VOLUME – I

INSTALLATION COMMISSIONING

AND

OPERATION MANUAL

FOR

63.9 MVA, 11/132KV

GENERATOR TRANSFORMER

INSTRUCTION MANUAL: 90021

CUSTOMER: ABIR CONSTRUCTIONS PRIVATE LIMITED

P.O.NO. ABIR/MALANA/GT/E&M/-001 DATED 12.02.2008.

Customer: Abir Constructions Private Limited Page 1

 Instruction Manual 90021

Comprises

Vol I : Description, Installation, Commissioning,

Operation & Maintenance Instructions.

Vol II : Drawings

Vol III: Test Certificates

 POWER
TRANSFORMERS
The Energising
Solution

………..for Over 3 decades! TRANSFORMING THE FUTURE

Vijai Electricals Limited – Transformers PROFILE

Vijai Electricals Ltd. established in 1973, has witnessed over 3 decades of un

parallel growth with an electrifying attitude, a fusion of experience, advanced
technology dedicated work force, superior manufacturing skills, exacting
standards of quality and diverse and distinctive competencies that converge, Vijay
Electricals Ltd., offers a comprehensive portfolio of products and services for
generation, transmission and distribution and utilization of power in various
applications. Its presence is well established and widespread notability in utilities,
industry, agriculture, and lifestyle products.

Vijay Electricals Ltd. today is the largest private sector organization in Electrical
Industry having widest range of transformers in distribution, Special purpose and
Power transformers. Our designs incorporate the latest transformer technology
and combine economy of operation with superior quality and high reliability. Years
of experience working with varied requirements have given us the ability to
translate specific criteria into design of quality product. There is a continuous
effort on the part of the company to keep abreast of the latest technology, in
tune with customer’s needs and expectations for more than 34 years.

VEL believes in backward integration so as to deliver the best to the customer in

line with the toughest standards. This helps Vijai to get an edge over the
competitors in terms of quality, price and delivery schedules, while maintaining an
effective and complete control on the entire supply chain. The world class
infrastructure in Rudraram serves as the best instance which has about 15
different units spread over 165 acres to manufacture all the parts and
components of the Transformers.

Today, the need of the country can be best summarised, “energy saved is energy
generated”. Realising the responsibility as a leader, VEL’s contribution to this
national objective of energy saving is the introduction of new amorphous metal
core distribution transformers.

VEL has technical collaboration up to 500 KV Class & ratings up to 500 MVA with
M/s Daihen Corporation, Japan (formerly known as Osaka Transformers), world
class Power transformers manufacturers who have supplied to various countries
across the globe including GEB & DESU in India.

Customer: Abir Constructions Private Limited Page 2

The purpose of this manual is to explain how power transformers should be
unloaded, installed, commissioned and maintained during their service to ensure a
long trouble free performance. We have also provided set of drawings; all these
drawings should be carefully studied before carrying out any work on the
transformers supplied. They should be energized only after completing all the
necessary work and pre-commissioning checks and tests prescribed in this
manual.

MANUFACTURING AND TEST FACILITIES

Design and development, to incorporate latest changes in customer need,

manufacturing techniques, and technological innovations, is a continuous
programme with VEL- Transformers. VEL transformers are manufactured in
modern plant and latest testing facilities ISO certified. The shop floor is Ferro
concrete finished to prevent formation of dust. The whole workshop was designed
with utmost care to prevent dust infiltration.

Core building, winding, core-coil assembly and tanking are the critical
manufacturing processes incorporating hi-tech machinery and equipment for
quality outputs and high performance

We give below some of the details of special manufacturing facilities installed at

our works. List of major plants and equipments in Hyderabad plant is attached
herewith.

CORE CUTTING

The new high speed “GEORG” CNC machines for core slitting and cropping ensure
stress- free laminations with out burrs for fully aligned core building.

WINDINGS

Windings are made with a great care in dust free air conditioned environment
(20-30C & humidity of 40%) to prevent moisture absorption in coil the insulation
and to ensure reliability by well experienced techno-craft men on vertical or
horizontal winding machines.

WINDING STABILIZATION EQUIPMENT

Isostatic pressing system offers rigid and stable windings ensuring a higher
reliability against electro dynamic forces due to short circuit.

INSULATION

Pre compressed insulation ensures long service stability due to dimensional

stability.

Customer: Abir Constructions Private Limited Page 3

COIL CLAMPING

Completed coils are compressed by predetermined clamping force in a hydraulic

press ensuring that the designed geometrical position of the individual winding is
maintained.

VAPOUR PHASE DRYING PLANT :

The core coil assembly is dried by automated Vapour Phase Drying (VPD) plant
dries it to less than 0.5% moisture content. This plant has been developed
indigenously by M/s Savas Engineering Co. Ltd.
The advantages of the VPD can be outlined as below.

1) In view of the fact that VPD takes place in an oxygen free atmosphere and also
much shorter duration than conventional hot air/vacuum drying method, the rate
and total deterioration of the insulation during the process is actually lower
compared to conventional hot air/ vacuum drying method.

2) As oily coil tend to attract dust which cannot be effectively removed by drying
process. However in this method the condensed solvent flowing over the coils,
clean the coils from the dust and foreign particles. Since VPD method removes
the dust completely and windings are thoroughly cleaned, impregnation and there
by stabilisation of the dimensions of windings are possible. This in turn improves
the short circuit withstand capability of the transformers.

TANKING

Core coil assembly is put in to the tank with proper locating arrangements. The
tank is filled with hot oil under vacuum to ensure least exposure to atmosphere.

HIGH VACUUM OIL TREATMENT PLANT

Oil filtration plant 10,000 litres/Hrs capacity from VPI ensures oil with less than
5ppm moisture content, free from particles above 0.5 microns size and very low
gas content. This is achieved by processing of the oil at low temperature of 50-60
degree centigrade, which reduces any chances of aging of the oil during oil
processing.

TANK FABRICATION

The fabrication shop at VEL-transformers has sophisticated and power full

machines specially adapted for the fabrication of tanks for large transformers.
Tanks are built using mild steel to with stand full vacuum. Tanks are designed to
roll and to skid in desired directions. Tanks for smaller rating are with top cover
while for large rating above 100MVA, bell type construction is used.

Customer: Abir Constructions Private Limited Page 4

LIFTING AND TRANSPORTATION EQUIPMENT

Over head travelling crane 150 tonnex2Nos

Air pallets 300 tonne for movement to Test Laboratory.

TESTING FACILITIES

# Switching and lightening impulse test system.

# Partial discharge and radio interference measurement facilities.
# Noise level measurement.
# Temperature rise test plant.
# Dissolved gas analysis for oil.
# Harmonic measurement and analysis.

QUALITY ASSURANCE

VEL-transformers quality assurance systems at Rudraram plant conforms to ISO

9001-2000 standards. For ensuring continuous improvement, a structured TQM
programme is in place which shall take us to world class quality standards. The
quality assurance system is backed by a strong in-house R&D which continuously
works towards up gradation of quality and systems to ensure total reliability.

Customer: Abir Constructions Private Limited Page 5

 Table of Contents
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TABLE OF CONTENTS

Introduction

Chapter 1 List of standards

Chapter 2 Rating Data

Chapter 3 Design and Construction Features

Chapter 4 Transportation, Receiving and Storage at site

Chapter 5 Installation

Chapter 6 Evacuation

Chapter 7 Commissioning

Chapter 8 System Normal Operation & Shutdown Instructions

Chapter 9 Preventive & Corrective Maintenance Requirements/

Instructions
Chapter 10 Troubleshooting Guide

Customer: Abir Constructions Private Limited Page 6

Chapter – 1: List of Standards

CHAPTER 1

LIST OF INDIAN STANDARDS

S. No. Standard Description

Spec. No.
1 IS – 2026 (P-1) Power Transformers (General)
2 IS – 2026 (P-2) Power transformers (Temperature rise)
3 IS – 2026 (P-3) Power transformers (Insulation level and
dielectric tests)
4 IS – 2026 (P-4) Power Transformers (Terminal markings, tapings
and connections)
5 IS – 2026 (P-5) Power transformers ( Transformer / reactor
bushings – Minimum external clearances in air)
6 IS – 3347 Dimensions for transformer bushings (porcelain)
7 IS – 7421 Specification for porcelain bushings for
alternating voltage up to and including 1000V
8 IS-2099/3347 Transformer bushing for use in Heavily polluted
atmosphere
9 IS – 6600 Guide for loading of oil immersed transformers
10 IS – 335 New insulating oil for transformers
11 IS – 5 Specification for colours for ready mixed paints
12 IS-2074 Ready mixed paint, air drying red oxide ,zinc
chrome, priming
13 IS – 9335 Specification for insulating Kraft paper
14 IS – 1576 Specification for insulating press board
15 IS – 1271 Classification of insulating materials
16 IS – 3043 Code of practice for earthing
17 IS – 5216 Guide for safety procedures and practices in
electrical work
18 IS – 10028 Code of practice for selection, installation and
maintenance of transformer (Part-I, II & III)
19 CBIP Manual Manual on transformers
Indian Electricity rules-2003
Indian Electricity act-2003

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Chapter – 2: Rating Data
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CHAPTER 2

RATING DATA

2.1 Rating Data

2.1.1 Electrical features
2.1.2 Mechanical features
2.1.3 Tables of Auxiliary Supplies
2.2 History

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Chapter – 2: Rating Data
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2.1 Rating Data:

The Generator Transformer is of 3 Phase 63.9MVA, 11/132 kV. It has ODWF cooling
and is provided with heat exchangers. The salient features of the Transformer are as
follows

Work Order No: 90021

Transformer Sl. No. : 90021A

OGA Drawing No. : 2 CD01 0006 Rev03
R&D Plate Drawing No. : 1 5630 0033

2.1.1 Electrical Features:

Capacity (MVA) : 63.9

Cooling : ODWF
Voltage (KV) HV/ LV : 132/11

BIL (KVP) : HV LI 650 AC 275

LV LI 75 AC 28
HVN LI 95 AC 38

No. of Phases : Three

Frequency : 50 Hz

Connection & Symbol : YNd11

2.1.2 Mechanical Features:

Mounting : Roller Mounted on Rails

Weights & Oil Quantities : Refer Rating & Diagram Plate
Type of Conservator : COPS
Type of Tank : Bell type
Type of Tap changer : Off Circuit
Location of Tap changer : HV side
Cooling Plant : Heat Exchangers

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Chapter – 2: Rating Data
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Type of Bushing : 145kV/650kVp/800A

24kV/125kVp/5000A
36kV/630A

Location of Current Transformers : Refer R & D Plate

Vacuum withstand level for tank

& conservator : Full Vacuum

Oil sampling arrangement

provided on : Tank Top & Bottom

Control panels : Cooler Control Cabinet

2.1.3 Tables of Auxiliary Supplies:

List of Monitoring Instrumentation:

S1.
Description Range Location
No.
1. Winding Temperature Local control panel
0- 150°C
Indicator (WTI) (Marshalling box)
2. Oil Temperature Local control panel
0- 150°C
Indicator (OTI) (Marshalling box)

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Chapter – 2: Rating Data
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2.2 History:

The transformer has been designed, manufactured and tested at VIJAI ELECTRICALS
LTD. EHV division, Hyderabad.

The erection of the transformer was taken up by …………………….

The transformer entered in commercial service on ……………………

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Chapter 3 Design Information
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CHAPTER 3

DESIGN INFORMATION

3.1 Pertinent design considerations and system (equipment)

principle mode of operation
3.2 Principle of operation
3.2.1 Preface
3.2.2 Transformer construction
3.2.2.1 Core
3.2.2.2 Windings
3.2.2.3 Cooling
3.2.2.4 Tank Construction
3.2.2.5 Conservator (COPS)
3.2.2.6 Pressure Relief Device
3.2.2.7 Gas & Oil Actuated Buchholz Relay
3.2.2.8 Silica gel Breather (Main & OCTC)
3.2.2.9 Winding Temperature Indicators
3.2.2.10 Oil Temperature Indicators
3.2.2.11 Bushings
3.2.2.12 Tap changer
3.2.2.13 Control & Monitoring System
3.3 List of instruments with functions, alarm & trip set points
3.4 List of valves position & service position

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Chapter 3 Design Information
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3.1 Pertinent Design Considerations And System (Equipment)

Principle/Mode of Operation:

Sr. Equipment Design Considerations Equipment Parameters

No. Part
1) CRGO steel laminations
No load loss 42 kW max 2) Step lap joints at the corners
1) Core
3) Resi glass banding of core
laminations
1) Current density control
1) Load loss 190kW & Auxiliary loss 2) Electrolytic copper
5kW max 3) Radial and axial oil ducts in
2) Winding 2) Temp. rise – Oil 55°C windings for cooling
– winding 65°C 4) Radial and axial supports in
windings for countering short
circuit forces
1) Insulation system with
HV LI 650 AC 275 Class-A Paper/Pressboard and oil
LV LI 75 AC 28 2) Pre compressed board for
3) Insulation
HVN LI 95 AC 38 core-winding & winding-winding
3) Adequate oil clearances to tank
and other metal parts
ONAN/ONAF cooling system with
Temperature rise - oil 55°C
4) Cooling adequate number of finned
- winding 65°C
radiators and Fans
Voltage variation from
5) OCTC -5% to +7.5% in 2.5% Off Circuit Tap Changer

6) Controls Cooler controls, OCTC controls Refer drawing

Alarm & trip contacts for adequate
Protection protection of the equipment with
7) Refer drawing
devices Protective Relays in Transformer relay
panel
HV: Bare with terminal connectors HV:Bare with terminal connectors
LV:Bare with terminal connectors LV:Bare with terminal connectors
8) Terminations
HV-Neutral: Bare with terminal HV-Neutral: Bare with terminal
connectors connectors

1) Tank construction with

adequate stiffeners
Vacuum with stand ability 2) Bottom tank bolted to Bell
9) Tank
Oil Pressure with stand ability Tank
3) Nitrile Rubber gaskets

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Chapter 3 Design Information
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3.2 Principle of Operation:

3.2.1 Preface:

Transformer is a static piece of apparatus which converts electrical energy

from one voltage to another. As the system voltage goes up the techniques to
be used for the design, manufacturing, operation and maintenance also
becomes more and more critical.

If proper care is exercised in the installation, operation, maintenance and

condition monitoring of the transformer, it can give the user trouble free
service throughout the expected life of equipment which is of the order of 30-
40 years. Hence, it is very essential that the persons associated with the
installation, operation or maintenance of the transformer are thorough with
the instructions provided by the manufacturer.

3.2.2 Transformer Construction:

The techniques used in the design and manufacturing of high voltage

transformers vary from manufacturer to manufacturer. Our transformers are
of core type construction with the windings placed concentric to the core.

The active parts of the transformers consist of core and windings.

3.2.2.1 Core:

Transformer core is manufactured from lamination of Cold Rolled Grain

Oriented Silicon Steel which gives very low specific loss at operating flux
densities. Joints of the laminations are designed such that the electromagnetic
flux is always in the direction of grain orientation. The core clamping structure
is designed such that it takes care of all the force produced in the windings in
the event of any short circuit. The core is of 3 Phase, 3 limb design. The core
limbs are banded with resi glass bands to eliminate the use of limb bolts.
Yokes are clamped by solid mild steel plates with yoke studs and resiglass
bands and ensuring rigidity to withstand mechanical shocks during lifting,
transportation, installation and short circuits.

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Chapter 3 Design Information
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3.2.2.2 Windings :

Windings are made from paper insulated copper conductors. Parallel

conductors are transposed at regular intervals throughout the winding for
ensuring equal flux linkage and current distribution between strands. Shielded
disc construction is adopted for the high voltage windings to ensure uniform
distribution of impulse voltages. Insulation spacers in the windings are
arranged such that oil is directed through the entire windings for ensuring
proper cooling.

3.2.2.3 Cooling system:

Main Function is to transfer heat from the oil into water in heat exchanger,
thus cooling the transformer. For OFWF cooling oil flows through the winding
and external oil flows through pumps to water cooler units attached to the
transformer. The Heat exchanger transfers heat of oil to water tubes is of
construction having the anti corrosion expanded tubes wherein the oil
dissipates heat into the cooling water. The necessary oil flow meter, water
flow meter and differential pressure gauge are provided as per OGA drawing
and respective leaflets are given in the manual.

3.2.2.4 Tank Construction:

Tank is of Bell type construction. Tanks are manufactured by welding Low

carbon steel plates of adequate thickness and are suitable for withstanding full
vacuum (760mm of mercury) and positive pressure of 1 atmosphere, give
full service life after installation. Welds are cleaned and smoothed to provide
an ideal surface for paint adhesion. The out side finish will resist wind
abrasion and weathering minimizing maintenance and providing a long lasting,
attractive appearance. Construction of the tank is such that these can be lifted
by crane or jacked, transported by road/Railways without over straining any
joints and without causing leakage of oil.

