KOTSONS PRIVATE LIMITED

INSTALLATION OPERATION
AND
MAINTENANCE MANUAL

THREE PHASE POWER TRANSFORMER

MANUAL No.- KPL-M-003 RELEASE-01

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PREFACE
KOTSONS Three Phase Power Transformers are designed, manufactured, and tested to applicable standards of
practice. This manual provides general information for the installation; operation and maintenance of oil immersed
Three Phase, Power transformers.
Careful observation of the instructions presented in this manual, and regular maintenance, will ensure continuous
trouble-free performance of the transformers.
If any further information is required, it will furnish on request. In any communication please quote the particulars
stamped on the transformer rating plate, including the Maker’s serial Number.
Transformers should be energised only after completing all the necessary work and carrying out
pre-commissioning checks and tests described in this manual.
SPECIAL NOTE
The instructions provided in this manual are given for information and guidance, and the company cannot accept the
responsibility for the manner in which they are observed and for any consequences thereof.

ABOUT TRANSFORMER
Transformer is one of the most vital and important electrical machinery. It is a static electrical device that transforms
A.C. energy from one level to another level without changing frequency. The Power transformers are an important
link between the power system and millions of electricity consumers. Any failure of this important equipment, apart
from adversely affecting the consumers, will also mean considerable financial loss to the electricity undertaking. It is
therefore of important that utmost care is taken in the design, manufacturing, testing, installation and maintenance of
transformers. A transformer consists of a magnetic core made out of insulated silicon steel laminations. Two distinct
sets of windings, one called primary and other called secondary winding, are wound on such core. The transformer
helps in converting high voltage into low voltage or visa-versa and accordingly the transformer is termed step-down
or step-up. The transformer works on the principle of electro-magnetic induction. Such phenomena can take place in
a static device,
If the magnetic flux is continually varying, it is therefore clear that static transformers can only be used with
alternating currents only. When an alternating EMF is applied to the primary winding of a transformer with the
secondary winding open circuited, a small current flows in the primary winding which serves to magnetize the core
and to feed the iron losses of the transformer. As primary and secondary windings are wound on the same core, the
magnetizing flux is the same for both the windings. The magnetizing flux corresponds to the magnetizing current in
the primary and the number of turns of the primary winding. Primary and secondary windings are wound on the same
core, hence the induced voltage per turn is the same for both primary and secondary winding. Also the absolute value
of induced voltage in the primary and secondary windings is proportional to the number of turns in the respective
windings.

CONSTRUCTION DETAILS
The main parts of transformer are;
 Magnetic Circuit (core)
 Electric Circuit (Windings & Connections)
 Transformer Tank and Radiators.

Magnetic Circuit (Core)

Magnetic circuit of every transformer, generally called CORE is made up of special Cold Rolled Grain Oriented
Silicon steel laminations. The Core assembly is hold by means of clamps made of mild steel. Class “A”- insulating
press board is used to isolate the core assembly from mild steel clamp structure, however the Core assembly is
grounded by using copper strip with clamps to keep the Core at zero potential.

Electric Circuit (Windings & Connections)

The High voltage (HV) or Primary winding is made of Paper covered rectangular conductors.
The Low voltage (LV) or Secondary winding is made of Paper covered rectangular conductor.
The shape of coils is cylindrical. Windings in each limb are isolated suitably from each other by means of maintaining
necessary gap between them. The gap is filled with insulated runners & the solid cylinders. Its starting & finishing
leads are on the opposite side duly insulated. Tapping leads are also taken out on the same side as the HV winding
starting & finishing leads.
Both windings are braced suitably for High Voltage class. Transformers are made by using the Class 'A' insulating
paper & press boards enabling the winding to bear the short circuit forces as per IEC-76
The Primary (HV) windings are connected in Delta or Star as specified with separately taken out neutral in star
connection. The secondary (LV) windings are connected in Star or Delta as specified with separately taken out
neutral in star connection. Both connections are done as the requirement of vector group satisfied. The tap leads are
connected to the tap changer suitable for HV % variation as specified.

