Disclosure to Promote the Right To Information

Whereas the Parliament of India has set out to provide a practical regime of right to
information for citizens to secure access to information under the control of public authorities,
in order to promote transparency and accountability in the working of every public authority,
and whereas the attached publication of the Bureau of Indian Standards is of particular interest
to the public, particularly disadvantaged communities and those engaged in the pursuit of
education and knowledge, the attached public safety standard is made available to promote the
timely dissemination of this information in an accurate manner to the public.

1 +, 1 + 01 ' 5
Mazdoor Kisan Shakti Sangathan Jawaharlal Nehru
The Right to Information, The Right to Live Step Out From the Old to the New

IS 8478 (1977): Application guide for on-load tap changers

[ETD 16: Transformers]

! $ ' +-
Satyanarayan Gangaram Pitroda
Invent a New India Using Knowledge

! > 0 B


BharthariNtiatakam
Knowledge is such a treasure which cannot be stolen
 IS : 8478.1977
( Reaffirmed 2001 )
Indian Standard
APPLICATION GUIDE FOR
ON-LOAD TAP-CHANGERS
[ Second Reprint JANUARY 1991 )

ULX 621.314.214.332

0 Copyright 1978

BUREAU OF INDIAN STANDARDS

MANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARG
NEWDELHIllOOU2
Gr3 January 1978
 IS : 8478. 1977

Indian Standard
APPLICATION GUIDE FOR
ON-LOAD TAP-CHANGERS

Transformers Sectional Committee, ETDC 16

Chairman
SHKI U. K. PATWAHDHAN
Prayog Electricals Pvt Ltd, Bombay

Members
SHRI S. AMMEERJAN
SHRI N. S. S. AROK~~WAMV
SHRI M. K. SUNDARARAJAN (Alternate)
SWRI B. G. BHAKEY
DR B. N. JAYARAM (Alternate)
SHRI A. V. BHEE~IARAO
SHRI J. S. IYER (A&mate)
SHRI S. D. CHOTRANEY
SHRI Y. K. PALVANKAR(Alternate)
DIRECTOR(TRANSMISSION)
DEPUTY DIRECTOR(TRANSMISSION)
SHRI T. K. GHOSE
SHRI P. K. BI~ATTACHARJEE (Alternate)
JOINT DIRECTOR(SUB-STATION)
DEPUTY DIRECTORSTANDARDS
(ELECTRICAL)(Alternate)
SIIRI J. K. KHANNA
SHRI K. L. GARB (Alternate)
SIIRI B. S. KOCHAR
SFIRIR. D. JAIN (Alte,mtcj
SIIRI J. R. MAHAJAN
SHRKP. K. PHILIP (Altej/late)
SHRI D. B. MEHTA
SHRI R. CHANDRAMOULI (Alterna?)
SHRI D. V. NARKE
SHRI ISHWAKCIIANDRA (A&mate I)
SHRI PREM CIIAND (Alternate II),
SIIRI I. S. PATEL
ReprerenCing
Bharat Heavy Electricals Ltd (R&D Unit), Bhopal
Tamil Nadu Electricity Board, Madras
Kirloskar Electric Co Ltd, Bangalore
Gujarat Electricity Board, Vadodara
Bombay Electric Supply and Transport Under-
taking, Bombay
Central Electricity Authority, New Delhi
(Altemate)
Calcutta Electric Supply Corporation Ltd, Calcutta
Research, Designs and Standards Organization
(Ministry of Railways), Lucknow
Directorate General of Supplies and Disposals
(Inspection Wing), New Delhi
Rural Electrilication Corporation Ltd, New Delhi
Indian Electrical Manufacturers Association,
Bombay
Tata Hydro-Electric Power Supply Co Ltd,
Bombay
Bharat Heavy Electricals Ltd, Bhopal
Hindustan Brown Bovcri Ltd, Bombay

(Continued on page 2)

I
0 Coprright 1978
BUREAU Oe INDIAN STANDARDS
This publication is protected under the Zndiun Copyright Act (XXV of 1957)
and
reproduction in whole or in part by any means except with written permission of the
publisher shall be deemed to be an infringement of copyright under the said Act.
IS : 8478- 1977

