TRANSFORMER LIFE MANAGEMENT (TLM) BULLETIN:

Dynamic measurements of on-load tap

changers (OLTC)

A transformer tap changer allows control over the ratio of a transformers output voltage to its input voltage. It is a mechanical device
and one of a transformers few components with moving parts (others including pumps and fans). A tap changer changes the ratio
of transformation by adding or subtracting sections of tap windings to or from the HV or LV main windings of the transformer. A
tap changer may also be used to change configuration of the windings, as provided through the use of a de-energized tap changer
(DETC) one of two (2) classes of tap changers. A DETC must never be moved while a transformer is energized! However, the second
and arguably more indispensable tap changer class, that is, on-load tap changers (OLTC), allows for selection of a ratio change while
the transformer is in service. By varying the transformer ratio under load without interruption, OLTCs enable voltage regulation and/
or phase shifting.
Studies support the case for testing tap changers. [1] There are several tests available to assess the condition of and/or diagnose a
problem in a tap changer , including: exciting current, turns ratio, winding resistance, SFRA, dissolved gas analysis (DGA), continuity,
timing and dynamic measurements.
Static Measurements: Exciting current, turns ratio, winding resistance, and SFRA tests are performed while the OLTC (and DETC) is
stationary at each of a number of selected tap positions. With regard to tap changer diagnostics, these tests are valuable in assessing
the integrity of the additional portions of tap windings included in the measurement, the contacts (e.g., that movable and stationary
are not pitted, have no coking, are not loose, and are fully mating), and, in the case of reactive-type OLTCs, the condition of the
preventative autotransformer (PA), series autotransformer or series transformer, etc. Unlike a resistive-type OLTC, a reactive-type
OLTC uses the bridging position1 as a service position, so when performing a static measurement on an odd numbered tap position,
bridging components are included in the test circuit and are assessable. A resistive type OLTC never spends more than approximately
40 60 ms in a bridging state so when performing a static measurement, bridging components such as diverter resistors are not
included in the test circuit.
Dynamic Measurements (for OLTCs only): Continuity tests, timing tests and other dynamic measurements are performed during
the operation of the OLTC (i.e., while it is executing a tap change). Continuity checks, which verify that contacts make before others
break, have been in use for years. Dynamic measurements on OLTCs, including timing of the operation, are newer and gaining in
acceptance. Most experience with dynamic measurements are with resistive-type OLTCs, which are in widest use worldwide, as
opposed to reactive-type OLTCs, the predominant and widespread use of which is in North America. This bulletin addresses these
dynamic measurements.

Dynamic Measurements of OLTCs

Existing methods and techniques for dynamic measurements on OLTCs are based on measuring current and/or voltage on the
primary side of the transformer (or secondary, depending on which winding the OLTC is associated with2) while often short-circuiting
the secondary (or primary) side to minimize the inductance in the circuit. A new, patent-pending technique is to combine current
measurement with voltage measurements on both primary and secondary sides of the transformer and then use the transformer
parameters to calculate inductive and resistive voltages to be able to calculate the dynamic resistance during a tap change. [2]

A bridging position is a position whereby two consecutive taps are selected at the same time and some form of impedance, resistive
or reactive, is present to limit resulting circulating current.
1

Resistive type on-load tap-changers, common in Europe, Asia, Africa and South America, are connected to the HV winding of the
transformer. Reactive type on-load tap-changers, common in North America, are almost always connected to the LV side of the
transformer.
2

Dynamic measurements of on-load tap changers (OLTC)

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Dynamic measurements of
on-load tap changers (OLTC)
Common for all methods of dynamic measurements on an OLTC is that a current is injected in the tap changer, either in one phase
or all phases, and during the operation of the tap changer, the current and/or the voltage is measured as a function of time. The
test current varies from about 0.1 A to a magnitude that is standard for winding resistance measurements, typically 1 to 10% of the
transformer windings rated current. The test may be performed at the same time as the winding resistance test or as a separate test.
Standard methods are:
nn

Continuity/break-before-make testing

nn

Dynamic measurements

Dynamic current/ripple (often called DRM)

Dynamic voltage (as a means to calculate dynamic resistance)

Dynamic resistance, DRM

Continuity tests (discontinuity detection)

This method is used to detect if there is a break-before-make condition in the OLTC by monitoring current or voltage change. The
measurement is typically performed at the same time as winding resistance measurements and the instrument detects if the contact
switching is continuous or if there is an interruption in the current path.
Open contact detection can be made by current change detection, detecting di/dt changes or detecting voltage change on the
generator output or opposite side of the transformer (i.e. if the tap changer is on the HV side, the detection is performed by
measuring voltage transients on the corresponding LV winding).

Dynamic current measurement

Dynamic current measurement is similar to discontinuity testing. However, in addition to detecting discontinuity, the test current is
measured and the result is presented in a current-time diagram (Figure 1) or as a percentage ripple value. Ripple is the magnitude by
which the test current decreases during the tap change and is expressed as a percentage of the test current, given by:
[(test current) (minimum current measured during tap change operation)]
(test current)

Figure 1. Current-time diagram for operation of a typical diverter

switch (ripple, R, is identified)

The intention is to give a value that describes the conditions during operation and provide contact timing. For example, if the ripple
is uncharacteristically large, this indicates an increase in the resistance of the transition path and/or that the tap operation is slower
than it should be. [3] The percent ripple is plotted for each OLTC transition for all three phases (Figure 2).
Dynamic current measurements depend upon the test current and source impedance of the test set. The core must be saturated
and the current stable before representative and repeatable test results should be expected. If the test is performed at a current level
below saturation level, the inductance in the transformer winding is high and smoothes the current change. If the test is performed
at a current level at or above saturation level, the inductance is low and current level change will be higher [4].

