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 e-T FOTECH 2020- International Conference on Transformers

From the Desk of Chairman of Organising Commi ee

Dear Readers,

It is my privilege and honour to present the e-T FOTECH 2020 Journal.

e pandemic has put most of the business sectors in an unprecedented state
of ux and agility in adapting & responding to the new world order has
become the need of the hour. Amongst the affected sectors, the power sector
has truly emerged as a savior, demonstrating resilience and perseverance,
keeping the lights on amidst nationwide lockdowns in many parts of the
world. Although it seems that the worse is over, I believe that the impact on
society will be long and partly unforeseen. e industry and the people
behind it will have to unlearn and re-learn a new language and grammar.

While we all have been affected in one way or the other and had to adjust our life style drastically, It opened up a
lot of opportunities for the sector by paving way for landmark reforms, policy changes and de ning the future
roadmap towards resiliency, energy transition and the drive to be self-relaint. It gives me immense pleasure to
bring this edition of e-Trafotech journal which is a rich collection of interesting papers around the theme
“Transformers – Today & Tomorrow” that address the challenges & provide possible solutions related with
Power Transformers.
You will nd some high-quality papers on the timely topics such as speci cation enhancement, adaption to
latest standards and trends in transformer design. It also covers the broader spectrum of reliability of the
transformer & its sub-components, emerging monitoring techniques, digitalization and asset maintenance.

Before I say goodbye, I would like to put on record, my sincere thanks to all Authors who have contributed and
entrusted us with the publication of their valuable work. And above all my heartfelt appreciation to all the
members of the Organizing & Technical Commi ees and IEEMA Secretariat colleagues, whose untiring
efforts have resulted in ensuring that the proud legacy of the T FOTECH Conference is sustained and
be ered, year a er year.
ank you all for continuing to support Trafotech and pray that your families & you stay safe and healthy.

Shouvik Bha acharya

Chairman, IEEMA Power Transformer Division
 e-T FOTECH 2020- International Conference on Transformers

From the Desk of Chairman of Technical Commi ee

Dear Readers,

It is my privilege and honor as Chairman of the Technical Commi ee to

present your e-TrafoTech’2020 Journal. During the current pandemic crisis,
companies are forced to rethink their business strategies with a new normal
way of remote working despite several challenges and have affected our
lifestyle drastically. But it has also opened a lot of opportunities for the sector.
e chosen theme of this e-TrafoTech’2020 is “Transformer for Today and
Tomorrow” is more apt in present dynamic grid environment. A glance
through the list of technical papers and keynote speeches will reveal the
diversity of topics wri en by domain experts to align with the theme and
relevance to stakeholders.

Day-1 papers are bid stage and OEMs factory oriented. ey focus on speci cation enhancement proposals, In-
depth design, trends in manufacturing of transformers, emerging trends in bushings technologies to achieve
reliable product performance at the site. Day 2 papers are Sub-vendor and System oriented. ey focus on the
selection of critical components like bushings, tap changers, accessories & emerging technologies of online
monitoring, and digitalization systems for transformers. Day 3 papers are customer and site-speci c. ey focus
on Best practices of site management - right from storage, transportation, site installation, commissioning,
relevant reliability-based maintenance, repair, and case studies of failure restoration. I expect that study of this
conference journal will help in-depth learning on EHV transformer and reactor to enhance our engineering
knowledge.

Before I say goodbye, I would like to put on record, my sincere thanks to all authors & keynote speakers who
have contributed and entrusted us with the publication of their valuable work. Also, I wish to thank Mr. Shouvik
Bha acharya, Chairman of Organizing commi ee and IEEMA Transformer Division for his support and
guidance. Let me thank and appreciate all members of e-Trafotech TC, Advisory Commi ee and OC
commi ee members including Mr. Neeraj Goyal, Co-Chairman, Mr. R Prakash, Mr. Imteyaz Siddiqui and Mr.
Ramachandran and all technical paper evaluators for helping me to shape up the technical papers in the shortest
possible time. My sincere thanks to IEEMA secretariat team under Mr. Pande and Mr. U am Kumar for their
hard work for the past several months in planning and executing this conference.

ank you all for continuing to support Trafotech and pray that your families & you stay safe and healthy.

C. Jayasenan
Chairman, Technical Commi ee, e-TrafoTech’2020
 e-T FOTECH 2020- International Conference on Transformers

Organising Commi ee

Chairman
Mr. Shouvik Bha acharya
Siemens Ltd.

Mr. Neeraj Goyal, Vice Chairman Schneider Electric India Pvt Ltd
Mr. Imteyaz Siddiqui ISA Advance Instruments (I) Pvt. Ltd.
Mr. R. Prakash Easun-MR Tapchangers (Pvt) Ltd.
Mr. Gunjan Agrawal Power Grid Corporation of India Ltd
Mr. Y V Joshi Gujarat Energy Transmission Corporation Limited
Mr. Rajib Chaudhary Toshiba Transmission & Distribution Systems (India) Pvt. Ltd.
Mr. Shashi Prasad Cargill India Pvt. Ltd.
Mr. Vinamra Agarwal Technical Associates Ltd.
Mr. Manoj Rai Chha isgarh State Power Transmission Company Limited
Mr. P K Patnaik Odisha Power Transmission Corporation Limited
Mr. Rajarshi Ghosh Calcu a Electric Supply Corporation Limited
Mr. Sameer Gaikwad Doble Engineering Company
Mr. Sharat Chandra Shirdi Sai Electricals Limited
Mr. M Purushothaman Prolec GE
Mr. S K Ray Mohapatra Central Electricity Authority
Mr. Ruchir Mayank GE T&D India Ltd.
Mr. Keyur Shah Yash Highvoltage Insulators Pvt. Ltd.
Mr. Sanjay Vyas CTR Manufacturing Industries Limited

Mr. U am Kumar
Organising Secretary
 e-T FOTECH 2020- International Conference on Transformers

Technical Commi ee

Chairman
C. Jayasenan
Siemens Ltd.

Mr. Vikrant Joshi GE T&D India Ltd.

Mr. Anirudh S. Jhala Transformers & Recti ers (India) Ltd.
Mr. Maneesh Jain GE T&D India Ltd.
Mr. Nagarjuna Babu Nannapaneni Shirdi Sai Electricals Limited
Mr. Gautam Mazumder CG Power and Industrial Solutions Ltd.
Mr. S K Gupta Bharat Heavy Electricals Limited
Mr. Tarun Garg Hitachi ABB Powergrids
e-T FOTECH 2020- International Conference on Transformers

Advisory Commi ee

Mr. P Ramachandran Sr. Consultant

Mr. Virendra Lakhaini
Mr. M Vijayakumaran
Mr. B N De Bhowmick
Mr. B P Soni
Sr. Consultant
Prime Meiden Limited
Power Grid Corporation of India Limited
Gujarat Energy Transmission
Corporation Limited
e-T FOTECH 2020- International Conference on Transformers

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SPONSORS
e-T FOTECH 2020- International Conference on Transformers

DIAMOND
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e-T FOTECH 2020- International Conference on Transformers

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INDEX

Day & Date Topic Author

Technical Session-I: Standard specifica ons and emerging trends
Day 1: Keynote- CEA standard specifica on of EHV Mr. S.K Ray Mohapatra
5th Nov, 2020 transformer & Shunt reactor Chief Engineer - PSETD Division
1630 Hrs. to Central Electricity Authority
Ministry of Power, Govt. of India
2000Hrs.

Specifica on enhancements and alignment with Mr. Shashank Kulkarni

standards. Team Leader – Electrical Design
Siemens Ltd.

Latest trends in Transformer design & Mr. Vikrant Joshi

Manufacturing. PTR Scien fic Leader
GE T&D India Limited
Effec ve procurement process of EHV Mr. S.K.Gupta
transformer & Shunt reactors AGM
BHEL, Jhansi

Emerging Technology of Bushings Mr. Lars Liden

Product Marke ng Specialist
Bushings and tap-changers
Hitachi ABB Power Grids Sweden

Session Moderator Mr. Tarun Garg

Engineering Manager, Power Trf.
Hitachi ABB Power Grids
 e-T FOTECH 2020- International Conference on Transformers

Day & Date Topic Author

Technical Session-II: Reliability of OLTC/Bushings and digi sa on
Day2: Applica on Guideline and fail-safe opera on Mr. Shrikant B. Potnis
6th Nov, 2020 of on Load Tap Changers Chief Execu ve Officer
1630 Hrs. to Easun MR Tap Changers Pvt. Ltd.
2000Hrs.
Selec on & applica on of Bushings, tap Mr. A.S. Jhala
changers, accessories Transformers & Re c fiers

Role of Digital system for transformer Mr. P.K.Patnaik

applica on- U li es perspec ve Dy. General Manager ( Electrical)
Odisha Power Transmission
Corpora on Ltd.

Digitaliza on & Emerging Online monitoring Mr. Thomas Buijs

devices Hitachi ABB Power Grids

State of art tes ng at factory (including Mr. Rakesh Pa l

remote FAT) for dielectrics, losses, thermal & Chief Manager – Quality Management
emissions Siemens Ltd.

Session Moderator Mr. Vikrant Joshi

PTR Scien fic Leader
GE T&D India Limited
 e-T FOTECH 2020- International Conference on Transformers

Day & Date Topic Author

Technical Session-III: Best prac ces in site management
Day 3: Par al Discharge in EHV Transformers and Mr. Stephen Heberer
7th Nov, 2020 Reactors and their monitoring and diagnos cs Vice President System
1630 Hrs. to Altanova Group
2000Hrs.
Best prac ces in storage, transporta on, site Mr. Adish Kumar Gupta
erec on and commissioning Chief General Manager
Power Grid
Reliability based maintenance & trends in Mr. Gunjan Agrawal
condi on assessment DGM (Engineering-S/S)
Power Grid Corpora on of India Ltd.

Site Repair and Refurbishment Mr. Gautam Mazumdar

Assistant General Manager-
Transformer Service
CG Power and Industrial Solu ons
Limited

Restora on & overhauling case studies a er Mr. A J Chavda

major breakdowns Superintending Engineer (Tes ng &
Condi on Monitoring)
GETCO

Session Moderator Mr. B P Soni

I/C Superintending Engineer (Engg.)
GETCO
Panel Discussion: One Na on- One Mr. S.K. Ray Mohapatra
Specifica on( Standardiza on of Specifica ons Chief Engineer, PSET&D
of Power Transformer & Reactors) d Central Electricity Authority
Mr. P Ramachandran
Sr. Consultant & Transformer Expert

Representa ve from PGCIL* – Name

to be confirmed shortly
Session Moderator Mr. C Jayasenan
Chairman, Technical Commi ee
 e-T FOTECH 2020- International Conference on Transformers

DAY

01 Key Note Papers

 e-T FOTECH 2020- International Conference on Transformers

CEA STANDARD SPECIFICATION

FOR EHV T NSFORMERS AND REACTORS
S. K. Ray Mohapatra
Central Electricity Authority - Ministry of Power (Govt. of India)

ABST CT
Transformer and reactor are vital and expensive asset in
power delivery chain. Quality, reliability and availability
of such important assets plays crucial role in achieving
the ultimate objective of delivery of uninterrupted
(24x7) quality power to all consumers at affordable rate
and smooth operation of Power System. e of 220kV and above voltage levels as on Sept’2020).
standardization of technical speci cation of transformer
& reactor incorporating the best practices & state-of-art
technology is the need of hour to ensure quality,
reliability and long & trouble-free service. ere may be
nancial implication on the overall cost of transformer or
reactor due to standardization of certain technical
parameters, xation of losses, inclusion of certain speci c
construction features and use of speci c component &
material etc. However, if the overall Life Cycle Cost
(LCC) is taken into consideration, the bene t will
ultimately outweigh the initial increase in cost. e
ultimate goal of “One Nation One Speci cation” would
be always in the overall interest of the Power System of
the country.
Key Words: Standardization, Life Cycle Cost (LCC),
One Nation One Speci cation
1. INTRODUCTION
Growth of Power Sector is crucial for economic and
industrial growth of the country. e growth of Indian
Power Sector is phenomenal. e present installed
generation capacity including generation from
Renewable sources, peak demand, energy requirement
and planned future expansions are as follows:
Year Installed Peak Energy
Capacity demand in BUs
(Renewable) In GW
in GW
Sept’2020 373 (88) 170 ~1400
2020-21 480 (175) 226 1566
2029-30 830 (440) 340 2325
Matching with the installed generation capacity, a vast
power Transmission (both HVAC and HVDC) and
Distribution network is spread across the country with
highest transmission system voltage of 765kV AC and ±
800kV HVDC (>430,000ckms of transmission network
e phenomenal growth of Indian Power transmission
system has resulted in the formation of one of the
“Largest” Single Synchronous Grids (One Nation One
Grid) in the world. e transmission system establishes
the vital link between the generating source and the
distribution system connected to the ultimate
consumers. A Robust, Reliable and Optimally Planned
transmission network would facilitate in achieving the
ultimate objective of delivery of 24x7 Quality Power to
all consumers at affordable rate. In coming years, huge
generation capacity addition including large scale
integration of generation from renewable sources,
expansion of electricity market and power exchange
between India & neighbouring countries would further
require commensurate expansion & strengthening of the
associated Transmission & Distribution network. e
increase in demand for energy will further require
enhancement in transformation capacity as well as
reactive compensation requirement.
e present transformation capacity in substations
(≥220kV voltage levels) is about 985GVA (as on
Sept’2020) and is expected to increase to about
1105GVA by the end of current plan period ending on
2021-22.
India has >600 manufacturers of transformer are there,
out of which about 35 are manufacturers of ≥66kV
voltage class transformers and 9 manufacturers have the
 e-T FOTECH 2020- International Conference on Transformers
capability and facility for manufacturing transformers
and reactors upto 765kV class. e estimated
manufacturing capacity of transformers and reactors in
India is about 500GVA per annum including distribution
class transformer (power transformer about 325GVA
per annum & Distribution Transformer about 175GVA
per annum).
e complexity of Indian Power System has increased
manifold over the years. With operation of multiple
agencies (State Utilities, Central Utilities, and Private
players) in power sector, high availability & reliable
operation assumes tremendous importance in present
scenario. In such a scenario, the major assets of a power
system would play an important role not only in terms of
investment but also in terms of availability and reliability
of the system.
Transformer and reactor are the vital and expensive
assets in Power delivery system. Reliability and
availability of such assets play important role in smooth
operation of a power system. Emphasis needs to be laid
o n i m p roved d es ig n , q u a l i t y co nt rol d u r i ng
manufacturing, use of right components/accessories,
maintenance and safety during operation of such vital
assets. Generally, due to poor quality of raw material,
workmanship, manufacturing techniques or due to
normal and abnormal stresses of the system during the
operation (like frequent system faults, over loading,
environmental effect, unexpected continuous operating
voltage and over voltage stresses), and poor maintenance
practice, transformers/reactors fail much before their
expected life span (expected life span of about 35 years).
e failure of such vital equipment can have a signi cant
economic impact due to high cost, long lead time in
procurement, manufacturing and installation. A failed
transformer usually takes a few weeks to replace, if spare
is available, or months to a year for major repair or to
build / procure a new unit.
2. NEED AND BENEFIT OF
STANDARDIZATION
In present Tariff Based Competitive Bidding (TBCB)
regime, it is the fact that the focus has shi ed more
towards commercial / nancial aspect. e quality &
reliability has been sidelined, leaving everything at the
mercy of service provider who is supposed to maintain
the assets for 25-35 years. In such scenario, the
importance of standardization increases manifold and
the role of standardization becomes very crucial.
Moreover, in order to support “Make in India” (MII)
initiatives of Government of India (GoI) with an
ambitious goal of “Local to Global”, standardization of
speci cation, including stringent quality control,
inspection & testing norms as per relevant national /
international standard for equipment & associated
component / material can only bring quality of
manufactured product and enhance the acceptability in
International market.
ere is no uniform practice across the utilities in the
Country as far as the technical speci cation of
transformer/reactor is concerned. At present, same
rating/class of transformers/reactors are being designed
differently even for the same user. Even for same
speci cations, manufacturer review design for successive
tenders considering prevailing market condition. is
resu l t s i n u n n ecessar y i n c rea se i n d es ig n &
manufacturing cycle time, cost, human efforts &
inventories. In view of above, there was need to address
this issue and develop a standard/common design &
engineering speci cation for transformer & reactor
incorporating the best practices of various utilities, latest
technological development and future trends, which
would be followed by utilities & reputed manufacturers
across the Country.
is standardization process shall have following
advantages:
• e procurement process will be simpli ed, and
delivery time would be reduced resulting in early
completion of project.
 e-T FOTECH 2020- International Conference on Transformers
• Due to standard design, frequent design reviews can be
avoided.
• Standard ratings and standard civil foundation block
would facilitate interchangeability of different make of
transformer / reactor
• Standard ings & accessories
• Lesser requirement of inventories
• e overall efficiency, quality and productivity in the
entire value chain of transformer / reactor procurement
and operation would be enhanced.
3. CENT L ELECTRICITY AUTHORITY
(CEA) STANDARDIZATION OF
SPECIFICATION FOR EHV T NSFORMERS
AND REACTORS
Keeping in view above objective and initiative of IEEMA
in above direction, Ministry of Power (MoP), Govt. of
India had constituted a commi ee under the Leadership
/ Chairmanship of CEA with representation from stake
holders, power utilities and manufacturers.
e objective of this initiative was to discuss & deliberate
in detail to formulate a standard document bringing out
critical technical parameters of transformer and reactors
which affects the quality, reliability, efficiency and cost of
such assets by adoption of best practices and latest
technological developments.
Important points considered while preparing this
document are as under:
• Standardization of ratings of transformer / reactor at
different voltage levels and limiting it to frequently used
ratings of Power transformers (PT), Generator
Transformers (GT) and Shunt reactors (SHR)
• Fixation of component losses for transformers (No load
loss, I2R loss, load loss and auxiliary loss) & shunt
reactors (I2R loss and Total losses) to eliminate the need
for capitalization of losses.
• Provision of tertiary and On Load Tap Changer
(OLTC) (Conventional & Vacuum type)
• Use of Resin Impregnated Paper (RIP) / Resin
Impregnated Synthetic (RIS) bushings in place of Oil
Impregnated Paper (OIP) bushings at higher voltage
levels.
• Standardization of rating and dimension of bushing end
termination inside the transformer / reactor including
the space for Bushing Current Transformer (BCT)
• Standardization of various technical parameters like
BIL (including BIL for 230kV and 110kV class) for
winding and bushings, temperature rise, %Impedances,
tap range & steps and location of taps, oil parameters etc.
• Digitalization of Remote Tap Changer Control
(RTCC) and integration with Bay Control Unit (BCU) /
Supervisory Control & Data Acquisition (SCADA)
system
• Short Circuit (SC) Testing and similarity criteria with
reference to Short Circuit tested transformer as per
relevant standard
• Design review & mode of design review
• Basic Manufacturing facility at manufacturer’s works
• Manufacturer Quality Plan (MQP) and various test
plans at manufacturer’s works & at site during erection &
commissioning
• Transportation, handling, loading-unloading, erection,
testing and commissioning; checks a er receipt at site
and storage at site etc.
• Introduction of Virtual inspection and testing as an
alternative to conventional practice of physical presence
of representative of utility at manufacturer’s works
during inspection & testing.
• Interchangeability of transformers & reactors of
different make on same foundation block
• Roles and responsibilities of utility and manufacturer
during the warranty period
• Condition assessment / monitoring aspect, different
diagnostic methods / tests to assess the health of
transformer & reactor and for planning of run, refurbish
and replacement decision.
Brief Highlights of the Document
a) e ratings of transformer and reactor has been
standardized for frequently / commonly used ratings,
which includes 17 rating of Power Transformers (765kV
Class: 1, 400kV Class: 6, 220kV Class: 4, 132kV Class: 3
& 66kV Class: 3); 5 ratings for GTs (765kV Class: 2,
400kV Class: 3); 8 ratings for Reactors (765kV Class:2,
400kV class: 4, 220kV Class: 2).
 e-T FOTECH 2020- International Conference on Transformers
b) e xation of maximum permissible loss values for
transformers (No load loss, I2R loss, load loss and
auxiliary loss) and reactors (I2R loss and Total losses)
has been done in consultation with utilities and
manufacturers. e method of calculation of losses has
been explained along with a typical example for verifying
the guaranteed values and measured value at
manufacturer’s works so that all utilities across the
country get transformer and reactor of similar quality
and efficiency. Manufacturer would be penalized heavily,
if losses measured during Factory Acceptance Test
(FAT)/Routine tests are within +2% of tolerance,
beyond which transformer/reactor would be liable for
rejection. However, no incentive would be given to
manufacturer for maintaining the losses less than the
speci ed values. It has been proposed to review the loss
gures periodically based on the feedback from utilities
and the manufacturers.
c) In general, the tertiary windings have been removed in
case of 3 limbed transformers (upto 200 MVA, 220kV
class transformer) to eliminate the possible failure due to
tertiary winding, improve reliability and reduce overall
cost. Unless there is special requirement like loading the
tertiary, utilities have been advised to avoid tertiary
winding in transformers up to above mentioned ratings.
d) Keeping in view the infrequent use of OLTC and no
signi cant voltage control/variation is being achieved by
such use at 400 kV and 765 kV levels, it has been decided
to have tap less 765/400/33kV ICTs in order to simplify
the design, eliminate failure due to OLTC, reduce the
overall cost of transformer and improve the reliability of
transformers. Based on the experience & feedback of the
manufacturers and utilities, further initiative can be
taken to have tap less transformers at lower voltage
level(s) depending on system operation requirement.
Reduction in tap range in case of other voltage class
transformer will simplif y the tap changer and
transformer connection. Hence, utilities have been
advised to explore the possibility of reduction in the tap
range in OLTC depending on their requirement and
system condition.
e) e bushing is one of the major causes of failure of
transformer and in many cases, this has led to severe
consequences like re/burning of transformer/reactors
and explosion. Hence, RIP/RIS bushings have been
speci ed at various voltage levels in place of conventional
OIP bushings. RIS would have been a be er/preferred
alternative to OIP, but due to limited manufacturer in the
world, both RIP & RIS options have been considered.
f ) e technical speci cation covers performance
parameters like hot spot temperature, suitability to
withstand various over voltages (TOV, over voltage due
to Lightning and switching operations), thermal SC
withstand capability (2 secs. for ICTs / 3 secs. for GT /
SAT) & dynamic SC withstand capability, broad
construction features of winding, core, tank, bushing,
conservator, other ings and accessories (valves, WTI,
OTI, PRD, SPR / PRRR, Buchholz relay etc.), technical
parameters like insulation levels of winding & bushings
(LI, LIC, SI & PF), normal current of bushing, type of
cooling, OLTC (location, range & no. of steps),
maximum temperature rise of oil & winding, cooling &
on load tap changing system and associated digital
control integrated with BCU / SCADA system, oil
parameters, and technical parameters of BCT etc. e
insulation level of terminal bushings has been considered
as one step higher than corresponding winding
insulation level. e information to be provided on rating
& diagram plate and the format listing the Guaranteed &
other technical parameters to be furnished by the
manufacturer have also been included.
g) e requirement of SC testing has been emphasized in
line with the provision of CEA (Technical Standards for
Construction of Electric Plants and Electric lines)
Regulations and repetition of SC test is not required
provided the similarity can be established with reference
to the SC tested transformer.
h) Emphasis has been given to design review, which is the
most important task to be carried out before
commencement of the manufacturing of transformer /
 e-T FOTECH 2020- International Conference on Transformers
reactor to ensure its quality. e design review may be
carried out by the purchaser or a consultant appointed by
the purchaser. Design Review carried out by one utility
for a speci c transformer of a particular make, can also be
used by another utility for the same design with the
consent of the manufacturer. e standardized
Guaranteed Technical Particulars, submi ed by the
manufacturer to the purchaser/ utility, would be used for
technical evaluation, design review and veri cation of
the similarity criteria with reference to the SC tested
transformer.
e method of calculation of weight of core, ux density,
no load loss, load loss, weight of copper, and current
density etc. along with typical example has been given to
help the user to verify the corresponding Guaranteed
values.
I) Customer / Purchaser always w i shes that
transformer/reactor manufactured and delivered must
perform trouble free service for its “Speci ed Design
Life”. It is always a challenge for supplier/manufacturer to
keep consistency in material used & manufacturing
process, which are main cause for variation in quality of
transformer/reactor. Customer practically cannot
monitor them and is not expected to do so. e change in
sub-vendors and skilled manpower (in the factory) from
time to time also require due diligence to control and
maintain the consistency of manufacturing process. It is
also equally very important that transformer/reactor is
manufactured in a clean dust free environment with
humidity control. Any compromise on this aspect will
have adverse effect on expected design life of
transformer/reactor, despite good workmanship and
quality of material usage. e manufacturers are
expected to develop their manufacturing facility at par
with the global practices/standards to improve quality
and manufacturing processes for transformer and
reactor. is would enhance the export potential and
international acceptability of the product. e broad list
of facilities the manufacturers should have are provided
in the document. In case the manufacturer(s) do not have
such facilities, it is to be ensured that such facilities are in
place/developed within the speci ed period of release of
the document.
j) Typical Manufacturer’s Quality Program (MQP),
Inspection and testing including Stage inspection,
Factory Acceptance Tests, testing of ings and
accessories, Tank tests and pre-shipment checks at
manufacturer’s works etc. are covered in the document.
e key issues relating to transportation, handling,
l o a d i n g - u n l o a d i n g , E r e c t i o n , Te s t i n g a n d
commissioning; checks a er receipt at site; storage at
site; safety measures & precautions during erection
including oil lling; pre-commissioning checks/ tests;
and nal commissioning checks before energization are
also covered. Considering the experience of COVID-19
pandemic, virtual inspection and testing has been
Introduced as an alternative to conventional practice of
physical presence of representative of utility at
manufacturer’s works during inspection & testing.
k) e manufacturers have different arrangement of
jacking and different spacing between jacking pads.
Hence, it was difficult to standardize the civil foundation
drawing based on jacking pad locations / arrangement.
Design of block foundation based on maximum weight
of transformer / reactor for a particular MVA / MVAR
rating along with speci ed no. of rails with standard
gauge (1676mm) and provision of suitable size of
portable metal plate for jacking have been suggested to
f ac i l i t ate t h e p hy s i c a l i n te rc h a ngeab i l i t y o f
transformers/reactors of different make on same
foundation block. us, the outage time of replacement
of spare / new transformer or reactor of different makes
would be minimized as it can be accommodated in the
same space with no or minor modi cation in foundation.
e design requirement of soak pit and oil collecting pit
for transformer / reactor has been clearly speci ed so that
foundation design takes into account such provision.
l) It is the fact that during initial 5 years of operation /
operation many transformers / reactors have failed.
erefore, during deliberation, utilities were insisting for
 e-T FOTECH 2020- International Conference on Transformers
inclusion of extended warranty / defect liability period
for transformer/reactor up to 5 years to ensure supply of
quality product by manufacturer. Manufacturers were of
the opinion that utilities have a major role to play in long
and trouble-free ser vice of such assets. Good
maintenance practice and regular monitoring of health of
assets is equally important. Successful operation of
transformer/reactor depends on operating conditions
and O&M practices being followed by the utility. e
extended warrantee period beyond normal period of
warranty would have implication on overall cost of
transformer/reactor. All utilities may not like to bear the
extra burden on account of extended warranty, rather
such utility may prefer to maintain the health of their
assets properly for a long & trouble-free service. Being a
commercial issue, utilities and manufacturer can
mutually decide about extended warranty/defect
liability period. However, the responsibilities of
manufacturer and utility have been clearly highlighted in
the document.
m) In general, all necessary steps should be taken to
ensure that proper condition assessment / monitoring
and maintenance of transformer/reactor is carried out
effectively for a long trouble-free service. e condition
monitoring tests include measurement of Insulation
Resistance (IR), capacitance & tan-delta for winding &
bushing, magnetic balance, winding resistance, turns
ratio, oil Break Down Voltage (BDV), Dissolved Gas
Analysis (DGA), thermal scanning, and Sweep
Frequency Response Analysis (SF ) etc. e Refurbish-Replacement of transformers / reactors.
frequency of tests and threshold values of various
diagnostic parameters has been given to assess the
condition of transformer or reactor for reference and
guidance of utility.
e utilities have been advised as follows: (i) e
frequency of tests may be increased depending on the
condition assessment of transformer / reactor.
(ii) e Pre-commissioning test results and the results of
various tests carried out subsequently at sites shall be
recorded religiously by the utilities.
(iii) e trend analysis shall be carried out to take further
course of action.
(iv) e utility may employ various diagnostic
equipment like DGA, winding resistance meter, SF ,
capacitance and tan delta measuring units etc. either for
each substation or cluster of substations depending on
their assessment or requirement.
(v) Health indexing of transformer/reactor based on
various indicators derived through condition-based
analysis shall be done for Residual Life Assessment
(RLA) and for taking Run/Refurbish/Replacement
decision.
e management of such vital assets, when they are in
service/operation as well as when they have outlived
their expected life/at the end-of-life, is a challenging task
for all utilities in a reformed power sector. Residual Life
Assessment (RLA) would play a vital role while taking
appropriate decisions on "Run-Refurbish-Replace (3
R’s)", investment and future planning of the entire power
system.
For the oil- lled transformers, particularly which are in
service for more than 15 years, it is advisable that the
residual life should be estimated by assessing the extent
of degradation of solid cellulosic paper insulation
through Furan content analysis of oil and degree of
polymerization of paper insulation. is would help
utilities in making optimum use of transformers /
reactors and also taking timely decision regarding Run-
n) ough the document prescribes uninhibited or
inhibited mineral insulating oil, utilities can use Ester
(synthetic/natural) uid for Transformer/Reactor as per
their requirement. New generation insulating oils may
also be considered prov ided any National or
International standard is available for such oil.
Accordingly, the temperature rise of oil over ambient
temperature may be modi ed.
 e-T FOTECH 2020- International Conference on Transformers

o) e document does not cover transformers suitable
for Static Var Compensator (SVC), Static Compensator
(STATCOM), traction transformers, welding
transformers, testing transformers, mining transformers,
furnace transformers and inverter transformer for
Renewable generators
4. CONCLUSIONS
Transformer and reactor are vital and expensive asset in
power delivery chain starting from generation to ultimate
consumption level. Transformer is a static device and is
the most efficient equipment in power system (efficiency
> 99%). Quality, Reliability and availability of such
important assets would play crucial role in achieving the
ultimate objective of cost effective uninterrupted (24x7)
quality power to all consumers and smooth operation of
Power System.
Abbreviations used
ICT: Inter-Connecting Transformer,
GT: Generator Transformer,
SAT: Station Auxiliary Transformer,
BIL: Basic Insulation Level,
TOV: Temporary Over Voltage,
LI: Full wave lightening Impulse Withstand Voltage,
LIC: Chopped Lightening Impulse Withstand Voltage
SI: Switching Impulse Withstand Voltage,
PF: Power frequency Withstand Voltage
WTI: Winding Temperature Indicator,
OTI: Oil Temperature Indicator,
PRD: Pressure Relief Device,
SPR/PRRR: Sudden Pressure Relay / Rapid Pressure
Rise Relay

