Transformer Maintenance: Content

TRANSFORMER MAINTENANCE
CONTENT
Chapter Page
I Introduction 1
II Transformer
Constructional 5
Details
III Transformer Oil 18
IV Transformer Cooling 31
V Maintenance And
Maintenance 44
Auxiliary Schedule
VI Maintenance And
Testing Of 58
Transformer
CHAPTER I
INTRODUCTION
Transformer is a static piece of apparatus by means of which electric power is
transferred from one circuit to another without change in frequency. It can raise or lower the
voltages with a corresponding decrease or increase in current. It is accomplished by
Faraday’s law of electromagnetic induction. In simplest form, a transformer consists of two
conducting coils having mutual inductance. The primary winding is one, which receives
electric power from the supply, and the secondary winding is the one, which delivers to the
load. The coils are wound on a laminated core of magnetic material. It operates the mutual
inductance between the two circuits linked by a common magnetic flux through a path of low
reluctance as shown in figure (1.1).
The EMF equation for the windings of transformer is given as,
E = 4.44FNBm A
N - Number of turns in primary/secondary

F - Frequency in hertz
E - E.m.f. induced in primary/ secondary
Bm - Maximum flux density in weber/m2
A - Area of cross-section of the core in m2
-1-
Transformation Ratio,
Es Ns Ip
--- = --- = --- = K
Ep Np Is
1. Ns > Np, K > 1 is known as step up transformer.

2. Ns < Np, K < 1 is known as step down transformer.
In an ideal transformer,
Input VA = Output VA
VpIp = VsIs
Types of Transformer,
The transformers are also be classified as given below based on their function and
application: -
1. Power transformer: It is used for step up or step down the voltage.
2. Autotransformer: It is used for linear voltage variations.
3. Instrument transformer: It is used for measuring high voltages and high currents and also
it is used for protection purposes.
Typical transformers are installed in 210MW thermal power station is described below: -
Main generator transformer (GT)

The power transformer is used for stepping up the generator voltage for transmission into the
grid. Voltage level (15.75/220KV or 15.75 / 400KV).
Unit auxiliary transformer (UAT) / Unit service transformer (UST)

The unit auxiliary transformer caters to individual unit auxiliaries Unit auxiliary
transformer is a step down transformer with transformation ratio of Generator terminal
voltage to unit auxiliary voltage (15.75/6.6KV).
Station service transformer (SST) / Station auxiliary transformer (SAT)
The station service transformer caters for the supply to the common auxiliaries of the
station. In addition, station service transformer supplies to the unit auxiliaries at the time of
-2-
start up and serves as reserve supply during failure of UAT. This is a step down transformer
with transformation ratio of grid voltage to the station auxiliary supply level. (220/6.6KV)
Excitation transformer
The excitation power is taken from generator output and fed to the excitation
transformer which steps down to the required voltage for SCR bridge and then is fed through
the field breaker to generator field. It is a dry type cast coil transformer and is most suitable
for static excitation system. This transformer must supply the rated excitation voltage
/current continuously and must be capable of supplying the ceiling current and the ceiling
excitation voltage within a short period of ten seconds.
Interconnecting transformer/Auto transformer
This type of transformers has been provided with three windings. The third winding
is called as tertiary winding. Tertiary winding is an additional winding provided in the power
transformers in addition to its normal winding. It is an auxiliary Delta connected winding.
Tertiary winding has to be provided for 3 phase 3 limb core type star connected transformer
having neutral solidly earthed, for above 100 MVA capacity.
Functions of tertiary winding,

Tertiary winding is used
 To reduce the third harmonic contents of the output voltage thereby stabilising the
potential of the neutral point.
 To suppress third harmonic current which causes communication interference?
 To permit the transformation of unbalanced 3-phase load.
 To reduce system zero sequence impedance for effective grounding where solid
grounding is not provided.
 To supply the additional auxiliary loads.
The power transformer could be either of the single-phase type or three-phase type.
The single-phase units are smaller, easier to handle and transport but one single unit
-3-
needs to be kept as spare. Three-phase units are larger in size. On the other hand three
phase units are cheaper and occupy less space for given output.
The Modern power transformer is of very high efficiency, approaching a value of 99%
being static equipment. Transformers could be classified as core type and shell type as per
core construction. Both the types could be used for Power station service with appropriate
design. But however core type transformer is preferred due to economic consideration.
Transformers could be further classified as outdoor type and indoor type. In indoor type
transformer, transformer oil should not be used due to the possibility of accidental fire
hazard. Hence, indoor type transformer may have to be necessarily dry type (air-cooled) or
synthetic liquid cooled type transformer.
The class of insulation used in power transformer is Class “A”insulation. The maximum
permissible total temperature of Class A insulation is 105 oC. The total temperature is the
addition of ambient plus rise in temperature. Normally ambient temperature will be
considered as 40oC and hence maximum rise in temperature will be about 65oC (Hot spot
temp.) The losses (iron & copper loss) in the core and windings are transferred to the oil in
the form of heat in the oil cooled transformer and the oil is in turn cooled by the ambient air
either by natural or forced cooling.
-4-
CHAPTER II
BRIEF DETAILS OF CONSTRUCTION
Main Parts of Transformer
 Core
 Windings & Tapping
 Insulation
 Tanks
 Radiators
 Conservator and Breather
 Explosion vent
 Bushing
 Cable sealing box
 Tap changers
 Buchholz relay(above 500 KVA transformer)
The typical Power transformer 400 KVA and 250 MVA, 15.75/230KV are shown in fig.
(2.1&2.2)
-5-
-6-
Core
Core forms the magnetic circuit of a transformer. In order to keep the eddy and
hysteresis losses to a minimum; core is made up of thin laminations of cold rolled grain
oriented silicon steel (CRGO) which has high permeability, low loss and higher saturation
flux density. Laminations are insulated from each other with the coating of inorganic
insulation film over the steel. The thickness of lamination varies from 0.28mm to 0.35mm.
The laminations are cut according to the size and they are annealed before using for reducing
the stress. Magnetisation of the lamination produces a phenomenon known as
magnetostriction i.e. expansion and contraction of the core material. This change in
dimension is not directly proportional to the flux, but generally follows the alternating
magnetisation and demagnetisation of the core. Due to magetostriction vibration is produced
that causes audible noise. Magnetostriction is the inherent property of the core material and
varies with different grades of iron. The CRGO Steels are made in various grades like M4,
M5, M6 and M7, while low loss HI-B steels are available in grades like M-0H, M-1H, M-2H,
M-3H and M-4H. The cold rolled grain oriented steel has a special feature that losses in the
direction of the grain orientation are much lower than in the direction perpendicular to the
grain. Therefore the interleaved core construction which was earlier used with hot rolled steel
has become obsolete and now the practice is to use stepped core construction or mitred core
construction which has joints cut at 45o /55o angle.
-7-
Fig. (2.3) shows interleaved and mitred core construction. It can be seen that, with
mitred joints the flux flows along the grains in almost the entire core resulting in lower loss.
However to impart sufficient mechanical rigidity to the mitred core, the mitred joints of each
layer is interleaved to some extent by the next layer thus avoiding formation of butt joints
throughout the core.
Windings
Generally the current rating, short circuit strength, temperature rise, overload
condition, impedance voltage strength and transportation decide the type and arrangement of
the winding to be used. There are 3 types of transformer windings:
 Helical type winding
 Spiral type winding
 Continuous disc type winding
Helical Type Winding
It is used for low voltage and high current coils. This type of winding is normally
used for LV side of the transformer with thick cross sectional area. (Refer fig.2.4)
-8-
Spiral type winding
It is used for medium current applications i.e. smaller capacity transformer. Normally
the distribution transformers will have spiral type winding.
Continuous disc winding
It is preferable for high voltage and low current applications. This type of winding is
normally used for HV side of power transformer. The number of discs in each coil of the
transformer depends upon the system voltage.
In all the transformers the LV winding is placed nearer to the core and HV
winding is placed over the LV winding. The requirement of insulation between LV winding
and earth is very less when compared to HV winding to earth. In view of this the low voltage
winding is placed nearer to the core irrespective of the number of windings. (Refer fig.2.5)
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Axial cooling ducts on the inside and outside surface of the coils are created by dove
tail strips and spacers, which are locked in dove tail blocks. Radial cooling ducts are created
by dove tail blocks. When more than one conductors are used in parallel it becomes
necessary to interchange this radial position to avoid flow of circulating currents due to
varying leakage flux in radial build up of the coil. In disc type of coils the transposition is
done at each section crossover and whereas in helical coils type, the coils are transposed at
equally spaced position throughout the axial length of coil.
Tapping
The tap changing is used to adjust the terminal voltage with in the statutory limits. It
is also used to control the active and reactive power flow in the system. There are two types
of tap changers. i.e.” off load, “and “on load “tap changers for varying output voltage.
Tapping is normally provided in the high voltage side.
Depending upon the tapping range, tapping is either placed at the centre of high
voltage coil so that it provides electro magnetic balancing on the windings or by a separate
tapping coil. In case of on load tap changing having higher tapping range, a separate tapping
coil is invariably provided to limit the short circuit forces. Placement of tapping coil with
respect to main coil (i.e. either inside the main coil or outside) changes the pattern of
impedance at extreme taps. Therefore, it is necessary to specify the impedance at extreme
taps for any transformer intended for parallel operation.
INSULATION
The main elements of insulation in a transformer are: -
Major insulation
Major insulation consists of the insulation between the high voltage and low voltage
windings of the same phase and from the windings to the ground. The insulation between
different windings and inner winding to core consist of a number of pressboard cylinders
separated by oil ducts. Pressboard barriers are provided between windings of different phases
and between the windings and tank. Adequate number of angle rings and angle washers
depending on voltage class are provided for insulation of the end windings. The different
types of materials used as major insulation are: thermally upgraded Kraft paper cylinders,
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synthetic resin bonded pressboard cylinder, high density organic sticks bonded with synthetic
resin and pressboard sheets for phase insulation and collars.
Minor insulation
This is the insulation provided between adjacent turns in a winding and between
different sections of the same windings. The different materials used for minor insulation are
pressboard spacers, cellulose tape and synthetic enamel wire.
Phase-to-phase insulation
This is the insulation provided between the windings of different phases. (Examples:
Heavy Kraft paper or pressboard). The paper used is electric grade Kraft paper having high
chemical purity, high mechanical and electrical strength and free from conducting particles.
In high voltage windings the end turns are reinforced to take care of non-linear distribution of
impulse voltage that may results in higher impulse and to improve the voltage distribution on
line end turns of the HV windings. Further reinforced insulation is used for end windings to
provide protection against voltage surges (Refer fig. 2.6). Nowadays, transformer oil itself is
used for phase to phase insulation instead of Kraft paper.
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TRANSFORMER TANK
Transformer tanks are classified as: -
 Plain tank
 Shaped tank
 Bell-shaped tank
 Corrugated tank
 Stub end type tank
Plain tank
Plain tanks are rectangular box type in shape. These tanks may some times also have
rounded corners. These are commonly used for small and medium rating transformers. This
type of construction may however be uneconomical for larger sized tanks.
Shaped tank
In order to make the transformer more economical; it is possible to shape the profile
of the tank body, so that the inside volume of the tank is less. It is suitably truncated in the
lower portion for ease of loading inside the wagon and also ensures the required minimum
electrical clearance at all points. Usually, shaped tanks have the tank walls shaped towards
HV-leads side, where electrical clearances required are comparatively much larger, and a flat
wall towards the LV side. Structurally the curved portions in the tank wall act as stiffener
against the short circuit forces. The shaped tank construction is decided by the electrical
layout considerations of transformer windings and terminal gear/tap changer mounting
arrangements.
Bell-shaped tank
Sometimes it is desirable to construct the tank in two parts, so that if the top portion is
removed, the height of the lower part is such that the core and the windings of the
transformer are easily accessible for inspection and maintenance. This arrangement is
preferable at site, where it is not possible to lift the core and windings together from the tank
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for inspection and maintenance work. Such tanks are known as bell type tanks. The profile of
the tank walls can be either rectangular or bell shaped.
Corrugated tank
The vertical ribs to form corrugation on the plates are made by suitably folding the
plates. These corrugations play the role of stiffeners and this process reduces welding by
replacing the welding of vertical ribs on the tank walls. Normally this type of tank is made
with corrugated plates. The corrugation acts as horizontal stiffeners at the bottom. This is to
provide necessary structural strength against bending stresses. Another advantage of
corrugated tank wall is that, it provides additional cooling area.
Stub-end wagon type tank

