Transformer PC Test

Part I
Power Transformer
Contents
Section I
1.
2.
3.
4.
5.
6.
7.
8.
GENERAL
Basic working principle of Transformer

Selection of transformer
Major Parts and accessories
Major Supplier
Raw Material used
Relevant BIS
Compliance with Indian electricity rules
Inspection and testing at manufacturer works
Section II TRANSPORTATION AND STORAGE

1.
2.
3.
4.
5.
Transportation
External Inspection (Before unloading)
Unloading at site
Assembly of Wheels
Storage
Section III ERECTION

1.
2.
3.
4.
5.
6.
7.
General
Internal inspection
Assembling of accessories
Preparation of insulating oil (Quality and treatment)
Oil filling
Pressure testing of transformer
Hot Oil Circulation
Section IV COMMISSIONING
1.
2.
3.
4.
5.
Pre commissioning checks

Pre commissioning test
Final IR check
Final check prior to commissioning
Energizing
6.
Check immediately after commissioning
Section I
GENERAL
1.
Basic working principle of Transformer
A transformer is a static piece of apparatus used for transferring power from one circuit
to another without change in frequency. It can raise or lower the voltage with a
corresponding decrease or increase in current. In its simplest form, a transformer
consists of two conducting coils having a mutual inductance. The primary is the
winding which receives electric power, and the secondary is the one which may deliver
it. The coils are wound on a laminated core of magnetic material.
The physical basis of a transformer is mutual inductance between two circuits linked
by a common magnetic flux through a path of low reluctance.
The two coils possess high mutual inductance. If one coil is connected to a source of
alternating voltage, an alternating flux is set up in the laminated core, most of which is
linked up with other coil in which it produces mutually induced emf ( electromotive
force) according to
Faradays laws electromagnetic induction, i.e.
E= M (di/dt)
Where, e = induced emf
M = mutual inductance
If the second circuit is closed, a current flows in it and so electric energy is transferred
(entirely magnetically) from the first coil (primary winding) to the second coil
(secondary winding.)
2.
Selection of transformer
Depending upon the system design, DTL has adopted power transformer as per
following specification in its various substations
Voltage Ratio
Capacity
33/11 kV
16 MVA
Winding/Connection Voltage
Regulation
Two winding
On load
Page 1 of 56
Two winding
On load
66/11 kV
220/66-33/11 kV
20 MVA
20 MVA
350/3 MVA
Three winding
On load
220/66-33/11 kV
400/220/33 kV
100 MVA
315 MVA
Three winding
Auto Connection
On load
On load
DTL has adopted policy to procure the new power transformer with built in Nitrogen
injection fire extinguishing system and similarly existing transformer of DTL substation
will also be fitted with same extinguishing system.
3.
Major Parts and accessories
Main tank, Core, Winding, Tap changer, Driving mechanism, Bushing, Radiator,
Header, Main Conservator, Air Cell, Tap changer, conservator, Turret with CT,
Breather, PRV, Sudden pressure release valve, Marshalling Box, Magnetic Oil Gauge
Buchholz relay, Oil Surge Relay, Winding Temp Gauge, Oil Temp Gauge, Thermo
siphon, Cooling Fan, Oil pump, OLTC etc.
4.
Major Supplier
Major suppliers of power transformer in DTL are BHEL and CGL, however few
transformer of AREVA, TELK, EMCO and NGEF make are also installed in DTL
substations.
5.
Raw Material used
CRGO Steel, Copper Conductor, Kraft Insulating Paper, Sheet, Un-impregnated

densified Laminated Wood, Polyester Resin Impregnated Weft less Glass Tape,
Synthetic Rubber Bonded Cork Sheet, Pre-compressed press board, Nitrile Rubber,
Steel.
6.
Relevant BIS:
Following are the relevant IS for power transformer published by BIS as on April 2006
Standard
IS 2026 ( Part 1):1977
Title
Power transformers: Part 1 General ( first revision)
IS 2026 ( Part 2):1977
Power transformers : Part 2 Temperature- rise
IS 2026 (Part 3): 1981
Power transformer : Part 3 Insulation level and

dielectric tests ( second revision)
Page 2 of 56
IS 2026 (Part 4): 1977
Power transformers: Part 4 Terminal Marking,

tapping and connection (First revision)
IS 2026(Part 5): 1995
Power transformers: Part 5 Terminal/ Reactor bushings

minimum external clearance in air specification
IS 10028 (Part 1):1985
Code of practice for selection, installation and

maintenance of transformers: Part 1 selection
IS 10028 (Part 2):1981

maintenance of transformers: Part 2 Installation
(superseding IS: 1886)
IS 10028 (Part 3):1981

maintenance of transformers: Part 3 Maintenance
(superseding IS: 1886)
IS 3043:1987
Code of practice for earthing
IS 335:1993
New insulating oil (Fourth revision)
IS 1866: 2000
Code of practice for maintenance and supervision of

Mineral insulating oil
7.
Compliance with Indian Electricity Rules and Other Regulations.
All electrical installations shall comply with the requirements of the Indian Electricity
Act and Rules made there under and with any other regulations that may be applicable,
such as those made under Factories Act, 1948 and Fire Insurance Act. The following
rules of Indian Electricity Rules, 1956, are particularly applicable: 35,
35,50,51,59,61,63,64, 67, 68, 69 and 114.
7.1
Installation requirement
(a)
Soak pit and drain pit
Transformer foundation shall be surrounded by a suitable soak pit enclosed by a 150

mm high non combustible curb. This soak pit shall be filled with coarse crushed
stone about 25 mm diameter to a minimum depth of 300 mm. As the oil quantity of all
power transformer used in the DTL is more than 5 kL The volume of soak pit minus
volume of stones should be sufficient to contain at least one third of total oil content of
Page 3 of 56
transformer. The excess oil should be laid through two or more hume /concrete pipes
(minimum 150 mm diameter ) from bottom of pit to a central remote burnt oil pit.
Control cables emanating from transformer shall be passed through hume pipes laid in
the soak pit. The marshalling kiosk of the transformer shall be installed outside the pit
(b)
Barrier between transformer
Barriers / fire wall of brick or reinforced cement concrete shall be provided for
separation of transformer whenever adequate place is not available. The barrier shall
extend at least 300 mm above highest transformer bushing and pressure release vent and
lengthwise 600 mm beyond the transformer including any radiator and tap changer
enclosure
A summary of fire protection and fighting system for indoor and outdoor transformers
recommended by CBIP and being adopted by various power utilities is given below
Size (each)
Number
Transformer protection
(a) under 10 MVA
One or more
Hydrant protection
(b) 10 to 100 MVA
One only
Hydrant protection with water spray

equipment
More than one
1. Provide a 7.5 m clearance between

units and 60 mm hose with portable
spray nozzles
or
2. Masonry barrier between units with
60 mm hose with portable spray
nozzles
or
3. Fixed automatic water spray with
separate piping for each unit
One only

equipment
More than one
1. Fixed automatic water spray

(emulsifier) with separate piping for
each unit
and
2. Provide a 7.5 m clearance
or
masonry barrier between units
(c) Above 100 MVA
Page 4 of 56
(d) Above 200 MVA
8.
One only

equipment
More than one
1. Fixed automatic water spray with

separate piping for each unit
and
2. Provide 15 m clearance
or
masonry barrier between units
Inspection and testing at manufacturer works
During process of manufacturing, inspection & testing are carried out at various stages
and final routine test at works before dispatch for ensuring quality product.
Page 5 of 56
Section II
TRANSPORTATION AND STORAGE
1.0
Transportation
Depending upon the weight/height restrictions and/or other considerations, Power

Transformers are transported either filled with oil or nitrogen.
Large Oil filled Transformers are transported filled with dry Nitrogen, due to weight
limitations, at a positive pressure of 0.175 kg/cm to protect the active parts against
moisture .The internal gas pressure at the time of shipment is painted on the tank.
Small size Transformers are transported filled with oil such that about 10% of the tank
volume is left clear for oil expansion to limit the excess internal air pressure to 0.35 kg/
cm.
All openings resulting from the removal of fittings for shipment are sealed with suitable
gasketted blanking plates during transport. Fittings dismantled before transports are
packed in separate packing cases in line with shipping list.
2.
External Inspection (Before unloading)
In connection with receiving and unloading at site, and at the final storing place before
assembling, the transformers shall be inspected carefully. External visible damages as
dents, paint etc. may imply that the transformer has been subjected to careless handling
during transport and/or loadings, and a careful investigation is therefore justified.
After the arrival of the material at receiving points, the condition of packing and of the
visible parts should be checked before unloading. Drums containing oil, which have
been dispatched separately, should be examined carefully for leaks or any sign of
tampering. In case of possible damage/loss of any component, the necessary claims
should be registered with the concerned agency as per purchase order.
In order to protect the active part against moisture, the transformer tank is filled with
Nitrogen during transport at an over pressure of 0.175 kg/ sq. cm (2.5 psi)
approximately at room temperature.
Check immediately the gas pressure at the arrival. A positive pressure indicates that the
tank and the transformer components respectively are tight, and that the active part
including the insulation materials is dry.
If there is no positive gas-pressure, transformer should be immediately filled with dry
Nitrogen gas at a pressure of 0.175 kg/cm without loss of time as per the following
procedure.
(i)
Pull 500 mm mercury vacuum after blanking off all openings.

Page 6 of 56
(ii)
(iii)
(iv)
(v)
(vi)
3.
Break the vacuum by admitting dry nitrogen through a convenient valve at the
top of the tank and drain the oil completely.
Continue to supply nitrogen until it maintains a steady pressure of 0.175 0.02
kg/cm above the atmosphere.
Pressure of nitrogen gas shall be maintained at 0.175 0.02 kg/cm at same
reference temperature.
Pressure would be monitored by taking three readings within 24 hours to ensure
that there is no leakage of gas.
Shut off the gas supply valve and fit dry nitrogen back up cylinders through
nitrogen regulator valve.
Unloading at site
Foundation drawing must be referred before placing the transformer on final location.
As DTL substations are not having adequate crane facility, hence transformer are
unloaded from trailer on to a sleeper platform and gradually lowered to plinth level and
dragged on a rail by winches and placed on a foundation. If foundation is not ready
transformer is to be placed on level concrete on wooden sleeper to avoid direct contact
with water and to have free air passage. A typical unloading arrangement of the
transformer is shown in fig. 1
Fig.- 1
4.
Assembly of Wheels
Page 7 of 56
Mounting of wheels under transformer is to be done as per roller arrangement drawing

supplied by OEM. It should be ensured that wheel shafts are well greased and rotate
freely. While fixing the roller, flange should come on inner side of rails after placing the
transformer in the correct position. Transformer wheels must be locked for arresting the
movement of transformer
5.
Storage
5.1.1 Main Tank:

If the storage time is expected to exceed 3 months, the transformer should be provided
with oil conservator including oil-level indicator and breather and to be filled with oil as
per procedure laid down in the installation.
Wherever possible it would be most desirable to keep the transformer energized even at
a low voltage so that its temperature is higher than the ambient temperature. The low
voltage may be applied under open circuit or short circuit conditions. It may be
ascertained whether partial cooling is required in such a case. The oil quality should also
be periodically monitored. If for some reason, oil filling cannot be carried out after a
storage period longer than 3 months, the nitrogen pressure shall be maintained and
supervised carefully. If the storage time without oil exceeds 18 months OEM should be
consulted about measures to be taken. If required Dew point of nitrogen to be measured.
5.1.2 Dew point measurement
Dew point is the temperature at witch water vapors present in the gas begin to condense.
If gas pressure of nitrogen was not possible to maintain during storage period there is
every possibility to absorb the moisture in transformer active part/insulation. In such
cases, to check the dryness of insulation, dew point measurement is carried out at site in
consultation with OEM before starting the erection.
For transformer of gas pressure of 0.3 psi, the acceptable limit of dew point as
recommended by CBIP shall be as under
Temperature
insulation in F
0
5
10
15
20
25
30
of Maximum
permissible
point in F
-78
-74
-70
-66
-62
-58
-53
Temperature
dew insulation in C
-17.77
-15.00
-12.22
-9.44
-6.66
-3.33
-1.11
of Maximum
permissible
point in C
-61.11
-58.88
-56.66
-54.44
-52.22
-49.99
-47.22
Page 8 of 56
dew
35
40
45
50
55
60
65
70
75
80
85
90
95
100
110
120
130
140
5.2
-48
-44
-40
-35
-31
-27
-22
-18
-14
-10
-6
-1
+3
+7
+16
+25
+33
+44
+1.66
+4.44
+7.44
+9.99
+12.77
+15.55
+18.33
+23.11
+23.88
+26.66
+29.44
+32.22
+34.99
+37.75
+43.33
+48.88
+54.44
+59.99
-44.44
-42.22
-39.39
-37.22
-34.99
-32.77
-29.99
-27.77
-25.55
-23.33
-21.11
-18.33
-16.11
-13.88
-8.88
-3.88
+0.55
+5.55
Accessories:
Accessories are packed to protect against normal handling and transport stresses. The
instructions for lifting given on the packages must be complied to avoid damages.
5.2.1 Storing indoor
Following accessories should be stored indoor
(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
Insulation material as paper, pressboard, bakelite, wood, cotton tape etc.

