Unit 4

KERALA STATE ELECTRICTY BOARD LIMITED

TECHNICAL AUDIT ON POWER TRANSFORMERS

Technical Audit Report (south Zone)

Report No.01/Tech. Audit/Trfr./2016-17 Date:21/06/2017

I GENERAL
1 Date of Technical Audit 21/6/2017
2 Name of Substation Sabarigiri Power House
3 Transmission Division Generation Division Moozhiyar
4 Transmission Circle Generation Circle Moozhiyar
5 Substation Category Grid
6 Substation capacity 2 x 200MVA 220 KV
7 Earth resistance 0.5 Date of measurement 2017
7.1 DC leakage in the station No leakage
8 Audit Group members Sri. Jayashankar-AEE
Sri, Santhosh-AE-220KV SUB STATION
EDAPPON
Sri. Midhun Varghese-AE-220kV SUB STATION
PALLOM

9 Personnel assisted the Audit

10 Officers present Mr. Rajendran Assistant Executive Engineer

Electrical Maintenance Subdivision
Sabarigiri Hydro Electric Project
Mr. Saby Lal M.K,Assistant Engineer
Mr.Praveen, Assistant Engineer
Mr.Ajayakumar V.P, Assistant Engineer
II Index
Transformer capacity(UNIT 4) Make year
1 25MVA NO R phase CGL 2010
2
3
4
5
6

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7
8
9
10
Description Transformer unit Spare Transformers
II.
Transformer Asset name and ---
Asset Code number.
1 Capacity HV: 25MVA IV LV 25MVA
2 Voltages: HV: 220000/3 kV IV: LV: 11000 kV
3 Rated Current: HV: 196 IV: LV: 2272.7
4 Vector group YNd1
5 Type of Cooling OFWF
6 Percentage Impedance HV-IV 12.8% HV-LV IV-LV
7 Guaranteed Temp. rise in Oil/ Wdg 450 C, 550 C
8 Serial No. and Year of make T09836/1 Year2010

9 Date of commissioning 2010

10 Type of Tap Changer OFF Load Tap Changer
11 No. of taps with normal tap 5
12 Copper loss
13 Core loss
14 Gross Weight 52900 kg
15 Transportation weight 24400 kg
16 Total oil quantity 12100ltr
17 Tertiary winding No
17.1 Whether loaded NA
17.2 Type of protection provided? NA
Is tertiary winding brought out NA
17.3
and one point earthed
17.4 Condition of tertiary bus NA
Whether road access is available NA
18 to transformer
Whether fire protection wall
19
provided
Whether fire fighting system is
20
provided

A General Conditions Fully welded tank

General condition based on Ok
A.1
visual inspection
A.1.a gasket Ok
A.1.b oil Ok

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A.1.c breather Breather is not ok

A.1.d leak B phase transformer slight leak noticed
A.1.e painting Done in every year
A.1.f cooler No cooler fins
A.1.g Condition of transformer plinth Ok
A.1.h Tank/roller Ok but no locking provided
Condition of gaskets: various air Ok
release plugs, Drain plugs, valves
A.2
, band gaskets , all flanges,
radiator flanges , etc.
A.2.a How many times replaced When required
A.2.b How many times retightened Na
A.2.c Tightening torque for each No
gasketed joints
A.2.d Principle adopted for applying Normal method
uniform torque
A.2.e Material of gasket Main tank no gasketo-rings
Condition of the painting of Ok
A.3
transformer and accessories
A.3.a Frequency of painting and paint 2016
shade
A.3.b How many coatings 2
A.3.c Enamel/polyurethane/ Enamel
composition
A.4 Earthing of the transformer
A.4.1 No of earthings for main tank
No. of earthing for attachments
A.4.2 like cooler cubicle /OLTC DM
/Marshallingkiosk,etc
A.4.3 No. of earthing for flanged joints
Is subststion provided with earth No, Plate earthing system
A.4.4
mat
A.4.5 Grounding of Neutral
A.4.6 Size and number of risers
A.4.7 Is neutral earthing by plate NA
For Plate earthing, any provision NA
A.4.8.
for watering.
Condition of auxiliary control
A.5
cable /any damages
Whether segregation provided for
A.5.1
power and control cables
A.5.2 Whether cable are armoured
Whether cable tranches are
A.5.3
properly covered
A.6 Condition of transformer mounted