e Standardization of technical speci cation of

transformer & reactor incorporating the best practices &
state-of-art technology is the need of hour to ensure
quality, reliability and long & trouble-free service. is
initiative would support the ambitious goal of “Local to
Global” of Government of India (GoI) under “Make in
India” (MII) program and would enhance the overall
efficiency, quality and productivity in the entire value
chain of transformer / reactor procurement & operation.
ere may be nancial implication on the overall cost of
transformer or reactor due to standardization of certain
technical parameters, xation of losses, inclusion of
certain speci c construction features and use of speci c
component & material etc. However, if the overall Life
Cycle Cost (LCC) is taken into consideration, the
bene t will ultimately outweigh the initial increase in
cost. e goal of “One Nation One Speci cation” would
be always in the overall interest of the Power System of
the country.
5. REFERENCES
[1] CEA’s Dra Standard Speci cations and Technical
parameters for Transformer and Reactor (≥66kV Voltage
Class)
[2] Latest IEC 60076 / IS 2026 and Parts thereof
 e-T FOTECH 2020- International Conference on Transformers
SPECIFICATION ENHANCEMENTS FOR RELIABILITY
AND ALIGNMENT WITH LATEST STANDARDS
Shashank Kulkarni
Siemens Ltd, Mumbai
ABST CT
EHV Power Transformers & Shunt reactors (66kV &
above) are vital national assets in the power system. eir
site performance & reliability is most crucial for utilities,
OEMs & transformer sub-vendors. e transformer is a
matured product having more than 13 decades of
experience in terms of its design, manufacturing &
successful eld operation. But in Indian context, the last
een years, transformer Industry has seen several
instances of premature failures. Focus is required on
following topics to address the same.
On account of purchaser:
1. Age old speci cations,
2. Relaxed qualifying criteria,
3. Absence of level playing evaluation criteria,
4. Lack of transparency of data base of failures,
On account of Equipment Manufacturers:
1. Site quality inconsistency,
2. Use of outdated design and manufacturing technology,
3. High failure rate, Mind set of manufacturers
4. High capacity in transformer factories
5. Low pro tability for long term viability
On account of Market & competence.
1. High import content, High cost reduction pressures
due to erce competition
2. Limited sub-vendors.
erefore, these problems must be addressed by original
equipment manufacturers (OEM’s), equipment
purchasers & sub-supplier ’s through modern
speci cations backed by regulatory interventions. e
speci cation enhancement is an a empt by which these
issues faced by the customers are fully addressed.
Some of the points of Spec enhancement are already
partially covered by CEA standard speci cation [1],
which has been agreed by all leading manufacturers and
purchasers. As a part of continuous improvement, the
speci cation shall address continuous invention in raw
materials, new technology development, digitalization
prospects, eld experiences, change in manufacturing
practices, availability of the indigenous solutions &
environmental conditions. is paper deliberates some
of the topics that can be included in standard technical
speci cation to build standardized, optimized & reliable
EHV Transformers & Reactors.
ABST CT
is paper is deliberating on following areas where we
can see some potential to generate few ideas for
be erment of technical speci cation of power
transformer.
1. Additional speci cation requirements (in terms of
dielectric, Electromagnetic, ermal, noise emissions &
split-up of load loss)
2. Adherence to latest standards
3. Quali cation Requirement (QR) for Short Circuit
proof Designs
4. Manufacturing facility & Processes
5. Test lab accuracy Requirement
6. Digitization & Cyber security
However, the roles & responsibilities for maintenance of
the transformer & site activities are treated as beyond the
scope of this paper.
 e-T FOTECH 2020- International Conference on Transformers
1. ADDITIONAL SPECIFICATION
REQUIREMENTS
In absence of split-up of load losses, unrealistic and wide
range of stray losses has been observed in the Indian
Transformer industry which results in non-level playing
competition.
Based on the discussion with various manufacturers, I2R
loss & total load loss has been frozen by CEA dra
speci cation [1] to address the above challenge.
e high value critical components like core, winding,
insulation and bushings were de ned with stringent
numerical values along with detailed speci cation
instead of generic brief statements, thereby allowing the
purchasers to verify them by measurement. e relevant
nomenclatures of CRGO are de ned as per IS 3024.
e insulation quality has been de ned by the density
values as per IEC 60641 (parts there-of) & as per leading
pressboard supplier’s recommendation. (Pressboard
with 1.15 gm/cc minimum for load bearing and 0.95
gm/cc minimum for non-load bearing, kra paper with
0.75gm/cc minimum).
Materials used for Tank construction are de ned as per
the relevant IS standards.
It is observed that various utilities in the country have
been following different limits of operating ux densities
in the core (up to 1.73T at rated voltage) and current
densities in winding conductors (3.0A/mm2 for main
windings & 5.0A/mm2 for Tertiary). Now these values
are harmonized in the dra CEA dra speci cation [1].
e perineal issues like oil leakage, paint peel-off &
aesthetic has been clearly de ned in CEA dra
speci cation [1] with the type of surface preparation
requirements and minimum DFT requirements (>155
µm) as per ISO 12944-5-2017 for normal corrosion
category, unlike 80µm mentioned earlier.
Lenient noise limits (NEMA+5 dB) have been made
stringent to lower limits, especially for shunt reactors, in
line with international practice of leading manufactures.
In some utility speci cation, internal inconsistencies of
the speci cation and different requirement for different
voltage class transformers have to be eliminated. Practice
of following different speci cation for each rating
has to be avoided, with common generic speci cation for
all rating. It is also recommended to remove non-
applicable speci cation for be er clarity.
It is recommended that each general speci cation should
be marked with revision index to track the changes made
by all stake holders.
Selection criteria for accessories like PRD, MOG,
Conser vator has been numerically de ned for
harmonized selection by OEMs.
As per IS2026-2, Temperature limits are given as follows:
• Top Oil Rise: 50 °C
• Average winding Rise: 55 °C
• Hotspot Winding Temperature Rise: 66 °C
Above limits are speci ed considering following ambient
conditions mentioned in IS2026-1:
• Yearly average ambient: 32 °C
• Maximum average ambient: 50 °C
However, due to greenhouse effect and global warming,
maximum ambient temperature in some parts of India is
reaching up to 55°C. Hence, it is recommended to reduce
temperature rise limits by 5°C as follows in line with CEA
dra speci cation [1]:
• Top Oil Rise: 45 °C
• Average winding Rise: 50 °C
• Hotspot Winding Temperature Rise: 61 °C
Alternatively, thermally upgraded paper can be opted for
winding conductors to have additional thermal margin.
Tank hot spot limits (110°C) & its measurement
methodology during temperature rise test are de ned
under CEA Dra speci cation [1], to give early warning
signal for gassing issues. e value speci ed 110°C is
more stringent than IEC 60076-7.
 e-T FOTECH 2020- International Conference on Transformers
2. ADHE NCE TO LATEST STANDARD
It has been observed that in some utility speci cations,
the switching impulse (SI) withstand voltage level for
220kV transformer was absent (as per old IEC
standards), though it was highlighted by CEA commi ee
reports. A s per latest IEC 60076-3, technical
speci cations should include SI test values for 220kV
class transformers.
As per bushing standard IEC 60137- 2017, the dry power
frequency withstand voltage for transformer bushings
are mentioned as one level higher (approx. 10%) than the
w inding insulation levels. e same shall be
incorporated in transformer speci cations for increased
safety of bushings which are exhibiting higher failure
rates.
As agreed with bushing manufacturers, more stringent
tan δ of bushing (0.005) is mentioned than IEC 60137
speci ed limit of 0.007.
It is recommended to include all abnormal operating
conditions (altitude, higher ambient, current & voltage
harmonic, seismic acceleration, transport limits,
con ned installation etc.) mentioned in IEC 60076-1
[2], so that necessary precautions can be taken right from
design stage.
Guidelines for location and number of ber optic probes
as per IEC 60076-2 recommendation have to be
incorporated in the speci cation.
3. QR FOR SHORT CIRCUIT PROOF DESIGN
In most of the Technical Speci cation OEMs are asked to
submit the successful dynamic short circuit test report of
similar transformer as a part of quali cation requirement
(QR). It is also mentioned that the similarity shall be
proved either by test or by calculations with reference
transformer. It is proposed that the similarity criteria
shall be strictly checked as per IEC 60076-5 (Annex B).
However, there is o en ambiguity in proving the
similarity of offered transformer with the reference
transformer due to different perception & understanding
of reference transformer.
We would like to propose three distinct categories to
differentiate the acceptance criteria of similar
Category A: Transformer is meeting the similar
transformer de nition of IEC 60076-5 [3]. However,
change in some materials does not affect the short circuit
performance of the offered transformer.
Examples of Category A:
1. Change of bushings, & external accessories.
2. Change of CRGO grade,
3. Change of cooling method shall not impose any
restrictions for validation of short circuit. except Oil
Directed cooling (OD)
Category B: Transformer is meeting the similar
transformer de nition of IEC 60076-05, but the change
in these aspects may affect the short circuit performance
of offered transformer. ese changes can be accepted
during design review stage by checking the calculations
OR by tracking the records of the material used.
Examples of Category B:
1. Change in basic parameters like Voltage ratio, MVA
rating, % impedance, losses, vector group, tap range.
However, the rating is ing into the similarity de nition
given in IEC 60076-5
2. Change in cooling from ON/OF to OD: ermal
design must be evaluated during design review stage as
OD cooling may change the clamping frame structure
and/or major insulation in winding assembly.
3. All de nitions of similar transformer are matched
except ‘Type of Operation’: From design point of view
‘Generator Transformer’ is quite similar to ‘SVC
coupling transformer’ in terms of short circuit design.
Regulation winding may not be present in coupling
transformer which shall be accepted a er design review.
4. For three phase transformers with 5 limb construction
or 3 limb construction may be accepted a er Design
Review.
 e-T FOTECH 2020- International Conference on Transformers
Category C: e change in these parameters is not
acceptable from short circuit point of view.
Examples of Category C:
1. Change in number of wound limbs compared to
reference transformer. E.g. one wound limb with two
return limbs versus two wound limbs & two return limbs.
(Short circuit current magnitude are different & thus the
forces are different).
2. Reference Transformer test reports are from factory
having different manufacturing practices.
4. MANUFACTURING FACILITY AND
PROCESS
e advanced step-lap core construction has been
preferred instead of conventional mitred core joints to
achieve improved performance in terms of losses, noise
& magnetizing current.
e dust free environment in the winding area has been
introduced to reduce the possibilities of dielectric failure
for improved reliability.
Similarly, Air quality management is critical in terms of
reliability. e particle counts are a good measure to
ensure air quality of conditioned room.
e insulation storage is de ned to have be er shelf life.
It is preferred that the manufacturer shall furnish
facilities to measure particle counts in oil at his work, as a
quali cation requirement. e particle analysis shall be
carried out in factory. Below particle limit shall be
ensured by manufacturer, implying low contamination,
as per CIGRE Brochure 157 of WG 12.17, Table 8 [5].
Similarly, a er ltration, the oil is to be ushed and
particle count to be measured for transformers and
reactors having Um ≥275kV.
Limiting value for the particle count are
1000 particle /100 ml ; particle size ≥ 5 µm.
130 particle /100 ml ; particle size ≥ 15 µm
In the same way dew point gives good indication for the
moisture ingress in transformer lled with dry air. Dew
point measurement of dry air a er 24 hours of lling
inside transformer before dispatch. e moisture
content must be:
• <0.75 weight % for transformers with Um >72,5. ≤ 170
kV,
• <0.5 weight % for transformers with Um > 170 kV
Dew Point value of dry air a er 24 hours of lling inside
transformer is recommended as below:
-38°C at 20°C ambient temperature
-36°C at 30°C ambient temperature
-30°C at 40°C ambient temperature
e above values of moisture content and Dew point are
taken from experience of author’s employer.
5.TEST LAB SPECIFICATION
As per latest IEC 60076-3, IVPD is a routine test for
Um>170kV. According to IEC60076-3 standard, the
test can only be considered valid if the measured
background PD level does not exceed 50pC at both the
beginning and end of the test, at the measuring frequency
as per IEC 60270. e measurement of PD at high
frequency above 1MHz shall be avoided. For shunt
reactors a background PD level of up to 100pC at 100-
250kHz to be ensured.
Some of the other criterion mentioned by this standard
for successful PD test are:
• none of the PD levels recorded during the one-hour
period exceed 250pC; (few Speci cations in India
require this value shall be <100pC)
• the measured PD levels during the one-hour period do
not increase by more than 50 pC
Considering low value of PD measurement during IVPD
testing (<100pC in India), low background PD shall be
ensured. Following recommendations are given based on
experience of author’s employer:
• EHV lab for FAT must have valid NABL accreditation
of ISO/IEC 17025.
• Low background PD are achievable w ith
electrostatically shielded EHV lab.
• Additionally, manufacturer shall have high voltage and
high current lters to reduce background Pds.
• PD sensitivity range of 1 to 100000pC
 e-T FOTECH 2020- International Conference on Transformers
Accurate loss measurement during Factory Acceptance
Te s t (FAT ) i s a n i m p o r t a n t . B e l ow a re o u r
recommendations for loss measurement at FAT:
• Winding resistance meter shall have accuracy of +/-
0.05% for measurement scale of 100 mΩ.
• Power Analyzer calibrated at low power factors of Unity
PF (FSC 110% voltage and 120% current input to
wa meter according to Instrument Tx) / 0.5 PF Lag / 0.2
PF Lag / 0.1 PF Lag / 0.05 PF Lag / 0.01 PF Lag (40-60%
Voltage and 40%-80% current input to wa meter
according to instrument Tx).
6. DIGITIZATION & CYBER SECURITY
With INDUSTRY 4.0 developments in the world of
digitization, we can unleash the potential of IoT, digital
twin & cloud-based computing for asset management of
Transformers & reactors.
A digitally enabled Power Transformer which provides
end-to-end access to digitalization, incl. the sensor
hardware, digital connectivity and cloud-based data
storage, including visualization and analytics capability.
e physical hardware shall be designed in a robust way,
reducing vulnerability and maintenance to a minimum.
e solution should be integral part of the Transformer.
e transformer shall be at minimum equipped with
following measurement sensors:
a. Oil Level Indicator: indicate the status of the top oil
level
b. Oil temperature: PT100 Resistor ermometer.
c. Winding current: the integrated current transducer
with an output between 4-20mA indicates the actual
value of the winding current with a galvanic separation
between the primary and secondary circuit. A current
transformer is mandatory in order to transform the
current value.
d. GPS location of the asset.
e. Detailed thermal image of the transformer including
Hotspot information. (Digital Twin).
f. Overload capability of the transformer.
g. Residual life assessment of the transformer.
h. Integrated DGA analyser with H2 and moisture
indication as bare minimum.
I. Integrated Tan delta measurement of bushings.
j. e system should be scalable to adapt to new
technology without any major shutdown.
e IoT gateway and cloud applications must comply
with the latest international cybersecurity standards (as
applicable). e data storage and visualization shall have
following features:
• Compliant with relevant cyber security standards - ISO
27001 and IEC 62443-4-2.
• Compliant with all relevant standards (e.g. EMC
Directive 2014/30/EU, IEC/EN 60529 and IEC/EN
61010, IEC/EN 61000, IEC/EN 60068).
• Cloud based data storage with capacity for the usual
transformer lifetime.
• Secure cloud-based data storage with SHA1 based
integrity checks and 2-level user authentication.
• Remote Firmware update via the cloud management
platform has to be supported by the connectivity device.
CONCLUSION
e well-balanced speci cation covering all the best
global practices will result in reliable transformer
procurement & operation. Standardization of the ratings
& its technical speci cation will bene t all the stake
holders. CEA dra speci cation [1] shall be adhered by
all utilities.
e above paper addresses some of the key technical
requirements which are in line with CEA dra
speci cation [1] . is endeavor will help us to evolve
with reliable & cost-effective solution along with the
focus on streamlined manufacturing, advanced testing
facilities, upcoming technologies, environmental
changes & harmonized interpretations of various
standards, site experiences.
 e-T FOTECH 2020- International Conference on Transformers

REFERENCES
[ 1 ] Ce n t ra l E l ec t r i c i t y A u t h o r i t y, St a n d a rd
Spec i cat ions and Technical Parameter s for
Transformers and Reactors (66 kV & above voltage class)
Chapter 2 (Dra 2020)
[2] Power Transformers –Part 1: General, IEC60076-1,
Edition 3.0 2011-04
[3] Power Transformers –Part 5: Ability to withstand
short circuit, IEC60076-5, Edition 3.0 2006-02
[4] Power Transformers –Part 3: General, IEC60076-3,
Edition 3.0 2011-04
[5] Effect of particles on transformer dielectric strength,
CIGRE Brochure 157, WG 12.17, Year: 2000
[6] Security for industrial automation and control
systems - Part 4-2: Technical security requirements for
IACS components, IEC 62443-4-2:2019
 e-T FOTECH 2020- International Conference on Transformers
LATEST TRENDS IN T NSFORMER DESIGN
AND MANUFACTURING
Vikrant Joshi
GE T&D India Ltd.
ABST CT
Transformer design and manufacturing is an evolving
eld. e latest trends and developments in the power
system and the economy, a new shi towards energy
conservation and environment friendliness as well as the
ever-increasing demand of reliability put new and
unprecedented demands on the transformer. e
transformer design needs to address these new demands
and make a design meeting them at a competitive cost.
For achieving this, the proven, matured technology is
complemented by the new techniques which take
advantage of the developments in materials, IT enabled
tools for accurate performance prediction and improved
manufacturing processes. ese techniques are also
backed by experimental and analytical research in the
various related elds such as solid insulation, mineral oil,
esters, dielectrics, electromagnetics, magnetostriction to
name a few.
1 INTRODUCTION
ere are a few major trends that put more and more
onerous demand on today’s transformers. ey are:
Efficiency (energy conservation)- requiring reduction in
transformer losses, and very high capitalization/penalty
rates on losses. is also requires a compact design of
transformer active part and tank, leading to more
onerous dielectric stresses.
Harmonic loading of transformers due to renewable in-
feed tends to increase the transformer losses and noise
under service conditions. e transformers of today
must be designed keeping in mind that the losses/hot
spots not only under the acceptance test condition, but
also under the service condition are important for a
reliable transformer.
Highly interconnected grids that substantially increase
the system fault levels as well as cause more faults on the
transformer.
Requirement of environment friendly transformers that
require more and more use of bio-degradable components,
especially the insulating and cooling uid has given a huge
demand for transformers lled with ester based (natural or
synthetic) uids. e properties and behavior of these
esters is, while quite like the mineral oil, is not exactly like
the mineral oil. In view of this, using esters in transformers
is a new challenge. Also, the interface of esters and other
components inside the transformer (immersed ends of
bushings, tap-changers) is affected by this difference in the
properties of ester. So designing ester lled transformers, or
retro- lling existing mineral oil lled transformers requires
special considerations and state-of-the-art technology.
Looking at these important trends, the paper discusses
their impact on:
. e load and no-load loss
. ermal performance
. Dielectric design
. Short circuit withstand capability
. Transformers with bio-degradable uids
e transformers considered here are the liquid lled core
type power/distribution transformers with stacked core
and concentric windings.
2 NO LOAD LOSS AND LOAD LOSS
No load loss: Controlling and reducing the no load loss in a
transformer is of vital importance, especially when the
capitalization/penalty rates are very high.
e no load loss mainly depends upon:
. e CRGO grade used (its thickness and metallurgy, grain
orientation)
. e operating ux density
. Core mass
. e type of core (1-phase, 3-phase, 3-limb, 5-limb etc.)
. e type of joint between the limb and yoke (mitred-
interleaved or step-lap)
 e-T FOTECH 2020- International Conference on Transformers
We discuss these factors one by one.
e speci c losses of a core grade are reduced by the core
manufacturers by reducing the thickness, increasing the
resistivity and improving the grain orientation. Today,
CRGO grades with thickness as low as 0.20 mm, and
with laser scribing are available, which can give a very low
speci c loss. Implementing these grades in transformer
cores requires special care in manufacture of the
laminations, due to the reduced thickness.
Frequently used CRGO grades
(IEC60404-8-7 2020):
Type W/kg at 1.7 T, 50 hz
M120-27S5 Conventional 1.2
M100-27P5 High permeability 1.0
M75-23R5 Domain refined 0.75
e no-load loss can be reduced by operating on the
lower ux density. However, this is not the most
economical way of no-load loss reduction, since the
reduction in ux density would increase the mass and
dimensions of the core (for a given volt per turn) and
would increase the material cost for the core. e ux
density in the core must be chosen judiciously. O en it is
best to work on highest allowable ux density to achieve
the required no-load losses in design.
e type of core also in uences the no-load losses. For
example, the no -load loss building factor for a 3-phase 5
limb core may be higher than that of a 3 phase 3 limb core.
e building factor is de ned as:
No-load loss ÷ core mass ÷ W/kg for the CRGO grade
e building factor gets worsened if the handling of the
laminations on the shop- oor is not correct. Multiple
assembly and dis-assembly of core laminations,
improper supporting of the laminations during the
manufacturing process can lead to increased losses.
e joint between the limb and yoke plays a vital role in
reducing the no-load loss of the transformer. e latest
trend is to provide a step-lap joint, rather than a
conventional mitred-interleaved joint. e mitred-
interleaved joint not only has a higher wa loss at the
joints, but it also increases the no-load current of the
transformer and so also its noise.
Load loss: e 3 components of the load loss are- the I2R
loss, the eddy loss in winding conductors and the stray
losses in structural parts.
Reducing the I2R losses is straightforward, by providing
higher cross-sectional area of the winding conductors.
However, the increased conductor mass due to this, as
well as increased dimensions of the single strands would
increase the eddy losses in the windings, can partly offset
the reduction in the I2R losses. Under service
Eddy loss = K. f2 X t2
Where K is a constant depending on material, geometry
and mass of the winding, f is the supply frequency and t is
the dimension of the conductor perpendicular to the
leakage ux.
From the equation above, the harmonics cause the eddy
current loss in winding conductors to further increase.
is would lead to increased load loss, oil temperature
and winding hot-spot temperature in service. In order to
avoid this, the latest strategy is to use CTC conductors
wherever feasible. e use of CTC conductors also
eliminates the circulating current losses that may occur
when large quantity of parallel conductors is employed
with limited crossovers between them.
For accurate estimation of the eddy loss, it is necessary to
accurately calculate the leakage ux. is calculation is
best performed using advanced computer programs
based on ROTH or nite element method.
e remaining part of the load loss, the stray losses in
structural parts is very important, since an ill-designed
transformer can have high localized stray loss leading to
unacceptable hot spots. Especially, the vulnerable
members are the itch-plates, the core steps facing the
windings, parts of the tank, and structural members near
high current carrying leads and bushings. Today, the
design engineers rely on 2 and 3-dimensional eld
calculations for accurate prediction of structural stray
loss and the hot spots.
Figure-1: 2D Magnetic eld plot- auto transformer
 e-T FOTECH 2020- International Conference on Transformers
3 THERMAL PERFORMANCE
With high peak loads and lower redundancy of
substation transformers, today’s transformers operate
close to the nameplate rating for a longer time and are
o en overloaded. Also, the generator step-up
transformers are almost always loaded to its nameplate
capacity regardless of the ambient temperature. While
this may be an acceptable condition, the modern
transformer has a much higher thermal stress. e effects
of operating temperature of uid and the solid insulation
have a detrimental effect on the life and reliability of the
transformer and deserves an elaboration here.
Here the thermal performance is considered in
two parts:
. e internal- cooling of windings
. e external- cooling through heat exchangers
Cooling of windings: e uid enters the winding from
bo om and rises upwards due to the natural/forced
convection and collects the heat from the windings as it
rises upward. Because of this, the winding temperature at
top is higher than at bo om. Also, at the upper (and
lower) end of the winding, the additional eddy losses
because of the radial fringing of the leakage ux [7] and a
worsened oil ow cause a further increase in the winding
temperature at top. IEC 60076-2, annexure B provides a
guidance on estimating the hot-spot factor for
transformers. is is well explained by way of the gure-2
below. Figure-3 provides an example of a bad oil ow at
the upper end of the winding.
Figure-2
Figure-3
For a good overload capability, we need a low hot spot
temperature for which a reasonably low hot spot gradient
is necessary to achieve. Ascertaining a low hot-spot
temperature requires very specialized knowledge of uid
dynamics and practical manufacturing difficulties.
Optimum quantity and placement of the oil guiding
washers, as well as controlling the radial eld eddy loss in
the end discs/turns of the winding [3]. Excessive oil
velocity in the radial and axial cooling ducts must be
avoided, as it may lead to static electri cation.
In large power transformers, use of CTC conductors
helps reduce the eddy current loss. However, the bulging
of paper covering on the CTC conductor can cause
reduction of the radial oil cooling duct, reducing the oil
ow. In such a case, it is essential to increase the cooling
duct dimension. Today, the CTCs without paper
insulation are also available, and they can be used in low
voltage windings (e.g. the LV winding of a GSU). e use
of such special conductors further improves the removal
of heat from the conductors, reducing the gradient.
For transformers with forced oil cooling, it is important
to provide directed oil circulation.
e state-of-the-art today is to use computational uid
dynamics alongside of the practical information and test
results for estimating accurate gradients.
External cooling: e external heat exchangers collect
the heat from the oil and dissipate it to the external
cooling medium (air or water). Large transformers are
o en provided with forced cooling system by way of fans
and pumps. Selecting optimum pump capacity, the
capacity and quantity of fans is an important
consideration. A sub-optimal fan placement can lead to
wastage of the forced air and can lead to high oil
temperature. Here again, the use of computational uid
dynamics alongside the test data are used to calculate the
air ow on the heat exchangers.
 e-T FOTECH 2020- International Conference on Transformers
Figure-4: CFD calculation of air ow
Where space is a limitation, the compact oil-air heat
exchangers with integrated fans and pumps provides a
very effective solution. Some of the large transformers,
which are required to be placed in urban areas have
effectively utilized this solution (e.g. PGCIL, GETCO in
India). Some utilities even turn on or off the heat
exchangers depending upon the load conditions, thus
saving on the power consumed by the cooling
equipment.
Some utilities (e. g. NTPC, India), in collaboration with
transformer manufacturers have developed special
SMART schemes. ese schemes utilize the composite
monitoring system for sensing the cooling requirement,
and variable frequency drive for speed control of the
pumps. e compact oil-air heat exchangers are
automatically controlled based on the hot-spot winding
temperature in the transformer winding with least
possible energy consumption in the forced cooling
equipment [10].
4 DIELECTRIC DESIGN
On the one hand, the grid is becoming more complex
with a higher occurrence of transient overvoltage and has
ever increasing GIS systems causing very fast transient
overvoltage (VFTO).
Figure-5: VFTO waveform (CIGRE TB 519)
On the other hand, the transformers are becoming more
and more compact, requiring reduced clearances in the
active part as well as from the active part to the tank. is
phenomena poses a great challenge to the insulation
design in a transformer.
e lightning and the chopped lightning voltage
distribution along the winding length is not easy to
calculate; simplistic methods based on capacitive voltage
distribution alone can give very erratic results. For this
purpose, the leading manufacturers of transformers have
computer programs that consider the capacitances,
inductances and the non-linear elements (surge arrester
blocks across tapping steps etc.) and calculate the
impulse voltage distribution at all the points in the
transformer winding [5]. Withstand of the internal
insulation is then calculated using the semi-empirical
calculations based on electro-static eld calculations and
experimental research.
Figure-6: Electro-static eld plot
 e-T FOTECH 2020- International Conference on Transformers
e insulation design of high voltage power transformers
is veri ed by:
- Evaluating the worst-case equivalent voltage that
appears between the different electrodes. is requires
converting the voltages occurring during various test and
service conditions to an equivalent voltage (typically, an
ac voltage for 60s duration), and choosing the worst case
among them.
- Plo ing the electro-static eld using 2D or 3D eld
plo ing so ware as appropriate
- Based on the electric eld levels, calculate the withstand
on the bare/insulated electrodes, in the oil gaps and
along the oil-pressboard interfaces [6]. is is based on
experimental research on models; years of testing and
analysis goes into this. ere are only a handful
companies, including GE, who have such research
facilities.
In the EHV/UHV systems, the occurring overvoltage in
the system interact with the transformer [2]. If some
frequency components of these over-voltages match
with the natural frequency of the windings, resonance
can occur in some parts of the winding. In the worst case,
this can lead to insulation failure. It is pointed out that the
system overvoltage can create stresses different and
higher than the standard factory acceptance tests. It is
important on the part of the customer to identify and
provide the details of such overvoltage to transformer
manufacturer. Based on this, the manufacturer can
strengthen the insulation as necessary.
In the EHV/UHV systems, the occurring overvoltage in
the system interact with the transformer [2]. If some
frequency components of these over-voltages match
with the natural frequency of the windings, resonance
can occur in some parts of the winding. In the worst case,
this can lead to insulation failure. It is pointed out that the
system overvoltage can create stresses different and
higher than the standard factory acceptance tests. It is
important on the part of the customer to identify and
provide the details of such overvoltage to transformer
manufacturer. Based on this, the manufacturer can
strengthen the insulation as necessary.
5 SHORT CIRCUIT WITHSTAND CAPABILITY
It is evident from the increasing customer requests for
short circuit testing all over the world, that the grids have
increased frequency of short circuits.
Designing a transformer for short circuit withstand is a
challenge; the success rates during the short circuit tests
world over is quite low.
e design tries to minimize the magnitude of short
circuit forces and to improve the strength of the
transformer windings and clamping structure.
e balancing of axial amp-turns is key to reducing the
unbalance forces. Designers use magnetic eld
calculation programs to accurately balance the axial amp-
turns and minimize the forces. Use of calibrated key-
spacers between the discs and turns helps precisely
achieve the required axial dimensions of the winding.
e hoop compressive stress on the windings is perhaps
the most onerous, causing radial buckling of the winding.
Here, some customers demand that windings must
withstand the stress without any internal supports. O en
this condition cannot be met by plain conductors and
epoxy bonded conductors are necessary for achieving
the withstand. In many large transformers, the inner
windings are made using the epoxy bonded conductors.
e accumulated axial compressive forces in the key-
spacers tend to cause tilting of the conductors in the
disc/turn of a winding; in large power transformers, plain
conductors o en cannot withstand such forces, and the
use of epoxy bonded conductors is the latest trend.
e leads external to the windings are also subject to
severe mechanical forces and vibrations during the short
circuit event, and a rigid supporting arrangement is
provided to prevent their movement.
e clamping structure in the transformer plays an
important role of rigidly locating the winding system
against the axial unbalance forces, as well as the dynamic
forces during the short circuit event. Today the design of
clamping structure relies on use of high tensile strength
in critical load bearing members as well as on a detailed
structural analysis using 3D so ware programs.
Needless to emphasize that a good design alone cannot
ensure a short circuit withstand capability of a
transformer. A big expertise in the manufacturing
process is necessary to manufacture and assemble the
windings precisely in line with the design. e modern
manufacturing processes like iso-static clamping during
the winding dry-out ensure the stability of the so axial
insulation which is utmost necessary to ensure a short
circuit withstand. e manufacturing skills require
continuous improvement by training and assessment
and the necessary infrastructure for this also provides a
consistent product.
 e-T FOTECH 2020- International Conference on Transformers

6 USE OF BIODEG DABLE FLUIDS 8 REFERENCES

Natural and synthetic esters are now being increasingly [1] IEC 60076-1, Power transformers- Various parts
speci ed in transformers in view of their higher ash
point as well as excellent biodegradability. [2] CIGRE Technical brochure 577A. Electrical
In combination with solid insulation materials of high transient interaction between transformer and the power
temperature class, esters can allow operation of system. Part 1- Expertise. 2014
transformers at elevated temperatures without abnormal
ageing [4]. [3] CIGRE Technical brochure 659. Transformer
thermal modelling. June 2016
ere are some differences in the characteristics of esters
than those of mineral oil: [4] CIGRE Technical brochure 738- Ageing of liquid
- Esters are generally more viscous- especially at lower impregnated cellulose for power transformers. August
temperature. 2018
- e dielectric withstand capability of esters, for long
gaps is lower than mineral oil and sows a more statistical [5] CIGRE Technical brochure 785- Electromagnetic
sca er. computation methods for lightning surge studies with
- Esters have higher dielectric constant than the mineral emphasis on the FDTD method. December 2019
oil.
[6] CIGRE Technical brochure 794- Field grading in
In view of the above, additional care needs to be exercised electrical insulation systems. March 2020
about:
- Cooling ducts in the winding [7] Transformer Engineering- Design, Technology and
- Quantity of radiators to achieve a given temperature rise Diagnostics. Book by S. V. Kulkarni, S. A. Khaparde.
- Electrical clearances for long gaps must be increased or Second edition 2013
these gaps would need to be subdivided
- Usually vacuum type OLTCs are preferred when their [8] MR Brochure- Alternative liquids for tap changers
lling medium is esters. In such cases, the torque
required to drive the OLTC is also higher [9] ABB Brochure- Selecting bushings for ester
- Interface between bushing surfaces and ester as well as insulation uids
the OLTC selector and ester. A derating of the voltage of [10] M/s. Minal Kataria, Venkatesh Vuppuluri. Smart
these components may be necessary to achieve the coolers for future power transformers- Technical paper
required dielectric withstand [8], [9]. Trafotech 2018 Tenth International Conference on
ere are other issues such as material compatibility, Transformers
transformer processing and impregnation, DGA
interpretation etc., which need special a ention.
Manufacturers are recommended to have dedicated
systems for handling and storage of esters.
7 CONCLUSIONS
Today’s power transformers are subject to severe stresses
and the design engineers strive to ensure reliability of the
transformers by a judicious choice of advanced materials,
processes and advanced computation techniques,
supported by basic research. Improved manufacturing
processes are also necessary to ensure high reliability of
the transformer under onerous service conditions.
 e-T FOTECH 2020- International Conference on Transformers

EFFECTIVE PROCUREMENT OF EHV POWER T NSFORMERS AND REACTORS

S.K.Gupta N.N.Raman
BHEL Jhansi BHEL Jhansi

1. SYNOPSIS:
Since last two decades, there has been many a empts to operational parameters are available on line, which may
standardize the technical speci cation of power be connected to the system for adequate feedback,
transformers & reactors at various forums. Lately Central control & protection and asset management.
Electricity Authority, India (CEA) along with leading Interchangeability is also a very important parameter
manufacturers & utilities of the countr y have towards effective procurement process.
standardized the technical speci cation and xed some
standard ratings of power transformers and reactors. is paper throws light on the basic aspects of effective
Many utilities have already started following this procurement, like how to select and qualify the right
speci cation. However, this is applicable only for some manufacturers, pu ing the right technical
standard ratings and does not encompass the entire speci cation/material as per latest industry practice,
requirements of the Indian subcontinent. As such, there ensuring proper design, manufacturing & testing,
is no such globally acceptable speci cation of all range of selection of proper ings and accessories and
EHV power transformers & reactors in vogue. standardization of losses, basic technical parameters and
interchangeability aspects have also been touched upon.
Presently many utilities have their own set of
1. SIX PILLARS FOR AN EFFECTIVE
speci cation, which not only varies in main technical
PROCUREMENT PROCESS:
parameters, but also in ings, accessories, limitations,
losses, quali cation criteria etc. which are all derived a. Qualifying the right manufacturer
from their own rich eld experience over decades b. e right technical speci cation
On the utility/ industry experience perspective, while c. Effective design review
some utilities are more than 5 decades old, others do not d. Selection of proper ings and accessories
have that wide experience. Coming to the transformer e. Effective control on material, manufacturing and
industry in the Indian subcontinent, many new entrants testing
have also come up in past two decades; while on the other f. Standardization of ratings, losses and basic technical
hand, some have closed their transformer business and it parameters and interchangeability.
is a dynamic scenario.
In this context, it becomes imminent for the utilities to
ensure that they purchase the right equipment, which is
not only reliable in short run, but it should sustain its
integrity in long run. Other important parameter is the
value of purchase. e speci cation must be designed
accordingly and must be neither be too lenient nor too
stringent so as to increase the price without adding any
desirable value. Apart from the basic duties, the product
must be futuristic like it must be digitally compatible
with the power system control system, wherein all the
 e-T FOTECH 2020- International Conference on Transformers

PROCESS CHART OF T NSFORMER PROCUREMENT PROCESS (CIGRE Guide 530)

 e-T FOTECH 2020- International Conference on Transformers

FLOW CHART FOR AN EFFECTIVE PROCUREMENT PROCESS

BEFORE FLOATING ENQUIRY

Formulating
Qualification of Selection of Interchangeability,
optimum
Right optimal fittings Standardisation
technical
Manufacturer and accesories and futuristic
specification

