SECTION SECTION SECTION SECTION Big CHAPTER 4 INSTALLATION & MAINTENANCE OF TRANSFORMER CONTENTS PAGE No. 41 TRANSPORT OF TRANSFORMER 19 4.2 INSTALLATION 21 4.2.1 RECEPTION AND ASSEMBLING OF TRANSFORMERS: 21 DESPATCHED PARTLY DISMANTLED AND FILLED WITH NITROGEN. 4.2.2 STORING OF TRANSFORMER DESPATCHED FILLED 27 WITH NITROGEN. 4.2.3 ASSEMBLING OF EXTERNAL PIPES 28 4.2.4 INSULATING OIL, QUALITY AND TREATMENT. 30 4.25 OIL FILLING UNDER VACUUM 31 4.26 OIL FILLING INSTRUCTIONS FOR 34 CONSERVATORS WITH AIR CELL. 4.2.7 UNTANKING OF ACTIVE PART 36 4.2.8 MOUNTING OF GASKETS. 38 429 WELDED COVER (IF APPLICABLE) 39 4.2.10 EARTHING OF ACTIVE PART AND CORE 39 INSULATION TEST 4.2.11 TOUCH-UP PAINTING. 40 4.3 COMMISSIONING 51 4.3.1 TESTING AFTER ASSEMBLY OF 31 THE TRANSFORMER AT SITE. 4.3.2 COMMISSIONING CHECK - TRANSFORMER 52 4.4 MAINTENANCE AND OPERATION 59 441 SUPERVISION OF TRANSFORMER 59 44.2 SUPERVISION CONTROL OF OIL 63 4.4.3 TROUBLE SHOOTING 63 4.4.4 PARALLEL OPERATION 70 1841 411 41.2 CHAPTER 4 TRANSPORT OF TRANSFORMER Power Transformers depending upon the restriction imposed by transport weight and/or other consideration, have to be transported either filled with oil or nitrogen 2s per the description given below. The transformer is loaded on wagon as per loading guage drawing prepared in each case. WITH OIL, The Transformer is filled with oil such that about 10% of the tank volume is left clear for expansion to limit the excess internal air pressure to 0.35 Kg/sq. cm, Fittings dismantled before transport are packed in packing cases in line with shipping list. Alll openings resulting from removal of fittings for shipment are sealed with suitable gasketted blanking plates during transport. The balance oll quantity required for the complete filling of the transformer is supplied separately. A transformer despatched according to this method can be stored at site or elsewhere for one year proviided, that all insulating materials are covered with oil and silicagel breather is mounted and quality of is maintained as per IS:1866. Measures to be taken on reception at site are given clause 4.2.1 WITH NITROGEN Large oil filled transformers are not normally oil filled during shipping due to weight limitations. To protect the active part against moisture the transformer tank is filled with dry Nitrogen at a positive pressure of 0.175 kg/sq cm (2.5psi) at BHEL works before dispatch. The internal pressure at the time of shipment is painted on the tank. All openings resulting from the removal of fittings for shipment are sealed with suitable gasketted blanking plates during transport. A Transformer despatched according to this method should normally be stored upto 3 months after arrival at site or elsewhere. For control of gas perssure and maintaining the pressure during transport and Possible storage before assembling, the transformer is equipped with an automatic device. This device is called two stage Nz regulator and is kept in a steel box and mounted on,the frame provided on tank side for keeping two back up Nitrogen cylinders. Nitrogen regulator is connected to two cylinders by copper tubes and to tank by a rubber hose as as shown in the Fig. 1.1. Regulator reduces cylinder high pressure of 120 to 140 kg/sq em to required low pressure of 0.175 kg/sq cm in two stages. One guage provided on the first stage indicates the cylinder pressure, whereas other gauge provided on second stage indicates the tank pressure. Regulator is fixed at factory. ‘When tank pressure falls below 0.15 kg/sq cm due to leakage/fall of ambient temperature, regulator automatically feeds the gas from cylinders, to build up required pressure in the tank. 19The gas consumption during transport and possible storage is difficult to estimate as it depends on ambient temperature variation, possible leakages as well as (on the duration of transport and storage. However, two back up cylinders are provided to meet the gas requirement. Normally one cylinder is kept open and the other shut. When the pressure of first cylinder falls to 10 Kg/sq cm this should be considered as empty and immediately its valve should be closed and the valve of second cylinder should be opened. When cylinder is required to be removed for refilling, disconnect copper tubing from cylinder viave. Use only dry Nitrogen gas to IS:1747 with 50 ppm moisture and 1% oxygen by volume. If the storage time exceeds 3 months, the transformer is filled with oil according to direction given in clause 4.2.5. If for some reason oil filling is not possible, then nitrogen must be continuously manitained at a positive pressure. Measures to be taken on receipt at site are given in clauses 4.2.1 4.1.3. INSTRUCTIONS FOR FILLING DRY PURE NITROGEN GAS WITH BACK UP CYLINDERS (AT WORKS) Lower the oil level to the minimum necessary to dismantle the items (such as bushing and turrets) which must be removed for shipping. Pull 500 mm mercury vaccum after blanking off all openings. Continuse, to supply nitrogen until it maintains a steady rressure of 0.17+0.02 kg/cm? above the atmosphere. Pressure of nitrogen gas shall be maintained at 0.17+0.02 kg/cm at same reference temperature. Pressure should be monitored by taking three readings within 24 hours to ensure that there is no leakage of gas. Shut off the gas supply valve and fit dry nitrogen back up cylinders through nitrogen regulator valve. 204.2 4.2.1 4.2.1.1 4.2.1.2 SECTION 4.2 INSTALLATION RECEPTION AND ASSEMBLING OF TRANSFORMER DESPATCHED PARTLY DISMANTLED AND FILLED WITH NITROGEN. To ensure that a Transformer will function satisfactorily, it is imporatant that handling, lifting, storing and assembling are carried out with great care and cleanliness by experienced personnel who know the various working operations very well. This sectio gives instructions how handling lifting, storing and assembling should be carried out. For large Transformers it is recommended that the work is done by BHEL or is under supervision by experts from BHEL. INSPECTION In connection with receiving and unloading at site, and at the final storing place before assembling, the transformers shall be inspected carefully. External visible damages as dents, paint damages eic. may imply that the transformer has been subjected to careless handling during transport and/or reloading, and 2 careful investigation is therefore justified. After the arrival of the material at receiving points, the customer should, in case of possible damage/loss of any component, make the necessary claims with the contractors representatives under intimation to supplier so that such claims can be registered with the transport agents, Before unloading, the condition of packing and of the visible parts should be checked and possible traces of leaks verified (condenser bushings). If necessary, appropriate statements and claims should be made. Drums containing oil which have been despatched separately should be examined carefully for leaks or any sign of tampering. All drums are despatched filled upto their capacity and any shortage should be reported. In order to protect the active part against moisture, the transformer tank is filled with nitrogen during transport at an pressure of 0.17 kg/sq.cm. (2.5 psi) approximately at room temperature. Check immediately the gas pressure at the arrival. A positive pressure indicates that the tank and the transformer components respectively are tight, and that the active part including the insulation materials is dry. If there is no positive gas-pressure, transformer should be immediately filled with dry Nitrogen gas at a pressure of 0.17 kg/sq. cm (2.5 psi) withottt loss of time as per instructions given para 4.1.3 Otherwise, it should be checked if the core isolation is satisfactory and that accessories packed separately have not been damaged during the transport. Instruction for checking of the core isolation are given in clause 4.2.6 UNLOADING Typical unloading arrangement of the transformer is shown in fig 4.2.1 Whenever rollers/trolleys are supplied with transformer, movement of 214.2.1.3 4.2.1.4 4.2.1.5 transformer at site is carried out by mounting their rollers/trolleys. For mounting of rollers refer roller mounting drawing. Alternatively for movement of transformer from loading bay to actual site of the equipment, skidding on greased rails etc can also be resorted to. STORING Dismantled equipment and components are packed to be protected against normal handling and transport stresses. The instructions for lifting given on the Packages, must be complied with to avoid damages. Goods stored outdoors must be placed directly on the ground, and should be covered carefully with tarapaulin or similar material. Oil drums should be stored in horizontal (lying) position with both the closed openings also in horizontal position. LIFTING Lifting devices on the transformer tank are dimensioned for lifting of the completé transformer filled with oil. The positioning of the lifting devices, permissible lifting angles, minimum height to crane hook and transformer weight, are given in the OGA drawing. Checks at lifting of complete transformer that the lifting wires/ropes are not in contact with bushing or other components on the cover. For lifting with hydraulie jacks, the transformer is provided with jacking pads dimensioned for lifting of complete transformer filled with oil. The position of the pads appear on the OGA drawings. If active part is to be lifted refer instructions given in clause 4.2.7 LOCATION AND SITE PREPARATION a) Transfomer shall be placed either directly on plinth or with rollers as per foundation pian drawing. Therefore it is very important to refer foundation drawing before placing the transformer on final location. b) Transformer should be placed on the foundation so that easy access is available all around and diagram plates, thermometers, valves, oil guages etc. can be easily reached or read. Adequate electrical clearances are also to be provided from various live points of the transformer to earthed parts. ©) _ ONAN type transformers depend entirely upon the surrounding air for carrying away the heat generated due to losses. For indoor installation, therefore, the room must be well ventilated so that the heated air can escape readily and be replaced by cool air. Air inlets and outlets should be of sufficient size and number to pass adequate air to cool the transformer. The inlets should be as near the floor as possible and outlets as high as the building will allow. Where necessary, exhaust fans can be installed for the purpose d) The transformers should always be separated from one another and from all walls and partitions to permit free circulation of air. In this connection reference is also drawn to IS:10028 (Part IN). e) Where rollers are not fitted, level concrete plinth with bearing plates of sufficient size and strength can be adopted for outdoor transformers, To prevent the formation ‘of rust, it is essential to avoid presence of air and water in the space between the plinth and the base of the transformer by use of cretex or similar bitminous compound 22Poe 1) Where rollers are fitted, suitable rails or tracks should be used and the wheels locked to prevent accidental movement of the transformer. Where walls are provided, it should be ensured that the transformer gets a good ventilation ‘as mentioned above for indoor transformers. Provision should be made for the emergency drainage of the oil from the transformers (e.g. in case of fire in neighbouring apparatus or bushing or the transformer tank), by surrounding the transformer plinth with sump filled with small pebbles. INTERNAL INSPECTION AND CHECK POINTS FOR ASSEMBLING THE TRANSFORMER (a) Check-points before starting assembly: Condition of leads. Bracing, clamping of leads. Connections. Tapchanger checks. General conditions of insulation. Core check that it has not moved in transit. Core-ground; this is checked with the megger after removing earth connection. CTs, including the secondry leads and their passage through metal parts. Check that shipping frame for bushings have been removed. Check that coil position has not moved in transit, Check for dirt, metal swarf, moisture. Check that the bushing leads set without being too close to ground or other points of different potential. (b) Check-points during Assembly By means of the Part list and the transformer OGA, the assembling of a fully completed transformer is carried out according to the following instructions. The following precautions are to be taken: (i) Fire-fighting equipment shall be available at the oil-treatment equipment as well as at work on and adjacent to the transformer. (i). Welding work on or adjacent to the transformer shall be avoided, but if this is not possible, the work shall be supervised by fire-protection personnel ili) Smoking on or near the transformer shall not be allowed. (iv) Transformer tank, control cabinet etc., as well as assembling and oil-treatment equipment shall be connected with the permanent earthing system of the station. (v) Check that there is no overpressure in the transformer when blanking plates ‘or connection lids are to be opened. (vi) All loose objects, tools, screws, nuts etc., shall be removed from the transformer cover before opening the connection and blanking lids. (vil) All loose objects (tools, pencils, spectacles etc.,) shall be removed from the boiler-suit pockets etc. before starting the work through man holes. (viii) Tools to be used inside the transformer e.g. for tightening of screw-joints shall be fastened to the wrist or another fixed point by means of cotton tape or string. 