1

KIRLOSKAR ELECTRIC
C O N T E N T S
1.0 PREFACE
2.0 INSPECTION AND STORAGE
3.0 INSTALLATION
4.0 TESTING AND COMMISSIONING
5.0 INSTRUCTIONS FOR OPERATION
6.0 MAINTENANCE
7.0 FAULTS AND FAILURES
8.0 SPARES
9.0 WARRANTY
TABLE -1 : APPLICATION AND INTERPRETATION OF TESTS ON OIL IN
TRANSFORMERS
TABLE -2 : RECOMMENDED MAINTENANCE SCHEDULE FOR
TRANSFORMERS OF CAPACITIES LESS THAN 1000 KVA
TABLE -3: RECOMMENDED MAINTENANCE SCHEDULE FOR
TRANSFORMERS OF CAPACITIES OF 1000 KVA AND ABOVE
TABLE -4 : PERMISSIBLE CONCENTRATIONS OF DISSOLVED GASES IN
THE OIL OF A HEALTHY TRANSFORMER
TABLE -5: CODE FOR EVALUATING ANALYSIS OF GAS DISSOLVED IN
MINERAL OIL
APPENDIX -A: DISSOLVED GAS ANALYSIS, FAULT IDENTIFICATION AND
REMEDIAL ACTION.
TABLE -6 : TROUBLE -SHOOTING CHART FOR ALL TRANSFORMERS
TABLE -7 : RECORD OF INSULATION RESISTANCE DURING
DRYING OF OIL
TABLE -8: TYPICAL LOG SHEET
APPENDIX -B : PRE-COMMISSIONING CHECKS
TABLE -9 : RECOMMENDED RECORD OF MAINTENANCE
APPENDIX -C : SITE FAILURE / COMPLAINT FORMAT
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KIRLOSKAR ELECTRIC
1.0 PREFACE
KIRLOSKAR Transformers are desi gned,
Manufactured, and tested to high standards of
practice and, are required to their quality, and
reliability in service.
This manual covers the installation, operation and
maintenance of oil immense distribution and power
transformers including transformers for special
applications.
Careful observation of the instructions presented in
this manual, and regular maintenance, will ensure
continuous trouble free performance of the
transformers.
If any further information is required, it will be
furnished on request, In any communication please
quote the particulars stamped on the transformer
rating plate, including the transformer number.
1.1 Special Note :
The information provided in this manual are given
for information and guidance, and the company
cannot accept the responsibility for the manner in
which they are observed and for any consequences
thereof.
2.0 INSPECTION AND STORAGE
2.1 Inspection on arrival :
Transformers are dispatched from our works in one
of the following ways, depending upon the transport
weight and dimensional limitations.
a. Completely filled with the oil and ready for
service.
b. With all covering the core and windings only
the balance oil being sent separately or
c. With no oil in the tank, the transformer being
filled with dry air, nitrogen or other inert gas at
a small positive pressure, and all the oil being
sent separately.
In the case of large transformers, some of the
external things such as conservator, detachable,
radiators, bushings rollers, explosion vent, Buchholz
Relay etc. are removed and dispatched separately.
Accessories such as dehydrating breathers which
are liable to get damaged in transit are also removed
and packed separately.
The transformer tank generally do not require ay
external protection apart from the hoods temporarily
filled over any projecting terminals. Immediately on
arrival if the transformer at site, a thorough external
examination should be made for any signs of
damage in transit, particular attention being paid to
the following:
a. Tank sides of radiators dented.
b. Protecting fittings damaged.
c. Oil sight glass broken.
d. Explosion vent diaphragm broken.
e. Bushings cracked or broken.
f. Accessories sent in separate packages
damaged or broken. Contents of packages
should be checked as per the packing list
supplied with the dispatch documents.
g. Both loose due to vibration in transit.
h. Oil leakage particularly along the welds if the
transformer is dispatched filled with oil, or
reduction in the pressure of inert gas if the
transformers is dispatched gas filled, In the
case of large transformers dispatched with oil,
the prismatic oil level gauge provided at the
top corner of the tank to indicate the oil level
during transport, should be checked.
Damages, Shortages, Pilferage, theft etc.,
if suspected, should be reported immediately to
the insurance underwriters, the transporter, and to
out nearest branch office. Open delivery is to be
taken and particulars of the damages shortages
should be mentioned on the goods consignment
note by the consignee, so the same can be
investigated and the shortage made up as per the
terms of contract.
When the transformer is dispatched gas filled,
the temperature and pressure at the time of gas
filling will be marked on a tag. On arrival of the
transformer at site, the temperature and pressure
should be checked to ascertained whether there
was any leakage of atmospheric air into the tank
during transit. In case of leakage, it is possible that
the windings may have absorbed moisture, and the
transformer will have to be dried out as detailed
under clause 3.10 Drying of Transformers. If the
pressure is positive and varies with temperature of
the surrounding air, the seal can be taken to be
effective. In case there has been a fall in pressure
the IR values between windings and between
windings and earth should be compared with the
values given in the test certificate. If the IR values
are low, it indicates that the windings have absorbed
moisture. In order to prevent further absorption of
moisture by the windings, and to improve the IR
INSTALLATION OPERATION AND MAINTENANCE
INSTRUCTION MANUAL FOR OIL IMMERSED TRANSFORMERS
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KIRLOSKAR ELECTRIC
values, freshly filtered oil in hot condition is filed
into the tank through a filter machine, and hot oil
circulation is done for 8 to 12 hours to achieve the
required IR values. If the IR values are low and show
no sign of improving, then drying of the core and
windings as explained under clause 3.10 would be
necessary . The IR values at room temperature
and at regular intervals during the drying period
should be recorded as per Table 7 of clause 3.11
and a curve plotted as shown in Fig. 1 (Clause
3,10,2,1) to determine the dryness of the windings.
Drums containing transformer oil which have been
dispatched separately should be examined carefully
for leaks, and any shortage should be improved.
When the transformer is dispatched filled with oil, a
sample of oil should be taken from the bottom of
the tank and tested to IS:335 Specification for new
insulating oils. If the sample of oil does not meet
the requirements, the matter should be reported to
us along with the insulation resistance values of
the various windings to earth.
2.2 Storage:
Transformers received at site and not expected to
be installed immediately are likely to absorb
moisture. Hence it is desirable to erect and
commission the transformer should be erected at
its permanent location with the conservator and
breather fitted, and dry oil filled to the correct level,
if this is also no possible, is then it is preferable
that the tank containing the core and coils be placed
under shed. The tank should preferably be filled
with clean dry oil.
Indoor type transformers should be stored under
cover, preferably filled with oil to reduce the extent
of possible consideration of moisture, and the
breathing pipe should be plugged. Transformers which
are required to be kept in storage for long period
should preferably be drained of oil and the tanks
should be filled with dry nitrogen under slight
pressure. However, if it is necessary to store the
transformer outdoors, it should be covered to prevent
moisture and foreign material from entering into the
tank. When it becomes necessary to store a partially
or completely disassembled transformer, the core
and code dry room having as uniform a temperature
as possible. If the unit is stored outdoors without
oil, moisture may condense in the tank due to
variations of air temperature, and this may be
absorbed by the windings. To avoid this, it should
be filled with nitrogen or any other inert gas.
In case the storage period is long, all accessories
and fragile components, including bushings, if not
mounted on the transformer, should be repacked
and stored carefully under should be stored under
cover with the drums placed on their slides.
When in storage, the gas pressure, oil samples,
dehydrating breather, packages containing
accessories, painted surfaces etc,, should be
examined periodically so that any deterioration can
be checked before lasting damage occurs.
3.0 INSTALLATION
3.1 Compliance with Regulations:
It should be ensured that the electrical installation
complies with the requirements of the Indian
Electricity Act and Rules made thereunder and with
any other statutory regulations that may be
applicable. In this regard, reference may also be
made to IS: 100028 Code of practice for Selection,
Installation and Maintenance of Transformers.
The electrical installation should be carried out only
by authorized persons competent to undertake such
work.
3.2 Precautions:
a. As far as possible no erection work should be
done during rainy season to avoid moisture
absorption by the transformer.
b. Extreme care should be taken to prevent any
foreign material from being dropped into the
transformer. Any Spanners or other tools used
should be securely tied so that they can be
recovered easily if accidentally dropped.
c. Fibrous cleaning materials should not be used.
The presence of loose fibres in suspension in
transformer oil can reduce materially its
insulating properties.
d. All components dispatched separately should
be cleared inside and outside before being
fitted.
3.3 Handling:
Transformers should be lifted by the lugs provided
for the purpose and simultaneous use should be
made of all such lugs in order to imbalance in lifting.
Before lifting the complete transformer, it should be
ensured that at cover both are tightened. Apart from
the main lifting points designed to take the total
weight of the unit, the transformer has subsidiary
lifting points suitable for particular components
only. Care must be taken to distinguish between
them. While lifting the transformer it must be earned
that the wire ropes or chains used, do not touch
delicate parts such as bushings and pipe work.
Where it is necessary to use jacks for lifting, the
jacking lugs provided should never be placed under
valves or radiators.
The crane or jack used for lifting should be of
sufficient capacity to carry the weight of the
transformer safely. The transformer should always
be handled in the normal upright position. During
the handling operation care must be taken to
prevent overturning or even tilting of the transformer.
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KIRLOSKAR ELECTRIC
Sl. No. Description
A UNLOADING
Experienced material handler should be engaged
Suitable crane capacity as per our General Assembly Drawing to be selected
B HAULING
Ensure transformer is mounted on its own roller or on plate with pipes for dragging (Use jack
or crane for lifting up) Use hauling holes with shackles and wire rope for pulling.
C Assembly Details of Tool Required Size of Tool
C1 Roller Assembly Mounting Open Double End Spanner 13x15 25x28 31x33 37x39
C2 Fan Assembly mounting Open Double End Spanner 19x21 25x28
Screw Driver 100 mm long
C3 Radiators mounting Open Double End Spanner 25x27
Ring Spanner 25x27
C4 Radiator Valve(Open/Close) Open Double End Spanner 13x15 19x21
C5 HV/LV Bushing Assembly Open Double End Spanner 16x18 19x21 41x43 64x70 75x80
C6 H.V Turret mounting Open Double End Spanner 19x21
C7 OLTC Mounting Open Double End Spanner 19x21 25x27
C8 Conservator to Tank Oil Feed Open Double End Spanner 19x21 25*27
Pipe Assembly
C9 Equaliser Pipe Assembly Open Double End Spanner 16x18 19x21
C10 OLTC Oil Feed Pipe Open Double End Spanner 16x18 19x21
Assembly
C11 Explosion Vent Assembly Open Double End Spanner 16x18 19x21
3.3.1. RECOMMENDATION OF TOOLS FOR HANDLING
TRANSFORMER ASSEMBLY AT SITE
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KIRLOSKAR ELECTRIC
Sl.No. Description Details of Tool Required Size of Tool
C12 Pressure Relief Value Mounting Open Double End Spanner 16x18 19x21
C13 Hand Holes / Inspection Open Double End Spanner 19x21 25x27
C14 CT Terminal Box Assembly Open Double End Spanner 13x15 16x18 19x21
Openings
C15 Marshaling Box Assembly Open Double End Spanner 13x15 16x18 19x21
C16 Cooler Control Cubicle-Cum Opened End Spanner 13x15 16x18 19x21
Marshalling Box Assembly Box Screw Driver 100 mm long (M5)
Screw Driver 100mm long
C17 Air Valves Assembles Open Double End Spanner 16x18 12x19 25x27
C18 Cable Box / Bus-Duct Open Double End Spanner 16x18 19x21
Assembly
C19 Air Release Plugs Open Double End Spanner 19x21
C20 OTI/WTI fixing of capillary Open Double End Spanner 30x32
Bulbs/ Stem Screw Driver 100 mm long
C21 Lifting of Conservator D-Shackles 16 dia. Rod
Cable Box, Bus Duct, HV Turret J-Hock 16 dia. Rod
C22 Lifting of Radiators D-Shackles 2 Tonnes 16,20 dia rods
Capacity
J-Hock 16 dia
C23 Fixing of FRP Supports Open Double End Spanner 19x21
(Handle with care as it is
fragile)
C24 Fixing of Ladder Anti- Open Double End Spanner 19x21
Climbing device 16x18
C25 Earthing Pad Bolts Open Double End Spanner 19x21
C26 Magnetic Oil Level Gauge Open Double End Spanner 19x21 16x18
C27 Breather Flanged or Screw Open Double End Spanner 19x21
Type Pipe watch
C28 R&D Plate Rivitted
C29 Conservator Support Open Double End Spanner 19x21 25x27
C30 Prismatic Oil Level Gauge Open Double End Spanner 16x18
C31 On-Load Tap Changer (OLTC) Open Double End Spanner Refer Manufacturers O&M Manual
C32 Gas Collection Device Open Double End Spanner 13x15
Screw Drivers 100 mm long
TABLE
Nut Spanner
Size Size
M5 8x10
M6 10x12
M8 13x15
M10 16x18
M12 19x21
M16 25x27
M20 30x32
M24 36x38
M30 46x48
M42 65x67
M48 75x77
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KIRLOSKAR ELECTRIC
3.4 Location of Transformers :
The installation site should be such that there is
easy accessibility for inspection. The transformer
installation position should be such that the breather,
oil level indicator, rating and diagram plate, dial
thermometers, etc., can be safely examined with
the transformer energized. It should also be possible
to have access to the operating mechanism of the
on load tap changer/off circuit tap switch,
marshalling box, etc., The sampling valve, drain
valve, etc., should be at convenient locations.
