Instruction Manual For Power Transformers

INSTALLATION, COMMISSIONING,
OPERATION AND MAINTENANCE

MANUAL
FOR
TRANSFORMERS
INDO TECH TRANSFORMERS LIMITED,

P.O. Rajakulam,
KM 64, Chennai Bangalore Highway,
Kancheepuram Dist., Tamil Nadu – 631561
Our Customer Service Mail ID: services@Prolec-GEIndia.com

Customer Service Contact No.: 044-30289843

Installation, Operation and Maintenance Manual
Power Transformers
CONTENTS
Section Description Page

1 Health and Safety Aspects 3
2 General Construction 16
3 Packing & Despatch 22
4 Receipt & Storage at Site 31
5 Installation 40
6 Insulation Dry out at Site 60
7 Commissioning 64
8 Operation 69
9 Maintenance 72
10 Trouble Shooting 79
11 Check Lists 92
12 Reference Standards 118
13 Transformer Accessories: 122
(a) Temperature Indicator 123
(b) Gas & Oil Operated Relays 132
(c) Condenser Type OIP Bushings 145
(d) Silica Gel Breather 157
(e) Oil Level Indicator 161
(f) Pressure Relief Device 166
(g) Exhaust Fan 171
14 Appendix 176
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
Rev. 1: General revision of entire document ITTL/TM/1103

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Power Transformers
SECTION - 1
HEALTH & SAFETY ASPECTS

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Power Transformers
INTRODUCTION
PROLEC GE transformers are designed and manufactured with the highest
quality standards to provide efficient, reliable and long lasting service.
In order to achieve the intended performance of the transformer, the following
aspects should be taken care:
 Appropriate protective schemes MUST be provided on both Primary &

Secondary sides of the transformer as recommended in the “CBIP Manual on
Transformers (Oil Immersed): Publication No. 295 (Revised) - Section M”.
 The transformer shall be installed in a location suitable for its designed
purpose.
 The installation is done by qualified and competent persons.
 The installed equipment is operated and maintained in accordance with the
manufacturer's instructions by qualified and competent persons familiar with the
type of equipment involved and its working environment.
 Work is done competently and in accordance with good engineering practices
and in a manner, which is not hazardous either to personnel or to equipment.
 The recommended pre-commissioning checks are done before energising the
transformer.
 The operation of protective systems and devices for the transformer are
checked regularly.
 Neglect or deliberate overriding of protection system or device could allow a
minor problem to develop into a major problem resulting in total loss of the
transformer, damage to other equipment and injury to personnel.
 Prolonged operation under over load, over voltage or over excitation condition
can have a seriously detrimental effect on the life of equipment.
 The pressure relief devices are designed to eject liquid, which is likely to be
very hot in the event of a fault developing within the transformer.
 Equipment such as pressure relief devices incorporates heavy springs in
compression. If the equipment is dismantled without due safeguard, damage
and /or injury may result.
 The internal atmosphere of a transformer tank, if N2 filled, is replaced by
breathable dry air of dew point less than –60OC for a minimum period of twenty
four hours.
This manual does not intend to cover all possible contingencies during
installation, operation or maintenance, and all details or variations of this
equipment. For further information, contact service department of PROLEC GE
India.
In this manual, checklists for receiving, storage, internal inspection, erection, pre-
commissioning and site test results and maintenance inspection have been
provided to assure the proper execution of the entire transformer related
activities. In order to maintain the agreed upon warranty, these checklists must
be filled out accordingly and sent to service department of PROLEC GE India.

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Power Transformers
1.0 GENERAL PRECAUTIONS

The purpose of this manual is to guide the user on Installation, Commissioning,
Operation and Maintenance of Transformers manufactured and supplied by
INDO TECH TRANSFORMERS LIMITED (with PROLEC GE Brand name).
If proper care is exercised in the installation, operation, maintenance and
condition monitoring of the transformer, it can give the user trouble free service
throughout the expected life of equipment which is of the order of 25~35 years.
Hence, it is very essential that the personnel associated with the installation,
operation or maintenance of the transformer are thorough with the instructions
provided in this manual.
This Manual contains few general descriptions about transformers & certain
instruments which are commonly provided on transformers of large rating and
specific details about the particular contract against which the transformer is
supplied.
Also, it contains instructions regarding the safety aspects, do’s and don’ts when
dealing with the erection, commissioning, operation, maintenance activities.
The Manual also contains explanation about the common problems encountered
in day to day operations and trouble shooting of large capacity Power
Transformers.
1.01.00 SAFETY
Power transformer installation, operation, and maintenance shall follow strict
safety procedures. A complete understanding and implementation of this Safety
Section will minimize or eliminate possible dangerous situations and conditions.
In addition, the following safety regulation standards must be applied:
• OSHA regulations
• State and local safety laws
• Your corporate safety working standards
• National Electrical Safety Code
1.02.00 BASICS
1.02.01 PERSONAL SAFETY
Personal safety should be given first priority. Stop all activities, if unsafe working
conditions exist. All team members must follow safety practices in order to avoid
unsafe actions. For achieving the objectives, all those who are involved in the
erection, operation and maintenance of the transformer should be thorough with
instructions provided by the manufacturer.
1.02.03 STAY ALERT

Certain conditions can lead to emergencies. A risk assessment plan should be
available prior to the start of any job.

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Power Transformers
1.02.04 FIRST AID

All personnel involved in the transformer activities should be aware of First Aid
practices and CPR (cardiopulmonary resuscitation). Contact information for
professional emergencies services should be available.
1.02.05 PERSONAL PROTECTION
Personal protective clothing and equipment must be worn as the work task
dictates. Wear long sleeve cotton shirts, safety shoes, rubber boots, leather
gloves, safety glasses, hard hats, safety harnesses and hearing protection as
required. Avoid loose fitting clothing, jewelry (rings, watches and chains), tennis
shoes, shorts, short sleeve shirts and radio earphones.
1.02.06 PROTECTION FOR MECHANICAL HAZARDS
Avoid working under blocked or raised equipment and never attempt to repair
equipment under operation. Severe personal injury may occur.
1.02.07 PROTECTION FOR ELECTRICAL HAZARDS
Avoid working on energized circuits. Use protective tag and lockout system.
Utilize temporary grounds. Utilize wiring diagrams to identify power supply
sources.
1.03.00 TRANSFORMER FIRE SAFETY
Do not allow smoking, welding, or exposed flames on top and/or inside of the
transformer or near any oil handling equipment.
Do not pressurize a transformer with pure oxygen as an explosion may occur.
Do not weld on a transformer unless it is unavoidable and previously approved
by the PROLEC GE, India Service Department
If any welding needs to be done, the unit must be completely filled with either oil
or dry nitrogen.
• Firefighting equipment should always be available whenever working on the

transformer.
1.04.00 CAUTION
Recommendations when the Transformer is under Pressure or Vacuum.
If the transformer is pressurized or under vacuum do not attempt to open any
manhole cover or remove any devices bolted to the transformer. Severe personal
injury may occur.
For dry air/nitrogen shipments, use the upper filling valve to release the pressure
slowly. For oil filled shipments, release the pressure through the gas cabinet
sampling valve or through the vacuum pressure bleeder vent if applicable.
Failure to follow these instructions may cause severe personal injury, death or
equipment damage.
Pressure gauge reading could be inaccurate and zero reading should be
confirmed by releasing pressure from the upper filling valve or the vacuum

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Power Transformers
pressure bleeder if applicable.

• Do not attempt to lift or jack up a transformer with more than 3 psig internal
pressure. The excessive pressure could cause base plate problems.
• Do not attempt to move, hit or work on the transformer if the unit is under
vacuum
• Do not start the vacuum process on the main tank if the load tap changer
compartment is not maintained at the same pressure equalized with the main
transformer tank using appropriate interconnection tubing. Once the vacuum
pulling process is complete, this tubing must be removed and the valves
plugged. This is to prevent connection board breakdown or leak problems.
1.05.00 GROUNDING PRECAUTIONS

The transformer tank must be grounded during and after installation
All bushings must be grounded during the transformer installation and vacuum
filling process expert when tests are performed. Before energizing assure the
proper removal of the temporary grounds.
• Test equipment must be properly grounded according to its user’s manual.
• Current transformer leads without connection to auxiliary circuits must be
shorted and grounded.
• Oil processing equipment must be grounded.
Maintain all grounds on transformer line terminals for a minimum of 6 hours after
oil filling or recirculation.
Polarization of insulating materials produces a voltage that sometimes takes
days to completely disappear.
1.06.00 INTERNAL ENVIRONMENT.
Only authorized and qualified personnel may go inside the transformer to perform
internal activities
• Large transformers are usually shipped with high quality dry air with less than
0.05% impurities and dew point -60°C or lower.
• Before going inside any transformer, verify that the internal environment
contains a minimum 19.5% oxygen and maximum of 50 ppm (parts per
million) CO for an exposure period of up to 8 hours. For further information,
refer the OSHA regulations.
• Internal components, insulation and oil can absorb oxygen thereby reducing
the overall content. Going inside a transformer with less than 19.5% oxygen
content will cause immediate faint, which would soon lead to asphyxiation and

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Power Transformers
death hazard.
• Continuously monitor the oxygen and CO content inside the transformer (top
and bottom).
• Once the transformer is opened, maintain the required level of oxygen by
means of a dry air source. Airflow must be maintained at all times.
• When any internal activities are performed inside the transformer, always post
a fully trained safety supervisor near the open manhole. He must have at all
time visual contact or other type of communication with the personnel inside
the transformer.
1.07.00 TRANSFORMER OIL HANDLING

• Transformer oil shall not be spilled on the ground.
• An oil spill container kit should be available at all times while working in the
transformer.
• Prolonged contact with transformer oil may cause skin rash and/or eye
irritation.
• Do not open a transformer valve without first checking if the valve is
connected to an oil handling equipment.
• Never remove a valve plug unless the valve is closed and a catch pan is
below the valve plug.
1.08.00 ELECTRICAL HAZARDS

Do not perform any related work on the control cabinet or any electric circuit
unless all power supply sources have been identified and de-energized. Confirm
the absence of voltage with an approved testing device.
• Never attempt to open a closed current transformer energized circuit, as this
will cause an electrical shock.
• Do not work in any electrical circuit unless no back feed is present, the power
source is removed and a lock out and tag out (LOTO) procedure is in effect.
• Do not apply electrical power to any terminal or circuit when the tank is under
vacuum, as an internal discharge might occur.
• Respect appropriate electrical clearances while bushing or winding tests are
being performed. High turn ratios will transform low potential sources into
dangerously high potential sources.
• Condenser type bushings are capable of storing an electric al charge. Do not

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Power Transformers
touch these bushings; unless the bushing cap has been grounded for at least
5 minutes.
1.09.00 MECHANICAL HAZARDS.

• Extreme caution must be taken while working on top of a transformer. Spilled
oil and water will make the cover very slippery.
• Always install a safety rope barrier around the perimeter of the transformer
cover, or supply a fall restraint (full body safety harness) while working on top
of the transformer.
• Never lift or jack up a transformer unless the appropriate lifting lugs or jacking
pads are used. Certified personnel and listed equipment should be
considered. Never jack from the bottom tank floor or bottom or side braces.
1.09.01 GENERAL SAFETY RULES AND PROCEDURES

Do not attempt to install, operate or perform any maintenance activity on this
transformer without the proper knowledge and experience. Read the entire
instruction book carefully before attempting to handle, install or energize the
transformer. Failure to follow these precautions will result in equipment damage,
severe personal injury or death.
The following is a list of some safety and cleanliness precautions that must be
followed by anyone involved in moving, installing, operating or maintaining the
transformer.
1.09.02 CAUTIONS FOR CLIMBING ON THE TRANSFORMER

In order to prevent damage to the transformer or injuries, none of the
components (pipes, valves, radiators) shall be used for climbing or attaching
safety lines
Since the surface might be slippery, caution must be taken while working on top
of the transformer.
1.09.03 LIQUID LEVEL INDICATION
Low level of oil could cause an electrical internal failure. Do not drain the
transformer while energized. Oil samples may be taken from the bottom drain
valve when the transformer is energized. When the transformer is in operation,
the radiator valves and connection valves to the conservator tank must be fully
opened.
1.09.04 COOLING EQUIPMENT
Prior to energizing, the transformer’s cooling system must be correctly installed
and operational. Radiator and proper conservator valves must be opened.
Improper operation will cause alarms and trip signals. Cooling fans and pumps
must be operable.

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Power Transformers
1.09.05 TRANSFORMER ELECTRICAL TESTS

Do not touch any energized parts while tests are in progress. Dangerous
voltages may exist.
1.09.06 CONDENSER BUSHING
Caution should be taken while handling this type of bushing, as they are capable
of storing electric charge after energizing transformer windings
If any job is required on the bushing, it must be grounded before touching the top
terminal. For further information, refer to the manufacturer’s manual.
1.09.07 CLEANLINESS
Before going inside the transformer, wearing of clean protective coveralls and
shoe covers or rubber is necessary. Avoid entering with coins, pens, jewelry,
foreign materials or any other metallic items.
All items taken inside the transformer should be listed; tied off with string or
cotton tape and accounted for when work is complete.
1.10.00 HAZARDOUS SUBSTANCES
1.10.01 TRANSFORMER OIL

Normally, transformer oil presents no hazard to health. However, serious neglect
may affect the skin and cause irritation.
Oil is a hydrocarbon and will burn. Carbon dioxide, dry chemical, foam or water
fog is the extinguishants.
1.10.02 MERCURY
Mercury switches or thermometers containing mercury should be handled
carefully. Mercury vapour can be hazardous over a period of time, especially in
poorly ventilated room.
1.11.00 ENVIRONMENTAL HAZARDS DUE TO OIL SPILLAGE & FIRE
CONSEQUENT TO FAILURE OF TRANSFORMER AT SITE
Oil spillage from Transformer tank, bushing, pipe joints etc. may cause the
source of major fires. It is recommended that Transformer shall be inspected
daily for the oil spillage.
The general CBIP recommendations for the Transformer installation are:
a. Soak pits
b. Drain pits
c. Barrier walls
d. Fire detection system
e. Fire hydrant system
f. Fire mulsifyre system

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Power Transformers
1.11.01 CONTROL OF OIL SPILLAGE

Keep a track of the maintenance schedule of transformer & ensure that the
required routine & preventive maintenance are done as per the schedule
On noticing any leakages from the Transformer immediately place a tray
/container to collect the spillage and inform the maintenance department for
immediate corrective action (for example replacement of gasket etc.). Oil shall
not be allowed to fall on to ground.
In case any leakage to ground take place, remove the same with cotton/ cloth/
saw dust.
In case large scale spillage, inform the shift in charge immediately & start
collecting the spilled oil into suitable container and assess the risk of continuous
operation of the Transformer
1.11.02 CONTROL OF FIRE
It is necessary to check the healthiness of the Transformer fire protection system
regularly so that the fire risk can be minimized
There shall not be any oil leakage.
During hot oil circulation in the Transformer keep fire extinguisher ready near the
Transformer, all the combustible materials shall be kept at a safe distance.
Terminal connector, Fuses shall be checked against spark.
Condition of Transformer oil shall be checked regularly
Proper Housekeeping near Transformer may help to reduce the risk of fire.
Proper fire fighting system as per CBIP recommendation shall be installed near
Transformer. Regular inspection & maintenance to be done on the Fire fighting
system.
1.11.03 PRECAUTIONS AGAINST FIRE
Welding on oil filled Transformer shall be carried out if unavoidable, as per the
instructions of the Manufacturer.
Hot oil circulation shall be carried out only under the round the clock supervision
to prevent chances of fire on lagging materials etc.
1.12.00 GENERAL SAFETY NOTATIONS AND ALERTS.
1.12.01 DANGER
Immediate hazards which will result in severe injury, death or property and
catastrophic equipment damage.
1.12.02 WARNING
Hazard or unsafe work practices which may result in severe injury, death or
property and catastrophic equipment damage.
1.12.03 CAUTION

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Power Transformers
Hazard or unsafe work practices which may result in minor injuries or property
and unnecessary equipment damage.
1.13.00 DO’S AND DON’TS for safety measures / precautions

Safety measures / precautions should be given top most priority during
inspection / erection / maintenance work. Any mishap during the process will
result in delay in erection, endangering human life, endangering equipment life
etc.
1.13.01 DO’S
 Insulating oil and insulation of windings and connections are inflammable.
Watch for fire hazards.
 Before entering inside the Transformer, replace Nitrogen gas completely with
air if it was transported with nitrogen gas inside.
 Make sure that nothing is kept inside the pockets before one enters inside
the main unit. Also take off the wristwatches and shoes.
 List up all the tools and materials to be taken inside and check it after coming
out to make sure that no tools are left inside.
 There must be a protective guard for lamp to be taken inside.
 Keep inspection covers open for supply of fresh air when someone is
working inside.
 When one person is working inside, second person must be available
outside for emergency help.
 Use rings spanners and tie them to the wrist of the person or somewhere
outside the tank.
 Be careful during connections where bolted joints are involved so that nut,
washers etc. Are not dropped inside the tank.
 If it is required to weld some lugs or brackets etc., these should be welded to
tank stiffeners taking all precautions to avoid fire hazards.
 De-energise the unit by circuit breakers and line switches while working on
energised unit.
 Check the diaphragm of explosion vent and replace it if cracked.
 Attach the caution tags “DO NOT OPERATE THE SWITCHES” while
working on units, which are energised.
 Make sure that the fire fighting equipment is available at the oil treatment
equipment as well as workplace and adjacent to the transformer.

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Power Transformers
 Fire fighting equipment should be checked regularly and should have

sufficient quantity of extinguishant.
 Transformer tank, control cabinets etc. As well as oil treatment equipment
shall be connected with permanent earthing system of the station.
 Check and thoroughly investigate the transformer whenever any alarm or
protective device is operated.
 Check air cell in conservator.
 Attend leakage on the bushings.
 Examine the bushings for dirt deposits and clean them periodically.
 Check the oil in transformer and OLTC for dielectric strength and moisture
content and take suitable action for restoring quality.
 Check the oil level in oil cup and ensure air passages are free in breather. If
oil is less make up the oil.
 If inspection covers are removed or any gasket joint is to be tightened, then
tighten the bolts evenly to avoid uneven pressure.
 Check and clean the relay and alarm contacts. Check also their operation
and accuracy and if required change the setting.
 Check the protection circuits periodically.
 Check the pointers of all gauges for their free movement.
 Clean the oil conservator thoroughly before erecting.
 Check the OTI and WTI pockets and replenish the oil if required.
 Gas filled storage of transformer at site should be limited to a maximum of 3
months.
 Check the door seal of the Marshalling box. Change the rubber lining if
required.
 Ensure proper tightness of top terminal of condenser bushings to avoid entry
of rainwater.
 Check oil level in condenser bushing, any discrepancy should be reported
immediately to the manufacturer.
 Do jacking only at jacking pad.
1.13.02 DON'TS
 Do not take any fibrous material such as cotton waste inside while repairing.
 Do not drop any tools / material in side.
 Do not stand on leads / cleats.

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Power Transformers
 Do not weld, braze or solder inside the tank.

 Do not weld anything to the tank wall from outside.
 Do not weld anything to the conservator vessel if Air cell bag is inside.
 Do not smoke near the transformer.
 Do not use fibrous material for cleaning as it can deteriorate the oil when
mixed with it.
 Do not energise without thorough investigation of the transformer whenever
any alarm of protection has operated.
 Do not re-energise the transformer unless the Buchholz gas is analysed.
 Do not re-energise the transformer without conducting all pre-commissioning
checks. The results must be compared with factory test results.
 Do not handle the off circuit tap switch when the transformer is energised.
 Do not energise the transformer unless the off circuit tap switch handle is in
locked position.
 Do not leave off circuit tap switch handle unlocked.
 Do not use low capacity lifting jacks / slings on transformer for jacking /
slinging.
 Do not change the setting of WTI and OTI alarm and trip frequently. Setting
should be done as per manufacturer's instructions.
 Do not leave any connection loose.
 Do not meddle with the protection circuits.
 Do not leave marshalling box doors open, they must be locked.
 Do not switch off the heater in marshalling box except to be periodically
cleaned.
 Do not allow unauthorised entry near the transformer.
 Do not close any valve in pump circuit for taking stand by pump and motor
into circuit.
 Do not allow water pressure to exceed the oil pressure in oil to water heat
exchangers.
 Do not mix transformer oils of different make/ base, unless oil is new and
conforms fully to IS: 335.
 Do not continue with pink (wet) silica gel, this should immediately be
changed or reactivated.
 Do not store transformer in gas filled condition for more than three months

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Power Transformers
after reaching site. If storage is required for longer duration, the main body
should be filled up with oil.
 Do not leave tertiary terminals unprotected outside the tank.
 Do not allow WTI / OTI temperature to exceed 70°C during dry out of
transformer and filter machine temperature beyond 75°C
 Do not parallel transformers, which do not fulfil the conditions for paralleling.
 Do not over load the transformers beyond limit specified in IS: 6600.
 Do not leave secondary terminals of any CT open.
 Do not measure insulation resistance by using megger when the transformer
is under vacuum.
 Do not stand on any vessel, which is under vacuum.

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Power Transformers
SECTION – 2
GENERAL CONSTRUCTION

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Power Transformers
2.0 GENERAL CONSTRUCTION OF A TRANSFORMER

Transformer is a tailer made product and the components provided on the
transformer are as specified by the purchaser. The construction of high voltage
transformers varies from manufacturer to manufacturer.
The active parts of the transformers consist of core and windings.
2.1 CORE
Core is manufactured from Grain Oriented Silicon Steel (GOS), which gives very
low specific loss at operating flux densities. Joints of the laminations are
designed such that the electromagnetic flux is always in the direction of grain
orientation. The core clamping structure is designed such that it takes care of all
the forces produced in the windings during the normal operation and also under
short circuit conitions.
2.2 WINDINGS
Windings are made from paper insulated copper conductors which are
transposed at regular intervals throughout the winding for ensuring equal flux
linkage and current distribution between strands.
Interleaved or inter shielded construction is employed for the high voltage
windings to ensure uniform distribution of impulse voltages. Oil flow is directed
through the entire windings for ensuring proper cooling.
2.3 COOLING
For ONAN/ONAF cooling, oil flows through the winding and external cooler unit
attached to the tank by the natural thermosyphonic action.
For OF AF/OD AF/ OF WF cooling, the oil is directed through the winding by oil
pumps provided in the external cooler unit.
External cooler unit/units consists of pressed steel sheet radiators mounted
directly on the tank or on separate cooler banks for air-cooled transformers and
oil to water heat exchangers for water cooled transformers.
2.4 TANK & COVER
Tank and Cover are manufactured by welding steel plates and are suitable for full
vacuum and positive pressure test as per CBIP Manual. For large capacity power
transformers, the tank may be of bell type construction. This is to facilitate
inspection of core and windings without lifting of the heavy core & coil assembly
which will require a large capacity crane. The weight of upper tank will be much
less compared to that of core & windings and can be lifted by using a small
capacity crane.
Construction of the tank and cover are such that pockets for water collection are
avoided. Transformer tank and the separately mounted cooler frames are
provided with two earthing terminals each. While earthing the cooler frame, cable
box, busduct etc., it should be ensured that no closed loop is formed because of
multiple earthing connections.

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Power Transformers
2.5 CONSERVATOR
Conservator is intended to take care of the expansion and contraction of
transformer oil, which takes place during normal operation of the transformer.
Wherever specified by Purchaser, flexible separator or air cell is provided in the
conservator to prevent direct contact of air with the transformer oil.
A smaller oil expansion vessel is provided for the On Load Tap Changer. Some
times the OLTC conservator may be made as a compartment at one end of the
main conservator.
Magnetic oil level gauge is fitted on the conservator which can give alarm/ trip in
the event of the oil level falling below the pre-set levels due to any loss of oil.
2.6 PRESSURE RELIEF DEVICE
A device for limiting high oil pressure build up inside the transformer during fault
conditions is fitted on top of the tank. The pressure relief device allows rapid
release of excessive pressure that may be generated in the event of a serious
fault. This device is fitted with a trip switch.
The pressure relief device has a spring loaded diaphragm, which provides rapid
amplification of its actuating force and will reset automatically, as soon as the
pressure inside the tank drops down to the pre-set pressure.
A bright colour coded mechanical indicator pin in the cover moves with the
diaphragm during the operation of the pressure relief device and is held in
position even after the diaphragm goes back to its original position. This pin is
clearly visible from ground level, which gives an indication that the device has
operated.
The indicator pin may be reset manually. The relief device is provided with a
shielded weatherproof alarm / trip contact and is operated by the movement of
the diaphragm.
For small Capacity transformers, an explosion vent is provided with a diaphragm,
which will rupture in the event of abnormal increase in internal pressure. Some
times the explosion vent is provided with double diaphragm such that the outer
one remains intact even after the inner one is ruptured. Rupturing of inside
diaphragm can be checked by viewing through the oil level gauge provided in
between the diaphragms.
2.7 GAS & OIL ACTUATED (BUCHHOLZ) RELAY
Gas and oil actuated relay is fitted in the feed pipe from the transformer tank to
the expansion vessel for collection of gas, if generated in the oil. The relay
operates on the fact that almost every type of fault in an oil immersed transformer
gives rise to generation of gas. This gas is collected in the body of the relay, and
is used to close the alarm switch. In the event of any severe fault, the sudden
increase in oil pressure causes an oil surge towards the expansion vessel and
this is used to close the trip contacts. This oil surge will impinge on the flap fitted
to the trip element causing it to rotate about its axis and thus bringing the
mercury switch to the closed circuit position, which in turn operates the tripping
device.

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Power Transformers
In the event of serious oil loss from the transformer, both alarm and trip elements
operate in turn in the manner previously described for gas collection.
Two brass petcocks are fitted at the top of the relay body, the outlets of which are
threaded to take a bleed pipe if required for collection of gas samples.
In the pipe connection between On Load Tap Changer and its oil expansion
vessel a single float Oil Surge Relay is fitted. This relay operates on the principle
of oil surge impinging on a flap causing operation of the mercury switch
connected to the trip circuit. Gas actuated alarm switch is eliminated because the
gas generated during normal tap changing operation will give unnecessary
alarm.
2.8 SILICAGEL BREATHER
Expansion and contraction of oil cause breathing action. The silicagel-
dehydrating breather absorbs any humidity in the air breathed. An oil seal in the
air intake prevents external moisture being absorbed when no breathing occurs.
The breather container is filled with silicagel crystals. It is arranged such that the
air breathed must pass through it. The desiccant contains blue and white
crystals. When the silicagel is fully active, the blue crystals will have a deep blue
colour and changes to pink as it absorbs moisture. When saturated with moisture
and the charge contained should be replaced. The gel removed from the
breather may be arranged for regeneration and preserved for future use.
The size of the breather is chosen such that it can operate effectively over a
period of six months approximately. The factors, which influence the selection of
size of the silicagel breather required for a particular transformer, depend on
many factors like, the oil quantity in the transformer, the adsorption capacity of
silicagel, the loading pattern and the atmospheric conditions prevailing at site.
The loading pattern and the site conditions are difficult for the transformer
manufacturer to assess. Hence, the selection of breather is based on certain
assumptions and it is difficult to fix up a time schedule for the regeneration of
silicagel. It is advisable to have a periodic inspection (say monthly) of the
indicator so that the gel can be regenerated or replaced as soon it is saturated
with moisture.
2.9 WINDING TEMPERATURE INDICATORS
The winding temperature relay indicates the winding temperature of the
transformer and operates the alarm, trip and cooler control contacts. This
instrument operates on the principle of thermal imaging and it is not an actual
measurement.
Winding temperature indicator consists of a sensor bulb placed in oil filled pocket
in the transformer tank cover. The bulb is connected to the instrument housing by
means of two flexible capillary tubes. One capillary is connected to the
measuring bellow of the instrument and the other to a compensation bellow. The
measuring system is filled with a liquid, which changes its volume with rising
temperature. Inside the instrument is fitted with a heating resistance which is fed
by a current proportionate to the current flowing through the transformer winding.
The instrument is provided with a maximum temperature indicator. The heating

Date : Mar 15, 2011 Page 19 of 193
Power Transformers
resistance is fed by a current transformer associated to the loaded winding of the

transformer. (The heating resistance is made out of the same material as that of
the winding) The increase in the temperature of the resistance is proportionate to
that of the winding. The sensor bulb of the instrument is located in the hottest oil
of the transformer, therefore, the winding temperature indicates a temperature of
hottest oil plus the winding temperature rise above hot oil i.e. the hot spot
temperature.
2.10 OIL TEMPERATURE INDICATOR
The oil temperature indicator consists of a sensor bulb, capillary tube and a dial
thermometer, the sensor bulb is fitted at the location of hottest oil. The sensor
bulb and capillary tube are fitted with an evaporation liquid. The vapour pressure
varies with temperature and is transmitted to a bourden tube inside the dial
thermometer, which moves in accordance with the changes in pressure, which is
proportional to the temperature.
2.11 BUSHINGS
The high voltage connections pass from the windings to terminal bushings.
Terminal bushings upto 36 kV class, 3150 Amps, are normally of plain porcelain
and oil communicating type. Higher current rated bushings and bushings of 52
kV class and above will be of oil impregnated paper condenser type. The oil
inside the condenser bushings will not be communicating with the oil inside the
transformer. Oil level gauge is provided on the expansion chambers of the
condenser bushings.
Oil in the condenser bushing is hermetically sealed and it should not be disturbed
in normal operation. Oil level may be checked regularly and any oil leakage
should be reported to the bushing manufacturer for immediate attention.
While connecting the overhead transmission line conductor to the bushing
terminal, ensure that the line pull is limited to the cantilever strength of the
bushing. The cantilever strength of bushings as per IS: 2099 for various types of
bushings are as shown below.
Rated Voltage Cantilever Strength (kg.) – Ref. IS 2099
(kV)  800 1000 ~ 1600 2000 ~ 2500  3150
(Amps) (Amps) (Amps) (Amps)
 52 102 127 204 320
72.5 & 123 102 127 204 408
145 & 245 127 163 254 408
420 254 254 320 510
2.12 TAP CHANGER
Tap changers of power transformer are specifically of two types-
1. On Load Tap changer
2. Off Circuit Tap changer
In the case of off circuit tap changer, the tap changing takes place only when the
transformer is de-energised, but in the case of on load tap changers the tap

Date : Mar 15, 2011 Page 20 of 193
Power Transformers
changing takes place when the transformer is in operation. The tap changer can
be designed for changing the taps.
I. Manually
II. Automatically &
III. From remote
The On load tap changer will be a self-contained unit housed in the main
transformer tank. Since some amount of arcing takes place during the switching
operations from one tap to the other, the oil inside the tap selector will deteriorate
faster. Hence, this oil cannot be allowed to mix with the oil in the main
transformer. On load tap changer is provided with a separate conservator and oil
surge relay.
For details of construction and maintenance, please refer to the OLTC supplier's
manual attached with Specific Instructions at the end of this manual.
2.13 CONTROL & MONITORING SYSTEM
Local control and monitoring of the cooler, tap changer and alarm and trip
indicators is carried out at the marshalling kiosk. Automatic control of the tap
changer is carried out at the remote control panel.
2.14 FIRE DETECTION & FIRE FIGHTING SYSTEM
It is recommended to always install suitable fire detection and fighting system
with all transformers. CBIP Manual prescribes guidelines for the selection and
installation of Fire Protection System.
“Automatic Mulsifyre System” or “Drain and Stir System” with nitrogen injection
inside the transformer are more prominent among the fire fighting systems for
large capacity Power Transformers. In the Drain and Stir System, oil is partially
drained from the transformer and nitrogen gas is bubbled through the oil in the
transformer tank to stir and create a blanket of inert gas above the oil to quench
the fire.
Owner of the Transformer has to ensure provision of requisite Contacts/ Relays
in his control panel as per requirement specified in the Fire System Instruction
Manual for connecting the Fire Detection and Fire Fighting System.

