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Ieema-25-2014 Power Trans.
Ieema-25-2014 Power Trans.
Ieema-25-2014 Power Trans.
POWER TRANSFORMER
STANDARDISATION MANUAL
JANUARY 2014
IEEMA-25-2014
ii POWER TRANSFORMER - STANDARDISATION MANUAL
POWER TRANSFORMER - STANDARDISATION MANUAL iii
Preface
Power Transformer is very vital equipment in our Transmission System, High Voltage AC and DC transmission to supply
bulk power from generation source to load points is successful only through effectively and efficiently designed Power
Transformers, Converter Transformer and Reactors.
It is heartening to note that India has put up enough manufacturing capacity to the order of 300000 MVA to meet
market demand of power transformers. Indian companies are capable of designing and supplying transformers up
to 1200 kV.
Transformer Industry has undergone many changes and transformations in terms of design philosophy, selection of
materials and field applications.
While suppliers have focused on cost competitive product by optimizing designs, Utilities and customers choice and
demand has been reliable and defect free product. The wide fluctuating raw material cost dominates the design
process. However, IT has supplemented designers to implement their innovative design ideas. Customer feed back
and field data on transformer performance played vital role in design improvement.
Concept of Asset Management has not picked up well among Utilities in India, but realization has come to assess the
health of power transformer through condition monitoring.
There is always concern and keen interest from all stakeholders to have Power Transformers, which does not fail
before its expected life. It is not simple to get answer to this wish, because many aspects from procurement to
commissioning are required to be carefully and rightly addressed. Role of Utility / Customer is very important to
address The need and actual application of power transformer with proper data. Many a times, a bulky document
with multiple and superlative requirements is given. It ultimately leads to contractual dispute and delay in delivery.
In many occasions, power transformers remain at site without erection & commissioning for long time. The storage
and preservation are important. Erection and commissioning has to be done with utmost care duly following erection
manual of suppliers.
There are several interface points with switchyard layout, which need to be accounted from day one.
In commercial front, Utilities assign importance to transformer losses and therefore loss capitalisation exercise is
done at tender evaluation stage. Whereas designers are constrained to satisfy the loss figures once bid is awarded,
Utility is equally compelled to accept unit with penalty. It is not a desirable practice.
Under the above background, Technical Committee of TRAFOTECH-2010 decided to review, discuss & finalize the
standardisation process through committee. Accordingly, during closing meeting on 18th February, 2010, it was
decided to commence the process of standardization as early as possible.
The task was assigned to Mr S.K. Negi, MD, GETCO, as Chairman of standardisation committee under the aegis of
IEEMA. It was an open invitation to participate and contribute, however technical experts and designers from leading
companies, Institutions and utilities would be permanent members.
It was decided in first meeting that emphasis will be to standardize design & engineering specification, drawings,
quality plans, erection, testing and commissioning in the form of data and figures as far possible to understand quickly
and facilitate the process of procurement and commissioning.
iv POWER TRANSFORMER - STANDARDISATION MANUAL
Further, Steering Committee on “Power Transformer Standardisation manual” was constituted as below:
The task was divided into various chapters and allocated to team of domain experts. The chapter was thoroughly
debated to standardize design requirements in the simplest form of data which can be implemented universally
according to rating and voltage class of power transformer and leave no scope of subjectivity between supplier and
customer for commercial and technical parameters.
In the above standardization process, idea of adding chapters on Design Review and Frequently Asked Questions
(FAQs) emerged for inclusion in the manual. It will greatly help practicing engineers to take key decisions and sharpen
their skills in the entire value chain of transformer business.
Transmission system in India is becoming large and complex with a highest system voltage of 765 kV. We cannot
afford break-downs and outages of any kind. It is essential that continuous customer feed back system is in place to
gauge the design and manufacturing quality of each and every unit installed, in Utilities. This Standardisation Manual
will definitely help Utilities in procurement to commissioning process of power transformer, for defect free service
beyond its design life.
POWER TRANSFORMER - STANDARDISATION MANUAL v
INDEX
OLTC
Design and Engineering 284
Erection and Commissioning 285
BUSHING
Design and Engineering 286
Erection and Commissioning 286
POWER TRANSFORMER - STANDARDISATION MANUAL 1
Chapter - 1
CHAPTER - 1
INTRODUCTION:
1. Ratings, Voltage Ratio, Tapping range, Impedance and other technical parameters may be selected as per CBIP
Publication No. 295, Manual on Transformers, 2012.
2. This Manual gives the recommended losses for the standardised ratings of power transformers (Annexure - 1.1).
Two ranges of losses are given - High Losses (for maximum specific loadings of current density 3A/mm2 and flux
density 1.7 T at rated tap) and Low Losses (for maximum specific loadings of 2.3 A/mm2 and flux density of 1.6 T
at rated tap). Current Density refers to all taps and flux density refers to at rated tap and voltage. Low losses may
be adopted where the capitalization rates are high (say ` 2 lakhs per no-load loss kW and ` 1 lakh per load loss
kW) and high losses where low capitalization rates are applicable (say ` 1 lakh per no-load loss kW and ` 0.5 lakh
per load loss kW). When fixed maximum losses are specified, transformer buyers need not capitalize the losses
for bid comparison. With fixed losses and using standardised GTP, buyers can compare various bids effectively
and expeditiously. They can compare quoted weights of active materials with standardised losses. Indicated
stray losses and type of conductors (rectangular conductor Vs continuously transposed cable – CTC) can be
compared. Hardness of conductor and epoxy coated CTC gives an indication of short circuit withstand strength
of winding.
3. Where the buyer wants losses different from the above standardised losses, he may get losses from reliable
vendors after indicating the loss capitalization rates or maximum specific loadings. After evaluating the market
losses, fixed losses for the special duty transformers may be decided and bids may be invited for the fixed
losses.
4. The GTPs are prepared in two parts. One is to be specified by buyer and other by vendor. The tick mark ‘ √ ’ is
shown in the column indicate by whom the data is to be filled in.
5. Ratings are also standardised covering 132 kV and above and up to 765 kV class transformers and accordingly
considered in this manual (Annexure - 1.2).
6. List of applicable standards for transformer is enclosed for ready reference (Annexure - 1.3).
A. GENERAL
1 General Information
i) Supplier
ii) Manufacturer √
iii) Place of Manufacture
iv) Type of Transformer (Core/Shell)
2 Applications
i) Indoor/Outdoor
√
ii) 2Wdg/3Wdg/Auto
iii) GT/Step down/ICT/Station Start up/Auxiliary/Rail Trackside Supply
4 Applicable Standards
i) IEC: 60076
√
ii) IS : 2026
iii) ANSI C57.12.00
5 Type
i) Liquid Immersed √
ii) Dry
9 Rated Frequency Hz √
i) Active part kg √
ii) Oil kg √
v) Overall dimensions L x B x H mm √
12 LV Winding
13 Tappings
i) OLTC/OCTC √
ii) Tappings on √
iii) Variation on √
v) No of Steps √
ii) Eddy current and stray loss at rated tap and 75 0C (indicative) kW √
B. MAGNETIC SYSTEM
1 Core Type √
i) Mitred
3 CRGO
a) Thickness mm √
b) Max. Specific loss at 1.7 T, 50Hz. W/kg √
6 Stacking Factor % √
6 POWER TRANSFORMER - STANDARDISATION MANUAL
C. CONDUCTING SYSTEM
HV IV LV Reg
1 Type of Winding
√ √ √ √
Helical/Disc/Layer/interwound
2 Type of Conductor
√ √ √ √
PICC/CTC/CTCE/CTCEN/BPICC
7 Number of Turns/Phase √ √ √ √
i) Interleaved winding
ii) Wound in Shield
iii) Others
iv) Others
POWER TRANSFORMER - STANDARDISATION MANUAL 7
D. COOLING SYSTEM
1 Type of Cooling √
i) ONAN ii) ONAN/ONAF iii) ONAN/ONAF/OFAF
iv) ONAN/ONAF1/ONAF2 v) ONAN/ONAF/ODAF
vi) OFAF vii) ODAF viii) OFWF ix) ODWF
4 Type of Cooler
i) Radiator Bank
v) Tank Mounted
5 Cooling Fans
i) Type
ii) Size mm
6 Oil Pumps
i) Type
ii) Size
ii) Type √
iii) Rating √
8 POWER TRANSFORMER - STANDARDISATION MANUAL
9 Radiators:
Width of elements mm
Thickness mm
√
Length mm
Numbers No.
E. DIELECTRIC SYSTEM
2 Regulating Winding
i) Body Tap √
ii) Separate √
i) Top √
ii) Center √
Offered
(by Vendor)
F. ACCESSORIES
1 Tap Changers
i) Control √
a-Manual b-Automatic c-Remote d-Local
ii) Voltage Class and Current Rating of Tap Changers √
iv) Minimum Clearance height from rail for lifting Active Part mm √
v) Wheels : Numbers/Plane/Flanged/Uni-Directional/ √
Bi-Directional/Locking Details
vi) Vacuum withstand Capability mm of Hg √
vii) Tank/Radiators/Conservator/Accessories √
Offered
(by Vendor)
3 Bushings HV IV LV HVN/IVN
i) Termination Type
a - Outdoor b - Cable Box (oil/Air/SF6) c - Plug in Type
ii) Type of Bushing : Porcelain/OIP/RIP
v) Rated Current A
4 Indicative
Main Conservator
OLTC Conservator
Main Tank
Main Conservator
OLTC Conservator
5 Transformer Oil
iii) Manufacturer
6 Press Board
i) Make √
ii) Type
ANNEXURE 1.1
Legend: NLL - No Load Loss in kW; FLL - Full Load Loss in kW; AL - Auxiliary Loss in kW
2 10 10 12/80/- 8.5/70/-
4 16 10 15/110/- 11/100/-
5 20 10 17/130/- 12/110/-
6 25 10 18/140/- 14/115/-
ANNEXURE 1.2
21/420 kV,
260 MVA, 1Ø
21/420 kV,
333 MVA, 1Ø
14 POWER TRANSFORMER - STANDARDISATION MANUAL
ANNEXURE 1.3
1. APPLICATION GUIDES
2. Specifications
3. Testing
4. Transformer Oil
5. Accessories
Bushing
-General 60137-2008 C57.19.00-2000
-HVDC Bushings - C57.19.03-1996
-Dimensions - C57.19.01-2000
-Terminals 60518-1975 -
Bushing Application Guide - C57.19.100-1995
Bushings - Seismic Qualification - TS 61463-2000
Reactors
-Specifications C57.21-2008 (Shunt)
-Testing 60076-6 C57.16-1996
-Dry type series
6. Raw Materials
Winding Wires:
Paper tape covered Rectangular Wire 60317 ed4.0- 2013 -
Magnetic Materials -
Part 8-7-Specifications
for individual materials (Cold-rolled grain-
oriented electrical steel strip -
61061-3-1
and sheet delivered in the fully processed
state).
Electrical Papers -
Part 1 Definitions 60554-1
Part 2 Methods Of Test 60554-2
Part 3-1General Purpose Paper 60554-3-1
Part 3-2Capacitor Paper 60554-3-2
Part 3-3 Crepe Paper 60554-3-3
Part 3-4 Electrolytic capacitor paper 60554-3-4 -
Part 3-5 Special Papers 60554-3-5
Loading guide
- Oil filled Transformer 60076-7 ed1.0(2005-12) C57.91-2011
- Dry type transformer 60076-12 ed1.0(2008-11) C57.96-1999
Substation-Fire protection
979-1994(R2004)
Containment &control of oil spills in -
980-1994(R2001)
substations
Operational 170-2000 Static Electrification C57.91-2011 Loading Guide for Oil 60076-7:2005
Problems 228-2002 Ageing Process Immersed Loading Guide
323-2007 Ageing of Cellulose Transformers for Oil Immersed
349-2008 Moisture Equilibrium and C57.96-1999 Loading Guide for Dry Transformers
migration in insulation system Type Transformers 60905-1987
378-2009 Copper sulfide in insulation Loading Guide
393-2009 Thermal performance of for Dry type
Transformers Transformers
445-2012 Maintenance
Chapter - 2
CHAPTER - 2
To resolve all these issues and to define standard architectural features and accessories, this Working Group had 5
rounds of meetings and discussions in the subject matter. However, standardisation refers to limit the variation in
terms of layout, general arrangements, interchangeability, accessories selection guide including data sheet, drawings,
schematic, mounting arrangement/interface with tank, critical check points for installation and commissioning, etc.
Interchangeability has been referred here mainly to transformers of similar rating, voltage and other technical
characteristics, even when they are being purchased from different suppliers under different contracts so as to arrive
at common dimensions and layout, to allow physical interchangeability with minimum of adaptation and optimize
spare holding inventory. It is possible for transformers purchased earlier to be replaced later by more modern designs,
even with larger ratings but designed to accommodate in the same space. Utilities purchase transformers to meet
requirements of this kind in order to increase availability and reduce costs by minimising the outage time in the event
of a transformer having to be removed from service and replaced by spare/new transformer available. The concept
may apply for separately cooler bank mounted transformer in which case the requirement of interchangeability can be
even made applicable to the main transformer excluding cooler bank.
This policy will reduce the complexity of the purchaser’s stock of transformers, bushings, fittings, tap changer
components, etc and will minimize maintenance practice and costs.
Aesthetic (Appearance) of Transformer: Mounting of fittings to be same as far as possible, mounting & location of
Cooler bank, Conservator etc. shall be at standard position. A typical plan & section drawing showing accessories
like Bushings, Tap changer, conservator, OLTC Drive Mechanism, Neutral Earthing arrangement, Marshalling box,
etc. are enclosed in this Manual. Tank mounted radiators are recommended, for ratings up to 100 MVA and they
can be separate for higher than 100 MVA.
Tank Type: Bell type, Bolted /Welded construction, Conventional & Form Fit type
Cooler: The Fin thickness of radiator will be minimum 1.0 mm. Only 4 heights are proposed (2.0 M, 2.5 M, 3.0 M
& 4.5 M) with number of elements to be 20, 24 & 26. Radiator (external) shall be hot dip galvanized or painted as
per Data Sheet of Radiator given in this Manual. For internal surface galvanizing is not recommended. Corrosion
resistant paints may be applied on galvanized surface for better appearance.
Rail, Roller & Roller Assembly: It is proposed to remove provision of rail as nowadays transformers are not
transported by railway but rails are required for transformers to achieve center line of transformer, provision may
be provided for rail. However, Transformers are recommended to put directly on plinth without rollers & roller
assembly will be standardised. Only one set of roller is recommended for each substation. Since Roller is casted,
hence only Roller assembly is needed to be galvanized.
Valve Schedule: Valve specification, type & application shall be standardised. This will be reviewed with experts
and finalized.
Conservator: Main conservator should be with Aircell. OLTC conservator shall be separate to avoid intermixing of
oil. Maintenance free type dehydrating silica gel breather may be provided in remote operation substation.
26 POWER TRANSFORMER - STANDARDISATION MANUAL
Internal Earthing of Metal Parts: Earthing point shall be robust and made accessible for the inspection to the
extent possible.
Painting: Tank, Radiator & Fittings may be of different shades. Epoxy coating to be avoided for outermost layer.
It should be PU only. Casting parts not necessarily painted for matching shade. Any fabricated accessory should
be either galvanized or outer side PU. Powder coating may be accepted provided it should be sun light / outdoor
/ UV ray resistant. Being not Eco-friendly, Zinc Chromate is not to be used. Bottom plate of tank may be accepted
with water based paint. Internal paint shall be oil resistive with thickness of 25 to 40 micron only.
Hardware / Bolts: Material will be MS with grade 8. To avoid bending High Tensile Steel (HTS) is also recommended.
Stainless Steel should not be used in the main tank joint.
Gasket: Since one side of gasket is exposed to the transformer oil of different quality (old, new, inhibited,
un-inhibited, Paraffin base oil, Naphthenic base oil & vegetable oil etc.) & other side is water, moisture, humidity,
air, oxygen, pollution, saline etc., hence gasket to be reliable & suitable for these applications. Chord (Nitrile
Chord) for all flange joints are recommended. Top cover of tap changer to be suitable for O-Ring or chord with
interchangeable with older one.
Marshalling Box / Common Marshalling Box: The enclosure (shell) shall be made of cold rolled sheet and
galvanized / painted. Stainless steel and Aluminum may also be considered for Marshalling Box.
OTI & WTI: Switches shall be Mercury-free.
Breather: Cobalt is a banned material, hence not recommended to use. Size of silica gel is to be standardised,
either it can be one of 100% or two of 100% in parallel. Valve over breather is not recommended.
Pressure Release Device (PRD): PRD shall be mounted on top cover. One PRD is recommended per every 40 KL
oil quantity. The oil discharge chamber and terminal box of the PRD shall be water tight with Protection class
IP 56 or better as per IEC 60529.
Ladder: Ladder (Fixed type) with safety locking device to be provided. Provision for fixing safety barriers shall be
provided on top tank cover. Ladder for conservator may be provided considering safety for working at height.
Fire Protection System (FPS): Provision of FPS is recommended in line with CEA regulation, i.e. for 10 MVA &
above. It is recommended to keep provision in each transformer.
Health, Safety and Environment (HSE): All the HSE aspects shall be covered while preparing standard GA
drawing. Adequate working space on top of transformer with suitable railing for safety shall be provided.
Ratings of Transformer: Standard ratings considered are as per Annexure 1.2.
Rail gauge shall be standard (1676 mm). Plinth mounted tank design may be adapted, as a specific requirement.
Rating wise rail gauge are standardised as below:
1. 765 kV & 400 kV, 1-Phase Generator Transformer (having two rails or three rails)
2. 765 kV & 400 kV, 1-Phase Auto Transformer (having four rails)
Note: 3-Phase ratings for above also to be considered depending on size and transportability.
3. 400 kV, 3-Phase Auto Transformer (having four rails)
4. 400 kV & 220 kV, 3-Phase Generator Transformer (having two rails)
5. 220 kV & 132 kV, Power Transformer (having two rails)
Location of OLTC: The number and location will be as per OLTC type & its specification.
Interchangeability & Common Architecture: The OGA is prepared in the form of block diagram & all important
fittings positions are shown (Annexure 2.1). Marshaling Box, Cooler control cabinet and any other cabinet required
for any monitoring devices will be tank mounted. Grounding inter phase is considered to minimize.
Jacking: 4 nos. of jacks shall be provided.
Cooler bank foundation: Modular block foundation is to house any make radiator in the standard foundation.
Maximum Height of Conservator to be standardised to make the firewall uniform.
The tertiary and neutral bushing shall be provided on top of the tank cover. The provision on side wall of the
tank is not recommended in view to avoid lowering of oil level in case of bushing replacement which is time
consuming.
Due to winding capacitances, the tertiary winding faces transferred surge voltages during impulse application on
HV/IV winding. Therefore, the bushings of 52 kV rating are provided for 33 kV tertiary winding.
POWER TRANSFORMER - STANDARDISATION MANUAL 27
Provision for connecting cooling bank on both sides shall be provided. Pipe work on main tank to be designed in
such a way that position of the cooler bank, conservator etc. can be changed at site by simple reconnection.
Specification for separately mounted radiator bank distance (for oil pipe connection) from main tank to be kept
standard or minimum. Position of cooling fan to be bottom of radiator bank but cooler fan support from ground
is not recommended.
Modular block foundation will be explored to house any make of radiator in the standard foundation.
Tank mounted Unit cooler option for Generating / Large transformers can be considered.
If more than one unit is provided, the breather for main tank shall be in parallel.
No. of OLTC and its location will be as per OLTC type & its specification.
Jacking: 4 - jacks shall be provided and their locations to be decided by the manufacturer such that it will not foul
rail, rollers or other accessories.
Hot dip galvanized with a minimum thickness of 70 µm and painting as per the following specification.
Surface Primer coat Intermediate Finish coat Total dry Colour shade
ITEM preparation undercoat film
thickness
(DFT)
Main tank, pipes, Shot Blast Epoxy base Epoxy high build Aliphatic Minimum RAL 7035
conservator tank, cleaning Zinc primer Micaceous iron polyurethane 155 μm
oil storage tank Sa 2½* (30-40 μm) oxide (HB MIO) (PU)
etc. (external (75 μm) (Minimum
surfaces) 50 μm)
Main tank, pipes Shot Blast Hot oil - - Minimum Glossy white for
(above 80 NB), cleaning resistant, 30 μm paint
conservator tank, Sa 2½* non-corrosive Max
oil storage tank varnish or 40 µm
etc. (internal paint or epoxy
surfaces)
Radiator (external Chemical/ Epoxy base Epoxy base Zinc PU paint Minimum Matching shade
surfaces) Shot Blast Zinc primer primer (30-40 μm) (minimum 100 μm of tank/differ-
cleaning (30-40 μm) 50 μm) rent shade
Sa 2½* aesthetically
matching to tank
Control cabinet/ Seven tank Zinc chromate - EPOXY paint Minimum RAL 7035 shade
marshalling box process as primer (two with PU top 80 μm for exterior and
per IS:3618 coats) coat interior
& IS:6005
Note : * indicates Sa 2½ as per Swedish Standard SIS 055900 of ISO 8501 Part-1.
The quality of paint should be such that its colour should not fade during vapor phase drying process and shall be
able to withstand temperature up to 120 0C.
Transformer shall be put on plinth but provision of roller shall be provided. The nos. of jacking points / pads and
lifting bollards / hooks / devices shall be 4 only. Location shall be such that it should not interfere with loading
and unloading from trailer.
28 POWER TRANSFORMER - STANDARDISATION MANUAL
Internal arrangement drawing of the active part and lead exit to be provided in the Instruction Manual by
manufacturer for better assessment of probable fault location when reflected in abnormal DGA results.
Line diagram for core, core clamp and tank earthing diagram shall be provided in the Instruction Manual.
Location of OLTC Driving mechanism box, Marshalling box, and optical fiber termination shall be on the same
side.
The main and OLTC conservator shall be integrated type with separate compartments so that they are at same
height with no pressure difference. In the case of separate cooler bank or if there is difficulty, OLTC conservator
can be separate.
POWER TRANSFORMER - STANDARDISATION MANUAL 29
Chapter - 2
INTRODUCTION
On Load Tap changers (OLTC) are the most important equipment used in the power transformers for changing the
tap of a winding (to vary effective transformation ratio of the transformer) whilst, the transformer is energized or is
on load.
Performance requirements of these OLTCs for use in transformers and their routine and type tests are described in
IEC 60214-1. Selection criteria of the OLTC, their various types, fittings and accessories etc. are covered in the
IEC 60214-2 “Application Guide”.
CBIP Manual on transformers (Publication 317) in ‘Section GG’ gives guidelines for voltage control of Power
Transformers employing OLTC.