It may not be possible to transport, very large rated power transformer, on any
conventional wagon. The height of the girder on which the consignment rest adds to the
overall transport height. As a remedy, such large-size transformers are not supported on such
girders. The tanks are suitably designed such that they can be supported from either end by
stub-end wagons and the transformer hangs in the vertical position, leaving the minimum
necessary clearance between the bottom of the tank and railway track. These tanks are of
special construction and designed to withstand the dynamic loads during transit in addition to
static loads.
Tap changers are mounted either inside the tank or in a separate pocket depending
upon the type of tap used. The tap changer is normally mounted inside the tank. Tank bodies
are of rolled steel plate. The inner surface is shoot-blasted and painted with oil resistive paint.
The outer surface is treated with anti-corrosive material together with a weather resisting
paint.
Radiators
The radiator consists of a bank of flat tubes, which gives away the heat of the oil to
atmosphere. Oil is circulated inside the radiator tubes and air is circulated around the radiator
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tubes. Both oil and airflow will be either natural or forced circulation. The radiator could be
either mounted on the transformer tank walls or separately.
Conservator or Expansion Chamber and Breather

To provide for the expansion or contraction of oil in the transformer tank, a
conservator is provided over the tank. By having a conservator, the surface area of oil
exposed to atmospheric air is also reduced. The conservator is filled with oil to a specified
level, indication being provided by gauge glass and or other level indicating devices. The air
space in the conservator is in communication with atmosphere through a breather which is
filled with a moisture absorbent viz. silicagel, to prevent ingress of moisture in the oil. The
pipe connecting the conservator and the transformer tank should protrude at least 2.5 cm.
inside the conservator to prevent condensed moisture entering from conservator to the main
tank. The conservator capacity is about 8 to 10% of the main tank.
The breather is used to dry the air that enters in to the conservator during expansion
and contraction of the oil. Air entering the breather is first drawn through an oil seal and
passes upward through silicagel crystals to the conservator tank. The oil seal prevents all the
dust particles from the atmospheric air and the silicagel absorbs moisture when the
transformer is breathing. The silicagel used is an indicating type silicagel. The dry silicagel
will have Sky-blue colour and when saturated with moisture it changes in to pink colour.
There are also power transformers, which do not have a breather. Instead the top
portion of the conservator is filled with an inert gas (nitrogen) under pressure and sealed. In
the later design of large capacity transformers the conservator tank is built with partition
diaphragm to totally avoid the contact between the atmospheric air and oil.
Explosion Vent
This pressure-relieving device is mounted on the tank cover or on the side of the tank
to protect against high-pressure build up inside the transformer tank. This consists of a
vertical pipe work closed by a diaphragm made up of thin Bakelite sheet (mica or glass may
also be used) at the top. This diaphragm bursts or slides out in the event of abnormal pressure
build up inside tank. A diverter plate is fitted at the bottom of the explosion vent. In the event
of failure of the explosion vent, the diverter plate prevents the liberated gases entering in to
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the explosion vent pipe. This plate diverts the gases towards buchholz relay. A bypass is
provided to allow the oil to enter the vent and equalise the pressure on each side of the
diverter plate.
Bushings
The leads of H.V. and L.V. coils are brought out through bushings, which are made of
porcelain, the conductor being in the centre. The space between conductor and insulator is
filled with an insulating medium like oil, air or gas. This type of bushings is generally limited
to the system voltage of 36KV, beyond which they become very bulky. (Refer fig.2.7). For
higher voltages condenser bushings are used.
Condenser bushings
- 15 -
In the porcelain type of bushing, the concentration of electric stress does not permit
efficient use of insulating material. This difficulty is overcome by using the principle of
condenser. The insulation wall thickness is divided into a number of capacitors by concentric
conducting cylinders. The concentric conducting cylinders are made up of aluminium foil.
This type of arrangement reduces the size of the bushings. The core insulation of a condenser
bushing generally consists of the following types: -
 Synthetic resin bonded paper
 Oil impregnated paper
 Resin impregnated paper
Synthetic resin bonded paper (SRBP) bushing

In this type, the central metallic tube is tightly wound with resin coated paper tape
with interleaving of layers of condenser foils at specified diameters. The resin used on the
paper is of thermosetting type and is therefore wound under temperature and pressure. The
core surface is treated with special anti-tracking epoxy varnish to provide glossy finish and to
prevent moisture ingress. The annular space between condenser core and porcelain insulator
is filled with transformer oil.
Oil impregnated paper (OIP) and resin impregnated paper (RIP) bushing
In the OIP type, the condenser core is built-up using Kraft paper on a central metallic tube,
whereas in the RIP type, crepe Kraft paper impregnated with epoxy resin is used for making the core.
The condenser core with or without porcelain is dried under vacuum and deaerated. Further the
condenser core is degassed and impregnated with oil. The bushing are hermetically sealed. The partial
discharge level of these bushings is much lower compared to SRBP bushing. (Refer 2.8)
A chamber is provided at the top of the bushing to indicate the level of oil in the
bushing.
Cable Sealing Box
It is used for termination of leads of low voltage and high voltage. A cable sealing
box is designed for the purpose of receiving and protecting the ends of the cables and it
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contains a suitable insulating medium. The insulating medium in a cable sealing box can be
air or bituminous compound. This type of cable sealing box is generally used for lower
capacity indoor type transformer.
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CHAPTER III
TRANSFORMER OIL
Introduction
The insulating oil is mainly mineral oil obtained from the fractional distillation of
crude petroleum. This fluid serves three primary purposes: -
 Provides dielectric strength for the transformer insulation system
 Provides efficient cooling
 Protects the transformer core and coil assembly from chemical attack
Properties of Oil
They are divided into three types: -
 Physical property
 Electrical property
 Chemical property
PHYSICAL PROPERTY
Density
This has special significance when transformer is operated in a very low
temperature zone. The maximum value of density of the oil fixed at 27 º C ensures that water
in the form of ice present in oil remains at the bottom and does not tend to float up to a
temperature of about -10 º C.
Interfacial tension (IFT)

This is a measure of the molecular attractive force between oil and water molecules at
their interface. This provides a means of detecting soluble polar contaminants and products
of deterioration, which decrease the molecular attractive force between oil and water. The
IFT gives an indication of degree of sludging of oil. Minimum IFT value is 0.04 NM at 220C.
- 18 -
Moisture content
The amount of free and dissolved water present in the oil is its moisture content and is
expressed in ppm (parts per million by weight, i.e.mg/kg). Presence of moisture is harmful
since it adversely affects the electrical characteristics of oil and accelerates deterioration of
insulating paper.
Table shows physical constants of oil
Sl.No. Property Value

