
greater than 10.
The transformer is found to be ok and after all other tests conducted on it were
satisfactory, it was energized.
Field Sample-2
The nameplate and test result below(Figure-6 and Table-3) are that of T1-60MVA
132/33KV transformer at Ikorodu T/S.
The test was carried after protective circuit tripped both HV and LV circuit breakers
of the transformer.
12
Figure-6
Table-3
13
Observations:
(1) The date, location and complete nameplate data are copied, including voltages
for other tap positions apart from nominal tap as reflected on table-3
less than limit of 20mA
(3) The design ratio at nominal tap(tap-5) for the above transformer is
132000V33000V = 4, this means if line voltage of 422V is applied on HV winding,
expected voltage on corresponding secondary winding is 422V 4 = 105.5V,
comparing this value with above table shows correlation with the measured value at
nominal tap.
(4) Deviation in percentage has maximum negative value of -1.09 at tap-2, maximum
positive value of 0.44 at tap-14 and least value of 0(i.e. no deviation) at tap-16. There
are possibilities for these observations, it might be an indication that the tap changer
required maintenance since at some tap positions excellent result were got and at
some, deviation is far away from 0.5% which is International standard. Also, one
might compute average of three values above which is -0.22%.
(5) Measured LV winding voltage and the magnetizing current shows gradual
increment from tap-1 to tap-17 as expected.
(6) The impedance ratio at tap-5 is (422/0.00469) (132000/262.4). The value is very
far greater than 10.
The transformer is found to be ok and after all other tests conducted on it were
satisfactory, it was energized.
Field Sample-3A
The nameplate and test result below(Figure-7 and Table-4) are that of 60MVA
132/33KV transformer.
The test was carried out as part of pre-commissioning tests at the substation.
14
Figure-7
Table-4
15
Observations:
(1) The nameplate data is copied without date and location specified.
less than limit of 20mA
(3) The design ratio at nominal tap(tap-5) for the above transformer is
132000V34500V = 3.83, this means if line voltage of 423.3V is applied on HV
winding, expected voltage on corresponding secondary winding is 423.3V 3.83 =
110.52V, comparing this with the table shows some amount of correlation with the
value at nominal tap, although measured value is higher.
(4) Deviation in percentage has maximum negative value of -2.45 at tap-16,
minimum negative value of -1.29 at tap-1. These values are far higher than standard
of 0.5%, the easiest thing to do is to compare the values with those obtained
during FAT
The FAT values for the transformer is found to be ok and other test conducted too,
hence test equipment and human errors are likely and ideal thing will be to re-test
the transformer for turn ratio test.
increment from tap-1 to tap-17 as expected confirming that that tap changer
contacts are making and breaking effectively.
(6) The impedance ratio at tap-5 is (423/0.0025) (132000/174.95). The value is very
far greater than 10.
Field Sample-3B
The transformer above was re-tested using TTR test set and table-5 shows the result
obtained
16
Table-5 RATIO TEST Using MICRON CPC 100

