Ekarat Engineering (Public) Co., Ltd.

9/291 U.M. Tower 29th Fl. Ramkhamhaeng Rd.,

Suanluang, Bangkok 10250 Thailand

Tel: +66 2 719 8777

Fax: +66 2 719 8758

Transformer’s Equipments Maintenance

Transformer Rating: 10,000kVA, 34,500V-6,600V, YNd1, 3 phase, 60Hz, ONAN

Project owner: Ibiden Philippines Inc.

Maintenance Standards
In order to maintain the transformer in perfect condition, the past operating
data of the transformer have to be studied, utmost care has to be paid in routine op-
eration and appropriate treatment has to be arranged without fail whenever any
change in service condition is noticed. It is also necessary to de-energize the trans-
former at a regular interval and conduct minute inspection.
By these routine and regular inspections the degree of deterioration and other
facts will be found on the other hand. Since a transformer consists of many parts such
as insulating oil, tap-changing equipment, etc. besides the core and coil, there are
standards for maintenance for each component, respectively as described below, ac-
cording to which the transformer should be maintained.

• Pressure Relief Device

• Buchholz Relay
• Temperature Indicators (Oil and Winding)
• Conservator with Rubber Air cell
• Oil Level Indicator
• Dehydrating Breather
 Outline Drawing

Pressure Relief Device

Buchholz Relay

Oil Level Gauge

Conservator with Rubber Air Cell

Silica Gel Breather Winding Temperature

Indicator

Top Oil Temperature

Indicator
 Pressure Relief Device

Working
When pressure in the tank rises, the total force on the area defined by the top gasket on the operating
disc also increases. As soon as this force exceeds the load applied by the springs, the operating disc
moves slightly upwards. This exposes the transformer pressure to a greater area corresponding to the
diameter of side gasket, resulting in sudden increase of force. The disk lifts instantaneously and vents
out the excess pressure in the transformer. When the pressure falls to allowable values, the spring
forces the disc back to its original position.

A potential free “trip” contact must connect to the main shut-off switch to de-energized the Trans-
former. If the Pressure Relief Device is operated, it need to investigate the cause before the Trans-
former is re-energized.

Please see circuit diagram in the Control box for detail of contact.

Checking and Inspection

Check to see if there are any oil leakage around the Device.
 Buchholz Relay

Working
The gas and oil actuated (Buchholz) relay is designed to detect faults as well to minimize the propaga-
tion of any damage which might occur within oil-filled transformers supplied with oil conservator.

Slight faults (Alarm): When a slight or incipient fault occurs in the transformer, the small bubbles of
gas, which pass upwards towards the conservator, are trapped in the relay housing, thus causing its oil
level to fall. As a result, the upper float rotates on its hinge and operates the alarm switch, thus operat-
ing an external alarm device.
This accumulation of gas will activated the alarm contact.
A potential free “alarm” contact must connect to a visual and audible alert in the operator control room.

Serious faults (Trip): When a serious fault occurs in the transformer, the gas generation is violent and
causes the oil to rush through the connecting pipe to the conservator. This oil surge will activated the
trip contact.
A potential free “trip” contact must connect to the main shut-off switch to de-energized the Trans-
former, and a visual and audible alert in the operator control room. If the Pressure Relief Device is op-
erated, it need to investigate the cause before the Transformer is re-energized.

Please see circuit diagram in the Control box for detail of contact.

Checking and Inspection

Check to see if there are any oil leakage around the Device. Check the accumulation of gas from the
inspection window of the Device. Clean the glass of the inspection window, inspect inside and check if
the floats move in normal condition with the supporting arm as its center of rotation, at a regular inter-
val.
 Temperature Indicators (Oil and Winding)

Working
The Oil Temperature Indicator (OTI) measures the top-oil temperature. It is a standard accessory for
cooling, control and protection on all transformers. It has 2 potential free contact setting—one for
“alarm” and another for “trip” function.

An potential free “alarm” contact was preset from factory at 80 degree Celsius.
The alarm contact must connect to a visual and audible alert in the operator control room.

A potential free “Trip” contact was preset from factory at 90 degree Celsius.
The trip contact must connect to the main shut-off switch to de-energized the Transformer, and a visual
and audible alert in the operator control room. If the trip fuction is operated, it need to investigate the
cause before the Transformer is re-energized.

