Private Limited

Operation & Maintenance Manual

for

Oil-Cooled Distribution Transformers

Issued: September 2008 Rev: 4

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Guidelines for Packing, Loading & Un-Loading of transformer

PLEASE HANDLE WITH CARE

1. Packing Instructions:

Cover the transformer HV & LV bushing with a soft bubble wrap or

sponge wrap. After that use stretchable polythene around it.

Complete transformer to be covered by cardboard paper in two

layers.

Then apply one layer of air bubble packing paper / thermocol on

complete transformer. Special care should be given to
CORRUGATED FINS, as they can be easily damaged.

Finally cover the complete transformer by stretchable polythene in

multi layer covering.

Complete packed transformer to be fixed on wooden pallet to avoid

transportation damage. Or the transformer bottom should be welded
to the truck / lorry so that it does not move.

2. Loading Instructions:
Keep the packed transformer on wooden pallet & tight it properly
to avoid damage in transit.

Use proper 4 Nos. lifting lug & loading sleeves for loading of
transformer.

4 Nos. L Clamps to be tighten at the four corners of the

transformer bottom to avoid transit damage during
transportation. The transformer bottom may be welded to the
truck / lorry so that it does not move.

3. Unloading Instructions

Unloading of transformer to be done with the help of 4 Nos. of

lifting lugs of transformers with 2 Nos of cross loading sleeves.

During loading & unloading use crane for it & jobs must be in
vertical position at the time of unloading in order to minimize the
chances of damage or any kind of leakage.

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Contents:

I General

II Packaging and Transport

III Handling

IV Installation

V Commissioning

VI Operation and Maintenance

VII Trouble-shooting

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I General
Distribution transformers are getting larger in their capacity to meet increasing power
demand, so emergency or unexpected power outages due to transformer trouble cause
serious loss of production as well as inconvenience. It is therefore essential to assure
trouble-free performance by a well-planned maintenance program. Daily or other regular
periodical inspections will result in the detection of abnormal conditions in transformers and
parts before they cause any more serious trouble. A regular program of inspection should
be established and vigorously implemented for the preventive maintenance of distribution
transformers. This manual describes inspection & maintenance methods to keep Danish
transformers in good condition.

II Packaging and Transportation

Pls refer to 1st sheet for guidelines for packing, loading and unloading.
While receiving the transformers, please check if any transport damage occurred. A
case of damage needs to be reported including digital pictures immediately to
the manufacturer and to insurance.

III Installation
The following list is not exhaustive of the points to take care of Installation:
Consider relevant documents such as GTP and Drawings
The packaging and transportation materials should be removed and the
transformer should be cleaned.
Move the transformer to its place of location.
Also the load per surface needs to be able to carry the weight of the
transformer (weight = see rating plate).
The place for the transformer also needs a ventilation system. This system
needs to be able to dissipate the thermal energy generated by load and no
load losses
A couple of transformer parts might have been packed separately for
transportation, like OTI, WTI, Plug-in bushing connectors, etc. Remove the
packing materials and mount them.

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In case protection enclosures have been delivered, assemble them.

Connect the HV and the LV terminals.
Pay attention to the terminal markings.
Ground the transformer: Earthing at designated transformer areas.

Correct installation of the transformer depends on its location, the visibility of the control
apparatus, the accessibility of the valves and the simplicity of the connections to the mains.
The site, together with the cooling surface of the transformer, provides for efficient cooling.
The following conditions should be met:
(a) Keep the temperature of the transformer as low as possible.
(b) Prevent the stagnation of hot air above the transformer
This means, for distribution transformers in buildings or in metal sub-stations, that:
- Fresh air, preferably from outside, should be provided to give sufficient air
circulation.
- There should be certain minimum free space above and around the transformer

IV Commissioning
The following list is not exhaustive:
Check if all the bolts are tight.
In case a forced cooling system needs to be used, check if the fan motors are
working and if the fan rotates into the right direction.
If necessary adjust the tap position
Working on transformer or in adjacencies only if transformer is off-circuit and
grounded.
Check Connection and control of the earthing conductors.
Megger test to verify that HV to LV and HV or LV to earth resistances are
correct.

V Operation and Maintenance

Operation
For general regulations and conditions of operations please refer to
specifications such as IS 2026, IEC 76, IEC 726 or IEEE 57.12.01.

