Power Tranformer Standarization Manual

POWER TRANSFORMER - STANDARDISATION MANUAL 1
Chapter - 1
Technical Specification & Parameters
Working Group Members

Mr. P. Ramachandran - ABB Ltd.
Mr. M. L. Jain - EMCO Ltd.

2 POWER TRANSFORMER - STANDARDISATION MANUAL
CHAPTER - 1
TECHNICAL SPECIFICATION & PARAMETERS
INTRODUCTION:
1. Ratings, Voltage Ratio, Tapping range, Impedance and other technical parameters may be selected as per CBIP
Publication No. 295, Manual on Transformers, 2012.
2. This Manual gives the recommended losses for the standardised ratings of power transformers (Annexure - 1.1).
Two ranges of losses are given - High Losses (for maximum specific loadings of current density 3A/mm2 and flux
density 1.7 T at rated tap) and Low Losses (for maximum specific loadings of 2.3 A/mm2 and flux density of 1.6 T
at rated tap). Current Density refers to all taps and flux density refers to at rated tap and voltage. Low losses may
be adopted where the capitalization rates are high (say ` 2 lakhs per no-load loss kW and ` 1 lakh per load loss
kW) and high losses where low capitalization rates are applicable (say ` 1 lakh per no-load loss kW and ` 0.5 lakh
per load loss kW). When fixed maximum losses are specified, transformer buyers need not capitalize the losses
for bid comparison. With fixed losses and using standardised GTP, buyers can compare various bids effectively
and expeditiously. They can compare quoted weights of active materials with standardised losses. Indicated
stray losses and type of conductors (rectangular conductor Vs continuously transposed cable – CTC) can be
compared. Hardness of conductor and epoxy coated CTC gives an indication of short circuit withstand strength
of winding.
3. Where the buyer wants losses different from the above standardised losses, he may get losses from reliable
vendors after indicating the loss capitalization rates or maximum specific loadings. After evaluating the market
losses, fixed losses for the special duty transformers may be decided and bids may be invited for the fixed
losses.
4. The GTPs are prepared in two parts. One is to be specified by buyer and other by vendor. The tick mark ‘ √ ’ is
shown in the column indicate by whom the data is to be filled in.
5. Ratings are also standardised covering 132 kV and above and up to 765 kV class transformers and accordingly
considered in this manual (Annexure - 1.2).
6. List of applicable standards for transformer is enclosed for ready reference (Annexure - 1.3).
Guaranteed Technical Particulars for Power Transformers
A. GENERAL
Item Description Unit Specified Offered

(by Buyer) (by Vendor)
1 General Information
i) Supplier
ii) Manufacturer √
iii) Place of Manufacture
iv) Type of Transformer (Core/Shell)
2 Applications
i) Indoor/Outdoor
√
ii) 2Wdg/3Wdg/Auto
iii) GT/Step down/ICT/Station Start up/Auxiliary/Rail Trackside Supply
3 Corrosion Level at Site

√
i) Light ii) Medium iii) Heavy iv) Very Heavy

4 Applicable Standards
i) IEC: 60076
√
ii) IS : 2026
iii) ANSI C57.12.00
5 Type
i) Liquid Immersed √
ii) Dry
6 Full Load Rating (HV/IV/LV) MVA √
7 3 Phase/Bank of Three Phase/Single Phase ( A,B,C) √
8 Rated No Load Voltages (HV/IV/LV) kV

√
Currents (HV/IV/LV) Amp
9 Rated Frequency Hz √
10 Connections and phase displacement symbols (Vector Group) √
11 Weight Schedules (Maximum) / (Minimum with no negative tolerance)
i) Active part kg √

ii) Oil kg √

iii) Tank and Fittings kg √

iv) Total Weight kg √
v) Overall dimensions L x B x H mm √
vi) Size of heaviest package L x B x H mm √
vii) Weight of heaviest package kg √
11.a Transport Limitation √
12 LV Winding
i) Stabilizing tertiary (Yes/No) √
ii) Loaded (Yes/No) √
13 Tappings
i) OLTC/OCTC √

ii) Tappings on √

iii) Variation on √
iv) Range of variation % √
v) No of Steps √
vi) Parallel Operation Requirements √
14 Impedance and Losses
i) Calculated I2R Loss at rated tap and 75 0C kW √
ii) Eddy current and stray loss at rated tap and 75 0C (indicative) kW √
iii) Calculated Load Loss(I2R+Eddy and Stray)at rated tap and 75 0C kW √
iv) Guaranteed Load loss at rated tap and 75 0C (Max) kW √


HV- HV- IV-

IV LV LV

v) Guaranteed Impedance (Base MVA at Principal tap) % √ √ √
Tolerance % √ √ √

vi) Impedance at extreme tappings
a) Max. Voltage tap % √
b) Min. Voltage tap % √
Tolerance % √

vii) Regulation at full load 0.8 pf at 75 0C winding temperature % √
viii) Guaranteed No Load Loss (Max) kW √
ix) Calculated Fan Loss kW √
x) Calculated Pump Loss kW √
xi) Guaranteed Auxiliary Loss (Max) kW √
xii) Guaranteed maximum Magnetizing Current at rated Voltage % √
xiii) Efficiency at rated load, unity PF % √
xiv) Load for Maximum efficiency % √
15 Any limitations in the performance of the required test? √

If Yes, State limitations
16 Deviations from specifications (if any) √
B. MAGNETIC SYSTEM

1 Core Type √
i) 3 Phase 3 Limb (3 wound Limbs)

ii) 3 Phase 5 Limb (3 wound Limbs)
iii) 1 Phase 2 Limb (2 wound Limbs)

iv) 1 Phase 3 Limb (1 wound Limb)
v) 1 Phase 4 Limb (2 wound Limbs)
vi) 1 Phase 5 Limb (3 wound Limbs)
2 Type of Core Joint √
i) Mitred

ii) Step Lap
3 CRGO
a) Thickness mm √
b) Max. Specific loss at 1.7 T, 50Hz. W/kg √
4 Core bolts in Limb/Yoke Yes/No √
5 Minimum Gross Area of Core/Limb/Yoke/Unwound Limb cm2 √

(May be verified during manufacturing stage)
6 Stacking Factor % √

7 Voltage per Turn V √
8 Apparent Core Density for Weight Calculation √
9 Minimum Net Weight of Silicon Steel Lamination CRGO kg √

(may be verified during manufacturing stage by calculation using input
from item -5)
10 Max Flux density at Rated Voltage and Frequency T √

(may be verified during manufacturing stage by calculation)
12 W/kg at working flux density w √
13 Building Factor considered √
14 Calculated No Load Loss at rated voltage and Frequency kW √

(Net Weight x W/kg x Building factor)
15 Maximum Sound Level dB √
17 Core Isolation test kV √
C. CONDUCTING SYSTEM
Item Description Unit Offered

(by Vendor)
HV IV LV Reg
1 Type of Winding
√ √ √ √
Helical/Disc/Layer/interwound
2 Type of Conductor
√ √ √ √
PICC/CTC/CTCE/CTCEN/BPICC
3 Minimum Yield Strength of Conductor N/mm2

√ √ √ √
(0.2% elongation)
4 Maximum Current density at any tap A/mm2 √ √ √ √
5 Bare Weight of copper without paper insulation and lead kg

√ √ √ √
(Minimum)
6 Per Phase Maximum resistance of winding at rated tap @ 75OC Ohm √ √ √ √
7 Number of Turns/Phase √ √ √ √
9 Dielectric Shielding used √ √ √ √

i) Interleaved winding
ii) Wound in Shield
iii) Others
10 Magnetic Shielding Used √ √ √ √
i) Yoke Shunt on core clamp

ii) Magnetic shunt on tank

iii) Electromagnetic (Copper/Aluminum) shield on tank
iv) Others
D. COOLING SYSTEM

(by Buyer) (by vendor)
1 Type of Cooling √
i) ONAN ii) ONAN/ONAF iii) ONAN/ONAF/OFAF
iv) ONAN/ONAF1/ONAF2 v) ONAN/ONAF/ODAF
vi) OFAF vii) ODAF viii) OFWF ix) ODWF
2 Percentage Rating Corresponding to Cooling Stages (HV/IV/LV) √
3 Guaranteed Maximum Temperature rise at 1000m altitude
i) Top Oil by Thermometer 0

C √
ii) Average Winding by resistance 0

C √
iii) Winding Hot Spot 0

C √
4 Type of Cooler
i) Radiator Bank
ii) Oil to Air Heat Exchanger
iii) Oil to Water Cooler (Single Tube)
iv) Oil to Water Cooler (Double Tube) √
v) Tank Mounted
vi) Header Mounted
vii) Separately Mounted
5 Cooling Fans
i) Type
ii) Size mm
iii) Rating (kW) kW √
iv) Supply Voltage V
v) Quantity (Running + Standby) No.
6 Oil Pumps
i) Type
ii) Size
iii) Rating (lpm and kW) lpm

√
kW
iv) Supply voltage V
v) Quantity (Running + Standby) No.
7 Coolers (Oil to Air)
i) Quantity (Running + Standby) No. √
ii) Type √
iii) Rating √
8 Coolers (Oil to Water)
i) Quantity (Running + Standby)

ii) Type and Rating

iii) Oil flow rate lpm
√
iv) Water flow rate lpm
v) Nominal Cooling rate kW
vi) Material of tube
9 Radiators:
Width of elements mm
Thickness mm
√
Length mm
Numbers No.
E. DIELECTRIC SYSTEM

1 Geometric Arrangement of winding with respect to core √

e.g.: Core-LV-IV-HV-Reg Coarse-Reg Fine
2 Regulating Winding
i) Body Tap √
ii) Separate √
3 HV Line Exit point in winding
i) Top √
ii) Center √
4 Varistors used across Windings Yes/No √
If yes, give details √
Offered
(by Vendor)
5 Insulation Levels HV IV LV HVN IVN
i) 1.2/50 μs Impulse kVp

ii) Chopped Impulse kVp

iii) Switching Impulse kVp √ √ √ √ √
iv) AC (Short duration / Long duration) kVrms
v) Max PD level at 1.5 PU PC

F. ACCESSORIES

1 Tap Changers
i) Control √
a-Manual b-Automatic c-Remote d-Local
ii) Voltage Class and Current Rating of Tap Changers √
iii) Make and Model √
iv) Make and Type of AVR √
v) Power Supply for control motor √

(No of Phase/Voltage/Frequency)
vi) Rated Voltage for control circuit √
(No of Phase/Voltage/Frequency)
2 Tank
i) Tank Cover : Conventional/Bell/Bottom Plate √

Tank cover : Bolted /Welded
ii) Plate thickness : side, bottom, cover mm √
iii) Rail Gauge AXB mm √
iv) Minimum Clearance height from rail for lifting Active Part mm √
v) Wheels : Numbers/Plane/Flanged/Uni-Directional/ √
Bi-Directional/Locking Details
vi) Vacuum withstand Capability mm of Hg √
vii) Tank/Radiators/Conservator/Accessories √
viii) Radiator fins / conservator plate thickness mm √
Offered
(by Vendor)
3 Bushings HV IV LV HVN/IVN
i) Termination Type
a - Outdoor b - Cable Box (oil/Air/SF6) c - Plug in Type
ii) Type of Bushing : Porcelain/OIP/RIP
iii) Bushing housing - Porcelain / polymer
iv) Rated Voltage Class kV
v) Rated Current A
vi) Rated 1.2/50 us Impulse Withstand kVp √ √ √ √
vii) Rated One minute AC withstand, Dry kVrms
viii) Minimum Creepage Distance mm
ix) Make and Model
x) Terminal Pad details
xi) BCT Requirements

Item Description Unit Offered

(by Vendor)
4 Indicative
i) Winding temperature thermometer
ii) Oil temperature thermometer
iii) Temperature sensors by Fibre optic
iv) Oil actuated/gas operated relay
v) Pressure Relief Device
vi) Dehydrating Breathers
vii) Conservator Bag(air cell)
viii) Oil level Indicators √
Main Conservator
OLTC Conservator
ix) Oil Sight Window
Main Tank
Main Conservator
OLTC Conservator
x) Tap Changer protective device
xi) Bushing CTs
5 Transformer Oil
i) Grade as per IEEMA spec (see Chapter 6 of this Manual) /

IEC60296
Inhibited / Uninhibited √
ii) Spare oil as percentage of first filling
iii) Manufacturer
6 Press Board
i) Make √
ii) Type
7 Conductor Insulating Paper

(Kraft paper, thermally upgraded Kraft paper, Nomex) √
ANNEXURE 1.1
Legend: NLL - No Load Loss in kW; FLL - Full Load Loss in kW; AL - Auxiliary Loss in kW
STANDARDISED LOSSES FOR POWER TRANSFORMERS
145kV CLASS TRANSFORMER
Sl.No MVA IMPEDANCE HIGH LOSS LOW LOSS

% NLL/FLL/AL NLL/FLL/AL
1 7.5 8.35 8.5/45/- 7/35/-
2 10 10 12/80/- 8.5/70/-
3 12.5 10 14/100/- 10/80/-
4 16 10 15/110/- 11/100/-
5 20 10 17/130/- 12/110/-
6 25 10 18/140/- 14/115/-
7 31.5 12.5 20/150/- 18/125/-
8 40 12.5 25/185/- 20/140/-
9 50 12.5 30/200/- 25/160/-
10 63 12.5 32/240/5 27/190/4
11 80 12.5 40/275/6 32/230/5
245kV CLASS TRANSFORMERS

1 50 12.5 33/215/- 26/160/-
2 80 12.5 44/280/6 35/235/5
3 100 12.5 55/320/8 45/270/7
4 125 15 60/370/9 55/300/8
5 160 15 74/445/11 64/365/10
245kV CLASS TRANSFORMERS(GT)

1 140 12.5 80/400/10 65/340/10
2 250 14 130/600/13 110/500/12
3 315 14 140/750/16 130/650/15
4 600(3*200) 14 100/450/14 80/380/12
245kV CLASS TRANSFORMERS (AUTO)

1 100 12.5 30/240/6 25/210/6
2 160 12.5 38/350/8 35/300/8
3 200 15 45/430/12 40/330/12

400kV CLASS AUTO - TRANSFORMERS

1 100(400/132/33) 12.5 60/300/8 50/250/8
2 200(400/132/33) 12.5 80/400/10 65/325/10
3 315(400/220/33) 12.5 95/565/15 75/520/15
4 500(400/220/33) 12.5 150/700/18 120/650/16
5 3*105 12.5 50/175/7 40/165/8
6 3*166.67 12.5 60/250/12 50/210/12
7 3*200 12.5 65/300/13 60/260/13
8 3*250 12.5 78/360/15 70/310/15
9 100 12.5 45/300/8 40/270/8
10 200 12.5 76/400/10 65/350/10
11 315 12.5 95/550/13 78/440/13
12 500 12.5 140/600/16 115/600/16
13 3*105 12.5 37/195/6 33/185/6
14 3*166.7 12.5 48/270/11 42/250/11
15 3*200 12.5 60/350/12 55/320/12
16 3*250 12.5 70/420/15 60/380/15
420kV CLASS TRANSFORMERS (GT)

1 250 14.5 150/600/14 140/550/12
2 315 14.5 175/650/16 160/600/14
3 3*200 14 120/410/12 110/380/12
4 3*260 14.5 135/500/14 125/460/14
5 3*333 15 157/615/6 140/580/16
800kV CLASS TRANSFORMERS (AUTO)

1 3*333 14 74/510/15 55/400/8
2 3*500 14 83/660/16 62/510/10
800kV CLASS TRANSFORMERS(GT)

1 3*200 15 75/464/35 70/280/10
2 3*260 15 92/565/40 92/340/12
3 3*333 15 125/650/40 115/495/12

ANNEXURE 1.2
LIST OF TRANSFORMER RATINGS

CONSIDERED IN STANDARDISATION MANUAL
Type 132KV 220KV 400KV 765KV
Two Winding 132/33 kV, 220/66 kV, - -
Transformers 40/50 MVA 100 MVA
Auto Transformers 132/66 kV, 220/132 kV, 400/220/33 kV, 765/√3 // 400/√3
40/50 MVA 100 MVA, 3Ø 315 MVA, 3Ø & 333 MVA, 1 Ø
500 MVA, 3Ø 500 MVA, 1 Ø
132/33 kV, 220/132 kV, 400/220/33 kV

25/31.5 MVA 160 MVA, 3Ø 167 MVA, 1 Ø
Generating - 15.75/235 kV, 3Ø 15.75/420 kV, 21/765 kV,
Transformers 315 MVA 315 MVA, 3Ø 260 MVA, 1Ø
21/420 kV, 21/765 kV,

200 MVA, 1Ø 333 MVA, 1Ø
21/420 kV,
260 MVA, 1Ø
21/420 kV,
333 MVA, 1Ø
ANNEXURE 1.3
List of applicable Standards for Transformers
1. APPLICATION GUIDES
Particulars IEC ANSI/IEEE
Transformers 60076-8 ed1.0 -
Converter Transformers 61378-3 -
Tap Changers 60214-2 -
Transformers using High Temp. Insulation 60076-14 ed1.0-2013 IEEE 1276-1997

Materials
Transformers connected to Generators - C57.116-1989
Transformers for non-sinusoidal currents - C57.110-2008

(loads with Harmonics)
Loss Evaluation Guide - C57.120-1991
Phase shifting transformer 62032 ed2.0 C57.135-2012

(Application, Specification, Testing Guide)
Terminal Marking & Connections TR 60616-1978 C57.105-1978 (Connections)

C57.12.70-2000 (Terminal markings)
Apparatus Bushings - C57.19.100-1995
Standard Terminology 60050-421 C57.12.80-2010
Through fault current duration-

(Equipment damage curves)
Dry - C57.12.59-2001
Oil filled C57.12.109-1993
Insulation co-ordination 60071-1,2,3 1313.1-1993 (Definition & principles)

60664-1 (Low voltage) 1313.2-1999 (Application guide)
Preferred Voltage Ratings 60038-2009 1312-1993
Transformers for Nuclear Generating - 638-1992

station
Bar coding of Distribution transformers - C57.12.35-2007
Selection of insulators for polluted TS 60815-2008 -

environments
Permissible temperature rise for terminal 60943-1998 -
Bushings - Seismic Qualification TS 61463-2000 -
Seismic Guide for Transformers & Reactors - C57.114-1990 (withdrawn in 1996)
Recommended Practice for Seismic design - 693-2005

of substations
Direct connection details between 61639-1996 -

transformers & GIS
Determination of sound level 60076-10-1 (2005)ed1.0 C57.136-2000

Guide for sound abatement C57.12.58-1991
Cleaning of Insulators - 957-2005
Occurrence and Mitigation of Switching - C 57.142/ 2010

transients induced by transformers
Standard Terminology 60050-421-1990 C57.12.80-2010
Metric conversion of transformer - C57.144-2004

standards
Transient Voltage Analysis of Dry type - C57.12.58-1991

transformer Coil
Determination of maximum winding - IEEE Std 1538-2000

temperature rise in liquid filled
transformers
Electrical Power System Device Function 61850-7-4 C37.2-2008

Numbers, Acronyms, Contact designations
Recommended electrical clearances in air - IEEE Std 1427-2006

insulated electrical power substations
Guide for protecting Transformers - C37.91-2008

Guide for protection of network
Transformers C37.108-2002
Guide for Protection of Shunt Reactors
Application of CTs used for Protective C37.109-2006
Relays
C37.110-2007
Safety of Transformers - EMC requirements 62041 ed2.0-2010 -
2. Specifications
-Oil filled 60076-1 ed3.0-2011 C57.12.00-2006
-Dry 60076-11 ed1.0 C57.12.01-2005
-Self protected liquid filled transformer 60076-13 ed1.0 -
-SF-6 filled 60076-15 -
-Converter transformer 61378-1 ed 2.0 (2011-07) C57.18.10-1998
-HVDC transformer 61378-2 C57.129- 2007
-Traction transformer 60310-2004
-Phase shifting transformer 62032-2005 C57.135-2005
Transformers < 230 kV, - C57.12.10-1997

1~10 MVA single phase,
0.8~100 MVA 3 Phase
Overhead distribution transformers - C57.12.20-2005

< 500 kVA, 34.5/13.8 kV
Pad mounted 3 Phase DT - C57.12.22-1993

< 2.5MVA 34.5/0.48kV
Pad mounted single Phase DT < 167 kVA - C57.12.25-1990

34.5/0.48kV
With separable HV Connector
Pad mounted 3 Phase DT - with insulated - C57.12.26-1992

HV connectors
< 2.5MVA 34.5/____kV with separable HV
connector
Pad Mounted Compartmental type Single - C57.12.21-1992

Phase Distribution Transformers
(HV 34.5 kV / LV 240-120 V ≤167 kVA)
Pad mounted 3 Phase DT - C57.12.34-2004

< 5 MVA 34.5/0.48kV
Enclosure Integrity-Pad mounted - C57.12.28-2005
Enclosure Integrity-Pad mounted for - C57.12.29-2005

coastal environments
Enclosure Integrity-Pole mounted - C57.12.31-2002
Enclosure Integrity-Submersible equipment - C57.12.32-2002
Electronics Power Transformers - IEEE Std 295-1969
Liquid immersed distribution substation - C57.12.36-2007

transformers
Secondary network transformers – subway - C57.12.40-2006

and vault type
Secondary network protectors - C57.12.44-2005
Ventilated, Dry type power transformers - C57.12.51-1981

1~500 kVA single phase
15~500 kVA 3 phase
Sealed, dry power transformers - C57.12.52-1981

> 0.5 MVA 3 phase 34.5 kV
Dry type transformers used in unit - C57-12.55-1987

substations
Transformers for Wind Turbine applications 60076-16 ed1.0(2011-06) -
Step Voltage Regulators_standard 60076-21 ed1.0 -

requirements ,terminology and test code (2011-12)
Design, testing and application of liquid 60076-4 ed1.0 (2013) PC57.154/D9.1-2012-06

immersed transformers using high
temperature insulation
3. Testing
Particulars IEC ANSI
Testing 60076-1 ed2.1

-General, Dry transformer C57.12.91-2001
-General, oil filled C57.12.90-2010
-HVDC transformer C57.129-2007
Dielectric tests 60076-3 ed3.0-2013 C57.12.90-2006
Temperature rise test 60076-2 ed3.0 -2011

-Oil filled C57.12.90-2006,
-Dry transformer IEEE 1538-2000
-Determination of hot spot temperature of C57.134-2000
dry type transformer
Impulse/ switching surge test 60076-4 ed1.0 C57.98-1993

Recommended practice for impulse test of C57.138-1998
distribution transformer
Short circuit withstand requirements & 60076-5 ed3.0 C57.12.90-2006

testing
Loss measurement - C57.123-2010
Temperature rise test for Overload - C57.119-2001
PD testing 60270-2000 / 60076-3-2000

-Oil filled C57.113-1991
-Acoustic C57.127-2007
-Dry Transformer C57.124-1991
Test for thermal evaluation of dry - C57.12.60-1998

type transformers (Cast resin & Resin
encapsulated)
Test for thermal evaluation of dry type - C57.12.56-1986

transformers (Ventilated dry type)
Test for thermal evaluation of dry type - IEEE 259-2004

transformers (Dry type specialty and
general purpose)
Guide for determination of maximum - IEEE 1538-2000

winding temperature rise in liquid filled
transformers
Test procedure for thermal evaluation of - C57.100-2011

insulation systems for liquid immersed
transformers
Measurement of frequency response 60076-18 ed1.0(2012-07) C57.149 -2012
Determination of uncertainties in loss 60076-19 ed1.0(2013) -

measurement
4. Transformer Oil
Particulars IEC ANSI / IEEE / ASTM
Mineral Oil Specifications 60296-2012 ASTM D3487-08
Mineral Oil- Recycled Oil 62701 ed1.0-2013 -
Silicone Oil Specifications 60836-2005 ASTM D4652-1987
Natural Ester Oils 62770 ed1.0- 2013 -
Organic Ester Oil Specifications 61099-1992 -
Synthetic Aromatic oil specifications 60867-1993 -
Mineral oil Maintenance 60422-2005 C57.106-2013
Natural Ester oil maintenance - C57.147-2008
Silicon oil maintenance 60944-1988 C57.111-1989
Synthetic Organic Ester Maintenance 61203-1992 -
Hydrocarbon fluid maintenance - C57.121-1998
Sampling 60475-1974 ASTM D923-97

60567-2005 ASTM D3613-98
BDV 60156-1995 ASTM D1816-97

ASTM D 877-00
Oxidation stability 61125 ASTM D2440

ASTM D2112-01
Water content 60814 ASTM D1533-05
DGA - Interpretation of results 60599-1999 C57.104-2008
DGA - Bushings TS 61464-1998 -
DGA – OLTC - C57.139-2012
DGA –During factory test 61181-2007 PC57.130/D17-2006
DGA – Sampling 60567-2005 -
DGA – Test method - ASTM D 3612-01
DGA – Silicone oil filled transformers - C57.146-2005
Reclamation of Oil - IEEE 637-1985 (R2007)
DGA –Ester Fluids - PC57.155D4

5. Accessories
Tap changers 60214-1 C57.131-2012
Bushing
-General 60137-2008 C57.19.00-2000
-HVDC Bushings - C57.19.03-1996
-Dimensions - C57.19.01-2000
-Terminals 60518-1975 -
Bushing Application Guide - C57.19.100-1995
Bushings - Seismic Qualification - TS 61463-2000
Reactors
-Specifications C57.21-2008 (Shunt)
-Testing 60076-6 C57.16-1996
-Dry type series
-Smoothing reactors for HVDC - IEEE 1277-2000
Induction voltage regulator C57.15-1999
Control Cabinet C 57.148-2011
6. Raw Materials
Winding Wires:
Paper tape covered Rectangular Wire 60317 ed4.0- 2013 -
Magnetic Materials -
Part 8-7-Specifications
for individual materials (Cold-rolled grain-
oriented electrical steel strip -
61061-3-1
and sheet delivered in the fully processed
state).
Non-impregnated densified ,laminated

wood for electrical purposes :
Part 1 Definitions
Part 2-Methods of Test 60404-8-7 ed3.0—2008 -
Part 3-1 Specifications for Sheets
Part 3-2 Specifications for rings
Electrical Papers -
Part 1 Definitions 60554-1
Part 2 Methods Of Test 60554-2
Part 3-1General Purpose Paper 60554-3-1
Part 3-2Capacitor Paper 60554-3-2
Part 3-3 Crepe Paper 60554-3-3
Part 3-4 Electrolytic capacitor paper 60554-3-4 -
Part 3-5 Special Papers 60554-3-5
Non cellulosic Electrical Paper

Part3-3 Unfilled aramide(aromatic 60819-3-3 ed3.0-2011
polyamide)
Pressboard and press paper for electrical

purposes
Part 1 Specifications 60641-1
Part 2 Methods of Test 60641-2
Part 3 -1 Press Board 60641-3-1ed2.0-2008
Part 3-2 Press Paper 60641-3-2
-
Laminated Press Board
Part 1Definitions 60763-1 ed2.0-2010
Part 2 Methods of Test 61628-2 ed1.1-2007
Part 3-1 Laminated pre compressed Press 60763-3-1 ed2.0-2010
Board
7. Installation, Operation & Maintenance
Particulars IEC ANSI/ IEEE
Guide for Transportation of Transformers

57.150-2012
&Reactors
Installation & maintenance

-Oil filled Transformer - C57.93-2007
-Dry type Transformer - C57.94-1982
Loading guide
- Oil filled Transformer 60076-7 ed1.0(2005-12) C57.91-2011
- Dry type transformer 60076-12 ed1.0(2008-11) C57.96-1999
Failure investigation - C57.125-1991
Reporting failure data - C57.117-1986
Evaluation and Reconditioning of oil filled

- C57.140-2006
transformers
Diagnostic field testing - C57.152-2013
Monitoring of transformers & accessories - C57.143-2012
Substation-Fire protection
979-1994(R2004)
Containment &control of oil spills in -
980-1994(R2001)
substations
Guide for the design, construction and

operation of Electric Power substations for
- 1127-1998
community acceptance and environmental
compatibility
8. Operation & Maintenance:
Item CIGRE Brochures IEEE Standard IEC Standard
Operational 170-2000 Static Electrification C57.91-2011 Loading Guide for Oil 60076-7:2005
Problems 228-2002 Ageing Process Immersed Loading Guide
323-2007 Ageing of Cellulose Transformers for Oil Immersed
349-2008 Moisture Equilibrium and C57.96-1999 Loading Guide for Dry Transformers
migration in insulation system Type Transformers 60905-1987
378-2009 Copper sulfide in insulation Loading Guide
393-2009 Thermal performance of for Dry type
Transformers Transformers
445-2012 Maintenance
Life 227-2003 Life Management Techniques C57.93-2007 Installation & 60422-2005

Assessment 248-2004 Economics of Management Maintenance of Maintenance
298-2006 Life time Data Management Transformers of Oil
413-2010 Oil regeneration and C57.106-2002 Maintenance of Oil
Dehalogenation C57.140-2006 Evaluation &
Reconditioning
637-1985(R2007) Reclamation of Oil
Diagnostics 254-2002 Dielectric Response 62-1995 (R2005) Diagnostic Field 60076-18-2012

296-2006 Recent developments in the Testing of Transformers SFRA
interpretation of DGA & Reactors 60567-2011
342-2008 SFRA C57.104-2008 DGA of Oil Sampling of
343-2008 Recommendations for Condition C57.117-1986 Guide for reporting gases for DGA
Monitoring and condition failure data of 60599-1999
assessment facilities for transformers DGA
transformer C57.125-1991 Guide for Site failure interpretation
414-2010 Dielectric response methods for investigation of
transformer windings Transformers
420-2010 Life Time Condition Assessment C57.146-2005 DGA of Silicon Oil
436-2010 Experiences in service with new filled Transformers
Insulating Liquids C57.200-2000 PD detection by
443-2010 DGA on non-mineral oil and Accoustics
OLTC oil. PC 57.139 D12-2009 DGA of OLTC Oil
444-2010 Guide lines on unconventional PC 57.143 D21-2010 Transformer
PD measurements Monitoring
494-2012 Furanic Compounds for
Diagnosis
9. CIGRE Brochures for Asset Management of T&D equipment:
Standing A2 A3 B1 B2 B3 C1 D1 Other SC’s

Committee/ Transformer HV Cables Lines Substations Asset Material
Product Equipments Management
Condition 393 083 - - 300 - 226 SC A1:

Assessment 436 259 380 437, 386
& Monitoring WG 381
A3.06 400
End of Life 227 165 358 353 252 422 296 -

Issues 368 409
414
Risk 248 - - - 300 309 420 SC C3 :

Management 472 327 340,383
and AM 422
Decision
Making
Grid - 335 - 385 - 176 - -

Development 336
Maintenance 445 259 279 230 380 - - -

Processes 319
& Decision
Making
Collection 298 - - - - - - SC B5: 329

of Asset SC D2: 341
Data and
Information
Chapter - 2
Design and Engineering features
(1) Architectural Features, General Arrangement Drawings & Accessories

Mr. M. Vijayakumaran – ALSTOM Ltd
Mr. P. Ramachandran – ABB Ltd
Mr. Y. V. Joshi – GETCO
Mr. M.M. Goswami – POWERGRID
Mr. T. Vijayan – T&R Ltd

CHAPTER - 2
DESIGN AND ENGINEERING FEATURES
Part 1 - Architectural Features, General Arrangement Drawings & Accessories

INTRODUCTION
In a process of standardisation of transformer from procurement to commissioning, architectural features do have

major role. At present, same rating/class transformers are being designed differently even for same user. Even for
same specifications, manufacturer reviews design for successive tender considering prevailing market condition and
thereby make changes in transformer architectural features and general arrangements. This reviewing activity not
even leads to increase in design & manufacturing cycle time, cost, human efforts and inventories but also keep user
away from preparing for footprint in his switch-yard.
To resolve all these issues and to define standard architectural features and accessories, this Working Group had 5
rounds of meetings and discussions in the subject matter. However, standardisation refers to limit the variation in
terms of layout, general arrangements, interchangeability, accessories selection guide including data sheet, drawings,
schematic, mounting arrangement/interface with tank, critical check points for installation and commissioning, etc.
Interchangeability has been referred here mainly to transformers of similar rating, voltage and other technical
characteristics, even when they are being purchased from different suppliers under different contracts so as to arrive
at common dimensions and layout, to allow physical interchangeability with minimum of adaptation and optimize
spare holding inventory. It is possible for transformers purchased earlier to be replaced later by more modern designs,
even with larger ratings but designed to accommodate in the same space. Utilities purchase transformers to meet
requirements of this kind in order to increase availability and reduce costs by minimising the outage time in the event
of a transformer having to be removed from service and replaced by spare/new transformer available. The concept
may apply for separately cooler bank mounted transformer in which case the requirement of interchangeability can be
even made applicable to the main transformer excluding cooler bank.
This policy will reduce the complexity of the purchaser’s stock of transformers, bushings, fittings, tap changer
components, etc and will minimize maintenance practice and costs.
Aesthetic (Appearance) of Transformer: Mounting of fittings to be same as far as possible, mounting & location of
Cooler bank, Conservator etc. shall be at standard position. A typical plan & section drawing showing accessories
like Bushings, Tap changer, conservator, OLTC Drive Mechanism, Neutral Earthing arrangement, Marshalling box,
etc. are enclosed in this Manual. Tank mounted radiators are recommended, for ratings up to 100 MVA and they
can be separate for higher than 100 MVA.
Tank Type: Bell type, Bolted /Welded construction, Conventional & Form Fit type
Cooler: The Fin thickness of radiator will be minimum 1.0 mm. Only 4 heights are proposed (2.0 M, 2.5 M, 3.0 M
& 4.5 M) with number of elements to be 20, 24 & 26. Radiator (external) shall be hot dip galvanized or painted as
per Data Sheet of Radiator given in this Manual. For internal surface galvanizing is not recommended. Corrosion
resistant paints may be applied on galvanized surface for better appearance.
Rail, Roller & Roller Assembly: It is proposed to remove provision of rail as nowadays transformers are not
transported by railway but rails are required for transformers to achieve center line of transformer, provision may
be provided for rail. However, Transformers are recommended to put directly on plinth without rollers & roller
assembly will be standardised. Only one set of roller is recommended for each substation. Since Roller is casted,
hence only Roller assembly is needed to be galvanized.
Valve Schedule: Valve specification, type & application shall be standardised. This will be reviewed with experts
and finalized.
Conservator: Main conservator should be with Aircell. OLTC conservator shall be separate to avoid intermixing of
oil. Maintenance free type dehydrating silica gel breather may be provided in remote operation substation.
Internal Earthing of Metal Parts: Earthing point shall be robust and made accessible for the inspection to the
extent possible.
Painting: Tank, Radiator & Fittings may be of different shades. Epoxy coating to be avoided for outermost layer.
It should be PU only. Casting parts not necessarily painted for matching shade. Any fabricated accessory should
be either galvanized or outer side PU. Powder coating may be accepted provided it should be sun light / outdoor
/ UV ray resistant. Being not Eco-friendly, Zinc Chromate is not to be used. Bottom plate of tank may be accepted
with water based paint. Internal paint shall be oil resistive with thickness of 25 to 40 micron only.
Hardware / Bolts: Material will be MS with grade 8. To avoid bending High Tensile Steel (HTS) is also recommended.
Stainless Steel should not be used in the main tank joint.
Gasket: Since one side of gasket is exposed to the transformer oil of different quality (old, new, inhibited,
un-inhibited, Paraffin base oil, Naphthenic base oil & vegetable oil etc.) & other side is water, moisture, humidity,
air, oxygen, pollution, saline etc., hence gasket to be reliable & suitable for these applications. Chord (Nitrile
Chord) for all flange joints are recommended. Top cover of tap changer to be suitable for O-Ring or chord with
interchangeable with older one.
Marshalling Box / Common Marshalling Box: The enclosure (shell) shall be made of cold rolled sheet and
galvanized / painted. Stainless steel and Aluminum may also be considered for Marshalling Box.
OTI & WTI: Switches shall be Mercury-free.
Breather: Cobalt is a banned material, hence not recommended to use. Size of silica gel is to be standardised,
either it can be one of 100% or two of 100% in parallel. Valve over breather is not recommended.
Pressure Release Device (PRD): PRD shall be mounted on top cover. One PRD is recommended per every 40 KL
oil quantity. The oil discharge chamber and terminal box of the PRD shall be water tight with Protection class
IP 56 or better as per IEC 60529.
Ladder: Ladder (Fixed type) with safety locking device to be provided. Provision for fixing safety barriers shall be
provided on top tank cover. Ladder for conservator may be provided considering safety for working at height.
Fire Protection System (FPS): Provision of FPS is recommended in line with CEA regulation, i.e. for 10 MVA &
above. It is recommended to keep provision in each transformer.
Health, Safety and Environment (HSE): All the HSE aspects shall be covered while preparing standard GA
drawing. Adequate working space on top of transformer with suitable railing for safety shall be provided.
Ratings of Transformer: Standard ratings considered are as per Annexure 1.2.
Rail gauge shall be standard (1676 mm). Plinth mounted tank design may be adapted, as a specific requirement.
Rating wise rail gauge are standardised as below:
1. 765 kV & 400 kV, 1-Phase Generator Transformer (having two rails or three rails)
2. 765 kV & 400 kV, 1-Phase Auto Transformer (having four rails)
Note: 3-Phase ratings for above also to be considered depending on size and transportability.
3. 400 kV, 3-Phase Auto Transformer (having four rails)
4. 400 kV & 220 kV, 3-Phase Generator Transformer (having two rails)
5. 220 kV & 132 kV, Power Transformer (having two rails)
Location of OLTC: The number and location will be as per OLTC type & its specification.
Interchangeability & Common Architecture: The OGA is prepared in the form of block diagram & all important
fittings positions are shown (Annexure 2.1). Marshaling Box, Cooler control cabinet and any other cabinet required
for any monitoring devices will be tank mounted. Grounding inter phase is considered to minimize.
Jacking: 4 nos. of jacks shall be provided.
Cooler bank foundation: Modular block foundation is to house any make radiator in the standard foundation.
Maximum Height of Conservator to be standardised to make the firewall uniform.
The tertiary and neutral bushing shall be provided on top of the tank cover. The provision on side wall of the
tank is not recommended in view to avoid lowering of oil level in case of bushing replacement which is time
consuming.
Due to winding capacitances, the tertiary winding faces transferred surge voltages during impulse application on
HV/IV winding. Therefore, the bushings of 52 kV rating are provided for 33 kV tertiary winding.
Cooler Bank Design:
Provision for connecting cooling bank on both sides shall be provided. Pipe work on main tank to be designed in
such a way that position of the cooler bank, conservator etc. can be changed at site by simple reconnection.
Specification for separately mounted radiator bank distance (for oil pipe connection) from main tank to be kept
standard or minimum. Position of cooling fan to be bottom of radiator bank but cooler fan support from ground
is not recommended.
Modular block foundation will be explored to house any make of radiator in the standard foundation.
Tank mounted Unit cooler option for Generating / Large transformers can be considered.
If more than one unit is provided, the breather for main tank shall be in parallel.
No. of OLTC and its location will be as per OLTC type & its specification.
Jacking: 4 - jacks shall be provided and their locations to be decided by the manufacturer such that it will not foul
rail, rollers or other accessories.
Height of Conservator & HV bushing shall be same.
Hot dip galvanized with a minimum thickness of 70 µm and painting as per the following specification.
Surface Primer coat Intermediate Finish coat Total dry Colour shade
ITEM preparation undercoat film
thickness
(DFT)
Main tank, pipes, Shot Blast Epoxy base Epoxy high build Aliphatic Minimum RAL 7035
conservator tank, cleaning Zinc primer Micaceous iron polyurethane 155 μm
oil storage tank Sa 2½* (30-40 μm) oxide (HB MIO) (PU)
etc. (external (75 μm) (Minimum
surfaces) 50 μm)
Main tank, pipes Shot Blast Hot oil - - Minimum Glossy white for
(above 80 NB), cleaning resistant, 30 μm paint
conservator tank, Sa 2½* non-corrosive Max
oil storage tank varnish or 40 µm
etc. (internal paint or epoxy
surfaces)
Radiator (external Chemical/ Epoxy base Epoxy base Zinc PU paint Minimum Matching shade
surfaces) Shot Blast Zinc primer primer (30-40 μm) (minimum 100 μm of tank/differ-
cleaning (30-40 μm) 50 μm) rent shade
Sa 2½* aesthetically
matching to tank
Radiator and Chemical Hot oil proof, - - - -

pipes up to 80NB cleaning, if low viscosity
(internal surfaces) required varnish
Control cabinet/ Seven tank Zinc chromate - EPOXY paint Minimum RAL 7035 shade
marshalling box process as primer (two with PU top 80 μm for exterior and
per IS:3618 coats) coat interior
& IS:6005
Note : * indicates Sa 2½ as per Swedish Standard SIS 055900 of ISO 8501 Part-1.
The quality of paint should be such that its colour should not fade during vapor phase drying process and shall be
able to withstand temperature up to 120 0C.
Transformer shall be put on plinth but provision of roller shall be provided. The nos. of jacking points / pads and
lifting bollards / hooks / devices shall be 4 only. Location shall be such that it should not interfere with loading
and unloading from trailer.
Internal arrangement drawing of the active part and lead exit to be provided in the Instruction Manual by
manufacturer for better assessment of probable fault location when reflected in abnormal DGA results.
Line diagram for core, core clamp and tank earthing diagram shall be provided in the Instruction Manual.
Location of OLTC Driving mechanism box, Marshalling box, and optical fiber termination shall be on the same
side.
The main and OLTC conservator shall be integrated type with separate compartments so that they are at same
height with no pressure difference. In the case of separate cooler bank or if there is difficulty, OLTC conservator
can be separate.
Chapter - 2
(2) Power Transformer Fittings and Accessories - OLTC

Mr. V. K. Lakhiani - T&R Ltd.
Mr. R. V. Talegaonkar - CTR Mfg. Ind. Ltd.
Mr. S. Rajan - CTR Mfg. Ind. Ltd.
Mr. R. Prakash - Easun, MR
Mr. Vijayakumaran - ALSTOM Ltd.
Mr. R. K. Shukla - On Load Gears
Mr. M. M. Goswami - POWERGRID

Part 2 - Standard On-Load-Tap Changers for Power Transformers
INTRODUCTION
On Load Tap changers (OLTC) are the most important equipment used in the power transformers for changing the
tap of a winding (to vary effective transformation ratio of the transformer) whilst, the transformer is energized or is
on load.
Performance requirements of these OLTCs for use in transformers and their routine and type tests are described in
IEC 60214-1. Selection criteria of the OLTC, their various types, fittings and accessories etc. are covered in the
IEC 60214-2 “Application Guide”.
CBIP Manual on transformers (Publication 317) in ‘Section GG’ gives guidelines for voltage control of Power
Transformers employing OLTC.
As a general practice, end user of the transformer gives the requirement of voltage regulation (on HV or LV side), range
of percent voltage variation (from maximum voltage to minimum voltage, expressed as % of rated voltage), number
of steps, % impedance of transformer at maximum voltage and minimum voltage tap positions in case of parallel
operation with existing transformer and other control schematic requirements.
Transformer manufacturer, meeting the above requirement, decides the location of tapping winding (physical as well
as electrical), based on his design philosophy and experience and estimates the current and voltages seen by the
tapping winding (across range, between steps, to earth and between phases). Based on this data, OLTC supplier
provides a suitable tap changer from his available range.
This IEEMA standard on OLTC purports to define the specification requirements and selection criteria of OLTC and
recommends the standard parameters of OLTC to be used in transformers of prevalent standard ratings in the country
standardised by CBIP.
SCOPE
This standard covers specification requirements and selection of On Load tap changers for Power Transformers in the
country.
1.0. General requirements for selection of OLTC parameters:
1.1. Standards Applicable
The tap changer shall conform to latest edition of IEC 60214 Part1: Performance Requirements & Test
Methods; and IEC 60214 Part 2: Application Guide.
1.2. Tap Changer Specification
For comprehensive specification of OLTCs, certain data need be specified by the transformer manufacturers
depending upon the transformer design & construction, apart from the specifications provided by the end
users. These specification requirements are therefore divided in to two parts.
1.2.1. Specification requirements from end users (Utilities)
1.2.1.1 Transformer Details

