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ERECTION, COMMISSIONING,

OPERATION AND MAINTENANCE


MANUAL FOR
POWER TRANSFORMERS

PTRM : 0708
Page 1 of 205

ERECTION, COMMISSIONING,
OPERATION AND MAINTENANCE
MANUAL
FOR

TRANSFORMERS

AREVA T&D India Limited,


P.O. NAINI,
ALLAHABAD 211008 (U.P.)
INDIA

: +91 (532) 2697422 ~ 24


: +91 (532) 2697447 / 48
: +91 (532) 2697601 ~ 03
: +91 (532) 2697604/ 606

: +91 (532) 2696784

E-mail : customer-service.pti@areva-td.com
ISSUE/ REVISION
DATE

20/10/05

28/01/07

01/08/07

AREVA Confidential Information.


Must not be disclosed, copied or used for Manufacturing, Tendering or for any other purpose without prior written permission.

ERECTION, COMMISSIONING,
OPERATION AND MAINTENANCE
MANUAL FOR
POWER TRANSFORMERS

PTRM : 0708
Page 2 of 205

CONTENTS
Section

ISSUE/ REVISION
DATE

Description

Page

General

Transport, Packing & Despatch

18

Storage

26

Installation

34

Insulation Dryout at Site

57

Commissioning

59

Erection Checklists

64

Commissioning Checklists

68

Operation

79

10

Maintenance

81

11

Trouble Shooting

89

12

Reference Standards

102

13

Transformer Accessories:

114

20/10/05

(a)

Temperature Indicator

115

(b)

Gas & Oil Operated Relays

124

(c)

Condenser Type OIP Bushings

140

(d)

Silica Gel Breather

152

(e)

Oil Level Indicator

156

(f)

Pressure Relief Valve

161

(g)

Exhaust Fan

167

(h)

Flow Indicators

171

(i)

Transformer Oil Pump

184

(j)

Flexible Separator

192

(k)

Thermosiphon Filter

197

(l)

Oil to Water Heat Exchanger

200

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ERECTION, COMMISSIONING,
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MANUAL FOR
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PTRM : 0708
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MUST READ
THE FOLLOWING CLAUSES IN THIS MANUAL ARE OF
UTMOST IMPORTANCE AS REGARDS SAFETY AND HEALTH
OF THE PERSONNEL AND EQUIPMENT ARE CONCERNED.
HENCE, EVERY ONE INVOLVED IN THE ERECTION,

COMMISSIONING, OPERATION OR MAINTENANCE


OF THE EQUIPMENT SHOULD STUDY THE CONTENTS OF
THESE CLAUSES CAREFULLY BEFORE TAKING UP ANY OF
THE SAID ACTIVITIES.
Caluse1.2 on Pages 10 ~ 13

: (Health & Safety matters)

Clause 1.3 on Pages 14 ~ 17

: (Dos & Donts)

Clause 2.3 on Page 20

: (Lifting & Jacking)

Clause 3.0 on Pages 26 ~ 33

: (Receipt & Storage)

Clause 4.2 on Pages 38 ~ 39

: (Oil sampling & Filtering)

Clauses 4.5 ~ 4.8 on Pages 40 ~ 44

: (Erection Precuations)

Clause 4.2 on Page 56

: (Mixing of Transformer Oil)

Clause 6.0 on Page 51

: (Commissioning)

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ERECTION, COMMISSIONING,
OPERATION AND MAINTENANCE
MANUAL FOR
POWER TRANSFORMERS

1.0

PTRM : 0708
Page 4 of 205

GENERAL
Transformer is a static equipment, which converts electrical energy
from one voltage to another. As the system voltage goes up, the
techniques to be used for the Design, Construction, Installation,
Operation and Maintenance also become more and more critical.

If proper care is exercised in the installation, operation, maintenance


and condition monitoring of the transformer, it can give the user
trouble free service throughout the expected life of equipment which
is of the order of 25~35 years. Hence, it is very essential that the
personnel associated with the installation, operation or maintenance
of the transformer are thorough with the instructions provided by the
manufacturer.

This Manual contains general descriptions about Transformers &


specific details about the particular contract against which the
Transformer is supplied. Also, it contains instructions regarding the
safety aspects, erection, commissioning, operation, maintenance &
trouble shooting of large capacity Power Transformers.

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ERECTION, COMMISSIONING,
OPERATION AND MAINTENANCE
MANUAL FOR
POWER TRANSFORMERS

1.1

PTRM : 0708
Page 5 of 205

TRANSFORMER CONSTRUCTION
The techniques used in the design and construction of high voltage
transformers varies from manufacturer to manufacturer.

The active parts of the transformers consist of core and windings.


1.1.1

CORE
Core is manufactured from lamination of Cold Rolled Grain Oriented
Silicon Steel, which gives very low specific loss at operating flux
densities. Joints of the laminations are designed such that the
electromagnetic flux is always in the direction of grain orientation. The
core clamping structure is designed such that it takes care of all the
forces produced in the windings in the event of any short circuit.

1.1.2

WINDINGS
Windings are made from paper insulated copper conductors which are
transposed at regular intervals throughout the winding for ensuring
equal flux linkage and current distribution between strands.

Interleaved or shielded construction is adopted for the high voltage


windings to ensure uniform distribution of impulse voltages. Insulation
spacers in the winding are arranged such that oil is directed through
the entire windings for ensuring proper cooling.

1.1.3

COOLING
For ONAN/ONAF cooling, oil flows through the winding and external
cooler unit attached to the tank by thermo-syphonic effect.

For OF AF/OD AF/ OF WF cooling, the oil is directed through the


winding by oil pumps provided in the external cooler unit.

External cooler unit/units consists of pressed steel sheet radiators


mounted directly on the tank or separate cooler banks for air-cooled
transformers and oil to water heat exchangers for water cooled
transformers.

1.1.4

TANK & COVER


Tank and Cover are manufactured by welding steel plates and are
suitable for withstanding full vacuum and positive pressure test as per
CBIP Manual. For large capacity power transformers, the tank will be of
bell type construction. This is to avoid lifting of heavy core and
windings, which requires very large capacity crane at site. The weight
of upper tank will be much less in comparison with that of core &
windings and can be lifted by using a small capacity crane.

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ERECTION, COMMISSIONING,
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PTRM : 0708
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Construction of the tank and cover are such that pockets for water
collection is avoided.

The tank and cover are designed such that these can be transported
by railways/road/water as per customer specification.

Note:
Transformer tank is provided with two earthing terminals. While
earthing the cable box, busduct etc., it should be ensured that no
closed loop is formed because of multiple earthing connections.

1.1.5

CONSERVATOR
Conservator is provided to take care of the expansion and contraction
of transformer oil, which takes place during normal operation of the
transformer.

Wherever specified flexible separators or air cell if provided in the


conservator can prevent direct contact of air with the transformer oil.

A smaller oil expansion vessel is provided for the On Load Tap


Changer.

Magnetic oil level gauge is fitted on the main conservator which can
give alarm / trip in the event of the oil level falling below the pre-set
levels due to any reason.

1.1.6

PRESSURE RELIEF DEVICE


A device for avoiding high oil pressure build up inside the transformer
during fault conditions is fitted on top of the tank. The pressure relief
device allows rapid release of excessive pressure that may be
generated in the event of a serious fault. This device is fitted with an
alarm/trip switch.

The pressure relief device has a spring-loaded diaphragm, which


provides rapid amplification of its actuating force and will reset
automatically, as soon as the pressure inside the tank drops down to
the pre-set pressure.

A bright colour coded mechanical indicator pin in the cover moves with
the valve disc during the operation of the pressure relief device and is
held in position by an 'O' ring in the pin bushing. This pin is clearly
visible from ground level, which gives an indication that the device has
operated.

The indicator pin may be reset manually by pushing it downward until it


rests on the valve disc. The relief device is provided with a shielded
weatherproof alarm / trip and is operated by the movement of valve
disc.
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ERECTION, COMMISSIONING,
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MANUAL FOR
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PTRM : 0708
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For Small Capacity transformers, an explosion vent is provided with a


diaphragm, which will break in the event of abnormal increase in
internal pressure. Some times the explosion vent is provided with
double diaphragm such that the outer one remains intact even after the
inner one is ruptured. Rupturing of inside diaphragm can be checked
by viewing through the oil level gauge provided in between the
diaphragms.

1.1.7

GAS & OIL ACTUATED (BUCHHOLZ) RELAY


Gas and oil actuated relay is fitted in the feed pipe from the transformer
tank to the expansion vessel for collection of gas, if generated in the
oil. The relay operates on the fact that almost every type of fault in an
oil immersed transformer gives rise to generation of gas. This gas is
collected in the body of the relay, and is used to close the alarm switch.
In the event of any severe fault, the sudden increase in oil pressure
causes an oil surge towards the expansion vessel and this is used to
close the trip contacts. This oil surge will impinge on the flap fitted to
the trip element causing it to rotate about its axis and thus bringing the
mercury switch to the closed circuit position, which in turn operates the
tripping device.

In the event of serious oil loss from the transformer, both alarm and trip
elements operate in turn in the manner previously described for gas
collection.

Two brass petcocks are fitted at the top of the relay body, the outlets of
which are threaded to take a bleed pipe if required for collection of gas
samples.

In the pipe connection between On Load Tap Changer and its oil
expansion vessel a single float Oil Surge Relay is fitted. This relay
operates on the principle of oil surge impinging on a flap causing
operation of the mercury switch connected to the trip circuit. Gas
actuated alarm switch is eliminated because the gas generated during
normal tap changing operation will give unnecessary alarm.

1.1.8

SILICAGEL BREATHER
Expansion and contraction of oil cause breathing action. The silicageldehydrating breather absorbs any humidity in the air breathed. An oil
seal in the air intake prevents external moisture being absorbed when
no breathing occurs.

The breather container is filled with silicagel crystals. It is arranged


such that the air breathed must pass through it. The desiccant contains
blue and white crystals. When the silicagel is fully active, the blue
crystals will have a deep blue colour and changes to pink as it absorbs
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ERECTION, COMMISSIONING,
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MANUAL FOR
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PTRM : 0708
Page 8 of 205

moisture. When saturated with moisture and the charge contained


should be replaced. The gel removed from the breather may be
arranged for regeneration and preserved for future use.

The size of the breather is chosen such that it can operate effectively
over a period of six months approximately. The factors, which influence
the selection of size of the silicagel breather required for a particular
transformer, depend on many factors like, the oil quantity in the
transformer, the adsorption capacity of silicagel, the loading pattern
and the atmospheric conditions prevailing at site. The loading pattern
and the site conditions are difficult for the transformer manufacturer to
assess. Hence, the selection of breather is based on certain
assumptions and it is difficult to fix up a time schedule for the
regeneration of silicagel. It is advisable to have a periodic inspection
(say monthly) of the indicator so that the gel can be regenerated or
replaced as soon it is saturated with moisture.

1.1.9

WINDING TEMPERATURE INDICATORS


The winding temperature relay indicates the winding temperature of the
transformer and operates the alarm, trip and cooler control contacts.
This instrument operates on the principle of thermal imaging and it is
not an actual measurement.
Winding temperature indicator consists of a sensor bulb placed in oil
filled pocket in the transformer tank cover. The bulb is connected to the
instrument housing by means of two flexible capillary tubes. One
capillary is connected to the measuring bellow of the instrument and
the other to a compensation bellow. The measuring system is filled
with a liquid, which changes its volume with rising temperature. Inside
the instrument is fitted with a heating resistance which is fed by a
current proportionate to the current flowing through the transformer
winding.
The instrument is provided with a maximum temperature indicator. The
heating resistance is fed by a current transformer associated to the
loaded winding of the transformer. (The heating resistance is made out
of the same material as that of the winding) The increase in the
temperature of the resistance is proportionate to that of the winding.
The sensor bulb of the instrument is located in the hottest oil of the
transformer, therefore, the winding temperature indicates a
temperature of hottest oil plus the winding temperature rise above hot
oil i.e. the hot spot temperature.

1.1.10

OIL TEMPERATURE INDICATOR


The oil temperature indicator consists of a sensor bulb, capillary tube
and a dial thermometer, the sensor bulb is fitted at the location of
hottest oil. The sensor bulb and capillary tube are fitted with an

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ERECTION, COMMISSIONING,
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MANUAL FOR
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PTRM : 0708
Page 9 of 205

evaporation liquid. The vapour pressure varies with temperature and is


transmitted to a bourden tube inside the dial thermometer, which
moves in accordance with the changes in pressure, which is
proportional to the temperature.

1.1.11

BUSHINGS
The high voltage connections pass from the windings to terminal
bushings. Terminal bushings upto 36 kV class, 3150 Amps, are
normally of plain porcelain and oil communicating type. Higher current
rated bushings and bushings of 52 kV class and above will be of oil
impregnated paper condenser type. The oil inside the condenser
bushings will not be communicating with the oil inside the transformer.
Oil level gauge is provided on the expansion chambers of the
condenser bushings.
Oil in the condenser bushing is hermetically sealed and it should not be
disturbed in normal operation. Oil level may be checked regularly and
any oil leakage should be reported to the bushing manufacturer for
immediate attention.
While connecting the overhead transmission line conductor to the
bushing terminal, ensure that the line pull is limited to the cantilever
strength of the bushing. The cantilever strength of bushings as per IS:
2099 for various types of bushings are as shown below.
Rated
Voltage
(kV)
52
72.5 & 123
145 & 245
420

1.1.12

800
(Amps)
102
102
127
254

Cantilever Strength (kg.)


1000 ~ 1600 2000 ~ 2500
(Amps)
(Amps)
127
204
127
204
163
254
254
320

3150
(Amps)
320
408
408
510

TAP CHANGER
Tap changers of power transformer are specifically of two types1.
2.

On Load Tap changer


Off Circuit Tap changer

In the case of off circuit tap changer, the tap changing takes place only
when the transformer is de-energised, but in the case of on load tap
changers the tap changing takes place when the transformer is in
operation. The tap changer can be designed for changing the taps.
a.
Manually
b.
Automatically &
c.
From remote

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The On load tap changer will be a self-contained unit housed in the


main transformer tank. Since some amount of arcing takes place
during the switching operations from one tap to the other, the oil inside
the tap selector will deteriorate faster. Hence, this oil cannot be allowed
to mix with the oil in the main transformer. On load tap changer is
provided with a separate conservator and oil surge relay.
For details of construction and maintenance, please refer to the OLTC
supplier's manual attached with Specific Instructions at the end of this
manual.

1.1.13

CONTROL & MONITORING SYSTEM


Local control and monitoring of the cooler, tap changer and alarm and
trip indicators is carried out at the marshalling kiosk. Automatic control
of the tap changer is carried out at the remote control panel.

1.1.14

FIRE DETECTION & FIRE FIGHTING SYSTEM


It is recommended to always install suitable fire detection and fighting
system with all transformers. CBIP Manual prescribes guidelines for
the selection and installation of Fire Protection System.
Automatic Mulsifyre System or Drain and Stir System with nitrogen
injection inside the transformer are more prominent among the fire
fighting systems for large capacity Power Transformers. In the Drain
and Stir System, oil is partially drained from the transformer and
nitrogen gas is bubbled through the oil in the transformer tank to stir
and create a blanket of inert gas above the oil to quench the fire.
Owner of the Transformer has to ensure provision of requisite
Contacts/ Relays in his control panel as per requirement specified in
the Fire System Instruction Manual for connecting the Fire Detection
and Fire Fighting System.

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ERECTION, COMMISSIONING,
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1.2

PTRM : 0708
Page 11 of 205

HEALTH & SAFETY MATTERS


Even though the manufacturer of the transformer has put every effort to
comply with the rules and regulations applicable to the safe operation
of the transformer, the equipment described in this manual is safe to
use provided that:
It is installed in a location suitable for its designed purpose.
The installation is done by qualified and competent persons.
The installed equipment is operated and maintained in
accordance with the manufacturer's instructions by qualified and
competent persons familiar with the type of equipment involved
and its working environment.
All work is done competently and in accordance with good
engineering practices and in a manner, which is not hazardous
either to personnel or to equipment.
The recommended pre-commissioning checks are done before
energising the transformer.
The operation of protective systems and devices for the
transformer are checked regularly.
Neglect or deliberate overriding of protection system or device
could allow a minor problem to develop into a major problem
resulting in total loss of the transformer, damage to other
equipment and injury to personnel.
Prolonged operation under over load, over voltage or over
excitation condition can have a seriously detrimental effect on the
life of equipment. The pressure relief devices are designed to
eject liquid, which is likely to be very hot in the event of a fault
developing within the transformer.
Equipment such as pressure relief devices incorporates heavy
springs in compression. If the equipment is dismantled without
due safeguard, damage and /or injury may result.
The internal atmosphere of a transformer tank, if N2 filled, is
replaced by breathable dry air of dew point less than 400 C for
a minimum period of twenty four hours.

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ERECTION, COMMISSIONING,
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1.2.1

PTRM : 0708
Page 12 of 205

ELECTRICAL SAFETY
The following hazards are commonly associated with the installation,
operation and maintenance of electrical equipment

Existence of AC and DC voltage.

Possible existence of toxic hazards associated with material


used in the construction of electronic components, cleaning
agent and solvents.

Electric shock due to incorrect earthing, moisture on insulation,


bad engineering or working practices.

Fire or burn out due to incorrect setting or over load or protective


devices, incorrect cables or fuses, insufficient ventilation or
incorrect operating voltage.

Short circuit flash over due to dust or moisture on insulation or


short circuit on live conductors.

No work should be done to transformer or its associated


equipment unless it is disconnected from supply and all
terminals have been solidly earthed.

If the secondary of a current transformer is disconnected, a


dangerously high voltage can be induced in the circuit. If the
secondary circuit of a current transformer is to be disconnected
it must be shorted by a link capable of carrying the rated current.

Do not apply any voltage or even high voltage megger when the
equipment is under vacuum.

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ERECTION, COMMISSIONING,
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1.2.2

HAZARDOUS SUBSTANCES

1.2.2.1

TRANSFORMER OIL

PTRM : 0708
Page 13 of 205

Normally, transformer oil presents no hazard to health.


However, serious neglect may affect the skin and cause
irritation.
Oil is a hydrocarbon and will burn. Carbon dioxide, dry chemical,
foam or water fog is the extinguishants.

1.2.2.2

MERCURY
Mercury switches or thermometers containing mercury should
be handled carefully. Mercury vapour can be hazardous over a
period of time, especially in poorly ventilated room.

1.2.3

ENVIRONMENTAL HAZARDS DUE TO OIL SPILLAGE & FIRE


CONSEQUENT TO FAILURE OF TRANSFORMER AT SITE
Oil spillage from Transformer tank, bushing, pipe joints etc. may cause
the source of major fires. It is recommended that Transformer shall be
inspected daily for the oil spillage.
The general CBIP recommendations for the Transformer installation are:
a. Soak pits
b. Drain pits
c. Barrier walls
d. Fire detection system
e. Fire hydrant system
f. Fire mulsifyre system

1.2.3.1

CONTROL OF OIL SPILLAGE


Responsibility: Respective operator of Sub station
Keep a track of the maintenance schedule of Transformer & ensure
that the required routine & preventive maintenance are done as per
the schedule
On noticing any leakages from the Transformer immediately place a
tray /container to collect the spillage and inform the maintenance

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1.2.3.2

PTRM : 0708
Page 14 of 205

department for immediate corrective action (for example replacement


of gasket etc.). Oil shall not be allowed to fall on to ground.
In case any leakage to ground take place, remove the same with
cotton/cloth/ saw dust.
In case large scale spillage immediately inform the shift in charge &
start collecting the spilled oil to suitable container and assess the risk
of continuous operation of the Transformer

CONTROL OF FIRE
It is necessary to check the healthiness of the Transformer fire protection
system regularly so that the fire risk can be minimized
There shall not be any oil leakage.
During hot oil circulation in the Transformer keep fire extinguisher
ready near the Transformer, all the combustible materials shall be kept
at a safe distance.
Terminal connector, Fuses shall be checked against spark.
Condition of Transformer oil shall be checked regularly
Proper Housekeeping near Transformer may help to reduce the risk of
fire.
Proper fire fighting system as per CBIP recommendation shall be
installed near Transformer. Regular inspection & maintenance to be
done on the Fire fighting system.

1.2.3.3

PRECAUTIONS AGAINST FIRE

ISSUE/ REVISION
DATE

Welding on oil filled Transformer shall be carried out if unavoidable, as


per the instructions of the Manufacturer.

Hot oil circulation shall be carried out only under the round the clock
supervision to prevent chances of fire on lagging materials etc.

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1.3

PTRM : 0708
Page 15 of 205

DO'S AND DON'TS


FOR SAFETY MEASURES / PRECAUTIONS
Safety measures / precautions should be given top most priority during
inspection / erection / maintenance work. Any mishap during the
process will result in delay in erection, endangering human life,
endangering equipment life etc.

1.3.1

DO'S
Insulating oil and insulation of windings and connections are
inflammable. Watch for fire hazards.
Before entering inside the Transformer, replace Nitrogen gas
completely with air if it was transported with nitrogen gas inside.
Make sure that nothing is kept inside the pockets before one
enters inside the main unit. Also take off the wristwatches and
shoes.
List up all the tools and materials to be taken inside and check it
after coming out to make sure that no tools are left inside.
There must be a protective guard for lamp to be taken inside.
Keep inspection covers open for supply of fresh air when some
one is working inside.
When one person is working inside, second person must be
available out side for emergency help.
Use rings spanners and tie them to the wrist of the person or
some where outside the tank.
Be careful during connections where bolted joints are involved
so that nut, washers etc. are not dropped inside the tank.
If it is required to weld some lugs or brackets etc., these should
be welded to tank stiffeners taking all precautions to avoid fire
hazards.
De-energise the unit by circuit breakers and line switches while
working on energised unit.
Check the diaphragm of explosion vent and replace it if cracked.

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PTRM : 0708
Page 16 of 205

Attach the caution tags "DO NOT OPERATE THE SWITCHES"


while working on units, which are energised.
Make sure that the fire fighting equipment is available at the oil
treatment equipment as well as workplace and adjacent to the
transformer.
Fire fighting equipment should be checked regularly and should
have sufficient quantity of extinguishant.
Transformer tank, control cabinets etc. as well as oil treatment
equipment shall be connected with permanent earthing system
of the station.
Check and thoroughly investigate the transformer whenever any
alarm or protective device is operated.
Check air cell in conservator.
Attend leakage on the bushings.
Examine the bushings for dirt deposits and clean them
periodically.
Check the oil in transformer and OLTC for dielectric strength
and moisture content and take suitable action for restoring
quality.
Check the oil level in oil cup and ensure air passages are free in
breather. If oil is less make up the oil.
If inspection covers are removed or any gasket joint is to be
tightened, then tighten the bolts evenly to avoid uneven
pressure.
Check and clean the relay and alarm contacts. Check also their
operation and accuracy and if required change the setting.
Check the protection circuits periodically.
Check the pointers of all gauges for their free movement.
Clean the oil conservator thoroughly before erecting.
Check the OTI and WTI pockets and replenish the oil if required.
Gas filled storage of transformer at site should be limited to a
maximum of 3 months.

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Page 17 of 205

Check the door seal of the Marshalling box. Change the rubber
lining if required.
Ensure proper tightness of top terminal of condenser bushings
to avoid entry of rainwater.
Check oil level in condenser bushing, any discrepancy should
be reported immediately to the manufacturer.
Do jacking only at jacking pad.

1.3.2

ISSUE/ REVISION
DATE

DON'TS

Do not take any fibrous material such as cotton waste inside


while repairing.

Do not drop any tools / material in side.

Do not stand on leads / cleats.

Do not weld, braze or solder inside the tank.

Do not weld any thing to the tank wall from outside.

Do not weld any thing to the conservator vessel if Air cell bag is
inside.

Do not smoke near the transformer.

Do not use fibrous material for cleaning as it can deteriorate the


oil when mixed with it.

Do not energise without thorough investigation of the


transformer whenever any alarm of protection has operated.

Do not re-energise the transformer unless the Buchholz gas is


analysed.

Do not re-energise the transformer without conducting all precommissioning checks. The results must be compared with
factory test results.

Do not handle the off circuit tap switch when the transformer is
energised.

Do not energise the transformer unless the off circuit tap switch
handle is in locked position.

Do not leave off circuit tap switch handle unlocked.

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Do not use low capacity lifting jacks / slings on transformer for


jacking / slinging.

Do not change the setting of WTI and OTI alarm and trip
frequently. Setting should be done as per manufacturer's
instructions.

Do not leave any connection loose.

Do not meddle with the protection circuits.

Do not leave marshalling box doors open, they must be locked.

Do not switch off the heater in marshalling box except to be


periodically cleaned.

Do not allow unauthorised entry near the transformer.

Do not close any valve in pump circuit for taking stand by pump
and motor into circuit.

Do not allow water pressure to exceed the oil pressure in oil to


water heat exchangers.

Do not mix transformer oils of different make/ base, unless oil is


new and conforms fully to IS: 335.

Do not continue with pink (wet) silica gel, this should


immediately be changed or reactivated.

Do not store transformer in gas filled condition for more than


three months after reaching site. If storage is required for longer
duration, the main body should be filled up with oil.

Do not leave tertiary terminals unprotected outside the tank.

Do not allow WTI / OTI temperature to exceed 70C during dry out
of transformer and filter machine temperature beyond 75C

Do not parallel transformers, which do not fulfil the conditions for


paralleling.

Do not over load the transformers beyond limit specified in IS: 6600.

Do not leave secondary terminals of any CT open.

Do not measure insulation resistance by using megger when the


transformer is under vacuum.

Do not stand on any vessel, which is under vacuum.

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2.0

TRANSPORT, PACKING & DESPATCH

2.1

GENERAL

PTRM : 0708
Page 19 of 205

Depending on the restriction imposed by the weight and transport


dimensions, the transformer will be despatched either in oil filled or
nitrogen gas filled condition.

In case of transformer despatched without oil, the transformer will be


pressurised with dry nitrogen gas to minimise the likelihood of
condensation or moisture entering the tank.

Transformers are supplied, fitted with nitrogen gas cylinder to


maintain positive pressure during transportation and storage before
erection.

While transformers are in transit, gas pressure must be checked on


daily basis and any loss of pressure must be made up by feeding
gas from the cylinder. For allowable range of pressure at various
ambient temperatures, please refer to Fig. 2.I.
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Accessories and cooler are despatched separately. All oil pipes and
chambers are despatched in sealed condition to avoid entry of water
during transportation and storage.

2.2

PACKING
When any internal part like tap changer, CT's etc. are removed from
the main body for transportation, they shall be despatched in tanks
filled with oil or dry nitrogen gas or suitable measures are taken so
that they do not absorb moisture.

All fragile parts such as temperature indicators, oil level gauges etc.
shall be carefully packed to avoid breakage in transit.

Air cell type conservator shall be despatched with air cell mounted
inside the conservator and inflated with air at a slightly positive
pressure so that it remains fully tight inside the conservator. This is
to avoid relative movement of air cell inside the conservator during
transit and to avoid damages to air cell during handling.

All blanking plates, valves guards etc., which are used exclusively
for transportation are painted with a different colour shade than the
transformer (normally post office red) and shall be preserved for
future use.

2.3

RAIL TRANSPORT
Large capacity transformers are normally transported by rail due to
considerations of safety and economy. Depending on the weight and
dimension of the main body suitable wagons are selected for
transport. It should be ensured that the dimensions of the main body
when it is loaded on the particular wagon do not project beyond the
limiting dimensions specified by the Railways.

Movement sanction should be obtained form all the Railways


through which the transformer has to be transported to site from the
factory.

Detached parts are packed and normally despatched along with the
main body so that all parts are received at site along with the main
unit.

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2.3.1

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Page 21 of 205

LIFTING & JACKING


Transformers should be lifted only by using the lifting bollards
provided on the main body for the purpose. All the lifting bollards
should be used simultaneously. Care should be taken to use the
correct size of sling for lifting and the lifting angle should not exceed
600.

Safe loads of wire ropes and the multiplying factor to be used


corresponding to the lifting angles are shown in Fig. 2.2

Lifting Angle

Slinging Angle

MULTIPLYING
FACTOR FOR
DIFFERENT LIFTING
ANGLES
Lifting Multiplying
Angle
Factor

0
20
40
60

Fig. 2.2
Correct method of slinging

2.3.2

1.000
1.015
1.065
1.155

SAFE LOAD OF WIRE


ROPES
Dia. of
Safe
Wire
Load
Rope
mm
kg.

6
12
16
20
24
28
32
36
40
44
56
64
70

600
1,300
2,300
3,500
5,000
7,000
9,000
11,000
14,000
17,000
24,500
33,500
40,000

JACKING
For the purpose of jacking, only the jacking pads provided on the
tank are to be used. Capacity of Jacks should be at least 1.5 times
the weight of transformer. Put sufficient wooden/steel packing below
the jack to support the weight. Do not lift more than 30 mm at a time.
Use all jacks simultaneously. Jacks should not be left in the loaded
position for long time. Transformer should be handled only in the
normal upright position.

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2.3.3

PTRM : 0708
Page 22 of 205

LASHING
The transformer is lashed on all four sides by wire ropes or chain of
adequate size and is tightened using turnbuckles with locking facility.
After the movement of the consignment for a short distance the
tightness should be checked.

2.4

ROAD TRANSPORT
Generally road transport is resorted to in case of smaller units and of

2.5

site where rail link is not available or where well developed road
system exists.
Multi-axle tractors driven low-platform trailers are used for transport.
Prior to taking decision to transport the heavy consignment by road a
route survey has to be conducted to confirm strength of bridges and
the road worthiness and to identify constraints if any enroute.
Weak bridges if any should be strengthened with the help of,
Highways department.
A pilot vehicle with all-necessary tools and tackles and trained staff
should be run in front of the vehicle. Red flags and danger lamps
should be exhibited on the consignment.
Tightness of lashing should be verified at frequent intervals during
movement.

WATER TRANSPORT
Special cares to be taken during manufacture, packing and despatch
of transformers which are to be shipped through high seas. Even if it
is not specified by the purchaser the transformer should be applied
with anti corrosive coating and packaging should be strong enough
for possible rough handling enroute. Accessories should have
polythene covering and should contain silicagel or any other suitable
moisture absorbent.

2.6

SHIPMENT OF ACCESSORIES
Accessories are packed and despatched separately. Items, which
are detached from the main body for transportation, are listed on the
outline drawing. These will be transported in suitable crates.
Crates containing fragile items should be marked 'FRAGILE' and
handled carefully during loading on vehicle, shipment and unloading
at site.
Crates containing accessories, which should not be kept upside
down like condenser bushings, control panel etc. should marked
'THIS SIDE UP' and should be handled as per manufacturer's
instruction only.

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Page 23 of 205

Caution symbols for handling are painted on the packing cases.

FIG. 2.3
2.7

SHIPMENT OF OIL
Transformer oil is despatched to site in sealed steel drums or

tankers.
When oil is filled in drums, there should be sufficient air space to
allow for expansion and contraction of oil due to variations in
temperature.
Drums should be stacked only in horizontal position with the oil. This
will avoid collection of water on top of the drum, which may be
sucked in by the vacuum created inside the drum due to the
expansion and contraction of oil owing to changes in ambient
temperature.
Due to any reason, if the drums are kept in vertical position, drums
should be covered with polythene or tarpaulin sheet to avoid risk of
water getting collected on top and eventually leaking into the drums.
Filter holes and air release holes shall be in one horizontal line. This
will avoid breathing in of moist air. If there is any leakage of oil it can

FIG. - 2.4
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Page 24 of 205

easily be identified.
When oil is transported in tankers, there should be storage tanks of
sufficient capacity available at site. Such tanks should be fitted with
dehydrating breathers.

2.8

IMPACT RECORDERS
Impact recorders are attached to the main body of the transformer
during transportation to monitor the shock, which the transformer
may be subjected to, during transportation. Impact Recorders are of
two types, viz. Mechanical analogue type and electronic digital type.
Both types of shock recorders have ability to record shock and
impact from all directions.

2.8.1

MECHANICAL TYPE IMPACT RECORDERS


The Mechanical type recorder used is of Impact-O-graph Impact
Recorder Model M1 supplied by "Impact-O-Graph, Division of
Chatsworth Data Corporation, 20710 Lassen Street, Chatsworth,
California, U.S.A. The record will be in the form of chart, which will
show the total number of impacts that have occurred, the magnitude,
the direction and the time at which they occurred. Impact is recorded
in both magnitude and direction through three independently
operating mechanisms, which record
i.
Lateral shock ('x' axis)
ii.
Longitudinal shock ('y' axis)
iii.
Vertical shock ('z' axis)
Typical sensitivity (rating) values of impact recorders are as follows:
i.

Trucks trailer

Smooth road

2g

ii.

Truck trailers

Rough road

6g

iii.

Railway wagons -

6g

Movement of the graph paper is powered by battery operated clock


mechanism. The battery has a normal life of 6 months. At the time of
despatch of the transformer from the factory, the recorders should be
switched 'ON' and the time set. The cover may be locked or sealed to
avoid possibility of tampering with the chart on the way.

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Page 25 of 205

Procedure for analysing impact recorder chart results:


(i)

Determine the numbers of days between switching ON the


impact recorder and switching OFF and check that all the
number of days has been recorded on the chart.

(ii)

For each stylus measure the length of the trace from centre line
in one direction to the end of the arc that extends farthest from
the centre line.

(iii)

Use the table below to find equivalent 'g' levels in the designated
column (X column for 'x' axis shocks etc.)
Direction

2.8.2

mm

space

2g

6g

6g

2g

6g

0.4

1.7

1.4

0.4

1.2

0.8

3.3

2.8

0.8

2.5

1.3

5.0

4.2

1.3

3.7

12

1.7

6.3

5.5

1.7

5.0

15

2.1

8.2

6.9

2.1

6.2

ELECTRONIC DIGITAL TYPE IMPACT RECORDERS


The Impact Recorder is of Sensorex Minishock supplied by :
M/s. International Business Park Archamps, 74165 Saint Julien,
En, Genevois, France.

