Transformer Manual

TRANSFORMERS
INSTALLATION, COMMISSIONING
AND MAINTENANCE MANUAL
INDEX
1 GENERAL 01
1.1 Introduction 01
1.2 Construction 01
1.2.1 Core 01
1.2.2 Winding 01
1.2.3 Tank, Cover, Conservator etc. 01
1.2.4 Cooling Equipment 01
1.2.5 Protection 01
1.2.6 Tap changer 01
1.3 Health & Safety 02
1.4 Packing & dispatch 02
1.4.1 Dispatch of main unit 05
1.4.2 Loading of accessories 05
1.4.3 Inspection prior to unloading 05
1.4.4 Unloading of main unit 07
1.4.5 Unloading of drums & other cases 08
1.4.6 Unloading of crates 08
1.4.7 Unloading of pallets 08
1.5 Storage 08
1.5.1 Storage of main unit 08
1.5.2 Storage of accessories 09
2 IMPORTANT FITTINGS AND ACCESSORIES 11
2.1 Lifting bollards 11
2.2 Jacking pads (lugs) 11
2.3 Rollers/Skids 11
2.4 Towing lugs 11
2.5 Lashing lugs 11
2.6 Bushings 11
2.6.1 Bushing Assembly (12, 36 kV/630 Amps) 12
2.6.2 Bushing Assembly (12, 36 kV/1000, 2000 & 3150 Amps) 15
2.6.3 Bushing Assembly (52 kV/630 Amps) 18
2.6.4 Bushing Assembly (12, 24, 36 kV/4500 Amps , 24kV/6300 Amps) 21
2.6.5 Oil impregnated paper condenser bushing assembly (72.5,145,245 kV/800 Amps) 24
2.6.6 Oil impregnated paper condenser bushing assembly (72.5 kV/1250 Amps) 26
2.6.7 Oil impregnated paper condenser bushing assembly (145,245 kV/1250 Amps) 26
2.6.8 Oil impregnated paper condenser bushing assembly (72.5,145,245 kV/2000 Amps) 29
2.7 Cable Boxes 32
2.8 Conservator 34
2.8.1 Atmo-seal Type Conservator 36
2.9 Buchholz relay 38
2.10 Pressure relief valve 39
2.11 Double Diaphragm Explosion Vent 41
INDEX
2.12 Radiators 42
2.13 Earthing terminals 44
2.14 Silica gel breather 45
2.15 Magnetic Oil Level Indicator 47
2.16 Marshalling Box 48
2.17 Oil Temperature Indicator (OTI) 50
2.18 52
2.18.1 Winding Temperature Indicator (WTI) 52
2.18.2 RTD ( Resistance Temperature Detector for Oil/ Winding) 52
2.19 Fans 54
2.20 Current Transformers 54
2.21 Air release plugs 54
2.22 Earthing terminal and magnetic circuit check window 54
2.23 Off circuit Tap changing Switch 54
2.24 On load tap changer, automatic voltage regulating relay and oil surge relay 56
2.25 RTCC Panel 56
3 INSTALLATION 57
3.1 Precautions 57
3.2 Site preparation 57
3.3 Transformer oil 58
3.4 Oil filling in the transformer 59
3.4.1 General 59
3.4.2 Oil Filling Under Vacuum 59
3.4.3 Oil filling in Atmo sealed type of conservator 60
3.4.4 Hot Post Drying of Transformer Active Part at site 60
3.5 Gasket and gasketed joint. 62
4 COMMISSIONING 64
4.1 General 64
4.2 General checks 64
4.3 Pre-commissioning checks /Tests 65
4.2.1 SCHEDULE I, II, III 65
4.4 Parallel operation 72
4.5 Energizing 72
5 MAINTENANCE 73
5.1 General 73
5.2 Factors affecting the life of the transformer 73
5.3 Maintenance Procedure 73
5.4 Recommendations for maintenance 73
5.4.1 Transformer Oil 73
5.4.2 Conservator and oil level indicator 74
5.4.3 Silica gel breather 74
5.4.4 Buchholz relay 75
INDEX
5.4.5 Explosion Vent 75

5.4.6 OLTC ( On Load Tap Changer) 75
5.4.7 Temperature indicators 75
5.4.8 Bushing 76
5.4.9 External connections including earthing 76
5.4.10 Gaskets (Gasket joints.) 76
5.4.11 Pressure relief valve 76
5.4.12 Rollers 76
5.4.13 Paint work 76
5.4.14 Recommended Maintenance Schedule 76
5.5 Faults & Failure 80
5.6 Trouble shooting chart for Transformer 81
5.7 Checks for transformer tripped on relays 84
5.8 DO'S & DON'T'S 86
6 PRODUCT SPECIFICATION FOR ORDERING NEW TRANSFORMER 87
1. GENERAL
1.1 Introduction
As the continuity of electric supply is of paramount importance in modern power systems, it is
necessary to take all possible precautions during erection and commissioning of the transformers
followed by regular maintenance. Bharat Bijlee transformers are designed and manufactured
with utmost care as per the latest technology. The purpose of this manual is to explain how
the transformers as ordered and supplied, should be installed, commissioned and maintained
during service. A separate set of drawings including General Arrangement drawing of the
transformer is supplied, for each transformer. It is necessary that all these drawings should
be carefully studied before doing any work on the transformer. Transformers should be energized
only after completing all the necessary work and carrying out pre commissioning checks
and tests described in this manual.
1.2 Construction
1.2.1 Core
The transformer core is made from high grade non aging cold rolled grain oriented
silicon steel sheet. This gives very low specific loss at operating flux densities. Joints of
the laminations are designed such that the magnetic flux is always in the direction
of grain orientation. The core clamping structure is designed such that it withstands
the impact of short circuit forces.
1.2.2 Windings
Windings are made from paper covered electrolytic grade copper conductors.
The conductors are transposed at suitable intervals in order to equalize the current
distribution and flux linkage along the winding.
Insulation spacers are arranged in the winding to allow the oil flow through the
entire winding for ensuring proper cooling.
1.2.3 Tank, cover, conservator, etc.
Tank and cover are fabricated from mild steel and are of welded construction. The tank
is suitable to withstand pressure and vacuum as per CBIP. Conservator is provided
to take care of the expansion and contraction of transformer oil, which takes place
during normal operation of the transformer.
1.2.4 Cooling Equipment
The transformer is provided with radiators, fans, oil pumps, heat exchanger depending
upon different type of cooling.
1.2.5 Protection
The transformer is provided with buchholz relay, winding temperature indicator,
oil temperature indicator, oil surge relay, pressure relief valve, etc. as applicable
for protection.
1.2.6 Tap changer
Tap changer are of two types.
A: On load tap changer B: Off circuit tap changer
On load tap changer can be operated when transformer in energized condition.
Off circuit tap changer must be operated when transformer is de-energized.
1
1.3 Health and Safety
Following precautions should be taken for the safe operation of transformer & safety of persons.
• The installation, operation and maintenance should be done in accordance with the
manufacturer's instructions by qualified and competent persons.
• Ensure open / close position of all valves as per valve schedule plate.
• Do not megger or apply voltage when the transformer is under vacuum.
• The recommended pre-commissioning checks & tests should be done before energizing
the transformer.
• The operation of protective systems and devices for the transformer should be checked
regularly.
• Do not override protection systems
• In case of nitrogen filled transformer, purge nitrogen with dry air before entering in to tank.
• Prolonged operation under over load, over voltage or over excitation condition can have
a serious detrimental effect on the life of the transformer and hence should be avoided.
• No work should be done on the transformer or its associated equipment unless it is isolated
and all terminals have been solidly earthed.
1.4 Packing & Dispatch
After testing and inspection at our Works, transformers are dispatched to destinations
given by customer. Main unit is dispatched oil filled or nitrogen filled as specified by the
customer and agreed by BBL.
If customer has not specified oil or nitrogen filled transport, then if the transportation weight
permits transformer is dispatched with transformer oil. The oil is filled up to oil level marked in
transport oil gauge. Space above oil in the tank is sufficient for the expansion of oil during
transit/storage on account of temperature variation. Silica gel breather is fitted to the
transformer tank for moisture free breathing due to ambient temperature variations.
All detachable parts liable for transit damage are removed during transit. Refer Fig. 1.
If the transportation weight with oil does not permit or if the customer specifies then main
unit is dispatched filled with dry Nitrogen Gas. The nitrogen gas pressure 3 PSI is maintained
at the time of dispatch.
(3 PSI = 0.2 kg/cm2) at 35 degrees Centigrade approx.)
All valves on tank are blanked off and pressure gauge is fitted on one valve to indicate nitrogen
pressure inside tank during transportation. Typical position of valve and pressure gauge is
shown in Sketch No. 1. In case of transformers with On Load Tap Changers, the main tank and
OLTC are equalized. Due to variation in ambient temperature gas pressure inside tank will
vary. There should always be a positive pressure inside the tank to avoid ingress of moisture.
While the transformer is in transit, checks must be made on the nitrogen pressure. For
allowable range of pressure for various temperatures Refer Fig. 2A
Fittings and accessories removed from the transformer are dispatched in separate crates /
cases / pallet. All the detachable items are indicated in the List of fittings of the transformer.
Oil for filling and topping up in tank and in radiators, conservator, disconnecting chamber of
cable box (if applicable) is sent separately in sealed drums. All the packages containing
the detached parts are clearly marked with the transformer work order and serial number.
Contents are clearly indicated in the packing slips attached to each crate / case.
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4
1.4.1 Dispatch of main unit
1.4.1. 1 Loading of main unit (Refer sketch 2B)
• Lift main unit by using lifting tackles of suitable capacity. Keep three pairs
of wooden planks of approximately two meters long on trailer below
horizontal member of transformer bottom skid. Load the transformer
keeping HV side on driver side & adjust main unit on trailer or
as specified by customer
• Lower main unit slowly on trailer, Adjust center of gravity slightly towards
driver side but ensure that horizontal members of bottom skid are resting
on middle two 'I' Beam of trailer. Adjust wooden planks below bottom
skid properly. Let the main unit just rest on trailer.
• Put wooden packing below all roller plates, lower the main unit completely
on trailer.
• Take the confirmation from Driver about the position of the main unit on
trailer, before removing slings.
• Rollers shall be loaded on the trailer along with main unit. There should
be sufficient gap between Roller case & main unit to avoid damage in
transit. Supports should be welded at four corners of case to restrict
the movement of the roller case.
1.4.1.2 Locking of main unit On mechanical trailer
• Weld MS angle/channel support below all jacking pads living 10 mm gap
between pad and support.
• Weld stoppers on all corners of main unit, or on all corners of roller pad,
such that main unit does not shift during transit.
1.4.1.3 Lashing & Covering of main unit
• Lashing shall be done from both side of the main unit to trailer body by using
Chain & Tie bars between lashing lugs provided on transformer & rings
on trailer body. Tighten all the four slings equally & gently.
• Cover the main unit by HDPE cover of suitable size.
1.4.2 Loading of accessories
• All crates/cases of accessories are loaded with due care.
1.4.3 Inspection prior to unloading
As soon as Transformer Main Unit reaches site, it should be thoroughly inspected for
external damages. Check sealing of all valves fitted on transformer.
All other packages should be checked for transit damages. Oil drums should be
examined for leakages & tampering.
Any discrepancies in above should be immediately reported to BBL and Insurance
company. Photographs or other useful evidence should be submitted wherever possible.
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1.4.3.1 Inspection for oil filled transformer
As soon as main unit reaches destination, it should be thoroughly examined
for external damages.
Check Oil level marked on transport oil gauge
Confirm the oil level by dipping stick from Air release plug as mentioned in
Delivery Challan.
Transformers dispatched with oil is fitted with Silica gel Breather. Condition of
silica gel should be checked on receipt. If it is not dark blue, It should be
reactivated immediately Ref. Cl. 5.3.3.
Oil sample should be taken from bottom sampling valve of the tank and tested
as per IS 1866 for BDV & PPM, Ref. Cl. 1.5.1.1.
1.4.3.2 Inspection for gas filled transformer
1. As soon as unit reaches destination, Check nitrogen pressure & record in
the document sent along with main transformer. Send this document duly
signed back to M/s. Bharat Bijlee Ltd.
2. If the pressure inside tank is zero and if cylinders are empty, report matter
to M/s. Bharat Bijlee Ltd. immediately. However, fill up the Main Tank with
dry Nitrogen Gas having dew point of - 50o C to an internal pressure of
3 PSI at the earliest.
1.4.3.3 Inspection of parts supplied in crates/cases/pallets
All the packages containing the detached parts are inspected and then
dispatched from the Works in suitably packed condition to their destinations.
As soon as they reach the destination, they should be thoroughly examined
for external damages.
The various packages should be checked to ensure that:
i. Case / Crates are not damaged.
ii. Case numbers tally with Packing List / Challan.
iii.Contents of Case / Crate tally with Packing List on Case / Crate.
iv. Oil drums should be examined carefully for leaks or signs of tampering.
Damage or loss of any other component from the transformer should be
mentioned on backside of L R with client's stamp & signature & also to be
reported to BBL and the insurance company immediately. Photographs or
other useful evidence should be submitted wherever possible. Following
details should be included in the report of damages:
I. Work Order, Case number and description of the damaged component.
ii. Quantity of damaged component.
iii.Severity of damage.
1.4.4 Unloading of main unit
Main unit should be lifted by suitable capacity crane. Slinging should be done on
Lifting Bollards. These bollards are designed to take the total weight of the main unit.
Transformer has subsidiary lifting points suitable for lifting only certain components.
Refer General Arrangement Drawing to identify Main Lifting Bollards. Lifting angle
of rope should be restricted to 30 degrees to vertical (Refer fig 2B).
7
It is desirable to place the transformer on its plinth as mentioned in the "Storage at Site"
to avoid subsequent handling.
In case Plinth is not ready, place Main Unit on strong wooden sleepers below the
bottom skid so that vales, pipes at bottom level of tank shall not get damaged.
1.4.5 Unloading of oil drums & other cases
Drums & accessories cases should be unloaded by crane by using suitable lifting
tackles. Under any circumstances cases & drums should not to be dropped from the truck.
1.4.6 Unloading of crates
Crates should be lifted by suitable capacity crane. Access is provided to put
sling/chain in the lugs provided for lifting, Put the sling/chain of appropriate capacity
and lift the crate. Keep the crate on leveled surface.
1.4.7 Unloading of pallets
Pallets should be lifted by suitable capacity crane. Keep the pallets on level surface.
1.5 Storage
1.5.1 Storage of main unit
1.5.1.1 Storage of oil filled main unit
• After arrival of transformer at site, mount the rollers and place Transformer
Main unit on its foundation to avoid subsequent handling.
• It is desirable to erect and commission the transformer without any delay on
its arrival. In case this is not possible, fit the Conservator and other accessories.
Fill the oil in conservator up to filling level.(30 degrees Mark) and fit breather
to Conservator. Ensure color of silica gel is deep blue and fill the oil in sealing
cup up to the level indicated.
• If conservator is not fitted, ensure that transportation breather is kept
connected to tank as it is. THE DEHYDRATING BREATHER MUST BE FITTED
ON ALL OILFILLED TRANSFORMERS. THE CONDITION OF THE SILICAGEL
MUST BE MONITORED EVERY FORTNIGHT. BREATHER HAS OIL SEALING
CUP WHICH MUST BE FILLED WITH CLEAN TRANSFORMER OIL UPTO
THE LEVEL MARKED.
• Oil filled transformer should not be stored more than 6 months.
• During storage check oil as mentioned in Cl. 1.4.3.1 (inspection of oil filled
transformers).
• Check the PPM & BDV as per table given below
Property Highest Voltage Of Equipment

