IMP POWERS LTD.

&
BPC
Vision & Mission

To continuously add value to our Customers which

helps increasing their profitability

To be amongst the Top 5 Power Transformer

manufacturing companies in the country

To Step up…….Right up to 1200 kV class

To continuously innovate and improve on Quality,

Delivery & Performance

To contribute efficiently in the growth of T & D

sector of the country
 IMP POWERS LTD.
A flagship company of
the 800cr IMP-MANGALAM group
is a name to be reckoned with manufacturing of
EHV power transformers & special application
transformers up-to 315MVA, 400kV class.
 INTRODUCTION
 IMP POWERS LTD is 58-Years old reputed
manufacturer (OEM) and supplier of EHV
transformers in India.
 Our thousands of transformers are working
satisfactorily in transmission network of
different states in India.
 IMP is amongst Top 3-Companies in India
manufacturing 132kV & 220kV transformers.
 We have state-of-art manufacturing facility with
installed capacity of 15000MVA p.a. and voltage
class upto 400kV.
 Our company has accreditations of ISO-
9001:2015 for Quality systems, ISO-14001:2015
for Environmental protection system and NABL
for In-house EHV testing laboratories.
 Product Range
(OEM having widest range of transformers, with Make in India vision)

VOLTAGE COMMENCED SMALLEST HIGHEST TOTAL POPULATION

CLASS IN YEAR RATING RATING QTY POWER

MVA MVA Nos MVA
≤ 11 kV 1969 0.016 28 19000 4434
22 kV 1973 0.010 30 3804 1422
33 kV 1976 0.005 55 7344 24686
66 kV 1983 1.0 31.5 1456 19818
132 kV 1987 2.0 80 2018 60690
≥ 220 kV 1999 20 315 804 82428
SUMMARY 0.005 315 34427 193478
 Product Mix
(Top Transformer Manufacturer of India in 132kV & 220kV class )
132 kV
31%

66 kV
10%

33 kV
13%
22 kV
1%
≤ 11 kV
2% ≥ 220 kV
43%
 IMP is valued customer of CPRI
Awarded for 100% success in SC testing.
The only firm in INDIA who have successfully short circuit tested
160MVA (3 variants) & 100MVA (4 variants) 220kV transformers,
within 2-years, which proves consistency of our robust Design &
Quality. IMP has been awarded with valued customer award from CPRI
for three times.
2009 2016
160 MVA, 230/110/11kV Auto Transformer
160 MVA, 220/132kV Auto Transformer
160 MVA, 220/66kV Power Transformer

2017
100 MVA, 230/110/11kV Auto Transformer
100 MVA, 220/132kV Auto Transformer
100 MVA, 220/66kV Power Transformer

100 MVA, 220/33kV Power Transformer

 SHORT CIRCUIT WITHSTAND TEST
IMP has tested successfully 42 Transformers in last few years
A Record
kV TRANSFORMER RATING (MVA) CLIENTS
11 0.250 , 0.630 & 15 PGCIL, NTPC

33 0.315, 0.400, 0.630, 2.5, 3.15, 5 & 10 PGCIL, MSEDCL, PVVNL

66 10 , 12.5 , 15 , 16 , 20 & 31.5 HVPNL, PSTCL, GETCO, KPTCL

PGCIL, RRVPNL, JKPDD,

132 5 , 10 , 20 , 25 , 31.5 & 50
HVPNL, KSEB, KPTCL
170 66 VRA-GHANA
220 100 & 160 TANTRANSCO, HVPNL
 OUR MAJOR CUSTOMERS IN INDIA
CLIENTS No NAME
S.E.B 22 APTRANSCO, AEGCL, BSPTCL, CSPTCL, DTL, GETCO, HVPNL, HPSEB,
JSEB, JKPDD, KPTCL, KSEB, MPPTCL, MSETCL, OPTCL, PTCUL, PSPTCL,
RRVPNL, TSTRANSCO, TANTRANSCO, UPPTCL, WBSETCL.

UTILITIES 8 DVC, HAL, NTPC, NHPC, NEEPCO, NLC, PGCIL, SAIL.

