Electrical Maintenance of

High Voltage Transformers

TRANSFORMER MAINTENANCE

 Power transformer is such a prime and costly equipment of the transmission

and distribution systems and needs to be continuously monitored and
maintained for its well-being, and the reliability of the systems.
 Fault investigation is a major issue of power transformer maintenance. The
outcome of the investigation usually forms the basis of a decision either to
continue operation, re-energize the protection-tripped transformer after
treatment, partly/fully repair or replace the failed transformer.
 Some faults can be investigated while the transformer is in service while a lot
of other investigations could only take place when the transformer is de-
energised.
PHYSICAL INSPECTION

 The following physical inspections and tests can be carried out with the
transformer in service:
 Checks on vibrations, change in sound, leakages etc.
 Taking oil samples for BDV (Break down voltage) and DGA (dissolve gas
analysis).
 Check on hot and cold spots through thermovision Infrared scanning (IR
thermography).
Physical inspection
S/N Tests Purpose Results

To determine the dielectric strength of the oil by indicating the Minimum acceptable value:
presence of contaminating agents in the oil, such as water, dirt, 30kV for < 72.5 kV
Oil Break Down Voltage carbon, or any other conducting particles. 40kV for 72.5 - 70kV
1. 50kV for > 170 kV
(BDV) 2.5mm gap.

The results are generally compared

To determine the concentration of dissolved (fault) gases in the oil
Dissolve Gas Analysis with historical or original data
2 which are generated by overheating of conductors, overheating of
(DGA) measured in factory as per IEC: 60599
insulating fluid, partial discharges, and arcing.
– 1999

A thermo vision Camera determines the temperature distribution

Thermovision Infrared on the surface of the tank as well as in the vicinity of the Jumper The information obtained is useful in
3 scanning (IR connection to the bushing (hot spots). Leakage points (cold spots) predicting the possible location of
thermography) on radiator fins and pipings are also exposed. incipient faults.
OUT OF SERVICE INVESTIGATIONS

 Tests conducted after an equipment failure are performed to determine, to

the greatest extent possible, the location, magnitude, and cause of the
failure. The results obtained are used to determine whether the equipment
can be restored back to service, repaired in place or needs to be transported
to a repair workshop or manufacturer.
TESTS for investigation
S/N Tests Purpose Results

To reveal the condition of insulation (i.e. degree of dryness of paper insulation), Minimum acceptable value at 300C are 300MΩ, 400MΩ
1. Insulation Resistance (IR). presence of any foreign contaminants in oil and also any gross defect inside the and 500MΩ for 11kV, 33kV and 66kV & above windings
transformer. ratings respectively.

To check for abnormities due to loose connection, broken strands of conductor, high The results are generally compared with historical or
2. Winding Resistance
contact resistance in tap changers, high voltage leads and bushings. original data measured in factory.

To determine the ratio between the primary and secondary of the transformer, to
confirm the proper alignment and operation of the tap changers, verify nameplate
3. Transformer Turns Ratio. ratio, polarity and tap changer operation for both acceptance and maintenance
testing. It can also be used as an investigative tool to check for shorted turns or open
windings.
The results are generally compared with historical or
original data measured in factory and must be within
0.5% of nameplate values to be acceptable.

No Load Current/ Open If values obtained are higher compared to factory test
4. This measurement can detect faults in winding and core.
Circuit. results, it indicates faulty condition.
Investigation of faults from relay indication
S/N Tests Purpose Results

To reveal the condition of insulation (i.e. degree of dryness of paper insulation), Minimum acceptable value at 300C are 300MΩ, 400MΩ
1. Insulation Resistance (IR). presence of any foreign contaminants in oil and also any gross defect inside the and 500MΩ for 11kV, 33kV and 66kV & above windings
transformer. ratings respectively.

To check for abnormities due to loose connection, broken strands of conductor, high The results are generally compared with historical or
2. Winding Resistance
contact resistance in tap changers, high voltage leads and bushings. original data measured in factory.