< 72.5 72.5 to 170 > 170
Water Content (PPM) 20 15 10
Breakdown voltage (kV) 40 50 60
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1.5.1.2 Storage of nitrogen filled main unit
• After arrival of transformer at site, mount the rollers and place Transformer
Main unit on its foundation to avoid subsequent handling.
• Pressure of nitrogen gas inside the tank and ambient temperature should be
checked and logged daily at a fixed time.
• If the pressure drops to 1 PSI, fill nitrogen into main unit to raise the internal
pressure to 3 PSI.
• N2 cylinder should be replaced when cylinder pressure drops to 15 kg/cm2.
• Transformer tank and cover to be covered with tarpaulin / canvas to prevent
ingress of dust / moisture.
• Gas filled transformers should be filled with oil preferable within 3 months.
1.5.2 Storage of accessories
• All accessories must be stored in a dry place, under the cover/roof.
• Panels must be stored in vertical condition in dry place under the roof.
• Bushings & Fans shall be kept in dry place. Cases should be stored by putting
wooden packing of minimum 250 mm below the cases. If cases are opened for
verification, they should be repacked. Cases having control items and copper parts
should be preferably kept under lock and key.
• Conservator crate should be stored in such a way that Magnetic Oil Gauge, Plain Oil
gauge and Valves does not get damaged.
• These cases/crates shall be kept preferably in dry place stored by putting wooden
packing of minimum 250 mm below the cases. The cases shall be covered by
Tarpaulin / polyethylene sheet. Sufficient gap should be kept in between for
handling purpose.
• The oil drums should be stored on raised platform at horizontal position with
bungs at 45 degree to horizontal direction. This will insure bungs are at positive
pressure. (Refer sketch no.3)
• It should be ensured that there is no damage to the gasketed joints and that
all the bolted flanges are tightly clamped.
• The storage area must be accessible for inspection.
• Fragile components should be stored carefully.
• Heaters for cooler control cabinet, OLTC motor drive, etc. shall be kept energized.
• While in storage all the packages should be checked regularly for any physical
damage or rusting.
*Note: The Conservator and associated pipe work must be checked for rust and foreign
matter and then flushed with clean transformer oil before fitting. Magnetic Oil Gauge
float arm should be fitted to dial after removing gear locking in case of conventional
conservator, before filling oil in conservator. All paintwork should be examined and
if touching up is needed it must be done without delay.
Refer oil-filling instructions in Clause No. 3.4.2 if transformer is received nitrogen filled
and oil is filled at site.
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2. IMPORTANT FITTINGS AND ACCESSORIES
2.1 Lifting Bollards

Transformer should be lifted by using lifting bollards provided on the transformer. All bollards
should be simultaneously used to avoid any unbalance on lifting. Rope slings or chains used
should have adequate capacity to handle the weight of the transformer. Location of main
lifting bollards are on tank side and is clearly indicated in the General Arrangement drawing
of transformer. Care should be taken at site to see that the slings or chains do not foul
with fittings on tank cover.
2.2 Jacking pads (lugs)
The transformer is provided with 4 jacking pads (lugs). Screw jacks or hydraulic jacks of suitable
capacity should be used for jacking. Extreme care should be taken to lift the transformer
slowly and simultaneously on all jacks to avoid overturning.
2.3 Rollers/Skids
Generally all transformers are provided with bi-directional rollers, either flat or flanged type
as per the requirement, to enable the movement of the transformer either parallel to or across
the major axis of the transformer. Roller spacing should be checked as indicated in GA drawing.
In some cases, if specially asked for, skids are provided instead of rollers for longitudinal
or transverse movement.
2.4 Towing lugs
Skids are provided with towing lugs. Only these lugs should be used for attaching suitable ropes
or slings while pulling the transformer. Care should be taken that no valves or other fittings
are damaged during the pulling operation. As far as possible transformer should be pulled with
slings along the major axis of transformer. Care should be taken to avoid jerks.
2.5 Lashing lugs
Lashing lugs are provided on transformers for lashing the transformer properly to the trailer
or rail wagon during transport only. These lugs should not be used for lifting or towing of the
transformer as they are not designed for lifting or towing.
2.6 Bushings
Oil communicating bushing : These bushings are generally used up to 52kV class.
Air venting should be done by using air vent screw till oil comes out.
Condenser bushing : These bushings are generally used from 52 kV class & above.
These bushings are hermetically sealed. Check the oil level in the oil indicator of the bushing
before installation.
In case of any oil leakage from bushing report to M/S BBL.
11
2.6.1 Bushing Assembly (12, 36 kV / 630 Amps): (Refer Fig. 4)
Item No. Description Material No. off / assembly

1 Insulator Porcelain 1
2 Stem Copper/brass 1
3 Cap Brass 1
4 Vent screw Brass 1
5 Seal ring NBR 1
6 Separator Press board 1
7 Gasket RBC / NBR 1
8 Washer Teflon 1
9 Hex Nut Brass 3
10 Plain washer Brass 2
11 Spring washer Spring steel 1
12 Clamping ring MS 1
13 Clamp Zinc alloy / Aluminium 6
14 Hex Nut MS 6
15 Plain washer MS 6
16 Connecting plug copper 1
17 Connecting stud Copper/Brass 1
18 Lock Nut Brass 1
19 Lock washer Copper 1
20 Insulating tube Fibre glass 1
12
Dispatch
Bushing insulator and metal parts are dispatched separately.
The bushing mounting hole is blanked off by M.S. blanking plate and gasket.
Connecting plug (16) is brazed on lead.
Mounting
• Refer General Arrangement drawing for the position of bushings on transformer.
• Inspect insulator (1) , Insulating tube (20) and stem (2)
• Ensure that the oil level is below the tank cover. (Check it by unscrewing air release plug
provided on the tank cover. No oil should come out).
• Remove the blanking plate from tank cover. Replace gasket (7) if found damaged .
Keep away nuts, washers etc so that nothing should fall into tank .
• Put the lock washer (19) over the connecting stud (17). Screw the connecting stud to the
connecting plug (16). Use two spanners on the flat surface provided on plug and connecting
stud. Bend the ends of lock washer (19) over the flat surfaces of plug and stud .
• Insert the insulating tube (20) over the connecting stud (17) till top portion of connecting
stud is accessible.
• Fix the stem (2) on top of the connecting stud (17) and then lock them with lock nut (18).
• Ensure the separator (6) is present on the stem.
• Insert the clamping ring (12) over bushing mounting stud. Place the insulator (1) on the
cover carefully through stem assembly such that stem is properly engaged inside the groove
of the bushing.
• Insert seal ring (5), cap (3) and fix them in position by hexagonal nut (9).
• Clamp the insulator (1) by means of clamping ring (12), clamp (13), washer (15) and
hexagonal nut (14). See that the insulator is tightened evenly and carefully at all places.
• Fix hexagonal nut (9), plain washer (10) and spring washer (11) as shown.
• Release the trapped air inside the bushing by slightly unscrewing the vent screw (4) till
a little quantity of oil comes out.
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14
2.6.2 Bushing Assembly (12, 36 kV/1000, 2000 & 3150 A): (Refer Fig. 5)
Item No. Description Material No. off/assembly

2 Stem Copper 1
3 Cap Brass 1
4 Washer Brass 1
5 Seal ring NBR 1
6 Separator Pressboard 1
7 Top gasket RBC / NBR 1
8 Gasket RBC / NBR 1
9 End cap Copper/Brass 1
10 Collar Brass 1
11 Snap ring Copper 1
12 Hexagonal nut Brass 1
13 Grub screw Brass 2
14 Clamping ring Aluminum 1
15 Clamp Aluminum 6
16 Plain washer M.S. 6
17 Hexagonal nut M.S. 6
19 Washer Teflon 1
20 Potential ring Brass 1
21 Insulating tube Fiber Glass 1
15
Dispatch
Connector assembly with flexible jumper is clamped and supported in position by two insulation
supports inside the transformer tank.
Mounting
• Refer General Arrangement drawing for the position of bushings on transformer.
• Inspect insulator (1) , Insulating tube (21) and stem (2)
• Remove the blanking plate from tank cover. Replace gasket (8) if found damaged.
Keep away nuts, washers etc so that nothing should fall into tank .
Stem is in assembled condition. Remove end cap (9), Nut (12), Washer (4), seal Ring (5)
Potential ring (20), cap (3) an0d keep aside. Ensure separator (6) is in place.
• Screw stem (2) into the Connector assembly. (Use spanner on flat surface of the stem).
• Insert clamping ring (14) over bushing mounting studs and then insert the insulator over
the stem. Ensure that the collar (10) is properly engaged inside the groove of the insulator (1).
• Fix the insulator (1) by means of clamping ring (14), clamp (15), plain washer (16) and
• Place top gasket (7), cap (3), potential ring (20) and seal ring (5) on insulator.
• Place washer (4) above seal ring (5)
• Tighten hexagonal nut (12).
• Fit end cap (9) and clamp it firmly over stem (2) with hexagonal nuts provided.
• For air venting unscrew the vent screw (18) till a little quantity of oil comes out.
Note: Before carrying out cable or bus bar termination check that the gap at the fixing
screws of the End cap is not closed. Touching of both the ends would prevent proper
tightening of the end cap on the stem (2). Loose fitting of end cap on the stem would result
in heating of stem and end cap.
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17
2.6.3 Bushing Assembly (52 kV/630 Amps): (Ref. Fig. 6)
Item No. Description Material No. off/assembly
2 Stem Brass 1
3 Cap Brass 1
4 Washer Brass 1
5 Seal ring NBR 1
6 Separator Pressboard 1
7 Gasket RBC/NBR 1
8 Top gasket RBC/NBR 1
9 Hexagonal nut Brass 1
10 Clamping ring Aluminum 1
11 Clamp Zinc alloy 6
12 Plain washer Mild Steel 6
13 Hexagonal nut Mild Steel 6
15 Sealing washer Teflon 1
16 Insulating tube Fibre glass 1
17 Connecting stud Brass 1
18 Connecting plug Copper 1
19 Lock nut Brass 1
20 Lock Nut Brass 1
21 Potential Ring Brass 1
18
Dispatch
Mounting
• Inspect insulator (1), Insulating tube (9) and stem (2)
• Refer to General Arrangement drawing for the position of bushings on transformer.
• Remove the blanking plate from tank cover. Replace washer (7) if found damaged .
• Remove connecting stud (17) from stem (2).
• Put lock nut (20) over the connecting stud (17).
• Screw the connecting stud (17) to the connecting plug (18). Use two spanners on the flat
surfaces provided. Tighten the Locknut (20).
• Insert the insulating tube (16) over the connecting stud (17) till top end of connecting
stud is accessible.
• Fix the stem (2) on the top of the connecting stud (17) and lock them with lock nut (19).
• Insert the clamping ring (10) over bushing mounting studs. Place the insulator (1) on the
cover carefully through the stem assembly such that stem is properly engaged inside
the groove of the bushing.
• Fix the insulator (1) by means of clamping ring (10), clamp (11), plain washer (12) and
• Place top gasket (8), cap (3), potential ring (21), and seal ring (5) and washer (4) on the insulator.
• Tighten hexagonal nuts (9).
• For air venting unscrew the vent screw (14) till a little quantity of oil comes out.
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2.6.4 Bushing Assembly (12, 24, 36 kV / 4500 Amps , 24 kV / 6300 Amps): (Ref. Fig. 7, Fig 8)
No. off / assembly