Date : Mar 15, 2011 Page 21 of 193

Power Transformers
SECTION – 3
PACKING AND DESPATCH

Date : Mar 15, 2011 Page 22 of 193

Power Transformers
3.0 PACKING & DESPATCH
3.1 GENERAL
Depending on the restriction imposed by the weight and transport dimensions,
the transformer will be despatched either in oil filled or nitrogen gas filled
condition.
In case of transformer despatched without oil, the transformer will be pressurised
with dry air or nitrogen gas to minimise the likelihood of condensation or moisture
entering the tank.
Transformers are supplied, fitted with nitrogen gas cylinder to maintain positive
pressure during transportation and storage before erection.
While transformers are in transit, gas pressure must be checked on daily basis
and any loss of pressure must be made up by feeding gas from the cylinder. For
allowable range of pressure at various ambient temperatures, please refer to Fig.
3.I.
Accessories and cooler are despatched separately. All oil pipes and chambers
are despatched in sealed condition to avoid entry of water during transportation
and storage.
Fig. 3.1

Date : Mar 15, 2011 Page 23 of 193
Power Transformers
3.2 PACKING
When any internal part like tap changer, CT's etc. are removed from the main
body for transportation, they shall be despatched in tanks filled with oil or dry
nitrogen gas or suitable measures are taken so that they do not absorb moisture.
All fragile parts such as temperature indicators, oil level gauges etc. shall be
carefully packed to avoid breakage in transit.
Air cell type conservator shall be despatched with air cell mounted inside the
conservator and inflated with air at a slightly positive pressure so that it remains
fully tight inside the conservator. This is to avoid relative movement of air cell
inside the conservator during transit and to avoid damages to air cell during
handling.
All blanking plates, valves guards etc., which are used exclusively for
transportation are painted with a different colour shade than the transformer
(normally post office red) and shall be preserved for future use.
3.3 RAIL TRANSPORT
Large capacity transformers are normally transported by rail due to
considerations of safety and economy. Depending on the weight and dimension
of the main body suitable wagons are selected for transport. It should be ensured
that the dimensions of the main body when it is loaded on the particular wagon
do not project beyond the limiting dimensions specified by the Railways.
Movement sanction should be obtained form all the Railways through which the
transformer has to be transported to site from the factory.
Detached parts are packed and normally despatched along with the main body
so that all parts are received at site along with the main unit.
3.4 LIFTING & JACKING
Transformers should be lifted only by using the lifting bollards provided on the
main body for the purpose. All the lifting bollards should be used simultaneously.
Care should be taken to use the correct size of sling for lifting and the lifting
angle should not exceed 600.
Safe loads of wire ropes and the multiplying factor to be used corresponding to
the lifting angles are shown in Fig. 3.2

Date : Mar 15, 2011 Page 24 of 193
Power Transformers
MULTIPLYING SAFE LOAD OF WIRE

Lifting Angle FACTOR FOR ROPES
DIFFERENT LIFTING Dia. of Safe
ANGLES Wire Load
Lifting Multiplying Rope
Angle Factor mm kg.
Slinging Angle 0 1.000 6 600
20 1.015 12 1,300
40 1.065 16 2,300
60 1.155 20 3,500
24 5,000
28 7,000
32 9,000
36 11,000
Fig. 3.2 40 14,000
44 17,000
Correct method of slinging 56 24,500
64 33,500
70 40,000
3.5 JACKING
For the purpose of jacking, only the jacking pads provided on the tank are to be
used. Capacity of Jacks should be at least 1.5 times the weight of transformer.
Put sufficient wooden/steel packing below the jack to support the weight. Do not
lift more than 30 mm at a time. Use all jacks simultaneously. Jacks should not be
left in the loaded position for long time. Transformer should be handled only in
the normal upright position.
3.6 LASHING
The transformer is lashed on all four sides by wire ropes or chain of adequate
size and is tightened using turnbuckles with locking facility. After the movement
of the consignment for a short distance the tightness should be checked.
3.7 ROAD TRANSPORT
Generally road transport is resorted to in case of smaller units and of site where
rail link is not available or where well developed road system exists.
Multi-axle tractors driven low-platform trailers are used for transport.
Prior to taking decision to transport the heavy consignment by road a route
survey has to be conducted to confirm strength of bridges and the road
worthiness and to identify constraints if any enroute.
Weak bridges if any should be strengthened with the help of, Highways
department.
A pilot vehicle with all-necessary tools and tackles and trained staff should be run

Date : Mar 15, 2011 Page 25 of 193
Power Transformers
in front of the vehicle. Red flags and danger lamps should be exhibited on the
consignment.
Tightness of lashing should be verified at frequent intervals during movement.
3.8 WATER TRANSPORT
Special cares to be taken during manufacture, packing and despatch of
transformers which are to be shipped through high seas. Even if it is not specified
FIG. – 3.3
by the purchaser the transformer should be applied with anti corrosive coating
and packaging should be strong enough for possible rough handling enroute.
Accessories should have polythene covering and should contain silicagel or any
other suitable moisture absorbent.
3.9 SHIPMENT OF ACCESSORIES
Accessories are packed and despatched separately. Items, which are detached
from the main body for transportation, are listed on the outline drawing. These
will be transported in suitable crates.
Crates containing fragile items should be marked 'FRAGILE' and handled
carefully during loading on vehicle, shipment and unloading at site.
Crates containing accessories, which should not be kept upside down like
condenser bushings, control panel etc. should marked 'THIS SIDE UP' and
should be handled as per manufacturer's instruction only.
Caution symbols for handling are painted on the packing cases.
3.10 SHIPMENT OF OIL
Transformer oil is despatched to site in sealed steel drums or tankers.
When oil is filled in drums, there should be sufficient air space to allow for
expansion and contraction of oil due to variations in temperature.
Drums with oil should be stacked only in horizontal position. This will avoid
collection of water on top of the drum, which may be sucked in by the vacuum
created inside the drum due to the contraction of oil owing to changes in ambient
temperature.
Due to any reason, if the drums are kept in vertical position, drums should be
covered with polythene or tarpaulin sheet to avoid risk of water getting collected

Date : Mar 15, 2011 Page 26 of 193
Power Transformers
on top and eventually leaking into the drums.

Filter hole and air release hole s shall be in one horizontal line. This will avoid
breathing in of moist air. If there is any leakage of oil it can easily be identified.
When oil is transported in tankers, there should be storage tanks of sufficient
capacity available at site. Such tanks should be fitted with dehydrating breathers.
3.11 IMPACT RECORDERS
When specified, impact recorders are attached to the main body of the large
transformers during transportation to monitor the shock, which the transformer
may be subjected to, during transportation. Impact Recorders are of two types,
viz. Mechanical analogue type and Electronic digital type. Both types of shock
recorders have ability to record shock and impact from all directions.
3.11.1 MECHANICAL TYPE IMPACT RECORDERS
The Mechanical type recorder used is of Impact-O-graph Impact Recorder Model
M1 supplied by "Impact-O-Graph”, Division of Chatsworth Data Corporation,
20710 Lassen Street, Chatsworth, California, U.S.A. The record will be in the
form of chart, which will show the total number of impacts that have occurred, the
magnitude, the direction and the time at which they occurred. Impact is recorded
in both magnitude and direction through three independently operating
mechanisms, which record –
a) Lateral shock ('x' axis)
b) Longitudinal shock ('y' axis)
c) Vertical shock ('z' axis)
Typical sensitivity (rating) values of impact recorders are as follows:
1) Trucks trailer - Smooth road 2g
2) Truck trailers - Rough road 6g
3) Railway wagons - 6g
Movement of the graph paper is powered by battery operated clock mechanism.
The battery has a normal life of 6 months. At the time of despatch of the
transformer from the factory, the recorders should be switched 'ON' and the time
set. The cover may be locked or sealed to avoid possibility of tampering with the
chart on the way.
Procedure for analysing impact recorder chart results:

Definitions:
G = Magnitude of gravity acceleration
X – AXIS = Transversal (lateral) acceleration (sideways motion)
Y – AXIS = Longitudinal acceleration (forward and backward motion)
Z – AXIS = Vertical acceleration (up and down motion)
1) Open impact recorder and turn it off. Manually swing back and forth
the stylus to indicate the movement of deactivation.

Date : Mar 15, 2011 Page 27 of 193
Power Transformers
2) Remove impact recorder tape.

3) Record on the tape the following information
 Time and date of deactivation
 Name of the person opening the impact recorder
 Name of the Rail or Truck carrier
4) If external or hidden damage is suspected, the railroad or carrier
inspector has to be present and sign the appropriate claim form.
5) If accelerations in any axis exceed the magnitude indicated in the
following table, internal inspection must be performed to confirm the
absence of any internal damage.
6) For each stylus measure the length of the trace from centre line in one
direction to the end of the arc that extends farthest from the centre
line.
7) Use the table 3.4 to find equivalent ‘g’ levels in the designated column
(X column for ‘x’ axis shocks etc.)
Shipping weight Transverse Longitudinal Vertical
(Tonnes) G’s G’s G’s
X Y Z
~ 23 1.50 10.00 3.50
> 23 ~ 57 1.50 9.00 3.50
> 57 ~ 80 1.50 8.00 3.50
> 80 ~ 114 1.50 7.50 3.50
> 114 ~ 182 1.0 6.50 3.00
> 182 ~ 239 1.0 5.50 3.00
> 239 ~ 454 0.75 4.50 2.50
Table 3.4 Allowable accelerations in each axis vs. shipping weight
The chart should be read using the following instructions:
 When the centreline of the stylus tracing is discernable the Table 3.5 Column
1 should be used to determine the amount of G’s recorded. Count the number
of spaces, or equivalent, from the centreline, one way, to the end of the arc
that extends furthest from the centreline. Find the appropriate row on Column
1 and read the X, Y or Z accelerations.
 When the centreline is not discernable use the Table 3.5 Column 2. Count
spaces from peak to peak (full swing of stylus trace) and lookup the
appropriate row on Column 2 and read the X, Y or Z acceleration.
 Time is recorded on the topside of the chart. 75 mm approximately equals
one day.
 The effects of resonant vibration of lo magnitude G-force accelerations for
extended periods can also cause damage. Resonance can be included
depending on railcar speed, rail gap, the railcar wheelbase length or bad road
conditions.
 If the impact recorder graph indicates resonant induced vibration of low
magnitude less than 1.0 G for periods greater than 8 hours, then complete the
damage claim form in the Appendix Section.

Date : Mar 15, 2011 Page 28 of 193
Power Transformers
 The recorder graph (paper recording tape) should be kept by the customer for
any future reference.
Column 1 Column 2
Read from centreline Read full swing of arc
(refer to Figure 3.6) (refer to Figure 3.7)
Axis  X Y Z X Y Z
Device max. 
recording limit 6G 15 G 10 G 6G 15 G 10 G
mm Space
3.175 1 1.7g 3.5g 2.0g 1.0g 2.1g 1.2g
6.35 2 3.3g 7.0g 4.0g 2.0g 4.1g 2.4g
9.525 3 5.0g 10.5g 6.0g 3.0g 6.2g 3.5g
12.7 4 6.3g 14.0g 8.0g 3.9g 8.2g 4.7g
15.875 5 8.2g 17.5g 10.0g 4.9g 10.3g 5.9g
19.05 6 5.9g 12.4g 7.1g
22.225 7 6.7g 14.4g 8.2g
25.4 8 7.4g 16.5g 9.4g
27.00 8.5 7.8g 17.5g 10.0g
Table 3.5 Typical instrument recording limits and reading of impact recorder chart
Figure 3.6 Figure 3.7

3.11.2 ELECTRONIC DIGITAL TYPE IMPACT RECORDERS
The Minishock is a recorder designed for the simple instrumentation of the
conditions of transport. With three accelerometers, the 128 highest shocks are
measured, dated and memorised in each X, Y and Z-axes. Provisions for
recording temperature and humidity are optional in this type of instrument.
The Minishock is a self contained reorder designed for use in the transport and
packaging sectors. This instrument will measure and date shock, temperature
and humidity (optional).
Shocks are recorded when the acceleration passes a pre-determined threshold
in each of the X, Y and Z-axes. Only the 128 shocks of greatest intensity are
memorised, thus reducing the data overload.
Before the mission, the threshold limits above which the shocks are to be
recorded are determined and the Minishock is activated. During the mission, the
acceleration is measured continuously and recorded together with the date and
time, whenever the threshold is exceeded. After the mission, the data is
downloaded via a RS 232 link and visualised using the Logishock software. The
data can be visualised graphically or in the form of tables.

Date : Mar 15, 2011 Page 29 of 193
Installa
ation, Operration and Maintenan
nce Manuaal
Power Transformerrs
The Senssor charactteristics are as follow

ws:
a. Range :  10 g
b. Resolu
ution : 0.1 g
c. acy (25oC)
Accura :  0.22g
d. Thresh
hold : from 1.5g ~ 10 g
e. Band width
w : 25/ 50/
5 100/ 20 00 Hz
f. Sampliing periodss : 1 min nute to 4 hours.
h
g. Power source : Work ks with a sttandard lith
hium batte
ery
he transforrmer suffers serious shock durring shipment, the co
In case th ore and co
oil
will havee to be subjected d to thorrough insspection b before ereection and
commissiioning.
Fig. 3.8 Electronic type impact reccorder
This docuument and anyy information prrovided in thiss Manual are the confidential property of PR ROLEC GE and must not be
disclosed, copied or used
d for Manufactu
uring, Tendering g or for any othe
er purpose witho
out written perm
mission. PROLE
EC GE shall not
assume any
a responsibilitty or have any liiability resulting from such unauuthorised use of any informatio
on.
Rev. 1: General reviision of entire document IT

TTL/TM/1103
Date : Mar 15, 2011 Pag
ge 30 of 193
Power Transformers
SECTION – 4
RECEIPT AND STORAGE AT SITE

Date : Mar 15, 2011 Page 31 of 193

Power Transformers
4.0 RECEIPT AND STORAGE OF MAIN UNIT AND ACCESSORIES

4.1 TRANSFOMER RECEIPT
Read the entire instruction Manual carefully before attempting to enter inside
the main unit, handle, install, use or service the transformer. Failure to follow
instructions could result in severe personal injury, death or property damage
and may void the warranty.
4.2 RECEIVING MAIN UNIT AND ACCESSORIES
IMPORTANT NOTICE
In order to preserve the agreed warranty on your
transformer, the following checklists, included in the
Section 11, must be completed, archived by the
customer and provided to PROLEC GE for future
warranty purposes.
• Receiving Inspection
• Storage Inspection (if applicable)
• Internal Inspection
• Transformer Erection Checklist
• Pre-Commissioning & Site Test Results
• Every Six Months and Annual Maintenance
Inspection
PROLEC GE India Transformer Service Department

Mail ID: services@Prolec-GEIndia.com
Customer Service Contact No.: 044 30289843

Date : Mar 15, 2011 Page 32 of 193
Power Transformers
General Flow Chart for Transformer Receipt, Assembly, Operation and

Maintenance
PROCESS DOCUMENTATION
Receiving
inspection
Transformer checklist
Receipt
Receiving
inspection
To be NO checklist
installed Storage
immediately
YES
Transformer
erection
Erection checklist
YES Insulation dryout

High moisture process
NO
Vacuum filling
process
Pre
commissioning
Pre commissioning checks & site
tests test results
Maintenance
Transformer inspection
operation & checklist
maintenance

Date : Mar 15, 2011 Page 33 of 193
Power Transformers
These instructions provide information related to shipping, receiving, handling

and storage of your power transformer. Compliance with these instructions will
ensure satisfactory operation and quality and will maintain the transformer’s
warranty.
These instructions do not intend to cover all possible contingencies, which may
occur during shipping, receiving handling and storing the transformer.
If you require further information, please contact PROLEC GE India Service
Department.
When a transformer arrives at site a careful external inspection must be made of
the unit, its cooling system and all sealed components, referring to the general
arrangement drawing and the shipping list.
Inspect all packing cases and loose components for damage or missing items.
Check whether the transformer has arrived at site with a positive gas pressure in
case of despatch without oil. In case of despatch of main body in oil filled
condition, the oil level should be checked. One transport oil level gauge is welded
near the top of the tank for indicating the level of oil in the tank.
Should the transformer arrive at site without pressure (owing to gas leakage) it
must be assumed that moisture has entered the tank and that the moisture will
have to be driven out. In such cases the manufacturer’s advice must be sought.
Confirm that case numbers match with the packing list. Check their contents tally
with the packing list if the packing case is damaged.
IMPORTANT:
If any scratches or damage to the paint is noticed on receipt of Main body or
Accessories, touchup painting should be done immediately over the damaged
area. For procedures of touchup painting, refer to “ Clause 5.23: Touchup
Painting at site”.
4.3 REPORT OF DAMAGE PARTS ETC.
If any damage is noticed, claim must be lodged with the insurance agency and
the matter must be reported promptly to the manufacturer. The report should
contain sufficient details of damaged parts and extent of damage so that the cost
of replacement /rectification can be worked out.
4.4 INSPECTION OF MAIN UNIT GAS FILLED
After receipt of consignment at site, gas pressure inside the tank and the
temperature at the time of measurement should be recorded. The value obtained
should be compared with the gas pressure versus temperature chart furnished in
the instruction manual. (Refer fig.– 3.1 of chapter 3)
4.5 INSPECTION OF MAIN UNIT OIL FILLED
Upon arrival at site, check oil level inside the tank. If a transparent oil level gauge
is not provided, the oil level can be measured by connecting a transparent hose

Date : Mar 15, 2011 Page 34 of 193
Power Transformers
between the bottom and top sampling valves.

Check for damages to valves etc.
A sample of oil should be taken from the bottom of the tank and tested for BDV
and moisture content. If the values do not meet the relevant standards the matter
should be taken up with the manufacturer.
4.6 UNLOADING OF MAIN UNIT
In cases where the substations are having adequate crane facility; the
transformer is unloaded by crane. Alternatively, mobile cranes are used. Where
no crane facility is available a trench is dug to a depth equal to height of the
trailer platform and the transformer is slid to position. If this also is not possible
the transformer is unloaded into a sleeper platform and gradually lowered to
plinth level (Refer Figure 4.1 for guidance). The sleeper platform level is to be at
a slightly higher level to allow for the increase in height of the trailer while the
load is released due to the springs getting relaxed. Winches are to be used for
putting the transformer into position.
Fig. 4.1
Lift the main body of the transformer with a mobile crane and wire ropes. The
crane capacity must be at least 10% higher than the weight of consignment.
Lifting angle of ropes should be limited to 30 deg. to vertical.
Unloading must be done with maximum care, avoiding any jerking movements or
dropping.
Use only the lifting bollards/hooks for slinging while lifting.
For lifting with hydraulic jacks, the transformers are provided with jacking pads
dimensioned for lifting the complete transformer filled with oil.

Date : Mar 15, 2011 Page 35 of 193
Power Transformers
If the foundation of the transformer is not ready and if the transformers are to be
unloaded temporarily, it should be done on leveled hard surface. Under base of
the transformer should not rest on the ground as it will lead to rusting of the
transformer.
Place at least 300 to 400 mm wooden sleepers to facilitate jacking.
4.7 PLACING IN POSITION
If foundation is ready and if rail link between unloading point/storage place is
available, then the main body of the transformer must be moved on its own
rollers to the foundation where the transformer is to be erected finally.
If the transformer is not provided with rollers and if it is to be erected on its skid
base, the transformer must be slid to its final position using greased steel plates
to protect the plinth surface and make movement easier. The plates should form
a continuous surface and it must clear the final jacking areas.
The transformer must be pulled by using slings and winches. Use only the
specified haulage lugs for pulling. Pulling capacity of winches should be more
than (Main body weight x 0.15/4) tons. Pulleys should have a capacity of (Main
body weight x 0.15/2) tons.
When jacking (e.g. to remove steel plates), position the jacks under specified
jacking pads only. When jacking, ensure that all four jacks are operated
simultaneously.
Before lowering, clean all grease dirt etc. from the under base of the transformer.
4.8 UNPACKING AND INSPECTION OF ACCESSORIES
Crates / packages are to be opened carefully so that the tools used for opening
do not cause damage to the contents.
Drums containing transformer oil, which have been despatched separately, shall
be examined carefully for leakage.
In case of Condenser Bushings, oil level shall be checked. Porcelain should be
checked thoroughly for any crack or chipping. Any oil leakage or damage to
porcelain must immediately be reported.
Fragile instruments like oil level gauges, temperature indicators etc. are to be
inspected for breakage or other damages.
Any damage or short shipment should be reported to the manufacturer.
4.9 STORAGE OF MAIN BODY
4.9.1 GENERAL
Transformer ground pad must be solidly connected to ground during the

storage period
It is preferable to erect the transformer immediately on receipt at site and fill with
transformer oil. However, if it is not possible, the following precautions should be

Date : Mar 15, 2011 Page 36 of 193
Power Transformers
taken for storing the main body and accessories for longer duration:
Storage period Recommendation
Upto 90 days Store the transformer filled with dry air or nitrogen
(dew point of -50OC or lower)
Between 90 and 180 If the transformer has been filled with dry air, it
days should be evacuated and replaced with nitrogen.
More than 180 days The transformer must be vacuum filled with oil.
To avoid internal condensation the transformer’s control panel, the respective

space heaters must be energised and operating during its entire storage
period.
The storage area should be adequate and should be easily accessible for
inspection.
The surface on which it should be stored is strong and levelled.
Surrounding area of storage is not polluted and water does not accumulate in the
storage area.
Sufficient space is provided underneath for free flow of air and also for lifting,
jacking etc.
4.9.2 GAS FILLED STORAGE
It is recommended to keep the transformer oil filled immediately after receipt. If
oil can not be filled immediately after receipt of main body, it must be retained
with dry nitrogen gas filled at a positive pressure of 0.2 kg/ cm2 at about 20oC.
(Please ref. Fig.– 3.1 of Chapter 3 for Pressure Vs Temperature Chart).
The duration of gas filled storage should be limited to 90 days from the receipt of
main body at site.
If the pressure of gas inside drops due to leakage, the leakage point may be
detected by using soap water. The matter shall be reported to the manufacturer
for immediate corrective action.
Should it not be possible to rectify the leak immediately, the transformer must be
covered by putting a tarpaulin sheet over the whole tank until remedial measures
can be carried out.
Gasket must not be tightened indiscriminately as this could result in loss of
gasket property due to over compression.
Pressure inside the transformer should be monitored on daily basis and any
pressure drop should be made up by opening the cylinder and operating the
pressure regulator. The cylinder should be kept closed.
Before deciding on loss of pressure, the pressure versus temperature chart (Fig.
–3.1) shall be referred to.
If the storage period of transformer at site is expected to be beyond 180 days, it
is recommended to keep it filled with transformer oil.

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4.9.3 OIL FILLED STORAGE

If the gas pressure on arrival at site is found satisfactory, it can be assumed that
there is no leakage.
Before filling oil, all the valves, which were detached during transport, should be
fitted back and blanked.
If possible, the main body shall be fitted with its own rollers and supported on
rails and locked in position.
Assemble conservator, pipe work and fix silicagel breather. Oil shall be filled upto
the conservator corresponding to the ambient temperature.
If the transformer foundation is not ready, it may be stored in any convenient
location. In that case, oil shall be filled upto the level so as to immerse all the
insulation parts in oil and the space above should filled with dry gas.
Fix silicagel breather at any convenient point on the cover.
If the main unit is received at site filled with oil, fit a silicagel breather on any
opening on cover with a suitable pipe.
Before filling oil inside the transformer, its BDV and moisture content should be
measured. If values are not within limit specified, the oil should be filtered.
4.10 STORAGE OF OIL
If the oil is received at site in tankers, it is necessary to provide an oil storage
tank of enough capacity to hold the oil for one transformer.
The oil storage tank should be equipped with valves for oil filling, draining,
sampling and filtration, oil level gauge, silicagel breather and a manhole on top
cover. The inside of the tank should be painted with oil resistant paint / varnish.
Before filling oil, the inside of the tank should be cleaned thoroughly.
If the oil is received at site in sealed drums it may be stored in horizontal position.
If the drums are kept in vertical position, they should be covered with tarpaulin
sheet. Filter holes and air release holes on the drums shall be in one horizontal
line. This will avoid breathing in of moist air. If there is any leakage of oil it can
easily be identified.
The storage area should be free from fire hazards.
4.11 STORAGE OF ACCESSORIES
Accessories and parts must have indoor storage. If indoor storage is not
possible, a weatherproof tarpaulin must be used to cover accessories
wooden boxes.
The following points may be taken care of in order to keep accessories in good
condition without damage, rust and dust.
Check and confirm that all packing cases as per packing list are received in good
condition.

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If erection work is not likely to commence immediately the boxes, which are
opened for inspection, should be repacked and the packing list retained for future
reference and records.
All packing cases should be kept above ground on suitable support so as to allow
free circulation of air underneath. Water should not collect in the storage area.
There should be sufficient space for inspection, handling and transport.
All fragile items and instruments should be stored indoors.
If for any reason, the bushings were not stored according to the
recommendation mentioned above, they must be placed in vertical position
for 48 hours prior to testing or energisation.
The bushings must be stored in their shipping crate. If a bushing is not sored in
its shipping crate, precautions should be taken to provide adequate oil coverage
by positiong the upper end at a level higher than the lower end. An angle of
seven degrees or higher above horizontal must be maintained.
All crates should be kept as per the markings provided on the crates by
manufacturer. As a general rule, all control boxes such as RTCC Panel,
Marshalling Box, Drive Mechanism etc. should be kept indoors in vertical
position.
Crates should not be stacked one over the other.
Strictly adhere to the specific storage instruction provided by the manufacturer for
specific items.
Table - 1 may be referred to for further guidelines for storage and periodical
inspection of transformer accessories.

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SECTION – 5
INSTALLATION

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5.0 INSTALLATION
5.1 TOOLS AND EQUIPMENT REQUIRED AT SITE FOR ASSEMBLY:
Sr. No. Tool/ Equipment Qty. Specifications
1 Oil Storage Tank 1 No. Mild Steel Tank of sufficient

capacity to store the complete
oil in the transformer. The tank
shall be fitted with inlet and
outlet valves of 50 mm diameter.
Inside of the tank shall be
thoroughly cleaned and coated
with hot oil resistant varnish/
paint.
2 Oil Purifier 1 No. Oil purification plant shall have
at least 6 kiloliters/ hr. capacity
and vacuum dehydrator, oil
heater and filtering device.
3 Vacuum Pump 1 Set Vacuum Pump should have
capacity to evacuate the tank
mentioned above and having a
maximum leak rate of 0.5 torr. in
one hour to an ultimate vacuum
of 0.1 torr. in 2 hours.
4 Flexible Oil Hoses: Flexible oil hoses of 50 mm dia.
with flanges on either end.
(of 3 m length) 5 Nos.
These hoses shall be capable of
(of 10 m length) 2 Nos. withstanding vacuum of 0.1 torr.
(of 10 m length) 2 Nos. 50 mm dia. with flanged ends
and capable of withstanding
120O C

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5 Flexible Vacuum Hoses 2 Nos. Flexible vacuum hoses of 75

of 10 m length mm diameter with flanged ends.
The hoses shall be capable of
withstanding full vacuum.
6 Oil testing equipment 1 Set Oil testing equipment shall be
capable of checking break down
voltage of transformer oil across
2.5 mm sphere gap 60 kV
(min.).
7 Vacuum Gauge 2 Nos. Vacuum gauge of
Mc Leod type capable of
measuring vacuum less than
0.01 torr
8 Compound Gauge 1 No. Compound gauge for a pressure
range of
-760 to +760 mm of mercury
9 a) Megger 1 No. Megger of 5 kV with
motor operation is preferable.
b) “ 1 No. Megger of 2 kV.

c) “ 1 No. Megger of 500 Volts.
10 Multi meter 1 No.
11 a) Voltmeter 3 Nos. 0 ~ 300 V AC range.
b) “ 3 Nos. 0 ~ 75 V AC range.
12 Electric Hand Lamp 2 Nos. 100 W Lamp of 100 V or less
with sufficient length of flexible
cable and bulb protector.

