What testing and factory acceptance tests (FAT) are performed on each Power Transformer before delivery?

Before a power transformer leaves the manufacturing facility, it must undergo rigorous testing to ensure safety, performance, and compliance with international standards such as IEC, IEEE, or ANSI. Factory Acceptance Tests (FAT) serve as a critical checkpoint to verify that the transformer operates according to design specifications and is free of manufacturing defects. These tests offer peace of mind for both manufacturers and customers by minimizing the risk of failures during installation or operation.


What Is the Purpose of FAT for Power Transformers?

Before a power transformer leaves the factory, it must undergo a rigorous verification process known as Factory Acceptance Testing (FAT). This is not a formality—it is a critical engineering checkpoint that confirms whether the unit meets the design specifications, safety standards, and functional requirements agreed upon in the contract.

FAT is conducted to validate the electrical, mechanical, thermal, and operational performance of a power transformer before shipment. It ensures compliance with IEC/IEEE standards, confirms that manufacturing tolerances have been met, and provides buyers the confidence that the equipment is free from defects. FAT also allows customer representatives to witness the results and approve the unit before dispatch.

This process reduces the risk of field failure, minimizes site commissioning delays, and is essential for quality assurance in high-voltage equipment procurement.

FAT is an optional procedure and not necessary for power transformers.False

Factory Acceptance Testing (FAT) is a mandatory procedure in most power transformer projects to validate performance, quality, and contract compliance before delivery.


🔍 Key Objectives of FAT

ObjectiveBenefit
Verify performance parametersConfirms no-load loss, load loss, impedance, insulation values
Detect manufacturing defectsIdentifies internal faults, insulation flaws, or assembly errors
Validate contract complianceEnsures ratings, taps, bushings, and materials match P.O.
Demonstrate functional readinessConfirms OLTC operation, relay settings, gauges, alarms
Enable client approvalWitness testing ensures buyer accepts unit before shipment

⚙️ Typical FAT Test Scope (per IEC 60076 & IEEE C57)

Test TypePurpose
Measurement of ResistanceCheck winding resistance symmetry and connections
Turns Ratio & Polarity TestConfirms correct winding configuration and tap accuracy
Insulation Resistance TestEnsures dry and clean insulation environment
Dielectric Strength (Induced & Impulse Tests)Verifies BIL withstand capability
Load Loss & Impedance VoltageMeasures copper losses and leakage reactance
No-Load Loss & Excitation CurrentValidates core quality and magnetic behavior
Temperature Indicators & OLTC Function TestVerifies control systems and moving parts
Partial Discharge TestEnsures insulation integrity under high voltage stress

🧠 Why FAT Is Critical for Buyers

ReasonImpact on Project
Mitigates Installation DelaysIssues are caught at factory, not during energization
Supports Grid ReliabilityReduces risk of early-life failure or misconfiguration
Assures ROI and Warranty ValidityBuyer has documented proof of performance
Simplifies CommissioningFactory-tested devices integrate more smoothly at site
Strengthens Legal Contract EnforcementFAT report becomes binding QC document

🛠️ Optional Additional Tests in FAT (per contract)

Optional TestPurpose
Sound Level MeasurementEnsures noise meets substation limits
Temperature Rise SimulationConfirms thermal limits of windings under load
Core Grounding TestDetects unwanted circulating current paths
Sweep Frequency Response (SFRA)Establishes mechanical integrity baseline
Gas & Oil Leak TestValidates tank welding, gaskets, and oil tightness

🧾 What Happens After FAT?

  1. Test reports are signed by manufacturer and client witness
  2. Corrective actions (if needed) are agreed upon before shipment
  3. Packing list and shipping docs are finalized based on approved unit
  4. Transport insurance is activated after FAT clearance
  5. Site team is briefed using FAT data to prepare for commissioning

💬 Engineer's View

“FAT gives us complete confidence. We verify winding resistance, dielectric strength, and OLTC functionality with our own test instruments. If we catch issues now, we save weeks of downtime later.”
Transmission Project QA Manager, South Asia


What Routine Tests Are Typically Performed on Power Transformers?