3.2.2.5 Conservator:

The conservator is provided to take care of the expansion and contraction of

transformer oil which takes place during normal operation of the transformer.
Conservator is large usually cylindrical structure which contains oil in
communication with transformer tank oil. It also has an air space which in
some cases is separated from the oil by a sealed diaphragm called as air
bag/cell. The air bag is installed inside the conservator (Inflated by N2 gas

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Chapter 3 Design Information
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pressure to 0.5 PSI) and fitted to it through the flange connected to the plate
of the top manhole. Thus, as tank oil expand and contracts due to
temperature changes, the flexible diaphragm accommodates these volume
changes while maintaining sealed oil environment. A separate expansion
space is provided for the On Load Tap changer. Magnetic oil level gauge is
fitted on the main/OCTC conservator which can give alarm in the event of the
oil level falling below the pre-set levels due to any reason and or Plain oil
gauge provide with marking of oil filling level at 30 degree.

3.2.2.6 Pressure Relief Device :

A device for oil pressure relief for the transformer tank and cooling system is
fitted with a trip relay. The pressure relief device allows for the rapid release
of excessive pressure that may be generated in the event of a serious fault
within a transformer and which might result in damage to the equipment. A
pressure relief device (spring operated type) capable of releasing the pressure
in the tank when it rises above a predetermined safe limit. The flag and the
switch remain operated until they are rest manually.

3.2.2.7 Gas & Oil Actuated Buchholz Relay:

Gas and oil actuated relay is fitted in the feed pipe from the expansion vessel
to the tank for collection of gas generated in the oil. A pre-set volume of gas
collection in the relay, or an oil surge towards the expansion vessel will cause
the alarm or trip contacts to operate respectively.

In the event of serious oil loss from the transformer, both alarm and trip
elements operate in turn in the manner previously described for gas collection.
Two brass petcocks are fitted at the top of the relay body, the outlets of which
are threaded to take a bleed pipe, if required, for collecting gas samples.

In the pipe connection between Off Load Tap changer and its oil expansion
vessel an oil surged relay is fitted. This relay operates on the principle of oil
surge impinging on a flap causing operation of the mercury switch connected
to the trip circuit. Gas actuated alarm switch is eliminated because the gas
generated during normal tap changing operation will give unnecessary alarm.

3.2.2.8 Silica gel Breather:

Expansion and contraction of oil cause breathing action. Any humidity in the
air breathed is absorbed by the silica gel dehydrating breather. An oil seal in

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Chapter 3 Design Information
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the air intake prevents external moisture being absorbed when no breathing
occurs.
The breather container is filled with silica gel crystals. It is arranged such that
the air breathed must pass through it. Self indicating (blue) silica gel contains
dye cobalt chloride which has potential health hazards and when the silica gel
crystals are fully active, they are of deep blue color. If color changes to a
whitish pink, they are then saturated with moisture and the charge container
should be replaced by a new reactivated one.

The size of the breather is chosen to operate effectively over a period of six
months approximately. The amount of silica gel required is dependent upon
the quantity of oil in the transformer, the load cycle and the atmospheric
conditions on site.

3.2.2.9 Winding Temperature Indicator:

The winding temperature relay indicates the winding temperature of the

transformer and operates the alarm, trip and cooler control contacts.

Winding temperature indicator consists of a sensor bulb placed in an oil filled

pocket in the transformer tank cover. The bulb is connected to the Instrument
housing by means of two flexible capillary tubes. One capillary is connected to
the measuring bellow of the instrument and the other to a compensating
bellow. The measuring system is filled with a liquid which changes its volume
with rising of temperature. Inside the instrument is fitted a heating resistance
which is fed by a current proportionate to the current flowing through the
transformer winding.

The instrument is provided with a maximum temperature indicator. The

heating resistance is fed by a current transformer associated to the loaded
winding of the transformer. The increase in the temperature of the resistance
is proportionate to that of the winding. The sensor bulb of the instrument is
located in the hottest oil of the transformer, therefore, the winding
temperature indicates a temperature of hottest oil plus the winding
temperature rise above hot oil Level the hotspot temperature.
3.2.2.10 Oil Temperature Indicator:

The oil temperature indicator consists of a sensor bulb, capillary tube and a
dial thermometer. The sensor bulb is fitted at the location of hottest oil. The
sensor bulb and capillary tube are fitted with an evaporating liquid. The vapor
pressure varies with temperature and is transmitted to a bourdon tube inside

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Chapter 3 Design Information
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the dial thermometer which moves in accordance with the changes in pressure
which is proportional to the temperature.

3.2.2.11 Bushing:

Bushings are designed to insulate a winding conductor from transformer tank.

The winding connection passes from the windings to terminal bushings.
Terminal bushings up to 36 kV class, 3150 Amps, are normally of plain
porcelain and oil in contact type. Bushings of 52 kV class and above are of oil
impregnated paper condenser type. The oil inside the condenser bushings will
not be communicating with the oil inside the transformer. Oil level gauge is
provided on the expansion chambers of the condenser bushings.

3.2.2.12 Tap changer:

Transformers are provided with off circuit tap changers. Tap changing can be
designed for changing the taps in following modes:

a) Manually from Motor Drive unit

b) Remote from RTCC Panel
c) Automatically from the Transformer panel through AVR

The on load tap changing will be a self contained unit housed in the main
transformer tank. This consists of selector unit. Since some amount of arcing
takes place during the switching operation from one tap to other, the oil inside
the Tap changer will deteriorate faster. Hence, this oil in Tap changer
chamber cannot be allowed to mix with the oil in the main transformer. On
load tap changer is provided with a separate conservator and oil surge relay.

3.2.2.13 Control & Monitoring System:

Local control and monitoring of the cooler, Alarm and trip circuit are provided
out at the marshalling box. All alarm and Trip circuits are taken to Control &
Relay Panel. Local Tap changer control is provided at the Drive Mechanism.

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Item
Sr
No. of Description Function Alarm Trip
No
GA Drg
Provided with alarm &
trip contacts to protect
Buchholz
1. 23 the transformer from Pre-set Pre-set
Relay
surges and any internal
faults
Prismatic Oil To indicate oil level in
Level Gauge conservator and give Not
2. 28 Pre-set
OCTC alarm if oil level is applicable
Conservator minimum
Winding
Temperature To indicate the winding
Indicator temperature. Provided
3. 49
Mounted in with alarm & trip 100°C 110°C
Cooler control contacts
cubicle
Oil
Temperature
To Indicate the top oil
Indicator
temperature. Provided
4. 48 Mounted in 85°C 95°C
with alarm & trip
Cooler control
contacts
cubicle

To release, the
excessive pressure in
Pressure
case of fault rapidly and Not
5. 56 Relief Device Pre-set
instantaneously. It is applicable
provided with contacts
to trip the transformer

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Chapter 3 Design Information
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3.4 List of Valves Location & Service Position:

Refer Rating & Diagram Plate

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 Chapter-4: Transportation, Receiving &
Storage at site
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CHAPTER - 4

TRANSPORTATION, RECEIVING AND STORAGE AT SITE

4.1 Transportation to site

4.1.2 Gas filled dispatch
4.2 Considerations before unloading the main unit
4.2.1 Unloading of the main unit with/with out crane
4.2.2 Precautions while lifting the main unit
4.3 Precautions while jacking the main unit
4.4 Precautions while hauling/pulling eyes the main unit
4.5 Handling the main unit from unloading point to plinth
4.5.1 Checks while handling
4.6 Storage
4.6.1 Check main unit(oil filled) for immediate installation
4.6.2 Check main unit(gas filled) for immediate installation
4.7 Inspection of accessories
4.8 Report of damaged parts
4.9 Handling/storage/ disposal of packing material
4.10 General Instructions for Delayed Installation
4.10.1 Storage of main unit if Delayed Installation
4.10.2 Storage of accessories if Delayed Installation
4.11 Storage of oil drums
4.11.1 Inspection during storage
4.12 Inspection of accessories

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 Chapter-4: Transportation, Receiving &
Storage at site
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Transportation, Inspection & Storage at site:

4.1 Transportation at site

After testing at works, the main unit transformer is dismantled for external
fittings, all tank openings are closed with blanking plates & suitable gaskets
and dispatched either N2 gas filled or oil filled. Further considering the
weight/Height restriction, mode of dispatch is decided either by road or rail
depending on the size of the transformer. Economy is also a major
consideration before deciding the means of transportation.

To facilitate safe transportation of transformer the centre of gravity of

transformer tank is punched at bottom on all four sides. Transformer is loaded
on the trailer by placing Wooden planks/ battens in between transformer
bottom Plate and top bed of the trailer. After placing the transformer on trailer
MS stopper pieces (Channels/ Angles) are welded at least 8-12 places on the
bed of trailer, to restrict the movement of the transformer during transit. The
transformer is lashed on longer sides by wire ropes or chain of adequate size
and tightened using turn buckles. Movement of the transformer shall be
through the route surveyed for the purpose and no deviation of the route shall
be followed unless it is surveyed again.

The Bushings, Radiators, auxiliary cooling equipment and accessories which

will be dismantled from main unit Transformer prior to dispatch are marked
with “ * ” in the list of fittings and are packed separately with packing list
nailed on the smaller side of cases/crates.

All blanking plates, valve guards, hood/pocket, etc used exclusively for
transportation is to be preserved for future use.

Oil for filling and topping up in the transformer is dispatched to site in sealed
drums or in tankers.

4.1.1 Gas filled dispatch:

When weight is a constraint, the transformer is dispatched with dry nitrogen.

After testing of the transformer oil is drained under N2 cushion and this is
pressurized to 0.5kg/sq.cm at the time of dispatch. A Nitrogen regulating
system is connected, which takes care of the loss of pressure during transit.

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 Chapter-4: Transportation, Receiving &
Storage at site
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4.2 Considerations before unloading of main unit :

i. Availability and readiness of approach road

ii. Readiness of foundation
iii. Position and orientation of main unit w.r.t. foundation
iv. Before unloading lashing must be removed
v Unloading should be done on levelled hard surface. Under base
of main unit should not rest on ground, place at least 300 mm to
400 mm wooden sleepers to facilitate jacking

4.2.1 Unloading of the main unit with/with out crane :

(i) Method suggested for unloading main unit from trailer without
crane (Manually)

Main unit should be unloaded on to sleeper platform slightly higher level to

release the trailer and gradually lower it to the plinth level. Winches are to
be used for putting/ pulling the main unit into position.

(ii) Method suggested for unloading main unit from trailer with crane:

The transformer foundation is to be verified and the orientation is to be

confirmed. Lift the transformer with crane having capacity more than 33 %
of the total weight of the transformer. Place the transformer on the plinth
w.r.t. the foundation / layout drawing.

4.2.2 Precautions while lifting of main unit:

Transformer tank is provided four Lifting lugs at the bottom suitable for
lifting the transformer complete with oil and in order to avoid any
unbalance during lifting.

i. Use endless wire ropes of adequate length and strength based on

weights (safe working load) given in Rating & Diagram plate
ii. Use all four lifting lugs/points for complete lifting of main unit
transformer shown in outline drawing.
iii. Ensure that the ropes are tight
iv. Do not lift high
v. Do not lift with bushings, if these are mounted in position
vi. Always lift vertically up

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vii. Lifting angle of the rope should be restricted to 30 ° to vertical

4.3 Precautions while jacking the main unit :

Transformer tank is provided with four jacking pads in accessible

positions to unable the transformer oil filled, to be raised or lowered
using hydraulic / screw jacks

i. Each hydraulic / screw jack capacity should be equal to or more than

50 % of the total consignment load
ii. Put jacks only at the points specified on outline drawing and
indicated with labels. Put sufficient wooden and steel packing
below the jacks to have better support and friction
iii. Use all the jacks simultaneously
iv. Do not lift more than 50 mm at a time
v. Immediately after each jacking insert wooden sleepers under
the base of consignment to take the load off the jacks
vi. Keep roller mounting pads free, if rollers are to be mounted

4.4 Precautions while hauling/pulling eyes the main unit :

i. Use winches to pull the unit.

ii. Use only the haulage points/pulling eyes as shown in the
outline drawing
iii. Do not put rope at any other point.

4.5 Handling of main unit from unloading point to plinth/storage place

In case the foundation is ready as also the approach road between the point
of unloading and the plinth, then the main unit should be taken on its own
rollers from unloading point to plinth.

Place the consignment on rails but supported on wooden packing. Keep area
for fixing the rollers clear of any supports etc. Raise the main unit by jacking
(only by 50 mm at a time) 500 mm above top level.

Main unit should be positioned on rails considering the final position on

foundation. Centre line of the main unit should match with the centre line of
rail track to ensure that roller flange finally match with rails, assemble
rollers.

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Bio directional rollers can be turned through an angle of 90 degree when

the transformer is jacked up clear of the rails or floor. Detachable rollers and
locking pads, if provided, may be removed while moving the main unit if
found fouling, however, these should be fitted when main unit is placed on
plinth.

After attaching all the roller assembly, raise the main unit further and
remove corresponding wooden packing such that when the main unit is
lowered on rails the remaining packing can be easily removable. Lower the
main unit slowly so that roller will be resting on rail top surface.

4.5.1 Checks while handling :

All rollers are resting on rails. Rollers are to be used only if shown in outline
drawings.

There is at least 5 to 6 mm gap between roller flange and side of rail

Capacity of winch (if two winches & pulley are used) should be more than
(main body weight X 0.15) / 4 tonnes and

Capacity of pulley should be more than (main body weight X 0.15) / 2

tonnes.

4.6 Storage :
Immediately after the receipt of main unit transformer and the accessories,
those should be thoroughly checked/inspected and if found satisfactory, the
unit should be erected completely and filled with processed transformer oil as
per the instruction.

However, if that is not possible, then it should be stored (preferably oil filled)
at suitable locations. The following points must be considered .

4.6.1 Check the main unit (oil filled) for immediate installation :

a) Verify the condition of the transformer in general

b) Verify the oil level in the main tank
c) Verify oil leakages, if any
d) Equalizing arrangement between the OCTC and main unit is open
e) Check for any abnormality including theft, if any

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4.6.1 Check main unit (gas filled) for immediate installation :

a) Verify the condition of the transformer in general

b) N2 pressure inside the transformer shall be positive
c) Equalizing arrangement between the OCTC and main unit is open
d) Check for any abnormality including, theft if any

4.6 Inspection of accessories for immediate installation :

a) Crates / packing cases need be opened carefully so that tools used for
opening do not cause damages to the contents
b) Transformer oil drums should be examined carefully, leaks or damages if
found need be reported immediately
c) In case of bushings, the oil level indicator should be facing
downwards. The porcelain portion is to be checked for any crack or
chipping. The terminals should be checked for any bends.
d) Fragile instruments like Buchholz relay, MOG, Brass encased thermo
meter, WTI/OTI temperature indicators, etc. are to be inspected for
breakage or other damages.
e) Any damaged or missing components should be reported to Vijai
Electricals Ltd., within the insurance liability period, so that the same can
be investigated and shortages / damages replenished as per the terms of
contract.
f) Verify the total number of cases and their condition, damages if any
should be reported to Vijai Electricals Ltd.,
h) Verify that the case numbers and their contents w.r.t. packing list or
shortages / damages

4.8 Report of damaged parts :

Following details should be included in the report of damages:

i. Case number with description and quantity of damaged components

ii. Item number of components
iii. Whether damaged is substantial and whether it is possible to
fix/repair the same at site

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On receipt of the consignment, following inspection should be made.

Enclosed TABLE 1 can be used for check on receipt.

TABLE 1

TYPE OF INITIALS /
ITEM NO. CASE NO. OBSERVATIONS
CHECK DATE

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4.9 Disposal of packing material/Oil at site :

Due care shall be taken in Handling, storage and disposal of packing

materials/oil. The following table gives the guidelines.

TABLE 2

Handling/storage/disposal
Sr. No Material
method
1. Packing wood Reuse
2. Plastic covering sheet
Recycle/reuse
above 20 micron
3. Transformer oil Recycle/reuse
4. Mild steel items.& Recycle/reuse
hardware

4.10 General instructions for delayed installation: (Oil Filled)

In case immediate installation is not possible, then main unit should be stored
at suitable locations with oil up to the transport tank oil level gauge or up to 6
inches below top cover, fit silica gel breather with suitable piping. In any
case the storage period should never exceed 3 / 6 months from date
of receipt of transformer. The following points must be taken care :

a) Storage area should be adequate and should be easily accessible for

inspection
b) The surface on which it is to be stored is strong and leveled
c) Surrounding area of storage place is not polluted and water does not
accumulate in and around this area.

4.10.1 Storage of main unit if installation is delayed: (Gas Filled)

If the main unit is received gas filled, before oil filling, all the detached valves
from transformer tank should be refitted closed and blanked off properly.

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It is preferable to store the main unit on its own location / foundation.

In case the foundation is not ready, the main unit should be stored at suitable
location. Fill oil as per instructions up to transport oil level gauge, under vacuum.
Fit silica gel breather with suitable piping.

The oil from the main unit should be tested for di-electric strength and moisture
contents once in every three months. The oil sample should be taken from
bottom valve. If di-electric strength is less and moisture contents is higher than
given in instructions then oil should be filtered.

4.10.2 Storage of accessories if installation is delayed:

After receiving the accessories at site, all Items should be checked/ inspected &
repacked properly into their own packing cases and packing list should be
retained.

All the packing cases should be kept above ground, ensuring free air flow
underneath. The storage area should be easily accessible for inspection, free from
water clogging and ease in handling / transport.

