Siemens Transformer - O & I Manual

Distribution Transformers
TABLE OF CONTENTS
PREFACE2
PRESERVATION OF ENVIRONMENT..3
PERSONAL SAFETY4
FIREFIGHTING MEASURES....4
IMPORTANT SAFETY INSTRUCTIONS...3
ELECTRICAL SAFETY.5
DISTRIBUTION TRANSFORMERS .................................................................................................. 6
O OVERVIEW ............................................................................................................................ 6
O ACCESSORIES (PURPOSE AND FUNCTIONALITY) ........................................................................ 8
O TRANSFORMER MAINTENANCE .............................................................................................. 19
O FAILURE REPORT FORM ........................................................................................................ 28
1.1. OVERVIEW ............................................................................................................................ 7
1.1.1.GENERAL.......................................................................................................................... 7
1.1.2.CONSTRUCTION ................................................................................................................ 7
1.1.3.TAP CHANGER ................................................................................................................... 7
1.1.4.TRANSPORTATION & LIFTING .............................................................................................. 7
1.1.5.CHECK & ACCEPTANCE ..................................................................................................... 7
1.1.6.COMMISSIONING AND INSTALLATION .................................................................................... 8
1.1.7.ENERGIZING...................................................................................................................... 8
1.2. ACCESSORIES (PURPOSE AND FUNCTIONALITY)........................................................................ 9
1.2.1.BUCHHOLZ RELAY ............................................................................................................. 9
1.2.2.OIL TEMPERATURE INDICATOR ......................................................................................... 11
1.2.3.OIL LEVEL INDICATOR ...................................................................................................... 13
1.2.4.PRESSURE RELIEF DEVICE (PRD) .................................................................................... 14
1.2.5.TAP CHANGER ................................................................................................................ 16
1.2.6.CURRENT TRANSFORMER (CT) AND BUSHING ................................................................... 18
1.2.7.SILICAGEL BREATHER ...................................................................................................... 19
1.2.8.BUSHING TERMINATION, EARTHING AND VENTILATION ....................................................... 20
1.3. TRANSFORMER MAINTENANCE.............................................................................................. 21
O ROUTINE INSPECTION AND MAINTENANCE .............................................................................. 22
O PERIODIC INSPECTION AND MAINTENANCE ............................................................................. 23
O PREVENTIVE MAINTENANCE CHART ..................................................................................................... 24
O TROUBLE SHOOTING ............................................................................................................ 26
1.3.1.ROUTINE INSPECTION AND MAINTENANCE ......................................................................... 22
1.3.2.PERIODIC INSPECTION AND MAINTENANCE ........................................................................ 23
1.3.3.PREVENTIVE MAINTENANCE CHART .................................................................................. 24
1.3.4.TROUBLE SHOOTING........................................................................................................ 26
1.4. TRANSFORMER FAILURE REPORT FORM ................................................................................ 30
1.5. TEST REPORT...................................................................................................................... 34
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TR-Sales 837236 Page 1 / 34 DT Manual.doc
PREFACE
Dear Customer,
Thank you for purchasing transformer from Siemens Pakistan Engg Co. Ltd;
your reliable transformer supplier.
Please througly read this manual before energizing the transformer. The
instructions in red color are very important and must strictly be followed for
ensuring safety of personell and equipment.
These Instructions do not purport to cover all details or variations in

equipment, nor do they provide every possible contingency to be met in
connection with installation, operation, maintenance and trouble shooting.
Should further information be desired or should a particular problem arises
which is not covered sufficiently for the users purpose, the matter should be
referred to the nearest Siemens Transformer Sales Representative or contact
as mentioned below:
Please refer to:
Postal address: Office address: Web Site : www.siemens.com.pk
Manager Sales TR, Manager Sales TR, E-mail :

