TRANSFORMER

Transformer is static equipment which converts electrical energy from one voltage
to another.

Transformer construction:

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 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.

2) Windings:

Windings are made from proper insulated copper conductor which is transposed at
regular intervals through out the winding for ensuring equal flux linkage & 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 winding for ensuring
proper cooling.

3) Cooling:

For ONAN /ONAF cooling, oil flows through the winding & external cooler unit
attached to the tank by thermos phonic effect. An external cooler unit consists of pressed
steel sheet radiators, mounted directly on the tank or separate cooler banks for air cooled
transformers.

4) Tank & cover:

Tank & cover are manufactured by welding steel plates & are suitable for
withstanding full vaccume & positive pressure of 0.35 Kg/cm above the normal oil head.
The tank & cover are designed such that these can be transported by railways, roads,
water as per customer’s specification.

5) Conservator:

Conservator provided to take care of the expansion & contraction of transformer

oil, which takes place during normal operation of the transformer.
A smaller oil expansion vessel is provided for the ON LOAD TAP CHANGER.
Magnetic oil gauge is fitted on the main conservator which can give Alarm / Trip in the

1
event of the oil level falling below the preset level due to any reason.

6) Pressure release device:

A device for oil pressure relief for transformer tank & cooling system is fitted
with an Alarm / Trip switch. The PRD allows for the rapid release of excessive pressure
that may be generated in the event of serious fault. PRD is spring loaded device which
provides rapid amplification of its actuating force.
In old & small capacity transformers i.e. 22 Kv-10/12.5 MVA capacity
transformers, an explosion vent is provided with a diaphragm, which will break in the
event of abnormal increase in the internal pressure.

7) Gas & Oil actuated (Buchholz) Relay:

Gas & oil actuated relay is fitted in the feed pipe from the expansion vessel to the
tank for collection of gas generated in oil. A present volume of gas collection in the relay,
or an oil surge towards the expansion vessel will cause the Alarm/ Trip contacts to
operate.
When the serious fault occurs, the generation of gas is so rapid that an oil surge is
set up through the relay. This oil surge impinge on the flap fitted to the trip element
causing it to rotate about its axis & so 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 & trip an element
operates in turn in the manner previously described for gas collection.
In the pipe connection between ON LOAD TAP CHANGER & its oil expansion
vessel a single float Oil Surge relay is fitted. This relay operates on the principal of surge
impinging on flap causing operation of mercury switch. This switch is connected to trip
circuit. Gas actuated alarm switch is illuminated because the gas generated during normal
tap changing operation will give unnecessary alarm.

8) Silica gel breather:

Expansion & contraction of oil cause breathing action. Any humidity in the air
breathed is observed by the silica gel dehydrating breather. An oil seal in the air intake
prevents external moisture being observed when not breathing occurs.
The breather container is filled with silica gel crystals. It is arranged such that the
air breathed must pass through it. The desiccant is impregnated with cobalt chloride &
when those silica gel crystals are fully active, they have a dip blue colour. If colour
changes to whitish pink, they are then saturated with moisture & the charge contained
should be replaced by a new reactivated one.

9) Winding Temperature Indicator:

The winding temperature relay indicates the winding temperature of the

transformer & operates the alarm, trip & cooler control contacts. This instrument operates
on principle of thermal imaging & it is not an actual measure. Winding temperature

2
indicator consists of a sensor bulb placed in an 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 & 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 the 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 winding.)
The increase in the temperature of the resistance is proportional to that of 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. hot spot temperature

10) Oil temperature indicator:

The oil temperature indicator consists of a sensor bulb, capillary tube & dial
thermometer. The sensor bulb is fitted at the location of hottest oil. The sensor bulb &
capillary tube are fitted with evaporation liquid. The vapor pressure varies with
temperature & is transmitted to a burden tube inside the dial thermometer, which moves
in accordance with the changes in pressure, which is proportional to the temperature.

11) Bushing:

The high voltage connections pass from the winding to terminal bushings.
Terminal bushings up to 36 Kv class, 3150 Amps, are normally of plain porcelain & oil
communicating type.

12) Tap changer:

A) On load tap changer

B) Off circuit tap changer
For on load tap changer, the tap changer takes place when the transformer is in
operation. The tap changer can be designed for changing the taps a) Manually b) From
remote.
The on load tap changer will be self contained unit housed in the main
transformer tank. Since some amount of arcing takes place during the switching
operations from one tap to another. The oil inside the tap selector will deteriorate faster.
Hence this oil can not be allowed to mix with the oil in the main transformer. On load tap
changer is provided with a separate conservator & oil surge relay.