To determine the ratio between the primary and secondary of the transformer, to
confirm the proper alignment and operation of the tap changers, verify nameplate
3. Transformer Turns Ratio. ratio, polarity and tap changer operation for both acceptance and maintenance
testing. It can also be used as an investigative tool to check for shorted turns or
open windings.
The results are generally compared with historical or
original data measured in factory and must be within
0.5% of nameplate values to be acceptable.

No Load Current/ Open If values obtained are higher compared to factory test
4. This measurement can detect faults in winding and core.
Circuit. results, it indicates faulty condition.
SUMMARY of fault investigation in
Transformer
 The following are the recommended actions to be taken on transformers that are taken out of
service on fault:
 Before investigation commences, ensure that the transformer is isolated from sources of supply.
 Check any associated fault recorders for evidence of an electrical fault.
 Check and record the operation of protective devices, alarm systems and winding-temperature
actual and maximum settings.
 Make an external examination, paying particular attention to oil expulsion, oil-level gauges,
bulging of the tank, the state of the explosion vent or oil-pressure-relief device, any smell from
the oil indicating gas or burning, and the position of any on-load tap changer.
 Oil samples should be taken from the transformer main tank and tap-changer diverter and
selector tanks for BDV, DGA, etc.
 Check the insulation resistance between: each winding and earth; between windings (for a two-
winding transformer); and between core and earth.
 Check the winding resistances and compare with the historical or commissioning results.
 Carry out a magnetising-current, ratio and tap- changer continuity test and compare with the
commissioning results
TESTS ON TRANSFORMER

 Tests carried out on transformers can be divided into three categories:

 Commissioning tests
 Periodic/routine tests
 Tests after failure
Commissioning Tests

 The following tests should be conducted before commissioning a transformer:

 Turns ratio
 Insulation resistance test with polarization Index
 Power factor
 Resistance (winding)
 Polarity and phase relation
 Oil tests (DGA, moisture, BDV, etc.)
 No load loss test
 Visual inspection
Periodic / Preventive Tests

 Periodic tests are conducted after the transformer is installed and commissioned
in its permanent location. The main purpose of this test is to monitor the
condition of the transformer so that any potential trouble may be spotted early
before a failure occurs. Some of these tests are listed below:
 Turns ratio
 Insulation resistance test with polarization index
 Power factor
 Resistance (winding)
 Oil tests (DGA, moisture, BDV, etc.)
 Excitation current test
 Visual inspection
 An unscheduled outage and the potential of outright failure can be prevented by
following a periodic test schedule.
Tests after Failure

 Failure tests conducted on electric transformers are:

 Turns ratio
 Insulation resistance test with polarization index
 Power factor
 Resistance (winding)
 Oil tests (DGA, moisture, BDV, etc.)
 Excitation current test
 Combustible gas/ gas-in-oil analysis
 Visual inspection (internal)
 The outcome of failure tests will decide whether the transformer can be repaired at the site
or returned to its manufacturer, or a specialized centre for repair. By comparing the results of
the tests with the established norms, a 'history' of the transformer can be compiled, and the
reasons for failure can be diagnosed.
ROUTINE AND PREVENTIVE MAINTENANCE

 Generally two categories of maintenance inspections are performed on

transformers:
 While they are energized (in operation) and
 When de-energized (out-of operation)
ROUTINE inspection on energized transformer
 The routine inspections comprises of following:
 Current and voltage readings
 Temperature readings
 Oil level indicators
 Pressure/Vacuum gauge reading
 Gauges and alarms
 Cabling system
 Visual inspection
 Relief Devices
 High-Voltage Bushings (HVB)
 Secondary Cable Connections
 Paint
 Electrical Grounds
 Foundations
 Radiators
 Cabinets
 Grounding equipment (tank, stress cores, conduits etc)
ENERGIZED TRANSFORMER monitoring sheet
ROUTINE inspection on de-energized
transformer
 The routine annual inspections and maintenance on de-energised transformers include the following:
 Application for protection guarantee by a competent maintenance engineer (permit holder) who is going to be
responsible for the maintenance activities.
 Making sure the transformer is properly isolated, tagged and grounded.
 Proper safety gears and safety ethics, procedures and protocols must be adhered to throughout the inspection
and maintenance activities up to the end (Surrendering permit and energising of transformer back to service).

