TRANSFORMERS

OPERATIONS AND
CONSTRUCTION
 Definition
 Transformer is an
electrical device without
continuously moving parts
in its basic design, which
by electromagnetic
induction transforms
electric energy from one
or more circuits to one or
more other circuits at the
same frequency, usually
with a change in voltage
and current.
 Why Transformer

• To optimize cost of bulk transmission of power

from generators to consumers
• Reduction in transmission losses
• To reduce or increase voltage in ac system
• Enables safe supply voltage to consumers
• Isolation of two systems for voltage regulation

3
 Transformer Classification
Transformers are adapted to numerous engineering
applications and may be classified in many ways

• By power level from fraction of a volt-ampere(VA) to

over a thousand MVA
• By application power supply, impedance matching,
circuit isolation
• By frequency range power frequency, audio
frequency, radio frequency(RF)
• By voltage class a few volts to about 765 kilovolts

4
 Transformer Classification
• By cooling type air cooled, oil filled, fan cooled, water
cooled (Natural/ Forced) etc.
• By purpose distribution, rectifier, arc furnace, amplifier
output etc.
• By ratio of the number of turns in the coils
• Step-up - secondary has more turns than the
primary
• Step-down - secondary has fewer turns than the
primary
• Connection Single phase, Three phase – Star/Star, Star/
delta etc
• Construction Core Type, Shell Type 5
 Classification - Insulating Medium
Dry Type
• Self-cooled
• Forced air cooled
Liquid-Filled Transformer
• Self-cooled
• Forced air cooled
• Forced air cooled and forced oil cooled
• Water cooled

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 Classification - Construction
Tank Construction
• Free breathing
• Conservator or expansion-tank
• Sealed tank
Core Construction
• Core type
• Shell type

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 Classification – Application & Use
• Power transformers
– Used in transmission network of higher voltages, deployed
for step-up and step down transformer application (400kV,
220kV, 132kV, 66kV, 33kV) and has a rating in excess of 500
kVA and primarily used in transforming energy from
generating stations to transmission lines, from transmission
lines to distribution substations
• Distribution transformers
– Used for lower voltage distribution networks as a means to
end user connectivity (11kV, 6.6kV, 3.3kV, 440V, 230V) and
has a rating from 3 to 500 kVA
– Virtually all distribution transformers are self-cooled
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 Classification
• Isolating Transformer – Application & Use
– Intended to transform from one voltage to the same voltage.
The two coils have approximately equal numbers of turns,
although often there is a slight difference in the number of
turns, in order to compensate for losses (otherwise the
output voltage would be a little less than, rather than the
same as, the input voltage)

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 Classification – Application & Use
• Variable Voltage Transformer
– The primary and secondary have an adjustable number of turns which
can be selected without reconnecting the transformer
• Arc-Furnace Transformer
– used in process industries, low-voltage and high-amperage transformer
and is specially braced to withstand mechanical stresses caused by
fluctuating current requirements
– Due to distorted waveform because of arcs, it has extra winding
insulation
• Rectifier Transformer
– special purpose transformer used in the rectification of AC to DC
applications in the process industry
– These transformers are specially braced to withstand mechanical
stresses produced by high currents

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Types and Application of Transformers
Basic Transformer Principles

A transformer consist of two or more windings

linked by a magnetic circuit.
 The transformer is based on two principles:
 An electric current can produced a magnetic
field (electromagnetism).
 A changing magnetic field within a coil of wire
induces voltage across the ends of the coil
(Faraday’s Law of electromagnetic induction).
Cont.
Transformer Equations

