Impulse Testing Techniques and Failures of Power Transformers

IMPULSE TESTING OF
TRANSFORMERS
Dharmesh. Y
High Voltage Division
Central Power Research Institute
Bangalore
26th October 2018

Seminar on Transformer Technologies, Best Design Practices,
Standards and Testing Techniques
OVERVIEW
• Introduction
• Surge Phenomenon in Winding
• Recommended Impulse Test Connections
• Impulse Generation Issues
• LI test procedures
• SI test procedure
• Std. presented different failure cases
• LI testing of Transformers Case Studies with
TF&CF analysis
26 October 2018 Central Power Research Institute
Bangalore
INTRODUCTION
System generated over voltages

-Continuous, Transient(Switching)
Nature generated over voltages

-Lighting over voltages

Bangalore
Table 1 – Classes and shapes of overvoltages, Standard voltage shapes and Standard withstand voltage tests

Bangalore
SURGE PHENOMENON IN WINDING
g g
s
g g

Bangalore
SURGE PHENOMENON IN WINDING
Simple Equivalent Circuit

Bangalore
SURGE PHENOMENON (Initial: t=0+)
𝑑2 𝑒 1 𝐶𝑔 𝑙−𝑥
𝑐𝑜𝑠ℎ 𝛼 𝐶𝑔 Capacitance between winding and ground
− 𝑒=0 𝑙 𝛼=
𝑑𝑥 2 𝑙 2 𝐶𝑠 𝑒 = 𝐸0 𝐶𝑠 line end and neutral end
cosh(𝛼)

Bangalore
SURGE PHENOMENON (Initial: t=0+)
𝑑2 𝑒 1 𝐶𝑔 𝑙−𝑥
𝑐𝑜𝑠ℎ 𝛼
− 𝑒=0 𝑙
𝑑𝑥 2 𝑙 2 𝐶𝑠 𝑒 = 𝐸0
cosh(𝛼)

Bangalore
SURGE PHENOMENON (After t=0+)
𝒅𝟒 𝒆 𝑳 𝑪𝒔 𝒅𝟒 𝒆 𝑳 𝑪𝒈 𝒅𝟐 𝒆 𝒙 𝟐𝝅𝒏𝒙
− + =𝟎 𝒆 = 𝑬𝟎 − 𝑬𝒏 𝒔𝒊𝒏 𝒄𝒐𝒔𝝎𝒏 𝒕
𝒅𝒙𝟒 𝒍𝟐 𝒅𝒙𝟐 𝒅𝒕𝟐 𝒍𝟒 𝒅𝒕𝟐 𝒍 𝒍
Bangalore
SURGE PHENOMENON (After t=0+)
𝒅𝟒 𝒆 𝑳 𝑪𝒔 𝒅𝟒 𝒆 𝑳 𝑪𝒈 𝒅𝟐 𝒆 𝟐𝝅𝒏𝒙
− + =𝟎 𝒆 = 𝑬𝟎 − 𝑬𝒏 𝒄𝒐𝒔 𝒄𝒐𝒔𝝎𝒏 𝒕
𝒅𝒙𝟒 𝒍𝟐 𝒅𝒙𝟐 𝒅𝒕𝟐 𝒍𝟒 𝒅𝒕𝟐 𝒍
Bangalore
INFERENCES
Voltage distribution is not uniform
Voltage distribution varies with 𝛂 (design

parameter)
Voltage distribution varies with time
Voltage distribution depends on type of connection

at other end(neutral end) of the winding.
Bangalore
METHODS TO IMPROVE INITIAL VOLTAGE
DISTRIBUTION
• Co-ordinated insulation on the windings where the

insulation is proportional to control and to withstand
the surges which appear across it.
• Increasing Cs by interleaving winding conductors

or adding capacitors in parallel with the winding
• Neutralizing Cg by electrostatic shields
• Connecting nonlinear resistors in parallel with the

winding.
Bangalore
Lightning Impulse Test Connections
3 phase auto transformer

winding connections
Bangalore
Switching Impulse Test Connections
Fig.(a)
Fig.(b)

Bangalore
Lightning Impulse Test Waveforms
 Based on data compiled on natural lightning by
AIEE and NEMA, it was concluded that system
disturbances were best represented by THREE
basic waveforms-
 Full wave
 Chopped wave
 Front-of-wave
 Standards stipulate, both shape and level of
voltages, to be used in a HV impulse test
 Apparatus are to be tested by these waveforms
Bangalore
Stresses and Test Waveforms
 The three waves are different in shape, duration and
rate of rise & fall, so, produces different stresses
 FW 
 relatively long-duration causes major oscillations
to develop in winding and hence stresses large
portions of winding & between winding & ground
 CW 
 because of rapid dv/dt (rise, fall) stresses turn-
turn and disk-disk insulation