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13 Mobile Crane 1 No. Mobile crane of 5 or

10 Tonnes capacity with a
maximum lift of 20 meters.
14 Slings and Shackles Sufficient Nos. Slings and
shackles of sufficient length to
handle weight up to 25 tonnes.
15 Water Proof Sheets 40 m2 For temporary covering of
exposed parts
16 Vinyl Hose 30 Transparent vinyl hose of 12
meters mm dia. to be used as oil level
gauges.
17 Hose Nipple 2 Nos. 12 mm hose nipples

with flanges on one side to
match valve flanges.
18 Methyl Ethyl Ketone / 10 litres For cleaning purpose.
Carbon tetra chloride
19 Rag Cotton cloths 20 kgs. For cleaning purpose.
20 Unstarched Mill Cloth 10 m. For cleaning internal Parts.
21 Knife 2 Nos. For cutting insulation parts.
22 Spanners 2 Sets All standard sizes for both
metric sizes up to 42 mm and
BS ½ to 1½.
23 Screw Driver 2 Nos. 6" Screw driver (-).

24 Painting Brushes 6 Nos. 15 mm, 25 mm & 75 mm
each

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25 a) 3 Phase, 440 Volts,

50 Hz. Electric
Power Supply for
Operating the
vacuum pump
and filter machine
b) Water Supply if
Purifier is water
cooled.
26 Pulling winches/ Pulleys 2 Sets Please refer section 4.3.
each
27 Hydraulic/Mechanical 4 Nos. 50% of total weight of main body
Screw Jacks with with oil.
Locking facility
28 Measuring Tapes 2 Nos. 10 meter long.
29 Spirit Level/Level tube 1 No.
(Plastic)
30 Dry Air Generator (For 1 No. Capacity; 4~5 m3/hr. Dew Point
Transformers of 400 kV –40O C Temperature 25 ± 5OC,
class and above) Outlet pressure 200 Aq.

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5.2 TRANSFORMER ASSEMBLY NOTES

A checklist to aid the customer in performing an internal inspection is provided in
the “Section – 11 Check Lists” of this manual. The internal environment of
transformers of 400 kV class above must be purged with dry air before and during
internal work. Dry air must have a dew point of – 50OC or lower.
Do not open any covers or fittings unless zero gauge pressure exists inside
the unit. Failure to release the pressure may cause equipment damage and
personal injury or death.
The items removed and shipped separately are listed on the outline drawing, such
as bushings, cooling equipment, oil pumps, gas and oil relays etc. Please refer to
the outline for accessories mounting location.
5.3 INTERNAL INSPECTION
 Be certain the internal pressure in the transformer is at zero before opening

the man hole.
 Do post a fire watch at the manhole.
 Do not open the transformer when raining.
5.4 OXYGEN CONTENT
Do not enter any transformer until the gas in the tank is replaced by dry air.
Oxygen content inside the transformer must be at least 19.5% before entering
the transformer. Dry air filled shipment does not imply that the oxygen content
test may be safely omitted. Oxygen content less than 19.5% may cause
drowsiness and/ or injury and death.
If oxygen content is less, it can be corrected by pulling vacuum and re-

pressurising with dry air with dew point of -50OC or lower or by purging through a
sampling valve. The air must be of high purity.
5.5 OIL SAMPLING AND FILTERING
Oil should not be filled in the transformer directly from the drums or transport
container as there is a chance of precipitated water or sediments may also be
pumped into the transformer along with the oil.
Oil from the drums or transport container should be filled into the oil storage tank
and oil parameters should be tested before it is filled into the transformer.
If oil is received in drums, samples should be taken for testing from as many
drums as shown in the Table -1 at random.

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Table -1
Selection of Samples from drums
No. of Drums in a Batch No. of Drums from which Samples to
be taken
2 to 5 2
6 to 20 3
21 to 50 4
61 to 100 7
101 to 200 10
201 to 400 15
401 and more 20
Samples for testing should be collected from the bottom of the drums.
If oil is received in containers, oil sample shall be collected through the sampling
valve at the tank outlet or by means of thief dipper as suggested for sampling of
oil from drums. The container should be allowed to stand for atleast one hour
before drawing the sample.
Conduct the following tests for ascertaining the quality of oil.
a) Breakdown Voltage test
b) Moisture content test
c) Tan delta
d) Resistivity
If oil does not meet the specified criteria, oil should be filtered and stored in the
oil storage tank before filling in to the transformer.
While pumping oil from the barrels, the barrels may be tilted suitably to ensure
that complete oil is taken out from each barrel.
5.6 PRECAUTIONS:
During erection it is advisable that only one hand hole cover is opened at a time
in order to minimise the ingress of moisture. The hand hole cover should be
replaced as soon as the operation is completed.
Dry air of dew point –60oC or better must be fed through the inside of tank when
covers are removed in case of 400 kV and higher class of transformers to avoid
direct contact of winding insulation with moist air outside.
It is essential that the transformer be filled with oil immediately on completion of
each day’s work. The exposure of core and winding should not exceed 16 hours
at a stretch.
Insulation resistance between core frame and tank must be checked before oil
filling with a 2 kV megger, the insulation resistance must be compared with the
factory test results.
Measure the insulation resistance between:

Date : Mar 15, 2011 Page 46 of 193
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a) HV – Earth (Tank)
b) LV/ IV – Earth (Tank)
c) HV – LV/ IV
d) Core Frame – Earth (Tank)
5.7 ERECTION PROCEDURE
The following sequence is flowed for the erection of large capacity transformers
at site.
a) Preparation for Installation
b) Placement of Main body on plinth
c) Receiving Inspection and Storage
d) Oil receiving and filtering
e) Replacing inert gas with Oil
f) Assemble Bushing turrets
g) Assembly Bushings and Cable Boxes
h) Assemble Coolers
i) Assemble Conservator
j) Assemble Pressure Release Device
k) Assemble H V Bushings
l) Assemble Accessories
m) Internal Lead connections
n) Control Wiring
o) Oil Leakage Tests
p) Oil Filling under Vacuum
q) Touch Up Painting
5.8 REPLACE DRY GAS WITH OIL

After installing the transformer on the foundation dry gas in the transformer
should be replaced with treated oil.
Oil should be tested for breakdown voltage and it should be above 60 kV /
2.5mm gap.
Make sure that the hose and pipe interiors are cleaned in advance.
Connect the oil pipes to the lower filter valve on Tank.
Attach a transparent vinyl hose to indicate the level of oil being filled in the
transformer.
Open the top filter valve or any other bolted covers on topmost point on the
transformer for releasing dry gas at the time of oil filling.

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Open the bottom filter valve on the transformer and top air release valve on the
oil storage tank.
Oil should be filled upto a level above the top insulation of transformer winding.
A small gas space (approx. 5~10%) should be left above oil for expansion of oil.
During oil filling, if the filter press stops due to any reason, the top filter valve and
any other opening on the top of the transformer should be closed immediately to
prevent air getting into the transformer.
Oil level shall be continuously monitored during oil filling.
While filling oil directly from the barrels, the barrels shall be tilted suitably to
ensure that complete oil is taken from the barrels.
After filling oil, if the storage is expected to be for a long period, dry gas should
be filled above the oil at a pressure of 0.1 ~ 0.2 kg/cm2.
Assembling work should start from the bottom of the tank so that after initial oil
filling, oil need not be drained again for assembling work.
5.9 PRECAUTION TO MAINTAIN QUALITY

As a precautionary measure to restrict absorption of moisture, the transformer
should not be exposed to atmosphere for more than 16 hours continuously and
erection work should be scheduled accordingly.
Following each day’s work, transformer should be kept oil filled.
For high voltage jobs of 400 kV and above, dry air having dew point below -50oC
should be purged inside the tank during internal assembling work.
Transformer should be tested for B.D.V. before filling and it should be more than
60 kV at 2.5 mm gap.
Extreme care shall be taken against any foreign objects falling inside the
transformer tank during inside working.
Keep only one man hole open at a time and close it as soon as possible.
Avoid inside working on rainy days.
Earthwork near the transformer should be avoided when internal assembly is in
progress to avoid ingress of dust.
While scraping the gasket surfaces of bushing bases, inspection covers etc.,
keep a cloth below to avoid the scraped material falling into the transformer.
Any tools taken inside should be tied by string or cotton tape to the person who is
using the same.
No. of tools shall be counted and recorded before and after each days work in
order to ensure that no tools are left inside.
Gaskets used are of synthetic rubber bonded cork material. These are to be
compressed to 50 ~ 60% of its original thickness. Over tightening and under
tightening of gaskets should be avoided as these may cause oil leakage and
shortening of gasket life.

Date : Mar 15, 2011 Page 48 of 193
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Tightness of all inside connection should be checked and proper locking shall be
provided.
Persons working inside the transformer or top of the transformer should not wear
wristwatches, pen, coins etc.
5.10 ERECTION OF PIPE WORK
All items of pipe work are match marked.
All joints are to be assembled with gasket only and without joining compounds or
grease.
Joints must be fully tightened only when the transformer has been fully erected;
by that stage the pipes can be centralised.
No joint must be under excessive assembled load as subsequent expansion or
contraction could cause leaks.
Ensure that all accessories belong to the same unit.
Vent piping system shall not be used to attach the safety harnesses. Using
this tubing as a safety hook up point, will cause damage to the tubing, leaks
on fittings and may cause an accident.
5.11 ERECTION OF COOLER BANK

Generally for oil forced cooled transformers radiators will be mounted in a
separate cooler bank.
Cooler headers supporting ‘A’ frame are mounted on separate foundations. Refer
"FOUNDATION DRAWING" for details.
Since cooler headers are provided with butter fly type shut off valve, oil from
main body need not be drained for assembling cooler.
Cooler Assembly should be carried out referring to "GENERAL
ARRANGEMENT" of the transformer.
Check and ensure that level of all the foundations for cooler support are in same
level as that of the top surface of rails. Level difference should be compensated
by putting shims if the level is lower and chipping the concrete foundation if the
level is higher.
Fix cooler header mounting frames as per dimensions shown in General
arrangement and Foundation Plan drawing.
Mount cooler headers loosely. Final tightening to be done only after proper
alignment.
Top and bottom butterfly valves of all radiators should be in the vertical line. This
should be confirmed by a plumb.
Remove blanking plates from the butterfly valves.
Tighten the cooler frame foundation bolt, and clamping bolts of cooler headers
and pipe connections.

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While mounting the oil pump and oil flow indicators, care should be taken to
ensure the arrows indicating the oil flow direction are towards the transformer
tank.
While mounting radiators care should be taken to ensure that the weight is
balanced.
Ensure that a fresh gasket is used while mounting the radiators.
In case of separately mounted coolers, the oil pipes are provided with expansion
joints. Tack welded bars on expansion joints should be removed.
Fix the fan mounting frames and fans as indicated in the general arrangement
drawing.
Fan & mounting frame shall be connected to the earth grid.
5.12 CONSERVATOR
Mount the conservator as shown in G.A. Drawing.
Very often the small conservator for on load tap changer is attached to the main
conservator.
Usually the main conservator is provided with Magnetic Oil level Gauge having
low oil level alarm contacts and OLTC conservator is provided with oil sight
window.
Magnetic oil level gauge shall be mounted after attaching the float to the gauge.
Check and confirm free movement of float arm and proper locking of float to the
float arm.
Mount all valves as shown in GA drawing on the conservator.
Mount the connecting pipe with Buchholz relay from the main tank to the
conservator. Ensure direction of Buchholz Relay by the direction of arrow on
Buchholz Relay towards conservator.
Ensure to remove the Buchholz shipping spacer protection for the alarm and
trip switches.
Mount connecting pipe with oil surge relay from OLTC to the conservator.
Mount breather connecting pipes and silica gel breathers for the main tank and
OLTC conservators.

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Power Transformers
The shipping plastic storage plugs must be removed to allow free breathing.
Failure to remove these plugs will cause a unit shut down and/ or cause
leaks at various gasket locations.
METHOD OF MOUNTING FLEXI SEPARATOR (AIR CELL) INSIDE THE

CONSERVATORPROCEDURE - I (OIL FILLING WITHOUT VACUUM)
Set up the air cell in side the conservator. Care should be taken to see that the
hooks on air cell are properly engaged in the brackets provided in side the
conservator.
Inflate the air cell at a pressure as shown in the instruction plate (DO NOT
APPLY EXCESS PRESSURE AS IT MAY DAMAGE THE AIR CELL) through the
breather connection pipe. Follow the instructions given in the Instruction Plate
fixed on the transformer.
Ensure that there is no leakage.
The conservator with Air Cell is pressure tested and despatched from the factory
at a slightly positive pressure. Confirm that there is no oil leakage.
Fix three numbers air release valves on the conservator.
Fig 5.1 Conservator with air cell
Keep air release valves open. Fix air filling adapter on breather pipe and inflate
the air cell at an air pressure indicated on the INSTRUCTION PLATE affixed on
the transformer and hold air pressure.
Open the air release valves and start oil filling from the bottom filter valve of the
transformer.
Observe the air release valves and as soon as oil starts overflowing, close the air
release valves one by one. Stop oil filling when all air release valves are closed.
Remove the air filling adapter.

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Continue oil filling and observe the Magnetic Oil Level Gauge (MOLG)
Stop the filling when the needle of MOLG shows the level corresponding to the
ambient temperature at the time of filling.
Fix silica gel breather.
CAUTION:
a) Do not open any of the air release valves after completion of oil filling. If air
release valve is opened, air will enter and oil level will drop.
b) The plain oil level gauge on the end cover of the conservator should
indicate full oil level always. If air enters the conservator, it can be seen by
a fall in the oil level in plain oil level gauge.
c) The plain oil level gauge should be monitored on regular basis.
FILLING PROCEDURE UNDER VACUUM IN CONSERVATOR
The conservator, with its separator, being set up and plugged in above the
transformer, is connected to its oil filling reserve by a pipe in its lower part.
Proceed as follows:
Create a vacuum in separator.
With the same source of vacuum, create a vacuum in the conservator.
Open the oil filling valve of the transformer. Because of the vacuum in the
conservator, the oil level rises automatically.
Stop the oil filling once the required volume in the conservator is attained.
While maintaining the conservator under vacuum, allow Dry Air or Nitrogen gas
to enter into the internal part of the separator. Then, the separator inflates by
itself, and takes all the free space due to the fact that the conservator was not
completely full. In particular, during the operation, the oil is going to rise to the top
of the conservator.
Inflate the separator at a maximum as shown in the INSTRUCTION PLATE.
Check on the vent-holes, and confirm that there is no more air in the conservator
or, if necessary, adjust the level.
CAUTION:
The above mentioned CAUTION regarding the opening of air release valves
after completion of oil filling is applicable for this case also.
5.13 PRESSURE RELIEF DEVICE
Mount PRD as per manufacturers leaflet and also the G.A. drawing of
Transformer.
Check operation of alarm/trip contacts.

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5.14 ERECTION OF HV TURRETS AND BUSHINGS

Before starting the erection work of Condenser Bushing, lift the Bushing from its
crate and keep it vertical and check the oil level. Confirm that oil level is up to the
centre of oil sight window of Bushing.
If oil is drained from the tank a continuous supply of dry air should be ensured
Fig. 5. 2 METHOD OF LIFTING CONDENSER BUSHINGS FROM

PACKING CASE AND MOUNTING ON THE
TRANSFORMER AT AN ANGLE
while removing the blanking plates and fixing the bushing turrets and bushings.
Dry air shall have a dew point of -60OC or better.
Total exposure time should not exceed 8 hrs.
At the end of each day’s work, blank off all openings and pressurise with dry air.
If weather is bad (rain, snow or fog) the tank should not be opened unless
adequate shelter is provided.
For details of connections from winding to the bushing please refer to the specific
drawing and suppliers catalogue given in the instruction manual.
Ensure that a fresh gasket is used while mounting the bushing.
Ensure that the air release pipe connections are oriented towards the correct
directions, as shown in the GA and part marking drawings.
Check for match markings on the mating flanges.
Bushing shall be mounted in the order of B, A, C or B, C, A.
While mounting the bushings, ensure that the oil level gauge is oriented away

Date : Mar 15, 2011 Page 53 of 193
Power Transformers
from the transformer.

While lowering draw lead type condenser bushing the cable shall be held tightly
by using strong steel/plastic rope. Remember that dropping of cable can cause
injury to the personnel and damage to the transformer.
Check and ensure that secondary terminal of turret mounted C.T. if any are
connected to the proper terminals on the terminal board.
Check and ensure that secondary leads of C.T's. mounted inside the transformer
are connected to the proper terminals in the terminal board.
If holes are not provided in the CT terminal box for fixing cable glands, suitable
holes shall be drilled and cable glands assembled.
Fix all air release pipes between bushing turrets and Buchholz relay connecting
pipe. Please refer to the part marking drawing for respective part numbers of air
release pipes.
5.15 TEMPERATURE INDICATORS
Sensing elements of oil and winding temperature indicators are to be fitted on to
the thermometer pockets welded on the top cover of the transformer.
Before mounting the thermal sensing bulbs, inside of the pocket should be
cleaned thoroughly and filled with transformer oil upto a depth of half the pocket.
Care should be taken not to damage the capillary tubing. Capillary tubes should
be clamped properly.
RTD (if provided and shown in GA drawing) sensor element and heater coil are
fitted on the cover.
Fill oil in the pocket after cleaning.
CT leads shall be connected on one side and sensor leads are taken from the
other side.
RTD instruments are mounted on the remote panel in the control room.
5.16 OLTC DRIVE MECHANISM

In case of on load tap changing transformer, the OLTC driving mechanism has to
be mounted on the transformer. Please refer to the OLTC instruction manual
supplied by the OLTC manufacturer.
Check for mechanical stops at extreme positions by manually operating with the
handle.
Bring the tap position in DM to the tap position 1.
Connect 3-phase supply with correct phase sequence.
Check raise/lower operations. If direction is correct, check electrical end stops at
extreme positions.
Bring back the DM to the tap position 1.
Different manufacturers of OLTC adopt different designs for the DM. Some
manufacturers adopt dry type gear box for the motor and some manufacturers

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Power Transformers
adopt oil filled gear box. Oil, if required, shall be filled as per the manufacturer's
instructions.
Coupling up of drive mechanism and OLTC bevel gear shall be done only after
ensuring that both are at the same tap position. Normally the transformer is
despatched from the factory at rated Tap position.
Operate the DM manually from rated tap to tap no. 1 and then to the other
extreme tap position and bring back to rated tap.
Operate DM electrically. Check and confirm that for each impulse given in both
raise and lower directions, diverter switch operation sound is heard before the
motor stops. After hearing the sound, the travel of the tap position indicating disc
upto the green band shall be equal in both forward and backward crank
operation.
Verify the ratios on all taps using ratio meter or digital voltmeter.
5.17 CABLE BOX ASSEMBLY
If cable box is provided, the assembly shall be carried out referring to the cable
box assembly drawing provided in the Instruction Manual.
Cable sealing ends shall be fitted on to the end of the cable before it is inserted
and bolted on to the cable box.
Cable box assembly may be bolted to the disconnecting chamber on the
transformer tank.
Flexible connections shall be made between bushings and cable box bus bars
through the Inspection Cover.
5.18 INSTRUCTIONS REGARDING USAGE OF GASKETS
Gasket materials used are either Synthetic Rubber Bonded Cork (SRBC) sheet
or nitrile rubber.
SRBC material conforms to RC-70C of IS : 4253(Part II); thickness used are 6.0
mm and 10.0 mm.
Gaskets should be stored in stress free condition and must be protected from
moisture, oil and grease.
Synthetic rubber bonded cork sheets once used should not be used again.
Gasket seating surfaces should be smooth and free from scratches, oil, grease,
dirt etc.
Gasket should be properly located before tightening.
Gasket joints are designed with 40~50% compression.
Gasket joints should be tightened evenly with a diametrically opposite sequence.
Full compression should not be achieved in one go.
Over tightening will cause the gasket material to loose its properties and under
tightening may not prevent oil leakage.
5.19 CHECKING LEAK RATE UNDER VACUUM

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Power Transformers
Fig. 5.3 Oil filling under vacuum process equipment setup.

Step 1: Start vacuum pump and slowly open valve.
Step 2: When the vacuum levle reaches 1 TORR (1 mm Hg) in the transformer,
perform a vacuum drop test to verify whether there is any leakage.
A. “Blank off” the pump by clossing valve 3 and maintain the vacuum pump
running and verify the vacuum levels in the vacuum gauge provided on the
pump. The pressure should drop drastically reaching 50 microns or below
within 5 ~ 10 minutes.
B. Open valve 3 and close valve 1, this is to verify the sealing within the hose.
The variation in the level of vacuum should not be more than 0.05 TORR. If
the variation is more, leakage should be suspected.
C. Open valve 1 and wait 5 minutes for the pressure to stabilise in the

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Power Transformers
transformer. Record the level of vacuum reached.

D. Wait exactly 15 minutes after the pressure has stabilised and re-check the
vacuum level in the transformer.
E. The difference of 5 and 15 minutes readings is used to calculate the leak rate.
If the leak rate exceeds 50 torr – liters per second, then there is a leakage
present in the transformer.
To calculate the leak rate, use the following formula
P V
L Where: P = Change in level of vacuum (torr)
V = Total volume of oil (in litres obtained from the
Rating & Diagram plate)
L = Leak rate (torr – litres/ second)
F. Repeat the above procedure until the leak rate is below 50 torr liters per
second.
5.20 INSULATION OF CORE AND FRAME TO TANK
If the internal body earthing lead is brought out through low voltage bushings, the
megger values shall be measured using 2 kV megger and the values recorded.
5.21 OIL LEAKAGE TEST
Oil leakage test is done after attaching the oil pipes, bushing, radiators,
conservator, relief device and all the instruments.
Remove the breathers and connect dry gas cylinder with pressure gauge to the
connecting pipes if conservator is not provided with air cell. If conservator is fitted
with air cell, pressure shall be applied after connecting an equaliser pipe between
the air release valve and breather connection pipe. Otherwise the air cell may get
damaged.
Remove PRD and explosion vent if provided and blank the opening.
Open all valves between conservator, main tank and OLTC.
Fill oil in the transformer upto 1/3 rd of the conservator through oil filter.
Apply a gas pressure above the oil such that the pressure at the base of the tank
is between 0.7 kg/cm² to 1.0 kg/cm².
Check for oil leakage at all bolted and welded joints by keeping the pressure for
24 Hrs.
 Apply powder and alcholhol mix on every gasket joint removed for site
installation/ assembly
 Monitor for 24 hours and confirm that no leak is present.
If any leakage is noticed, rectify the leak and continue the test.
Break pressure and reassemble breathers, PRD, explosion vent etc.
5.22 VACUUM OIL INJECTION
Please refer to Fig 5.3 for the oil filling equipment setup.

Date : Mar 15, 2011 Page 57 of 193
Power Transformers
COLUMN 1 2 3 4
BIL (kVp) Upto 350 450 ~ 550 650 ~ 750 825 ~ 1425
Initial Vacuum Level 2 Torr 1 Torr 0.5 Torr 0.25 Torr
Level of vacuum to be 2 Torr 2 Torr 1 Torr 1 Torr
maintained during oil
filling
Soaking period before 8 Hours 12 Hours 24 Hours 48 Hours
energising
Table 5.1 – Vacuum oil filling requirements
Minimum level of vacuum to be maintained during oil filling of transformers of
different voltage class are shown in Table 5.1. The vacuum shall preferably be
measured by using McLeod Vacuum Gauge.
After draining the oil completely from the transformer, vacuum should be pulled
from the oil filling hole on main conservator. If the conservator is fitted with air
cell, pressure equalising connection is required to avoid damage to the air cell.
For facilitating evacuation of main transformer and diverter switch compartment
of OLTC simultaneously, an equaliser pipe (Refer GA drawing for item number &
location) is supplied. This is to be fitted during evacuation and removed after
vacuum oil filling.
Before starting vacuum, all bolted connections shall be checked.
Radiator valves shall be kept open.
If explosion vent is provided, the pressure shall be equalised on either side of the
diaphragm to avoid damage to the diaphragm.
Vacuum shall be maintained for 6 hours.
The oil temperature during the start of filling shall be maintained at 50 ~ 60OC.
Oil may be injected through the bottom filter valve until the level reaches 35oC
marking on the Magnetic Oil Level Gauge of the conservator.
Initial oil filling shall be done at a slow rate (do not exceed 150 lpm) . Rise in oil
level per hour inside the transformer shall be limited to 300 mm.
Natural rubber hose shall not be used as sulphur in the rubber may react with oil.
Oil inlet valve shall be closed and after one hour the vacuum shall be broken.
Install all remaining components.
Oil level indicating vinyl hose can be removed by closing the bottom sampling
valve.
Vacuum gauges may be detached and breathers assembled in its position.
Pressure equalising connection provided for explosion vent diaphragm and
OLTC diverter chamber shall be removed.

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Power Transformers
5.23 TOUCH UP PAINTING AT SITE

Any damage to the painting of the transformer and accessories shall be made
good after erection work is completed.
If a welding has been done on the transformer at site, the paint film burnt by the
welding shall be removed by wire brush or metal spatula.
Remove the rust by wire brush and emery paper #80 / #100.
Wash away the oil, grease, dirt and dust by using suitable solvent and dry it up.
Polish the surface to be painted by using emery paper #80 /#100 and then clean
the surface.
After cleaning, stir the ready mixed rust resistant primer paint 'Yellow
Zinchromate' or 'Red Oxide' primer paint. Before applying the paint, confirm the
correct viscosity.
Apply the paint uniformly by using a brush. drying time for the paint is normally 4
hours.
After the first coat of paint is dried up, mix and stir the finish coat paint to the
desired viscosity and apply by brush uniformly. Drying time of finish coat paint is
normally 6 hours.
Inspect the repainted surface and do re-painting if the painting is not uniform and
unpainted surface is visible.
Recommended viscosities for painting :
(i) For brushing : 50 ~ 55 sec.
(ii) For spraying : 20 ~ 25 sec.
(iii) Pressure for spraying : 55 ~ 60 psi.
(iv) Time gap between two coatings : 24 Hours.
(v) Total dry film thickness after final coating: as per data sheet
(80 ~ 100 microns if not specified)
5.24 MIXING OF TRANSFORMER OIL

Some times a need arises at site to top up a transformer with oil of a different
make.
New oils can be mixed with each other irrespective of the source or degree of
refinement if both the oils meet the same standard specification.
Inhibited oils can be mixed only if the inhibitor used is same in both the oils or the
other one is uninhibited.
At any point of time, the percentage of new oil topped up shall be limited to 10%
of the total oil quantity.

Date : Mar 15, 2011 Page 59 of 193

Power Transformers
SECTION – 6
INSULATION DRYOUT AT SITE

Date : Mar 15, 2011 Page 60 of 193

Power Transformers
6.0 INSULATION DRY OUT AT SITE

The following flow chart shall be used to decide the proper vacuum dry-out
process needed.
Leak Test @
(5 – 7 p.s.i)
Moisture content
Verification
Yes Less or equal

than 0.5 %?
No
Hot oil dry–out

Temperature Yes Process
below 10°C? (According to the
Appendix Section)
No
Greater than or
Yes
equal to 1.8%?
No
Vacuum dry –
out Process
(According to
Appendix A.4)
Vacuum filling`
Process
(According to
Section 5.22)
Vacuum dry-out and oil filling flowchart

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Power Transformers
6.1 HOT OIL CIRCULATION

Connect bottom filter valve of tank to inlet point of filter machine.
Connect top filter valve of tank to outlet of vacuum filter machine and start
oil circulation.
The filter outlet temperature should be limited to 60 ~ 70OC.
Continue filtration for 4 cycles.
Oil circuit should include a vacuum chamber in which oil drawn from the
transformer is sprayed and the moisture and gases are released from the
oil are extracted by the vacuum pump.
Oil drawn from transformer is passed through a filter press before being
admitted to the vacuum chamber to remove impurities
A minimum capacity of 6000 litres per hour is recommended for the
circulation equipment.
Cooler connection at inlet shall be kept closed to minimise loss of
temperature during circulation. Outlet valve shall be kept open to allow
expansion of oil inside the cooler.
Coolers also shall be included in the hot oil circulation towards the end of
the process.
Drain the oil by simultaneously admitting dry air or nitrogen gas from the
top. This is to avoid winding insulation coming in contact with moisture.
Apply vacuum of 1.0 torr or better and maintain for 6 Hrs.
Inject oil under vacuum upto a level of approximately half of the
conservator.
Start hot oil circulation again as explained earlier and continue for 4 cycles.
Maintain temperature of 60 ~ 70o C.
Drain oil by feeding dry air or nitrogen gas as explained.
Apply vacuum as explained
Repeat vacuum/hot oil circulation cycle till required dryness is obtained.
Normally 3 or 4 cycles of hot oil circulation and evacuation will be sufficient
to obtain the required dryness for the insulation.

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Power Transformers
Variation of Insulation Resistance with Temperature

Dryness of insulation is determined by measuring insulation resistance of
transformer winding.
Insulation resistance between each pair of windings and also between
windings and earth shall be measured by using a 5 kV megger. Readings
shall be comparable with the factory test results.
Direct heating of transformer is not recommended for dry out at site.
Oil samples shall be tested for moisture content, (Below 20/15/10 for
145/220/400 kV class respectively). Break down voltage (More than 60 kV
at 2.5 mm gap). Resistivity ( 1012 ohm meter) before final oil filling.
Do not measure insulation resistance when the transformer in under
vacuum.