𝐸1 𝐸2 𝐸1 𝑁1
 = 𝑜𝑟 =
𝑁1 𝑁2 𝐸2 𝑁2

 P1 = P2 𝑜𝑟 E1I1 = E2I2

𝐸1 𝐼2
 E1I1 = E2I2 𝑜𝑟 =
𝐸2 𝐼1

𝑁1 𝐼2
 =
𝑁2 𝐼1
Purpose of Transformers
 To change (transforms) an alternating
voltage and current from one level to
another.
 To minimize I2R losses of long transmission
lines between generating stations to
consumers.
 Transformers are very efficient machines,
operating at close to 99%.
 Transformers are reliable when maintained
properly.
Uses and Application of Transformers
 It can increase or decrease the value
of capacitor, an inductor or resistance
in an AC circuit. It can thus act as an
impedance transferring device.
 It can be used to prevent DC from
passing from one circuit to the other.
 It can isolate two circuits electrically.
Construction of Transformers
 The basic elements of a transformer consist of:
1. Two coils having mutual inductance.
2. Laminated steel core.
3. The two coils are insulated from each other and are also insulated
from the steel core.
4. Suitable container (tank) for assembled core and windings.
5. Means of insulating the core and its windings from the tank.
6. Suitable bushings (porcelain, oil-filled, capacitor-type or
composite) for insulating and bringing out terminals of windings
from the tank.
 Basic Components of Transformer
• Magnetic flux conductor -
Laminated Steel Core
• Current conductors –
Windings (primary/
secondary/ tertiary,
HV/IV/LV etc.)
• Insulation
• Cooling system
• Protection system
• Supporting accessories

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Core Construction
Generally, the magnetic core of
transformers are classified into
two forms:
1.Core-type
2.Shell type.
3.Another recent development is
spiral-core or wound-core type.
•
Core
Core is the “conductor” for the flux and provides low
reluctance path for magnetic flux linking primary and
secondary windings
• Core of power transformer is a two, three or five
legged construction
• Coils which are of cylindrical shape are assembled
over the legs
• Higher the number of steps in cross section, better is
space utilization and smaller is the core diameter
• 90 to 95 % utilization factor is optimal

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Core
• Core is constructed of Core
sheet steel lamination to provide
continuous magnetic path with a minimum of air gap
• CRGO (cold rolled grain oriented silicon steel) material
used for core making is low reluctance magnetic steel
containing 3 to 4% silicon and have high permeability
and a low hysteresis loss at the usual operating flux
densities
• The eddy currents loss is minimized by laminating the
core with the laminations being insulating from each
other by a high coat of core plate varnish or by an
oxide layer on the surface (thickness of laminations
vary from 0.30 mm to 0.5mm)
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Core – Type Transformers
 In the core-type the windings surround most of the core.
 The primary and secondary windings are shown located on
the opposite limbs (legs) of the core.
Cont.
 In actual construction, the windings are always
interleaved to reduce leakage flux.
 Half of the primary and half of the secondary winding are
placed side by side (concentrically on each limb).
Cont.

 Advantages of Core-type construction

are:
1. Construction is simpler.
2. Cooling is better.
3. Repair is easier
View of built up core
Cont.

 Three-Legged core lamination  Cylindrical winding.

 Cont.

 3-phase core & windings arrangement.  Cylindrical winding machine.

Shell –Type Transformers
 In the shell form transformer, the magnetic core surrounds
the windings.
 The coils are typically multi-layer disc wound in the form of
pancakes to form the winding configuration.
 The different layers are insulated from each other by paper.
Core
Spiral-Core Transformers
 The spiral-core transformers employ the newest development in
core construction.
 The core is assembled of a continuous strip or ribbon of
transformer steel wound in a form of a circular or elliptical
cylinder.
 By using such construction the core flux always follows along the
grains of the iron.
 Cold-rolled steel of high silicon content is cut at every other turn
to permit assembly.
 The spiral-core construction is used from small distribution
transformers and its practical use has been generally limited to
smaller core construction.
•
Winding
Windings are designed and constructed to withstand
an over voltages and impulse voltages
• Windings are made from paper insulated copper
conductors which are transposed at regular intervals
throughout the winding for ensuring equal flux
linkage between strands
• Insulation spacers in the windings are arranged such
that oil is directed through the entire windings for
ensuring proper cooling

PMI Revision 01 32
Winding
Windings
Winding leads
•
Low Voltage Winding
Hard drawn high conductivity copper used for
windings
• Less no. of turns
• More current
• Usually positioned nearest to the core
• LV Windings in Transformers are either
– Spiral wound for low current ratings (No radial
ducts for cooling)
– Helical Wound with radial cooling ducts for cooling
in higher current ratings
PMI Revision 01 36
Low voltage Windings
•
High
Large no. of turns
Voltage Winding
• Less current

• Disc coils are the best choice for the HV windings

where a single disc can have turns as high as 25 nos.
(multilayer helical winding would be lacking in
mechanical strength)
• Normally, Glued Paper Insulated rectangular Copper
Conductors (P.I.C.C.) are used for HV windings

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High Voltage windings
High voltage Windings