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relays
A.6.1 Is the relay contacts intact
Any corrosion for Alarm &trip
A.6.2
contacts
A.6.3 Method of glanding of cable
Any chance of water entry in to
A.6.4
terminal box
How frequently TB checked
A.6.5
/gasket changed
A.7 Leakage
Is it gasket leakage or welding NA
A.7.1
leakage
A.7.2 How frequent leakage is checked When leakage noticed
A.7.3 How frequent action taken As per the severity of the problem

B Tank
B.1 General condition of tank
B.2 Normal tank or bell tank Normal tank
B.3 Completely welded tank Yes
B.4 Any re welding done on the tank How and when -No
B.5 Locking arrangement of No
transformer wheels
C Conservator tank
Condition of /MOLG of main Ok
C.1
conservator
C.2 Make of /MOLG SukrutUdyog
C.3 Are MOLG replaced NO
C.4 Any difficulty in reading the Is reading correct-Yes
gauge
C.5 How often transformer topped up When required
C.6 How often MOLG terminal Monthly
box/contacts checked
C.7 Whether air cell is provided Condition of air cell-NA
C.8 How air cells condition checked. NA
C.9 Any problem with topping up of NA
transformer or vacuuming of the
transformer with air cell
C.10 Any intention in providing air cell NO
in normal type conservator.
C.11 Any other remarks No
D Conservator for OLTC No
Condition of prismatic oil level
D1 gauge/ OK Visible

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D2 Make of Oil Level gauge / Sukrut

Are MOLG replaced NO
D3
Any difficulty in reading the NO
D4 gauge
D5 How often OLTC topped up -NA NA
E Breather Assembly
General condition of the breather Breather assembly is available
E.1
assembly All breather silica gel to be replaced
Any joints or valves in breather Joints are their in the connecting pipe
E.2
pipe
Condition of the container and
E.3
window assembly
Frequency of
E.4
changing/regenerating silica gel
E.4.1 For Main tank
E.4.2 For OLTC
E.4.3 For Cable boxes
E.5 Any additional remarks
Buchholz Relay (Main& OLTC
F
)
Make of Bucholz relay /oil surge Not available
F.1
relay
F.2 Direction of mounting Arrow towards conservator tank
F.3
Are Bucholz relay /oil surge relay NO
F.4
replaced
F.5 Condition & Visibility of glasses Visible
F.6 Gas sampling cock provided Yes
How often gas collection / Monthly
F.7
terminal box/contacts checked?
Pressure Relief Valve /Device Yes
G
(PRD/PRV)
G1 Make of pressure relief device Not visible
G2 Are PRD / diaphragm replaced No
Condition & Visibility of PRD Ok
G.3
operation indication flag
Any decision to replace the NA
G.4
explosion vent with PRD