234.2.1.7 4.2.1.8 4.2.1.9 (ix) Tools with loose sleeves and tools with catches must not be used at work inside the transformer. (x) Greatest possible cleanliness shall be observed at work inside the transformer, and handling of parts to be mounted inside the transformer. Fibrous cleaning material should not be used as it can deterorate oil when mixed with it. (xii) All components despatched separately should be cleaned insided and outside before being fitted. (xiii) A transformer is best protected from damp hazard by circulating warm, dry, deaerated oil through it until it temperature is 5° C to 10° above ambient. This should be done before allowing external access to the interior of the tank. The warm oil should be circulated all the time transformer is open to atmosphere, (xiv) Oil pump & all joints in the oil pipe work should be air tight to avoid entrance of air through leakage joints. (xv) The active part (core and winding) sould be exposed to the surrounding air as short time as possible (Open therefore only one blanking plate or connection lid at 2 time for remounting of bushings, valves etc. (xiv) Objects which-despite all precaution have dropped inside the transformer, must absolutely be taken out from the transformer. (xvii) Check that the oxygen content inside the transformer tank is minimum 20% if a person is to enter the tank. ASSEMBLY OF WHEELS ‘Mounting of wheels under transformer is to be done as per roller arrangement drawing. Transformer placement can be with or without rollers as per applicable OGA/foundation drawing. ASSEMBLY OF BUSHINGS In case the bushings are mounted on turrets on the transformer cover, they are either delivered mounted on their turret or - incase of large bushngs - dismantled from the turrets. ‘The turrets are often indivdually adapted; check therefore that they are re-mounted in correct places, which appear from the OGA drawing and part list. Assembling of bushings is carried out according to the detailed information documents available. ASSEMBLY OF VALVES Valves which may affect the loading gauge, or will be subjected to damages, should be dismounted before delivery. Re-mount the valves-the positionings appear from the OGA drawing and part list.. The gasketting surfaces shall be cleaned well and new gaskets fitted. Check that all valves are closed. 4.2.1.10 ASSEMBLY OF COOLING DEVICES Valves which are not dismantled like shut-off valves for radiators, coolers and possible headers are provided with blanking plates during transport. Remove blanking plates when assembling of the coolers is to be started. Check first, that the valves are closed. 244.21.11 4.2.1.12 4.2.1.13 4.21.14 41.115 4.2.1.16 4.2.1.17 Check that each radiator and possible headers are assembled in the correct Positions according to OGA drawing. In case of OFAF or OFWF cooler mounting shall be done as per the relevant leaflet. The shut-off valves against the transformer tank shall be’ closed until the oil-filling is started. ASSEMBLY OF OIL CONSERVATOR ‘The conseravator, which may be with or without aircell is assembled either on the transformer, or on a separate frame. Before the conservator is assmebled it shall be checked that belonging equipment- e.g. Oil-level indicator-functions satisfactorily. ‘The breather is connected to the oil conservator, and it is very important that joints and couplings in the pipe between breather and conservator are air tight. Refer Clause 4.2.6 for detailed instruction for oil filling. ASSEMBLY OF PIPE WORK Pipes with flanges for connection of conservator, radiators, as well as Pipes for equalising of turrets etc. are mostly delivered completely ready for assembling according to OGA & part list. In certain cases-e.g. at a separately assembled oil conservator-certain fitting and welding of pipes and flanges on site is however required. Instruction for such assembley of external pipes is given in clause 4.2.3 FLANGES, BLANKING PLATES When re-mounting blanking plates, connection flanges, etc., the gasketting surface shall be cleaned well and new gaskets fitted. ACCESSORIES Accessories like cocling fans, pumps, OLTC and components for supervision and control, oil-levels indicator, flow indicators, gauges, Buchnolz relay, PRV, thermometers etc. are assembled according to leaflet/description valid for the components. After assembaling locking strip/card/pin shall be removed for correct. functioning of OFI ete. CONTROL CABLING Assemble the control cables according to the drawing of wiring system and connect the cable ends to terminal blocks in instruments, terminal boxes, Junction boxes and control cabinets according to valid connection diagram. GASKETS The sealing system normally used against oil and gas in BHEL's transformers and belonging components has rubber gaskets in grooves and nitrile rubber bonded cork gaskets at other places. Refer clause 4.2.8 for general information and assembly instructions for gasket mounting, OIL FILLING The completely mounted Transformer is oil-filled according to directions in Clause 4.2.56 4.2.6. The oil shall be treated according to Clause 4.2.4 The lower and upper shut off valves for radiators/coolers and possible heaters shall be open during evacuation and oil-filling. The hose for filling of oil is connected to the bottom valve of the transformer which must not be opened until the hose has been deaerated and completely filled with oil. 254.2.1.18 4.2.1.19 CLEANING & PAINTING The transformer and its equipment are cleaned carefully from dirt, lubricating grease, and damaged surfaces are touch-up painted with the primer paints and finish paints. EXCHANGE OF BUSHING When exchanging a damaged bushing or other component on the cover of a fully oil-filled transformer, we should proceed according to the following Close the valve in the pipe between the transformer and the oil conservator. Pump oil from the transformer tank into the oil conservator so that the oil quantity which need be drained off to lower the oil-level enough below the transformer cover is pushed to the conservator. As the oil is being transferred from tank to conservator, fill up the tank with dry nitrogen via a suitable valve (on the cover or in turrets. Exchange the faulty bushing and then transfer the oil from conservator to tank by opening the valve in the pipe between conservator and main tank. De-air the bushings and turrets. 26aa 4.2.2 STORING OF TRANSFORMER DESPATCHED FILLED WITH NITROGEN 4.2.2.1 STORING BEFORE COMPLETE ASSEMBLING The storing place should be easily accessible for inspection and maintenance of the transformer. The bedding for the equipment should be larger than its bottom surface and dimensioned for the load. The transformer is placed on boardings or beams so that good ventilation is obtained underneath the transformer bottom. Before storing, the transformer is inspected according to directions in Clause 4.2.1 “Reception and assembling of transformer despatched partly dismantled and filled with nitrogen”. A transformer without remarks may be stored up to 3 months after arrival at the site without cil-filling. During the storing time, the inert gas (nitrogen) filling shall be maintained and pressure regulated, so that exposure of active Part to atmospnete is avoided. If the storage time is judged to exceed 3 months, the transformer should be provided with oil conservator including oil-level indicator and breather, and oil-filled according to Clause 4.2.5. “Oil filling under vacuum’. Certain valves must be re-mounted to enable the oil-filling being carried out. Furthermore, at the time of oil-filling of a completely assembled transformer, certain rules in Clause 4.2.5 & 4.2.6 must be complied with absolutely. Wherever possible it would be most desirable to keep the transformer energised even at a low voltage so that its temperature is higher than the ambient temperature. The low voltage may be applied under open circuit or short circuit conditions. It may be ascertained whether partial cooling is required in such a case. The oil quality should also be perodically monitored. If for some reason, il filling cannot be carried out after a storage period longer than 3 months, the nitrogen pressure shall be maintained and supervised carefully. If the storage time without oll exceeds 18 months BHEL should be consulted about measures to be taken. 4.2.2.2 STORING OF COMPONENTS AND ACCESSORIES BEFORE COMPLETE ASSEMBLING. Independent of the duration of the storing time, the directions below apply for dismounted components and accessories, as well as for material to be used in connection with the assembling work. (@) Storing indoors in a dry room In such a room, the followiing articles should be stored: (Insulation material as paper, pressboard, bakelite, wood, cotton tape etc. (ii) Insulated details as paper-insulated conductors, press-board insulated shielding bodies etc. (ii) Chemicals as solvents, glues, varnishes, hardners etc (iv) Breathers, drying agents. (v) Terminal boxes, connection boxes, control cabinets. (vi) Turrets with build-in current transformers. (vii) Radiators. (viii) Gas relays, oil-level indicators, thermometers, pressure valves etc, 27(ix) Pipes to oil-conservator, radiators, turrets etc. (x) Bushings. (x) MBox. OLTC motor drive, Fans, Pumps, instruments & fittings. (Heating elements provided shall be connected to supply) (b) Storing outdoors The below components may be stored outdoors. They should be placed above ground and covered with tarpaulin etc. () —Oll-conservator with blanking plates for all openings. (ii) Radiators and coolers with blanking plates for all openings. (iii) Structures, A frames, Pipe supports, Supports oil-conservators, radiators, control cabinets etc. 4.2.2.3, SUPERVISION During the storing time, the storing place, transformer components and accessories are inspected regularly. Tap changer if provided should be operated at 6 monthly intervals. Two or three runs from one end of the range to the other and back are sufficient. Observations, readings, measures and dates should be noted and BHEL should be contacted for directions about possible measures. Check at even intervals and further more at weather changes as.rain, storm, frost or thawing the foundation material (boardings, beams etc.) and the conditon of the ground. Inspect the transformer periodically with regard to possible external faults and/or rust-damage. Check also that screws and nuts in sealing joints (covers, lids etc.) are tightened. Check every second week that the connected-in heating elements in control cabinets function. If the Transformer is inert gas filled, one shall check every second week the overpressure or inert gas consumption. If the transformer is oil-filled, one shall take oil-samples after 6 months. and then min, once a year. The oil is investigated with regard to Electric Strength (BDV) and moisture content. Inspect periodically stored components and accessories with regard to possible external damages and/or rust damages. If any touching up of paint is required it should be carried out as per clause 4.2.11. Check at the same time that insulation material and insulated details are not damaged or have become dirty. 