EPC 51 A2Z, AMAR RAJA, ASHA BANU, ADEPT, BAJAJ, BS, BRG, ETA, ERL,
FEDDERS, GODREJ, GREENAGE, GAJA, GENUS, GVPRL, HPL, ISAT,
IVRCL, ISOLUX, JYOTI, JSP, KAILASH, KALPATARU, KEC, NCC, NKG,
NARESH AGRAWAL, OMICRON, PUNJ, PACE POWER, PRATHIBHA,
PRATEEK, REGEN, RENEW, SAFETY, SHREEM, SPIC, S.K.AGRAWAL, SMS,
SKS-BUILD, SUDHIR, SHYAMA, SHAYAM-FERRO, SHYAM-SEL, SHYAM-
INDUS, SUNIL HITECH, TATA, UB, VIHAN, VIKRAN, VISHWANATH.

WIND Co. 2 INOX, SUZLON.

SOLAR Co. 3 M&M, RUMS, RSDCL, UJJAS.

POWER Co. 5 ESSAR, TATA POWER, RELIANCE, BEST, LANCO.

Leading Transformer Manufacturing MNC have regularly bought IMP
Transformers - proving our capability & their trust in IMP.

Company ABB CGL G.E SIEMENS SKIPPER TBEA

Name

Voltage
11kV to 132kV 11kV to 220kV 11kV to 220kV 11kV to 220kV 220 kV 220 kV
Class
Smallest
100 kVA 100 kVA 100 kVA 100 kVA 100 MVA 100 MVA
Rating
Highest
31.5 MVA 100 MVA 100 MVA 160 MVA 100 MVA 100 MVA
Rating

Qty (nos) 77 198 112 42 2 11

 EXPORTS PERFORMANCE
IMP transformers are in operation at more than 40 countries.
Voltage Countries
400 kV ZAMBIA
220 kV BOTSWANA, IVORY COST, NEPAL, SENEGAL
132 kV AFGHANISTAN, BANGLADESH, BOTSWANA, CAMEROON, CONGO, LAOS,
MAYANMAR, NEWZELAND, NEPAL, USA, U.K.
66 kV AUSTRALIA, MAYANMAR, NEPAL, NEWZELAND, S.A, ZAMBIA
33 kV AFGHANISTAN, AUSTRALIA, BANGLADESH, BHUTAN, INDONESIA, JORDAN,
KENYA, KAZAKHASTAN, MALYSIA, NEPAL, NEWZELAND, NIGERIA, OMAN,
PHILIPPINES, SRILANKA, TANZANIA, UAE, USA, UK.
More than 900 IMP transformers are installed in UK grid &
More than 100 IMP transformer are in mining fields of Australia.
Why only IMP
 Leader in the 132kV and 220kV Class Transformers in
India
 Over 55 years of manufacturing & Design Excellence
 The ONLY Company in India to have Successfully
passed Short Circuit Tests in the FIRST ATTEMPT on 4
Nos. of 100MVA, 220kV & 2 Nos. 160 MVA class
Transformers, within a span of TWO YEAR
 85% Repeat Orders Showing High Customer
Satisfaction
 Amongst the FIRST 5 Companies in INDIA, To have
received NABL Accredited Certification since 2013
 Installed base of 100,000 MVA in INDIA and 26
Countries across the globe
Why only IMP
 Impeccable testing record with over 150 Nos. Short
Circuit Tests successfully Passed in the First Attempt
 Offers Complete Solutions from Design,
Manufacturing, Testing, Installation & Commissioning
and Maintenance
 Over 15,000 Prototype Designs available for reference
 State-of-Art Manufacturing & Testing Facilities for EHV
Transformers (Upto 315 MVA, 400kV)
 NABL Accredited EHV Test Lab
Business Vertical
Business Vertical
IMP through its rich experience in transformers
since 1961 and global market presence has created
a special service cell to provide comprehensive
maintenance and repair services for all brands and
types of transformers in India and overseas market.