Before any power transformer is shipped, it undergoes a set of standardized routine tests, also known as Type R tests per IEC 60076 and IEEE C57. These tests are essential to verify that each manufactured unit meets its nameplate specifications, electrical characteristics, and safety thresholds. They do not involve stress beyond rated levels but focus on validating performance consistency and production quality.

Routine tests on power transformers typically include winding resistance, voltage ratio and polarity, insulation resistance, no-load and load losses, impedance voltage, induced overvoltage, and separate-source withstand voltage tests. These are mandatory for every unit and form the baseline quality record for future maintenance, commissioning, and warranty claims.

Whether a 10 MVA distribution transformer or a 100 MVA transmission unit, routine tests are the factory's assurance of conformity and customer trust.

Routine tests are optional and only performed on request for transformers.False

Routine tests are mandatory under IEC and IEEE standards and must be conducted on every power transformer to verify electrical performance and safety.


🔍 List of Routine Tests Per IEC 60076-1 and IEEE C57

Test NamePurpose
Winding Resistance MeasurementDetects conductor continuity, joint quality, and winding symmetry
Turns Ratio & Polarity TestEnsures voltage transformation accuracy and connection integrity
Insulation Resistance TestVerifies dielectric quality between windings and ground
No-Load Loss and Current TestMeasures core loss and magnetization current at rated voltage
Load Loss and Impedance VoltageEvaluates copper losses and leakage reactance at rated current
Induced Overvoltage TestChecks inter-turn insulation strength under elevated voltage
Separate Source AC Withstand TestAssesses ground insulation withstand with external voltage
Oil Pressure & Leak TestConfirms mechanical tightness and tank integrity (for oil-filled units)

🛠️ Detailed Test Descriptions

TestDescription
Winding ResistanceInjects low DC current into each winding; temperature-corrected to 75 °C
Turns Ratio Test (TTR)Measures voltage ratio across HV/LV terminals and verifies tap accuracy
Insulation Resistance (IR)Uses megohmmeter to test winding-to-ground resistance (typically ≥1000 MΩ)
No-Load LossAssesses iron/core loss at rated voltage under no-load condition
Load LossMeasured with rated current injected; determines total copper I²R loss
Impedance VoltageDetermines short-circuit voltage required to circulate rated current
Induced Voltage TestApplies 2× rated frequency to secondary winding for 1 minute
Separate Source WithstandApplies 1.5× rated voltage to HV or LV winding, grounded opposite terminal

📊 Typical Acceptance Criteria for Routine Tests

ParameterStandard Tolerance
Turns Ratio DeviationWithin ±0.5% of nameplate
Winding Resistance Unbalance≤2% between phases (for identical windings)
IR Value (Dry-type)≥1000 MΩ at 20 °C (varies by voltage)
No-Load Loss (Core Loss)Within specified factory tolerance
Load Loss (Copper Loss)Within guaranteed or specified limits
Leakage Impedance±10% of nameplate value

🧪 Instruments Commonly Used

Instrument TypeUsed For
Digital Micro-ohmmeterWinding resistance
TTR Test SetRatio and vector group confirmation
Megohmmeter (IR Tester)Insulation resistance
Core Loss TesterNo-load loss and excitation current
Load Box + CT/PT SetLoad loss and impedance voltage
High Voltage AC SourceWithstand voltage test

🔁 When Are Routine Tests Conducted?

  • Post-assembly, pre-painting phase (for initial electrical measurements)
  • After full tanking and oil filling (or drying for dry-type)
  • Before Factory Acceptance Test (FAT)
  • After repairs or major component replacements (for revalidation)

💬 Industry Insight

“Routine testing provides our engineering and quality teams with a consistent dataset to confirm that each unit meets its rated electrical behavior. Without it, we’d risk delivering incomplete or unsafe transformers.”
Chief Electrical Engineer, OEM Factory


What Type Tests Are Included in FAT for Power Transformers?