DURING EXECUTION OF CONTRACT

Effective
Effective Adherence to
control on raw
Effective control on
materials, standards during
Design Revew manufacturing
fittings & testing
process
accesories
 e-T FOTECH 2020- International Conference on Transformers
2.1. QUALIFYING THE RIGHT
MANUFACTURER:
e eld experience of EHV class power transformers &
reactors indicates that it is one of the most critical
equipment of an EHV power network and any inherent
weakness may result into failure and bring the whole
power network chain to a standstill. erefore qualifying
the right manufacturers is the rst step towards an
effective procurement process.
ere is CIGRE guide 530 published by working group A
2.36 titled “Guide for conducting factory capability
assessment for power transformers”. It expresses the best
practices in the industry to secure high quality of the
delivered transformer. e guide can be applied as a pre-
quali cation process prior to issuing a tender to avoid
unsuitable factories for being invited to tender. As
minimum requirements, the guide covers many areas
such as commercial risks, design and engineering,
manufacturing and test facilities, transport capability,
quality control etc. It does not point out speci c
solutions or methodologies but aims more at seeking
evidence that the methods chosen are proven by testing,
measurements or simulations.
Mere theoretical calculations or adequacy may not be
adequate to prove the integrity of EHV power
transformer or reactor under stringent site conditions. It
is very important to select proper quali cation criteria for
manufacturers, which must be just right i.e. neither too
rigid nor too lenient. If the criteria is open or too lenient,
then there is a risk that new manufacturers not having
adequate experience/expertise might qualify which may
put the equipment and the utility at risk. On the other
hand pu ing very rigid requirements may not ensure
right competition resulting into higher price of the
equipment.
Based on the present scenario of the industry and the
product in the Indian subcontinent, the following steps
are recommended for proper quali cation criteria in
order to ensure the entry of right manufacturers:
SUGGESTED FACTORS FOR
QUALIFICATION:
1. Adequate Field experience: is is the rst step
towards quali cation of a right manufacturer. Utility
must have at least 5 years successful eld experience for
the rated Voltage kV class and MVA rating must be at least
80% of the proposed transformer/reactor.
2. Short circuit capability: is is one of the most
critical parameter to judge the manufacturer’s overall
capability. Generally, short circuit test is a costly affair as
well as time consuming since transformer is to be sent to
an outside laboratory. However, to ensure that the
transformer is suitable for the intended short circuit
duties at site, the manufacturer must have successful SC
test report (TC not more than 5 years old) on similar
transformer (similarity criteria to be as per IEC 60076-
5). Utility has also the option to ask for short circuit
capability (instead of SC TC) in line with calculations as
per IEC 60076-5.
3. Design, Engineering and R&D: e manufacturer
must have a dedicated team of experienced designers
having capability to independently design the EHV
power transformers/reactors and a separate R &D wing
for analysis, improvement and for development of
transformers/ reactors at par with international practice.
4. Manufacturing capability and facility: Must have
adequate manufacturing facility for core assembly,
complete in-house manufacturing of windings
(controlled environment), its assembly, processing
(VPD process plant for 220 kV class & above). e
facility must be adequate for manufacturing the
transformers being quoted.
5. Adequacy of testing facility: Must have NABL
accreditation for conducting all routine/type test as per
IEC 60076 for the range of transformers/ reactors being
quoted. It must have dielectric test set up having impulse
generator and other high voltage equipment to test LI, SI,
LTAC, PD test etc. All test instruments must be duly
calibrated.
6. Quality assurance: Must have a separate quality
department to verify raw materials and manufacturing
p ro ces s f o r a p ro p er q u a l i t y co nt ro l d u r i ng
manufacturing. All equipment/measuring instruments
must be calibrated and duly certi ed before use.
 e-T FOTECH 2020- International Conference on Transformers
2.2 THE RIGHT TECHNICAL
SPECIFICATION:
Having quali ed the right manufacturer, next important
step is the preparation of the right technical speci cation
of the EHV transformer/ reactors. In this context, there is
a CIGRÉ Technical Brochure 528: Guide for Preparation
of Speci cations for Power Transformers. Reference may
be drawn from this Brochure. More importantly, Utilities
are suggested to follow the latest CEA speci cation for
standard rating transformers and ings.
Based on the present trend of speci cation by utilities,
some salient points towards an effective speci cation are
elaborated hereunder:
Project Speci c Data: Each utility has its own application
and basic parameters viz. MVA, kV, Impedance, Tapping
range, cooling type, transport/size limitation etc. ese
parameters are site/customer/system speci c and are
normally xed.
Apar t from these, there are cer tain technical
parameters/limitations, put by some utilities based on
their experience, although there is no mention by
national/international standard. Some of these are:
I. Limitation of ux density at rated voltage and
frequency – Some utilities specify limit of ux density as
1.55 or 1.6 tesla, although it is not speci ed in any
national/international standards. e present day
CRGO material is suitable for ux density of even more
than 1.9 Tesla. Considering 10% margin for over uxing,
ux density of 1.7 Tesla approx. is technically acceptable.
Core hot spot calculation is a routine design affair and
wherever required, oil ducts are provided to limit the core
hot spot temperature. Specifying a lower ux density
results into costlier and bulkier transformer. It is
recommended to mention limit of 1.9 T at 110% over
uxing and also suitability to take care of sudden load
throw off as per CBIP manual on transformers viz 110%
continuous, 125 % for 1 min, 140% for 5 sec etc.
ii. Limitation of current density: Some utilities specify
current density limit of 2.0, 2.5 or 3.0 A/sq mm, although
the electrolytic grade copper is suitable for current
density of even 3.5 A/mm2. In many cases, this
requirement results into costlier and bulkier requirement
specially if this limit is also applicable for tertiary and at
all taps along with tap winding. Current density limit of
3.5 A/ sq mm is technically adequate, with properly
designed oil ow channels through windings and hot
spot calculation based on manufacturers analysis.
Instead of xing current density, it is be er to specify
ma x imum grad ients v i z . 18 / 21 / 24 K for
ONAN/ONAF/OFAF or OFWF cooling respectively.
It will facilitate designer to freely choose the most
optimum current density and also limit the hot spot
temperatures for be er life. e optimum cooling
calculation will result when the gradients of different
windings are in the same range.
If a utility needs lower No Load/ Load losses, then high
Loss capitalization rates may be put in the speci cation.
In that case, the utility can get a transformer, which has
lower losses, but due to be er optimization of core and
winding design, the transformer cost is not increased in
that proportion.
iii. Lower Oil and winding temperature rise limits: IS
2026 speci es Top oil & average winding rise as 50 & 55⁰
K respectively over maximum daily and yearly average
maximum of 50 & 32⁰ C. However, some utilities specify
these limits up to 35 & 40⁰ K. ough this is feasible, but
results into a bulkier cooling equipment design. e
utility logic is that with lower temperature rise, the
transformer life will increase. While this may be partially
correct for those large generator transformers, which are
expected to run on full load and overloads at most of the
times. However, other transformers like auto and system
transformers are many times lightly loaded and there is
no need to go for lower temperature rises. e life of
insulation is up to 30 years even with the rises of 50/55 ⁰
K in a well-designed transformer. Many transformers
with this design are under successful operation even a er
3-4 decades. However if utility is keen to have margin
then they may specify thermally upgraded paper.
iv. Requirement of OLTC: OLTC is the only moving
part in the transformer and one of the most critical item.
Many utilities do not use Tap Changer in their
transformers either because they are able to meet the
requirements by control through Generator excitation or
 e-T FOTECH 2020- International Conference on Transformers
otherwise. Some utilities like NHPC have already
deleted it from their speci cation and many transformers
without any Tap changer are already in use. Some other
utilities are also working in this direction. is shall
simplify the transformer to great extent and shall also
result in cost reduction, more compact and shall also add
to reliability on account of OLTC or leads. Elimination of
OLTC will make the transformer a fully static device and
more robust. Utilities may ponder on this aspect, based
on actual site feedback of OLTC operation, voltage data
etc.
2.3 EFFECTIVE DESIGN REVIEW:
Although the onus of a suitable design, meeting the
operational and stringent site requirements falls under
the purview and expertise of manufacturer. However,
utility may conduct design review of EHV transformers
generally in line with CIGRÉ Technical Brochure 529:
Guide for Conducting Design Reviews for Power
Transformers. While some utility carry out design review
on their own, others appoint external consultants:
2.3.1 EHV Transformer design is very elaborate process,
which requires detailed study of electromagnetic
parameters, dielectric design, thermal design,
mechanical design etc. Now a days many analysis is done
through sophisticated FEM so ware and utility uses
their own design computation tools. It is not possible to
conduct in-depth design review by the utility to the level
of designer.
2.3.2 However, as a con dence building measure and for
knowledge of utility, design review may be conducted.
e main parameters to be veri ed is generally guided by
CIGRE brochure referred above. e adequacy of
various technical guaranteed parameters under normal
operation like losses, impedance, ratio, magnetic circuit,
dielectric integrity, SC integrity, thermal ability,
mechanical integrity circuit, mechanical design etc. are
generally veri ed. Capability of transformer under
onerous site conditions like fault, Short circuit, dielectric
overstressing like Lightning impulse, switching etc. can
be evaluated in line with CIGRE guidelines. While utility
team may have access to the calculated vs withstand
values against each technical parameter, however
con dentiality of the documents also needs to be
ensured.
2.3.3 Each manufacturer has its own safety factors,
depending on internal guidelines, experience, shop
tolerances and the safety factors may vary from
manufacturer to manufacturer. However, manufacturer
must be able to demonstrate the suitability in line with
speci ed parameters.
2.3.4 In the design review, utility may also share their
experience to have a more fruitful design review.
2.4 RIGHT CONTROL ON MATERIAL,
MANUFACTURING AND TESTING:
Hav ing selected the right manufacturer, right
speci cation and adequate design, next critical area is to
ensure the adequacy of implementation actions wrt right
materials, adherence to norms during manufacturing and
a proper nal testing as per IEC-60076.
e manufacturer’s factories must have implemented a
quality management system that complies with the ISO
9001 Standard as formal quali cation criteria. However,
only having ISO 9001 is not sufficient to ensure a proper
control on material and manufacturing process.
e utility has to adopt a product speci c process to get
the optimum product by having a right control on the
material quality, the manufacturing and the nal testing:
2.4.1 Control on Raw material and critical items:
Ensuring the right quality of materials from right sources
is one of the prime requirements. While all materials are
important, most critical material/ ings are bushings,
Tap changer, insulation items, CRGO, Winding
conductors, oil etc., which needs to be critically
monitored. It is also suggested to follow FIFO concept
for critical items having shelf life viz gaskets, standard
insulation items etc.in order to ensure its be er life,
throughout transformer operation. Oil to be used for
impregnation/ testing needs to be periodically tested
and should be periodically replaced whenever
parameters violation as per norms is noticed.
2.4.2 Proper Vendor list: Selection of proper vendors for
accessories/ raw material is a very important activity and
a comprehensive vendor list should be a part of contract.
Otherwise, contract speci c vendor list may be nalized
at the time of contract execution with mutual consent.
e best approach would be prepare own vendor list for
each speci c raw material or ing which should be
exhaustive and must include at least 2-3 vendors each
from at least 3
 e-T FOTECH 2020- International Conference on Transformers
major manufacturers. is shall bridge the gap between
the utility vendor list and the manufacturer. e
performance of each vendor should be evaluated at least
every two years and if there is any repetitive issue then the
vendor may be delisted or may be warned. Also in case of
critical materials like CRGO, insulation items etc.
tracking of mill TC wrt the CRGO rolls/insulation used
must be ensured.
2.4.3 Proper manufacturing quality plan/document: e
critical stages of manufacturing are core, winding,
insulation shop, assembly and processing. It is suggested
to have a quality document i.e. Manufacturing Quality
Plan, which properly addresses all these stages for a
proper control.
e transformer winding shop and the nal assembly
shop are the most critical areas and this area must be
sufficiently clean and preferably pressurized or
controlled especially for 400 kV class and above rating.
Brazing of electrical connections, welding of structural
items like tank etc. are another critical manufacturing
process, which needs proper a ention. Brazer and welder
quali cation should also be a part of contract. In
addition, manufacturer should have proper tools for
handling core, winding and the transformer assembly.
e processing of active part and its subsequent oil
impregnation are another critical area, which needs
proper a ention. However, the quality control document
should not be so stringent to hinder the manufacturing
process ow.
2.4.4 Less important activities: Some utilities specify to
measure the weight of winding, core and active part as a
part of witness. Normally such facility is not a part of
regular transformer manufacturing and hence this calls
for creation of additional facility in the core/winding and
assembly area, which is not mandatory, and it also adds
additional time in the process. It is suggested to use
physical parameters like measuring core dimensions,
winding conductor dimension and other details to arrive
at the desired parameters as per design or nal test values
like resistance, loss etc. may be used to verify the
technical adequacy rather than weight. Transformer
being a technical intensive product, must be ve ed by
physical dimensioning/test values rather than weight.
2.4.5 Ensuring the adequacy of Test laboratory: e
adequacy of the transformer to meet the desired duties is
of paramount importance to ensure the right quality of
the product. ese are proven by the factory testing of the
transformer. As such, the adequacy of test laboratory for
testing of all the routine and type tests as per IEC 60076 is
very important. e test laboratory must be NABL
accredited and it must have all equipment like Impulse
generator for LI/ SI, test equipment for LTAC/ACPD
test, No Load/ Load Loss/ temperature rise etc. for the
range of transformer to be procured. For proper PD test,
the High Voltage laboratory should be shielded. All the
test instruments must be of reputed make and duly
calibrated.
2.5 FI INGS, ACCESSORIES and OIL:
2.5.1 Mandatory ings: Fi ings like PRV, Buchholz
relay, OTI, W TI, bushings, conservator etc. are
mandatory ings, which are necessarily required, even
if utility do not specify the same.
2.5.2 Optional ings and state of art sensors: ere are
some optional ings/systems, which are optional and
asked by speci c utilities e.g. On line partial discharge
system, maintenance free breather, Online drying
system, On Line DGA, On line condition monitoring
system, Fiber Optic temperature monitoring system,
Nitrogen Injection Fire prevention system. While these
ings are useful and futuristic too, however its use in all
the transformers needs to be reviewed by utility based on
their budget and site requirements. If budget permits it is
always be er to go for these state of art sensors/ ings
viz On Line DGA, ON line oil drying, Maintenance free
breather etc. for effective operation and maintenance of
transformer.
2.5.3 Speci cation of optional ings: Some utilities
specify detailed and stringent technical speci cation of
these ings and many times it is noticed that their
speci cation is met only by one or two vendors only,
which does not create a healthy competition and it results
into a costly affair. e On Line ings line OLDGA,
OLPD etc. are meant to judge the relative health of
transformer/reatcor and they are not meant for a
laborator y precision level measurement. It is
recommended that utility may decide whether and
which of these ings are mandatory, depending on their
budget & eld technical experience and specify
parameters, which promotes a heathy competition,
maintaining the basic intended duties.
 e-T FOTECH 2020- International Conference on Transformers

2.5.4 Speci cation of Oil : e current trend of I2R loss in addition to total load losses as a guaranteed
speci cation indicates that there are more than 10 parameter. is has been done with an intent to ensure
different varieties of mineral insulating oil. e that there is fair play with regard to quantum of
speci cations of different utilities vary in chemical material/copper used in transformer. Also with regard to
composition (Naphthenic vs paraffinic vs GTL), standardization of other transformers/ reactors, the
additives (Uninhibited, Inhibited or trace inhibited), following is suggested:
technical parameters viz. oxidation stability, pour point, 2.6.1 Layout standardization with regard to placement of
ash point, Tan delta, impulse withstand, gassing cooling equipment, bushings, ings, marshalling box,
tendency and so many other parameters. PRV etc. Tank mounted coolers/ radiators may be
While latest version of IEC 60296-2020 has been provided by utilities/manufacturers wherever possible,
released, which speci es 2 basic categories of oil i.e Cat A resulting into compact transformers/ reactors and
& B, which can further formulated into many different reduced foundation requirements.
subcategories. In this IEC, a 4 le er codi cation has been 2.6.2 Standardization of basic technical parameters:
assigned to select the desired category of transformer oil Apart from losses, CEA has also nalized the basic
as hereunder: parameters. All utilities are requested to pick the
technical details from the speci cation in the range. It
Table 1 – Identifying 4 letter codes in will be highly bene cial for not only manufacturers but
ordering mineral oil to IEC 60296-2020
(For eg TVAU) also utilities in terms of value for money, delivery,
st
1 Letter = T – S – - erection, commissioning and even interchangeability.
Equipment Transformer Switchgear 2.6.3 Interchangeability: As a further extension of
nd
2 Letter = V – Unused R – - standardization of basic technical parameters, the
Declaration (Virgin) Recycled
rd
transformer/reactor layout is also standardized. With
3 Letter = A – B–
Type Specification Specification this, it shall signi cantly ease the interchangeability of
-
Type A (High Type B similar transformers/ reactors. Utilities may select the
grade) (Standard standard layouts, which will result into signi cant bene t
grade)
th
in terms of eng ineer ing/ draw ing approval s,
4 Letter = I – inhibited U– T–
Antioxidant uninhibited trace procurement of materials and delivery and also
inhibited interchangeability between various similar transformers
IEC has been prepared by international experts based on of the same or different manufacturers. It will also
worldwide research and experience. It is recommended improve the overall reliability of the system.
that utilities may select oil from IEC 60296-2020 (rather 2.6.4 Plan for outage- Utility should plan for a faster
than formulating own speci cations), which is overall mechanism, of replacement of the spare
technically suitable and this will result into a healthy transformer wherever available and the location of spare
competition, be er value and be er miscibility/ transformer should be such that it is easy to replace the
replacement. same. In fact, wherever it permits, the spare transformer
may be kept in vicinity in hot condition i.e. with all
2.6 STANDARDIZATION OF LOSSES, BASIC accessories and cooling equipment mounted and with
TECHNICAL PA METERS/LAYOUT AND oil. As soon as there is failure, the spare transformer shall
INTERCHANGEABILITY come into operation through a switching system, which
Standardization by CEA along with a team of leading will rst isolate the failed transformer, and the spare
utilities and manufacturers in the eld of standardization transformer is taken into service without necessitating to
of losses for standard rating transformers/ reactors may physically shi the transformer. is practice is already
be followed. It includes followed by some utilities.
 e-T FOTECH 2020- International Conference on Transformers
2.7 T NSFORMER FOR SPECIAL
APPLICATIONS (GIT):
Gas Insulated Transformer (GIT) with SF6 gas is the one
of the solutions for special applications viz. hydropower,
underground substations, densely populated cities,
mission critical substations, and offshore substations for
be er safety and reliability. Its major advantages are re
proofness, leak proofness, reduced footprint and lower
long-term maintenance requirements. Transformers
with Voltage ratings up to 500 kV and 400 MVA, have
already been developed. From design perspective,
cooling calculations for large rating transformers is a
challenge and therefore manufacturers with adequate
experience in this eld should be quali ed.
2.8 EFFECT OF NEW PROCUREMENT
PROCESS ON THE T NSFORMER
INDUSTRY:
Now a days many utilities are adopting
auction), wherein manufacturer has to immediately
respond to the rock-bo om prices by the competitors.
While on the short term basis it appears to bene t the
buyer due to quantum drop in prices. However, many
times, it results into prices, which are not feasible with the
speci ed technical parameters, materials, speci ed
vendor list and requirement of international standards.
As a result, sometimes manufacturer has to execute an
order, which is very near to material price, adversely
impacting the minimum level of pro tability to sustain
operations.
is causes signi cant erosion in the pro tability of
t ran s f o r m er i n d u st r y es p ec i a l l y f o r rep u ted
manufacturers. Sometimes this could also result in some
unfair practices for sur vival or compromise in
quality/material.. Presently the industry is facing very
stiff challenge due to price erosion and some of the
manufacturers have already closed their business, while
many reputed manufacturers are facing stiff challenges in
operations. It is recommended to rethink about
process so that long-term interests of the transformer
industry as well as purchaser is safeguarded.
2.9 CONCLUSION
Transformer & reactors being one of the most critical
equipment of the power system needs not only technical
intervention wrt selection of right manufacturers but
also an optimum speci cation, which strikes a ne
balance between the selection of right varieties of
manufacturers and a well-balanced set of technical
limits/performance parameters. ough the onus of
design lies with manufacturer, however for con dence
building, design review as per CIGRE guide for all new
designs may be done to ensure that the transformers &
reactors have adequate margins in the performance and
integrity parameters. In the present scenario where price
and delivery is a big challenge, it is important to ensure
that there is a well-designed Manufacturing quality plan
to have an effective control on materials, manufacturing
and testing. e ings and latest state of art sensors
(reverse needs to be carefully selected, which will result into a
be er asset management of the eet of transformers. As
far as possible, utilities must use standard speci cation,
which is nalized by CEA for signi cant bene t in the
overall effectiveness of procurement process.
REF:
1. CIGRE guide 530 (WG A 2.36) “Guide for
conducting factory capability assessment for power
transformers”
2. CIGRÉ Technical Brochure 529: Guide for
Conducting Design Reviews for Power Transformers
3. IEC 60296-2020
4. Toshiba Press release regarding Gas Insulated
Transformer, available on internet
 e-T FOTECH 2020- International Conference on Transformers

EFFECTIVE PROCUREMENT OF EHV POWER T NSFORMERS AND REACTORS

Lars Liden
Hitachi ABB Power Grids Sweden

ABST CT
e high voltage condenser bushing is a critical
component found in all electrical networks and whose
failure can have serious consequences. Due to high
electrical stress levels in bushings, failure mechanisms
tend to result in sudden and catastrophic failures of an
explosive nature. A lot is gained if the consequences of a
failure can be reduced hence, we see a shi in
technologies in the bushing designs, mainly with new
materials. is paper will focus on the emerging
technologies with its development challenges, special
testing that the industry been facing during the ongoing
technology transition.
1. INTRODUCTION
High voltage condenser bushings facilitate electrical Figure 1 – Schematic view of condenser core with coaxially
stress control through the insertion of oating equalizer located aluminum foils in a web of insulating material.
screens made of aluminum or other conducting
materials. e condenser core in which the screens are 2. TRENDS
located decreases the eld gradient and distributes the
Many utilities have realized the bene ts of dry bushing
eld along the length of the insulator. e screens are
technologies as a risk mitigator. Resin Impregnated
located coaxially resulting in an optimal balance between
Paper (RIP) technology is a great contributor in reaching
external and internal puncture strength; see Figure 1
higher performance gures. RIP technology has been in
Condenser cores are generally impregnated with
service for more than 25 years now but is still in many
transformer grade mineral oil and placed inside a
countries to be considered an emerging technology. e
envelope of oil and porcelain, which prevents the
somewhat differently designed condenser core is heated,
bushings oil from mixing with transformer oil. e
dried and vacuum impregnated by a curable epoxy resin
system is called Oil Impregnated Paper (OIP) and
to form a solid unit, free from oil. e step up to the
accounts for more than 75%of all installed bushings.
highest voltage levels, however, has taken time. is due
to both technical challenges as well as the general
conservatism in the power industry. An emerging
technology is the latest step in the dry bushing concepts,
Resin Impregnated Synthetics (RIS), where the paper
web is replaced with a polymeric ber to obtain a dry
insulated solution that does not absorb moisture during
handling and storage. is technology has started to gain
acceptance by the end users and is now moving up into
 e-T FOTECH 2020- International Conference on Transformers

4. VERIFYING TESTS
higher voltage levels. e outer insulation can be of two [1] Manufacturers must comply with certain tests to
types, ceramic or polymeric Ceramic insulators have a verify the design as such, as well as, routine testing to
long history and will be used for many years to come, it is verify the quality of the individual bushings Some
likely however, that their role will diminish in the examples are;
foreseeable future as the industry seeks improved Inner insulation:
insulators performance in order to reduce overall costs, • Electrical
and to improve safety, seismic withstand and pollution • Mechanical
performance along with insulator weights. • ermal
e major difference between RIP technology and RIS Outer insulation
technology is, as earlier explained, that the paper is • Tracking and erosion
replaced by polymeric ber. However, there are • 1000-hr salt fog test
differences between the bushing manufacturers both in • Hardness
materials used and ways of manufacturing, for example Additional tests may also be carried out to verify long-
kni ed vs non-woven mesh and lled vs non- lled term performance, or performance under extreme
epoxy. conditions some examples are;
RIS has been in service much shorter time compared to • Various cycling tests e.g temperature and bending
RIP but so far, no differences have been noted when it • Arcing tests
comes to ser v ice performance and reliability. • Seismic tests
Application wise will RIS by time reach the same level as • Hydrophobicity test
RIP has today. • Ageing tests
Fire tests, speci c of interest for dry bushings with
3 STANDARDS AND SPECIFICATIONS
silicone insulators have been carried out by the authors
e bushings are standardized by the international company. e purpose of these tests was to quantify the
standard IEC 60137, with latest edition dated 2017, differences between OIP and RIP bushings regarding re
where RIS have been officially introduced. IEEE resistance.
C57.19.00 and IEEE C57.19.01 is mainly applicable for • Time to ignition in seconds, a critical parameter
the North American market and there are also local in all re testing
standards like IS2099. One must note that the standards
only set the basic requirements meaning that developing
and qualifying new products and materials requires
extensive testing above and outside the standards. Some
of major utilities in the world have stringent quali cation
process with speci c tests outside the standards which
can help the manufacturer in their development efforts.
When writing speci cations especially around dry
bushings with silicone insulators the utility or industrial
customer must have a thorough approach and for • Peak heat release in kW/m2, a given amount of material
example not only write “Dry bushings with silicone can burn slowly or fast and the peak heat release is one of
insulator”. Another important aspect is to follow-up several parameters which describes the effect of a re as
deliveries vs speci cation requirements. well as the possibility to conduct efficient re ghting.
Note that free oil represents more than 60% of the total
energy in an OIP bushing
 e-T FOTECH 2020- International Conference on Transformers

4.2 INTERNAL ARCH TEST

RIS main advantage is the resistance to moisture
absorbance have been shown by the authors company in
a test where the bushing was boiled 42 hours in deionized
water containing 1kg/m3 NaCl. A er the test the
bushings passed a complete type test in accordance with
IEC 60137
ere are several bushing technologies available on the
market; like OIP with porcelain or silicone insulators,
completely dry RIP with silicone or porcelain insulators,
RIP with small amounts of oil and gas and RIS with
silicone insulators.
e authors company together with a research institute
[3] conducted a full-scale destructive test where three
different 245kV oil-to-air bushing concepts were chosen:
• OIP with ceramic insulator (le in all three pictures)
• OIP with composite insulator (middle in all three
pictures)
• RIP with composite insulator lled with gel (right in all
three pictures)

4.1 END CUSTOMER SPECIFIC TESTS

Two major utilities in Europe have as part of their
homologation process that the bushing manufacturer
must perform an Internal Arcing Test. e authors
company have done that which also have given vital
knowledge for future developments.
To simulate the most serious type of ashover inside a
One of the major utilities in North America have
heavily stressed section, the bushing was ed with very
installations at extremely low temperatures hence they
precisely positioned internal arching gaps that would
require a special temperature cycling test to be
trigger a massive pressure build-up when a short circuit
performed with temperatures below -50 degrees C. is
current was released.
test is very tough for the silicone insulator and it gave vital
information regarding the design of the silicone insulator
when the authors company conducted the test. Please
note that mutual agreements between the utility and the
bushing manufacturer, regarding testing procedures ant
pass/fail criteria needs to be in place before these special
testing take place.
In IEC 60317 clause 9.2.3, table 8 is the speci ed limit for
tan delta for RIP/RIS set to maximum 0,7%. A low value
of tan delta is a sign that the drying process have been
completed in a controlled and quality manner. In India
the utilities have decided to set a maximum limit of 0,4 or
0,5 to assure quality. ese levels are for most of the
bushing manufacturers a normal value measured at
routine test. Specifying lower levels for example below Several types of detectors were used to record the total
0,3 is not viable as it is a major risk for reduction of the received radiative energy and the ux density over time in
bushing life. different wavelengths.
 e-T FOTECH 2020- International Conference on Transformers

e investigation included studies of the probability oil
ignition, as well as thermal damages of epoxy coating,
cable insulation and silicone rubber on the transformer.
Test parameters:
• Peak current value 102kA
• Test currents r.m.s.
o 41kA at the beginning of tests
o 39.2kA at end of tests
• Test current time 510ms
All tested bushings suffered severe damages and
illustrated very well the violence of internal ashovers
and the risk of damages to adjacent components or
persons.
problems occurred mainly due to UV-radiation. Todays
used silicone material have the correct mixture of
ingredients for a long and trouble-free service life. ere
are three main types:
• RTV, Room Temperature Vulcanized
• LSR, Liquid Silicone Rubber
• HTV, High Temperature Vulcanized
RTV are sometimes used to improve the hydrophobicity
behavior on porcelain insulators however not suitable to
build insulators. LSR is quite commonly used for
insulators and gives a good long-term performance.
HTV has the highest performance especially for
applications in harsh environment such as saline areas,
deserts and in heavy polluted industrial areas.
ere are two main manufacturing methods of silicone
insulators, molding and extrusion. Extrusion gives the
advantage that the tip of the sheds will have a radius
hence reduce stresses and the pro le of the sheds can also
be altered for different applications.

orough studies, analysis and calculations was made on

the test results from detectors to show the effect on
material on transformers.
e conclusions made on the study shows that the
thermal exposure from the two oil- lled bushings will
affect other components in the transformer station; the
epoxy coating, silicone rubber and cable insulations
might not necessarily ignite but will be severely damaged
and the oil released from the transformer main tank is Example of molded insulator shed tip
very likely to ignite. e RIP bushing with silicone
insulator has a radiant heat ux emi ed that is
signi cantly lower than the oil- lled bushings, which
indicates a drastically lower impact.
5. INSULATORS
A signi cant trend is the move from porcelain insulators
to silicone insulators, this to gain the optimal solution on
a RIP or RIS bushing. e rst installations were made as
string insulators for overhead lines. At that time the
materials were not suitable for installation hence Example of extruded insulator shed tip
 e-T FOTECH 2020- International Conference on Transformers

Extensive laboratory and eld testing have been speci ed type tests but even more to assure long time
performed to qualify the silicone rubber material and the performance of the RIP/RIS bushings with silicone
way of production to give the long-term trouble-free insulators.
performance required by the industry. is valid both for 8. REFERENCES
normal polluted areas as well as in harsh environments.
Long time service experience is question rightly asked by [1] Lars Jonsson, Ander Holmberg and Ma ias
end users. A CIGRE paper that describes long-terms Lundborg ABB Sweden Dry transformer bushings with
service experience was published 2013 in Auckland, composite insulators – the obvious combination for
New Zealand [2]. is paper describes and proves good increased reliability, Published at TechCon AU, April
service experience. e authors company can con rm 2013
continued good service records both in AC and DC
applications on world-wide basis. [2] Igor Gutman, Christian Ahlholm STRI Sweden. Ulf
Åkesson, Anders Holmberg, Dong Wu, Lars Jonsson
6. HANDLING/STO GE ABB Long-term service experience and inspection
It is strongly recommended to thorough study the results of HV equipment made of silicone rubber
Installation and Maintenance Guidelines issued by the insulators Published at CIGRE in Auckland New
bushing manufacturer in order to not jeopardize the Zealand 2013
lifetime of the bushings Some general comments on
long-term storage (> 6 months). [3] L Jonsson, R Hedlund ABB AB Components,
• OIP – indoor unpacked in safe vertical position. Keep Ludv i ka Sweden. A Andersson, H Skoogh, P
dry, clean and protected from mechanical damage or in Mindykowski, M Försth RISE Research Institutes of
wooden crate protected from water at a certain angel to Sweden, Borås, Sweden. Fire and safety aspects of
cover the complete condenser core with oil. ashovers in high voltage transformer bushings.
• RIP – indoor unpacked in safe vertical position. Keep Published at the 5th International CIGRÉ Colloquium
dry, clean and protected from mechanical damage or in "Transformer Research and Asset Management”, Rijeka -
wooden crate protected from water. Oil side must be Croatia, October 2019.
protected to avoid moisture ingress. Simple method with
silica gel bags in steel container to avoid any complication
like risk of oil or gas leaks from container.
• RIS – indoor unpacked in safe vertical position. Keep
dry, clean and protected from mechanical damage or in
wooden crate protected from water.
7. CONCLUSIONS
ere is a major trend ongoing in the bushing market, the
shi from OIP with porcelain to RIP/RIS with silicone
insulators. e driving force behind this trend is the
increased focus on safety both for personnel as well as for
equipment. RIP and RIS are acknowledged to be the best
risk mitigators.
is paper has described the advantages with the
emerging technologies as well as the need of thorough
testing during product development both to ful ll the
 e-T FOTECH 2020- International Conference on Transformers

DAY

02 Key Note Papers

 e-T FOTECH 2020- International Conference on Transformers

APPLICATION GUIDELINES AND FAIL-SAFE OPE TION

OF ON LOAD TAP CHANGER
Shrikant B Potnis
Easun-MR Tap Changers (P) Ltd., Chennai

ABST CT 2. SELECTION OF OLTC

On load tap changers (OLTCs) are one of the vital parts
in Transformers, used to regulate the Voltage without de-
energizing the Transformer. Since on load tap changing
requires switching the power from one tapping to the
other online, it requires complete understanding about
the OLTC operating principle and its methods. is
paper highlights the OLTC types, design selection
criteria for power & auto transformers, interface between
transformer manufactures & OLTC manufacturers, the
common challenges along with their possible solutions.
e OLTC online diagnostics methods are brie y
illustrated.
1. INTRODUCTION
When tap changing technology evolved, it started with
very limited number of taps and then in the form of Off-
circuit tap changers which offers the luxury of having
required number of tapings, but a time-consuming
process. When power consumption took a sharp upward
trend since the year 1920s, voltage regulation by
changing the tap on-load became very much essential.
As shown in Fig 1- If we wish to change tap from 1 to 2,
either we have to rst disconnect switch at 1 and then
connect to 2 or we have to bridge the two taps- but in this
process there will be heavy arcing if we disconnect the
load or we will make inter turn shorting if taps 1 and 2 are
bridged and both are not acceptable. Historically, in
OLTCs, this short circuit path is established either with
Resistors or Reactors. Among these, Resistor type is the
widely used technique.
Selection of OLTC for a given application must be made
carefully as per IEC 60214-2, Application guide for Tap
changer, for long term reliability of transformers. is
standard gives complete overview of
- Type of tap changer
- Location of tap changer
- Insulation level of tap changer
- Major ing and accessories of tap changer
- Operation, maintenance, and monitoring methods
- Information to be provided by manufacturer
- Protection and Safety aspects.
2.1 TYPE OF ONLOAD TAP CHANGERS
Based on type of transfer of load current from the
connected to the pre-selected tap, it is either achieved
using by means of “resistor” or “reactors”. In many
countries including India, high speed resistor type is
used, while reactor transition is common in USA. Both
working methods are in Fig. 2

Fig. 1 – OCTC Principle Fig.2 – Resistor & Reactor OLTC Type

 e-T FOTECH 2020- International Conference on Transformers

In terms of mounting, 2 types of OLTCs “In-tank” &

“External ange” are possible.

Fig.5 – Switching sequence of Diverter-Selector OLTC

Fig.3: In-Tank type OLTC

Based on internal constructions, there are two types of

In-Tank OLTCs available, namely,
a) Diverter-Tap Selector type
b) Selector Switch type.
ough both OLTCs operate on same high- speed
transition operating principles, their structure and
Fig.6 – Selector switch type OLTC
switching principles are different.
In this type, there will not be any dedicated Diverter
switch compartment but the tap selection and switching
will happen in the same compartment, i.e., in Selector
Diverter
Switch.

Tap Selector

Fig.4–Diverter–Tap Selector Type OLTC

In diverter-selector types, the next desired tap will be

selected in the “Tap Selector” rst and then the power
will be switched from the previous tap to the newly
selected tap in the Diverter, as shown in Fig.5
 e-T FOTECH 2020- International Conference on Transformers

2.2 LOCATION OF TAP WINDINGS

Based on transformer type, winding connection (Star or
Delta), location of OLTCs are decided by transformer
designer in consultation with OLTC manufacturer.
In case of 2 or 3 winding transformers, following voltage
variations are feasible,
- Taps on HV for HV variation
- Taps on HV for LV variation
- Taps on HV for Combined variation
Based on the location of tap windings, model and
con guration of OLTC also will varies considerably.
In auto transformers, many OLTC combinations are
possible from most simple to complex.
Following tapping arrangement (a) to (d) are possible for
auto transformers with HV variation.

OLTC taps location can be any one of the following.

a) Line-end of winding
b) Middle of the winding
c) Neutral end of star connected windings.

Frequently encountered tap windings are,

However, on load tap changer provided at line end of MV
- 3-ph Star with taps in neutral
(U2) to permit HV(U1) voltage over a range of as
- 3-ph Star with taps in line end
speci ed, with constant voltage on MV(U2) is most
- 3-phStar with taps within winding
common. Type “C1” is mostly applied in 315/500MVA,
- 3-phDeltawith taps within windings
400/220/33kV ICT in India with U1 variation.
- 3-phDelta with taps at line end
Similarly, following tapping arrangement (a) to (d) are
- 1-ph with taps at line end
feasible for auto transformers with MV (U2) variation.
- 1-phase with taps within winding

In 2-winding transformers with “star” HV windings,

OLTCs are mostly provided in the neutral end of
winding to permit HV variation, with constant LV
voltage.
In 2-winding transformers with “Delta” connected HV
windings, OLTCs are mostly provided either “at line
end” or “electric center” of HV winding to permit HV
voltage, with constant LV voltage.
In “Delta” connected windings, number of poles of 2.3 TAP WINDING CONFIGU TIONS
OLTC is decided based on internal dielectric
Technically feasible basic arrangements of taps are linear,
requirements. It can be in single pole, or two poles or 3
single reversing change over selector, double reversing
poles as shown here.
change over selector, single coarse- ne change over
selector & multi coarse change over selector.