 The activities follows:

 Check for oil leakage on main tank, bushings, radiators etc.
 Check for cleanliness and de-coloration of bushings.
 Check for oil level in the bushings, Main conservator tank and OLTC tank.
 Check for correct setting of arching horn gaps.
 Check for good functioning of temperature monitoring gauges/indicators.
 Cleaning of venting plugs.
Inspection cont’d.

Check for quality of silica gel and

servicing of breathers.
Inspection cont’d.

 Check the condition of

explosion vents and Pressure
relief device (PRD).
Inspection cont’d.
 Check for rust, corrosion and painting quality.
 Check the tightness of terminal clamps on the Transformer bushings.
 Inspect the cabling and wirings on the Transformer.
 Clean the control cubicle of the cooler system and On-load tap changer.
 Check for correct operation of on-load tap changers and its control mechanism.
 Check and record operation counters on OLTC mechanism and HV surge & LV surge arresters.
 Check for correct functioning of Pumps and Fans.
 Check and test grounding of the Transformer.
 Carry out the following tests:
 Voltage Ratio Test.
 Magnetizing Current Test.
 Short Circuit Test.
 Magnetic Balance Test.
 Transformer Turn Ratio (TTR) Test
 Zero Sequence Impedance Test.
 Cooling Fans Test
 Transformer Guard Alarm and Trip Test.
 Transformer Cooling Equipment Test
 Earth Resistance Test
 Carry out Dissolve gas analysis (DGA) tests and oil dielectric tests.
 Inspection/Maintenance of diverter switch.
Diverter switch maintenance

 The opportunity of de-energising the transformer during annual maintenance

is utilized to carry out inspections and maintenance of the diverter switch as
follows:
 Check tap position on the diverter switch correspond with that on the control
mechanism.
 Check for correct sequence of taps during operation.
 Check for smooth operation both manually and motorized.
 Mark and disconnect the shaft from the diverter switch head case.
Diverter cont’d.

 Open the diverter switch head

case cover and check the
carbonization of oil in the
chamber.
Diverter cont’d.

 Drain the oil if

carbonized.
Diverter cont’d.

 Carefully loose the nuts that

hold the diverter switch to the
chamber and lift the diverter
switch out of the chamber.
(Applicable only to the
withdraw able types)
Diverter cont’d.

 Wash and clean the diverter switch properly.

 Inspect the electrical contacts on the switch and chamber for burning and
pitting.
 Inspect the switch parts for signs of crack or failure.
 Check the bolts, nuts and screws of the switch for tightness.
 Measure the resistance of the current limiting resistors on the switch and
compare for sameness with that on the switch name plate.
 Fix the switch back into the chamber and ensure correct positioning.
Diverter cont’d.

 Fill new transformer oil

into the chamber.
Diverter cont’d.

 Close the head case cover and tighten the nuts.(Ensure the correct sequence
of the cover)
 Fix back the driving shaft.
 Ensure that the tap position on the head case corresponds with that on the
control cubicle.
 Ensure no stiffness is felt during manual operation of the tap changer.
 Carry out Insulation resistance and Ratio test before and after OLTC
maintenance.
 Remove the temporary ground.
 Surrender back permit to system operator for lifting isolation.
De-energized transformer inspection format
TESTS AND MEASUREMENTS

