A

PROJECT REPORT
On

Transformer Testing and Repairing.

Submitted to

STATE BOARD OF TECHNICAL EDUCATION

&TRAINING
in Partial Fulfillment for the award of

DIPLOMA
IN
“ELECTRICAL AND ELECTRONICS
ENGINEERING”
Submitted by

G.ANIL (16002-EE-028)

JAWAHARLAL NEHRU GOVERNMENT POLYTECHNIC COLLEGE,

RAMANTHAPUR, HYDERABAD
2016-2019
 J.N GOVT POLYTECHNIC
RAMANTHAPUR – 500013
Electrical and Electronics Engineering.

Certificate

This is to certify that MR.GUNDA ANIL S/o G.ODELU bearing

PIN 16002-EE-028 is a student of Diploma in Electrical &
Electronics Engineering , J.N Govt Polytechnic, Ramanthapur,
R.R.Dist 500013, has undergone six (6) months training from 05-11-
2018 to 03-05-2019 in K.R.K. POWER TRANSFORMERS PVT.
LTD. Hyderabad, as partial fulfillment of Industrial Training which
is prescribed for VI semester C-16 Curriculum by State Board of
Technical Education and Training, Telangana State, Hyderabad.

In-charge Industry/Organisation
Signature with Seal
Head of Section Principal
 DECLARATION

We here to declare that, this dissertation titled, “TRAINING

IN TRANSFORMER TESTING AND REPAIRING” embodies
the report of our project work carried out during Diploma Third year
VI semester, 2019, and has not submitted previously for any degree
or diploma by me to any other institution.

BY:
G.ANIL (16002-EE-028)
 ACKNOWLEDGEMENT

We have done the Project entitled,

“TESTING AND REPAIR OF POWER
TRANSFORMERS” at, Industrial Development Area ,
Uppal, Hyderabad, 500039. We thank Mr. K.RAVI KIRAN
(Manager) and our supervisors AVINASH AND PRAMOD at
workshop for making project possible and also our internal guide
for valuable suggestions.

We also thank our Head of the Department

Mrs. P. BHARATHI for allowing us to complete the project
in time successfully. We take this opportunity to express our
in datedness to all people who have cooperated and
encouraged us to transform our ideas into practical form.

We also thank all employees of “K.R.K POWER

TRANSFORMERS PVT. LDT.” Hyderabad for their co-
operation throughout the project for helping us to complete
our project.
 INDEX
CHAPTERS DESCRIPTION

1. MANUFACTURING PROCESS,
QUALITY ASSURANCE PROGRAM
MANUFACTURING PROCESS & TESTING

2. DESCRIPTION OF EQUIPMENT AND

ACCESSORIES OF TRANSFORMER

3. TRANSPORT OF TRANSFORMER

4. FINAL COMMISSIONING CHECKS OF

TRANSFORMER

5. MAINTENANCE & OPERATION

 Chapter 1

QUALITY ASSURANCE PROGRAM:

SL No. Name of the component Characteristics is exercited Remark

and isso indicate type
quantum of check
1 Aluminum/Copper conductor i) Dimension Three places in every bobbin
ii) Electrical Once in every lo
conductivity
2 Insulating paper Dielectric Dielectric strength of paper Every lot
strength of paper
3 Core laminations Dimension Thickness of few laminations
& stack will be checked for
each lot
4 MS Plate and sections Dimension For each job
5 Press Board & Parma Wood i) Dimension 10% of the lot recived
ii) Physical
properties
(Density, tensile
strength, received
compressibility, of
absorption shrinkages)
6 a) Copper contacts. i) Surface finish Each piece will be examined
ii) Dimension
iii) Contact surface.
7 nsformer Oil. i)Moisture content. Few samples will be taken
ii) Dielectric Strength and tested

8 Radiator i)Strength & leal Each Radiator

ii) Dimension Each Radiator
9 Tank Conservator & Steel i)Checking of major weids ON each tank
fabricated. ii) Dimension items. Iii)
Vacuum test of leak

10 Core Pre core losses and EDV Each job will be teased
11 Winding i) Checking of dimension. Each coil
ii) i Tightness of HV LV
winding
iii)Checking of paper sit
Each coil dimension
iv) Checking of spacer and
their Each coil spacing
v) checking for pre-
shrinkages Each coil and pre
stressing
12 Drying i)Drying process Every job
ii)Oil (only dielectric Every job
strength & moisture content
to be measured.)
13 Other components Check insulation for channel Every job
14 After assembly Winding axial heights Every job
ii) Electrical and end Every job
clearance

CHAPTER 2

DESCRIPTION OF EQUIPMENT & ACCESSORIES OF TRANSFORMER GENERAL :

The transformer an oil filled equipment conforming to IS:2026 with ONAN ONAF or
ONAN/ONAF OFAF type cooling condition. Transformer is provided with radiators. fans. pumps,
OPWE coolers depending upon their cooling conditions. Radiators are clothes directly mounted on
the tank or on headers. It is equipped either with OLTC 0 off circuit switch depending upon
requirement for variation of HV or LV voltage

TRANSFORMER:
CORE:

The magnetic circuit is three limb or three limb plus two auxiliary limb type. Each limb being
mixed with top and bottom yokes. The laminations are made from high grade non aging cold rolled
grain oriented silicon alloy steel. The insulation of lamina tion is of carlite coating. The core has
stepped cross section. The tubes are clamped with end frames by yoke bolts or by fibre glass tape
and limbs are clamped by means of fibre glass tape over clamp plates. For iting the core with
winding assembly, four numbers of Lifting lugs are provided on end frame cover The yoke bolts,
end frames, clamp plates and core are insulated from cach other to withstand a test pressure of 2
KV .ms at 50 HZ for one minute.