Sr. No. Description Material 12,24,36kV/ 24 kV/
4500 Amps 6300 Amps
1 Insulator Porcelain 1 1
2 Copper stem Copper 1 1
3 Cap Brass 1 1
4 Top washer Brass 1 1
5 Vent / Screw Brass 1 1
6 Gasket Nylon 1 1
7 Seal Ring NBR 1 1
8 Separator NBR 1 1
9 Gasket RBC/NBR 1 1
10 Gasket RBC/NBR 1 1
11 End cap Brass/copper 1 2
12 Collar Copper 1 1
13 Nut Brass 1 1
14 Hex. Nut MS 2 4
15 Washer MS. 2 8
16 Grub screw MS 2 4
17 Bushing mounting stud MS. 6 6
18 Clamping ring Aluminum 1 1
19 Clamp Aluminum 6 6
20 Nut MS 6 6
21 Washer MS 6 6
Dispatch
The bushing mounting hole is blanked by M.S. blanking plate and gasket.
Mounting
• Assemble the bushing and stem together as shown in fig. 7 or 8
• Ensure the oil level in tank is below the bushing connection window. Open window Cover.
Open blanking plate of bushing mounting hole.
• Suitably raise the bushing.
• Insert clamping ring in bushing mounting studs (17) .
• Bring the bushing over the bushing mounting drilling such that orientation of oil end
connector matches with jumper provided on busbar inside the tank.
• Fix insulator assembly (1) by means of clamping ring (18), clamps (19), Washer (21), Nut (20).
• Ensure that the insulator is tightened evenly & carefully at all places.
• Oil end side connector of the bushing should be connected to respective jumper through
window provided on tank.
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22
23
2.6.5 Oil impregnated paper condenser bushing assembly
(72.5, 145, 245 kV/800 Amps): (Ref. Fig. 9A)
Flexible type connection lead.
Dispatch
i. Bushing is dispatched in crate/case along with top terminal, pin, washers & detachable
shield (if applicable). The draw lead is generally coiled & tied to blanking plate
provided to blank bushing opening, In some of the 145 Kv bushing assemblies
& all 245 Kv bushing assembly the draw lead is made in two pieces & connected
by two half connectors by bolting together for ease in assembly. Part of the
connection lead is dispatched in inserted condition with bushing
ii. Bushing mounting hole is blanked by MS plate & gasket on turret/tank
Mounting
i. Refer General Arrangement Drawing for the position of the bushing on Transformer.
ii. Ensure the oil level in transformer is below the bushing inspection window.
Inspect the bushing for damages; ensure bushing oil level in sight glass provided
on Bushing Conservator. Clean the bushing properly before mounting .
Type I
i. Remove the blanking plate fitted on bushing mounting hole. Take out the draw lead
Put 4 mm dia wire or 8/10 mm dia nylon rope of suitable length through bushing.
Lift the bushing vertically, connect the wire by bolt to the top thimble of draw
lead, slowly lower the bushing & keep pulling draw lead up. See that when bushing
will rest on mounting flange at the same time top thimble should appear at top
of bushing. Put locking pin (3) in thimble & bushing, check lead entry at the oil
end side of bushing through Bushing inspection window provided on tank wall.
The lead should enter in the bushing properly & no loop formation should take
place at bottom of stress ball.
ii. Tighten the bushing mounting flange evenly.
iii. Screw top terminal cap (1) over top thimble. Ensure that gasket / sealing ring at
top (5) is at place & top terminal cap is tight.
iv. For air venting unscrew Air vent screw (7)
Type II
Remove the blanking plate fitted on bushing mounting hole. Take out the draw lead.
Bolt the half connectors of draw lead in bushing & lead from transformer side.
Tighten the screws of both half connectors carefully to ensure firm contact. Put 4 mm
dia wire or 8/10 mm dia nylon rope of suitable length through bushing. Lift the
bushing vertically, connect the wire by bolt to the top thimble of draw lead, slowly
lower the bushing & keep pulling draw lead up. See that when bushing will rest on
mounting flange at the same time top thimble should appear at top of bushing.
Put locking pin ( 3 ) in thimble & bushing, check lead entry at the oil end side of
bushing through Bushing inspection window provided on tank wall. The lead
should enter in the bushing properly & no loop formation should take place at
bottom of stress ball. Repeat steps ii to iv type I above
24
25
(72.5 kV/1250 Amps): ( Ref. Fig. 9B )
Dispatch
i. Bushing is dispatched in crate along with top terminal, pin, washers & detachable
shield (if applicable).
ii. Bushing mounting hole is blanked by MS plate & gasket.
Mounting
I. Refer General Arrangement Drawing for the position of the bushing on Transformer.
ii. Ensure the oil level is below the bushing connection window.
iii. Remove the blanking plate fitted on bushing mounting hole. Open respective
Bushing connection window provided on tank wall.
iv. Inspect the bushing for damages; ensure bushing oil level in sight glass provided
on bushing Conservator. Clean the bushing properly before mounting.
v. Lift the bushing vertically & lower it slowly through the hole such that the
orientation of oil end connector matches with jumper provided on connecting lead.
vi. Tighten the bushing mounting flange evenly.
vii.Connect the lead from winding to oil end side connection through window.
viii.Ensure top terminal cap is tight.
ix. For air venting unscrew Air vent screw (7)
(145, 245 kV/1250 Amps): (Ref. Fig. 9 C)
Draw rod type lead connection
Dispatch
i. Bushing is dispatched in crate/case along with top terminal, pin, washers &
detachable shield (if applicable).
Mounting
ii. Ensure the oil level is below the bushing inspection window. Inspect the bushing
for damages; ensure bushing oil level in sight glass provided on bushing
Conservator. Clean the bushing properly before mounting.
iii. Remove the blanking plate fitted on bushing mounting hole. Put 4 mm dia wire
or 8/10 mm dia nylon rope of suitable length through bushing, connect the wire end
to the draw rod by bolt, insert the draw rod in bushing from bottom of bushing.
Lift the bushing vertically, pull the draw rod up such that the half thimble part
of draw rod is below the bushing oil end Take out the lead from turret, bolt the
lead & draw rod. Tighten the screws of half connectors very carefully to ensure
firm contact. Slowly lower the bushing & keep pulling draw rod up. See that
when bushing will rest on mounting flange at the same time top thimble should
appear at top of bushing. Put locating pin (3) in thimble & bushing, check lead entry
26
at the oil end of bushing through Bushing inspection window provided on tank
wall. The lead should enter in the bushing properly & no loop formation should
take place at bottom of stress ball.
iv. Tighten the bushing mounting flange evenly.
v. Screw top terminal cap (1) over top thimble. Ensure that gasket/ sealing ring (5)
at top is at place & top terminal cap is tight.
vi. For air venting unscrew Air vent screw (7)
27
28
(72.5, 145, 245 kV/2000 Amps): (Ref. Fig. 10)
With bottom terminal
Dispatch
i. Bushing is dispatched in crate/case along with top terminal, pin, washers &
detachable shield (if applicable).
Mounting
ii. Ensure the oil level is below the bushing connection window.
iii. Remove the blanking plate fitted on bushing mounting hole. Open respective
Bushing connection window provided on tank wall.
iv. Inspect the bushing for damages. Ensure bushing oil level in sight glass provided
on bushing Conservator. Clean the bushing properly before mounting.
v. Lift the bushing vertically & lower it slowly through the hole such that the
orientation of oil end connector matches with jumper provided on connecting lead.
vi. Tighten the bushing mounting flange evenly.
vii. Connect the lead to oil end side connection through window.
viii.Ensure top terminal cap is tight.
ix. For air venting unscrew Air vent screw (7)
29
30
31
2.7 Cable Boxes:
A. Cable Boxes: Air Filled Type (Refer Fig. 12)
Cable boxes are provided as per customer's requirement. These boxes are designed for
receiving and protecting cable ends and to ensure effective sealing of cable against ingress
of moisture, dirt, dust and vermin.
All cable boxes for PVC or XLPE cables are designed with air clearances and hence these
cable boxes are not required to be filled with compound or oil.
Cable boxes are provided with detachable gland plates.
Earthing terminals are also provided on these gland plates for earthing the armour of
individual cables.
B. Cable Boxes: Oil Filled Type
Oil Filled Cable boxes are provided with conservator to maintain oil level in cable box.
OIL IN CABEL BOX SHOULD BE TESTED FOR BREAKDOWN STRENGTH EVERY SIX MONTHS
AND SHOULD BE CHANGED OR FILTERED IF THE VALUE FALLS BELOW 50 kV.
32
IT. No. 14 & 15 supplied, if in BBL's scope of supply.
33
2.8 Conservator: (Refer Fig. 13 & Fig. 14)
Conservator is used on transformer for providing adequate space for expansion of oil when
transformer is loaded or when ambient temperature changes. It also conserves the insulating
property of oil from deterioration and protects the transformer against failure on that account.
Conservator also acts as a reservoir for the transformer. Please refer enclosed Sketch Nos. 13 & 14
for detailed description of components/accessories.
1. Cylinder 13. Horizontal support

2. Flange 14. Buchholz relay
3. Gasket 15. Oil surge relay
4. Conservator pipe 16. Isolating valve
5. Breather pipe 17. End plate
6. Filling hole with Blanking plate 18. Cover plate
7. Drain valve 19. Name plate
8. Oil level indicator 20. Breather extension pipe
9. Magnetic oil level indicator 21. Cover pipe
10. Test plug 22. Lifting lugs
11. Equalizer pipe 23. OLTC pipe
12. Vertical support
Construction
Conservator consists of a cylinder closed from both ends to form a container. Inspection cover
or detachable end plate is provided on one side to facilitate cleaning and maintenance.
Conservator pipe projects inside the conservator and is provided with a cap. This construction
forms a sump at conservator bottom and prevents sludge and sediment entering the
transformer tank.
Breather fixing pipe
This pipe enters the conservator cylinder from top.
This arrangement ensures that oil does not enter the breather even at highest operating level.
Mounting
Conservator with its pipe work and supporting structure is detached during transport to
avoid transit damages. Conservator with pipe work should be assembled on supporting
structure making sure that all gasket joints are oil tight and pipe work is clean and free from
moisture. It is recommended that conservator and pipes should be cleaned. Pipes shall be
flushed with transformer oil before erection. The conservator should be mounted in such
a fashion that the flanges in the pipe line match with fittings like isolating valve and buchholz
relay/oil surge relay. Slots are provided on supporting structure for necessary adjustments.
Suitable lugs are provided on conservators for lifting.
Operation
When the ambient temperature around the transformer rises or when the transformer is
loaded, the oil inside the transformer expands towards the conservator pushing away
34
corresponding quantity of air in conservator through breather. Similarly, when ambient
temperature lowers or when load on transformer is reduced or switched off, oil in the tank
contracts, the oil in conservator flows towards the tank and outside air is then 'breathed' in
through the breather, to take place of conservator oil going in the tank. In no case, outside
air is allowed direct contact with transformer oil.
35
2.8.1 Atmoseal Type Conservator: (Refer Fig. 15)
See Fig 15 for constructional details of the conservator.
In this type of conservator, Air cell made of NBR material is fitted inside the conservator.
The Silica gel breather is connected to Air cell. During service of the Transformer,
the oil level in the conservator falls or rises and accordingly the air cell gets inflated
or deflated. When the air cell gets deflated the air inside the Air cell is pushed out
through the breather and when the air cell is inflated outside air rushes in through
the breather. However, in no case the transformer oil comes in contact with
atmospheric air, thereby decreasing the ageing rate.
The space outside Air cell in the conservator is completely displaced by filling oil in
the conservator and venting air through top air vents provided on conservator.
Refer fig 15 for oil filling procedure.
36
Fig. 15
37
2.9 Buchholz relay: (Refer Fig. 16)
Application
Buchholz relay is a very sensitive, gas and oil operated instrument which detects low oil level,
formation of gas or development of sudden pressure inside the oil filled transformer. It has
to be connected to protection circuits to give an early audible alarm in case of low oil level and
gas collection and to disconnect the transformer from supply in case of severe fault inside
the transformer.
Mounting
After filling the oil in the transformer, air trapped inside the relay is to be released through
valve . Pipe extension from valve is brought down for gas collection. It must be ensured that
valve is kept open and the above pipe is full of oil. When gas is collected, oil from pipe will
flow out initially, followed by gas.
Fig. 16
38
2.10 Pressure relief valve: (Refer Fig. 17)
Application
The purpose of the pressure relief valve is to prevent mechanical damage to the transformer
tank by releasing any excess pressure over the set limit. The valve is basically a spring-loaded
device, which closes automatically when the pressure inside the tank drops to the set limit
after releasing excess pressure over the pre set limit.
General
Site maintenance is not required.
The springs of pressure relief valve are designed for a specific operating pressure, which
cannot be changed at site. Hence clamping arrangement of the spring should not be disturbed.
For details of construction and operation refer manufacturer's catalogue.
Description (Pressure Relief Valve)
1 Gasket
2 Base Plate for shroud
3 U gasket
4 PRV sub assembly
5 Lug for Shroud
6 Shroud
7 Nut
8 Stud
9 Sr. no. label
10 Product label
11 Flag
12 Limit switch
13 Rubber bellow
14 Flange
39
Fig. 17
40
2.11 Double Diaphragm Explosion Vent: (Refer Fig. 18)
Application
The purpose of the explosion vent is to prevent damage to transformer tank by releasing any
excess pressure that may be generated inside the tank.
Construction
Explosion vent consists of a bent pipe with aluminum diaphragms at both ends. A protective
wire mesh is fitted on the opening of the transformer to prevent the pieces of ruptured
diaphragm from entering the tank. Wire mesh is also provided at upper end to protect
upper diaphragm from mechanical damages.
Near the lower end of the vent, there is a small oil level indicator. When the lower diaphragm
ruptures, transformer oil rises in the vent pipe and is visible through the indicator indicating
the failure of the lower diaphragm. In case the pressure developed is not reduced to safe value
after the bursting of lower diaphragm, upper diaphragm also gives way throwing the gas
and oil outside and thus protecting the transformer tank from mechanical damage.
Sometimes conservator and explosion vent are connected with an equalizer pipe with or
without a valve.
The pipe equalizes the pressure between conservator and explosion vent.
Note: Equalizer pipe is not provided to conservator with flexible separator.
Dispatch
The explosion vent (1) is detached from the transformer at the time of dispatch and sent
separately. The top end assembly is kept undisturbed as shown in the drawing. The bottom
end of explosion vent is blanked by blanking plate and gaskets (2). The diaphragm (3) at the
bottom end is fixed between gaskets (2) and fitted on the opening of the explosion vent on
transformer cover and the opening is blanked with a plate. One more set is packed with
accessories to be used either at the bottom or top in case one of the diaphragms is damaged.
Mounting
Refer General Arrangement drawing for the position of explosion vent on the transformer.
Remove blanking plates from explosion vent and check if gasket (2) and diaphragm (3) at the
upper end are intact. If found broken or damaged, replace them.
Remove blanking plate from opening on tank cover. Check if gasket (2) is intact. Mount the
explosion vent on the opening as shown in the drawing. Ensure that the diaphragm (3) is intact
and without any wrinkles and pin-holes.
Clamp the bottom flange of vent properly and evenly at all places. Also check if clamping
hardware on the explosion vent at other places is tightened properly.
Important: Since diaphragms are not designed for pressure or vacuum test, they MUST be
removed before carrying out any pressure test or applying vacuum to the tank for oil filling.
41
Fig. 18
2.12 Radiators: (Refer Fig. 19)

Transformer is provided with detachable pressed sheet radiators with isolating valves.
Owing to transport limitation and considering possible transit damages, the radiator valves
are closed at the time of dispatch and radiators are detached and sent separately keeping
the valves in position on tank flange. The valve blanking plate is to be removed only
when the radiator is ready for mounting on flanges. On removal of blanking plate, a small
quantity of oil, which may have collected between valves and blanking plate, will seep out.
Collect this oil in a clean container and use it.
After filling the oil in radiators and venting air from them, radiator valves at top and bottom
MUST be kept in "OPEN" position and sealed.
For general construction of radiators refer figure 19.
Dispatch of Transformer Radiators
At the time of dispatch, radiator flanges are blanked by gaskets and blanking plates.
The radiator valves on tank are blanked by blanking plates. Every radiator valve is locked
by screw arrangement On radiator valve cap. Radiators are packed in robust crates.
Mounting
a. Special care should be taken while removing radiators from crates subsequent handling
operations and while mounting on tank. Any damage while handling may result in cracks
and oil may leak when fitted on tank and filled.
b. Check that the radiators are not damaged in transit. Check that all the radiator valves (6)
are locked in 'shut off' position. Also check that the blanking plates on the radiator valves and
those on the radiators are not disturbed in transit. Clean the radiators externally.
c. It is necessary to clean the radiator thoroughly from inside by flushing with transformer oil.
d. Only one radiator should be assembled at a time. The assembly of the radiators should
commence from the shorter portion of the tank or from a place where the adjacent radiators
have more clear space in-between than the other radiators. This will give more working
space during assembly. The next radiator to be assembled should be the nearest to the first
radiator. The remaining radiators should be assembled in the same sequence.
42
Fig. 19
The item numbers given below correspond to Fig.19.