transformers.pk@siemens.com
Business Unit Transformers, Siemens Pakistan
Engineering UAN : 111 077 088
PTD Division
Co. Ltd. Tel : (021) 2592615-18
Siemens Pakistan Engineering Co.
Ltd. B-72, Estate Avenue, Fax : (021) 2577791
SITE, Karachi
P.O.Box 7158, B-72, S.I.T.E.,
Karachi 75700
Note :
The contents of this manual can be changed without prior notice.
The equipments shown in this manual can differ from those actually installed on the transformer.
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IMPORTANT SAFETY INFORMATION
The following warning and caution notes apply to the operation of this equipment.
Failure to comply with these warnings may result in serious personal injury or
damage to the equipment.
Tank ground (Earthing of Transformer)
The first electrical connection made must be to ground the transformer tank. This
connection is made form the tank ground pad to a permanent low impedance ground.
The tank ground must also be connected to the system ground.
Lifting
Lift the transformer utilizing all the lugs. Use proper spreaders to obtain a vertical lift.
Do not use radiators for lifting or jacking.
Oil level
Oil level must be at the proper level. Check each transformer prior to applying
voltage. Under no circumstances should the transformer be operated when the liquid
level gauge indicates min level.
Bushings
Remove all dirt and foreign material from all the bushings before placing unit in
service.
Make sure that the bushings are absolutely tension free.
PRESERVATON OF ENVIRONMENT
The transformer contains insulating oil. Spilling of oil on ground is to be avoided to
prevent soil contamination. Any leakage of oil must be fixed immediately; any
residues of oil are to be cleaned.
Our Transformers are manufactured to work safely with oil. Under normal operation
the oil will not leak / spill from the transformer, however under following conditions oil
can be spilled on the ground.
Development of a leakage from the transformer / operation of PRD (if fitted)

Replacement of transformer oil
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If the oil is spilled on the ground, following measures are to be taken.

Wear hand gloves and nose mask for personal safety.
If the oil is spilled on the solid ground, it must be wiped with cloth or cotton
waste. The contaminated cloths are to be sealed in plastic bags and handed
over to Municipal Authourity for safe disposal.
If the oil is spilled on soil, then the contaminated sand is to be removed and
collected in bags, which are to be handed over to the Municipal Authourity for
environmentally safe disposal.
If the oil is to be changed, then it is to be ensured that the oil is not spilled on the
ground and necessary measures as mentioned above are to be taken. The replaced
oil must be stored in sealed cans / drums which must be labled for their contents. For
safe disposal either these are to be handed over to authorized dealers or to Municipal
Authourity.
While handling transformer oil the following actions must be ensured.

Oil is not to be drained in Municipal waste.
Oil is not to be burned.
Oil is not to be spilled on ground.
Oil is not to be disposed off in any type of water resource or channel.
PERSONAL SAFETY
Although no special risks are involved in the handling and use of Mineral
Insulating Oils, attention is drawn to the need for personal hygiene (washing of
skin and clothing which has come into contact with oil) by those working with
these products.
First Aid Measures.

Eye Contact
Flush thoroughly with water. If irritation occurs, seek medical
attention.
Skin Contact
Wash contact areas with soap and water. Remove contaminated
clothing. If the clothing is to be disposed seal it in plastic bags
and hand aver to Municipal Authuority for safe disposal.
Launder contaminated clothing before reuse.
Inhalation
Not expected to be a problem. If uncomfortable, seek
medical assistance.
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FIRE-FIGHTING MEASURES
In case of fire always disconnect the transformer from

Incoming and out going circuits.
Extinguishing media.
Only use those types of extinguishers, which are approved for
use on electrical installations such as CO2 type.
ELECTRICAL SAFETY
The minimum safe electrical distance is 1cm per kV this distance must be
observed while working near energized electrical installations.
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DISTRIBUTION TRANSFORMERS
This instruction manual covers a brief description about the energization,

commissioning, operation, routine/preventive maintenance and
precautionary activities for the Distribution transformer.
o Purpose and functionality of the accessories is explained with the

help of pictures.
o Failure report form is included to help the customer to explain the
problem to the manufacturer in detail, in case a fault arises in the
transformer.
o Routine and Preventive maintenance chart is available in the leaflet
for performing maintenance activities at the customer end.
o For on site trouble shooting a Trouble shooting chart is also included
to help the customer to rectify the problems, which can easily be
handled at the site.
Contents:
o Overview
o Accessories (purpose and functionality)
o Transformer Maintenance
o Failure report form
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1.1. Overview
1.1.1. General
This leaflet describes general operation / maintenance of 3-phase two
winding oil immersed distribution transformers with a capacity of 4000
kVA, up to a voltage of 33 kV, manufactured according to IEC / BS
standards
1.1.2. Construction
The transformer is composed of core, coils, oil, tank, bushings, name
plate, off circuit tap changer & other accessories as required by the
customer. Details are mentioned in the dimension drawing.
1.1.3. Tap changer

Tapping switch mounted on tank cover or sidewall is used to adjust the
voltage. Before rotating the tapping switch, ensure that the transformer is
completely isolated from high & low voltage sides. For Tap changer
adjustment according to desired voltage, please refer nameplate
1.1.4. Transportation & Lifting

