Power Measurements and Basic Electrical Diagnostic Tests

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1 Power Measurements and Basic Electrical Diagnostic Tests

2 Instrument Basics Burden VA Sources V and I Meters V and I KVL and KCL Kelvin Connection

3 KVL and KCL

4 Kelvin Connection 4-Wire Technique Exclude the resistance from the measurement circuit leads and any contact resistance at the connection points of these leads Voltage sense leads (P3 and P4) "inside" the current leads (P1 and P2)

5 Test Properties 1. Overall PF/CAP 2. Bushing PF/CAP (C1, C2, EC) 3. Exciting Current (Phase A, B, C) 4. Surge Arresters 5. Insulating Fluids (Main Tank, LTC) 6. Turns Ratio (H-X, H-Y, H-T, X-Y, X-T) 7. Leakage Reactance (3 Equiv, Per ) 8. Insulation Resistance 9. DC Winding Resistance (H, X, Y)

6 Topics of Discussion 1. Diagnostic Test Methods 2. Transformer Test Protocol 3. Transformer Test Plan 4. Analyzing the Results

7 Diagnostic Testing - OVERALL DGA Oil Screen Power Factor / Capacitance Exciting Current Transformer Turns Ratio Leakage Reactance DC Winding Resistance SFRA (Sweep Frequency Response Analysis) FRAnalyzer DFR (Dielectric Frequency Response) DIRANA Thermal Imaging FLIR Insulation Resistance MEGGER Partial Discharge MPD PDL DAYCORE

8 Transformer Tests Dielectric Thermal Mechanical DGA DGA SFRA Oil Screen Oil Screen Leakage Reactance PF/TD CAP IR PF/TD CAP Exciting Ima DC Winding RES Exciting Ima Turns Ratio Tests DC Winding RES DFR Insulation Resistance Partial Discharge

9 Diagnostic Testing - FOCUS 1. Power Factor / Capacitance 2. Exciting Current 3. Transformer Turns Ratio 4. Leakage Reactance 5. Insulation Resistance 6. DC Winding Resistance 1. Overall PF/CAP 2. Bushing PF/CAP (C1, C2, EC) 3. Exciting Current (Phase A, B, C) 4. Surge Arresters 5. Insulating Fluids (Main Tank, LTC) 6. Turns Ratio (H-X, H-Y, H-T, X-Y, X-T) 7. Leakage Reactance (3 Equiv, Per ) 8. Insulation Resistance 9. DC Winding Resistance (H, X, Y)

10 Power Factor Tests 1. Overall PF/CAP 2. Bushing PF/CAP (C1, C2, EC) 3. Surge Arresters 4. Insulating Fluids (Main Tank, LTC) Dependent on Transformer Type 2-Winding XFMR 3-Winding XFMR Autotransformers Will cause variances in test plans from protocol.

11 Overall PF/CAP Type Main Insulation Bushings Surge Arresters 2-Winding CH, CL, CHL Up to 8 C1, C2, EC 3-Winding CH, CL, CT CHL, CHT, CLT Up to 12 C1, C2, EC Auto w/tert CAuto, CT, CAutoT Up to 10 C1, C2, EC Auto wo/tert CAuto Up to 7 C1, C2, EC Up to 6 Stacks Up to 9 Stacks Up to 9 Stacks Up to 6 Stacks Insulation Fluids Main Tank Tap Changer Main Tank Tap Changer Main Tank Tap Changer Main Tank Tap Changer

12 Power Factor / Capacitance Measurement I TOT I R I C Insulation can be modeled through: Capacitance (Physical Geometry) Resistance (Losses) V R C I R Losses can be categorized as: Conductive Polarization (60 Hz Range) I TOT I C Power Factor 0.00% - 100% cos φ = I R /I TOT x 100% Power Factor measures bulk degradation: Moisture Aging Contamination V

13 Insulation Losses Loss Types: Conductive Losses: Electrons and Ions Polarization Losses: Electrons, Molecular, Interfacial Polarization Partial Discharge PD: Locally Discharge Loss Dependences: Aging Moisture Contamination Temperature Insulation Geometry Electrical Field Strength (PD)

14 Power Factor / Capacitance Applied Test at Rated Frequency (60 Hz) Measurements Normalized to 20 C. Test voltages for a typical field test set range from below 100 V to as high as 12 kv. (IEEE Std. 62) 10 kv is Normally Applied a) 2000 VA b) 80,000 pf Data should be analyzed by: a) Limits b) Trending c) Nameplate

15 Power Factor vs. Capacitance Power Factor Aging Moisture Contamination Capacitance Change in Dielectric Constant (Aging and Contamination) Air(Vacuum) : 1.0 Oil: 2.2 Porcelain: Physical and Mechanical Changes (Movement).