Item No. Description Item No. Description
1 Main tank 14 Gasket
2 Main cover 15 Blanking plate
3 Pipe 16 Hex. bolts
4 Pipe flange 17 Hex. lock nuts
5 Gasket 18 Spring washers
6 Radiator valve 19 Hex. nuts
7 Operating handle 20 Washers
8 Locking wire 21 Hex. bolts
9 Radiator flange 22 Hex. nuts
10 Radiator 23 Flat for bracing strap clamping
11 Lifting lug 24 Bracing straps
12 Air release plug 25 Hex. bolts
13 Drain plug/valve 26 Hex. nuts
43
e. Use a clean container to collect the little quantity of oil in the radiator valve behind the
blanking plate. Remove the blanking plates (15) from top and bottom radiator valves.
Keep the nuts (19) and spring washers (18) for fixing the radiators. While removing the
blanking plate, if the gasket surface is damaged, use fresh gasket supplied as part of
erection consumables.
f. Lift the radiator vertically. Bring the radiator nearer to the valve (6) whose blanking
plates are moved. Slide the radiator on to the bolts from pipe flange and radiator valve and
tighten using plain washer, spring washer and nuts. Tighten all the nuts in sequence
applying uniform pressure on the gaskets to make a proper leak proof assembly.
Assemble all the radiators in the same manner.
g. Bracing straps are provided to keep required distance between adjacent radiators at outer
ends of header pipe. Drawing shows typical bracing strap fixing arrangements. Required
number of bracing straps are packed in separate box & supplied along with radiator crate.
h. Fill only one radiator at a time. Open the bottom radiator valve. Slowly unscrew the air
release plug (12) on the top of the radiator until the air starts escaping till the oil appears
through the air release plug (12) open the top radiator valve (6) immediately, and close
the air release plug if no more air is coming through it. Seal both top and bottom radiator
valves in "OPEN" position.
Fill the remaining radiators as stated above.
Operation
When transformer is in operation, warm oil rises and enters the radiators from the top valve,
cools and then descends to enter the bottom of the tank through the bottom radiator valve.
This cycle is continuously repeated. Cooling can also be assisted by blast of air provided by fans.
Maintenance
In case of minor leakage use M Seal for sealing. Welding of sections to header pipe is to be
done by gas welding and flanges to header pipe are to be done by electric arc welding.
The gas welding rods to be used should be 1.5 to 3 mm diameter copper coated filler rods.
The oxyacetylene flame should be neutral flame. Welding on radiator is to be done without
oil by skilled welders. Firefighting equipment should be available before start of welding.
All paint abrasions must be retouched by removing grease/oil, applying primer and finishing
with touch up paint provided.
Note: After radiator mounting oil filling should be done immediately so as to avoid leaking
of oil through radiator valves into radiator resulting in exposure of core and winding.
2.13 Earthing terminals:

The transformer should be effectively earthed by means of suitable connections to earthing grid.
It is recommended to take reference to the latest rules in code of practice for earthing as
per local laws. A good low resistance-earthing mat at substation is a must for adequate
protection. Earthing leads should have sufficient Cross-Section. The contact surfaces must be
properly cleaned before making connections and accessories like marshalling boxes, fan motors,
winding neutrals, should also be earthed. All earth points are individually identified by green
color and earth symbol. Equipotent copper bands are provided between cable box flange
and transformer tank cover and tank.
44
2.14 Silica gel breather: (Refer Fig. 20)
Application
Whenever there is a change in the ambient temperature or in the load on oil-immersed
transformer, there is a change in the volume of oil in tank and conservator. This change forces
the air above the oil level in the conservator to be either pushed out or breathed in from
outside atmosphere. Whenever the air is breathed in, there is a possibility of moisture and
dust from atmosphere to be sucked in. This is dangerous to the insulating properties of oil.
Silica gel breathers are provided to prevent this and to ensure that dry and clean air is
breathed in and out through the breather.
Construction
Conventional silica gel breather has following main components:
1. casing.
2. Silica gel crystals.
3. oil seal arrangement at the lower end of the casing.
The casing is made of completely transparent acrylic material through which the entire column
of silica gel can be seen. If metallic casing is given then there are windows in casing for
observing the silica gel. It has flanged connection at top for connecting it to pipe from conservator.
Oil sealing arrangement is provided at the lower end in the form of removable cup, which is
screwed on to the tie bar in the centre. This cup is transparent for observing the oil level.
Mounting
Breather is provided for oil filled dispatch of main unit. Silica gel breather for transformer is
dispatched separately. Check the color of the silica gel crystals. If the color is dark blue,
the breather can be fitted to the conservator after completion of erection. In case the color
of the silica gel crystals is pink and not dark blue, it is necessary to dry the crystals. (Refer Cl. 5.3.3
for details). After reactivating, fit the breather to the breather pipe.
Mount the breather and support it as shown in the G A drawing. Fill clean transformer oil
up to level marked on cup.
Operating
Dry silica gel crystals, which are dark blue in color, have a very good capacity to absorb
moisture. When the air from outside is breathed in the conservator, it passes through the
crystals and the moisture in the air is absorbed. Thus, the air that reaches the conservator
is dry. Dust particles are partly trapped in the oil seal and partly trapped by the crystals of
the silica gel.
Silica gel crystals change their color from dark blue to pink depending upon absorption
of certain quantity of moisture. On turning pink efficiency of absorption of moisture is
very low. Heating them can reactivate the crystals. The moisture absorbed then gets evaporated
and the crystals again turn dark blue and are ready for re-use.
The oil seal acts as a barrier between the outside air and the silica gel crystals inside the
casing when there is no flow of air. Thus, contact between the most air and the dry crystals
is avoided and the moisture absorbing capacity is not used up when not required.
When there is sufficient pressure difference between the air inside the conservator and
the outside air, the oil levels in the two compartments of the oil seal change until the lower
45
oil level just reaches the rim of the inverted cup. Air then moves from high-pressure
compartment to the low-pressure compartment in the oil seal. This happens both when
the air is breathed in and it is pushed out from the conservator.
The oil also acts as coarse filter and removes dust and the moisture from the outside air
when it passes around the rim of the inverted cup.
Maintenance
Silica gel crystals can be reactivated a number of times and therefore, they can be used
over a long period. Refer maintenance instructions for silica gel. (Ref. Cl. 5.3.3) The quantity
of moisture absorbed depends upon the humidity of air and the load cycle of the transformer.
Change oil in oil seal once the color changes from light or pale yellow to dark brown.
Fig. 20
Sr. no. Description