But 3 basic tapping con gurations are commonly used

are,
a) Linear
b) Reversing,
c) Coarse- ne
 e-T FOTECH 2020- International Conference on Transformers
Fig.7 – Linear, Reversing & Coarse- ne
winding con gurations
e selection of linear, reversing, and coarse- ne
regulation is decided by transformer manufacturer in
consultation with OLTC manufacturer, a er evaluation
of appearing dielectric voltages at various location of tap
changer, step capacity, current ratings, interphase
voltages.
2.4 INSULATION LEVEL OF OLTC
Following voltages occurring on all tap positions of the
transformers must be veri ed against its permissible
voltage stresses guaranteed by OLTC manufacturer.
- Power frequency voltage appearing on various parts of
OLTC during transformer testing or service.
- Full wave & Chopped wave Impulse voltage appearing
on various parts of OLTC during transformer testing or
in service.
- Switching impulse voltage appearing on various parts of
OLTC during transformer testing.
Review of internal voltages is essential selection of OLTC
during transformer testing and site operation.
- across the ne-tap winding or between the end of the
ne-tap winding and end of the coarse winding of same
phase.
- between any taps of the ne-tap winding of different
phases or between the end of the coarse winding of
different phases.
- between the beginning of the coarse winding of
different phases.
- between the beginning and end of the coarse winding of
the same phase.
- between the beginning of coarse winding and common
terminal or current carrying contacts.
- between any part of tap changer and ground
2.5 CURRENT CAPACITY OF OLTC
e maximum rated through current of OLTC should be
greater than the highest possible current which ows
through the tap winding of the transformer in any tap
position. e selected OLTC should be suitable over-
load speci ed for the subject transformer in accordance
with IEC 60076-7.
e rated through current (highest tap current) and
highest voltage per step of the transformer should be
withing the values of maximum rated through current
and relevant step voltage of the OLTC.
Similarly, OLTC short circuit withstand current should
be greater than the expected short circuit current of the
tap winding of the transformer in any tap position
considering transformer impedance.
2.6 DISCHARGE WITH
CHANGER-OVER SELECTORS.
e operation of change-over selector takes place in the
mid-position of OLTC. During this operation, the load
current ow through the tap windings. erefore, the tap
windings are temporarily disconnected from the main
windings and potential of the winding oats. In such
cases, discharge between the opening and closing
contacts occurs during the operation of the change-over
selectors. To avoid difficulties regarding the dielectric
stress and possible formation of gases, special precaution
like tie-resistor, potential switches etc., may be necessary.
e same to be carefully evaluated by both transformer
and OLTC manufacturer during its selection process.
2.7 OTHER SELECTION CRITERIA
In addition to above, mechanical duty needs to be
considered based on expected number of operations per
year, especially for applications like transformers for use
in rolling mills, electrolytic plants or furnace application.
 e-T FOTECH 2020- International Conference on Transformers
e motor drive mechanism requirement should ful l
the end customer requirements including type of
controls agreed.
e expected pressure, vacuum withstand, low
temperature requirement if any should be reviewed
during the selection of OLTC.
3. FAILURE MODES OF TAP CHANGER
Following should be evaluated for reliable OLTC
operation
- Inspection at regular intervals as per number of
operations
- Summary of inspection carried out
- Cleaning of diverter and selector switches
- Contact wear and tear and its replacement
- Re-installation of tap changer
- Condition of oil inside OLTC
- Frequency of operations per day, month, year
- Oil ltration frequency
4. SOLUTIONS TO COMMON PROBLEMS
At Transformer Manufacturer’s Factory:
i) Control the rate of temperature rise less than
10˚C/hour as some insulating materials are very
sensitive to rapid rise in temperature and likely to get
damaged.
ii) A er Vapour Phase Drying, it is very much essential to
clean the Diverter chamber with clean Oil before closing
the Drain valve. Ensure the Diverter chamber is
absolutely clean, and no foreign particles are present
before tightening the drain plug.
iii)Don’t operate either the diverter Switch or tap
selector without rinsing it thoroughly with clean oil.
Kerosene removes all lubrication and the mechanism is
totally dry to perform even a single operation correctly.
Lubricate with clean oil.
iv) Ensure that O-ring is si ing properly in its groove
before reassembling Diverter unit. Use small quantity of
silicone grease if required to secure O-ring properly in
the groove so that it does not pop up and get displaced
while reassembling.
v) Always ensure proper phase sequence before
connecting supply to Motor Drive unit.
vi)Ensure that Motor Drive unit and OLTC pole units
are on the same tap positions while coupling connecting
sha s. Ensure exact mid position of poles as well as
Motor Drive unit while coupling sha s. Pl ensure that
Diverter Switches operate almost at the same time as
far as possible (when 3 poles are gang operated) and also
ensure that the number of Hand Crank revolutions w.r.t
the mid position in raise and lower directions are almost
equal. (Ref manufacturer’s manual).
vii) Operate OLTC with hand crank starting from the
middle of the tapping range and ensure that the hand
crank revolutions in raise directions as well as lower
direction are almost equal. Operate OLTC manually
through hand crank up to the Lower most position and
ensure that mechanical end stoppers and end limit
switches are functioning correctly. en operate OLTC
manually through hand crank up to the upper most
position and again check mechanical end stopper and
electrical limit switches are operating correctly.
viii) While dismantling the Motor Drive for despatching
it to site, ensure that you bring OLTC to the mid position
and then dismantle the connecting sha s etc.
ix)If Tie In Resistor has been recommended by OLTC
manufacturer never try to eliminate the same for any
reason as it is very essential or else problem is likely to
be faced on Change Over Switch - may not be
immediately but a er a few
operations of COS.
5. SOLUTIONS TO COMMON PROBLEMS
At Site,
i) Follow all the points mentioned from 5 to 7 earlier
under factory checks without fail.
ii) While ltering Oil either of main Transformer tank or
of Diverter switch chamber, ensure that Diverter is
connected to conservator so that there is a room for oil to
expand to the conservator. If conservator is not
connected, then lower about 10% oil quantity from
 e-T FOTECH 2020- International Conference on Transformers

Diverter chamber allowing oil to expand when oil vi) Operate OLTC regularly; Keeping it idle for a longer
temperature goes up. Remember even when main tank time may create more problems…like coking etc.
oil is being ltered, Oil in Diverter chamber also expands
and we must provide room for its expansion or else the vii)Carry out regular inspection as per manufacturer’s
safety diaphragm of the Diverter Chamber is likely to instruction manual and that too through a skilled person.
burst. viii) It is important to check tightness of all the hardware
iii) In case there is any oil leak in the Diverter Chamber it at a regular interval as per guidelines given in the
is always recommended to repair it as early as possible or operating manual. Ensure tightness of hardware.
else the moisture from atmosphere will enter the ix)It is mandatory to maintain more than 30kV BDV and
Diverter chamber and it is very dangerous. Although moisture content <30ppm in Insulating uid.
there is Oil head of the conservator, moisture will enter
the Diverter chamber and hence it is essential to get the x) Since arcing takes place during every tap change
leak repaired as early as possible. Filter Diverter chamber operation, carry out DGA is not required for OLTCs.
oil a er the leak is repaired to ensure all moisture is 6. ONLINE OLTC FAULT DIAGNOSTICS
removed from the chamber.
Conventional method of OLTC-Transformer diagnostic
iv) While changing the direction of tap change, i.e. while technique involves opening of OLTC, Draining of
you are changing tap from say tap position no. 4 to 6 Transformer and OLTC oil, deputation of manpower
&then if you reverse the direction a er reaching tap and arranging required equipments etc, which is a
position 6 to come back to Tap position no 5 then in this cumbersome process.
case tap selector contacts do not move as the odd moving Dynamic Contact Resistance Measurement (DCRM) is
contact is already on tap no 5 and they maintain their an analytical tool, which can be used to analyze OLTC-
position. Transformer without taking out the OLTC from
Transformer. DCRM can indicate us the nature of fault
v) When you are changing Tap Manually through Hand and fault location in OLTC (if there is any) within an
Crank then you rst complete the tap being changed and hour of testing, which will save lot of money and time.
then only reverse the direction if required. Don’t rotate
Crank Handle for a few revolutions and then reverse
the direction of its rotation in between. is is very
important while operating OLTC through Hand crank
or else you will leave Tap Selector contact at a oating
potential unnecessarily and there may be capacitive
current discharges between contacts.
is is very important especially while changing taps
near mid position of the tapping range when a change
over switch is used as the change over switch
operates while changing tap from mid position to the Fig.8 – Typical DCRM Result
next higher Tap position or lower Tap position. It is not
advisable to keep contacts at a oating potential for a long
time due to possibility of local capacitive current
discharges. While operating OLTC electrically we never
face this problem as it will complete the initiated tap
change operation without fail.
 e-T FOTECH 2020- International Conference on Transformers
DCRM – G PH EXPLANATION
Fig.9 - DCRM – Detailed view
With careful study of graphs by competent persons, it is
possible to nd if there is any fault in OLTC& its possible
location and the nature of fault.
Before opening of the Transformer Tank for inspection
of Tap Selector to look for any probable fault, it is
advisable to carry out DCRM which gives indication
whether to open the Transformer Tank or not.
7. CONCLUSIONS
OLTC being such a vital element in Transformer, due
care has to be given in its functional understanding,
Factory and Site testing, Site operation and its
maintenance schedule. Knowing the Dos and Don’ts
about OLTCs will ensure that there won’t be any
operator and testing related issues which will ensure
unnecessary failures and power outages. It is also equally
essential to have knowledge about the advanced
analytical tools available in OLTC segment.
REFERENCES:
[1] On-load tap-changers for Power transformers -
Operation principles, applications and Selections by Mr.
Axel Kramer.
[2] OLTC operating manual of Easun-MR
 e-T FOTECH 2020- International Conference on Transformers
APPLICATION AND SELECTION OF BUSHINGS,
TAP CHANGERS AND T NSFORMER ACCESSORIES
A. S Jhala
T&R India Ltd.
1. ABST CT
Every transformer or reactor is equipped with a variety
of accessories to monitor and protect the equipment.
Some accessories are integral parts for cooling, voltage
regulation or connecting to the outside power grid.
Present paper broadly divides commonly used
accessories in to ve groups and explains areas of
application, selection guidelines and relevant reference
standards.
Paper also dwells upon the future developments that may
come up in transformer accessories.
2. ACCESSORIES
International Electrotechnical Vocabulary (IEV) de nes
Accessory as, “A device supplementing a main device or
apparatus, but not forming part of it, that is needed for its
operation or to confer on it speci c characteristics”
(Reference 151-11-24). Each transformer and reactor is
equipped with a variety of accessories for protection and
monitoring the performance. Some of them are integral
parts of transformer for cooling, voltage control or
operational safety.
Accessories in transformers can broadly be divided into
ve categories viz. protection, monitoring, cooling,
insulating liquid handling and preservation, condition
monitoring and life enhancement. Bushings and tap
changers are directly connected to transformer active
part and considered as integral parts of transformers;
hence these are covered separately.
Summary of commonly used accessories are,
Category: Protection:
Gas/Oil Actuated Relays, Pressure relief Device (PRD),
Rapid Pressure rise relay (RPRR), Fire suppression
system, Conservator shut off Non-Return valves (NRV),
Bushing current Transformers (BCT), Air cell-rupture
relay.
Category: Monitoring Instruments
Magnetic oil level gauge (MOG), Prismatic oil level
guage, Oil temperature indicator (OTI), Winding
temperature indicator (WTI), Oil/Water ow indicator
(OFI/WFI), Fibre optic sensor (FOS) for winding
hotspot temperature.
Category: Cooling
Radiators, Pumps, Fans, Oil to air/water heat-
exchangers.
Category: Insulating Liquid handling
& preservation
Flexi-separator (Air cell), de-hydrating breather & Valves
Category: Condition assessment & life
enhancement
Dissolved gas analyser (DGA), Bushing monitoring
system, Online oil drying system (ODS), Online PD
monitoring system, Transport bushings & Impact
recorder, Core-Frame-Tank earthing links.
3. STANDARD OVERVIEW
Transformer product standards IEC 60076-1[1] and IS
2026-1[2] do not cover any recommendations for
mandatory accessories to be provided along with
transformer/reactor. Indian users and manufacturers
generally refer to “Manual on transformer” Publication
No: 317 from CBIP[3] for this purpose.
IEEE standard C57.12.10[4] covers standard and
optional accessories and their recommended mounting
locations. In India, requirement of accessories is mainly
governed by the product technical speci cation prepared
by purchaser.
Indian standard IS 3639[5], published in 1966, covers
speci cations for ings and accessories for power
transformers. Another Indian standard IS 3637[6]
covers speci cations for gas operated relays.
 e-T FOTECH 2020- International Conference on Transformers
EN standard series 50216[7], in twelve different parts
cover speci cations for various accessories and
components used in transformers and reactors. IEC TC
14 commi ee is also working on similar lines to publish
similar standards under series IEC 60076-22[8]
Five parts of the series are already published.
It is understood that IS:3639 standard for ings and
accessories is under revision by BIS ETD 16 commi ee.
4. SELECTION CONSIDE TIONS
While selecting any accessory under the groups
mentioned in Table 1.0, the following general criteria
shall be checked.
a) Degree of Protection (e.g. IP55, IP65 for Outdoor &
IP 41 for Indoor application).
b) Level of Corrosion (e.g. C3, C4 or C5 as per ISO
12944[9]).
c) Environmental conditions (e.g. ambient temperature,
altitude, pollution level etc.).
d) Insulating liquid type (e.g. Mineral or Ester)
e) Seismic acceleration (zone at installation location).
f) Auxiliary power supply (e.g. AC/DC, Volts).
g) Contact rating of switches (e.g. making/breaking
capacity).
h) Cable gland interfaces.
Speci c key selection requirements against Bushing, Tap
Changer and other accessories in each group are covered
below.
5. BUSHINGS
IEV de nes Bushing as, “device that enables one or
several conductors to pass through a partition such as a
wall or a tank, and insulate the conductors from it
(reference: 471-02-01).
Bushings are one of the most critical components of
transformers and due care shall be taken during
selection. While selecting bushings, the following shall
be considered.
IEC standard 60137[10] and Indian standard IS
2099[11] covers the product requirements of AC
bushings above 1000 Volts.
5.1 TECHNOLOGY USED
OIP (Oil Impregnated Paper) or RIP (R esin
Impregnated Paper) or RIS (Resin Impregnated
Synthetic) or Solid epoxy cast with polymer covering or
Plain porcelain type.
For Ur=12-36kV range, plain porcelain bushings as per IS
3347 series[23] is the standard. Solid Epoxy cast
bushings are used for indoor applications and in air lled
cable boxes. Special resin cast bushings with a polymer
(LSR–liquid silicon rubber) housing and a metallic
capacitance screen moulded inside resin are available.
ese are PD free bushings with test tap.
For Ur>36 kV, for oil to air HV application, OIP
condenser bushings (IS: 12676[24]) are generally used.
Dry type bushings (RIP or RIS) are preferred in this
range from re safety angle with oil to air medium
application.
Oil lled cable boxes with oil to oil type bushings are
used sometimes for installations having space
constraints. As far as possible, oil lled cable boxes
should be avoided from re safety angle. External,
outdoor cable pot head and dry type oil to air bushings in
transformer linked with a jumper connection is the ideal
solution from re safety point of view. For oil to oil or oil
to SF-6 medium applications, either OIP or RIP
bushings are used.
5.2 ELECTRICAL
a) Rated voltage
b) Rated/overload current
c) Continuous highest operating voltage
d) BIL rating (Impulse/Power Frequency)
e) Short circuit current & duration (Dynamic / thermal)
f) Insulating uid type used
g) Permissible power factor for capacitively graded
(condenser type) bushings
h) Tap requirement (test tap/voltage tap, voltage)
I) Arcing horns
j) Power factor limits for capacitor type
 e-T FOTECH 2020- International Conference on Transformers
5.3 MECHANICAL
a) Orientation (vertical, inclined & horizontal), Medium
of interfaces (oil to air, oil to oil, oil to SF6)
b) Cantilever load during operation and test load,
Seismic acceleration
c) Wind velocity
d) Ice load
e) Type of insulators (porcelain, composite or polymer)
f) Bus duct temperature de-rating factors
5.4 SITE CONDITIONS
a) Altitude at Installation
b) Level of pollutions (Creepage distance: protective and
total),
c) Storage: Short-term or long-term, methods
5.5INTERFACE
a) Type of lead connection (draw rod, draw lead, stem
type)
b) Mounting ( ange PCD, hole size, number of bolts
etc.)
c) Interface with bi-metallic connectors
d) BCT Space
e) Oil end Dimensions (Diameter/length)
f) Oil end corona geometries and design options of
interconnection
W hile selecting bushings, in addition to above,
reputation and operational experience of the brand and
make plus availability of valid type test report are
important.
6. TAP CHANGERS
IEV de nes changer as, “A device for changing the
tapping connections of a winding” (reference: 421-11-
01). Depending upon the application it may be On Load
(suitable for operation while the transformer is energized
or on load) of De energised (suitable for operation only
while the transformer is De-energised).
Like bushings, tap changers are critical component in
transformers. While selecting on-load tap changer, below
aspects are checked.
6.1 TECHNOLOGY
a) Vacuum or Oil (with supplements: Continuous Oil
lter device),
b) High speed transition resistor or reactor type
6.2 ELECTRICAL
a) Type of connection (linear, coarse ne, reversing)
b) Highest working voltage of tap changer
c) Maximum test voltage of tap changer contacts (LI, SI,
AC 1min)
d) Maximum rated through current, Step voltage
e) Voltage across tap range (coarse, ne), Number of tap
position (operating and run through)
f) Type of insulating uid
g) Auxiliary control circuits (independent, parallel
operation, local manual, local electrical, remote
electrical, automatic with or without line drop
compensation)
6.3 MECHANICAL
a) In-tank or ange mounted
b) Conventional or bell mounted type
IEC standard 60214[12} covers product requirements
and application of tap changers. Indian standard
8468[13] speci cations for On Load Tap Changers are in
the process of revision by BIS ETD 16.
While selecting tap changers, in addition to above,
reputation and operational experience of the brand and
make plus availability of valid type test report are
important.
7. CATEGORY: PROTECTION
Accessories provided for Transformer protection
respond to incipient faults and trip the unit before
developing in to damaging failures.. e devices are
equipped with switches to either give an alarm signal or,
trip signal in case of developing failure, to switch off the
transformer.
 e-T FOTECH 2020- International Conference on Transformers
7.1 GAS/OIL ACTUATED RELAY
Gas/Oil actuated relay, popularly known as Buchholz
Relay, is provided in the oil path between tank and
conservator with two intended functions:
a) Give alarm incase of fault gas evolution.
b) Give trip signal during oil surges in the relay pipe
consequent to major inside breakdown.
Indian standard IS 3637[6] (under revision) provides
speci cations for Buchholz relays. Such relays are
available in nominal pipe bore sizes 25, 50 and 80 mm.
For medium and large rating transformers size of 80 mm
is popularly being used. Fig 1 shows typical view of
Buchholz relay.
Fig 1: Typical Buchholz Relay
When selecting the relay, ow se ings shall be taken to
avoid mal operation of relay while switching operation of
oil pumps associated with coolers.[14]
International standards EN 50216-2[7] and IEC
60076-22[8] covers product requirements for Buchholz
relay.
7.2 PRESSURE RELIEF DEVICE (PRD)
A ash over or a short circuit occurring inside oil lled
transformer is accompanied by a dynamic pressure wave
in the tank due to gas formed by the decomposition of
the oil. e pressure relief device is provided to release
the tank over pressure to avoid the tank rupture and
consequent re.
CIGRE Technical Brochure 528, Guide for preparation
of speci cations for Power Transformers[15] has
mentioned minimum number of PRD as 1 No. each for
main tank and OLTC, preferable mounting location
being on Top cover. e number of PRD required is
dependent on the total oil volume of the transformer
(One PRD for every 40,000liter of transformer oil is
recommended by supplier).
Operating pressure of PRV should be less than the tank
oil pressure test values with an intention to avoid damage
to transformer tank in case of over pressure situations. Fig
2 shows typical view of PRD.
Fig 2: Typical PRD with mechanical indicator
Presently there is no Indian Standard for PRD,
Internationally, EN standard 50216-5[7] and IEC
standard 60076-22[8] covers product requirements of
PRD.
When provided, PRD should have suitable pipe work
connected to direct the spilled oil towards the base tank
pit.
e disadvantage of PRD is longer operating time.
During severe transformer faults when fault location is
far away from PRD device, it may not operate before tank
rupture. erefore PRD cannot be relied upon to prevent
tank rupture for high energy arcing faults on all
occasions.
 e-T FOTECH 2020- International Conference on Transformers
7.3 RAPID PRESSURE RISE RELAY (RPRR)
Rapid pressure rise relay (RPRR), also known as sudden
pressure relief device aimed to pick up the oil pressure
wave in the transformer tank when a serious fault occurs.
e device is able to distinguish between rapid and slow
rates of pressure rise and will give signal if rate of pressure
increase is faster than speci ed rate. Such device is
generally provided on transformer tanks of large and
critical units. Fig 3 shows RPRR ed on 500 MVA, 765
kV class transformer.
Fig 3: RPRR ed on 500 MVA 765 kV
class transformer
7.4 FIRE SUPPRESSION SYSTEMS
As per Central Electricity Authority (CEA) regulations
2010[16],
a) Transformers or reactors of 10 MVA and higher rating
or oil lled transformers with oil capacity of more than
2000 Ltrs shall be provided with automatic high velocity
water spray system or Nitrogen injection based re
protection system.
b) e transformers or reactors of 220 kV or higher
voltage may preferably be provided with Nitrogen
injection based re protection system in addition to
water spray system.
Both technologies are widely used and selection of
technology is to be made by the purchaser.
7.5 NON-RETURN VALVE
Pre-Stressed Non Return Valve (PNRV), also known as
conservator shut off valve is generally ed in the oil pipe
connecting the conservator and the main tank. It is also
provided between the conservator and oil lled cable
boxes.
Typical construction of this valve allows oil ow in both
directions (main tank to conservator and conservator to
main tank) at a ow rate commensurate with thermal
expansion and contraction within the normal operation
of the transformer.
e valve prevents the oil ow (shut off condition) in
case the oil ow from conservator back into transformer
main tank / cable box exceeds the pre-determined
calibrated value say 100LPM and initiates an alarm. Such
situations are likely to come in case of bushing breakage
or rupture of the main tank.
e shut off valve prevents the oil from the conservator
spilling out through a bushing turret, damaged bushings,
ruptured cable box or a minor rupture near the top of the
main tank. It reduces the amount of oil (fuel) spilling
from the conservator and feeding to a re consequent to
tank rupture.
Earlier such valves were part of re protection systems.
Now days, such valves are used right upto 765 kV class
transformers irrespective of usage for re protection
systems. Fig 4 shows use of conservator shut off valve for
40 MVA transformer.
Fig 4: Conservator shut off valve for
40 MVA transformer
 e-T FOTECH 2020- International Conference on Transformers
7.6 BUSHING CURRENT
T NSFORMER (BCT
Bushing current transformers are used for
protection/metering purposes and are mounted in
turret. BCT rating viz. Nos. of cores, ratio, accuracy,
protection class etc. are decided a er power system and
relay co-ordination studies and is speci ed by
customers.. It is preferred that BCTs are provided with
test w ind ing to fac i l itate the test ing dur ing
commissioning and service conditions[17]. Fig 5 shows
typical BCT and mounting arrangement in turret.
Fig 5 Bushing Current Transformer
7.7 AIR CELL RUPTURE RELAY
Air cell rupture detection relay is used in conservators
having exi separator. is device is intended to detect
non-functionality of exi separator and gives alarm
signal. Such relays are essential for natural ester uid
lled transformers where proper functioning of air cell is
mandatory to avoid deterioration of esters. Fig 6 shows
typical view of Air cell rupture relay.
Fig 6 Typical Air cell rupture detection relay
8. CATEGORY:MONITORING
8.1 MAGNETIC OIL LEVEL GAUGE (MOG)
Conservators of the main tank and tap changer diverter
compartments are ed with magnetically operated oil
level gauge to monitor the oil level in the conservator. In
large transformers 250mm dial sized gauges are used for
visibility from ground level. e indicators are equipped
with signal contacts for high and low oil levels.
At present there is no Indian Standard for MOG,
Internationally, EN standard 50216-5[7] and IEC
standard 60076-22[8] covers product requirements of
MOG. Fig 7 shows typical view of Magnetic oil level
guage.
Fig 7 Typical Magnetic oil level Gauge
8.2PRISMATIC OIL LEVEL GAUGE
Prismatic oil level gauge is generally provided on main
transformer tank and conservator. It gives visual
indication of oil level. Such gauges are useful to read the
main tank oil level during transportation. In absence of
air cell rupture relay, functioning of air cell (whether in
in ated condition) can be judged by checking the gauge
shows always full. Fig 8 shows typical view of Prismatic
oil level gauge.
Fig 8 Typical Prismatic oil level gauge
 e-T FOTECH 2020- International Conference on Transformers

8.3 OIL AND WINDING TEMPE TURE

INDICATORS (OTI/WTI)
Oil temperature indicator (OTI) measures the top oil At present there is no Indian Standard for ow indicators,
temperature. W TI simulates winding hot spot International standards EN50216-5[7] and IEC
temperature by sensing top oil temperature and winding standard 60076-22[8] covers product requirements of
current and outcome is displayed on dial. ow indicators. Fig 10 shows typical view of ow
indicator.
For transformers quantity of OTI is 1 No. Quantity of
WTI generally depends on client requirements of
monitoring single/all winding temperatures.

OTI and WTI are equipped with alarm and trip

contacts. Indicators signals on reaching pre-set
temperature values. For remote indication, inbuilt PT
100 sensor is provided within temperature indicator.
Indicators with dial size of 150 mm and angular sweep of
270° are commonly used power transformers.
International standards EN 50216-11[7] and
IEC standard 60076-22[8] covers product requirements
of temperature indicators. Fig 9 shows typical view of
temperature indicator.
Fig 10 Typical oil ow indicator
8.5 FIBRE OPTIC SENSORS
Fibre optic sensors are used for measuring directly the
hot spot temperature inside the winding. Fibre optic
sensors when used during the temperature rise test
enables to nd out directly the winding hot spot
temperature and winding gradient a ained during full
load and overloads. is information can be used for
v a l i d at i n g t h e c a l c u l at i o n s o w a re u s e d b y
manufacturers and for calibrating conventional winding
temperature indicators used in transformers.

Decision of providing bre optic sensors is driven by

criticality of the unit and also preferred when the rating
per limb exceeds 33 MVA.

