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0311

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ERECTION, COMMISSIONING,
OPERATION AND MAINTENANCE

MANUAL
FOR

POWER TRANSFORMERS

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NAINI WORKS, P.O. NAINI,
ALLAHABAD - 211008
(UTTAR PRADESH, INDIA)

PHONES: +91 (532) 2697422 ~ 24

+91 (532) 2697447 / 48
+91 (532) 2697601 ~ 03
FAX: +91 (532) 2697604 / 2697606
VOICE MAIL: +91 (532) 2696784
e - mail : [email protected]

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CONTENTS

Section Description Page

1 General 3
2 Transport, Packing & Despatch 17
3 Storage 25
4 Installation 31
5 Insulation Dryout at Site 54
6 Commissioning 56
7 Erection Checklists 61
8 Commissioning Checklists 66
9 Operation 78
10 Maintenance 81
11 Trouble Shooting 90
12 Reference Standards 106
13 Transformer Accessories: 119
(a) Temperature Indicator 120
(b) Gas & Oil Operated Relays 129
(c) Condenser Type OIP Bushings 145
(d) Silica Gel Breather 157
(e) Oil Level Indicator 161
(f) Pressure Relief Valve 166
(g) Exhaust Fan 172
(h) Flow Indicators 176
(i) Transformer Oil Pump 189
(j) Flexible Separator 197
(k) Thermosiphon Filter 202

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1.0 GENERAL

• Transformer is a static equipment, which converts electrical energy

from one voltage to another. As the system voltage goes up, the
techniques to be used for the Design, Construction, Installation,
Operation and Maintenance also become more and more critical.

• 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 by the
manufacturer.

• This Manual contains general descriptions about Transformers &

specific details about the particular contract against which the
Transformer is supplied. Also, it contains instructions regarding the
safety aspects, erection, commissioning, operation, maintenance &
trouble shooting of large capacity Power Transformers.

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1.1 TRANSFORMER CONSTRUCTION

• The techniques used in the design and construction of high voltage
transformers varies from manufacturer to manufacturer.
• The active parts of the transformers consist of core and windings.
1.1.1 CORE
• Core is manufactured from lamination of Cold Rolled Grain Oriented
Silicon Steel, 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 in the event of any short circuit.
1.1.2 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 shielded construction is adopted for the high voltage
windings to ensure uniform distribution of impulse voltages.
Insulation spacers in the winding are arranged such that oil is
directed through the entire windings for ensuring proper cooling.
1.1.3 COOLING
• For ONAN/ONAF cooling, oil flows through the winding and external
cooler unit attached to the tank by thermo-syphonic effect.
• 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 separate cooler banks for air-cooled
transformers and oil to water heat exchangers for water cooled
transformers.
1.1.4 TANK & COVER
• Tank and Cover are manufactured by welding steel plates and are
suitable for withstanding full vacuum and positive pressure test as
per CBIP Manual. For large capacity power transformers, the tank
will be of bell type construction. This is to avoid lifting of heavy core
and windings, which requires very large capacity crane at site. The
weight of upper tank will be much less in comparison with that of
core & windings and can be lifted by using a small capacity crane.

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• Construction of the tank and cover are such that pockets for water
collection is avoided.
• The tank and cover are designed such that these can be transported
by railways/road/water as per customer specification.

1.1.5 CONSERVATOR
• Conservator is provided to take care of the expansion and
contraction of transformer oil, which takes place during normal
operation of the transformer.
• Wherever specified flexible separators or air cell if provided in the
conservator can prevent direct contact of air with the transformer oil.
• A smaller oil expansion vessel is provided for the On Load Tap
Changer.
• Magnetic oil level gauge is fitted on the main conservator which can
give alarm / trip in the event of the oil level falling below the pre-set
levels due to any reason.

1.1.6 PRESSURE RELIEF DEVICE

• A device for avoiding 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 an alarm/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 valve disc during the operation of the pressure relief device
and is held in position by an 'O' ring in the pin bushing. This pin is
clearly visible from ground level, which gives an indication that the
device has operated.
• The indicator pin may be reset manually by pushing it downward
until it rests on the valve disc. The relief device is provided with a
shielded weatherproof alarm / trip and is operated by the movement
of valve disc.
• For Small Capacity transformers, an explosion vent is provided with
a diaphragm, which will break in the event of abnormal increase in

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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.
1.1.7 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.
• 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.
1.1.8 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.

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• 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.
1.1.9 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 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.
1.1.10 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

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moves in accordance with the changes in pressure, which is
proportional to the temperature.
1.1.11 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.
1.1.12 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 changing takes place when the transformer is
in operation. The tap changer can be designed for changing the
taps.
a. Manually

b. Automatically &

c. 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.

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1.1.13 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.

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1.2 HEALTH & SAFETY MATTERS

Even though the manufacturer of the transformer has put every effort to
comply with the rules and regulations applicable to the safe operation
of the transformer, the equipment described in this manual is safe to
use provided that: —

Ø It is installed in a location suitable for its designed purpose.

Ø The installation is done by qualified and competent persons.
Ø 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.
Ø All 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.
Ø The recommended pre-commissioning checks are done before
energising the transformer.
Ø The operation of protective systems and devices for the
transformer are checked regularly.
Ø 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.
Ø 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.
Ø 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.
Ø The internal atmosphere of a transformer tank, if N2 filled, is
replaced by breathable dry air of dew point less than –400 C for
a minimum period of twenty four hours.

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1.2.1 ELECTRICAL SAFETY

The following hazards are commonly associated with the installation,

operation and maintenance of electrical equipment

♦ Existence of AC and DC voltage.

♦ Possible existence of toxic hazards associated with material

used in the construction of electronic components, cleaning
agent and solvents.

♦ Electric shock due to incorrect earthing, moisture on insulation,

bad engineering or working practices.

♦ Fire or burn out due to incorrect setting or over load or protective

devices, incorrect cables or fuses, insufficient ventilation or
incorrect operating voltage.

♦ Short circuit flash over due to dust or moisture on insulation or

short circuit on live conductors.

♦ No work should be done to transformer or its associated

equipment unless it is disconnected from supply and all
terminals have been solidly earthed.

♦ If the secondary of a current transformer is disconnected, a

dangerously high voltage can be induced in the circuit. If the
secondary circuit of a current transformer is to be disconnected
it must be shorted by a link capable of carrying the rated current.

♦ Do not apply any voltage or even high voltage megger when the
equipment is under vacuum.

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1.2.2 HAZARDOUS SUBSTANCES

1.2.2.1 TRANSFORMER OIL

l Normally, transformer oil presents no hazard to health.

However, serious neglect may affect the skin and cause
irritation.

l Oil is a hydrocarbon and will burn. Carbon dioxide, dry chemical,

foam or water fog is the extinguishants.

1.2.2.2 MERCURY

l 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.

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1.3 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.
1.3.1 DO'S
þ Insulating oil and insulation of windings and connections are
inflammable. Watch for fire hazards.
þ Before entering inside the Transformer, replace Nitrogen gas
completely with air if it was transported with nitrogen gas inside.
þ Make sure that nothing is kept inside the pockets before one
enters inside the main unit. Also take off the wristwatches and
shoes.
þ 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.
þ There must be a protective guard for lamp to be taken inside.
þ Keep inspection covers open for supply of fresh air when some
one is working inside.
þ When one person is working inside, second person must be
available out side for emergency help.
þ Use rings spanners and tie them to the wrist of the person or
some where outside the tank.
þ Be careful during connections where bolted joints are involved
so that nut, washers etc. are not dropped inside the tank.
þ 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.
þ De-energise the unit by circuit breakers and line switches while
working on energised unit.
þ Check the diaphragm of explosion vent and replace it if cracked.

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þ Attach the caution tags "DO NOT OPERATE THE SWITCHES"
while working on units, which are energised.
þ Make sure that the fire fighting equipment are available at the oil
treatment equipment as well as workplace and adjacent to the
transformer.
þ Fire fighting equipment should be checked regularly and should
have sufficient quantity of extinguishant.
þ Transformer tank, control cabinets etc. as well as oil treatment
equipment shall be connected with permanent earthing system
of the station.
þ Check and thoroughly investigate the transformer whenever any
alarm or protective device is operated.
þ Check air cell in conservator.
þ Attend leakage on the bushings.
þ Examine the bushings for dirt deposits and clean them
periodically.
þ Check the oil in transformer and OLTC for dielectric strength
and moisture content and take suitable action for restoring
quality.
þ Check the oil level in oil cup and ensure air passages are free in
breather. If oil is less make up the oil.
þ If inspection covers are removed or any gasket joint is to be
tightened, then tighten the bolts evenly to avoid uneven
pressure.
þ Check and clean the relay and alarm contacts. Check also their
operation and accuracy and if required change the setting.
þ Check the protection circuits periodically.
þ Check the pointers of all gauges for their free movement.
þ Clean the oil conservator thoroughly before erecting.
þ Check the OTI and WTI pockets and replenish the oil if required.
þ Gas filled storage of transformer at site should be limited to a
maximum of 3 months.

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þ Check the door seal of the Marshalling box. Change the rubber
lining if required.
þ Ensure proper tightness of top terminal of condenser bushings
to avoid entry of rainwater.
þ Check oil level in condenser bushing, any discrepancy should
be reported immediately to the manufacturer.
þ Do jacking only at jacking pad.

1.3.2 DON'TS
x Do not take any fibrous material such as cotton waste inside
while repairing.
x Do not drop any tools / material in side.
x Do not stand on leads / cleats.
x Do not weld, braze or solder inside the tank.
x Do not weld any thing to the tank wall from outside.
x Do not weld any thing to the conservator vessel if Air cell bag is
inside.
x Do not smoke near the transformer.
x Do not use fibrous material for cleaning as it can deteriorate the
oil when mixed with it.
x Do not energise without thorough investigation of the
transformer whenever any alarm of protection has operated.
x Do not re-energise the transformer unless the Buchholz gas is
analysed.
x Do not re-energise the transformer without conducting all pre-
commissioning checks. The results must be compared with
factory test results.
x Do not handle the off circuit tap switch when the transformer is
energised.
x Do not energise the transformer unless the off circuit tap switch
handle is in locked position.
x Do not leave off circuit tap switch handle unlocked.

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x Do not use low capacity lifting jacks / slings on transformer for
jacking / slinging.
x Do not change the setting of WTI and OTI alarm and trip
frequently. Setting should be done as per manufacturer's
instructions.
x Do not leave any connection loose.
x Do not meddle with the protection circuits.
x Do not leave marshalling box doors open, they must be locked.
x Do not switch off the heater in marshalling box except to be
periodically cleaned.
x Do not allow unauthorised entry near the transformer.
x Do not close any valve in pump circuit for taking stand by pump
and motor into circuit.
x Do not allow water pressure to exceed the oil pressure in oil to
water heat exchangers.
x Do not mix transformer oils of different make/ base, unless oil is
new and conforms fully to IS: 335.
x Do not continue with pink (wet) silicagel, this should immediately
be changed or reactivated.
x Do not store transformer in gas filled condition for more than
three months after reaching site. If storage is required for longer
duration, the main body should be filled up with oil.
x Do not leave tertiary terminals unprotected outside the tank.
x Do not allow WTI / OTI temperature to exceed 70°C during dryout of
transformer and filter machine temperature beyond 75°C
x Do not parallel transformers, which do not fulfil the conditions for
paralleling.
x Do not over load the transformers beyond limit specified in IS:6600.
x Do not leave secondary terminals of any CT open.
x Do not measure insulation resistance by using megger when the
transformer is under vacuum.
x Do not stand on any vessel, which is under vacuum.

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2.0 TRANSPORT-PACKING & DESPATCH

2.1 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 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. 2.I.

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• 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.

2.2 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.

2.3 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.

ISSUE/ REVISION 99/07 01/11 02/08 03/11

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2.3.1 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. 2.2

MULTIPLYING SAFE LOAD OF WIRE

FACTOR FOR ROPES
DIFFERENT LIFTING Dia. of Safe
ANGLES Wire Load
Lifting Multiplying Rope
Angle Factor mm kg.
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
40 14,000
44 17,000
56 24,500
64 33,500
Fig. 2.2 70 40,000

2.3.2 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.

ISSUE/ REVISION 99/07 01/11 02/08 03/11

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2.3.3 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.

2.4 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 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.

2.5 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 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.

ISSUE/ REVISION 99/07 01/11 02/08 03/11

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2.6 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.

FIG. – 2.3

2.7 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 should be stacked only in horizontal position
with the oil. This will avoid collection of water on top of the drum,
which may leak into the oil drum.
• Filter holes and air release holes 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.

ISSUE/ REVISION 99/07 01/11 02/08 03/11

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• 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.

FIG. - 2.4

2.8 IMPACT RECORDERS

• Impact recorders are attached to the main body of the transformer
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.

2.8.1 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 –

ISSUE/ REVISION 99/07 01/11 02/08 03/11

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i. Lateral shock ('x' axis)

ii. Longitudinal shock ('y' axis)
iii. Vertical shock ('z' axis)
Typical sensitivity (rating) values of impact recorders are as follows: -
i. Trucks trailer - Smooth road 2g
ii. Truck trailers - Rough road 6g
iii. 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:

(i) Determine the numbers of days between switchi ng ON the

impact recorder and switching OFF and check that all the
number of days has been recorded on the chart.

(ii) 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.

(iii) Use the table below to find equivalent 'g' levels in the designated
column (X column for 'x' axis shocks etc.)