1 Threaded plug
2 Top lid
3 Nut
4 Tightening cover
5 Top gasket
6 Stud
7 Transparent cylinder
8 Connector ring
9 Silica gel crystals
10 Bottom gasket
11 Bottom lid
12 Oil cup seating gasket
13 Oil cup
46
2.15 Magnetic Oil Level Indicator: (Refer Fig. 21)
Application
This is a direct oil level indicating device provided on conservator. The low oil level contacts
provided on the magnetic oil level indicators can be used for automatic alarm (or disconnection)
when the oil level in the conservator falls to a low level. This protection prevents transformers
from damages attributed to loss of oil due to any reason.
Dispatch condition
Non Air cell type conservator :MOG is fitted on the conservator without float & arm. Float
& arm are detached separately to prevent damage. The mercury switch operating arm and
bevel gear are also locked in position. An instruction plate is fixed on the dial for float
mounting at site.
Air cell type conservator, MOG is fitted on conservator along with its float & arm.
Maintenance
Normally no maintenance is required on the indicator. The dial is already calibrated as shown
in figure. The Mercury/ Micro switch is accessible after removing the switch box cover on the
top of the dial. Adjustment in switch closing or replacement of switch is then possible even
if conservator contains oil.
Refer to manufacturer's catalogue for details.
Fig-21
47
2.16 Marshalling Kiosk: (Refer Fig. 22)
Application
The transformer is protected by fittings such as PRV, MOG, Buchholz relay, OSR etc. mounted
on the transformer at different locations. These fittings usually have contacts/terminals,
which are connected to the protection scheme. The connection to protective scheme gives
various types of alarm indications and also disconnects the transformer from incoming and
outgoing supply in case of fault conditions. In order to facilitate connections of all such devices
to the protective scheme, the leads of all protective device contacts are wired to a weatherproof
kiosk. This kiosk also houses indicators for oil temperature, winding temperature and heater.
This kiosk is also called Fan Control Cubicle when fans are provided for cooling.
Construction
Hinged lockable front door is provided with a glass window from which the temperature
readings on the indicators can be observed. The locking device is provided to prevent
unauthorized tampering with accessories fitted in it. The sensor along with capillaries from
each indicator take off from the indicators, come out from the side of the marshalling box
through apertures fabricated to prevent ingress of dust etc.
Terminal block is mounted on channel. The enclosure is completely weatherproof and has
a detachable gland plate through which cables from CT secondary, magnetic oil level indicator,
buchholz relay etc. are connected to the terminals. Temperature indicator terminals are
wired internally from indicator to terminal block.
The entire kiosk has a rain shed provided on top to prevent ingress of water due to heavy
rains falling directly over the marshalling kiosk.
Other fittings
It is also provided with door operated switch for internal lighting. To prevent internal
condensation in moist weather a heater with thermostat controlled/manual switch is provided.
Mounting
The marshalling kiosk with its mounting brackets is dispatched separately. The temperature
indicators are mounted inside the box and are already wired up. The location of the box
on the transformer is indicated on the General Arrangement drawing of the transformer.
On receipt check the box for damages and check the contacts of the oil and winding
temperature indicators with a multi-meter.
Mount the box at the location indicated on the General Arrangement drawing.
Remove the gland plate and drill holes for control cable glands as required. It should be noted
that control cables should always be terminated through cable glands to maintain the
weatherproof nature of the terminal chamber.
Uncoil the capillary tubing of the OTI & WTI and lay suitably upto relevant pocket on cover.
Use the brackets supplied to support the capillary. Avoid sharp bends in the capillary tube
to prevent breakages.
Do not cut the capillary in case of excess lengths.
Connect the cables from other accessories to the relevant terminals as shown in wiring
diagram. The wiring diagram is kept inside of the marshalling kiosk for ready reference.
48
Check the operation of each fitting with a multi-meter across the terminals in the terminal
chamber after all cables are connected.
If the contacts from each instrument are showing proper operation at the marshalling box
terminals chamber end, then connect the control cable to the terminals provided and
ultimately connect the control cable to the relevant protective circuit.
After all connections in the terminal chamber are completed and tested, close and lock
the front door.
49
2.17 Oil Temperature Indicator (OTI)
Application
Oil temperature indicator :
The Oil Temperature Indicator (OTI) measures the top oil temperature. It is used for control
and protection of transformer.
Operation
The Oil temperature is measured with the help of sensing bulb immersed in the pocket by
using liquid expansion in the bulb through the capillary line to operating mechanism.
A link and lever mechanism amplifies this movement to the disc-carrying pointer and
switches, which indicates the temperature on the dial of the thermometer.
For details refer to manufacturer's catalogue.
Note
1. Thermometer pocket must be filled with transformer oil prior to insertion of bulb of OTI.
Refer to Fig. 23 attached.
2. Remove locking screw of OTI dial before taking in service.
Remote Temperature Indicator
A Precision Potentiometer mounted inside the instrument case functions as a transmitter
and operates an electrical repeater for remote reading of measured temperature. In one
scheme the transmitter is directly connected to the repeaters and alternative scheme is to
connect the transmitter to a resistance transducer, which will supply direct current for
operating repeaters.
For details refer to manufacturer's catalogue.
50
OTI / WTI SENSING BULB MOUNTING
51
2.18
2.18.1 Winding Temperature Indicator (WTI)
Application
For oil immersed transformers operating under varying loads, supervision of the
winding temperature is of great importance. The use of a winding temperature
indicator permits the winding temperature to be constantly monitored and harmful
overloads can be avoided, by restricting the loads which lead to temperature rise
beyond permissible limits.
Description and Operation
Winding Temperature Indicator (WTI) measures the Hot Spot winding temperature.
WTI is basically an OTI with additional specially designed heater coil connected to
CT secondary of the transformer which simulates the winding temperature. The life
of transformer depends on the winding temperature ,which determines the
deterioration of the insulating material. For safe over loading of a transformer
WTI is an important protection device.
The winding temperature will be depending upon the load (current through the
winding) of the transformer and the temperature of oil. These two parameters are
measured and combined result is indicated as winding temperature.
Winding temperature is measured by connecting the CT secondary of the transformer
through a shunt resistor inside the winding temperature indicator to the heater coil
around the operating bellows.
2.18.2 RTD (Resistance Temperature Detector for Oil / Winding):
This scheme consists of : PT-100 sensor, Current converter unit (CCU), Remote
indicator with power supply unit, Thermometer pocket.
This scheme consists of PT-100 sensor for sensing the oil & winding temperature,
the sensor used for measuring the oil temperature is placed on transformer top
cover in suitable pocket. A CT with suitable Current Ratio is used for winding
temperature indication along with RTD. When there is no current flowing through
the CT the winding temperature will be same as oil temperature. When current is
passed through the CT the signal proportional to preset temperature rise will add
up the signal from oil temperature and the output will proportional to the total
winding temperature.
If required Winding temperature can be converted in to 4-20 mA DC outputs.
An indicator, Analog/ Digital is calibrated for the temperature range is connected
to the 4-20 mA (Output -1) signal.
Note : Check if the sensor by measuring the resistance before connecting to the
circuit as below
RTD terminals Multi-meter indication
A to B - Zero
A/ B to C - Should be 100 ohms + 1 ohms /3 deg C (Approx)
52
PT 100 Character tics Curve for Temperature, Resistance & output current
Temp in Deg C Resistance in Ohms Output signal in
milliAmp.( 4-20 ma )
0° 100 4.000
10° 103.9 5.067
20° 107.79 6.133
30° 111.6 7.200
40° 115.54 8.267
50° 119.4 9.333
60° 123.24 10.400
70° 127.07 11.467
80° 130.89 12.533
90° 134.7 13.600
100° 139.5 14.667
110° 142.29 15.733
120° 146.06 16.000
130° 149.82 17.067
140° 153.58 18.933
150° 156.31 20.000
53
2.19 Fans
Whenever transformer is on ONAF condition fans are provided for cooling. These are mounted
on brackets which are fixed on tank wall or on ground. The fans are controlled from FCC and
sometimes from RTCC and can be operated manually or on auto mode. When fans are on auto
mode they are switched on using one of the mercury switches of the WTI mounted in FCC.
The setting of the switch should be such that no hunting takes place. For this the temperature
differential should be minimum 6 deg. To 7 deg. between switching ON and OFF of fans.
2.20 Current Transformers
All current transformer secondary terminals should be short circuited and earthed or loaded
before energizing the transformer. This will prevent excessive voltage developing across
C.T. terminals which can damage the C.T.
2.21 Air release plugs
Air release plugs/valves are provided on various equipments. All plugs/valves should be opened
to ensure that no air is trapped anywhere in the transformer. Plugs need not be fully removed
for air release purpose. All plugs/valves should be partly opened during oil-filling operation.
As soon as some oil starts coming out from plug/valve, retighten plug/valve and clean the
plug/valve thoroughly from outside so that dirt/dust does not deposit.
2.22 Earthing terminal and magnetic circuit check window
All earthing points are marked in green color and are carrying the symbol.
Magnetic circuit earthing arrangement to clamping structure is provided at one point only
through a removable link and its location is as indicated in GA drawing.
This is not a standard feature and is provided as an optional requirement.
2.23 Off circuit Tap changing Switch:
To maintain the secondary voltage reasonably constant at the user's end when incoming
voltage and/or load on the transformer changes, it is necessary to adjust the voltage ratio
(i.e. turns ratio of the windings) of the transformer. This is achieved by operating the tap
changing switch.
Important
As the name "Off Circuit" implies the transformer must be Electrically isolated from
the mains, before operating the switch. It is also dangerous to approach the location of
the switch handle on a "live" transformer when bare live terminals are in the neighborhood.
The best practice is to switch off the secondary and primary sides of the transformer.
Steps for operating the switch
1. Decide the desired change in the voltage referring to Rating & Diagram Plate. Note
the position.
2. Disconnect the transformer from the mains. For absolute safety, ensure that both primary
and secondary switchgear is locked in "OFF" position and earthed.
3. Remove lock of tap switch handle.
4. Pull locking pin and rotate switch handle until switch pin is exactly in the required position
on the indicating plate.
5. Ensure locking pin is correctly engaged in new position.
6. Fix lock on locking pin.
7. Check LV voltage after energizing transformers to check desired change.
54
Fig-24
Typical Horizontal OCTC
Typical Vertical OCTC
55
2.24 On load tap changer
On load tap changer (OLTC) functions in the same fashion as Off circuit tap changing
switch. However, in cases of OLTC the transformer NEEDS NOT BE ELECTRICALLY ISOLATED
FROM HV & LV SIDE. The tap changer can be operated on load. The tap changer is an integral
part of the transformer and is suitable for power flow in the direction indicated on the
OLTC nameplate. For constructional details, refer manuals of manufacturer.
Automatic voltage regulating relay
This relay is used to operate OLTC to change the tap automatically & maintain desired voltage.
Refer supplier manual for details.
oil surge relay:
This relay used on OLTC to protect the transformer from fault developed in diverter
switch housing.This relay trip the breaker & isolate the transformer from power system.
Refer supplier manual for details.
2.25 RTCC Panel:
Whenever Transformer is provided with OLTC, if ordered, a separate Control Panel is provided,
called RTCC (Remote Tap Change Control Cubicle). This Panel is located in the Control room
from where OLTC operation is controlled.
Generally, RTCC is fitted with Raise & Lower push buttons for Raise/Lower command
of OLTC, TPI (Tap Position Indicator) for indicating tap number of OLTC. The other features
like OTI & WTI repeaters, AVR, Voltmeters, etc. are provided on RTCC on order and are not
standard features.
56
3. INSTALLATION
3.1 Precautions:
As far as possible no work should be carried out during the rainy season to avoid moisture
absorption by the transformer. Extreme care should be taken to prevent any foreign material
from being dropped into the transformer. Workmen having access to the interior of
transformer should empty their pockets of all loose articles. Any spanners or tools used
should be securely tied with strings to the hand of the workmen so that they can be
recovered if accidentally dropped.
FIBROUS CLEANING MATERIAL SHOULD NOT BE USED. The presence of loose fibers in
suspension in oil can reduce its insulating properties. If any cleaning or wiping is necessary,
this should be done with clean and dry oil for cleaning and with soft non-fluffy cloth for wiping.
All detached components should be cleaned inside and outside before being fitted. Internal
surfaces in contact with oil should receive special attention. Before fitting the radiators on the
transformer tank, they should be flushed with transformer oil to remove traces of dirt or
foreign particles.
Transformer oil is flammable and under certain circumstances in a confined space may
become explosive and hence naked lights and flame should never be used near the transformer.
Transformer oil and cellulose based solid insulation normally used in transformer construction
absorb moisture easily particularly when cold. Condensation can be caused if the interior of the
tank is exposed to the atmosphere. But by taking adequate precautions, this can be minimized.
If access is needed to the interior of tank during installation, the transformer is best protected
from the moisture hazards by circulating dry and hot air into transformer until its temperature
is slightly above ambient. This should be done before allowing external access to the interior
of the tank.
3.2 Site preparation:
Check the foundation as per foundation plan drawing for main tank and cooling system
before placement of equipment.
All accessories, hardware, gaskets, pipe works etc. shall be verified as per packing list and
actual requirement as per GA drawing for any shortage / damage.
Check the following as soon as transformer received at site :
N2 gas pressure, if dispatched with N2 filled (positive pressure) and oil level, if dispatched
oil filled.
Check IR value between Core to Tank & record for reference. Matter must be reported to BBL,
if IR found zero.
Any discrepancy noted shall be reported to BBL.
The transformer should be installed on a leveled foundation. The foundation or surface
should be strong enough to bear the weight of transformer and to prevent accumulation
of water. Foundation incorporating special oil draining facility during fire and emergency is
strongly recommended for large transformers.
Transformer should be installed in such a way that easy access is available all around to read
rating and diagram plate, thermometers, valves, oil level indicators etc. Adequate electrical
clearances are also to be provided from various live points of transformer to earthed parts.
For transformer installed indoors, the room must be well ventilated so that hot air can escape
easily and be replaced by cool air. Air inlets and outlets should be sufficient in size and
numbers to pass adequate air to cool transformer.
When rollers are fitted, suitable rails or tracks should be used and the wheels locked to prevent
movement of transformer. Transformer can also be bolted to the foundation for this purpose.
57
While fitting rollers, Transformers should be jacked up by using suitable jacks at the jacking
points only. Wheel shafts should be properly greased before fitting rollers. Rollers, if
provided, are bi-directional and can be fitted in any desired direction.
3.3 Transformer oil :
Transformer oil dispatched to site is in sealed drums. At the time of filling from drums, it is to be
ensured that the oil is clean and dry. It is possible that moisture might have entered while in
transit and therefore it is imperative that this oil should be filtered again in separate tank
at site before filling into the tank and after achieving a minimum dielectric strength of 60 kV.
Oil sample to be checked as below from drums:
No. of Drums supplied No. of Drums from which oil samples to be checked
1 to 5 2
6 to 20 3
21 to 50 7
51 to 100 10
From storage tank or tanker 3 samples to be tested
BDV of composite sample as per above sampling plan should be min.30kV (unfiltered).
It is advisable to preserve seals removed from drums, till transformer is commissioned.
Oil samples from oil filled units in storage or oil tanks should be taken through bottom
sampling/filter valve. For taking out oil samples from oil drum use clean plastic tube to siphons
oil from drum.
Note:
1. Use clean bottles to collect oil samples and flush the bottle well with oil before collecting
sample.
2. Put a tag on the bottle after sampling to show location, date and time of collection of sample.
3. While collecting samples through valves, allow some oil to flow through the valve to
wash out dirt.
4. Oil sample shall be collected in clear and dry weather preferably sunny.
Dielectric strength test of oil
Oil samples from top and bottom of the tank and diverter switch tank of on load tap changer
should be tested. In order to obtain representative sample of the oil, extreme care should be
taken and absolute cleanliness observed when extracting the sample. Proceed as follows:
a) Use only wide-necked glass bottles of at least one liter capacity with glass stoppers
(not corks) for collecting the sample (Dark colour).
b) Before use, the bottles should be thoroughly cleaned with pure benzene or petrol or carbon
tetrachloride and then rinsed with oil from transformer before collecting sample.
c) The sample is to be drawn from the respective valve after the transformer is left undisturbed
for sufficient time.
d) In order to remove any moisture or dirt adhering to the valve passage, allow about 4 to 5
litres of oil to drain off into a clean dry vessel before extracting the sample into the bottle.
58
e) The sample should then be tested for its dielectric strength as per the latest IS 1866. It is
expected that every transformer pass the test, if the normal transit and storage precautions
are taken. However, if the oil does not come up to the required standard even after
filtration, Bharat Bijlee should be consulted for necessary action.
3.4 Oil filling in the transformer :
3.4.1 General:
Before filling oil in tank, it should be tested to meet the requirements laid down in
this clause. In case the oil does not meet the requirements, it should be processed in
separate storage tank and should be filled in transformer tank only when it meets
the requirements i.e. BDV More than 60KV & PPM less than 15. Whenever windings
are out of oil, oil filling of all power transformers should be done under vacuum.
All power transformers have their tanks designed to withstand full vacuum.
When filling transformer with oil, it is recommended that the oil is pumped in from
the bottom of the tank under vacuum and that a filter press or any other reliable oil
drying and cleaning device is interposed between the pump and the tank. This process
of oil filling under vacuum avoids trapping of air bubbles in inaccessible corners
of winding. Any air that remains will dissolve in the partially de-aerated oil when
vacuum is broken. Transformer is to be filled with oil to working level. After erection , oil
shall be filled through top filter valve which goes to top of tank. The oil shall be
filled only after testing and passing through filter.
Parameters of the oil acceptable before commissioning:
Characteristics Parameters
1. Electric Strength (BDV) More than 60 KV.
2. Resistivity at 90 degrees C 6 x 1012ohm cm (min)
3. Dielectric Dissipation factor 0.01 (max)
(tan delta) at 90 degrees C
4. Moisture content Less than 15 PPM.
3.4.2 Oil filling under vacuum: (Refer Fig. 25)

The following procedure should be adopted for filling oil under vacuum for transformers
dispatched without oil and with positive pressure of Nitrogen gas.
A. Make suitable connections from top filter valve to the vacuum pump.
B. Main Tank and OLTC Diverter Vessel should be equalized through equalizing pipe
before vacuum.
C. Make suitable connections from the bottom filter valve to the oil storage
tank/barrels through oil filter machine.
D. Apply vacuum to the transformer to achieve vacuum below 5 torr & maintain vacuum
for period mentioned below.
Rated Voltage kV Vacuum period in hours before filling oil
Up to and including 66 24
Above 66 and up to & including 220 48
E. After vacuuming the transformer for the above mentioned period, fill processed
& tested oil in the transformer under vacuum at temperature of 45-50 ° C up to
the level of inspection window for HV/LV bushings connections. Break the vacuum
through silicagel breather and now the transformer is ready for further erection work.
59
F. After erection is complete, top up the transformer with filtered oil through main tank
top filter valve up to desired level mark in MOG of conservator.
3.4.3 Oil filling in Atmoseal type conservator
Refer Fig. 15 of clause no. 2.8.1 for oil filling procedure.
3.4.4 Hot Post Drying of Transformer Active Part at site is required in following cases:
A. In case of very low insulation resistance value, very low dielectric strength of oil
and low PI value.
B. In case of very long storage without commissioning (period in excess of 6 months
from date of dispatch).
C. In case of transformers dispatched filled with oil, if the oil is lost in transit thereby
exposing the transformer core and windings to atmosphere.
D. Any other cause at site resulting in exposure of the transformer core and windings
to the atmosphere for a sufficiently long duration of time.
Method of Hot Post Drying of Active Part
1. Isolate conservator and radiator from main tank. Fill the main tank with
transformer oil.
2. Filter the main tank oil by connecting the bottom filter valve to inlet of filter
machine and top filter valve to outlet of the filter machine. The Main Tank should
be lagged/ covered from all sides to reduce loss of heat due to dissipation.
The outlet temperature of filter machine should not exceed 70 ºC.
3. Continue filtration till the temperature difference between top and bottom oil of
tank is within 5ºC.
4. Drain the oil completely and immediately apply vacuum through the top filtered
valve to evacuate the tank below 5 Torr & maintain vacuum for 48 hours.
5. Fill oil under vacuum till the tank is almost full, measure temperature and insulation
resistance value and repeat operation 2 to 4 cycles. Continue the process till the
insulation resistance value of two adjacent cycles at same temperature is almost
same. When this stage is reached, fill oil under vacuum and allow the transformer
to come to ambient temperature. Measure the insulation resistance value of all
windings again. If the values have improved proceed further. If improvement
is not satisfactory, repeat the cycles till satisfactory results are obtained.
Note:
1. OLTC oil shall be filtered and insulation resistance shall be checked.
2. Oil temperature in filter machine should not exceed 65° C for Hi - vacuum machine.
3. The IR should not be measured when transformer is in vacuum. This will mislead
and may show very low value.
Alternative method of drying out : ( by heating, vacuuming and N2 filling)
a. Isolate conservator before Buchholz and radiators from main tank by providing
blanking plates.
b. Make suitable covering arrangement of transformer to avoid heat loss.
c. Arrange pure and dry N2 gas of dryness not less than -50° C dew point at 30° C
temperature. The quantity will be equal to oil quantity. Generally one normal cylinder
has 7 m3 gas which can displace 7 KL of oil.
60
d. Arrange concealed type of heaters and fix them around the tank wall at distance
of 100 to 150 mm away from tank wall and also at bottom of tank.
e. First apply vacuum in tank up to 1 Torr for 24 hrs. Fill N2 gas in tank up to 4-5
PSI pressure. Start heating of tank with heaters and raise temperature about
65-70° C. Maintain the tank pressure with N2 gas for 24 Hrs.
f. The dew point of gas shall be checked just before filling in tank (from cylinders)
and after 24 Hrs of filling. The difference will indicate the presence of moisture
in transformer.
g. The IR value can also be monitored during N2 gas filled cycle.
h. Repeat the drying cycle till, dew point is achieved up to - 24° at 24° C gas temperature.
I. After achieving dew point parameter; oil filling and further erection activities
can be completed as stated in manual.
61
3.5 Gasket and gasketed joint
Whenever blanking plate are removed to fix the detachable part such as bushing, turret, etc.
the old gasket should be replace with new erection spare gasket.
Most of the gaskets are made out of rubber bonded cork sheets. They are usually cut to
size and shape required. However, some may be supplied as straight, angled or in plain
sheet form, from which complete gaskets can be built up, according to the requirement at site.
Either scar fed joint or dovetailed joint should be used at the junction of two gaskets.
The joint should be located away from corners and bolt holes and should be well bonded,
smooth and free from local thickening. Neoprene solution is recommended for main tank
cover curb gasket. To make a gasket joint, first clean the metal surfaces ensuring that they
are free from oil, rust, scale etc. Using flanges or blanking plate as templates, punch the
necessary bolt holes in gasket material. Insert the gasket and tighten bolts diagonally in sequence,
a little every time so that uniform pressure is exerted on the gasket until the gasket is
compressed properly
Spare gaskets should be stored flat in a sealed container in a cool place. These must be
protected from heat, moisture, oil and grease.
Rubber cords are used between tank cover and curb joints. These cords are protected from
over compression by mechanical stops.
Sequence of erection:
1. Check the following before erection.
i. Check foundation of transformer, radiator banks pipe supports, FCC etc as per drawing.
ii. Placement of transformer on plinth and mounting of roller assembly.
iii. Check IR value, polarity and continuity of turret mounted CTs.
iv. Check IR values of all condenser type bushings with 5 KV Megger for 60 seconds and record
the values for reference.
v. Check IR value between Core to Tank.
vi. Check Buchholz, OSR, PRV, WTI, OTI, valves, fans etc. for its healthiness before fitting.
2. Flush radiators & pipes with oil.
3. Prepare oil in separate tank for BDV > 60 KV.
4. Evacuate transformer up to full vacuum (760 mm of Hg) and maintain as per clause 3.4.2
(d). and fill the oil up to core level ( for gas filled transformer).
5. Erect turrets, bushings, radiators, conservator along with its valves & pipe work.
6. Fill oil / top up to conservator level and also in radiators with its pipes. Release air from
all air release points. Fill oil in OLTC diverter up to level marked on its conservator also.
7. Close equalizer valve or removed and blanked the hole of tank and OLTC diverter after
oil filling..
8. Carry out filtration of oil in transformer tank, radiators etc. to meet the desired oil parameters
as per IS 1866
9. Lay cables and terminate between devices i.e. cooling fans, Buchholz, OSR, PRV, CTs, MOG
etc to marshalling Box (FCC). Care must be taken while connecting cable to CTs, PRV, OSR,
Buchholz, Fan etc to avoid rain water entry to their terminal box through cable glands.
Cable gland may be sealed by using sealing compound wherever it is necessary especially
in case of horizontal entry of cable.
10.Earthing: Connect transformer neutral with two independent earth pits. Also ensure
earthing of main tank, turrets, fans, radiators, cooling structure, diverter etc.
62
FLOW CHART FOR SITE ACTIVITIES FOR TRANSFORMER
Receipt of Main Tank Receipt of Accessories
Check oil level for oil filled / Check Crates/ boxes and loose items shall be
gas pressure (Positive Pressure). checked for any physical amage.
For N2 gas filled. Physical checks for
any dents/ damages. Report to BBL
if found damages. Storage of accessories in covered shed.
Unload the transformer tank at hard and