As a general practice, end user of the transformer gives the requirement of voltage regulation (on HV or LV side), range
of percent voltage variation (from maximum voltage to minimum voltage, expressed as % of rated voltage), number
of steps, % impedance of transformer at maximum voltage and minimum voltage tap positions in case of parallel
operation with existing transformer and other control schematic requirements.
Transformer manufacturer, meeting the above requirement, decides the location of tapping winding (physical as well
as electrical), based on his design philosophy and experience and estimates the current and voltages seen by the
tapping winding (across range, between steps, to earth and between phases). Based on this data, OLTC supplier
provides a suitable tap changer from his available range.
This IEEMA standard on OLTC purports to define the specification requirements and selection criteria of OLTC and
recommends the standard parameters of OLTC to be used in transformers of prevalent standard ratings in the country
standardised by CBIP.
SCOPE
This standard covers specification requirements and selection of On Load tap changers for Power Transformers in the
country.
The tap changer shall conform to latest edition of IEC 60214 Part1: Performance Requirements & Test
Methods; and IEC 60214 Part 2: Application Guide.
For comprehensive specification of OLTCs, certain data need be specified by the transformer manufacturers
depending upon the transformer design & construction, apart from the specifications provided by the end
users. These specification requirements are therefore divided in to two parts.
§§ ………….Volts
§§ The power frequency voltage appearing between opening and closing contacts of change-
over selector shall be specified. (Note: OLTC supplier shall also verify / calculate recovery
voltage based on winding capacitance furnished by transformer manufacturer).
POWER TRANSFORMER - STANDARDISATION MANUAL 33
1.3.1.1 Externally mounted - out of tank, oil environment On Load Tap changers
§§ These OLTCs are available up to 66 kV, 300 Amps, star / delta connected winding, and for
132 kV neutral end applications. Depending on overall economy of the transformer design,
this type of OLTC is used.
§§ These OLTCs are available for all the transformer ratings up to 220 kV line end application, up
to 700 Amps neutral end and upto 2100 Amps line end applications. These tap-changers are
suitable for high voltage application up to 765 kV Class of transformers.
The OLTCs covered in this standard are of high speed transition resistor type. On-load tap-changer
shall be according to selector switch principle or shall consist of a tap selector and a diverter switch
with spring operated mechanism. The diverter /selector switch which arcs during tap change operation
shall be so designed to ensure that its operation once commenced shall be completed independently
of the control relays or switches, failure of auxiliary supplies etc. The current diverting contacts shall be
housed in a separate oil chamber not communicating with the oil in main tank of the transformer.
Rated through current of the OLTC should be more than or equal to the highest value of tap current
at the assigned rated power of the transformer. This ensures meeting the overload requirements of
transformers as per IEC 60076-7.
The rated step voltage of the tap-changer is more than or equal to the highest step voltage of the
tapped winding.
The breaking capacity requirements are met if the highest tap current and the highest step voltage
of the transformer are within the declared values of rated through-current and relevant rated step
voltage.
The rated insulation level of the OLTC is checked for Power frequency and Lightning Impulse voltages
and switching impulse voltages (if specified) appearing during tests on the transformer. These insulation
levels are checked at following points:
34 POWER TRANSFORMER - STANDARDISATION MANUAL
§§ Tap-Changer to earth
§§ Between phases
§§ Across Range (Between first and last contact of tap selector or selector switch)
§§ Between change-over selector contacts.
§§ Between two adjacent contacts
§§ Between Open contacts of diverter contact
The Tap-changers are available up to 21 positions (20 steps) in linear and up to 35 positions (34 steps)
in coarse-fine/ reversing arrangement of the tapping winding.
§§ Scheme, as shown in (a) in above figure, is used for autotransformer with a ratio 2:1 and for
moderate regulating range of say 15%. The advantage of this scheme is that the tap winding is at
the neutral end and be designed for graded insulation and a three phase neutral end tap changer
can be used. This arrangement is ideally suitable for 765 / 400 kV auto transformers. In this case,
VFVV (variable flux and variable voltage) type regulation is foreseen with change in tertiary voltage
which is accepted since tertiary is a stabilizing winding in most cases.
POWER TRANSFORMER - STANDARDISATION MANUAL 35
§§ For auto transformers on systems where the medium voltage is regulated, schemes as shown in
(b) & (d) are used. For tapping range of approximately 20% and with linear tapings scheme (b) is
generally used. Higher regulating range may be achieved with scheme (d).
§§ For auto transformers where regulation is required in HV voltage, scheme (c) is used. It has the
advantage that the through current of the OLTC is lower and allows the use of an OLTC with a
lower current rating. It may be noted that in case of arrangement (d) tapings carry IV line current
and in case of (b) tapings carry series or common current and in case of (c) tapings carry series
current.
During change-over operation of reversing switch or coarse tap selector, the tap winding is disconnected
temporarily from the main winding. The tap winding receives a potential determined by the winding
capacitances. The difference in voltage will therefore, appear during contact operation of the change-
over selector as a recovery voltage. The tap-changer manufacturer declares the safe limit for the allowed
recovery voltage across change-over contacts. It is ensured that the recovery voltage appearing during
change-over operation is within the declared allowed recovery voltage by the tap-changer supplier.
In case the recovery voltage exceeds the allowed voltage, the same is specified by the transformer
designer. The tap-changer manufacturer then provides additional devices like tie-in resistors or two
way change-over selectors to limit the recovery voltage to a safe level.
The motor drive unit has following features as specified in IEC 60214.
1.4.1 Operation
OLTC gear shall be motor operated for local as well as remote electrical operation. An external handle
shall be provided for local manual operation. Interlock shall be provided to prevent electric drive when
the manual operating gear is in use.
1.4.2 Housing
Drive mechanism cubicle is mounted as integral part on tap-changer tank in case of external out-of-tank
construction or suitable for mounting on transformer tank in case of an In-Tank construction. The motor
drive cubicle is in accessible position. It is adequately ventilated and provided with anti-condensation
heaters. All contactors, relay coils and other parts are protected against corrosion, deterioration due
to condensation, fungi etc. The motor drive cubicle shall meet protection requirement of IP 55 as per
IEC 60529.
The OLTCs and motor drive units are fully type tested in accordance with cl. 5.2 and 6.2 of IEC 60214-1.
These tests are as below:
This test is conducted at 1.2 times the maximum rated through current of OLTC.
This includes 50000 test operations at maximum rated through current as service duty and 40
operations at double the maximum rated through current as breaking capacity tests.
This test is conducted at 20 times the maximum rated through current up to 100 amps and 10
times the maximum rated through current of 400 amps and more. The test current should be
interpolated between these two ratings using the slope as per IEC 60214-1. The test duration
should be 2 seconds.
This test is conducted at 1.5 times the maximum rated through current of OLTC for continuous
operation of half cycle (equal to number of tap positions). This ensures suitability of transition
resistor design for continuous operations of OLTC under over loading condition of transformers.
The tap-changer shall be tested for 5,00,000 operations using complete tap range as per cl.5.2.5.1
of IEC 60214-1.
The diverter switch/ selector switch compartment shall be tested for hot oil pressure test by filling
oil inside the cylinder and heating up to 80° C. The cylinder shall be pressurized for a minimum
pressure of 10 psi (0.7 kg/cm²) for 1 hour. All joints of the compartment are thoroughly checked
for leakages.
The tap-changer should be tested across all points as per cl. 1.3.6 of this chapter and insulation
levels shall be declared. The tests shall be conducted in line with cl. 5.2.6 of IEC 60214-1.
OLTC manufacturers shall conduct all the routine tests as specified in cl. 5.3 and 6.3 of IEC 60214-1 on
every unit, before dispatch to assure the quality of the product
§§ Standard parameters of OLTC based on standard transformer ratings as per CBIP are recommended as
given in the attached Annexure 2.2.
§§ In case the transformer ratings are not conforming to CBIP standard, customers shall specify OLTC
requirements as per cl.1.2 of this standard.
§§ Precautions to be taken while installing In-tank tap changer at site are given in Annexure2.4
ANNEXURE 2.1
2n
1N 2u 2v 2w
1U 1V 1W
POWER TRANSFORMER - STANDARDISATION MANUAL
400kV, 315 MVA TRANSFORMER
( COOLING MOUNTED SEPARATELY )
Trans- Voltage Ratio (kV) Tapping Number Highest tap Max. Step Rated Winding Tapping Rated Insulation Levels of OLTC Max. Value Location
former range of tapping current of rated Voltage Step Connection arrangement Impulse kVrms / kVp of duration of
MVA positions winding through (Trans- Voltage of short Tapping
current of former of OLTC circuit Winding
OLTC require- Star / Delta Linear / Tap Across Between current
ment) Reversing / changer tapping adjacent
Coarse-Fine voltage to range Taps
earth
16 132/33 (+) 5 to 17 82.33 100 953 1200 Star Linear/ 140/325 45/200 15/90 2 KA for 2 Neutral
POWER TRANSFORMER - STANDARDISATION MANUAL
Trans- Voltage Ratio (kV) Tapping Number Highest tap Max. Step Rated Winding Tapping Rated Insulation Levels of OLTC Max. Value Location
former range of tapping current of rated Voltage Step Connection arrangement Impulse kVrms / kVp of duration of
MVA positions winding through (Trans- Voltage of short Tapping
Star / Delta Linear / Tap Across Between
current of former of OLTC circuit Winding
Reversing / changer tapping adjacent
OLTC require- current
Coarse-Fine voltage to range Taps
ment)
earth
250 15.75/235 (-) 10 to 13 682.5 800 1696 1800 Star Reversing/ 230/550 80/350 15/90 15kA for 2 Neutral
(+) 5 of Coarse-Fine sec. End
HV of HV
Winding
315 15.75/235 (-) 10 to 13 860 1000 1696 1800 Star Reversing/ 230/550 80/350 15/90 16KA for 2 Neutral
(+) 5 of Coarse-Fine sec End
POWER TRANSFORMER - STANDARDISATION MANUAL
HV of HV
Winding
260 24/420/√3 (1ph) (-) 10 to 13 1191.35 1500 3031 3100 star Reversing/ 325/750 80/350 15/90 24KA for 2 Neutral
(+) 5 of Coarse-Fine sec End
HV of HV
Winding
250 15.75/420 (-) 5 to 13 361.75 500 3031 3100 Star Reversing/ 325/750 80/350 15/90 8kA for 2 Neutral
(+) 10 of Coarse-Fine sec. End
HV of HV
Winding
315 15.75/420 (-) 5 to 13 456 600 3031 3100 Star Reversing/ 325/750 80/350 15/90 8kA for 2 Neutral
(+) 10 of Coarse-Fine sec. End
HV of HV
Winding
200 “21/420 (1 ph)” (-) 5 to 13 868.2 1000 3031 3100 Star Reversing/ 325/750 80/350 15/90 16KA for 2 Neutral
(+) 10 of Coarse-Fine sec End
HV of HV
Winding
100 400/132/33 (-) 10 to 17 160.4 200 2886 3000 Star Reversing 325/750 80/350 15/90 3.5KA for 2 220 kV
(+) 10 of sec. End of
HV Series
Winding
200 400/132/33 (-) 10 to 17 320.75 400 2886 3000 Star Reversing 325/750 80/350 15/90 6KA for 2 220 kV
(+) 10 of sec. End of
HV Series
Winding
250 400/220/33 (-) 10 to 17 401 500 2886 3000 Star Reversing 460/1050 100/460 15/90 8kA for 2 220 kV
(+) 10 of sec. End of
HV Series
Winding
315 400/220/33 (-) 10 to 17 505.2 600 2886 3000 Star Reversing 460/1050 100/460 15/90 8kA for 2 220 kV
(+) 10 of sec. End of
HV Series
Winding
500 400/220/33 (-) 10 to 17 802 1000 2886 3000 Star Reversing 460/1050 100/460 15/90 16KA for 2 220 kV
(+) 10 of sec. End of
HV Series
Winding
630 400/220/33 (-) 10 to 17 1010 1200 2886 3000 Star Reversing 460/1050 100/460 15/90 16KA for 2 220 kV
(+) 10 of sec. End of
HV Series
Winding
167 400/220/33 (1 (-) 10 to 17 795 1000 2886 3000 Star Reversing 460/1050 100/460 15/90 16KA/2 220 kV
ph) (+) 10 of sec End of
HV Series
Winding
210 400/220/33 (1 (-) 10 to 17 1010.4 1200 2886 3000 Star Reversing 460/1050 100/460 15/90 16KA/2 220 kV
ph) (+) 10 of sec End of
HV Series
Winding
210 765/√3/ (-) 5.5 to 23 500.5 600 2760 3000 Star Reversing 230/550 100/460 15/90 8KA/2 sec Neutral
400/√3/33 (+) 5.5 of End
HV of HV
Winding
333.3 765/√3/ (-) 5.5 to 23 794.34 1000 2760 3000 Star Reversing 230/550 100/460 15/90 16KA/2 Neutral
400/√3/33 (+) 5.5 of sec End
HV of HV
Winding
500 765/√3/ (-) 5.5 to 23 1191.64 1200 2760 3000 Star Reversing 230/550 100/460 15/90 16KA/2 Neutral
400/√3/33 (+) 5.5 of sec End
HV of HV
Winding
POWER TRANSFORMER - STANDARDISATION MANUAL
53
54 POWER TRANSFORMER - STANDARDISATION MANUAL
ANNEXURE 2.3
1. Check that the unit serial number of drive mechanism, gear boxes are identical to that of tap changer
2. Check that the tap changer and drive mechanism are at same tap position
3. Ensure proper coupling of drive mechanism and tap changer without disturbing gearbox setting to avoid any
misalignment. Refer OLTC Manual
4. Connect earth screw of tap changer head and its cover to transformer cover using earth conductor
5. Connect earth screw of motor drive housing to transformer tank using earth conductor
7. Fill diverter compartment with new filtered mineral oil and vent air from compartment and suction pipe
8. Check, if all stop valves between the oil conservator and driving unit (head) of the OLTC are open
9. Check the oil tightness of the seals on the driving unit (head), protective relay and piping
10. Avoid dropping of any parts or objects into the diverter switch oil compartment
11. Operate manually tap changer for one full cycle. Check end limit stops
12. Operate one cycle electrically and ensure motor drive direction of rotation and continuity
13. Check the protective relay mounting and ensure its contacts are connected in tripping circuit of the main circuit
breaker
POWER TRANSFORMER - STANDARDISATION MANUAL 55
Chapter - 2
Standard Specifications of bushings used in Transformers up to 1200 kV class are given in Section II of CBIP Manual on
Transformers (Publication No. 317). The Section also purports to standardise dimensions of condensers bushings from
52 kV to 1200 kV with a view to enable interchangeability with different makes of bushings. These recommendations
have also been adopted in IS: 12676.
The dimensional parameters of the bushings up to and including 36 kV voltage class (solid porcelain bushings) have
already been standardised in IS: 3347.
Beside standard dimensions, CBIP Manual also recommends standard values of BILs & test levels, creepage distances,
current ratings, BCT, top and bottom terminations etc. This IEEMA Standard on bushings addresses selection criteria
for bushings for transformers and suggests standard bushings to be used for popular rating transformers standardised
by CBIP working group.
These guidelines are prepared to enable user / manufacturer of the transformer to specify / use standard bushings for
the transformers. If a non-standard bushing is specified / used, the same shall be subject to mutual agreement.
SCOPE
This standard covers Outdoor type Standard Bushings comprising outdoor Oil Impregnated Paper (OIP) bushings with
values of highest system voltage for equipment (Um) from 52 kV up to 1200 kV voltage class and solid porcelain and
oil communicating type bushings for voltage class up to 36 kV for use in oil filled Power Transformers popularly used
in the country.
§§ The condenser bushings shall conform to IEC 60137 / IS: 2099 / IS: 12676 and porcelain bushings shall
conform to IS: 3347.
§§ All exposed ferrous metal parts shall be hot dip galvanized, wherever possible.
§§ Any stress shield shall be considered as an integral part of the bushing assembly for external clearances and
field plotting.
§§ Preferred lead arrangements for condenser bushings upto 800 Amps shall be draw lead type, upto 1250
Amps, shall be draw rod and 2000 Amps and above, in all cases shall be stem type. However, 52 kV and
72.5 kV condenser bushings shall be solid stem type for all current ratings as standardised by CBIP .
§§ For 100 kV and 110 kV class transformers also, 145 kV class bushing is recommended for the purpose of
variety reduction.
§§ Make of the condenser bushings shall be approved by customer. However, dimensionally they shall conform
to CBIP Manual section II. Porcelain bushings are generally assembled by Transformer Manufacturers
(porcelain and copper parts are purchased separately and assembled, porcelain conforming to IS:3347).
§§ The standard current ratings have been adopted. Minimum current rating of bushing is greater than or equal
to the maximum winding current × 1.2 or as mutually agreed.
§§ The neutral bushing not intended to carry load between phase and neutral is dimensioned for earth fault
current (except single phase transformer) unless otherwise specified by the customer.
§§ The lead joint in case of draw-lead or draw-rod type condenser bushings shall be as per fig 2 (a) & (b) of
CBIP Manual (section II). The bottom portion of the joint shall be in flush with the bottom of the flange of
the bushing. The top portion of the lead shall be transported with the bushings. The winding end of the lead
joint shall be suitably anchored while transporting the transformer.
58 POWER TRANSFORMER - STANDARDISATION MANUAL
§§ The minimum value of creepage distance specified is 25 mm/kV of the rated voltage of bushing up to 1200
kV class.
§§ For areas with very heavy or extremely heavy pollution, the minimum creepage distance shall be 31mm/kV
or as specified by the user.
§§ Bushing Current Transformer (BCT): To accommodate the bushing current transformers, space provided on
various voltage class bushings shall be as under:
§§ Altitude:
Bushings corresponding to this standard are suitable for operation at any altitude not exceeding 1000 M.
In order to ensure that the external withstand voltages of the bushings are sufficient at altitudes exceeding
1000 M, the arcing distance normally required shall be increased by a suitable amount. The arcing distance
correction shall be done as per clause No. 5.2 of IEC 60317.
§§ Short time current rating of the bushings shall be 25 times of the rated current of the bushings for 2
seconds.
72.5 350 / NA / 155 800 Solid 1815 66 kV winding of 20 MVA, 66kV class
Stem transformer (also used for neutral of
220 kV class for the purpose of IOV
test).
420 1425 / 1050 / 695 1250 Draw 10500 315 MVA and 500 MVA, 400 kV class,
Rod 3 phase, auto transformers
52 250 / 105 3150 Solid stem 1300 a) 33 kV tertiary winding of 315 MVA
and 500 MVA, 3 phase, 400 / 220 /
33 kV auto transformer.
b) 167 MVA, 1 phase, 400/√3 /
220/√3 / 33 kV, auto transformer.
36 1000 Solid Stem 900 25 / 31.5 MVA, 132/22 kV, 132/33 kV, double
wound transformers.
§§ During testing, 72.5 kV, 800 Amp condenser bushing can be used where neutral receives 1/3rd voltage
during IOV test. e.g. 132 and 220 kV class transformers. However, after testing 72.5 kV test bushing is
to be replaced by 36 kV neutral bushing. For 400 kV transformer, where ACSD test is specified, neutral
test bushing shall be 145 kV, 800 Amp.
§§ In certain cases, high current 36 kV condenser bushings can also be used, subject to mutual
agreement.
§§ When LV bushings are housed in busduct, suitable derating factor to be considered for current rating.
Standard ratings of bushings for the transformers are as given in Table No.2.1.
62
MVA kV ratio Tapping HV current 1.2 × Ihv HV Bushing IV current IIV 1.2 × IIV IV Bushing LV current ILV 1.2 × ILV LV Bushing
range Ihv
16 132/33 (-) 15, (+) 5 82.33 98.796 145/800A NA NA NA 279.92 335.904 36/1000
25 132/11 (-) 15, (+) 5 128.6 154.32 145/800A NA NA NA 1312.15 1574.58 36/2000
31.5 132/11 (-) 15, (+) 5 162.1 194.52 145/800A NA NA NA 1653.31 1983.972 26/2000A
POWER TRANSFORMER - STANDARDISATION MANUAL
140 11/138 (-) 10 , (+) 5 650.8 780.96 145/800A NA NA NA 4242.42 5090.904 29/8000A
140 13.8/138 (-) 10 , (+) 5 650.8 780.96 145/800A NA NA NA 3381.65 4057.98 24/8000A
250 15.75/138 (-) 10, (+) 5 1162.14 1394.57 145/1600A NA NA NA 5291.21 6349.452 24/8000A
50 220/66 (-) 10, (+) 10 145.8 174.96 245/1250A NA NA NA 437.38 524.856 72.5/800A
100 220/66 (-) 10, (+) 10 291.6 349.92 245/1250A NA NA NA 874.77 1049.724 72.5/1250A
50 220/33 (-) 10, (+) 10 145.8 174.96 245/1250A NA NA NA 874.77 1049.724 36/1000A
100 220/33 (-) 10, (+) 10 291.6 349.92 245/1250A NA NA NA 1749.54 2099.448 36/3150
100 220/132 (-) 5, (+) 15 262.43 314.916 245/1250A 460.4 552.48 145/800A NA NA NA
160 220/132 (-) 5, (+) 15 419.9 503.88 245/1250A 736.65 883.98 145/1250A NA NA NA
200 220/132 (-) 5, (+) 15 524.86 629.832 245/1250A 920.8 1104.96 145/1250A NA NA NA
140 11/235 (-) 10, (+) 15 351.43 702.86 245/1250A NA NA NA 7348.1 8817.72 36/12500A
MVA kV ratio Tapping HV current 1.2 × Ihv HV Bushing IV current IIV 1.2 × IIV IV Bushing LV current ILV 1.2 × ILV LV Bushing
range Ihv
250 15.75/235 (-) 10, (+) 15 682.4 818.88 245/1250A NA NA NA 9164.3 10997.16 36/12500A
315 15.75/235 (-) 10, (+) 15 859.8 1031.76 245/1250A NA NA NA 11547 13856.4 36/16000A
260 24/420/√3 (-) 10, (+) 15 1191.35 1429.62 420/2000A NA NA NA 10833.33 13000 36/16000A
250 15.75/420 (-) 5, (+) 10 361.75 434.1 420/1250A NA NA NA 9164.29 10997.15 36/12500
315 15.75/420 (-) 5, (+) 10 455.8 546.96 420/1250A NA NA NA 11547 13856.4 24/16000A
200 21/420/√3 (-) 5, (+) 10 868.2 1041.84 420/1250A NA NA NA 9523.8 11428.56 24/12500A
100 400/132/33 (-) 10, (+) 10 160.4 192.48 420/1250A 437.38 524.856 145/800A 1009.09 1210.91 52/3150A
200 400/132/33 (-)10, (+) 10 320.75 385 420/1250A 874.77 1049.724 145/1250A 2020 2424 52/3150A
250 400/220/33 (-)10, (+) 10 401 481.2 420/1250A 656.08 787.3 245/1250A 2525.15 3030.18 52/5000A
315 400/220/33 (-)10, (+) 10 505.18 606.216 420/1250A 826.66 991.992 245/1250A 3181.8 3818.16 52/5000A
167 400/√3/220/√3/33 (-)10, (+) 10 803.5 964.2 420/1250A 1314.78 1577.74 245/2000A 1686.86 2024.232 52/3150A
210 400/√3/220/√3/33 (-)10, (+) 10 1010.36 1212.432 420/1250A 1653.32 1983.98 245/2000A 2121.2 254544 52/5000A
200 21/765/√3 (-) 5, (+) 5 476.65 571.98 800/2500A NA NA NA 9523.8 11428.6 36/12500
260 24/765/√3 (-) 5, (+) 5 619.6 743.52 800/2500A NA NA NA 10833.3 12999.96 36/16000
210 765/√3/400/√3/33 (-) 5, (+) 5 500.5 600.6 800/2500A 909.32 1091.184 420/1250A 2121.21 2545.45 52/3150A
333.3 765/√3/400/√3/33 (-) 5, (+) 5 794.35 953.22 800/2500A 1443.36 1732.032 420/2000A 3366.66 4039.992 52/5000A
500 765/√3/400/√3/33 (-) 5, (+) 5 1191.64 1429.97 800/2500A 2165.06 2598.072 420/2500A 5081 6097.2 52/5000A
POWER TRANSFORMER - STANDARDISATION MANUAL
63
64 POWER TRANSFORMER - STANDARDISATION MANUAL
POWER TRANSFORMER - STANDARDISATION MANUAL 65
Chapter - 2
All external components & fittings provided on the transformer tank form an integral part of the transformer and are
essential for its satisfactory performance in service. Some essential fittings, which are mandatorily provided on a
wide range of transformers, are listed in IS 2026 Part I. However, depending on the rating, some additional fittings
and accessories are also provided on large rating transformers as per the specified requirement.