X Y Z

mm space 2g 6g 6g 2g 6g
3 1 0.4 1.7 1.4 0.4 1.2
6 2 0.8 3.3 2.8 0.8 2.5
9 3 1.3 5.0 4.2 1.3 3.7
12 4 1.7 6.3 5.5 1.7 5.0
15 5 2.1 8.2 6.9 2.1 6.2

ISSUE/ REVISION 99/07 01/11 02/08 03/11

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2.8.2 ELECTRONIC DIGITAL TYPE IMPACT RECORDERS

• The Impact Recorder is of “Sensorex Minishock” supplied by :
• M/s. International Business Park – Archamps, 74165 Saint Julien,
En, Genevois, France.
• 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.
The Sensor characteristics are as follows:
i. Range : ± 10 g
ii. Resolution : 0.1 g
iii. Accuracy (250 C) : ± 0.2 g
iv. Threshold : from 1.5g ~ 10 g
v. Band width : 25/ 50/ 100/ 200 Hz
vi. Sampling periods : 1 minute to 4 hours.
vii. Power source : Works with a standard lithium battery
• In case the transformer suffers serious shock during shipment, the
core and coil will have to be subjected to through inspection before
erection and commissioning.

ISSUE/ REVISION 99/07 01/11 02/08 03/11

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3.0 STORAGE
3.1 RECEIVING MAIN UNIT AND ACCESSORIES
• 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 4.22: Touchup Painting at site”.
3.1.1 REPORT OF DAM AGE 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.
3.1.2 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.– 2.1 of chapter 2)

ISSUE/ REVISION 99/07 01/11 02/08 03/11

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3.1.3 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 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.

3.2 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.
3.3 STORAGE OF MAIN BODY
3.3.1 GENERAL
• 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 taken for storing the main body and
accessories for longer duration:
• 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.

ISSUE/ REVISION 99/07 01/11 02/08 03/11

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• Sufficient space is provided underneath for free flow of air and also
for lifting, jacking etc.
3.4 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 200C. (Please ref. Fig.– 1 of Chapter 2 for
Pressure Vs Temperature Chart).
• The duration of gas filled storage should be limited to 3 months 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.

1. Cylinder Key.
2. Top sampling valve of
transformer.
3. Gauge for reading gas pressure
inside the transformer
4. Adapter.
5. Gauge to indicate gas pressure in
the cylinder
6. Gas pressure regulator.
7. Gauge to indicate gas pressure
from the regulator
8. Pneumatic pressure hose.
9. Hose clip.
10. Nitrogen cylinder.

FIG. — 3.1

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• 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.
• The arrangement for gas filled storage is shown in fig. - 3.1
• 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. –2.1) shall be referred to.
• If the storage period of transformer at site is expected to be beyond
3 months, it is recommended to keep it filled with transformer oil.

3.5 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.

ISSUE/ REVISION 99/07 01/11 02/08 03/11

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3.6 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 as shown in Fig 3.2 and covered with tarpaulin
sheet. Filter holes and air release holes 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.

Fig. 3.2

3.7 STORAGE OF ACCESSORIES

• 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.

ISSUE/ REVISION 99/07 01/11 02/08 03/11

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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.
• 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.
Table- 1

Sr. Accessories Storage Position Precautions Special Inspection

No. Position Location Instructions check
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17

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4.0 INSTALLATION

4.1 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
(of 3 m length) 5 Nos.
end. These hoses shall be
(of 10 m length) 2 Nos. capable of withstanding
vacuum of 0.1 torr.
(of 10 m length) 2 Nos. 50 mm dia. with flanged
ends and capable of
withstanding 120 C
0

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Sr. No. Tool/ Equipment Qty. Specifications

5 Flexible Vacuum 2 Nos. Flexible vacuum hoses of 75

Hoses 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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Sr. No. Tool/ Equipment Qty. Specifications

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 upto 25
tonnes.
15 Water Proof Sheets 40 m2 For temporary covering of
exposed parts
16 Venyl Hose 30 Transparent venyl hose of
meters 12 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 upto 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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Sr. No. Tool/ Equipment Qty. Specifications

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/ 2 Sets Please refer section 4.3.
Pulleys each
27 Hydraulic/Mechanical 4 Nos. 50% of total weight of main
Screw Jacks with body 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
Transformers of 400 Point –40° C Temperature
kV class and above) 25 ± 5°C, Outlet pressure 200
Aq.

ISSUE/ REVISION 99/07 01/11 02/08 03/11

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4.2 UNLOADING FROM WAGGON / TRAILER

• Lift the main body of the transformer with a mobile crane and wire
ropes. The crane capacity must be atleast 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. DO NOT APPLY ANY HORIZONTAL
PUSHING FORCE DIRECT TO TRANSFORMER TANK BODY.
• 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.
• If the foundation of the transformer is not ready and if the
transformers are to be unloaded temporarily, it should be done on
levelled 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.
4.3 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 as
shown in fig.-4.1. 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.

ISSUE/ REVISION 99/07 01/11 02/08 03/11

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FIG. — 4.1

• 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.
4.4 OIL RECEIVING AND FILTERING

FIG. – 4.2

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• Quality of transformer oil must be checked before it is filled into the
transformer. Oil samples should be taken from 5 drums at random.
Samples should be collected from the bottom of the drums as shown
in fig.–4.2 for testing.

• Conduct the following tests for ascertaining the quality of oil.

♦ Breakdown Voltage test
♦ Moisture content test
♦ Tan delta
♦ 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.

FIG. – 4.3

ISSUE/ REVISION 99/07 01/11 02/08 03/11

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POWER TRANSFORMERS

4.5 ERECTION PRECAUTIONS

NOTE:
PRECAUTIONS MUST BE TAKEN TO ENSURE THAT ALL GAS
PRESSURE IN THE TRANSFORMER IS RELEASED BEFORE ANY
ATTEMPT IS MADE TO REMOVE A COVER AND DRYNESS (DEW
POINT) OF GAS IS CHECKED BEFORE A GAS CYLINDER IS
USED.

• 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 –400C 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 work. The exposure should not be allowed more than
16 hours at 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:

I. HV – Earth (Tank)
II. LV/ IV – Earth (Tank)
III. HV – LV/ IV
IV. Core Frame – Earth (Tank)

ISSUE/ REVISION 99/07 01/11 02/08 03/11

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OPERATION AND MAINTENANCE
MANUAL FOR
Page 39 of 204
POWER TRANSFORMERS

4.6 ERECTION PROCEDURE

The following flow chart shows the installation procedure generally
followed at site.

PREPARATION FOR INSTALLATION .

INSTALLATION OF MAIN BODY ON FOUNDATION .

RECEIVING INSPECTION AND STORAGE .

OIL RECEIVING AND FILTERING .

REPLACING DRY GAS WITH OIL .

ASSEMBLE BUSHING TURRET .

ASSEMBLE LV BUSHING AND CABLE DUCT .

ASSEMBLE COOLERS .

ASSEMBLE CONSERVATOR .

ASSEMBLE PRESSURE RELIEF DEVICE .

ASSEMBLE HV BUSHINGS .

ASSEMBLE ACCESSORIES .

INTERNAL LEAD CONNECTIONS .

CONTROL WIRING

OIL LEAKAGE TEST .

OIL FILLING UNDER VACUUM .

PAINTING (Ref. Cl. 4.22) .

ISSUE/ REVISION 99/07 01/11 02/08 03/11

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MANUAL FOR
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4.7 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
55 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. Ref. fig.– 4.4

Oil Storage Transformer

Tank Dry Gas

Filter Press Transparent

Vinyl Hose
(For oil level
Indication)

FIG. – 4.4

• 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.
• 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.

ISSUE/ REVISION 99/07 01/11 02/08 03/11

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• Oil level shall be continuously monitored during oil filling.
• 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.

4.8 PRECAUTION TO MAINTAIN QUALITY

• As a precautionary measure to restrict absorption of moisture, the
transformer should not be exposed to atmosphere for more than 8
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 -400C 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 55kV 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.
ISSUE/ REVISION 99/07 01/11 02/08 03/11
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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.

4.9 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 pre determined torque values are applicable.
• 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. Indent No., Unit
No. and Serial numbers of each item are marked on each item. This
is to avoid mismatching at site.
E.g.: T-6576/4/209 shows the transformer: -
Indent No.: T-6576,
Unit No.: 4 and
Serial No. of item : 209
• Serial numbers of all items, which are dismantled from the main
body and sent separately, are shown in "PART MARKING AND
CABLE WIRING" drawing.

4.10 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" and "PART MARKING DRAWING" of the
transformer.

ISSUE/ REVISION 99/07 01/11 02/08 03/11

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• 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.
• 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.
4.11 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.

ISSUE/ REVISION 99/07 01/11 02/08 03/11

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• 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.
• 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.

METHOD OF MOUNTING FLEXI SEPARATOR (AIR CELL)

INSIDE THE CONSERVATOR

PROCEDURE - 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.
ISSUE/ REVISION 99/07 01/11 02/08 03/11
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• 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.
• 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:
Ø 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.
Ø 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.
Ø 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.

ISSUE/ REVISION 99/07 01/11 02/08 03/11

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• 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 valve after completion of oil filling, is applicable for this
case also.

4.12 PRESSURE RELIEF DEVICE

• Mount PRD as per manufacturers leaflet and also the G.A. drawing
of Transformer.
• Check operation of alarm/trip contacts.
4.13 ERECTION OF HV TURRETS AND BUSHINGS

FIG.— 4.5
METHOD OF LIFTING CONDENSER BUSHINGS FROM PACKING
CASE AND MOUNTING ON THE TRANSFORMER AT AN ANGLE

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OPERATION AND MAINTENANCE
MANUAL FOR
Page 47 of 204
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• 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 upto the centre of oil sight window of
Bushing.
• Part numbers of Bushing turrets are indicated in the part marking
drawing.
• If oil is drained from the tank a continuous supply of dry air should be
ensured while removing the blanking plates and fixing the bushing
turrets and bushings.
• Dry air shall have a dew point of -400C 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 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.
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• 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.

4.14 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.

4.15 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

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some manufacturers 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.
4.16 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.
4.17 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.

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• 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.
4.18 CHECKING LEAK RATE UNDER VACUUM
• Drain oil & create vacuum of 200 torr inside the tank, close the valve
between vacuum pump and tank and stop the pump and hold the
vacuum. There should be no appreciable loss of vacuum over one
minute.
• If there is leak, find out the leak and rectify.
• Start the pump and open the valves and continue till a vacuum of 10
torr is achieved.
• Close vacuums valve and stop the pump.
• There should not be an increase of pressure of more than 1 torr over
half an hour.
• IF the rise in pressure is more, find out leak and rectify.
• If results are satisfactory, restart the vacuum pump open the valves
and continue pumping to obtain a vacuum of 1 torr or better and
maintain this vacuum for more than 24 hrs. before and during
subsequent oil filling operations.

4.19 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.
4.20 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.
ISSUE/ REVISION 99/07 01/11 02/08 03/11
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and must not be disclosed, loaned, copied or used for Manufacturing, Tendering or for any other purpose without written permission.
 ERECTION, COMMISSIONING, Ref. No. TRM. 0311

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• 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 12 Hrs.
• If any leakage is noticed, rectify the leak and continue the test.
• Break pressure and reassemble breathers, PRD, explosion vent etc.
4.21 VACUUM OIL INJECTION
• Oil injection shall be made under full vacuum (1.0 torr or better) for
transformers above 66kV. 380 mm Hg or better vacuum is required
for transformers rated for 66kV and below. 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.
• A transparent vinyl hose shall be connected to the bottom sampling
valve (Refer Fig. – 4.4) for indicating the oil level.
• 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.
• Oil may be injected through the bottom filter valve until the level
reaches 350C marking on the Magnetic Oil Level Gauge of the
conservator.
• Initial oil filling shall be done at a slow rate. Rise in oil level per hour
inside the transformer shall be limited to 300 mm.

ISSUE/ REVISION 99/07 01/11 02/08 03/11

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• 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.
• 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.

4.22 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 coating : 24 Hours.
ISSUE/ REVISION 99/07 01/11 02/08 03/11
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 ERECTION, COMMISSIONING, Ref. No. TRM. 0311

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(v) Total dry film thickness after final coating: as per data sheet
(80 ~ 100 microns if not specified)

4.23 MIXING OF TRANSFORMER OIL

• Some times a need arises at site to top up a transformer with oil of a
different make.
• New oil 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 either
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.

ISSUE/ REVISION 99/07 01/11 02/08 03/11

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5.0 INSULATION DRY OUT AT SITE

5.1 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 ~ 700C.
• 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 ~ 700 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.

ISSUE/ REVISION 99/07 01/11 02/08 03/11

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FIG.— 5.1

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 ( á1012 ohm meter) before final oil
filling.
• Do not measure insulation resistance when the transformer in under
vacuum.

ISSUE/ REVISION 99/07 01/11 02/08 03/11

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6.0 COMMISSIONING
6.1 POST ERECTION CHECKS

6.1.1 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.

6.1.2 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.
ISSUE/ REVISION 99/07 01/11 02/08 03/11
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• 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 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.

6.2 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.

6.3 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.

ISSUE/ REVISION 99/07 01/11 02/08 03/11

© This document and any Information or Descriptive Matter set out herein are the Confidential and Copyright Property of ALSTOM
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6.4 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,

6.5 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.
Ø CAUTION:
If there is a residual magnetism present in the core, it can give
erratic readings.

6.6 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.
6.8 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.

ISSUE/ REVISION 99/07 01/11 02/08 03/11

© This document and any Information or Descriptive Matter set out herein are the Confidential and Copyright Property of ALSTOM
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• Convert the resistances to 750C.
• For copper windings:
• R (75) = R (measured) x (234.5 + 75)
(234.5 + Oil temperature at the time of measurement)
• Compare the values with factory test results.
6.9 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).
• Compare the values with factory test results.
6.10 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.

6.11 BUCHHOLZ RELAY OPERATION

• Check inclination of Buchholz relay pipe. The slope should be in
upward direction, between 3 ~ 90 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.