4.2.3 ASSEMBLING OF EXTERNAL PIPES 4.2.3.1 This technical description shall be applied at assembling of transformers, when external pipes, for some reasons are not fully completed at delivery but require some kind of machining or fitting at site. At the design occassion it is judged which details that can be made fully completed in the workshop and which details that must be fitted into position at site. Fully completed details are delivered with complete surface treatment Details of the pipe work despatched can be seen at shipping list. 284.2.3.2 4.2.3.3 4.2.3.4 4.2.3.5 4.2.3.6 4.2.3.7 BREATHER PIPE The pipe is normally made of 15 NB painted steel pipe. The pipe shall be cleaned carefully after machining. Supplementary surface treatment is not required normally. It is very important that the pipe is tight. Possible leakage will cause moisture entering the transformer with the service disturbances. Mounting of the breather pipe shall be as per OGA drawing. OIL CONSERVATOR For position of conservator along with necessary supports, refer OGA drawing. OIL CONSERVATOR PIPE ‘The pipe has dimension 80 mm usually and has welded flanges. The pipe shall be painted internally with a yellow, oil-resistant paint, and externally with ‘a paint specified on the drawing. The pipes shall always incline upwards minimum 3 to 7 degrees from the transformer. EQUALISING PIPES The pipe system in connection with the transformer cover Is as a rule manufactured in workshop. The pipe between transformer and conservator may be pre-assembled. The pipe is provided with welded-flanges. No pipe part is allowed to be so long that internal inspection and cleaning is difficult to carry out. Besides straight extensions, each pipe part may contain one bend. The pipes shall always be placed with minimum 3 to 7 degrees inclining upwards from the transformer. Internal surface treatment is with yellow oil resistant paint. External surface treatment is made as specified on the drawing as per specification. Cleanliness is extremely important. COOLERS The positioning of the radiators/coolers is indicated on OGA drawing. These are positioned so that the highest point of the oil-pipe system is always positioned below the bottom level of the conservator. The pipe system is provided with filter valves at the start and finish to enable pumping the oil through the system, All places where air may be collected are provided with air release plugs/valves. COOLER PIPES The pipe having dimensions as per OGA drawing and expansion joints are provided with welded-flanges. No pipe part is allowed to be so long that internal inspection and cleaning will be difficult. The pipes shall be placed so that air release plugs will be positioned at the highest point of the pipe part. The pipes shall be painted internally with a yellow, oil-resistant paint and externally according to the paint as per specification. 294.2.4 INSULATING OIL, QUALITY AND TREATMENT 4.2.4.1 QUALITY The oil to be filled in transformer generally complies witt of the customer's specification. The characteristics of fresh oil as per IS: "Specification for New Insulating Oil” are given below: CHARACTERISTICS AND PARAMETERS OF NEW INSULATING OIL Sr. No.| Characteristics Gnit Requirement 1 Appearance The oil shall be clear, transparent & free from suspended matter or sediments. 2 Density at 29.5° gm/cc 0.89 3. Kinematic Viscocity 27 at 27° C (Max.) st 4 Interfacial tension Nim 0.04 at 27° C (Min) 5. Flash Point (Min) c 140 6. Pour Point (Max) c 6 7. Neutralisation Value mg/KOHig | 0.03 (Total Acidity) (Max) 8. Corrosive Sulphur Non-corrosive 9. Electric strength (breaakdown voltage) (Min) (a) | New untreated oil KV (rms) 30 (if the above value is not obtained the oil shall be filtered in laboratory) (b) | After filtration KV (rms) 60 10 Dielectric dissipation factor 002 (Tan o) at 90° C (Max) i Water content (Max) ppm 50 12, Specific resistance (Min) at 90°C ‘ohm-cm 35x10!7 at 27° ¢ ohm-cm 1500x10"? 13. | Oxidation stability (a) | Neutralisatiion Value (Max) mg/KOH/g | 0.4 (b) | Total sludge after oxidation (Max) mg/KOH/g | 0.10% 14. Ageing characteristics after accelerated ageing (Open beaker method with copper catalyst.) fa) | Resistivity (Min) at 90°C ohm-em 0.2x10"7 At 27? ohm-cm 25x10"? (b) | Tano at 90° C (Max) 02 (c) | Total acidity (Max) mh/KOH/g | 0.05 (d) | Sludge content by weight (Max) 0.05% 15, Presence of oxidation inhibitor il shall not contain oxidation inhibitor Note : Methods of test shall be as per [5:335 304.2.4.2, SUPPLY AND TESTING The transformer oil is despatched directly to site from oil refinery. The oil is thoroughly inspected and tested at oil supplier's works in presence of BHEL and/or customer's reprensentative or their authorised representatives. Test certificate giving velues obtained for all characteristics is issued HANDLING The oil drums should be carefully handled at site, details of which are given in Clause 9.1 of IS:1866. RECONDITIONING Transformer oil is usually contaminated during handling, transport and storage cue to ingress of moisture and solid impurities. Hence, oil shall be vacuum filtered separately at 50°C-70°c using a suitable filtration machine and a spare clean tank before filling in the transfomer. Details of filteration are given in Clause 9.2 of 1S:1866. Oil treatment shall be terminated when the following parameters are attained TABLE 4.2.1 KV Class of transformer Recommended Permissible limit Electric Strength Moisture Content (BDV) in kV (Min) ppm (Max) Upto 145 60 20 245 65 15 420 70 15 Strong tank shall be used as per typical arrangement shown in fig 2.2 Electric strength and moisture content shall be determined following the test procedure of 1S:335. 4.2.5 OIL FILLING UNDER VACUUM 4.2.5.1 APPLICATION Transformer with vacuum-proof tanks shall be filled with oil according to this method. 4.2.5.2, STORING TIME Generally it applies that Transformers which during transport are filled with dry nitrogen on arrival at the sile shall be evacuated and oil filled. Before storing, the equipment shall be inspected according to the directions given in Clause 4.2..1 “Reception and assembling of transformer despatched partly dissembled and filled with nitrogen". During the storing time, overpressure shall be maintained, ritrogen consumption checked according Clause 4.2.2.4.2.5.3 FLOW CHART FOR HANDLING In Annexure 4.4.2.1 is given a flow chart of handling procedures. The pressure should be measured at different times. The pressure is OK if it is maintained according to instructions given in Clause 4.2.2. Reference is also drawn to para 9.0 of IS:1866 regarding handling and filling of oil 4.2.5.4 UNITS Annexure 4.2.1 gives the relation between different units. 4.2.5.5 EVACUATION ‘The transformer tank (excluding cooler bank & conservator) shall be evacuated to 2 pressure of 1.00 torr. max. The pressure shall be maintained for the time given in Table 4.2.2 TABLE 4.2.2 VACUUM TREATMENT System Voltage Evacuate and hold Standing time after oil vaccum for circulation before application of voltage Kv hours hours Upto 145 12 12 Above 145 & upto 220 24 48 The equipment required for vacuum treatment and oil-filling under vaccum should generally be as per Annexure 4.4.2.2. The transformer tank and electrical terminals shall be earthed for safety reasons. No electrical test on the Transformer is permitted during the evacuation. Fig. 4.2.3 shows a typical example of pipe work and valve positioning. Oil conservators are not evacuated. Valve 7 shall be closed Valve 6 shall be open unless a breather is fitted. 4.2.5.6 OIL FILLING 4.2.5.6.1 OIL QUALITY The transformer shall be filled under vacuum with oil which has been purified and degassed to Clause 4.2.4. 4.2.5.6.2 OIL FILLING IN MAIN TANK. The oil shall_be heated to 2 temperature of 50°-70°C measured at the filter outlet valve. The pressure during the filling shall be max. 1 torr. During the oil-filling, a transparent plastic tube (5) can be used as an oil-level guage. The tube which should be a wall thickness of 5-8mm, may be connected to a top and 2 bottom valve on the transformer. Oil-filling of the tank is done through valve (12) at a low level on the transformer and at a maximum rate of 4-5 kL/hour. The pressure in the oil 32pipes shall be kept positive and shall be checked by a manometer 13 (if provided). When the oil-level has reached about 50 mm below the cover/the vacuum pump is stopped it is preferred that dry nitrogen Is introduced in the tank by opening valve (8). Valve (7) is then opened and valve (6) closed and the filling is continued in tank and conservator until the correct oil-level has been reached in the conservator. Conservator supplied with rubber air cell shall be filled according to Clause 4.2.6. For oil filling in diverter switch assembly of a OLTC refer leaflet (Vol. 1) Seperate vacuum-proof cooler system/radiators can be evacuated for about 1-2 hours and filled separately with purified and degassed oil. The oil is then irculated through the vacuum filter at least twice via drain valves as near as possible to the transformer. When the oil circulation has been completed the valves between coolers and main tank shall be opened. Care should be taken to keep all air release plugs and valves open to allow escape of trapped air during oil filling operation. These valves/plugs should be closed after completion of oil filling. 4.2.5.7 HOT OIL CIRCULATION To facilitate oil-penetration and absorption of possible gas bubbles, the temperature of transformer shall-after completed oil-filling--be increased by circulating the oil through the vacuum filter and with circulation direction according to Fig. 4.2.4 The oil will be circulated through a vacuum filtration machine till the parameters are attained as per table 4.2.3 below. TABLE : 4.2.3 KV Class of Recommended Permissible Limits Transformer Electric Strength | Moisture Content] Resistivity % | Tan delta x (BDV) in kV (min) ppm (Max) at 90°C at 90°C {Ohm-cm) Upto 72.5 40 25 ind? 0.05 145 50 20 ix1d? 0.05 245 60 15 1x10? 0.05 ¥ subject to availability of testing facilty at site. Method of test for Electric Strength and moisture content shall be as per IS:335. CAUTION: The temperature during oil circulation should not increase beyond 70° C otherwise this may cause oxidation of oil 4.2.5.7.1 | SAMPLING Oil sampling at various stages shall be done in accordance with IS:6855. When samples are taken from transformer tank, will be drawn from bottom of the tank. When it is desired to know gas content and composition of dissolved gases in transformer oil before commissioning for reference purposes (required 33for interpretation of Dissolved Gas Analysis results during service), sampling shail be done as per IS 9434. 4.2.5.8 STANDING TIME Standing time is the time between oil circulation and energisation. The time shall be as per table 4.2.2. 