IMP service portfolio offers utilities and industry

highest reliable and quick response time ensuring
maximum returns on assets, highest guaranteed
performance improvement and repair activity
backed by complete end to end in house set up
from designing to testing with latest technology and
automation tools.
Business Vertical - ETC
 Proper erection and commissioning of EHV
Transformers for long life and trouble free
operation
 Erection done as per IMP / IS 10028
recommendation
 First hand experience in Erection testing and
commissioning of transformers up to 400kV
Class.
 Dedicated team of engineers engaged in
erection testing and commissioning of
transformers.
Repairing of EHV transformers
 IMP has requisite facilities and resources for
effective repairs.
 Repairs is done at a fraction of cost of a new
transformer.
 Transformer is remanufactured strictly adhering
to well established processes and norms of IMP.
 It is possible to redesign the transformer it include
innovative features as required which further helps
customers to get enhanced capacity transformers
within the same size and foundation.
 Repair adequacy is verified and demonstrated
through testing in conformance to the relevant
standards
Overhauling
 Cleaning of Core Coil Assembly (CCA) and
removal of sludge.
 Retightening of all the clamping ensuring
adequate torque & clamping pressure in Core
Coil Assembly
 Removal of moisture from oil and insulation to
enhance the life of the transformer.
 Improvement in the dielectric parameters.
 Functional checks of supervisory device.
 Overhauling of OLTC.
Spares

 IMP is fully geared to supply spares of all ratings

and make of transformers.

 Spares are procured and checked as per standard

quality norms of IMP / customer requirements.

 Spares are procured from approved sources .

 Minimum cycle time through planning foresight,

focus and thrust.
Other Services
 Determination of the remnant life of Transformer
(RLA studies).
 Carry out condition monitoring and recommend
condition based maintenance action.
 Carry out special tests like DP, Furan content in
oil etc.
 Health check up of OLTC.
 Supply of 33 & 66kV Flange Mounted OLTC
 Retrofitting of OLTC
 Carry out diagnostic testing of transformers.
 Failure analysis and cost effective and efficient
restoration
 Annual maintenance contracts.
NABL EHV Test Lab-Commercial Use

We have started NABL testing on commercial basis

from April’13.
Following are some of our regular customers:
1. M/s Jodhpur Vidyut Vitaran
2. M/s Orissa Distribution Company
3. M/s Rajasthan Powergen Limited.
4. M/s Indian Transformer Company
5. And many OEM of transformers
Contact Details

pmyadav@imp-powers.com

customerservices@imp-powers.com
 Power Transformer:
Erection, Testing & Commissioning
at Site
 Receipt, Storage, Erection & Processing of
Transformer at Site
1. Receipt of Main Unit: Inspect main unit for its transit damage /
Paint & Note reading of Impact Recorder
2. Receipt of Accessory : Check transit / unloading damage to
Bushing Crates, Radiators, Drive Mechanism & Oil Drums
3. Core Isolation: Check Core - Frame is intact
4. N2/Dry Air filled Transformer: Check Tank Valve & Cylinder is
in open condition. Also check pressure gauge is showing positive
reading of N2 / Dry Air along with its dew point.
5. Oil Filled Transformer: Check Oil Level as per manufacturers
guideline & Oil BDV.
6. Insurance Coverage: Ensure coverage of Transit Damage /
Shifting Damage, Damages during ETC, if noticed. Report to
manufacturer to cover in Insurance Claim / Do as per the Terms &
Condition of Contract
 Storage –Check Points

1) Erect the transformer after its receipt and commission

2) Maintain positive N2 / Dry Air pressure at 0.175 kg/cm2 during
transportation and throughout the storage period.
3) Transformer filled with N2 / Dry Air should not be stored for more
than 3 months
4) The Main Tank shall preferably be filled with processed oil up to
core & winding level and fill N2 / Dry Air pressure above the oil
 Shifting / Sorting of Material

1. Material Shifting & Sorting

2. Checking for any Damage / Shortage / Theft / Leakage
3. If any discrepancy in (2) above, report to Manufacturer to cover
the same in Insurance Claim / Do as per the Terms & Condition of
Contract
 Checkpoint for Erection

1. Inspect Rail Level & distance between rails

2. Check Foundations w.r.t. rail line level for ‘A’ Frames & Supports
–Ref. Foundation Drawing
3. Check any fouling of fittings & report to manufacturer and get
confirmation for rectification
4. Check Marshalling Box Foundation does not obstruct withdrawal of
transformer from the plinth
5. Check Fire System, MB Foundation & Oil Sump pit are as per
drawing
 Checkpoint for Erection

