Condition Monitoring Documentation

CONDITION MONITORING OF POWER TRANSFORMERS
CONDITION MONITORING OF POWER TRANSFORMER
CONTENTS
Page No
CHAPTER-I
1.1INTRODUCTION TO APGENCO
1.2 INTRODUCTION TO KTPS
1.3 GENERAL LAYOUT
1.4 BASIC OPERATION
1.5 BASIC EQUIPMENTS
CHAPTER-II
TRANSFORMERS
2.1 INTRODUCTION TO TRANSFORMER
12
2.2 WORKING PRINCIPLE OF TRANSFORMER
13
2.3 DIFFERENT PARTS OF TRANSFORMER
13
2.4 TYPES OF TRANSFORMERS
20
2.5 FAULTS AND FAILURES OF TRANSFORMER
23
2.6 TRANSFORMER LOSSES
25
CHAPTER-III
CONDITION MONITORING OF POWER TRANSFORMER

3.1 INTRODUCTION
3.2 TRANSFORMER ASSESMENT
3.3 CRITICAL COMPONENTS
3.4 TYPES MAJOR FAILURES
27
28
29
30
DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING

ANNAMACHARYA INSTITUTE OF TECHNOLOGY & SCIENCES
page 1

CHAPTER-IV
TRANSFORMER TESTS
4.1 INTRODUCTION
4.2 WINDING RESISTANCE MEASUREMENTS
4.3 CAPACITANCE AND TAN FOR WINDING
4.4 INSULATION RESISTANCE(IR) AND POLARIZATION INDEX
32
32
33
34
CHAPTER-V
DISSOLVED GAS ANALYSIS
5.1 INTRODUCTION
36
CHAPTER VI
TROUBLE SHOOTING CHART FOR ALL TRANSFORMERS
37
CHAPTER VII
CASE STUDIES
43
CONCLUSION
46
BIBOLOGRAPHY
47

page 2
CHAPTER.I
BRIEF HISTORY OF KOTHAGUDEM THERMAL
POWER STATION:
1.1 INTRODUCTION TO APGENCO:
Andhra
Pradesh
Power
Generation
Corporation
Limited
(APGENCO) is the electricity generation company of the Government of Andhra

Pradesh found in the year 1998 as a part of the network of APSEB (Andhra
Pradesh State Electricity Board) in India. It has an installed capacity of
7048.4 MW which makes it the third largest power generation company in India.
Andhra Pradesh Power Generation Corporation Limited is one of the pivotal
organizations of Andhra Pradesh, engaged in the business of Power generation.
Apart from operation & Maintenance of the power plants it has undertaken the
execution of the ongoing & new power projects scheduled under capacity
addition programme and is taking up renovation & modernization works of the
old power stations.
APGENCO came into existence on 28.12.1998 and commenced operations
from 01.02.1999. This was a sequel to Governments reforms in Power Sector to
unbundle the activities relating to Generation, Transmission and Distribution of
Power. All the Generating Stations owned by erstwhile APSEB were transferred to
the control of APGENCO. The installed capacity of APGENCO as on September 30,
2010 is 8135.9 MW comprising 4382.50 MW Thermal, 3751.40 MW Hydro and
2 MW Wind power stations, and contributes about half the total Energy
Requirement
of
Andhra
Pradesh.
APGENCO
is
third
largest
power
generating utility in the Country next to NTPC and Maharashtra. It's installed
Hydro capacity of 3703.4 MW is the second highest among the Country.
Types of power plants APGENCO operates:

Source Installed Capacity (MW)
Thermal
Hydel
4382.5 MW
3751.40 MW

page 3

Wind
2.00 MW
Table1.1: Statistical Information Regarding Different

Thermal Power Plants Operating Under APGENCO:
Power
Station
Operat
or
Location
District
Unit
Wise
capacit
y
Installe Plant
d
Coordinates
capacit
y
Ramagund
am
B thermal
Power
Station
APGENC
O
Ramagunda
m
karimnag
ar
162.5
62.5
184331N7930
47E
Kothagud
em
Thermal
Power
Station
APGENC
O
Paloncha
Khamma
m
460,
4120
720
173718N804
1,15E
Kothagud
em
Thermal
Power
Station
V&IV
Stage
APGENC
O
Paloncha
Khamma
m
2250
1500
500
500
173724N804
2060E
Dr Narla
Tatarao
TPS
APGENC
O
Ibrahinpatn
am
Krishna
6210,
1500
1760
163558N8032
12E
Rayalasee
ma
Thermal
Power
Station
APGENC
O
Cuddapah
YSR
4210
840
144214N7827
29E

page 4

Kakatiya
Thermal
Power
APGENC
O
Chelpur
Warangal
1500
500
182302N7949
42E
1.2 ABOUT KTPS:

Electricity is being produced at thermal, nuclear, hydel generating stations.
Kothagudem
thermal power station is one of the major power generating stations of the Andhra Pradesh. The main
raw material is coal is supplied by singereni collieries, Kothagudem and a water source is from
kinnerasani project, which is about 12kms. From paloncha.
For the power generation with 2x110 MW and 3x210 MW of K.T.P.S. authorities are
required to be operative to active full operation. The auxiliaries are basically operation either on L.T.
System i.e. 415 V 3 power supply is made available to the system after providing the station
transformer of 3x50 MVA capacity with voltage 220 KV/ 7.2/7.2 KV & different service transformers
of capacity 1.0 MVA, 1.5 MVA, 2.0 MVA, which are located near the load centre as the transformer
having the voltage of 6.6 KV /415 V. The 6.6 KV power is distributed through 6.6 KV interconnected
Bus System for all the five units with a control through DC of 220 V.
The 415 V power supply is done through a L.T. SWGR (Switchgear) which are
located nearby the distribution transformer as well as the load centers. The all in -comers, which are
breaker controlled , are having the control the L.T. SWGR are having the control system on 110/ 220
V AC. The 6.6 KV power supply which are either MOCB (Minimum Oil Circuit Breaker) of JYOTI
MAKE or Air Circuit Breakers.
The 6.6 KV power supply to various draining equipments i.e. more is made through
breakers which are either MOCB of jyothi make air circuit breaker which are either of voltage makers
as well as SF 6 of NGEF make. The LT supply is also controlled through air break circuit breaker
which are either L&T make or English Electric Company of India. The various H.T. motors are
switched on / started through on direct ON line (DOL) in order to inverse the availability of
equipment at full efficiency without time gap.
Further , the 6.6 KV system which is normally in delta configuration and terms as an
unearthed system so also to keep the running motor complete in operating condition in case of any
one .phase of motor winding is earthed due to any one reason. Earthling is detected by an protection
system with alarm facility to take remedial measures immediately and at the same time to maintain
page 5

the generation level in the same condition, prior to occurring the earth fault the single phase earth
fault is detected in due course till the motor is not earthed to other or another phase.
Soot Blowers are there in the boiler area on the furnace side or Zone which helps in
blowing the soot / ash deposition regularly of the furnace wall / economizer tubes to keep heat transfer
at the required parameter.
In April 1973, Central Electricity Authority prepared a Project Report for power
station comprising of the two units of each of capacity 110 MW for RSEB subsequently in September,
1975 this was revised by the Consultant Thermal Design Organization , Central Electricity Authority
for invention of 2x110 MW units being manufactured by BHEL, Hyderabad in 1 st Stage.
The planning commission cleared the project report in Sept., 1976 for installation of
two units each of 110 MW in first estimated cost of Rs. 143 Chores
Table 1.2: total installed capacity:

NAME
NOOF UNITS
Individual capacity
Total capacity
Station A
60 MW
240 MW
Station B
120 MW
240 MW
Station C
120 MW
240 MW
Stage V
250 MW
500 MW
Stage VI
500 MW
500 MW
TOTAL
1720 MW
1.3 General Layout & Basic Idea:

A control system of station basically works on Rankin Cycle. Steam is produced in
Boiler is exported in prime mover and is condensed in condenser to be fed into the boiler again. In
practice of good number of modifications are affected so as to have heat economy and to increase the
thermal efficiency of plant.
The Kothagudem Thermal Power Station is divided into four main circuits:
page 6
Fuel and Ash Circuit.

