On Load Tap Changers

On Load Tap
Changers
Topics to be covered
What is tap changer
Types of tap changers
Principle of tap change
Tapping winding arrangements
Tap change operation
Parts of tap changer
Inspection of tap changer
Maintenance of tap changer
What is tap changer?
An equipment used for voltage
regulation of transformers in energy
net works and industrial applications.
By changing tapping on a winding, it
varies the turns ratio and hence the out
put voltage.
Types of Tap Changers
Based on application
Off-Circuit tap changer
On Load Tap Changer (OLTC)
Based on mounting (for OLTC)

Internal
External
Internally Mounted OLTC
Externally mounted OLTC/1
Externally mounted OLTC/2
Types of Tap Changers
Based on function
Constant Flux Voltage Variation (CFVV)
Variable Flux Voltage Variation (VFVV)
Combination of above both
Based of method of tap change
Linear
Reversing
Coarse Fine
Bridging
Principles of Tap Change
Constant Flux Voltage Variation (CFVV)
Variable Flux Voltage Variation (VFVV)

Principles of Tap Change
Constant Flux Voltage Variation Variable Flux Voltage Variation

Tap Changer Location
Neutral End
Middle of the Winding
Line End
Tap Changer Location
Neutral End Middle of winding Line End

Tapping Winding Arrangements
Linear
Reversing
Coarse-Fine
Linear Reversing Coarse Fine
Basic conditions of operation
Load current must not be interrupted during
tap change operation.
Tap change must occur without short-
circuiting the tap winding directly.
Positive change of tap position.
It means make-before-break mechanism to be
used. This calls for a transition impedance.
Also the mechanism should be fast acting type
spring loaded.
General Design considerations
Capable to normal load/overloads on
transformer.
Maximum system voltage
Step voltage & no. of steps
Test voltage to earth and across tapping
range
Maximum surge voltage to earth and across
range.
Maximum test voltages between phases
(where applicable)
Current rating normal and overload
Parts of Tap Changer
Selector switch
Tap selection takes place in this switch
Diverter Switch
Make before-break mechanism with
transition impedance. Arcing takes place
and hence housed in a separate
compartment.
Surge relay
Conservator with oil level gauge.
Transition Impedance
Reactor type
Resistor type
Requirements of Transition
Impedance
No voltage fluctuations during
switching cycle
Circulating currents should not be
excessive
Duration of arc should be minimum
to minimize contact erosion and
reduce contamination of oil.
TAP CHANGER CONTROLS
Manual / Electrical
Local / Remote
Manual / Automatic
Independent Operation
Parallel Operation
Group Control
Master
Follower
Principle of Tap changer operation
8
7
6 5
4 3
1
2
R2 R1
M2 T2 T1 M1
N
1 2 3
M2 T2 T1 M1 M2 T2 T1 M1 M2 T2 T1 M1
M2 T2 T1 M1 M2 T2 T1 M1 M2 T2 T1 M1
4 5 6
Parts of Tap Changer
Motor drive mechanism
Should rotate in both the directions
Step-by-step operation
Tap change in progress indication
Tap change complete indication
Sequence contact
Remote Tap position control & indication
Tap Changer Head Cover
Diverter Switch
Transition Resistance
Blow-up view of
Diverter Switch
Inspection
Intervals
Inspection Intervals
Inspection can be done in one day.
Recommended to call OLTC manufacturer
at least first time.
Table gives number of tap change operations
determining inspection intervals
Regardless of number of operations, inspect
after 4 years if the operating voltage is 220
KV and 6-7 years if <220KV
Inspection Intervals
Tap selectors are generally maintenance-free.
For industrial transformers where no. of
operations are very high, inspect after about
1,000,000 operations.
Diverter switch unit to be replaced after
about 800,000 operations.
If no. of operations/year is >15000, use oil
filter for the diverter unit. This increases the
life by removing most of abrasive particles
responsible for mechanical wear.
Summary of inspection work
Withdrawing and reinstalling diverter unit
Cleaning diverter oil switch compartment and
diverter switch unit and OLTC conservator.
Changing the diverter oil.
Determining contact wear
Measuring transition resistors
Checking protective relay.
Diverter should not be exposed to air for
more than 10 hours
Tap Changer Oil Quality
Standard values for transformer oil testing according to
CIGRE 12 13 (1982) apply to tap changer oil at
service temperature.
Use of tap changer Water content Dielectric strength
At neutral point of < 40 ppm > 30 KV

windings
At positions other < 30 ppm > 40 KV
than neutral end
Maintenance of Tap Changers
Sl Check Periodicity Action
No
1 Diverter oil Manufacturers Process/replace oil
recommendation
2 Diverter contacts - DO - Replace if badly
pitting & contact pitted & inform
pressure manufacturer if
pressure is less
3 Oil surge relay Half-yearly Rectify/replace
healthiness
4 Selector contacts & Manufacturers Replace/inform
pressure recommendation manufacturer
OLTC Faults
Mechanical: Related to drive
mechanism, shafts, springs etc
Electrical: Related to drive mechanism,

contact wear and tear, dielectric
failures, etc
Thermal: Burning of diverter contacts

On Load Tap Changers

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On Load Tap Changers

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On Load Tap

Based on mounting (for OLTC)

Variable Flux Voltage Variation (VFVV)

Constant Flux Voltage Variation Variable Flux Voltage Variation

Neutral End Middle of winding Line End

Use of tap changer Water content Dielectric strength

At neutral point of < 40 ppm > 30 KV

Electrical: Related to drive mechanism,

Thermal: Burning of diverter contacts

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