G.5 Any other remarks

H Winding Temperature
Indicator
H1 Make of relay/indicator Precimeasure and control pvt ltd
H2 Is relay/indicator replaced , if so NO
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when
Condition of WTI Capillary
H3 sensor/capillary/switches
/repeater/etc
Switch Settings and functions R
H4
ph
Switch Settings and functions Y
H5
ph
Switch Settings and functions B
H6
ph
Date of last calibration of WTI & Not available
H7
result
H8 How often contacts checked? Monthly
H9 Any remarks
I Oil Temperature Indicator
I1 Make of relay/indicator Precimeasure and control pvt ltd
Is relay/indicator replaced , if so NO
I2
when
Condition of OTI Capillary
I3 sensor/capillary/switches
/repeater/etc
I4 Switch Settings and functions
Date of last calibration of OTI & -
I5
result
I6 How often contacts checked? Monthly
I7 Any remarks
8
J Radiators Not available
Are radiators tank mounted or
J1
separately mounted
If separately mounted , provided
J2
with expansion joints
J3 Functioning of non-return valve
Is the arrangement of cooler
J4
proper for effective maintenance
J5 No. of radiators on each bank
Condition of radiators and make
J6
of radiator
How often Radiators cleaned,
method of cleaning of radiators, Is
J7
cleaning possible without
shutdown?
J8 Any radiator added , or replaced
Intention to add radiators in
J9
future

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Any other remarks

K Oil flow indicator

K1 Make of relay/indicator
Is relay/indicator replaced , if so
K2
when
K3 Condition of indicator
How often terminal box/contacts
K4
checked?
K5 Any remarks
L Bushings
L1 OIP type bushings
L1.1 Type & Make Condenser type - visible in the bushing
Level of oil in the bushings, any OK No leakage noted.
L1.2
leakage noticed
LI.3 Colour of oil in the bushings Clear
L1.4 Condition of Test tap Ok
L1.5 Any damage to bushing s? No
How often bushing is cleaned / Monthly
K1.6
terminal connector tightened

How often bushings are replaced? NA

L1.7 Is the work supervised/done by
OEM?
L1.8 How often bushings are tested Yearly by PET
Value of main insulation C1 and
L1.9
Tan of bushing with date of test
L1.10.1 HV C& tan
C&tan
C&tan
LV C& tan NA
L1.10.2 C&tan
C&tan
TRy C& tan NA
L1.10.3 C&tan
C&tan

Neutral C& tan

L1.10.4
Neutral C&tan
Whether Arcing horns are NO
L1.11
provided, if provided the gap
L1.12 Condition of Terminal connectors OK
M Plain porcelain bushings

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M.1 Type & Make

How often bushing is cleaned /
M.2
terminal connector tightened
M.3 Any oil leak? No
M.4 How often bushings are replaced Na
M.5 Any damage to bushing s? No
Whether Arcing horns are No
M.6
provided, if provided the gap
N Cooler Control Cubicle
General /physical conditions NA
N1
including painting.
N2 Condition of hinges and handles
Condition of various contactors,
N3
switches,TBs ,wiring etc.
Working of space heater &
N4
Thermostat
Whether all dummy gland holes
N5
are properly sealed?
Status of cubicle indication bulb
N6
and socket.
Condition of door gasket
N7
N8 Any remarks

O Marshalling kiosk
General /physical conditions
O1
including painting.
O2 Condition of hinges/handles
Working of space heater &
O3
Thermostat
Whether all dummy gland holes
O4
are properly sealed?
Status of cubicle indication bulb
O5
and socket.
Any remarks
O6

P Cooling Fans
P1 No. of fans in each group
Make and type and ratings of the
P2
fans
General working and appearance
P3
of fans
P4 Operation of all fans in

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Independent mode
Working of fans in auto mode
P5 and actual temperature of
switching.
Auto starting of standby fans on
P6
failure of Service fans
P7 Current taken by fans (average)
P8 Whether bird guards are provided
P9 How often fans are cleaned /
Whether fans were replaced ,
P10
cause /last replaced
P11 Any remarks

Q Cooling Pumps
No. of pumps in each group
Q1
Q2 Make and type of pumps
Q3 Whether pumps are replaced
General working and appearance
Q4
of pumps
Working of pumps in auto mode
Q5 and actual temperature of
switching.
Auto starting of standby pumps
Q6
on failure of Service pumps
Q7 Current taken by pumps (average)
Q8 How often pumps are checked
Is transformer shutdown essential
Q9 for pump replacement/
maintenance
Q10 Any other remarks