4.2.5.9 FINAL OIL FILLING OR TRANSFORMERS DESPATCHED OIL FILLED. Smaller transformers are often factory-filied with degassed oil up to about 10% below the cover and transported in this condition. The final filling up to the correct level in the conservator is made at site. 4.2.5.9.1 | TRANSFORMER WITH SYSTEM VOLTAGE 36KV The filling is performed as described above, but atleast a paper filter must be used for drying the oil 4.2.6 OIL FILLING INSTRUCTIONS FOR CONSERVATORS WITH AIR CELL 4.2.6.1 INTRODUCTION In all transformers specially in high voltage class, maintenance of insulating oil notably its dielectric property forms one of the determining factors of reliability of equipment in service. Oxidation and contamination of transformers oil can be avoided in a simple and effective way by use of above oll preservation system. The complete system is known as “Conservator with Air Cell” In this oil preservation system a flexible air cell made of oil resistant nitrile rubber is placed inside the conservator and floats on the oil surface, The air cell inflates or defiates as the oil level in the conservator falls or rises depending on the ambient temperature and load on the transformer. The inside of the rubber bag (Air Cell) is put into communication with atmosphere by means of a silica gel breather which ensures dry atmosphere inside the air cell. In addition to the above this system provides following advantages. (i) It avoids saturation of absorbed gases. (li) As no gas is used in this system, which operates at constant pressure, this formaton of gas bubbles at low ambient temperature and load is eliminated. The system thus preserves the oil quality particularly its dielectric Properties. The conservator with air cell is provided with a magnet oil gauge having one electrical contact, The indication shown on the dial physically corresponds to the oil level in the conservator which is due to balance of static pressure between the oil of the conservator and the atmospheric air inside the air cell. This system is also provided sometimes with a set of pressure and 344.2.6.2 4.2.6.3 4.2.6.4 vacuum valves. These valves operate to pass either oil or air in the event of over filling or under filling the conservator during installation. DESCRIPTION OF OPERATION Figure 4.2.5 indicates the general arrangement of oil preservation system. The oil connection between conservator and transformer tank is made through Buchholz relay and valves are provided in bet-veen. The flexible air cell is connected to the top of the conservator through gasketted Joint. Under normal condition air cell is completely surrounded by oil and floats in the conservator. The air cell inflates/deflates as the oil volume changes. The float of the MOG which is always in contact with inner side of the air cell moves up and down and indicates the oil level. The cell will sink in the remote event if it is damaged and MOG alarm will operate. The conservator then functions 2s a conventional conservator without effecting the performance of the transformer. INSTALLATION This system is shipped separately from main tank. The air cell is shipped filted in the conservator. A low pressure of less then .07 kg/sq.cm {1 psi) is maintained to avoid excessive movement of air cell in the conservator during transit. MOG is also shipped filted on the conservator. Install the conservator and associate parts except breather as per transformer outline drawings and assemble oil pipe work. OIL FILLING The following procedure is recommended. (i) Close and blank the valve (14) to isolate the conservator from main tank. Fill the oll in transformer under vacuum upto Buchholz level as per instructions given else where (ii) After filing the oil in transformer and breaking the vacuum, oil can be filled in the conservator either through transformer or by drain valve (4). (ill) Remove the inspection cover (111) provided on the side of the conservator and check the air cell assuring that it is inflated. The air cell must remain in fully inflated condition during oil filling operation. If the air cell is found deflated fit the inspection cover and inflate the air cell with dry/nitrogen gas to 0.035 kg/sq.cm max. through connection (8). A gauge may be put by removing plug (10). After filling close these connections. (iv) Remove air release plugs(5), (6) and (7) provided on top of the conservator. (v) Slowly pump the oil through the main transformer /drain valve (4) Temporarily stop filling operation when oil starts coming from opening (5) and (6) after ensuring that no air bubbles come out through these air release holes. Fit the two air release plugs. (vi) Continue oil filling till oil start coming from air release plug (7) stop oil after ensuring that no air bubbles come out. Fit the plug (7). (vii) Now release the air pressure held inside the air cell from point (8) and continue oil filling until magnetic oil guage (3) indicates 35° C level. (viii) Remove oil pump and connect air cell to breather (9) from point (8), Also remove pressure gauge and put plug (10). (ix) The system is now properly filled. Air release plugs (5), (6) and (7) are fitted in normal operation, 354.2.6.5 4.2.6.6 4.2.6.7 4.2.7 4.2.7.1 PRECAUTIONS (i) Oil filling in the conservator and also draining whenever required must be done very slowly. During oil filling, pressure in the air cell should not exceed 0.1kg/sa.cm (1.5 psi.) (i) If a pressure or vacuum is ever applied to the main transformer tank the conservator must be disconnected and 2 blanking plate fitted on shut off valve Do not weld on conservator to avoid damage to the air cell. Once all the air has been driven out during oil filling in the conservator do not remove air release plugs (5), (6) and (7). Otherwise air will be sucked inside the air conservator. MAINTENANCE Little maintenance work will normally be required except routine visual inspection. However, it is desirable to check the breather opening to ensure it is not blocked. Further silicagel should be regenerated/replaced when its colour changes from blue to pink. AIR CELL* Air cell is made from Nylon fabric coated with Nitrile rubber. In the event it becomes necessary to replace or test the air cell for leaks the following method is recommended, (i) De-energies the transformers. (ii) Isolate the conservator by closing the valves(14) (il) Drain the oil from the conservator form valve (4) by removing air release plugs (5) and (6). (iv) Remove inspection cover(11) if necessary. Install the pressure guage on point (10). ()Pressurise the air cell (2) by dry air/nitrogen to a max. pressure of 1,.5 psi and seal, Check the pressure for 6 hours. (vi) If leaks are found, air cell to be repaired by patchiing or replaced by @ new air cell (vil) For taking out the air cell from conservator, remove the air cell flange and loops from hooks provided on inside of the conservator top. Collapse the air cell slowly and fold, remove it from conservator very carefully. (viii) In the event air cell is not available immediately, conservator may be used as a conventional conservator. UNTAKING OF ACTIVE PART GENERAL If for some reason it becomes necessary to untank the active part (core and_windings) of @ lerge transformer, it ought to be done under supervision by BHEL erectors. Universal instruction for the untanking procedure cannot be given, as the design practices of large equipment vary. The following general directions are, however, applicable in most cases. The untanking must be done indoors. If there is no suitable hall available, lifting can be done in the temporarily arranged room. eg. a tent. The oil & the internal parts of the transformer must not in any case be exposed to rain or humidity. In case of bell shaped transformer, only bell cover is lifted for access to active part. 364.2.7.2. OIL DRAINAGE Drain off the oil from the transformers either partly or completely. 4.2.7.3 DISCONNECTING Disconnect leads to bushings, current transformers, winding temperature devices and earthing leads between active part and cover or tank side. Disconnections mentioned above can usually be made through handholes in cover or tank side. 4.2.7.4 REMOVAL Remove all large bushings, cover mounted coservator and lightning arrestors (if provided). Break all conections between cover and tank-piping to oil conservator and cooler thermometers etc. Remove the cover bolts. If the cover is welded to the tank flange, free the cover according to directions given in Clause 4.2.9. 4.2.7.4.1 COVER When lifting the cover use the cover-lifting eyes which are designed for a minimum angle of 60 degrees between sling branches and the horizontal plane. The length of the sling should therefore be sufficient for at least this angle. Place the cover on suitable wooden supports and in such a way that thermometers pockets, small bushing etc. under neath the cover are not damaged. No grinding or cleaning up of the tank flange is to be carried out before the active part is lifted out of the tank. 4.2.7.4.2. UNTANKING Loosen locking devices, if any, between top core clamps and tank side. Lift the active part by means of lifting eyes or lifting lugs provided on the top core clamps. The untanking height is shown on the transformer outline drawing. To avoid damages on the active part it is important that it is centered carefully in the tank during lifting procedure. After untanking, place the active part on a horizontal foundation. 4.2.7.5 RETANKING Grinding or/and cleaning up of the tank flange has to be done before the active part is lowered into the tank. Check that the tank inside is free from contaminations. Retanking is then done in the reverse order that is outlined above. Note that guiding pins or blocks are welded to the tank bottom to prevent the active art from moving in the tank. When lowering the active part, check that it fits exactly the guiding pins or blocks 4.2.7.6 REASSEMBLING Wipe the underside of the cover free from any dirt or foreign matter before lifting it into correct position above the transformer tank. Lower the cover the last few inches exactly into position without sliding on the gaskets. Reassemble bolts nuts of supporting devices. Weld the cover when the welded Construction is used. Reassmble Bushings, conservator etc., and reconnect pi leads to bushings, current trasformers, etc. Reassemble inspection covers. 374.2.8 4.2.8.1 4.2.8.2 Alter the transformer is complteley assembled, it may be necessary to dry it before oil filling see clause 4.2.5. MOUNTING OF GASKETS The gaskets have a circular/flat cross-section and are made of oil and heat resistant synthetic nitrile rubber/nitrile rubber bonded cork. For small gaskets, O-rings are used with diameter 3,5.0 or 8.0mm, while round rubber cords with diameters 8,12 or 19 mm are used for large gaskets. The groove is normally milled or turned, but for large flanges the groove is created by means of steel bars welded on top of the flange. The width of the groove slightly smaller than the corss-section diameter of the gasket in order to keep the gasket in position during assembling work. Opened sealing joints may be sealed again using the same gasket provided that the same has not been damaged. If the gasket has been hard or got small cracks on the surface, it is recommended to change the gasket by a new one. When handling and lifting flange, cover etc. with gasket grooves, care should be taken when using tools and lifting devices to avoid that the grooves getting damaged or deformed Before assembling of groove gaskets, it is checked that the grooves and contact-sutface in the joint are free from foreign particles and that the paint is free from thick coatings, trickles and drops. When assembling the rubber cord in the groove, the cord length shall be continuous. The gasket is given a small surplus length to compensate for shrinkage. The gasket is pressed down into the groove without stretching or slackening, To prevent the gasket from falling from the groove on vertical surfaces, the gasket may be spot-glued to the bottom of the groove. The screws in the sealing joints shall be tightened so that an even pressure is obtained on the gasket. This is obtained preferably by means of a moment spanner. Rubber gaskets in grooves need not normally be re-tightened, Above description is followed generally for turrets. inpection cover etc, For Main tank rim joint, LV turrets of Generator Transformer where metallic stops are provided, nitrile rubber bonded cork is used, for which following instructions shall apply. (Gaskets when supplied loose, have no bolt holes in them. They are usually cut to the size and shape required, although they may be supplied as straight, angled pieces from which complete gaskets can be built up. (ii) __Searfed joints should be used. A 40 mm scarf in 5 mm thick material is recommended. Joints should be located away from corners and bolt holes, and should be well bonded, smooth and free from local thickening. Neoprene solution is used as an adhesive for joints. (ili) Gaskets are best stored in hermetically sealed containers in a cool place. ‘They must be protected from damp, oil and grease. (iv) To make a gasket joint, first clean the metal surfaces ensuring that they are free from oil, rust, scale etc. Using one of the flanges as a template, Punch the necessary bolt holes. Insert the bolts and tighten the bolts sequentially, @ little every time so that uniform pressure is exerted on the gasket until the 38(ere) Ty gasket is compressed to about 2/3 of its original thickness. Joints should not be subjected to pressure until tightening is complete. If care Is taken in making Joints, and in handling the gasket, it is possible to break and re-make a joint several times, using the same gasket. (V) For making leak proof and good gasket joints, it is necessary that uniform pressure is achieved all over the gasket after mating rims/flanges have been clamped by bolts/studs. Following instructions be followed for proper tightening of bolts/studs. (a) Tigthen lightly the bolts/studs diagonally in the sequences as shown in the fig 4.2.6 b) Tighten again bolts/studs in the same sequence with full pressure tll gasket, thickness is reduced to 2/3 of original thickness. In case of metallic stoppers, tighten until metal contact is achieved. ©) Do not overtighten, otherwise gasket will get crushed. 