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Manual for

Maintenance of Distribution Transformers


Source: TQM activities of MeSEB, 2007-08

January 21, 2010

Meghalaya State Electricity Board

MANUAL FOR MAINTENANCE OF DISTRIBUTION TRANSFORMER


Source: TQM activities of MeSEB, 2007-08

A Distribution Transformer (DT) is utilized to step down the voltage from 11 KV to 0.433
KV/0.250KV so that the electrical power is usable for providing supply to the customers such as
domestic, commercial, industrial, LT, etc. A registered consumer expects uninterrupted power supply
because during the failure of power supply, all works be it domestic, official, commercial or industrial
comes to a standstill. Hence, transformer failure leads to consumer complaints and unnecessary
emergency for the Utility to restore the power supply. In urban areas, the reason for failure of power
supply due to failure of transformer is not too frequent, whereas in rural areas most of the power
failures are attributable to the failure of distribution transformers.
Failure of distribution transformers results in considerable revenue loss and entails heavy
expenditure for replacement.
This manual on DT maintenance and reduction of failure does not describe the engineering
know-how of prevention but ensures the use of these skills from the huge collective knowledge of our
vast human resources.
Reasons for failure of Distribution Transformers and the remedial measures thereof:
The reasons for failure of Distribution Transformers in both urban and rural areas are the following:

Sl Probable Causes
No

Factors

Remedial Measures

1.

Overloading

A) Absence of record on the


loading of the transformer.
B) Granting of load sanction
without taking into account
loading on the transformer.
C) Unauthorized usage/theft of
power

2.

Imbalance loading

A) Absence of record on the


phase
B)
loading of the transformer.
C) B)
Improper
service
connection to consumers
without taking into account
the phase load

A) Maintaining proper record of


the total number of consumers
along with the connected load.
B) Maintaining proper record on loading
of the transformer.
C) DT metering (static).
D) Augmentation of transformer or
construction of new sub-station.
E) Disconnection of illegal connections
A) Maintaining the record of the phasewise loading and regular load balance
accordingly
B) Service connection to be given from
the appropriate phase(s) only after
taking proper shutdown
C) Phase conversion

D) Long single/two phase line.


3.

Low transformer
oil level

A) Leakage of oil
B) Theft of oil

4.

Low break Down


Value (BDV) of
the transformer oil
and poor insulation
resistance(IR)
Value

5.

Poor earthing
or
absence
earthing

A) Overheating of transformer.
B) Entry of moisture and
contaminants.
C) Burnt out insulation in the
winding & core.
D) Acidity formation due to the
combined effect of heat,
dissolution of varnishes &
cellulose.
E) Sludge formation due to
continuous
heating
and
thereby decomposition of the
insulation material which then
gets dissolved in the oil.
A) High soil resistivity of the A) Periodical checking of the soil
earth pit
resistivity. Renovation of earth pit or
B) Disconnected earth wire or
making a new earth pit.
rusted earth wire.
B) Periodical
checking
of
earth
connections. Tightening of the terminal
connections.
A) High soil resistivity of the A) Periodical checking of the soil
earth pit
resistivity. Renovation of earth pit or
B) Undersized loop, especially
making a new earth pit.
from the conductor to the B) Usage of the appropriate size of
L.A.
earthing loop
C) Disconnection earth wire and C) Periodical checking of earth wire
rusted earth wire.
and earth connection.
D) Common earthing.
D) Tightening of the terminal connections.
E) Absence
of
lightning E) Earthing loop of LAs is to be
arrestors / damaged lightning
separate.
arrestors.
F) Installation/ replacement of LAs
A) Loose connection
A) Proper
tightening
of
terminal
B) Poor lugging
connections.
B) Proper lugging and usage of
appropriate size of lugs.
A) Leakage of oil at terminals.
A) Proper tightening of terminals and
B) Short circuit between cables
joints, and replacement of loose burnt
due to failure of insulation.
out gaskets
C) Fire due to weeds/ jungles etc B) Regular check of the insulation of
cables.
C) Periodical cleaning of substation.
A) Long LT line span
A) Erection of intermediary poles where
B) Poor safety clearance.
necessary.
C) Sagging of conductors.
B) Place spacers where necessary and

of

6.