leveled surface. Verify the material received as per
the packing list and report to BBL for
any shortages / damages
Check the foundation/ plinth of main
tank and cooler assembly as per
foundation plan drawing.
Placement of transformer on plinth

and mount roller etc. Store oil drums horizontally with bungs
at 45 ° to the horizontal on leveled and
hard surface. Also ensure no
Preparation of oil in separate tank water accumulation is there.
and test for BDV > 60 KV
For Oil filled
For Gas filled
Evacuation of transformer for full

vacuum i. e. 760 mm of Hg. And
maintain as per guidelines given
in manual.
Fill transformer with processed and

tested oil under vacuum up to
core level.
Mount turrets, bushings, conservator,

radiators and its pipe work.
Filling of oil in radiators, conservator.

Hot oil circulation to meet oil
parameters as per IS 1866.
Cabling and terminations of

protective devices.
Precommissioning checks as per Commissioning.

schedule I, II & III
63
4. COMMISSIONING
4.1 General
After the installation work is over, the transformer is to be kept ready for commissioning.
Prior to putting the transformer into service, attention should be paid to the following checks
and tests. These should be carried out under the strict supervision of an experienced person.
The instructions given below are of a general nature and are likely to vary depending upon
the site conditions and design features of the transformers. Problems arising out of peculiar
situations have to be assessed and solved on case-to-case basis. In the event of any difficulty
or doubt, reference should be made to 'Bharat Bijlee Ltd.' for necessary clarifications.
Please refer Schedule I before carrying out pre-commissioning checks/tests on transformers.
4.2 General checks:
1. Inspect the transformer all over for oil leakages and check all flanged joints and fitting for
oil leaks. If found necessary, retighten the bolts. Welding on transformer tank can be done
only after consulting BBL.
2. Check the transformer is placed on leveled foundation.
3. Buchholz relay is to be mounted in position inclined at a rising angle of 3 degrees to 9 degrees
approx. towards conservator. Ensure arrow mark on relay points towards conservator.
4. Isolating valve/s of Buchholz relay should be fully open. Also make sure that all radiator
valves (butterfly valves) are fully opened and locked in position by sealing cap.
5. Open plug/venting screws on radiators, bushings, and Buchholz relay, tank cover until oil
appears and then closes them, making sure that no air remains inside the transformer tank.
6. Check and correct the level of oil in main and OLTC conservator.
7. Make sure that all thermometer pockets for oil and winding temperature indicators are
filled with transformer oil.
8. Minimum clearances between live parts and between live parts to earth must be at least
as indicated in General Arrangement drawing of transformer and cable boxes.
9. Ensure that equipments are mounted in position as shown in general arrangement drawing.
10.Check that the colour of silica gel in breather is dark blue. Also oil in oil cup is filled up to
the level indicated on indicator. Check that air passage of breather is not blocked.
11.Check the various protective devices (viz. OTI, WTI, Buchholz relay, M.O.G. PRV etc.) and
their signaling and tripping contacts for foolproof operation. Make sure that Buchholz
relay floats are un- locked and the relay is set in 'service' position.
12.Check that switches for alarm and trip contacts on oil temperature and winding
temperature indicators are set at the desired temperature setting.
13.Check incoming voltage and set the OLTC on the corresponding tap position.
14.Check whether transformer is earthed properly by two independent earth connections.
Also check earth connections on all points marked in GREEN colour.
15.Check terminal clamps on bushings and cable end terminations on bus bars, etc. for proper
connections and tightness.
16.Check functioning of the breakers associated with transformer by actual operation of
protective relays and supervisory equipments of transformer.
64
4.3 . Pre-commissioning checks /Tests.
4.3. 1 SCHEDULE 1
Customer Site
W. O. No. /Sl. No
Rating Ratio
The following should be ensured before carrying out the pre-commissioning checks/
tests on the transformer:
1. Clearance in the air checked as per GA drawing between live part &earth..
2. Arcing Horn Gap checked & adjusted as per GA drawing.
3. Buchholz relay/Oil Surge relay arrow pointing towards the Conservators.
4. Ensure Magnetic Oil Gauge Float is fitted.
5. Oil flow indicator mercury switch transit locking released.
6. Isolating valves of the Buchholz relay/Oil Surge relay in fully open.
7. Oil filled in Silica gel breather cup up to filling level.
8. All radiator valves and in line cooling pipe valves are open.
9. Oil filled in Oil temperature indicator and Winding temperature indicator pockets.
10.OLTC operated manually for two full cycles for smooth operation.
11.Control cabling carried out completely.
12.Buchholz relay gas collection pipe (if provided) checked for gas release.
13.Buchholz Relay test screws in service position.
14.Oil in Conservator filled up to 30 degree filling mark.
15.Oil filled in the air cell conservator as per the procedure stated in manual.
16.Off Circuit tap switch brought to desired position and locked.
17.Ensure Turret / Tank mounted CTs connected with relay/ burden. Unused CT
secondary should be properly shorted.
18.Core to Tank and End frame Shorting link are fitted.
19.WTI CT loop resistance should be checked to ensure CT is connected with burden/
heater of meter.
20.Ensure Earthing of Tan Delta Test tap of Condenser Bushing.
21.Air venting done from bushings, radiators, headers, Buccholz, OLTC diverter and
Main Tank.
22.Oil level in condenser bushing.
Signature & Seal of customer Signature of BBL rep.
65
SCHEDULE- 2
LOW VOLTAGE TESTS :
1. Insulation Resistance Test:
Make of Instruments: _________ Test Voltage: ________________ KV Temperature : ________° C
IR value between IR Value for 60 second

LV To Earth
HV To Earth
LV To HV
HV To Tertiary
LV To Tertiary
Tertiary To Earth
Core To Earth (Use 1kV megger)
2. Magnetic Balance Test:

Apply 1 Phase 230 V AC / 2 phase 415 volts on HV/ LV side (whichever have neutral) between phase
and neutral and record induced voltage on other phases as below.
*1U1N = V 1V1N = V 1W1N = V

*
*
*
Note: * indicate applied voltage.
3.Final Oil BDV& PPM test:
{Avg of 6 reading on a sample after interval of 1 min. by sphere gap of 2.5 mm}
Sample Taken Date Weather Condition PPM BDV

Main Tank Top Oil Clear /cloudy
Main Tank Bottom Oil Clear /cloudy
OLTC Clear /cloudy
66
4. Magnetizing current :
1 phase 230 volts / 3 phase 415 volts applied to HV or LV and other winding kept open.
HV Side LV Side
Applied Voltage Current Measured Applied Voltage Current Measured
1U1N/1U1V mA 2u2n/2u2v mA
1V1N/1V1W mA 2v2n/2v2w mA
1W1N/1W1U mA 2w2n/2w2u mA
5. Voltage Ratio:
In case TTR is not available, the ratio can be measured by applying Constant 1 ø Voltage on HV through
Variac and measure the induced voltage of LV simultaneously.
Applied Voltage on HV Measured Voltage on LV

Tap no
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
67
6.Vector Group
{Apply 3 phase, 3 wire supply to U, V, W, (HV winding) & measure voltage at different point after
shorting ( Short 1U-2U.--------------)
• 1U-1N : __________________V
• 2U-2N :__________________ V
• 1N-2N :__________________ V
• 1V-2W :__________________ V
• 1V-2V :__________________ V
• 1W-2V :__________________ V
• 1W-2W :__________________ V
Condition to be satisfied.:
1.
2.
3.
Hence Vector Group is ____________
7. Winding Resistance Measurement
HV Side:
Temperature : _______ °C Instrument Used:
Make :________________ Type : ___________
Tap No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
68
15
16
17
18
19
20
21
22
23
24
25
LV Side:
Temperature : _______ °C
Tap no.
69
8. Short Circuit Test: LV side shorted.
Applied Voltage: 1U1V= 1V1W= 1W1U=
Current Measured in HV Current Measured in LV

Tap no U phase V phase W phase U phase V phase W phase
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
OLTC continuity checked during Short Circuit Test and found no break during change of Tap for all Taps
70
SCHEDULE - 3
Functional Checks of OLTC, Cooling Fans and Protective Devices.
1. OLTC operation checked in following mode and found ___________.
I) Local Manual : YES / NO
ii) Local Electrical : YES / NO.
iii) Remote : YES / NO.
iv) Auto : YES /NO
v) TPI indication at Remote : YES /NO
2. Settings Of OTI And WTI
Setting OTI WTI(HV) WTI (LV)
Alarm
Trip
Fan "ON"
Fan "OFF"
Oil Pump "Start"
Oil pump "Stop”
3.Protection Relay Operational Checks.

OPERATION
Sr. No. PROTECTIVE DEVICE ALARM TRIP

1. Buchholz Relay
2. OTI
3. WTI (HV)
4. WTI (LV)
5. PRV(Main)
6. PRV(OLTC)
7. OSR
8. Oil Flow Fail
9. Fan Fail
10. Oil Pump Fail.
11. Differential
12. REF
13. Over current / EF relay.
71
Transformer charged on "NO LOAD" on _______________ date at ______hrs. successfully. Incoming
voltage _________ _________V, Top oil Temperature__________
Ambient Temperature________________ Tap no:_______________
 Transformer put "ON LOAD" ___________ at ____________incoming voltage ___________

KV load on Transformer _____________ KVA, Tap No.______.
Signature & Seal of customer Signature of BBL rep.
Name : Name :
Designation : Designation :
Date : Date :
4.4 Parallel operation:

For satisfactory operation in parallel, the concerned transformer shall have identical (a)
phase displacement, (b) voltage ratio, and (c) equal % impedance within permissible
tolerances. Provided the polarities of the winding correspond, transformer with the following
connection operates satisfactory in parallel. Connection in group A shall not be parallel
with those in group B.
Group A: Star/ Star, Delta/ Delta, Delta / Zigzag.
Group B : Delta/ Star, Star / Delta, Star/Zigzag.
Every condition mentioned in IS 10028 Part II should be fulfilled for this purpose. Difference
in impedance values causes circulating currents to flow in addition to usual share of current.
4.5 Energizing :
When all the checks and tests are found satisfactory, Air should be vented from all Air release
plugs/screws provided on the main transformer, radiators, bushings, Buchholz Relay, etc.
Settling time of about 24 Hrs. shall be allowed after use of filter machine with tank.
After complete venting the air out, the transformer should be energized and maintained on
no load for duration of preferably 24 hours. During these 24 hours, the Buchholz Relay
should be constantly monitored for any collection of air.
After commissioning of the transformer, detailed report of pre-commissioning test should
be sent as early as possible to Bharat Bijlee Ltd., As per schedule I, II. & III. for reference and record.
72
5. MAINTENANCE
5.1 General
As compared to most electrical equipments, a transformer requires relatively little attention.
A regular system of inspection and preventive maintenance will ensure long life and trouble free
service. Records must be maintained giving details of all inspections and testing made and of
unusual occurrences. The causes of breakdown of Transformer are generally classified as below.
a. Incorrect installation of accessories.
b. Overloading beyond permissible limit.
c. Poor maintenance.
d. Faulty design or construction.
e. Accidents
5.2 Factors affecting the life of the transformer:
Transformer oil readily absorbs moisture from the air. This reduces dielectric strength of oil,
which is also reduced by solid impurities. Care should be taken to eliminate air from transformer
preferably by filing the transformer under vacuum. Presence of oxygen inside oil causes
sludge formation, which blocks the free circulation of oil over winding
5.3 Maintenance Procedure:
Precautions:
No work shall be done on any part of the transformers unless it is disconnected from external
circuits and all windings have been fully earthed. Naked lights and flames should be kept well
away from the transformer while doing maintenance. Oil level should be reduced below tank
cover while opening nuts and bolts on cover and before unsealing the tank, radiators,
conservator, explosion, vent and any other piping on tank cover.
5.4 Recommendations for maintenance:
Transformer tank, cover and other parts should be inspected periodically for any oil leakages,
peeling of paint or rust formation. Rusted portion should be properly cleaned and repainted.
Oil leakages should be immediately attended to. Clamping bolts on gasket joints should be
tightened properly and if necessary gaskets shall be replaced.
5.4.1 Transformer Oil:
Oil level should be checked at frequent intervals and if necessary conservator should
be topped up. Oil for topping up should be clean fresh filtered and complying with IS
1866 and should preferably from same source as the original oil.
Samples of oil should be taken at regular intervals and tested. It may be mentioned
that normal method of oil purification by using high vacuum filter machine only
improve dielectric strength and reduces PPM of oil. However, the dielectric strength
does not give a true indication of the correct condition of the oil. Even oil, which is
highly deteriorated, may give high dielectric strength, if it is dry. Therefore, it is
necessary to carry out chemical tests and other test as given in IS 1866 in addition
to the above tests.
Oil deterioration takes place generally by the following contaminants:
a. Increase of water contents in oil.
b. Polar substances
73
c. Increase of acidity
d. Formation of sediments & perceptible sludge.
e. Generation of dissolved gases..
It may be noted that reconditioning by centrifugal separator or filtration does not remove
the acidity from the oil but will remove sludge, dust, etc. and will tend to retard the
process of deterioration. Filters with fuller's earth will help to reduce the acidity in the
used oil and in addition improve the resistivity.
Measurements of resistivity, dissipation factor and interfacial tension help in detection of
Polar substances. This contamination is generally due to oil soluble components, material
used in construction, and oxidation of oil.
Relationship exists between resistively and Dissipation factor. If dissipation factor
increases resistivity decreases.
Satisfactory result of resistivity at 90 deg. Indicates presence of Moisture or general

& unsatisfactory result at lower temperature Contamination
Unsatisfactory results at both temperatures. Indicates greater contamination.