While routine tests confirm that a power transformer was built correctly, type tests validate whether it is designed correctly—capable of operating safely and reliably under real-world electrical, thermal, and mechanical stress. Type tests, typically conducted during FAT (Factory Acceptance Testing) on one or more units of a design family, are specified by IEC 60076 and IEEE C57 standards.

Type tests included in FAT evaluate a transformer’s performance under extreme or prolonged stress conditions and include lightning impulse tests, temperature rise tests, short-circuit withstand verification, and sound level measurements. These tests prove that the transformer design meets safety, thermal, and reliability requirements before mass production or commissioning.

Type testing ensures design validation, especially for new models, special applications, or regulatory compliance.

Type tests are not necessary during Factory Acceptance Testing of transformers.False

Type tests are mandatory for design validation, especially on the first unit of a transformer series, and are often included in FAT per IEC or IEEE standards.


🧪 List of Common Type Tests in FAT (Per IEC 60076-1 / IEEE C57.12.90)

Type TestPurpose
Temperature Rise TestValidates thermal design and cooling system under rated load
Lightning Impulse Withstand TestSimulates high-voltage surges from lightning or switching operations
Sound Level TestConfirms compliance with noise emission limits at no-load
Short-Circuit Withstand TestDemonstrates mechanical robustness of windings under fault currents
Dielectric Type TestsVerifies insulation system under electrical overstress conditions
No-Load Loss vs. Design Curve ValidationConfirms magnetic flux distribution and core optimization
Zero-Sequence Impedance TestRequired for grounding system analysis in certain transformer types

🔬 Type Test Descriptions

TestMethodology
Temperature Rise TestTransformer loaded to rated power for 6–10 hours; winding and top-oil temps measured
Impulse TestApplies standard lightning impulse waveform (1.2/50 μs) at rated BIL (e.g., 950 kV)
Sound MeasurementMicrophones placed at 1 m distance in semi-anechoic space; dB(A) level recorded
Short-Circuit Test (Design Proof)Conducted on prototype unit or simulated via FEM + mechanical test data
Dielectric Strength TestsCombination of induced overvoltage, impulse withstand, and AC withstand tests

📊 Typical Type Test Limits

ParameterIEC/IEEE Threshold (Typical)
Top-Oil Rise (ONAN)≤55 K over ambient
Winding Hot Spot (ONAN)≤65–70 K over ambient
Lightning ImpulseWithstand 650–1050 kV (depending on voltage class)
Sound Level (dB)≤55–60 dB at 1 m distance
Short-Circuit Duration2–3 sec at 25× rated current (simulated or verified)

🛠️ Equipment Used in Type Testing

EquipmentUsed For
HV Impulse GeneratorSimulates BIL waveform for lightning impulse testing
Loading Bank + Current SourcesConducts temperature rise and impedance heat runs
Precision MicrophonesCapture sound level for acoustic compliance testing
Thermocouples/RTDsMeasure hot-spot and top-oil temperatures
FEM Software + Test JigSimulates short-circuit mechanical forces

📋 When Are Type Tests Performed?

  • First unit of a design series (prototype)
  • Custom-built or high-rating transformer (>132 kV or >40 MVA)
  • As per customer contract or grid compliance standard
  • As part of third-party certification or tender qualification

💬 Engineer’s Note

“When we qualify a new transformer model for a national grid, we always insist on full type testing. The impulse withstand and thermal rise test are our benchmarks for long-term operational safety.”
Chief QA Inspector, Middle East Utility


Are Special Tests Required for Customer-Specific Needs in Power Transformers?

While routine and type tests verify standard compliance and core design reliability, some transformer projects—especially for critical infrastructure, renewables, HVDC, or unique grid requirements—demand customized, special tests. These are driven by client-specific operational concerns, grid code requirements, or integration with advanced monitoring systems.

Yes, special tests are often required to fulfill customer-specific needs in transformer projects. These may include tests for inrush current, harmonic generation, ferroresonance behavior, transient response, SCADA integration, insulation coordination simulations, and third-party calibration. Special tests are defined in the contract or technical specification and often tailored to site, utility, or project needs.

They enhance grid reliability, operational predictability, and compliance with emerging standards—especially where transformer behavior affects power quality or protection schemes.