 Interleaved or shielded construction is adopted for the high voltage windings

to ensure uniform distribution of impulse voltages
Transformer Insulation System
 Insulation is one of the most important component in a
transformer.
 The primary and secondary windings have different potential with
respect to earthed tank and the earthed core, therefore insulation
is necessary between the following:
1. HV and LV windings.
2. HV winding to earth
3. LV winding to earth
4. Between turns of the same winding
5. Other conducting parts at different potential with respect to each
other and with respect to the tank and core.
Properties of Insulating Materials
 High dielectric strength at working
temperature.
 Good thermal conductivity.
 Long life at working temperature (ageing
property).
 Good mechanical properties such as ease of
working, application and bending.
 Resistant to vibrations and abrasion.
 Compatible with oil and surrounding medium.
 Non-hygroscopic.
 Low dielectric loss.
Solid Insulation
 Themost widely used materials to insulate
winding conductors from each other and
from ground is paper insulation.
 Electrical
grade paper is made from high
quality pulp that has been refined to
remove chemicals found in ordinary paper.
 When dried and impregnated with good
quality oil, electrical grade papers have
high dielectric strength.
Insulating components and their function

S/N COMPONENT FUNCTION

Press board or synthetic resin bonded paper cylinder -Insulation between Core and LV winding.
1
(S.R.B.P) -Insulation between HV and LV winding.

For supports, for spacers between Core/LV winding/HV

2 Synthetic resin bonded paper bar.
winding.

3 Types of paper for conductor Conductor insulation in oil immersed transformers.

4 Glass paper Synthetic resin coating casting Conductor insulation for dry transformers.
Class, Temperature and Insulating Materials
S/N CLASS TEMPERATURE INSULATING MATERIALS

Cotton, Natural silk, Cellulose fibre, Paper and Paper products, Press boards,
1 Y 900C
Vulcanizing fibre etc.

Impregnated cotton, Silk, , Paper and Paper products, Oil enamels, Laminated wood,
2 A 1050C
Enamel wire based on polymide resins etc.

Wire enamels based on polyvinyl formal, Poly urethane or Epoxy resins, Phenol
3 E 1200C formaldehyde moldings of cotton, paper etc. Polyester resins, Epoxy resins, Cellulose,
Triacetate etc.

Glass fibre asbestos, Oil modified synthetics, Resin varnished class fibre and asbestos,
4 B 1300C Shellac, Asphalt bituminous compound, Built up mica, Glass fibre laminates, Asbestos
laminates etc.

Alkyd, Epoxy, Polyesters, Silicon-Alkyd and Silicon-Phenolic resin impregnated glass

5 F 1550C fibre cloth, Built up Mica and Alkyd, Epoxy, Cross linked polyester and polyurethane,
Resin with superior thermal stability silicon, Silicon Alkyd resins.

Silicon varnished impregnated glass fibre cloth, Mica silicon resin bonded, Built up
6 H 1800C mica and combinations of mica and other class material with suitable bonding
material.

7 C Above 1800C Mica porcelain, Glass Quartz, Asbestos, Built up mica and Treated Glass fibre cloth.
Liquid Insulation
 Mineraloil is the most common fluid in use
today as insulating oil in power
transformers.
 Newsystems of fluids are constantly being
developed.
 Polychlorinatedbiphenyl (PBCs) are banned
in most countries due to environmental
factors.
•
Transformer Insulation
Transformer Oil - derivative of petroleum crude
– It has good dielectric strength
– It is also a good cooling medium and absorbs heat from the
windings in transformer
– The mineral oil has a flash point of 140°C to 160°C and also
can sustain the combustion with its own energy, once it
catches fire, thus this is unsuitable for the transformer
located indoors
– The indoor transformers are filled with a synthetic liquid
known as silicon based transformer oil which is fire resistant
and has flash point well above 300°C

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 Transformer Insulation
• Use of transformer oil with crude base as
naphthenic/ paraffinic
–Naphthenic
values whenbase oils generally
compared have base
to paraffinic higher
oils resistivity
and have
better oxidation stability
– Equally good parameters can be achieved with paraffinic base oils also,
when properly refined
– Oil parameters are important. Base of oil is not important (none of the
standards specify the base of oil)