§§ Number of Phases: Single phase or three phase
§§ Rated Power: MVA
§§ Rated Voltage: HV kV / LV kV
§§ Winding Connection: HV / LV (e.g. Star, Delta, Star Auto)
§§ % Tapping range of rated winding voltage: (+)……% to (-) ……% for HV (or LV) variation.
§§ Number of tapping positions (No. of steps and % step voltage)
§§ Direction of Power flow: Unidirectional/Bidirectional
§§ Over Loading requirements (if different from IEC 60076-7).
1.2.1.2 Drive Mechanism and control scheme

§§ Local electrical independent control
§§ Local automatic independent control
§§ Remote electrical independent control
§§ Remote automatic independent control
§§ Parallel electrical control of two or more transformers
§§ Parallel automatic control of two or more transformers
§§ Supervisory control
1.2.1.3 Auxiliary Supply voltage

§§ For Motor
§§ For control circuitry
1.2.1.4 Site Operating Conditions
§§ Maximum & Minimum ambient temperatures
1.2.2. Specification requirements from Transformer Manufacturer
1.2.2.1 Type of construction of On Load Tap Changer

§§ External - out of tank
§§ Internal - in tank
1.2.2.2 Tap winding arrangement

§§ Linear, Reversing or Coarse / Fine
1.2.2.3 Position of taps in the winding
§§ Line end, Middle, Neutral point
1.2.2.4 Highest tap current of the winding

§§ …………..Amps
1.2.2.5 Highest step voltage
§§ ………….Volts
1.2.2.6 Insulation levels of On Load Tap Changers

§§ Tap-Changer to earth (Highest voltage between any tap and earth)
§§ Between phases (Where applicable)
§§ Across Tap Range and between change-over selector contacts (Highest voltage between the
extreme taps)
§§ Between adjacent contacts of tap selector and selector switch (Highest step voltage)
§§ Between diverter switch contacts (Highest step voltage)
1.2.2.7 Short Circuit Current
§§ Maximum value …..kA; and duration 2 Sec
1.2.2.8 Change-over selector Recovery voltage
§§ The power frequency voltage appearing between opening and closing contacts of change-
over selector shall be specified. (Note: OLTC supplier shall also verify / calculate recovery
voltage based on winding capacitance furnished by transformer manufacturer).
1.2.2.9 Mounting Arrangements for In-tank OLTCS

§§ Standard flange or Bell type for OLTC
§§ Motor drive and shaft arrangements
1.2.2.10 Protective Devices
§§ Oil Surge Relay

§§ Rupture disc / Diaphragm with or without trip contact
§§ Pressure relief device (optional)
§§ Over pressure Relay (optional)
1.2.2.11 Paint Type and shade
1.3. On Load Tap Changer Ratings and Selection Criteria
1.3.1 Type of construction of On Load Tap Changers
1.3.1.1 Externally mounted - out of tank, oil environment On Load Tap changers
§§ These OLTCs are available up to 66 kV, 300 Amps, star / delta connected winding, and for
132 kV neutral end applications. Depending on overall economy of the transformer design,
this type of OLTC is used.
1.3.1.2 Internally mounted - in tank Oil environment Tap Changers
§§ These OLTCs are available for all the transformer ratings up to 220 kV line end application, up
to 700 Amps neutral end and upto 2100 Amps line end applications. These tap-changers are
suitable for high voltage application up to 765 kV Class of transformers.
1.3.2 Operating Principle
The OLTCs covered in this standard are of high speed transition resistor type. On-load tap-changer
shall be according to selector switch principle or shall consist of a tap selector and a diverter switch
with spring operated mechanism. The diverter /selector switch which arcs during tap change operation
shall be so designed to ensure that its operation once commenced shall be completed independently
of the control relays or switches, failure of auxiliary supplies etc. The current diverting contacts shall be
housed in a separate oil chamber not communicating with the oil in main tank of the transformer.
1.3.3 Rated Through-Current of OLTCs
Rated through current of the OLTC should be more than or equal to the highest value of tap current
at the assigned rated power of the transformer. This ensures meeting the overload requirements of
transformers as per IEC 60076-7.
1.3.4 Rated Step Voltage of OLTCs
The rated step voltage of the tap-changer is more than or equal to the highest step voltage of the
tapped winding.
1.3.5 Breaking Capacity of OLTCs
The breaking capacity requirements are met if the highest tap current and the highest step voltage
of the transformer are within the declared values of rated through-current and relevant rated step
voltage.
1.3.6 Insulation level of OLTCs
The rated insulation level of the OLTC is checked for Power frequency and Lightning Impulse voltages
and switching impulse voltages (if specified) appearing during tests on the transformer. These insulation
levels are checked at following points:
§§ Tap-Changer to earth
§§ Between phases
§§ Across Range (Between first and last contact of tap selector or selector switch)
§§ Between change-over selector contacts.
§§ Between two adjacent contacts
§§ Between Open contacts of diverter contact
1.3.7 Number of tap positions
The Tap-changers are available up to 21 positions (20 steps) in linear and up to 35 positions (34 steps)
in coarse-fine/ reversing arrangement of the tapping winding.
1.3.8 Winding connection and position of taps in the winding
§§ OLTC in star connected winding:

For transformers having star connected tapping winding, the tappings are provided at the neutral
end of the high voltage winding.
§§ OLTC in delta connected windings:

In delta connected windings, 3 pole middle of the winding arrangements is used up to 110 kV
Class of transformers. 33 kV windings are mostly used in delta configuration by all utilities. 66 kV
windings are also used in delta by some utilities like Gujarat and Karnataka. In some states like
Tamil Nadu and Karnataka 110 kV delta systems are also in vogue. Tap-changers are available up
to 66 kV class delta arrangement as external out-of-tank construction and up to 110 kV class in
in-tank construction.
§§ Position of OLTC in auto transformer
§§ Scheme, as shown in (a) in above figure, is used for autotransformer with a ratio 2:1 and for
moderate regulating range of say 15%. The advantage of this scheme is that the tap winding is at
the neutral end and be designed for graded insulation and a three phase neutral end tap changer
can be used. This arrangement is ideally suitable for 765 / 400 kV auto transformers. In this case,
VFVV (variable flux and variable voltage) type regulation is foreseen with change in tertiary voltage
which is accepted since tertiary is a stabilizing winding in most cases.
§§ For auto transformers on systems where the medium voltage is regulated, schemes as shown in
(b) & (d) are used. For tapping range of approximately 20% and with linear tapings scheme (b) is
generally used. Higher regulating range may be achieved with scheme (d).
§§ For auto transformers where regulation is required in HV voltage, scheme (c) is used. It has the
advantage that the through current of the OLTC is lower and allows the use of an OLTC with a
lower current rating. It may be noted that in case of arrangement (d) tapings carry IV line current
and in case of (b) tapings carry series or common current and in case of (c) tapings carry series
current.
1.3.9 Change-over Selector recovery voltage
During change-over operation of reversing switch or coarse tap selector, the tap winding is disconnected
temporarily from the main winding. The tap winding receives a potential determined by the winding
capacitances. The difference in voltage will therefore, appear during contact operation of the change-
over selector as a recovery voltage. The tap-changer manufacturer declares the safe limit for the allowed
recovery voltage across change-over contacts. It is ensured that the recovery voltage appearing during
change-over operation is within the declared allowed recovery voltage by the tap-changer supplier.
In case the recovery voltage exceeds the allowed voltage, the same is specified by the transformer
designer. The tap-changer manufacturer then provides additional devices like tie-in resistors or two
way change-over selectors to limit the recovery voltage to a safe level.
1.4 Motor Drive Mechanism
The motor drive unit has following features as specified in IEC 60214.
1.4.1 Operation
OLTC gear shall be motor operated for local as well as remote electrical operation. An external handle
shall be provided for local manual operation. Interlock shall be provided to prevent electric drive when
the manual operating gear is in use.
1.4.2 Housing
Drive mechanism cubicle is mounted as integral part on tap-changer tank in case of external out-of-tank
construction or suitable for mounting on transformer tank in case of an In-Tank construction. The motor
drive cubicle is in accessible position. It is adequately ventilated and provided with anti-condensation
heaters. All contactors, relay coils and other parts are protected against corrosion, deterioration due
to condensation, fungi etc. The motor drive cubicle shall meet protection requirement of IP 55 as per
IEC 60529.
1.4.3 Step-by-Step Control

This control feature ensures operation of OLTC by one voltage step only even in the case of continuous
or repeat signals.
1.4.4 Tap Position Indication

The position of OLTC is indicated locally on motor drive unit preferably by a mechanical device, however,
if any electrical or electronic device is used, it is ensured that the tap position is indicated correctly even
in the event of a power failure. The tap position is visible clearly even when the motor drive door is
closed.
1.4.5 Limiting Devices

There are both electrical and mechanical limiting devices to prevent operations beyond end positions.
1.4.6 Operation Counter

A minimum five-digit non-resettable counter is provided to record the number of operations completed
by the tap-changer. In case of electrical / electronic counter it shall be ensured that the counter, is
capable of recording local manual operations also.
1.5 Test Requirements
1.5.1 Type tests
The OLTCs and motor drive units are fully type tested in accordance with cl. 5.2 and 6.2 of IEC 60214-1.
These tests are as below:
1.5.1.1 Temperature rise of contacts
This test is conducted at 1.2 times the maximum rated through current of OLTC.
1.5.1.2 Switching tests
This includes 50000 test operations at maximum rated through current as service duty and 40
operations at double the maximum rated through current as breaking capacity tests.
1.5.1.3 Short circuit current test
This test is conducted at 20 times the maximum rated through current up to 100 amps and 10
times the maximum rated through current of 400 amps and more. The test current should be
interpolated between these two ratings using the slope as per IEC 60214-1. The test duration
should be 2 seconds.
1.5.1.4 Transition Resistor test
This test is conducted at 1.5 times the maximum rated through current of OLTC for continuous
operation of half cycle (equal to number of tap positions). This ensures suitability of transition
resistor design for continuous operations of OLTC under over loading condition of transformers.
1.5.1.5 Mechanical Endurance Test
The tap-changer shall be tested for 5,00,000 operations using complete tap range as per cl.5.2.5.1
of IEC 60214-1.
1.5.1.6 Pressure Test
The diverter switch/ selector switch compartment shall be tested for hot oil pressure test by filling
oil inside the cylinder and heating up to 80° C. The cylinder shall be pressurized for a minimum
pressure of 10 psi (0.7 kg/cm²) for 1 hour. All joints of the compartment are thoroughly checked
for leakages.
1.5.1.7 Dielectric Tests
The tap-changer should be tested across all points as per cl. 1.3.6 of this chapter and insulation
levels shall be declared. The tests shall be conducted in line with cl. 5.2.6 of IEC 60214-1.
1.5.2 Routine Tests
OLTC manufacturers shall conduct all the routine tests as specified in cl. 5.3 and 6.3 of IEC 60214-1 on
every unit, before dispatch to assure the quality of the product
2.0 Standard ratings of OLTCs
§§ Standard parameters of OLTC based on standard transformer ratings as per CBIP are recommended as
given in the attached Annexure 2.2.
§§ In case the transformer ratings are not conforming to CBIP standard, customers shall specify OLTC
requirements as per cl.1.2 of this standard.
3.0 Installation of in-tank tap changers
§§ Precautions to be taken while installing In-tank tap changer at site are given in Annexure2.4
ANNEXURE 2.1
220kV, 100 MVA AUTO TRANSFORMER

( COOLING MOUNTED SEPARATELY )
POWER TRANSFORMER - STANDARDISATION MANUAL
37
38
220kV, 100 MVA AUTO TRANSFORMER

( COOLING MOUNTED ON TANK )
2n
1N 2u 2v 2w
1U 1V 1W
400kV, 315 MVA TRANSFORMER
( COOLING MOUNTED SEPARATELY )
RAIL GAUGE=1676 RAIL GAUGE=1676

ROLLER CENTER = 1743
ROLLER CENTER=1743 1079 1079 ROLLER CENTER=1743
39
50
Annexure 2.2: Standard Parameters of OLTC for Standard Transformer Ratings
Trans- Voltage Ratio (kV) Tapping Number Highest tap Max. Step Rated Winding Tapping Rated Insulation Levels of OLTC Max. Value Location
former range of tapping current of rated Voltage Step Connection arrangement Impulse kVrms / kVp of duration of
MVA positions winding through (Trans- Voltage of short Tapping
current of former of OLTC circuit Winding
OLTC require- Star / Delta Linear / Tap Across Between current
ment) Reversing / changer tapping adjacent
Coarse-Fine voltage to range Taps
earth
16 132/33 (+) 5 to 17 82.33 100 953 1200 Star Linear/ 140/325 45/200 15/90 2 KA for 2 Neutral
(-) 15 of Coarse-Fine/ sec. End

HV Reversing of HV
Winding
25 132/11 (+) 5 to 17 128.6 200 953 1200 Star Linear/ 140/325 45/200 15/90 3.5KA for 2 Neutral
HV Reversing of HV
Winding
31.5 132/11 (+) 5 to 17 162.1 200 953 1200 Star Linear/ 140/325 45/200 15/90 3.5KA for 2 Neutral
HV Reversing of HV
Winding
50 132/66 (-) 5 to 17 230.2 300 953 1200 Star Linear/ 140/325 45/200 15/90 4KA for 2 Neutral
(+) 15 of Coarse-Fine/ sec. End
HV Reversing of HV
Winding
63 132/66 (-) 5 to 17 290 300 953 1200 Star Linear/ 140/325 45/200 15/90 4KA for 2 Neutral
(+) 15 of Coarse-Fine/ sec. End
HV Reversing of HV
Winding
140 11/138 (-) 10 to 17 650.8 800 996 1200 Star Reversing/ 140/325 45/265 15/90 8kA for 2 Neutral
(+) 5 of Coarse-Fine sec. End
HV of HV
Winding
140 13.8/138 (-) 10 to 17 650.8 800 996 1200 Star Reversing/ 140/325 45/265 15/90 8kA for 2 Neutral
HV of HV
Winding
250 15.75/138 (-) 10 to 17 1162.14 1200 996 1200 Star Reversing/ 140/325 45/265 15/90 16KA for 2 Neutral
(+) 5 of Coarse-Fine sec End
HV Of HV
Winding
50 220/66 (-) 10 to 17 145.8 200 1588 1600 Star Reversing/ 230/550 80/350 15/90 3.5kA for 2 Neutral
HV Of HV
Winding
HV Of HV
Winding
50 220/33 (-) 10 to 17 145.8 200 1588 1600 Star Reversing/ 230/550 80/350 15/90 3.5kA for 2 Neutral
HV Of HV
Winding
HV Of HV
Winding
100 220/132 (-5) to (+) 17 460.5 500 953 1200 Star Linear/ 325/750 80/350 15/90 8kA for 2 Line End
15 of LV Reversing sec. of IV
Winding
160 220/132 (-5) to (+) 17 736.65 800 953 1200 Star Linear/ 325/750 80/350 15/90 15KA for 2 Line End
15 of LV Reversing sec of IV
Winding
200 220/132 (-5) to (+) 17 921 1000 953 1200 Star Linear/ 325/750 80/350 15/90 16KA for 2 Line End
15 of LV Reversing sec of IV
Winding
HV Of HV
Winding
HV Of HV
Winding
51
52
Trans- Voltage Ratio (kV) Tapping Number Highest tap Max. Step Rated Winding Tapping Rated Insulation Levels of OLTC Max. Value Location
former range of tapping current of rated Voltage Step Connection arrangement Impulse kVrms / kVp of duration of
MVA positions winding through (Trans- Voltage of short Tapping
Star / Delta Linear / Tap Across Between
current of former of OLTC circuit Winding
Reversing / changer tapping adjacent
OLTC require- current
Coarse-Fine voltage to range Taps
ment)
earth
HV of HV
Winding
315 15.75/235 (-) 10 to 13 860 1000 1696 1800 Star Reversing/ 230/550 80/350 15/90 16KA for 2 Neutral
HV of HV
Winding
260 24/420/√3 (1ph) (-) 10 to 13 1191.35 1500 3031 3100 star Reversing/ 325/750 80/350 15/90 24KA for 2 Neutral
HV of HV
Winding
HV of HV
Winding
315 15.75/420 (-) 5 to 13 456 600 3031 3100 Star Reversing/ 325/750 80/350 15/90 8kA for 2 Neutral
HV of HV
Winding
200 “21/420 (1 ph)” (-) 5 to 13 868.2 1000 3031 3100 Star Reversing/ 325/750 80/350 15/90 16KA for 2 Neutral
HV of HV
Winding
100 400/132/33 (-) 10 to 17 160.4 200 2886 3000 Star Reversing 325/750 80/350 15/90 3.5KA for 2 220 kV
(+) 10 of sec. End of
HV Series
Winding
200 400/132/33 (-) 10 to 17 320.75 400 2886 3000 Star Reversing 325/750 80/350 15/90 6KA for 2 220 kV
HV Series
Winding
250 400/220/33 (-) 10 to 17 401 500 2886 3000 Star Reversing 460/1050 100/460 15/90 8kA for 2 220 kV
HV Series
Winding
315 400/220/33 (-) 10 to 17 505.2 600 2886 3000 Star Reversing 460/1050 100/460 15/90 8kA for 2 220 kV
HV Series
Winding
500 400/220/33 (-) 10 to 17 802 1000 2886 3000 Star Reversing 460/1050 100/460 15/90 16KA for 2 220 kV
HV Series
Winding
630 400/220/33 (-) 10 to 17 1010 1200 2886 3000 Star Reversing 460/1050 100/460 15/90 16KA for 2 220 kV
HV Series
Winding
167 400/220/33 (1 (-) 10 to 17 795 1000 2886 3000 Star Reversing 460/1050 100/460 15/90 16KA/2 220 kV
ph) (+) 10 of sec End of
HV Series
Winding
210 400/220/33 (1 (-) 10 to 17 1010.4 1200 2886 3000 Star Reversing 460/1050 100/460 15/90 16KA/2 220 kV
ph) (+) 10 of sec End of
HV Series
Winding
210 765/√3/ (-) 5.5 to 23 500.5 600 2760 3000 Star Reversing 230/550 100/460 15/90 8KA/2 sec Neutral
400/√3/33 (+) 5.5 of End
HV of HV
Winding
333.3 765/√3/ (-) 5.5 to 23 794.34 1000 2760 3000 Star Reversing 230/550 100/460 15/90 16KA/2 Neutral
400/√3/33 (+) 5.5 of sec End
HV of HV
Winding
500 765/√3/ (-) 5.5 to 23 1191.64 1200 2760 3000 Star Reversing 230/550 100/460 15/90 16KA/2 Neutral
400/√3/33 (+) 5.5 of sec End
HV of HV
Winding
53
ANNEXURE 2.3
Precautions required to be taken during installing tank tap-changer at site
1. Check that the unit serial number of drive mechanism, gear boxes are identical to that of tap changer
2. Check that the tap changer and drive mechanism are at same tap position
3. Ensure proper coupling of drive mechanism and tap changer without disturbing gearbox setting to avoid any
misalignment. Refer OLTC Manual
4. Connect earth screw of tap changer head and its cover to transformer cover using earth conductor
5. Connect earth screw of motor drive housing to transformer tank using earth conductor
6. Apply vacuum to transformer and diverter chamber
7. Fill diverter compartment with new filtered mineral oil and vent air from compartment and suction pipe
8. Check, if all stop valves between the oil conservator and driving unit (head) of the OLTC are open
9. Check the oil tightness of the seals on the driving unit (head), protective relay and piping
10. Avoid dropping of any parts or objects into the diverter switch oil compartment
11. Operate manually tap changer for one full cycle. Check end limit stops
12. Operate one cycle electrically and ensure motor drive direction of rotation and continuity
13. Check the protective relay mounting and ensure its contacts are connected in tripping circuit of the main circuit
breaker
Chapter - 2
(3) Standard Bushings for Power Transformers

Ms. Elizabeth Johnson - ALSTOM Ltd
Mr. M. Vijayakumaran - ALSTOM Ltd
Mr. Manish Jain - ABB Ltd
Mr. Shailesh Mahajan - CGL
Mr. Aseem Dhamija - BHEL
Mr. Sai Prasad - T&R

Part 3 - Standard Bushings for Power Transformers

INTRODUCTION
Standard Specifications of bushings used in Transformers up to 1200 kV class are given in Section II of CBIP Manual on
Transformers (Publication No. 317). The Section also purports to standardise dimensions of condensers bushings from
52 kV to 1200 kV with a view to enable interchangeability with different makes of bushings. These recommendations
have also been adopted in IS: 12676.
The dimensional parameters of the bushings up to and including 36 kV voltage class (solid porcelain bushings) have
already been standardised in IS: 3347.
Beside standard dimensions, CBIP Manual also recommends standard values of BILs & test levels, creepage distances,
current ratings, BCT, top and bottom terminations etc. This IEEMA Standard on bushings addresses selection criteria
for bushings for transformers and suggests standard bushings to be used for popular rating transformers standardised
by CBIP working group.
These guidelines are prepared to enable user / manufacturer of the transformer to specify / use standard bushings for
the transformers. If a non-standard bushing is specified / used, the same shall be subject to mutual agreement.
SCOPE
This standard covers Outdoor type Standard Bushings comprising outdoor Oil Impregnated Paper (OIP) bushings with
values of highest system voltage for equipment (Um) from 52 kV up to 1200 kV voltage class and solid porcelain and
oil communicating type bushings for voltage class up to 36 kV for use in oil filled Power Transformers popularly used
in the country.
1. General Requirements and Selection Criteria of Standard Bushings
§§ The condenser bushings shall conform to IEC 60137 / IS: 2099 / IS: 12676 and porcelain bushings shall
conform to IS: 3347.
§§ Unless otherwise specified, the glaze of porcelain shall be brown in colour.
§§ All exposed ferrous metal parts shall be hot dip galvanized, wherever possible.
§§ No arcing horns shall be provided on bushings unless otherwise specified.
§§ Any stress shield shall be considered as an integral part of the bushing assembly for external clearances and
field plotting.
§§ Preferred lead arrangements for condenser bushings upto 800 Amps shall be draw lead type, upto 1250
Amps, shall be draw rod and 2000 Amps and above, in all cases shall be stem type. However, 52 kV and
72.5 kV condenser bushings shall be solid stem type for all current ratings as standardised by CBIP .
§§ For 100 kV and 110 kV class transformers also, 145 kV class bushing is recommended for the purpose of
variety reduction.
§§ Make of the condenser bushings shall be approved by customer. However, dimensionally they shall conform
to CBIP Manual section II. Porcelain bushings are generally assembled by Transformer Manufacturers
(porcelain and copper parts are purchased separately and assembled, porcelain conforming to IS:3347).
§§ The standard current ratings have been adopted. Minimum current rating of bushing is greater than or equal
to the maximum winding current × 1.2 or as mutually agreed.
§§ The neutral bushing not intended to carry load between phase and neutral is dimensioned for earth fault
current (except single phase transformer) unless otherwise specified by the customer.
§§ The lead joint in case of draw-lead or draw-rod type condenser bushings shall be as per fig 2 (a) & (b) of
CBIP Manual (section II). The bottom portion of the joint shall be in flush with the bottom of the flange of
the bushing. The top portion of the lead shall be transported with the bushings. The winding end of the lead
joint shall be suitably anchored while transporting the transformer.
§§ The minimum value of creepage distance specified is 25 mm/kV of the rated voltage of bushing up to 1200
kV class.
§§ For areas with very heavy or extremely heavy pollution, the minimum creepage distance shall be 31mm/kV
or as specified by the user.
§§ Bushing Current Transformer (BCT): To accommodate the bushing current transformers, space provided on
various voltage class bushings shall be as under:
Voltage class (kV) BCT length (mm)

100
52
300
100
72.5
300
300
145
600
300
245
600
420 400
800 600
1200 300
§§ Altitude:
Bushings corresponding to this standard are suitable for operation at any altitude not exceeding 1000 M.
In order to ensure that the external withstand voltages of the bushings are sufficient at altitudes exceeding
1000 M, the arcing distance normally required shall be increased by a suitable amount. The arcing distance
correction shall be done as per clause No. 5.2 of IEC 60317.
§§ Short time current rating of the bushings shall be 25 times of the rated current of the bushings for 2
seconds.
2. Standard Bushings and their Application
a. Condenser Bushings for line terminals:

The basic insulation level, rated voltage, rated current and creepage distances for various voltage class
condenser bushings are as under:
Voltage Insulation Level Current Type of Creepage Remarks

rating LI / SI / AC (kV) rating (A) lead distance
(kV) (mm)
72.5 350 / NA / 155 800 Solid 1815 66 kV winding of 20 MVA, 66kV class
Stem transformer (also used for neutral of
220 kV class for the purpose of IOV
test).
1250 Solid 66 kV winding of 100 MVA, 220/66 kV

Stem transformer
3150 Solid 66 kV winding of high rating

Stem transformers above 100 MVA e.g. 160
MVA, 220/66kV
Voltage Insulation Level Current Type of Creepage Remarks

rating LI / SI / AC (kV) rating (A) lead distance
(kV) (mm)
145 650 / NA / 305 800 Draw 3625 132 kV winding of transformers up to

lead 100 MVA, 3 phase.
(e.g. 100 MVA, 220/132/11 kV auto
transformer and
50 MVA, 132/33 kV two winding
transformer)
1250 Draw 132 kV class transformers up to 200
Rod MVA, 3 phase.
(e.g. 200 MVA, 220 / 132 kV auto
transformer and
160 MVA 220 / 132 kV auto
transformer)
2000 Solid 132 kV winding of Higher rating
Stem (e.g. 250 MVA, 220 / 132 kV auto
transformer)
245 1050 / 850 / 505 1250 Draw 6125 220 kV class transformers up to 315
rod MVA, 3 phase.
(e.g. 315 MVA, 220 kV GSU or 315
MVA, 400 / 220 kV auto transformers)
2000 Solid 400 / 220 kV class transformers of
stem 500 and 630 MVA, 3 phase.
420 1425 / 1050 / 695 1250 Draw 10500 315 MVA and 500 MVA, 400 kV class,
Rod 3 phase, auto transformers
2000 Solid 400 kV single phase generator

Stem transformers of 260 and 315 MVA
2500 Solid 400 kV winding of 500 MVA, single

stem phase, 765/√3 / 400/√3 / 33 kV, auto
transformer
800 2100 / 1550 / 970 2500 Solid 20000 500 MVA, single phase, 765/√3 /
Stem 400/√3 / 33 kV auto transformer and
260 & 333 MVA, 1 phase, 765 kV
class, GSU
1200 2400 / 1950 / 1320 2500 Solid 30000 1000 MVA, single Phase, 1150/√3 /
Stem 400/√3 / 33 kV auto transformer
b) Condenser bushings for tertiary winding:

§§ 33 kV tertiary in 400 kV & above kV class transformer is designed for 250 kVp transferred surges.
Hence, 52 kV class bushings shall be used in such cases. The standard 52 kV bushings are as follows:
Voltage Insulation Current Type of lead Creepage Remarks

rating Level rating distance
(kV) LI / AC (A) (mm)
(kV)
52 250 / 105 3150 Solid stem 1300 a) 33 kV tertiary winding of 315 MVA
and 500 MVA, 3 phase, 400 / 220 /
33 kV auto transformer.
b) 167 MVA, 1 phase, 400/√3 /
220/√3 / 33 kV, auto transformer.
5000 Solid stem a) 33 kV tertiary winding of 500 MVA,

1 phase, 765/√3 / 400/√3 / 33 kV
auto transformer
b) 33 kV tertiary winding of 1000
MVA, 1 phase, 1150/√3 / 400/√3
/ 33 kV auto transformer (2 Nos.
per phase)
c) Porcelain bushings for tertiary winding

§§ 11 kV as well as 33 kV class tertiary windings of 220 kV & below class, auto transformers are designed
for 170 kVp transferred surges. Hence, 36 kV class porcelain bushing shall be used in such cases.
§§ In case of stabilizing winding of auto transformer, 1/3rd of equivalent 2 winding rating shall be considered
for calculation of bushing current.
§§ These porcelain bushings are also to be used for 33 kV winding of double wound transformer with and
without tertiary winding.
§§ For 11 kV and 22 kV class, 36 kV bushings only are standardised of current ratings 1000 amps, 2000
amps and 3150 amps.
§§ In case of stabilizing winding of auto transformer, 4 bushings shall be used for testing. After testing
only 2 bushings, forming the corners of the delta, shall be provided. They will be externally shorted and
earthed to the tank.
§§ In case of loaded tertiary only 3 bushings shall be provided for testing as well as for site use.
Voltage Current Type of lead Creepage Remarks

rating (kV) rating (A) distance
(mm)
36 1000 Solid Stem 900 25 / 31.5 MVA, 132/22 kV, 132/33 kV, double
wound transformers.
2000 Solid stem 11 & 33 kV stabilizing windings of

auto transformers up to 200 MVA.
e.g. i) 200 MVA, 220/132/11 or
33 kV, 3 phase, auto transformers
ii) 160 MVA 220/132/11 or 33 kV,
3 phase, auto transformers
iii) 100 MVA, 220/132/11 kV 3 phase,
auto transformers
iv) 25 MVA 132/11 kV double wound
transformer
3150 Solid stem 3 phase auto transformers of 160 MVA and

above, using 11 kV tertiary.
(e.g. 160 & 200 MVA, 220/132/11 kV auto
transformer and 50 MVA, 132/11 kV 3 phase,
double wound transformer).
d) Bushings for neutral end terminal
Voltage Current Type of lead Creepage Remarks

rating (kV) rating (A) distance (mm)
36 1000 Solid stem 900 Up to 315 MVA, 3 phase, transformers

(auto as well as double winding)
2000 Solid stem 3 phase, auto transformers of 500 MVA and

above (auto and double winding).
§§ During testing, 72.5 kV, 800 Amp condenser bushing can be used where neutral receives 1/3rd voltage
during IOV test. e.g. 132 and 220 kV class transformers. However, after testing 72.5 kV test bushing is
to be replaced by 36 kV neutral bushing. For 400 kV transformer, where ACSD test is specified, neutral
test bushing shall be 145 kV, 800 Amp.
e) Bushings for LV of generator transformers

§§ LV voltages of GTs are typically 11 kV, 13.8 kV, 15.75 kV and 21 kV.
§§ For all these voltages, 24 kV porcelain bushings, oil communicating type have been standardised. The
standard current bushings selected are 8, 12.5, 16 & 20 kA. In case of non availability of 16/20 kA
bushings, 8/12.5 kA bushings, 2 in parallel can be used.
§§ In certain cases, high current 36 kV condenser bushings can also be used, subject to mutual
agreement.
§§ When LV bushings are housed in busduct, suitable derating factor to be considered for current rating.
Voltage Current Type of Creepage Remarks

rating rating lead distance
(kV) (kA) (mm)
8 Solid 600 i) 100 MVA, 3 phase, GT with LV winding of 11 kV.

stem ii) 150 MVA, 3 phase, GT with LV winding of 13.8 kV.
iii) 82 MVA, 1 phase, GT with LV winding of 15 kV.
24
12.5 Solid i) 150, 200 and 250/260 MVA 3 phase, GT with LV winding of
stem 11, 13.8 and 15.75 kV respectively.
ii) 200 MVA 1 phase, GT with LV winding of 21 kV.
iii) 105 MVA 1 phase, GT with LV winding of 11 kV.
16 Solid 600 i) 250 MVA 3 phase, GT with LV winding of 11 kV

stem ii) 260 MVA 1 phase, GT with LV winding of 21 kV
iii) 315 MVA 3 phase, GT with LV winding of 13.8 kV and
15.75 kV.
iv) 400 MVA 3 phase, GT with LV winding of 21 kV
24
20 Solid i) 315 MVA 1 phase, GT with LV winding of 21 kV
stem ii) 600 MVA 3 phase, GT with LV winding of 21 kV
iii) 315/333 MVA 1 phase, GT with LV winding of 21 kV
3. Standard ratings of Bushings for transformers
Standard ratings of bushings for the transformers are as given in Table No.2.1.
62
Table No. 2.1 Standard Bushings for Transformers
MVA kV ratio Tapping HV current 1.2 × Ihv HV Bushing IV current IIV 1.2 × IIV IV Bushing LV current ILV 1.2 × ILV LV Bushing
range Ihv
16 132/33 (-) 15, (+) 5 82.33 98.796 145/800A NA NA NA 279.92 335.904 36/1000
25 132/11 (-) 15, (+) 5 128.6 154.32 145/800A NA NA NA 1312.15 1574.58 36/2000
31.5 132/11 (-) 15, (+) 5 162.1 194.52 145/800A NA NA NA 1653.31 1983.972 26/2000A
50 132/66 (-) 5 , (+) 15 230.2 276.24 145/800A NA NA NA 437.38 524.856 72.5/800A
63 132/66 (-) 5 , (+) 15 290 348 145/800A NA NA NA 551.01 661.212 72.5/800A
140 11/138 (-) 10 , (+) 5 650.8 780.96 145/800A NA NA NA 4242.42 5090.904 29/8000A
140 13.8/138 (-) 10 , (+) 5 650.8 780.96 145/800A NA NA NA 3381.65 4057.98 24/8000A
250 15.75/138 (-) 10, (+) 5 1162.14 1394.57 145/1600A NA NA NA 5291.21 6349.452 24/8000A
50 220/66 (-) 10, (+) 10 145.8 174.96 245/1250A NA NA NA 437.38 524.856 72.5/800A
100 220/66 (-) 10, (+) 10 291.6 349.92 245/1250A NA NA NA 874.77 1049.724 72.5/1250A
50 220/33 (-) 10, (+) 10 145.8 174.96 245/1250A NA NA NA 874.77 1049.724 36/1000A
100 220/33 (-) 10, (+) 10 291.6 349.92 245/1250A NA NA NA 1749.54 2099.448 36/3150
100 220/132 (-) 5, (+) 15 262.43 314.916 245/1250A 460.4 552.48 145/800A NA NA NA
160 220/132 (-) 5, (+) 15 419.9 503.88 245/1250A 736.65 883.98 145/1250A NA NA NA
200 220/132 (-) 5, (+) 15 524.86 629.832 245/1250A 920.8 1104.96 145/1250A NA NA NA
140 11/235 (-) 10, (+) 15 351.43 702.86 245/1250A NA NA NA 7348.1 8817.72 36/12500A
MVA kV ratio Tapping HV current 1.2 × Ihv HV Bushing IV current IIV 1.2 × IIV IV Bushing LV current ILV 1.2 × ILV LV Bushing
range Ihv
250 15.75/235 (-) 10, (+) 15 682.4 818.88 245/1250A NA NA NA 9164.3 10997.16 36/12500A
315 15.75/235 (-) 10, (+) 15 859.8 1031.76 245/1250A NA NA NA 11547 13856.4 36/16000A
260 24/420/√3 (-) 10, (+) 15 1191.35 1429.62 420/2000A NA NA NA 10833.33 13000 36/16000A
250 15.75/420 (-) 5, (+) 10 361.75 434.1 420/1250A NA NA NA 9164.29 10997.15 36/12500
315 15.75/420 (-) 5, (+) 10 455.8 546.96 420/1250A NA NA NA 11547 13856.4 24/16000A
200 21/420/√3 (-) 5, (+) 10 868.2 1041.84 420/1250A NA NA NA 9523.8 11428.56 24/12500A
100 400/132/33 (-) 10, (+) 10 160.4 192.48 420/1250A 437.38 524.856 145/800A 1009.09 1210.91 52/3150A
200 400/132/33 (-)10, (+) 10 320.75 385 420/1250A 874.77 1049.724 145/1250A 2020 2424 52/3150A
250 400/220/33 (-)10, (+) 10 401 481.2 420/1250A 656.08 787.3 245/1250A 2525.15 3030.18 52/5000A
315 400/220/33 (-)10, (+) 10 505.18 606.216 420/1250A 826.66 991.992 245/1250A 3181.8 3818.16 52/5000A
167 400/√3/220/√3/33 (-)10, (+) 10 803.5 964.2 420/1250A 1314.78 1577.74 245/2000A 1686.86 2024.232 52/3150A
210 400/√3/220/√3/33 (-)10, (+) 10 1010.36 1212.432 420/1250A 1653.32 1983.98 245/2000A 2121.2 254544 52/5000A
200 21/765/√3 (-) 5, (+) 5 476.65 571.98 800/2500A NA NA NA 9523.8 11428.6 36/12500
260 24/765/√3 (-) 5, (+) 5 619.6 743.52 800/2500A NA NA NA 10833.3 12999.96 36/16000
210 765/√3/400/√3/33 (-) 5, (+) 5 500.5 600.6 800/2500A 909.32 1091.184 420/1250A 2121.21 2545.45 52/3150A
333.3 765/√3/400/√3/33 (-) 5, (+) 5 794.35 953.22 800/2500A 1443.36 1732.032 420/2000A 3366.66 4039.992 52/5000A
500 765/√3/400/√3/33 (-) 5, (+) 5 1191.64 1429.97 800/2500A 2165.06 2598.072 420/2500A 5081 6097.2 52/5000A
63
Chapter - 2
(4) Power Transformer Fittings and Accessories

Mr. M. L. Jain - EMCO Ltd.
Mr. Rabindranath Mahapatro - EMCO Ltd.
Mr. Bharat Panchal - EMCO Ltd.
Mr. V. Janardhanan - Precimeasure
Mr. S. R. Doraiswamy - Perfect Controls
Mr. Vishal Shah - Scientific Controls
Mr. Himanshu Choudhary - Jadhao Engineers
Mr. K. Y. Daftary - Hi-Tech Radiators
Mr. Jitendra Palnitkar - Tarang Engg
Mr. Sujit Gupta - Pradeep Sales & Service
Mrs. J. J. Patel - EMCO Electronics
Mr. Vinay Gupta - Atvus Industries
Mr. Atul Bapat - Sukrut Udyog
Mr. D. M. Jadhav - CTR
Mr. Rajesh Khanna - SERGI
Mr. Mahendra Sule - Lumasense
Mr. Jagdish Sandhanshiv - Consultant
Mr. S. Paulraj - Klemmen Engineering

Part 4 - Power Transformer Fittings and Accessories

INTRODUCTION
All external components & fittings provided on the transformer tank form an integral part of the transformer and are
essential for its satisfactory performance in service. Some essential fittings, which are mandatorily provided on a
wide range of transformers, are listed in IS 2026 Part I. However, depending on the rating, some additional fittings
and accessories are also provided on large rating transformers as per the specified requirement.
This section covers various fittings & accessories that are generally provided on the 132 kV & above class of Power
Transformers. As components with varying features are available commercially, in the absence of any authoritative
guidelines, the users are often unable to clearly specify the items that would address their long term requirements.
This section briefly covers some vital fittings and accessories as listed below, describing broadly the purpose of
each fitting, its working principle, the data sheet, the selection criteria, the care to be taken during installation &
commissioning, etc. While presently no single Standard comprehensively covers all the fittings and accessories, the
British Standard BSEN 50216, which is divided in several parts, covers some of the vital components. Therefore,
efforts have been made to broadly align details of the items covered herein with these standards and some other
available references. However, for the users a list of some references is appended under ‘Bibliography’ for further
details.
Doc. Type of Accessory Purpose Reference

No. Standard
1 Temperature Indicators These instruments are installed in the marshaling box (in BS EN 50216-11
transformer yard) measurement of top oil temperature &
1.1 Oil Temperature Indicator winding hot spot indication
(OTI)
1.2 Winding Temperature

Indicator (WTI)
1.3 Remote Temperature This is a repeater dial installed in the Control Room for BS EN 5021.6-11
Indicator (ROTI/RWTI) remote indication of top oil temperature & winding hot spot
temperature
1.4 RTD (PT 100) Scheme for ROTI RTD scheme, comprises RTD sensor, transducer and indicator BS EN 5021.6-11
/ RWTI is used for measurement of oil and winding temperatures of the
transformers
2 Fiber Optic Temperature For real time measurement of winding hotspot temperatures IEC 60076-2
Sensor (FOS)
3 Gas & Oil Actuated Relay Fitted in the pipe between tank and the conservator to BS EN 50216-2
(Buchholz Relay) actuate alarm & trip relays in the event of accumulation of gas
generated due to fault inside the transformer
4 Pressure Relief Valve (PRV) Fitted on the tank cover to limit the tank over pressure on BS EN 50216-5
an internal fault, thereby reducing risk of tank rupture or
uncontrolled spillage of oil
5 Magnetic Oil Level Gauge Fitted on the main tank conservator and OLTC conservator for BS EN 50216-5
(MOG) indication of oil level
6 Oil / Water Flow Indicators (FI) Fitted in the oil/water cooling pipe line for the control of the oil/ BS EN 50216-5
water flow out of the pumps on transformer with forced oil/
water cooling equipment
7 Air Cell / Flexi-Separator Installed inside the conservator as a barrier to prevent contact -
between atmospheric air and the transformer oil
8 Conservator Protection Relay Also called ‘air cell puncture detection relay’, is externally -
(CPR) installed on the top of conservator to give alarm in the event of
lowering of oil in the conservator due to puncture of air cell in
service
9 Removable Radiators for oil- These are directly/separately mounted on the tank to permit BS EN 50216-6
immersed transformers flow of hot oil through it for cooling and returning to tank
10 Automatic Voltage Regulating Provided in the RTCC (Remote tap changers control cubicle) & -
Relay (AVR) connected to OLTC to maintain a constant secondary voltage at
all times
11 Fire Fighting Systems Installed in the vicinity of main transformer to protect it against CEA -The Gazette
catching of fire/spread of fire in the event of internal failure of of India, 2010
11.1 Nitrogen Injection Fire transformer or external fire in the close vicinity
Prevention System (NIFPS)
11.2 Automatic Water Mulsifier

System
12 Terminal Connector Used for connection of transformer to the overhead power line. IS: 5561
Attempts have been made to standardise some vital fittings & accessories used for power transformers to facilitate
interchangeability & to rationalize their use such as would be commonly acceptable to manufacturers & users.
It may be noted that the above list is not exhaustive. Some items, like cooing fans, oil/water pumps, pressure gauges,
RTD, valves, breathers, rollers, earthing terminals, heat exchangers, unit coolers, etc. are presently not covered here
and could be considered in the subsequent revisions in future.
1 Temperature Indicators
1.1 Oil Temperature Indicator (OTI)