Lightning

7.

Improper or poor
cable terminal

8.

Burning
transformer

9.

External
circuit

of

short

A) Proper tightening of terminals and


joints and replacement of loose/burnt
out gaskets
B) Proper sealing of valves
C) Use of REC valves
A) Augmentation of transformer or
construction of a new substation.
B) Proper tightening of terminals and
joints.
C) Replacement of deteriorated gaskets.
D) Replacement of cracked bushings.
E) Prompt replacement of deteriorated
silica gel & dirty oil in the breather.
F) Periodical testing of oil.
G) Filtration/overhauling of transformer
oil as & when required after testing

10.

Overrated fuses

11.

Flash over

12.

Lack of testing of
transformer and
sub-station
equipments

13.

Vandalism

D) Accumulation of dust on
maintain safety clearance between
bushings.
conductors.
E) Contact of the conductor with C) Maintain sag of conductors as per
trees / branches.
standard.
D) Cleaning of bushings
E) Regular jungle clearing
A) Non availability of rated
A) Prompt requisition and procurement of
fuse.
fuse.
B) Ignorance of the field staff on B) Training of staff on the purpose of
the appropriate ratings.
fuse, correct size and implications of
C) Use of conductor as fuse
overrating.
C) Discourage the use of conductor as
fuse wire
A) Absence of arcing horn or
A) Proper fitting of arcing horns.
arcing horns are not fitted
B) Periodical cleaning of bushings.
properly.
B) Dirty bushings
A) Non availability of megger
A) Each sub-division should have megger,
earth tester, filter machine, oil
tong tester, and earth tester and each
testing kit.
division should have an oil filter
B) Absence of a routine for
machine and oil testing kit.
testing.
B) Testing schedule to be compiled and
C) Shortage of staff
implemented.
C) Outsourcing of the testing.
A) Unsecured sub-station
A) Proper fencing and the gate(with lock
B) Lack of awareness among the
if needed).
public
B) Danger plate in the substation.
C) Public awareness through media and
meetings.

From the table above it can be seen that the main factors which contribute to Distribution Transformer
failure are:
1. Non implementation of the construction standards.
2. Absence of records on number of consumers, loading and history of the sub-station.
3. Absence of a well prepared action plan for distribution transformer failure reduction.
4. Absence of inspection, testing and maintenance schedule and non-implementation thereof.
5. Absence of inspection, testing and maintenance record on every sub-station.
6. Irresponsibility and carelessness on the part of some personnel.
7. Absence of proper reporting and clear guidelines at different levels.
8. Shortage of staff.

Steps to be taken for Distribution Transformer Maintenance


1.

Data collection & upkeep of database


a.
b.
c.
d.
e.
f.
g.

2.

Total number of DTs in the Division/Sub-division.


Monthly DT failure report in each sub-division. A separate report in a uniformly
prescribed format for each DT failure.
Weekly/Monthly interruption report in a sub-division.
HT feeder with sub-stations including the single line diagram showing line length and
sub-station capacity.
LT feeder single line diagram indication the line length.
Monthly record of consumer complaints and records of failure against each DT.
Computerization of database in uniformly prescribed formats throughout the board.

Inspection & Maintenance Schedule for Distribution Transformers:

Sl

Inspection
frequency

Items to be inspected

Inspection notes

1.

Fortnightly

(i) Dehydrating
Breather

Check that air passages


are clear

(ii) Oil Level in


Transformer

Check colour of active


agent (silica Gel)
Check transformer oil
level

2.

Monthly

3.

Quarterly

4.