4.2.9 WELDED COVER (IF APPLICABLE) In order to obtain a good sealing between the transformer tank and the cover a welded joint is recommended. The welding is performed in a certain way to permit opening and new welding repeated a number of times. The chiselling up and re-welding will take about the same time as dismantling and reassembling of bolted cover. If the welded cover for any reason has to be removed proceed as follows: 4.2.9.1 OPENING THE COVER When opening the cover the welding joint should be removed by a suitable grinding wheel. The cover should be clamped to the frame by means of G-clamps to prevent iron chips from penetrating into the tank. Any parts of the weld which may possibly remain on the tank flange should be removed by a chisel to enable a good result of the re-welding. 4.2.9.2 REASSEMBLY When fitting the cover again cork-rubber gaskets, 25X5 or as specified are fitted on the tank flange, see fig. 4.2.7 The gaskets are kept in the correct position with glue based on rubber base. The cover should be clamped to the tank flange by means of G-clamps evenly distributed along the flange with about 600 mm spacing. Tack welding Is carried out with about 100 mm spacing. An extra G-clamp is used during the tack welding and is moved along the flange during the progress of the work. The continuous weld is then applied. Finally the weld should be cleaned and painted. WARNING When welding, a fire-extinguishing equipment should be available, and the work supervised by fire-protection personnel. 4.2.10 EARTHING OF ACTIVE PART AND CORE INSULATION TEST 4.2.10.1 TRANSFORMERS For checking core insulation refer Fig. 4.2.9. for connection details and 2.2.14, 39ra) 4.2.11 TOUCHING UP PAINTING 4.2,11.1PURPOSE | aa A basic principle at touch-up painting should be to restore a damaged paint coat on a surface to the same quality and finish as of the surrounding surface. The touch-up painting should be limited to @ surface as small as possible. 4.2.11.2CLEANING Both damaged and surrounding surface should be cleaned so that all grease, dust and other impurities will be removed. 4.2.11.3GRINDING OF DAMAGES Large damages and defects are ground by means of a coarse abrasive paper, eg. No. 100. The surface is then ground with a finer paper in connection with the damage, e.g. 150 or 180. Damages that are limited to the paint coat only, should be ground off completely at which glazing can be avoided. 4.2.11.4PRIMER PAINTING Damages on the primer paint and grinding down to the steel surface should be painted with two coats of anti-corrosive priming paint. 4,2.11.5FINISHING PAINT Two coats of finishing paint should be applied as per specification which is generally light grey shade No. 631 of IS:5. Please refer Table 4.2.4 for suppliers reference. TABLE 4.2.4 Suppliers Reference si Suppliers No, Name Anti corrosive High Quality full Oil resistant alt printing paint for gloss outdoor drying synthetic outside painting finishing paint enamel 1 Addison 15 2907 Shade 631 of IS 5 Jasmine yellow shade no. 397 of IS 5 for inside painting 2. Asian 32/F3257 ‘Apcolte synthetic : 3 Berger BPL Red oxide Luxol 3H 1 Glass Zine chromate synthetic enamel : 4 Alkali 32-781 Dulux synthetic enamel Chemicals enamel : 5. Garware PR-4460 : - 6. Shalimar Sample No, 5999/1 Superlac syathetic BIN 1. Goodiass’ 205/023, 500 Series 548/101 40ANNEXGRE : 4.4.2.1 FLOW CHART FOR HANDLING ARRIVAL AT. SITE MEASUREMENT OF PRESSURE Lassenouy ] EVACUATION AND OIL FILLING OIL-CIRCULATION THROUGH FILTER STANDING TIME. ACCORDING TO TABLE 2.2 VOLTAGE APPLICATION Relationship between different units 1 bar 10° Pa = 750 Torr = 14.5 psi = 1.02 kg/sq.cm 1 Torr 1.33 mbar = 0.133 kPa 1 kPa 10° Pa = 10 mbar = 7.501 Torr 1 MPa 10° Pa Force Volume 1kp = 9.807N 1 litre = 0.26 US gallons 1S gallon = 3.78 litres 1 litre = 0.22 Imp gallons 1 Imp = 4.55 litres gallon Temperature = 5 x(F-32)/9 x(C#32)/5 41a (i) (a wi) w) wi) wil) viii) (x) oo ANNEXGRE : 4.4.2.2 EQUIPMENT FOR OIL-FILLING UNDER VACUUM High-vacuum 2 stage oil filtration plant provided with themostat-controlled oil heaters and vacuum proof house with independent vacuum pumping system for tank evacuation. Capacity : 6000 Iph Oil-storage tanks provided with silica gel breathers and inlet/outlet valves for oil circulaton. Recommended capacity 20KL-30KL (Clause 4.2.4.4) Vacuum gauges provided in fitration plant. Equipment for measurement of electric strength (BDV) of oil-100 kv. set. Equipment for moisture content of oil Equipment for measurement of Resistivity and Tan delta at 90° C. Oil-sampling cans for bottles. ‘Transparent vacuum proof tubes for checking of oil level during oil filling. Valves, fittings, gaskets ete. Dry nitrogen cylinders. 42eb EI F q WAWMOUSNVUL JHL JO LNIWIONVEV ONIGVOTND ToIdAL F2" “OL 9 Satie te O©CO C DNIOVOND JO SWI IHL LV ais LV Lhd 38 THM SUIGITIS ASH! (8) ' “ATT GNNOND (2) DNlddIS LNANREd OL SL¥OdANS (9) “iva 196 (S) NOOVA TIAA ATS (P) C J NOV (€) DNTDNIMDE (2) 1 SOW 3DVINVH (1)MNVI JOVUOLS TO 4O LNAWIONVEAV TVDIdAL 2°2"P “DLL “SOM € JDNVTd ONDINVIG HIM S71OH DNILNDOW ONIHSNa ‘ON | MW $2 JA'IVA NOLLVDITddV WONOVA “ON | 310H NV “oN | ww gt ONTd NIV “OW L wwog AATVA NIVUG + sont 2 wos ANTVA WALTI “SON 2 UIST BATA DNMIAWVS "0 ‘FInd 7.06 NAA} BEdOIL-FILTERING PLANT WITH HEATER OIL-STORAGE TANK HIGH-VACUUm PUMP CONSERVATOR OIL-LEVEL INDICATOR VALVE VALVE VALVE VALVE VALVE DRY-N2 CONTAINER VALVE MANOMETER FIG. 4.2.3 45‘TRANSFORMER VACUUM FILTER FIG. 4.2.4 46OIL PRESERVATION SYSTEM WITH AIR CELL B.S ESN 10 0 AIR CELL IN PARTIALLY DEFLATED POSITION \2 \4 1 5 2 | iS GENERAL ARRANGEMENT z MAGNETIC OIL GAUGE 3 [areaTae S| AIR RELEASE LORS pi nearer acne rrr] 9. PRESSURE GAUGE CONNECTION (WITH PLUG) uu BREATHER CONNECTING FLANGE. 12. | CONGERVATOR EN COVER FIG. 4.2.5 474 8 2 24 20 13 9 5 1410 6 19 FIG. 4.2.6 (SEQUENCE OF TIGHTNING OF BOLTS) 1 29 7 > - 4 a + ia a7 -}- 7 3 10. FIG. 4.2.7 48SECTION A-A FIG. 4.2.8 49CONNECTION TO TANK CONNECTION FROM CORE CONNECTION FROM TOP YOKE CLAM 1P FIG. 4.2.9 NOTE: 1. WHILE DISCONNECTION/EARTHING CONNECTION BETWEEN CORE/YOKE CLAM & TANK, REMOVE LINK. 2. _ IN SERVICE PLACE LINKS IN POSITION. EARTHING CONNECTIONS FROM CORE AND TOP YOKE CLAMP. 504.3 4.3.1 4.3.1.1 4.3.1.1 4.3.1.3 3 B SECTION: 4.3 COMMISSIONING TESTING AFTER ASSEMBLY OF THE TRANSFORMER AT SITE. After the transformer has been assembied at site, it shall be tested in order to check that it has not been damaged during transport and assembly to such an extent that its future operation will be at risk. Regarding the performance of the test, refer to the testing method as per standards. The results of the test shall be documented as detailed in Clause 4.3.2 “commissioning check “Transformers”. APPLICATION OF VOLTAGE If possible, the voltage should be increased step by step up to rated voltage. This may be done by connecting the transformer to a generator whose voltage is raised slowly. The higher the rated voltage of transformer the more important it become that the application of the voltage is done as described. If it is not possible to use a generator, the transformer may be connected directly to a live line. After the first application, the transformer shall be checked carefully (gas relay, temperature, leakage etc.) When the transformer has been in service for some weeks with normal working temp. all sealed joints shall be re-tightened. ENERGISING The initial magnetising current at the time of switching will be very high. This depends on the particular moment in the cycle. The transformer should always be soaked for few hours under constant care Le. keep it energized. If the breaker trips on differential, Buchholz or any other device, the cause must be investigated before re-energising the transformer. After successful charging, performance of the transformer OTI,WTI readings should be monitored for 24 hours and ensured that they are as per loading. ANALYSIS OF GAS The gas collected in the relay will help to identify the nature of the fault. It is suggested that the following checks are made at convenient intervals or following the indication of accumulation of gas through alarm signal. 1. Rate of gas collection The greater the rate of gas collection, the more severe is the nature of the developing fault. 2. Colour of the gas helps in finding the affected meterial as follows. : 51COLOUR INDENTIFICATION White Gas of decomposed paper and cloth insulation Yellow Gas of decomposed wood insulation. Grey Gas of overheated oil due to burning of iron portion Black Gas of decomposed oil due to electric arc. 3. Combustibility of Gas-A small amount of gas drawn through the top pet cock if brightens the test flame, then the gas is combustible. Incombustible gas indicates air. 4. Chemical Analysis of the Gas-The princples of working gas analyzing equipment is illustrated in the figure 4.3.1 ‘Two solutions are prepared as detailed below and best results are obtained with freshly Prepared solution. Solution 1: 5 gms of silver nitrate (AgNO3) dissolved in 100 ml distilled water. Solution 2: A week solution of ammonia in water slowly added to 100 ml of Solution 1, until a white curdled precipitate which forms first disappears in the mixture. The gas analyser loaded with these solution is then connected to the top pet cock. Small quantities of gas collected in the relay is allowed to pass through the two solutions as illustrated. The results are identified as follows : 1. Both solutions are clear Gas is air 2. Solution 1- White precipitates Gas of oil decomposition. turning brown on exposure to sunlight 3. Solution 2 - turning to Dark brown : Gas of decomposed paper, cotton or precipitates wood insulation. NOTE: THE ABOVE INFORMATION ON GAS ANALYSIS ARE AS DETAILED IN 'S:3638-1966. PLEASE REFER S:3638-1966 FOR ALTERNATIVE METHOD OF CHEMICAL ANALYSIS. 4.3.2 COMMISSIONING CHECKS 4.3.2.0 SCOPE This schedule cover the tests to be done at site after transformer has been installed and dried out. 524.3.2.1 GENERAL Check the following : SI. No. Description Remarks Breather Silicagel (Blue when dry) Oil in the Breather housing cup. All valves for their correct opening and closing sequence. Oil level in conservator tank. Oil in cooling system. Oil level in bushings. Release air, wherever necessary. Cooling accessories (Pump motors, Fan motors etc.) for direction and O/L setting, 9. Buchholz, oil level indicator, pressure gauges, thermometer, Temp. indicators etc. for operation. 10, Earthing of main tank M.Box T/C driving gear, divertor switch Pump & Fan motor etc. 11. Neutral earthing. 12, Earth Resistance of Electrodes. 