6. Check distance between Main tank & Fire Wall should be as per
statutory requirement
7. Check A Frames & Radiator position
8. Assembly of Coolers (Radiators / Heat Exchangers), Conservators
& other accessories
9. Erection & alignment of OLTC DM & Bevel Gear Shaft
10. Checking of Lead Entry during bushing erection
 Preliminary Testing

1. Check Dew Point of Main Tank, N2 Pressure, Humidity & Ambient

Temp before erection
2. Check Turret CTs for Polarity & Knee Point, IR, Ratio, and Winding
Resistance to avoid major work after erection & oil filling
3. Check Bushings for Capacitance, Tan Delta & IR & Visual
inspection for any damage to porcelain, Low Oil Level & oil
leakage, if any
4. Check MOG NO/NC Contact
5. Pressurize the flexi-separator (inflate) with dry air or N2 to 1-1.5
psi (max) and lock the pressure for 24 hrs by closing the valve
provided on conservator and ensure that there is no leakage
 Preliminary Testing

5. Checking healthiness of external connection of FOS thro’ 1 ph.

supply to control box
6. Check Radiators for leak-proofness at pressure of 2.0 kg/cm2 for
a period of 30 minutes. The Radiators are type tested to
withstand a vacuum of 5.0 mm Hg absolute for one hour and
permanent deflection measured at the centre should not exceed
0.5mm.
 Dew Point Chart
(Ref. CBIP Manual)
For transformers with a gas pressure of 0.3 PSI, the acceptable limits of
dew point shall be as under:
Temperature Maximum Temperature Maximum
of insulation permissible dew of insulation in permissible
in 0F point in 0F 0C dew point in 0C
0 -78 -17.77 -61.11
5 -74 -15.0 -58.88
10 -70 -12.22 -56.66
15 -66 -9.44 -54.44
20 -62 -6.66 -52.22
25 -58 -3.33 -49.99
30 -53 -1.11 -47.22
35 -48 +1.66 -44.44
40 -44 +4.44 -42.22
45 -40 +7.44 -39.39
50 -35 +9.99 -37.22
55 -31 12.77 -34.99
60 -27 15.55 -32.77
 Dew Point Chart
(Ref. CBIP Manual)
For transformers with a gas pressure of 0.3 PSI, the acceptable limits of
dew point shall be as under:
Temperature of Maximum Temperature of Maximum
insulation permissible insulation in 0C permissible
in 0F dew point in 0F dew point in 0C
65 -22 18.33 -29.99
70 -18 23.11 -27.77
75 -14 23.88 -25.55
80 -10 26.66 -23.33
85 -6 29.44 -21.11
90 -1 32.22 -18.33
95 +3 34.99 -16.11
100 +7 37.75 -13.88
110 +16 43.33 -8.88
120 +25 48.88 -3.88
130 +33 54.44 +0.55
140 +44 59.99 +5.55
 Precautions During Internal Inspection

1. Evacuate N2 by applying vacuum up to or better than 25 Torr.

2. Retain vacuum for minimum 1 hour.
3. Release the vacuum thro’ breather – provision is given on cover
4. Ensure slim person should enter the transformer
5. Any tools carried should be tied at one end to tank body at some
accessible point from outside to avoid risk of their accidentally
falling inside the transformer
6. When a person enters the tank, he should come out for fresh air
every 20 minutes, so that suffocation / giddiness can be avoided.
7. Whenever a person enters the tank, one person should be
available outside on tank cover; he should keep talking to the
person inside the tank to ensure his safety.
 Internal Inspection Check Points
1. Check for any internal transit damage
2. Check the Core & Winding for intactness during transport
3. Check OLTC Contacts for looseness
4. Check for any foreign materials
5. Check there is no dirt / water ingress in transformer
6. Check Insulation & Lead condition
7. Check looseness of Internal connection of FOS
8. Check condition of bushing lead, remove the temporary lead
support provided inside the transformer during transportation
purpose, if any
9. Check HV, LV, HVN & other CT internal/secondary connection
10. Check that the bushing leads are set maintaining proper
clearances without being too close to ground or other points of
different potential
 Oil Filling procedure in Transformer at site
(for N2 Gas filled job)
For transformer tank designed to withstand less than 25 Torr
vacuum, the oil filling procedure shall be as follows
1. It must be ensured that all the valves are in closed position and
all openings are blanked off.
2. N2 gas cylinders to be disconnected and the N2 gas valve on tank
to be mounted at this stage.
3. Radiators, Bushing, Buchholz Relay, PRV, Conservator are not to
be mounted at this stage.
4. Equalize all OLTC diverter chambers with main tank as per the
arrangement provided.
5. Remove N2 gas from the tank by means of a vacuum pump
connected to the top filter valve
 Oil Filling procedure in Transformer at site
(for N2 Gas filled job)