Dynamic measurements of on-load tap changers (OLTC)

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Dynamic measurements of
on-load tap changers (OLTC)

Figure 2. Dynamic Current results, displayed as percent ripple

A method to reduce transformer inductance when performing tap changer measurements is to short-circuit the untested corresponding
LV (or HV) windings. This action is principally replacing the inductance of the winding with the short-circuit impedance. Inductance
is greatly reduced and changes in current can be measured more precisely. Meggers application note, Guide to Transformer Tap
Changer Testing, shows dynamic current measurements on a 30 MVA, 130/46 kV, YNyn0 transformer using different test currents
and with LV windings open and shorted [5], illustrating the inconsistency of the results given differing variables [6].

Dynamic resistance measurement

Dynamic resistance measurement (DRM) tests have been used for circuit-breaker diagnostics for over 20 years. Noting similarities
between an OLTC and a circuit breaker, some understanding of DRMs place in circuit breaker testing may prove useful for the
introduction of this method as a tool to diagnose OLTC problems. When a circuit breaker is in a static position, for example, the
breaker is closed (which is a state the breaker exists in for > 99% of its life), contact resistance measurements are an insightful
diagnostic. Further assessment of how the circuit breaker will behave when it is working (e.g., to break/open the circuit, open
and then immediately close, etc.) is desired too. To this end, timing and motion tests are used to assess a circuit breakers mechanical
condition. When the timing and motion results indicate an abnormality, the dynamic resistance measurement (DRM) test can be
an effective way to further diagnose the internal condition of the breaker contacts. Dynamic resistance measurement (DRM) is an
interesting technique that can also be used to verify the switching operation of on-load tap changers (OLTC).

Dynamic Voltage measurement (to calculate dynamic resistance)

A relatively small test current (0.1 to 1A) is injected through the on-load tap changer using a high-impedance current source and the
LV windings (or HV, i.e., opposite windings of that under test) of the transformer are short-circuited. The voltage over the test circuit
is measured and resistance versus time can be calculated. Contact timing as well as diverter resistor values can be measured and
irregularities (in the diverter resistor values) and interruptions are readily noticed. An example from a 20MVA, 22/10 kV transformer
is shown in figures 3 and 4.

Dynamic measurements of on-load tap changers (OLTC)

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Dynamic measurements of
on-load tap changers (OLTC)

Figure 3. DRM on OLTC, 0.1 A test current, constant current source,

Figure 4. H1 OLTC transition times (ms); 1-2 to 16-17 tap

shorted LV. Current (red); Resistance (blue)

change

Dynamic resistance measurement (with open LV)

A new, patent-pending method is to measure dynamic resistance in the on-load tap-changer by simultaneously measuring the test
current together with voltages on both HV and LV windings and combine the results with transformer modelling. The difference in
this test setup and that for the previous method is that the LV winding is left open. An example of a measurement is shown in figure
5.

Figure 5. DRM on OLTC using a 5 A test current and 10 source impedance ,

[Test current (green); voltage measured across the HV winding (red); voltage
measured across the LV winding (blue), Resistance (black)]

The source impedance in this example is about 10 Ohm and we can see a small current change during the tap change (green trace
in Figure 5). Due to the inductance in the circuit (recalling that for this measurement the opposite or LV winding is left open), the
change in voltage measured across the HV winding (red trace in Figure 5) is rather large. This voltage is a sum of inductive and resistive
voltage and cannot be used for directly calculating the resistance in the circuit. However, the voltage measured across the LV winding
is purely inductive and if we use transformer model parameters to calculate the inductive voltage on the primary, we can deduct this
value from the measured HV winding voltage and calculate the resistance in the circuit. The result is given in figure 5.

Dynamic measurements of on-load tap changers (OLTC)

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Dynamic measurements of on-load tap changers

(OLTC)
References

[1]

Cigre_WG 12-05 An international survey on failures in large

power transformers in service, Electra No. 88, 1983.

[2]

Matz Ohlen, Nils Wcklen, Rene Yvrard, New Techniques for

Dynamic Resistance Measurements on Load Tap-Changers, ISH 18th
International Symposium on High Engineering, Seoul, Korea, 2013.

[3]

Duplessis, J. (2013) Electrical Field Tests for the Life

Management of Transformers, Austria: Omicron

[4]

Dinesh Chhajer and Matz Ohlen, Preventive Maintenance of Transformer

Accessories - Bushings & Tap Changers, WEIDMANN Diagnostic Solutions
Annual Technical Conference, Las Vegas, NV, USA, October 2011.

[5]

J. J. Erbrink et al, Reproducibility of Dynamic Resistance Measurement

Results of On-Load Tap Changers Effect of Test Parameters,
Proceedings of the 2010 International Conference on Condition
Monitoring and Diagnosis, Tokyo, Japan, September 6-11, 2010.

[6]

Megger Application note, Guide to Transformer Tap Changer Testing, 2014.

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