1.1.1 Description
This is used to measure the temperature of top oil in transformer.
1.1.2 Principle of Operation
The top oil temperature of oil immersed power transformer is sensed by mMeasuring system based on
volumetric expansion of liquid proportional to rise in temperature. A sensing bulb, measuring bellow
and a small bore capillary connecting the two form the measuring system which is filled with liquid.
When the sensing bulb is exposed to rise in temperature, the liquid inside expands proportionately
causing the bellows to expand and drive the linkages for indication and separately, linkages & disc for
switch operation. This system is self contained and does not depend on any outside power source for
its operation.
Complete ambient temperature compensation on sensing bulb & line / capillary is provided with a
second bellow / compensating bellow and a capillary that terminates at head of the sensing bulb. The
liquid filled inside this responds to ambient temperature changes. The measuring and compensating
bellows are linked in such a way that they cancel out. Thus, the net measuring bellow output is
dependent only on the sensing bulb temperature and not on ambient temperature.
1.1.3 Data Sheet
Technical Parameters
Parameter Variant - 1 Variant – 2
Dial Range 0 to 150 ° 0 to 150 °
Dial angular sweep 270 ° 270 °
Case shape Rectangular Rectangular
Paint detail of case Powder coated, RAL7032 Powder coated, RAL7032
Graduation 2 °C 2 °C
Parameter Variant - 1 Variant – 2

Accuracy class ±1.5 % FSD ±1.5 % FSD
No. of micro switches 2 Nos. Change over 2 Nos. Change over
Contact rating 15A, 250V AC & 15A, 250V AC &
0.25A at 250V DC 0.25A at 250V DC
Switch differential 6°C to 8°C (Fixed) 6°C to 8°C (Fixed)
Switching accuracy ±4°C of Set Value ±4°C of Set Value
Switch adjustable range Independently adjustable to close Independently adjustable to close
between 30-150°C between 30-150°C
With built-in RTD (PT100) Not Available Available
and CCU
External PSU with 2Nos. Not Available Available
of 4-20mA DC outputs
Bulb 1” BSP with male type union (Fig.2.1) 1” BSP with male type union (Fig.2.2)
Material Case - Cast Aluminum; Case -Cast Aluminum;

Bulb - Brass with silver joint, natural Bulb - Brass with silver joint, natural
finish; finish;
Bellows - Phosphor Bronze, natural Bellows - Phosphor Bronze, natural
finish; finish;
Capillary - Stainless Steel Armour Capillary - Stainless Steel Armour
sheathed copper capillary; sheathed copper capillary;
Window - clear and transparent Window - clear and transparent
Polycarbonate Polycarbonate
Capillary & electrical entry From the bottom of OTI From the bottom of OTI
Dial marking Black with white back ground Black with white back ground
Resettable maximum Red in colour Red in colour
reading pointer
Degree of protection IP:55 IP:55
Immune to vibration of Yes Yes
switches
Notes: 1) 4 to 20mA correspond to 0 to 150 °C respectively.
2) In case of failure of analog type indicator (Variant-2), PSU will give continuous 4 to 20mA output.
Fig. 2.1: Bulb fitting arrangement for Variant 1 Fig. 2.2: Bulb fitting arrangement for Variant 2
1.1.4 Standard Wiring Diagram
Any one of the following terminal configurations can be selected as per requirement.
The contact position shown below is under normal operating condition of OTI.
Variant - 1 Variant - 2
1.1.5 Selection criteria
4 to 20 mA output required or not for remote/SCADA indication
1.1.6 Routine Tests
a) Mount the temperature Indicator on Test Stand Vertically,

b) Connect as per scheme diagram.
c) Micro switch terminals with multimeter / Buzzer (Continuity test).
d) “Thermal image” bellow heater terminal (CT Terminal) with current source
e) Close the Top cover
f) Set oil bath temperature at 40°C, with reference to the standard Thermometer.
g) Loosen union screw and remove the union (Ensure minimum immersion length of 140 mm).
Immerse sensing bulb in hot oil bath.
h) Record the instrument temperature after 5 minutes, the bath reaches the steady temperature.
i) Increase the oil bath temperature in steps of 20°C and record the temperature of the instrument
after 5 minutes when the bath reaches the steady state temperature.
j) Simultaneously observe and record the switch operation (ON) as instrument temperature rises.
k) Remove the sensing bulb from oil bath and keep in ambient temperature till the instrument reading
reaches the ambient temperature.
l) Simultaneously observe and record the switch operation (OFF) as instrument temperature
decreases (To check switch differential)
m) Insulation Test (2 kV between contact and earth)
1.1.7 Installation and Pre-commissioning checks
i. Before installation, check for possible damages from transport handling.

ii. Do not carry the instrument by holding the capillary line.
iii. Ensure not to twist the capillary line while unpacking, storage or installation.
iv. Avoid sharp bends of capillary line and allow minimum of 50 mm bending radius.
v. Keep the instrument on mounting surface and fix it.
vi. Make sure that instrument is mounted in a vertical position.
vii. Clamp the capillary line along its entire length at approximately 500 mm intervals. The excess
length can be wound in spiral with minimum diameter of 100 mm.
viii. Oil is to be filled in the pocket. Insert the sensing bulb through union/ pocket/ flange (insert fully),
tighten nut to optimum level. Ensure min. immersion length 140 mm.
ix. Care must be taken that, Sensing bulb is not damaged while tightening.
x. In case of further transport or storage, wind the armor and pack the instrument in the same way
as received from the supplier.
xi. Check the connection as per wiring diagram before commissioning.
xii. Cable entry should be through cable gland to avoid dust entering
xiii. Top cover should be put in place and tighten properly to avoid dust. Ensure that the maximum
pointer is positioned after the indicating pointer.
xiv. Make sure there are no loose connections.
xv. Test knob, if provided externally, shall be locked properly after testing.
1.2 Winding Temperature Indicator (WTI)
1.2.1 Description
This is used to measure the hotspot temperature of the winding.
The top oil temperature of Oil Immersed Power transformer is sensed by measuring system based on
volumetric expansion of liquid proportional to rise in temperature. A Sensing bulb, measuring bellow
and a small bore capillary connecting the two form the measuring system which is filled with liquid.
When the sensing bulb is exposed to rise in temperature, the liquid inside expands proportionately
causing the bellows to expand and drive the linkages for indication and separately, linkages & disc for
switch operation. This system is self contained and does not depend on any outside power source for
its operation.
Complete ambient temperature compensation on sensing bulb & line/capillary is provided with a second
bellow/compensating bellow and a capillary that terminates at head of the sensing bulb. The liquid
filled inside this responds to ambient temperature changes. The measuring and compensating bellows
are linked in such a way that they cancel out. Thus, the net measuring bellow output is dependent only
on the sensing bulb temperature and not on ambient temperature.
The winding temperature is simulated by passing CT secondary current (from the transformer line)
to an electrical heater coil fitted around the measuring bellows. This simulates the winding to top oil
temperature differential which is added to the top oil temperature, being measured by the instrument
bulb. The temperature in the hottest part of the winding or hotspot temperature is displayed directly by
the instrument. Thus, the instrument functions as a winding temperature indicator. The time constant
of the temperature rise will be 63.7% of final temperature rise within 7-8 minutes.
Since the thermal time constant of the heater coil is nearly the same as the transformer winding, the
instrument simulates closely the actual temperature of the winding in relation to time.
The primary current of CT feeding the thermal image of WTI shall be of rated transformer current
corresponding to lowest tap and secondary nominal output of 2A. The heating system of WTI shall
be designed for a winding gradient of 35°C at CT current input of 2A. It shall be designed to operate
continuously at 150% of the rated current and shall not suffer injurious overheating with 200% of
rated current for a period of 15 minutes. Based on the heat run test data, the parallel shunt resistor to
heater coil shall be adjusted by transformer manufacturer such that the current through heater coil will
correspond to the winding hotspot gradient as per the heat run test result.
1.2.3 Data Sheet
Parameter Variant - 1 Variant - 2
Dial Range 0 to 150 ° 0 to 150 °
Dial angular sweep 270 ° 270 °
Case shape Rectangular Rectangular
Paint detail of case Powder coated, RAL7032 Powder coated, RAL7032
Graduation 2 °C 2 °C
Accuracy class ±1.5% FSD ±1.5% FSD
No. of micro switches 4 Nos. change over 4 Nos. change over
Contact rating 15A, 250V AC & 15A, 250V AC &

0.25A @ 250V DC 0.25A @ 250V DC
Switch differential 6°C to 8°C (Fixed) 6°C to 8°C (Fixed)
Switching accuracy ±4°C of Set Value ±4°C of Set Value
Switch adjustable range Independently adjustable to close Independently adjustable to close

between 30-150°C between 30-150°C
With built-in RTD Not Available Available

(PT100) and CCU
External PSU with 2 Nos. Not Available Available

of 4-20 mA DC outputs
Bulb 1” BSP with Male type union (Fig.2.3) 1” BSP with Male type union (Fig.2.4)
Material Case - Cast Aluminium; Case - Cast Aluminium;

Bulb - Brass with silver joint, natural Bulb - Brass with silver joint, natural
finish; finish;
Bellows - Phosphor Bronze, natural Bellows - Phosphor Bronze, natural
finish; finish;
Capillary - Stainless Steel Armour Capillary - Stainless Steel Armour
sheathed copper capillary; sheathed copper capillary;
Window - clear and transparent Window - clear and transparent
polycarbonate polycarbonate
Capillary & electrical From the bottom of OTI From the bottom of OTI
entry
Dial marking Black with white back ground Black with white back ground
Resettable maximum Red in colour Red in colour

reading pointer
Degree of protection IP:55 IP:55
Immune to vibration of Yes Yes

switches
Notes: 1) 4 to 20 mA correspond to 0 to 150 °C respectively.

2) In case of failure of analog type indicator (Variant-2), PSU will give continuous 4 to 20 mA output.
Fig. 2.3: Bulb fitting arrangement for Variant 1 Fig. 2.4: Bulb fitting arrangement for Variant 2
The contact position shown below is under normal operating condition of WTI.
Variant - 1:
Variant - 2:
4 to 20 mA output for remote/SCADA indication - Yes / No.

1.2.6 Routine Tests
a) Mount the temperature indicator on test stand vertically,

b) Connect as per scheme diagram.
§§ Micro switch terminals with multimeter / Buzzer (Continuity test).
§§ “Thermal image” bellow heater terminal (CT Terminal) with current source
c) Close the Top cover.
d) Set oil bath temperature at 40°C, with reference to the standard Thermometer.
e) Loosen union screw and remove the union (Ensure minimum immersion length of 140 mm).
Immerse sensing bulb in hot oil bath.
f) Record the instrument temperature after 5 minutes, the bath reaches the steady temperature.
g) Increase the oil bath temperature in steps of 20°C and record the temperature of the instrument
after 5 minutes when the bath reaches the steady state temperature.
h) Simultaneously observe and record the switch operation (ON) as instrument temperature rises.
i) Remove the sensing bulb from oil bath and keep in ambient temperature till the instrument reading
reaches the ambient temperature.
j) Simultaneously observe and record the switch operation (OFF) as instrument temperature
decreases (To check switch differential).
k) Insulation test (2 kV between contact and earth).
1.2.7 Installation and Pre-commissioning Checks
a) Before installation, check for possible damages from transport handling.

b) Do not carry the instrument by holding the capillary line.
c) Ensure not to twist the capillary line while unpacking, storage or installation.
d) Avoid sharp bends of capillary line and allow minimum of 50 mm bending radius.
e) Keep the instrument on mounting surface and fix it.
f) Make sure that instrument is mounted in a vertical position.
g) Clamp the capillary line along its entire (3/4) length at approximately 500 mm intervals. The excess
length can be wound in a spiral with a min diameter of 100 mm.
h) Oil is to be filled in the pocket. Insert the sensing bulb through union / pocket / flange (insert fully),
tighten nut to optimum level.
i) Care must be taken that sensing bulb is not damaged while tightening.
j) In case of further transport or storage, wind the armor and pack the instrument in the same way
as received from the supplier.
k) Check the connection as per wiring diagram before commissioning.
l) Cable entry should be through cable gland to avoid dust entering
m) Top cover should be put in place and tighten properly to avoid dust. Ensure that the maximum
pointer is positioned after the indicating pointer.
n) Make sure there are no loose connections.
o) Set the Hot oil bath temperature at 60°C/75°C, Immerse the sensing bulb.
p) Inject the rated current as per requirement or graph for 40 minutes, and check the temperature
rise of winding temperature over oil temperature.
q) Test knob, if provided externally, shall be locked properly after testing.
1.3 Remote Oil / Winding Temperature Indicator (ROTI/RWTI)
1.3.1 Description
This is used to measure the temperature of oil / winding at the remote control panel.
This system takes 4 to 20 mA, DC analog input from the local OTI / WTI and caliberate the same in
terms of degrees C to repeat the temperature of local OTI / WTI on the remote control panel
1.3.3 Data Sheet

The different types of Remote Temperature indicators are as follows:
Parameter Variant - 1 Variant - 2 Variant - 3
Type Digital (96 sq mm) Digital (96 sq mm) Digital (96 sq mm)
Auxiliary Supply 90 – 260V AC/DC 90 – 260V AC/DC 90 – 260V AC/DC
Temperature Range 0 – 150 °C 0 – 150 °C 0 – 150 °C
Temperature Indicator 3½ digits 7-segement 3½ digits 7-segement LED 3½ digits 7-segement
LED display red in colour display red in colour LED display red in
colour
Accuracy of the system ± 1% FSD ± 1% FSD ± 1% FSD

(of local OTI / WTI) (of local OTI / WTI) (of local OTI / WTI)
Warm up time after 15 Minutes (Minimum) 15 Minutes (Minimum) 15 Minutes (Minimum)
switching ‘ON’
Input 4 to 20 mA DC 4 to 20 mA DC 4 to 20 mA DC
No. of 4 - 20 mA 4 1 1
Output
Alarm & Trip Contacts Not Available Available (1 No. each) Not Available
RS485 port module Not Available Not Available Available

Degree of Protection of IP 20 IP 20 IP 20
enclosure
Note: 4 to 20 mA corresponds to 0 to 150 °C respectively.
Any one of the following terminal configurations can be selected as per requirement. The contact
position shown below is under normal operating condition.
Variant 1 Variant 2 Variant 2


§§ No. of 4 to 20 mA output - Yes / No
§§ Alarm & trip contacts - Yes / No
§§ RS485 port module - Yes / No
1.3.6 Tests
a) HV Test: All mA terminals shall be tested for 500V AC, 50Hz for one minute. All other terminals
shall be tested for 2kV AC, 50Hz for one minute.
b) I.R. Test: Insulation resistance shall be ≥ 20 Meg. Ohms when checked by 500V DC Insulation
Tester.
1.3.7 Installation and pre-commissioning checks

a) Check the proper electrical earthing.
b) Use shielded cable for input signals
c) Ensure that input signal and power cables are isolated.
d) Make sure the proper supply voltage is applied.
e) Switch off the power supply while wiring.
f) Ensure tightness of all the contacts.
1.4 RTD (PT100) Scheme for ROTI / RWTI
1.4.1 Description
This scope covers the standard specifications of the PT100 Resistance Temperature Detector (RTD)
Oil Temperature indicator (OTI) and Winding Temperature indicator (WTI) for use with liquid immersed
power transformers and reactors for indoor or outdoor installation.
1.4.2 Oil Temperature Indicator
The system measures the top oil temperature of oil immersed transformer with the PT100 RTD sensor
and transmits the measured values to a remote point by dc current mode signal.
The PT100 sensor is mounted in an oil filled pocket located in the hottest oil zone of the transformer.
The PT100 resistance in the sensor changes with the change in the top oil temperature. The Transducer
(Resistance to Current Converter Unit) measures the variations in the Sensor Resistance (corresponding
to the top oil temperature) and produces two independent channels of 4-20 mA dc current output
signals directly proportional to the PT100 sensor resistance.
Fig. 2.5: Block Diagram of PT100 ROTI – Dual Output Channel

1.4.4 Winding Temperature Indicator

The system measures the Top Oil temperature of oil immersed transformer with the PT100 RTD sensor,
simulates the Winding hot-spot temperature with a thermal imaging device & transmits the measured
value to a remote point by dc current mode signal.
Thermal Imaging method:

The PT100 Sensor assembly is mounted in an oil-filled pocket located in the hottest oil of the
transformer. A Heater Coil (H) and Shunt (RS) assembly either mounted in the PT100 sensor assembly
(as shown in Fig. 2.6) or in the Transducer (as shown in Fig. 2.7) is fed with current from a CT placed in
the transformer load circuit. The Heater simulates the hot-spot Temperature rise of the winding over the
top oil temperature corresponding to the transformer load current. The PT100 Sensor assembly reacts
to this simulated temperature rise in addition to the top oil temperature. To obtain precise thermal
image, a portion of the current through the Heater is shunted through a calibrating Shunt Resistor. The
thermal time constant of the Heater is nearly the same as that of the transformer winding. Hence, the
Sensor assembly simulates closely the actual hot-spot temperature of winding in relation to time.
The Resistance to Current Converter Unit (Transducer) measures the variations in the Sensor Resistance
corresponding to top oil plus simulated windings hot spot temperature and produces a directly
proportionate two independent channels of 4-20 mA dc current output signals.
Fig. 2.6: Block diagram of PT100 RWTI – Dual Output Channel Thermal Sensing Method - Scheme 1.
Fig. 2.7: Block diagram of PT100 RWTI – Dual Output Channel Thermal Sensing Method - Scheme 2.
1.4.6 Data sheet & selection criteria
Sl No Description Specification
1 Sensor PT100 3-Wire Sensor (Simplex/Duplex)
2 Union 1” BSP Male type union (Fig. 2.8)
3 Sensor As per figures 2.9 & 2.10
4 Sensing for Winding Hot Thermal Sensing
spot temperature
Sl No Description Specification
5 Transducer Resistance to Current Converter Unit
6 Power Supply 90-260V, ac/dc
7 Analog output 4-20 mA (single / dual optional)
8 Burdon on output ≥ 500 Ω
9 CT input 2 Amp
10 Temperature Rise/Gradient The standard temperature gradient must be adjustable up to 35°C
11 Accuracy ±0.2 mA at any point of 4-20 mA suitable for 500 Ω burden including
loop resistance.
12 Insulation Resistance ≥20MΩ Between Earth to all terminal when measured with 500 V DC
Insulation tester
13 Isolation 2500Vrms, AC between Power all terminals to earth for 60 Sec
14 Warm Up time 15 minutes (minimum)
15 Ambient Temperature 0 to 50°C , 45 to 80% RH
16 Storing Temperature -10°C to 60°C, 25 to 85% RH
17 Range 0-150°C
18 Panel Protection Level IP40
19 Mounting DIN Rail / Panel Mounting
Fig. 2.8
Fig. 2.9 Simplex Type Sensor Fig. 2.10 Duplex Type Sensor
1.4.7 Tests
1.4.7.1 Routine Tests
a) Temperature Vs Resistance:
It is checked across PT100 sensor leads from 0-150°C using the test equipment and test
procedure as per resistance table Annexed as Annexure 2.4.
b) Temperature Vs Output Signal:

Sensor, heater & shunt connected to Transducer and calibrated to Oil temperature Transmitter
to the temperature range 0-150°C Output Signal 4-20 mA DC as per Annexure 2.5.
Accuracy of each channel output signal ± 0.2 mA. Minimum settling time 40 minutes allowed
before taking each step reading.
The same system calibrated as Winding Temperature transmitter by passing specified input
current through heater & shunt network maintaining bath oil temperature at 80°C constant
and allowing 40 minutes settling time as per CT Current Vs Gradient Graph. In the test reports
for the system, the bath oil temperature 80°C plus simulated temperature rise for specified
input current will be recorded. Accuracy of each channel output signal is ± 0.2 mA.
1.4.7.2 Type Tests
a) High Voltage Test:

Test at 2500 Vrms, 50Hz for 60s.
All Terminals to earth (case)
Power Supply terminals to signal input/output terminals.
b) Insulation Resistance Test:

Measured at 500V dc under normal ambient temperature between all terminals and earth
(enclosure) ≥ 20 Mega Ohms.
c) Soak test:
Transducer Unit energized for a period of 72 hrs to simulate normal operating conditions
for determining the input and output conditions and the functions performed during this
period.
1.4.8 Transportation care

Instruments are to be properly packed with necessary buffers to prevent from any mechanical damage
to the Thermal pocket, Transducer enclosure, Terminal block etc
Utmost care to be taken to prevent the instrument from coming in contact with moisture, high
temperature and sharp edges.
1.4.9 Storage care

Instrument should be stored in a dry and moisture-free place.
Sensor, Transducer and Digital Indicators should be handled carefully so that they are not subjected to
excessive mechanical force / falling down.
Electronic Transducer and digital Indicator are to be stored in cool and dry place away from moisture
and heat.
1.4.10 Installation care

PT100 RTD sensor is to be installed in the thermometer pocket of the transformer after filling the pocket
with transformer oil in the Pocket up to ¾ level.
Transducer is to be fitted inside the control panel in the DIN rail / Panel mounting.
Digital Indicator is to be fitted on the control panel by inserting it from the front and at the back using
the screw fixing clamps.
All the wiring is to be done as per the terminal marking on the instruments.
Recheck the wiring before energizing the transformer specially the power supply connections.
Ensure that the Loop resistance of the interconnecting cables does not exceed the specified burden of
the Transducer analog output.
Use independent 2.5 sq. mm cable between PT100 Sensor to Transducer and Digital Indicator.
The 4-20 mA cable from Transducer to Remote indicator/SCADA should not run along with a power
cable.
No calibration required to be done at site.
Calibration by user not to be attempted as it may damage the instrument.
2 Fibre Optic Sensors
2.1 Description
Fibre Optic Temperature Monitoring System comprising :

§§ Fibre optic probes (Installed inside the transformer).
§§ Tank wall plate.
§§ External fibre optic extension cable
§§ Measuring Instrument.
§§ Instruction Manual.
2.2 Purpose
Direct real time hotspot temperature measurement of windings, oil, and other parts of the core-coil
assembly of power transformer.
2.3 Working Principle

Light signal, sent from the FOT instrument excites the sensor mounted at the tip of fibre optic cable (probe).
Depending on the temperature at that point, the sensor sends a return signal which is correlated with the
corresponding temperature by the FOT instrument and the same is displayed.
2.4 Installations of Sensors

Sensors are placed in direct contact with the insulation of the winding conductors in the regions where the
hot-spots are to be measured.
The location for fixing the probes shall be decided by the transformer manufacturer based on the expected
location of hotspots and shall be finalized by agreement with the Purchaser.
2.5 Temperature Range

Temperature range of the system should be -30°C to +200°C & accuracy of ± 2°C with no need for
recalibration for the entire life time of the FOT system.
2.6 Selection Criteria for number of sensors to be installed

Reference: IEC Standard 60076-2: 2011 (Annex E)
Minimum recommended number of sensors for three-phase transformers
Rated power Cooling Number and phases of installation

MVA system
Total On central phase On each lateral phase
HV winding LV winding HV winding LV winding
≥ 100 All system 8 2 2 1 1
From ≥ 20 to ON - OFF 6 1 1 1 1
< 100
OD 8 2 2 1 1
For single-phase transformers, the minimum recommended number of sensors for each wound column should
be those indicated in the table below:
Minimum recommended number of sensors for single-phase transformers
Rated power Cooling system Number of sensors
MVA Total HV winding LV winding
≥ 50 All system 4 2 2
Besides the above, installation of at least one sensor is recommended for Top Oil temperature measurement.
2.7 Selection Criteria for Probes

§§ The temperature sensing tip along with the fiber optic cable shall be of proven/type tested design.
§§ They shall withstand exposure to hot kerosene vapour during the transformer insulation drying process
(VPD).
§§ Probes shall be compatible with hot transformer oil.
§§ The probes shall be partial-discharge-free in the high electrical stress areas inside the transformer.
§§ Probes shall be all silica, teflon jacketed fibre with perforations / slits in the outer jacket to allow
complete oil filling. The fibre with Teflon jacket shall be strong enough to withstand the severe
conditions prevailing inside an EHV transformer.
§§ The Fibre optic cables are to be brought out of the main tank through tank wall plate. The plate shall be
welded / bolted on to the tank such that no oil leakage / moisture ingress will occur.
§§ The tank wall plate shall be covered with a protection-hood to avoid accumulation of dust and water
ingress.
§§ The external fibre optic cable shall then be run to main control cabinet, routed through suitable conduits
with large bend radius.
2.8 Selection Criteria for FOT Measuring Instruments.

i. Analog Outputs
4 - 20 mA output for remote Indication or SCADA.
ii. Relay Outputs
Provision of min 6 programmable relays for Alarm/Trip and Cooling Control.
iii. Communication
Suitable computer interface and SCADA interface on IEC 61850
iv. Memory / Data Storage
Suitable for recording of 3 months data at 1 reading / minute interval.
2.9 Tests
a) At FOS Supplier’s Works
The FOS supplier shall provide the transformer manufacturers with the following test certificates:
Type tests:
§§ Dielectric tests on probes
§§ Surge test for FOT measuring instrument as per IEEE C37.90.1-1989
Routine tests:
§§ Calibration
b) At Transformer manufacturer’s Works during transformer manufacturing
§§ Temperature rise (Heat Run) testing if specified by end customer: Measurements shall be made
with the FOT measurement system. The equipment shall be operational during temperature rise
test and the data shall be recorded.
§§ Before dispatching the transformer, all probes shall be checked with the same measuring instru-
ment going along with that particular transformer and the temperature data should be recorded.
c) Inspection and pre-commissioning tests at Site:
§§ Check for any physical damage for the entire system.
§§ Check all probes for functional healthiness and record the temperature readings.
3 Gas & Oil Actuated Relay (Buchholz Relay)
3.1. Description
This is a gas and oil actuated relay for liquid immersed power transformers and reactors with conservator.
The device is intended to detect:
§§ Gas release from the unit to be protected
§§ Oil surge from the tank to the conservator
§§ Complete loss of oil in the conservator
3.2 Principle of Operation

Buchholz relay is completely filled with oil under normal operation of the transformer. In the event of an in-
ternal fault in the transformer, gas bubbles are produced in oil, which accumulate in the Buchholz relay. This
leads to drop in oil level in the BR, thereby causing operation of the alarm switch contact.
In case the oil continues to drop due to excess gas accumulation, it triggers operation of the trip contact.
3.3 Data sheet
Parameter Buchholz Relay 80 NB
Mounting arrangement Ref Fig. 2.12
Liquid in tank Transformer oil
Operating temperature -20o to +110o C of oil
Contact system Magnetic Reed Switch
Type of contact Ref Fig. 2.11
Contact rating - a.c. 240 V, 2 A
- d.c. 240 V, 2 A
Breaking capacity 400 VA a.c. or 250 W d.c.
Gas volume for alarm 200 to 300 cc
Surge velocity test 120 to 160 cm/s for trip contact
Vibration test Vibration test at the frequency of 5 to 35 Hz with acceleration

up to 6g in all directions.
3.4. Standard wiring diagram

The contact position shown below is under normal operating condition of buchholz relay.
3.4.1 Wiring Diagram for Model with 2 NO Contacts
Alarm 1 NO 1 No.
Contact
Trip 1 NO 1No.
Contact
Fig. 2.11
3.4.2 Wiring Diagram for Model with 3 NO Contacts
Alarm 1 NO 1 No.
Contact
Trip 1 NO 2 Nos.
Contact
Fig. 2.11
3.4.3 Wiring Diagram for Model with 2 Change-over Contacts
Alarm 1 Change-over 1 No.

Contact
Trip 1 Change-over 1 No.
Contact Fig. 2.11
3.4.4 Wiring Diagram for Model with 2 NC Contacts
Alarm 1 NC 1 No.
Contact
Trip 1 NC 1 No.
Contact
Fig. 2.11
3.5 Selection criteria
§§ Quantity of oil inside the transformer to be protected

Normally 80 NB size BR is used for power transformers ≥10 MVA rating as per CBIP Publication No. 317.
3.6 Mounting details
BILL OF MATERIAL
14 Plaster Plug
13 Plug & Socket Assembly
12 Cap for Pneumatic Testing Device
11 Pneumatic Test Device
10 Electric Testing Device
9 Cap for Electric Testing Device
8 Connector 1/8“ x 1/8“ BSP
7 Plug D83
6 1/4” BSP Cap for Petcock with chain
5 1/4” BSP MX1/4”BSP F Petcock
4 1/4” BSP Petcock
3 Aluminium Terminal Box Cover
2 Aluminium Cover
1 Aluminium Relay Body
Sr. Description
No.
Reference Pipe Size A B C D E F
1 80 NB 312 215 185 145 18
Fig. 2.12: Mounting details
3.7 Tests
3.7.1 Type tests
a) Tests as per IS: 3637
b) Vibration Test at 5 to 35 Hz at 6g acceleration in all directions
c) Degree of protection - IP:67

3.7.2 Routine tests
Test Test Parameter Testing Procedure Pass Criteria
Alarm Test 200 to 300 CC Gas collection by draining the oil to match As per testing
reading on scale parameters
Trip Test 120 to 160 cm/s Create the surge to check velocity As per testing
parameters
High Voltage 2 kV a) Applied between terminal to terminal for 1 min No breakdown

Test b) All terminal shorted with BR for 1 min
Leakage Test Test of Housing with To check housing for leakage with compressed No leakage from
/ Loss of Oil compressed air air at 2.5 kg/cm2 any point
Test of assembled To check assembled Buchholz Relay for leakage No leakage from
Buchholz Relay with with Transformer Oil at 2.5 kg/cm2 for 140 hrs any point
Transformer Oil
3.8 Installation and pre-commissioning checks
a) Transit damage.
b) Dimensional check for installation suitability.
c) Electric contact by operating lever/Push rod provided on the BR.
d) Get all fasteners, gaskets and other tools before taking out BR for the fitment.
e) Check pipe line alignment, gap between pipe line flanges to put BR in position.
f) Hold BR in position with positive inclination of 3° to 7° (see Fig. 2.13 below) to the horizontal axis in the
direction of arrow marked on the BR body, provide suitable gaskets and fit the BR with fasteners in the
pipe line.
g) Ensure tightness of all the contacts.
h) Connect electrical contacts with battery and check the operation.
i) Fill BR with oil and check tightness of bolted joint for any oil leakage.
Fig. 2.13: Mounting of Buchholz Relay

4 Pressure Relief Valve (PRV)
4.1 Description
The PRV is suitable for oil filled power transformer. It operates when Pressure in the tank rises above prede-
termined safe limit and performs the following functions.
No. Function Description

1 Relieve Excess The PRV instantaneously relieves the oil pressure built inside the transformer tank by
Pressure lifting the diaphragm resting on the port of about 150 mm diameter and discharges
the oil from tank, thus relieving pressure. To avoid oozing of oil, the diaphragm is
spring loaded to close the port as soon as the pressure in the tank is relieved.
2 Visual Indication The PRV gives visual indication of valve operation by raising a flag. Flag remains in
operated condition till it is manually reset.
3 Switch Operation As soon as the PRV is operated it operates an electrical switch (Micro/Limit switch).
Switch contacts can be used to give audible alarm or isolate the transformer from
circuit. Switch should remain in operated condition till it is manually reset.

A Spring Loaded Stainless Steel diaphragm is used to keep the port opening of about 150 mm diameter of
PRV in closed condition. The diaphragm gets lifted from its position as soon as the oil pressure in the tank
rises above predetermined operating pressure and releases the oil / vapour to relieve pressure in tank. The
lifting of diaphragm operates electrical switch & flag. The Switch & Flag remain in operated condition till they
are manually reset.
4.3 Data Sheet
Parameters Values
Liquid in Tank Transformer Oil
Mounting On Tank cover or side wall i.e. Horizontal or Vertical
On 6 Studs of M12 Equally spaced on 235 PCD
Port Opening Nominal 150 mm Diameter with spring loaded Diaphragm.
Operating Pressure 0.42, 0.49, 0.56, 0.7 kg/cm2 (any one value, shall be specified by the transformer
manufacturer)
Operating Tolerance ± 0.07 kg/cm2
Operating Time Instantaneous
Valve Resetting Automatic
Visual Indication By flag
Visual Indicator Resetting Visual Indicator Resetting Manually
Operating Temperature 0 to 100 °C (of Liquid on Tank)
Duty Outdoor / Indoor
Contact system Micro switch
Type of Switch 2 NO + 2 NC
Rating of Switch Micro Switch – 5A, 240V AC / 0.2 A , 240V DC
Switch Resetting Manual
Mounting Gaskets Nitrile Rubber Gasket of suitable size to fit on PRV Groove
Cable Entry Hole with 3/4” Conduit threads for cable gland
Degree of Protection IP 67
Hardware Stainless Steel
Rain Protection Cover Metallic Type
4.3.1 Shroud
Shroud with pipe connecting flange can be used to avoid spilling of discharge from PRV.
Flange of shroud can be connected through 360 degrees orientation in horizontal plane.
This arrangement can avoid injury to person and also avoids pollution.
Fig. 2.14: PRV with shroud
4.3.2 Weather proof plug & socket arrangement for connecting cable :
Fig. 2.15: PRV with shroud with weather proof plug and socket arrangement for connecting cable
4.4 Standard wiring diagram

The contact position shown below is under normal operating condition of PRV.
Fig. 2.16: Wiring diagram for Model with 2 NO + 2 NC Contacts

§§ Operating Pressure
4.6 Tests
4.6.1 Routine tests
TEST DESCRIPTION
Operation of PRV Operation of PRV at specified Pressure with compressed air
Power Frequency Test Power frequency test at 2.5 kV, 50 Hz for one minute from switch terminals to other
parts of PRV
Insulation Resistance Test between Terminal to Body –Should not be less than 100 MΩ at 500V
Leakage Test Leakage test at 75 % of operating pressure with air for 24 hours
4.6.2 Type test
PRV to be tested for IP:67.

Check transit damage
Dimensional check for installation suitability.
Get all fasteners, gaskets and other tools before taking out PRV for the fitment.
Take gasket with 6 holes, 14 diameter on 235 mm PCD
Ensure tightness of all the contacts
Connect electrical contacts with battery and check the operation
5 Magnetic Oil Level Gauge (MOG)
5.1 Description
A magnetic oil level gauge (MOG) is provided on the transformer conservator for indication of oil level in
the transformer. A float is used as a device for indication of oil level inside the conservator on a calibrated
dial gauge. The dial is marked as “EMPTY”, “¼”, “½ (or 35°C)”, “3/4” and “FULL”. Calibration of marks
“EMPTY” and “FULL” (Fig. 2.17) is done after leaving 65 mm from the bottom and the top of the conservator
to avoid striking of the float to the conservator oil.
Fig. 2.17
Magnetic Coupling: The float touches the oil surface level and it moves up and down with change in the
level of oil. Transfer of float movement to the pointer provided on the dial gauge by use of pair of permanent
magnets (Fig. 2.18).
Fig. 2.18
5.3 Data sheet
Parameter MOG
(For Main / OLTC Conservator)
Dial size 100mm/150mm/250mm
Operating temperature -30o to +120oC of oil
Pressure 0 to 1kg/cm2
Contact system Micro switch
Type of contact Normally open
Contact rating 240 V, 5 A AC
240 V, 0.2 A DC
No of contacts 1No. (for LOLA)/ 2 Nos. (for LOLA, HOLA)
Contact Position Normally Open at Filling Level
Colour of marking Black markings on white background
Pointer Black
Material Float - Brass, Float arm - SS

5.3.1 Mounting:
MOG for conservator with aircell
Fig. 2.19
MOG for conservator without aircell
Fig. 2.20
Variable Parameters (to be provided by Transformer manufacturer)

1. Diameter of conservator (in mm)
2. Application : for main / OLTC conservator
3. Average ambient temperature.
4. Float Arm Length (FAL) FAL to be selected from table below
Sr. No. Conservator diameter F.A.L. for 30 degree F.A.L. for vertical
Ø inclined mounting mounting
1 350 N/A 156
2 750 707 438
3 800 778 474
4 900 919 545
5 1000 1060 615
6 1200 1343 757
7 1300 1485 827
8 1400 1626 898
9 1600 1909 1040
5.3.2 Method of Cable Termination
Weatherproof Plug & Socket arrangement for cable
Fig. 2.21

Any one of the following terminal configurations (Fig. 2.22 and Fig. 2.23) can be selected as per
requirement.
The contact position shown below is for normal operating condition of MOG.
Fig. 2.22: Wiring Diagram for Model with 2 NO Contacts Fig. 2.23: Wiring Diagram for Model with 1 NO Contact

§§ Type of conservator (for Main or OLTC conservator)
§§ Diameter of conservator
§§ No. of contacts required
§§ Dial size of MOG
5.6 Tests
5.6.1 Routine tests

a) Leak test at 2 kg / sq cm for 2 min. at ambient temperature.
b) Float position shall be calibrated to the diameter of conservator and the dial of MOG.
c) Position of low oil level alarm to be checked.
d) Power frequency test at 2.5 kV, 50 Hz for 1 minute from switch terminals to other parts of MOG.
e) Insulation Resistance Test between Terminal and Body; it should not be less than 100MΩ at
500V.
f) Micro switch at 5 amps, 240 V AC.
5.6.2 Type tests
Degree of Protection - IP67.

a) Take 8 studs of M10 with nuts & washers.
b) Take gasket with 8 holes, 12 mm dia on 225 mm PCD.
c) Mount the MOG as shown in Mounting arrangement diagram (Fig. 2.19 and Fig. 2.20).
d) Handle the MOG float & float-arm carefully being delicate items.
e) Ensure tightness of all the contacts
f) Connect electrical contacts with battery and check the operation
6 Oil / Water Flow Indicators (FI)
6.1. Function
The function of Flow indicator is:
§§ To indicate the flow of oil / water in pipeline in required direction.
§§ To operate two switches, first, when the rate of flow drops to 80% & second, when the rate of flow
further drops to 70%.
Fig. 2.24

Magnetic Coupling
A metallic spring loaded vane is kept suspended in the pipe (Fig. 2.24). The vane deflects, when the flow of
liquid strikes. The vane & return spring remain inside the liquid. A pointer is linked to vane with the help of a
pair of permanent magnet. Thus, the pointer follows the deflection of vane. Pointer & vane mechanism are
separated by a non magnetic metallic solid wall to avoid leakage of liquid in pipe. Two switches are provided
which operate at 80% & 70% respectively when rate of flow starts dropping.
6.3 Data Sheet
Parameter Specification
Liquid in pipe Oil or Water
Rate of full flow Of liquid in pipe in LPM
Pipe size Nominal Bore in mm
Direction of flow Any one from the following
- Left to Right
- Right to Left
- Vertically Up
- Vertically Down
No of contacts Two
Type of contacts NC (Open at full flow)
Contact rating 5 A, 240 V AC & 0.25 A, 240 V DC
Two micro switches for operation at 80% & 70% of full flow
First and second contacts get closed when flow drops at 80% & 70% of full flow respectively.
6.4. Dial
Parameters
- 100 mm round
- Back markings on white dial
- Black Pointer
Markings on dial
- Indication markings: FULL FLOW, NO FLOW (Fig. 2.25)
- Other markings - Pipe size, Value of Full Flow, Liquid in pipe & Direction indicating arrow.
Fig. 2.25
The contact position shown below is under normal operating condition of flow indicator.
Fig. 2.26: Wiring Diagram for Model with 2 NC Contacts
6.6 Tests
6.6.1 Routine tests

- Leakage test at 7 kg / cm2
- Flow: Full Flow test as specified by buyer.
- Switch operation at 80% & 70% when rate of flow is dropping
- Power frequency test between live terminals to body at 2 kV for 2 minutes
6.6.2 Type tests

Degree of Protection - IP 67.
6.7 Mounting
6.7.1 “T” Mounting

When a flange matching with holes of FI & projecting from the pipeline, “T” Mounting is
provided. The FI is installed on the T mounting. After mounting, the vane of FI is positioned in
Centre of pipe.
Fig. 2.27
6.7.2 Weatherproof Plug & Socket arrangement for cable
Fig. 2.28

a) Take FI with suitable gasket, 4 bolts with nuts & washers of M12
b) Install the FI so that dial is in erect position.
c) Make electric connection with a cable gland
d) Ensure tightness of all the contacts.
7 Air Cell or Flexi-separator
7.1 Description
The flexible separator is a sealed envelope made from nylon fabric coated with synthetic elastomer nitrile
and hot vulcanized. The separator is installed inside the conservator and fitted to it through the flange con-
nected to the plate of the manhole.
7.1.1 Schematic diagram of Air Cell
Fig. 2.29: Schematic Diagram of Aircell

7.1.2 Drawing of Air Cell
Fig. 2.30: Drawing of Air Cell
7.1.3 Selection of Air Cell
Requirement can be specified by giving dimension of X, Y & G (calculated as per formula given below)
Formula: Y = (3.142 x D)/2 + 40 mm, X = L - D + Y, G = X - Y - 200
Example: For Conservator of 700 dia x 2000 long
Values will be X = 2240, Y = 1140, G = 1100
7.1.4 Connecting Flange
Fig. 2.31: Connecting Flange

7.2 Standard sizes of Air Cell
Standard Sizes of Air Cell

Sr. F S P - Size Expansion Conservator Aircell Size (mm)
No. Volume
Dia (mm) Length Volume Length Width “G”
(litres)
(mm) (litres)
1 500 - 500 500 500 2710 530 3035 825 2010
2 500 - 600 500 600 1970 560 2352 982 1170
3 750 - 600 750 600 2850 810 3232 982 2050
4 750 - 700 750 700 2180 840 2620 1140 1280
5 1000 - 700 1000 700 2830 1090 3270 1140 1930
6 1000 - 800 1000 800 2260 1130 2757 1297 1260
7 1500 - 800 1500 800 3250 1630 3747 1297 2250
8 1500 - 900 1500 900 2660 1690 3214 1454 1560
9 2000 - 900 2000 900 3440 2190 3994 1454 2340
10 2000 - 1000 2000 1000 2880 2260 3491 1611 1680
11 2500 - 1000 2500 1000 3520 2760 4131 1611 2320
12 2500 - 1100 2500 1100 3000 2850 3668 1768 1700
13 3000 - 1100 3000 1100 3520 3350 4188 1768 2220
14 3000 - 1200 3000 1200 3050 3450 3775 1925 1650
15 4000 - 1200 4000 1200 3940 4450 4665 1925 2540
16 4000 - 1300 4000 1300 3450 4580 4232 2082 1950
17 5000 - 1300 5000 1300 4200 5580 4982 2082 2700
18 5000 - 1400 5000 1400 3710 5720 4549 2239 2110
19 6000 - 1400 6000 1400 4360 6720 5199 2239 2760
20 6000 - 1500 6000 1500 3900 6880 4796 2396 2200
7.3 Tests
7.3.1 Routine tests
Coated fabric
- Mass surface
- Tearing strength
- Breaking strength
- Elongation
- Adhesion
Basic fabric
- Breaking strength
- Elongation
Finished Product
- Pressure testing by compressed air
- Leakage testing
7.3.2 Type tests
Coated fabrics
- Heat ageing
- Compression test
- Low temperature, flexibility
- Sludge content
- Acidity
- Ozone resistance
- Air permeability
- Bursting strength
7.4 Installation care
7.4.1 Assembly of Air Cell inside conservator
Fig. 2.32: Aircell inside the conservator