This section covers various fittings & accessories that are generally provided on the 132 kV & above class of Power
Transformers. As components with varying features are available commercially, in the absence of any authoritative
guidelines, the users are often unable to clearly specify the items that would address their long term requirements.
This section briefly covers some vital fittings and accessories as listed below, describing broadly the purpose of
each fitting, its working principle, the data sheet, the selection criteria, the care to be taken during installation &
commissioning, etc. While presently no single Standard comprehensively covers all the fittings and accessories, the
British Standard BSEN 50216, which is divided in several parts, covers some of the vital components. Therefore,
efforts have been made to broadly align details of the items covered herein with these standards and some other
available references. However, for the users a list of some references is appended under ‘Bibliography’ for further
details.
1 Temperature Indicators These instruments are installed in the marshaling box (in BS EN 50216-11
transformer yard) measurement of top oil temperature &
1.1 Oil Temperature Indicator winding hot spot indication
(OTI)
1.3 Remote Temperature This is a repeater dial installed in the Control Room for BS EN 5021.6-11
Indicator (ROTI/RWTI) remote indication of top oil temperature & winding hot spot
temperature
1.4 RTD (PT 100) Scheme for ROTI RTD scheme, comprises RTD sensor, transducer and indicator BS EN 5021.6-11
/ RWTI is used for measurement of oil and winding temperatures of the
transformers
2 Fiber Optic Temperature For real time measurement of winding hotspot temperatures IEC 60076-2
Sensor (FOS)
3 Gas & Oil Actuated Relay Fitted in the pipe between tank and the conservator to BS EN 50216-2
(Buchholz Relay) actuate alarm & trip relays in the event of accumulation of gas
generated due to fault inside the transformer
4 Pressure Relief Valve (PRV) Fitted on the tank cover to limit the tank over pressure on BS EN 50216-5
an internal fault, thereby reducing risk of tank rupture or
uncontrolled spillage of oil
5 Magnetic Oil Level Gauge Fitted on the main tank conservator and OLTC conservator for BS EN 50216-5
(MOG) indication of oil level
6 Oil / Water Flow Indicators (FI) Fitted in the oil/water cooling pipe line for the control of the oil/ BS EN 50216-5
water flow out of the pumps on transformer with forced oil/
water cooling equipment
7 Air Cell / Flexi-Separator Installed inside the conservator as a barrier to prevent contact -
between atmospheric air and the transformer oil
8 Conservator Protection Relay Also called ‘air cell puncture detection relay’, is externally -
(CPR) installed on the top of conservator to give alarm in the event of
lowering of oil in the conservator due to puncture of air cell in
service
68 POWER TRANSFORMER - STANDARDISATION MANUAL
9 Removable Radiators for oil- These are directly/separately mounted on the tank to permit BS EN 50216-6
immersed transformers flow of hot oil through it for cooling and returning to tank
10 Automatic Voltage Regulating Provided in the RTCC (Remote tap changers control cubicle) & -
Relay (AVR) connected to OLTC to maintain a constant secondary voltage at
all times
11 Fire Fighting Systems Installed in the vicinity of main transformer to protect it against CEA -The Gazette
catching of fire/spread of fire in the event of internal failure of of India, 2010
11.1 Nitrogen Injection Fire transformer or external fire in the close vicinity
Prevention System (NIFPS)
12 Terminal Connector Used for connection of transformer to the overhead power line. IS: 5561
Attempts have been made to standardise some vital fittings & accessories used for power transformers to facilitate
interchangeability & to rationalize their use such as would be commonly acceptable to manufacturers & users.
It may be noted that the above list is not exhaustive. Some items, like cooing fans, oil/water pumps, pressure gauges,
RTD, valves, breathers, rollers, earthing terminals, heat exchangers, unit coolers, etc. are presently not covered here
and could be considered in the subsequent revisions in future.
1 Temperature Indicators
The top oil temperature of oil immersed power transformer is sensed by mMeasuring system based on
volumetric expansion of liquid proportional to rise in temperature. A sensing bulb, measuring bellow
and a small bore capillary connecting the two form the measuring system which is filled with liquid.
When the sensing bulb is exposed to rise in temperature, the liquid inside expands proportionately
causing the bellows to expand and drive the linkages for indication and separately, linkages & disc for
switch operation. This system is self contained and does not depend on any outside power source for
its operation.
Complete ambient temperature compensation on sensing bulb & line / capillary is provided with a
second bellow / compensating bellow and a capillary that terminates at head of the sensing bulb. The
liquid filled inside this responds to ambient temperature changes. The measuring and compensating
bellows are linked in such a way that they cancel out. Thus, the net measuring bellow output is
dependent only on the sensing bulb temperature and not on ambient temperature.
Technical Parameters
Graduation 2 °C 2 °C
POWER TRANSFORMER - STANDARDISATION MANUAL 69
Fig. 2.1: Bulb fitting arrangement for Variant 1 Fig. 2.2: Bulb fitting arrangement for Variant 2
70 POWER TRANSFORMER - STANDARDISATION MANUAL
Any one of the following terminal configurations can be selected as per requirement.
The contact position shown below is under normal operating condition of OTI.
Variant - 1 Variant - 2
viii. Oil is to be filled in the pocket. Insert the sensing bulb through union/ pocket/ flange (insert fully),
tighten nut to optimum level. Ensure min. immersion length 140 mm.
ix. Care must be taken that, Sensing bulb is not damaged while tightening.
x. In case of further transport or storage, wind the armor and pack the instrument in the same way
as received from the supplier.
xii. Cable entry should be through cable gland to avoid dust entering
xiii. Top cover should be put in place and tighten properly to avoid dust. Ensure that the maximum
pointer is positioned after the indicating pointer.
xv. Test knob, if provided externally, shall be locked properly after testing.
1.2.1 Description
The top oil temperature of Oil Immersed Power transformer is sensed by measuring system based on
volumetric expansion of liquid proportional to rise in temperature. A Sensing bulb, measuring bellow
and a small bore capillary connecting the two form the measuring system which is filled with liquid.
When the sensing bulb is exposed to rise in temperature, the liquid inside expands proportionately
causing the bellows to expand and drive the linkages for indication and separately, linkages & disc for
switch operation. This system is self contained and does not depend on any outside power source for
its operation.
Complete ambient temperature compensation on sensing bulb & line/capillary is provided with a second
bellow/compensating bellow and a capillary that terminates at head of the sensing bulb. The liquid
filled inside this responds to ambient temperature changes. The measuring and compensating bellows
are linked in such a way that they cancel out. Thus, the net measuring bellow output is dependent only
on the sensing bulb temperature and not on ambient temperature.
The winding temperature is simulated by passing CT secondary current (from the transformer line)
to an electrical heater coil fitted around the measuring bellows. This simulates the winding to top oil
temperature differential which is added to the top oil temperature, being measured by the instrument
bulb. The temperature in the hottest part of the winding or hotspot temperature is displayed directly by
the instrument. Thus, the instrument functions as a winding temperature indicator. The time constant
of the temperature rise will be 63.7% of final temperature rise within 7-8 minutes.
Since the thermal time constant of the heater coil is nearly the same as the transformer winding, the
instrument simulates closely the actual temperature of the winding in relation to time.
The primary current of CT feeding the thermal image of WTI shall be of rated transformer current
corresponding to lowest tap and secondary nominal output of 2A. The heating system of WTI shall
be designed for a winding gradient of 35°C at CT current input of 2A. It shall be designed to operate
continuously at 150% of the rated current and shall not suffer injurious overheating with 200% of
rated current for a period of 15 minutes. Based on the heat run test data, the parallel shunt resistor to
heater coil shall be adjusted by transformer manufacturer such that the current through heater coil will
correspond to the winding hotspot gradient as per the heat run test result.
72 POWER TRANSFORMER - STANDARDISATION MANUAL
Technical Parameters
Graduation 2 °C 2 °C
Bulb 1” BSP with Male type union (Fig.2.3) 1” BSP with Male type union (Fig.2.4)
Capillary & electrical From the bottom of OTI From the bottom of OTI
entry
Dial marking Black with white back ground Black with white back ground
Fig. 2.3: Bulb fitting arrangement for Variant 1 Fig. 2.4: Bulb fitting arrangement for Variant 2
Any one of the following terminal configurations can be selected as per requirement.
The contact position shown below is under normal operating condition of WTI.
Variant - 1:
Variant - 2:
1.3.1 Description
This is used to measure the temperature of oil / winding at the remote control panel.
This system takes 4 to 20 mA, DC analog input from the local OTI / WTI and caliberate the same in
terms of degrees C to repeat the temperature of local OTI / WTI on the remote control panel
Technical Parameters
Parameter Variant - 1 Variant - 2 Variant - 3
Type Digital (96 sq mm) Digital (96 sq mm) Digital (96 sq mm)
Auxiliary Supply 90 – 260V AC/DC 90 – 260V AC/DC 90 – 260V AC/DC
Temperature Range 0 – 150 °C 0 – 150 °C 0 – 150 °C
Temperature Indicator 3½ digits 7-segement 3½ digits 7-segement LED 3½ digits 7-segement
LED display red in colour display red in colour LED display red in
colour
Any one of the following terminal configurations can be selected as per requirement. The contact
position shown below is under normal operating condition.
1.3.6 Tests
a) HV Test: All mA terminals shall be tested for 500V AC, 50Hz for one minute. All other terminals
shall be tested for 2kV AC, 50Hz for one minute.
b) I.R. Test: Insulation resistance shall be ≥ 20 Meg. Ohms when checked by 500V DC Insulation
Tester.
1.4.1 Description
This scope covers the standard specifications of the PT100 Resistance Temperature Detector (RTD)
Oil Temperature indicator (OTI) and Winding Temperature indicator (WTI) for use with liquid immersed
power transformers and reactors for indoor or outdoor installation.
The system measures the top oil temperature of oil immersed transformer with the PT100 RTD sensor
and transmits the measured values to a remote point by dc current mode signal.
The PT100 sensor is mounted in an oil filled pocket located in the hottest oil zone of the transformer.
The PT100 resistance in the sensor changes with the change in the top oil temperature. The Transducer
(Resistance to Current Converter Unit) measures the variations in the Sensor Resistance (corresponding
to the top oil temperature) and produces two independent channels of 4-20 mA dc current output
signals directly proportional to the PT100 sensor resistance.
The Resistance to Current Converter Unit (Transducer) measures the variations in the Sensor Resistance
corresponding to top oil plus simulated windings hot spot temperature and produces a directly
proportionate two independent channels of 4-20 mA dc current output signals.
Fig. 2.6: Block diagram of PT100 RWTI – Dual Output Channel Thermal Sensing Method - Scheme 1.
Fig. 2.7: Block diagram of PT100 RWTI – Dual Output Channel Thermal Sensing Method - Scheme 2.
Sl No Description Specification
1 Sensor PT100 3-Wire Sensor (Simplex/Duplex)
2 Union 1” BSP Male type union (Fig. 2.8)
3 Sensor As per figures 2.9 & 2.10
4 Sensing for Winding Hot Thermal Sensing
spot temperature
78 POWER TRANSFORMER - STANDARDISATION MANUAL
Sl No Description Specification
5 Transducer Resistance to Current Converter Unit
6 Power Supply 90-260V, ac/dc
7 Analog output 4-20 mA (single / dual optional)
8 Burdon on output ≥ 500 Ω
9 CT input 2 Amp
10 Temperature Rise/Gradient The standard temperature gradient must be adjustable up to 35°C
11 Accuracy ±0.2 mA at any point of 4-20 mA suitable for 500 Ω burden including
loop resistance.
12 Insulation Resistance ≥20MΩ Between Earth to all terminal when measured with 500 V DC
Insulation tester
13 Isolation 2500Vrms, AC between Power all terminals to earth for 60 Sec
14 Warm Up time 15 minutes (minimum)
15 Ambient Temperature 0 to 50°C , 45 to 80% RH
16 Storing Temperature -10°C to 60°C, 25 to 85% RH
17 Range 0-150°C
18 Panel Protection Level IP40
19 Mounting DIN Rail / Panel Mounting
Fig. 2.8
Fig. 2.9 Simplex Type Sensor Fig. 2.10 Duplex Type Sensor
POWER TRANSFORMER - STANDARDISATION MANUAL 79
1.4.7 Tests
a) Temperature Vs Resistance:
It is checked across PT100 sensor leads from 0-150°C using the test equipment and test
procedure as per resistance table Annexed as Annexure 2.4.
c) Soak test:
Transducer Unit energized for a period of 72 hrs to simulate normal operating conditions
for determining the input and output conditions and the functions performed during this
period.
All the wiring is to be done as per the terminal marking on the instruments.
Recheck the wiring before energizing the transformer specially the power supply connections.
Ensure that the Loop resistance of the interconnecting cables does not exceed the specified burden of
the Transducer analog output.
Use independent 2.5 sq. mm cable between PT100 Sensor to Transducer and Digital Indicator.
The 4-20 mA cable from Transducer to Remote indicator/SCADA should not run along with a power
cable.
No calibration required to be done at site.
Calibration by user not to be attempted as it may damage the instrument.
2.1 Description
2.2 Purpose
Direct real time hotspot temperature measurement of windings, oil, and other parts of the core-coil
assembly of power transformer.
From ≥ 20 to ON - OFF 6 1 1 1 1
< 100
OD 8 2 2 1 1
POWER TRANSFORMER - STANDARDISATION MANUAL 81
For single-phase transformers, the minimum recommended number of sensors for each wound column should
be those indicated in the table below:
Minimum recommended number of sensors for single-phase transformers
Rated power Cooling system Number of sensors
MVA Total HV winding LV winding
≥ 50 All system 4 2 2
Besides the above, installation of at least one sensor is recommended for Top Oil temperature measurement.
3.1. Description
This is a gas and oil actuated relay for liquid immersed power transformers and reactors with conservator.
The device is intended to detect:
§§ Gas release from the unit to be protected
§§ Oil surge from the tank to the conservator
§§ Complete loss of oil in the conservator
In case the oil continues to drop due to excess gas accumulation, it triggers operation of the trip contact.
Technical Parameters
- d.c. 240 V, 2 A
Alarm 1 NO 1 No.
Contact
Trip 1 NO 1No.
Contact
Fig. 2.11
Alarm 1 NO 1 No.
Contact
Trip 1 NO 2 Nos.
Contact
Fig. 2.11
POWER TRANSFORMER - STANDARDISATION MANUAL 83
Alarm 1 NC 1 No.
Contact
Trip 1 NC 1 No.
Contact
Fig. 2.11
BILL OF MATERIAL
14 Plaster Plug
13 Plug & Socket Assembly
12 Cap for Pneumatic Testing Device
11 Pneumatic Test Device
10 Electric Testing Device
9 Cap for Electric Testing Device
8 Connector 1/8“ x 1/8“ BSP
7 Plug D83
6 1/4” BSP Cap for Petcock with chain
5 1/4” BSP MX1/4”BSP F Petcock
4 1/4” BSP Petcock
3 Aluminium Terminal Box Cover
2 Aluminium Cover
1 Aluminium Relay Body
Sr. Description
No.
3.7 Tests
Alarm Test 200 to 300 CC Gas collection by draining the oil to match As per testing
reading on scale parameters
Trip Test 120 to 160 cm/s Create the surge to check velocity As per testing
parameters
Leakage Test Test of Housing with To check housing for leakage with compressed No leakage from
/ Loss of Oil compressed air air at 2.5 kg/cm2 any point
Test of assembled To check assembled Buchholz Relay for leakage No leakage from
Buchholz Relay with with Transformer Oil at 2.5 kg/cm2 for 140 hrs any point
Transformer Oil
a) Transit damage.
b) Dimensional check for installation suitability.
c) Electric contact by operating lever/Push rod provided on the BR.
d) Get all fasteners, gaskets and other tools before taking out BR for the fitment.
e) Check pipe line alignment, gap between pipe line flanges to put BR in position.
f) Hold BR in position with positive inclination of 3° to 7° (see Fig. 2.13 below) to the horizontal axis in the
direction of arrow marked on the BR body, provide suitable gaskets and fit the BR with fasteners in the
pipe line.
g) Ensure tightness of all the contacts.
h) Connect electrical contacts with battery and check the operation.
i) Fill BR with oil and check tightness of bolted joint for any oil leakage.
4.1 Description
The PRV is suitable for oil filled power transformer. It operates when Pressure in the tank rises above prede-
termined safe limit and performs the following functions.
Parameters Values
Liquid in Tank Transformer Oil
Mounting On Tank cover or side wall i.e. Horizontal or Vertical
On 6 Studs of M12 Equally spaced on 235 PCD
Port Opening Nominal 150 mm Diameter with spring loaded Diaphragm.
Operating Pressure 0.42, 0.49, 0.56, 0.7 kg/cm2 (any one value, shall be specified by the transformer
manufacturer)
Operating Tolerance ± 0.07 kg/cm2
Operating Time Instantaneous
Valve Resetting Automatic
Visual Indication By flag
Visual Indicator Resetting Visual Indicator Resetting Manually
Operating Temperature 0 to 100 °C (of Liquid on Tank)
Duty Outdoor / Indoor
Contact system Micro switch
Type of Switch 2 NO + 2 NC
Rating of Switch Micro Switch – 5A, 240V AC / 0.2 A , 240V DC
Switch Resetting Manual
Mounting Gaskets Nitrile Rubber Gasket of suitable size to fit on PRV Groove
Cable Entry Hole with 3/4” Conduit threads for cable gland
Degree of Protection IP 67
Hardware Stainless Steel
Rain Protection Cover Metallic Type
86 POWER TRANSFORMER - STANDARDISATION MANUAL
4.3.1 Shroud
Shroud with pipe connecting flange can be used to avoid spilling of discharge from PRV.
Flange of shroud can be connected through 360 degrees orientation in horizontal plane.
This arrangement can avoid injury to person and also avoids pollution.
4.3.2 Weather proof plug & socket arrangement for connecting cable :
Fig. 2.15: PRV with shroud with weather proof plug and socket arrangement for connecting cable
§§ Operating Pressure
4.6 Tests
TEST DESCRIPTION
Power Frequency Test Power frequency test at 2.5 kV, 50 Hz for one minute from switch terminals to other
parts of PRV
Insulation Resistance Test between Terminal to Body –Should not be less than 100 MΩ at 500V
Leakage Test Leakage test at 75 % of operating pressure with air for 24 hours
5.1 Description
A magnetic oil level gauge (MOG) is provided on the transformer conservator for indication of oil level in
the transformer. A float is used as a device for indication of oil level inside the conservator on a calibrated
dial gauge. The dial is marked as “EMPTY”, “¼”, “½ (or 35°C)”, “3/4” and “FULL”. Calibration of marks
“EMPTY” and “FULL” (Fig. 2.17) is done after leaving 65 mm from the bottom and the top of the conservator
to avoid striking of the float to the conservator oil.
Fig. 2.17
88 POWER TRANSFORMER - STANDARDISATION MANUAL
Magnetic Coupling: The float touches the oil surface level and it moves up and down with change in the
level of oil. Transfer of float movement to the pointer provided on the dial gauge by use of pair of permanent
magnets (Fig. 2.18).
Fig. 2.18
Technical Parameters
Parameter MOG
(For Main / OLTC Conservator)
Pressure 0 to 1kg/cm2
240 V, 0.2 A DC
Pointer Black
5.3.1 Mounting:
Fig. 2.19
Fig. 2.20
Sr. No. Conservator diameter F.A.L. for 30 degree F.A.L. for vertical
Ø inclined mounting mounting
1 350 N/A 156
2 750 707 438
3 800 778 474
4 900 919 545
5 1000 1060 615
6 1200 1343 757
7 1300 1485 827
8 1400 1626 898
9 1600 1909 1040
Fig. 2.21
Fig. 2.22: Wiring Diagram for Model with 2 NO Contacts Fig. 2.23: Wiring Diagram for Model with 1 NO Contact
POWER TRANSFORMER - STANDARDISATION MANUAL 91
5.6 Tests
6.1. Function
The function of Flow indicator is:
§§ To indicate the flow of oil / water in pipeline in required direction.
§§ To operate two switches, first, when the rate of flow drops to 80% & second, when the rate of flow
further drops to 70%.
Fig. 2.24
92 POWER TRANSFORMER - STANDARDISATION MANUAL
Parameter Specification
Liquid in pipe Oil or Water
Rate of full flow Of liquid in pipe in LPM
Pipe size Nominal Bore in mm
Direction of flow Any one from the following
- Left to Right
- Right to Left
- Vertically Up
- Vertically Down
No of contacts Two
Type of contacts NC (Open at full flow)
Contact rating 5 A, 240 V AC & 0.25 A, 240 V DC
Two micro switches for operation at 80% & 70% of full flow
First and second contacts get closed when flow drops at 80% & 70% of full flow respectively.
6.4. Dial
Parameters
- 100 mm round
- Back markings on white dial
- Black Pointer
Markings on dial
- Indication markings: FULL FLOW, NO FLOW (Fig. 2.25)
- Other markings - Pipe size, Value of Full Flow, Liquid in pipe & Direction indicating arrow.