1. Permittivity 2.2(-0.001)
2. Specific heat 2.06kJ/kg0c(0.0038)
3. Thermal conductivity 0.13 W/m0c
4. Coefficient of expansion 0.00078 / 0c
5. Mean density correction factor over 0.00065 / 0c
the normal range operating
temperature
Flash point
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It is the temperature at which oil gives so much vapour that this vapour, when mixed
with air, forms an ignitable mixture and gives a momentary flash on application of flame
under prescribed conditions. A minimum flash point is specified in order to prevent the risk
of fire that might result by accidental ignition. Minimum specified flash point is 140 0c as per
IS: 335.
Viscosity
It is a measure of oil resistance to continuous flow without the effect of external
forces. The oil must be mobile, as heat transfer in transformers occurs mainly by convection
current. Since viscosity increases with decrease in temperature, it is necessary that viscosity
be as low as possible at low temperatures. Maximum kinematic viscosity at 27 oC is 27 Cst
(Centistokes) as per IS 335.
Pour point
The temperature at which oil will just flow under the prescribed conditions is known
as the pour point. If the oil becomes too viscous or solidifies, it will hinder the formation of
convection currents and thus cooling of the equipment will be severely affected. Pour point is
the lowest temperature at which it ceases to be fluid. (- 9.0oC) as per IS 335.
ELECTRICAL PROPERTY
Electric Strength (breakdown voltage)
BDV is the voltage at which breakdown occurs between two electrodes in oil when
the oil is subjected to an electric stress under prescribed conditions. Electric strength is the
basic parameter for insulation system design of a transformer. It serves to indicate the
presence of contaminating agents like moisture, fibrous materials, carbon particles,
precipitable sludge and sediment. It is usually expressed in kV across a specified spark gap
under certain conditions. The value of electric strength has meaning only in relation to the
test method to which it refers. The test is widely used to assess the suitability of insulating
oils for service. It is a test, not of the quality of oil, but of its freedom from contaminants
especially moisture and fibrous substance. Test: IS 6792-1972
- 20 -
The BDV test kit consists of a cell made of glass or plastic, which is transparent and
non-absorbent. It will have an effective volume between 300 to 500 ml. Copper, brass,
bronze or stainless steel polished electrodes of spherical shape (12.5 to 13.0mm diameter) are
mounted on a horizontal axis. One of the electrodes is adjustable to maintain the gap of 2.5
mm between the electrodes. The gap between them shall be set to an accuracy of 0.1mm by
means of thickness gauges. The axis of the electrodes is immersed to a depth of
approximately 40mm. One of the electrodes is earthed. The minimum BDV values are as
under:
 New unfiltered oil 30 kV (rms.) (If this value is not attained, the oil shall be filtered)
 After filtration 50 kV (rms)
Dielectric dissipation factor (tan)

The dielectric dissipation factor of oil is the ratio of the power dissipated in the oil in
watts, to the product of the effective voltage and current in volt-amperes of sinusoidal supply.
This is numerically equivalent to the cosine of the phase angle or the sine of the loss angle.
Dielectric dissipation factor is a numeric or dimensionless quantity. It may be expressed as a
numeric value or as percentage, for example 0.010 or 1.0 percent. Power factor test readily
respond to the presence of contaminating material which might have been picked up by the
insulating oil or derived from the oil, due to improper manufacture or during use of the
equipment. It also indicates the presence of soluble varnishes, resins and moisture. The test is
influenced considerably by the temperature, testing voltage and frequency. The Indian
standard prescribes an average stress of 200V/mm for power factor measurements at power
frequency. The standard also specifies a maximum value for tan as 0.005 when measured at
90oC. The power factor is measured by using a schering bridge with suitably designed cell.
In a perfect insulating materials I leads V by 90o. But normally I does not lead exactly
by 90oC. This angle varies according to the quality of insulation, moisture content,
contamination, heterogeneity, ageing of the material etc. The ratio Ia/Ic gives a measure of
the dielectric loss in insulation and it is known as the dielectric loss angle or dielectric
dissipation factor.
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If angle  is defined as 90-. Since  = 90-, sin = sin (90-) i.e., Sin = Cos,
The dielectric loss VIa = VI cos
= VI Sin
I = Ic / Cos
VIa = V (Ic / Cos)* Sin
= VIc (Sin / Cos)

= V.Ic Tan
Since the tangent of the dielectric loss angle does not depend upon the capacitance of
the specimen, the same value of tan will be obtained for various sizes of components made
from the same material. The power factor angle (or dielectric loss angle) remains practically
constant up to a certain value of voltage. At some point A, called the ionisation point the
value of Tan sharply rises with increasing voltage. This is due to irreversible ionisation
occurring in the insulation at the critical voltage Vc.
The inflection point of the curve corresponding to the ionisation voltage Vc is termed
as critical point and for a satisfactory bushing or winding it should not occur below a value
which has a reasonable margin over the working voltage. The shape of the tan curve with
increasing voltages gives an indication of the quality of insulation value of the material. The
value of tan increases with temperature.
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CHEMICAL PROPERTY
Neutralisation value (Total acidity)
Any good unused oil should be free from mineral acids and virtually free from
organic acids, to safeguard the equipment from damage through corrosive attack.
Neutralisation value is the measure of the total acidity of the oil. It is expressed as the mg. of
potassium hydroxide (KOH) per gm of oil. For good oil, total acidity value should not exceed
0.03 mg of KOH/gm of oil.
Inorganic acidity
It is the measure of inorganic acids present and is expressed as mg. of potassium
hydroxide required neutralising these acids in one gram of the oil.
Oxidation stability
This is the measure of neutralisation value and sludge after simulating the actual
service conditions of transformer oil. The oxidation stability test is essential for new oil also
and oxidation stability indicates the presence of natural inhibitors, which impart anti-
oxidation characteristics to oil.
Sediment and precipitable sludge

These are oil deterioration products or contaminants, which are insoluble after
dilution of the oil with n-heptane under prescribed conditions. However, precipitable sludge
is soluble in the solvant mixture of equal parts of toluene, acetone and alcohol but sediment
is insoluble in this solvent mixture. These contaminants are determined for oil in service. Oil
is considered unsatisfactory for use if sediment or precipitable sludge is detected.
Corrosive sulphur
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Crude petroleum usually contains sulphur compounds, most of which are removed
during the refining process. This test is designed to detect any traces of free corrosive sulphur
that may be present in the oil. Presence of corrosive sulphur in the oil will result in pitting
and black deposit on the surface of bare copper conductor used in transformer, which will
adversely affect the dissipation of heat and consequently the performance of the equipment.
IS 335 specifies the characteristics of Transformer oil and the extract is given below
for reference.
EXTRACTED FROM ISI: 335 : 1983

SCHEDULE OF CHARACTERISTICS OF TRANSFORMER OIL
Sl.No Characteristics Requirements Method of test
.
1 Appearance Clear, transparent and free Representative sample
from suspended matter or of the oil shall be
sediments examined in a 100mm
thick layer at 270c
0 3
2 Density at 27 C, Max. 0.89 g/cm IS:1448[P:16]-1977
(hydrometer method )
3 Kinematic viscosity at 270C 27 centistrokes (27 cst) IS:1448[p:25]-1976
max determine of
kinematic and
dynamic viscosity
4 Interfacial tension at 270c, Min 0.04 NM IS:6104:1971(interfaci
al tension of oil
against water by ring
method
0
5 Flash point min 140 C IS:1448(p:21)1970
6 Pour point max -90c IS:1448(p:10) 1970
7 Neutralisation value
a) total acidity max 0.03 mg KOH/g IS:1448 [p:2]-1967
b) inorganic acidity/alkalinity nil -do-
8 Corrosive sulphur Non-corrosive IS:6792-1972
9 Electric strength
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(min break down voltage )
a) New unfiltered oil 30KV(rms)
b) After filtration If the above value is not
attained the oil shall be
filtered and the final value
should be 50KV(rms.)
10 Dielectric dissipation factor .005 IS: 6262-1971
(tan) at 900C ,Max.
11 Specific resistance
(resistivity)
a) at 900C,min 30x1012 ohms cm
b) at 270C,min 500x1012 ohms cm
12 Oxidation stability
a) Neutralisation value after 0.40 mg KOH/g
oxidation, Max.
b) Total sludge, after 0.10 percent by weight
oxidation, max.
14 Presence of oxidation inhibitor The oil shall not contain
antioxidant additives
15 Water content,max 50 ppm
For further details IS:335:1983 may be referred
Askarels
Askarels are synthetic oil used as insulating and cooling medium in indoor
transformers. Where transformers are used in doors as in the case of generating stations for
- 25 -
auxiliary supply and where fire will be a hazard, it is necessary to use non-inflammable
synthetic liquids instead of transformer oil (mineral oil) as insulating and cooling medium.
The NEMA of USA has designated these synthetic liquids as askarel. Askarels are 60/40
mixture of chlorinated biphenyl and tri-chlora benzene. It is known by various trade names in
different country (e.g.) Pyranol (USA), Pyroclor (Great Britain), Clophen (German), and
Sevtol (USSR).
Their general characteristics are that they are heavier than water, have a higher
dielectric strength than mineral oil, non-inflammable and non-explosive. They are not
susceptible to deterioration by oxidation, have a lower co-efficient of expansion than mineral
oil and will dissolve some insulating material and paints. At operating temperature their
viscosity is the same as that of mineral oil. The dielectric strength of askarel is reduced by the
presence of emulsified water. With the use of askarel, special insulating materials will have
to be used. As askarel has a high dielectric strength, distance between line parts can be
decreased; their lower co-efficient of expansion makes it possible to do away with
conservator.
Since askarel is heavier than water, samples for dielectric tests should be taken from
the top of the main tank of transformer where as mineral oil (transformer oil) samples are
collected from the bottom of the main tank so that it will reflect the correct electric strength.
The testing procedure for askarel is same as for mineral oil. Reconditioning of askarel can be
done with centrifuges of suitable design. Askarel can cause irritation of skin and hence
gloves or skin protection creams are to be used while handling askarel. The creams can be
washed away with ordinary soap. The fumes may cause eye irritation, coughing etc. They
have pungent odour. Gas mask may be used where necessary. When arcing occurs in tank,
chlorine is liberated and hence units over 25 kVA have pre-relief vent and gas absorber
installed on transformer casing. Since askarel is a human hazard now askarel is seldom used.
The trend is to use mineral oil for indoor transformer or to use dry type indoor transformer.
TAP-CHANGERS
The modern power transformers used in large generating stations are mostly provided
with off load tap changer as the voltage regulation is taken care of by the AVR. Whereas
- 26 -
power transformers in receiving station are normally provided with on load tap changer. In
power station, station service transformers are generally provided with on load tap changers.
The taps are usually provided in the high voltage winding of the transformer for better
control of the voltage.
Off-load tap-changers
The tap positions are changed with the transformer de-energised. The equipment
consists of an operating handle, pointer, a non-corrosive indicator plate and a latch. Lifting
the latch and turning the handle can change taps. The latch will drop into place on the
indicator plate when the new position is reached. Steel tube and pin that fits into a slotted
sleeve on the drive shaft connects the external mechanism with the internal tap changer. A
stuffing box seal is provided to prevent oil leakage around the operating handle shaft. A pair
of heavy copper bars supported from the operating shaft form the moving contacts. The
stationary contacts are mounted on a Bakelite panel with tap leads connected to them.
Three most common tapping arrangements of transformer winding are a) Linear
b) Coarse fine c) reversing as shown in Fig (3.2). In the linear arrangement, number of
voltage positions available is equal to number of tappings. In the other two methods number
of voltage positions available are almost double of the number of tapping. Therefore the last
two tap changing methods are useful where large number of voltage positions are needed.
In the coarse fine arrangement each fine selector tap gives two voltages, first with
change over selector in a position to exclude coarse tap winding from circuit and then in
other position. Similarly in the reversing arrangement each fine tap gives two voltages, first
with change over selector in a position where fine winding is added to the main winding and
then in other position where fine winding is subtracted from the main winding.
- 27 -
On-load tap-changer
This type of tap changer is used where the voltage variation is done while transformer is in
energised condition. On load tap changers have the following main parts:
a) Tap selector
b) Diverter switch
c) Operating mechanism
d) Motor drive
- 28 -
 The tap selector consists of a number of contacts generally arranged in a circle. It does
not make or break any current but only selects the proper tapping to be used.
 A diverter switch consists of a set of contacts, which actually diverts the current from the
tap in use to the tap to be used. All arcing and oil carbonisation takes place in diverter
switch.
 The operating mechanism controls the proper movement and timing of various tap
selector and diverter contacts. It consists of gears, Geneva wheels, quick motion
mechanism, levers, linkages etc.
 The motor drive consists of an electrical motor and speed reduction gearbox for operation
of the tap changer. It also consists of a number of control and indicating devices.
 The operating system can be a separate part or an integral part of tap selector or diverter
switch or both together.
Switching cycle
A complete switching cycle showing how the continuity of supply is maintained is
shown in figure 3.3. During change over from one tap to another the two adjacent taps are
temporarily shorted through the transition resistors R1 and R2. The upper position is known
as tap selector as it only selects a tap for use and does not make or break the current. The
lower portion is known as diverter switch. It actually diverts the current from one tap to
another and all the arcing takes place in these contacts. To change it from tap position No.4
to tap 5 the diverter main contact M1 and T2 are shorted through resistors R1 and R2. The
circulating load current, both flows during this period through transition resistors. T1 is then
opened and load current is transferred to tap 5 and it flows through transition resistor R2.
Diverter switching operation