R Bushing CT
R1 No. of bushing WTI CTs HV IV LV - 1
Is protection class CT cores No
R2
provided
R3 Ratio
Condition of terminal connection OK. No Leak
R4
fixture and any oil leak
Sec. current measurement Primary Current applied :
R5
Sec. Current measured :
R6

S Tap Changer & DM

S1 Make

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S2 On Load or Off Load Off load tap changers

Whether suitable for reverse Yes
S3
power flow
S4 Voltage rating
Status of OLTC (Operational or
S5
Not)
Whether the TC is operating
S6
regularly, when last operated
If regularly operated ,the tap
S7 range at which operation is
essential
S8 Condition of oil in the DS
How often OIL BDV,PPM
S9
checked
S10 How often Oil filtered
S11 How often OLTC overhauled
How often DS taken out for
S12
inspection and cleaning
How often arcing contacts
S13
replaced
Present Counter reading and no.
S14 of operations after last
overhauling of OLTC
T Driving Mechanism
T1 Local /manual Operations
T2 Is electrical operation possible
Whether Emergency Stop is
T3
wired to remote?
T4 Capacity of Motor
Condition of Lubricant oil , if
T5
applicable
T6 Condition of hinges of DM
T7 Condition of TBs and Wiring
Whether all dummy gland holes
T8
are sealed
Working of space
T9
heaters/Thermostat
Condition of cubicle lighting and
T10
Sockets
U Remote Tap Changer Cubicle
(RTCC)
General condition, including
U1
painting
Remote Operation Master/,
U2
follower/independent

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U3 Auto operation functional

Whether all indication bulbs and
U4
annunciations are working.
U5 Remote indication of temperature
Are all transformer trouble alarm
U6 and trip functional , windows
working
Condition of TBs and internal
U7
wiring
Whether all dummy gland holes
U8
are sealed
V Surge Arresters
Whether SAs are provided for all
V1
phases/windings
V2 Condition of SAs, grounding
V3 Condition of structure earthing
Whether periodic checking of
V4
counter done /present reading
What is the present leakage
V5
current -reading
PET wing test result remarks, if
V6
any
V6.1 Watt loss
V6.2 Third harmonic current
Whether surge arrestor lead has
V7
any coiling
Location of surge arrestor ( shall
V8
be near to bushings)

W Protection
Whether Main-1 & Main-2
W1
Differential protections provided
HV and LV REF protection
W2
Provided
O/C & E/f protection with high
W3
set are provided on HV & LV
W4 Over flux protection
Whether busbar protection is
W5
available
Whether LBB protection is
W6
provided for Trfr. CBs
Condition of Protection panel &
W7
Accessories
Whether all trouble trip wired to
W8
Master trip

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NDR protection Provided For

W9
tertiary winding
W10 Conditions of panel

X PETs Test remarks

X1 Date of Last PETs testing
X2 REMARKS by PETS
X2.1 On Transformer
X2.2 On bushings
X2.3 On LAs
X2.4 On oil
X3 Remarks from PETs
Review of Action taken against
X4
PETs remarks

Y Relay Test Remarks

Y1 Date of last Relay Testing
Y2 Whether any relay replaced NO
Whether all protection functions
Y3
working satisfactorily
Review of Action taken against
Y4
Relay wing remarks
Z Maintenance & Up-keeping No separate maintenance register available for
Maintenance Records the transformers but an overall maintenance
registers are available including the transformer
and generator etc.
Whether standard and separate No
Z1 maintenance register is available
for each transformer
Whether the maintenance are Yes
Z2
carried out as per schedule
Whether the following are
Z3 properly recorded in the
maintenance registers
Z3.1 checkingof bushing oil level no
Z3.2 Checkingof oil level in no
conservator.
Z3.3 checkingof oil level in OLTC no
conservator
Z3.4 manualactuation of cooler oil no
pumps and fans

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Z3.5 checkingof oil leaks no