 The following tests should be carried out on power transformer as part of the
annual preventive maintenance:
 Voltage Ratio Test.
 Magnetizing Current Test.
 Short Circuit Test.
 Magnetic Balance Test.
 Transformer Turn Ratio (TTR) Test
 Zero Sequence Impedance Test.
 Cooling Fans Test
 Transformer Guard Alarm and Trip Test.
 Transformer Cooling Equipment Test
 Ground Resistance Test
Voltage ratio test

 Apply three phase AC

supply to the primary side
of the transformer and
measure primary and
secondary Voltage.
Measurement of winding resistance

 Measurement of winding resistance

This test measures the resistance of the HV & LV winding. The values of
resistance should be balance for all three phases and should match the
designed values.
Equipment used : Digital resistance meter.
Measurement of insulation resistance

 Measurement of insulation resistance

Measures the insulation resistance of HV & LV windings with respect to earth
(body) and between LV & HV winding.
INSULATION TESTER OR MEGGER IS USED.
Recommended Values are
2000Mohms for HV & 500 Mohms for LV.
Separate source voltage withstand test
(High Voltage tests on HV & LV)
 Separate source voltage withstand test (High Voltage tests on
HV & LV)- This test checks the insulation property between
Primary to earth, Secondary to earth and between Primary &
Secondary.

HV high voltage test : LV winding connected together and earthed.

HV winding connected together and given 28 KV ( for 11KV
transformer) for 1 minute.
LV high Voltage test : HV winding connected together and earthed.
LV winding connected together and given 3 KV for 1 minute.
Equipment used : High Voltage tester ( 100KV & 3KV)
Inter-turn Insulation Test

 Induced Over voltage Withstand test (DVDF test)-

This test checks the inter turn insulation.

For a 11KV/415V transformer,830 Volts are applied at

the 415V winding with the help of a Generator for 1
minute. This induces 22KV on 11KV side. The
frequency of the 830V supply is also increased to
100HZ.
Equipment used : MOTOR GENERATOR SET
Magnetization current test; HV/LV
connections
Short circuit test

 Apply 3-phase to the

primary side of the
transformer with the
secondary side shorted
and measure the current
on primary and secondary
side of the transformer.
Short Circuit cont.

 Measurement of LOAD LOSS & IMPEDENCE.(EFFICIENCY & REGULATION)

This test measures the power consumed by the transformer when the LV winding
is short circuited and The rated current is passed through the HV winding.
This is also called short circuit test
Equipment used : Wattmeters or power analyser.
Open Circuit Test

 Measurement of NO LOAD LOSS & current.

The iron losses and no load current are measured in
this test. The 415V winding is charged at 415V supply
& the 11KV winding is left open .The power consumed
by the transformer at no load is the no load loss in
the transformer. This is also called open circuit test
Effect of actual frequency must be taken into
account.
Equipment used : Wattmeters or power analyzer.
Magnetic balance test using AVO multi-
meter; HV/LV connections
Turns ratio test

 Instrument used for the

test: Megger Three Phase
TTR Test set.
 Circuit connection for the
test is as shown in Figure
Zero sequence impedance test

 Instruments used for the test: Avo

meter (FLUKE 189 TRUE RMS
MULTIMETER) and Leakage
Current Clamp Meter UNITEST
CHB4.
 Circuit connection for the test is as
shown in Figure
 Apply single phase to HV and
neutral side with LV Side shorted.
 Zero sequence impedance test
results obtained are tabulated
Vector Group Verification test

 Vector Group Verification test

This test verifies the Dyn-11 or Dyn-1 vector group of a distribution transformer.

Equipment used : voltmeter.

Oil BDV TEST.

 Oil BDV TEST.

