Transformer Vector Technic

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Electrical Installation
Techniques
Medium sized
Distribution
Transformers
Nag Ramesh
31
st
December 2007
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Contents
21 Transformers Standard Accessories - Conservator 7
22 Transformers Standard Accessories - Oil level gauge 8
23 - 24 Transformers Standard Accessories - Silica Gel Breather 9
25 - 26 Transformers Standard Accessories - Buchholtz Relay 10
27 Transformers Standard Accessories - Gas drawing device 11
28 - 29 Transformers Standard Accessories - Pressure relief valve/
Explosion vent
12
20 Transformers Standard Accessories Arcing Horns 6
18 - 19 Transformers Standard Accessories - Bushings 5
16 -17 Transformers Standard Accessories - Wheels 4
7 Caution 1
8 - 12 Types of Transformers 2
13 - 15 Transformers Standard Accessories 3
Slide No. Topic Sl. No.
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Contents
47 Lifting of Transformer by Lugs and Jacks 22
40 -43 A completely assembled Transformer (typical 1600 kVA) 19
35 - 36 Transformers Standard Accessories -
Winding Temperature Indicator (WTI)
16
30 -32 Transformers Standard Accessories Radiators, Radiators
assembly and disassembly
13
46 Transfer of responsibility, Handling and lifting 21
44 - 45 Transportation of Transformers 20
39 Transformers Gaskets 18
37 - 38 Transformers Standard Accessories -
Protection Junction Box (Cable Termination Box)
17
34 Transformers Standard Accessories -
Oil Temperature Indicator (OTI)
15
33 Transformers Standard Accessories - Butterfly Valve for Radiator 14
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Contents
65 Oil sampling kit and test cup for dielectric strength 35
48 Lifting of Transformer by Fork Lift and transferring 23
49 Lifting of Transformer Wire Ropes 24
50 -51 Receiving the transformer at site 25
52 - 53 Storage of Transformer prior to energizing 26
54 - 57 Indoor Installation 27
64 Oil sampling from an oil drum or tanker 34
63 Oil sampling from a Transformer 33
62 Minimizing noise emission 32
61 Shifting to and placement on foundation 31
60 Foundation Construction oil pit and oil sump 30
59 Foundation Construction rails and shims 29
58 Outdoor Installation 28
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Contents
106 107 Energisation 47
75 Oil Filtration 40
66 Erection of Transformers transported fully assembled and filled with
Oil
36
67 - 69 Erection of Transformers transported with loose parts and filled with
Oil
37
70 -73 Erection of Transformers transported with out Oil 38
74 Additional Supports 39
104 105 Check-list to be filled in before energisation 46
88 - 103 Pre-energisation Checks 45
82 - 87 Power Circuit Connections 44
81 Oil Filtration Process - Oil filtration performance analysis 43
77 - 80 Oil Filtration Process 42
76 Oil Filtration Machine 41
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Contents
108 Energisation Check List 48
109 - 113 Operation Temperature rise and loading capacity 49
114 - 116 Parallel Operation of Transformers 50
117 Load distribution between parallel running Transformers 51
118 - 120 Protection of Transformers 52
121 - 123 Maintenance and supervision during operation 53
135 - 136 Acknowledgement and references 59
137 Disclaimer 60
138 Power and Productivity for a better world 61
133 - 134 Applicable Standards 58
132 Installation Record for Transformers 57
130 - 131 Safety Precautions 56
129 Repairs and Spare Parts 55
124 - 128 Investigation of Transformer disturbances 54
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Medium sized Distribution Transformers
Caution
1. Installation of Transformer should be done by skilled personnel or contractors who are trained
and qualified in installation of Transformer and similar electrical equipment. All on-site
regulations must be carefully observed (installation regulations for electrical systems,
regulations for Transformers and environmental safety).
2. In order to eliminate danger to anyone, the Transformer must be installed in such a way that
touching the Transformer is impossible after it has been energized.
3. Precautions must be taken to ensure that access to the Transformer is possible only after it
has been isolated from the mains (e.g., by forced interlock between the switchgear and the
Transformer access doors), exceptions are customer requirements and Transformers with
cable boxes for both primary and secondary and Transformers mounted on pedestals with
porcelain to ground clearance > 2,74 m.
4. To prevent any risk, suitable measures must be taken during erection and maintenance work to
ensure that the Transformer cannot be reconnected by any unauthorized persons.
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Types of Transformers
Transmission of energy is generally divided in two parts; first is transmission over long
distances at high voltages, which is supported by Power Transformers.
The second part is distribution of the energy from substations to the various users; this
is supported by Distribution Transformers in various hierarchies.
1. LARGE DISTRIBUTION TRANSFORMERS, LDT
Power range 5000 kVA and above
Primary voltage Up to 72,5 kV
Available fluids Mineral oil, dimethyl silicone,
esters and synthetic hydrocarbons.
Transformers of this type are used for receiving the energy from higher voltage
levels and to transform and distribute the energy to lower voltage level
substations (11 or 33 kV) or directly to large industrial consumers.
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2. MEDIUM DISTRIBUTION TRANSFORMERS, MDT
Power range 315 - 5000 kVA
Primary voltage Up to 36kV
Available fluids Mineral oil, dimethyl silicone, esters and synthetic
hydrocarbons.
Transformers of this type are used to step down three phase high voltage to low
voltage for energy distribution, mainly in metropolitan areas and for industrial
applications.
These transformers are available in three phase dry type and oil filled (hermetically
sealed or with Oil Conservator and Breather). In hermetically sealed type, flexible
corrugated tank walls enable sufficient cooling of the transformer and compensate
for changes in the oil volume due to temperature variations during operation.
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SMALL DISTRIBUTION TRANSFORMERS, SDT
Power range Up to 315 kVA
Primary voltage Up to 36kV (generally 11 kV)
Available fluids Mineral oil, dimethyl silicone, esters and synthetic
hydrocarbons.
Transformers of this type are used to step down three-phase high voltage to low
voltage for energy distribution, mainly in the countryside or low-density populated
areas.
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DRY-TYPE DISTRIBUTION TRANSFORMERS
Dry-type Transformers are used to minimize fire hazard and other environmental
contamination on surroundings and people, like in large office buildings, hospitals,
shopping centers and warehouses, sea going vessels, oil and gas production
facilities and other sites where a fire has potential for catastrophic consequences.
They are available as resin impregnated, vacuum cast resin and Resibloc versions.
Resin impregnated Transformers are rarely used in distribution applications.
Vacuum cast resin dry-type Transformers
Power range 50 kVA up to 30 MVA
Primary voltage Up to 52 kV (generally 33 kV)
Climate class C2
Vacuum cast means that the high voltage windings are cast-in in epoxy and cured
in vacuum. The high voltage windings are typically disk winding.
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Resibloc
dry-type Transformers
Power range 30 kVA up to 40 MVA
Primary voltage Up to 52 kV
Climate class C2
Resibloc is an ABB patented process for the high voltage winding. The high
voltage winding is multi layer type with a cross wound glass fiber insulation soaked
in epoxy, cured in open atmosphere.
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Transformers Standard Accessories
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Wheels
They are always bi-directional, flat-type or flanged. They are usually supplied disassembled
from the transformer. Their assembly can be executed lifting the transformer with a crane or
with some jacks placed on special brackets in one of the three ways shown in the enc. dwg.
1. Trolley 2. Flask
3. Wheel 4. Trolley
5. Pivot 6. Wheel
7. Spacers 8. Fastener plaque pins with screw
9. Flask
Type 1 Medium sized Distribution
Transformers: fix the flask unit (with
the wheels) to the trolley by means of
the two special screws in the suitable
direction.
Type 2 Small sized Transformers:
insert the pin into the wheel and into
the trolley holes in the suitable
direction, together with the spacers.
Fasten the pin with the help of the
special plaque and screw.
Type 1 Type 2
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Wheels
Type 3 Medium transformers: fix the flask (with the
wheels) to the back flask with the four special screws
in the suitable direction.
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Bushings
The components of the bushings are:
- metallic stem coupling internal and
external live parts of the transformer;
- insulating porcelain;
- oil-tight gaskets;
- coupling and clamping nuts;
- Arcing horns.
Instructions for Bushing
replacement:
Unscrew the nuts (13) without letting the
stem turn (3). Remove the cap (4), the
gasket (7), the porcelain (1) and the
gasket (9). After replacing the damaged
part reassemble the bushing operating in
the opposite direction taking care not to
let the stem turn (3). Breathe where
necessary (Buchholz relay, bushings)
loosening the nuts (13).
1. Upper porcelain
2. Lower porcelain
3. Stem
4. Cap
5. Washer
7. Gasket
8. Gasket
9. Gasket
10. Gasket
11. Gasket
12. Washer
13. Nuts
14. C- Washer
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Bushings
Bushings are usually already assembled on the transformer: in some particular cases, they are
shipped separately and must be assembled upon arrival, following manufcaturers instruction,
after removing the closing caps on the transformer and with the oil level below the transformer
cover.
Bushings must be stored in their original package, until their assembly. The porcelain part is
particularly fragile, therefore maximum care must be taken when handling or fixing the external
connection, avoiding dangerous stresses.
No particular maintenance is required, except the periodical cleaning (once every 6 months) of
the external porcelain surface.
In case of oil leakage, check:
- the pressure on the gasket;
- the porcelain conditions;
- the gaskets conditions.
When the replacement of one of the bushing components is required, follow the instruction
supplied with the part. In any case, it is advisable to keep one or more spare bushing and
relative gaskets as emergency spares.
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220 140 170 36
155 100 125 24
155 70 95 17.5
85 60 75 12
IEC ABB kV kV
Arcing Horn
Distance K (mm)
BIL
Level
System
Voltage
Arcing Horns on Bushings
They are provided on the bushings as a protection to the
transformer against transient over-voltages across
windings and earth due to lightning and switching surges.
They are generally provided on request. The lower horn
is fastened on to flange of the bushing with one of the
fixing screws and the upper horn is fixed to top end nut
of the bushing by means of a bracket.
Adjust the gaps K and C as per manufacturer's
recommendation.
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Conservator
1) air inlet pipe (transformer side) 8) pipes and fittings for connection to the transformer tank
2) conservator filling plug (transformer side) 9) pipes and fittings for connection to the tap changer
3) conservator supporting brackets 10) oil level gauge of the tap changer
4) bracket fixing plates 11) conservator. drain plug (tap changer side)
5) lifting lugs 12) conservator filling plug (tap changer side)
6) conservator drain plug (transformer side)
7) oil level gauge
8
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Oil level gauge
1 - Signalling switch
2 - Float
3 - Rod
4 - Gland
The switch contact is normally closed. Perform the electrical connections according to the Wiring Diagram
(being the terminal numbered on the board), or find the terminals through a simple continuity test. The level
gauge grounding is performed by a suitable little connecting terminal.
Before the transformer start-up, it is advisable to check the gauge and the switch for perfect operation, taking
into consideration that the switch trips slightly in advance in respect to the minimum level signal. No particular
maintenance is required for the level gauge. Eventual oil leakage can be eliminated by replacing the tight
gasket, after having lowered the oil level in the conservator.
The level gauge is made up of the following
components:
- main body with Plexiglas graded
window
- float and drive
- magnet with external signalling
disk
- minimum oil level signalling switch
Usually the oil level gauge is supplied
already assembled on the conservator.If not,
it has to be fixed to the proper stud bolts,
inserting the relevant gaskets. During
transformer filling utmost care has to be
taken to check that the gauge index is
corresponding to the oil temperature (taken
by the thermometer).