To reduce the thermal rating of transition resistors they are kept in circuit for the
shortest possible time. The operation of diverter contacts M1, T1, T2 and M2 is carried out
by a spring operated quick motion mechanism. The diverter operating time is generally of the
order of 50 to 60 milli seconds. Fig. (3.3) shows the resistor transition on- load tapchanger.
- 29 -
- 30 -
CHAPTER IV
TRANSFORMER COOLING
Using the following mediums can do cooling of the equipment
 Solid medium cooling
 Liquid medium cooling
 Gas medium cooling
Solid Medium
Epoxy/Resin cast compound (electrical grade)
Liquid Medium
Transformer oil and synthetic liquid
Gas Medium
Air, Nitrogen (gas).
The generally accepted symbols for these mediums are as given below:
Sl.no. Medium Symbol
1. Solid (Epoxy, “S”

compound)
2. Liquid a. Mineral Oil “O”
b. Syn. Liquid “L”
c. Water “W”
3. Gas a. Air “A”
b. Nitrogen “G”
Out of all the cooling mediums, liquid cooling is the best and the rate of cooling can
be varied effectively in the liquid cooling medium. There are two types of circulation of the
above mediums. Viz. Natural circulation & Forced circulation. The symbols used for natural
and forced circulation are “N” & “F” respectively.
- 31 -
The nomenclature for indicating the type of cooling is expressed as follows:
Illustration
“OFAF”
12 3 4
There are 4 capital letters (symbols) used in the above nomenclature.
First letter: Indicates the cooling medium, which is having direct contact
with (Direct coolant) transformer (core & winding)
Second letter: It indicates the type of circulation of the above (First letter)
Third letter: It indicates the cooling medium (Indirect coolant) which cools
the direct coolant (First letter).
Fourth letter: It indicates the type of circulation of indirect coolant.
First two letters indicate the internal cooling (Direct coolant) and its circulation.
Second two letters indicate the external cooling (Indirect coolant) and its circulation.
The service life of a transformer depends upon the mechanical strength of insulation,
to withstand mechanical stresses due to surge and short circuit conditions. The rate of
deterioration of mechanical strength of materials used in constructing the windings, doubles
for every 8 to 10oC increase of winding temperature. Deterioration also depends upon time
and hence excessive temperature for short duration are not very dangerous but still sustained
excessive temperature should be avoided so that the transformer is reliable, for 20 years or
more. The hot spot temperature of transformer winding cannot be easily measured and hence
the limiting temperatures are stipulated in terms of temperatures rise (above a specified
ambient temperature). This measurement is carried out by employing RTD (resistance
temperature detector). Cooling plays a very important role in transformers for extracting the
heat from the windings.
- 32 -
The various types of cooling methods used for power transformer are given below (IS 2026:
1962)
Cooling Oil Cooling method Winding temperature
classification circulation rise limits (resistance
method)
“ON” Natural Air-natural 550C
“ONAF” Natural Air-blast/Forced 550C
“OFAN” Forced Air-natural 600C
“OFAF” Forced Air-natural 600C
“OFW” Forced Water(Forced) 650C
Top oil temperature measured by thermometer for all types of cooling is 400c
(Ambient temperature)
The above symbols indicate the different types of cooling in transformer employing
mineral oil. The temperature rise of transformer windings, oil and core should not exceed the
limits prescribed in the above table.
For water cooled transformers, the temperature rise specified is that measured above
the inlet water temperature. For other types of cooling, the temperature rise given is that
measured above the temperature of cooling air (ambient air temperature not exceeding 40oC)
TERMINAL MARKING PLATES AND RATING PLATES

Terminal Marking plate and rating plates are provided on the transformer. This plate provides
the complete information about the equipment.
When tapping switches or links are provided the plate shall show the relative position,
number and link connections corresponding to the different voltages, the switch position
corresponding to the maximum number of turns in the tapped winding and it’s starting
position i.e. tap no.1. The terminal marking plate shall include the manufacturers drawing
number, connection diagram which will give information regarding vector diagram and
group number, insulation level of each winding, the insulation level of neutral point when
graded insulation is used and interconnections.
- 33 -
TYPICAL TERMINAL MARKING PLATE FOR DELTA/STAR
CONNECTED 3 PHASE TRANSFORMERS
Rating Plate
All transformers shall be fitted with rating plates giving the following information:
A. The number of the standard. Ref. IS : 2026 : 1962
B. Manufacturers name and country of manufacture
C. Manufacturer’s serial number
D. Rated KVA
E. Frequency
F. Number of phases
G. Rated voltage at no load in HV and in LV, in the case of single phase transformers
manufactured for operation in star connected groups on a poly-phase system is expressed
in terms of the system voltage, for example 132 kV/3.
H. Rated current (HV/LV)
I. Percentage impedance voltage at 75oC.
J. Winding connection and phase displacement symbols of vector diagrams i.e. vector
group
K. Type of cooling
L. Weight of core and windings assembly in Kgs.
M. Total quantity and weight of insulating liquid in litre’s and Kgs.
N. Total weight of transformer in Kgs.
O. Temperature rise of oil for which the transformer is designed.
P. Year of manufacture
Q. Customer’s reference (if given)
- 34 -
DEFINITION AND EXPLANATION OF SOME OF THE ABOVE
RATINGS
Impedance Voltage
For two winding transformer:
 The voltage required to be applied at rated frequency between the line terminals of a
polyphase winding or between the terminals of the single phase winding to cause the
rated current to flow through these terminals while the terminals of the other winding are
short-circuited. This measured value of voltage after correction for an average
temperature of 75oC of the windings when expressed, as a percentage of the rated voltage
of the transformer winding is known percent impedance voltage.
 In case of multi-winding transformer, this applies only to any pair of windings; the
remaining winding being left open circuited.
Vector Diagrams
In vector diagrams, the vector represents induced voltages and the phase displacement
between HV winding and LV winding. (Ref. Fig.4.1 to 4.4)
Vector Groups
There are four major vector groups and each group includes three methods of
connection of high voltage and low voltage windings, which give the same phase
displacement between the windings. These groups are shown in table.
Group no. Phase displacement Clock hour no.

