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Best practice guide for

power transformer
maintenance

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Maintenance Inspection Tasks

Despite there being many tests available to
evaluate power transformer condition,
experience shows that visual inspection is very
effective, and sometimes the only way, to
detect certain power transformer problems.
Maintenance engineers know this. This best
practice guide provides a list of the various
inspections that may be applied to a power
transformer, either in or out of service.

Checking transformer fans and radiators

Infrared Thermography
Infrared thermography is a technique that
provides an image of invisible infrared light
emitted by objects due to their thermal
condition without any direct contact with the
scanned object. This technique can be used to
detect a defective connection on transformer
bushings, hot spots on surge arresters,
blocked cooling systems, and circulating
currents affecting localized overheating of the
tank wall, or to confirm oil level.

For compartment type OLTCs, infrared

thermography can sometimes detect abnormal
heating of degraded contacts (coking, low
pressure) or other malfunctions that cause
temperature rise on the compartment.

Such problems are easily discerned on these

OLTC designs because the OLTC
compartment is normally cooler than the main
tank, and any IR scan that shows to the
contrary should trigger an investigation.

Figure 1 – Thermography inspection of the power

transformer

Main Tank and Conservator

The tank contains the transformer active
element (core and coil assembly) and its
insulating fluid. An on-load tap changer
compartment can also be included in the
assessment of tank condition. The integrity of
the tank is dictated primarily by its mechanical
characteristics. The tank must hold pressure
and should not leak.

The integrity of the tank depends primarily

on the condition of:

the gasket containing surfaces,

the hand hole, manhole, and tap changer
door gaskets,
and the integrity of tank welds.

Deficiencies are detected by

observing oil leakage. The inability
to adequately seal a tank may
render a tank environmentally
unacceptable for its current
installation. External sealant repair
systems, involving specialty sealants
and unique hardware containing
gasket provisions, may also prove
effective in stopping leaks.

The tank should also be inspected for

indications of deformation. Tank deformation
may result from extreme pressure or electrical
arc experienced during a fault, improper
foundation support, and for spare
transformers, frequent installation and removal.

Figure 2 – Transformer oil tank

The integrity of a bladder may be checked in

service by inserting a swab stick with a cotton
cloth on the end through the bladder access
port in the top of the conservator tank and
gently swabbing the inside of the bladder. If
the cotton swab becomes saturated with oil,
this indicates that there is a leak in the
bladder, and it must be replaced.

Transducers that can detect rupture

include:

A capacitive transducer that detects

contact with oil
A gas collection relay mounted in the
head of the conservator to detect air

The oil level in the conservator

system should be checked regularly
to make sure that it is at the proper
level and to verify there is no
undetected oil leak in the
transformer. There is normally a
25°C gradation mark on the oil level
gauge to use in adjusting the proper
oil level.

In the past, conservator tanks were not

necessarily designed to withstand full vacuum.
In these designs, whenever a vacuum is
applied to the main tank, the valve between
the main tank and the conservator tank must
be closed. However, most modern conservator
tanks are designed for full vacuum and the
valve should be left open. In all cases, the
transformer manual or manufacturer should be
consulted.

The desiccant for the bladder type conservator

system should be checked regularly and
replaced when it reaches the end of its
moisture removal capability. Operating such a
system with a non-functioning desiccant,
(especially in a humid environment) can allow
moisture to enter the tank, or cause the
bladder to age prematurely.

Figure 3 – Transformer bladder failure relay

The following actions can be performed on

the main tank:

Check for oil leaks, re-seal if necessary

Check for paint damage and corrosion,
repair if necessary
Check oil levels in all compartments
Check air drier and main conservator
bladder – refill or replace if necessary
Check air freezer – if installed
Check grounding of the main tank and
neutral terminals
Check electrical insulation for tank base
where fitted
Check the status of all valves before
putting back into service

Where silica gel is used for air-

drying, the color change in the
silica gel indicates that the silica gel
is saturated with water and that the
air passing through the breather will
remain humid. During the inspection,
silica gel replacement should be
done when more then 50% of the
material has changed colour.

Moreover, the color change should be

observed to start from the fresh air input side
only (where air first enters the breather on its
pathway toward the conservator). If the silica
gel changes color on the conservator side of
the breather, or if the color of the silica gel
remains unchanged after several months, then
this indicates there is air leakage in the
connection piping allowing air to bypass the
breather.

Figure 4 – Transformer breather

Cooling System
Oil Pumps
Visual inspection of the transformer oil cooling
circuit components should be performed
regularly and usually not exceeding every 12
months. Oil Pumps should be manually
energized to ensure proper operation. Any
significant noises (grinding, rubbing, scraping,
oil flow cavitation) should be noted,
investigated further, and corrected. Flow
gauges should indicate full flow without
fluctuation. All areas including piping, valves
and the surrounding ground area must not
show evidence of oil leakage.