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Characteristics of Insulation Oil
 Oil is used to provide heat transfer and improve insulation properties.
 These characteristics are:
1. High dielectric strength.
2. Permit good transfer of heat.
3. Low specific gravity.
4. Low viscosity.
5. Low pour point.
6. High flash point.
7. Not attack insulating and structural materials.
8. Have chemical stability to ensure lifelong service.
Transformer Cooling System
 Heatis produced in normal transformer
operation by:
 Copper, Core and Stray Losses.
 Looseelectrical connection in the
transformer leads to high contact resistance.
 Heating at curb bolts in the path of stray
field.
Cont.
 Means must be provided to continuously
remove the heat from these losses without
allowing the core, windings and structural
parts to reach a temperature which will
cause deterioration of the insulation.
 Otherwise, they would get progressively
hotter, and eventually result in the failure
of the transformer.
Cont.
 The two major coolants used in
transformers are:
 Air
 Oil.
 Transformers using air as coolant are called
dry type transformers.
 Transformers using oil as coolant are called
oil immersed transformers.
Dry-Type Transformers
 Depend primarily on air circulation to draw away
heat generated by the transformer’s losses.
 The cooling method used for dry type transformers
are:
1. Air
Natural: This method uses the ambient air as
the cooling medium.
2. AirBlast: Cooled by continuous blast of cooling air
forced through the core and windings by external
fans.
Oil Immersed Transformers

 Heatfrom the core and windings is

transferred through the oil, to the
tank wall, then conducted through the
tank wall, and radiated to the
surrounding air.
ONAN Cooling
ONAF Cooling
OFAF Cooling
Unit Coolers
 OFAF cooling is provided through the use of compact
heat exchangers when there is space constraint at
site (underground and inside buildings).
 In this small box type structure, an adequate surface
area is provided by means of fined tubes.
 Disadvantage: Only one rating available (with running
of fans and pumps).
 ONAN rating is not available.
 Continuity of auxiliary supply to fans and pumps must
be ensured.
OFWF Cooling
 Most transformers installed in hydropower
stations, where there is abundance of water oil-
to-water heat exchangers are used.
 Tubing is used to circulate water inside the tank,
through the oil near the top, where it is the
hottest.
 Ensure that the oil pressure is always more than
the water pressure so that the possibility of water
leaking into the oil is eliminated.
 Accessories & Auxiliaries
• Cooling fans, oil pumps, oil to water heat exchangers (Cooling
ONAN / ONAF/ OFAF/ OFWF external coolers)
• Tank
• Radiators
• Conservators
• Breathers
• Oil Level Indicators (Magnetic Oil Gauge)
• Pressure Relief Device
• Buchholz Relay/Oil Surge Relay
• Temperature Indicators- WTI, OTI
• Bushings
• Tap Changer (On load/Off load)
• Marshalling Box/ Control cubicle

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Accessories and Auxilliaries
Cooling
• For ONAN/ONAF cooling oil flows through the winding and external cooler unit
attached to the tank by thermosyphonic effect
• For ODAF /ODWF cooling, the oil is directed through the winding by oil pumps
provided in the external cooler unit
Radiator

• External cooler unit/units consists of

pressed steel sheet radiators mounted
directly on the tank or separate cooler
banks for air cooled transformers and
oil to water heat exchangers for water
cooled transformers
• Radiators are used to increase
 the cooling surface area
Radiators

• Due to transformer losses oil gets

heated up and hot oil rises to top
and flows to radiator
• In radiator while flowing down, oil
dissipates heat to cooling medium
• Cold oil again enters transformer at
bottom of radiator
• Radiators are provided with air release
plug and oil drain plug and shut-off
valve to stop the oil flow if the radiator
is leaking
 Tank and Cover
• Provides containment for core & winding and for dielectric fluid
• Tank and cover are manufactured by welding mild steel plates
and are suitable for withstanding full vacuum and positive
pressure of 0.35 kg/cm2 above the normal oil head
• Construction of the tank and cover are such that these can be
transported by railways/ road/ waterways as per customer
specification and must withstand forces imposed during
transportation
• Tank temperature should not exceed 80oC up to a height of
2.8m above plinth level
– Sometimes provided with packets of core steel to the wall of
the tank to act as flux shunts between the source of MMF
and the tank side
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Tank and cover

• Tank assembly consists of

– Sliding cannels and trolley
truck
– Lifting hooks
– Hydraulic jack pads
– Anchor foundation bolts
– Grounding connections
between tank parts and
grounding terminals
– Vacuuming, oil draining, oil
 filling and oil sampling valves
– Ladder
– Rating name plate
 Tank and Cover
• Tank & Cover can be classified in two
types
– Conventional type
– Bell type
• Conventional Tank
– A tank in which the cover is flat and tank
to cover junction is at the top of the tank
• Bell Tank
– A tank in which the cover is not flat and
tank to cover junction is near the bottom
of the tank
– Thus the tank has two parts – Top tank and
Bottom tank