Insulated items as paper-insulated conductors, pressboard insulated shielding
bodies etc.
Chemicals as solvents, glues, varnishes, hardeners etc.
Breathers, drying agents.
Terminal boxes, connection boxes, control cabinets.
Gas relays, oil-level indicators, thermometers, pressure valves etc.
M Box, OLTC motor drive, Fans, Pumps, Instruments & fittings etc. (Heating
elements provided shall be connected to supply)
5.2.2 Storing outdoor

The following components may be stored outdoors. They should be placed above
ground and covered with tarpaulin etc.
(i)
(ii)
Oil-conservator with blanking plates for all openings.

Radiators and coolers with blanking plates for all openings.
Page 9 of 56
(iii)
(iv)
Structures, A frames, Pipe supports, Supports for oil-conservators, radiators,

control cabinets etc
Oil drums should be stored in horizontal (lying) position with both the bungs also
in horizontal position.
Section III
Page 10 of 56
ERECTION
1.
General
Erection of transformer is divided in following section

(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
General
Internal inspection
Preparation of insulating oil
Oil filling
Pressure testing
Hot oil circulation in the transformer
As transformer tank is filled with nitrogen to protect from possibility of absorbtion of

moisture in the active parts during transportation and storage,. minimum possible time
should be taken between opening of the inspection plate and filling of oil to avoid the
absorption of moisture. To achieve this, erection work of radiator and conservator shall
be completed before opening the main tank. Preparation of oil should be taken in
advance so that transformer oil is ready by the time assembly of accessories are
completed.
Before taking up assembling of accessories, following items should be available at site
(i)
Crane of suitable capacity

(ii)
High-vacuum two-stage oil filtration plant provided with thermostat controlled
oil heaters and vacuum-proof hoses with independent vacuum pumping system
for tank evacuation. Capacity: 6000 lph.
(iii)
Oil-storage tanks provided with silica-gel breathers and inlet/outlet valves for oil
circulation. Recommended capacity 20 kL -30 kL
(iv) Vacuum gauges provided in filtration plant.
(v)
Equipment for measurement of electric strength (BDV) of oil- 100 kV set.
(vi)
Equipment for measurement of moisture content of oil.
(vii) Equipment for measurement of resistivity and Tan delta at 90 C.
(viii) Oil-sampling bottles.
(ix) Transparent vacuum-proof tubes for checking of oil-level during oil filling.
(x)
Valves, fittings, gaskets etc.
(xi) Dry nitrogen cylinders.
2.
Internal inspection
Before starting assembling of accessories on tank, the transformer must be internally

inspected. Before opening the inspection plate the following precaution are to be taken
(i)
Check that there is no over pressure in the transformer when blanking plates or
connection lids are to be opened.
Page 11 of 56
All loose objects, tools, screws, nuts etc. shall be removed from the transformer
cover before opening the connection and blanking lids.
(iii)
All loose objects (tools, pencils, spectacles etc.,) shall be removed from the
boiler-suit (dangri) pockets etc. before starting the work through manholes.
(iv) Tools to be used inside the transformer -e.g. for tightening of screw-joints- shall
be fastened to the wrist or another fixed point by means of cotton tape or string.
(v)
Tools with loose sleeves and tools with catches must not be used at work inside
the transformer.
(vi) Greatest possible cleanliness shall be observed at work inside the
transformer/reactor, and at handling of parts to be mounted inside the
transformer.
(vii) Fibrous cleaning material should not be used as it can detoreate oil when mixed
with it.
(viii) The active part (core and winding) should be exposed to the surrounding air for
as short time as possible. Therefore, only one blanking plate or connection lid
shall be opened at a time for remounting of bushings, valves etc.
(ix)
Sufficient oxygen should be inside the transformer tank to enter a person in to the
tank.
(ii)
2.1
Following points are to be checked on internal inspection
(i)
(ii)
(iii)
Conditions of leads.
Bracing, clamping of leads.
Connections (confirm connection on secondary winding on dual ratio transformer
as per sub station voltage requirement)
(iv) Tap changer checks.
(v)
General conditions of insulation.
(vi) Core check that it has not moved in transit.
(vii) CTs, including the secondary leads and their passage through metal parts.
(viii) Check that shipping frame for bushings have been removed.
(ix) Check that coil position has not moved in transit.
(x)
Check for dirt, metal swarf, moisture.
(xi)
Check that the bushing leads are set without being too close to ground or other
points of different potential
(xii) Core-ground check: This is checked with the megger after removing earth
connection. Refer figure 2
The values of the insulation shall be at least 1 Mega ohm or as recommended
by the manufacturer.
Service aged equipment
: > 1 Mega ohm
Insulation deterioration
: > 1 Mega ohm
Destructive circulating current : < 100 Kilo ohm
Page 12 of 56
Earthing Connections from core and top yoke clamp.(fig.2)

Note:
(ii)
While disconnecting/earthing connection between core/yoke clamp & tank,

remove the link.
While putting in service place links in position.
3.
(i)
To avoid any confusion and repetition of work assembling of accessories must be

carried out by referring the part list and transformer OGA supplied by manufacturer
along with OEM manual. Identify each accessories referring part list number given in
OGA with number marked on each accessories.
3.1
During process of assembling following precaution are to be taken
(i)
Fire-fighting equipment shall be available at the oil-treatment equipment as well

as at work on and adjacent to the transformer .
Welding work on or adjacent to the transformer shall be avoided.
Smoking on or near the transformer shall not be allowed.
Transformer tank, control cabinet etc. as well as assembling and oil treatment
equipment shall be connected with the permanent earthing system of the station.
All components dispatched separately should be cleaned inside and outside
before being fitted.
Despite all precaution, if any objects are dropped inside transformer this must be
taken out from the tank.
All the gasketting surfaces shall be cleaned well and new gaskets should be
fitted.
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
3.2
Valves
If main tank is received at site without the valve mounted on it re-mount the valves as
per the position appearing in the OGA drawing and part list. Check that all valves are
closed and locked.
Page 13 of 56
3.3
Turrets
Turrets are cylindrical shaped metallic part mounted on top plate of the transformer
used as housing of the HV and LV condenser bushings. Y phase turret of HV and LV
are internally mounted with CT, used for measuring for winding temperature. Mount
the respective turrets in correct position by aligning the punching mark given in turret
and transformer tank
3.4
Bushings
For 66 kV and above voltage level, oil impregnated paper (OIP) condenser bushings are
generally used
3.4.1 Design and Construction
The general constructional details of 220 kV OIP condenser bushing are shown in figure
The active part of the bushing consists of an Oil Impregnated Paper (OIP) condenser
core (2) manufactured from superior grade Kraft Paper wound on a metal tube. The
bushing is voltage graded by suitably interposed aluminum foils forming condenser
layers. Thus, the electrical stresses are controlled through out the thickness and along
the surface avoiding any highly concentrated zones.
The Condenser core (2) is assembled with a central mounting flange (6) and porcelain
insulator ( 3,23) at both outdoor and oil immersed. End joints are made leak proof by
means of gaskets and the complete assembly is held tight by means of a powerful spring
pack located in the top cap (22). This top cap also serves as an in built oil conservator
to cater for oil expansion and has an oil level indicator (1).
The bushing is vacuum dried and impregnated with high grade degassed and dehydrated
transformer oil under a carefully controlled and monitored process .
Set of adjustable gap arcing horns (4,5) is some times also provided. At the oil
immersed end, a special epoxy coated stress shield (7) is provided to control the high
stresses in the oil inside the transformer.
The central mounting flange (6) has provision for the following attachments
(i)
(ii)
(iii)
(iv)
(v)
Oil drain plug (9) for sampling of oil, when necessary.

Air vent plug if provided to bleed (16) out the transformer turret air during
topping up or for connection to a Buchholz relay.
Rating plate (24) giving the rating and identification details of the bushing.
Space for ring type CTS on the oil immersed end of bushing.
Test tap (10) for the measurement of power factor & capacitance and the
insulation resistance (IR) of the bushing. It is connected via tapping lead to the
Page 14 of 56
last condenser foil within the bushing during normal service This taping is
electrically connected to the mounting flange (6) through a self grounding
arrangement. The test tap must always be kept protected with its cover screwed
properly.
Page 15 of 56
3.4.2 Handling and unpacking:

The unpacking should be done at the time of installation. While unpacking all the
mechanical stresses or blows are to be avoided on the bushing. The smaller bushings
may be handled by hand whereas the larger units are handled by some lifting device.
Suitable slinged with manila ropes shown in figure. When positioning the bushing
upright, care should be taken to avoid any shock, blow or scratch to the lower end, the
porcelains (3,23) and bottom stress shield (7) of the bushing.
In case of bushing supplied with loose stress shield (7) the same may be fixed with
screws on the bottom terminal with the bushing held vertical.
Page 16 of 56
3.4.3 Checks before installation

Mount the bushing vertically on a suitable stand, clean the outer surfaces thoroughly
with a non-fluffy cloth and carry out the following tests.
(i)
(ii)
(iii)
Inspect the bushing physically for any leakage or damage to the porcelains.
Check the oil level in the gauge and ensure it is up to the centers of the gauge if
it is to be topped up, use the oil filling plugs (15) and fill high grade transformer
oil to IS 335 IEC: 296 (with minimum BDV of 70 KV)
Measure the IR value of the bushing with a 2.5/5 kV Megger between end
terminal and flange. It should not be less than 10,000 Mega Ohms. Normal R
value is found above 10,000 Mega ohms, but the atmosphere (humidity) surface
cleanliness of the porcelain etc. affect the values adversely.
Page 17 of 56
3.4.4. Installation
3.4.4.1 Bushing with solid stern
Generally bushing up to 66 kV are with solid non removable type conductor. This type
of bushing is mounted on the turret and connections are made to the top and bottom
terminals individually.
3.4.4.2 Bushing with - draw lead and draw rod type connection
Bushings of 220 kV and above voltage level are supplied with draw lead and draw rod
connection type. Mounting of this type bushings are to be carried out according to the
detailed information given by OEM instruction manual
3.5
Motor driving mechanism
3.5.1 Installation
Install the driving mechanism, bevel gear, and driving shaft, match the tap position of
driving unit with diverter switch as per procedure laid down by OEM manual.
3.5.2 Warning
Before coupling the tap changer with motor drive, ensure the following to avoid damage
of OLTC.
(vi)
Motor drive unit is on the same tap position as that of OLTC visible on TC head
cover window from top of transformer.
Tap position visible from the window provided on TC mounted on tank cover
matches with Tap position actually determined after performing the transformer
ratio test.
Equalizing pipe connected between flanges on TC head is removed and opening
suitably blanked with the elbow pipe and blanking plates supplied loose. This
pipe is required only during transport to avoid pressure difference between
transformer tank and OLTC diverter switch sealed compartment.
The vertical drive shaft is completely vertical and aligned properly between bevel
gear and motor drive unit.
Horizontal shaft is aligned properly between upper gear unit and bevel gear If
required swivel the upper gear unit mounted on TC head by loosening 12 bolts on
its thrust collar.
The diverter switch oil compartment is filled with clean transformer oil IS 335.
3.6
Oil Conservator
(i)
(ii)
(iii)
(iv)
(v)
Page 18 of 56
The conservator, which may be with or without air cell is assembled either on the
transformer, or on a separate frame.
3.6.1 Constructional feature of conservator with air cell
In all transformers especially in high voltage class, maintenance of insulating oil notably
its dielectric property forms one of the determining factors of reliability of equipment in
service. Oxidation and contamination of transformers oil can be avoided in a simple and
effective way by use of above oil preservation system. The complete system is known as
"Conservator with Air Cell".
In this oil preservation system a flexible air cell made of oil resistant nitrile rubber is
placed inside the conservator and floats on the oil surface. The air cell inflates or
deflates as the oil level in the conservator falls or rises depending on the ambient
temperature and load on the transformer``. The inside of the rubber bag (Air Cell) is put
into communication with atmosphere by means of a silica gel breather which ensures
dry atmosphere inside the air cell. In addition to the above this system provides
following advantages.
(i)
(ii)
It avoids saturation of absorbed gases.