Inspection after receiving main unit:

When transformer arrives at site a careful external inspection must be made of the
unit.

3
 Inspect all packing cases & loose components for damage or missing items.
Confirm that case numbers match with packing list. Check their contents tally with
packing list if the packing case is damaged. If any scratches or damage to the paint is
noticed on receipt of main body or accessories, touch up painting should be done
immediately over the damaged area. If any damaged noticed claim must be lodged with
the insurance agency & the matter must be reported promptly to the manufacturer.

Inspection of main unit oil filled:

Upon arrival of site, check oil level inside the tank. Check damages to valves
etc.A sample of oil should be taken from the bottom of the tank & tested for BDV &
moisture content. If value does not meet the relevant standards the matter should be taken
up with the manufacturer.

Unpacking & Inspection of accessories:

1) Crates / packages are opened to be carefully so that the tools used for opening do not
cause damage to the contents.
2) Drums containing transformer oil, which have been dispatched separately, shall be
examined carefully for leakages.
3) Bushing porcelain should be checked for any crack or chipping.
4) Oil level gauge, Temperature indicators etc. are to be inspected for breakage or any
damages.

Inspection of site (transformer bay) & marking:

Inspect the site where transformer to be installed. As per the transformers overall
dimensions, marking to be done in the bay. There should be 1 meter to 1.5 meter
clearance from the wall so that we can easily move around the unit. While marking,
orientation of the transformer to be considered.

Movement of transformer:

If the foundation is ready & if rail link between unloading places is available, then
main body of the transformer must be moved on its own rollers to the foundation where
the transformer is to be erected finally.
If transformer is not provided with rollers if it is to be erected on its said place, the
transformer must be slide to its final position using steel plates to protect plinth surface &
make movement easier. The transformer must be pulled by using slings. When jacking
(to remove steel plates) position, the jacks under specified jacking pads only. When
jacking, ensure that all four jacks are operated simultaneously.

Assembling of Bushings

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 open

4
the top cover of the wooden case & inspect the bushing thoroughly for any transit
damage. Ensure all the accessories are received in good condition & report, in case found
to be missing. Install the bushing as per the manufacturers drawing. Fresh gasket to be
used for installation of bushing.

H.V. & L.V. Dividing Box Assembly:

The assembly shall be carried out referring to the cable box assembly drawing
provided in the instruction manual. Cable box assembly may be bolted to the
disconnecting chamber on the transformer tank. Flexible connections shall be made
between bushings & cable box bus bars through the inspection cover.

Testing of transformer:

PRE-COMMISSIONING CHECK / TEST’S LIST

1. Location :- Receiving Substation

2. Transformer Make :-
3. Sr. No. Capacity :- 16 MVA
4. Voltage Ratio Primary : 33kV Secondary : 11KV
5. Date of Testing :- Date of Commissioning :- _________

Sr. Description Whether

No. Yes/No
1 Buchholz relay / oil Surge relay arrows pointing towards the Yes
conservator/s.
2 Explosion vent diaphragms mounted at both ends of the pipe. N.A.
Gaskets in the Equalizer pipe (if any) duly punched to ensure
communication between Conservator top and Explosion vent.
3 No Oil visible in Explosion vent sight glass N.A.
4 a. Buchholz relay test screws in service position or Yes
4 b. Buchholz relay float locking released.
5 Oil surge relay float locking released. Yes
6 Magnetic Oil Level Indicator level gear released from transit Yes
locking.
7 Isolating valves of the Buchholz relay / Oil Surge relay in fully Yes
open condition
8 Magnetic level indicator mercury switch transit locking released. Yes
9 O.T.I. & W.T.I. transit lock removed. Yes
10 Oil filled in Oil Silca-gel breather upto filling level. Yes
11 Oil in conservator filled upto the filling level Yes
12 All radiators flushed with hot Oil Yes

5
 13 Oil filled in Oil temperature indicator and winding temperature Yes
indicators pockets.
14 All radiators valve open. Yes
15 OLTC operated and main breather seal gaskets removed. Yes
16 OLTC operated manually for two full cycles for smooth operation Yes
17 Control cabling carried out completely. Yes
18 Earthing of transformer, marshling box, OLTC, CPRP Panel Yes
19 Change over link kept on 6.6/11KV position and properly tightened N.A.
20 Stenciling on Tr. LV/HV dividing box, CPRP . Yes
21 Cable entries properly sealed in LV/HV dividing box and Sw/gear. Yes
22 Draughtsman booking. Yes
23 To check breather locking. Yes

INSULATION RESISTANCE WITH __5 __KV INSULATION TESTER

A) Before connecting any accessories, Transformer Tank just positioned on the

foundation.

a.1 Primary to Earth -- 9 K. Mega ohms

a.2 Secondary to Earth -- 7 K. Mega ohms

a.3 Primary to Secondary -- 12.5 K. Mega ohms.