The Minishock is a recorder designed for the simple instrumentation


of the conditions of transport. With three accelerometers, the 128
highest shocks are measured, dated and memorised in each X, Y
and Z-axes. Provisions for recording temperature and humidity are
optional in this type of instrument.

The Minishock is a self contained reorder designed for use in the


transport and packaging sectors. This instrument will measure and
date shock, temperature and humidity (optional).

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Page 26 of 205

Shocks are recorded when the acceleration passes a predetermined threshold in each of the X, Y and Z-axes. Only the 128
shocks of greatest intensity are memorised, thus reducing the data
overload.

Before the mission, the threshold limits above which the shocks are
to be recorded are determined and the Minishock is activated.
During the mission, the acceleration is measured continuously and
recorded together with the date and time, whenever the threshold is
exceeded. After the mission, the data is downloaded via a RS 232
link and visualised using the Logishock software. The data can be
visualised graphically or in the form of tables.
The Sensor characteristics are as follows:
i. Range

: 10 g

ii. Resolution

: 0.1 g

iii. Accuracy (250 C)

: 0.2 g

iv. Threshold

: from 1.5g ~ 10 g

v. Band width

: 25/ 50/ 100/ 200 Hz

vi. Sampling periods

: 1 minute to 4 hours.

vii. Power source

: Works with a standard lithium battery

In case the transformer suffers serious shock during shipment, the


core and coil will have to be subjected to through inspection before
erection and commissioning.

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Page 27 of 205

3.0

STORAGE

3.1

RECEIVING MAIN UNIT AND ACCESSORIES


When a transformer arrives at site a careful external inspection must
be made of the unit, its cooling system and all sealed components,
referring to the general arrangement drawing and the shipping list.

Inspect all packing cases and loose components for damage or


missing items.

Check whether the transformer has arrived at site with a positive gas
pressure in case of despatch without oil. In case of despatch of main
body in oil filled condition, the oil level should be checked. One
transport oil level gauge is welded near the top of the tank for
indicating the level of oil in the tank.

Should the transformer arrive at site without pressure (owing to gas


leakage) it must be assumed that moisture has entered the tank and
that the moisture will have to be driven out. In such cases the
manufacturers advice must be sought.

Confirm that case numbers match with the packing list. Check their
contents tally with the packing list if the packing case is damaged.

IMPORTANT:
If any scratches or damage to the paint is noticed on receipt of Main
body or Accessories, touchup painting should be done immediately
over the damaged area. For procedures of touchup painting, refer to
Clause 4.22: Touchup Painting at site.

3.1.1

REPORT OF DAMAGE PARTS ETC.


If any damage is noticed, claim must be lodged with the insurance
agency and the matter must be reported promptly to the
manufacturer. The report should contain sufficient details of
damaged parts and extent of damage so that the cost of
replacement /rectification can be worked out.

3.1.2

INSPECTION OF MAIN UNIT GAS FILLED


After receipt of consignment at site, gas pressure inside the tank and
the temperature at the time of measurement should be recorded.
The value obtained should be compared with the gas pressure
versus temperature chart furnished in the instruction manual. (Refer
fig. 2.1 of chapter 2)

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3.1.3

PTRM : 0708
Page 28 of 205

INSPECTION OF MAIN UNIT OIL FILLED


Upon arrival at site, check oil level inside the tank. If a transparent oil
level gauge is not provided, the oil level can be measured by
connecting a transparent hose between the bottom and top sampling
valves.

Check for damages to valves etc.


A sample of oil should be taken from the bottom of the tank and
tested for BDV and moisture content. If the values do not meet the
relevant standards the matter should be taken up with the
manufacturer.

3.2.1

UNLOADING OF MAIN UNIT


In cases where the substations are having adequate crane facility;
the transformer is unloaded by crane. Alternatively, mobile cranes are
used. Where no crane facility is available a trench is dug to a depth
equal to height of the trailer platform and the transformer is slid to
position. If this also is not possible the transformer is unloaded into a
sleeper platform and gradually lowered to plinth level (Refer Figure
3.1 for guidance). The sleeper platform level is to be at a slightly
higher level to allow for the increase in height of the trailer while the
load is released due to the springs getting relaxed. Winches are to be
used for putting the transformer into position.

Fig. 3.1

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Lift the main body of the transformer with a mobile crane and wire
ropes. The crane capacity must be at least 10% higher than the
weight of consignment. Lifting angle of ropes should be limited to 30
deg. to vertical.
Unloading must be done with maximum care, avoiding any jerking
movements or dropping.
Use only the lifting bollards/hooks for slinging while lifting.
For lifting with hydraulic jacks, the transformers are provided with
jacking pads dimensioned for lifting the complete transformer filled
with oil.
If the foundation of the transformer is not ready and if the
transformers are to be unloaded temporarily, it should be done on
leveled hard surface. Under base of the transformer should not rest
on the ground as it will lead to rusting of the transformer.
Place at least 300 to 400 mm wooden sleepers to facilitate jacking.

3.2.2

PLACING IN POSITION

ISSUE/ REVISION
DATE

If foundation is ready and if rail link between unloading point/storage


place is available, then the main body of the transformer must be
moved on its own rollers to the foundation where the transformer is
to be erected finally.
If the transformer is not provided with rollers and if it is to be erected
on its skid base, the transformer must be slid to its final position
using greased steel plates to protect the plinth surface and make
movement easier. The plates should form a continuous surface and
it must clear the final jacking areas.

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3.2.3

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Page 30 of 205

The transformer must be pulled by using slings and winches as


shown in Fig. - 3.2. Use only the specified haulage lugs for pulling.
Pulling capacity of winches should be more than (Main body weight
x 0.15/4) tons. Pulleys should have a capacity of (Main body weight
x 0.15/2) tons.
When jacking (e.g. to remove steel plates), position the jacks under
specified jacking pads only. When jacking, ensure that all four jacks
are operated simultaneously.
Before lowering, clean all grease dirt etc. from the under base of the
transformer.

UNPACKING AND INSPECTION OF ACCESSORIES


Crates / packages are to be opened carefully so that the tools used
for opening do not cause damage to the contents.

Drums containing transformer oil, which have been despatched


separately, shall be examined carefully for leakage.

In case of Condenser Bushings, oil level shall be checked. Porcelain


should be checked thoroughly for any crack or chipping. Any oil
leakage or damage to porcelain must immediately be reported.

Fragile instruments like oil level gauges, temperature indicators etc.


are to be inspected for breakage or other damages.

Any damage or short shipment should be reported to the


manufacturer.

3.3

STORAGE OF MAIN BODY

3.3.1

GENERAL
It is preferable to erect the transformer immediately on receipt at site
and fill with transformer oil. However, if it is not possible, the
following precautions should be taken for storing the main body and
accessories for longer duration:

The storage area should be adequate and should be easily


accessible for inspection.

The surface on which it should be stored is strong and levelled.


Surrounding area of storage is not polluted and water does not
accumulate in the storage area.

Sufficient space is provided underneath for free flow of air and also
for lifting, jacking etc.
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3.4

PTRM : 0708
Page 31 of 205

GAS FILLED STORAGE


It is recommended to keep the transformer oil filled immediately after
receipt. If oil can not be filled immediately after receipt of main body,
it must be retained with dry nitrogen gas filled at a positive pressure
of 0.2 kg/ cm2 at about 20OC. (Please ref. Fig. 1 of Chapter 2 for
Pressure Vs Temperature Chart).

The duration of gas filled storage should be limited to 3 months from


the receipt of main body at site.

If the pressure of gas inside drops due to leakage, the leakage point
may be detected by using soap water. The matter shall be reported
to the manufacturer for immediate corrective action.

1. Cylinder Key.
2. Top sampling valve of
transformer.
3. Gauge for reading gas pressure
inside the transformer
4. Adapter.
5. Gauge to indicate gas pressure in
the cylinder
6. Gas pressure regulator.
7. Gauge to indicate gas pressure
from the regulator
8. Pneumatic pressure hose.
9. Hose clip.
10. Nitrogen cylinder.

FIG. 3.3
Should it not be possible to rectify the leak immediately, the
transformer must be covered by putting a tarpaulin sheet over the
whole tank until remedial measures can be carried out.

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Gasket must not be tightened indiscriminately as this could result in

3.5

OIL FILLED STORAGE


If the gas pressure on arrival at site is found satisfactory, it can be

3.6

loss of gasket property due to over compression.


The arrangement for gas filled storage is shown in fig. - 3.1
Pressure inside the transformer should be monitored on daily basis
and any pressure drop should be made up by opening the cylinder
and operating the pressure regulator. The cylinder should be kept
closed.
Before deciding on loss of pressure, the pressure versus
temperature chart (Fig. 2.1) shall be referred to.
If the storage period of transformer at site is expected to be beyond
3 months, it is recommended to keep it filled with transformer oil.

assumed that there is no leakage.


Before filling oil, all the valves, which were detached during
transport, should be fitted back and blanked.
If possible, the main body shall be fitted with its own rollers and
supported on rails and locked in position.
Assemble conservator, pipe work and fix silicagel breather. Oil shall
be filled upto the conservator corresponding to the ambient
temperature.
If the transformer foundation is not ready, it may be stored in any
convenient location. In that case, oil shall be filled upto the level so
as to immerse all the insulation parts in oil and the space above
should filled with dry gas.
Fix silicagel breather at any convenient point on the cover.
If the main unit is received at site filled with oil, fit a silicagel breather
on any opening on cover with a suitable pipe.
Before filling oil inside the transformer, its BDV and moisture content
should be measured. If values are not within limit specified, the oil
should be filtered.

STORAGE OF OIL
If the oil is received at site in tankers, it is necessary to provide an oil
storage tank of enough capacity to hold the oil for one transformer.

The oil storage tank should be equipped with valves for oil filling,
draining, sampling and filtration, oil level gauge, silicagel breather
and a manhole on top cover. The inside of the tank should be
painted with oil resistant paint / varnish. Before filling oil, the inside of
the tank should be cleaned thoroughly.

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PTRM : 0708
Page 33 of 205

If the oil is received at site in sealed drums it may be stored in


horizontal position as shown in Fig 3.2 and covered with tarpaulin
sheet. Filter holes and air release holes shall be in one horizontal
line. This will avoid breathing in of moist air. If there is any leakage of
oil it can easily be identified.

The storage area should be free from fire hazards.

Fig. 3.4
3.7

STORAGE OF ACCESSORIES
The following points may be taken care of in order to keep
accessories in good condition without damage, rust and dust.

Check and confirm that all packing cases as per packing list are
received in good condition.

If erection work is not likely to commence immediately the boxes,


which are opened for inspection, should be repacked and the
packing list retained for future reference and records.

All packing cases should be kept above ground on suitable support


so as to allow free circulation of air underneath. Water should not
collect in the storage area. There should be sufficient space for
inspection, handling and transport.

All fragile items and instruments should be stored indoors.


All crates should be kept as per the markings provided on the crates
by manufacturer. As a general rule, all control boxes such as RTCC
Panel, Marshalling Box, Drive Mechanism etc. should be kept
indoors in vertical position.
ISSUE/ REVISION
DATE

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28/01/07

01/08/07

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PTRM : 0708
Page 34 of 205

Crates should not be stacked one over the other.


Strictly adhere to the specific storage instruction provided by the
manufacturer for specific items.

Table - 1 may be referred to for further guidelines for storage and


periodical inspection of transformer accessories.
Table- 1
Sr.

Accessories Storage

No.

Position

Position

Precautions

Location

Special

Inspection

Instructions

check

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28

ISSUE/ REVISION
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PTRM : 0708
Page 35 of 205

4.0

INSTALLATION

4.1

TOOLS AND EQUIPMENT REQUIRED AT SITE FOR


ASSEMBLY:
Sr. No.

ISSUE/ REVISION
DATE

Tool/ Equipment

Qty.

Specifications

Oil Storage Tank

1 No.

Mild Steel Tank of sufficient


capacity
to
store
the
complete
oil
in
the
transformer. The tank shall
be fitted with inlet and outlet
valves of 50 mm diameter.
Inside of the tank shall be
thoroughly
cleaned
and
coated with hot oil resistant
varnish/ paint.

Oil Purifier

1 No.

Oil purification plant shall


have at least 6 kiloliters/ hr.
capacity
and
vacuum
dehydrator, oil heater and
filtering device.

Vacuum Pump

1 Set

Vacuum Pump should have


capacity to evacuate the
tank mentioned above and
having a maximum leak rate
of 0.5 torr. in one hour to an
ultimate vacuum of 0.1 torr.
in 2 hours.

Flexible Oil Hoses:

20/10/05

(of 3 m length)

5 Nos.

(of 10 m length)

2 Nos.

(of 10 m length)

2 Nos.

28/01/07

Flexible oil hoses of 50 mm


dia. with flanges on either
end. These hoses shall be
capable of withstanding
vacuum of 0.1 torr.
50 mm dia. with flanged
ends
and
capable
of
O
withstanding 120 C

01/08/07

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PTRM : 0708
Page 36 of 205

Sr. No.

Tool/ Equipment

Qty.

Specifications

Flexible Vacuum
Hoses of 10 m length

2 Nos.

Flexible vacuum hoses of 75


mm diameter with flanged
ends. The hoses shall be
capable of withstanding full
vacuum.

Oil testing equipment

1 Set

Oil testing equipment shall


be capable of checking
break down voltage of
transformer oil across 2.5
mm sphere gap 60 kV
(min.).

Vacuum Gauge

2 Nos.

Vacuum gauge of
Mc Leod type capable of
measuring vacuum less than
0.01 torr

Compound Gauge

1 No.

Compound gauge for a


pressure range of
-760 to +760 mm of mercury

a)

Megger

1 No.

Megger of 5 kV with
motor operation is
preferable.

b)

1 No.

Megger of 2 kV.

c)

1 No.

Megger of 500 Volts.

10

Multi meter

1 No.

11

a)

3 Nos.

0 ~ 300 V AC range.

3 Nos.

0 ~ 75 V AC range.

2 Nos.

100 W Lamp of 100 V or


less with sufficient length of
flexible cable and bulb
protector.

Voltmeter

b)
12

ISSUE/ REVISION
DATE

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Electric Hand Lamp

28/01/07

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Sr. No.
13

Tool/ Equipment
Mobile Crane

Qty.
1 No.

PTRM : 0708
Page 37 of 205

Specifications
Mobile crane of 5 or
10 Tonnes capacity with a
maximum lift of 20 meters.

14

Slings and Shackles

Sufficient Nos. Slings and


shackles of sufficient length
to handle weight up to 25
tonnes.

15

Water Proof Sheets

40 m2

For temporary
exposed parts

16

Vinyl Hose

30
meters

Transparent vinyl hose of 12


mm dia to be used as oil
level gauges.

17

Hose Nipple

2 Nos.

12 mm hose nipples

covering of

with flanges on one side to


match valve flanges.

ISSUE/ REVISION
DATE

18

Methyl Ethyl Ketone / 10 litres For cleaning purpose.


Carbon tetra chloride

19

Rag Cotton cloths

20

Unstarched Mill Cloth

10 m.

For cleaning internal Parts.

21

Knife

2 Nos.

For cutting insulation parts.

22

Spanners

2 Sets

All standard sizes for both


metric sizes up to 42 mm
and BS to 1.

23

Screw Driver

2 Nos.

6" Screw driver (-).

24

Painting Brushes

6 Nos.
each

15 mm, 25 mm & 75 mm

20/10/05

28/01/07

20 kgs. For cleaning purpose.

01/08/07

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Sr. No.

Tool/ Equipment

25

Qty.

PTRM : 0708
Page 38 of 205

Specifications

a) 3 Phase, 440
Volts, 50 Hz.
Electric Power
Supply for
Operating the
vacuum pump
and filter machine
b) Water Supply if
Purifier is water
cooled.

ISSUE/ REVISION
DATE

26

Pulling winches/
Pulleys

2 Sets
each

Please refer section 4.3.

27

Hydraulic/Mechanical
Screw Jacks with
Locking facility

4 Nos.

50% of total weight of main


body with oil.

28

Measuring Tapes

2 Nos.

10 meter long.

29

Spirit Level/Level tube


(Plastic)

1 No.

30

Dry Air Generator (For


Transformers of 400
kV class and above)

1 No.

20/10/05

28/01/07

Capacity; 4~5 m3/hr. Dew


Point 40O C Temperature
25 5OC, Outlet pressure 200
Aq.

01/08/07

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4.2

PTRM : 0708
Page 39 of 205

OIL SAMPLING AND FILTERING


Oil should not be filled in the transformer directly from the drums or
transport container as there is a chance of precipitated water or
sediments may also be pumped into the transformer along with the
oil.
Oil from the drums or transport container should be filled into the oil
storage tank and oil parameters should be tested before it is filled
into the transformer.
If oil is received in drums, samples should be taken for testing from
as many drums as shown in the Table -1 at random.
Table -1
Selection of Samples from drums
No. of Drums in a Batch

No. of Drums from which


Samples to be taken

2 to 5

6 to 20

21 to 50

61 to 100

101 to 200

10

201 to 400

15

401 and more

20

Samples should be collected from the bottom of the drums as shown


in fig.4.2 for testing.

FIG. 4.2
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If oil is received in containers, oil sample shall be collected through


the sampling valve at the tank outlet or by means of thief dipper as
suggested for sampling of oil from drums. The container should be
allowed to stand for atleast one hour before drawing the sample.
Conduct the following tests for ascertaining the quality of oil.

Breakdown Voltage test

Moisture content test

Tan delta

Resistivity

If oil does not meet the specified criteria, oil should be filtered and
stored in the oil storage tank before filling in to the transformer.

While pumping oil from the barrels, the barrels may be tilted suitably
to ensure that complete oil is taken out from each barrel.

FIG. 4.3

ISSUE/ REVISION
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4.5

PTRM : 0708
Page 41 of 205

ERECTION PRECAUTIONS
NOTE:
PRECAUTIONS MUST BE TAKEN TO ENSURE THAT ALL GAS
PRESSURE IN THE TRANSFORMER IS RELEASED BEFORE ANY
ATTEMPT IS MADE TO REMOVE A COVER AND DRYNESS (DEW
POINT) OF GAS IS CHECKED BEFORE A GAS CYLINDER IS
USED.

During erection it is advisable that only one hand hole cover is


opened at a time in order to minimise the ingress of moisture. The
hand hole cover should be replaced as soon as the operation is
completed.

Dry air of dew point 40OC or better must be fed through the inside
of tank when covers are removed in case of 400 kV and higher class
of transformers to avoid direct contact of winding insulation with
moist air outside.

It is essential that the transformer be filled with oil immediately on


completion of work. The exposure should not be allowed more than
16 hours at stretch.

Insulation resistance between core frame and tank must be checked


before oil filling with a 2 kV megger, the insulation resistance must
be compared with the factory test results.

Measure the insulation resistance between:


I.
II.
III.
IV.

ISSUE/ REVISION
DATE

HV Earth (Tank)
LV/ IV Earth (Tank)
HV LV/ IV
Core Frame Earth (Tank)

20/10/05

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4.6

PTRM : 0708
Page 42 of 205

ERECTION PROCEDURE
The following flow chart shows the installation procedure generally
followed at site.
PREPARATION FOR INSTALLATION .
INSTALLATION OF MAIN BODY ON FOUNDATION .
RECEIVING INSPECTION AND STORAGE .
OIL RECEIVING AND FILTERING .
REPLACING DRY GAS WITH OIL .
ASSEMBLE BUSHING TURRET .
ASSEMBLE LV BUSHING AND CABLE DUCT .
ASSEMBLE COOLERS .
ASSEMBLE CONSERVATOR .
ASSEMBLE PRESSURE RELIEF DEVICE .
ASSEMBLE HV BUSHINGS .
ASSEMBLE ACCESSORIES .
INTERNAL LEAD CONNECTIONS .
CONTROL WIRING
OIL LEAKAGE TEST .
OIL FILLING UNDER VACUUM .
PAINTING (Ref. Cl. 4.22) .

ISSUE/ REVISION
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4.7

PTRM : 0708
Page 43 of 205

REPLACE DRY GAS WITH OIL


After installing the transformer on the foundation dry gas in the
transformer should be replaced with treated oil.

Oil should be tested for breakdown voltage and it should be above


55 kV / 2.5mm gap.

Make sure that the hose and pipe interiors are cleaned in advance.
Connect the oil pipes to the lower filter valve. Ref. fig. 4.4
Transformer

Oil Storage
Tank

Dry Gas
Filter Press

Transparent
Vinyl Hose
(For oil level
Indication)

FIG. 4.4
Attach a transparent vinyl hose to indicate the level of oil being filled
in the transformer.

Open the top filter valve or any other bolted covers on topmost point
on the transformer for releasing dry gas at the time of oil filling.

Open the bottom filter valve on the transformer and top air release
valve on the oil storage tank.

Oil should be filled upto a level above the top insulation of


transformer winding.

A small gas space (approx. 5~10%) should be left above oil for
expansion of oil.

During oil filling, if the filter press stops due to any reason, the top
filter valve and any other opening on the top of the transformer
should be closed immediately to prevent air getting into the
transformer.
ISSUE/ REVISION
DATE

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PTRM : 0708
Page 44 of 205

Oil level shall be continuously monitored during oil filling.


While filling oil directly from the barrels, the barrels shall be tilted
suitably to ensure that complete oil is taken from the barrels.

After filling oil, if the storage is expected to be for a long period, dry
gas should be filled above the oil at a pressure of 0.1 ~ 0.2 kg/cm2.

Assembling work should start from the bottom of the tank so that
after initial oil filling, oil need not be drained again for assembling
work.

4.8

PRECAUTION TO MAINTAIN QUALITY


As a precautionary measure to restrict absorption of moisture, the
transformer should not be exposed to atmosphere for more than 8
hours continuously and erection work should be scheduled
accordingly.

Following each days work, transformer should be kept oil filled.


For high voltage jobs of 400 kV and above, dry air having dew point
below -400C should be purged inside the tank during internal
assembling work.

Transformer should be tested for B.D.V. before filling and it should


be more than 55kV at 2.5 mm gap.

Extreme care shall be taken against any foreign objects falling inside
the transformer tank during inside working.

Keep only one man hole open at a time and close it as soon as
possible.

Avoid inside working on rainy days.


Earthwork near the transformer should be avoided when internal
assembly is in progress to avoid ingress of dust.

While scraping the gasket surfaces of bushing bases, inspection


covers etc., keep a cloth below to avoid the scraped material falling
into the transformer.

Any tools taken inside should be tied by string or cotton tape to the
person who is using the same.

No. of tools shall be counted and recorded before and after each
days work in order to ensure that no tools are left inside.

ISSUE/ REVISION
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PTRM : 0708
Page 45 of 205

Gaskets used are of synthetic rubber bonded cork material. These


are to be compressed to 50 ~ 60% of its original thickness. Over
tightening and under tightening of gaskets should be avoided as
these may cause oil leakage and shortening of gasket life.

Tightness of all inside connection should be checked and proper


locking shall be provided.

Persons working inside the transformer or top of the transformer


should not wear wristwatches, pen, coins etc.

4.9

ERECTION OF PIPE WORK


All items of pipe work are match marked.
All joints are to be assembled with gasket only and without joining
compounds or grease.

Joints must be fully tightened only when the transformer has been
fully erected; by that stage the pipes can be centralised.

No pre determined torque values are applicable.


No joint must be under excessive assembled load as subsequent
expansion or contraction could cause leaks.

Ensure that all accessories belong to the same unit. Indent No., Unit
No. and Serial numbers of each item are marked on each item. This
is to avoid mismatching at site.
E.g.:

670700002 / 4 / 209 shows: Sale Order No.: 670700002,


Unit No.: 4 and
Serial No. of item : 209

Serial numbers of all items, which are dismantled from the main
body and sent separately, are shown in "PART MARKING AND
CABLE WIRING" drawing.

4.10

ERECTION OF COOLER BANK


Generally for oil forced cooled transformers radiators will be
mounted in a separate cooler bank.

Cooler headers supporting A frame are mounted on separate


foundations. Refer "FOUNDATION DRAWING" for details.

Since cooler headers are provided with butter fly type shut off valve,
oil from main body need not be drained for assembling cooler.
ISSUE/ REVISION
DATE

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Page 46 of 205

Cooler Assembly should be carried out referring to "GENERAL


ARRANGEMENT" and "PART MARKING DRAWING" of the
transformer.

Check and ensure that level of all the foundations for cooler support
are in same level as that of the top surface of rails. Level difference
should be compensated by putting shims if the level is lower and
chipping the concrete foundation if the level is higher.

Fix cooler header mounting frames as per dimensions shown in


General arrangement and Foundation Plan drawing.

Mount cooler headers loosely. Final tightening to be done only after


proper alignment.

Top and bottom butterfly valves of all radiators should be in the


vertical line. This should be confirmed by a plumb.

Remove blanking plates from the butterfly valves.


Tighten the cooler frame foundation bolt, and clamping bolts of
cooler headers and pipe connections.

While mounting the oil pump and oil flow indicators, care should be
taken to ensure the arrows indicating the oil flow direction are
towards the transformer tank.

While mounting radiators care should be taken to ensure that the


weight is balanced.

Ensure that a fresh gasket is used while mounting the radiators.


In case of separately mounted coolers, the oil pipes are provided
with expansion joints. Tack welded bars on expansion joints should
be removed.

Fix the fan mounting frames and fans as indicated in the general
arrangement drawing.

Fan & mounting frame shall be connected to the earth grid.


4.11

CONSERVATOR
Mount the conservator as shown in G.A. Drawing.
Very often the small conservator for on load tap changer is attached
to the main conservator.

ISSUE/ REVISION
DATE

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PTRM : 0708
Page 47 of 205

Usually the main conservator is provided with Magnetic Oil level


Gauge having low oil level alarm contacts and OLTC conservator is
provided with oil sight window.

Magnetic oil level gauge shall be mounted after attaching the float to
the gauge. Check and confirm free movement of float arm and
proper locking of float to the float arm.

Mount all valves as shown in GA drawing on the conservator.


Mount the connecting pipe with Buchholz relay from the main tank to
the conservator. Ensure direction of Buchholz Relay by the direction
of arrow on Buchholz Relay towards conservator.

Mount connecting pipe with oil surge relay from OLTC to the
conservator.

Mount breather connecting pipes and silica gel breathers for the
main tank and OLTC conservators.

METHOD OF MOUNTING FLEXI SEPARATOR (AIR CELL)


INSIDE THE CONSERVATOR

PROCEDURE - I (OIL FILLING WITHOUT VACUUM)

Set up the air cell in side the conservator. Care should be taken to
see that the hooks on air cell are properly engaged in the brackets
provided in side the conservator.

Inflate the air cell at a pressure as shown in the instruction plate (DO
NOT APPLY EXCESS PRESSURE AS IT MAY DAMAGE THE AIR
ISSUE/ REVISION
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PTRM : 0708
Page 48 of 205

CELL) through the breather connection pipe. Follow the instructions


given in the Instruction Plate fixed on the transformer.

Ensure that there is no leakage.


The conservator with Air Cell is pressure tested and despatched
from the factory at a slightly positive pressure. Confirm that there is
no oil leakage.

Fix three numbers air release valves on the conservator.


Keep air release valves open. Fix air filling adapter on breather pipe
and
inflate the air cell at an air pressure indicated on the
INSTRUCTION PLATE affixed on the transformer and hold air
pressure.

Open the air release valves and start oil filling from the bottom filter
valve of the transformer.

Observe the air release valves and as soon as oil starts overflowing,
close the air release valves one by one. Stop oil filling when all air
release valves are closed.

Remove the air filling adapter.


Continue oil filling and observe the Magnetic Oil Level Gauge
(MOLG)

Stop the filling when the needle of MOLG shows the level
corresponding to the ambient temperature at the time of filling.

Fix silica gel breather.


CAUTION:
Do not open any of the air release valves after completion of oil
filling. If air release valve is opened, air will enter and oil level will
drop.
The plain oil level gauge on the end cover of the conservator should
indicate full oil level always. If air enters the conservator, it can be
seen by a fall in the oil level in plain oil level gauge.
The plain oil level gauge should be monitored on regular basis.
FILLING PROCEDURE UNDER VACUUM IN CONSERVATOR
The conservator, with its separator, being set up and plugged in above
the transformer, is connected to its oil filling reserve by a pipe in its
lower part.

ISSUE/ REVISION
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PTRM : 0708
Page 49 of 205

Proceed as follows:
Create a vacuum in separator.
With the same source of vacuum, create a vacuum in the
conservator.

Open the oil filling valve of the transformer. Because of the vacuum
in the conservator, the oil level rises automatically.

Stop the oil filling once the required volume in the conservator is
attained.

While maintaining the conservator under vacuum, allow Dry Air or


Nitrogen gas to enter into the internal part of the separator. Then,
the separator inflates by itself, and takes all the free space due to
the fact that the conservator was not completely full. In particular,
during the operation, the oil is going to rise to the top of the
conservator.

Inflate the separator at a maximum as shown in the INSTRUCTION


PLATE.

Check on the vent-holes, and confirm that there is no more air in the
conservator or, if necessary, adjust the level.
CAUTION:
The above mentioned CAUTION regarding the opening of air release
valves after completion of oil filling is applicable for this case also.

4.12

PRESSURE RELIEF DEVICE


Mount PRD as per manufacturers leaflet and also the G.A. drawing
of Transformer.

Check operation of alarm/trip contacts.

ISSUE/ REVISION
DATE

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ERECTION, COMMISSIONING,
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4.13

PTRM : 0708
Page 50 of 205

ERECTION OF HV TURRETS AND BUSHINGS

FIG. 4.5
METHOD OF LIFTING CONDENSER BUSHINGS FROM PACKING
CASE AND MOUNTING ON THE TRANSFORMER AT AN ANGLE

Before starting the erection work of Condenser Bushing, lift the


Bushing from its crate and keep it vertical and check the oil level.
Confirm that oil level is up to the centre of oil sight window of
Bushing.

Part numbers of Bushing turrets are indicated in the part marking


drawing.

If oil is drained from the tank a continuous supply of dry air should be
ensured while removing the blanking plates and fixing the bushing
turrets and bushings.

Dry air shall have a dew point of -40OC or better.


Total exposure time should not exceed 8 hrs.
At the end of each days work, blank off all openings and pressurise
with dry air.

If weather is bad (rain, snow or fog) the tank should not be opened
unless adequate shelter is provided.
ISSUE/ REVISION
DATE

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PTRM : 0708
Page 51 of 205

For details of connections from winding to the bushing please refer


to the specific drawing and suppliers catalogue given in the
instruction manual.

Ensure that a fresh gasket is used while mounting the bushing.


Ensure that the air release pipe connections are oriented towards
the correct directions, as shown in the GA and part marking
drawings.

Check for match markings on the mating flanges.


Bushing shall be mounted in the order of B, A, C or B, C, A.
While mounting the bushings, ensure that the oil level gauge is
oriented away from the transformer.

While lowering draw lead type condenser bushing the cable shall be
held tightly by using strong steel/plastic rope. Remember that
dropping of cable can cause injury to the personnel and damage to
the transformer.

Check and ensure that secondary terminal of turret mounted C.T. if


any are connected to the proper terminals on the terminal board.

Check and ensure that secondary leads of C.T's. mounted inside the
transformer are connected to the proper terminals in the terminal
board.

If holes are not provided in the CT terminal box for fixing cable
glands, suitable holes shall be drilled and cable glands assembled.

Fix all air release pipes between bushing turrets and Buchholz relay
connecting pipe. Please refer to the part marking drawing for
respective part numbers of air release pipes.

4.14

TEMPERATURE INDICATORS
Sensing elements of oil and winding temperature indicators are to be
fitted on to the thermometer pockets welded on the top cover of the
transformer.

Before mounting the thermal sensing bulbs, inside of the pocket


should be cleaned thoroughly and filled with transformer oil upto a
depth of half the pocket.

Care should be taken not to damage the capillary tubing. Capillary


tubes should be clamped properly.

ISSUE/ REVISION
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PTRM : 0708
Page 52 of 205

RTD (if provided and shown in GA drawing) sensor element and


heater coil are fitted on the cover.

Fill oil in the pocket after cleaning.


CT leads shall be connected on one side and sensor leads are taken
from the other side.

RTD instruments are mounted on the remote panel in the control


room.

4.15

OLTC DRIVE MECHANISM


In case of on load tap changing transformer, the OLTC driving
mechanism has to be mounted on the transformer. Please refer to
the OLTC instruction manual supplied by the OLTC manufacturer.

Check for mechanical stops at extreme positions by manually


operating with the handle.

Bring the tap position in DM to the tap position 1.


Connect 3-phase supply with correct phase sequence.
Check raise/lower operations. If direction is correct, check electrical
end stops at extreme positions.

Bring back the DM to the tap position 1.


Different manufacturers of OLTC adopt different designs for the DM.
Some manufacturers adopt dry type gear box for the motor and
some manufacturers adopt oil filled gear box. Oil, if required, shall be
filled as per the manufacturer's instructions.

Coupling up of drive mechanism and OLTC bevel gear shall be done


only after ensuring that both are at the same tap position. Normally
the transformer is despatched from the factory at rated Tap position.

Operate the DM manually from rated tap to tap no. 1 and then to the
other extreme tap position and bring back to rated tap.

Operate DM electrically. Check and confirm that for each impulse


given in both raise and lower directions, diverter switch operation
sound is heard before the motor stops. After hearing the sound, the
travel of the tap position indicating disc upto the green band shall be
equal in both forward and backward crank operation.

Verify the ratios on all taps using ratio meter or digital voltmeter.

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ERECTION, COMMISSIONING,
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4.16

PTRM : 0708
Page 53 of 205

CABLE BOX ASSEMBLY


If cable box is provided, the assembly shall be carried out referring
to the cable box assembly drawing provided in the Instruction
Manual.

Cable sealing ends shall be fitted on to the end of the cable before it
is inserted and bolted on to the cable box.

Cable box assembly may be bolted to the disconnecting chamber on


the transformer tank.