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Silica Gel Breather
1 - internal thread
2 - inox cylinder
3 - transparent hose
4 - labyrinth
5 oil cup
Silicagel braether is a transparent tank of salts of Silica chemically
pure, with Cobalt indicator. The air sucked into the transformer (due
to thermic contractions of oil mass) passes through this.
Silicagel absorbs humidity in the air signalling the reached degree of
saturation by change of colour:
Orange or Blue = completely dry
Purple or Pink or White = completely saturated.
The salts contained in the breather can be taken off and regenerated
by heating them at 120-150C until they get their original blue colour
again. The upper and lower parts of the breather consist of compact
casting in aluminium alloy. The transparent hose, which contains the
salts, is of Plexiglas or glass (for chlorinated oil transformer) and it is
protected by a stainless steel cylinder drilled in such a way as to
allow the visual inspection of salts.
In the lower part there is a closing system which prevents the contact
between air and salts: this closing system can be mechanical or
hydraulic, and allows the air passage in the two directions (inlet and
outlet) only when there is a pressure difference between the inside
and the outside of the transformer.
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Silica Gel Breather (contd.)
Silicagel breather is normally shipped disassembled to avoid alteration due to oil leakage
caused by transports jolts. It must be assembled to the suitable pipes coming from the
conservator of the transformer. The oil cup must be attached to the breather after removing the
cork plug on the breather. Fill the oil cup with oil up to the mark on the cup before fitting it on to
the breather. Silicagel breather needs no particular maintenance, apart from periodical
regeneration (or replacement) of salts, and periodical check of oil level in the cup.
Silicagel breather, before assembling,
has to be stored in its original package.
The breather should be removed during
oil filtration to avoid oil getting mixed
with Silica gel during oil filtartion, and
the pipe from the conservator must be
plugged.
When 2/3rd of the Silicalgel has turned
Purple, Pink or White, it has to be
replaced or regenerated.
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Buchholtz Relay
1. Terminal board
2. Breather cock
3. Mechanical test button
4. Gland
5. Drain plug
6. Inspection holes
7. Pneumatic test valves
Buchholtz relay usually has two contacts (tripping and alarm)
And can operate closed - open - or one closed and one open.
It Is made of:
- an external case complete with its parts as shown on the
drawing;
- an internal metal frame float, mercury switches or magnetic
controlled switches; a metal fan calibrated for signal at strong
oil back flows (from the transformer to the conservator).
Usually Buchholz relay is supplied already mounted on small
& medium rating transformers and disassembled on high
rating ones.
Eventually it must be assembled during erection as per
manufacturers instruction, generally observing the following:
1. Before assembly, check that the Buchholz is not damaged
and it is free from humidity. If not so, it has to be dried in a
furnace at a temperature not higher than 70C;
2. Assemble the Buchholz and related gaskets between
the flanges of the pipes placed between the cover of the
transformer and the conservator; an arrow on the relay
shows the direction of assembly from the transformer to
the conservator.
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Buchholtz Relay
3. Connect the earth, alarm & tripp terminals: their identification is
made with the diagram on the relay.
4. Make sure that eventual shut-off valves are open; then fill the
Buchholz relays with oil through the conservator.
5. Breath the Buchholz with the breather cock.
6. Test operation of Buchholz relay as follows:
6.1 Mechanical test:
Remove the protective cap screwed on the button (item 3); push
the button checking the contact closing (or opening) by a
continuity test;
6.2 Pneumatic test:
Blow-in air through the suitable valve (item 7) checking the closing (or opening) contact as above;
Alternatively, close the shut-off valves (if there are any) at the top and at the bottom of the Buchholz:
drain the relay through the drain plug checking the contact closing (or opening) as above. Then fill
the Buchholz again, and breath.
In any case, both contacts have to be handled with care in order to avoid internal damages and de-
calibration. Such relays must be stored in their original packages during storage. However, it is
advisable to keep at least one spare part complete of gaskets because model change and it is not
always possible to interchange them.
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Gas drawing device
1. Connection to Buchholz relay
2. cock
3. Breathing and gas drawing cock
4. Oil drawing and drain cock
5. Gas inlet valve for relays circuit test
The gas drawing device must be connected to the breather pipe
of Buchholz relay by means of the suitable tube foreseen for
this purpose, and must be fixed to proper support according to
the overall dimension drg.
After filling it with oil, breathe from the cock (item 3).
During the normal working the cock (item 2) is open, while 3
and 4 are closed. This way the box and the tube are filled with
oil.
If you want to draw the eventual gas collected in the Buchholz
relay, open cock 4 taking care to let cock 2 always open: thus
the oil can come out from the box and the gas contained in the
relay can enter the box.
When gas has moved into the box (check through the
graduated hole) close cocks 2 and 4. To drain gas open cock 3.
The gas drawing device is also equipped with a gas inlet valve
for the relays circuit test. This test has to be carried out before
starting the transformer up, operating the same way as stated
for the Buchholz relays. Before assembling, keep the device
stored in its original package.
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Pressure relief valve/ Explosion vent
1. Switch for opening signal
2. Breathing screw
3. Spacer
4. Gasket
5. Holes for screw stud
6. Visual Indicator for valve opening
7. Orienting cover
8. Fixing screws for the protecting cover
9. Valve body
10. Gasket seat
11. Calibrating nut
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Pressure relief valve/ Explosion vent
Spring loaded explosion valve is usually supplied already mounted on the transformer.
Its assembly must be carried out placing the valve case and its gaskets on the proper hole on the
transformer, as indicated in manufcaturers drawing.
After filling the transformer with oil, trapped air must be let out by loosening the breathing screws
and then tightening them back.
At this point the protecting cap must be so positioned by orienting it as to direct the hot oil sprays
in the least dangerous direction, in case of eventual opening.
These vents are equipped with the following devices:
- a calibrating nut placed on the central stem, which blocks the springs. If the nut is screwed up the pressure
rises, and viceversa. The calibration ranges normally from about 0,2 to 0,7 atmosphere;
- a visual indicator for valve opening: this is a pin projecting from the central part of the protective cover
when the valve opens. To make it go back to its right position it is necessary to push it in side wards;
- a signalling switch: this is a quick-trip limit switch enclosed into a tight box. It operates simultaneously with the
visual indicator; the contact can be normally closed or open. Signalling is continuous until the visual indiactor
is put again in its normal position. Pressure relief valve/ Explosion vent has to be stored in its original packing
until assembly. Before assembling, it has to be made are free from dirt and moisture. No particular
maintenance is required.
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Radiators
A - Lifting hook B - Upper shut-off valve
C Gasket D - Upper breathing valve
E - Fixing plaque for radiators F - Lower shut-off valve
G - Oil drain valve H - Shut-off valve Lever
On distribution and small rating transformers, radiators are
welded to the tank and need no particular maintenance, except
for usual and periodical cleanings which are necessary in
the long run.
On higher rating transformers, radiators are usually of
detachable type.
When radiators are supplied disassembled, and the storage is
foreseen to be long, it is advisable to keep them stored indoor,
in order to prevent deterioration of surfaces due to atmospheric
condensing.
The flange closing the caps must not be removed: if
accidentally removed, make sure that radiators are free from
humidity, rust or dirt before assembling.
It is better to keep a complete set of gasket as emergency
spares and to keep the closing caps of radiators and flanges for
an eventual reuse.
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Radiators Assembly
- Make sure that the shut-off valve (B&F) are safely closed: remove the caps from
valves and radiators;
- Place the gasket (C) in the proper seats;
- Assemble one radiator at a time, fill it with oil, proceeding as follows:
a) open the breathing valve (D) of the upper header;
b) open the lower shut-off valve (F) making the oil flow into the radiator
very slowly, in order to avoid air bubbles;
c) when the radiator is filled with oil, close the upper breathing valve;
d) open the upper shut-off valve (B) to permit the oil circulation.
Proceeding as above, the oil level in the conservator decreases: therefore
it is necessary to restore the oil level in the conservator as gradually as
radiators are assembled and filled.
Assemble the radiator fixing plaques by means of the proper flanges (E).
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Radiators disassembly
- Close both the shut-off valves (F&B);
- Open the upper breathing valve (D);
- Open the drain valve (G); empty the radiator pouring oil into a dry clean
receptacle;
- Remove the radiator, place the closing caps on the shut-off valves (B&F)
without removing the gasket (C) from their seats;
- Place the rubber blanking caps on the radiators headers in order to
avoid internal dirt and moisture;
- Close the breathing and drain valves (D&G).
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Butterfly Valve for Radiator
Opening and closing of radiators
butterfly valves have to be
performed as follows:
- loosen the ring nut (2) in order
to reduce the pressure on the
gasket (3);
- turn the lever (1) in order to
open or close the valve;
- tighten the ring nut (2).
To replace the gasket (3), remove
the pin (4), remove the lever (1),
unscrew and remove the ring nut
(2), remove the block (5) and
withdraw the gasket (3) by means
of a nail.
Then replace the gasket.
After the replacement, fit again all
parts in the reverse sequence.
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Oil Temperature Indicator (OTI)
1. Bulb for temperature measurement
2. Rotating female plug
3. Capillary plated with lead and flexible pipe
4. Pipe union with spring for application of
vibration damping suspension
5. Sealing threaded ring
6. Sealing box for connecting terminals
7. Pointers for fixed contacts of alarm and trip
It is generally a pneumatic tmeperature indicator and is used
usually for top oil temperature measurement. It is supplied
already assembled. Electrical signalling and tripping must be
carried out according to the Wiring Diagram. The thermometer
grounding is carried out from a suitable terminal.
Dip the bulb into its pocket (thermo well filled with oil) and fit it
with the rotating female plug. The trip contact pointer has to be
calibrated as follows:
- For OFAF: sum of the values of max. ambient
temperature and max over-temperature allowed for
the oil;
- For OFWF: sum of the values of the cooling water
temperature and max. over-temperature allowed for the oil.
The alarm contact pointer has to be calibrated at 5-10C less
than the trip one. Some thermometers are provided with a fourth
pointer for showing the maximum temperature reached.
They are usually supplied already calibrated: If not so, calibration
must be carried out with its proper screw. All thermometers must
be handled carefully to avoid damages of capillary. Before being
assembled they have to be stored in their original packing.
When a remote temperature indication is required, a pt100
sensor inserted into the thermo well is used.
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Measurement of winding temperature is carried out in an
indirect way. The windings hot spot is assumed to be near top
of the windings where they are surrounded by top oil. Further
the temperature gradient between winding hot spot and top oil
is dependent on losses in the winding. Winding losses are
proportaional to square of the current. Hence winding hot spot
temperature can be approximated by top oil temperature + a
value proportional to the temperature diffrence i.e. a value
proportional to square of the current.
This is realised by sensor similar to OTI inside a resistor
immersed in top oil, and current from secondary of a current
transformer which reflects the winding current is made to flow
through the resistor. A shunt is provided across the resistor for
adjusting the indicated temperature to winding temperature
calculated or measured during heat run test. Hence the
temperature indiactor measures the top oil temperature to
which is added the temperature difference between winding
and top oil. The current transformer is mounted inside the
transformer tank or in the cable termination box.
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For remote indication, a pt100 element is used instead of pneumatic instrument.