All power transformer tests are fixed by standards and cannot be customized per customer needs.False

Special tests are widely accepted in power transformer projects and can be customized based on utility specifications, site conditions, and integration needs.


🧪 Common Special Tests Requested by Customers

Test NamePurpose
Inrush Current TestMeasures magnetizing surge to size protection relays or breakers
Harmonic Content AnalysisEvaluates core nonlinearity and THD under low voltage excitation
Capacitance and Tan Delta TestDetects aging in insulation and bushings
SCADA/RTU Communication TestVerifies integration of IEDs, sensors, and remote alarms
Zero-Sequence ImpedanceUsed in protection coordination and grounding system design
Ferroresonance SimulationChecks susceptibility to voltage resonance under switching conditions
Magnetizing Curve RecordingGenerates B-H characteristics for power quality modeling
Sweep Frequency Response Analysis (SFRA)Detects winding deformation after transport or faults
Dynamic Short-Circuit SimulationAnalyzes mechanical survivability during fault transients

📋 Contractual Definition of Special Tests

How Tests Are DefinedExample Clauses
Technical Specifications“Supplier shall perform inrush and harmonics tests at LV”
Grid Code Requirements“Transformer must be SCADA-ready with dry contact alarm simulation”
EPC Scope Agreements“All auxiliary relays and RTUs shall be factory-tested for I/O mapping”
Tender Addenda or FAT Protocols“Include dielectric Tan Delta tests on bushings >72.5 kV”

🛠️ Instruments & Setups for Special Tests

Equipment UsedFor These Tests
Current Surge RecorderInrush and peak flux measurement
Power Quality AnalyzerHarmonic spectrum, wave shape recording
Tan Delta MeterCapacitance/dissipation factor of insulation systems
Simulation Relay PanelSCADA integration, IED signal tests, control loop emulation
High-Speed OscilloscopeFerroresonance and switching transient monitoring
SFRA AnalyzerWinding integrity baseline check

📊 Special Tests and Their Strategic Value

TestUsed ByPurpose
SCADA TestUtilities, industrial sitesVerify alarm, I/O, and remote response
HarmonicsRenewable grid operatorsEnsure transformer won’t distort waveform
Tan DeltaNuclear or aging facilitiesPre-commissioning insulation check
SFRAExport transformers, HVDC sitesConfirm no winding movement post-shipping
InrushProtection engineering teamsCT and relay settings

💬 Engineer's Insight

“One of our HV customers required us to prove that the transformer’s harmonic distortion stayed below 2% during low-voltage excitation. Another wanted a full simulation of SCADA command loss. These special tests became the deciding factor in approval.”
FAT Supervisor, OEM Transformer Division


How Are FAT Results Documented and Reviewed for Power Transformers?

Factory Acceptance Testing (FAT) is not complete until the results are formally recorded, verified, and approved by both the manufacturer and the client. These results serve as the official evidence that the transformer complies with contractual specifications and relevant standards. For high-voltage assets, these documents are critical for commissioning, warranty enforcement, and long-term maintenance planning.

FAT results are documented in a structured test report that includes all measured values, test conditions, equipment used, reference standards, deviations, and approval signatures. These reports are reviewed by the supplier’s quality control team and the customer (or third-party inspector) before the transformer is cleared for shipment.

This documentation ensures legal traceability, technical transparency, and quality assurance for every delivered transformer.

FAT results are not officially recorded and are only for internal use.False

FAT results are formally documented, reviewed by all parties, and form part of the official quality and delivery acceptance process in transformer manufacturing.


📋 What’s Included in a FAT Report?

SectionContents
Cover SheetTransformer model, serial number, date, location, PO reference
Test Summary TableList of all tests performed with status (PASS/FAIL)
Measured Values & LimitsActual test data vs. specification (e.g., winding resistance, losses)
Equipment UsedList of test instruments, calibration records
Test ConditionsAmbient temperature, humidity, test voltage, power supply rating
Reference StandardsIEC 60076, IEEE C57, or national standards followed
Customer Remarks & ApprovalsObservations, deviations accepted, witness sign-off
Certificates AttachedCalibration certs, safety compliance, material declarations

🧠 How Are Results Reviewed?