Flexible connections shall be made between bushings and cable box


bus bars through the Inspection Cover.

4.17

INSTRUCTIONS REGARDING USAGE OF GASKETS


Gasket materials used are either Synthetic Rubber Bonded Cork
(SRBC) sheet or nitrile rubber.

SRBC material conforms to RC-70C of IS : 4253(Part II); thickness


used are 6.0 mm and 10.0 mm.

Gaskets should be stored in stress free condition and must be


protected from moisture, oil and grease.

Synthetic rubber bonded cork sheets once used should not be used
again.

Gasket seating surfaces should be smooth and free from scratches,


oil, grease, dirt etc.

Gasket should be properly located before tightening.


Gasket joints are designed with 40~50% compression.
Gasket joints should be tightened evenly with a diametrically
opposite sequence.

Full compression should not be achieved in one go.


Over tightening will cause the gasket material to loose its properties
and under tightening may not prevent oil leakage.

4.18

CHECKING LEAK RATE UNDER VACUUM


Drain oil & create vacuum of 200 torr inside the tank, close the valve
between vacuum pump and tank and stop the pump and hold the
vacuum. There should be no appreciable loss of vacuum over one
minute.

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PTRM : 0708
Page 54 of 205

If there is leak, find out the leak and rectify.


Start the pump and open the valves and continue till a vacuum of 10
torr is achieved.

Close vacuums valve and stop the pump.


There should not be an increase of pressure of more than 1 torr over
half an hour.

IF the rise in pressure is more, find out leak and rectify.


If results are satisfactory, restart the vacuum pump open the valves
and continue pumping to obtain a vacuum of 1 torr or better and
maintain this vacuum for more than 24 hrs. before and during
subsequent oil filling operations.

4.19

INSULATION OF CORE AND FRAME TO TANK


If the internal body earthing lead is brought out through low voltage
bushings, the megger values shall be measured using 2 kV megger
and the values recorded.

4.20

OIL LEAKAGE TEST


Oil leakage test is done after attaching the oil pipes, bushing,
radiators, conservator, relief device and all the instruments.

Remove the breathers and connect dry gas cylinder with pressure
gauge to the connecting pipes if conservator is not provided with air
cell. If conservator is fitted with air cell, pressure shall be applied
after connecting an equaliser pipe between the air release valve and
breather connection pipe. Otherwise the air cell may get damaged.

Remove PRD and explosion vent if provided and blank the opening.
Open all valves between conservator, main tank and OLTC.
Fill oil in the transformer upto 1/3 rd of the conservator through oil
filter.

Apply a gas pressure above the oil such that the pressure at the
base of the tank is between 0.7 kg/cm to 1.0 kg/cm.

Check for oil leakage at all bolted and welded joints by keeping the
pressure for 12 Hrs.

If any leakage is noticed, rectify the leak and continue the test.
Break pressure and reassemble breathers, PRD, explosion vent etc.
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4.21

PTRM : 0708
Page 55 of 205

VACUUM OIL INJECTION


Oil injection shall be made under full vacuum (1.0 torr or better) for
transformers above 66kV. 380 mm Hg or better vacuum is required
for transformers rated for 66kV and below. The vacuum shall
preferably be measured by using McLeod Vacuum Gauge.

After draining the oil completely from the transformer, vacuum


should be pulled from the oil filling hole on main conservator. If the
conservator is fitted with air cell, pressure equalising connection is
required to avoid damage to the air cell.

For facilitating evacuation of main transformer and diverter switch


compartment of OLTC simultaneously, an equaliser pipe (Refer GA
drawing for item number & location) is supplied. This is to be fitted
during evacuation and removed after vacuum oil filling.

Before starting vacuum, all bolted connections shall be checked.


Radiator valves shall be kept open.
A transparent vinyl hose shall be connected to the bottom sampling
valve (Refer Fig. 4.4) for indicating the oil level.

If explosion vent is provided, the pressure shall be equalised on


either side of the diaphragm to avoid damage to the diaphragm.

Vacuum shall be maintained for 6 hours.


Oil may be injected through the bottom filter valve until the level
reaches 35OC marking on the Magnetic Oil Level Gauge of the
conservator.

Initial oil filling shall be done at a slow rate. Rise in oil level per hour
inside the transformer shall be limited to 300 mm.

Natural rubber hose shall not be used as sulphur in the rubber may
react with oil.

Oil inlet valve shall be closed and after one hour the vacuum shall be
broken.

Oil level indicating vinyl hose can be removed by closing the bottom
sampling valve.

Vacuum gauges may be detached and breathers assembled in its


position.

Pressure equalising connection provided for explosion vent


diaphragm and OLTC diverter chamber shall be removed.
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4.22

PTRM : 0708
Page 56 of 205

TOUCH UP PAINTING AT SITE


Any damage to the painting of the transformer and accessories shall
be made good after erection work is completed.

If a welding has been done on the transformer at site, the paint film
burnt by the welding shall be removed by wire brush or metal
spatula.

Remove the rust by wire brush and emery paper #80 / #100.
Wash away the oil, grease, dirt and dust by using suitable solvent
and dry it up.

Polish the surface to be painted by using emery paper #80 /#100


and then clean the surface.

After cleaning, stir the ready mixed rust resistant primer paint 'Yellow
Zinchromate' or 'Red Oxide' primer paint. Before applying the paint,
confirm the correct viscosity.

Apply the paint uniformly by using a brush. drying time for the paint
is normally 4 hours.

After the first coat of paint is dried up, mix and stir the finish coat
paint to the desired viscosity and apply by brush uniformly. Drying
time of finish coat paint is normally 6 hours.

Inspect the repainted surface and do re-painting if the painting is not


uniform and unpainted surface is visible.
Recommended viscosities for painting :
(i) For brushing
: 50 ~ 55 sec.
(ii) For spraying
: 20 ~ 25 sec.
(iii) Pressure for spraying
: 55 ~ 60 psi.
(iv) Time gap between two coatings
: 24 Hours.
(v) Total dry film thickness after final coating: as per data sheet
(80 ~ 100 microns if not specified)

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4.23

PTRM : 0708
Page 57 of 205

MIXING OF TRANSFORMER OIL


Some times a need arises at site to top up a transformer with oil of a
different make.

New oil can be mixed with each other irrespective of the source or
degree of refinement if both the oils meet the same standard
specification.

Inhibited oils can be mixed only if the inhibitor used is same in either
oils or the other one is uninhibited.

At any point of time, the percentage of new oil topped up shall be


limited to 10% of the total oil quantity.

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5.0

INSULATION DRY OUT AT SITE

5.1

HOT OIL CIRCULATION

PTRM : 0708
Page 58 of 205

Connect bottom filter valve of tank to inlet point of filter machine.


Connect top filter valve of tank to outlet of vacuum filter machine and
start oil circulation.

The filter outlet temperature should be limited to 60 ~ 70OC.


Continue filtration for 4 cycles.
Oil circuit should include a vacuum chamber in which oil drawn from
the transformer is sprayed and the moisture and gases are released
from the oil are extracted by the vacuum pump.

Oil drawn from transformer is passed through a filter press before


being admitted to the vacuum chamber to remove impurities

A minimum capacity of 6000 litres per hour is recommended for the


circulation equipment.

Cooler connection at inlet shall be kept closed to minimise loss of


temperature during circulation. Outlet valve shall be kept open to
allow expansion of oil inside the cooler.

Coolers also shall be included in the hot oil circulation towards the
end of the process.

Drain the oil by simultaneously admitting dry air or nitrogen gas from
the top. This is to avoid winding insulation coming in contact with
moisture.

Apply vacuum of 1.0 torr or better and maintain for 6 Hrs.


Inject oil under vacuum upto a level of approximately half of the
conservator.

Start hot oil circulation again as explained earlier and continue for 4
cycles. Maintain temperature of 60 ~ 700 C.

Drain oil by feeding dry air or nitrogen gas as explained.


Apply vacuum as explained
Repeat vacuum/hot oil circulation cycle till required dryness is
obtained.

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PTRM : 0708
Page 59 of 205

Normally 3 or 4 cycles of hot oil circulation and evacuation will be


sufficient to obtain the required dryness for the insulation.

FIG. 5.1
Variation of Insulation Resistance with Temperature
Dryness of insulation is determined by measuring insulation
resistance of transformer winding.

Insulation resistance between each pair of windings and also


between windings and earth shall be measured by using a 5 kV
megger. Readings shall be comparable with the factory test results.

Direct heating of transformer is not recommended for dry out at site.


Oil samples shall be tested for moisture content, (Below 20/15/10 for
145/220/400 kV class respectively). Break down voltage (More than
60 kV at 2.5 mm gap). Resistivity ( 1012 ohm meter) before final oil
filling.

Do not measure insulation resistance when the transformer in under


vacuum.
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PTRM : 0708
Page 60 of 205

6.0

COMMISSIONING

6.1

POST ERECTION CHECKS

6.1.1

INSPECTION AND MAINTENANCE LOG SHEET


It is important that an inspection and maintenance log sheet be kept
regularly. The original of this log sheet should be kept along with the
Instruction Manual for future reference and record.

The log should include dates and details of all inspections and
maintenance carried out.

Results of oil tests and insulation resistance together with the


temperatures at the time of measurement should also be recorded in
the log sheet.

Before commencing the test it should be ensured that the secondary


terminals of all current transformers are kept short-circuited. After
test these shorting connections shall be removed.

6.1.2

PHYSICAL CHECKS
Check oil levels in the level gauges of all condenser bushings.
All air release plugs shall be loosened and closed after releasing
trapped air if any.

Check and confirm tightness of all fasteners.


Check and confirm that valves are either open or closed as indicated
the valve schedule plate.

Check all bolted gasket joints and confirm that there is no oil leak.
All blanking plates and spares including spare gasket should be
stored carefully for future use.

Check all cable terminations and ensure that cables are properly
connected and cable numbering ferrules are provided.

Check and ensure that all protective covers like valve guards, LV
bushing protection covers etc. are removed.

Check and confirm that all bushing porcelain are cleaned thoroughly
and are without damage.

Check & confirm that the test tap caps of all Condenser type
Bushings are tightened.

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PTRM : 0708
Page 61 of 205

Remove the cap provided at the bottom of silicagel breather for the
transportation purpose.

Arcing horns if provided are set to the specified gap


All earthing connections are tightened properly.
Anti condensation heaters are functioning correctly.
Rating and connection diagram plates and other marking labels are
fitted properly.

All isolating switches are set at ON position.


Cooler control switch is set to AUTO.
All alarm circuits are reset.
OLTC to Transformer equalising pipe shall be removed after oil filling
under vacuum and the opening shall be coverd by blanking plate
supplied with the transformer.

6.2

INSULATION RESISTANCE CHECK


Check and record insulation resistance between pair of windings and
windings and earth using 5 kV Motorised megger megger and record
the values at 15, 60 & 600 seconds.

Calculate the ratios of insulation resistances IR 600/ IR 60


(Polarisation Index.) and IR 60/ IR 15

Compare the values with factory test results.


Check insulation resistance between core and frame to ground if the
earthing connection is brought out through bushings.

Do not apply any voltage or even high voltage megger when the
equipment is under vacuum.

6.3

RATIO TESTS
Connect 3-phase 415 volts supply between HV terminals and
measure the voltage ratios at all taps and record.

Earth connections from star point shall be removed during


measurement and reconnected after tests.

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6.4

PTRM : 0708
Page 62 of 205

VECTOR GROUP TESTS


Connect 415 V, 3-phase supply to HV winding terminals. The
transformer shall be at rated tap.

Connect one HV terminal to one LV terminal and measure voltage


between each HV terminal to each LV terminal in turn. Compare the
values with factory test results.
E.g. for Ynyno: Measure voltage between
1u -1V, 1u - 1W , 1V2 - 1W,
1u -2V, 1u - 2W, 2V2 - 2W,
1u -2V, 1W - 1W, 1W2 - 2W,

6.5

MAGNETIC BALANCE TEST


Single-phase 240 volts is applied across any HV winding and
voltage induced across the other phases are measured and
compared with the factory test results.
CAUTION:
If there is a residual magnetism in the core, it can give erratic
readings.

6.6

SHORT CIRCUIT IMPEDENCE


LV terminals are shorted by using suitable cables.
3 phase 415 volts supply is connected to HV winding and HV
exciting current of all the phases and LV circulating currents of all
the phases are measured and recorded.

Percentage impedance = Rated current x Applied voltage x 100


Measured current x Rated voltage

Compare the results with factory test results.


6.8

WINDING RESISTANCE MEASUREMENT


Note down the oil/winding temperature. If the measurements are
done after hot oil circulation; the oil/winding temperature may be
different from the ambient temperature.

Measure the resistance of all windings using a Whetstone Bridge or


Kelvin bridge.

Convert the resistances to 75OC.


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PTRM : 0708
Page 63 of 205

For copper windings:

R (75)

= R (measured) x (234.5 + 75)


(234.5 + Oil temperature at the time of measurement)

Compare the values with factory test results.


6.9

TAN DELTA AND CAPACITANCE


Measure tan delta and capacitance of Condenser bushings of 52 kV
and above and compare with the factory test results (Refer to
"INSTRUCTIONS FOR INSTALLATION AND MAINTENANCE OF
OIP CONDENSER BUSHINGS" provided elsewhwhere in this
Manual).

Compare the values with factory test results.


6.10

6.11

OPERATION CHECKS

Check direction of rotation of pumps and fans.

Check and confirm that flow indicators are mounted correctly.

Check signalling circuits for pump fail/fans fail etc., and reset.

Check setting of over load relays and reset.

BUCHHOLZ RELAY OPERATION


Check inclination of Buchholz relay pipe. The slope should be in
upward direction, between 3 ~ 9O to horizontal towards the
conservator.

Connect a compressed air line (Pressure 4 kg/cm2) or a nitrogen


cylinder to the petcock on top of the Buchholz relay.

Open the petcock slowly and allow air to enter into the Buchholz
relay.

Check the continuity of alarm contacts by using a multimeter.


Record the volume of air in the Buchholz Relay at which the alarm
switch contact closes.

Close the air supply and release all the air by opening the other
petcock on the Buchholz relay.

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PTRM : 0708
Page 64 of 205

Open the petcock quickly and allow air full flow with surge. Record
the minimum pressure required to operate the surge contacts.

Release all the air trapped in the Buchholz relay.


6.12

WINDING TEMPERATURE INDICATOR CALIBRATION


Rotate the indicator pointer slowly and confirm that the alarm signal
is received at the set temperature.

Rotate the pointer slowly and confirm that the trip signal is received
at the set temperature.

For set values of alarm and trip contacts, please refer to the
instruction manual.

Repeat the test for all winding temperature indicators if more than
one indicator is provided.

Remove the thermal sensing bulb from the transformer cover and
insert in hot oil bath.

Check the readings with clinical thermometer.


Replace the sensing element in transformer pocket and check the
readings or remote winding temperatures if provided.

For any adjustment if needed please refer to the instrument


supplier's catalogue.

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POWER TRANSFORMERS

PTRM : 0708
Page 65 of 205

APPENDIX A

ERECTION CHECK LIST


TRANSFORMER ERECTION CHECK LIST
This checklist is intended for use at site by Site Engineers. It outlines the minimum
on site checks expected to be carried out during the erection activity.
CUSTOMER

EQUIPMENT DETAILS:
SITE

SL. No.
1

CHECK POINT

O.K.

NOT
O.K.

REMARKS

AVAILABILITY OF DOCUMENTATION
Erection drawings including OGA
Erection / Maintenance Manual
Transport packing list

RECEIPT OF TRANSFORMER
Externally inspected damage (if any)
Gas pressure on receipt (Where
applicable)
Oil level (in case of oil filled transformer)
Unit correctly positioned

RECEIPT OF ACCESSORIES
All materials stored correctly
Packing Cases inspected, damage if any
Marshalling box inspected, damage if any
Control panels (RTCC)inspected damage
if any

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SL. No.

CHECK NPOINT

O.K

PTRM : 0708
Page 66 of 205
NOT O.K.

REMARKS

Materials received corresponded to Advise


note
Any shortages / wrong supply
Materials comply with shipping specification
Remark (if any)
4

ERECTION
Transport rollers mounted
Conservator mounted
Buchholz relay and oil surge relay mounted
(arrow marked should be towards conservator)
Breather mounted and duly charged
HV Bushings mounted
LV Bushing mounted
Tertiary Bushing mounted (if applicable)
HV neutral Bushing mounted
LV Neutral Bushing mounted
Bushing installed at correct angles
Diaphragm checked
MOLG mounted
Radiator mounted
Fans mounted
Pressure Relief valves mounted
Alignment of all pipe work
OLTC Conservator mounted
Heat Exchangers assembled with pipe work
Topping up of transformer oil
Leakage observed after 24 hrs.(if any)
Rating Diagram and identification plate fitted

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MANUAL FOR
POWER TRANSFORMERS

PTRM : 0708
Page 67 of 205

Marshalling box aligned


Control panel (RTCC) aligned
Control panel (OLTC) aligned

OIL FILLING
All bushing oil level
Tap changer selector oil level
Diverter switch oil level
Auxiliary unit oil level
Radiator, Headers oil filled
Transformer / OLTC Conservator oil tight
Complete transformer oil tight
All air release plug vented
Valves in service position
All drain / filter valves blanked

MULTICORE CABLE
All tray work adequately secured
All cables adequately tied/clipped back to tray
Cables glanded correctly
WTIs and OTIs satisfactorily installed

BREATHERS
Transformer silica gel breather satisfactory
Tap changer silica gel breather satisfactory
Drycol breather correctly installed

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8

PTRM : 0708
Page 68 of 205

FANS
Fans rotate freely & quickly
Pumps installed for correct flow
Flow indication visible

CONTROL PANELS
Cable termination
Cable glanding
Control cabinet clean & tidy
Heater supplied
Locking arrangement

10

CLEANING & TOUCH UP PAINTING OF


COMPLETE TRANSFORMER

Date:
Signature: ----------------------------------

----------------------------------

Name:

----------------------------------

----------------------------------

(FOR AREVA)

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POWER TRANSFORMERS

PTRM : 0708
Page 69 of 205

APPENDIX -B
PRE-COMMISSIONING CHECKS & TEST RESULTS
Customer: ______________________

Site:______________________________

EQUIPMENT DETAILS:
(Rating, Ratio, Maker's Ref., Sl. No., Year etc.)
___________________________________________________________________
Vector Group: -------------------------- Amps. (H/I/L) ---------------------------------------------Tapping Range: --------------------%

Impedance at Normal tap ---------------------------

Temperature Rise: Oil -----------------------

Wdg. ---------------------------

GENERAL CHECKS:
STATUS

CHECK POINTS

OK
1

Direction & mounting angle of O.S.R. & Buchholz relay

Dryness of silica gel, seal removal & oil level in bottom


cup

Oil level in Main conservator.

Oil level in OLTC conservator.

Oil filled in OTI / WTI pockets.

Earthing of Main tank, cooler bank, neutral, fans,


pumps, etc

Absence of oil seepages / leakages.

Bushing -their oil levels & test cap covering.

Explosion vent & rupture pin setting.

10

Touch up painting & washing.

11

Overall clearances.

12

Atmoseal commissioned (top gauge glass to show full


oil )

13

Sagging of radiator / pipes

14

Tightness of bushing top seal

15

Distortion in expansion bellows / removal of transit


support

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REMARKS

NOT OK

01/08/07

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A. MARSHALLING BOX (Sl. No. & Rating : _____________________________)


STATUS
CHECK POINTS
OK
1

REMARKS

NOT
OK

W.T.I. (Sl.No., Make & Model)


a. Transit lock release.
b. Switch settings & operation.
c. Connections.
d. Ambient reading.
e. Heater shunt shorting link.
f. Matching with repeaters.
g. Power supply & current converter

O.T.I (Sl. No., Make & Model)


a. Transit lock release
b. Switch setting & operation.
c. Connections.
d. Ambient reading.
e. Matching with repeaters.

Space heater & Thermostat settings.

Cabling, Glanding, Termination etc.

Earthing & Touch up painting.

Stand by supply change over operation

Timer settings.

Closure of openings & tidiness.

B. FANS: (Model, RPM, KW / HP ) ____________________________________


1

Glanding & Earthing.

Mounting & Terminal cover condition.

Direction & Smoothness of operation :


a. Manual -Local.

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b. Manual Remote
c. Auto & Stand by operation
4

Overload setting

Starting current

Running current

Megger values

C. O.L.T.C. (Sl No. , Make & Type) ____________________________________


STATUS
CHECK POINTS

OK

Alignment of all shafts & Drive Mechanism

Oil fill in gear box (Where reqd.)

Mechanical end limits of D.M.

Coupling Position & rotation lag.

Manual operation.

Local electrical operation.

Electrical end limit operation.

Remote electrical operation.

Tightness of external shaft coupling

10

Bending of lock washer.

11

Fitment of window & shaft covers.

12

Cabling, Termination, Glanding etc.

13

Space heater & thermostat setting.

14

Continuity check during transition by voltage


application.

15

Earthing.

16

TPI counter reading

17

CCU for TPI

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D. R.T.C.C.: (Sl. No. & Rating): _________________________________________


1

Installation & Earthing.

Cabling, Glanding, Termination etc.

Setting of Timers.

Functioning of Indication Lamps.

Functioning of Hooter / Buzzers.

Annunciation / Relay Checks:


a.
b.
c.
d.
e.
f.
g.
Make & Model

Tap position indicator.

W.T.I. Repeater.

O.T.I. Repeater.

10

O.L.T.C. Operations :
a. Individual :
b. As Master :
c. As Follower :

11

Emergency Trip.

12

Out of step & MP Timer operation.

13

Operation of A.V.R. & L.D.C.

E. Operation of Pumps, NRV, Flow Indicators:


1

Direction of pump operation.

Manual operation.

Auto operation.

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Stand-by changeover.

Non Return Valve operation.

Overload setting

Starting current

Running current

10

Stability of alarm & trip contacts of Buchholz relay


during oil pump starting by manual / Auto mode

11

Megger value (500 V / 1000 V Megger )

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PART 2
S I T E T E S T R E S U L T S:
NOTE: Instruments provided by Customer will normally he used for the tests after
ascertaining their operation in the applicable ranges.
A. Insulation Resistance:
Range, Make, kV rating & Type of tester: _________________________________
1

Top oil Temperature:

Megger Values:
60
Sec.
H.V. to L.V.:

600
Sec.

60 Sec.

H.V. to T.V.:

H.V. To
Earth
T.V. To Earth

L.V. to T.V.:

L.V. To Earth

600
Sec.

CORE to TANK ( By 1000 V


Megger )
CORE to FRAME ( By 1000 V
Megger )
B. Current Transformers: C. TAN DELTA & CAPACITANCE TEST OF BUSHINGS:
C. T. DETAILS

CHECK POINT
Continuity
Approx. Ratio
Polarity (Only for REF
/ DIFFL. C.T)
Saturation check only
for PS class C.T's

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C. TAN DELTA & CAPACITANCE TEST OF BUSHINGS:


a. Atmospheric condition & temperature:
b. Equipment used for test:
c. Bushing position on test:
Bushing
Sl. No.

Make

Rating A / V

Tan delta

Capacitance Megger value

NOTE: Please ensure that the bushings are absolutely clean. Atmosphere should be
dry & bushing should be in vertical or mounted on transformer during testing. Test
O

tap should be cleaned with CTC & dried out using a hot air dryer (60 C) if need be.
Short the terminals of other bushings & connect to earth. Arcing horns & line
terminals to be removed.
D. SHORT CIRCUIT TEST ON TRANSFORMER:
Method of testing:
Tap Position

Current in Amps
HV

LV

IV

NEUTRAL

FIRST
NORMAL
LAST
REMARKS: Value of short circuit current should be observed on other taps for any
abnormality & abnormalities if any may be recorded.
E. PHASING CHECK ON MULTI-RUN OF CABLES (HV & LV):
Ensure absence of cross connections by physical inspection, and continuity check.
PHASING CHECK BEFORE PARALLELING:
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Ensure absence of cross connections by physical inspection and by


measurement of voltage across corresponding phases on the LV By applying
low voltage on HV.
Approximate Voltage Ratio: Apply single phase 240 or 440 volts on each
HV line lead and N or pair of HV line leads and Measure LV voltage on all
taps in all phases.

F.

Tap
No.

HV Volts (applied)
1U-1V
1U1N

1V1W

LV1 Volts

1W-1U 2U-2V

1V-1N 1W-1N

2U2N

2V2W

LV2 / Tertiary

2W-2U

3U-3V

3V-3W

3W-3U

2V-2N 2W-2N

3W-3N

3V-3N

3W-3N

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
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G. MAGNETIC BALANCE: (For star winding only)


AT NORMAL TAP POSITION
VOLTAGE ACROSS

1U-1N

1V-1N

1W-1N

2U-2N

2V-2N

2W-2N

TAP No.

H. EXCITATION WITH REDUCED VOLTAGE:


1.
For LV winding of up to 1.1 KV class, apply single phase, 2 wire, 415 volts
from HV side (Keeping neutrals isolated) on each leg.
2.
For L.V. winding of class higher than 1.1 KV, apply single phase, 2 wire, 415
volts from LV side (Keeping neutrals isolated) on each leg.
Applied Volts ( V )
Measured current (A)
Tap No
1U-1V

1V-1W

1W-1U

1U

1V

1W

I. OIL BREAKDOWN VALUES: (Average of six readings with 2.5 mm gap)


(a) Main tank top oil sample : ______________________________
(b) Main tank bottom oil sample : ______________________________
(c) O.L.T. C. oil sample: ______________________________
J. VECTOR GROUP CHECK:
Short terminals 1U to 2U and apply 3 phase, 3 wire 415 volts supply across
1U-1V-1W and measure voltage across terminals and confirm the group
STAR -STAR CONNECTION

STAR -DELTA CONNECTION

1V -2V :
1V -2W :
1W -2W :
1W -2V :

1V -2V :
1V -2W :
1W -2W :
1W -2V :
1U -1V :
1V -1W :
1W -1U :
(Signature & Name): _____________ (Signature & Name): _______________
AREVA ENGINEER
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CUSTOMER'S ENGINEER
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Page 78 of 205

PART 3
PRE-COMMISSIONING CHECKS
To be carried out after transformer is connected to lines & before energisation
CHECK POINTS
1
2
3
4

6.

STATUS
O.K. NOT OK

REMARK
S

Clearances in air (refer O.G.A.)


Arcing horn gap set (refer O.G.A.)
Tightness of bushing lugs, cable / line connections,
terminals, etc.
Simulation of Alarm & Trip circuits (verify breaker /
Master trip operation by initiating operating contacts of)
a. Buchholtz relay
b. Winding temperature indicator
c. Oil temperature indicator
d
Oil surge relay
e. Pressure relief device / vent switch
f.
M.O.L.G.
g. Oil / Water flow indicators / D.P.G.
h. Sudden pressure relay
I.
Over current relay
j.
Earth fault relay
k. Differential relay
l.
Inter tripping relay
m. Others
Air venting from:
a. Bushings
b. Radiators, headers, couplings
c. Buchholtz relay
d. O.L.T.C. cover / head
e. Main tank cover / Thermosyphon
f.
Disconnecting chamber
a. H.V. Lightening Arrester counter reading
b. L.V. Lightening Arrester counter reading

Transformer successfully energised on __________ at _______ Hrs on Tap No. ___


Load & is operating satisfactorily.
Transformer put on _______ Amps. / MVA load on _______ at _______ Hrs and is
operating satisfactorily.
Signature : ____________________
Signature: _________________
(AREVA ENGINEER)
(CUSTOMER'S ENGINEER)
Name
: _________________
Name: _____________________
Designation: __________________
Designation: _________________

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Page 79 of 205

DATA REGARDING ACCESSORIES:


1

H.V.BUSHINGS:
Make:
Rating:
Sl. No.:

L.V.BUSHINGS:
Make:
Rating:
Sl. No.:

O.L.T.C. DETAILS:
Make:
Type:
Sl. No.:

FACIA DETAILS:
Make:
Sl. No.:
Model:
No. of windows :
Voltage:

PRESSURE RELIEF DEVICE:


Make:
Sl.No:
Pressure Setting:

Name of Service Engineer:


Signature:
Date:

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7.0

PTRM : 0708
Page 80 of 205

OPERATION
After the inspection and pre-commissioning tests are successfully
completed the transformer can be energised at no load.

Oil soaking/ settling duration of 2 days for transformers up to 245


kV class and 3 days for 400 kV and above class are recommended
after completion of hot oil circulation and before energising.

Excessive vibration if any on any part of the transformer shall be


located and rectified.

Transformer shall be observed for any abnormality.


If any gas is collected inside the Buchholz relay, it shall be analysed
for its combustibility. If gas is not combustible, it indicates air
trapped inside the transformer.

All instruments should be checked for any abnormal indication.


Check winding temperature and oil temperature readings at least
once in every shift.

Check and confirm that tap position indicators is same in local and
remote indicators.

Check and confirm that none of the alarms are indicated.


Ensure that cooler power supply isolator is ON.
Ensure that cooler control is in AUTO.
Ensure that pumps and fans are running smoothly as temperature
dictates. If the temperature is below the ON setting neither the
pump nor fan should be running.

After watching the operation of the transformer at no load for 24


hours and confirming that everything is normal, the transformer
shall be taken on load.

Observe the rise in temperature of oil and winding temperature


indicators.

While temperature is rising, confirm that fans and pumps are


switched on automatically at the preset temperatures.

While temperature is falling, observe that the pumps and fans are
switched off at preset temperature.

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7.1

PTRM : 0708
Page 81 of 205

ROUTINE / PERIODIC INSPECTION SCHEDULE FOR POWER


TRANSFORMER

S. No.

Items to be inspected

Frequency

Load current

Hourly

Terminal Voltage

Hourly

Ambient Temperature

Hourly

Winding Temperature

Hourly

Oil Temperature

Hourly

Tap position

Daily

Air cell conservator

Daily

Oil level in Conservator

Daily

Oil level in Bushings

Daily

10

Oil level in OLTC Conservator

Daily

11

Oil level in breather cup

Daily

12

Connections

Monthly

13

Dust deposits & physical damages to bushings

Monthly

14

Air passage & colour of silica gel in breather

Quarterly

15

Cable boxes, gasket joints, gauges etc.

Quarterly

16

Dielectric strength of transformer oil

Half yearly

17

Moisture content of transformer oil

Half yearly

18

Dissolved gas analysis of transformer oil

Half yearly

19

Resistivity of transformer oil

Half yearly

20

Insulation resistance of windings

Yearly

21

Tan delta & Capacitance of condenser


bushings

Yearly

22

Operation of relays and their circuit

Yearly

23

Surface paint

2 ~ 3 Years**

Note:
** Duration of surface repainting depends on the level of pollution prevailing at site.
If pollution level is high, a frequent repainting schedule may have to be worked
out.

Lifting of core and windings are not recommended as a routine inspection.

Core and coils are to be inspected only if such an inspection is warranted by test
results of dissolved gas analysis, any abnormality in performance or for
suspected internal damages due to external short circuit.

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8.0

PTRM : 0708
Page 82 of 205

MAINTENANCE
Maintenance Schedule
Periodicity

Preventive Maintenance
Procedures
3
Replacement / Regeneration of
Silica gel Breather

8.1

Months
6

12

Scheduled
outage

Dissolved Gas Analysis

Oil Sampling

Buchholz Relay Functional Tests

Tan Delta & Capacitance


Measurement of Condenser
Bushings

OTI/ WTI Tests

Tap changer operation

Insulation Resistance of Windings

Oil Filtration

Surface Painting

Oil Sampling
Oil sample should be tested for the following and results recorded: -

8.1.1

Electric Strength
If the dielectric strength of oil in transformer is less than 55 kV at 2.5
mm gap, the oil must be filtered to improve the characteristics.
For line end OLTC diverter chamber, oil filtration is recommended
when the BDV is 40 kV at 2.5 mm gap.
For neutral end OLTC diverter chamber, oil filtration is recommended
when the BDV is less than 30 kV at 2.5 mm gap.

8.1.2

Moisture Content
For transformers of 400 kV and above class, if the moisture content is
found to have increased beyond 20 ppm oil should be filtered.
For transformers of voltage class up to 245 kV, if the moisture content
is found to have increased beyond 25 ppm oil should be filtered.

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8.1.3

PTRM : 0708
Page 83 of 205

Acidity
It the acidity is increased beyond 0.5 mg KOH/g, than the oil needs
filtration.
After draining the oil completely from the transformer, core, winding,
insulation and interior of tank should be washed by hot oil jet. The oil
being used for washing of internal body also must be drained
completely.
Refilling of oil in transformer should be done under vacuum.

8.2

Sampling procedure
Special care in oil sampling is required for Delta connected transformer
and autotransformers.

8.2.1

Tools required

8.2.2

Spanner set
Thermometer
Steel sampling bottles with polyethylene cone caps.
Silicon rubber tubing 10 mm bore - 1 m long.
Clean synthetic sponge.
Polyethylene sheet - 1 m square
Clean cloths
Self adhesive labels

Procedure
The sampling bottles shall be labelled and marked with information like

source of sample, date and time & sample temperature.


Sample bottle shall not be opened before it is needed for testing.
Sampling point should be cleaned by using sponge.
Blanking plate of sampling valve shall be removed by using spanner.
Clean the silicon rubber tubing thoroughly and fit to sampling point
nipple.
Rinse the bottle in oil stream and reduce the rate of oil flow to 1
litre/minute.
Put the end of rubber tubing to sampling bottle and fill the bottle from
bottom.

No air bubble shall be introduced into the bottle.


The bottle is allowed to overflow before it is closed.
Measure and record the temperature of oil sample as soon as it is
taken.
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Put back and tighten the blanking plate.


Remove all tools, excess oil container and oil sample from the area.
Arrange for testing oil sample at laboratory.
8.3

WINDING TEMPERATURE INDICATOR TESTS

8.3.1

Tools and materials

8.3.2

Hot oil bath (with heating facility)


Secondary injection test set
Multimeter
Clinical thermometer
Keys of marshalling box.

