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Techniques Distribution
Transformers
Apr ’02 , Author: Nag Ramesh
Nag Ramesh
© ABB India, BMTG - 1 -
60 Disclaimer 137
61 Power and Productivity for a better world 138
Medium sized Distribution Transformers
Caution
1. Installation of Transformer should be done by skilled personnel or contractors who are trained
and qualified in installation of Transformer and similar electrical equipment. All on-site
regulations must be carefully observed (installation regulations for electrical systems,
regulations for Transformers and environmental safety).
2. In order to eliminate danger to anyone, the Transformer must be installed in such a way that
touching the Transformer is impossible after it has been energized.
3. Precautions must be taken to ensure that access to the Transformer is possible only after it
has been isolated from the mains (e.g., by forced interlock between the switchgear and the
Transformer access doors), exceptions are customer requirements and Transformers with
cable boxes for both primary and secondary and Transformers mounted on pedestals with
porcelain to ground clearance > 2,74 m.
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4. To prevent any risk, suitable measures must be taken during erection and maintenance work to
ensure that the Transformer cannot be reconnected by any unauthorized persons.
Types of Transformers
Transmission of energy is generally divided in two parts; first is transmission over long
distances at high voltages, which is supported by Power Transformers.
The second part is distribution of the energy from substations to the various users; this
is supported by Distribution Transformers in various hierarchies.
Transformers of this type are used for receiving the energy from higher voltage
levels and to transform and distribute the energy to lower voltage level
substations (11 or 33 kV) or directly to large industrial consumers.
Types of Transformers
2. MEDIUM DISTRIBUTION TRANSFORMERS, MDT
Power range 315 - 5000 kVA
Primary voltage Up to 36kV
Available fluids Mineral oil, dimethyl silicone, esters and synthetic
hydrocarbons.
Transformers of this type are used to step down three phase high voltage to low
voltage for energy distribution, mainly in metropolitan areas and for industrial
applications.
These transformers are available in three phase dry type and oil filled (hermetically
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sealed or with Oil Conservator and Breather). In hermetically sealed type, flexible
corrugated tank walls enable sufficient cooling of the transformer and compensate
for changes in the oil volume due to temperature variations during operation.
Types of Transformers
Transformers of this type are used to step down three-phase high voltage to low
voltage for energy distribution, mainly in the countryside or low-density populated
areas.
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Types of Transformers
Vacuum cast means that the high voltage windings are cast-in in epoxy and cured
in vacuum. The high voltage windings are typically disk winding.
Types of Transformers
Resibloc® dry-type Transformers
Type 1 Type 2
Transformers – Standard Accessories
Wheels
When the replacement of one of the bushing components is required, follow the instruction
supplied with the part. In any case, it is advisable to keep one or more spare bushing and
relative gaskets as emergency spares.
Transformers – Standard Accessories
Arcing Horns on Bushings
They are provided on the bushings as a protection to the
transformer against transient over-voltages across
windings and earth due to lightning and switching surges.
They are generally provided on request. The lower horn
is fastened on to flange of the bushing with one of the
fixing screws and the upper horn is fixed to top end nut
of the bushing by means of a bracket.
Adjust the gaps ‘K” and “C” as per manufacturer's
recommendation.
System BIL Arcing Horn
Voltage Level Distance K (mm)
kV kV ABB IEC
12 75 60 85
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17.5 95 70 155
24 125 100 155
36 170 140 220
Transformers – Standard Accessories
Conservator
8
1) air inlet pipe (transformer side) 8) pipes and fittings for connection to the transformer tank
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2) conservator filling plug (transformer side) 9) pipes and fittings for connection to the tap changer
3) conservator supporting brackets 10) oil level gauge of the tap changer
4) bracket fixing plates 11) conservator. drain plug (tap changer side)
5) lifting lugs 12) conservator filling plug (tap changer side)
6) conservator drain plug (transformer side)
7) oil level gauge
Transformers – Standard Accessories
Oil level gauge 1 - Signalling switch The level gauge is made up of the following
2 - Float components:
3 - Rod - main body with Plexiglas graded
4 - Gland window
- float and drive
- magnet with external signalling
disk
- minimum oil level signalling switch
The switch contact is normally closed. Perform the electrical connections according to the Wiring Diagram
(being the terminal numbered on the board), or find the terminals through a simple continuity test. The level
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Before the transformer start-up, it is advisable to check the gauge and the switch for perfect operation, taking
into consideration that the switch trips slightly in advance in respect to the minimum level signal. No particular
maintenance is required for the level gauge. Eventual oil leakage can be eliminated by replacing the tight
gasket, after having lowered the oil level in the conservator.
Transformers – Standard Accessories
Silica Gel Breather
Silicagel braether is a transparent tank of salts of Silica chemically
1 - internal thread pure, with Cobalt indicator. The air sucked into the transformer (due
2 - inox cylinder to thermic contractions of oil mass) passes through this.
3 - transparent hose Silicagel absorbs humidity in the air signalling the reached degree of
4 - labyrinth saturation by change of colour:
5 – oil cup Orange or Blue = completely dry
Purple or Pink or White = completely saturated.
The salts contained in the breather can be taken off and regenerated
by heating them at 120-150°C until they get their original blue colour
again. The upper and lower parts of the breather consist of compact
casting in aluminium alloy. The transparent hose, which contains the
salts, is of Plexiglas or glass (for chlorinated oil transformer) and it is
protected by a stainless steel cylinder drilled in such a way as to
allow the visual inspection of salts.
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In the lower part there is a closing system which prevents the contact
between air and salts: this closing system can be mechanical or
hydraulic, and allows the air passage in the two directions (inlet and
outlet) only when there is a pressure difference between the inside
and the outside of the transformer.
Transformers – Standard Accessories
Silica Gel Breather (contd.)
Silicagel breather is normally shipped disassembled to avoid alteration due to oil leakage
caused by transports jolts. It must be assembled to the suitable pipes coming from the
conservator of the transformer. The oil cup must be attached to the breather after removing the
cork plug on the breather. Fill the oil cup with oil up to the mark on the cup before fitting it on to
the breather. Silicagel breather needs no particular maintenance, apart from periodical
regeneration (or replacement) of salts, and periodical check of oil level in the cup.