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 The Core – coil assembly is baked in oven at a temperature of 120 Deg. C for removing moisture & making it dry. It is
then put in to the tank & oil.
TANK AND RADIATORS
Transformer tank is made up of mild steel. The size of tank varies according to the size of core – coil assembly which
is to be put in to the tank. The surface are of the tank body dissipates heat of the transformer during its operation to
keep temperature rise of transformer within specified limits.
The transformer tanks are made for cooling area to dissipate the heat generated as a result of No Load losses & the
load losses during operation of transformer. The sufficient cooling area achieved by adding the pressed steel
radiators. The oil circulates in these radiators.
The Pressed steel radiators are designed such that the temperature rise of transformer remains within specified
limits.
Complete tank with its radiator, top cover & conservator is pressure tested to ensure leak free. Tanks are sufficiently
welded & suitably stiffened to bear the pressure, without any deformation.
Tanks are provided with provision for fixing specified accessories. Tanks & Radiators are cleaned by sand / grit
blasting to a surface finish of SA 2½ followed by application of Zinc rich primer & finish paint of specified shade
externally. Varnish / Oil & Heat resistant paint is applied on the inner surface of the tanks.
FITTINGS & ACCESSORIES
Some Standard Fittings listed below are normally provided on the power transformers for the correct and safe
operations. These fittings conform to the requirement of International Standard IEC-60076.
1- Rating & term inal m arking plate 18- Oil tem perature indicator (OTI)
2- Tap changing s witch (Off circuit) 19- Winding tem perature indicator (WTI)
3- On load tap changer (OLTC) 20- Current trans form er (CT) term inals
4- RTCC panel with AVR 21- Radiators
5- Prim ary (HV) bus hings 22- Earthing term inals
6- Secondary (LV) bus hings 23- Air releas e plugs
7- Cable boxes 24- Drain valve
8- Cons ervator with drain valve 25- Filter valve
9- Oil filling Hole with cap 26- Sam pling valves
10- Magnetic oil level gauge (MOLG) 27- Shut off valve
11- Plain oil level gauge 28- Lifting Lugs
12- Silicagel breather 29- Jacking lugs (Pads )
13- Buchholz relay 30- Las hing lugs
14- Pres s ure relief valve (PRV) 31- Towing lugs
15- Explos ion vent 32- Skid-m ounting bas e
16- Therm om eter Pocket 33- Roller As s em bly
17- Mars halling box

1- Rating & Terminal marking plate: - The transformer is supplied with rating & terminal marking plate of a non
corrosive metal indicating all information about the Rating, Voltage ratio, weights, oil quality, vector-group etc. along
with the serial number of the unit.
2- Off circuit tap changing switch: - The transformer is fitted with an off circuit tap changing switch to obtain required
tap voltage. It is hand operated by a hand wheel mounted at the tank side plate on the tank cover. It is important that
the transformer should be isolated from the source or live lines, before moving the switch hand wheel. If the
transformer is energized, will damage the switch contacts due to severe arcing between the contacts, and may
damage windings also.
3- On load tap changer: - On load tap changer is the integral part of the transformer and connected to winding tap
leads. Function of OLTC is same as off circuit tap changing switch, but in case of OLTC the transformer need not be
electrically isolated primary & secondary side. The tap changer can be operated ON LOAD. For constructional
details, operation and maintenance instructions refer manual of OLTC manufacturer provided with unit.
4- RTCC panel with AVR: - Transformer with OLTC (if ordered) a separate Control Panel is provided, called RTCC
(remote tap change control) panel. This panel is located in the control room at site from where OLTC operation is
controlled. Generally, RTCC is fitted with raise & lower push buttons for raise/lower command of OLTC, TPI (tap
position indicator) for indicating tap No. of OLTC. The AVR is also housed in it. The other non standard features like
OTI & WTI repeaters, AVR voltmeters etc. are provided on RTCC on order.
5- Primary (HV) Bushing: - Porcelain bushings or Resin cast Plug in bushings are provided with nuts and clamps to
take windings lead on one side and incoming cable on the other side. The incoming cables should be connected via
suitable connectors with bushing. Nuts & clamps which exert pressure on bushing should be tightened evenly or else
the bushing may creak. Arcing horns (if applicable) should be fixed in proper position.