ISSUE/ REVISION 99/07 01/11 02/08 03/11

© This document and any Information or Descriptive Matter set out herein are the Confidential and Copyright Property of ALSTOM
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• 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.
6.12 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.

ISSUE/ REVISION 99/07 01/11 02/08 03/11

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APPENDIX - A

ERECTION CHECK LIST

l This Checklist is intended for use at site by Site Engineers and

outlines the minimum on-site checks expected to be carried out
during erection activity.

l This checklist has been prepared with a view to avoid human

error in case erection is carried by Customer or by a third party
without the involvement of ALSTOM.

l It is recommended that the check list may be filled in and a copy

sent to the Customer Service Department of ALSTOM Limited,
at the address given elsewhere in this Manual for their review,
suggestions/ comments if any.

SITE ................................ INDENT/ SERIAL NO. ....................………...

TRANSFORMER ...................... MVA ............/..……......./……....... kV

SIGNED .......…...........………….

DATE .......................………..

1. DOCUMENTATION CHECK

Instruction Manual/ Drawings ___________ _________

2. RECEIPT OF TRANSFORMER

External inspection observation ______________________

Gas pressure at receipt ______________________

Condition of lashing of ______________________

Transformer with trailer/ wagon ______________________

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3. RECEIPT OF ANCILLARY MATERIALS

All materials stored correctly

Packing cases inspected ___________ _________

Observation
Marshalling box inspected ___________ _________

Observation
Quantities tally with shipping list ___________ _________

Any shortages/
Observation ___________ _________

4. ERECTION

All pipe connections

internally inspected ___________ _________

Observation
Radiators internally inspected ___________ _________

Observation
All valves fitted on main tank ___________ _________

Observation
Inside surface of condenser
Bushing pipe inspected ___________ _________
Observation

Flexible connectors checked ___________ _________

Draw leads of condenser

bushings checked ___________ _________

Bushing porcelain, flanges

Gasket surface checked ___________ _________

ISSUE/ REVISION 99/07 01/11 02/08 03/11

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Buchholz relay
installed at correct angle ___________ _________

Air release pipes fitted correctly ___________ _________

Acing horn gap set correctly ___________ _________

PRD(s) fitted correctly ___________ _________

Rating Diagram plate and other

labels fitted in position ___________ _________

All clamping bolts are fully tight

Final paint touch up ___________ _________

Alignment of cooler pipes correct ___________ _________

Alignment of cooler bank correct ___________ _________

Gasket compression is correct ___________ _________

5. OIL FILLING

All bushing oil levels correct ___________ _________

Diverter switch oil level correct ___________ _________

Oil level in Main conservator ___________ _________

No. oil leakage ___________ _________

All air release plugs vented ___________ _________

Open/close condition of all

valves checked. ___________ _________

ISSUE/ REVISION 99/07 01/11 02/08 03/11

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6. CABLING

All cables are adequately tied ___________ _________

Cable glands fitted correctly ___________ _________

Cable identification ferrules ___________ _________

WTI's & OTI's cabling/capillary

Satisfactory ___________ _________

Cabling/Wiring visually
Satisfactory ___________ _________

7. BREATHERS

Main Transformer breather

Satisfactory ___________ _________

Tap changer silica gel

breather satisfactory ___________ _________

Oil level in breather oil cups ___________ _________

8. FANS AND PUMPS

Fans rotate freely & quietly ___________ _________

Pumps installed in correct

direction of flow ___________ _________

Flow indicators visible ___________ _________

9. KIOSK/DRIVING MECHANISM

Mounting satisfactory ___________ _________

All multicore cables terminated ___________ _________

ISSUE/ REVISION 99/07 01/11 02/08 03/11

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Cabinet clean & tidy ___________ _________

Heaters connected ___________ _________

10. GENERAL

Blanking plates and

spares stored properly ___________ _________

11. SERIAL NO./TYPE OF ACCESSORIES

Sr. ACCESSORIES MAKE Sr. No./

No. TYPE No.
1 HV Bushings ……………kV

2 IV Bushings ……………kV

3 LV Bushings ……………kV

4 HV Neutral Bushing .……kV

5 LV Neutral Bushing .……kV

6 Oil Temperature Indicator

7 Winding Temp. Indicator

8 Buchholz Relay

9 Pressure Relief Device

10 Oil Surge Relay

11 Oil Pump

12 Cooling Fan

13 Magnetic Oil Level Gauge

14 Oil Flow Indicator

15 Water Flow Indicator

16

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APPENDIX B

COMMISSIONING CHECK LIST

SITE ___________________ TRANSFORMER SPEC.____________________

ERECTION CARRIED OUT BY ________________________

ERECTION SUPERVISED BY ________________________

ERECTION STARTED ______________ COMPLETED __________________

1. GENERAL DATA

MANUFACTURER'S INDENT/SERIAL NO.

CUSTOMER'S REFERENCE NO.

HV LV1 LV2 TER

RATING ON AN/ON AF/ OFAF/ OFW MVA

Nominal Voltage kV
Full load current at rated tap Amp.
Vector group
Percentage Impedance HV/LV OR HV/LV1
HV/IV OR HV/LV2
LV/IV OR LV1/LV2
Tapping range + _________ % to – __________% in ______ steps of ______ % on
HV/LV winding.

2. GENERAL CHECKS HV IV LV
a. Arcing horns positioned correctly
b. Arcing horns gaps
c. Arching horns gaps
d. Oil levels in bushing correct
e. Air release plugs vent

ISSUE/ REVISION 99/07 01/11 02/08 03/11

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f. Pressure relief diaphragm intact ___________ _________

g. Earthing connections satisfactory ___________ _________
h. All insulators cleaned thoroughly ___________ _________
i. Complete transformer oil tight ___________ _________
j. Painting visually satisfactory ___________ _________
k. Rating & Diagram plate and
other labels fitted correctly ___________ _________
l. Tightness of all clamping bolts ___________ _________
m. Breathers and connection pipes fitted properly ___________ _________
n. All cabling and wiring visually satisfactory ___________ _________
o. Kiosk and cubicle heaters operating satisfactorily__________ _________
p. Current Transformers fitted and wired correctly.___________ _________
q. All valves in correct operational position ___________ _________
r. All blanking plates correctly stored ___________ _________
s. Oil level in oil cups of breathers ___________ _________

3. GENERAL TESTS

a. Insulation Resistance:
(i) Core frame/Tank at ______ 0C m?
(ii) Windings at _____ 0C with _____ kV megger
HV - E Core frame m?
IV - E earthed to m?
LV - E tank m?
HV - IV m?
HV - LV m?
IV - LW m?

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b. Ratio and HV Magnetising Current Test:

l Ratio checked at all taps and continuity checked during each tap
changing.

l Magnetising current measured at all tap positions.

l Impedance shall be measured at all tap positions.

l With 3-phase 415 volts supply connected to HV terminals and

the transformer neutral earthing connections removed.
HV HV Mag. Current LV (1) Tert. or LV (2)
Volts (mA) Volts Volts
Tap A-N A-N A-N A B C a-N a-N a-N a-b b-c c-a
No. A-B A-B A-B
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23

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C. Vector Group Check:

Connect one HV terminal to one LV (or tertiary) terminal. With transformer on

nominal tap. Measure the following voltages as necessary.

LV – LV1
A-a2 A-b2 A-c2
B-a2 B-b2 B-c2
C-a2 C-b2 C-c2

HV – LV2 (Tertiary)
A-a2 A-b2 A-c2
B-a2 B-b2 B-c2
C-a2 C-b2 C-c2

Vector group from test report ______________________

ISSUE/ REVISION 99/07 01/11 02/08 03/11

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POWER TRANSFORMERS

d. Motors and overload Devices of Pumps, Fans and Tap Changer:

Note: The above checks shall apply to individual motors and each phase of
individual overload devices. The values shall be maximum for any type of
motor.

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e. Buchholz Device :
Main Tap changer
Make ________ __________

Type ________ __________

Serial No. ________ __________

Inclination in degrees ________ __________

Qty. of air to operate alarm contacts (cc) ________ __________

Approx. pressure to operate trip contact(kg/cm2)________ __________

f. Winding Temperature Indicator Contact Settings:

WTI 1 WTI 2 WTI 3

Manufacturer

Serial No.

Type/Model

Contact Functions Setting Functions Setting Functions Setting

Contact
Function
and
Setting

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Winding Temperature Indicator Heater Coil Circuits

CT Ratio (Amps) WTI 1 WTI 2 WTI 3

Ratio Checked

Heater Coil Resistance

ONAN OFAF ONAN OFAF ONAN OFAF
or or or
OFWF OFWF OFWF
Shunt Resistance
across heater coil
Heater Coil Test
Amps.
0
Top Oil Temp C
Initial Temp
Steady Temp
0
after min C
0
Temp. increment C

Calibration Tests on Winding Temperature Indicator and Adjustment or Repeaters

WTI - 1 WTI - 2 WTI - 3

WTI Temp 0C
Indicator
Reading 0C

Repeater WTI
Reading 0C

Repeater
Reading 0C

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g. Inspection of site wiring:

a. Insulation

b. Kiosk, Tap changer DM Drg. No.

and Marshalling Box Revision

Equipment Wiring Drg. No.

Checked to Revision

c. Rating of O/L Relays and Starters to be verified with respect to relevant

drawings. Incorrect ones should be replaced and the matter brought to
the notice of the supplier.

h. Pressure Relief Device:

Check operation of pressure relief trip switch

4. OPERATIONAL TESTS
a. Tap changer Equipment Raise Lower
Max. interval between operating times of
diverter switches of single phase tap changes.
Local raising and lowering (full range)
Remote raising and lowering (full range)
Local/Remote switch
Hand operation and handle interlock switch
Check circuit for correct sequence.
Limit switch operates.
Mechanical position indicator
Remote electrical position indicator
Tap change incomplete alarm
Tap change counter operates correctly
Tap change counter reading initial/final

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b. Cooling Equipment Operation & Alarms and Indications:

Cooler A Cooler B
Cooler control Switch
Auto Control from WTI
Time delay for pumps (Auto) sec.
Manual
Pump failure alarm
Auto start of stand by pump
Stand by pump running indication
Cooler fail alarm
Fuse ratings correct
Differential pressure alarm

5. MARSHALLING KIOSK

a. Buchholz relay/ OSR Main OLTC

Check surge contact operates appropriate

flag and trip relays in series

Check operation of alarm contacts

b. Winding Temperature Indicators WTI-1 WTI-2 WTI-3

Trip contacts operate flag relay and
appropriate trip relay

Alarm contacts operate

alarm relay

c. Pressure Relief Device

Manual activation of switch

operates flag relay.

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d. Oil level gauge

Low oil level operates alarm

6. ALARM SIGNALS
Check the following indicators are enunciated:

Tap change Incomplete

Tap changer Thermal
Tap changer Buchholz
Low oil Level
Main Buchholz
Pressure Relief
HV Winding Temperature High
LV Winding Temperature High
LV2/TER. Winding Temperature High
Cooling Pump A fail
Cooling Pump B fail
Cooling Fan A fail
Cooling Fan B fail

7. AUTOMATIC VOLTAGE RELAY

a. Type of Relay _________________________
b. Serial No. _________________________
c. Nominal Volts _________________________
d. Auxiliary Volts _________________________
e. Frequency _________________________
f. Operation:
Under/Over voltage supervision circuits
Tap change blocked
Time delayed alarm

CAUTION :

1. These relays use components, which are sensitive to electrostatic discharge.

Care should be taken to avoid contacts with components and connections.

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2. For electronic instruments/repeaters, TPI & WTI FACIA, please check the
voltage to be applied (AC/DC, 110/220 Volts) & also potential free contacts,
before energising the circuit. Incorrect voltage or polarity of supply may
damage the instrument.
3. For connecting digital repeater instruments independent screened or
armoured cables should be used. Resistance of cable should be kept
minimum to avoid any drop in signal.

8. OIL TESTS
Oil supplier _________________________
Oil sample should be taken after commissioning and prior to energising the
unit and at every three months thereafter.

a. Date Apparatus checked Test results

b. Dissolved Gas Analysis (DGA)

Dissolved gases in oil samples should be analysed immediately on energising
the transformer and at every three months thereafter. Any increase in gas
content of any particular gas should be monitored from time to time.
GAS CONTENT IN OIL BY FAULTS:
Please refer to Clause 9.7 (Trouble Shooting) for further information on DGA.

Type of faults Gas generated

1. Over heat of oil CH4, C 2H4, H2, (C 2H6, C 2H2, C 3H6 , C 3H8)
2. Arcing in oil H2, C 2H2, (CH4 , C 2H4)
3. Over heat of solid CO, CO2, (H2 C2H4)
insulating material
4. Over heat of oil and CH4, C 2H4, CO, CO2 , H2

paper combinations
5. Arcing of oil and H2, C 2H2, CO, CO2, C 2H4

paper combinations

ISSUE/ REVISION 99/07 01/11 02/08 03/11

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9. Tests on CTS
(a) Sl. No.
(b) Ratio
(c) Polarity
(d) Magnetising current
(e) Knee point voltage
(f) Winding resistance
(g) Ambient Temp. at the time of measurement

ISSUE/ REVISION 99/07 01/11 02/08 03/11

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7.0 OPERATION

• After the inspection and precommissioning tests are successfully

completed the transformer can be energised at no load.

• Oil soaking/ settling duration of 2 days for transformers upto 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 atleast

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.

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• 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.