Transformer installed indoors should be kept well
away from the wall as shown in Fig A to ensure
proper verification and access to accessories. The
site should be so chosen that it is not normally damp
because, besides corroding the tank body and
radiators, the dampness may find its way to the
bushings and may cause them to flashover. There
should be no chance of water dripping either on the
transformer or anywhere in the transformer or
anywhere in the transformer room as they corrode
the tank and also cause the oil to deteriorate.
For indoor installations the air inlets and outlets
should be of adequate sizes and so placed as to
ensure proper air circulation for the efficient cooling
of the transformers.
0.5
0.75
0.75
1.0 1.0
1.0
1.25 1.25
1.25
A- WALL ON ONE SIDE
B - WALL ON TWO SIDES
C - WALL ON THREE SIDES
D - ENCLOSED ROOM
ALL DIMENSIONS IN METRES
FIG. A MINIMUM RECOMMENDED SPACING BETWEEN THE WALLS AND TRANSFORMER PERIPHERY
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KIRLOSKAR ELECTRIC
The minimum clearance between the highest point
of the conservator tank to the ceiling of the
transformer room should be sufficient to remove
the mounting on the transformer like the conservator.
The transformer should be so installed that service
vibrations are not transmitted to its body. Only
transformers designed for outdoor use should be
installed outdoors in case of location where the
atmosphere is polluted, it is desirable that the
transformer is located in a suitable covered shelter
to minimize the adverse effects of polluted
atmosphere. Also care should be taken regarding
cleaning of bushings etc., or otherwise flashover
may occur from the live part of earth.
3.5 Facilities for Maintenance:
In the case of heavy units of equipment, adequate
passageways and doorways should be provided,
where practicable, to allow the passage of the
equipment at a later date for repairs or maintenance
should be considered in relation to the accessibility
of the equipment. For lifting the transformer core
and for handling heavy equipment, it is advisable
to arrange for the incorporation of a lifting beam in
the structure of the building, the beam being located
at a suitable height immediately over such lappets
of the equipment as may require attention and being
capable of supporting the maximum weight involved.
3.6 Foundations:
Special foundation is not required for the installation
of a transformer, except a level floor storing enough
to support the weight and to prevent accumulation
of water. The transformer foundation should
provided with adequate oil soak pits and drains.
For outdoor installations, a level concrete plinth
correct size to accommodate the transformer in
such way that no person may step on the plinth,
should be provided for transformers. Where rollers
are lifted, suitable rails or tracks should be provided,
and when the transformer is in the final position the
wheel should be locked to prevent accidental
movement of the transformer.
3.7 Safety Precautions:
The transformer should be so installed that there is
no risk of anyone receiving an electric stock. With
all metal parts of the metal tank bonded together
and properly earthed, the tank may be considered
quite safe. With the use of cable boxes and terminal
boxes the terminals are well protected. However, if
the metal lends of the bushings are exposed,
precautions working near the transformer from
accidentally touching the live parts. For complete
safely it may be necessary to provided an enclosure
for the transformer with a door or gate which may
be kept locked when the transformer is energized.
In order to limit the spread of fire in the event of
ignition of insulating oil, fire protection walls may
be necessary on either side of large and costly
transformers for isolating each transformer from the
rest.
3.8 Oil:
The oi l suppl i ed wi th the transformer i s a
hydrocarbon mineral oil, clean and sufficiently free
from moisture and other foreign matter, and
conforming to the requirements of the latest issue
of IS:335 for insulating oil; it must be ensured that
when fresh oil is used for topping up or refilling,
only new oil complying in all respects with the
requirements of the above specification is used.
Table 1 gives the values of permissible limits for
various characteristics of the oil.
3.8.1 Precautions:
a. Oil is easily contaminated. It is very important
when sampling the oil and filling the tank, to
keep the oil free from contamination.
b. Flexible steel houses are recommended for
handling insulating oil. Ordinary rubber houses
should not be used since the sulphur in the
rubber woul d di ssol ve i n oi l , thereby
contaminating the oil, causing the dielectric
strength of the oil to be lowered, and also the
dissolved sulphur would attack the copper in
the windings. The hose used for handling
should be clean and free from loose rust and
scale.
c. Transformers must always be disconnected
from the electricity supply system before the
oil level in the tank is lowered.
d. Oil must not be emptied near naked lights, as
the vapour released is inflamable.
e. It is preferable not to mix oils from different
sources. Compatibility tests may be required
to determine the feasibility of mixing new oils
of different type and origin, or new oil with oil
in service, if the make up is more than 5
percent. The main characteristics of the
mixture, including oxidation stability should not
be less favourable than those of the worst
individual oil. Topping up should preferably be
with unused insulating oil conforming to IS:335.
In no case should the properties of the oil
added be worse than those of the in-tank oil.
Unused oils conforming to IS:335 are
considered to be compatible with each other
and can be mixed in any proportion.
3.8.2 Sampling:
Oil takes up moisture readily and its condition should
always be checked before use. Oil of a muddy colour
is certain to be wet. Water and water saturated oil
are both heavier than dry oil and sink to the bottom
of any container. Samples of oil should therefore be
taken from the bottom of the transformer tank or
drum after the oil has been allowed to settle for
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KIRLOSKAR ELECTRIC
atleast 24 hours if from a drum, or 2 to 3 days if
from large transformer. However the oil sample will
be more representative of the bulk it is drawn while
the transformer is still hot from recent loading and
hence recent circulation. Reference may also be
made to IS:6855. Method of sampling for liquid
dielectrics.
3.8.2.1 Receptacles for Samples:
Receptacles for samples should preferably be
bottles of clear glass with ground glass stoppers
and 1 litre capacity. Sample bottles should be clean
and dry. Touching the inside of a receptacle with a
damp hand or wiping round with an apparently clean
dry cloth may seriously reduce the breakdown
strength of a sample of good oil.
3.8.2.2 Samples from Tank:
When taking samples from the tank all dirt from the
sampling valve or plug should be removed. To
ensure that the valve is clean, allow some oil flow
into a separate container before collecting samples
for testing. Samples should be collected in clear
glass receptacles so that any water present will
settle at the bottom of the receptacle and will be
clearly visible.
3.8.2.3 Samples from Oil Drum:
Before taking samples from an oil drum, the drum
should be allowed to stand with the bung vertically
upwards for atleast 24 hours. The areas around the
bung should be cleaned carefully. A clean glass or
brass tube long enough to reach within 10 mm of
the lowermost part of the drum should be inserted,
keeping the uppermost end of the tube tightly closed
with the thumb. The thumb should then be removed
to allow oil to enter the bottom of the tube. The top
of the tube should again be lightly closed and the
oil sample withdrawn. The first two samples should
be discarded.. Thereafter, the samples should be
released into a suitable receptacle.
3.8.3 Testing of oil:
The oil after filtration should meet the requirements
as laid down in IS:335. However, to know the
condition, the following preliminary tests can be
carried out.
a. Electric Strength:
Before commissioning a transformer, a sample of
oil should be taken from the bottom of the transformer
tank and its electric strength ascertained in
accordance with the method described in IS:67321.
Method for determination of electric strength of
insulating oils. The oil should withstand the voltage
specified in Table 1 for one minute when tested in a
standard test set. Failure in the electric strength
test should be taken as indication that filtration of
the oil is required. The electric strength test should
be repeated after oil filtration.
b. Crackle Test
If however a standard test set is not
available, a rough test set is not available, a rough
test, generally known as Crackle Test may be made
by closing one end of a piece of steel tubing,
heating the closed end to just under dull red heat
and plugging it into the oil sample with the ear close
to the open end. If the oil contains much moisture,
a sharp crackle will be heard. Dry oil will only sizzle.
The crackle test is based upon the fact that the
presence of quite minute amounts of the free water
(i.e., undissolved water) can be detected by the
audible crackle caused by its instantaneous
expansion to vapour as a result of very rapid heating
to well above its boiling point.
If moisture is present, the oil should be filtered
until the electric strength is satisfactory.
3.9 Oil filling:
Before filling with oil, the transformer should be fitted
with all accessories such as valves, gauges,
thermometers and plugs, and made oil-tight. The oil
used for filling should be tested to meet the
requirements as laid down in IS:335. In case the oil
does not meet the requirements, it should be
processed, and should only be used when it meets
the requirements.
It should be ensured in oil filling operation that no
air pockets are left in the tank, that no dust or
moisture enters the oil, and that it is atleast as warm
as the surrounding air. Oil should be filled through
centrifuge or filter press type of oil filter using flexible
sheet hoses or hoses of completely oil resistant
material. To prevent aeration of the oil, the
transformer tank should be filled through the bottom
drain valve. In a conservator type of transformer,
the rate of oil flow should be reduced when the level
is almost upto the bottom of the main cover to
prevent internal pressure from rupturing the
explosion vent diaphragm.
After the oil has been added to the correct level,
trapped air should be released from the equipment
by carefully unscrewing all the venting plugs.
Depending on the fittings, these will be located on
the main transformer tank, tap charger tank,
radiators, and all other parts which are not vented
by pipe connections. The Plugs should remain
unscrewed while hissing of escaping air continues
and tightened down when oil begins to overflow. Air
should be released when the gas operated relay by
opening he top petcock. After venting, the oil level
should be checked and further topping up carried
out until the required level is again reached.
Sufficient time (12 to 24 hours) should be allowed
for the oil to permeate the transformer and for the
locked-up air bubbles to escape. The sides of the
transformer tank may be tapped with a hammer to
9
KIRLOSKAR ELECTRIC
release locked up air. An alternate method for
removing the trapped air from large transformers is
to keep the transformers energised at no load for
about 6 to 12 hours at the end of which the air cocks
on the transformer are opened to allow the released
air to escape.
Vacuum filling may be used for large transformers
with tanks designed to withstand full vacuum. A
vacuum pump may be connected to the top valve
of the transformer and the oil hose to the top filter
press valve. The tank shall be tightly sealed and
evacuated and oil hose to approximately 700 mm
of mercury and the vacuum maintained for 2 hours
or longer depending on the seize and voltage of the
transformer. The oil valve may then be opened and
the oil allowed to flow slowly into the tank. The
vacuum should be maintained for a short time after
the tank is full. Filling of oil inside the tank is done
under vacuum for transformers despatched gas
filled.
Some radiators may be suitable only for
partial vacuum. No higher vacuum than that which
could be withstood by the radiators assembled, even
if the radiator valves are closed. It should also be
ensured that the bushings, tap changer board,
explosion vent diaphragm, buchholz relay,
conservator, etc.,, are not subjected to full vacuum
as they are not generally designed for the same.
In case the transformer is provided with an on-
load tap changer, while evacuating the main
transformer tank, the diverter switch compartment
may also be evacuated simultaneously so that no
undue pressure is allowed on the tap changer
chamber. While releasing vacuum, the tap changer
chamber vacuum shoul d al so be rel eased
simultaneously.
3.10 Drying of Transformers :
The transformer i s thoroughl y dri ed after
manufacture, before tanking, so that drying out on
site should not be necessary. If however as a result
of tests carried out on the oil in accordance with
clause 3.8.3 presence of moisture is indicated, or
the i nsul ati on resi stance readi ngs are not
satisfactory, it will be necessary to dry out the
transformer.
3.10.1 Precautions when drying:
a. Only spirit type thermometers should be used
for temperature measurement. Mercury
thermometers should not be used anywhere
except in the pockets provided for the purpose.
b. In no case should the transformer be left
unattended during any part of the dry out period.
The transformer should be carefully watched
throughout the dryout process and al l
observations should be carefully recorded.
c. It is necessary to ensure that the fighting
equipment is available near the transformer
when it is being dried out.
3.10.2 Methods of Drying:
The process of drying out a transformer is one
requiring care and judgement. If the drying out
process is carelessly or improperly performed, great
damage may result to the transformer insulation
through overheating. Various methods can be
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KIRLOSKAR ELECTRIC
adapted for drying out a transformer depending upon
the facilities available at site. The methods generally
adopted are described below.
3.10.2.1 Drying out a transformer using
Filter Machine:
The most practical method of drying out is by
circulation of hot oil through a streamline filter
machine incorporating oil heater and vacuum
chamber. The vacuum pump of the filter machine
should have the capacity of creating vacuum as
high as possible but not less than 710 mm of
mercury. It is preferable to lag or blanket the
transformer tank to prevent loss of heat. To start
with, oil is drawn from the bottom and let into the
transformer at the top. This will remove any settled
moisture/ impurities. After about 8 to 12 hours
circulation in this manner, the cycle is reversed, i.e
oil is drawn from the top and fed at the bottom.