WINDINGS POWER TRANSFORMERS :

Windings are arranged in concentric formation with lowest voltage winding next to the core. In
case, tertiary winding is arranged then this winding Is placed next to the core Over LV winding

HV tapping & HV main winding are placed. Sometimes, tapping winding is placed after HV main
winding depending upon requirement of impedances between various windings. Various type of
windings used for making coils are as follows.
Tertiary winding spiral/helical
Low voltage helical/disc
High voltage Partially interleaved disc/winding or disc winding
Tapping windings Intertwined spiral or helical coil. Interleaved disc
or ordinary disc Paper covered Insulated copper strips or continuously transposed cables are used
for making winding. Windings are dried in a oven and compressed before assembly and remain in
compressed position by means of clamping bolts.

CORE WINDING ASSEMBLY

LV. HV and Tapping Windings are placed on core limbs. Adequate insulation and winding ducts
are provided between core to winding and between windings. High voltage winding leads are taken
out from the top of the 11V winding or from the centre wherever two parallel coils anangement is
adapted. Leads are rigidly secured and terminated to voltage regulating device or bushings.

TERMINAL ARRANGEMENT
 Bushings are of OJP condensor type or porcelain type depending upon the voltage class. For
details of OIP bushings reler Instruction book enclosed. For dimensional details and rating of
bushing refer drawing enclosed.

CURRENT TRANSFORMERS

a) Current Transformer for winding temperature indicator are provided on Windings of the
transformer at either the terminals or on the bus bar of terminal. The secondary winding of
the current transformers are connected to a terminal box through Epoxy Bushing Current
transformer terminals from terminal box are wired to winding temperature indicator mo in
marshalling box
b) CT. for Protection purpose are provided in the HV. Turet & Secondary Tenninals are
brought out through Epoxy bushings.
c) The Neutral CT. is provided for REF. protection. The CT. will be either mounted in side of
the turret or outdoor on the tank

TANK
 The tank is of welded mild steel plate construction sand/shot blasted on inside outside to
remove scale before painting. Tanks are designed to withstand a vacuum in line with CBIP
recommendation on Transformer. On the outside oil is applied with anticorrosive primer paint
and final coat of synthetic enamel to shade No. 631, 632 of IS-5
The cover is cither bell type or flat and remains mounted on the top of the tank or bolted to the
bottom tank rim. Adequate number of inspection covers are provided. To make joints oil tight
neoprene bonded cork or nitrile rubber gasket are used. The gasket are cut to size and shape
and where required joints are provided on the gaskets.

Bidirectional flanged rolleis suitable for moving the transformer on rail guage are provided.
The direction of rollers can be changed by jacking up the assembly. Dirce tional flanged rollers
can be locked la required direction by botting. The tank is provided with all the things and
accessories as per the list given in GA drawing

COOLING EQUIPMENT

The transformer is having either single or mixed cooling of OFWE OFAP. ONAF and ONAN
Radiator, Fan, Pumps Heat Exchangers are tied depending upon diligent type of cooling Fans
with wire mesh are mounted on separate lines supported fx either tank wall on A

CONSERVATOR
As the temperature of oil increases or decreases during operation there is a cone sponding rise
or fall in volume To account for this an expansion vessel (conservator is connected to the
transformer tank. The conservator has a capacity oll level equal to 7.5% of the total oil in
transformer. The conservator is provided with magnetic oil level gauge on one of the end
covers which has low oil level alarm. The dial indicates empty. %, 30° C. 1. %. and full oil
level. The low oil level alarm is suitable for 240V D.C or 240V AC The terminals of low oil
level alarm switch are wired upto M. Box. A Prismatic oil gauge is also fitted at the other end.
For atmoscal type conservator, it is filled with oil to level appropriate to the filling temperature
and in the remaining position Air Cell is connected to atmosphere through breathers. As the
breathing is through the Air Cell, no moisture or Air comes in contact with oil. The pipe
connect ing the transformer tank with conservation projects above the lowest point in the
conservator such that the po:tion below acts as a sump where the impurities in the conservator
collect. A valve is fitted at the lowest point of the conservator for draining and sampling of oil.
On the feed pipe buchholz relay is mounted. Between conserva tor and buchholz relay,
isolating valves are provided as shown in GA drawing.

AIR CELL
The air cell is a flexible rubber bag and is placed inside the conservator. It floats on the oil
surface. The Air cell inllates or dellates depending upon the expansion on contraction of oil
The out side surface of the air cell is compatible to hot transformer oil & the inner surface of
the cell is ozone resistant. The dry air sucked into the cell do not come in direct contact with
oil, then climinates the probability of contarnina tion. For oil filling of transformer with air
cells, please refer : OIL FILLING INSTRUC TION plate attached to the transformer

BUCHHOLZ RELAY

The transformer is fitted with double float buchholz relay. It is fitted in the feed pipe from
conservator to tank and is provided with two sets of mercury contacts. The device comprises of
a cast iron housing containing the hinged loats, one in upper part and the other in the lower
part. Each float is fitted with a mercury switch, leads of which are connected to a terminal box.
An arrow is cast on the housing to indicate the direction of the conservator. the operation of
buchholz relay should be tested before installation by injecting air at the lower cock (test cock).
After the inspection and tests, any air which may have accumulated in the gas chamber must be
released from the upper pet cock to ensure that the chamber is full of oil. The top most points
of turrets are piped to the main pipe on which the buchholz relay is mounted so that the gases
liberated In the transformer are diverted to the buchholz relay without being bapped any where
Also refer leaflet on buchholz relay. From the upper petcock the gas is collected in the testing
bottle through gas collcting pipe.