Refer Fig. 2.32 for general arrangement of Conservator and Aircell. Valve No. 1, 2, 3, 4 & 5 are fitted with
direction marked next to the valve.
Remove the detachable end cover of the conservator as shown in Figure 2.32.
Fig. 2.33: Loops on the Aircell with the hooks inside the conservator
Assemble the Oil Level Indicator (MOG) as shown at location shown in Figure 2.32. Terminal box of the
MOG should be vertically below the indicator dial. Carefully attach the float and float arm to MOG. Air
cell, MOG, float and float arm are delicate, utmost care should be taken while assembly to avoid even
slightest damage.
After the assembly of air cell and MOG are over, clean the conservator inside surface with clean cloth.
Do not use cotton waste. Refit the detachable end cover.
Now the conservator is ready for installation in position and also for oil filling.
Before installing in position, check the air cell for any leakage as under.
It is to be noted that pipes, valves, pressure gauge shown in dotted line and N2 cylinder and vacuum
pump are not supplied by manufacturer of these instruments. These should be made available at
site, keeping in mind that oil filling of the conservator is to be done after installing the same in proper
position.
7.4.3 Leakage Test of Air Cell
Inflate (fill) the air cell at a max, of 2 psig through valve 6 (use N2 gas) while leaving a vent hole i.e. valve
4 open.
Adjust the pressure after 6 hours (i.e. pressure to be retained at 1 psig). Check the temperature and
maintain the air cell at that temperature for 24 hours. Watch the possible loss of pressure during that
period. If there is no loss of pressure during 24 hours, this means the setting of air cell inside the
conservator and also the air cell is considered leak tight. This also ensures that all gaskets joints are
leak tight. Assemble the conservator at proper position.
7.5 Oil filling under Vacuum

Use transformer oil for filling. This oil should be same as used for transformer filling.
Fill oil into the conservator upto Filling Level on MOG via ‘B’ relay pipe, valve 5 by pumping the oil from bot-
tom of the transformers.
Keep air cell open to atmosphere by opening valve 6 & 7 to atmosphere. Open also valve No.2 so that pres-
sure inside the conservator and air cell will be same. Connect valve 7 to vacuum pump. (Valves 6 & 2 open)
Valves 3 & 1 closed.
Pull the vacuum up to 760 mm Hg simultaneously to air ell and conservator. When 760 mm vacuum is
achieved close valve 2
Push oil through valve No.5 till the MOG shows Full oil level.
Close valve 6, 2, & 3 and connect N2 cylinder to valve 7.
Maintain conservator under vacuum and admit N2 into air cell at a max, of 1 PSIG through valve 6. Then the
air cell inflate by itself and takes all the free space due to the fact that the conservator was not completely
full. Fill the conservator till the moment the oil is going to rise to the top of conservator. Continue to admit
nitrogen into air cell at one psig and simultaneously drain oil from valve 3.
Drain the oil up to filling level. Immediately close Valve 3 and check that all the valves and openings on con-
servator except valve 5 are closed.
Connect air cell to silica gel breather.
Caution
When the assembly is ready to work, it is important not to open vent holes / valves on upper part. Plain oil
gauges are usually provided on the opposite end of MOG on conservator. These gauges might show full
irrespective of oil level in conservator. Hence refer MOG reading for checking the oil level in the
conservator.
8 Conservator Protection Relay (CPR) / Aircell Puncture Detection Relay
8.1 Description
Conservator protection relay (CPR), also called Air cell puncture detection relay, is a single-float type relay to
provide a signal in case of puncturing of air cell.
8.1.1 Schematic diagram of Conservator Protection Relay
Fig. 2.34: Schematic Diagram of CPR
8.1.2 Drawing of Conservator Protection Relay
Fig. 2.35: Drawing of Conservator Protection Relay

8.1.3 Standard wiring diagrams

Choose any one model out of the following options.
Contact position is shown in healthy condition.
8.1.3.1 Model with 1 NO contact
8.1.3.2 Model with 1 change over contact
Fig. 2.36: Standard wiring diagram
8.1.4 Mounting details
Fig. 2.37: Mounting details of CPR

8.2 Data sheet
Parameter Specification
Model Refer Fig. 2.36 Standard wiring diagrams
Mounting arrangement Refer Fig. 2.37
Operating temperature -20 oC to +110 oC of oil
Environment Indoor or Outdoor
Contact system Magnetic Reed Switch
Type of contact As per wiring diagram (Figure 2.36)
Contact rating - a.c. 240 V, 2A for point 1.3.1
240V, 1A for point 1.3.2
- d.c. 240 V, 2 A for point 1.3.1
240 V, 1 A for point 1.3.2
Breaking capacity 400 VA a.c. or 250 W d.c.
Gas volume for Alarm 400 +/- 50 cc
Ingress protection IP 67
Vibration test Vibration test at the frequency of 5 to 35 Hz with acceleration up to 6g in all
directions
8.3 Tests
8.3.1 Routine tests
Test Testing Parameter Testing Procedure Observations
Trip Test 400 +/- 50 cc Gas collection by draining the oil to match As per testing
reading on scale parameters
High Voltage 2 kV a) Applied between terminal to terminal for 1 No breakdown

Test minute
b) All terminals shorted with body for 1 minute
Leakage Test Test of Housing with To check housing for leakage with compressed No leakage
/ Loss of Oil compressed air air at 2.5 kg/cm2 from any point
Test of assembled CPR To check assembled CPR for leakage with No leakage
with transformer oil transformer oil at 2.5 kg/cm2 from any point
8.3.2 Type tests

To be carried out at third party laboratory at an interval of 5 years.
i) Vibration Test.
ii) Ingress Protection Test - IP 67
8.4 Pre-commissioning tests

Following checks/test to be carried out on delivery at site.
i. Transit damage.
ii. Dimensional check for installation suitability.
iii. Terminal connections as per order specification.
iv. Electric contact by operating provided device. (Lever / Push rod)
8.5 Installation care

i. Get all fasteners, gaskets and other tools before taking out CPR for the fitment.
ii. Check mounting flange dimensions to put CPR in position.
iii. Mount CPR in such a way that the Glass Window is visible from outer side and fix it with the fasteners.
iv. Connect electrical contacts with battery and check the operation.
9 Removable Radiators for Oil-immersed Transformers

9.1 Description
Radiators, i.e. the thermal exchangers, are used for cooling of transformer oil with natural ambient air circu-
lation. Such radiators are made of several elements with cooling channels connected in parallel.
This specification defines the overall dimensions and ensures the mechanical interchangeability achieving
the same thermal performances.
9.2 Reference Standard

BS EN 50216-1:2002 & IEEMA 9
9.3 Data sheet

Material and other general construction shall be as follows:
No. Technical Parameter Specification
1. Section Width / Channels / Flutes 520mm / 21 to 28.
2. Centre distance - 2000 mm to 4500 mm in step of 100 mm.
between top and bottom header pipes (CC) - Tolerance : ±3 mm
- Pipe size : Up to 3000 mm : 80 NB
Above 3000 mm : 100 NB
3. Number of Sections 4 to 40
4. Pitch Minimum 45 mm with a tolerance of ±1 mm.
5. Flanges STEP Flange of 18 mm thickness.
6. Bracing Straps/Rods: - Size : 8/10 mm
- Material : Bright round mild steel
- No of pairs : 5 pairs for CC 2800 mm to 3500 mm
6 pairs for CC above 3500 mm
7. Lifting lug - Up to 3000 mm :50x65x12, φ 25 mm
- Above 3000 mm :100x85x12; φ 50 mm
Tying lug - 60x40x8 mm, φ14 mm
8. Materials a) Radiator Sections: CRCA sheet conforming to Gr D of IS 513
- Up to 3000 mm : 1.0 mm (Tol. ± 0.05 mm)
- Above 3000 mm : 1.2 mm (Tol. ± 0.05 mm)
b) Header Pipe (Top & Bottom): 90 mm OD pipes of ERW/
CRCA tubes of 2.5 mm thickness (as per IS 1239)
c) End Cap : 60x40x8 mm; φ 14 mm
d) Air Release and Drain plug: 1/2 inch BSP
e) Sealing for plug: Teflon washer / Nitrile ‘O’ ring
f) Bracing Bar: 8/10 mm dia weldable structural steel round
bars conforming to Fe410WA of IS 2062.
9. Width-wise top & bottom edge sealing of fin TIG Welding / GTAW
10. Header pipe to fin throat sealing TIG Welding / GMAW
11. Assembly weld tacking TIG Welding / GMAW
12. Leak repairs Oxy Acetylene gas welding
13. Surface preparation for painting SA 2 ½
14. Painting a) Internal surface:
Flush coated with phenolic-based hot oil- resistant varnish
b) External surface: Epoxy Zinc primer – DFT 60 microns
PU Finish paint – DFT 40 microns
Total (minimum) - DFT 100 microns
Note: Zinc chromate is not recommended as it is carcinogenic.
Abbreviations: MIG – Metal Inert Gas, GMAW – Gas Metal Arc Welding, TIG – Tungsten Inert Gas,
GTAW – Gas tungsten Arc Welding, MMAW – Manual Metal Arc Welding.
9.4 Tests
Description Test Type Standard Specification
Type Test a) Vacuum Test

- Vacuum 10 Torr
- Deflection Deflection not to exceed +0.5 mm.
b) Pressure Test At 200 kPa for 3 hours at 60 °C (± 5 °C) oil temperature
Routine Test a) Dimensional -
b) Leakage At air pressure of 2kg/cm2 for a minimum period of 30 minutes
10 Automatic Voltage Regulating Relay (AVR)
10.1 Description
AVR is used for regulating the secondary voltage of power transformer with on-load tap changer. The
required dead-band settings are set by setting the nominal value and L & R levels independently. The Time
Delay setting on the front panel eliminates the relay operations for momentary fluctuations of the regulated
voltage, thus reducing the number of operations of the tap changer.
When the regulated voltage falls below the specified Under Voltage limit, the control relays are automati-
cally blocked i.e. there is no voltage correction, and a pair of relay contacts is made available for alarm.

The dead-band (bandwidth) can be set by setting the nominal value (NVA) to the required value and then
setting the L & R limits around the NVA.
The desired time delay can be set on the front panel and the control action will take place only if the voltage
continues to remain outside the dead-band after the time delay has elapsed. For voltage corrections requir-
ing more than one tap change, time delay is initiated again before further tap change. The relay is reset au-
tomatically after the voltage is brought within the selected dead band. The time delay is effectively reduced
to provide a voltage time integral response of the regulator for repeated short duration voltage fluctuations
on the same side of the dead-band.
Operation of the Raise Control Relay is automatically inhibited when the voltage falls below the specified
under voltage limit or it fails. One pair of normally open relay contacts are provided to effect the tap change
during Raise and Lower operation and to trigger an alarm in case of Under Voltage / P.T. fail conditions.
10.3 Data Sheet
10.3.1 Option 1: Standard AVR without communication ports
S. No. Feature Standard

1 Aux. Supply 90-260V AC/DC
2 PT Supply 110V AC, 2.5VA
3 Nominal Voltage adjustment +/-10% of PT supply (continuous)
4 Sensitivity (Dead Band) 1 V to 9.9 V (continuous)
5 Time delay setting Voltage independent, 10 to 120s in steps of 1s
6 Time delay resetting Instantaneous resetting with voltage deviation in

opposite direction
7 Under voltage blocking Internal blocking at 80% and restoration at 85% of
nominal voltage
8 Control relays One pair of NO potential free contact 5A at 230V AC

9 Control operation Single pulse operation with 2s (approx.) on-time.
10 Terminal block numbers Terminal block nos. as shown in Cl. No. 10.4
11 Type of terminal block numbers Combicon type terminal blocks suitable for 2.5 Sqmm cable
(external).
12 Cut-out dimensions 185 (W) x 90(H) mm
13 Optional Features
13.1 Line drop compensation With CT current input of 1A; %R & %X setting to be set in ‘%’
(optional)
13.2 AVR control fail relay One pair of NO potential free contact 5A at 230V AC
13.3 Under voltage relay One pair of NO potential free contact 5A at 230V AC
13.4 Aux. supply fail relay One pair of NO potential free contact 5A at 230V AC
13.5 PT supply fail relay To be incorporated in control scheme
13.6 AVR fail ** One pair of NO potential free contact 5A at 230V AC
** One LED shall be provided for “AVR HEALTHY” display
10.3.2 Option 2: AVR with communication ports

In addition to the features covered in Option-1, following additional features are to be provided:
a) Communication Interface for SAS (Substation Automation System) - through both RJ45 (Ethernet)
& FO Cable with IEC 61850 Protocol.
b) Tap Position No. Display with inputs of both 4-20 mA & Resistance of 1 kilo ohm per step
c) 1 no. 4-20 mA output for TPI.
d) OLTC Operation Counter for each tap at the remote.
e) Real Time Voltage Display (kV) as per the PT input at the remote.
10.4 Termination details
S. No. Function Connection Pins
1. Auxiliary Input 1-2
2. PT Input 3-4
3. CT Input 5-6
4. Auxiliary supply Fail Relay (AFR) (NC) 7-8
5. Lower Relay (NO) 9-10
6. Raise Relay (NO) 11-12
7. Under Voltage (UV) / PT Fail (PTF) 13-14
8. Control Fail Relay (CFR) (NO) 15-16
9. 1 Kilo Ohms per step input for TPI 17-18
10. 4-20 mA Input for TPI 19-20
11. 4-20 mA Output for TPI 19-20
10.5 Tests
10.5.1 Routine tests
a) Contactor (Raise / Lower) Operation
b) Time Delay Calibration
c) Functional Check of AVR fail / Aux. supply fail relays

d) LDC Module Calibration
e) Burn-in test
f) 2kV Test
10.5.2 Type tests
a) Dry Heat test at 50°C for 3 hours.
b) Cold test at -20°C for 3 hours.
c) Vibration test at 10-55 Hz, displacement +/- 0.75 mm (p-p), duration 15 min./axis (X, Y, Z).
d) Bump test (packed condition): Acceleration 40g, Pulse duration 6ms, Normal axis, 1000 bumps.
e) EMI / EMC Test specifications : BS EN61326 : 1998
Set up as per
i. EMI / EMC Test specifications : BS EN61326 : 1998
ii. EMI / EMC Test specifications : BS EN61326 : 1998
iii. EFT : As per BS EN61000-4-4, 1995
iv. Radiated Susceptibility : As per BS EN61000-4-3, 1995

a) Check the proper electrical earthing.
b) Use shielded cable for input signals.
c) Ensure that input signal and power cables are isolated.
d) Make sure the proper supply voltage is applied.
e) Switch off the power supply while wiring.
f) Ensure tightness of all the contacts.
11 Transformer Fire Protection System
11.1 Nitrogen Injection Fire Prevention System (NIFPS)

11.1.1 Description
This standard lays down the specification for Nitrogen Injection Explosion prevention and Fire
Extinguishing system for oil cooled transformer/ reactor. Dedicated Nitrogen injection system is used
to :
§§ Prevent transformer tank explosion and possible fire, in the event of internal fault and as such it
acts as fire preventer.
§§ Also act as firefighting system
System comprises Cubicle (installed near the transformer), Control Box ( installed in control room), Conservator
isolation valve (installed in conservator pipe line), Fire detectors (on transformer top cover), Piping for oil and
nitrogen, Copper Cables.
11.2 Reference Standards

a) Central Electricity Authority, The Gazette of India, Extraordinary 2010
b) Technical standards for constructions of sub-stations and switchyards
c) Technical standards for construction of Thermal Generating Stations
d) Safety provisions for electrical installations and apparatus of voltage exceeding 650 volts
e) CBIP Manual on Transformers - Publication no. 317
Depressurization process commences through oil drain and simultaneously nitrogen is injected at a pre-
determined flow rate to create stirring action and to bring down temperature of top oil below ignition
point, evacuates gases formed thereby preventing explosion of tank and in case of fire, it extinguishes
fire within minimum 30 seconds. During fault condition, system operates and conservator isolation
valve blocks oil flow to isolate conservator tank oil. Also in case of fire, it prevents escalation of fire.
The system comes in to operation automatically / remotely / manually under following conditions.
Auto Mode
a) For Prevention of Fire, signals in series :
§§ Differential Relay Operation,
§§ Buchholz Relay paralleled with Pressure Relief Valve or RPRR (Rapid Pressure Release Relay)
§§ Tripping of all connected breakers (HV & LV side) is a pre-requisite for initiation of system
activation.
b) For Extinguishing Fire, signals in series :

§§ Fire Detector,
§§ Buchholz Relay paralleled with Pressure Relief Valve or RPRR.
§§ Tripping of all connected breakers (HV & LV/IV side) is a pre-requisite for initiation of system
activation.
Manual Mode (Remote)

activation.
Manual Mode (Mechanical)

activation.
The system shall be designed to be operated manually (oil draining and N2 injection) in case of failure of
power supply to the system.
11.1.4 Sequence of Operation

After receipt of operating signals, sequence of operation will be as shown in figure 2.38.
11.1.5 System features

§§ System shall have interlock to ensure operation of system only after transformer electrical isolation
to avoid nitrogen injection in energized transformer.
§§ Pressure monitoring switch for back-up protection for nitrogen release as redundancy to first
signal of oil draining commencement for Nitrogen release shall be provided.
§§ Nitrogen release scheme shall be designed in such a way that the nitrogen gas shall not enter the
energised transformer/reactor tank even in case of passing/leakage of valve.
§§ System shall have provision of testing during commissioning, during annual maintenance and on
live transformers to ensure healthiness at all times.
11.1.6 Selection Criteria
Transformer Rating Capacity of Nitrogen Cylinder Depressurization Scheme

Above 10 MVA & below 100 MVA 6/10 m gas at pressure of 150 kg/cm
3 2
Oil drain pipe size 80mm
100 MVA and below 250 MVA 10 m3 gas at pressure of 150 kg/cm2 Oil drain pipe size 125mm
250 MVA and above 20 m3 gas at pressure of 150 kg/cm2 Oil drain pipe size 125mm
Fig. 2.38: Flowchart showing sequence of operation
11.1.6 Provisions on Transformer tank for Fitting N2 System
Sr. Transformer Oil Drain N2 Injection Quartz Fire Conservator isolation valve
no. rating Gate Valve Valve detector on top arrangement between bu-
cover chholz and conservator.
1 Above 10 MVA Size 80 Size 25 mm: 8 to 12 nos. Dummy pipe 80/50 mm

and below 100 mm : 1No. 4 to 6 Nos,
MVA Maximum
2 100 MVA and Size 125 Size 25 12 to 16 nos. Dummy pipe 80 mm

below 250 MVA mm : 1No. mm: 6Nos,
Maximum
3 250 MVA and Size 125 Size 25 mm: 16 to 20 nos. Dummy pipe 80 mm
above mm : 1No. 6 to 8Nos,
Maximum
Mounting support/ frame on any tank side wall for signal box shall be provided.
11.1.7 Data Sheet
Sr. No. Description Specifications
1. Type and Model Nitrogen Injection Explosion Prevention and Extinguishing

System for transformer rating
a) Above 10 MVA & below 100 MVA
b) 100 MVA and below 250 MVA
c) 250 MVA and above
2 Details of system equipments Cubicle, Control Box, Conservator Isolation Valve, Signal Box and
Fire Detectors.
3 Cubicle, split door
3.1 Dimensions (LXBXH) mm a) For above 10 MVA & below 100 MVA
1200 x 500 x 1900/1700
b) For 100 MVA and below 250 MVA
1200 x 500 x 1900
c) For 250 MVA and above
1600 x 600 x 1900
3.2 Weight a) & b) 500 kg (Approx.)

c) 600 kg (Approx.)
3.3 Capacity and quantity of a) & b) Above 10 MVA & below 250 MVA :
Nitrogen cylinder Minimum 1 no. 10 m3 gas at pressure of 150 kg/cm2
c) 250 MVA and above :
Minimum 2 no. 10 m3 gas at pressure of 150 kg/cm2
3.4 Pressure of Nitrogen filing Maximum 150 kg/cm2
3.5 Minimum distance of FE cubicle from 5 M or beside fire / safety wall

the transformer
3.6 Method of mounting Floor / Plinth
3.7 Items provided in the cubicle
3.7.1 Contact manometer For showing nitrogen cylinder pressure. Falling pressure,
Electrical contact, dual indicator for actual pressure as well as
level for low pressure signal.
3.7.2 Pressure Regulator With safety relief Inlet pressure : 150 kg/cm2 (+/- 10%)
valve to increased temperature Outlet pressure range : 8 to 12 kg/cm2
variation compensation.
3.7.3 Pressure gauge For showing nitrogen injection pressure.
3.7.4 Oil Release Unit and suitable to Electro- mechanical type, operating on substation DC supply as
operate without power well with provision for operation using manual lever in case of
DC supplier loss. It shall have mechanical locking arrangement
to ease in maintenance and avoid unnecessary operation during
maintenance test.
3.7.5 Gas release unit and suitable to Electro- mechanical type, operating on substation DC supply as
operate without power well with provision for operation using manual lever in case of
DC supplier loss. It shall have mechanical locking arrangement
to ease in maintenance and avoid unnecessary operation during
maintenance test.
3.7.6 Oil drain assembly Electro- mechanical type, operating on substation DC supply as
well with provision for operation using manual lever in case of
DC supplier loss.
3.7.7 Pressure monitoring switch as Provisions of Limit switch with Pressure Switch
backup in addition to signal from (Back up)
limit switch to initiate nitrogen
release simultaneously with oil drain
commencement.
3.7.8 Limit switches with No of contacts 1. Oil drain Valve closed. (G02), 2 NO
& spare contacts (NO&NC) 2. Oil drain Valve open.(G03), 2 NO
3. Gas valve closed.(G04), 1NO+ 1NC
4. Gas injection started.(G04), 1NO+ 1NC
5. Oil drain unit locked mechanically. (G05) 2NO/1NC+1NO
6. N2 release unit locked mechanically.(G06) 2NO/1NC+1NO
3.8 Oil drain Valve (above cubicle) for system isolation from transformer
3.8.1 Material and Type Mild steel, Butterfly valve
3.8.2 Size a) Above 10 MVA & below 100 MVA : 80 mm

b) 100 MVA and below 250 MVA : 125 mm
c) 250 MVA and above : 125 mm
3.9 Nitrogen Injection Valve (above Cubicle) for system isolation from transformer
3.9.1 Material and Type Gun metal, Lockable, Stem rising
3.9.2 Size 25 NB
3.10 Oil drain pipe size a) Above 10 MVA & below 100 MVA : 80 mm
b) 100 MVA and below 250 MVA : 125 mm
c) 250 MVA and above : 125 mm
3.10.1 Length and Number of openings in As per site location, Transformer to cubicle & cubicle to oil pit, 1
the transformer tank no.
3.10.2 Material MS, ERW, Heavy duty for TRS to cubicle & GI, Medium for cubicle
to oil pit.
3.11 Degree of protection IP 55
4 Control Box
4.1 Dimensions (LXBXH) mm 500 x 270 x 700
4.2 Weight 45 kg maximum
4.3 Type & Thickness of sheet steel CRCA, 16/14 SWG
4.4 Details of components provided in the MCB, Relays, Hooters, Contactors, Indicating lamps, Operating
control box switches.
4.5 Control voltage 110 / 220 VDC / Substation voltage. AC-DC / DC-DC
converter, timer shall not be used for reliable operation.
4.6 Method of mounting Wall / Frame
4.7 Whether audio and visual alarms Yes with different volume (dB) levels
provided?
4.8 Degree of protection IP 42
5 Conservator Isolation Valve
5.1 Type Operating mechanically on Transformer oil flow rate with visual
position indicator.
5.2 Location Horizontally in the conservator pipe line between Conservator

and Buchholz relay.
5.3 Whether suitable for pipe of size As per transformer conservator pipe size
80mm dia i.e. 80 mm or 50 mm.
5.4 No of contacts & spare contacts (NO Normally Open contact shall be provided.
& NC)
5.5 Padlocking provision for service, Required.

filtration / refilling / filling
5.6 Visual position indicator similar to For physical close indication.

Buchholz relay for inspection
5.7 Transformer Conservator Isolation 40 ltr / minute for 50 mm conservator pipe.

valve setting for normal operation
(valve should not close) to ensure no
obstacle for transformer breathing.
5.8 Transformer Conservator Isolation 60 L / minute (minimum) for 80 mm conservator pipe.

valve setting for operation during
abnormal flow of oil due to rupture /
explosion of tank or bushing / oil drain
during system operation.
6 Fire Detectors
6.1 Type Quartz bulb, Heat sensing.
6.2 Quantity required Depending upon Transformer top cover area.
6.3 Method of fixing Bolting on Fire Detector bracket on Transformer top cover using
fire survival, copper cables (capable to withstand 750 °C.)
6.4 Temperature for heat sensing 141 °C
6.5 Number of contacts 2 NO
6.6 Necessity and condition of refilling After operation.
7 Power Supply
7.1 For Control Box For operation : 110 / 220 VDC / substation DC voltage
For DC fail alarm : 230 VAC
7.2 For Cubicle For illumination and heating : 230 VAC
8 Extinction period
8.1 On commencement of Nitrogen Maximum 30 Seconds

injection
8.2 On system activation Maximum 3 minutes
9 Other technical details On line supervision of operating signals,

DC supply monitoring,
Test facility (excluding CIV, FD) on live transformer,
Anti condensation heater for Cubicle,
Manual operation in DC supply fail,
Separate oil drain and Nitrogen release mechanism.
11.1.9 Tests
Functional test of following equipment is to be carried out during inspection and / or prior to dispatch:
a) Cubicle, showing oil drain and nitrogen injection.
b) Conservator isolation valve.
c) Control box.
d) Fire Extinguishing Performance test.

11.1.10 Typical site layout of Nitrogen Injection Fire Prevention System
Fig. 2.39
11.1.11 Ordering Information
Project / Enduser details :
Transformer details and Quantity :
Manufacturer : Serial number. :
MVA Rating : Voltage ratio :
Oil Qty in tank : Litres

Oil Qty in Conservator : Litres
Power Supply (Pl tick √ ):

Substation/ Control room D.C. Supply : 220V 110V 48V 24V Other
A.C. Supply available : Control room Marshaling box : Single phase, 240V, 50 Hz
Conservator pipe diameter : mm Conservator pipe angle : degree
Spare contacts in relay panel :

Differential RPRR Trip Buchholz Trip Restricted
relay trip 1 number NO potential 1 number NO potential Earth-fault
1 number NO potential free Free Free Relay 1 number NO potential
Free
OLTC oil surge Master relay PRV Trip HV & LV circuit
relay trip Trip 1 number NO breaker trip,
1 number NO potential free 1 number NO Potential free potential 1 number each NC potential
Free free
NO : Normally Open, NC : Normally Close, RPRR : Rapid Pressure Rise Relay
Main Dimensions of tank :

L= mm
B= mm
H= mm
A= mm
Bevelled cover Yes No
Built-in On load Tap Changer : Yes No

Oil Filled Cable Box : Yes No
If Yes : Provide general arrangement drawings
Cooling details :
If OF type Number of pumps : Head : Flow :
KW/HP : Back Flow when Pump Switch off : LPM
Installation : New Post
Distance from Transformer to control room through cable trench : mtrs

Distance from Control room to Relay Panel through cable trench : mtrs
Additional information :
11.1.12 Erection Flow Chart

11.1.13 Erection Check List
PROJECT :
CUBICLE NO : SIGNAL BOX NO. :
CONTROL BOX NO: FIRE DETECTOR NO.
CONSERVATOR ISOLATION VALVE NO. :
PARTICULARS PARTICULARS
1.0 Erection Oil drain pipe slope 2 to 3 degree Towards cubicle
1.1 Civil work Tightness of flange and bolts
CUBICLE plinth as per approved drawing. External cleaning
Painting red oxide and P.O. red
1.2 Oil pit / Tank 2.2 Pipe connection from cubicle to Oil pit
Sealing of top cover. Weld joint
Termination arrangement of pipe to CUBICLE Aluminium paint at weld joints
Capacity suitable for transformer Fitment of drain pipe to CUBICLE collar
Pipe slope 5 to 10 deg .towards oil pit
1.3 Cubicle 2.3 Conservator Isolation Valve
Check oil drain isolation valve above Mounting as per position marked on
Closed CIV as per Drg. No.
Check N2 isolation valve above CUBICLE Tightness of flanges and bolts
Closed Pump test with one pump
Door opening as per approved Pump test with two pumps
Alignment 2.4 Fire Detector
Tightness of foundation bolts Mounting of fire detectors
1.4 Control Box (CB) Mounting of fire detectors rain guards.
Wall mounting/Frame mounting, alignment 2.5 Earthing
Mounting at eye level Signal box, CUBICLE, Control box & FD
1.5 Signal box (SB) 2.6 Cable Laying
Mounting at working height Control box to signal box FRLS 12 core
Fitment Control box to relay panel FRLS 12 core
1.6 Fire detector (FD) Control box to CUBICLE FRLS 12 core
FD mounting as per drawing Control box to DC-DC convertor 4 core
1.7 Conservator Isolation Valve CIV to signal box FRLS 4 core
Visual crack/damage Control box to DC source FRLS 4 core
Space availability Control box to AC source FRLS 4 core
Valve availability for isolation CUBICLE to AC source FRLS 4 core
2.0 Installation FD to signal box FS 4 core
2.1 Pipe connection from Transformer to Cubicle 2.7 Cable Termination
Weld joint & weld joint fitup Continuity of cable
Internal cleaning, varnishing & coating Crimping quality of lugs
No leakage at 3.5 kg/cm for 1 hour
2
No excess length of cables
Alignment Dressing and glanding
Pipe support at minimum 5 mtrs interval Termination as per
Pipe support alignment Interconnection Drg. No.
11.1.14 Commissioning Check / Site Test Procedure
SR. DETAILS OF CHECKS/TESTS AND DESIRED RESULTS PLEASE √ AFTER

N0. TEST
1.0 READINESS FOR TESTS

1.1 Transformer is out of service and de-energized.
1.2 Test equipments available for simulation of Differential relay, RPRR, Pressure Relief Valve,
Buchholz, Transformer isolation.
1.3 All cables are properly connected as per interconnection drawing No.___________________
operation scheme diagram No._______________________ and terminal screws are
tightened.
1.4 Close the isolation valve on oil drain pipe connected above Cubicle.
1.5 SWITCH ON main power supply 220V DC/110V DC and 230V to control box.
1.6 SWITCH ON main power supply 230V AC to cubicle
2.0 CONSERVATOR ISOLATION VALVE(CIV)

2.1 Unlock the lever, functional test of Limit Switch by moving lever clock-wise.
Alarm ‘CIV closed’ must be activated on control box.
2.2 Re-establish original operating conditions by resetting lever.
3.0 FIRE DETECTORS

3.1 Un- screw the heat sensor, alarm ‘Fire detector trip’ must be activated on control box. Test all
fire detectors individually.
3.2 Re-establish original operating conditions.
4.0 CONTROL BOX

4.1 Functional test “Lamp Test”
4.2 Functional test “Differential relay Trip” (COMMAND TO BE GIVEN BY OPERATING DIFFERENTIAL
RELAY FROM RELAY PANEL.). Signal shall appear on control box.
4.3 Functional test “PRV/RPRR Trip (COMMAND TO BE GIVEN BY OPERATING PRV/RPRR RELAY
FROM RELAY PANEL.). Signal shall appear on control box.
4.4 Functional test “BUCHHOLZ TRIP (COMMAND TO BE GIVEN BY OPERATING BUCHHOLZ RELAY
FROM RELAY PANEL.) Signal shall appear on control box.
4.5 Functional test “TRANSFORMER TRIP (COMMAND TO BE GIVEN BY OPERATING HVCB&LVCB/
MASTER TRIP RELAY FROM RELAY PANEL).Signal shall appear on control box.
4.6 Confirm by operating Transformer protection used in para 4.2, 4.3, 4.4 not interconnected with
any other protection Viz. REF, WTI, OTI etc. expect Transformer Trip protection.
Lamp indication for “Oil Drain Valve Closed” available.
Lamp indication for “Gas Inlet Valve Closed” available.
4.7 Functional test for “Visual/Audio alarm”.
4.8 Functional test for “DC SUPPLY FAIL” visual/audio alarm by isolating DC supply to control box.
5.0 CUBICLE
5.1 Insert locking pin to lock oil drain mechanically. Alarm for “Out of service” must be activated.
5.2 Insert locking pin to lock Nitrogen injection mechanically Alarm for “Out of service” must be
activated.
5.3 Nitrogen Cylinder pressure greater than 135Kg/cm2.
5.4 Adjustment Nitrogen injection pressure as per manufacturer standard setting.
5.5 Tightness test of nitrogen injection valves, hoses, main gas valve, 2 and 3 way ball valves.
SR. DETAILS OF CHECKS/TESTS AND DESIRED RESULTS PLEASE √ AFTER

N0. TEST
5.6 Check sealing of Gas Flow Control Unit is not disturbed.

5.7 Perform ‘Differential relay trip’, ‘Buchholz/PRV/RPRR trip, and ‘Transformer trip, By OPERATING
THE DIFFERENTIAL, Buchholz/PRV/RPRR, HVCB & LVCB/MASTER TRIP RELAY FROM RELAY
PANEL (AUTO PREVENTION MODE).
Lifting magnet Y01 must be activated.
Remove the above connections. Lifting magnet Y01 must be de-energized.
5.8 Perform ‘Fire Detector trip’, ‘Buchholz/PRV/RPRR trip, and ‘Transformer trip, By OPERATING
Buchholz/PRV/RPRR, HVCB & LVCB/MASTER TRIP RELAY FROM RELAY PANEL (AUTO
PREVENTION MODE).Lifting magnet Y01 must be activated.
Press limit switch G03. Lifting magnet Y02 must be energized.
5.9 Release limit switch G03. Lifting magnet Y02 must be de-energized.
5.10 Turn 3 way ball valve in horizontal position (Inspection position. Lifting magnet Y02 must be
energized. Remove wire connections mentioned in 5.8. Lifting magnet Y01 must be de-
energized. Turn 3 way ball valve in “In service” position (vertical).
5.11 Perform ‘Transformer trip’ (BY OPERATING THE HVCB AND LVCB/MASTER TRIP RELAY FROM
RELAY PANEL and operate S02 for ‘ON’ position, Y01 must energize. Keep S02 in ‘OFF’ position
(REMOTE ELECTRICAL MODE).
5.12 Push lever A for operation of Y01 and push lever B for operation of Y02 (LOCAL MECHANICAL,
MANUAL MODE).
5.13 Unscrew the end of the flexible hose clamps of the gas supply fastened to throttle valve and
withdraw the hose.
Activate the extinction release device by withdrawing locking pin 2 and lifting magnet Y02
manually – gas will blow out of hose.
5.14 Alarm for ‘Extinction in progress’ must be activated.
Re- set extinction release device and insert locking pin 2 in test position.
Fasten the end of flexible hose of gas supply to Gas Flow Control unit and check tightness
again.
5.15 Adjust contact on manometer to the actual pressure line. Alarm for “Cylinder pressure low”
must be activated.
5.16 Reset electrical contact in manometer at______kg/cm2 (as per manufacturer standard
setting).
5.17 Visual check of tightness of quick oil drain valve by unscrewing the transparent inspection cover
of oil drain pipe in cubicle. Fix inspection cover.
5.18 Functional test of heater and thermostat operation.
5.19 Set thermostat operation contact at _ _ _ ºc
(as per manufacturer standard setting).
6.0 GENERAL CHECKS

6.1 Cables are well supported at various cable clamps
6.2 All cable glands are properly tightened.
6.3 All screws/bolts of piping are properly tightened.
6.4 Painting of oil drain and Nitrogen pipe line.
6.5 The embedded oil drain pipe from oil pit fits well into the pipe connection collar of cubicle.
6.6 Transformer oil drain valves and Nitrogen Injection valves and Isolation valve above cubicle are
open.
6.7 Main Nitrogen cylinder valve is open.
6.8 Locking pin for oil drain and locking pin for nitrogen release are in operation position.
11.2 Automatic Mulsifire System
11.2.1 Description
This system is widely used for fire fighting of outdoor transformers. Spray type fire protection essentially
consists of a network of projectors and an array of heat detectors used to sense high temperature near
the transformer / reactor to be protected. If the temperature exceeds the set value, the automatic
mulsifire system sprays water at high pressure through a Deluge valve from the pipe network laid for
this system. Fire detectors located at various strategic points are on the surface of the transformer to
control fire on any burning oil spilled over.
11.2.2 Subsystems used to make a complete mulsifire system
a) Main Hydrant
This is used to carry the water to various parts of the switchyard or transformer substation and
forms the backbone of the system. Sturdy corrosion-free pipes and valves are used for this
purpose. The materials should be able to withstand fire for a reasonable duration.
b) Fire Detector
Fire detectors can either be thermocouples or specially designed bulbs which burst when they
experience a high temperature and release any valves or checking device to start the water
supply.
c) Ring Mains and Nozzles

Ring mains, which surround the transformer are provided to feed the water to the nozzles at
various levels. Since the water pressure is high, the ring mains should be designed to withstand
this pressure. Nozzles should be located such that the water spray, in the event of a fire, envelopes
the entire surface of the transformer. The whole system should be periodically checked to detect
any leakages. .
d) Pumps
Pumps are provided to fill the hydrants initially and to maintain its pressure. Pumps driven by
electrical motors are a standard provision; however, the standby pumps should preferably be
diesel engine driven. It is recommended that the main and standby pumps in a pump house be
segregated.
11.2.3 Electrical Safety
As per Powergrid specification, from safety considerations, the following electrical clearances
are recommended between the mulsifier system pipe work and live parts of the transformer to be
protected.
§§ 420 kV bushing 3500 mm
11.2.4 Installation Care
§§ Deluge Valve shall be water pressure operated manual reset type.
§§ Each Deluge valve shall be provided with a local panel from which will enable manual electrical
operation of the valve.
§§ In addition to this, each valve shall be provided with local operation latch.
§§ Test valves shall simulate the operation of Deluge valves and shall be of quick opening type
12 Terminal Connector
12.1 Selection Criteria
Type of Connector (Construction)
a) Bolted type
b) Crimping type
c) Wedge type
d) Welded type
Type of Connector (Functional)
a) Horizontal / Vertical / Through type
b) Rigid / Flexible type (for Tubular Bus)
12.2 Technical Data Required for Design of Connector
a) System Voltage
b) Continuous current rating
c) Short time rating
d) Ambient temperature & limit of maximum temperature rise
e) Visual corona withstand voltage (for connectors of 220 kV and above)
f) Maximum permissible RIV level at a specified voltage (for connectors of 220 kV and above)
g) Size of Busbar & direction of approach
12.3 Design Criteria

a) To carry the desired current safely
b) To withstand the mechanical loads imposed during erection / during short circuit
c) To offer lowest resistance in the current path
d) To limit the visual corona & RIV within permissible level
e) To avoid sharp edges so that busbar does not get damaged during erection / in service
12.4 Tests on Connectors

12.4.1 Type Tests
a) Carried out on three samples of each type
b) Dimensional check & visual examination
c) Short time current test
d) Visual corona withstand test & RIV measurement (for connectors of 220 kV and above)
e) Temperature rise test
f) Resistance Test
g) Tensile test (Slip test)
h) Galvanizing test on bolts & nuts
12.4.2 Acceptance Tests

Carried out on random selected samples during inspection & to be witnessed by customer’s
representative (on 0.5% of quantity)
a) Dimensional check & visual examination
b) Tensile Test (Slip test)
c) Resistance test
d) Galvanizing test on bolts & nuts
12.4.3 Routine Tests:
Carried out on 100% quantity by manufacturers
a) Dimensional Check
b) Visual Examination
12.5 Applicable Standard: IS: 5561
ANNEXURE 2.4
PT 100 Resistance
Temerature Vs Resistance
(BS 1904: 1984 & IEC 751: 1985)
ANNEXURE 2.5
PT 100
Temerature Vs Output Signal
Temperature Range: 0 - 150 oC
Signal Range: 4 - 20 mA
Chapter - 3
Contract Drawings for Power Transformers

Mr. V. M. Varkey - SIEMENS Ltd.
Mr. P. Ramachandran - ABB Ltd.
Mr. Anilkumar Bhatia - CGL
Mr. Shekhar Vora - CGL

CHAPTER - 3
CONTRACT DRAWINGS FOR POWER TRANSFORMERS
1. INTRODUCTION
This part of Manual lists the typical drawings submitted by manufacturer to the customer for approval and
reference. The purpose of these drawings is to ensure that transformers being planned for manufacture meet
the guaranteed technical particulars as per order, functional requirements as per customer specifications and
interfaces at site. The Manual lists up the minimum details required in drawings and can be used as a check list for
manufacturers, customers and consultants while preparing, verifying and approving these contract drawings.
2. LIST OF CONTRACT DRAWINGS
Drawings list should have the revision status and date of submission / approval.
1. Rating & Diagram Plate
2. General Arrangement drawing for Transformer
3. List of Accessories
4. Bill of Materials
5. Foundation Plan
6. Bushing Details
7. Transport Dimensions
8. General Arrangement Drawing of Marshalling Box/ Cooler Control Cubicle
9. General Arrangement Drawing of RTCC panel
10. General Arrangement Drawing of Junction box (if applicable)
11. Tap Changer Control Scheme
12. Cooler Control Scheme
13. Alarm / Trip Indication Scheme
14. Interconnection between DM and RTCC
15. General Arrangement Drawing for Cable Box (If applicable)
16. General Arrangement Drawing for bus duct termination (if applicable)
17. Valve Schedule Plate
3. GENERAL GUIDELINES
a. All drawings shall be “to scale”
b. Drawings can be either in first angle or third angle projection. Angle of projection shall be mentioned in
drawing. Preferred projection is First Angle Projection.
c. Title block shall contain customer reference (Customer name, PO/LOI number), Transformer MVA rating and
voltage.
d. All drawings may be either in A3 or A4 size for easier up-keeping.
e. Drawings shall also be submitted in soft form.
4. MINIMUM DETAILS REQUIRED IN DRAWINGS
4.1 Rating & Diagram Plate

§§ Rating & Diagram Plate drawing shall be in line with the guide lines in CBIP Transformer Manual.
§§ Plate can be made in one part or two. In case of two plates, cross reference shall be given in both
sheets.
§§ Keep blank columns to fill after testing for % Impedance, measured losses, weight schedule and oil
volume for first filling at site. Weight schedule shall contain (a) Core - coil assembly weight (b) Tank &
fittings weight (c) Oil weight (d) Total Weight, (e) Transport weight (f) Net copper weight (g) Net silicon
steel weight (h) Net mild steel weight (i) Type, grade and standard of oil
§§ Transport weight can be either oil filled or gas filled (Dry Air or Nitrogen) depending on transport
limitations & road route survey. Hence, it shall be indicated as Transport Weight (with oil / without oil)
§§ Material of rating plate shall be stainless steel of minimum 1.0 mm thickness.
§§ Location and terminal markings of BCTs.
§§ Diagram plate shall indicate actual physical connections of windings (e.g. line entry of HV, with two
halves in parallel, set of parallel / series windings in two limbs of core etc.)
§§ Provision of special accessories connected to windings, zinc oxide elements across regulating winding,
tie-in-resistor in tap changer, external neutral grounding resistors etc.
§§ In case air cell is provided in conservator, add a note “Conservator is fitted with an air cell”.
§§ CT details like ratio, accuracy class, burden, Knee point etc.
§§ Rating Plate Drawing shall be in English language. In second language on request.
4.2 General Arrangement Drawing

§§ All accessories & fittings can be numbered with standard logic in line with DIN 42513 so that same
number can be used for identical items. (Annexure 3.1).
§§ Approximate Weight & Oil quantity schedule (Weight of core-coil assembly, tank & fittings, weight &
volume of oil for first filling, total weight of completely assembled transformer and transport weight
(gas or oil filled) as per final design.
§§ Minimum electrical clearances (Phase – Phase & Phase – Earth) as per CBIP guidelines / customer
specifications.
§§ Minimum four views (Plan, Elevation, Right hand side & Left hand side view looking from HV side). 3D
views can also be given for additional clarity.
§§ View showing maximum lifting weight / height of core – coil assembly or upper tank as the case may be
and maximum clearance over tank top required for taking out the bushing.
§§ Tank Earth pad details.
§§ Core grounding details through terminal board or bushings suitable for 2 kV AC (one minute) isolation
test. In case of large transformers (100 MVA and above) the core, core clamp connections shall be
brought out independently at tank cover in a terminal box and earthed to ground.
§§ OLTC diverter switch to main tank equalizing details (applicable in case of OLTC only)
§§ Transformer center line (reference line) shall be the center line of rail gauge.
§§ Overall dimensions and maximum dimensions on either side of Transformer center line shall be
indicated.
§§ Show dimensions up to bushing top terminals from rail level for interface between Transformer and
station equipments.
§§ Show the height and other co-ordinates upto bus duct/SF6 duct and cable pot head mounting with a
tolerance of ±10mm
§§ All dimensions to show the height shall be from rail level, until and unless specified in technical
requirement.
§§ Transformer pull out direction shall be marked and make sure that there are no obstructions for pulling
out transformer from the foundation.
§§ Make sure the jacking pad position is not fouling with the rail line.
§§ OLTC conservator shall preferably be at same level as main conservator level.
§§ Buchholz relay shall be accessible for inspection, preferably from tank top.
§§ Accessibility to ladder and from ladder to tank top shall be clear from other accessories and pipelines.
Ladder shall be provided with anti-climbing device.
§§ Positioning of cable box shall not be in the path of transformer dragging out path.
§§ It is preferable to mount the coolers on the transformer tank instead of separate mounting.
§§ Dial of magnetic oil level indicator shall be visible from the ground.
§§ Provision shall be made on tank cover for fixing safety barriers.
§§ If air cell is provided in the conservator, air cell failure indication (by air operated relay or oil sight
window) shall be provided.
§§ Upper filter and sampling valves shall be accessible from ground level. All valves shall be provided with
identification labels.
§§ Rating and diagram plate shall be visible and near to OLTC driving mechanism. Marshalling box with
indicators shall be near to it. Dials of all indicating and protection meters shall be visible clearly when
viewed from the front of transformers.
§§ Following notes and cross reference document numbers shall be given.
§§ Tolerance on weights and dimensions will be ± 5% unless marked separately.

