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2.1 Introduction Transformer Is The Most Important
2.1 Introduction Transformer Is The Most Important
1 Introduction
Transformer is the most important unit in an electrical distribution network. All transformers
are subjected to thorough tests at the manufacturer’s works before despatch to the
destination of erection.Due to limitations in transport, large capacity transformers are dis-
assembled into various components before despatch. At site, the transformers are re-
assembled with the various components like bushings, coolers, conservator etc. and then the
internal body is dried out to remove the surface moisture sticking to the paper insulation
during exposure at site. As erection of transformers involve assembly of various components,
pre-test inspection of transformers have greater importance than other parts of an electrical
system. The following paragraphs explain the pre-test inspections/pre-commission checks
and the pre-commission tests to be conducted on power transformers prior to energisation of
the unit.
2.2 Recording the salient parameters
As the service life of a transformer is expected to cover very many years, it is necessary to
record the salient parameters of the transformer for future reference. Rated capacity, rated
voltage ratio,connection, make, maker’s serial number, year of manufacture, date of
completion of erection,insulation dry out details at site etc. may be documented in a register
as permanent record. It is also necessary to record the serial number, rating and make of
various components like bushings, tap changer, tap changer control cubicle, cooler control
cubicle, cooling fans, oil pumps, Buchholtz relay,temperature indicators, heat exchangers, oil
flow meter, water flow meter, pressure gauges, oil level gauge etc. For easy reference, the
details of the main body and various components may be recorded in separate pages of a
register. This register will serve as a record of the service of the transformer.Details of
replacement of components may also be recorded in the same register.
2.3 Pre-commission checks
Before commencing the pre-commission tests, it is necessary to visually inspect various
parts,components and accessories of the transformer and also to conduct operational check
for various protective devices. Check lists may be followed for the visual inspection and the
operational checks so that the pre-commission checks are conducted in a systematic manner
and also that no check/test is omitted. Model check lists for General checks and Functional
checks are given at the end of thischapter in Appendix 2.1 and 2.2 respectively.
2.3.1 General checks
(i) General arrangement
The General arrangement of the electrical installation shall be checked for concurrence with
the
scheme approved by the Department of Electrical Inspectorate. Special emphasis may be
given to the
following:
· size of cables
· size of bus bars
· size of bus trunking
· size of earthing conductors
· adequacy of various clearances
· spacing between supports
· ventilation
· oil drain facilities
· fire protection walls
· fire fighting arrangements
(ii) Terminations
The transformer terminal connections may be checked for the following:
· flexibility and area of cross section of flexible connections at bushings
· clearances of live jumper connections from transformer tank and accessories
· socket size
· perfection of crimpings
· tinning of contact surfaces to prevent bimetalic action
· clearances inside cable end box
· clearances of bus bar trunking
· conformity of cable end box with the relevant IP( Ingress Protection) classification
· correctness of cable glanding and adequacy of cable gland earthing or pig tail
· support of cables at terminations and unsupported lengths
(iii) Perfection of connections
Connections to the following shall be checked for proper surface contact, seating and
tightness.
· to bushings
· to the tap changer
· to earth leads
· to control and protective cables
· to thermometers
(iv) Earthing
Check the size of earthing conductors, tinning of contact surfaces, area of contact and
seating,effectiveness of bolting, socketing, riveting, welding etc.for the earthing of the
following:
· Duplicate earthing for neutral and body
· Main tank and top cover
· Fan motors
· Pumps
· On Load Tap Changer (OLTC) chamber
· Tap changer driving gear
· Divertor switch
· Cable glands/termination
· Marshalling box
(v) Control cable connections
Check the control cable connections between the following
· transformer accessories and marshalling box
· marshalling box and sub-station panel
· tap changer control cubicle and sub-station panel
(vi) Radiator
Check the radiator for release of air and position of valves. The valves shall be in open
position.