16 2-Winding XFMR

17 3-Winding XFMR

18 Autotransformers WITH & WITHOUT Tertiary WITH WITHOUT

19 Two-Winding Transformer Model Windings are short-circuited to remove unwanted inductance CH, CL and CHL insulation systems CH includes H-C1 CL includes X-C1

20 GST Measurement Both CH and CHL are measured together

21 GST GUARD Measurement - CH CH is isolated by use of the GSTg measurement circuit

22 UST Measurement - CHL CHL is isolated by use of the UST measurement circuit

23 Overall Test Data 2-WINDING TRANSFORMER OVERALL Measurement Type kv Test # Energize Ground Guard UST Test kv I ma Cap pf Watt Loss PF [%] Measured PF [%] Corrected Correction Factor ICH+ICHL H (prim) L (sec) GST Mode Insulation Condition ICH H (prim) L (sec) GST ga PASS ICHL H (prim) L (sec) UST A PASS Calculated ICHL PASS ICH-C1 = ICH minus H (prim) bushings; HV C1 ONLY PASS ICL+ICHL L (sec) H (prim) GST ICL L (sec) H (prim) GST ga PASS ICHL L (sec) H (prim) UST A PASS Calculated ICHL PASS ICL-C1 = ICL minus L (sec) bushings; LV C1 ONLY PASS

24 Transformer Test Results

25 Transformer Test Results Notice severe exponential increase!

26 Bushing Taps

27 Field Tests The following test are electrical field tests performed with portable test equipment to determine bushing suitability for service. Condenser Bushing with Potential Tap Condensers Bushing with Test Tap Non Condenser Visual Inspection Visual Inspection Visual Inspection C1 Power Factor (60 Hz) C1 Power Factor (60 Hz) Energize Collar Test C1 Capacitance (60 Hz) C1 Capacitance (60 Hz) Infrared Test C2 Power Factor (2.5 kv) C2 Capacitance (2.5 kv) Advance Power Factor Measurements Power Factor Tip Up Test C2 Power Factor (0.5 kv) C2 Capacitance (0.5kV) Advance Power Factor Measurements Power Factor Tip Up Test Infrared Test Infrared Test

28 Power Factor / Capacitance - BUSHING C1 Bushing H1-C1 UST All Terminals Remain Shorted

29 Bushing C1 Test Data Bushings - NAMEPLATE Bushing Manufact. Model/ Serial Catalog Drawing BIL kv A C1 C1 Year Type Number Number Number kv Rating Rating PF[%] Cap (pf) H1 ABB O+C H2 ABB O+C H3 ABB O+C H0 C2 PF[%] C2 Cap (pf) X1 ABB O+C X2 ABB O+C X3 ABB O+C X0 ABB O+C Bushings - C1 Measurement Type Ref@10 kv Bushing Energize Ground Guard UST Test kv I ma Cap pf Watt PF [%] PF [%] Correction Mode Insulation Loss Measured Corrected Factor Condition H1 Conductor - - Tap UST A PASS H2 Conductor - - Tap UST A PASS H3 Conductor - - Tap UST A PASS H0 Conductor - - Tap n/a n/a n/a 1.00 UST A X1 Conductor - - Tap UST A PASS X2 Conductor - - Tap UST A PASS X3 Conductor - - Tap UST A PASS X0 Conductor - - Tap UST A PASS

30 Bushing Standard Limits Power Factory limits at power frequency and corrected to 20 C Insulation %PF IEEE (C ) %DF (IEC 60137) Typical %PF New values Oil Impregnated Paper <0.5% <0.7% 0.2%-0.4% Resin Impregnated Paper <0.85% <0.7% 0.3% - 0.4% Resin Bonded Paper <2.0% <1.5% 0.5%-0.6%

31 Power Factor / Capacitance - BUSHING C2 H1-C2 GST ga

32 Bushing C2 Test Data Bushings - C2 Measurement Type Ref@10 kv Bushing Energize Ground Guard UST Test kv I ma Cap pf Watt Loss PF [%] PF [%] Measured Corrected Correction Factor Mode Insulation Condition H1 Tap - Conductor GST ga PASS H2 Tap - Conductor GST ga PASS H3 Tap - Conductor GST ga PASS H0 Tap - Conductor - n/a n/a n/a 1.00 GST ga X1 Tap - Conductor GST ga PASS X2 Tap - Conductor GST ga PASS X3 Tap - Conductor GST ga PASS X0 Tap - Conductor GST ga PASS