Take special care in transportation. Tie the transformer with proper rope.
Maintain clearance between two transformers transported on one vehicle.
During transportation, the road condition must also be taken into
consideration & during transportation on slopes, the transformers should
not be tilted more than 15. Never try to lift the transformer other than the
correct fittings (lifting lugs) provided for this purpose.
1.1.5. Check & Acceptance

After receiving the transformer, immediately verify that it is in conformity
with the order contract & according to delivery documents. Also, check for
any external damages & position of the accessories.
Any abnormality must be reported immediately to SIEMENS or its
representative.
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1.1.6. Commissioning and Installation

After installation & before operation it is recommended to perform the
following tests on transformers.
o Visual Inspection
o Oil level
o Oil test
o Resistance measurement
o Insulation resistance
o Turns ratio
o Check the color of silcagel; in case it is pink, replace it.
1.1.7. Energizing
When a transformer is energized for the first time, the tap changer should
be set at nominal voltage. It is adviseable to start running the transformer
at no load. Check for any abnormalities eg. sounds. If no abnormality is
observed then gradually increase the load.
Make sure that the cables / bus bars at HV/LV sides are connected in
such a way that there is no tension (or pulling force) on bushings
Note:-
FOR ANY ABNORMALITY PLEASE CONTACT OUR SALES
DEPARTMENT FOR ASSISTANCE
REPAIR & SERVICE OF TRANSFORMER IS A HIGHLY SKILLED

JOB AND MAY EVEN CAUSE DEATH OF PERSONELL AND
DAMAGE TO EQUIPMENT IF NOT CARRIED OUT BY
PROFESSIONALLY SKILLED STAFF
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1.2. Accessories (purpose and functionality)
1.2.1. Buchholz Relay

Purpose:
Buchholz Relay is the main protection device of the transformer. It is used
to detect:
o Gas formation in the transformer tank (First Alarm and then tripping)
o Sudden flow of oil from tank body towards the conservator (normally
internal flashovers are the causes of oil flow) and Direct Tripping.
Functional Check:
Mostly all of the Buchholz relays are equipped with two Normally Open
(NO) Contacts (see Figure 1). The functional test (continuity) of these
contacts can be performed via a push button available on the relay (see
Figure 3).
o Half press of this button will change the state of Alarm contact from
Normally open (NO) to Normally Close (NC)
o Full press of this button will change the state of Trip contact from
Normally open (NO) to Normally Close (NC) too
Two Normally Open (NO Contacts)
Figure 1
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Before energizing the transformer, the buchholz relay must be subjected to

bleeding (removal of trapped air), which is possible via a bleeding point
(see Figure 2)
Bleeding Point
Figure 2
Transportation and Protection of Contacts:

For the protection of contacts during the transportation of the
transformer, a red colored small rubber piece is provided in the cap over
the functional test push button (see Figure 3). This rubber piece must be
removed before energizing the transformer.
Red colored rubber piece
Functional Test Push

B ut t on
Figure 3
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1.2.2. Oil Temperature Indicator

Purpose:
Oil Temperature Indicator is used to monitor the top oil temperature of the
transformer. Mostly all of the temperature indicators are located on the top
plate. Usually three types of temperature indicators are used.
o Without contacts
o With 2 contacts (First Alarm and then tripping)
o With 4 contacts (First Fan OFF, Second Fan ON, Third Alarm &
Fourth Trip)
Alarm Setting Tab
Trip Setting Tab
Fans ON Setting Tab

Fans OFF Setting Tab
Resetting knob
Indicator showing Temperature of

the oil
Indicator showing Maximum

Temperature reached at any instant
of time
Figure 4
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Functional Check:
Temperature indicators can be checked for the proper functionality of their
contacts (see Figure 4). Mostly all of the contacts are Normally Open (NO)
contacts.
o Sliding the alarm tab below the oil temperature indicator will change
the state of Alarm contact from Normally open (NO) to Normally
Close (NC)
o Sliding the trip tab below the oil temperature indicator will change the
state of Trip contact from Normally open (NO) to Normally Close
(NC)
o For the settings of Alarm and Trip contacts please refer nameplate
data.
o Fans can be switched ON and OFF as per customers requirements.
However, typical settings are:
a- Fans are to be switched OFF at 60 C for hot areas and 70 C for
cold areas
b- Fans are to be switched ON at 70 C for hot areas and 80 C for cold

areas
o The maximum temperature knob can be reset at any time via a knob
available on the indicator (see Figure 4)
Example:
Ambient Temperature : 50 C (From Name Plate)
Oil Temperature : 40 C (From Name Plate)
a- Alarm Setting:
= Ambient Temperature (C) + Oil Temperature (C) - 10(C)
= 50 + 40 10 = 80 (C)
b- Trip Setting:
= Ambient Temperature (C) + Oil Temperature (C)
= 50 + 40 = 90 (C)
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1.2.3. Oil Level Indicator