(vii) Main conservator and OLTC conservator
Check the oil level in the main conservator and OLTC conservator . The conservator shut off
valve in the Buchholtz relay pipe line shall be in open position.
(viii) Bushings
Check the oil level in the bushings if sealed bushings are used. Release air from bushings if
air release plugs are provided.
(ix) Breather
Check the oil level in the oil seal of the breather. Check the colour of the silica gel in the
breather .
(x) Cooler units, fans and pumps
Check fans and pumps for proper mounting. The number of fans and their position on the
radiators shall be in conformity with the general arrangement drawings.
· Check the direction of rotation of cooling fans and pumps
· Check the direction of oil flow
· Check flow of water in heat -exchangers
· Measure the Insulation Resistance (IR) of fans and pumps
· Check the settings for operation of fan motors and oil pumps
· Check the cooler unit for correct indication of oil flow and setting of the thermometer
(xi) Winding Temperature Indicator (WTI) and Oil Temperature Indicator (OTI)
· Check whether thermometer pocket is filled with oil
· Check whether the connections of the CT for winding temperature indicator to the
thermometer pocket is properly made as per the instructions given on the WTI terminal box.
· Check whether the contacts of WTI and OTI for alarm and trip are set at required
temperatures depending upon ambient temperature and loading conditions. For oil filled
transformers, the maximum permissible temperature rise above the ambient temperature is
usually taken as 450C for oil and 550C for winding. In the case of cast resin transformers, the
alarm contact of the winding temperature relay is usually designed to operate at 1400 C and
trip contact at 1600 C for transformers upto 1000 kVA. For higher ratings, the temperatures
are 1600 C and 1800C respectively.
· Calibration of the WTI/OTI may be checked with hot oil. Working of the WTI/RTD repeaters
shall be checked at the control room.
(xii) Buchholtz relays
· Check the angle of mounting of the Buchholtz relay using a spirit level
· Check the floats for free movement
· Release air in the Buchholtz relay
· In the case of forced oil cooled transformers, make sure that the Buchholtz relay does not
operate when the pumps are switched on
xiii) Magnetic Oil Level Gauge
Move the float level of the oil level indicator up and down between the end positions to ensure
that the mechanism does not get stuck at any point. The low oil level alarm of the gauge shall
be checked.
(xiv) Arcing horn gap
Check arcing horn gaps of bushings for conformity with standard values. The standard values
are given below:
The transformer IR values in oil drained condition will be 15 to 20 times more than in oil filled
condition.
Influence of temperature on IR
IR. values decrease sharply with the rise in temperature of the oil. The following correction
factors may be used for arriving at the IR value with difference in temperature.
Repeat the test at different tap positions by lowering and raising taps. The current measured
in the HV winding should tally with the calculated value of HV short circuit current.
Wide difference between the measured and calculated values of HV short circuit current is an
indication of loose contact in tap changer or lead connections.
2.4.7 Measurement of Magnetising current
The magnetising current is measured to test any fault in the magnetic circuit and winding. The
measured values are compared with the factory test values. A balanced three phase 415V ac
supply is applied to the LV winding and the simultaneous current readings of the three phases
are taken using low range a.c ammeters of the same accuracy class. For a core type
transformer, the middle phase magnetising current will be approximately half that in other
windings. In YyO, Dy1 and Dy11 connections, the currents in ‘u’ and ‘w’ phases will be nearly
double the current in ‘v’ phase. In a Yd1 connected transformer, currents in ‘v’ and ‘w’ phases
will be nearly equal and the current in ‘u’ phase more than that in ‘v’ and ‘w’ phases. In a
Yd11 connection, currents in ‘u’ and ‘v’ phases will be nearly equal and the current in ‘w’
phase more than that in ‘u’ and ‘v’ phases. If the measured values widely differ from the
above values or from the factory test values, there is reason to suspect some defect in the
transformer core and the manufacturer may be consulted. The
measured values of magnetising current may be used as bench marks for the service life of
the transformer. Sample format for recording the magnetising current is given below:
Appendix