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During energization of the transformers inrush currents occur. The peak

values of these inrush currents possibly sum up to 10 15 times of the rated
transformer current. Therefore it is necessary to consider this instance during
the adjustment of the transformer protection relay.
Do not switch off the transformer during the inrush event, because very high
over voltages may be excited.
In case the taps need to be changed during operation: de-energize and
ground the transformer before tap changing. For your own safety, please
keep the relevant safety regulations in mind. PLEASE BE CAREFUL IN TAP
CHANGING. ENSURE YOU FOLLOW THE INSTRUCTIONS WRITTEN ON THE
TAP CHANGER (DIFFERENT FOR DIFFERENT TYPES). THE TAP SHOULD HAVE
BEEN COMPLETELY CHANGED TO A POSITION BEFORE ENERGISING THE
TRANSFORMER AGAIN.
For ON LOAD TAP CHANGER, please follow instructions of OLTC Operation
Manual which should have been provided in case of an OLTC Transformer.

Maintenance
The following is a list of routine checks and periodic checks that should be made on
the Oil cooled Transformers:

Routine Inspection to be done once a week

Items Method Action
Oil Read the indication on the Check if the thermometer is functioning
temperature thermometer correctly.

Compare this reading with data If the thermometer is not functioning,

previously obtained. When oil
temperature rise above ambient
temperature is greater than the
normal temperature rise indicated on
the transformer plate, inspect the
thermometer
replace it with a new one.
If the thermometer is functioning
correctly check and note the load
current

Load Current Load current and ambient temperature

should be recorded at the same time
as the oil temperature

Oil level in Read the indication of the oil-level If the oil level is abnormal, adjust it
transformer gauge on the transformer or according to the instructions.
(See Note) conservator.

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Oil leaks Check visually for oil leaks from the
thermometer oil-gauge, flanges, pipes,
transformer tank, etc.,
If oil is leaking from a gasket, tighten
the bolts or replace the gasket.
In the case of oil leaks from welded
parts, apply adhesive material or weld
the leaking part on again.

Abnormal Abnormal or unusual noise should be When any supporters, pipes and other
noise and carefully listened for. parts are vibrating due to loose bolts,
vibration Abnormal vibration can be checked tighten them with a wrench.
comparatively easily by hand.
Appearance
Bolt Connection Confirm tightness of bolts When any loose bolts are found,
tighten them with a wrench.

Discoloration Check visually that all connections are When any connections show signs of
normal, without any discoloration due having been hot, clean and tighten
to local heating. bolts and nuts.

Dust Inspect visually for dust, especially on Clean away dust if it threatens to
radiators. reduce the cooling capacity of
radiators.
Rust Inspect visually for rust, especially on
radiators. Repainting is recommended once every
five years. Anti-rust and final coats of
paint should be applied after rubbing
off rust and old paint.
NOTE: The oil level will vary in accordance with the temperature of the transformer.
The oil level must not be allowed to fall below the specified level even when
the transformer is not being operated in cold weather.

Standard Periodical Inspection Items and frequencies

Inspection items Frequency of Inspection Method Action

Insulation Every 3 years More than 50 m.ohms

resistance between HV-LV, HV-E, & --
LV-E

Oil withstand- Every 3 years Using an oil tester,

Voltage test confirm that Dielectric
strength is more than 30 --
kV / 2.5mm gap

Oil performance When abnormalities are

test detected in the two tests -- --

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above

Oil filtering When abnormalities are Filter the oil, if

detected in the three -- abnormalities are
tests above detected

Inspection of Every 2 years

bushing --

Inspection of Every 6 months Check the discoloration of If more than 2/3rd of the
breather silica gel in the breather silica gel have turned
due to moisture in pink, dry out or replace
breathed air it.

Inspection of Annually
thermometer -- --

Connections Occasionally All external connections Any connection that

to the transformer shows signs of having
should be inspected to been hot should be
see whether they are in thoroughly cleaned and
good condition, free bolted together tightly.
from discoloration that
would indicate hot
connections

General Cleaning and maintenance

Material & Maintenance frequency Remarks
Parts
Porcelain Cleaning should be done periodically.
insulators such The interval will depend on the actual --
as bushings circumstances and conditions at the
site.