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6- Secondary (LV) Bushing: - Porcelain bushings or Resin cast Plug in bushings are provided to take windings lead on
one side and load cable on the other side. The load cables should be connected via suitable connectors with
bushing. Before energizing the transformer the connectors should be properly tightened.
7- Cable boxes: - To ensure safety of operating personal in outdoor/indoor installation, cable boxes are used. These
boxes are for receiving & protecting cable ends against ingress of moisture, dirt, dust & vermin. Cable boxes are
provided with detachable gland plates, earthing terminals & inspection covers on big cable boxes. Primary/secondary
Bushing are housed in these boxes. Supply cable passes through the glands. Armouring of cable is clamped inside
or outside the gland and earthed suitably. Provision of Disconnecting chambers also provided on order. In this
provision two sets of bushings one set on transformer and the other on the cable box. Disconnecting links are
provided for disconnecting bushings on transformer from the bushings on cable box. Disconnecting chamber facilities
cable testing, disconnection of cable box for replacement or for removing the transformer for repairs without
disturbing the cables.
8- Conservator with drain valve: - Conservator is provided on transformer which provides the space for the
expansion/contraction of oil on account of the variation of oil temperature during service. It prevents the oil in the tank
from coming in direct contact with the atmosphere and protects it from deterioration. Conservator is provided with
silicagel breather, oil level gauge, oil filling hole with blanking plate and drain valve for draining/sampling of oil
contaminated by moisture and sludge.
9- Oil filling hole with cap: - It is provided on the conservator. If oil level indicator shows less than min. then open this
cap and topping up of oil till it shows max.
10- Magnetic oil level gauge (MOG):- This is a direct oil level indicating device through needle in its dial & mounted
directly on the conservator to indicate oil level. This is supplied with low level alarm contacts (if asked for) and the
electrical connections of which are brought out to a terminal box mounted on it. Suitable alarm circuit may be
connected to these terminals. This oil gauge is not dispatched separately, but is mounted on the conservator with
float arm adjusted to correct length.
11- Plain oil level gauge: - This is window type indicating device & mounted directly on the tank or conservator to
indicate oil level. Window opening is fitted with grooved Perspex sheet and metal frame to give clear indication of oil
level. It helps to identify the failure of MOG needle gears or any obstructions of MOG working.
12- Silicagel dehydrating breather: - Silica gel breather is fitted with silica gel which absorbs moisture from the air
entering the transformer, thus preventing deterioration of oil and insulation due to moisture condensation. The
breather contains oil unit at the bottom which prevents the entry of dust solid particles present in the air. The colour of
silicagel is blue when dry and turns pink when it has absorb a certain percentage of moisture by weight. The change
in colour of gel can be observed through window on a container. Breather when fitted should examined to ascertain,
that the silica gel is dry (blue in colour). The frequency of inspection of gel depends upon local climate and operating
conditions.
13- Gas and oil actuated Buchholz relay: - In the event of fault in oil filled transformer gas is generated, due to which
buchholz relay gives warning of developing fault. Buchholz relay is provided with two elements one for minor faults
(gives alarm) and other for major faults (tripping).
The alarm elements operate after a specific volume gets accumulated in the relay. Examples of incipient faults which
will generate gas in oil are:-
1. Failure of core bolt insulation.
2. Shorting of lamination and core clamp.
3. Bad Electrical contact or connections.
4. Excessive hot spots in winding.
5. For low oil level in the event of oil leakage.
The trip element operates due to sudden oil surge in the event of more serious fault such as: -
1. Earth fault due to insulation failure from winding to earth.
2. Winding short circuit inter turn, interlayer, inter coil etc.
3. Short circuit between phases.
4. Puncture of bushing.
5. The trip element will also operate if rapid loss of oil occurs.
IMPORTANT- During the operation of transformer, if there is an alarm transformer should be isolated from line and
possible reasons, listed above for the operation of relay should be checked starting with simple reason such as loss
of oil due to leaks, air accumulation in relay chamber which may be the absorbed air released by oil due to change in
temperature etc. Rating of contacts: - 0.5 Amps. At 230 Volts AC or 220 Volts. DC.
14- Pressure relief valve (PRV): - The PRV is used to prevent mechanical damage to transformer tank by releasing any
cxcess pressure over the set limit. This valve is basically a spring loaded device which closes automatically when the
pressure inside the tank drops to the set limit after venting cxcess pressure over the set limit.
15- Explosion Vent: - Explosion vent is provided to give protection against the excessive pressure that may developed
inside the transformer due to internal fault. On specific requirement the explosion vent is provided with two
diaphragms one at the bottom (near tank) and the other at the top. If excessive pressure is developed in the tank,
both diaphragms will rupture and oil in tanks will be thrown out through the vent. One pressure equalizer pipe is
provided between explosion vent and the conservator to maintain equal pressure in the empty spaces of vent and
conservator. In this case oil level indicator is provided on the explosion vent to indicate rupture of bottom diaphragm.
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16- Thermometer Pocket: - This pocket is provided on the tank cover to measure temperature of the top oil in tank. It is
essential to fill the pocket with transformer oil before inserting the thermometer, to have uniform and correct reading.
17- Marshalling Box: - It is an enclosure housing mounted on transformer. Terminal blocks are provided in this box to
take the incoming and outgoing cable leads from various protection instruments fitted on transformers e.g. Buchholz
relay, Pressure relief valve, Winding temperature indicator, Oil temperature indicator, Magnetic oil level gauge etc.
Box is provided with Blank gland mounting plate, which should be drilled suitably to receive glands. Temperature
indicators with capillary tubes and electrical contacts are mounted inside this box.
18- Oil Temperature Indicator (OTI): - Oil temperature indicator provides local temperature of top oil. Instrument is
provided with temperature sensing bulb with capillary, the instrument provided with a temperature recording dial main
pointer. Maximum pointer and resetting device and two sets of contacts for alarm and trip.
19- Winding temperature Indicator (WTI): - The windings temperature indicator indicates ‘’ Hot spot’’ temperature of the
winding. This is a ‘’Thermal Image type’’ indicator. This is basically an oil temperature indicator with a heater
responsible to raise the temperature equal to the ‘’Hot spot’’ gradient between winding and oil over the oil
temperature. Thus, this instrument indicates the ‘’Hot Spot’’ temperature of the windings. Heater coil is fed with a
current proportional to the windings current through a current transformer mounted on the winding under
measurement. Heater coil is either placed on the heater bulb enveloping the sensing element of the winding
temperature indicator immersed in oil or in the instrument. The value of the current fed to the heater is such that it
raises the temperature by an amount equal to the hot spot gradient of the winding, as described above. Thus
temperature of winding is simulated on the dial of the instrument. Pointer is connected thought a mechanism to
indicate the hot spot temperature on dial. WTI is provided with a temperature recording dial main pointer. Maximum
pointer and resetting device and two sets of contacts for alarm and trip.
20- C.T. Terminals: - CT secondary leads are brought out to the CT terminals & covered metallic cover located at
appropriate place as shown on outline drawing. The cover is supplied with gland. These terminals are wired up to
marshalling box.
21- Radiators: - Plain sheet steel tank is used where the size of the tank not provides adequate cooling surface to
dissipate the heat generated on account of losses inside the transformer. The detachable radiator banks are provided
for additional/required cooling surface. The radiator bank consists of pressed steel plate assembly welded into top
and bottom headers. The radiator bank is bolted on to the tank wall and two isolating valves are fitted into the oil inlet
and outlet. In case dual rating of transformer, forced air cooling could be provided by means of suitable fans.
Transformer is provided with detachable pressed sheet radiators with isolating valves. Due to transport limitation and
considering possible transit damages, the radiator valves are closed at the time of dispatch and radiators are
detached and sent separately duly packed keeping the valve in position on tank flange. Blanking plates are put on
each valve to stop the dirt or moisture entering inside and avoid the contamination of the transformer oil. Each
radiator have drain plug, air release plug & lifting lug for handling.
22- Earthing Terminals: - Transformer should be effectively earthed by means of suitable connections to earthing
station. It is recommended to take reference to the latest rules in code of practice for earthing as per local laws. A
good low resistance earthing strip at substation must be used. Core lamination assembly is connected to core
clamping structure by a Cu strip, which is in turn connected to the tank. Two earthing terminals are provided on the
tank which should be connected to the earthing system of supporting structure of transformer or the station. Cable
boxes, marshalling box & winding neutral should be earthed. All earth points are individually identified by earth
symbol.
23- Air release plug: - Air release plug is normally provided on the tank cover/inspection cover and bushing turrets if
provided. Space is provided in the plug which allows air to be escaped without removing the plug fully from the seat.
Plug should be unscrewed till air comes out from cross hole or groove cut and as soon as oil flows out it should be
closed.
24- Drain valve: - Transformer is equipped with Drain valve at bottom of tank. It fitted with plug/blanking plate to stop the
dirt or moisture entering inside and avoid the contamination of the transformer oil. It is provided to drain out oil.
25- Filter valve: - Transformer is equipped with filter valve at top of tank. The valve is fitted with plug / blanking plate to
stop the dirt or moisture entering inside and avoid the contamination of the transformer oil. It is provided to connect
with filter machine for filtration purpose to improve oil Break down Value (BDV).
26- Sampling valve: - Transformer is equipped with sampling valves at bottom, middle & top of tank. It fitted with
plug/blanking plate to stop the dirt or moisture entering inside and avoid the contamination of the transformer oil. It is
provided to take sample for test. (if given)
27- Shut off valve: - Transformer is equipped with shut off valve either side of buchholz relay on pipe line between
conservator and transformer tank cover. These valves are provided to replace the buchholz relay in case it is not
working without lowering oil from conservator. These valves should be fully opened when transformer is running.
28- Lifting Lugs: - Four lifting lugs of adequate capacity are provided on tanks to lift completely assembled transformer
filled with oil. All lugs are designed for simultaneous use and should be used simultaneously to lift the transformer.
Four lifting lugs are provided on core clamps for un-tanking the core and windings. All heavy fittings are also provided
with individual lifting lugs.
29- Jacking lugs (Pads): - Four jacking lugs are provided for transformer. All lugs should be used simultaneously to
avoid damage to jacking pads and tank. Suitable hydraulic or mechanical jacks may be used to jack up the
transformer.