As no gas is used in this system, which operates at constant pressure, this
formation of gas bubbles at low ambient temperature and load is eliminated. The
system thus preserves the oil quality particularly its dielectric properties.
The conservator with air cell is provided with a magnetic oil gauge having one electrical
contact. The indication shown on the dial physically corresponds to the oil level in the
conservator which is due to balance of static pressure between the oil of the conservator
and the atmospheric air inside the air cell. This system is also provided sometimes with
a set of pressure and vacuum valves. These valves operate to pass either oil or air in the
event of over filling or under filling the conservator during installation.
Page 19 of 56
Page 20 of 56
3.6.2 Operation of conservator air cell

The oil connection between conservator and transformer tank is made through Buchholz
relay and valves are provided in between.
The flexible air cell is connected to the top of the conservator through gasketted joint.
Under normal condition air cell is completely surrounded by oil and floats in the
conservator. The air cell inflates/deflates as the oil volume changes. The float of the
MOG which is always in contact with bottom side of the air cell, moves up and down
and indicates the oil level. The air cell will sink in the remote event if it is damaged and
MOG alarm will operate. The conservator then functions as a conventional conservator
without effecting the performance of the transformers.
3.6.3 Installation of oil conservator
Generally oil conservator of transformer 100 MVA and above are supplied with air cell
assembled. Mount and check the function of Magnetic oil gauge. Healthiness of air cell
for any leakage must be checked and inflate the air cell as per procedure laid down by
OEM instruction manual before mounting on transformer. Conservator should be
cleaned thoroughly inside.
3.7
Breather Pipe
Mount breather pipe as per OGA drawing. Joint of pipe must be tighten properly to
avoid any air leakage which may cause moisture entering into transformer. Breather
pipe must be supported firmly.
3.8
Equalizing Pipe
All equalizing Pipes of turrets should be mounted according to OGA & part list. The
pipes shall always incline 3 to 7 degrees upwards from the transformer
3.9
Buchholz Relay
Page 21 of 56
3.9.1 Principle of Operation of gas operated relay

Relay serves main protection for any minor or major faults that may develop in side the
transformer, such fault allowed result in generation of the gas which causes operation of
the mercury switch giving signal of audible alarm and isolate the transformer from the
network
3.9.2 Construction
It comprises of cast housing which contained pivoted bucket, each bucket being counter
balanced by a weight. Each assembly carries mercury switch, the leads from which are
taken to a terminal block.
3.9.3 Operation
In a healthy condition of the transformer relay is full of oil and the both the mercury
switches are open. In the event of a minor fault like damage to the core bolt insulation,
local overheating, etc, the arcing causes slow generation of gas in the oil, which passes
in the pipe and gets trapped in the relay housing. As gas accumulates, oil level in the
relay falls, leaving the buckets full of oil.
When a sufficient volume of gas is collected in the relay, the top bucket tilts because of
its extra weight due to contained oil, overcoming the balance weight which closes the
mercury switch and initiates an audible alarm.
With a major fault like short circuits between turns, coils or between phases, generation
of gases is rapid and gas displaced oil surges to the relay and impinges on the baffle
causing the lower assembly to tilt and close the mercury switches. This provides the
signal for tripping the circuit breaker, which disconnect the transformer from the bus
bar.
3.9.4 Installation
Before installing functional test of the relay is to be carried out as per procedure given in
OEM manual. The relay must be mounted in the pipe at an inclination of 3 to 7 degree
and arrow (shown in bucholtz) towards conservator, test cock and air vent are at the top
and entry of connecting lead should from bottom of the relay. Before commissioning
ensure that test key of buchholz relay remains in the S (service) position and test key
bolt is tightened. Buchholz relay should be mounted as shown in the figure below
Page 22 of 56
3.10
Pressure Relieve Valve (PRV)
3.10.1 Application
This is a mechanical protective device used on transformer. When pressure in the tank
rises above predetermined set limit this valve operates and performs the following
functions
(i)
(ii)
(iii)
Allows the pressure to drop by instantaneously opening a port of about 150 mm

dia.
Gives visual indication of valve operation by rising a flag.
Operates a micro switch. Hence switch can be effectively used in control circuit.
Page 23 of 56
3.10.2 Installation
Each valve should be cleaned from inside ( tank side) with compressed air jet. All
particles should be removed from tank side While cleaning, care should be taken that the
jet does not attack the switch and the flag mechanism. The PRV should be installed
considering the following aspects. The indicating flag is easily seen from distance, The
valve is accessible for manual resetting and for routine manual checking. While
installing remove dirt and clean the mounting surface, remove all traces of oil, grease.
The rubber gasket supplied with the valve should be property cleaned & re located
properly in the recess carefully. All the bolts should be tightened evenly so that equal
pressure is exerted on basket and base. Connect control circuits to terminal plate
provided in the switch box through cable gland. As per wiring diagram check the
operation of flag and switch by lifting operating rod and confirm that both controls
operate as required.
3.11
Sudden Pressure Relay (SPR)
3.11.1 General description and working

The Sudden Pressure Relay is a device designed to respond to the sudden increase in gas
pressure in a power transformer which would be caused by an internal arc. The Relay
consists of three main parts: a pressure sensing bellows, a Micro switch, and a pressure
Page 24 of 56
equalizing orifice, all enclosed in a sealed case and mounted on the outside of the
transformer at the gas space.
When an arcing internal fault in the transformer produces an abnormal rise in gas
pressure, the bellows will expand, operate the Micros witch and signal the occurrence of
the fault. The equalizing orifice is a non corrosive plug with a very small hole,
which
will equalize the pressures in the Relay and gas space during the slow pressure
variations associated with transformer load changes. It will throttle an abnormal increase
in transformer pressure, however, and cause a signal.
3.11.2 Operation
It will operate on a sudden increase of gas pressure regardless of the operating pressure
on the transformer.
(i)
(ii)
(iii)
(iv)
A pressure rise of 5.5 psi per second will operate the Relay in three to four cycles
on a 50 Hertz circuit.
At high rates of rise: 30 to 40 psi per second, it will operate in a half cycle.
It will not operate on changes in pressure due to normal transformer operation.
It will detect abnormal disturbances which are sufficient to operate the
conventional pressure relief device.
Figure given below shows the operating characteristics of the Relay.
Page 25 of 56
3.11.3 Installation
The Sudden Pressure Relay is mounted above the maximum oil level in the gas space
when applied on transformers. The Relay can be satisfactorily mounted on the
transformer cover, particularly when applied to transformers in the field. When vacuum
filling a transformer on which a Sudden Pressure Relay is mounted, care must be taken
that the Relay is not filled with oil. Also pull vacuum and break vacuum at 1/4 psi
/second maximum to avoid any possibility of straining the bellows. If the transformer is
shipped with a dummy plate mounted in place of the Sudden Pressure Relay, the
transformer should be filled with oil before the Relay is mounted. If the Relay should
accidentally be filled with oil, it should be replaced.
3.12
Cooling Bank
Erect the cooling bank support structure/frame. Mount the header. Check that all
radiator valves of the main tank are closed. Remove the blanking plates of the radiators,
headers etc. when the assembling of the coolers is to be started. Mount the radiators,
connect cooling bank pipe, oil pump (arrow mark must be to wards main tank), oil flow
indicator (Before mounting, unlock the device and check the function of mercury switch
of oil flow indicator) etc. according to OGA drawing.
3.13
OLTC conservator tank and oil surge relay
Mount the tank, surge relay and breather pipe as per OGA drawing.
Page 26 of 56
3.14
Marshalling Kiosk
All temperature indicators, switches, contactors for controlling pumps and fans are fitted
in marshalling kiosk. All cable from transformer accessories and RTCC are terminated
in marshalling kiosk. This should be installed as per lay out drawings near to
transformer so that length of the capillary of WTI & OTI do not fall short and also to
keep sufficient space for opening of the front and rear door.
3.15
WTI & OTI temperature bulb
These are the sensing device connected with a expansion bellow housing in WTI at
other end through capillary filled with liquid and sealed. The bulbs along with
capillaries are coiled and kept in side marshalling kiosk along with mounted WTI.
3.15.1 Installation
The bulbs are to be installed in the respective pocket provided on the top of transformer
tank after filling oil in the pocket Care must be taken for not to stretch hard ,twist or
bend the capillary to a radius less then 75mm. Continuously support the capillary by
suitable clips at intervals of 300 to 450 mm. Allow necessary slack at the bulb end for
mounting and removing the bulb without sharp bend at the joint.
3.16
Thermo siphon
All the transformer 100 MVA and above in DTL are fitted with Thermo Siphon filter
arrangement. These are provided for preservation of transformer oil quality and are
normally installed having ONAN and ONAF cooling system
3.16.1 Design: Thermo- Siphon Filters consist of steel container fitted with perforated
steel trays. These trays are filled with alumina balls and so arranged that there will be
effective circulation of oil through proper contact with Alumina. The assembly is
mounted on transformer and connected with pipes and shut off valves.
As a result of difference in temperature between upper and lower layers of the oil in
the tank of transformer in operation, the oil circulates through the filter from top to
bottom by convection.
The absorbent removes moisture and acid etc. from the oil which speeds up the ageing
of the oil and also paper insulation.
3.16.2 Installation
Following procedure shall be adopted for commissioning thermo siphon filter.
Page 27 of 56
(i)
(ii)
Regenerate the Alumina before putting into trays. Trays should be filled up to
depth of 30 mm
Complete the assembly as shown in OGA drg. of the transformer.
3.16.3 Procedure for regeneration of Alumina

Alumina should be thoroughly washed in clean transformer oil and heated in a oven.
It should be reactivated separately in a container and not in trays provided in the filter.
The adsorbent should be fried at 140C for 12 hours or at 210C for 8 hours. The dried
alumina must be stored in a sealed container.
It is important that transformer oil should not be poured immediately after regeneration
of Alumina which will cause charring of oil. Alumina should be allowed to cool at 60C.
Fill the trays with adsorbent and (complete the tray assembly and lower this assembly in
container immediately and commission the filter.
3.17
Neutral CT
Erect the LV and HV neutral CT and connect the bus bar to the respective HV & LV
neutral bushing as per OGA. Flexible copper bus bar connection should be provided
between LV neutral bushing and solid earthing bus to have sufficient flexibility so that
excessive force is not applied to bushing
3.18
Control, relay and tap changer panel
Install the transformer control, relay and remote tap changer panel in control room.
Ensure that all the protective relays required for transformer are provided in the panel
3.19
Cabling
Complete the cabling connecting all accessories of the transformer (MOG, PRV, SPR,
turret CT, Buchholz relay, oil surge relay, cooling fan, cooling pump, oil flow indicator,
Driving mechanism, Marshalling kiosk) with relay panel and RTCC panel as per
schematic cable schedule.
Note: all cable should be properly ferruled, and glanded with tag identification tags
3.20
Earthing
(i)
transformer tank, marshaling box, OLTC, motor drive, radiator, supporting

structure etc should be earthed and connected to main earth mesh
LV and HV neutral CT should be earthed to separate bored earthed pit and also to
be connected to main mesh. In case of 33 kV neutral double earth strip must be
provided
Control, relay and tap changer panel to be connected to earthed
(ii)
(iii)
Page 28 of 56
(iv)
Tertiary winding :As per DTL practice in 220/66-33/11 kV transformer, any one
phase of tertiary winding that is 11 kV winding is externally earthed and
connected with substation mesh. Similarity of the earthing phase should be
maintained with existing transformer if any.
3.21
Touch up paint
Damages on the primer paint and grinding done the steal surface should be painted with
two cats of anti corrosive priming paints
4.0
Preparation of insulating oil (Quality and treatment)
4.1
Quality
The oil to be filled in transformer generally complies with the requirements of the
customer's specification. The characteristics of fresh oil as per IS: 335 "Specification
for New Insulating Oil" are given below:
Characteristics and Parameters of New Insulating Oil
S No. Characteristics
1.
Appearance
Unit
2.
3.
4.
5.
6.
7.
8.
9.
Density at 29.5C
Kinematic Viscosity At 27C ( max)
Interfacial tension at 27C ( Min)
Flash Point (Max)
Pour point ( Max)
Neutralization value (Total acidity), (Max)
Corrosive sulphur:
Electric strength (breakdown voltage
(min)
gm/cc
Cst
N/m
C
C
mg/KOH/g
(a)
New Untreated Oil,
KV (rms)
(b)
10.
After filtration
KV (rms)
Dielectric dissipation Factor (tan&) at
90C (Max)
Water Content ( Max)
ppm
Specific resistance ( Min)
11.
12.
Requirement
The oil shall be clear,
transparent & free
from
suspended
matter or sediments.
0.89
27
0.04
140
-6
0.03
Non- corrosive
30
(If the above value is
not obtained the
the oil shall be
filtered in laboratory).
60
0.002
50
Page 29 of 56
13.
14.
15
4.2
at 90C
at 27 C
Oxidation stability
a) Neutralization value ( Max)
b) Total sludge after oxidation(max)
Ageing characteristics after accelerated
ageing ( open beaker method with copper
catalyst)
a) Resistivity ( Min)
at 90 C
at 27 C
b) Tan delta at 90 C Max
c) Total acidity(Max)
d) Sludge content by weight ( Max)
Presence of oxidation
Ohm-cm
Ohm-cm
mg/KOH/g
35 x 10
1500 x 10
0.4
0.10%
Ohm-cm
Ohm-cm
mg/KOH/g
mg/KOH/g
0.210
2.510
0.2
0.05
0.05 %
Oil shall not contain
inhibitor
oxidation
inhibitor
Reconditioning
Transformer oil is usually contaminated during handling, transport, and storage due to
ingress of moisture and solid impurities. Hence, oil shall be vacuum filtered separately
at 50 C to 60 C using a suitable filtration machine and a spare clean tank before filling
in the transformer. Transfer the oil from drum to storage tank
4.2.1 Method of sampling from storage tank
Remove all dirt from the sampling valve or plug. Allow some oil to flow through an oilsampling container (figure below) before collecting sample for testing. Sample should
be testes in accordance with IS 335
Page 30 of 56
Oil treatment shall be terminated when the following parameters are attained.
Table
kV Class of transformer
Up to 145
245
420
5.0
Recommended Permissible limit