Air and Gas Circuit.
Feed water and Steam Circuit.
Cooling Water Circuit.

page 7
Objectives
page 8

One of the important objectives of K.T.P.S. is to generate thermal power
efficiently and economically. It is also fulfilling the role of social responsibility
objective by encouraging local small-scale industries, providing employment to
the people of the backward and tribal areas. It has crores of rupees controlling
pollution by installing Electrostatic Precipitators (ESP).
LOCATION:
The Kota Thermal Power Station is ideally on the left bank of Chambal River
at Up Stream of Kota Barrage. The large expanse of water reached by the
barrage provides an efficient direct circulation of cooling system for the power
station. The 220 KV GSS is within km \ from the power station.
LAND:
Land measuring approx. 250 hectares was required for the project in 1976, For disposal of
ash tank very near to power station is acquired which the ash in slurry form is disposed off through
ash and slurry disposal plants.
1.4 BASIC IDEA OF OPERATION:

The basic principle involved is Faradays law of electro-magnetic
induction i.e. whenever a conductor cuts a magnetic flux emf is

page 9

induced across its ends.
The very first thing we need to provide is a conductor cutting magnetic flux.
So this can be done in two basic ways i.e. either the conductor can be moved in
the magnetic field or the field can be varied according to the required emf that is
to be generated. The process we follow here is we rotate the rotor of a generator
in the magnetic field and emf is generator at the stator and this generated emf is
further utilized according to the purpose.
To meet the purpose of rotating the rotor of a generator, the rotating shaft
is in turn connected to a turbine which is made to rotate at a rated speed by an
external energy source. So we need an energy source to rotate the turbine. To
rotate the turbine energy must be transferred from a medium to the turbine so
page 10

that energy from the external source is converted to rotational energy of turbine.
In general to rotate an object which is mounted we need to apply some torque.
To produce torque we need to apply force in the tangential direction. For the
purpose of application of force we chose steam as a medium of transfer. For
hydel plants water is directly allowed from a very great height to collide with the
turbine blades with a great force.
In the same way we need to send the steam with a greater force in turn with a
greater pressure to make the turbine rotate. The basic physics involved in this is
the internal energy and enthalpy of the steam gets converted to mechanical
energy that rotates the turbine.
Our target is to produce steam at a very high pressure. Pressure of the steam
can be increased by various auxiliaries through different mechanisms. So
basically we need to produce steam. For the production of steam water is to be
heated to high temperatures with the help of available fuel. Combustion of fuel is
done and evolved heat is utilized for production of steam.
Total idea is to be implemented in a highly efficient way to balance the finance
and economy. Environmental protection should also be the point of concern
because burning of fuel may evolve gases which are responsible for harmful
effects that distract our ambience.
1.5 BASIC REQUIREMENTS:
Fuel
Water
Heating system
Steam circuit
Regenerating system
Steam turbine
Generator
Transformer
COAL:
Coal India limited owns and operates all the major coal fields in India through its coal
producing subsidiary companies viz. Eastern Coal Fields Limited, Western Coal Fields Limited/Coal
India limited is supply coal from its coal mines of coal producing subsidiaries BCCL, SECL & ECL
to Kota Thermal Power Station through railway wagons. The average distances of SECL, ECL &
BCCL are 800, 950 and 1350 Kms. respectively.
page 11

WATER:
The source of water for power station is reservoir formed by Kota Barrage on the
Chambal River. In case of large capacity plants huge quantities of coal and water is required. The
cost of transporting coal and water is particularly high. Therefore, as far as possible, the plant must be
located near the pit rather than at load centre for load above 200 MW and 375 MW. The
transportation of electrical energy is more economical as compared to the transportation of coal.
The design of steam power station requires wide experience as the subsequent
operation and maintenance are greatly affected by its design. The most efficient design consist of
properly sized component designed to operate safely and conveniently along with its auxiliaries and
installation.
HEATING SYSTEM:
A heating system is a mechanism for maintaining
temperatures at an acceptable level; by using thermal energy within a power

plant.
REGENERATIVE SYSTEM:
It is a designed loop for effective utilization of
energy to increase the efficiency of the process.

In general furnace is meant to produce the steam from water. But total energy
evolved from combustion of coal is excessive for this. So this heat energy from
the furnace is repeatedly utilized wherever necessary through
SUPER HEATER COILS

REHEATER COILS
ECONOMISER
STEAM TURBINE:
To generate EMF the rotor of the generator need to be
rotated which in turn is operated by a shaft which is rotated with the help of
three turbines.
HIGH PREESSURE TURBINE (HP TURBINE)

INTERMEDIATE /MEDIUM PRESSURE TURBINE (IP TURBINE)
LOW PRESSURE TURBINE
Each turbine has its own operating temperature and pressure
GENERATOR:
It converts mechanical energy to electrical energy. As we
have discussed the 3 turbines rotate a single shaft at a rated speed of 3000 RPM.
page 12

This shaft is in turn connected to a TURBO GENERATOR which can generate an
EMF of 11 KV.
TRANSFORMER:
Transformers are static devices used for transferring
power from one circuit to another without change in frequency.

Different types of transformers are used for stepping up and stepping down the
generated voltage either for supplying to the grid or for self utilization.
1.
2.
3.
GENERATOR TRANSFORMER
UNIT AUXILIARY TRANSFORMER
STATION TRANSFORMER
CHAPTER.II
Transformers
page 13

2.1 Introduction:
A transformer is a device with two or more stationary electrical circuits that are conductively
disjointed magnetically coupled by a common time-varying magnetic field. Transformers are static
devices used for transferring power from one circuit to another without change in frequency.
Transformers are basically passive devices for transforming voltage and current. It can raise or lower
the voltage corresponding decrease or increase in current. One of the windings, generally termed as
secondary windings, transforms energy through the principle of mutual inductance and delivers power
to the load. The voltage levels at the primary and the secondary windings are usually different and any
increase or decrease of the secondary voltage is accompanied by corresponding increase or decrease
in current.
Transformers are among the most efficient machines 95% efficiency being common in
lower capacity ranges, while an efficiency of 95% is achievable in high capacity ranges.
Theoretically, there is no upper limit to the power handling capacity; transport constraints,
handling facilities, etc. being the limiting factors. The lower limit is governed by the
allowable no-load losses.
The physical basis of a transformer is mutual induction between two circuits linked by
a common magnetic field. The primary circuit carrying a current has associated with it, as a
manifestation of electrical phenomenon of current flow, a magnetic field in its immediate
vicinity. When the circuit is alternating, the magnetic field at any point in the surrounding
medium will vary in both magnitude and direction I accordance with the change of current
with time. The secondary being in the vicinity the primary circuit will link with some of the
primary magnetic flux produced. With an alternating primary current, and therefore flux, the
changing linkages will produce in secondary winding an emf. The more closely the primary
and the secondary circuits are mutually linked, the more direct becomes the change of energy
between them. Major electrical parameters of a transformer are iron and copper losses,
hysteresis losses, efficiency, regulation. Essentially the chief elements of construction of a
transformer comprise materials for magnetic circuit, terminals, tapping switches, oil as well
as cooling devices.
2.2 Working principle of a transformer:

page 14

The physical basis of a transformer is mutual inductance between two circuits linked by a
common magnetic flux through a path of low reluctance. The two coils named primary and
secondary posses high mutual inductance. If one coil connected to a source of alternating
voltage, alternating flux is set up in laminated core, most of which is linked up with the other
coil in which it produces mutually induced emf according to the faradays law of
electromagnetic induction, ie
E=M*(di/dt)
Where E=induced emf,
M=mutual inductance.
EMF induced in a transformer is given by
the equation
E=4.44 m f N volts, m=BmA
If second circuit is closed, a current flow in it and so electrical energy is transferred entirely
magnetically from the first coil to the second coil.
2.3 Different Parts of transformer:

Core:
The core forms the magnetic circuits of a
transformers. There are two 1) core type and
2) shell type. In core type transformer, the
windings surround a considerable part of core
where as in shell type transformers; the core
surrounds a considerable part of windings. In
both core and shell type transformers, the
individual laminations are cut in the form of
long strips of Ls, Es, Is and the laminations
are butted against each other.
The material used are COLD ROLLED GRAIN ORIENTED ELECTRICAL STEEL SHEETS
(CRGO). CRGO made from ferrous base present maximum magnetisability i.e. permitting high
induction. Iron crystallizes into body centre cubic lattice with the cube edges of lattice pointing in the
page 15

direction of easiest magnetizability and lowest core loss. Grain oriented electrical sheets consists of
silicon-iron alloy, with the crystallites being predominately oriented by the means of a specific
manufacturing process, in such a way as to have four cube edges pointing the rolling direction and
diagonal plain being parallel to the sheets surface. In this way the rolling direction becomes the
direction of maximum magnetic properties direction and approaching the ideal properties of the
individual crystallite. The CRGO has the following properties such as maximum magnetic properties,
minimum specific core loss, low apparent power input, low magnetostriction, high grade surface
insulation, good mechanical processing properties.
Insulating oil:
Insulating oil forms a very significant parts of a transformer insulation system and has the
important function of acting as an electrical insulation as well as coolant to the dissipate heat losses.
This basic raw material for the production of transformer oil is a low viscosity lube termed as
TRANSFORMER OIL BASE STOCK (TOBS) which is normally obtained by fractional distillation
and subsequent treatment of crude petroleum. TOBS is further refined by acid treatment process to
yield transformer oil.
Chemical Properties:
Transformer oil consist of four major generic classes of organic compounds, namely
paraffins, naphthenes, aromatics and olefins. All these are hydrocarbons and hence insulating oil is
called a pure hydrocarbon mineral oil. For good fresh insulating oil, it is desirable to have more of
saturated paraffin, less of aromatic or naphthenes and none of olefins. However, for better stability of
properties, it is necessary to have optimum aromatic or naphthenes hydrocarbons. Such as optimum
balance is carefully struck by a carefully controlled refining process. Depending upon the
predominance, oil is usually termed as of paraffinic base or naphthenic base.
Electrical properties:
Electric strength (Breakdown voltage): BDV is the voltage at which breakdown occurs
between two electrodes when oil is subjected to an electric field 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 material, carbon
particles, perceptible sludge and sediment.

Resistivity (specific resistance): This is the most sensitive property of oil requiring
utmost care for its proper determination. Resistivity in ohm-cm is numerically equivalent to
the resistance between opposite phases of a centimeter cube of liquid. Insulation resistance of
page 16

windings of a transformer is also dependent upon the resistivity of oil. A low value indicates
the presence of moisture and conductive contaminants.

Dielectric dissipation factor (DDF): DDF is numerically equal to sign of the loss angle
(approx. equal to tangent of loss angle for dielectrics) and is a good tool to indicate the quality
of insulation. A high value of DDF is an indication of the presence of contaminations or
deterioration products such as water, oxidation produced.
Table 2.1: Characteristics of oil:

Characteristic
Density at 27c, max
Kinematics viscosity at 27c, max
Interfacial tension at 27c, mini
Flash point, mini
Pour point, max
Neutralization value, max
Corrosive sulphur
Electric strength as received
Electric strength after filtration
Dielectric dissipation factor(tan delta) at
90c, max
Specific resistance at 90c
Specific resistance at 27c
Oxidation stability neutralization value after
oxidation, max
Total sludge after oxidation
Presence of oxidation inhibitor
Water content as received, max
Requirement as per standards

0.89g/cu.cm
27cSt
0.04N/m
140c
-9c
0.03mg KOH/g
Non-corrosive
30KV(rms)
50KV(rms)
0.005
30*10^12ohm cm
500*10^ohm cm
0.4mg KOH/g
0.1%by weight
The oil shall not contain antioxidant
additives
50 ppm by weight
Winding:
The transformer consists of two coils called WINDINGS which are wrapped around a core.
The transformer operates when a source of ac voltage is connected to one of the windings and a load
device is connected to the other. The winding that is connected to the source is called the PRIMARY
WINDING. The winding that is connected to the load is called the SECONDARY WINDING.

page 17
It has more number of turns.
Thickness of the wire is less.
Tapings are taken from this coil

because of low currents.
Low Voltage Coil:
It has less number of turns.
Thickness of the wire is high.
Tapings are not taken from this coil

because of high currents.
High Voltage Coil:
Tap-Changing: There is considerable voltage drop between generating sources and consumers in
modern electricity supply. So transformers provided with number of taps at the ends of the lowcurrent winding i.e. H.V side so that the voltage ratio can be adjusted to suit loading conditions. There
are two types of tap-changers, they are
Off-load Tap- changer

On-load Tap-changer
Off-load Tap-changer: The transformer is normally fitted with a off-load tap changing to obtain
required tap voltage. It can be hand operated by a switch handle mounted in tank. Locking device is
fitted to handle to padlock it on any tap position and also to prevent any unauthorized operation of
switch. The switch mechanism is such that it can be locked only when it is bridging two contacts on
any particular tapping position and cannot be locked in any intermediate position.
It
is important that the transformer should be isolated from the live line before moving the switch.
Operating the switch when the transformer is energized, will damage the switch contacts due to serve
arching between the contacts, and may damage the winding also.
On-load Tap-changer: On-load tap changers are employed to change turn ratio of transformer to
regulate system voltage while the transformer is delivering normal load. With the introduction of onload tap changer , the operating efficiency of electrical system has considerably improved. Now-adays, almost all large transformers are fitted with on-load tap changer. All forms of on-load tap
changing circuit posses impedance, which is introduced to prevent short circuiting of tapping section
page 18

during, tap changer operation. The impedance can be either a resistor or a center tapped reactor. The
on-load tap changer can be classified as two types i.e. resistor type and reactor type.
Conservator:
Conservator is a sort of a drum, mounted on the top of the transformer. A level
indicator is fixed to it.