Reviewer RoleResponsibilities
Factory Quality EngineerVerifies completeness and equipment calibration
Test EngineerConfirms data accuracy and explains test setup
Customer QA InspectorWitnesses key tests, raises concerns or accepts deviations
Third-Party Auditor (if any)Ensures adherence to tender specs or regulatory compliance
Project ManagerLogs acceptance milestones and authorizes shipment post-approval

🛠️ Tools Used for Review & Sign-Off

ToolPurpose
Digital FAT DashboardLive or remote monitoring of test values and sequence
Printed FAT Report BookSigned reference document delivered with transformer
Electronic Test Reports (PDF/XML)Shared with ERP or client platforms for traceability
Non-Conformance Report (NCR) FormsRaised if test deviations are outside tolerance
Final Approval CertificateSigned by client to authorize packing and shipment

📊 FAT Documentation Compliance Snapshot

Test ParameterStandardExample Measured ValueResult
Turns Ratio (TTR)±0.5%0.13% deviationPASS
Insulation Resistance (HV-E)≥1000 MΩ1257 MΩPASS
No-Load Loss @ 50 Hz≤1120 W1085 WPASS
Load Loss @ 75°C≤6.5 kW6.3 kWPASS
PD Level≤10 pC5 pCPASS

🔄 Post-FAT Document Handling Flow

  1. FAT Completed
  2. Raw test data collated into report template
  3. QC verifies and signs internal validation
  4. Customer review meeting or remote sign-off
  5. Digital & hard copies shared with customer and site engineer
  6. Report archived for warranty and future diagnostics

💬 Buyer Testimonial

“The FAT report gave us full visibility into how the transformer was built and tested. It included all test results, calibration proof, and even oscilloscope screenshots. This level of detail makes commissioning and grid approval much faster.”
Transmission Utility QA Officer, South America


Can Customers Witness or Participate in the FAT Process for Power Transformers?

Factory Acceptance Testing (FAT) is not only a technical validation stage—it’s a collaborative milestone where customers have the right to witness, inspect, and approve the transformer before shipment. This direct participation ensures transparency, builds trust, and gives buyers confidence that the equipment meets both contractual and operational expectations.

Yes, customers can—and often are strongly encouraged to—witness or participate in the FAT process. During FAT, customer representatives can observe key electrical tests, verify measurements, inspect mechanical assemblies, ask technical questions, and approve the transformer for shipment. Virtual witnessing is also available using live video and digital dashboards when travel is not feasible.

Witnessing a FAT gives customers the opportunity to catch deviations, verify documentation, and gain hands-on understanding of the transformer before commissioning.

Customers are not allowed to witness or participate in transformer FAT.False

Customers are frequently invited to witness or participate in FAT to verify compliance, build confidence, and approve delivery readiness.


🎯 Benefits of Customer Participation in FAT

BenefitDescription
Verification of SpecificationsConfirm nameplate ratings, test parameters, and component models
Transparency & TrustDirect view into manufacturing and test quality
Risk ReductionSpot deviations before shipment; request corrective actions
Familiarization for Site TeamEngineers learn installation, wiring, and protection features
Legal & Warranty ProtectionWitnessed results serve as binding QA documents

🧪 What Customers Typically Witness During FAT

Test CategoryExample Tests Observed
Routine TestsTurns ratio (TTR), winding resistance, insulation resistance
Type Tests (if applicable)Temperature rise, impulse withstand, sound level
Control System ChecksOLTC operation, relay logic, wiring scheme
Protection Device FunctionBuchholz relay, PRD, temperature alarms
Physical InspectionBushings, core clamping, nameplate, gaskets, paintwork

📋 How to Prepare for FAT as a Customer

StepAction Item
Review FAT Protocol in AdvanceGet the test plan from supplier and clarify scope
Assign Qualified EngineersChoose staff with electrical background and project knowledge
Attend Briefing SessionJoin pre-FAT orientation on test safety, sequence, and limits
Bring ChecklistsUse standard observation forms for routine and special tests
Note Deviations for NCRDocument concerns and request corrections before sign-off