1. Terminal board
2. Assemble the Buchholz and related gaskets between
2. Breather cock
the flanges of the pipes placed between the cover of the
3. Mechanical test button
4. Gland
transformer and the conservator; an arrow on the relay
5. Drain plug shows the direction of assembly from the transformer to
6. Inspection holes the conservator.
7. Pneumatic test valves
Transformers – Standard Accessories
Buchholtz Relay
3. Connect the earth, alarm & tripp terminals: their identification is
made with the diagram on the relay.
4. Make sure that eventual shut-off valves are open; then fill the
Buchholz relays with oil through the conservator.
In any case, both contacts have to be handled with care in order to avoid internal damages and de-
calibration. Such relays must be stored in their original packages during storage. However, it is
advisable to keep at least one spare part complete of gaskets because model change and it is not
always possible to interchange them.
Transformers – Standard Accessories
Gas drawing device
The gas drawing device must be connected to the breather pipe
of Buchholz relay by means of the suitable tube foreseen for
this purpose, and must be fixed to proper support according to
the overall dimension drg.
After filling it with oil, breathe from the cock (item 3).
During the normal working the cock (item 2) is open, while 3
and 4 are closed. This way the box and the tube are filled with
oil.
If you want to draw the eventual gas collected in the Buchholz
relay, open cock 4 taking care to let cock 2 always open: thus
the oil can come out from the box and the gas contained in the
relay can enter the box.
When gas has moved into the box (check through the
graduated hole) close cocks 2 and 4. To drain gas open cock 3.
1. Connection to Buchholz relay
2. cock
3. Breathing and gas drawing cock The gas drawing device is also equipped with a gas inlet valve
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4. Oil drawing and drain cock for the relays circuit test. This test has to be carried out before
5. Gas inlet valve for relays circuit test starting the transformer up, operating the same way as stated
for the Buchholz relays. Before assembling, keep the device
stored in its original package.
Transformers – Standard Accessories
Pressure relief valve/ Explosion vent 1. Switch for opening signal
2. Breathing screw
3. Spacer
4. Gasket
5. Holes for screw stud
6. Visual Indicator for valve opening
7. Orienting cover
8. Fixing screws for the protecting cover
9. Valve body
10. Gasket seat
11. Calibrating nut
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Transformers – Standard Accessories
Pressure relief valve/ Explosion vent
Spring loaded explosion valve is usually supplied already mounted on the transformer.
Its assembly must be carried out placing the valve case and its gaskets on the proper hole on the
transformer, as indicated in manufcaturer’s drawing.
After filling the transformer with oil, trapped air must be let out by loosening the breathing screws
and then tightening them back.
At this point the protecting cap must be so positioned by orienting it as to direct the hot oil sprays
in the least dangerous direction, in case of eventual opening.
These vents are equipped with the following devices:
- a calibrating nut placed on the central stem, which blocks the springs. If the nut is screwed up the pressure
rises, and viceversa. The calibration ranges normally from about 0,2 to 0,7 atmosphere;
- a visual indicator for valve opening: this is a pin projecting from the central part of the protective cover
when the valve opens. To make it go back to its right position it is necessary to push it in side wards;
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- a signalling switch: this is a quick-trip limit switch enclosed into a tight box. It operates simultaneously with the
visual indicator; the contact can be normally closed or open. Signalling is continuous until the visual indiactor
is put again in its normal position. Pressure relief valve/ Explosion vent has to be stored in its original packing
until assembly. Before assembling, it has to be made are free from dirt and moisture. No particular
maintenance is required.
Transformers – Standard Accessories
Radiators A - Lifting hook B - Upper shut-off valve
C – Gasket D - Upper breathing valve
E - Fixing plaque for radiators F - Lower shut-off valve
G - Oil drain valve H - Shut-off valve Lever
- Make sure that the shut-off valve (B&F) are safely closed: remove the caps from
valves and radiators;
- Place the gasket (C) in the proper seats;
- Assemble one radiator at a time, fill it with oil, proceeding as follows:
a) open the breathing valve (D) of the upper header;
b) open the lower shut-off valve (F) making the oil flow into the radiator
very slowly, in order to avoid air bubbles;
c) when the radiator is filled with oil, close the upper breathing valve;
d) open the upper shut-off valve (B) to permit the oil circulation.
Proceeding as above, the oil level in the conservator decreases: therefore
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- Open the drain valve (G); empty the radiator pouring oil into a dry clean
receptacle;
- Remove the radiator, place the closing caps on the shut-off valves (B&F)
without removing the gasket (C) from their seats;
In some designs, winding top oil temperature gradient is added to top oil temperature in the dispaly
unit using only an OTI and winding current transformer output. Like OTI, WTI also has alarm and
trip contacts. On actuation of trip contact, upstream circuit breakers must be tripped with proper
wiring from WTI/ marshalling box to HT Panel. Sometimes additional contacts are provided in WTI
for control of additional forced cooling equipment.
Normally a WTI does not need any calibration at site. Mounting instructions are similar to that of
OTI.
In case of dry type type transformers, WTI will be 3 or 6 pt100 elements or thermistors embeded in
the top of the winding and the sensors are connected to a temperature indicator-cum-scanner
mounted on terminal box.
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Transformers – Standard Accessories
Protection Junction Box (Cable Termination Box)
1-2-3 - Fastening methods fixing the junction box to the transformer cover
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1. Connect the Junction box to top cover of Transformer (or its termination box already assembled on to
transformer). Remember to use the gasket (although not shown in the above diagram).
2. Connect the cable termination busbars to the bushings.
3. Assemble the glands and the gland plate to the box.
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Some accessories like Surge Arrestors and Current Transformers are also mounted inside the Cable
Termination Box.
Transformers – Gaskets
Gaskets of the cover, flanges and bushings are usually made of oil-resistant,
vulcanized cork-sheets or oil resistant rubber. When the gaskets are leaking, the leaks
can usually be stopped by tightening the bolts. When a gasket has to be detached or
replaced, the sealing surfaces should be carefully cleaned and smeared with sealing
varnish (oil resistant Shellac).
When joining two gaskets, their ends should be bevelled and glued.
Oil-resistant rubber rings are used as gaskets for bushing bolts, shafts and spindles.
Oil-resistant and heat-resisting plastic gaskets can also be used as shaft and spindle
gaskets. All these gaskets can be tightened and replaced from outside the tank. When
tightening the gaskets utmost care must be taken to prevent breaking of bolts or
gaskets. In particular stud nuts must be tightened very carefully.