The oil temperature as measured by the oil
temperature indicator should be of the order of 60
O
C. It should be seen that the oil temperature at the
filter machine in no case exceeds 70 degree
Celsius. The circulation is continued till the
i nsul ati on resi stance and oi l sampl es test
satisfactorily.
Plot IR values taken at regular intervals against
temperature readings. It will be observed that in the
beginning IR values drop down as the temperature
goes up. The IR values will be low while moisture is
coming out of the insulation, and then starts rising
before steadying. A typical dry-out curve is shown
in Figure 1. The heat can also be provided by short
circuit heating method as mentioned in clause
3.10.2.2.
3.10.2.2 Drying with core and coils in oil by the
short circuit method.
In this method , the core and windings are
immersed in oil. The oil level in the tank is lowered
a few centimeters below the main cover below the
drying is started. The diaphragm of the relief pipe is
removed and the inspection covers are raised by
about 15 cm to allow moist air to escape during
drying. All openings should be protected from the
weather. The top of the main cover and relief pipe
shoul d be thoroughl y l agged to prevent
condensation of moisture. Radiation from radiators
may be prevented by lowering the of bellow the top
inlets. If radiators are provided with valves, the top
valve may be closed to prevent circulation.. Both
the valves should not be closed since high pressure
caused due to expansion may damage the valves.
If the transformer is provided with tappings, the
connections should be so made that all the windings
is including in the circuit so that the entire winding
can be dried. Filtering the oil through a circulating
type oil filter during drying out will aid materially in
removing the moisture and in maintaining a uniform
temperature of oil at all levels, and will also hasten
the process of drying.
The transformer is heated up by short circulating
one of the windings by means of conductors capable
of carrying continuously the full load current of the
shorted winding and applying a suitable voltage on
the other. Normally, the low voltage winding is short
circulated and a reduced voltage is supplied at the
high voltage terminals. The supply voltage should
be maintained in such a way that the short circuit
current in the windings does not exceed 70 percent
of normal full load current. The current values should
be so adjusted as to maintain the temperature of oil
at about 65 to 70
O
C constant watch is to be kept to
ensure that the temperature limits are not exceeded.
The temperature of the windings,which can be
measured by the following formula, should in no
case exceed 90
O
C:
R
2
T2= (235+T1)-235
R
1
Where
T2 = Final average temperature of copper
T1 = Initial average temperature of copper
R
2
= Final resistance of the windings
R
1
= Initial resistance of the windings
The voltage and current readings are taken
by means of an ammeter and a voltmeter in the
supply circuit, which must be provided with suitable
fuse protection. For the measurement of top of
temperature, pour transformer oi l i nto the
thermometer pocket on the tank cover and insert a
standard strai ght steam al cohol -i n-gl ass
thermometer. Spot bulb thermometers are preferred
to mercury bulb thermometers since they are no
affected by stray magnetic fields.
The i nsul ati on resi stance shoul d be
measured every hour with a meggar, and the
temperature of the top oil recorded, when the latter
reaches a values of 70
O
c the supply to the
transformer should be switched on again. This
procedure should be continued throughout the drying
out period, readings being taken every hour, until
all insulation resistance being taken every hour, until
all insulation resistance readings reach a value of
not less than 100 megohms. Please note that before
taking Megger readings the supply leads should be
temporarily removed from the HV terminals so that
no external equipment is included in the test. It is
important to continue the drying out process without
a break, maintaining the temperature of the oil in
the transformer at a specified value of say 70
O
c,
and a log sheet should be maintained.
11
KIRLOSKAR ELECTRIC
Drying should be continued until oil from the top
and bottom of the tank attains the minimum
breakdown voltage specified in Table 1 to 7
consecutive tests taken 4 hours apart , when tested
as described in clause 3.8.3(a). Thereafter oil should
be maintained at the maximum temperature for the
load held without filtering. All ventilating openings
should then be closed and the transformer kept at
the same temperature for another 24 hours without
filtering the oil, and as before the oil should be tested
at 4 hours intervals. A decrease in the dielectric
strength of the oil indicates that moisture is still
passing from the transformer into the oil. Unless
constant or increasing dielectric strength is shown
by the tests, the ventilators should be kept open,
the oil filtered and the drying continued till dielectric
strength of oil and the insulation resistance of
windings are altogether satisfactory.
3.10.2.3 Drying with oil removed:
a. By internal heat
The transformer should be left in its tank without
the oil and the cover is lifted to allow free circulation
of air. One of the windings should be short circulated
and sufficient voltage impressed across the other
winding to circulate enough current in the coils to
maintain the temperature of winding measured by
change in resistance at about 80
O
C to 90
O
C. The
impressed voltage necessary to circulate current
varies from 0.5 to 1.5 percent of normal voltage
depending on type and size of the transformer.
The amount of current may be controlled by a
rheostat.. This method of drying is slow and
superficial and should only be used with small
transformers and when local conditions prevent use
of other methods.
b. By external heat:
The transformer is placed in its own tank without
oil. Externally heated air is blown into the tank at
the bottom through the main oil valve. A smaller
blower or fan should be used to get the proper
circulation suitable baffles should be provided in
order to force as much of the heated air as possible
through the ducts in the transformer windings.
Heated air can be obtained by blowing air through
heated grid resistors housed in a fireproof box. The
temperature of the air entering from the grid should
not exceed 115
O
C. The temperature of the winding
should be maintained at 80 to 90
O
C. The temperature
of windings should be measured frequently by
resistance measurements to make sure that the
transformer is not overheated.
Heating of air may also be done by direct combustion
but it is essential that none of the products of
combustion is allowed to enter into the transformer
tank. Heati ng of ai r by combusti on i s not
recommended except where electricity is not
available.
It is essential that every precaution be taken to
prevent fire when drying out by this method. The
set- up should be watched very carefully during the
entire drying operation. It the blower should shop,
the grid current should be switched off at once to
prevent overheating.
c. By both external and internal heat:
This is a contribution of methods given in 3.10.2.5
(a) and (b) above. The transformer should be placed
in its own tank, if possible, and all precautions taken
as outlined fewer than 3.10.2.3.(b). .The current
circulated in the windings should of course, be less
than that when drying out is done in accordance
with 3.10.2.3.(a) only.
3.10.2.4 Drying under vacuum:
The vacuum method employing either external or
internal heat is a quick and effective way of drying
transformer insulation.
Large transformers may be dried in their own tasks
by this method if that tanks can safely withstand
the external pressures resulting from a vacuum of
635 mm or more. The vacuum will be drawn from
the top of the tank. Except for the vacuum tight
tank, the drying procedure shall, in general, follow
that described for the short circuit methods for
transformers less than 5,000 KVA, 66 kV. KV.. For
transformers of rating 5,000KVA and above, or
voltage 66KV and above, it may be necessary to
use additional means to distribute the head to all
parts of the insulation.
One method of distribution the heat is to blow hot
air through the transformer in addition to circulating
current in the windings. This makes use of external
and internal heat.
Another method is to cover the coils and insulation
and to heat by circulating current in windings. With
both methods the maximum temperature of the
insulation should be raised slowly to approximately
55
O
C in the first 8 hours; to 65
O
C in the second 8
hours; and 75
O
C or 80
O
C temperature has been
reached, the transformer should be disconnected
from the source of power and if oil is used to distribute
the heat, the oil should be drained out and a vacuum
applied immediately. The vacuum should be a
minimum of 635 mm but preferably 710 mm. The
vacuum should be maintained until the transformer
is dry or until the temperature drops to 50
O
C when
the heat should be applied again and the cycle
repeated. Megger readings should be taken every 3
to 4 hours and the drying process continued until
the megger readings rise and become constant.
The drying time after the vacuum has been obtained
may vary from 8 to 150 hours or longer depending
on the temperature, vacuum, size and condition of
the transformer, and the drying set-up. After the
12
KIRLOSKAR ELECTRIC
transformer is once thoroughly heated, it is possible
to keep the temperature up by circulating a low
current (Usually 10 to 20 percent of the normal)
periodically for a short time. Check the temperature
rise of copper in vacuum may be very rapid and the
insulation may be overheated unless extreme
caution is used until the amount and time of heating
are determined by measurement. The temperature
of the copper should be checked by resistance
measurement as there is no other satisfactory
method to measure copper temperature when the
coils are in vacuum. If the current is circulated in
the windings under vacuum, the voltage should be
kept to a minimum because the dielectric strength
of air under partial vacuum is low. For this reason,
it is generally better to short-circuit the high voltage
winding and circulate the current from the low voltage
winding.
3.11 Measurement of Insulation Resistance:
The measurement of insulation resistance is of
importance in determining the status of drying only
when the transformer is without oil.. If the initial
insulation resistance is measured at ordinary
temperature, it may be high although the insulation
is not dry , but as the transformer is heated up, the
insulation resistance value drops rapidly.
As the drying proceeds at a constant temperature,
the insulation resistance will generally increase
gradually until towards the end of the drying period
when the increase becomes more rapid. Sometimes
the resistance rises and falls through a short range
one or more times before reaching a already high
point which is caused by moisture in the interior
parts of the insulation working its way out through
the outer portions which were dried at first.
As the temperature varies, the insulation resistance
also varies greatly. Therefore, the temperature
should be kept nearly constant and the resistance
measurements should all be taken at as nearly the
same temperature as possible. The insulation
resistance in megohms varies inversely with the
temperature and for a 10
O
C change of temperature
the megohms change by ratio of 2:1. Measurements
should be taken every 2 hours during the drying
period, and a record of insulation resistance is kept
as given in Table7.
The insulation resistance should be measured by
atleast 1000V megger. Every time the voltage
should be applied for 1 minute.
The insulation resistance should be taken with all
windings earthed except the one being tested.
3.12 Mounting of Fittings and Accessories:
All components and parts removed for transport
and dispatched separately should be cleared
thoroughly and fitted on the transformer at site after
the transformer is placed in its final position. The
transformer outline drawing supplied with every order
should be referred to for correct mounting of the
accessori es. The fol l owi ng sequence i s
recommended for mounting of the accessories.
3.12.1 Mounting of Rollers:
1. The transformer should be lifted either by an
overhead travelling crane of adequate capacity
or by applying hydraulic or mechanical jacks
at the jacking pads provided on the transformer
tank.
2. Fit the roller assembly to the transformer under
base or its extension after checking that the
rollers run freely.
3. Place the transformer on its foundation and look
the rollers either by means of locks or by driving
wedges or angles in the foundation, to prevent
accidental movement of the transformer.
3.12.2. Mounting of Conservator:
1. The conservator is aligned in the desired
position as shown in the outline drawing and
boiled to the brackets or supports, and the
supports are in turn boiled to the main tank
cover.
2. Assemble the paperwork making sure that the
pipework is clean and free from moisture, and
that all gasket joints are of tight.
3. The mechanism of the float type oil gauge inside
the conservator might be locked to prevent
damage during transit, and it should be released
after placing the conservator in position.
3.12.3. Mounting of Buchholz relay:
1. Before fitting the gas operated Buchholz relay
into position, ensure that the floats are free.
2. The Buchholz relay is mounted on the pipe
connecting the conservator to the main tank.
The relay is correctly mounted when the arrow
on the casing is in the direction of the
conservator.
The angle of incineration is also to be checked
and should be between 3 and 7 degrees.
3 Check the relay for correct functioning of the
mercury switches by injecting air through the
test petcock when full of oil.
3.12.4 Mounting of Dehydrating Breather:
1. The breather is mounted on the breather
extensi on pi pe, whi ch i s fi tted to the
conservator. Ensure that the breather pipe work
is properly cleaned.
2. The oil level in the oil seal at the bottom of the
breather should be filled to the correct level
with transformer oil.
13
KIRLOSKAR ELECTRIC
3. Ensure that dirt, etc do not block the breathing
hole at the bottom of the seal.
4. Ensure that the silicagel filled into the breather
is blue in colour.
3.12.5 Mounting of Explosion Vent
1. The temporary cover, which is provided over
the explosion vent flange on the tank cover,
should be removed and the explosion vent will
be usually mounted facing the LT side of the
transformer.
2. Pressure equator pipe is fitted.
3. Check the blakelised paper diaphragm and
ensure that the top diaphragm with its gaskets
makes an air-light joint.
3.12.6. Mounting of Pipework:
The associated paperwork includes the main tank
of feed pipe, breather extension pipe, and pressure
equalizer pipe and explosion vent pipe. The outline
drawing supplied along with the transformer
indicates the appropriate positions of the various
pipes. The mounting of the pipework should be
carried out as follows:
1. Check that all welded joints in the pipe are out-
lighted by passing hot oil at 100
O
C.
2. Check that all the pipes are clean. If necessary
clean by flushing hot dry oil through them.
3. Remove blanking plates fitted on the openings.
Fill the pipes at the appropriate locations with
suitable gaskets, and check that the joints do
no leak.
