IS : 8478.

1977

Indian Standard
[

( Reaffirmed 1996 )

APPLICATION GUIDE FOR ON-LOAD TAP-CHANGERS

Second Reprint JANUARY 1991 )

ULX

621.314.214.332

Copyright 1978 INDIAN

BUREAU

OF

STANDARDS

MANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARG NEWDELHIllOOU2

Gr3

January

1978

IS : 8478. 1977

Indian Standard
APPLICATION GUIDE FOR ON-LOAD TAP-CHANGERS
Transformers Sectional
SHKI U. K.

Committee,

ETDC

16

Chairman PATWAHDHAN Prayog Electricals Pvt Ltd, Bombay ReprerenCing Members Bharat Heavy Electricals Ltd (R&D Unit), Bhopal SHRI S. AMMEERJAN Tamil Nadu Electricity Board, Madras SHRI N. S. S. AROK~~WAMV SHRI M. K. SUNDARARAJAN (Alternate) SWRI B. G. BHAKEY Kirloskar Electric Co Ltd, Bangalore DR B. N. JAYARAM (Alternate) SHRI A. V. BHEE~IARAO Gujarat Electricity Board, Vadodara SHRI J. S. IYER (A&mate) SHRI S. D. CHOTRANEY Bombay Electric Supply and Transport Undertaking, Bombay SHRI Y. K. PALVANKAR(Alternate) DIRECTOR(TRANSMISSION) Central Electricity Authority, New Delhi DEPUTY DIRECTOR(TRANSMISSION) (Altemate) SHRI T. K. GHOSE Calcutta Electric Supply Corporation Ltd, Calcutta SHRI P. K. BI~ATTACHARJEE (Alternate) Research, Designs and Standards Organization JOINT DIRECTOR(SUB-STATION) (Ministry of Railways), Lucknow DEPUTY DIRECTORSTANDARDS (ELECTRICAL)(Alternate) Directorate General of Supplies and Disposals SIIRI J. K. KHANNA (Inspection Wing), New Delhi SHRI K. L. GARB (Alternate) SIIRI B. S. KOCHAR Rural Electrilication Corporation Ltd, New Delhi SFIRIR. D. JAIN (Alte,mtcj SIIRI J. R. MAHAJAN Indian Electrical Manufacturers Association, Bombay SHRKP. K. PHILIP (Altej/late) Tata Hydro-Electric Power Supply Co Ltd, SHRI D. B. MEHTA Bombay SHRI R. CHANDRAMOULI (Alterna?) SHRI D. V. NARKE Bharat Heavy Electricals Ltd, Bhopal SHRI ISHWAKCIIANDRA (A&mate I) SHRI PREM CIIAND (Alternate II), SIIRI I. S. PATEL Hindustan Brown Bovcri Ltd, Bombay (Continued on page 2)
I

0 Oe

Coprright

1978

BUREAU

This publication is protected under and reproduction in whole or in part by any means except with written permission of the publisher shall be deemed to be an infringement of copyright under the said Act.

INDIAN STANDARDS the Zndiun Copyright Act (XXV of 1957)

IS : 8478- 1977
(Continued from page 1)
SHRI V. N. PRAZILAD SHRI A. G. GURJAR (Alternate) SHRI K. N. RAMASWAMY

Members

National Electrical Industries Directorate General New Delhi

Refwesenting

Ltd, Bombay
Development,

of Technical

SHRI S. K. PALHAN (Alternate) Pradip Lamp Works, Patna SHRI CHANDRA K. ROHATCI SHRI D. P. SAHGAL Siemens India Ltd, Bombay SHRI A. R. SALVI (Alternate) Delhi Electric Supply Undertaking, New Delhi SHRI I. C. SANGAR SHRI R. C. KHANNA (Alternate) NGEF Ltd, Bangalore SHRI K. G. SHANMUKHAPPA SHRI P. S. RAMAN (Alternate) SHRI.M. A. SHARIFF Karnataka Electricity Board, Bangalore SHRI B. C. ALVA (Alternate) Andhra Pradesh State Electricity Department, SUPERINTENDING ENGINEER(OPERA(Electricity Projects and Board), Hyderabad TION) SUPERINTENDING N G I N E E K E TECHNICAL (PROJECTS)(Alternate) SHRI C. R. VARIER Crommon Greaves Ltd, Bombay SHP.I S. V. MANERIKAR (Alternate) * SI~RI T. RAJARMAN, Director General, IS1 (Ex-o#cio Member) Deputy Director (Elec tech)