Oil can be restored to satisfactory level by drying
at low temperature by filtration
Oxidation of oil encourages deterioration of pressboard, insulating paper. When acidity

reaches 0.5 mg KOH/gm check acidity once in 6 months till 1.0 mg KOH/gm level is
reached when oil is to be processed. Pungent odour indicates higher acidity.
5.4.2 Conservator and oil level indicator:
Generally two types of conservators are used. One is conventional type which has
MOG & prismatic gauge glass for oil indication, where as other one comprises
of an additional air cell separator to avoid entry of direct air to oil in conservator.
Conservators are so designed that the lower part acts as a sump in which impurities
and sludge may collect. A valve is fitted at the lowest portion of the conservator for
draining and sampling. The inside of the conservator should be cleaned periodically.
A detachable end plate is provided to facilitate cleaning on all power transformers.
Oil indicator glass should be kept clean so that oil level is clearly visible. Broken
indicator glass should be replaced immediately. When conservator is taken for
maintenance, magnetic oil level indicator mechanism should also be cleaned and
inspected for operation. Float should be checked to see that there is no oil in the float.
5.4.3 Silica gel breather:
Breather should be inspected frequently especially where temperature and humidity
changes are considerable and when transformer is subjected to fluctuating loads.
So long as silica gel is in active stage, its colour is dark blue as it becomes saturated
with moisture, its colour changes to pale blue/pink then it should be reactivated.
74
For reactivating the silicagel remove the oil cup at bottom and empty the contents
of the breather in a tray. Heat the crystals in oven at a temperature of about 100C
for eight hours. Check the colour of the crystals after 4 hours. When they have
turned to dark blue remove the gel from oven and refill in breather. Immediately
fit the oil-sealing cup after filling oil up to the level marked on the cup. The oil must
be changed when its colour changes from pale yellow to dark brown. The oil level
in the oil seal must be maintained at the level marked on the oil cup. Refill the oil
when necessary.
At the time of activating, sudden heating to high temperatures should be avoided
otherwise crystal will become brittle and break into fine particles which offer high
resistance to passage of air.
Remove the silica gel breather only when the ambient temperature and load of the
transformer is increasing and oil is expanding to avoid breathing in of air into
conservator directly.
5.4.4 Buchholz relay:
Routine operation and mechanical inspection tests should be carried out as
recommended. During service, if gas is found to be collecting and giving alarm,
the gas should be tested and analyzed to find out the probable nature of the fault.
Sometimes, it may be noticed that the gas collected is only air. The reason for this
may be that the oil is releasing absorbed air due to change in temperature.
The absorbed air is released only in initial period of six months, when no vacuum is
applied during filling of oil in transformer. The nature of internal faults can be
identified to a great extent by a chemical analysis of gas.
Buchholz relay will also give alarm or trip the breaker due to oil level falling below
Buchholz relay. Isolating valve between the conservator and Buchholz relay facilitates
removal of Buchholz relay for repairs /checking without lowering the oil level in
conservator. It should be ensured that isolating valves of Buchholz relay are kept fully
open for unhindered oil flow during service.
5.4.5 Explosion Vent.
The diaphragm fitted at the exposed end and Transformer cover end of the vent
should be inspected at frequent intervals and replaced if damaged. Whenever lower
diaphragm ruptures oil rises inside the explosion vent pipe and is visible in the level
indicator on explosion vent. Failure to replace the other diaphragm quickly will allow
ingress of moisture which will contaminated the oil. If diaphragm is broken because of
fault in the transformer, an inspection should be carried out to determine the nature
and cause of the fault.
5.4.6 OLTC ( On Load Tap Changer)
Please refer manufacturer's manual.
5.4.7 Temperature indicators:
During yearly maintenance, Dial glasses should be kept clean and if broken replaced
as soon as possible to prevent damage to the instrument. Temperature indicators
found reading incorrectly should be calibrated with standard thermometer
immersed in hot oil bath. Also check the pocket/s for presence of water and if found,
clean the pocket and refill with fresh oil and seal the opening properly. If armoring
of capillary is exposed, then re-taping must be done by PVC tape of good quality to
prevent further damage to the armoring or capillary.
75
5.4.8 Bushing:
Generally two types of bushings are used. One without condenser (oil communicating
type) having porcelain and stem where as other one with condenser type oil filled
bushing. The following checks shall be carried out for these bushings.
1) Porcelain should be cleaned and free from any physical damage like porcelain
chipped out, hair Crack/minor crack. The bushing should be replaced if crack
developed.
2) Air from communicating type bushing should be removed till oil comes out from
venting hole.
3) The oil level of condenser type bushing shall be monitored regularly. If level goes
down considerably, The reason must be find out and reported to BBL.
5.4.9 External connections including earthing:
All connections should be tight. If they appear blackened or corroded, Unbolt the
connection and clean with emery paper till it turns bright metal. Re-connect and
apply a coat of petroleum jelly. It is particularly important that heavy current carrying
connections should be properly maintained.
5.4.10 Gaskets (Gasket joints.)
Check the transformer for leakages periodically. The bolts should be tightened evenly
around the joints to avoid uneven pressure and also avoid over tightening of gasket.
Damaged gaskets should be examined carefully and should be replaced as
soon as possible.
5.4.11 Pressure relief valve:
No maintenance is required. Ensure that no water enters in connection box through
cable/gland during rainy season.
5.4.12 Rollers
After the transformer has been in service for a long period the condition of the rollers
should be examined. Apply paint if necessary.
5.4.13 Paint work:
During storage and service, the paintwork should be critically inspected at least once
a year and where necessary painting and retouching should be carried out. If the
metal surface is exposed and becomes rusty or greasy due to delay in touching work,
the surface must be thoroughly cleaned before repainting with primer and final paint.
Paint as mentioned in the general arrangement drawing of transformer should be
used. In case paint of another chemical base is to be used, paint manufacture
should be consulted for compatibility with existing paint.
5.4.14 Recommended Maintenance Schedule :
The maintenance schedule given is to be used as a general guide under normal
condition. The frequency of inspection should also determine by the size of the
transformer and local climate condition.
76
MAINTENANCE SCHEDULE
Sr. No. Frequency of Items to be Inspection Notes Action required if inspection shows
Inspection Inspected unsatisfactory conditions
1. Hourly Ambient Temp. Record temperature

2. Do Winding & Record temp. In case temp. is higher than the
oil Temp. in daily log book. desired value reduced load and
increase cooling.
3. Do Load (amperes) Check against rated Reduce load if more than the rated
& Voltage figure and record in value. Adjust voltage to desired value
daily log book. with the help of tap changer.
4. Daily Oil level of main Check w. r. t. If low, top up with dry& tested oil.
and OLTC transformer oil Examine transformer for any leak
conservator & temperature and attend the same..
bushing.
5. Do Relief vent Check diaphragm Replace if cracked or broken.
diaphragm and also oil in
indicator.
6. Do Dehydrating Check colour of the If silica gel is pink change by spare
breather silica gel, it should charge. The old charge may be
be dark blue. Also reactivated for further use. Fill oil in
check oil in breather cup if less.
cup.
7. Quarterly Bushing Examine for cracks Clean for dirt deposit and replace if
and dirt deposits. found crack developed..
8. Do Oil in Check for dielectric Take suitable action by carry out
transformer and strength and water filtration of oil to restore quality.
tap changer content
9. Do Cooler fan and Lubricate bearings, Replace defective part if any.
pump for its check gear box.
proper operation Examine contacts.
& greasing/ Check manual
oiling of bearings. control and
interlocks
10. Do On load tap Lubricate bearings, Replace defective part if any.
(refer OLTC changer driving check gear box oil
manual also) mechanism level and examine
contacts.
77
11. Do On load tap Check all circuits Replace defective part if any.
changer operation independently.
on manual / Check step by step
electrical / operation including
automatic control limit switches.
12. Do Oil leakage from Check for any Replace defective part if any.
main tank, leakage and attend
radiators, pipes, immediately.
OLTC etc.
13. Half yearly OFAF/OFW oil Check proper Replace the defective part if any.
coolers. working of cooling Apply grease/oil to fan bearings.
fans, pumps,
pressure gauges of
OFW coolers etc.
14. Do On load tap Check for all Clean, adjust or replace part if
changer and moving parts, developed defect
driving gear contacts, etc..
mechanism.
15. Yearly Oil in transformer Check oil Filter oil to meet requirements.
(or earlier if parameters as per
transformer IS 1866 latest
can version.
conveniently
be taken out
for checking)
16. Do Insulation Compare with Process oil if required. Weather
resistance values at the time must be clear while measurement
of commissioning of IR.
17. Do Gasket joint.. Check for any Tighten the bolts evenly to avoid
leakage. uneven pressure. Replace gasket if
required.
18. Do Cable boxes Check for sealing Replace gaskets if leaking.
arrangements for Change compound if dry and
filling holes. developed crack
Examine Compound
for cracks. Check
moisture condensate
if any in air filled
boxes
78
19. Do Protective Examine the Clean the components or replace
devises i.e. operation of devices contacts and fuses, if necessary.
Buchholz, PRV, /relays for alarm/ Change the setting if necessary.
OTI, WTI, OSR, trip function &
Cts etc. Check relay accuracy,
etc.
20. Do Temperature Pockets holding Oil to be replenished if required.
indicator thermometers
should be checked
for oil.
21. Do Dial type oil Check pointer for Adjust if required.
gauge free movement.
22. Do Paint work Should be inspected Painting or retouching should be
for pill off, rust etc. done if necessary.
23. Do Earth resistance Check earth Take suitable action if earth
resistance for proper resistance is higher than 0.5 ohm.
equipment and by watering in pit or by making new
accessories earthing earth pit..
including neutral.
24. Do Oil Conservator Internal Inspection Should be thoroughly cleaned.
25. 5 years Transformers Overall inspection Wash by hosing down with clean
including lifting of dry oil. Tighten coil clamping
core and coils. arrangements and other bolts,
nuts if loose.
26. 7 to 10 years Transformers of Do Do
all rating.
79
5.5 Faults and failure
Although failure in transformer is rare, faults do occur and the reason may be broadly
classified as:
(a) Failure in magnetic circuit
Common causes for this failure are-
• Breakdown of insulation of core bolt and core to tank / end frames.
• High flux density in the core resulting in large magnetizing current increase during switching.
(b) Failure in electrical circuit
Common causes of this failure are-
• Drying out of transformer is not carried out properly.
• Moisture penetrates into the windings insulation.
• Development of heavy short circuit forces on windings resulting in dislodging of turns.
• Switching, lightening surges producing high voltage at the end turns.
• Loose connections, bolted joints.
• Sustained overloads resulting in overheating.
(c) Failure in dielectric circuit
• Contamination of oil during service.
• Moisture entering oil due to breathing.
• Blockage of oil ducts in winding causing insufficient cooling.
• Sustained overloading resulting in deterioration of oil due to excessive oil temperature.
(d) Failure in structural & mechanical fitting
• Looseness of clamping of leads from winding to terminal board over a period of time resulting
in short circuit.
• Poor welding, loose fittings, causes leakage of oil.
• Improper ventilation causes over heating of oil.
80
5.6 TROUBLE SHOOTING CHART FOR TRANSFORMERS
Trouble - 1 Cause - 2 Remedy - 3
RISE IN TEMPERATURE
High temperatures Over Voltage Control voltage within limit.
Over Current If possible, reduce load. Heating can often be
reduced by improving power factor & load,
Check parallel circuits for circulating currents
which may be caused by improper ratios or
impedances. See Electrical Trouble, below.
High ambient Improve ventilation. Switch on cooling
temperatures fans/pumps.
Insufficient cooling If unit is artificially cooled, make sure
cooling is adequate.
Sludge formation in Oil. Filter oil to remove sludge.
Short-circuited Core Test exciting current and no-load loss.
If high, inspect core and repair.
See Electrical Trouble, below.
ELECTRICAL TROUBLES
Winding Failure Lightning, short-circuit. Usually, when a transformer winding fails,
Overload, Oil of low the transformer is automatically disconnected
dielectric, Foreign from the power source by the opening of the
Material. supply breaker. Carry out low voltage tests &
compare with earlier results.
Core Failure Core-Insulation Buchholz alarm or trip may occur.
breakdown (Core, bolts, Test oil DGA and based on that following action
clamps, or between can be taken.
laminations) a) Measure core insulation resistance.
b) Arrange for internal inspection of core..
High exciting current Short-circulated core Test core loss. If high, it is probably due to a
short-circuit in winding or core lamination
shorting.. Carry out low voltage test of winding,
i.e. ratio, resistance, mag. Balance etc.
Also test core insulation. If laminations are
welded together, refer matter to BBL.
81
Incorrect voltage Supply voltage abnormal Change tap position to desired level.
Audible internal Floating (Ungrounded) The sources should be immediately determined.
noise and radio metallic part in flux zone. Make sure that all normally grounded parts are
interference properly grounded, such as the clamps and core.
Loose connection Same as above. Tighten all connections.
Bushing flash over Lightning Provide adequate lightning protection.
Dirty bushings Clean bushing porcelains, frequency depending
on dirt accumulation.
Less Oil Inform BBL
MECHANICAL TROUBLES
Leakage through Foreign material in Rectify defects.
screw joints threads. Oval nipples.
Poor threads. Improper
filler, Improper assembly
Leakage at gasket Poor joints Insufficient or Make proper joint in gasket and holes at the
joints. uneven Compression proper place so that no bulging on gasket.
Improper preparation Make tight screw joints or gasket joints.
of gaskets and gasket
surfaces
Leakages in welds Shipping strains, Repair leaks by welding
imperfect weld
Explosion vent Improper assembly. Replace diaphragm. Inspect inside of pipe for
diaphragm damaged Mechanical damage evidence of rust or moisture and clean properly.
Pressure–relief Valve/ Internal Fault, oil flow Check that valve between tank and conservator
Device operated. obstructed between is open and breather pipe is not blocked .
transformer tank and Clean terminal box from inside & provide
conservator or breather sealing on cable gland.
pipe blocked. water entry
in terminal box.
Audio noise Loose fitting of accessories Make sure all joints are tight. Tighten loose
and external transformer parts. Releasing pressure and shimming will
parts giving loud noise be remedy for this condition.
due to vibration
Rusting and Abraded surfaces and Repaint properly.
deterioration of weathering
paint finish
Fractured metal or Unusual strains offered Cables and bus-bars attached to transformer
porcelain parts of on terminal connection terminals should be adequately supported.
bushings In case of heavy leads, flexible connections
should be provided to remove strain on the
terminal and bushing porcelain.
82
OIL TROUBLES (SEE ALSO IS:1866)
Low dielectric Broken explosion vent Replace diaphragm. Reactivate silica gel.
strength diaphragm. Silica gel of
breather become pink
Oil leakage Leaks around cover & Change gasket if necessary*
accessories
Badly discolored oil Contaminated by Filter oil using high vacuum filter machine.
varnishes Carbonized oil Replace oil if resistivity and tan delta is below
due to Switching Winding desired level. ( IS 1866).
or core failure.
Oxidation (Sludge or Exposure to air. Ageing 'Wash down' core and coils and tank. Filter and
acidity) reclaim or replace oil.
High operating Same as above. Either reduce load or improve
temperature cooling.
* In any event, filter oil or dry transformer by heating, or both, to restore dielectric strength.
Reference – IS:10028 (Part II) 'Code of practice for Selection, Installation and
Maintenance of Transformers.
83
5.7 CHECKS FOR TRANSFORMER TRIPPED ON RELAYS
Sr.No Relay operated Possible causes Checks to be done
1. Differential, REF, Internal fault developed a) Check IR of windings.
Buchholz, PRV b) Magnetic Balance,
operated. c) Magnetizing Current,
d) Winding Resistance,
e) DGA of oil.
2. Only Buchholz relay Internal fault / a) Check Buchholz relay for accumulation
operated Air in buchholz relay / core of gases / air.
insulation damaged. b) Check the gas whether inflammable
or not.
c) If found inflammable carry out DGA
d) In case no gas / air found in relay.
e) Check the terminal block connection for
shorting of wires/ entry of water.
Check IR of core to tank.
3. Only PRV of main Pressure developed inside a) Check whether valve are closed between
tank operated tank. main tank and conservator, main tank to
Radiator.
b) Check whether oil has flown out thru.
PRV. If not, check the terminal connection
for shorting of wires /entry of water.
c) Check IR and Magnetizing current.
4. Only PRV / Internal fault.& pressure a) Check whether valve between diverter
diaphragm of OLTC developed inside diverter and conservator is open.
operated of OLTC b) Check IR and Magnetizing current.
5. Only OSR operated Internal fault in OLTC a) Check whether actual relay operated or
diverter. not, OSR relay flag turn down. If operated.
b) In case OSR is not operated check
terminal connection for water
accumulation
or shorting in wiring..
c) In case OSR is operated, diverter shall be
inspected.
6. Only Differential Suspected high a) Check the voltage and frequency of
relay operated. charging inrush system.
current or internal b) IR and magnetizing current of
fault. transformer.
c) Check the setting of relay.
d) Check CT & its connection.
84
Sr.No Relay operated Possible causes Item to be Checked
7. Only REF relay Suspected neutral CT a) Check neutral CT polarity to suit REF
operated. polarity reversed. scheme.
Internal winding Earth b) Check neutral earthing.
fault. c) Check IR and magnetizing current of
transformer.
8. Over current and Higher inrush current. a) Check the relay setting & time can be
Earth fault relay set for higher side.
operated at the
time of charging
9. Indication of ROTI, Suspected wiring a) Check wiring as per drawing.

