A Learning Report On Transformer

Title Transformer
Author Karthikeyan S
Date 2022-06-04 Page 1 of 36
TITLE SHEET
TRANSFORMER
Karthikeyan SK
Karthikeyan S https://www.linkedin.com/in/simplykarthik/
Title Transformer
Date 2022-06-04 Page 2 of 36
LIST OF CONTENTS
TITLE SHEET ........................................................................................................................................................................ 1
LIST OF CONTENTS ............................................................................................................................................................ 4
LIST OF FIGURES ................................................................................................................................................................. 5
LIST OF TABLES ................................................................................................................................................................... 6
LIST OF ABBREVIATION ................................................................................................................................................... 7
1. POWER TRANSFORMER ........................................................................................................................................... 8
2. HISTORY ........................................................................................................................................................................ 9
3. BASIC FUNDAMENTALS ............................................................................................................................................ 9
4. ENGINEERING PARAMETERS ................................................................................................................................. 9
4.1. RATED POWER ........................................................................................................................................................ 9
4.2. RATED VOLTAGE.................................................................................................................................................... 9
4.3. INSULATION CLASS ............................................................................................................................................... 9
4.4. NO LOAD LOSS ......................................................................................................................................................... 9
4.5. LOAD LOSS ................................................................................................................................................................ 9
4.6. SHORT CIRCUIT VOLTAGE ............................................................................................................................... 10
4.7. SHORT CIRCUIT IMPEDANCE ........................................................................................................................... 10
4.8. INSULATION LIFE (IEC 60076-7) ....................................................................................................................... 10
4.9. SITE TEMPERATURE ........................................................................................................................................... 10
4.10. HIGHEST VOLTAGE FOR EQUIPMENT (Um) ................................................................................................ 11
5. CONNECTION GROUPS............................................................................................................................................ 11
6. CORE ............................................................................................................................................................................. 12
7. WINDING...................................................................................................................................................................... 12
7.1. STAR(Y) CONNECTION OF WINDINGS: .......................................................................................................... 13
7.2. DELTA(D) CONNECTION OF WINDINGS: ....................................................................................................... 14
7.3. ZIG-ZAG CONNECTION OF WINDINGS .......................................................................................................... 14
8. CONSERVATOR.......................................................................................................................................................... 14
9. BUCHHOLZ RELAY................................................................................................................................................... 15
10. PRESSURE RELIEF VALVE ................................................................................................................................. 16
11. EXPLOSION VENT ................................................................................................................................................. 16
12. BREATHER .............................................................................................................................................................. 16
13. MAGNETIC OIL LEVEL GAUGE PROTECTION ............................................................................................ 17
14. CABLE BOXES: ....................................................................................................................................................... 17
14.1. AIR FILLED TYPE .................................................................................................................................................. 17
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Date 2022-06-04 Page 3 of 36
14.2. OIL FILLED TYPE .................................................................................................................................................. 17