Also note the following points:

a) All fragile material should be stored in a closed room under lock and
key
b) All other accessories should be stored under the shed
c) All openings should be blanked off with suitable blanking plates.
d) Packing cases should be positioned as per their markings
e) Do not stack packing cases one over the other except for radiators.
Even in case of radiators maximum two packing cases should be
stacked.
f) For detailed and specific storage instructions refer the respective
brochures. These should be strictly adhered to.

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4.11 Storage of oil drums :

a) Oil drums should be stored under roof or should at least be covered

with tarpaulin
b) The drums should be stored in a area free from fire and explosion
hazards, with suitable HAZARD Labels
c) Keep bungs tight. Protect the drums from weather and contact with
water
d) Drums should never be stored standing on ends
e) Store drums horizontally with bungs at 45 °. This will ensure that
bungs are under a positive oil pressure

4.11.1 Inspection during storage :

During storage the main unit and accessories should be inspected regularly
as specified in Table-3. Observations, recordings should be noted in
separate register date wise. In case any abnormality is observed, Vijai
Electricals Ltd Hyderabad should be informed.

Check the condition of supporting ground as well as the supporting structures

whenever there is weather change such as heavy rains storm etc.

Condition of silica gel in oil filled storage should be inspected every 15 days.
Oil samples should be tested for di-electric every three months and oil
leakage check every 15 days.

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TABLE- 3

Instructions for storage of accessories and inspection during storage

Sr. Storage Storage Precauti Special Inspection

Accessories
No. Position Location on Instruction Checks

1. Into their Cover

All condenser Under Refer Manual Physical
own with
bushings the shed for Bushings damage.
crates Tarpaulin
2. Porcelain Into a Physical
bushings and Post -do- closed damage
insulation room
3. Under All openings
Damage
Radiators -do- the shed must be
and rust
or open blanked off
4. Cover
MOG
with
guard.
Under Damage
Conservator -do- All
the shed and rust
valves/
openings
to be
blanked
5. Space heater
Into a Should be
Fan control
closed connected to Space
cubicle / M Box & -do-
room or electric Heaters ON
TJ Box
Open supply to be
kept ON.
6. OCTC Drive
-do- -do- -do- -do-
Mechanism

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Sr. Storage Storage Precauti Special Inspection

Accessories
No. Position Location on Instruction Checks

7. Buchholz relay,
MOG, Breather,
Pressure relief
device, Valves,
Refer
Hardware items Into their Into a
respective
paint, Oil own closed
Instruction
operated relays, crates room
Manual
small brackets.
Clamps, pipes for
bleed valves and
other small items
8. Into their
Under damage and
Pipe work own -do-
the Shed rust
crates
9 Refer
Closed respective
Fan assembly -do-
room Instruction
Manual
10 Air insulated cable
Boxes/ Under
No crates damage and
disconnection the Shed
rust
chambers
11 In its Into a Do not
Physical
Gaskets own closed fold. Do
damage
crate room not roll
12 Oil
Oil leakage
No samples to
Oil drums Physical
crates be
damage
checked

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CHAPTER - 5
INSTALLATION
5.1 Planning and Arranging facilities
5.2 Verifying Placement of main unit
5.3 Verifying N2 pressure in main unit
5.4 Installation of turret
5.4.1 Installation of Bushing
5.4.2 Installation of Cable box
5.4.3 Installation of conservator and supports
5.4.4 Installation of pipe work
5.4.5 Installation of cooler bank
5.4.6 Installation of OCTC
5.4.7 Installation of Drive mechanism
5.4.8 Installation of Off circuit tape changer
5.4.9 Installation of Fan control cubical/ Marshalling box
5.4.10 Installation of CT Terminal box
5.4.11 Installation of Thermo junction box
5.4.12 Installation of Protective instruments
5.4.13 Installation of Magnetic Oil gauge (Main)
5.4.14 Installation of Magnetic Oil gauge (OCTC)
5.4.15 Installation of Pressure relief device (Main)
5.4.16 Installation of Pressure relief device (OCTC)
5.4.17 Installation of Buchholz relay
5.4.18 Installation of Oil surge relay
5.4.19 Installation of Sudden pressure relay
5.4.20 Installation of Non return valve, if required
5.4.21 Installation of Pump
5.4.22 Installation of Fans
5.4.23 Installation of RTCC
5.4.24 Installation of fire protection system, if required

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5.0 Planning and arranging facilities (Site preparation):

Before mobilization of various site activities including men, materials and

machine/ Instruments for erection, testing and commissioning of the
transformer, erection work schedule is to be prepared as per contract
agreement with specific time period and work involved for each activity. All
the assembly and erection drawings should be available at site.

The transformer should be erected on level concrete foundation. It should be

able to bear the weight and vibration due to humming of the transformer and
prevent accumulation of water. A foundation design incorporating a special oil
soak pit or oil draining facility during fire and emergencies. The transformer
should be installed with easy access provided all around. All instruments and
valves should be easily read and operated. Sufficient clearance from various
live points of the transformer to earthed parts should also be maintained as
per electricity Acts and Rules.

All tools and tackles and other equipments required for erection work may be
arranged at the site before the work is started.

Precautions:

1) Transformer oil is inflammable up to 140 deg. As per IS 335. Under

certain circumstances and in confirmed space, the oil may become
explosive. Hence flames should never be brought or kept near the
transformer.

2) As far as possible, no work should be carried out during the monsoon to

avoid moisture absorption by the transformer. Extreme care should be
taken to prevent any foreign material from being dropped into the
transformer. Workmen/ Engineers with access to the interior of the
transformer should empty their pockets of loose articles. Spanner and
other tools used should be tied with strings to the hand of the workmen,
so that they can be recovered if accidentally dropped.

3) Fibrous cleaning material should not be used, since the presence of loose
fiber suspended in oil can reduce its insulating properties. If any cleaning
or wiping is necessary, it should be done with clean and dry cloth.

4) The transformer oil and cellulose-based solid insulation normally used in

transformer construction absorb moisture easily, particularly when cold. If
access is needed to the interior of the tank during erection the transformer

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is best protected from moisture hazards by circulating dry and hot

transformer oil until temperature is slightly above the ambient, prior to
allowing access to the interior.

5) All components dispatched separately shall be cleaned inside and outside

before being fitted.

5.1 Inspection of Transformer & Accessories before erection:

Before the erection work is taken up, inspect all the accessories and main unit
as listed below. Check that all the accessories including gaskets and fasteners
are available in good condition and sufficient quantity. Check all the
equipments for erection are available in good condition. Sufficient quantity of
oil is available. Weather is not cloudy/rainy. Erection yard is clean, foundation
levels and rail levels are proper.

TABLE 4

Sr. No Description Inspection Checks

1. Main unit Gas/Oil Filled(Oil up to the mark level)
Dirt Clean
Rust Clean & Paint
Loose bolts Tighten them
2. All condenser Physical checks
bushings Visual cracks/breakages & Oil leakage
Dirt - cleaning
Oil level
Bushing leads available (dispatched along with
bushing)
3. Bushings Any missing metal part & Visual cracks/breakage
4. Pin/Post insulators Dirt cleaning & Any breakage
5. Fans Dirt cleaning & check physical damage

6. All pipe work Dirt cleaning & rust

7. Radiators Dirt cleaning, check physical damage & rust

8. Check all other accessories as per respective individual leaflets

9. All other fabricated items, brackets/supports, check physical damage, rust
10. Control panels Physical damage, paint finish. Heater working. All
parts available.
11. Samples from Oil Drum

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The oil drum should first be allowed to stand with bung vertically upward for
at least 24 hours. The area around the bung should be cleaned. A clean
glass/brass tube long enough to reach within 10 mm of the lower most part of
the drum should be inserted, keeping uppermost end of the tube sealed with
the thumb while doing so. Remove thumb, thereby allowing oil to enter the
bottom of the tube. Reseal the tube and withdraw an oil sample. The first two
samples should be discarded. Thereafter, the sample should be released into
suitable receptacle.

5.2 Verifying placement of main unit:

Confirm direction of HV, LV sides as per the outline general arrangement

drawing.
Confirm that the centre line marks/ punched on transformer are matching with
the foundation centre lines.
Confirm that in case of roller mounted transformers, the rollers are locked to
restrict the movement of rollers. While fixing the rollers, flange should come
on the inner side of the rails. Foundation bolts are supplied, to be used for
arresting the moment of the transformer, including anti earthquake device.
Confirm that packing/s between transformer top roller pad and bottom
mounting pad is required or not to maintain transformer in level and height as
OGA.

5.3 Verifying nitrogen pressure in main tank :

Check the nitrogen pressure, N2 Pressure inside tank should be positive. It

should be as per the graph given in the E&M manual with respect to ambient
temperature. If found less top up the nitrogen to the required pressure. If N2
gas pressure in the cylinder is about or less 15Kg/cm sq replace the cylinder
with new one.

5.4 Installation of turrets:

Before fixing the turrets the following points should be taken care :

Do not allow this lead to fall inside while mounting the turret.
Identify turrets as per Item No. on outline drawing and identification
Number punched on turrets. Assemble them at right place

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Verify the terminal nos. of turret CT’s from inside with the one’s outside the
CT terminal board and also the proper crimping and termination at the
terminals
Test the CT for Ratio, Polarity and Insulation Resistance
Clean the turrets & install the same using new gasket.

5.4.1 Installation of bushings:

Bushing installation is a very critical operation and calls for special care and
attention. Select the best technicians/workmen available in the lot. Before
proceeding brief the technicians associated with this operation, about the risk
involved in case any tool or other material falls inside the transformer. Take
specific care to avoid undue pull to the winding leads which are tied onto the
turret blanking plates.

Verify that the oil level indicator is facing downwards

Remove the bushings from their packing cases with care
Verify the oil level in the bushings
Clean the bushings with cotton cloth
Check the bushing for any crack, chip off on to the porcelain portion.
Measure the tan delta & Capacitance as well as insulation resistance of the
bushing
Tie the tools to be used for internal connections & fix them to hand or
suitable outside point

Open the inspection windows to allow the N2 gas to escape and further free
breathing. In case oil filled transformer, oil level should to be lowered little
below the inspection windows.

Remove bushing mounting blanking plates.

Lift the bushings with nylon belts/manila rope for installation
In case of inclined positioning of bushings, use chain pulley to achieve the
desired angle
Never hold / support the bushing at its tail portion, this could lead to shifting
of the sealing gasket between the metallic portion and tail porcelain

Connect the bushing lead with a pilot and pull wire connected to a “D” shackle
/ pulley fitted to the crane hook and lower the same to facilitate the
connection with winding lead, at the bushing flange.
Install bushings in position using new gasket & with UTMOST CARE

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Ensure that the winding lead enters the bushing tube without hitting, while
lowering the bushing into the turret. Install the locking pin at the top of the
bushing and remove the pull wire.

Ensure proper connection & verify tightness of the bushing & winding lead
connectors.

Fix the stress shield at the bushing end if required.

Caution: The test tap must always be earthed and not to be left
open under any circumstances

Oil Communicating Bushing/s:

After removal of the bushing from packing cases, the flexible jumpers /
connection ropes to be connected at bottom end
Clean the bushing with cotton cloth
Check the bushing for any crack, hairline crack on to the porcelain portion
Make sure that neutral bushings are effectively earthed

5.4.2 Installation of cable box:

a) Installation of disconnecting chamber :

Confirm position as shown in the drawing.

Remove the blanking plates.
Clean it from inside.
Install it taking care of the installed bushings.

b) Installation of cable box with supports :

Confirm position as shown in the drawing.

Remove the blanking plates.
Clean it from inside.
Install it taking care that the bolting of the joint is done while the load
is taken by crane & not by releasing the crane.

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5.4.3 Installation of conservator with supports:

The conservator with air cell is pressure tested and dispatched from the
factory at slightly positive pressure or 0.5 PSI. Confirm that there is no leak.
There are air release plug on the conservator. Keep air release plug open. Fix
air filling adopter on breather pipe and inflate the air cell at 0.5 PSI pressure.
Open the air release plugs and start oil filling from the bottom filter valve of
the transformer. Observe the air release plug and as soon as oil starts
overflowing, close the air release plugs one by one. Stop oil filling when air
release plugs are closed. Remove the air filling adopter. Continue oil filling and
observe the MOG. Stop filling when the needle of MOG shows the level
correspondence to the ambient temperature at the of filling. Fix silica gel
breather.

Caution:

Do not open any air release plugs after completion of oil filling. If air release
plug is opened, air will enter and oil level will drop.

The plain oil level gauge on the cover of conservator should indicate full oil
level always. If air enters the conservator, It can be seen by a fall in the oil
level in the plain oil level gauge.

The plain oil level gauge should be monitored on the regular basis.

5.4.4 Installation of pipes work:

Pipe work - General:

a. All open ends of pipe are blanked.

b. Ensure that the accessories belong to the unit bearing the same Works
order number and serial number are engraved on R&D plate.

c. All the fabricated items including pipes/Supports are punched mark on

side flanges for W.O & Item No. as per OGL and flanges having same
match mark and match marks to be aligned.

Install the pipes as per the W.O & item number and positioning as per the
drawing.

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5.4.5 Installation of cooler bank/s if required)::

a) Installation of separately mounted cooler bank(if required):

Installation of cooler bank calls for proper and exact alignment of the
pipes, supports w.r.t each other. Ensure proper cleanliness inside the
radiators, coolers and pipes prior to installation.
Erect the “A” frames taking care of their alignment and secure them
with adequate supports
Fix top and bottom headers on to these “A” frames taking care of the
alignment with help of spirit level / plumb level, refer the drawing for
positioning
Remove blanking plates & clean the cooler pipes from inside. Install
top & bottom cooler pipes as per item number and drawing. Verify
suitability of gasket or else use new gaskets
Check the cooler pipes for proper alignment. Ensure that the air release
plug of expansion bellow is on the top side
Open radiator crates and check the same for any damages / cleanliness
If required flush the radiators with clean oil
Fix the radiator one on either side for proper balancing of the “A”
frames, ensuring that the gasket does not slip out, and connect the ties
Grout all the supports adequately and till such time provide temporary
support to the cooler pipes

b) Installation of tank mounted radiators with headers and pipes (if

required)
Install the headers with the supports as per the item number
Verify the alignment with help of spirit level / plumb level, refer the
drawing for positioning
Remove blanking plates & clean the cooler pipes from inside. Install
top & bottom cooler pipes as per item no. & drawing. Use new gaskets
Check the cooler pipes for proper alignment. Ensure that the air release
plug of expansion bellow is on the top side
Open radiator crates and check the same for any damages / cleanliness
Fix the radiator using new gaskets, ensuring that the gasket does not
slip out, and connect the ties.

c) Installation of tank mounted radiators without headers (if required)

Open radiator crates and check the same for any damages / cleanliness
If required flush the radiators with clean oil

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Fix the radiator using new gaskets, ensuring that the gasket does not
slip out, and connect the ties

5.4.6 Installation of on load tap changer (if required)::

The diverter vessel of OLTC is always installed at the factory. But the drive
shaft & Bevel gear etc. are supplied loose some times in case of transport
restriction. If they are supplied loose, then install the gear supports, drive
shafts as shown in the drawing and also referring the supplier’s manual
provided in our E&M manual.

Use spirit level & plumb line for proper installation of OCTC & drive shafts.

5.4.7 Installation of Drive mechanism( if required)::

The transformer main unit is transported along with Drive Mechanism of on

load tap changer; the erection work is needed only for the connection of
OCTC to conservator and oil filling. In case the transformer main unit is
transported without OCTC Drive Mechanism or coupling removed for any
reason, then refer OCTC Erection and Maintenance manual.

Mount the Drive Mechanism at the location shown in the drawing. Confirm
alignment with the spirit level.

5.4.8 Installation of off circuit taps changer:

Off Circuit Tap Changer are always installed at the factory & hence not
necessary to install at the site. But some times considering the damage risks,
the operating handle of OCTC is fixed with the protective cover during transit.
This cover should be removed at the site & operation of OCTC need to be
checked.

Also the proper operation of safety limit switch need to be confirmed on the
movement of OCTC operating handle.

5.4. Installation of Marshalling box:

Mount the marshalling box at the location shown in the drawing. Confirm
alignment with the spirit level.

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5.4.10 Installation of CT terminal boxes :

Current Transformer should be kept flat at all the time. If it is not handled
properly, it will deform in shape resulting in an increase in excitation current.
All CT secondary terminals should be connected before energizing the
transformer. This will prevent excessive voltage developing across CT
secondary, which can damage the CT and be a hazard if touched. All CT
secondary terminals should be shorted and and earthed, if not in use.

Mount the CT terminal box at the location shown in the drawing. Confirm
alignment with the spirit level.

5.4.11 Installation of Thermo junction box :

Mount the Thermo Junction Box at the location shown in the drawing. Confirm
alignment with the spirit level. Ensure that the capillary line are not given the
sharp bends.

5.4.12 installation of protective instruments :

a) Installation of Oil temperature indicator :

In most of the cases temperature indicators are installed inside the

Thermo Junction Box/ M Box. In that case there is no need of
separately installing this instrument. In some cases temperature
indicators are supplied loose. In that case install the instrument at the
location shown in the drawing.