Fig. 2.25
POWER TRANSFORMER - STANDARDISATION MANUAL 93
Any one of the following terminal configurations can be selected as per requirement.
The contact position shown below is under normal operating condition of flow indicator.
6.6 Tests
6.7 Mounting
Fig. 2.27
94 POWER TRANSFORMER - STANDARDISATION MANUAL
Fig. 2.28
7.1 Description
The flexible separator is a sealed envelope made from nylon fabric coated with synthetic elastomer nitrile
and hot vulcanized. The separator is installed inside the conservator and fitted to it through the flange con-
nected to the plate of the manhole.
Requirement can be specified by giving dimension of X, Y & G (calculated as per formula given below)
Formula: Y = (3.142 x D)/2 + 40 mm, X = L - D + Y, G = X - Y - 200
Example: For Conservator of 700 dia x 2000 long
Values will be X = 2240, Y = 1140, G = 1100
7.3 Tests
Coated fabric
- Mass surface
- Tearing strength
- Breaking strength
- Elongation
- Adhesion
Basic fabric
- Breaking strength
- Elongation
Finished Product
- Pressure testing by compressed air
- Leakage testing
POWER TRANSFORMER - STANDARDISATION MANUAL 97
Coated fabrics
- Heat ageing
- Compression test
- Low temperature, flexibility
- Sludge content
- Acidity
- Ozone resistance
- Air permeability
- Bursting strength
Refer Fig. 2.32 for general arrangement of Conservator and Aircell. Valve No. 1, 2, 3, 4 & 5 are fitted with
direction marked next to the valve.
Remove the detachable end cover of the conservator as shown in Figure 2.32.
Fig. 2.33: Loops on the Aircell with the hooks inside the conservator
Assemble the Oil Level Indicator (MOG) as shown at location shown in Figure 2.32. Terminal box of the
MOG should be vertically below the indicator dial. Carefully attach the float and float arm to MOG. Air
cell, MOG, float and float arm are delicate, utmost care should be taken while assembly to avoid even
slightest damage.
After the assembly of air cell and MOG are over, clean the conservator inside surface with clean cloth.
Do not use cotton waste. Refit the detachable end cover.
Now the conservator is ready for installation in position and also for oil filling.
Before installing in position, check the air cell for any leakage as under.
It is to be noted that pipes, valves, pressure gauge shown in dotted line and N2 cylinder and vacuum
pump are not supplied by manufacturer of these instruments. These should be made available at
site, keeping in mind that oil filling of the conservator is to be done after installing the same in proper
position.
POWER TRANSFORMER - STANDARDISATION MANUAL 99
Inflate (fill) the air cell at a max, of 2 psig through valve 6 (use N2 gas) while leaving a vent hole i.e. valve
4 open.
Adjust the pressure after 6 hours (i.e. pressure to be retained at 1 psig). Check the temperature and
maintain the air cell at that temperature for 24 hours. Watch the possible loss of pressure during that
period. If there is no loss of pressure during 24 hours, this means the setting of air cell inside the
conservator and also the air cell is considered leak tight. This also ensures that all gaskets joints are
leak tight. Assemble the conservator at proper position.
Caution
When the assembly is ready to work, it is important not to open vent holes / valves on upper part. Plain oil
gauges are usually provided on the opposite end of MOG on conservator. These gauges might show full
irrespective of oil level in conservator. Hence refer MOG reading for checking the oil level in the
conservator.
100 POWER TRANSFORMER - STANDARDISATION MANUAL
8.1 Description
Conservator protection relay (CPR), also called Air cell puncture detection relay, is a single-float type relay to
provide a signal in case of puncturing of air cell.
Parameter Specification
Model Refer Fig. 2.36 Standard wiring diagrams
Mounting arrangement Refer Fig. 2.37
Liquid in tank Transformer oil
Operating temperature -20 oC to +110 oC of oil
Environment Indoor or Outdoor
Contact system Magnetic Reed Switch
Type of contact As per wiring diagram (Figure 2.36)
Contact rating - a.c. 240 V, 2A for point 1.3.1
240V, 1A for point 1.3.2
- d.c. 240 V, 2 A for point 1.3.1
240 V, 1 A for point 1.3.2
Breaking capacity 400 VA a.c. or 250 W d.c.
Gas volume for Alarm 400 +/- 50 cc
Ingress protection IP 67
Vibration test Vibration test at the frequency of 5 to 35 Hz with acceleration up to 6g in all
directions
8.3 Tests
Trip Test 400 +/- 50 cc Gas collection by draining the oil to match As per testing
reading on scale parameters
Leakage Test Test of Housing with To check housing for leakage with compressed No leakage
/ Loss of Oil compressed air air at 2.5 kg/cm2 from any point
Test of assembled CPR To check assembled CPR for leakage with No leakage
with transformer oil transformer oil at 2.5 kg/cm2 from any point
9.4 Tests
10.1 Description
AVR is used for regulating the secondary voltage of power transformer with on-load tap changer. The
required dead-band settings are set by setting the nominal value and L & R levels independently. The Time
Delay setting on the front panel eliminates the relay operations for momentary fluctuations of the regulated
voltage, thus reducing the number of operations of the tap changer.
When the regulated voltage falls below the specified Under Voltage limit, the control relays are automati-
cally blocked i.e. there is no voltage correction, and a pair of relay contacts is made available for alarm.
Operation of the Raise Control Relay is automatically inhibited when the voltage falls below the specified
under voltage limit or it fails. One pair of normally open relay contacts are provided to effect the tap change
during Raise and Lower operation and to trigger an alarm in case of Under Voltage / P.T. fail conditions.
2. PT Input 3-4
3. CT Input 5-6
10.5 Tests
10.5.1 Routine tests
a) Contactor (Raise / Lower) Operation
b) Time Delay Calibration
106 POWER TRANSFORMER - STANDARDISATION MANUAL
Depressurization process commences through oil drain and simultaneously nitrogen is injected at a pre-
determined flow rate to create stirring action and to bring down temperature of top oil below ignition
point, evacuates gases formed thereby preventing explosion of tank and in case of fire, it extinguishes
fire within minimum 30 seconds. During fault condition, system operates and conservator isolation
valve blocks oil flow to isolate conservator tank oil. Also in case of fire, it prevents escalation of fire.
The system comes in to operation automatically / remotely / manually under following conditions.
Auto Mode
a) For Prevention of Fire, signals in series :
§§ Differential Relay Operation,
§§ Buchholz Relay paralleled with Pressure Relief Valve or RPRR (Rapid Pressure Release Relay)
§§ Tripping of all connected breakers (HV & LV side) is a pre-requisite for initiation of system
activation.
100 MVA and below 250 MVA 10 m3 gas at pressure of 150 kg/cm2 Oil drain pipe size 125mm
250 MVA and above 20 m3 gas at pressure of 150 kg/cm2 Oil drain pipe size 125mm
108 POWER TRANSFORMER - STANDARDISATION MANUAL
Sr. Transformer Oil Drain N2 Injection Quartz Fire Conservator isolation valve
no. rating Gate Valve Valve detector on top arrangement between bu-
cover chholz and conservator.
3 250 MVA and Size 125 Size 25 mm: 16 to 20 nos. Dummy pipe 80 mm
above mm : 1No. 6 to 8Nos,
Maximum
Mounting support/ frame on any tank side wall for signal box shall be provided.
POWER TRANSFORMER - STANDARDISATION MANUAL 109
2 Details of system equipments Cubicle, Control Box, Conservator Isolation Valve, Signal Box and
Fire Detectors.
3.1 Dimensions (LXBXH) mm a) For above 10 MVA & below 100 MVA
1200 x 500 x 1900/1700
b) For 100 MVA and below 250 MVA
1200 x 500 x 1900
c) For 250 MVA and above
1600 x 600 x 1900
3.3 Capacity and quantity of a) & b) Above 10 MVA & below 250 MVA :
Nitrogen cylinder Minimum 1 no. 10 m3 gas at pressure of 150 kg/cm2
c) 250 MVA and above :
Minimum 2 no. 10 m3 gas at pressure of 150 kg/cm2
3.7.1 Contact manometer For showing nitrogen cylinder pressure. Falling pressure,
Electrical contact, dual indicator for actual pressure as well as
level for low pressure signal.
3.7.2 Pressure Regulator With safety relief Inlet pressure : 150 kg/cm2 (+/- 10%)
valve to increased temperature Outlet pressure range : 8 to 12 kg/cm2
variation compensation.
3.7.4 Oil Release Unit and suitable to Electro- mechanical type, operating on substation DC supply as
operate without power well with provision for operation using manual lever in case of
DC supplier loss. It shall have mechanical locking arrangement
to ease in maintenance and avoid unnecessary operation during
maintenance test.
3.7.5 Gas release unit and suitable to Electro- mechanical type, operating on substation DC supply as
operate without power well with provision for operation using manual lever in case of
DC supplier loss. It shall have mechanical locking arrangement
to ease in maintenance and avoid unnecessary operation during
maintenance test.
3.7.6 Oil drain assembly Electro- mechanical type, operating on substation DC supply as
well with provision for operation using manual lever in case of
DC supplier loss.
110 POWER TRANSFORMER - STANDARDISATION MANUAL
3.7.7 Pressure monitoring switch as Provisions of Limit switch with Pressure Switch
backup in addition to signal from (Back up)
limit switch to initiate nitrogen
release simultaneously with oil drain
commencement.
3.7.8 Limit switches with No of contacts 1. Oil drain Valve closed. (G02), 2 NO
& spare contacts (NO&NC) 2. Oil drain Valve open.(G03), 2 NO
3. Gas valve closed.(G04), 1NO+ 1NC
4. Gas injection started.(G04), 1NO+ 1NC
5. Oil drain unit locked mechanically. (G05) 2NO/1NC+1NO
6. N2 release unit locked mechanically.(G06) 2NO/1NC+1NO
3.8 Oil drain Valve (above cubicle) for system isolation from transformer
3.9 Nitrogen Injection Valve (above Cubicle) for system isolation from transformer
3.9.2 Size 25 NB
3.10 Oil drain pipe size a) Above 10 MVA & below 100 MVA : 80 mm
b) 100 MVA and below 250 MVA : 125 mm
c) 250 MVA and above : 125 mm
3.10.1 Length and Number of openings in As per site location, Transformer to cubicle & cubicle to oil pit, 1
the transformer tank no.
3.10.2 Material MS, ERW, Heavy duty for TRS to cubicle & GI, Medium for cubicle
to oil pit.
4 Control Box
4.4 Details of components provided in the MCB, Relays, Hooters, Contactors, Indicating lamps, Operating
control box switches.
4.5 Control voltage 110 / 220 VDC / Substation voltage. AC-DC / DC-DC
converter, timer shall not be used for reliable operation.
4.7 Whether audio and visual alarms Yes with different volume (dB) levels
provided?
5.1 Type Operating mechanically on Transformer oil flow rate with visual
position indicator.
5.3 Whether suitable for pipe of size As per transformer conservator pipe size
80mm dia i.e. 80 mm or 50 mm.
5.4 No of contacts & spare contacts (NO Normally Open contact shall be provided.
& NC)
6 Fire Detectors
6.3 Method of fixing Bolting on Fire Detector bracket on Transformer top cover using
fire survival, copper cables (capable to withstand 750 °C.)
7 Power Supply
7.1 For Control Box For operation : 110 / 220 VDC / substation DC voltage
For DC fail alarm : 230 VAC
8 Extinction period
11.1.9 Tests
Functional test of following equipment is to be carried out during inspection and / or prior to dispatch:
c) Control box.
Fig. 2.39
POWER TRANSFORMER - STANDARDISATION MANUAL 113
Cooling details :
If OF type Number of pumps : Head : Flow :
KW/HP : Back Flow when Pump Switch off : LPM
Additional information :
114 POWER TRANSFORMER - STANDARDISATION MANUAL
PROJECT :
CUBICLE NO : SIGNAL BOX NO. :
CONTROL BOX NO: FIRE DETECTOR NO.
CONSERVATOR ISOLATION VALVE NO. :
PARTICULARS PARTICULARS
1.0 Erection Oil drain pipe slope 2 to 3 degree Towards cubicle
1.1 Civil work Tightness of flange and bolts
CUBICLE plinth as per approved drawing. External cleaning
Painting red oxide and P.O. red
1.2 Oil pit / Tank 2.2 Pipe connection from cubicle to Oil pit
Sealing of top cover. Weld joint
Termination arrangement of pipe to CUBICLE Aluminium paint at weld joints
Capacity suitable for transformer Fitment of drain pipe to CUBICLE collar
Pipe slope 5 to 10 deg .towards oil pit
1.3 Cubicle 2.3 Conservator Isolation Valve
Check oil drain isolation valve above Mounting as per position marked on
Closed CIV as per Drg. No.
Check N2 isolation valve above CUBICLE Tightness of flanges and bolts
Closed Pump test with one pump
Door opening as per approved Pump test with two pumps
Alignment 2.4 Fire Detector
Tightness of foundation bolts Mounting of fire detectors
1.4 Control Box (CB) Mounting of fire detectors rain guards.
Wall mounting/Frame mounting, alignment 2.5 Earthing
Mounting at eye level Signal box, CUBICLE, Control box & FD
1.5 Signal box (SB) 2.6 Cable Laying
Mounting at working height Control box to signal box FRLS 12 core
Fitment Control box to relay panel FRLS 12 core
1.6 Fire detector (FD) Control box to CUBICLE FRLS 12 core
FD mounting as per drawing Control box to DC-DC convertor 4 core
1.7 Conservator Isolation Valve CIV to signal box FRLS 4 core
Visual crack/damage Control box to DC source FRLS 4 core
Space availability Control box to AC source FRLS 4 core
Valve availability for isolation CUBICLE to AC source FRLS 4 core
2.0 Installation FD to signal box FS 4 core
2.1 Pipe connection from Transformer to Cubicle 2.7 Cable Termination
Weld joint & weld joint fitup Continuity of cable
Internal cleaning, varnishing & coating Crimping quality of lugs
No leakage at 3.5 kg/cm for 1 hour
2
No excess length of cables
Alignment Dressing and glanding
Pipe support at minimum 5 mtrs interval Termination as per
Pipe support alignment Interconnection Drg. No.
116 POWER TRANSFORMER - STANDARDISATION MANUAL
5.0 CUBICLE
5.1 Insert locking pin to lock oil drain mechanically. Alarm for “Out of service” must be activated.
5.2 Insert locking pin to lock Nitrogen injection mechanically Alarm for “Out of service” must be
activated.
5.3 Nitrogen Cylinder pressure greater than 135Kg/cm2.
5.4 Adjustment Nitrogen injection pressure as per manufacturer standard setting.
5.5 Tightness test of nitrogen injection valves, hoses, main gas valve, 2 and 3 way ball valves.
POWER TRANSFORMER - STANDARDISATION MANUAL 117
11.2.1 Description
This system is widely used for fire fighting of outdoor transformers. Spray type fire protection essentially
consists of a network of projectors and an array of heat detectors used to sense high temperature near
the transformer / reactor to be protected. If the temperature exceeds the set value, the automatic
mulsifire system sprays water at high pressure through a Deluge valve from the pipe network laid for
this system. Fire detectors located at various strategic points are on the surface of the transformer to
control fire on any burning oil spilled over.
a) Main Hydrant
This is used to carry the water to various parts of the switchyard or transformer substation and
forms the backbone of the system. Sturdy corrosion-free pipes and valves are used for this
purpose. The materials should be able to withstand fire for a reasonable duration.
b) Fire Detector
Fire detectors can either be thermocouples or specially designed bulbs which burst when they
experience a high temperature and release any valves or checking device to start the water
supply.
d) Pumps
Pumps are provided to fill the hydrants initially and to maintain its pressure. Pumps driven by
electrical motors are a standard provision; however, the standby pumps should preferably be
diesel engine driven. It is recommended that the main and standby pumps in a pump house be
segregated.
As per Powergrid specification, from safety considerations, the following electrical clearances
are recommended between the mulsifier system pipe work and live parts of the transformer to be
protected.
§§ 420 kV bushing 3500 mm
§§ 245 kV bushing 2150 mm
§§ 145 kV bushing 1300 mm
§§ 52 kV bushing 630 mm
§§ 36 kV bushing 320 mm
§§ Each Deluge valve shall be provided with a local panel from which will enable manual electrical
operation of the valve.
§§ In addition to this, each valve shall be provided with local operation latch.
§§ Test valves shall simulate the operation of Deluge valves and shall be of quick opening type
POWER TRANSFORMER - STANDARDISATION MANUAL 119
12 Terminal Connector
12.1 Selection Criteria
Type of Connector (Construction)
a) Bolted type
b) Crimping type
c) Wedge type
d) Welded type
Type of Connector (Functional)
a) Horizontal / Vertical / Through type
b) Rigid / Flexible type (for Tubular Bus)
12.2 Technical Data Required for Design of Connector
a) System Voltage
b) Continuous current rating
c) Short time rating
d) Ambient temperature & limit of maximum temperature rise
e) Visual corona withstand voltage (for connectors of 220 kV and above)
f) Maximum permissible RIV level at a specified voltage (for connectors of 220 kV and above)
g) Size of Busbar & direction of approach
ANNEXURE 2.4
PT 100 Resistance
Temerature Vs Resistance
(BS 1904: 1984 & IEC 751: 1985)
POWER TRANSFORMER - STANDARDISATION MANUAL 121
ANNEXURE 2.5
PT 100
Temerature Vs Output Signal
Temperature Range: 0 - 150 oC
Signal Range: 4 - 20 mA
122 POWER TRANSFORMER - STANDARDISATION MANUAL
POWER TRANSFORMER - STANDARDISATION MANUAL 123
Chapter - 3
CHAPTER - 3
1. INTRODUCTION
This part of Manual lists the typical drawings submitted by manufacturer to the customer for approval and
reference. The purpose of these drawings is to ensure that transformers being planned for manufacture meet
the guaranteed technical particulars as per order, functional requirements as per customer specifications and
interfaces at site. The Manual lists up the minimum details required in drawings and can be used as a check list for
manufacturers, customers and consultants while preparing, verifying and approving these contract drawings.
Drawings list should have the revision status and date of submission / approval.
1. Rating & Diagram Plate
2. General Arrangement drawing for Transformer
3. List of Accessories
4. Bill of Materials
5. Foundation Plan
6. Bushing Details
7. Transport Dimensions
8. General Arrangement Drawing of Marshalling Box/ Cooler Control Cubicle
9. General Arrangement Drawing of RTCC panel
10. General Arrangement Drawing of Junction box (if applicable)
11. Tap Changer Control Scheme
12. Cooler Control Scheme
13. Alarm / Trip Indication Scheme
14. Interconnection between DM and RTCC
15. General Arrangement Drawing for Cable Box (If applicable)
16. General Arrangement Drawing for bus duct termination (if applicable)
17. Valve Schedule Plate
3. GENERAL GUIDELINES
a. All drawings shall be “to scale”
b. Drawings can be either in first angle or third angle projection. Angle of projection shall be mentioned in
drawing. Preferred projection is First Angle Projection.
c. Title block shall contain customer reference (Customer name, PO/LOI number), Transformer MVA rating and
voltage.
d. All drawings may be either in A3 or A4 size for easier up-keeping.
e. Drawings shall also be submitted in soft form.
126 POWER TRANSFORMER - STANDARDISATION MANUAL
§§ Transformer pull out direction shall be marked and make sure that there are no obstructions for pulling
out transformer from the foundation.
§§ Make sure the jacking pad position is not fouling with the rail line.
§§ OLTC conservator shall preferably be at same level as main conservator level.
§§ Buchholz relay shall be accessible for inspection, preferably from tank top.
§§ Accessibility to ladder and from ladder to tank top shall be clear from other accessories and pipelines.
Ladder shall be provided with anti-climbing device.
§§ Positioning of cable box shall not be in the path of transformer dragging out path.
§§ It is preferable to mount the coolers on the transformer tank instead of separate mounting.
§§ Dial of magnetic oil level indicator shall be visible from the ground.
§§ Provision shall be made on tank cover for fixing safety barriers.
§§ If air cell is provided in the conservator, air cell failure indication (by air operated relay or oil sight
window) shall be provided.
§§ Upper filter and sampling valves shall be accessible from ground level. All valves shall be provided with
identification labels.
§§ Rating and diagram plate shall be visible and near to OLTC driving mechanism. Marshalling box with
indicators shall be near to it. Dials of all indicating and protection meters shall be visible clearly when
viewed from the front of transformers.
4.6 Bushings
§§ Bushing shall be as per latest relevant IS/IEC/CBIP specifications
§§ Short time current rating shall be 25 times rated current for 2 second up to 4000 A bushing and 100 kA
for 2 second for bushings above 4000 A as per IS/IEC, or as specified by Purchaser.
§§ Maximum angle of inclination and cantilever strength shall be indicated.
§§ Arcing horns are not recommended for the bushings.
§§ Material of components shall be indicated.
§§ Weight of oil and bushing shall be indicated.
§§ Bushing top terminals shall be marked.
§§ Test tap details shall be shown in bushing drawing.
§§ Creep distance shall be 31 mm / kV for all bushing upto 420 kV in open air. Creep distance is not
applicable for oil to oil to SF6 bushing. Creep distance for bushing inside cable box / bus duct shall be
20 kV / mm minimum.
Tapchanger
4.11.1 Besides the local and remote electrical control, on-load tap changers, when specified, should be suit-
able for remote electrical parallel control as in clause 4.11.2.
B. General
§§ Local control items shall be mounted inside the on-load tap changer driving mechanism or
marshalling box. Remote control items are to be mounted on remote control cubicle installed in
the control room. All the control items are to be mounted in easily accessible position and clearly
labeled. All control item shall be of best quality and or class most suitable for working under the
conditions specified and shall withstand the variation of temperatures and atmospheric condition
arising under working conditions so also withstand vibrations. All control items shall be wired and
connected as per ‘Schematic Diagram of tap changer control equipment given in Scheme .
4.11.4 Motor
On-load tap changer driving gear Motor shall be of squirrel cage totally enclosed type and shall comply
with Indian Standard IS: 325. It shall be suitable for direct starting and continuous running from 415
volts 3-phase 50 Hz supply. Motor shall be capable of continuous operation at any frequency between
48 and 51.5 Hz together with any voltage within 10 per cent of nominal value. Motor shall have ball or
roller bearing and vertical spindle motor shall have bearing capable of withstanding thrust due to the
weight of the moving parts. The stator windings shall be adequately braced and suitably impregnated
to render them non-hygroscopic.