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30- Lashing lugs: - The holes provided in the lifting lugs are suitable for lashing the transformer to transport activities.
31- Towing lugs: - The holes provided in the under base arrangement are suitable for towing the complete transformer.
32- Skid mounting base: - It is the base of transformer & welded with tank bottom. It is used to fix the transformer on
platform.
33- Roller assembly: - It is fixed with the transformer base by fasteners provided at site. It is used to move the
transformer on the platform for appropriate position. Four roller assemblies, plain or flanged type, are provided on
each & every transformer (if required). Suitable arrangement of track for the rollers should be made at site, to
facilitate movement of the transformer. The track provided should be leveled properly so that all wheels rest on the
track. Rollers are normally detached from the tank base at the time of transport.
PACKING AND DESPATCH
After testing & inspection at KOTSONS works transformers are dispatched to their destinations depending upon the
mode of transport or as required & agreed by the buyer.
If the transportation weights & size limits, the transformer is dispatched with oil covering coils & yoke. The oil level
reduced below the tank cover to provide space in the tank sufficient for the oil expansion during transit/storage on
account of temperature variation. Pressure relief valve is fitted to the transformer tank.
Fitting & accessories removed from the transformer are dispatched in separate crates/cases/container. Radiators,
bushings, conservator, explosion vent, buchholz relay, etc. are detached & sent separately. All the detachable items
are clearly indicated in the Out Line General Arrangement Drawing of the Transformer.
Oil quantity for filling & topping up in tank, radiators, conservator & disconnecting chambers for cable boxes (if
applicable) is sent separately in sealed drums along with transformer. All the packages containing the detached parts
clearly marked. Contents are clearly indicated in the packing slips attached to each crate/case.