In some designs, winding top oil temperature gradient is added to top oil temperature in the dispaly
unit using only an OTI and winding current transformer output. Like OTI, WTI also has alarm and
trip contacts. On actuation of trip contact, upstream circuit breakers must be tripped with proper
wiring from WTI/ marshalling box to HT Panel. Sometimes additional contacts are provided in WTI
for control of additional forced cooling equipment.
Normally a WTI does not need any calibration at site. Mounting instructions are similar to that of
OTI.
In case of dry type type transformers, WTI will be 3 or 6 pt100 elements or thermistors embeded in
the top of the winding and the sensors are connected to a temperature indicator-cum-scanner
mounted on terminal box.
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Protection Junction Box (Cable Termination Box)
1-2-3 - Fastening methods fixing the junction box to the transformer cover
4 - Junction box 5 - Air outlet 6 - Cover
7 - Air inlet 8 - Cable Gland 9 - Cable
10 - Transformer Bushing 11 - Direct coupling to bushing
12 - Cable termination busbar 13 - Cable termination
14 - Support insulator 15 - Front Cover with manholes or flange for panel (if required)
16 - Disconnecting chamber 17 - Copper Flexibles
18 - Gland Plate
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Protection Junction Box (Cable Termination Box) - Assembly
1. Connect the Junction box to top cover of Transformer (or its termination box already assembled on to
transformer). Remember to use the gasket (although not shown in the above diagram).
2. Connect the cable termination busbars to the bushings.
3. Assemble the glands and the gland plate to the box.
4. Assemble the power cables to glands.
5. Connet cable terminals to cable termination busbars
6. Connect the earthing of glands to junction box.
Some accessories like Surge Arrestors and Current Transformers are also mounted inside the Cable
Termination Box.
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Transformers Gaskets
Gaskets of the cover, flanges and bushings are usually made of oil-resistant,
vulcanized cork-sheets or oil resistant rubber. When the gaskets are leaking, the leaks
can usually be stopped by tightening the bolts. When a gasket has to be detached or
replaced, the sealing surfaces should be carefully cleaned and smeared with sealing
varnish (oil resistant Shellac).
Rubber gaskets are not to be smeared with varnish.
When joining two gaskets, their ends should be bevelled and glued.
Oil-resistant rubber rings are used as gaskets for bushing bolts, shafts and spindles.
Oil-resistant and heat-resisting plastic gaskets can also be used as shaft and spindle
gaskets. All these gaskets can be tightened and replaced from outside the tank. When
tightening the gaskets utmost care must be taken to prevent breaking of bolts or
gaskets. In particular stud nuts must be tightened very carefully.
Cork gaskets are not re-used.
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A completely assembled Transformer (typical 1600 kVA)
1. Transformer Tank
5. OLTC
6. Inspection cover for
OLTC connection
7. Flat Roller (bi-
directional)
8. Base Channel
9. Earthing Terminal
10. Rating & Diagram Plate
15. Conservator with lifting
lugs, oil filling cap and
drain plug
18. Silica Gel Breather
20. Pressure equaliser pipe
21. Jacking Pad
22. Drain cum bottom filter
valve with plug
24. Buchholtz Relay
25. Shut-off valve
29. OTI
30. WTI
33. OLTC Surge Relay
34. Surge Relay shut-off
valve
39. Anti earth-quake
clamping
Elevation
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Side View
16. Oil level gauge
17. Conservator
compartment
for OLTC
19. Explosion vent
with oil sight
glass with
double
diaphragm
36. Silica Gel
breather for
OLTC
conservator
compartment
37. Bottom Oil
sampling valve
with plug
38. Dial type
magnetic oil
level gauge
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Plan
2. HV Cable Box with
disconnecting chamber
3. LV Busduct
4. LV additional neutral
bushing
11. Air release plug
12. Thermometer Pocket
for Glass bulb
Thermometer
13. Radiator with air
release plug, lifting lug
and drain valve
14. Radiator valve
23. Top filter valve with
plug
26. Lifting lug for complete
transformer
27. Lifting lug for top cover
and active part
28. Marshalling Box
31. Pocket for OTI
32. Pocket for WTI
35. WTI CT
40. Neutral CT
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Other Details
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Transportation of Transformers
Preferably all construction work should have been carried out to the
Transformer bay before the Transformer reaches site to prevent it from
getting dirty or damaged.
The transformer is supplied filled with oil and normally all accessories fitted,
except for the largest units. The radiators, condenser bushings and
conservator may be dismantled during transport.
The Transformer may be provided with dehydrating breather or sealed if
provided with pressure relief device.
During transportation the transformer is filled with oil so that active part is
fully immersed in oil and oil level is below the lower cover surface;
however, the oil level is left sufficiently low for bushing installation.
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Transportation of Transformers
During transport the following should be considered:
Angle of tilting exceeding 10 must be specified in the contract;
Prevention of damage to bushings, corrugated panels or radiators and
accessories;
Larger transformers should preferably be positioned with the longitudinal axis in
the direction of movement;
Secure against movement/ sliding by means of transport beams, wedges/
wooden blocks and fastening wire/ lashes to ensure safety during road traffic
conditions;
Vehicle capacity/ suspension must be adequate for the transport weight of
the transformer;
Adapt vehicle speed to the road conditions;
Any impact recorders to be specified in the contract;
Any use of crates or containers.
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Transfer of responsibility, Handling and lifting
Transfer of responsibility
This depends of the agreed terms and conditions of the contract.
Handling, lifting
The Transformer must be kept in normal upright position, unless otherwise indicated by the
documents.
Only approved and suitable lifting equipment should be used.
Forklift should be used only under transport pallets or transformer bottom.
Load should not be applied to corrugated fins or radiators and their supports.
While lifting the Transformer, only the fixtures provided should be used (transport eyebolts/
lifting lugs, bugles, lifting/ jack pads).
When hydraulic jacks are used, only provided jacking points should be used, and in such a
way that twisting forces on the transformer tank are avoided.
Bushings, Cable Boxes or Conservators should not be used for lifting, pulling or pushing the
Transformer.
When lifting a transformer with cable boxes on the cover, special care must be taken.
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Lifting of Transformer by Lugs and Jacks
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Lifting of Transformer by Fork Lift and transferring
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Lifting of Transformer (Wire Ropes)
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Receiving the transformer at site
1. Upon receiving the transformer at site, do the following:
- Check the way in which the transformer has been secured on the trailer,
- Check whether the delivery is complete according to order confirmation,
- Compare the packing list with the goods received:
- Check standard accessories:
- Packed together with transformer;
- Separately packed.
2. Inspect the following:
- The transformer nameplate;
- Liquid level, when applicable. Any leakages?;
- External damage, e.g. cracks in bushings; any damage to Radiator Fins;
- Dents or damages to Radiators;
- Colour matching of loose parts like conservator and radiator with colour of Transformer
tank;
- Impact recorders indications when applicable;
The receipt of the unit shall be signed for, and the result of the inspection shall be noted.
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Receiving the transformer at site
3. Transformer shipments are normally insured.
In case of damage revealed during the receiving inspection, do the following:
Make necessary arrangement to avoid further damage,
Contact the insurance company concerned and Supplier,
Make a report of the damage immediately,
Do not start repairs until responsibilities are clarified and actions are agreed
upon by all involved parties.
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Storage of Transformer prior to energizing
When storage of the transformer is required, the following
recommendations should be noted:
Store preferably in dry and clean locations, without any possibilities of mechanical
damage and on a solid foundation.
If the transformer does not have a structural steel base, it should be placed upon
supports to allow ventilation under the bottom of the transformer base.
If the Transformer is not filled with oil, fix the conservator and dehydrating Breather
and fill it with oil up to the level corresponding to normal service temperature.
The Oil conservator and dehydrating breather must be checked to ensure that dry
air is breathed (Conservator type only). Oil samples to be analyzed regarding
moisture content prior to energizing.
Humidity/ condensation in control cubicles, driving mechanism for on-load tap
changer, cable boxes and in cabinets of dry-type transformers etc. should be
inspected/ removed.
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Storage of Transformer prior to energizing
When storage of the transformer is required, the following recommendations
should be noted:
Any drying and heating equipment of the cabinet (if any) must be connected to electric supply,
to prevent the Transformer getting damp (especially in the case of dry type Transformer).
Storage temperature for dry-type transformer is in general: -25C to 50
o
C, however for
Resibloc: -60C to 50
o
C. Oil filled Transformer: 5
o
to 50
o
C. Relative humidity should be less
than 75%. If such a storage area is not available, then the Transformer must be kept under a
sun-roof covered all around with thick plastic sheets with good ventilation.
Surface damage caused by transportation and installation must be repaired by touching up
with paint of original color and shade. It is better to get a small can of the paint from the
manufacturer of Transformer along with the Transformer.
Prior to energizing, perform a megger test between the different windings, and from the
windings to earth. This applies to dry-type in particular.
Conservators must be stored into closed rooms without removing the gauges and the flange
caps.
Bushings must be kept in a dry indoor space, in their original packing.
Radiators can be kept outdoor, but their mounting flanges must be protected against corrosion.
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Indoor Installation
1. The Transformer room has to be dry, dust-free, suitably spacious and adequately
ventilated.
2. Floor area must be adequate so that the Transformer is accessible for cleaning and
inspection from all sides. Clearance between the wall and the transformer should be
0.75 m (wall on one side), 0.75 m (wall on two sides), 1.0M (wall on three sides),
1.25 m (wall on four sides, for transformers installed in cell/ collapsible front wire
mesh).
3. Height of the room is defined by the space required for bushings, cables entrance
and by air flow required for cooling. Minimum vertical clearance between the top of
conservator tank and ceiling shall be 0.6 m.
4. When required it must be possible to lift the active part of the Transformer out of the
tank while in the Transformer room for inspection. Otherwise, the Transformer will
have to be moved to a place with necessary clearance height for lifting the active
part.
5. The Transformer room has to meet the safety regulations regarding the construction
and location. Pay attention to requirements as per Indian Electricity Code regarding
civil engineering of Transformer rooms, safety regulations and fire protection
regulations. The door of the room must open outwards and must be built on outer
wall of the building. Doors leading to other areas inside the building must be
avoided. If such a door is built, it must fulfill prescribed fire resistance class.
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Indoor Installation
6. For naturally cooled
Transformer (ONAN),
satisfactory ventilation
must be arranged to
dissipate heat losses.
The principle of cooling is
shown in the adjoining
figure.
A fresh-air channel must
be built under the
Transformer so that the
cooling air is divided as
evenly as possible
between the radiators.
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Indoor Installation
7. A ventilation duct or opening leading out must be built on the ceiling or upper
part of the wall. The area of the duct or opening has to be at least 10% more
than the area of the inlet opening.
If possible, air inlet and outlet openings should be located diagonally across the
room, however both of them should lead out of the building and not into the
building.
Give customer or civil agency the calculation of ventilation openings for
a normal Transformer room when ventilation is based on natural draught. Let
them take help of a ventilation expert if required.
Unless more complete air flow planning is available (which the expert can do),
the free cross section of air inlet opening can be calculated from the formula
given below:
Where:
P = Total losses of the Transformer at full load;
h = Effective height difference of air draught.
This formula is valid for temperature difference
of 15
0
C between inlet and outlet air.
If the space available does not allow big enough cooling openings,
motorized fans will have to be used.