Oil breakdown voltage is checked as per IS-335.
100 mm L X 70 mm B X 80 mm Ht. glass pot.
500ml Oil sample.
Spherical electrodes with gap of 2.5 mm
Recommended value : 60KV
Equipment used : OIL BDV TEST SET.
LIGHTENING IMPULSE TEST

 LIGHTENING IMPULSE TEST

All the dielectric tests check the insulation level of the job.
Impulse generator is used to produce the specified voltage impulse
wave of 1.2/50 micro seconds wave
One impulse of a reduced voltage between 50 to 75% of the full
test voltage and subsequent three impulses at full voltage.
For a three phase transformer, impulse is carried out on all three
phases in succession.
The voltage is applied on each of the line terminal in succession,
keeping the other terminals earthed.
The current and voltage wave shapes are recorded on the
oscilloscope and any distortion in the wave shape is the criteria
for failure.
Test on cooling fans

Fan No.
Start Up Running
Remarks
 Instruments used for the test:
Current (A) Current (A)
Leakage Current Clamp Meter
1 1.92 0.57 Ok UNITEST CHB4.
2 2.05 0.58 Ok
 The start up and running
3 1.92 0.56 Ok
current for each fan are
4 2.12 0.64 Ok
obtained and tabulated
5 2.12 0.60 Ok

6 2.18 0.64 Ok
 Remarks: - Fans are in order.
7 2.12 0.63 Ok

8 1.98 0.59 Ok

9 2.00 0.62 Ok

10 2.04 0.61 Ok
Guard alarm and trip test

These tests are carried

Test Alarm Trip Observation Remarks

Alarm and indication showing Buchholz

out by simulation
Buchholz In In Buchholz Protection
warning & trip came up and the CBs
Main order order In order.
Tripped.

Buchholz In In
Alarm and indication showing OLTC
Buchholz OLTC
(injecting 110VDC) on the
Buchholz trip came up and Tripped the
OLTC order order
CBs.
Protection In order.
respective protective
PRV Main
In
order
In
order
Alarm and indication showing PRV Main
trip came up and tripped the CBs.
PVR Main Protection
In order.
devices on the
Alarm and indication showing PRV
transformer.
In In PVR OLTC
PRV OLTC OLTC Trip came up and tripped the
order order Protection In order.
CBs.

Oil Level
In In Alarm and indication showing Oil Level Oil level low main
low/high
order order Low main warning came in. warning In order.
main

Oil Level In In Alarm and indication showing Oil Oil level low OLTC
low OLTC order order Level Low OLTC warning came in. warning In order.
Cooling test

Test
Fans Came
in at
Alarm Came
in at
CB Trip
at
Observation Remarks
 The cooling tests were
carried out by dialing the
Winding and oil Temp
Winding
Alarm and indication
showing Winding
Winding
temperature
Relay indicator on the
transformer.
750C 900C 1150C
temperature temperature warning & trip Protection In
came up. order.

Alarm and indication Oil temperature

Oil
750C 900C 1150C showing Oil temperature Protection In
temperature
Warning & trip came up. order.
Ground resistance test

S/N Location Resistance (Ω) Remarks

 Instrument used for the
1 All earth terminals points on the Transformer 0.7 Good test: Clamp on Ground
2 HV surge arrester terminal points 0.7 Good resistance tester
3 HV Primary Isolator 0.7 Good

4 HV Primary CB 0.6 Good  Ground Resistance Test

5 HV CT 0.7 Good Results for all equipment
6

7
HV Bus Isolator

HV CVT
0.7

0.7
Good

Good
and gantries on
8 HV Bus bar 0.7 Good transformer primary and
9 HV support structures 0.7 Good secondary Bays are
10

11
LV VT gantry

LV Earthing Transformer Earth points

0.6

0.7
Good

Good
tabulated as shown
12 LV Secondary Circuit Breaker 0.7 Good
Operation and Observation
Operations and Observations cont.
FAILURES & CAUSES

 Insufficient Oil level.