Z3.6 checkingcondition of silica gel in no
breather
Z3.7 checkingof oil level in oil seal of no
breather
Z3.8 checking the colour of oil in all no
bushings
Z3.9 checking the sound of fans NA
Z3.10 Testing of oil BDV and other no
parameters
Z3.11 checking of air trapped in no
buchholz relay-main tank
Z3.12 condition of RVT checked NA
capacitance and tandelta
Z3.13 check the condition of gaskets of ok
terminal boxes of PRD, buchholz
relay, MOLG etc. replace if
required
Z3.14 lubricating the hinges of MK no
(trfr& OLTC)
Z3.15 PETs /maintenance test results Ok, available
Z3.16 IR measurement of windings ok
(polarization index and DA.
ratio)
Z3.17 Tan , capacitance , ok
Z3.18 BDV ,ppm, acidity , IFT no
Z3.19 DGA no
Z3.20 Furan analysis no
Z3.21 BDV, PPM of OLTC diverter no
switch compartment oil
Z3.22 tightening of terminations in yes
kiosks
Z3.23 checking of contactors, space ok
heaters, illumination, etc.in the
kiosk
Z3.24 cleaning of marshalling boxes of
transformer and OLTC
Z3.25
Z3.26 Cleaning of all bushings ok
Z3.27 checking the tightness of HV ok
,IV,HVN& LV terminal
connections
Z3.28 checking the current taken by na
fan motors
Z3.29 checking the current taken by no
pump motors
Z3.30 External cleaning of radiators na

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(before summer)
Z3.31 Checking of auto starting of Pump will start when switch on the machine
cooler pumps and fans
Z3.32 Checking of auto starting of na
cooler pumps and fans
Z3.33 checkingof all remote no
indications (WTI and tap
position indicator)
andtop up oil pockets, if
required.
Z3.34 Electricalchecking/testing of no
pressure relief device, buchholz
relay, OLTCsurge
relay/checking of alarm/ trip
replacement of the gaskets of
the terminal box.
Z3.35 checking/testing of buchholz yes
relay by oil draining
Z3.36
Z3.37 physical verification of oil in yes
conservator tank
Z3.38 checking the inter trip from HV yes
to LV
Z3.39 checking the inter trip from LV yes
ref to HV
Z3.40 Checking of the actual tripping
of CB on the operation of all
relays on HV &LV

Z3.41 Condition of the CBs of the Ok, very good condition

transformer
Z3.42 Adequacy and condition of CTs ok
of the transformer.
Z3.43
AA History na
AA1 Whether this transformer was No
earlier in service at anywhere
else
AA2 Erection procedure As per oem standards
/commissioning procedure
adopted
AA3 Test report ( FAT , Not available
commissioning , etc available )
AA4 Whether any major over hauling no
/repair works done on the
transformer
AA5 Any failure recorded no

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AA6 Whether abstract of routine test yes

reports is available for checking
the trend
AA7 When OLTC overhauled NA
/replaced
AA8 Status of OLTC (Operational or Yes
Not)
AA9 Whether the TC is operating Na
regularly, when last operated
AA10 When Transformer overhauled No
AA11 How often PETs testing on Yearly
transformer is done , when last
AA12 Average no. of tripping on No
downstream (through fault)
AA13 Test Results (Tan , IR values, Available
PI ,capacitance,etc)
AA14 When HOC conducted
AA15 Oil BDV,ppm ,tan , acidity, IFT No
AA16 When DGA conducted and No
values and the trend
AA17 WTI /OTI trip setting Ok
AA18 OLTC oil BDV,PPM checked Na
and latest values
AA19 How often OLTC Oil filtered
AA20 How often OLTC overhauled
AA21 How often DS taken out for NA
inspection and cleaning
AA22 How often arcing contacts
replaced
AA23 OIP bushing Test Results (Tan ok
, IR values, capacitance,etc)
AA24 Furan analysis done , if so no
values

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