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Indoor Installation
If adequate natural draught is not available, then force ventilate the
transformer room with exhaust fans. As a guide each kilowatt of losses
requires 4 cubic meters of air circulation per minute. Fresh air intake should
be at floor level, and a ventilation duct leading to outer air must be built on
the ceiling or upper part of the wall.
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Outdoor Installation
1. The installation site be must such that there is as little as possible direct
exposure to radiation from sun. A separate sun shade roof is recommended.
2. The installation site must also not neither gather excess snow in winter and
water should not drip from the roof directly onto the Transformer.
3. The Transformer location has to meet Indian electricity code requirements
regarding safety and Transformer installation.
4. The Transformer must not be located near combustible material.
5. Clearance between protective barrier and the Transformer should be minimum
2.13 m.
6. Transformers must not be placed closer than 10 m from each other unless a
protective wall exists between them. Depending on the structure of the
protective wall, they can be placed as close to each other as cooling and access
conditions allow. For example, a steel concrete wall, which reaches to a height
of 600 mm above tallest part of the Transformer and extends 1 m on both sides
of the Transformers, can be used as a protective wall. Protective walls also help
against vandalism and noise suppression.
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Foundation Construction rails and shims
1. Transformers are usually installed on a concrete foundation equipped with
horizontal mounting rails. The Transformers are delivered with rollers installed or
without rollers installed. Transformers on rollers must be fastened to foundation
by wedges welded or bolted to rails or other means to prevent movement.
2. In order that gas, which may be generated in the Transformer, can freely move
to the gas relay (Buchholtz relay), the Transformer has to be installed
horizontally or slightly ascending towards the relay. The recommended ascent is
1-2
0
. This can be accomplished by means of intermediate plates (shims) placed
between the Transformer and foundation or between rollers and roller beams.
Shims may also be used to adjust any minor height difference between
Transformer secondary terminations and bus ducts leading from secondary to
Switchgear Panels.
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Foundation Construction oil pit and oil sump
3. An oil pit is recommended to be built under the Transformer location to prevent any
oil fire spreading to other equipment. Its purpose, in case of oil leakage due to
damage to Transformer, is to prevent and extinguish fire and collect the oil to
prevent the fire from spreading.
The oil pit has to extend beyond the Transformer on all sides and is generally
made of concrete. It must be big enough to contain the total oil quantity or
alternatively allow the oil to be led via a discharge pipe into a separate oil sump.
The oil pit must be so designed that the oil is extinguished when it runs into the
sump. Wire netting is suitable for this purpose. The net must be installed over the
mouth of the cavity built at the bottom of the pit and which leads to the oil discharge
pipe. Coarse gravel is also suitable for this purpose. Then the pit must be covered
with a dense steel grating at the bottom leaving 7.5-10 cm bottom clearance. Top
of the grating must be covered with 25-50 cm deep layer of flatter stones and on
the surface with 35-50 cm of gravel.
If the installation has several Transformers, a common oil sump for collecting oil
can be built outside the building. The oil pits of different Transformers must not be
connected to each other, but they can be connected to a common pipe leading to
the oil sump.
The oil pits must be periodically maintained so that they meet the requirements all
the time. The stone layers, net and grating must be kept clean.
It also has to be seen that excessive amount of water is not collected in the pit.
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Shifting to and placement on foundation
1. The height of the Transformer foundation, with respect road level, depends on how the
Transformer will be transported and shifted on to its foundation. If the Transformer is transported
on a carriage or by deep-load truck, it is very important that height of the foundation is same as
the loading height of the carriage or truck. Then the Transformer can be un-loaded sideways.
2. In case of a large Transformer, it is advisable for the rails of the foundation to reach the transport
path and be at the same level.
3. If the transport truck is driven close to guide rails, the Transformer can be lowered onto rails by
means of cranes.
4. Then two jacking points which are on one of the smaller sides are lifted up simultaneously and
slowly by hydraulic jacks by 50 mm max and then other two jacking points are similarly lifted.
This is repeated until the Transformer is lifted enough to fix the rollers/ wheels. Alternatively all
the four jacking points may be lifted simultaneously. Then all the rollers/ wheels are fixed and
the Transformer is lowered not more than 50 mm on each side until the Transformer rests firmly
on its wheels/ rollers. Then jacks are removed and the Transformer is drawn to its final place
along the rails.
5. If a crane is used to move the Transformer from its place of storage or unload from a truck on to
its foundation, the foundation height is not of great importance, but space must be allowed for
moving the crane boom & hook around and above the foundation. The foundation must be
provided with locations for hydraulic jacks which have to be installed according to the
corresponding lifting levels of the Transformer. The foundation must be provided with hauling
hooks for fixing of pulling ropes.
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Minimizing noise emission
Depending on the location of the Transformer room, it may be necessary to provide
sound insulation, e.g. anti-vibration pads to avoid transmission of vibrations to
the structure.
Cooling fans, reflections from walls and resonance added to the noise emitted from
the Transformer may increase the noise level considerably. Therefore, it is
advisable to install the Transformer as far away as possible from walls.
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Oil sampling from a Transformer
Accurate sampling is extremely important to ensure
that the sample is representative of the oil in the
Transformer.
Use a 300cc stainless steel oil sample bottle with
plastic tubing available from a laboratory or the
manufacturer. Check that sample bottle is sealed. If
the seal is broken, then clean the bottle with acetone,
blow it out with dry air and dry it under vacuum. To
take oil sample, connect the two sections of the plastic
tubing to the sample bottle through gas cock
connectors. Attach one tube to the sampling valve on
the Transformer. The open end of the other tube
should be placed in a scarp liquid container.
Open both the valves of the sample bottle. The
sample bottle should be held in vertical position with
connection to the Transformer sampling valve below
the sampling bottle. Very carefully open the sampling
valve of the Transformer and fill the sample bottle until
the oil overflows through the top and into the scrap
container.
Continue overflowing until no bubbles can be seen through the plastic tubing and until two quarts
of oil have been collected in the scrap container. Close the top valve of the sample bottle, then
bottom valve of the sample bottle and finally close the Transformer sampling valve and
disconnect the plastic tubing. Tag the sample bottle showing the Transformer serial number,
date of sampling, location and owner of the Transformer and send the bottle to a laboratory for
analysis. Avoid shaking and jerks to the sample bottle.
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Oil sampling from an oil drum or tanker
The sampling bottle should
have a trap at the bottom.
The bottle must be rinsed
with solvent thoroughly dried
prior to being used. Where
large number of drums are
involved, samples from up to
five drums are mixed and if
the dielectric strength of the
composite sample is 30 kV
min, then oil of all the drums
may be added to the
Transformer. If the dielectric
strength is less than 30 kV,
then samples from all the
drums will have to be tested.
It is also necessary to check
the moisture content
similarly (max 50 ppm).
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Oil sampling kit and test cup for dielectric strength
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Erection of Transformers transported fully assembled and filled with Oil
1. Inspect the Transformer carefully to find possible transport damages paying
special attention to possible oil leaks, surface damages and bushings.
2. Check and tighten all gaskets and carry out cleaning operations.
3. Check oil level in the oil conservator and top up with oil if necessary.
4. The dielectric strength of the oil will be normally given Transformers operation
and maintenance manual. Test the dielectric strength of the oil, if less than
required arrange for oil filtration. The minimum value should be 40 kV/ 2.5 mm
when tested with a device as per IEC 60156.
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Erection of Transformers transported with loose parts and filled with Oil
1. The transformer must be inspected on receipt as already mentioned.
2. All parts removed for transportation must be re-fitted as per manufacturer's
manual/ instructions.
3. The condition of the oil in the Transformer and in the separate drums must be
checked and their dielectric strength tested. The minimum dielectric strength must
be 40 kV/ 2.5 mm when tested with a device conforming to IEC 60516 (IS 335).
4. Bushings must be installed as per separate instructions given by the Transformer
manufacturer.
5. The conservator must preferably dried in a furnace at a temperature of 80-90
0
C.
The inside of conservator must be cleaned. The cleaning can be performed by
rinsing the conservator with hot and clean (vacuum treated) Transformer oil. The
conservator must first be mounted on its brackets provided on the Transformer and
then following accessories must be assembled:
- any pipes for the tap changer oil and tap changer;
- pipes to transformer flanges
- Buchholz relay,
- shut off valves,
- silicagel breather;
- level gauges,
with manufcaturer supplied gaskets.
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6. During transportation, inlet and outlet of radiators (if any) are covered with solid flanges to
prevent ingress of humidity and impurities into the radiators. These flanges must be
removed then the radiators must be installed on the flanges provided on the Transformer
tank.
7. For removal and installation of radiators, the fixing flanges of the Transformers are provided
with shut-off valves which ensure that the Transformer is not emptied of oil. If the radiators
are to be removed for a longer period, e.g. for transportation, then the mounting flanges of
the transformers are also blocked with solid flanges. These flanges are also to be removed
after ensuring that the shut-off valves are completely closed.
8. After all the parts are fitted, the oil required for the radiators and oil conservator must be
added to the Transformer. While filling the oil, ensure that clean Transformer oil is carefully
pumped into the oil conservator. If possible use a vacuum filter to process the oil in separate
drums during filling.
The lower shut-off valves must be open and upper shut-off valves must be first closed during
oil filling. The air release screws on top of the radiators should also be open until
the radiators are filled with oil. Keep them open until oil starts oozing out of the air release
screws of the radiators. Then upper shut-off valves of the radiators must be opened.
Top-up the conservator with oil until oil level indicator rises up to the height corresponding to
temperature that will prevail in the normal operation.
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Then trapped air must be released after oil filling in following order:
- Transformer tank cover (lid);
- Bushings;
- Buchholtz relay.
Releasing air can be carried out by using air release screws fitted at suitable
places. For bushings which do not have air release screws, upper gaskets must
be loosened and retightened after the air is released.
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Erection of Transformers transported with out Oil
1. The Transformer is filled at the factory either by dry air or Nitrogen at
overpressure of 50 kPA (approx 0.5 bar) or at normal pressure depending on the
conditions of the journey, transport method, distance, etc.
2. For supervising the over pressure, the Transformer is provided with a manometer.
The Transformer should be filled with oil at site with in six weeks of dispatch from
the factory. If oil is filled after this period, the pressure must be checked
continuously and dry air or Nitrogen must be added when the overpressure falls
below 10 kPA (0.1 bar).
3. Further, humidity of insulation used inside the Transformer must be inspected
before filling the Transformer with oil. More details on inspection of insulation,
humidity and filling of the oil are given subsequent slides.
4. Transformer provided with normal-pressure dry air is generally provided with a
dehydrating breathers and sealed for transportation. The operating condition of
the dehydrating breather must be checked until the Transformer is filled with oil.
Further details on maintaining the breather are given in subsequent slides.
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5. Fix all the accessories in the sequence and manner indicated in the installation
manual supplied along with the Transformer by the manufacturer. Precautions to
be taken while assembling conservator and radiators have already been explained.
6. Before filling, take samples of oil from each drum and test the dielectric strength of
oil. The value should not be below 30 kV/ 2.5 mm.
Maintaining Nitrogen pressure at 0.5 bar, force oil into the Transformer tank from
bottom drain valve on the tank.
Then fix Radiators, Conservator and Bushings. Then fill radiators with oil as
already explained and top up the conservator.
Follow any recommendation or procedure given by manufacturer for oil filling. It
may be necessary to filter the oil while filling using an oil filtration machine. It may
also be required to fill the oil under vacuum with hot oil circulation for removal of
trapped air in the active part and moisture in the windings. In case the active part
has been exposed to outside atmosphere or in case external air ingress, consult
the manufacturer. The active part may have to be dried in such cases, before oil
filling.