In both the cases, i.e. either instrument is mounted inside the thermo
junction box or outside, the transport locking screw provided on the
temperature dial need to be removed. Also the temperature settings
will have to be made by adjusting the screws provided on mercury
switch fulcrum.

The sensor probe will have to be laid up to the pocket provided on the
transformer for the instrument, taking care that the sharp bends are
avoided. The pocket needs to be filled in with the oil & then the probe
will have to be inserted inside slowly & to be tightened securely.

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b) Installation of Winding temperature indicator (HV) :

In most of the cases temperature indicators are installed inside the

Thermo Junction Box/ M Box. In that case there is no need of
separately installing this instrument. In some cases temperature
indicators are supplied loose. In that case install the instrument at the
location shown in the drawing.

In both the cases, i.e. either instrument is mounted inside the thermo
junction box or outside, the transport locking screw provided on the
temperature dial need to be removed. Also the temperature settings
will have to be made by adjusting the screws provided on mercury
switch fulcrum.

The sensor probe will have to be laid up to the pocket provided on the
transformer for the instrument, taking care that the sharp bends are
avoided. The pocket needs to be filled in with the oil & then the probe
will have to be inserted inside slowly & to be tightened securely.

c) Installation of Winding temperature indicator (IV) :

In most of the cases temperature indicators are installed inside the

Thermo Junction Box/ M Box. In that case there is no need of
separately installing this instrument. In some cases temperature
indicators are supplied loose. In that case install the instrument at the
location shown in the drawing.

In both the cases, i.e. either instrument is mounted inside the thermo
junction box or outside, the transport locking screw provided on the
temperature dial need to be removed. Also the temperature settings
will have to be made by adjusting the screws provided on mercury
switch fulcrum.

The sensor probe will have to be laid up to the pocket provided on the
transformer for the instrument, taking care that the sharp bends are
avoided. The pocket needs to be filled in with the oil & then the probe
will have to be inserted inside slowly & to be tightened securely.

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d) Installation of Winding temperature indicator (LV) :

In most of the cases temperature indicators are installed inside the

Thermo Junction Box/ M Box. In that case there is no need of
separately installing this instrument. In some cases temperature
indicators are supplied loose. In that case install the instrument at the
location shown in the drawing.

In both the cases, i.e. either instrument is mounted inside the thermo
junction box or outside, the transport locking screw provided on the
temperature dial need to be removed. Also the temperature settings
will have to be made by adjusting the screws provided on mercury
switch fulcrum.

The sensor probe will have to be laid up to the pocket provided on the
transformer for the instrument, taking care that the sharp bends are
avoided. The pocket needs to be filled in with the oil & then the probe
will have to be inserted inside slowly & to be tightened securely.

5.4.13 Installation of Magnetic oil level gauge (Main conservator) :

In most of the cases magnetic oil level gauges are despatched mounted on
the conservator. In that case there in no need to install it separately. But if
supplied loose, will have to be installed on the conservator referring the
drawing for location, position & float arm length.

Also ensure that the transport locking provided in the mercury switch box has
been removed.

5.4.14 Installation of Magnetic oil level gauge (OCTC conservator) :

In most of the cases magnetic oil level gauges are despatched mounted on
the conservator. In that case there in no need to install it separately. But if
supplied loose, will have to be installed on the conservator referring the
drawing for location, position & float arm length.
Also ensure that the transport locking provided in the mercury switch box has
been removed.

5.4.15 Installation of Pressure relief device (Main transformer):

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Pressure relief devices are despatched loose. In that case, install it on the
transformer referring the drawing for location. Ensure the proper seating of
the gasket.

VERY IMPORTANT: Do not disturb any of the screws provided on the top of
the pressure relief device which have been set at the factory. The screws
provided for limit switch cover, limit switch can be opened for termination &
testing.

5.4.16 Installation of Pressure relief device ( OCTC tank) :

In some cases pressure relief devices are despatched loose. In that case,
install it on the transformer referring the drawing for location. Ensure the
proper seating of the gasket.

5.4.17 Installation of Buchholz relay :

Installation of Buchholz Relay should be taken up after completion of

installation of conservator & pipe work. At this stage after tightening all the
fasteners of conservator & pipe work, ensure that the flanges provided in the
pipe work for B.R. are parallel to each other & perfect gap is there for sliding
in the B.R. with gaskets. If not so, then align the pipe work again & then on
getting the satisfactory condition, insert the B.R. with gasket & tighten. This
will avoid the excessive pressure on B.R. & prevent it from cracking. Ensure
that the direction arrow shown on B.R. is pointing towards the conservator.

5.4.18 Installation of Oil surge relay (OCTC) :

Installation of Oil Surge Relay should be taken up after completion of

installation of conservator & pipe work. At this stage after tightening all the
fasteners of conservator & pipe work, ensure that the flanges provided in the
pipe work for OSR are parallel to each other & perfect gap is there for sliding
in the OSR. with gaskets. If not so, then align the pipe work again & then on
getting the satisfactory condition, insert the OSR with gasket & tighten. This
will avoid the excessive pressure on OSR & prevent it from cracking. Ensure
that the direction arrow shown on OSR is pointing towards the conservator.

5.4.19 Installation of Sudden pressure relay, if required:

In some cases Sudden Pressure Relay is despatched loose. In that case, install
it on the transformer referring the drawing for location. Ensure the proper
seating of the gasket.

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VERY IMPORTANT: Do not disturb any of the screws provided on the top of
the SPR which have been set at the factory.

5.4.20 Installation of Non return valve, if required :

Refer the drawing for location of the valve. Ensure that the direction arrow
shown on NRV is pointing towards the conservator.

5.4.21 Installation of pumps :

After tightening all the fasteners of related pipe work, ensure that the flanges
provided in the pipe work for pump are parallel to each other & perfect gap is

there for sliding in the pump with gaskets. If not so, then align the pipe work
again & then on getting the satisfactory condition, insert the pump with
gasket & tighten. This will avoid the excessive pressure on pump & ultimately
prevent it from cracking & leaking. Ensure that the direction of oil flow is
towards the transformer bottom.

5.4.22 Installation of fans :

Fans are supplied loose & in assembled condition. Mount it on the transformer
referring the drawing for the location & position. Direction of air flow should
be upwards in case of bottom mounting & inside in case of side mounting.
The drain plugs provided on some of the fan motors need to be positioned
referring the manufacturer’s instruction provided in E&M manual.

5.4.23 Installation of RTCC :

Install RTCC at the location provided by the customer in control room. Position
of the RTCC to be decided consulting the customer. Confirm alignment with
spirit level.

5.4.24 Installation of fire protection system, if required:

Install all the pipe work & control panel as shown in the drawing. Install d
different sensor cables / sensors with extra precaution

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5.4.25 Installation of breather :

Breathers are dispatched loose. Assemble them as shown in outline drawing.

Check oil seal if necessary fill oil up to the level marked in oil cup. Also ensure
breathing hole in oil cup is unobstructed. Check color of silica gel.

Silica gel Color

Dry Blue
When moisture is absorbed Pink

5.4.26 Installation of Gaskets:

Whenever blanking plates are removed to fix the detached parts such as
bushing turrets, etc a new gasket shall be used while fixing the same. A set of
new unused gasket of correct size and thickness is supplied with every
transformer for this purpose. All gasket used for making oil tight joints are flat
Nitrile Rubber Gasket. The recommended compression for the various gasket
materials is:

Synthetic Resin Bonded Cork 43% Compression

Nitrile Rubber Gasket 33% Compression

When a gasket is subjected to the pressure from the flange bolts, it will
deform which implies that the pressure is reduced and the bolts become
loose. It is therefore necessary that gaskets are retightened

The gasket surfaces must be thoroughly clean. Remove all oil grease, varnish,
dust and dirt by scraping surface and wiping out with a cloth wetted with a
solvent, such as Trichloroethylene. Cut the gasket to conform to the surfaces
to be sealed. If the gasket is not a one piece gasket, the length of the overlap
will be equal to four times the thickness of the gasket. The mitering should be
done with a fine toothed saw or sharp knife or a miter box to assure a clean
uniform cut and to obtain full gasket thickness at the lap joint. Dovetail joints
may have been used at the factory. A special tool is required to make this
joint. A scarf joint may be used if this tool is not available.

Gasket should be stored in stress free condition. If it is stored in folded or

rolled up condition, it will loose all its properties. Cork Gaskets once used
should not be used again. When blanking inspection openings after the
inspection of internal parts, use new Gaskets. While replacing gaskets. Use
same thickness and width of original gaskets.

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5.4.27 Installation of Earthing :

Transformer should be earthed at earthing terminals.

Earthing strips are provided for same fixed potential of the tank and
cover. For other locations like Marshalling box, OCTC, motor drive unit,
Dis. Chamber, cable box etc, earthing to be done at site.

5.4.28 Touch Up Paint:

Instructions given below are applicable for attending to minor damages to

paint prior to commissioning:

Clean the damaged painted surface with Emery paper No. 20, by giving very
light dry cut, use (if available) air hose to remove loose paint, dust etc. Ensure
that the cleaned surface is free from loose paint, dirt, dust, grease etc. Use
cotton rags for cleaning the surface but do not use cotton waste. Apply epoxy
primer and finishing paint allowing minimum 4 hours between the coats

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Installation Check List :

a) Radiators and pipe connections should be

checked inside before assembly, in order to
ensure that there are no foreign particles.
b) Before mounting the pumps, check the
mounting direction

c) IR value of pump using 2 kV meggar

d) Before mounting the oil flow indicator, check the
oil flow direction marked on the dial

e) Unlock the magnetic oil level gauge before

mounting

f) Check contact operation of magnetic oil level

gauge before mounting

g) IR values of fans before mounting

h) Run the fans separately before mounting and
observe the performance
i) Coupling between OCTC and driving mechanism
should be done strictly as per instructions.
Absolutely no mismatching can be allowed in the
timing
j) To check correct couple between phases (Poles)
of OCTC. Absolutely no mismatching can be
allowed in the timing.
k) If specified, gear oil should be filled to the
required level for the gears in the driving
mechanism
l) Electrical operation of the OCTC should be
checked only at the middle tap

m) Electrical checking of limit switch operation

n) Before mounting the bushing turrets, check
the continuity of CTs inside the turrets
o) 2 kV test on CTs inside the turrets before
mounting the turrets

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p) IR values of condenser bushings before

mounting shall be at least 5000 mega ohms
q) Cover on the test Tab of bushings shall be tight
r) After making the condenser bushings vertical,
check for any physical damages like hairline
cracks on the porcelain. Also look for any oil
leakages.
s) Oil level in condenser bushings

t) While mounting the 245 kV & 145 kV

Bushings, the lead attached to the windings
should enter the bottom of the bushing without
being hit by the bushing
u) After mounting the bushings, the terminal caps
should be tightly fitted with sealing gasket
v) Check the mounting direction of main buchholz
relay before mounting
w) Check the mounting direction of Pre stressed
non return valve of the fire fighting . system and
is in between Buchholz .Relay and Conservator,
if provided
x) Check contact operation after mounting the
buchholz relay
y) Check operation of plate valves
z) Contact operation of Sudden Pressure Relay
should be checked before mounted, if
provided.
aa) Contact operation of pressure relief device
should be checked using the test knob and then
reset
bb) Electrical operation checked on T J Box/
marshalling box
cc) Complete assembly of the transformer should be
checked for conformity with General
Arrangement Drawing.

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LIST OF ERECTION EQUIPMENTS TOOLS

1. Mobile crane/Hydra having a free vertical lift suitable for lifting HV

bushing and lifting capacity 3 or 5 tonnes each.
2. Manila/Nylon ropes and 'D' shackles for lifting 3 tonnes weight
3. Filter machine of capacity 6000 liters per hour or more in excellent
working condition. It must be capable of heating transformer oil up to 80
deg.C (heating should be indirect) and must be equipped with in-built
high vacuum degassing chamber filter elements. The following
accessories should also be provided.

a. Non-collapsible hose pipes of adequate length and size provided with

nipples/adapters.
Hose pipes should be of oil resistant material, natural rubber should not
be used.
b. 3 Nos. flanges each of sizes 25, 50 & 80 mm pipe suitably threaded for
connecting the hose pipes and provided with holes for fastening on
main unit valves.
c. The incoming electricity supply capacity must be adequate to operate
the machine with all its heaters 'ON'.

4. Vacuum pump of capacity 1500-2500 LPM and capable of an ultimate

vacuum of 1.3 millibar, along with the following accessories:

a. Non-collapsible hoses with suitable flanges for connecting to main tank.

b. Condenser for condensation of moisture.
c. Gauge for measuring up to 1.3 millibar vacuum to confirm efficiency of
vacuum pump.

5. Storage tank for transformer oil of adequate capacity (6-10KL) provided

with 50 mm bottom drain-cum-filter valve and another 50 mm top valve.
The tank should have an air tight inspection cover at the top and must
be provided with a breather and oil level gauge. Tank must be painted
with oil resistant paint from inside and must be cleaned thoroughly
before storing the oil.
6. Tarpaulin for covering main unit during filtration.
7. complete sets of fixed/ Ring ended spanners metric sizes 4-36.
8. 1 complete set of Allen keys.
9. Set of screw drivers, pipe wrenches, pliers, hammers, ladders, hole
punches and other tools normally required for such work.
10. 6 mm thick, 3 ply nylon ropes of 15 meters length
11. Devcon putty and Holdite.

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12. Oil test set (BDV kit) in good working condition having 2.5 mm gauges
for adjusting the sphere gap.
13. 2.5/5kV megger, preferably motor driven and capable of reading up to
50,000 meg. ohms.
14. Multi meters, preferably digital type having the following ranges: AC
voltage: O - 2.5, 0 - 25, 0 - 100, 0 - 250, & 0 - 1000
AC current; 0 - 100 mA, O - 1A, 0 - 10A
15. Carbon tetra chloride- 3 liters
16. Muslin cloth and cotton waste in sufficient quantities
17. Hot air blower for drying porcelain bushings.
18. Vacuum Hose pipes for oil connections should be of oil resistant material.
Natural rubber should not be used. Should withstand full vacuum.
Necessary adapters for connecting to filter machine outlet and inlet, filter
valves on main unit, Buchholz relay pipe, oil filling pipe on
conservator etc.
19. Pulling winches/pulleys
20. Steel ropes
21. Steel plates
22. Grease
23. Wooden sleepers.
24. Hydraulic/mechanical screw jacks with locking arrangement
capacity of each should be minimum 50% of the total weight of main
unit with oil.
25. Power pack system to operate all the Jacks simultaneously.
26. Measure tapes.
27. Level bottle/Level tube (plastic).
28. Stainless steel bottles for oil samples.
29. N2 cylinder with regulator and pressure gauges
30. Welding machine
31. Gas cylinders with nozzles and torch for gas cutting
32. Pressure/vacuum equalization pipes and valves
33. Adapters: 80 mm to 25 mm - 3 nos. each
80 mm to 50 mm - 3 nos. each
50 mm to 25 mm - 3 nos. each
34. Valves 25 mm flanged type with position indicators and locking devices.
50 mm flanged type with position indicators and locking devices.
35. Adapters suitable for valve and pressure gauge.
36. Bushing lifting equipments as specified in the instructions on bushings.
37. Vacuum gauge range 0-50 mbar with least count of 1 mbar.
38. transparent PVC tube to use as oil gauge shall be capable of
withstanding full vacuum

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CHAPTER – 6

EVACUATION AND OIL PROCESSING OF TRANSFORMER

6.0 Evacuation
Checklist/Table-5 for vacuum processing
6.1 Oil filling and processing (Gas/Oil filled)
Checklist/Table 6/7/ 8 for Oil processing
6.2 Air venting
6.3 Pressure testing
6.4 Settling time and again air venting

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6.0 Evacuation :

Make all necessary arrangements for evacuation and oil processing so that
once the bushings erection is completed, evacuation and oil filling will follow
immediately. The active parts inside tank core and windings is then
impregnated and protected.

Evacuation/Vacuum is the most critical and important operation in processing

of the transformer. The entire service life of transformer depends on the
degree and level of vacuum achieved, as it effects the dryness of the
transformer insulation.

A vacuum may be taken to the design vacuum level during oil filling or prior to
final N2 purging. Instruments/ accessories that may be damaged by
vacuum should not be fitted and all openings should be closed by blanking
plates. Vacuum pipe is connected to the tank top cover (preferably buchholz
relay pipe) to keep the oil in tank under vacuum. It is preferable to blanket
the transformer tank to prevent loss of heat. During filtration, oil is drawn
from the bottom and let into the transformer at the top. This will remove any
settled moisture/impurities. The filter outlet temperature should be limited
to 55°C. After about 8-12 hours circulation in this manner, the cycle is
reversed and oil is drawn the top and fed at the bottom. The circulation is
continued till the insulation resistance and oil samples tests are satisfactory.

Caution:

1. Ensure that the equalizing valve between the OCTC and main unit
is open

2. Ensure that the COPS type conservator is not applied vacuum.

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This check-list has been prepared with a view to avoid human error in case vacuum
is carried out.