RECEIVING AND INSPECTION

All the transformers are inspected and then dispatched from KOTSONS works in suitable packed condition for
transport to their destinations.
Immediately upon receipt, and before being put into service, transformers should be inspected for external damage or
loose parts caused by transport and handling. Damage presumed to have occurred during transport should be noted
and Kotsons representative shall be contacted.

UNLOADING OF TRANSFORMER AT SITE

The transformer should be unloaded by means of a crane or suitable lifting device of sufficient capacity (For weight
details, please refer the Rating & Terminal marking Plate). Always use lifting mechanisms, crane, chain pulleys, etc.
of adequate capacity. Use of any under capacity lifting mechanism or accessories could result in severe damage to
the transformer, lifting equipment and possibly personnel involved in handling the transformer. For lifting, suitable
lugs are provided on the cover or on sides of tank. Lifting lugs on the sides of tank are for lifting the complete unit as
long as the bushings or any other parts are not obstructed.

HANDLING
Transformers should be lifted by the lugs provided for the purpose and simultaneous use should be made of all such
lugs in order to avoid any unbalance in lifting. The transformer bushings should not be used for lifting or moving the
transformer into position. The transformer should be kept upright at all times and not tipped over on its side for any
reason. This will prevent air bubbles from entering the coil which could degrade the dielectric strength. Skid-Mounting
base/roller assemblies (as ordered) are provided.

STORAGE
All the accessories must be stored in a covered dry place. The storage area must be accessible for inspection.
Although outdoor transformers may be stored outside, it is preferable to store all transformers in an area where
ambient temperature variation is small. Immediately after received of main unit and accessories, these should be
checked if found in order should be erected on its foundation & filled with transformer oil.
However, if it is not possible, main unit should be stored on strong & leveled storage area where water should not
accumulate

NSTALLATION
Adopt the following for safe installation
1. Unpack the transformer & its accessories
2. Remove wooden pallets
3. Keep transformer on a uniform & leveled surface.
4. Use the lifting lugs provided.
5. Do not use rod/strip fixed to Radiators. It is not meant for lifting.
6. Lift the transformer using Lifting lugs provided on tank/cover.
7. Ensure that the lifting chain or sling do not break the bushings.
8. In case of transformer with dual ratio, be sure the tap corresponding to voltage of the system feeding the
transformer itself.

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 Preparation & Checks
1. Rating & terminal marking plate - Check the details of transformer for ensuring that the transformer
matches your need & the system Voltage.
2. Transformer tank, conservator & radiators - In good condition (leak free & not damaged)
3. Bushings – No crack, leak free, no dust & dirt.
4. Arcing horn (If applicble) – Fix the Arcing Horns on all HV bushings such that top & bottom arcing horn
tips points each other to avoid misalignment. Maintain gap as indicated in below table.