6. Create a vacuum of at least 25 Torr; maintain it for 4 hrs and then

fill processed oil under this vacuum.
7. Before filling oil in the tank, it should be tested for BDV and PPM
as per IS: 335/IEC 60296, as applicable. In order to improve oil
breakdown value (kV) and water content (PPM), it should be
processed in separate storage tanks till the desired values are
achieved.
8. Fill the processed oil from the TOP of the transformer tank
through the filter valve.
9. Fill the oil in transformer tank as high as possible ensuring that
windings are immersed in oil and the oil level is about 300mm
below the upper part of the cover.
 Oil Filling procedure in Transformer at
site (for N2 Gas filled job)

10. Stop filling and close the Top filter valve.

11. Maintain vacuum for approximately one hour.
12.Gradually break the vacuum in the tank through temporary silica
gel breather connected to valve on top side of cover with valve.

Note:
For transformers supplied with in-tank type/ external OLTC, the
diverter / OLTC compartment shall be equalized with the main tank
before applying vacuum

Rate of filling of oil should not be more than 3-4 kL/hr, to permit
proper impregnation of insulation with oil and avoid trapping of air
bubbles.
 Fitting of Turret, Bushing & Other Parts

1. Fit PRV, Turret & its pipeline, Buchholz Pipe Line, OLTC Pipe line.
2. Fit bushings – check lead entries in bushings & clearances around.
3. Check mounting direction mark on Buchholz Relay & OSR
direction towards conservator.
4. Start tightening the parts from main tank towards conservator.
5. Fit Radiator, Heat Exchanger etc.
6. Now the transformer is ready for oil topping up.
Bushing Lead Entry

39
 Rated Voltage & Vacuum Application

Rated Voltage of the Transformer Vacuum Level

Less than 110 kV Less than 3,0 mmHg

More than 110 kV Less than 1,5 mmHg

More than 220 kV Less than 1,0 mmHg

*The leakage rate has to be less than 40mbar-lit/sec

 EVACUATION
The transformer tank (excluding cooler bank & conservator) shall be
evacuated to a pressure of 1.00 Torr max. The vacuum shall be
maintained for a duration indicated in the Table below.

System Voltage Evacuate and hold Standing time after

vacuum for oil circulation
before application
of voltage
kV hours Hours
Up to 145 12 12
145 & up to 420 24 48
Above 420 36 120
 Tightening Sequence & Torque

The bolt shall be fastened four times or five times symmetrically and
uniformly, not dispossibly one by one from the position of diagonal.
See the Figure, the sequence is 1～2～3～4～5～6～7～8～1～.

fastening the flanges and bolts

The fastening torque of bolt
Bolt specification M12 M16 M20 M24 M36
Torque (N.m) 80 250 420 500 700
 Oil Filling & Topping Up

1. After fitment of PRV, start oil topping up through top filter valve
2. Fill oil in OLTC through equalizer pipeline
3. Remove equalizer between OLTC & Main transformer.
4. Open valves towards conservator.
5. Open top side valves of heat exchanger or radiators.
6. During oil filling, monitor air release from all possible points.
7. Fill oil in conservator level up to 2-3 stud heights of prismatic
gauge.
8. In OLTC conservator oil to be filled separately through oil filling
hole provided at the top of conservator up to the level marked on
the gauge.
9. Transformer is ready for carrying out oil filtration.
 Oil Filtration

1. Ensure Buchholz Pipe line is open up to main conservator

2. Close valves of Radiators / Heat Exchangers
3. Filter oil in main transformer by feeding hot oil through top filter
valve & take out cold oil from bottom filter valve.
4. Maintain top oil temp. 600C - 650C during filtration
5. Check and record IR / PI values at 3 hours interval
6. Filter OLTC oil for 1½ hour per diverter chamber through
conservator.
7. Stop oil filtration in main tank after achieving the desired BDV
 Oil Filtration