Secretary
SHRI VIJAI Deputy Director

(Elec

tech),

IS1 ETDC 16 : P5

Panel for On-Load Cowener

SHRI D. V. NARKE

Tap-Changers,

Bharat Heavy Elcctricals Ltd, Bhopal

SHRI S. C. AGARWAL (Alternate to SHRI D. V. NARKE) Tatd SHRI R. C. CHANDRAMOULI SHRI S. V. MANEIUKAR SHRIV.N.PRAHLAD SHRI A. G. GURJAR (Alternate) SHRI c. s. N. RAJU

Members

Hvdro-Electric Power Supply Co __ Bombay Crompton Greaves Ltd, Bombay National Electrical Industries Ltd, Bombay Ltd, Bangalore

Ltd,

NGEF

IS : 847% 1977 -

APPLICATION GUIDE FOR ON-LOAD TAP-CHANGERS

0. FOREWORD 0.1
This Indian Standard was adopted by the Indian Standards Institution on 24 May 1977, after the draft finalized by the Transformers Sectional Committee had been approved by the Electrotechnical Division Council. 0.2 In the preparation of this standard assistance has been derived from IEC DOC: 14 (Central Office) 9, Draft application guide for on-load tapchangers, issued by the International Electrotechnical Commission. 0.3 For the purpose of deciding whether a particular requirement of this standard is complied with, the final value, observed or calculated, expressing the result of a test, shall be rounded off in accordance with IS : 2- 1960. The number of significant places retained in the rounded off value shodd he the same as that of the specified value in this standard.

1. SCOPE 1.1 This application guide is intended to assist in the selection of suitable on-load tap-changers for use in conjunction with the tapped windings of transformers or reactors (referred to as transformers in the following text).
NOTE 1 -All the tap-changers referred to shall be presumed to comply with the requirements specified in IS: 8468-1977t. NOTI% 2 -The provisions of this application guide are not mandatory and only represent advice to the tap-changer manufacturers and purchasers. The responsibility for the correct application of the fully assembled tap-changer in connection with the tramformer is with the manufacturer of the transformer.

2. SELECTION

OF A TAP-CHANGER

2.1 General - Since the on-load tap-changer represents only a small part of the total cost of the equipment in which it is used, it should be freely chosen to suit the ~equipment. However, account should be taken of the available standard types of tap-changers. 2.2 Insulation Level - The following values occurring on all tapping positions of the transformer should be checked against the tap-changer manufacturers declared values in accordance with IS : 8468-1977t : a)
*Rules

Normal power frequency tap-changer in service,

operating

voltages

appearing

on

the

for rouhding off numerical values (revbd). tspecification for on-load tap-changers.

IS : 8478 - 1977 1~) Power frequency voltages appearing tests on the transformer, and c) on the tap-changer during

can be abnormally high, for cxamplc, star-point tappings in auto-transformers, line-end tappings, and booster transformer arrangements. Ihrsc voltages can br aKectcd considerably by the choice of linear, coarse/fine or revrrsing lapping arrangcnxnts. Variable flux voltage variation (VFVV) and combined voltage variation (cbVV) as defined in IS: 2026(Part IV)-1977* also can affect the voltages appearing on various parts of the tap-changer.

