TRANSFORMERMAINTENANCE

1.INTRODUCTION:
The transformer is a vital apparatus in the electrical equipment in every stage viz.
Generation, transmission, distribution and utilization of electricity. Failure of a transformer in
the chain causes interruption in electricity supply and dislocation of all the works going on.
Care and maintenance of the transformer therefore requires attention from time to time to
avoid sudden, unpredicted failure. If a developing defect is detected early, remedial action
can be taken immediately and service continuity of the transformer maintained.
The troubles which would occur in service, methods of detecting them early and
remedies & repairs to bring back the transformers in service are described below.
The transformer in service may fail according to nature of troubles developed in the
transformer itself or due to some external causes. The external causes may be excessive
overloading on the transformer, short circuits near the transformer, failure of other auxiliary
equipment nearby, failure of its controlling breaker, failure of protection to operate and so
on. Internal causes of failure are failures of transformer insulation, failure of winding due to
excessive heating, internal short circuits, failure of winding joints, ingress of moisture in the
oil and insulation, deterioration of insulating oil, and failure of other auxiliary internal
equipment, such as reactor of the tap changer, contacts of the tap changer etc.
Failure of transformer can also take place if proper care has not been taken during its
erection. While receiving the transformer, unloading, storing and assembling, the instructions
of the manufacturer should be followed strictly. If the transformer is received with oil inside,
all care as if the transformer is in service, is required with nitrogen gas. A very strict watch is
required on maintenance of pressure and purity of gas, all the time the transformer is stored.
The auxiliary equipment such as radiators, conservator, piping, explosion vent are to be
stored with proper care. Conservator and radiators should be maintained airtight. The HT and
LT bushings should be immediately tested and H. T. bushings stored vertically. Similarly while
assembling the transformer every equipment such as H. T. & L. T. bushings of the
transformer windings, oil tap changer, diverter tank, connections of lead with bushing etc.
should be tested separately according to standards specified.
If the erection and commissioning is done properly, maintenance is required on the
transformer to judge the performance in service. It consist of regular inspection, testing and
reconditioning wherever necessary.
2. Factors affecting the life of the transformer : (i.e. factors responsible for degradation of
insulation.)
The normal expected life of a power transformer is about 35 years. Life of a power
transformer essentially means life of its insulation system comprising mainly : i) Solid
dielectric [paper, varnish, cloth, pressboard]; ii) Liquid dielectric [mineral oil].
A.EffectofMoisture
Transformer oil readily absorbs moisture from the air. This water in oil decreases the
dielectric strength of the oil as well as that of the insulating paper which absorbs and stores
the moisture due to higher affinity of water to paper than to oil.
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B.EffectofOxygen

Oxygen may be present inside the transformer due to air remaining in oil, air pockets
trapped in the winding etc. The oxygen reacts on the cellulose of the insulating paper, and
the decomposition products of the cellulose lead to the formation of organic acids which
dissolve in oil and consequently form sludge. This sludge blocks the free circulation of the oil.
Thus the adverse effect of oxygen, which may be aggravated by catalytic action between
hot oil and bare copper, increases the operating temperature.
C.EffectofSolidImpurities/Dirtetc.
The dielectric strength of oil is appreciably diminished by even minor quantities of solid
impurities present in the oil. New transformers may contain particles of insulating materials
and other solid impurities. It is therefore a good practice to filter the oil after it has been in
service for a short time, especially for the units of higher-voltage class.
D.EffectofVarnishes
Some varnishes, particularly of the oxidizing type, enter readily and react with the
transformer oil and precipitate sludge on the windings. Synthetic varnishes having acidinhibiting properties generally delay the natural formation of acid and sludge in the oil. This
factor needs consideration during maintenance.
E.EffectofSlacknessofWinding
Slackness of windings may cause a failure due to repeated movement of coils, which
may wear the conductor at some places and lead to an inter-turn failure. The coils may also
get displaced under load conditions or momentary short circuits, which may cause electric
and magnetic unbalance and produce even greater displacement. It is therefore a good
practice to lift the core and windings of a transformer and correct any slackness, by
tightening the tie rods or pressure screws, during the first inspection.
F.AgingofInsulation
The aging of insulating materials is defined as irreversible negative change of
pertinent property. The quality of insulation declines during the aging process, to different
extents, depending upon various operating conditions, due to both physical and chemical
effects. The dielectric strength of the conductor insulation deteriorates extremely slowly. If
the same is not mechanically disturbed much. However, mechanical properties (tensile
strength) deteriorate more significantly in the course of time, and are hence taken as the
criteria to determine aging of paper.
G.OperatingTemperature
If the sustained operating temperature of the insulation exceeds the normal operating
temperature limit of 980C (hot spot temperature), there will be a shortening of life of the
transformer. In this condition, loading procedure as per IS-1972 define the life of material in
the insulating system as influenced by temperature alone, which may also be affected by
mechanical and electrical stresses.
3. MAINTENANCE OF TRANSFORMERS i) Transformers require only a little care as far as day
to day work is concerned Maximum temperature of oil corresponding to load and atmosphere
condition, oil level in the
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conservator, condition of silicagel in breather, leakages of oil if any, explosion vent