§§ External painting system and shade number e.g. shade number (631 of IS:5), epoxy zinc primer +
epoxy intermediate + polyurethane paint (preferred system)
§§ Document number of Bill of Material for cross reference, if accessories are listed up in a separate
drawing
§§ Drawing numbers of Rating & diagram plate, Valve schedule plate, Foundation plan, Transport
dimension and bushings.
§§ Design features generally meet the statutory, regulatory and safety requirements in terms of
earthing arrangement, danger / warning labels, air clearances and provision of pressure relief
device, gas operated relay and earthquake withstand clamping to foundation.
§§ Terminal Connector shall be arranged by Customer.
4.3 List of Accessories

§§ List of Accessories can be on separate sheets. GA drawing number shall be given as a cross
reference.
§§ Description, Make and quantity of all accessories shall be given.
§§ Items disassembled for transport shall be indicated clearly.
§§ Mercury filled actuating switches shall be avoided in all accessories.
4.4 Bill of Materials

§§ Bill of materials shall be on separate sheets. One or more A4 / A3 sheets can be used. GA drawing
number shall be given as a cross reference.
§§ Description, Make and quantity of all accessories shall be given.
4.5 Foundation Plan

§§ Constructional and fixing details of foundation bolt.
§§ Foundation bolts shall be under the scope of transformer supplier. Grouting of bolt shall be done at the
time of transformer erection for matching purpose.
§§ Load on each support shall be clearly stated.

§§ Transformer Pull out direction shall be marked in line with GA
§§ Foundation bolt shall be part of BOM.
§§ Rail gauge shall be marked in foundation drawing.
§§ Anti-earthquake features in foundation/clamping (in case of transformers for seismic zones).
4.6 Bushings
§§ Bushing shall be as per latest relevant IS/IEC/CBIP specifications
§§ Short time current rating shall be 25 times rated current for 2 second up to 4000 A bushing and 100 kA
for 2 second for bushings above 4000 A as per IS/IEC, or as specified by Purchaser.
§§ Maximum angle of inclination and cantilever strength shall be indicated.
§§ Arcing horns are not recommended for the bushings.
§§ Material of components shall be indicated.
§§ Weight of oil and bushing shall be indicated.
§§ Bushing top terminals shall be marked.
§§ Test tap details shall be shown in bushing drawing.
§§ Creep distance shall be 31 mm / kV for all bushing upto 420 kV in open air. Creep distance is not
applicable for oil to oil to SF6 bushing. Creep distance for bushing inside cable box / bus duct shall be
20 kV / mm minimum.
4.7 Transport Dimensions

§§ Center of Gravity during Transport condition must be clearly marked.
§§ Transport condition (oil filled /gas filled) shall be indicated. In case of gas filled, clearly identify whether
it is Dry air or Nitrogen. Gas filled transport shall be with a positive gas pressure.
§§ Transport weight shall be clearly indicated.
§§ Lifting bollards / Jacking Pads / Lashing lugs and Pulling eyes shall be identified.
§§ Impact recorder location (if applicable)
§§ Direction of transport movement shall be indicated.
4.8 General arrangement Drawing of Marshalling box / Cooler Control Cubicle

§§ Cubicle shall be according to guide lines in CBIP Transformer Manual.
§§ Degree of protection shall be IP:55
§§ Glass window shall be at a level to view the temperature indicators.
§§ Undrilled gland plate for use by customers shall be provided.
§§ External & internal Paint type and colour shade shall be indicated.
§§ Cable and lug size shall be specified along with gland sizes.
4.9 General Arrangement Drawing of RTCC Panel

§§ RTCC panel shall be suitable for IP:41 degree of protection.
§§ External & internal Paint type and colour shade to be furnished.
§§ Not more than two wires shall be taken from any terminal
4.10 General Arrangement Drawing of Junction Box (if applicable)

§§ In case of floor mounted M/Box, a separate junction box shall be mounted on transformer to terminate
all wirings.
§§ Interconnection between junction box to M/Box to be done at site.
§§ Junction box shall be suitable for IP:55 degree of protection
4.11 Tap changer control scheme
Tapchanger
4.11.1 Besides the local and remote electrical control, on-load tap changers, when specified, should be suit-
able for remote electrical parallel control as in clause 4.11.2.
4.11.2 Remote Electrical Parallel Control (Figure 3.1)

§§ In addition to the methods of control as in clause 2, the following additional provision shall be
made.
§§ Suitable selector switch be provided, so that anyone transformer of the group can at a time be
selected as ‘Master’, ‘Follower’ or ‘Independent’.
§§ Necessary interlock blocking independent control when the units are in parallel, shall be
provided.
§§ The scheme will be such that only one transformer of a group can be selected as ‘Master’.
§§ An out-of-step device shall be provided for each transformer which shall be arranged to prevent
further tap changing when transformers in a group operating in ‘Parallel control’ are one tap out-
of-step.
4.11.3 On-load Tapchanger Control Scheme

A. The control scheme for tap changer can be as under:
§§ Non-automatic independent - The scheme used for independent control from local or remote
panel.
§§ Non-auto / automatic independent - The scheme used for independent control with automatic
voltage control relay and line drop compensation as optional. If required, non-auto condition can
be availed.
§§ Non-automatic simultaneous parallel operation - The scheme used for non-automatic simultaneous
parallel operation.
§§ Non-automatic / automatic simultaneous parallel operation - The scheme used for simultaneous
parallel operation with automatic voltage control relay and line drop compensation as optional. If
required, non-auto condition can be availed.
B. General
§§ Local control items shall be mounted inside the on-load tap changer driving mechanism or
marshalling box. Remote control items are to be mounted on remote control cubicle installed in
the control room. All the control items are to be mounted in easily accessible position and clearly
labeled. All control item shall be of best quality and or class most suitable for working under the
conditions specified and shall withstand the variation of temperatures and atmospheric condition
arising under working conditions so also withstand vibrations. All control items shall be wired and
connected as per ‘Schematic Diagram of tap changer control equipment given in Scheme .
4.11.4 Motor
On-load tap changer driving gear Motor shall be of squirrel cage totally enclosed type and shall comply
with Indian Standard IS: 325. It shall be suitable for direct starting and continuous running from 415
volts 3-phase 50 Hz supply. Motor shall be capable of continuous operation at any frequency between
48 and 51.5 Hz together with any voltage within 10 per cent of nominal value. Motor shall have ball or
roller bearing and vertical spindle motor shall have bearing capable of withstanding thrust due to the
weight of the moving parts. The stator windings shall be adequately braced and suitably impregnated
to render them non-hygroscopic.
4.11.5 Overload Protection Relay

The overload protection relay shall be of robust, adjustable triple-pole construction. It should provide
accurate and reliable protection against overload, single phasing, overheating and short circuit. The
relay should be provided with temperature compensating device to off-set the effect of ambient tem-
perature variation. For single phase motor, over-load protection device with feature similar to those of
the three-phase motor as far as these are applicable shall be provided.
4.11.6 Contactors / Relays

Contactors / Relays shall be of robust and compact construction and shall comply with Indian Standard
IS : 2959. The electromagnetically operated air break type contactor with sufficient number of con-
tacts shall be suitable for mounting on a vertical supporting structure. The contactors shall be suitable
for operation at 110 Volts A.C.-15 per cent to + 10 per cent 50 Hz. Main and auxiliary contacts of con-
tactor shall be suitably rated. For sufficient long life, these contacts shall be break type and shall make
contacts practically bounce-free.
4.11.7 Control Supply Transformer

The control supply transformer shall be single phase having ratio 415/55-0-55V. It’s insulation shall be
suitably impregnated to render it non-hygroscopic.
4.11.8 Control Selector Switches

All the control selector switches shall be of robust and compact construction and shall comply with
Indian Standard IS : 4064 and 4047. The control switches shall be suitable for on-load switching of re-
sistive and inductive loads. The switches shall incorporate multi air break type wiping contacts housed
in an assembly of packets moulded from anti tracking material. The knob of the handle of the switch
shall be suitably designed so that while operating a firm grip is obtained.
4.11.9 Remote Tap Position Indicator

Remote tap position indicator mounted on remote control panel shall show accurately same tap posi-
tion as indicated by local tap position indicator on on-load tap changer. The remote indication can be
by means of a digital indicator. Transmitter switch in the driving gear shall be make before break type.
This switch in the driving gear shall be mounted in accessible position so that it can be cleaned and
maintained regularly. The remote indicator mounted on control panel shall not be affected by normal
auxiliary voltages supply variation.
4.11.10 Indicating Lamp and Indication Circuit Diagram

Necessary indicating lamps provided shall be of low watt consumption and of filament type or Neon or
LED type. Lamps shall be of such construction so that these can be replaced very easily. Typical Indica-
tion Circuit diagram for RTCC panel is attached as Fig. 3.2.
4.11.11 Space Heater

Space heater of adequate capacity and robust construction shall be provided inside each control cabi-
net to prevent moisture condensation. Space heaters shall be rated for 240 volts 1 phase, 50 Hz sup-
ply. Heater shall be complete with miniature circuit breaker. Mounting of the heater and its location
shall not cause localized intensive heating of control equipment and wiring.
4.11.12 Wiring
All the wiring shall be carried out for motor circuit with 1100 volts grade PVC insulated stranded copper
conductors of size 2.5 sq mm and for control circuit with 650 volts grade PVC insulated copper conduc-
tor of size 1.5 sq mm suitable for tropical atmosphere. All wiring shall be in accordance with relevant
IS. Engraved core identification ferrules, marked to correspond with the wiring diagram shall be fitted
at both ends of each wire. Ferrules shall fit tightly on the wires and shall not fall off when the wire is
removed. All wiring shall be terminated on terminal blocks through suitable lugs. Insulated sleeves
shall be provided at all the wire terminations. All wiring shall be neatly bunched and cleated without
affecting access to equipment mounted within the cabinet. One piece moulded 600 V grade terminal
blocks complete with insulation barriers, terminal studs, washers, nuts and lock nuts shall be used.
Terminal blocks shall be numbered for identification and grouped according to function. 10 per cent
spare terminal blocks for control wire termination shall be provided on each panel. Terminal board rows
should be spaced adequately apart to permit convenient access to wires and terminations. Terminal
boards shall be so placed with respect to the cable gland plate (at a minimum distance of 70 mm) as
to permit satisfactory arrangement of multi core cable tails without undue stress or bends. Opening of
door should not disturb or stress the wire termination.
4.11.13 Voltage Regulating Relay

(i) Introduction: Voltage Regulating Relay is used for regulating the secondary voltage of power
transformers with on-load tap changers. The required dead band settings are set by setting the
nominal value, and lower and upper levels independently. The time delay setting on the front
panel eliminates the relay operations for momentary fluctuations of the regulated voltage thus
reducing the number of operations of the tap changer. “ When the regulated voltage falls below
the specified under voltage limit, the control relays are automatically blocked, i.e., there is no
voltage correction, and a pair of contacts is made available for alarm.
(ii) General Description: Voltage regulating relay should be designed for maximum operational
simplicity for regulating the secondary voltage of power transformer with on load tap changers.
The dead band (band width) can be set by setting the nominal value adjustment (NVA) to the
required value “110 V + 10 per cent”.
The desired time delay can be set on the front panel and the control action will take place only if the
voltage continues to remain outside the dead band after the time delay has elapsed. For voltage
corrections requiring more than one tap change, time delay is initiated again before further tap
change. The relay is reset automatically after the voltage is brought within the selected dead band.
For repeated short duration voltage fluctuations on the same side of the dead band, the time delay
is effectively reduced to provide a voltage time integral response of the regulator. Operation of the
Raise Control relay is automatically inhibited when the voltage falls below the specified under-
voltage limit. One pair of normally open relay contacts are provided to effect the tap changer,
Raise and Lower operation and to trigger an alarm in case of under voltage conditions.
(iii) Specifications
Auxiliary Supply : -15% / + 10% 50 Hz
PT Supply (regulated Voltage) : 110 V ± 10 per cent 50 Hz
Sensitivity (Dead Band) : Nominal value adjustable (NVA)
and Nominal Value Range between + 0.75 to + 2.5 per cent
Time Delay Setting: Fixed, i.e., (Voltage independent) time delay continuously adjustable from 10
to 110 secs.
Time Delay Resetting: Instantaneous resetting with voltage deviation occurring in opposite
direction.
Under Voltage Blocking: Internal blocking at 80 per cent of regulated value. Restoration at 85 per
cent of regulated value.
Control Relays: One pair of normally open potential free contacts of suitable rating.
Control Operation: Single pulsed operation of sufficient duration to initiate tap changer.
Operating Temperature : – 5° to + 50°C
Option: Line drop compensator with resistive and reactive compensation of either polarity up to
20 per cent adjustable in steps or continuously and suitable for operation with 1 Amp. current
transformer. If required suitable interposing current transformer to be used to get 1 Amp.
Secondary current.
1 pair of NC (UV) contacts provided.
4.11.14 Line Drop Compensator (LDC) : Description

i. The Line Drop Compensator is an optional unit designed to match with the Automatic Voltage
Regulator Relay. The unit is housed in the same enclosure or separately mounted.
The voltages at the generating end and at the receiving end are not the same due to the drop across
the line. The LDC is used to compensate for this line drop, and the amount of compensation required
is calculated as a per cent of the nominal voltage knowing the length of the line, its resistance/unit
length, its reactance/unit length and the rated current, and set on the front panel.
The line current is stepped down to 1 Amp. & fed to the LDC. The resistive and reactive drops are
simulated by having 90° phase shifted voltage and their polarity selected by polarity switches. The net
compensation is then fed to the stepped down PT voltage.
ii. Specifications
Resistive Compensation: 0-20 per cent of the regulating value continuously adjustable.
Reactive Compensation: 0-20 per cent of the regulating value continuously adjustable.
Input Rated Current: 1 Amp. 50 Hz.
Power Consumption: As required (CT burden will depend on power consumption).
Accuracy : 10 per cent.
Max. Overcurrent : 50 per cent of rated current (1.5 Amp.)
Polarity Selection : Both positive and negative compensation.
iii. Operating and Connection Requirements

Connection to the LDC unit are made through the rear panel terminals. The line current is stepped
down to 1 Amp. 50 Hz and fed to the LDC. The net compensation is fed to the AVR circuit internal
or external connections.
The required amount of percent R and per cent X compensation can be set on the front panel of
the LDC. The polarity selector switches provide both positive and negative compensation. The per
cent R and per cent X settings can be calculated from the following formulae:
√ 3*IL*RL
Per cent R = x 100 per cent
Per cent X = x 100 per cent
Where, IL = the primary rated current of the line.
VL = the voltage between lines of the power transformer.
XL = the line reactance in ohms/phase.
RL = the line resistance in ohms/phase.
Note : When LDC unit is not to be used, keep per cent R and per cent X settings to Zero, i.e., on
minimum position.
4.11.15 Local Electrical Operation

This is possible only in the independent position. Set the switch ‘S32’ to Local position in D.M.
Box. When switch ‘S32’ is kept on Local Mode, the control supply is made available to the Raise/
Lower switch in D.M. Using the Raise/Lower switch, Local Electrical Operation can be carried
out.
4.11.16 Remote Electrical Operation
Remote Electrical Operation is carried out as follows :
Select one Transformer as “Master’ and others as its ‘Followers’. Then control supply will be
tapped from D.M. Box to RTCC panel. Through the S/W S5 in RTCC1, which is set at ‘Master’
mode the Control supply is passed on to S/W S40 in D.M.1 which is an Odd/Even type of S/W.
Its every 2nd position is linked e.g. 1, 3. 5. 7. 9. 11. 13. 15, 17 etc. This is to reduce number of
interconnecting wires between RTCC panels. Suppose, Transformer 1, which is set as a “Master’,
is at Tap 1, then through its odd/Even S/W in D.M.1, the Control Supply now goes to RTCC2 and
from there it goes to Odd/Even S/W S40 of D.M.2. If the D.M.2 is also at Tap 1, then the control
supply will be returned to RTCC2 set at “Follower’ mode and energizes Contactor K11 in RTCC2.
Normally Open Contact of this K11 is wired up in RTCC1 and once it becomes closed, supply is
available at Auto/Manual S/W S9, in RTCC1.
If the S/W S9 is set at Manual mode, then thro’ Push Button S1 or S2 Raise/ Lower operation is
carried out. S1 will energize Contactor K4 for Raise tap and S2 will energize K5 for Lower contactor.
Once the Raise or Lower Contactor in Master RTCC is picked up, it will extend the command to
Follower RTCC to Raise or Lower Contactor and hence tap will be changed in both Transformers
simultaneously. If the Tap change operation is not completed within prescribed time duration,
then the Timer is energized in D.M. Box which indicates Tap Change incomplete indication and
D.M. MCB is tripped. Contactor K6 in RTCC will act as a Blocking relay which will block the Tap
Change operation in case both RTCC’ s are not at same Tap position. In that case the timer K29 is
picked up and will indicate Tap change Out of step indication.
Remote Auto Operation:
Remote Auto Operation is carried out as follows:
Set Auto/Manual S/W S9 on Auto Mode. The Raise/Lower Tap position decision is taken care by
Automatic Voltage Regulator. As per its instruction either K4 or K5 is energized and then it gives
command to Follower RTCC accordingly.
4.12 Cooler Control Scheme
Cooler control systems follow different practices and vary depending upon customer specs, manufacturers
standard practices, however, standard control schematic will allow end customer to operate cooler control
with more ease and similar representation of schemes and ease of maintenance. For cooler control sche-
matics, standardisation of schemes will lead only to way of representation and mode of control like Auto/
Manual or Local/Remote. Typical Cooler Control Circuit is attached as Fig. 3.3.
The standard methods for drawing are as follows:
4.12.1 Index
Fig. 3.1: Type of symbols
A. Device Designation
Terminals to be defined in the following way:

All terminal number strips will start with letter “ X” and prefixed by “ –“. Individual terminal number
will follow with “: “.
e.g. –X1: 12.
All contactors and Timers to be designated starting from letter “K” and prefixed by “-“.
e.g.-K5.
All MCBs and Phase failure relays to be designated with letter “F” and prefixed by “-“.
e.g.–F1.
All control switches, sequence selector switches and push buttons to be designated with letter
“S” and prefixed by “-“.
e.g.–S2.
AVR and annunciators to be designated with letter “A” and prefixed by “-“.
e.g. -A1.
Indicating Lamps to be designated with letter “H” and prefixed by “-“.
e.g. –H1.
Instruments like signal converter or Transducers, power supply module etc to be designated by
letter “U” and prefixed by “-“.
e.g. –U2.
MPCB (Motor Protection Circuit Breaker) to be designated by letter “Q” and prefixed by “-“.
e.g. –Q10.
B. Ferruling and Signal linking

Where ever ferruling is required, it should be cross ferruling, indicating connection point near
connection and originating point after it for easy tracing in the event of fault finding.
e.g.
Fig. 3.2
Where control schematic drawings are prepared in A3 or A4 size sheets, signal linking has to be
done in following fashion:
Signal designation to start with letter “L” followed by signal number followed by the destination
sheet and column in which destination is located. e. g.. --|L1/5.2. In this example, signal L1 is
terminated on 5th sheet and in 2nd column.
C. Designation of Devices used in proposed scheme

Devices used in the attached drawings are:
Sr. Instrument Purpose Location
No.
1 K4 Impulse relay for Raise Tap command RTCC
2 K5 Impulse relay for Lower Tap command RTCC
3 K6 Blocking Relay RTCC
4 K11 Parallel Operation ready relay RTCC
5 K29 Timer for Out of step indication RTCC
6 S1 Push button for Raise Tap RTCC
7 S2 Push button for Lower Tap RTCC
8 S3 Push button for Emergency stop command RTCC
9 S5 Master/Follower/Independent Selection Switch RTCC
10 S9 Auto/Manual Selection Switch RTCC
11 S40 Odd/Even Switch D.M.
4.13 Alarm and Tripping Scheme

As per drawing (Figure 3.4).
4.14 Interconnection between DM & RTCC

As per drawing (Figure 3.5).
4.15 General Arrangement Drawing for Air filled Cable Box (If applicable)
§§ Number & size of cables/phase as per customer specification shall be indicated.
§§ Cable box shall be provided with silica gel breather.
§§ Provision shall be made to move the transformer without disturbance keeping cable box in position.
§§ Earthing links shall be provided between cable box, disconnecting chamber and cable gland plate.
§§ Minimum one meter distance shall be provided from gland plate to bus bar.
§§ External Painting procedure of tank shall be applicable for both inside and outside of cable box.
§§ In case of ground mounted cable box support, same shall be in line with foundation plan.
§§ Cable Lugs and glands are not part of transformer supply.
§§ All bus bars and flexible inside the cable box shall be tin plated.
§§ Epoxy or porcelain insulator shall be used inside the cable box for bus bar support with minimum
creepage distance of 20mm/kV
4.16 General Arrangement Drawing for Bus Duct termination (if applicable)
§§ Position of bus duct mounting flange shall be dimensioned from transformer center line and from rail
level with a tolerance of ± 5mm.
§§ Electrical clearance boundary shall be indicated so that bus duct (supplier scope) should not enter into
the minimum clearance zone.
§§ Bushing top terminal details shall be clearly indicated for further connection by bus duct supplier.
§§ Drain plug shall be provided at the bottom most point of bus duct fixing flange on transformer.
4.17 Valve Schedule Plate

§§ All valves, air vents and drain plugs shall be shown in valve schedule plate.
§§ Table shall contain, type, size, material and quantity of valves.
§§ Open and close indication of each valve at service, transport and oil filling should be marked.
§§ In case of water cooled Transformers, a heat exchanger single line diagram is required.
5. Typical Cable Schedule is enclosed for reference (Annexure 3.2).
6. Over and above, following drawings may also be generated if required:

1. Cooler Diagram plate
2. GA of common marshalling box (for 1-phase transformers)
3. GTP (Technical data)
4. Neutral formation Drawing (for 1-phase transformers)
5. Combined foundation Drawing (for 1-phase transformers)
6. Test plan/procedure.
7. Others – Oil filling instruction, nitrogen fire protection system etc. if applicable.
8. QAP, FQP, TTR, Erection manual shall be submitted.
9. Disposal plate
10. Roller Drawing
11. Terminal Connector details (if applicable)
ANNEXURE 3.1
Code for Transformer Accessories in line with DIN42513
1. AA001~XXX Valves
2. AB001~XXX Drain plugs
3. AC001~XXX Radiators, Oil to water heat exchangers, oil to air heat exchangers
4. AE001~XXX Rollers, skid base, foundation bolts, anti-earthquake locking arrangements, refilling device for
dry air
5. AN001~XXX Cooling fans
6. AP001~XXX Cooling pumps
7. AT001~XXX Dehydrating breather, Air cell
8. BB001~XXX Lower tank, upper tank, cover, conservator for main tank, conservator for tap changer
9. BQ001~XXX Thermometer pockets, detachable ladders, jacking pad, lifting lugs, lashing lugs, pulling eyes,
hook for safety belt, bracket for conservator, cooler pipe
10. BR001~XXX Pipes
11. BZ001~XXX Manholes, hand holes, inspection windows, terminal for tank earthing, rating plate, labels, valve
schedule plate, caution plate, air cell installation notice
12. CF001~XXX Accessories (protective, monitoring) bushings, tap changer, control cubicle, motor for tap
changer, impact recorder, terminal connectors.
ANNEXURE 3.2
Typical Cable Schedule
M.BOX Page To MOTOR DRIVE(DM) Page CABLE DETAIL Details
Ter.Strip Terminal Ter.Strip Terminal
X4 9 -- X1 2 4Sq.mm,4core cable 3 Ph supply for OLTC Motor
X4 10 -- X1 3
X4 11 -- X1 4
X4 5 -- X1 6 2.5Sq.mm,2 core Cable 1 Ph AC Supply for Heater ckt
X4 6 -- X1 7
M.BOX Page To RTCC1 Page

X5 1 -- X2 8 2.5Sq.mm,19 core cable TO RTCC Panel For LED
for indication Indicators
X5 2 -- X2 9
X5 3 -- X2 10
X5 4 -- X2 11
X5 5 -- X2 12
X5 6 -- X2 13
X5 7 -- X2 14
X5 8 -- X2 15
X5 9 -- X2 16
X5 10 -- X2 17
X5 11 -- X2 18
X5 12 -- X2 19
X5 64 -- X2 20
M.BOX Page To RTCC1 Page

X5 13 -- X2 27 2.5Sq.mm,16 core cable To RTCC Annunciator Window
for Annunciation
X5 14 -- X2 28
X5 15 -- X2 29
X5 16 -- X2 30
X5 17 -- X2 31
X5 18 -- X2 32
X5 19 -- X2 33
X5 20 -- X2 34
X5 21 -- X2 35
X5 22 -- X2 36
X5 23 -- X2 37
X5 24 -- X2 38
TJB Page To RTCC1 Page

X5 33 -- X5 14 2.5Sq.mm,24 core cable 4-20mA i/p TPI to A-Eberle
for A-Eberle RELAY
X5 34 -- X5 15
X5 36 -- X1 24 4-20 mA i/p to TPI indicator
X5 37 -- X1 23
X5 11 -- X1 40 4-20 mA i/p to OTI/WTI
indicator
X5 12 -- X1 26
X5 19 -- X1 41
X5 20 -- X1 27
X5 27 -- X1 42
X5 28 -- X1 28
X5 66 -- X1 38
X5 67 -- X1 39
X5 8 -- X5 7 4-20mA i/p HV-WTI to
A-Eberle from Lumacense
X5 9 -- X5 8
X5 16 -- X5 9 4-20mA i/p LV-WTI to
X5 17 -- X5 10
X5 24 -- X5 11 4-20mA i/p TV-WTI to
X5 25 -- X5 12
X5 64 -- X5 13 4-20mA i/p OIL to A-Eberle
from Lumacense
X5 65 -- X5 13A
M box Page To RTCC1 Page

X5 65 -- X5 42 2.5Sq.mm,12 core cable Binary I/p to A-Eberle
for A-Eberle RELAY
X5 66 -- X5 18
X5 67 -- X5 20
X5 68 -- X5 19
X5 69 -- X5 21
X5 70 -- X5 22
X5 71 -- X5 23

X2 123 X5 1 2.5Sq.mm, 2 core cable CT i/p from LDC CT to
for A-Eberle RELAY A-Eberle
X2 124 X5 2
X61 3 -- X5 38 2.5Sq.mm,4core cable Fan & Pump start from

for A-Eberle relay A-Eberle
X61 6 -- X5 39
X61 12 -- X5 38
X61 9 -- X5 40
DM Page To RTCC1 Page

X1 9 -- X1 1
X1 10 -- X1 2
X1 12 -- X1 3 2.5Sq.mm,19 core cable TAP RAISE & LOWER FROM
for A-Eberle relay a-Eberle
X1 13 -- X1 4
X1 14 -- X1 5
X1 16 -- X1 30 Emergency stop
X1 33 -- X5 41 Binary i/p to A-Eberle OLTC
Loc /rem
X1 34 -- X5 28
X1 35 -- X5 29
X1 36 -- X5 27
CRP Page To RTCC1 Page

X4 15 2.5Sq.mm,2 core cable PT supply Y-B to A-Eberle
for A-Eberle relay
X4 16
M.BOX Page To TJB Page

X5 25 -- X5 1 2.5Sq.mm,24 core Cooler control
cable for M.BOX to TJB interconnection M.Box &
X5 26 -- X5 2
interconnection RTCC
X5 27 -- X5 3
X5 28 X5 4
X5 53 -- X1 41 Buchholz,PRD,PNRV & Fire
detector signals
X5 54 -- X1 42
X5 55 -- X1 43
X5 56 -- X1 44
X5 57 -- X1 45
X5 58 -- X1 46
X5 59 -- X1 47
X5 60 -- X1 48
X4 7 -- X4 3 1 Ph. 240V ac supply
X4 8 -- X4 4
X4 1 -- X4 5 220V DC supply Lumesense
X4 2 -- X4 6
X4 1 -- X4 1 220V DC Supply RTD
X4 2 -- X4 2
DM Page To RTCC1 Page

X1 17 -- X2 1 2.5Sq.mm,12 core common
cable from DM to RTCC
X1 18 -- X2 7 OLTC motor Trip
interconnection
X1 19 -- X2 6 TC Supply healthy
X1 20 -- X2 2 Tap changer In progress
X1 21 -- X2 4 OLTC in Local
X1 22 -- X2 5 OLTC in Remote
X1 24 -- X2 3 Tap changer incomplete
Fig. 3.1 (a): Typical Parallelling Circuit Diagram - Master Unit
141
142
Fig. 3.1 (b): Typical Parallelling Circuit Diagram - Follower Unit

Fig. 3.2 (a): Typical RTCC Indication Signals

144
Fig. 3.2 (b): Typical Indication Signals for Customer Panels

Fig. 3.2 (c): Typical Indication Signals to RTCC
145
146
Fig. 3.3 (a): Typical Supply Changeover Circuit

Fig. 3.3 (b): Typical Control Circuit for Fan and Pump Group – 1
147
148
Fig. 3.3 (c): Typical Power Circuit for Fan and Pump Group – 2
Fig. 3.3 (d): Typical Control Circuit for Fan Group – 1
149
150
Fig. 3.3 (e): Typical Control Circuit for Fan Group – 2

Fig. 3.3 (f): Typical Control Circuit for Fan Group 1 & 2
151
152
Fig. 3.3 (g): Typical Control Circuit for Pumps

Fig. 3.3 (h): Typical Indication Signals

Fig. 3.3 (i): Typical Indication Signals

Fig. 3.3 (j): Typical Heater and Lighting Circuit
155
Fig. 3.3 (k): Typical Device Configuration

Fig. 3.3 (l): Typical Device Configuration

Fig. 3.4 (a): Typical Alarm and WTI Circuit

Fig. 3.4 (b): Typical Trip Circuit

160
Fig. 3.4 (c): Typical Winding and Oil Temperature Signals

Fig. 3.4 (d): Typical Tap Position Signals

Fig. 3.5 : Typical OLTC Schematic Diagram

Chapter - 4
STANDARD MANUFACTURING QUALITY PLAN (MQP)

Mr. S. K. Negi - GETCO
Mr. M. M. Goswami - POWERGRID
Mr. Y. V. Joshi - GECO
Mr. Krishnan - Mahindra Intertrade
Mr. Gautam Bhatia - ENPAY
Mr. Baghel - ATSA Conductors
Mr. Bharat Tolia - Bharat Corrub
Mr. R S Thakkar - GETCO

CHAPTER - 4
STANDARD MANUFACTURING QUALITY PLAN (MQP)
It is a contract document between customer and supplier to express commitment for delivery of transformer as per
agreed technical specification and match the type tested design.
Over a period of time as the transmission grid has grown leaps and bounds, with HVDC and 765 kV AC network,
this commitment document is gaining importance, because of rise in transformer failure rate and causing anxiety to
maintain uninterrupted supply for consumer and industry. Customer always wishes that transformer manufactured
and delivered must perform defect free service for its “specified design life”. It is always a challenge for supplier
(manufacturer) to keep consistency in material used and manufacturing process, which are the main cause for variation
in quality of transformer. While customer practically cannot monitor them and not expected to do so, manufacturers
are on their toes to offer cost competitive and cost effective product. The cost of material plays an important role,
considering the fact that majority of parts and components like bushing, OLTC, tank body, radiators, insulation, copper,
core material etc. are outsourced. The selection of material, its grades / type and design philosophy ultimately decide
the loss capitalization figures of final product. On the manufacturing process front, seamless integration of parts
/ components through mechanical and electrical design is the prerequisite. The change in sub-venders and skilled
manpower time to time at factory also require due diligence to control and maintain the consistency of manufacturing
process. Therefore a “balanced view“ is needed to manufacture and deliver ideal Transformer meeting contract
specification and match type tested design.
It is evident from above background that there is need of mutually agreed manufacturing quality plan (MQP). Apart
from primary objective to have ideal transformer as per customer wish as explained above, the major benefit of MQP
would be timely delivery and any conflict shall be address upfront, so that manufacturing could take place uninterrupted
in a faithful manner. The role of design review is important to provide all necessary inputs for structuring the MQP.
It is proposed in this power transformer standardisation manual to have MQP covering following elements:
1. Material quality and characteristics.
2. Stage inspection of material.
3. Stage inspection and manufacturing process.
4. Routine and Acceptance tests.
5. To capture “Signature values “.
6. Product dimension and physical condition before dispatch.
It is equally very important that Transformer is manufactured in a dust free clean environment with humidity control.
Any compromise on this aspect will have adverse effect in expected design life of Transformer, however good is the
quality of material used.
Standard Manufacturing Quality Plan (MQP) has been designed in a manner to share the responsibility depending upon
the source of supply, testing, location and criticality of test for the performance of Transformer. Responsibility of sub-
vendor is important for testing of raw material and components (P), but manufacturer has to play a role of verification
(V) as they have to integrate them for actual design of transformer. Similarly, responsibility of manufacturer is crucial
for routine tests (P) but customer has to actively witness (W) these tests to ensure that results are complying the
contract requirements and design review data.
166
Sr. Item/Components List of Tests Sampling Reference / Acceptable Value Category of Reponsibility*
No. rate Standard
Sub Manuf- Customer
Vendor acturer
A Raw Material & Components
1 Winding Conductor 1. Visual & Dimensional check of Bare One sample IS 1897 Bare conductor P V W
(PICC)/ (CTC)/ Lead Conductor. Thickness & width of bare per type per IS 13730 Width /thick (mm) Tolerance (in ± mm)
wires conductor, Covered width & thickness lot IS 7401 Up to 3.15 - 0.03
3.16 to 6.30 - 0.05
6.31 to 12.5 - 0.07
12.51 to 16 - 0.10
> 16 mm - 0.10
Insulated conductor
Covering thick(mm) Tolerance (%)

0.25 to 0.5 - -10
0.51 to 1.25 - -7.5
Over 1.25 - -5
2. Resistivity at 20 deg.C IS 13730 For annealed conductor P V --
0.01727 ohm/mm2 / m(max) at 20 deg
For half hard conductor
0.01777 ohm-mm2 / m (max)
3. Insulation for bunched IS 13730 As per approved drawing P V W
conductor
a). No. of conductors.
b). Thickness & width of bare
conductor, Covered width &
thickness
c). Voltage test between strands
4.Tesile strength and elongation test IS 7404 Thickness tensile stregth elongation P V --
IS 13730 (mm) (Nm/m2) %
Up to 2.5 205-265 30 min
>2.5-5.6 205-255 32 min
5. Hardness test IS 7404 Max hardness should be RF 65, when measured P V --
IS 13730 in Rockwell ‘F” scale
6. 0.2% Proof strength of work hardened IS 7404 As per design requirement P V --
conductor IS 13730
* Category of Responsibility: P - Actual Test Performance V - Verify and Accept W - Witness Actual testing, verify and accept
No. rate Standard
Sub Manuf- Customer
Vendor acturer
7. Radius of corner of bare conductor IS 7404 Thikness (mm) P V W
IS 13730 Over/Upto Corner Radius(mm)
Up to 1.0 - 0.50
1.01 to 1.60 - 0.50
1.61 to 2.24 - 0.65
2.25 to 3.55 - 0.80
3.56 to 5.60 - 1.00
2 Kraft Insulating 1. Visual check & Measurement One sample IEC 60554- 1. Paper to be smooth, unglazed surface & P V --
Paper of Thickness per type per 3-1 free from dust particles
2. Density lot IEC 60554- 2. 0.8 ±0.05 gm/ cm3
3. Substance (grammage) 3-5 3. Thick (µm) Sub (g/cm3) Tolerence
IEC 50 40 10
60554-2, 65 52 05
Methods of 75 60 05
Test 90 72 05
4. Moisture Content 4. 8 % max
5. Tensile Index MD 5. 93 NM/gm (min)
6. Tensile Index CD 6. 34 NM/gm (min)
7. Elongation at Break MD 7. NA
8. Elongation at Break CD 8. NA
9. Electric Strength in Air 9. NA
10. Ash Content 10. 1 % max
11. PH of Aqueous extract 11. 6 to 8
12. Conductivity of Aqueous 12. 10 mS/m (max)
extract
13.Air Permeability 13. 0.5 to 1.0 µm/Pa.s
14.Tear Index MD 14. 5 mN m2 /g (min)
15.Tear Index CMD 15. 6 mN m2 /g (min)
16. Water Absorption (Klemn 16. 10 %
Method)
17.Heat Stability 17. Type test report
a.) Reduction of Degree of
Polymerization
b.) Reduction of Bursting
Strength
c.) Increase of Conductivity of
Aqueous extract.
167
168
No. rate Standard
Sub Manuf- Customer
Vendor acturer
3 CRGO Laminations Check following documents Each Lot IS 3024 As per approved design P V --
(a) Invoice of Supplier IEC 60404
(b) Mill’s Test certificate ASTM 4343
(c) Packing List
(d) Bill of Lading
(e) Bill of Entry
Check points:
1. Visual, Dimension & Thickness 1. Visually defect free, as per design
One sample requirement
2. Cutting Burr per lot 2. Less than 2 micron burr
3. Bend / Ductility test 3. As per IS 649