(Continued from page 1)

Members
SHRI V. N. PRAZILAD
SHRI A. G. GURJAR (Alternate)
SHRI K. N. RAMASWAMY
SHRI S. K. PALHAN (Alternate)
SHRI CHANDRA K. ROHATCI
SHRI D. P. SAHGAL
SHRI A. R. SALVI (Alternate)
SHRI I. C. SANGAR
SHRI R. C. KHANNA (Alternate)
SHRI K. G. SHANMUKHAPPA
SHRI P. S. RAMAN (Alternate)
SHRI.M. A. SHARIFF
SHRI B. C. ALVA (Alternate)
SUPERINTENDING ENGINEER(OPERA-
TION)
SUPERINTENDING E NGI NEEK
TECHNICAL (PROJECTS)(Alternate)
SHRI C. R. VARIER
SHP.I S. V. MANERIKAR (Alternate)
SI~RI T. RAJARMAN,
Deputy Director (Elec tech)
Refwesenting
National Electrical Industries Ltd, Bombay
Directorate General of Technical Development,
New Delhi
Pradip Lamp Works, Patna
Siemens India Ltd, Bombay
Delhi Electric Supply Undertaking, New Delhi
NGEF Ltd, Bangalore
Karnataka Electricity Board, Bangalore
Andhra Pradesh State Electricity Department,
(Electricity Projects and Board), Hyderabad
Crommon Greaves Ltd, Bombay
*
Director General, IS1 (Ex-o#cio Member)

Secretary
SHRI VIJAI
Deputy Director (Elec tech), IS1

Panel for On-Load Tap-Changers, ETDC 16 : P5

Cowener
SHRI D. V. NARKE Bharat Heavy Elcctricals Ltd, Bhopal

Members
SHRI S. C. AGARWAL (Alternate to
SHRI D. V. NARKE)
SHRI R. C. CHANDRAMOULI Tatd Hvdro-Electric Power Supply__ Co Ltd,
Bombay
SHRI S. V. MANEIUKAR Crompton Greaves Ltd, Bombay
SHRIV.N.PRAHLAD National Electrical Industries Ltd, Bombay
SHRI A. G. GURJAR (Alternate)
SHRI c. s. N. RAJU NGEF Ltd, Bangalore

2
 IS : 847%- 1977

APPLICATION GUIDE FOR

ON-LOAD TAP-CHANGERS
0. FOREWORD
0.1 This Indian Standard was adopted by the Indian Standards Institution
on 24 May 1977, after the draft finalized by the Transformers Sectional
Committee had been approved by the Electrotechnical Division Council.
0.2 In the preparation of this standard assistance has been derived from
IEC DOC: 14 (Central Office) 9, Draft application guide for on-load tap-
changers, issued by the International Electrotechnical Commission.
0.3 For the purpose of deciding whether a particular requirement of this
standard is complied with, the final value, observed or calculated, expressing
the result of a test, shall be rounded off in accordance with IS : 2- 1960. The
number of significant places retained in the rounded off value shodd he
the same as that of the specified value in this standard.

1. SCOPE
1.1 This application guide is intended to assist in the selection of suitable
on-load tap-changers for use in conjunction with the tapped windings of
transformers or reactors (referred to as transformers in the following text).
NOTE 1 -All the tap-changers referred to shall be presumed to comply with the
requirements specified in IS: 8468-1977t.
NOTI% 2 -The provisions of this application guide are not mandatory and only re-
present advice to the tap-changer manufacturers and purchasers. The responsibility for
the correct application of the fully assembled tap-changer in connection with the tram-
former is with the manufacturer of the transformer.

2. SELECTION OF A TAP-CHANGER
2.1 General - Since the on-load tap-changer represents only a small part
of the total cost of the equipment in which it is used, it should be freely
chosen to suit the ~equipment. However, account should be taken of the
available standard types of tap-changers.
2.2 Insulation Level - The following values occurring on all tapping
positions of the transformer should be checked against the tap-changer
manufacturers declared values in accordance with IS : 8468-1977t :
a) Normal power frequency operating voltages appearing on the
tap-changer in service,
*Rules for rouhding off numerical values (revbd).
tspecification for on-load tap-changers.