7.1 Routine / Periodic inspection schedule for Power

Transformer

S.No. Items to be inspected Inspection frequency

1. Ambient Temperature Hourly

2. Winding Temperature Hourly

3. Oil Temperature Hourly

4. Load current Hourly

5. Terminal Voltage Hourly

6. Oil level in Transformer Daily

7. Oil level in Bushings Daily

8. Oil level in OLTC Conservator Daily

9. Oil level in silica gel breather cup Daily

10. Dust deposits & physical damages Monthly

to bushings

11. Condition of silica gel in breather Quarterly

12. Dielectric strength of transformer oil Quarterly

13. Moisture content of transformer oil Quarterly

14. Resistivity of transformer oil Quarterly

ISSUE/ REVISION 99/07 01/11 02/08 03/11

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15. Dissolved gas analysis of Quarterly

transformer oil

16. Tan delta & Capacitance of Yearly

condenser bushing

17. Insulation resistance of windings Yearly

18. Relays and their circuit Yearly

19. Surface paint 2 ~ 5 years ] ]

Note:
] ]
Duration of surface repainting depends on the level of
pollution prevailing at site. If pollution is more, 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.

ISSUE/ REVISION 99/07 01/11 02/08 03/11

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8.0 MAINTENANCE

Maintenance Schedule

Preventive Maintenance Procedures Periodicity

Weeks Scheduled
13 26 52 outage
Oil Sampling 4
Replacement / Regeneration of Silicagel 4
Breather
Dissolved Gas Analysis 4
Buchholz Relay Functional Tests 4
Tan Delta & Capacitance Measurement 4
of Condenser Bushings
OTI/ WTI Tests 4
Tap changer operation 4
Insulation Resistance of Windings 4
Oil Filtration 4
Surface Painting 4

8.1 Oil Sampling

Oil sample should be tested for the following and results recorded: -
8.1.1 Electric Strength
• If the di-electric 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.

8.1.2 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 upto 245 kV, if the moisture content is
found to have increased beyond 25 ppm oil should be filtered.

ISSUE/ REVISION 99/07 01/11 02/08 03/11

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8.1.3 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.

• Refilling of oil in transformer should be done under vacuum.

8.2 Sampling procedure
• Special care in oil sampling is required for Delta connected transformer
and autotransformers.

8.2.1 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

8.2.2 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.

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• 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.

8.3 WINDING TEMPERATURE INDICATOR TESTS

8.3.1 Tools and materials

• Hot oil bath (with heating facility)

• Secondary injection test set
• Multimeter
• Clinical thermometer
• Keys of marshalling box.

8.3.2 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.

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8.3.3 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 5 °C.
• Confirm from control room that remote temperature readings are
tallying with the local readings.
• Replace the sensing element into the transformer pocket.
For any adjustment, see the manufacturer's catalogue.

8.3.4 SECONDARY INJECTION TESTS

8.3.5 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.

8.3.6 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.

8.4 BUCHHOLZ RELAY FUNCTIONAL TEST

Tools and Materials Required.
• Multimeter
• Nitrogen cylinder with regulator and pressure gauge or air supply (4
kg/cm²)

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• Bucket
• 10 mm polythene tube, 10 meters.
8.4.1 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.
• 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.

8.5 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.

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• Transformer shall be isolated and earthed.
• 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.
8.6 OIL FILTRATION
• Purpose of this maintenance is to improve the unsatisfactory condition
of oil found during sampling.
• Transformer shall be isolated and earthed.

8.6.1 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

8.6.2 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.
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• Continue until oil condition is acceptable.

8.7 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.

8.8 REMOVING AND REFIXING OF PUMPS

8.8.1 Tools and materials

• Jib crane or chain pulley block to handle the weight of pumps.
• Oil drip tray
• Blanking plates
• New gaskets.
8.8.2 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.

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8.9 REMOVING AND RE FITTING RADIATOR

8.9.1 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.

8.9.2 Procedure
• Transformer shall be isolated and earthed.
• Set the cooler supply isolator of OFF.
• Close the inlet and outlet valves if radiator are mounted on a separate
cooler tank.
• 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.

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• Open the bottom radiator isolating valve.
• 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.

8.10 REMOVING AND RE FITTING FAN & MOTOR

8.10.1 Tools and materials

• Forklift truck to take weight of fan and motor assembly.
8.10.2 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.

8.10.3 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.

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9.0 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 else where in this Manual. When the
matter is referred to the manufacturer it shall contain the following: -
♦ Transformer Rating.
♦ Voltage Rating.
♦ Manufacturers Indent No. / Serial No.
♦ Year of Manufacture.
♦ Date / Time.
♦ Brief description of the problem.
♦ Checks done and their results.

9.1 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 Renew the gland packing

be not fitted and adjust gla nd packing
opened correctly. nuts evenly.

Valve spindle bent. Fit new valve spindle.

Seating for valve Dismantle Valve, Free
plug corroded valve plug or fit new valve.

ISSUE/ REVISION 99/07 01/11 02/08 03/11

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9.2 PUMPS

SYMPTOM PROBABLE CAUSE REMEDY

Pump Motor Impeller binding Remove the pump and
over heats investigate the problem.

Insulation failure Remove the pump and

of Motor Winding investigate the problem.

Two phase operation Check power supply.

Pump motor Motor bearings worn Remove pump and

vibrating investigate the reason

Impeller damaged Remove the pump and

investigate the reason

Pump bearing bushes Remove the pump and

or rings worn. Investigate the reason.

Pump Valve not fully open Open the valve fully.

running
but output Impeller damaged Remove pump and
low or worn investigate the reason.

Speed too low Check electric supply.

9.3 FANS

SYMPTOM PROBABLE CAUSE REMEDY

Fan motor Motor bearing worn Remove the fan and

overheats investigate reason.
Two phase operation Check electric supply
Fan Fan blades out of Balance the fan or replace.
vibrating balance and noisy
Mounting bolts loose Check and tighten
fasteners.

ISSUE/ REVISION 99/07 01/11 02/08 03/11

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Page 92 of 204
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9.4 BUCHHOLZ RELAY

SYMPTOM POSSIBLE REMEDY

CAUSE

Rate of Electrical Identity Class of Inference

gas Response of of gas Fault
evolution relay.

None Trip mechanism None Hydraulic Faulty operation

operated by surge of oil pump
oil surge

Sudden Large masses

vaporisation of metal heated
of oil at Eg.: Earth fault,
260~4000C short circuit
maintained for
longer period
than usual but
not c ausing
insulation
failure.

Boiling of Simultaneous
water in occurrence of a
exceptional heat producing
cases fault and entry
of water into
the tank .

RAPID Alarm operates Air or Major leak Fracture of tank,

and repeats inert due to pipe, or
immediately gas mechanical Buchholz
after releasing fault casing or faulty
gas circulating oil
pump.

ISSUE/ REVISION 99/07 01/11 02/08 03/11

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Trip and alarm Hydrogen Thermal

Local, very high
mechanism decompo-
current, hot spot
operates -sition of
not involving
oil by temp.
insulation, arc
above
over between
4000C metal parts of
Terminal gear or
terminal to tank .
Hydrogen Thermal Local hot spots
and decompo- due to very high
Carbon -sition of current faults in
Monoxide oil and contact with solid
insulation insulants
Eg. Insulation
failure followed
by arc between
insulated
conductors and
earth, short
circuit turn etc .
MEDIUM Alarm operates Air or Air leaks Fracture of tank
and repeats inert due to pipe or Buchholz
within minutes gas mechanical fault relay casing
or hours after fault or faulty oil
each release circulating
of gas pumps.
Hydrogen Thermal Local hot spots not
decompo- involving insulants.
-sition of Faultyjoint/contacts,
oil above core faults causing
0
400 C burning, any
incipient fault not
involving solid
insulants eg. core
not
properlyearthed)

ISSUE/ REVISION 99/07 01/11 02/08 03/11

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Hydrogen Thermal Local hot spots

and decompo- in contact with
carbon - sition of solid insulants.
mo- oil and Eg. Low power
noxide solid arcs between
insulants insulated
conductors and
earth, core
faults. Faulty
joints/contact.
Any incipient
Fault involving
solid insulation.

SLOW Alarm Air or Presence Release of

operates inert of air entrapped air
gas due to during early life
mechan- of transformer,
-ical Small fracture
fault or of tank, pipe or
physical Buchholz
absorption casing, gasket
leak, Faulty
oil pump
Hydrogen Decompo- Low current
-sition sparking not
of oil involving solid
only insulants, low
electric strength
of oil gap
causing
sparking,
gassing
caused by high
electric stress,
corona
discharge.

ISSUE/ REVISION 99/07 01/11 02/08 03/11

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Hydrogen Decompo- Low current

and -sition sparking
carbon of oil and involving
mono- solid decomposition
-xide insulants solid insulants,
creepage
through solid
insulants,
oxidation of
insulants.
No gas Alarm NA Low oil Incomplete oil
pressure operated level level of
in transformer,
Buchholz fracture of
relay tank, pipe
damaged
Buchholz relay.

9.5 PROTECTIVE DEVICES

NO. DETECTIVE DESCRIPTION
DEVICE
1. Pressure Relief When the internal pressure increases
Device beyond the preset value of PRD it operates.
This may also happen if the breather
connection is choked. Judgement based on
the inspection of other protective relays is
essential.

2. Differential This relay detects the internal defects by

Relay comparing 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.

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3. Oil temperature This thermometer gives Alarm when the

Indicator Alarm/ temperature rises beyond the set value.
Winding Over loading, insufficient cooling because
Temperature of contamination of fan impellers,
Indicator Alarm stoppage of fans/pumps etc. are to be
checked.

4. Over current These are intended for detecting faults in

relay, ground power system associated with the
fault relay transformer. A fault in the 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

Ammeter noted 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.

Human sense can play an important role

6. Human Sense 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.

ISSUE/ REVISION 99/07 01/11 02/08 03/11

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Page 97 of 204
POWER TRANSFORMERS

9.6 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 Point Description Criteria

1. Measurement Measurement must be

of Insulation taken after isolating the
Resistance of transformer from the
Windings circuit and cleaning the
surfaces of porcelain
insulators.

Insulation failures can be

detected by this
measurement.

2. Measurement When measurement is Comparison

of Winding made in one circuit, with factory
Resistance other circuit must be test results.
kept open circuited.

This measurement can

detect winding faults.

3. Measurement This can be conducted Comparison

of Transformer by applying 230 volts, with factory
ratio which can be readily test results.
available at site.
For three phase jobs,
measure ratios phase by
phase.

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4. Measurement Measurement can be If values obtained

of no load made by applying 230 are higher
current volts under normal compared to factory
conditions by making use test results, it
of locally available power indicates faulty
source. condition.

This measurement can

detect fault in windings
and core.
Judgement to be
5. Testing of oil Measure Breakdown made with
Voltage, moisture reference to
content, tan δ & check tables 9.1, 9.2,
for sludge formation, 9.3, 9.4 & 9.5
discoloration and
unusual smell.
Comparison with
6. Measurement Abnormal increase means factory test result
of Tan delta of deterioration of insulation.
Windings Manufacturer
7. Analysis of When gas is accumulated in may be
gas collected Buchholz relay. It should be contacted for
in Buchholz analysed by gas advice
relay chromatograph to check
presence of combustible
gases.
Refer to tables
8. Dissolved gas Development of internal 9.6, 9.7 & 9.8
Analysis incipient fault can be Contact
judged from the results. manufacturer for
Increase in gas advice.
composition to be
monitored at periodic
interval.

ISSUE/ REVISION 99/07 01/11 02/08 03/11

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Table 9.1: Dielectric Strength of Insulating Oil

12.5mm 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 9.2: Acid content of insulating oil (By neutralisation)

No Judgement 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 9.3: Resistivity of insulating oil

0
No Judgement Resistivity of oil at 90 C (Ω - cm)

1 Good More than 0.1x1012

2 Fair 1x1011 to 0.1x1012

3 Poor Less than 0.1x1011

Table 9.4: Water Content

No Nominal Voltage of Transformer Water Content (ppm)
1 400 kV Class & above Less than 20 ppm
2 Upto 245 kV Class Less than 25 ppm .

Table 9.5: Dielectric Dissipation Factor

No. Nominal Voltage of Transformer At 900 C, 40 ~60 Hz

1 145 kV Class & above 0.2 Max.

2 Below 145 kV Class 1.0 Max

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9.7 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 9.6
"Normal" Values of Dissolved Key Gas Concentration Limits in oil of
Power Transformers in Service [Parts Per Million – ppm].
(Ref. FIST 3-30 tt : 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

tt
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.

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Condition - 1

Total Dissolved Combustible Gas (TDCG) and any individual combustible gas
below this level indicates 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 9.7 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.

Refer Table 9.7 for recommended sampling frequency and actions.

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.

Refer Table 9.7 for recommended sampling frequency and actions.

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.

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Page 102 of 204
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Table 9.7
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
condition based Trans.
on individual 10 ~ 30 Quarterly
gas from Table Exercise caution. Analyse
9.5 > 30 Monthly individual gases to find cause.
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

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Page 103 of 204
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Table –9.8
Transformer Fault Types and the gases they produce.

Key Gases Possible Faults Possible Findings

H2, possible trace of CH4 and Partial discharge (Corona) Weakened insulation from
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, C2 H4 and C2H2 High energy discharges Metal fusion, (poor contacts in
present in large amounts. If (arcing). tap changer or lead
C2H2 is being generated, it connections). Weakened
indicates continuance of arcing. insulation, from ageing and
CO will be present if paper is electrical stress. Carbonised oil.
being heated. Paper over heating/ destruction
if it is in the arc path.
0
H2, CO. Thermal faults less than 300 C Discoloration of paper
in an area close to paper insulation. Overloading or
insulation (Paper is being cooling problem. Bad
heated) connections. Stray current path
and/or stray magnetic flux.
0
H2, CO, CH4, C2H6 and C2H4 Thermal fault between 300 C Paper insulation destroyed. Oil
0
and 700 C heavily carbonised.
All the above gases and High energy electrical arcing Same as above with metal
0
acetylene in large amounts. 700 C and above. discoloration. Arcing may 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 down stream,
static electric discharges, multiple core earthing, sustained operation under
over load, over/under voltage etc. may also be seen.