15. MARSHALLING KIOSK ........................................................................................................................................ 17
16. OIL TEMPERATURE INDICATIOR ................................................................................................................... 18
17. WINDING TEMPERATURE INDICATOR ......................................................................................................... 18
18. COOLING SYSTEM ................................................................................................................................................ 18
18.1. RADIATOR ............................................................................................................................................................... 20
19. BUSHING .................................................................................................................................................................. 23
20. TAP CHANGER ....................................................................................................................................................... 23
20.1. OFF CIRCUIT TAP CHANGER ............................................................................................................................ 24
20.2. NO LOAD TAP CHANGER.................................................................................................................................... 24
20.3. ON LOAD TAP CHANGER.................................................................................................................................... 24
20.3.1. COMPONENT ...................................................................................................................................................... 25
20.3.1.1. MOTOR DRIVE UNIT .................................................................................................................................... 25
20.3.1.2. DIVERTER SWITCH ...................................................................................................................................... 25
20.3.1.2.1. RESISTOR TYPE ........................................................................................................................................ 26
20.3.1.2.2. REACTOR TYPE ........................................................................................................................................ 27
20.3.1.3. TAP SELECTOR ............................................................................................................................................. 27
20.3.1.4. SWITCHING SEQUENCE ............................................................................................................................. 28
20.3.2. TAPPING VOLTAGE VARIATION ................................................................................................................. 29
20.3.2.1. CONSTANT FLUX VARIABLE VOLTAGE. .............................................................................................. 29
20.3.2.2. VARIABLE FLUX VARIABLE VOLTAGE. ............................................................................................... 29
20.3.2.3. COMBINED VARIABLE VOLTAGE. .......................................................................................................... 29
20.3.3. MOUNTING LOCATION ................................................................................................................................... 29
20.3.4. PLACEMENT ....................................................................................................................................................... 30
20.3.5. SWITCHING ........................................................................................................................................................ 31
20.3.5.1. LINEAR............................................................................................................................................................. 31
20.3.5.2. COARSE/FINE ................................................................................................................................................. 31
20.3.5.3. REVERSING .................................................................................................................................................... 31
21. AUTOMATIC VOLTAGE REGULATING RELAY ........................................................................................... 32
22. OIL SURGE RELAY ............................................................................................................................................... 33
23. RTCC PANEL........................................................................................................................................................... 33
24. RATING AND DIAGRAM PLATE ........................................................................................................................ 33
25. PRELIMINARY DESIGN DETAILS ..................................................................................................................... 34
26. ACTIVE PART ......................................................................................................................................................... 35
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Date 2022-06-04 Page 4 of 36
LIST OF CONTENTS
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LIST OF FIGURES
LIST OF FIGURE 1 - POWER FLOW DIAGRAM OF TRANSFORMER .................................................................................. 8
LIST OF FIGURE 2 – VARIOUS PARTS OF A TRANSFORMER ............................................................................................ 8
LIST OF FIGURE 3 - TRANSFORMER EQUATION ................................................................................................................ 9
LIST OF FIGURE 4 - LOSSES IN A TRANSFORMER ........................................................................................................... 10
LIST OF FIGURE 5 - THERMAL MODEL OF A TRANSFORMER(IEC) ............................................................................... 11
LIST OF FIGURE 6 - CONNECTION GROUPS OF A TRANSFORMER................................................................................ 11
LIST OF FIGURE 7 - CORE OF A TRANSFORMER .............................................................................................................. 12
LIST OF FIGURE 8 - WINDINGS OF A TRANSFORMER ..................................................................................................... 13
LIST OF FIGURE 9 - STAR CONNECTED WINDING ........................................................................................................... 14
LIST OF FIGURE 10 - DELTA CONNECTED WINDINGS .................................................................................................... 14
LIST OF FIGURE 11 - ZIG ZAG CONNECTED WINDING .................................................................................................... 14
LIST OF FIGURE 12 - CONSERVATOR OF A TRANSFORMER .......................................................................................... 15
LIST OF FIGURE 13 - BUCHHOLZ OF A TRANSFORMER.................................................................................................. 16
LIST OF FIGURE 14 - BREATHER OF A TRANSFORMER .................................................................................................. 17
LIST OF FIGURE 15 - PT100 DETAILS .................................................................................................................................. 18
LIST OF FIGURE 16 - RADIATOR OF A COOLING SYSTEM.............................................................................................. 20
LIST OF FIGURE 17 - ONAN COOLING SYSTEM ................................................................................................................ 21
LIST OF FIGURE 18 - OFAF COOLING SYSTEM ................................................................................................................. 21
LIST OF FIGURE 19 - OFWF COOLING SYSTEM ................................................................................................................ 22
LIST OF FIGURE 20 - VARIOUS COOLING SYSTEM ......................................................................................................... 22
LIST OF FIGURE 21 - BUSHING OF A TRANSFORMER ..................................................................................................... 23
LIST OF FIGURE 22 - OCTC OF A TRANSFORMER ............................................................................................................ 24
LIST OF FIGURE 23 - OLTC OF A TRANSFORMER ............................................................................................................ 25
LIST OF FIGURE 24 - DIVERTER SWITCH .......................................................................................................................... 26
LIST OF FIGURE 25 - RESISTOR TYPE ................................................................................................................................ 26
LIST OF FIGURE 26 - REACTOR TYPE................................................................................................................................. 27
LIST OF FIGURE 27 - TAP SELECTOR ................................................................................................................................. 28
LIST OF FIGURE 28 - SWITCHING SEQUENCE................................................................................................................... 29
LIST OF FIGURE 29 - IN TANK TYPE OLTC ........................................................................................................................ 30
LIST OF FIGURE 30 - COMPARTMENT TYPE OLTC .......................................................................................................... 30
LIST OF FIGURE 31 - WINDING ARRANGEMENT OF OLTC ............................................................................................. 31
LIST OF FIGURE 32 - SWITCHING SCHEME OF OLTC ...................................................................................................... 32
LIST OF FIGURE 33 - AVR..................................................................................................................................................... 32
LIST OF FIGURE 34 - ACTIVE PARTS OF A TRANSFORMER............................................................................................ 36
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LIST OF TABLES
LIST OF TABLE 1 - DEFINITIONS OF A TRANSFORMER ................................................................................................... 8
LIST OF TABLE 2 - INSULATION LIFE OF A TRANSFORMER .......................................................................................... 10
LIST OF TABLE 3 - COOLING SYSTEM EXAMPLE ............................................................................................................ 19
LIST OF TABLE 4 - DETAILS OF COOLING SYSTEM......................................................................................................... 19
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LIST OF ABBREVIATION
IEC International Electrotechnical Commission
IEEE Institute Of Electrical And Electronics Engineers
MOG Magnetic Oil Gauge
PRV Pressure Releif Valve
OSR Oil Surge Relay
OTI Oil Temperature Indication
WTI Winding Temperature Indication
Pt Platinum
CT Current Transformer
FCC Fan Control Cubicle
RTCC Remote Tap Changer Control
AN Air Natural
AF Air Forced
ONAN Oil Natural Air Natural
ONAF Oil Natural Air Forced
OFAF Oil Forced Air Forced
ODAF Oil Directed Air Forced
ODWF Oil Directed Water Forced
SF6 Sulphur Hexafluoride
OCTC Off Circuit Tap Changer
OLTC On Load Tap Changer
MDU Motor Drive Unit
CFVV Constant Flux Variable Voltage
VFVV Variable Flux Variable Voltage
CBVV Combined Variable Voltage
LDC Line Drop Compensation
AVR Automatic Voltage Regulating Relay
TPI Tap Position Indicator
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1. POWER TRANSFORMER
STANDARD PART NUMBER DEFINITION
a static piece of apparatus with two or more windings which, by electromagnetic
induction, transforms a system of alternating voltage and current into another
IEC 60076-1 system of voltage and current usually of different values and at the same frequency
for the purpose of transmitting electrical power
A transformer that transfers electric energy in any part of the circuit between the
IEEE C57.12.80 generator and the distribution primary circuits.
LIST OF TABLE 1 - DEFINITIONS OF A TRANSFORMER
LIST OF FIGURE 1 - POWER FLOW DIAGRAM OF TRANSFORMER
LIST OF FIGURE 2 – VARIOUS PARTS OF A TRANSFORMER
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2. HISTORY
1885 - 1886: George Westinghouse and William Stanley (USA) create a transformer that is practical to produce
1889: Mikhail Dobrovolsky developed the first three – phase transformer in Germany at AEG
3. BASIC FUNDAMENTALS
Faraday Law: The induced electromotive force in any closed circuit is equal to the negative of the time rate of
change of the magnetic flux through the circuit.
LIST OF FIGURE 3 - TRANSFORMER EQUATION
4. ENGINEERING PARAMETERS
4.1. RATED POWER
A conventional value of apparent power assigned to a winding which, together with the rated voltage of the
winding, determines its rated current.
4.2. RATED VOLTAGE