3
IS : 8478 - 1977

1~) Power frequency voltages appearing on the tap-changer during

tests on the transformer, and
c)Impulse voltages appearing on the tap-changer during tests on the
transformer or in service.
NOTE- With some winding arrangements the voltages appearing on thr transformer
can be abnormally high, for cxamplc, star-point tappings in auto-transformers, line-end
tappings, and booster transformer arrangements.
Ihrsc voltages can br aKectcd considerably by the choice of linear, coarse/fine or re-
vrrsing lapping arrangcnxnts. Variable flux voltage variation (VFVV) and combined
voltage variation (cbVV) as defined in IS: 2026(Part IV)-1977* also can affect the
voltages appearing on various parts of the tap-changer.

2.3 Current - Ihc tap-changer should satisfy the conditions specified

in 2.3.1 to 2.3.3.
2.3.1 Rated Through-Current - The rated through-current of the tap-
changer as defined in IS : 8468-1977t should not be less than that resulting
from the highest value of tapping current of the tapped winding of the
transformer [sue 4.1 of IS : 2026 (Part I)-1977$].
2.3.2 Overload Current - When tap-changers are fitted on transformers
which are subjected to overload conditions in accordance with IS : 6600-
19724, they shall generally be restricted to the occasional overload conditions
stated in 4.1 of IS : 2026 (Part I)-1977: unless specifically ordered for
other overload conditions by the transformer manufacturer.
The above requirements are met:
a) if the maximum rated through-current of the tap-changer is at least
1.2 times the highest tapping current of the transformer, or
b) if the tap-changer manufacturer is able to demonstrate that the
temperature rise limits given in 8.5 of IS : 8468-1977t are not
exceeded when the contacts carry 1.2 times the maxinium rated
through-current. (The values of current to apply for the other tests
specified in 8 of IS : 8468-19771_ remain based on the value of the
maximum rated through-current.)
The number of tap-changer for each occasional overload period is limited
to the number of operations corresponding to one half of one complete
operating cycle and the peak temperature rise of the transition resistors
does not exceed 300C for oil-environment tap-changers.
Where tap-changers are subject to overload conditions not in accordance
with the limitations stated in IS : 2026 (Part I)-1977: with regard to
IS : 6600-19729, the tap-changer manufacturer should be consulted giving
current magnitude and duration so that the correct tap-changer can be
recommended for the duty required.
.
*Specification for power transformers: Part IV Terminal markings, tappings and connec-
tions (first r&ion).
tspecification for on-load tap-changers.
$3pecification for power transformers: Part I General (Jirst r&&n).
Guide for loading of oil immersed transformers.

4
 PS : 8478 - 1977

2.3.3 Short-Circuit Current - The short-circuit current of the tap;changer

as given in 8.7 of IS : 8468-19.77* ghould not be less than that resulting
from the overcurrent of the associated transformer as given in IS : 2026
(Part I)-1977t.
NOTE - Particular care should be taken to check this current on low impedance and
booster transformers. In some instances, the fault-current value could dictate the choice
of tap-changer.

2.4 Breaking Capacity -The highest tapping current and the voltage
per step of the transformer shall be within the values of rated throdgh-
current and relevant rated step voltage declared by the tap-changer manu-
facturer for the particular tap-changer.
For values outside of those declared, the tap-changer manufacturer should
be consulted.
For application to individual transformers with different currents and
step voltages, the transition impedance shall be designed so that the switched
current and recovery voltage in the tap-changer do not exceed those covered
by the type tests.
NOTE - In certain applications, such as furnace transformers, the tap-changer may be
called upon, if required, to operate during periods of momentary overloads of two to three
times the transformer continuous maximum rating. The diverter switch or selector switch
should be chosen so that it is capable of meeting this condition.
Where appropriate, the effect of variable flux voltage variation and combined voltage
variation on the step voltage, and in consequence on the breaking capacity should be
considered.