3.12.7. Mounting of Bushings:
The bushings should be carefully inspected
for cracks or chips and thoroughly cleaned before
installing them, making sure that the gaskets are in
their proper places. Nuts or bolts, which exert
pressure on the porcelain, should be tightened evenly
or else the bushings may crack. Arcing horns it any
should be fixed in the proper position.
3.12.8 Mounting of radiators:
1. Remove the blanking plate provided on the
flanges on the transformer tank and on the
detachable type radiator, after ensuring that the
shut-off valve is closed.
2. Thoroughly clean and flush the radiator with
clean dry transformer oil before assembly.
3. Lift the radiator until and bolt it to the tank at
the flanges with suitable gaskets.
4. Open the air release plugs at the top of the
radiator. After ensuring that the top shut-off
valve of the radiator is closed, open the bottom
shut-off valve slowly. The radiator gets filled
with oil. Close the air release plug at the top
when the oil starts coming out through it.
5. All the radiators are mounted and immediately
filled with oil as described above, making sure
that oil in the conservator is maintained at
the required level by continuous topping-up.
6. After all the radiators are mounted, the air
release plugs are opened once again, and it
should checked that the oil coming out does
not contain any air bubbles. The plugs are
then closed and the radiator top shut-off
valves are opened.
7. Check the level of oil in the conservator and
top-up if necessary.
8. Anti-vibration stiffeners if provided, should
be filled on the radiators.
3.12.9 Mounting of Temperature Indicators:
Before insulating, the accuracy of the
instrument should be checked by hot oil or water
bath. The switches should be adjusted to make
contact at the desired temperature depending upon
the site conditions, i.e., ambient temperature,
loading conditions, etc.
For a self-coded (ONAN) transformer having
a guaranteed temperature rise at rated KVA of 50
O
C
as a measured in top oil by thermometer, and 55
O
C
average winding rise by measurement of resistance,
the recommended settings of the alarm and trip
contacts of the oil temperature indicator (OTI) and
working temperature indicator (WTI), are as follows:
ALARM TRIP
OTI: 67
O
C 77
O
C
WTI: 88
O
C 98
O
C
The above settings are based on a weighted
average annual ambient temperature of 32
O
C as per
IS:6600 Guide for loading of oil immersed
transformers. At other ambients, the temperature
settings will have to be correspondingly changed.
For forced air cooled (ONAF) transformers, the
recommended setting of the contracts of the WTI
for control of cooling fans, and the settings of the
alarm and trip contracts of the OTI, will be indicated
in the transformer test certificate.
The temperature rise is the difference between the
temperature of the transformer part under
consideration and the ambient temperature is the
highest temperature inside the transformer winding.
It is greater than the measured average temperature
of the winding conductors. The average temperature
rise of winding is the temperature rise of winding is
the temperature rise of winding conductors. The
average temperature rise of the winding is the
temperature above ambient due to the unit operating
at full load rating. The hottest-spot temperature rise
corresponding to a winding rise (by resistance) of
55
O
C for a transformer with natural oil circulation,
14
KIRLOSKAR ELECTRIC
is calculated as follows:
Average winding temperature rise
(Measured by resistance) = 55
O
C
Top oil temperature rise = 50
O
C
Mean of temperature rise = 50
O
C x 0.8 = 40xC
Gradient = 55
O
C 40
O
C = 15
O
C
Hottest-spot temperature rise
= Top oil temperature
rise + 1.1 x Gradient
= 50
O
C + 1.1 x 15
O
C
= 66.5
O
C or say 66
O
C
It must be kept in mind that the transformer
temperature i ndi cator gi ves an operati ng
temperature, and not a temperature rise. To
determine the temperature rise in an in service
transformer, subtract the ambient, temperature from
the indicated temperature. For example, if a
transformer rated for 66
O
C (hottest-spot rise) is
operating in a 32
O
C ambient, the indicated operating
temperature of winding should be no greater then
98
O
C if the insulation is to have normal life
expectancy.
Care must be taken when installing the temperature
indicators that the instruments are mounted
vertically and the capillary tubing is not bent sharply
or kinked. On no account should the capillary tube
be cut.
The transformer pocket into which the temperature
sensitive element is placed, should be filled with
transformer oil.
In the case of large transformers, the winding
temperature indicator and oil temperature indicator
will be housed inside the marshalling box, which is
mounted on the transformer.
3.12.10 Mounting of cooling fans:
In the case of ONAF cooled transformers, the
cooling fans should be tested for insulation value
and normal running before they are mounted.
3.12.11 Installation of Cooler Control Cubicle:
1. The operation of the cooling fans is controlled
from the cooler control cubicle, which is
installed at a suitable location near the
transformer.
2. The electrical connection top the fans are made
the operation of the fans and the control cubicle
is checked.
3. Check that the fans rotate in the correct
direction so as to blow air on to the radiators.
3.12.12. Cable Boxes:
If the transformer is fitted with cable boxes
and is to be connected by paper insulated cables,
the cable ends should be sealed to prevent their
absorbing moisture.
In case it is required to fill the cable boxes with
compound. It is recommended that all cable
terminations are made and the cable boxes
compounded under the direct supervision of a
qualified cable jointer.
Care must be taken with the cable box to obtain
compound tight and weather tight joints. Cork
gaskets are usually provided for the gland joint and
also for the cover plate joint.
The weight of the cable must be supported at all
times of the bushings until the gland is finally
secured in position.
The preparation of the cable should be entrusted to
a qualified cable joiner since the methods and
proportions of the taping crepe lengths, etc, depend
on the circuit ,voltage and type of cable used, and
since the cable insulation can be easily ruined by
unskilled handling.
After the cable end has been prepared, and after
ensuring that the interior surfaces of the box and
insulators are dry, clean and free from rust, the
detachable portion of the box and the gland should
be bolted in position after first treating the joint
surface to render them compound and weather tight
as previously described.
Dirt, damp or overheating will seriously impair the
insulating properties of compound .
Although the viscous compound can be poured all
normal temperature, it must be first heated to
approximately 105
O
C to dry of any moisture, which
may be present. Any frothing or cracking must cease
before the compound is poured.
Always use a clean, dry bucket or container for
melting compound and avoid direct contact between
the container and a fierce flame by interposing a
thick sheet of the container should be melted first
to allow heating. Stirring is essential whole melting
and the compound must not be poured until the
manufacturer specified temperature has been
reached and any frothing or cracking has ceased. If
the latter persists, the compound should be
discarded. The temperature of the compound should
be measured with a thermometer.
Before lifting, the box and cover plate should be
evenly heated by means of blowpipe unit just too
hot to touch. Heating should be maintained on the
continued at this temperature until no moisture is
present.
Care should be taken to open all air vents before
filling and to pour the compound slowly and steadily.
15
KIRLOSKAR ELECTRIC
Avoid air locks forming. The compound should not
be poured directly into the box, so as to avoid
cracking them.
Heating should be maintained on the outside of the
box for about one quarter of an hour after the box
has been filled, to drive any air bubbles to the surface.
To prevent chilling at the sides and to avoid local
overheating., the heat should be played evenly over
the surface of the box.
3.12.12.1 LV Cable Box Assembly
Procedure at Site
Refer page 31
3.12.13 Marshalling Box:
The control wiring from the alarm/trip contracts of
the winding temperature indicator oil temperature
indicator, Buchholz relay, and magnetic oil level
gauge is terminated inside wiring diagram supplied.
.The outgoing connections from the marshalling box
to the control room should be done using suitable
multicore PVC copper control cables.
3.13 Gaskets:
Synthetic rubber bonded cook gaskets can be used
for all oil light and air tight joints, care being taken
that they are securely and uniformly champed and
the metal surfaces are free from oil, rust, scale etc,
When tightening the cover bolts, they should be
tightened with care, slowly and uniformly increasing
the pressure. An unevenly compressed gasket may
spring up a lead. If oil leaks cannot be stopped by
retightening, new gaskets should be used. When
covers bushings, or radiators are removed, the old
gaskets should be replaced by new ones when the
unit is reassembled.
Gaskets should be stored in hermetically sealed
containers in a cool place and protected from damp,
oil and grease.
3.14 Completion of erection work
After the erection work is completed, final topping
up is done with clean dry oil to a level in the
conservator commensurate wi th fi l l i ng oi l
temperature, and the interposing valves between
the radiators and the tank are opened
The external wiring of the various alarm/trip
contracts, fan motors , and other apparatus should
be installed in accordance with the external wiring
diagram.
Earthing of the neutral should be carried out. The
tank should be effectively earthen before making
the equipment alive. Earthing pads are provided for
this purpose and the positions are shown on the
transformers outline drawing supplied with every
order .For transformers with bushings on the cover,
a small copper strip to bridge the top cover of the
transformer and the tank should be provided to
avoid earth fault currents passing through the
fastening bolts when there is a lighting surge, high
voltage surge, or failure of bushings.
The tank surface should be retouched with paint
wherever required and the transformer is make
ready for the commissioning tests.
4.0 TESTING AND COMMISSIONING
If the foregoing instructions have been carefully
followed, the transformer can now be safely put
into service after pre-commissioning tests.
It is advisable to keep a record of the various pre-
commissioning checks made, as per
4.1 Pre-commissioning Tests:
The following pre-commissioning tests should be
carried out.
4.1.1 Checking of Ratio, Polarity and phase
Relationship:
Using a turns ratio meter, the ratio should be
checked on all taps and between all the windings
and the result should tally with the values indicated
in our test report.
The polarity and interfuse connections should also
be checked.
4.12 Measurement of Winding Resistance:
The resistance of windings should e measured
using a Kelvin Bridge meter. Tapped winding
resistance should be measured at all taps.
4.13 Insulation Resistance:
The IR values between windings and between
windings to earth should be checked. While
checking IR values, no external lines, lighting
arrests, etc, should be in the circuit. Bushings
should be thoroughly cleaned before taking IR
values. A 2500 V or 1000 V Megger preferably
motor operated, should be used for measuring IR
values. Care should be taken that the lead wires
of the Megger do not have joints.
4.1.4 Magnetising Current and Iron Loss:
A three-phase 415v supply is given to the HV
winding of the three-phase transformer and
simultaneous current readings of the three phases
are taken. The watt input during this test should
also be measured and compared with the value
indicated in our test report.
4.1.5 Tap Changer:
Check that the taps operate simultaneously on all
the phases. For transformers provided with off
circuit tap switch, check whether the mechanical
operation including the looking arrangement is
satisfactory.
16
KIRLOSKAR ELECTRIC
For transformers provided with on load tap changer,
check should be made for the following.
a. Whether manual operation is satisfactory
b. Whether l ocal el ectri cal operati on i s
satisfactory
c. Whether remote electrical operation is
satisfactory.
d. Whether operation beyond end positions is not
possible.
e. Whether all lamps, buzzers etc are working
satisfactorily.
TITLE : OPERATION OF LINEAR TAPSWITCH
At factory, after all routine and type tests
(wherever applicable) the tapswitch is set at
normal tap position i.e., Tap corresponding to
nominal primary voltage. To change the tap to
different tap position, adopt the following
procedure.
1. Based on the primary voltage prevailing at that
point of time, select the tap number referring
to rating and diagram plate.
2. Unscrew the locking head (Red in colour)
3. Pull up the control knob (Black in colour)
4. Ensure the slot in the control knob (Black in
colour) is cleared off from positioning ring
(Metallic Indicator)
5. Rotate the control knob to the required tap
position as selected in item-1 above.
6. Push down the control knob (Black in colour)
such that the positioning ring is in correct
position.
7. Screw the locking head (Red in colour) by
turning the same clockwise.
4.1.6 Buchholz Relay:
a. Check that the arrow on the casing points
towards the conservator.
b. Check that the inclination of the pipe is proper
by placing a spirit level on the top of the relay.
c. Check the alarm and trip circuits by injecting
air through the test petcock.
d. Check that there is no air trapped in the
Buchholz relay.
e. Check that the test knob (inside the terminal
box) is on service mode. If not shift knob to
service mode.
4.1.7 Magnetic Oil Level Gauge:
The float level of the magnetic oil level indicator is
moved up and down between the end positions to
check that the mechanism does not stick at any
point. The operation of the low of level alarm of the
oil gauge should be checked.
4.1.8 Temperature Indicators:
The contacts of the WTI and OTI for alarm and trip
should be checked and set at the required
temperatures depending upon the ambient
temperature and loading conditions.
Check that the pointers are not locked.
4.1.9 Dehydrating Breather:
Check that the color of the silicagel is blue. Check
that the bottom sealing cup contains oil.
4.1.10 Bushings:
Check whether line connections have been properly
done. Also ensure that arcing horn gaps have been
properly set.
4.1.11 Fans and Pumps:
It should be checked that the specified number of
fans are mounted as indicated in the transformer
outline drawing supplied. The IR values and settings
for operation of fan motors and pumps should be
checked. Also check that the direction of rotation
of fans and pump is correct.
4.1.12 Marshalling Box:
The wiring from the various accessories to the
marshalling box should be checked.
4.1.13 Oil:
Oil samples from the top and bottom of main tank,
conservator on l oad tap charmer tank,
radiators, etc, should be tested as per IS:335.