diaphragm, cleanliness of bushings, proper working of cooling system of the transformer,

electrical load conditions, and transformer hum etc. are the factors requiring regular
observation. ii) The transformer in service should not be subjected to overvoltage and
overload. Incoming
voltage, and taps should be correctly adjusted. iii) Every transformer has a cooling
system to limit the temperature rise of the transformer. The loading of transformer in KVA
depends on the temperature rise and therefore the cooling system should be maintained in
good condition. If ventilation fans do the cooling they must be available at the set value of
temperature as recommended by the manufacturer. For the transformer oil systems, cooled
by water, sufficient quantity of clean water should be available. Coolers also should be
maintained clean. Watch should be kept for leakage if any in the oil cooler. Alarms for
stoppage of oil and water flow should be maintained in working order. Instructions available
for the ventilation and cooling of the transformer should be strictly followed. All small
naturally cooled transformers should be installed at well ventilated places. Permissible
continuous overloading for a short period and overloading during emergency is determined by
the normal running temperature and therefore the transformer should be run at temperature
as low as possible. iv) General maintenance of the transformer demands cleanliness of the
surrounding yard and the transformer with all its auxiliaries, leakages of oil should be
attended as quickly as possible. Silicagel in breathers should be replaced as soon as it
indicates wetness by change of colour. All the silicagel breathers are provided with sealing oil
and the latter should be replaced from time to time. Foundation and fixing should be checked
for firmness. Checking performance of radiators, cooling system equipment, earthing of the
transformer, temperature-indicating instruments, signals and protection equipment of
transformers should be done regularly. v) The current transformer, potential transformer
lightening arrestor, isolators, circuit breakers installed for the transformers should also be
maintained in order. Current transformers and potential transformers also require equal care
as the main transformer. Contact resistance of isolators & circuit breaker will also effect the
performance of the transformer. All these equipment should be maintained in order.
vi) Due to leakage in the transformer, oil topping up is necessary. Lot of research and
experiments are going on, regarding mixing of oils. The results indicate that the oil of two
different sources though conforming to the same standards should not be mixed as the
sludging properties of the oil are considerably affected by mixing. Topping up of oil should
therefore, be done by the original grade of the oil as far as possible. If the mixing up of two
grades is unavoidable, the two grades of oils should be tested thoroughly before mixing.
Topping up with mixed oil should be undertaken only when oil topped up is small in comparison
to total transformer oil content, if the results of test show similarity of characteristics.
Recommendationsformaintenance:A.General:
No work shall be done on any of the transformers unless it is disconnected from
external circuits and all windings have been fully earthed. Naked lights and flames should be
kept well
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away from the transformer while doing maintenance. Oil level should be reduced below tank
cover while opening nuts and bolts on cover and before unsealing the tank, radiators,

conservator, explosion vent and any other piping on tank cover.