Fiber optic sensors are useful to monitor the higher

winding hot spot temperatures accurately during
overloading.
Fig 9 Typical Winding temperature indicator
IEC standard 60076-2[18] w ide Annex ure E
8.4 FLOW INDICATORS (OFI/WFI) recommends the number of sensors for various ratings
Oil and water ow indicators are used to indicate the and cooling types.
oil/water ow in case of forced cooling in transformers.
Such indicators with visual indication of ow give alarm
in case ow rate falls below pre-set values. In both cases
ow values are matched with pump capacity ( ow in
LPM).
 e-T FOTECH 2020- International Conference on Transformers
9. CATEGORY: COOLING
Depending on the cooling type of transformers, cooling
accessories viz. radiator, pumps and fans are provided.
9.1 RADIATORS
Radiator size and numbers are decided by designer for
the required heat dissipation from transformers. For
power transformers pressed steel radiators of width of
520 mm are popularly used. Other technical
requirements on radiators such as thickness of panel,
diameter of header etc. are covered in EN 50216-6[7]
and IEC 60076-22 standards [8]. In absence of any
Indian standard, IEEMA-9 standard[19] on radiators is
unanimously accepted and followed amongst
manufacturers and purchasers within India.
Depending upon the environmental conditions,
radiators with painting or hot dip galvanising (HDG) are
used. Fig 11 shows typical radiators with painting and
HDG (hot dip galvanizing).
(a) (b)
Fig 11 Radiator with HDG (a) and Paint (b)
9.2 PUMPS
For forced oil (OF) cooled transformers with radiator
banks, to facilitate the smooth oil ow during natural oil
ow (ON) conditions axial ow type pumps are used.
For forced oil (OF) cooled transformers with unit
coolers and heat exchangers natural ow is not envisaged
and hence centrifugal pumps are used.
Capacity and pressure head of pumps in both cases are
selected by designer for the required heat dissipation and
expected hydraulic pressure loss. Pumps with high
pressure heads o en can cause phantom operation of
Buchholz relay[14], is shall be taken care during
selection.
At present there is no Indian Standard for axial type oil
pumps, International standards EN standard
50216-7[7] and IEC standard 60076-22[8] covers
product requirements of pumps for transformer oil.
General trend of cooling in transformers is to opt for
ONAN or ONAN/ONAF cooling even to the highest
ratings (e.g. 1500 MVA auto-transformer bank) to
reduce maintenance liability.
9.3 FANS
For forced air (AF) cooled transformers fans are used to
increase the heat dissipation capacity of the radiators.
Numbers of fans are decided by designer based on
required air ow (CFM). Fans are contributing towards
noise level of transformer and for low noise transformers
due care i s to be taken w hi le select ing the
type/diameter/noise level of fans.
At present there is no Indian Standard for transformer
fans, International standards EN 50216-12[7] and IEC
standard 60076-22[8] covers product requirements of
transformer fans. Fig 12 shows typical arrangement of
fans mounted on radiators.
Fig 12 Typical arrangement of fans
mounted on radiators
 e-T FOTECH 2020- International Conference on Transformers
9.4 OIL TO AIR/WATER COOLERS
Oil to Air/Water coolers are used for dissipation of heat
and occupy very less foot print as compared to radiator
banks. Both types of coolers require pump in running
condition all the time (higher auxiliary losses)
irrespective of loading. Oil to water cooler requires water
supply (cooling tower). Double tube oil to water heat
exchangers are standard now by which water to oil leak is
completely eliminated.
Oil to water cooler is used in hydro generating stations in
view of easy availability of water.
Oil to air cooler is widely used in thermal power stations
and mobile substations. Such types of coolers has
limitations when the atmosphere is dust laden (e.g.
Aluminium smelters).
At present there is no Indian Standard for Oil to Air
coolers. Indian standard IS 6088[21] covers oil to water
heat exchanger for transformers and IS 4503[22] covers
shell and tube type heat exchangers. International
standard EN 50216-9/10[8] cover s product
requirements of Oil to Air/Water coolers. Fig 13 shows
typical view of Oil to air cooler and mounting of Oil to
water coolers.
(a) (b)
Fig 13 Typical view of Oil to air cooler (a)
and mounting of Oil to water coolers (b)
10. CATEGORY: INSULATING LIQUID
H A N D L I N G / P R E S E R VAT I O N
10.1 FLEXI SEPA TOR
Flexi separators (also known as bladder or balloons or air
cell) are used in conservator of liquid immersed
transformers and reactors with intention to,
a) Isolate transformer insulating liquid from contact with
atmospheric air.
b) Provide in ation / de ation to accommodate oil
volume displacements due to transformer temperature
variation.
Dimensions of exi separator are decided by designer
based on conservator dimensions. At present there is no
product standard for exi separator. Fig 14 shows typical
view of in ated exi separator.
Fig 14 Typical In ated exi separator
10.2 BREATHER
Silica gel breather is provided over the conservator to
prevent moisture ge ing in to conservator. Automatic
regenerating breathers are available today to avoid
frequent maintenance work of drying out of silica gel.
e quantity of silica gel in breather is normally
dependent on the total oil volume of the transformer.
When provided in multiple numbers, breathers are
recommended to be connected in series than parallel.
At present there is no Indian Standard for breather.
International standards EN 50216-5 [7] and IEC
standard 60076-22[8] covers product requirements of
breather. Fig 15 shows typical view of silica gel breather.
 e-T FOTECH 2020- International Conference on Transformers
Fig 15 Typical silica gel breather
10.3 VALVES
Oil preservation and handling transformers is supported
by variety of valves for different applications viz.
draining, ltration, sampling, vacuum pulling etc.
CIGRE TB 528 Guide for preparations of speci cations
for Power Transformers [15] recommends variety of
valves for different applications in transformers and
reactors.
European standard EN 50216-8[7] covers product
requirements of bu er y valves.
11. CATEGORY: CONDITION ASSESSMENT
& LIFE ENHANCEMENT
Condition assessment and diagnostic techniques
provide accurate health conditions of the transformer
and help users to minimise forced outages. Some of the
online condition monitoring tools commercially
available at present include, DGA, moisture in oil,
bushing monitoring, partial discharge monitoring etc.
Requirement of condition monitoring and diagnostic
tools along with new transformer shall be made wisely
based on rating, application and criticality of the unit.
IEC standard 60076-1 [1] and CIGRÉ Technical
Brochure 343 [20] provide recommendation on supply
and provision of various condition assessment tools
along with new transformers.
12. WAY AHEAD
12.1 INTERCHANGEABILITY
Interchangeability refers principally to accessories that
are or have been purchased from different suppliers,
expected to have common dimensions and layout, in
order to allow them to be physically interchangeable with
each other. Utilities o en strategically intend to keep
stock of critical accessories for transformers under eet.
Accessories presently offered by various suppliers in
India have different contact ratings, terminations and at
some cases variation in physical sizes.
Interchangeability within accessories from sourced from
different suppliers is essential and much needed.
12.2 STANDARDISATION
Indian standard IS 3639[5] published in the year 1966,
covers the dimensional requirements for Buchholz relay
mounting ange, valve size and ange, threads for
breather pipes, thermo meter pockets, uid level
indicator dial size, rollers and earthing terminal bolt sizes.
Another Indian standard IS 3637 [6] earlier published in
year 1966 covers the performance requirements of gas
operated relays.
EN standard 50216 series[7] in 12 different parts have
covered the construction, performance and test
requirements of various accessories. In similar lines IEC
TC 14 commi ee is working to cover transformer
accessories in IEC 60076-22[8] standard wherein
ve parts are already published.
Standardisation in lines with EN and IEC standards is
much needed in India in order to achieve
interchangeability aspects and maintain performance
and test requirements within accessories offered by
various suppliers.
12.3 SMART ACCESSORIES FOR SMART
T NSFORMERS
Smart transformers as part of smart grid, work
independently and maintain contact with smart grid to
allow remote monitoring and administration. Such
transformers include smart accessories and monitoring
devices which sense the various parameters, access the
 e-T FOTECH 2020- International Conference on Transformers
condition of transformer and give intelligent
recommendations.
World is moving to digital and in years to come majority
of all substations will be unmanned and centrally
monitored/controlled. Smart accessories shall pave a
way to make this happen.
12.4 DIGITAL MANUALS
Conventionally, operating manuals of accessories are
shared as hard copy/electronic format. With increased
use of smart phones and digitization it is aimed that each
accessory is provided with a ached QR code to facilitate
immediate retrieval of operating manuals by scanning.
13. CONCLUSION
Paper has broadly divided commonly used accessories in
ve categories. Application and selection of accessories
for each category is described. Status on National /
International product standards against each accessory is
mentioned.
Author has identi ed that Interchangeability,
standardisation and smartness in accessories are need of
the hour in India which shall be taken up and completed
at the earliest.
With increased use of smart phones, suggestion for
immediate retrieval of digital manuals by scanning QR
codes a ached to accessory is given.
REFERENCES
1. IEC standard 60076-1, Edition 3.0-2011, Power
Transformers - General.
2. IS standard 2026-1.
3. CBIP Publication 317 – 2013, Manual on
Transformers.
4. IEEE standard C57.12.10.
5. IS 3639, Speci cations for ings and accessories for
power transformers.
6. IS 3637, Speci cations for gas operated relays.
7. EN 50216 Parts 1-12, Power transformer and reactor
ings.
8. IEC 60076-22 multiple parts, Power Transformers –
Power transformer and reactor ings.
9. ISO 12944 multiple parts, Paints and varnishes –
Corrosion protection of steel structures by protective
paint systems.
10. IEC 60137, Edition 7.0-2017, Insulating bushings for
alternating voltages above 1000 V.
11. IS 2099, Speci cations for bushings for alternating
voltage above 1000 V.
12. IEC 60214 multiple parts, Tap changers.
13. IS 8468, Speci cation for on load tap changers.
14. Mal functioning of Buchholz relays – Field
experience and learnings, P. Ramachandran, 12th India
Doble power forum – 2014.
15. CIGRE TB 528, Guide for preparations of
speci cations for Power Transformers.
16. Central Electricity Authority (CEA) regulations
2010.
17. BCT Testing of Transformers at site and at Test
Station – An Approach, A.S Jhala, Malav Shah,
T FOTECH 2012 workshop – 2012.
18. IEC standard 60076-2, Edition 3.0-2011, Power
Transformers – Temperature rise for liquid immersed
transformers.
19. IEEMA 9, IEEMA standard for pressed steel radiators
for transformers.
20. CIGRE TB 343, Recommendations for condition
monitoring and condition assessment facilities for
transformers.
21. IS 6088, Speci cation for oil to water heat exchangers
for transformers.
22. IS 4503, Shell and tube type heat exchangers.
23. IS 3347, Dimensions for porcelain transformer
bushings for use in normal and lightly polluted
atmospheres.
24. IS 12676, Oil impregnated paper insulated condenser
bushings – dimensions and requirements.
 e-T FOTECH 2020- International Conference on Transformers
ROLE OF DIGITAL SYSTEM
FOR T NSFORMER APPLICATION – UTILITIY PERSPECTIVE
P.K. Pa anaik
OPTCL - Odisha
ABST CT
In Power System, Electrical power ow takes the path of
four important areas that starts from the Generating
Station and ends with Load center (Generation,
Transmission, Distribution and Load Centre). In each
sector, T NSFORMER is the inter-linking electro-
mechanical device that holds the nerve of power system
dynamics, transforming the electrical energy as per the
stage requirement of voltage to meet the need of the
utility consumers and plays the pivotal link among the
energy stake holders. Considering its importance in the
system, every utility does concern about its healthy status
for stable and reliable supply system.
In the present era of ever-increasing load demand with
the network complexity, this device during its life cycle is
subjected with various stresses (Electrical, Mechanical,
ermal and Chemical) which in turn deteriorate its
condition. In order to protect the transformer from these
stresses, various electro-mechanical protection devices
are generally used like electrical relays, temperature
sensors (OTI, WTI), Gas relays (Buchholz Relay),
PRD/PRV etc... ese devices actuate a er occurrence
of the faults, resulting with partial or fully damage of the
active parts. e present devices rarely help to indicate
about the pre-hand information to take pro-active action
on the system.
But, need of the hour is to obtain early information on the
deteriorating components for quick preventive action.
is is possible by using modern digital intelligent
sensors on the transformer system. e gradual change of
system parameters could be sensed by using modern on-
line sensors which prepare the signals for the process bus
with automated action linked management tool to
control over the system developing reliable and cost-
effective solution. is type of transformer embedded
with digital sensors and supported intelligent network
is termed as SMART T NSFORMER. Not only the
condition monitoring, the digital system could also be
integrated to the total life cycle of the transformer,
starting from its inception, successful operation to the
end of the life, even a er math during postmortem also.
is paper has been focused on the discussion note
regarding the role of digital system that could be used on
different stages of the transformer life. Various Technical
tools, modern innovative concepts have also been
described on the consideration of utility’s perspectives.
1. INTRODUCTION
Electrical Network is embracing the major disruptive
changes. e substantial growth in all categories is
making the situation bit complex due to huge approach of
RE (Renewable Energy) and its integration with the
ever-increasing load demands. Moreover, the inter-
connected GSS (Grid Sub-Station) suffers the challenge
of handling this complex power that ows in different
directions aiming towards the system availability for
24×7 with multiple and multipa ern generators, modern
concept of prosumers with DER (Distributed Energy
Resources). e other multi-bound practical issues make
the situation still critical, like running the system with
existing old-ageing infrastructures, reluctant approach of
end users on the acceptance to the advanced
technologies, their over-conscious approach to the
technoeconomical aspects etc… Energy utilities being
the actual end users face the real junk of these challenges
during the initial take off and acceptance of the
innovative technologies.
Any new concepts may crawl into this updated electrical
network, but we have to depend upon the transformer
 e-T FOTECH 2020- International Conference on Transformers
the only old age eld proven option for the availability of
safe and sure power for our requirement. Over the years,
we have come across many of the technological
adoptions on transformers, like use of low loss
amorphous core, use of bio-degradable oil, use of
modern and improved conductors for highly efficient
applications. But need of the time is to improve the
system availability based on quality and reliable power to
the end user. ese all depend upon in-time data
handling of the system parameters to get actionable
information for automated decision making towards
operation and maintenance of the assets under control.
Moreover, in the present era towards adaption to smart
grids, the data availability and communication link from
all the available primary devices need to be integrated to
the automated system. Transformer- the vital primary
device among all, must be inter-connected to the smart
system loop for greater visibility and best control in terms
of monitoring, supervision and operation. e basic
behind the best concept of handling of this device
depends upon the management of AI (Analog Inputs)
and conversion of the same to scalable DI (Digital
Inputs) for SCADA system. So in totality, the
transformer, equipped with sensors for the preparation
of AI and subsequent DI, shall be termed as DIGITAL
Transformers.
Digital transformers are becoming an integral part of the
new electricity grid, which provides all the control
parameters at the HMI (Human Machine Interface)
screen for pro-active action towards proper regulation of
voltage and other important parameters. e use of these
transformers is gaining popularity both in transmission
and distribution level. ese transformers are equipped
with intelligent electronic devices, and smart monitoring
and automated diagnostics features.
e transformer condition is monitored continuously
and evaluated for appropriate asset management
decisions. Asset management needs to be both cost-
effective and reliable, sensing solutions that provide asset
managers with actionable intelligent data.
e focus shall be on the development of an electrical
system, the network with monitoring, supervising of the
electrical parameters that can control for maximum
availability of electrical power to our consumers. One-
line a ention in this subject shall be spoken that of PQRS
(Power with Quality, Reliability Safety and security) by
the suitable selection of Digital Embedded Smart
2. WHY DIGITAL SYSTEM
In practice, the be er system operation always demands
the quick availability of signals at the interface point for
detail processing and subsequent real time action
execution. e quick availability of signals depends upon
the medium/communication channel through which it
is transmi ed. Moreover, the risk of the signal loss or
breakage is also another important reason of delay or
failure of the work execution. In broad sense, this
medium is considered as hardware type or so ware type.
Say an example, transfer of signal in the form of energy
pocket by the use copper wire is termed as the hardware
signal. Transfer of signal by the wireless form or by use of
bre optics is termed as so ware type. e faster
availability can be a ained by so ware form and the
possibility of loss or breakage of the signal is also less in
this form. So, continuation of the signal availability can
help us for perfect actuation of the work management.
We have the following advantages for digitisation of the
process.
• Extensive self-diagnosis through sensors used in the
system ensures the maximum uptime.
• Sequential seamless control and operation with
interlocks for safety of equipment and working
personnel.
• Increased system Reliability, Safety Security, and
Efficiency.
• Optimisation of Transformer operation that reduces
the operational and maintenance cost.
• Easy Data recording helps for improved measurement
accuracy and subsequent Analysis for corrective action
towards repair and maintenance.
 e-T FOTECH 2020- International Conference on Transformers
• Reduction of Copper wire and possibility of signal loss
due to looseness, breakage or short-circuit.
• Improved Communication capabilities like data
exchange between intelligent devices intra and inter-
substation.
• Be er EMC performance and quick isolation of circuits
as per requirement.
• Less or nil dependence on human beings.
2.1. BASIC WORKING ACTION
Digital transformer system network largely contains
three important areas (Hardware, So ware and Process
Application).
a. Hardware part is the primary device that used in the
transformer to collect the system parameters for the
application process at the CCS (Central Control
Station). is basically are called sensors, transducers,
converters, instruments etc ed inside or outside of the
transformer at the suitable region. In digital system we
call it as AI (Analog Input).
b. So ware part is the intermi ent device that manages to
convert the hardware signal to the scalable digital signal
for readiness to the application purposes at the CCS.
ese include the device called A to D converter (Analog
to Digital), Opto-couplers etc... e output of this
so ware part reports directly to the process bus for the
integration to the automation network. Now for perfect
system operability a common communication is chosen
and presently IEC 61850 is the protocol that
interconnects all so logics for seamless deliver towards
reliability and efficiency of the device. In this digital
system we call as BI or DI (Binary or Digital Input).
c. Application Process is the nal process bus part of the
system for real time action towards supervision, control
and monitoring of the system. Built-in components like
digital sensors, dissolved gas analysers and digital safety
devices collect data for monitoring, diagnostics and
control at the common house. e action of suitable
control is extended by the signal called BI or DI (Binary
or Digital Output).
2.2. TYPICAL APPLICATION NOTE
is application note has been described from utilities
perspective. All utilities do concern about the Power
system availability with Quality, Reliability, Safety and
Security. During working operation, due to change of
environments on the transformer, it is subjected with
electrical, chemical and mechanical stresses. Among all
the parameters, temperature plays the important role that
affects the transformer materials quicker in comparison.
So, it requires continuous condition monitoring of the
temperature pro le on the transformer. Moreover, the
loading pa ern in the system is always un-certain that
needs to be monitored and controlled based on
temperature recording with respect to the load pa ern. In
present practice we use bre optics directly with the
transformer winding, core, oil immersion etc... that
provides accurate temperature rise and its analysis at the
CCS can decide about the operational control of the
transformer helping the device for higher efficiency and
life span. (Refer Fig.1)
2.3. MODERN APPLICATIONS
Digital technologies are also being embedded by
technology providers in different type of transformers,
Fig.1 Typical Application
of Fiber Optics for Temp.
be it oil type or dry type. More relevant for the dry-type
transformers, designed to work without oil, where the
core and the coil are cooled by natural or forced air and
non ammable high grade solid insulation material.
 e-T FOTECH 2020- International Conference on Transformers
is makes them safer and more environmentally
friendly. Such transformers are ideally suited for high-
risk applications such as in offshore and densely
populated areas, and in sensitive ecosystems. In digitally
enabled dry-type transformers, smart sensors collect
data and combine them to provide powerful analytics.
For the higher rating transformers, these sensors
embedded digital response transformers could also be
the best solution to monitor for proactive action towards
its control and necessary action.
Digital technologies embedded robots now have reached
to the eld application for submersible transformer
inspection which perform fast, safe and cost-effective
internal inspection, reducing personnel risk and lesser
down time with cost effective solution. Another
advantage is that this could also be controlled wireless
from remote
BI HMI
In
Fu
BO
Fu
AI
A. Fu
tBI ion
rar
Int.
Lib
y Final inspection & testing,)
BO
B
Fig 2. Basic Digital System
center, maintaining point to point security control. Many
other applications include like RTCC bank controller,
Cooler Kiosk Controller by MCU (Motor Controller
Unit), Online DGA, Piezoelectric camera controller,
Online condition monitoring etc... (Refer Fig 2.)
3. ROLE OF DIGITAL SYSTEM FOR
T NSFORMER APPLICATION
Transformer being the most vital and valuable
equipment in the T&D system, the technical
speci cation is prepared by utilities with utmost care and
caution considering the techno commercial aspects. In
the era of competitive bidding the manufacturers are also
bound to continuously innovate and optimize their
design processes, to meet the expectations of the
customers. Even a er the system is in service, preventive
maintenance and condition monitoring activities are
judiciously followed to improve the life expectancy of the
transformers. However, human errors and process
de ciencies are bound to occur, which hence leads to
meteoric result than expected. erefore, the critical
analysis and systematic observation of the events and
happenings during the lifecycle of the transformer shall
be helpful in improving the domain expertise and
diagnostic capabilities of various stake holders at all
fronts. e digital system and its application can
judiciously guide us to land upon the corrective action at
each level of life cycle starting from its inception stage to
a er math death for postmortem analysis. e detail life
cycle points are enunciated below.
a. e inception and planning for giving birth of this
equipment. (Preparation of GTP & speci cations,
tendering and award of contract)
b. From embryonic stage to infancy. (Stage inspection,
c. e methods for adoption of the same, at the utility’s
premises. (Dispatch, delivery & transportation,)
d. Care with immunization and preparatory acceptance
for the new society during infancy. (installation &
erection, precommissioning test & charging)
e. Successful Operating and Maintenance (Modern
innovative LMS- Loading Management Schedule with
CBMCondition Based Maintenance.)
 e-T FOTECH 2020- International Conference on Transformers
f. Condition monitoring practices during young and
dynamic stage. (online & offline condition monitoring &
testing).
g. Health monitoring, testing and care during old age.
(RLA study, overhauling process etc.)
h. Postmortem analysis (upon accidental or
natural death).
3.1. INCEPTION AND PLANNING STAGE
Planning for bringing the new/uprating transformers in
the network depends upon the system study with the
available load and future possible load growth in the
system. With the available data and computing the same
with the present system, the requirement of the
transformer is decided. While considering the same few
of the following points are considered.
a. Matching of parameters like Rating, % impedance for
addition to the existing GSS (Grid Sub-Station).
b. Category and pa ern of Loading.
c. Smooth Maintenance possibility.
d. Judicious calculation to the Short circuit fault MVA.
e. Suitable protection schemes.
Once the requirement gets nalized about its rating,
terminal parameters calculation etc... the GTP and
Speci cation of the transformer is planned to prepare.
3.1.1. ROLE OF DIGITAL SYSTEM
a. e accurate calculation on the available and future
loading pa ern could be obtained by using proper
sensors/instruments in the integration mode.
b. e running data and future prospective data shall be
computed with pre-de ned so ware.
c. eoretical result and actual value shall be compared
and simulated to arrive at the accurate requirement of the
Transformer.
d. en with data bank and past values, the GTP and
speci cation can be prepared.
e. en by using e-Tendering digital system, the tender
can be explored to maintain free fair transparent process.
Similarly, the associated works like opening of price bid,
technical data scrutiny till award of the contract could be
completed by the digital system.
3.2. STAGE AND FINAL INSPECTION AND
TESTING
Every utility has certain pre-recorded guidelines,
procedures and referrals for the checking, testing and
inspection of the transformers. e inspection process
includes different stages starting from the preliminary
point of design review, technical data comparison, stage
inspection with raw materials and assembly inspection
and nal inspection etc... Each time few of the pre-
de ned tests are conducted.
3.2.1. ROLE OF DIGITAL SYSTEM
a. Preference has been considered for the preparation of
digital set up with the available guidelines, procedures
and referrals for easy scrutiny of the documents.
b. Regarding different stage inspections, updated and
innovative micro-sensors could be utilized for obtaining
the accurate data and conclusion regarding the use of
correct materials.
c. 3rd Eye high resolution camera could be integrated to
the customer premises for easy, quick and economical
inspection. Moreover, this audio-video coverage could
be kept for future record reference and quotation for the
similar job.
d. Digital testing equipment with facility of data storage,
retrieval and data analysis is another choice for accurate
testing during the inspection. e updated SCREEN
SHARE concept is also gaining popularity for the remote
control on the testing of the job with satisfaction and
quick access to the result preparation.
e. Most important point of developing of DATA BANK
for the entire process on digital base helps in recording
the time for future reference.
 e-T FOTECH 2020- International Conference on Transformers
3.3. DISPATCH, T NSPORTATION AND
SITE DELIVERY
e present practice of issuance of Delivery report
depends upon the central Procurement Team a er due
review of the test reports during inspections, that results
delaying of the job dispatch. Similarly, the old method
still prevailing of transporting the job by the trailer
without proper tracking. e site veri cation during
delivery is continuing by the material count veri cation.
Need of the hour for the inclusion of Digital system into
these processes.
3.3.1. ROLE OF DIGITAL SYSTEM
a. Proposal of Authority Extension to the Inspector for
issuance of Delivery Report/Order in consultation with
central team by Digital stamping or digital signature on
the order.
b. Similarly, by the use of GPS and sim card on the job on
transit, the transformer can be tracked on the enroute for
proper planning towards receipt and early delivery at site.
As the tracking data gets available in the cloud, the
information could be available all the stake holders for
necessary action.
c. e delivery at site and compliance in case of short fall
could be prepared digitally with audio-video data backup
for quick action.
d. So, digital system can also be quite helpful for the
bene t of the utility for quick response.
3.4. INSTALLATION, ERECTION AND SITE
CHARGING:
With the help of company representative, the site
installation and erection is done. en on successful pre-
commissioning testing and checking, the transformer
gets energized. But in maximum cases, the issues develop
on the availability of OEM representative due to scarcity
of sufficient manpower, that results in delaying of the
commissioning process.
3.4.1. ROLE OF DIGITAL SYSTEM
a. Use of Audio-video system, the expert’s advice could
be obtained for correct and successful erection of the job
at site, instead managing by the novice
representative at site.
b. e digital instruments are the next option for correct
testing and comparison of the same with the factory
results.
c. Due to use of Digital result sheet, the site and factory
value could be analyzed for taking nal decision during
charging of the transformer.
3.5. SUCCESSFUL OPE TION AND
MAINTENANCE
is is the prime functional area need utmost care for
successful running of the transformer in the network to
maintain stable and reliable power system. Every
developing nation is now in the search of clean electricity,
encouraging energy harvest through Renewable sources.
is situation demands with new technical challenges
regarding integration of the RE with conventional
system. Smart system is the only option for early
detection of the system parameters and corrective action
towards control of the system. In the era of Smart Grid
evolution, the assets in the system should also be smart
enough to pace with the system. So Smart Transformer is
the option for successful Operation Control and in
subsequent for Maintenance feature also.
3.5.1. APPLICATION TOWARDS
SUCCESSFUL OPE TION
a. Use of Digital System: Digital Bays equipped with
modern NXIT (Nonconventional Instr ument
Transformers), MU (Merger Units) and SCU (Switching
Control Unit), smooth, accurate and con rmed
operation can be achieved.
b. Preparation of L MS (L oad Management
Schedule): With the available transformers and proper
running of these units, the available loads can be
managed successfully. For preparation of accurate
management system, following points need to be
considered.
 e-T FOTECH 2020- International Conference on Transformers
i. Future and past load survey on the system.
ii. Capacity of the available transformers and
geographical positioning w.r.t load centers.
iii. Importance of the loading pa ern and category of
loading on the sub-station.
iv. Limitation of the network and system equipment.
v. Electrical parameters like Iron loss, copper loss & %
impendence, of the transformers
vi. In service electrical parameters. (Current, voltage,
load etc.)
vii. Electrical and mechanical characteristics.
Fig. 3 Typical RMU with LADR
of associated equipment (Circuit breaker, Isolators etc.)
All the above parameters could be availed as the in service
data and to be fed to the computing machine for
preparation of a Loading Management Schedule (LMS).
Before application of the output results, the theoretical
simulation shall be done for the operation of
transformers. e actual and theoretical LMS shall be
compared for practical modi cation. Finally, the LMS
shall be rolled into the system for efficient loading of the
transformers. During this digital data as obtained from
sensors help for quick decision.
c. Concept of NODAL Transformer: By RING main
System, the system availability can be enhanced and few
of the main transformers could be considered as the
nodal transformers in the system. e role of these
transformers as such manages the available in case of link
failure. All these systems get well connected with the
digital system. e typical RMU is shown with the
application of LADR (Load Accessed Directional Relay)
and RLADR (Restricted LADR) concept.
d. Use of Digital RTCC (Remote Tap Changer
Control Cubicle) and MCU (Motor Controller Unit)
based DM: In transformer the only available running
device is the tap changer Diverter switch, that creates
problem due to its cumbersome physical wiring control.
Similarly, the case of Cooler Controller Unit that
contains contactors, relays, switches etc… But in the era
of digitization and use of Digital controller unit, the use
of copper wires, contactors, coils, switches etc... could be
eliminated and compacted in the digital form inside the
controller. So the control, operation, troubleshooting
etc... becomes that con rms the reliable and steady
operation.
e. Preparation of TCC (Transformer
Condition Code) for CBM (Condition
Based Maintenance: e data bank is prepared with the
online eld data and testing analysis of laboratory data.
By these data (Values from different Test methods), the
GMD (Geometric Mean Data) is prepared to obtain the
condition code of the transformer. e other aspect of
the equipment is its residual life expectancy. is factor
also plays an important role to determine the condition
code of the equipment. is factor is called Survive factor
(δ).
Now, by considering the history, commissioning data,
present technical and non-technical parameters of the
Transformer, prepared GMD (Geometric Mean Data)
and Survive factor (δ) the condition code is formulated
as follows
Transformer Condition Code (TCC) = D δ
D = Geometric Mean Data (GMD)
δ = Survive Factor.
 e-T FOTECH 2020- International Conference on Transformers
e detail preparation of Transformer Condition Code
(TCC) and the application of the same for nding the
Condition Based Rank (CBR) of the transformer helps
to perform the Condition Based Maintenance (CBM),
which becomes economical in comparison to the old
method i.e. TBM (Time Based Maintenance). (Refer Fig
no 4)
Fig 4 On-Line sensor Module
f. Role of Digital System: For this section Digital system
helps to satisfy the successful operation in many of the
aspects as described above, which in turn have the
following advantages.
Advantages:
i. Energy conservation results due to reduction of
transformation loss.
ii. Life span of the transformer increases, because of
proper loading on them.
iii. Life span of other equipment increases.
iv. Maintenance becomes easy with no interruption of
the system loads.
3.6. CONDITION MONITORING AND
HEALTH INDEXING
Utilities’ main concern is to keep the important devices
in healthy condition to serve reliable and stable supply
system. In the conventional method we generally use
OFF-LINE monitoring system to know the health status
of the transformers.
3.6.1. ROLE OF DIGITAL SYSTEM
a. Condition Monitoring : In present system
transformer is equipped with multiple intelligent
electronic instruments/sensors at the suitable location
of the device which assess the condition of the
transformer system and send the signal to the CCS for
intelligent recommendations and suitable prescription
towards corrective action. is becomes Online data
acquisition and important tool for the operator to
monitor the behavior of the transformer core, windings,
oil, tap changer and bushings. Many other parameters
could also be monitored like Tank Pressure, Oil
Temperature pro le (Oil, Winding, Core, Yoke),
Operation transformer mounted Protection devices,
status of Cooler Control units (Fans, Oil Pumps).
Ambient Temperature, humidity, Bushing Tan delta
value, Online moisture content and DGA etc... e
typical sensor controller model is shown in the Fig. 4.
b. Health Indexing: Similarly, on obtaining the data
either by ON-LINE or OFF-LINE, the sampling could
be done to prepare the TCC as described above. is
TCC helps to prepare the health indexing of the
transformer for corrective action towards repair and
maintenance.
3.7. POSTMORTEM ANALYSIS
Every utility does the postmortem analysis for the failure
transformers. e death may be of natural or accidental,
the detail analysis can help the utility engineers to know
the cause a er investigation of the incidences and
sequence of events on the transformer.
3.7.1. ROLE OF DIGITAL SYSTEM
e transformers equipped with electronic sensors send
the signals to the memory buffer in the event recorder
and remain stored. During situation requirement, these
events could be retrieved for detail analysis to investigate
the reason of the incident. Moreover, digital relays
(Protection and Monitoring) and BCU (Bay Controller
Units) are also used in the system to record the electrical
parameters as per the program so ware loaded in these
devices. A er tripping of the transformer, diagnosis
testing is also conducted to sum up the fact for detail
report preparation.
 e-T FOTECH 2020- International Conference on Transformers

CONCLUSION
So, a er death of the equipment, the autogenerated data Total Life cycle management module of the transformer
bank, Event loggers, Disturbance recorders, Test report can be tagged with digital system, which can help the
analysis etc... are framed into the nal report for the utility to reduce investment cost, running cost and
learning session to the utility engineers for corrective maintenance cost at large. is can also manage the
actions as per the recommendation of the commi ee. judicious operation of all rating transformers in the
system. e digital approaches with smart sensors on
4. UTILITY’S PERSPECTIVES
condition monitoring system, enables the maintenance
e wish list of every utility is to have PQRS in the system crew to take corrective action to prevent unplanned
network (Power with Quality Reliability, Safety and downtime.
Security). In the complex network system, sooner the
be er the adaption to digital system by the utility shall Hence sooner the be er, utilities should adopt this
enhance the credibility and its efficient response to the Digital System for Transformer to make it smart and
consumers in the system. Some study reveals the intelligent enough.
advantages and extract from CIGRE study supplements
the same with strong fact, “Guide on Economics of
Transformer Management (Technical Brochure 248)”,
the digitalisation of transformers will provide the
following bene ts – 75% reduction in repair costs due to
early detection, 60% reduction in revenue loss due to
unanticipated problems/outages, 50% reduction in the
risk of catastrophic failures and 2% annual cost savings,
which is equivalent to the replacement cost of a new
transformer.
 e-T FOTECH 2020- International Conference on Transformers

DIGITALIZATION & EMERGING ONLINE

T NSFORMER MONITORING DEVICES
omas Buijs
Hitachi ABB Power Grids Canada

ABST CT
e electrical grid is going through a fundamental
transition as the world shi s away from fossil fuels to
renewables and electri cation. On the one hand
electrical production is becoming distributed and on the
other hand electrical consumption is becoming less
predictable. is leads to variable and bi-directional
power ows that can signi cantly impact the lifecycle
and operational efficiency of transformer assets. Figure 2 - World electricity production om
Fortunately, these assets can be managed through the 2018 - source: international energy agency
advent of new digital technologies and knowledge-based For the same reasons we are seeing accelerated
mitigation can be implemented. electri cation of transports, a trend is driving variability
on the demand side.
1. INTRODUCTION
Electrical production has been shi ing towards
renewables for some time and the trend is now
accelerating with pressure mounting on decarbonization
to ght climate change.

e latest data form the international energy agency

indicates that renewables accounted for 25% of the
worlds electrical production in 2018 and that 7% is
variable in nature. Figure 3 - Annual global EV sales - source:
Bloomberg New Energy Finance

2. T NSFORMER RELIABILITY
When transformers are used in relatively steady
conditions one can estimate their lifecycle with
reasonable accuracy. is lifecycle is driven by the
constant degradation over time of the insulating
materials leading to something close to an ideal lifecycle
curve

Figure 1-World electricity production om

1990 to 2017 - source: international energy agency

Figure 4 - Ideal transformer life cycle

 e-T FOTECH 2020- International Conference on Transformers
However, when variability is introduced the lifecycle
curve becomes much harder to predict as in gure 5.
Figure 5 - Real world transformer life cycle
Without effective monitoring and connectivity to
provide an understanding of the real conditions of
transformer assets it is difficult to optimize their useful
life and also avoid expensive unplanned outages.
In order to implement effective monitoring, one needs to
understand the failure modes of transformers.
Figure 6 - failure location analysis on transformers
manufactured a er 1980 - source Cigré SCA2.37 Report
Technical Brochure 642/2015 Transformer Reliability Survey
Based on the data from Cigré it is clear that half of all
faults occur in the bushings and tap changers followed by
nearly 40% in the windings.
3. T NSFORMER MONITORING
To effectively monitor transformer assets, we need to
monitor parameters to which we have access. ese
parameters can be divided into measurable thermal,
electrical, mechanical and chemical parameters.
ese parameters can then be converted into a
probability of failure through the use of a digital
transformer engineering model based on IEEE and IEC
standards.
Once the probability of failure for a group of assets is
understood we can optimize maintenance costs by
focusing on the assets most likely to fail. We can extend
the useful life of those assets by keeping them in service
as long as the likelihood of failure remains low.
3.1 THERMAL AND ELECTRICAL PROPERTIES
e thermal and electrical properties that can be directly
measured on a transformer are:
- Transformer tank top and bo om oil temperatures
- Temperatures in the windings measured using ber
optic probes
- Oil temperature at the radiator inlets and outlets
- e ambient temperature
- Tap changer tank oil temperature
- Voltage and Load
- Bushing leakage current
- High speed electrical transients
- Magnetic elds from the transformer
Using these measurements one can determine many
operational parameters and detect incipient faults before
they lead to outages.
From the measurement of the oil temperatures and load
one can determine by digital simulation how hot the
windings will get given the factory data for the
transformer. e winding temperature in turn
determines the aging rate of the paper insulation inside
the transformer; the ho er it gets the faster it ages. A ber
optic temperature sensor can be used to monitoring the
temperature directly in the windings in order to provide a
more accurate picture and serves to con rm that the
calculations are correct.
Based on the measurement of the oil inlet and outlet
temperatures one can determine the efficiency of the
cooling system and detect any degradation that may
occur over time. is can happen for example if there is
buildup of sludge in the radiator that is restricting oil
circulation.
e ambient temperature can be used to determine the
maximum load the transformer can support without
exceeding its design temperature and suffering
premature aging due to overheating.
 e-T FOTECH 2020- International Conference on Transformers
By monitoring the temperature of the tap changer tank
relative to the main tank we can determine if there is a
malfunction of the diverter switch; indeed if it gets much
ho er than the main tank we have a clear indication that
the tap changer is bleeding energy while switching tap
positions. is should not occur and the tap changer
should be overhauled before the transformer fails
catastrophically.
e leakage current from the bushings can be measured
through the diagnostic taps at the base of each bushing.
e vector sum of the three phases should equal 0 if the
bushings are all identical in terms of capacitance and
power factor.
Any change in the capacitance or power factor of one of
the bushings will unbalance the system and lead to a
nonzero vector sum of currents. is provides a clear
indication of impending bushing failure.
Figure 7 – Zero sum of currents for system
with three good bushings
For example, if the phase 2 bushing starts to deteriorate
leading to an increase in capacitance and in power factor
it will increase the amplitude of the leakage current and
cause its phase to shi .
Figure 8 – Nonzero sum of currents with phase 2
current increased by 50% and 10 degrees phase shi
is deterioration of the bushing can also precipitate
partial discharge events, whereby we get a short term
momentary discharge across one of the insulation layers.
ese discharges will tend to degrade the insulator
rapidly and can lead to a cascade failure. It is possible to
provide early evidence of partial discharge activity by
monitoring the bushing tap at high frequency and
looking for pa erns of high speed transients.
Partial discharges can also occur in the winding
insulation layers and lead to the same type of failures in
the core of the transformer.
One of the challenges with detecting partial discharges is
to determine their origin and distinguish them for high
frequency perturbations coming form the network
outside the transformer.
e analysis of partial discharge data lends itself well to
smart machine learning algorithms that can interpret the
data based on previously observed pa erns. e analysis
of partial discharge data is a relatively new aspect of
transformer monitoring.
Finally, we can measure the strength of the magnetic eld
around the transformer. Any change in this magnetic
eld is indicative of a change in the mechanical
con guration of the windings and can be used to predict
incipient faults.
3.2 MECHANICAL
e types of mechanical parameters that can be
measured are sounds, vibrations and torques.
For example the torque required to change tap changer
positions or to start a cooling fan can be used to predict
impending failures.
e hum vibration of a transformer can be monitored
and used to determine changes in the winding
con guration.
e vibrations of the cooling fans can be monitored in
order to detect developing bearing failures and the
vibrations of the tap changer changing positions can be
indicative of a fault developing in the tap changer.
3.3 CHEMICAL
Chemical analysis mainly deals with the composition of
the transformer oil in terms of dissolved gases and
moisture.
If a hot spot develops inside the main tank of a
transformer it will locally heat up the long chain
molecules that make up standard transformer mineral
oil. Heat it up enough and the chemical bonds will start to
break leading to the release of small fragments made of
carbon and hydrogen atoms. ese are species like
hydrogen, methane, acetylene, ethylene and ethane.
 e-T FOTECH 2020- International Conference on Transformers

4. CONCLUSION
By monitoring various thermal, electrical, mechanical
and chemical parameters on a transformer we can detect
insipient faults that le unchecked will lead to unplanned
outages.
By interlinking these types of sensors, connecting them
to the internet of things and taking advantage of cloud
computing we can monitor eets of transformers from a
central location to optimize operational costs, reduce
maintenance, delay replacements and avoid unplanned
outages.

Figure 9 - oil breakdown products when overheated

In the same manner if the paper insulator is overheated

and breaks down oxygenated species will be released
because paper has oxygen atoms in its makeup.

Figure 10 - paper breakdown products

e relative quantities of these gases in dissolved state in

transformer oil is related to the temperature of the hot
spot and the mechanism of its formation.
Water and oxygen are not fault indicators but will act to
accelerate paper degradation and therefore should be
monitored and kept as low as possible to maximize the
life expectancy of the transformer.
Moisture is also monitored to ensure low enough levels
to avoid generating free water and/or bubbles in the
transformer which could lead to partial discharges and
signi cantly damage an operating transformer.
 e-T FOTECH 2020- International Conference on Transformers

STATE OF ART TESTING AT FACTORY (INCLUDING REMOTE FAT)

FOR DIELECTRICS, LOSSES, THERMAL & EMISSIONS
Rakesh Patil
Siemens Ltd., Navi Mumbai

ABST CT
Testing is the critical process as it ensures the quality
assurance of product, materials used and processes
during different manufacturing stages. It is also a
compliance to the product’s characteristics as per
customer speci cation and standards. Usage of modern
state-of-art factory testing facility will ensure accurate
measurements of various test parameters during Factory
Acceptance Test (FAT) which is essential for long term
reliability of transformers and shunt reactors.
Dielectric tests are intended to verify withstand
capability under stresses caused due to transient over
voltages, switching surges, lightning impulses and
changeovers i.e. both normal and abnormal conditions.
Determination of the operational losses is obviously
important to ful l the contractual obligations and to
check on operational costs in the form of component
losses.
Compliance with thermal limits is critical for long term
reliable operation during the intended life of the product.
Emission like sound level, vibrations are important
factors with installations in populated urban areas.
Vibrations in shunt reactors will determine the
healthiness of the construction and within speci ed
limits.
In the present pandemic of covid-19, remote FAT to
customers to ensure optimal performance of the product
and maintain safety of inspection officials. Such virtual
FAT is gaining momentum across businesses and
industry segments. is paper highlights the basic
requirements for such remote FAT for the bene t of
stakeholders.
1. INTRODUCTION
Transformers and reactors are the most critical and
expensive equipment in transmission system and need to
give uninterrupted service for their intended life of at
least 30 years. e quality of these equipment’s must be
ensured by performing routine, type & special tests
according to the national/international standards in
state-of-the-art facility having NABL accreditation
according to ISO/IEC17025.
An important milestone of each transformer/shunt
reactor project is the FAT. is process is proof that the
equipment is manufactured according to the contract
speci cations, reference national, international
standards and ready for shipment to site. Normally the
FAT is conducted formally and witnessed by the
customer.
Conducting remote FAT for the customers is challenging
to change the mindset of customer from being physically
present to watching a remote FAT as the practice of
physical presence is followed for ages. e aim of
2. DIELECTRICS
Lightning and Switching Impulse test
All factory acceptance tests, test procedures are well
de ned in IEC60076 and parts thereof. However, this
paper highlights salient features of tests / measurements
for improved accuracy of the test.
Dielectric tests are conducted to verify dielectric
capability of the transformer insulation.
Lightning impulse test is intended to verify the capability
of the transformer to withstand transients in service like
lightning strikes. e test veri es the withstand strength
of the transformer under test when the impulse is applied
to its terminals.
 e-T FOTECH 2020- International Conference on Transformers

Standard full wave lightning impulses (1.2/50µs Fig. 2 & 3 highlights the bene t in overshoot reduction of
waveform) produces non-uniform stresses in the impulse waveform due to usage of OC.
windings. Chopped on tail lightning impulse test
(chopping time: 2 to 6µs) is intended to verify the
capability of the transformer to withstand some high
frequency phenomena that may occur in service.

Switching impulse test (100/200/1000µs) is intended to

verify the capability of the transformer to withstand long
duration transient voltages occurred due to switching
operations in service. SI test veri es the switching
impulse withstand strength of the line terminals and the
connected winding(s) to earth and other windings. e
test also veri es the withstand strength between phases
Fig. 2: “Without” compensation
and along the winding(s) under test.
To perform lightning and switching impulse tests, a
robust, reliable, and accurate test system is required. For
testing of large power transformers and reactors, modern
impulse voltage generators with Multiple chopping gap
and voltage dividers are generally used. A 4-Channel
impulse analysing system with diagnostic tools is
necessary for accurate and reliable measurements.
Impulse generator having overshoot compensation
circuit, a patented method introduced by Haefely Test
AG under the name “Overshoot Compensation” (OC) is
recommended.
e series compensation arrangement should consists of
a Compensating Capacitor (CC) in parallel with a
Fig. 3: “With” series compensation
resistor RC and an inductance LC. e necessary
inductance LC is not a separate component but the For switching impulse, a special Loading Capacitor with
inherent self-inductance suitable capacitance & voltage rating is recommended for
of the resistor RC. e series compensation shall be be er waveshape in line with impulse generator
connected in series with the impulse generator as shown manufacturer recommnedation.
in Fig. 1.
Applied Voltage Test (AV)
e test is intended to verify the alternating voltage
withstand strength of the line and neutral terminals and
their connected windings to earth and other windings.
Generally, for this test, High Voltage AC Resonance
systems are used. Tuning of inductive reactance with
capacitive reactance of test object is the key to create the
Fig. 1: Equivalent impulse circuit diagram resonance for raising the voltage.
with series compensation
 e-T FOTECH 2020- International Conference on Transformers
Induced Voltage tests
e test is intended to test the dielectric strength of
windings and its associated insulation like turn to turn,
between phases, phases to earth along with or without
PD pulse measurement. It helps to detect faulty
insulation, bad contacts, improper electrode
con guration with overstressed areas, inadequate
processing, material defects etc. Induced voltage test
with Partial Discharge Measurement (IVPD) is as an
important test or quality assurance test of transformers
or shunt reactors. is test is intended to ensure that the
equipment is free from harmful partial discharges under
normal operating conditions.
Being IVPD measurement is sensitive and critical test,
following testing features are recommended.
1. As per IEC, IVPD test can only be considered valid, if
the measured background PD level does not exceed 50
pC for transformers and 100pC for shunt reactors, at
both the beginning and the end of the test at the
measur ing f requenc y, as per I EC 60270 and
measurement of PD at high frequency above 1MHz shall
be avoided.
2. Low background/ambient PD levels is a m u s t f o r
which Electrostatically Shielded Laborator y is
recommended to eliminate unnecessary disturbances
and signals.
3. Very low earth resistance values to be achieved by well-
maintained earth pits / mesh.
4. Strong and stable power source with Variable
Frequency Drive (VFD) and Motor Generator.
5. Variable voltage capacitor banks and reactor of
adequate capacity for capacitive and reactive
compensation.
6. High voltage lters are required to lter out
disturbances from generator circuit and transformer
circuit.
7. Smooth Corona Shields are essential for uniform
voltage distribution at high voltages.
8. Accurate and sensitive PD measuring system should
be used with precise calibrators.
9. Acoustic or ultrasonic sensors (Refer Fig 4) mounted
on tank are very useful for the localization of source of PD
whether inside or outside of tank.
Fig. 4: Acoustic Sensors
For switching impulse, a special Loading Capacitor with
suitable capacitance & voltage rating is recommended for
be er waveshape in line with impulse generator
manufacturer recommnedation.
3. MEASUREMENT OF LOSSES
Losses being a guaranteed performance parameter as per
contractual requirement, its measurement accuracy
during FAT is important. e measured losses are fed
during temperature rise test to evaluate the thermal
performance of transformer and shunt reactors. e
measured impedance voltage of transformers at normal
and extreme tap positions are used for determining the
regulation, short circuit current & in the evaluation for
parallel operation of transformers.
• e power factor for power transformer load loss
measurements are usually in the range of 0,005 to 0,05.
• Even minor phase-angle errors in the current and
potential transformers can cause errors in the measuring
system leading to measurement uncertainty and may give
chance for rigging the results.
• During No-Load loss measurements, power factor is
high with smaller magnetizing current magnitude.
• Winding resistance meter shall have preferred accuracy
of ±0.05%.
• Accurate measurement system with power analyzer
plays very important role in the measurement of losses.
Power Analyzer should be calibrated at various power
factors including ultra-low power factors. e.g.
• Unity PF (110% Voltage & 120% current)
• 0.5 PF lag, 0.2 PF lag, 0.05 PF lag
• 0.01PF lag (40-60% Voltage & 40%-80% current)
• CT/PTs of minimum 0.1 class is recommended for
accurate loss measurement to achieve measurement
uncertainty of <3%.
 e-T FOTECH 2020- International Conference on Transformers

4. THERMAL TESTS
Temperature rise test is conducted to verify guaranteed In comparison to a physical FAT, a virtual one brings a
values for oil, winding and hot-spot temperature rises saving of overall testing time and cost. Remote FAT also
(winding & tank) and oil-winding gradient. is provides opportunities for multiple inspectors/project
information is vital for loading or overloading and long directors to witness the testing of the equipment, from
and reliable service life of transformer. their own offices. is provides effective utilization of
Measurement of temperatures at top oil, cooler top & test lab as well as time of customers. Even different
bo om, shall be done by special precision sensors officials can check for different testing activities
preferably mounted on coolers or pipelines directly for independently as per their areas of interest.
obtaining correct values. Temperature data acquisition Simultaneous physical check of connection, oil lab, test
system with paper-less recorder is a preferred way for object as shown in Fig 5, 6 & 7 is possible.
maintaining log of the temperatures during test.
Dissolved Gas Analysis (DGA) system is a must for
veri cation of presence of fault gases before and a er
temperature rise test.
5. EMISSIONS
Major emission from transformers and reactors is sound
level which is critical for installation in populated area. It
needs to be demonstrated to check compliance with
standard and customer’s requirements.
Acoustically shielded laboratory is required for lower
Fig. 5: Physical check of connections
ambient sound levels (without external noise) preferably
<50dB for improved accuracy.
Measurements are conducted with advanced Sound
Level analyser with recording options and FFT analysis
so ware.
6. REMOTE FACTORY ACCEPTANCE
TESTS (FAT)
Normally the FAT is conducted formally and witnessed
by the customer.
e current global pandemic crisis has made necessary
Fig. 6: Checking of oil testing
the implementation and application of digital
technologies, for conducting remote FAT.

ough initially proposed as an interim solution during

pandemic to maintain regular testing of
Transformers/Reactors, remote FAT is poised to
become the new normal in the future for all inspection
related activities which will ensure safety, while saving on
customer travel, cost, and time.