SYSTEM VOLTAGE ARCING HORN GAP

FOR 36 KV 220 mm
FOR 24 KV 155 mm
FOR 12 KV 85 mm
5. Off Circuit Tap Changer – Knob should be locked at suitable Position for rated Voltage at HV Side.
(Refer Rating & Diagram Plate)
6. On Load Tap Changer - In good condition (No damage) & functions working
7. RTCC Panel with AVR - In good condition (No damage), intactness of window glasses & functions
working
8. Cable boxes - In good condition (No damage)
9. Pressure relief Valve – No oil spill around the PRV & indication flag set in position & wiring
10. Magnetic oil level gauge - Oil level satisfactory & intactness of dial glass & wiring
11. Oil level indicator – Oil level satisfactory & intactness of window glass
12. Silicagel breather – No damage, clear blue coloured gel & intactness of window glass
13. Buchholz relay – No damage, arrow mark towards conservator, gas release cocks closed, intactness of
window glasses, shut off valves opened & wiring
14. Explosion vent - In good condition (No damage), no rupture in diaphragm, no oil leak from joints &
opened equalizer valve
15. Thermometer pocket – Fill it with transformer oil for temperature measurement
16. Marshalling box - In good condition (No damage) & wiring
17. Oil temperature indicator – Working to be checked by dipping its capillary sensing bulb in hot oil,
intactness of dial glass & wiring
18. Winding temperature indicator – Working to be checked by dipping its capillary sensing bulb in hot oil,
intactness of dial glass & wiring
19. CT terminals – No crack, leak free, no dust & dirt.
20. Earthing terminals – No paint, dust, dirt & tightness of earthing strip.
21. Air release plugs – Leak free, no dust & dirt.
22. Drain Valve - Leak free
23. Filter Valve - Leak free
24. Sampling Valves - Leak free
25. Shut off Valve - Leak free & opened condition
26. Oil filling Cap – perfectly tight
Important – If any rusted Corroded components found, should be cleaned thoroughly to remove the rust, dirt and
grease and paint with one coat of red oxide primer and two coats of paint. Retouching of paint may be required where
it is damaged during transit.

PRECAUTIONS
Ensure that the connecting palms on bushings are perfectly tight & aligned with each other.
Ensure that the cables & the bus bars are properly supported; No load voltage should be applied to the transformer
connecting palms.
In case the transformer is mounted on the ground, on a plinth, it should be suitably hold with necessary bolts /
stopper in its bottom to avoid any kind of movement / vibration during transformer operation.
In case the transformer is mounted on the rails, it should be suitably hold with necessary bolts & stopper also to be
provided for the rollers on the rails to avoid any kind of movement / vibration during transformer operation or earth
quack.
Check earth continuity to ensure the safety of operating personnel, the transformer earthing system must be
grounded.
Make its connections with incoming supply line on HV bushing terminals & ensure that it is perfectly tight.
All safety devices to be connected.
The clearance between phase cables shall be more than the clearance between the HV bushing terminals.

PRE COMMISSIONING SITE TEST:-

Following pre commissioning site tests should be performed before energizing the transformer, to check the
healthiness.
1. Insulation Resistance (Meager) (HV- E ,LV-E, HV-LV)
2. Voltage Ratio Test
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 3. Winding Resistance Test
4. Magnetic Balance & Magnetizing Current.
5. Oil Break Down Voltage Test ( Should be >=60 KV)

ENERGIZING
Energize the transformer with its LV terminals open circuited (No load), it should be kept charged for minimum 8
hours and ensure / check the following.
1. All protection relays must be connected to circuit breaker before energizing the transformer.
2. No abnormal Humming and stray sound
3. Satisfactory No-load / charging current
4. Satisfactory Oil temperature rise
5. All radiators are evenly hot
6. No oil leakage
7. No sparking at terminals
Load the transformer gradually and follow the maintenance schedule for trouble free operation of
transformer.

MAINTENANCE
No maintenance work to be done unless all external circuits are disconnected.
1. If a transformer is to give long and trouble free service, it should receive a reasonable amount of attention
and maintenance
2. Maintenance consists of regular inspection, testing and reconditioning where necessary
3. Records should be kept giving details of any unusual occurrence and also of any test results taken
4. The principal object of maintenance is to maintain insulation in good condition. Moisture, dirt and
excessive heat are the main causes of insulation deterioration and avoidance of these will in general keep
the insulation in good condition
5. Periodically proper checks for following should be made for smooth functioning and for any physical
damage:

1- Tap changer 9- Explosion vent diaphragm

2- Bushings 10- Temperature indicators
3- Ta nk, radia tors , cons ervator 11- Current transformer (CT) terminals
4- Oil level gauge 12- Earth pionts
5- Silicagel breather 13- Valves
6- Buchholz relay 14- Roller Assembly
7- Pressure relief valve (PRV) 15- Gaskets
NOTE: Recommended Maintenance Schedule is given in Table A.

