Inspection and Test Plan for Power Transformer

The inspection and test plan for power transformer article provides you information
about power transformer test and power transformer inspection in manufacturing shop.
The draft Inspection and test plan provided as well.
Click here if you like immediately review the Inspection & Test Plan for Power
Transformer draft sheet.
You may need to review this sheet in conjunction of Third Party Inspection for Power
Transformer article.
Click following link if you need to review general definition for Inspection and Test Plan.
Inspection and Test Plan
The IEC, NEC, NEMA, FDF, ISO ANSI, CI, IPCEA standard requirements normally are
applied for inspection and test plan in manufacturing shop.
The witness of some inspection and test by third party inspector is mandatory and
cannot be waived.
Some others must only monitored and fully witnessing are not necessary, for these
thing, the inspection man-days etc. depends to the purchaser decision, some prefer
stringent monitoring and even assign resident inspector in manufacturing shop and
some others relay to quality control system of the manufacture and assign only few
days for monitoring points.
These are some of inspection points which need to be witnessed, checked, monitored
and reviewed by third party inspector in Power Transformer manufacture shop.
Inspection and Test Plan for Power Transformer - Important Points

Witness of out of tank inspection, consisting of check of wiring for

adequacy of insulation, cleaning and termination, if tap changer switch
fitted, check for all electrical connections and switch mechanism and check
for identification of winding ends (primary, secondary and phase)

Final inspection after tanking, consisting of witness full tests, including heat
run or standard abbreviated tests as may be specified, check tank seams
for signs of oil leakage, check of handling for cable boxes, size and
quantity of cable glands and position of entries, functionally test alarm
relays, if fitted, for position of contacts, check of all ancillary equipment

fitted as requisitioned, dimensional check to GA Drawing and check for

rating plate and general paint etc.

Click here to see Inspection & Test Plan for Power Transformer draft sheet.

Third Party Inspection for Power Transformer

The Third Party Inspection for Power Transformer article provides you with
information about the power transformer test and power transformer inspection in
the manufacturing shop.
You may need to review this article along with the following article:
Inspection and Test Plan for Power Transformer
This content guides you through all the necessary stages in the production of the
power transformers, including the raw material, final inspection, preservation and
packing, and dispatch to site.
You need to take this point into account: this article is written for a typical power
transformers and might not be detailed for special cases.
This content may be useful for second party inspectors, power transformers
manufacturer quality control personnel, engineering companies, and purchasers,
as well.
All power transformers inspection and testing is done against the approved
drawings, purchase order specifications, purchasers or company standards, and
within the practices and rules of the country, state or province and any
government decrees, laws, ordinance or regulation as may apply.

The applicable codes and specifications for a power transformers that is under
the construction process is:

Design code

Purchase order specification

Purchaser's standards

Approved drawings

The applicable codes and standards may be based on any international standards. This
content is general and can be useful for all recognized standards.
Required Documents for Third Party Inspector Review:
The list of documents normally is agreed upon in the Pre-Inspection meeting, which is
held several weeks before the actual commencement of the inspection work. The
parties that participate in this meeting are the manufacturer, purchaser and third party
inspection agency representatives.
This is already explained in the Inspection and Test Plan for Power Transformer article.
These are the list of documents that are normally agreed upon to be presented to the
inspector:

Power Transformer Purchase Order or Contract

Power Transformer Manufacture Quality Control Plan

Power Transformer Inspection and Test Plan

Power Transformer Data Sheet

Power Transformer Approved Drawings, (arrangements, schematics, wiring,

single line)

Power Transformer Weld Procedures and Procedure Qualification Records (if

applicable)

Power Transformer Material Test Reports

Power Transformer Calibration Certificates for Test Equipment

Power Transformer Special Procedures

Power Transformer Special Qualifications

Power Transformer Preparation and Painting/finishing Procedure

Power Transformer Preservation, Packing and Shipping Procedure

Power Transformer Packing List

Third Party Inspection for Power Transformer-Material Inspection

The first actual inspection work in the power transformers is the raw materials
inspection.
The original or authenticated copies of mill certificates of material normally are available
at the manufacturer's premises.
The third party inspector examines these certificates for compliance with specifications,
and where appropriate, drawings.
The review includes checks on:

Makers name and location

Certificate number, grade

Batch number

Chemical composition

Cast number (for metal parts)