4. Surface insulation resistivity check 4. 10 Ω cm2 min average
05 Ω cm2 min individual
5 Aging test (type test) 5. 4 % max increase in specific measured loss
6. Test on stacking factor 6. As per table no. 4 of IS 3024
7. Test for specific Watt loss test One sample IS 3024 Losses as per grade of CRGO lamination used -- P V
from
offered lot
No. rate Standard
Sub Manuf- Customer
Vendor acturer
4 Pre-compressed 1. Visual & dimensional check, thickness, One sample IEC 60641- (1) No surface defects P V V
Press Board width & length/. of each size 3-1
2. Apparent Density per lot IEC (2) Up to 1.6 mm TK -1.0-1.2
60641-2, >1.6-3 mm TK -1.1-1.25
Methods of >3-3.6 mm TK -1.15-1.30
Test >6-8 mm TK -1.2-1.3
3. Compressibility C (3) Up to 1.6 -10 %; >1.6-3 mm - 7.5 %
>3-3.6 mm - 5 %; >6-8 mm TK -4 %
4. Reversible part Compressibility (4) Up to 1.6 -45 %; >1.6-3 mm - 50 %
>3-3.6 mm - 50 %; >6-8 mm TK -50 %
5. Oil Absorption (5) Up to 1.6 mm TK -11 min
> 1.6-3 mm TK - 9 min
> 3 - 3.6 mm TK -7 min
> 6-8 mm TK - 7 min
6. Mositure Content (6) 6 % max
7. Shrinkage MD, CD & PD (7) MD - 0.5 % max, CD- 0.7 % max, Thick -5
% max
8. pH of aqueous extract (8) 6-9 for solid boards
9.conductivity of aqueous extract (9) Up to 1.6 - 5 max (mS/m)
> 1.6-3 mm - 6 max, > 3-3.6 mm - 8 max
> 6-8 mm TK - 8-10 max
10. Electric Strength in Air (10) Up to 1.6 - 12 kV/ mm
> 1.6-3 mm - 11 kV/mm
> 3-3.6 mm - 10 kV / mm
> 6-8 mm TK - 9 kV/mm
11.Electric Strength in Oil (11) Up to 1.6 - 40 kV/ mm
> 1.6-3 mm - 35 kV/mm
> 3-3.6 mm - 30 kV / mm
> 6-8 mm TK - 30 kV/mm
12. Ash Content (12) 1 % maximum
MD CD
13. Elongation MD, CD (13) Up to 1.6 - 3 % 4 %
>1.6-3 mm - 3 % 4 %
>3-3.6 mm - 3 % 4 %
>6-8 mm TK -3 % 4 %
14. Tensile strength MD, CD
15. Ply Bond Resistance
16. Flexural strength MD, CD (Laminated
Boards)
***TC --- Test Certificate PD--> Perpendicular Direction CD--> Cross Direction
169
170
No. rate Standard
Sub Manuf- Customer
Vendor acturer
5 Permawood 1. Visual & dimensional check, thickness, One sample IS 3513 1. Shall be free from surface defect P V --
width & length. of each size IS 1708
2. Density per lot IS 1736 2. 0.8 to 1.3 gm/cc
3. Moisture content IS 1998 3. Max 7%
4. Oil Absorption at 90 °C 4. Min 5%
5. Electric Strength at 90 °C 5. Min 60 KV
6. Tensile strength 6. Min for LD - 700 KV /cm2
7. Compressive strength test 7. Min for LD - 1400 KV /cm2
8. Shear strength age-wise 8. Min for LD - 450 KV /cm2
9. Thickness 9. Thikness (mm) Tolerance (+/- mm)
10 to 25 - 1.2
26 to 50 - 1.4
51 to 150 - 2.0
6 Porcelain Bushings 1. Visual & dimensional check. 100% IS 2099 1. As per approved drawing. P V --
(Hollow) 2. Power frequency voltage withstand test 2. As per IS 2099
As per IS/
IEC
7 Polyster Resin 1. Visual Check Each lot IS 15208 1. Free from visual defect P V --
Impregnated Glass 2. Verification of shelf life 2. 12 months
Fibre Tape 3. Thickness 3. 0.25 to 0.35 mm (± 0.07)
4. Width 4. 20 to 50 mm (± 2)
5. Tensile Strength 5. Min 200 N/mm
6. Resin Content 6. 27 (± 3%)
7. Softening point of resin 7. Max 200 °C
8 Synthetic Rubber 1. Visual check, thickness, length, width One sample IS 4253 1. Free from surface deffect P V --
Bonded Cork sheet 2. Hardness per lot 2. 70 ± 10 IRHD
(SRBC) 3. Compression set 3. 85 % max
4. Side flow under compression 4. NA
5. Tensile strength 5.1550 kpa (min)
6. Flexibility 6. Should be satifactory when bent though
1800 round the material of diameter three
times the thickness of specimen.
7. Compressibility 7. 25-35 %
8. Recovery 8. 80 % min
9. Aging in Oil-Finish, Flexibility & change 9. Change in volume 15 % max for 70 hours at
in volume 100 deg c in oil
10. Ph value 10. 5-8.5
No. rate Standard
Sub Manuf- Customer
Vendor acturer
9 Condenser Bushing Routine Test 100% IS 2099 P W
(1) Measurement of dilectric dissipation IEC 60137 1. Tan Delta - 66 kV - 0.7% V --
factor and capacitance Above 66 kV - 0.4% V --
(2) Dry power frequency voltage withstand 2. As per approved GTP V --
test V --
P
(3) Measurement of partial discharge 3. As per IEC - No flash-over/ puncture V W
(4) Pressure test 4. No leakage V W
(5) Tightness test 5. No leakage
(6) Creepage distance 6. As per approved GTP
(7) Visual & dimensional check 7. As per approved drawing
10 Buchholz Relay 1. Type & make 100% IS 3637 1. As per approved drawing P V --
2. Porosity 2. No leakage
3. High voltage 3. 2 KV for 1 min. withstand
4. Insulation resistance 4. Min 10 MΩ by 500 V DC megger
5. Element test 5. No leakage at 1.75 Kg/cm2 oil pressure for
15 mins
6. Gas volume test at 5° ascending towards 6. GOR - 1: 90 to 165 CC
conservator GOR - 2: 175 to 225 CC
GOR - 3: 200 to 300 CC
7. Loss of oil & Surge test 7. GOR - 1: 70 to 130 CC
GOR - 2: 75 to 140 CC
GOR - 3: 90 to 160 CC
11 Bimetallic Terminal 1. Dimensional 100% IS 5561 1. As per approved drawing P V --
Connector 2. Visual check 2. Free form defects
3. Tensile strength 3. As per type test report
4. Resistance 4. As per type test report
12 Marshalling Box 1. Dimension & Visual check 100% Approved 1. As per approved drawing P V --
2. 2kV test for Auxillary wiring drawing 2. 1 min withstand
3. Paint shade & Thickness and speci- 3. As per approved drawing
4. Wiring routing check fication 4. Firm and aesthetic
5. Functional Check 5. As per approved drawing
13 Remote Tap 1. Dimension & Visual Check 100% Approved 1. As per approved drawing P P --
Changer Control 2. 2kV test for Auxillary wiring drawing 2. 1 min withstand
Cabinet 3. Paint shade & Thickness and speci- 3. As per approved drawing
4. Wiring routing check fication 4. Firm and aesthetic
5. Functional Check 5. As per approved drawing
6. Verification of BoQ 6. As per approved drawing
171
172
No. rate Standard
Sub Manuf- Customer
Vendor acturer
14 Air cell (Flexi Air 1. Make, Visual & Dimensions 100% IS 3400 1. As per approved deawing P P --
Separator) 2. Pressure test at 0.105 Kg/cm2 2. No leakage for 24 hours
3. 10 times inflation and deflation test at 3. No deformation
0.105 Kg/cm2
15 Roller Assembly 1. Visual & Dimensions. One sample IS 8500 1. Free from surface defect P V --
2. Mech. Properties & Chemical per melt/ 2. For shaft as per MS EN8, BS 970-1
composition of raw material used for heat For roller wheel of cast iron IS 210
shaft & roller forging treatment For roller wheel of Cast steel IS 1030
batch
16 Oil & winding 1. Type & make 100% -- 1. As per approved drawing P P --
Temperature 2. Calibration 2. ± 1.5% of FSD
Indicator 3. 2kV HV test for 1 min between 3. Withstand for 1 min
all terminals & earth 4. operation within ± 2° C of setting
3. Switch contact operation test
17 Pressure Relief 1. Type & Make 100% IS 2500 1. As per approved drawing & free from defect P P --
Device 2. Operating air pressure 2. No leakage
3. Switch/contact testing 3. Satisfactory operation at pressure release
4. HV test 4. 2 kV withstand for 1 min
18 Magnetic Oil Level 1. Type & make 100% -- 1. As per approved drawing & free from defect P P --
Gauge (MOG) 2. Dial Calibration for level 2. Check pointer position for Max, Min and
3. 2kV HV test for 1 min between center level
all terminal & earth 3. Withstand for 1 minute
4. Leak test 4. No leakage at 4 kg/cm2
5. Switch/contact operation test 5. Operate at Min level indication
19 Valves 1. Type, make & Visual 100% IS 778 1. As per approved drawing & free from defect P P --
2. Leakage test/ Seepage test 2. No leakage
20 Transformer Oil Routine Test as per IS 335 100% IS 335 As per IEEMA specification (see Chapter 6) P V V
IEC 60296
No. rate Standard
Sub Manuf- Customer
Vendor acturer
21 Tank & Accessories 1. Check for a fit up for butt 100% CBIP 1. Check for proper welding P P --
welds on tank walls, base & manual
cover 2013
2. DP test on Butt welds after fit 2. Check for proper welding
up & load bearing welds
3. Visual & Dimensional check 3. Free from defect
after final welding
4. Air leakage test on assembled tank with 4. No leakage
turrets & on conservator
5. Visual check of paint shade, 5. Paint thickness
paint film thickness & film Outside: 155 micron
adhesion Inside : 30 micron
No peel-off
6. Tank - one per CBIP 6.1) Twice the normal head + 30 KN/m2 for 1 hr. P W W
6.1 Presseure test design manual Withstand
6.2 Vaccum test 2013 6.2) 760 mm of Hg for 1 hr. withstand
22 Radiators 1. DP test on lifting lugs 100% IEEMA 1. No welding defect P W W
2. Surface cleaning of header standard 2. Free from surface defect
support and bracing details by
sand/shot blasting
3. Air pressure test on elements 3. As per relevent standards /CBIP
4. Dimensional check after final 4. As per approved drawing
welding
5. Air pressure test on radiator 5. 2 kg/cm2 for 30 minutes - no leakage
assembly
6. Visual check of paint shade, 6. As per tech spec, coating thickness more
paint film thickness & film than 70 micron
adhesion
23 OLTC 1. Auxiliary circuit insulation test at 2kV for 100% IEC 60214 1. To Withstand for 1 min P P V
1min.
2. Function test on OLTC 2. Satisfactory working as per drawing
approved
3. Pressure test on divertor switch oil 3. No leakage
compartment
4. Mech. Operation test 4. Satisfactory operation for 1 complete cycle
5. Sequence test 5. Switching time within permissible limit
6. Visual & Dimentional check 6. Free from defects
7. Operational test on Surge relay 7. Satisfactory working of trip & reset
173
174
No. rate Standard
Sub Manuf- Customer
Vendor acturer
24 Cooling Fans 1. Type & Make 100% IS 2312 1. As per approved drawing P P V
2. Power consumption, rating test 2. As per approved drawing
3. HV test 3. 1.3 kV for 1 min or 1.8 kV for 5 sec
4. Insulation resistance value 4. 10 MΩ min with 500 V DC megger
25 Nitrile Rubber 1.Dimensions 1 sample/ BS 2751 1. Within tolerance P P --
Gasket 2.Shore Hardness Lot 2. 70 ± 5 IRHD
3.Tensile Strength 3. 12.5 N/mm2 min
4.Compression set test 4. 20% max
5. Elongation at break 5. 250% min
6. Accelerated aging in air 6. Max change in harness - 10 IRHD

7. Accelerated aging in oil 7. Change in weight - 5 to 8.5%
Change in thickness - 4% max
Change in width & length - 0.2% max
26 Bushing CT 1. Dimensions 100% IS 2705 1. As per approved drawing P P --
2. Verification of terminal 2. As per IS 2705
marking & polarity
3. Overvoltage inter-turn test 3. Rated current withstand for 1 min
4. Determination of error 4. As per IS 2705
5. HV Test 5. 3 kV AC for 1 min withstand
27 Remote 1. HV test 100% -- 1. 500 V AC for 1 min withstand P P --
Temperature 2. Calliberation accuracy check 2. ± 1% of FSD
detector 3. IR value 3. 10 MΩ min with 500 V DC megger
28 Oil pump 1. No load test 100% -- 1. Satisfactory performance & no load losses P P --
within limit
2. HV test 2. 2 kV AC for 1 min withstand
3. Oil pressure test 3. 5 Kg/cm2 at 90° C for 30 mins withstand
4. Locked rotor test 4. Statisfactory operation of protection
Sr. Item/Process Sampling rate Reference / Standard Acceptable Value Category of Reponsibility*
No.
Sub Vendor Manufacturer Customer
B In Process Inspection No of turns / disc
1 Lamination for core
Visual check One sample of -- Prime CRGO and Free from defect -- P V
each type
Dimensional check One sample of -- As per design drawings -- P V
each type
Check for burr One sample of -- Less than 20μn -- P V
each type
Edge bow One sample of IS 3024 As per IS 3024 -- P V
each type
2 Core Building
Visual check 100% -- Free from defect -- P W
Total stack height 100% As per design drawings within specified tolerence of design -- P W
Core Diameter 100% As per design drawings within specified tolerence of design -- P W
Leg Centre & Leg length 100% As per design drawings within specified tolerence of design -- P W
Assembly of limb Insulation 100% Design drawing As per design -- P V
& plates
Rectangularity of Core 100% Design drawing As per design -- P V
Assembly
Check for Overlaps & air gap 100% Design drawing As per design -- P V
at joints
Leaning of Core 100% Design drawing No leaning -- P V
Earthing of Core 100% Design drawing Proper connection -- P V
Limb Clamping & Binding 100% Design drawing As per design drawings -- P V
Insulation test between core 100% As per specification shall withstand 2 kV for 1 min -- P W
& core clamp / frame
Loss measurement on built 100% As per specification / GTP Within limit as per GTP -- P W
up core assembly.
3 Winding
Visual check for drum lable 100% As per design drawings Within limit as per design -- P V
and Conductor Size
175
176
No.
3 Nos of discs 100% As per approved drawings / As per Factory drawing -- P V
Factory drawing
No of turns / disc
Dimensional checks 100% As per approved drawings / As per Factory drawing -- P V
i) Outer diameter Factory drawing
ii) Inner diameter
iii) Unshrunk height
iv) Radial thickness
Brazing procedure and -- Customer approval As per approval -- P V
brazer's qualification
Visual inspection of brazed 100% As per brazing procedure As per approval -- P V
joints
Visual check for transposition 100% As per design drawings As per design -- P V
Insulation arrangement 100% As per design drawings As per design -- P V
Lead & coil indentification & 100% As per design drawings As per design -- P V
marking
Continuity test 100% -- No breaking of continuity -- P V
Inter-turn Insulation 100% As per design drawings As per design -- P V
4 Core Coil Assembly
Visual check for intercoil 100% -- As per design -- P W
insulation
Lead & coil indentification & 100% -- As per design -- P W
marking
Brazing / Crimping of Joints 100% -- Shall be smooth and no sharped age -- P W
Visual chek for completeness 100% -- Complete assembly shall be free from dust/ -- P V
and cleanliness particles
Ratio test 100% As per IS 2026 / IEC 60076 Tolerance as per standards -- P V
Magnetic balance test 100% As per IS 2026 / IEC 60076 Tolerance as per standards -- P V
Magnetizing current test 100% As per IS 2026 / IEC 60076 Tolerance as per standards -- P V
Alignment of Spacers/Blocks 100% -- Aligned -- P V
HV test 100% Mfgrs standard 2 kv for 1 min withstand -- P W
No.
5 Connections and checks before tanking
OLTC fitting & connections 100% Manufacturer standard Manufacturer standard -- P ---
Check for cable sizes 100% As per design drawings As per design -- P V
Check for clearance from 100% As per design drawings As per design -- P V
tank walls
Visual checks for crimped 100% -- Shall be smooth and no sharped age -- P V
joint
Visual checks for bushing CT 100% -- Assembly tightness -- P V
assembly tightness
Ratio test 100% As per IS 2026 / IEC 60076 Tolerance as per standards -- P V
6 Tank
Thickness of walls 100% As per approved drawings As per approved drawings -- P V
Dimensions 100% As per approved drawings As per approved drawings -- P V
Pressure test 100% As per CBIP To withstand, permenat deflection shall not -- P W
exceed as per specification
Vacuum test 100% As per CBIP To withstand, permenat deflection shall not -- P W
exceed as per specification
7 Ovening, Tanking and Oil filling
Drying 100% Manufacturer standard Low voltage tan delta and PI values shall -- P V
be checked periodically and after achieving
the satisfactory values the process will be
declared complete
Checks for complete 100% Manufacturer standard As per design -- P V
tightness before tanking
a) Tightness of all joints /
screws
b) Application of thread
locking adhesive
c) Padding of top yoke
d) Pressing of active parts
e) Fitting of wall shunts &
packing
177
178
No.
7 Cleanliness of tank before 100% Manufacturer standard Shall be clean. -- P ---
tanking
Tanking of active parts and 100% As per design drawings As per design -- P V
check for clearance from
tank walls
2 kV HV test between 100% As per specification To withstand 2 kV for 1 min -- P V
(i) Core & end frame
(ii) Core & yoke bolts
(iii) End frame and yoke bolts
Check for oil qualtity before 100% As per specification As per specification -- P V
impregnation
Oil filling & Air release 100% Manufacturer standard Manufacturer standard -- P ---
Impregnation process 100% Manufacturer standard Sufficient impregnation time shall be given -- P ---
before conducting the electrical test on the
transformer
Sr. No. Test Description of Test Sampling rate Reference / Stan- Acceptable Value Category of Reponsibility*
dard
Manufacturer Customer
C Routine Tests 100% IS:2026 / IEC 60076 As per applicable
/ specification standard
1 Resistance of each winding. P W
2 Turn ratio for all sets of windings on each tap, with P W
percentage error / Voltage
3 Polarity and phase relationship (Vector group) P W
4 Impedance between each pair of winding / P W
Impedence Voltage
5 Excitation losses at 90, 100 and 110 % rated P W
voltage measured by the average voltmeter
method
6 Positive phase sequences impedance P W
measurement on three phase transformers
7 Regulation at rated load and unity, 0.9, 0.8 lagging P W
P.F.
8 Load losses, measured at rated frequency, by P W
applying a primary voltage sufficient to produce
rated current in the windings with secondary
windings short circuited
9 Separate source voltage with stand test. P W
As per applicable standard
10 Induced over voltage with stand test P W

11 Auxiliary losses (fans. Pumps etc.) P W
IS:2026 / IEC 60076 / specification
12 SFRA test P W
13 Zero Sequence impedance test P W
14 Tests on tap-changer (IEC:214) P W
15 Tan delta & capacitance measurement test for P W
bushings and windings
16 Tests on transformer oil including DGA on selected P W
sample as per IS:9434/IEC:567, before and after
temp rise test and at final stage before dispatch.
Corrosive sulphur detection test as per ASTM
D1275 subjecting oil for 150oC for 48 hrs.
179
180
dard
C 18 Tank leak test at 5 psi (35 kN/m2) for 12 hrs with P W
oil & 1 hr with air.
19 Magnetic Balance & current test on all winding P W
20 HV withstand test on auxiliary equipments and P W
wiring
21 Measurement of Insulation Resistance P W
22 Measurement of acoustic noise level
23 Measurement of harmonics of no load current
24 Measurement of Partial Discharges of transformer
As per applicable standard

25 Measurement of no load current with 415 V AC P W
supply on LV side.
IS:2026 / IEC 60076 / specification

26 Tests on air cell
27 ACLD test (For 220 kV class transformer)
28 Moisture content in active part measurement test 0.5 % max P W
D Type Tests One from Lot or as
agreed between
Manufacturer and
Purchaser.
1 Temperature rise test IS:2026 / IEC 60076 As per standards P W
2 Lightning Impulse Voltage withstand test with IS:2026 / IEC 60076 As per standards P W
chopped wave
Switching Impulse Voltage withstand test
3 Vacuum and pressure test on tank CBIP manual Permanent W W
deflection within
limit as per length
of plate used.
4 Short circuit withstand capability test (Optional) IS:2026 / IEC 60076 As per standards
5 Tests on OLTC IEC 60214 As per standards P W
dard
E Special Tests (Optional)
1 Degree of protection (IP55) for control cabinets IS 13947/IEC 60529: -- P W
& RTCC panel, OLTC driving mechanism, terminal 2001
boxes of PRV, MOG, Buchholz Relay, pump motors,
fans etc
2 Measurement of transferred surge in LV due to IS:2026 / IEC 60076 -- P W
Lightning impulse on HV & LV
3 Short Time Current withstand test on offered HV IS:5561 -- P W
and LV terminal connectors for 40 kA for 3 Sec for
220 kV & 132 kV Class and 25 kA for 3 sec for 66
kV & below class
F Packing & Dispatch - Main tank P --
1 Pipes and headers 100% P --
2 Radiators 100% P --
3 Verification of completeness of accessories 100% P --
4 Bushings 100% P --
5 Conservator tank 100% P --
Manufacturer’s Standard
6 Transformer oil 100% P --

7 Check Nitrogen / dry air pressure after filling 100% 0.15 to 0.2 kg/ P --
cmsq above ATM
Pr
Manufacturer’s Standard
8 Mesurement of dew point of nitrogen or dry air 100% P --

before and after filling in tank before dispatch
9 Check proper blanking of all openings and leakage, 100% P --
if any
Standard
10 Provision of Impact recorder / tracking system 100% P --

Manufacturer’s
11 Check for soundness of packing 100% P --
181
Chapter - 5
Transportation, Erection, Testing and Commissioning

Mr. Gautam Mazumdar - CGL
Mr. Umapathi - Voltech
Mr. Y. V. Joshi - GETCO
Mr. D. C. Patel - J. H. Parabia
Mr. N. G. Patel - GETCO
Ms. Asha Agravatt - GETCO

CHAPTER - 5
TRANSPORTATION, ERECTION, TESTING AND COMMISSIONING
INTRODUCTION
Considering main objectives of standardisation Manual, this chapter will cover important procedures, check points,
flow charts, suggestive tools-tackles, testing formats, etc. which are required for transport, storage, installation &
erection, testing and commissioning of power transformer for its good performance during operation.
Transportation and Unloading at site
Power transformers are usually very reliable, but it requires lot of care during all stages of its life & particularly during
transportation. If a transformer experiences any mechanical shocks more than suggested “g” level, damage that may
occur covers
§§ Displacement / distortion of windings or core
§§ Inter turn insulation damage due to movement of active part
§§ Loosening of winding clamps due to vibration
§§ Compromise safe clearances between tank & active parts
It is therefore required that transporter should take note of following transport restrictions.
§§ Axial load distribution
§§ Brake force distribution between tractor & trailer as per trailer manufacturer’s guide.
§§ Maintain proper ratio between the gross mass of the trailer and tractor
§§ Adhere to designated route.
§§ Avoid travelling during foggy, heavy rain, etc restricting ambient visibility to less than 500 meters.
§§ Actual survey & planned route
§§ Permissions
1] Modes of Transport
According to weight of Transformer to be transported, the size & capacity of Trailer, plinth size and mode of transport
can be standardised as below.
Sr. No. Standard Ratings Approx. Trailer size Mode of Transport

Weight in MT (No. of axles)
A Two Winding Transformers
1 132/33 kV, 40/50 MVA 70 6 ROAD
2 220/66 kV, 100 MVA 107 9 ROAD
B Auto Transformers
1 132/66 kV, 40/50 MVA 60 5 ROAD
2 132/33 kV, 25/31.5 MVA 50 4 ROAD
3 220/132 kV, 100 MVA, 84 7 ROAD
4 220/132 kV, 160 MVA, 83 - 130 7 - 10 ROAD

5 400/220/33 kV, 315 MVA, 3Ø 185 - 230 14 - 18 ROAD
6 400/220/33 kV, 500 MVA, 3Ø 250 19 ROAD / RAIL
7 400/220 kV 167 MVA, 1 Ø 85 - 104 7-8 ROAD
8 765/√3 // 400/√3, 333 MVA, 1 Ø 160 13 ROAD / RAIL
9 765/√3 // 400/√3, 500 MVA, 1 Ø 192 15 ROAD / RAIL
C Generating Transformers
1 15.75/235 kV, 315 MVA 3Ø 190 15 ROAD
2 15.75/420 kV, 315 MVA, 3Ø 230 18 ROAD
3 21/420 kV, 200 MVA, 1Ø 155 12 ROAD
4 21/420 kV, 260 MVA, 1Ø 180 14 ROAD
5 21/420 kV, 333 MVA, 1Ø 220 17 ROAD
6 21/765 kV, 260 MVA, 1Ø 175 14 ROAD / RAIL
7 21/765 kV, 333 MVA, 1Ø 205 16 ROAD / RAIL
* Note: Weights are approximate and may vary from manufacturer to manufacturer
Mode of transportation may be rail, road or water. Depending on size of transformer, destination, delivery time &
route limitations the mode of transportation can be decided.
a) Rail Transport
Where the weight and dimension of main body exceed limits, special well wagons are employed. Detached parts
are packed/crated and normally dispatched along with main body of transformer so that all the parts are received
at the destination with unit. If the siding facility is not available either at loading or unloading end, mobile cranes
or railway cranes can be used for loading into wagons.
b) Road Transport
Multi axle tractor driven, low platform trailers are used for transporting transformers on roads. Transformers may
be transported by road, where well developed roads exist & the route conditions permit.
2] Selection of Trailer
Multi axle tractor driven low platform trailers are used for road transport. The tractors are to have adequate hauling
capacity and the trailers should have adequate loading capacity. There are two types of trailers available.
i) Low bed Mechanical Articulated Trailer

This is useful for concentrated load like Transformer. The maximum Gross load permissible in Mechanical
Articulated trailer is 49 MT (Gross load = Weight of consignment + weight of trailer + weight of pulling unit,
tractor)
ii) Hydraulic axle Trailer

Useful for all types of loads including transformers. The maximum Gross load permissible in Hydraulic axle
trailer is 18 MT Per axle. Depending upon the weight, the number of axles can be attached one after an-
other. Normally Hydraulic axle unit are available in the combination as a unit of 2 axle, 3 axle, 4 axle, 6 axle
and 8 axle (weight of each axle is approx.: 3.5 to 4.5 MT) depending upon Manufacturer. The axle width is
generally 3 Mtrs. 1 ½ side axle can also be joined if the width of the consignment is exceeding 4 Mtrs. Total
width of the axle in this case will be 4.5 Mtrs.
3] Capacity of Puller
Presently Pullers (figure 5.1) are available to pull loads from 1 to 240 MT.
Fig. 5.1
4] No. of Axles
No. of hydraulic axles of any transportable consignment can be determined in the following manner. One puller
carried load of the consignment on two hydraulic axles.
Weight of tractor (ra) + trailer (rb) = X (say, 10 MT)
Weight of Transformer : (a) e.g. 70 MT
Gross weight permissible per axle : (b) e.g. 18 MT
Weight of each axle : (c) e.g. 4.5 MT (standard weight)
Weight of Goods that can be loaded (d) : (b-c) = (18 MT – 4.5 MT) = 13.5
Hence, for 70 MT Transformer axles to deploy = {X+(a)}/(d) = {10+70}/13.5 = 5.92
Therefore number of axles which need to be deployed are 6.
In the up gradient of hills or roads extra puller of same rating shall be provided.
In down gradient of ghat section use power brake attached to the hydraulic modular trailer.
5] Route Survey
The route Survey Report is for safe and speedy transport of over dimensional / sophisticated consignments by
deployment of well suitable equipment, driver and escorts (both) with professional & technical expertise and
their rich experience is the answer of safe and speedy transport.
Based on the dimension and weight of the consignment extensive study is being carried out, first calligraphically
wherein most feasible routes for the transportation to the destination site is selected and there after exhaustive
field verification are carried out. After collection and compilation of massive data that was collected during the
route surveys, only the most feasible route is being selected and detailed report of Survey is being prepared.
Efforts to be made for best alternative solution while highlighting the problems that are anticipated for safe
and speedy transportation of over dimension / sophisticated consignment
a) Elements of route survey

The road system is examined in detail on the following points:
i. Normally width of the road should be more than 5 m.
ii. Bridges and culverts should have sufficient strength to take the moving load (in this regard,
consultation with highway department is necessary)
iii. Hindrance on route like telephone, telegraph, traction and HT/LT wires, avenue trees, sub ways etc are
to be assessed.
iv. Sharp bends & road worthiness (i.e. sandy stretches, waterlogged areas, crowded localities like market
places, schools and public places)
6] Speed
For the normal running uniform speed of 10 to 20 kmph shall be maintained on good roads. For bad roads it is
desirable to run the vehicle at much lower speeds. However, while crossing bridge it shall be 5 kmph. No breaks
should be applied during bridge cross over. Movement of other vehicle should be stopped while crossing bridge.
Long before the approach to the bridge, the speed should be brought down and the vehicle allowed proceeding
over the bridge without creating any impact.
The brake system on the tractor-trailer has to be carefully operated whenever the vehicle is running with load.
7] Night Travel & Halt
Normally night travel is avoided except where it is restricted for heavy vehicles to travel in day time i.e. cities,
towns & small villages. Transportation should be avoided during heavy rains also. In the case of night halt or
stoppage of the loaded trailer for a fairly long duration the trailer should be supported either by sleepers or
providing supporting jacks on all sides thus releasing the load from the tyres. Danger lights should be displayed
in the front and rear of the vehicle.
8] Safe movement under O/H lines
The Supervisor should ensure that sufficient line clearance from line conductor to the top most part of transformer
and trailer is available as per IE Rules and as per the rating of transmission lines. The transportation during
monsoon period should be avoided as far as possible if sufficient clearances are not available. If it is found that
the clearances are critical, the hydraulic axle platform can be lowered by 250 to 300 MM as per the provision
made in hydraulic axle to avoid any danger of electrical faults.
9] Special spares / tools to be carried during transport
1. Insulated LT wire lifting device
2. Extra tyres
3. Hydraulic Jacks
4. Tools Box
5. Crow bar
6. Tarpaulin
7. Slings for fastening
8. First Aid kit
9. Small Spares
10. Torch
11. Baton sticks
12. Red & Green Flags

10] Crew Size

1. Supervisor - 1 Person
2. Driver - 1 Person
3. Axle operator - 1 Person
4. Helpers - 3 Persons
5. Wire lifting - 3 / 4 Persons.
All above should be equipped with helmet, safety shoes & hand gloves and Supervisor, Axle operator and Driver are
with suitable communication facility.
11] Document verification for puller capacity

Registration book issued by RTO department to know the horse power of puller.
12] Movement
A pilot vehicle with all tools and tackles, jacks, sleepers, chequered plates, crowbars, etc., and sufficient trained
staff should run in front of the vehicle. Red flags and danger lamps should be exhibited at prominent places to
warn traffic on the route.
The branches of avenue trees that are likely to foul the equipment should be cleared while the load is moved.
Electric utility power lines likely to foul should be switched off and lifted temporarily / dismantled while the load
is moved.
After moving the load for a short distance, tightness of the lashing should be checked.
13] Check Points during Transportation

a) Provide suitable impact recorder which give waveform data and frequency analysis. As per IEEE guide line
PC57.150, it is recommended to provide two recorders per transformer to eliminate chances of loss of data
due to failure of recorder.
b) Place both the recorders as low as possible and in diagonally opposite positions for best results.
c) Check pressure of dry air or nitrogen as shown below on daily basis. Any loss in pressure shall be made up.
For this, Transformer shall be supplied with filled gas cylinder to maintain positive pressure during transpor-
tation (figure 5.2).
d) The purity shall be 99.9% for nitrogen gas or dry air conforming to DIN 3188.
e) Weak bridges, if any should be strengthened with the help of highway department.
f) Red flags and danger lamps should be exhibited on the unit.
g) Check tightness of lashing at regular intervals during movement.
Fig. 5.2:
14] Receipt of Transformer at Site

i. 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.
ii. Inspect all packing cases and loose components for damage or missing items.
iii. Check whether the transformer has arrived at site with a positive gas pressure in case of dispatch without
oil. In case of dispatch of main body in oil filled condition, check oil level and leakages if any.
iv. Should the transformer arrive at site without pressure (owing to gas leakage), it must be assumed that mois-
ture has entered the tank and that the moisture will have to be driven out. In such cases, the manufacturer’s
advice must be sought.
v. In case of any oil leakage or damage is discovered, the transportation company, the transport insurer and
manufacturer shall be informed immediately.
vi. A record of damage must be prepared in conjunction with other participants and supplier representative.
Minor damage which may appear unimportant should also be recorded.
vii. Confirm that case numbers match with the packing list. Check their contents tally with the packing list if the
packing case is damaged.
viii. Fill in the check list for external as well as internal inspections.
ix. For oil filled transformers 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.
x. Down load impacts recorded by impact recorder and analyze the same in consultation with supplier.
15] Unloading of Transformer
All the transformer unloading and handling work should be carried out and supervised by specialized people,
following all safety rules and using supporting points indicated on drawing. The use of any other points will result
in severe damages to the transformer.
a) The following should be avoided during the unloading process

§§ The transformer imbalance (Maximum 10 degree)
§§ Abrupt movements
§§ Impact against the ground
§§ Side Impact
The transformer should be unloaded from trailer by using wooden sleepers and rails for dragging the transformer
to its plinth.
b) Considerations before unloading

§§ Availability of access road between unloading point and plinth.
§§ Ensure overhead crane capacity for weight of main unit.
§§ Readiness of foundation
§§ Keep under base of main unit at least 300 – 400 mm above ground level by providing wooden slippers
to facilitate jacking.
§§ Remove lashing before unloading.
c) Unloading from Trailer

i. Unload main unit only on wooden slippers
ii. Jack the transformer at jacking pad only.
iii. Ensure simultaneous operation of all 4 jacks.
iv. Use only haulage lugs for hauling.
v. Ensure capacity of winches and wire ropes to be used for haulage.
vi. Do not use chain pulley block in place of winches.
d) After checking of exact position of transformer, the following sequence should be followed
i Install all wheels to transformer using hydraulic jacks sized for at least 50% of the units weight.
ii Before resting the wheels into groove, make sure all of them properly adjusted.
iii Lower the transformer with the help of the hydraulic jacks until it remains resting on the bottom of the
groove. Never allow the transformer to remain inclined.
Fig. 5.3:
e) List of major tools for unloading
Sr. No. Item Capacity

1 Mobile crane Min. 110% of weight of transformer
2 Hydraulic Jack 1.5 times weight of transformer
3 Lifting slings Size of slings to be selected according to weight and angle of lifting
4 Winch machine 115% of weight of transformer divided by 4
5 Wooden sleepers 300 to 400 mm thick
6 Greased steel plates Adequate numbers
7 Pulleys 115% of weight of transformer divided by 2
8 Oil storage tank 25 kL with motor pump.
9 Oil filter machine /oil purifier 5000 lph
10 Vacuum pump 760 mm of Hg
11 Water proof tarpaulins 30 to 40 M2
12 Flexible hoses for vacuum and 10 M long – 4 nos
oil 3 M long – 2 nos
13 Oil test kit – 100 kV
ERECTION, TESTING AND COMMISSIONING

The complete process of erection from point of dispatch from factory to commissioning is illustrated in the form of
flow diagram to follow sequence of activities scrupulously with check points.
1 Erection
Erection of power transformer requires great deal of planning and arrangement of resources. It is essential to
have erection agency with skilled manpower having experience of EHV class power transformer. Each and every
unit is to be treated like a project, so that cost, quality and time are controlled and monitored through a process
(Flow chart - see Fig. 5.4). It will ensure that erection activities are carried uninterrupted with safety and without
any damage to transformer parts / items.
It is suggested to have kick off meeting (KoM) with following main agenda:
1. Competency of erection agency and their manpower skills.
2. To confirm receipt of transformer as per BOQ in full shape
3. To confirm availability of T&P as per requirement of unit, size and rating. (Refer list as per this manual)
4. To confirm readiness of plinth and radiator foundation as per requirement (Physical check of dimensions)
5. To confirm over head conductor take off or power cable terminations arrangement as the case may be.
6. To confirm safety measures adopted and location hazards, if any.
7. Organization reporting structure, data recording, responsibility and clearances.
8. To confirm insurance, workmen compensation and labor related statutory requirements.
9. Comply to specific requirements agreed in Design Review.
2 Minimum Tools & Plants and Other Items
a) General T&P
The following tools and plants can be arranged during erection, overhauling activity at site.
Sr. Item Optimum Quantity

No. Recommended
1 Spanners :
a) Double end (size -32) 2 Set
b) Ring (size -32) 2 Set
c) Box/socket type (size 6-36) with a/2” drive complete with ratchet, universal, 2 Set
ordinary handle and extension bar of size 75mm and 150mm
2 Single end spanners (36,41,46,50,55) 5 Nos.
3 Slugging wrench (32,36,41) 3 Nos.
4 Tubular spanner (size 6-32) 1 Set.
5 Torque wrench (1/2” drive) 5 to 22 kgm 1 No.
6 Adjustable spanner 8” 2 Nos.

- do - 12” 2 Nos.
- do - 18” 1 No.
- do - 24” 1 No.
7 Pipe wrench 12” 1 No.

- do - 18” 1 No.
- do - 24” 1 No.
8 Spanner for opening transformer butterfly valves (squre) 1 No. for each type of
valve
9 Spanner for opening oil drum 2 Nos.
10 Screw Driver
a) 10mm (D0 x 400mm (L) 2
b) 10mm (D0 x 300mm (L) 2
c) 8mm x 300mm (L) 4
d) 8mm x 200mm (L) 4
e) 6mm x 250mm (L) Insulated 4
f) 6mm x 200mm (L) Insulated 4

No. Recommended
11 Star screw driver (size 1mm to 6mm) 1 Set.
12 Nut driver stet (up to 10 mm) 1 Set.
13 Allen Keys (size 1 mm to 16mm) 1 Set.
14 Cutting pliers insulated - 8” 2 Nos.

10” 2 Nos.
15 Nose pliers insulated - 6” 2 Nos.

8” 2 Nos.
10” 2 Nos.
16 Cir-clip pliers – Internal 1 No.

External 1 No.
17 Wire stripper for 2.5 sq. mm 2 Nos.
18 Hammer - ½ kg 1 No.
2 kg 1 No.
5 kg 1 No.
19 a) Teflon mallet (medium size) 1 No.

b) Wooden mallet (medium size) 1 No.
20 a) Dot punch 1 No.

b) Hole punch kit up to 32mm 1 Set
21 Brass rod (300mm L x 20mm D) 1 No.
22 Files.
a) Needle file 1 Set
b) Flat file 12” (rough & smooth) each one 2 Nos.
c) Half round 8” 1 No.
d) -do- 10” 1 No.
e) Round file 8” 1 No.
f) -do- 10” 1 No.
g) Triangular file 8” (rough & smooth) each one 2 Nos.
23 a) Hacksaw frame - 12” 1 No.

b) Wood saw - 12” 1 No.
24 Sheet cutter - 12“ 1 No.
25 Scissors - 8” 1 no.
26 Flat Chisel - 8” 1 No.

Round Chisel - 10” 1 No.
27 Industrial knife high carbon sheet 1 No.
28 Knife for wire cutting 2 Nos.
29 Measuring tape
a) 3 meter (flexi-measure) 2 Nos.
b) 15 meter (plastic) 1 No.
c) 30 meter (plastic) 1 No.
30 Steel rule – 30 mm 1 no.
31 Varnier Caliper - 300mm 1 No.
32 Filler gauge - 100mm - 24 blade (metric) 1 No.
33 Tri square 10” 1 No.


No. Recommended
34 Plumb 1 No.
35 Sprit level 1 No.
36 Bench vice - 8” 1 No.
37 Pipe vice for pipe up to - 2” 1 No.
38 Pipe die set up to -2” 1 Set.
39 Crimping tool
a) Hand operated up to 16 sq. mm 1 No.
b) Hydraulic 1 No.
40 Bearing puller - 3 leg (size 300mm) 1 No.
41 Hand operated oil can 1 No.
42 Grease gun ( medium size) 1 No.
43 Hand operated oil pump (for oil drums) 1 No.
44 Drilling machine portable (0-13mm) 1 No.

Model WD 34C, Make : Wolf
45 Drilling machine heavy duty along with drill chuck, sleeves and arbor 1 No.
Model NW 10, Make : Wolf
46 Drill bits : 10 Nos.

a) size upto 10mm straight shank 13 Nos.
b) size 12 to 25mm tapper shank
47 Hand Grinder (AG-7) Make : Wolf
48 Bench Grinder, Model TG6-E wheel dia. 150mm 1 No.
49 Vacuum cleaner cum blower with hot air attachment 1 Set
50 Hydraulic jacks (100 t. capacity) 4 Nos.
51 Pulling and lifting machine (Tirfor 5 t. capacity) 2 Nos.
52 Chain pulley block

a) 10 T 1 No.
b)1 T 1 No.
53 C-clamps (12”) 6 Nos.
54 D Shackle
a) 2 T capacity 6 Nos.
b) 5 T capacity 4 Nos.
c) 10 T 4 Nos.
d) 20 T 4 Nos.
55 Bull dog clamp heavy duty suitable for 10mm, 12mm wire sling 5 Nos. each
56 Single sheave pulley

(a) 1.5 ton (12 mm) 1 No.
(b) 2.5 ton (12 mm) 1 No.
57 Slings.
(a) 12mm dia. with standard loop on both ends having 6 mtr. length 4 Nos.
(b) 12mm dia. with standard loop on both ends having 10 mtr. length 2 Nos.
(c) 10mm wire rope length 100 mtr
(d) 32mm dia. with standard loop on both ends having 10 mtr. length 2 Nos.
(e) Wire rope slings double legged with ring at one end and hook at other end 2 Nos.
with 12mm roper of 4 mtr. length

No. Recommended
58 Polypropylene rope
a) 6 mm 50 mtr
b) 12 mm 100 mtr
c) 16 mm 100 mtr
59 Welding machine with flexible welding cable, insulated electrode holder, 1 Set.
protective masc., chisel, chipping hammer, wire brush and leather gloves (model
RED-301 of Advani oerlicon Ltd)
60 Brazing, soldering and gas cutting kit 1 Set.
61 Pipe GI or Iron – 25mm and 40mm 3 Nos.

50mm dia (1 mtr length each)
b) Miscellaneous Items
Sr. Item Optimum quantity

No. recommended
1 Torch light (large size) 2 Nos.
2 Emergency light 5 Nos.
3 Flood lights fittings :

- Sodium vapor (70 W) 5 Nos.
- Halogen (500 W) 5 Nos.
4 Tarpaulins (large size) 10 Nos.
5 Ladder (Aluminum)
(a) Self supporting ladder 1.8 mtr 2 Nos.
(b) -do- 3.6 mtr 1 No.
(c) extension ladder 4.8 mtr 2 Nos.
7 Heaters (2.0 kW x 40 Nos.) 2 Sets.
8 Wooden sleepers 50 Nos.
9 U-clamp for connecting OLTC chamber to main tank at the time of vacuum pulling 1 No.
10 Oil sampling bottle 10 Nos.
11 Oil sample flange 2 Nos.
12 Switch boards for extending supply having 15A/5Amp socket, bulb, holder & 3 Nos.
switch
13 Earth rods 5 Nos.
14 Fire extinguisher
CO2 (22.5kg) 2 Nos.
Foam ( 9kg) 2 Nos.
Halon (3 kg) 2 Nos.
15 Dry air cylinders 30 Nos.

c) Special T&P and Instruments
Sr. ITEM Quantity.

No.
1 Filter machine 6000 L 1 No.
2 Oil tanks (30 KL capacity) 1 No.
3 Oil hose 100 mtr.
4 Vacuum pump 1
5 Vacuum hose 20 mtr
7 400A switch board for power supply to Filter machine 2 Nos.
8 BDV kit 1 No.
9 5KV/10KV megger 1 No.
10 Tan delta & capacitance kit 1 Set.
11 SFRA kit 1 Set.
12 Ratio meter 1 No.
13 Winding resistance measurement meter with leads 1 No.
14 Multi meter 3 Nos.
15 Clip on meter 1 No.
16 Primary injection kit with leads 1 Set.
17 Variac for 3-phase supply (15 Amp) 1 No.
18 Online PPM Meter 1 No.
19 Dew Point Meter 1 No.
20 Pressure Gauge 2 Nos.
21 Vacuum Gauge 2 Nos.
22 Mobile Crane Hydra 1 No.
3 Safety Measures & Precautions
1. Keep recommended fire extinguishers at site.
2. During hot oil circulation, keep fire extinguisher ready near transformer.
3. Carry out all pre-commissioning Test and final commissioning check as elaborated in this Manual before
energizing transformer.
4. Take precaution while handling PRV devices having heavy springs in compression to safeguard person and
system.
5. Replace N2 filled tank by breathable dry air of dew point less than (-40 oC) at least for 24 hours.
6. Provide adequately rated cables & fuses.
7. Never apply voltage when transformer is under vacuum.

8. Oil spillage shall be inspected regularly and attended if any. Oil shall not be allowed to fall on ground.
9. Keep all combustible items away at safe distance to reduce risk of fire.
10. Welding on oil filled transformer may be avoided or done as per instruction of manufacturer only.
11. All erection personnel must use Personal Protective Equipments like, helmet, safety shoe, boiler suit, etc.
12. No welding work shall be taken up near transformer.
13. Electrical equipment like filter machine, dry air generator etc., must be earthed.
14. First Aid box shall be kept ready at site.
15. Adequate lighting must be available for clear visibility
16. Cordon off the working area, particularly when transformer augmentation work in a switchyard is taken
up.
17. All major erection activity like bushing, conservator and radiators must be carried out with crane of ad-
equate capacity and boom size.
18. Never carry out work with unskilled workers.
19. Safety posters, like “No Smoking”, “Wear Helmet”, etc., must be displayed.
20. Testing circuit and procedures are important to follow as per manual to avoid any induction effect before
and after the Test. Approved and tested Earth rods are essential for this purpose.
21. Safety Nodal Officer to make sure that site is cleared on daily basis to prevent fire hazards.
4 Precomissioning Tests:
Preparation for SAT (Site Acceptance Tests)

4.1
§§ Site study
§§ Collection of Factory Acceptance Test reports
§§ Finalization of action plan for carrying out SAT
§§ Prepare testing program schedule.
§§ Check whether the transformer under Test had been isolated from other electrical equipments and
from induction using earth switch or local earthing arrangement.
§§ Make the Test procedure
§§ Make the Test formats
§§ Get the guidance of Dos and Don’ts from the experts in the field
§§ Ensure for all safety assessments of Helmets, Gloves and Safety shoes.
§§ Execute the tests according to the program schedule.
§§ Compile the Test reports.
§§ Do analysis of the Test results and ensure for healthiness of transformer.