Procedures
The purpose of this check is to confirm that the winding temperatures
Indicators are functioning accurately.
The transformer shall be isolated and earthed.
Rotate the indicator pointers slowly to the alarm set value and confirm
from the control room that the alarm signal has been received.
Rotate the pointer still further and confirm from the control room that
trip signal is received.

8.3.3

Calibration
Remove the thermal sensing bulbs from the transformer and insert it
into the hot oil bath.
Check the winding temperature readings up and down the scale at
intervals of 5 C.
Confirm from control room that remote temperature readings are
tallying with the local readings.
Replace the sensing element into the transformer pocket.
For any adjustment, see the manufacturer's catalogue.

8.3.4

SECONDARY INJECTION TESTS

8.3.5

ONAN Rating
Set the cooler supply isolator of OFF position.
Connect the secondary injection test set across the heater coil
terminals.
Inject current and check the resultant gradient for ONAN rating.

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8.3.6

OFAF Rating

8.4

PTRM : 0708
Page 85 of 205

In order to carry out these tests the pump must be running.


Set the cooler isolator to ON position.
Set the cooler switch to fans and pumps.
Check and confirm that the pump is running.
Inject current in the heater coil and check the gradient for OFAF rating.
Disconnect.
Set the cooler control switch to AUTO.

BUCHHOLZ RELAY FUNCTIONAL TEST


Tools and Materials Required.
Multimeter
Nitrogen cylinder with regulator and pressure gauge or air supply (4
kg/cm)
Bucket
10 mm polythene tube, 10 meters.

8.4.1

Procedure
The purpose of this test is to ensure correct operation of Buchholz

ISSUE/ REVISION
DATE

relay.
Transformer shall be isolated and earthed.
Connect nitrogen cylinder to the top petcock of Buchholz relay.
Open the other petcock.
Allow gas to enter the relay.
Check and confirm from control room that alarm signal is received.
Check continuity of alarm contact by using multimeter.
Close petcock on gas supply side and release all gases trapped in
relay casing.
Increase the gas pressure to approx. 2 kg/cm (30 psi)
Open the test petcock and allow full surge of gas to enter the relay
casing.
Check and confirm from control room that trip signal has been
received.
Check continuity of trip contacts by using multimeter.
Close Buchholz relay test cocks.
If relay has not operated, increase gas pressure and repeat the test.

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Page 86 of 205

If the relay is found faculty replace it with a new one.


Open conservator shut off valve and release all gases trapped.
8.5

TAPCHANGER OPERATION
Regular inspection of tap changing equipment is not required because

8.6

mechanical operation of tap changer does not involve significant


contact wear.
It is sufficient to operate the tap changer through the whole range of
tap selector positions twice a year.
The purpose of this check is to ensure correct mechanical operation of
tap changer.
Transformer shall be isolated and earthed.
Note the tap position.
Operate the tap changer through operating handle through entire range
of tap positions.
Return to the original tap position.
Set the local selector switch to LOCAL.
Press RAISE button and release. Check and confirm the tap position
indication has changed and that limit switch stops the tap changing at
preset tap.
Repeat.
Press the LOWER button and release. Check and confirm that limit
switch has operated and tap position indication has changed.
Repeat till the tap position has returned to the original value.
Set the local selector switch to REMOTE.

OIL FILTRATION
Purpose of this maintenance is to improve the unsatisfactory condition
of oil found during sampling.
Transformer shall be isolated and earthed.

8.6.1

Tools and Materials

8.6.2

Oil conditioning plant (Filter Machine)


50 mm flexible hoses of sufficient length for oil inlet and outlet.
Hose adapters to match the flanges of top and bottom filter valves.
Cleaning cloths

Procedure
Remove the blanking plate from filter valves and connect the oil inlet
hose to top filter valve and oil outlet hose to the bottom filter valve.

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PTRM : 0708
Page 87 of 205

Open the filter valves and start circulation of hot oil. Oil temperature
shall be 55C to 70C.
Circulate the oil for 4 full passes.
Re sample and arrange to test.
Continue until oil condition is acceptable.

8.7

CORRECTIVE MAINTENANCE
All flange gaskets must be renewed wherever joints are dismantled.
Cleanliness of gasket surfaces and correct compression (40 % ~ 50%
approx.) of gasket must be ensured during reassembling.

8.8

REMOVING AND REFIXING OF PUMPS

8.8.1

Tools and materials

8.8.2

Jib crane or chain pulley block to handle the weight of pumps.


Oil drip tray
Blanking plates
New gaskets.

Procedure

Transformer is isolated and earthed.


Close the isolating valves on either side of pump
Disconnect the motor supply wires
Remove the drain plug of the pump and drain oil from the pump.
Remove the clamping bolts and remove the pump
Blank off the isolating valve.
For re-fixing the pump, remove the blanking plates.
Fix new gaskets.
Replace and tighten the clamping bolts.
Open the isolating valves on cooler side.
Open air release plug and close when oil starts flowing out.
Open the isolating valve on transformer tank side.

8.9

REMOVING AND RE FITTING RADIATOR

8.9.1

Tools and Materials

ISSUE/ REVISION
DATE

Jib crane to handle the weight of radiator.


Oil container (capacity approx. 1000 litres)
Oil drain hose 50 mm bore
Hose adapter to match flanges of fitter valve.
20/10/05

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Oil filter machine


New gaskets.
8.9.2

Procedure
Transformer shall be isolated and earthed.
Set the cooler supply isolator of OFF.
Close the inlet and outlet valves if radiator is mounted on a separate

cooler tank.
Close the top and bottom isolating valves of radiator.
Open the top air release plug.
Remove the bottom drain plug and drain the oil to oil container under
gravity.
Sling the radiator with jib crane.
Remove the radiator clamping bolts.
Remove radiator.
Blank off the radiator and header openings.
Close the air release and drain plugs.
For Re fitting the Radiator.
Remove the blanking plates.
Fix new gaskets.
Assemble the radiator and tighten the clamping bolts.
Open the top header air release plug.
Open the bottom radiator isolating valve.
If the radiator is on a separate cooler bank, oil shall be filled into the
radiator bank through the bottom header valve by using the filter
machine. If the radiator is tank mounted, the oil from the oil tank should
be pumped into the tank by using the filter machine.
Close the air release plug on top as soon as oil starts flowing through
the air release plug.
Shut down the oil filter machine
Open top header isolating valve.
In case of separate cooler banks, air should be released through the
top common header air release plugs.

8.10

REMOVING AND RE FITTING FAN & MOTOR

8.10.1

Tools and materials


Forklift truck to take weight of fan and motor assembly.

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8.10.2

Procedure

8.10.3

PTRM : 0708
Page 89 of 205

The transformer is to be isolated and earthed.


Set cooler supply isolator to OFF and lock the marshalling box.
Disconnect the fan motor supply wires.
Support the weight of fan and motor assembly by using fork lift truck.
Unbolt fan and motor form fan mounting frame.
Lower the fan from the fan-mounting frame.

Re fitting Fan and Motor


Assemble the fan and motor in position and tighten clamping bolts.
Re connect the power supply wires.
Unlock marshalling box and set cooler supply isolator to ON.

ISSUE/ REVISION
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9.0

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Page 90 of 205

TROUBLE SHOOTING
Following table shows some of the symptoms, possible causes and
remedies in case of abnormal situations:
If the abnormality is of a major nature, the manufacturer should be
contacted at the address given else where in this Manual. When the
matter is referred to the manufacturer it shall contain the following: Transformer Rating.
Voltage Rating.
Manufacturers Indent No. / Serial No.
Year of Manufacture.
Date / Time of failure.
Brief description of the problem.
Checks done and their results.

9.1

ABNORMAL OPERATING CONDITIONS

TROUBLE
High Winding/ Oil
Temperature

Electrical
Troubles/ Winding
Failure

ISSUE/ REVISION
DATE

20/10/05

CAUSE

REMEDY

Over voltage

Change the circuit voltage or transformer


connections to avoid over excitation.

Over current

If possible, reduce load. Heating can be


reduced by improving power factor of load.
Check parallel circuits for circulating
currents, which may be caused by improper
ratios or impedances.

High ambient
temperature

Either improve ventilation or relocate


transformer in lower ambient temperature.

Insufficient cooling

If unit is artificially cooled, make sure


cooling is adequate.

Low oil level

Top up oil to proper level.

Deterioration/

Use filter press to wash off core and coils.

sludge formation
of oil.

Filter oil to remove sludge.

Short circuited
core

Test for exciting current and no load loss. If


high inspect core and repair. See Electrical
Troubles, below.

Lightning, short
circuit, Overload
Oil of low dielectric
strength.

Usually, when a transformer winding fails,


the transformer is automatically
disconnected from the circuit by the circuit
breaker.

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9.2 DIAGNOSIS OF INTERNAL FAULTS

When the operation of a protective device does not clearly indicate an internal
fault, it is desirable to conduct the preliminary measurements and analysis
before dismantling the transformer.
Conditions before and after the development of fault should be taken into
consideration in arriving at a conclusion.
No

CHECK POINT

DESCRIPTION

CRIETERIA

Measurement
of Insulation
Resistance of
Windings

Measurement must be taken after


isolating the transformer from the circuit
and cleaning the surface of insulators.
Insulation failures can be detected by
this measurement.

Measurement
of winding
resistance

When measurement is made in one


circuit, other circuit must be kept open
circuited. This measurement can detect
winding faults.

Measurement
of Transformer
Ratio.

This can be conducted by applying 230


volts, which can be readily available at
site. For three phase jobs, measure
ratios phase by phase.

Measurement
of No Load
Current

Measurement can be made by applying


230 volts under normal conditions by
making use of locally available power
source. This measurement can detect
fault in windings and core.

If values obtained
are higher
compared to
factory test results,
it indicates faulty
condition.

Testing of oil

Measure Break Down Voltage, moisture


content, tan delta & check for sludge
formation, discoloration and unusual
smell.

Judgment to be
made with
reference to tables
9.1, 9.2, 9.3, 9.4 &
9.5

Measurement
of Tan delta of
Windings

Abnormal increase means deterioration


of insulation.

Comparison with
factory test result

Analysis of gas
collected in
Buchholtz
Relay

When gas is accumulated in Buchholz


relay. It should be analysed by gas
chromatograph to check presence of
combustible gases.

Manufacturer may
be contacted for
advice

Dissolved Gas
Analysis

Development of internal incipient fault


can be judged from the results.
Increase in gas composition to be
monitored at periodic interval.

Refer to tables 9.6,


9.7 & 9.8 Contact
manufacturer for
advice.

ISSUE/ REVISION
DATE

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Comparison with
factory test results.

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9.3

PROTECTIVE DEVICES
No.
1

9.4

PTRM : 0708
Page 92 of 205

DETECTIVE
DEVICE

DESCRIPTION

Pressure Relief
Device

When the internal pressure increases beyond the preset


value of PRD it operates. This may also happen if the
breather connection is choked. Judgment based on the
inspection of other protective relays is essential
Differential Relay This relay detects the internal defects by comparing the
input current and the output current of the transformer. If
it functions simultaneously it indicates internal fault.
Please note that this relay sometimes operates due to in
rush current when transformer is energised and this is
not an internal fault.
This thermometer gives Alarm when the temperature
Oil Temperature
Indicator/ Winding rises beyond the set value. Over loading, insufficient
cooling because of contamination of fan impellers,
Temperature
stoppage of fans/pumps etc. are to be checked.
Indicator Alarm
Over Current
These are intended for detecting faults in power system
Relay/ Earth Fault associated with the transformer. A fault in the
Relay
transformer results in operation of these relays. This is
accompanied by actuation of protective devices of the
transformer. Identification of fault should therefore be
made on the basis of a thorough analysis of these
functions.
Voltmeter/
If a sudden change in voltage or current is noted when
Ammeter
there is no abnormality in the power system or an
unbalance of voltage or current is noted between
phases, the reasons should be investigated.
Human Sense
Human sense can play an important role in detection of
faults.
a) Discoloration or odour of insulating oil. If pieces of
insulating materials or copper are found in oil, an
internal fault can be suspected.
b) Abnormal noise or vibration.

VALVES, GASKETS, WELD JOINTS


SYMPTOM
Oil Leak

Valve cant
be opened

ISSUE/ REVISION
DATE

20/10/05

POSSIBLE CAUSE
Loose joint
Welding joint
Gland packing not
fitted correctly.
Valve spindle bent.
Seating for valve plug
corroded

28/01/07

REMEDY
Tighten the joint evenly. If the leak does not
stop, renew the gasket.
Take the help from manufacturer.
Renew the gland packing and adjust gland
packing nuts evenly.
Fit new valve spindle. Dismantle valve, free
valve plug or fit new valve.

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9.5

PUMPS
SYMPTOM
Pump Motor
over heats

POSSIBLE CAUSE
Impeller binding

Pump motor
vibrating

Pump running;
but output low.

Insulation failure of
Motor Winding
Two phase operation
Motor bearings worn
Impeller damaged
Pump bearing
bushes or rings worn.
Valve not fully open
Impeller damaged or
worn
Speed too low

9.6

REMEDY
Remove the pump and investigate the
problem.
Remove the pump and investigate the
problem.
Check power supply.
Remove pump and investigate the reason
Remove pump and investigate the reason
Remove pump and investigate the reason
Open the valve fully.
Remove pump and investigate the reason
Check electric supply.

FANS
SYMPTOM

9.7

PTRM : 0708
Page 93 of 205

POSSIBLE CAUSE

REMEDY

Fan motor
overheats

Motor bearing worn

Remove the fan and investigate reason.

Two phase operation

Check electric supply

Fan vibrating

Fan blades out of


balance and noisy

Balance the fan or replace

Mounting bolts loose

Check and tighten fasteners.

BUCHHOLZ RELAY
SYMPTOM

POSSIBLE
CAUSE

Rate of gas
evolution

Electrical
response
of relay

NONE

None
Trip
mechanism
operated
by oil
surge

ISSUE/ REVISION
DATE

20/10/05

28/01/07

Identity Class of fault


of gas

REMEDY
Inference

Oil surge

Faulty operation of oil pump

Sudden
vaporisation of
oil at
260~400OC

Large masses of metal


heated Eg.: Earth fault, short
circuit not causing insulation
failure.

Boiling of water
in exceptional
cases

Simultaneous occurrence of
a heat producing fault and
entry of water into the tank.

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RAPID

MEDIUM

Alarm
operates
and
repeats
after
releasing
gas

Air or
inert gas

Major leak due


to mechanical
fault

Fracture of tank, pipe,


or Buchholtz relay
casing or faulty oil
circulating pump.

Trip and
alarm
mechanism
operates

Hydrogen

Thermal
decomposition
of oil above
400OC

Hydrogen
and
carbon
monoxide

Thermal
decomposition
of oil and
insulation

Air or
inert
gas

Air leaks or
leakage due to
mechanical
fault.
Thermal
decomposition
of oil above
400OC

Local, very high


current, hot spot not
involving insulation, arc
over between metal
parts of Terminal gear
or terminal to tank.
Local hot spots due to
very high current faults
in contact with solid
insulation.
Eg. Insulation failure
followed by arc
between insulated
conductors and earth,
short circuited turn
etc.
Fracture of tank pipe or
Buchholz relay casing
or faulty oil circulating
pumps
Local hot spots not
involving insulation,
faulty joint/ contacts,
core faults causing
burning, an incipient
fault not involving solid
insulation
Eg. Core not properly
earthed
Local hotspots in
contact with solid
insulation. Low power
arc between insulated
conductors and earth,
core faults. Faulty
joints/ contact. Any
incipient fault involving
solid insulation
Release of entrapped
air during early life of
transformer of

Alarm
operates
and
repeats
within
minutes or
hours after
each
release
of gas

Hydrogen

Hydrogen
and
carbon
monoxide

Alarm
operates

SLOW

ISSUE/ REVISION
DATE

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Air or
inert
gas

Thermal
decomposition
of oil and solid
insulation.

Presence of
air due to
mechanical

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Hydrogen

Hydrogen
and
carbon
monoxide

No gas
pressure in
Buchholtz
relay

ISSUE/ REVISION
DATE

20/10/05

Alarm
operated

28/01/07

N. A.

PTRM : 0708
Page 95 of 205

fault or
physical
absorption
Decomposition
of oil only

transformer, crack in
tank, pipe or relay
casing, faulty oil pump.
Low current arcing not
involving solid
insulation,
gassing caused by high
electrical stress, corona
discharge
Decomposition Low energy arcing
of oil and solid involving
insulation
decomposition
of solid insulation,
creepage through solid
insulation, oxidation of
insulation
Low oil level
Oil level falling below
the level of Buchholtz
relay due to oil leakage

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Table 9.1: DIELECTRIC STRENGTH OF INSULATING OIL


(12.5 mm dia. Spheres, 2.5 mm gap)
No.

Nominal Voltage Of Transformer Dielectric Strength of Insulating Oil (kV)

145 kV class and above

More than 50

72.5 kV class to less than 145 kV

More than 40

Less than 72.5 kV class

More than 30

Table 9.2: ACID CONTENT OF INSULATING OIL (BY NEUTRALISATION)


No.

Judgment

Acid Content of Oil (mg KOH/g)

Good

Less than 0.2

Replace or do filtration

0.3 ~ 0.5

Replace immediately

Above 0.5

Table 9.3: RESISTIVITY OF INSULATING OIL


No.

Judgment

Good

Fair

1x1011 to 0.1x1012

Poor

Less than 0.1x1011

Resistivity of Oil at 90OC ( -cm)


More than 0.1x1012

Table 9.4: WATER CONTENT


No. Nominal Voltage of Transformer

Water Content (ppm)

400 kV Class & above

Less than 20.

Upto 245 kV Class

Less than 25.

Table 9.5: DIELECTRIC DISSIPATION FACTOR


No. Nominal Voltage of Transformer

At 90OC, 40 ~ 60 Hz

145 kV Class & above

0.2 Max.

Below 145 kV Class

1.0 Max

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9.8

PTRM : 0708
Page 97 of 205

DISSOLVED GAS ANALYSIS


O2

(Oxygen)

N2

(Nitrogen)

CO2

(Carbon dioxide)

CO

(Carbon monoxide)

H2

(Hydrogen)

CH4

(Methane)

C2H2

(Acetylene)

C2H4

(Ethylene)

C2H6

(Ethane)

C3H6

(Propylene)

C3H8

(Propane)

Table 9.6
"Normal" Values of Dissolved Key Gas Concentration Limits in oil of
Power Transformers in Service [Parts per Million ppm].
(Ref. FIST 3-30 : October 2000)
CH4
C2H2 C2H4 C2H6
CO
CO2*
TDCG**
Status
H2
Condition 1
100
120
35
50
65
350
2500
720
Condition 2
101~
121~
36~
51~
66~
351~
2500~
721~
700
400
50
100
100
570
4000
1920
Condition 3
701~
401~
51~
101~ 101~ 571~
4001~
1921~
1800
1000
80
200
150
1400
10000
4630
Condition 4
>1800 >1000 >80
>200 >150 >1400 >10000
>4630

Ref.: FIST 3-30 (Transformer Maintenance; Facilities, Instructions, Standards


and Techniques by United States Department of the Interior Bureau of
Reclamation, Denver, Colorado).

CO2 is not considered in the calculations for TDCG, because it is not a


combustible gas

**

TDCG means Total Dissolved Combustible Gas.

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Condition - 1
Total Dissolved Combustible Gas (TDCG) and any individual combustible gas
below this level indicate normal operation of the transformer. If any gas
exceeds the specified level, it needs investigation.

Condition - 2
TDCG and any individual combustible gas in this range indicate greater than
normal combustible gas level. A fault may be present. Further monitoring is
required.
Refer Table 9.7 for recommended sampling frequency and actions.

Condition - 3
TDCG and any individual combustible gas in this range indicate a high level of
decomposition of cellulose insulation and / or oil.
Refer Table 9.7 for recommended sampling frequency and actions.

Condition - 4
TDCG and any individual combustible gas in this range indicate excessive
decomposition of cellulose insulation and / or oil. Continued operation could
result in failure of the transformer.
Refer Table 9.7 for recommended sampling frequency and actions.

Note:
A sudden increase in key gases and the rate of gas generation are more
important in evaluating a transformer than the amount of gas.

ISSUE/ REVISION
DATE

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Table 9.7
Action based on Dissolved Combustible Gas concentration.
Conditions

Condition 1

TDCG Level or
Highest
Individual Gas
(Ref. Table 9.5)

TDCG
Generation
Rates
(ppm / day)

720 ppm of
TDCG or
highest
condition based
on individual
gas from Table
9.5

Condition 2

Condition 3

Condition 4

ISSUE/ REVISION
DATE

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Sampling Intervals and Operating Actions for


Gas Generation Rates
Sampling
Interval

< 10

Annually/ 6
Monthly for
EHV Trf.

10 ~ 30

Quarterly

> 30

Monthly

< 10

Quarterly

10 ~ 30

Monthly

> 30

Monthly

< 10

Monthly

10 ~ 30

Weekly

> 30

Weekly

< 10

Weekly

10 ~ 30

Daily

> 30

Daily

Operating Procedures
Continue normal operation

Exercise caution. Analyse


individual gases to find cause.
Determine load dependence.
Exercise caution. Analyse
individual gases to find cause.
Determine load dependence.
Exercise caution. Analyse
individual gases to find cause.
Plan outage. Contact
manufacturer for advice.
Exercise caution. Analyse
individual gases to find cause.
Plan outage. Contact
manufacturer for advice.
Consider removal from service.
Contact manufacturer for
advice

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Table 9.8
Transformer Fault Types and the gases they produce.
Key Gases
H2, possible trace of CH4
and C2H6, possible CO

Possible Faults
Partial discharge (Corona)

Possible Findings
Weakened insulation from
ageing and electrical
stress.

H2, CH4 (CO if discharges


involve paper insulation).
Possible trace of C2H6.

Low energy discharges


(sparking)

Pinhole puncture in paper


insulation with carbon and
carbon tracking. Possible
carbon particles in oil.
Loose grounding of metal
objects.

H2, CH4, C2H6, C2H4 and


C2H2 present in large
amounts. If C2H2 is being
generated, it indicates
continuance of arcing. CO
will be present if paper is
being heated.

High energy discharges


(arcing).

Metal fusion, (poor


contacts in tap changer or
lead connections).
Weakened insulation, from
ageing and electrical
stress. Carbonised oil.
Paper over heating/
destruction if it is in the arc
path.

H2, CO.

Thermal faults less than


3000C in an area close to
paper insulation (Paper is
being heated)

Discoloration of paper
insulation. Overloading or
cooling problem. Bad
connections. Stray current
path and/or stray magnetic
flux.

H2, CO, CH4, C2H6 and


C2H4

Thermal fault between


3000 C and 7000 C

Paper insulation
destroyed. Oil heavily
carbonised.

All the above gases and


acetylene in large
amounts.

High energy electrical


arcing 7000 C and above.

Same as above with metal


discoloration. Arcing may
have caused a thermal
fault.

Note: Transformers are so complex that it is impossible to put all causes into a chart.
Several other reasons like high current surges due to faults down stream,
static electric discharges, multiple core earthing, sustained operation under
over load, over/under voltage etc. may also be seen.
ISSUE/ REVISION
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Page 101 of 205

Dissolved Gas Analysis using Key-gas Ratios


(Ref. CIGRE Report 15.01.01: October 1999)
Key ratio No. 1: (INDICATION: DISCHARGE)
C2H2 (acetylene /ethane) : >1 indicates fault
C2H6
Key ratio No. 2: (INDICATION: PARTIAL DISCHARGE)
H2 (hydrogen /methane) : >10 indicates problem
CH4
Key ratio No. 3: (INDICATION: THERMAL FAULT)
C2H4 (ethylene /ethane) : >1 indicates thermal fault
C2H6
Key ratio No. 4: (INDICATION: CELLULOSE DEGRADATION)
CO2 (carbon dioxide /carbon monoxide) : >10 indicates thermal
CO
over heating
>3 indicates electrical fault
Key ratio No. 5: (INDICATION: INTANK TAPCHANGER)
C2H2 (acetylene /hydrogen) : >2 & C2H2 >30 ppm indicates possibility
H2
of tap changer oil leaking into main tank
Note:
Ratios are to be calculated only if the concentrations of both the
gases are above the detection levels.

ISSUE/ REVISION
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Page 102 of 205

FLOW CHART FOR FAILURE INVESTIGATION


Ref.: IEEE Std. C 57. 125 - 1991
SELECTED TESTS

TRANSFORMER
TRIPPED OR
MALFUNCTIONED

ROUTINE TESTS
SHOW DEVIATION
FROM PAST

ANALYSIS OF DATA

DATA GATHERING
TABLES 2 AND 3

MONITOR

YES

NO
PROBLEM

YES

CANDIDATE
FOR REPAIR

YES

NO

DAMAGE
IS
OBVIOUS

RETURN TO SERVICE

TESTING
TABLE 4 AND TABLE 5

FOCUSED TESTS
SELECTED FROM
TABLE 4 AND TAB LE 5

SELECTED
TESTS

NO
ANALYZE TEST
RESULTS
APPENDIX A

SCRAP

INTERNAL INSPECTION
TABLE 8
ANALYZE-SECTION 6

YES

PROBLEM
FOUND

TESTING
TABLE 4 AND TABLE 5

NO

NO

PERFORM
CORRECTIVE
ACTION

FURTHER
TESTING

YES

YES

FIELD
REPAIR

NO

NO

FACTORY
REPAIR
DECISION

YES
TEARDOWN-TABLE 10
ANALYZE-SECTION 6

FIG. 9
NOTE: For further details please refer to IEEE Std. C. 57. 125 - 1991
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10.0

PTRM : 0708
Page 103 of 205

NATIONAL AND INTERNATIONAL STANDARDS


APPLICABLE TO POWER TRANSFORMER AND ALLIED
PRODUCTS.

10.1

INDIAN NATIONAL STANDARDS.

10.1.1

POWER TRANSFORMERS:
IS 1866

: 2000 Code of Practice for Maintenance and


Supervision of Insulating Oil in Equipment.

IS 1885 (Part 38) : 1993 Electrical Vocabulary - Transformers and


Reactors.
IS 2026 ( Part 1) : 1977 Power Transformers - General.
IS 2026 (Part 2 ) : 1977 Power Transformers - Temperature rise
IS 2026 (Part 3 ) : 1981 Power Transformers - Insulation level and
dielectric tests.
IS 2026 (Part4)

: 1977 Power Transformer - Terminal marking,


Tapping & Connections

IS 2026 ( Part5)

: 1994 Transformer / Reactor bushing minimum


external clearance in air

IS 6600

: 1972 Guide

for

loading

of

oil

immersed

transformers.
IS 10561

: 1983 Application guide for power transformers.

IS 11171

: 1985 Dry type transformers.

IS 10028(Part1)

: 1985 Code of practice for selection installation &


maintenance of transformers- Selection

ISSUE/ REVISION
DATE

IS 10028 (Part 2) : 1981 "

"

Installation

IS 10028 (Part 3) : 1981 "

"

Maintenance

20/10/05

28/01/07

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10.1.2

PTRM : 0708
Page 104 of 205

MATERIALS, FITTINGS AND ACCESSORIES OF POWER


TRANSFORMERS.
IS 1747

: 1972 Nitrogen.

IS 1576

: 1992 Solid Press board for electrical purposes.

IS 2312

: 1967 Propeller type AC ventilating fans.

IS 3024

: 1997 Grain Oriented Electrical steel sheet and


strips.

IS 3070 (Part3)

: 1993 Lightning arresters for alternating current


System; Metal oxide lightning arresters
without gaps.

IS 3151

: 1982 Earthing transformers.

IS 3231 (Parts 0~3)

Electrical relays for power System


Protection

IS 1367 (Part13) : 1983 Hot dip galvanised coating on threaded


fasteners.
IS 1363 (Part 1)

: 2002 Hexagonal head bolts, screws, and nuts of


product grade

C, Hexagonal head bolts

(M5 to M64)
IS 1363 (Part 2)

: 2002 Hexagonal head bolts, screws, and nuts of


product grade C, Hexagonal head screws
(M5 to M64)

IS 1363 (Part 3)

: 1992 Hexagonal head bolts, screws, and nuts of


product grade

C, Hexagonal head nuts

(M5 to M64)

ISSUE/ REVISION
DATE

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28/01/07

01/08/07

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Must not be disclosed, copied or used for Manufacturing, Tendering or for any other purpose without prior written permission.

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IS 8603 (Part 1)

: 1977 Dimensions
bushings

PTRM : 0708
Page 105 of 205

for

for

porcelain

use

in

transformer

heavily

polluted

atmosphere 12/17.5 kV Bushings.


IS 8603 (Part 2)

: 1977 Dimensions
bushings

for

for

porcelain

use

in

transformer

heavily

polluted

atmosphere 24 kV Bushings.
IS 8603 (Part 3)

: 1977 Dimensions
bushings

for

for

porcelain

use

in

transformer

heavily

polluted

atmosphere 36 kV Bushings.
IS 8603 (Part 4)

: 2003

IS 12676

: 1989 Dimensions

52 kV Bushing.
for

oil

impregnated

paper

insulated condenser bushings.


IS 13305

: 1992 Permissible limits of visual defects for


insulating porcelains for electrical circuits.

IS 13312

: 1992 Dimensions of porcelain oil filed transformer


bushings (rated 52 kV) in medium polluted
atmospheres.

IS 15137

: 2002 Metal Connecting Lugs for Porcelain


Transformer Bushings - Specification

IS 1573

: 1986

Electroplated coatings of zinc on iron &


steel

IS 2629

: 1985 Recommended

practice

for

hot

dip

galvanising of iron and steel.


IS 2633

: 1986 Methods for testing uniformity of coating of


zinc coated articles.

IS 4759
ISSUE/ REVISION
DATE

20/10/05

: 1996 Hot dip zinc coating on structural steel.


28/01/07

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POWER TRANSFORMERS

PTRM : 0708
Page 106 of 205

IS 3401

: 1992 Silica gel

IS 3588

: 1987 Electric Axial flow fans.

IS 3637

: 1966 Gas operated relays.

IS 3639

: 1966 Fittings & accessories for power


Transformers

IS 4253 (Part1)

: 1980 Cork Composition Sheet - Plain cork

IS 4253(Part2)

: 1980 Cork Composition Sheet - Cork & Rubber.

IS 5561

: 1970 Electric power connectors.

IS 6088

: 1988 Oil

to

water

heat

exchanger

for

transformers.
IS 1666

: 1961 Paper

Covered

Rectangular

Copper

Conductors for transformer winding.


IS 8468

: 1977 On load tap Changers.

IS 8478

: 1977 Application guide for on load tap Changers.

IS 104

: 1979

Ready mixed paint, brushing, zinc chrome,


priming.

IS 2074

: 1992 Ready mixed paint, air drying, red oxide zinc chrome, priming.

IS 2932

: 1993 Enamel, synthetic, exterior


(a)

undercoating,

(b)

finishing.

IS 13213

: 1991 Polyurethane full gloss enamel.

IS 13238

: 1991 Epoxy based zinc phosphate primer (two


pack).

IS 1554 (Part 1)

: 1988 PVC insulated (heavy duty) electric cables


for working voltages upto and including
1100 V.

ISSUE/ REVISION
DATE

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MANUAL FOR
POWER TRANSFORMERS

PTRM : 0708
Page 107 of 205

IS 1554 (Part 2)

: 1988 " from 3.3 kV upto and including 11 kV

IS 9147

: 1979 Cable sealing boxes for oil immersed


transformers; 12 kV ~ 36 kV.

1S 9700

: 1991 Activated alumina.

IS 12943

: 1990 Brass Glands for PVC Cables.

IS 13947 (Parts 1~5):

Low voltage Switch Gear and Control Gear General rules.

IS 4257 (Part 1)

: 1981 Dimensions

for

clamping

arrangements

porcelain transformer bushings for 12 kV to


36 kV bushings.

10.1.3

INSTRUMENT TRANSFORMERS
IS 1885 (Part28) : 1993 Electro Technical Vocabulary Instrument
Transformers.
IS 2705 (Part1)

: 1992 Current Transformers - General.

IS 2705 (Part2)

: 1992 Current Transformers - Measuring.

IS 2705 (Part3)

: 1992 Current Transformers - Protective.

IS 2705 (Part4)

: 1992 Current Transformers Protective


Current transformers for special
purpose application.

IS 3156 (Part1)

: 1992 Voltage transformer - General.

IS 3156 (Part2)

: 1992 Measuring Voltage transformers.

IS 3156 (Part3)

: 1992 Protective Voltage transformers.

IS 3156 (Part4)

: 1992 Capacitive Voltage transformers.

IS 4146

: 1983 Application guide for Voltage


transformers.

ISSUE/ REVISION
DATE

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28/01/07

01/08/07

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ERECTION, COMMISSIONING,
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MANUAL FOR
POWER TRANSFORMERS

IS 4201

PTRM : 0708
Page 108 of 205

: 1983 Application guide for Current


transformers.

IS: 5547

: 1983 Application guide for Capacitive


Voltage transformers.

10.1.4

TRANSFORMER BUSHING
IS 1885 (Part54) : 1993 Electro Technical Vocabulary - Insulators.
IS 2099

: 1986 Bushings for alternating Voltages above


1000 V.

IS 3347(Part 1to8)

Dimension

for

porcelain

transformer

bushings.
IS 4257 (Part 1)

: 1981 Dimension for Clamping arrangements for


bushing 12 kV to 36 kV.

IS 5621

: 1980 Hollow porcelains for use in electrical


equipment.

IS 8263

: 1976 Methods for radio interference test on


high Voltage insulators.

IS 8603 (Part1~3): 1977

Dimension

for

porcelain

transformer

bushings for heavily polluted atmospheres


12, 24 & 36 kV.
IS 8603 (Part 4)

: 2003

52 kV Bushing

IS 8704

: 1995 Artificial pollution tests on high Voltage


insulators to be used on AC Systems.