4.1.14 General Checks
a. Check whether all oil valves are in correct
position, closed or opened as required.
b. Check that no air pockets are left in the tank.
c. Check that all thermometer pockets are filled
with oil.
d. Check whether oil is at the correct level in the
conservator, on load tap changer tank,
bushings, etc.
e. Check whether earthling connections have been
properly done.
LOCKING
HEAD
CONTROL
KNOB
POSITIONING
RING
17
KIRLOSKAR ELECTRIC
f. Check heaters wherever provided, in cubicles,
marshalling box, conservator etc,
g. Check the pressure gauge readings on both
water and oi l si des of OFW cool ed
transformers, and ensure that the water
pressure is less than the oil pressure. The
quantity of oil and wart flow should not be less
than that specified.
h. Check control panels for proper connections.
Check ammeters, voltmeters, etc. on both HV
and LV sides.
i. Check that the transformer is properly installed
and there is no possibility of any movement
during operation.
4.2 Commissioning:
If all the above pre-commissioning tests/ checks
are found satisfactory, allow a settling time of atlas
24 hours for oil and release air from all points. The
transformer can now be energized at no load with
the tap changer at normal position, after setting the
protective relays to the minimum extent possible.
The voltage should be built up in steps wherever
possible. Check whether the primary voltages and
currents are balanced. Also check if there is any
undue noise or vibration during commissioning. After
a few hours of energisation at no load, the
transformer should be switched off. The Buchholz
relay should be checked for collection of air/gas.
Abnormalities noticed should be collection of air/
gas. Abnormalities noticed should be connected.
All protective relay should be reset to normal values.
The transformer can now energised and loaded
gradually. Check whether the voltages and currents
on the HV and LV sides are balanced increase the
load to the rated value and check that the noise is
not appreciable. A good transformer operates with
a healthy hum. Observe the operation for a few
hours. If the operation is satisfactory, the transformer
is kept on load and readings of voltages and currents
on all the phases of both HV and LV sides are
checked. Check the temperature of top oil at regular
intervals. A typical logbook sheet recommended for
recording voltage, loading on the transformer, oil
temperature, etc., is given in Table 8.
5.0 INSTRUCTIONS FOR OPERATION
5.1 Parallel Operations:
For satisfactory operation of transformers in parallel,
they should have identical phrase displacement,
voltage ratio and percentage impedance. The
following conditions must be fulfilled:
a. Check that the no load voltage ratio of the
transformers is the same
b. Check that the percentage impedances of the
transformers are the same.
c. Check that the polarity and phase sequence
are the same.
d. Check that the rated output of the smallest
transformer in the group is not less than 33%
of the rated output of the largest transformer in
the group.
e. Check that the tap positions are the same
f. Check that on independent operation the
voltage and currents of the transformers are
balanced.
Satisfactory parallel operation can be achieved if
all the above conditions are satisfied. Condition (d)
above need not be satisfied if the percentage
impedances of the transformers are the same.
However it is generally observed that if the ratio of
the rating of the larger transformer to the rating of
the smallest transformer is more than three it will
not be possible to have the percentage impedances
of the two transformers exactly the same. Difference
in the impedance levels if it exists, causes
circulating currents to flow in addition to the normal
share if load sharing will be in proportion to the ratings
of the transformers if the percentage impedances
are equal.
The transformers should be so connected that their
C B A
c a b c a b
C B A
TRANSFORMER
SECONDARY BUSBARS
X Y
PRIMARY BUS BARS
Fig. 2 Phasing in a three-phase transformer
18
KIRLOSKAR ELECTRIC
polarity and phase rotation is identical. It is
immaterial whether the phase rotation is clockwise
or anti-clockwise so long as it is the same for all
the transformers that have to work in parallel.
However, it is recommended that the standard phase
sequences in the anti-clockwise direction, should
be adopted. A positive check will help in ensuring
correct external connections. The simplest
procedure is to correct all the primary terminals of
two transformers X and Y to their corresponding
busbars, and to connect all the secondary terminals
of one transformer , say X, to its busbars. Assuming
that both secondary windings are unearthed, it is
necessary to establish a link between the
secondary windings of the two transformers, and
for this purpose any lone terminal of transformer Y
should be connected, via the busbars, to what is
thought to be the corresponding terminal of the other
transformer. These connections are shown in
Figure-2.
After ensuring that both transformers are on the
same tap, voltage measurements should now be
taken across the terminals AA and bb, and if in
both instances zero readings are indicated, the
transformers are of the same polarity and phrase
sequence, and permanent connections may be
made to the busbars.
5.1.1 Procedure:
The procedure to be followed while paralleling the
transformers is as given below:
i. Check that the conditions mentioned in clause
5.1 above are fully satisfied.
ii. if everything is alright, the connections may
be made initially to the primary windings only.
iii. Check the voltages and phase sequence on
the secondaries.
iv. If this is satisfactory, connect the secondary
windings also.
v. Check parallel operation on no load for some
time.
vi. The transformers are then gradually loaded, and
the loading on individual transformers is
checked.
When paralleling transformers provided with on load
tap charging gear, set the sequence selector switch
of on e of the transformers on Master and the
remaining transformers on Follower,. Before
paralleling, check that the transformers and their
on load tap changers are working properly. The
operation of control circuit, interlocks, and relays
should be carefully checked on individual units
before they are paralleled.
5.1.1 Switchgear:
The switchgear provided for independent operation
of transformers would be designed for a particular
fault level. Since the fault level goes up when
transformers are paralleled, the switch gear
should be checked to ascertain that it will withstand
the increased fault level. Setting of protective
devices of individual transformers should be properly
done before paralleling.
5.2 Operation of Tap Changers:
In the case of transformers fitted with off circuit tap
switch, it must be ensured that the transformer is
isolated from supply on all windings before changing
the taps. The tap switch should be padlocked in the
working position to that the contacts are correctly
and fully engaged. In no case should the tap switch
handle be left half way and unlocked, to prevent
damage due to inadvertent operation . In the case
of transformers fitted with on load tap changer, it
should be ensured that the tap changer a filled with
clean transformer oil upped the required level in the
conservator. In case an oil surge relay is provided,
its operation should be checked. For detailed
instructions on the operation and measurement of
on load tap changers, reference should be made to
the OLTC manufacturers manual which is supplied
along with the tap changer.
6.0 MAINTENANCE
6.1 General:
If a transformer is to live long and trouble free
service it should receive reasonable amount of
attenti on and mai ntenance, the causes of
breakdown of transformers may be classified as
follows:
a. Faulty design or construction.
b. Incorrect installation or use.
c. Overload
d. Neglect
e. Wear and tear and other deterioration
f. Accidents
A rigorous system of inspection and preventive
maintenance will ensure long life ,trouble-free service
and low maintenance cost. Maintenance consists
of regular inspection, testing and reconditioning
where necessary. Records should be kept of the
transformer, living details of all inspections and tests
made, and of unusual occurrences if any. The
principal object of maintenance is to maintain the
insulation in good condition. Moisture, dirt and
excessive heat are the causes of insulation
deterioration and avoidance of these will in general
keep the insulation in good condition.
19
KIRLOSKAR ELECTRIC
6.2 FACTORS AFFECTING THE LIFE OF
TRANSFORMERS:
6.2.1 Effect of Moisture:
Transformer oil readily absorbs moisture from the
air. The effect of moisture in the oil is to decrease
the dielectric strength of both oil as well as insulating
paper which absorbs and stores the moisture due
to higher affinity of water to paper over oil. All
possible preventive steps should therefore be taken
to guard against moisture penetration to the inside
of the transformers. This includes blocking of all
openings for the access of air in storage and frequent
reactivation of breathers in service.
6.2.2 Effect of Oxygen:
Oxygen may be present i nsi de the
transformer due to air remaining in oil , air pockets
trapped in the windings, etc,. The oxygen reacts
with the cellulose of the insulation and the
decomposition products of the cellulose lead to the
formation of organic acids, and sludge which blocks
the free circulation of oil. The adverse effect of
oxygen, which may be aggravated by catalytic
action between hot oil and bare copper, increases
the operating temperature rapidly.
6.2.3 Effect of solid impurities:
The dielectric strength of oil is diminished
appreciably by minute quantities of solid impurities
present in the oil. It is a good practice to filter the oil
after the transformers, especially units of higher
voltage class, have been in service for some time.
6.2.4 Effect of Varnishes:
Some varnishes, particularly of the oxidizing
type, enter readily in reaction with transformer oil
and precept sludge on the windings. Synthetic
varnishes having acid inhibiting properties generally
delay the natural formation of acid and sludge in
the oil.
6.2.5 Effect of Slackness of Windings:
Al though preshrunk coi l s are used i n the
transformers, natural setting of coils may take place
during operation. Slackness of windings may cause
a failure due to repeated movement of coils which
may wear the conductor insulation at some places
and lead to an inter-turn failure. The coils may also
get displaced under load conditions or momentary
short circuits, which may cause electric and
magnetic unbalance and produce even greater
displacement. It is good practice to lift the core and
windings and take up any slackness which may
have developed, by tightening the tie rods or
pressure screws at the first inspection.
6.3 MAINTENANCE PROCEDURE
6.3.1 Safety Precautions:
Arrangements should be made to carry out the
maintenance of transformers in safety. Before
starting any maintenance work the transformer
should be isolated from the supply and the terminals
earthed. The level of oil in the transformer should
be borne in mind when undoing nuts and boils and
before unsealing the tank. No fire should be kept
near the transformer while maintenance work is
going on.
6.3.2 Oil:
The oil level varies with the oil temperature. The
indicator generally shown the cold level when the
oil is at temperature of about 25 degree centigrade.
The transformer should be topped up as necessary
with clean transformer oil. If the oil level drops
applicability over a short period, the tank should be
checked for leaks. In case there is a leak on a
welded joint, it should be rewarded. A leaking gasket
may be remedied by tightening the bolts. If this is
not sufficient, the gasket should be replaced. In case
the seal on the tapping switch is leaky, the matter
should be reported to us.
6.3.2.1 Oil Deterioration:
Insulating oils are subject to deterioration or
contamination in storage or in handling or in service.
Accordingly, a periodic treatment to maintain the
oil in fit condition is required by new oil. In service,
insulation oils are subject to normal deterioration
due to the conditions of use. For example, in many
applications the oil is in contact with the air. It is,
therefore, subject to oxidation reactions accelerated
by temperature and the presence of catalysts (solid
i ron and copper, and di ssol ved metal l i c
compounds),. As a result, the oil darkens in color
and its acidity begins to increase. There will be a
si mul taneous change i n the el ectri cal
characteristics, such as a fall in resistively values
and/or an increase in the dielectric dissipation factor.
In the advanced stages of oxidation, sludge
formation may also occur. The development of an
odor and a change in color, give useful indications
about the trend of changes in the oil. The oil in a
transformer operating under normal load conditions,
adequately ventilated and free from moisture will
show little deterioration after years of service. If,
due to overload or inadequate ventilating conditions,
the oil temperature is high for prolonged periods,
deterioration of the oil will be accelerated. Tests for
electric strength, acidity, sludge, flash point,
dielectric dissipation factor, resistively and
interfacial tension should be carried out at 12
monthly intervals, and records of all tests should
be kept together with records of load and operating
conditions. Excessive increased deterioration can
thus be assessed and operating conditions modified
before damage to the oil and the transformer results.
The following contaminants may be found in
insulating oils in service.
20
KIRLOSKAR ELECTRIC
a. Water its presence is determined by the Karl
Fischer method.
b. Sediment and perceptible sludge-Those are
determined by the method given in Appendix
A of IS: 1866-1983.
c. Pol ar substances Thei r presence i s
determined by electric dissipation factor,
specific resistance and interfacial tension tests.
d. Acids-Their presence is determined by
neutralization value.
e. Dissolved gasses These can be detected by
gas chromatography.
f. Light hydrocarbons These can be detected
by flash point test. The presence of these
contaminants or any kind of deterioration of an
oil is made evident by changes in any one or
more of the properties covered by these tests.
6.3.2.2 Inspection of oil samples.
The color and color of the sample will supply useful
information, such as:
a. Cloudiness in oil may be due to suspended
moisture or sediments such as iron oxide or
sludge. Undissolved water present in oil may
be determined by crackle test (see clause
3.8.3)
b. Very dark colored oil may have suffered
oxidation to a point where sludge formation is
imminent; however, the coloration of the oil may
be due to its contamination, for example, with
bituminous compound.
c. A green color indicates the presence of
dissolved copper compounds and a rapid
deterioration of the oil may be expected.
d. Acrid acid smell indicates the presence of
volatile acids, which can cause corrosion. This
may render the oil unsuitable for treatment on
site.
The information thus obtained should be noted or
record purposes. Careful visual inspection is of value
to extend the periodicity of laboratory tests as given
in Table 1.