4.11.12 Wiring
All the wiring shall be carried out for motor circuit with 1100 volts grade PVC insulated stranded copper
conductors of size 2.5 sq mm and for control circuit with 650 volts grade PVC insulated copper conduc-
tor of size 1.5 sq mm suitable for tropical atmosphere. All wiring shall be in accordance with relevant
IS. Engraved core identification ferrules, marked to correspond with the wiring diagram shall be fitted
at both ends of each wire. Ferrules shall fit tightly on the wires and shall not fall off when the wire is
removed. All wiring shall be terminated on terminal blocks through suitable lugs. Insulated sleeves
shall be provided at all the wire terminations. All wiring shall be neatly bunched and cleated without
affecting access to equipment mounted within the cabinet. One piece moulded 600 V grade terminal
blocks complete with insulation barriers, terminal studs, washers, nuts and lock nuts shall be used.
Terminal blocks shall be numbered for identification and grouped according to function. 10 per cent
spare terminal blocks for control wire termination shall be provided on each panel. Terminal board rows
should be spaced adequately apart to permit convenient access to wires and terminations. Terminal
boards shall be so placed with respect to the cable gland plate (at a minimum distance of 70 mm) as
to permit satisfactory arrangement of multi core cable tails without undue stress or bends. Opening of
door should not disturb or stress the wire termination.
transformers with on-load tap changers. The required dead band settings are set by setting the
nominal value, and lower and upper levels independently. The time delay setting on the front
panel eliminates the relay operations for momentary fluctuations of the regulated voltage thus
reducing the number of operations of the tap changer. “ When the regulated voltage falls below
the specified under voltage limit, the control relays are automatically blocked, i.e., there is no
voltage correction, and a pair of contacts is made available for alarm.
(ii) General Description: Voltage regulating relay should be designed for maximum operational
simplicity for regulating the secondary voltage of power transformer with on load tap changers.
The dead band (band width) can be set by setting the nominal value adjustment (NVA) to the
required value “110 V + 10 per cent”.
The desired time delay can be set on the front panel and the control action will take place only if the
voltage continues to remain outside the dead band after the time delay has elapsed. For voltage
corrections requiring more than one tap change, time delay is initiated again before further tap
change. The relay is reset automatically after the voltage is brought within the selected dead band.
For repeated short duration voltage fluctuations on the same side of the dead band, the time delay
is effectively reduced to provide a voltage time integral response of the regulator. Operation of the
Raise Control relay is automatically inhibited when the voltage falls below the specified under-
voltage limit. One pair of normally open relay contacts are provided to effect the tap changer,
Raise and Lower operation and to trigger an alarm in case of under voltage conditions.
(iii) Specifications
Auxiliary Supply : -15% / + 10% 50 Hz
PT Supply (regulated Voltage) : 110 V ± 10 per cent 50 Hz
Sensitivity (Dead Band) : Nominal value adjustable (NVA)
and Nominal Value Range between + 0.75 to + 2.5 per cent
Time Delay Setting: Fixed, i.e., (Voltage independent) time delay continuously adjustable from 10
to 110 secs.
Time Delay Resetting: Instantaneous resetting with voltage deviation occurring in opposite
direction.
Under Voltage Blocking: Internal blocking at 80 per cent of regulated value. Restoration at 85 per
cent of regulated value.
Control Relays: One pair of normally open potential free contacts of suitable rating.
Control Operation: Single pulsed operation of sufficient duration to initiate tap changer.
Operating Temperature : – 5° to + 50°C
Option: Line drop compensator with resistive and reactive compensation of either polarity up to
20 per cent adjustable in steps or continuously and suitable for operation with 1 Amp. current
transformer. If required suitable interposing current transformer to be used to get 1 Amp.
Secondary current.
1 pair of NC (UV) contacts provided.
ii. Specifications
Resistive Compensation: 0-20 per cent of the regulating value continuously adjustable.
Reactive Compensation: 0-20 per cent of the regulating value continuously adjustable.
Input Rated Current: 1 Amp. 50 Hz.
Power Consumption: As required (CT burden will depend on power consumption).
Accuracy : 10 per cent.
Max. Overcurrent : 50 per cent of rated current (1.5 Amp.)
Polarity Selection : Both positive and negative compensation.
The required amount of percent R and per cent X compensation can be set on the front panel of
the LDC. The polarity selector switches provide both positive and negative compensation. The per
cent R and per cent X settings can be calculated from the following formulae:
√ 3*IL*RL
Note : When LDC unit is not to be used, keep per cent R and per cent X settings to Zero, i.e., on
minimum position.
Select one Transformer as “Master’ and others as its ‘Followers’. Then control supply will be
tapped from D.M. Box to RTCC panel. Through the S/W S5 in RTCC1, which is set at ‘Master’
mode the Control supply is passed on to S/W S40 in D.M.1 which is an Odd/Even type of S/W.
Its every 2nd position is linked e.g. 1, 3. 5. 7. 9. 11. 13. 15, 17 etc. This is to reduce number of
interconnecting wires between RTCC panels. Suppose, Transformer 1, which is set as a “Master’,
is at Tap 1, then through its odd/Even S/W in D.M.1, the Control Supply now goes to RTCC2 and
from there it goes to Odd/Even S/W S40 of D.M.2. If the D.M.2 is also at Tap 1, then the control
supply will be returned to RTCC2 set at “Follower’ mode and energizes Contactor K11 in RTCC2.
Normally Open Contact of this K11 is wired up in RTCC1 and once it becomes closed, supply is
available at Auto/Manual S/W S9, in RTCC1.
If the S/W S9 is set at Manual mode, then thro’ Push Button S1 or S2 Raise/ Lower operation is
carried out. S1 will energize Contactor K4 for Raise tap and S2 will energize K5 for Lower contactor.
Once the Raise or Lower Contactor in Master RTCC is picked up, it will extend the command to
Follower RTCC to Raise or Lower Contactor and hence tap will be changed in both Transformers
POWER TRANSFORMER - STANDARDISATION MANUAL 133
simultaneously. If the Tap change operation is not completed within prescribed time duration,
then the Timer is energized in D.M. Box which indicates Tap Change incomplete indication and
D.M. MCB is tripped. Contactor K6 in RTCC will act as a Blocking relay which will block the Tap
Change operation in case both RTCC’ s are not at same Tap position. In that case the timer K29 is
picked up and will indicate Tap change Out of step indication.
Set Auto/Manual S/W S9 on Auto Mode. The Raise/Lower Tap position decision is taken care by
Automatic Voltage Regulator. As per its instruction either K4 or K5 is energized and then it gives
command to Follower RTCC accordingly.
Cooler control systems follow different practices and vary depending upon customer specs, manufacturers
standard practices, however, standard control schematic will allow end customer to operate cooler control
with more ease and similar representation of schemes and ease of maintenance. For cooler control sche-
matics, standardisation of schemes will lead only to way of representation and mode of control like Auto/
Manual or Local/Remote. Typical Cooler Control Circuit is attached as Fig. 3.3.
4.12.1 Index
A. Device Designation
All control switches, sequence selector switches and push buttons to be designated with letter
“S” and prefixed by “-“.
e.g.–S2.
AVR and annunciators to be designated with letter “A” and prefixed by “-“.
e.g. -A1.
Indicating Lamps to be designated with letter “H” and prefixed by “-“.
e.g. –H1.
Instruments like signal converter or Transducers, power supply module etc to be designated by
letter “U” and prefixed by “-“.
e.g. –U2.
MPCB (Motor Protection Circuit Breaker) to be designated by letter “Q” and prefixed by “-“.
e.g. –Q10.
Fig. 3.2
Where control schematic drawings are prepared in A3 or A4 size sheets, signal linking has to be
done in following fashion:
Signal designation to start with letter “L” followed by signal number followed by the destination
sheet and column in which destination is located. e. g.. --|L1/5.2. In this example, signal L1 is
terminated on 5th sheet and in 2nd column.
POWER TRANSFORMER - STANDARDISATION MANUAL 135
4.15 General Arrangement Drawing for Air filled Cable Box (If applicable)
§§ Number & size of cables/phase as per customer specification shall be indicated.
§§ Cable box shall be provided with silica gel breather.
§§ Provision shall be made to move the transformer without disturbance keeping cable box in position.
§§ Earthing links shall be provided between cable box, disconnecting chamber and cable gland plate.
§§ Minimum one meter distance shall be provided from gland plate to bus bar.
§§ External Painting procedure of tank shall be applicable for both inside and outside of cable box.
§§ In case of ground mounted cable box support, same shall be in line with foundation plan.
§§ Cable Lugs and glands are not part of transformer supply.
§§ All bus bars and flexible inside the cable box shall be tin plated.
§§ Epoxy or porcelain insulator shall be used inside the cable box for bus bar support with minimum
creepage distance of 20mm/kV
4.16 General Arrangement Drawing for Bus Duct termination (if applicable)
§§ Position of bus duct mounting flange shall be dimensioned from transformer center line and from rail
level with a tolerance of ± 5mm.
§§ Electrical clearance boundary shall be indicated so that bus duct (supplier scope) should not enter into
the minimum clearance zone.
§§ Bushing top terminal details shall be clearly indicated for further connection by bus duct supplier.
§§ Drain plug shall be provided at the bottom most point of bus duct fixing flange on transformer.
§§ Open and close indication of each valve at service, transport and oil filling should be marked.
§§ In case of water cooled Transformers, a heat exchanger single line diagram is required.
5. Typical Cable Schedule is enclosed for reference (Annexure 3.2).
ANNEXURE 3.1
Code for Transformer Accessories in line with DIN42513
1. AA001~XXX Valves
2. AB001~XXX Drain plugs
3. AC001~XXX Radiators, Oil to water heat exchangers, oil to air heat exchangers
4. AE001~XXX Rollers, skid base, foundation bolts, anti-earthquake locking arrangements, refilling device for
dry air
5. AN001~XXX Cooling fans
6. AP001~XXX Cooling pumps
7. AT001~XXX Dehydrating breather, Air cell
8. BB001~XXX Lower tank, upper tank, cover, conservator for main tank, conservator for tap changer
9. BQ001~XXX Thermometer pockets, detachable ladders, jacking pad, lifting lugs, lashing lugs, pulling eyes,
hook for safety belt, bracket for conservator, cooler pipe
10. BR001~XXX Pipes
11. BZ001~XXX Manholes, hand holes, inspection windows, terminal for tank earthing, rating plate, labels, valve
schedule plate, caution plate, air cell installation notice
12. CF001~XXX Accessories (protective, monitoring) bushings, tap changer, control cubicle, motor for tap
changer, impact recorder, terminal connectors.
138 POWER TRANSFORMER - STANDARDISATION MANUAL
ANNEXURE 3.2
Typical Cable Schedule
M.BOX Page To MOTOR DRIVE(DM) Page CABLE DETAIL Details
Ter.Strip Terminal Ter.Strip Terminal
X4 9 -- X1 2 4Sq.mm,4core cable 3 Ph supply for OLTC Motor
X4 10 -- X1 3
X4 11 -- X1 4
X4 5 -- X1 6 2.5Sq.mm,2 core Cable 1 Ph AC Supply for Heater ckt
X4 6 -- X1 7
Fig. 3.3 (c): Typical Power Circuit for Fan and Pump Group – 2
Fig. 3.3 (d): Typical Control Circuit for Fan Group – 1
POWER TRANSFORMER - STANDARDISATION MANUAL
149
150
POWER TRANSFORMER - STANDARDISATION MANUAL
Chapter - 4
CHAPTER - 4
It is a contract document between customer and supplier to express commitment for delivery of transformer as per
agreed technical specification and match the type tested design.
Over a period of time as the transmission grid has grown leaps and bounds, with HVDC and 765 kV AC network,
this commitment document is gaining importance, because of rise in transformer failure rate and causing anxiety to
maintain uninterrupted supply for consumer and industry. Customer always wishes that transformer manufactured
and delivered must perform defect free service for its “specified design life”. It is always a challenge for supplier
(manufacturer) to keep consistency in material used and manufacturing process, which are the main cause for variation
in quality of transformer. While customer practically cannot monitor them and not expected to do so, manufacturers
are on their toes to offer cost competitive and cost effective product. The cost of material plays an important role,
considering the fact that majority of parts and components like bushing, OLTC, tank body, radiators, insulation, copper,
core material etc. are outsourced. The selection of material, its grades / type and design philosophy ultimately decide
the loss capitalization figures of final product. On the manufacturing process front, seamless integration of parts
/ components through mechanical and electrical design is the prerequisite. The change in sub-venders and skilled
manpower time to time at factory also require due diligence to control and maintain the consistency of manufacturing
process. Therefore a “balanced view“ is needed to manufacture and deliver ideal Transformer meeting contract
specification and match type tested design.
It is evident from above background that there is need of mutually agreed manufacturing quality plan (MQP). Apart
from primary objective to have ideal transformer as per customer wish as explained above, the major benefit of MQP
would be timely delivery and any conflict shall be address upfront, so that manufacturing could take place uninterrupted
in a faithful manner. The role of design review is important to provide all necessary inputs for structuring the MQP.
It is proposed in this power transformer standardisation manual to have MQP covering following elements:
It is equally very important that Transformer is manufactured in a dust free clean environment with humidity control.
Any compromise on this aspect will have adverse effect in expected design life of Transformer, however good is the
quality of material used.
Standard Manufacturing Quality Plan (MQP) has been designed in a manner to share the responsibility depending upon
the source of supply, testing, location and criticality of test for the performance of Transformer. Responsibility of sub-
vendor is important for testing of raw material and components (P), but manufacturer has to play a role of verification
(V) as they have to integrate them for actual design of transformer. Similarly, responsibility of manufacturer is crucial
for routine tests (P) but customer has to actively witness (W) these tests to ensure that results are complying the
contract requirements and design review data.
166
Sr. Item/Components List of Tests Sampling Reference / Acceptable Value Category of Reponsibility*
No. rate Standard
Sub Manuf- Customer
Vendor acturer
A Raw Material & Components
1 Winding Conductor 1. Visual & Dimensional check of Bare One sample IS 1897 Bare conductor P V W
(PICC)/ (CTC)/ Lead Conductor. Thickness & width of bare per type per IS 13730 Width /thick (mm) Tolerance (in ± mm)
wires conductor, Covered width & thickness lot IS 7401 Up to 3.15 - 0.03
3.16 to 6.30 - 0.05
6.31 to 12.5 - 0.07
12.51 to 16 - 0.10
> 16 mm - 0.10
Insulated conductor
POWER TRANSFORMER - STANDARDISATION MANUAL
* Category of Responsibility: P - Actual Test Performance V - Verify and Accept W - Witness Actual testing, verify and accept
Sr. Item/Components List of Tests Sampling Reference / Acceptable Value Category of Reponsibility*
No. rate Standard
Sub Manuf- Customer
Vendor acturer
7. Radius of corner of bare conductor IS 7404 Thikness (mm) P V W
IS 13730 Over/Upto Corner Radius(mm)
Up to 1.0 - 0.50
1.01 to 1.60 - 0.50
1.61 to 2.24 - 0.65
2.25 to 3.55 - 0.80
3.56 to 5.60 - 1.00
2 Kraft Insulating 1. Visual check & Measurement One sample IEC 60554- 1. Paper to be smooth, unglazed surface & P V --
Paper of Thickness per type per 3-1 free from dust particles
2. Density lot IEC 60554- 2. 0.8 ±0.05 gm/ cm3
3. Substance (grammage) 3-5 3. Thick (µm) Sub (g/cm3) Tolerence
IEC 50 40 10
60554-2, 65 52 05
Methods of 75 60 05
Test 90 72 05
4. Moisture Content 4. 8 % max
5. Tensile Index MD 5. 93 NM/gm (min)
6. Tensile Index CD 6. 34 NM/gm (min)
7. Elongation at Break MD 7. NA
8. Elongation at Break CD 8. NA
9. Electric Strength in Air 9. NA
10. Ash Content 10. 1 % max
11. PH of Aqueous extract 11. 6 to 8
12. Conductivity of Aqueous 12. 10 mS/m (max)
extract
13.Air Permeability 13. 0.5 to 1.0 µm/Pa.s
14.Tear Index MD 14. 5 mN m2 /g (min)
15.Tear Index CMD 15. 6 mN m2 /g (min)
16. Water Absorption (Klemn 16. 10 %
Method)
17.Heat Stability 17. Type test report
a.) Reduction of Degree of
Polymerization
b.) Reduction of Bursting
Strength
c.) Increase of Conductivity of
Aqueous extract.
* Category of Responsibility: P - Actual Test Performance V - Verify and Accept W - Witness Actual testing, verify and accept
POWER TRANSFORMER - STANDARDISATION MANUAL
167
168
Sr. Item/Components List of Tests Sampling Reference / Acceptable Value Category of Reponsibility*
No. rate Standard
Sub Manuf- Customer
Vendor acturer
3 CRGO Laminations Check following documents Each Lot IS 3024 As per approved design P V --
(a) Invoice of Supplier IEC 60404
(b) Mill’s Test certificate ASTM 4343
(c) Packing List
(d) Bill of Lading
(e) Bill of Entry
Check points:
1. Visual, Dimension & Thickness 1. Visually defect free, as per design
One sample requirement
2. Cutting Burr per lot 2. Less than 2 micron burr
POWER TRANSFORMER - STANDARDISATION MANUAL
* Category of Responsibility: P - Actual Test Performance V - Verify and Accept W - Witness Actual testing, verify and accept
Sr. Item/Components List of Tests Sampling Reference / Acceptable Value Category of Reponsibility*
No. rate Standard
Sub Manuf- Customer
Vendor acturer
4 Pre-compressed 1. Visual & dimensional check, thickness, One sample IEC 60641- (1) No surface defects P V V
Press Board width & length/. of each size 3-1
2. Apparent Density per lot IEC (2) Up to 1.6 mm TK -1.0-1.2
60641-2, >1.6-3 mm TK -1.1-1.25
Methods of >3-3.6 mm TK -1.15-1.30
Test >6-8 mm TK -1.2-1.3
3. Compressibility C (3) Up to 1.6 -10 %; >1.6-3 mm - 7.5 %
>3-3.6 mm - 5 %; >6-8 mm TK -4 %
4. Reversible part Compressibility (4) Up to 1.6 -45 %; >1.6-3 mm - 50 %
>3-3.6 mm - 50 %; >6-8 mm TK -50 %
5. Oil Absorption (5) Up to 1.6 mm TK -11 min
> 1.6-3 mm TK - 9 min
> 3 - 3.6 mm TK -7 min
> 6-8 mm TK - 7 min
6. Mositure Content (6) 6 % max
7. Shrinkage MD, CD & PD (7) MD - 0.5 % max, CD- 0.7 % max, Thick -5
% max
8. pH of aqueous extract (8) 6-9 for solid boards
9.conductivity of aqueous extract (9) Up to 1.6 - 5 max (mS/m)
> 1.6-3 mm - 6 max, > 3-3.6 mm - 8 max
> 6-8 mm TK - 8-10 max
10. Electric Strength in Air (10) Up to 1.6 - 12 kV/ mm
> 1.6-3 mm - 11 kV/mm
> 3-3.6 mm - 10 kV / mm
> 6-8 mm TK - 9 kV/mm
11.Electric Strength in Oil (11) Up to 1.6 - 40 kV/ mm
> 1.6-3 mm - 35 kV/mm
> 3-3.6 mm - 30 kV / mm
> 6-8 mm TK - 30 kV/mm
12. Ash Content (12) 1 % maximum
MD CD
13. Elongation MD, CD (13) Up to 1.6 - 3 % 4 %
>1.6-3 mm - 3 % 4 %
>3-3.6 mm - 3 % 4 %
>6-8 mm TK -3 % 4 %
14. Tensile strength MD, CD
15. Ply Bond Resistance
16. Flexural strength MD, CD (Laminated
Boards)
***TC --- Test Certificate PD--> Perpendicular Direction CD--> Cross Direction
* Category of Responsibility: P - Actual Test Performance V - Verify and Accept W - Witness Actual testing, verify and accept
POWER TRANSFORMER - STANDARDISATION MANUAL
169
170
Sr. Item/Components List of Tests Sampling Reference / Acceptable Value Category of Reponsibility*
No. rate Standard
Sub Manuf- Customer
Vendor acturer
5 Permawood 1. Visual & dimensional check, thickness, One sample IS 3513 1. Shall be free from surface defect P V --
width & length. of each size IS 1708
2. Density per lot IS 1736 2. 0.8 to 1.3 gm/cc
3. Moisture content IS 1998 3. Max 7%
4. Oil Absorption at 90 °C 4. Min 5%
5. Electric Strength at 90 °C 5. Min 60 KV
6. Tensile strength 6. Min for LD - 700 KV /cm2
7. Compressive strength test 7. Min for LD - 1400 KV /cm2
8. Shear strength age-wise 8. Min for LD - 450 KV /cm2
9. Thickness 9. Thikness (mm) Tolerance (+/- mm)
POWER TRANSFORMER - STANDARDISATION MANUAL
10 to 25 - 1.2
26 to 50 - 1.4
51 to 150 - 2.0
6 Porcelain Bushings 1. Visual & dimensional check. 100% IS 2099 1. As per approved drawing. P V --
(Hollow) 2. Power frequency voltage withstand test 2. As per IS 2099
As per IS/
IEC
7 Polyster Resin 1. Visual Check Each lot IS 15208 1. Free from visual defect P V --
Impregnated Glass 2. Verification of shelf life 2. 12 months
Fibre Tape 3. Thickness 3. 0.25 to 0.35 mm (± 0.07)
4. Width 4. 20 to 50 mm (± 2)
5. Tensile Strength 5. Min 200 N/mm
6. Resin Content 6. 27 (± 3%)
7. Softening point of resin 7. Max 200 °C
8 Synthetic Rubber 1. Visual check, thickness, length, width One sample IS 4253 1. Free from surface deffect P V --
Bonded Cork sheet 2. Hardness per lot 2. 70 ± 10 IRHD
(SRBC) 3. Compression set 3. 85 % max
4. Side flow under compression 4. NA
5. Tensile strength 5.1550 kpa (min)
6. Flexibility 6. Should be satifactory when bent though
1800 round the material of diameter three
times the thickness of specimen.