Bangalore
HV Impulse Generation - Basics

Bangalore

Bangalore

Bangalore
Tests for Different Rating Transformers
Um ≤ 72.5 kV 72.5 kV < Um Um > 170 kV

Rating ≤ 170 kV
Test
Full wave lightning impulse test for the
line terminals (LI)
Type Routine ---
Chopped wave lightning impulse test
for the line terminals (LIC)
Special Special Routine
Lightning impulse test for the neutral
terminals (LIN)
Special Special Special
Switching impulse test for the line
terminal (SI)
--- Special Routine

Bangalore
LI Parameter Definition as per IEC 60060-1
Vtest±3%, T1±30%, T2±20%, Overshoot≤10%

T1: 1.2𝛍s, T2: 50𝛍s
Bangalore
LI Parameter Definition as per IEC 60060-1
Vtest±3%, T1±30%, Overshoot≤10%, 0<Undershoot<30%

T1: 1.2𝛍s, TC: 2 to 5𝛍s

Bangalore
Practical Difficulties
 Double-exponential waveforms are far too idealistic

 Can be generated ONLY for purely capacitive test
objects, and under controlled lab conditions
 Practical difficulties encountered during waveform
generation (e.g. during test on transformers) are-
 Stray Inductances
 Large Loops
 Ground Transients
 Single Point Grounding
 Actual HV impulses are often superimposed with
• - Oscillations, Overshoot and Noise !!

Bangalore
LI Waveform Generation Issues

Bangalore

Bangalore
Energy Requirement of Generator

Bangalore
Wave form relaxations in the Standard
• For Chopped LI test - T1≤2.5𝛍s
• With agreement between manufacturer and

purchaser the T2 can be less than 40 𝛍s.
• Minimum tail time should be 20𝛍s≤T2 (Vtest should be

increased by 1% for each 2𝛍s less than the 40𝛍s)
• For Um˃800kV rating transformers winding the

T1>2.5 𝛍s (with agreement)

Bangalore
LI test sequence
Test type IEC/IEEE
RFW
Full wave 3 no. of FW
RFW
FW
Chopped
wave test RCW
2 no of CW
2 no of FW
RFW: Reduced Full Wave(50-70% of BIL)

FW: Full Wave (100% of BIL)
RCW: Reduced Chopped Wave(50-70% of BIL)
CW: Chopped Wave (110% of BIL)

Bangalore
LI test sequence on
Transformers with non-linear elements
Full Wave Test
a) one reference impulse  50% to 60% of BIL
≥10% of BIL
b) one reference impulse 60 % to 75 % of BIL
≥10% of BIL
c) one reference impulse 75 % to 90 % of BIL
d) three consecutive 100 % full wave impulses
e) a comparison impulse APA the same voltage as c) above
f) a comparison impulse APA the same voltage as b) above
g) a comparison impulse APA the same voltage as a) above

Bangalore
LIC test sequence on
Transformers with non-linear elements
Chopped Wave Test
a) One reference impulse  50% to 60% of BIL
≥10% of BIL
b) One reference impulse 60 % to 75 % of BIL
≥10% of BIL
c) One reference impulse 75 % to 90 % of BIL
d) One full wave of 100% BIL
e) Two chopped waves of 110% BIL
f) Two full waves of 100% BIL
g) a comparison impulse APA the same voltage as c) above
h) a comparison impulse APA the same voltage as b) above
i) a comparison impulse APA the same voltage as a) above

Bangalore
Tap position under LI test
If Tap rang is <±5% and transformer rating ≤2500kVA then
Test shall be conducted at Principal tapping
LI test on neutral terminal