IS 12676

: 1989 Dimensions

for

oil

impregnated

paper

insulated Condenser bushings.


IS 13134

: 1992 Guide

for

Selection

of

insulators

respect of pollution Conditions.


ISSUE/ REVISION
DATE

20/10/05

28/01/07

01/08/07

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Must not be disclosed, copied or used for Manufacturing, Tendering or for any other purpose without prior written permission.

in

ERECTION, COMMISSIONING,
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MANUAL FOR
POWER TRANSFORMERS

IS 13305

PTRM : 0708
Page 109 of 205

: 1992 Permissible limits for Visual defects

for

insulating porcelains for electrical circuits.


IS 13312

: 1992 Dimensions

of

porcelain

oil

filled

transformer bushing (rated 52 kV) for


medium polluted atmosphere.
IS 15137

: 2002 Metal Connecting Lugs for Porcelain


Transformer Bushings - Specification

10.1.5

REACTORS
IS 5553 (Part 1)

: 1989 Reactors - General.

IS 5553 (Part 2)

: 1990 Shunt Reactors.

IS 5553 (Part 3)

: 1990 Current

limiting

reactors

and

neutral

earthing reactors.
IS 5553( Part 6) : 1990 Earthing transformers (Neutral Couplers)
IS 5553( Par 8)

10.1.6

: 1990 Smoothing Reactors

TRANSFORMER OIL AND OIL TESTING


IS 335

: 1993

New insulating oils.

IS 1448 (Part 10) : 1970 Method for test for petroleum and its
products cloud point and pour point.
IS 1448 (Part 16) : 1990 Density of crude petroleum and liquid
petroleum products by Hydrometer method.
IS 1448 (Part 21) : 1992 Petroleum and its Products - Flash point by
Pensky Martens Apparatus.
IS 1448(Part 25) : 1976 Determination of Kinematic and Dynamic
Viscosity.
ISSUE/ REVISION
DATE

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ERECTION, COMMISSIONING,
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MANUAL FOR
POWER TRANSFORMERS

IS 1866

PTRM : 0708
Page 110 of 205

: 2000 Code of practice for maintenance


and

supervision

of

insulating

oils

in

equipment.
IS 2362

: 1993 Determination of water by Karl Fisher


method.

IS 6103

: 1971 Method of test for specific resistance


(resistivity) of electrical insulating liquids.

IS 6104

: 1971 Method of test for interfacial tension

of

oil against water by ring method.


IS 6262

: 1971 Method of test for power factor and


dielectric constant of electrical

insulating

liquids.
IS 6792

: 1992 Method of determination of electric strength


of insulating oils.

IS 6855

: 2003 Method of sampling for liquid dielectrics.

IS 9434

: 1992 Guide for sampling and analysis of free and


dissolved gases and oil from oil filled
electrical equipment.

IS 10593

: 1992 Methods of evaluating the analysis of gases


in oil filled electrical equipment.

IS 12177

: 1987 Methods of test for oxidative ageing of


electrical insulating petroleum oils by open
beaker method.

IS 13567

: 1992 Determination of water in insulating liquids


and in oil impregnated paper & press board

ISSUE/ REVISION
DATE

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28/01/07

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Must not be disclosed, copied or used for Manufacturing, Tendering or for any other purpose without prior written permission.

ERECTION, COMMISSIONING,
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MANUAL FOR
POWER TRANSFORMERS

by

automatic

PTRM : 0708
Page 111 of 205

Coulometric

Karl

Fisher

Titration - Method of Test.


IS 13631

: 1993 Method of test for detection & determination


of antioxidant additives in insulating oils.

IS 12463

10.1.7

: 1988 Inhibited Mineral Insulating oils.

INSULATION CO ORDINATION AND HIGH VOLTAGE


TESTING
IS 1876

: 1961 Method

for

voltage

means
IS 2071 (Part1)

measurement

by

of sphere gaps.

: 1993 High voltage test techniques;

General

definitions and test requirements.


IS 2071 (Part 2)

: 1974

Test procedures.

IS 2071 (Part3)

: 1976

Measuring devices.

IS 2165 (Part1)

: 1977 Phase to earth insulation co-ordination


principals and rule.

IS 2165 (Part2)

: 1983 Phase to phase insulation co-ordination


principles and rules.

IS 3716

: 1978 Application

guide

for

insulation

for

partial

co-

ordination.
IS 6209

: 1982 Methods

discharge

measurements.
IS 8690

: 1977 Application guide for measuring devices for


high voltage testing.

ISSUE/ REVISION
DATE

IS 2551

: 1982 Danger notice plates.

IS 8923

: 1978 warning symbol for dangerous voltages.

20/10/05

28/01/07

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ERECTION, COMMISSIONING,
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MANUAL FOR
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IS 12776

: 2002 Galvanised

strand

PTRM : 0708
Page 112 of 205
for

earthing

Specification.

10.2

IEC STANDARDS
IEC 60071-1 (2006)

Insulation co-ordination; Definitions,


principles and rules.

IEC 60071-2 (1996)

Insulation co-ordination; Application guide.

IEC 600761 (2000)

Power transformers; General.

IEC 600762 (1993)

Power transformers; Temperature rise.

IEC 600763 (2000)

Power

transformers;

Insulation

levels,

dielectric tests and external clearances in


air.
IEC 600764 (2002)

Power transformers; Guide to the lightning


impulse and switching impulse testing.

IEC 600765 (2006)

Power transformers; Ability to withstand


short circuit.

IEC 600767 (2005)

Power transformers; Loading guide for oil


immersed power transformers.

IEC 600768 (1997)

Power transformers; Application guide.

IEC 6007610 (2005)

Power

transformers;

Determination

of

sound levels Application Guide.


IEC 6007610-1 (2005)

Power

transformers;

Determination

of

sound levels.
IEC 6007611 (2004)

Power transformers; Dry type transformers.

IEC 6007614 (2004)

Power transformers; Design & Application


of liquid immersed power transformers
using high temperature insulation materials.

IEC 60137 (2003)

Insulating bushings for alternating voltages


above 1000 V

ISSUE/ REVISION
DATE

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MANUAL FOR
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IEC 60156 (1995)

PTRM : 0708
Page 113 of 205

Method for determination of the electric


strength for insulating oils.

IEC 60044-1 (2003)

Current Transformers.

IEC 60044-2 (2003)

Inductive Voltage Transformers.

IEC 60044-5 (2004)

Capacitor Voltage Transformers.

IEC 60044- 6 (1992)

Protective Current Transformer for transient


performance.

IEC 60214-1 (2003)

Tap changers; Performance requirements


and test methods

IEC 60214-2 (2004)

Tap changers; Application Guide

IEC 60168 (2001)

Tests on indoor and outdoor post insulators


greater than 1000 volts.

IEC 60270 (2000)

High

Voltage

Test

techniques:

Partial

discharge measurements.
IEC 60289 (1988)

Reactors.

IEC 60296 (2003)

Fluids for electro-technical applications unused

mineral

insulating

oils

for

transformer and switch gear.


IEC 60310 (2004)

Railway

applications

Traction

Transformers and inductors.


IEC 60422 (2005)

Mineral insulating oil in electrical equipment


- Supervision and maintenance guide.

IEC 60445 (2006)

Identification of equipment terminals and


termination of certain designated
conductors including general rules for an
alpha numeric system.

IEC 60475 (1974)

ISSUE/ REVISION
DATE

20/10/05

28/01/07

Method of sampling liquid dielectric.

01/08/07

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IEC 60529 (2001)

PTRM : 0708
Page 114 of 205

Degrees of protection provided by


enclosures (IP Codes).

IEC 60554 (Part 1 ~ 3)

Specification for cellulosic papers for


electrical purposes.

IEC 60567 (2005)

Guide for the sampling of gases and of oil


from oil filled electrical equipment and for
the analysis of free and dissolved Gases.

IEC 60599 (1999)

Guide to the interpretation of dissolved and


free

gases

in

mineral

oil-impregnated

electrical equipment in service.


IEC 60616 (1978)

Terminal and tapping marking for power


transformers.

IEC 60628 (1985)

Gassing of insulating liquids under electrical


stresses and ionisation.

IEC 60905 (1987)

Loading

guide

for

dry

type

Power

Transformer.
IEC 60947 (Part 1 to 7)

Low voltage switchgear and control gear.

IEC 61378-1 (1997)

Converter Transformer for industrial


application.

IEC 61378-2 (2001)

Converter Transformer for HV DC


application.

IEC 61639 (1996)

Direct

Connection

transformer

and

gas

between
insulated

power
metal

enclosed switchgear for rated voltages of


72.5kV and above.
********************

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PTRM : 0708
Page 115 of 205

TRANSFORMER
ACCESSORIES

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PTRM : 0708
Page 116 of 205

TEMPERATURE INDICATOR

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MANUAL FOR
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PTRM : 0708
Page 117 of 205

INSTALLATION AND MAINTENANCE


INSTRUCTIONS
1.

APPLICATION
The Temperature indicator is used as an Oil Temperature Indicator (OTI) or
as Winding Temperature Indicator (WTI) for the protection of liquid immersed
power transformer. In the case of dry type transformers it is used as
Temperature Indicator (T.I.) to monitor the temperature of the windings.

2.

SCOPE OF SUPPLY
OTI & TI: Instrument with specified Range, Number of control switches, length
of capillary and sensing bulb.
WTI: Same as 2.1 but fitted with specified thermal image device.
TRANSMITTER (OPTIONAL): A precision potentiometer is mounted inside
the case of OTI or WTI (2.1 or 2.2) to transmit the measured temperature to
remote point(s).
REPEATER (OPTIONAL): Analogue indicator supplied separately for remote
indication of the temperature measured by OTI or WTI (2.1 or 2.2)

3.

OPERATION
The instrument operates as OTI when its sensing bulb is mounted in an oil
filled pocket located in the hottest oil of an oil immersed transformer.
The instrument operates as TI when its sensing bulb is exposed to the
medium adjacent to the windings of a dry type transformer.
When a proportionate load current of the transformer is passed through the
thermal image device, the instrument operates as a WTI integrating the
simulated temperature rise of the thermal image device and the top oil
temperature measured by the sensing bulb.
Remote indication of the temperature measured by the OTI or WTI is provided
by connecting the transmitter to the repeater either directly or through a
resistance transducer (resistance to current converter).

4.

CONSTRUCTION
LIQUID-FILLED SYSTEM (Refer Fig. 1): A sensing bulb (25), a measuring
bellows (2) and a small bore capillary tube (24) connecting the two, form the
measuring system. A second bellows (16-compensating bellows)

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PTRM : 0708
Page 118 of 205

connected with a second capillary (24) running parallel to the first capillary
and terminated at the head of the bulb from the temperature compensating
system. Both the systems are completely filled with the same liquid (other
than mercury). The two bellows are linked to a compensating lever (15) in
such a manner that the effect of ambient temperature changes on the
capillary line and measuring bellows is compensated. The movement of the
measuring bellows is related only to the temperature being measured by the
sensing bulb. This movement is amplified by the link and lever mechanism
(6), which directly drives the rotating disc (21) carrying the control switches.
The same mechanism moves, through rack and pinion a separately mounted
indicating pointer (Fig. 2, 11) over a calibrated dial. Head compensation is
provided by sealing both the systems under initial pressure, which is greater
than the possible head pressure due to differences in the elevation between
the bulb and indicator.
MAXIMUM POINTER (RED COLOURED) located on the indicator lid, is
resettable from outside the case by a screw driver blade. Unscrew and
remove black cap to reach the screw driver-slot.
CAUTION: Never use the switch testing knob for setting the maximum
pointer. If used, the switch contacts will close and initiate the external control
circuits when the instrument is in operation.
SWITCH TESTING KNOB: It is fitted on the indicator lid to check mercury
switches setting and potentiometer operation. This knob when rotated moves
the indicating pointer, switch mechanism and potentiometer wiper together
and facilitates testing these circuits without opening the lid. Rotate the knob
slowly and steadily for an accurate check. Never allow the knob to spring back
suddenly or quickly, as this will cause damage.
THERMAL IMAGE DEVICE (Refer Fig. 1): A heater coil (3-Bellows Heater) is
fitted around the measuring bellow (2) and supplied from a current
transformer in the load circuit of transformer. The heater coil simulates hotspot temperature of the winding over top oil temperature for a given load. The
measuring bellows reacts to this simulated temperature rise in addition to the
top oil temperature measured by the sensing bulb and the instrument
functions as a WTI displaying the hottest spot temperature of the winding. An
adjustable shunt resistor (17-calibrating shunt) is provided for shunting portion
of the current through the heater coil to obtain precise thermal image.

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PTRM : 0708
Page 119 of 205

FIG. 1
INDICATOR
(LID & DIAL REMOVED)

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PTRM : 0708
Page 120 of 205

REMOTE INDICATION (OPTIONAL): Refer Fig. 1, A precision potentiometer


(20) is mounted inside the indicator to function as a transmitter for remote
indication of the temperature measured by the OTI/WTI. Technical Data of the
transmitter and repeater along with details of adjustments are given in the
relevant data sheet supplied with each indicator.
ELECTRICAL CONNECTION: All internal electrical connection are wired to
the terminal block (Fig. 1, 14) mounted inside the indicator case. A wiring
diagram is fixed inside the case of each indicator. Switches are identified by
markings S1, S2, S3 and S4 on them. Terminal Nos. wired to each circuit are
detailed below.

TERMINAL Nos.

WIRED TO

1,2 Switch
3,4
5,6
7,8
9,10,11
12,13,14

5.

S1 Alarm
S2 Trip
S3 Cooler Control 1
S4 Cooler Control 2
Bellows, Heater & Shunt
Potentiometer-Min., Wiper, Max

PRE-INSTALLATION TESTING
EQUIPMENT:
1. Controlled constant temperature bath with continuously stirred liquid.
2. Certified Standard Thermometer.
3. A continuity test circuit.
4. High voltage breakdown tester.
5. A constant current source.
Note: Calibration baths are generally suitable for use only in workshop. If
required for use in the field, they should be used under cover and in a non
hazardous environment.

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PTRM : 0708
Page 121 of 205

PRE-CONDITIONING: Before commencing any tests check the following: 1. The instrument is as per purchaser specification.
2. The instrument is not damaged in any way and any such damage is
rectified before testing.
3. The instrument is mounted correctly. (Refer 6.1)
3. The shipping stop (22 - Fig. 1) is removed.

OTI CALIBRATION: Place the sensing bulb of the temperature indicator


under test in the well-stirred constant temperature bath. Allow 5 minutes
settling time before taking readings. Check the reading near to but not less
than minimum value of the indicator scale. For increasing values of
temperature, repeat the procedure to obtain at least two further readings the
highest value being near to but not greater than the maximum scale value of
the indicator. The readings should agree with the standard thermometer within
1.5% f.s.d. (Maximum scale value). Otherwise following adjustments should
be made.

ZERO ADJUSTMENT: Use this adjustment for correcting readings near


minimum scale value. Referring to Fig. 1, firmly hold the tongue adjuster (50
by a 2BA spanner and slacken the lock nut (4) with a second 2BA spanner.
To move the indicting pointer (19) up or down the scale, turn the tongue
adjuster (5) by a small amount anticlockwise or clockwise respectively. Retighten the lock nut holding firmly the tongue adjuster. Do not twist the
measuring bellows while carrying out this adjustment as this may cause
damage to the linkage/bellows.

SPAN ADJUSTMENT: Use this adjustment for correcting reading near the
maximum scale value. Referring to Fig. 1, slacken the shoulder screw (7) half
a turn but do not remove the same. Turn the range adjuster screw (8)
anticlockwise or clockwise to increase or decrease respectively the sweep of
the pointer. Make the adjustment in small increments and carefully. Half a turn
in either direction may correspond to approximately 0.5 reading. After
adjustment, retighten the shoulder screw.

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Ensure that the lock nut (4) and shoulder screw (7) are properly tightened after
the above adjustments. Repeat the tests in cold and hot bath until the
accuracy limit of 1.5% f. s. d. is achieved.

WTI CALIBRATION: During Calibration, keep the instrument lid fixed in


position. Place the sensing bulb in the continuously stirred oil bath, the
temperature of which is maintained at the specified value. Allow 5 minutes
setting time and apply the specified current to the bellows heater and
calibrating shunt network. The current must remain switched on at specified
value for at least 40 minutes before taking reading. To achieve the readings
within the accuracy limits or to reset the temperature rise to a different value,
the following adjustments should be made.

GRADIENT ADJUSTMENT: After opening the instrument lid, carefully remove


the dial. Withdraw the calibrating shunt (17-Fig. 1) after removing the nut and
retaining washer. One adjustable centre band and two fixed bands at the ends
are provided in the shunt. One supply lead is connected to the centre band and
the other lead to the lower band on the shunt. Slacken the screw in the
retaining clip of the centre band. To reduce the temperature rise, move the
centre band nearer to the lower band, to increase the temperature rise reverse
the procedure. Retighten the screw on the centre band after adjustment.
Replace the shunt, dial and lid. Repeat the calibration, check after adjustments
until the accuracy limits achieved.
SWITCH SETTING: The switch settings are adjustable as indicated below: Indicator Scale Range Switch setting adjustable Switch differential (close to
to close between
open) adjustable between
0 - 120 C

40 C and 120 C

6 C and 80 C

20 - 120 C

50 C and 120 C

6 C and 90 C

30 - 120 C

50 C and 120 C

6 C and 100 C

0 - 150 C

45 C and 150 C

7.5 C and 105 C

0 - 240 C

80 C and 240 C

12 C and 160 C

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NOTE: Unless specified otherwise, the instruments are supplied with


minimum switch differential.
Connect across the switch contacts the continuity test circuit and check the
correct operation of the switches at their set points to make (close) and break
(open) contacts. The switches should operate at set point within 2.5% of
switch setting arm pointer (10-Fig. 1) indication, otherwise the following
adjustment should be made.
SWITCH ADJUSTMENTS: Referring to Fig. 1 slacken switch setting screw
(11) on each switch setting arm (10). Move the left hand arm pointer over the
switch scale (9) to the required temperature for making (closing) contact and
right hand arm pointer to the required temperature for breaking (opening)
contact. Retighten both switch setting screws. By closing the left hand arm
pointer to the right hand arm pointer minimum differential is obtained. A builtin stop automatically sets the minimum differential. While slackening and
tightening the setting screw, steady the disc with the other hand to prevent
undue strain on the mechanism. The indicating pointer can be moved with a
finger in a clockwise direction to check the operation of the switches at set
points. By moving the pointer slowly and steadily, an accurate check is
obtained. Never allow the pointer to spring back suddenly or quickly and also
force the pointer in an anticlockwise direction. By doing so the measuring
bellows is likely to be damaged. An alternative procedure is to check the
switch operation while calibrating the instruments for temperature readings.

INSTALLATION
MOUNTING: Mount the instrument in a vertical position. Otherwise errors,
particularly in the horizontal plane, will upset the zero setting of the mercury
switches. Place a sprit level on the top of the indicator case to ensure correct
positioning and operation of the mercury switches.
If vibration exists at the mounting position, mount the indicator on a nonvibrating structure. Suitable anti-vibration mountings are supplied. Do not use
these mountings during transport.
CAPILLARY LINE: Do not stretch hard twist or bend the capillary to a radius
less than 75 mm. Continuously support the capillary by suitable clips at
intervals of 300 to 450 mm. Allow necessary slack at the bulb and for

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mounting and removing the bulb without sharp bend at the joint. Wind in spiral
(minimum dia. 150 mm) the possible excess length of capillary close to the
indicator or the bulb.

7.

HANDLING AND STORAGE


Handle the instrument with utmost care. Do not twist the capillary while
unpacking, storage or installation. Avoid sharp bends especially where the
capillary joins the indicator and bulb. Allow minimum 75 mm radius of bend.
Never lift or carry the instrument by holding the capillary only. Before storing
or transporting, pack the instrument in the paper board box supplied. Before
lowering the instrument into the box, fix the shipping stop (22) and wind the
capillary in spiral close to the indicator (minimum, spiral dia 150 mm) locate all
the cushions before closing and sealing the box. Where necessary, provide
additional wooden packing case for transport.
IMPORTANT: When Anti-Vibration mountings are supplied, do not use these
during transport.

8.

MAINTENANCE
Normally no maintenance is required for the temperature indicator. However,
adjustment or replacement of switches and resetting of the maximum pointer
may become necessary.

9.

REPAIRS
If a mercury switch is damaged in anyway, it may be unclipped from the
switch carrier and the leads removed with a hot soldering iron. After resoldering the leads to a new switch and locating back the switch in the clip,
the switch should be re-balanced. This is done by making the switch to topple
in its carrier at the instant when the mercury flows toward or away from the
electrodes. By sliding the switch a little in the appropriate direction in the clip,
correct topping is achieved. After correctly balancing the switch, check the
operation at preset temperature. If necessary re-zero the switch scale by
slackening the switch zeroing screw (12-Fig. 1) at the top of the switch scale
and rotating the scale to required position. Retighten the screw after
adjustment. If the bellows, bulb or capillary are damaged, repairs can be done
only at the manufacturer's factory.

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GAS & OIL OPERATED


(BUCHHOLZ) RELAYS

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CONTENTS
I.

General

2.

Applications

3.

Advantages

4.

Construction

5.

Functional Test

6.

Electrical Connection

7.

Installation and Maintenance

8.

Basic Characteristics

9.

Function

10.

Operating Characteristics

11.

Relays for use in areas of Seismic Disturbances

12.

Specifications of Relays

13.

Overall Dimensional drawing

14.

Dimensions and ratings

PREFACE
The ever increasing demand for electrical energy goes together with the demand for
more and more efficient and reliable "protection devices'' for power, distribution and
supply facilities. In the field of power supply, transformers represent key installations
that demand effective protection to ensure the constant availability of electrical
energy.
One of the most essential devices to protect a transformer is a Buchholz relay. For
more than 20 years, Buchholz relays have been manufactured in India. They are
made by an experienced staff of skilled workers, highly qualified technicians and
engineers ensuring a high degree of precision and quality.
A wide range of type corresponding to the BIS & International Standards are
available to meet the many requirements of manufacturers and users of
transformers.
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GENERAL
Power Transformers are considered to be a highly reliable type of equipment,
yet, in order to ensure the continuity of service that modern conditions
demand, protective devices are required. The purpose of such devices is to
disconnect faulty apparatus before large-scale damage is caused by a fault
to the apparatus or to other connected apparatus. Such devices generally
respond to a change in the current or pressure arising from the faults and are
used for either signalling or tripping the circuits.
Protective devices in the ideal case must be sensitive to all faults, simple in
operation, robust for service and economically feasible. Considering liquid
immersed transformers, a near-ideal 'protective device' is available in the form
of Gas and Oil relay described here. The relay operates on the well-known
fact that almost every type of electric fault in a `liquid immersed transformer'
gives rise to gas. This gas is collected in the body of the relay and is used in
some way or other to close the alarm or the tripping circuit
The principle of the Gas and Oil relay was first successfully demonstrated and
utilised by 'Buchholz' many years back. In a series of experiments carried out
extensively in Germany it was proved that the Relay is capable of bringing to
light incipient fault thereby preventing further spreading of the fault and
extensive damage and thus saving expensive and protracted repairs. So
successful is the principle of this Relay that despite the continued search for
better protective devices in other electrical fields the Gas-and-Oil Relay is still
on its own in providing protection against a variety of faults.

2.

APPLICATIONS
Double element relays can be used in detecting minor faults in a transformer.
The alarm element will operate, after a specified volume of gas has collected
to give an alarm indication. Examples of incipient faults are a)

Broken-down core bolt insulation

b) Shorted laminations
c) Bad contacts
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d) Overheating of part of windings.


The alarm element will also operate in the event of oil leakage, or if air gets
into the oil system.
The trip element will be operated by an oil surge in the event of more serious
fault such as a)

Earth faults

b)

Winding short circuits

c)

Puncture of bushings

d)

Short circuit between phases

The trip element will also be operated if a rapid loss of oil occurs. Single
element relays can be used to detect either incipient or major faults in oil filled
potential transformers, reactors, capacitors etc. A special single element relay
is available for the protection of on load tap-change equipment.

3.

ADVANTAGES
a)

Castings treated against porosity through a special process.

b)

Unique internal design of 'housing' prevents false air traps on top of the
relay.

c)

Well-designed internal layout gives clear view of colour of gas inside


the relay through glass window for fault analysis.

d)

Bucket type float design with inherent ability to withstand vacuum


treatment of transformers.

e)

Built in test facility for checking continuity of both Alarm and Trip
circuits.

f)

Antivibration custom-built mercury switches give high stability against


mechanical shocks and vibrations.

g)

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4.

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CONSTRUCTION
The Buchholz relay essentially consists of enclosure 1 i.e. an oil tight
container and an inserted assembly 2 comprising of two pivoted elements
fitted with switches (Refer fig. above). The enclosure is provided with inlet 1.1
and outlet 1.2 for the liquid. To allow connection of pipes, the enclosure
openings can be designed with pipe thread or flange.
The front inspection glass is provided with a graduation (100 to 300 cm) to
allow readings the accumulated volume of gas and observe colour of gas for
fault analysis.
For checking the function of the inserted assembly a Test Key (1.3) is
provided. There is also a visual indication on the scale (1.4) of service and
Test/Locking position, in the form of movement of red indicator on the reading
scale. This allows the testing of the alarm and Trip circuits before installation
and even when the transformer is in service.
Just above the inspection glass an arrow shows the specified direction of flow
of the insulation liquid to the conservator. Enclosure 1 and its inserted
Assembly cover are made out of Cast Iron.

5.

FUNCTIONAL TEST

5.1

Testing the relay Function with the test key.


A test system is provided in the Buchholz relay that allows the functional test
of the upper and lower switching system.
To test the relay function loosen the nut (1.5) on the Test Key (1.3) and rotate
the key with a screwdriver in the Anticlockwise direction till the SLOT on the
TEST.
Key points towards the T/L position. Both the alarm (upper switching system)
and Trip (lower switching system) will show continuity.
On bringing the SLOT on the Test Key to S (service) position by rotating the

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'key' clockwise the Alarm and Trip circuits will not show continuity. The circuits
will be actuated to 'ON' position only when there will be a fault in the
transformer.
Repeat the functional test each time a relay is started or maintenance
completed.
5.2

Testing the relay Function with the Test Pump. Screw the test pump/Air bottle
to the test cock. Open the test cock and pump air gently into the Buchholz
relay until the upper switching system operates.
For operating the lower switching system air has to be pumped suddenly with
a jerk which will in turn operated the lower switching system.

6.

ELECTRICAL CONNECTION
To allow installation of the 'signal wire' open the terminal box cover
comprising of the nameplate and the instruction sticker on the backside. Then
pass the wire through one of the two-conduit screwings (1.6) into the terminal
box. By using either one or the other openings, facility is given for the cable
to enter the terminal box from the left or right. The upper two studs are
terminals for the Alarm switching circuit and are denoted by A. Likewise
the lower two studs are terminals or the Trip switching circuit and are
denoted by T.

7.

INSTALLATION

7.1

Installation in to pipeline.
For installing the relay into pipeline proceed as follows:
-

See that the Buchholz relay is positioned with the arrow pointing towards
the conservator, the connection box is in the Y plane (vertical) and to Test
cock. (1.7) and air vent cock (1.8) are at the top.

Mount the Buchholz relay as close as possible to the tank in the pipeline
between transformer and conservator.

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Keep pipe bends as wide as possible between transformer and


conservator.

Make sure pipe ascends to the conservator at angle between three degree
to seven degrees.

See that the relay enclosure is not subjected to stress. If necessary, use
expansion compensators.

Ensure that he slot on the Test Key remains in the T/L (Test/Locking)
position during storage or loose transportation of the relay.

- Ensure that the slot on the Test Key remains in the 'S' (Service) position
and the Test Key Bolt is Tightened just before commissioning of the relay.
7.2

Filling with insulation Liquid


To fill the Buchholz relay, proceed as described below:

7.3

Remove the protective acorn nut (1.9) from the air vent cock.

Open the air vent cock to let air escape until insulation liquid emerges.

Shut the air vent cock.

Check liquid level in conservator.

Maintenance
The Buchholz relays are not sensitive to external influences. No servicing is
needed during operation. On routine inspections of the protection equipment,
test the function of the Buchholz relay as described earlier and check the
alarm and trip devices connected to them.

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Basic Characteristics
The Gas and Oil relay provide protection against a number of internal faults
but it also is able to indicate in several cases the type of fault. This is possible
because the gas collected in relay can, from its colour, odour and
composition, indicate where the fault may be and what its nature is. By
examining the gases collected it is possible to infer the nature of fault.
Thus :
a. If the gas is colourless and odourless or with only a faint odour of oil, the
gas is air trapped in the oil or the insulation.
b.

If the gas is Greyish White with sharp and penetrating odour and noninflammable it is due to overheated or faulty insulation (fuller board etc.)

c.

If the gas is yellowish in colour and inflammable it may be due to surface


leakage on material like wood.

d. lf the gas is dark Grey and inflammable it may be due to a flashover in oil
or due to excessive overheating of the oil caused by a fault in the winding
or the core.
On the operation of the alarm if investigation of the collected gas does not
indicate a serious fault it is possible to leave the transformer in service till it is
convenient to carry out a through inspection. This occurrence is possible on a
newly commissioned transformer due to air trapped in the oil or the insulation.
On repeated and frequent alarm signals the transformer should be taken out
of service for thorough check up.

9.

FUNCTION
The function of a double element relay will be described here.
During normal operation of a transformer the Buchholz relay is completely
filled with oil. Buoyancy and the moment due to counter weights keep the
floats in their original top positions.

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In the event some fault in the interior of the transformer tank gas bubbles are
produced and accumulate in the Buchholz relay on the way to the
conservator. In consequence, the oil level in the relay enclosure drops which
in turn lowers the upper bucket.
This causes the mercury switch/Reed switch to operate an alarm signal.
The lower bucket does not change its position, because when the gas
reaches the upper inside wall of the pipe it can escape into the conservator.
Hence, minor fault in the transformer tank will not trigger the lower switching
assembly and will not trip the transformer.
In case the liquid continues to drop due to loss of oil, the lower also goes
down. In consequence lower switching system operates if the level of oil goes
below the bottom level of the pipe connected to the relay.
The lower bucket, does not change its position, because when the gas
reaches the upper inside wall of the pipe it can escape into the conservator.
Hence, minor fault in the transformer tank will not trigger the lower switching
assembly and will not trip the transformer.
In case the liquid continues to drop due to loss of oil, the lower also goes
down. In consequence lower switching system operates if the level of oil goes
below the bottom level of the pipe connected to the relay.
Alternately in the event the liquid flow exceeds a specific value (which is
continuously adjustable, by means of a flap) the lower bucket is forced down,
thus triggering the lower switching system to operate.
As the liquid flow rate decreases or the level of the liquid rises the bucket
returns to its original position. The single element relay has only one operating
element and it responds to either gas collection or oil surges. The method of
operation is similar to that described for double element relay. Single element
relays are suitable for the protection of oil filled reactors, capacitors and
potential transformers. The single element oil Surge relay has been
specifically designed for use with on load tap change equipment and it will
bypass normal amounts of gas which are generated by tap change operations
and will only respond to oil surges and loss of oil.
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OPERATING CHARACTERISTICS
Relays of the double element type are made in three sizes. The sizes are
distinguished by the numerical prefix 1, 2 or 3. This refers to the diameter of
the bore of the oil pipe connecting the transformer to the conservator tank.
They are referred to as Type GOR 1, GOR 2 and GOR 3, where the
Alphabets indicate 'Gas and Oil Operated Relay' and the number refers to the
pipe bore diameter as 25, 50 and 80 mm. respectively.
The implications of the various Type Nos. and their operating conditions can
be listed as follows: TYPE NO.

SPECIAL OPERATING CONDITIONS.

GOR 1
GOR 2

Double element Mercury switch type Buchholz Relays


Normally open type.

GOR 3
SR 1

25 mm. Single element Mercury switch type Surge relay


suitable for OLTC

SR 1/V

25 mm. Single element Mercury switch type for Gas


volume Alarm suitable for reactors, capacitors, potential
and distribution transformers.

GOR 1E

Double element Mercury Switch type Buchholz relays.

GOR 2E

Made as per UNEL-UTE-DIN-BS standards normally


open type.

The symbol /VO following their type markings indicate that the relays contain
Reed switches and normally open type

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The symbol /S following their type markings of all relays mentioned indicate
that the relays are suitable for Silicon Oil normally used in Electro static
precipitator transformers.
All relays mentioned above are normally open types. Normally closed type
relays can also be supplied on request.

11.

Relays for use in Areas of Seismic Disturbance


When transformers are required for use in areas subject to earthquakes or for
traction applications, we can supply special relays, which use magnetically
operated Reed Switches instead of mercury switches.

The outward appearance of these relays are exactly the same as those with
mercury switches but they are distinguished from them by the symbol /VO
following their type marking. The latter V (for vibration) indicates that the relay
contains reed switches and the latter O that the contacts are normally open.
Thus a Type GOR 2/VO signifies a 50 mm. (pipe size). Double float relay with
normally open Reed Switches.
OPERATION
In the double element relay, collection of gas causes the oil level within the
relay to fall. This in turn causes the upper element to rotate on its pivots,
bringing the magnet it carries into a position where it operates the Alarm
Switch.
An oil surge through the relay will cause the lower element to rotate about its
pivots and its magnet into a position so as to operate the tripping switch.
CONNECTIONS
The terminal box and the terminals are the same as that of mercury switch
type relays. In the reed switch relays, each reed switch is protected by, an
inductor in series. These inductors are intended to protect the reed switch
contacts from the effects of capacitive loads, such as are imposed by long
leads or pilot cables, and must not be removed from relays in service.