Date : Mar 15, 2011 Page 63 of 193

Power Transformers
SECTION – 7
COMMISSIONING

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Power Transformers
7.0 COMMISSIONING
7.1 POST ERECTION CHECKS
7.1.1 INSPECTION AND MAINTENANCE LOG SHEET

It is important that an inspection and maintenance log sheet be kept regularly.
The original of this log sheet should be kept along with the Instruction Manual for
future reference and record.
The log should include dates and details of all inspections and maintenance
carried out.
Results of oil tests and insulation resistance together with the temperatures at
the time of measurement should also be recorded in the log sheet.
Before commencing the test it should be ensured that the secondary terminals of
all current transformers are kept short-circuited. After test these shorting
connections shall be removed.
7.1.2 PHYSICAL CHECKS

Check oil levels in the level gauges of all condenser bushings.
All air release plugs shall be loosened and closed after releasing trapped air if
any.
Check and confirm tightness of all fasteners.
Check and confirm that valves are either open or closed as indicated the valve
schedule plate.
Check all bolted gasket joints and confirm that there is no oil leak.
All blanking plates and spares including spare gasket should be stored carefully
for future use.
Check all cable terminations and ensure that cables are properly connected and
cable numbering ferrules are provided.
Check and ensure that all protective covers like valve guards, LV bushing
protection covers etc. are removed.
Check and confirm that all bushing porcelain are cleaned thoroughly and are
without damage.
Check & confirm that the test tap caps of all Condenser type Bushings are
tightened.
Remove the cap provided at the bottom of silicagel breather for the transportation
purpose.
Arcing horns if provided are set to the specified gap
All earthing connections are tightened properly.
Anti condensation heaters are functioning correctly.
Rating and connection diagram plates and other marking labels are fitted

Date : Mar 15, 2011 Page 65 of 193
Power Transformers
properly.
All isolating switches are set at ON position.
Cooler control switch is set to AUTO.
All alarm circuits are reset.
OLTC to Transformer equalising pipe shall be removed after oil filling under
vacuum and the opening shall be coverd by blanking plate supplied with the
transformer.
7.2 INSULATION RESISTANCE CHECK

Check and record insulation resistance between pair of windings and windings
and earth using 5 kV Motorised megger megger and record the values at 15, 60
& 600 seconds.
Calculate the ratios of insulation resistances IR 600/ IR 60 (Polarisation Index.)
and IR 60/ IR 15
Compare the values with factory test results.
Check insulation resistance between core and frame to ground if the earthing
connection is brought out through bushings.
Do not apply any voltage or even high voltage megger when the equipment is
under vacuum.
7.3 RATIO TESTS

Connect 3-phase 415 volts supply between HV terminals and measure the
voltage ratios at all taps and record.
Earth connections from star point shall be removed during measurement and
reconnected after tests.
7.4 VECTOR GROUP TESTS

Connect 415 V, 3-phase supply to HV winding terminals. The transformer shall
be at rated tap.
Connect one HV terminal to one LV terminal and measure voltage between each
HV terminal to each LV terminal in turn. Compare the values with factory test
results.
E.g. for Ynyno: -
Measure voltage between
1u -1V, 1u - 1W , 1V2 - 1W,
1u -2V, 1u - 2W, 2V2 - 2W,
1u -2V, 1W - 1W, 1W2 - 2W,
7.5 MAGNETIC BALANCE TEST

Single-phase 240 volts is applied across any HV winding and voltage induced
across the other phases are measured and compared with the factory test
results.

Date : Mar 15, 2011 Page 66 of 193
Power Transformers
 CAUTION:
If there is a residual magnetism in the core, it can give erratic
readings.
7.6 SHORT CIRCUIT IMPEDENCE

LV terminals are shorted by using suitable cables.
3 phase 415 volts supply is connected to HV winding and HV exciting current of
all the phases and LV circulating currents of all the phases are measured and
recorded.
Percentage impedance = Rated current x Applied voltage x 100
Measured current x Rated voltage
Compare the results with factory test results.
7.7 WINDING RESISTANCE MEASUREMENT

Note down the oil/winding temperature. If the measurements are done after hot
oil circulation; the oil/winding temperature may be different from the ambient
temperature.
Measure the resistance of all windings using a Whetstone Bridge or Kelvin
bridge.
Convert the resistances to 75oC.
For copper windings:
R (75) = R (measured) x (234.5 + 75)
(234.5 + Oil temperature at the time of measurement)
7.8 TAN DELTA AND CAPACITANCE

Measure tan delta and capacitance of Condenser bushings of 52 kV and above
and compare with the factory test results (Refer to "INSTRUCTIONS FOR
INSTALLATION AND MAINTENANCE OF OIP CONDENSER BUSHINGS"
provided elsewhwhere in this Manual).
7.9 OPERATION CHECKS

Check direction of rotation of pumps and fans.
Check and confirm that flow indicators are mounted correctly.
Check signalling circuits for pump fail/fans fail etc., and reset.
Check setting of over load relays and reset.
7.10 BUCHHOLZ RELAY OPERATION

Check inclination of Buchholz relay pipe. The slope should be in upward

Date : Mar 15, 2011 Page 67 of 193
Power Transformers
direction, between 3 ~ 9O to horizontal towards the conservator.

Connect a compressed air line (Pressure 4 kg/cm2) or a nitrogen cylinder to the
petcock on top of the Buchholz relay.
Open the petcock slowly and allow air to enter into the Buchholz relay.
Check the continuity of alarm contacts by using a multimeter.
Record the volume of air in the Buchholz Relay at which the alarm switch contact
closes.
Close the air supply and release all the air by opening the other petcock on the
Buchholz relay.
Open the petcock quickly and allow air full flow with surge. Record the minimum
pressure required to operate the surge contacts.
Release all the air trapped in the Buchholz relay.
7.11 WINDING TEMPERATURE INDICATOR CALIBRATION

Rotate the indicator pointer slowly and confirm that the alarm signal is received at
the set temperature.
Rotate the pointer slowly and confirm that the trip signal is received at the set
temperature.
For set values of alarm and trip contacts, please refer to the instruction manual.
Repeat the test for all winding temperature indicators if more than one indicator is
provided.
Remove the thermal sensing bulb from the transformer cover and insert in hot oil
bath.
Check the readings with clinical thermometer.
Replace the sensing element in transformer pocket and check the readings or
remote winding temperatures if provided.
For any adjustment if needed please refer to the instrument supplier's catalogue.

Date : Mar 15, 2011 Page 68 of 193
Power Transformers
SECTION – 8
OPERATION

Date : Mar 15, 2011 Page 69 of 193

Power Transformers
8.0 OPERATION
After the inspection and pre-commissioning tests are successfully completed the
transformer can be energised at no load.
Oil soaking/ settling duration of 2 days for transformers up to 245 kV class and 3
days for 400 kV and above class are recommended after completion of hot oil
circulation and before energising.
Excessive vibration if any on any part of the transformer shall be located and
rectified.
Transformer shall be observed for any abnormality.
If any gas is collected inside the Buchholz relay, it shall be analysed for its
combustibility. If gas is not combustible, it indicates air trapped inside the
transformer.
All instruments should be checked for any abnormal indication.
Check winding temperature and oil temperature readings at least once in every
shift.
Check and confirm that tap position indicators is same in local and remote
indicators.
Check and confirm that none of the alarms are indicated.
Ensure that cooler power supply isolator is ON.
Ensure that cooler control is in AUTO.
Ensure that pumps and fans are running smoothly as temperature dictates. If the
temperature is below the ON setting neither the pump nor fan should be running.
After watching the operation of the transformer at no load for 24 hours and
confirming that everything is normal, the transformer shall be taken on load.
Observe the rise in temperature of oil and winding temperature indicators.
While temperature is rising, confirm that fans and pumps are switched on
automatically at the preset temperatures.
While temperature is falling, observe that the pumps and fans are switched off at
preset temperature.

Date : Mar 15, 2011 Page 70 of 193
Power Transformers
8.1 ROUTINE / PERIODIC INSPECTION SCHEDULE FOR POWER

TRANSFORMER
S. No. Items to be inspected Frequency
1 Load current Hourly
2 Terminal Voltage Hourly
3 Ambient Temperature Hourly
4 Winding Temperature Hourly
5 Oil Temperature Hourly
6 Tap position Daily
7 Air cell conservator Daily
8 Oil level in Conservator Daily
9 Oil level in Bushings Daily
10 Oil level in OLTC Conservator Daily
11 Oil level in breather cup Daily
12 Connections Monthly
13 Dust deposits & physical damages to bushings Monthly
14 Air passage & colour of silica gel in breather Quarterly
15 Cable boxes, gasket joints, gauges etc. Quarterly
16 Dielectric strength of transformer oil Half yearly
17 Moisture content of transformer oil Half yearly
18 Dissolved gas analysis of transformer oil Half yearly
19 Resistivity of transformer oil Half yearly
20 Insulation resistance of windings Yearly
21 Tan delta & Capacitance of condenser bushings Yearly
22 Operation of relays and their circuit Yearly

23 Surface paint 2 ~ 3 Years**
Note:
** Duration of surface repainting depends on the level of pollution prevailing at site. If
pollution level is high, a frequent repainting schedule may have to be worked out.
 Lifting of core and windings are not recommended as a routine inspection.
 Core and coils are to be inspected only if such an inspection is warranted by test
results of dissolved gas analysis, any abnormality in performance or for suspected
internal damages due to external short circuit.

Date : Mar 15, 2011 Page 71 of 193
Power Transformers
SECTION – 9
MAINTENANCE

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Power Transformers
9.0 MAINTENANCE
Maintenance Schedule
Periodicity
Preventive Maintenance
Procedures Months Scheduled
3 6 12 outage
Replacement / Regeneration of 
Silica gel Breather
Dissolved Gas Analysis 
Oil Sampling 
Buchholz Relay Functional Tests 
Tan Delta & Capacitance 
Measurement of Condenser
Bushings
OTI/ WTI Tests 
Tap changer operation 
Insulation Resistance of Windings 
Oil Filtration 
Surface Painting 
9.1 Oil Sampling

Oil sample should be tested for the following and results recorded: -
9.1.1 Electric Strength
If the dielectric strength of oil in transformer is less than 55 kV at 2.5 mm gap, the
oil must be filtered to improve the characteristics.
For line end OLTC diverter chamber, oil filtration is recommended when the BDV
is  40 kV at 2.5 mm gap.
For neutral end OLTC diverter chamber, oil filtration is recommended when the
BDV is less than  30 kV at 2.5 mm gap.
9.1.2 Moisture Content
For transformers of 400 kV and above class, if the moisture content is found to
have increased beyond 20 ppm oil should be filtered.
For transformers of voltage class up to 245 kV, if the moisture content is found to
have increased beyond 25 ppm oil should be filtered.
9.1.3 Acidity
It the acidity is increased beyond 0.5 mg KOH/g, than the oil needs filtration.
After draining the oil completely from the transformer, core, winding, insulation
and interior of tank should be washed by hot oil jet. The oil being used for
washing of internal body also must be drained completely.

Date : Mar 15, 2011 Page 73 of 193
Power Transformers
Refilling of oil in transformer should be done under vacuum.

9.2 Sampling procedure
Special care in oil sampling is required for Delta connected transformer and
autotransformers.
9.2.1 Tools required
Spanner set
Thermometer
Steel sampling bottles with polyethylene cone caps.
Silicon rubber tubing 10 mm bore - 1 m long.
Clean synthetic sponge.
Polyethylene sheet - 1 m square
Clean cloths
Self adhesive labels
9.2.2 Procedure
The sampling bottles shall be labelled and marked with information like source of
sample, date and time & sample temperature.
Sample bottle shall not be opened before it is needed for testing.
Sampling point should be cleaned by using sponge.
Blanking plate of sampling valve shall be removed by using spanner.
Clean the silicon rubber tubing thoroughly and fit to sampling point nipple.
Rinse the bottle in oil stream and reduce the rate of oil flow to 1 litre/minute.
Put the end of rubber tubing to sampling bottle and fill the bottle from bottom.
No air bubble shall be introduced into the bottle.
The bottle is allowed to overflow before it is closed.
Measure and record the temperature of oil sample as soon as it is taken.
Put back and tighten the blanking plate.
Remove all tools, excess oil container and oil sample from the area.
Arrange for testing oil sample at laboratory.
9.3 WINDING TEMPERATURE INDICATOR TESTS
9.3.1 Tools and materials
Hot oil bath (with heating facility)
Secondary injection test set
Multimeter
Clinical thermometer
Keys of marshalling box.
9.3.2 Procedures
The purpose of this check is to confirm that the winding temperatures Indicators
are functioning accurately.
The transformer shall be isolated and earthed.
Rotate the indicator pointers slowly to the alarm set value and confirm from the
control room that the alarm signal has been received.
Rotate the pointer still further and confirm from the control room that trip signal is
received.

Date : Mar 15, 2011 Page 74 of 193
Power Transformers
9.3.3 Calibration
Remove the thermal sensing bulbs from the transformer and insert it into the hot
oil bath.
Check the winding temperature readings up and down the scale at intervals of
5OC.
Confirm from control room that remote temperature readings are tallying with the
local readings.
Replace the sensing element into the transformer pocket.
Note: For any adjustment, see the manufacturer's catalogue.
9.3.4 SECONDARY INJECTION TESTS
9.3.5 ONAN Rating
Set the cooler supply isolator of OFF position.
Connect the secondary injection test set across the heater coil terminals.
Inject current and check the resultant gradient for ONAN rating.
9.3.6 OFAF Rating

In order to carry out these tests the pump must be running.
Set the cooler isolator to ON position.
Set the cooler switch to fans and pumps.
Check and confirm that the pump is running.
Inject current in the heater coil and check the gradient for OFAF rating.
Disconnect.
Set the cooler control switch to AUTO.
9.4 BHOLZ RELAY FUNCTIONAL TEST
Tools and Materials Required.
Multimeter
Nitrogen cylinder with regulator and pressure gauge or air supply (4 kg/cm²)
Bucket
10 mm polythene tube, 10 meters.
9.4.1 Procedure
The purpose of this test is to ensure correct operation of Buchholz relay.
Transformer shall be isolated and earthed.
Connect nitrogen cylinder to the top petcock of Buchholz relay.
Open the other petcock.
Allow gas to enter the relay.
Check and confirm from control room that alarm signal is received.
Check continuity of alarm contact by using multimeter.
Close petcock on gas supply side and release all gases trapped in relay casing.
Increase the gas pressure to approx. 2 kg/cm² (30 psi)
Open the test petcock and allow full surge of gas to enter the relay casing.
Check and confirm from control room that trip signal has been received.
Check continuity of trip contacts by using multimeter.
Close Buchholz relay test cocks.

Date : Mar 15, 2011 Page 75 of 193
Power Transformers
If relay has not operated, increase gas pressure and repeat the test.
If the relay is found faculty replace it with a new one.
Open conservator shut off valve and release all gases trapped.
9.5 TAPCHANGER OPERATION
Regular inspection of tap changing equipment is not required because
mechanical operation of tap changer does not involve significant contact wear.
It is sufficient to operate the tap changer through the whole range of tap selector
positions twice a year.
The purpose of this check is to ensure correct mechanical operation of tap
changer.
Note the tap position.
Operate the tap changer through operating handle through entire range of tap
positions.
Return to the original tap position.
Set the local selector switch to LOCAL.
Press RAISE button and release. Check and confirm the tap position indication
has changed and that limit switch stops the tap changing at preset tap.
Repeat.
Press the LOWER button and release. Check and confirm that limit switch has
operated and tap position indication has changed.
Repeat till the tap position has returned to the original value.
Set the local selector switch to REMOTE.
9.6 OIL FILTRATION
Purpose of this maintenance is to improve the unsatisfactory condition of oil
found during sampling.
9.6.1 Tools and Materials
Oil conditioning plant (Filter Machine)
50 mm flexible hoses of sufficient length for oil inlet and outlet.
Hose adapters to match the flanges of top and bottom filter valves.
Cleaning cloths
9.6.2 Procedure
Remove the blanking plate from filter valves and connect the oil inlet hose to top
filter valve and oil outlet hose to the bottom filter valve.
Open the filter valves and start circulation of hot oil. Oil temperature shall be
55°C to 70°C.
Circulate the oil for 4 full passes.
Re sample and arrange to test.
Continue until oil condition is acceptable.
9.7 CORRECTIVE MAINTENANCE
All flange gaskets must be renewed wherever joints are dismantled.
Cleanliness of gasket surfaces and correct compression (40 % ~ 50% approx.) of
gasket must be ensured during reassembling.

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Power Transformers
9.8 REMOVING AND REFIXING OF PUMPS

Jib crane or chain pulley block to handle the weight of pumps.
Oil drip tray
Blanking plates
New gaskets.
9.8.2 Procedure
Transformer is isolated and earthed.
Close the isolating valves on either side of pump
Disconnect the motor supply wires
Remove the drain plug of the pump and drain oil from the pump.
Remove the clamping bolts and remove the pump
Blank off the isolating valve.
For re-fixing the pump, remove the blanking plates.
Fix new gaskets.
Replace and tighten the clamping bolts.
Open the isolating valves on cooler side.
Open air release plug and close when oil starts flowing out.
Open the isolating valve on transformer tank side.
9.9 REMOVING AND RE FITTING RADIATOR
9.9.1 Tools and Materials
Jib crane to handle the weight of radiator.
Oil container (capacity approx. 1000 litres)
Oil drain hose 50 mm bore
Hose adapter to match flanges of fitter valve.
Oil filter machine
New gaskets.
9.9.2 Procedure
Set the cooler supply isolator of OFF.
Close the inlet and outlet valves if radiator is mounted on a separate cooler bank.
Close the top and bottom isolating valves of radiator.
Open the top air release plug.
Remove the bottom drain plug and drain the oil to oil container under gravity.
Sling the radiator with jib crane.
Remove the radiator clamping bolts.
Remove radiator.
Blank off the radiator and header openings.
Close the air release and drain plugs.
For Re fitting the Radiator.
Remove the blanking plates.
Fix new gaskets.
Assemble the radiator and tighten the clamping bolts.
Open the top header air release plug.
Open the bottom radiator isolating valve.

Date : Mar 15, 2011 Page 77 of 193
Power Transformers
If the radiator is on a separate cooler bank, oil shall be filled into the radiator
bank through the bottom header valve by using the filter machine. If the radiator
is tank mounted, the oil from the oil tank should be pumped into the tank by using
the filter machine.
Close the air release plug on top as soon as oil starts flowing through the air
release plug.
Shut down the oil filter machine
Open top header isolating valve.
In case of separate cooler banks, air should be released through the top common
header air release plugs.
9.10 REMOVING AND RE FITTING FAN & MOTOR
Forklift truck to take weight of fan and motor assembly.
9.10.2 Procedure
The transformer is to be isolated and earthed.
Set cooler supply isolator to OFF and lock the marshalling box.
Disconnect the fan motor supply wires.
Support the weight of fan and motor assembly by using fork lift truck.
Unbolt fan and motor form fan mounting frame.
Lower the fan from the fan-mounting frame.
9.10.3 Re fitting Fan and Motor

Assemble the fan and motor in position and tighten clamping bolts.
Re connect the power supply wires.
Unlock marshalling box and set cooler supply isolator to ON.

Date : Mar 15, 2011 Page 78 of 193
Power Transformers
SECTION – 10
TROUBLE SHOOTING

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Power Transformers
10.0 TROUBLE SHOOTING

Following table shows some of the symptoms, possible causes and remedies in
case of abnormal situations: –
If the abnormality is of a major nature, the manufacturer should be contacted at
the address given elsewhere in this Manual. When the matter is referred to the
manufacturer it shall contain the following: -
10.1 Transformer Rating.
 Voltage Rating.
 Manufacturers Indent No. / Serial No.
 Year of Manufacture.
 Date / Time of failure.
 Brief description of the problem.
 Checks done and their results.
10.2 ABNORMAL OPERATING CONDITIONS
TROUBLE CAUSE REMEDY
High Winding/ Oil Change the circuit voltage or transformer
Over voltage
Temperature connections to avoid over excitation.
Over current If possible, reduce load. Heating can be
reduced by improving power factor of load.
Check parallel circuits for circulating currents,
which may be caused by improper ratios or
impedances.
High ambient Either improve ventilation or relocate
temperature transformer in lower ambient temperature.
Insufficient cooling If unit is artificially cooled, make sure cooling
is adequate.
Low oil level Top up oil to proper level.
Deterioration/ Use filter press to wash off core and coils.
sludge formation Filter oil to remove sludge.
of oil.
Short circuited Test for exciting current and no load loss. If
core high inspect core and repair. See Electrical
Troubles, below.
Electrical Lightning, short Usually, when a transformer winding fails, the
Troubles/ Winding circuit, Overload transformer is automatically disconnected
Oil of low dielectric from the circuit by the circuit breaker.
Failure
strength.

Date : Mar 15, 2011 Page 80 of 193
Power Transformers
10.3 DIAGNOSIS OF INTERNAL FAULTS

When the operation of a protective device does not clearly indicate an internal
fault, it is desirable to conduct the preliminary measurements and analysis before
dismantling the transformer.
Conditions before and after the development of fault should be taken into
consideration in arriving at a conclusion.
No CHECK DESCRIPTION CRIETERIA
POINT
1 Measurement Measurement must be taken after
of Insulation isolating the transformer from the
Resistance of circuit and cleaning the surface of
Windings insulators. Insulation failures can be
detected by this measurement.
2 Measurement When measurement is made in one Comparison with
of winding circuit, other circuit must be kept factory test results.
resistance open circuited. This measurement
can detect winding faults.
3 Measurement This can be conducted by applying
of Transformer 230 volts, which can be readily
Ratio. available at site. For three phase
jobs, measure ratios phase by
phase.
4 Measurement Measurement can be made by If values obtained
of No Load applying 230 volts under normal are higher
Current conditions by making use of locally compared to factory
available power source. This test results, it
measurement can detect fault in indicates faulty
windings and core. condition.
5 Testing of oil Measure Break Down Voltage, Judgment to be
moisture content, tan delta & check made with reference
for sludge formation, discoloration to tables 9.1, 9.2,
and unusual smell. 9.3, 9.4 & 9.5
6 Measurement Abnormal increase means Comparison with
of Tan delta of deterioration of insulation. factory test result
Windings
7 Analysis of When gas is accumulated in Manufacturer may
gas collected Buchholz relay. It should be be contacted for
in Buchholtz analysed by gas chromatograph to advice
Relay check presence of combustible
gases.
8 Dissolved Gas Development of internal incipient Refer to tables 9.6,
Analysis fault can be judged from the results. 9.7 & 9.8 Contact
Increase in gas composition to be manufacturer for
monitored at periodic interval. advice.

Date : Mar 15, 2011 Page 81 of 193
Power Transformers
10.4 PROTECTIVE DEVICES

No. DETECTIVE DESCRIPTION
DEVICE
1 Pressure Relief When the internal pressure increases beyond the
Device preset value of PRD it operates. This may also
happen if the breather connection is choked.
Judgment based on the inspection of other protective
relays is essential
2 Differential This relay detects the internal defects by comparing
Relay the input current and the output current of the
transformer. If it functions simultaneously it indicates
internal fault. Please note that this relay sometimes
operates due to in rush current when transformer is
energised and this is not an internal fault.
3 Oil Temperature This thermometer gives Alarm when the temperature
Indicator/ rises beyond the set value. Over loading, insufficient
Winding cooling because of contamination of fan impellers,
Temperature stoppage of fans/pumps etc. are to be checked.
Indicator Alarm
4 Over Current These are intended for detecting faults in power
Relay/ Earth system associated with the transformer. A fault in the
Fault Relay transformer results in operation of these relays. This
is accompanied by actuation of protective devices of
the transformer. Identification of fault should therefore
be made on the basis of a thorough analysis of these
functions.
5 Voltmeter/ If a sudden change in voltage or current is noted
Ammeter when there is no abnormality in the power system or
an unbalance of voltage or current is noted between
phases, the reasons should be investigated.
6 Human Sense Human sense can play an important role in detection
of faults.
a) Discoloration or odour of insulating oil. If pieces
of insulating materials or copper are found in oil,
an internal fault can be suspected.
b) Abnormal noise or vibration.
10.5 VALVES, GASKETS, WELD JOINTS
SYMPTOM POSSIBLE CAUSE REMEDY
Oil Leak Loose joint Tighten the joint evenly. If the leak does
not stop, renew the gasket.
Welding joint Take the help from manufacturer.
Valve can’t Gland packing not Renew the gland packing and adjust gland
be opened fitted correctly. packing nuts evenly.
Valve spindle bent. Fit new valve spindle. Dismantle valve,
Seating for valve free valve plug or fit new valve.
plug corroded

Date : Mar 15, 2011 Page 82 of 193
Power Transformers
10.6 PUMPS
Pump Motor Impeller binding Remove the pump and investigate
over heats the problem.
Insulation failure of Remove the pump and investigate
Motor Winding the problem.
Two phase operation Check power supply.
Remove pump and investigate the
Motor bearings worn
reason
Pump motor Remove pump and investigate the
Impeller damaged
vibrating reason
Pump bearing bushes Remove pump and investigate the
or rings worn. reason
Pump Valve not fully open Open the valve fully.
running; Impeller damaged or Remove pump and investigate the
but output worn reason
low. Speed too low Check electric supply.
10.7 FANS
Remove the fan and investigate
Fan motor Motor bearing worn
reason.
overheats
Two phase operation Check electric supply
Fan vibrating Fan blades out of Balance the fan or replace
balance and noisy
Mounting bolts loose Check and tighten fasteners.
10.8 BUCHHOLZ RELAY
SYMPTOM POSSIBLE
REMEDY
CAUSE
Rate of Electrical Identity of Class of fault Inference
gas response of gas
evolution relay
NONE Trip None Oil surge Faulty operation of oil
mechanism pump
operated by
Sudden Large masses of
oil surge
vaporisation of metal heated Eg.:
oil at Earth fault, short
260~400OC circuit not causing
insulation failure.

Date : Mar 15, 2011 Page 83 of 193
Power Transformers
Boiling of Simultaneous
water in occurrence of a heat
exceptional producing fault and
cases entry of water into
the tank.
RAPID Alarm Air or inert Major leak due Fracture of tank,
operates and gas to mechanical pipe, or Buchholtz
repeats after fault relay casing or faulty
releasing oil circulating pump.
gas
Trip and Hydrogen Thermal
Local, very high
alarm decomposition
current, hot spot not
mechanism of oil above
involving insulation,
operates 400OC
arc over between
metal parts of
Terminal gear or
terminal to tank.
Hydrogen Thermal Local hot spots due
and carbon decomposition to
monoxide of oil and very high current
insulation faults in contact with
solid insulation.
Eg. Insulation failure
followed by arc
between insulated
conductors and
earth, short circuited
turn
etc.
MEDIUM Alarm Air or inert Air leaks or Fracture of tank pipe
operates and gas leakage due to or Buchholz relay
repeats mechanical casing or faulty oil
within fault. circulating pumps
minutes or Hydrogen Thermal Local hot spots not
hours after decomposition involving insulation,
each release of oil above faulty joint/ contacts,
O
of gas 400 C core faults causing
burning, an incipient
fault not involving
solid insulation
Eg. Core not properly
earthed

Date : Mar 15, 2011 Page 84 of 193
Power Transformers
Hydrogen Local hotspots in

and contact with solid
carbon insulation. Low
monoxide power arc between
Thermal
insulated conductors
decomposition
and earth, core
of oil and solid
faults. Faulty joints/
insulation.
contact. Any
incipient fault
involving solid
insulation
SLOW Alarm Air or inert Release of entrapped
Presence of
operates gas air during early life of
air due to
transformer of
mechanical
transformer, crack in
fault or
tank, pipe or relay
physical
casing, faulty oil
absorption
pump.
Hydrogen Decomposition Low current arcing
of oil only not
involving solid
insulation,
gassing caused by
high
electrical stress,
corona discharge
Hydrogen Decomposition Low energy arcing
and of oil and solid involving
carbon insulation decomposition
monoxide of solid insulation,
creepage through
solid
insulation, oxidation
of
insulation
No gas Alarm N. A. Low oil level Oil level falling below
pressure operated the level of Buchholtz
in relay due to oil
Buchholtz leakage
relay

Date : Mar 15, 2011 Page 85 of 193
Power Transformers
Table 10.1: DIELECTRIC STRENGTH OF INSULATING OIL

(12.5 mm dia. Spheres, 2.5 mm gap)
No.
Nominal Voltage Of Transformer Dielectric Strength of Insulating Oil (kV)
1 145 kV class and above More than 50

2 72.5 kV class to less than 145 kV More than 40
3 Less than 72.5 kV class More than 30
Table 10.2: ACID CONTENT OF INSULATING OIL (BY NEUTRALISATION)
No. Judgment Acid Content of Oil (mg KOH/g)

1 Good Less than 0.2
2 Replace or do filtration 0.3 ~ 0.5
3 Replace immediately Above 0.5
Table 10.3: RESISTIVITY OF INSULATING OIL
No. Judgment Resistivity of Oil at 90OC (Ω - cm)

1 Good More than 0.1x1012
2 Fair 1x1011 to 0.1x1012
3 Poor Less than 0.1x1011
Table 10.4: WATER CONTENT
No. Nominal Voltage of Transformer Water Content (ppm)

1 400 kV Class & above Less than 20.
2 Upto 245 kV Class Less than 25.
Table 10.5: DIELECTRIC DISSIPATION FACTOR
No. Nominal Voltage of Transformer At 90OC, 40 ~ 60 Hz
1 145 kV Class & above 0.2 Max.