 Only Full Wave LI test
 The allowable T1≤13𝛍s

Bangalore
Switching Impulse
T1 ≥ 100uS, Td ≥ 200uS, T2 ≥ 500uS

Bangalore
Switching Impulse
• The impulses are applied either directly or

inductively
• In a three-phase transformer,
Utest ( line-line) ~ 1.5 Utest (line-earth)
• Lower level opposite polarity shots shall

be applied to avoid saturation of the core
and change in the wave form
• sudden collapse of voltage or discontinuity in
the voltage or current
Bangalore
Measurement and Recording of
Impulse waveforms
 Lightning Impulse
• Voltage waveforms (There should not be any
terminating resistance at digitizers)
1. CW: 5 to 10𝛍s
2. FW: 50 to 100𝛍s
• Earth current waveforms (There should be 75ohms

terminating resistance at digitizers) : 100 to 600𝛍s
 Switching Impulse
• Voltage waveforms (There should not be any
terminating resistance at digitizers): 1000 to 3000𝛍s
(should cover first zero crossover point)
Bangalore
Std. reference of failed cases-LI Full Wave
Voltage Earth current
Line-to-neutral breakdown across high-voltage winding of 400 kV

generator transformer

Bangalore
Std. reference of failed cases-LI Full Wave
Earth current
Voltage
interlayer breakdown in coarse-step tapping winding of a 400/220 kV

transformer

Bangalore
Std. reference of failed cases- LI Full Wave
Earth current
Voltage
Breakdown short-circuiting one section of the fine-step tapping winding of a

220 kV transformer

Bangalore
Std. reference of failed cases- LI Full Wave
Earth current
Voltage
Breakdown between parallel conductors of a main high-voltage winding

of a 220/110 kV transformer

Bangalore
Std. reference of failed cases- LI Chopped Wave
Earth current
Voltage
Breakdown between turns in the main high-voltage winding of a 115 kV

transformer

Bangalore
LI Chopped Wave with identical chop timings

Impulses at different voltage levels with identical times to chopping
when testing a 115 kV transformer

Bangalore
LI Chopped Wave with different chop timings

Effects of differences in times to chopping when testing a 220 kV transformer

Bangalore
SI test
Satisfactory test on a 400 kV three-phase generator transformer

Bangalore
SI test
Breakdown by axial flashover of the main high-voltage winding of a 525 kV

single-phase, generator transformer

Bangalore
CASE 1

Bangalore
CASE 1

Bangalore
CASE 1

Bangalore
CASE 1
Reduced Full Wave: 1st Shot

Last Full Wave: 7th Shot

Bangalore
CASE 2

Bangalore
CASE 2

Bangalore
CASE 2

Bangalore
CASE 2

First Full Wave: 2nd Shot

Bangalore
CASE 2

Full Wave: 6th Shot

Bangalore
CASE 2

Last Full Wave: 7th Shot

Bangalore
DISCUSSIONS
&
CLOSURES
Bangalore

Impulse Testing Techniques and Failures of Power Transformers

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IMPULSE TESTING OF

26th October 2018

System generated over voltages

Nature generated over voltages

High Voltage Division

High Voltage Division

High Voltage Division

Simple Equivalent Circuit

High Voltage Division

High Voltage Division

High Voltage Division

Voltage distribution is not uniform

Voltage distribution varies with 𝛂 (design

Voltage distribution varies with time

Voltage distribution depends on type of connection

• Co-ordinated insulation on the windings where the

• Increasing Cs by interleaving winding conductors

• Neutralizing Cg by electrostatic shields

• Connecting nonlinear resistors in parallel with the

3 phase auto transformer

High Voltage Division

High Voltage Division

High Voltage Division

High Voltage Division

High Voltage Division

Um ≤ 72.5 kV 72.5 kV < Um Um > 170 kV

High Voltage Division

Vtest±3%, T1±30%, T2±20%, Overshoot≤10%

Vtest±3%, T1±30%, Overshoot≤10%, 0<Undershoot<30%

High Voltage Division

 Double-exponential waveforms are far too idealistic

High Voltage Division

High Voltage Division

High Voltage Division

High Voltage Division

• With agreement between manufacturer and

• Minimum tail time should be 20𝛍s≤T2 (Vtest should be

• For Um˃800kV rating transformers winding the

High Voltage Division

RFW: Reduced Full Wave(50-70% of BIL)

High Voltage Division

High Voltage Division

High Voltage Division

LI test on neutral terminal

High Voltage Division

High Voltage Division

• The impulses are applied either directly or

• Lower level opposite polarity shots shall

• Earth current waveforms (There should be 75ohms

Voltage Earth current

Line-to-neutral breakdown across high-voltage winding of 400 kV

High Voltage Division

interlayer breakdown in coarse-step tapping winding of a 400/220 kV

High Voltage Division

Breakdown short-circuiting one section of the fine-step tapping winding of a

High Voltage Division

Breakdown between parallel conductors of a main high-voltage winding

High Voltage Division

Breakdown between turns in the main high-voltage winding of a 115 kV

High Voltage Division

Voltage Earth current

High Voltage Division