Impulse voltages appearing on the tap-changer during tests on the transformer or in service. NOTE- With some winding arrangements the voltages appearing on thr transformer

2.3 Current - Ihc tap-changer in 2.3.1 to 2.3.3.

should

satisfy

the

conditions

specified

2.3.1 Rated Through-Current - The rated through-current of the tapchanger as defined in IS : 8468-1977t should not be less than that resulting from the highest value of tapping current of the tapped winding of the transformer [sue 4.1 of IS : 2026 (Part I)-1977$]. which 19724, stated other The

2.3.2 Overload Current -

When tap-changers are fitted on transformers are subjected to overload conditions in accordance with IS : 6600they shall generally be restricted to the occasional overload conditions in 4.1 of IS : 2026 (Part I)-1977: unless specifically ordered for overload conditions by the transformer manufacturer. above requirements are met: if the maximum rated through-current of the tap-changer is at least a) 1.2 times the highest tapping current of the transformer, or

if the tap-changer manufacturer is able to demonstrate that the temperature rise limits given in 8.5 of IS : 8468-1977t are not exceeded when the contacts carry 1.2 times the maxinium rated through-current. (The values of current to apply for the other tests specified in 8 of IS : 8468-19771_ remain based on the value of the maximum rated through-current.) The number of tap-changer for each occasional overload period is limited to the number of operations corresponding to one half of one complete operating cycle and the peak temperature rise of the transition resistors does not exceed 300C for oil-environment tap-changers. Where tap-changers are subject to overload conditions not in accordance with the limitations stated in IS : 2026 (Part I)-1977: with regard to IS : 6600-19729, the tap-changer manufacturer should be consulted giving current magnitude and duration so that the correct tap-changer can be recommended for the duty required. .

b)

*Specification for power transformers: Part IV Terminal markings, tappings and connections (first r&ion). tspecification for on-load tap-changers. $3pecification for power transformers: Part I General (Jirst r&&n). Guide for loading of oil immersed transformers.

PS : 8478 - 1977 2.3.3 Short-Circuit Current - The short-circuit current of the tap;changer as given in 8.7 of IS : 8468-19.77* ghould not be less than that resulting from the overcurrent of the associated transformer as given in IS : 2026 (Part I)-1977t.
NOTE - Particular booster transformers. of tap-changer. care should be taken to check this current on low impedance and In some instances, the fault-current value could dictate the choice

2.4 Breaking Capacity -The highest tapping current and the voltage per step of the transformer shall be within the values of rated throdghcurrent and relevant rated step voltage declared by the tap-changer manufacturer for the particular tap-changer. For values outside of those declared, be consulted. the tap-changer manufacturer should

For application to individual transformers with different currents and step voltages, the transition impedance shall be designed so that the switched current and recovery voltage in the tap-changer do not exceed those covered by the type tests.

NOTE - In certain applications, such as furnace transformers, the tap-changer may be called upon, if required, to operate during periods of momentary overloads of two to three The diverter switch or selector switch times the transformer continuous maximum rating. should be chosen so that it is capable of meeting this condition. Where appropriate, the effect of variable flux voltage variation and combined voltage variation on the step voltage, and in consequence on the breaking capacity should be considered.
The number ofinherent tap positions of the tap-changers is generally standardized with various manufacturers equipment. The selection of the number of service tap positions shou!d preferably be made within that range. As the extent of the tapping range increases, the voltages to be catered for also increase and care shall be taken to avoid excessive voltages over the tapping range when operating or testing at minimum winding positions. The effect can be very marked on furnace and rectifier transformers feeding electrolytic plant where wide tapping ranges tit-e often necessary and the tap-changer is in the constant voltage winding (variable flux voltage variation). 2.6 Discharge Problems with Changeover Selectors - It should be noted that, under certain conditions, tap-changers with changeover selectors In such cases, can allow momentary disconnection of the tapped winding. discharges between the opening and closing contacts can occur during the operation of the changeover selector, and in order to avoid difficulties with regard to the dielectric stress and the formation ~of gases which could arise when the tap-changer operates under high voltage to earth, s ecial precautions shall be applied. There are many different metho a s of over*Specification for on-load tap-changers, TSpecification for power transformers: Part I General (first revision). 5

2.5 Number of Tapping Positions -

IS : 8478 - 1977 coming the problem, resistors, or capacitive portion of the winding the use of two-way changeover selectors, control control between the main winding and the tapped are some examples.