Fig. 7: Checking of test object.

 e-T FOTECH 2020- International Conference on Transformers

Cybersecurity - InfoSec Requirements

All Testing instruments inside or outside of Control While conducting remote FAT, due care shall be taken to
Room and on shop oor (for in-process inspection or keep the data safe while transmi ing from factory to
testing) can be made accessible to customer in real time customers through a web-based application.
through portable cameras, parallel screens with help of Some of the Information Security stringent protocols are
isolated network and safe cloud connectivity. Schematic as under:
diagram for remote FAT is given in Fig. 8 • Database Security
• End-to-End SSL
Wireless Wireless • Secure WebSocket
IP Camera1 Camera2
Camera1 • Authentication for users/test engineers
• Strong Password Policy
IP WLAN • Access Control
Camera2 • Restricted Access via 2-Factor Authentication for
Customer customers
LAN
Serial • Single Session Only / Timed Sessions
Device1
• Rese ing Passwords
• Password Expiry Policy
Serial Server • Validated 3rd Party Dependencies
Device2
Cloud connectivity is considered as one of the best
methods for transfer and secure storage of data with all
Laptop Router Cloud the precautionary measures in place.
7. CONCLUSIONS
Fig. 8: Schematic diagram for remote FAT
In this paper, major testing requirements for Dielectrics
Various devices like mobiles, tabs or iPads, portable test (Lightning & Switching Impulse, Induced Voltage
cameras, laptops, computers for equipments or with PD, Applied Voltage), Losses, ermal and
instruments with Wi-Fi and Bluetooth capability can be Emissions (Sound) are covered. Some of the necessary
used effectively for remote FAT as shown in Fig. 9. From tools & its features, for achieving accurate test results and
the customer’s side, good quality network with Wi-Fi or analysis are highlighted.
data connections is essential. Need of remote FAT in today’s context and its various
bene ts for customers and manufacturers is discussed.
It is preferred to have good resolution cameras with e remote FAT methodology along with the devices
“Zoom in/out” feature to focus on the test object. and security protocols are covered elaborately. New
Portable cameras are recommended for witnessing low digital technologies will be extensively used for
voltage tests. conducting remote FAT, inspections, audits,
maintenance and troubleshooting in near future and will
prove to be bene cial for all and it will secure the
con dence of customer.

Fig. 9: Different devices used

for remote FAT
 e-T FOTECH 2020- International Conference on Transformers

8. REFERENCES
[1] Power Transformers –Part 1: General, IEC60076-1,
Edition 3.0 2011-04

[2] Power transformers – Part 3: Insulation levels,

dielectric tests and external clearances in air
IEC60076-3, Edition 3.1 2018-03

[3] Load range extension methods for lightning impulse

testing with high voltage impulse generators - Haefely
Test AG

[4] SIEMENS Test eld Digitalization Project

Approach Paper - 2020
 e-T FOTECH 2020- International Conference on Transformers

DAY

03 Key Note Papers

 e-T FOTECH 2020- International Conference on Transformers

PARTIAL DISCHARGE IN EHV T NSFORMERS & REACTORS

AND THEIR MONITORING AND DIAGNOSTICS
Stephan Heberer
ALTANOVA Group

INTRODUCTION
Managing an electrical power system asset economically In EHV transformer & reactors, insulation of solid
and maintaining the quality criteria requires applying (paper, Pressboard, laminated wood, berglass, etc.) and
quality control and diagnostic techniques to electrical liquid (mineral or ester uids) are used. A typical
network components. is will increase not only their insulation structure of the EHV transformer is given in
reliability but reduce direct and indirect costs also. Such Fig No 1.
techniques form the basis for efficient and reliable asset
management, as they can ultimately reduce the failure
rate.
EHV Power transformers and shunt reactors are one of
the most vital and expensive components of an electrical
power system. ese kinds of equipment may experience
insulation failures caused by internal discharges in
insulation, improper connections & sharp points,
leading to corona and surface discharges.
PURPOSE OF PARTIAL DISCHARGE
Fig No 1: Typical insulation structure
A partial discharge measurement (PD-measurement) is a
non-destructive tool used to establish the condition of a PD normally develops in a liquid insulating medium or
transformer or reactor insulation system. e goal of solid insulation surfaces or inside solid insulation due to
partial discharge measurement is to certify that no weakness or defects in the insulation system. Refer to Fig
harmful PD-sources exist. A PD-measurement makes it No 2 for the typical mid-way defect.
possible to detect and localize areas within the
transformer exposed to elevated dielectric stresses. ese
stresses, in the long run, can be harmful to a safe
transformer operation.
Partial discharge measurements are explicitly speci ed in
national and international standards or customer’s
speci cations. ey are carried out in conjunction with
dielectric tests in high voltage laboratories. Partial
discharge measurements are generally the last dielectric Fig No. 2: Midway defect
test conducted on the transformer.
Excessive stress in weakness or defect can result from
PARTIAL DISCHARGE IN T NSFORMER design aws, contamination, or deviation from
As per IEC 60270, Partial discharge is a localized permissible tolerances in the manufacturing process,
electrical discharge that only partially bridges the insulating material aws, etc. Another possibility is
insulation between conductors and which can or cannot hidden damage to the insulation caused by preceding
occur adjacent to a conductor [1]. tests.
 e-T FOTECH 2020- International Conference on Transformers

PHYSICS OF PARTIAL DISCHARGE

Partial discharge (PD) is an electric breakdown in the During a typical PD measurement, the magnitude of the
weak region of an entire transformer’s insulating detectable value of partial discharge activity is recorded
structure. as a function of the applied voltage.
An electric breakdown of the insulating material between
two electrodes means, generally, that the distance A typical partial discharge pulse, along with the applied
between them has been bridged by electric charges (high voltage, is shown in Fig No. 3. A high voltage is applied
ohm resistance has changed to low ohm resistance). across the electrodes having solid insulation containing
Electric breakdown occurs if the following conditions are void inside it, where Va represents the voltage across the
ful lled: healthy insulation, and Vc represents the voltage across
• local electric eld E (in kV/mm) is greater than the the void. At certain voltage stress, discharges occur in the
breakdown eld strength Eb in kV/mm of the speci c void due to its breakdown [2].
insulating material (different values for different
insulating materials)
• starting electrons are available
For a homogeneous electric eld (main insulation
between the windings (e.g., Fig No 1) the breakdown
eld strength Eb is
de ned as:

Eb = Vb / d, Where, Fig No. 3: Voltage and Current

Eb = Breakdown eld strength in kV/mm
Vb = Breakdown voltage in kV
d = Distance between electrodes in mm
e transformer insulation structure has many locations
where the electric eld is non-homogeneous. e
calculated homogeneous electric eld must be
multiplied by the electrode shape factor to estimate the
maximum electric eld.
In well-designed transformers, the maximum electric
eld strength of critical location is evaluated thoroughly
using electrostatic eld calculation design tools.
in discharging cavity
Since PD is correlated to insulation aging, it is the cause
and the effect of insulation degradation.
TYPES OF PARTIAL DISCHARGE
INTERNAL PD
It can occur inside the insulating system defect, such as
voids, contaminants or impurities, conducting particles,
and eventually triggering electrical treeing. PD pulses
can be observed in the air cavities inside solid insulation if
eld strength is higher than PD inception voltages.

Below physical mechanisms describe the electric

breakdown between two electrodes
• generation of primary electrons to start the electric
breakdown
• charge multiplication and transport phenomena to
bridge the distance between electrodes
• charge storage phenomena to support the next electric
breakdown Fig No. 4: Internal PD
 e-T FOTECH 2020- International Conference on Transformers
e insulating liquids are used for the impregnation of
cavities and gaps between insulation. e impregnation
of cellulose-based solids is mainly based on the capillary
effect, which depends on the viscosity of the oil (mineral
or ester).
e electrical eld strength of impregnated brous
materials is due to the bers’ barrier effect, which divides
the volume into a large number of very small oil gaps or
pores sizes, as shown in Fig No. 5 microscopic structure
of the paper.
Fig No. 5: Microscopic structure of the paper
SURFACE PD
It can occur in surfaces of insulating materials if the
electric eld is high and can provoke insulation tracking
along the surface.
Fig No. 6: Surface PD or super cial PD
It is usually observed at the interface of two different
dielectric media under high-voltage stress.
CORONA PD
It originates in correspondence of sharp tips of any
electrodes or protrusions or the lead connections or
bushing interfaces or due to a highly non-uniform
electric eld near the sharp tips or protrusions. In the
case of transformers, it causes the local breakdown of oil,
leading to an increase in the concentrations of hydrogen
and hydrocarbon gases trapped in transformer oil gas-
pockets.
Fig No. 7: Corona PD
MITIGATION OF PARTIAL DISCHARGE
As explained earlier, in transformers, with a solid-liquid
composite medium as the main insulation, PD can be
caused by a complex structure and non-uniform electric
eld distr ibution. Dur ing PD and insulation
deterioration, pulse discharge, gaseous products,
ultrasonic and electromagnetic radiation, light, localized
hotspot, and energy loss o en occur [3]. e shape, size,
and geometry of the electrode arrangement in uence the
electric eld strength. In the case of non-uniform or
quasi-uniform elds, the breakdown can occur at lower
voltages [4].
General requirements of good insulation include the
following.
. High dielectric strength
. High creepage resistance
. High PD inception voltage
. High thermal stability
. Good thermal conductivity
. Compatibility with other materials
. Effective drying and moisture removal
. Good oil impregnation of solid insulation
. Reduction or avoidance of sharp & bare electrodes
 e-T FOTECH 2020- International Conference on Transformers
Good impregnation a er effective drying, moisture
removal helps in reducing the possibility of cavity or
voids. Good thermal conductivity helps to reduce the
chances of bubble formation. Strict quality checks and
standard practices need to be followed to reduce PD
during manufacturing transformers. is may include
improving the design to reduce/avoid sharp edges,
which may act as a source of corona discharges. e
shape, size, and geometry of the electrode arrangement
in uence the electric eld strength. e electric eld is
highly non-uniform near these regions, increasing the
potential gradient and causing an easy breakdown of oil
as soon as it reaches the transformer oil’s breakdown
voltage.
Insulation barriers made of pressboard (PB) hinder the
electron transport from the cathode to the anode, as they
prevent the particle dri over longer distances.
e dielectric strength & PD inception voltage of
selected paper-pressboard-oil insulation used in EHV
transformer and reactors are to be determined
experimentally. e same should be used in electrostatic
evaluation with an adequate design margin supported by
test performance. Correct values of insulating materials
relative permi ivity should be used during electrostatic
evaluations in the engineering phase.
e electrical eld strength changes with the type of
electrodes (bare or insulated), shape (e.g., round, plane,
conical), and electrode geometry (e.g., radius) as it
changes the eld concentrations [4]. Reduction in eld
strength in liquid and enlargement of an effective corner
radius will reduce PD inception voltages.
Sometimes, a poor or bad assembly of different parts of a
transformer may become the main reason PD occurs due
to poor contacts.
e solid insulation of the windings should be of good
quality. e manufacturing process should not be
compromised to minimize or avoid micro-voids inside
the insulation. It must be tested for speci ed thermal,
electrical, and mechanical stresses as per relevant IEC
standards.
Nowadays, alternatives are available to replace mineral
oil in the transformer as an insulant. Ester is found to have
the lowest PD activity in dry and wet conditions
compared to mineral oil and arti cial ester. But other
aspects, such as breakdown strength, the in uence of
humidity, etc. need to be studied before proposing
natural ester as insulant to replace mineral oil [5].
Special care should be given while lling the transformer
tank with oil. e trapped air-bubbles in oil may become
the weakest link causing partial discharge inside the tank.
Particle contamination is the main factor for dielectric
degradation of insulations used. e most dangerous are
conductive mode particles, metals, carbons, wet bers,
etc. e particle analysis shall be carried out in oil as per
procedure and interpretation and recommendation of
CIGRE report WG-12.17- “Effect of particles on
transformer dielectric strength.”
Particle count limit shall be 1000 particle/100 ml with
size ≥ 5 μm; 130 particle/100 ml with size ≥ 15 μm, as per
CIGRE Brochure 157, Table 8.
LATEST TRENDS IN MONITORING
AND DIAGNOSTICS
PD measurement, monitoring, and analysis are major
tools to detect any defect or damage and identify any
weak spot that may lead to insulation failure. However,
this technology is not so popular earlier but is gaining
popularity as an effective technique to carry out
condition-based-maintenance (CBM) and risk analysis.
In reality, the degree of harmfulness associated with
partial discharges can only be assessed if the kind of
source generating them can be identi ed. For example,
large partial discharges happening at the insulation
system’s surface are generally less harmful than low
amplitude partial discharges occurring in cavities or
voids inside the insulation. In addition to this, most of the
time, partial discharges are mistaken for noise and
disturbances. Hence, a misinterpretation of data
acquired during PD measurement may lead to proactive
maintenance. Moreover, PDs themselves might not be
the fastest cause of insulation degradation, nor they cover
the diagnosis of all insulation defects.
 e-T FOTECH 2020- International Conference on Transformers

CHALLENGES IN PD MEASUREMENT CONVENTIONAL METHOD (USED DURING

One of the major challenges during the acquisition of FACTORY ACCEPTANCE TESTS)
data in PD measurement is the rejection of background It involves the standardized measurement of PD as per
noises or external disturbances or PD in nearby systems. IEC 60076-3 & IEC 60270. e PD measurement is
External disturbances include corona discharges or done during Induced over-voltage tests.
discharges on insulators’ external surface, PD in HV As per IEC 60076-3:2018, Table 1, Induced voltage test
connections, etc. Another issue is the separation of these with PD measurement (IVPD) is a
external disturbances, noise, and multiple PD activities • “routine test” for Um>72.5kV class transformer
within the equipment under test (EUT). and reactors.
• “special test” for Um≤72.5kV class transformer
In the case of transformers, these discharges and and reactors.
disturbances might occur in the bushing insulation, cable e detailed test procedure and acceptance criteria
terminations, insulating oil, and other insulation inside during the IVPD test are clearly de ned in IEC 60076-3,
the transformer, etc. Identi cation of PD phenomena is clause 11.3. e main feature of the test sequence is given
another issue that includes identifying the nature and in Fig No 8.
characteristics of PD activities. e most difficult task is
the risk analysis, which will evaluate the danger
associated with the detected or identi ed PD activity.
Due to the above reasons, few transformer OEMs still
believe that Partial Discharge (PD) measurements are
lab technology to view possible nuisance of faulty alarm
signals from online PD monitors. erefore, most
Fig No 8: IVPD test sequence
reliable online PD monitors are recommended, which
should have advanced denoising techniques to avoid Enhancement voltage of 1.80Ur/√3 for ≥15s (based on
false alarms coming due to noise and/or external test frequency) & PD measurement voltage of
disturbances. 1.58xUr/√3 for ≥ 60min, is induced as per IEC 60076-3,
MONITORING AND DIAGNOSTIC PROCEDURES clause 7.3
Electrical signals propagate by the winding’s galvanic
PD recognition is the prerequisite for correct diagnosis.
coupling and are decoupled by bushing capacitance or
Different manufacturers have come up with various
with an external coupling capacitor. PD is measured
solutions to overcome these challenges, proving to help
using the bushing-tap or by connecting a capacitive
diagnose transformers’ problems.
coupler parallel to the bushing (if no bushing-tap is
Many denoising techniques based on Fast-Fourier-
available), as shown in Fig No. 9 [1].
Transform (FFT), Low-pass ltering, notch- ltering,
wavelet-based ltering, etc. are available with different
OEMs providing PD monitoring system, e.g., T-F Map,
3PARD, etc.
PDs in transformers can be measured offline, online,
and/or a continuous monitoring system can be installed
to monitor PD’s time-trend pa ern. When PD activities
are initiated, the resulting energy is transformed into
mechanical, electrical, thermal, and chemical energy.
Different detection methods like electrical, UHF, Fig No. 9: Test circuit for measurement
chemical, and acoustic can detect PD in transformers. at the tapping of a bushing
 e-T FOTECH 2020- International Conference on Transformers

e conventional method gives the value of apparent Few typical PD sources (not an exhaustive!) and PD
charge in pico-Coulomb (pC), where calibration is pa ern as described in reference [6] are furnished for
performed at bushing terminals. is serves as the ready reference:
acceptance criteria in routine testing of transformers as
Conducting material (sharp electrode)
PD’s value (in pC) is an insulation quality indicator.
with direct contact to the metallic
electrode
Acceptance criteria for the IVPD test as per clause no.
11.3.5 of IEC 60076-3 are as under,
• no collapse of test voltage occurs
• PD≤250pC (#) during the 1-hr period
(#) 100pC for many Indian utilities
• no rising PD-trend during the 1-hr and no increase by
more than 50pC
• no sudden sustained increase during the last 20 min of Conducting material “without” contact to
the test the metallic electrode
• PD≤ 100 pC at 1,2Ur/√3 a er the 1 hr period.

B el ow ac t i o ns are reco m m en d ed d u r i ng t h e
investigation of external PD sources.
• Conducting particles on the bushing surface;
• Non-shielded sharp points on the transformer or in the
test circuit;
• Bad connections on shielding electrodes; Non-conducting material cavity “with”
• Unearthed metallic objects close to the transformer; direct contact to the metallic electrode
• Noise or internal PD from the voltage source;
• Electric discharges in the air (corona) generated by
sharp electrodes by using a portable ultra-sonic detector.

PD pa ern characteristics that should be analyzed are

• Phase position of the PD signal
• e symmetry of the PD signals during the positive and
negative sine wave
Non-conducting material cavity without
• Number of PD signals per cycle
direct contact with the metallic
• Reproducibility of the PD pa ern electrode.
Interpretation and screening of the correct PD pa ern
from the real PD pa ern results require experience and a
strong interpolation capability.

PD pa erns are based on physical electric discharge

processes in the weakness or defects. ey can be
detected in any insulating system. [6].
 e-T FOTECH 2020- International Conference on Transformers
UHF METHOD
e UHF method is advantageous for onsite/online
monitoring of transformers because UHF sensors do not
require high-voltage coupling capacitors or bushing-tap
measurement. ey are less affected by external PD
sources (e.g., corona at bushing outdoor connection) due
to different shielding effects and ltering methods
available [8].
Electromagnetic signals travel directly through the
transformer oil towards the tank. Faraday shielding of the
transformer tank and low-pass lters provided by HV
bushings shield the UHF PD measurements against
external disturbances [7].
is method uses the ultra-high frequency range
(300MHz – 3GHz) for the detection of PD. Such a large
bandwidth enables this method to have distinctive PD
pulses and easy rejection of low-frequency noise and/or
external disturbances.
Sensors can either be placed at existing drain-valves
(DN50/DN80 drain-valves) using UHF drain-valve
sensors or retro ed on dielectric-windows in new
transformers in the factory, using UHF disk/plate type
sensors [8].
CIGRE Working Group WG A2-27 recommends in
brochure 343 to provide DN50 valves at all transformers
for later ing of UHF probes [9]. e CIGRE Technical
Brochure 662 [10] recommends installing dielectric
windows in newly manufactured transformers for
mounting UHF sensors; however, it does not mention
where to position them. A UHF disk/plate sensor on the
dielectric window is shown in Fig No. 10.
Fig No. 10: UHF disk sensor on the
transformer tank
PD sources can be localized by using this method. e
optimal con guration requires four sensors in cross-
diagonal arrangement to triangulate PD source, as shown
in Fig No. 11 [11].
Fig No. 11: Optimal UHF sensor
positions to locate PD source
PD measured by this method can’t be expressed in pico-
Coulomb (pC) as calibration of charge to pC is not
possible in the UHF detection method. Also, UHF
sensors are limited by the availability of dielectric-
windows or drain-valves in a transformer.
CHEMICAL METHOD (DGA)
is method involves the dissolve-gas analysis of
transformer oil, which is an indirect detection of PD in
transformers. PD activity is usually indicated by
increasing concentrations of its characteristic failure
gases, H2, and CH4. Although this method doesn’t
quantify and identify the PD occurring inside the
transformer, it indicates possible PD in transformers. e
response time for DGA is usually slow when compared to
PD detection. e localization of the PD source is not
possible by this method.
A combined monitoring system involving PD and DGA
(single gas to multi-gases) can be highly advantageous for
asset management.
ACOUSTIC METHOD
When PD occurs in insulation, acoustic waves are also
generated. ese waves travel through transformer oil
and strike its tank. ese acoustic waves can be
decoupled using acoustic sensors. Acoustic sensors are
 e-T FOTECH 2020- International Conference on Transformers
are immune to external electrical and electromagnetic
interferences. On the other hand, the acoustic sensor can
be sensitive to external mechanical noises [12].
In the transformers, the propagation of acoustic waves is
largely affected by the complex structure of the insulating
system (windings, core, and tank walls). In a complex
structure, both the amplitude and the shape of the
acoustic signal emi ed by a PD source change along its
propagation path [6].
e acoustic method is very helpful in the localization of
PD. At least three sensors at different locations must
triangulate the PD source by time difference of arrival
(TDOA) method. However, PD defects in the
transformer’s main insulation are the most difficult to
detect due to the transformer board barriers and outer
winding. Acoustic waves caused by PD defects in the core
are very difficult to analyze and may, at times, give
misleading results [6].
For continuous monitoring, the UHF method proves to
be more successful than the acoustic method, as it is more
sensitive to PD occurring in the main insulation or core
of the transformer.
Apart from PD and DGA monitoring, bushing
monitoring needs to be more practical to know the
bushing condition. Bushing failure contributes to a
signi cant percentage when it comes to the reasons for
transformers’ failure. Hence, monitoring tan-delta and
capacitance of bushings is, in any way, much be er than
no monitoring at all.
Recent trends in the monitoring of power transformers
also include temperature monitoring (top oil, bo om oil,
hotspot, winding temperature, hotspot calculation, etc.),
cooling efficiency, and tap-changer monitoring
(mechanical contacts, arcing, etc.).
CONCLUSION
Proven design, standard practices, and strict quality
checks must be ensured during manufacturing
transformers to mitigate partial discharges during
operation.
As PD can’t be reduced completely, it is recommended to
go for online monitoring and regular testing to trend PD
behavior with time.
It can be summarized that, when PDs are the most
suitable diagnostic property for a certain insulation
system, their identi cation, as well as localization,
becomes necessary because only the correct a ribution
of the acquired PD pulses to their source(s) will allow a
consistent evaluation of their harmfulness arising out of
the insulation defects. erefore, measurement systems
that provide advanced tools for identifying PD can
optimize condition-based-maintenance (CBM)
procedures by increasing the reliability and efficiency at a
reduced cost.
REFERENCES
[1]. IEC 60270, High-voltage test techniques – Partial
discharge measurements, 2000.
[2]. F. H. Kreuger, “Partial Discharge Detection in High-
Voltage Equipment,” Bu erworths, London, 1989.
[3]. Morshuis P., Cavallini A., Fabiani D., Montanari
G.C., and Azcarraga C., “Stress conditions in HVDC
equipment and routes to in-service failure,” IEEE Trans.
Dielectr. Electr. Insul. 2015, 22, pp. 81–91.
[4]. Kuffel E., Zaengl W.S., and Kuffel J., “High Voltage
Engineering Fundamentals”, Elsevier India P Ltd, 2005.
[5]. J. Fabian et al., “Partial discharge behavior of
environmentally friendly and hardly in ammable ester
liquids compared to mineral oil for power transformers,”
IEEE International Conference on Condition
Monitoring and Diagnosis, 23-27 September 2012, Bali,
Indonesia.
[6]. ABB, “Testing of Power Transformers – Routine
tests, Type tests, and Special tests,” 1st Edition, Pro Print
GmbH, Düsseldorf, 2003.
[7]. M. Judd, “Partial Discharge Monitoring for Power
Transformers Using UHF Sensors Part 2: Field
Experience,” IEEE Electrical Insulation Magazine, Vol.
21, No. 3 May/June 2005
 e-T FOTECH 2020- International Conference on Transformers

[8]. S. Tenbohlen, M. Beltle, and M. Siegel, “PD

monitoring of power transformers by UHF sensors”,
International Symposium on Electrical Insulating
Materials (ISEIM), Toyohashi, Nov. 2017 - Sep. 2017,
pp. 303–306.

[9]. CIGRE WG A2.27, “Recommendations for

Condition Monitoring and Condition Assessment
Facilities for Transformers,” Cigre Brochure 343.

[10]. Gulski E., Koltunowicz W., and Tenbohlen S.,

“Guidelines for partial discharge detection using
conventional (IEC 60270) and unconventional
methods,” Cigre Technical Brochure 662, 2016.

[11]. C. P. Beura, M. Beltle and S. Tenbohlen,

“Positioning of UHF PD Sensors on Power Transformers
Based on the A enuation of UHF Signals,” IEEE
Transactions on Power Delivery, Volume: 34, Issue: 4, pp.
1520 – 1529, Aug. 2019

[12]. M. Harbaji et al., “Classi cation of Common

Partial Discharge Types in Oil-paper Insulation System
Using Acoustic Signals,” IEEE Trans. Dielectr. Electr.
Insul. Vol. 22, No. 3; pp. 1674-1683, June 2015.
 e-T FOTECH 2020- International Conference on Transformers

BEST P CTICES IN STO GE, T NSPORTATION, SITE ERECTION

AND COMMISSIONING OF POWER T NSFORMERS
Adish Kumar Gupta, Rohit Kumar Jain and Deo Nath Jha
adiskumargupta@powergridindia.com
Power Grid Corporation of India Limited, Gurgaon
1. ABST CT
Power transformers are usually a very reliable equipment
for power transmission sector, but they require a lot of
care during all stages of their life starting from
manufacturing, factory testing and transportation to site,
site storage and erection and commissioning. Proper
adherence to pre-commissioning procedures enhances
the useful service life of the transformer.
is paper discusses the best practices being followed by
POWERGRID in transportation, site storage, erection
and commissioning of Power Transformer. Fig-1. Bathtub Curve of transformer failures

2. INTRODUCTION Proper erection and commissioning of transformers

POWERGRID currently has a eet of about 1350
transformers and 1750 reactors w ith total
transformation capacity of 419,815 MVA. Power
Transformers are one of the most critical equipment in
the operation of this transmission network. It is also one
of the most complex electrical equipment. Even a slight
disturbance in its operation may lead to long outage
hours causing huge nancial losses. us, proper
erection and commissioning of Power Transformers is
very crucial in ensuring its trouble free operation.
e failure statistics of Power Transformers generally
display a bathtub curve as shown in g-1.
e failure rate is high during the initial years of
operation. is is generally due to any manufacturing
defect/ improper commissioning of transformers.
involves many steps such as proper transportation of the
unit, Site arrival checks, Storage of the main unit and the
accessories at site, internal inspection of the unit,
Erection of the unit (including Vacuum treatment and oil
lling), pre-commissioning and post commissioning
checks and tests.
Proper adherence to stipulated procedures at each stage
of transformer commissioning lead to optimum
performance during service life.
3. PRESENT P CTICES OF POWERGRID
e pre-commissioning practices for transformers in
POWERGRID have been constantly evolved over the
past 30 years. It re ects various worldwide advances
made in the eld of transportation, storage, erection,
testing and commissioning of transformers. e same is
detailed below.

A er the period of infancy, the failure rate comes down in
the middle age. Again, the failure rate rises when the unit
reaches nears the end of its service life due to ageing
effect. is has been shown in the curve below.
4.T NSPORTATION AND CHECKS ON
SITE ARRIVAL
Power transformers are transported with dry air lled in
main tank with necessary pressure gauge to monitor the
drop in pressure during transit. Upon receipt of
Transformer at site, pressure and dew point of dry air is
 e-T FOTECH 2020- International Conference on Transformers
checked and compared with the value recorded at factory
during dispatch. Generally, the gas pressure should
remain positive even in the coldest weather. If the gas
pressure is zero, there is a possibility that outside air and
moisture may have entered the tank. In some instances,
dry air leak was observed upon receipt of unit at site. To
avoid the same, a practice of transporting the unit ed
along with Dry air cylinder with regulating valve was
adopted. Pressure is monitored on daily basis during
transportation and gas top up is done if any pressure drop
is observed.
Further, the transformers are ed with electronic
impact recorders - at least 2 numbers for 400 kV and
above Class Transformer and 1 number for below 400 kV
class Transformers, to measure the magnitude and
duration of the impact in all three directions. Acceptance
limits of impact for the Transfor mer dur ing
transportation and handling in all three directions
should not exceed “3g” for 50 ms (20Hz). e top level of winding. e oil in the unit is tested for BDV
transformers are usually transported by road on a GPS
mounted hydraulic trailer.
Before dismounting of transformer at site, Core
Insulation Test is carried out to check insulation between
Core (CC & CL) and Ground.
Unpacking and inspection of all accessories is carried out
by taking all precautions so that the tools used for
opening does not damage the contents. Proper storage of
all accessories is ensured a er unpacking. Fragile
instruments like oil level gauge, temperature indicators,
etc. are stored indoor. Any damaged or missing
component is immediately reported to equipment
manufacturer and insurance agency so that the same can
be investigated or shortage made up as per the terms/
conditions of the contract.
5. STO GE OF THE MAIN UNIT AND THE
ACCESSORIES AT SITE
If erection work cannot start immediately, accessories are
repacked into their own crates properly. All packing cases
are kept above ground by suitable supports so as to allow
free air ow underneath. e storage space area is such
that it is accessible for inspection; water does not collect
on or around the area and handling/transport would be
easy. Proper drainage arrangement in storage areas is
ensured to prevent submergence of any component in
water due to rain, ooding etc.
If the transformer is to be stored up to three months due
to delayed erection, it is stored in dry air lled condition.
Dry air pressure is monitored on daily basis so that
chances of exposure of active part to atmosphere are
avoided. In case of drop in dry air pressure, leaks are
identi ed and recti ed and dry air is lled to the required
pressure.
In case the transformer is stored for more than 3 months
or is to be used as spare, it is stored in oil lled condition
on a dedicated foundation. Processed oil is lled upto the
and moisture content once in every three months.
For long storage of transformers which are kept away
from station earth mat area, a practice of lightning mast
installation has been started to protect the unit from
6. INTERNAL INSPECTION
Before erection is started, thorough internal inspection
of transformer is to be carried out, preferably in dry and
sunny weather. In special cases (such as ester oil unit),
where the transportation is done with, there is a
possibility of trapped nitrogen pockets. In this case,
sufficient vacuum is applied for a predetermined period
of time and the vacuum released and re lled with dry air.
During the entire internal inspection process with
personnel inside the tank, a minimum ow of 20 cfm of
breathable dry air with additional 5 cfm for each
additional person is purged in the tank. To avoid any
foreign objects falling into the transformer, all loose
articles are removed from the pockets of anyone working
in the open transformer tank.
 e-T FOTECH 2020- International Conference on Transformers
e inspection includes the following:
• Examination for indication of core shi ing
• Tests for unintentional core or core clamp grounds
• Visual inspection of windings, leads, and connections
including clamping, bracing, blocking, spacer alignment,
phase barriers, oil boxes, and coil wraps
• Inspection of Dead End Tap Changer and in-tank LTCs
including contact alignment and pressure
• Inspection of current transformers, including supports
and wiring harness
• Checks for dirt, metal particles, moisture, or other
foreign material
• Any other suspected damage based on impact recorder
readings.
7. ERECTION
During erection, efforts are made to minimize the
exposure of active parts (core and coils). Further, either
dry air generator is kept running all the time to minimize
ingress of moisture. Transformer is never allowed to be
opened without application of dry air. It is practical to
apply a slight overpressure overnight with dry air inside –
less than 300 mbar (0.3 kg/cm2). Next day, the pressure
is checked and suspected leaks are detected with soap
water or with plastic bags tightened around valves (being
in ated by leaking air).
A er all parts have been assembled, the tank is sealed and
pressure tested to ensure that all joints are tight. Main
tank is purged with dry air till pressure of 4-5 psi (0.3
kg/cm2) is achieved and is retained for 24 hours. A er 24
hours of dry air purging cycle, dew point and pressure of
dry air is measured.
In case pressure remains same, vacuum cycle is started.
Before applying the full vacuum (about 1 Torr), vacuum
drop test is carried out. In case of drop in pressure,
leakages are identi ed and a ended.
If the leak test is successful, the vacuuming is continued,
until the pressure has come down to 0.13 kPa (1 Torr) or
less. e vacuum is then held for suitable time (48 hrs. for
400kV and above and 24 hrs. for 220kV and below units)
and also maintained during the subsequent oil lling
operations by continuous running of the vacuum pumps.
e main requirement of adequate vacuum treatment is
to remove trapped air and moisture from the insulation
and enable the insulation to a ain its full dielectric
strength.
Small gas bubbles have much lower dielectric strength
than the dielectric liquid and may lead to failure, if it is
present nearby high stress zone. By application of
vacuum for desired period, gas bubbles/ trapped air are
removed. Vacuum alone may not be adequate for
excessive moisture removal and heating of the core and
coi ls may also be required at lower ambient
temperatures.
In case the transformer is provided with an OLTC, while
evacuating the main transformer tank, the diverter
switch compartment is also evacuated simultaneously so
that no undue pressure is allowed on the tap changer
chamber. While releasing vacuum, the tap changer
chamber vacuum is also released simultaneously. For
this, one pressure equalizer pipe is connected between
main tank and tap changer. Care is taken to protect the air
cell/ diaphragm in the conservator during evacuation.
In the last few years, the design and technical
speci cations of transformers across var ious
manufacturers have been standardised. is has helped
in interchangeability of accessories and easier installation
of transformer at sites.
8. OIL FILLING
"GET THE T NSFORMER UNDER OIL AS SOON
AS POSSIBLE!"
Generally, inhibited mineral oil is used as insulating
medium for transformers. Oil is transferred to oil storage
tank for ltration before lling inside the transformer.
e drums or trailer tanks are not emptied completely to
the last drop - a sump of an inch or so is le , to avoid
possible solid dirt or water on the bo om. Before being
used, the tanks and hoses are visually inspected, any
liquid residue from earlier use is carefully removed, and
 e-T FOTECH 2020- International Conference on Transformers
the container is ushed with a small quantity of new oil,
which is then discarded. A er ltration, oil sample is
tested to meet speci cation for BDV, water content, tan
delta (90 deg C) and IFT. In recent years, particle count
analysis of oil is also being done before lling in tank. is
has helped in improved insulation performance during
service life.
A er meeting required speci cations, oil is lled in the
equipment and ltration carried out till achieving the
required BDV and water content.
9. PRE- COMMISSIONING CHECKS/ TESTS
FOR T NSFORMERS
Once oil ltration is completed, various pre-
commissioning checks/ tests are performed to ensure
the healthiness of the transformer prior to its
energization. ese tests and their signi cance is given
below :
Core insulation test - To investigate accidental grounds
which results in circulating currents if there is more than
one connection between the core and ground.
Earth pit resistance measurement - To check the
resistance of earth pit provided for Transformer.
Insulation Resistance (IR) measurement – To check the
condition of insulation (i.e. degree of dryness of paper
insulation), presence of any foreign contaminants in oil
and also any gross defect inside the transformer.
Capacitance and Tan δ of bushings at variable frequency
– To check the presence of moisture layer, short circuits
or open circuits in the capacitance network.
Capacitance and Tan δ of windings - To ascertain the
general condition of the ground and inter-winding
insulation.
Turns ratio (Voltage ratio) measurement - To determine
the turn ratio of transformers to identify any abnormality
in tap changers/ shorted or open turns etc. Vector Group
& Polarity - To determine the phase relationship and
polarity of transformers.Magnetic Balance test - To check
the imbalance in the magnetic circuit.
Floating Neutral point measurement - To ascertain
possibility of short circuit in the winding.
Measurement of Short Circuit Impedance - To detect
winding movement that usually occurs due to heavy fault
current or mechanical damage during transportation or
installation.
Magnetising current measurement - To locate defect in
magnetic core structure, shi ing of windings, failures in
turn to turn insulation or problems in tap changers.
Operational checks on OLTCs - To ensure smooth &
trouble free operation of OLTC during operation
Checks on Bushing Current Transformers - To ascertain
the healthiness of bushing current transformer at the
time of erection.
Operational Checks on protection System - Operational
Checks on cooler bank (pumps & Fans), Breathers
(Silicagel or Drycol), MOG, temperature gauges
(WTI/OTI), gas/pressure actuated relays (Buchholz,
PRD, SPR etc.) and simulation test of protection system
Stability test for Differential, REF of Transformer
To check the proper operation of Differential & REF
protection of Transformer by simulating actual
conditions.
Frequency Response Analysis (F ) measurement - To
assess the mechanical integrity of the transformers. is
is also kept as base results/ benchmark for evaluation of
test results in future.
Winding resistance measurement - To check for any
abnormalities due to loose connections, broken strands
and high contact resistance in tap changers.
Dissolved Gas Analysis (DGA) of oil sample – To ensure
the healthiness of unit before and a er charging.
All the results for site tests are compared with respective
factory values and pre commissioning norms for
acceptance. e results are also kept for future records.
 e-T FOTECH 2020- International Conference on Transformers