33 Power Factor / Capacitance - BUSHING EC H1-EC GST or UST UST and GUARD circuits can be used for external contamination investigation and/or isolation

34 Energized Hot Collar Test Data Bushings - Energized Collar Measurement Type Ref@10 kv Bushing Energize Ground Guard UST Test kv I ma Watt Loss Mode Insulation Condition H1 Collar GST PASS H2 Collar GST PASS H3 Collar GST PASS H0 Collar n/a GST X1 Collar GST PASS X2 Collar GST PASS X3 Collar GST PASS X0 Collar GST PASS

35 Transformer Exciting Current Test Vs 1. Apply Voltage Vs on on primary phase, secondary winding left floating 2. Measure currurent I ex 3. The current required to force ``transformer action (the use of one winding to induce a voltage in the second winding).

36 Exciting Current Test Considerations: The exciting current test is an open-circuit test; the secondary side bushings should not be shorted together. If the secondary winding is a Wye-configuration, the Neutral must be grounded. Apply AC Voltage across each winding phase, measuring the current and watts. On a HV Delta-Configured winding, the third terminal must be grounded, or the results can no longer be characterized as a single phase measurement. Voltage sensitive test, must apply the same voltage to each phase and as that used for previous results in order to compare.

37 Analyzing Results Unexpected results can be observed from the following: 1. Full or partially short circuited turns 2. Open Turns 3. Core Construction Problems 4. Saturated Core

38 Exciting Current Test Procedure Routine Test Perform test on each phase with the DETC on its as found position. DETC should not be moved unless specified by company or manufacturer Ideally test should be performed on all phases at each LTC positions

39 Analyzing Results Confirm Expected Phase Pattern Confirm Expected LTC Pattern (For load tap changing transformers) Compare to Previous Results Make sure same voltage is applied Magnitudes do not have to match Any change should be uniform across phases (similar percent change).

40 Analyzing Results Confirming the Expected Phase Pattern: 1. High Low High (HLH) Pattern Expected for a 3-legged core type transformer. Expected for a 5-legged core (or shell) type transformer with a Delta connected secondary winding. 2. Low High Low (LHL) Pattern Will be obtained on a 3-legged core type transformer if the traditional test protocals are not followed. Neutral on high side Wye-configured transformer is inaccessible Forget to ground 3 rd terminal on a Delta-connected transformer Expected for a 4-legged core type transformer. 3. All 3 Similar Pattern Expected for a 5-legged core (or shell) type transformer with a non-delta secondary winding.

41 Exciting Current Test Transformer: HV Delta LV - Wye H2 X2 X1 X0 H1 H3 X3 Test HV Lead LV Lead Ground Float Mode Measure Result 1 H1 H3 H2, X0 X1,X2,X3 UST H1-H ma 2 H2 H1 H3, X0 X1,X2,X3 UST H2-H ma 3 H3 H2 H1, X0 X1,X2,X3 UST H3-H ma

42 Exciting Current Test Transformer: HV Wye LV - Delta H2 X2 H1 H0 H3 X1 X3 Test HV Lead LV Lead Ground Float Mode Measure Result 1 H1 H0 NONE X1,X2,X3 UST H1-H ma 2 H2 H0 NONE X1,X2,X3 UST H2-H ma 3 H3 H0 NONE X1,X2,X3 UST H3-H ma

43 Exciting Current Test Transformer: HV Wye LV - Delta Inaccessible Neutral Bushing (H0) X2 H2 H1 H3 X1 X3 Test HV Lead LV Lead Ground Float Mode Measure Result 1 H1 H2 NONE H0,X1,X2,X3 UST H1-H ma 2 H2 H3 NONE H0,X1,X2,X3 UST H2-H ma 3 H3 H1 NONE H0,X1,X2,X3 UST H3-H ma

44 Exciting Current Exciting Current LTC Pattern Reactor Type Exciting Current A B C L 15L 14L 13L 12L 11L 10L 9L 8L 7L 6L 5L 4L 3L 2L 1L N 1R 2R 3R 4R 5R 6R 7R 8R 9R 10R 11R 12R 13R 14R 15R 16R LTC Position OMICRON

45 Demag. Routine Before and After

46 Stacking Arresters Arresters can be found in the following stack options: Pos.4 Pos.5 Pos.4 Pos.3 Pos.3 Pos.3 Pos. 2 Pos.2 Pos.2 Pos.2 Pos. 1 Pos. 1 Pos. 1 Pos. 1 Single Stack Two Stack Three Stack Four Stack Five Stack