1 00 0
2 1800 6
3 -300 1
4 +300 11
- 35 -
- 36 -
- 37 -
- 38 -
- 39 -
Vector Symbols
The group connections (with reference to the relevant vector diagram) and the phase
displacement are identified by the use of three alphanumeric symbols. In case of two winding
transformers, the symbols have following significance.
First symbol – higher voltage winding connection (Capital letter)
Second symbol – Lower voltage-winding connection (Small letter)
Third symbol – Phase displacement expressed as the clock hour number
Winding Connections
The connection of the higher voltage and lower voltage windings are indicated by the
use of letters as given in table.
Winding Type of connection Designation

connection
High Voltage Delta D
Star Y
Interconnected star Z
Low Voltage Delta d

Star y
Interconnected star Z
Phase Displacement
Phase displacement is the angular difference between the vectors representing the
voltages induced between the corresponding high voltage and low voltage terminals having
the marking letter for the vector group and its respective neutral points (real or imaginary).
A convention adopted internationally to indicate phase displacement is to use a figure
that represents the hour indicated by a clock. The minutes hand takes the place of line to
neutral voltage vector for the high voltage winding and is set at 12 O’clock. The hour hand
represents line to neutral voltage vector for the low voltage winding.
- 40 -
Note: It follows that the clock hour number (except for zero displacement) is obtained by
dividing the phase displacement angle in degrees by 30. For example in (fig.4.3) per phase
displacement is minus 30o and the clock hour number is therefore 1.
Parallel Operation of Transformer

For operating transformers in parallel, the transformers should have the following principal
characteristics.
 The same phase angle difference between the primary and secondary terminals.
 Same voltage ratio
 Same percentage impedance
 Same polarity
 Same phase sequence
As per the first condition, transformer of same vector group number can only be paralleled.
- 41 -
It is also possible to operate a 3 phase transformer of vector group number 3 in
parallel with another 3 phase transformer of vector group number 4. This can be done
without any change in the internal connection between phase windings of the transformers
but just by transposing the external connections of one of the transformer (see Fig.4.6).
Method: For paralleling transformers in vector group 3 and 4, any one of the transformer
irrespective of the windings whether delta or star connected, interchange any two of the
external HV connections in the supply side and also the corresponding LV external
connections (Fig.4.6).
- 42 -
From fig.4.6 it may be noted that, the vector diagram of the transformer with vector
symbols Dyl is identical with that in fig.4.3. But for the transformer with vector symbols Yd
11 the vector diagram differs from that in fig.4.4 because for that transformer the phase
sequence has been reversed from ABC to ACB.
Transformer connected in accordance with vector group No.1 and No.2 cannot be
operated in parallel with one another without altering the internal connection of any one of
them. Apart from four general vector groups described above there are other special vector
group used in power transformers for special application. (e.g. Excitation transformer having
vector group Dy5).
- 43 -
CHAPTER V
MAINTENANCE SCHEDULE
For maintaining continuity of supply and to prevent damage to the transformer, which
involves a considerable investment, it is necessary to inspect the transformers periodically
and maintain them in serviceable condition. Complete maintenance may be impossible to
justify if it costs more than the failure of the transformer.
Modern transformer of large sizes have a number of auxiliary devices such as cooling
fans, oil pumps, etc. whose proper functioning is necessary for the efficient operation of
transformers. Hence periodic inspection of a transformer on the following lines is generally
adopted.
1. Checking of thermometers (their accuracy), their contacts (for alarm and trip circuit).
2. Checking of bearings of fans (cooler fan or blower) and oil pumps etc.
3. Checking of ground connections and earth resistance.
4. Checking of oil level in bushing, checking for chipped or broken porcelain, excessive
deposits, and traces of flash over, gaskets for leaks. The porcelain is to be cleaned with
water or carbon tetrachloride; the chipped spots are to be painted with lacquer such as red
glyptal. Gaskets are to be replaced if necessary and bolts to be tightened.
5. Checking of oil samples for dielectric strength and presence of moisture. Replenish or
replace oil if required.
6. Checking of bushing CT and PT devices, their insulation resistance, ratio etc. Tightening
the connections.
7. Checking of tank cover, radiator joints, flanges, valves for leakage and tightening,
renewal of gaskets etc.
8. Checking of relief diaphragm replace if cracked or broken.
9. Checking of transformer for unusual noises.
10. Checking of surge diverter (lightening arrestor) for cracks, deposits their earth resistance
relays and alarms circuits for their accuracy and operation.
- 44 -
11. Checking of tap changer mechanism, motor gears, lubrication, contacts, spring operating
mechanism, etc.
12. Checking of insulation resistance between each winding to ground. For finding out
polarisation index, note the readings at the end of 1 minute and at 10 minute. The ratio
R10/ R1 is called polarisation index or absorption factor. It is an indication of the
deterioration or ageing of the insulation. (In Russian practice, the polarisation index is
determined by observing at 15 Sec and at 60 sec. The ratio R60/R15 should be about 1.3).
If, IR10/IR1 = 1.0 to 1.1 - suspicious
= 1.1 to 1.3 - good
= 1.3 to 1.5 - very good
The usual practice is to use the following test voltages for determining the insulating
resistance:
 10/5KV megger for EHV transformers
 2.5kV Megger for windings of 10.5kV and above
 1000V Megger for windings of 3.3kV and above
 500V Megger for windings of LT Voltages
 250V for thermocouples embedded in winding.
The general thumb rule for insulation resistance with a 2.5 kV megger is 2 Meg-
ohm/kV at 60oc temperature. Corresponding values at different temperatures can be obtained
from the chart provided by the manufacturer.
The IR Values at site should not be less than 75% of the original test value. Normally
the absorption factor values are measured at ambient condition. The insulation resistance will
increase with the decrease in temperature.
The insulation resistance to be ascertained between: -
 H.V. winding to earth
 L.V. winding to earth
 Between H.V. and L.V. winding.
13. Checking for leakage of water, water-piping etc., in case of water-cooled transformers.
- 45 -
14. Checking if inert gas tanks, regulators, gauges, piping and valves in case where an inert
gas is used in the conservator tank. Checking of bus ducts/cable boxes, the bus ducts have
to be checked for water collection and insulation resistance. Change the gaskets if
necessary, tighten bolts etc. In the case of cable boxes examine for filling holes, cracking
of compound etc.
15. Checking of gas in the buchholz relay – routine examination of the buchholz or gas relay for gas collection. The gas can be released
through the vent provided and examined for its colour or odour.
Colour of Nature of fault

gas
White grey Ageing of Paper or
pressboard
Yellow Ageing Wooden
parts
Black Burnt Oil
16. Checking of oil level in the conservator and topping up if necessary. If the oil level goes
down, the gas relay may act.
17. Checking up of breather and renewal of silicagel when necessary.
When indicating silicagel absorbs moisture it turns in to pink colour. The saturated silical
gel can be reactivated by heating on a sand bath at a temperature of 100 oC - 120oC till it
changes to sky blue colour. Ensure that while drying the silicagel, it is not burnt by over
heating.
PREPARATION OF SILICAGEL
NON INDICATING TYPE: -
The silicagel of 3 to 7mm sizes is impregnated with calcium chloride solution.
The preparation of non-indicating type silicagel: - Take calcium chloride 4 parts by
weight and 8 parts of water (1:2). Mix these two into a solution. Take 10 parts of dry silicagel
(at 60oC ) by weight and add this to the solution and stirred. (The thickness of layer of
silicagel is not to exceed 150mm for thorough impregnation). Heat the prepared material to a
temperature of 400oC for 3 hours.
INDICATING TYPE: -
The silicagel of 3 to 7 mm sizes is impregnated with cobalt chloride solution.
- 46 -
Preparation of indicating silicagel: - Take cobalt chloride 0.3 parts by weight 0.3 parts of
water (1:1) and mix these two in to a solution. Take ten parts by weight dry silicagel and then
added. The mixture along with silicagel is allowed to stand still till the entire solution is
absorbed. Heat the prepared material to a temperature of 100 oC - 120oC for 15 to 20 hours
until it acquires uniform sky blue colour.
Checking of dielectric strength and acidity of oil. Mineral oils are composed of
hydrocarbons.
The most common cause of deterioration of insulating oil is contamination by
moisture. This cause can be corrected by purification of oil (drying of oil). The less rapid but
more serious deterioration viz. formation of acids and sludge is caused by oxidation. The
oxygen in air and water in the oil causes oxidation. Further, an increase of temperature of
10oC generally doubles the rate of oxidation. So transformers should not be overloaded
during summer. Water can be present in oil in (a) dissolved form (b) as emulsion and (c) in a
free state at the bottom. The dissolved water has little effect on the dielectric strength. The
amount of moisture dissolved in oil increases with temperature.
A small amount of moisture as an emulsion has a marked influence in reducing
dielectric strength of oil. The emulsified water and water in free state is readily removed by
filtering or centrifuging. The sludge caused by the oxidation of oil and interaction between
acids and in turn forms insulation blankets on the core and coil thus preventing effective heat
transfer. The sludge may also block the flow of oil through the cooling ducts. As a result the
transformer insulation gets damaged which may eventually lead to break down. Tests have
indicated that acidity is proportional to the amount of oxygen absorbed by oil. It has been
estimated that different types of transformers would take following periods of time before
sludging takes place on the basis of loading:
Transformers with free air 10 Years

access
Transformers with conservator 15 Years
Transformers bolted up tight 50 Years
Transformers with Nitrogen 67 Years
- 47 -
over oil
The above periods may not correspond to actual field experience, on account of
different load conditions from those assumed. It has also been found that certain chemicals
retard oil oxidation until such time as they are consumed. So the addition of an inhibitor to
the oil prolongs the life of oil. Ditertiary butyl-pancrool (DBPC) is found to be effective
when added to oil in small concentration on account of its stability and anti-oxidant features.
When the acidity value has reached 1.0 (Neutralisation number) i.e. 1.0 mg of
KOH/gm of oil, for neutralising the acid in the oil, it will be essential to replace the oil or
reclaim the oil. The reclaiming processes involve the use of fuller’s earth, or fuller’s earth in
combination with trisodium phosphate. Oil can be percolated through coarse clay (fuller’s
earth) either by gravity or under pressure or by passing through hot finely divided fuller’s
earth.
With trisodium-phosphate-activated fuller’s earth method, the oil and trisodium-
phosphate solution are mixed and maintained at 80oC for an hour and then allowed to
separate. Trisodium phosphate solution is drained and the oil is washed with water spray for
removing any traces of unwanted material and then decanted through a centrifuge and heater
to a tank where (200 mesh) activated fuller’s earth is added and the mixture agitated for
about 15 minutes. The mixture is allowed to standstill by overnight and then the oil is washed
with hot water, decanted through centrifuge. Passing through a dehydrator the oil is
dehydrated. An inhibitor can then be added. As moisture in oil reduces the dielectric strength
of the oil, it is necessary to test the oil at regular intervals. Standard BDV tests kit is used for
determining the dielectric strength.
The prescribed limits of dielectric strength are as follows:
Rating Fresh oil Oil in

service
Up to 10kv 35kv 20kv
11kv to 35kv 25kv
33kv
33kv to 40kv 35kv
- 48 -
220kv
220kv to 50kv 45kv
500kv
The inspection and maintenance of oil will involve dielectric strength test, acidity test,
reconditioning and reclaiming of oil.
Buchholz Relay (REF. FIG.5.1)