B) After connecting the accessories, topping & filtering of oil.

b.1 Primary to Earth -- K. Mega ohms

b.2 Secondary to Earth -- K. Mega ohms

b.3 Primary to Secondary --- K. Mega ohms.

1. TRANSFORMER OIL BREAK DOWN VALUE

a) Before connecting any accessories (2 Samples)

Top Bottom
50 kV 56 kV

b) After filtering (2 Samples)

6
 Top Bottom
60 kV 64 kV

c) Before handing over the Transformer to O&M

Division (2 Samples)
Top Bottom

RATIO TEST

Give 3 phase 415 Volts supply to Primary side and measure the voltage at
Secondary side for all the 17 taps.

(Actual Voltage – RY- 402 V, YB - 400 V, BR – 400 V

Rn – V, Yn – V, Bn- V)

LV VOLTAGE MEASURED

TAP r-y y-b b-r r-n y-n b-n

NO.
1 123 123 123 69 69 69
2 125 125 124 70 70 70
3 126 126 126 71 71 71
4 128 128 128 72 72 72
5 130 130 129 73 73 73
6 132 132 131 74 74 74
7 133 133 132 75 75 75
8 135 135 134 76 76 76
9 137 137 136 77 77 77
10 139 139 138 78 78 78
11 141 141 140 79 79 79
12 143 143 142 80 80 80
13 145 145 144 81 81 81
14 147 147 146 82 82 82
15 149 149 148 83 83 83
16 151 152 151 85 86 85
17 154 154 152 86 87 86

7
 PHASING
H.V. ______ O.K.
L.V. ______ O.K.

Operation of the Tap change gear

Manually - OK –
Local (Electrical) - OK –
From Remote Control – OK –
Audible and visible indication – OK –
On R.T.C.C. Panel

-: PART – VII :-
VECTOR GROUP
Apply 415 Volts, 3 Phase supply to H.V. winding and short Primary “ R “ phase
with secondary “r” phase & measure the following voltages.
Y-y = 290 V Y-b = 422 V
B-b = 291 V B-y = 292 V
(If B-b = B-y & Y-y < Y-b then Vector group is “Dynl” )
Rn + Bn = RB 1U
71 + 323 = 394 V

2W
2U
2V
1W 1V

8
 Magnetic Balance Test :-

Conditions Primary voltages Secondary voltages Voltages between

between between Neutral & Phase
R-Y Y-B B-R r-y y-b b-r r-n y-n b-n
‘R’ phase 272 401 123 25 126 98 20 48 74
removed
‘Y’ phase 232 167 403 119 10 107 107 40 28
removed
‘B’ phase 401 248 149 103 123 15 15 74 44
removed

Phase Sequence - Rr – 165, Ry – 297, Rb – 240

Yr – 243 Yy – 167, Yb – 299
Br – 300, By – 241, Bb – 167
Installation of radiator:
Tools required for installation of radiator – a) Jib crane b) New gasket
Procedure –
a) Remove the blanking plate
b) Fix new gasket
c) Assemble the radiator & tighten the clamping bolts.
.
Installation of Conservator:

a) Mount the conservator as shown in the supplier’s drg .by using jib crane.
b) Usually the main conservator is provided with magnetic oil level gauge having low oil
level alarm contacts & OLTC conservator is provided with oil sight window.
c) Mount all valves as shown in supplier drg. of conservator.
d) Mount the connecting pipe with buchholze relay from the main tank to the
conservator. Ensure the direction of buchholze relay arrow towards conservator.
e) Mount connecting pipe with oil surge relay from OLTC to conservator.
f) Mount breather connecting pipe & silica gel breather from main &OLTC conservator.

Marshalling box:

Mount marshalling box as shown in suppliers drawing by using jib crane.

Pressure release device:

PRD should be installed considering the following aspects.

a) The indicating flag easily seen from distance.

b) The valve is easily accessible for manual resetting & for routine checking.

9
 While installing remove dirt & clean the mounting surface, remove all tresses of
oil & grease.
The rubber gasket supplied with the valve should be properly cleaned. All the nut
bolts should be tightened evenly so that equal pressure is exerted on the gasket & base.
Connect control circuits to terminal plate provided in the switch box through
cable gland.
As per the wiring diagram check the operation of flag & switch by lifting
operating rod & confirm that both controls operates as required. PRD can be put to
service.