13. Earthing of bushing test tap. 14. Check oil leakage for 24 hrs. 15. Check Auxiliary circuit voltage (415 V) 16. Calibration of OTI/WTI with hot oil 17. Check Working of WTI/RTD repeaters at control room. 18. IR of core to earth. SNOMRUNS 4.3.2.2 INSULATION RESISTANCE TEST Sl. } Description Date | Time |Megger | IR Temp. | Remarks. No. in Hrs [used Value 1. | Control wiring (Not less! 2. | Tap Changer than a) Motor 500V b) Control megger) 3. | Cooling system a) Motor Fan b) Motor Pump ¢) Control wiring 4. | Main winding a) HV/E+LV (Not less B) IV/E+HV Than, ©) LV/E+HV+LV 1000v d) HV/IV megger) e) IV/LV ) HV/LV Note:(1) While checking these values no external line, lightning arrestors etc. should be in circuit. (2) Special care should always be taken while meggering the transformer winding 53to ensure that there is no leaking in the leads. 4.3.2.3 OIL CHARACTERISTICS. Take necessary preacaution (regarding rinsing the bottle, cleaning hand, air bubble etc.) while withdrawing the samples. Each sample should be free of air bubbles and should not be tested when it is hot. The sample should satisfy IS:1866. Sl No. Time & Condition Oil Sample Moisture] Break- From Date | Time} Weather | in PPM | down Voltage in kV. Tan-& at 90°C Remarks Tank Top Sample Bottom system Cooling system Top Sample Bottom Sample oLT¢ Divertor Switch (each phase) dq v w 4.3.2.4 TESTS ON CT 1. Ratio 2. Polarity 3. Magnestising current. 4, IR value 4.3.2.5 ON LOAD TAP CHANGER Sl.No] Description Date Observation Remarks Visual Inspection of equipment. Hand operation on all taps. Complete wiring of the circuits. Limit Switch ‘Over running device Remote Panel wiring. ‘Over load Device of Driving Motor. Local Operation (Electrical) Remote Operation (Electrical) Tap Position Indicator. Step by step contactor Out of Step Relay. Note: While operating the mechanism on Electrical Control, check once again limit switches, step by step contactor cover running device etc for their actual operation and prove that they are functioning properly 544.3.2.6 OFF CIRCUIT TAP SWITCH Tapswitch handle should not be left halfway and/or unlocked 4.3.2.7 CONTINUITY TEST Continuity between line and neutral (for neutral end TC) or line to line (for line end TC) with multimeter on all taps and phases to be confirmed. 4.3.2.8 MEASUREMENT OF WINDING RESISTANC! affa Winding Tap No. Phase U | Phase V | Phase W] Temp | Remarks a ~) HV 1 Winding 2 a 4 5 6 7 8 9 ta) 9 (b) 9 tc) 10 uw 12 13 14 15 16 17 Vv Winding Lv Winding 55= 4.3.2.9 VOLTAGE RATIO TEST Ratio on all taps is to be checked by hand operation only. This can be done any time, once the tap changer is completely erected. Start the tap changer from lowest tap and then go on increasing tap by while checking the value instead of starting normal tap. Tap Voltage applied Voltage Measured Ratio obtained | Remarks Nos. opv iw 1 2. 3 4 5 6. 7. 8 9.ta) 9b) 9.40) 10. u 12, 13. 14. 15. 16. 17. 4.3.2.10 MAGNETISATION CURRENT a) Apply 3 phase 415V on HV Terminals and keep LV open. Voltage Applied Current measured Remarks a Volts | U phase m Amps vw Volts | V phase m Amps aw Volts | W phase m Amps b) Apply 3 phase 415 V on LV terminals and keep HV open. Voltage Applied Current measured Remarks uy volts | u phase m Amps w volts | v phase m Amps uw volts | w phase m Amps Note:in case of single phase transformer apply 230 V. 1 phase between line and central terminal, aca 564.3.2.11 VECTOR GROUP Check the vector group of the transformer by connecting in a suitable manner. Vector Diagram of Diagram as connected Remarks group connection for test CONDITIONS TO BE PROVED VOLTAGE MEASURED 1 1 2. 2. 3, 3. 4,3.2.12 FINAL IN CHECKS. ‘The megger readings finally after the transformer is connected to the system. Date. Time... Temp... Windings HV/EsLV IV/E+HV+IV LV/E+HVsIV HV/IV IV/LV HV/LV Megger Value obtained in Remarks used Mega ohms 4.3.2.13 OTHER TEST WTI Setting Set for Proved OTI Setting Set for | Proved Alarm Trip Fan Start Fan Stop Pump Start Pump Stop Alarm Trip 574.3.2.14 PROTECTION AND ALARMS Prove the tripping of associated breakers by actual operation of the various devices and relays. UNDER NO CIRCUMSTANCES SHORTING OF ELECTRICAL CONNECTIONS SHOULD BE DONE Si. | Device Set for Proved | Remarks No. Alarm] Trip _ [Alarm] Trip 1. | Buchholz 2. | Excessive Winding temperature 3. | Excessive Oil Temp. 4. | Oil flow failure 5. | Water flow failure 6. | Differential pressure (Low cooling system) 7. | Fan failure 8. | Low oil level (conservator tank) 9. | Pressure relief valve 10. | Differential relay 11. | Over current relay 12.| Earth fault (REF) 13. | Instt. Earth fault 14,| Inter trip, if any 15. | Trip free check 4.3.2.15 RECORD THE FOLLOWING AFTER CHARGING 2) No load current at relay terminal G phase A V phase A CT Ratio W phase A b) Temperature (at the time of charging) OT! c wT *c Ambient " ©) Maximum temperature after 24 hours °c 5844 4.4.1 4.4.1.1 4.4.1.2 4.4.1.3 SECTION : 4.4 MAINTENANCE AND OPERATION SUPERVISION OF TRANSFORMER GENERAL In order to avoid faults and disturbances, it is important that a careful and regular supervision and control of the transformer and its components is planned and carried out. The frequency and extent of such a supervision and control is dependent ‘on climate, environment and service conditions etc. The directions for a certain transformer are therefore prefeably based on experience and service conditions etc, A supervision and maintenance program according to schedule in ANNEXURE 4.1 is recommended. Spare transformer are supervised and mantained according to the same schedule as transformers in service. GENERAL MAINTENANCE Dirt/Dust The external transformer surfaces shall be inspected regularly; and when required cleaned from dust, insects, leaves and other airborne dirt, Possible Leakage Alter energising of the transformer, a certain settling may appear in sealing Joints. These should therefore be retightened according to schedule in ANNEXURE 4.1. This applies especially to sealing joints with plain gaskets that are not placed in grooves. Rust damages touch-up painting A regular inspection of the external surface treatment of the transformer should be carried out. Possible rust damages are removed and the surface treatment restored to original state by means of primer and finish paints that are despatched with the transformer. OIL PRESERVATION SYSTEM, MOISTURE ABSORPTION Transformer oil absorbs easily moisture from the surrounding air. The moisture absorption is prevented by means of rubber sack in conservator which acts as a separating wall between the oil and the surrounding air. Rubber bellow is provided as per customer requirment, In conventional conservator the moisture absorption is prevented by a breather connceted to the conservator. The active drying agent (silica gel) should be exchanged or regenerated when 2/3 of the agent has been red-coloured by absorbed moisture. The breather contains also an oll-seal that prevents spontaneous air circulation. This seal should be filled with oll to the level specified, 4.4.1.3.1 OIL LEVEL INDICATOR FOR OIL CONSERVATOR The Transformer oil conservator is provided with an oil-level indicator At an oil temperature of 45 °C, the conservator should be half. If the level exceeds the viaue “full”, ofl must be drained off. If the value is “low”, vil 594.1.3.3 4.1.3.3 4,4.1.3.4 SLUDGE, ACID 4.4.1.3.5 OIL, MISCELLANEOUS 4.4.1.4 4.4.1.4.1 a) ig must be filled in. Normal oil level should be at 35 °C mark. GAS-OPERATED RELAY (Buchholz Relay) The use of gas-operated relay as protection for oil-immersed transformer is based on the fact that faults as flashover, short-circuit and local overheating normally result in gas-generation. The gas-bubbles gathering in the gas-operated relay affect a float-controlled contact which gives an alarm signal in case of incipient fault and trip signal in case of earth fault etc. MOISTURE If the oil has been subjected to moist air, the moisture content and the electric strength of the oil shall be checked. Normally the BHEL transformers have uninhibited oil. Sometimes inhibited oil is used. The inhibitor works so that it breaks the chain reaction by which sludge and acid are produced. This retards the ageinig process and extends the utilization time of the oil. If sludge is being produced in the oil, the oil changes colour and becomes darker and turbid. The sludge can be removed by means of filteration, but if the sludge formation has started, it will increase with time. The oil should therefore be exchanged if the neutralisation value according to IS:1866 exceeds 0.5 mg KOH/g or precipitable soluble sludge is produced. The oil exchange should preferably be carried out when the transformer is warm and the oil viscosity is low. The exchange should be as complete as possible, because old oil will affect the new one, speeding up the ageing. Oil which is not too much oxidized may in certain cases be regenerated, but this is economical only for large oll quantities. For supplementary information about transformer oil, see clause 4.4.2 “Supervision and control of oil” TEMERATGRE SUPERVISION The service life of a transformer is highly dependent on the temperature prevailing in the core and windings under operation. It is thus important to keep the oil and winding temperatures under observation continuously. The temperature should be read regularly and the measured values registered. These values will give guidance for judging the service life of the transformer, cooling system functions etc. OVERLOAD A Transformer can normally be overloaded at a low ambient temperature, However, the permissible overioad must not be judged only with regard to the oil temperature. We must also consider that the‘temperature difference between winding-oil will increase with the load. Therefore, also the winding temperature must be supervised during overloading. For determination of the overload capacity for modern transformers refer 1S:6600. If the temperature in a transformer shows a tendency of rising without 60ffexaxca) gz 2 corresponding increase of the load, this may be caused by a reduction o the cooling ability of the cooling equipment (dirt, dust). The thermometer should also be checked in this case. Opening of radiator valves, buchholz relay valve shall also be checked. All valves in cooling circuit shall be in open position. 4.4.1.4.2 THERMOMETER FOR MEASUREMENT OF TOP-OIL TEMPERATURE The thermometer consists of a cylinder sensing body with a flange, 2 capillary tube, and a thermometer housing with dial and contact-device. The measuring system is filled with a liquid, which changes its volume at temperature variations, and affects springy bellows. The movements of the bellows are transferred to the pointer and signal contacts via a link system. The thermometer is provided with two signal contacts of mercury switches. The contacts can be set independently of each other. For control adjustment of the thermometer, see OTI leaflet enclosed. 4.4,1,4.3 WINDING-TEMPERATGRE INDICATOR The thermometer system consists of a sensing body with assembling details, a capillary tube and a thermometer housing, which contains a scale with an indicating pointer and a max. pointer, heating and adjusting resistor, as well as contact-device for four switches. For further information about function, control and adjustment of winding temperature indicator, see WTI Leaflet. 4.4.1.4.4 REMOTE CONTROL OF WINDING TEMPERATURE For remote control of winding temperature we use either 2 resistance-temperature device with a heating element built into the same housing or a slave repeater of the local WTI. The heater element is fed by the secondary current of a current transformer. For setting of the heating element there is a parallel connected adjusted resistor installed in the control cabinet/Marshlling box. For further information about function and calibration, see RTD/WTI Leaflet. 4.4.1.4.5 RADIATORS The external cooling surfaces shall be inspected regularly and when required cleaned from dust. insects, leaves or other airborne dirt. This is especially important in case of fancooling. The cleaning is suitably cartied out by means of water flushing at high pressure. Normally, no measures are necessary for keeping the internal cooling surfaces clean as long as the oil is in good condition. If, however, sludge formation has set in, the sludge may deposit on horizontal surfaces in radiator. If such a case, the radiator should be flushed internally with clean oil. If the sludge does not loosen, we can firstly flush with petrol etc. and then with oil 4,4,1.4.6 CONTROL CABINET The operation of the control cabinet and devices normally included, are described in chapter 3. 