Purpose:
Oil level indicator is used to monitor the oil level in the conservator. Mostly
all of the oil level indicators are located on the sidewalls of the conservator.
Usually three types of oil level indicators are used in distribution
transformers. These are:
o Visual or Glass-tube type (see Figure 5)
o Magnetic type Without contacts
o Magnetic type With contacts (see Figure 5)
a- Maximum level (MAX) having two contacts (1 NO and 1 NC)
b- Minimum level (MIN) having two contacts (1 NO and 1 NC)
Maximum level display
Oil level indicator
Minimum level display
Chamber containing contacts

of the indicator
Visual or Glass-tube type Magnetic type (with contacts)
Figure 5
Functional Check:
The display is typically labeled with MAX, +20 C and MIN values. In
Magnetic type indicators with contacts, the functionality of the contacts can
be electrically checked by checking their continuity and discontinuity when
their state changes. The level indicator needle can be moved manually to
make or break these contacts.
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1.2.4. Pressure Relief Device (PRD)

Purpose:
Pressure relief device is used to give a relief to the oil pressure built up in
case a short circuit occurs inside the transformer. In the absence of this
device, the dangers of explosion or tank deformation exist. Mostly the
pressure relief device is placed on top plate. The spring type construction
enables the PRD to automatically reset itself as soon as the oil pressure is
released. Usually two types of PRD are used:
o Without contacts (see Figure 6.1)
PRD without contact

shown without PVC
protection cap
Figure 6.1
o With contacts (1 NO contact and 1 NC contact) (see

Figure 6.2). The yellow pointer as shown in the picture needs to be reset
manually.
Yellow pointer is ejected out

in case PRD operates
Chamber containing
contacts of PRD
Figure 6.2 (PRD with contact)

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Functional Check:
The functionality of the contacts can be electrically checked by checking
the continuity and discontinuity of the contacts when their state changes. A
lever as shown in the picture sets the PRD and another lever resets its
contacts to their initial state (see Figure 7).
Lever to set the PRD
Lever to reset the PRD

Figure 7
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1.2.5. Tap Changer

Purpose:
Voltage variations that occurr on high voltage side are regulated by the tapchanger and a
constant voltage is available at the output of the transformer. There are mainly two types
of tapchangers:
o OFF Load tapchangers
o ON Load tapchangers
OPERATION OF TAPCHANGER:
For OFF-Load Tapchanger proper placement and tap selection is very important for
trouble free operation of the transformer. For the tap selection first check the incoming
voltage to the transformer and select the tap position accordingly. Refer nameplate of the
transformer and before tap changing activity it must be ensured that the transformer is
isolated from both incoming and outgoing sides.
Almost all of the tapchangers are operated in the same manner
(see Figure 8),
1. Pull the lever upwards
2. Rotate it to the desired

tap position
3. Push the lever downwards to

its final resting position
NOTE: TAP CHANGER SHOULD BE OPERATED OFF VOLTAGE ONLY. SUBJECT IT

TO REPEATED OPERATIONS THROUGH ALL POSITIONS AT LEAST ONCE A YEAR.
Figure 8
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o First pull the lever upwards,

o Then rotate it to the desired tap position,
o Finally push the lever downwards to its final resting position
For proper operation of ON-load Tap changer please refer operating

manual of the Tapchanger
SAFETY OF TAPCHANGER:
To keep the contacts of the tapchanger in healthy condition it is
recommended to operate the tapchanger on all of its tap positions at least
once a year. Any prolonged operation on a particular tap may cause
carbonization or hot spot formation at the contact.
For ON load tap changers before energizing, bleeding of tapchanger is
necessary (see Figure 9). Secondly, On load tapchangers need preventive
maintenance after a certain number of operations or after a certain length
of time, depending upon the manufacturer and type of the tapchanger
(please refer ON load tapchanger manual for details of preventive
maintenance of the tapchanger).
Bleeding point of the

ON load tapchanger
Figure 9
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1.2.6. Current Transformer (CT) and Bushing