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While filling oil under vacuum, bottom drain valve of the tank is connected to a vacuum
machine and a vacuum of of o.5 bar (6.5 psi) is created. Then, the valve of the vacuum
pump is closed and the oil is forced into the tank from bottom drain valve. Filling speed is
correct if the vacuum does not considerably decrease during filling. Oil filling is
stopped when the windings and insulation parts are below the oil level. When de-aerated oil
is used, the vacuum must be maintained for several hours so that all the residual gas is
removed from the oil. Then the oil level is made up by filling the oil through the conservator
top valve.
7. If temperature of oil in the Transformer is different from 25
o
C, then oil level in the conservator
must be corrected to correspond to actual temperature. If the oil level indicator has
temperature scale, then oil is added or drained until the oil level is up to the prevailing
temperature.
If the oil level indicator does not have temperature scale, then the conservator is first filled up
to half the volume and then:
- if the oil temperature is higher than 25
o
C, oil level must be made up to above the middle
level;
- if the oil temperature is less than 25
o
C, then oil must be drained from the tank below middle
level.
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The volume of oil to be added or drained is calculated according to following
formulae:
V = 0.00088 x dT x M for mineral oil;
V = 0.00104 x dT x M for silicone oil;
Where V is the volume of oil to be added or drained in liters;
M is the mass of oil in the Transformer at 25
o
C (given on the name plate)
dT is the deviation of actual oil temperature from 25
o
C.
8. After filling the oil, allow the oil to settle to settle for 24-72 hours as per
manufacturer's recommendation for trapped air to come out and collect at the top.
9. Release any trapped air by opening air release vents provided on the Transformer.
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Additional Supports
It may be necessary to provide supports made out of MS angles or channels for
following accessories:
1. HT Cable Box;
2. LT Cable Box;
3. OLTC.
Refer Transformer manufacturer's manual and drawings for dimensional details.
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Oil Filtration
The Transformer Oil is processed with the help of an Oil Filtration Machine on
three occasions:
1. When filling oil for the first time from oil drums to prevent contaminated oil
being filled into the Transformer.
2. For purifying the oil during periodic maintenance as recommended by
Transformer manufacturer
3. For regeneration of oil after several years of usage.
It is done to:
Extract moisture from the oil;
Filter the particulates (solid particles and carbon residues);
Degas the oil (removal of gases generated and dissolved in the oil during
operation) especially light hydro-carbons;
To remove acidity and restore oxidation stability;
To rectify color;
To remove sludge collected inside the Transformer.
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Oil Filtration Machine
Capacity: 250 to 6000 Liter/ Hour
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Oil Filtration Process
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1. Connect the Oil Filtration Machine to the Transformer by hoses in a closed
loop arrangement (Oil should enter the Transformer through bottom valve of the
tank and go out through its top valve of the tank) and fill the entire system
including hoses with oil before starting the filtration process.
2. Once the system is filled with oil, circulate the oil for 10 minutes to eliminate air
from the system, air vents provided at various points on the Transformer will have
to be slowly opened occasionally to let out the air and then closed.
3. The Filtration machine may have two modes of operation: Purification and
Regeneration. The choice of the mode depends on degree of contamination as
determined by oil analysis done prior to filtration, application and manufacturer's
recommendation.
4. Purification:
This is limited to moisture extraction, degassing and particulate filtration. The oil
enters the machine where it is first heated by a set of electric heaters to maintain
the oil temperature between 65 to 70oC.
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Then the oil is pumped through a pre-filter (5 microns) and a fine filter (0.5
microns). Then it enters a vacuum chamber and passes through fiberglass
coalescing elements where it is exposed to high vacuum and is degassed and
dehydrated. Then it is pumped back into the Transformer. The process is
repeated until moisture content falls below desired level and the required dielectric
strength is reached. The oil is tested at 4 to 12 hour interval (depending on the
size of the Transformer and manufacturer's recommendation) for moisture content
and dielectric strength
5. Regeneration
Oil is regenerated by forced percolation through columns of adsorptive media at
around 65
o
C. The adsorptive media consists of Fuller Earth (a type of clay).
Regeneration removes acids, sludge, restores oxidation stability and rectifies color.
After regeneration, oil is pumped through a 0.5 micron filter and then it is degassed
and pumped back into the Transformer. The process of regeneration takes around
8-12 hours depending on the quality of oil being treated and the size of the
Transformer.
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After several hours of regeneration, the clay beds get saturated and will have to
be reactivated. It is done by circulating the hot oil between the regeneration
columns and reactivation columns. After reactivation, a small quantity of (0.1% of
oil processed) oil scum is collected in a holding tank which drummed for resale
and reprocessing or for disposal as hazardous waste. Clean oil trapped in the
clay is recovered. Reactivation takes around 16 hours and upon its completion,
oil regeneration can be resumed.
6. De-sludging
Transformer may have to be de-sludged after several years of operation. The
process is similar to regeneration except that oil temperature will be above its
aniline point of about 75
o
C in order to dissolve the sludge inside the Transformer.
It is done with freshly regenerated oil.
Oil purification, regeneration and de-sludging can be done with the Transformer in
either de-energized or energized condition. However for first filling of oil and
purification at site, the Transformer has to be in de-energized condition. When done
in energized condition, Oil flow rate has to be kept low, as per manufacturer's
recommendation, to prevent turbulence inside the transformer.
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Oil Filtration Process - Oil filtration performance analysis
Oil filtration performance analysis
Restored Depleted --- IEC 61125
164 Hours
Oxidation Stability
0.01 8 % v/ v GC Gas content
>35 <15 mN/ M ASTM/ ISO
6295
Interfacial Tension
<0.015 <0.01 --- IEC 60247 Tan Delta (90
o
C)
<20 < 2000 ppm IEC 60814 Moisture content
>55 <30 kV IEC 60156 Breakdown Voltage
Clear Light Yellow Brown/ Cloudy Visual --- Color appearance
<0.03 0.25 mg KOH/ g IEC 60296 Acidity
Required Results after
single pass
Initial Oil Condition Unit Method Test Description
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Power Circuit Connections
1. All electrical connections to the Transformer must be made by using appropriate
terminals. Refer outline (general assembly) drawing given by the manufacturer.
2. Cables and busbars must be of sufficient cross section in accordance with load
current.
3. Sharp bends in high voltage connections must be avoided.
4. Connections must be made with out causing mechanical tension or torque on
the connection terminals. All cables must be brought into termination box through
cable glands or must be secured appropriately.
5. For connections above 1000 A, flexible links must be used between busbars and
the Transformer terminals to compensate for thermal expansion of busbars.
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6. Following minimum clearances in air for phase-to-phase and phase-to earth
parts must be maintained. This also applicable for distances between cables and
windings.
325 250 170 125 95 75 60 40 Lightning Impulse withstand
voltage (kV)
630 450 280 210 170 110 90 60 Minimum Clearance acc. To
IEC 60076-3 phase-to-phase or
phase-to-earth (mm)
72.5 52 36 24 17.5 12 7.2 3.6 System Voltage (kV)
As most sites in India are lightning prone, it is advisable to consider above values.
7. Bolted connections must be protected against corrosion by applying petroleum jelly
on exposed metal surfaces and between joints.
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8. Spring washers must be used to compensate for thermal expansions and for plastic
deformations and maintain the necessary contact pressure.
1. Bushing terminal
2. Al. Busbar or cable lug
3. Pressure Washer (SFS 3738)
4. Conical Spring Washer (SF 3737)
5. Galvanized bolt and Nut
Tightening should be stopped when the conical
Washer just becomes flat.
Bolted Copper connections are made in the same
way as Al joints. It is not however necessary to
use pressure Washers. In Sulphurous
atmospheres, the joint surfaces must be protected
by Petroleum Jelly. All joints must be tight and
secure. Torque Wrenches must be used for
tightening. Aux. circuits of the Transformer and
Tap changer must be connected as per wiring
diagrams. All current transformers must be
connected to measuring or instrumentation
circuits. Secondary terminals of any CT not used
must be shorted or earthed.
120190 M16
5075 M12
3044 M10
1522 M8
6 9 M6
Tightening Torque (Nm) Bolt Size Cl. 8.8
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9. Earthing connections
The earthing terminals of the Transformer must be connected to protective earthing system.
The earthing terminals are usually provided diagonally on the base beams. Cross section of
earthing conductors/ connections must be according to regulations and conditions at site.
10. Cable/ Busbar terminations
Cable terminations must be selected according to cables used and as per cable
manufacturers recommendation. Normally indoor terminations are used inside
enclosures. Cables must be fixed by clamps welded on to the enclosure or by glands
on removable gland plates. With single core cables, it is better to use stainless steel gland
plates to avoid gland plate heating. In case of busduct connection, flexible connectors are
recommended.
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10. Cable/ Busbar terminations (continued)
High voltage connection is normally performed by copper cables and copper cable lugs. In
some cases heat shrinkable connectors or elbow connectors are used.
For aluminium-copper joints the copper is coated with tin, or bi-metal sheets (one side of
copper and the other of aluminium) can be used between the joint.
The aluminium surface must be larger than the copper surface. Aluminium parts shall always
be placed above copper parts so that water cannot drain from the copper parts onto the
aluminium (corrosion).
It must be remembered that good contact between joined aluminium surfaces can be achieved
only if non-conducting oxide film is removed with a wire brush, file or similar immediately before
joining, and renewed oxidation is prevented by applying a thin protective film of grease (neutral
Vaseline).
Jointing compound, which prevents the access of air and humidity into joints, must be used in
the joint. The zinc crystals of the compound break down the layer of oxide on the aluminium.
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11. Neutral Link
Neutral link must be provided at a convenient location between Transformer
Neutral terminal and Earth. If it is mounted on a wall, it must be at height of 1.8 to
2.6 m. Cables used for neutral earthing should be taken only through PVC pipes.
12. Tap Changer
Tap changer to be tried in all the positions for free operations and ensure equal
resistances between 3 phases in all taps of tap changer.
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Pre-energisation Checks
The following checks have to the performed after erection and before
start-up.
1. Deaeration of HV and LV bushing
Remove the eventual air within the HV and LV bushing as indicated in manufacturers
instructions.
2. Deaeration of radiators
Open the upper breathing plug of radiators and remove the eventual air within.
3. Deaeration of Buchholz relay
Open the lower drain plug of Buchholz relay for remove the eventual air within.
4. Check nameplate data against data sheets
Check whether details given on name plate are same as those in technical submittal
approved by customer and our specification.
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5. Check mechanical damage and paint
Repair either of painted parts, or of parts damaged during the transport or during the placing
of the transformer on its site.
For repairing damage paint consider the following cases:
A. Scratches in the paint, of limited depth, the metal is still covered with a
coat of paint, even of just some mm:
Use a clean cloth imbued with non-oil solvents (for example thinner used for vinyl paints)
to clean accurately the area, then proceed with the repairing of paint, with brush or roller
respect to the range of damage paint.
B. Deep cuts, up to the metal, with rust where the paint has been taken away:
Using abrasive paper, remove the paint from the area till the metal is white and
completely devoid of rust. Clean with a cloth imbued with non-oily solvents. Apply the
paint cycle suitable for such transformer, following strictly the suggestions provided for
this type of transformer
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5. Check mechanical damage and paint (contd.)