67
 Conservator
• A conservator is fabricated steel tank provided to take care of
the expansion and contraction of transformer oil
• Allow the main tank to be filled to the cover
• Reduces the area of interface between air and oil hence
reduces oxidization of oil and also reduces the level of dissolved
oxygen which shorten insulation life
• It is provided with oil level indicator, oil draining valve, air
valve, and diaphragm

68
 AS OIL EXPANDS IN TRANSFORMER
TANK AIR CELL WILL SQUEEZE AND
FLOAT WILL LIFT TO FLOW MORE OIL
IN CONSERVATOR AND VICE VERSA

CONSERVATOR

AIR GAUGE
AIR CELL GLASS

OIL
MOG

FLOAT
BREATHER
SILICA GEL
TO TRANSFORMER
TRANSORMER CONSERVATOR
PMI Revision 01 69
• Both transformer Silica
oil and Gel Breather
cellulosic paper are highly hygroscopic
• The moisture, if not excluded from the oil surface in
conservator, will find its way finally into the paper insulation
and causes reduction insulation strength of transformer
• Whenever oil contracts, transformer breaths in through
breathers and lot of moisture which is present in the air go
inside with air, the silica gel present in the breathers absorb
moisture and only dry air goes inside
• The oil seal ensures that the silica gel absorbs moisture only
when the transformer is breathing
• After a certain level of adsorption, the color of cobalt chloride
in silica gel crystals changes from blue to pink and then these
particles need to be recharged or replaced
• The size of the breather is chosen to operate effectively over a
period of six months approximately
PMI Revision 01 70
Silica gel
 Magnetic Oil Gauge (MOG)
• Magnetic Oil Gauge (MOG) with low oil level alarm
• A float used as sensor of oil level inside conservator tank
• Swing of hinged float due to change in oil level utilized to
indicate level on a calibrated dial and to operate switch for
external alarm unit
• Use of magnetic coupling in the indicator achieves complete
sealing of oil inside conservator from surrounding atmosphere
• This results in avoiding any leakage of costly oil and avoiding
contamination of insulating oil due to seepage of surrounding
air in the conservator
• Glass mercury switch to give alarm when the oil level falls
below a threshold limit

60
Magnetic oil gauge (MOG)
Transformer Auxiliaries

 Gas Operated (Buchholz) Relay  Oil Level Indicator

Cont.
 Oil & Winding Temperature
Indicators.  Pressure Relief Valve (PRV)
Cont.
 Bushings  Bushing Materials and their Voltage Ratings.

TYPE OF VOLTAGE RATING

S/N INSULATION
MATERIAL (kV)

1 Solid Ceramic High alumina Up to 25

2 Porcelain Oil-filled 25 to 60

3 Porcelain Compound (epoxy) filled 25 to 69

Synthetic resin bonded

4 Porcelain 34.5 - 115
paper-filled

Oil-impregnated paper- above 69, specifically

5 Porcelain
filled above 275
 Major parts of Bushing

1. Condenser Core
2. Porcelain
3. Oil level Gauge
4. Top cap
5. Test Tap
6. Mounting Flange
7. Oil side Stress Shield
Tap Changers
 Transformers generally operate under:
1. Changing primary voltages or
2. To provide a number of different secondary voltages.
 To accomplish this task most transformers are
equipped with a tap changer to adjust the voltage
ratio by means of adding or removing of voltage taps
from the winding.
 Tap changers can be categorized into no-load
(manually) and on-load (with- load).
No-Load Tap Changers
 Tap changing is accomplished on the high voltage side of a
step-down transformers.
 The transformer must be de-energized before the tap
position can be changed.
 Tappings are terminated just below oil level and are
changed by means of swinging links or plugs mounted on a
terminal board operated by an external handle.
 Tappings are changed by a rotary movement of the
selector hand-wheel.
 No-load tap changers are usually used for long-term
variations in the primary voltage feed.
On-Load Tap Changers (OLTC)
 Located on the low voltage side of the transformer.
 They permit voltage changes without interrupting the load.
 They are used to control the current and voltage as the load is varied.
 The OLTC comprises of the following basic components:
1. Diverter switch
2. Selector switch
3. Operating mechanism
4. Control and operation of mechanism
5. Automatic
6. Remote/Manual
7. Hand crank
8. Mechanical and Electrical limit
Cont.
 Diverter and Selector Switch  Selector Switch
OLTC