Purpose:
For some particular application, for example transformers with Automatic
Voltage Regulators (AVR) or Winding Temperature Indicator (WTI), current
transformers are installed in distribution transformers.
Connection and Safety of CT:
The secondary circuit of CT, in every case (in use or when not in use),
must be complete. Opening the CT secondary circuit, during operation of
the transformer, is hazardous to the person operating the device and might
damage the CT as well. When intended for use, the CT secondary circuit
must be thoroughly checked and verified by electrical testing. It is
recommended that the CT circuit is checked by secondary current injection
sets. The circuit must be through and in no case should it be open. For the
secondary circuit, one terminal of the CT must be earthed for safety of the
CT.
In case when the CT is not used, all the terminals of the CT must be
shorted together and earthed. The same practice should be adopted for the
CT in case of transformer transportation (see Figure 10)
1. When not in use the CT

secondary terminals must
be properly shPull the
lever upwards
orted and earthed
Bushings with provision of

bleeding, must be subject to
bleeding before energization of
the transformer
Figure 10
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1.2.7. Silicagel Breather

Purpose:
The purpose of silicagel is to absorb moisture during the contraction of oil
in the transformer. During this process, the transformer inhales air from the
atmosphere. The air intake must be moisture free. Absorption of moisture
by the oil will affect (decrease) the dielectric strength of the oil and will
ultimately cause flashover in the transformer. Mostly all types of Breathers
are without any contact.
Window to view the color

of the silicagel
Figure 11
Condition of Silicagel:
Usually blue color shows the healthiness of the silicagel (see
Figure 11). With the passage of time, after moisture absorption, the color of
the silicagel will turn to pink. This shows that the silicagel is exhausted and
needs to be replaced.
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1.2.8. Bushing Termination, Earthing and Ventilation

Bushing Termination:
Termination of HV terminals (bushings) is very important and if proper and
suitable procedures are not adopted then it causes oil leakages from
bushings gaskets / sealings. Normally, either cable terminations are used
or for heavy currents bus bar arrangements are used. For both
arrangements, no tension (axial or radial) should affect the bushings. The
bushings must be absolutely tension free. For bus bars arrangements one
additional care must be taken regarding thermal expansion of the bus bars.
At the time of energiziging, the temperature of the bus bars is the same as
the ambient temperature. However, when the transformer is loaded and the
temperature of its oil increases, the bus bar temperature normally rises as
well. This causes thermal expansion of the bus bars and ultimately exerts
tension on the bushings gasket. Suitable measures should be taken to
avoid the effects of thermal expansion. For this, usually bus bar is cut into
two halves and in-between flexible conducting joints are provided.
Sometimes depending on the weight, length and size (area) of the bus bar,
additional insulators are also provided along the length to support the bus
bars so that weight and thermal expansion effects do not travel to wards
the bushings.
Earthing:
For the safety of equipment itself, the load connected to the transformer
and the personnel, earthing is very important. The transformer must be
earthed at the point where the manufacturer has provided the earthing
termination. Earth resistance must be checked periodically for the
effectiveness of the earthing.
Ventilation:
For transformers that are installed indoor, suitable ventilation must be
provided for heat exhaust.
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1.3. TRANSFORMER MAINTENANCE

The scope of routine and preventive maintenance covers following
activities,
Contents:
o Routine Inspection and Maintenance
o Periodic Inspection and Maintenance
o Preventive Maintenance Chart
o Trouble Shooting
Note:
During operation, transformer is exposed to atmospheric conditions
and electrical and mechanical stresses. In order to ensure
uninterrupted operation, it is necessary to inspect and maintain the
transformer carefully. Inspection and maintenance can be categorized
into routine and periodic inspection and maintenance.
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1.3.1. Routine Inspection and Maintenance
Routine inspection and maintenance can be carried out while the transformer
is online. The following should be considered:
o Paying attention to abnormal noise, irregular vibration, external damages,
color of silicagel and deterioration of paint.
o A record of the readings/recordings from the meters/gauges provided on
the transformer should be maintained and compared with past values.
In case of abnormalities, suitable measures should be taken.
Routine inspection and maintenance should include but not be limited to the
following:
Transformer Temperature : Take and record the reading of oil/winding

temperature indicator
Oil Level : Take and record the reading of oil level indicator
Noise : Check for abnormal sounds
Oil Leakages : Check oil leaks especially on location of valves,

indicators, packing and welded parts
Breather : Pay attention to the color of silicagel.