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Protection of reed switch contacts against the effects of inductive loads, such
as those imposed by contactors and Electro-Magnetic relays, is achieved by
means of a diode wired across each load. This diode must be rated with
forward current at least as high as the steady load current and connected
observing polarity so as to absorb the back e.m.f.. These diodes are not
provided with the relay.
The Mounting position and Testing on site procedure are same as that of
'Mercury Switch type' Buchholz relay.
OPERATING CHARACTERISTICS
All double element relays are adjusted so that their performances lie within
the limits given in table 14. In addition the Reed Switch Relay is capable of
withstanding shocks of up to 4g. Such shocks will not of themselves cause the
relay to operate.

SWITCH DATA:
TYPE ---------------------------------------------------------- Normally Open
CONTACT RATlNG ------------------------ 250VA A.C. (r.m.s.) or D.C. max.
SWITCHING CURRENT --------------------------------- 5A A C or D.C. max.
SWITCHING VOLTAGE --------------------------------------- 300 V D.C. max.
----------------------------- 240 Volts A.C. (r.m.s.) max.
BREAKDOWN VOLTAGE --------------------------------- 650 Volts D.C. min.
INITIAL CONTACT RESISTANCE ------------------------- 70 milli-ohms max.
RESONANT FREQUENCY ------------------------------- greater then 700 Hz.
ACTUATING TIME (Including Bounce) -------------- 2 milli-seconds (Typical)
THESE SWITCHES HAVE RHODIUM CONTACT, LOCATED MIDWAY
ALONG THE LENGTH OF THEIR GLASS TUBES, THE TUBES CONTAIN
AN ATMOSPHERE OF NITROGEN.
PROTECTION OF REED SWITCH CONTACTS:

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THE EFFECTS OF CAPACTIVE LOADS SUCH AS ARE IMPOSED BY


LONG LEADS, ARE SUPPRESSED BY MEANS OF SMALL INDUCTORS
MOUNTED WITHIN THE RELAY AND WIRED ONE IN SERIES WITH EACH
SWITCH.
THE EFFECTS OF INDUCTIVE LOADS SUCH AS ARE IMPOSED BY
CONTACTORS AND E.M. RELAYS ARE SUPPRESSED BY MEANS OF A
DIODE WIRED ACROSS EACH LOAD. DIODE TO BE RATED WITH
FORWARD CURRENT AT LEAST AS HIGH AS STEADY LOAD CURRENT
AND CONNECTED SO AS TO ABSORB BACK e.m.f..
ARRANGEMENT OF TERMINALS AND MEANS OF PROTECTION FOR
REED SWITCH CONTACT.

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12.

PTRM : 0708
Page 139 of 205

SPECIFICATION OF RELAYS
Parameter

Rating

Tolerance

Contact System

Mercury switch

Type of contact

Make Contact

Optional make or break

Switching voltage

220V AC/DC

12 V to 250V AC/DC

Switching Current

5 Amp AC/2 Amp DC

0.05 to 5 Amp

Switching Capacity

1000 W/VA

1 W/VA to 1000 W/VA

Frequency

50 HZ

0 to 60 HZ

Limiting temp of
insulation liquid

+ 120 C

140 C for two hrs.

Gas volume alarm

100 cm to 300 cm

Insulating liquid flow

65 cm/sec to 160
cm./sec. (depending
on size)

Relay casing tested at

8 KG/cm for 1 minute

Max. Permissible flow


rate of insulating liquid

400 cm/sec.

Vibration sensitivity

0.01 inches peak to


peak at frequency of
100 cycle/sec.

Continuously adjustable

Assembled relays are pressure tested with transformer oil at 3kg/cm for 60 minutes.
Electrical circuits are tested at 2000 volts R.M.S. for one minute.
Insulation resistance measured at 500 volts is not less than 10 Megaohms in air.

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PTRM : 0708
Page 140 of 205

IMPORTANT
The various part of a relay including the body, form one complete calibrated unit and
must not be inter changed with those of other relays.
We strongly recommend that relay should not be taken apart, and under no
circumstances should any alteration be made to the angle of the flap on the trip
element. This has been correctly adjusted during manufacturing.

RELAY
TYPE
GOR 1

RELAY
TYPE
SR1

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Page 141 of 205

OIP CONDENSER TYPE


BUSHINGS

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PTRM : 0708
Page 142 of 205

CONTENTS

1.

Design and construction

2.

Packing and storage

3.

Unpacking and handling

4.

Checks before installation

5.

Installation

6.

Checks after installation

7.

Periodical check and maintenance

8.

Unmounting and packing

9.

Safety

These instructions are crucial for the proper


handling, installation, operation & maintenance of Oil
Impregnated Paper Condenser Bushings and these should
be in the possession of those who are responsible for the
above activities.

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PTRM : 0708
Page 143 of 205

INSTRUCTIONS FOR INSTALLATION, OPERATION AND


MAINTENANCE OF OIP CONDENSER BUSHINGS
1.

DESIGN AND CONSTRUCTION


The general constructional details of the bushing, intended for oil-air
application are shown in Fig. 1. The active part of the bushing consists of an
Oil Impregnated Paper (OIP) core (1) manufactured from superior grade Kraft
insulating paper with condenser graded layers for field control, wound under
tension on central tube / conductor (2). The innermost condenser layer is
electrically connected to the central tube / conductor (2) and the outermost
layer is electrically connected to the fixing flange (3) through a test tap (11).
The core is dried under heat and vacuum and then impregnated with superior
grade of insulating oil.
Porcelain insulators (4&5) on the upper and lower sides of the bushing, oil
resistant high quality rubber gaskets & O rings (6) are held together with the
central tube by means of a set of powerful springs (7). The fixing flange (3) is
provided with a test tap (11) for the measurement of Capacitance and Tan
delta, air releasing screw (10) to release the air trapped in the transformer
during topping up of oil or can be connected to Buchholz relay, name plate
giving the product details, handle / eyebolt for lifting and space for ring type
CT's on the oil end of the bushing. At the oil end, an epoxy coated stress
shield or base plate (15) is provided to control the high stresses in oil inside
the transformer. A detachable bottom arc shield is provided for bushing rated
245 kV and above. The intervening space between the core and the porcelain
insulators is filled with specially treated mineral oil under vacuum.
A Prismatic (upto 300kV) or magnetic (upto 400 kV) Oil sight glass (14) is
provided on the expansion bowl (8). A top terminal (12) is provided to connect
to the over head line. Arcing horns (16, 17) are provided on request. (Ref. Fig.
3). Test Tap: - (Refer Fig. 2)
The test tap (11) is provided for the measurement of Capacitance, Tan delta
and Insulation Resistance (IR) values of the bushing. It is connected with a
copper lead to the last condenser foil of the core directly. During normal
service this test tap is electrically connected to the mounting flange through
test tap cover. The threaded test tap cover must be fixed properly (Fig 2a)
before putting into service.

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Page 144 of 205

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2.

PTRM : 0708
Page 145 of 205

PACKING AND STORAGE:


Please refer to Fig. 4
To prevent physical damage to the
bushings, generally only one
bushing is packed in wooden
packing case. At times, more than
one bushing is also packed in the
case of bushings of lower voltage
rating. The bushing is placed in
the packing case at an angle of 68
degrees
to
horizontal.
Accessories like arcing horns,
terminals etc. are also packed in
the same packing case.
The bushing may be stored either
in the same case or removed and
placed vertically or placed at an
angle of 6-8 degrees from
horizontal. This is to ensure the
core remains immersed in oil.
When the packed bushings are
stored outdoors, they should be
kept horizontal and covered with
tarpaulin for protection from rain
and
other
atmospheric
contaminants.

3.

HANDLING AND
UNPACKING:
Please refer to Fig. 5, 6 & 7
The unpacking should be done at
the time of installation. During
unpacking, mechanical stresses or
jerks are to be avoided on the
bushings. On receipt, carefully

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PTRM : 0708
Page 146 of 205

open the top cover of the wooden case and inspect the bushings thoroughly
for any transit damage. Ensure all the accessories are received in good
condition and report, in case found to be missing.
Note: Any damage or shortages should be reported immediately.
Bushing should be handled only with mechanical lifting arrangements, such
as the illustrated in Fig. 5.
When bushings are taken out of the packing case, they must not be allowed
to rest on the lower part of the bushing. The operation is best carried out two
lifting gears and two ropes as shown in Fig. 6. One rope is slung around the
lower end of the metallic flange and let directly to the hook of the first crane
and the other passed around the shell, between two sheds and then led to the
hook of the second crane. The bushing is raised sufficiently in the same
inclination angle as in the packing case with hoists and then lowered at the
flange end. When positioning the bushing upright (Fig. 7), care should be
taken to avoid any shocks, jerks or scratch to the oil end porcelain and bottom
stress shield. On no account the bushing should be balanced on rope, passed
around the porcelain at its centre of gravity.

4.

CHECKS BEFORE INSTALLATION:


i)

Mount the bushing vertically on a suitable stand and clean the surface
thoroughly with a dry cloth, particularly the oil end. Inspect the bushing
physically for any leakage or damage on the porcelains. The oil end and
inner portion of the central tube should be further cleaned with transformer
oil. Care should be taken to prevent scratching of the painted surface of
the bottom stress shield / base plate.

ii)

Check oil level of the bushing in vertical position. The oil level should be
such that the oil level is clearly visible through the oil sight glass provided
on the bushing. The oil level is filled in the factory upto the mid point of the
sight glass, which is considered to be the normal oil level. The oil in the
prismatic type sight glass can be identified by the
highlighting of the red colour reflector at any position mounted from vertical
upto a maximum of 30 degrees.

iii)

Ensure the top terminal is tightened firmly with its gasket provided to avoid
water / moisture entry into the transformer.

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iv)

PTRM : 0708
Page 147 of 205

Measure and record the IR values of the bushing with a 2.5 kV meggar.
The recommended values are:

4000 Meg ohms (Min) between oil end terminal or top and test tap.

1500 Meg ohms (Min) between test tap and flange with 1 kV meggar.
The IR values may vary due to the atmospheric condition (humidity), surface
cleanliness of the porcelains, dryness of test tap etc. In such cases,
preheating of porcelains, terminals test tap etc., with hot air is recommended.
This is only an indicative test, however, the healthiness of the bushings can
be known only after measurement of Tan delta & capacitance values.
v) Capacitance and Tan delta values of the bushing should be measured
between the top terminal and test tap at 2 kV to 10 kV (Maximum). The
measurement should be preferably carried out indoors with RH not exceeding
60% and at ambient temperature, with the facilities and procedure as
described as described below:

Schering Bridge

Standard loss free capacitor

High voltage supply

Necessary screened connecting leads.


Place the bushing vertically on suitable stand. Remove the threaded test tap
cover. Insert a plug / clip into the central stud of the test tap and connect to
the Schering Bridge through a screened cable. The flange body should be
grounded. Connect the high voltage supply to the top terminal. Measure the
capacitance & tan delta value of bushing upto a maximum of 10 kV.
Note:

The voltage applied on the bushing should be limited to 10 kV, when the
bottom end is not immersed in oil. Utmost care should be taken to avoid
any contact with the bushing during testing as this may result in fatal
injury to the personnel.

The test tap should be dry, free from any moisture condensation and dirt
deposition. The threaded test tap cover should be fixed back to the test
tap, immediately after the test.

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PTRM : 0708
Page 148 of 205

Factory test values of tan delta and capacitance are indicated in the test
report of individual bushing at working voltages. However, site values may
vary, as they do not resemble factory test conditions. The site values recorded
at the time of commissioning should be taken as the reference values for
comparison with future measurements. The bushing can be commissioned, if
tan delta value measured is less than or equal to 0.007, and capacitance
value as per the factory test value with maximum variation of 10%. If higher
values are obtained, please contact ALSTOM, Customer Service Department
giving full details of testing arrangement, for further advice.
Note:
The bushing should be kept vertical or mounted on transformer for a minimum
period of 24 hours before application of voltage.

5.

INSTALLATION:
Please refer to Fig. 8
The bushing is suitable for
installation for a maximum angle of
30 degrees from vertical. During the
lowering of the bushing into the
transformer, extreme care should
be taken to prevent the lower
porcelain hitting the wall of the tank.
The bushing should be so mounted
on the transformer that the oil sight
glass is visible from the ground
level. Ensure the visibility of the oil
level to the naked eye.
Maximum stress experienced by the
bushing is at the bottom stress
shield
during
testing.
Hence
sufficient care should be taken to
avoid any flashover from the stress
shield to the wall of the
turret. The flashover voltage depends on the clearance maintained in oil
between the stress shield and turret, oil

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PTRM : 0708
Page 149 of 205

quality, surface smoothness, presence of barriers,


shape of the stress shield and turret etc. The recommended size of the turret
to be maintained for various voltage class of bushings is given in the
manufacturers booklet / respective drawings.
BUSHING WITH DRAW LEAD CONNECTION:
Please refer to Fig. 9.
Each bushing is supplied with a top
terminal (12), cable bolt (9), cable bolt
pin and a gasket placed separately in
the packing case.
Drill a hole of suitable diameter based
on the size of the flexible transformer
cable at the bottom end of the cable
bolt and braze the cable into it. Insert
an M8 bolt at the upper end of the
cable bolt and tie a wire or a fish cord
on to it.
Clean the gasket seating surface on
top face of the transformer and place
the gasket in position. Lift the bushing
above the transformer turret and clean
the bottom end of the bushing.
Lower the bushing slowly into the
transformer, simultaneously pull the transformer cable brazed with cable bolt
through the central tube with the help of the fish cord. Secure the cable bolt to
the central tube with the cable bolt pin. Remove the fish cord. Bolt the bushing
into position taking care to correctly position the gasket joint. Ensure the
threads on the terminal and the cable bolt are clean. Tighten the terminal to
the cable bolt ensuring full thread engagement for proper current transfer.
Sometimes the cable bolt is supplied along with the brazed flexible lead upto
the flange seat with a half connector at bottom end. In such cases the flexible
lead from the transformer winding should be brazed to the other half
connector and should be fastened with the draw lead connector of the
bushing using bolts and nuts.

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PTRM : 0708
Page 150 of 205

BUSHING WITH DRAW-ROD CONNECTIONS:


Please refer to Fig. 10
Bushings of higher current ratings are
provided with draw rod type arrangement with
a half overlap bolted joint at the flange seat.
Remove the draw rod through the bushing
tube or take it out from the packing case.
Clean the outer surface and braze the
transformer cable to the lower half connector.
Clamp the upper and lower half connectors
together with bolts and nuts. Follow the
installation instructions as described for draw
lead type of bushing.
BUSHING WITH SOLID STEM:
Refer to Fig.11
In solid stem type of bushings, the central
conductor forms the current carrying part.
Mount the bushing on the turret and
connections should be made to the top and
bottom terminals individually. The transformer
cable termination should be connected to the
bottom terminal with bolts & nuts, through the
viewing port of the transformer. The top
terminal should be fixed directly to the central
conductor.

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6.

PTRM : 0708
Page 151 of 205

CHECKS AFTER INSTALLATION:


i) After installation, clean the bushing thoroughly with a dry cloth and carry
out physical inspection for any damage on the porcelain / leakage that
might have occurred during installation.
ii) Check the oil level of the bushing.
iii) Ensure the top terminal is fixed tightly with the gasket provided to avoid
entry of moisture in to the transformer.
iv) Measure and record the capacitance and tan delta values of the bushing.
Here again the values may differ from the previous ones.
Note:

The threaded test tap cover should be fixed back to the test tap
immediately after the test.

The bushing should be kept vertical mounted on the transformer for a


minimum of 24 hours before energisation.

CAUTION:
THE TEST TAP WILL ALWAYS BE EARTHED AS LONG AS THE
THREADED CAP IS FIXED (Fig. 2a). HENCE THE CAP SHOULD NEVER
BE KEPT OPEN.

7.

PERIODICAL CHECKS AND MAINTENANCE:


As the bushing is a self contained unit, as such there is no specific
maintenance to be carried out. However, a periodical check of the oil level
and cleaning of the porcelain will normally suffice.
In order to determine the healthiness of the bushing, measurement of
capacitance and tan delta may be carried out during annual maintenance.
These values are to be compared with the pre-commissioning test results.
Tan delta value more than 0.007 and increase in capacitance by more than
10% or more, if observed, should immediately informed to ALSTOM for further
advice.

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8.

PTRM : 0708
Page 152 of 205

UNMOUNTING AND PACKING:


Whenever bushings are to be further transported, they have to be dismantled
from the transformer and handled in the same way as explained under
PACKING. The bushing should be repacked in the same wooden packing
case or in a similar packing case suitable for transportation.

9.

SAFETY:
Understanding the procedures and instructions are a must while handling
bushings. Also, all applicable safety procedures such as regional or local
safety rules and regulations must be followed. Safe working practices and
good judgement are essential by the personnel while installing, testing,
maintaining or disposing the bushings.
CAUTION:
FAILURE TO FOLLOW THE INSTRUCTIONS MIGHT RESULT IN FATAL
INJURY TO PERSONNEL OR DAMAGES TO PROPERTY INCLUDING
TRANSFORMER AND ITS ALLIED EQUIPMENT.

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PTRM : 0708
Page 153 of 205

SILICAGEL BREATHER

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PTRM : 0708
Page 154 of 205

SILICAGEL DEHYDRATING BREATHER FOR TRANSFORMER


A dehydrating breather is used to dry the air that enters a transformer as the
volume of oil decreases because of fall in temperature.
Air entering the breather is first drawn through an oil seal and passes upwards
through the silicagel crystals to the connecting pipe at the top. During this
upward passage of air, any moisture present is absorbed by the dry silicagel.
The oil seal ensures that the gel absorbs moisture only when the transformer
is breathing.
INSTALLATION
The breather is usually detached from the tank and shipped separately; the
silicagel charge is shipped in at the top with a plug. To install, it is necessary
to:
1. Remove top cover by unscrewing cap nut and fill with silicagel.
2. Remove the plug.
3. Pipe up to the tank or conservator.
4. Fill the oil cup with transformer oil to the indicated level.

MAINTENANCE
Inspect the breather on monthly basis; more frequently, if found necessary by
experience (eg. highly humid atmosphere).
When the breather is first installed, the crystals have a blue tint, and after a
period of operation, the colour of the tinted crystals gradually changes to pink;
this is an indication that the silicagel is becoming saturated and losing its
absorbent properties. When there is a preponderance of pink crystals the geI
should be changed or reactivated.
Silicagel may be reactivated by heating in a shallow pan at a temperature of
150 C to 200 C for two to three hours when the crystals should have
regained their original blue tint.
Before filling the container with silicagel, clean and dry all parts of the
breather. Verify that the oil Level in the oil cup is correct when reassembling.
Ensure that the breather is not choked and is free for passage of air.

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Page 155 of 205

SECTIONAL VIEW OF BREATHER

TYPE 1

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Page 156 of 205

SILICAGEL BREATHER

TYPE 2

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Page 157 of 205

OIL LEVEL INDICATOR

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PTRM : 0708
Page 158 of 205

OIL LEVEL INDICATOR

SIDE VIEW

FRONT VIEW

PARTS LIST FOR FIG. 1


Sr. No. DESCRIPTION
1.
2.
3.
4.
5.
6.

MATL.

Float 50 p x 100
Terminal Box
Cover for T. B.
Dial Body with switch housing
Mercury switch
Nut for Switch Adj.

Brass
Cast Al.
Cast Al.
Cast Al.
Glass
Brass

Sr. No.
7.
8.
9.
10.
11.
12.

DESCRIPTION

MATL.

Bolts 'B'-6 Nos.- M6


Base with Mtg. Holes
Limit stoppers
Gear with lever
Float Arm 9.5 p tube
Check Nut

M.S.
Cast. Al.
Brass
Brass
Brass
Brass

Fig. 1
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Page 159 of 205

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PTRM : 0708
Page 160 of 205

OIL LEVEL INDICATOR


MODEL SO-HE-10
APPLICATION
This model of indicator is manufactured considering Transformer application.
It can also be used as Content Gauge on other tanks where level of liquid
inside the tank is required to be indicated continuously on a dial.

CONSTRUCTION, WORKING & FEATURES


A float is used as sensor of liquid level inside the conservator (tank). Swing of
hinged float due to change in liquid level is utilised to indicate level on a
calibrated dial and to operate a switch for external alarm unit.
Use of magnetic coupling in the indicator achieves complete sealing off of
liquid inside the conservator from surrounding atmosphere. This results in
avoiding any leakage of costly oil and avoiding contamination of insulating oil
due to seepage of surrounding air in the conservator.
The glass mercury switch is nylon encapsulated to avoid breakage and
spilling of mercury. Switch is accessible for servicing while indicator is
mounted on the conservator without any necessity of draining the oil.

CALIBRATION
The standard calibration of dial is Empty, 1/4, 1/2, 3/4, Full. Calibration of
marks Empty & Full is done after leaving 65 mm from bottom and top of
conservator to avoid striking of float to conservator wall. Different calibrations
are done to suit customer's needs.

MOUNTING
In fig. 2, indicator is shown mounted by keeping dial and mounting pad in
vertical position. However, indicator can be mounted in titled position towards
ground (max 30) for easy viewing by fixing mounting pad at desired angle.
The position of indicator on the conservator can be selected to suit site
condition. Float mechanism passes through the hole in pad (see Fig. 2).

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PTRM : 0708
Page 161 of 205

ALARM SWITCH & CONNECTIONS


One mercury switch is provided for Low Level Alarm. The Normally Open
switch closes when oil level drops to 10 mm above Empty level i.e. 75 mm
from bottom of conservator. Leads from mercury switch are brought into a
terminal box positioned at the bottom of indicator. (see Fig. 4B), A two-way
terminal strip is provided which is accessible for connection after removing
cover of terminal box. A hole with 3/4 B.S.P. is provided for cable gland.
Wiring should be done as per Fig. 4B.

SPECIFICATIONS
1.

Operating Liquid

Transformer Oil to IS: 335

2.

Working Temperature

0 to 100 C of Oil

3.

Working Pressure

0 to 4 kg/cm

4.

Environment

For Indoor & Outdoor use

5.

Size

See Fig. 2 & 3

6.

Weight

6.6 Kg. with Float & Float-arm

7.

Mounting Specifications

See Fig. 2 & 3

8.

Float Travel

Float moves in right angle plane to


seating face (See Fig.2)

9.

Electrical witch

One SPST Mercury Switch

10.

Contact Rating

5 Amps 240 V.AC. 50 Hz. 1.2 Amps


240 V.DC.

11.

Switch Setting

Normally Open Closes when oil level


drops to Empty level.
Switch opens automatically when oil
level rises.

12.

Dial Size

250 mm dia.

13.

Dial Position

Vertical or Inclined

14.

Conservator dia

Available for use in range of


600 to 1500 mm dia.

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Page 162 of 205

PRESSURE RELIEF VALVE

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Page 163 of 205

GLOSSARY OF TERMS
PRV
: Pressure Relief Valve
Tank
: Tank in which transformer winding & oil etc. are housed.
Figures : Figures in brackets in write-up refer to part list of Drg. CD-601-R-3

1.

APPLICATION:
This PRV is designed to be used on Power Transformer. When pressure in
the tank rises above predetermined safe limit this valve operates and
performs following functions.
Allows the pressure to drop by instantaneously opening a port of about
150 mm diameter.
Gives visual indication of valve operation by rising a flag.
Operates a micro switch.
This switch has 1 NO and 1 NC contacts (Four terminals). Hence switch can
be effectively used in control circuit.

2.

SPECIFlCATIONS:
See Drg. No. CS-601-R-3.

3.

TESTS:
Tests are carried out as per test certificate attached to this leaflet.

4.

CONSTRUCTION & WORKING:


(Refer Drg. CS-601-R-3)
This PRV has an integral flange with six holes for mounting. The valve can be
mounted vertically or horizontally on the tank. The PRV has got a port of
about 150 mm dia. This port is sealed by a stainless steel diaphragm. The
diaphragm rests on an 'O' ring (3) and is kept pressed by two heavy-duty
springs, thereby keeping the port closed. The other side of the diaphragm is
exposed to tank pressure. Whenever the pressure in the tank rises due to any
reason, the same pressure acts on the diaphragm from inside. When pressure
rises above predetermined safe limit the diaphragm gets lifted from its seat.
This lifting is instantaneous and allows vapours, gases or liquid to come out of
tank depending upon the position of valve on tank.

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The diaphragm restores its position as soon as pressure in the tank drops
below set limit. The lift of the diaphragm is utilised to operate flag ( 10) and
micro switch ( 11) with the help of rod (8). The flag and switch remain
operated until they are reset manually.

5.

CHECK FOR VALVE:


The PRV is generally packed in a corrugated box. The method of packing
may vary. The PRV should be checked as follows before it is installed.
Remove the valve from packing and keep it on a table. Remove all packing,
strings fixed to valve. Check that no parts are damaged in transit. If any
damage is found refer to faults and remedies in this leaflet.
Remove the cover of switch box (13). By lifting the operating rod (8) check
operations of switch as stated in Test 4 in test certificate with the help of an
AVO meter. After checking, reset the switch by pressing knob (12). Replace
the cover.
The flag operation should be checked manually by lifting the rod (8) as per
test 1.2 in the test certificate. Reset the flag by turning it down. Handling of
flag should be done very carefully.
The product label indicates the suitability of valve for synthetic liquid or for
transformer oil. A proper valve should be selected. Normally Red product
label is used for synthetic liquid and Black label for transformer oil.
A Gasket (2) for base is supplied with each valve. It should be noted for
general guidance that Red gasket (silicone) is provided for synthetic liquid and
Black for transformer oil.
Each PRV is tested at our works as per test certificate. However, customer is
advised to check the valve by stimulating pressure conditions before it is
actually installed on Transformer. While conducting such Tests at your end
care should be taken that small Particles do not have a passage through the
port opening. Such particles are likely to be trapped between diaphragm and
gasket, which will affect functioning of Valve.

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6.

PTRM : 0708
Page 166 of 205

CHECK FOR INSTALLATION:


The following checks should be observed before installation of PRV on
Transformer.
Check that the orientation of pad is properly done.
Check that the proper bolts, M12x40 with thick washers are taken for
installation. Bolts other than this size should not be used.
Any other gasket than supplied with the valve should not be used.
Provide cable gland of "3/4" BS conduit with suitable bush for cable to be
used.
After all above check the PRV is ready for installation.

7.

INSTALLATION
Each valve should be cleaned from inside (tank side) with compressed air jet.
All particles should be removed from tank side. While cleaning, care should
be taken that the jet does not attack the switch and the flag mechanism. The
PRV should be installed considering the following aspects.
The indicating flag (10) is easily seen from distance, The valve is accessible
for manual resetting and for routine manual checking. While installing remove
dirt and clean the mounting surface, remove all traces of oil, grease.
The rubber gasket supplied with the valve should be properly cleaned & be
located properly in the recess carefully.
All the bolts should be tightened evenly so that equal pressure is exerted on
gasket and base.
Connect control circuits to terminal plate provided in the switch box through
cable gland (14).
As per wiring diagram (ref. fig. 1 drg. CS-601-R-3), check the operation of flag
and switch by lifting operating rod (8) and confirm that both controls operate
as required.
The PRV can be put to service.

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8.

PTRM : 0708
Page 167 of 205

FAULTS AND REMEDIES:


The valve has rugged construction and it is not likely to get damaged easily.
However, the indicating flag (10) is delicate item. Hence if is likely to get
damage. The indicating flag can be replaced by either making similar flag at
your end or by asking for replacement.
You can repair with the help of good instrument mechanic minor faults
occurring in working of switch or flag mechanisms. However for breakage or
damage to major parts like diaphragm, base, valve cover. Send the PRV back
to us.
In any case the Sr. No. of PRV must be informed so that sending correct
replacement is possible. This will also save lot of communication.

9.

GENERAL NOTES:
Store the valve on its base duly packed in polythene bag to ensure that dirt
or other solid particles do not enter the valve port from tank side.
Do not remove the protection cover on flag box and switch box when it is
stored.
Keep the flat gasket (2) duly tied to the valve. Remove it only when it is to be
installed. This gasket should be kept dry.
After installation of valve on transformer, test periodically the functioning of
switch operation and flag operation by lifting the operating rod manually.
This will ensure the switch operation and flag operation when valve opens
due to rise in pressure inside the tank.
It is not possible to change the operating pressure at site.
The valve gaskets are of entirely different nature for synthetic liquid and
transformer oil. Hence use proper valve for liquid as described on product
label.

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PTRM : 0708
Page 168 of 205

EXHAUST FAN

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Page 169 of 205

COOLING FANS
GENERAL
Exhaust type cooling fans used on transformers are designed to operate
outdoors in all weather conditions. Generally the following sizes of fans are
used.

SIZE

(mm)

450

610

610

915

915

SPEED

(r.p.m.)

1400

700

900

550

700

INPUT

(watts)

410

240

500

700

1200

PHASE

VOLTAGE (volts)
FREQUENCY (Hz)

415
50

415
50

415
50

415
50

415
50

CURRENT

0.9

0.5

0.9

1.5

2.5

(amps.)

The fans are designed to operate outdoors in all weather conditions.

MOTORS
The fans are powered by totally enclosed, squirrel cage induction motors. The
motors are adequately rated to give reliable service for many years.

IMPELLER
The impeller is designed to give maximum volume at minimum noise level
with minimum power consumption.
For reducing vibrations, special shoes made of rubber are provided at fixing
points of fan lugs.

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Page 170 of 205

MOUNTING
1.

The arm is secured by the resilient mounting caps, which are placed
over the rubber sockets and secured to the diaphragm with 8 screws,
nuts and washers provided. The lock washers should be fitted under
the heads of the screws.

2.

Rubber sockets fitted to arms. To be fitted so that flat side will come in
contact with the diaphragm.

3.

Arms to be secured to motor by the 4 screws in motor carton.


NOTE: Lock washers are supplied and should be fitted.

4.

ISSUE/ REVISION
DATE

Setscrew in blade should engage in dimple nearest the end of the


shaft. After blade is fitted, see that split pin 5 is replaced in end of shaft.

20/10/05

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Page 171 of 205

CONSTRUCTIONAL DETAILS

No.
1
2
3
4
5
6
7
8
9
10
11
12
13

ISSUE/ REVISION
DATE

PART NAME
TERMINAL BLOCK
BALL BEARING
STATOR WINDING
EARTH SCREW
ROTOR STAMPING
STATOR STAMPING
RESILIENT CAP
RUBBER SLEEVE
BACK COVER FIXING SCREW
BACK COVER
FAN FIXING BOLT
WING
CH. HD. SCREW

20/10/05

28/01/07

No.
14
15
16
17
18
19
20
21
22
23
24
25

PART NAME
WING FIXING BOLT
SPLIT PIN
SHAFT
HUB FIXING BOLT
HUB
BALL BEARING
LUBRICATOR SCREW
MOUNTING ARM
MOTOR FIXING BOLT
DIE CAST AL. ROTOR
CH. HD. SCREW
DIAPHRAGM

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Page 172 of 205

FLOW INDICATORS

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PTRM : 0708
Page 173 of 205

FLOW INDICATORS
FUNCTION
Flow indicators included in this catalogue are mainly designed as a safety device
looking to the need of an electrical signal on failure of forced circulation of liquid in
pipeline. They perform following functions:
1.

Indicate the rate of full flow in proper direction in specified pipe.

2.

Operate one or two mercury switches when rate of flow drops near to 70% of
specified full flow.
These switches can be used to initiate precautionary systems or safety
devices.

APPLICATION
Consider the case of furnace transformer in which one Flow Indicator can be
mounted on suitable member of oil circulating pipe and one on water circulating pipe
of heat exchanger. The pointer of respective Flow Indictor will indicate whether
desired rate of flow is maintained or not and switch will operate if the flow drops near
to 70% to initiate precautionary system. For similar purpose it can be used on liquid
circulating pipes in chemical processes, heavy-duty bearings, compressors, etc.

MOUNTING
To introduce these Flow Indicators in a pipe line a `T-Mounting is necessary. In this
catalogue we have tabulated dimensions of 'T-Mounting' for range of size from 40
mm (1.5") to 250 mm (10") N.B. Pipes. But customer can always specify if his
requirement is different than the tables on page 8.

CONSTRUCTION & WORKING


A suspended vane is used as sensor. Its surface is kept at right angle to direction of
flow. When liquid starts flowing through pipe, the vane gets deflected along with
vane shaft. This deflection is used to indicate flow inside the pipe and to operate
mercury switch or switches as follows:
A pair of permanent magnets is used as gland-less coupling. The driving magnet is
connected with vane, therefore it rotates with vane and remains in liquid. The
follower magnet, separated by a non-magnetic wall, is kept outside in air and
acquires position corresponding to driving magnet. The follower magnet carries a

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PTRM : 0708
Page 174 of 205

pointer and a cam. The pointer is set to read the specified rate of full flow and the
cam is set to operate one or two mercury switches when flow drops near to 70%.
A return spring is used which acts in the opposite direction of flow. Hence any steady
position of pointer is the result of equilibrium of force due to impinging liquid on vane,
spring tension & weight of vane. The pointer does not remain steady for unsteady
flows. The size and shape of vane and tension on return spring is adjusted to suit
specified full flow. The vane occupies very small area out of full cross section of pipe
at NO-FLOW position. At full flow it becomes almost parallel to flow. Hence there is
practically no head-loss across Flow Indicator.

DIAL MARKING
The spread of flow indicating portion of dial is only about 70. Hence it is not possible
to print more markings. Usually PUMP ON-PUMP OFF or FULL FLOW-NO FLOW
type of limit markings is printed. Intermediate markings such as ALARM. TRIP is also
printed if required. Besides, specifications such as value of full flow, liquid, pipe size
and direction of flow are also printed. The background of dial is white. Direction
indicating arrow is in red colour and all other markings in black colour.

SWITCHES
One or two mercury switches of SPST type are provided. The contact position can
be set to No or NC at full flow. If required, switch can be changed from NO to NC or
vice versa at site.
In case of single switch, it is set to operate near 70% when flow is falling. In case of
two switches, both are mounted on same plate. Hence both operate at same rate of
flow. But in order to satisfy design requirements, one switch can be set to operate
near 80% and the other near 70% or one near 70% and the other near 60%. It is not
possible to set a switch to operate at lower value than 60%. Even when both
switches are set to operate at lower value than 60%. Even when both switches are
set to operate at same rate of flow, some switching differentiate is observed due to
use of mercury as switching element, We can modify setting suitably if switching
requirements are clearly specified.