 BASIC ARRANGEMENT OF TAPPED

WINDING
Paralleling Transformers
Transformers are said to be in
parallel operation when, they (two
or more transformers) are
connected to a same supply on the
primary side and to a same load on
the secondary side.
Reasons for Parallel Operation
 Optimal efficiency of the electrical
system
 Provide electrical system availability
 Maximize power system reliability
 Flexibility of the electrical system
 Easier transportation
Conditions for Parallel Operation
 The convenient conditions are:
1. Same voltage Ratio and Turns Ratio.
2. Same Percentage Impedance.
3. Same KVA Rating.
4. Same Position of Tap changer.
 The mandatory conditions are:
1. Same Phase Angle Shift.
2. Same Polarity.
3. Same Phase Sequence.
4. Same Frequency.
Transformer terminal marking system
 The HV windings of a three-phase power
transformer are denoted by capital letter. The
letters used are A B C.
 The LV winding has a small letter. The letters used
are a b c.
 The neutral terminal of a winding having star or
zigzag connection is denoted by the letter N for
high voltage and n for low voltage winding.
 Letters are the same for all windings on the same
limb.
Cont.

 A third winding, known as a tertiary winding, is prefixed

with the number 3 followed by the capital letter for that
limb as shown below.
Cont.
 A suffix number indicates the potential of the terminal;
with the number 1 being the lowest potential and the
number increasing for tappings of the winding to the
highest potential, as shown below.
 Major Transformers in Power Plant
and Substations

• Generator Transformer (GT)

• Unit Auxiliary Transformer (UAT)
• Station Transformer (ST)
• Excitation Transformer
• Neutral Grounding Transformer
• Auxiliary transformers
• Tie / Auto transformer
• Shunt Reactor 89
Instrument Transformers (ITs)
 Designed to transform voltage or current from the high values in
the transmission and distribution systems to the low values that
can be utilized by low voltage metering devices, relays and
instruments.
 There are three primary applications for which ITs are used:
1. Metering (for energy billing and transaction purposes).
2. Protection control (for system protection and protective relaying
purposes).
3. Load survey (for economic management of industrial loads).
 Types: potential (voltage) transformers and current transformers.
Voltage Transformers (VTs)
 33kV Voltage Transformer  VT connection with LA’s.
Current Transformers (CTs)
 132kV Current Transformer.  33kV CT connection.
Protective Switchgears 1 (Over-voltage)

Over voltage conditions are of

two kinds:
1.Transient surge voltages
2.Power frequency voltages
Surge Diverters (Lightning Arresters)
Arcing Horn
Grounding (Earthing)
 Objective of grounding (earthing) is to provide a zero
potential surface in, around and under the area where
the electrical equipment is installed or erected.
 Therefore, grounding is provided for:
1. Safety of Personnel and Public.
2. Prevention or at least minimization of damage to
equipment as a result of flow of heavy fault currents.
3. Improves reliability of Power supply.
Grounding Transformers

 Zigzag connection  Zigzag connection with Ground Fault.

Protection schemes 2 (Over-current and
Earth fault)
 Overcurrent is a situation where a larger than intended
electric current exists through a conductor, leading to
excessive generation of heat, and the risk of fire or damage
to equipment.
 Causes include short circuits, excessive load, incorrect
design, and earth fault.
 The purpose of an overcurrent protective device is to
provide protection to service entrance, feeder and branch
circuit conductors and equipment.
 Types include fusible switches, circuit breakers,
temperature sensors and current limiters.
Commissioning Testing Procedures
1. Ratio test.
2. Winding resistance measurements on all taps.
3. Insulation resistance between all windings and each
winding to earth.
4. Insulation resistance core-to earth, core-to frame and
core frame-to earth.
5. Vector (Phasor) Group Check test.
6. Magnetisation test (No-load current measurement at
reduced voltage).
Cont.
7. Magnetic Balance test.
8. Operation of tap changer up and down its range.
9. Oil samples taken and checked for breakdown strength
and moisture content.
10. All controls, alarms and protection checked for correct
operation.
11. Tank and all earth connections checked as well as the
grounding of the HV neutral.
12. FRA (Frequency Response Analysis) measurements
should be confirmed.
Power Transformers Maintenance Checklist
Observe ambient, oil and winding If temperature rise is persistently higher than
1 Hourly
temperatures and record. normal, isolate the transformer and investigate.
Check against rated figures. Correct Voltage and tap
2 Observe Load amps/Load voltage. Hourly
position.
Check the colour of silica gel in the breather If silica gel colour changes from blue to pink by 50%,
3 Daily
and also oil level of the oil seal. the silica gel is to be reconditioned or replaced.