2.5 Number of Tapping Positions - The number ofinherent tap posi-

tions of the tap-changers is generally standardized with various manu-
facturers equipment. The selection of the number of service tap positions
shou!d preferably be made within that range.
As the extent of the tapping range increases, the voltages to be catered
for also increase and care shall be taken to avoid excessive voltages over
the tapping range when operating or testing at minimum winding positions.
The effect can be very marked on furnace and rectifier transformers feeding
electrolytic plant where wide tapping ranges tit-e often necessary and the
tap-changer is in the constant voltage winding (variable flux voltage
variation).
2.6 Discharge Problems with Changeover Selectors - It should be
noted that, under certain conditions, tap-changers with changeover selectors
can allow momentary disconnection of the tapped winding. In such cases,
discharges between the opening and closing contacts can occur during the
operation of the changeover selector, and in order to avoid difficulties with
regard to the dielectric stress and the formation ~of gases which could arise
when the tap-changer operates under high voltage to earth, s ecial pre-
cautions shall be applied. There are many different metho a s of over-
*Specification for on-load tap-changers,
TSpecification for power transformers: Part I General (first revision).

5
IS : 8478 - 1977

coming the problem, the use of two-way changeover selectors, control

resistors, or capacitive control between the main winding and the tapped
portion of the winding are some examples.

2.7 Mechanical Life - The mechanical duty may need consideration if

the expected number of operations per annum exceeds 20 000, for example,
this can occur on transformers for use on rolling mills, electrolytic plant
or furnace supplies.

2.8 Motor-Drive Mechanism - If the motor-drive mechanism is pur-

chased from a manufacturer other than the manufacturer of the tap-
changer then it is the purchasers responsibility to ensure that the motor-
drive mechanism is suitable for all its necessary duties.
2..9 Pressure and Vacuum Tests - Where applicable, the tap-changer
when fully assembled has to withstand all the pressure and vacuum tests of
its associated transformer. For these, the relevant instructions of the tap-
changer manufacturer have to be taken into account.

2.10 Low Temperature Conditions - Should the tap selectors, diverter

switches or selector switches be located in separate containers outside the
main transformer tanks, in air, and the ambient temperature be lower than
-5C, it is advisable to specify the quality of the insulating and/or lubricating
oils.
Shouldthe tap selectors, diverter switches or selector switches be located
inside the main transformer tank and the oil temperature can be lower
than -5C during operation, the tap-changer manufacturer shall be con-
sulted, taking the quality ofthe main transformer oil into consideration.
If necessary, automatically controlled heating devices could be provided
or, alternatively, means of preventing tap-change operation at abnormally
low temperatures may be considered.
2.11 Continuous Operation - If the tap-changer is required to operate
continuously the temperature conditions may need to be checked and the
tap-changer manufacturer should be consulted.

3. LOCATION OF OIL-IMMERSED TAP-CHANGER

COMPONtiNTS

3.1 Tap Selectors - Unless otherwise agreed between thr manufacturer

and the purchaser, the tap selectors may be located within the main trans-
former oil.
3.2 Diverter and Selector Switches - To prevent contamination of
the main transformer oil, oil-immersed diverter or selector switches should
be in a separate container which may be located inside oroutside the main
transformer oil. When located in the main transformer oil, it is not necessary
for the container to be absolutely oil-tight, providing that precautions are
 IS : 8478 - 1977

taken to avoid any mixing of the switch oil with the transformer oil and
that the oil in the container can be changed easily without lowering the oil
in the main transformer tank. Where appropriate, arrangements should
bc made for it to be made clear in the transformer maintenance instructions
that the main transformer oil should not be drained until all of the oil leas
been removed from the diverter switch container.
If an oil-tight container is required it should bc spcciliccl by the p~~rchascr.