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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 & C 2H2 >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.

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FLOW CHART FOR FAILURE INVESTIGATION

Ref. : IEEE Std. C 57. 125 - 1991
ROUTINE TESTS
SELECTED TESTS ANALYSIS OF DATA SHOW DEVIATION
FROM PAST

TRANSFORMER
DATA GATHERING
TRIPPED OR MONITOR
TABLES 2 AND 3
MALFUNCTIONED

YES NO
PROBLEM RETURN TO SERVICE

YES DAMAGE NO
TESTING
IS
TABLE 4 AND TABLE 5
OBVIOUS

YES FOCUSED TESTS

CANDIDATE SELECTED
SELECTED FROM
FOR REPAIR TESTS
TABLE 4 AND TABLE 5

NO

ANALYZE TEST
TESTING
SCRAP RESULTS
TABLE 4 AND TABLE 5
APPENDIX A

INTERNAL INSPECTION YES NO PERFORM

PROBLEM
TABLE 8 CORRECTIVE
FOUND
ANALYZE-SECTION 6 ACTION

NO YES
FURTHER
TESTING

YES
FIELD
REPAIR

NO

NO FACTORY YES
TEARDOWN-TABLE 10
REPAIR
ANALYZE-SECTION 6
DECISION

FIG. — 9
NOTE : For further details please refer to IEEE Std. C . 57. 125 - 1991

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10.0 NATIONAL AND INTERNATIONAL STANDARDS

APPLICABLE TO POWER TRANSFORMER AND ALLIED
PRODUCTS.

10.1 INDIAN NATIONAL STANDARDS.

POWER TRANSFORMERS :
10.1.1 IS 1866 : 2000 Code of Practice for Maintenance and

Supervision of Insulating Oil in Equipment.

IS 1885 (Part 38) : 1993 Electrical Vocabulary - Transformers and

Reactors.

IS 2026 ( Part 1) : 1977 Power Transformers - General.

IS 2026 (Part 2 ) : 1977 Power Transformers - Temperature rise

IS 2026 (Part 3 ) : 1981 Power Transformers - Insulation level and

dielectric tests.

IS 2026 (Part4) : 1977 Power Transformer - Terminal marking,

Tapping & Connections

IS 2026 ( Part5) : 1994 Transformer / Reactor bushing minimum

external clearance in air

IS 6600 : 1972 Guide for loading of oil immersed

transformers.

IS 10561 : 1983 Application guide for power transformers.

IS 11171 : 1985 Dry type transformers.

IS 10028(Part1) : 1985 Code of practice for selection installation &

maintenance of transformers- Selection

IS 10028 (Part 2) : 1981 " " - Installation

IS 10028 (Part 3) : 1981 " " - Maintenance

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Page 107 of 204
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10.1.2 MATERIALS, FITTINGS AND ACCESSORIES OF POWER

TRANSFORMERS.
IS 1747 : 1972 Nitrogen.

IS 1576 : 1992 Solid Press board for electrical purposes.

IS 2312 : 1967 Propeller type AC ventilating fa ns.

IS 3024 : 1997 grain Oriented Electrical steel sheet and

strips.

IS 3070 (Part1) : 1985 Lightning arresters for alternating current

System; Non linear resistor type.

IS 3070 (Part3) : 1993 Lightning arresters for alternating current

System; Metal oxide lightning arresters

without gaps.

IS 3151 : 1982 Earthing transformers.

IS 3231 (Parts 0~3) Electrical relays for power System

Protection

IS 1367 (Part13) : 1983 Hot dip galvanised coating on threaded

fasteners.

IS 1363 (Part 1) : 1992 Hexagonal head bolts, screws, and nuts of

product grade C, Hexagonal head bolts

(M5 to M64)

IS 1363 (Part 2) : 1992 Hexagonal head bolts, screws, and nuts of

product grade C, Hexagonal head screws

(M5 to M64)

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Page 108 of 204
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IS 1363 (Part 3) : 1992 Hexagonal head bolts, screws, and nuts of

product grade C, Hexagonal head nuts

(M5 to M64)

IS 8603 (Part 1) : 1977 Dimensions for porcelain transformer

bushings for use in heavily polluted

atmosphere 12/17.5 kV Bushings.

IS 8603 (Part 2) : 1977 Dimensions for porcelain transformer

bushings for use in heavily polluted

atmosphere 24 kV Bushings.

IS 8603 (Part 3) : 1977 Dimensions for porcelain transformer

bushings for use in heavily polluted

atmosphere 36 kV Bushings.

IS 12676 : 1989 Dimensions for oil impregnated paper

insulated condenser bushings.

IS 13305 : 1992 Permissible limits of visual defects for

insulating porcelains for electrical circuits.

IS 13312 : 1992 Dimensions of porcelain oil filed transformer

bushings (rated 52 kV) in medium polluted

atmospheres.

IS 1573 : 1986 Electroplated coatings of zinc on iron &

steel

IS 2629 : 1985 Recommended practice for hot dip

galvanising of iron and steel.

IS 2633 : 1986 Methods for testing uniformity of coating of

zinc coated articles.

IS 4759 : 1996 Hot dip zinc coating on structural steel.

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Page 109 of 204
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IS 3401 : 1992 Silica gel

IS 3588 : 1987 Electric Axial flow fans.

IS 3637 : 1966 Gas operated relays.

IS 3639 : 1966 Fittings & accessories for power

Transformers

IS 4253 (Part1) : 1980 Cork Composition Sheet - Plain cork

IS 4253(Part2) : 1980 Cork Composition Sheet - Cork & Rubber.

IS 5561 : 1970 Electric power connectors.

IS 6088 : 1988 Oil to water heat exchanger for

transformers.

IS 7404(Part2) : 1991 Paper Covered Copper Conductors -

Rectangular Conductors.

IS 8468 : 1977 On load tap Changers.

IS 8478 : 1977 Application guide for on load tap Changers.

IS 104 : 1979 Ready mixed paint, brushing, zinc chrome,

priming.

IS 2074 : 1992 Ready mixed paint, air drying, red oxide -

zinc chrome, priming.

IS 2932 : 1993 Enamel, synthetic, exterior

(a) undercoating, (b) finishing.

IS 13213 : 1991 Polyurethane full gloss enamel.

IS 13238 : 1991 Epoxy based zinc phosphate primer (two

pack).

IS 1554 (Part 1) : 1988 PVC insulated (heavy duty) electric cables

for working voltages upto and including

1100 V.

ISSUE/ REVISION 99/07 01/11 02/08 03/11

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IS 1554 (Part 2) : 1988 " from 3.3 kV upto and including 11

kV

IS 9147 : 1979 Cable sealing boxes for oil immersed

transformers; 12 kV ~ 36 kV.

1S 9700 : 1991 Activated alumina.

IS 12943 : 1990 Brass Glands for PVC Cables.

IS 13947 (Part1) : 1993 Low voltage Switch Gear and Control Gear -

General rules.

IS 4257 (Part 1) : 1981 Dimensions for clamping arrangements

porcelain transformer bushings for 12 kV to

36 kV bushings.

IS 4257 (Part 2) : 1986 " for 72.5 kV to 123 kV bushings.

10.1.3 INSTRUMENT TRANSFORMERS
IS 1885 (Part28) : 1993 Electro Technical Vocabulary Instrument

Transformers.

IS 2705 (Part1) : 1992 Current Transformers - General.

IS 2705 (Part2) : 1992 Current Transformers - Measuring.

IS 2705 (Part3) : 1992 Current Transformers - Protective.

IS 2705 (Part4) : 1992 Current Transformers – Protective

Current transformers for special

purpose application.

IS 3156 (Part1) : 1992 Voltage transformer - General.

IS 3156 (Part2) : 1992 Measuring Voltage transformers.

IS 3156 (Part3) : 1992 Protective Voltage transformers.

IS 3156 (Part4) : 1992 Capacitive Voltage transformers.

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IS 4146 : 1983 Application guide for Voltage

transformers.

IS 4201 : 1983 Application guide for Current

transformers.

IS: 5547 : 1983 Application guide for Capacitive

Voltage transformers.
10.1.4 TRANSFORMER BUSHING
IS 1885 (Part54) : 1993 Electro Technical Vocabulary - Insulators.

IS 2099 : 1986 Bushings for alternating Voltages above

1000 V.

IS 3347(Part1to8) Dimension for porcelain transformer

bushings.

IS 4257 (Part1) : 1981 Dimension for Clamping arrangements for

bushing 12 kV to 36 kV.

IS 4257 (Part2) : 1986 Dimension for clamping arrangement

for bushing 72.5 & 123 kV.

IS 5621 : 1980 Hollow porcelains for use in

electrical equipment.

IS 8263 : 1976 Methods for radio interference test on

high Voltage insulators.

IS 8603 (Part1~3): 1977 Dimension for porcelain transformer

bushings for heavily polluted atmospheres

12, 24 & 36 kV.

IS 8704 : 1995 Artificial pollution tests on high Voltage

insulators for use on AC Systems.

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IS 12676 : 1989 Dimensions for oil impregnated paper

insulated Condenser bushings.

IS 13134 : 1992 Guide for Selection of insulators in

respect of pollution Conditions.

IS 13305 : 1992 Permissible limits for Visual defects for

insulating porcelains for electrical circuits.

IS 13312 : 1992 Dimensions of porcelain oil filled

transformer bushing (rated 52 kV) for

medium polluted atmosphere.

10.1.5 REACTORS
IS 5553 (Part1) : 1989 Reactors - General.

IS 5553 (Part2) : 1990 Shunt Reactors.

IS 5553 (Part3) : 1990 Current limiting reactors and neutral

earthing reactors.

IS 5553( Part6) : 1990 Earthing transformers (Neutral Couplers)

10.0.6 TRANSFORMER OIL AND OIL TESTING

IS 335 : 1993 New insulating oils.

IS 1448 (Part 10) : 1970 Method for test for petroleum and its

products cloud point and pour point.

IS 1448 (Part 16) : 1990 Density of crude petroleum and liquid

petroleum products by Hydrometer method.

IS 1448 (Part 21) : 1992 Petroleum and its Products - Flash point by

Pensky Martens Apparatus.

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IS 1448(Part 25) : 1976 Determination of Kinematic and Dynamic

Viscosity.

IS 1866 : 2000 Code of practice for maintenance

and supervision of insulating oils in

equipment.

IS 2362 : 1993 Determination of water by Karl Fisher

method.

IS 6103 : 1971 Method of test for specific resistance

(resistivity) of electrical insulating liquids.

IS 6104 : 1971 Method of test for interfacial tension of

oil against water by ring method.

IS 6262 : 1971 Method of test for power factor and

dielectric constant of electrical insulating

liquids.

IS 6792 : 1992 Method of determination of electric strength

of insulating oils.

IS 6855 : 1973 Method of sampling for liquid dielectrics.

IS 9434 : 1992 Guide for sampling and analysis of free and

dissolved gases and oil from oil filled

electrical equipment.

IS 10593 : 1992 Methods of evaluating the analysis of gases

in oil filled electrical equipment.

IS 12177 : 1987 Methods of test for oxidative ageing of

electrical insulating petroleum oils by open

beaker method.

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IS 13567 : 1992 Determination of water in insulating liquids

and in oil impregnated paper & press board

by automatic Coulometric Karl Fisher

Titration - Method of Test.

IS 13631 : 1993 Method of test for detection & determination

of antioxidant additives in insulating oils.

IS 12463 : 1988 Specification for Inhibited Mineral Insulating

oils.

10.1.7 INSULATION CO ORDINATION AND HIGH VOLTAGE

TESTING
IS 1876 : 1961 Method for voltage measurement by

means of sphere gaps.

IS 2071 (Part1) : 1993 High voltage test techniques; General

definitions and test requirements.

IS 2071 (Part 2) : 1974 “ “ Test procedures.

IS 2071 (Part3) : 1976 “ “ Measuring devices.

IS 2165 (Part1) : 1977 Phase to earth insulation co-ordination

principals and rule.

IS 2165 (Part2) : 1983 Phase to phase insulation co-ordination

principles and rules.

IS 3716 : 1978 Application guide for insulation co-

ordination.

IS 6209 : 1982 Methods for partial discharge

measurements.

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IS 8690 : 1977 Application guide for measuring devices for

high voltage testing.

IS 2551 : 1982 Danger notice plates.

IS 8923 : 1978 warning symbol for dangerous voltages.

IS 12776 : 1989 Galvanised strand for earthing.

ISSUE/ REVISION 99/07 01/11 02/08 03/11

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10.2 IEC STANDARDS

IEC 60071-1(1993) Insulation co-ordination; Definitions,

principles and rules.

IEC 60071-2(1996) Insulation co-ordination; Application guide.

IEC 60076–1 (2000) Power transformers; General.

IEC 60076–2 (1993) Power transformers; Temperature rise.

IEC 60076–3 (2000) Power transformers; Insulation levels,

dielectric tests and external clearances in

air.

IEC 60076–5 (2000) Power transformers; Ability to withstand

short circuit.

IEC 60076–8 (1997) Power transformers; Application guide.

IEC 60076–10 (2001) Power transformers; Determination of

sound levels.

IEC 60137 (1995) Insulating bushings for alternating voltages

above 1000 V

IEC 60156 (1995) Method for determination of the electric

strength for insulating oils.

IEC 60044-1 (1996) Current Transformers.

IEC 60044- 6 (1992) Protective Current Transformer for transient

performance.

IEC 60186 (1987) Voltage Transformers.

IEC 60214 (1989) On load tap changers

IEC 60233 (1974) Tests on hollow insulators for use in

electrical equipment.

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IEC 60296 (1982) Specification for unused mineral insulating

oils for transformer and Switch gear.