 Seepage of water in oil.
 Prolonged Over loading.
 Single Phase loading.
 Unbalanced loading.
 Faulty Termination (Improper sized lugs etc)
 Power Theft.
 Prolonged Short Circuit.
 Faulty operation of tap changer switch.
 Lack of installation checks.
FAILURES & CAUSES
 Faulty design
 Poor Workmanship
 Improper formation of core.
 Improper core bolt insulation.
 Burr to the lamination blades
 Improper brazing of joints.
 Burr /sharp edges to the winding conductor.
 Incomplete drying.
 Bad insulation covering.
 Insufficient cooling ducts in the winding.
FAILURES & CAUSES
 Bad Quality of raw material.
 Transit damaged transformers.
 After failure , transformer is removed and replaced with new/repaired
one without removing the cause of failure which results in immediate or
short time failure.
TROUBLE SHOOTING
TROUBLE SHOOTING
TROUBLE SHOOTING
TROUBLE SHOOTING
TROUBLE SHOOTING
TROUBLE SHOOTING
TROUBLE SHOOTING
CODES AND STANDARDS
 In Nigeria, the codes and standards regarding maintenance of transformers and general safety in and
around it are established by the Nigerian Electricity Regulatory Commission.
 The body that is empowered by law (EPSR Act 2005) to “establish or as the case may be approve
appropriate operating codes and safety, security, reliability and quality standards” in the Nigerian
deregulated power sector.
 The commission has developed the Nigerian Electricity Health and Safety Code and Nigerian Electricity
Health and Safety standard Manuals (part 1 to 5) that contain the basic provisions for safeguarding of
persons from hazards arising from the installation, operation, or maintenance of transformers.
 The Grid code and the Distribution code are also established by the commission to guide the day-to-day
operational procedures and principles governing the development, maintenance and operation of an
effective, well co-ordinated and economically viable transmission and distribution systems for the
electricity sector in Nigeria.
 The standard protection code provides the necessary protection for employees when working on or in the
vicinity of electrical equipment and on other equipment.
 The general safety rules (100 series), general rules for all employees engaged in construction, operation or
maintenance (200 series), tools and safety equipment (300 series) and operation and station work (800
series) are all safety standards guiding the day-to-day operations and maintenance of equipment in the
Nigerian electricity industry.
 Other international standards like IEC, ANSI and IEEE are recognised and used in Nigeria and most often
provide the only guide to operations and maintenance of all types of transformers.
EXERCISES ON TRANSFORMER MAINTENANCE
 Q1. Name any three checks and fault investigations that can be carried out while the
transformer is energized and state the purpose for each?
 Q2. Name any three checks and fault investigations that can be carried out while the
transformer is de-energized and state the purpose for each?
 Q3. Protective relays senses faults and gives signal for the isolation of faulty
equipment or circuit. Name any four types of relay indications and the likely causes
of each relay tripping and the possible location of the fault in the transformer.
 Q4. What danger is inherent in the leaking oil on a plinth of a power transformer and
what safety measure should be taken to arrest the situation?
 Q5. What action should be taken to quench fire in a cable trench filled with
transformer oil?
 Q6. Who is competent to be issued Permit to Work on annual routine preventive
maintenance of power transformer?
 Q7. A workman touches a gantry, a tower or a switchyard fence and receives shock.
You are now approached by your management to advice on what action should be
taken to prevent future occurrence?
EXERCISES ON TRANSFORMER MAINTENANCE
 EX1. Identify the various accessories that are checked during energized inspection of power
transformer.
 EX2. Assuming you are a competent maintenance personnel and issued with a permit to carry
out routine annual maintenance on a power transformer. Perform the following activities:
 EX3. In a group of five, carry out the maintenance of diverter switch and identify all the steps in
the process.
 EX4. In a group of three, using the available tests equipment carryout any 3 of the following
tests on the transformer and record and analyze the readings you obtain.
 Voltage Ratio Test.
 Magnetizing Current Test.
 Short Circuit Test.
 Magnetic Balance Test.
 Transformer Turn Ratio (TTR) Test
 Zero Sequence Impedance Test.
 Earth Resistance Test.
 EX5. Remove the temporary ground and explain the lifting of isolation sequence.
 THE END

 THANK YOU FOR YOUR ATTENTION

QUESTIONS?

68 NAPTIN, Power Trainer with a

difference