Electric Strenth
Moisture Content
(BDV) in kV ( Min)
ppm (Max)
60
20
65
15
70
15
Oil filling
After assembling accessories transformer tank should be put under vacuum. Before
starting the vacuum following precaution to be taken
(iii)
(iv)
Oil conservator and radiator are not to be evacuated there fore valve between
conservator and main tank, and all valve of the radiator and cooling fans must be
closed.
Equalizing pipe between main tank and diverter switch assembly should be
mounted and the valve if any must be kept open
Valve between the ratio chamber and main tank must be kept open.
No electrical test on the Transformer is permitted during the evacuation.
5.1
Evacuation
(i)
(ii)
The vacuum pump may be connected to the top valve of transformer. Transformer tank
(Excluding cooler bank and conservator) shall be evacuated to a pressure of 1.00 Torr
max, and vacuum to be maintained for the time given in table below
TABLE
System Voltage
Evacuate
and
vacuum for
KV
Upto 145
145 - 420
Hours
12
24
5.2
hold Standing time after oil

circulation
before
application of voltage
Hours
12
48
Oil Filling in main tank
The oil shall be heated to a temperature of 50- 60C measured at the filter outlet valve.
The pressure during the filling shall be maximum 1 Torr. During the oil-filling, a
transparent plastic tube can be used as an oil-level gauge. The tube which should be a
Page 31 of 56
wall thickness of 5-8 mm, may be connected to a top and a bottom valve on the
transformer.
Oil-filling in the tank is done through valve at a low level on the transformer and at a
maximum rate of 4-5 kL/hour. When the oil-level has reached about 50 mm below the
cover/the vacuum pump is stopped. Continue the oil filling level up to bucholz relay
5.3
Oil Filling in diverter switch assembly
Oil will be automatically filled in diverter switch assembly when oil level in transformer
main tank reach up to OLTC equalizing pipe. Dismantle equalizing pipe and blank with
elbow pipe and blanking plates supplied loose.
5.4
Oil filling in cooling bank
Cooling bank to be filled separately with purified and degassed oil. The oil is then
circulated through the vacuum filter at least twice via drain valves as near as possible to
the transformer. When the oil circulation has been completed the valves between coolers
and main tank shall be opened.
Care should be taken to keep all air release plugs and valves open to allow escape of
trapped air during oil filling operation. These valves/plugs should be closed after
completion of oil filling.
5.5
Oil filling in conservator tank
The following procedure is recommended.

(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
Open the valve between conservator and main tank after removing blanking and
connecting pipe
Remove the inspection cover provided on the side of the conservator and check
the air cell assuring that it is inflated. The air cell must remain in fully inflated
condition during oil filling operation. If the air cell is found deflated fit the
inspection cover and inflate the air cell with dry air/nitrogen gas to 0.035 kg/cm
max. through connection. A gauge may be put by removing plug. After filling
close these connections.
Remove air release plugs and provided on top of the conservator.
Slowly pump the oil through the main tank . Temporarily stop filling operation
when oil starts coming from opening and after ensuring that no air bubbles come
out through these air release holes. Fit the two air release plugs.
Continue oil filling till oil start coming from air release plug stop oil after
ensuring that no air bubbles come out. Fit the plug.
Now release the air pressure held inside the air cell from point and continue oil
filling until magnetic oil gauge indicates 35 C mark.
Remove oil pump and connect air cell to breather from point. Also remove
pressure gauge and put plug.
Page 32 of 56
(viii) The system is now properly filled. Air release plugs are fitted in normal
operation.
5.5.1 Precautions
(i)
(ii)
(iii)
(iv)
Oil filling in the conservator and also draining whenever required must be done
very slowly. During oil filling, pressure in the air cell should not exceed 0.1 kg/
sq.cm (1.5 psi).
If a pressure or vacuum is ever applied to the main tank the conservator must be
disconnected and a blanking plate fitted on shut off valve.
Do not weld on conservator to avoid damage to the air cell.
Once all the air has been driven out during oil filling in the conservator do not
remove air release plugs. Otherwise air will be sucked inside the conservator.
5.6
Oil filling in Thermo siphon
Oil can be filled in thermo siphon taking oil from main tank by opening bottom shut off
valve and releasing the air provided on top of the thermo siphon tank. Open the top shut
off valve. Both the top and bottom thermo siphon valve should kept open to keep the
thermo siphon in service.
6.0
Pressure testing of transformer
(i)
After completion of oil filling, lock PRV and pressurize the air cell by filling
nitrogen/ dry air to 5.0 p.s.i. (0.35 Kg/ cm).
Maintain above pressure for at least 12 hours.
Inspect all joints for leakage, if any.
Record pressure testing as given below.
After pressure testing unlock PRV and release the nitrogen/ dry air pressure of air
cell.
(ii)
(iii)
(iv)
(v)
NOTE: In case of conventional oil preservation system (without air cell) pressurize
conservator by filling nitrogen/dry air in conservator .
Record of pressure testing at site
Date
Time of testing
Initial
Pressure
Pressure
Remarks
after
12
hours
Started Finished
on
on
If leakages are observed. Same to be arrested and pressure testing is to be repeated.

Page 33 of 56
7.0
Hot Oil Circulation
7.1
Main tank
After completing oil-filling the temperature of the transformer is increased by

circulating the oil through the vacuum filter and with circulation direction according to
facilitate oil-penetration and absorption of possible gas bubbles.
The most practical method of drying out is by circulation of hot oil through a streamline
filter machine incorporating oil heater and vacuum chamber (or other oil cleaning and
moisture removing device). The vacuum pump of the filter machine should have the
capacity of creating vacuum as high as possible. Where possible, a vacuum pump can be
connected to the tank top cover to keep the oil in tank under vacuum consistent with
tank suitability. This may speed up the drying out process. It is preferably to lag or
blanket the transformer tank to prevent loss of heat. To start with, oil is drawn from the
bottom and let into the transformer at the top. This will remove any settled moisture
impurities. After about 8-12 hours circulation in this manner the cycle is reversed i.e. oil
is drawn from the top and fed at the bottom. The oil temperature as measure by the oil
temperature indicator should be of the order of 60 C. During this process IR value of
the winding should be measured at regular interval of 4 hours measured and plotted.
Sl No
between time
terminal
IR value
15
sec
60 60
sec 0
sec
Ambient
Temp
C
Dielectric PI
Remarks
absorption
60/15
600/6
Page 34 of 56
It will be observed that in the beginning IR values drop down as the temperature goes
up. IR values will be low till moisture coming out of the insulation and start rising
before steadying. Typical dry out curve is shown below.
Caution: The temperature during oil circulation should not increase beyond 70 C
otherwise this may cause oxidation of oil.
The oil will be circulated through a vacuum filtration machine till the parameters are
attained as per table below.
kV Class of Electric
Moisture
Transformer
Strength
content ppm
( BDV) in KV ( Max )
( min)
Up to 72.5
40
25
145
50
20
245 and 420
60
15
7.2
Resistivity at Tan delta

90 C (ohm- at 90 C
cm)
1 x 10 12
1 x 10 12
1 x 10 12
0.05
0.05
0.05
Diverter switch
Hot oil circulation is carried out separately in diverter switch to remove moisture from
the tap changer terminal board and tested separately till oil result is satisfactory and
meet the requirement as peer IS 1866
Page 35 of 56
Section IV
COMMISSIONING
1.
Pre commissioning checks
The following checks to be done at site after transformer has been installed and dried
out.
Breather Silica gel (Blue colour when dry)
Oil in the Breather housing cup.
All valves for their correct opening and closing sequence.
Oil level in conservator tank.
Oil in cooling system.
Oil level in bushings.
Release air, wherever necessary.
Cooling accessories (Pump motors, Fan motors etc.) for direction and O/L
setting.
(ix)
Buchholz, oil level indicator, pressure release valve, thermometer, temp.
indicators etc. for operation.
(x)
Earthing of main tank, M. Box, T/C driving gear, diverter, Pump Fan motor etc. .
(xi) Neutral earthing.
(xii) Earth Resistance of Electrodes.
(xiii) Earthing of bushing test tap.
(xiv) Check oil leakage for 24 hrs.
(xv) Check Auxiliary circuit voltage (415 V).
(xvi) Calibration of OTI/WTI with hot oil.
(xvii) Check Working of WTI/RTD repeaters at control room.
(xviii) All valve open to transformer blanked.
(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
(viii)
2.
Pre commissioning test
The following test to be done at site after transformer has been installed and dried out.
Insulation Resistance test
(ii)
Test on tap changer.
(iii) Test on turret CT.
(iv)
Continuity test
(v)
Voltage ratio test.
(vi)
magnetization current
(vii) Magnetic balance test
(viii) Measurement of winding resistance
(ix)
Verification of vector group and polarity
(x)
Measurement of Capacitance and Dissipation Factor.
(i)
Page 36 of 56
Single phase short circuit test (Measurement of short ckt impedance at low
voltage)
(xii) FRA
(xiii) WTI OTI Setting
(xiv) Protection and alarm check
(xi)
Purpose and procedure of test along with formats is given below

2.1
Insulation Resistance Measurement.
Insulation resistance tests are made to determine the insulation resistance from
individual winding to ground or between individual windings. The insulation resistance
in such tests is commonly measured in mega-ohms, or may be calculated from
measurements of applied voltage and leakage current.
The test is conducted with the help of mega-ohmmeter. IR is proportional to the leakage
current through/over the insulation after capacitive charging and absorption currents
become negligible on application of DC voltage. Insulation resistance shall be measured
after the intervals of 15 sec, 60 sec and 600 sec. The polarization index (PI) is defined
as the ratio of IR values measured at the intervals of 600 and 60 seconds respectively.
Whereas, the dielectric absorption is the ratio of IR values measured after 60 sec and 15
sec. IR is normally measured at 5 kV DC or lower test voltage, but the test voltage
should not exceed half the rated power frequency test voltage of transformer windings.
Polarization index (PI) is useful parameters for logistic interpretation of IR test results.
This ratio is independent of temperature and gives more reliable data for large power
transformers. PI of more than 1.3 and dielectric absorption factor of more than 1.25
are considered satisfactory for a transformer when the results of other low voltage
tests are found in order. PI of less than 1 calls for immediate corrective action.
The IR value of transformer is dependent on various factors such as configuration of
winding insulation structures, transformer oil, atmosphere condition etc. therefore,
present trend is to monitor oil characteristics for judging the condition of dryness of the
transformer and not to rely solely on absolute values of IR. It may be noted that no
national/international standards specify minimum insulation resistance values of
transformers. The value of IR may be very low under heavy fog or humid
conditions.
During IR measurement, we must ensure following conditions:
Transformer is disconnected from other associated equipment.

Bushings are cleaned and free of moisture
Transformer tank and core are properly grounded.
Both ends of windings under test are short circuited.
Page 37 of 56
2.1.1
IR - Temperature relation (Conversion of IR value at different
temperature)
A curve for guidance of the field staff is given below. This curve can not be taken for
absolute value but will serve as a good guide for conversion of IR values at different
temperatures. A simple example is given as to how to calculate the value at different
temperature.
Suppose IR value of 70C is 300 M Ohm and we want to convert at 40C, the curve
will give a factor K for difference in temperature i.e. ( 70C-40C=) 30C
K for 30 temperature difference = 4.2
So the value at 40C = 4.2 x 3000 = 1260 M ohms
Value thus converted fairly tally with the actual value when transformer is
cooled.
The factor are tabulated as below
Difference
in temp.
Factor K
10C
20C
30C
40
1.65
2.6
4.2
6.6
50
Page 38 of 56
2.1.2 Winding
between
terminal
IR value
15
sec
60 60
sec 0
sec
Ambient
Temp
C
Dielectric PI
Remarks
absorption
60/15
600/6
2.1.3 OLTC Motor

Description
between terminal IR value
Megger
Remarks
Voltage
2.1.4
Cooling fan and pump motor
Description
Sr. No.
IR value
Remarks
Page 39 of 56
2.2
On Load Tap Changer
Sl.NO.
1.
Description
Date
Visual Inspection of
equipment
Hand Operation on all taps.
Complete wiring of the
circuits
Limit Switch
Over running device.
Remote Panel wiring
Over load
Device of Driving Motor
Local Operation (Electrical).
Remote Operation
(Electrical).
Tap Position Indicator
Step by step contractor.
Out of Step Relay.
Emergency Stop
2.
3.
4.
5.
6.
7
8.
9.
10.
11.
12.
13
Observation
Remarks
Note: While Operating the mechanism on Electrical Control, check once again limit
Switches, step by step contractor, over running device etc. for their actual operation and
ensure that they are functioning properly.
2.3
Test on turret CT.
Ratio test
HV CT
LV CT
LV CT
Primary current %
Y Phase
S1-S2
S1-S3
S1-S4
S1-S2
S1-S3
S1-S4
S1-S2
S1-S3
Page 40 of 56
S1-S4
Polarity test
HV CT
S1(+ve) and S2 (-ve)
IV CT
LV CT
Magnetizing current
0.25X 0.50X 0.75X 1.00X 1.10 X
KVp KVp KVp KVp KVp
HV CT
LV CT
LV CT
S1-S2
S1-S3
S1-S4
S1-S2
S1-S3
S1-S4
S1-S2
S1-S3
S1-S4