DEHYDRATING BREATHER
The conservator or the abilis connected to inside atmospheric through
dehydrating (Silica Gel filled breather to make sure, that the air in the conservator or the cell is
dry. When the silica gel in saturated with moisture it's colour changes to pink. By heating the
gel at 100 c for 48 hours. it can be made reusable

PRESSURE RELIEF VALVE

In case of major fault in the transformer, like short circuit in the winding the intemal pressure
is built up to a very high level which may result in rupture of tank. To avoid such acontingency
a pressure relief valve is fitted on the transformer. It is sell scaling spring loaded type and has
contacts for tripping the transformer. Refer catalogue for details

OIL TEMPERATURE INDICATOR

Oil temperature indicator is a distance thermometer operating on the principle of liquid

expansion. It provides local indication of the top oil temperature at the marshal ling Box. The
connection between the thermometer bulb and the made by flexible steel capillary tube. The
bulb is enclosed in a pocket and the pocket is fixed on the transformer at the hottest oil region.
The pocket has to be filled with transformer oil. The oil temperature indicator is provided with
 a maximum pointer and two mercury switches one for alarm and other for trip. Switches are
adjustable to make contact between 50° C and 120° and have fixed differential of 10° C OTI
repeater is suitable for 110V AC. Pefer catalogue
The temperature for alarm and trip contact settings shall be as under:
Alarm = 85 Deg. C
Trip = 90 Deg. C
(At an ambient temperature of 45 Deg).

WINDING TEMPERATURE INDICATOR

This indicator operating on the principle of liquid expansion provides local indication at the
marshalling box of hot spot temperature of winding. The winding hot spot to top oll temperature
differential is simulated by means of CT current led to a liter col fitted ir the operating bellows. The
bulb of the WTI Fitted at the top senses top oil temperature. Thus winding temperature indicators
temperature readings are proportional to load curent plus top oil temperature. The Thermometer
bulb is connected by capillary tubing to the local indicator and by wiring from the local indicator to
repeater on control panel in control room Repeater is suitable for 110V
AC
The indicator is fitted with maximum pointer and four mercury switches. One is used for
alarm and 2nd is used for trip and 3rd for fan control and 4th for pump control. All the
switches are adjustable on their individual scales over the entire working range of the
instrument. All mercury switches are suitable for 250V AC or DC. For details tele catalogue on
WTL The WTI pocket has to be filled with transformer oil

The temperature for alarm and trip contact settings shall be as under
a) Alam ……………………….......90 Deg.C
b) Trip ……………………………95 Deg.C
c) Fan on ……………………………60 Deg.C
d) Pump on ……………………………70 Deg.C

EARTHING ARRANGEMENT
a) Core Earthing : Connecting leads from core and end frame are being teminated at the top of
cover. By connecting them to tank cover, core and core frame are carthed as shown on GA
drawing. Insulation resistance between The leads from core and end frame or between lead from
core and earth point can be checked by 500 volts megger

b) Tank to Tank cover.earthing: Tank to tank cover earthing is done by connecting copper straps
between tank rim and tank cover.

d) Earthing of Tank: For earthing tank, two number earthing pads have been provided on tank
as shown on GA drawing. 4 Nos. M-12 Bolts are required to make perfect carthing between
pads on tank and extemal earthing strip

ANNEXURE A TO PAGE NO. 7

 OIL FILLING IN TRANSFORMER AT SITE FOR N2 GAS FILLED JOBS
FOR TRANSFORMER TANK DESIGNED TO WITHSTAND 25 TORR VACUUM

The oil filling procedure shall be as given below

N2 gas cylinders to be disconnected and the N2 gas valve on tank to be closed.

It must be ensured that all the valves are in closed position and all openings blanked off

Radiators, bushings. buchholz relay, PRV, conservator are not be mounted at this stage

Remove N2 gas from the tank by means of a vaccum pump connected to the top filter valve

Create a vaccum of 25 torr approximately and filling of processed oil to be done under this
vaccum

Before filling oil in the tank it should be tested to 15:335

It it does not conform to the standards then it should be processed in two separate storage
tanks till all the valu are retaincd

Feed the processed oil into the bottom of the transformer tank through the filter valve

Fill the transformer tank as high as possible so that of level is about 300 mm below the upper
part of the cover.

Stop filling and close the bottom filter valve.

Maintalk vacuum for approximately one hour

Gradually break the vaccum in the tank through silica gel breather

Note; Por transformers supplied with NGEP EASUN or BHEL make OLTC the dheiter
compartment is to be equalised with main tank before creating wccum
INSPECTION AT SITE

Reception Assembling of Transformer Despatched Partly Dismantled and filled with Nitrogen.

To ensure that a Transformer will function satisfactorily, It important that handling lifting storing
and assembling are carried out with great care and cleanliness by experienced personnel who know
the various working operations very well.

This section gives Instructions how handling liting storing and assembling should be carried out.
For large transformers it is recommended that the work is done under supervision by experts. For
this EMCO's help can be sought.

In connection with receiving and unloading at site, and at the final storing place before assembling,
the transformers shall be inspected carefully. Extemal visible damages as dents, paint damages etc.
may imply that the transformer has been subjected to careless handling during transport and/or re-
loading, and a careful investigation is required. Any damages observed shall be intimated to
EMCO before proceeding for rectification. Before unloading the condition of packing and all
visible parts should be checked and possible damages of the accessories viz. OIL Leakage from
OIL & bushings, OTI, WT1 capillaries ctc. shall be intimated to EMCO. If necessary, appropri ate
statements and claims should be made.