The Winding Temperature Indicator (WTI) measures the winding temperature. The life of the trans-
former depends on the winding temperature because the winding temperature is determine the tem-
perature and deterioration of the insulating material. Due to the high electric potential of the winding, it
is not practical to measure the winding temperature directly. By making a “Thermal Image” of the
winding, the WTI simulates the winding temperature. The WTI is basically an OTI with a specially de-
signed heating element connected to the current transformer (CT).

An potential free “alarm” contact was preset from factory at 100 degree Celsius.
The alarm contact must connect to a visual and audible alert in the operator control room.

A potential free “Trip” contact was preset from factory at 115 degree Celsius.
The trip contact must connect to the main shut-off switch to de-energized the Transformer, and a visual
and audible alert in the operator control room. If the trip fuction is operated, it need to investigate the
cause before the Transformer is re-energized.

Two spare contacts are provided for both OTI and WTI.

Make sure that a “Short link” in the terminal for CT (XC) is removed.

Please see circuit diagram in the Control box for detail of contact.

Checking and Inspection

Check and record the temperatures daily. Notice the Maximum pointer and recorded.
 Conservator with Rubber Air Cell

Working
A conservator is attached on the upper part of the transformer in order to reduce the surface area of
contact between oil and air. An oil-proof rubber is used inside the conservator to enclose air out from
the oil surface. This will prevent the oil from contacting directly with air to consequently prevent insu-
lating oil deterioration.
 Oil Level Indicator

Working
A float is used as a sensor of liquid level inside the conservator. Swing of hinged float due to change in
liquid level is utilized 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 conser-
vator from surrounding atmosphere. This results in avoiding any leakage of costly oil and avoiding con-
tamination 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.

One mercury switch is provided for Low Level Alarm. The normally open switch closes when oil level
drops to 10mm above Empty level i.e., 75mm from bottom of conservator. Leads from mercury switch
are brought into a terminal box positioned at the bottom of indicator. A two-way terminal strip is pro-
vided which is accessible for connection after removing cover of terminal box.

Please see circuit diagram in the Control box for detail of contact.

Checking and Inspection

During shut down and oil temperature at 30 deg Celsius, the oil level should pointed at 2.5 level.
The oil level will increase as the load and the oil temperature increase. At normal operation of the load
about 75% and ambient air temperature not more than 30 deg Celsius, the oil level should be about 3.5
to 4 level.

The potential free “alarm” contact must connect to a visual and audible alert in the operator control
room.
 Dehydrating Breather

Working
This breather is meant for removing moisture and dust that are taken into the transformer due to air
movement as the result of the temperature fluctuation of the transformer oil, and is fixed between the
air passage to the transformer and the atmosphere.

It is composed of the pot of dehydrating agent (silica gel) and oil and the supporting metal parts for
fixing. The gasket has to be checked if it is clamped well as no air should be taken into the transformer
from any part other than the air breathing hole. Also, check if the oil level of the oil pot is not lower
than the breathing holes level.

If the silica gel is found wet with oil, it is due to too much oil in the oil pot.

The new type of silica gel is used. It is semi-transparently Orange color and glass like in appearance
with spherical granule. The Orange silica gel discolors variously with the increasing of moisture absorp-
tion. It uses a non-toxic, non-Cobalt organic compound as discoloring agent. In this way, it can suc-
cessfully get rid of Cobalt hazard (found in Blue color silica gel) to environment and human health. It
discolors from orange into green and at last into blue-purple with variation of moisture absorption de-
gree.

The moisture absorbed silica gel can be dried and reuse. In drying, put the wet silica gel in a clean tray
or pan and agitate while heating up to the temperature 100—110 deg Celsius and continue heating till
the color changes back to orange, or spread the wet silica gel thin and put in oven. Do not inhale the
vapor of the silica gel. Please use personal protecting device such as mask and glove during heating of
the silica gel.

Checking and Inspection

Please replace the silica gel when it absorbs moisture about 3/4 of the Cylinder.

If it is necessary to clean the Breather cylinder, please clean it with care. Resealed the glass cylinder
with silicone sealant to prevent leakage around the bottom and top of glass cylinder.

Filled the cup with the same type of transformer oil used in the transformer 2-3 mm above the breath-
ing holes.