M ohm
HV CT
LV CT
LV CT
2.4
Primary to secondary
Secondary to earth
Secondary to earth
Secondary to earth
Continuity test
Page 41 of 56
This test is carried out to confirm the continuity of winding from line and neutral or line
to line with multimeter on all taps and phases
2.5
Voltage ratio test.
To determine the turns ratio of transformers during commissioning the procedure shall
be following:
Keep the terminals of IV and LV open.
Apply 3 phase or single-phase supply according to the transformer type on HV
terminals.
Measure the voltage ratio of HV and IV as well as HV and LV.
Repeat the steps for each tap position separately.
The Test shall be conducted with three phase supply and voltmeters. The voltage ratio
shall be measured between all pairs of windings of a transformer with externally
available terminals.
Results of the transformation turns/voltage ratio are absolute, and may be compared
with the specified values measured during factory testing. The acceptance criteria
should be that the measured values are within 0.5% of the specified values for all
windings. One should also consider the trend of voltage ratio values with reference to
values measured during the commissioning tests.
The voltage should be applied only in the high voltage winding in order to avoid unsafe
voltage.
Apply 3-ph, 4 wire, 415v ac on HV terminals and keep IV
open
RATIO : HV / IV
TAP
POSITION
VOLTAGE APPLIED
1Y1B 1R - N
N
N
VOLTAGE MEASURED
2R N
2Y - N
2B - N
RATIO
R
RATIO : HV / LV
TAP
VOLTAGE APPLIED
VOLTAGE
MEASURED
RATIO
Page 42 of 56
POSITION
LOWEST
NORMAL
HIGHEST
1R - N
1YN
1B N
3R 3Y
3Y 3B
3R 3B
RATIO : IV / LV
TAP
POSITION
NORMAL
2.6
VOLTAGE APPLIED
2Y2B 2R - N
N
N
VOLTAGE
MEASURED
3R 3Y 3R 3Y
3B
3B
RATIO
R
Magnetization current
This test is performed to locate defect in the magnetic core structure, shifting of
windings, failure in turn to turn insulation or problems in tap changers. These
conditions change the effective reluctance of the magnetic circuit thus affecting the
current required to establish flux in the core.
The procedure is as follows:
a)
b)
c)
d)
e)
f)
First of all keep the tap position in the lowest position and IV and LV terminals
open.
Apply 3 phase 415 V supply on the line terminal for 3-phase transformers and 1
phase, 230 V supply on single phase transformer.
Measure the voltage applied on each phase (Phase-Phase) on line terminals and
current in each phase of the line terminal.
After completion of the above steps, keep the tap positioning at normal position
and repeat the steps a to c.
After completion of the above steps keep the tap positioning at highest position
and repeat steps a to c.
Repeat the test with tap position in normal position.
The test shall be conducted with single phase or three phase supply according to test
requirement, voltmeter and multimeter.
The acceptance criteria for the results of exciting current measurement should be based
on the comparison with the previous site test results or factory test results. The general
pattern is two similar high readings on the outer phases and one lower reading on the
centre phase, in case of three phases transformers. An agreement to within 30% of the
measured exciting current with the previous test is usually considered satisfactory. If
Page 43 of 56
the measured exciting current value is 50 times higher than factory tests, then it is likely
to have a fault in the winding which needs further analysis.
The residual magnetism results of higher value than normal exciting current. Care
should be taken during exciting current measurement to avoid the effect of residual
magnetism in the transformer core.
a.
Apply 3-phase, 415 V AC on H.V terminals and keep I.V and LV open.
Tap Position
Between
R-Y
Y-B
R-B
R-Y
Y-B
R-B
R-Y
Y-B
R-B
Lowest
Normal
Highest
b.
Current measured(mA) Remarks

(V)
R
Y
B
R
Y
B
R
Y
B
Apply 3-phase, 415 V AC on I.V terminals and keep H.V and LV open.
Tap Position
Lowest
Normal
Highest
2.7
Voltage applied
Voltage applied(V)
2R-2Y
2Y-2B
2R-2B

R
Y
B
Magnetic balance test
This test is conducted only on three-phase transformer to check the imbalance in the
magnetic circuit.
The procedure for conducting test is as follows:
Keep the tap in normal tap position.

Disconnect the transformer neutral from ground.
Apply single phase 230 V across one of the HV winding terminal and neutral
then measure voltage in other two HV terminals across neutral. Repeat the test
for each of the three phases.
Repeat the above test for IV winding also.
The test shall be conducted with 230 V single phase supply and voltmeter. The voltage
induced in the center phase may be 50% to 90% of the applied voltage. However, when
Page 44 of 56
the center phase is excited then the voltage induced in the outer phases may be 30% to
70% of the applied voltage.
Zero voltage or very negligible voltage induced in the other two windings should be
investigated.
Disconnect transformer neutral from ground and no winding terminal should be
grounded, otherwise results would be erratic and confusing.
APPLY 1-PH 230V
AC
VOLTAGE MEASURED IN VOLTS
REMARK
ACROSS
(1) BETWEEN
(2) BETWEEN (3)
1R - N
V 1Y - N
V 1B - N
V
1Y - N
V 1R - N
V 1B - N
V
V 1Y - N
V 1R - N
V
1B - N
2R - N
2Y- N
2B - N
2.8
V 2Y-N
V 2R-N
V 2Y-N
2B - N
2B - N
2R - N
V
V
V
Winding Resistance Measurement.
Transformer winding resistances are measure at site in order to check for abnormalities
due to loose connections, broken strands of conductor, high contact resistance in tap
changers, high voltage leads, and bushings. Presently resistance is measured by digital
meters/bridge method.
The test shall be conducted at all taps of in case of tap winding and the measured value
shall be converted at 75 degree C.
The acceptance criteria is usually agreement to within 5% of resistance measurements
made separately on different phases, under field condition. But, for large transformers,
it is recommended to compare the resistance values with original data measured in the
factory and in case of large variation, connection tightness to be checked.
The current used for these measurements should not exceed 15% of the rated current in
order to avoid heating the winding thereby changing its resistance. However, the
current should not be too small, which may not be sufficient to avoid inductive effect,
due to core magnetization.
Page 45 of 56
The winding resistance shall preferably be measured when the different in the top and
bottom temperature of the oil (temperature of oil in steady-state condition) is equal to or
less than 5 degree C.
Winding resistance measurement shall be done only after measurement of magnetic
balance and magnetization (excitation current). The polarity of the core magnetization
shall be kept constant during all resistance measurement. A reversal in magnetization of
the core can change the time constant and results in erroneous readings.
Winding Temperature at the time of testing
RESISTANCE AT 75 FACTORY
DEG. C
VALUE
TAP
WINDING RESISTANCE
1R1 - 1Y1 - 1B1 POSITION 2R1
2Y1
2B1
R
Inter mediate voltage side
BETWEEN
WINDING
2R1 - N
2Y1 - N
2B1 - N
RESISTANCE
SITE VALUE
RES AT 75 DEG C IN
OHMS
FACTORY
SITE
REMARK
RES AT 75 DEG C IN
OHMS
FACTORY
SITE
REMARK
Low voltage side
BETWEEN
WINDING
3R1 - 3B1
3Y1 - 3R1
3B1 - 3Y1
2.9
RESISTANCE
SITE VALUE
(a) Connect neutral point of star connected winding to earth

(b) Join 1U of HV and 2U of LV terminal
Page 46 of 56
(c) apply 415 volt, 3 phase supply to LV terminals

For example Dy-1 transformer winding measured as follows
1W-2V ----------, 1W-2W----------,1V-2V--------,1V-2W-------,1U-2W--------,
Voltage relation
1U-1W=1U-2W+2W-1W
1V-2W< 1V-2W
1W-2V=1W-2W
For example of transformer of Vector group Yna od 11

Procedure for the test is as follows and varies with the type of vector group
Connect neutral point and LV Phase with earth
Join 1R1 and 3B1 terminals
Apply 415 volt, 3-phase supply to HV terminal
TERMINALS
1R1 - 1Y1
1Y1 - 1B1
1B1 - 1R1
3Y1 - 1B1
3Y1 - 1Y1
3R1 - N
3Y1 - N
1R1- N
2R1 - N
2Y1 - N
2B1 - N
VOLTAGE
MEASURED
REMARKS
The following reading combination should be confirmed

Page 47 of 56
2R1-N = 2Y1-N =2B1-N=Constant

As 3R1-N>3Y1-N and 3Y1-1B1>3Y1-1Y1
2.10
Measurement of Capacitance and Dissipation Factor.
The insulation dissipation factor (tan delta) is the ratio of the resistive current to the
capacitive current flowing through the insulation on application of sinusoidal voltage
under prescribed condition. The capacitance values are relatively independent of
temperature and prevailing atmospheric conditions.
The larger component is the capacitive current whose magnitudes is determined by the
test voltage, the dimensions of the capacitor and by the dielectric constant of the
insulating material. The smaller component is the resistive current whose magnitude is
determined by
the test voltage and the resistive losses of the insulating material.
The capacitive component of the current leads the voltage by 90C. . The resistive
component of the current is in phase with the test voltage E. The resultant total current
leads the test voltage by an angle defined as . And it is always less than 90. Cosine
is known as power factor and for our purpose cos will be known as the powerfactor of the insulation (or insulation power-factor).
The voltage to be applied shall not exceed half of the power frequency test voltage or 10
KV whichever is lower
The test is conducted with high voltage supply and Schering bridge.
Low dissipation factor is indicative of problem in insulation structure and predictive
ageing of insulation. But the comparative values of tests taken at periodic intervals are
useful ink identifying potential problems rather than an absolute value of tan delta. The
initial reference can be drawn from the tan delta values measured during factory testing.
However, the tan delta values measured in the field are not very accurate and deviation
up to 30% from the values measured at the works should be accepted.
The acceptance criterion to assess the probable condition of the insulation of the
transformer is no substantial variation in the measured values of tan delta (dissipation
Page 48 of 56
factor) at periodic interval when compared with previous references. For bushings, the
tan delta value shall not exceed 0.7%.
The main capacitance of the bushing i.e. the capacitance between high voltage terminal
and test tap is not affected by the surrounding conditions and the accepted deviation
from the values measured at factory tests should be less than 10%. The capacitance
between bushing test tap and ground is largely influence by the stray capacitance to
ground parts in the transformer and hence large deviation in the measured value shall be
accepted when compared with the factory test value.
Environmental factors like variation in temperature, relative humidity, surrounding
charged objects etc. have great influence on measurement of dissipation factor. Care
shall be taken to control the above factory during measurements.
Tan delta and capacitance measurement of bushing
High voltage bushing
CAPACITANCE
(MEASURED VALUE)
VOLTAGE
R PHASE
Y PHASE
B PHASE
REMARK
SITE FACTORY SITE FACTORY SITE FACTORY
2 KV
10 KV
TAN DELTA
(MEASURED VALUE)
VOLTAGE
R PHASE
Y PHASE
B PHASE
2 KV
10 KV
REMARK
Intermediate voltage bushing

VOLTAGE
CAPACITANCE
(MEASURED VALUE)
R PHASE
Y PHASE
B PHASE
REMARK
TAN DELTA
(MEASURED VALUE)
R PHASE
Y PHASE
B PHASE
REMARK
2 KV
10 KV
VOLTAGE
2 KV
10 KV
Page 49 of 56
Low Voltage bushing

voltage
capacitance
(measured value)
R phase
Yphase
B phase
site
factory site factory
site
factory
remark
Tan Delta
(MEASURED VALUE)
R Phase
Y Phase
B Phase
site
factory site factory
site
factory
Remark
2 kV
10 kV
Voltage
2 Kv
10 Kv
Winding
VOLTAGE
2 KV
10 KV
2 KV
10 KV
2 KV
10 KV
BETWEEN
CAPACITANCE
TAN DELTA
SITE FACTORY SITE FACTORY
REMARK
HV + IV / LV
+ TANK + E
HV + IV +
LV / TANK +
E
LV / HV + IV
+ TANK + E
2.11 Single phase short circuit test (Measurement of short circuit Impedance at
Low Voltage)
To find out the short circuit impedance of transformer.
Page 50 of 56
The measurement is performed in single phase mode. This test is performed for the
combination of two windings. The one of the winding is shorts circuited and voltage is
applied to other winding. The voltage and current reading are noted.
The test shall be conducted with variac of 0-280 V, 10 A, precision RMS voltmeter and
ammeter.
The acceptable criteria should be the measured impedance voltage having agreement to
within 3% of impedance specified in rating and diagram nameplate of the transformer.
Variation in impedance voltage of more than 3% should be considered significant and
further investigated.
The conductors used for short-circuiting of the transformer windings should have low
impedance (less than 1 m-ohm) and short length. The contracts should be clean and
tight. Percentage impedance can be calculated from test result as under.
% impedance = (Voltage applied rated current 100) / ( rated voltage
current measured)
2.12 Frequency Response Analysis
Dielectric faults in transformers may be caused by mechanical displacement

occurring during transportation, short circuit forces or inadequate clamping
possibly caused by shrinkage of windings due to ageing. Such changes cannot be
detected through DGA, winding resistance, C &Tan $ measurement etc. FRA
has proved to be easy to perform in the field and provide an reliable indication
of mechanical condition of transformers even if reference results are not
available.
Standard Network/ Spectrum Analyzer, consisting of one main unit and