STORAGE

Main Transformer :-
After arrival at Site, it is desirable to erect & commission the transformer with minimum delay.
Before storing the following has to be checked.

Main Tank :-
Transformer filled with Nitrogen.
(1) Check that the gas Pressure is 2.5 PSI (in pressure)
(2) If there is nolive) pressure then the transformer tank should be immediately filled with Diy N2
at a pressure of 0.17 kg/sq, cm. (2.5 PSI).

Transformer filled with oil.

(1) Ensure that the oil is at required level as marked on the tank

For Transformer filled with Nitrogen if the storage time exceeds three months. The oll is to be
filled under vacuum Or the Transformer is filled with oil but commissing is delayed the oil BDV
should be checked every three months as per Is-1866 latest addition

STORAGE OF ACCESSORIES
Storing Indoor in a Dry Room
The following items shall be stored indoor
(1) All the Bushing
(2) Insulating Materials & Paints
(3) M. Box & RTCC & Motor Drive of OLTC
(4) Turrets with CT mounting
(5) Components like B. Relay, MOG. PRV Pressure gauges & ow Indicators Breathic
(6) Cooling fans and Pumps.
 Outdoor Storage
(1) Oil Drums -- To be kept Horizontal & Over Two wooden planks. Care to be taken
that the caps shall be at 45 deg. from Vertical.
(2) Radiators & Conservator
(3) FRAMES, Pipes & Pipe supports.
(4) Rollers. Cable Box
NOTE: (1) All the openings of the Above Accessories are blanked up properly
(2) Frequent checks shall be canied out at repetitive intervals to ensure the healthiness of the
accessories

LOCATION AND SITE PREPARATION

Transformer shall be placed cither directly on plinth or with rollers as per foundation plan drawing.
Therefore it is very important to refer foundation drawing before placing the transformer on final
location.

Transformer should be placed on the foundation so that casy access is available all around and
diagram plates, thermometers, valves, oil gauges etc. can be casily reached or read. Adequate
electrical clearances are also to be provided from various live points of the transformer to earthed
parts.

Transformers depend entirely upon the sumOunding air for carrying away the heal generated due
to losses. For indoor installation, therefore. the room must be well ventilated so that the heated air
can escape readily and be replaced by cool air. Air Inlets and outlets should be to pass adequate air
to cool the transformer. The inlets should be as near the floor as possible and outlets as high as the
building. Where necessary, exhaust fans can be installed for the purpose

The transformers should always be separated from one another and from all walls and partitions to
permit free circulation of air. In this connection reference is also drawn to IS: 10028 (Part II).

Where rollers are fitted, suitable rails or tracks should be used and the wheels locked to prevent
accidental movement of the transformer. Where walls are provided. it should be ensured that the
transformer gets a good ventilation as mentioned above for indoor transformers. Provision should
be made for the emergency drainage of the oil from the transformers by surrounding the
transformer plinth with sump filled with small pebbles.

INTERNAL INSPECTION AND CHECK POINTS FOR ASSEMBLING THE TRANSFORMER

a) Check points before starting assembly

1. Condition of leads
2. Bracing, camping of leads
3. Connections
4. Tapchanger checks
5. Core that it has not moved In transit
6. CTs Including the secondary leads and their passage through metal parts
7. Check that coll position has not moved in transit
8. Check for diy metal swarf, moisture
 9. Check that the bushing leads set without being too close to ground or ethis points of different
Potential.

b) Check-points during Assembly :

By means of the part list of transformer GA dig the assembling of trans former is canied out according
to the following instructions. The following precautions are to be taken:

1. Fire-lighting equipment shall be available at the oil treatment equipment as well as at work on and
adjacent to the transformer.
2. Welding work on or adjacent to the transformer shall be avoided, but if this is nou possible the work
shall be supervised by responsible person.
3. Smoking on or near Use transformer shall not be allowed
4. Transformer tank control cabinet etc. as well as assembling and roll-trainer cquipment shall be
connected with the permanent earthing system of the station.
5. Check that there is no vein pressure in the transformer when blanking plates or connection lids are to be
opened.
6. All loose objects, tools. screws, nuts etc. shall be removed from the transformer cover before opening
the connection and blanking lids.
7. All loose objects (tools, pencils, spectacles etc) shall be removed from the pockets etc. before starting
the work through man holes.
8. Tools to be used inside the transformer c.g. for tightening of screw shall be fastened to the wrist or
another fixed point by means of cotton tape or string
9. Tools with loose sleeves and tools with catches must not be used at work Inside the transformer.
10. Fibrous cleaning material should not be used as it can deteriorate oil when mixed with it.
11. All components despatched separately should be cleaned Inside and outside before being fitted
12. Objects which despite all precaution have dropped inside the transformer, must absolutely be taken out
from the transformer.

ASSEMBLY OF WHEELS

Mounting of wheels under transformer is to be done as per roller arrangement drawing The Locking to the
wheels should be as per the Drawing.