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30. WTI
33. OLTC Surge Relay
34. Surge Relay shut-off
valve
39. Anti earth-quake
clamping
A completely assembled Transformer (typical 1600 kVA)
Side View 16. Oil level gauge
17. Conservator
compartment
for OLTC
19. Explosion vent
with oil sight
glass with
double
diaphragm
36. Silica Gel
breather for
OLTC
conservator
compartment
37. Bottom Oil
sampling valve
with plug
38. Dial type
magnetic oil
level gauge
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A completely assembled Transformer (typical 1600 kVA)
Plan 2. HV Cable Box with
disconnecting chamber
3. LV Busduct
4. LV additional neutral
bushing
11. Air release plug
12. Thermometer Pocket
for Glass bulb
Thermometer
13. Radiator with air
release plug, lifting lug
and drain valve
14. Radiator valve
23. Top filter valve with
plug
26. Lifting lug for complete
transformer
27. Lifting lug for top cover
and active part
28. Marshalling Box
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The transformer is supplied filled with oil and normally all accessories fitted,
except for the largest units. The radiators, condenser bushings and
conservator may be dismantled during transport.
During transportation the transformer is filled with oil so that active part is
fully immersed in oil and oil level is below the lower cover surface;
however, the oil level is left sufficiently low for bushing installation.
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Transportation of Transformers
During transport the following should be considered:
Handling, lifting
The Transformer must be kept in normal upright position, unless otherwise indicated by the
documents.
Only approved and suitable lifting equipment should be used.
Forklift should be used only under transport pallets or transformer bottom.
Load should not be applied to corrugated fins or radiators and their supports.
While lifting the Transformer, only the fixtures provided should be used (transport eyebolts/
lifting lugs, bugles, lifting/ jack pads).
When hydraulic jacks are used, only provided jacking points should be used, and in such a
way that twisting forces on the transformer tank are avoided.
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Bushings, Cable Boxes or Conservators should not be used for lifting, pulling or pushing the
Transformer.
When lifting a transformer with cable boxes on the cover, special care must be taken.
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- Check the way in which the transformer has been secured on the trailer,
- Check whether the delivery is complete according to order confirmation,
- Compare the packing list with the goods received:
tank;
- Impact recorders indications when applicable;
The receipt of the unit shall be signed for, and the result of the inspection shall be noted.
Receiving the transformer at site
3. Transformer shipments are normally insured.
In case of damage revealed during the receiving inspection, do the following:
• Make necessary arrangement to avoid further damage,
• Contact the insurance company concerned and Supplier,
• Make a report of the damage immediately,
• Do not start repairs until responsibilities are clarified and actions are agreed
upon by all involved parties.
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Storage of Transformer prior to energizing
When storage of the transformer is required, the following
recommendations should be noted:
• Store preferably in dry and clean locations, without any possibilities of mechanical
damage and on a solid foundation.
• If the transformer does not have a structural steel base, it should be placed upon
supports to allow ventilation under the bottom of the transformer base.
• If the Transformer is not filled with oil, fix the conservator and dehydrating Breather
and fill it with oil up to the level corresponding to normal service temperature.
• The Oil conservator and dehydrating breather must be checked to ensure that dry
air is breathed (Conservator type only). Oil samples to be analyzed regarding
moisture content prior to energizing.
• Humidity/ condensation in control cubicles, driving mechanism for on-load tap
changer, cable boxes and in cabinets of dry-type transformers etc. should be
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inspected/ removed.
Storage of Transformer prior to energizing
When storage of the transformer is required, the following recommendations
should be noted:
• Any drying and heating equipment of the cabinet (if any) must be connected to electric supply,
to prevent the Transformer getting damp (especially in the case of dry type Transformer).
• Storage temperature for dry-type transformer is in general: -25°C to 50oC, however for
Resibloc: -60°C to 50oC. Oil filled Transformer: 5o to 50oC. Relative humidity should be less
than 75%. If such a storage area is not available, then the Transformer must be kept under a
sun-roof covered all around with thick plastic sheets with good ventilation.
• Surface damage caused by transportation and installation must be repaired by touching up
with paint of original color and shade. It is better to get a small can of the paint from the
manufacturer of Transformer along with the Transformer.
• Prior to energizing, perform a megger test between the different windings, and from the
windings to earth. This applies to dry-type in particular.
• Conservators must be stored into closed rooms without removing the gauges and the flange
caps.
• Bushings must be kept in a dry indoor space, in their original packing.
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• Radiators can be kept outdoor, but their mounting flanges must be protected against corrosion.
Indoor Installation
1. The Transformer room has to be dry, dust-free, suitably spacious and adequately
ventilated.
2. Floor area must be adequate so that the Transformer is accessible for cleaning and
inspection from all sides. Clearance between the wall and the transformer should be
0.75 m (wall on one side), 0.75 m (wall on two sides), 1.0M (wall on three sides),
1.25 m (wall on four sides, for transformers installed in cell/ collapsible front wire
mesh).
3. Height of the room is defined by the space required for bushings, cables entrance
and by air flow required for cooling. Minimum vertical clearance between the top of
conservator tank and ceiling shall be 0.6 m.
4. When required it must be possible to lift the active part of the Transformer out of the
tank while in the Transformer room for inspection. Otherwise, the Transformer will
have to be moved to a place with necessary clearance height for lifting the active
part.
5. The Transformer room has to meet the safety regulations regarding the construction
and location. Pay attention to requirements as per Indian Electricity Code regarding
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of 600 mm above tallest part of the Transformer and extends 1 m on both sides
of the Transformers, can be used as a protective wall. Protective walls also help
against vandalism and noise suppression.
Foundation Construction – rails and shims
1. Transformers are usually installed on a concrete foundation equipped with
horizontal mounting rails. The Transformers are delivered with rollers installed or
without rollers installed. Transformers on rollers must be fastened to foundation
by wedges welded or bolted to rails or other means to prevent movement.
2. In order that gas, which may be generated in the Transformer, can freely move
to the gas relay (Buchholtz relay), the Transformer has to be installed
horizontally or slightly ascending towards the relay. The recommended ascent is
1-20. This can be accomplished by means of intermediate plates (shims) placed
between the Transformer and foundation or between rollers and roller beams.
Shims may also be used to adjust any minor height difference between
Transformer secondary terminations and bus ducts leading from secondary to
Switchgear Panels.