🛠️ Tools Provided During FAT for Customers

Tool or FacilityPurpose
Observation DeckSafe, elevated view of testing floor
Real-Time Test ScreenMonitor voltage, current, resistance, and alarms
Hard Copy Test SheetsHandwritten results for witness signature
Digital Report AccessPDF or dashboard summaries of each completed test
Translation or Technical SupportAssist international customers with standards or terms

🌐 Virtual FAT Witnessing Options

FeatureDescription
Live Camera FeedsMultiple angles of test benches and transformer
Shared Test DashboardsReal-time readings of voltage, loss, temperature
Digital Sign-Off ToolsUpload feedback and approve online
Recorded Video ArchiveFull playback for audit or review
Secure VPN Access (if required)Direct login to test control systems

💬 Customer Testimonial

“Being present for the FAT helped us clarify key installation questions and catch a small wiring mismatch in the OLTC panel. The supplier corrected it instantly. It gave us full confidence to approve shipment.”
Utility Commissioning Manager, East Africa


Conclusion

Factory Acceptance Testing is a vital quality control step in the manufacturing of power transformers. By conducting a series of standardized and customer-specific tests, manufacturers like Luneng Taishan ensure that each unit performs reliably from the outset. A well-documented and transparent FAT process enhances trust, ensures technical compliance, and reduces risk during field commissioning and operation. For optimal outcomes, customers are encouraged to engage early and participate in FAT reviews tailored to their project’s specifications.


FAQ

Q1: What is a Factory Acceptance Test (FAT) for power transformers?
A1: A Factory Acceptance Test (FAT) is a comprehensive set of tests conducted at the manufacturing facility before shipment. It verifies that the power transformer meets design specifications, safety standards, and performance criteria as per IEC 60076 or IEEE C57.12 standards.

Q2: What are the routine tests performed during FAT?
A2: Routine tests are mandatory for each unit and include:

Winding resistance measurement

Insulation resistance and polarization index

Voltage ratio and phase displacement

Vector group verification

Short-circuit impedance and load loss

No-load loss and excitation current

Dielectric test (Applied and Induced Voltage)

Partial discharge measurement (for high voltage units)

Q3: What type tests may be included during FAT?
A3: Type tests are performed on one unit per design family, including:

Temperature rise test (heating under full load)

Lightning impulse test (BIL test)

Switching impulse test (for transformers ≥300kV)

Frequency response analysis (to check mechanical integrity)

Sound level measurement
These validate the transformer’s thermal, electrical, and mechanical performance.

Q4: Are any special tests conducted for custom or critical transformers?
A4: Special tests may be requested depending on the contract, including:

Tan delta and capacitance measurement of bushings and windings

Oil Dissolved Gas Analysis (DGA)

Core insulation test

Zero-sequence impedance test

Sweep frequency response analysis (SFRA)
These help assess design integrity, especially for large or grid-critical units.

Q5: What documents and certifications are provided after FAT?
A5: Upon successful testing, manufacturers provide:

FAT report with full test results

Test certificates (calibrated per ISO/IEC standards)

Transformer datasheet and nameplate details

Wiring diagrams and final drawings

Third-party inspection certificates, if required
Customers may witness the FAT onsite or remotely to verify compliance.

References

"IEC 60076 Transformer Testing Standards" – https://webstore.iec.ch/publication/654

"IEEE C57.12 Power Transformer Testing" – https://ieeexplore.ieee.org/document/8456762

"Energy Central: Power Transformer Testing Requirements" – https://www.energycentral.com/c/ee/transformer-factory-testing

"Hitachi Energy: FAT for Utility-Grade Transformers" – https://www.hitachienergy.com/transformer-factory-testing

"Transformers Magazine: FAT Best Practices" – https://transformers-magazine.com/factory-acceptance-tests

"Doble Engineering: Electrical Testing of Transformers" – https://www.doble.com/transformer-diagnostic-tests

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Norma Wang

Focus on the global market of Power Equipment. Specializing in international marketing.

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