IEC 60310 (1991) TractionTransformers and inductors.

IEC 60354 (1991) Loading guide for oil immersed power

transformers.

IEC 60422 (1989) Supervision and maintenance guide for

insulating mineral oils in electrical

equipment.

IEC 60445 (1999) Identification of equipment terminals and

termination of certain designated

conductors including general rules for an

alpha numeric system.

IEC 60475 (1974) Method of sampling liquid dielectric.

IEC 60529 (2001) Degrees of protection provided by

enclosures (IP Codes).

IEC 60542 (1976) Application guide for on load tap changers.

IEC 60554 (Part 1 ~ 3) Specification for cellulosic papers for

electrical purposes.

IEC 60567 (1992) 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 (1999) 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.

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IEC 60628 (1985) Gassing of insulating liquids under electrical

stresses and ionisation.

IEC 60722 (1982) Guide for lightning impulse and switching

impulse testing of power transformer.

IEC 60726 (1982) Dry type Power Transformer.

IEC 60905 (1987) Loading guide for dry type Power

Transformer.

IEC 60947 (Part 1 to 7) Low voltage switchgear and control gear.

IEC 61378-1 (1997) Converter Transformer for HV DC

application.

IEC 61378-2 (2001) Converter Transformer for industrial

application.

IEC 60289 (1988) Reactors.

********************

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TRANSFORMER

ACCESSORIES

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TEMPERATURE INDICATOR

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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): Analog 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)

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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.

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FIG. 1
INDICATOR
(LID & DIAL REMOVED)

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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.

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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)
4. The shipping stop (22 - Fig. 1) is removed.

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.

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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.

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

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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

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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 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.

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GAS & OIL OPERATED

(BUCHHOLZ) RELAYS

FOR THE PROTECTION OF OIL FILLED

TRANSFORMERS, CAPACITORS, REACTORS
AND ON-LOAD TAP CHANGE EQUIPMENT
RELAY TYPE GOR

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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.

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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 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.

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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 for the protection of on load tap-change equipment.

3. ADVANTAGES

a) Castings treated agains t porosity through a special process.

b) Unique internal design of 'housing' prevents false air traps on top of the
relay.

c) Well-designed internal layout gives clear view of colour of gas inside

the relay through glass window for fault analysis.

d) Bucket type float design with inherent ability to withstand vacuum

treatment of transformers.

e) Built in test facility for checking continuity of both Alarm and Trip
circuits.

f) Antivibration custom-built mercury switches give high stability against

mechanical shocks and vibrations.

g) ISI Mark of quality on every relay

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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

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'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 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.

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- 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 insula tion 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 trip devices connected to them.

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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.

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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 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.

ISSUE/ REVISION 99/07 01/11 02/08 03/11

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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

SR1 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

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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.

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.

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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.

SWITCH DATA:
TYPE ---------------------------------------------------------- Normally Open

CONTACT RATlNG ------------------------ 250VA A.C. (r.m.s.) or D.C. max.

SWITCHING CURRENT --------------------------------- 5A A C or D.C. max.

SWITCHING VOLTAGE --------------------------------------- 300 V D.C. max.

----------------------------- 240 Volts A.C. (r.m.s.) max.

BREAKDOWN VOLTAGE --------------------------------- 650 Volts D.C. min.

INITIAL CONTACT RESISTANCE ------------------------- 70 milli-ohms max.

RESONANT FREQUENCY ------------------------------- greater then 700 Hz.

ACTUATING TIME (Including Bounce) -------------- 2 milli-seconds (Typical)

THESE SWITCHES HAVE RHODIUM CONTACT, LOCATED MIDWAY

ALONG THE LENGTH OF THEIR GLASS TUBES, THE TUBES CONTAIN
AN ATMOSPHERE OF NITROGEN.

PROTECTION OF REED SWITCH CONTACTS:

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THE EFFECTS OF CAPACTIVE LOADS SUCH AS ARE IMPOSED BY

LONG LEADS, ARE SUPPRESSED BY MEANS OF SMALL INDUCTORS
MOUNTED WITHIN THE RELAY AND WIRED ONE IN SERIES WITH EACH
SWITCH.

THE EFFECTS OF INDUCTIVE LOADS SUCH AS ARE IMPOSED BY

CONTACTORS AND E.M. RELAYS ARE SUPPRESSED BY MEANS OF A
DIODE WIRED ACROSS EACH LOAD. DIODE TO BE RATED WITH
FORWARD CURRENT AT LEAST AS HIGH AS STEADY LOAD CURRENT
AND CONNECTED SO AS TO ABSORB BACK e.m.f..

ARRANGEMENT OF TERMINALS AND MEANS OF PROTECTION FOR

REED SWITCH CONTACT.

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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.

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IMPORTANT

The various part of a relay including the body, form one complete calibrated unit and
must not be inter changed with those of other relays.

We strongly recommend that relay should not be taken apart, and under no
circumstances should any alteration be made to the angle of the flap on the trip
element. This has been correctly adjusted during manufacturing.

RELAY
TYPE
GOR 1

RELAY
TYPE
SR1

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INSTRUCTIONS
FOR
INSTALLATION, OPERATION
AND MAINTENANCE
OF OIP CONDENSER TYPE
BUSHINGS

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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.

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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.

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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

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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.

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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
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.

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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 ALSTOM, 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.

5. INSTALLATION:
Please refer to Fig. 8
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,

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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 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.

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BUSHING WITH DRAW-ROD CONNECTIONS:

Please refer to Fig. 10
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.

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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 ALSTOM for further
advice.

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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.

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SILICAGEL
BREATHER

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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.

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SECTIONAL VIEW OF BREATHER

TYPE 1

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SILICAGEL BREATHER
TYPE 2

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OIL LEVEL INDICATOR

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OIL LEVEL INDICATOR

SIDE VIEW FRONT VIEW

PARTS LIST FOR FIG. 1

Sr. No. DESCRIPTION MATL. Sr. No. DESCRIPTION MATL.
1. Float 50 p x 100 Brass 7. Bolts 'B'-6 Nos.- M6 M.S.
2. Terminal Box Cast Al. 8. Base with Mtg. Holes Cast. Al.
3. Cover for T. B. Cast Al. 9. Limit stoppers Brass
4. Dial Body with switch housing Cast Al. 10. Gear with lever Brass
5. Mercury switch Glass 11. Float Arm 9.5 p tube Brass
6. Nut for Switch Adj. Brass 12. Check Nut Brass

Fig. 1

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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).

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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.

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PRESSURE RELIEF VALVE

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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.
l Allows the pressure to drop by instantaneously opening a port of about
150 mm diameter.
l Gives visual indication of valve operation by rising a flag.
l 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.

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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.

ISSUE/ REVISION 99/07 01/11 02/08 03/11

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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.

ISSUE/ REVISION 99/07 01/11 02/08 03/11

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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.

ISSUE/ REVISION 99/07 01/11 02/08 03/11

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EXHAUST FAN

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Page 173 of 204
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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.

ISSUE/ REVISION 99/07 01/11 02/08 03/11

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MOUNTING
1. The arm is secured by the resilient mounting caps, which are placed
over the rubber sockets and secured to the diaphragm with 8 screws,
nuts and washers provided. The lock washers should be fitted under
the heads of the screws.
2. Rubber sockets fitted to arms. To be fitted so that flat side will come in
contact with the diaphragm.
3. Arms to be secured to motor by the 4 screws in motor carton.
NOTE: Lock washers are supplied and should be fitted.

4. Setscrew in blade should engage in dimple nearest the end of the

shaft. After blade is fitted, see that split pin 5 is replaced in end of shaft.

ISSUE/ REVISION 99/07 01/11 02/08 03/11

© This document and any Information or Descriptive Matter set out herein are the Confidential and Copyright Property of ALSTOM
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CONSTRUCTIONAL DETAILS

No. PART NAME No. PART NAME

1 TERMINAL BLOCK 14 WING FIXING BOLT
2 BALL BEARING 15 SPLIT PIN
3 STATOR WINDING 16 SHAFT
4 EARTH SCREW 17 HUB FIXING BOLT
5 ROTOR STAMPING 18 HUB
6 STATOR STAMPING 19 BALL BEARING
7 RESILIENT CAP 20 LUBRICATOR SCREW
8 RUBBER SLEEVE 21 MOUNTING ARM
9 BACK COVER FIXING SCREW 22 MOTOR FIXING BOLT
10 BACK COVER 23 DIE CAST AL. ROTOR
11 FAN FIXING BOLT 24 CH. HD. SCREW
12 WING 25 DIAPHRAGM
13 CH. HD. SCREW

ISSUE/ REVISION 99/07 01/11 02/08 03/11

© This document and any Information or Descriptive Matter set out herein are the Confidential and Copyright Property of ALSTOM
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MANUAL FOR
Page 176 of 204
POWER TRANSFORMERS

FLOW INDICATORS

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OPERATION AND MAINTENANCE
MANUAL FOR
Page 177 of 204
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FLOW INDICATORS
FUNCTION
Flow indicators included in this catalogue are mainly designed as a safety device
looking to the need of an electrical signal on failure of forced circulation of liquid in
pipeline. They perform following functions:
1. Indicate the rate of full flow in proper direction in specified pipe.
2. Operate one or two mercury switches when rate of flow drops near to 70% of
specified full flow.
These switches can be used to initiate precautionary systems or safety
devices.
APPLICATION
Consider the case of furnace transformer in which one Flow Indicator can be
mounted on suitable member of oil circulating pipe and one on water circulating pipe
of heat exchanger. The pointer of respective Flow Indictor will indicate whether
desired rate of flow is maintained or not and switch will operate if the flow drops near
to 70% to initiate precautionary system. For similar purpose it can be used on liquid
circulating pipes in chemical processes, heavy-duty bearings, compressors, etc.
MOUNTING
To introduce these Flow Indicators in a pipe line a `T-Mounting’ is necessary. In this
catalogue we have tabulated dimensions of 'T-Mounting' for range of size from 40
mm (1.5") to 250 mm (10") N.B. Pipes. But customer can always specify if his
requirement is different than the tables on page 8.
CONSTRUCTION & WORKING
A suspended vane is used as sensor. Its surface is kept at right angle to direction of
flow. When liquid starts flowing through pipe, the vane gets deflected along with
vane shaft. This deflection is used to indicate flow inside the pipe and to operate
mercury switch or switches as follows:
A pair of permanent magnets is used as gland-less coupling. The driving magnet is
connected with vane, therefore it rotates with vane and remains in liquid. The
follower magnet, separated by a non-magnetic wall, is kept outside in air and
acquires position corresponding to driving magnet. The follower magnet carries a

ISSUE/ REVISION 99/07 01/11 02/08 03/11

© This document and any Information or Descriptive Matter set out herein are the Confidential and Copyright Property of ALSTOM
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pointer and a cam. The pointer is set to read the specified rate of full flow and the
cam is set to operate one or two mercury switches when flow drops near to 70%.
A return spring is used which acts in the opposite direction of flow. Hence any steady
position of pointer is the result of equilibrium of force due to impinging liquid on vane,
spring tension & weight of vane. The pointer does not remain steady for unsteady
flows. The size and shape of vane and tension on return spring is adjusted to suit
specified full flow. The vane occupies very small area out of full cross section of pipe
at NO-FLOW position. At full flow it becomes almost parallel to flow. Hence there is
practically no head-loss across Flow Indicator.

DIAL MARKING
The spread of flow indicating portion of dial is only about 70°. Hence it is not possible
to print more markings. Usually PUMP ON-PUMP OFF or FULL FLOW-NO FLOW
type of limit markings is printed. Intermediate markings such as ALARM. TRIP is also
printed if required. Besides, specifications such as value of full flow, liquid, pipe size
and direction of flow are also printed. The background of dial is white. Direction
indicating arrow is in red colour and all other markings in black colour.

SWITCHES
One or two mercury switches of SPST type are provided. The contact position can
be set to No or NC at full flow. If required, switch can be changed from NO to NC or
vice versa at site.
In case of single switch, it is set to operate near 70% when flow is falling. In case of
two switches, both are mounted on same plate. Hence both operate at same rate of
flow. But in order to satisfy design requirements, one switch can be set to operate
near 80% and the other near 70% or one near 70% and the other near 60%. It is not
possible to set a switch to operate at lower value than 60%. Even when both
switches are set to operate at lower value than 60%. Even when both switches are
set to operate at same rate of flow, some switching differentiate is observed due to
use of mercury as switching element, We can modify setting suitably if switching
requirements are clearly specified.
WIRING
Leads from mercury switch/switches are brought into a terminal box positioned at
the bottom of indicator. A two-way or four-way terminal strip is provided. Terminals
are accessible for wiring after removing cover. A hole with conduit threads is

ISSUE/ REVISION 99/07 01/11 02/08 03/11

© This document and any Information or Descriptive Matter set out herein are the Confidential and Copyright Property of ALSTOM
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provided for fixing cable gland to box. Terminals are marked. Wiring should be done
as per respective wiring diagrams.
SETTING
Full Flow- Each indicator is set in water-flowing condition. Pipe size, pipe position,
direction of flow is maintained. By adjusting a valve in pipeline, the specified rate of
full flow is established, then the pointer is set to read the full flow mark. This method
of setting gives very accurate results as it is based on equilibrium of vane at full flow.
In case of liquids other than water, proportional rate of flow of water is maintained for
setting.
Switch - After setting of pointer at full flow, switches are set in the sequence ordered
by customer. Flow is reduced to check operation of switch & increased to check
automatic resetting. The rate of flow at which switching occurs is approximate. The
switch position is kept adjustable to compensate difference in pipe gradient at site.
TESTING
Static Pressure: At 7 kg/cm².
Flow: Indicator is mounted on pipe. Water is allowed to flow in specified direction.
Rate of flow is checked when pointer reads full flow. For Liquids other than water
proportional rate of flow of water is checked.
Switch: Switch operation is checked by reducing and increasing flow in pipeline.
Contact rating: Switches are tested in laboratory at 5A.24OV.AC
Dielectric strength: Live terminals are checked at 2 kV with body.
A test Certificate is provided with each instrument.
DESIGN FEATURES
1. Switch contacts are not affected by dust, humidity or corrosive atmosphere.
2. Switches can be serviced without need of stopping flow.
3. Causes negligible head-loss.
4. Low maintenance cost.
5. Robust construction & trouble free service.
6. Does not get damaged due to excess flow or reverse flow.