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Foundation Construction – oil pit and oil sump
3. An oil pit is recommended to be built under the Transformer location to prevent any
oil fire spreading to other equipment. Its purpose, in case of oil leakage due to
damage to Transformer, is to prevent and extinguish fire and collect the oil to
prevent the fire from spreading.
The oil pit has to extend beyond the Transformer on all sides and is generally
made of concrete. It must be big enough to contain the total oil quantity or
alternatively allow the oil to be led via a discharge pipe into a separate oil sump.
The oil pit must be so designed that the oil is extinguished when it runs into the
sump. Wire netting is suitable for this purpose. The net must be installed over the
mouth of the cavity built at the bottom of the pit and which leads to the oil discharge
pipe. Coarse gravel is also suitable for this purpose. Then the pit must be covered
with a dense steel grating at the bottom leaving 7.5-10 cm bottom clearance. Top
of the grating must be covered with 25-50 cm deep layer of flatter stones and on
the surface with 35-50 cm of gravel.
If the installation has several Transformers, a common oil sump for collecting oil
can be built outside the building. The oil pits of different Transformers must not be
connected to each other, but they can be connected to a common pipe leading to
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2. In case of a large Transformer, it is advisable for the rails of the foundation to reach the transport
path and be at the same level.
3. If the transport truck is driven close to guide rails, the Transformer can be lowered onto rails by
means of cranes.
4. Then two jacking points which are on one of the smaller sides are lifted up simultaneously and
slowly by hydraulic jacks by 50 mm max and then other two jacking points are similarly lifted.
This is repeated until the Transformer is lifted enough to fix the rollers/ wheels. Alternatively all
the four jacking points may be lifted simultaneously. Then all the rollers/ wheels are fixed and
the Transformer is lowered not more than 50 mm on each side until the Transformer rests firmly
on its wheels/ rollers. Then jacks are removed and the Transformer is drawn to its final place
along the rails.
5. If a crane is used to move the Transformer from its place of storage or unload from a truck on to
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its foundation, the foundation height is not of great importance, but space must be allowed for
moving the crane boom & hook around and above the foundation. The foundation must be
provided with locations for hydraulic jacks which have to be installed according to the
corresponding lifting levels of the Transformer. The foundation must be provided with hauling
hooks for fixing of pulling ropes.
Minimizing noise emission
Depending on the location of the Transformer room, it may be necessary to provide
sound insulation, e.g. anti-vibration pads to avoid transmission of vibrations to
the structure.
Cooling fans, reflections from walls and resonance added to the noise emitted from
the Transformer may increase the noise level considerably. Therefore, it is
advisable to install the Transformer as far away as possible from walls.
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Oil sampling from a Transformer
Accurate sampling is extremely important to ensure
that the sample is representative of the oil in the
Transformer.
Use a 300cc stainless steel oil sample bottle with
plastic tubing available from a laboratory or the
manufacturer. Check that sample bottle is sealed. If
the seal is broken, then clean the bottle with acetone,
blow it out with dry air and dry it under vacuum. To
take oil sample, connect the two sections of the plastic
tubing to the sample bottle through gas cock
connectors. Attach one tube to the sampling valve on
the Transformer. The open end of the other tube
should be placed in a scarp liquid container.
Open both the valves of the sample bottle. The
sample bottle should be held in vertical position with
connection to the Transformer sampling valve below
the sampling bottle. Very carefully open the sampling
valve of the Transformer and fill the sample bottle until
the oil overflows through the top and into the scrap
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container.
Continue overflowing until no bubbles can be seen through the plastic tubing and until two quarts
of oil have been collected in the scrap container. Close the top valve of the sample bottle, then
bottom valve of the sample bottle and finally close the Transformer sampling valve and
disconnect the plastic tubing. Tag the sample bottle showing the Transformer serial number,
date of sampling, location and owner of the Transformer and send the bottle to a laboratory for
analysis. Avoid shaking and jerks to the sample bottle.
Oil sampling from an oil drum or tanker
The sampling bottle should
have a trap at the bottom.
2. Check and tighten all gaskets and carry out cleaning operations.
3. Check oil level in the oil conservator and top up with oil if necessary.
4. The dielectric strength of the oil will be normally given Transformer’s operation
and maintenance manual. Test the dielectric strength of the oil, if less than
required arrange for oil filtration. The minimum value should be 40 kV/ 2.5 mm
when tested with a device as per IEC 60156.
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Erection of Transformers transported with loose parts and filled with Oil
6. During transportation, inlet and outlet of radiators (if any) are covered with solid flanges to
prevent ingress of humidity and impurities into the radiators. These flanges must be
removed then the radiators must be installed on the flanges provided on the Transformer
tank.
7. For removal and installation of radiators, the fixing flanges of the Transformers are provided
with shut-off valves which ensure that the Transformer is not emptied of oil. If the radiators
are to be removed for a longer period, e.g. for transportation, then the mounting flanges of
the transformers are also blocked with solid flanges. These flanges are also to be removed
after ensuring that the shut-off valves are completely closed.
8. After all the parts are fitted, the oil required for the radiators and oil conservator must be
added to the Transformer. While filling the oil, ensure that clean Transformer oil is carefully
pumped into the oil conservator. If possible use a vacuum filter to process the oil in separate
drums during filling.
The lower shut-off valves must be open and upper shut-off valves must be first closed during
oil filling. The air release screws on top of the radiators should also be open until
the radiators are filled with oil. Keep them open until oil starts oozing out of the air release
screws of the radiators. Then upper shut-off valves of the radiators must be opened.
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Top-up the conservator with oil until oil level indicator rises up to the height corresponding to
temperature that will prevail in the normal operation.
Erection of Transformers transported with loose parts and filled with Oil
Then trapped air must be released after oil filling in following order:
Releasing air can be carried out by using air release screws fitted at suitable
places. For bushings which do not have air release screws, upper gaskets must
be loosened and retightened after the air is released.
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Erection of Transformers transported with out Oil
1. The Transformer is filled at the factory either by dry air or Nitrogen at
overpressure of 50 kPA (approx 0.5 bar) or at normal pressure depending on the
conditions of the journey, transport method, distance, etc.