Conservator is connected through a pipe to the
transformer tank containing oil. This oil
expands and contracts depending upon the
heat produced and so the oil level in the
conservator rises and falls. Pipe connected to
the conservator is left open to the atmosphere
through a breather so that the extra air may go
out or come in.
Breather:
The breather is a box containing calcium chloride or silica gell to absorb moisture of air entering the
conservator as it is a will known fact that the insulating property of the transformer oil is lost if a
small amount of moisture enters in it, so dry air is allowed to pass in through this breather.
Breather should be inspected frequently

especially in a situation where temperature and
humidity changes are considerable and when
transformer is subjected to fluctuating loads.
So long as silica gel is in active stage, it color
is dark blue but as it becomes saturated
moisture, its color changes to pale blue/pink
when it should be reactivated.
valves:
Transformer is equipped with drain cum filter valve at the bottom of the tank and filter
valve at the top of the tank. Valves are fitted with plug/blanking plates to stop the dirt or moisture
entering inside the valve and avoid the contamination of the transformer oil.

page 19

Types of valves:
Plug type
Wheel valve with female screw threads
Wheel valve with flanges
- Up to 500 KVA units

- 501 to 2000 KVA units
- Above 2001 KVA units
Buchholz relay: This relay gas actuated relay which is meant for the protection of oil immersed
transformer from insulation failure, core heating or any type of internal fault which may cause the
heating of coil beyond the specified temperature.
Due to any internal fault, oil is heated up and oil vapour so formed causes either the alarm circuit(for
less fault) or the trip circuit (for severe faults). The relay is situated in the pipe connected between the
transformer and the conservator.
Explosion Vent:
It is also a safety device of a transformer which protects the transformer tank
from the gases induced by any type of short circuit in the transformer.
Temperature gauge:
It is also a
protection device fitted to a transformer to
contacts. The instrument is provided with a

maximum temperature indicator .
indicate the temperature of transformer and

operates the alarm, trip and cooler control

page 20
Radiators: Radiators are commonly used for cooling. ONAN, ONAF and OFAF are the types of
cooling. Radiators consist of elements joined to top and bottom headers.
Elements are made by welding two previously

rolled and pressed thin steel sheets to from a
number of channels or flutes through which oil
flows. These radiators can be either mounted
directly on the transformer tank or in the form
of a bank or connected to tank through pipes.
The surface area available for dissipation heat
is multiplied manifolds by using various
elements in parallel. As oil passes downwards,
either due to natural circulation or force of a
pump in the cooling circuit, heat is carried
away by the surrounding atmosphere air
There are two types of radiators named tank mounted radiators and bank mounted radiators.
The total number of radiators required for the cooling of transformer can be arranged in many
ways. Usually one bank of radiators for 100% capacity is sufficient. However, if desired 2-50% banks
can be formed by dividing number of radiators into two equal parts. But each part is completed with
separate auxiliary cooling equipment like fans and a pump. So if we divide the bank into number of
parts then the auxiliary parts increase and ultimate in increase of cost.
Bushings:
Porcelain insulators and connectors should be
examined for the cracks or other defects.
cleaned at convenient intervals and minutely
Small or narrow cracks are difficult to detect.

page 21

However, they are likely to develop rapidly.
All such bushings should be replaced.
Similarly oil communicating type bushings
top. The cause of any serious loss of oil should
be investigated. In case of any sign of oil
leakage in the bushings, the matter should be
referred to the corresponding company.
2.4 TYPES OF TRANSFORMER:

Depending upon the type of construction used, the transformers are classified into two categories,
they are Core type transformer
Shell type transformer
Core type transformer:

page 22
It has one magnetic path only.
Average length of core is more.
Here area of cross-section is less, so

more turns are required.
On every leg both primary and

secondary windings are there so
leakage flux is less.
It is used for high voltage and less

output.
Most portion of winding is visible so it is easy to insulate and repair.
Shell type transformer:
In this type core encloses the winding,

so the cooling is good for core.
It has two magnetic paths.
Average length of core is less.
Area cross-section is more. So less

turns are required.
It is used for low voltage and high

output.
To reduce losses here the winding is done in PANCAKES-primary, secondary windings are
on the central limb.
Depending upon the cooling medium. The transformers are classified into two types. They are Dry type transformers
Oil filled transformers

page 23

Dry type transformer: These are further classified as air cooled transformers and air blast
transformers. The air cool transformers are of very small output (say 5or 10 KVA) and cooled by
circulation of air. Air blast transformers are cooled by a forced circulation of air through core and
windings. Such transformers are limited to voltages not exceeding 25 KV. These are used in
substations located in thickly populated areas where oil is considered a fire hazard.
Oil filled transformer: in general transformers are of oil-immersed type. The oil used for this
purpose is mineral one which provides better insulation in addition to cooling. These transformers are
further classified as oil immersed natural cooled, oil immersed forced air cooled, oil immersed water
cooled, oil immersed forced oil cooled transformers.
Depending upon the power rating, the transformers are classified into two categories,
they are Distribution Transformers
Power Transformers
Distribution Transformers:
Transformers of rating up to 200KVA , used to step down the
distribution voltage to a standard service voltage are known as distribution transformers. They are
kept in operation all the 24 hours a day whether they are carrying any load or not. They are of the self
cooling type and are almost invariably oil-immersed. Energy is lost in iron losses throughout the day
while the copper losses account for ioss in energy when the transformer is loaded. Therefore
distribution transformers should have their iron losses small as compared to full load(about 50%).
Owing to low iron loss, the distribution transformers have good all-day efficiency. These transformers
should have a good voltage regulation.
Power transformers: The transformers of rating above 200KVA used in generating station and
substations at each end of a power transmission line for stepping up or stepping down the voltage are
known as power transformers. They are put in operation during load hours and disconnected during
light load hours. Therefore, power transformers should be designed to have maximum efficiency at or
near full load. Power transformers are designed to have considerably greater leakage reactance than is
permissible in distribution transformers because in the case of power transformers, voltage regulation
is less important than the current limiting effect of higher leakage reactance. They may be self oil
cooled, forced air cooled or forced water cooled.
2.5 Faults and failures:

page 24

Although failure in transformers is rare, faults do occur and the reasons may be broadly classified
as:
Failure in magnetic circuit

Failure in electric circuit
Failure in dielectric circuit
Failure in structural and mechanical fittings.
Failure in magnetic circuit:

Common causes for this failure are
Breakdown of insulation of core bolt.

High flux density in the core resulting in large magnetizing current increase during
switching.
Failure in electric circuit:

Common causes of this failure are
Presence of sharp edges on conductors.

Drying of a transformer is not carried out properly
If moisture penetrates into the winding insulation
Incorrect pressure on windings resulting in dislodging of turns
Switching, lightening surges producing high voltage at the end turns
Loose connections, bolted joints
Sustained overloads resulting in over heating
Failure in dielectric circuit:

Common causes of this failure are
Moisture entering oil due to breathing

Narrow oil ducts in winding causing insufficient cooling
Sustained overloading resulting in deterioration due to excessive oil temperature
Failure in structural and mechanical fittings:

Common causes of this failure are-

page 25
Inadequate clamping of leads from windings to terminal boards resulting in short
circuit.
Poor welding, leaky fittings cause leakage of oil resulting in overheating.
Improper ventilation causes overheating of oil.
Dos for power transformers:

1. Connect gas cylinder with automatic regulator if transformer is to be stored for long
duration, in order to maintain positive pressure.
2. Fill the oil in the transformer at the earliest opportunity at site and follow storage
instructions. It must be commissioned as soon as possible.
3. Open the equalizing valve between tank and OLTC diverter compartment, whenever
4.
5.
6.
7.
provided, at the time of filling the oil in the tank and close the same during operation.
Clean the oil conservator thoroughly before erecting.
Check the pointers of all gauges for their free movement before erection.
Inspect the painting and if necessary do retouching.
If inspection covers are opened or any gasket joint is tightened, tighten the bolts evenly
with the proper sequence to avoid uneven pressure.