2 Below 145 kV Class 1.0 Max

Date : Mar 15, 2011 Page 86 of 193
Power Transformers
10.9 DISSOLVED GAS ANALYSIS
O2 (Oxygen)
N2 (Nitrogen)
CO2 (Carbon dioxide)
CO (Carbon monoxide)
H2 (Hydrogen)
CH4 (Methane)
C2H2 (Acetylene)
C2H4 (Ethylene)
C2H6 (Ethane)
C3H6 (Propylene)
C3H8 (Propane)
Table 10.6
"Normal" Values of Dissolved Key Gas Concentration Limits in oil of
Power Transformers in Service [Parts per Million – ppm].
(Ref. FIST 3-30* : October 2000)
Status H2 CH4 C2H2 C2H4 C2H6 CO CO2† TDCG‡
Condition 1 100 120 35 50 65 350 2500 720
Condition 2 101~ 121~ 36~ 51~ 66~ 351~ 2500~ 721~
700 400 50 100 100 570 4000 1920
Condition 3 701~ 401~ 51~ 101~ 101~ 571~ 4001~ 1921~
1800 1000 80 200 150 1400 10000 4630
Condition 4 >1800 >1000 >80 >200 >150 >1400 >10000 >4630
*
Ref: FIST 3-30 (Transformer Maintenance; Facilities, Instructions, Standards and
Techniques by United States Department of the Interior Bureau of Reclamation, Denver,
Colorado)
†
CO2 is not considered in the calculations for TDCG, because it is not a combustible gas
‡
TDCG means Total Dissolved Combustible Gas

Date : Mar 15, 2011 Page 87 of 193
Power Transformers
Condition - 1
Total Dissolved Combustible Gas (TDCG) and any individual combustible gas
below this level indicate normal operation of the transformer. If any gas exceeds
the specified level, it needs investigation.
Condition - 2
TDCG and any individual combustible gas in this range indicate greater than
normal combustible gas level. A fault may be present. Further monitoring is
required.
Refer Table 10.7 for recommended sampling frequency and actions.
Condition - 3
TDCG and any individual combustible gas in this range indicate a high level of
decomposition of cellulose insulation and / or oil.
Condition - 4
TDCG and any individual combustible gas in this range indicate excessive
decomposition of cellulose insulation and / or oil. Continued operation could result
in failure of the transformer.
Note:
A sudden increase in key gases and the rate of gas generation are more
important in evaluating a transformer than the amount of gas.

Date : Mar 15, 2011 Page 88 of 193
Power Transformers
Table 10.7
Action based on Dissolved Combustible Gas concentration.
Conditions TDCG Level or TDCG Sampling Intervals and Operating Actions for
Highest Generation Gas Generation Rates
Individual Gas Rates Sampling Operating Procedures
(Ref. Table 9.5) (ppm / day) Interval
Condition 1 720 ppm of Annually/ 6 Continue normal operation
TDCG or < 10 Monthly for
highest EHV Trf.
condition based 10 ~ 30 Quarterly
on individual Exercise caution. Analyse
gas from Table > 30 Monthly individual gases to find cause.
9.5 Determine load dependence.
Condition 2 < 10 Quarterly Exercise caution. Analyse
10 ~ 30 Monthly individual gases to find cause.
> 30 Monthly Determine load dependence.
Condition 3 < 10 Monthly Exercise caution. Analyse
10 ~ 30 Weekly individual gases to find cause.
> 30 Weekly Plan outage. Contact
manufacturer for advice.
Condition 4 < 10 Weekly Exercise caution. Analyse
individual gases to find cause.
10 ~ 30 Daily Plan outage. Contact
manufacturer for advice.
> 30 Daily Consider removal from service.
Contact manufacturer for advice

Date : Mar 15, 2011 Page 89 of 193
Power Transformers
Table –10.8
Transformer Fault Types and the gases they produce.
Key Gases Possible Faults Possible Findings

H2, possible trace of CH4 Partial discharge (Corona) Weakened insulation from
and C2H6, possible CO ageing and electrical stress.
H2, CH4 (CO if discharges Low energy discharges Pinhole puncture in paper
involve paper insulation). (sparking) insulation with carbon and
Possible trace of C2H6. carbon tracking. Possible
carbon particles in oil. Loose
grounding of metal objects.
H2, CH4, C2H6, C2H4 and High energy discharges Metal fusion, (poor contacts
C2H2 present in large (arcing). in tap changer or lead
amounts. If C2H2 is being connections). Weakened
generated, it indicates insulation, from ageing and
continuance of arcing. CO electrical stress. Carbonised
will be present if paper is oil. Paper over heating/
being heated. destruction if it is in the arc
path.
H2, CO. Thermal faults less than Discoloration of paper
3000C in an area close to insulation. Overloading or
paper insulation (Paper is cooling problem. Bad
being heated) connections. Stray current
path and/or stray magnetic
flux.
H2, CO, CH4, C2H6 and Thermal fault between Paper insulation destroyed.
C2H4 3000 C and 7000 C Oil heavily carbonised.
All the above gases and High energy electrical Same as above with metal
acetylene in large arcing 7000 C and above. discoloration. Arcing may
amounts. have caused a thermal fault.
Note: Transformers are so complex that it is impossible to put all causes into a chart.
Several other reasons like high current surges due to faults downstream, static
electric discharges, multiple core earthing, sustained operation under over load,
over/under voltage etc. may also be seen.

Date : Mar 15, 2011 Page 90 of 193
Power Transformers
Dissolved Gas Analysis using Key-gas Ratios

(Ref. CIGRE Report 15.01.01: October 1999)
Key ratio No. 1: (INDICATION: DISCHARGE)
C2H2 (acetylene /ethane) : >1 indicates fault

C2H6
Key ratio No. 2: (INDICATION: PARTIAL DISCHARGE)
H2 (hydrogen /methane) : >10 indicates problem

CH4
Key ratio No. 3: (INDICATION: THERMAL FAULT)
C2H4 (ethylene /ethane) : >1 indicates thermal fault

C2H6
Key ratio No. 4: (INDICATION: CELLULOSE DEGRADATION)
CO2 (carbon dioxide /carbon monoxide) : >10 indicates thermal

CO over heating
> 3 indicates electrical fault
Key ratio No. 5: (INDICATION: INTANK TAPCHANGER)
C2H2 (acetylene /hydrogen) : >2 & C2H2 >30 ppm indicates possibility
H2 of tap changer oil leaking into main tank
Note:
Ratios are to be calculated only if the concentrations of both the gases are
above the detection levels.

Date : Mar 15, 2011 Page 91 of 193
Power Transformers
SECTION – 11
CHECKLISTS

Date : Mar 15, 2011 Page 92 of 193

Power Transformers
Receiving Inspection Checklist

Unit Serial No. Date (dd/mm/yyyy)
Inspected at
(location)
Transformer is on: Railroad Truck Ground Installation Other:
Car platform pad ____________
ITEM CHECK POINT OR ACTION Done RECORDE COMMENTS

D VALUE
1 Visual inspection of transformer. Take

Damage in tank walls, protruding pictures of
parts, wood crates, accessories, the unit
control cabinet. Check if there
any oil leaks or loose tie downs
BEFORE OFF-LOADING
2 Verify internal gas pressure of Pressure :
the transformer, record value. ………..PSI/
Kg/cm.sq
3 Verify that the impact recorder is Store If applicable
operating, mark needle position recorder
(if analogue)and sign off chart for
including Date and time, send future
back at PROLEC GE for report reference
4 Perform an insulation resistance Resistance

test (megger) of core to ground : Mohms
test (megger) of Clamp to : Mohms
ground
test (megger) of Core and clamp : Mohms
7 Verify condition of de-energized
tap changer.
8 Transformer maintained at the
proper angle
9 No more than 3 psi when lifting
10 Lifted only from lifting lugs
11 Proper jack positioning (if

applicable)

Date : Mar 15, 2011 Page 93 of 193
Power Transformers
12 Transformer tank base sitting flat

on concrete pad
BEFORE OFF-LOADING
13 Electrical connections inside the
control cabinet are tight and the
Manual is inside.
14 Verify operation of de-energized
tap changer
15 Perform OLTC and OLTC
cabinet inspection
16 Inspect radiator valves and
transformer cove
17 All the accessories, shipping
crates and parts are complete
and on site.
18 The transformer is grounded.
Additional comments
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
Inspected by
Name Signature

Date : Mar 15, 2011 Page 94 of 193
Power Transformers
Storage Inspection Check List
Unit Serial No. Date

Storage Location
Estimate time the Less than 3 months Between 3 and 6 More than 6 months
unit will be stored months
ITEM Check point or action Recorded Done

Comments
Value
1 Perform an external receiving Receiving
inspection of the unit inspection
check list
FOLLOW THESE STEPS IF THE UNIT IS GoIng TO BE STORED LESS Than 3
MONTHS
2 Fill with nitrogen or dry air at 3 psi Filling For gas filled
pressure jobs only
3 Check for leaks with soap and
water.
4 Verify all steel components have
blanking plates installed
(radiators, conservator tank,
manifolds, pumps, pipes)
5 Verify all the bushings are stored
in the proper position.
6 Verify all the crate boxes
containing accessories are
closed, undamaged and protected
from the environment.
7 Verify all the items in the Packing
Lists are accounted for.
8 Verify the proper operation of the
nitrogen equipment (if applicable)
9 Record pressure of the nitrogen
bottle (if applicable)
10 Initiate the attached periodic
pressure recording form and put it
inside the Nitrogen Equipment
cabinet. (if applicable)
11 Stop the impact recorder, sign off Date & Time
and include date, time and the impact
transformer location. recorder was
stopped
FOLLOW THESE STEPS IF THE UNIT IS GOING TO BE STORED BETWEEN

3 AND 6 MONTHS

Date : Mar 15, 2011 Page 95 of 193
Power Transformers
The same steps that are followed for less than three months of storage per that if the
transformer is going to be stored up to 6 ONLY approved gas that may be used to fill
the transformer is high purity nitrogen (-50°C / -58°F dew point or lower).
FOLLOW THESE STEPS IF THE UNIT IS GOING TO BE STORED more than 6 MONTHS
12 Assembly the Accessories and fill

the oil as per instruction manual
13 Verify the proper operation of the
nitrogen equipment (If applicable)
14 Record the pressure of the Nitrogen Pressure
cylinder
15 Initiate the attached periodic
pressure recording form and put it
inside the Nitrogen Equipment
cabinet. (If applicable)
16 Stop the impact recorder, sign off Date and
and include date, time and Time of
transformer location. removal
Additional comments
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
Inspected by
Name Signature
Periodic Pressure Recording Form

Date & Time Transformer N2 Bottle Pressure Temperature
Pressure (p.s.i.) (p.s.i.)

Date : Mar 15, 2011 Page 96 of 193
Power Transformers
INTERNAL INSPECTION CHECK LIST
Unit Serial No. Date

Storage Location
Customer
Notes:
1) If any damage is found during internal inspection, PROLEC GE should be
immediately notified.
2) For the purpose of this list, “tight” means that it cannot be moved applying the hand
force.
ITEM Check point or action Done Recorded Comments

Value
1 Verify adequate oxygen content Oxygen
content
2 Verify that the personnel going into
the transformer is wearing the
appropriate clothes.
3 Verify the quality of the purging air For 400kV and
(-50°C / -58°F dew point or lower). above
4 Connection of lead in OLTC
selector. Check operation of OLTC
manually for proper connection of
fixed contact and moving contacts
5 Record time of opening
6 Inspection of core condition. Take pictures
where
possible
7 Inspection of clamps and core- Take pictures
clamp insulation where
All clamp bolts tight. Insulation tight possible
and in its place.
No loose ground straps between
clamp pieces.
8 Inspection of current transformers. Take pictures
Tight installation. Insulation pieces where
not loose. Wiring in place and no possible
visible damage due to
transportation movement.
9 Inspection of bushings
10 Internal hardware tightness

Date : Mar 15, 2011 Page 97 of 193
Power Transformers
11 Insulation pieces and support

frames inspection.
All insulation pieces in place and
tight.
Nylon bolts are tight and in place
No crack or damage wood structure
pieces.
Remove any shipping braces.
Absences of abnormal looseness or
movement causes by shipping.
Hardware securing the unit in the
tank and winding jacking screws
must be tight.
12 Inspection of jacking screws.
13 Inspection of OLTC
14 Inspection of main tank and MOG
15 Cleanliness
No foreign material inside the main
tank or on the floor of the
transformer. All tools and material
have been removed from the
interior
16 Entrance manholes have been
reseal with new gasket
17 Unit re-pressurized with nitrogen or Pressure :
dry air
18 Record time of closure Time :
Additional comments
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
Inspected by
Name Signature

Date : Mar 15, 2011 Page 98 of 193
Power Transformers
TRANSFORMER ERECTION CHECK LIST

This checklist outlines the minimum checks expected to be carried out on the
transformer at the end of site erection activity.
Wherever the erection is carried out by Customer, one copy of the filled up check list
may be sent to PROLEC GE India for reference and records.
CUSTOMER : ……………………………………………………………
EQUIPMENT DETAILS: ……………………………………………………………
SITE : ……………………………………………………………
ITEM CHECK POINT REMARKS

1 AVAILABILITY OF DOCUMENTATION
Erection drawings
Erection / Maintenance Manual
Transport packing list
2 RECEIPT OF TRANSFORMER
External damages (if any)
Gas pressure on receipt (Where applicable)
Oil level (in case of oil filled transformer)
Unit correctly positioned
3 RECEIPT OF ACCESSORIES
All materials stored correctly
Packing Cases inspected, damage if any
Marshalling box inspected, damage if any
Control panels (RTCC)inspected damage if any
Materials received corresponded to Advise note
Any shortages / wrong supply

Observations (if any)
4 ERECTION
Mounting of rollers
Conservator mounted correctly

Date : Mar 15, 2011 Page 99 of 193
Power Transformers
Buchholz relay/ Oil surge relay mounted (arrow marked should be

towards conservator)
Breather mounted with silicagel
HV Bushings mounted
LV Bushing mounted
Tertiary Bushing mounted (if applicable)
HV neutral Bushing mounted
LV Neutral Bushing mounted
Bushing installed at correct angles
Explosion vent diaphragm checked
MOLG mounted
Radiators mounted
Fans mounted
Pressure Relief valves mounted
Alignment of all pipe work
OLTC Conservator mounted
Heat Exchangers assembled with pipe work
Topping up with transformer oil
Leakage observed after 24 hrs.(if any)
Rating Diagram and identification plate fitted
Marshalling box aligned
RTCC aligned
OLTC Drive Mechanism aligned
5 OIL FILLING
Oil level in all bushings

Tap changer oil level
Radiator, Headers oil filled
Complete transformer oil tight
All air release plug vented
Valves in service position
All drain / filter valves blanked
6 CABLING

Date : Mar 15, 2011 Page 100 of 193
Power Transformers
All cables adequately tied

Cables glanded correctly
WTIs and OTIs satisfactorily installed
7 BREATHERS
Condition of silica gel in breathers breather satisfactory
8
FANS
Fans rotate freely

Pumps installed for correct flow
Flow indication visible
9
CONTROL PANELS
Cable termination
Cable glanding
Control cabinet clean & tidy
Heater supplied
Locking arrangement
10 CLEANING & TOUCH UP PAINTING
Date:
Signature: ---------------------------------- ----------------------------------
Name: ---------------------------------- ----------------------------------
(FOR PROLECGE) (FOR CUSTOMER)

Date : Mar 15, 2011 Page 101 of 193
Power Transformers
VACUUM PROCESS LOG

Customer
Date & Vacuum Ambient Relative Date & Vacuum Ambient Relative
Time Level Temperature Humidity Time Level Temperature Humidity
(Torr/ (OC) (%) (Torr/ (OC) (%)
millibar) millibar)
Vacuum Drop Test Recording Chart

Date & Time Vacuum Level
Reading Time Vacuum Level
(minutes)
1
2
3
4
5
6
7
Result Reading
calculation 7–1=

Date : Mar 15, 2011 Page 102 of 193
Power Transformers
PRE-COMMISSIONING CHECKS & SITE TEST RESULTS
Customer : ________________________________________________________
Site : ________________________________________________________
TRANSFORMER RATING:
MVA: _____________________ Ratio: ___________________________________
Vector Group: -------------------------- Amps. (H/I/L) ----------------------------------------------
Tapping Range: --------------------% Impedance at Normal tap ---------------------------
Temperature Rise: Oil ----------------------- Wdg. ---------------------------

GENERAL CHECKS:
REMARKS
CHECK POINTS
1 Direction & mounting angle of O.S.R. & Buchholz relay
2 Dryness of silica gel & oil level in bottom cup
3 Oil level in Main conservator.
4 Oil level in OLTC conservator.
5 Oil filled in OTI / WTI pockets.

6 Earthing of Main tank, cooler bank, fans, pumps and HV/ LV Neutral
7 Absence of oil seepages / leakages.
8 Bushing -their oil levels & test cap in position.
9 Explosion vent
10 Touch up painting & washing.

11 Overall clearances.
12 Aircell commissioned
13 Sagging of radiator / pipes

14 Tightness of bushing top terminal
15 Distortion in expansion bellows
MARSHALLING BOX
1 W.T.I. (Sl.No., Make & Model)
a. Transit lock released

Date : Mar 15, 2011 Page 103 of 193
Power Transformers
b. Switch settings & operation.

c. Connections.
d. Ambient reading.
e. Heater shunt shorting link.
f. Matching with repeaters.
g. Power supply & current converter
2 O.T.I (Sl. No., Make & Model)
a. Transit lock released
b. Switch setting & operation.
c. Connections.
d. Ambient reading.
e. Matching with repeaters.
3 Space heater & Thermostat settings.
4 Cabling, Glanding, Termination etc.
5 Earthing & Touch up painting.
6 Stand by supply change over operation
7 Timer settings.
8 Closure of openings & tidiness.
FANS (Model, RPM, KW / HP ):
1 Glanding & Earthing.
2 Mounting & Terminal cover condition.
3 Direction & Smoothness of operation :
a. Manual -Local.
b. Manual – Remote
c. Auto & Stand by operation
4 Overload setting
5 Starting current
6 Running current
7 Megger values
O.L.T.C. (Sl No. , Make & Type):
1 Alignment of all shafts & Drive Mechanism
2 Oil fill in gear box (Where reqd.)

Date : Mar 15, 2011 Page 104 of 193
Power Transformers
3 Mechanical end limits of D.M.

4 Coupling Position & rotation lag.
5 Manual operation.
6 Local electrical operation.
7 Electrical end limit operation.
8 Remote electrical operation.
9 Tightness of external shaft coupling
10 Bending of lock washer.
11 Fitment of window & shaft covers.
12 Cabling, Termination, Glanding etc.
13 Space heater & thermostat setting.
14 Continuity check during transition by voltage application.
15 Earthing.
16 TPI counter reading
17 CCU for TPI
R.T.C.C.: (Sl. No. & Rating):
1 Installation & Earthing.
2 Cabling, Glanding, Termination etc.
3 Setting of Timers.
4 Functioning of Indication Lamps.
5 Functioning of Hooter / Buzzers.
6 Annunciation / Relay Checks:
i.
ii.
iii.
iv.
v.
vi.
vii.
Make & Model
A Tap position indicator.
B W.T.I. Repeater.

Date : Mar 15, 2011 Page 105 of 193
Power Transformers
C O.T.I. Repeater.
O.L.T.C. Operations :
a. Individual :
b. As Master :
c. As Follower :
Emergency Trip.
Out of step & MP Timer operation.
Operation of A.V.R. & L.D.C.
Operation of Pumps, NRV, Flow Indicators:
1 Direction of pump operation.
2 Manual operation.
3 Auto operation.
4 Stand-by changeover.
5 Non Return Valve operation.
6 Overload setting
7 Starting current
8 Running current
9 Stability of alarm & trip contacts of Buchholz relay during oil
pump starting by manual / Auto mode
10 Megger value (500 V / 1000 V Megger )
S I T E T E S T R E S U L T S:
Insulation Resistance:
Range, Make, kV rating & Type of tester:
1 Top oil Temperature:
2 Megger Values:
60 600 600
60 Sec.
Sec. Sec. Sec.
H.V. to L.V.: H.V. To
Earth
H.V. to T.V.: T.V. To
Earth
L.V. to T.V.: L.V. To
Earth

Date : Mar 15, 2011 Page 106 of 193
Power Transformers
CORE to TANK ( By 1000 V

Megger )
CORE to FRAME ( By 1000
V Megger )
Current Transformers:
C. T. DETAILS
CHECK POINT
Continuity
Approx. Ratio
Polarity (Only for REF /
DIFFL. C.T)
Saturation check only
for PS class C.T's
TAN DELTA & CAPACITANCE TEST OF BUSHINGS:
Atmospheric condition & temperature:
Equipment used for test:
NOTE: Please ensure that the bushings are absolutely clean and the test is caaried out
in dry weather conditions. Arcing horns if any, should be removed.
Bushing Sl. Make Rating A / V Tan delta Capacitance Megger value
No.
SHORT CIRCUIT TEST ON TRANSFORMER:

Method of testing:
Tap Position Current in Amps
HV LV IV NEUTRAL
Maximum Tap
Normal Tap
Min. Tap
VOLTAGE RATIO:

Date : Mar 15, 2011 Page 107 of 193
Power Transformers
Apply single phase 240 or 440 volts on each HV line lead and ‘N’ or pair of HV line leads
and Measure LV voltage on all taps in all phases.
Tap HV Volts (applied) LV1 Volts LV2 / Tertiary
No.
1U- 1V- 2U- 2V-
1W-1U 2W-2U 3U-3V 3V-3W 3W-3U
1V 1W 2V 2W
1U- 1V- 2U-
1W-1N 2V-2N 2W-2N 3W-3N 3V-3N 3W-3N
1N 1N 2N
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
MAGNETIC BALANCE AT NORMAL TAP POSITION : (For star winding only)
VOLTAGE ACROSS 1U-1N 1V-1N 1W-1N 2U-2N 2V-2N 2W-2N

TAP No.

Date : Mar 15, 2011 Page 108 of 193
Power Transformers
EXCITATION WITH REDUCED VOLTAGE:

1. For LV winding of up to 1.1 KV class, apply single phase, 2 wire, 415 volts from
HV side (Keeping neutrals isolated) on each leg.
2. For L.V. winding of class higher than 1.1 KV, apply single phase, 2 wire, 415
volts from LV side (Keeping neutrals isolated) on each leg.
Tap No Applied Volts ( V ) Measured current (A)
1U-1V 1V-1W 1W-1U 1U 1V 1W
TESTING OF TRANSFORMER OIL

BREAKDOWN VALUES: (Average of six readings with 2.5 mm gap)
(a) Main tank top oil sample : ________________________________
(b) Main tank bottom oil sample : ______________________________
(c) O.L.T. C. oil sample: _____________________________________
VECTOR GROUP CHECK:
Short terminals 1U to 2U and apply 3 phase, 3 wire 415 volts supply across 1U-1V-1W
and measure voltage across terminals and confirm the group
STAR -STAR CONNECTION STAR -DELTA CONNECTION
1V -2V : 1V -2V :
1V -2W : 1V -2W :
1W -2W : 1W -2W :
1W -2V : 1W -2V :
1U -1V :
1V -1W :
1W -1U :
PRE-COMMISSIONING CHECKS:
To be carried out after transformer is connected to lines & before energisation
1 Clearances in air (refer O.G.A.)
2 Tightness of bushing lugs, cable / line connections, terminals, etc.
3 Simulation of Alarm & Trip circuits (verify breaker / Master trip
operation by initiating operating contacts of)
a. Buchholz relay
b. Winding temperature indicator
c. Oil temperature indicator
d Oil surge relay
e. Pressure relief device / vent switch
f. M.O.L.G.
g. Oil / Water flow indicators / D.P.G.
h. Sudden pressure relay
I. Over current relay

Date : Mar 15, 2011 Page 109 of 193
Power Transformers
j. Earth fault relay

k. Differential relay
l. Inter tripping relay
m. Others
5 Air vented from:
a. Bushings
b. Radiators, headers, couplings
c. Buchholz relay
d. O.L.T.C. cover / head
e. Main tank cover / Thermosyphon
f. Disconnecting chamber
6. a. H.V. Lightening Arrester counter reading
b. L.V. Lightening Arrester counter reading
Transformer successfully energised on __________ at _______ Hrs on Tap No. ___
Load & is operating satisfactorily.
Transformer put on _______ Amps. / MVA load on _______ at _______ Hrs and is
operating satisfactorily.
Signature : ____________________ Signature: _________________

(PROLECGE ENGINEER) (CUSTOMER'S ENGINEER)
Name : _________________ Name: _____________________
Designation: __________________ Designation: _________________

Date : Mar 15, 2011 Page 110 of 193
Power Transformers
DETAILS OF ACCESSORIES:
1 H.V.BUSHINGS:
Make:
Rating:
Sl. No.:
2 L.V.BUSHINGS:
Make:
Rating:
Sl. No.:
3 O.L.T.C. DETAILS:
Make:
Type:
Sl. No.:
4 FACIA DETAILS:
Make:
Sl. No.:
Model:
No. of windows :
Voltage:
5 PRESSURE RELIEF DEVICE:
Make:
Sl.No:
Pressure Setting:

Date : Mar 15, 2011 Page 111 of 193
Power Transformers
MAINTENANCE INSPECTION CHECK LISTS
General Inspection Recording Form
Customer:
ITEM CHECK PONITS RESULT REMARKS

1 Tap Position Local DM ___
RTCC ___
2 No. of Tap Changer operations
3 Winding temperature readings HV ___________
LV ___________
4 Oil temperature readings Temp._________
5 Oil level gauge reading High _____
25OC_____
Low _____
6 OLTC oil level gauge reading (if applicable) High _____
25OC_____
Low _____
7 Oil leakages if any from bolted or threaded
joints
8 Oil level in OIP bushings and colour (if Level _______
applicable) Colour _______
9 Readings of On-line monitoring system (if Gas level ______
applicable) Hourly trend ____
(ppm/hr.)
Daily trend ____
(ppm/day)
10 Surge counter readings (if applicable)
11 Condition of porcelain insulators
12 Current cooling mode in operation ___ONAN
___ONAF-1
___ONAF-2
___ODAF
___OFAF
___OFWF
13 Test alarm annunciator panel (if applicable) All lights are OK?
___ Yes
___ No
14 Check condition of silicagel of Main & OLTC Colour ______
conservators
INSPECTED BY:
______________________________ ____________________________
NAME SIGNATURE

Date : Mar 15, 2011 Page 112 of 193
Power Transformers
OIL TEST RECORDING FORM
Customer:
Note:
1. All samples for oil testing should be drawn from the bottom/ top sampling valve
and it should be noted from where the sample is drawn.
2. Temperature of oil in the transformer at the time of sampling should be recorded.
Physical & Chemical Properties

Sample No. Sampling Date :
Oil Temperature:
Test Standard Result
Dielectric strength IS 6792 _______ kV
Power factor IS 6262 _______ %
Specific Gravity IS 1448 [P : 16] _________
Colour ASTM D1500 _________
Interfacial Tension IS 6104 ______ ppm
Neutralisation Value IS 1448 [P: 2] _______ mgKOH/g
Water Content IS 13567 _______ ppm
INSPECTED BY:
______________________________ ____________________________
NAME SIGNATURE

Date : Mar 15, 2011 Page 113 of 193
Power Transformers
OIL TEST RECORDING FORM

Dissolved Gas Analysis Result
Customer:
Sample No. Sampling Date :

Gas Symbol Value
Hydrogen* H2 ______ ppm
Methane* CH4 ______ ppm
Ethylene* C2H4 ______ ppm
Ethane* C2H6 ______ ppm
Acetylene* C2H2 ______ ppm
Carbon Monoxide* CO ______ ppm
Carbon Dioxide CO2 ______ ppm
Oxygen O2 ______ ppm
Nitrogen N2 ______ ppm
* - The asterisk denotes a combustible gas
INSPECTED BY:
______________________________ ____________________________
NAME SIGNATURE

Date : Mar 15, 2011 Page 114 of 193
Power Transformers
MAINTENANCE EXTERNAL INSPECTION RECORDING FORM
Customer:
ITEM CHECK POINTS OR ACTION RECORDED VALUE REMARKS

A – Transformer Energised (Date __________ )
1 Manually raise and lower the on load tap
changer using the Raise/ Lower switch in the
Drive Mechanism.
Warning: This would modify the voltage
output of the transformer.
2 Verify fans operation
3 Verify oil pump operation by turning them on

and watching the oil flow indicator.
4 Check grounding system conditions. Verify
everything is tight and corrosion free.
5 Check the inside of the main control cabinet.
Verify if there is any condensation inside the
cabinets and the cabinet heaters are working
correctly.
6 Check whether there is any oil leak from
bolted or threaded joints.
B – Transformer De-energised (Date __________ )

7 Verify external electrical connections for
tightness and for any sign of discoloration,
indicating a hot spot. If there is any doubt,
the suspicious connection should be cleaned
and reconnected. If discolouration is
extensive, further investigation is
recommended.
8 Check the absence of oil leaks on all bolted
and threaded joints, especially on the
transformer’s cover.
9 Inspect heat exchangers looking for any
airborne debris or foreign material in the
cooling surfaces. In case cleaning is
required, it may be carried out using
compressed air and/or water.
10 Operation of off circuit tap changer (OCTC)
INSPECTED BY:
______________________________ ____________________________
NAME SIGNATURE

Date : Mar 15, 2011 Page 115 of 193
Power Transformers
ROUTINE ELECTRICAL TESTS CHECKLIST
Customer:
Note:
All electrical tests should be performed while the transformer is de-energised. Never
attempt to test a transformer while it is energised; doing so may cause severe damage to
property or death.
ITEM TEST RECORDED VALUE DONE (YES/NO)
1 Thermography
2 Winding resistance
3 Insulation Power Factor
4 Bushing Power Factor
5 Excitation Current
6 Insulation Resistance
INSPECTED BY:
______________________________ ____________________________
NAME SIGNATURE

Date : Mar 15, 2011 Page 116 of 193
Power Transformers
TRANSFORMER PROTECTIVE DEVICES TEST RECORDING FORM
Customer:
ITEM CHECK POINTS RECORD VALUE COMMENTS

1 Temperature protective relays,
Oil Temperature Indicator,
Winding Temperature Indicator.
2 Low Oil Level Alarm/ Trip
3 Pump relays (if applicable)
4 Fans protective relays
5 Manually operate oil pumps (if applicable)
6 Operate annunciator panels (if applicable)
7 Pressure relief device relays
8 Sudden pressure relays (if applicable)
9 Buchholz relays
10 Oil surge relay (if applicable)
11 Hydran
12 Other
INSPECTED BY:
______________________________ ____________________________
NAME SIGNATURE

Date : Mar 15, 2011 Page 117 of 193

Power Transformers
SECTION - 12
REFERENCE STANDARDS

Date : Mar 15, 2011 Page 118 of 193

Power Transformers
12. IEC STANDARDS
IEC 60071-1 (2006) Insulation co-ordination; Definitions, principles

and rules.
IEC 60071-2 (1996) Insulation co-ordination; Application guide.
IEC 60076–1 (2011) Power transformers; General.
IEC 60076–2 (2011) Power transformers; Temperature rise.
IEC 60076–3 (2000) Power transformers; Insulation levels, dielectric
tests and external clearances in air.
IEC 60076–4 (2002) Power transformers; Guide to the lightning
impulse and switching impulse testing.
IEC 60076–5 (2006) Power transformers; Ability to withstand short
circuit.
IEC 60076–6 (2007) Reactors
IEC 60076–7 (2005) Power transformers; Loading guide for oil
immersed power transformers.
IEC 60076–8 (1997) Power transformers; Application guide.
IEC 60076–10 (2001) Power transformers; Determination of sound
levels.
IEC 60076–10-1 (2005) Power transformers; Determination of sound
levels - Application Guide.
IEC 60076–11 (2004) Power transformers; Dry type transformers.
IEC 60076–12 (2008) Loading Guide for Dry Type Power
transformers.
IEC 60076–13 (2006) Self Protected Liquid filled Power transformers.
IEC 60076–14 (2009) Power transformers; Design & Application of
liquid immersed power transformers using high
temperature insulation materials.
IEC 60076–15 (2008) Gas filled Power transformers.
IEC 60137 (2008) Insulated bushings for alternating voltages
above 1000 V

Date : Mar 15, 2011 Page 119 of 193
Power Transformers
IEC 60156 (1995) Method for determination of the electric strength

for insulating oils.
IEC 60044-1 (2003) Current Transformers.
IEC 60044-2 (2003) Inductive Voltage Transformers.
IEC 60044-5 (2004) Capacitor Voltage Transformers.
IEC 60044- 6 (1992) Protective Current Transformer for transient
performance.
IEC 60214-1 (2003) Tap changers; Performance requirements and
test methods
IEC 60214-2 (2004) Tap changers; Application Guide
IEC 60168 (2001) Tests on indoor and outdoor post insulators
greater than 1000 volts.
IEC 60270 (2000) High Voltage Test techniques: Partial discharge
measurements.
IEC 60296 (2003) Fluids for electro-technical applications -
unused mineral insulating oils for transformer
and switch gear.
IEC 60310 (2004) Railway applications - Traction Transformers
and inductors.
IEC 60422 (2005) Mineral insulating oil in electrical equipment -
Supervision and maintenance guide.
IEC 60445 (2010) Basic and Safety principles for man-machine
interface ; Identification of equipment terminals
and termination of certain designated
conductors.
IEC 60475 (1974) Method of sampling liquid dielectric.
IEC 60529 (2001) Degrees of protection provided by enclosures
(IP Codes).
IEC 60554 (Part 1 ~ 3) Specification for cellulosic papers for electrical
purposes.