6.3.2.3 Test of Deterioration:
a. Electric strength test:
The electric strength does not give a true indication
of the deteriorated condition of the oil. Oil, which is
significantly oxidized, may show high dietelctric
strength in the absence of moisture. Normal methods
of oil purification only maintain the electric strength
but do not improve the deteriorated oil. It is, therefore,
inadvisable to rely solely on the electric strength of
the oil by periodic tests, without verifying its other
characteristics.
b. Water content test:
Water may originate from the atmosphere or be
produced by the deterioration of insulating materials.
Its presence in oil is harmful as it lowers the electric
strength and resistively of the oil and accelerates
the deterioration of solid insulating materials,
particularly paper. The water content may be
determined in accordance with the procedure laid
down in Appendix E of IS: 335-1983.
c. Sludge test:
Sludge is the end stage of the deterioration process
and is a visible sigh that the oxidation process has
long been at work. Sludge is a resinous partially
conductive substance, which is moderately soluble
in oil. Lit is formed when the acids attack the iron,
copper, varnishes, paints, etc., and these materials
come into solution, and combine together. This
sludge eventually precipitates out of solution, and
forms a heavy substance which address to the
insulation and the side walls of the tank, and settle
in the oil ducts, radiators, etc. when comparison of
records as suggested in clause 6.3.2.1. Oil
Deterioration indicates an increase in sludge
formation; it is advisable to inspect the core and
winding and to filter the oil. The initial sludge deposit
is very soft and can easily be removed by washing
with transformer oil. When sludge is allowed to
accumulate, the oil-circulating duct becomes
choked, with the result that high temperatures occur
within the transformer. Due to these high temperature
slugging is accelerated and serious damage to the
windings will result.
d. Polar substances:
These are oil-soluble compounds resulting from
oxidation of the itself, or from the solution in the oil
external contaminants or materials used in the
construction of the equipment.
Measurements of the dissipation factor and to a
lesser extent, resistively and interfacial tension of
the oil enable such contamination to be detected
and periodically assessed.
(i) Dielectric dissipation factor test:
This characteristic is very sensitive to the presence
in the oil of soluble contaminants and ageing
products. Changes in this characteristic may be
monitored even if the oil is heavily contaminated.
The test should be carried out in accordance with
IS: 6232.
(ii) Specific resistance test:
For any given oil, there is generally a relationship
between dissipation factor and resistively if the
dissipation factor increases there is a reduction in
resistively. Useful additional information may be
obtained when it is possible to carry out the
resistively test both at ambient temperature and at
21
KIRLOSKAR ELECTRIC
90
O
C. A satisfactory result at 90
O
C. coupled with
an unsatisfactory value at the lower temperature
is an indication of the presence of water or cold
perceptible material, without undue chemical
deteri orati on or general contami nati on
unsatisfactory results at both temperature indicate
a greater extent of contamination than a poor value
at the lower temperature only, and that the oil is
therefore likely to be restored to a satisfactory level
by drying and low temperature filtration.
The test is performed at 90
O
C. in accordance with
method described in IS:6103.
(iii) Interfacial Tension (IFT) Test:
The characteristics changes fairly rapidly during
the initial stages of ageing. Afterwards the rate of
change decreases as the values themselves
become lower.
The interfacial tension value of oil against water
provides a very sensitive means of determining
the degree of contamination. New oils will have
AB IFT value of 0.04 N/m. The value falls during
service and the decrease is proportional to the
concentration of the contaminants particularly in
the initial stages of services. Tests carried out on
oils have revealed that the interfacial tension value
of an oil falls to about 0.220 to 0.025N/m in the
initial stages due to the dissolution of varnish, etc.,
from within the equipment. This fall is not to be
interpreted as a result of excessive oil deterioration.
It has also been found that sludge formation in the
oil is possible if the interfacial tension value falls
below 0.018N/M and that oil with an IFT value of
0.018N/M or above is generally free from sludge.
e. Neutralization value (Total Acidity) Test:
The acid products formed by the oxidation of the
oil actively encourage deterioration of insulating
paper and pressboard. It is therefore essential to
detect and monitor the process.
The determination of neutralization value is the
most convenient and direct method of assessing
the chemical ageing of the oil.
The rate of increase in acidity is small initially, but
tends to increase rapidly after a value of 0.5mg
KOH/g will necessitate inspection of the internal
steel surfaces above oil level.
Experience shows that slight corrosion of the steel
commences with acidity slightly above 1.0 mg
KOH/g and due to the acceleration in acidity after
this value has been reached, serious corrosion will
occur as the acid value reaches 3 or 4 mg KOH/g.
It the testing of acidity cannot be carried out the
pungent odour of the oil will give an indication of
acidity. If such an odour is present immediate
inspection for corrosion of the tank and cover
above the oil level should be carried out and steps
taken to ascertain the acidity value.
Cleaning and wire brushing the corroded parts and
painting of steel above oil level with an air drying
spirit varnish will delay further corrosion but it is
advisable to replace the oil with new oil, or re-
processed oil as soon as possible. The acidity of
oil may be determined by either of the two method
given in IS:1448 (P:2) 1967.
For quickly determining the total acidity of insulating
oils, a portable kit for carrying out this test has
also been devised with which the test for acidity
of oils could be done at site with ease. The details
of the portable kit for carrying out this test given in
Appendix B of IS:1866-1983.
f. Dissolved Gases:
Under normal service conditions gases are formed
in oil-filled transformers due to natural ageing, but
at an extremely slow rate. However gases are
formed to a much greater extent as a result of
faults. Both the oil and cellulose insulating
materials like paper, pressboard, etc, breakdown
as a result of electrical discharges or thermal
stresses to yield gases, and to some extent these
gases dissolve in the oil. Periodic analysis of oil
samples for the amount and composition of
dissoloved gases is a means of detecting faults.
The most si gni fi cant gases generated by
decomposition of oil are hydrogen (H2), methane
(CH4), ethane (C2H6), and ethylene (C2H4) and
acetylene (C2H2). Where cellulose materials are
involved at a fault, further gases, mainly carbon
dioxide (CO2) and carbon monoxide (CO) are also
generated.
The presence and quantity of these individual
gases, extended from the oil and analysed, reveal
the type and degree of the abnormally responsible
for the gas generation.
Dissolved gas analysis is a powerful diagnostic
technique for monitoring the internal condition of
oil-filled transformers. In this laboratory method an
oil sample is taken from a transformer, the
dissoloved gases are then extracted, separated,
identified, and quantitatively determined. The
analysis helps in detecting faults in the incipient
stage before they develop into major faults and
cause serious damage to the transformer. By this
analysis it is possible to check whether a
transformer in service is undergoing normal ageing
or whether there are incipient faults such as hot
spots, arcing, overheating, or partial discharges
which may otherwise remain undetected.
Sampling of oil:
The accuracy of the test results will depend on
22
KIRLOSKAR ELECTRIC
the care with which oil samples are collected. To
avoid gas losses before extraction, the sampling
vessel should be filled to the brim without air space,
and the oil sample should be allowed only minimum
exposure to atmosphere before the sampling vessel
is sealed gas-tight. Samples may be collected in
aluminium sampling tubes or in amber coloured
bottles with screwed plastic caps as described in
Appendix B of IS:9434-1979. Guide for Sampling
and Analysis of Free and Dissolved gases and oil
from oil filled Electrical equipment.
Testing of oil sample for dissolved gasses:
The Gas Chromatograph is used for determining
the dissolved gas content in an oil sample. Facilities
for carrying out this test are available at CPRI
Bangalore, ERDA Vadodara, and also at our works.
Level at which Dissolved Gases are Significant:
The Permissible concentration of dissolved
gases in the oil of a healthy transformer is in service.
The recommended maximum permissible gas
concentrations for healthy transformers of various
ages are given in Table 4.
Di agnosi s of faul ts from Rel ati ve
Concentration of Individual Gases Dissolved in Oil:
If the measured gas concentration indicate
that there may be a fault in the transformer. It is
necessary to diagnose the fault and take remedial
action. A convenient basis for fault diagnosis is the
calculation of ratios of the concentrations of the
gases in the oil. The ratios used in the following
evaluation scheme are.
Table 5 shows various limits of the ratios
corresponding to normal ageing and to various types
of faults, from which a diagnosis of the nature of a
fault may be obtained. The table shows a code for
each range of the ratios of the characteristic gases;
numeral have been allocated so that code 000
represents normal ageing conditions.
Appendix A shows a flow chart summarzing actions
to be taken dissolved gas analysis on a routine oil
sample, and steps that should be followed after
diagnosis shows the likelyhood of a fault.
Reference may also be made to IS 105931983
Method of Evaluating the Analysis of Gases in oil-
filled Electrical Equipment in Service.
g. Flash Point:
Li ght hydrocarbons are formed duri ng the
degradation of oil under the influence of heat and /
or electrical stresses. Large amount of these
hydrocarbons may be an indication of an incipient
fault in the equipment. The presence of some lower
hydrocarbon deterioration products may be
detectable by measuring the flash point of the oil.
Flash point tests should be made more frequently
if the oil has been subjected to high tempreature
due to internal faults or shows any sign of unsual
odour.
A slow fall of flash point of oil in a transformer is
not harmful. A fall exceeding 15
0
C or flash point
125
0
C may indicate unsatisfactory working
condition, such as electrical discharge, excessively
high internal temperature, core faults or foreign
matter providing a conducting path between live
parts and the frame. In such cases, the transformer
shall be taken out of service for examination. Special
precautions shall be taken to avoid risk of fire or
explosion, particularly when oil has been drained
from the tank.
The flash point may be determined by the method
given in IS 1448 (P: 21) 1970.
6.3.2.4 Action to be taken:
The following cases are considered as a function
of the degree of deterioration of the oil;
a. The characterstics are normal-no action is
necessary.
b. Only the value of the electric strength is too
low remove water and solid particles by
recondi ti oni ng (for exampl e, fi l teri ng,
centrifuging, or vacuum dehydrating). In case
of abnormal increase of water content in oil
and abnormal decrease of electric strength
beyond the permissible limits given in Table 1,
it may be necessary to dry the solid insulation
of the transformer also, and the condition of
the breather should be checked.
c. One or more characteristics of the oil change
rapidly conduct further tests of the oil.
d. If one or more characteri sti cs are
unsatisfactory- according to economic factors
and local circumstances, it should be decided
to examine the oils more thoroughly, in order
to reclaim the oil or to replace it altogether.
In case where oil is reclaimed or replaced, the
equipment should be thoroughly flushed before
refilling, with special alteration to the windings, to
minimize contamination of the new oil by ageing
products.
6.3.2.5 Reconditionings, Reclaiming and
Replacement of oil :
a. Reconditioning:
This is a process to eliminate by physical means
only, solid particles from the oil and to decrease
the water content to acceptable level. The physical
23
KIRLOSKAR ELECTRIC
means that are used for removing water and solids
from oil include several types of filter, centrifuge
and vacuum dehydrator.
Contamination due to moisture or solids can be dealt
with satisfactorily on site. Centrifugal separators are
effecti ve i n removi ng free water and,
generally,finelydivided solid impurities, whereas
filters, although generally capable of removing small
quantities of water, deal more effectively with solid
impurities.
The choice of oil temperature for purification depends
upon the circumstances. Sludge depends upon the
circumstances. Sludge and free water are more
soluble in hot oil than in cold and are therefore most
effectively removed by cold teatment. Also the
tendency of the oil to oxidation is minimised if the
temperature at atmospheric pressure is limited to
50
O
C. Dissolved water and small amounts of free
water are effectively removed by oil circulation under
vacuum, in which case temperature upto 70
O
C and
advantageous.
b. Reclaiming:
This is a process to eliminate from the used oil,
with characteristics similar to those of new oil.
Reclaiming is a process normally performed by an
oil refiner.
c. Replacement:
When replacing deteriorated oil with clean oil, the
transformer core and windings should be thoroughly
drained and carefully washed down with a spray or
jet of clean oil before the introduction of a fresh
charge. The degraded oil can be returned for
reconditioning or reclaiming to an oil supplier who
has the necessary plant to carry out such work.
Careful and thorough washing down of the core and
winding of the unit is imperative if contamination of
the fresh change of oil is to be reduced to a minimum
and its life accordingly prolonged.
6.3.3 Dehydrating Breather:
Silicates dehydrating breathers are fitted with a
slight glass so that the colour of the crystals may
be taken. The colour gradually charges from blue to
pale pink as the crystals absorb moisture. The gel
should then be replaced or reactivated. The gel can
be reactivated by heating in an oven at a
temperature of about 150 to 200
O
C until the whole
masses are at this temperature and the blue color
has been restored. Silicagel dehydrating breathers
are provided with the oil seal which ensures that
the silicagel is not in contact with the external
atmosphere when no breathing is taking place. The
level of oil in the sealing cup at the bottom must be
maintained at the level marked on the cup. The
breathers must be installed in a vertical position
and the oil seal filled with oil to the level indicated.
6.3.4 External connections:
As connections should be tight. If they appear
blackened or corroded, undo the correction and
clean down to bright metal with emery paper.
Remake the connection and give it a heavy coating
of grease. If the metal has the characteristics blush
tinge which indicate that it has been hot, then either
the connection has become loose or dirty, or the
conductor is not suitable for carrying the current.