7. Compressibility 7. 25-35 %
8. Recovery 8. 80 % min
9. Aging in Oil-Finish, Flexibility & change 9. Change in volume 15 % max for 70 hours at
in volume 100 deg c in oil
10. Ph value 10. 5-8.5
* Category of Responsibility: P - Actual Test Performance V - Verify and Accept W - Witness Actual testing, verify and accept
Sr. Item/Components List of Tests Sampling Reference / Acceptable Value Category of Reponsibility*
No. rate Standard
Sub Manuf- Customer
Vendor acturer
9 Condenser Bushing Routine Test 100% IS 2099 P W
(1) Measurement of dilectric dissipation IEC 60137 1. Tan Delta - 66 kV - 0.7% V --
factor and capacitance Above 66 kV - 0.4% V --
(2) Dry power frequency voltage withstand 2. As per approved GTP V --
test V --
P
(3) Measurement of partial discharge 3. As per IEC - No flash-over/ puncture V W
(4) Pressure test 4. No leakage V W
(5) Tightness test 5. No leakage
(6) Creepage distance 6. As per approved GTP
(7) Visual & dimensional check 7. As per approved drawing
10 Buchholz Relay 1. Type & make 100% IS 3637 1. As per approved drawing P V --
2. Porosity 2. No leakage
3. High voltage 3. 2 KV for 1 min. withstand
4. Insulation resistance 4. Min 10 MΩ by 500 V DC megger
5. Element test 5. No leakage at 1.75 Kg/cm2 oil pressure for
15 mins
6. Gas volume test at 5° ascending towards 6. GOR - 1: 90 to 165 CC
conservator GOR - 2: 175 to 225 CC
GOR - 3: 200 to 300 CC
7. Loss of oil & Surge test 7. GOR - 1: 70 to 130 CC
GOR - 2: 75 to 140 CC
GOR - 3: 90 to 160 CC
11 Bimetallic Terminal 1. Dimensional 100% IS 5561 1. As per approved drawing P V --
Connector 2. Visual check 2. Free form defects
3. Tensile strength 3. As per type test report
4. Resistance 4. As per type test report
12 Marshalling Box 1. Dimension & Visual check 100% Approved 1. As per approved drawing P V --
2. 2kV test for Auxillary wiring drawing 2. 1 min withstand
3. Paint shade & Thickness and speci- 3. As per approved drawing
4. Wiring routing check fication 4. Firm and aesthetic
5. Functional Check 5. As per approved drawing
13 Remote Tap 1. Dimension & Visual Check 100% Approved 1. As per approved drawing P P --
Changer Control 2. 2kV test for Auxillary wiring drawing 2. 1 min withstand
Cabinet 3. Paint shade & Thickness and speci- 3. As per approved drawing
4. Wiring routing check fication 4. Firm and aesthetic
5. Functional Check 5. As per approved drawing
6. Verification of BoQ 6. As per approved drawing
* Category of Responsibility: P - Actual Test Performance V - Verify and Accept W - Witness Actual testing, verify and accept
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172
Sr. Item/Components List of Tests Sampling Reference / Acceptable Value Category of Reponsibility*
No. rate Standard
Sub Manuf- Customer
Vendor acturer
14 Air cell (Flexi Air 1. Make, Visual & Dimensions 100% IS 3400 1. As per approved deawing P P --
Separator) 2. Pressure test at 0.105 Kg/cm2 2. No leakage for 24 hours
3. 10 times inflation and deflation test at 3. No deformation
0.105 Kg/cm2
15 Roller Assembly 1. Visual & Dimensions. One sample IS 8500 1. Free from surface defect P V --
2. Mech. Properties & Chemical per melt/ 2. For shaft as per MS EN8, BS 970-1
composition of raw material used for heat For roller wheel of cast iron IS 210
shaft & roller forging treatment For roller wheel of Cast steel IS 1030
batch
POWER TRANSFORMER - STANDARDISATION MANUAL
16 Oil & winding 1. Type & make 100% -- 1. As per approved drawing P P --
Temperature 2. Calibration 2. ± 1.5% of FSD
Indicator 3. 2kV HV test for 1 min between 3. Withstand for 1 min
all terminals & earth 4. operation within ± 2° C of setting
3. Switch contact operation test
17 Pressure Relief 1. Type & Make 100% IS 2500 1. As per approved drawing & free from defect P P --
Device 2. Operating air pressure 2. No leakage
3. Switch/contact testing 3. Satisfactory operation at pressure release
4. HV test 4. 2 kV withstand for 1 min
18 Magnetic Oil Level 1. Type & make 100% -- 1. As per approved drawing & free from defect P P --
Gauge (MOG) 2. Dial Calibration for level 2. Check pointer position for Max, Min and
3. 2kV HV test for 1 min between center level
all terminal & earth 3. Withstand for 1 minute
4. Leak test 4. No leakage at 4 kg/cm2
5. Switch/contact operation test 5. Operate at Min level indication
19 Valves 1. Type, make & Visual 100% IS 778 1. As per approved drawing & free from defect P P --
2. Leakage test/ Seepage test 2. No leakage
20 Transformer Oil Routine Test as per IS 335 100% IS 335 As per IEEMA specification (see Chapter 6) P V V
IEC 60296
* Category of Responsibility: P - Actual Test Performance V - Verify and Accept W - Witness Actual testing, verify and accept
Sr. Item/Components List of Tests Sampling Reference / Acceptable Value Category of Reponsibility*
No. rate Standard
Sub Manuf- Customer
Vendor acturer
21 Tank & Accessories 1. Check for a fit up for butt 100% CBIP 1. Check for proper welding P P --
welds on tank walls, base & manual
cover 2013
2. DP test on Butt welds after fit 2. Check for proper welding
up & load bearing welds
3. Visual & Dimensional check 3. Free from defect
after final welding
4. Air leakage test on assembled tank with 4. No leakage
turrets & on conservator
5. Visual check of paint shade, 5. Paint thickness
paint film thickness & film Outside: 155 micron
adhesion Inside : 30 micron
No peel-off
6. Tank - one per CBIP 6.1) Twice the normal head + 30 KN/m2 for 1 hr. P W W
6.1 Presseure test design manual Withstand
6.2 Vaccum test 2013 6.2) 760 mm of Hg for 1 hr. withstand
22 Radiators 1. DP test on lifting lugs 100% IEEMA 1. No welding defect P W W
2. Surface cleaning of header standard 2. Free from surface defect
support and bracing details by
sand/shot blasting
3. Air pressure test on elements 3. As per relevent standards /CBIP
4. Dimensional check after final 4. As per approved drawing
welding
5. Air pressure test on radiator 5. 2 kg/cm2 for 30 minutes - no leakage
assembly
6. Visual check of paint shade, 6. As per tech spec, coating thickness more
paint film thickness & film than 70 micron
adhesion
23 OLTC 1. Auxiliary circuit insulation test at 2kV for 100% IEC 60214 1. To Withstand for 1 min P P V
1min.
2. Function test on OLTC 2. Satisfactory working as per drawing
approved
3. Pressure test on divertor switch oil 3. No leakage
compartment
4. Mech. Operation test 4. Satisfactory operation for 1 complete cycle
5. Sequence test 5. Switching time within permissible limit
6. Visual & Dimentional check 6. Free from defects
7. Operational test on Surge relay 7. Satisfactory working of trip & reset
* Category of Responsibility: P - Actual Test Performance V - Verify and Accept W - Witness Actual testing, verify and accept
POWER TRANSFORMER - STANDARDISATION MANUAL
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174
Sr. Item/Components List of Tests Sampling Reference / Acceptable Value Category of Reponsibility*
No. rate Standard
Sub Manuf- Customer
Vendor acturer
24 Cooling Fans 1. Type & Make 100% IS 2312 1. As per approved drawing P P V
2. Power consumption, rating test 2. As per approved drawing
3. HV test 3. 1.3 kV for 1 min or 1.8 kV for 5 sec
4. Insulation resistance value 4. 10 MΩ min with 500 V DC megger
25 Nitrile Rubber 1.Dimensions 1 sample/ BS 2751 1. Within tolerance P P --
Gasket 2.Shore Hardness Lot 2. 70 ± 5 IRHD
3.Tensile Strength 3. 12.5 N/mm2 min
4.Compression set test 4. 20% max
5. Elongation at break 5. 250% min
POWER TRANSFORMER - STANDARDISATION MANUAL
* Category of Responsibility: P - Actual Test Performance V - Verify and Accept W - Witness Actual testing, verify and accept
Sr. Item/Process Sampling rate Reference / Standard Acceptable Value Category of Reponsibility*
No.
Sub Vendor Manufacturer Customer
B In Process Inspection No of turns / disc
1 Lamination for core
Visual check One sample of -- Prime CRGO and Free from defect -- P V
each type
Dimensional check One sample of -- As per design drawings -- P V
each type
Check for burr One sample of -- Less than 20μn -- P V
each type
Edge bow One sample of IS 3024 As per IS 3024 -- P V
each type
2 Core Building
Visual check 100% -- Free from defect -- P W
Total stack height 100% As per design drawings within specified tolerence of design -- P W
Core Diameter 100% As per design drawings within specified tolerence of design -- P W
Leg Centre & Leg length 100% As per design drawings within specified tolerence of design -- P W
Assembly of limb Insulation 100% Design drawing As per design -- P V
& plates
Rectangularity of Core 100% Design drawing As per design -- P V
Assembly
Check for Overlaps & air gap 100% Design drawing As per design -- P V
at joints
Leaning of Core 100% Design drawing No leaning -- P V
Earthing of Core 100% Design drawing Proper connection -- P V
Limb Clamping & Binding 100% Design drawing As per design drawings -- P V
Insulation test between core 100% As per specification shall withstand 2 kV for 1 min -- P W
& core clamp / frame
Loss measurement on built 100% As per specification / GTP Within limit as per GTP -- P W
up core assembly.
3 Winding
Visual check for drum lable 100% As per design drawings Within limit as per design -- P V
and Conductor Size
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176
Sr. Item/Process Sampling rate Reference / Standard Acceptable Value Category of Reponsibility*
No.
Sub Vendor Manufacturer Customer
3 Nos of discs 100% As per approved drawings / As per Factory drawing -- P V
Factory drawing
No of turns / disc
Dimensional checks 100% As per approved drawings / As per Factory drawing -- P V
i) Outer diameter Factory drawing
ii) Inner diameter
iii) Unshrunk height
iv) Radial thickness
Brazing procedure and -- Customer approval As per approval -- P V
POWER TRANSFORMER - STANDARDISATION MANUAL
brazer's qualification
Visual inspection of brazed 100% As per brazing procedure As per approval -- P V
joints
Visual check for transposition 100% As per design drawings As per design -- P V
Insulation arrangement 100% As per design drawings As per design -- P V
Lead & coil indentification & 100% As per design drawings As per design -- P V
marking
Continuity test 100% -- No breaking of continuity -- P V
Inter-turn Insulation 100% As per design drawings As per design -- P V
4 Core Coil Assembly
Visual check for intercoil 100% -- As per design -- P W
insulation
Lead & coil indentification & 100% -- As per design -- P W
marking
Brazing / Crimping of Joints 100% -- Shall be smooth and no sharped age -- P W
Visual chek for completeness 100% -- Complete assembly shall be free from dust/ -- P V
and cleanliness particles
Ratio test 100% As per IS 2026 / IEC 60076 Tolerance as per standards -- P V
Magnetic balance test 100% As per IS 2026 / IEC 60076 Tolerance as per standards -- P V
Magnetizing current test 100% As per IS 2026 / IEC 60076 Tolerance as per standards -- P V
Alignment of Spacers/Blocks 100% -- Aligned -- P V
HV test 100% Mfgrs standard 2 kv for 1 min withstand -- P W
* Category of Responsibility: P - Actual Test Performance V - Verify and Accept W - Witness Actual testing, verify and accept
Sr. Item/Process Sampling rate Reference / Standard Acceptable Value Category of Reponsibility*
No.
Sub Vendor Manufacturer Customer
5 Connections and checks before tanking
OLTC fitting & connections 100% Manufacturer standard Manufacturer standard -- P ---
Check for cable sizes 100% As per design drawings As per design -- P V
Check for clearance from 100% As per design drawings As per design -- P V
tank walls
Visual checks for crimped 100% -- Shall be smooth and no sharped age -- P V
joint
Visual checks for bushing CT 100% -- Assembly tightness -- P V
assembly tightness
Ratio test 100% As per IS 2026 / IEC 60076 Tolerance as per standards -- P V
6 Tank
Thickness of walls 100% As per approved drawings As per approved drawings -- P V
Dimensions 100% As per approved drawings As per approved drawings -- P V
Pressure test 100% As per CBIP To withstand, permenat deflection shall not -- P W
exceed as per specification
Vacuum test 100% As per CBIP To withstand, permenat deflection shall not -- P W
exceed as per specification
7 Ovening, Tanking and Oil filling
Drying 100% Manufacturer standard Low voltage tan delta and PI values shall -- P V
be checked periodically and after achieving
the satisfactory values the process will be
declared complete
Checks for complete 100% Manufacturer standard As per design -- P V
tightness before tanking
a) Tightness of all joints /
screws
b) Application of thread
locking adhesive
c) Padding of top yoke
d) Pressing of active parts
e) Fitting of wall shunts &
packing
* Category of Responsibility: P - Actual Test Performance V - Verify and Accept W - Witness Actual testing, verify and accept
POWER TRANSFORMER - STANDARDISATION MANUAL
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178
Sr. Item/Process Sampling rate Reference / Standard Acceptable Value Category of Reponsibility*
No.
Sub Vendor Manufacturer Customer
7 Cleanliness of tank before 100% Manufacturer standard Shall be clean. -- P ---
tanking
Tanking of active parts and 100% As per design drawings As per design -- P V
check for clearance from
tank walls
2 kV HV test between 100% As per specification To withstand 2 kV for 1 min -- P V
(i) Core & end frame
(ii) Core & yoke bolts
(iii) End frame and yoke bolts
POWER TRANSFORMER - STANDARDISATION MANUAL
Check for oil qualtity before 100% As per specification As per specification -- P V
impregnation
Oil filling & Air release 100% Manufacturer standard Manufacturer standard -- P ---
Impregnation process 100% Manufacturer standard Sufficient impregnation time shall be given -- P ---
before conducting the electrical test on the
transformer
* Category of Responsibility: P - Actual Test Performance V - Verify and Accept W - Witness Actual testing, verify and accept
Sr. No. Test Description of Test Sampling rate Reference / Stan- Acceptable Value Category of Reponsibility*
dard
Manufacturer Customer
C Routine Tests 100% IS:2026 / IEC 60076 As per applicable
/ specification standard
1 Resistance of each winding. P W
2 Turn ratio for all sets of windings on each tap, with P W
percentage error / Voltage
3 Polarity and phase relationship (Vector group) P W
4 Impedance between each pair of winding / P W
Impedence Voltage
5 Excitation losses at 90, 100 and 110 % rated P W
voltage measured by the average voltmeter
method
6 Positive phase sequences impedance P W
measurement on three phase transformers
7 Regulation at rated load and unity, 0.9, 0.8 lagging P W
P.F.
8 Load losses, measured at rated frequency, by P W
applying a primary voltage sufficient to produce
rated current in the windings with secondary
windings short circuited
9 Separate source voltage with stand test. P W
As per applicable standard
12 SFRA test P W
13 Zero Sequence impedance test P W
14 Tests on tap-changer (IEC:214) P W
15 Tan delta & capacitance measurement test for P W
bushings and windings
16 Tests on transformer oil including DGA on selected P W
sample as per IS:9434/IEC:567, before and after
temp rise test and at final stage before dispatch.
Corrosive sulphur detection test as per ASTM
D1275 subjecting oil for 150oC for 48 hrs.
* Category of Responsibility: P - Actual Test Performance V - Verify and Accept W - Witness Actual testing, verify and accept
POWER TRANSFORMER - STANDARDISATION MANUAL
179
180
Sr. No. Test Description of Test Sampling rate Reference / Stan- Acceptable Value Category of Reponsibility*
dard
Manufacturer Customer
C 18 Tank leak test at 5 psi (35 kN/m2) for 12 hrs with P W
oil & 1 hr with air.
19 Magnetic Balance & current test on all winding P W
20 HV withstand test on auxiliary equipments and P W
wiring
21 Measurement of Insulation Resistance P W
22 Measurement of acoustic noise level
23 Measurement of harmonics of no load current
POWER TRANSFORMER - STANDARDISATION MANUAL
* Category of Responsibility: P - Actual Test Performance V - Verify and Accept W - Witness Actual testing, verify and accept
Sr. No. Test Description of Test Sampling rate Reference / Stan- Acceptable Value Category of Reponsibility*
dard
Manufacturer Customer
E Special Tests (Optional)
1 Degree of protection (IP55) for control cabinets IS 13947/IEC 60529: -- P W
& RTCC panel, OLTC driving mechanism, terminal 2001
boxes of PRV, MOG, Buchholz Relay, pump motors,
fans etc
2 Measurement of transferred surge in LV due to IS:2026 / IEC 60076 -- P W
Lightning impulse on HV & LV
3 Short Time Current withstand test on offered HV IS:5561 -- P W
and LV terminal connectors for 40 kA for 3 Sec for
220 kV & 132 kV Class and 25 kA for 3 sec for 66
kV & below class
F Packing & Dispatch - Main tank P --
1 Pipes and headers 100% P --
2 Radiators 100% P --
3 Verification of completeness of accessories 100% P --
4 Bushings 100% P --
5 Conservator tank 100% P --
Manufacturer’s Standard
* Category of Responsibility: P - Actual Test Performance V - Verify and Accept W - Witness Actual testing, verify and accept
POWER TRANSFORMER - STANDARDISATION MANUAL
181
182 POWER TRANSFORMER - STANDARDISATION MANUAL
POWER TRANSFORMER - STANDARDISATION MANUAL 183
Chapter - 5
CHAPTER - 5
INTRODUCTION
Considering main objectives of standardisation Manual, this chapter will cover important procedures, check points,
flow charts, suggestive tools-tackles, testing formats, etc. which are required for transport, storage, installation &
erection, testing and commissioning of power transformer for its good performance during operation.
Power transformers are usually very reliable, but it requires lot of care during all stages of its life & particularly during
transportation. If a transformer experiences any mechanical shocks more than suggested “g” level, damage that may
occur covers
§§ Displacement / distortion of windings or core
§§ Inter turn insulation damage due to movement of active part
§§ Loosening of winding clamps due to vibration
§§ Compromise safe clearances between tank & active parts
It is therefore required that transporter should take note of following transport restrictions.
§§ Axial load distribution
§§ Brake force distribution between tractor & trailer as per trailer manufacturer’s guide.
§§ Maintain proper ratio between the gross mass of the trailer and tractor
§§ Adhere to designated route.
§§ Avoid travelling during foggy, heavy rain, etc restricting ambient visibility to less than 500 meters.
§§ Actual survey & planned route
§§ Permissions
1] Modes of Transport
According to weight of Transformer to be transported, the size & capacity of Trailer, plinth size and mode of transport
can be standardised as below.
B Auto Transformers
C Generating Transformers
* Note: Weights are approximate and may vary from manufacturer to manufacturer
Mode of transportation may be rail, road or water. Depending on size of transformer, destination, delivery time &
route limitations the mode of transportation can be decided.
a) Rail Transport
Where the weight and dimension of main body exceed limits, special well wagons are employed. Detached parts
are packed/crated and normally dispatched along with main body of transformer so that all the parts are received
at the destination with unit. If the siding facility is not available either at loading or unloading end, mobile cranes
or railway cranes can be used for loading into wagons.
b) Road Transport
Multi axle tractor driven, low platform trailers are used for transporting transformers on roads. Transformers may
be transported by road, where well developed roads exist & the route conditions permit.
2] Selection of Trailer
Multi axle tractor driven low platform trailers are used for road transport. The tractors are to have adequate hauling
capacity and the trailers should have adequate loading capacity. There are two types of trailers available.
3] Capacity of Puller
Presently Pullers (figure 5.1) are available to pull loads from 1 to 240 MT.
Fig. 5.1
4] No. of Axles
No. of hydraulic axles of any transportable consignment can be determined in the following manner. One puller
carried load of the consignment on two hydraulic axles.
Weight of Goods that can be loaded (d) : (b-c) = (18 MT – 4.5 MT) = 13.5
In the up gradient of hills or roads extra puller of same rating shall be provided.
In down gradient of ghat section use power brake attached to the hydraulic modular trailer.
5] Route Survey
The route Survey Report is for safe and speedy transport of over dimensional / sophisticated consignments by
deployment of well suitable equipment, driver and escorts (both) with professional & technical expertise and
their rich experience is the answer of safe and speedy transport.
Based on the dimension and weight of the consignment extensive study is being carried out, first calligraphically
wherein most feasible routes for the transportation to the destination site is selected and there after exhaustive
field verification are carried out. After collection and compilation of massive data that was collected during the
route surveys, only the most feasible route is being selected and detailed report of Survey is being prepared.
Efforts to be made for best alternative solution while highlighting the problems that are anticipated for safe
and speedy transportation of over dimension / sophisticated consignment
188 POWER TRANSFORMER - STANDARDISATION MANUAL
6] Speed
For the normal running uniform speed of 10 to 20 kmph shall be maintained on good roads. For bad roads it is
desirable to run the vehicle at much lower speeds. However, while crossing bridge it shall be 5 kmph. No breaks
should be applied during bridge cross over. Movement of other vehicle should be stopped while crossing bridge.
Long before the approach to the bridge, the speed should be brought down and the vehicle allowed proceeding
over the bridge without creating any impact.
The brake system on the tractor-trailer has to be carefully operated whenever the vehicle is running with load.
Normally night travel is avoided except where it is restricted for heavy vehicles to travel in day time i.e. cities,
towns & small villages. Transportation should be avoided during heavy rains also. In the case of night halt or
stoppage of the loaded trailer for a fairly long duration the trailer should be supported either by sleepers or
providing supporting jacks on all sides thus releasing the load from the tyres. Danger lights should be displayed
in the front and rear of the vehicle.
The Supervisor should ensure that sufficient line clearance from line conductor to the top most part of transformer
and trailer is available as per IE Rules and as per the rating of transmission lines. The transportation during
monsoon period should be avoided as far as possible if sufficient clearances are not available. If it is found that
the clearances are critical, the hydraulic axle platform can be lowered by 250 to 300 MM as per the provision
made in hydraulic axle to avoid any danger of electrical faults.
2. Extra tyres
3. Hydraulic Jacks
4. Tools Box
5. Crow bar
6. Tarpaulin
9. Small Spares
10. Torch
All above should be equipped with helmet, safety shoes & hand gloves and Supervisor, Axle operator and Driver are
with suitable communication facility.
12] Movement
A pilot vehicle with all tools and tackles, jacks, sleepers, chequered plates, crowbars, etc., and sufficient trained
staff should run in front of the vehicle. Red flags and danger lamps should be exhibited at prominent places to
warn traffic on the route.
The branches of avenue trees that are likely to foul the equipment should be cleared while the load is moved.
Electric utility power lines likely to foul should be switched off and lifted temporarily / dismantled while the load
is moved.
After moving the load for a short distance, tightness of the lashing should be checked.
Fig. 5.2:
190 POWER TRANSFORMER - STANDARDISATION MANUAL
All the transformer unloading and handling work should be carried out and supervised by specialized people,
following all safety rules and using supporting points indicated on drawing. The use of any other points will result
in severe damages to the transformer.
d) After checking of exact position of transformer, the following sequence should be followed
i Install all wheels to transformer using hydraulic jacks sized for at least 50% of the units weight.
ii Before resting the wheels into groove, make sure all of them properly adjusted.
iii Lower the transformer with the help of the hydraulic jacks until it remains resting on the bottom of the
groove. Never allow the transformer to remain inclined.