ISSUE/ REVISION 99/07 01/11 02/08 03/11

© This document and any Information or Descriptive Matter set out herein are the Confidential and Copyright Property of ALSTOM
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Page 180 of 204
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Fig. 1 SCHEMATIC
Item Description
1 - Pointer & Dial
2 - Mercury Switch
3 - Switch Operating Cam
4 - Return Spring
5 - Vane Shaft
6 - Vane
7 - Main Pipe
8 - Driving Magnet
9 - Non-magnetic Wall
10 - Follower Magnet

Fig. 2 WORKING POSITIONS

Item Description
1 - Main Pipe
2 - T - Mounting
3 - Connecting Flanges
4 - Flow Indicator
5 - Flange of indicator

Horizontal Pipe
Vertical Pipe

NOTES:
I. Flow indicators are not interchangeable for different liquids, pipe dia.,
direction of flow or rate of full flow. Hence they should be ordered
separately.
2. The rate of full flow is not adjustable.
3. The switch operation point is not adjustable.

ISSUE/ REVISION 99/07 01/11 02/08 03/11

© This document and any Information or Descriptive Matter set out herein are the Confidential and Copyright Property of ALSTOM
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OPERATION AND MAINTENANCE
MANUAL FOR
Page 181 of 204
POWER TRANSFORMERS

(Actual Supply may not be exactly same)

Fig. 3 Wiring Diagram
For Series 4021.

Fig. 4 Dimension Drawings for Series 4021

Hardware for indicator

(Supplied at extra cost)
M 12 x 65 Bolts, Nuts - Nos.
Washer & Suitable gasket.

Accessories
(Supplied at extra cost if agreed)
T-Mounting, Weldable connection,
Flanges, hardware.

Part List
No. Description
1 – Cover for terminal box
2 – Base with mounting holes
3 – Vane shaft
4 – Vane
5 – Product label
6 – Cable entry
7 – Terminals
8 – Mercury switch
9 – Nut for adjusting switch
10 – Cover for switch box
Weight - 3.8 kg.

ISSUE/ REVISION 99/07 01/11 02/08 03/11

© This document and any Information or Descriptive Matter set out herein are the Confidential and Copyright Property of ALSTOM
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MANUAL FOR
Page 182 of 204
POWER TRANSFORMERS

Flow Indicators Series 4021 & 4022

It may noted that mounting specifications, flow sensing mechanism, vane orientation
and size of dial is same in both series. Basic difference between two series is that in
Series 4021 only one mercury switch is provided. Whereas in Series 4022 two
mercury switches are provided. Proportionately, number of terminals, size of switch-
box and size of terminal box differ,
After suitable series is selected, requirement should be specified as per 'How to
Order' column on Page 3 of this catalogue. Because each indicator is set to suit
requirement specified by customer.

Common specifications of Series 4021 & 4022 working:

Principal of working, switch operation and other details as explained on page 2 & 3
of this catalogue.

Operating specifications (in ranges)

Liquid — Water, oils
Pipe — 37 to 250 NB (1.5" to 10”)
Switch — One or two SPST mercury switches
depending on series.
Environment — Indoor or Outdoor
Working temperature — 0° to 100° C of liquid in pipe
Working pressure — 0 to 4 Kg/cm²
Material of Construction
Wetted Parts
Vane shaft, return spring St. Steel
Vane, spring housing, screws Brass
Base Aluminium (G. M. on Order)
Magnet Alnico.
Note: All Brass Parts chrome plated and Aluminium Parts anodised.
Other Parts
Dial Body, switch housing, terminal box, covers Aluminium
Dial shield Tough glass
Terminals Brass
Mercury switch Hg in hard glass

ISSUE/ REVISION 99/07 01/11 02/08 03/11

© This document and any Information or Descriptive Matter set out herein are the Confidential and Copyright Property of ALSTOM
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 ERECTION, COMMISSIONING, Ref. No. TRM. 0311

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MANUAL FOR
Page 183 of 204
POWER TRANSFORMERS

Fig. 5
Details of vane orientation common to Series 4021 & 4022

Details of symbols used in Fig. 5

Direction of flow liquid in pipe as seen from dial side of indicator.
Force due to return impinging liquid
Force due to return spring
Vane at no-flow
Vane at full-flow
Pipe

Fig. 5 above shows vane positions at no-flow as seen from dial side of indictor.

Indicators are set for any one direction out of four illustrated in Fig. 5. T figure also
shows direction of forces acting on vane due to impinging liquid and return spring
(gravitational force not shown).

ISSUE/ REVISION 99/07 01/11 02/08 03/11

© This document and any Information or Descriptive Matter set out herein are the Confidential and Copyright Property of ALSTOM
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Page 184 of 204
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Fig. 6 Wiring Diagram

For Series 4022

Fig. 7 Dimension Drawings For Series 4022

Hardware for indicator

(Supplied at extra cost)
M 12 x 65 Bolts, Nuts - Nos.
Washer & Suitable gasket.

Accessories
(Supplied at extra cost if agreed)
T-Mounting, Weldable connection,
flanges, hardware.

Part List
No. Description
1 – Cover for terminal box
2 – Base with mounting holes
3 – Vane shaft
4 – Vane
5 – Product label
6 – Cable entry
7 – Terminals
8 – Mercury switch
9 – Nut for adjusting switch
10 – Cover for switch box
Weight - 4.0 kg.

ISSUE/ REVISION 99/07 01/11 02/08 03/11

© This document and any Information or Descriptive Matter set out herein are the Confidential and Copyright Property of ALSTOM
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OPERATION AND MAINTENANCE
MANUAL FOR
Page 185 of 204
POWER TRANSFORMERS

(Actual Supply may not be exactly same)

Fig. 8 Wiring Diagram

For Series 4031

Fig. 9 Dimension Drawings For Series 4031

Hardware for indicator

(Supplied at extra cost)
M 12 x 65 Bolts, Nuts - Nos.
Washer & Suitable gasket.

Accessories
(Supplied at extra cost if agreed)
T-Mounting, Weldable connection,
flanges, hardware.
Part List
No. Description
1 – Cover for terminal box
2 – Base with mounting holes
3 – Vane shaft
4 – Vane
5 – Product label
6 – Cable entry
7 – Terminals
8 – Mercury switch
9 – Nut for adjusting switch
10 – Cover for switch box

Weight - 4.3 kg.

ISSUE/ REVISION 99/07 01/11 02/08 03/11

© This document and any Information or Descriptive Matter set out herein are the Confidential and Copyright Property of ALSTOM
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OPERATION AND MAINTENANCE
MANUAL FOR
Page 186 of 204
POWER TRANSFORMERS

Flow Indicators Series 4031 & 4032

It may noted that mounting specifications, flow sensing mechanism, vane orientation
and size of dial is same in both series. Basic difference between two series is that in
Series 4021 only one mercury switch is provided. Whereas in Series 4022 two
mercury switches are provided. Proportionately, number of terminals, size of switch-
box and size of terminal box differ,
After suitable series is selected, requirement should be specified as per 'How to
Order' column on Page 3 of this catalogue. Because each indicator is set to suit
requirement specified by customer.

Common specifications of Series 4031 & 4032 working:

Principal of working, switch operation and other details as explained on page 2 & 3
of this catalogue.

Operating specifications (in ranges)

Liquid — Water, oils
Pipe — 37 to 250 NB ( 6" to 10" )
Switch — One or two SPST mercury switches
depending on series.
Environment — Indoor or Outdoor
Working temperature — 0° to 100° C of liquid in pipe
Working pressure — 0 to 4 kg/cm²
Material of Construction
Wetted Parts
Vane shaft, return spring St. Steel
Vane, spring housing, screws Brass
Base Aluminium (G. M. on Order)
Magnet Alnico.
Note : All Brass Parts chrome plated and Aluminium Parts anodised.

Other Parts
Dial Body, switch housing, terminal box, covers Aluminium
Dial shield Tough glass
Terminals Brass
Mercury switch Hg in hard glass

ISSUE/ REVISION 99/07 01/11 02/08 03/11

© This document and any Information or Descriptive Matter set out herein are the Confidential and Copyright Property of ALSTOM
and must not be disclosed, loaned, copied or used for Manufacturing, Tendering or for any other purpose without written permission.
 ERECTION, COMMISSIONING, Ref. No. TRM. 0311

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OPERATION AND MAINTENANCE
MANUAL FOR
Page 187 of 204
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Fig. 10
Details of vane orientation common to Series 4031 & 4032

Details of symbols used in Fig. 10

Direction of flow liquid in pipe as seen from dial side of indicator.
Force due to return impinging liquid
Force due to return spring
Vane at no-flow
Vane at full-flow
Pipe

Fig. 10 above shows vane positions at no-flow as seen from dial side of indictor.

Indicators are set for any one direction out of four illustrated in Fig. 5. T figure also
shows direction of forces acting on vane due to impinging liquid and return spring
(gravitational force not shown).

ISSUE/ REVISION 99/07 01/11 02/08 03/11

© This document and any Information or Descriptive Matter set out herein are the Confidential and Copyright Property of ALSTOM
and must not be disclosed, loaned, copied or used for Manufacturing, Tendering or for any other purpose without written permission.
ERECTION, COMMISSIONING, Ref. No. TRM. 0311

abcd
OPERATION AND MAINTENANCE
MANUAL FOR
Page 188 of 204
POWER TRANSFORMERS

(Actual Supply may not be exactly same)

Fig. 11 Wiring Diagram

For Series 4032

Fig. 12 Dimension Drawings For Series 4032

Hardware for indicator
(Supplied at extra cost)
M 12 x 65 Bolts, Nuts - Nos.
Washer & Suitable gasket.

Accessories
(Supplied at extra cost if agreed)
T-Mounting, Weldable connection,
flanges, hardware.

Part List
No. Description
1 – Cover for terminal box
2 – Base with mounting holes
3 – Vane shaft
4 – Vane
5 – Product label
6 – Cable entry
7 – Terminals
8 – Mercury switch
9 – Nut for adjusting switch
10 – Cover for switch box
Weight - 4.8 kg.

ISSUE/ REVISION 99/07 01/11 02/08 03/11

© This document and any Information or Descriptive Matter set out herein are the Confidential and Copyright Property of ALSTOM
and must not be disclosed, loaned, copied or used for Manufacturing, Tendering or for any other purpose without written permission.
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OPERATION AND MAINTENANCE
MANUAL FOR
Page 189 of 204
POWER TRANSFORMERS

TRANSFORMER OIL PUMP

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OPERATION AND MAINTENANCE
MANUAL FOR
Page 190 of 204
POWER TRANSFORMERS

IN LINE TRANSFORMER OIL PUMP

INSTALLATION, OPERATION & MAINTENANCE

INSTRUCTIONS

GENERAL CONSTRUCTION

PUMP
The pump set is a single stage axial flow gland-less type, integral with the drive
motor. It has been specifically designed for forced circulation of oil through the
cooling system of large transformer & allows thermo syphonic flow.
It is designed for flange mounting directly to the pipe circuit of transformers in either
horizontal or vertical position.
All the moving parts are completely enclosed and gasket thus permitting open air
installation, without any need for protective cover. It is compact in design.
The Nameplate gives details of pump and motor output along with respective
connecting pipe size.

MOTOR
The motor is of squirrel cage induction type suitable for 3 PHASE A.C. Power supply.
It is coaxial with the pump and is designed to operate in hot transformer oil. The
bearings are lubricated by transformer oil.
PRECAUTIONS
1. Store the unit in clean and dry place.
2. Do not remove the M. S. end covers till the pump set is to be installed in pipe
circuit. These are meant to protect the internal components against dirt and
dust during transit and storage.
3. It is important that all pipe work must be supported independently so that it
imposes no under strain in bending or torsion on the pump flanges.
4. The bearings are lubricated by the transformer oil and hence the pump should
not run dry, to avoid damage to bearings.
5. Keep the entire pipe circuit perfectly clean and free from moisture and foreign
material.

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© This document and any Information or Descriptive Matter set out herein are the Confidential and Copyright Property of ALSTOM
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Page 191 of 204
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6. Ensure that the electrical supply available is suitable for data given on the
pump rating plate.
7. Care should be taken that the valves are in the 'open' position, when the
pump set is operated, because the pump works correctly only when all valves
are fully opened. The oil filled pump will produce Pressure even with the
valves closed, but there is no circulation, there will be oil churning inside the
pump set and the pump motor might also get overheated.
INSTALLATION
Before mounting on pipeline check the following:
1. Remove the terminal box cover (8), and check the insulation resistance of the
set with a meggar to ensure minimum resistance of 10 meg-ohms.
2. Remove end covers and check for free rotation of the rotor. Ensure that
Impeller (5) and locking screw (19) with washer are in their proper position.
3. Connect the supply terminals and ensure rotation of impeller as per 'Arrow
Mark' on the Impeller Housing i.e. anti-clockwise rotation when looking
through the impeller housing opening.
NOTE: In case of wrong direction of rotation of impeller, there will be no discharge.
OPERATION
After installation on the pipe circuit, start filling the system with clean transformer oil
until it completely fills the pump unit, Release all air by the air vent plug initial
continuous air free oil seeps out. It is important that no air is trapped in the pump. It
is always a good practice to allow the pump to run for about 30 minutes before
energising the transformer, to ensure that any air not removed by venting has been
pumped out.
MAINTENANCE
Check periodically the behaviour regarding leakage, vibration, noise, and
current/power consumption of the pump set. In case the pump is to be removed,
allow the unit to cool and drain the oil completely from the set and replace the end
covers. Store as prior installation.
Dismantling of Pump and Motor may be carried out as detailed on Page 201.
TROUBLE SHOOTING
Trouble Checks
1) Reduced or No delivery : a) Casing Suction Pipe not filled with liquid
b) Discharge head too high.
c) Wrong direction of rotation.
d) Air not vented out.