A gas and oil actuated protective device commonly known as a Buchholz protective
relay is used in all power transformers of the rating 500KVA and above. Buchholz relays are
provided with “alarm” and trip contacts, and are located in the pipe work between the tank
and conservator. When an incipient fault occurs or due to any other reasons if sufficient
amount of gases are liberated from the oil and gets trapped in the buchholz relay the top float
falls down and the alarm contact is made so as to activate the alarm. The device relies on the
fact, that if an electrical fault inside is high enough to create a surge of oil from the tank to
the conservator the oil in the Buchholz relay chamber is then displaced. If the velocity of this
surge of oil is greater than approximately 90 cm/sec, it will cause the bottom float to fall and
operate the relay, which in turn causes the circuit breaker to open. It provides protection
against all types of internal faults developing in the transformer tank. The device is
particularly useful for detecting fault conditions even of very low magnitudes such as inter
turn fault, incipient winding fault, and core fault due to core bolt insulation failure giving rise
to a short circuit and subsequent arcing and gas.
- 49 -
Dissolved Gas Analysis (DGA)
Dissolved gas analysis is a powerful diagnostic technique, for on line monitoring of
the internal condition of large transformers, due to its capability to detect defects in the
incipient stage, before they develop into faults and cause serious damage to the transformer.
The conventional “Buchholz relay” or “Gas operated relay” are universally used for
the above purpose. However, these have the limitation that enough gas must be generated
first to saturate the oil fully and then to come out of solution. Often, by the time the Buchholz
relay detects the gas, the damage has already been done. Also, the Buchholz relay was never
meant to be a diagnostic device. The DGA technique is very sensitive technique that uses
vacuum extraction system and gas chromatograph to detect gas in parts per million of the oil,
while it is still dissolved in the oil. It is possible to check whether a transformer is being
subjected to a normal working and heating, or whether there are incipient defects such as hot
- 50 -
spots, sparking, partial discharges or over heating. Such incipient faults could otherwise
remain undetected until they lead to actual failures.
Principle of Dissolved Gas Analysis
There are four basic types of faults, which can occur in a transformer. These are
 Arcing or high current breakdown
 Low energy sparking or partial discharges
 Localised overheating or hot sports and
 General over heating due to inadequate cooling or sustained over loading.
Each of these faults results in thermal degradation of the oil or oil in combination
with paper insulation. This gives rise to the evolution of the various hydrocarbon gases,
hydrogen and oxides of carbon, in different quantities depending on the type and severity of
the fault.
Heavy current arcing is characterised by the evolution of significant quantities of
hydrogen and acetylene (C2H2). If the arcing involves paper insulation the oxides of carbon
will also be present. Partial discharge usually results in the evolution of hydrogen and the
lower order hydrocarbons [Hydrocarbon gases like propane (C3H8) propylene (C3H6) and
Butane (C4H10)]. Localised over heating or hot spots give rise to methane (CH4) and Ethane
(C2H6) in appreciable amounts. Prolonged over loading or impaired heat transfer can cause
CO and CO2 to be generated due to over heated paper insulation.
The gases evolved during incipient faults will normally go into solution with the oil
and continue to be so until the saturation level of each gas in the oil is attained. This usually
takes considerable time depending on the severity of the fault and solubility of each gas. The
technique of dissolved gas analysis involves the detection and identification of faults in the
incipient stage by extraction of the dissolved gases from the oil, by separation of each gas
from the extracted mixture of gases, and quantitative analysis by gas chromatograph.
Faults and Their Gases
Sl.No. Type of fault Main gases produced

1. Hot spot in oil H2,CH4,C2H4,C2H6,C3H6,C3H8
2. Over heating of solid CO,CO2,H2,CH4,C2H4,C2H6,C3H6,C3H3
insulation
3. Arcing in oil H2,CH4,C2H2,C2H4,C3H6
4. Arcing in solid insulation CO,CO2,H2,CH4,C2H2,C2H4,C3H6
- 51 -
INSPECTION AND MAINTENANCE SCHEDULE
(Based on ISI recommendation )
Sl.No. Frequency Items of inspection Inspection notes
of inspection
1. Hourly Oil and winding Check the temp.rise is
temp. normal
2. Hourly Load and voltage Check against rated
figures
3. Daily Oil level in the Check the oil for correct
bushing Level
4. Daily Oil level in -do-
transformer
5. Daily Relief diaphragm Check for cracks
6. Daily Breather Check colour of silicagel
7. Daily Oil and water piping Check for leakage
8. Daily Oil pumps, cooling Check for leakage
fans, values, plugs
Items 3 to 8 could be done weekly instead of daily
9. Monthly Fan motors Check IR values
Items 3 to 8 are repeated
10. Quarterly Bushings Check for cracks
11. Quarterly Oil in transformer Check the dielectric
strength
12. Quarterly Gas relay Release the gas, testing
of gas
13. Quarterly Windings Check the winding
resistance
14. Quarterly Terminals Check the terminal for
the security of the
tightness
15. Quarterly Fan bearings Check for freeness
16. Half yearly Item 3 to 15
17. Yearly or Oil in transformer Check for acidity, Test
earlier if Tr. oil
Is available
on shut down
18. - do- Bushings
19. -do- Gasket joints
20. -do- Cable boxes
21. -do- Surge divertor and Check for cracks etc.
gaps
22. -do- Earth resistance
23. -do- Relays, alarm and Check contacts,
their circuits operation accuracy etc.
- 52 -
24. -do- Tap changer
In addition items 3 to 16
25. Unscheduled Transformer capacity Overall inspection
or 7-10 above 3000KVA including lifting core
yearly and coils
For transformer 1000-3000KVA once in 5 years
Transformer Troubles and Their Remedies
Sl. Symptom Trouble Cause Remedies

no.
1. Temp. rise a) Overload a) Over load or low a) Reduce load or
above the b) In- power factor increase p.f. of the
specified -sufficient oil b) Due to a leakage system
values in oil c) Oil jellied of oil or in b) Add more oil and
cooled tr. sufficient oil when weld tank,
installed. Note: the core and coils
should be fully
immersed in oil.
c) Excessive heat. (In c) If insulation is not
this case the damaged, flush the tank
windings will be with new oil until all
roasted and the the old oil is removed
insulation has to and refill with new oil.
be revived).
2. Temp.rises a) Overload a) Same as in 1(a) a) Same as in 1(a)
above the
specified b) In- b) Blower speed is b) Increase the speed
values in Air- -sufficient air too low or air of the blower, clean
cooled tr. circulation ducts clogged air ducts.
Note: In cleaning air
ducts care must be
exercised.
If compressed air is
used full voltage should
be applied on the
windings immediately,
as there will be
moisture in compressed
air. Voltage should be
applied on HT winding
with LT short-circuited.
A transformer thus
treated may be put back
into service after 5
- 53 -
hours of drying.
3. Temp. rises a)Over load a) Same as in 1(a) a) Same as in 1(a)
above
specified b)Insufficient b) Pressure low or b) Increase water flow
values in water flowing tubes obstructed rate. Choked tubes
water cooled in the heat are to be cleaned
transformer exchanger with caustic soda in
water solution.
c) Oil c) Oil leakage around c) Stop the leakage,

saponified on water inlet. and fill the
outside of the transformer tank
Cooling coils with oil.
d) Cooling coils d) Remove cooling
plugged and water or apply air
Tr.operated at too under a pressure of
low temperature. 250 lbs./sq.” with
care other wise the
pressurised water
lines may burst.
The cooling tubes
should be cleaned with
solution of HCL &
water in equal parts
atleast once in 6
months. This solution is
to be allowed to stand
in the coils for not more
than one hour, after
which the coils are to
be flushed and cleaned
with water.
4. Temperature a) Short a) Moisture in oil a) Test for moisture in
rise above circuit may be due to leak oil. BDV value
specified between in the cooling coils should not be less
value and adjacent or due to than 25KV (2.5mm
explosions layers of breathing. gap). If the testing
occur in tr. HV equipment is not
Tank winding. available crystal of
blue vitriol (copper
sulphate) are heated
till they turn white
and dropped in a
bottle containing oil
samples.
- 54 -
Sweating is caused If crystals turns blue,
by operating in a damp moisture is present and
location at too low oil should be filtered
temperature.(The through a filter (8”x 8”
temperature of the sheets in all 125nos.) at
transformer should not a pressure of 250
be below 100c) lbs./sq.”. filtering will
require about 4 to 5 hrs.
for a large power
transformer. The
transformer need not be
taken out of service
while filtering unless it
is defective.
b) Short b) Breakdown of b) Replace the

circuit Insulation. affected windings.
between
HV&LV
windings.
c) Insulation c) As in (b) above
punctured due to
lightning surges.
d) Shifting of coils d) Replace the coil to

due to switching the correct position.
ON and OFF
heavy loads.
e) Insufficient e) As in (b) above.