8. Filter Radiator / Heat Exchanger separately

9. Open Radiator / Heat Exchanger valves & complete 2 cycles of
filtration.
10. Measure oil BDV, IR values etc.
11. Continue filtration of oil till BDV is achieved.
 The Recommended Values

The Highest Equipment

Voltage, kV Water
Tan delta at
BDV, kV content
900C
Up to and ppm, max.
Above
including

- 72.5 60 20 < 0.05

72.5 245 65 15 < 0.02

245 420 70 10 < 0.01

420 800 75 10 < 0.01

*High water content accelerates the chemical deterioration of the

insulating paper and is indicative of the undesirable operating
conditions or maintenance requiring correction.
 Insulation Resistance
(Ref: CBIP Manual)

1. Insulation resistance tests are made to determine the

insulation resistance from individual winding to ground or
between windings. The insulation resistance is commonly
measured in megohms, or may be calculated from
measurements of applied voltage and leakage current.

2. Insulation resistance values shall be recorded & measured for

60 sec and 600 sec.
 Temperature Correction Factor IR for
Oil Filled Transformer
Av. Oil Factor (Multiply Av. Oil Factor (Multiply
Temperature ºC by) for correction Temperature ºC by) for correction
during IR to 20ºC during IR to 20ºC
measurement ºC measurement ºC
0 0.25 40 3.75
5 0.36 45 5.60
10 0.50 50 7.85
15.6 0.74 55 11.20
20 1.00 60 15.85
25 1.40 65 22.40
30 1.98 70 31.50
35 2.80 75 44.70
Formula for temp correction: IR20 = IRt x K
Note:
1. The correction factors indicated above are based on insulation systems using mineral oil
as an insulating liquid.
2. Insulation temperature may be considered to be that of the average oil temperature.
 Temperature Correction Factor –
Insulation Power Factor (Winding)

Formula for temp correction: Tan δ20 = Tan δt ÷ K

 Polarisation Index
(Ref: CBIP Manual)

1. The polarization index (PI) is defined as the ratio of IR values

measured at the intervals of 600 and 60 seconds respectively.

2. A PI of more than 1.3 is considered satisfactory for a transformer

when the results of other low voltage tests are found in order.
Lesser value of PI calls for extended filtration of oil.

3. For bushings, an IR value of above 10000 M-ohms is considered

satisfactory.
Air Cell Commissioning
Air Cell Commissioning

Check the
Fitting of
Air Cell
Air Cell Commissioning

Air Cell
after giving
pressure
 Air Cell Commissioning

1. Loosen air release plugs (labeled as ‘C’ & ‘D’ - refer Oil-filling
Instructions Plate provided on the transformer).
2. Pressurize the flexi-separator (Inflate) with dry air or N2 to
1-1.5 psi (max) by closing the valve in the breather pipe line.
3. Push oil from bottom till it starts flowing from all the air
release plugs, thus allowing removal of the air trapped inside
the conservator. Stop oil filling at this stage for a while &
tighten all the air release plugs after oil release/bleeding. At
this stage, the prismatic oil level gauge will show full oil level,
where as the MOG will be indicating zero oil level.
Air Cell Commissioning

The oil level in the

Prismatic Oil Gauge full
confirms successful
commissioning of air
cell;
If the oil level in the
gauge comes down
after air cell
commissioning, it
indicates there is
leakage
 Air Cell Commissioning

4. Continue oil filling at slow rate. During oil pushing the pressure
inside the air separator will rise. Maintain the pressure in side
the separator between 1 to 1.5 psi by releasing N2 / Dry Air
through the valve.
(Note: The pressure of 1-1.5 psi could be maintained by opening the valve in
the breather pipeline by maintaining rate of release of N2 / Dry Air
approximately equal to the rate of filling of oil).