4.4.1.4.7 BUSHINGS Bushing porcelains shall be cleaned from dust and dirt regularly. In areas where the air conatins impurities as salt, cement dust, smoke or chemical substances, shorter intervals are required. See also the Instructions in the special information documents about bushings that are included in chapter Il 61Cite 4,4.1.4.8 CONNECTIONS In order to avoid prohibited temperature rises in the electrical connections of the transformers all screw-joints should be checked and re-tightened according to schedule enclosed. 4.4.1.4.9 ACCESSORIES Seperate leaflet/instructions should be followed for various fittings (as applicable) for Flow indicators, Oil Gauge, OLTC, pressure relief valve ete. as listed in chapter 1 These leaflet are enclosed with the manual. 4.4.1.5 MAINTENANCE SCHEDULE Maintenance schedule given at Annexure 4.4.1 should be followed. With proper maintenance as per this schedule normal life of Transformer can be expected. 4.4.1.6 IR TEMPERATURE RELATION It has always been the question from our customers as to how the IR values can be converted at different temperatures. We have drawn a curve (Fig. 4.4.1) for guidance of the operating staff on the basis of our experience. So that they can judge the IR Value at any temperature. This curve cannot be taken for absolute value but will serve as a good guide for conversion of IR values at different temperatures. A simple example is given as to how to calculate the value at different temperature. Suppose IR viaue of 70°C is 300 M. Ohms and we want to convert at 40°C, the curve wil give you a factor K for difference in temperature i.e. (70°C-40°C)=30°C K for 30°C temperature difference = 4.2 So the value at 40°C = 4.2X300 = 1260 M.Ohms. Value thus converted fairly tally with the actual Value when cooling the transformer. The factor are tabulated as below: Difference in 10°C 20°C 30°C 40°c 50°C temp. Factor K 1.65 2.6 4.2 6.6 10.54.4.2 4.4.2.1 4.4.2.2 4.4.3 4.4.3.1 4.4.3.2 4.4.3.3 4.4.3.4 4.4.3.5 SUPERVISION AND CONTROL OF OIL GENERAL The oil in a transformer provides an electrically insulating and a cooling medium. The service reliability of an oll-immersed transformers is therefore mainly, depending on the oil quality. In service, oil is subjected to normal deterioration due to the conditions of use mainly due to air, water and solid particles/sediment. ‘SCHEDULE The oil should be maintained as per the guidelines of S:1866. Periodicity of tests and permissible limits for important parameters of oil-electric strength, water content, resistivity, tan-delta, neutralization value, sediment and precipitable sludge, flash point and interfacial tension are given in Annexure 4.2. Health of transformer can be effectively monitored by Dissolved Gas Analysis (DGA) technique described in detail in 1S:9434 and IS:10593. This technique helps in detection of incipient faults in transformers. TROUBLE SHOOTING General measures for trouble shooting are described in this section. Items to be informed to BHEL in case of trouble. Followings are items to be informed to BHEL. 1) Transformer specifications Capacity Serial number Year of manufacture 2) Load current (A) or Load (kW) 3) Operating tap position 4) Conditions at time of trouble a) Date, time b) Trouble phenomena <) Checked items and results. 4) Weather Transformer troubles and check items Troubles their possible causes and items to be checked are given in Table 4.1 & 4.2 Detective devices and their standard Refer to table 4.3 Check items and judging standard Refer to table 4.4 Detection method of oil or gas leaks Refer to table 4.5 63v9 ‘anbsoy Buqespdo 24ssanx] Lei “ON fej Jo anyen Bu ado pure asop pew) zy ayer jue Jo Burda Ky a woqysod dew das-o-o Jo Bus veY> ‘ey ajduosu 0 anp suonsod Surddoys Jado Tad wioqy fue ‘sya. Jo uonendo Muy 1 smendo apap aps sunsaxd 40 jas young tpg jew uy 22 joxpauy 1% pip jap aunssa nine ypu Jaan jayps asnsard pu ( sauo}sues Jo Burddors a ‘puss uo S31 OPA Popoip 94 07 wa, sasne a1gss04 sajqnoat (iabueys dey peof-uo Jo ase UI) sa]qnorl AUUOJSURLL ZY ACL39 oe ce “anyen wana yroID-UOUS €°¢ qwaniro yn nuadiey Se ‘away Bundnszaey 19Buey> waists ay ut || ‘prs saojhap Butpsooo1 ut punoy s; Kyeusouqy 7S {J grosp-yoys so ypns sy reuang VS Bede ‘ayeiado “379 soysaute = “fejas punoi6 ‘Aejas asinosa40 se upns Kee ammersduraa ‘saseB panjossip ou doup uappns uy 2 K——7 Jo uonnjona 30 se paddesl, f+ == ====4 sayerado (wuepe) Avjai 2joyypng K\uQ sishreue se "py : . a sajeiads sanjaap Jays aunssaid AUQ Bee RD FEL __| spo ste ove de “BHE Loqu ‘sayerado (dun) Aepat 2joulpng KUO joann 2 fumes 12 Ce a smelado Ae enUAIaHIP AUD jo ay ve wenn ysmuyy | lo a yap pips amnssard poe fe sisAjeue sep panjossid 2'1 uauin> BuNDX, “owes a6eyj0y aoueysisai vine} rearayu aunioysuen Jo Buxddorg ee a ie x pax2ay> aq 0) S19] sasne aqissod soiqnouy, (aaBueys dey peoj-uo ydaoxg) sajqnoay s2UUOJsUeLL Ty P1d2LTable 4.4.3: Detective devices and their funct feat eh No] Detective Description device 1. Buchholz This relay detects the gas evolution due to internal trouble and relay gives alarm, and is suited to the detection of minor or slowly (ist stage) developing faults. The nature of the detected fault can be judged to an extent by analyzing the gas and oil. Incase of nitrogen gas sealed transformer, part of dissolved nitrogen gas comes out due to the sudden temperature drop, which sometimes results in the actuation of this relay. Buchholz relay (2nd Stage) When a major fault suddenly takes place inside the transformer, oil flows suddenly from the transformer tank fo the conservator. The second stage of Buchholz relay is actuated by this oil flow. If the second stage of the relay function independently, check the ait breather, nitrogen gas sealing device ete. If it function combinedly with the over current relay etc. it is suspected that 2 serious internal defect is in existent. In such a case, take all tentative measures and contact BHEL immediately . 3.| Pressure When the internal pressure of the transformer rises above the set relief value, the pressure relief device functions. It also functions, though device occasionally by the choking of the air breather. The self-excited pressure relief plate is subject to brittleness caused by secular change. Comprehensive judgement based on the inspection of other protective relays is the key to determining whether the function of this device is an erroneous operation or a normal ‘operation caused by internal defect. 4.| Differential | This relay detects the internal defect by compering the input relay current and the output current of the transformer. If it functions combinedly with other protective de it is indicative, in almost all cases, of an internal fault. Note that this relay sometimes ‘operates due to inrush current when the transformer is energized, and this is of course not an internal fault. 5.| Dial thermo | This thermometer gives alarm when the temperature rises beyond meter alarm | the preset value. Insufficient cooling effect of cooling equipment contact due to contamination of cooling fins, Stoppage of oil pumps, fans and so forth is one of the reasons that operates this device. 6.| Overcurrent | These are intended for detecting fault in the electric system relay, ground| connected with the transformer. A fault on the transformer results fault relay | in the function of these telays, which is always accompanied by the actuation of protective devices of the transformer. Detection of the fault in the electric system should therefore be made on the basis of a comprehensive judgement of these functions. 7.| Voltmeter, | If a sudden change in voltage or current is noted when no ammeter abnormalities are detected in the electric system, or an abnormal unbalance of voltage or current is noted between phases, investigate the cause. 8.| Human Note that human senses also play an important role in fault senses detection. Following are the points to be checked by your senses. 1. Discolouration or odour of insulation oil (blackening or stink). If pieces of insulating materials or copper particles are found in the oil, it is suspected that an internal defect has developed. 2. Abnormal vibration or sound 66Table 4.4. Check items and judging standard No.| Check Point Description Judging standard 1. | Measurement | Grounding fault can be detected by Judgement to be made of insulati this measurement, though to some by comparison with resistance extent. The measurement must be values obtained by proceeded after disconnecting the periodical inspection transformer from lines and cleaning of bushing surfaces. 2. | Measurement | This is primary means to be employed | Judgement to be made ‘of winding | for detecting the fault of windings. The | by comparison with the resistance resistance should preferably be factory test report measured independently by the D.C drop of potential method. 3. | Measurement | This can be conducted by applying 2 Ditto of voltage voltage of about 200V which can be ratio readily obtained at job-site. Accurate Measurement at job site entails some difficulties due to source voltage variation and errors of instruments. In case of 3-phase transformers, it is essential to measure the ratio phase by phase and check the variation of the ratio between phases. 4. | Measurement | This measurement is very usefull to | 1. Comparison of the of exciting | detect fault in windings and/or cores. | measured values with current Local short-circuit in windings or cores | previously obtained ones. often causes an increase in the exciting | 2. Significant difference current. The test can be made by in value among phases. applying a low voltage (200-400 volts) to a winding. 5. | Checking of | Measure dielectric strength and check | Judgement to be made insulation oi! | for carbon sludge, offensive odour and | with reference to discoloration. Annexure 4.4.1 & 4.4.2 6. | Measurement Judgement to be made of dielectric = by comparison with loss factor, values obtained by tané Periodical inspection. 7. | Analysis of | When gas is accumulated in the Contact BHEL. gas Buchholz relay, its composition must accumulated | be clarifed by the gas chromatograph in Buchholz | analyzer to check for the possible relay internal defect. 8. | Analysis of | Existence of internal defect can be Contact BHEL dissolved gas | judged, though to a limited degree, by in oll ‘sampling and analyzing oil by a gas chromatograph. (Refer 4.4.3.2) 67mn Table 4.4.5 : Method for detecting oil or nitrogen leaks Leak Measures Description Oil leak Clean the suspected leak part with The following are thinner or gasoline, apply chalk powder | susceptible to leakage. to it. The leak part will present itself as |(1) Gasketed joints. a soiled spot. (2) Welded parts Nitrogen leak (in [Step up Nitrogen gas pressure to 0.17 |The following are case of Nitrogen | ka/em* susceptible to leakage sealed system) (1) Accessories for pressure relief (2) Flanges (3) Welded parts 4.4.3.6 GAS ANALYSIS ON TRANSFORMER OIL Incipient faults in oil filled transformer are usually the result of eltctrical or thermal excess stress of either transformer oll or insulating materials. It is known that such excessive stresses produce a mixture of gases characteristic ‘of which give an indication of the type of faults, and materials associated with the faults, It is recommended that analysis of dissolved gases in transformer oil by gas chromatographic equipment is made, at the time of commissioning and then after an interval of one year for transformers of 145 kV class and above. 4.4.3.7. ANALYSIS METHOD 4.4.3.7.1 SAMPLING OF OIL FROM TRANSFORMERS. Oil in transformers can be sampled through drain or sampling vaive near bottom of the tank. Special care shall be taken not to introduce air, foreign matter, oF dirty oil into sampling container. For this purpose, first 0.5 - 1.0 litre of oll from the transformer shall be over-flown through the oil-container. Shape of the sampling container may be that as shown in Fig. 4.4.2 and sampling method shall be in accordance with Fig. 4.4.3 See also IS:9497. Sampled oil shall not be exposed to air before analysis. 