SOUTHERN POWER EQUIPMENT COMPANY PVT LTD.

,
BANGALORE

CONTENTS

1. Handling, Receipts and Storage

2. Installation

3. Commission

4. Operation

5. Periodic Maintenance

• Daily
• Quarterly
• Half-Yearly
• Yearly
• 5/7 Yearly

6. Trouble Shooting

7. Useful I.S Specifications for Transformer

8. Drawings.
1. HANDLING RECEIPT AND STORAGE

1-1 HANDLING:
For lifting Transformer, use appropriate lifting devices and lugs. Weight of
the heaviest package has been indicated on it. Do not use Lugs provided for
partial lifting e.g for active part, conservator, etc or other parts for lifting
transformer. Use all lugs to avoid undue stressing. Ensure slings do not touch
components.

RECEIVING:

Transformer should be carefully examined for Transit Damages. External

damages can indicate severe internal damages.

Similarly, packed components should also be carefully unpacked and

examined for Transit damages.

Check that all materials listed in the Packing Slip/Delivery Challan are
received.

All shortages and transit damages must be immediately reported to the

suppliers.

1-2 STORAGE:
When required to store for longer duration.
i. Fit the Silica gel breather
ii. Check weekly that colour of silica is blue.
iii. Keep Transformer energized at a low voltage.
iv. Jack up the Transformer and assemble rollers to allow free flow
Of air from its bottom.
v. The tap changer must be operated once in six months throughout its
entire range.
vi. Accessories like Bushings, Buchholtz Relay, Thermometers, Radiators
and associated pipe work should be stored indoor.
vii. Oil drums should be stored in a covered space with their curved
surface on the floor and their bungs 45o down wards.
2. INSTALLATION

2-1 DOCUMENTS REQUIRED:

i. General Arrangement Drawings of Transformer, Cable Box Marshalling
Box etc
ii. Schematic and Wiring Diagrams of O.L.T.C, R.T.CC, Marshalling Box
etc., Ensure that drawings match with the apparatus supplied
iii. Service Manual.
2-2 EQUIPMENT AND TOOLS REQUIRED:
i. Crane or chain pulley block along with wire rope, slings and D-
Shackles.
ii. Transformer Oil Filtering Machine with hoses. Capacity such as to
Complete one pass in 8 to 10 hrs.
iii. For EHV and Large rating Transformers:
a. A Vacuum pump
b. Oil Storage tank
iv. Set of spanners
v. Set of drum opener, crowbar, pipes, hammer, vinyl hose to draw oil
samples, and to serve as oil level indicator.
vi. Set of screw drivers, cutting pliers, screw spanners, pipe wrench.
vii. Clean cotton cloth.
viii. Oil BDV tester.
ix. 500, 2500, 5000 V Megger as per Winding Voltage.
x. Voltmeters, milli-ammeter.
xi. Multi Meter
xii. P.V.C Wires
xiii. Electric Hand Lamp
xiv. Brushes for painting
xv. 25mm dia Manila Rope for bushing mounting
2-3 INSTALLATION:
i. Locate Transformer in a well ventilated place, leaving working space all
Around.
ii. Provide Rails for rollers.
iii. Provide Oil Soak Pits and Separation Walls when required.
iv. Assemble the dismantled components taking below-mentioned:
a. Main tank: Lock the rollers.
b. Bushings: Check for hairline cracks. Fully tighten test tapcap {used in
condenser bushings for tan delta measurement}.
c. Conservator and MOG :Check oil level in Transformer and OLTC
 conservator. Remove MOG locking lever.
d. Buchholz Relay :Release Buchholz Relay floats. If test lever is
provided, it must be the ‘S’ {service} position. Arrow direction must be
towards Conservator.
e. Breathers: Main tank and OLTC are sometimes provided with separate
Breathers. Transformer breather will be bigger compared to OLTC
breather. Ensure that they are fitted accordingly. Check that color of
silica gel is blue. Remove seas closing the openings.
f. Radiators: Assemble only one radiator at a time. Let each radiator
draws oil. Final tapping up should be only upto the filling mark.
g. Marshalling Box: Fill oil in OTI and WTI packets. OTI and WTI
bulbs must be lifted in respective pockets. Identifying labels are fixed
near these pockets.Wire the terminals properly.
h. All other fittings.
2-4 EARTHING:
Solidity earth the Transformer tank using the 2 Pads/bushes provided.
Similarly earth Cable Box, Marshalling Box, etc.
3 COMMISSIONING:

3-1 CONFIRM HEALTHINESS OF ACTIVE PART BY THEFOLLOWING

TESTS:
i. Insulation Resistance: Bushing surface should be cleared using Carbon
Tetra Chloride. Read value 1 minute after voltage application. Note
Temperature. This measurement shall be done when weather is dry and
Clean.
ii. Ratio
iii. Magnetizing Balance
iv. Magnetizing Current
v. Short Circuit
vi. Vector Group Check
3-2 CONFIRM PROPER CONDITIONS OF:
i. Characteristics of Oil in min tank, OLTC, Cable Box {if oil filled}
by checking BDV AND PPM values as given below:
Sr.No. Characteristic Voltage Class Recommended
{HSV} Values
1. BDV {Min} 72.5KV 40KV {rms}
72.5 145KV 50KV {rms}
145KV 60KV {rms}
2. PPM {Max.} 72.5KV 25ppm
72.5 145KV 20ppm
145KV 15ppm

ii. Oil level in main Tank/OLTC Conservators, Main/OLTC breather,

 Cable Box{if oil filled} OTI AND WTI Packets.
iii. Silica Gel Colour in Breathers of Transformer/OLTC {Blue}
3-3 CONFIRM FOLLOWING VALVES/COVERS/CAPS ARE TIGHTLY
CLOSED:
i. All sampling, drain and filtration valves.
ii. Conservator oil filling cap.
iii. Air release value of Buchholz Relay.
iv. No Oil leakage from any where.
v. Test tap caps of all condenser bushings.
3-4 CONFIRM FOLLOWING VALVES ARE FULLY OPEN:
i. Top and Bottom Values of all Radiators.
ii. Values on either side of Buchholz Relay.
iii. OLTC Oil Surge Relay Shutt Off value.
iv. Main Tank to Cable Box Value { if provided}
3-5 CONFIRM PROPER OPERATION OF:
i. Tapping Switch/OLTC
ii. Alarm and Trip contacts of OTI, WTI, MOG, Buchholz Relay, OSR {on
OLTC}, Pressure Release Value {whichever are provided}
3-6 CONFIRM RELEASE OF:
i. Air from all Bushings, all Bushings Pockets, Buchholz Relay,Main Tank
Cover, all Radiators, OSR, OLTC Tank Cover.
ii.Locks of MOG, Buchholz Relay,OSR.
iii.Sealing Tapes of Breather of main Tank and OLTC.
3-7 CONFIRM PROPER SETTINGS OF:
i. Arcing Horn Gaps on HV and LV Bushings.
ii. Alarm and Trip Temperatures on OTI typically –95c T-105 C
iii. Temperatures on WTI for starting and stopping of cooling fans {if
provided}
iv. Pressure on Pressure relief value{if provided}
v. release on circuit Breakers and Current and time settings on Relay {if
provided}.
vi. OLTC/Off circuit switch in desired positon and properly locked.
vii. Current Ratio in case of multi-ratio CTs.

3-8 CONFIRM THE FOLLOWING:

i. All Bushing surfaces are clean.
ii. All External connections are tight.
iii. Main Tank,Cable Boxes, additional Neutral C.T., Secondary Terminals
are properly earthed.
iv. Arrow Heads of Buchholz Relay and OSR are painting towards respective
conservators.
v. Roller locking, if provided, has been done.
vi. There is no oil seen in explosion Vent Slight Gas –if provided.
 Vii Diaphragm at the top end of explosion Vent is intact.
vii. Marshalling Box/Fan Control Cubicle/R.T.C.C. Panel are duly wired
and earthed.
4. OPERATIONAL:
CONTROL ON ‘HOURLY’ BASIS FOLLOWING:
Sr. No. Item Recommended Action
H1 Load Current If more than ‘rated’, reduce non-priority
loads.
H2 Voltage Control appropriate voltage –H.V Voltage of
H.V Variation and L.V Voltage for L.V
variation. If OLTC is provided, change Tap
Position appropriately. If off circuit tap
switch is provided observations of several
days can suggest a change in Tap Position.
H3 OTI and WTI Check that observed temperatures are not
Readings. high for the prevailing load and ambient
temperature.

5. PERIODIC
5-1 DAILY
Sr. Item Recommended Action
No.
D1 Oil levels in Transformer Check oil levels in respective conservators.
and OLTC Check that they are commensurate Ambient
Temperature and Load. If low, top up with dry
Transformer oil. Examine Transformer for leaks.
D2 Explosion Vent Diaphragms Observe for oil in the sight glass of Explosion
Vent. If present, indicates that lower Diaphragm
is bust. Proceed as per trouble-shooting
instruction Sr.No.7. If absent, confirms
healthiness. Observe upper Diaphragms. If
broken replace.