Replace if color has changed from blue to pink
Tapchanger : Check whether the tap position is correct
Bushings : Check for excessive bushing contamination.
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1.3.2. Periodic Inspection and Maintenance
The period for the inspection is not absolute and is dependent on atmospheric
and operating conditions of each transformer. The recommended period under
normal conditions is one year.
Periodic maintenance and inspection should include but not be limited to the
following (many of these require the transformer to be shut down):
Tank : Check for oil leaks and paint finish
Radiators : Check for oil leaks, paint finish and

contaminations
Bushing : Check for local heating, damages, contamination

and oil leaks
Insulating oil : Check for dielectric strength, carbon sludge,

offensive odor and discoloration
Tapchanger : Refer to relevant annexure.
Dehydrating breather : Check for discoloration of silicagel breather
Indicators1 : Check for proper functioning
NOTE:
IF ANY ABNORMALITY / MALFUNCTIONING / DETERIORATION IS
NOTICED IT SHOULD BE RECTIFIED IMMEDIATELY. DO NOT DELAY
IN ANY CORRECTIVE ACTION.
1
meters, gauges, relays and other devices
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1.3.3. Preventive Maintenance Chart
Duration
S. Time Interval
Work to be carried out of work
No.
hour w2 m3 y4 v5
1- Tank and conservator

1.1 Checking the oil temperature <1 1
1.2 Checking the dehydrating breather <1 1 16
1.3 Checking the oil levels <1 1
Checking the flanged joints and welds for oil
1.4 <1 1
leakage
Checking the paint finish and declining the
1.5 3 6
surface
Checking the earthing systems (protective
1.6 2 1
earthing)
1.7 Oil sampling (for oil analysis) <1 4
3- Cooling system
3.1 Checking the oil temperature <1 1
3.2 Checking the butterfly valves <1 6
3.4 Checking the oil sight pot <1 6
3.5 Checking the fans 2 1
3.6 Checking the coolers (radiators) 8 1
4- Control cubicle and terminal box
4.1 Checking the heating of the control cubicle. <1 6
4.2 Checking the enclosure for water tightness <1 1
5- Bushing
5.1 Checking for oil leaks <1 1

5.2 Checking the porcelain 8 6
5.3 Cleaning the protective spark gaps. <1 2
2
w= week
3
m= month
4
y= year
5
v= variable
6
2 hours, if the desiccant is to be replaced
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6- Current Transformers
6.1 Checking the terminal connections <1 1
6.2 Cleaning the terminal earthing <1 1
7- Monitoring devices
7.1 Checking the Buchholz Relay <1 6
Checking the diverter switch relay and Pressure
7.2 <1 6
relief diaphragm/device
7.3 Checking the thermometers <1 1
7.4 Checking the temperature monitors <1 1
7.7 Checking the oil level indicators <1 1
Checking the pressure relief device on the
7.8 <1 1
transformer tank
7.9 Checking for gas in the Buchholz relay ~1 6
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1.3.4. Trouble Shooting

Protective, monitoring
devices and various Fault Possible Cause Remedial Measures
components
Operation can be continued. However, following tests and examination for fault
analysis should be made as soon as possible.
1- Check oil level, pipes, position of valves
2- Check the electrical connections
3- Check the tripping mechanism of the Buchholz relay
4- Pass part of the gas through the gas analyzer
o Oil loss. 5- Take oil sample (1liter) from tank bottom and check for dielectric strength
o Accumulation of air. 6- Undo all bushing connections and make the following measurements
Buchholz relay- o Gas generation due to 6.1. Measure the insulation resistance between the winding and tank wall
Buchholz relay
alarm inside failure. and between the winding themselves. (Rough guide value: 1 M ohm per
o Violent vibration kV rated voltage)
o False tripping. 6.2. Ratio measurement either by Ratiometer or by applying low voltage to
the HV side
6.3. Measure the DC winding resistance DC
6.4. Measure the no-load current by applying low voltage
7. Compare the result with the certificates of the operating instructions
8. Vent the transformer and put it back into operation when faults cannot be
found or faults have been eliminated
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o Oil loss.
o Violent oil surge due to
inside flasher. o Maintain shutdown status.
Buchholz relay Buchholz relay- o Violent gas generation due o Carry out tests and measurements described under point 1 to 8
tripping to inside failure. o Vent the transformer and put it back into operation when faults cannot be
o Violent vibration. found or faults have been eliminated.
o False tripping.
o Reduce load of the transformer.
Oil temperature
Dial Type thermometer o Put fans or cooling equipment in service.
too high
o Transformer overload or o Clean the cooling equipment.
inadequate cooling. o Check position of butterfly valves.
o Incorrect temperature o Adjustment incorrect temperature setting.
Winding or oil
Thermal Replica adjustment. o Check the thermometer due comparative measurement.
temperature too
o Check the electrical connection and the tripping mechanism.
high.
o Check control device for cooling equipment.
o Check the current transformer and thermometer.
Magnetic oil level Not enough oil. o Check for tightness
Oil level too low.
Indicator (low temperature or oil loss) o Top up oil.
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o High atmospheric humidity o Replacement dehydrating agent