2. For supervising the over pressure, the Transformer is provided with a manometer.
The Transformer should be filled with oil at site with in six weeks of dispatch from
the factory. If oil is filled after this period, the pressure must be checked
continuously and dry air or Nitrogen must be added when the overpressure falls
below 10 kPA (0.1 bar).
6. Before filling, take samples of oil from each drum and test the dielectric strength of
oil. The value should not be below 30 kV/ 2.5 mm.
Maintaining Nitrogen pressure at 0.5 bar, force oil into the Transformer tank from
bottom drain valve on the tank.
Then fix Radiators, Conservator and Bushings. Then fill radiators with oil as
already explained and top up the conservator.
has been exposed to outside atmosphere or in case external air ingress, consult
the manufacturer. The active part may have to be dried in such cases, before oil
filling.
Erection of Transformers transported with out Oil
While filling oil under vacuum, bottom drain valve of the tank is connected to a vacuum
machine and a vacuum of of o.5 bar (6.5 psi) is created. Then, the valve of the vacuum
pump is closed and the oil is forced into the tank from bottom drain valve. Filling speed is
correct if the vacuum does not considerably decrease during filling. Oil filling is
stopped when the windings and insulation parts are below the oil level. When de-aerated oil
is used, the vacuum must be maintained for several hours so that all the residual gas is
removed from the oil. Then the oil level is made up by filling the oil through the conservator
top valve.
7. If temperature of oil in the Transformer is different from 25oC, then oil level in the conservator
must be corrected to correspond to actual temperature. If the oil level indicator has
temperature scale, then oil is added or drained until the oil level is up to the prevailing
temperature.
If the oil level indicator does not have temperature scale, then the conservator is first filled up
to half the volume and then:
© ABB Inida, July 14-15/‘03 - 72, Author: Nag Ramesh
- if the oil temperature is higher than 25oC, oil level must be made up to above the middle
level;
- if the oil temperature is less than 25oC, then oil must be drained from the tank below middle
level.
Erection of Transformers transported with out Oil
The volume of oil to be added or drained is calculated according to following
formulae:
V = 0.00088 x dT x M for mineral oil;
V = 0.00104 x dT x M for silicone oil;
Where V is the volume of oil to be added or drained in liters;
M is the mass of oil in the Transformer at 25oC (giveno
on the name plate)
dT is the deviation of actual oil temperature from 25 C.
8. After filling the oil, allow the oil to settle to settle for 24-72 hours as per
manufacturer's recommendation for trapped air to come out and collect at the top.
9. Release any trapped air by opening air release vents provided on the Transformer.
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Additional Supports
It may be necessary to provide supports made out of MS angles or channels for
following accessories:
1. HT Cable Box;
2. LT Cable Box;
3. OLTC.
It is done to:
• Extract moisture from the oil;
• Filter the particulates (solid particles and carbon residues);
• Degas the oil (removal of gases generated and dissolved in the oil during
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2. Once the system is filled with oil, circulate the oil for 10 minutes to eliminate air
from the system, air vents provided at various points on the Transformer will have
to be slowly opened occasionally to let out the air and then closed.
3. The Filtration machine may have two modes of operation: Purification and
Regeneration. The choice of the mode depends on degree of contamination as
determined by oil analysis done prior to filtration, application and manufacturer's
recommendation.
4. Purification:
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This is limited to moisture extraction, degassing and particulate filtration. The oil
enters the machine where it is first heated by a set of electric heaters to maintain
the oil temperature between 65 to 70oC.
Oil Filtration Process
Then the oil is pumped through a pre-filter (5 microns) and a fine filter (0.5
microns). Then it enters a vacuum chamber and passes through fiberglass
coalescing elements where it is exposed to high vacuum and is degassed and
dehydrated. Then it is pumped back into the Transformer. The process is
repeated until moisture content falls below desired level and the required dielectric
strength is reached. The oil is tested at 4 to 12 hour interval (depending on the
size of the Transformer and manufacturer's recommendation) for moisture content
and dielectric strength
5. Regeneration
Oil is regenerated by forced percolation through columns of “adsorptive media” at
around 65oC. The adsorptive media consists of Fuller Earth (a type of clay).
Regeneration removes acids, sludge, restores oxidation stability and rectifies color.
After regeneration, oil is pumped through a 0.5 micron filter and then it is degassed
and pumped back into the Transformer. The process of regeneration takes around
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8-12 hours depending on the quality of oil being treated and the size of the
Transformer.
Oil Filtration Process
After several hours of regeneration, the clay beds get saturated and will have to
be reactivated. It is done by circulating the hot oil between the regeneration
columns and reactivation columns. After reactivation, a small quantity of (0.1% of
oil processed) oil scum is collected in a holding tank which drummed for resale
and reprocessing or for disposal as hazardous waste. Clean oil trapped in the
clay is recovered. Reactivation takes around 16 hours and upon its completion,
oil regeneration can be resumed.
6. De-sludging
Transformer may have to be de-sludged after several years of operation. The
process is similar to regeneration except that oil temperature will be above its
aniline point of about 75oC in order to dissolve the sludge inside the Transformer.
It is done with freshly regenerated oil.
Oil purification, regeneration and de-sludging can be done with the Transformer in
either de-energized or energized condition. However for first filling of oil and
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2. Cables and busbars must be of sufficient cross section in accordance with load
current.
5. For connections above 1000 A, flexible links must be used between busbars and
the Transformer terminals to compensate for thermal expansion of busbars.
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Power Circuit Connections
6. Following minimum clearances in air for phase-to-phase and phase-to earth
parts must be maintained. This also applicable for distances between cables and
windings.
System Voltage (kV) 3.6 7.2 12 17.5 24 36 52 72.5
Minimum Clearance acc. To 60 90 110 170 210 280 450 630
IEC 60076-3 phase-to-phase or
phase-to-earth (mm)
Lightning Impulse withstand 40 60 75 95 125 170 250 325
voltage (kV)
As most sites in India are lightning prone, it is advisable to consider above values.
M6 6 …9
Tap changer must be connected as per wiring
M8 15…22 diagrams. All current transformers must be
connected to measuring or instrumentation
M10 30…44
circuits. Secondary terminals of any CT not used
M12 50…75 must be shorted or earthed.
M16 120…190
Power Circuit Connections
9. Earthing connections
The earthing terminals of the Transformer must be connected to protective earthing system.
The earthing terminals are usually provided diagonally on the base beams. Cross section of
earthing conductors/ connections must be according to regulations and conditions at site.