Erection of pipe works:

All joints are to be assembled with gasket only & without joining compounds &
grease.
Joints must be fully tightened only when the transformer has been fully erected.
By that stage the pipes can be centralized. No predetermined torque value is applicable.
No joints must be under excessive assembled load as subsequent expansion or contraction
could cause leak.

Temperature Indicators:

Sensing element of oil & winding temperature indicators are to be fitted in the
thermometer pockets, welded on top cover of transformer. Before mounting the thermal
sensing bulbs, inside the pocket should be cleaned thoroughly & filled with transformer
oil up to the depth of half the pocket. Care should be taken not to damage the capillary
tubing. Capillary tubes should be clamped properly. Fill oil in the pocket after cleaning.

Installation of Buchholz relay:

Sea the buchholze relay is positioned with the arrow pointing towards the
conservator. Mount the relay as close as possible to the tank in the pipeline between
transformer & conservator. Keep pipe bends as wide as possible between transformer &
conservator. Make sure that pipe ascends to the conservator at angle between 3 degrees to
7 degrees.

Installation of silica gel breather:

Remove top cover by unscrewing cap nut & fill it with silica gel. Remove the
plug. Fill the oil cup with transformer oil to the indicated level.

Control wiring:

1) To lay 2.5sq.mm / 12 core control cable from OLTC to CPRP

2) To lay 2.5sq.mm / 4 core control cable from OLTC to Battery charger.
3) To lay 2.5sq.mm / 12 core control cable from marshalling box to CPRP

10
1) 2.5sq.mm / 12 core control cable cores are used as below.

1 -- For remote phase

2 -- For remote tap raise
3 -- For remote tap lower
4 -- For indicating tap maximum
5 -- For indicating tap variable
6 -- For indicating tap minimum
7 -- For tap change in progress
8 -- Neutral 110 volts A.C.

2) 2.5sq.mm / 4 core control cable from OLTC to Battery charger.

This cable is laid for 440 volts A.C. supply for three phase motor.

3) 2.5sq.mm / 12 core control cable from marshalling box to CPRP – cable cores
used as below.

1 -- For Buchholze trip

2 -- For Oil Surge Relay trip
2 -- For Pressure release device trip
4 -- For Oil temperature alarm
5 -- For Oil low level alarm
6 -- For Winding temperature alarm
7 -- For Buchholze alarm
8 -- For Extended Positive

Connect the control cables laid from marshalling box to buchholze relay, PRD,
OTI, OSR on transformers per manufacturers drawing. After wiring of marshalling box &
OLTC, test the commands on control & relay panel by shorting contacts of PRD, OSR,
Buchholze relay, OTI & WTI on transformer.

33 KV Cable Termination:

After fixing bushing, extending bus bar & installing H.V. dividing box, cleating
arrangement for supporting 33 KV cable size 300 / 3 core XLPE is to be made.
To lay 300 /3 core XLPE cable between primary breaker & transformer.
Terminate cable in H.V. dividing box by making heat shrinkable termination.

11 KV cable Termination:

After fixing bushing, extending bus bar & installing L.V. dividing box, cleating
arrangement for supporting 11 KV cable size 500 / 1 core XLPE is to be made.

11
 To lay 500 / 1 core XLPE cable X 7 pieces (2 pieces per phase & 1 piece for
neutral) between secondary breaker & transformer. Terminate cable in transformer
secondary side by making heat shrinkable terminations.

Earthing:

Two earthing strips of size, 40mm X 5mm copper to be brought from main station
earthing channel. Following parts of the transformer to be earthed.
1) Main tank earthing – 40mm X 5mm copper strip
2) On load tap changer earthing—25mm X 3mm copper strip
3) Marshaling box earthing – 25mm X 3mm copper strip
4) H.V. Dividing box earthing – 25mm X 3mm copper strip
5) L.V. Dividing box earthing – 25mm X 3mm copper strip

Oil topping:

Procedure – Close both stop cock connected to buchholze relay. Firstly fill up
conservator tank & check magnetic oil gauge. Then open the first valve between
conservator & buchholze relay, fill up the oil in buchholze relay & check function of
buchholze relay .Open the second valve between buchholze relay & main tank. Release
the air through air vent & check sure that the tank is full. Then open the bottom side
butter fly valve of first radiator & open top side air vent & release the air in the radiator
till the oil overflowing from top side air vent. As per the above procedure fulfill all the
radiators. Release the air from H.V. & L. V. bushings. After filling oil in the transformer
i.e. 1/3 level at conservator check the oil leakages at the joints between main tank &
radiator , piping, buchholze relay oil surge relay, H.V.dividing box & L. V. dividing box .