Fig. 5.3:
1 Erection
Erection of power transformer requires great deal of planning and arrangement of resources. It is essential to
have erection agency with skilled manpower having experience of EHV class power transformer. Each and every
192 POWER TRANSFORMER - STANDARDISATION MANUAL
unit is to be treated like a project, so that cost, quality and time are controlled and monitored through a process
(Flow chart - see Fig. 5.4). It will ensure that erection activities are carried uninterrupted with safety and without
any damage to transformer parts / items.
It is suggested to have kick off meeting (KoM) with following main agenda:
1. Competency of erection agency and their manpower skills.
2. To confirm receipt of transformer as per BOQ in full shape
3. To confirm availability of T&P as per requirement of unit, size and rating. (Refer list as per this manual)
4. To confirm readiness of plinth and radiator foundation as per requirement (Physical check of dimensions)
5. To confirm over head conductor take off or power cable terminations arrangement as the case may be.
6. To confirm safety measures adopted and location hazards, if any.
7. Organization reporting structure, data recording, responsibility and clearances.
8. To confirm insurance, workmen compensation and labor related statutory requirements.
9. Comply to specific requirements agreed in Design Review.
a) General T&P
The following tools and plants can be arranged during erection, overhauling activity at site.
1 Spanners :
a) Double end (size -32) 2 Set
b) Ring (size -32) 2 Set
c) Box/socket type (size 6-36) with a/2” drive complete with ratchet, universal, 2 Set
ordinary handle and extension bar of size 75mm and 150mm
8 Spanner for opening transformer butterfly valves (squre) 1 No. for each type of
valve
10 Screw Driver
a) 10mm (D0 x 400mm (L) 2
b) 10mm (D0 x 300mm (L) 2
c) 8mm x 300mm (L) 4
d) 8mm x 200mm (L) 4
e) 6mm x 250mm (L) Insulated 4
f) 6mm x 200mm (L) Insulated 4
POWER TRANSFORMER - STANDARDISATION MANUAL 193
194 POWER TRANSFORMER - STANDARDISATION MANUAL
18 Hammer - ½ kg 1 No.
2 kg 1 No.
5 kg 1 No.
22 Files.
a) Needle file 1 Set
b) Flat file 12” (rough & smooth) each one 2 Nos.
c) Half round 8” 1 No.
d) -do- 10” 1 No.
e) Round file 8” 1 No.
f) -do- 10” 1 No.
g) Triangular file 8” (rough & smooth) each one 2 Nos.
25 Scissors - 8” 1 no.
29 Measuring tape
a) 3 meter (flexi-measure) 2 Nos.
b) 15 meter (plastic) 1 No.
c) 30 meter (plastic) 1 No.
34 Plumb 1 No.
39 Crimping tool
a) Hand operated up to 16 sq. mm 1 No.
b) Hydraulic 1 No.
45 Drilling machine heavy duty along with drill chuck, sleeves and arbor 1 No.
Model NW 10, Make : Wolf
54 D Shackle
a) 2 T capacity 6 Nos.
b) 5 T capacity 4 Nos.
c) 10 T 4 Nos.
d) 20 T 4 Nos.
55 Bull dog clamp heavy duty suitable for 10mm, 12mm wire sling 5 Nos. each
57 Slings.
(a) 12mm dia. with standard loop on both ends having 6 mtr. length 4 Nos.
(b) 12mm dia. with standard loop on both ends having 10 mtr. length 2 Nos.
(c) 10mm wire rope length 100 mtr
(d) 32mm dia. with standard loop on both ends having 10 mtr. length 2 Nos.
(e) Wire rope slings double legged with ring at one end and hook at other end 2 Nos.
with 12mm roper of 4 mtr. length
196 POWER TRANSFORMER - STANDARDISATION MANUAL
58 Polypropylene rope
a) 6 mm 50 mtr
b) 12 mm 100 mtr
c) 16 mm 100 mtr
59 Welding machine with flexible welding cable, insulated electrode holder, 1 Set.
protective masc., chisel, chipping hammer, wire brush and leather gloves (model
RED-301 of Advani oerlicon Ltd)
b) Miscellaneous Items
5 Ladder (Aluminum)
(a) Self supporting ladder 1.8 mtr 2 Nos.
(b) -do- 3.6 mtr 1 No.
(c) extension ladder 4.8 mtr 2 Nos.
9 U-clamp for connecting OLTC chamber to main tank at the time of vacuum pulling 1 No.
12 Switch boards for extending supply having 15A/5Amp socket, bulb, holder & 3 Nos.
switch
14 Fire extinguisher
CO2 (22.5kg) 2 Nos.
Foam ( 9kg) 2 Nos.
Halon (3 kg) 2 Nos.
4 Vacuum pump 1
2. During hot oil circulation, keep fire extinguisher ready near transformer.
3. Carry out all pre-commissioning Test and final commissioning check as elaborated in this Manual before
energizing transformer.
4. Take precaution while handling PRV devices having heavy springs in compression to safeguard person and
system.
5. Replace N2 filled tank by breathable dry air of dew point less than (-40 oC) at least for 24 hours.
8. Oil spillage shall be inspected regularly and attended if any. Oil shall not be allowed to fall on ground.
9. Keep all combustible items away at safe distance to reduce risk of fire.
10. Welding on oil filled transformer may be avoided or done as per instruction of manufacturer only.
11. All erection personnel must use Personal Protective Equipments like, helmet, safety shoe, boiler suit, etc.
13. Electrical equipment like filter machine, dry air generator etc., must be earthed.
16. Cordon off the working area, particularly when transformer augmentation work in a switchyard is taken
up.
17. All major erection activity like bushing, conservator and radiators must be carried out with crane of ad-
equate capacity and boom size.
19. Safety posters, like “No Smoking”, “Wear Helmet”, etc., must be displayed.
20. Testing circuit and procedures are important to follow as per manual to avoid any induction effect before
and after the Test. Approved and tested Earth rods are essential for this purpose.
21. Safety Nodal Officer to make sure that site is cleared on daily basis to prevent fire hazards.
4 Precomissioning Tests:
§§ Site study
§§ Check whether the transformer under Test had been isolated from other electrical equipments and
from induction using earth switch or local earthing arrangement.
§§ Get the guidance of Dos and Don’ts from the experts in the field
§§ Ensure for all safety assessments of Helmets, Gloves and Safety shoes.
4.2 Following checks should be carried out before commencing the pre-commissioning Test of the Power
Transformer.
§§ Ensure that Power Transformer and its auxiliaries should be free from visible defects on physical
inspection
§§ Ensure that all fittings should be as per out line General Arrangement Drawing
§§ Ensure that bushings should be clean and free from physical damages
§§ Ensure that oil level in Main / OLTC Conservator tank in MOG is as desired.
§§ Ensure that OTI and WTI pockets are filled with transformer oil
§§ Ensure that cap in the tan delta measurement point in the bushing is grounded
§§ Ensure unused secondary cores of Bushing CT’s, if any, has been shorted
§§ Ensure CT secondary star point has been formed properly and grounded at one end only as per
scheme
§§ Ensure that Buchholz Relay is correctly mounted with arrow pointing towards conservator
§§ Ensure all cables and ferrules are provided with number as per cable schedule
§§ Ensure that external cabling from junction box to relay / control panel is completed
§§ Ensure indication of tap position on Diverter switch, Drive mechanism & RTCC are same.
12 Tests on bushing CT s Digital multi meter, CT primary current injection kit, Knee
point voltage measurement kit, Insulation resistance
tester
The transformer is considered to be a complex network of RLC components. The contribution to this
complex mesh of RLC circuit are from the resistance of the copper winding, inductance of the winding
coils and capacitance from the insulation layers between coils, between winding, between winding and
core, between core and tank, between tank and winding etc. (figure 5.5).
Fig. 5.5:
POWER TRANSFORMER - STANDARDISATION MANUAL 201
The test involves measuring the frequency response of each individual winding. The frequency is mea-
sured by injecting a sine wave signal with respect to earth at one end of winding to be tested and mea-
suring the signal amplitude there and at other end of winding. The attenuation (in db) of the transmit-
ted signal relative to reference signal at the input terminal is measured over a frequency range from 20
Hz to 2 MHz. SFRA is used to check the eventual change in the internal geometry of the active part of
the transformer whether displacement of deformation i.e. the mechanical integrity of the transformer.
Transformers while experiencing severity of short circuit current looses its mechanical property by way
of deformation of the winding or core. During pre-commissioning, this test is required to ascertain that
Transformer active part has not suffered any severe impact/ jerk during transportation.
SFRA Kit
Fig. 5.6:
Type of connections for the test (figure 5.7) and typical waveform (figure 5.8).
Fig. 5.7:
Fig. 5.8:
1. Feed the frequency signal from 20 Hz -2 MHz in the transformer R ph of the HV winding with
respect to the neutral (for star winding) and R ph of HV winding with Y ph of HV winding (for delta
winding).
2. Both the reference leads should be earthed properly.
3. Keep LV open ( including core)
4. Kit will receive the response of the impedance characteristic in the transformer.
5. Response will be plotted in logarithmic scaled graph.
6. Repeat the all procedures for other phases
Fig. 5.9:
Fig. 5.10:
1. Feed the frequency signal from 20 Hz -2 MHz in the transformer R ph of the LV winding with
respect to the neutral (for star winding) and R ph of HV winding with Y ph of LV winding (for delta
winding).
4. Kit will receive the response of the impedance characteristic in the transformer.
Fig. 5.11:
Fig. 5.12:
Fig. 5.13:
POWER TRANSFORMER - STANDARDISATION MANUAL 205
Fig. 5.14:
1. Feed the frequency signal from 20 Hz -2 MHz in the transformer R ph of the HV winding with
respect to the LV winding
2. Both the reference leads should be earthed properly.
3. Keep LV winding open
4. Kit will receive the response of the impedance characteristic in the transformer.
5. Response will be plotted in logarithmic scaled graph.
6. Repeat all the procedures for other phases
Test 3 H3-X3
Test 6 X3-H0X0
Test 9 Y3-Y2
Test 12 H3-H0X0
Test 15 H3-H0X0
Test 18 X3-H0X0
206 POWER TRANSFORMER - STANDARDISATION MANUAL
e) Acceptance Criteria
Test results should match with the factory results
(In general changes of +/- 3dB)
Equipment Detail:
HV-N side
10
11
12
13
14
15
16
17
POWER TRANSFORMER - STANDARDISATION MANUAL 207
IV-N side
Normal
LV side
Normal
HV-N side
10
11
12
13
14
15
16
17
208 POWER TRANSFORMER - STANDARDISATION MANUAL
IV-N side
Normal
LV side
Normal
HV-N side
10
11
12
13
14
15
16
17
POWER TRANSFORMER - STANDARDISATION MANUAL 209
IV-N side
Normal
LV side
Normal
a) b) c)
Fig. 5.15:
As seen in figure, the angle delta ’between the total current “Ir” and capacitive current “IC” allows
to make evaluation about the loss properties of the insulator.
The loss angle delta, depends heavily on the thick ness of the insulating material and surface
condition, structural property of the insulator, type of the material, (humidity, foreign materials/
particles, air gaps, etc. which cause ionization the insulating material).
210 POWER TRANSFORMER - STANDARDISATION MANUAL
The conditions which increase the power losses of the insulator also decrease the insulation
strength. For this reason, loss angle measurement is a very valuable criterion for evaluating the
insulation material at a defined operating frequency. Periodical measurements made during
operating are also important to show the general condition of the insulating material. In this way,
it is possible to gather information about aging of the solid insulating materials and degradation
of the oil.
The active loss of the measurement circuit can be calculated according to below equation:
(It is accepted that in very small angles, Cos delta will be equal to tan delta)
Capacitance, tan delta, active loss and Cos delta can be measured by bridge methods at defined
voltages or by a “power factor” (Cos delta) measuring instrument.
The measurement is made between windings and between the windings and the tank. During the
test, the temperature of the transformer should also be recorded and corrected in accordance
with the reference temperature.
The loss factor depends heavily on temperature. For this reason, in order to make comparisons
later, it has to be converted to reference temperature (for example 20 deg reference temperature)
by a coefficient.
Correction equation:
F20 = Ft / K
10 0.8
15 0.9
20 1
25 1.12
30 1.25
35 1.4
40 1.55
45 1.75
50 1.95
55 2.18
60 2.42
65 2.70
70 3.0
POWER TRANSFORMER - STANDARDISATION MANUAL 211
b) Connection diagram
Fig. 5.16:
For tan delta of bushings, connections are to be carried out in UST mode.
For tan delta between windings, connections are to be carried out in UST mode.
For tan delta of windings with earth, connections are to be carried out in GST mode.
1. Short all the three phases of HV winding and make the zero sequence impedance. In other
words, make the current flow only in capacitance region (Omit inductance) in the impedance
network of the transformer.
212 POWER TRANSFORMER - STANDARDISATION MANUAL
3. Select the test mode GST-G for capacitance measurement in between windings and GST-YG
for capacitance measurement in between windings.
3. Apply 10 kV voltage in the stepwise manner and cross check the values in all step voltages.
4. Note the measurement values of applied voltage, leakage current, power factor and
dissipation factor, capacitance, humidity and ambient temperature.
Fig. 5.17:
Fig. 5.18:
1. Short all the three phases of HV and LV winding and make the zero sequence impedance.
In other words, make the current flow only in capacitance region (Omit inductance) in the
impedance network of the transformer.
3. Select the test mode UST-YG for capacitance measurement in between tank and winding.
4. Apply 10 kV voltage in the stepwise manner and cross check the values in all step voltages.
6. Note the measurement values of applied voltage, leakage current, power factor and
dissipation factor, capacitance, humidity and ambient temperature.
Fig. 5.19:
1. Short all the three phases of LV winding and make the zero sequence impedance. In other
words, make the current flow only in capacitance region (Omit inductance) in the impedance
network of the transformer.
2. Make HV cable connection at LV terminals and LV cable at Neutral terminals. (Ground should
be isolated). If it is delta connection then LV cable connection to be made in next phase.
3. Select the test mode GST-G for capacitance measurement in between windings and GST-YG
for capacitance measurement in between windings.
4. Apply 10 kV voltage in the stepwise manner and cross check the values in all step voltages.
5. Connections of the leads to be carried out as per diagram
6. Note the measurement values of applied voltage, leakage current, power factor and
dissipation factor, capacitance, humidity and ambient temperature.
Fig. 5.20:
214 POWER TRANSFORMER - STANDARDISATION MANUAL
1. Short the all three phases of LV and HV winding and make the zero sequence impedance.
In other words, make the current flow only in capacitance region (Omit inductance) in the
impedance network of the transformer.
2. Make HV cable connection at LV terminals and LV cable at HV terminals.
3. Select the test mode UST-YG for capacitance measurement in between tank and windings.
4. Apply 10 kV in the stepwise manner and cross check the values in all step voltages.
5. Connections of the leads to be carried out as per diagram
6. Note the measurement values of applied voltage, leakage current, power factor and
dissipation factor, capacitance, humidity and ambient temperature.
Fig. 5.21:
POWER TRANSFORMER - STANDARDISATION MANUAL 215
Test equipment
2 KV
HV-IV/ LV UST
10 KV
2 KV
HV-IV/ LV+G GST
10 KV
2 KV
HV-IV/ LV with
GSTg
Guard
10 KV
2 KV
LV/ HV-IV UST
10 KV
2 KV
LV/ HV-IV+G GST
10 KV
2 KV
LV/ HV-IV with
GSTg
Guard
10 KV
2 KV
1U UST
10 KV
2 KV
1V UST
10 KV
2 KV
1W UST
10 KV
2 KV
2U UST
10 KV
2 KV
2V UST
10 KV
2 KV
2W UST
10 KV
216 POWER TRANSFORMER - STANDARDISATION MANUAL
0.5 KV
3U
1.0 KV GST
0.5 KV
3V GST
1.0 KV
0.5 KV
3W GST
1.0 KV
f) Acceptance Criteria
To determine
a. Any abnormality in tapings in the winding
b. Any abnormality in the winding
c. Result ensures the inductance property of the transformer
Fig. 5.22:
The total voltage induced into the secondary winding of a transformer is proportional to the
number of turns in the primary to the number of turns in the secondary, and by the amount of
voltage applied to the primary.
e) Test Equipment
7
218 POWER TRANSFORMER - STANDARDISATION MANUAL
10
11
12
13
14
15
16
17
Ratio HV/LV
Ratio IV/LV
g) Acceptance Criteria
The variation of result should be within ± 0.5 % from specified values.
e) Equipment
Test equipment
HV/IV
10
11
12
13
14
15
16
17
220 POWER TRANSFORMER - STANDARDISATION MANUAL
(b) HV/LV
(c) IV/LV
g) Acceptance Criteria
Fig. 5.23:
POWER TRANSFORMER - STANDARDISATION MANUAL 221
f) Test Equipment
1U-1N 1U 1U 1U
1V-1N 1V 1V 1V
1W-1N 1W 1W 1W
2U-2N 2U 2U 2U
2V-2N 2V 2V 2V
2W-2N 2W 2W 2W
h) Acceptance Criteria
§§ Excitation current < 50 mili-Amperes, then difference between two higher currents should be less
than 10%.
§§ Excitation current > 50 mili-Amperes, then difference between two higher currents should be less
than 15 %.
§§ Value of center leg should not be more than either outside for a three phase reactor.
§§ Results between similar single phase units should not vary more than 10%.
Fig. 5.24:
f) Test Equipment
1U-1N
1V-1N
1W-1N
IV side (Tap N)
LV side (Tap N)
3U-3V
3V-3W
3W-3U
h) Acceptance Criteria
§§ The identical results confirm no damage due to transposition.
§§ Zero voltage or very negligible voltage induced in any of the other two phases shall be
investigated.
§§ The applied voltage may be expressed as 100% voltage and the induced voltage may be expressed
as percentage of the applied voltage. This will help in comparison of the two results when the
applied voltages are different.
§§ The voltage induced in the centre phase shall be 50 to 90% of the applied voltage.
§§ However, when the centre phase is excited then the voltage induced in the outer phases shall be
30 to 70% of the applied voltage.
§§ Zero voltage or very negligible voltage induced in the other two windings should be investigated.
Fig. 5.25:
2R1-N=2Y1-N=2B1-N=Constant
2R1-1B1=3R1-N>3Y1-N>3B1-N
3Y1-1B1>3Y1-1Y1
e) Test Equipment
Rn
Nn
RN
POWER TRANSFORMER - STANDARDISATION MANUAL 225
Bb
Yy
By
bY
g) Acceptance Criteria
Verify that all arithmetical relations are maintained as in the above formula as per the vector group of
transformer
Rated full load current to flow through this winding when secondary winding is shorted, is known as
impedance voltage
Fig. 5.26:
1. Connect the 3 ph 440 V supply to the HV winding and short the 3 phase of LV winding.
3. Carry out the test on min., normal and max. Tap positions.
226 POWER TRANSFORMER - STANDARDISATION MANUAL
f) Test Equipment
HV/IV (Tap 1)
1U-1V 1U 2U
1V-1W 1V 2V
1W-1U 1W 2W
HV/LV (Tap N)
IV/LV (Tap N)
2U-2V 2U 3U
2V-2W 2V 3V
2W-2U 2W 3W
POWER TRANSFORMER - STANDARDISATION MANUAL 227
Tap no. Average S/C Average Voltage measured Impedance voltage % Impedance
current on LV side for S/C current on HV side voltage
13
17
Tap no. Average S/C cur- Average Voltage measured Impedance voltage % Impedance
rent on LV side for S/C current on HV side voltage
Tap no. Average S/C Average Voltage measured Impedance voltage % Impedance
current on LV side for S/C current on HV side voltage
h) Acceptable Criteria
The measured impedance voltage should be within 3 percent of impedance specified in rating and
diagram nameplate of the transformer.
Variation in impedance voltage of more than 3% should be considered significant and further
investigated
Kelvin bridge technique was adopted in the way of modern digital micro processor method for measur-
ing the winding resistance. Voltage drop is proportional to the winding resistance by injecting the DC
current. Voltage drop across the winding terminal in the phase is in the following manner
Fig. 5.27:
15. Take the winding temperature reading while doing the resistance measurement.
f) Test Equipment
Temperature reading
Temp.- deg C
OTI
WTI
(a) HV-N
10
11
12
13
14
15
16
17
230 POWER TRANSFORMER - STANDARDISATION MANUAL
(b) IV-N
(c) LV
h) Acceptance criteria
All readings should be within +/- 1% of each other.
There should be even increase or decrease of resistance value for the winding having tapping winding
for all three phase
Fig. 5.28:
POWER TRANSFORMER - STANDARDISATION MANUAL 231
b. LV/E + HV Shorted
Fig. 5.29:
Fig. 5.30:
f) Test Equipment
Temp.- deg C
OTI
WTI
Amb.
232 POWER TRANSFORMER - STANDARDISATION MANUAL
HV to E
LV to E
HV to LV
h) Acceptance Criteria
Min. insulation values for one minute resistance for transformer
R=C*E/ (KVA) ^0.5.
Where,
C=1.5 for oil filled Tr at 20oC.
E= Voltage rating in V (Ph-Ph for delta and Ph-n for Y)
KVA= Rated capacity of the Tr.
As per CBIP guideline, acceptable value is 2 Mega Ohm per KV at 60 oC
Rated voltage Recommended accepted limit as a thumb rule as per CBIP guideline Min IR
Value for 1 min. at 30 deg
11 KV 300 M Ohm
33 KV 550 M Ohm
66 KV 625 M Ohm
1.0-1.1 Poor
1.1-1.25 Fair
1.25-2.0 Good
>2.0 Dry
>3 Not good (Poor impregnation of oil in insulation paper, charging current is still
increasing and not steady state)
POWER TRANSFORMER - STANDARDISATION MANUAL 233
To check that core is not earthed other than the specific earth point.
e) Test Equipment
60 Sec
CC-CL
CL-G
CC-G
g) Acceptance Criteria
4. Carry out the Test and take reading at which oil insulation break down
7. Oil sample to be collected from bottom of the main tank and to be sent to ERDA to carry out tests
as per IS 1866
8. Oil sample to be collected from bottom of the main tank and to be sent to ERDA to carry out tests
for DGA
d) Test Equipment
OLTC tank
f) Acceptance Criteria
Sr. no. Particular Accepted norms at the time of first charging As per Standard
Sr. no. Particular Accepted norms at the time of first charging As per Standard
POWER TRANSFORMER - STANDARDISATION MANUAL 235
F Resistivity
M Oxidation stability of
uninhibited oil
If BDV value is very low and unacceptable (<30 KV/2.5 mm gap), then it is necessary to dry out & clean
the oil till the insulation reaches the satisfactory value.