2.7 Mechanical Life - The mechanical duty may need consideration if the expected number of operations per annum exceeds 20 000, for example, this can occur on transformers for use on rolling mills, electrolytic plant or furnace supplies. 2.8 Motor-Drive Mechanism - If the motor-drive mechanism is purchased from a manufacturer other than the manufacturer of the tapchanger then it is the purchasers responsibility to ensure that the motordrive mechanism is suitable for all its necessary duties. 2..9 Pressure and Vacuum Tests when fully assembled has to withstand its associated transformer. For these, changer manufacturer have to be taken Where applicable, the tap-changer all the pressure and vacuum tests of the relevant instructions of the tapinto account.

2.10 Low Temperature Conditions - Should the tap selectors, diverter switches or selector switches be located in separate containers outside the main transformer tanks, in air, and the ambient temperature be lower than -5C, it is advisable to specify the quality of the insulating and/or lubricating oils. Shouldthe tap selectors, diverter switches or selector switches be located inside the main transformer tank and the oil temperature can be lower than -5C during operation, the tap-changer manufacturer shall be consulted, taking the quality ofthe main transformer oil into consideration. If necessary, automatically controlled heating devices could be provided or, alternatively, means of preventing tap-change operation at abnormally low temperatures may be considered. 2.11 Continuous Operation - If the tap-changer is required to operate continuously the temperature conditions may need to be checked and the tap-changer manufacturer should be consulted. 3. LOCATION OF OIL-IMMERSED COMPONtiNTS TAP-CHANGER

3.1 Tap Selectors - Unless otherwise agreed between thr manufacturer and the purchaser, the tap selectors may be located within the main transformer oil. 3.2 Diverter and Selector Switches - To prevent contamination of the main transformer oil, oil-immersed diverter or selector switches should be in a separate container which may be located inside oroutside the main transformer oil. When located in the main transformer oil, it is not necessary for the container to be absolutely oil-tight, providing that precautions are

IS : 8478 - 1977 taken to avoid any mixing of the switch oil with the transformer oil and that the oil in the container can be changed easily without lowering the oil in the main transformer tank. Where appropriate, arrangements should bc made for it to be made clear in the transformer maintenance instructions that the main transformer oil should not be drained until all of the oil leas been removed from the diverter switch container. If an oil-tight 4. FIELD container is required it should bc spcciliccl by the p~~rchascr.

SERVICE devices as may be considered necessary with the manufacturers instructions. ~h~ul~l be

4.1 Safety of Operation 4.1.1 Such protective connected in accordance

4.1.2 In order to minimize switching under excessive overload or .&ortcircuit conditions, it is recommended that, in the case of motor control, a protective device should be fitted to prevent, ar if initiated to interrupt, an operation of the motor-drive mechanism when the transformer load The protective device may be in the form of a exceeds the agreed value. contactor in the motor-drive mechanism. NATE - In the case of manual control, protective devices are not considered necessary

as it is not normal practice to tap-change manually during periods of overload and the probability of coincidence of a tap-change operation under short-circuit conditions is negligible.

4.2 Parallel Operation - In the case of parallel operation of transformers with-tapped winding, care should be taken by the manufacturer and the user of the transformer to ensure that the currents circulating between the transformersare limited to an acceptable value. 4.3 Contact Erosion and Oil Contamination - Tap-changers have expendable items in their construction and the manufacturers figures should be noted for maintenance periods in terms of time and in numbers of operations. Generally, expected contact life for a particular tap-changer is given at rated through-current. If the load current of the transformer is less than this value, contact life is increased. The number of operations before oil-change is necessary, is conditional on the oil being in good condition originally and maintained in a dry state. For good utilization of the tap-changer, it is necessary to follow the mai tenance instruction book of the tap-changer manufacturer which general 3y gives the above as a function of: a) rated through-current, and b) the service duty of the transformer. REQUIRED WITH ENQUIRY OR ORDER following

5. INFORMATION

5.1 In order that the correct tap-changer can be supplied, the information should be given by the transformer manufacturer. 7