D3 Breather on Transformer and Checks colour of Silica Gel. It should be blue. If

OLTC Pink, replace by a spare charge. Charge
removed should be heat treated for next usage.

D4 Oil level in condenser Oil should be seen in the sight glass, otherwise,
Bushings refer to Bushing Service Manual for further
action. Different manufacturers have different
recommendations.
5-2 Quarterly
Sr. No Item Recommended Action

Q1 Bushings Clean the surface, Examine for Chips and

Cracks. If necessary replace.
Q2 Fan Motors Lubricants bearings off an Motors. Check
controls and interlocks. Replace worn out
contacts.
Q3 OLTC driving mechanism Check oil level. Add if required.

Q4 OLTC controls and Check all circuits independently. Check step

interlocks by step operation including limit switches.

Q5 Breathers on Transformers Check oil level in oil cup.

and OLTC

Q6 Ventilators {For indoor Check that air passages are free.

Transformers

5-3 HALF-YEARLY Recommended Action

Sr. No. Item
HY1 Cable Boxes, Gasketed Inspect, Make good any deficiency noticed.
joints, gauges, external
paint.

5-4 YEARLY
Sr.No Item Recommended Action
Y1 Oil Transformer Check for {I} Die electric Strength, {ii}Water
Content, {[iii}Acidity,{iv} Sludge.
If the MVA and importance justify, test for
dissolved Gas analysis.
Y2 Gasket Check for tightness. If required, tighten.
joints,Cable
Box, Covers, etc. Clean, if dirty. Replace porcelain if cracked.
Y3 Surge Diverter Arcing horns Check for satisfactory operations and
Y4 Relays Alarms, etc settings.
Take suitable action if it measures high,
Y5 Earth resistance compared to the initial value.
5-5 5/7 YEARLY
5Y1 Overall Inspection 5 Yearly for Transformers rated 3000KVA and
below.

Overall Inspection 7 Yearly for Transformers greater than

3000KVA.
Lift core and coil assembly. Wash by hosing
down with clean dry oil. Tighten clamping
nuts pressing the coil assembly and top and
bottom yokes.
Tank the core – coil assembly in shortest
possible time but not more than 8 hours.
Circulate tank oil at 70 C for 2 passes by
means of Filter Machine.

6. TROUBLE
SHOOTING
Sr. Symptom Possible Causes Recommended Action
No.
1. Alarm in OTI or a} High Ambient Check OTI setting and if required,
WTI Temp. adjust setting appropriate to
Ambient Temperature.

b} Insufficient Cooling Check dust, cement, coal etc.,

deposits on Tank and Radiator
surfaces. Oil leakage is conducive
to dust collection.
c} Overload Clean the affected surfaces.
Check load current. If greater than
rated, reduce load other than
priority load.
d} Sludge formation in Check oil for sludge. If required
oil. filter oil
2. Alarm in MOG a} Oil level gone down Top up conservator with fresh, dry
Transformer oil.
b} Terminals shorted in Clean terminals and their
Terminal Box. surrounding space.
3. Alarm in a} Oil level gone down Top up conservator with fresh, dry
Buchholz Relay transformer oil.
b} Terminals shorted Clean terminals and their
in Terminal Box. surrounding space.
c} Gas collected in Release gas, observe whether alarm
Buchholz Relay. comes again and after what time.
Carry out dissolved Gas Analysis
{DGA}. Check with previous results
and identify the fault. If
required, take manufacturer’s
help.
4. Output Voltage Incorrect Tap Position Check whether tap position
High or Low Matches the input voltage. If not
and if provided with an OLTC,
adjust proper tap position.
If provided with an off circuit
switch, observe the consistency of
voltage for a few days. If justified,
change tap position with due
precautions.
5. Leakage through Insufficient or uneven Check and if required tighten Nuts
threaded joints or compression. and Bolts.
at gaskets.
6. Leakage from Imperfect weld Repair leaks by welding.
welds.
7. Oil explosion A}Internal Fault Conduct Ratio and M.B tests and if
Vent fault is indicated, identify the fault.
8. Excessive B} Improper joints. Tighten loose parts and all joints.
Audible Noise

7. USEFUL I.S SPECIFICATIONS FOR TRANSFORMER

i. I.S 10028 {Part –II} –1981
Code of Practice for selection, Installation and
maintenance of
Transformers –Installation.
ii. I.S 10028 {Part –III} –1981
Code of Practice for selection, Installation and
maintenance of
Transformers – Maintenance.
iii. I.S 1866:1983 – REAFFIRMED 1991
Code of Practice for maintenance and supervision of
mineral insulating oil
in equipment.