RWTI, tap position connection loose or open.. b) Check resistance of PT100 for RTD,
indicator on RTCC c) Check resistance of Potentiometer placed
not proper. in WTI and OTI
d) Check resistance of dial switch in DM Box
for tap position indicator.
10. Low IR value. Suspected presence of a) Oil purification is required to improve
moisture in oil of main BDV and PPM.
transformer and OLTC. b) Replace oil if value goes beyond
Low resistivity and high permissible limit specified in IS-1866
tan delta due to ageing
of oil.
85
5.8 DO'S AND DON'TS FOR POWER TRANSFORMERS.
DO'S
1. Connect gas cylinder with automatic regulator if transformer is to be stored for long, in order
to maintain positive pressure of 2.5 psi approx.
2. Fill the oil in transformer at the earliest opportunity at site and follow storage instructions.
3. Equalize the diverter compartment of OLTC by connecting equalizing pipe between flange
joints provided on tap changer head during evacuation.
4. All loose objects (tools, pencils, coins etc) to be removed from personnel pockets before
starting the work in manholes.
5. Check and thoroughly investigate the transformer whenever any alarm or protection operated.
6. Examine the bushings for dirt deposit and coats, and clean them periodically.
7. Check the oil in transformer and OLTC for BDV, PPM, resistivity, tan delta and acidity
as per IS/IEC and take suitable action for restoring the quality.
8. Check the oil level in oil cup and ensure air passage is free in breather. If oil is less, make
up the oil.
9. Check the protection circuit periodically.
10.Remove the air through vent plugs of all high points and diverter switch before you
energize the transformer.
11.Remove equalizing between tank and OLTC, after filling the oil in tank.
DONT'S
1. Do not energize without thorough investigation of transformer, whenever any alarm of
protection has operated.
2. Do not re-energize the transformer without conducting all pre-commissioning checks.
The results must be comparable with results at works.
3. Do not handle the OFF CIRCUIT tap switch when transformer is energized.
4. Do not reenergize the transformer, unless the OFF CIRCUIT tap switch handle is in locked
position.
5. Do not leave the tertiary terminals unprotected outside the tank; connect them to tertiary
lightening arrestor's protection scheme when connected to load.
6. Do not parallel the transformer which does not fulfill the condition of parallel operation.
7. Do not overload the transformer other than the specified limits as per IS: 6600.
8. Do not allow conservator oil level to fall below ¼ level.
9. Do not allow oil level to fall in bushings.
10.Do not allow water to cooler unless oil pump is switched ON, in case of water cooled jobs.
11.Do not allow inferior oil to continue in transformer. The oil should be immediately
processed and to be used only when BDV/ PPM are as per requirement.
12.Do not mix oil unless it confirms fully relevant standards.
13.Do not continue with pink silica gel, this should be immediately changed or regenerated.
14.Do not leave the secondary terminal open of an unloaded CT.
86
6. PRODUCT SPECIFICATION FOR ORDERING NEW TRANSFORMER
POWER TRANSFORMER
/ / MVA
/ / kV
Phase , Hz
FITTED WITH
**ON LOAD TAP CHANGER**
CUSTOMER
CONSULTANT
PROJECT
BBL REF No.
WO:
PURCHASE ORDER No.
87
TRANSFORMER RATING
(REF R&D DRG **** AND GA DRG ****)
RATED POWER ***/***/*** MVA
FREQUENCY 50 Hz
IMPEDANCE (%Z) ** At **MVA BASE
COOLING ONAN/ONAF/OFAF
TEMP RISE 50/55 o C
VOLTAGE RATIO CONNECTION

HV ***kV HV STAR
IV ***kV IV AUTO STAR
LV ***kV LV DELTA
TRY ***kV TRY DELTA
PHASE ** VECTOR ***
RATED CURRENT (Amp) INSULATION LEVEL

ONAN ONAF OFAF
HV *** HV **kVrms/**kVpeak
IV *** IV **kVrms/**kVpeak
LV *** LV **kVrms/**kVpeak
TRY *** TRY **kVrms/**kVpeak
88
BRIEF SITE RECORD
(To be filled in by site In-charge /Engineer)
Customer Ref Number :
BBL - WO No. /UNIT No. :
Site / location Address :
Tel / Fax
Date of Installation :
Date of Commissioning :
Load : MVA
________________________________________________________________________________
Parallel Operation Yes/NO
If Yes, details of Other Transformer in parallel
Transformer Make :
MVA :
Vector Group :
Impedance (Min / Normal / Max Tap) : %Z
OLTC Make :
OLTC Type :
Commission Date/ Year :
________________________________________________________________________________
Installation/ commissioning remarks
________________________________________________________________________________
In service Observations.
Date Description / Observations
89
DESCRIPTION OF TRANSFORMER
GENERAL
BBL WO: ****
This transformer is suitable for *** kV and *** kV system. The neutral is effectively earthed.
It is designed for bidirectional power flow. Transformer is rated **/**/*** MVA with respective
ONAN/ONAF/OFAF cooling. The Tertiary is ** kV and suitable for **/**/** MVA. R&D Plate gives
Electrical parameters, BCT and other details. Terminal (Bushing) orientation and other fittings
details are shown in General Arrangement drawing given in Drawings section of this manual.
CORE
The magnetic circuit is of three - limb core type construction. Mitered joint core design with
laminations of high grade Cold Rolled Grain Oriented (CRGO) steel is used for the construction
of core. Core Yokes are clamped with yoke Frame and limbs are with fibre glass band. Core and
clamping frames are electrically isolated and earthed as per the standard.
WINDING
Electrolytic grade copper is used for the manufacture of windings. Windings are arranged over
the core limb with low voltage winding near to the core. The order of windings from core are
core/**/**/**. The line end HV *** kV lead is taken from *** (Center/Top) of HV winding.
Insulation co-ordination and oil ducts are designed to reduce the voltage stress and winding
'hot-spot'. The whole internal assembly is processed in vacuum/VPD and clamped with
hydraulic pressing system.
COOLING
The transformer is provided with Radiator, Fan and Pump for ONAN/ONAF/OFAF cooling.
Ref the cooler control drawings for the operation and circuit details. Radiators are to be
maintained clean for good heat transfer and cooling. Catalogue section gives the details of
accessories and fittings. While replacing the radiator, the new one has to be cleaned by flushing
with transformer oil, to remove dust, dirt and moisture.
TAPCHANGER (**OLTC/OCTC**)
Make : ***** Type : *******
This transformer is provided with taps on ***, for varying *** voltage. The tap range is -**% to
+ **% in *** steps of ** % per step. The tapping arrangement is **(Linear/ Reversing/ coarse
Fine type)**. The Tap Changer is suitable for
a) LOCAL INDEPENDENT
b) REMOTE INDEPENDENT
c) MASTER/ FOLLOWER OPERATION
(Ref: Commissioning section of this manual for parallel operation conditions)
An RTCC panel is provided which gives all the above control requirements. Indication are
provided in the RTCC panel Tap position, Tap change in progress, out of step, supply on etc.
Details are given in the RTCC control drawings attached in the drawing section of this manual.
LIST OF DRAWINGS AND CATALOGUES
DRAWING LIST NUMBER :
CATALOGUES :
90
91
B H A R AT B I J L E E L I M I T E D
TRANSFORMER DIVISION
REGISTERED OFFICE WORKS AND CENTRAL MARKETING OFFICE

Electric Mansion, 6th Floor, No 2 MIDC , Thane - Belapur Road
Appasaheb Marathe Marg, Opp. Airoli Railway Station,
Prabhadevi Mumbai - 400 025 Navi Mumbai - 400 708
Tel +91 022 - 24306237 / 24306375 Tel +91 022 - 27637200
Fax +91 022 - 27637423 / 27637419
EXPORT CUSTOMER SERVICE

No 2 MIDC, Thane - Belapur Road No 2 MIDC, Thane - Belapur Road
Opp. Airoli Railway Station, Opp. Airoli Railway Station,
Navi Mumbai - 400 708 Navi Mumbai - 400 708
Tel +91 22 - 27637200 Tel +91 22 - 27637498
Fax +91 22 - 27637423 / 27637419 Fax +91 22 - 27637423
NORTHERN REGION EASTERN REGION

1st Floor, 7 B Rajindra Mansarower, 2nd Floor
Park Pusa Road, Flat No. 8, 3B - Camac Street
New Delhi – 110060 Kolkata - 700 016
Tel: +91 11 25816931/32/33/35/38 Tel +91 33 - 22172382 / 83
Fax: +91 11 25816940 Fax +91 33 - 22172467
E-mail : trafodelhi@bharatbijlee.com E-mail : bblcalcutta@bharatbijlee.com
WESTERN REGION SOUTHERN REGION

501-502, Swastik Chambers, 204-207, Ramanashree Chambers,
5th Floor, CST Road, 2nd Floor, 37 Lady Curzon Road,
Chembur, Mumbai - 400 071 Bangalore - 560 001
Tel: +91 22 - 61457200 Tel +91 80 - 25592646 / 25592137
Fax: +91 22 - 61457255 Fax +91 80 - 25592823
E-mail : trafosales@bharatbijlee.com E-mail : trafobangalore@bharatbijlee.com
Bharat Bijlee Limited

Electric Mansion 6th Floor Appasaheb Marathe Marg
Prabhadevi Mumbai 400 025
T: +91 22 2430 6237 / 6071 Email: transformers@bharatbijlee.com

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TRANSFORMERS

5.4.5 Explosion Vent 75

Property Highest Voltage Of Equipment

2.1 Lifting Bollards

Item No. Description Material No. off / assembly

Item No. Description Material No. off/assembly

No. off / assembly

1. Cylinder 13. Horizontal support

2.12 Radiators: (Refer Fig. 19)

The item numbers given below correspond to Fig.19.

2.13 Earthing terminals:

Sr. no. Description

Typical Horizontal OCTC

Typical Vertical OCTC

Oil sample to be checked as below from drums:

3.4.2 Oil filling under vacuum: (Refer Fig. 25)

Receipt of Main Tank Receipt of Accessories

Unload the transformer tank at hard and

Placement of transformer on plinth

Evacuation of transformer for full

Fill transformer with processed and

Mount turrets, bushings, conservator,

Filling of oil in radiators, conservator.

Cabling and terminations of

Precommissioning checks as per Commissioning.

Signature & Seal of customer Signature of BBL rep.

IR value between IR Value for 60 second

2. Magnetic Balance Test:

*1U1N = V 1V1N = V 1W1N = V

Sample Taken Date Weather Condition PPM BDV

Applied Voltage on HV Measured Voltage on LV

7. Winding Resistance Measurement

Current Measured in HV Current Measured in LV

3.Protection Relay Operational Checks.

Sr. No. PROTECTIVE DEVICE ALARM TRIP

13. Over current / EF relay.

 Transformer put "ON LOAD" ___________ at ____________incoming voltage ___________

4.4 Parallel operation:

Satisfactory result of resistivity at 90 deg. Indicates presence of Moisture or general

Unsatisfactory results at both temperatures. Indicates greater contamination.

Oxidation of oil encourages deterioration of pressboard, insulating paper. When acidity

1. Hourly Ambient Temp. Record temperature

9. Indication of ROTI, Suspected wiring a) Check wiring as per drawing.

BBL REF No.

PURCHASE ORDER No.

VOLTAGE RATIO CONNECTION

RATED CURRENT (Amp) INSULATION LEVEL

REGISTERED OFFICE WORKS AND CENTRAL MARKETING OFFICE

EXPORT CUSTOMER SERVICE

NORTHERN REGION EASTERN REGION

WESTERN REGION SOUTHERN REGION

Bharat Bijlee Limited

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 Transformer put "ON LOAD" _ at incoming voltage _