Heat treatment condition

Surface finish

Structural observations, notable defects

Ancillary items may be supported by test certification, or by certificates of conformity. It

is necessary the content of certification to be appropriate to the required scope of the
items. Instruments normally are supported by instrument calibration records.
Then the inspector witnesses the materials identification on the certificates against the
materials marking. It is also necessary to check these with the power transformers
drawing datasheet, material list and other specifications as appropriate.
Visual inspection for surface finish and probable defects is done and dimensional
compliance with specification need to be controlled, as well.
When the third party inspector carries out the material inspection, then provides the
inspection visit report (IVR), the report contains the following items:

Confirmation of satisfactory document review

Record of the endorsement of certification reviewed/witnessed

Record of all non-conformities

Record of any tests witnessed and the result

Third Party Inspection for Power Transformer Fabrication

When the power transformers raw material inspection is carried out, and the results
were satisfactory or non-conformities were closed by remedial action, then the power
transformers manufacturer will start fabrication.
The third party inspector checks the following points on the power transformers, based
on the inspection and test plan (ITP), which has already been agreed upon between the
purchaser and the power transformers manufacturer.
The inspection scope is determined in the ITP. Some purchasers prefer to have
stringent controls and assign the TPI for more hold or witness points for inspection and
test activities, and some others prefer less hold or witness points and assign the TPI
much more work in the review document.
This depends in the inspection budget, which purchasers assign for inspection. Much
more inspection will have a much larger cost and less risk, and conversely, less
inspection will have less cost but more risks.

For more details, review the Inspection and Test Plan for Power Transformer
article. There is a draft of the ITP in this article, which we believe is the best
practice for power transformers inspection.
The third party inspector checks following in accordance of approved drawings
and applicable standards:

Fabrication, protective finishes and cleanliness of all tank areas and of formers
and frames

Correctness of windings, terminations, insulation, spacing and general

construction

Freedom from damage (with particular attention to insulation), contamination and

foreign objects

Manually check security of wedges

If the third party inspector is not in the hold or witness point in the ITP for this
inspection stage, then he/she will review the power transformers manufacturer
quality control report in his/her coming visit or on the final inspection day.
Third Party Inspection for Power Transformer - Construction Check
The third party inspector checks following in accordance of approved drawings
and applicable standards:
Paint using specified colour swatch, measure thickness, if specified
Name plate
Outline dimensions, interface dimensions and clearances and other
specified dimensions
Similarly, If the third party inspector is not in the hold or witness point in the ITP
for this inspection stage, then he/she will review the power transformers
manufacturer quality control report in his/her coming visit or on the final
inspection day.
Third Party Inspection for Power Transformer - General Arrangement Check
The third party inspector checks that all instruments, terminal boxes,
compartments, control switches etc. are correctly rated and are correctly located,
with specified labelling

The inspection is done based of approved drawings.

Similarly, If the third party inspector is not in the hold or witness point in the ITP
for this inspection stage, then he/she will review the power transformers
manufacturer quality control report in his/her coming visit or on the final
inspection day.
Third Party Inspection for Power Transformer - Winding Resistance Test
Resistance of all windings are measured, with winding temperature at recorded
ambient, using a milliohmeter and acceptance criteria is power transformer
datasheet.
Similarly, If the third party inspector is not in the hold or witness point in the ITP
for this inspection stage, then he/she will review the power transformers
manufacturer quality control report in his/her coming visit or on the final
inspection day.
Third Party Inspection for Power Transformer - Winding Ratios Test
Primary to secondary winding ratios, for each phase, for all tappings are
measured using a ratiometer and acceptance criteria is power transformer
datasheet.
Similarly, If the third party inspector is not in the hold or witness point in the ITP
for this inspection stage, then he/she will review the power transformers
manufacturer quality control report in his/her coming visit or on the final
inspection day.
Third Party Inspection for Power Transformer - Temperature Rise Test -Type
Test
The transformer is subjected to full load current at rated voltage (various loading
methods may apply), with normal tap selected, with monitoring of oil
temperature (lower and upper); cooling air temperature measured by at least 3
thermometers in liquid providing a time constant of 2H, placed at 1 to 2 metres
from the cooling surface for Air Natural cooling (for Air Forced cooling, the
thermometers should be within the air input flow, at 1 to 2 metres).
Conditions are maintained until oil temperature stabilises (generally specified as
less than 3C rise in 1 hour).
Winding temperatures are then ascertained using the resistance method:
T2= R2/R1(235+T1)-235 for copper