TAP
001
002
003
004
005
006
007
008
009
010
011
012
013
014
015
016
017
PRIM
NOM.
(V)
13860
0
13700
0
13530
0
13370
0
13200
0
13040
0
12870
0
12710
0
12540
0
12380
0
12210
0
12050
0
11880
0
11715
0
11550
0
11385
0
11220
0
SEC
NO
M.
(V)
3450
0
3450
0
3450
0
3450
0
3450
0
3450
0
3450
0
3450
0
3450
0
3450
0
3450
0
3450
0
3450
0
3450
0
3450
0
3450
0
3450
0
Inj.
(V)
149.
97
149.
96
149.
96
149.
96
149.
98
149.
96
149.
98
149.
97
149.
96
149.
96
149.
99
149.
96
149.
97
149.
98
149.
96
149.
97
149.
96
RED PHASE
Mea Dev. Mag
s.
(%)
I
(V)
(mA)
64.4
2.35
-0.28
76
10
65.2
2.49
-0.26
64
20
66.0
2.53
-0.23
78
20
66.9
2.57
-0.20
13
50
67.7
2.63
-0.17
81
10
68.6
2.67
-0.14
49
10
69.5
2.73
-0.11
59
60
70.4
2.77
-0.08
81
80
71.4
2.82
-0.05
24
80
72.4
2.88
-0.01
02
90
73.4
2.96
0.02
18
40
74.4
2.99
0.05
31
50
75.5
3.05
0.09
00
70
76.5
3.13
0.12
96
30
77.7
3.19
0.16
07
70
78.8
3.27
0.20
71
80
80.0
3.36
0.24
58
30
YELLOW PHASE
Inj. Mea Dev. Mag
(V)
s.
(%)
I
(V)
(mA)
149. 64.4
1.86
-0.27
96 77
60
149. 65.2
1.91
-0.25
96 71
70
149. 66.0
1.94
-0.22
95 83
80
149. 66.9
1.99
-0.19
96 23
00
149. 67.7
2.01
-0.16
97 84
40
149. 68.6
2.05
-0.13
96 56
50
149. 69.5
2.09
-0.10
96 55
50
149. 70.4
2.14
-0.07
96 81
80
149. 71.4
2.19
-0.04
96 32
00
149. 72.4
2.23
-0.01
96 08
60
149. 73.4
2.28
0.03
96 12
80
149. 74.4
2.34
0.06
98 48
70
149. 75.5
2.38
0.10
96 03
30
149. 76.5
2.42
0.13
96 94
80
149. 77.7
2.48
0.17
96 18
90
149. 78.8
2.56
0.20
00
98 80
149. 80.0
2.60
0.25
96 66
90
Inj.
(V)
149.
96
149.
98
149.
97
149.
97
149.
95
149.
96
149.
97
149.
97
149.
96
149.
97
149.
96
149.
96
149.
96
149.
98
149.
98
149.
97
149.
96
BLUE PHASE
Mea Dev. Mag
s.
(%)
I
(V)
(mA)
64.4
2.30
-0.28
75
40
65.2
2.42
-0.26
73
90
66.0
2.40
-0.22
87
40
66.9
2.49
-0.20
22
90
67.7
2.57
-0.16
70
00
68.6
2.60
-0.14
52
50
69.5
2.62
-0.10
59
30
70.4
2.71
-0.08
82
80
71.4
2.79
-0.04
30
90
72.4
2.84
-0.01
07
10
73.4
2.87
0.03
09
20
74.4
2.98
0.05
35
70
75.4
3.05
0.09
95
10
76.5
3.07
0.12
97
00
77.7
3.19
0.16
18
90
78.8
3.25
0.21
76
40
80.0
3.33
0.24
58
40
17
Observations:
(1) The test was carried out with relatively lower voltages applied by the equipment
to transformer terminals with each phase percentage deviation computed by the
test set separately.
(2) The highest value of magnetizing current is 3.334mA which is far lower than
20mA and is comparable with earlier value gotten using Voltmeter method
(3) The maximum absolute value of percentage deviation is 0.28%, far less than
0.5%, thus confirming the transformer ratio is good.
increment from tap-1 to tap-17 as expected confirming that that tap changer
contacts are making and breaking effectively.
The observations above confirmed that the transformer ratio and magnetizing
current tests are good and with all other tests being satisfactory, the transformer
was successfully energized and put into the grid.
Conclusion
The various field results analyzed above have confirmed postulations concerning
voltage ratio and magnetizing current tests earlier stated at the beginning of the
report and more importantly, the last field sample depicted how to handle
unexpected result by exploring more accurate method especially for a new
transformer-TTR gives more accurate result which can be used as basis for further
evaluating subsequent test results on the same transformer.
Finally, this report shall be quite useful for any trainee on transformer testing and
contents are good reference materials for experienced hands as well.
References
1. Transformer Tests Procedure-www.besttrafo.com.tr- Balikesir Elektromekanik
Sanayi Tesileri(BEST)
2. Power Transformer Principles and Applications by John J Weiders, Jr. Published
under copyright by Marcel Dekker, Inc.(2002).
3. IEC 60076-1 Transformers Edition 2.1(1999).
4. Archive of PC&M, TCN Egbin Work Centre, Lagos.
5. FAT documents on Transformer from Crompton Greaves on Lot 2008-6.
6. http://electrical4u.com/voltage-and-turn-ratio-test-of-transformer.
18

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TCN

VOLTAGE AND MAGNETIZING

A Technical Presentation to PC & M Department of Transmission Company of Nigeria, Egbin

VOLTAGE RATIO AND MAGNETIZING CURRENT TESTS

PART-A : Detailed Description

Designed Turn Ratio: refers to ratio of HV winding voltage to LV winding voltage as

Measured Primary Voltage

Recall, from ideal transformer equation, turn ratio

Percentage Deviation: refers to the difference in measured turn ratio as compared

(Measured Turn Ratio) -( Designed Turn Ratio) x 100%

Tap Changer: this is a winding ratio changing device installed on a transformer

Requirement for Voltage Ratio/Magnetizing Current Test

Analyzing Test Result

PART-B: FIELD RESULTS ANALYSIS

Table-5 RATIO TEST Using MICRON CPC 100

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