4. FIELD SERVICE

4.1 Safety of Operation

4.1.1 Such protective devices as may be considered necessary ~h~ul~l be
connected in accordance with the manufacturers instructions.
4.1.2 In order to minimize switching under excessive overload or .&ort-
circuit conditions, it is recommended that, in the case of motor control,
a protective device should be fitted to prevent, ar if initiated to interrupt,
an operation of the motor-drive mechanism when the transformer load
exceeds the agreed value. The protective device may be in the form of a
contactor in the motor-drive mechanism.
NATE - In the case of manual control, protective devices are not considered necessary
as it is not normal practice to tap-change manually during periods of overload and the
probability of coincidence of a tap-change operation under short-circuit conditions is
negligible.

4.2 Parallel Operation - In the case of parallel operation of transformers

with-tapped winding, care should be taken by the manufacturer and the
user of the transformer to ensure that the currents circulating between the
transformersare limited to an acceptable value.
4.3 Contact Erosion and Oil Contamination - Tap-changers have
expendable items in their construction and the manufacturers figures should
be noted for maintenance periods in terms of time and in numbers of opera-
tions. Generally, expected contact life for a particular tap-changer is
given at rated through-current. If the load current of the transformer is
less than this value, contact life is increased.
The number of operations before oil-change is necessary, is conditional
on the oil being in good condition originally and maintained in a dry state.
For good utilization of the tap-changer, it is necessary to follow the mai -
tenance instruction book of the tap-changer manufacturer which general 3y
gives the above as a function of:
a) rated through-current, and
b) the service duty of the transformer.

5. INFORMATION REQUIRED WITH ENQUIRY OR ORDER

5.1 In order that the correct tap-changer can be supplied, the following
information should be given by the transformer manufacturer.

7
KS : 8478- 1977

5.1.1 Xatity otld General Bata

a) Relevant Indian Standard.
b) Number of tap-changers required.
c) Single-phase or polyphase units.
d) Number of phases in system.
cj Frequency.
fj J<atcd power, in I<VA, of apparatus to which the tap-changer is to
IK connected.
g) Rated voltage of the winding to which the tap-changer is to be
connected.
11j Winding connections.
j) Tapping range required given as percent above and below the
rated voltage of the winding [see IS : 2026 (Part IV)-1977].
lr) Number of service tap positions ~required, the numbering of these
positions and their identification with reference to the transformer
lappings.
m) Tapping arrangement, that is, linear, reversing or coarse/fine.
n) Position of tappings in winding, for exampJe, line end, middle, star-
point.
p) Highest tapping current of the winding to which the tap-changer
is to be connected [see IS: 2026 (Part IV)-1977*].
q) Maximum value and duration of short circuit current passing
through the tap-changer.
r) Phase voltage per step (if the step voltage varies over the range,
give full details together with associated currents).
sj On star-point tap-changers, if one neutral terminal or three separate
neutral terminal4 required.
t) The power frequency voltage appearing between the opening and
closing contacts of the changeover selector (see 2.6).
NOTE - The power frequency voltage has two componet+, that is! an inductive compo-
nent and a capacitive component, during the time the windmg is dlsconnected.
5.1.2 hulation I;evel - The following impulse voltage and power
frequency voltage test value should be given:
a) Highest voltage between the extreme tappings and, where applica-
ble, the highest voltage between the ends of the coarse tapping
winding section and the fine tapping section.
b) Highest voItage between the most onerously stressed tapping and
earth.
c) Highest voltage between tapping of adjacent phases.

*Specification for power transformers: Part IV Terminal markings, tappings and con-
nections (@t revision).

8
 IS : 8478 - 1977

d) Highest voltage between the diverter switch and earth.