Date : Mar 15, 2011 Page 120 of 193
Power Transformers
IEC 60567 (2005) Guide for the sampling of gases and of oil from
oil filled electrical equipment and for the
analysis of free and dissolved Gases.
IEC 60599 (2007) Guide to the interpretation of dissolved and free
gases in mineral oil-impregnated electrical
equipment in service.
IEC 60616 (1978) Terminal and tapping marking for power
transformers.
IEC 60628 (1985) Gassing of insulating liquids under electrical
stresses and ionisation.
IEC 60947 (Part 1 to 7) Low voltage switchgear and control gear.
IEC 61378-1 (1997) Converter Transformer for industrial application.
IEC 61378-2 (2001) Converter Transformer for HV DC application.
IEC 61378-3 (2006) Converter Transformers; Application Guide.
IEC 61639 (1996) Direct Connection between power transformer
and gas insulated metal enclosed switchgear for
rated voltages of 72.5kV and above.

Date : Mar 15, 2011 Page 121 of 193

Power Transformers
SECTION - 13
TRANSFORMER ACCESSORIES

Date : Mar 15, 2011 Page 122 of 193

Power Transformers
TEMPERATURE INDICATOR

Date : Mar 15, 2011 Page 123 of 193
Power Transformers
INSTALLATION AND MAINTENANCE INSTRUCTIONS
1. APPLICATION
The Temperature indicator is used as an Oil Temperature Indicator (OTI) or as
Winding Temperature Indicator (WTI) for the protection of liquid immersed power
transformer. In the case of dry type transformers it is used as Temperature
Indicator (T.I.) to monitor the temperature of the windings.
2. SCOPE OF SUPPLY
OTI & TI: Instrument with specified Range, Number of control switches, length of
capillary and sensing bulb.
WTI: Same as 2.1 but fitted with specified thermal image device.
TRANSMITTER (OPTIONAL): A precision potentiometer is mounted inside the
case of OTI or WTI (2.1 or 2.2) to transmit the measured temperature to remote
point(s).
REPEATER (OPTIONAL): Analogue indicator supplied separately for remote
indication of the temperature measured by OTI or WTI (2.1 or 2.2)
3. OPERATION
The instrument operates as OTI when its sensing bulb is mounted in an oil filled
pocket located in the hottest oil of an oil immersed transformer.
The instrument operates as TI when its sensing bulb is exposed to the medium
adjacent to the windings of a dry type transformer.
When a proportionate load current of the transformer is passed through the
thermal image device, the instrument operates as a WTI integrating the simulated
temperature rise of the thermal image device and the top oil temperature
measured by the sensing bulb.
Remote indication of the temperature measured by the OTI or WTI is provided by
connecting the transmitter to the repeater either directly or through a resistance
transducer (resistance to current converter).
4. CONSTRUCTION
LIQUID-FILLED SYSTEM (Refer Fig. 1): A sensing bulb (25), a measuring
bellows (2) and a small bore capillary tube (24) connecting the two, form the
measuring system. A second bellows (16-compensating bellows)

Date : Mar 15, 2011 Page 124 of 193
Power Transformers
connected with a second capillary (24) running parallel to the first capillary and
terminated at the head of the bulb from the temperature compensating system.
Both the systems are completely filled with the same liquid (other than mercury).
The two bellows are linked to a compensating lever (15) in such a manner that the
effect of ambient temperature changes on the capillary line and measuring
bellows is compensated. The movement of the measuring bellows is related only
to the temperature being measured by the sensing bulb. This movement is
amplified by the link and lever mechanism (6), which directly drives the rotating
disc (21) carrying the control switches. The same mechanism moves, through
rack and pinion a separately mounted indicating pointer (Fig. 2, 11) over a
calibrated dial. Head compensation is provided by sealing both the systems under
initial pressure, which is greater than the possible head pressure due to
differences in the elevation between the bulb and indicator.
MAXIMUM POINTER (RED COLOURED) located on the indicator lid, is
resettable from outside the case by a screw driver blade. Unscrew and remove
black cap to reach the screw driver-slot.
CAUTION: Never use the switch testing knob for setting the maximum pointer. If
used, the switch contacts will close and initiate the external control circuits when
the instrument is in operation.
SWITCH TESTING KNOB: It is fitted on the indicator lid to check mercury
switches setting and potentiometer operation. This knob when rotated moves the
indicating pointer, switch mechanism and potentiometer wiper together and
facilitates testing these circuits without opening the lid. Rotate the knob slowly and
steadily for an accurate check. Never allow the knob to spring back suddenly or
quickly, as this will cause damage.
THERMAL IMAGE DEVICE (Refer Fig. 1): A heater coil (3-Bellows Heater) is
fitted around the measuring bellow (2) and supplied from a current transformer in
the load circuit of transformer. The heater coil simulates hot-spot temperature of
the winding over top oil temperature for a given load. The measuring bellows
reacts to this simulated temperature rise in addition to the top oil temperature
measured by the sensing bulb and the instrument functions as a WTI displaying
the hottest spot temperature of the winding. An adjustable shunt resistor (17-
calibrating shunt) is provided for shunting portion of the current through the heater
coil to obtain precise thermal image.

Date : Mar 15, 2011 Page 125 of 193
Installa
nce Manuaal
Power Transformerrs
FIG. 1
INDICAT
TOR
(LID & DIAL RE
EMOVED)
d for Manufactu
er purpose witho
out written perm
mission. PROLE
EC GE shall not
assume any
on.

TTL/TM/1103
Date : Mar 15, 2011 Page
e 126 of 193
Power Transformers
REMOTE INDICATION (OPTIONAL): Refer Fig. 1, A precision potentiometer (20)

is mounted inside the indicator to function as a transmitter for remote indication of
the temperature measured by the OTI/WTI. Technical Data of the transmitter and
repeater along with details of adjustments are given in the relevant data sheet
supplied with each indicator.
ELECTRICAL CONNECTION: All internal electrical connection are wired to the
terminal block (Fig. 1, 14) mounted inside the indicator case. A wiring diagram is
fixed inside the case of each indicator. Switches are identified by markings S1,
S2, S3 and S4 on them. Terminal Nos. wired to each circuit are detailed below.
TERMINAL Nos. WIRED TO

1,2 Switch S1 — Alarm
3,4 S2 — Trip
5,6 S3 — Cooler Control – 1
7,8 S4 — Cooler Control – 2
9,10,11 Bellows, Heater & Shunt
12,13,14 Potentiometer-Min., Wiper, Max
5. PRE-INSTALLATION TESTING
EQUIPMENT:
1. Controlled constant temperature bath with continuously stirred liquid.
2. Certified Standard Thermometer.
3. A continuity test circuit.
4. High voltage breakdown tester.
5. A constant current source.
Note: Calibration baths are generally suitable for use only in workshop. If
required for use in the field, they should be used under cover and in a non
hazardous environment.
PRE-CONDITIONING: Before commencing any tests check the following: -
1. The instrument is as per purchaser specification.
2. The instrument is not damaged in any way and any such damage is
rectified before testing.
3. The instrument is mounted correctly. (Refer 6.1)
3. The shipping stop (22 - Fig. 1) is removed.

Date : Mar 15, 2011 Page 127 of 193
Power Transformers
OTI CALIBRATION: Place the sensing bulb of the temperature indicator under
test in the well-stirred constant temperature bath. Allow 5 minutes settling time
before taking readings. Check the reading near to but not less than minimum
value of the indicator scale. For increasing values of temperature, repeat the
procedure to obtain at least two further readings the highest value being near to
but not greater than the maximum scale value of the indicator. The readings
should agree with the standard thermometer within ± 1.5% f.s.d. (Maximum scale
value). Otherwise following adjustments should be made.
ZERO ADJUSTMENT: Use this adjustment for correcting readings near minimum
scale value. Referring to Fig. 1, firmly hold the tongue adjuster (50 by a 2BA
spanner and slacken the lock nut (4) with a second 2BA spanner. To move the
indicting pointer (19) up or down the scale, turn the tongue adjuster (5) by a small
amount anticlockwise or clockwise respectively. Re-tighten the lock nut holding
firmly the tongue adjuster. Do not twist the measuring bellows while carrying out
this adjustment as this may cause damage to the linkage/bellows.
SPAN ADJUSTMENT: Use this adjustment for correcting reading near the
maximum scale value. Referring to Fig. 1, slacken the shoulder screw (7) half a
turn but do not remove the same. Turn the range adjuster screw (8) anticlockwise
or clockwise to increase or decrease respectively the sweep of the pointer. Make
the adjustment in small increments and carefully. Half a turn in either direction
may correspond to approximately 0.5° reading. After adjustment, retighten the
shoulder screw.
Ensure that the lock nut (4) and shoulder screw (7) are properly tightened after
the above adjustments. Repeat the tests in cold and hot bath until the accuracy
limit of ± 1.5% f. s. d. is achieved.
WTI CALIBRATION: During Calibration, keep the instrument lid fixed in position.
Place the sensing bulb in the continuously stirred oil bath, the temperature of which
is maintained at the specified value. Allow 5 minutes setting time and apply the
specified current to the bellows heater and calibrating shunt network. The current
must remain switched on at specified value for at least 40 minutes before taking
reading. To achieve the readings within the accuracy limits or to reset the
temperature rise to a different value, the following adjustments should be made.

Date : Mar 15, 2011 Page 128 of 193
Power Transformers
GRADIENT ADJUSTMENT: After opening the instrument lid, carefully remove the
dial. Withdraw the calibrating shunt (17-Fig. 1) after removing the nut and retaining
washer. One adjustable centre band and two fixed bands at the ends are provided
in the shunt. One supply lead is connected to the centre band and the other lead to
the lower band on the shunt. Slacken the screw in the retaining clip of the centre
band. To reduce the temperature rise, move the centre band nearer to the lower
band, to increase the temperature rise reverse the procedure. Retighten the screw
on the centre band after adjustment. Replace the shunt, dial and lid. Repeat the
calibration, check after adjustments until the accuracy limits achieved.
SWITCH SETTING: The switch settings are adjustable as indicated below: -
Indicator Scale Range Switch setting adjustable Switch differential (close to
to close between open) adjustable between
0 - 120° C 40° C and 120° C 6° C and 80° C
20 - 120° C 50° C and 120° C 6° C and 90° C
30 - 120° C 50° C and 120° C 6° C and 100° C
0 - 150° C 45° C and 150° C 7.5° C and 105° C
0 - 240° C 80° C and 240° C 12° C and 160° C

Date : Mar 15, 2011 Page 129 of 193
Power Transformers
NOTE: Unless specified otherwise, the instruments are supplied with minimum
switch differential.
Connect across the switch contacts the continuity test circuit and check the
correct operation of the switches at their set points to make (close) and break
(open) contacts. The switches should operate at set point within ± 2.5% of switch
setting arm pointer (10-Fig. 1) indication, otherwise the following adjustment
should be made.
SWITCH ADJUSTMENTS: Referring to Fig. 1 slacken switch setting screw (11)
on each switch setting arm (10). Move the left hand arm pointer over the switch
scale (9) to the required temperature for making (closing) contact and right hand
arm pointer to the required temperature for breaking (opening) contact. Retighten
both switch setting screws. By closing the left hand arm pointer to the right hand
arm pointer minimum differential is obtained. A built-in stop automatically sets the
minimum differential. While slackening and tightening the setting screw, steady
the disc with the other hand to prevent undue strain on the mechanism. The
indicating pointer can be moved with a finger in a clockwise direction to check the
operation of the switches at set points. By moving the pointer slowly and steadily,
an accurate check is obtained. Never allow the pointer to spring back suddenly or
quickly and also force the pointer in an anticlockwise direction. By doing so the
measuring bellows is likely to be damaged. An alternative procedure is to check
the switch operation while calibrating the instruments for temperature readings.
INSTALLATION
MOUNTING: Mount the instrument in a vertical position. Otherwise errors,
particularly in the horizontal plane, will upset the zero setting of the mercury
switches. Place a sprit level on the top of the indicator case to ensure correct
positioning and operation of the mercury switches.
If vibration exists at the mounting position, mount the indicator on a non-vibrating
structure. Suitable anti-vibration mountings are supplied. Do not use these
mountings during transport.
CAPILLARY LINE: Do not stretch hard twist or bend the capillary to a radius less
than 75 mm. Continuously support the capillary by suitable clips at intervals of 300
to 450 mm. Allow necessary slack at the bulb and for mounting and removing the
bulb without sharp bend at the joint. Wind in spiral (minimum dia. 150 mm) the
possible excess length of capillary close to the indicator or the bulb.
7. HANDLING AND STORAGE

Handle the instrument with utmost care. Do not twist the capillary while
unpacking, storage or installation. Avoid sharp bends especially where the
capillary joins the indicator and bulb. Allow minimum 75 mm radius of bend. Never

Date : Mar 15, 2011 Page 130 of 193
Power Transformers
lift or carry the instrument by holding the capillary only. Before storing or
transporting, pack the instrument in the paper board box supplied. Before
lowering the instrument into the box, fix the shipping stop (22) and wind the
capillary in spiral close to the indicator (minimum, spiral dia 150 mm) locate all the
cushions before closing and sealing the box. Where necessary, provide additional
wooden packing case for transport.
IMPORTANT: When Anti-Vibration mountings are supplied, do not use these
during transport.
8. MAINTENANCE
Normally no maintenance is required for the temperature indicator. However,
adjustment or replacement of switches and resetting of the maximum pointer may
become necessary.
9. REPAIRS
If a mercury switch is damaged in anyway, it may be unclipped from the switch
carrier and the leads removed with a hot soldering iron. After re-soldering the
leads to a new switch and locating back the switch in the clip, the switch should
be re-balanced. This is done by making the switch to topple in its carrier at the
instant when the mercury flows toward or away from the electrodes. By sliding the
switch a little in the appropriate direction in the clip, correct topping is achieved.
After correctly balancing the switch, check the operation at preset temperature. If
necessary re-zero the switch scale by slackening the switch zeroing screw (12-
Fig. 1) at the top of the switch scale and rotating the scale to required position.
Retighten the screw after adjustment. If the bellows, bulb or capillary are
damaged, repairs can be done only at the manufacturer's factory.

Date : Mar 15, 2011 Page 131 of 193
Power Transformers
GAS & OIL OPERATED

(BUCHHOLZ) RELAYS

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Power Transformers
CONTENTS
I. General
2. Applications
3. Advantages
4. Construction
5. Functional Test
6. Electrical Connection
7. Installation and Maintenance
8. Basic Characteristics
9. Function
10. Operating Characteristics
11. Relays for use in areas of Seismic Disturbances
12. Specifications of Relays
13. Overall Dimensional drawing
14. Dimensions and ratings
PREFACE
The ever increasing demand for electrical energy goes together with the demand for
more and more efficient and reliable "protection devices'' for power, distribution and
supply facilities. In the field of power supply, transformers represent key installations that
demand effective protection to ensure the constant availability of electrical energy.
One of the most essential devices to protect a transformer is a Buchholz relay. For more
than 20 years, Buchholz relays have been manufactured in India. They are made by an
experienced staff of skilled workers, highly qualified technicians and engineers ensuring
a high degree of precision and quality.
A wide range of type corresponding to the BIS & International Standards are available to
meet the many requirements of manufacturers and users of transformers.
1. GENERAL
Power Transformers are considered to be a highly reliable type of equipment, yet,
in order to ensure the continuity of service that modern conditions demand,
protective devices are required. The purpose of such devices is to disconnect
faulty apparatus before large-scale damage is caused by ‘a’ fault to the apparatus
or to other connected apparatus. Such devices generally respond to a change in

Date : Mar 15, 2011 Page 133 of 193
Power Transformers
the current or pressure arising from the faults and are used for either signalling or
tripping the circuits.
Protective devices in the ideal case must be sensitive to all faults, simple in
operation, robust for service and economically feasible. Considering liquid
immersed transformers, a near-ideal 'protective device' is available in the form of
Gas and Oil relay described here. The relay operates on the well-known fact that
almost every type of electric fault in a `liquid immersed transformer' gives rise to
gas. This gas is collected in the body of the relay and is used in some way or
other to close the alarm or the tripping circuit
The principle of the Gas and Oil relay was first successfully demonstrated and
utilised by 'Buchholz' many years back. In a series of experiments carried out
extensively in Germany it was proved that the Relay is capable of bringing to light
incipient fault thereby preventing further spreading of the fault and extensive
damage and thus saving expensive and protracted repairs. So successful is the
principle of this Relay that despite the continued search for better protective
devices in other electrical fields the Gas-and-Oil Relay is still on its own in
providing protection against a variety of faults.
2. APPLICATIONS
Double element relays can be used in detecting minor faults in a transformer. The
alarm element will operate, after a specified volume of gas has collected to give
an alarm indication. Examples of incipient faults are -
a) Broken-down core bolt insulation
b) Shorted laminations
c) Bad contacts
d) Overheating of part of windings.
The alarm element will also operate in the event of oil leakage, or if air gets into
the oil system.
The trip element will be operated by an oil surge in the event of more serious fault
such as -
a) Earth faults
b) Winding short circuits
c) Puncture of bushings
d) Short circuit between phases
The trip element will also be operated if a rapid loss of oil occurs. Single element
relays can be used to detect either incipient or major faults in oil filled potential
transformers, reactors, capacitors etc. A special single element relay is available

Date : Mar 15, 2011 Page 134 of 193
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Power Transformerrs
for the pro

otection of on load tap
p-change equipment
e t.
3. ADVANT
TAGES
a) Casstings treatted againsst porosity through
t a special
s pro
ocess.
b) Unique intern ng' preventts false air traps on
nal design of 'housin n top of the
ay.
rela
c) Well-designedd internal layout give
es clear view of colo
our of gas
s inside the
rela
ay through glass winddow for fau
ult analysiss.
d) Buccket type float design
n with inherent abilityy to withsta
and vacuum
m treatmen
nt
of transformers.
e) Built in test facility for ch
hecking continuity of both Alarm
m and Trip circuits.
f) Antivvibration custom-buillt mercury switches give
g high stability aga
ainst
mecchanical shocks and vibrations.
v
g) ISI Mark
M of qua
ality on eve
ery relay
d for Manufactu
er purpose witho
out written perm
mission. PROLE
EC GE shall not
assume any
on.

TTL/TM/1103
e 135 of 193
Power Transformers
4. CONSTRUCTION
The Buchholz relay essentially consists of enclosure 1 i.e. an oil tight container
and an inserted assembly 2 comprising of two pivoted elements fitted with
switches (Refer fig. above). The enclosure is provided with inlet 1.1 and outlet 1.2
for the liquid. To allow connection of pipes, the enclosure openings can be
designed with pipe thread or flange.
The front inspection glass is provided with a graduation (100 to 300 cm³) to allow
readings the accumulated volume of gas and observe colour of gas for fault
analysis.
For checking the function of the inserted assembly a Test Key (1.3) is provided.
There is also a visual indication on the scale (1.4) of service and Test/Locking
position, in the form of movement of red indicator on the reading scale. This
allows the testing of the alarm and Trip circuits before installation and even when
the transformer is in service.
Just above the inspection glass an arrow shows the specified direction of flow of
the insulation liquid to the conservator. Enclosure 1 and its inserted Assembly
cover are made out of Cast Iron.
5. FUNCTIONAL TEST
5.1 Testing the relay Function with the test key.
A test system is provided in the Buchholz relay that allows the functional test of
the upper and lower switching system.
To test the relay function loosen the nut (1.5) on the Test Key (1.3) and rotate the
key with a screwdriver in the Anticlockwise direction till the SLOT on the TEST.
Key points towards the T/L position. Both the alarm (upper switching system) and
Trip (lower switching system) will show continuity.
On bringing the SLOT on the Test Key to S (service) position by rotating the
'key' clockwise the Alarm and Trip circuits will not show continuity. The circuits will
be actuated to 'ON' position only when there will be a fault in the transformer.
Repeat the functional test each time a relay is started or maintenance completed.
5.2 Testing the relay Function with the Test Pump. Screw the test pump/Air bottle to
the test cock. Open the test cock and pump air gently into the Buchholz relay until
the upper switching system operates.
For operating the lower switching system air has to be pumped suddenly with a
jerk which will in turn operated the lower switching system.
6. ELECTRICAL CONNECTION
To allow installation of the 'signal wire' open the terminal box cover comprising of

Date : Mar 15, 2011 Page 136 of 193
Power Transformers
the nameplate and the instruction sticker on the backside. Then pass the wire
through one of the two-conduit screwings (1.6) into the terminal box. By using
either one or the other openings, facility is given for the cable to enter the terminal
box from the left or right. The upper two studs are terminals for the Alarm
switching circuit and are denoted by A. Likewise the lower two studs are
terminals or the Trip switching circuit and are denoted by T.
7. INSTALLATION
7.1 Installation in to pipeline.
For installing the relay into pipeline proceed as follows:
- See that the Buchholz relay is positioned with the arrow pointing towards the
conservator, the connection box is in the Y plane (vertical) and to Test cock.
(1.7) and air vent cock (1.8) are at the top.
- Mount the Buchholz relay as close as possible to the tank in the pipeline
between transformer and conservator.
- Keep pipe bends as wide as possible between transformer and conservator.
- Make sure pipe ascends to the conservator at angle between three degree to
seven degrees.
- See that the relay enclosure is not subjected to stress. If necessary, use
expansion compensators.
- Ensure that he slot on the Test Key remains in the T/L (Test/Locking) position
during storage or loose transportation of the relay.
- Ensure that the slot on the Test Key remains in the 'S' (Service) position and
the Test Key Bolt is Tightened just before commissioning of the relay.
7.2 Filling with insulation Liquid
To fill the Buchholz relay, proceed as described below:
- Remove the protective acorn nut (1.9) from the air vent cock.
- Open the air vent cock to let air escape until insulation liquid emerges.
- Shut the air vent cock.
- Check liquid level in conservator.
7.3 Maintenance
The Buchholz relays are not sensitive to external influences. No servicing is
needed during operation. On routine inspections of the protection equipment, test
the function of the Buchholz relay as described earlier and check the alarm and

Date : Mar 15, 2011 Page 137 of 193
Power Transformers
trip devices connected to them.

8. Basic Characteristics
The Gas and Oil relay provide protection against a number of internal faults but it
also is able to indicate in several cases the type of fault. This is possible because
the gas collected in relay can, from its colour, odour and composition, indicate
where the fault may be and what its nature is. By examining the gases collected it
is possible to infer the nature of fault.
Thus :
a. If the gas is colourless and odourless or with only a faint odour of oil, the gas is
air trapped in the oil or the insulation.
b. If the gas is Greyish White with sharp and penetrating odour and non-
inflammable it is due to overheated or faulty insulation (fuller board etc.)
c. If the gas is yellowish in colour and inflammable it may be due to surface
leakage on material like wood.
d. lf the gas is dark Grey and inflammable it may be due to a flashover in oil or
due to excessive overheating of the oil caused by a fault in the winding or the
core.
On the operation of the alarm if investigation of the collected gas does not indicate
a serious fault it is possible to leave the transformer in service till it is convenient
to carry out a through inspection. This occurrence is possible on a newly
commissioned transformer due to air trapped in the oil or the insulation. On
repeated and frequent alarm signals the transformer should be taken out of
service for thorough check up.
9. FUNCTION
The function of a double element relay will be described here.
During normal operation of a transformer the Buchholz relay is completely filled
with oil. Buoyancy and the moment due to counter weights keep the floats in their
original top positions.
In the event some fault in the interior of the transformer tank gas bubbles are
produced and accumulate in the Buchholz relay on the way to the conservator. In
consequence, the oil level in the relay enclosure drops which in turn lowers the
upper bucket.
This causes the mercury switch/Reed switch to operate an alarm signal.
The lower bucket does not change its position, because when the gas reaches the
upper inside wall of the pipe it can escape into the conservator. Hence, minor fault
in the transformer tank will not trigger the lower switching assembly and will not

Date : Mar 15, 2011 Page 138 of 193
Power Transformers
trip the transformer.

In case the liquid continues to drop due to loss of oil, the lower also goes down. In
consequence lower switching system operates if the level of oil goes below the
bottom level of the pipe connected to the relay.
The lower bucket, does not change its position, because when the gas reaches
the upper inside wall of the pipe it can escape into the conservator. Hence, minor
fault in the transformer tank will not trigger the lower switching assembly and will
not trip the transformer.
In case the liquid continues to drop due to loss of oil, the lower also goes down. In
consequence lower switching system operates if the level of oil goes below the
bottom level of the pipe connected to the relay.
Alternately in the event the liquid flow exceeds a specific value (which is
continuously adjustable, by means of a flap) the lower bucket is forced down, thus
triggering the lower switching system to operate.
As the liquid flow rate decreases or the level of the liquid rises the bucket returns
to its original position. The single element relay has only one operating element
and it responds to either gas collection or oil surges. The method of operation is
similar to that described for double element relay. Single element relays are
suitable for the protection of oil filled reactors, capacitors and potential
transformers. The single element oil Surge relay has been specifically designed
for use with on load tap change equipment and it will bypass normal amounts of
gas which are generated by tap change operations and will only respond to oil
surges and loss of oil.

Date : Mar 15, 2011 Page 139 of 193
Power Transformers
10. OPERATING CHARACTERISTICS

Relays of the double element type are made in three sizes. The sizes are
distinguished by the numerical prefix 1, 2 or 3. This refers to the diameter of the
bore of the oil pipe connecting the transformer to the conservator tank.
They are referred to as Type GOR 1, GOR 2 and GOR 3, where the Alphabets
indicate 'Gas and Oil Operated Relay' and the number refers to the pipe bore
diameter as 25, 50 and 80 mm. respectively.
The implications of the various Type Nos. and their operating conditions can be
listed as follows: -
TYPE NO. SPECIAL OPERATING CONDITIONS.
GOR 1
GOR 2 Double element Mercury switch type Buchholz Relays
Normally open type.
GOR 3
SR 1 25 mm. Single element Mercury switch type Surge relay
suitable for OLTC
SR 1/V 25 mm. Single element Mercury switch type for Gas volume
Alarm suitable for reactors, capacitors, potential and
distribution transformers.
GOR 1E Double element Mercury Switch type Buchholz relays.
GOR 2E Made as per UNEL-UTE-DIN-BS standards normally open
type.
The symbol /VO following their type markings indicate that the relays contain
Reed switches and normally open type
The symbol /S following their type markings of all relays mentioned indicate that
the relays are suitable for Silicon Oil normally used in Electro static precipitator
transformers.
All relays mentioned above are normally open types. Normally closed type relays
can also be supplied on request.

Date : Mar 15, 2011 Page 140 of 193
Power Transformers
11. Relays for use in Areas of Seismic Disturbance

When transformers are required for use in areas subject to earthquakes or for
traction applications, we can supply special relays, which use magnetically
operated Reed Switches instead of mercury switches.
The outward appearance of these relays are exactly the same as those with
mercury switches but they are distinguished from them by the symbol /VO
following their type marking. The latter V (for vibration) indicates that the relay
contains reed switches and the latter O that the contacts are normally open. Thus
a Type GOR 2/VO signifies a 50 mm. (pipe size). Double float relay with normally
open Reed Switches.
OPERATION
In the double element relay, collection of gas causes the oil level within the relay
to fall. This in turn causes the upper element to rotate on its pivots, bringing the
magnet it carries into a position where it operates the Alarm Switch.
An oil surge through the relay will cause the lower element to rotate about its
pivots and its magnet into a position so as to operate the tripping switch.
CONNECTIONS
The terminal box and the terminals are the same as that of mercury switch type
relays. In the reed switch relays, each reed switch is protected by, an inductor in
series. These inductors are intended to protect the reed switch contacts from the
effects of capacitive loads, such as are imposed by long leads or pilot cables, and
must not be removed from relays in service.
Protection of reed switch contacts against the effects of inductive loads, such as
those imposed by contactors and Electro-Magnetic relays, is achieved by means
of a diode wired across each load. This diode must be rated with forward current
at least as high as the steady load current and connected observing polarity so as
to absorb the back e.m.f.. These diodes are not provided with the relay.
The Mounting position and Testing on site procedure are same as that of 'Mercury
Switch type' Buchholz relay.
OPERATING CHARACTERISTICS
All double element relays are adjusted so that their performances lie within the
limits given in table 14. In addition the Reed Switch Relay is capable of
withstanding shocks of up to 4g. Such shocks will not of themselves cause the
relay to operate.