4.4.3.7.2 Gas analysis Gases to be analysed and criteria for the gases found in transformer oil are tabulated in table 4.4.6. 4.3.8 ASSESING THE TEST RESULTS Test results on gas contents in oil by some typical faults in transformer active Part models are shown in table 4.4.7. Table 4.4.6 and table 4.4.7 may be refered to evaluate transformer co: ion. To analyse DGA test results, flow chart given at Appendix A of IS:10593 should be followed. Standard values may be taken from CBIP Technical report no. 62 of April 88 titled “Guide for testing of Transformer by Sampling and analysis of free and dissolved gases’. Ratio technique of IS:10593 should be used to know the nature of fault. 1S:9434 and IS:10593 have been adopted from IEC pub 567 and IEC pub 599. 68cock VACUUM GREASE VACUUM ROOM ‘SAMPLING OIL QUANTITY : APPROX 300 mi FIG. 4.4.2 EXAMPLE OF OIL SAMPLING CONTAINER SAMPLING CONTAINER VALVE L| a TRANSFOn.AER TANK Fic. 44.3 EXAMPLE OF OIL SAMPLING METHOD 6sTable 4.4.6 Gases to be analysed and criteria 1. Gases to be analysed normally Qa, Nz, Ha, CO, CO2, CHe 2. Gases to estimate abnormality He, CHe, Catlz, CaH., CoHe 3. Gases to estimate deterioration CO, C02, CHs Table 4.4.7 Gas content in oll by faults Type of faults Decomposable gases in transformer oil 1. Overheat of oil Ce, Cotte, He,t lc, CaHa, CsHs, Calta) 2. Arcing in oil He, CaH2,(CHa, CHa) 3. Overheat of solid insulating materials CO, CO2,(He, C2Ha) 4, Overheat of oll and paper combination CHa, Catla,CO, CO2, Hz 5. Arcing of oil and paper combination He, C2H2,CO, COz,(CaHe) ) shows gas contents which appear rarely. PARALLEL OPERATION 0) If it is desired to parallel a transformer which is not identical in design with BHEL, transformer, it is preferable to refer the matter to BHEL for advice. (ii) The voltage ratings/ratios and impedance values at all taps should match for the two transformer that are to be paralleled. Only certain combinations of vector groups are capable of being paralleled. The table 4.4.8 below indicates the more common permissible combinations. Table 4.4.8 TRANSFORMER (B) H.V. Delta Star_ Delta Star L.V. Star Delta Delta Star HV.LV. Delta/Star Yes Yes No No TRANSFORMER (A) | Star/Delta Yes Yes No No Delta/Delta No__No Yes __ Yes Star/Star No No Yes Yes(iii) Reference to the connection diagrams of two transformers should indicate the terminals to be paralleled. (iV) The reversal of two leads on either side of a three- phase transformer will reverse the polarity changing them in sequence (e.g. form UVW to VWU ‘or WUV) will swing the vector through 120° (V) Phase sequences and polarity can be checked by energising both transformers on the primary side before paralleling, and measuring the open-circuit voltage appearing across each pair of terminals which will ultimately be paralleled. (vi) 1S:2026 and IS:10561 may also be referred. ANNEXGRE 4.4.1 MAINTENANCE SCHEDULE Si. | items to be inspected Inspection notes ‘Action required ] HOURLY 1. | Ambient temperature Winding ternperature Check that temperature rise is | Shutdown the transformer & 3. | Oil temperature reasonable investigate, if either is persistently higher then normal. 4, | Load amps. Check against rated figures ‘An improper tap position can ‘cause excessive core loss. Voltage and tap position should be corrected DAILY 1. | il level in transformer conservatot Check il level from oil gauge. | Top up, if found low. 2. | Oil level in tap changer divertor | Check oil evel from the gauge | Top up if found low switch glass. 3. | Oil level in bushings Check oil level from the gauge | Top up, if found low sls. 4. | Pipework and accessories for | Inspect the transformer for leakged If leakages are observed tighten leakages evenly the gasket joints. Replace “O' ring or washer suitably. Replace gasket if needed MONTHLY 1. | Buchholz Relay Check oil level Release collected gas/ai 2. | Dehydrating breather Check colour of silcagel Reactvat replace with new charge, if found 3. | Leakages of water into cooler. pink investigate and rectify after taking shutdown, QUARTERLY Bushings Examine for ditt deposition and | Clean and tighten plug. Cracked tightness of oil fing plugs porcelain should be Examine for cracks in procelain. | rectiied/replaced 2, | Transformer oll and tap Check for di-electric strength and } Take suitable action to changer cil moisture content. restore quality of ol 3, | Cooler fan, bearing and Check contacts, manual Lubricate the fan bearings controls, pumps control and interlocks. Replace worn out contacts and other parts. Clean/adjust controls and interlocks.eit 10 ul 12. 13. 14] (On load tap changer Dehydrating breather Transformer oil Cable box * Alarm and protection circuits OTI & WTI pockets, Earth strip Packing gaskets of fans Fan motors ‘Tank and accessories Gasket joints Divertor servicing Diverter switch of con-load tap chagner Diverter switch oil ‘Tank cover and conservator Bushing top connectors. Examine contacts, check step by step mechanism operation, end positon limit switches emergency limit switches and brakes. Also check oil in driving gear mechanism. Check oil level in the cup and ensure air passages are free. YEARLY Check for characteristics in with 1S:1866 Check for proper sealing of compound filling holes. Check for cracks in the compound. (if used) Check all protections and alarm circuits by actual external initiation, Check operation of relays and their sensitivity Check oil in the WTI and OT! pockets. Check earthing resistance. Inspect the condition of packing gaskets. Check IR viaue of motor winding after rainy season. Noise & vibration of fans. Check painting and surface finish, Mechanical inspection of all accessories Check the tightness of bolts One year after commissioning Check the contacts for burning cr pitting marks. + Filter oil irrespective of strength. Dutt, Dirt, Surface Check contact joints. Replace all worn out and burnt contacts. Set limit switches in position. Clean/replace brake shee lining. Lubricate all bearing and coupling points suitably. (Refer Seperate leaflet) Top up, if found low. Clean air passages. Fitter replace as required to restore the quality. Replace sealing washer, if found damaged. Replace burnt out fuses, Adjust the setting and check wiring circuits. Adjust relay setting, if needed. Replace damaged relays. Replenish, if required. Take suitable action, if resistance is noted Replace, if worn out or resilience lost. Dry out, if found low, check balancing of fans. Touch up/repeint, if required Replace any component found damaged Tighten evenly all loose bolts, nuts, locking etc. Draw out diverter, clean tighten contacts Recondition/replace, if required. Replenish with new oil, if oil is too much contaminated. ‘Clean touch-up painting Reltighten. 721. | Oil conservator General Inspection including air cell. punctured. 2. | Transformer oil Examine values as per 1S:1866 | Filter oil if required. 3. | Buchholz relay Mechanical inspection. of buchholz | Set floats, if required. 7-10 YEARLY Transformer and tap changer | Overall intemal inspection Tighten all clamping Assembly including lifting of core and coil | arrangements, loose cleating assembly etc. Tighten all nuts and bolts ‘TWO YEARLY ‘Clean, if required. Ensure proper functioning of indiator/Replace if checking the opertion of gauges (on it. Check heathiness of and check locking arrangements and fasteners. Wash core and coil with dry transformer ol. NOTES : In addition to the above instructions, reference should also be made to IS:10028 “Code of practice for selection installation and maintenance of transformers.” Reference of IS:1866 “Code of practise for Maiintenance and Supervision of Mineral Insulating. Oil in Equipment" should be made for maintenance of oil while transformer is in service. Table 1 & 2 of IS:1866 are given at annexure 4.4.2 & 4.4.3 for ready reference. The inspection schedule specified for longer periods automatically includes those specified for shorter period. All maintenance test results and observations should be specifically recorded. Where matter given in the inspection book differs from that given in IS referred to, the transformer user should follow the instruction books. In case of anything abnormal occuring during service, advice from suppliers should be obtained giving them complete particulars as to the nature and extent of occurrence, together with the name plate particulars in order to assist identification of the transformer. As efforts are being constantly made to improve designs and service, the transformer supplied may differ in minor details from data given herein. 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The full application of these recommendations to small transformers upto 1 MVA or below 36 KV will be technically necessary only in cases where high reliability is required. It will normally be uneconomic. in most cases, it could be limited to the simpler field tests and the periodicity of tests will be determined with relation to the reliability required. Inspection of oil in pole-mounted transformers is assumed to be uneconomic. Characteristics are normally well above the permissible limits given in col 7 at the time of test of transformer in the manufacturer's works. However, no Separate limits have been fixed for this stage. Higher limits may be required for electric strength and lower limits for water gontent prior to testing in the factory and prior to energizing the transformer. Special instructions given by the manufacturer may be followed. Suggested initial periodicity of tests have been given in col. 6. Subsequent intervals may vary depending on previous test results (progress of ageing) and on changed service conditions. Instructions of equipment manufacturers should be taken into account in adoption of the recommendation of this table. For application and interpretation of test in diverter tanks of on-load tap changers, guidance shall be taken from the manufacturer. Alternatively an indication of the presence and effect of water content can be obtained from a resistivity comparison at 27 C and 90 C (see 6.4.1.2) Water content and acidity influence the values of the specific resistance. The limit is indicative only and when value falls below this limit the cause should be ascertained by other tests. Perform test more frequently when value exceed 0.3mg KOH/g. For transformers subject to test (ii), methodis) it will be necessary to test more frequently to establish when neutralization value (total acidity) exceeds 0.1 mg KOH/¢. This test may also be required when an unusual odour is noted or when an internal fault has accured. 76ANNEXGRE : 4.4.3 GUIDELINES FOR THE CHARACTERISTICS OF OIL TO BE ENERGIZING NEW TRANSFORMERS USING NEW INSULATING OILS ACCORDING TO IS:335-1983 SL, CHARACTE ISTIC EQUIPMENT. TEST METHOD No. VOLTAGE (REF TO 1S:OR) (APPENDIX) a (2) 3) 4) (i) Electric strength Below 72.5 kV 18:6792-1972 (Breakdown voltage kV) 72.5 KV & less than 145 kV 145 KV and above (ii) Specific resistance All voltages IS:6103-1971 (resistivity ohm-cm at 906 C) (iii) Dielectric dissipation All voltages 1$:6262 - 1971 factor (tand) at 90° C Max. (iv) Water content, ppm Below 72.5 kV 18:335-1983 Max. 72.5 KV and less than 145 kV 145 KV and above (v) Interfacial tension All voltages 1$:6104-1971 at 27° C (Min) Nim (vi) Dissolved gas content145 kV and above (Under consideration) (ware) A OBTAINED BEFORE PERMISSIBLE UuMIT SATISFACTORY FOR USE (5) 40 kV min kV min 60 kV min (rms) 50 (rms) (rms) 1x10! ohm -cm (Min) 0.05 15 ppm 20 ppm 15 ppm 0.030 7(iz) a 1.R. TEMPERATURE CURVE 20 10 5.0 4.0) 3. 2. x 1.0 = 2 5 & 1 0: 10 oe 20 30 40 50 60 TEMPERATURE °C Fig:4.4.1 786.0 OPOLYETHYLENE TUBE, 6.500 —25QHOLE 250 SOLUTION KNURLED BRASS COUPLING. THREADS SOLUTION 2 THREADS TO SUIT OUTLET (9.5 OUTSIDE DIAMETER) OF TEST PITCOCK ON GAS-OPERATED RELAY. ALL DIMENSIONS IN MILLIMETERS. FIG. 4.3.1 APPARATUS FOR GAS ANALYSIS. 19