Oil filtering:

Procedure –Connect bottom filter valve of transformer tank to inlet valve of filter
machine. Connect top filter valve of tank to outlet of filter machine. Both valves should
be in close position.
1) First start vaccume pump.
2) After sufficient vaccume, start inlet pump & open inlet valve take the oil in filter
machine.
3) Open outlet valve & start outlet pump.
4) After oil starts circuiting, heater switches to be switched on. The filter outlet
temperature should be limited up to 60 to 70 degree centigrade.
Oil circuit should include a vaccume chamber in which oil drawn from the
transformer is spread & the moisture & gases are released from the oil are extracted by
the vaccume pump.
Oil drawn from transformer is passed through a filter press before be admitted to
the vaccume chamber to remove impurities

12
A minimum capacity of 6000 liters per hour is recommended for the circulation
equipment. After oil filtration oil sample shall be tested for moisture contains. Break
down voltage should be more than 60 Kv at 2.5 mm gap.

On Load Tap Changer Drive Mechanism:

OLTC driving mechanism has been mounted on the transformer. Check for
mechanical stops at extreme position by manually operating with the handle.Connect 3
phase supply with the correct phase sequence. Check raise & lower operation electrically.
If direction is correct check electrical end stops at extreme position.OLTC diverter
chamber & OLTC conservator shall be filled with transformer oil. Operate the drive
mechanism rated tap i.e. 17 to tap no.1.Then to the other extreme tap position & bring
back to rated tap.
Operate drive mechanism electrically. Check & confirm that for each impulse
given in both raise & lower directions, diverter switch operation sound is heard before
motor stops. After hearing the sound, the travel of the tap position indicating disc up to
the green band shall be equal in both forward & backward crank position.Veryfy the ratio
on all taps using ratio meter or digital voltmeter.

Oil Surge Relay:

A protective oil operated relay is sensitive to both low oil level & oil surge
conditions. The relay must be fitted in the pipe connection from the tap changer
conservator pad to the conservator & its contacts must be connected to inter tripping
system so as to isolate both sites of the transformer. The pipe work rising to the
conservator should be arranged at an angle of 5 degree above the horizontal to ensure
effective operation of the protective relay. The connection of the relay contacts in the trip
circuit such that the transformer is fully isolated will prevent damage to the tap changer
in of low oil level.

Operation of on load tap changer:

Each phase of the selector switch assembly comprises a phase board with as many
fixed contacts as there are tap positions & moving contact arm. The fixed contacts on
each board are connected to the main terminal board. The moving contact arm carries two
pairs of contacts. One pair (main) is connected to the sliding contacts & sling ring which
is connected to the terminal board. The other pair (transition) is connected via a transition
resister to the same sliding contact.
In the working position, the main contact is in the middle of the face of the fixed
contacts corresponding to the tapping in use. During process of the tap change, the
transition contacts which is between selector contacts in the running position, first makes
contacts with the fixed contacts corresponding to the next tapping. The two tapping are
thus bridged by the two moving contacts & step voltage is applied across the transition

13
resistor. The main contacts leaves the fixed contacts of the original tapping , resistor
circulating current is interrupted & current flow is transferred to pass through the resistor
to the next tapping. The main contacts then makes on the fixed contacts of the next
tapping & the tap change is completed by the transition contact moving in the rest
position between the fixed contacts. This sequence is reversed when operating in the
opposite direction.

Transformer Name Plate

Type of cooling :- ONAN

Rated Power H.V. :- 16mVA
Rated Voltage :- H.V. – 33 kV
At no load :- L.V. - 11kV
Rated Line Current :- H.V. – 279.9 Amp.
L.V. - 839.8 Amp.
No. of phases :- Tap-1 - 10.12%
Impedance Tap-5 - 9.75%
Voltage Tap-17 – 9.12%
Max. Temp. Rise :- Top Oil - 450 c
Over on Amb.temp.: - 500 c
Year of Manufacturing: - 2007
Guaranteed no load loss: - 9.00kW maximum
Guaranteed Full load loss :- 50kW maximum
Sr. No. :-
Type :- Double Wound
Vector Group :- Dyn1
Frequency :- 50 Hz.
Insulation Level :- H.V. –L1-170 A.C. 70kV
L.V. –L1- 75 A.C. 28kV
LVN- L1 – 75 A.C. 28 kV
Wt. Core & Winding :- 23200 kG
Tank Fitting :- 11100 kG
Mass of Oil :- 9000 kG
Total Mass :- 43300 kG
Total Mass with oil & Partial :- 37750 kG
Gas
Volume of oil :- 10400kG
Noise Level :- 60db at 1 M

14