Date : Mar 15, 2011 Page 141 of 193
Installa
nce Manuaal
Power Transformerrs
H DATA:
SWITCH
TYPE ------------------------------------------------------------ Normally O
Open
CONTACT
T RATlNG ------------------------- 250VA
2 A.C
C. (r.m.s.) o
or D.C. ma
ax.
SWITCHIN
NG CURRENT ----------------------------------- 5A A C o
or D.C. max
x.
SWITCHIN
NG VOLTA
AGE ------------------------------------------ 300 V D.C. max.
------------------------------- 240 Volts A.C. (r.m.s.) max.
m
BREAKDO
OWN VOLT
TAGE ------------------------------------ 650 Voltss D.C. min
n.
INITIAL CONTACT RESISTAN
R NCE --------------------------- 70 millli-ohms ma
ax.
RESONAN
NT FREQU hen 700 Hz.
UENCY -------------------------------- greater th
ACTUATIN
NG TIME (Including
( Bounce) --------------- 2 milli-seco
onds (Typical)
WITCHES HAVE RH
THESE SW HODIUM CONTACT
C T, LOCATE
ED MIDWA
AY ALONG
G
THE LENNGTH OFF THEIR GLASS TUBES, THE TUBBES CONNTAIN AN
N
ATMOSPHHERE OF NITROGE
EN.
PROTECT
TION OF REED
R SWITCH CON
NTACTS:
THE EFFEECTS OF CAPACTIVE LOAD

DS SUCH AS ARE IMPOSED BY LONG G
LEADS, ARE
A SUPPPRESSED BY MEANNS OF SMMALL INDUUCTORS MOUNTED
D
WITHIN THE RELAY
Y AND WIR
RED ONE IN SERIES WITH EA
ACH SWIT
TCH.
THE EFFFECTS OF
O INDUC OADS SUCH AS A
CTIVE LO ARE IMPPOSED BYY
CONTACTTORS AND E.M. RELAYS
R ARE
A SUPP PRESSED
D BY MEA ANS OF A
DIODE WIRED ACR
ROSS EAC
CH LOAD. DIODE TO O BE RATE
ED WITH FORWARD
F D
CURRENTT AT LEEAST AS HIGH ASA STEA ADY LOAAD CURR RENT ANDD
CONNECTTED SO AS
A TO ABS
SORB BAC
CK e.m.f..
ARRANGEMENT OF
O TERMIN
NALS AND
D MEANS OF PROT
TECTION FOR
F REED
D
SWITCH CONTACT
C T.
d for Manufactu
er purpose witho
out written perm
mission. PROLE
EC GE shall not
assume any
on.

TTL/TM/1103
e 142 of 193
Power Transformers
12. SPECIFICATION OF RELAYS

Parameter Rating Tolerance
Contact System Mercury switch
Type of contact Make Contact Optional make or break
Switching voltage 220V AC/DC 12 V to 250V AC/DC
Switching Current 5 Amp AC/2 Amp DC 0.05 to 5 Amp
Switching Capacity 1000 W/VA 1 W/VA to 1000 W/VA
Frequency 50 HZ 0 to 60 HZ
Limiting temp of + 120° C 140° C for two hrs.
insulation liquid
Gas volume alarm 100 cm³ to 300 cm³
Insulating liquid flow 65 cm/sec to 160 Continuously adjustable
cm./sec. (depending
on size)
Relay casing tested at 8 kg/cm² for 1 minute
Max. Permissible flow 400 cm/sec.
rate of insulating liquid
Vibration sensitivity 0.01 inches peak to
peak at frequency of
100 cycle/sec.
Assembled relays are pressure tested with transformer oil at 3kg/cm² for 60
minutes.
Electrical circuits are tested at 2000 volts R.M.S. for one minute.
Insulation resistance measured at 500 volts is not less than 10 Megaohms in
air.

Date : Mar 15, 2011 Page 143 of 193
Installa
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Power Transformerrs
IMPOR
RTANT
The va
arious partt of a relayy including
g the body
y, form one complette calibrate
ed unit and
must not be interr changed with
w those of other re elays.
We sttrongly recommend that rela ay shouldd not be taken ap part, and under no
circumstances sh
hould any alteration
a b made to
be o the angle
e of the fla
ap on the trrip element.
as been co
This ha orrectly adjusted during manufa
acturing.
RELLAY
TYP
PE
GOR R1
RELLAY
TYP
PE
SR
R1
d for Manufactu
er purpose witho
out written perm
mission. PROLE
EC GE shall not
assume any
on.

TTL/TM/1103
e 144 of 193
Power Transformers
OIP CONDENSER TYPE BUSHINGS

Date : Mar 15, 2011 Page 145 of 193
Power Transformers
CONTENTS
1. Design and construction
2. Packing and storage
3. Unpacking and handling
4. Checks before installation
5. Installation
6. Checks after installation
7. Periodical check and maintenance

8. Unmounting and packing
9. Safety
These instructions are crucial for the proper handling,

installation, operation & maintenance of Oil Impregnated
Paper Condenser Bushings and these should be in the
possession of those who are responsible for the above
activities.

Date : Mar 15, 2011 Page 146 of 193
Power Transformers
INSTRUCTIONS FOR INSTALLATION, OPERATION AND

MAINTENANCE OF OIP CONDENSER BUSHINGS
1. DESIGN AND CONSTRUCTION

The general constructional details of the bushing, intended for oil-air application
are shown in Fig. 1. The active part of the bushing consists of an Oil Impregnated
Paper (OIP) core (1) manufactured from superior grade Kraft insulating paper with
condenser graded layers for field control, wound under tension on central tube /
conductor (2). The innermost condenser layer is electrically connected to the
central tube / conductor (2) and the outermost layer is electrically connected to the
fixing flange (3) through a test tap (11). The core is dried under heat and vacuum
and then impregnated with superior grade of insulating oil.
Porcelain insulators (4&5) on the upper and lower sides of the bushing, oil
resistant high quality rubber gaskets & ‘O’ rings (6) are held together with the
central tube by means of a set of powerful springs (7). The fixing flange (3) is
provided with a test tap (11) for the measurement of Capacitance and Tan delta,
air releasing screw (10) to release the air trapped in the transformer during
topping up of oil or can be connected to Buchholz relay, name plate giving the
product details, handle / eyebolt for lifting and space for ring type CT's on the oil
end of the bushing. At the oil end, an epoxy coated stress shield or base plate
(15) is provided to control the high stresses in oil inside the transformer. A
detachable bottom arc shield is provided for bushing rated 245 kV and above. The
intervening space between the core and the porcelain insulators is filled with
specially treated mineral oil under vacuum.
A Prismatic (upto 300kV) or magnetic (upto 400 kV) Oil sight glass (14) is
provided on the expansion bowl (8). A top terminal (12) is provided to connect to
the over head line. Arcing horns (16, 17) are provided on request. (Ref. Fig. 3).
Test Tap: - (Refer Fig. 2)
The test tap (11) is provided for the measurement of Capacitance, Tan delta and
Insulation Resistance (IR) values of the bushing. It is connected with a copper
lead to the last condenser foil of the core directly. During normal service this test
tap is electrically connected to the mounting flange through test tap cover. The
threaded test tap cover must be fixed properly (Fig 2a) before putting into service.

Date : Mar 15, 2011 Page 147 of 193
Power Transformers

Date : Mar 15, 2011 Page 148 of 193
Power Transformers
2. PACKING AND STORAGE:

Please refer to Fig. 4
To prevent physical damage to the
bushings, generally only one
bushing is packed in wooden
packing case. At times, more than
one bushing is also packed in the
case of bushings of lower voltage
rating. The bushing is placed in the
packing case at an angle of 6-8
degrees to horizontal. Accessories
like arcing horns, terminals etc. are
also packed in the same packing
case.
The bushing may be stored either in
the same case or removed and
placed vertically or placed at an
angle of 6-8 degrees from
horizontal. This is to ensure the
core remains immersed in oil. When
the packed bushings are stored
outdoors, they should be kept
horizontal and covered with
tarpaulin for protection from rain
and other atmospheric
contaminants.
3. HANDLING AND
UNPACKING:
Please refer to Fig. 5, 6 & 7
The unpacking should be done at
the time of installation. During
unpacking, mechanical stresses or
jerks are to be avoided on the
bushings. On receipt, carefully

Date : Mar 15, 2011 Page 149 of 193
Power Transformers
open the top cover of the wooden case and inspect the bushings thoroughly for
any transit damage. Ensure all the accessories are received in good condition and
report, in case found to be missing.
Note: Any damage or shortages should be reported immediately.
Bushing should be handled only with mechanical lifting arrangements, such as the
illustrated in Fig. 5.
When bushings are taken out of the packing case, they must not be allowed to
rest on the lower part of the bushing. The operation is best carried out two lifting
gears and two ropes as shown in Fig. 6. One rope is slung around the lower end
of the metallic flange and let directly to the hook of the first crane and the other
passed around the shell, between two sheds and then led to the hook of the
second crane. The bushing is raised sufficiently in the same inclination angle as in
the packing case with hoists and then lowered at the flange end. When positioning
the bushing upright (Fig. 7), care should be taken to avoid any shocks, jerks or
scratch to the oil end porcelain and bottom stress shield. On no account the
bushing should be balanced on rope, passed around the porcelain at it’s centre of
gravity.
4. CHECKS BEFORE INSTALLATION:
i) Mount the bushing vertically on a suitable stand and clean the surface
thoroughly with a dry cloth, particularly the oil end. Inspect the bushing
physically for any leakage or damage on the porcelains. The oil end and inner
portion of the central tube should be further cleaned with transformer oil. Care
should be taken to prevent scratching of the painted surface of the bottom
stress shield / base plate.
ii) Check oil level of the bushing in vertical position. The oil level should be such
that the oil level is clearly visible through the oil sight glass provided on the
bushing. The oil level is filled in the factory upto the mid point of the sight
glass, which is considered to be the normal oil level. The oil in the prismatic
type sight glass can be identified by the
highlighting of the red colour reflector at any position mounted from vertical
upto a maximum of 30 degrees.
iii) Ensure the top terminal is tightened firmly with its gasket provided to avoid
water / moisture entry into the transformer.
iv) Measure and record the IR values of the bushing with a 2.5 kV meggar. The
recommended values are:
 4000 Meg ohms (Min) between oil end terminal or top and test tap.
 1500 Meg ohms (Min) between test tap and flange with 1 kV meggar.
The IR values may vary due to the atmospheric condition (humidity), surface

Date : Mar 15, 2011 Page 150 of 193
Power Transformers
cleanliness of the porcelains, dryness of test tap etc. In such cases, preheating of
porcelains, terminals test tap etc., with hot air is recommended.
This is only an indicative test, however, the healthiness of the bushings can be
known only after measurement of Tan delta & capacitance values.
v) Capacitance and Tan delta values of the bushing should be measured between
the top terminal and test tap at 2 kV to 10 kV (Maximum). The measurement
should be preferably carried out indoors with RH not exceeding 60% and at
ambient temperature, with the facilities and procedure as described as described
below:
 Schering Bridge
 Standard loss free capacitor
 High voltage supply
 Necessary screened connecting leads.
Place the bushing vertically on suitable stand. Remove the threaded test tap
cover. Insert a plug / clip into the central stud of the test tap and connect to the
Schering Bridge through a screened cable. The flange body should be grounded.
Connect the high voltage supply to the top terminal. Measure the capacitance &
tan delta value of bushing upto a maximum of 10 kV.
Note:
 The voltage applied on the bushing should be limited to 10 kV, when the
bottom end is not immersed in oil. Utmost care should be taken to avoid any
contact with the bushing during testing as this may result in fatal injury to the
personnel.
 The test tap should be dry, free from any moisture condensation and dirt
deposition. The threaded test tap cover should be fixed back to the test tap,
immediately after the test.
Factory test values of tan delta and capacitance are indicated in the test report of
individual bushing at working voltages. However, site values may vary, as they do
not resemble factory test conditions. The site values recorded at the time of
commissioning should be taken as the reference values for comparison with
future measurements. The bushing can be commissioned, if tan delta value
measured is less than or equal to 0.007, and capacitance value as per the factory
test value with maximum variation of 10%. If higher values are obtained, please
contact PROLECGE, Customer Service Department giving full details of testing
arrangement, for further advice.
Note:
The bushing should be kept vertical or mounted on transformer for a minimum
period of 24 hours before application of voltage.

Date : Mar 15, 2011 Page 151 of 193
Power Transformers
5. INSTALLATION:
The bushing is suitable for installation for a
maximum angle of 30 degrees from
vertical. During the lowering of the bushing
into the transformer, extreme care should
be taken to prevent the lower porcelain
hitting the wall of the tank. The bushing
should be so mounted on the transformer
that the oil sight glass is visible from the
ground level. Ensure the visibility of the oil
level to the naked eye.
Maximum stress experienced by the
bushing is at the bottom stress shield
during testing. Hence sufficient care should
be taken to avoid any flashover from the
stress shield to the wall of the turret. The
flashover voltage depends on the
clearance maintained in oil between the
stress shield and turret, oil quality, surface
smoothness, presence of barriers,
shape of the stress shield and turret etc.
The recommended size of the turret to be
maintained for various voltage class of
bushings is given in the manufacturer’s
booklet / respective drawings.
BUSHING WITH DRAW LEAD

CONNECTION:
Please refer to Fig. 9.
Each bushing is supplied with a top
terminal (12), cable bolt (9), cable bolt pin
and a gasket placed separately in the
packing case.
Drill a hole of suitable diameter based on the size of the flexible transformer cable

Date : Mar 15, 2011 Page 152 of 193
Power Transformers
at the bottom end of the cable bolt and braze the cable into it. Insert an M8 bolt at
the upper end of the cable bolt and tie a wire or a fish cord on to it.
Clean the gasket seating surface on top face of the transformer and place the
gasket in position. Lift the bushing above the transformer turret and clean the
bottom end of the bushing.
Lower the bushing slowly into the transformer, simultaneously pull the transformer
cable brazed with cable bolt through the central tube with the help of the fish cord.
Secure the cable bolt to the central tube with the cable bolt pin. Remove the fish
cord. Bolt the bushing into position taking care to correctly position the gasket
joint. Ensure the threads on the terminal and the cable bolt are clean. Tighten the
terminal to the cable bolt ensuring full thread engagement for proper current
transfer.
Sometimes the cable bolt is supplied along with the brazed flexible lead upto the
flange seat with a half connector at bottom end. In such cases the flexible lead
from the transformer winding should be brazed to the other half connector and
should be fastened with the draw lead connector of the bushing using bolts and
nuts.

Date : Mar 15, 2011 Page 153 of 193
Power Transformers
BUSHING WITH DRAW-ROD CONNECTIONS:

Bushings of higher current ratings are
provided with draw rod type arrangement with a
half overlap bolted joint at the flange seat.
Remove the draw rod through the bushing
tube or take it out from the packing case.
Clean the outer surface and braze the
transformer cable to the lower half connector.
Clamp the upper and lower half connectors
together with bolts and nuts. Follow the
installation instructions as described for draw
lead type of bushing.
BUSHING WITH SOLID STEM:
Refer to Fig.11
In solid stem type of bushings, the central
conductor forms the current carrying part.
Mount the bushing on the turret and
connections should be made to the top and
bottom terminals individually. The transformer
cable termination should be connected to the
bottom terminal with bolts & nuts, through the
viewing port of the transformer. The top
terminal should be fixed directly to the central
conductor.

Date : Mar 15, 2011 Page 154 of 193
Power Transformers
6. CHECKS AFTER INSTALLATION:

i) After installation, clean the bushing thoroughly with a dry cloth and carry out
physical inspection for any damage on the porcelain / leakage that might have
occurred during installation.
ii) Check the oil level of the bushing.
iii) Ensure the top terminal is fixed tightly with the gasket provided to avoid entry
of moisture in to the transformer.
iv) Measure and record the capacitance and tan delta values of the bushing. Here
again the values may differ from the previous ones.
Note:
 The threaded test tap cover should be fixed back to the test tap immediately
after the test.
 The bushing should be kept vertical mounted on the transformer for a
minimum of 24 hours before energisation.
CAUTION:
THE TEST TAP WILL ALWAYS BE EARTHED AS LONG AS THE THREADED
CAP IS FIXED (Fig. 2a). HENCE THE CAP SHOULD NEVER BE KEPT OPEN.
7. PERIODICAL CHECKS AND MAINTENANCE:

As the bushing is a self contained unit, as such there is no specific maintenance
to be carried out. However, a periodical check of the oil level and cleaning of the
porcelain will normally suffice.
In order to determine the healthiness of the bushing, measurement of capacitance
and tan delta may be carried out during annual maintenance. These values are to
be compared with the pre-commissioning test results. Tan delta value more than
0.007 and increase in capacitance by more than 10% or more, if observed, should
immediately informed to PROLECGE for further advice.

Date : Mar 15, 2011 Page 155 of 193
Power Transformers
8. UNMOUNTING AND PACKING:

Whenever bushings are to be further transported, they have to be dismantled from
the transformer and handled in the same way as explained under PACKING. The
bushing should be repacked in the same wooden packing case or in a similar
packing case suitable for transportation.
9. SAFETY:
Understanding the procedures and instructions are a must while handling
bushings. Also, all applicable safety procedures such as regional or local safety
rules and regulations must be followed. Safe working practices and good
judgement are essential by the personnel while installing, testing, maintaining or
disposing the bushings.
CAUTION:
FAILURE TO FOLLOW THE INSTRUCTIONS MIGHT RESULT IN FATAL
INJURY TO PERSONNEL OR DAMAGES TO PROPERTY INCLUDING
TRANSFORMER AND ITS ALLIED EQUIPMENT.

Date : Mar 15, 2011 Page 156 of 193
Power Transformers
SILICAGEL BREATHER

Date : Mar 15, 2011 Page 157 of 193
Power Transformers
SILICAGEL DEHYDRATING BREATHER FOR TRANSFORMER

A dehydrating breather is used to dry the air that enters a transformer as the
volume of oil decreases because of fall in temperature.
Air entering the breather is first drawn through an oil seal and passes upwards
through the silicagel crystals to the connecting pipe at the top. During this upward
passage of air, any moisture present is absorbed by the dry silicagel.
The oil seal ensures that the gel absorbs moisture only when the transformer is
breathing.
INSTALLATION
The breather is usually detached from the tank and shipped separately; the
silicagel charge is shipped in at the top with a plug. To install, it is necessary to:
1. Remove top cover by unscrewing cap nut and fill with silicagel.
2. Remove the plug.
3. Pipe up to the tank or conservator.
4. Fill the oil cup with transformer oil to the indicated level.
MAINTENANCE
Inspect the breather on monthly basis; more frequently, if found necessary by
experience (eg. highly humid atmosphere).
When the breather is first installed, the crystals have a blue tint, and after a period
of operation, the colour of the tinted crystals gradually changes to pink; this is an
indication that the silicagel is becoming saturated and losing its absorbent
properties. When there is a preponderance of pink crystals the geI should be
changed or reactivated.
Silicagel may be reactivated by heating in a shallow pan at a temperature of 150°
C to 200° C for two to three hours when the crystals should have regained their
original blue tint.
Before filling the container with silicagel, clean and dry all parts of the breather.
Verify that the oil Level in the oil cup is correct when reassembling.
Ensure that the breather is not choked and is free for passage of air.

Date : Mar 15, 2011 Page 158 of 193
Power Transformers
SECTIONAL VIEW OF BREATHER

TYPE 1

Date : Mar 15, 2011 Page 159 of 193
Installa
nce Manuaal
Power Transformerrs
SILICA
AGEL BR
REATHE
ER
TYPE 2
d for Manufactu
er purpose witho
out written perm
mission. PROLE
EC GE shall not
assume any
on.

TTL/TM/1103
e 160 of 193
Power Transformers
OIL LEVEL INDICATOR

Date : Mar 15, 2011 Page 161 of 193
Installa
nce Manuaal
Power Transformerrs
OIL LE VEL IN DICAT OR
SIDE
E VIEW FRON
NT VIEW
S LIST F OR FIG . 1
PARTS
Sr. No.. DESCRIPTION MA
ATL. Sr. No.
N DES
SCRIPTION
N MATL.
M
1. Float 50 p x 100 Brasss 7. Bolts 'B'-6 Nos.- M
M6 M.S.
M
2. Terminal Box
B Casst Al. 8. Base with Mtg. Ho oles Cast.
C Al.
3. Cover for T.
T B. Casst Al. 9. Limit stoppers Brass
B
4. Dial Body wiith switch housiing Casst Al. 10. Gear with lever Brass
B
5. Mercury sw witch Glasss 11. Float Arm 9.5 p tuube Brass
B
6. Nut for Swwitch Adj. Brasss 12. Check Nut Brass
B
Fig. 1
d for Manufactu
er purpose witho
out written perm
mission. PROLE
EC GE shall not
assume any
on.

TTL/TM/1103
e 162 of 193
Installa
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Power Transformerrs
d for Manufactu
er purpose witho
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mission. PROLE
EC GE shall not
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on.

TTL/TM/1103
e 163 of 193
Power Transformers
OIL LEVEL INDICATOR

MODEL SO-HE-10
APPLICATION
This model of indicator is manufactured considering Transformer application. It
can also be used as Content Gauge on other tanks where level of liquid inside the
tank is required to be indicated continuously on a dial.
CONSTRUCTION, WORKING & FEATURES
A float is used as sensor of liquid level inside the conservator (tank). Swing of
hinged float due to change in liquid level is utilised to indicate level on a calibrated
dial and to operate a switch for external alarm unit.
Use of magnetic coupling in the indicator achieves complete sealing off of liquid
inside the conservator from surrounding atmosphere. This results in avoiding any
leakage of costly oil and avoiding contamination of insulating oil due to seepage of
surrounding air in the conservator.
The glass mercury switch is nylon encapsulated to avoid breakage and spilling of
mercury. Switch is accessible for servicing while indicator is mounted on the
conservator without any necessity of draining the oil.
CALIBRATION
The standard calibration of dial is Empty, 1/4, 1/2, 3/4, Full. Calibration of marks
Empty & Full is done after leaving 65 mm from bottom and top of conservator to
avoid striking of float to conservator wall. Different calibrations are done to suit
customer's needs.
MOUNTING
In fig. 2, indicator is shown mounted by keeping dial and mounting pad in vertical
position. However, indicator can be mounted in titled position towards ground
(max 30°) for easy viewing by fixing mounting pad at desired angle. The position
of indicator on the conservator can be selected to suit site condition. Float
mechanism passes through the hole in pad (see Fig. 2).

Date : Mar 15, 2011 Page 164 of 193
Power Transformers
ALARM SWITCH & CONNECTIONS

One mercury switch is provided for Low Level Alarm. The Normally Open switch
closes when oil level drops to 10 mm above Empty level i.e. 75 mm from bottom
of conservator. Leads from mercury switch are brought into a terminal box
positioned at the bottom of indicator. (see Fig. 4B), A two-way terminal strip is
provided which is accessible for connection after removing cover of terminal box.
A hole with 3/4” B.S.P. is provided for cable gland. Wiring should be done as per
Fig. 4B.
SPECIFICATIONS
1. Operating Liquid : Transformer Oil to IS: 335
2. Working Temperature : 0 to 100° C of Oil
3. Working Pressure : 0 to 4 kg/cm²
4. Environment : For Indoor & Outdoor use
5. Size : See Fig. 2 & 3
6. Weight : 6.6 Kg. with Float & Float-arm
7. Mounting Specifications : See Fig. 2 & 3
8. Float Travel : Float moves in right angle plane to
seating face (See Fig.2)
9. Electrical witch : One SPST Mercury Switch
10. Contact Rating : 5 Amps 240 V.AC. 50 Hz. 1.2 Amps
240 V.DC.
11. Switch Setting : Normally Open Closes when oil level
drops to Empty level.
Switch opens automatically when oil
level rises.
12. Dial Size : 250 mm dia.
13. Dial Position : Vertical or Inclined
14. Conservator dia : Available for use in range of

600 to 1500 mm dia.

Date : Mar 15, 2011 Page 165 of 193
Installa
nce Manuaal
Power Transformerrs
PRESS
SURE
E RELIEF
F DEV
VICE
E
d for Manufactu
er purpose witho
out written perm
mission. PROLE
EC GE shall not
assume any
on.

TTL/TM/1103
e 166 of 193
Power Transformers
GLOSSARY OF TERMS
PRV : Pressure Relief Valve

Tank : Tank in which transformer winding & oil etc. are housed.
Figures : Figures in brackets in write-up refer to part list of Drg. CD-601-R-3
1. APPLICATION:
This PRV is designed to be used on Power Transformer. When pressure in the
tank rises above predetermined safe limit this valve operates and performs
following functions.
 Allows the pressure to drop by instantaneously opening a port of about 150
mm diameter.
 Gives visual indication of valve operation by rising a flag.
 Operates a micro switch.
This switch has 1 NO and 1 NC contacts (Four terminals). Hence switch can be
effectively used in control circuit.
2. SPECIFlCATIONS:
See Drg. No. CS-601-R-3.
3. TESTS:
Tests are carried out as per test certificate attached to this leaflet.
4. CONSTRUCTION & WORKING:
(Refer Drg. CS-601-R-3)
This PRV has an integral flange with six holes for mounting. The valve can be
mounted vertically or horizontally on the tank. The PRV has got a port of about
150 mm dia. This port is sealed by a stainless steel diaphragm. The diaphragm
rests on an 'O' ring (3) and is kept pressed by two heavy-duty springs, thereby
keeping the port closed. The other side of the diaphragm is exposed to tank
pressure. Whenever the pressure in the tank rises due to any reason, the same
pressure acts on the diaphragm from inside. When pressure rises above
predetermined safe limit the diaphragm gets lifted from its seat. This lifting is
instantaneous and allows vapours, gases or liquid to come out of tank depending
upon the position of valve on tank.

Date : Mar 15, 2011 Page 167 of 193
Power Transformers
The diaphragm restores its position as soon as pressure in the tank drops below
set limit. The lift of the diaphragm is utilised to operate flag ( 10) and micro switch
( 11) with the help of rod (8). The flag and switch remain operated until they are
reset manually.
5. CHECK FOR VALVE:

The PRV is generally packed in a corrugated box. The method of packing may
vary. The PRV should be checked as follows before it is installed.
Remove the valve from packing and keep it on a table. Remove all packing,
strings fixed to valve. Check that no parts are damaged in transit. If any damage
is found refer to faults and remedies in this leaflet.
Remove the cover of switch box (13). By lifting the operating rod (8) check
operations of switch as stated in Test 4 in test certificate with the help of an AVO
meter. After checking, reset the switch by pressing knob (12). Replace the cover.
The flag operation should be checked manually by lifting the rod (8) as per test
1.2 in the test certificate. Reset the flag by turning it down. Handling of flag should
be done very carefully.
The product label indicates the suitability of valve for synthetic liquid or for
transformer oil. A proper valve should be selected. Normally Red product label is
used for synthetic liquid and Black label for transformer oil.
A Gasket (2) for base is supplied with each valve. It should be noted for general
guidance that Red gasket (silicone) is provided for synthetic liquid and Black for
transformer oil.
Each PRV is tested at our works as per test certificate. However, customer is
advised to check the valve by stimulating pressure conditions before it is actually
installed on Transformer. While conducting such Tests at your end care should be
taken that small Particles do not have a passage through the port opening. Such
particles are likely to be trapped between diaphragm and gasket, which will affect
functioning of Valve.

Date : Mar 15, 2011 Page 168 of 193
Installa
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Power Transformerrs
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er purpose witho
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mission. PROLE
EC GE shall not
assume any
on.

TTL/TM/1103
e 169 of 193
Power Transformers
6. CHECK FOR INSTALLATION:
The following checks should be observed before installation of PRV on

Transformer.
Check that the orientation of pad is properly done.
Check that the proper bolts, M12x40 with thick washers are taken for installation.
Bolts other than this size should not be used.
Any other gasket than supplied with the valve should not be used.
Provide cable gland of "3/4" BS conduit with suitable bush for cable to be used.
After all above check the PRV is ready for installation.
7. INSTALLATION
Each valve should be cleaned from inside (tank side) with compressed air jet. All
particles should be removed from tank side. While cleaning, care should be taken
that the jet does not attack the switch and the flag mechanism. The PRV should
be installed considering the following aspects.
The indicating flag (10) is easily seen from distance, The valve is accessible for
manual resetting and for routine manual checking. While installing remove dirt and
clean the mounting surface, remove all traces of oil, grease.
The rubber gasket supplied with the valve should be properly cleaned & be
located properly in the recess carefully.
All the bolts should be tightened evenly so that equal pressure is exerted on
gasket and base.
Connect control circuits to terminal plate provided in the switch box through cable
gland (14).
As per wiring diagram (ref. fig. 1 drg. CS-601-R-3), check the operation of flag and
switch by lifting operating rod (8) and confirm that both controls operate as
required.
The PRV can be put to service.