The drying
glass cylinder leaky
crystals turn from
o Moisture in conservator, o Seal pipe leaks; check the oil for moisture content
blue to pink and
pipe leaky, glass cylinder
Dehydrating breather then to white.
leaky
From below
o Glass cylinder burst, o Flush the conservator with dry air or nitrogen.
from the top
maintenance interval too
in general
long.
o Breather inoperable or o Put breather into operation
transformer in service very
Breakdown
long
Electrical break-down voltage too low.
o Leaks in water cooling o Seal or repair coolers
voltage of oil Water content too
system
high.
o Water pressure reducer o Contact manufacturer, dry the oil if necessary
inoperable.
Protective spark gap on Frequent Electric arcing distance no
Adjust the clearance between the arcing horns and screw them tight
bushing operation longer correct
Terminal lugs on Discoloration of o Clear the contact faces.
Poor contact making
bushings control connecting parts o Tighten the screws.
Issue 01-10-2006. Rev-0

o Electrical o Excessive humidity in o Set the cabinet heater to a higher temperature

Apparatus control cabinet
does not
operate
properly.
o Contacts o Water or dust inside the o Seal the cabinet door; fit a dust filter if necessary
Control cabinet
corroded or cabinet
contaminated
o Apparatus o Excessive high o Protect the cabinet against solar irradiation provide for better ventilation.
housing bent. temperature in the cabinet.
o Excessive currents due to o Clean the contacts tighten the screws and check the electrical distances
external flashovers
Earthing line
Earthing connection o Impermissible current o Open up current loops. Only one earthing with a sufficient cross section.
interrupted
loops through multiple
earthing.
Issue 01-10-2006. Rev-0

1.4. Transformer Failure Report Form
Customer Information:
Company :
Site/Location :
Contact Person :
Department :
Address :
Phone : Fax : E-Mail :

Test Object Information:
Manufacturer:
Generator transformer Network transformer Other (Specify Type)
Distribution Transformer Indoor Installation Outdoor Installation
Auto Transformer Two Winding Transformer Three Winding Transformer
1 - phase 3 - phase
Step-up Transformer Step-down Transformer
Serial No.: Year of Manufacturer:
Rated Power (ONAN/ONAF): / (kVA / MVA)
Voltage Ratio: / Vector Group:
A) Fault Description:
B) Fault Details:
1- ALARM :
Oil level Indicator (Tank) Oil level Indicator (OLTC)
Oil Temp Indicator Buchholz Relay (Tank)

2- TRIPPING :
Buchholz Relay (Tank) Protective Relay (OLTC)
Oil level Indicator (Tank) Oil level Indicator (OLTC)
Oil Temperature Indicator Differential
Pressure Relief Device Earth fault
Over load Short circuit
Issue 01-10-2006. Rev 0

2- Fans :
3- CONDITIONS OF ACCESSORIES & COMPONENTS AT THE TIME OF FAULT:
a) Silica gel (Tank & OLTC) : Pink, Blue,
b) Oil Temp ( C) :
c) Tap changer Tap Position / No. of operations : /
d) Gas found : NO YES (state the details below)

Buchholz : YES NO
LV Bushings : YES NO
HV Bushings : YES NO
e) Gas color : Combustible Non-combustible
f) Oil color / Appearance :
C) On Site Tests details (if performed):*
S. No. Test Description Test Performed Test Results
1 Megger (Insulation Resistance) YES NO PASS FAIL

Ratio (TTR) & vector group
2 YES NO PASS FAIL
confirmation
3 Winding Resistance YES NO PASS FAIL
No Load Test (Open circuit test) low
4 YES NO PASS FAIL
voltage
Load Test (Short circuit test) low
5 YES NO PASS FAIL
voltage
6 Dielectric Strength of oil YES NO PASS FAIL
7 Other YES NO PASS FAIL
* Note: Reference for the post fault test results are manufacturer's factory test results and pre-
commissioning test results of the transformer. Please provide a copy of the performed test results separately
for the fault analysis of the transformer
D) Additional Information:
1- Tap Changer & Motor Drive :
Make (OLTC) : Type :
Make (MDU) : Type :
OLTC (Sr. No.): MDU (Sr. No.):
Tap Changer operations :