The earthling connections should be properly
maintained.
6.3.5 Bushings:
The bushings should be cleaned at regular intervals
and kept free from dust and dirt. The bushing
porcelains should be examined for cracks or chips.
If any damage is observed, the porcelain will have
to be changed. In some cases, the conducting rod
is cemented into the porcelain and the complete
bushi ng wi l l have to be changed. It i s
recommended to have a spare always in stock.
The oil level in oil filled bushings should be checked
periodically.
6.3.6 Conservator and magnetic oil gauge:
Conservators are so arranged that the lower part
act as a sump in which any impurities entering the
conservator can collect. A valve/plug is fitted at
the lowest point of the conservator for draining oil.
The inside of the conservator should be cleaned
every two or three year. A removable end plate is
generally provided for this purpose, in the case of
large transformers.
The conservator presents a minimum oil surface
to the atmosphere and reduces oil deterioration to
a minimum. It acts as an expansion chamber for
the oil and provides a means for the connection of
the Buchholz relay.
Magnetic oil level gauge or plain type oil level
indicator is provided on the conservator. The
magnetic oil gauge has standard calibration marks
at Empty, 25
O
C cold oil level and full, with
additional intermediate markings to suit particular
requirements, and with one set of contacts for low
oil level alarm. When the conservator is dismantled
for cleaning, the mechanism of the magnetic oil
gauge should be inspected and cleaned.
The plain type oil level in indicator has calibration
mark showing the 25
O
C cold oil level. The back of
the indicator is tinted yellow enabling the level of
oil to be clearly observed.
The oil level indicators should be kept clean and
examined at regular intervals, and oil should added
when the level indicated is low.
6.3.6.1 Oil Filling Procedure for Air-cool
Conservator
Refer Page No 31
24
KIRLOSKAR ELECTRIC
6.3.7 Explosion Vent
The transformer is filled with a pressure relief pipe
designed to afford a safe and rapid release of oil in
the event of a serious fault with the transformer.
The pressure relief pipe is fitted with a diaphragm
at the top, and provision is made to ensure that any
gases generated due to an incipient fault within the
transformers is not allowed to enter the relief pipe,
but are deflected towards the Buchholz relay.
The diaphragm should be inspected at frequent
intervals and replaced if damaged. Failure to replace
the diaphragm immediately may result in the ingress
of moisture, which will contaminate the oil. If the
diaphragm has broken because of a fault in the
transformer, a thorough examination must be carried
out to determine the nature and cause of the fault,
and suitable remedial action should be taken.
6.3.8 Temperature Indicators:
The level of oil in the pockets holding the
thermometer bulbs should be checked periodically,
and the oil replenished if required. The capillary
tubing should be fastened down if it has become
loose. Dial glasses should be kept clean, and if
broken it should be replaced as soon as possible to
prevent damage to the instrument. If the temperature
indicators are found to be reading incorrectly, they
should be calibrated with a standard thermometer
immersed in a got oil bath.
6.3.9 Buchholz relay:
The gas and oil actuated ( Buchholz) relay is
mounted on the pipe connection between the
transformer tank and the conservator. The principle
of its operation is based on the fact that gases are
generated whenever a fault develops within the
transformer. The gas operated relay makes use of
gases to operate an alarm in the event of an incipient
fault, and to disconnect the transformer from the
supply by tripping the circuit breaker in the event of
a serious fault within the transformer.
The relay comprises an oil-tight housing provided
with two hinged floats which operate mercury
switches which have to be wired to the external
alarm and tripping circuits. Normally the gas operated
relay is full of oil and the floats, because of their
buoyancy, rotate on their hinges and occupy the
position at which the mercury switch contacts are
open. When an incipient fault occurs within the
transformer, small bubbles of gas are generated
whi ch whi l e passi ng upwards towards the
conservator get trapped in the housing of the relay,
thereby causing the oil level to fall. The upper
float gradually comes down, and when
sufficient oil has been displaced the mercury
switch contacts close thereby completing the
external alarm circuit. Some of the faults which
normally initiate the alarm circuit via the top float of
the relay are as follows:
a. Failure of core bolt insulation.
b. Local overheating in the winding.
b. Low oil level in the transformer due to any
reason.
c. Accumulation of air.
d. Short circulated core laminations.
e. Bad electrical contacts.
In the event of a serious fault within the transformer
the gas generation is more violent and the displaced
oil rushes towards the conservator through the
connecting pipe. This sudden surge of oil clauses
the lower float if the relay to be deflected, thus
closing the contacts of the second mercury switch
and completing the external tripping circuit of the
transformer from the supply. Some of the serious
faults which normally initiate the tripping circuit via
the bottom float of the relay as follows:
a. Short Circuit between phases
b. Short circuit in the windings.
c. Winding earth fault.
d. Puncture of bushings.
The switch would also operate if the oil level falls
below that of the float due to any reason.
The relay is provided with glass windows on both
sides of the housing. One window has graduated
scale which indicates the volume of gas collected
inside the relay. The other windows permit
observation of the inside of the relay. A drain hole
with plug is provided under the relay body. A petcock
which is provided on the top of the relay can be
used for releasing all the air trapped in the
transformer or the relay. It can also be used for taking
out gas samples for analysis. From the results of
the gas analysis. From the results of the gas
analysis, and approximate diagnosis of the nature
the fault can be made as follows:
a. If the gas is colourless and odourless. It may
be air which may have been displaced from
the windings or oil. It may also be an indication
that the oil level in the transformer has been
allowed to fall low.
b. If the gas is white in colour, it may be due to
overheating of paper insulation.
c. If the gas is yellow in colour, it may be an
indication of damaged wooden parts.
d. If the gas is black in colour, it may be due to
flashover in oil or overheating of oil caused by
a fault in the winding or core.
A petcock is provided on the top of the relay towards
25
KIRLOSKAR ELECTRIC
the inlet and which permits tests being carried out.
For this purpose of testing, a source of compressed
air is required. It should be connected to the petcock
with a suitable length of rubber tubing. Slow release
of air to the relay operate the upperfloat, while rapid
release of air causes the lower topping float to
operate.
The relay should be tested periodically to ensure
that the floats and other parts are in proper working
condition.
6.3.10 Gaskets:
Gaskets sometimes shrink during service.
Hence it is necessary to check the tightness of
bolts of gasketed joints. The bolts should be
tightened evenly round the joints to avoid uneven
pressure. Leaking gaskets should be replaced as
soon as circumstances permit.
6.3.11 Small pipe work:
The pipe work should be inspected periodically for
leaks. Leaking joints should be tightened. If the leaks
are due to badl y seal ed j oi nts caused by
misalignment, the pipes should be aligned properly
and the joints remade.
6.3.12 Rollers:
The rollers should be examined after the transformer
has been in service for a long period. They should
be greased and rotated to see that they turn freely.
6.3.13 Tank Body:
The transformer tank and other parts should be
inspected periodically for any rust or leak. Rusted
portions, if any, should be thoroughly cleaned and
repainted with the proper paint. The complete
transformer should be painted at suitable intervals.
If any leak is found, it should be investigated and
necessary remedial action taken.
6.3.14 Radiators and cooling fans:
Maintenance of radiators primarily consists in
replacing damaged elements, cleaning the outer
surface to remove settled dust, repainting, etc.
The cooling fans blades are cleaned to remove dust.
Bearings of the fan motors should be lubricated
occasionally. Grease should not be added while the
motor is running.
6.3.15 On Load tap changer:
For maintenance of on load tap changers, reference
should be made to the OLTC manufacturers
instructions manual which is supplied along
with the tap changer. However, the following
points may be noted:
a. Diverter switch:
The diverter switch contacts should be inspected
at regular intervals. The oil level in the diverter switch
chamber should be checked and the oil should be
replaced when it becomes unsuitable for further use.
b. Motor drive mechanism
i) Do not allow dirt to accumulate between
contact rings of notching controller.
ii) Do not use oil/grease on contact rings of
notching controller.
iii) Check the operation of anti condensation
heater.
iv) If the contacts of contractors are silver faced,
no touching up should be done, but the contacts
must be replaced when they are worn out.
Copper contacts may be lightly touched up with
a file when they become rough. The pole faces
of electromagnets should be kept clean.
v) Do not oil/grease the contact surface of radial
multi contact switches, unless is special
contact lubricant is used. The space between
the rings should be clarified occasionally.
C. Selector switch:
As the selector switch contacts do not make or
break current, the wear is only due to mechanical
movement of moving contacts. These may be
inspected once in 2 to 3 years.
6.4 Internal inspection:
The core and windings should be lifted from the
tank for visual inspection only if necessary as per
the recommended maintenance schedules given in
the Table 2 and 3, or when some fault is located in
the core/windings. The inspection should be done
under covering in a clean and dry place free from
dust, etc. A suitable lifting device, depending on
the weight of the core and windings, should be
arranged. Before disturbing anything, the insulation
resistance of the transformer should be measured.
6.4.1 Opening the transformer:
Ensure that the transformer is disconnected from
the supply and the oil level is lowered, before opening
it. The tank contains oil with oil vapour and therefore
care should be taken to prevent a fire. Naked lights
and flames should be kept well away while the tank
is open. If an inspection lamp is required, only a
protected electric lamp, preferably an extra low
voltage lamp should be used. The lamp should be
kept off when not in use.
Before opening the tank cover, it should be properly
cleaned, removed of any dust, moisture, etc, from
the top. The persons opening the tank cover should
not have anything in their breast pocket, and should
not wear a watch or ring. The spanner should be
clean and should be held by a cotton strap or string
tied securely round the waist or wrist of the person
opening the tank cover. All nuts and bolts, etc,
should be removed from the top of the cover before
26
KIRLOSKAR ELECTRIC
removing it.
6.4.2 Removing the cover:
Before removing the cover, the accessories like
Buchholz relay, winding temperature indicator, etc.
are removed. Open the inspection cover, remove
the internal connections to the bushings, and
dismantle them. The accessories like conservator
explosion vent pipe, breather, etc. should also be
removed.
The method of removing the cover depends on the
construction of the transformer if the core and
windings are separate from the cover, the cover can
be carefully removed after dismantling the bushings
mounted on the top. If however the core and
windings are suspended from the tank cover,
substantial lifting lugs will be provided on the core
and windings vertically. It should also be ensured
that spanners or other tools used in connection with
the work are not dropped into or left inside the tank.
6.4.3 Lifting the core and windings:
Before lifting the core and winding from the tank, it
is necessary to disconnect the windings from the
bushings or cable boxes. Remove the mechanical
connection to the off circuit tap switch hands or
disconnect the leads of the on load tap changer, as
the case may be. Remove any earthling strips
between the core clamps and the tank.
The core and windings should then be lifted vertically
by slinging it from the lifting lugs provided for this
purpose. Allow oil from the core and windings to
drain into the tank for sometime. The core and
windings should then be lowered carefully on wooden
beams placed in metal tray filled with sawdust or
sand.
6.4.4 Inspection:
After removing the core and windings from the tank,
the following should be carefully checked making
sure that nothing is disturbed unnecessarily and the
leads are not pulled out of their places unless they
are unsatisfactory.
a. All bolts and nuts should be adequately tight.
If they are too tight the clamps etc., may bend.
b. The windings should be clean and free from
sludge. Slight traces of sludge should be
cleaned by transformer oil. But if there are
heavy deposits, it is likely that the ducts are
blocked. In such cases the matter should be
referred to us.
c. The winding should be firmly clamped without
any movements. There should be no loose
spaces or and blocks. If loose windings or
spacers are noticed, the vertical tie-bars which
put pressure on the coil stacks should be
adjusted. Special coil adjustment bolts. If
provided should be tightened properly.
d. Properly operation of tap changing switch may
also be checked.
e. All connections should be tight and clear.
f. If the megger tests done before untaking gave
low value, it should be repeated. If now the
test gives satisfactory value, the low value is
attributed to some other cause. However, if the
test still gives low value, the matter should be
reported to us.
g. If there is sludge deposition at the bottom of
the tank, it should be removed while filtering
the oil.
6.4.5 Reassembly:
If everything is found satisfactory, the core should
be lowered into the tank. Tap changing switch, if
provided bushing etc. should be reconnected. At
the end, insulation resistance should be again
measured to ensure that the bushing leads are not
touching the tank.
6.5 Inspection and Maintenance Schedule:
The frequency of inspections should be determined
by the size of the apparatus. Local climatic and
atmospheric conditions will also influence the
inspection schedule.
The recommended maintenance schedule for
transformer of rating less than 1000KVA and above
are given in Table 2 and 3 respectively. The hourly
and daily inspection time are applicable for attended
substations, these items should be inspected as
frequently as possible.
The maintenance schedules given in Tables 2 and
3 are a good indication of the attention required to
be given to the transformer under average
conditions, and they can be used as guide for
determi ni ng the i nspecti on schedul e. The
recommended record of Maintenance is given in
Table 9.