Half yearly

(iii) Physical
Condition
(i) Connections (HT & LT
terminals)
(ii) Explosion vent
(iii) Diaphragm (Pressure
relief device)
Bushings

(i) Non oil


conservator tank
transformer
(ii) Cable boxes, gasket
joints, gauges and general

Check tightness
Check for cracks/
damages
Check for any oil
spillage
Examine for cracks
and dirt deposits
Check for external
connection
Check for moisture
under cover
Inspect

Action required if inspection


shows
un-sactisfactory
conditions
Clean air passages. If silica gel is
pink, change with spare.
Charge. The old charge may be
reactivated for use again.
If oil level is low, top up with dry
oil. Examine transformer for
leaks. If loose. Tighten: replace if
cracked
Tighten the terminal connections
Replace lugs if required
Replace the gasket

Clean or replace
Tighten, if required

Improve ventilation
Maintenance of breathers to be
ensured
Take remedial measures

5.

paint work
(i) Oil in transformer

Yearly

(ii)Earth resistance

3.

Check for dielectric Oil filtration to restore quality of


strength Check for oil.
acidity and sludge
<I ohm
Take suitable action if earth
resistance is high

Communication

a.

Monthly meetings on DT maintenance among AEE/AE/JE and line staff.

b.

Monthly/biomonthly meetings of CEOs with EEs and AEEs.

c.

Quarterly meetings convened by the CE (Distribution) with the Zonal ACEs, ACE
(MM), CEOs & EEs.

d.

Coordination with local dorbars on DT problems and pilferage.

e.

Capacity building programs for different levels.

NOTE :

It has also been observed that one of the reasons for failure of distribution transformers is
the supply of sub-standard transformers, which is a result of improper vendor rating and lack of
routine test prior to dispatch by the manufacturer & issue for use. It is therefore proposed as
follows:
a. Vendors should be approved only after confirming the adequacy of the manufacturing &
testing facilities at the works.
b. Procurement should be on the guaranteed technical particulars and not necessarily L-I rate.
c. Routine tests should be observed at the works and the transformer should be tested prior to
issue for utilization.

4.

Inspection & Maintenance of transformer and accessories within the sub-station and its
proximity.
A. Overall Sub-station Inspection cum Maintenance Report.
(to be filled up by the concerned inspector viz. Lineman/ES/JE/AE/AEE)

a.
b.
c.
d.
e.
Sl
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

17
18
19
20

Name of Sub-station
Code of Sub-station
Capacity of Transformer
Number of LT feeders
Date of inspection

Items to be inspected
Physical condition of the transformer
DOs/Main switch/Cut-Out
LT feeders
Cable Lugs
Earthing, Earthing Leads, etc
Lightening Arrestor
Arching Horn
Transformer Bushing
Breather
Condition of silica gel
Radiator
Oil level
Oil leakage in any
HT Terminal
LT Terminal
Current (Amps)
Peak Hours

Condition/Observations/Remarks

a. R-phase
b. Y-phase
c. B-phase
Off-Peak Hours
a. R-phase
b. Y-phase
c. B-phase
a.
HT-LT
I R Value
b.
HT-E
c.
LT-E
Number of illegal consumers receiving supply from DT
Number of illegal consumers disconnected from the DT
General upkeep and overall cleanliness of substation
(weeds, litter, etc)

21
22
23

Fencing & gate of the substation


Danger plate
Others

B. Sub station premises:


Sl
No.
1.
2.
3
4.
5.
6.

Items to be inspected during sub-station Inspection notes


maintenance work

Action
required
if
inspection shows unsactisfactory conditions

HT & LT Fuses
LAs
Earthing
DOs Main switch, Cut out
Cleanliness of sub-station
Checking of sub-station station loading
by tong tester or DT metering
C. HT /LT Lines in the proximity of the substation:

Sl

Items to be inspected during sub-station Inspection notes


maintenance work

1.

Condition of HT/LT Poles including


stay wire
Span of LT lines/need for LT spacers
Whether poles are covered with creepers
Whether HT/LT Lines are having
minimum clearance from trees/branches
Whether
illegal connection like
hooking, illegal service connection are
present or not
Likely cause of failure due to nearby HT
Lines

2.
3.
4.
5.

6.

NOTES:

Action
required
if
inspection shows unsactisfactory conditions

Signature/seal of person(s) inspecting


Compiled by HRD Centre MeSEB,Umiam

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