Observe oil levels in (a) main conservator tank

Top up oil if found low. If oil leakage found
(b) OLTC conservator (c) bushings and examine
4 Daily retighten loss bolts and gasket joint, if excessive
oil leaks from the transformer, piping’s and
shut down and replace gaskets and seals completely.
accessories.

Visual check of overheating if any at terminal If red spots are observed shut down and retighten or
5 connections (red spots) and observe any unusual Daily in each shift replace clamps. Internal noise carryout thorough
internal noise. tests.

Check noise, vibration or any abnormality in

cooling fans & oil pumps of power transformers. Lubricate and grease fans and pumps, if persistent
6 Daily
Standby pumps & fans are also to be run and replace completely.
their condition to be observed.

Visual check of explosion vent diaphragm for any

7 Daily If cracks are observed replace completely.
cracks.
Check any water leakage into cooler in case of Daily Retighten bolts and gaskets/seals joints, if
8
forced cooling system. persistent replace gaskets/seals completely.

Physical examination of diaphragm of vent pipe

9 Monthly If cracks are observed replace completely.
for any cracks.

Clean bushings, inspect any cracks or chippings If cracks are observed carryout thorough test on
Monthly
10 of the porcelain and check tightness of clamps bushings, if failed tests replace with new bushings.
and jumpers. Retighten clamps and jumpers.
Cont.
Measure IR values of transformer with 2.5kV
Compare measured values with values obtained
Megger up to 33kV rating and 5.0kV Megger
during commissioning tests, if any variations are
11 above 33kV rating. Record the values and Monthly
observed detailed investigations should be
specify the temperature which
carried out.
measurements are taken.

If breather glass cover is dull or cracks are

12 Clean Silica gel breather. Monthly
observed, replace with new one.
Check temperature alarms by shorting Confirm proper operations, continuity of contacts
13 Monthly
contacts and operating the knobs. and display on control panel.
Note oil level in the inspection glass of
14 Monthly Top up if oil level is low and arrest oil leakages.
Buchholtz relay and check for oil leakages.
If BDV is below acceptable value (20kV) and /or
Test of main tank oil for BDV and moisture
15 Quarterly moisture content is high, filtration of oil (or other
content.
suitable remedies) should be done.
If BDV is below acceptable value (20kV) and /or
16 Test OLTC oil for BDV & moisture content. Quarterly
moisture content is high, replace oil in OLTC.
Test Buchholtz surge relays & low oil level
17 Quarterly Confirm proper operations.
trips.
Confirm proper operations. Clean contactors and
18 Check auto start of cooling fans and pumps. Quarterly replace worn out and burnt contacts.
Clean/adjust controls and interlocks.
Check of Buchholtz relay for any gas Analyze the gas collected (chromatography) and
19 Quarterly or during fault
collection. take appropriate measure.
Check all connections on the transformer for
Retighten loss bolts & nuts, and replace bad
20 tightness such as bushings, tank earth Quarterly
clamps.
connection.
Quarterly or as given in Confirm proper operations. Set limit switches in
Lubricate /Grease all moving parts of OLTC
21 the manufacturers position, clean/replace brake shoe lining and top
mechanism.
manual up oil level in driving gear mechanism.
Cont.
Check control circuitry, interlocks of oil pumps
and cooling fans for auto start and stop Confirm proper operations and replace worn out
22 Half yearly
operations at correct temperatures and also and burnt contacts.
for manual operation.

Check the operation of Bucholtz relay by air Half yearly or during Confirm proper operations and adjust floats and
23
injection ensure actuation alarm & trip. shutdown switches.

Compare DGA result with one during commissioning.

If C2H2 (acetylene) is present or amount flammable
24 Testing of oil for dissolved gas analysis (DGA). Half yearly gases exceed 0.06% by volume, appropriate action
should be taken by filtration of oil or on-line
regeneration of oil, etc.