C. Rusted metal-plates, devoid of paint;
If possible, sand blast till the metal becomes white, or alternatively take off the rust with
a metal brush; then rub down the border and, if necessary, retouch the brushed area.
Apply the painting cycle scheduled for the transformer, following the suggestions
indicated.
D. Paint swellings, with disjunction of the paint from metal.
With a metal spatula lift and take away the paint as far as possible, insisting on
the borders, and then carry out the workings indicated in the previous point.
Before the application, check whether the the paint to be used for the retouches is of
the same type as the paint applied originally by the Transformer manufacturer. It is
better to get a can of the original paint from the Transformer manufcaturer.
The above described suggestions are valid for all the metallic parts of the transformers.
As far as radiators are concerned, in case C or D check either the possibility of restoring
the paint or of replacing them. Do not use stucco to level the surface.
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6. Check oil leakage.
7. Check nuts and bolts tightness with torque wrench as per values given
earlier, setting the torque on the wrench in the middle of the range given.
8. Check alarm-trip contacts of Buchholz relay
Check the alarm-tip contacts release:
a) acting on the test buttons;
b) lowering the relay oil level.
9. Check trip contact of pressure relief device
Check the contact trip release by acting manually on microswicht pin.
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11. Check alarm contact of oil level indicator
Check the alarm contact release through shunting the contact terminals.
12. Check all valves
Verify correct state of valve.
13. Check oil level
Verify the oil level of conservator and add or drain oil if necessary.
10. Check contact calibration of thermometer
Oil temperature indicator: take out the bulb of the temperature indicator, dip it in hot water
and check the alarm contact release and insert the bulb back into the thermpmeter pocket on
the tank and fill the pocket with oil.
135C 105C Winding temperature indicator setting
105C 90C Oil thermometer setting, when combined with a
winding temperature indicator
100C 85C Oil thermometer setting
Trip Alarm Recommended settings for ONAN transformers Temperature settings
for dry-type
transformers should
be according to the
relevant temperature
class of insulation.
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14. Check silicagel breather
Verify the colour of salts of silicium and change or re-charge them if required. Check oil level
in the liquid seal of the breather and make it up if necessary up to the mark.
15. Earthing correct
Check that all metallic parts are correctly grounded.
16. Auxiliary circuits & Terminal blocks
Check whether auxiliary circuits are wired up as per schematic diagram and whether wires
coming to terminal blocks are properlu fixed and are in correct position. If not correct them
after discussing with the manufacturer.
17. Check auxiliary (marshalling box) wiring
Verify that the connections are in according of the schematic diagram.
18. Check installation of emergency push button switch near the Transformer or on the
door of its enclosure and wiring to upstream breaker trip circuit in HT Panel.
19. Instruments correctly installed
Verify that the instruments are in according of the overall dimensions (GA) drawing.
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20. Insulation resistance (M Ohm)
Resistance of Insulation between:
- HV Terminals and LV Terminals+Tank/
Earth;
- LV+HV Terminals and Tank/ Earth;
- HV and LV Terminals;
- Tank and Earth before making earth
connections, in some special cases.
Test results should conform to Test
Certificates/ reports submitted by
manufacturer.
2500 V 22 to 33 kV
1000 V Up to 11 kV
Voltage of Megger Voltage of HV Wdg.
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20. Insulation Resistance (Contd.)
The insulation resistance must be several thousand Mega-Ohm. However the value widely
depends on measuring time and the temperature of the Transformer. Convert the measured
values by multiplying with the conversion factors given in the following table:
44.70 75 1.98 30
31.75 70 1.40 25
22.40 65 1.0 20
15.85 60 0.75 15
11.20 55 0.5 10
7.85 50 0.36 5
5.60 45 0.25 0
3.95 40 0.18 -5
2.8 35 0.13 -10
Correction Factor T (Ambient)
o
C Correction Factor T (Ambient)
o
C
Two readings must be taken one at 15 s and another at 60 s. Minimum value of 60 s reading must be
1000 Mega-Ohm. Further, difference between the readings taken at 15 s and 60 s is used to determine
dryness of the Transformer. R60/ R15 is normally between 1.2 3.0 in a dried Transformer. Value less
than 1.2 indicates that the Transformer has moisture.
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21. Auxiliary circuit insulation
Check the whole auxiliary circuits insulation by applying a 2000V-50 Hz for 6 s.
Measured value must be greater than 2 Mega-Ohm.
22. Check Oil dielectric strength and moisture content, if already done, review test results.
22. Voltage ratio measurement
- If measurement is carried out by a Ratio Tester,
all measurements have to comply with the report
test;
- If a voltmeter is used, then feed one winding of
the transformer from HV side with a voltage of
415 V through a regulating Transformer and an
Isolation Transformer and check whether
corresponding LV side voltage is proportionally
in compliance with that on the rating plate.
Repeat the test for other two windings. Because
of accuracy of voltmeters used, measured
values may differ by test report values by a few
percent. Refer diagram for making connections.
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23. Vector group measurement
This test is important especially when two or more transformers are to be operated in parallel.
It is always better to carry out this test at the same time as voltage ratio measurement and
verify that the actual vector group corresponds to that indiacted on the rating plate.
1. Discommect any and all neutral earthing (both primary an seconday side)
2. Connect R phase terminal of primary to R phase terminal of secondary
3. Apply 3ph, 415 V, 50 Hz supply to HT side (which is usually primary).
Measure various voltages given below and verify that measured values conform to realtions
indiacted for concerned vector group.
23.1 Vector group Dd
0
23.2 Vector group Yy
0
R, r
Y
B
y
b
U
Yy
< U
Yb
U
Bb
< U
By
U
RY
= U
Ry
+ U
yY
R, r
Y
B
y
b
U
Yy
< U
Yb
U
Bb
< U
By
U
RN
+ U
Rn
= U
nN
N
n
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23.3 Vector group Dz
0
23.4 Vector group Dy
5
U
Yy
< U
Yb
U
Bb
< U
By
U
RB
= U
Rb
+ U
bB
R, r
Y
B
y
b
U
Yy
= U
Yb
U
Bb
> U
By
U
nY
= U
nr
+ U
rY
n
23.5 Vector group Yd
5
23.6 Vector group Yz
5
R, r
Y
B
y
b
U
Yy
= U
Yb
U
Bb
> U
By
U
bN
= U
br
+ U
rN
N
U
Yy
= U
Yb
U
Bb
> U
By
U
Yb
> U
By
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23.7 Vector group Dd
6
23.8 Vector group Yy
6
U
Yy
> U
Yb
U
Bb
> U
By
U
yY
= U
yr
+ U
rY
R, r
Y
B
y
b
U
Yy
> U
Yb
U
Bb
> U
By
U
nN
= U
nr
+ U
rN
23.9 Vector group Dz
6
R, r
Y
B
y
b
N
U
Yy
> U
Yb
U
Bb
> U
By
U
Yb
= U
By
n
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23.10 Vector group Dy
11
23.11 Vector group Yd
11
U
Yy
= U
Yb
U
Bb
< U
By
U
RY
= U
Rn
+ U
nY
R, r
Y
B
y
b
U
Yy
= U
Yb
U
Bb
< U
By
U
RN
= U
Rb
+ U
bN
23.12 Vector group Yz
11
R, r
Y
B
y
b
N
U
Yy
= U
Yb
U
Bb
< U
By
U
Yb
= U
By
n
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24. No-load current measurement (required only in case of a suspected
damage)
A small voltage is fed between terminals of each
phase and star point (in a star connected
Transformer) or between phases (in a delta
connected Transformer) via a regulating and an
isolating Transformers and a series connected
ammeter (0-100 mA range). The no-load current
will be a few tens of mA depending on the
impedance of the Transformer. Readings are
taken for all phases with the same applied voltage.
Currents for all the phases should be more or less
same. In a damaged phase of the Transformer,
the current can rise to tens of Ampere, hence the
regulating Transformer must be protected by
suitable MCB or a fuse.
HT
LT
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25. OLTC protective relay alarm contact
Check the protective relay of OLTC as per Instruction manual supplied by
Manufacturer.
26. OLTC oil level indicator contact
Check the alarm contact of OLTC oil level indicator release through
shunting the contact terminals.
27. Operation of Tap Changer (OCTC or OLTC)
Check whether tap position changes or not on giving rise and lower
commands and check tap position indication. Uaually On-Load Tap
Changer is provided with a motor drive mechanism and a protective relay to
monitor sudden flow of oil from diverter switch oil compartment to
conservator. Check wiring and operation of protective relay and operation
of motor drive. Refer manufcaturers instruction for operation and
maintenance of OLTC.
28. If it is suspected that the Transformer has suffered a damage,
the following additional measurements must also be carried out.
27 a. Winding Resistance
27 b. Winding capacitance.
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An ordinary multi-meter may not be able to measure these values at all due to long
time constant and weak dc source of the meter. A dc source of 24 Vdc or higher
and an accurate resistance bridge and capacitance bridge will be required for these
measurements. Measured results must be verified with test reports of the
manufcaturer to arrive at any conclusion.
29. If the Transformer has been stored for a long time or has been inoperative for a
long time, dielectric strength of and moisture content in the oil inside the
Transfomer must be checked. The dielectric strength must be higher than 50 kV/
2.5 mm and moisture content must be less than 20 ppm. If not, oil level must be
made up and the oil must be filtered using an oil filteration machine.
In cold Transformers the humidity is mostly absorbed in the the paper insulation
which can not detected on the basis of oil study. In such cases monitor moisture
content in the oil once in 48 hours after putting the Transformer on load. If there is
a significant increase in the moisture content, take the Transfomer out of operation,
the active part may have to dried in consultation with the manufcaturer.
The Silica gel breather must also be checked and gel re-activated if required.
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Check-list to be filled in before energisation
Earthing correct 15
Check silicagel breather 14
Check oil level 13
Check all valves 12
Check alarm contact of oil level indicator 11
Check contact calibration of thermometer (OTI & WTI) 10
Check trip contact of pressure relief device 9
Check alarm - trip contacts of Buchholz relay 8
Check tightness of nuts and bolts 7
Check oil leakage 6
Check mechanical damage and paint 5
Check nameplate data against data sheets 4
Deaeration of Buchholz relay 3
Deaeration of radiators 2
Deaeration of HV and LV bushing 1
Remarks Controlled Details Sl. No.
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Check-list to be filled in before energisation
OLTC protective relay alarm contact 28
OLTC oil level indicator contact 29
Operation of Tap Changer (OCTC or OLTC) 30
No-load Current 27
Vector group 26
HV to LV+E insulation resistance (MOHM) 20
Voltage ratio measurement 25
Check oil dielectric strength and moisture content 24
Auxiliary circuit insulation 2kV - 50Hz, 1 min. 23
HV to LV insulation resistance (MOHM) 22
HV+LV to E insulation resistance (MOHM) 21
Installation of Emergency PB Switch on Trafo Enclosure Door 19
Instruments correctly installed 18
Check auxiliary wiring 17
Auxiliary Circuits & Terminal blocks correct 16
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Energisation
1. Check all signalling in control room.
2. Check HV and LV connection to bus-bar system.
3. Put tap-changer in correct position prior to putting the Transformer in to operation
(off-voltage conditions). Tap-changer usually has a handle,
a position indicator and a locking device. After putting the tap-changer into correct
position, secure the locking device. Normally smaller position number indicates
higher voltage ratio and lower voltage on secondary side. Refer connection diagram
provided by manufacturer.