8. Clean the buchholz relay and check the operation of alarm and trip contacts.
9. Check the oil level in oil cup and ensure that the air passages are free in the breather. If
oil is less, make up the oil level.
10. Check the oil in the transformer and OLTC for the dielectric and moisture content, and
take suitable action for restoring the quality of oil.
11. Attend to leakages on the bushing immediately.
12. Check the diaphragm of the relief vent. If cracked or broken, replace it.
13. Remove the air from vent plug of the diverter switch before energizing the transformer.
14. Check the gear box oil level in the tap changer. If less, top up with specified oil.
15. Check the OTI and WTI pockets and replenish the oil, if required.
16. Examine the diverter and selector contacts of tap changer and if found burnt or worn
out, replace the same.
17. Check and thoroughly investigate the transformer whenever any alarm or protection is
operated.
18. Examine the bushing for dirt deposits and coats and clean them periodically.
19. Check all bearings and operating mechanism of the tap changer and lubricate as per
schedule.
20. Keep the wall connected between the conservator of tap changer and its diverter
compartment open, during transformer operation.
Donts for transformer:

1. Do not allow WTI, OTI temperature to exceed 75c during dry out of transformer, and
filter machine temperature beyond 85c.
page 26

2. Do not re-energize the transformer, unless the buchholz gas is analyzed.
3. Do not re-energize the transformer without pre-commissioning checks.
4. Do not energize the transformer, unless the off-circuit tap switch handle is in locked
5.
6.
7.
8.
9.
position.
Do not leave off-circuit tap switch handle unlocked.
Do not leave tertiary terminals unprotected outside the tank.
Do not leave any connection loose.
Do not meddle with the protection circuit.
Do not leave maximum temperature indicating pointer behind the other pointer in OTI
and WTI.
10. Do not change the setting of WTI and OTI alarm and trip frequently.
11. Do not allow oil level in bushings to fall, they must immediately top up.
12. Do not allow conservator oil level to fall below one-fourth level.
13. Do not leave secondary terminals on an unloaded CT open.
2.6 Transformer losses:

In transformer as there is no rotating part, there is no friction and wind age losses. Hence, the only
losses occurring are-
Core losses:
Core losses are caused by alternating flux in the core. These are also called as iron
losses. The iron losses are constant on every load. These losses can be found out by open circuit test
on the transformer. It consist of
Hysteresis losses
Eddy current losses
Hysteresis losses: Each time the magnetic field is reversed, a small amount of energy is lost due the
hysteresis within the core. For a given core material, the loss is proportional to the frequency, and is a
function of the peak flux density to which it is subjected.
Eddy current losses: due to variation in magnetic flux eddy currents are induced on the surface of
iron core which in turn produce heating and therefore reduce the amount of power to the secondary
coil. In order to avoid eddy currents, the core is laminated, made of thin sheets of soft iron. Each sheet
is separated from the next by a layer of insulating varnish.
Copper losses:
These losses are due to resistance of winding and are proportional to (current)^2
or (KVA)^2. These can be obtained experimentally by means of short circuit test.

Copper Loss = I2R
Where I is the current flowing in the conductor and R the resistance of the conductor. With I
in ampere and R in ohms, the calculated power loss is given in watts.

page 27

With high-frequency currents, winding loss is affected by proximity effect and skin effect, and cannot
be calculated as simply. For low-frequency applications, the power lost can be minimized by
employing conductors with a large cross-sectional area, made from low-resistivity metals.
CHAPTER.III
Condition monitoring
3.1 Introduction:
Reliable and quality power is need of the hour for the economic
development of a country. For providing reliable electrical energy, it is very
necessary
to
have
highly
reliable
associated
electrical
equipment.
The
transformer, being a key element in the transmission and distribution of

electrical energy, improving its reliability is of utmost importance. System
abnormalities, loading, switching and ambient condition normally contributes
towards accelerated aging and sudden failure, hence, it is, all the more essential,
to employ continuous monitoring techniques and on-site diagnostics followed by
quality maintenance for having trouble-free and reliable operation with minimum
outage.

page 28
The article, being submitted, shall present a survey of new monitoring and diagnostic
technologies in power transformer for the purpose of condition assessment. Also, life assessment and
extension program for transformer in service will be highlighted. Case studies citing site experiences
of problem faced on transformer in service and various diagnostic tools employed for finding
solutions will be cited.
Insulation monitoring: Insulation is the major component, which plays
an important role in
the life expectancy of the transformer. Transformer life known to us is based on the designed
parameter with respect to normal operation and climate conditions. To determine the performance and
aging of the asset, insulation behavior is a main indicator [1]. Most of the transformers in a system,
around the world are exceeding their designed life. In the absence of insulation assessment, good
number of transformer failed due to insulation problems, before reaching to their designed technical
life.
It is important to investigate the cause(s) of the insulation degradation with respect to age.
Average age of the transformers that failed due to insulation deterioration during the last ten years was
17.8 years [2]. A good number of aged transformers are still performing well, it is vital to monitor the
insulation behavior rather than replacing with new one. Transformer insulation behavior is different
with respect to operation mode, climate (ambient condition) and frequency of subjected faults. Load
growth has influence on the insulation degradation. The insulation degradation trend needs regular
assessment.
An accurate analysis of the insulation can suggest operating condition, de-rating of the
transformer will increase the life expectancy [3, 4]. The unit can be proposed for relocation, subjected
to less stress. Cost effective maintenance strategies can be developed. Insulation aging in transformer
is a complex and irreversible phenomena. To ensure higher reliability and safety, insulation condition
monitoring and trend analysis are of major concern. Insulation trend analysis will conclude type of
failure as well as severity of the fault. This will make easy to understand type of maintenance
required, loading constraints and future management required. The analysis will predict the life
expectancy of the asset. It is significant to recommend insulation assessment for the aged and
suspicious behavior transformers. The overall integrity of the asset can be assessed, with minimum
risk of sudden failure. The environmental risk can be reduced. Effect of aging rate on the life
expectancy can be established. Condition monitoring provides information on the developing
insulation problems and incipient faults [5, 6]. Thus early warning of any abnormality can avert the
catastrophic failure.
Purpose of condition monitoring:
To avoid forced outages

page 29
To minimize failures and optimize the maintenance cost
Monitoring scheme must be:
Simple
Low cost
Without disruption of power
Data must be focused on results to:
Prevent problems
Define the severity of a problem
Provide information to take action
Provide on-line and off-line diagnostics
Enable trending of data
Avoid intrusive maintenance
3.2 TRANSFORMER ASSESSMENT:

Since 1885 transformers (0.15 MVA) are serving the power industry and are being produced
with higher rating (> 2000MVA). Majority of transformer population is serving in many of the
transmission and distribution utilities are 20 to 40 years old. As an example the installed power
transformer (United States) capacity has reduced from 185 GVA (Giga Volt Amperes) to 50 GVA per
year over the past twenty-five years [7].
The average load growth rate observed is approximately 2% [7]. Transformer utilization has
increased by 22% on average, causing oil hot spot temperature to increase by approximately a 48%, at
normal peak load [7, 8]. Due to gradual increase in the temperature, peak load insulation life will be
reduced by a factor of approximately 8 [7, 9]. Economic pressures and factors such as an increasing
proportion of aged power transformers are combining to dictate more efficient plant maintenance
management.
Life assessment is becoming increasingly important as the average age of the asset increases,
due to economic pressures and a relatively low load growth, with fewer major re-development
projects.
A scientific remnant life assessment would be an important tool towards higher reliability of
the system and asset management. After determining the critical indicator responsible for aging as
well as asset technical assessment, the rate of ageing can be reduced by implementing the correct
operational and maintenance strategies. The early and failures due to aging can be effectively
minimized. Better asset management system can be implemented (timely relocation / replacement can
be planned).
page 30
The transformer's condition assessment can be broken down into the

following areas of concern:
Operating performance to design criteria.