Pumps equipped with a bearing condition

monitor should have readings taken annually
to ensure bearing integrity. Pumps with ball
bearings are particularly vulnerable to in-
service failure. Therefore, their replacement by
pumps with sleeve bearings should be
considered.

Figure 5 – The evidence of oil leaking from oil pump

Radiators and Fans

Fans should be manually energized to
ensure proper operation. Similarly to the oil
pumps, significant fan motor noise or fan
imbalance shudder should be noted,
investigated further, and corrected. Fan blade
guards must be maintained for the safety of
personnel. Obvious obstructions to the through
airflow caused by debris should be noted and
cleaned.

Periodic infrared imaging of the radiators

should be made to ensure proper oil flow and
heat transfer. All areas including piping,
valves, and the surrounding ground area must
not show evidence of oil leakage.

Typical oil leakage points

include pipe work flange
joints, valve stems, oil
pump electrical
connections, radiator
headers, and air bleed
plugs.

Figure 6 – Checking transformer fans and radiators

Forced Oil-Air Coolers

Forced Oil-Air Coolers are used on many
generator step-up transformers and mobile
transformers, and some substation
transformers. These coolers depend upon both
the full airflow from their fans and full oil flow
from their associated pumps, in order to
provide the amount of cooling required to
dissipate the transformer losses.

Without both the fans and pumps operating,

these coolers are essentially non-functional.
Depending on the environmental conditions
where the transformer is in service, after
several years the coolers may deteriorate to
the extent that they approach their end of life.
One or more of the following conditions may
cause the premature end of life for these
coolers.

Transformer Cabinets
As most accessories are connected through
the Transformer Cabinet, this component
requires special attention. The following
inspection tasks are suggested:

Check power supply, back-up feed, and

its signaling
Check functionality of anti-condensation
heaters
Tighten screws and clean contacts on all
current-carrying parts
Check service hour counter, if installed

Figure 7 – Operator in action for inspection of Terminal

box of power transformer

Buchholz Relay Operation and

Recommended Actions when It
Operates
This section provides guidance on the
possible causes of Buchholz relay
operation and recommends actions following
the receipt of a Buchholz surge trip or gas
collection alarm. It covers both operational
situations and situations that arise during the
commissioning of new transformers.

Buchholz relays installed on the transformer

main tank have two elements described in
more detail below:

Gas Collection Element

This element collects any gas escaping from
the transformer and closes a contact when the
gas volume reaches a certain limit. If gas
continues to be produced after this limit is
reached, it will escape out of the relay into the
conservator and no further operation will take
place. The transformer should have been
carefully designed to avoid any internal
pockets where gas can collect so that any gas
bubbles will rise through the pipework to be
collected in the relay.

The gas collection element operates when a

certain volume of gas is collected. Therefore it
gives no direct indication of the rate of gas
production.

Figure 8 – Checking the Buchholz Relay

Oil Surge Element

Primarily, this element is pre-set to operate
and close contact at a certain oil velocity
through the relay. This will correspond to the
oil flow expected during an arcing fault where
oil surges from the main tank towards the
conservator.

However, this element will not operate on gas

collection because the relay is designed to
accumulate only a set volume of gas before
allowing all excess gas to pass on to the
conservator. This releases the excess gas
before it can reach the level of the surge
element float, allowing an oil surge event to be
discriminated from a gas collection event.

Secondly, if for any reason the oil level in the

relay should drop (for example if the oil is
escaping from the transformer and the oil level
drops below the level of the relay), then this
element will also operate.

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Title: Best practice guide for power

transformer maintenance –
Working Group A2.34 (C.
Rajotte ( CA) – (Convener), TF
Leaders: M. Foata (CA), P.
Jarman (UK), F. Larese (FR), P.
Lorin (CH), B. Pahlavanpour
(UK), J.P. Patelli (FR), J. Velek
(CZ), R. Willoughby (AU), R.
Barrento (PT), P. Boman (US), I.
Diaconu (RO), A. Drobyshevski
(RU), Y. Ebisawa (JP), T.
Fagarasan (RO), N. Fantana
(DE), H. Gago (ES), J. Gebauer
(DE), P. Gervais (CA), M.
Krüger (AT), G. Lawler (IR), R.
Maina (IT), C. Moldoveanu
(RO), P. Mueller (CH), D. Olan
(CA), L Paulhiac (FR), M. Pena
(BR), E. Perez-Moreno (ES), S.
Quintin (ES),V. Samoilis (GR), F.
Simon (FR), A. Shkolnik (IS), B.
Sparling (CA), P. Warczynski
(PL))
Format: PDF
Size: 2.12 MB
Pages: 123
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