Date : Mar 15, 2011 Page 170 of 193
Power Transformers
8. FAULTS AND REMEDIES:

The valve has rugged construction and it is not likely to get damaged easily.
However, the indicating flag (10) is delicate item. Hence if is likely to get damage.
The indicating flag can be replaced by either making similar flag at your end or by
asking for replacement.
You can repair with the help of good instrument mechanic minor faults occurring
in working of switch or flag mechanisms. However for breakage or damage to
major parts like diaphragm, base, valve cover. Send the PRV back to us.
In any case the Sr. No. of PRV must be informed so that sending correct
replacement is possible. This will also save lot of communication.
9. GENERAL NOTES:
Store the valve on its base duly packed in polythene bag to ensure that dirt or
other solid particles do not enter the valve port from tank side.
Do not remove the protection cover on flag box and switch box when it is stored.
Keep the flat gasket (2) duly tied to the valve. Remove it only when it is to be
installed. This gasket should be kept dry.
After installation of valve on transformer, test periodically the functioning of
switch operation and flag operation by lifting the operating rod manually.
This will ensure the switch operation and flag operation when valve opens due to
rise in pressure inside the tank.
It is not possible to change the operating pressure at site.
The valve gaskets are of entirely different nature for synthetic liquid and
transformer oil. Hence use proper valve for liquid as described on product label.

Date : Mar 15, 2011 Page 171 of 193
Installa
nce Manuaal
Power Transformerrs
E AUS
EXHA ST FA
AN
d for Manufactu
er purpose witho
out written perm
mission. PROLE
EC GE shall not
assume any
on.

TTL/TM/1103
e 172 of 193
Power Transformers
COOLING FANS
GENERAL
Exhaust type cooling fans used on transformers are designed to operate outdoors
in all weather conditions. Generally the following sizes of fans are used.
SIZE (mm) 450 610 610 915 915

SPEED (r.p.m.) 1400 700 900 550 700
INPUT (watts) 410 240 500 700 1200
PHASE 3 3 3 3 3
VOLTAGE (volts) 415 415 415 415 415
FREQUENCY (Hz) 50 50 50 50 50
CURRENT (amps.) 0.9 0.5 0.9 1.5 2.5
The fans are designed to operate outdoors in all weather conditions.
MOTORS
The fans are powered by totally enclosed, squirrel cage induction motors. The
motors are adequately rated to give reliable service for many years.
IMPELLER
The impeller is designed to give maximum volume at minimum noise level with
minimum power consumption.
For reducing vibrations, special shoes made of rubber are provided at fixing points
of fan lugs.

Date : Mar 15, 2011 Page 173 of 193
Installa
nce Manuaal
Power Transformerrs
MOUNTIING
1. Thee arm is se
ecured by the resilie
ent mountin
ng caps, w which are placed
p ove
er
the rubber so
ockets and secured tot the diap
phragm witth 8 screw ws, nuts and
wasshers provvided. The lock wash hers should be fitted
d under th
he heads of
o
the screws.
2. Rub
bber socke ets fitted to
t arms. To
T be fitted w come in
d so that fflat side will
con
ntact with th
he diaphra agm.
3. Arm
ms to be se
ecured to motor
m by th
he 4 screws in motor carton.
NO
OTE: Lock washers
w arre supplied
d and shou
uld be fitted
d.
4. Setscrew in blade
b shou
uld engage e in dimple
e nearest the end of
o the shafft.
Afte
er blade is fitted, see
e that split pin
p 5 is rep
placed in e
end of shafft.
C
CONSTR
RUCTIONAL DETA
AILS
d for Manufactu
er purpose witho
out written perm
mission. PROLE
EC GE shall not
assume any
on.

TTL/TM/1103
e 174 of 193
Installa
nce Manuaal
Power Transformerrs
No. PAR
RT NAME No. PART N
NAME
1 TER
RMINAL BLOOCK 14 WIN
NG FIXING BBOLT
2 BAL
LL BEARINGG 15 SPL
LIT PIN
3 ATOR WINDING
STA 16 SHAAFT
4 EAR
RTH SCREW W 17 HUBB FIXING BO
OLT
5 ROT
TOR STAMP PING 18 HUBB
6 ATOR STAMPING
STA 19 BAL
LL BEARING G
7 RES
SILIENT CAPP 20 LUB
BRICATOR S SCREW
8 RUB
BBER SLEEV VE 21 MOUNTING AR RM
9 BAC
CK COVER FIXING
F SCR
REW 22 MOTOR FIXING G BOLT
100 BAC
CK COVER 23 DIE CAST AL. R
ROTOR
111 FAN
N FIXING BO
OLT 24 CH.. HD. SCREWW
122 WIN
NG 25 DIA
APHRAGM
133 CH. HD. SCREW
W
d for Manufactu
er purpose witho
out written perm
mission. PROLE
EC GE shall not
assume any
on.

TTL/TM/1103
e 175 of 193

Power Transformers
APPENDIX

Date : Mar 15, 2011 Page 176 of 193

Power Transformers
Dew Point Measurement & Graphics
A.1 Dew Point Measurement

A Dew Point Measurement can detect the presence of moisture on the insulation
package that may have entered the transformer during transit, storage or assembly.
Dew point is important because it is related directly to the partial pressure of water
vapor that in turn can be used to determine the percentage of water content in the
insulation package.
A.1.1 - Dew Point and Percent of Moisture Content.
A.1.1.1 - Establish a gas connection between the Dew Point Measurement device
and the pressurized internal transformer environment.
A.1.1.2 - Satisfy the following requirements for accuracy:
1.(1) Transformer has been leak free since factory shipment.
1.(2) The temperature of the internal insulation is known.
1.(3) Transformer internal pressure is known.
1.(4) Twenty-four hours has elapsed since dry gas was added to the tank.
A.1.1.3 - Bleed off tank to dew point device tubing for approximately 5 minutes at
the device connection.
A.1.1.4 - Purge device of any atmospheric air.
A.1.1.5 - Follow dew point device instructions
A.1.1.6 - Read dew point and record.
A.1.1.7 - Refer to Chart A.1 - Dew Point to Vapor Pressure Conversion Chart
A.1.1.8 - Locate recorded dew point on vertical axis.
A.1.1.9 - Trace a horizontal line until the zero pressure line is crossed.
A.1.1.10 - From this point drop vertically to obtain an un-corrected vapor pressure
value.
A.1.1.11 - Read and record tank internal pressure.
A.1.1.12 - This vapor pressure must be corrected using the following equation:
Where:
• PVC = Corrected Vapor Pressure in μHg
• PA = Atmospheric Pressure in kg/ cm2
• PT = Transformer Tank Pressure in kg/ cm2
• PV = Dew Point Vapor Pressure in μHg (from A.1.1.7 - )
A.1.1.13 - Measure and record insulation package temperature. The temperature of
the core and coil assembly may be determined by reading the
temperature of the gas inside the transformer from the dew point
measurement device. As an alternative, this temperature may be

Date : Mar 15, 2011 Page 177 of 193
Power Transformers
obtained by placing a ball of putty at or on the base of the transformer

(make sure the putty does not have an evaporating agent). Then, insert a
thermometer into the putty touching the transformer steel. The
thermometer can also be taped to the base of the transformer.
Preferably, perform this step early in the morning when the entire
transformer package temperature is in equilibrium. Record temperature in
degrees Celsius.
A.1.1.14 – Go to Chart A.2 – Moisture Equilibrium Chart
A.1.1.15 – Find on Chart A.2 - Moisture Equilibrium Chart, left vertical axis, mark
Vapor Pressure from step A.2.1.12 - .
A.1.1.16 – Find on Chart A.2 - Moisture Equilibrium Chart, horizontal axis, Insulation
Temperature step A.1.1.13 -.
A.1.1.17 – Locate the intersection of these two points on the graph.
A.1.1.18 – After finding the intersection point, draw a diagonal line down (staying
parallel to established diagonal line) to the right hand axis.
A.1.1.19 – The intersection of this diagonal line and the right axis is the percent of
moisture contained in the transformer.
A.1.1.20 – A value of 0.5% is the upper limit of what is considered normal.
A.1.1.21– Anything above 0.5% moisture content dictates a drying process is
required.

Date : Mar 15, 2011 Page 178 of 193
Power Transformers
Chart A.1 - Dew Point to Vapour Pressure Conversion Chart

Date : Mar 15, 2011 Page 179 of 193
Power Transformers
TEMPERATURE OC
Chart A.2 Moisture Equilibrium Chart.


Date : Mar 15, 2011 Page 180 of 193
Power Transformers
A.1.2 - Moisture Equilibrium.

A.1.2.1 – Customer Results Cautions
1. (1) For accurate results, the Insulation Temperature must be known
exactly.
1. (2) The accuracy of the readings is much more affected during cold
weather than during warm weather seasons.
1. (3) Many parameters affect the dew point measurement. All can affect
the accuracy of the measurement process.
1. (4) Parameters affecting results are as follows:
(a) Permeability of gas probe
(b) Condition of gas hose
(c) Proper purging of hose and dew point device
(d) Exact insulation temperature
(e) Dew point device operator skill
(f) Type of dew point device
(g) Skill of using the chart
(h) Precision of pressure indicating device or gauge

Date : Mar 15, 2011 Page 181 of 193
Power Transformers
Insulation Dry-out Process
According to IEEE Std. C57.93.1995 – “Guide for Installation of Liquid Immersed Power
Transformers”, there are mainly four methods that may be used to dry the insulation in
case the moisture content is beyond the acceptable value. In this section, a brief
description of two of them is given to inform the customer about the different choices
available to achieve the required insulation dryness. However, it is recommended that
the user interested in having more information and detail on this matter; consult IEEE
Std. C57.93.1995.
A.2 - Disclaimer.
Even though all the methods described in this section are industry-wide recognized
methods; their inclusion in this manual is for informational purposes only. It is the
sole responsibility of the customer to choose the method most suitable to their
particular environmental conditions or equipment availability. GE-PROLEC will not
be held liable for any damage or injury that the use of any of these methods may
cause.
A.3 - Circulating Hot Oil Method.
This method requires the use of a suitable oil filter plus an oil heater. The heater
must be capable of rising and maintaining a top oil temperature of approximately
85°C as the oil is circulated in the transformer tank until the insulation is dry. As the
oil circulates through the core and coil, it picks up the moisture contained in the
insulation and takes it to the processing equipment, where the moisture is removed
from the oil. Any steps taken to maintain hot oil the temperature in the transformer
will result in a much quicker moisture removal process. Where possible, it is
recommended to insulate the tank and piping of the transformer and keep the
radiator or cooler valves closed. The effectiveness of this method will depend upon
the water removal capabilities of the filter system, either if a blotter-press filter or a
vacuum-drier filter is used. Sometimes, this method is used as a preparation
process. When the oil filling process is to be performed under cold weather
conditions (less than 10°C ambient temperature), Hot Oil Recirculation may be
used to heat the core and coils before starting a vacuum drying process.

Date : Mar 15, 2011 Page 182 of 193
Power Transformers
Fig. A.2 A typical hot oil process under cold ambient temperature conditions
(Transformer main body is covered with tarpaulins)
A.4 High Vacuum Method.
This is probably one of the most commonly used methods to dry a transformer.
It requires a vacuum pump capable of pumping down to an absolute pressure
of 0.05 mmHg or 50 μHg or 0.05 Torr and an optional refrigerated vapor trap to
collect the water. After the tank has being completely sealed, a vacuum hose
should be connected to the transformer. Either a specially designated valve or
the flange for the mechanical pressure relief device is generally used for this
purpose. The extraction of moisture begins as soon as the residual vapor
pressure in the tank is reduced below the vapor pressure of the water in the
insulation. The temperature of the insulation system must be above zero
degrees centigrade. The dry out will be much faster if the insulation
temperature is 85°C. The vacuum should be maintained as long as water is
being removed from the transformer. Each manufacturer establishes a series
of guidelines to use as reference for the duration of this process.

Date : Mar 15, 2011 Page 183 of 193
Power Transformers
Winding Resistance and Insulation Power Factor Correction Tables
Winding Power Factor Correction Table
Correction Factor for Winding Power Factor

Insulation Insulation Insulation Insulation Insulation Insulation Insulation Insulation Insulation Insulation
Temp. P.F. Temp. P.F. Temp. P.F. Temp. P.F. Temp. P.F.
O O O O O
( C) Correction ( C) Correction ( C) Correction ( C) Correction ( C) Correction
Factor Factor Factor Factor Factor
0 1.56 10 1.38 20 1.00 30 0.63 40 0.42
1 1.54 11 1.35 21 0.96 31 0.60 41 0.40
2 1.52 12 1.31 22 0.91 32 0.58 42 0.38
3 1.50 13 1.27 23 0.87 33 0.56 43 0.37
4 1.48 14 1.24 24 0.83 34 0.53 44 0.36
5 1.46 15 1.20 25 0.79 35 0.51 45 0.34
6 1.45 16 1.16 26 0.76 36 0.49 46 0.33
7 1.44 17 1.12 27 0.73 37 0.47 47 0.31
8 1.43 18 1.08 28 0.70 38 0.45 48 0.30
9 1.41 19 1.04 29 0.67 39 0.44 49 0.29
50 0.28
Insulation Resistance Correction Table
Correction Factor for Insulation Resistance (Megger)

Insulation Insulation Insulation Insulation Insulation Insulation Insulation Insulation Insulation Insulation
Temp. P.F. Temp. P.F. Temp. P.F. Temp. P.F. Temp. P.F.
O O O O O
( C) Correction ( C) Correction ( C) Correction ( C) Correction ( C) Correction
Factor Factor Factor Factor Factor
0 0.25 10 0.50 20 1.00 30 1.98 40 3.95
1 0.27 11 0.54 21 1.08 31 2.14 41 4.28
2 0.29 12 0.58 22 1.16 32 2.30 42 4.61
3 0.31 13 0.63 23 1.24 33 2.47 43 4.94
4 0.33 14 0.67 24 1.32 34 2.63 44 5.27
5 0.36 15 0.74 25 1.42 35 2.83 45 5.66
6 0.38 16 0.76 26 1.51 36 3.03 46 6.05
7 0.41 17 0.82 27 1.63 37 3.26 47 6.50
8 0.44 18 0.88 28 1.74 38 3.49 48 6.95
9 0.47 19 0.94 29 1.86 39 3.72 49 7.39
50 7.83

Date : Mar 15, 2011 Page 184 of 193
Power Transformers
Insulation Resistance Correction Worksheet
Two Winding Transformer

Megger Resistance Insulation Correction Corrected
between Measurement Temperature Factor Resistance
O
1 HV-LV & E __________ MΩ __________ C X _________ = _________ MΩ
O
2 LV-HV&E __________ MΩ __________ C X _________ = _________ MΩ
O
3 HV&LV-E __________ MΩ __________ C X _________ = _________ MΩ
Three Winding Transformer

O
1 HV-LV,TV&E __________ MΩ __________ C X _________ = _________ MΩ
O
2 LV-HV,TV&E __________ MΩ __________ C X _________ = _________ MΩ
O
3 TV-HV,LV&E __________ MΩ __________ C X _________ = _________ MΩ
O
4 HV,LV&TV-E __________ MΩ __________ C X _________ = _________ MΩ
Auto Transformer with Tertiary Winding

O
1 HV&IV-TV&E __________ MΩ __________ C X _________ = _________ MΩ
O
2 TV-HV, IV&E __________ MΩ __________ C X _________ = _________ MΩ
Auto Transformer without Tertiary Winding

O
1 HV&IV-E __________ MΩ __________ C X _________ = _________ MΩ

Date : Mar 15, 2011 Page 185 of 193
Power Transformers
Quick Decision Continuous Capacity Chart
CLASS OF COOLING LOSS CONDITION CONTINUOUS CAPACITY

ONAN 1 or more radiators Use formula 1
ONAN-ONAF 1 or more fans Use formula 2
ONAN-ONAF Loss of all fans Use ONAN rating
ONAN-ONAF-ONAF 1 or more fans Use formula 2
ONAN-ONAF-ONAF Loss of 1 bank of fans Use ONAN-ONAF rating
ONAN-ONAF-ONAF Loss of 2 banks of fans Use ONAN rating
ONAN-ONAF-ONAF Loss of pump Use ONAN-ONAF-ONAF rating
ONAN-ONAF-ONAF Loss of 1 or more fans Use formula 2
ONAN-ONAF-ONAF Loss of 1 bank of fans Use ONAN-ONAF rating
ONAN-ONAF-ONAF Loss of 2 banks of fans Use ONAN rating
OFAF Continuous Loss of 1 or more fans Use formula 1
OFAF Continuous Total of loss of cooling equipment Take steps to shut down transformer
ONAN – Oil Natural Air Natural cooling (with radiator)

ONAF – Oil Natural Air Forced cooling (with radiator & fans)
OFAF – Oil Forced Air Forced cooling (with radiator, fans and pumps)
A.3 – Percent of Continuous Capacity (%CC) Formulae

Formula 1 Formula 2
In case of loss of a heat exchange In case of loss of a forced air element
component (radiator) (fans)
N = Total number of radiators N = Total number of fans

η = Radiators out of service η = Fans out of service

Date : Mar 15, 2011 Page 186 of 193
Power Transformers
General Maximum Torque Value Table

Bolt Size Pitch of Steel Fasteners Stainless Steel Fasteners
(mm) Thread
(kg. cm) (ft. lb) (kg. cm) (ft. lb)
(mm)
6 1.0 110 8 70 5
8 1.25 205 15 140 10
10 1.50 345 25 205 15
12 1.75 620 45 415 30
16 2.00 1310 95 900 65
20 2.50 1660 120 1100 80
24 3.00 2070 150 1380 100
30 3.50 2900 210 1935 140
36 4.00 3595 260 2420 175
Notes:
 This table is for steel plate to steel plate application. Do not use it for bushing
installation.
 When Prolec GE employs stainless steel fasteners for external transformer
application, the customer is advised to use an anti – seize lubricant on threads of
these fasteners during assembly.
 When thread lubricant is used for assembly, the amount of torque to achieve the
same effect is about 70 ~ 75% of the torque value specified in the above table.

Date : Mar 15, 2011 Page 187 of 193
Power Transformers
Specific Component Torque Value Table
Oil sealing fasteners.
When gaskets are installed in retaining groves, a proper seal will be achieved when the
mating flanges are flush with each other. Additional torque will not improve the seal.
Tightening the fasteners in an “X” pattern to the list values will provide oil and air seal. If
flanges cannot be pulled flush, the device should be removed and the surface examined
to determined to determine the cause; misaligned or entrapped gasket, foreign material,
damage, etc.
Internal fasteners.
Electrical connections between the internal flexible/ cables require that the mating
surfaces be flush and full contact. After tightening, the contact surface should be verified.
Component Bolt/ thread size Pitch of Thread Torque value
(mm) (mm) (kg. cm.) (ft. lb.)
Radiators 16 2.00 1437 104
Radiator valves 16 2.00 1437 104
Radiator top & ½ “ NPT 1.8 249 18
bottom plugs
Man hole covers 12 1.75 719 52
Gas & oil relay 12 1.75 719 52
16 2.00 1437 104
Bushings with 12 1.75 304 22
metal flange 16 2.00 622 45
20 2.50 954 69
Bushing w/ 12 1.75 276 20
porcelain flange 16 2.00 346 25
20 2.50 415 30
Bushing turrets 12 1.75 719 52
16 2.00 1437 104
20 2.50 1820 130
Valves/ flanges/ 12 1.75 719 52
Air release pipes 16 2.00 1437 104
20 2.50 1820 130
Insulation Studs 12 1.75 69 5
(internal fasteners) 16 2.00 124 9
20 2.50 235 17
Temperature ½ “ NPT 1.8 249 18
indicator 3
/8“ NPT 1.4 152 11

Date : Mar 15, 2011 Page 188 of 193
Power Transformers
Current Transformers
Introduction
Current transformers (CT’s) are installed in power transformers as a source of current for
relaying and metering purposes and in connection with winding temperature devices and
line-drop compensators. CT’s will safely carry a continuous current and a momentary
over load equal to that of the equipment in which they were originally furnished. CT’s
have output currents proportional to their primary currents and are designed with varying
degrees of accuracy, depending on the application. When furnished for a particular
purpose a CT should not be used in any other application without checking its
characteristics. Refer to (IS 2075 (Parts 1 ~ 4) & IEC6044 (Parts 1 & 6): for Standard
Requirement of Instrument Transformers) for accuracy classes of relaying and metering
CT’s.
Receiving, Handling and Storage.
Current transformers are normally shipped installed, completely assembled and ready for
service except when ordered as renewal or spare parts. CT’s mounted in removable
bushing turrets are left in the turret when it is removed for shipment are to be installed
with the adapter turret as an assembly. When ordered as renewal parts, carefully
disassemble the CT shipping crate to avoid winding damage. Always lay the CT flat
during handling or storage and store in a dry protected area.
Description.
Two types of CT’s are used in power transformers, the bushing type and the cable or bus
bar type. The bushing type consists of a ribbon-wound core of high permeability, low loss
silicon steel on which a coil is wound.
When the transformer bushing is installed through the CT, the CT serves as a secondary
and the bushing as a one-turn primary winding. The manufacture of a cable or bus bar
CT is identical to a bushing type, except it has a smaller internal diameter for the
primary. They are installed internal on the main winding superstructure and use a cable
or copper bus bar as their primary. Cable is used for looping through the CT if more than
a one-turn primary is required.
Current transformer when applied to bushing and cable or bus bar CT’s refers only to the
core and its secondary winding. The CT in itself does not provide adequate insulation for
full circuit voltage between primary and secondary and therefore depends on the
bushing, cable, bus bar, or other material for this insulation.
Secondary windings are of the distributed type, with turns equally spaced around the
circumference of the CT core. This distribution gives the CT a low leakage reactance,
thus maintaining a high degree of accuracy when the transformer is subjected to over
load currents. This winding may be tapped to obtain multi-ratio characteristics when
required.
The polarities of primary and secondary currents are subtractive as shown in view
drawing. The H1 mark on the secondary coil indicates the polarity of the primary
conductor with reference to the secondary terminal. When current in the primary
conductor flows toward the H1 side of the CT, current in the secondary coil flows out
from the terminal X1. With any combination of taps, the tap numerically nearest terminal
X1 has the same polarity as X1.

Date : Mar 15, 2011 Page 189 of 193
Power Transformers
CT Outlet.
Secondary leads from CT’s are brought out of the transformer through a CT terminal box
that is located on bushing turret, the cover or sidewall of the transformer. The
transformer nameplate lists the current ratios and all characteristics for the various taps
of each CT.
Insulation Resistance.
Checking the current transformer for accidental grounding or low leakage resistance may
be performed with either a 500 or 1000 volt “Megger”. Short circuit the secondary
windings, disconnect all external leads from the terminal boards and Megger the
resistance between the secondary winding and station ground. This resistance should
have a value in mega ohms. If the resistance is unusually low, the transformer and
secondary leads should be inspected for accidental grounding.
Maintenance.
CT’s rarely will require attention other than occasional inspection to see that all
connections are clean and tight and that the leads have not been damaged. However, if
it is necessary to perform an excitation, ratio, ratio and phase angle or insulation
resistance test while primary current is flowing in a CT, it is vital that great care is taken
in changing burdens or taps to assure that the secondary is not accidentally open-
circuited.
Connections.
CAUTION: The secondary circuit of an energized CT MUST NOT be opened at any time.
It must be burdened with a load or short-circuited with a screw at the terminal connection
block. If the secondary is opened with current flowing in the primary, an excessive peak
voltage of many thousands of volts will develop in the secondary that will cause a hazard
to personnel and can magnetize the core and possibly damage insulation.
Installation.
CT’s shipped apart from the transformer should have their condition checked before
installing. Should moisture have entered during transit or storage it is important that the
CT be dried in an oven for 24 hours at a temperature no greater than 90ºC.
Testing.
When testing is required, the following recommendations are useful.
Excitation Test.
CT excitation characteristics can be checked, whether in or out of the
transformer, by injecting a current of the correct frequency through the primary
or secondary of the CT. When current is applied to the primary the induced
voltage can be measured across any two secondary leads. Refer to the
following circuit drawing:

Date : Mar 15, 2011 Page 190 of 193
Power Transformers
When energized through the secondary the CT acts like an ideal

autotransformer, meaning the current can be injected into and the voltage
measured from any combination of taps. Refer to the following circuit drawing:
This test is an open-circuit test and must be performed without any load except
the averaging voltmeter connected to the current transformer. The results
obtained may be reduced to a common basis or number of secondary turns
because both the ampere-turns and the volts per turn are constant for any
single value of excitation. When performing this test first demagnetize the core.
This is done automatically by checking the excitation at the saturation voltage
first and then reducing the current slowly to check the next point without
interrupting the circuit and continuing until the lowest point desired has been
taken. Note that the power transformer must be de-energized since the
excitation current must be under control. If the excitation current is high, it may
indicate that a shorted turn exists which could affect the CT ratio.
Ratio (Relay CT)
Inject a voltage to the secondary, with the primary open circuited as follows:

Date : Mar 15, 2011 Page 191 of 193
Power Transformers
If the normal burden is small in magnitude, connect a resistance, Rw (equal to

the resistance between points 1 and 2 through the transformer), in series with
the load. The ratio correction factor at the secondary current (Is) will be equal to
the quotient of the two-meter readings.
(RCF=(Ip/N)1/Is).
The error introduced by this method will be minimal with the resistor (Rw) in the
circuit. De-magnetize the core before testing is started.
De-magnetizing
CT cores may acquire a residual magnetism, which is not erased by load currents. This
magnetism may have been produced by energizing the primary with the secondary open
circuited or by high over currents. This can occur when a circuit breaker interrupts a high
instantaneous current. This will change the flux density at which the core operates,
increasing exciting current and affecting the accuracy of the CT. This error in accuracy,
although small should be removed by demagnetizing the core. Raise the flux density to
the saturation level and then gradually reduce it.
Excitation may be obtained with the transformer energized or de-energized.
To demagnetize a core while the power transformer is energized use the following:

Date : Mar 15, 2011 Page 192 of 193
Power Transformers
The resistance should be increased from zero to a magnitude that the ammeter reading
will decrease to at least one half of its original value. Then gradually reduce the
resistance to zero and repeat the process several times. To determine the magnitude of
the resistance needed, obtain the CT saturation voltage from the excitation curve and
divide this amount by one-half of the recorded secondary current. This quotient can then
be adjusted to the tap being used. Therefore, if the saturation level for a CT is 100 volts
on a given tap and the recorded secondary current is 5 amps, the required resistance
would be 100/2.5 or 40 ohms.
To de-magnetize the CT core with the power transformer de-energized, refer to the
excitation curve and determine the amount of secondary current required to saturate the
core. Be aware of the turns ratio and tap being used, gradually apply saturation current
to either the primary or secondary with the other winding open-circuited. Use diagrams 1
or 2. Then slowly reduce the current to zero. Repeat the process several times.
View of typical Current Transformer

Date : Mar 15, 2011 Page 193 of 193

Instruction Manual For Power Transformers

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INSTALLATION, COMMISSIONING,

OPERATION AND MAINTENANCE

INDO TECH TRANSFORMERS LIMITED,

Our Customer Service Mail ID: services@Prolec-GEIndia.com

Section Description Page

Rev. 1: General revision of entire document ITTL/TM/1103

HEALTH & SAFETY ASPECTS

Rev. 1: General revision of entire document ITTL/TM/1103

 Appropriate protective schemes MUST be provided on both Primary &

Rev. 1: General revision of entire document ITTL/TM/1103

1.0 GENERAL PRECAUTIONS

1.02.03 STAY ALERT

Rev. 1: General revision of entire document ITTL/TM/1103

1.02.04 FIRST AID

• Firefighting equipment should always be available whenever working on the

Rev. 1: General revision of entire document ITTL/TM/1103

pressure bleeder if applicable.

1.05.00 GROUNDING PRECAUTIONS

Rev. 1: General revision of entire document ITTL/TM/1103

1.07.00 TRANSFORMER OIL HANDLING

1.08.00 ELECTRICAL HAZARDS

Rev. 1: General revision of entire document ITTL/TM/1103

1.09.00 MECHANICAL HAZARDS.

1.09.01 GENERAL SAFETY RULES AND PROCEDURES

1.09.02 CAUTIONS FOR CLIMBING ON THE TRANSFORMER

Rev. 1: General revision of entire document ITTL/TM/1103

1.09.05 TRANSFORMER ELECTRICAL TESTS

1.10.00 HAZARDOUS SUBSTANCES

1.10.01 TRANSFORMER OIL

Rev. 1: General revision of entire document ITTL/TM/1103

1.11.01 CONTROL OF OIL SPILLAGE

Rev. 1: General revision of entire document ITTL/TM/1103

1.13.00 DO’S AND DON’TS for safety measures / precautions

Rev. 1: General revision of entire document ITTL/TM/1103

 Fire fighting equipment should be checked regularly and should have

Rev. 1: General revision of entire document ITTL/TM/1103

 Do not weld, braze or solder inside the tank.

Rev. 1: General revision of entire document ITTL/TM/1103

Rev. 1: General revision of entire document ITTL/TM/1103

Rev. 1: General revision of entire document ITTL/TM/1103

2.0 GENERAL CONSTRUCTION OF A TRANSFORMER

Rev. 1: General revision of entire document ITTL/TM/1103

Rev. 1: General revision of entire document ITTL/TM/1103

Rev. 1: General revision of entire document ITTL/TM/1103

resistance is fed by a current transformer associated to the loaded winding of the

Rev. 1: General revision of entire document ITTL/TM/1103

Rev. 1: General revision of entire document ITTL/TM/1103

PACKING AND DESPATCH

Rev. 1: General revision of entire document ITTL/TM/1103

3.0 PACKING & DESPATCH

Rev. 1: General revision of entire document ITTL/TM/1103

Rev. 1: General revision of entire document ITTL/TM/1103

MULTIPLYING SAFE LOAD OF WIRE

Rev. 1: General revision of entire document ITTL/TM/1103

Rev. 1: General revision of entire document ITTL/TM/1103

on top and eventually leaking into the drums.

Procedure for analysing impact recorder chart results:

Rev. 1: General revision of entire document ITTL/TM/1103

2) Remove impact recorder tape.

Rev. 1: General revision of entire document ITTL/TM/1103

Figure 3.6 Figure 3.7

Rev. 1: General revision of entire document ITTL/TM/1103

The Senssor charactteristics are as follow