Aging of insulating materials due to stress imposed both thermal and electrical.
Chemical deterioration from moisture, oxygen and acidity and other contaminations.
Mechanical strength of the solid insulating and bracing materials.
3.3 Critical Components: Core, windings, insulation oil, bushing and on-load tap-changer
are the main active parts of the transformer insulation chain . The degradation of insulation systems is
accompanied by phenomenon of changing physical parameters or the behavior of insulation systems.
The degradation of insulation systems is a complex physical process. Many parameters act at the
same time thus making the interpretation extremely difficult. The aging process in the oil/cellulose
insulation system under thermal stress and their measurable effects are due to chemical reactions in
the dielectric. The temperature of the oil/paper dielectric is the critical aging parameter to cause
enough change in the mechanical and electrical properties of the material. Apart from high
temperatures, other important parameters affecting the aging of the solid and liquid insulation include
the presence of water and oxygen in the system . The monitoring and assessment of such components
is vital to achieve better reliability of the system. By implementing correct operational and
maintenance strategies the insulation aging/ degradation process can be controlled and the asset life
can be extended effectively. Assets critical component monitoring (strict) is required for the technical
assessment (normal to end of life) to ensure economical and safe operation. Also better asset
management policies can be implemented .
3.4 Types of Major Failures:

Following are the major components, which have a direct bearing on reliability of the
transformers
Winding and electrical circuit,
Core and clamping structure,
Bushings and external connections,
Tap chargers,
Coolers and cooling medium,
Control and supervisory equipment

page 31

The types of failure which occur on transformer are many, one with serious concerns to condition
monitoring techniques are listed below -
Core:
Breakdown in core bolt insulation, core plate insulation or insulation between core and core clamps
leads to circulating currents and usually sparking at the fault. Gases are evolved, which dissolve in oil.
These can be monitored by Dissolved Gas Analysis (DGA).
Windings and Inter-winding Insulation:

Overheating due to poor joints is a common fault in any part of the electrical circuit. Breakdown of
inter-strand insulation results in circulating current causing overheating of insulation and hot spots at
point of fault. This can be a result of winding movement. A turn-to-turn fault produces a similar effect
but with much more energy and can usually be detected and identified. Partial discharge faults can
develop between various parts of the insulation structure as a result of contamination (including
moisture) or due to poor impregnation or overstressing. Over heating of stress shields results in
breakdown and circulating current. A fault between windings and a fault from line-to-ground usually
results in serious damage.
Tanks, Flux shields and Fittings:

The breakdown of insulation between portions of the tank shields or between the shields and tank can
lead to circulating current, which is a function of load current. Circulating current in the tank due to
proximity of heavy current conductors can produce hot spots in the tank and across gasket joints.
Bushings:
Ingress of moisture, loosed/bad joints may lead to failure of bushings.
Deterioration and failure factors:
The factors responsible for failures and accelerated
deterioration are categorized as:
Operating Environment (electrical)

Transient over-voltages, load current, short circuit (fault currents), lightening and switching
surges.
Operating Environment (physical)

Temperature (operating full load with high ambient temperature-humidity index), wind, rain,
seismic and pollution
Operating Time
Time in service and time under abnormal conditions or extreme condition (load variation,
change in thermal stresses).
Number of Operations of Tap-changer

Number of on-load tap-changer operation.
page 32
Vibration Effect
Sound and material fatigue.
Contaminants
Moisture (water content in oil), presence of oxygen and particles in oil.

page 33
CHAPTER.IV
TRANSFORMER TESTS
4.1 INTRODUCTION:
A Transformer is very vital equipment in a power system & its availability, reliability is very
important. The transformer primarily comprises of core, winding, and insulation. The insulation
comprises of solid, liquid and combination of oil and cellulose paper. The condition monitoring of oil
is performed by prescribed tests as below-
Things to be monitored:
Winding resistance measurements

Capacitance and tan for winding
Insulation resistance(IR) and Polarization index(PI) measurement
Oil parameters
Furan Analysis
Degree of polymerization(DP)
Partial Discharge(PD) Measurements
Frequency Response Analysis(FRA)
Recovery voltage measurement(RVM)
Surge comparison test
Dc step voltage measurement
Capacitance and tan for bushings
Dissolved Gas Analysis(DGA)
4.2 Winding Resistance Measurements:

This is nothing but the resistance measurement of the windings by applying a small
d.c. voltage to the winding and measuring the current through the same. The ratio gives the winding
resistance, more commonly feasible with high voltage windings. For low voltage windings a
resistance-bridge method can be used. From the d.c resistance one can get the a.c resistance by
applying skin effect corrections. Winding resistance is measured by using MEGGER.
Megger used:
To measure resistance of windings.

To compare with factory results.
As part of a regular maintenance program.
To help locate the presence of defects in transformers, such as loose connections.
To check the make-before-break operation of on-load tap-changers.

page 34
PURPOSE OF TESTING:
Winding resistance measurements in transformers are of fundamental importance for the following
purposes:
Calculations of the I2R component of conductor losses.

Calculation of winding temperature at the end of a temperature test cycle.
As a base for assessing possible damage in the field.
Increase in resistance indicates:
Loose joints- leads to local hot spots and eventual melting of joints.
Worn out contacts- leads to contact erosion.
4.3 Capacitance and tan for winding:

This test measures and records the capacitance between the high and low voltage windings,
between the high voltage winding and the tank (ground), and between the low voltage winding and
the tank (ground). Changes in these values as the transformer ages and events occur, such as nearby
lightning strikes or through faults, indicate winding deformation and structural problems such as
displaced wedging and winding support.

page 35

Similarly in a Dielectric material when a cavity or deterioration starts, the life of the material
starts deteriorating, as there is a resistance getting added and hence leakage current increases In tan
Delta we find the difference in the angle and periodically note down the pace at which deterioration
takes place.
Measure capacitance and tan of each pair of windings and windings with respect to earth.
Compare with factory results
It indicates healthiness of insulation system-paper, press-board and oil.
Increase in tan indicates :
Deterioration of insulation system.