measurement unit can be used for FRA measurement. Connection of the
instrument to the transformer using three coaxial test leads are shown in Fig. It
can be seen from the diagram that the swept frequency sinusoidal signal output
(S) of approximately 2 V rms from the measurement unit of analyzers and one
measuring input are connected to the one end of a winding . While other end of
the winding is connected to the other measuring input (T). The voltage are
applied and measured with respect to the earthed transformer tank.
It should be ensured that winding not being tested, are terminated in open
condition in order to avoid the introduction of differences between the responses
of three phases. The same procedure is followed on subsequent tests on the same
or similar transformer, to ensure that measurements are entirely repeatable.
Page 51 of 56
The voltage transfer function TI/RI is measured for each winding for four
standard frequency scans from 5 HZ to 2 MHz and amplitude and phase shift
results are recorded on floppies for subsequent analysis
Analysis of Measured Frequency Responses.
Frequency responses recorded as above are analyzed in any of the following manner:
Shift in the response in the winding
Differences between the responses of all the phases of the same transformer.
Differences between the responses of transformers of the same design.
In all the above cases major frequency shifts especially in low frequency range is cause
for concern.
As per Euro Double Client Committee, the traces in general will change shape and be
distorted in the low frequency range ( Below 5 kHz), If there is core problem. The
traces will be distorted and change shape in higher frequencies(above 10 kHz), if there
is winding problem. Changes of less than 3 decibels dB ( or more) in following
frequency range may indicate following faults.
Table: Probable faults detectable by FRA
Frequency
Range
5 Hz to 2 kHz
50 Hz to 20
kHz
500 Hz to 2
MHz
25 Hz to 10
MHz
Probable fault
Shorted turns, open circuit, residual magnetism or core
movement
Bulk movement of windings relative to each other
Deformation within a winding
Problems with winding leads and/ or test lead placement
It is normally sufficient to consider only amplitude responses, although phase

responses are being recorded too. In practical situation, FRA has confirmed of no
winding movement and has enabled transformer to be returned to service quickly
after incident such as tap changer faults thus avoiding a costly internal
inspection. This test is sensitive, immune to electromagnetic interference and
repeatable being insensitive to the disposition of test leads and not influenced
by weather. A typical FRA curve with Amplitude and phase angle is
It should be borne in mind that although FRA technique is very powerful and
effective tool and capable of detecting a range of transformer faults, it is
Page 52 of 56
nevertheless primarily a mechanical condition assessment test and must be used

in conjunction with other diagnostic tests if a complete picture of the condition of
the transformer is to be obtained.
2.13 WTI OTI Setting
Setting to be carried as per OEM manual
Settings
HV
Set
Proved
IV
Set
for
for
Proved
LV
Set
Proved
Oil
Set
for
for
Remark
Proved
Fan Start
Fan Stop
Pump
Start
Pump
Stop
Alarm
Trip
2.14
Protection and alarm check
After completing works of associated breaker and other bay equipments tripping of the
breakers through various protection devices should be checked as follows
Sl No
1
2
Device
Set for
Alarm
Trip
Proved
Alarm
Remarks
Trip
Main
buchholz
Surge
Relay
Page 53 of 56
Excessive
Winding
Temp
Excessive
Oil Temp
Oil level
PRV
SPR
Differential
relay
HV REF
Relay
LV REF
Relay
Over flux
relay
Earth Fault
Relay
Over
current
Relay
Inter trip
4
5
6
7
8
9
10
11
12
13
14
15
3.0
Final IR check
After successful pre commissioning test transformer should be connects with the system
on the final megger value should be checked.
Main Winding
between
terminal
4.1
IR value
15
sec
60 60
sec 0
sec
Ambient
Temp
C
Dielectric PI
Remarks
absorption
60/15
600/6
Following check list to be filled up and necessary action taken

(a) Pre commissioning check carried out
(b) Commissioning check carried out
Yes/No
Yes/No
Page 54 of 56
(c) standing time as per manual before final air release operation
(d) Bushing test cap tight ness ensured
(e) Bushing oil level ensured
(f) Tank cover / bell tank earthing strips connected
(g) Neutral grounding ensured
(h) All Pre commissioning results satisfactory
4.2
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Energizing
TEST WITNESSED BY
CUSTOMERS REPRESENTATIVE
OEM REPRESENTATIVE
SIGNATURE
SIGNATURE ..
NAME
NAME .
DESIGNATION..
DESIGNATION...
DATE. Place Date.. Place
Transformer charged on.. at . Hrs
successfully.
The initial magnetizing current at the time of switching will be very high. This depends
on the particular moment in the cycle. The Transformer should always be soaked for
few hours under constant care i.e keep it energized on open circuit before putting it on
load.
4.3
Check immediately after commissioning and record the following
a)
b)
c)
i)
Transformer humming/ noise/ vibration : ________________________

Any abnormal noise from Bushing/OLTC : _______________________
Record any other abnormality observed and obtain clarification from OEM on
such : _________________________________
If noise from any loose items due to vibration, tighten same and observed
Observe for 12 hours for any abnormality :
No oil leaks from any point: _________________
Any other observation. Obtain confirmation from OEM in such
points:_____________________
No load current at relay terminal
R phase
m Amp
CT Ratio
Y phase
m Amp
B phase
m Amp
Temperature at the time of charging
j)
O. T.I
C
W.T.I
C
Ambient
C
Maximum temperature after 24 hours
d)
e)
f)
g)
h)
C
Page 55 of 56
DTL
Representative
OEM Representative
Page 56 of 56
Site Inspection Record (SFQP)

Equipment: Transformer
Doc No : SFQP/TRF/IR/01
Site:
Bay:
Equipment Sr No.:
Make:
Rating:
Voltage level:
Page 1 of 24
1. RECEIPT
a. Receiving inspection
All items are received with respect to the following
delivery challans:
__________________.
Delivery Challan Nos.

b)
__________________.
Visual check
Shortages and damages checked w.r.t packing list:
__________________.
shortages and damages:
__________________.
Yes/No
c)Proper Storage of T/F and oil drum

a)All items are stored properly ( the costly items kept in lock
andkey
__________________.
b)All items shall be stored on pacca floor /metallic road
__________________.
c)The site shall be visited by civil engineer fore ensuring the same
before storage
__________________.
d)The site of unloading of transformer tank shall be visited by

civil and construction Deptt jointly
__________________.
e)Special instruction from manufacturer regarding

storage followed:
__________________.
f) During storage both lids should be horizontal position
__________________.
d. Inspection of main transformer tank:

External Damages, if any
Nitrogen
pressure
in
Yes /No
the
main
___________________.
tank
as
per
&
manual:
_____________kg/sqcm.
Ambient Temp.:
value for the above IR is 5 M ohms.
REMARKS:____________________________________________________________________
______________________________________________________________________________
e) Rating plate details
Type of cooling:
______________
Phase:
____________
Rating HV & I.V (MVA):
______________
Frequency:
____________
Rating LV (MVA):
______________
Connection Symbol: ____________
No Load Volts HV (kV):
______________
No Load Volts I.V (kV):
______________
INSULATION LEVEL

Site:
Bay:
Equipment Sr No.:
Make:
Rating:
Voltage level:
Page 2 of 24
Impedance
HV Position 9/I.V
H.V:
Voltage at Base
HV Position 9/LV
I.V:
I.V/ LV
LV:
_____________
_____________
MVA:____________
_____________
No Load volts (kV):
______________
Line Current HV (Amps):
______________
Line Current I.V (Amps):
______________
Line Current LV (Amps):
______________
Oil temperature rise,
above ambient temperature: < Deg. C ________________.
Winding temperature rise, above ambient temperature: < Deg. C ________________.

Makers and serial No.
______________
Year Of Manufacture:
______________
Core and winding weight in kg: ______________

Weight of oil in kg:
______________
Total weight in kg:
______________
Oil quantity in kL
______________
Transport weight:
______________
Untanking weight:
______________
P.O. No.

Site:
Bay:
Equipment Sr No.:
Make:
Rating:
Voltage level:
Page 3 of 24
2. STORAGE
a. Main transformer tank Nitrogen pressure:
Check Nitrogen pressure is maintained at min 0.2 -.4 kg/sq.cm and record in the register
every 15 days.
Date
Pressure
Date
Nitrogen Filling Record
Pressure
Date
Pressure
Before
b.
After
OLTC: In case OLTC is separately mounted, Nitrogen pressure is to be maintained in

the same manner as that of main transformer tank: _____kg/sq.cm as per O &
M manual.
c.
Marshalling Boxes/control boxes:

Check that these boxes contain silica gel or heater is switched on: __________
d.
Special
instruction
from
manufacturer
regarding
storage
followed:
_______________
Remarks:_______________________________________________________________________
______________________________________________________________________________
_____________________________________________________________________________.

Site:
Bay:
Equipment Sr No.:
Make:
Rating:
Voltage level:
Page 4 of 24
3. Pre Installation Checks

a. Checked availability of drawings ,manuals & inspection report
________________
b. Checked availability of materials as per BOM/packing list
________________
c. Availability of rating plate of equipment:
_______________.
d. Power transformer foundation is checked that they are

properly leveled as per foundation drawings( Jointly checked
by civil& const Deptt
_________________.
e. Checked that tools, tackles and manpower are available at site:
_________________.
f. Contract for ETC has been awarded
_________________.
g.
_________________.
Ensure dragging is done properly with all precaution
REMARKS:____________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________

Site:
Bay:
Equipment Sr No.:
Make:
Rating:
Voltage level:
Page 5 of 24
4. Installation Checks
( in the presence of Original Equipment Manufacturer Engineers
YES / NO
a. Checked proper placement of transformer on plinth:

_______________.
b. Internal inspection of tank ( In the presence of OEM engineer)
_______________.
c. Check IR value of core( In the presence of O.E.M. Engineer)
IR of Core:
Use 1000V Megger
CC G
________________ M ohm; CC: Core Clamp
CL G
________________ M ohm; CC: Core Limb
CC CL
________________ M ohm; G: Ground ( Tank body)
Acceptable value for the above IR is 5 M ohms.

I.
BUSHING ASSEMBLY:
Note: Ensure the following before/after mounting of bushings:

i. Tan delta and capacitance test is to be done,
_______________.
ii. Test on turret CT are to be done before they are mounted:
_______________.
a. Inside of turret is clean and undamaged:
_______________.
b. Check of turret CTs for healthiness and correctness, CT
terminals/terminal plates are OK:
_______________.
c. Sealing gaskets are of correct size and shall be replaced with new
_______________.
d. Checked positive Nitrogen gas pressure above oil (wherever
applicable) and adjusted as per recommendations, if low.
_______________.

Site:
Bay:
Equipment Sr No.:
Make:
Rating:
Voltage level:
Page 6 of 24
e. Bushings are clean and free from physical damage and are clean with
CTC/ cloth. Check for any hairline crack, megger IR value of bushing
before erection. (HV test tap, Tt-E, HV-E).
_______________.
f. Bushing is lifted properly as per instructions. Ensure proper use of
sling and ensure proper angle of bushing:
_______________.
g. Visual inspection of installed bushing to check that this is sealed
properly. Check for oil level indicator orientation and oil level
h. Check line lead connections for tightness. Ensure use of proper
torque wrench:
_______________.
i.
Ensure turret and bushing flanges are grounded (Copper jumper)
between two flanges:

_______________.
II.
TAP CHANGER ASSEMBLY

(In the presence of O.E.M. Engineer)
a. Visual inspection of damages, if any:

_______________.
b. Check that OLTC driving mechanism and drive shaft are aligned
properly. The selector and driving gear taps are synchronized before
connecting coupling shaft:
_______________.
c. Handle for manual operation is properly placed:
_______________.
d. Surge relay is mounted in correct direction as per arrow mark:
_______________.
e. Tap-changer is grounded
_______________.
f.
III.
Check the manual operation

MARSHALLING BOXES
a. No damage to components inside the box:

_______________.

Site:
Bay:
Equipment Sr No.:
Make:
Rating:
Voltage level:
Page 7 of 24
b. Box is rigidly fixed and sufficient clearance is available for opening

of the door:
_______________.
c. Door gaskets are OK:
_______________.
d. Cable glands are fitted properly. Gland plates are earthed and extra
holes on gland plate are sealed:
_______________.
e. Wiring is complete and T.B are tight:
_______________.
f. Marshalling box is grounded:
_______________.
g. Heaters are connected
h.
Provision of door light to be checked
i.
All wiring from the tank to marshalling box shall be through cable
tray
_______________.
IV.
CONSERVATOR ASSEMBLY
a. Locking device for mechanism of oil gauge is removed after latter

erection in position:
_______________.
b. Gaskets for mounting accessories are new and of proper size:
_______________.
c. Vacuum release valve is working properly:
_______________.
d. Check the healthiness of air cell by putting 0.07 kg/sq cm of nitrogen
dry air for 12 hrs
_______________.
V.
COOLING SYSTEM AND PIPE WORK
a. Visual inspection to check cooling fans, pump, motors, valves, flow

indicators, pressure gauges, thermometers and cooling pipes
_______________.