Transformer tank, cover and other parts should be inspected periodically for any oil
leakage, peeling of paint or rust formation. Rusted portion should be properly cleaned and
painted. Oil leakage should be immediately attended to. Clamping bolts on gasket joints
should be tightened properly and if necessary gaskets to be replaced. Leaks through welded
joints should be stopped by welding. Welding should be done with no oil in transformer tank
and radiators.
B.Transformeroil:
Oil level should be checked at frequent intervals and if necessary conservator should
be topped up. Oil for topping up should be clean fresh filtered and complying with IS 335 and
should preferably be from the same source as the original oil.
For maintenance of oil reference may be made to Indian Standard Specification IS:
1866, which gives detailed recommendations for maintenance of insulating oil. Sample of oil
should be taken at regular intervals and tested. It may be mentioned that normal method of
oil purification only maintains dielectric strength of oil. However the dielectric strength does
not give a true indication of the correct condition of the oil. Even oil, which is highly
deteriorated, may give high dielectric strength, if it is dry. Therefore, it is necessary to carry
out chemical tests and other test as given in IS: 1866 in addition to the above tests.
It may be noted that reconditioning by centrifugal separator or filtration does not
remove the acidity from the oil but will remove only sludge, dust etc. and will tend to retard
the process of deterioration. Filters with fullers earth will help to reduce the acidity in the
used oil and in addition improve the resistivity.
C.Conservatorandoillevelindicator:
Conservators are so designed that the lower part acts as a sump in which impurities
and sludge may collect. A valve is fitted at the lowest portion of the conservator for draining
and sampling. The inside of the conservator should be cleaned periodically. A detachable end
plate is provided to facilitate cleaning on all power transformers.
Oil indicator glass should be kept clean and its holes at top & bottom be kept cleared
so that oil level is clearly and correctly visible. Broken indicator glass should be replaced
immediately. When conservator is taken for maintenance, magnetic oil level indicator
mechanism should also be cleaned and inspected for operation. Float should be checked to
see that there is no oil in the float. Float be air tight and properly calibrated in line with oil
indicator glass by adjusting the float arm length.
D.SilicagelBreather:
Breathers should be inspected frequently especially in a situation where temperature
and humidity changes are considerable and when transformer is subjected to fluctuating
loads. So long as silica gel is in active stage, its colour changes to pale blue/pink/white.
Heating it upto 110-1300C for about 8 hours should reactivate silica gel.
The oil level in the oil seal must be maintained at the level marked in the cap. Renew
the oil when necessary. When two silica gel breathers are connected one below the other, oil
seal is provided only on the lowest breather. Breathers should be checked for clear air
passage. It can be confirmed by unscrewing the vent screw on breather. If air passage is
clear, on

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unscrewing the vent screw, oil level comes in gauge glass centre otherwise remains

unbalance. The air pipe be made clear.

E.Buchholzrelay:
Routine operation and mechanical inspection tests should be carried out as
recommended. During service, if gas is found to be collecting and giving alarm, the gas should
be tested and analysed to find out the probable nature of the fault. Sometimes, it may be
noticed that the gas collected is only air. The reason for this may be that the oil is releasing
absorbed air due to change in temperature. The absorbed air is released only in initial period
on charging and loading, when no vacuum is applied during filling of oil in transformer. The
nature of internal faults can be identified to a great extent by a chemical analysis of gas.
Buchholz relay will also give alarm or trip the breaker due to oil level falling below the
Buchholz relay. Isolating valve between the conservator and Buchholz relay facilitates
removal of Buchholz relay for repairs/checking without lowering the oil level in conservator. A
dummy flanged pipe is also supplied for fitting it in place of Buchholz relay for keeping the
transformer in operation without Buchholz relay. It should be ensured that isolating valves on
either side of Buchholz relay are kept fully open for unhindered oil flow. The jamming of float
pivot in the fulcrum may be caused due to sludge & sedimentation. It should be removed and
cleared by operating the float with little uplifting from the drain hole by rodding to float
gently.
F.Explosionvent:
The diaphragms fitted at the exposed end and inner end of the vent should be
inspected at frequent intervals and replaced if damaged. Whenever lower diaphragm
ruptures, oil rises inside the explosion vent pipe and is visible in the level indicator on
explosion vent, Failure to replace the outer diaphragm quickly will allow ingress of moisture
which will contaminate the oil. If diaphragm is broken because of fault in the transformer, an
inspection should be carried out to determine the nature and cause of the fault.
G.Temperatureindicators:
At each yearly maintenance inspection, the level of oil in the pockets holding the
thermometer bulbs should be checked and the oil be replenished, if required. The capilary
tubing should be fastened down again if it has become loose. Dial glasses should be kept
clean and if broken replaced as soon as possible to prevent damage to the instrument.
Temperature indicators found reading incorrectly should be calibrated with standard
thermometer immersed in hot water bath. Thermometer pockets should be filled with oil. Also
check the pocket/s for presence of water and if found, clean the pocket and refill with fresh
oil and seal the opening properly. If armoring of capillary is exposed, then retaping must be
done by PVC tape of good quality to prevent further damage to the armoring or capillary.
H.Bushings:
Porcelain insulators and connectors should be cleaned at convenient intervals and
minutely examined for any cracks or other defects. Small or narrow cracks are difficult to
detect. However, they are likely to develop rapidly. All such bushings should be replaced.
Similarly oil inside the oil communicating type bushings should be checked by unscrewing air
release screws provided on bushing top. The cause of any serious loss of oil should be
investigated. In case of any sign of oil leakage in the bushings, the matter should be referred
to manufacturer. In case of capacitance bushing, Tan delta I.R. value and capacitance be