Oil Filter Machine :

a) Capacity (6 KL) :
b) Make

c) Lubricating oil of vacuum

pump to be changed

d) Cleaning of Filter Packs

e) Flushing of whole filter
machine with fresh oil
f) Vacuum obtained without
load (milli bar)

Vacuum pump for evacuation of Transformer :

a) Lubricating oil to be
changed
b) Vacuum obtained without
load (millibar)
c) Diameter of vacuum hose
(50 mm)

Check hoses for cleanliness and puncture/ damage. Also ensure that these
are sustainable to vacuum and non collapsible. Sulfur in a natural rubber hoses
may dissolves in oil, causing the dielectric strength to be lowered. Dissolved
sulfur also deteriorates the conductor in transformer windings.

Connect the vacuum machine hose pipe to the top of transformer B. relay Pipe
with the valve on transformer closed. Run the vacuum pump for some time
such that it becomes hot, open the transformer valve and continue pulling
vacuum till a level of 50 mbar is achieved.

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After reaching a level of 50 mbar, close the vacuum pump and close the
valve between transformer and vacuum pump. Hold for 1 hour and record for
drop in vacuum, if any.

In case the leak, identify the leakage source by lighted Agarbatti and attend to the
same. If leak rate is within limit, continue pulling vacuum till reaching 1.3 mbar.

a) For transformers up to and including 245 kV class, continue pulling vacuum

and after reaching 1.3 mbar hold the vacuum for 24 hours.

b) For transformers of 420 kV class and above, continue pulling vacuum and
after reaching 1.3 mbar hold the vacuum for 36 hours.

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TABLE- 5

Vijai Electricals Ltd, Hyderabad

VACUUM PROCESSING

CUSTOMER : ________________ SITE : ____________________

DATE TIME VACUUM LEVEL REMARKS

00:00
01:00
02:00
03:00
04:00
05:00
06:00
07:00
08:00
09:00
10:00
11:00
12:00
13:00
14:00
15:00
16:00
17:00
18:00
19:00
20:00
21:00
22:00
23:00
24:00

WEATHER :
AMBIENT :
FILTER MACHINE TECHNICIAN :

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6.1 Oil filling & Processing :

Oil filling under vacuum, the insulation system should be virtually free from
trapped gas bubbles, which might be dangerous for voltage with stand
strength and to improve dryness of the transformer insulation. Moisture may
have been absorbed during the re assembly at site or due to mishaps during
the transit, so that addition drying is advice before commissioning

The following activities need the inspection covers to be opened. During

such operations the active parts (core and windings, leads, supports,
insulations) will be treated as exposed.

Exposure for the other activities such as:

a) Jumper connections LV Bushing.

b) Jumper connections Neutral bushing.
c) Fixing Turrets on cover.
d) Fixing Turrets on side.
e) Core insulation checking.
f) Bushing mounting.
g) Buchholz relay pipe work fixing on cover.
h) Air vent/ Gas release pipes/equalizer pipe fixing.
i) Some one has to enter inside the tank for connections/inspection etc.

A final internal inspection should be made for any work has been done inside
the tank. All electrical connections should be checked for tightness. All
electrical clearances inside the tank should be checked. One final check should
be made that all tools or any materials that have been used inside the
transformer, have been removed.

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This check-list has been prepared with a view to avoid human error in case
Oil filling and processing is carried out.

Oil Storage Tank :

d) Inside shall be painted or :
should be cleaned with cotton
rag.
e) Silica gel breather provided :
f) No opening shall be left :
uncovered
g) Name plate indicating weight :
of the oil storage tank and
capacity in liters
h) Cleanliness of inside of pipes :
/hoses to the storage tank

During the assembly on site, the transformer will be sealed off after end of
working hours. It is then practical to apply a slight over pressure over night
with N2 inside the tank. Next morning it is checked that the pressure still
remains. Suspected leaks may be located with leak detection i.e. soap water

Erect the Turrets, bushings and complete the main buchholz relay/ Air vent
piping work. Transformer exposure time should not exceed 12 hrs. It is
advisable to start erection early in the morning on a day when rain is not
forecast

The above process cycle is for a maximum exposure of 12 hours. If the

exposure is excess of 12 hours, repeat heating and vacuum cycle, if required.
In any case exposure should not exceed 36 hours.

Oil that has been delivered to the site in drums or tanker is collected in one or
more storage tanks shall be processed through filter machine and oil samples
are taken to check BDV values before filling starts.

Before the oil filling is started a final check will be made of the tightness of
the complete Transformer with its cooling equipments. This is done with
vacuum

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The preferred method of oil filling is to feed oil from storage tanks into
transformer by the BOTTOM FILTER VALVE. A vacuum proof plastic tube may
be connected to the valves at the top and bottom for the use as an oil level
indicator. When the oil has reached the level indicated above, the valve in the
vacuum line is closed. Filling of oil from bottom continues, oil in tank rises. At
last the tank is completely filled, and the meter shows atmospheric pressure.
The filling is continued for a short time, so that a slight over pressure builds
up in the tank. Then the valve between buccholz relay and conservator is
gently open. Filling is continued until the conservator has the correct oil level.

Exposure during Erection :

Transformer kept sealed with
N2 in between.
First Day Hrs. :
E
Second Day Hrs. :
X
p Third Day Hrs.
0
Nitrogen Pressure applied
S
after each days erection work
U
PSI
R
Ambient Temperature 0C :
E
Average Relative Humidity :

Weather Condition :

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Nitrogen Sealing in case of delay in oil filling or under

conditions of humidity exceeding 70% :
i) Number of N2 cylinders
used for displacing the air
inside the tank
(N2 purging)
j) N2 admitted from bottom
valve

k) Valve at diametrically
opposite end at top kept
open

l) Number of cylinders used

for building up 2 PSI

Filtration of OCTC Oil :

a) Temperature of filter
0
outlet oil C
b) Duration of filtration Hrs.
c) Oil BDV (2.5 mm gap)
kV
d) Time gap between
completion of filtration &
complete filling of OTLC
conservator Hrs
e) Is the OCTC, Breather
attached Hrs.

Oil filling in conservator (COPS) :

a) In case of COPS,
instructions in Brochure
to be followed
b) Oil filling rate < 2000
LPM

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a) Gas filled Transformer :

1. The oil shall confirm to IS: 335. Normally supplied along with the first
filling and 10% top up quantity of oil in non returnable drums directly
from refinery.
2. Oil received at site in drums/ tanker; need to be treated in storage tank
before filling inside the transformer.
3. It is always better to fill the main tank up to transport level gauge
with treated oil under vacuum, immediately after placement of main
unit on plinth. Oil can be drained up to required level for installation of
bushings & again to be filled back through filter machine.
4. After installation of bushings, cooler bank/s & all the accessories, fill
processed oil under vacuum up to half level of conservator & also in
cooler bank/s.
5. Isolate cooler bank/s & carry out oil filtration in main tank for two
passes.
6. Check Break down Voltage of this oil. If ok, stop the filtration. If not ok,
continue for two more passes.
7. Carry out oil filtration of isolate cooler bank/s for two passes.
8. Check Break down Voltage of this oil. If ok, stop the filtration. If not ok,
continue for two more passes.
9. When main tank & cooler bank/s oil are ok, open the cooler bank
valves & carry out oil filtration in main tank ( Cooler bank open ) for
two passes
10. If cooler bank/s is provided with oil pumps, run all the pumps ( not at a
time but in a sequence ) for at least 6 Hrs. each.
11. Carry out oil filtration in OCTC diverter vessels for two passes.
12. Check Break Down Voltage of this oil. If ok, stop the filtration. If not
ok, continue for two more passes.
13. Carry out air venting from all the port provided on Transformer
(Including OCTC)
14. Carry out COPS processing on conservator provided with COPS bag &
bring the oil level in conservator to the required level.

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15. In case of conventional conservator, bring the oil level in conservator

to the required level.
16. In case of OCTC conservator, bring the oil level in to the required level.

b) Oil filled Transformer :

1. Oil received at site in drums/ tanker; need to be treated in storage tank

before filling inside the transformer.
2. Oil can be drained little below inspection covers for installation of
bushings & again to be filled back under vacuum.
3. After installation of bushings, cooler bank & all the accessories, fill oil
up to half level of conservator.
4. Isolate cooler bank & carry out oil filtration in main tank for two passes.
5. Check Break down Voltage of this oil. If ok, stop the filtration. If not ok,
continue for two more passes.
6. Carry out oil filtration in cooler bank separately for two passes.
7. Check Break down Voltage of this oil. If ok, stop the filtration. If not ok,
continue for two more passes.
8. When main tank & cooler bank oil are ok, open the cooler bank valves
& carry out oil filtration in main tank (Cooler bank open) for two
passes.
9. If cooler bank is provided with oil pumps, run all the pumps ( not at a
time but in a sequence ) for at least 6 Hrs. each.
10. Carry out oil filtration in OCTC diverter vessels for two passes.
11. Check Break down Voltage of this oil. If ok, stop the filtration. If not ok,
continue for two more passes.
12. Carry out air venting from all the port provided on Transformer (
including OCTC )
13. Carry out COPS processing on conservator provided with COPS bag &
bring the oil level in conservator to the required level.
14. In case of conventional conservator, bring the oil level in conservator to
the required level.
15. In case of OCTC conservator, bring the oil level in to the required level.

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3) Oil filling in Main unit with Tank mounted radiator

After the unit processing is complete as per procedure given above, for filling
oil in radiators and main unit, adopt following procedure.

a) Open only top radiator valve and pull vacuum 1.3 mb or less in the
transformer tank.

b) Open bottom valve of radiator and start filling previously filtered oil
through tank top filter valve by maintaining vacuum at 5 mb. Fill previously
filtered oil at 2-3 kilo litre per hour at a temperature of 45-55°C up to tank
oil level gauge.

c) Wait for 30 minutes level may fall down due to rising of oil level in
radiator.

d) Again fill oil and adjust Oil level up to tank gauge.

e) Break vacuum by opening valve in the breather pipe

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TABLE- 6

Vijai Electricals Ltd, Hyderabad

OIL PROCESSING

CUSTOMER______________ SITE : ____________________

DATE TIME Filter machine Filter machine Remarks

Inlet Outlet
Temperature Temperature
00:00
01:00
02:00
03:00
04:00
05:00
06:00
07:00
08:00
09:00
10:00
11:00
12:00
13:00
14:00
15:00
16:00
17:00
18:00
19:00
20:00
21:00
22:00
23:00
24:00

WEATHER : REMARKS :
AMBIENT :
FILTER MACHINE TECHNICIAN :

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TABLE- 7

Vijai Electricals Ltd, Hyderabad

OIL TESTING

CUSTOMER : ______________SITE : __________________________

PARAMETERS STORAGE TANK 1 STORAGE TANK 2 REMARKS

DATE OF TEST
TIME OF TEST
OIL TEMP.
BDV VALUE

DATE OF TEST
TIME OF TEST
OIL TEMP.
BDV VALUE

DATE OF TEST
TIME OF TEST
OIL TEMP.
BDV VALUE

DATE OF TEST
TIME OF TEST
OIL TEMP.
BDV VALUE

DATE OF TEST
TIME OF TEST
OIL TEMP.
BDV VALUE

DATE OF TEST
TIME OF TEST
OIL TEMP.
BDV VALUE

DATE OF TEST
TIME OF TEST
OIL TEMP.
BDV VALUE

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TABLE- 8

Vijai Electricals Ltd, Hyderabad

OIL TESTING

CUSTOMER : _______________SITE : ____________________________

OIL SAMPLE TAKEN FROM MAIN TRANSFORMER (TOP)

DATE OF TEST
TIME OF TEST
OIL TEMP.
BDV VALUE

OIL SAMPLE TAKEN FROM MAIN TRANSFORMER (BOTTOM)

DATE OF TEST
TIME OF TEST
OIL TEMP.
BDV VALUE

OIL SAMPLE TAKEN FROM ON LOAD TAP CHANGER

DATE OF TEST
TIME OF TEST
OIL TEMP.
BDV VALUE

REMARKS :

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6.2 Air venting/ Topping up : Air venting is very important activity in processing
of the transformer.

• After completion of oil filling & processing, carry out air venting from all the ports
provided on transformer main tank, pipes, turrets, bushings, OCTC, headers,
radiators, pumps, expansion bellows, on line filter, instruments like Buchholz
Relay etc.
• Carry out air venting at the bottom most point first & top most point at last.
• Allow complete air to come out of the port. At some stage, a mixture of oil & air
will come out. Continue venting un till oil starts flowing with out mixture of air.
• Air venting arrangement is either through a plug, bolts, screw, combination of
plug & screw, combination of screw & spring loaded plug, ball valve etc.
• Most of the OCTCs have at least two venting arrangements. One for top of the
diverter vessel & other for suction pipe. Both the plugs are provided on top cover
of diverter vessel. The arrangement is either combination of plug & screw or
combination of screw & spring loaded plug.
• Buchholz Relay air venting arrangement is mostly through a ball valve.
• Condenser bushings have air venting arrangement through bolt at the flange
level.
• Oil communicating bushings have air venting arrangement through a screw.
• Pumps have air venting arrangement through bolt.
• Transformer tank cover, pipes, headers, radiators, turrets, expansion bellows, on
line filter etc. have air venting arrangement through plugs.

6.3 Pressure testing :

• Pressure testing on transformer is carried out to confirm leak proof ness at

maximum operating temperatures in future.
• For this purpose a higher pressure than a normal operating head is applied on the
oil through conservator for 24 Hours.
• The Silica gel breather is removed & a nitrogen filling arrangement with valve is
connected to the breather pipe flange.
• A nitrogen pressure gauge or a oil pressure gauge is provided at nitrogen filling
arrangement or at the bottom filter valve of transformer main tank respectively.
• Gradually increasing the nitrogen pressure through regulator, read _____PSI on
oil pressure gauge or on nitrogen pressure gauge _____PSI
• Note down the pressure ( Oil pressure or Nitrogen pressure ), time & ambient
temperature at the time of completion of nitrogen filling.

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• Close the valve, Remove nitrogen pressure gauge ( if opted ), nitrogen filling
arrangement & blank off the valve.
• After 24 Hours, preferably at same ambient temperature, note down the oil
pressure ( if opted for oil pressure gauge ). If opted for nitrogen pressure gauge,
remove valve blanking plate, fix the pressure gauge, open the valve & check the
nitrogen pressure.
• No drop in the pressure indicates leak proof ness of transformer.

6.4 Settling time & Again air venting/ Topping up :

Settling time :

a) Up to 245 kV Class transformer : 24 Hours

b) 420 kV & above Class Transformer : 72 Hours.

After completion of settling time as per applicable voltage class, carry out
again air venting from all the ports.

Completion of Erection work:

Final topping up is now done up to level in conservator. Any other work

such as wiring of various alarm/trip contacts, fan motors, pump motors,
and other apparatus, earthing of neutral and tank is also to be
completed. The interposing valves between the radiators and the tank
are opened. Tank surface is retouched with paint where is required and
transformer is made ready for commissioning tests

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CHAPTER – 7

TESTING AND COMMISSIONING

7.0 Commissioning of Transformer

7.1 Pre-commissioning Oil Checks
7.2 Pre commissioning Transformer Tests
7.2.1 Requirements of Instruments used for
7.2.2 Pre-commissioning Tests
7.3 Alarm/ Trip Responses
7.4 Do's and Don’ts
Pre-commissioning check list

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7.0 Testing and Commissioning of Transformer:

If the foregoing instructions have been carefully followed, the

Transformer can be now safely put into service after Pre-commissioning
checks and tests.

7.1 Pre-commissioning Oil Checks

Test oil sample for BDV and water content. Conduct Dissolved gas analysis
on oil samples before commissioning to serve as a record for future.

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TABLE -9
During processing : Measurement of Break Down Voltage :

Acceptable
Measured Break
Break down
down Voltage
Oil sample Voltage
Sampling frequency Remarks.
from Testing method Testing method
ASTM IEC ASTM IEC
D877 296 D877 296
Drums One in every 5 drums. 25 kV 40 kV
Tanker Before filling into 25 kV 40 kV
storage tank
Storage Before start of filtration 25 kV 40 kV
tank
Storage After filtration (Before 35 kV 70 kV
tank filling into transformer)
Transformer After 2 passes of 35 kV 70 kV
main tank filtration
bottom
Transformer After completion of 35 kV 70 kV
main tank main tank filtration
bottom
Cooler A After 2 passes of 35 kV 70 kV
filtration
Cooler A After completion of 35 kV 70 kV
filtration
Cooler B After 2 passes of 35 kV 70 kV
filtration
Cooler B After completion of 35 kV 70 kV
filtration
Transformer After mixing of main 35 kV 70 kV
bottom tank & cooler oil
Transformer After completion of 35 kV 70 kV
bottom settling time
OCTC After 2 passes of 35 kV 70 kV
filtration
OCTC After completion of 35 kV 70 kV
filtration

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TABLE -10
After processing

Oil sample Sampling Acceptable Measured Remarks.

from frequency Break down Break down
Voltage Voltage
Testing Testing
method method
ASTM IEC ASTM IEC
D877 296 D877 296
Transformer After 35 kV 70 kV
Top & completion
bottom of settling
time
OCTC After 35 kV 70 kV
completion
of settling
time

TABLE-11

Measurement of moisture content

Oil Sampling Acceptable moisture Tested moisture Remarks

sample frequency content in ppm content in ppm
from Up to 145 kV Above
145kV to 245
Class 245 kV kV
Class Class
Transfor After
mer completion
bottom of settling
time
OCTC After
completion
of settling
time

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7.2 Pre commissioning Transformer Tests :

7.2.1 Requirements of Instruments used for:

Sr. Test Measuring Instrument Required Least

No. Instrument Range Accuracy Count
1) Ratio, Polarity and Voltmeter 0 to 500 V ±2% 5V
Phase relationship
and Magnetic
balance
2) Resistance Bridge 0-100 Ω ±2% 1 x 10-6 Ω

3) Insulation Resistance Megger 0-50,000 M ±5% 5 M Ω at

Ω the lowest
scale

4) Excitation Current Ammeter 0-200 mA ±0.5% 1 mA

5) Oil BDV BDV Meter 0-100 kV ±2% 2 kV

2.5 mm gauge 2.5 mm ±0.1 mm Go - No go

6) Moisture in oil Moisture 0-100 ppm 1 ppm 1 ppm

meter

Use the instruments with valid calibration certificates for conducting the
tests at site.