Site:
Bay:
Equipment Sr No.:
Make:
Rating:
Voltage level:
Page 8 of 24
b. Fans and pumps are correctly installed w.r.t. direction of rotation

marked on them:
_______________.
VI.OIL PREPARATION AND FILLING
a. Oil filtration in the closed separate tanker and oil properties are tested
as per requirement:
_______________.
i)BDV:
_______________.
ii)Moisture content:
_______________.
b. Transformer is put under vacuum as per O & M instructions:
_______________.
i)Vacuum measurement
_______________.
ii)Time of application of vacuum
_______________.
c. Oil filled up in the main tank
d. Oil is completely filled in OLTC, gear box unit, cooling system and
conservator tank
_______________.
e. Air is completely released from all air release plugs/valves/Buchholz
relays:
_______________.
f. Oil level in breather cup is up to the mark and free air is passing:
_______________.
g. Equalizing pipe fitted on diverter switch top cover is removed after
oil filling in the main tank and blanking of hole is done properly:
_______________.
h. Check no oil is leaking from any joint:
_______________.
Before
Charging

Site:
Bay:
Equipment Sr No.:
Make:
Rating:
Voltage level:
Page 9 of 24
i.
Oil is circulated as per instruction for 72 hrs(min)

_______________.
j.
Oil testing after circulation: _______________.

Electric BDV strength:
__75-80_______kV ( Min)
Moisture content:
___>10_________ ppm
k. Colour of silica gel in breather is blue:

_______________.
l.
All oil isolation valves are open:

_______________.
REMARKS:____________________________________________________________________
______________________________________________________________________________
5. Pre-commissioning check
(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
Check colour of Breather Silica gel (Blue colour when dry)

Check Oil in the Breather housing cup.
Check all valves for their correct opening and closing sequence.
Check oil level in conservator tank.
Check oil level in bushings.
Release air, wherever necessary.
Check cooling accessories (Pump motors, Fan motors etc.)
for direction and O/L setting.
(viii) Check direction of Buchholz relay (Arrow should be towards
conservator)
(ix)
Check operation of buchholz relay, oil level indicator,
pressure release valve, temperature indicators etc..
(x)
Check earthing of main tank, M. Box, T/C driving gear, diverter,
Pump Fan motor, cable glands etc
(xi)
Check all neutral properly earthed to a permanent earthing point.
(xii) Check earth Resistance of Electrodes.
(xiii) Check earthing of bushing test tap.
(xiv) Check oil leakage for 24 hrs.
(xv) Check Auxiliary circuit voltage (415 V).
(xvi) Check calibration of OTI/WTI with hot oil.
(xvii) Check Working of WTI,OTI and tap position repeaters at control room.
(xviii) Check blanking of all valve open to transformer.
(xix) Check clearances as per OGA
(xx) Check all the terminals for no debris of HV terminal
yes/no
Yes/no
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No

Site:
Bay:
Equipment Sr No.:
Make:
Rating:
Voltage level:
Page 10 of 24
Remarks:_________________________________________________
_________________________________________________________
_________________________________________________________
Megger used
Make
Model
Serial no.
Voltage Range
6. Pre Commissioning Test

(i)
Insulation Resistance Measurement
(a)
Winding
between
terminal
IR value
15
sec
60
sec
600
sec
Ambient
Temp
C
Dielectric
absorption
60/15
PI
Remarks
600/60
Note: Use megger voltage range 5000V

While measurement ensure no external line, lightening arresters etc
should be in circuit.
(b)
OLTC Motor
Megger used (500v Megger)

Site:
Bay:
Equipment Sr No.:
Make:
Rating:
Voltage level:
Page 11 of 24
Make
Sl No.
Model
Voltage range
Description
between terminal
IR value
Megger
Remarks
Voltage
(c)
Cooling fan and pump motor

Description
Sr. No.
IR value
C-1 Fan Motor

Fan motor no. - 1
Fan motor no. - 2
Fan motor no. - 3
Fan motor no. - 4
Fan motor no. - 5
Fan motor no. - 6
Fan motor no. - 7
Fan motor no. - 8
Fan motor no. - 9
Fan motor no. - 10
Fan motor no. 11
Fan motor no. - 12
S. No. _ _ _ _ _ _ _
S. No. _ _ _ _ _ _ _
S. No. _ _ _ _ _ _ _
S. No. _ _ _ _ _ _ _
S. No. _ _ _ _ _ _ _
S. No. _ _ _ _ _ _ _
S. No. _ _ _ _ _ _ _
S. No. _ _ _ _ _ _ _
S. No. _ _ _ _ _ _ _
S. No. _ _ _ _ _ _ _
S. No. _ _ _ _ _ _ _
S. No. _ _ _ _ _ _ _
C-2 Pump Motor

Pump Motor - 1
Pump Motor - 2
Pump Motor - 3
Pump Motor - 4
Pump Motor - 5
Pump Motor 6
S. No. _ _ _ _ _ _ _
S. No. _ _ _ _ _ _ _
S. No. _ _ _ _ _ _ _
S. No. _ _ _ _ _ _ _
S. No. _ _ _ _ _ _ _
S. No. _ _ _ _ _ _ _
Note: Acceptance value is >1M ohm

Remarks:_________________________________________________
_________________________________________________________
(ii) Oil Testing
Remarks

Site:
Bay:
Equipment Sr No.:
Make:
Rating:
Voltage level:
Page 12 of 24
( Sample to be taken prior to charging of transformer and it should fulfill the

recommendations as per IS 1866)
oil sample
IS-1866
IS-1866
IS-1866
Top
main
tank Bottom
BDV moisture
tan delta
(min)
(kV)
(max)
(ppm)
(max)
(90 c)
60
50
40
15
20
25
0.05
0.05
0.05
resistivity
interfacial
tension at 27
(min)
deg.
(ohm-cm)
(min) n/m
1 x 10
1 x 10
1 x 10
0.03
0.03
0.03
OLTC
Remarks:
remarks
for kV class
> 145 kV
< 145kV but > 72.5 KV
< 72.5 KV
SAMP.
DATE :
SAMP.
DATE :
_____________________________________________________
_____________________________________________________
(iii)
DGA
Dissolved
gases
just
before
charging
Oil sample schedule

just
24 hrs
7 days
after
after
after
charging
charging
charging
15 days
after
charging
H2
CH4
CO
CO2
C2H4
C2H6
C2H2
C3's
FG
TCG
Remarks:_________________________________________________
_________________________________________________________
(iv)
Sl.No.
1.
2.
3.
On Load Tap Changer

Description
Date
Visual Inspection of equipment
Hand Operation on all taps.
Complete wiring of the circuits
Observation
Remarks

Site:
Bay:
Equipment Sr No.:
Make:
Rating:
Voltage level:
Page 13 of 24
4.
5.
6.
7
Limit Switch
Over running device.
Remote Panel wiring
Over load
Device of Driving Motor
Local Operation (Electrical).
Remote Operation (Electrical).
Tap Position Indicator
Step by step contractor.
Out of Step Relay.
Emergency Stop
8.
9.
10.
11.
12.
13
Note: While Operating the mechanism on Electrical Control, check once again limit Switches,
step by step contractor, over running device etc. for their actual operation and ensure that they are
functioning properly.
Remarks:
_____________________________________________________
_____________________________________________________
(v)
Test on turret CT.
(a)

M ohm
HV CT
Secondary to earth
Secondary to earth
Secondary to earth
IV CT
LV CT
(b)
Continuity test
between
terminal
(c)
HV
OK/Not
OK
OK/Not
OK
IV
OK/Not
OK
OK/Not
OK
LV
OK/Not
OK
OK/Not
OK
Winding resistance
between
terminal
HV
factory
IV
site
factory
site
LV
factory
site
ohm

Site:
Bay:
Equipment Sr No.:
Make:
Rating:
Voltage level:
Page 14 of 24
ohm
ohm
ohm
(d)
Ratio test
HV CT
LV CT
LV CT
(e)
Primary current %
Y Phase
S1-S2
S1-S3
S1-S4
S1-S2
S1-S3
S1-S4
S1-S2
S1-S3
S1-S4
Polarity test
HV CT
IV CT
LV CT
(f)

Magnetizing current
0.25X
kVp
HV CT
LV CT
LV CT
S1-S2
S1-S3
S1-S4
S1-S2
S1-S3
S1-S4
S1-S2
S1-S3
S1-S4
0.50X
kVp
0.75X
kVp
1.00X
kVp
1.10 X
kVp

Site:
Bay:
Equipment Sr No.:
Make:
Rating:
Voltage level:
Page 15 of 24
Remarks:_________________________________________________
_________________________________________________________
_________________________________________________________
(vi)
Continuity test
This test is carried out to confirm the continuity of winding from line and neutral or line to line
with multimeter on all taps and phases
Continuity test by multimeter
Between Terminal
R-N
Y-N
B-N
R-Y
Y-B
B-R
HV
Continuity
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
IV
Continuity
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
LV
Continuity
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Remarks
(vii) Voltage ratio test.

Apply 3-phase, 415 V AC on HV terminals and keep open LV. Measure voltage on I.V
terminals.
Ratio : HV / IV
TAP
POSITION
1
2
3
4
5
6
7
8
VOLTAGE APPLIED
1R - N 1Y- N 1B - N
VOLTAGE MEASURED
2R - N
2Y - N
2B - N
RATIO
Y

Site:
Bay:
Equipment Sr No.:
Make:
Rating:
Voltage level:
Page 16 of 24
The ratio measurement method depends on the type of instrument used .Diverter ratio can
also be measured by modern equipment
REMARKS:____________________________________________________________________
________________________________________________________________________
Ratio : HV / LV
TAP
VOLTAGE APPLIED
POSITION
LOWEST
NORMAL
HIGHEST
1Y
-N
1R - N
1B
-N
VOLTAGE
MEASURED
3R
3R - 3Y
3Y - 3B 3B
RATIO
R
REMARKS:
_______________________________________
_______________________________________
Ratio : IV / LV
tap
voltage applied
position
normal
(viii)
voltage
measured
2Y
-N
2R - N
2B
-N
3R - 3Y
3Y - 3B
ratio
3R
3B
Magnetization current
a.
Apply 3-phase, 415 V AC on H.V terminals and keep I.V and LV open.
Tap Position
Lowest
Voltage applied
between
R-Y
Y-B
R-B
R
Y
B
(V)

Site:
Bay:
Equipment Sr No.:
Make:
Rating:
Voltage level:
Page 17 of 24
R-Y
Y-B
R-B
R-Y
Y-B
R-B
Normal
Highest
b.
R
Y
B
R
Y
B
Apply 3-phase, 415 V AC on I.V terminals and keep H.V and LV open.
Tap Position
Lowest
Voltage applied(V)
2R-2Y
2Y-2B
2R-2B
Normal
Highest

R
Y
B
Remarks:
___________________________________________________________________________
___________________________________________________________________________
(ix)
Apply 1-Ph 230v Ac

Voltage Measured In Volts
Across
(1) Between
(2) Between
1R - N
V 1Y - N
V 1B - N
1Y - N
V 1R - N
V 1B - N
V 1Y - N
V 1R - N
1B - N
2R - N
2Y- N
2B - N
V 2Y-N
V 2R-N
V 2Y-N
2B - N
2B - N
2R - N
Remark
(3)
V
V
V
V
V
V
Remarks:
___________________________________________________________________________
___________________________________________________________________________
(x)
Floating neutral voltage measurement
disconnect the transformer neutral from the ground

apply 3 phase 415 volts to the high voltage winding and make the measurement in the
iv winding with respect to neutral and neutral point to ground.
tap
primary
voltage
IV
voltage
remarks, if any

Site:
Bay:
Equipment Sr No.:
Make:
Rating:
Voltage level:
Page 18 of 24
position
normal ( )
normal ( )
normal ( )
winding
1R - N
1Y - N
1B - N
applied
winding
2R - N
2Y - N
2B - N
N - earth
measured
Apply 3 phase 415 volts to the intermediate voltage winding and make the measurement
in the tertiary winding with respect to neutral and neutral point to ground.
IV
winding
2R - N
2Y - N
2B - N
(xi)
voltage
applied
IV
winding
3R - N
3Y - N
3B - N
N - earth
voltage
measured
remarks, if any
Winding Resistance Measurement
High Voltage side

resistance at 75c
tap
position
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
winding resistance
1R1 - 1Y1 - 1B1
2R1
2Y1
2B1
factory
value
site value
R
Inter mediate voltage side

between
winding
2R1 - N
resistance
site value
res at 75 deg c in ohms

factory
site
remark

Site:
Bay:
Equipment Sr No.:
Make:
Rating:
Voltage level:
Page 19 of 24
2Y1 - N
2B1 - N
Low voltage side
between
winding
3R1 3B1
3Y1 3R1
3B1 3Y1
(xii)
resistance
site value
res at 75 deg c in ohms

factory
site
remark
For example of transformer of Vector group Yna od 11

Procedure for the test is as follows which varies with the type of vector group combination
Connect neutral point and LV Phase with earth
Join 1R1 and 3B1 terminals
Apply 415 volt, 3-phase supply to HV terminal
terminals
1R1 - 1Y1
1Y1 - 1B1
1B1 - 1R1
3Y1 - 1B1
3Y1 - 1Y1
3R1 - N
3Y1 - N
1R1- N
2R1 - N
2Y1 - N
2B1 - N
voltage measured
remarks
The following reading combination should be confirmed