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checked for satisfactory level. Test tap be kept earthed after the test is over. Bushing
arcing horn gap be adjusted properly as per operating voltages. Oil level in bushing gauge

glass be properly maintained with transformer oil of the same grade and quality.
I.Externalconnectionsincludingearthing:
All connections should be tight. If they appear balckened or corroded, unbolt the
connection and clean down to the bright metal with emery paper. Remake the connections
and give it a heavy coating of grease. It is particularly important that heavy current carrying
connections should be properly maintained.
Before opening the transformer at site (i.e. untanking the active part), Manufacturer
specific instructions be made available and followed scrupulously with care.
J.Gasket:
Check the transformer for leakages periodically. The bolts should be tightened evenly
around the joints to avoid uneven pressure. Broken or leaking gaskets should be replaced as
soon as possible with proper jointing & fixing.
K.Rollers:
After the transformer has been in service for a long period, roller should be examined
carefully. They should be greased and rotated to see that they turn freely.
L.Paintwork:
During storage and service, the paint work should be critically inspected atleast once
a year and where necessary painting and retouching be carried out. If the metal surface is
exposed and becomes rusty or greasy due to delay in touching work, the surface must be
thoroughly cleaned before repainting with primer and final paint. Paint as mentioned in the
General Arrangement drawing of transformer should be used. In case paint of another
chemical base is to be used, paint manufacturer should be consulted for compatibility with
existing paint.
M.RecommendedMaintenanceSchedulefortransformers:
The maintenance schedule given below is to be used as a general guide under normal
conditions. The frequency of inspection should also be determined by the size of the
transformer and local climatic conditions.
N.MaintenanceSchedule:
The maintenance schedule given in Annexture is a good indication of the attention
required to be given to the transformer under normal conditions.
4.TYPESOFDAMAGESINFAILEDTRANSFORMERS:
The types of damages generally noticed in failed transformers are as follows: i) Cut in
delta (HT) formation; ii) Cut in star (LT) formation; iii) Damage to winding (HT or LT or both);
iv) Damage in LT bushing stem; v) Defect in tap changer; Puncture in explosion vent
diaphragm; vi) Defect in breather;
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vii) Flash over of bushing; viii) Buldge in tank; ix) Choke in radiator tubes; x) Deteriorated oil.