47 Dielectric Loss Measurement The Loss measurement can provide valuable information to help identify physical changes, deterioration, moisture ingress, and most importantly help determine suitability for service. Each arrester in the stack should be measured independently Only Watts and Current are measured; Power Factor is not calculated due to the small magnitude of the current Test Arrester Pos 2 10 kv UST Test Equipment

48 Dielectric Loss Measurement The Loss measurement can provide valuable information to help identify physical changes, deterioration, moisture ingress, and most importantly help determine suitability for service. Each arrester in the stack should be measured independently Only Watts and Current are measured, Power Factor is not calculated due to the small magnitude of the current Test Arrester Pos 1 10 kv GST-gA Test Equipment

49 Routine Test The following test should be performed on a routine basis and compared to previous results Routine Tests Visual Inspection Dielectric Loss Measurement Infrared Analysis

50 Analyzing Results The results should be analyzed by the following methods: 1. Previous Test Result 2. Similar Specimens Analyzing Dielectric Loss Results The result should compare to similar arresters. Make sure you are comparing A phase position 1 to B Phase position 1 to C phase position 1, and so on. Typically watts loss measurement are very low under 0.1 watts. Current measurement should compare very close to similar units due to same design and construction

51 Analyzing Results Abnormal Dielectric Loss Measurement (Watts) Silicon Carbide Arrester Metal Oxide Arrester Higher than Normal Losses Contamination located inside or externally Corroded Gaps Crack porcelain housing Higher than Normal Losses Contamination located inside or externally Crack porcelain housing Lower than Normal Losses Broken Shunt Resistor Poor Contact among elements Lower than Normal Losses Discontinuities in internal configuration

52 Example Arrester Test Results

53 IR Surge Arrester Heating Due to Internal Leakage Path 15 C Rise Differential

54 Surge Arrester - ZOOM

55 Leakage Reactance Leakage flux is flux that does not link all the turns of the winding Leakage flux creates reactive magnetic energy that behaves like an inductor in series in the primary and secondary circuits Winding movement changes the reluctance of the leakage flux path, resulting in a change in the expected leakage reactance measurement.

56 Leakage Reactance

57 Leakage Reactance Short circuit LV winding or winding pairs Inject % of rated current 60 Hz (Line-to-Line) A variable 280 VAC source is recommended Measure Series Current and Terminal Voltage RESULT - Z, R, and X There are two ways to perform the measurement 1. 3 Phase Equivalent 2. Per Phase

58 Leakage Reactance 3 Phase Equivalent Short LV terminals; do not include neutral Compare to nameplate +/- 3% Inject Short Measure H1-H3 X1, X2, X3 ZA, RA, XA, LA H2-H1 X1, X2, X3 ZB, RB, XB, LB H3-H2 X1, X2, X3 ZC, RC, XC, LC 1 UNIT 3 UNIT

59 Leakage Reactance Per Phase Short corresponding LV terminals Compare deviation from average Inject Short Measure H1-H3 X1-X0, X1-X3 ZA, RA, XA, LA H2-H1 X2-X0, X2-X1 ZB, RB, XB, LB H3-H2 X3-X0, X3-X2 ZC, RC, XC, LC

60 Leakage Reactance NAMEPLATE

61 Leakage Reactance Example Nameplate: 6.85% 69 kv 12.5 MVA Phase V I Z R X L H1-H H2-H H3-H

62 Insulation Resistance Insulation Check (Main Insulation, Bushings, Core Grounds) Insulation resistance measurements on transformers are normally performed at dc voltages up to 5000 VDC 1. Capacitive Charging Current 2. Absorption Current 3. Leakage Current Temperature Sensitive (Inverse) Polarization Index PI = R(10)min/R(1)min PI for Transformer Insulation < 1.0 => FAIL >1.0 => Acceptable

63 Transformer Turns Ratio Primary winding Np turns + Secondary winding Ns turns Basic Ideal Transformer Circuit Ip Is Np:Ns + Vp Vs L Turn Ratio (N) Equation Np N = Ns Vs = Vp = Vs Np Ns Is = Ip Vp

64 Turns Ratio Test Field Turns Ratio Test obejective Example: Transformer Nameplate Tap Voltage Measure transformer turn ratio of each phase and tap position (Matching Nameplate) HV Winding Measure Phase Angle of the voltage from the high voltage winding and low voltage winding Polarity check is performed as well LV Winding

65 Turns Ratio Test How is it performed? H2 X2 Three Phase Transformer X1 X0 HV 34500GRDY/19920 Volts LV Volts H1 H3 X3 A Phase Test Input Measure Phase Ratio 1 H1-H3 X1-X0 A 2 H2-H1 X2-X0 B 3 H3-H2 X3-X0 C Calculated Ratio = 1.51 Measurement Ratio % Dev Angle % 0.05