For aluminium-copper joints the copper is coated with tin, or bi-metal sheets (one side of
copper and the other of aluminium) can be used between the joint.
The aluminium surface must be larger than the copper surface. Aluminium parts shall always
be placed above copper parts so that water cannot drain from the copper parts onto the
aluminium (corrosion).
It must be remembered that good contact between joined aluminium surfaces can be achieved
only if non-conducting oxide film is removed with a wire brush, file or similar immediately before
joining, and renewed oxidation is prevented by applying a thin protective film of grease (neutral
Vaseline).
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Jointing compound, which prevents the access of air and humidity into joints, must be used in
the joint. The zinc crystals of the compound break down the layer of oxide on the aluminium.
Power Circuit Connections
11. Neutral Link
Tap changer to be tried in all the positions for free operations and ensure equal
resistances between 3 phases in all taps of tap changer.
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Pre-energisation Checks
The following checks have to the performed after erection and before
start-up.
2. Deaeration of radiators
Open the upper breathing plug of radiators and remove the eventual air within.
Check whether details given on name plate are same as those in technical submittal
approved by customer and our specification.
Pre-energisation Checks
5. Check mechanical damage and paint
Repair either of painted parts, or of parts damaged during the transport or during the placing
of the transformer on its site.
A. Scratches in the paint, of limited depth, the metal is still covered with a
coat of paint, even of just some µ mm:
Use a clean cloth imbued with non-oil solvents (for example thinner used for vinyl paints)
to clean accurately the area, then proceed with the repairing of paint, with brush or roller
respect to the range of damage paint.
B. Deep cuts, up to the metal, with rust where the paint has been taken away:
Using abrasive paper, remove the paint from the area till the metal is white and
completely devoid of rust. Clean with a cloth imbued with non-oily solvents. Apply the
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paint cycle suitable for such transformer, following strictly the suggestions provided for
this type of transformer
Pre-energisation Checks
5. Check mechanical damage and paint (contd.)
If possible, sand blast till the metal becomes white, or alternatively take off the rust with
a metal brush; then rub down the border and, if necessary, retouch the brushed area.
Apply the painting cycle scheduled for the transformer, following the suggestions
indicated.
With a metal spatula lift and take away the paint as far as possible, insisting on
the borders, and then carry out the workings indicated in the previous point.
Before the application, check whether the the paint to be used for the retouches is of
the same type as the paint applied originally by the Transformer manufacturer. It is
better to get a can of the original paint from the Transformer manufcaturer.
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The above described suggestions are valid for all the metallic parts of the transformers.
As far as radiators are concerned, in case C or D check either the possibility of restoring
the paint or of replacing them. Do not use stucco to level the surface.
Pre-energisation Checks
6. Check oil leakage.
7. Check nuts and bolts tightness with torque wrench as per values given
earlier, setting the torque on the wrench in the middle of the range given.
18. Check installation of emergency push button switch near the Transformer or on the
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door of its enclosure and wiring to upstream breaker trip circuit in HT Panel.
22 to 33 kV 2500 V
Pre-energisation Checks
20. Insulation Resistance (Contd.)
The insulation resistance must be several thousand Mega-Ohm. However the value widely
depends on measuring time and the temperature of the Transformer. Convert the measured
values by multiplying with the conversion factors given in the following table:
30 1.98 75 44.70
Two readings must be taken one at 15 s and another at 60 s. Minimum value of 60 s reading must be
1000 Mega-Ohm. Further, difference between the readings taken at 15 s and 60 s is used to determine
dryness of the Transformer. R60/ R15 is normally between 1.2 – 3.0 in a dried Transformer. Value less
than 1.2 indicates that the Transformer has moisture.
Pre-energisation Checks
21. Auxiliary circuit insulation
Check the whole auxiliary circuits insulation by applying a 2000V-50 Hz for 6 s.
Measured value must be greater than 2 Mega-Ohm.
22. Check Oil dielectric strength and moisture content, if already done, review test results.
This test is important especially when two or more transformers are to be operated in parallel.
It is always better to carry out this test at the same time as voltage ratio measurement and
verify that the actual vector group corresponds to that indiacted on the rating plate.
1. Discommect any and all neutral earthing (both primary an seconday side)
2. Connect R phase terminal of primary to R phase terminal of secondary
3. Apply 3ph, 415 V, 50 Hz supply to HT side (which is usually primary).
Measure various voltages given below and verify that measured values conform to realtions
indiacted for concerned vector group.
Y
UYy < UYb U =U
Yy Yb
U <U U >U
Bb By Bb By
R, r UnY = Unr + UrY
URB = URb + UbB B
b n
y
Y U =U UYy = UYb
Yy Yb
N
© ABB Inida, July 14-15/‘03 - 98, Author: Nag Ramesh
UYy = UYb
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HT LT
Pre-energisation Checks
25. OLTC protective relay alarm contact
Check the protective relay of OLTC as per Instruction manual supplied by
Manufacturer.
26. OLTC oil level indicator contact
Check the alarm contact of OLTC oil level indicator release through
shunting the contact terminals.
27. Operation of Tap Changer (OCTC or OLTC)
Check whether tap position changes or not on giving rise and lower
commands and check tap position indication. Uaually On-Load Tap
Changer is provided with a motor drive mechanism and a protective relay to
monitor sudden flow of oil from diverter switch oil compartment to
conservator. Check wiring and operation of protective relay and operation
of motor drive. Refer manufcaturer’s instruction for operation and
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maintenance of OLTC.
28. If it is suspected that the Transformer has suffered a damage,
the following additional measurements must also be carried out.
27 a. Winding Resistance
27 b. Winding capacitance.
Pre-energisation Checks
An ordinary multi-meter may not be able to measure these values at all due to long
time constant and weak dc source of the meter. A dc source of 24 Vdc or higher
and an accurate resistance bridge and capacitance bridge will be required for these
measurements. Measured results must be verified with test reports of the
manufcaturer to arrive at any conclusion.
29. If the Transformer has been stored for a long time or has been inoperative for a
long time, dielectric strength of and moisture content in the oil inside the
Transfomer must be checked. The dielectric strength must be higher than 50 kV/
2.5 mm and moisture content must be less than 20 ppm. If not, oil level must be
made up and the oil must be filtered using an oil filteration machine.