10. ENERGIZING THE T NSFORMER 12. CONCLUSION

A er completion of pre-commissioning test, se ling e afore-mentioned checks and practices have resulted
time of 24 hrs to 72 hrs (based on voltage class) is given in ensuring proper commissioning of about 3100 units of
before charging the unit. transformers and reactors in POWERGRID. During the
A practice of energizing the transformer preferably from past few years, various advancements in testing and
IV side on NO LOAD through Controlled Switching commissioning of transformers have been made which
Devices (CSD) has been adopted to control the initial have helped to reduce the failure rate of Transformers.
magnetizing current. is has helped in reducing Inclusion of latest condition monitoring tests such as
switching stresses on transformer insulation and Frequency Response Analysis (F ), Frequency
enhances its operating life. Domain Spectroscopy (FDS) and advances in DGA
e transformer should be kept in energized condition at interpretation has enabled early identi cation and
no load for 24 hours for 220kV and above class recti cation of faulty units.
transformers and 12 hours for 132kV transformers. e present commissioning practices are constantly
is period of energization at no load is helpful to evolved based on advances in transformer design, testing
understand and evaluate the transformer in this techniques and acceptance criterions. It is hoped that
condition prior to applying load. During this energizing these advanced practices shall further bring down the
period, before loading the transformer, following failure rate and enhance the optimum performance of
surveillance activities are performed: Power Transformers.
• Check for excessive audible noise and vibration
• Monitoring of the OTI & WTI along with ambient (Note: e authors are thankful to Power Grid Corporation
temperature, recording to be taken every hour until of India Ltd. (POWERGRID) for preparation and
stabilization presentation of this paper at Trafotech 2020. e views
• Inspect for oil leaks and check all oil level indicators and presented in this paper are that of the authors and not
gas detector relay necessarily that of POWERGRID)
• Operation of air cell by checking the breathing of
transformer/ reactor.
11. POST COMMISSIONING CHECKS
e Post Commissioning checks include ermovision
Infra-red scanning (IR thermography), Online Moisture
Measurement and DGA.
e ermovision test data is useful in predicting the
temperature pro le within the inner surface of tank and
cooling bank and is likely to provide approximate details
of heating mechanism. Online moisture measurement is
used to determine the moisture content in paper
insulation by measuring percentage relative saturation.
is test is carried out once the Transformer is stabilized
and operating at higher temperature (>60 deg C).
DGA samples are taken and analysed as per following
practice - a er 24 hrs. of Energizing, one week, 15 days,
one month and three months a er charging, therea er as
per normal frequency of 6 months.
 e-T FOTECH 2020- International Conference on Transformers

RELIABILITY BASED MAINTENANCE & TRENDS IN

CONDITION ASSESSMENT
Gunjan Agrawal
Power Grid Corporation of India Ltd., Gurgaon, HARYANA

ABST CT
In the present era of Deregulated and competitive power
sector, utilities are commi ed to provide reliable and
uninterrupted power to the consumers. is objective
demands continual improvement in design, operation,
and maintenance activities. erefore, the need for
utilities in now days is to balance these factors while
remaining competitive. Maintenance is a key aspect
among these areas. e main objective of maintenance is
to extend the lifetime of equipment and/or reduce the
probability of failure. Maintenance activities play an
important role in improving system reliability by keeping
the condition of a system's equipment within an
acceptable level.
Reliability Centered Maintenance (RCM) is the process
of nding out the most effective maintenance approach.
e most cost-effective maintenance approach is the one,
which gives a high level of reliability while keeping
maintenance cost minimum [5]. e transformer, which
is the costliest equipment in any Substation, has a
signi cant role in the power system overall reliability.
In this paper, role of RCM on the eet of Transformers in
any utility and approach for replacement decisions is
presented. Some case studies and practical examples are
also presented to correlate the RCM philosophy in real
time.
1. INTRODUCTION
RCM is the process to identify the most cost effective and
applicable maintenance techniques to minimize the risk
and impact of failure of a system or equipment, doing so
in the most economical manner. RCM enhances the
traditional types of maintenance by integrating them all
and integrating the strength of each approach so as to
meet the required operational level of each asset [2].
Generally, Maintenance is classi ed into following
categories:
Fig 1: Various maintenance philosophies
Philosophy of working under each type of maintenance
is explained in later section of this paper to understand
the pros and cons of each type and nding out most
suitable one or combination of various maintenance
philosophies to suit the utility’s requirement.
One major aspect, which sometimes get ignored or le
inadvertently by major utilities and decision makers is
the Life cycle cost of the equipment, which is a very
important parameter.
2. LIFE CYCLE OF ASSET
It is a well-known fact that Transformer is the costliest
equipment in a substation. Each unit can supply
numerous customers, but a failure of a single unit can
result in loss of service with a considerable amount of
expenditure associated with lost revenue. Most utilities
expect to manage it well and expect it to perform its
intended purpose without any trouble. But the main task
in managing assets of any kind (including Transformers)
is not so much the assets themselves. Rather, it’s the value
that the particular asset delivers to the utility over the
whole of its life or what is more commonly called the
“asset life-cycle”.
 e-T FOTECH 2020- International Conference on Transformers
Fig 2: Stages in the asset management lifecycle
As such, it is a multi-step process to be done slowly and
properly. is includes:
. Identi cation of procurement need and its Planning
. Efforts in Design (including minimum Technical
speci cations or improvement in design based on
previous experience)
. Procurement process
. Commissioning or properly installing to make sure that
the business gets everything promised in the purchase
contract
. Operating, maintaining and monitoring on a continual
basis including any modi cation or upgradation required
if possible, subject to commercial viability
. Decision for Decommissioning or disposing of so that it
can be appropriately replaced
In order to maximize the value of the Transformers, the
utility needs to track the activities related to the
Transformers throughout their life cycles, to make sure
they align with the utility’s ongoing strategic and
operational objectives.
erefore, Asset Management is broader than simply
maintaining and repairing as asset.
3. VARIOUS MAINTENANCE ST TEGIES
For maintenance of equipment in any Power
Transmission/ Distribution network, generally two
maintenance strategies are followed namely Preventive
and Corrective.
3.1 PREVENTIVE MAINTENANCE (PM)
is type of maintenance is carried out to maintain the
system operational, before its failure occurs. It consists of
regular scheduled inspections, testings, repairs,
replacement of accessories and major overhauling.
It is further classi ed into following two categories:
a) Time based maintenance
b) Condition based maintenance
3.1 PREVENTIVE MAINTENANCE (PM)
Time based maintenance (TBM) is performed without
regard to equipment condition. In this, inspection and
maintenance is performed at regular, xed intervals in
line with utility’s procedures. As per the experience of
many utilities, time based maintenance can result in
signi cant increase in cost without adding much
reliability to the system.
Condition based maintenance (CBM) is based on the
condition of the equipment obtained from various
condition monitoring techniques including systematic
inspections, measurements and monitoring including
On Line monitoring. CBM substitutes the TBM
technique with maintenance that is scheduled only when
warranted by the equipment condition. CBM generally
broadens the gap between successive maintenance thus
proves to be having lesser cost than TBM.
3.2 CORRECTIVE MAINTENANCE (CM)
In this type of maintenance, also called Run-to-Failure
(RTF), maintenance is not performed until the
equipment failed. us, the main task in CM is to restore
the equipment by repair or major overhauling. is
technique is suitable when the cost of failure to utility is
not extensive.
It is further classi ed into following two categories:
a) Immediate maintenance
b) Deferred maintenance
 e-T FOTECH 2020- International Conference on Transformers
e onus of selection between Immediate maintenance
and deferred maintenance lies on the utility based on the
criticality of the equipment.
4. RELIABILITY CENTERED MAINTENANCE
Reliability Centered Maintenance program includes the
features of all the above four techniques. It is the process
of determining the most effective maintenance strategy.
RCM can not only improve the reliability of the system, it
can reduce the required maintenance signi cantly that
too with signi cant reduction in O&M cost.
Fig 3: Features in RCM
Opting for RCM in early stages of asset management
affect the life cycle cost of the asset.
e basic rule of RCM is that maintenance should be
linked to failure probability. Hence, maintenance is
required to be performed only when the equipment’s
failure probability is signi cantly high. Further,
consequence of failure also have an impact on it.
e ability of separating Transformer operating in a grid
to various small constituents and pin pointing the root
cause of possible failure modes can make RCM approach
most effective.
5. RCM FOR T NSFORMERS
As explained above, RCM should be linked to failure
probability. Failure probability can further be divided
into following categories:
5.1 BATH TUB CURVE FAILURE PA ERN
e failure probability of a Transformer generally follows
a bath tub curve.
Fig 4: Bath Tub Curve failure pa ern
Considering the above, it is necessary to monitor the
Transformers in stringent ways in its early stages to avoid
infant mortality rate. Some utilities, where they have
contingent arrangements and can afford single failure,
may also opt to avoid higher monitoring costs in early
part of its operating life as the equipment is generally
covers under warranty at that time.
5.2 FAILURE TE ESTIMATION
Generally, despite all precautions and rigorous
inspections, Transformer / components of Transformers
of certain ratings/ make fails to perform at site and thus
the prediction of failure is easy. Maintenance philosophy
thus directs towards the components/ makes which are
more prone to failure, thus avoiding unnecessary
maintenance for other components/ makes.
Example:
During a certain period, the Bushing failure rate for OIP
Bushings were very high in Indian network. is was
resulted in devastating failures of many Transformers &
Reactors.
Based on above, utilities focused more maintenance on
Bushings.
Subsequently, RIP Bushings were started to be speci ed
in Technical Speci cation. ough expensive compared
to OIP Bushings, the failure rate of Bushings declined
and the life cycle cost of Transformer was reduced
signi cantly.
 e-T FOTECH 2020- International Conference on Transformers

5.5 COMPREHENSIVE T NSFORMER

Further, Bushing Tan Delta monitoring, which was FLEET MANAGEMENT
earlier a time based activity and impacting severely on e major utilities are now a days monitoring the
maintenance cost, now as a part of RCM, being complete Transformer eet in one window where the
monitored less frequently. Asset managers can take decisions to take out the
5.3 FAILURES DUE TO AGEING Transformer based on criticality or even replacement of
Transformer due to ageing / other parameters. ough
Ageing is also one of an important parameter which one-time investment is required, this type of solutions
indicates equipment which are having high probability of are very effective and proved to be cost effective in longer
failures. run.
Furan measurement, DP measurement of paper
insulation are some of the techniques which can provide
estimation of remnant life of the Transformer. ere are
various algorithm based so ware solutions are available
these days which can also predict the remaining life of the
Transformers quite effectively. ese so ware programs
takes input from various Online devices (DGA, Fibre
Optic hot spot temperature units, moisture values,
Bushing Tan delta. Partial Discharge, Loading pa ern,
OTI, WTI, OLTC conditions etc.).
5.4 OPE TING CONDITIONS AND
TECHNOLOGY Fig 5: Online monitoring of Transformers eet
Transformers running with higher number of OLTC
operations, operating in harsh environment conditions, 6. ROLES OF DESIGNERS IN RCM
manufactured with older Technologies are also more As explained above, Transformer design, which is part of
prone to failure [1]. With be er monitoring including Life cycle cost of Transformers, plays a major role for
Online devices and frequent maintenance checks, life of RCM.
these Transformers can be enhanced and failures can be Asset managers provides their operational feedbacks to
be er predicted. the Design team and the designers have a role to
implement these feedbacks in the design process.
In case Transformers are installed in Urban areas, a single
Example:
failure can cause lot of panic. Further, environmental
765kV Transformers when started to be manufactured
pollution on account of failure is also a major concern in
and commissioned in Indian Transmission system,
city areas. Application of Ester insulating uid is a proven
different manufacturers were having different layouts of
solution to meet this challenge. ough, having higher
Bushing termination arrangement. is was found to be
initial investment, it covers the safety concerns.
critical, in case of some failure when replacement is
required. Further, implementation of too much
In some of the cases, failure of a small rating Transformer
complex ity was required to adopt a different
in an Industrial applications is more critical as it could
arrangement, thus adding risk to the system.
lead to long outage and affect production. In such cases,
us, based on inputs from Asset managers, the Bushing
users don’t hesitate to provide more margins in design so
termination arrangement were made standard for all
as to achieve longer Transformer operating life.
makes.
 e-T FOTECH 2020- International Conference on Transformers
Similar philosophy of standardization was made for
Transformer Bushings, foundations, placement of cooler
banks etc.
is has given very positive outcome on the restoration
time for replacement of failed Transformers, maintaining
lesser inventory levels, lesser time for Engineering
activities etc.
7. CONCLUSION
Transformer outage has serious consequences on the
Transmission system. Accordingly, more emphasis is
required on the Transformer maintenance. Reliability
Centered Maintenance not only improve the reliability
of the system, it can reduce the required maintenance
signi cantly by improving Design, Operation and
Maintenance. RCM can provide reduced maintenance
costs, enhanced Transformer life, enhanced safety
during operation and minimized accidents. It is upto the
users to use it judiciously.
(Note: e author is thankf ul to Power Grid
Corporation of India Ltd. (POWERGRID) for
preparation and presentation of this paper at Trafotech
2020. e views presented in this paper are that of the
authors and not necessarily that of POWERGRID)
8. REFERENCES
1. CIGRE 445 (Guide for Transformer Maintenance):
Working Group A2.34
2. Reliability Centered Maintenance Implementation on
the e ekwini Electricity Network for System
Maintenance Process Optimization by Musawekkosi
Phillemon Lokothwayo.
3. A procedure for Diagnosis and Condition based
Maintenance for Power Transformers by Alireza
Setayeshmehr et.all.
4. e Key to Condition Based Asset Strategies for Power
Transformers by David J. Woodcock, Weidmann
Systems International.
5. Reliability Centered Maintenance by Al Rose
6. Power Transformer Life Extension through Be er
Monitoring by Brian D Sparling et all.
7. Operational Management of Grid Transformers-An
experience of POWERGRID by P N Dixit, S Victor, V K
Bhaskar, Gunjan Agrawal.
 e-T FOTECH 2020- International Conference on Transformers
SITE REPAIR AND REFURBISHMENT
Gautam Mazumder, Vijay Singh
M/s. CGPISL-Transformer Division-Mandideep Bhopal
ABST CT
is paper intends to address a very controversial and
least appreciated procedure for both decision-makers
and practicing engineers engaged in power transformer
maintenance activities.
Aging of the installed base of transformers has lead to
increased interest in the assessment of the transformer
condition. e Indian power transformer population
inclusive of the utilities and industry could be between
80000-120000 units with a minimum rating to start the
count at 20 MVA and above. e time based
maintenance policy followed for power transformers has
hampered the development of the alternative methods
possible. e monitoring of certain parameters has led to
inadequate maintenance conditions as the transformer
ages. e concept of condition based maintenance is not
well understood and there is a lack of appreciation of the
importance of the same.
e Govt. sector decision-making criteria are L1 based
and in many places, the value of the repairs should be
limited to 40% of a new transformer cost. Enumerating
the reasons for repair & refurbishment at the site, is an
economically sound decision, it is a technically correct
decision and it can be implemented faster. At present site
based repair and refurbishment activities on power
transformers are being adopted only in case of no option
possibility.
1 INTRODUCTION
Power transformer repairs/refurbishment at the site are
an established norm world over. Transformers and
reactors subjected to failure of accessories like bushings,
oil-water heat exchangers, OLTCs, internal insulation
component failure etc. due to a variety of abnormal
conditions eg. moisture ingress, particulate ma er
contamination, adverse weather conditions, and
super cial damage are the ideal cases for refurbishments
at the site.
Large power transformers subjected to improper storage
conditions, long durations of storage, super cial damage
in transit, or exposure to atmospheric conditions due to
accidental actions can be easily refurbished and
rehabilitated at the site.
e some of the advantages of on-site repair considered
by decision makers are also transportation difficulties or
impossibility of road and rail tracks, inadequate axle load
withstand capacity for roads, bridges and changed
alignment.
High transportation cost.
High transportation risk (poor road condition, and
inadequate road and rail capacity, aged insulation)
Reduce down time on the units by avoiding long
transportation time.
e world over for the last 2 decades there has been very
very successful a empts and actions for the site-based
repair and retro ing.
e major actions have been undertaken in Europe (e.g.
France, Spain, Hungary etc) and South America (e.g.
Brazil)
WHAT IS RETROFI ING:
It is a procedure adopted to incorporate features that are
not part of the original manufacturing. Incorporation of
these features is intended to bring about improved
monitoring and informed decision making, improved
safety for the equipment and people, and minimizing
harmful environmental impact.
WHAT IS REFURBISHMENT:
It is the procedure to improve the existing condition
leading to increased reliability, improve life expectancy
and, minimize the rate of deterioration. e outage could
be due to improper maintenance, accidental handling
and exposure to adverse atmospheric conditions due to
component failure. Minor failures can be very much
 e-T FOTECH 2020- International Conference on Transformers
considered to be treated at the site. Condition
monitoring can be also the basis for such activities to be
carried out before the forced outage of the equipment.
WHAT IS REPAIR:
Restoration to the original working condition a er the
equipment has ceased to provide the intended function.
Many hydro power stations in India posses spare
windings, with a intent to have a faster turn around time
for the site repair. As these facilities are remotely located
and the time frame for the repairs is huge, the revenue
loss is high for the duration of the outage.
2. CONSIDE TIONS FOR
REFURBISHMENT/ REPAIR:
Power transformers and reactors are one of the main and
among the largest components in any installation. A
transformer outage can cause serious economic and
social disruptions. Refurbishment activities initiated at
the appropriate time can avoid serious outage incidents.
e considerations for site-based activities should be
l o o ke d f ro m b o t h n a n c i a l a n d o p e rat i o n a l
considerations.
e instances or incidents that can be addressed are
1. Minor faults and oil leakage issues in the transformer.
2. Improper insulation conditions due to inadequate
maintenance issues.
3. Accessories failure, inadequate operational conditions
leading to Improper insulation condition due to
exposure to adverse weather conditions.
4. Particulate contamination of the insulation media due
to internal ashovers and components failure.
5. Minor transit damage issues.
6. Inadequate insulation conditions due to inadequate
storage conditions or improper maintenance issues.
7. Life extension of equipment arising due to aging and
removal of contamination to minimize the rate of aging.
8. For the repair activities, there are many considerations,
cost of repair, cost of transportation, cost of forced outage
duration, cost of availability, time for to and fro
transportation, time of repair.
For repair activities at the site Tool and Plant
requirement increases and also the quantum of work
content.
1. e preferred method is to make the critical winding
and components at the manufacturing facility.
2. e required material is then processed and soaked in
oil and sized properly to make it ready for use condition.
3. e material and the other required materials are then
packed in suitable containers and lled with oil and sent
to the site.
4. e required procedure is then followed at the site for
the repair activities and the processing activities
undertaken as is required.
3. DETERMINING THE CONDITION AND
RECOMMENDED ACTION:
Transformers and reactors life is a function of the
composite solid and liquid insulation condition:
Condition assessment tests are recommended as the
equipment aging progress under normal operating
conditions.
Presently liquid insulation monitoring and its
maintenance is the most widely practiced procedure.
e oil quality tests are the most widely followed
procedure & easily followed at site.
e solid insulation condition is difficult to access as they
are not directly accessible. e liquid insulation
parameters are used to determine the solid insulation
condition.
Trending of the data is the most authentic way to
determine the stability and the deterioration rate of the
insulation condition.
e liquid insulation DGA parameters are utilized to
determine the fault condition, intensity, and severity.
Some of the electrical test parameters indicate an
abnormality in the oil-immersed transformer and
reactors.
Trend analysis based on the intensity and severity of the
violating condition determines the line of action to be
adopted and avoiding catastrophic failures.
e insulation quality tests and moisture determination
tests are to be increased in the tests being carried out as
part of maintenance procedures.
 e-T FOTECH 2020- International Conference on Transformers
As the transformer insulation ages, the capability to
withstand fault conditions deteriorates. e dielectric
and mechanical strength of the paper are among the main
considerations for certain refurbishment activities.
4. BENEFITS OF SITE BASED
“REFURBISHMENT /REPAIR”
Points in favor of site-based activities:
Time-Saving and Cost Saving:
1. e action being initiated locally is time-saving on to
and fro transportation to the facility.
2. e cost of to and fro transportation is substantial and
this is a major saving for the owner.
3. e transportation time frame can vary from a few days
to months based on the size and the distance of the
appropriately equipped facility.
4. e second important factor is the time required for
the preparation of the equipment for the to and fro
movement.
5. e processing time at the facility could be shorter
compared to the site but the same may be an overdo for
the condition.
6. e transformer/reactor having performed its
intended function grants credence that the design is safe
enough for initiation of site activities.
7. e process to be followed for the activities at the site
can be in line with the established and proven norms for
similar activities.
8. e transformer/reactor can be tested for almost all
the parameters except HV high voltage testing as is
performed at the manufacturing facility.
5. QUALITY AND WORKMANSHIP
CONSIDE TIONS:
e two main considerations for site activities are the
facility and the workmen. Based on the criticality of the
work the facility speci cations are devised.
For the refurbishment activities in which the Core Coil
Assembly (CCA) is not required to be detanked, the
main tank can serve as an enclosure.
e environment control within the main tank can be
exercised by the injection of >-55oC dew point dry air
from a machine capable of delivering 35-60 m3/hr. e
machine should have particulate ma er ltration
capability. Humidity and particle control ensures good
quality during the time of the repair and refurbishment
activities.
e refurbishment activities should be carried out by a
trained supervisor and workmen. e procedure for the
restoration of the affected or damaged components is to
be guided by the manufacturers representative making a
proper assessment of the suitability of use of the same for
future use.
Brie y, the temporary repair facility considerations for
carrying out the refurbishment/repair activities are as
under
1. e base for the placement of the CCA should be
strong enough to withstand the full weight of the
transformer main tank.
2. CCA should preferably be placed in a suitable
contained platform or a tray so that the access is restricted
and the oil based cleaning and ushing activities have
minimum spillage.
3. e working area considering the duration of the
facility (enclosed by dismantlable metallic structure and
outer cover with an internal 2nd cover of waterproof
tarpaulins) to accommodate the disassembled
transformer and the dismantled components.
4. e covered working area is weathertight and
stormproof. e critical Tool & Plant area should be
accommodated inside e.g. dry air generator and the
various tools and facilities.
5. e li ing arrangement can be accommodated within
the structure made or the top cover of the facility should
be removable for the duration of the li ing equipment
requirement.
Brief speci cations of the tools and plants for the site
activities to include
1. Adequate capacity oil storage tankers.
2. Suitable capacity double stage vacuum pulling
equipment for achieving vacuum of 1 torr level.
3. Vacuum gauges to measure a vacuum level of 1 torr and
below.
4. Dew point measuring instrument capable of
measuring dew point of >-60oC.
 e-T FOTECH 2020- International Conference on Transformers
5. e insulation drying procedure requires insulation
heating and then vacuum application for removal of the
contaminating moisture and oxidation products.
6. Heating arrangement of approximately 60kW capacity
around the main tank to heat the internal insulation to
increase the temperature of the insulation between 60-80
oC.
7. e tank internal environment to be lled with dry
nitrogen preferably and/or dry air.
8. e alternate heating procedures followed are the use
of transformer oil circulation.
a. Oil spray under vacuum application.
b. Low-frequency heating method of core coil assembly.
c. Induction heating of the core coil assembly by the
wrapping of the tank with coils.
9. During the heating procedure the transformer main
tank to be covered as much as possible to minimize heat
loss.
10. Post achievement of temperature fast oil draining,
before vacuum application.
11. With the oil-based heating procedure, the rate of
moisture extraction from the thick insulation is slower
and the time taken for drying out is longer.
12. e moisture extraction during the vacuum should
be monitored for proper documentation of the drying
out process.
Brie y the procedure for the drying out of the
transformer and reactor at the site are as under
a. A pressure test to verify the leak-proof status of the
complete assembly.
b. Dew point measurement of the gas inside the
transformer a er 24 hours.
c. Heating of the transformer for a duration of a minimum
of 60-72 hours duration.
d. Vacuum pulling of the transformer for a duration of
minimum 60-72 hours.
e. Re-pressurisation of the transformer or reactor and
dew point measurement a er 24 hours.
f. Continue the heating and pull vacuum again for 40-48
hours and repressurize again.
13. e procedure to be repeated multiple times until the
moisture extraction data reduces to limits as
recommended by the manufacturer over two continuous
cycles.
5 ECONOMICAL CONSIDE TIONS
e constraints for such activities to be conducted at the
site are multifold.
e decision making criteria are different for different
users
1. Perceived reliability of operation.
2. Time required for repair/refurbishment activities.
3. Revenue loss arising from outage.
4. With the changed scenario where nancial revenue is
linked to availability.
5. Outage costs are more linked to the loss of xed costs.
6. When the equipment is a spare unit the anticipation of
the forced outage of the ongoing units.
6 TESTING DURING AND AFTER
THE PROCEDURE:
To date, Indian utilities and the user industry think that
the Factory Acceptance Test including HV tests are the
only testing that certi es the healthiness in the
transformer core coil assembly.
e process and test equipment available in the market
overseas enables the HV testing of the transformer core
coil assemblies.
In India, no such mobile HV test facility is available to
carry out HV tests at the site. So many manufacturers and
the user industry conduct the site procedures without
the nal high voltage tests and have had a high success
rate in pu ing back the assets into operation.
Nevertheless, negative experiences have been also
experienced and the same are generally a ributed to
non-adherence to the procedure required to be followed
for the situation being addressed.
e transformer manufacturing process is well
established that the adherence to the same procedures at
the site will ensure the same reliability in the work carried
out at site. Insulation quality and oil quality tests
performed at regular intervals including DGA, have
proven the quality of work done. Trouble free operation
and reliability of the process to deliver factory
manufactured quality for site repairs.
 e-T FOTECH 2020- International Conference on Transformers

and reliability of the process to deliver factory [2] I. Pinkiew icz, M. K azmierski, ON−SITE
manufactured quality for site repairs. PROCESSING OF INSULATION SYSTEM OF
e author’s organization have carried out site repair L ARGE POWER T NSFORMERS AND
activities for transformer windings in remote sites of HOT−SPOT COMPUTER DETERMINATION
Hydroelectric substations & at Steel Authority of India ,Published in 2004 CIGRE
Limited substations. e transformers in which repair
and refurbishment activities were carried out at the site, [3] R. Blanc, G. Buffiere, J-P. Taisne, A. Tanguy,
have been energized and put into operation even with a P.Guffinic, T NSFORMER REFURBISHMENT
performance warranty of 8-12 months. Some of the sites POLIC Y AT RTE CONDITIONED BY THE
have gone ahead and ordered spare windings with an RESIDUAL LIFETIME ASSESSMENT, Published in
intent to carry out repairs in next 6 months. 2008 CIGRE
We have also successfully conducted these activities
overseas also and are preparing for similar refurbishment [4] M. Olivia(*), M. A. del Rey, A. Marinj. I. Anguas, S.
and retro ing operation on some of our transformers Quintin, ST TEGIES TO REPLACE, REFURBISH,
supplied to countries in Europe, South America & REPAIR AND UPG DE POWER
Bangladesh. T NSFORMERS: THE SPANISH EXPERIENCE,
Published in 2008 CIGRE
7 CONCLUSIONS
Globally mutual collaboration, data sharing and support [5] Working Group A2.34, CIGRE TB 445, GUIDE
between the transformer user and the manufacturer over FOR T NSFORMER MAINTENANCE, Published
the last 20 years have led to clear understanding of the in 2011 CIGRE.
complexities involved in operation, maintenance,
retro t , ref urbi shment and repairs of power [6] Nick Lelekakis, Daniel Martin, Wenyu Guo,and
transformers. Jaury Wijaya, A FIELD STUDY OF TWO ONLINE
is experience has been well documented and data DRY- OU T METHODS FOR PO W ER
collected shared in the international forums and have T NSFORMERS, Published in 2011 IEEE Electrical
been discussed and enhanced by the collective Insulation Magazine.
intelligence and experience of the people and
organisations involved.
In India also the procedure has been followed but the
quantum is limited and so also the experience sharing.
Indian market acceptance and the post activity
experience sharing needs improvement.
8 REFERENCES
[1] Aleksandar Bojkovic1 Dragomir Gucic, Petar
Nikolic, Bogosav Petrovic, FAILURE OF A BIG
T NSFORMER IN HPP–ASSESSMENT OF
DAMAGE, REPAIR AND TESTS, Published in 2008
International Conference on Condition Monitoring and
Diagnosis, Beijing, China, April 21-24, 2008
 e-T FOTECH 2020- International Conference on Transformers
REVIVIFICATION OF T
Ashok Chavda, J. V. Patel
Gujarat Energy Transmission Corporation Limited(GETCO), Vadodara
ABST CT
Power transformer is the critical & most expensive asset
of a substation. A major fault or forced outage of a
transformer affects the power supply reliability and leads
to revenue loss to the utility. erefore, in such case, the
rst priority for utility is to restore the power transformer
as early as possible. In case of a shutdown due to fault,
visual inspection, protection operated, post fault testing
&analysis and co-relation of all these a ributes help in
proper fault diagnosis and accordingly, repair &
restoration can be done. Similarly, if transformer is taken
out from service for some major corrective actions or
overhauling, restoration depends on the work involved in
it. Two such case studies, one each of restoration a er
major fault and overhauling of transformer, done by
utility at site, are discussed in this paper.
Key words- Power Transformer, Reliability, Major fault,
Restoration, Overhauling.
1. INTRODUCTION
Power transformer is a costly and important element in
power system network. Power transformer experiences
excessive electrical as well as mechanical stresses
throughout its service life span due to faults. As it is one of
the most strategically important components, its
unscheduled major shutdown leads to long term
unavailability of power supply. erefore, outage of
power transformer is always looked upon with great
concern by the utilities. Following steps proved helpful
to assess the situation a er fault and subsequent
restoration.
NSFORMERS - CASE STUDIES
. Visual inspection of transformer and its condition a er
fault i.e. oil level, condition of bushing, operation of
NIFPS, PRV, Buchholz Relay, etc. Checking associated
bay equipments.
. Investigating cause of transformer tripping
. Identifying Location of fault, whether it is out-side or
in-side the transformer.
. Study of protection operated and disturbance record
(DR) analysis to get the information about fault, its
intensity and time duration.
. History of transformer and study of past test data
. Testing of transformer to accurately determine the
condition of transformer.
. If the fault is external, then also transformer is required
to test to ascertain its healthiness.
. Co-relation of results of all the tests and comparison
with past test data to arrive at the conclusion of fault and
possible damage to the transformer
. If found necessary from above steps, carrying out
Internal inspection by making necessary arrangement for
prevention of moisture ingress to transformer and taking
all safety precautions.
. Ensure availability of the material required /
anticipated to a end the fault and keeping it ready
. A ending the fault with minimum exposure of active
part of the transformer as much as possible
. Lastly, carrying out nal testing and comparing with
post fault and past test results, so that the transformer can
be restored with con dence.
Above modality was followed in the case of successful
restoration of transformer, presented in this paper.
 e-T FOTECH 2020- International Conference on Transformers

2. TESTS FOR FAULT DIAGNOSIS 3. CASE STUDIES

Transformer tests and ability of each test to provide In GETCO, the population of power transformers is
inferences about type and location of fault is tabulated 5226 Nos. and approx. 270 Nos. of transformers are
below, in table 1. added every year. In this transformer eet, 10 to 14 Nos.
Test Information about fault of transformers per year experience major fault. In this
Insulation Transformer Insulation section one such major occurrence of power
Resistance transformers is presented with fault details and how it
Magnetizing Core, Inter-turn shorting was restored. A case study of overhauling of a transformer
current
Magnetic Core, Inter-turn shorting is also discussed.
balance
Turn Ratio Winding information
3.1 CASE STUDY-1: RESTO TION OF
Winding Joints, overall winding T NSFORMER AFTER FIRE
Resistance condition Substation: 220kV Morbi
Oil Routine BDV, PPM, resistivity, etc.
Parameters to assess Transformer Rating: 220/66kV, 100MVA Date:
transformer oil condition 01.11.2019, at 12:45hrs
DGA About fault and its intensity Occurrence: Sudden heavy re on 66KV side of
Transformer (Figure. 3)
Capacitance Integrity of insulation
and Tan material like, paper , oil ,
Delta bushings, press board etc.
SFRA Winding distortion, Core
movement, Inter-turn
shorting, open winding,
lead movement, etc.