insulation of end Reinsulate the end
turns. This should turns to proper
have 2 to 5 times thickness.
greater insulation
level than inside
turns.
f) Electromagnetic f) Tr.is to be returned

stresses are too to factory for
great owing to rebuilding. This
improper core trouble is seldom
construction. met with.
g) Tr. Coils not g) Short circuit

properly baked secondary and
before assembly. impress twice
- 55 -
secondary voltage
on primary
windings.
h) Lightning h) Repair damaged

discharge without coils or replace with
protection. new coils
i) Insulation roasted i) As in (b) above

by constant
overload.
c) Ground a) Lightning a) As in(h) above

between discharge.
LV
winding b) Insulation b) As in (h) above
and core. breakdown due to
line surge or
c) Shifting of coils. c) As in(h) above
d) Short Moisture in oil. Remove the terminal

circuit on board, bake and
terminal revarnish. Pass oil
board. through a filter process.
e) Short Bushing broken or Replace bushings.

circuit cracked.
between
HV or LV
bushings.
f) Improper Parallel operation of When banks of

division of transformer with transformers with
load. different different impedance are
characteristics. paralled, reactance coils
are inserted between
the two banks.
g) LV Ground on HV side of Remove ground, repair

windings an under grounded LV windings and
punctured. neutral system. ground both high and
low voltage neutrals.
- 56 -
Ground on HV side of as in the above
the system with only
LV neutral grounded
5. Voltage too Wrong ratio Leads not connected Connect the leads to the
low to the proper ratio taps correct tap.
6. Voltage too Wrong ratio a) Same as in 5. a) Same as in 5.
high
b) Tr. Paralleled has b) Change the winding

different ratio. to make the all
transformers have
the same ratio or
replace
transformers or
install the auto
Transformer.
CHAPTER VI
- 57 -
MAINTENANCE AND TESTING OF
TRANSFORMER
Procedure Document No.1
Aim: To measure the values of winding temperature, oil temperature, HV&LV voltages
and sound.
Procedure
1. Identify the winding temperature indicator (WTI). Note down the reading with time.
2. Identify the oil temperature indicator (thermometer). Note down the reading with time.
3. Note down the HV&LV voltages in all phases with time.
4. Observe for any sound. Record the same in a format and report.
Aim: To check oil level in transformer, oil level in bushing, to check for any crack in
diaphragm, to observe the colour of the active agent in breather.
Procedure
1. Observe for the prescribed oil level in the conservator
2. Observe the level of the oil from the magnetic level gauge provided for measuring the
level of the oil in the conservator.
3. Observe the level of oil in the bushing.
4. If the level is low, report
5. Using a 5-cell torchlight, observe for any crack in diaphragm of the explosion vent.
6. Observe the colour of the active agent in the breather and report.
Aim: To inspect the bushings.

1. If any protective coatings are applied, using gloves the coatings may be wiped off and
cracks if any may be observed.
Note: Please do not use any knife or iron scrapper to remove the coatings lest the
glazing on the insulator will be destroyed.
- 58 -
2. If there are no protective coatings, use wet cloth to wipe and then dry cloth to observe for
any crack.
3. Report.
Aim: To conduct IR Test on a transformer

Test equipment required:
Hand operated megger for lower ranges OR
Transistorised megger/Motorised Megger (for higher ranges) with
1. selectors for different voltage ranges
2. selectors for different IR ranges
3. provision for discharge electrodes
Pre-requisite: (The person testing should have known the factors affecting IR & PI value
of a transformer)
Procedure
1. Taking safety precautions, discharge all the windings at least for ½ hour.
2. Clean the bushings
3. Notedown the temperature of oil and windings
4. Read the instructions for the test equipment.
5. Select the appropriate test voltage depending upon the rated voltage of the winding to be
tested (selection of voltage vide Table 1).
6. Connect the megger between,
 LT to ground (a2-earth, b2-earth,c2-earth)
 HT to ground ( A8 – earth, B8 – earth, C8 – earth)
 HT to LT (a2-A8, b2-B8, C2-C8)
and note down the respective values of IR as per sl.no. 8 below.
7. Except the winding to be tested, other windings should be connected to earth. (While
testing LT, HT should be grounded and vice-versa)
- 59 -
8. Apply the voltage for 10 min and take the readings at 15, 30, 45 and 60 seconds and then
every minute thereafter for a total of 10 minutes. Record the readings.
9. Discharge the winding after the each test.
10. Conduct the test in the similar manner for other windings in turn.
TABLE 1
Machine D.C. Test

Voltage Voltage
Up to 2000 V 500 V
2001 to 4000 V
1000 V
4001 to 8000 V
8001 and above 2500 V
5000 V

Aim: To conduct winding resistance test
Test Equipment required
 Wheatstone Bridge or Micro Ohmmeter or any precision low resistance measurement
equipment for the measurement of resistance.
Pre-requisite: The person testing should know the relevancy of this test.
Procedure
1. Read the instruction manual of the test equipment.
2. Knowing the different configurations of transformer windings, the measurement may be
taken and the readings are recorded.
3. Temperature of the windings to be noted.
4. Winding Resistance can be calculated at any temperature. For example, say at 75 oC is
computed by using the formulae.
234.5 + 75
R 75O C = R test X ---------------------------------------
234.5 + winding temperature o C
- 60 -
5. The calculated reading may be recorded.

Aim: To conduct Ratio Test on a transformer.
Method-1 (direct reading test)
Test equipment required:
1. TTR (Transformer Turns Ratio) Test set
2. Wires
Pre-requisites: The person conducting the test should know the relevancy of this test.
Procedure
1. The ratio of the standard transformer in the test set is adjusted until its voltage is exactly
equal to that of the transformer under test.
2. The ratio of the standard transformer then indicates the ratio of the transformer under test.
3. The test has to be carried out in all tap positions both in the ascending order and also in
descending order.
Method-2 (indirect reading test)

Test equipment required
1. A known voltage source.
2. Precision volt meters (class 0.5)
3. Wires
Procedure
1. Keep the tap position in No.1
2. Apply voltage to H.T. terminals of the transformer (about 400 volts)
3. Measure the voltage applied to the HT terminals of the transformer
4. Measure the voltage between phases on the LT side of the transformer.
5. Repeat step (3) and (4) in each tap position of transformers both in the ascending order
and in the descending order.
6. All the readings may be recorded in a format.
7. Note down the voltage in the name plate and compare the actual results:
- 61 -
The ratio as given in name plate for example: 50KVA Transformer Actual value
Tap nos. HT in LT in voltage Transformation HT in volts LT in volts Transformation

volts i.e. LT, VL=VPH/3 ratio HT/LT ratio HT/LT
VL – line voltage
VPH – phase voltage
1 10450 43. 51
2 10725 44. 65
11000 45. 79 AS
3
11275 416 46. 94 4OO MEASURED Calculated
4
11550 = 48. 09 BY Value
5
240.18 VOLTMETER

Aim: To conduct Polarity Test on a transformer
Method-1
During the test as per procedure document No.3, Method-1, the polarity will be
simultaneously known.
Method-2
This test is applicable to all types of transformers.
Notations are given as example for transformer connections of Dy11. The primary is Delta
connected. The secondary is star connected.
1. During the ratio test, the neutral will be known. Mark the same.
2. From the name plate of the transformer mark the other LT terminals of the transformer
and then relative HT terminals.
Note: The supply from the LT side of the transformer shall be as per the name plate
detail since cable, relays, motor connections would have been installed as per the polarity
marked in the name plate.
3. Apply voltage to any two H.T. terminals of the transformer such that there is maximum
voltage between a2 and “n” on the secondary side of the transformer and the supply may
be switched off immediately.
- 62 -
4. Then these two terminals may be either A8 or B8 but definitely the terminal which has not
been connected must be C8.
5. To verify which terminal is A8& which one is B8, remove one of the two connections,
which was connected earlier and now connected to the third terminal. Assume it as to be
C8.
6. Now apply the voltage between the assumed HT terminal A8 and C8 and observe for the
maximum voltage on the secondary side between c2 and n.
7. If the assumption is correct, then there will be maximum voltage between c2 and n.
8. Observe for the max voltage between c2 and n on the secondary side for confirmation that
HT terminal is C8.
Method-3
Test equipment required
1. Battery (6V)
2. Centre zero galvanometer or Avometer
Procedure
1. The neutral of the transformer would have been known from the Ratio Test.
2. From the name plate detail, in relation to the neutral, mark the other terminals of LT.
3. The standard chart is given below as an example.
- 63 -
Primary winding(HT) Secondary winding(LT)
A2b2 b2c2 c2a2
(+) (+) (+)
A8B8(+) + 0 -
B8C8(+) - + 0
C8A8(+) 0 - +
Explanatory Notes
1. Connect any HT terminal A8 to the +ve terminal of the battery and connect another HT
terminal B8 to the –ve terminal of the battery through a switch. On the secondary side
connect the +ve terminal of the galvanometer or AVO to a 2 and –ve terminal to b2.
Observe the deflections in the galvanometer or AVO when the switch is closed. One will
find that there is positive deflection. Now switch may be opened. Then connect the +ve
terminal to b2 and –ve terminal to c2 and observe for the deflection in galvanometer or
AVO, when the switch is closed. It will be zero or the deflection will be very little when
compared to the previous one. Open the switch. Repeat the operation for c 2 (+ve) and a2
(-ve). One will find that the deflection is negative.
2. Repeat the above operation for HT terminals (B8 C8 & C8 A8) and the deflection in the
galvanometer or AVO will be as per row 2 & 3 respectively of the above table.