Conclusions on the sources of fault developed in distribution transformers are

generally based on the nature and extent of damages. Normally, the causes for such
damages could be any one of the following: a) Surge voltage. b) Heavy leakage of oil. C)
Loose connections. D) Ingress of moisture by loose gasket or non-replacement of silica gel.
e) Poor earthing. f) Overloading. g) LT line faults. h) Inadequate protections against overload
short-circuit and lightning.
REMEDIES:
It is generally observed that damage to HT winding is found in a vast majority of failed
transformers. Inadequate protection on LT side can be compensated by the provision of
moulded case circuit breakers (MCCBs) which afford better protection than fuse wires. Dry
type transformers will do away the need for supervision and maintenance of oil and
associated problems like breather maintenance, provided it is cost effective. Completely self
protected transformers have lightning arrestors LA closer to HT bushings unlike conventional
transformers where LA are installed separately. Fail safe transformers have protection
features based on thermal sensing and hence are considered to be far superior. LT phase
separators would prevent midspan clashing of LT line conductors and thus reduce frequent
stressing of windings in transformers and their consequential failures.
5. DOS FOR POWER TANSFORMER/ REACTOR i) Check and thoroughly investigate the
transformer/ reactor whenever any alarm or
protection operated. ii) Check air cell in conservator. iii) Attend the leakages on the
bushing immediately. iv) Examine the bushings for dirt deposits and coats and clean them
periodically. v) Check the oil in transformer and OLTC for di-electric strength and moisture
content
and take suitable action for restoring the quality. vi) Check the oil level in oil cup and
ensure air passages are free in the breather. If oil is
less, make up the oil. vii) Check the oil for acidity and sludge as per IS : 1866. viii) If
inspection covers are opened or any gasket joint is to be tightened, then tighten the
bolts evenly to avoid uneven pressure. ix) Check and clean the relay and alarm
contacts. Check also their operation and accuracy
and if required change the setting. x) Check the protection circuits periodically. xi)
Check the pointers of all gauges for their free movement. xii) Clean the oil conservator
thoroughly before erecting. xiii) Check the bushholz relay and readjust the floats, switches
etc. xiv) Inspect the painting and if necessary retouching should be done. xv) Check the OTI
and WTI pockets and replenish the oil if required.
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xvi) Remove the air through vent plug of the diverter switch before you energize the

transformer. xvii) Check the oil level in the diverter switch and if found less, top up
with fresh oil conforming
to IS: 335. xviii) Check the gearbox oil level, if less, top up with specified oil. xix)
Examine and replace the burnt or worn out contacts as per Maintenance Schedule. xx) Check
all bearings and operating mechanism and lubricate them as per schedule. xxi) Open the
equalizing valve between tank and OLTC, wherever provided at the time of
filling the oil in the tank. xxii) Connect gas cylinder with automatic regulator if
transformer is to be stored for long, in
order to maintain positive pressure. xxiii) Fill the oil in the transformer/ reactor at the
earliest opportunity at site and follow
storage instructions. xxiv) Check the door seals of marshalling Box. Changes the
rubber lining if required. xxv) Equalize the diverter compartment of the OLTC by connecting
equalizing pipe between
flange joints provided on the tap changer head.
6. DONTS FOR POWER TANSFORMER/ REACTOR i) Do not energize without thorough
investigation of the transformer/ reactor, whenever
any alarm of protection has operated. ii) Do not re-energize the transformer/ reactor,
unless the Buchholz gas is analyzed. iii) Do not re-energize the transformer/ reactor without
conducting all precommissioning
checks. The results must be comparable with results at works. iv) Do not handle the
off-circuit tap switch when the transformer is energized. v) Do not energies the transformer,
unless the off-circuit tap switch handle is in locked
position. vi) Do not leave off circuit tap switch handle unlocked. vii) Do not leave
tertiary terminals unprotected outside the tank, connect them to tertiary
lightning arrestors protection scheme, when connected to load. viii) Do not allow WTI/
OTI temperature to exceed 650C during dryout of transformer, and
filter machine temperature beyond 700C. ix) Do not parallel transformers that do not
fulfil the condition of paralleling. x) Do not use low capacity lifting jacks on transformer/
reactor for jacking. xi) Do not move the transformer/ reactor with bushings mounted. xii) Do
not overload the transformer other than the specified limits as per IS : 6600. xiii) Do not
change the settings of WTI and OTI alarm and trip frequently. The setting
should be done as per the site condition. xiv) Do not leave red pointer behind the
black pointer in OTI and WTI. xv) Do not leave any connection loose. xvi) Do not meddle with
the protection circuits. xvii) Do not allow conservator oil level to fall below 14 level. xviii) Do
not allow oil level in the bushings to fall below minimum level xix) Do not leave marshalling box
doors open, they must be locked. xx) Do not switch off the heater in marshalling box except
to be periodically cleaned.
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xxi) Do not allow dirt and dust deposits on bushings, they should be periodically cleaned. xxii)
Do not allow unauthorized entry near the transformer/ reactor. xxiii) Do not leave ladder