ej Highest voltage between phases of the diverter switch..
f) Highest voltage betkeen open diverter switch contacts.
NOTE - If applicable, partial discharge and switching impulse levels should be given.
5.2 Pressure, Vacuum and Temperature Requirements
a) Maximum working pressure when oil-filled.
b) Maximum pressure during oil-tests on the apparatus.
c)Maximum vacuum to be applied.
d) Type of processing, maximum temperature, vacuum and duration
if the tap-changer is fitted before this operation.
e) Temperatures in s,>ecial environments, for example, noise enclo-
sures, etc.
f) Minimum ~operating temperatures and details of any special low
temperature requirements if below -5C.
5.3 Special
a) Details of periods of overload, value and duration (see 2.3.2 and
_IS : 6600-1972*).
b) Details of duty of apparatus, for example, distribution transformer,
arc furnace tranSfOrJnCr, etc.
c) Details of transport of transformer.
d) Any special reqltircments of the specification.
5.4 Fittings - Items not covered by the tap-changer manufacturers
standard, for cxamplc, valves, should bc spccikd.
5.5 Motor-Drive Mechanism- ro enable the correct control devices
to be included in the Jnotor-drive mechanism the fullest possible details
of the control scheme should be given, including any of the following basic
control functions if required, together with the type of device necessary
for the function.
Local electrical control and indication.
Remote electrical control and indication.
Automatic control and indication, with or without line drop
compensation.
Parallel control of two or more transformers. c
Supervisory control and indication.
In the case of remote and supervisory control and indication, the
approximate distance between the tap-changer and the control
point should be stated.
Auxiliary supply details for electrical motor and control equip-
ment, that is, normal voltage, maximum and minimum voltage
limits ifnot within the standard limits given in 9.2 of IS : 8468-l 977t,
ac or dc. If ac, frequency, number of phases and availability of
neutral.
*Guide for loading of oil-immersed transformer+
~Specilicntion for on-load tap-changers.

9
BUREAU OF INDIAN STANDARDS
Headquarters:
Manak Bhavan, 9 Bahadur Shah Zafar Marg, NEW DELHI 110002
Telephones: 331 01 31, 331 13 75 Telegrams: Manaksanstha
( Common to all Offices )
Regional Offices: Telephone
Central : Manak Bhavan, 9 Bahadur Shah Zafar Marg, I 331 01 31
NEW DELHI 110002 331 1375
*Eastern : l/l 4 C. I. T. Scheme VII M, V. I, P. Road, 36 24 99
Maniktola. CALCUTTA 700054
Northern : SC0 445-446, Sector 35-C, I 21643
CHANDIGARH 160036 3 1641
41 24 42
Southern : C. I. T. Campus, MADRAS 600113 ( 41 25 19
41 2916
tWestern : Manakalaya, E9 MIDC, Marol, Andheri ( East ), 6 32 92 95
BOMBAY 400093
Branch Offices:
Pushpak, Nurmohamed Shaikh Marg, Khanpur, I 2 63 48
AHMADABAD 380001 2 63 49
+,Peenya Industrial Area 1st Stage, Bangalore Tumkur Road I 38 49 55
BANGALORE 560058 38 49 56
Gangotri Complex, 5th Floor, Bhadbhada Road, T. T. Nagar, 667 16
BHOPAL 462003
Plot No. 82/83. Lewis Road, BHUBANESHWAR 751002 5 36 27
53/S. Ward No. 29, R.G. Barua Road, 5th Byelane, 3 31 77
GUWAHATI 781003
5-B-56C L. N. Gupta Marg ( Nampally Station Road ), 23 1083
HYDERABAD 500001
63471
R14 Yudhister Marg, C Scheme, JAIPUR 302005
{ 6 98 32
117/418 B Sarvodaya Nagar, KANPUR 208005 I :: e: 3;
Patliputra Industrial Estate, PATNA 800013 6 23 05
T.C. No. 14/l 421. University P.O.. Palayam 16 21 04
TRIVANDRUM 695035 16 2-1 17
inspection Offices ( With Sale Point ):
Pushpanjali. First Floor, 205-A West High Court Road, 2 51 71
Shankar Nagar Square, NAGPUR 440010
Institution of Engineers ( India ), Building, 1332 Shivaji-Nagar, 5 24 35
PUNE 411005

*Sales Office in Calcutta is at 6 Chowringhre Approach, P. 0. Princsp 27 68 00

Street, Calcutta 700072
tSales Office in Bombav is at Novelty Chambers. Grant Road. 89 66 28
Bombav 400007
tsaks~office in Bangalore is at Unity Building, Narasimharaia Square; 22 36 71
Bangalore 560002
Reprography Unit, BIS, New Delhi, India