7.2.2 Pre-commissioning Tests :

Note: Refer to Rating and Diagram Plate and all other instruction plates before
tests.

1. Turns Ratio :

The ratio should be checked on all taps and between all the windings and the
results should tally with factory test reports as well as the rating and
diagram plate details. Ratio shall be checked by applying a single phase
230-300 V supply on the high voltage side and measuring the voltage on
the low voltage side at all tap positions.

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2. Magnetizing Current :

A three phase low voltage supply is given to the HV winding of the 3

phase transformer and simultaneous current readings of the three phases
are taken using low range A.C. ammeters. Reading should be recorded for
future reference.

3. Magnetic Balance :

Apply single phase 230V supply to each phase of a star connected winding,
and measure voltage induced in other phases. When centre phase is applied
the other phase voltage should be 30 to 70%. When extreme phase is
applied, centre phase voltage should be 50 to 95%.

4. Short Circuit Test :

Apply single phase voltage on LV side. Short the correspondence HV

connections. Currents through shorting should be calculated considering
impedance of the transformer & test voltage to be applied. Test voltage to be
decided considering the available size of cables, measuring instruments & set
up. This test is for checking impedance of the transformer.

5. Insulation Resistance :

The insulation resistance between windings and between windings and

earth should be measured with 2500/5000 volts megger and the values
should be compared to the test report values. If there is much variation,
the same should be intimated to the manufacturer.

IR at 60 sec.
The dielectric absorption factor = ------------------ should be ≥ 1.3
IR at 10 sec.

It is preferable to have a motor operated megger. Before measuring the

insulation resistance, it should be ensured that the bushings are cleaned
thoroughly.

6. Winding Resistance Test :

A Kelvin Bridge should be used for the measurement of resistance at all

windings. Tapped winding resistance shall be measured at all tap positions.

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Absolute steady reading should be obtained for minimum 1 minute. The

tap winding resistance trend shall be gradually increasing / decreasing.

7. Capacitance & Tan Delta of Bushings :

This test is carried out on all condenser type bushings. The Capacitance & Tan
Delta values are measured with normally 10 kV bridge. The measurement is
carried out between line terminal & test tap terminal of bushing. The values
should be comparable with factory test results however in any case the tan
Delta value of bushing should never be more than 0.7 %

8. Vector Group :

This can be checked by the voltmeter method. The primary and secondary
windings are connected together at one point. A low voltage three phase
supply is then applied to the terminals. Voltage measurements are then taken
between various pairs of terminals and vector group is verified.

9. Insulation Resistance of Core Earthing Terminal :

The link provided between core earthing terminal & earth should be removed
first. The insulation resistance between core & earth should be measured with
1000 volts megger and the value should be noted for further reference. It is
preferable to have a motor operated megger. Before measuring the insulation
resistance, it should be ensured that the terminal is cleaned thoroughly. Zero
insulation resistance indicates that the core is getting earthed at some other
point also.

10. Insulation Resistance of CTs :

The link provided between CT secondary terminal & earth should be removed
first. The insulation resistance between each core to other core & each
core to earth should be measured with 500/1000 volts megger and the
values should be noted for further reference. It is preferable to have a
motor operated megger. Before measuring the insulation resistance, it
should be ensured that all the terminals are cleaned thoroughly. Zero
insulation resistance indicates that the CT is getting earthed or shorted (as
the case may be) at some point.

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11. Insulation Resistance of Fans :

The insulation resistance between winding to earth should be measured with

500/1000 volts megger and the values should be noted for further
reference.
It is preferable to have a motor operated megger. Before measuring the
insulation resistance, it should be ensured that all the terminals are cleaned
thoroughly. Zero insulation resistance indicates that the fan motor is getting
earthed at some point.

12. Insulation Resistance of Pumps :

The insulation resistance between winding to earth should be measured with

500/1000 volts megger and the values should be noted for further reference.

It is preferable to have a motor operated megger. Before measuring the

insulation resistance, it should be ensured that all the terminals are cleaned
thoroughly. Zero insulation resistance indicates that the pump motor is getting
earthed at some point.

13. Continuity of CTs :

The link provided between CT secondary terminal & earth should be removed
first.
The winding resistance between different terminals of each core should be
measured with multimeter in ohms range. Values should be noted for further
reference.

7.3 Alarm/ Trip Responses :

7.3.1 Setting of instruments :

a) Setting of Oil temperature indicator/ Winding temperature indicator :

Generally two types of Oil temperature indicators have been provided:

Dial Type Indicator

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Digital Type Indicator

There are two types of dial Type Indicators:

Dial Type Indicator with Mercury Switches.

Dial Type Indicator with Snap Action Switches.

In case of dial type indicator, ensure that the transport locking screw has
been removed after receipt at site.

Dial Type Indicator with Mercury Switches.

In case of mercury switch, for setting the switch there are two pointers below
each switch. Right hand side pointer is for ON setting & left hand side pointer
is for OFF setting. Each pointer can be loosened & repositioned with the
provided screw. The temperature indicating dial provided behind the mercury
switch is just for guidelines.

On cover of this instrument there is one spring operated lever provided for
turning the switch mechanism mounting plate to simulate the test position of
any temperature. This spring loaded lever ultimately operates one more lever
on the left side of the temperature indicator.(This lever can be seen on
opening the cover of the instrument ). By operating any one of these levers
different temperature positions can be simulated.
Alarm, Trip or Cooler Control settings can be made using the screws & guiding
dial plate behind the switch. After each setting, tighten the screws & by
rotating the dial with the help of lever, confirm that the setting is correct &
mercury switch operates at the desired setting.

Dial Type Indicator with Limit Switches.

In case of indicators with limit Switch, there are pointers & screws provided
for setting the switch. Each pointer can be loosened & repositioned with the
provided screw. In this type of indicator, provision is given only for adjusting
ON setting. OFF setting is automatically selected as 10 Deg. less than ON
setting.

By operating the lever, different temperature positions can be simulated.

Alarm, Trip or Cooler Control settings can be made using the screws & guiding
dial plate. After each setting, tighten the screws & by rotating the dial with the
help of lever, confirm that the setting is correct & limit switch operates at the
desired setting.
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Digital Type Indicator

Digital type indicators are generally provided in the electronically controlled

transformer monitoring system. In this system, the input signal is from PT 100
transducer & the digital out put is displayed on the screen.
For settings refer the separate broacher of manufacturer.

a) Setting of Magnetic oil level gauge :

These are fitted & set at factory. However in case for some reason if it is
required to be set at site, then referring the design data about minimum &
maximum positions of floats with respect to the indications in dial, the float
arm & gear mechanism need to be set.

b) Setting of oil flow indicator : If provided

These are fitted & set at factory. However in case for some reason if it is
required to be set at site, then referring to the designed setting of the limit
switch at a designed flow rate ( % of flow ), the limit switch can be adjusted
to function at the designed flow rate.

c) Setting of water flow indicator : If provided

These are fitted & set at factory. However in case for some reason if it is
required to be set at site, then referring to the designed setting of the limit
switch at a designed flow rate ( % of flow ), the limit switch can be adjusted
to function at the designed flow rate.

d) Setting of water pressure switch : If provided

These are set at factory. However at site the setting can be changed just by
turning the setting knob to the required setting.

e) Setting of oil pressure switch : If provided

These are set at factory. However at site the setting can be changed just by
turning the setting knob to the required setting.

f) Setting of Differential pressure switch : If provided

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These are set at factory. However at site the setting can be changed just by
turning the setting knob to the required setting.

g) Checking of cooler control box : If provided

a. Wiring as per Schematic diagram ( Only Out Going Terminals ).

b. Check out going terminals for correctness of cable termination, polarity,

ferruling & neatness.

c. Heater & Illumination Circuit. Check functioning of heater & illumination

circuit as per schematic. Also check that the external cabling bunch in not
in the close vicinity of heater to effect damage / burning of the wiring.

d. Setting of Overload Relays / Breakers for Fans and Pumps. Set the relays
referring to the rating plate detail of fan & pump and their running
currents.

e. Cooler control functioning as per recommended temperature settings.

f. In the normalised condition of the cooler control, functioning of the fans /

pumps etc. should be checked by simulating the different temperature
conditions.

g. Direction of Fans. To be checked after termination of permanent power

supply to M. Box.

h. Direction of Pumps. To be checked after termination of permanent power

supply to M. Box.

h) Checking of OLTC operation ( local ) :

a) Hand operation ( Raise / Lower )

b) Electrical lperation ( Raise / Lower )
c) Checking of end Limits ( Hand Operation )
d) Checking of end Limits ( Electrical Operation )
e) Checking of mid Position Passage.
f) Checking of emergency Trip.
g) Tripping on Reverse Phase Sequence.
h) Matching of Tap Position on Top Cover & DM.
i) Setting of Overload Relay for motor.

i) Checking of RTCC :

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a) Remote Operation of OLTC ( Raise / Lower ).

b) Matching of Tap Position Indication with DM.
c) Different Indications of Cooler Control.
d) Different Controls of Cooler Control.
e) Different Controls of Transformer Monitoring System.
f) Heater & Illumination Circuit.

j) Checking of CT terminal box :

a) Wiring as per Schematic diagram ( Only Out Going Terminals ).

b) Heater & Illumination Circuit.

k) Checking of THERMO junction box :

a) Wiring as per Schematic diagram ( Only Out Going Terminals ).

b) Heater & Illumination Circuit.

If site tests have been carried out within last 3 months, then proceed further
otherwise repeat testing as per section 2.

l) Review of all the site test results :

a. Carry out test on oil as per TABLE 9/10/11

b. Carry out air venting from all the ports

c. In ct terminal box / thermo junction box, check all the C.T. connections. no
c.t. should remain open circuited. it should be either connected to a relay
or should be shorted with a link.

d. Check operation of master trip relay with initiation of trip command on BR,
OSR, PRD, OTI, & WTI.

e. Check actual tripping of breakers with initiation of at least one trip contact
on transformer.

f. Check provision of earth fault protection, over current protection

and differential protection. in case of gen. transformer, over fluxing
protection in addition to all the above mentioned protections.

g. Check direction of fans & pumps.

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h. Check cooler control operation.

i. Confirmed that the transformer, M. BOX, TJ BOX, DM Box, Ct Junction box

etc. have been earthed properly.

j. Confirm same tap positions in OCTC top cover, DM Box & RTCC.

k. Check direction of rotation of OCTC.

l. Check settings of OTI / WTI. (Alarm, Trip, Cooler Control On/Off)

m. Check test tap covers on all condenser bushings have been fitted in
place, tightly.

n. Check positions of all the valves ( gate valves & butterfly valves )

o. Check condition of silica gel.

p. Confirm the settling time given to transformer.

q. Check earthing of neutral bushing.

r. Confirm collection of oil sample for DGA test. (just before commissioning)

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TABLE -11
Checking of protective instruments up to individual M. Box

Terminals in
Instrument & Signal Checking method. Result
M. Box.
B.R. Alarm By operating the test knob
B.R. Trip By operating the test knob
OSR – R Trip By operating the test knob
OSR – Y Trip By operating the test knob
OSR – B Trip By operating the test knob
OTI Alarm By rotating the OTI up to Alarm
setting
OTI Trip By rotating the OTI up to Trip
setting
WTI HV Alarm By rotating the WTI up to Alarm
setting
WTI IV Alarm By rotating the WTI up to Alarm
setting
WTI LV Alarm By rotating the WTI up to Alarm
setting
WTI HV Trip By rotating the WTI up to Trip
setting
WTI IV Trip By rotating the WTI up to Trip
setting
WTI LV Trip By rotating the WTI up to Trip
setting
MOG Main Alarm Check when no oil in
conservator or by shorting the
terminals
MOG OCTC Alarm Check when no oil in
conservator or by shorting the
terminals
Sudden Pressure Trip By shorting the terminals
PRD Main Trip By operating the limit switch on
PRD
PRD OCTC Trip By operating the limit switch on
PRD
NRV By closing the valve or by
shorting the terminals
Water pressure switch
Oil pressure switch
Differential pressure switch
Off Circuit Tap Change
Switch

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7.4 Do's and Don’ts

Safety measures/precautions should be given the due importance during

inspection/ erection/maintenance work. Any mishap during the process will result
in delay in erection, endangering human life, endangering equipment life.

A) DO'S :

1. IMP. : Insulating oil and insulation for windings and connections are
inflammable. Watch for fire hazards.

2. Replace Nitrogen gas completely with air if it was filled in main unit for
transport/storage.

3. Make sure that nothing is kept inside the pockets before one enters inside
main unit. Also take off the wrist watches and shoes.

4. List up all the tools and material to be taken inside and check it after
coming out to make it sure that no tools is left inside.

5. There must be a protective guard for lamp to be taken inside.

6. Keep inspection covers open for supply of fresh air, when working inside.

7. When one person is working inside, second person must be outside for
emergency.

8. Use fix spanners and tie them to the wrist of the person or somewhere
outside the tank.

9. Be careful during connections where bolted joints (jumper connection)

are involved. So that, nuts/washers etc., are not dropped inside the tank.

10. Attach the caution tags "DO NOT OPERATE THE SWITCHES" while working
on energized unit.

11. Make sure that the fire-fighting equipment are available at the oil-
treatment equipment as well as work place and adjacent to the
transformer.

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12. Transformer tank as well as oil treatment equipment shall be connected

with permanent earthing system of the station.

13. Check air cell in conservator

14. Attend the leakages on the bushing.

15. Examine the bushings for dirt deposits and coats, and clean them
periodically.

16. Check the oil in transformer for Di-electric strength and moisture content
and take suitable action for restoring the quality.

17. Check the oil level in oil cup and ensure air passages are free in the
breather. If oil is less, make up the oil.

18. If inspection covers are opened or any gasket joint is to be tightened, then
tighten the bolts evenly to avoid uneven pressure.

19. Check and clean the relay and alarm contacts. Check also their operation,
and accuracy and if required change the setting.

20. Check the pointers of all gauges for their free movement.

21. Clean the oil conservator thoroughly before erecting.

22. Check the OTI and WTI pockets and replenish the oil, if required.

23. Fill the oil in the transformer at the earliest opportunity at site and follow
storage instructions.

24. Check the door seals of Thermo-junction Box. Change the rubber lining if
required.

25. Ensure proper tightness of top terminal cap of condenser bushings to

avoid rain water entry.

26. Check oil level in condenser bushing, any discrepancy should be reported
to Manufacturer.

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B) DON’TS :

1. Do not take any fibrous material such as cotton waste inside while
repairing.

2. Do not drop any tools/materials inside.

3. Do not stand on leads/cleats.

4. Do not weld, braze or solder inside the tank.

5. Do not weld anything to tank wall from outside.

6. Do not weld anything to conservator vessel if bag is inside.

7. Do not Smoke on or near the transformer.

8. Do not use Fibrous cleaning material, as it can deteriorate oil when mixed
with it.

9. Do not leave off circuit tap switch handle unlocked.

10. Do not use low capacity lifting jacks on transformer for jacking.

11. Do not change the settings of WTI and OTI alarm and trip frequently. The
setting should be done as per the site condition.

12. Do not leave any connection loose.

13. Do not meddle with the protection circuits.

14. Do not leave Thermo-junction box/ M. Box doors open, they must be
locked.

15. Do not switch off the heater in TJ Box/Marshalling box except to be

periodically cleaned.

16. Do not leave a ladder unlocked, when the transformer is `ON' in service, in
case it is provided.

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Do not store transformer for long after reaching site. It must be erected and
commissioned at the earliest.

After charging the transformer on No Load it is to be kept under observation

for 12 Hours on No Load. During this period Oil temperature indicator and
Winding temperature indicator temperature readings shall be recorded hourly.
After 12 Hours check buchholz relay for any gas/ air collection, If air is
collection, release air. If no abnormality is observed then transformer can be
loaded.