Contamination.
Moisture absorption.
4.4 Insulation resistance(IR) and Polarization index:

Insulation failure can cause electrical shocks, creating a real hazard to personnel and
machinery. A regular program of testing insulation resistance is strongly recommended to prevent this
danger, as well as to allow timely maintenance and repair work to take place before catastrophic
failure. All new equipment, motors, transformers, switch gears, and wiring should be tested before
being put into service. This test record will be useful for future comparisons in regular maintenance
testing.
Some of the more common causes of insulation failure include excessive heat or cold, moisture,
aging, corrosive atmospheres and vibration. Insulation values are in ohms, and insulation values
change according to temperature. Take all of your readings at 20 C. A general rule is to take 1/2 the
resistance reading for every 10 deg C increase, and double the resistance for every 10 deg C decrease.
For instance, if you measure 10 mega ohms at 30 deg C, a 10 deg increase, your true reading is 5
mega ohms.
Measure the insulation resistance values of each pair and with respect to earth.
Compare with factory results.
To determine gradual decrease in insulation resistance. This provides a means for predicting
future insulation failure.

Lower values indicate poor insulation.
PI: It is ratio of insulation resistance (IR )for 10 minutes to insulation resistance for 1 minute.
Measure PI values of each winding in pairs and with respect to earth.

I t should be 1.5
Table 4.1: range of polarization index
page 36

PI(Ratio of 10 min to 1min)
Less than 1
1.0-1.1
1.1-1.25
1.25-2.0
condition
Dangerous
poor
Questionable
fair

page 37
CHAPTER.V
DISSOLVED GAS ANALYSIS
5.1 INTRODUCTION: Transformers are vital components in both the transmission and
distribution of electrical power. The early detection of incipient faults in transformers is extremely
cost effective by reducing unplanned outages. The most sensitive and reliable technique used for
evaluating the health of oil filled electrical equipment is dissolved gas analysis (DGA). Insulating oils
under abnormal electrical or thermal stresses break down to liberate small quantities of gases. The
qualitative composition of the breakdown gases is dependent upon the type of fault. By means of
dissolved gas analysis (DGA), it is possible to distinguish faults such as partial discharge (corona),
overheating (pyrolysis) and arcing in a great variety of oil-filled equipment. Information from the
analysis of gasses dissolved in insulating oils is valuable in a preventative maintenance program. A
number of
Samples must be taken over a period of time for developing trends.
Data from DGA can provide

Advance warning of developing faults.
A means for conveniently scheduling repairs.
Monitor the rate of fault development
NOTE: A sudden large release of gas will not dissolve in the oil and this will cause the Buchholz
relay to activate.
Transformer insulating oils consists of different hydrogen molecules splitting some of
hydrocarbon bonds occur due to electrical and thermal faults, forming gases
Hydrogen (H2)
Methane(CH4)
Ethane(C2H6)
Ethylene(C2H4)
Acetylene(C2H2)
Low energy faults(like partial discharges) sufficient to split weak H-C bonds result in hydrogen as
main gas.
Higher temperatures are needed for splitting of C-C bonds .Higher temperature results in
Ethane, methane and ethylene at 500C
Acetylene requires temperature 800-1200C
Carbon particles from at 500 to800C as results of arcing in oil or around very hot spots.
CHAPTER.VI
TROUBLE SHOOTING CHART FOR ALL TRANSFORMERS
page 38
Trouble
(1)
Cause
(2)
Remedy
(3)
Over voltage
Change the circuit voltage or transformer

connection to avoid over excitation.
Rise in
Temperature
High Temperatures
Over current
High ambient
temperatures
Insufficient Cooling
If possible, reduce load. Heating can often be

reduced by improving power factor load. Check
parallel circuits for circulating currents which may
be caused by improper rations or impedances. See
Electrical Trouble, below.
Either improve ventilation or relocate transfer in
lower ambient temperature.
Lower liquid level

Sledged oil
If unit is artificially cooled, make sure cooling is

adequate.
Short-circuited core
Fill to proper level.

Use filter press to wash off core and coils. Filter
oil to remove sludge.
Test exciting current and no-load loss. If high,
inspect core and repair.
See Electrical Trouble, below.
Electrical
Troubles
Winding failure
Lightning, short-circuit.
Usually, when a transformer winding fails, the
Overload. Oil of low
transformer is automatically disconnected from the
Directive Foreign
power source by the opening of the supply breaker
Material
of
fuse.
Trouble
(1)
Cause
(2)
Remedy
(3)

page 39

Core failure
Core insulation
Smoke or cooling liquid may be expelled from the
breakdown
case, accompanied by When there is any such
(core, bolts, clamps or
evidence of a winding failure, the transformer
between laminations)
should not be re-energized at full rated voltage,

because this might result in additional internal
damage. Also it would introduce a fire hazard in
transformers.
After disconnection from both source and load, the
following observations and tests are
recommended:
a) External mechanical or electrical damage
to bushings, leads, patheads,
disconnection switches, or other
accessories.
b) Level of insulating liquid in all
compartments.
c) Temperature of insulating liquid whenever
it can be measured.
d) Evidence of leakage of insulating liquid or
sealing compound.
High exciting current
Short-circulated core
Test core loss. If high, it is probably due to a shortcircuited core. Test core insulation. Repair if
damaged. If laminations are welded together, refer
Open core joints
matter to the company.

Core-loss test will show no appreciable increase.
Pound joints together and retighten clamping
structure.
Trouble
(1)
Cause
(2)
Remedy
(3)

page 40
Incorrect voltage
Improper ratio
Change terminal-board connection or ratioadjuster position to give correct

voltage.
Audible internal
arching
Supply voltage
abnormal
Isolated metallic part
Change tap connections or readjust supply voltage.

The source should be immediately determined.
Make certain that all normally
grounded parts are grounded, such as the clamps
and core.
Loose connection
Same as above. Tighten all connections.
Bushing flash over
Mechanical
Troubles.
Low liquid level,

Exposing live parts
Maintain proper liquid level.
Lightning
Provide adequate lightning protection.
Dirty bushings
Clean bushing porcelains, frequency depending on

dirt accumulation.
Foreign materials in
Leakage through
threads. Oval nipples.
screw
Poor threads. Improper
Joints
Filler. Improper
Make tight screw joints or gasket joints.
assembly
Trouble
(1)
Cause
(2)
Remedy
(3)

page 41
Leakage at gaskets
Poor scarped joints
Make tight screw joints or gasket joints
Insufficient or uneven
Compression improper
Preparation of gaskets
and
Gasket surfaces
Leakage in welds
Shipping strains,
Repair leaks in weld
imperfect
Weld
Pressure-relief
Improper assembly.
Replace diaphragm. Inspect inside or pipe for
diaphragm
Mechanical damage
evidence of rust or moisture.

Be sure to dry out transformer if there is a chance
that drops of water may have settled directly on
winding or other vulnerable locations, as oil test
may not always reveal presence of free water.
Pressure-relief
Internal fault in
Check to see that valve between conservator and
diaphragm
conservator transformer
tank is open and that ventilator on conservator is
obstructed oil flow or
not blocked.
breathing.
In gas-seal transformer
Make certain that relief valve functions and that
obstructed pressure
values in discharge
relief value.
line are open.
In sealed transformer
Liquid level should be adjusted to that
liquid level
corresponding with liquid temperature to allow
too high.
ample space for expansion of liquid.
Trouble
(1)
Moisture
Cause
(2)
Improper or insufficient
Remedy
(3)
Make sure that all ventilator openings are free .