Where R1 is the cold resistance and R2 is the resistance, with cooling curve
corrections applied, after switching off.
Acceptance criterion is in according of applicable specification and datasheet.
Similarly, If the third party inspector is not in the hold or witness point in the ITP
for this inspection stage, then he/she will review the power transformers
manufacturer quality control report in his/her coming visit or on the final
inspection day.
Third Party Inspection for Power Transformer - Load Loss Test (Copper
Loss)-Type Test
Shorting links are applied (either to the primaries or to the secondaries,
dependant on test supply voltages). Voltage supply is applied to the opposing
windings and increased until rated current is achieved. Input and output powers
are measured and loss calculated.
Acceptance criterion is in according of applicable specification and datasheet.
Similarly, If the third party inspector is not in the hold or witness point in the ITP
for this inspection stage, then he/she will review the power transformers
manufacturer quality control report in his/her coming visit or on the final
inspection day.
Third Party Inspection for Power Transformer - No Load Loss Test (Iron
Loss)-Type Test
Rated voltage is applied to primaries or secondaries, with the opposing windings
open circuit. Input and output powers are monitored and loss calculated.
Acceptance criterion is in according of applicable specification and datasheet.
If third party inspector is not in hold or witness point for these stages, then will
review power transformer manufacture quality control report in his/her coming
visit or in final inspection day.
Third Party Inspection for Power Transformer Efficiency Type Test
Efficiency is calculated from the losses.
Third party inspector reviews the calculation in manufacture quality control
records.
Third Party Inspection for Power Transformer - Induced Overvoltage
Withstand Test (Overpotential Test)

There are three methods; dependent on winding category, the test would be
acceptable if no collapse occurs in test voltage.
Similarly, If the third party inspector is not in the hold or witness point in the ITP
for this inspection stage, then he/she will review the power transformers
manufacturer quality control report in his/her coming visit or on the final
inspection day.
Third Party Inspection for Power Transformer - Dielectric Test
Test requirements vary with winding category and acceptable level is in
according to applicable standard.
Similarly, If the third party inspector is not in the hold or witness point in the ITP
for this inspection stage, then he/she will review the power transformers
manufacturer quality control report in his/her coming visit or on the final
inspection day.
Third Party Inspection for Power Transformer Separate Source Voltage
Withstand Test
A single phase AC voltage of power frequency (not less than 80% of the rated
frequency) is applied. Peak value is measured. The peak value x sq. rt.2 = test
value. The voltage is gradually increased from 1/3 vale and sustained for 60
seconds.
The test is applied between each winding and the terminals of all other windings,
core, frame and tank, all connected together to earth.
The test would be acceptable if no collapse occurs in the test voltage.
Similarly, If the third party inspector is not in the hold or witness point in the ITP
for this inspection stage, then he/she will review the power transformers
manufacturer quality control report in his/her coming visit or on the final
inspection day.
Third Party Inspection for Power Transformer - Ancillaries Test
Ancillaries normally include Buchholz oil pressure protection, temperature
monitoring devises and ancillary wiring. These are checked as conforming to
drawings. Wiring is subjected to insulation test, where appropriate and withstand
test, where appropriate.
Similarly, If the third party inspector is not in the hold or witness point in the ITP
for this inspection stage, then he/she will review the power transformers

manufacturer quality control report in his/her coming visit or on the final

inspection day.
Third Party Inspection for Power Transformer - Reporting
The third party inspector provides an Inspection Visit Report (IVR) after each
visit, as well as a final report summarizing the activities carried out during the
power transformer production in accordance with the contract requirements and
circulated within the time limits specified in the contract.
The report is in the format required by the client and clearly indicates final
acceptance or rejection of the power transformer.
Third Party Inspection for Power Transformer - Release Note
When required by the contract or purchase order, a release note is issued by the
third party inspection agency and given to the manufacturer when the power
transformers have been accepted.
Third Party Inspection for Power Transformer - Packing, Marking and
Shipping
The following points are checked by the third party inspector:

Verify that the packing materials conform to specifications and accepted

practice for the mode of transport.

Verify protection against humidity, abrasion, distortion and other damage

Verify shipping marks to marking instructions and record.

Verify handling marks.