ASSEMBLY OF COOLING DEVICES

Valves which are not dismantled like shut of valves for radiators. coolers and headers are provided with
blanking plates during transport Remove blanking plates when assembling of the coolers is to be started.
Check tha the valves are closed before opening the blanking plates Check that cach radiator cooler and
headers are assembled in the concert positions according to a drawing

ASSEMBLY OF OIL CONSERVATOR & PIPE WORK

The conservator which may be with or without air cell.is assembled either on the transformer or on a
seperate frame. Before the conservator is assembled it shall be check that equipment e.g. oil-level indicator
air cell are in order. The breather is connected to the oil conservator, and it is very important that joints and
couplings in the pipe between breather and conservator are air tight
ASSEMBLY OF FITTING AND ACCESSORIES

As per GA drawing connect all other pipes and the accessories supplied along with the transformer like fans,
radiators, Buchholz relay, OSR. PRV, should be mounted as shown in GA drawing. Special care should be
taken for mounting the Buchholz relay of the main trans former. The pipe angle should be maintained
between 3 deg. to 7 deg. towards conservator. The shut off valve provided on either side of the Buchholz
relay should be mounted properly and kept open. Both the shut off valve should be closed when the relay is
taken out for maintenance. After attending the B.R. the valves should be opened and air release from B.R.
should be done.

MOUNTING OF OIP BUSHINGS.

The mounting of Bushing is a very Important process. It should be done as follows:

1. The Condensor Bushing shall be handled as shown in the catalogue.
2 After proper cleaning & checking of oil level the bushing can be mounted on the Transformer. Care
should be Taken for the correct & suaight lead entry in the bushing.
3.To check the lead entry the Insp. cover provided on the top cover between H. V. Bushings should be open
& lead entry should be checked & ensure that the Icad is positioned at the Centre of the Stress Ball. For
Non-oil Communicating type bushings ensure the oil in the Bushings before the Mounting.

CLEANING PAINTING

After the transformer is fully assembled. it should be cleaned with dry cotton waste & touch up painting
on the parts wherever required shall be done.

NOTE
1. A set of erection gasket is supplied along with the main accessories which should be stored
properly indoor
2. The cooling fans should be mounted in such a way that the cable gland position should be
downward
HARACTERISTICS AND PARAMETERS OF NEW INSULATING OIL"
as per IS-335 Latest

s.no. Characteristics Unit Requirement

1 Appearance The Oil shall be clear
transparent and free from
suspended matter Or
sediments
2 Density at 29.5°C (Max) 0.89 g/cm
3 Kinematic Viscocity at 27 C 27cSt
(Max
4 Interfacial tension at 27* C 0.04 N/m
(min)
5 Flash Point 140°C 140°C
6 Pour Point (Max) -6°C
7 Neutralisation Value 0.03 mg KOH/g
(Total Acidity (Max)
 8 Corrosive Sulphur Non-corrosive
9 Electric strength (breakdown voltage)
(Min)
a) New unfiltered oil 30 KV (ms)
b) After filtration (Min) 60 KV (ms)
100 Dielectric dissipation 0.002
factor (Tan at 90 C (Max)
11 Water content (Max) 50 ppm
12 Specific resistance (Min) at
a) 90°C 35x10 ohm cm
b) 27 C 1500x10 ohm.cm
13 Oxidation stability
a) Neutralisation after 0.4 mg KOH/g
oxidation value (Max)
b) Total sludge after oxidation O.1% by weight
Max
14 Ageing characteristics after
accelerated ageing
(Open beaker method with copper
Catalyst)
a) Specific resistance
(Resistivity) at
1) 27°C min 25x10 ohm cm
2) .90°C Mini 0.2x10 ohmcm
b) Dielectric dissipation factor
Tan & at 90°C (Max) 0.2
c) Total acidity (Max) 0.05 mg/KOH/g
d) Sludge content by weight 0.05%
(Max)

RECONDMONING

Transformer oil is usually contaminated during handling, transport and storage due to Ingress of moisture
and solid impurities. Hence, Oil shall be a vacuum filtered sepa rarely at 50°C - 70°C, using a suitable
filtration machine and a spare clean tank before filling in the transformer. Details of filtration are given in
Clause 9.2 of IS 1865. Oll treatment shall be tenninated when the following parameters are attained as per
Table No.1

TABLE No. 1

Recommended Permissible
limit
KV Class of With 2.5mm gap electrical
Moisture content ppm
strength (BDV in KV (Max)
(Min) (Avy. of Six
Reading
Upto 145 60 20
245 65 15

AFTER OIL FILLING & VACUUM APP.

 System Voltage Evacuate and hold Vacuum Standing time after
for circulation before
application of Voltage
KV hours hours
upto 145 12 12
Above 145 & up to 220 24 24

HOT OIL CIRCULATION

To filter the solid impurities from the oll and drying the oll for improving the ppm of moisture content it is
to be circulated Inside the Transformer by an oil filtration capacity.
Filtration shall be considered complete when the following parameters are

TABLE 2
KV Class of BDV in KV Moisture content Resistivity Tan delta
Transformer ppm At 90°(ohm-cm) 90°c

Upto 72.5 kv 50 25 1x10*12 0.05

145 kv 60 20 1x10*12 0.05
245 kv 65 15 1x10*12 0.05

Method of test for Electric strength and moisture content shall be as per IS:335
CAUTION
The temperature during oil circulation should not increase beyond 70°C
SAMPLINO
Oil sampling at various stages shall be done. When sample is to be taken from Transformer tank, it will be
drawn from top and bottom of the tank and from the OLTC
1. The oil SAMPLE should be taken either in the coloured glass Bottle or Steel Bottle as shown
in figure.
2. The sample should be taken with proper care after sample is taken It should be properly sealed if it is
to sent to laboratory

The Sample should have following Information:

1. Date of Sampling.
2. MVA Voltage Class of Transformer.
3. W.O. & Sr. No. of Transformer.
4. Whether the sample from Main Tanker or OLTC.
5. Sample Taken from Top or Bottom
6 Before filteration or After filtration
7. Before charging or After Charging
 CHAPTER - 4

Final Commissioning & checks of Transformers

SILICA GEL BREATHER :
a) Ensure that the Colour of the Silica is Blue if it is pink then either it should be changed or
heated at 100 deg C.until the original Blue Colour is regained. The pink colour of the silica is due to
absorption of moisture
b) Ensure that the oil-cup of breather is filled with oil at required level. Two Air Vents are provided on the
oll cup. Remove tape from the air vent and make it open for air entry

VALVES FOR CORRECT CLOSING/OPENING :

Study thc Valve Schedule PlateGA. drawing property and open/close the Valves as per the requirement

OIL LEVEL N CONSERVATOR

Oil in the conservator should be checked before commissioning. A conservator is fitted with Magnetic Oil
Level Gauge on one side and prismatic oil level gauge on other side. The M.O.G. have a marking with
empty, 1/4. 30°C, 1/2 3/4 & full levels of oil in conservator. If the oil level in MOG indicate below 1/4,
then It will give alarm indication. In normal condition the oil level should be between 30°C & 1/2 level.
The oil levet should be maintained as per the red paint mark on the gauge.

COOLING SYSTEM :

1. The Transformers are designed with ONAN, ONAF. OFAF or OW Cooling

Check that all the radiators are filled with oil & also the fans mounted are working satisfactory. The
direction of the fan should be a indicated on the fan. Also the Fans should be mounted in such a way
that the cable gland opening should be at bottom side. With OFWF and OFAP check the direction of
 ofl pumps. The valves should be open for running heat exchanger/pumps. For valve close/open
condition refer valve schedule plats attached to the transformer.

2. Check the pressure in line with cooler control scheme

3. Ensure that he minimum pressure in the old chocolate is more than this maximum pressure of the
water circuit To check the water intel water outletolt intel & ollie outie temperatures Indication are in
order

CHECKING OF BUSHING : (OIP Condensor bushing)

1) Check that oil is visible in the oil level gauge. If oil is less, then fresh filtered transformer oil conforming
to IS-335 can be filled. Check the tightness of the terminal connectors. Ensure that the oil-seal ring in
the Top Terminal is properly fitted.
Ensure that the shield cap is not loose. The capacitance measurement test cap terminal cover should be
tightend properly

CHECKING OF DIFFERENT ACCESSORIES :

1. Buchholz Relay: The Buchholz relay is provided with two contacts one for Alarm& one for Trip. The
Relay will operate on collection of gas in relay cavity

The relay can be checked pushing air into relay with the help of cycle pump. The continuity of the
contacts will be checked. If cycle pumps is not wallable drain the oil from Buchholz relay and check the
continuity of he contacts.

2 Oil Level Indicator that MOG is showing the correct level In the conservator.

2. Pressure Relief Device : Elier PRV or Explosion Vent is provided on the transformer to release the
pressure developed due to intemal fault in the Transformer. PRV is provided with one contact which
shall be used for Tripping of breaker. There is also mechanical flap provided to Indicate PRV operation.
The PRV can be checked by lifting the plunger & check Ing the continuity of the contact Also the
Mechanical Nag Indication will be seen. After operation the PRV shall be reset by pushing the reset
knob The flag shall be put down. In case of Explosion Vent a thin bakelite sheet is provided as
diaphragm at bottom and at top of vent. A thin wire mesh is also provided to protect the backlit
diaphragm. The explosion vent shall be equalised with atmospheric pressure is line with GA drawing,

CHECKING OF WTL & OTL

1. WILD is provided to Indicate the hot spot temperature of the Trans former. Check that O.T WTI.
pockets provided on Tank cover are filled with of. E.T.L is provided with four Mercury Switches for
Alarm, Trip. Fom & Pump controls. The Temperature setting of the switches shall be done as given in
chapter 2. Similarly O.TI. Alan & Trip can be set Aller setting the indicator is oper mar setting shall be
confirmed

W.TL Repeater is also provided on RT.C.C. Panel. As per drawing corect wiring from W.T.I. to repeater
should be done & giving 110V or 220 Volts supply to repeater the working can be checked. repeater
shows the same temperature as W. T. L Ensure that W. T. ICT. Terminals are wired to W.T.I. Terminals
provided In M. Box
CHECKING OF EARTHINGS :
On the main tank two earthing pads are provided. The main tank should be carthed property with proper
earthing flat. The earthing should not be loose. The contact surface must be free from nust The earthing
resistance should not be more than 1 ohms. The other Accessories like Cable box, M. Box. RTCC, OLTC
or motordrive shall be carthed property & with proper size Copper/M.S. Not

CHECKING OF CONTROL CKTS :

As per the drawings Interconnections of M. Box, RTCC & OLTC shall be done and functioning of each
shall be checked. The operation of Remote T.PL. shall with he working of OLTC

Before charging the transformer release the air from all the air release plugs shown in GA/Valve schedule
drawings such as main tank cover, relay pipe. HV bushing tuners, porcelain bushing air vents screw and
radiators plugs

PRE-COMMISSIONING TESTING :

Before charging the pre commissioning tests shall be performed in line with follow Ing check list

PRE COMMISSIONING TESTS

INSULATION RESISTANCE TEST

SI No. Description Date Megger IR Value Temp Remark
Control Wiring Not less
Tap changer than500
a) Motor megger
b) Control
Cooling System
a) Fan Motor
b) Pump Motor
c) Control Wiring
Main Winding Not less
a) HV/E+LV Than1000
b) LV/E+HV megger
c) HV/LV
d) HV/TV
e) TV/E
Note:
1) The above IR values shall be taken with the transformer isolated from broth LV HV side of the
system completely.
2) The connecting leads for meggers shall not be less than 6.6 kv grade