page 42

condensation in open
ventilators
type transformer and

air filled
compartments
Moisture
Cracked diaphragm.
condensation in
sealed transformers
See remedies above for cracked and ruptured

diaphragms.
moisture in oil
Filter oil.
Audio noise
Leaky gaskets and joints
Make certain all joints are tight. Tighten loose
parts. In some cases parts may be stressed into
Accessories and external
resonant state. Releasing pressure and shimming
transformer parts are set
will remedy this condition.
giving off loud noise.
Rusting and
Abraded surfaces and
Bare metal of mechanical parts should be covered
deterioration of paint
weathering.
with grease.
Fractured metal are
Unusual strains placed
Cables and bus-bars attached to transformer
porcelain parts of
on terminal connection.
terminals should be adequately supported. In the
finish
bushings
case of heavy leads, flexible connections should be

provided to remove strain on the terminal and
bushing porcelain.
Trouble
(1)
Cause
(2)
Remedy
(3)

page 43
Oil troubles
Condensation in open
Make sure that ventilating openings are
Low dielectric
type transformers from
unobstructed.
strength
improper ventilation.
Broken relief diaphragm
Replace diaphragms.
Leaks around cover
Replace gaskets if necessary.
Leaky cooling oil
Test cooling and repair.
Badly discolored oil.
Contaminated by
Retain oil if dielectric strength is satisfactory.
Varnishes Carbonized
oil due to switching
winding or core failure.
Oxidation (sludge of
Exposure to air
acidity)
wash down core and coils and tank. Filter and

reclaim or replace oil.
High operating
temperature
wash down core and coils and tank. Either

reduce load or improve cooling.
CHAPTER.VII
CASE STUDIES
CASE STUDY 1:
1. 125MVA, 11kv/ 220 kv , 50Hz, 3 generator transformer:
Sl . No.
: 6002681

page 44

Make
: Heavy Electricals (INDIA) Ltd, Bhopal
Year of manufacture
: 1973
Oil Temp.
: 28C
Winding Temp.
: 28C
Ambient Temp.
: 28C
Date of test
: 11.10.2010 & 12.10.2010
ANALYSIS:
HV& LV Windings:
Results of IR,PI and Tan test obtained on the generator transformer are presented below;
Table 6.1: case study of generator transformer:
Insulation section
Insulation resistance
60 sec (G)
Polarization index
Tan (%)
@10 KV
HV vs LV connected to
grounded tank
1.72
2.24
0.249
HV vs LV ungrounded
1.76
2.83
0.243
LV vs HV connected to
grounded tank
1.19
3.23
0.248
The IR and PI values obtained are in the normal acceptable range. The PI is regarded as index of
dryness of the insulation system. For a good, healthy and dry paper-oil insulation system the PI
shall be higher than 1.5.
The Tan test values obtained on three insulation sections of the transformer are low and lie in
the normal permissible range. These results indicated low dielectric losses in the transformer
insulation system. Typical values of Tan for a new transformer are 0.5%. the maximum
permissible value of Tan for an in-service and aged transformer is 2%.
CASE STUDY FOR DGA:

page 45

2. 750KVA, 11KV/ 433V, 50HZ failed transformer:
Commissioning & filtration date of analysis
3.11.1999
TGC
8.45
CH4
237
C2H6
54
C2H4
588
C2H2
2961
H2
1982
CO2
1548
Observation:
DGA indicates that the failure was due to severe arcing in the transformer.
CASE STUDY 3:
3. 20MVA POWER TRNASFORMER
ROUTINE MAINTAINCE
TGC
6.90

page 46

CH4
53
C2H6
C2H4
28
C2H2
437
H2
140
CO2
1125
Observation: Rogerss ratio (0011) indicates arc with persistent sparking, IEC ratio (202) indicates
continuous sparking in oil.
CONCLUSION
In the conditional monitoring, we test the transformer for reliability of the equipment and also to
avoid the forced outage. If faults are found to be occurring outages can be planned and the fault can
be rectified before major occur. With strict monitoring, accurate diagnostics interpretations and
realistic operational/ maintenance
Strategies implementation the following would be achieved effectively:

page 47

Asset economic loading conditions identification and assessment for maximum practicable operating
efficiency.
Premature failures risk minimization.
Remnant life estimation and timely asset replacement/ retiring planning.
Asset life extension by implementing correct operational and cost effective maintenance strategies
Improvement in the system performance ensuring good reliability as well as plant availability.
Minimization of the long-term operational cost.
Cost saving by eliminating the unplanned maintenance.
Minimizing the outage period.
Relocation/ retirement planning.
In time procurement of spare parts to get
BIBOLOGRAPHY
Hand Book Of Transformers, BHEL, Tata McGraw Hill

Basic Electrical Engineering by M.L.Anwani
Electrical Technology by B.L.Theraja
Electrical Machines by J.B.Guptha
Electrical Machines by P.S.Bhimbra
page 48

page 49

Condition Monitoring Documentation

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CONDITION MONITORING OF POWER TRANSFORMERS

CONDITION MONITORING OF POWER TRANSFORMER

1.2 INTRODUCTION TO KTPS

1.3 GENERAL LAYOUT

1.4 BASIC OPERATION

1.5 BASIC EQUIPMENTS

2.2 WORKING PRINCIPLE OF TRANSFORMER

2.3 DIFFERENT PARTS OF TRANSFORMER

2.4 TYPES OF TRANSFORMERS

2.5 FAULTS AND FAILURES OF TRANSFORMER

2.6 TRANSFORMER LOSSES

CONDITION MONITORING OF POWER TRANSFORMER

DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING

CONDITION MONITORING OF POWER TRANSFORMERS

DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING

CONDITION MONITORING OF POWER TRANSFORMERS

(APGENCO) is the electricity generation company of the Government of Andhra

Types of power plants APGENCO operates:

DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING

CONDITION MONITORING OF POWER TRANSFORMERS

Table1.1: Statistical Information Regarding Different

DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING

CONDITION MONITORING OF POWER TRANSFORMERS

1.2 ABOUT KTPS:

CONDITION MONITORING OF POWER TRANSFORMERS

Table 1.2: total installed capacity:

1.3 General Layout & Basic Idea:

CONDITION MONITORING OF POWER TRANSFORMERS

Fuel and Ash Circuit.

DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING

CONDITION MONITORING OF POWER TRANSFORMERS

CONDITION MONITORING OF POWER TRANSFORMERS

1.4 BASIC IDEA OF OPERATION:

DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING

CONDITION MONITORING OF POWER TRANSFORMERS

CONDITION MONITORING OF POWER TRANSFORMERS

1.5 BASIC REQUIREMENTS:

CONDITION MONITORING OF POWER TRANSFORMERS

A heating system is a mechanism for maintaining

temperatures at an acceptable level; by using thermal energy within a power

It is a designed loop for effective utilization of

energy to increase the efficiency of the process.

SUPER HEATER COILS

To generate EMF the rotor of the generator need to be

HIGH PREESSURE TURBINE (HP TURBINE)

Each turbine has its own operating temperature and pressure

It converts mechanical energy to electrical energy. As we

CONDITION MONITORING OF POWER TRANSFORMERS

Transformers are static devices used for transferring

power from one circuit to another without change in frequency.

CONDITION MONITORING OF POWER TRANSFORMERS

2.2 Working principle of a transformer:

CONDITION MONITORING OF POWER TRANSFORMERS

2.3 Different Parts of transformer:

CONDITION MONITORING OF POWER TRANSFORMERS

particles, perceptible sludge and sediment.

CONDITION MONITORING OF POWER TRANSFORMERS

the presence of moisture and conductive contaminants.

Table 2.1: Characteristics of oil:

Requirement as per standards

DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING

CONDITION MONITORING OF POWER TRANSFORMERS