7.0 FAULTS AND FAILURES
Al though the occurrence of breakdown i n
transformers is very rare, faults do occur from time
to time due to various reasons. The faults which
commonly arise in practice may be broadly
classified as follows:
a. Failure in the magnetic circuit, i.e., in the core,
yoke, clamping structure, etc.
b. Failures in the electric circuit, i.e., in the
windings.
c. Failures in the dielectric circuit, i.e., in the oil,
major insulation, etc.
d. Structure and mechanical failures.
7.1 Failure in the magnetic circuit:
27
KIRLOSKAR ELECTRIC
The common cause of failure in the magnetic
circuit are as follows:
a) Breakdown of insulation of the core bolts results
in local short circuits in the laminations which
produces intense local eddy currents. The heat
generated may distort the core and char the
winding insulation and cause a short circuit
between turns of the adjacent winding.
b) Failure of insulation between the laminations
and of insulations between the yoke clamping
plate produce large circulating eddy currents
which generate heat and damage the core and
winding insulation.
c) The core clamping bolts should be effectively
locked or else vibrations will be set up which
will weaken the core insulation and produce
failures as mentioned above.
d) The burns at the edges of the core and yoke
laminations produce local short circuits in the
laminations causing eddy currents with
consequent abnormal heating.
e) The presence of metallic fillings or small
turnings between the laminations causes
intense local eddy currents and excessive local
heating of the cores.
f) High flux density in the core results in large
magnetising current inrushes during switching
in on no load. Large electromagnetic forces
are set up while the heavy current lasts and
the windings are thereby strained. Repeated
switching in may cause movement of the
windings and ultimately a short circuit may
occur.
7.2 Failures in the electric circuit:
The common causes of failures in the electric circuit
are as follows:
a. The presence of sharp edges on the conductor
will cause short circuit between adjacent turns
of a winding. The sharp edges out through the
insulation when the transformer is subjected
to repeated electromagnetic shocks or if the
transformer vibrates when on load, thereby
making metal to metal contact between
adjacent turns.
b. During heavy external short circuits, one or
more turns of a winding may get dislodged.
Abrasion of insulation between adjacent
dislodged turns due to vibration of the
transformer when on load or due to repeated
electromagnetic shocks, may lead to short
circuit between the turns.
c. The adjustment of the coil clamping rings for
taking up any shrinkage of the windings in
service should be done correctly. If the correct
pressure is no applied to the windings, some
of the turns may get dislodged and short circuit
between turns as explained in (b) above may
take place.
d. Breakdown between turns can also occur if
moisture penetrates the winding insulation.
e. If drying out of a transformer is not carried out
properly at site, the insulation resistance of the
windings will be still low and if the normal
voltage or test voltage is applied at this stage,
there is every likelyhood of failure of insulation
between adjacent turns due to the presence of
moisture.
f. Hot spots in the winding will cause the conductor
insulation to become brittle and eventually a
short circuit between turn will occur.
g. Badly soldered joints become overhead on
load. The heat generated causes the insulation
to get charred and a short circuit between turns
will result.
h. Short circuit between turns and breakdown of
windings to earth may occur due to transient
phenomena such as switching surges and
lighting surges which produce high voltage rises
in the windings especially at the end turns.
i. Sustained overloads on the transformer causes
excessive heating of the windings and oil. The
winding insulation becomes brittle and flakes
off, resulting in short circuits between turns.
The heated oil forms sludge which is deposited
on the core and windings and on the bottom of
the tank, the sludge has a blanketing effect on
the core and windings and it also chokes the
oil circulating ducts. This intensifies the heating
and serious damage to the windings will result.
j. Bolted current carrying joints may become
loose in service due to vibration, if they are
not effectively locked. The joint becomes heated
up and failure of insulation may result.
7.3 Failure in the dielectric circuit
The common cause of failures in the dielectric circuit
are as follows:
a) Moisture entering the oil as a result of the
breathing action causes reduction in the
dielectric strength of oil. Breakdown may also
place from the windings to tank, or between
adjacent turns in the windings.
b) Sustained overloading of the transformer results
in deterioration of the oil due to excessive oil
temperature which accelerates the formation
of sludge, water, and acids.
28
KIRLOSKAR ELECTRIC
c) Presence of metal l i c parti cl es i n the
pressboard may result in puncture of the board.
d) Narrow oil ducts causes cooling to be
insufficient. The insulation gradually becomes
brittle and an interturn insulation failure will
take place eventually.
e) Oil should be topped up to the proper working
level regularly. If the oil lost due to evaporation
and oxidation or leakages are not replaced,
the transformer may get overheated due to
loss of cooling medium and tank reading
surface.
f) Insufficient clearances between phases may
result in short circuit between phases.
g) Flashover under oil of terminal leads to each
other and to the tank can take place due to
the presence of foreign conducting particles
in suspension in the oil.
7.4 Structural and Mechanical failures
The common causes of structural and mechanical
failures are as follows:
a) If the leads from the windings to the terminals
are not adequately braced, they may become
distorted and make contact in the event of an
external short circuit.
b) Poor welding, leaky fittings and rough handling
in transit may give rise to leakage oil from the
tank resulting in overheating and consequent
breakdown of the transformer.
c) Deposits of dust, dirt, salt, spray, or other
impurities on the surface of bushings can
cause them to flashover.]
d) When transformers are installed indoors,
proper ventilation should be provided and
adequate space should be provided around
the transformer to enable it to displace the
losses properly. If adequate spacing is not
provided, the temperature of the transformer
will increase, and this will adversely affect the
insulation of the windings and the condition of
the oil.
e) In the case of artificially cooled oil immersed
transformers, the temperature may rise to very
high values if there is some failure of the
auxiliary cooling equipment. In the event of
such a failure, the load on the transformer
should be decreased to such a value which it
can handle as a naturally cooled transformer
with the temperature rise being within
permissible limits.
f) The cooling tubes of water cooled transformers
should be periodically cleaned so that they
do not become clogged with deposits of lime
or other substances from the water supply. If
the tubes are not kept clean, the flow of water
will be reduced, and consequently the
temperature of the transformer will rise higher
than the permissible limits with the usual
adverse effects.
7.5
It has been observed from experience tat about
70 to 80 percent of transformer failures are caused
due to short circuit between turns, and as outlined
above these short circuits may be caused in a
number of different ways. With a fault of this type,
it is difficult to ascertain the exact cause destroyed
during the breakdown itself. A careful study of the
transformer and the operating conditions may give
a clue as to the real clause of the failure.
The remaining percentage of failures can be
minimised to a great extent by providing suitable
transformer protective apparatus and by regular
inspection of the transformer and supervision of
our representatives, or whether the transformer
should be sent to our works for repair. When in
doubt, the matter should be referred to us giving
complete details of the transformer and the nature
of the fault, as per Appendix-C Site failure/
Complaint Format.
Guidance to manage electrical and mechanical
troubles normally encountered in all types of
transformers are provided in Table 6.
8.0 SPARES
It is recommended that the following minimum
spares be kept in store for immediate replacement
in case of emergency.
(i) One bushing of each type.
(ii) One set of gaskets.
(iii) Two explosion vent diaphragms.
(iv) One silicagel dehydrating breather.
In addition to the above spares, transformer oil
should be stored in sufficient quantity for topping-
up purposes.
The type and quantities of spares to be kept in
stock should be decided depending on the desired
reliability of operation, the number of transformers
located at a particular place, etc.
8.1 Ordering of spares
Always quote the full details on the transformers
rating plate including the transformer number when
ordering spares. In addition, the detailed description
of the spares part, required should be furnished.
This will prevent delay in the supply of spares.
29
KIRLOSKAR ELECTRIC
9.0 WARRANTY
The transformer is warranted to be free from inherent
manufacturing defects undo normal use and preventive
measures. Our liability in respect of any defect in or
failure of goods supplied or for any loss, injury or damage
attributed thereto to making goods by replacement or
repair defects which under proper use appear therein
and arise solely from faulty design, materials or
workmanship, within TWELVE MONTHS from the date
or commissioning or FIFTEEN MONTHS from the date
of dispatch, whichever is earlier, provided they are
adequately protected by you, at the termination of which
period all liability on our part ceases.
In case of goods not manufactured by us, you are entitled
only to such benefits as we may receive under any
guarantee given to us in respect thereof. The warranty
does not cover the normal wear and tear, or damages
caused by accidents, wrong handling, and improper
maintenance.
30
KIRLOSKAR ELECTRIC
2W
2V 2U 2N
+
+
+
+
+
+ +
2W 2V 2U 2N
BUSHING
MOUNTING PLATE
1.1 kVBUSHING
BUSHING STUD NUT
DUCT CHAMBER FLANCE
BUSHING MOUNTING PLATE
GASKET REGION
1.1 kV BUSHING
EARTH STRIP
10
11 12 13
8
1
2
3
8
9
4
5
6
7
3.12.12.1 LV CABLE BOX ASSEMBLING PROCEDUREE AT SITE
1. CHECK FOR ANY OIL SEEPAGE IN CHAMBER AROUND EACH BUSHING ASSEMBLY IN GASKET REGION.
2. INSPECT BUSHING PROCELAIN BODY FOR ANY POSSIBLE BODY FOR ANY POSSIBLE CRACK OCCURED DURING
TRANSIT
3. BUSHING IS TO BE REPLACED IF CRACK IS FOUND ON PORCELAIN BODY
4. IF THERE IS NO CRACK FOUND ON PORCELAIN BODY TIGHTEN THE BUSHING STUD NUT 1 FOR ARRESTING OIL LEAK.
5. SCREW THE PALM TERMINAL 2 ON TO THE BUSHING STUD 1 AND LOCK IT IN POSITION BY TIGHTENING THE BOLT
3 ON PALM TERMINAL
6. ASSEMBLE THE CABLE BOX 5 ON DUCT CHAMBER FLANCE 10 AND REMOVE HAND HOLE COVER PLATE 6 FROM
CABLE BOX 5 CHECK AND FIX THE EPROXY SUPPORT INSIDE CABLE BOX
7. REST COPPER BAR EXTENSION 4 ON SUPPORTS 13 FIX THE COPPER BAR EXTENSION TO PALM TERMINAL 2 WITH
BOTL AND NUTS 11 WHILE DOING THIS ENSURE THE BUSIONG STUD 1 IS NOT STRAINED CAUSING OIL LEAKAGE
FROM BUSING GASKET REGION.
8. TIGHTEN THE ASSEMBLY BOLT 11 ON PALM TERMINAL AND ENSURE FULL CONTACT.
9. INSERT THE CUSTOMERS CABLE THROUGH CABLE GLAND 7 AND MAKE CONNECTIONS TO COPPER BAR.
10. CLOSE HAND HOLE COVER PLATE 6 ON TO THE CABLE BOX 5
11. MAKE EARTHING STRIP 8 CONNECTION BETWEEN FLANGES AS SHOWN ON ALL FLANGED JOINTS.
31
KIRLOSKAR ELECTRIC
DE-FLATED
AIR CELL
PRISMATIC
OIL GAUGE
(POG)
BREATHER
CONSERVATOR
FILLING VALVE STOPPER
FLOAT
POSN
FULL
EMPTY
FEED PIPE VALVE
MAGNETIC OIL
LEVEL GAUGE
(MOG)
TRANSORMER
BUCHHOLZ
RELAY
5. OPEN AIR VENT VALVE
6. CHECK MOG POINTER INDICATING EMPTY LEVEL
1. CONSERVATOR EMPTY WITHOUT OIL
AIR VENT VALVE
DE-FLATED
AIR CELL
PRISMATIC
OIL GAUGE
(POG)
BREATHER
CONSERVATOR
FILLING VALVE STOPPER
FLOAT
POSN
AIR VENT VALVE
FULL OIL
II. CONSERVATOR FILLING WITH OIL
FULL
EMPTY
FEED PIPE VALVE
MAGNETIC OIL
LEVEL GAUGE
(MOG)
TRANSORMER
BUCHHOLZ
RELAY
DE-FLATED
AIR CELL
PRISMATIC
OIL GAUGE
(POG)
BREATHER
CONSERVATOR
FILLING VALVE STOPPER
FLOAT
POSN
AIR VENT VALVE
FULL OIL
FULL
EMPTY
FEED PIPE VALVE
MAGNETIC OIL
LEVEL GAUGE
(MOG)
TRANSORMER
BUCHHOLZ
RELAY
5. CLOSE AIR VENT VALVE
6. CHECK MOG POINTER INDICATES FULL LEVEL
7. CHECK PRISMATIC OIL GAUGE (POG) INDICATES FULL OIL
6. RELEASE TRAPPED AIR FROM BUCHOLZ RELAY
7. CHECK MOG AND POG SHOWS FULL LEVEL INDICATION
8. IF MOG LEVEL IS NOT HOLDING CHECK AND ARREST
THE AIR LEAK IN THE CONSERVATOR ASSEMBLY
9. REPEAT THE PROCEDURE No. 1, 2 & 3
10. REMOVE PUMP AND OIL HOSE PIPE CONNECTION
6.3.6.1 OIL FILLING PROCEDURE FOR AIR CELL CONSERVATION