OIL CHARCTERISTICS

Si no. Oil Time & Condition Moisture Break Resisti- Tan Remark
sample Date Time Weather Down Vety At
Volt- 90 c 90 c
Age
In kv
1 Tank
 Top Sample
Bot. Sample
2 Cooling system
Top Sample
Bot Sample
3 OLTC Divestor
Switch (each
phase
U
V
W

TESTS ON CT
1. RATIO
2. POLARITY
3.IR VALUE

ON LOAD TAP CHANGER

Sl. No. Description Date Observation Remarks
1 Visual Inspection of equipment
2 Hand Operation on all taps
3 Complete wiring of the circuits
4 Complete wiring of the circuits
5 Overload Device of Driving
Motor
6 Local Operation (Electrica
7 Remote Operation (Electrica
8 Tap Position Indicator. (Local
& Remote).
9 Step by Step contactor.
10 actor. Out of Step Relay
11 Limit Switches-Extreme
Positions

OFF CIRCUIT TAP SWITCH

Tap Switch handles should not be left halway and/or unlocked. Micro switch to be wired to M. Box and
checked.

CONTINUITY neutral for neutral end) of line to line for line end TO with multimeter on all taps and
phases to be consumed

MEASUREMENT OF WINDING RESISTANCE

(f Resistance Bridge is available)
Winding Tap No. Phase U Phase V Phase W Temp Remarks

NOTE
 For Transformer with OFF circuit tap switch the resistance shall be taken positively at all the
taps
VOLTAGE RATIO TEST

Ratio at all taps is to be checked. Start the tap changer from lowest tap d then go on increasing tap
Instead of starting from nommal tap

Tap Voltage applied to Voltage Measured on Ratio obtained (Cal. Ratio)

NOS HV LV from
Upn Vpn Wpn Upn Vpn Wpn U V W Rating
plate
1.
2.
3.
4.
5.
6.
7.
8.

MAGNETISATION CURRENT
a) Apply to Neutral & phase 230V on HV phasc and keep LV open
Voltage Applied Current measured Remarks
U Phase Volts U Phase m Amps
V Phase Volts V Phase m Amps
W Phase Volts W Phase m Amps

MAGNETISATION CURRENT
b) Apply to Neutral & phase 230V on LV and keep HV open.
Voltage Applied Current measured Remarks
U Phase Volts U Phase m Amps
2. V Phase V Phase m Amps
Volts
W Phase Volts W Phase m Amps
Note : Por furnace and rectifier transformer no low voltage lest shall be called Our home LV Stde

SHORT CIRCUIT TEST

3 Phase supply to be given to HV and LV linc terminals to be shoited. HV Amps of all the three
phases shall be noted at all tips Also LV side cuitent with tongue tester shall be measured

AFTER CONNECTION TO SYSTEMS

IR Value: The megger readings finally after The transformer is connected to the system.
Date ………….… Time……………. Temp.(Oil)………………
Windings Megger used Value obtained in Remarks
Mega ohms
HV/E Minimum 1000V
LV/E megger is to be used
 HV/LV
HV/TV
LV/TV
TV/E

OTHER TESTS

WTI Setting set for proved OT1 setting set fo Proved

Alarm Trip Alarm Trip
Fan Start
Fan Stop
Pump Start
Pump Stop

i) Main Buchholz relay ALARM- TRIP-

ii) OLTC oil surge relay ALARM- TRIP-
iii) PRV ALARM- TRIP-
After charging te transformer on No-Load it is to be kept under observation for 12 Hours on No-
Load. During this period. O.T, W.TJ temperature reading sla be recorded aunty After 12 Hours
check buchholz for any gas/air collec tion I no abromality is observed the transformer can be
loaded
CHAPTER 5
(Maintenance & Operation)
For ensuring trouble free service of the transformer, it is necessary that periodic maintenance is
planned, conducted and maintained as per the schedule given below

MAINTENANCE SCHEDULE
Si.no. Items to be Inspected Frequency Action required
Of If inspection
Inspection and shows unsatisfactory
inspection to be Conditions
canceled out
(A) Monthly
1 Ambient Temp - -
2 Winding Temp. Check that temp Shut down the trans.
3 Oil Temperature ſomer and investigate
if either is persistently
higher than normal

4 Load (amperes) Check against rated Note: An improper lap

5 Voltage figure prsition can cause
excessive core loss
(B) Daily
6 Oil level In Check against If low. top up with dry
Transformer transformer oil oil. Examine
& on load tap level transformers for leaks
7 Oil In Buchholz Relay 1) If Air 1) Release to
atmosphere
2) if Gas 2) Do the Gas
Analysis as given later
 (C) Monthly
8 Dehydrating breather 1)Check colour o! the 1) Silica Gel is Piak
active agent change by spare
2) Oil level in charge The old charge
breather cup may be reactivated for
further use
2) Ir Req. oil is to be
filled
(D) Quarterly
9 Bushing 1)Examine for cracks 1) Clean or replace
and dirt deposits
2) All level in
Bushing Check
bearings & gear box
Note: 1. In addition to the above instructions given in this manuals reference should also be made
to IS I0028 Code of practice for Installation and maintenance of transformers.
2. in case any abnormality during service is observed advice from EMCO shall be oblained, giving
EMCO complete particulars as to the nature and the extent of occurrence, together wit the Sr. No.
of Transformer.