Lubricate/grease bearings and replace bad ones.

Overhauling of oil pumps and their motors also
25 Once in a year Clean contactors, switches and limit switches and
cooling fans & their motors.
replace bad ones.

Once in a year or number

Replace worn out contacts, Clean transition resistors
of operation as
and test their resistance, replace broken or
recommended by
26 Inspect OLTC mechanism and its diverter switch. deformed resistors. Also check springs insulation
manufacturers are
support and sliding parts, clean them and replace
completed whichever is
broken, scratched or corroded ones.
earlier.

Operation should be smooth without abnormal sound

Inspect OLTC driving mechanism and its driving
27 Once in a year or vibration. Retighten loose bolts & nuts and
shaft.
replace broken or worn out mechanical parts.
Cont.
Once in a year or
whenever number of
operation as
28 Replace oil in OLTC. recommended by Replace with new transformer oil.
manufacturers are
completed whichever is
earlier.
Adjustment should be made against error.
Calibrate thermometers (temperature Moisture, condensation and corrosion removed.
29 Yearly
indicators) and tap position indicator. Broken and cracked acrylic glass should be
replaced.
Compare measured values with values obtained
during commissioning tests, if major variations are
30 Bushings tan ∂ (delta) measurement. Yearly
observed detailed investigations should be carried
out.

Whenever the IR values

of transformers are
Filtration of oil, replacement of oil and on- below permissible limits To improve the dielectric strength properties of
31
line regeneration of oil. and oil test results the oil and remove sludge and contaminants.
require filtration /
replacement of oil.

General overhaul consisting (1) Inspection of

core & winding (2)Thorough washing of
32 windings (3) Core tightening (4) Check – up of
core bolt insulation (5) Replacement of
gaskets (6) Overhaul of OLTC
Tighten all clamping arrangement, loose coating
etc. Tighten all bots & nuts and check locking
Once in 10 years
arrangements and fasteners. Wash core and coil
with new dry transformer oil.
Transformer On-Line Monitoring
and diagnostics Systems
 Reduce the cost of maintenance
 Improve reliability and availability of the
equipment
 Reduce down time
 Reduce unplanned system outages
 Reduce costly repairs and
 Reduce the overheads associated with operations
(i.e staff cost).
Cont.
 The focus of most monitoring techniques is to collect
data from parameters that can be used to assess the
condition of winding and tap changers.
 Dissolved gases in oil
 Partial discharges (PD)
 Temperature
 Vibration
 Oil Level Gauges
 Water-in-Oil Sensors
 Other Methods.
Infra-red Scanning (Thermography)
 All objects emit heat in the form of infra-red radiation,
which is constantly being absorbed and re-emitted by
humans and everything around them.
 Thermography in electrical inspection is a non-contacting
(non-destructive) operation.
 Applied to in-service equipment while energized and
carrying load.
 Problems are detected either as a function of excessive
temperature rise (such as a poor connection) or
 Subnormal temperature (such as a cool transformer
radiator fin signifying a blocked passage).
Health, safety and environment
 Health, safe and environment issues as they
relate to power transformers can be viewed from
different perspectives, vis-à-vis:
 Regulations.
 Hazards and risks associated with working in
Electro-magnetic field environment.
 Health, safety and environment with relation to
transformer oil.
 Disposal of Transformer oil.
EXERCISES ON TRANSFORMER OPERATIONS AND CONSTRUCTION
 1.(a) State conditions that must be strictly observed in order that 3-phase transformers
may operate in parallel (state 5 conditions)
 (b) Find the load shared by 2 nos. of 132kv/33kv transformers of rating 15MVA and
25MVA, per unit impedances of the transformers are 0.67 p.u and 0.24 p.u
respectively.
 (c) What is your observation of the result above.
 2. a) Transformer can be broadly divided into five classes. Name the classes and give an
example of each.
 b) What are the three basic major parts of a transformer?
 c) Beside the main tank of a power transformer, it has another auxiliary tank. What is the
name of the tank and what is its function?
 3. a) A transformer, mostly, has two or more windings that are not electrically
connected. When one of the windings is connected to a source of supply, how do the
other one(s) get their source?
 b) List any three types of cooling system in a transformer.
 c) What is meant by the percentage impedance voltage of a transformer?
 THE END

 THANK YOU FOR YOUR ATTENTION

QUESTIONS?

110 NAPTIN, Power Trainer with a

difference