CERTAIN CAUSE OF FAILURE IN SERVICE

1- Prolonged over heating 7- Prolonged short circuit
2- Single phase loading 8- Inadequate maintenance
3- Unbalanced loading 9- Operation of Tap switch on load in case of off
circuil tap changer
4- Faulty termination 10- Poor quality of cables
5- Power theft and Hooking 11- Improper installation
6- Wrong earth connection 12- Loose connection of cable with transformer

NOTE: Trouble shooting given In Table B

FAILURE ANALYSIS
Failure in the Magnetic circuit
1. Break down of core bolt insulation
2. Failure of insulation of laminations and of insulation between the yokes and yoke clamping frame.
3. Improper clamping of yoke laminations.
4. Burrs in lamination.
5. Abnormal air gaps at core joints, while core building / during operation of transformer
6. Variation in thickness of laminations and reduced cross sectional area of core
7. High flux density.
8. Ageing of laminations.
9. Internal or external short circuits

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 Failure in the electric circuit
1. Inter turn / Inter layer short in winding.
2. Failure of end turn of coil due to over voltage surges.
3. Conductor insulation failure due to scissoring while over clamping
4. Moisture penetration between turns causing ageing & abrasion of insulation resulting in to internal Short Circuit.
5. Frequent Electrical or Magnetic shock
6. Excess hot spot Temperature
7. Poor soldering / bracing joints / Open Circuit
8. Lightning Impulses & flash overs
9. Sustained over load
10. Internal or external short circuits
11. Failure of Tap switch
Failure in the dielectric circuit
1. Presence of moisture in oil & insulation like press board, cylinder, tubes & terminal boards
2. Excessive heat and high oil temperature accelerates formation of sludge and other contaminants.
3. Contamination or occluded air in press board (during manufacture) used for cylinder, tubes, terminal boards.
4. Narrow oil ducts are a serious menace to serviceable life of Transformer.
5. Occasional presence of metallic particles in press boards or over coils causes puncture.
6. Low Oil level causing over heat.
7. Insufficient inter phase clearance and improper positioning of barrier
8. Insufficient drying of wooden cleats used for terminal supports
Failure in mechanical structure & others
1. Casual Handling.
2. Insufficient maintenance
3. Natural calamities
4. Accidental hitting
5. Insufficient welding.
6. Corrosion
7. Improper bracing of connection cable
8. Incorrect mounting of transformer on pole or on ground
9. Fire or explosion due to Short circuit or otherwise

FOR TABLE – A & B REFER NEXT SHEETS

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 TABLE - A
RECOMMENDED MAINTENANCE SCHEDULE FOR POWER TRANSFORMERS
Inspection Action Required if Inspection shows
Sr. No: Item to be Inspected Inspection Notes
Frequency Unsatisfactory Conditions
Ambient Temp. - -
Winding Temp. Shut down the trasnformer and
Check that temp. rise is reasonable investigate if either is persistently higher
1 Hourly Oil Temp than normal
Load (Amp.)
Check agaist rated figures _
Voltage
If low, top up with dry oil,examine
Oil Level in Transformer Check against oil level of transformer
transformer for leaks
Oil level in bushings - -
2 Daily Relief Diaphragm - Replace if cracked or broken
If silica gel is pink,change by spare
Check that air passages are
Dehydrating braether charge .the old charge may be
free.check color of active agent
reactivated for use again
Bushing Examine for cracks & dirt deposits Clean or replace
Check fro diectric strength and water Take suitable action to restore quality of
Oil in transformer
content oil
Lubricate bearings.Check gear
Cooling fan bearing and Replace burnt or worn contacts of other
3 Quarterly box,Examine contacts .check manual
operating mechanism parts
control and inerlocks
Check oil in OLTC Driving
OLTC -
Mechanisms
Indoor Transformers Check ventilation -

4 Half Yearly Oil cooler Test for pressure -

Oil in transformer Check for acidity and sludge Filter or replace
Oil filled bus hings Test oil Filter or replace
Tighten the bolts evenly to avoid uneven
Gasket joints -
pressure
Check for Sealing arrangments for
Cable Boxes filling holes.examine compound for Replace gaskets ,if leaking
5 Yearly cracks
Surge diverter & Gaps Examine for cracks & dirt deposits Clean or replace
Examine relay and alarma contacts, .Clean the components and replace
Relays, Alarms, their
their operations, fuese etc ,check contacts and fuses,if necessary.
circuits etc
relay accuracy etc. Changethe setting, if necessary.

Earth Resistance - Take suitable action if resistance is high

Over all Inspection including lifting of

5 Yearly 1000 to 3000 KVA Wash by hosing down with clean dry oil
6 core and coils
7 -10 Yearly Above 3000 KVA DO DO

Note 1. With respect to OLTC,the manufacurers recommendation should be followed.