Furan Degree of Polymerization

of paper insulation
( indirect method)
Table 1: Test and its ability to detect the fault
If transformer is lled with oil up to required level, the
routine tests like winding resistance and other low Figure 1: Fire incident of a 220/66kV, 100MVA Transformer
voltage tests can be carried out and it provides rst-hand
information about transformer condition. Dissolved Gas Substation: 220kV Morbi
Analysis (DGA) of transformer oil provides information Transformer Rating: 220/66kV, 100MVA Date:
about fault and its intensity. For be er judgment, past 01.11.2019, at 12:45hrs
data of DGA should also be studied. Capacitance & tan Occurrence: Sudden heavy re on 66KV side of
delta test is also an important test, provides information Transformer (Figure. 3)
about dielectric insulation. Sweep Frequency Response
Analysis (SF ) is the best test among all site tests which
can be carried out safely in any condition of power
transformer i.e. with oil, without oil, without bushing,
with faulty bushing etc. It provides useful information
about mechanical deformation of windings [1]. If base
SF test results are available, then comparison with it
provide important information about transformer
overall condition.
 e-T FOTECH 2020- International Conference on Transformers
Visual Inspection
. 66KV R, Y, B & Neutral, and HV Neutral bushings of
the transformer found red and heavily damaged.
. Buchholz relay, all OSRs, Transformer M.K. box and
control cables also found burnt and damaged badly.
Photographs of Transformer and Bushings taken a er
occurrence are shown below in gure 4.
Figure 2: 220/66KV, 100MVA Transformer a er
Fire extinction
Figure 3: 66kV R phase bushing damaged
Figure 4: HV Neutral bushing damaged
Protection Operated
. Transformer Differential Protection, Buchholz Relay,
PRV operated correctly and cleared the fault within
30ms.
From DR, around 1136 A and 16.7 current recorded
for HV R-phase and LV R phase respectively
Observations & Fault Analysis
. Failed bushings were inspected thoroughly. Tan Delta
Caps of all bushings were found intact. It indicated that,
no any bushing failed due to internal defect but bushings
failed due to external re / ashover.
. Spots of ashover observed on top portion of LV R
Phase and HV Neutral Bushings. Top metal part of LV R
phase bushing – facing HV Neutral Bushing found
melted (Fig. 3). Also, top metal part of HV Neutral
Bushing facing LV R phase bushing found melted
(Fig.4).
. It was suspected that, some foreign object (Like metal
wire) might have fallen between HV Neutral Bushing
and adjacent LV R Phase Bushing. It created short circuit
between these two bushings which further caused
damages to the bushings and converted into re as oil
came out from bushings & transformer.
. e main concern was to assess integrity of transformer
winding whether severe external fault caused any
damages to the transformer windings. It was required to
take decision whether to carry out recti cation work at
site or send the transformer to the manufacturer.
. Carrying out routine tests and Tan Delta testing was not
recommended as 66kV bushings were failed and
removed, and the oil level lowered down due to re.
. In these circumstances, only SF was feasible to check
mechanical integrity of transformer windings. Base
SF results were available. So SF testing was carried
out and the results were compared with the base results as
shown in below gures (5 to 10).
 e-T FOTECH 2020- International Conference on Transformers
Figure 5: HV R phase to Neutral SF test results
comparison between base available and a er fault
Figure 6: HV Y phase to Neutral SF test results
comparison between base available and a er fault
Figure 7: HV B phase to Neutral SF test
comparison between base available and a er fault
Figure 8: LV R phase SF test results comparison
with base available and a er fault
Figure 9: LV Y phase SF test results comparison
between base available and a er fault
Figure 10: LV B phase SF test results comparison
with base available and a er fault
. SF traces matched with base results except in high
frequencies area of all the three LV winding coils results,
but it was due to the exclusion of bushings & leads in
testing, as SF test was done without bushings & leads.
From comparison of SF results as shown in gure 5 to
10, we could draw inference that there is no damage /
displacement of transformer windings
From Visual inspection, DR analysis and aid of
information received form SF test, it was concluded
that fault was external only.
Restoration
A er completing above analysis, and availability of
material in scrap transformer, it was decided to take back
power transformer into service without help of OEM as
Morbi loaded with heavy industry load, and help of OEM
may delay restoration. Delay in restoration create critical
situation. Following actions were taken to restore the
transformer.
 e-T FOTECH 2020- International Conference on Transformers

. Internal inspection was carried out to check any

physical damage to winding, to check all the joints and
for cleaning debris of L2 part of bushing inside the
transformer. ere was no any internal damage.
. All damaged bushings and other accessories viz. PRV,
Buchholz Relay, OSRs, Marshaling Box etc. replaced.
. Damaged main tank gasket and other gaskets were
replaced.
Figure 13: LV B phase SF trace comparison with
. Oil ltration carried out.
base SF traces a er replacement of bushing
. SF Test taken. SF results taken a er replacement
of failed / damaged bushings compared with pre-fault . All routine tests and capacitance & tan delta test carried
results, and both traces are now seen matching as shown out - all results found satisfactory, and also compared
in g.13 -18. (Green color traces are SF results taken with previous results available.
a er replacement of Bushings.) . Repainting of the transformer done.
. Transformer put back in to service a er con rming all
logic checks and electrical & mechanical protection trips.

Figure 11: LV R phase SF trace comparison with

base SF traces a er replacement of bushing.

Figure 14: Transformer restored

Figure 12: LV Y phase SF trace comparison with
base SF traces a er replacement of bushing
It was difficult to know what geometric changes would
have occurred in the transformer but it was ensured by
carrying out SF test (post failure) and matching with
base SF test, and re-con rmed by internal inspection
that there is no internal damage and transformer could be
put back in to service a er carrying out recti cation work
at site without OEM, which saved lot of time (Total
outage period: 45 days) and money too.
 e-T FOTECH 2020- International Conference on Transformers

3.2 CASE STUDY-2: OVERHAULING OF A

T NSFORMER
Substation: 220kV Karamsad condition based Health Index Value as under Shown in
Transformer Rating: 220/132kV, 100MVA Table.1
Yr. of Mfg.: 1975 Transformer Condition based Health Index
Dielectric Strength(BDV) 2
(>60KV) 3
Transformer undergoes through electrical and (41-60KV) 2
mechanical stresses during fault events, switching surges (31-40KV) 1
(<=30KV) 0
etc. Oil leakage points, defects in breathing system and Moisture Content in oil(ppm) 2
(<=20) 3
maintenance in un controlled atmosphere prove sources (21-30) 2
(31-40) 1
of moisture ingress to transformer. Over a period, (>40) 0
insulation can deteriorate. erefore, operating Interfacial Tension(N/M)
(>=0.10) 3
1

transformer under such conditions poses a potential risk (0.041-0.09) 2

(0.016-0.040) 1
of breakdowns, outages and costly repairs. (<0.016) 0
Total Acidity,mg KOH/g of oil 2
So, at some point in life-cycle of a transformer, it becomes (<=0.01) 3
(>0.01-0.10) 2
necessary to inspect its internal parts to check for any (0.11-0.3) 1
(>0.3) 0
defects, re-tighten core clamping structure, to check all Specific Resitivity 0
(>0.5) 3
connections inside transformer main tank, to remove (0.5-0.21) 2
moisture from oil / replace oil, to remove moisture from (0.2-0.1)
(<0.1)
1
0
cel lulose insulat ion to inter r upt accelerated Tan Delta of winding ,Max 0
(<=1.0) 2
deterioration of transformer insulation. All these can be (>1.0-1.5) 1
(>1.5-2) 0
achieved through transformer overhauling. (>2) -1
Age 1
In GETCO, Transformer health index, giving due (<=10) 3
(20-11) 2
weightage to transformer oil parameters, winding tan (30-21) 1
(>30) 0
delta value, IR and PI values of winding, location and Last Overhauling done before year 0
(<1) 3
extent of oil leakages, age of transformer, Physical (1-3) 2
condition of the transformer, past maintenance history, (3-5) 1
(>5) 0
major occurrences etc., is derived for Power transformer Insulation Resistance Value,MOHM,Min 1
(>=1000) 3
at yearly frequency. Transformer overhauling decision is (625-999) 2
(201-624) 1
taken mainly based on Transformer health index. (100-200) 0
(<100) -1
Transformer health index value recorded as 12 for above Polarisation Index Value,Min 1
(>2) 2
transformer mainly due to high winding tan value and (2-1.2) 1
(<1.2) 0
deterioration of transformer oil properties. Transformer Physical Health of Transformer
"Major Oil leak from main tank" Yes = 0 , No = 1 0
health index value lower than 16 indicates need for Frequency of topping oil Yes = 0 , No = 1 0
immediate corrective actions. Looking to transformer Minor Oil leak from main tank Yes = 0 , No = 1
Condition of Gasket of main tankYes = 0 , No = 1
0
0
age also, overhauling was recommended. Age of Gasket of main tank Yes = 0 , No = 1 0
Oil leak from OLTC Yes = 0 , No = 1 0
Oil leak from conservator Yes = 0 , No = 1 0
Transformer health index value recorded as 12 for above Oil leak from inspection window,radiator
Yes = 0 etc, No = 1 0
Oil leak from bushing Yes = 0 , No = 1 1
transformer mainly due to high winding tan value and Oil leak from PRV, Buch, OSR Yes = 0 , No = 1 1
OLTC trouble Yes = 0 , No = 1 0
deterioration of transformer oil properties. Transformer Major occurance recorded Nil = 2 ,1-5 = 1 , >5 = 0 0
health index value lower than 16 indicates need for TOTAL Max 41 / Min (-2) 12

immediate corrective actions. Looking to transformer Table 1: Condition based Health Index of power
age also, overhauling was recommended. Transformer transformer
 e-T FOTECH 2020- International Conference on Transformers

Total Furan content in oil was 0.51 mg/kg, well within Improvement in transformer insulation properties can
limits. So, Transformer overhauling carried out with be visualized from comparison of results of testing
complete oil replacement. Process carried out is shown carried out before and a er overhauling:
brie y as under:
a) Tan delta test results:
. Transformer testing carried out.
. External surface of tank & ings cleaned to locate Test Before After
points of oil leakage Overhauling Overhauling
. Transformer oil heating by hot oil circulation at around
70°C %PF Cap. %PF Cap.
. Draining of Transformer oil in the storage tank ( Corr. PF ( Corr. PF
. All ings & accessories like HV & LV bushings, at at
20°C) 20°C)
turrets, Buchholz relay, PRV etc. dismantled
CH 3.29 9733 0.52 9427
. Transformer tank top cover li ed up
(Winding
. Inspection carried out for transformer active parts,
– Earth)
Tightness checked for all accessible nut bolts, joints,
selector switch connections etc. Table 2: Comparison of Tan delta test results
. IR Value measured for Core to frame and found
satisfactory
b) IR value measurement results for Transformer
. Cleaning of core-coil assembly carried out with hot oil
winding:
spray to remove sludge
. Main tank top cover gasket replaced, main tank top HV-LV PI WTI
cover ed again Winding to °C
. Gaskets of inspection windows, turrets, valves, Earth
radiators etc. replaced IR value in
. Maintenance carried out for OLTC diverter switches M Ohms
. Drying out process carried out for transformer active 1 min 10
parts through Nitrogen and vacuum cycles, and applying min
heating by providing external heaters surrounding main Before 43.5 47.2 1.08 48
tank walls Overhaul.
. Working of Buchholz relay, OSR etc. checked
. Radiators & other accessories etc. connected again After 926 1250 1.35 40
Overhaul.
. Oil lling carried out under Vacuum
. Oil ltration carried out, Hourly readings taken for IR
Table 3: Comparison of IR value measurement results
values for transformer winding during oil ltration
. Transformer oil allowed to cool
. Painting carried out a er cleaning external surface of
Main tank and other accessories
. Transformer testing carried out
. Transformer put back in service
 e-T FOTECH 2020- International Conference on Transformers

CONCLUSION
c) Routine test results for main tank oil sample: Fault analysis of power transformer is very crucial and
important for transmission utilities. And for this
Test Obtained value purpose, knowhow is required of all test methods
particulars Before After available in the basket of transformer testing. Over and
Overhaul. Overhaul. above, knowledge of protection relays and study of
Disturbance Records is also helpful to get more insight
Dielectric
into fault analysis. SF test is very important tool and
Strength 61 82
provides valuable information of power transformer
( KV rms)
even in such situation - where bushing was not available
Water
29 5 and with low oil level. In such circumstances, other tests
content, ppm
were not feasible / recommended - only SF could
Neutralization
0.23 0.065 provide insight into condition of Transformer active
value
parts. Inferences could be drawn from comparison of
Dielectric
SF results regarding intactness of the windings; and
dissipation
Transformer could be put in service carrying out
factor(Tan- 0.342 0.0069
recti cation work at site only.
delta) at 90° C
To enhance service life of the transformer and ensure
Specific
trouble free operation, Transformer overhauling is
resistance at 0.07X10^12 16X10^12
90°C, ohm-cm essential at speci c juncture of transformer condition
during transformer life cycle. Signi cant improvement in
Interfacial
tension, 17 37 transformer insulation achieved through overhauling for
MN/m at 27°C a 220/132kV transformer, as shown in case study-2.

Table 4: Comparison of routine test results of main ACKNOLDGEMENT

tank oil sample
Improvement in transformer insulation properties can
be visualized from comparison of results of testing
carried out before and a er overhauling:
Figure 15: Photograph of transformer taken a er overhauling
We are grateful to GETCO management to permit us to
present above case studies in this paper. We are also
thankful to all GETCO eld staff to co-operate us at every
stage and to provide us with all required information &
records.
REFERENCES
[1] E .P.Dick and C.C.Er ven,” Transfor mer
Diagnostics Testing by Frequency Response Analysis”,
IEEE Transaction on Power Apparatus and Systems,
Vol.97,pp. 2144 2153,Nov/Dec.1978.
[2] Asif Islam, Shahidul Islam Khan and Dr Aminul
Hoque,” Detection of Mechanical Deformation in Old
Aged Power Transformer Using Cross Correlation Co-
Efficient Analysis Method”, Energy and Power
Engineering, Vol.3, pp. 585–591, January 2011.
 e-T FOTECH 2020- International Conference on Transformers

[3] M. Arul Sathya, Savadamuthu,” Prediction of

Change in Equivalent Circuit Parameters of Transformer
Winding Due to Axial Deformation using Sweep
Frequency Response Analysis”, Journal of Electrical
Engineering and Technology, Vol.10, pp.983–989, May
2015

[4] Hormatollah Firoozi, Nami Mahmoodi, Mohammad

Kharezi and M.I.Ghiyasi, ”Frequency response analysis-
Low frequency characteristics and fault diagnosis on
power transformers”, IEEE International Conference on
Solid Dielectrics, Postdam, Germany, July2010.

[5] K.Ludwikowski, K. Siodla and W.Ziomek,”

Investigation of transformer model winding deformation
using sweep frequency analysis”, IEEE transaction on
Dielectrics and Electrical Insulation, Vol.19. December
2012.

[6] S.D.Mayer, J.J.Kelly and R.H.Parrish, ”A Guide to

Transformer Maintenance”, Transformer Maintenance
Institute, USA, Second printing,1988.
 e-T FOTECH 2020- International Conference on Transformers

DAY

01 Session Speakers
 e-T FOTECH 2020- International Conference on Transformers

Name S. K. Ray Mohapatra

Date of Birth 21st May 1961
Quali cation B.Sc Engg. (Electrical), M.Tech (Power System), MBA
Designation Chief Engineer
Present Organization Central Electricity Authority, Ministry of Power (Govt. of India)
Field of Expertise Design & Engineering of EHV Substation and Transmission
lines
Landline /Mobile No. 9818527857
Email skrmohapatra@rediffmail.com / skrmohapatra@nic.in /
skrmohapatra@gmail.com
Brief Pro le ( in 200 Words only)
Presently working as Chief Engineer in Central Electricity
Authority, Ministry of Power (Govt. of India), worked as
Member Secretary of NERPC, a Senior member of IEEE,
graduated in Electrical Engineering from Sambalpur
University, Orissa and had his Master's Degree from IIT,
Kharagpur and MBA from FMS, University of Delhi. His
professional experience of more than three decades includes
Planning of transmission system, design & engineering
consultancy, project appraisal, monitoring, grid operation &
commercial issues relating to grid, formulation of Regulations &
guidelines etc. pertaining to EHV transmission lines and
substations in CEA. Prior to joining in CEA, he was involved
with identi cation & investigation work for harnessing hydro
power potential of micro, mini & small hydroelectric power
projects and assessment of wind power potential in Govt. of
Orissa; testing & quality control of PVC & XLPE cables.
“Manual on Substation” of CBI&P has been released under his
Chairmanship. He has contributed number of papers and
articles in National & International seminars and Indian Power
magazines.
 e-T FOTECH 2020- International Conference on Transformers

Name Shashank Kulkarni

Date of Birth 5th May 1981

Quali cation Bachelors of Engineering (Electrical Engineering) +

Masters in Marketing Management

Designation Team Leader – Electrical Design

Present Organization Siemens Limited, Transformer Division, Navi Mumbai

Field of Expertise Electrical Design of Power Transformer & Shunt Reactors

up to 765kV Class.
Representative of Dielectric Work group within SIEMENS
factories.

Landline /Mobile No. +91 9820556588

Email shashank.kulkarni@siemens.com

Brief Pro le ( in 200 Words only)
I passed out Bachelors of Engineering (Electrical) in year
2002, from University of Mumbai. I have total experience of
17 years (Since 2003) in Transformer Industry in the eld
of Electrical Design of Power Transformer. I am involved in
developments of various transformers & shunt reactors
upto 765kV class. I am local key expert for my current
employer in the eld of Electrostatic Analysis. Since, 2013 I
am working as a team lead for the group of Electrical Design
Engineers in SIEMENS Ltd.
 e-T FOTECH 2020- International Conference on Transformers

Name Vikrant Shashikant Joshi

Date of Birth 22nd July 1967

Quali cation B. E. (Electrical), University of Bombay, 1988

Designation PTR Scienti c Leader

Present Organization GE T&D India Limited

Field of Expertise Transformers, shunt reactors, electromagnetics

Landline /Mobile No. +919769209105

Email Vikrant.joshi1@ge.com

Brief Pro le ( in 200 Words only) Expertise in design of power and special transformers and
shunt reactors. Involved in new product development an
introduction. Experienced in failure investigations at test
bed and eld. Expert in electrostatics and electromagnetics.
 e-T FOTECH 2020- International Conference on Transformers

Name S. K. Gupta

Date of Birth 14th June1968

Quali cation BE (Electrical)

Designation AGM

Present Organization BHEL Jhansi

Field of Expertise 28 years of experience in Power transformers design upto 1200

KV class. Expertise in HVDC converter transformers.

Landline /Mobile No. 0510-2412693/ 9425604584

Email guptask@bhel.in

Brief Pro le ( in 200 Words only)
Was one of the principal team member of the team, which
developed 1st 765 kV & 1200 kV transformers with in-house
efforts.
Was part of team which developed 1st phase shi ing
transformer and Controlled Shunt Reactor.
Experience in HVDC converter transformers upto 500 KV
HVDC. (Rihand Dadri, Ballia Bhiwadi etc.).
Held one patent titled “Novel design of HVDC converter
transformer valve windings”.
Rapporteur in Trafotech 2014 & 2016
 e-T FOTECH 2020- International Conference on Transformers

Name Lars Liden

Date of Birth 12th January 1962

Quali cation Bsc in Electrical Engineering

Designation Product Marketing Specialist

Present Organization Bushings and tap-changers

Field of Expertise Hitachi ABB Power Grids Sweden

Technical marketing with focus on bushings and tap-changers.
Back-ground also in transformers and reactors

Landline /Mobile No. +46703096456

Email lars.liden@hitachi-powergrids.com

Brief Pro le ( in 200 Words only)
Have spent all his career within ASEA/ABB/Hitachi ABB Power
Grids, Ludvika Sweden except a two-year period in UAE
supporting transformer business. Started in High Voltage as
designer of GIS followed by sales of Instrument Transformers.
Have besides that spent time in QA both for Power Capacitors and
Power Transformers. e last 20 years in the eld of Marketing &
Sales of transformers, reactors, bushings and tap-changers.
Nowadays specialised in technical marketing of bushings and tap-
changers with focus on end user homologation and acceptance.
Active participation in CIGRE WG A2 among other being part of
WG A2.48, WG A2.49 and currently secretary for WG A2.61
 e-T FOTECH 2020- International Conference on Transformers

Name Tarun Garg

Date of Birth 18th January1974

Quali cation B. Tech (Electrical), AMU

Designation Engineering Manager – Power Transformers

Present Organization Hitachi ABB Powergrids

Field of Expertise Power Transformers

Landline /Mobile No. +91-9724332979

Email tarun.k.garg@hitachi-powergrids.com

Brief Pro le ( in 200 Words only)
Tarun Garg is the head of design and engineering at Hitachi ABB
Powergrids’ Transformer business in India and possesses 25 years
of Design and Development experience in Power Transformers.
He gained experience in Transformers and Shunt Reactors that
nd application in Power Systems, Power Generation plants,
Engineering management and Digitalization projects.
 e-T FOTECH 2020- International Conference on Transformers

DAY

02 Session Speakers
 e-T FOTECH 2020- International Conference on Transformers

Name Shrikant Potnis

Date of Birth 15th April 1954

Quali cation B.E. + Post Graduation from I.I.T. Mumbai -in Ind. Design- in
1978
Designation
CEO Easun MR Tap Changers Pvt Ltd

Present Organization Easun MR Tap Changers Pvt Ltd

Field of Expertise Switchgear and On Load Tap Changers

Landline /Mobile No. 8056041299

Email p.shrikant@easunmr.com

Brief Pro le ( in 200 Words only)
Total Experience : More than 42 years in various elds.
Past Experience : Started career with Transformer Division of
Crompton Greaves in 1978 and worked for 33 years in various
different divisions of CGL. Worked for more than 10 years with
m/s Crompton Greaves Ltd as R & D Head of Switchgear
Division - Nasik.
Currently Working as CEO for more than 9 years with “ M/S
Easun MR Tap Changers Pvt Ltd “ - A German JV Company
manufacturing On Load Tap Changers for Transformers up to
765 kV–.
Presented more than 20 papers on various topics in conferences
like Swicon, Switrend, IET, MSETCL, PGCIL , CPRI, IEEMA,
Trafotech etc.
Possess 11 patents in various Switchgear/Tap Changer products,
** worked as a member of BIS commi ee on Circuit Breakers,
Cigre working group ET08 India chapter.
Travelled extensively for a ending conferences, Testing of
 e-T FOTECH 2020- International Conference on Transformers

Name A.S. Jhala

Date of Birth 25th September1983

Quali cation B. E (Electrical)

Designation DGM Technology

Present Organization T&R India Limited

Field of Expertise Design reliability, optimisation, value engineering, process

improvement, standardization, investigations, testing,
development and implementation of Technology for UHV
transformers and reactors

Landline /Mobile No. +91-9687659549

Email asjhala@transformerindia.com

Brief Pro le ( in 200 Words only)
A. S Jhala, born in 1983 has received Bachelor of Electrical
Engineering Degree with Gold Medal from Saurashtra
university of India in 2004. Since 2005 till present Mr Jhala has
been associated with various functions viz. Testing, Designs and
Technology Divisions of T & R India Ltd. Currently he is
working with Technology Division and involved in various
activities of design reliability, design optimization, value
engineering, process improvement, standardization,
development and implementation of Technology for UHV
transformers and reactors. Mr Jhala has contributed around 30
papers and case studies in various national and international
conferences.
 e-T FOTECH 2020- International Conference on Transformers

Name P.K. Pa anaik

Date of Birth 14th March 1965

Quali cation Graduate in Electrical And Electronics

Designation Dy. General Manager ( Electrical)

Present Organization OPTCL ( Odisha Power Transmission Corporation Ltd.)

Field of Expertise Protection Control

Landline /Mobile No. 9438907492

Email ppk110.pp@gmail.com
ele.pkpa anaik@optcl.co.in

Brief Pro le ( in 200 Words only)
29 years of technical experience in Designing, Testing and
Commissioning of Protection Control and operational Schemes,
project Implementation, co-ordination, operations &
maintenance of Electrical Equipment at various LT/ HT/ EHT
level Grid Sub- Stations.

With Publication of 110 technical papers in different

national/international proceedings/journals. Regular author for
the journal publications by reputed organizations like IEEMA,
CBIP, Electrical Mirror, Electrical India and many other. Also
authored many of the Technical books on electrical technology
and awarded in many of the national and international forum.
 e-T FOTECH 2020- International Conference on Transformers

Name omas Buijs

Date of Birth 25th May 1965

Quali cation Bachelor in Physics, University Laval

Masters in Chemistry, University McGill

Designation Global Sales Manager, Transformer components and service

Present Organization Hitachi ABB Powergrids

Field of Expertise Analytical Chemistry, Transformer Monitoring

Landline /Mobile No. +1418-559-9926

Email omas.l.buijs@hitachi-powergrids.com

Brief Pro le ( in 200 Words only)
Mr. omas Buijs is based out of Quebec city, Canada Graduated
from Laval university with a bachelor degree in physics and then
from McGill University with a Master degree in chemistry Has
had various roles over 35 years with ABB as a development
engineer, project manager and product manager. Most recently as
global sales manager for transformer monitoring sensors and
smart devices with Hitachi ABB Power grids.
 e-T FOTECH 2020- International Conference on Transformers

Name Rakesh Patil

Date of Birth 27th December1975
Quali cation D.E.E., PGDM - Operations
Designation Chief Manager – Quality Management
Present Organization SIEMENS Limited
Field of Expertise Transformer Testing, Quality Management
Landline /Mobile No. +91 9820985325
Email Rakesh.patil@siemens.com

Brief Pro le ( in 200 Words only)
•More than 25 years of experience in the eld of Quality
Management, Testing and commissioning of Transformers.
•Presently working as Head of Quality Management in SIEMENS
Transformer factory at Navi Mumbai, India.
•Responsible for Incoming Quality Assurance, In-process
Quality, Supplier Quality Management, Oil Test Lab and High
Voltage Transformer Test Laboratory.
•Mainly responsible for implementation and monitoring of
Quality Management System and ensure compliance to
Management System requirements.
•Ensuring strict adherence to all environmental, health and safety
related aspects and standards for safety of employees, customers
and visitors.
•Ensuring highest accuracy and reliability in testing of
transformers and reactors by procuring & maintaining state-of-
the-art test facility.
•Major involvement in guidance and support to team members
for troubleshooting, problem solving by root cause analysis,
corrective actions, monitoring of data, analysis and
improvements.
 e-T FOTECH 2020- International Conference on Transformers

DAY

03 Session Speakers
 e-T FOTECH 2020- International Conference on Transformers

Stephan Heberer holds a degree (Dipl. Ing. FH) in mechanical engineering with a focus on
power generation from the University for Applied Sciences in Nurnberg.

He started his career in 1993 working for ABB, where he held various management positions
in MV and HV switchgear and transformer.

Since 2008, he is active in the eld of condition monitoring for electrical apparatus with a main
focus on partial discharge. Working in Zurich, Glasgow, Manchester and lastly in Bologna, he
has been involved in various projects around the world for condition monitoring of
generators, switchgear, transformer and cables for different industries like power generation,
transmission and distribution, offshore windfarms and Oil&Gas.
 e-T FOTECH 2020- International Conference on Transformers

Name Adish Kumar Gupta

Date of Birth 6th May1967
Quali cation BE (Electrical), NIT Kurukshetra
Designation Chief General Manger, Asset Management
Present Organization Power Grid Corporation of India Limited
Field of Expertise Power Transformers
Landline /Mobile No. +91-9772207153
Email adiskumargupta@powergridindia.com

Brief Pro le ( in 200 Words only)
As CGM (AM), Adish provides the strategic direction for continual
improvement in Asset Management of transmission assets of
POWERGRID including preparing the exigency plans to overcome any
critical emergency situations and oversee the ful lment of the operational
objectives as per the expectations of the stakeholders. HIs primary
responsibility is to develop cost-efficient maintenance strategies for Power
Transformers and Transmission Lines. Further, he is also responsible for
developing timely Asset Replacement strategies to improve system
availability and reliability.

Over the past 27 years, he has been associated with the full spectrum of
substation management ranging from land procurement, erection and
commissioning of substations, carrying out O&M of transmission assets,
Regional project management and Corporate O&M policy formulation. He
was also involved in development of 500kV Bipole Rihand-Dadri Link -
India’s rst Bipole HVDC link.

He has spearheaded the efforts to develop a real time risk-based asset health
indexing system - PALMS (POWERGRID Asset Life Management
System). It provides a dashboard for real time health assessment of 3000
transformers and reactors giving bird’s eye view to asset managers for taking
timely O&M decisions for critical units.

Since 2018, Adish is a member representative from India on CIGRE WG

A2.58 – Installation of Power Transformers.
 e-T FOTECH 2020- International Conference on Transformers

Name Rohit Kumar Jain

Date of Birth 14th August 1974

Quali cation AMIE in Electrical Engg

Designation Chief Manger, Asset Management

Present Organization Power Grid Corporation of India Limited

Field of Expertise Power Transformers

Landline /Mobile No. +91-9599683560

Email rohit.jain@powergridindia.com

Brief Pro le ( in 200 Words only) Presently he is looking a er the assets management of transformer
and reactors in POWERGRID. He has been associated with the
development of various technical speci cations, commissioning
standards and maintenance norms for transformers and reactors.

He was associated during the in-house development of a real time

based assets health indexing system – PALMS (POWERGRID
Asset Life Management System) to monitor the health of
transformers and reactors.

During the past 24 years, he has been associated with the erection
and commissioning of substation and carrying out O&M of
transmission assets.
 e-T FOTECH 2020- International Conference on Transformers

Name Deo Nath Jha

Date of Birth 18th July 1991

Quali cation B. Tech (Electrical), IIT Dhanbad

Designation Deputy Manager, Asset Management

Present Organization Power Grid Corporation of India Limited

Field of Expertise Power Transformers

Landline /Mobile No. +91-9599814142

Email dnjha@powergridindia.com

Brief Pro le ( in 200 Words only)
As Deputy Manager (AM), Deo is responsible for O&M policy
making and execution for Power Transformers and Shunt
Reactors. Over the past 5 years, he has been associated with the
development of various technical speci cations, commissioning
standards and maintenance norms for transformers and reactors.
is entails formulation, incorporation and standardisation of
latest Condition monitoring practices for Power Transformers
and their acceptability limits.
 e-T FOTECH 2020- International Conference on Transformers

Name Gunjan Agrawal

Date of Birth 25th January 1975
Quali cation B Tech (Electrical)
Designation Sr DGM
Present Organization Power Grid Corporation of India Limited
Field of Expertise HVDC Construction & O&M, Asset Management, Engineering-
Sikkim Projects and Transformer Core
Landline /Mobile No. 9873918437
Email Gunjan.agrawal@powergridindia.com
Mr Gunjan Agrawal was born on 25th January 1975. A er
Brief Pro le ( in 200 Words only) completing B.Tech. in Electrical Engineering from KNIT,
Sultanpur in 1998, he joined Power Grid Corporation of India in
the year 2000.
A er joining POWERGRID, he was initially involved in the
commissioning of most prestigious project of ±500kV, 2000MW
East South Interconnector HVDC Bipole System. A er
commissioning of HVDC system, he was assigned the
responsibility of Operation and Maintenance of the system till the
system stabilized.
In 2006, Mr. Agrawal joined the Asset Management Department at Corporate Office in POWERGRID. ere
he looked a er the Operation and Maintenance of Power Transformers & Shunt Reactors in POWERGRID
network. Mr. Agrawal was involved in formulation of Maintenance guidelines of Transformers, commissioning
formats and introduction of latest condition monitoring techniques.
In 2015, Mr. Agrawal was assigned the task to head the core group of Transformers & Reactors in Corporate
Engineering Dep , where he is working presently. He is involved in making Technical speci cation of
Transformer and Shunt Reactors, responsible for design review, drawing approvals and Type testing of
Transformer and Shunt Reactors. He has been involved in design review of Transformers/ Reactors upto 765kV,
STATCOM Transformers and Series Reactors.
Apart from Transformer Core activities, Mr Agrawal is also looking a er Engineering of Sikkim Comprehensive
Scheme project for 28 nos. of S/S.
Mr. Agrawal has contributed various Technical papers on Transformers & Reactors. He is also member of the
working group of IS:335 on Transformer Oil and CIGRE group A2.63 for Transformer Impulse Testing.
 e-T FOTECH 2020- International Conference on Transformers

Name Gautam Mazumder

Date of Birth 25th May 1964
Quali cation Graduate Engineer in Computer Technology
Designation Assistant General Manager-Transformer Service
Present Organization CG Power and Industrial Solutions Limited-Power Transformer
Division- Mandideep, Bhopal.
Field of Expertise Transformer Manufacturing and Field Services
Landline /Mobile No. 9713064404
Email gautam.mazumder@cgglobal.com

Brief Pro le ( in 200 Words only)
In career span of 30 years in the Transformer Industry, worked in
various functions and the responsibilities executed:
1.Power Transformer Manufacturing experience upto 1200 kV
Class.
2.Quality in charge of transformer Manufacturing facility.
3.In charge of A er-Sales Service-transformer and reactors,
Worldwide responsibility.
4.Initiated and successfully completed Site Repair of power
transformers upto 400 kV class.
5.Rehabilitation of transformers and reactors at site post outage.
6.In charge of 765 kV Class Transformers and Reactors
installation at sites, turnkey responsibility.
7.In charge of revenue service business for power transformer and
reactors, Worldwide responsibility.
8.Key-Note speaker at Trafotech 2012 – Transformer Processing
at Site.
9.Contributary Author, CBIP- “Manual on Transformers”
Publication Number 317.
10.Contributar y Author, IEEEMA-Power Transformer
Standardisation Manual-Chapter 5.
 e-T FOTECH 2020- International Conference on Transformers

Name Ashok J Chavda

Date of Birth 5th September 1966

Quali cation BE Electrical , MBA , M.Tech

Designation Superintending Engineer (Testing & Condition Monitoring)

Present Organization GETCO

Field of Expertise Protection & Condition Monitoring

Landline /Mobile No. 9925209590

Email Acetel.getco@gebmail.com, ashokchavda5966@gmail.com,

Brief Pro le ( in 200 Words only)
Ashok J. Chavda works with Gujarat Energy Transmission Co.
(GETCO) since 1989, and currently works as Superintending
Engineer (Testing and condition monitoring engineer). Ashok
chavda received his Bachelor in Electrical Engineering from the
Gujarat University Ahmedabad, in 1989. He has completed
M.B.A. from IGNOU in 2001. He has completed Master Degree
in power system from R.K. University Rajkot in 2013. He is
currently pursuing Ph.D. work in eld of SF under guideline of
Prof. Vivek Pandya at Pandit Deendayal Petroleum University
formally known as PDPU, Gandhinagar. Interested area of Mr.
Ashok is Diagnosis of power transformer faults and remedies.
 e-T FOTECH 2020- International Conference on Transformers

Name Bankim P. Soni

11th July1967
Date of Birth B. E. (Electronics), BVM College of engineering, Vallabh
Vidyanagar
Quali cation I/C Superintending Engineer ( Engineering)
Gujarat Energy Transmission Corporation Limited, GETCO
Designation Substation design and Equipment Engineering
+91-99252 08733
Present Organization seengg.getco@gebmail.com

Field of Expertise Since 1990, he has worked in GEB/GETCO in the eld of

generation at Wanakbori TPS and 4X 60 MW Kadana Hydro
Landline /Mobile No. Power Station for 8 years. In the eld of transmission, he has
worked at 400 KV Asoj substation and 132 KV Nandesari sub-
Email station for 13 years.

Brief Pro le ( in 200 Words only)
Presently, he is working as an I/C Superintending Engineer at
Engineering Department -GETCO- Corporate office looking
a er Substation design engineering, Equipment engineering,
Protection & Automation, Civil and Transmission Line
engineering.
Experience: O&M of EHV substations, Telecommunication,
Protection and Automation, Substation design engineering and
Equipment engineering.
Membership:
ISO 9001:2015 Auditor from BVQI – TUV
Member – CIGRE
Member BIS commi ee: ETD 08 (HV Switchgear),
ETD-16 (Transformers),
ETD-30 (Surge Arresters),
ETD-34 (Instrument Transformers)
Technical Commi ee Member: CBIP for Substation Manual
2019