2R1-N = 2Y1-N =2B1-N=Constant
As 3R1-N>3Y1-N and 3Y1-1B1>3Y1-1Y1
Remarks:
___________________________________________________________________________
___________________________________________________________________________
(xiii)
Measurement of tan delta and Capacitance
High voltage bushing

Site:
Bay:
Equipment Sr No.:
Make:
Rating:
Voltage level:
Page 20 of 24
voltage
capacitance
(measured value)
R phase
Y phase
B phase
site
factory
site
factory
site
factory
remark
Tan delta
(measured value)
R phase
Y phase
B phase
site
factory
site
factory
site
factory
remark
2 kV
10 kV
voltage
2 kV
10 kV
Intermediate voltage bushing
voltage
capacitance
(measured value)
R phase
Y phase
B phase
site
factory
site
factory
site
factory
remark
2 kV
10 kV
tan delta
voltage
(measured value)
Y phase
B phase
site
factory
site
factory
remark
capacitance
(measured value)
R phase
Y phase
B phase
site
factory
site
factory
site
factory
remark
R phase
site
factory
2 kV
10 kV
Low Voltage bushing
voltage
2 kV
10 KV
Tan delta
voltage
site
R phase
factory
(measured value)
Yphase
B phase
site
factory
site
factory
remark
2 kV
10 kV
Winding
voltage
2 kV
between
HV + IV / LV +
capacitance
site
factory
site
tan delta
factory
remark

Site:
Bay:
Equipment Sr No.:
Make:
Rating:
Voltage level:
Page 21 of 24
TANK + E
10 kV
HV + IV + LV /
TANK + E
2 kV
10 kV
LV / HV + IV +
TANK + E
2 kV
10 kV
(xiv)
Short circuit test

apply 3 phase 415 volts to the high voltage
winding
tap
position
1
normal (
highest (
1
normal (
highest (
1
normal (
highest (
1
normal (
highest (
1
voltage
applied
IV winding
short
combination
)
)
3 phase short
)
)
3 phase short
and grounded
)
)
2 phase short
)
)
2 phase short
and grounded
normal ( )
highest ( )
primary current
measured
IR
IY
IB
1 phase
grounded
Remarks:
___________________________________________________________________________
___________________________________________________________________________
(xv)
Frequency Response Analysis

Remarks:
___________________________________________________________________________
___________________________________________________________________________
(xvi)
WTI OTI Setting
Setting to be carried as per OEM manual

Site:
Bay:
Equipment Sr No.:
Make:
Rating:
Voltage level:
Page 22 of 24
Settings
HV
Set
Proved
IV
Set
for
for
Proved
LV
Set
Proved
Oil
Set
for
for
Remark
Proved
Fan Start
Fan Stop
Pump Start
Pump Stop
Alarm
Trip
(xvii) Protection and alarm check
Sl No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Device
Set for
Alarm
Trip
Proved
Alarm
Remarks
Trip
Main
buchholz
Surge
Relay
Excessive
Winding
Temp
Excessive
Oil Temp
Oil level
PRV
SPR
Differential
relay
HV REF
Relay
LV REF
Relay
Over flux
relay
Earth Fault
Relay
Over
current
Relay
Inter trip
(xviii)Final IR check
After successful pre commissioning test transformer should be connects with the system on the
final megger value should be checked.
Main Winding

Site:
Bay:
Equipment Sr No.:
Make:
Rating:
Voltage level:
Page 23 of 24
between
terminal
(xix)
IR value
15
sec
60
sec
60
0
sec
Ambient
Temp
C
Dielectric PI
Remarks
absorption
60/15
600/6
Following check list to be filled up and necessary action taken

(a) Pre commissioning check carried out
(b) Commissioning check carried out
(c) standing time as per manual before final air release operation
(d) Bushing test cap tight ness ensured
(e) Bushing oil level ensured
(f) Tank cover / bell tank earthing strips connected
(g) Neutral grounding ensured Yes/No
(h) All Pre commissioning results satisfactory
7.
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Energizing
Test witnessed by
Customers Representative
OEM Representative
Signature
Signature ..
Name
Name .
Designation..
Designation...
Date. Place
Date Place
Transformer charged on.. at . Hrs successfully.
The initial magnetizing current at the time of switching will be very high. This depends on the
particular moment in the cycle. The Transformer should always be soaked for few hours under
constant care i.e keep it energized on open circuit before putting it on load.
Check immediately after commissioning and record the following
a)
b)
c)
d)
e)
f)
g)
h)
Transformer humming/ noise/ vibration : ________________________

Any abnormal noise from Bushing/OLTC : _______________________
Record any other abnormality observed and obtain clarification from OEM on such :
_________________________________
If noise from any loose items due to vibration, tighten same and observed
Observe for 12 hours for any abnormality :
No oil leaks from any point: _________________
Any other observation. Obtain confirmation from OEM in such
points:_____________________
No load current at relay terminal
R phase
m Amp
CT Ratio
Y phase
m Amp
B phase
m Amp

Site:
Bay:
Equipment Sr No.:
Make:
Rating:
Voltage level:
Page 24 of 24
i)
Temperature at the time of charging
j)
O. T.I
C
W.T.I
C
Ambient
C
Maximum temperature after 24 hours
DTL
Representative
OEM Representative
DELHI TRANSCO LTD

Standard Field Quality Plan
Name of Equipment: Transformer
Doc No: SFQP/TRF/01
Sl Characteristic /Item
Reference
No
document
/acceptance norms
1
RECEIPT
Receiving Inspection
Visual inspection
Proper storage of transformer and Tr. Oil drums
Inspection of main transformer tank
Rating Plate details
BOM/Packing
list/manufactures
instruction manual
STORAGE
Main Transformer tank Nitrogen pressure
OLTC Nitrogen pressure, if applicable
Marshalling box
Storage instruction compliance
Manufactures
instruction manual
PRE- INSTALLATION
Availability of Instruction Manual etc
Availability of all material
Availability of rating plate
Transformer foundation
Availability of tools, tackles and Man Power
Award of Contract for ETC
Proper dragging
Approved drawing/
Manufactures
instruction
manual/Test report
INSTALLATION
Proper placement of transformer
Internal inspection of tank
IR Value of the core
I.BUSHING ASSEMBLY
Tan delta and capacitance test
Test on turret CT
Cleanliness and damage of turret CT
Healthiness and correctness of turret CT and their
terminal plates
Sealing gasket
Nitrogen gas pressure
Cleanliness ,free from physical damage and IR
value
Bushing lifting
Bushing sealing
Oil level
Tightness of Line lead connection
Grounding of turret & Bushing flanges
II. TAP CHANGER ASSEMBLY
Approved drawing/
Manufactures
instruction
manual/Test report
Page 1 of 4
Remark
DELHI TRANSCO LTD

Doc No: SFQP/TRF/01
Reference
No
document
/acceptance norms
Visual inspection
OLTC driving mechanism and drive shaft
Handle for manual operation
Surge Relay mounting direction
Grounding of tape changer
Check of manual operation
III. MARSHALLING BOX

Physical inspection
Marshalling box fixing and clearance
Door gaskets
Cable gland fixing and gland plate
Wiring and terminals
Grounding of Marshalling Box
Heater connection
Provision of door light
Wiring through cable tray
IV. CONSERVATOR ASSEMBLY
Locking devices for mechanism
Gasket
Vacuum release valve
Healthiness of air cell
V. COOLING SYSTEM & PIPE WORK
Visual inspection
Direction of rotation of fan and motors
VI. OIL PREPARATION & FILLING
Oil filtration and oil properties
Vacuum as per O&M instruction
Filling of oil in the main tank
Oil filling in OLTC, gear box, cooling system etc
Air release
Oil level in breather
Equalizing pipe on OLTC switch top cover
Oil leakage
Oil circulation
Oil testing after circulation
Silica gel
Checking of isolation valve
5.
PRE-COMMISSIONING CHECK
Approved drawing/
Page 2 of 4
Remark
DELHI TRANSCO LTD

Doc No: SFQP/TRF/01
Reference
No
document
/acceptance norms
(i)
Breather Silica gel (Blue colour when

dry)
(ii)
Oil in the Breather housing cup.
(iii) All valves for their correct opening and
closing sequence.
(iv) Oil level in conservator tank.
(v)
Oil level in bushings.
(vi) Release air, wherever necessary.
(vii) Cooling accessories (Pump motors, Fan
motors etc.) for direction and O/L setting.
(viii) Direction of Buchholz relay
(ix)
Buchholz relay, oil level indicator,
pressure release valve, thermometer,
temp. indicators etc. for operation.
(x)
Earthing of main tank, M. Box, T/C
driving gear, diverter, Pump Fan motor,
cable glands etc
(xi)
(xii)
(xiii)
(xiv)
(xv)
(xvi)
(xvii)
Neutral earthing.
Earth Resistance of Electrodes.
Earthing of bushing test tap.
Check oil leakage for 24 hrs.
Check Auxiliary circuit voltage (415 V).
Calibration of OTI/WTI with hot oil.
Check Working of WTI/RTD repeaters at
control room.
(xviii) All valve open to transformer blanked.
(xix)
(xx)
6.
Clearances as per OGA

Checking of terminal
COMMISSIONING TEST
(i)
Insulation Resistance Measurement
(ii)
Oil Testing
(iii)
DGA
(iv)
On Load Tap Changer
(v)
Test on turret CT.
(vi)
Continuity test
(vii) Voltage ratio test.
(viii) Magnetization current
(ix)
(x)
Floating neutral voltage measurement
(xi)
Winding Resistance Measurement
(xii) Verification of vector group and polarity
(xiii) Measurement of tan delta and Capacitance
(xiv) Short circuit test
Manufactures
instruction
manual/Test report
Approved drawing/
Manufactures
instruction
manual/Test report
Page 3 of 4
Remark
DELHI TRANSCO LTD

Doc No: SFQP/TRF/01
Reference
No
document
/acceptance norms
(xv)
(xvi)
(xvii)
(xviii)
(xix)
Page 4 of 4
Remark
Frequency Response Analysis

WTI OTI Setting
Protection and alarm check
Final IR check
Note:
1) DTL specification shall mean DTL Technical Specification, approved drawings, LOA
provision for specific contracts.
2) Tests/Checks indicated at column No.2 of SFQP are only generally required to be conducted.
However, any other test /check required may be carried out as per site requirement.
3) All the testing and measuring equipment for testing should be calibrated.
4) Test check which is not applicable for particular equipment/mode/contract shall be considered
to have omitted.
5) Latest revision/amendment of specification/standard/drawings shall be followed.
6) For all checks suitable record shall be maintained.) Test /check indicated in column no 2 of
SFQP should be carried as per 100% sampling planning basis

Transformer PC Test

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Part I

Basic working principle of Transformer

Section II TRANSPORTATION AND STORAGE

Section III ERECTION

Pre commissioning checks

Check immediately after commissioning

Basic working principle of Transformer

Major Parts and accessories

Raw Material used

CRGO Steel, Copper Conductor, Kraft Insulating Paper, Sheet, Un-impregnated

IS 2026 ( Part 2):1977

Power transformers : Part 2 Temperature- rise

IS 2026 (Part 3): 1981

Power transformer : Part 3 Insulation level and

IS 2026 (Part 4): 1977

Power transformers: Part 4 Terminal Marking,

IS 2026(Part 5): 1995

Power transformers: Part 5 Terminal/ Reactor bushings

IS 10028 (Part 1):1985

Code of practice for selection, installation and

IS 10028 (Part 2):1981

Code of practice for selection, installation and

IS 10028 (Part 3):1981

Code of practice for selection, installation and

Code of practice for earthing

New insulating oil (Fourth revision)

Code of practice for maintenance and supervision of

Compliance with Indian Electricity Rules and Other Regulations.

Soak pit and drain pit

Transformer foundation shall be surrounded by a suitable soak pit enclosed by a 150

Barrier between transformer

(a) under 10 MVA

(b) 10 to 100 MVA

Hydrant protection with water spray

More than one

1. Provide a 7.5 m clearance between

Hydrant protection with water spray

More than one

1. Fixed automatic water spray

(c) Above 100 MVA

(d) Above 200 MVA

Hydrant protection with water spray

More than one

1. Fixed automatic water spray with

Inspection and testing at manufacturer works

Depending upon the weight/height restrictions and/or other considerations, Power

External Inspection (Before unloading)

Pull 500 mm mercury vacuum after blanking off all openings.

Mounting of wheels under transformer is to be done as per roller arrangement drawing

5.1.1 Main Tank:

Insulation material as paper, pressboard, bakelite, wood, cotton tape etc.

5.2.2 Storing outdoor

Oil-conservator with blanking plates for all openings.

Structures, A frames, Pipe supports, Supports for oil-conservators, radiators,

Erection of transformer is divided in following section

As transformer tank is filled with nitrogen to protect from possibility of absorbtion of

Crane of suitable capacity

Before starting assembling of accessories on tank, the transformer must be internally