Following checks should be carried out before commencing the pre-commissioning Test of the Power
4.2
Transformer.
§§ Ensure that Power Transformer and its auxiliaries should be free from visible defects on physical
inspection
§§ Ensure that all fittings should be as per out line General Arrangement Drawing
§§ Ensure that bushings should be clean and free from physical damages
§§ Ensure that oil level is correct in all bushings
§§ Ensure that oil level in Main / OLTC Conservator tank in MOG is as desired.
§§ Ensure gear box oil level in OLTC
§§ Ensure that OTI and WTI pockets are filled with transformer oil
§§ Ensure that cap in the tan delta measurement point in the bushing is grounded
§§ Ensure unused secondary cores of Bushing CT’s, if any, has been shorted
§§ Ensure CT secondary star point has been formed properly and grounded at one end only as per
scheme
§§ Ensure that Buchholz Relay is correctly mounted with arrow pointing towards conservator
§§ Ensure all power and control cable terminals are tightened
§§ Ensure all cables and ferrules are provided with number as per cable schedule
§§ Ensure that external cabling from junction box to relay / control panel is completed
§§ Ensure operation of OLTC manually, electrically at local and electrically by RTCC
§§ Ensure indication of tap position on Diverter switch, Drive mechanism & RTCC are same.
§§ Ensure working of numerical AVR
4.3
List of Site Acceptance Tests
Following pre-commissioning Tests / checks should be carried out:
Sr. No Test / Checks Name Testing Equipments
1 SFRA Test Automatic SFRA kit

2 Capacitance and Tan delta measurement Automatic Capacitance & Tan delta measurement kit
Test
3 Transformer turns ratio Test Digital Ratio meter
4 Magnetizing current Test Digital multi meter
5 Magnetic balance Test Digital multi meter
6 Verification of vector group and polarity Digital multi meter

test
7 Short circuit impedance test Digital multi meter
8 Measurement of winding resistance test Digital winding resistance meter

Sr. No Test / Checks Name Testing Equipments
9 Winding Insulation Resistance Digital insulation resistance meter

measurement
10 Core Insulation Resistance measurement Digital insulation resistance meter
11 Oil characteristic test Oil BDV test kit
12 Tests on bushing CT s Digital multi meter, CT primary current injection kit, Knee
point voltage measurement kit, Insulation resistance
tester
13 Operational tests and checks on other --

equipments
14 Measurement of earthing pit resistance Earth resistance measurement kit
15 Protection and alarms As per scheme

16 Contact resistance measurement Contact resistance measurement kit
17 Clearances Measurement tape/ Automatic Infra red gun
18 Protection relay settings As per scheme
19 Final documentation review As per requirement
4.3.1 SFRA Test
(a) Purpose of the test
The transformer is considered to be a complex network of RLC components. The contribution to this
complex mesh of RLC circuit are from the resistance of the copper winding, inductance of the winding
coils and capacitance from the insulation layers between coils, between winding, between winding and
core, between core and tank, between tank and winding etc. (figure 5.5).
(b) Principle of the test

Any form of physical damage to the transformer results in the changes of the RLC network. These
changes are looking for and employ frequency response to highlight these small changes in the RLC
within the transformer.
Fig. 5.5:
The test involves measuring the frequency response of each individual winding. The frequency is mea-
sured by injecting a sine wave signal with respect to earth at one end of winding to be tested and mea-
suring the signal amplitude there and at other end of winding. The attenuation (in db) of the transmit-
ted signal relative to reference signal at the input terminal is measured over a frequency range from 20
Hz to 2 MHz. SFRA is used to check the eventual change in the internal geometry of the active part of
the transformer whether displacement of deformation i.e. the mechanical integrity of the transformer.
Transformers while experiencing severity of short circuit current looses its mechanical property by way
of deformation of the winding or core. During pre-commissioning, this test is required to ascertain that
Transformer active part has not suffered any severe impact/ jerk during transportation.
(c) Equipments for the test

Automatic SFRA test kit with application software
(d) Circuit for the test (figure 5.6)
SFRA Kit
Fig. 5.6:
(e) Procedure for the test

§§ This test is carried out after completion of all commissioning activities.
§§ Factory FRA test report in soft form should be available at site.
§§ FRA signatures will be taken after assembly and oil filling and compared with factory testing to
ensure the healthiness of core /coil assembly during transportation.
§§ Interpretation of test results carried out
§§ Test results matching with the factory results
§§ 10 V AC is applied at variable frequency (20Hz to 2 MHz) to the winding for all possible connections
of the winding
§§ These signatures will be the benchmark for future reference.
§§ The FRA signatures should be analyzed in conjunction with Impact Recorder readings.
§§ Report of Impact recorder readings is to be obtained from manufacturer.
§§ It is recommended to follow the standard procedure for the SFRA measurement as per the
standard test procedure recommended by the manufacturer.
§§ It should be done on maximum, normal and minimum tap of the transformer.
Type of connections for the test (figure 5.7) and typical waveform (figure 5.8).
A. HV Phase to Neutral with LV open
Fig. 5.7:
Fig. 5.8:
1. Feed the frequency signal from 20 Hz -2 MHz in the transformer R ph of the HV winding with
respect to the neutral (for star winding) and R ph of HV winding with Y ph of HV winding (for delta
winding).
2. Both the reference leads should be earthed properly.
3. Keep LV open ( including core)
4. Kit will receive the response of the impedance characteristic in the transformer.
5. Response will be plotted in logarithmic scaled graph.
6. Repeat the all procedures for other phases
B. HV Phase to Neutral with LV shorted

(Connection see figure 5.9 and typical waveform figure 5.10)
respect to the neutral (for star winding) and R ph of HV winding with Y ph of HV winding (for delta
winding).
Fig. 5.9:
Fig. 5.10:
3. Keep LV winding shorted (core is avoided)

6. Repeat all the procedures for other phases
C. LV Phase to Neutral with HV open

1. Feed the frequency signal from 20 Hz -2 MHz in the transformer R ph of the LV winding with
respect to the neutral (for star winding) and R ph of HV winding with Y ph of LV winding (for delta
winding).
3. Keep LV winding open

Fig. 5.11:
Fig. 5.12:
D. Between HV and LV winding
Fig. 5.13:
Fig. 5.14:
respect to the LV winding
3. Keep LV winding open
Maximum possible combinations of connections for SFRA test

Test Type Test 3 phase 1 phase
Series winding (OC) Test 1 H1-X1 H1-X1
All other terminals floating
Test 2 H2-X2
Test 3 H3-X3
Common winding (OC) Test 4 X1-H0X0 X1-H0X0

Test 5 X2-H0X0
Test 6 X3-H0X0
Tertiary winding (OC) Test 7 Y1-Y3 Y1-Y2 (Y1-Y0)

Test 8 Y2-Y1
Test 9 Y3-Y2
Short circuit (SC) Test 10 H1-H0X0 H1-H0X0

High (H) to Low (L) Short (X1-H0X0)
Short (X1-X2-X3) Test 11 H2-H0X0
Test 12 H3-H0X0
Short circuit (SC) Test 13 H1-H0X0 H1-H0X0

High(H) to tertiary (Y) Short (Y1-Y2)
Short (Y1-Y2-Y3) Test 14 H2-H0X0
Test 15 H3-H0X0
Short circuit (SC) Test 16 X1-H0X0 X1-H0X0

Low(L) to tertiary (Y) Short (Y1-Y2)
Short (Y1-Y2-Y3) Test 17 X2-H0X0
Test 18 X3-H0X0
e) Acceptance Criteria
Test results should match with the factory results
(In general changes of +/- 3dB)
If changes are more than limit, it may indicate following faults:

Frequency Range Probable Fault
5 Hz to 2 KHz Shorted turns, open circuit, residual magnetism or core movement

50 Hz to 20 KHz Bulk movement of winding relative to each other
500 Hz to 2 MHz Deformation within a winding
5 Hz to 10 MHz Problem with winding leads and/or test lead problem
f) Format for the test report
Equipment Detail:
Make Type Sr. No. Range Cal. Due Date

Close
1.1 Low frequency region (20 Hz<1 kHz)
HV-N side
Tap position Resonance value in dB (Site) Resonance value in dB(Factory) Remarks

1U-1N 1V-1N 1W-1N 1U-1N 1V-1N 1W-1N
10
11
12
13
14
15
16
17
IV-N side
Tap position Resonance value in dB (Site) Resonance value in dB(Factory) Remarks

2U-2N 2V-2N 2W-2N 2U-2N 2V-2N 2W-2N
Normal
LV side
Tap position Resonance value in dB (Site) Resonance value in dB (Factory) Remarks

3U-3V 3V-3W 3W-3U 3U-3V 3V-3W 3W-3U
Normal
1.2 Medium frequency region (>1 kHz - 100 kHz)
HV-N side

1U-1N 1V-1N 1W-1N 1U-1N 1V-1N 1W-1N
10
11
12
13
14
15
16
17
IV-N side

2U-2N 2V-2N 2W-2N 2U-2N 2V-2N 2W-2N
Normal
LV side

3U-3V 3V-3W 3W-3U 3U-3V 3V-3W 3W-3U
Normal
1.3 High frequency region (>101 kHz – 2MHz)
HV-N side

1U-1N 1V-1N 1W-1N 1U-1N 1V-1N 1W-1N
10
11
12
13
14
15
16
17
IV-N side

2U-2N 2V-2N 2W-2N 2U-2N 2V-2N 2W-2N
Normal
LV side

3U-3V 3V-3W 3W-3U 3U-3V 3V-3W 3W-3U
Normal
4.3.2 Capacitance and Tan Delta Measurement Test
a) Purpose of the test

Dissipation factor / loss factor/ Tan delta is defined as the ratio of resistive components to that of
capacitive current flowing in an insulating material. Dissipation factor (tan delta) and capacitance
measurement of bushing/winding provides an indication of the quality and soundness of the
insulation in the bushing/winding.
Changes in the normal capacitance of an insulator indicate abnormal conditions such as the
presence of moisture layer, short -circuits or open circuits in the capacitance network.
b) Principle of the test

The capacitance and dissipation/loss factor (Tan δ / Cos φ) measurement are made to determine
the insulating condition of the transformer’s both winding to earth and between the windings, and
to form a reference for future measurements during operating the transformer.
There is a small amount of insulating loss in all insulators used in transformer applications at
normal operating voltage and frequency. In appropriate insulators, this loss is very small. This loss
changes in direct proportion with the “square “of the applied voltage. The insulator and equivalent
diagrams are given in figure 5.15.
a) b) c)
Fig. 5.15:
As seen in figure, the angle delta ’between the total current “Ir” and capacitive current “IC” allows
to make evaluation about the loss properties of the insulator.
The loss angle delta, depends heavily on the thick ness of the insulating material and surface
condition, structural property of the insulator, type of the material, (humidity, foreign materials/
particles, air gaps, etc. which cause ionization the insulating material).
The conditions which increase the power losses of the insulator also decrease the insulation
strength. For this reason, loss angle measurement is a very valuable criterion for evaluating the
insulation material at a defined operating frequency. Periodical measurements made during
operating are also important to show the general condition of the insulating material. In this way,
it is possible to gather information about aging of the solid insulating materials and degradation
of the oil.
The active loss of the measurement circuit can be calculated according to below equation:
P= U. I. Cos delta = U 2. C. ω. tan delta
(It is accepted that in very small angles, Cos delta will be equal to tan delta)
Capacitance, tan delta, active loss and Cos delta can be measured by bridge methods at defined
voltages or by a “power factor” (Cos delta) measuring instrument.
The measurement is made between windings and between the windings and the tank. During the
test, the temperature of the transformer should also be recorded and corrected in accordance
with the reference temperature.
The loss factor depends heavily on temperature. For this reason, in order to make comparisons
later, it has to be converted to reference temperature (for example 20 deg reference temperature)
by a coefficient.
Correction equation:
F20 = Ft / K
F20: loss factor at 20 oC temperature
Ft: loss factor value at t measuring temperature
K: correction factor is given in the table
Correction factor for transformer with mineral oil:
Measurement temperature Correction factor K

Deg. C
10 0.8
15 0.9
20 1
25 1.12
30 1.25
35 1.4
40 1.55
45 1.75
50 1.95
55 2.18
60 2.42
65 2.70
70 3.0
c) Equipment for the test:

10 KV or 12 KV fully automatic Capacitance and Tan delta test kit to be used for accurate
measurement and repeatability of test results
4.3.2.1 Transformer winding insulation tests
a) Procedure for the test
1. In a two winding transformer, there are three measurements of capacitance

i. HV to ground
ii. LV to ground
iii. HV to LV
2. These values of capacitance and their respective values of insulation factor (tan delta)
are to be measured.
3. All HV line terminals connected together and labeled (H); all LV line terminals connected
together and labeled (L); and a connection to a ground terminal, usually connected to
transformer tank labeled (G).
4. Leads from the instrument or bridge are connected to one or both terminals and
ground.
5. Either grounded specimen measurement of guarded measurements are possible, so
that all capacitance values and dissipation factor values can be determined.
6. These measurements are usually made at voltage of 10 kV or less, at power frequency.
b) Connection diagram
Fig. 5.16:
For tan delta of bushings, connections are to be carried out in UST mode.
For tan delta between windings, connections are to be carried out in UST mode.
For tan delta of windings with earth, connections are to be carried out in GST mode.
(i) HV winding measurement
1. Short all the three phases of HV winding and make the zero sequence impedance. In other
words, make the current flow only in capacitance region (Omit inductance) in the impedance
network of the transformer.
2. Make HV cable connection at HV terminals and LV cable at neutral (ground should be

isolated). If it is delta connection then LV cable connection to be made in next phase.
3. Select the test mode GST-G for capacitance measurement in between windings and GST-YG
for capacitance measurement in between windings.
3. Apply 10 kV voltage in the stepwise manner and cross check the values in all step voltages.
4. Note the measurement values of applied voltage, leakage current, power factor and
dissipation factor, capacitance, humidity and ambient temperature.
Fig. 5.17:
(ii) HV-LV connection
Fig. 5.18:
1. Short all the three phases of HV and LV winding and make the zero sequence impedance.
In other words, make the current flow only in capacitance region (Omit inductance) in the
impedance network of the transformer.
2. Make HV cable connection at HV terminals and LV cable at LV terminals.

3. Select the test mode UST-YG for capacitance measurement in between tank and winding.
5. Connections of the leads to be carried out as per diagram.
(iii) LV- Earth connection
Fig. 5.19:
1. Short all the three phases of LV winding and make the zero sequence impedance. In other
words, make the current flow only in capacitance region (Omit inductance) in the impedance
network of the transformer.
2. Make HV cable connection at LV terminals and LV cable at Neutral terminals. (Ground should
be isolated). If it is delta connection then LV cable connection to be made in next phase.
3. Select the test mode GST-G for capacitance measurement in between windings and GST-YG
for capacitance measurement in between windings.
5. Connections of the leads to be carried out as per diagram
(iv) LV-HV connection
Fig. 5.20:
1. Short the all three phases of LV and HV winding and make the zero sequence impedance.
In other words, make the current flow only in capacitance region (Omit inductance) in the
impedance network of the transformer.
2. Make HV cable connection at LV terminals and LV cable at HV terminals.
3. Select the test mode UST-YG for capacitance measurement in between tank and windings.
4. Apply 10 kV in the stepwise manner and cross check the values in all step voltages.
5. Connections of the leads to be carried out as per diagram
4.3.2.2 Transformer bushing insulation test
a) Procedure for the test
Measurement of C1 Capacitance and Tan delta

1. Connect the crocodile clip of the HV cable to the top terminal of the shorted HV/IV
bushings.
2. Unscrew the test tap cover, Insert a pin in the hole of the central test tap stud by pressing the
surrounding contact plug in case of 245 kV OIP Bushing and remove the earthing strip from
the flange by unscrewing the screw (holding earth strip to the flange body) in case of 420 kV
OIP Bushing.
3. Connect the LV cable to the test tap (strip/central stud) of the bushing under test to the kit
through a screened cable and earth the flange body.
4. Repeat the test for all Bushings by changing only LV lead connection of the kit to test tap of
the Bushing which is to be tested
Measurement of C2 Capacitance and Tan delta

1. HV lead to be connected to the test tap of the bushing under test (if required additional
crocodile type clip may be used) and LV of the kit to be connected to the ground. HV of the
bushing is to be connected to the Guard terminal of the test kit.
2. Test to be carried out in GSTg mode at 1.0kV.
3. Repeat the test for all Bushings by changing only LV lead connection of the kit to test tap of
the Bushing which is to be tested
Fig. 5.21:
b) Format of the Test Report
Test equipment
Make Type Sr. no. Range Cal. Due date

c) Format of the Test Report for Windings
VOLTAGE WINDING TEST CAPACITANCE TAN δ REMARK

COMBINATION MODE
SITE FACTORY SITE FACTORY
2 KV
HV-IV/ LV UST
10 KV
2 KV
HV-IV/ LV+G GST
10 KV
2 KV
HV-IV/ LV with
GSTg
Guard
10 KV
2 KV
LV/ HV-IV UST
10 KV
2 KV
LV/ HV-IV+G GST
10 KV
2 KV
LV/ HV-IV with
GSTg
Guard
10 KV
d) Format of the Test Report for Bushings (C1)
VOLTAGE Bushings/ TEST Capacitance C1 TAN δ REMARK

Make/ Sr. no MODE
2 KV
1U UST
10 KV
2 KV
1V UST
10 KV
2 KV
1W UST
10 KV
2 KV
2U UST
10 KV
2 KV
2V UST
10 KV
2 KV
2W UST
10 KV
e) Format of the Test Report for Bushings (C2)
VOLTAGE Bushings/ TEST Capacitance C2 TAN δ REMARK

Make/ Sr. no. MODE
0.5 KV
1U GST
1.0 KV
0.5 KV
1V GST
1.0 KV
0.5 KV
1W GST
1.0 KV
0.5 KV
2U GST
1.0 KV
0.5 KV
2V GST
1.0 KV
0.5 KV
2W GST
1.0 KV
0.5 KV
3U
1.0 KV GST
0.5 KV
3V GST
1.0 KV
0.5 KV
3W GST
1.0 KV
f) Acceptance Criteria
Tan δ for bushing (C1):
Type of bushing Tan δ (C1) Capacitance
% Limit % Change/annum % Change/annum
Resin impregnated paper insulated 0.85 +0.04 / -0.04 +1.0 / -1.0
Oil impregnated paper insulated 0.40 +0.02 / -0.06 +1.0 / -1.0
Tan δ for winding – Limit 0.01 (1.0%)
4.3.3 Voltage and Turns Ratio Measurement
4.3.3.1 Voltage Ratio Measurement
To determine
a. Any abnormality in tapings in the winding
b. Any abnormality in the winding
c. Result ensures the inductance property of the transformer
b) Equipment for the test

Digital multi meter
c) Principle for the Test
Fig. 5.22:
The total voltage induced into the secondary winding of a transformer is proportional to the
number of turns in the primary to the number of turns in the secondary, and by the amount of
voltage applied to the primary.
d) Procedure for the Test

1. Keep the tap position of the transformer in lowest position and LV in open
2. The voltage should be applied in the high voltage winding in order to avoid unsafe
voltage
3. Apply 3 phase 415 V on HV terminals
4. Measure the voltage on each phase (ph-ph) on HV and LV terminals simultaneously.
5. Ratio measurement must be made on all the taps to confirm the proper alignment and
operation of the tap changer.
6. Calculate the turns ratio in each tap position of tap: Vp/Vs
e) Test Equipment

f) Format of the Test Report

Ratio HV/IV
Tap Applied HV voltage Measured LV Ratio calculated Ratio

no. voltage actual
1U- 1V- 1W- 2U- 2V- 2W- 1U-1N/ 1V-1N/ 1W-1N/

1N 1N 1N 2N 2N 2N 2U-2N 2V-2N 2W-2N
1
2
3
4
5
6
7

no. voltage actual
1U- 1V- 1W- 2U- 2V- 2W- 1U-1N/ 1V-1N/ 1W-1N/

1N 1N 1N 2N 2N 2N 2U-2N 2V-2N 2W-2N
8
9
10
11
12
13
14
15
16
17
Ratio HV/LV

no. voltage actual
1U- 1V- 1W- 3W- 3U- 3V- 1U-1N/ 1V-1N/ 1W-1N/

1N 1N 1N 3U 3V 3W 3W-3U 3U-3V 3V-3W
N
Ratio IV/LV

no. voltage actual
2U- 2V- 2W- 3W- 3U- 3V- 2U-2N/ 2V-2N/ 2W-2N/

2N 2N 2N 3U 3V 3W 3W-3U 3U-3V 3V-3W
N
g) Acceptance Criteria
The variation of result should be within ± 0.5 % from specified values.
4.3.3.2 Transformer Turns Ratio Test

To determine the turns ratio of transformers to identify any abnormality in tap changers/
shorted or open turns etc.
b) Equipment for the test
Automatic Transformer turns ratio (TTR) meter
c) Principle for the test
The total voltage induced into the secondary winding of a transformer is proportional to the
number of turns in the primary to the number of turns in the secondary, and by the amount of
voltage applied to the primary.

1. Connect H1 and H2 leads on HV winding and X1 and X2 leads on LV winding.
2. Apply 110 V AC from the kit.
3. Adjust the phase angle error on zero.
4. Adjust % error knob such that null detector shows zero.
5. Carry out the test for all taps.
e) Equipment
Test equipment

HV/IV
Tap HV Voltage LV Voltage Theoretical Obtained Ratio Error in %

no. KV KV ratio
R Ph Y Ph B Ph
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
(b) HV/LV

no. KV KV ratio
R Ph Y Ph B Ph
N
(c) IV/LV

no. KV KV ratio
R Ph Y Ph B Ph
N
The variation of result should be within ± 0.5 % from specified values.
4.3.4 Magnetizing Current Test
a) Purpose of the Test

Excitation/ Magnetizing current test is performed to locate defect in magnetic core structure, shifting
of windings, failure in turn to turn insulation or problem in tap changer.
b) Principle of the Test

Excitation/ Magnetizing current is the current required to force a given flux through the core. It is the
RMS value of the current flowing through a line terminal of a winding when voltage is applied at rated
frequency, the other winding being open circuited.
c) Equipments for the Test

Digital multi meter
d) Circuit for the Test
Fig. 5.23:
e) Procedure for the Test

1. Apply 3 phase 440 V AC supply on HV terminals and keep LV open.
2. Measure current in all the three phases.
3. Carry out the test on max., normal and min. tap position.
4. Repeat the test for LV side.
f) Test Equipment

g) Format of the Test Report
Magnetizing current from HV
Voltage applied in Current measured in mA Current measured in mA Current measured in mA

volts Tap 1 Tap 13 Tap 17
1U-1N 1U 1U 1U
1V-1N 1V 1V 1V
1W-1N 1W 1W 1W
Magnetizing current from LV
Voltage applied in Current measured in mA Current measured in mA Current measured in mA

volts Tap 1 Tap 13 Tap 17
2U-2N 2U 2U 2U
2V-2N 2V 2V 2V
2W-2N 2W 2W 2W
h) Acceptance Criteria
§§ Excitation current < 50 mili-Amperes, then difference between two higher currents should be less
than 10%.
§§ Excitation current > 50 mili-Amperes, then difference between two higher currents should be less
than 15 %.
§§ Value of center leg should not be more than either outside for a three phase reactor.
§§ Results between similar single phase units should not vary more than 10%.
4.3.5 Magnetic Balance Test

To check the balance in the magnetic circuit (core balance) in three phase transformers. It verifies core
balance.

The voltage should be applied in one phase and measured in the other two phase of the winding. The
sharing of the voltage will be maximum in the next phase of the winding (clock wise) more than 60% of
the injected voltage and minimum voltage appear in another phase of the winding (clock wise) less than
40% of the injected voltage.
c) Equipments for the Test

Digital multi meter
Fig. 5.24:

1. For delta connected winding, apply 3 phase 440 V between phase to phase of a winding and
measure the voltage induced in other two phases of the same winding.
2. For star winding, apply 1 phase 230 V between phase and neutral and measure the voltage
induced in other two phases of the same winding.
3. Similarly all the phase should be checked with reference to other two phases
f) Test Equipment


HV side (Tap 1)
Voltage applied in volts Voltage measured at H.V. side
1U-1N 1V-1N 1W-1N
1U-1N
1V-1N
1W-1N
HV side (Tap 13)

1U-1N 1V-1N 1W-1N
1U-1N
1V-1N
1W-1N
HV side (Tap 17)

1U-1N 1V-1N 1W-1N
1U-1N
1V-1N
1W-1N
IV side (Tap N)

2U-2N 2V-2N 2W-2N
2U-21N
21V-2N
2W-2N
LV side (Tap N)
3U-3V 3V-3W 3W-3U
3U-3V
3V-3W
3W-3U
§§ The identical results confirm no damage due to transposition.
§§ Zero voltage or very negligible voltage induced in any of the other two phases shall be
investigated.
§§ The applied voltage may be expressed as 100% voltage and the induced voltage may be expressed
as percentage of the applied voltage. This will help in comparison of the two results when the
applied voltages are different.
§§ The voltage induced in the centre phase shall be 50 to 90% of the applied voltage.
§§ However, when the centre phase is excited then the voltage induced in the outer phases shall be
30 to 70% of the applied voltage.
§§ Zero voltage or very negligible voltage induced in the other two windings should be investigated.
4.3.6 Verification of Vector Group and Polarity

To verify the phase angle relationship in the winding and polarity of transformer

By shorting the R phase of HV and LV terminals, the magnitude of the phases by using the phase angle
relationship is obtained
c) Equipment for the Test

Digital multi meter

1. Keep the tap position of transformer at normal
2. Short 1U of HV and 2U of LV
3. Apply 440 V 3 phase supply to HV terminals
4. Measure the voltage across the following terminals as below
5. Make conditions in the way of arithmetical and logical for verifying the phase angle difference
For Yy0 transformer

Rn+Nn=RN
Bb=Yy
By=Yb
For Yna0d11 transformer
Fig. 5.25:
2R1-N=2Y1-N=2B1-N=Constant
2R1-1B1=3R1-N>3Y1-N>3B1-N
3Y1-1B1>3Y1-1Y1
e) Test Equipment

For star /star
Terminal Voltage measured
Rn
Nn
RN
Terminal Voltage measured
Bb
Yy
By
bY
Verify that all arithmetical relations are maintained as in the above formula as per the vector group of
transformer
4.3.7 Short Circuit Impedance Test

This test is used to detect winding movement that usually occurs due to heavy fault current or mechani-
cal damage during transportation or installation since dispatch from the factory. It is expressed as a
percentage of the rated voltage of former winding. In this case current flowing through secondary is
the full load current and is indicative of copper losses.
Rated full load current to flow through this winding when secondary winding is shorted, is known as
impedance voltage

Digital ampere meter
Fig. 5.26:
1. Connect the 3 ph 440 V supply to the HV winding and short the 3 phase of LV winding.
2. Measure primary voltage and current on HV and LV.
3. Carry out the test on min., normal and max. Tap positions.
f) Test Equipment

HV/IV (Tap 1)
Voltage applied Current measured in Amp

H.V. side L.V. side IN-n
1U-1V 1U 2U
1V-1W 1V 2V
1W-1U 1W 2W
HV/IV (Tap 13)

1U-1V 1U 2U
1V-1W 1V 2V
1W-1U 1W 2W
HV/IV (Tap 17)
1U-1V 1U 2U
1V-1W 1V 2V
1W-1U 1W 2W
HV/LV (Tap N)

1U-1V 1U 3U
1V-1W 1V 3V
1W-1U 1W 3W
IV/LV (Tap N)
2U-2V 2U 3U
2V-2W 2V 3V
2W-2U 2W 3W
Impedance Verification (HV/IV)
Tap no. Average S/C Average Voltage measured Impedance voltage % Impedance
current on LV side for S/C current on HV side voltage
1
13
17
Impedance Verification (HV/LV)
Tap no. Average S/C cur- Average Voltage measured Impedance voltage % Impedance
rent on LV side for S/C current on HV side voltage
N
Impedance Verification (IV/LV)
Tap no. Average S/C Average Voltage measured Impedance voltage % Impedance
current on LV side for S/C current on HV side voltage
N
h) Acceptable Criteria
The measured impedance voltage should be within 3 percent of impedance specified in rating and
diagram nameplate of the transformer.
Variation in impedance voltage of more than 3% should be considered significant and further
investigated
4.3.8 Measurement of Winding Resistance

To check for any abnormalities like loose connections, broken strands and high contact resistance in
tap changers due to vibrations, fault occurred due to poor design, assembly, handling, poor environ-
ment, over loading or poor maintenance and gross difference between the windings and for openness
in the connections.
Kelvin bridge technique was adopted in the way of modern digital micro processor method for measur-
ing the winding resistance. Voltage drop is proportional to the winding resistance by injecting the DC
current. Voltage drop across the winding terminal in the phase is in the following manner
U= R*I + (d0/dt); 0-flux

L= 0/t
When DC current is applied, (d0/dt) =0
So, U=R*I
Automatic winding resistance measurement kit which work on the principle of Kelvin Bridge.
Fig. 5.27:
1. Connect the current and potential leads to the transformer winding.

2. The potential leads must be connected between the current leads.
3. Do not clip the potential leads to the current leads.
4. Do not use additional extension cable leads.
5. Observe the polarity.
6. Select the test current range, which should be more than 1 % of rated current.
7. Test current should not be more than 10% of rated current.
8. If less than 1%, measured resistance is not consistent.
9. If more than 10%, it could cause erroneous readings due to over heating of the winding.
10. If possible, always inject test current to HV and LV simultaneously (two channel measurement).
11. This will magnetize the core more efficiently and shorten the time to get stable readings.
12. Measure the readings in both positive and negative polarities (tap position in ascending and
descending position)
13. During tap changing operation, continuity checks between HV to neutral to be carried out by
analog multi meter while changing tap.
14. For delta connected windings, such as tertiary winding of auto-transformers, measurement shall
be done between pairs of line terminals and resistance per winding shall be calculated as per the
following formula
a. Resistance per winding = 1.5 x Measured value
15. Take the winding temperature reading while doing the resistance measurement.
16. Calculate the resistance at 75°C as per the following formula
17. R = R (235+75)/(235+t ),Where R = Resistance measured at winding temperature t

f) Test Equipment

Temperature reading
Temp.- deg C
OTI
WTI
(a) HV-N
Tap no. Winding resistance in mili ohm
1U-1N 1V-1N 1W-1N
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
(b) IV-N
2U-N 2V-N 2W-N
N
(c) LV
3U-3V 3V-3W 3W-3U
N
h) Acceptance criteria
All readings should be within +/- 1% of each other.
There should be even increase or decrease of resistance value for the winding having tapping winding
for all three phase
4.3.9 Winding Insulation Resistance Measurement

This test reveals the condition of voids in the dielectric insulations like solid insulation in the winding
due to heat or moisture, any dampness solubility in the oil, presence of any foreign objects which is
having the corrosive characteristic present in the bushing.

If a test voltage ids applied across a piece of insulation, then by measuring the resultant current and
applying ohm’s law (R=E/I), the resistance of the insulation can be calculated. Effect of temperature in
measurement.
For every 10 deg increase in temperature, half the resistance; or for every 10 deg increase in
temperature, double the resistance. For example, a 100 Gohm resistance at 20 deg becomes 25 Gohm
at 40 deg. Cen.
Motorized or battery operated insulation tester (0-5 KV range)

a. HV/E+LV Shorted
Fig. 5.28:
b. LV/E + HV Shorted
Fig. 5.29:
c. HV /LV + Ground Open
Fig. 5.30:

1. Connect leads to HV winding and LV winding to measure IR between windings.
2. Apply 5 KV and take measurement at interval of 15 sec, 60 sec and 600 sec
3. Connect leads between winding and earth to measure IR between winding and earth.
4. Keep the other windings shorted and earthed.
5. Repeat the test.
f) Test Equipment

Temp.- deg C
OTI
WTI
Amb.
Conn. IR value in Mohm PI=IR at 600 sec/IR at 60 sec
15 Sec 60 Sec 600 Sec
HV to E
LV to E
HV to LV
Min. insulation values for one minute resistance for transformer
R=C*E/ (KVA) ^0.5.
Where,
C=1.5 for oil filled Tr at 20oC.
E= Voltage rating in V (Ph-Ph for delta and Ph-n for Y)
KVA= Rated capacity of the Tr.
As per CBIP guideline, acceptable value is 2 Mega Ohm per KV at 60 oC
Rated voltage Recommended accepted limit as a thumb rule as per CBIP guideline Min IR
Value for 1 min. at 30 deg
11 KV 300 M Ohm
33 KV 550 M Ohm
66 KV 625 M Ohm
132 KV 700 M Ohm
220 KV 750 M Ohm
400 KV 900 M Ohm
Polarization index insulation condition
PI value Insulation condition
Less than 1 Wet, Dangerous
1.0-1.1 Poor
1.1-1.25 Fair
1.25-2.0 Good
>2.0 Dry
>3 Not good (Poor impregnation of oil in insulation paper, charging current is still
increasing and not steady state)
4.3.10 Core Insulation Test
To check that core is not earthed other than the specific earth point.

The ground connection terminals for the transformer core are located at top plate of transformer in
a box. The terminals are protected by a cover. The terminal box contains a terminal block with three
terminals
1. Terminal marked CL is connected to core lamination
2. Terminal marked CC is connected to core clamps
3. Terminal marked G is connected to ground
c) Equipment for the Test:
Motorized or battery operated insulation tester (0-5 KV range)
d) Procedure for the Test:

1. Shorting link between Core, frame and earth to be removed
2. Apply 2.5 KV and take measurement at interval of 60 sec
3. After completion of Test, provide shorting link between core, frame and earth
e) Test Equipment

f) Format for the Test
Conn. IR value in Mohm
60 Sec
CC-CL
CL-G
CC-G
IR should be > 1000 MΩ
4.3.11 Oil Characteristisc Test

To check the electrical, mechanical & chemical property of the oil.
The dielectric break down voltage Test is an important Test to determine the withstanding capacity of
any insulating oil. There is a degradation of transformer oil or ingress of moisture and it is necessary to
Test the insulating oil periodically.
b) Equipment for the Test

Motorized oil BDV Test kit
c) Procedure for the Test:

1. Take oil sample from the bottom of the main tank in the oil cup. Always flush drain valve before
taking sample
2. Also flush the oil cup
3. Let the bubbles be settled down
4. Carry out the Test and take reading at which oil insulation break down
5. Take 6 readings at time interval of 10 min.
6. Average of the 6 readings is final BDV of oil
7. Oil sample to be collected from bottom of the main tank and to be sent to ERDA to carry out tests
as per IS 1866
8. Oil sample to be collected from bottom of the main tank and to be sent to ERDA to carry out tests
for DGA
d) Test Equipment

e) Format of the Test Report

BDV
Make BDV -1 BDV -2 BDV -3 BDV -4 BDV -5 BDV -6 Average
Main tank top
Main tank bottom
OLTC tank
Sr. no. Particular Accepted norms at the time of first charging As per Standard
A Appearance Clear, free from sediment and suspended matter Visual
B BDV (2.5 mm gap) 70 KV for < 72.5 KV IEC 60156

80 KV for 72.5 KV to 170 KV IEC 60156
90 KV for >170 KV IEC 60156
C Water content 20 ppm for <72.5 KV IEC 60814
15 ppm for 72.5 KV to 170 KV IEC 60814
10 ppm for >170 KV IEC 60814
D Acidity 1.2 KOH/g, maximum IS-1866-2000

IEC 61125
(method C)
E PCB content not detectable (less than 2 ppm) IEC 61619
Sr. no. Particular Accepted norms at the time of first charging As per Standard
F Resistivity
Resistivity at 90 OC 6x1012 Ohm-Cm IS-1866-2000
G Tan delta at 90 OC 0.02 maximum IEC 60247
H Interfacial Tension at 0.04 N/m ISO 6295

27 OC
I Flash point 135 OC ISO 2719
J Density at 29.5 OC 0.89 g/cm3 ISO 3104
K Kinetic viscosity at 27OC 27 cSt IS-1866-2000
L Pour point -30 OC IS-1448-P10

ISO 3016
M Oxidation stability of
uninhibited oil
1) Neutralization value 0.1 mg KOH/g IEC 62021-1/2

(Max)
2) Sludge (max) 0.8% by weight IS-1866-2000
Additional requirement minimum 0.25% IEC 60666

for inhibited oil maximum 0.40 %
If BDV value is very low and unacceptable (<30 KV/2.5 mm gap), then it is necessary to dry out & clean
the oil till the insulation reaches the satisfactory value.
4.3.12 Tests on Bushing CTs

These tests are carried out to identify the healthiness of bushing CT s and verifying the measuring and
protection systems
b) Equipment for the Test
Digital multi meter
Insulation tester
Knee point measurement kit
Current injection kit
c) Procedure for the Test
While testing, the other windings on the same phase of the transformer may have to short circuited in
order to obtain a stable reading. It is better to demagnetize any CT that is tested by impressing DC volt-
age across winding.
Rated parameters
CORE RATIO CLASS BURDEN kpV PROTECTION / METERING
Core - I
Core - II
Core - III
Core - IV
A. Polarity Test

The polarity should show in accordance with the terminal markings
b) Procedure for the Test

1. The polarity test can be done by inductive kick of direct current
2. In this test, a 1.5 V battery is connected to the primary P1-P2 of CT in such a manner that +ve
terminal of batter to be connected to P1 and –ve terminal to be connected to P2.
3 Connect +ve lead of voltmeter in S1 and –ve terminal in S2
4. Close the switch and apply 1.5 V DC, check the deflection
5. It should be in +ve deflection
c) Test Equipment

d) Format of the Test Report
CORE BETWEEN HV
R-Ø Y-Ø B-Ø N-Ø
Core I 1S1 (+ve) 1S2 (-ve)
1S1 (+ve) 1S3 (-ve)
Core II 2S1 (+ve) 2S2 (-ve)
2S1 (+ve) 2S3 (-ve)
Core III 3S1 (+ve) 3S2 (-ve)
3S1 (+ve) 3S3 (-ve)
Core IV 4S1 (+ve) 4S2 (-ve)
4S1 (+ve) 4S3 (-ve)
CORE BETWEEN LV
R-Ø Y-Ø B-Ø N-Ø
Core I 1S1 (+ve) 1S2 (-ve)
1S1 (+ve) 1S3 (-ve)
Core II 2S1 (+ve) 2S2 (-ve)
2S1 (+ve) 2S3 (-ve)
Core III 3S1 (+ve) 3S2 (-ve)
3S1 (+ve) 3S3 (-ve)
Core IV 4S1 (+ve) 4S2 (-ve)
4S1 (+ve) 4S3 (-ve)

All CT secondary polarity should be as per name plate
B. Current ratio Test

To measure the ratio of a primary to secondary current in the bushing CT and find the current ratio
error

1. Connect the current injection kit to the primary of the bushing CT and measure the current through
tong tester having the range of 300A
2. Measure the current through tong tester having the range of 300mA in secondary CT
3. Apply 20% of rated current to he primary side
4. Measure the corresponding primary and secondary current.
5. % error of CT ratio = (Measured current ratio- Theoretical ratio)/Theoretical ratio
c) Test Equipment

(a) HV R
Core Terminals Primary Current Secondary Theoretical Actual % of

% Actual Current Ratio Ratio Error
Core I (1S1 – 1S2) 20%
(1S1-1S3) 20%
Core II (2S1 – 2S2) 20%
(2S1-2S3) 20%
Core III (3S1 – 3S2) 20%
(3S1-3S3) 20%
Core IV (4S1 – 4S2) 20%
(4S1-4S3) 20%
(b) HV Y

Core I (1S1 – 1S2) 20%
(1S1-1S3) 20%
Core II (2S1 – 2S2) 20%
(2S1-2S3) 20%
Core III (3S1 – 3S2) 20%
(3S1-3S3) 20%
Core IV (4S1 – 4S2) 20%
(4S1-4S3) 20%
(c) HV B

Core I (1S1 – 1S2) 20%
(1S1-1S3) 20%
Core II (2S1 – 2S2) 20%
(2S1-2S3) 20%
Core III (3S1 – 3S2) 20%
(3S1-3S3) 20%
Core IV (4S1 – 4S2) 20%
(4S1-4S3) 20%
(d) HV N

Core I (1S1 – 1S2) 20%
(1S1-1S3) 20%
Core II (2S1 – 2S2) 20%
(2S1-2S3) 20%
Core III (3S1 – 3S2) 20%
(3S1-3S3) 20%
Core IV (4S1 – 4S2) 20%
(4S1-4S3) 20%
(e) IV R

Core I (1S1 – 1S2) 20%
(1S1-1S3) 20%
Core II (2S1 – 2S2) 20%
(2S1-2S3) 20%
Core III (3S1 – 3S2) 20%
(3S1-3S3) 20%
Core IV (4S1 – 4S2) 20%
(4S1-4S3) 20%
(f) IV Y

Core I (1S1 – 1S2) 20%
(1S1-1S3) 20%
Core II (2S1 – 2S2) 20%
(2S1-2S3) 20%
Core III (3S1 – 3S2) 20%
(3S1-3S3) 20%
Core IV (4S1 – 4S2) 20%
(4S1-4S3) 20%
(g) IV B

Core I (1S1 – 1S2) 20%
(1S1-1S3) 20%
Core II (2S1 – 2S2) 20%
(2S1-2S3) 20%
Core III (3S1 – 3S2) 20%
(3S1-3S3) 20%
Core IV (4S1 – 4S2) 20%
(4S1-4S3) 20%
(h) IV N

Core I (1S1 – 1S2) 20%
(1S1-1S3) 20%
Core II (2S1 – 2S2) 20%
(2S1-2S3) 20%
Core III (3S1 – 3S2) 20%
(3S1-3S3) 20%
Core IV (4S1 – 4S2) 20%
(4S1-4S3) 20%
Ratio error should match with factory results
C. Excitation Current

The magnetization test is conducted in order to see the condition of the turns of the secondary. This
test gives the indications regarding the shorting of turns CT secondary winding and to establish CT
characteristics as well as capability of CT.
b) Procedure of the test

1. Apply AC voltage to the secondary winding of the CT with primary open circuit
2. Vary the applied voltage from 25% of Vk to 110 % of Vk
3. Measure the current drawn by the winding at each selected value is recorded
4. Verify that, exciting current is less than specified at Vk/2
5. This test should not be performed for metering core
6. If Knee Point Voltage is not mentioned then Knee Point Current may be taken into consideration.
c) Test Equipment

i. HV R
Voltage Excitation Current Measurement

current
To Be Applied Actual Core – I Core – II Core – III Core – IV
Value 1S1-1S3 2S1-2S3 3S1-3S3 4S1-4S3
0.25 x KVp mA
0.50 x KVp mA
0.75 x KVp mA
1.00 x KVp mA
1.10 x KVp mA
ii. HV Y

current
Value 1S1-1S3 2S1-2S3 3S1-3S3 4S1-4S3
0.25 x KVp mA
0.50 x KVp mA
0.75 x KVp mA
1.00 x KVp mA
1.10 x KVp mA
iii. HV B

current
Value 1S1-1S3 2S1-2S3 3S1-3S3 4S1-4S3
0.25 x KVp mA
0.50 x KVp mA
0.75 x KVp mA
1.00 x KVp mA
1.10 x KVp mA
iv. HV N

current
Value 1S1-1S3 2S1-2S3 3S1-3S3 4S1-4S3
0.25 x KVp mA
0.50 x KVp mA
0.75 x KVp mA
1.00 x KVp mA
1.10 x KVp mA
v. IV R

current
Value 1S1-1S3 2S1-2S3 3S1-3S3 4S1-4S3
0.25 x KVp mA
0.50 x KVp mA
0.75 x KVp mA
1.00 x KVp mA
1.10 x KVp mA
vi. IV Y

current
Value 1S1-1S3 2S1-2S3 3S1-3S3 4S1-4S3
0.25 x KVp mA
0.50 x KVp mA
0.75 x KVp mA
1.00 x KVp mA
1.10 x KVp mA
vii. IV B

current
Value 1S1-1S3 2S1-2S3 3S1-3S3 4S1-4S3
0.25 x KVp mA
0.50 x KVp mA
0.75 x KVp mA
1.00 x KVp mA
1.10 x KVp mA
viii. IV N

current
Value 1S1-1S3 2S1-2S3 3S1-3S3 4S1-4S3
0.25 x KVp mA
0.50 x KVp mA
0.75 x KVp mA
1.00 x KVp mA
1.10 x KVp mA
Excitation current should not be more than specified on name plate.
10 % increase in the voltage from 100 % to 110 %, increase in current should not be more than 50%
D. Insulation Resistance Measurement