ANALYSIS OF GAS COLLECTED IN BUCHHOLZ RELAY

The gas collected in the relay will help to identify the nature of the fault. It is suggested that the
following checks are made a convenient intervals or following the Indication of accumulation of
gas through alarm signal

1. Rate of qas collection, The greater the rate of gas collection, the more severe is the
nature of the developing fault.
2. Colour, odour and composition of the gas helps in finding the affected material as
follows
a) If the gas is odour less and colour less or with only a faint odor of oil. the gas is air
trapped in the transformer
b) If the gas is greyisti wlilte witt shap peneration odou irnofla R s because of writing
c) If the gas is yellowish in colour and Inflamable may be due to surface leakage on
material like wood
d) the gas is dark grey and inflamable, it may be due to flashover in oll o duc to
excessive overheating of the oll caused by a fault in Uc winding or the core

DO'S AND DONT'S

DON'TS FOR POWER TRANSFORMER

1. Do not energise without thorough investigation of the transformer whenever any alarm of
protection has operated.
2. Do not re energise the transformer unless the Buchholz gas is analysed.
3. Do not re-energise the transfomer without conducting all pre commissioning checks. The
results must be comparable with results at worls
4. Do not operate the off-circuit tap switch when the transformer is energised.
5. Do not energise the transformer, unless the off circuit tap switch handle is in tucked position.
6. Do not leave off circuit tap switch handle unlocked.
7. Do not leave tertiary terminals unprotected outside the tank, connect them to tertiary lightning
arrestors protection scheme, when connected to load
8. Do not allow WT1/OTI temperature to exceed 65°C. during dryout of trans former, and filter
machine temperature beyond 70 C
9. Do not parallel transformer which do not fulfil the condition.
10. Do not use low capacity lifting jacks on transformer for jacking
11 Do not move the transformer with bushing mounted.
12 Do not overload the transformer other than the specified limits as per IS: 6600
13. Do not change the settings of WTI and OTI alarm and trip frequency. The setting should be
done as per the site condition
14 Do not leave red pointer behind the black pointer in OT and WTI
15. Do not leave any connection loose
16 Do not meddle with protection circuits
17 Do not allow conservator oil level to fall below 1/4 level
18 Do not allow oil level fall in the bushings, they must immediately be topped up
19 Do not leave marshalling box doors open they must be locked
20. Do not switch off the heater in marshalling box except to be periodically cleaned
21. Do not allow dirt and deposits on bushings they should be periodically
22 Do not allow unauthorised entry near the transformer.
23 Do not Have ladder unlocked, when the transformer is 'ON in service, in case it is provided.
24 Do not change the sequence of valve opening for taking standby pump and motor into circuit
25. Do not switch on water pump unless oil pump is switched on
26 Do not allow water pressure more than oil pressure in differential pressure gauge.
27 Do not mix the oil, unless it condoms fully to IS: 335
28. Do not allow inferior ch to continue in transformer. The oil should be immedi ately be
processed and to be used only when BDV/ppm conforms to IS: 1866.
29. Do not continue with pink silica gel, this should immediately be changed or regenerated.
30. Do not store transformer for long after reaching site. It must be erected and commissioned at
the earliest
31 Do not leave secondary terminal of an uniraded CT open.
32. Do not keep the transformer gas filled at site for a longer period.
33 Do not top up oil from comenator with air cell bag inside

DO'S FOR POWER TRANSFORMER

1. Check and thoroughly investigate the transformer whenever any alarm or protec tion is
operated.
2. Check air cell in conservator.
3. Attend the leakages on the bushing immediately
4. Examine the bushings for dirt deposits and cons, and clean them periodically.
5. Check the oil in transformer and OLTC for dielectric strength and moisture content and
take suitable action for restoring the quality
6. Check the oil level in oil cup and ensure air passages are free in the breather
7. Check the oil for acidity and sludge as per IS: 1866.
8. If Inspection covers are opened or any gasket joint is to b tightened, then tighten the bolts
evenly to avold uneven pressure.
9. Click&clean the relay and alarm contacts
 10. Check also their operation, and accuracy and if required change the setting
11. Check the protection chuil periodically.
12. Check the pointer of all gauges for their free movement
13. Clean the oil conservator thoroughly before erecting
14. Check the buchholz relay and readjust the floats switches

TESTING

TRANSFORMERS ARE TESTED AS PER IS: 2026/1977

1. IN PROCESS TEST:
1.Pre Core Losses
2.Ratio at each tap
3.Vector group
4.Magnetizing current Spill current in neutral
5.Magnetic balance test

2. ROUTINE TEST
1. Oil Dielectric strength Before and after filling
2. Ratio at each tap
3. Vector group
4 Winding resistance at principal tap & extreme taps
5. Insulation resistance before & after tanking
6. Separate source withstand test
7 Magnetizing current
8. No load losses Iron Losses at full load, 90% and 110% excitation
9. Test on On Load Tap Changer (OLTC), where appropriate
 10. Load loss measurement(Copper Losses) & Impedance at principal tap and at extreme tas
11. Induced voltage withstand test
12 Spill current in neutral
13. Magnetic balance test

3.PECIAL TEST
1. Temperature Rise Test Heat Run Test
2. Vacuum Test on Tank
3. Pressure Test on Tank
4. Oil leakage test
5 Measurement of Acoustic Noise Level Test

4.TYPE TESTER
1. Dynamic Ability to withstand Short Circuit Test
2. Lightning impulse Voltage Withstand Test