In cold Transformers the humidity is mostly absorbed in the the paper insulation
which can not detected on the basis of oil study. In such cases monitor moisture
content in the oil once in 48 hours after putting the Transformer on load. If there is
a significant increase in the moisture content, take the Transfomer out of operation,
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the active part may have to dried in consultation with the manufcaturer.
The Silica gel breather must also be checked and gel re-activated if required.
Check-list to be filled in before energisation
Sl. No. Details Controlled Remarks
1 Deaeration of HV and LV bushing
2 Deaeration of radiators
3 Deaeration of Buchholz relay
4 Check nameplate data against data sheets
5 Check mechanical damage and paint
6 Check oil leakage
7 Check tightness of nuts and bolts
8 Check alarm - trip contacts of Buchholz relay
9 Check trip contact of pressure relief device
10 Check contact calibration of thermometer (OTI & WTI)
11 Check alarm contact of oil level indicator
12 Check all valves
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breaker. It may not be because of any fault but because of magnetising in-rush
current of the Transformer. The value of in-rush current depends on construction
and size of the Transformer, magnetic remanace of the core and the moment of
connection to the network.
Energisation
5. Switch-off transformer from voltage supply and check the gas in
Buchholz relay.
During first few days after a new Transformer is connected to network,
some gas may collect in the Buchholtz relay causing an alarm. This is normally
due to air that remained under the cover during installation. When the
Transformer warms up, this air starts moving up and accumulates in the
Buchholtz relay. The quality of the gas can be seen from its colour and usually
from smell. If it is air, then it will be colourless and will not have any smell. If it is
otherwise, a gas sample will have to be taken and analysed in consulation with
the manufcaturer.
If the gas collected is air, and the gas can be released and operation of the
Transformer can be resumed.
6. If all tests carried out are favourable, put transformer into operation and load.
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Energisation – Check List
COMMENTS
Operation – Temperature rise and loading capacity
Aging of insulating materials is caused by changes in their chemical structure. Molecules
of Oil and Paper are slowly decomposing already at room temperature and when heated
the rate of decomposition increases. When Paper gets old, its cellulose molecule break
and its mechanical strength decreases.
When load on Transformer increases, temperature of winding and oil will rise and aging
of insulating materials accelerates. The aging rate will almost double and corresponding
life time of the Transformer will be halved when the temperature of hottest point inside the
winding (hot spot temperature) rises by 6 to 8oC, with in the temperature range of 80 to
140oC.
In addition to temperature, other factors such as dissolved oxygen, acids and moisture
also speed up the ageing of the insulation.
Hence, ageing sets limits for loading capacity of oil insulated Transformers. As per IEC
60354 (Loading guide for oil immersed transformers), the normal operation of an air
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Ambient air temperature oC -20 -10 +/-0 +10 +20 +30 +40
Permissible continuous loading in % 130 123 116 108 100 91 82
Oil temperature in oC 67 69 71 73 75 78 80
In Practice, a Transformer is very seldom continuously loaded at the same load. If the
Transformer loading is, part of the time, lower than the continuous load capacity at the
relevant permissible ambient air temperature, it can be correspondingly loaded more at
other times and still the aging can remain normal during the whole time (e.g. during 24
hours). IEC’s loading guide also gives short term loads on this basis. Next table gives
the short term loading capacity as a function of the ambient air temperature and the
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loading time provided loading at other times of the day does not exceed 25% off 90% of
the rated power. For short-term loading the temperature of the hottest spot in the
winding is limited to 140oC and the maximum permitted power is 1.5 times the rated
power.
Operation – Temperature rise and loading capacity
Ambient Temperature oC -20 -10 +/-0 +10 +20 +30 +40
Loading time Hours/ Day Permissible loading/ Rated Power = 100%
0.5 150 150 150 150 150 150 150 150 150 150 150 126 150 118
1.0 150 150 150 150 150 150 150 150 150 150 150 110 150 104
2.0 150 150 150 150 150 150 150 147 150 132 149 99 137 95
4.0 150 150 150 148 150 140 142 130 134 118 124 95 115 88
6.0 149 144 144 139 138 132 131 123 123 112 114 93 98 84
8.0 144 140 138 134 132 128 124 119 116 109 108 93 98 84
12.0 139 137 133 131 125 123 117 115 110 105 101 92 92 80
Outdoor air temperature -10oC, loading time 4 hours and load during other times of the day, i.e. 20
hours is 90%, then,
Short-term loading capacity for 4 hours = 148/100 x rated power, provided the load during other 20
hours is maximum = 90/100 x rated power.
Operation – Temperature rise and loading capacity
The temperature of the transformer’s insulating material can be monitored with
the winding temperature indicator, which is set to indicate approximately
the temperature of the hottest point in the winding. According to IEC’s loading guide,
the maximum short-term hot spot temperature can be +140oC. Due to practical
difficulties appearing in the definition of the hottest point, it is recommended to use
the values given in the following table to set the winding temperature's alarm and trip
levels.
It must be noted that a Transformer’s short-term load capacity can not be judged on
the basis of the oil temperature, because the oil temperature changes much slower with
the load than the temperature rise of the winding. Depending on the volume, temperature
of oil may rise 5 to 20 minutes slower than temperature of winding. Even at a continuous
overload, temperature can not be used to estimate the overload, with out knowing
the actual temperature rise, which takes place at the rated loading of the winding.
For supervision of continuous loading, it is recommended to set the oil thermometer
© ABB Inida, July 14-15/‘03 - 112, Author: Nag Ramesh
alarm and trip contacts according to top oil temperature value given in the following table.
If the Transformer has been provided with winding temperature indicator, the setting of
the oil thermometer contacts can be increased.
Operation – Temperature rise and loading capacity
Overloading of a Transformer implies that its construction and the accessories used in it
such as tap changer and bushing are correspondingly rated. In cases of doubt, contact
the manufacturer of the Transformer for confirming the overload capacity.
Overloading capacity of an old Transformer can be notably limited by aging of oil and
insulation humidity.
Above recommendation for alarm and trip settings are for ONAN Transformers.
Parallel Operation of Transformers
When two or more Transformers are to be connected in parallel, it is important to
remember that only the Transformers bearing identical indices (as given in following
table) can be run in parallel. The index is stamped on the Transformer rating plate.