To check any shorting of any CT secondary core with earth or between cores

1. IR measurement secondary core to earth
2. Connect insulation tester leads between CT secondary and earth
3. Apply 500 V DC and measure IR value
4. Carry out test for all cores of all HV and IV CTs
5. IR measurement secondary core to core
6. Connect insulation tester leads between CT secondary cores
7. Apply 500 V DC and measure IR value
8. Carry out test for all combinations of core to core for all HV and IV CTs
c) Test Equipment

Measurement Between Unit HV
R–Ø Y-Ø B-Ø N-Ø
Earth - Core I MΩ
Earth - Core II MΩ
Earth - Core III MΩ
Earth - Core IV MΩ
Measurement Between Unit IV
Earth - Core I MΩ
Earth - Core II MΩ
Earth - Core III MΩ
Earth - Core IV MΩ
Core I - Core II MΩ
Core I - Core III MΩ
Core I - Core IV MΩ
Core II - Core III MΩ
Core II - Core IV MΩ
Core III - Core IV MΩ
Measurement Between Unit IV
Core I - Core II MΩ
Core I - Core III MΩ
Core I - Core IV MΩ
Core II - Core III MΩ
Core II - Core IV MΩ
Core III - Core IV MΩ
Insulation resistance should be more than 50 Mega ohm

E. Continuity test of Bushing CT secondary winding
To check any open of any CT secondary core including pilot wires up to C & R panel
1. Connect multi meter across each core and check continuity up to Tr MK box and up to remote
protection panel end.
c) Test Equipment

Measurement Between Terminal HV

Between
Core - I 1S1-1S2
1S1-1S3
Core - II 2S1-2S2
2S1-2S3
Core - III 3S1-3S2
3S1-3S3
Core - IV 4S1-4S2
4S1-4S3
Measurement Between Terminal LV

Between
Core - I 1S1-1S2
1S1-1S3
Core - II 2S1-2S2
2S1-2S3
Core - III 3S1-3S2
3S1-3S3
Core - IV 4S1-4S2
4S1-4S3
Continuity test should be OK

F. Winding resistance measurement of bushing CT secondary winding

To check healthiness of winding of CT secondary up to MK Box of Transformer

1. Connect multi meter across each core and measure winding resistance up to Tr MK box.
c) Test Equipment


Between Terminal
Core - I 1S1-1S2 Ω
1S1-1S3 Ω
Core - II 2S1-2S2 Ω
2S1-2S3 Ω
Core - III 3S1-3S2 Ω
3S1-3S3 Ω
Core - IV 4S1-4S2 Ω
4S1-4S3 Ω
Measurement Between Unit LV

Between Terminal
Core - I 1S1-1S2 Ω
1S1-1S3 Ω
Core - II 2S1-2S2 Ω
2S1-2S3 Ω
Core - III 3S1-3S2 Ω
3S1-3S3 Ω
Core - IV 4S1-4S2 Ω
4S1-4S3 Ω
Winding resistance should be comparable with factory results

4.3.13 Operational Tests and Checks on other Equipments
A. Temperature Indicators
The function of temperature indicator is to monitor and control the temperature of oil and winding in
the transformer. There are two types of temperature indicators.
1. Winding temperature indicator in each winding
2. Oil temperature indicator
B. Winding Temperature Indicator
In WTI the first to check the working of cooler control, alarm and trip signal
a) Procedure for the Test

1. Access the local winding temperature indicator and rotate the temperature indicator pointer
slowly to the first stage cooling value (65 deg C). Check that the fans of those coolers are
working.
2. Continue rotating pointer to second stage cooling value (80 deg C). Check that the fans of
those coolers are working
3. Rotating the pointer to alarm value (110 deg C). Check in control room to ensure that alarm
signal
4. Rotate the pointer to (125 deg C) trip value. Check in control room to ensure that trip signal
has been received.
b) Procedure calibration of WTI with hot oil

1. Remove the winding temperature indicator bulb from transformer pocket.
2. Insert the bulb in to calibrated temperature controlled bath. Raise the temperature of the
bath in 5 deg C steps and check the response of winding temperature indicator after 10
minutes.
3. This continue up to 30 deg C. Allowable tolerance is =/- 3 deg C.
4. Reduce the temperature of the bath in 5 deg C steps and check corresponding temperature
in the indicator after 10 minutes. Allowable tolerance is +/-3 deg C
5. WTI OFAF rating check by using calibrated temperature controlled bath procedure:
6. Remove WTI sensor from transformer lid and put in to calibrated temperature controlled ol
bath.
7. Increase temperature of oil bath in 20 deg C steps from 30 deg C up to maximum temperature
of 150 deg C.
8. Check and record WTI output readings in milliamps DC against temperature in accordance
with table below.
Temperature mili amps
30 4.0
40 5.3
60 8.0
80 10.7
100 13.3
120 16.0
140 18.7
c) Procedure for Secondary Injection Test for WTI

1. First isolate all cooler supplies from WTI
2. Then replace WTI bulb in to calibrated temperature controlled bath and maintain constant
temperature of 50 deg C
3. Inject the rated current (4.9A) in to appropriate terminals on winding temperature indication
test panel
C. Oil Temperature Indicators
a) Procedure for the Test

1. Access the local winding temperature indicator and rotate the temperature indicator pointer
slowly to the alarm value (95 deg C). Check in control room to ensure that alarm signal.
2. Continue rotating pointer to (110 deg C) trip value. Check in control room to ensure that trip
signal has been received.
b) Procedure for calibration of OTI with hot oil

1. Remove the oil temperature indicator bulb from transformer pocket.
2. Insert the bulb in to calibrated temperature controlled oil bath.
3. Raise the temperature of the bath in 20 deg C steps and check the response of oil temperature
indicator after 10 minutes.
4. This continue up to 120 deg C. Allowable tolerance is =/- 3 deg C.
D. Operational checks of Magnetic Oil Gauge
The function of MOG is to indicate the continuous level of oil inside the transformer on a calibrated
dial.
The calibrated scale having three markings: Low, 35 deg fill level and High.
It should show 35 deg (normal level) of oil in the tank
E. Operational checks of Pressure Relief Valve
Procedure
Check the normality open and normality close contacts by lifting the pressure valve
F. Tests on OLTC
1. Conduct the visual inspection of equipment
2. Check the manual operation of all taps (Local)
3. Check complete wiring of the circuit
4. Check the limit switch
5. Check the over load device of driving motor by measuring the current
6. Check the local electrical operation of OLTC
7. Check the remote electrical operation of OLTC
8. Check the status of tap position indicator
9. Check operation of master and follower scheme (Parallel operation)

Sr. no Description Status

OK Not OK
1 Visual inspection of equipment
2 Manual operation of all taps (Local)
3 Overload device of driving motor
4 Local operation (Electrical)
5 Remote operation (Electrical)
6 Tap position indicator
7 Check operation with master follower scheme
G. Test on Buchholz Relay
1. Check the normality open and normality close contact by following steps
2. Close the conservator flow valve and tank flow valve which is present in the conservator pipe line
3. Drain the oil which is present in between the two valves
4. Ensure the contact change by using the multi meter in two steps alarm and trip
5. After closing the drain knob in buchholz relay then close the conservator valve first and close tank
valve
H. Cooling System Check
1. Check all radiator valves are open
2. To check the motor insulation healthiness by doing the IR test
3. To check the excitation current measurement in the motor winding
4. To check the direction of rotation in motor
5. To verify the cooling interlocks
4.3.14 Measurement of Earthing Pit Resistance
To measure value of earthing pit resistance and verify that, fault current has minimum resistance to
ground
There is hand operated D.C.generator. While feeding current to spike, D.C. current is converted into
A.C. current by the converter and A.C. current received from spike is again converted in D.C. current by
the help of rectifier, while going to generator. A.C. current is fed to the spike driven in earth because
there should not be electrolytic effect.
Earth tester
Fig. 5.31:

1. Earth tester is used for measurement of Earth resistance.
2. For measurement of earth pit resistance, pit earthing connection should be disconnected from
main grid.
3. Earth tester terminals C1 & P1 are shorted to each other and connected to the earth electrode
(pipe) under test.
4. Terminals P2 & C2 are connected to the two separate spikes driven in earth.
5. These two spikes are kept in same line at the distance of 25 meters and 50 meters due to which
there will not be mutual interference in the field of individual spikes.
6. If we rotate generator handle with specific speed we get directly earth resistance on scale.
7. If earth resistance is more, proper treatment is to be given.
f) Test Equipment

Earthing Pit Resistance
Pit no Resistance in ohm

Body earth 1
Body earth 2
HV Neutral earth 1
HV Neutral earth 2
LV Neutral earth 1
LV Neutral earth 2
Value of earth pit resistance should be less than or equal to 1 ohm.
4.3.15 Protection and Alarms
Sr. no Device Set for Actual
Alarm Trip Alarm Trip
1 Winding temperature high
2 Oil temperature high
3 Oil flow failure
4 Pressure relief valve
5 Main tank buchholz relay
6 OLTC buchholz relay
7 Fan failure
8 OTI main Tank
9 WTI main tank
10 Low oil level
11 Differential relay
12 Over load rely
13 Earth fault relay
14 Directional over current
15 Inter trip relay operated
16 Trip free check
17 Backup over current
18 Restricted earth fault
19 Over flux
a) Acceptance Criteria
Prove the tripping of associated breakers by actual operation of the various devices and relays as per
the schemes
4.3.16 Contact Resistance Measurement

To determine the firmness of torque level in between the bushing jumper and transmission line If torque
level is more than or less then the standard position, the heat will dissipated in the joints.
It leads to corrosion in the joints.

Voltage drop is proportional to the contact resistance by injecting the DC current. It depends on the
voltage drop across the contact terminal in between the transmission line and the jumper of the
bushing.
c) Procedure
Direct measurement of resistance by using micro ohm meter
d) Test Equipment

e) Format of the Test Report
Contact resistance R ph Y ph B ph
Across HV bushing terminal joints
Across IV bushing terminal joints
Across LV bushing terminal joints
Across Neutral connection point
Across surge arrestor connection
The value of contact resistance should not be more than 5 micro ohm per joint/ connector
4.3.17 Clearances
Check the clearances for live parts
a) Format of the Test Report
Particular Clearance
HV phase to phase
HV phase to earth
IV phase to phase
IV phase to earth
LV phase to phase
LV phase to earth
4.3.18 Protection Relay Settings
Particular Value
Settings of OTI alarm
Settings of OTI trip
Settings of WTI alarm
Settings of WTI trip
Settings of start & stop of cooling fan set -1
Settings of start & stop of cooling fans set-2

4.3.19 Final Documentation Review
1 Final document of pre commissioning checks reviewed and approved. YES NO
2 Documents regarding spares, equipment, O & M manuals etc are available at site for O YES NO
& M purpose.
3 After modification, if any, as built drawings are available at site
5 FINAL COMMISSIONING CHECKS
It is important to ensure seamless, full and final integration of power transformer in a substation after
commissioning tests specified above. These checks are related to functional and operational conditions within
transformer elements as well as external interfaces so that transformer can perform successfully in a transmission
system.
1. All the test results of unit are verified and compared with factory results before commissioning.
2. No leakage of oil in any part of unit.
3 Ensure external electrical clearance of conductor jumpers in the switchyard with transformer body, gantry,
column, jumpers, fire wall etc.
4. Ensure that tertiary winding terminals are insulated, when they are not used / connected to any system.
5. Ensure earthing of Neutral, main tank body, radiator frame structure, fans and motor.
6. Neutral earthing flat of suitable size must run through support insulator and connected to two separate
earthing pits which are in turn connected to main earth mat of switchyard.
7. Ensure that conductor jumpers connected to HV, LV and tertiary terminals are not tight and should have
the allowance for contraction. Also ensure that connectors are properly erected with tightness at bushing
terminal.
8. Ensure that R.Y.B designated terminals of transformer are matching with R,Y,B buses of switchyards on HV
and LV side.
9. Ensure oil level in the Bushings.
10. Ensure continuity of OLTC operation at all taps.
11. In a transformer bank of three single phase units, ensure master- slave OLTC scheme.
12. In a transformer bank of three single phase units, ensure tertiary connection and protection scheme.
13. Ensure oil filling in conservator tank according to temperature scale in MOG and also ensure oil level in pris-
matic glass.
14. Ensure that all valves between main tank and radiator banks are opened.
15. Ensure those radiator valves connected to header are open.
16. Ensure that valve to conservator tank via Buchholz relay is open.
17. Ensure physical operation of local protections like Buchholz, PRV, Surge relay of OLTC etc.
18. Ensure OTI and WTI settings of fan & pumps operation, Alarm and Trip as per approved drawings. Fan and
pump operation shall be ensured locally and remotely.
19. Review and ensure protection scheme of power transformer with over all protection scheme at remote end
in control room.
§§ Differential Protection
§§ Restricted Earth Fault Protection.
§§ Over current and Earth fault protection.
§§ Over fluxing Protection.
§§ OTI & WTI- alarm and trap
§§ RTCC panel interface with protection system
§§ Local protection like Buchholz, PRV etc.
§§ Integration of on-line condition monitoring equipments.
20. Ensure the common earthing of tank, frame and core provided in transformer.
21. Ensure the shorting of spare cores of bushing CT’s.
22. Ensure that cap in the tan delta measurement point in the bushing is put back.
23. Ensure Fire Protection System and oil drain valve operation before charging and commissioning.
24. Oil test results after filtration must be within specified limit.
25. Spares like bushings shall be tested and kept ready before charging and commissioning.
26. Allow minimum period of 24 hrs after filtration for oil temperature to settle down.
27. Ensure release of air from plugs provided on top of main tank, conservator and radiator headers.
28. Take charging clearance certificate from all erection agencies for removal of man, material and T&P from
site.
29. Ensure healthiness of Air Cell.
30. Ensure availability of oil in the breather cup in main tank/ OLTC tank.
31. Ensure all rollers are locked with rails.
32. Ensure door seals of Marshalling Box are intact and all cable gland plate’s unused holes are sealed.
33. Ensure change over operation of AC supply from source- I to source-II in local master control cubicle.
6 ENERGISATION OF UNIT AND SITE CLOSING

Commissioning of transformer is not complete unless it is put into regular service. Following activities to follow:-
1. Initially charge the transformer under no load and keep it energize for 24 hrs.
2. Gradually load the transformer observing the noise, vibration, temperature rise, oil leakage etc.
3. Check OLTC operation.
4. Carry out Thermo vision scanning of HV/LV terminals and tank body.
5. Carry out DGA test of oil as per schedule given in flow chart of this manual
6. Hand over testing and commissioning records to operation staff along with O&M manual of OEM.
7. Ensure closure of project by clearing site in all respect particularly removal of temporary sheds, T&P, Oil and
handing over spares to customer as per contract.
Chapter - 6
Transformer Oil

Mr. Atul Shah - Raj Petro Specialties
Dr. C. Narasimhan - Savita Oil Technologies Ltd.
Mr. Vinod K. Rishi - Savita Oil Technologies Ltd.
Mr. Sanjay Abhyankar - Apar Industries Ltd.
Mr. Arjun Lad - Nynas Naphthenic Pvt. Ltd.
Mr. Abhijit Sen Roy - Indian Oil Corporation
Mr. Nalin Nanavati - Raj Petro Specialties
Mr. D. V. Jagannathan - Apar Industries Ltd.

CHAPTER - 6
TRANSFORMER OIL
INTRODUCTION
Transformer oil is like a blood in human body. Once power transformer is charged and commissioned, transformer oil
becomes a key element to monitor the healthiness of unit and DGA is one of the important tools to predict probable
fault developing in unit as well as analyse insipient trippings. In service, it is continuously performing the role of
insulation under electric stress and cooling medium.
In India, the production technology, sourcing of petroleum crude and chemistry have undergone drastic changes in
last 5 decades and today we have fairly good understanding of our requirement based on field experience.
Standardisation Committee thoroughly deliberated on various aspects and has come out with universally acceptable
data-sheet of transformer oil specification, which could be easily produced and will perform in Indian weather
conditions.
It is nevertheless, important to note that transformer oil alone can’t perform unless designer takes care of following
key points:
1. Design of cooling system to keep temperature rise under control.
2. Correct quantum of oil depending upon voltage and MVA rating of transformer.
3. To plug all probabilities of moisture ingress in transformer – Air-cell/ silica-gel breather/ Sealing System.
4. To confirm that oil does not react with any insulation material used in transformer.
5. Characteristics of oil for ageing must be studied in advance depending upon application of transformer in a
system.
6. To take feedback from users on similar oil provided to other units in past for similar application.
The above key points must be covered in design review exercise.
Data Sheet
As per Annexure - 6.I and testing of oil as per specified standard is mandatory.
Pre-Commissioning Checks
1. Mode of transport and method of supply is important. Manufacturers and customers have to mutually agree on
this. In case of bulk supply in tankers, due care is required to ensure that tanker is chemically neutral inside and
sealed firmly for final inspection at its destination. In case, it is supplied in drums, it is to be ensured during usage
that drum seal is intact.
2. Transformer oil received at site in tanker must be unloaded to another tank through filter machine only. Its BDV and
PPM value for water content must be verified to ascertain that there was no infringement during transportation.
3. Transformer oil received in drums must be stored on an elevated platform. Drums are to be horizontally placed
with its opening cap in middle.
4. Before filling oil in transformer through filter machine, it has to be filtered separately in oil tanks and ensure BDV
and PPM value.
5. During filtration, temperature of oil must remain within 60°C.
6. Excessive filtration of oil must be avoided. In case BDV and PPM values are not achieved within 7 days, check the
entire process thoroughly.
ANNEXURE 6.1
IEEMA STANDARD SPECIFICATION FOR TRANSFORMER OIL

(for 132 KV & ABOVE CLASS UP TO 765 KV)
Sr. Characteristics of Transformer Oil Requirement Method of Test

No.
1 Appearance The oil shall be clear Visual.

transparent & free from (A representative sample of the oil shall
suspended matter of be examined in a 100 mm thick layer, at
sediments. ambient temperature.)
2 Density, gm/cm3
- at 29.5 0C maximum 0.89 IS: 1448 P16
- at 20 0C 0.895 ISO 3675 / ISO 12185
3 Kinematic Viscosity,
in CST (sqmm/sec)
ISO 3104
- at 40 0C, maximum 12
- at -20 0C, maximum 1800
4 Flash Point, 0C minimum 135

ISO 2719
Penskey-Marten (Closed)
5 Interfacial Tension at 27 0C Newton/M, 0.04

ISO 6295
minimum
6 Pour point, maximum - 30 0C IS: 1448 P:10 / ISO 3016
7 Neutralization Value
Total acidity 0.01 IEC:62021-1 or 2
mg KOH/gm, maximum
8 Corrosive Sulphur Not corrosive

IEC 62535
(In terms of classification of copper
(1500C for 72 hrs)
strip+paper)
9 Total Sulphur Content % w/w < 0.15

BS 2000 Part 373 or ISO 14596
10 Electric Strength
(Break down voltage)
New Untreated Oil 30 kV minimum (rms) IEC 60156
After treatment 70 kV minimum (rms)
11 Dielectric Dissipation Factor

IEC:60247
(Tan delta) at 90 0C 0.002 maximum
12 Oxidation Stability1 after 500 Hrs.

@ 120 0C, Max
Total Acidity in mg KOH/gm maximum 0.3 IEC 61125 (method C)
Total sludge % by weight maximum 0.05
DDF at 90 0C 0.02
13 Presence of Anti Oxidation Inhibitor

(Additive),
IEC:60666
Minimum 0.25 %
Maximum 0.4 %
14 Water Content PPM (maximum) < 30 (in bulk);

As delivered < 40 (in drum) IEC 60814

No.
15 Poly Chlorinated Biphenyls (PCB) Content Not detectable

IEC 61619
(< 2 PPM)
16 Poly Cyclic (PCA) content, maximum 3% BS 2000 part 346
17 2 FAL/ Furans, ppm < 0.1 IEC 61198
18 Impulse Breakdown Voltage Test > 145 kVp ASTM method

D 3300
Note:
1) In case utility decides to adopt uninhibited oil, only following change shall be applicable.

No.
12 Oxidation Stability after 164 Hrs. @ 120 0C, maximum IEC 61125 (method C)
a) Total Acidity in mg KOH/gm maximum 1.2
b) Total sludge % by weight maximum 0.8
c) DDF at 90 0C 0.05
2) In case of inhibited oil, content of additives shall be monitored by user at regular intervals and if depletion is
observed below specified limit, corrective action shall be taken to prevent transformer risk in future.
3) P N A content shall be taken as finger print value by oil supplier and shown in acceptance test report.
4) When pour point (maximum) has been decided as (-30 0C), Lowest Cold Start Energizing Temperature shall
be (-20 0C).
Chapter - 7
Design Review

Mr. M. Vijayakumaran – ALSTOM Ltd
Mr. S. K. Negi – GETCO
Mr. Y. V. Joshi – GETCO

CHAPTER - 7
DESIGN REVIEW
1. INTRODUCTION
A design review is a planned exercise to ensure that both parties understand the application and the requirements
of the applicable standards and specification. It is the opportunity for both parties to scrutinize the proposed
design to ensure that the requirements will be met not only technical requirements but also those relating to
other aspects of the contract, like quality. The whole emphasis of a design review is directed at establishing
what is being provided is fit for purpose in all respects for the intended performance in service and that the
manufacturer uses proven materials, design tools, methodology and experience to assure the product will meet
this requirement, also in all respects.
Design reviews implies also to strengthen the relationship between the purchaser and manufacturer and a
good opportunity for the purchaser to better understand the technical capabilities of the manufacturer and for
the manufacturer to understand the need of their customers for the sake to have products adapted to their
needs. Hence the design review is a good opportunity to interchange experiences that can be used to propose
enhancements or betterments. For these reasons it is strongly advisable for the purchaser to have expert
transformer engineer(s) with them during the meeting.
A design review, initiated and chaired by the purchaser should be held for the purpose of conducting an in-
depth review of the ordered Power Transformer and to allow the purchaser to have a clear understanding of the
transformers design, manufacture and test including the likelihood of operating in service as intended.
The following are the pre-requisites for carrying out the design review:
1. It is desirable to have vendor assessment of the manufacturer before placement of order.
2. Design review should be part of the tender inquiry and it becomes obligatory on the part of the customer
and manufacturer to ensure compliances with the contract specifications.
3. It is to be ensured that all stake holders are involved in the design review. The designer both mechanical
and electrical, ultimate user, production head and if possible, sub vendor also could be invited for the design
review. Agenda is to be prepared by customer and sent to manufacturer well in advance.
4. Review may include certain informations which are of proprietary nature. It is, therefore, desirable to have
mutual agreement between the purchaser and the manufacturer for the confidentiality of information.
5. It is important for the success of design review that both the purchaser and manufacturer are clear on the
requirements and well prepared to have open and frank sharing of information.
2. OBJECTIVES OF DESIGN REVIEW
Both the purchaser and manufacturer must understand that following objectives are met during the design
review:
1. To ensure that there is a clear and mutual understanding of the transformer technical requirements accord-
ing to purchaser specification and applicable industry standards.
2. To understand the application and verify the system and project requirements and to indicate areas where
special attention may be required.
3. To verify that the design complies with the technical requirements.
4. To identify any prototype features and evaluate their reliability and risks.
5. To interchange experiences that can be used to identify eventual betterments in the design and / or im-
provements and changes in the specification.
6. To better understand the technical capabilities of the manufacturer.
7. To strengthen the technical relationship between purchaser and manufacturer and eventually to improve
and go deep in the transformers design knowledge by some participant on the purchasers side.
3. ELEMENTS OF DESIGN REVIEW
Having understood the purpose of design review and objectives, it is important to know the various elements
of design review which will clear all the doubts about the functionality (application), soundness of designs with
margins, selection of material and components and also specific operating requirements for its designed life.
They are broadly as follows:
S. No. Elements
1. System data
2. Environmental data
3. Transformer parameters
4. Transformer design
5. Transformer ancillaries and accessories.
6. Transformer oil
7. Fabrication
8. Testing
9. Name plate
10. Transportation
11. Site erection, testing & commissioning
12. Health and safety equipments
13. Contract documents and drawings
14. Document submission time scale

Design review guidelines of Cigre WGA2.36 (Technical brochure 204) have elaborated above elements in detail
as under:
Sr. No. Elements of Check Points

design review
1. System data System Voltage Variations

Tap changers
System Frequency Variation
System Short Circuit Capacity
System Switching and Transformer Protection
High Frequency Transients (HFT)
Voltage Transients
Current Harmonics
Geomagnetic Induced Currents
2. Environmental Ambient temperature range, rate of change of temperature and effect on the overload
data capability
Lowest Cold Load Start-up (LCLS)
Solar radiation
Site altitude
Humidity
Pollution
Seismic zone and response spectra
Geomagnetic currents
Ultraviolet (UV) radiation
Isoceraunic level
3. Transformer Alternating Current Terminal Voltages

parameters Insulation Levels – line to line and line to ground
Winding Impedances
Cooling Provisions
Temperature Limits
Short Circuit Withstand Capability
Cable Connection Bushings and Isolated Phase Bus Bar Connections
Sound Levels
Losses – No load and load losses
Excitation
High Temperature Design
4. Transformer Core
design Windings
Thermal design
The short circuit capability
Core, Winding Assembly and Drying
Leads and Cleats
Insulation Design
Leakage Flux Control
Drying and Processing
Sound Level
Seismic
5. Transformer Bushings
ancillaries and Bushing and Internal Current Transformers
accessories. Tap Changers
Internal Surge Arresters
Control Cabinet and External Cabling
Online Monitoring Equipment
6. Transformer oil Review as per exclusive Chapter 6 of this Manual.
7. Fabrication General Construction

External Cooling Equipment
Conservators/Preservation Systems
Fabrication Drawings
Gas Collection System Design
Surface Preparation and Planning
Sr. No. Elements of Check Points

design review
8. Testing As per Annexure - 7.1
9. Rating Plate As per figure 7.1
10. Transportation Transportation Plan and Handling

Design for Transport
Transportation Shipping Profile
Transportation Routing
Transportation Shipping Impact Withstand
Fixtures on Transformer
Marking of Center of Gravity
Ship and Barge Issues
Rail Car Issues
Road Transport Issues
Transportation monitoring management of transformer
Transportation of transformer accessories, components removed from the transformer
Acceptance criteria for receiving transformer
Transformer Unloading to Foundation
11. Site erection, As per the exclusive Chapter 5 of this Manual.

testing &
commissioning
12. Health and safety As per guideline and policy of customer. Also refer Chapter - 5 on Erection, Testing and
commissioning of this Manual.
13. Contract As per Annexure - 7.2.

documents and
drawings
14. Document As agreed between purchaser and manufacturer.

submission time
scale
Design review does not absolve or substitute manufacturer’s ultimate responsibility for the adequacy of transformer
design and construction, including design limits and margins, quality, performance on test and in service.
REFERENCES
The following list may be referred, but this is not a limitation on referring to other standards and codes as long as it
serves the purpose for effective design review.
IEC 60044: Current Transformers.
IEC 60050: International Electrotechnical Vocabulary – Chapter 421: Power Transformers and Reactors.
IEC 60060-1: General Definitions and Test Requirements.
IEC 60071-1: Insulation Coordination - Part 1: Definitions, Principles and Rules.
IEC 60071-2: Insulation Coordination - Part 2: Application Guide
IEC 60076-1: Power Transformers - Part 1: General.
IEC 60076-2: Power Transformers - Part 2: Temperature Rise.

IEC 60076-3: Power Transformers - Part 3: Insulation Levels and Dielectric Tests.
IEC 60076-5: Power Transformers - Part 5: Ability to withstand Short-Circuit.
IEC 60076-6: Power Transformers - Part 6: Reactors
IEC 60076-7: Power Transformers - Part 7: Loading guide for oil- immersed Power Transformers.
IEC 60076-8: Power Transformers - Part 8: Application Guide for Power Transformers.
IEC 60076-10: Power Transformers - Part 10: Determination of Transformer and Reactor Sound Levels.
IEC 60076-11: Power transformers - Part 11: Dry-type transformers
IEC 60076-18: Power transformers - Part 18: Measurement of frequency response
IEC 60076-16: Power transformers - Part 16: Transformers for wind turbine applications
IEC 60137: Bushings for Alternating Voltage Above 1000 V.
IEC 60214-1: Tap-Changers - Part 1: Performance requirements and Test Methods.
IEC 60214-2: Tap-Changers - Part 2: Application guide.
IEC 60270: High-voltage test techniques - Partial discharge measurements
IEC 60296: Fluids for Electro-technical applications - Unused mineral insulating oils for transformers and switchgear
IEC 60815-1: Selection and dimensioning of high-voltage insulators intended for use in polluted conditions - Part 1:
Definitions, information and general principles
IEC 60815-2: Selection and dimensioning of high-voltage insulators intended for use in polluted conditions - Part 2:
Ceramic and glass insulators for a.c. systems
IEC 62032: Guide for the Application, Specification and Testing of Phase-Shifting Transformers
Other documents of relevance are:
ISO 9001: Quality System – Model for Quality Assurance in Design/Development.
CIGRÉ TB 209: Short Circuit Performance of Power Transformers
CIGRÉ TB 528: Guide for Preparation of Specifications for Power Transformers
CIGRÉ TB 530: Guide for Conducting Factory Capability Assessment for Power Transformers.
A
400
10
10
1
1
XXX Transformer Pvt. Ltd.
315 MVA 400/220KV AUTO TRANSFORMER
REF. STANDARDS IS:2026
COOLING ONAN/ONAF/OFAF
RATING (HV-MV) MVA 189/252/315 FREQUENCY Hz 50
PHASES. 3/3
(LV) MVA 63/84/105
HV V 400000 IMPEDANCE TAP.NO.1 %

VOLTAGE.
RATED MV V 220000 TAP NO.9 %
HV-MV(315MVA BASE)
2
2
VOLTAGE
LV V 33000 TAP NO.17 %
VECTOR GROUP REF. YNa0d11

HV A 272.79/363.73/454.66
FULL LOAD CORE MASS kg.
MV A 495.99/661.32/826.66
CURRENT
HV kg.
LV A 1102.21/1469.61/1837.02
COPPER MASS (BARE) MV kg.
HV kV 1300/1050/630
REG kg.
BASIC INSU. MV kV 1050/-/460
LEVEL LI/SI/P.F. CORE & COIL MASS kg.
LV kV 250/-/ 95
TRANSPORTATION MASS kg.
Neutral kV 95/-/ 38
TANK & FITTINGS MASS kg.
3
3
50°C at ONAN
OIL °C 55°C at ONAF/OFAF
GTD. TEMP. RISE MASS OF TOTAL OIL kg.
55°C at ONAN (WITHOUT 10% EXTRA OIL)
WDG °C 60°C at ONAF/OFAF
10% EXTRA OIL kg.
MAKER'S SR. NO.
TOTAL MASS kg.
YEAR OF MANUFACTURE
QUANTITY OF OIL IN OLTC Ltrs.
WORK ORDER NO. TRANSFORMER OIL QUANTITY Ltrs.
(WITHOUT 10% EXTRA OIL)
CUSTOMER
PO . NO. & DATE PAINT SHADE CHOICE
1U OLTC PRE H.V.
TAP M.V. L.V
CONECTION SELE- CURRENT(A)
POSN. VOLTAGE
IN EACH CTOR
600
ONAN ONAF OFAF VOLTAGE CURRENT VOLTAGE CURRENT

NO. (V)
VECTOR GROUP 2U
PHASE POSI. 189 MVA 252 MVA 315 MVA (V) (A) (V) (A)
4
4
1 13 - 12 440000 247.99 330.66 413.33
YNa0d11 3U 2 13 - 11 435000 250.84 334.46 418.08
3 13 - 10 430000 253.76 338.35 422.94

N 3V
4 13 - 9 425000 256.75 342.33 427.91
2W 2V 5 13 - 8 420000 259.80 346.41 433.01
3-4
3W 6 13 - 7 415000 262.93 350.68 438.22
1W 1V 7 13 - 6 410000 266.14 354.85 443.57 ONAN

1102.21
8 13 - 5 405000 269.43 359.24 449.05
ONAN (@63MVA)
33000
2 2 2 9a 13 - 4 400000 272.79 363.73 454.66 220000 495.99 ONAF
MV 9b 13 - 3 400000 272.79 363.73 454.66

ONAF
661.32
1469.61
(@84MVA)
OFAF OFAF
9c 13 - 12 400000 272.79 363.73 454.66 826.66 1837.02
(@105MVA)
1 1 1 10 13 - 11 395000 276.25 368.33 460.41
11 13 - 10 390000 279.79 373.05 466.32
12 13 - 9 385000 283.42 377.90 472.37
13 13 - 8 3-12 380000 287.15 382.87 478.59

5
5
2U 2V 2W 14 13 - 7 375000 290.98 387.97 484.97
3W1S1
TV WTI
3W1S2 15 13 - 6 370000 294.91 393.22 491.52

3U
3V 16 13 - 5 365000 298.95 398.60 498.26
3W
1N TMS CT
2U3S1 2V3S1
17 13 - 4 360000 303.10 404.14 505.18
2U3S2 MV WTI
2V3S2
1U 1V 1W kpV > Imag MAX

CT CORE RATIO ACC. BURDEN at Vk/2 TERMINAL
(Volt) SEC.RES. Application
NO. AMP. CLASS (VA) >
(OHM) MARKING
@2000/1ATap (in mA) @2000/1ATap
N1S1 1U1S1 2U1S1 1V1S1 2V1S1 1W1S1 2W1S1
N1S2 1U1S2 2U1S2 1V1S2 2V1S2 1W1S2 2W1S2 1U1S1-1U1S2-1U1S3-1U1S4
N1S3 1U1S3
1U1S4
2U1S3
2U1S4
1V1S3 2V1S3 1W1S3 2W1S3 CT1U 1 500-1000-2000/1 PS - 2000 30 10 1V1S1-1V1S2-1V1S3-1V1S4 REF.
N1S4 1V1S4 2V1S4 1W1S4 2W1S4
CT1W
CT2W
CT1U
CT2U
CT1V
CT2V
CTN
N2S1 1U2S1 2U2S1 1V2S1 2V2S1 1W2S1 2W2S1 1W1S1-1W1S2-1W1S3-1W1S4
N2S2 1U2S2 2U2S2 1V2S2 2V2S2 1W2S2 2W2S2 CT1V
N2S3 1U2S3 2U2S3 1V2S3 2V2S3 1W2S3 2W2S3 1U2S1-1U2S2-1U2S3-1U2S4
1U2S4 2U2S4 1V2S4 2V2S4 1W2S4 2W2S4
N2S4
1W3S1
CT1W 2 500-1000-2000/1 PS - 2000 30 10 1V2S1-1V2S2-1V2S3-1V2S4 Differential
HV WTI 1W2S1-1W2S2-1W2S3-1W2S4
1W3S2
1 1 1 2U1S1-2U1S2-2U1S3-2U1S4
CT2U 1 500-1000-2000/1 PS - 2000 30 10 2V1S1-2V1S2-2V1S3-2V1S4 REF.
2W1S1-2W1S2-2W1S3-2W1S4
3 3 3 CT2V
4 4 2U2S1-2U2S2-2U2S3-2U2S4
4
5 5 5 CT2W 2 500-1000-2000/1 PS - 2000 30 10 2V2S1-2V2S2-2V2S3-2V2S4 Differential
TO OLTC
6 6 6 2W2S1-2W2S2-2W2S3-2W2S4
7 7 7
4 8 4 8 4 8 UN1S1-UN1S2-UN1S3-UN1S4
9 3 9 3 9 CTNBF
3 12 12 10 12 10 1 500-1000-2000/1 PS - 2000 30 10 VN1S1-VN1S2-VN1S3-VN1S4 REF.
10
11 11 11 BEFORE WN1S1-WN1S2-WN1S3-WN1S4
12 12 12
NEUTRAL UN2S1-UN2S2-UN2S3-UN2S4
13 13
6
13 FORMATION 2 500-1000-2000/1 PS - 2000 30 10 VN2S1-VN2S2-VN2S3-VN2S4 Differential

2 2 WN2S1-WN2S2-WN2S3-WN2S4
2
UN1S4 VN1S4 WN1S4
1 PS - 30 10 N1S1-N1S2-N1S3-N1S4 REF.
HV
UN1S3 VN1S3 WN1S3 500-1000-2000/1 2000
UN1S2 VN1S2 WN1S2 CTN
UN1S1 VN1S1 WN1S1
CTNBF
UN2S4
CTNBF
VN2S4
CTNBF
WN2S4 2 500-1000-2000/1 PS - 2000 30 10 N2S1-N2S2-N2S3-N2S4 REF.
UN2S3 VN2S3 WN2S3
UN2S2 VN2S2 WN2S2
UN2S1 VN2S1 WN2S1 HV WTI 1 506/2 5 15 - - - 1U3S1-1U3S2 MEASURING
MV WTI 1 827/2 5 15 - - - 2V3S1-2V3S2 MEASURING

TYPE OF OIL :
TV WTI 1 1837/2 5 15 - - - 3W1S1-3W1S2 MEASURING
VACUUM WITHSTAND CAPABILITY 760 Hg
OLTC RATING & MAKE: TMS CT 1 827/1 5 5 - - - 2U3S1-2U3S2 MEASURING
GTD.(KW) MEASURED (KW) NOISE LEVEL: ________dB

NO LOAD LOSS
TAN DELTA OF WINDING : ________%
LOAD LOSS
STRAY LOSS MOISTURE CONTENT IN ACTIVE PART : ________% of wt.
AUXILLIARY LOSS
PROPERTY OF CUSTOMER NAME
6-Ø6 Holes.
7
TYPICAL RATING PLATE FOR POWER TRANSFORMER

E
A
J
Fig. 7.1: Typical Rating Plate

ANNEXURE 7.1
TESTING
Sr. no. Tests, measurements & checks
1 Dimensions, fittings and equipment
2 Turns ratio
3 Polarity & phase relationship
4 Insulation resistances
5 Winding resistances
6 Insulation power factor
7 Capacitances
8 Load loss & impedance voltage
9 Impedance characteristic across tap range
10 Zero-phase-sequence impedance
11 No-load loss & magnetizing current
12 Audible sound
13 Temperature rise
14 Gas in oil analyses
15 Lightning impulse voltage tests
16 Switching impulse voltage tests
17 Applied voltage tests
18 Induced voltage test & partial discharge
19 Single-phase magnetizing current test
20 Oil pressure
21 Control system, components, instruments
22 Ancillary equipment power losses
23 CT checks
24 RSO
25 Frequency Response Analysis (FRA)
26 Tap changer
27 Secondary wiring insulation resistances
28 Oil samples
29 Inventory
30 Contract documents
31 QA records
ANNEXURE 7.2
Contract Documents and Drawings for approval
Sr. No. Documents

1 Contract drawings
Certificates
a. ISO Quality Assurance
b. ISO Environmental
c. OHSAS
2 Product Source Schedule
3 Production Plan & Reporting Programme
4 Design Review Minutes
5 Quality System
6 Quality Plan
7 Test Plan
8 Factory Acceptance Test (FAT) Reports
9 Transport Plan
10 Transformer Site Commissioning Plan
11 Method Statements
12 Risk Assessments
13 Training
14 Site Works
15 Site Contractor(s) & Supervision.
16 Site Tests
17 Operation & Maintenance Manuals

Power Tranformer Standarization Manual

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POWER TRANSFORMER - STANDARDISATION MANUAL 1

Technical Specification & Parameters

Working Group Members

Mr. M. L. Jain - EMCO Ltd.

TECHNICAL SPECIFICATION & PARAMETERS

Guaranteed Technical Particulars for Power Transformers

Item Description Unit Specified Offered

3 Corrosion Level at Site

Item Description Unit Specified Offered

6 Full Load Rating (HV/IV/LV) MVA √

7 3 Phase/Bank of Three Phase/Single Phase ( A,B,C) √

8 Rated No Load Voltages (HV/IV/LV) kV

10 Connections and phase displacement symbols (Vector Group) √

11 Weight Schedules (Maximum) / (Minimum with no negative tolerance)

vi) Size of heaviest package L x B x H mm √

vii) Weight of heaviest package kg √

11.a Transport Limitation √

i) Stabilizing tertiary (Yes/No) √

ii) Loaded (Yes/No) √

iv) Range of variation % √

vi) Parallel Operation Requirements √

14 Impedance and Losses

i) Calculated I2R Loss at rated tap and 75 0C kW √

iii) Calculated Load Loss(I2R+Eddy and Stray)at rated tap and 75 0C kW √

iv) Guaranteed Load loss at rated tap and 75 0C (Max) kW √

Item Description Unit Specified Offered

viii) Guaranteed No Load Loss (Max) kW √

ix) Calculated Fan Loss kW √

x) Calculated Pump Loss kW √

xi) Guaranteed Auxiliary Loss (Max) kW √

xii) Guaranteed maximum Magnetizing Current at rated Voltage % √

xiii) Efficiency at rated load, unity PF % √

xiv) Load for Maximum efficiency % √

15 Any limitations in the performance of the required test? √

16 Deviations from specifications (if any) √

Item Description Unit Specified Offered

i) 3 Phase 3 Limb (3 wound Limbs)

2 Type of Core Joint √

4 Core bolts in Limb/Yoke Yes/No √

5 Minimum Gross Area of Core/Limb/Yoke/Unwound Limb cm2 √

Item Description Unit Specified Offered

7 Voltage per Turn V √

8 Apparent Core Density for Weight Calculation √

9 Minimum Net Weight of Silicon Steel Lamination CRGO kg √

10 Max Flux density at Rated Voltage and Frequency T √

12 W/kg at working flux density w √

13 Building Factor considered √

14 Calculated No Load Loss at rated voltage and Frequency kW √

15 Maximum Sound Level dB √

17 Core Isolation test kV √

Item Description Unit Offered

3 Minimum Yield Strength of Conductor N/mm2

4 Maximum Current density at any tap A/mm2 √ √ √ √

5 Bare Weight of copper without paper insulation and lead kg

6 Per Phase Maximum resistance of winding at rated tap @ 75OC Ohm √ √ √ √

9 Dielectric Shielding used √ √ √ √

10 Magnetic Shielding Used √ √ √ √

i) Yoke Shunt on core clamp

Item Description Unit Specified Offered

2 Percentage Rating Corresponding to Cooling Stages (HV/IV/LV) √

3 Guaranteed Maximum Temperature rise at 1000m altitude

i) Top Oil by Thermometer 0

ii) Average Winding by resistance 0

iii) Winding Hot Spot 0