4. Put transformer in to operation in NO-LOAD condition for a duration recommended
by the manufacturer. It is recommended to leave the Transformer connected to
network and on no-load for 1 to 2 days so that any air bubbles in the oil have time to
travel up and collect in the Buchholtz relay.
When the Transformer is energised for the first time at site, you may hear
a loud sound from the Transformer and the over-current relay may trip the HT
breaker. It may not be because of any fault but because of magnetising in-rush
current of the Transformer. The value of in-rush current depends on construction
and size of the Transformer, magnetic remanace of the core and the moment of
connection to the network.
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Energisation
5. Switch-off transformer from voltage supply and check the gas in
Buchholz relay.
During first few days after a new Transformer is connected to network,
some gas may collect in the Buchholtz relay causing an alarm. This is normally
due to air that remained under the cover during installation. When the
Transformer warms up, this air starts moving up and accumulates in the
Buchholtz relay. The quality of the gas can be seen from its colour and usually
from smell. If it is air, then it will be colourless and will not have any smell. If it is
otherwise, a gas sample will have to be taken and analysed in consulation with
the manufcaturer.
If the gas collected is air, and the gas can be released and operation of the
Transformer can be resumed.
6. If all tests carried out are favourable, put transformer into operation and load.
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Energisation Check List
COMMENTS
If all tests carried out are favourable, put transformer
in operation and load
6
Switch-off transformer from voltage supply and check
the gas in Buchholz relay.
5
Put transformer in to operation in NO-LOAD condition
for 1 to 2 days.
4
Put tap-changer in correct position prior to putting the
Transformer in to operation (off-voltage conditions).
3
Check HV and LV connection to bus-bar system. 2
Check all signalling in control room. 1
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Operation Temperature rise and loading capacity
Aging of insulating materials is caused by changes in their chemical structure. Molecules
of Oil and Paper are slowly decomposing already at room temperature and when heated
the rate of decomposition increases. When Paper gets old, its cellulose molecule break
and its mechanical strength decreases.
When load on Transformer increases, temperature of winding and oil will rise and aging
of insulating materials accelerates. The aging rate will almost double and corresponding
life time of the Transformer will be halved when the temperature of hottest point inside the
winding (hot spot temperature) rises by 6 to 8
o
C, with in the temperature range of 80 to
140
o
C.
In addition to temperature, other factors such as dissolved oxygen, acids and moisture
also speed up the ageing of the insulation.
Hence, ageing sets limits for loading capacity of oil insulated Transformers. As per IEC
60354 (Loading guide for oil immersed transformers), the normal operation of an air
cooled Transformer is considered to be continuous operation at rated power at an
ambient temperature of +20
o
C. The insulating material will age under these conditions at
a speed which can be considered to be normal provided the Transformer is properly
maintained.
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Continuous loading capacity at different ambient air temperatures is calculated based on
a hot spot temperature of 98
o
C which is same as the temperature considered for normal
operation. Following table gives loading capacity at different ambient air temperatures as
per IEC 60354 for ONAN/ ONAF Trafos.
80 78 75 73 71 69 67 Oil temperature in
o
C
82 91 100 108 116 123 130 Permissible continuous loading in %
+40 +30 +20 +10 +/-0 -10 -20 Ambient air temperature
o
C
In Practice, a Transformer is very seldom continuously loaded at the same load. If the
Transformer loading is, part of the time, lower than the continuous load capacity at the
relevant permissible ambient air temperature, it can be correspondingly loaded more at
other times and still the aging can remain normal during the whole time (e.g. during 24
hours). IECs loading guide also gives short term loads on this basis. Next table gives
the short term loading capacity as a function of the ambient air temperature and the
loading time provided loading at other times of the day does not exceed 25% off 90% of
the rated power. For short-term loading the temperature of the hottest spot in the
winding is limited to 140
o
C and the maximum permitted power is 1.5 times the rated
power.
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80 25 90 25 90 25 90 25 90 25 90 25 90 25
Load during other time of the
day is maximum
80 92 92 101 105 110 115 117 123 125 131 133 137 139
12.0
84 98 93 108 109 116 119 124 128 132 134 138 140 144
8.0
84 98 93 114 112 123 123 131 132 138 139 144 144 149
6.0
88 115 95 124 118 134 130 142 140 150 148 150 150 150
4.0
95 137 99 149 132 150 147 150 150 150 150 150 150 150
2.0
104 150 110 150 150 150 150 150 150 150 150 150 150 150
1.0
118 150 126 150 150 150 150 150 150 150 150 150 150 150
0.5
Permissible loading/ Rated Power = 100% Loading time Hours/ Day
+40 +30 +20 +10 +/-0 -10 -20 Ambient Temperature
o
C
The following example explains the use of above two tables:
Outdoor air temperature = -10
o
C
Continuous load capacity = 123/100 x rated power
Outdoor air temperature -10oC, loading time 4 hours and load during other times of the day, i.e. 20
hours is 90%, then,
Short-term loading capacity for 4 hours = 148/100 x rated power, provided the load during other 20
hours is maximum = 90/100 x rated power.
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The temperature of the transformers insulating material can be monitored with
the winding temperature indicator, which is set to indicate approximately
the temperature of the hottest point in the winding. According to IECs loading guide,
the maximum short-term hot spot temperature can be +140
o
C. Due to practical
difficulties appearing in the definition of the hottest point, it is recommended to use
the values given in the following table to set the winding temperature's alarm and trip
levels.
It must be noted that a Transformers short-term load capacity can not be judged on
the basis of the oil temperature, because the oil temperature changes much slower with
the load than the temperature rise of the winding. Depending on the volume, temperature
of oil may rise 5 to 20 minutes slower than temperature of winding. Even at a continuous
overload, temperature can not be used to estimate the overload, with out knowing
the actual temperature rise, which takes place at the rated loading of the winding.
For supervision of continuous loading, it is recommended to set the oil thermometer
alarm and trip contacts according to top oil temperature value given in the following table.
If the Transformer has been provided with winding temperature indicator, the setting of
the oil thermometer contacts can be increased.
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Overloading of a Transformer implies that its construction and the accessories used in it
such as tap changer and bushing are correspondingly rated. In cases of doubt, contact
the manufacturer of the Transformer for confirming the overload capacity.
Overloading capacity of an old Transformer can be notably limited by aging of oil and
insulation humidity.
135
o
C 105
o
C Winding temperature indicator setting
105
o
C 90
o
C Oil Thermometer setting when the Transformer is also provided
with a winding temperature indicator with alarm & trip contacts
100
o
C 85
o
C Oil Thermometer setting
Tripping Alarm Instrument
Above recommendation for alarm and trip settings are for ONAN Transformers.
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Parallel Operation of Transformers
Dy11
Yd11
Yz11
11
Dy5
Yd5
Yz5
5
Dd6
Yy6
Dz6
6
Dd0
Yy0
Dz0
0
Vector Diagram Connection Index Vector Diagram Connection Index
When two or more Transformers are to be connected in parallel, it is important to
remember that only the Transformers bearing identical indices (as given in following
table) can be run in parallel. The index is stamped on the Transformer rating plate.
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a b c
b a c
a c b
A B C
or
C B A
or
B A C
Transformer having connection Dy11,
Yd11, Yz5.
L1 L2 L3 L1 L2 L3 Main Busbar
LV side HV side
Transformers with indices 5 and 11 can also be run in parallel if the conductors of both
LV and HV side suitable crossed. Possible connections are given in following table.
Following figure shows one of the possible alternatives.
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Other conditions to be met for parallel operation are:
1. Poles having same polarity on the HV side and LV side should be connected in
parallel (except with Transformers with indices 5 and 11);
2. Transformers should have the same transformation ratio;
3. Their short circuit impedances should be same (with in 10% accuracy);
4. The rated outputs of the Transformers should not deviate from each other more than
1:3.
Before connecting the Transformers in parallel for the first time, it is vital to check
the voltages. For this purpose, only the HV sides should be connected in parallel and
only the star points of the LV sides or two corresponding phases should be connected
together. Then HV side should be energized and voltages between poles to be
connected in parallel on LV should be checked. These voltages should be zero, where
as voltages between phases should be normal. If this is not so, then the Transformers
are not correctly connected.
It is also essential to measure the currents in each Transformer after the Transformers
are put into parallel operation. The currents should be distributed in proportion to their
rated outputs.
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Load distribution between parallel running Transformers
Knowing rated output power crating S
N
and short circuit impedance Z
k
, the distribution
of load between the Transformers can be calculated. During parallel operation,
The Transformer with lowest short circuit impedance will be most heavily loaded.
The maximum available total output S
max
of the Transformer bank will be the total
output when this Transformer (lowest Z
k
) is loaded up to its rated output. Following
example shows the method of calculating S
max
.
Transformer 1 S
N1
= 500 kVA Z
k1
= 5.0%
Transformer 2 S
N2
= 800 kVA Z
k2
= 5.4%
Transformer 3 S
N3
= 1000 kVA Z
k3
= 6.0%
Total rated output S
N
= 2300 kVA
Z
kmin
= 5.0%
S
1
= 500 kVA
S
2
= 800 kVA x 5.0/5.4 = 740 kVA
S
3
= 1000 kVA x 5.0/6.0 = 830 kVA
S
max
= S
1
+ S
2
+ S
3
= 2070 kVA, i.e. 90% of total rated output of the bank.
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Protection of Transformers
A Transformer is a component in electrical distribution network which is most difficult to
replace. If it is damaged, it will probably cause either a break in electricity distribution
or require difficult emergency supply arrangements. Hence it has to be protected
against over-current, short-circuit, over-voltage and any excessive gas and intrinsic
faults.
1. Over-current protection
Provided by over-current relays in switchgear panels on primary and secondary
sides of the Transformer. It is advisable to use this protection as primary protection
and protection provided by winding temperature indicator as back-up protection.
The auxiliary supply used for these protections must be reliable and 48 Vdc or
110 Vdc from a well maintained battery bank is recommended.
2. Short Circuit protection
Also provided by the over-current relay with an instantaneous over-current setting.
Both the over-current and short circuit protections can also be provided by
circuit breakers in the Switchgear panels on HV and LV side.
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3. Over-voltage protection
Normally Transformers are designed to have adequate insulation level to withstand
any over-voltages arising in operation due to any switching surges in the network
and verified by subjecting them to impulse voltage withstand test (a type test). This
may not guarantee protection against over-voltages of atmospheric origin. Hence
spark gaps (arcing horns) in small and medium sized Transformers and surge
arrestors in case of large Transformers are used to protect Transformers against
such over-voltages.
When spark gaps are used Transformer manufacturer has to ensure that the
Transformer is designed to withstand the stress of chopped wave caused by
operation of the spark gaps.
If star point of a Transformer is not brought out and not earthed, then any three pole
over-voltage will cause voltage of star point to rise to a value higher than
the voltages influencing the terminals (50 to 100%). Then manufacturer has to
consider this additional voltage stress in the design of the Transformer. Same will
be the case when the star point is brought out but not earthed, but such
a Transformer can be protected by star point lightning arrestors (not by a spark gap)
of rating 70% higher than the highest system voltage and the star point insulation
should be adequate for the voltage stress.