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TABLE 12

CHECK LIST

Pre commissioning Checks HV IV LV Tert N

Mechanical aspects :
a) Tightness of bushing lead connectors nuts
and Lock nuts(cable side)
b) Tightness of bushing terminal caps with
bushing stem
c) Grounding of bushing test taps
d) Overhead connections to bushings to be
sufficiently flexible so that excessive
tension is not applied to bushings
e) Overhead cables should not be hanging
with excessive curvature, which could
swing violently during external short
circuits and damage bushings

f) Sufficient flexibility should be built into

the connection between LV Neutral
Bushings to earthing bar so that excessive
force is not applied to the bushings
g) In case steel earthing there should be a
flexible copper connection between
bushing and steel flat so that any
overheating of steel bar due to bad
surface conditions may not affect the
bushing and also a matching joint. Such a
copper flexible to be tinned at either end,
at least 60 mm length
h) The steel grounding bar should be
galvanized and of good surface condition

i) Breather pipe connections to be

sufficiently tight
j) Buchholz Pipe Valves open

k) All valves are open/closed

l) All valves open to atmosphere blanked

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m) Radiator top and bottom valves open

n) Cooler pipe valves open

o) Pipes on either sides of expansion joints,

if provided, shall be perfectly in line
rail levels under each roller shall be same
(check with water tube)

p) All valves shall be locked using pad lock

q) All gasketted joints leak tight

r) M Box/T J Box shall be properly sealed

(cable gland plate holes to be blocked)

Customer’s Representative VEL Representative

Customer: Abir Constructions Private Limited Page 89

Chapter-7: Testing and Commissioning
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Pre-commissioning Checks = External to Transformer :

a) Setting for differential relay not to
exceed 1%
b) Over-current and restricted earth
fault protecting provided
c) Over fluxing protection provided
d) Over fluxing limit set adequately
e) Over fluxing relay actuated by
voltage on untapped winding
f) Surge capacitors for tertiary winding
g) All terminals of the delta winding
shall be ungrounded
h) Tripping circuit for ground fault any
terminal of delta winding
i) The OSR trip circuit should be
connected independently of the main
transformer buchholz relay
j) The protection circuit should run on
DC supply and in the event of failure
of DC supply, a fail safe mechanism
to trip the transformer
k) Fire fighting system circuit
interconnection to RTCC and all its
operation checked as per its manual,
(if provided)
l) Transformer maintenance register to
be opened, which specifies frequency
of checks/ maintenance operations
and acceptable limits for -
Oil in the oil cup of breather
Cleaning the bushing porcelain
Oil level in bushings/conservators
Bushing tan delta/capacitance
Contacts of buchholz relays, pressure
relief devices, sudden pressure relay,
temperature indicators, oil flow
meters, etc.

Customer: Abir Constructions Private Limited Page 90

Chapter-7: Testing and Commissioning
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OCTC diverter contacts I oil

Painting
Tightness of fasteners of electrical
connections to bushings
Scales I leaks in water coolers
Sampling of oil from standby oil-to-
water Heat exchangers to detect
water leaks
Dissolved Gas Analysis
m) Lightning arrestor and neutrals shall
be solidly earthed
n) Bimetals shall be put at copper-
aluminum joints
o) If so, the copper face to touch to
copper and aluminum face to
aluminum
p) Preparation of all instruments for
electrical tests for commissioning.
ensure right working and calibration.
q) Check all protective equipments and
relays for correct functioning and
right setting

Customer’s Representative VEL Representative (if present)

Customer: Abir Constructions Private Limited Page 91

Chapter-7: Testing and Commissioning
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Commissioning Check-list for Transformers

Auditing of Previous Site Check-lists :

a) Receipt and storage check list
b) Erection check-list
c) Oil handling and insulation
processing check-list
d) Pre-commissioning tests

Commissioning check-list :
a) Ratio at all taps preferably with a
ratio meter, compare with factory
test results
b) Single phase short circuit test at
suitable voltage (230 V or less).
Calculate impedance at all taps
c) Magnetizing current at 415 V
d) Magnetic balance test
e) Insulation resistance values at 10
sees and 60 sees polarization
index should preferably be
comparable to factory test results
f) Break down strength of oil with
2.5 mm gap spacing (average of
six readings)
g) Moisture content in oil in ppm
h) Air releasing from all points in the
right sequence. Standing/settling
time and air release after
standing time
i) Oil level in main conservator
j) Silica gel Color
k) Condition of breather (cracks.
holes, etc.) and oil in the oil cup.
l) Buchholz Relay shall be in service
position and locked

Customer: Abir Constructions Private Limited Page 92

Chapter-7: Testing and Commissioning
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m) AII interconnecting valves shall

be open
n) Valves open to atmosphere shall
be closed and blanked
o) Select WTI CT terminals as per
manual
p) All CT secondary should be
shorted either through respective
instruments or directly
q) OTI alarm/trip settings should be
85/950C
r) WTI alarm/trip settings shall be
100/11O oC
s) Earthing of tank cover to tank
t) RTD (if provided) connection shall
be as per drawing
u) Alarm indication shall be checked
by closing alarm contacts of OTI,
WTI, Buchholz Relay and oil flow
indicator
v) Breaker tripping shall be checked
by closing the trip contacts OTI,
WTI, Buchholz Relay, Sudden
Pressure Relay, Pressure Relief
Device, as applicable
w) Setting and operation of
differential and REF protection
shall be verified.
x) Separate annunciations shall be
available for different alarms
y) The surroundings shall be clean
and degree of pollution within
tolerable levels

Customer: Abir Constructions Private Limited Page 93

Chapter-7: Testing and Commissioning
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Final Checks prior to Commissioning:

These check-lists are based on previous site problems and need to be filled for
every unit to ensure healthiness of units

Following check-lists to be filled up and necessary actions taken :

a) Receipt and storage
b) Pre-commissioning checks -
mechanical aspects
c) Pre-commissioning checks -
external to transformer
d) Commissioning check-list for
transformer
e) Rating plate/caution Plate
instructions read and required
action taken
f) Standing time as per manual given
before final air release operation
g) Any pressure application/oil
damage/ disturbance to oil circuit
done during standing time
h) If above is YES, standing time to be
counted after such operations and
standing time as per manual given
i) Final air release done as proper
sequence after standing time
j) Bushing test cap tightness ensures
k) Bushing tan delta/capacitance
measured and within limits as per
supplier leaflets
l) Bushing oil level ensured
m) Tank cover to bell curb earthing
strips connected
n) All pre-commissioning test result
satisfactory

Checks immediately after Commissioning:

Customer: Abir Constructions Private Limited Page 94

Chapter-7: Testing and Commissioning
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a) Transformer humming noise /

vibration
b) Any abnormal noise from
bushing/OCTC
c) No abnormal noise shall be heard
from bushing / OCTC
d) Record any other abnormality
observed and obtain clarification
from VEL on such
e) If noise from any loose items due
vibration, tighten same and
observed
f) f) Observe for 12 hours for any
abnormality
g) g) No oil leaks from any point
h) DGA after 24 hours
i) Any other observation. obtain
confirmation from VEL in such
points

Customer: Abir Constructions Private Limited Page 95

Chapter-7: Testing and Commissioning
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Start-up Instructions:

Step Test Equipment Inspection / Acceptance

Description
No . / Controls Action Norms
BDV tester
BDV > 60 kV
1. Oil & Water content BDV
Water < 10 ppm
tester
Spanner size
2. Air release plugs Release air All air expelled
17/19
Circuit breaker Satisfactory
Verify
3. incoming/out Alarm/trip circuit operation
correctness
going of breaker
At designated
4. Breathers Visual check Oil level in cup
level
Thermometer Oil inside
5. Visual check To maximum
pockets pocket
To be light at
earthing
6. Earthing pad Spanner size M12 Tightness
terminal and the
earth
Heater switch in
7. Visual check Switch ON Switch ON
control
Energize
Remote control to from
No
Incoming close the incoming
8. abnormal
breaker incoming side keeping
humming
breaker lowest
voltage top
Remote control to
Load current as
Outgoing close
9. Synchronize per
breaker outgoing
load shared
breaker

Customer: Abir Constructions Private Limited Page 96

Chapter-8: System Normal Operation
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CHAPTER – 8

SYSTEM NORMAL OPERATION

8.1 Requirements for inspection

8.1.1 General
8.1.2 Inspection records
8.2 Inspection during operation
8.2.1 Routine inspection
8.2.2 Periodic inspection / tests
8.3 Tests during normal operation:
8.3.1 All tests under sr. no. (i) to (10) should be Performed
8.3.2 Tests under sr. no. (9) & (11) should be carried out as per
supplier's catalogue / Manual
8.3.3 tests on oil and dissolved gas analysis should be carried out
8.4 Details of tests procedure & acceptance

SYSTEM SHUTDOWN INSTRUCTIONS

8.5 To standby mode
8.6 Additional instructions for maintenance mode

Customer: Abir Constructions Private Limited Page 97

Chapter-8: System Normal Operation
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8.1 Requirements for Inspection :

Periodic inspection will help in detecting abnormal conditions of a transformer

and its parts before they cause any more serious troubles.

8.1.1 General :

The inspection items during operation are classified into two categories:
a) Routine inspection during operation
b) Periodic inspection during operation.

8.1.2 Inspection records :

The following guidelines are suggested for keeping records for each
transformer. Records to be maintained separately in a job file to facilitate
traceability.

a) Equipment record :

This can be a card containing basic information of a transformer itself such as

rating, serial number, location, supply year etc.

b) Inspection check-list :

This will contain list of points to be checked during routine and periodic
inspection. Each of the above aspects have been covered under separate
tables with recommended period for inspection/tests

Customer: Abir Constructions Private Limited Page 98

Chapter-8: System Normal Operation

8.2 Inspection during operation :

8.2.1 Routine Inspection :

Test Action required. if inspection

Sr. Inspection
Item Equipments Inspection Notes shows unsatisfactory
No. Periodicity
Controls conditions
--- Check temperature. rise Check if indication of the
is reasonable and there instruments are correct. Shut
1. Hourly WTI is no abnormal increase down transformer and investigate
with respect to earlier if it is abnormally higher even
records under normal load conditions.
---
2. Hourly OTI -do- -do-
Reduce load in case the oil /
Load & Type of Check against rated
3. Hourly Control Panel winding temperature readings are
cooling values
excessive.
---
Voltage and Check tap position An improper tap position can
4. Hourly Noise of main matches cause excessive core loss / noise
unit with voltage due to over fluxing

Customer: Abir Constructions Private Limited Page 99

 Chapter-8: System Normal Operation

8.2.2 Periodic Inspection / tests :

Sr. Inspection Item Test Inspection Notes Action required. if inspection shows
No. Periodicity Equipments / unsatisfactory conditions
Controls
1. Oil level in
Check transformer oil If low, plan to top up with filtered oil,
Weekly conservator
temperature. examine the transformer for leaks.
(Main & OCTC)
2. Oil level in OIP If no oil indication, take shut down,
Check oil level is
Weekly condenser measure tan delta and capacitance. report
maintained
bushing to supplier
3. Check color of the If silica gel is pink, change by spare
De-hydrating
Weekly active agent. Check oil charge. Old charge may be reactivated for
breather
level in oil cup further use. Make up oil, If required.
4. Main unit
If oil leaks are from gasket, tighten bolts
Radiators / Check leaks of flanges
Weekly or ex-change gasket. In case leak is from
Cooler bank / / pipes, main tank etc.
welds, repair as per guidelines,
Pipe connection
5.
Check visually that all
connections are normal
In case of any sign of heat, dean and
Weekly All external without any
tighten bolts and nuts
discoloration due to
local heating
6.
Inspect visually for
Clear up dust. if any problem
Quarterly Dust dust especially on
envisaged in temperature values
radiators

Customer: Abir Constructions Private Limited Page 100

 Chapter-8: System Normal Operation

Test
Sr. Inspection Action required. if inspection shows
Item Equipments / Inspection Notes
No. Periodicity unsatisfactory conditions
Controls
7. Examine for cracks and Clean dirt/deposits. Replace if cracks are
Quarterly Bushings
dirt deposits noticed.
8. Refer Preventive
Oil in Refer Preventive
Quarterly Maintenance Refer Preventive Maintenance Table
transformer Maintenance Table
Manual
9. Refer Preventive
Dissolved gases Refer Preventive
Quarterly Maintenance Refer Preventive Maintenance Table
in oil Maintenance Table
Manual
10. Check cleanliness & soundness of bushings.
Insulation Meggar - min. Compare with value at
Yearly If very much lower,
Resistance 500 V time of commissioning
process needs to be planned.
11. Tighten bolts evenly to avoid uneven
Yearly Gasketted Joint Check for any leaks
pressure
12. Pockets holding
Temperature
Yearly thermometers should Oil to be replenished, if required
indicator
be checked
13. Examine relay & alarm
contacts and their Clean components or replace
Relays, alarm,
Yearly Functional check operation fuses, etc. contacts & fuses, if necessary.
their circuit etc.
Check relay for Change the setting, if necessary
accuracy etc.

Customer: Abir Constructions Private Limited Page 101

 Chapter-8: System Normal Operation

Sr. Inspection Item Test Inspection Notes Action required. if inspection shows
No. Periodicity Equipments / unsatisfactory conditions
Controls
14. Check water tightness
of boxes/terminal
Spanner/screw boxes. Ensure If required, replace gasket
Marshalling box,
Yearly driver, 500 V tightness of wiring Tighten if any looseness. If not OK,
CT terminal box
meggar Connections. Measure exchange with new cable.
insulation resistance of
cables
15. Pointer to
Dial type oil Check pointer for
Yearly correspond to oil Adjust, if required.
gauge movement
temperature
16. Internal inspection of
Diverter/selector based
As per Refer OCTC Contact manufacturer/OCTC
on number of
supplier's OCTC supplier's manual supplier. Refer to supplier's
operations/oil quality
catalogue enclosed. Manual enclosed.
etc. as per supplier's
Manual.
17. Refer Fire
As per Contact manufacturer/OCTC
Fire Protection protection. system
supplier's Refer to Manual supplier. Refer to supplier's
system supplier's manual
catalogue Manual enclosed.
enclosed.

Customer: Abir Constructions Private Limited Page 102

Chapter–8: System Normal Operation

8.3 Tests during Normal Operation :

8.3.1 All tests should be performed :

a) Before Re commissioning after any overhauling/shut down

b) After every 2 years during service

8.3.2 Tests should be carried out as per supplier's

catalogue/Manual :

8.3.3 Tests on oil and Dissolved Gas Analysis should be carried out :

a) 24 Hours after commissioning

b) 6 Months after commissioning
c) Every six months during service

Customer: Abir Constructions Private Limited Page 103

 Chapter–8: System Normal Operation

8.4 Details of Tests, Procedure & Acceptance :

Sr Test Instrument Procedure Acceptance Norms Remarks/Caution

No
1. Voltage ratio Voltmeter To be done phase by phase Compare the trend of Test should not be
Ammeter by applying 415V/230V voltage ratio with used for verifying
Series supply with a 40 W series reference to pre- exact ratio
lamp lamp in series to avoid commissioning values
damage to instrument in
case of an internal fault
2. Magnetization Voltmeter To be done phase by Compare the values with Ensure that the
current Ammeter 415V/230V preferably to respect to pre- comparison is
Series series Lamp phase by commissioning values. done to the value
lamp applying supply LV with Any abnormal increase of measured on HV
the order of 50 times or LV side with
indicate that there is a respect to earlier
fault inside. The series test
lamp is also expected to
glow under such
circumstances. Pattern of
current in different phases
can also provide
Information for further
analysis
3. Magnetic Voltmeters Apply 1 phase supply 230 V a) When extreme phase is This test is
balance test or 400 V to each phase of a excited, centre phase applicable only for
star winding (preferably LV voltage shall be 50 to 3 phase units. On
where LV voltage is greater 95% of applied voltage a 5 limb job. the
than 11 kV or more) and above trend is
measure voltage induced in b) When centre phase is applicable only if
other phases excited, extreme phase there is a closed
voltage shall be 30 to delta winding
70% of applied voltage.
4. Impedance Voltmeter Test to be conducted at Compare the values with In case the
test Ammeter Principal tap. Apply 3 phase respect to pre- frequency was
415V/1 phase 230V to the commissioning values. measured and the
transformer HV side with LV Any deviation beyond 5% values during pre-
side shorted. Calculate needs further analysis commissioning as
ohmic value I.e. VII and well as during
convert to percentage maintenance test
impedance. Where practical were available
measure frequency and after conversion to
convert value by direct rated frequency,
proportion. Test to be done deviation beyond
for each pair of winding 2% needs analysis
taken at a time for a 3
winding transformer.