5. In this condition, the air cell will float on oil and MOG will start
indicating the actual level of oil. Stop filling of oil when the
MOG indicates level corresponding to 35° mark, i.e.,
corresponding to temperature of top oil in transformer. Oil
level in the sight glass remains constant during the operation
& in service. While the MOG indicates the actual oil level in
conservator, the oil level indication in the prismatic sight glass
will be different
Air Cell Commissioning

Following the oil

procedure fill the oil in
the conservator till the
time the oil level in the
MOG touched 35°C
marking on its dial.
 Air Cell Commissioning

6. In case there is any leakage of air into the Conservator

through pressure gauge or air release plug etc, both the MOG
and prismatic oil level gauge will show equal level. This will
also be true incase the flexi-separator is punctured.
(Note: It needs to be confirmed whether the air leakage is through the
punctured flexi-separator or any other points).
7. Healthiness of the flexi-separator can be checked by taking
transformer shutdown and pressurizing the separator
repeating step no.6 & 7 above by draining oil from
conservator & keeping the inspection cover (provided on the
conservator) open this time. In case the pressure is
withstood, it could be construed that the flexi-separator is
intact and air is entering into the conservator from
elsewhere, say, air release plug etc. (excluding pressure
gauge or valve gland etc). However, if the pressure does not
sustain, the flexi-separator is to be checked for puncture.
 Air Cell Commissioning

PRECAUTIONS:

1. Oil filling in the conservator and also draining whenever required

must be done very slowly during oil filling, pressure in the air cell
should be exceed 0.07kg/ cm2
2. If a pressure or vacuum is ever applied to the main transformer
tank the conservator must be disconnected by closing both shut off
valves (A).
3. Do not carry out any welding operation on conservator to avoid any
damage to air cell.
4. Once the air has been driven out completely during oil filling in the
conservator, do not remove air release plugs (C) and (D).
5. After connecting breather (F) valve (B) to be kept in open position
 Silica gel -Orange

It is developed on the basis of Blue Silica Gel Indicator. It adopts

the new type of composite dyeing agent that is nontoxic. In this
way, it prevents the environment pollution caused by dyeing
agent from the very beginning. With its unique technique and
good adsorption performance, it has become a new type of
environmentally friendly product.
 Silica gel -Orange

Items Specifications Orange to Blue-green

Adsorption Capacity,% RH50% = 20
RH80% = 30
Appearance Nacarat
Loss at Heating-up, % = 4
Bead Size up to grade,% = 90
Color Showing RH50% Navy Blue or Indigo
RH80% Cyan
Notes: Other Special Specifications Can be Produced According to Your
Requirements.
 Erection & Commissioning of Optional
Accessories

1. Installation & Commissioning of fibber optic hotspot

temperature measuring system (Lumasmart)
2. Installation & Commissioning of On Line DGA system
3. Installation & Commissioning of On Line Dry-out system for
OLTC
4. Installation & Commissioning of AVR (Mini RTCC)
5. Installation & Commissioning of OLCCMS (DGA+ Bushing+
WTI &OTI)
6. Installation & Commissioning of TAPCON230 (MR Make)
 Pre-commissioning Check List