WIRING
Leads from mercury switch/switches are brought into a terminal box positioned at
the bottom of indicator. A two-way or four-way terminal strip is provided. Terminals
are accessible for wiring after removing cover. A hole with conduit threads is
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PTRM : 0708
Page 175 of 205

provided for fixing cable gland to box. Terminals are marked. Wiring should be done
as per respective wiring diagrams.

SETTING
Full Flow- Each indicator is set in water-flowing condition. Pipe size, pipe position,
direction of flow is maintained. By adjusting a valve in pipeline, the specified rate of
full flow is established, then the pointer is set to read the full flow mark. This method
of setting gives very accurate results as it is based on equilibrium of vane at full flow.
In case of liquids other than water, proportional rate of flow of water is maintained for
setting.
Switch - After setting of pointer at full flow, switches are set in the sequence ordered
by customer. Flow is reduced to check operation of switch & increased to check
automatic resetting. The rate of flow at which switching occurs is approximate. The
switch position is kept adjustable to compensate difference in pipe gradient at site.

TESTING
Static Pressure: At 7 kg/cm.
Flow: Indicator is mounted on pipe. Water is allowed to flow in specified direction.
Rate of flow is checked when pointer reads full flow. For Liquids other than water
proportional rate of flow of water is checked.
Switch: Switch operation is checked by reducing and increasing flow in pipeline.
Contact rating: Switches are tested in laboratory at 5A.24OV.AC
Dielectric strength: Live terminals are checked at 2 kV with body.
A test Certificate is provided with each instrument.

DESIGN FEATURES
1.

Switch contacts are not affected by dust, humidity or corrosive atmosphere.

2.

Switches can be serviced without need of stopping flow.

3.

Causes negligible head-loss.

4.

Low maintenance cost.

5.

Robust construction & trouble free service.

6.

Does not get damaged due to excess flow or reverse flow.

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Fig. 1

PTRM : 0708
Page 176 of 205

SCHEMATIC
Item Description
1 2 3 4 5 6 7 8 9 10 -

Fig. 2

Pointer & Dial


Mercury Switch
Switch Operating Cam
Return Spring
Vane Shaft
Vane
Main Pipe
Driving Magnet
Non-magnetic Wall
Follower Magnet

WORKING POSITIONS
Item Description
1
2
3
4
5

Main Pipe
T - Mounting
Connecting Flanges
Flow Indicator
Flange of indicator

Horizontal Pipe
Vertical Pipe

NOTES:
I.

Flow indicators are not interchangeable for different liquids, pipe dia.,
direction of flow or rate of full flow. Hence they should be ordered
separately.

2.

The rate of full flow is not adjustable.

3.

The switch operation point is not adjustable.

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Page 177 of 205

(Actual Supply may not be exactly same)

Fig. 3 Wiring Diagram


For Series 4021.

Fig. 4

Dimension Drawings for Series 4021

Hardware for indicator


(Supplied at extra cost)
M 12 x 65 Bolts, Nuts - Nos.
Washer & Suitable gasket.

Accessories
(Supplied at extra cost if agreed)
T-Mounting, Weldable connection,
Flanges, hardware.

Part List
No. Description
1
2
3
4
5
6
7
8
9
10

Cover for terminal box


Base with mounting holes
Vane shaft
Vane
Product label
Cable entry
Terminals
Mercury switch
Nut for adjusting switch
Cover for switch box

Weight - 3.8 kg.

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PTRM : 0708
Page 178 of 205

Flow Indicators Series 4021 & 4022


It may noted that mounting specifications, flow sensing mechanism, vane orientation
and size of dial is same in both series. Basic difference between two series is that in
Series 4021 only one mercury switch is provided. Whereas in Series 4022 two
mercury switches are provided. Proportionately, number of terminals, size of switchbox and size of terminal box differ,
After suitable series is selected, requirement should be specified as per 'How to
Order' column on Page 3 of this catalogue. Because each indicator is set to suit
requirement specified by customer.
Common specifications of Series 4021 & 4022 working:
Principal of working, switch operation and other details as explained on page 2 & 3
of this catalogue.

Operating specifications (in ranges)


Liquid
Pipe
Switch

Environment
Working temperature
Working pressure

Water, oils
37 to 250 NB (1.5" to 10)
One or two SPST mercury switches
depending on series.
Indoor or Outdoor
0 to 100 C of liquid in pipe
0 to 4 Kg/cm

Material of Construction
Wetted Parts
Vane shaft, return spring
St. Steel
Vane, spring housing, screws
Brass
Base
Aluminium (G. M. on Order)
Magnet
Alnico.
Note: All Brass Parts chrome plated and Aluminium Parts anodised.
Other Parts
Dial Body, switch housing, terminal box, covers Aluminium
Dial shield
Tough glass
Terminals
Brass
Mercury switch
Hg in hard glass

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Page 179 of 205

Fig. 5
Details of vane orientation common to Series 4021 & 4022

Details of symbols used in Fig. 5


Direction of flow liquid in pipe as seen from dial side of indicator.
Force due to return impinging liquid
Force due to return spring
Vane at no-flow
Vane at full-flow
Pipe
Fig. 5 above shows vane positions at no-flow as seen from dial side of indictor.
Indicators are set for any one direction out of four illustrated in Fig. 5. T figure also
shows direction of forces acting on vane due to impinging liquid and return spring
(gravitational force not shown).

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Page 180 of 205

Fig. 6 Wiring Diagram


For Series 4022

Fig. 7 Dimension Drawings For Series 4022


Hardware for indicator
(Supplied at extra cost)
M 12 x 65 Bolts, Nuts - Nos.
Washer & Suitable gasket.

Accessories
(Supplied at extra cost if agreed)
T-Mounting, Weldable connection,
flanges, hardware.

Part List
No. Description
1
2
3
4
5
6
7
8
9
10

Cover for terminal box


Base with mounting holes
Vane shaft
Vane
Product label
Cable entry
Terminals
Mercury switch
Nut for adjusting switch
Cover for switch box

Weight - 4.0 kg.

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PTRM : 0708
Page 181 of 205

(Actual Supply may not be exactly same)

Fig. 8

Wiring Diagram
For Series 4031

Fig. 9

Dimension Drawings For Series 4031

Hardware for indicator


(Supplied at extra cost)
M 12 x 65 Bolts, Nuts - Nos.
Washer & Suitable gasket.

Accessories
(Supplied at extra cost if agreed)
T-Mounting, Weldable connection,
flanges, hardware.

Part List
No. Description
1
2
3
4
5
6
7
8
9
10

Cover for terminal box


Base with mounting holes
Vane shaft
Vane
Product label
Cable entry
Terminals
Mercury switch
Nut for adjusting switch
Cover for switch box

Weight - 4.3 kg.

Flow Indicators Series 4031 & 4032


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PTRM : 0708
Page 182 of 205

It may noted that mounting specifications, flow sensing mechanism, vane orientation
and size of dial is same in both series. Basic difference between two series is that in
Series 4021 only one mercury switch is provided. Whereas in Series 4022 two
mercury switches are provided. Proportionately, number of terminals, size of switchbox and size of terminal box differ,
After suitable series is selected, requirement should be specified as per 'How to
Order' column on Page 3 of this catalogue. Because each indicator is set to suit
requirement specified by customer.
Common specifications of Series 4031 & 4032 working:
Principal of working, switch operation and other details as explained on page 2 & 3
of this catalogue.

Operating specifications (in ranges)


Liquid
Pipe
Switch

Environment
Working temperature
Working pressure

Water, oils
37 to 250 NB ( 6" to 10" )
One or two SPST mercury switches
depending on series.
Indoor or Outdoor
0 to 100 C of liquid in pipe
0 to 4 kg/cm

Material of Construction
Wetted Parts
Vane shaft, return spring
St. Steel
Vane, spring housing, screws
Brass
Base
Aluminium (G. M. on Order)
Magnet
Alnico.
Note : All Brass Parts chrome plated and Aluminium Parts anodised.
Other Parts
Dial Body, switch housing, terminal box, covers Aluminium
Dial shield
Tough glass
Terminals
Brass
Mercury switch
Hg in hard glass

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Page 183 of 205

Fig. 10
Details of vane orientation common to Series 4031 & 4032

Details of symbols used in Fig. 10


Direction of flow liquid in pipe as seen from dial side of indicator.
Force due to return impinging liquid
Force due to return spring
Vane at no-flow
Vane at full-flow
Pipe

Fig. 10 above shows vane positions at no-flow as seen from dial side of indictor.
Indicators are set for any one direction out of four illustrated in Fig. 5. T figure also
shows direction of forces acting on vane due to impinging liquid and return spring
(gravitational force not shown).

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Page 184 of 205

(Actual Supply may not be exactly same)

Fig. 11

Wiring Diagram
For Series 4032

Fig. 12 Dimension Drawings For Series 4032


Hardware for indicator
(Supplied at extra cost)
M 12 x 65 Bolts, Nuts - Nos.
Washer & Suitable gasket.

Accessories
(Supplied at extra cost if agreed)
T-Mounting, Weldable connection,
flanges, hardware.

Part List
No. Description
1
2
3
4
5
6
7
8
9
10

Cover for terminal box


Base with mounting holes
Vane shaft
Vane
Product label
Cable entry
Terminals
Mercury switch
Nut for adjusting switch
Cover for switch box

Weight - 4.8 kg.

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Page 185 of 205

TRANSFORMER OIL PUMP

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Page 186 of 205

IN LINE TRANSFORMER OIL PUMP


INSTALLATION, OPERATION & MAINTENANCE
INSTRUCTIONS
GENERAL CONSTRUCTION
PUMP
The pump set is a single stage axial flow gland-less type, integral with the drive
motor. It has been specifically designed for forced circulation of oil through the
cooling system of large transformer & allows thermo syphonic flow.
It is designed for flange mounting directly to the pipe circuit of transformers in either
horizontal or vertical position.
All the moving parts are completely enclosed and gasket thus permitting open air
installation, without any need for protective cover. It is compact in design.
The Nameplate gives details of pump and motor output along with respective
connecting pipe size.
MOTOR
The motor is of squirrel cage induction type suitable for 3 PHASE A.C. Power supply.
It is coaxial with the pump and is designed to operate in hot transformer oil. The
bearings are lubricated by transformer oil.
PRECAUTIONS
1.

Store the unit in clean and dry place.

2.

Do not remove the M. S. end covers till the pump set is to be installed in pipe
circuit. These are meant to protect the internal components against dirt and
dust during transit and storage.

3.

It is important that all pipe work must be supported independently so that it


imposes no under strain in bending or torsion on the pump flanges.

4.

The bearings are lubricated by the transformer oil and hence the pump should
not run dry, to avoid damage to bearings.

5.

Keep the entire pipe circuit perfectly clean and free from moisture and foreign
material.

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Page 187 of 205

6.

Ensure that the electrical supply available is suitable for data given on the
pump rating plate.

7.

Care should be taken that the valves are in the 'open' position, when the
pump set is operated, because the pump works correctly only when all valves
are fully opened. The oil filled pump will produce Pressure even with the
valves closed, but there is no circulation, there will be oil churning inside the
pump set and the pump motor might also get overheated.

INSTALLATION
Before mounting on pipeline check the following:
1.

Remove the terminal box cover (8), and check the insulation resistance of the
set with a meggar to ensure minimum resistance of 10 meg-ohms.

2.

Remove end covers and check for free rotation of the rotor. Ensure that
Impeller (5) and locking screw (19) with washer are in their proper position.

3.

Connect the supply terminals and ensure rotation of impeller as per 'Arrow
Mark' on the Impeller Housing i.e. anti-clockwise rotation when looking
through the impeller housing opening.

NOTE: In case of wrong direction of rotation of impeller, there will be no discharge.


OPERATION
After installation on the pipe circuit, start filling the system with clean transformer oil
until it completely fills the pump unit, Release all air by the air vent plug initial
continuous air free oil seeps out. It is important that no air is trapped in the pump. It
is always a good practice to allow the pump to run for about 30 minutes before
energising the transformer, to ensure that any air not removed by venting has been
pumped out.
MAINTENANCE
Check periodically the behaviour regarding leakage, vibration, noise, and
current/power consumption of the pump set. In case the pump is to be removed,
allow the unit to cool and drain the oil completely from the set and replace the end
covers. Store as prior installation.
Dismantling of Pump and Motor may be carried out as detailed on Page 201.
TROUBLE SHOOTING
Trouble

Checks

1) Reduced or No delivery

a) Casing Suction Pipe not filled with liquid


b) Discharge head too high.
c) Wrong direction of rotation.
d) Air not vented out.

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2) Low Pressure

PTRM : 0708
Page 188 of 205

a) Wrong direction of rotation.


b) No oil in the pump.

3) More Power Consumption

a) Shaft bent.
b) No free movement of rotating element.

4) Pump is noisy

a) Hydraulic Noise:
Cavitation, wrong direction of rotation
b) Mechanical Noise : Bearing worn-out.

5) Motor Does not Start

a) Supply failure.
b) Defective Phase.
c) Loose Contacts.
d) Rotor Mechanically locked.

6) Fuse blows out while starting :

a) Winding burnt.
b) Interphase shorts.

DISMANTLING OF PUMP AND MOTOR


Please refer Exploded view:
1. Remove Allen Cap Head Screw (19) and Washer (12).
2. Remove Impeller (5) by gently wrenching outwards with preferably a screw
driver.
3. Remove Key (20)
4. Remove End shield fixing screws (21).
5. Lightly tap end shield (2) & (5) with a wooden/nylon mallet until it dismantles
from bearing housing.
6. Remove Pre-loading washer (18).
7. Remove shaft with rotor (4).
8. Remove bearings (11) using a bearing puller.
9. In case required, the terminal arrangement, oil flow indicator (7) and plugs (13)
may be dismantled in the same order as shown.
For re-assembly follow reverse procedure.

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Page 189 of 205

EXPLODED VIEW OF INLINE OIL PUMP

No.

DESCRIPTION

QTY. No.

DESCRIPTION

QTY. No.

DESCRIPTION

QTY.

STATOR CASE WITH WINDING

12

IMPELLER WASHER

23

LOCK WASHER

16

ENDSHIELD (ODE)

13

AIR VENT PLUG & DRAIN PLUG

24

ENDSHIELD FIXING NUT

16

ENDSHIELD (DE)

14

AIR VENT & DRAIN PLUG WASHE

25

TERMINAL BOARD FIXING SCREW

SHAFT WITH ROTOR

15

TERMINAL BOX GASKET

26

TERMINAL BOX FIXING SCREW

I MPELLER

16

TERMINAL COVER GASKET

27

TERMINAL COVER FIXING SCREW

TERMINAL BOX

17

OIL FLOW INDICATOR WASHER

28

PLAIN WASHER

OIL FLOW INDICATOR

18

PRE LOADING WASHER

29

NUT FOR TERMINAL STUD

TERMINAL COVER

19

HEX SOCKET HEAD CAP SCREW

30

LOCK WASHER

TERMINAL BOARD

20

PARALLEL KEY (OER)

31

PLAIN WASHER

12

10

SQUARE RING

21

ENDSHIELD FIXING SCREW

16

11

BALL BEARING SKF 6306

22

PLAIN WASHER

32

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Page 190 of 205

CONSTRUCTIONAL FEATURES

TYPE OF PUMP

Wt. kg.

IL - 5A

345 200

25

502

380

240

270

295

23

65.0

IL - 3A

285

20

425

305

210

240

240

23

41.0

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Page 191 of 205

RADIAL FLOW (CENTRIFUGAL) OIL PUMPS


The pump set is a single stage radial flow gland-less type, integral with a squirrel
cage type induction motor suitable for three phase AC Power supply. The pump and
motor are coaxial and suitable for operation in hot transformer oil.
A well balanced impeller is co-axially mounted on the motor shaft through a key and
positively locked in position. A cast iron volute casing mounted on the stator case
through a spigot joint and sealing ring houses the impeller and imparts direction to
the flow of oil as indicated by an arrow cast on it.
Centrifugal type transformer oil pumps are used for circulating transformer oil
through windings and heat exchanger of oil immersed transformer. These type of oil
pumps are not suitable for natural cooling of transformer and hence these are used
only in association with oil to water heat exchanger where natural cooling is not
applicable. Normally oil to water heat exchangers are used on transformers where
water is available in plenty like hydroelectric stations or on transformers used for
furnace applications.

SPECIFICATIONS
MOTOR

4.3 HP and 7.5 HP

STATOR

3 Phase, 50 Hz, Induction Type

ROTOR

Squirrel Cage Type

BEARING

Ball Type, Lubricated by transformer oil itself.

COOLING

By circulating transformer oil itself.

PERFORMANCE

To IS: 325-1996; 3 Phase Induction Motor

PUMPS
CASING

: Cast Iron

IMPELLER

: Cast Aluminium/Bronzed keyed to the shaft

SEALING RINGS

: Neoprene rubber

FRAME

: Cast Iron totally enclosed integral part of the pump

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Page 192 of 205

PARTICULARS OF DUTY AND DIMENSIONS


4.3 HP

7.5 HP

DISCHARGE

(l.p.m.)

1190

1880

TOTAL HEAD

(m)

11.00

11.00

PIPE SIZE Inlet/Outlet

(mm)

100/100

150/150

Pump Ref.

Dis. Flange
P1 d1

M1

S1

Suc. Flange
LA1 N

P2

d2

M2

S2

Overall
LA2 L

HB

Wt.(kg.)
HC HD Net Gross

EL4.3R

220 100 180 18

18

220 100 180 18

18

460 220 125 290 195 360 71

111

EL7.5R

285 150 240 23

20

285 150 240 23

20

525 227 152 360 210 410 91

131

Fig.

Over all dimensions of 4.3 HP & 7.5 HP Centrifugal Pumps

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Page 193 of 205

FLEXIBLE SEPARATOR
(AIR CELL)

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Page 194 of 205

FLEXIBLE SEPARATOR
1.

INTRODUCTION
Flexible separator (Air Cell) is provided inside the conservator of power
transformers for avoiding direct contact of air with the transformer oil. Air Cell
provides a permanent, flexible and non porous barrier between the
atmosphere and the transformer oil without affecting the operational function
of the system.
The basic construction of the separator is a highly resistant fabric coated
externally to resist transformer oil and internally to Ozone and weather
resistant. Flexible separators offer the following advantages :-

Avoids contact between air and oil and consequently of condensation or


oxidation inside the transformer.

Protection against water vapour and gases.


Suppression of any gas bubble formation in oil.
Compensation of large volume changes.
2.

DESCRIPTION
Flexible separator is fitted inside a cylindrical conservator. Oil being outside,
the separator is in direct contact with atmosphere. This type of mounting
makes it possible to compensate for the oil volume displacements due to
temperature variations.

3.

CHARACTERISTICS OF MATERIAL
Flexible separators are made from coated fabric consisting of :

Textile reinforcement i.e. highly resistant polyamide fabric.

External coating chemically resistant to transformer oils

Inner coating resistant to Ozone and all weather conditions.

Major characteristics of materials are listed below:


Mass

1400 140 g/m

Coating

Poly acrylonitrile butadiene

Textile reinforcement

Polyamide

Breaking Strength
before immersion in oil

> 300 daN / 5 cm.

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4.

PTRM : 0708
Page 195 of 205

INSTALLATION PROCEDURE
1 Connection to the
inside of Air Cell
2 Connection to the
inside of
Conservator
3 Magnetic Oil
Level Gauge

Mounting Of Air Cell And Oil Level Gauge In Conservator

Fig. 1

Details Of Fixing Air Cell

Details Of Hook On

On Conservator

On Conservator And
Handle On Air Cell

Fig. 2

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5.

PTRM : 0708
Page 196 of 205

FILLING PROCEDURE WITHOUT VACUUM IN CONSERVATOR


The conservator with Air Cell is pressure tested and despatched from the

factory at a slightly positive pressure. Confirm that there is no oil leakage.

Fix three numbers air release valves on the conservator.

Keep air release valves open. Fix air filling adapter on breather pipe and
inflate the air cell at an air pressure indicated on the INSTRUCTION
PLATE affixed on the transformer and hold air pressure.

DO NOT APPLY EXCESS AIR PRESSURE AS IT MAY


DAMAGE THE AIR CELL.
Open air release valves and start oil filling from the bottom of the
conservator.

Observe the air release valves and as soon as oil starts overflowing, close
the air release valves one by one. Stop oil filling when all air release
valves are closed.

Remove the air filling adapter.


Continue oil filling and observe the Magnetic Oil Level Gauge (MOLG)
Stop the filling when the needle of MOLG shows the level corresponding to
the ambient temperature at the time of filling.

Fix silica gel breather.

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Page 197 of 205

CAUTION:
Do not open any of the air release valves after completion of oil
filling. If air release valve is opened, air will enter and oil level will
drop.
The plain oil level gauge on the end cover of the conservator
should indicate full oil level always. If air enters the conservator, it
can be seen by a fall in the oil level in plain oil level gauge.
The plain oil level gauge should be monitored on regular basis.

6. FILLING PROCEDURE UNDER VACUUM IN


CONSERVATOR
The conservator, with its separator, being set up and plugged in above
the transformer, is connected to its oil filling reserve by a pipe in its lower
part.

Proceed as follows:

Create a vacuum in separator.

With the same source of vacuum, create a vacuum in the conservator.

Open the oil filling valve of the transformer.

Because of the vacuum in the conservator, the oil level rises


automatically.

Stop the oil filling once the required volume in the conservator is
attained.

While maintaining the conservator under vacuum, allow Dry Air or


Nitrogen gas to enter into the internal part of the separator. Then, the
separator inflates by itself, and takes all the free space due to the fact
that the conservator was not completely full. In particular, during the
operation, the oil is going to rise to the top of the conservator.

Inflate the separator at a maximum as shown in the INSTRUCTION


PLATE.

Check on the vent-holes, and confirm that there is no more air in the
conservator or, if necessary, adjust the level.

The above mentioned CAUTION regarding the opening of air release


valve after completion of oil filling, remains valid for this case also.
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Page 198 of 205

THERMOSIPHON
FILTER

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PTRM : 0708
Page 199 of 205

THERMO SIPHON FILTER


FOR

POWER TRANSFORMERS
1.

INTRODUCTION
Thermosiphon filter is provided on large capacity, oil filled Power
Transformers for keeping the moisture level of insulating oil at a very low
level. At the time of initial erection and commissioning of transformer, most of
the moisture present in the oil is removed by hot oil circulation. The moisture
absorption of oil is eliminated by directing the air breathed in by the
transformer during its operation through silica gel desiccant. Air cell in
conservator avoids direct contact of oil with air and thereby eliminating the
chance of moisture absorption.
However, it is a well known fact that water is released to the oil from the paper
insulation due to ageing process. Thermosiphon filter helps in removing this
moisture from oil. When the transformer is on load, the thermosiphonic action
of liquid causes circulation of oil through the filter. The adsorbent filled in the
Thermosiphon filter adsorbs moisture and keeps the oil dry.

2.

CONSTRUCTION

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Page 200 of 205

Typical arrangement of the Thermosiphon filter is as shown in the figure.


Thermosiphon filters are provided with isolating valves at top and bottom to
enable its removal for maintenance purposes.

3.

MAINTENANCE
Thermosiphon filters do not require any routine maintenance. Oil samples
shall be tested periodically and the values of resistivity and tan delta shall be
compared with the values given in the Operation & Maintenance Manual. If
the results are within the limits, reactivation of the adsorbent needs to be done
only as part of the annual maintenance.
If there is a rapid deterioration in the values, reactivation of the adsorbent
should be done immediately.

4.

MONITORING
The periodicity of oil testing and acceptance criteria is explained in the
Instruction Manual of the Transformer. However, the same is reproduced here
for your ready reference.
a)
b)
c)

5.

Periodicity of measurement(Resistivity & Tandelta) : Quarterly


Resistivity at 90OC
: 0.1x 1012 cm
O
Tandelta at 90 C
:1%
(Ref. IS - 1866: 2000)

REGENERATION OF ADSORBANT
Regeneration of adsorbent can be done by circulation of hot gas at a
temperature of 180 to 250O C.
To confirm proper regeneration, the dew point of the purged gas may be
measured and it should be less than 70O C.
For regeneration of adsorbent, dry nitrogen gas is preferred. A continuous
stream of gas is to be maintained during heating and gas pressure is not
important.

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Page 201 of 205

OIL TO WATER
HEAT EXCHANGER

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Page 202 of 205

DOUBLE TUBE HEAT EXCHANGER

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PTRM : 0708
Page 203 of 205

OPERATION AND MAINTENANCE INSTRUCTIONS FOR OIL


TO WATER HEAT EXCHANGERS
(SHELL & TUBE TYPE)
1.

INTRODUCTION:
In transformer oil cooler, the hot oil from the transformer is passed through the
shell, which comes in contact with the external surface of the tubes, which is
constantly cooled by the incoming cooling water flowing inside the tubes. Heat
transfer takes place due to temperature difference between the oil and cooling
water flowing through tubes resulting in cooling of the oil.

2.

DESCRIPTION:
The transformer oil cooler is a shell and tube type oil cooler. It is also known
as lantern ring type oil cooler. The hot oil passes through the shell, and cooling
water passes through tubes, tubes are secured to the tube sheet by
expansion. Baffle plates have been provided to support the tube. The baffles
are held in position by tie rod and spacers. Baffles have thermal significance in
that the shell side fluid is made to flow to and fro across the bundle from one
end of the exchanger to the other end. The flow induced vibration is avoided
by proper spacing of the baffles. Separation of shell and tube side fluids at the
floating head is obtained by means of packing rings (o rings) installed
between outside of the floating tube sheet and recesses in the rear head
flanges. The shell and tube fluids have their own packing rings (o rings),
which are separated, by a lantern ring provided with weep holes for leak
detection. Leakage at the packing will not cause mixing of the shell side and
tube side fluids within the exchanger itself.
Channel side has been provided with pass partition arrangement so as to have
the flow of cooling water inside the tubes in each section. The inside surface of
channel except tube sheet have been coated with epoxy paint to prevent
corrosion of carbon steel material. Zinc anodes are provided to reduce the
galvanic corrosion.

3.

HYDRO TESTING:
The equipment shall be subjected to hot oil test on shell side and hydro test on
tube side to a pressure of 1 times of the design pressure to check for leaks.
Before conducting hydraulic test for new unit or one that has been out of
service for sometime or for unit that has been opened, carry out a thorough
internal and external inspection to ensure:

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Pressure gauges have been correctly calibrated
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4.

PTRM : 0708
Page 204 of 205

Vent on high point of unit (air vent) if installed is left open

OPERATING INSTRUCTIONS:
Inspect the transformer oil cooler and ensure that the external surfaces and
channels are free of dirt and ensure the readiness of cooling water supply on
the tube side.

5.

START UP PROCEDURE:
The start up of the oil cooler in a system consists of putting into service
various equipment in a definite logical operating sequence. Open the vent
and drain valve on the channel side of the oil cooler. Establish cooling water
flow through channel and tubes When water flows through the vent and drain
close the same. Open the oil side vent & drain and adopt the same
procedure as that of tube side Temperature of oil shall be raised gradually
with specified flow rate.

6.

PERFORMANCE OF THE OIL COOLER.


Use proper strainers on shell side and tube side.

7.

Do not operate the cooler beyond the specified working pressure


indicated in the nameplate.
Operate the cooler at the specified flow rate to obtain maximum
efficiency.
The oil should not have any contamination as the performance of
cooler get reduced.
Periodic cleaning of the cooler on shell side and tube side shall be
carried out for better performance.

SHUT DOWN PROCEDURE:


The oil flow should be completely stopped before stopping the water flow.

8.

CLEANING METHODS:

The bundle assembly is taken out and the internal and external surface
of the tubes are cleaned by smooth wire mesh or cleaning agent.

After cleaning, the bundle is inserted and the gasket and o ring are
replaced with new ones and the equipment is tested hydraulically
before setting the unit under operation.

ISSUE/ REVISION
DATE

20/10/05

28/01/07

01/08/07

AREVA Confidential Information.


Must not be disclosed, copied or used for Manufacturing, Tendering or for any other purpose without prior written permission.

ERECTION, COMMISSIONING,
OPERATION AND MAINTENANCE
MANUAL FOR
POWER TRANSFORMERS
9.

PTRM : 0708
Page 205 of 205

PRESERVATION

9.1

When the transformer oil cooler is out of service, preservation by


proper methods is essential to prevent corrosion.

It is recommended that during short duration of operational


interruptions as a preventive measure against stand still corrosion, a
continuous flow of cooling water through tubes is to be maintained. If
this is not possible then it is necessary to clean the tubes to remove
dirt, impurities etc. And fill with suitable clean water to retain in same
condition.

In case of longer shut down, the shell side of the oil cooler is to be
drained and rinsed with oil. Dry all internal surfaces of oil cooler by
using hot air. Blank all open nozzles to avoid ingress of dust. Clean the
tube side to remove dirt, impurities etc., and fill with suitable clean
water and retain in that condition.

TYPES OF PRESERVATION PROCESS:

9.1.1 WET PRESERVATION:


The wet preservation is used in case of short term shutdowns. In case of wet
preservation of plants/systems or components, it is to be observed that the
filling water is mixed with sufficient quantity of suitable corrosion inhibitors.
The preservative fluid should be circulated once in a week and analysed
periodically.
The consumed chemicals are to be substituted.
9.1.2 DRY PRESERVATION:

The dry preservation is used in case of long term shut downs. In case
dry preservation, it is important that the plants/systems or components
are completely dried before passing nitrogen or dry air.
The preservative air, which is to be blown through plants/systems or
components to be maintained dry, shall be dust free, oil free and free
from aggressive ingredients. The relative humidity of the out coming
O

preservative air should be less than 20% with reference to 20 C.


The effectiveness of the measure taken is to be checked at regular
intervals.

P.S.: The above instructions are applicable for single tube Heat Exchangers.

ISSUE/ REVISION
DATE

20/10/05

28/01/07

01/08/07

AREVA Confidential Information.


Must not be disclosed, copied or used for Manufacturing, Tendering or for any other purpose without prior written permission.

.A

Easun - MR Tap changers (P) Ltd.,


Chennai, India

ON-LOAD TAP CHANGER TYPE M


Operating Manual

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EMR

India
Phone : 91 44 26390863 (lluntmg) , l'ax : 91 44 26390881 , e-mail : helpdesk @easunmr.com

On Load Tap Changer Type M


Operating Manual

1. General
1.1 Operational principal of the on-load
changer (fig.1)
A tap-change operation begins with the tap selector
preselecting the desired tap on the transformer
winding.

The diverter switch transfers the current from the


tap in service to the preselected tap. During this quick
change-over, ohmic resistors are inserted in the circuit to ensure no-break transfer of the current.

On Load Tap Changer Type M


Operating Manual

1.2 Designation of an-load tap


changer models (fig.2)
Every type of tap changer is
available in a number of different
models. These design vary
according to: number at poles,
max rated through current,
insulation to ground, tap sector
size, and basic circuit diagram.
The designation incorporates all
these characteristics and permits
easy identification of the tap
changer. The basic circuit
diagram code in the model
designation identifies: number of
operating positions, number of
mid-positions, and type of changeover selector.

ON-LOAD TAP CHANGER


M

501 -

123 /

B-

10 19 1W

Type

Basic Circuit diagram

Number of
Poles

Tap selector size

Max. rated through.


current in amperes
and additonal indication
of model
Highes voltage for
equipment Um
Insulation go ground

Example in Fig.2:
On-load tap changer type M
single-pole, max rated throughcurrent 500A, insulation to ground
according to Um = 123 kV, tap
selector size B, basic circuit
diagram code 10 19 1 W
meaning: 10 contacts, 19
operating positions, with one midposition, change-over selector
used as reversing switch

BASIC CIRCUIT DIAGRAM


10

Pitch of
tap selector
contact circle

19

Max. number of
service positions

1.3 Principal parts of the onload tap changer (fig. 3)

- the diverter switch


compartment and

oil

without
10
12
14
16
18

10
12
14
16
18

with
09
11
13
15
17

Mid-positions
1
0
1
3

Change-over
selector

The principal parts of the unload


tap changer are
- the tap changer nead

19
23
27
31
35

Change-over
selector

coarse
tap selector

Reversing
switch

*) No designation without
change-over selector

- the tap selector


Diverter switch unit & Top drive
unit on tap head are subject to
inspection

Fig.2 Designation of Tap Changer model and basic circuit diagram

On Load Tap Changer Type M


Operating Manual

Principal parts of the on-load tap changer

Principal parts of the on-load tap changer


13

Tap changer head gasket

14

Position Indicator

15

lnspection glass

16

Drive shaft for position Indicator

21
22

Tap changer head


Cover bolt

23
24
25
26
27
28

Head cover gasket


Tap changer head cover
Upper gear unit with drive shaft 25a
Pipe connection R for protective relay
Pipe connection S for suction pipe
Pipe connection Q for return pipe
(with oil filter unit only)

29a
29b
29c

Bleeder valve of tap changer head cover


Bleeder facility for transformer oil
Bleeder screw for suction pipe

31

Diverter switch oil compartment

32

Bottom of oil compartment

33

Grading rings

34

Terminal of diverter switch oil compartment

35

Suction pipe

41
42
43
44
45

Tap selector support


Tap selector gear
Fine tap selector
Change-over selector
Tap selector terminal

51

Diverter switch unit

52

Support cylinder

53

Support plate

54

Fixing screw

55

Lifting lug

56

Transition resistors

Fig. 3 Centric Upper Gear Unit


4

On Load Tap Changer Type M


Operating Manual
1.4 Inspection intervals
IMPORTANT : We recommend
inspection of the tap changer
equipment at regular intervals
to maintain a high level of
operating reliability.
In general, the inspection can be
carried out within one day by EMR qualified and trained
personnel provided it is well
prepared and organized.
We strongly recommend to have
in-spections performed by our
Technical
Service.
This
Guarantees a professional
performance including all the
latest updating of specific
components to the latest
operation state.
Inquire for spare parts when
preparing an Inspection which
shall not be carried out by E-MR
personnel (please indicate tap
changer number and number of
operations).
The number of tap change
operations determining the
Inspection intervals indicated in
Table 1 are figures based on
experience with use of usual oil
qualities.
Regardless of the number of
operations we recommend
inspection after 6 to 7 years of
service, or after 4 years of
service, if the tap changer
operating voltage is > 220 kV.
The tap selectors of our on-load
tap changers are generally
main-tenance-free. However,
special care should be taken with
special applications. This applies
e.g. to industrial transformers
where high numbers of tap
change operations are to be
expected. Here we recorr-mend
to contact our Technical Service
afterabout 1,000,000 operations.
The divertor switch unit of the tap
changer has to be replaced by a
new one after about 800,000

operalion latest.
If the number of operations per
year Is 15,000 or higher, we
recommended the use of our oil
filter plant type 51 manufactured
by our principal MR Germany.