Tap Changer Servicing History (please specify details) :
Issue 01-10-2006. Rev 0

Quantity :
Operational Details OFF (C) ON (C)
1 Oil Temperature Indicator Settings
3- CT Connection Details :
Connected to external circuit
HV CTs :
.
Short circuited
Terminal grounded : S1 S2
LV CTs : Connected to external circuit .
Short circuited
Terminal grounded : S1 S2
4- Neutral Grounding Details :
Solidly grounded
Grounded by earth-fault neutralizer HV LV
Neutral ungrounded
5- Over Voltage Protection :
Spark Gaps Surge Arresters
Both None
6- Oil Conservator System :
Free Breathing via silica gel breather
Other (to be specified)
E) Operational History:
1- Service age to failure :
< 1 year 1 - 5 years
5 - 10 years 10 - 25 years
25 - 40 years > 40 years

2- Typical loading :
< 0.5 pu 0.5 - 0.8 pu
> 0.8 pu Variable
Not Known
3- Loading immediately prior to failure :
< 0.5 pu 0.5 - 0.8 pu
> 0.8 pu Variable
Not Known
Issue 01-10-2006. Rev 0

F) Remarks (If any):
Stamp (Name / Designation / Department) Signature / Date
Thank you for completing this form. It will assist us in specifying the most
appropriate solution/recommendation for your problem. If any additional
information is available please send in with this form.
Issue 01-10-2006. Rev 0

1.5. Test Reports
Enclosed please find test report of the transformer
Issue 01-10-2006. Rev 0


Siemens Transformer - O & I Manual

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Siemens Transformer - O & I Manual

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Distribution Transformers

Issue 01-10-2006. Rev-0

These Instructions do not purport to cover all details or variations in

Please refer to:

Postal address: Office address: Web Site : www.siemens.com.pk

Manager Sales TR, Manager Sales TR, E-mail :

IMPORTANT SAFETY INFORMATION

Tank ground (Earthing of Transformer)

Development of a leakage from the transformer / operation of PRD (if fitted)

Issue 01-10-2006. Rev-0

If the oil is spilled on the ground, following measures are to be taken.

While handling transformer oil the following actions must be ensured.

First Aid Measures.

Launder contaminated clothing before reuse.

Issue 01-10-2006. Rev-0

In case of fire always disconnect the transformer from

Issue 01-10-2006. Rev-0

This instruction manual covers a brief description about the energization,

o Purpose and functionality of the accessories is explained with the

o Accessories (purpose and functionality)

o Failure report form

Issue 01-10-2006. Rev-0

1.1.3. Tap changer

1.1.4. Transportation & Lifting

1.1.5. Check & Acceptance

Issue 01-10-2006. Rev-0

1.1.6. Commissioning and Installation

REPAIR & SERVICE OF TRANSFORMER IS A HIGHLY SKILLED

Issue 01-10-2006. Rev-0

1.2. Accessories (purpose and functionality)

1.2.1. Buchholz Relay

Two Normally Open (NO Contacts)

Issue 01-10-2006. Rev-0

Before energizing the transformer, the buchholz relay must be subjected to

Transportation and Protection of Contacts:

Red colored rubber piece

Functional Test Push

Issue 01-10-2006. Rev-0

1.2.2. Oil Temperature Indicator

Alarm Setting Tab

Trip Setting Tab

Fans ON Setting Tab

Indicator showing Temperature of

Indicator showing Maximum

Issue 01-10-2006. Rev-0

b- Fans are to be switched ON at 70 C for hot areas and 80 C for cold

Issue 01-10-2006. Rev-0

1.2.3. Oil Level Indicator

Maximum level display

Oil level indicator

Minimum level display

Chamber containing contacts

Issue 01-10-2006. Rev-0

1.2.4. Pressure Relief Device (PRD)

o Without contacts (see Figure 6.1)

PRD without contact

o With contacts (1 NO contact and 1 NC contact) (see

Yellow pointer is ejected out

Figure 6.2 (PRD with contact)

Lever to set the PRD

Lever to reset the PRD

Issue 01-10-2006. Rev-0

1.2.5. Tap Changer