1. Check OLTC with manual and electrical operation

2. Check OLTC remote operations with all indications
3. Check T. D. Relays settings in RTCC
4. Check setting of thermal relays for oil pump and fans contactors
5. Check directions of rotations of pump / fans
6. Oil is filled in RTD Pockets
7. Follow other points given in O & M manual checklist
 General Don’t for Power Transformer
1. Do not energize the transformer without conducting all pre-
commissioning checks. The results must be comparable with
results at works.
2. Do not leave off-circuit tap switch handle unlocked position.
3. Do not energize the transformer unless the off-circuit tap
switch handle is in locked position.
4. Do not leave tertiary winding terminals unprotected outside
the tank, connect them to tertiary lightning arresters
protection scheme, when connected to load. If it is not a
loaded tertiary, follow supplier’s instructions.
5. Do not allow WTI/OTI temperature to exceed 60 °C during
drying out process of transformer; filter machine temperature
should not be beyond 65 °C.
6. Do not use inadequate capacity lifting jacks on transformer
for jacking.
 General Don’t for Power Transformer
7. Do not move the transformer with bushings mounted.
8. Do not overload the transformer beyond the specified limits as
per IS-6600/IEC-60035.
9. Do not change the alarm & trip setting of WTI/OTI frequently.
The setting should be done as per the site condition or as
recommended by supplier.
10. Do not leave red pointer behind the black pointer in OTI &
WTI.
11. Do not leave any connection loose.
12. Do not meddle with protection circuits.
13. Do not allow conservator oil level to fall below ¼ level.
14. Do not allow oil level fall in the bushings. They must
immediately be topped up under guidance from supplier.
15. Do not leave marshalling box door open. It must be kept
locked.
16. Do not switch off the heater on marshaling box except during
periodical cleaning.
 General Don’t for Power Transformer
17. Do not allow dirt deposit on bushings; these should be
periodically cleaned.
18. Do not allow un-authorised entry near the transformer.
19. Do not leave the transformer ladder unlocked when the
transformer is ‘ON’ in service.
20.Do not change the sequence of valve opening for taking
standby pump & motor into circuit.
21.Do not allow water pressure more than oil pressure in
differential. pressure gauge (Applicable for OFWF cooled
transformer).
22.Do not mix the oil unless it conforms to IS-335/IEC-60296, as
applicable.
23.Do not allow inferior oil to continue in transformer. The oil
should be processed & used only when BDV/PPM conforms to
IS-1866.
24.Do not continue with pink silica gel; this should be changed or
regenerated.
 General Don’t for Power Transformer
25.Do not leave secondary terminal of an unloaded CT open.
26.Do not top up oil from conservator with air cell inside.
27. Do not smoke/allow flames on or near the transformer.
28. Do not use fibrous cleaning material such as cotton waste
inside the transformer, as it can cause deterioration in
electrical properties of oil when mixed with it.
29. Do not drop any tools/materials inside the transformer.
30. Do not weld, braze solder inside the tank.
31. Do not weld anything on tank walls from outside.
32. Do not weld anything on conservator vessels with air cell
inside.
 General Do’s for Power Transformer

1. Check if air cell is provided in conservator.

2. Attend the leakages on the bushing immediately.
3. Examine the leakages for the dirt deposits & coats & clean them
periodically.
4. Check the oil in transformer & OLTC for Dielectric strength &
moisture content and take suitable action to maintain value.
5. Check oil level in oil cup and ensure air passage is free in the
breather.
6. Check the oil for acidity and sludge as per IS:-1866. (Please refer
maintenance table.)
7. If inspection covers are opened or any gasket joint is to be
tightened then tighten the bolts evenly to avoid uneven pressure.
8. Check and clean the relay alarm contacts. Check also their
operation and accuracy, and if required, change the setting.
 General Do’s for Power Transformer
9. Check the protection circuits.
10. Check the pointer of all gauges for their free movement.
11. Clean the conservator thoroughly before erecting.
12. Check the buchholz relay & re-adjust the floats, switches etc.
13. Inspect the painting & if necessary, retouching should be
done.
14. Check the OTI & WTI pockets & replenish the oil, if required.
15. Release air through vent plug of the diverter switch before
energizing the transformer.
16. Check oil level in the diverter switch and if found less, top up
with fresh oil conforming to IS: -333/IEC-60296 as applicable
17. Open the equalizing valve between tank OLTC, wherever
provided, at the time of filling the oil in the tank.
18. Connect gas cylinder with automatic regulator (if the
transformer is to be stored for long period) in order to
maintain positive pressure.
 General Do’s for Power Transformer

19. Open the equalizing valve between tank OLTC, wherever

provided, at the time of filling the oil in the tank.
20. Connect gas cylinder with automatic regulator (if the transformer
is to be stored for long period) in order to maintain positive
pressure.
21. Fill the oil in the transformer at the earliest opportunity at site
and follow storage instructions.
22. Check the door seals of marshalling box. Change the rubber
lining, if required.
23. Equalize the diverter compartment of the OLTC by connecting
equalizing pipe between flange joints provided on the tap
changer head.
 Testing of Power Transformer
Electrical Testing:
1) Vector Group Test
2) Ratio Test
3) Magnetic Balance Test
4) Magnetic Balance Test
5) Open Circuit Test
6) Short Circuit Test
7) Capacitance, Tan Delta of bushing & Windings
8) SFRA Test
9) Insulation Resistance Winding & Core Isolation
10) Polarization Index Test
11) Winding Resistance

Oil Testing: As per IS 1866 Latest Revision all test & DGA

Functional Testing: All protection to be checked for its functional testing and
operation to be cross checked as per scheme