unlocked, when the transformer/ reactor is ON in service, in case

it is provided. xxiv) Do not change the sequence of valve opening for taking standby
pump and motor into
circuit. xxv) Do not switch on water pump unless oil pump is switched on. xxvi) Do not
allow water pressure more than oil pressure in differential pressure gauge. xxvii) Do not mix
the oil, unless it conforms fully to IS : 335. xxviii) Do not allow inferior oil to continue in
transformer/ reactor. The oil should be immediately
processed and to be used only when BDV/ ppm conforms to IS : 1866. xxix) Do not
continue with pink silicagel, this should immediately be changed or regenerated. xxx) Do not
leave secondary terminal of an unloaded CT open. xxxi) Do not store transformer/ reactor for
long after reaching sit. It must be erected and
commissioned at the earliest. xxxii) Do not keep the transformer/ reactor gas filled at
site for a longer period.
7.MAINTENANCESCHEDULEFORDISTRIBUTIONTRANSFORMERS:
Periodicity Maintenance works Monthly i) Cleaning of transformers (particularly the bushings).
ii) Checking of oil level and, if necessary, topping up. iii) Checking of earth connections. iv)
Replenishing of Silica gel in breathers. v) Renewal of fuses.
Quarterly i) Measurement of loads in the feeders.
ii) Measurement of voltages at transformer end. iii) Measurement of voltages at tail end.
Half-yearly i) Measurement of earth resistance.
ii) Measurement of insulation resistance of lightning arresters.
Yearly i) Checking and greasing of air-break switch.
ii) Testing oil for electric strength (BDV). iii) Trimming of branches of trees touching the LT
and HT lines. NOTE: 1. Oil filtration is to be done every three years.
2. Complete overhaul is to be done once in five year.
Unauthorized additions to existing loads as well as illegal tapping of power and loads
not yet sanctioned, lead to overloading of the transformers.
Whenever the cumulative expenditure towards rectification of damages in failed
transformer exceeds 50% of its original cost, the transformer itself is considered as
uneconomical for repair and disposed off. This is also the case when the core and yoke parts
of the transformer had got damaged.
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ANNEXTURE

NO.FREQ.OFITEMSTOBEINSPECTIONACTIONREQUIRED
INSPECTIONINSPECTEDNOTESIFINSPECTIONSHOWS
UNSATISFACTORYCONDITIONS
1 Hourly Ambient Temp. - 2 do Winding Temp. Check that temp. Shut down the transformer
rise is reasonable and investigate if either is
3 do Oil temperature persistently higher than normal.
4 do Load (amperes) Check against Note: An improper tap position
5 do Voltage rated figure can causeexcessive core loss.
6 Daily Oil level in Check against If low, top up with dry oil,
transformer & transformer oil examine transformer for leaks. on load tap temperature. changer
7 do Relief vent diaphragm - Replace if cracked or broken.
8 do Dehydrating breather Check colour of If silica gel is pink change by
the active agent. spare charge. Oil level in the oil filled Oil level should be
The old charge may be dehydrating breather. changing with reactivated for further use.
change in temp. of oil. Clear the Air path.
9 Quarterly Bushing Examine for cracks Clean or replace.
and dirt deposits.
10 do Oil in transformer Check for dielectric
and tap changer. strength and water Take suitable action to restore
content. quality of oil.
11 do Cooler fan and pump Lubricate bearings, Take suitable action to restore bearings
motors and check gear box. quality of oil. Replace burnt or operating mechanism Examine contacts
worn out contacts or other parts.
check manual control & interlocks.
12 do On load tap changer Lubricate bearings, Replace burnt or worn out
driving mechanism check gear box oil contacts or other parts.
level and examine contacts.
13 do On load tap changer Check all circuits automatic control independently.
Check step by step switch operation including limit switches.
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