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Page 192 of 204
POWER TRANSFORMERS

2) Low Pressure : a) Wrong direction of rotation.

b) No oil in the pump.
3) More Power Consumption : a) Shaft bent.
b) No free movement of rotating element.
4) Pump is noisy : a) Hydraulic Noise:
Cavitation, wrong direction of rotation
b) Mechanical Noise : Bearing worn-out.
5) Motor Does not Start : a) Supply failure.
b) Defective Phase.
c) Loose Contacts.
d) Rotor Mechanically locked.
6) Fuse blows out while starting : a) Winding burnt.
b) Interphase shorts.
DISMANTLING OF PUMP AND MOTOR
Please refer Exploded view:
1. Remove Allen Cap Head Screw (19) and Washer (12).
2. Remove Impeller (5) by gently wrenching outwards with preferably a screw
driver.
3. Remove Key (20)
4. Remove End shield fixing screws (21).
5. Lightly tap end shield (2) & (5) with a wooden/nylon mallet until it dismantles
from bearing housing.
6. Remove Pre-loading washer (18).
7. Remove shaft with rotor (4).
8. Remove bearings (11) using a bearing puller.
9. In case required, the terminal arrangement, oil flow indicator (7) and plugs (13)
may be dismantled in the same order as shown.
For re-assembly follow reverse procedure.

ISSUE/ REVISION 99/07 01/11 02/08 03/11

© This document and any Information or Descriptive Matter set out herein are the Confidential and Copyright Property of ALSTOM
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OPERATION AND MAINTENANCE
MANUAL FOR
Page 193 of 204
POWER TRANSFORMERS

EXPLODED VIEW OF INLINE OIL PUMP

No. DESCRIPTION QTY. No. DESCRIPTION QTY. No. DESCRIPTION QTY.

1 STATOR CASE WITH WINDING 1 12 IMPELLER WASHER 1 23 LOCK WASHER 16
2 ENDSHIELD (ODE) 1 13 AIR VENT PLUG & DRAIN PLUG 2 24 ENDSHIELD FIXING NUT 16
3 ENDSHIELD (DE) 1 14 AIR VENT & DRAIN PLUG WASHE 2 25 TERMINAL BOARD FIXING SCREW 4
4 SHAFT WITH ROTOR 1 15 TERMINAL BOX GASKET 2 26 TERMINAL BOX FIXING SCREW 4
5 I MPELLER 1 16 TERMINAL COVER GASKET 1 27 TERMINAL COVER F IXING SCREW 4
6 TERMINAL BOX 1 17 OIL FLOW INDICATOR WASHER 1 28 PLAIN WASHER 4
7 OIL FLOW INDICATOR 1 18 PRE LOADING WASHER 1 29 NUT FOR TERMINAL STUD 6
8 TERMINAL COVER 1 19 HEX SOCKET HEAD CAP SCREW 1 30 LOCK WASHER 6
9 TERMINAL BOARD 1 20 PARALLEL KEY (OER) 1 31 PLAIN WASHER 12
10 SQUARE RING 1 21 ENDSHIELD FIXING SCREW 16
11 BALL BEARING SKF 6306 1 22 PLAIN WASHER 32

ISSUE/ REVISION 99/07 01/11 02/08 03/11

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OPERATION AND MAINTENANCE
MANUAL FOR
Page 194 of 204
POWER TRANSFORMERS

CONSTRUCTIONAL FEATURES

TYPE OF PUMP P D T L E A B M S Wt. kg.

IL - 5A 345 200 25 502 380 240 270 295 23 65.0
IL - 3A 285 150 20 425 305 210 240 240 23 41.0

ISSUE/ REVISION 99/07 01/11 02/08 03/11

© This document and any Information or Descriptive Matter set out herein are the Confidential and Copyright Property of ALSTOM
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OPERATION AND MAINTENANCE
MANUAL FOR
Page 195 of 204
POWER TRANSFORMERS

RADIAL FLOW (CENTRIFUGAL) OIL PUMPS

The pump set is a single stage radial flow gland-less type, integral with a squirrel
cage type induction motor suitable for three phase AC Power supply. The pump and
motor are coaxial and suitable for operation in hot transformer oil.

A well balanced impeller is co-axially mounted on the motor shaft through a key and
positively locked in position. A cast iron volute casing mounted on the stator case
through a spigot joint and sealing ring houses the impeller and imparts direction to
the flow of oil as indicated by an arrow cast on it.

Centrifugal type transformer oil pumps are used for circulating transformer oil
through windings and heat exchanger of oil immersed transformer. These type of oil
pumps are not suitable for natural cooling of transformer and hence these are used
only in association with oil to water heat exchanger where natural cooling is not
applicable. Normally oil to water heat exchangers are used on transformers where
water is available in plenty like hydroelectric stations or on transformers used for
furnace applications.

SPECIFICATIONS
MOTOR : 4.3 HP and 7.5 HP
STATOR : 3 Phase, 50 Hz, Induction Type
ROTOR : Squirrel Cage Type
BEARING : Ball Type, Lubricated by transformer oil itself.
COOLING : By circulating transformer oil itself.
PERFORMANCE : To IS: 325-1996; 3 Phase Induction Motor

PUMPS
CASING : Cast Iron
IMPELLER : Cast Aluminium/Bronzed keyed to the shaft
SEALING RINGS : Neoprene rubber
FRAME : Cast Iron totally enclosed integral part of the pump

ISSUE/ REVISION 99/07 01/11 02/08 03/11

© This document and any Information or Descriptive Matter set out herein are the Confidential and Copyright Property of ALSTOM
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OPERATION AND MAINTENANCE
MANUAL FOR
Page 196 of 204
POWER TRANSFORMERS

PARTICULARS OF DUTY AND DIMENSIONS

4.3 HP 7.5 HP
DISCHARGE (l.p.m.) : 1190 1880
TOTAL HEAD (m) : 11.00 11.00
PIPE SIZE Inlet/Outlet (mm) : 100/100 150/150

Pump Ref. Dis. Flange Suc. Flange Overall Wt.(kg.)

P1 d1 M1 S1 LA1 N P2 d2 M2 S2 LA2 L G D HB HC HD Net Gross

EL4.3R 220 100 180 18 18 4 220 100 180 18 18 460 220 125 290 195 360 71 111

EL7.5R 285 150 240 23 20 8 285 150 240 23 20 525 227 152 360 210 410 91 131

Fig. Over all dimensions of 4.3 HP & 7.5 HP Centrifugal Pumps

ISSUE/ REVISION 99/07 01/11 02/08 03/11

© This document and any Information or Descriptive Matter set out herein are the Confidential and Copyright Property of ALSTOM
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OPERATION AND MAINTENANCE
MANUAL FOR
Page 197 of 204
POWER TRANSFORMERS

FLEXIBLE SEPARATOR
(AIR CELL)

ISSUE/ REVISION 99/07 01/11 02/08 03/11

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OPERATION AND MAINTENANCE
MANUAL FOR
Page 198 of 204
POWER TRANSFORMERS

FLEXIBLE SEPARATOR
1. INTRODUCTION
Flexible separator (Air Cell) is provided inside the conservator of power
transformers for avoiding direct contact of air with the transformer oil. Air Cell
provides a permanent, flexible and non porous barrier between the
atmosphere and the transformer oil without affecting the operational function
of the system.
The basic construction of the separator is a highly resistant fabric coated
externally to resist transformer oil and internally to Ozone and weather
resistant. Flexible separators offer the following advantages :-

• Avoids contact between air and oil and consequently of condensation or

oxidation inside the transformer.
• Protection against water vapour and gases.
• Suppression of any gas bubble formation in oil.
• Compensation of large volume changes.
2. DESCRIPTION
Flexible separator is fitted inside a cylindrical conservator. Oil being outside,
the separator is in direct contact with atmosphere. This type of mounting
makes it possible to compensate for the oil volume displacements due to
temperature variations.
3. CHARACTERISTICS OF MATERIAL
Flexible separators are made from coated fabric consisting of :
• Textile reinforcement i.e. highly resistant polyamide fabric.
• External coating chemically resistant to transformer oils
• Inner coating resistant to Ozone and all weather conditions.
Major characteristics of materials are listed below:
Mass — 1400 ± 140 g/m²
Coating — Poly acrylonitrile butadiene
Textile reinforcement — Polyamide
Breaking Strength
before immersion in oil — > 300 daN / 5 cm.

ISSUE/ REVISION 99/07 01/11 02/08 03/11

© This document and any Information or Descriptive Matter set out herein are the Confidential and Copyright Property of ALSTOM
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OPERATION AND MAINTENANCE
MANUAL FOR
Page 199 of 204
POWER TRANSFORMERS

4. INSTALLATION PROCEDURE

1 Connection to the
inside of Air Cell
2 Connection to the
inside of
Conservator
3 Magnetic Oil
Level Gauge

Mounting Of Air Cell And Oil Level Gauge In Conservator

Fig. 1

Details Of Fixing Air Cell Details Of Hook On

On Conservator On Conservator And
Handle On Air Cell
Fig. 2 Fig. 3

ISSUE/ REVISION 99/07 01/11 02/08 03/11

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OPERATION AND MAINTENANCE
MANUAL FOR
Page 200 of 204
POWER TRANSFORMERS

5. FILLING PROCEDURE WITHOUT VACUUM IN CONSERVATOR

• 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.
• 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.
DO NOT APPLY EXCESS AIR PRESSURE AS IT MAY
DAMAGE THE AIR CELL.
• Open air release valves and start oil filling from the bottom of the
conservator.
• 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.
• 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.

ISSUE/ REVISION 99/07 01/11 02/08 03/11

© This document and any Information or Descriptive Matter set out herein are the Confidential and Copyright Property of ALSTOM
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OPERATION AND MAINTENANCE
MANUAL FOR
Page 201 of 204
POWER TRANSFORMERS

CAUTION:

Ø 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.
Ø 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.
Ø The plain oil level gauge should be monitored on regular basis.
6. 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.

The above mentioned CAUTION regarding the opening of air release

valve after completion of oil filling, remains valid for this case also.

ISSUE/ REVISION 99/07 01/11 02/08 03/11

© This document and any Information or Descriptive Matter set out herein are the Confidential and Copyright Property of ALSTOM
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OPERATION AND MAINTENANCE
MANUAL FOR
Page 202 of 204
POWER TRANSFORMERS

THERMOSIPHON
FILTER

ISSUE/ REVISION 99/07 01/11 02/08 03/11

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OPERATION AND MAINTENANCE
MANUAL FOR
Page 203 of 204
POWER TRANSFORMERS

THERMO SIPHON FILTER

FOR
POWER TRANSFORMERS

1. INTRODUCTION
Thermosiphon filter is provided on large capacity, oil filled Power
Transformers for keeping the moisture level of insulating oil at a very low
level. At the time of initial erection and commissioning of transformer, most of
the moisture present in the oil is removed by hot oil circulation. The moisture
absorption of oil is eliminated by directing the air breathed in by the
transformer during its operation through silica gel desiccant. Air cell in
conservator avoids direct contact of oil with air and thereby eliminating the
chance of moisture absorption.
However, it is a well known fact that water is released to the oil from the paper
insulation due to ageing process. Thermosiphon filter helps in removing this
moisture from oil. When the transformer is on load, the thermosiphonic action
of liquid causes circulation of oil through the filter. The adsorbent filled in the
Thermosiphon filter adsorbs moisture and keeps the oil dry.

2. CONSTRUCTION

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OPERATION AND MAINTENANCE
MANUAL FOR
Page 204 of 204
POWER TRANSFORMERS

Typical arrangement of the Thermosiphon filter is as shown in the figure.

Thermosiphon filters are provided with isolating valves at top and bottom to
enable its removal for maintenance purposes.
3. MAINTENANCE
Thermosiphon filters do not require any routine maintenance. Oil samples
shall be tested periodically and the values of resistivity and tan delta shall be
compared with the values given in the “Operation & Maintenance Manual”. If
the results are within the limits, reactivation of the adsorbent needs to be done
only as part of the annual maintenance.
If there is a rapid deterioration in the values, reactivation of the adsorbent
should be done immediately.

4. MONITORING
The periodicity of oil testing and acceptance criteria is explained in the
Instruction Manual of the Transformer. However, the same is reproduced here
for your ready reference.

a) Periodicity of measurement(Resistivity & Tandelta) : Quarterly

b) Resistivity at 900C : ≥ 0.1x 1012 Ω cm
c) Tandelta at 900C :≤ 1%
(Ref. IS - 1866: 2000)
5. REGENERATION OF ADSORBANT
Regeneration of adsorbent can be done by circulation of hot gas at a
temperature of 180 to 2500 C.
To confirm proper regeneration, the dew point of the purged gas may be
measured and it should be less than –700 C.
For regeneration of adsorbent, dry nitrogen gas is preferred. A continuous
stream of gas is to be maintained during heating and gas pressure is not
important.

ISSUE/ REVISION 99/07 01/11 02/08 03/11

© This document and any Information or Descriptive Matter set out herein are the Confidential and Copyright Property of ALSTOM
and must not be disclosed, loaned, copied or used for Manufacturing, Tendering or for any other purpose without written permission.