Moisture Detector Test
Test Equipment required
1. Motorised Megger
2. Test leads
Procedure
1. Select 500 volts range.
2. Connect the megger to LT and apply for 1 minute.
3. Take down the megger reading
4. Select 2500 volts
- 64 -
5. Connect the megger to HT and apply for 1 minute
6. Take down the megger reading
7. Report

Aim: To conduct core loss test on a transformer
Test equipment’s required
1. 3 phase wattmeter
2. Voltmeters
3. Ammeters
4. Test leads etc.
Procedure
Connect the wattmeter, voltmeter and ammeter as shown below. During the test transformer
secondary is kept open condition.
Note: Wattmeter connection may be done as per test equipment manufacturer’s instruction.
1. Apply 10% of the rated line voltage.
2. Measure watts (W1 + W2).
3. Repeat the above test for different percentage of the rated voltage.
4. Record & Report the two-wattmeter readings.

Aim: Drying out the transformer
Method-1: Drying with core and coils in oil by the short circuit method.
- 65 -
1. Short the secondary (LT) terminals through ammeter by means of cable, capable of
carrying rated current (available from the name plate detail).
2. Keep the vent cock on the transformer cover, explosion vent, vent cock on the
conservator open.
3. Keep the tap position switch at the maximum so as to engage all the windings into
drying.
4. Keep the oil level below the radiator hole (This is to avoid hot oil to pass through radiator
pipes and get cooled due to oil circulation).
5. If the above is not possible keep the level of oil at 1 cm or 2 cm below the transformer
cover and completely cover the radiator pipes with canvass (This is to conserve the heat).
6. Apply voltage to the primary (HT) and gradually increase it till 25% of rated secondary
current (LT) is obtained.
7. After say half an hour increase HT voltage such that 50% of the rated current in the LT
winding is circulating. Thereafter, the HT voltage may be raised such that full rated
current is circulating.
8. Monitor the oil temperature using dial type thermometers or spirit type thermometer. It
shall not be allowed to go beyond 85oC.
9. If the temperature rises above 850c, reduce the circulating current.
10. Maintain a log sheet.
11. Conduct and record the BDV of oil with time in the log sheet.
12. Record the winding resistance with time in the log sheet.
13. Keep the transformer for 24 hours with heating by short circuit but without filtering.
14. All ventilating openings may be closed.
15. After 24 hours again conduct BDV test.
16. A decrease in dielectric strength indicates further drying is required.
17. A constant dielectric strength or increase in dielectric strength indicates stopping of
drying process.
- 66 -
18. To speed up the drying process, oil-filtering equipment can be used in addition to
circulating current in the secondary.
19. In this method, continue drying till the oil withstands the standard breakdown voltage
value for seven consecutive tests taken 4 hours apart.
Method-2: Drying core and coil without oil

Same as Method-1, but for the following changes:
1. Measuring winding resistance to monitor the temperature of winding.
2. Measuring insulation resistance of the winding to monitor the drying process.
3. Drying process may be discontinued when constant or increasing IR value is obtained.
Method-3: Drying with external heat.

1. The Core and coil may be left in the transformer tank without oil.
2. All vents may be opened.
3. Hot dry air may be passed.
4. The temperature of winding may be monitored as mentioned in Method-2.
5. The drying process may be monitored as mentioned in Method-3.
Method-4: Drying with D.C. supply (either with oil or without oil)
(The winding connection shall be in star for this application)
1. Apply D.C. voltage with +ve on a2 and –ve on b2 such that rated current is flowing.
2. After a period of time say 2 hours apply D.C. voltage with +ve on b 2 and –ve on C2 such
that rated current is flowing.
- 67 -
3. After 2 hours apply D.C. voltage with +ve on C2 and –ve on a2 such that rated current is
flowing.
4. Repeat this operation continuously till satisfactory IR value or Dielectric strength is
obtained as outlined in Method 1 or 2.
Note: - The test voltages are applied to the LT winding so that large amount of current
can be circulated.
Procedure document No.11

Aim: To obtain a representative sample of oil from transformer, switchgear etc.
Procedure
1. Open bottom-sampling valve of the transformer.
2. Let some quantity of oil to flow into the waste oil drum.
3. Close bottom-sampling valve.
4. Keep the sampling vessel beneath the sampling valve, and now open the bottom-
sampling valve till the sampling vessel is filled. (During filling ensure that no
unnecessary aeration is taking place).
5. After the sampling vessel is filled, the sampling valve is closed.
6. The oil is ready for testing.

Dielectric Strength Test
1. Obtain the representative sample of oil to be tested as per procedure in document No.11.
2. The test cell may be thoroughly cleaned and dried.
3. Slowly pour the oil over the electrodes. Rinse the test cell thoroughly and pour the oil
into drain.
4. With the help of a clean and dry gauge plate set the gap between the spherical brass
electrodes exactly 2.5mm.
5. Place the test cell in the correct position in the oil test kit.
6. Pour the oil over the electrodes slowly without allowing mush air bubbles to form.
- 68 -
7. Fill up the test cell with oil such that the level of the oil is above 40mm above the
electrodes.
8. With clean and dry glass rod the gas bubbles in the oil should be cleared. This is to
ensure that the no void is present in the oil.
9. The cover (with glass window for viewing) shall be closed (normally test equipment
fabricated as per ISS will have an interlock that, only when the cover is closed, we will
be able to energise the equipment.)
10. The oil should be allowed to settle for 10 minutes.
11. Check whether the equipment has been properly connected to earth.
12. Energise the test equipment.
13. Raise the voltage slowly till the breakdown occurs.
14. When the voltage is being raised see through the glass window for any arcing.
(In many design of the test equipment, whenever arcing accompanied by a break down
occurs, the voltmeter needle drops to zero. To know the voltage at which the breakdown
occurs, there is a provision of a Memory Switch. By pressing the memory switch one
will be able to know the voltage at which the break down has occurred). Ignore the minor
arcing and continue to rise the voltage till the breakdown occurs.
15. Repeat the test for six times and note down the readings.
16. The oil is allowed to settle for atleast 5 minutes. During this time the oil should be gently
stirred with a clean dry glass stick to remove air bubbles and soot particles etc.
17. The mean value of the six BDV values is to be taken as the BDV for the given oil.
18. Note the temperature and record the reading with date and time.

Acidity Test (Field Test)
The procedure adopted to conduct the test consists of pipetting 1.1 ml of oil to be
tested or by means of an unmarked dropper in to a clean dry test tube. Then 1.0 ml of
rectified spirit (ethyl alcohol) is added to the test tube. The contents are gently shaken to
facilitate soluble acids in the oil to be extracted by alcohol. Then 1.0 ml of 0.0085 N sodium
carbonate solution (drops 2) are now added to the oil and alcohol mixture. After shaking the
test tube again, five drops of the universal indicator (potassium hydroxide [KOH]) is added.
- 69 -
The resulting mixture develops a colour depending on pH value of the mixture. The colour
developed is compared with a standard chart, which gives the approximate number ranging
from 0 to 1.0 with an interval of about 0.1
Oils having an acid number of 0 to 0.5 show transition colours from Prussian blue to
yellow, whereas those having as acid number of 0.5 and above show a change from yellow to
vermilion.
The following acidity limit has been adopted for preparation of the Standard chart: -
A. When the acidity is less than 0.2 mg/KOH/g the oil is in good condition.
B. When the acidity is between 0.2 to 0.5 mg/KOH/g no immediate is action needed.
Whenever the transformer falls due for maintenance the oil may be treated.
C. When the acidity is between 0.5 to 1.0 mg/KOH/g the oil should be kept under
observation and oil should be treated as an when any shutdown in the plant is available.
D. When the acidity exceeds 1 mg/KOH/g the oil should be treated or discarded.
--0o0o--
- 70 -

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TRANSFORMER MAINTENANCE

III Transformer Oil 18

The EMF equation for the windings of transformer is given as,

N - Number of turns in primary/secondary

1. Ns > Np, K > 1 is known as step up transformer.

1. Power transformer: It is used for step up or step down the voltage.

2. Autotransformer: It is used for linear voltage variations.

Main generator transformer (GT)

Unit auxiliary transformer (UAT) / Unit service transformer (UST)

Station service transformer (SST) / Station auxiliary transformer (SAT)

Interconnecting transformer/Auto transformer

Functions of tertiary winding,

Stub-end wagon type tank

Conservator or Expansion Chamber and Breather

Synthetic resin bonded paper (SRBP) bushing

Cable Sealing Box

Interfacial tension (IFT)

Table shows physical constants of oil

Sl.No. Property Value

Dielectric dissipation factor (tan)

= VIc (Sin / Cos)

Sediment and precipitable sludge

EXTRACTED FROM ISI: 335 : 1983

Diverter switching operation

1. Solid (Epoxy, “S”

TERMINAL MARKING PLATES AND RATING PLATES

displacement between the windings. These groups are shown in table.

Group no. Phase displacement Clock hour no.

Winding Type of connection Designation

Low Voltage Delta d

Parallel Operation of Transformer

Colour of Nature of fault

Transformers with free air 10 Years

The prescribed limits of dielectric strength are as follows:

Rating Fresh oil Oil in

Buchholz Relay (REF. FIG.5.1)

Sl.No. Type of fault Main gases produced

Transformer Troubles and Their Remedies

Sl. Symptom Trouble Cause Remedies

c) Oil c) Oil leakage around c) Stop the leakage,

b) Short b) Breakdown of b) Replace the

d) Shifting of coils d) Replace the coil to

e) Insufficient e) As in (b) above.

f) Electromagnetic f) Tr.is to be returned

g) Tr. Coils not g) Short circuit

h) Lightning h) Repair damaged

i) Insulation roasted i) As in (b) above

c) Ground a) Lightning a) As in(h) above

d) Short Moisture in oil. Remove the terminal

e) Short Bushing broken or Replace bushings.

f) Improper Parallel operation of When banks of

g) LV Ground on HV side of Remove ground, repair

b) Tr. Paralleled has b) Change the winding

Procedure Document No.2

Procedure Document No.3

Aim: To inspect the bushings.

Procedure Document No.4

Aim: To conduct IR Test on a transformer

Machine D.C. Test