Dd0 Dd6
0 Yy0 6 Yy6
Dz0 Dz6
Dy5 Dy11
© ABB Inida, July 14-15/‘03 - 114, Author: Nag Ramesh
5 Yd5 11 Yd11
Yz5 Yz11
Parallel Operation of Transformers
Transformers with indices 5 and 11 can also be run in parallel if the conductors of both
LV and HV side suitable crossed. Possible connections are given in following table.
Following figure shows one of the possible alternatives.
HV side LV side
Main Busbar L1 L2 L3 L1 L2 L3
Transformer having connection Dy11, A B C a b c
Yd11, Yz5. or
C B A b a c
or
B A C a c b
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Parallel Operation of Transformers
Other conditions to be met for parallel operation are:
1. Poles having same polarity on the HV side and LV side should be connected in
parallel (except with Transformers with indices 5 and 11);
2. Transformers should have the same transformation ratio;
3. Their short circuit impedances should be same (with in 10% accuracy);
4. The rated outputs of the Transformers should not deviate from each other more than
1:3.
Before connecting the Transformers in parallel for the first time, it is vital to check
the voltages. For this purpose, only the HV sides should be connected in parallel and
only the star points of the LV sides or two corresponding phases should be connected
together. Then HV side should be energized and voltages between poles to be
connected in parallel on LV should be checked. These voltages should be zero, where
as voltages between phases should be normal. If this is not so, then the Transformers
© ABB Inida, July 14-15/‘03 - 116, Author: Nag Ramesh
Both the over-current and short circuit protections can also be provided by
circuit breakers in the Switchgear panels on HV and LV side.
Protection of Transformers
3. Over-voltage protection
Normally Transformers are designed to have adequate insulation level to withstand
any over-voltages arising in operation due to any switching surges in the network
and verified by subjecting them to impulse voltage withstand test (a type test). This
may not guarantee protection against over-voltages of atmospheric origin. Hence
spark gaps (arcing horns) in small and medium sized Transformers and surge
arrestors in case of large Transformers are used to protect Transformers against
such over-voltages.
When spark gaps are used Transformer manufacturer has to ensure that the
Transformer is designed to withstand the stress of chopped wave caused by
operation of the spark gaps.
If star point of a Transformer is not brought out and not earthed, then any three pole
over-voltage will cause voltage of star point to rise to a value higher than
the voltages influencing the terminals (50 to 100%). Then manufacturer has to
© ABB Inida, July 14-15/‘03 - 119, Author: Nag Ramesh
consider this additional voltage stress in the design of the Transformer. Same will
be the case when the star point is brought out but not earthed, but such
a Transformer can be protected by star point lightning arrestors (not by a spark gap)
of rating 70% higher than the highest system voltage and the star point insulation
should be adequate for the voltage stress.
Protection of Transformers
4. Excessive gas and intrinsic faults – Buchholtz Relay
The gas generated during such faults is collected in the Buchholtz Relay which is
located on a pipe between oil conservator and main tank. The gas will displace oil
in the relay and minor gas generation will cause functioning of alarm contact. If
excessive gas is generated or when oil level falls, alarm contact will function first
followed by tripping contact. Abrupt oil flow from the Transformer into
the conservator will cause immediate functioning of tripping contact.
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Maintenance and supervision during operation
Although a Transformer needs minimal maintenance, it has to be carried out to
ensure long life and good operating reliability. While carrying out any maintenance or
supervision, instructions regarding safety distances, safety equipment, earthing and
limitations to working on live conditions must be carefully followed.
- Pick-up time and currents and readings of operative protective equipment like
relays, Breakers, plotters relevant to the Transformer of interest.
Investigation of Transformer disturbances
1.3 Transformer (immediately after the fault)
- Is the Buchholtz relay filled with gas, if so, its color and odor;
- Is oil in Buchholtz relay sooty;
- Thermometer readings;
- Were coolers or tank damaged:
- Are there any marks of arc on the bushings or on tank cover;
- Preceding maximum load and mean value for last 3 hours.
2. Function of Transformer protective equipment
Operation of some protective equipment such as Buchholtz relay, temperature
protection or upstream over-current relay does not always mean that
the Transformer is damaged.
- a short circuit current has passed through the Transformer (no gas bubbles);
- a damage has taken place inside the Transformer (gas can be colored, have
a bad smell and is generally combustible).
Investigation of Transformer disturbances
Sequence of operations when Buchholtz relay operates is given below:
B uchholtz Alarm B uchholtz Trip
O perates O perates
C heck O il
D rain V alve
No Take the
Leaky Transform er out of
service and inform
the m anufacturer
Yes
Tighten D rain R elease gas, increase
© ABB Inida, July 14-15/‘03 - 126, Author: Nag Ramesh
C ontinue the
Transform er
in S ervice
Investigation of Transformer disturbances
2.2 Sequence of operations when temperature protection operates is given
below: Temperature protection operates
3. If it can be ascertained that the disturbance is not due to any damage to windings
or a damage inside the Transformer; the protective equipment can be re-set and
the Transformer energized again.
3. All failures during warranty period must be reported to ABB and in turn to
the manufacturer with out any delay.
If it is required to simplify the test record for a particular project, the non-applicable
rows may be deleted.
11. IEC 60076-4 Edition 1 Power transformers – part 4: Guide to lightning impulse and
switching impulse testing – Power transformers and reactors.
12. IEC 60076-5 Edition 2 Power transformers – part 5: Ability to withstand short circuit.
Flow charts for taking decisions during Transformer disturbances such as operation of some
protections have been added. A detailed installation record applicable for medium sized
distribution Transformers has been prepared and added.
The presentation is mostly practical and only on installation with almost nothing about Transformer
theory, design or calculations.
Mr. Sajith S Kumar has made a significant contribution in preparing this training module by
converting some parts of ABB’s Distribution Transformer Handbook into preliminary slides.
Mr. R. Shanbhag has contributed in identifying the course contents and by giving existing
installation check lists.
© ABB Inida, July 14-15/‘03 - 135, Author: Nag Ramesh
My sincere thanks to Authors of several ABB documents mentioned in the reference list.
I am also thankful to Mr. N. Narayana Rao, Mr. S. Prasanna, Mr. V. Srinivasu, Mr. R. Shanbhag
and Mr. Sajith S Kumar for taking part in reviewing this module for adequacy and correctness of
contents.
Acknowledgement and References
1. Distribution Transformer Handbook ABB Ident # 1LAC000003.