Customer: Abir Constructions Private Limited Page 104

 Chapter–8: System Normal Operation

S.No Test Instrument Procedure Acceptance Norms Remarks/Caution

5. Insulation >2.5 kV Insulation resistance to be Dangerous Care needs to be
resistance and Meggar measured at one minute Poor taken to ensure
Polarization and then every minute up Questionable Satisfactory bushings are clean
Index to 10 minutes. Good and free of
Calculate Polarization moisture. Also
index as In case dielectric ensure that trs. is
absorption factor is found disconnected from
= IR at 10 min IR at 1 which is ratio of other associated
min. = IR at 60 sec equipment. In case
IR at 10 sec of doubt, tan delta
then a value of > 1.3 is measurement of
considered satisfactory winding can be
done to confirm
healthiness of
insulation
6. Winding Wheatstone The test shall be Compare the values with This test shall be
Resistance bridge or conducted at all the taps pre·· commissioning/earlier the last test on
Voltmeter/ by applying dc current and values. Trend of variation winding to avoid
Ammeter values converted to 75°C shall be the same. DC flux remaining
method for comparison. Deviation in absolute in core and giving
Measurement shall be values to be within ±5% erroneous values
done when the difference to the other tests
in top and bottom temp.
of oil is < 5°C. Care to be
taken to keep at least 10
minutes interval between
readings to allow winding
to cool.
7. Check of CTs Ammeter 0.5 Ratio of the CTs to be Close to rated value In case knee point
kV or 1 kV verified before shut down voltage
Meggar Le. When transformer is in measurement is
operation. This is due to required, the same
current requirement on can be done by
the Primary of the CT > 1 Mega ohm exciting from
which is transformer lead. secondary
Otherwise low voltage
short circuit test need to
be conducted to get as
much current as possible
in the windings.
Sophisticated instruments
like ELTEL TTR CT tests
can be used, if available.
b) IR value of secondary
terminals
8. All indicating
and protection
Supplier's Instruction Manual and as per Sub-station norms
instruments
check

Customer: Abir Constructions Private Limited Page 105

 Chapter–8: System Normal Operation

Sr Test Instrument Procedure Acceptance Norms Remarks/Caution

No
9. Control boxes Standard sub- Check meggar values Minimum 5 Mega ohms If found less, space
station kit with 500 V meggar. heater to be made 'ON'
Ensure box gets warmer for sufficient time and
Check healthiness of after the heater Is kept recheck meggar value.
space heater ON for some time If found unhealthy,
check circuitry. If
required, replace heater
In case of any
abnormality
troubleshoot/check
circuitry & take
corrective action as
required.
10. Tests on
bushings, OL
TC and Fire
As per Supplier's Instruction Manual
Protection
system

11. Tests on oil Sampling i) BDV As per our Instruction Sampling should be
bottles, Oil test ii) PPM Manual done from active oil
kits/ Test
Laboratories
12. Oil DGA Sampling Dissolved Gas Analysis Sampling should be
bottles, Test done from moving oil.
Laboratories In case of any
abnormality, trend of
gases is important. If
the problem is not very
serious, degas
and further monitoring
on a weekly basis to be
done. Report to
manufacturer for his
comments

Customer: Abir Constructions Private Limited Page 106

Chapter–8: System Normal Operation

8.5 To Stand by Mode :

a) Switch off the circuit breakers on incoming and outgoing sides of the
transformer.

b) Open the isolators on both sides

c) Close the earth switches

8.6 Additional Instructions for Maintenance Mode :

a) Discharge the transformer with discharge rod and keep it connected during
maintenance.

b) Display notice boards "MEN AT WORK" in Control room as well as at the

site.

c) Switch off auxiliary supplies to drive mechanism of OLTC, cooler control

panels and Transformer relay panel

Customer: Abir Constructions Private Limited Page 107

Chapter-9: Preventive Maintenance
Requirements/Instructions
-----------------------------------------------------------------------------------------------------------------

CHAPTER – 9

MAINTENANCE
REQUIREMENTS / INSTRUCTIONS

9.1 Preventive maintenance

9.2 Corrective Maintenance Requirements

Customer: Abir Constructions Private Limited Page 108

 Chapter-9: Preventive Maintenance
Requirements/Instructions

9.1 Preventive Maintenance:

Maintenance of parts and materials should be planned according to the following table

Sr. Maintenance Special Consumables

Periodicity Item/Area Warning Caution
No. Required Tools Required
1. Porcelain insulator Safety
Cleaning should be
such as bushing, arrangement
done periodically.
-- lightning arrester, -- Water for --
Interval depends on
supporting hot line
actual condition at site
insulator washing
2. Oil filter Transformer
5 Yearly Radiator Oil flushing inside -- --
machine oil
3. Outermost coat
5 Yearly Paint Repainting -- Emery Paper --
is Polyurethane
4. Gaskets in
contact with oil Use Teflon for
10 Yearly Gaske1 Change -- --
are Nitrile plugs
based
5. No welding Take care of
5 Yearly Conservator Cleaning -- Transformer
allowed on tank COPS bag
6. Operation and
Yearly Buchhulz relay mechanical Test set - -- -
inspection tests
7. As per ON Load Tap
Please refer supplier's catalogue of OL TC attached herewith in Section - 15
suppliers changer & Motor
"Brochures of Fittings and accessories
catalogue drive Unit

Customer: Abir Constructions Private Limited Page 109

Chapter-9: Preventive Maintenance
Requirements/Instructions

9.2 Corrective Maintenance Requirements:

Sr. Dismantling Reassembly

Fault Preparation Required Safety Notes Repair Tolerances
No. Procedure Process
8. Disconnect sensor Fix the new
from thermometer Short WTI CT instrument, insert
Abnormal Replace with spare
pockets, disconnect terminals before the sensor in the
indication of instrument and inform
alarm/trip contacts disconnection. Replace pockets, reconnect --
temperature supplier for repair of the
and CT connection De-energise the
at OTIIWTI instrument
and remove the transformer alarm/trip contacts
instrument and CT terminals
9. De-energise the Refer
Abnormal Test and ensure Oil
transformer. Connect Oil Air release from conservator -
drop in oil BDV >60 kV Admit oil to
filter machine to Top -- conservator filling
level of Main & Water <15 ppm normal level
filter valve of process valves instructions in
conservator before filling
transformer Section-5,1
10. De-energise the Oil BDV > 60 kV
Low oil level transformer and open Moisture < 5 ppm
in the top filling plug of the before filling. The Admit oil to Close the filling To normal
-
condenser bushing. Prepare one plug should not be normal level plug level
bushing adapter between the left open when not
filling plug and filter hose filling
11. De-hydrating
Reactivate
breather Dismantle the
Oven for heating the till blue Refill in the
active agent breather and take out - Deep blue
active agent to 60°C color is breather
changes the active agent
achieved
to Pink color
12. Law oil in the
Transformer ail far Unscrew the ail cup Adjust oil
de-hydrating -- Re fix the ail cup Level mark
filling and take it out level
breather

Customer: Abir Constructions Private Limited Page 110

Chapter-9: Preventive Maintenance
Requirements/Instructions

Sr. Preparation Dismantling Reassembly

Fault Safety Notes Repair Tolerances
No. Required Procedure Process
13. Unfasten, and dismantle Foreign particles
Spare gasket Refer
Gaskets leaks, using crane Open should not fall into Fit the
Other arrangements Replace the
not stopped by inspection cavers far the active parts. component --
required for air gasket
tightening access to' disconnect Ensure min back
filling/draining in
electrical connection if any exposure
14. Disconnect the electrical Excess pull an
Abnormal tan
connection referring the internal Replace the Refer bushing
delta valve of Spare bushing --
bushing manual connection should bushing manual
bushings
be availed
15. Drain oil from main tank Refer Section- -5.1 Fill fresh oil or Complete oil
High Vacuum pump
Low insulation and evacuation to 1 Torr right quality. filling and air
and filter machine. --
resistance far 24 hours Refer Section- release. Refer
Refer Section-5.1
5.1 Section-5.1
16. Non-functional Drain oil to required level. --
Spare instruments.
MOG. Refer Section- 5.1 for After refilling
Oil filter machine Replace --
Buchholz details oil, air release
and oil storage tank
relay, OSR
17. Low insulation Dismantle the old cable -- -- --
resistance of Replace the
cables
wiring in control Cables
panels

SPARES:

It is healthy practice to have essential spares like one number of each type of bushings, one thermometer, one cooling
fan, pump, buchholz relay etc., for each group of similar transformer. Suppliers recommendation may also be considered
in this connection.

Customer: Abir Constructions Private Limited Page 111

Chapter-10 Trouble-Shooting
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CHAPTER – 10

TABLES TROUBLE-SHOOTING

10.1 General
10.2 Failure investigation flow diagram
10.3 check-list of preparation items for failure investigation
10.4 Check-list for general observations after failure
10.4.1 External
10.4.2 Transformer details
10.4.3 Indications associated with failure
10.4.4 Service condition of the transformer at the time of failure
10.4.5 Failure effect
10.4.6 Results of the tests conducted before and after failure
10.4.7 Failure mode
10.4.8 Presumed cause for the failure
10.4.9 Repair recommendation
10.5 Fault diagnosis
10.5.1 Troubleshooting flow chart for transformers
10.5.2 Chart for abnormal level of fault gases

Customer: Abir Constructions Private Limited Page 112

Chapter-10 Trouble-Shooting
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10.1 General:

A failure investigation is required when a transformer is tripped on some

protective relay or electrical/oil test results show deviation from the
previous results. Under these circumstances a failure investigation flow
diagram is to be followed so as to take corrective action.

10.2 Failure investigation flow diagram :

In case of transformer failure, the flow diagram as indicated below is to be

followed. This will help in taking proper decision, as regards the further
serviceability of the transformer, rectification at site or factory or scrapping
the transformer in case of damage beyond repair.

10.3 Check-list of preparation items for failure investigation :

a. Transformers test report - factory & field (erection commissioning test

report) & accessories test report.

b. Routine inspection reports & operation log book

c. One line diagram of substation

d. Relaying scheme including relay coordination chart, instrument settings

e. Maintenance log book, including previous reports of past problems

f. Camera

g. Measuring tape

h. Magnifying glasses

i. Bioscope

j. Flash light

k. Oil sample bottles and syringes

l. Failure report format

Customer: Abir Constructions Private Limited Page 113

Chapter-10 Trouble-Shooting
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10.4 Check-List for general observations after failure :

10.4.1 External :

a. No load/ on load

b. Load on transformers

c. Voltage on HV/LV

d. Ambient temperature at the time of failure

e. Storms or lightning in the area at the time/prior to failure

f. Unusual sounds, odorous

g. Evidence of animal contact

h. System disturbances

i. Switching configuration in station at the time of failure

j. Interview with witness/station operators present when unit tripped or

failed

k. Operation/maintenance log registers

l. Fire protection system

Customer: Abir Constructions Private Limited Page 114

Chapter-10 Trouble-Shooting
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10.4.2 Transformer Details:

1. Maker's Serial No.

2. Capacity in MVA
Voltage class of HV
3. IV
LV
4. Connection YyO/Yd11/Yd1
5. No. of Phases
6. Tap Changer On load/Off Circuit
7. Make, Type & SI. No. of Tap changer
8. Cooling
ON-Oil Natural, AN-Air Natural AF-Air
forced, OF-Oil Forced
WF-Water Forced
9. Oil Preservation System Conventional conservator/ Air
cell type conservator/Thermo
svphon Filter
10. Date of Manufacture
11. Date of First commissioning of the
transformer
12. Date of Failure
13. Dates of site inspection
14. Service history of the transformer
(Attach separate sheets if necessary)
15. Over Voltage Protection

1. Lightning Arrestor
2. Arcing Horn
3. Both
4. No over voltage protection
16. Neutral Earthing HV IV
LV
1. Insulation
2. Direct Earthing
3. Indirect Earthing
17. Line Connections HV IV
LV
1. Overhead line
2. Cable box

Customer: Abir Constructions Private Limited Page 115

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10.4.3 Indications Associated with Failure :

1. Main Tank Buchholz Relay

2. OCTC Buchholz Relay Alarm/Trip
3. WTI Alarm/Trip
4. OTI Alarm/Trip
5. MOG Alarm/Trip
6. PRO/Diaphragm Tripped / Operated
7. Over current Relay Trip
8. Differential Relay Trip
9. Earth Fault Relay Trip
Whether there IS gas collection In
buchholz relay of transformer. Yes/No
10. If yes, color of gas. Quantity of the Colorless/Dark
gas in cm3 Test results of Buchholz Inflammable/Non-inflammable
Relay Gas
Whether there is gas collection in the Yes/No
OCTC Buchholz relay
11. If yes; color of gas. Colorless/Dark
Quantity of the gas in cm3
Test results of OCTC Buchholz gas Inflammable/Non-inflammable

10.4.4 Service Condition of the Transformer at the time of Failure :

1. No Load/On Load taken

2. Voltage on HV side
3. Working Tap No.
Any tap changing operation at the
4.
time of failure
Oil level in the transformer
5.
conservator,
6. Oil level in the OCTC conservator
Running/Not Running/Running
7. Oil circulating pumps
reverse
8. WTI reading
9. OTI reading
10. Ambient temperature in the yard
Atmospheric condition
Yes / No
11. a. Rain.
Yes / No
b. Lightning

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10.4.5 Failure effect:

Bushings:

1. a) Oil level
b) Porcelain condition
c) Test Tap - Tan delta values
Tank:

a) Deformation
2. b) Welding cracks
c) Leakages
d) Tank explosion
e) Oil discharge through PRD
3. Damages due to fire, if any
Damages to auxiliary equipment :

a) OCTC
b) Pump
4. c) Fans
Yes/No
d) Unit Cooler
e) Heat Exchanger
f) Air cell conservator
g) Bursting diaphragm
Damages to other equipment
5.
installed near to the transformer

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10.4.6 Results of the Tests Conducted Before and After Failure :

Insulation Resistance
(Type, Make & Voltage Rating of
Megger)
1.
HV-Earth
LV-Earth
IV-Earth
OTI reading at the time of test
2.
(in Deq.C)
3. Continuity of the windings
4. Ratio
Exciting current at the low voltage
5.
(3 Phase. 415 V)
6. Winding resistance
Oil test results
Main tank.
7. OCTC tank BDV (KV) Water content (ppm)
OTI reading at the time of sampling
(in Deg.C)
8. DGA results
9. Other test results, if any

Note: Latest test results before failure to be furnished for comparison.

10.4.7 Failure Mode :

Component initially involved in the failure

10.4.8 Presumed Cause for the Failure :

(Give a brief explanation)

10.4.9 Repair Recommendation :

At Site / Repair Bay / Factory

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10.5 Fault diagnosis :

10.5.1 Trouble shooting Flow Chart for Transformers :

Symptom Possible Cause Item to be checked

Differential relay Shut down Electrical
and Buchholz relay of the tests and
or pressure relief transformer DGA
device operate
simultaneously
Buchholz relay and
pressure relief
device operate
simultaneously
Only differential Excessive Threshold values
relay operates inrush current of relays Level of
when the inrush current
transformer is
energized
Only Buchholz Faulty Wiring continuity
relay (trip) operation and condition
operates of relay or Contacts Oil-stop
device valve position
between tank and
conservator
Only Buchholz Internal fault Trapped air or Gas analysis
relay in the build up of Any sudden drop
(alarm) operates transformer gas in oil temperature
Choking in
breather
Over-current, External fault If heavy current is
ground arrestor such as flowing through
and other relays system the windings
operate short-circuit Whether OCTC is
Abnormal interrupting heavy
operation in the short-circuit
system or other current
recording device The duration and
value of short-
circuit current

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Symptom Possible Cause Item to be checked

Buchholz relay Shut down Electrical tests,
and pressure of the including
relief device transformer Faulty diverter measurement of
operate and the tap switch insulation
simultaneously changer Simultaneous resistance,
Operation of start of pumps voltage ratio,
incomplete tap exciting current,
changing relay and winding
resistance Gas Integrity of all
analysis Operation circuits and
Either Buchholz
Faulty Faulty of relays Any contacts
relay or
diverter operation external short Malfunctioning
pressure
switch of relay Circuits Whether of pressure
relief device
or device trip due to relief device
operates
simultaneous start
of both pumps
Incorrect
stopping
Shutdown
positions Operation of any circuit breakers
of the
because of Drive motor not Incorrect voltages
transformer
incomplete tap operating Motors, pilot switches and relays
and the tap
changing out of Control circuit
changer
step tap
positions
Drive motor
operates but Closing and opening positions of
incomplete tap switch contacts
changing takes Time setting for relay
place
Tap position where excessive torque
occurs
Excessive drive Torque value when using the
torque manual crack handle on the drive
mechanism and the number of times
the handle must be turned
Oil leakage from main tank to
High oil level of Oil level of main tank and OCTC and
OCTC compartment
OCTC oil temperature
Faulty operation of oil level
conservator Operation of oil level gauge
gauge

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10.5.2 Troubleshooting Flow Chart for Abnormal Level of Fault Gases:

In case of gas analysis of oil shows any abnormality then the following
flowchart for corrective action is suggested:

Possible Cause Item to be checked

Local overheating of oil and 1. Perform the gas dissolved gas analysis. In
insulating materials particular, reaffirm that there are combustible
Partial discharge and arcing gases detected by repeating the analysis. Also
perform consecutive analysis at regular
Deterioration caused by aging intervals to monitor changes in combustible
gas concentration.
2. Check the condition of the load being placed
on the transformer. There should be no
overloading, over excitation or irregularity in
the oil temperature.
3. Check that the transformer has suffered no
system faults, such as external short circuits,
ground lightning strikes, or operation of
protective relays.
4. Check the condition of ancillary equipment for
the transformer, such as overheating of oil
pumps. In the case of pump, check the motor
current.
Oil leakage between OL TC 1. Check that the oil level of the diverter switch
compartment and main tank compartment is correct for the oil
temperature.
2. Drain oil from the divert or switch
compartment, and check the insulating
cylinder, and gasketed joints for leakage.
External facts (caused by Check the history for the tank, such as whether it
welding and use of was welded recently. Date of oil replacement, etc
contaminated oil for example) .

Customer: Abir Constructions Private Limited Page 121