Rated parameters
Core - I
Core - II
Core - III
Core - IV
236 POWER TRANSFORMER - STANDARDISATION MANUAL
A. Polarity Test
c) Test Equipment
CORE BETWEEN HV
CORE BETWEEN LV
e) Acceptance Criteria
All CT secondary polarity should be as per name plate
c) Test Equipment
(a) HV R
(b) HV Y
(c) HV B
(1S1-1S3) 20%
(2S1-2S3) 20%
(3S1-3S3) 20%
(4S1-4S3) 20%
(d) HV N
(1S1-1S3) 20%
(2S1-2S3) 20%
(3S1-3S3) 20%
(4S1-4S3) 20%
(e) IV R
(1S1-1S3) 20%
(2S1-2S3) 20%
(3S1-3S3) 20%
(4S1-4S3) 20%
POWER TRANSFORMER - STANDARDISATION MANUAL 239
(f) IV Y
(1S1-1S3) 20%
(2S1-2S3) 20%
(3S1-3S3) 20%
(4S1-4S3) 20%
(g) IV B
(1S1-1S3) 20%
(2S1-2S3) 20%
(3S1-3S3) 20%
(4S1-4S3) 20%
(h) IV N
(1S1-1S3) 20%
(2S1-2S3) 20%
(3S1-3S3) 20%
(4S1-4S3) 20%
e) Acceptance Criteria
Ratio error should match with factory results
240 POWER TRANSFORMER - STANDARDISATION MANUAL
C. Excitation Current
c) Test Equipment
i. HV R
0.25 x KVp mA
0.50 x KVp mA
0.75 x KVp mA
1.00 x KVp mA
1.10 x KVp mA
ii. HV Y
0.25 x KVp mA
0.50 x KVp mA
0.75 x KVp mA
1.00 x KVp mA
1.10 x KVp mA
POWER TRANSFORMER - STANDARDISATION MANUAL 241
iii. HV B
0.25 x KVp mA
0.50 x KVp mA
0.75 x KVp mA
1.00 x KVp mA
1.10 x KVp mA
iv. HV N
0.25 x KVp mA
0.50 x KVp mA
0.75 x KVp mA
1.00 x KVp mA
1.10 x KVp mA
v. IV R
0.25 x KVp mA
0.50 x KVp mA
0.75 x KVp mA
1.00 x KVp mA
1.10 x KVp mA
vi. IV Y
0.25 x KVp mA
0.50 x KVp mA
0.75 x KVp mA
1.00 x KVp mA
1.10 x KVp mA
242 POWER TRANSFORMER - STANDARDISATION MANUAL
vii. IV B
viii. IV N
0.25 x KVp mA
0.50 x KVp mA
0.75 x KVp mA
1.00 x KVp mA
1.10 x KVp mA
e) Acceptance Criteria
Excitation current should not be more than specified on name plate.
10 % increase in the voltage from 100 % to 110 %, increase in current should not be more than 50%
c) Test Equipment
Earth - Core I MΩ
Earth - Core II MΩ
Earth - Core IV MΩ
Earth - Core I MΩ
Earth - Core II MΩ
Earth - Core IV MΩ
Core I - Core II MΩ
Core I - Core IV MΩ
Core II - Core IV MΩ
Core I - Core II MΩ
Core I - Core IV MΩ
Core II - Core IV MΩ
e) Acceptance Criteria
To check any open of any CT secondary core including pilot wires up to C & R panel
1. Connect multi meter across each core and check continuity up to Tr MK box and up to remote
protection panel end.
2. Carry out test for all cores of all HV and IV CTs
c) Test Equipment
Core - I 1S1-1S2
1S1-1S3
Core - II 2S1-2S2
2S1-2S3
3S1-3S3
Core - IV 4S1-4S2
4S1-4S3
Core - I 1S1-1S2
1S1-1S3
Core - II 2S1-2S2
2S1-2S3
3S1-3S3
Core - IV 4S1-4S2
4S1-4S3
e) Acceptance Criteria
c) Test Equipment
Core - I 1S1-1S2 Ω
1S1-1S3 Ω
Core - II 2S1-2S2 Ω
2S1-2S3 Ω
3S1-3S3 Ω
Core - IV 4S1-4S2 Ω
4S1-4S3 Ω
Core - I 1S1-1S2 Ω
1S1-1S3 Ω
Core - II 2S1-2S2 Ω
2S1-2S3 Ω
3S1-3S3 Ω
Core - IV 4S1-4S2 Ω
4S1-4S3 Ω
e) Acceptance Criteria
A. Temperature Indicators
The function of temperature indicator is to monitor and control the temperature of oil and winding in
the transformer. There are two types of temperature indicators.
1. Winding temperature indicator in each winding
2. Oil temperature indicator
In WTI the first to check the working of cooler control, alarm and trip signal
30 4.0
40 5.3
60 8.0
80 10.7
100 13.3
120 16.0
140 18.7
POWER TRANSFORMER - STANDARDISATION MANUAL 247
The function of MOG is to indicate the continuous level of oil inside the transformer on a calibrated
dial.
The calibrated scale having three markings: Low, 35 deg fill level and High.
It should show 35 deg (normal level) of oil in the tank
Procedure
Check the normality open and normality close contacts by lifting the pressure valve
F. Tests on OLTC
5. Check the over load device of driving motor by measuring the current
OK Not OK
1. Check the normality open and normality close contact by following steps
2. Close the conservator flow valve and tank flow valve which is present in the conservator pipe line
3. Drain the oil which is present in between the two valves
4. Ensure the contact change by using the multi meter in two steps alarm and trip
5. After closing the drain knob in buchholz relay then close the conservator valve first and close tank
valve
To measure value of earthing pit resistance and verify that, fault current has minimum resistance to
ground
There is hand operated D.C.generator. While feeding current to spike, D.C. current is converted into
A.C. current by the converter and A.C. current received from spike is again converted in D.C. current by
the help of rectifier, while going to generator. A.C. current is fed to the spike driven in earth because
there should not be electrolytic effect.
Earth tester
POWER TRANSFORMER - STANDARDISATION MANUAL 249
Fig. 5.31:
f) Test Equipment
Body earth 2
HV Neutral earth 1
HV Neutral earth 2
LV Neutral earth 1
LV Neutral earth 2
h) Acceptance Criteria
Value of earth pit resistance should be less than or equal to 1 ohm.
250 POWER TRANSFORMER - STANDARDISATION MANUAL
7 Fan failure
11 Differential relay
19 Over flux
a) Acceptance Criteria
Prove the tripping of associated breakers by actual operation of the various devices and relays as per
the schemes
c) Procedure
Direct measurement of resistance by using micro ohm meter
POWER TRANSFORMER - STANDARDISATION MANUAL 251
d) Test Equipment
Contact resistance R ph Y ph B ph
f) Acceptance Criteria
The value of contact resistance should not be more than 5 micro ohm per joint/ connector
4.3.17 Clearances
Particular Clearance
HV phase to phase
HV phase to earth
IV phase to phase
IV phase to earth
LV phase to phase
LV phase to earth
Particular Value
2 Documents regarding spares, equipment, O & M manuals etc are available at site for O YES NO
& M purpose.
It is important to ensure seamless, full and final integration of power transformer in a substation after
commissioning tests specified above. These checks are related to functional and operational conditions within
transformer elements as well as external interfaces so that transformer can perform successfully in a transmission
system.
1. All the test results of unit are verified and compared with factory results before commissioning.
3 Ensure external electrical clearance of conductor jumpers in the switchyard with transformer body, gantry,
column, jumpers, fire wall etc.
4. Ensure that tertiary winding terminals are insulated, when they are not used / connected to any system.
5. Ensure earthing of Neutral, main tank body, radiator frame structure, fans and motor.
6. Neutral earthing flat of suitable size must run through support insulator and connected to two separate
earthing pits which are in turn connected to main earth mat of switchyard.
7. Ensure that conductor jumpers connected to HV, LV and tertiary terminals are not tight and should have
the allowance for contraction. Also ensure that connectors are properly erected with tightness at bushing
terminal.
8. Ensure that R.Y.B designated terminals of transformer are matching with R,Y,B buses of switchyards on HV
and LV side.
11. In a transformer bank of three single phase units, ensure master- slave OLTC scheme.
12. In a transformer bank of three single phase units, ensure tertiary connection and protection scheme.
13. Ensure oil filling in conservator tank according to temperature scale in MOG and also ensure oil level in pris-
matic glass.
14. Ensure that all valves between main tank and radiator banks are opened.
16. Ensure that valve to conservator tank via Buchholz relay is open.
17. Ensure physical operation of local protections like Buchholz, PRV, Surge relay of OLTC etc.
18. Ensure OTI and WTI settings of fan & pumps operation, Alarm and Trip as per approved drawings. Fan and
pump operation shall be ensured locally and remotely.
POWER TRANSFORMER - STANDARDISATION MANUAL 253
19. Review and ensure protection scheme of power transformer with over all protection scheme at remote end
in control room.
§§ Differential Protection
§§ Restricted Earth Fault Protection.
§§ Over current and Earth fault protection.
§§ Over fluxing Protection.
§§ OTI & WTI- alarm and trap
§§ RTCC panel interface with protection system
§§ Local protection like Buchholz, PRV etc.
§§ Integration of on-line condition monitoring equipments.
20. Ensure the common earthing of tank, frame and core provided in transformer.
22. Ensure that cap in the tan delta measurement point in the bushing is put back.
23. Ensure Fire Protection System and oil drain valve operation before charging and commissioning.
24. Oil test results after filtration must be within specified limit.
25. Spares like bushings shall be tested and kept ready before charging and commissioning.
26. Allow minimum period of 24 hrs after filtration for oil temperature to settle down.
27. Ensure release of air from plugs provided on top of main tank, conservator and radiator headers.
28. Take charging clearance certificate from all erection agencies for removal of man, material and T&P from
site.
30. Ensure availability of oil in the breather cup in main tank/ OLTC tank.
32. Ensure door seals of Marshalling Box are intact and all cable gland plate’s unused holes are sealed.
33. Ensure change over operation of AC supply from source- I to source-II in local master control cubicle.
1. Initially charge the transformer under no load and keep it energize for 24 hrs.
2. Gradually load the transformer observing the noise, vibration, temperature rise, oil leakage etc.
4. Carry out Thermo vision scanning of HV/LV terminals and tank body.
5. Carry out DGA test of oil as per schedule given in flow chart of this manual
6. Hand over testing and commissioning records to operation staff along with O&M manual of OEM.
7. Ensure closure of project by clearing site in all respect particularly removal of temporary sheds, T&P, Oil and
handing over spares to customer as per contract.
254 POWER TRANSFORMER - STANDARDISATION MANUAL
POWER TRANSFORMER - STANDARDISATION MANUAL 255
Chapter - 6
Transformer Oil
CHAPTER - 6
TRANSFORMER OIL
INTRODUCTION
Transformer oil is like a blood in human body. Once power transformer is charged and commissioned, transformer oil
becomes a key element to monitor the healthiness of unit and DGA is one of the important tools to predict probable
fault developing in unit as well as analyse insipient trippings. In service, it is continuously performing the role of
insulation under electric stress and cooling medium.
In India, the production technology, sourcing of petroleum crude and chemistry have undergone drastic changes in
last 5 decades and today we have fairly good understanding of our requirement based on field experience.
Standardisation Committee thoroughly deliberated on various aspects and has come out with universally acceptable
data-sheet of transformer oil specification, which could be easily produced and will perform in Indian weather
conditions.
It is nevertheless, important to note that transformer oil alone can’t perform unless designer takes care of following
key points:
1. Design of cooling system to keep temperature rise under control.
2. Correct quantum of oil depending upon voltage and MVA rating of transformer.
3. To plug all probabilities of moisture ingress in transformer – Air-cell/ silica-gel breather/ Sealing System.
4. To confirm that oil does not react with any insulation material used in transformer.
5. Characteristics of oil for ageing must be studied in advance depending upon application of transformer in a
system.
6. To take feedback from users on similar oil provided to other units in past for similar application.
Data Sheet
As per Annexure - 6.I and testing of oil as per specified standard is mandatory.
Pre-Commissioning Checks
1. Mode of transport and method of supply is important. Manufacturers and customers have to mutually agree on
this. In case of bulk supply in tankers, due care is required to ensure that tanker is chemically neutral inside and
sealed firmly for final inspection at its destination. In case, it is supplied in drums, it is to be ensured during usage
that drum seal is intact.
2. Transformer oil received at site in tanker must be unloaded to another tank through filter machine only. Its BDV and
PPM value for water content must be verified to ascertain that there was no infringement during transportation.
3. Transformer oil received in drums must be stored on an elevated platform. Drums are to be horizontally placed
with its opening cap in middle.
4. Before filling oil in transformer through filter machine, it has to be filtered separately in oil tanks and ensure BDV
and PPM value.
5. During filtration, temperature of oil must remain within 60°C.
6. Excessive filtration of oil must be avoided. In case BDV and PPM values are not achieved within 7 days, check the
entire process thoroughly.
258 POWER TRANSFORMER - STANDARDISATION MANUAL
ANNEXURE 6.1
2 Density, gm/cm3
- at 29.5 0C maximum 0.89 IS: 1448 P16
- at 20 0C 0.895 ISO 3675 / ISO 12185
3 Kinematic Viscosity,
in CST (sqmm/sec)
ISO 3104
- at 40 0C, maximum 12
- at -20 0C, maximum 1800
7 Neutralization Value
Total acidity 0.01 IEC:62021-1 or 2
mg KOH/gm, maximum
10 Electric Strength
(Break down voltage)
New Untreated Oil 30 kV minimum (rms) IEC 60156
After treatment 70 kV minimum (rms)
Note:
1) In case utility decides to adopt uninhibited oil, only following change shall be applicable.
12 Oxidation Stability after 164 Hrs. @ 120 0C, maximum IEC 61125 (method C)
a) Total Acidity in mg KOH/gm maximum 1.2
b) Total sludge % by weight maximum 0.8
c) DDF at 90 0C 0.05
2) In case of inhibited oil, content of additives shall be monitored by user at regular intervals and if depletion is
observed below specified limit, corrective action shall be taken to prevent transformer risk in future.
3) P N A content shall be taken as finger print value by oil supplier and shown in acceptance test report.
4) When pour point (maximum) has been decided as (-30 0C), Lowest Cold Start Energizing Temperature shall
be (-20 0C).
260 POWER TRANSFORMER - STANDARDISATION MANUAL
POWER TRANSFORMER - STANDARDISATION MANUAL 261
Chapter - 7
Design Review
CHAPTER - 7
DESIGN REVIEW
1. INTRODUCTION
A design review is a planned exercise to ensure that both parties understand the application and the requirements
of the applicable standards and specification. It is the opportunity for both parties to scrutinize the proposed
design to ensure that the requirements will be met not only technical requirements but also those relating to
other aspects of the contract, like quality. The whole emphasis of a design review is directed at establishing
what is being provided is fit for purpose in all respects for the intended performance in service and that the
manufacturer uses proven materials, design tools, methodology and experience to assure the product will meet
this requirement, also in all respects.
Design reviews implies also to strengthen the relationship between the purchaser and manufacturer and a
good opportunity for the purchaser to better understand the technical capabilities of the manufacturer and for
the manufacturer to understand the need of their customers for the sake to have products adapted to their
needs. Hence the design review is a good opportunity to interchange experiences that can be used to propose
enhancements or betterments. For these reasons it is strongly advisable for the purchaser to have expert
transformer engineer(s) with them during the meeting.
A design review, initiated and chaired by the purchaser should be held for the purpose of conducting an in-
depth review of the ordered Power Transformer and to allow the purchaser to have a clear understanding of the
transformers design, manufacture and test including the likelihood of operating in service as intended.
The following are the pre-requisites for carrying out the design review:
2. Design review should be part of the tender inquiry and it becomes obligatory on the part of the customer
and manufacturer to ensure compliances with the contract specifications.
3. It is to be ensured that all stake holders are involved in the design review. The designer both mechanical
and electrical, ultimate user, production head and if possible, sub vendor also could be invited for the design
review. Agenda is to be prepared by customer and sent to manufacturer well in advance.
4. Review may include certain informations which are of proprietary nature. It is, therefore, desirable to have
mutual agreement between the purchaser and the manufacturer for the confidentiality of information.
5. It is important for the success of design review that both the purchaser and manufacturer are clear on the
requirements and well prepared to have open and frank sharing of information.
Both the purchaser and manufacturer must understand that following objectives are met during the design
review:
1. To ensure that there is a clear and mutual understanding of the transformer technical requirements accord-
ing to purchaser specification and applicable industry standards.
2. To understand the application and verify the system and project requirements and to indicate areas where
special attention may be required.
264 POWER TRANSFORMER - STANDARDISATION MANUAL
4. To identify any prototype features and evaluate their reliability and risks.
5. To interchange experiences that can be used to identify eventual betterments in the design and / or im-
provements and changes in the specification.
7. To strengthen the technical relationship between purchaser and manufacturer and eventually to improve
and go deep in the transformers design knowledge by some participant on the purchasers side.
Having understood the purpose of design review and objectives, it is important to know the various elements
of design review which will clear all the doubts about the functionality (application), soundness of designs with
margins, selection of material and components and also specific operating requirements for its designed life.
They are broadly as follows:
S. No. Elements
1. System data
2. Environmental data
3. Transformer parameters
4. Transformer design
6. Transformer oil
7. Fabrication
8. Testing
9. Name plate
10. Transportation
Design review guidelines of Cigre WGA2.36 (Technical brochure 204) have elaborated above elements in detail
as under:
2. Environmental Ambient temperature range, rate of change of temperature and effect on the overload
data capability
Lowest Cold Load Start-up (LCLS)
Solar radiation
Site altitude
Humidity
Pollution
Seismic zone and response spectra
Geomagnetic currents
Ultraviolet (UV) radiation
Isoceraunic level
4. Transformer Core
design Windings
Thermal design
The short circuit capability
Core, Winding Assembly and Drying
Leads and Cleats
Insulation Design
Leakage Flux Control
Drying and Processing
Sound Level
Seismic
5. Transformer Bushings
ancillaries and Bushing and Internal Current Transformers
accessories. Tap Changers
Internal Surge Arresters
Control Cabinet and External Cabling
Online Monitoring Equipment
12. Health and safety As per guideline and policy of customer. Also refer Chapter - 5 on Erection, Testing and
commissioning of this Manual.
Design review does not absolve or substitute manufacturer’s ultimate responsibility for the adequacy of transformer
design and construction, including design limits and margins, quality, performance on test and in service.
POWER TRANSFORMER - STANDARDISATION MANUAL 267
REFERENCES
The following list may be referred, but this is not a limitation on referring to other standards and codes as long as it
serves the purpose for effective design review.
IEC 60044: Current Transformers.
IEC 60050: International Electrotechnical Vocabulary – Chapter 421: Power Transformers and Reactors.
IEC 60060-1: General Definitions and Test Requirements.
IEC 60071-1: Insulation Coordination - Part 1: Definitions, Principles and Rules.
IEC 60071-2: Insulation Coordination - Part 2: Application Guide
IEC 60076-1: Power Transformers - Part 1: General.
A
400
10
10
1
1
XXX Transformer Pvt. Ltd.
315 MVA 400/220KV AUTO TRANSFORMER
REF. STANDARDS IS:2026
COOLING ONAN/ONAF/OFAF
PHASES. 3/3
(LV) MVA 63/84/105
2
VOLTAGE
LV V 33000 TAP NO.17 %
3
50°C at ONAN
OIL °C 55°C at ONAF/OFAF
GTD. TEMP. RISE MASS OF TOTAL OIL kg.
55°C at ONAN (WITHOUT 10% EXTRA OIL)
WDG °C 60°C at ONAF/OFAF
10% EXTRA OIL kg.
MAKER'S SR. NO.
TOTAL MASS kg.
YEAR OF MANUFACTURE
QUANTITY OF OIL IN OLTC Ltrs.
WORK ORDER NO. TRANSFORMER OIL QUANTITY Ltrs.
(WITHOUT 10% EXTRA OIL)
CUSTOMER
PO . NO. & DATE PAINT SHADE CHOICE
1U OLTC PRE H.V.
TAP M.V. L.V
CONECTION SELE- CURRENT(A)
POSN. VOLTAGE
IN EACH CTOR
600
4
1 13 - 12 440000 247.99 330.66 413.33
5
2U 2V 2W 14 13 - 7 375000 290.98 387.97 484.97
3W1S1
TV WTI
CT2W
CT1U
CT2U
CT1V
CT2V
CTN
N2S1 1U2S1 2U2S1 1V2S1 2V2S1 1W2S1 2W2S1 1W1S1-1W1S2-1W1S3-1W1S4
N2S2 1U2S2 2U2S2 1V2S2 2V2S2 1W2S2 2W2S2 CT1V
N2S3 1U2S3 2U2S3 1V2S3 2V2S3 1W2S3 2W2S3 1U2S1-1U2S2-1U2S3-1U2S4
1U2S4 2U2S4 1V2S4 2V2S4 1W2S4 2W2S4
N2S4
1W3S1
CT1W 2 500-1000-2000/1 PS - 2000 30 10 1V2S1-1V2S2-1V2S3-1V2S4 Differential
HV WTI 1W2S1-1W2S2-1W2S3-1W2S4
1W3S2
1 1 1 2U1S1-2U1S2-2U1S3-2U1S4
CT2U 1 500-1000-2000/1 PS - 2000 30 10 2V1S1-2V1S2-2V1S3-2V1S4 REF.
2W1S1-2W1S2-2W1S3-2W1S4
3 3 3 CT2V
4 4 2U2S1-2U2S2-2U2S3-2U2S4
4
5 5 5 CT2W 2 500-1000-2000/1 PS - 2000 30 10 2V2S1-2V2S2-2V2S3-2V2S4 Differential
TO OLTC
6 6 6 2W2S1-2W2S2-2W2S3-2W2S4
7 7 7
4 8 4 8 4 8 UN1S1-UN1S2-UN1S3-UN1S4
9 3 9 3 9 CTNBF
3 12 12 10 12 10 1 500-1000-2000/1 PS - 2000 30 10 VN1S1-VN1S2-VN1S3-VN1S4 REF.
10
11 11 11 BEFORE WN1S1-WN1S2-WN1S3-WN1S4
12 12 12
NEUTRAL UN2S1-UN2S2-UN2S3-UN2S4
13 13
6
6-Ø6 Holes.
7
A
J
ANNEXURE 7.1
TESTING
2 Turns ratio
4 Insulation resistances
5 Winding resistances
7 Capacitances
10 Zero-phase-sequence impedance
12 Audible sound
13 Temperature rise
20 Oil pressure
23 CT checks
24 RSO
26 Tap changer
28 Oil samples
29 Inventory
30 Contract documents
31 QA records
270 POWER TRANSFORMER - STANDARDISATION MANUAL
ANNEXURE 7.2
Contract Documents and Drawings for approval
5 Quality System
6 Quality Plan
7 Test Plan
9 Transport Plan
11 Method Statements
12 Risk Assessments
13 Training
14 Site Works
16 Site Tests