66 Turns Ratio Test Procedure Routine Test Should perform turns ratio test on as found DETC positions Unless specified by company or manufacturer Ideally turns ratio test on all LTC positions Place DETC in as found position

67 Analyzing Results The turn ratio measurement results should be within 0.5% of nameplate markings according to IEEE C Results should also compare very closely among phases Any winding open circuits, short circuits and turn to turn shorts will show up change this measurement The phase angle measured between the high voltage and low voltage winding is generally very low. Damage or deterioration in the core will increase the phase angle

68 Turn Ratio OMICRON

69 Turn Ratio OMICRON

70 Turn Ratio OMICRON

71 16R 15R 14R 13R 12R 11R 10R 9R 8R 7R 6R 5R 4R 3R 2R 1R N 1L 2L 3L 4L 5L 6L 7L 8L 9L 10L 11L 12L 13L 14L 15L 16L Exciting Current [ma] Turn Ratio 25.0 Low-Voltage Exciting Current A B C Tap Changer Position OMICRON

72 Turns Ratio Test

73 Turns-Ratio H-X

74 Transformer Winding Resistance One Phase Transformer Equivalent Circuit R1 = Power Loss in HV winding L1= Leakage Inductance of HV Winding Rn = Iron Loss in Core Lm = Core Inductance R2 = Power Loss in LV winding L2= Leakage Inductance of LV Winding

75 Failure Modes A change greater than the criteria mentioned can be indicative of the following: 1. Shorted Circuited Turns 2. Open Turns 3. Defective DETC or LTC (contacts) 4. A Poor Connection Between Terminals Measured

76 Winding Resistance Principle of Winding Resistance Test 1. Inject DC Current from one terminal to the other terminal of a phase 2. Measure the voltage drop across the two terminals under test once core magnetic circuit has stabilized 3. As long as stable voltage DC source is used, winding inductance Xp is negligible. Vp = Ip * Rp Rp = Ip / Vp

77 Winding Resistance Very Important when Performing this test 1. Transformer high voltage and low voltage terminals need to be disconnected and isolated 2. Be aware and use saftey at all time. Make sure the winding is discharged after a test by grounding the terminal. 3. Never inject a DC current higher than 15% of the winding rated current 4. Temperature affects the test results and should be corrected to a common temperature of 75 C or 85 C 5. The temperature of insulated liquid has to be stabilized (top and bottom temperature should not deviate more than 5 C

78 Winding Resistance Test Example of how is it performed? H2 X2 H1 H0 Three Phase Transformer HV 230 Amps LV 350 Amps H3 X1 X3 Winding Temperature 35 C B Phase H2 X2 Factory Result (75 C) DC + + V Ω Measurement H0 Core is neglected X1 Result Corr. %Dev

79 Winding Resistance Temperature Correction Resistance changes with temperature Results have to be corrected to either 75 C or 85 C to be compare Factory or Previous Field Test Formula Cf Rcor = Rm * Tc * Cf * Tw Rcor = Resistance Corrected Rm = Resistance measured Cf = Correction for material [Copper = 234.5, Aluminum 225] Tc = Corrected Temperature Tw = Winding Temperature at Test Previous Example Rcor = * * * 35 Rcor = 0.170

80 Winding ResistanceTest Procedure 1. By performing DC Winding Resistance test, this will magnetize your core. A magnetized core will affect your Exciting Current and SFRA Test Results. 2. Recommended to perform DC Winding Resistance last. 3. Imporant to let the measurement stabilize. Depending on the size of the transformer could take up to several minutes

81 Winding ResistanceTest Procedure Routine Test Should perform test for phases on as found DETC positions DETC should not be moved unless specified by company or manufacturer Ideally test for phases on all LTC positions Place DETC in as found position

82 DC Winding Resistance OMICRON

83 DC Winding Resistance Normal Pattern; but Unique OMICRON

84 DC Winding Resistance OMICRON

85 DC Winding Resistance OMICRON

86 Transformer Nameplate POS Volts LTC X1-X2-X3 A B 9 16R R R R R R R R R M 7R R R R R R R N N L L L L L L L L L L L L L L L L K Connection 7 Common to 14R and 4L

87

88 DC Winding Resistance OMICRON

89 DC Winding Resistance OMICRON

90 Analyzing Results The winding resistance measurement can be evaluated by the following three methods: (+/-5%) 1. Compare to Factory Results 2. Compare to Previous Results 3. Compare Among Phases

91 Thank You for Your Attention

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