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4. Excessive gas and intrinsic faults Buchholtz Relay
The gas generated during such faults is collected in the Buchholtz Relay which is
located on a pipe between oil conservator and main tank. The gas will displace oil
in the relay and minor gas generation will cause functioning of alarm contact. If
excessive gas is generated or when oil level falls, alarm contact will function first
followed by tripping contact. Abrupt oil flow from the Transformer into
the conservator will cause immediate functioning of tripping contact.
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Maintenance and supervision during operation
Although a Transformer needs minimal maintenance, it has to be carried out to
ensure long life and good operating reliability. While carrying out any maintenance or
supervision, instructions regarding safety distances, safety equipment, earthing and
limitations to working on live conditions must be carefully followed.
Maintenance and supervision activities to be carried out by operating personnel
include:
1. Inspection of oil level;
2. Inspection of oil and winding temperatures;
3. Noise measurement/ observation;
4. Operation of tap changer (if any). The tap changer must be turned from one
extreme position to another extreme position and back to original position (under
de-energized condition) at least once a year.
5. Condition of dehydrating breather;
6. Cleanliness of the Transformer including cleaning of insulators/ bushings during
service interruptions. Use white spirit, Chlorothne VG or NU or easily evaporating
cleaning agents for cleaning insulators/ bushings.
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7. Inspection of external conductor and busbar joints with bushings for tightness of
joints. Loose joints lead to overheated bushings and eventual damage to
gaskets.
The frequency of the above inspection has to be decided by the operating
personnel based on the size, location and importance of the Transformer in the
complete installation. Apart from the above, functioning of protective, alarm,
regulating and supervision instruments and equipment should be checked once
a year. A recommended maintenance practice is given below.
Full maintenance may be required once in 15 to 20 service years, for which it is
recommended to refer manufacturers instructions.
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Recommended maintenance schedule
Check wiring and termination of auxiliary circuits
Operation of indicators and any other measuring
instruments and operation of their contacts
Operation of tap changer
Dielectric strength and moisture content in insulating
oil
Check tightness of external connections and busbar
joints with bushings
Operation of Buchholtz Relay
Clean Bushings
Condition of dehydrating Breather
Check Oil level
Check Oil & Winding temperatures
Check Noise level
Once a
Year
Once
a Quarter
Once
a Month
Once
a Week
Once
a day
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Investigation of Transformer disturbances
If during operation, a Transformer protection gives an alarm or trips the Transformer
from the network, the cause must be immediately investigated to ascertain whether its
is a case of Transformer damage or some other disturbance in operation.
1. Recording of disturbances
1.1 General
- Date and time of occurrence;
- Network data: Supply Voltage, Frequency and Primary Current,
Secondary Voltage and Current;
- Any other relevant actions made when the disturbance took place;
- Weather data (thunderstorm, rain etc) and ambient temperature in the vicinity of
the Transformer.
1.2 Function of protective equipment
- List of relays and Breakers in the network that operated and their setting
currents and other parameters recorded by them (for example earth fault relay);
- Pick-up time and currents and readings of operative protective equipment like
relays, Breakers, plotters relevant to the Transformer of interest.
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1.3 Transformer (immediately after the fault)
- Is the Buchholtz relay filled with gas, if so, its color and odor;
- Is oil in Buchholtz relay sooty;
- Thermometer readings;
- Were coolers or tank damaged:
- Are there any marks of arc on the bushings or on tank cover;
- Preceding maximum load and mean value for last 3 hours.
2. Function of Transformer protective equipment
Operation of some protective equipment such as Buchholtz relay, temperature
protection or upstream over-current relay does not always mean that
the Transformer is damaged.
2.1 Buchholtz relay can operate for instance when:
- a trapped air bubble under the Transformer cover has become loose (an air
bubble is colorless and odorless);
- a short circuit current has passed through the Transformer (no gas bubbles);
- a damage has taken place inside the Transformer (gas can be colored, have
a bad smell and is generally combustible).
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Sequence of operations when Buchholtz relay operates is given below:
Buchholtz Alarm
Operates
Buchholtz Trip
Operates
No Gas Present Yes No Is Gas combustible
Yes
Check
Alarm
Circuit
No Is gas
combustible
Yes Get Gas sample
analyzed
Check Oil
Drain Valve

Leaky
No Take the
Transformer out of
service and inform
the manufacturer
Yes
Tighten Drain
Valve
Release gas, increase
supervision, inform the
manufacturer if
problem repeats
Continue the
Transformer
in Service
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2.2 Sequence of operations when temperature protection operates is given
below:
Temperature protection operates
Look for cause of over-load,
ambient higher than rated ambient,
cooling system not ok?
Alarm only Trip only Alarm & Trip
Check the setting & operation of
temperature indicators
Alarm contact correct Trip contact correct
Continue the Transformer
in service, but increase
supervision, do not allow
oil temperature to exceed
100
o
C
Continue the Transformer in
service, but increase
supervision, do not allow oil
temperature to exceed
100
o
C. Inform the
manufacturer if the problem
repeats
A
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2.3 An upstream over-current relay can operate, for example due to:
- passing short circuit;
- inrush current impulse;
- defective protective equipment;
- winding damage inside the Transformer.
3. If it can be ascertained that the disturbance is not due to any damage to windings
or a damage inside the Transformer; the protective equipment can be re-set and
the Transformer energized again.
4. In case of damage to windings or any other damage inside the Transformer is
suspected following tests must be carried out:
- insulation resistance of windings;
- transformation ratio (voltage ratio measurement);
- no-load current measurement;
- measurement of dc resistances of windings.
Results of above tests must be studied or referred to manufacturer for
ascertaining nature and extent of damage and necessary repairs.
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Repairs and Spare Parts
1. When performing repair work, all safety precautions mentioned earlier and
mentioned under section on safety must be followed.
2. It is the responsibility of the customer, after taking over of the Transformer
or installation, to inspect, maintain and keep the Transformer in good condition.
3. All failures during warranty period must be reported to ABB and in turn to
the manufacturer with out any delay.
4. All warranty repairs must be attended to by the manufacturer, if taken up by ABB
or the customer, should be done only after obtaining written approval from the
manufacturer with clear understanding on who should bear the repair costs.
6. It is recommended that on-site repairs are limited to replacement of broken
or damaged parts unless done in a well-trained repair shop. Many parts and
accessories are usually less expensive to replace than to repair.
7. For replacement deliveries of spare parts, inform manufacturer details of
serial number, year of manufacture, rating and voltages of the Transformer and
descriptions of the spare parts required.
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Safety Precautions
Following and any other safety advices during installation, commissioning and
maintenance:
1. Never work on transformers or any installed electrical equipment alone.
2. Do not move or lift a transformer without applying adequate equipment and safety
precautions.
3. Do not make any connections which do not comply with the rating plate.
4. Do not apply abnormal mechanical strain on the terminals.
5. Do not reconnect when the transformer is energized.
6. Do not attempt to change tap setting while the transformer is energized.
7. Do not energize or perform maintenance on the transformer without proper earth
connection.
8. Do not operate the transformer without alarm and monitoring systems connected.
9. Do not remove any enclosure panels while the transformer is energized.
10. Do not tamper with interlocks, alarms and control circuits.
11. Be aware of possible need for magnetic field protection.
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Safety Precautions
12. Perform a final inspection prior to energizing:
- All external connections have been made properly;
- All connections are tight and secure;
- All accessory circuits are operational;
- All tap connections are properly positioned;
- The neutral and earth connections have been properly made;
- Fans if supplied are operational;
- Proper clearance is maintained from high voltage bus to terminal equipment;
- The correct transformer ratio exists for units with internal terminal boards.
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Installation Record for Transformers
The attached installation record must be filled-in and signed by both the ABBs
representative and Customers representative. The record has provision for recording
the inspection details and test results of five Transformers.
If it is required to simplify the test record for a particular project, the non-applicable
rows may be deleted.
Transformers\Installation Record for Transformers.xls
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Applicable Standards
1. IS : 2026 (Part 1) -1977
Specification for power transformers; part 1 General.
2. IS : 2026 (Part 2) -1977 (Reaffirmed 2001) Edition 2.2
Specification for power transformers; part 2 Temperature rise.
Specification for power transformers; part 3 Insulation levels and dielectric tests.
Specification for power transformers; part 4 Terminal markings, tappings and connections.
5. IS : 2026 (Part 5) -1994 (Reaffirmed 1999)
Power transformers; part 5 Transformer/ Reactor bushings minimum external
clearance in air specification.
6. IS : 10028 (Part 2) 1981 (Reaffirmed 2001)
Code of practice for selection, installation and maintenance of transformers; part 2
Installation.
7. IS : 10028 (Part 2) 1981 (Reaffirmed 2003)
Code of practice for selection, installation and maintenance of transformers; part 3
Maintenance..
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Applicable Standards
8. IEC 60076-1 Edition 2.1 Power transformers part 1: General.
9. IEC 60076-2 Edition 2 Power transformers part 2:Temerature rise.
10. IEC 60076-3 Edition 2 Power transformers part 3: Insulation levels,
dielectric tests and external clearances in air.
11. IEC 60076-4 Edition 1 Power transformers part 4: Guide to lightning impulse and
switching impulse testing Power transformers and reactors.
12. IEC 60076-5 Edition 2 Power transformers part 5: Ability to withstand short circuit.
13. IEC 60076-8 Edition 1 Power transformers part 8: Application guide
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Acknowledgement and References
This training module has been prepared using mostly the information available with in ABB but
scattered. Some information has been borrowed from published literature of some manufacturers
of oil filtration machines. The collected information has been filtered to make it applicable for
installation of only medium sized distribution Transformers.
Flow charts for taking decisions during Transformer disturbances such as operation of some
protections have been added. A detailed installation record applicable for medium sized
distribution Transformers has been prepared and added.
The presentation is mostly practical and only on installation with almost nothing about Transformer
theory, design or calculations.
Mr. Sajith S Kumar has made a significant contribution in preparing this training module by
converting some parts of ABBs Distribution Transformer Handbook into preliminary slides.
Mr. R. Shanbhag has contributed in identifying the course contents and by giving existing
installation check lists.
My sincere thanks to Authors of several ABB documents mentioned in the reference list.
I am also thankful to Mr. N. Narayana Rao, Mr. S. Prasanna, Mr. V. Srinivasu, Mr. R. Shanbhag
and Mr. Sajith S Kumar for taking part in reviewing this module for adequacy and correctness of
contents.
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Acknowledgement and References
1. Distribution Transformer Handbook ABB Ident # 1LAC000003.
2. Manual for installation, start-up, operation & maintenence, Document
1LIT000004M02R0 Rev. 0 Date 20021129 of ABB T&D SpA Unit Operativa
Trasformatori di Distribuzione.
3. Oil Insulated Distribution, large distribution and special transformers Instructions
for transport, installation, operation and maintenance, 1LFI1136-en-rev. G of ABB,
Vassa, Finland.
4. Instructions for Transformer Insulating Oil, Instruction Leaflet 48-500-11F of ABB
Inc., USA.
5. Brochure and technical specification of Oil Filtration Equipment of Flitervac
International Inc, Canada.
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Disclaimer
Author will not be directly or indirectly responsible for any damages caused to
personnel, equipment or surroundings consequent to usage of this presentation
or material or information or knowledge contained in this presentation.
Author will not be directly or indirectly responsible for infringement of any
intellectual property rights, patents, copy rights or any other similar rights caused
due to usage of this presentation or material or information or knowledge
contained in this presentation.
Persons or organizations using this presentation or material or information or
knowledge contained in this presentation are requested to use their discretion before
such usage.
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