Noye 2 The silicagel may be reactivated by heating it to 150 to 200 C
Note 3 Every time the drying medium is changed, oil seal shoul also be changed
No work should be done on any transformer unless it is disconnected from all external circuits and the tank and all
Note 4
winding have been solidly earthed.

In case of anything abnormal occuring during service , makers advice should be obtained, giving him complete particulars
Note 5
as to the nature and extent of occurrence ,together with the name plate particulars in order to assist identification

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 TABLE - B
TROUBLE SHOOTING

Sr. No. Trouble Cause Necessary action

Faulty temperature indicator use calibrated temp. indicator

No oil in thermometer pocket indicates Fill oil in pocket
incorrect temp.
Radiators obstructed Ensure free air circulation around transformer

1 High temperature Over Voltage Select suitable Tap position

Reduce the load on the transformer. If temperature of oil is high, switch off
transformer till safe temperature is reached. If over load problem is occurring
Over Load for long duration, install another transformer in parallel. If ambient
temperature is higher than the considered in specification of transformer, de-
rate the transformer
Variation in Ratio Low or high input voltage Select suitable Tap position.
Transformers fail due to sustained over voltage, provide over fluxing
(Low or high out put protection and over voltage protection for bus bar. Flux density depends
Thermal effect of short-circuit
2 voltage) upon E/f ratio. Operate transformer at a most appropriate tap position so as
to get the rated out put voltage on LV side. Generator
currents on contact of tap switch Mal - adjustment of tap changer, Replace tap switch

Defect in winding Repair winding

Burnt-off leads on windings due to poor

Loss of voltage on quality of brazed / crimped joints or Apply megger or measure winding resistances and locate a point of
3
secondary side electro-dynamic forces in the wake of a interruption. Inspect transformer active parts.
complete short- circuit

Variable input voltage Control input voltage

Faulty measuring meter Use calibrated instrument

4 High exciting current
Loose magnetic circuit Needs correction in core assembly

Shorting of winding Needs winding replacement / correction

Wet terminals Dry the terminals

Faulty instrument Use calibrated instrument

5 Low IR Value Deteriorated gaskets of bushing Change bushing gaskets

Deteriorated gaskets of bushing perform filtration of oil / replace oil

Moisturized windings & insulation Bake dry winding & use new oil

Cracks in porcelain shells; low oil level in

Replace porcelain bushing & eliminate the cause to avoid further defect in
transformer and dirt on internal surfaces
bushing
of porcelain shells

Lightning Impulses Check meggar / Replace LA if required

6 Bushing / LA flash over Dust & dirt deposition Clean insulators & LA

Carbonized connection clean the connection

LA earth connection is long & curved LA earth connection to be short & straight

Ineffective discharge of earth current LA to be connected to low impedance ground for effective discharge

Moisture Change breather / silica gel / Oil Filtration

Sludge & other impurities Oil Filtration

Oil top up using inferior oil Refill new & filtered oil having BDV >= 60 Kv
Incorrect measurement technique/
7 Oil sample failure Test oil at recognized / certified test lab
method/ instrument
Excessive over-loading Cause should be determined and corrective action to be taken
Conducting particles on insulation surface creates sparking in oil
Carbon and other conducing particles in
temperature increases excessively causing reduction in insulation resistance
oil
and failure by tracking. Transformer needs overhauling

8 Magnetic Circuit failure Refer "Failure in Magnetic circuit" Cause should be determined and corrective action to be taken

Natural ageing or wear of insulation:

repeated over loads; dynamic forces due
9 Electric Circuit failure to complete short-circuit. Over current protection, Earth-fault protection, Differential protection

Note - Refer "Failure in Electric circuit"

Deterioration of gasket / poor fit of
Replace gasket
gasket
Leakage through loose bolts Tighten the bolts to correct torque
10
gasket / welding Impairment of welded or flanged joints as
a result of mechanical or temperature Chip out the area & re-weld perfectly
factors
Loose plugs, bolts & accessories Tighten the bolts & accessories

Presence of water Oil top up using inferior oil Top up / Refill with new & filtered oil having BDV >= 60 Kv
11
inside the transformer Variable loading of transformer Avoid loading the transformer with frequent variations

Frequently varying ambient conditions X

Power supply upset and load, Loose
12 Unusual Noise Restore normal condition, Tightening of loose parts
parts
Damage of Fitting & Casual handling
13 Careful handling, avoid accidents & replace faulty item
accessories Accidental actions

Though the Transformer windings are made to withstand external short-

Frequent external short Insufficient clearance on overhead lines, circuits, the overhead lines shall have safe clearance. Insulator shall be
14
circuits. accumulation of dust on insulators, cleaned at regular intervals Transformer should be provided with over
current protection.

11