KS : 8478- 1977 5.1.1 Xatity

a) b) c) d) Relevant Number Number otld General Indian Bata Standard. required. units.

of tap-changers or polyphase

Single-phase

of phases in system. to which the tap-changer the tap-changer is to is to be

cj Frequency. fj J<atcd power, in I<VA, of apparatus

IK connected. g) Rated voltage connected. of the winding

to which

11 Winding j j)

connections. the

Tapping range required given as percent above and below rated voltage of the winding [see IS : 2026 (Part IV)-1977].

lr) Number of service tap positions ~required, the numbering of these positions and their identification with reference to the transformer lappings. m) Tapping arrangement, that is, linear, reversing or coarse/fine. n) p) q) r) Position point. of tappings in winding, for exampJe, line end, middle, star-

Highest tapping current of the winding to which is to be connected [see IS: 2026 (Part IV)-1977*]. Maximum value and duration through the tap-changer. of short circuit

the tap-changer current passing

Phase voltage per step (if the step voltage varies give full details together with associated currents). On star-point tap-changers, neutral terminal4 required. if one neutral terminal

over the range, or three separate and

compo-

sj
t)

The power frequency voltage appearing between the opening closing contacts of the changeover selector (see 2.6).

NOTE - The power frequency voltage has two componet+, that is! an inductive nent and a capacitive component, during the time the windmg is dlsconnected.

5.1.2 hulation
frequency a) voltage

I;evel The following impulse test value should be given:

voltage

and

power

Highest voltage between the extreme tappings and, where applicable, the highest voltage between the ends of the coarse tapping winding section and the fine tapping section. voItage voltage between between the most onerously tapping of adjacent stressed phases. tapping and

b) Highest earth. c) Highest

*Specification for power transformers: Part IV Terminal markings, tappings and connections (@t revision).

IS d) Highest ej Highest f) Highest

NOTE -

: 8478 - 1977

voltage voltage voltage Vacuum

between between betkeen

partial

the diverter switch and earth. phases of the diverter switch.. open diverter switch contacts.
and switching impulse levels should be given.

If applicable,

discharge

5.2

Pressure, a) b) c) d)

and Temperature

Requirements

Maximum working pressure when oil-filled. Maximum pressure during oil-tests on the apparatus. Maximum vacuum to be applied. Type of processing, maximum temperature, vacuum and duration if the tap-changer is fitted before this operation. e) Temperatures in s,>ecial environments, for example, noise enclosures, etc. f) Minimum ~operating temperatures and details of any special low temperature requirements if below -5C.

5.3 Special a) Details of periods of overload, value and duration (see 2.3.2 and _IS : 6600-1972*). b) Details of duty of apparatus, for example, distribution transformer, arc furnace tranSfOrJnCr, etc. c) Details of transport of transformer. d) Any special reqltircments of the specification. 5.4 Fittings - Items standard, for cxamplc, not covered by the tap-changer valves, should bc spccikd. manufacturers

5.5 Motor-Drive Mechanismro enable the correct control devices to be included in the Jnotor-drive mechanism the fullest possible details of the control scheme should be given, including any of the following basic together with the type of device necessary control functions if required, for the function. Local electrical control and indication. Remote electrical control and indication. Automatic control and indication, with or without line drop compensation. Parallel control of two or more transformers. Supervisory control and indication. In the case of remote and supervisory control and indication, the approximate distance between the tap-changer and the control point should be stated. Auxiliary supply details for electrical motor and control equipment, that is, normal voltage, maximum and minimum voltage limits ifnot within the standard limits given in 9.2 of IS : 8468-l 977t, If ac, frequency, number of phases and availability of ac or dc. neutral.
*Guide for loading of oil-immersed transformer+ ~Specilicntion for on-load tap-changers.

BUREAU
Headquarters:

OF

INDIAN

STANDARDS

Manak Bhavan, 9 Bahadur Shah Zafar Marg, NEW DELHI 110002 Telephones: 331 01 31, 331 13 75 Telegrams: Manaksanstha ( Common to all Offices ) Telephone I 331 01 31 331 1375 36 24 99

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