Filtering of switching oil allows to


extend the inspection and oil
change intervals. Continuous
filtering also increases the
mechanical life of the diverter
switch by

Standard values for tap changer oil testing according to CIGRE


report 12-13 (1982) apply to Transformer oil at servIce
temperature:
Use of Tap Changer

Water content) Dielectric strength)

For use at the neutral point of windings


For use at a position other than the
neutral point of winding

<40 ppm

> 30 kV/2,5 mm

<30 ppm

> 40 kV/2,5 mm

*) measured accorclng to IS 13567/1992


**) measured according to 156792/I 972
On-load
tap changer

Transformer
rated current

Number of tap change


operations

M III 350

350 A

100 000

M Ill 500

350 A
500 A

100 000
80 000

MIII 600

350 A
600 A

100 000
80 000

M1 351

350 A

100 000

M1 501

500 A

100 000

M1 601

600 A

100 000

M1 802

500 A
800 A

100 000
80 000

M1 1200

800 A
1200 A

80 000
70 000

M1 1500

1200 A
1500 A

70 000
60 000

M1 1800

1500 A
1800 A

60 000
50 000

Table I Inspection Intervals


Note: 1. If Um >245 kV at the tapchanger the indicated numbers of
tapchange operation must be halved &
2. regardless of the number of tap change operations listed in
Table 1, inspection must becained out after 6 to 7 years
3. Regulation at the line end of the transformer with Um > 245
the first inspection must becanied out after 20,000 operations
or after 2 years of seniice respectively, which ever comes
first
5

On Load Tap Changer Type M


Operating Manual
ImmediateIy removing most of
abrasive particles responsible for
mechanical wear.
The user should regularly monitor
the transformer insulating oil in the
transformer according to the
ralevant standards.
If inspection is not carried out by
E-MR personnel, please give us
your report to supplement our
in-spection data, incase of need
recommendation for the next
in-spection can be given.
WARNING : Inspections of the
tap changer equipment are
obligatory. Disregarding the
Inspection intervals can
affect the trouble-free
operation of tap changer and
transformer.
1.5
Summary of inspection
work
A typical inspection includes the
following work:
Withdrawing arid reinstalling
the diverter switch unit
Cleaning the diverter switch oil
compartment and diverter
switch unit and, where
necessary, the tap changer oil
conservator tank.
Changing the switching oil
Checking the diverter switch
oil compartment and diverter
switch unit
Determining the contact wear
Measuring the transition
resistors
Checking the protective relay,
drive shaft, motor drive unit
and, where present; the oil
filter unit and voltage regulator.
The diverter switch unit should not
be exposed to air longer than
necessary (at max. for 10 hours).
Inspection work should not be
inter-rupted. Care and cleanliness
should be observed.

WARNING: inspection must be


carried out by qualified,
skilled personnel only. The
instructions should be
followed strictly.
Damage which is found
during inspection needs
immediate contact with E-MR
for assistance. Do not put the
tap changer in service until
the damage has been
corrected.
Do not alter or modify the tap
changer equipment without
prior consulting E-MR.
Improper or incomplete work
carried out during inspection
can aflect the trouble-free
operation of tap changer and
transformer. Under certain
circumstances this can cause
property damage andlor
per-sonal injury.
2. Preparation
2.1 Necessary equipment
empty vessels for dirty oil, the
necessary quantity of new
transformer oil for cleaning and
oil change;
kV
36 72.5 123 170 245
Litres 125 130 150 170 190
Table II Oil filling quantity in litres
an oil pump for draining and
refilling;
a drip pan;
miscellaneous brushes and
absorbent, non-fuzzing rags
for cleaning;
a work table;
a lifting device:
weight of diverter switch unit
max. 80 kg. required lifting
force is mdx. 1300 N;
kV
36 37.5 123 170 245
m m 830 870 1000 113 1230
Table Ill Withdrawal height in mm
inspection tool
spare parts

Please note: Lock tabs, self


lock-ing screws and nuts should
never be used twice and should
be replaced during reassembly.
CAUTION: Always use E-MR
authorized
replacement
parts. Parts of other origin
can affect the trouble-free
operation of tap changer and
transformer.
2.2 Safety precautions
WARNING: The user of the
plant should perform the
following safety measures.
The transformer must be
switched off, isolated and
secured against reclosing. All
terminals must be grounded
visibly (by means of ground
cables or ground switches).
The working area should be
marked clearly.
Start with inspection only
after all these safety
precautions have been
carried out. Dis-regarding
them endangers lives
2.3 Operating position when
withdrawing the diverter
switch unit
The diverter switch unit can be
withdrawn in any operating
posi-tion. Take note of the
operating
position
when
withdrawing the unit. However, we
recommend on prin-ciple to
withdraw the diverter switch in the
adjustment position which is
marked by an arrow on the
position indicating disc of the
motor drive unit.

On Load Tap Changer Type M


Operating Manual

CAUTION: Do not operate the


motor drive unit while the tap
changer is uncoupled, either
manually or electrically. To
prevent electrical operation
by remote control, it is good
safety practice to isolate the
motor drive unit by trIpping
the motor protective switch.
3.

Withdrawal
of
the
Diverter Switch Unit
(FIg.4)

Lowering the oil level:


Shut the stop valve between oil
conservator and tap changer
head.

Lower the oil level in the tap


changer head. To do this, open the
bleeder valve in the head cover
(remove screw cap M30/wrench
size 36, lift valve tappet by means
of a screwdriver) and the drain
valve.
WARNING: The switching oil
ol the tap changer should
always be handled as a I
lam-mable liquid. Moreover,
explosive
gases
can
accumulate under the tap
changer head cover, in the
switching oil or in the oil
com-partment. Therefore,
strictly avoid open fire. Use a
pump-ing equipment suitable
for flammable liquids.

In case of an oil filter plant: open


the return pipe sample valve and
operate the filter unit, drain about
10 litres of oil from the tap
changer head so that the support
plate is out of the oil (check
through the in-spection glass in
the head cover).
Uncoupling the drive shaft of
the upper gear unit:
Unscrew 6 screws M6 (w.s.1 0)
from the coupling. Take care not
to lose coupling baits, nuts and
lock tabs. Normally the drive shaft
can be moved to one side for
clearance. It not, remove the other
coupling on the bevel gear from
the square tube (screws, nuts and
lock labs as above) until the
horizontal drive shaft can be
removed.
Take off the tap changer head
cover (fig. 5)
Unscrew the cover bolts Ml 0.
Take care not to lose spring
washers. Remove the cover, take
care not to damage the Oring
gasket of the head cover.

5
Fig . 4 Tap Changer head

1. Drive shaft ( square tube )


2. Coupling brackets and bolt
3. Upper gear unit (centric arrangement)
4. Tap Changer head cover
5. Bleeder Screw of head cover
6. Pipe connection R for protective relay
7. Pipe connection S with bleeder screw for suction pipe

Dimantle In the following order


Remove the position indicator
disc (fig.6). Remove the clip from
the shaft end. The coupling pin
allows assembly in the correct
position only.

On Load Tap Changer Type M


Operating Manual

Fig. 10
Diverter Switch Unit

Take note of the marks on the


tap changer head and the
support plate
In the adjustment position the key
in the diverter switch drive shaft

matches with the triangle mark on


the support plate.
Undo the screws fixing the
support plate.
Standard design: 4 screws MB x

20 (Fig. 7).
Special design for bell-type
transformer cover. 5 studs MB
with nuts (Fig.8).
In both cases take care of bolts
or nuts and washers.
Carefully lift out the diverter switch
unit using the lifting lugs (FIg.9)
and put it on a flat, clean place.
4.
Cleaning
the
Oil
Compartment,
the
Oil
Conservator and the Diverter
Switch Unit
Oil compartment, oil conservator
Drain the oil compartment
completely. Open the stop valve
between tap changer head and oil
conservator. Drain oil from the
conservator until clean oil flows.
If necessary, flush the oil
conservator tank with clean
transformer oil. Drain the oil
compartment, flush with clean oil,
and drain again completely.
Diverter Switch Unit
Carryout the visual inspection of
divertor swithc external. Clean the
diverter switch unit by flushing
with clean transformer oil.
5.
Inspection
of
the
Dlverter Switch Unit
5.1 Withdrawal position
Before starting the inspection take
note of the switched position of
the diverter switch (=withdrawal
position). Note the position of the
trip lever of the spring energy
accumulator unit (Fig. 10) in order
to regain this position after
reassembly of the diverter switch
unit.
5.2 Measuring the transition
resistor (Fig. 11)
Measures the value of each
transition resistor. The values are
in the order of 0.3 ... 30 ohms.
Measure at the open side of the
diverter switch sector between
the stationary main switching
contacts
8

On Load Tap Changer Type M


Operating Manual

Fig.11 Measurement of transition resistor on distinct points


of the contact shells.

and transition contacts above and


below. For this purpose set the
diverter switch to the opposite
position by means of the operating

key Then measure again (Fig. 11).


Compare the measured values
against the indications on the
nameplate.
A 10 percent difference is
pefmissibie.
Detach the support cylinder. Undo
8 screws M8.20 (w.s.1 3) each
with a self-locking nut, at the 4
fish-plates of the spring energy
accumulator. When removing the
screws take not to drop the parts
into the diverter switch.
Take off the support cylinder.
Take off the in outling drive shaft
clean the support cylinder inside
and outside with a brush and

transformer oil. Finally flush with


transformer oil and dry.
5.3 Removing the contact
shells
Remove and reinstall contact
shells consecutively on one
diverter switch sector after the
other.
To remove the contact shells the
diverter switch must be set to its
mid-position where the transition
contacts are closed:
Release the spring energy
accumulator and turn the drive
shaft by means of the operating
key until the wind-up sledge and
the cocking sledge have reached
a stable position just about in the
middle (fig. 12,13, 14).
Undo the fixing screws of the
contact shells of one diverter
switch sector: first the 4 other
screws, then the 4 inner screws,
in total 8 screws M6 x 20 (w.s.
10), see fig. 15,16,17.
5.4 Removing the arc chutes
Withdraw the arc chutes
The outer arc chutes have split
sidewalls and must be refitted in
exactly their initial position.

12

On Load Tap Changer Type M


Operating Manual

Fig.21 Drive Shaft

5.7

5.5

Cleaning the diverter


switch unit
The contact shell with transition
resistors and stationary contact
system must be cleaned
thoroughly with transformer oil.
Special care should be taken
when cleaning insulating parts.
Flush all parts with clean oil.
Since the contact shells and
transi-tion resistors are to be
disassembled and reassembled
one sector before the next
perform cleaning of the diverter
switch
between
these
procedures.

5.6

Cleaning the diverter


switch Insulating drive
shaft:
To remove the insulating drive
shaft, the support cylinder with
support plate have to be detached
from the energy accumulator
case.
CAUTION : Take care not to
drop any parts Into the
diverter switch. Otherwise
the diverter switch can block
and cause severe damage to
the
tap
changer
and
transformer. There-fore, make
sure that the number its is
complete when disassembling
and reassem-bling) count
them to be sure.

Contact wear of main


switching contacts and
transition contact
The admissible contact wear of
the diverter switch contacts is
determined by:
a. The contact volume (see
tig.22). The max. admissible
contact wear of the individual
contact is 4 mm.
Contacts should be replaced if
this value is reached or expected
to be reached before the next
inspection.
b. the mechanical tap change
operation sequence (see section
1.1), shunt contact (A, B), main
switching contacts (a, b),
transition contacts (al, bl).
If the difference between main
switching and transition contacts
could become greater than
certain given limits, the correct
mechanical switching sequence
of the diverter switch is no longer
ensured.
Unfavourable
operating
conditions can cause increased
contact wear on transition
contacts.
10

On Load Tap Changer Type M


Operating Manual

switching and transition contacts


by vernier gauge. Determine the
contact wear by comparing the
difference between new contact
and measured value.
6.
Replacement of the
Diverter Arcing Contacts
and Contact Braids
6.1 Diverter switch arcing
contacts
Each diverter switch sector is
fitted with two main switching
contacts (a, b) and two transition
contacts (a1, b1). Each of these
contacts exists as stationary and
a movable contact.
Each stationary and movable
contact consists of two contact
tips.
Replacement of the contact tips
of the stationary and movable
contact system is simple
(attachment : 1 screw M6 for each
element). Note the following
details:
Stationary contact
(see tig.23, 24)
Each contact tip is fixed by one
hexagon socket screw M6 x 16
(w.s. 4 or 5), max. torque 9 Nm,
locked by centre punching the
groove of the screw head.
Movable contacts
(see fig. 25, 26, 27)
Each contact element is fixed by
one hex head screw M6 x 16 (w.s.
10), 2 dished washers, max.
torque 9 Nm, locked by lock tab.
WARNING:
Continued
operation of the diverter
switch with greatly differing
contact layer thickness on
arcing contacts can lead to
severe damage of tap
changer and transformer.

reached or is expected to be
reached before the next
inspection, the contacts shall be
replaced or matched to the other
contacts by interchanging or
milling.

The max. permissible difference


of contact layer thickness
between main switching and
transition contact is 2.5 ... 2.6 mm.
If this dif-ference has been

5.8

Determination of contact
wear
Measure and note the thickness
ot the contact layers on the
stationary and movable main

OLTC M III 350 M I 351:


Before undoing contact tips
remove the contact braids on top
and bottom (see section 6.2).
Note: In case of through-current
exceeding 200 A contacts of
tungsten

11

On Load Tap Changer Type M


Operating Manual

contact system to the slide


contact (= output terminal) of the
diverter switch sector.
These braids are fixed by a
screw, washer and self-locking
nut (fig. 28, 29).
As a precaution, the contact
braids should be replaced after
250,000 operations regardless of
replacement of diverter switch
contacts.
Please note:
OLTC 111350, M 1351 (see fig.
30)
There are 8 sets of contact
braids, two sets each on top and
bottom as well as two sets of two
in the middle of a sector.
The contact braids of the main
switching contacts and transition
contacts are joined together at the
output terminal.
2 sets ot contact braids (on top
and bottom)
Each fixed to the output terminal
by one bolt M6 x 28 (w.s.10) with
self-locking nut and washer, max.
torque 9 Nm.
Attachment to the main switching
contact (double braid) by one bolt
M6 x 18L, attachment to the
transi-tion contact (single braid)
by one bolt M6 x 16.
copper are used tor tne transition
contacts (a1, b1).
OLTC M III 500, M III 600, M I 501,
M l 601, M I 802, M I 1200, M I
1500, M I 1800.

All bolts with self-locking nut and


washer, max. torque 9 Nm.
4 sets of double contact braids
(in the middle)
Attachment to the output terminal:

Before undoing the contact tips


remove the contact braids on top
(see section 6.2).

each by one bolt M5 x 22 (w.s.8)


with self-locking nut and washer,
max. torque 5 Nm.

6.2

Each fixed to the main switching


contact by one bolt M6 x 1 BL
(w.s.1 0) with selt-locking nut and
washer, max. torque 9 Nm.

Contact braids

The contact braids connect the


main switching contacts and
transition contact of the movable

12

On Load Tap Changer Type M


Operating Manual

Attachment to the main switching


contact and transition contact:
each by one bolt M6 x 16 (w.s. 10)
with self-looking nut and washer.
max. torque 9 Nm.
Always use new self-locking nuts.
7.
Reattachment of the
contact shells
Reattach the contact shell in
reverse order to removal. The
diverter switch is in the midposi-tion. Insert a chucking wedge
between epoxy segment and
contact carder to hold back the
movable contact system of the
diverter switch.
This counters the pressure of the
movable contact system (fig. 32.
33) and makes attachment of the
contact shell easier.
Refit the arc chutes and make
sure that they are properly
seated.
Attachment of each contact shell
by 8 screws M6 x 20 (w.s. 10),
max. torque 5 Nm, with look tabs
(fig.34). Use new self-locking
screws and lock tabs.
After tightening the screws,
remove the chucking wedge in
upward direction (fig.35).
When all contact shells have been
reinstalled, the spring energy
accumulator must be set from the
mid-position into a switched
position of the diverter switch and
locked-in.
OLTC M III 500, M III 600, M I
501, M I 601, M I 802, M I 1200,
M I 1500 M I 1800 (sec fig. 31)
There are two sets of contact
braids on top only, connected to
main switching and transition
contacts.

The contact braid of the main


switching contacts and transition
contacts are joined together at the
output terminal.

Insert a screwdriver between


wind-up sledge and cooking
sledge of the energy accumulator
(fig. 36).

Attachment to the output terminal


by one bolt M6 x 28 (w.s. 10) with
self-locking nut and washer, max.
torque 9 Nm.

13

On Load Tap Changer Type M


Operating Manual

Actuate the eccentric by means


of the operating key until the pawl
locks-in (see fig. 37, 38).
Operate the diverter switch
several times to check its
mechanical function.
Finally check again the transition
resistors as described in section
5.2.
Set the diverter switch to its
withdrawal position (see
section 5.1).
The diverter switch unit is now
ready to be reinstalled.

8. Reattach the support


cylinder with support plate:
8 bolts M8 x 20 (w.s.13), each
with 2 washers, max. torque 22
Nm. En-sure alignment of triangle
marks on bottom at the spring
energy accumulator housing and
on top at the support plate (fig. 39,
40).
Operate the diverter switch
several times to check its
mechanical function (fig. 41).
Final ly check again the transition
resistors as described in section
5.2.

14

On Load Tap Changer Type M


Operating Manual

Fill up the oil conservator with


new oil to its original level.
CAUTION: The transformer
should be energised not
earlier than 1 hour after the
oil filling.
11. Motor Drive
The on-load tap changer type M
is operated by motor drive unit
MA2 mounted outside the
transformer tank, with maximum
operating posi. tion of 35.
Set the dlverter switch to Its
withdrawal position (see
section 5.1)
The diverter switch unit is now
ready to be reinstalled.

9.
Reinstallatlon ol the
diverter switch unit
Remove the tap changer head
cover.
Lift the diverter switch unit over
the open tap changer head. Lower
it down into the oil compartment
slowly and carefully.
When remounting the diverter
switch unit turn, if necessary, the
insulating shaft slightly until the
coupling engages.
Ensure alignment of marks on the
support plate of diverter switch
unit and in the tap changer head.
Fix the diverter switch unit by the
screws of the support plate.
Standard design: 4 screws MB x
20 (w.s. 13).
Special design for bell-type tank
installation: 5 nuts M8 (w.s. 13).
Both types secured by spring
washers, max. torque 22 Nm.
Reinstall the position indicating
disc (put on clip to shaft end).

10. Oil Filling


CAUTION: The tap changer oil
compartment
arid
the
associate oil conservator
must only be filled with new
mineral insuIating oil for
transformers as per IEC 296
(1982). The use of other oil
can affect the trouble-free
operation of tap changer and
transformer.
Fill new oil into the diverter switch
oil compartment up to the level of
the support plate. Put the cover
on the tap changer head making
sure that the gasket fits property;
if necessary replace the O-ring.
The head cover is attached by 24
bolts M10 (w.s. 17), max. torque
34 Nm, secured by spring
washers.
Open the stop valve between
protective relay and oil
conser-vator. Vent the tap changer
head through the bleeder valve in
the tap changer head cover
(remove screw cap M30 I w.s. 36
and lift valve tappet by means of
a screwdriver).
Vent the suction pipe (screw cap
M161w.s 22. bleeder screw M6
with chees head, max. torque 2
Nm). see fig. 42.
Units with stationary oil filter unit:
operate the oil fitter unit and
bleed.

The drive shaft is the mechanical


connection between motor drive
and tap changer head. The bevel
gear connects the vertical and
horizontal parts of the drive shaft.
The vertical part has to be
mounted between motor drive
unit and bevel gear, and the
horizontal part be-tween bevel
gear and tap changer head.The
drive shaft couplings are the
same for both parts. Both ends
of the square shaft are connected
to the respective implement by
two coupling brackets and one
coupling pin.
Square shaft have to be trimmed
to the required lengths when they
are mounted on the transformer.
11.1 Coupling instructions
When mounting observe the
following instructions:
1. Check the shaft length between
the two shaft ends.
2. Attach the coupling brackets to
the shaft by 6 screws M6
(wrench size 10) add flat washer
(m6) and lock washer (m6). Slide
the coupling brackets on the
square shaft as far as possible,
tighten the M6 nuts. (maximum
torque 9Nm).
3. Lubricate O ring and coupling
pin.

15

On Load Tap Changer Type M


Operating Manual

4. Place the coupling pin into the


trunion and slide the square shaft
together with the coupling.
5. Provide the opposite trunion
with coupling bracket and coupling
pin. Fit in the square shaft. Place
second coupling bracket and
tighten the 6 bolts (M6) with flat
washer, lock washer and (M6)
nuts.
6. Make sure that there is an axial
clearance of 2mm between
coupling pin and coupling
brackets.
7. Finally tighten the coupling
brackets (max. torque 9Nm)
placed on both side of the bevel
gear and next to the tap changer
head.
Note: The screws of coupling
brackets next to motor drive unit
must be tightened and locked
when the rotation lag of motor
drive has been equalized.
11.2 RotatIonal
lag
adjustment of the tap
changer and motor drive
For the following procedure the
tap changer and motor drive must
be the same tap position. The
motor drive has to be set to the
same position as found in the tap
changer.
Motor drive and tap changer cans
however, finally be coupled only
when the rotation lag (if there is

any) has been balanced. For this


purpose proceed as follows:
11.2.1Turn the hand crank
clock-wise towards Lower until
the energy accumulator of the tap
changer is released.
11.2.2Continue cranking and
count the revolutions necessary
br releasing the spring unit of the
motor drive, till a click which can
be distinctly heard (about 3 to 5
revolutions).
11.2.3Turn the hand crank
counter clockwise towards
Raise until the energy
accumulator of the lap changer is
released.
11.2.4Continue cranking and
count the revolutions, as in 11.2.1.
11.2.5Balancing the rotation lag is
necessary if the number of
clock-wise revolutions does not
equal that of the counter
clockwise revolu-tions. In this
case the vertical part of the driving
shaft is uncoupled. The hand
crank is then turned in the rotation
sense which required more
revolutions to be effected. The
number of the balancing
revolutions amounts to half the
difference between the clockwise
and
counter
clockwise
revolutions.
Example
(see Fig.43)

Turn the crank clockwise (e.g.


from position 6 to 5) rotation lag
deter mined 3 revolutions
(Fig.43). Turn the crank counter
clockwise (e.g. from position 5 to
6) rotation rag determined: 5
revolutions. Uncouple. Equalize
by truning the crank for half the
difference:
1/2 (5-3) = 1 revolution counter
clockwise. Recouple.
Checking the result:
Cranking clockwise (e.g. towards
position 5) and then counter
clock-wise (e.g. towards position
6) results in both oases in the
same number of revolutions
constituting the rotation lag (Ref.
Fig.43).

EMR/OI/M/0010
16

Part-No.

Designation

009 859 1)
009 859 2)
010 236 1)
011 586 1)
012 5982)
0125992)
012 600
017 3552)
046 942
047 020
047 640
047 652
048 053
049 039
049 113
049 823
051 873 2)
052 206
052 866
056 932 2)
073 284
085 253
090 982
092 120
092 121
260 930
262 331 1)
264 020
400 004
401 044
401 045
401 471
450 330
450 335
450 361
450 500
451 076
451 087
451 325
452 356
453 255
453 977
453 981
550 666
550 711 1)
550 719
560 031 .

Contact tip (tungsten-copper)


Contact tip (tungsten ~copper) for transition contact (> 200 A)
Flexible current strip
Flexible current strip
Flexible current strip
Flexible current strip
Connecting lead
Contact tip for main switching contact (> 200 A, for furnace/electrolysis transformer operation)
Contact holder
Flexible current strip
M 111500, M 1501, M 1802, M 11200: stationary main contact
Pressure plate
Washer
Pressure plate
Tubular spacer
Spring socket
Contact tip (copper)
Counterpiece
Washer
Stationary main contact, instead of 047 640, if needed
Washer
M Ill 600, M I 601, M 11500, M 11800: stationary main contact
Stationary main contact, instead of 085 253, if needed
Connecting lead
Connecting lead
Contact shell
Contact holder (main contact)
Contact holder (transition contact)
Washer
Hex. head screw M5 x 10
Hex. head screw M5 x 16, instead of 401 044, if needed
Hex. head screw M6 x 20, self-locking
Hex. head screw M5 x 8
Hex. head screw M5 x 20
Hex. head screw M6 x 25
Hex. head screw M6 x 22
Slotted socket screw MS x 16, recess head
Slotted socket screw M6 x 16, recess head
Washer
Dished washer
Hex. head screw M5 x 16
Hex. nut MS, self-locking
Hex. nut M5, self-locking
Helical spring, compression type
Helical spring, compression type
Helical spring, compression type
Molded insulator

Note:

ForM 111500, M 111600, M 1501, M 1601, M 1802, M 11200, M 11500, M 11800;


delete in case of MS 111300 ... M 1351

2l

ForMS Ill 300, MIll 350, MS I 300, M 1351 ;


delete in case of M 111500 ... M 11800

Easun- M R Ta p C han gers Ltd.,


C hcnn ai

On-load tap changer type M


Parts of diverter switch unit (stationary contact system)

Parts designation for 1


894 389:4E

450335

262331

047640
500 A [ (056 932)
600 A [ 085 253
(090982)

451325

011586

"
453977

-----

452356

-------

401044
(401 045)

Easun -MR Tap Changers Ltd.,


C hcnna i

On-load tap changer type M


Parts of diverter switch unit (stationary contact system)

894 389:4E

Part-No.

Designation

009 859
011 105
012 770
012 801
015 991
015 992
017 355
022 417
022 419
026 157
046 956
046 957
046 970
046 987
047 409
047 412
047 738
048 400
048 633
048 869
049 209
050 101
050 102
050 103
050 319
050 387
050 504
050 535
051 873
053 155
053 667
056 919
057 801
057 802
070 941
093 326
264 013
450 043
450 062
450 101
450 109
450 355
450 356
451 086
451 323
451 325
452 063
452 220
452 350
452 997
452 998
453 447
453 977
453 978
453 979
453 981
550 292
550 293
550 294
550 295
550 665
550 668
560 163

Contact tip (tungsten-copper) for transition contact (> 200 A)


Epoxy segment
Braided contact lead
Braided contact lead
Current strip
Current strip
Contact tip for main switching contact (> 200 A, for furnace/electrolysis transformer operation)
Washer
Washer, instead of 022 417, if needed
Washer
Tubular drive shaft
Drive star
Take-off bar
Pressure plate
Tubular spacer
Contact holder, main switching contact
Tubular spacer
Sliced spacing ring
Roller
Sliced spacer
Sectorial connection
Tubular spacer
Tubular spacer
Roller
Centering sliced spacer
Tubular spacer
Tubular spacer
Contact holder, transition contact
Contact tip (copper)
Threaded clamping stud
Washer
Screen cap
Contact holder
Contact holder
Lock tab
Braided contact lead
Epoxy guide plate
Hex. head screw M5 x 22
Hex. head screw M6 x 28
Hex. head screw M8 x 125
Hex. head screw M8 x 160
Hex. head screw M6 x 16
Hex. head screw M6 x 18 L
Slotted socket screw M6 x 20, recess head
Washer
Washer
Ball bearing
Circlip lock ring
Dished washer
Feather
Feather
Flat head screw M6 x 30
Hex. nut M6, self-locking
Hex. nut M8, self-locking
Hex. nut M 10, self-locking
Hex. nut M5, self-locking
Insulating tube
Tubular spacer
Tubular spacer
Tubular spacer
Tubular spacer
Helical spring compression type
Current take-off housing

Easun -MR Tap C hangers Ltd.,


C hennai

On-load tap changer type M


Parts of diverter switch unit M 350
(movable contact system MS Ill 300 ... M I 351))

Parts designation for dwg.

890 476:6E

453977

049209

453 977
1451325

~ 450 355

..

453979

451325
I 050319
I 450 062
"--

....--- - ~

453447 -~

451 323

450101
-----

----264013

453977

452
452220

On-load tap changer type M


Eas un -MR Tap C hangers Ltd.,
C henna i

Parts of diverter switch unit M 350


(movable contact system MS 111300 ... M 1351)

890 476:6E

Part-No.
009 859
010 725
010 736
011 1OS
015991
015 992
022 013
022 417
022 419
026 157
046 956
046 957
046 970
046 987
046 988
047 409
047 738
048 397
048 400
048 403
048 441
048 633
048 869
048 870
049 209
050 101
050 102
050 103
050 319
050 535
053 155
053 667
056 919
057 801
057 802
070 941
085 252
093 325
264 013
450 062
450 101
450 109
450 334
450 355
450 361
451 086
451 237
451 325
452 063
452 220
452 350
452 997
452 998
453 447
453 977
453 978
453 979
550 292
550 293
550 294
550 295
550 665
550 668
560 163

Designation
Contact tip (tungsten copper)

M Ill 500, M I 501 , M I 802, M I 1200: movable main contact


Triangular switching lever
Epoxy segment
Current strip
Current strip
Washer
Washer
Washer, instead of 022 417 if needed
Washer
Tubular drive shaft
Drive star
Take-off bar
Pressure plate
Lock tab
Tubular spacer
Tubular spacer
Tubular spacer
Sliced spacing ring
Bearing sleeve
Intermediate plate
Roller
Sliced spacer
Tubular spacer
Sectorial connection
Tubular spacer
Tubular spacer
Roller
Centering sliced spacer
Contact holder
Threaded clamping stud M 10 x 290
Washer
Screen cap
Contact holder
Contact holder
Lock tab
M 111600, M 1601, M 11500, M 11800: movable main contact
Braided contact lead
Epoxy guide plate
Hex. head screw M6 x 28
Hex. head. screw M8 x 125
Hex. head screw M8 x 160
Hex. head screw M5 x 18
Hex. head screw M6 x 16
Hex. head screw M6 x 25
Slotted socket screw M6 x 20, recess head
Hex. nut M5
Washer
Ball bearing
Circlip lock ring
Cup spring
Feather
Feather
Flat head screw M6 x 30
Hex. nut M6, self-locking
Hex. nut M8, self-locking
Hex. nut M1 0, self-locking
Tubular spacer
Tubular spacer
Tubular spacer
Tubular spacer
Helical spring compression type
Helical spring compression type
Take -off contact case

Easun -MR Tap C hangers Ltd .,


C hcnna i

On-load tap changer type M


Parts of diverter switch unit M 500/600
(movable contact system M Ill 500 ... M I 1800)

Parts designation for dwg.


894 388:5E

45397R ~t

453977

..

049209

453977JlJ-

046970

264013
453 447

,--- --~

r:::--~~

451237046988048441-

500A: 010725 ~~~~~;


600 A: 085 252
048441--

026157--~,;J

048 869-- -..~---~:::Ciiii>~~~~


047 409 ---~~;;:(;_<!~~

011105

'-----

450101

550 293-------053667 -----453979 ---..._


--452220

056919 ~

453977

Easun -MR Tap C hangers Ltd.,


C henna i

On-load tap changer type M


Parts of diverter switch unit M 500/600
{movable contact system M Ill 500 ... M I 1800)

894 388:5E

Part-No.

Designation

044 271
044 272
044 305
044 611
047 250
047 251
047 256
047 278
047 279
047 283
047 335
047 372
047 449
047 450
047 483
047 615
047 620
047 786
047 787
047 789
047 793
047 797
047 825
049 183
049 230
051 661
051 662
052 690
056 987
057 113
088 382
450 385
450 710
451 444
451 449
451 520
451 730
452 026
452 028
452 210
452 216
452 221
452 256
452 370
452 516
452 601
452 739
452 871
452 872
453 807
453 977
453 978
550 068
550 069
550 070
550 761

Axle
Bushing
Spring holder
Coupling
Pawl I
Pawl II
Slider
Rocker
Bushing
Bushing
Drive shaft
Disc
Eccentric cam
Bolt
Bolt
Rivet plate
Hub
Bushing
Guide bolt
Guide bolt
Guide block
Cocking sledge
Wind-up sledge
Disc
Disc
Disc
Disc
Breech cap
Drive crank
Housing
Bracket compl.
Hex. head screw M8 x 20
Recess head screw M6 x 20
Taper pin
Taper pin
Feather
Rivet, counter sunk
Ball bearing
Ball bearing
Circlip lock ring
Circlip lock ring
Circlip lock ring
Circlip lock ring
Plate spring
Feather
Circlip lock ring
Rivet, round head
Circlip lock ring
Circlip lock ring
Rivet
Hex.nut M6, self-locking
Hex.nut M8, self-locking
Compression spring (1 sector)
Compression spring (2 sectors)
Compression spring (3 sectors)
Pawl tension spring

On-load tap changer type M


Easun -MR Tap C hangers Ltd. ,
C henna i

Parts of diverter switch unit


{spring energy accumulator- drive system)

Parts designation for dwg.


890 784:1E

452516

550068
550069
550070

871

Easun -MR Tap C han gers Ltd.,


C hcnnai

On-load tap changer type M


Parts of diverter switch unit
(spring energy accumulator- drive system)

890 784:1E

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