Paint Repainting should be done once every First clean the surface to be painted
five years.

Gaskets Expected operating life is at least ten Replace with new gaskets if serious oil
(Cork- years. leaks occur from any gasket.
neoprene)

VI Troubleshooting
As mentioned previously, the primary objective of maintenance is to locate slow
deterioration before they become serious and to minimize the losses caused by failures.
Possible slow deterioration that may lead to failures include the following:

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(a) Transformers are generally designed and manufactured to be sufficiently sturdy both
mechanically and thermally. However, if mechanical shocks are frequently applied to
them, even small distortion may build up to such an extent that turn or layer
insulation breakdown or other winding faults may occur.

(b) Short-circuit current flows continuously, causing local heating, if a defect appears in
the core insulation, that causes a magnetic flux short circuit. When local heating
occurs, the local insulation further deteriorates, rapidly leading to serious trouble.

(c) Transformer insulation deteriorates naturally as time elapses. Abnormal overloading

causes overheating of the insulation, thus acceleration deterioration, and finally
leads to insulation breakdown.

(d) Faulty Accessories, Tank Oil Leakage.

The slow deterioration and eventual failures mentioned above can be detected
through routine inspection and periodic inspection

Failures can be detected by means of abnormal smell, abnormal noise, and changes
in the electrical characteristics of the insulating oil and the insulation resistance of
the transformer itself.

Types of Failure, Check Points, and Causes

Type of failure Check point and cause

High Period required to reach the maximum temperature and ambient temperature
temperature rise Load factor or type of load.
Connection diagram of bank and internal connection tap voltage
Arrangement of bank and cooling.
Temperatures of other transformers connected to the same bank.

Burned coil Date and time of burning, Installation site, Period of use (Immediately after
start of operation, or the total operation period).
Cause of failure : Overload
Lightning
Short circuiting (internal or external)
Others
Colour of transformer oil
Operation of protective devices (primary and secondary)

Local heating Heated point: Load factor or type of load:

Smoke: Discoloration.

Insulation Insulation resistance:

resistance High voltage winding to low voltage winding and tank.
failure Low voltage winding to high voltage winding and tank.
High voltage winding to low voltage winding.

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Temperature and humidity at which measurement is made.

Installation site (indoors or outdoors)
History of the transformer.
Dielectric strength of the insulation oil.

Noise Operating conditions (overload, normal load, No load, dielectric strength test)
Continuous noise, intermittent noise, hums, metallic noise, electric discharge
noise.
Surrounding noise or surrounding conditions, installation sites.
Tap voltage and applied voltage.

Excitation failure Electrical continuities of high and low voltage windings (if possible, include the
measured resistance values)
Excitation failure either during trial or in-service operation.
Whether voltage tap within transformer has been changed or not.
Connection diagram of the bank.

Damaged Portion, extent, and cause of damage.

bushing, Porcelain number of bushing.
terminal or
other
components

Whenever you need further technical advice for failures of the kinds detailed above,
you are requested to give us the information prescribed in Appendix II, with a
complete report.

APPENDIX - I Safety Precautions

Working Condition Safety Precautions

Exterior check Be careful not to approach live parts.

Electrical test and De-energize the transformer by circuit breakers and line
remedial work switches
Ground the line terminals of the transformer.

After inspection Make sure all foreign materials have been completely removed
before closing manhole and energizing.
Remove the grounding wires on the line terminals of the
transformer.
NOTE: When test and remedial work must be carried out under live conditions
for any special reasons, pay careful attention to the live parts to
protect yourself against electrical shock: and oversight will probably
be fatal.

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APPENDIX II
Technical information to be sent to the manufacturer

Whenever you need technical advice for any failures of parts and/or a transformer
itself you are kindly requested to let us know the following technical information:

1. Name of the power station or sub station where the transformer is in service.
2. Serial number and rating of the transformer in trouble
3. Name and type of the parts in trouble.
4. Detailed explanation in case of more severe troubles.
a. Duration and amperes of over current
b. Over voltage and / or surge applied to the transformer
c. Protective relays in operation
d. Load conditions (Voltage, current and power factor)
5. Any other information available about the trouble.
Your cooperation is requested in providing the necessary accurate and detailed
information rapidly, without which quick and appropriate actions for recovery will
be impossible.

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