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CAMTECH/E/2002/AT/1.

CHAPTER 4

PERIODIC OVERHAULING
Overhauling of a transformer is normally undertaken either if it is faulty (internal)
or at the end of 7 to 10 years of its service. Periodical Overhauling
(POH) of
transformer can be done either in repair shop or through trade.
4.1

TESTS PRIOR TO UNDERTAKING POH

Following tests shall be conducted on transformer before undertaking POH:
a) Measure dielectric strength (BDV), acidity and water content (PPM) of transformer
oil, ratio of transformer.
b) Dissolved gas analysis (DGA)of transformer oil.
c) Measure the insulation resistance of winding and polarization index.
Insulation resistance & polarization index of the windings and BDV, acidity & DGA
of transformer oil shall be recorded. The same shall be compared with the values
recorded after the completion of overhauling.

4.2

STEPS FOR OVERHAULING

4.2.1 Un-tanking of Transformer

Before commencing the work, drain out the oil, disconnect all leads and remove tank
top cover, accessories, conservator, fittings, HV & LV bushings and store them in a safe
place. One set of gasket of standard quality shall be available for replacement during
POH. Defects observed during inspection/test schedule for the subject transformer shall
be taken into account and defects like leakage in tank, conservators and radiators etc.
shall be attended permanently during POH of transformer.
4.2.2 Activities To Be Done During POH
The items which are required to be checked/attended
during overhauling are given below:
1.

Record brief history of the equipment

2.

Visual checking:
a.
Check condition of tank for cracks.
b.
Check HV. and LV. bushings for any
cracks/chipped discs.
c.
Check conservator tank, oil level indicator
glass.
d.
Check condition of silica gel container and
silica gel.

FIGURE 4.1
HV, LV BUSHING

Maintenance Handbook on Auxiliary Transformer

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e.
f.
g.

Check transformer oil leakage.

Check condition of drain valve.
Check condition of arcing horn.

3.

Before opening of equipment

a.
Measure I.R. values of windings.
b.
Measure BDV of transformer oil
c.
Check condition of tap changer.
d.
Measure Polarisation index
e.
Measure acidity, water content (PPM) and
tan delta.
f.
Measure DGA of transformer oil.
g.
Conduct ratio test.

4.

After opening the equipment

a.
Measure I.R. values of windings.

5.

FIGURE 4.2
WINDING AND TAP
CHANGER CONNECTION

b.

Check condition of core, windings and

lamination - core bolts

c.

Check earth connections

d.

Check for accumulation of water content/sludge inside the tank.

e.

Check condition of soldered joints.

Details of work to be carried out

a.
Clean winding and core with new filtered oil.
b.

Tighten core bolts and other fasteners to secure the core and winding
properly and replace by new one if worn out.

c.

Dry out winding and core by

keeping in oven.

d.

Observe daily improvement in I.R.

Values.

e.

Clean tank and apply insulated

paint, if required.

f.

Replace all gaskets, oil seal, O ring

or other rubber/neoprene items.

g.

Repair drain valve if needed.

h.

Tighten earth connection of the

equipment.

i.

Replace silicagel.

j.

Replace oil level indication glass, if required.

k.

Fill the equipment with new filtered oil with 50KV BDV, (60 KV BDV
for new oil as per RDSO requirement).

l.

Replace wornout contacts of tap changer.

Maintenance Handbook on Auxiliary Transformer

FIGURE 4.4
DRYING CHAMBER

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CAMTECH/E/2002/AT/1.

6.

After drying out the windings

a.

7.

Assemble the equipment with new gaskets.

Testing of equipment after assembling.

a. Conduct ratio test.
b. Measure winding resistance.
c. Measure voltage output at different taps.
d. Measure magnetising current.

8.

Final observation
a.

Check any unusual sound of equipment.

b.

Check leakage of transformer oil.

c.

Measure final I.R. Values and compare

with previous recorded values.
of

oil,

moisture

FIGURE 4.5
CHECKING OF WINDING
AND TAP CONNECTION

d.

Measure
BDV
content(ppm)

e.

Measure tan delta, polarization index and compare with previous recorded
values.

f.

Check acidity and DGA of oil

g.

Check control boxes, terminal boxes for water tightness against ingress of
moisture.

FIGURE 4.6
TERMINAL AND CONTROL BOXES
COMPONENTS

9.

Painting of equipment.
Performance of transformer after POH shall be evaluated by comparing
the result of Insulation Resistance , Polarization Index of windings , BDV, water
content (ppm), tan delta, acidity & DGA of transformer oil. All these values shall
be kept in records for monitoring the performance in service.
*****

Maintenance Handbook on Auxiliary Transformer

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February, 2002