The voltage assigned to be applied, or developed at no-load, between the terminals of an untapped winding, or
of a tapped winding connected on the principal tapping.
4.3. INSULATION CLASS

Rated withstand voltages which characterize the dielectric strength of the insulation.
4.4. NO LOAD LOSS

The active power absorbed when a rated voltage (tapping voltage) at a rated frequency is applied to the
terminals of one of the windings, the other winding or windings being open circuited.
4.5. LOAD LOSS

The absorbed active power at a rated frequency and reference temperature associated with a pair of windings
when rated current (tapping current) is flowing through the line terminals of one of the windings, and the
terminals of the other winding are short circuited.
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LIST OF FIGURE 4 - LOSSES IN A TRANSFORMER
4.6. SHORT CIRCUIT VOLTAGE

Parameter related to magnetic coupling of windings. It is the voltage (expressed in %Vnominal) that applied to
the HV winding determines the circulation of nominal current in LV in short-circuit.
4.7. SHORT CIRCUIT IMPEDANCE

Impedance measured by one winding while the other is closed on short – circuit.
Zcc e Vcc expressed in percentage value have the same values
4.8. INSULATION LIFE (IEC 60076-7)
LIST OF TABLE 2 - INSULATION LIFE OF A TRANSFORMER
4.9. SITE TEMPERATURE

The temperature of cooling air at the inlet to the cooling equipment not exceeding:
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LIST OF FIGURE 5 - THERMAL MODEL OF A TRANSFORMER(IEC)
4.10. HIGHEST VOLTAGE FOR EQUIPMENT (Um)

The temperature of cooling air at the inlet to the cooling equipment not exceeding: applicable to a transformer
winding is the highest r.m.s phase-to-phase voltage in a three-phase system for which a transformer winding is
designed in respect of its insulation.
5. CONNECTION GROUPS
LIST OF FIGURE 6 - CONNECTION GROUPS OF A TRANSFORMER
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Date 2022-06-04 Page 12 of 36
6. CORE
An unbroken path for magnetic flux. Magnetic Core is needed to confine magnetic flux and to realize and efficient
magnetic link between input and output windings. It gives rigidity to the mechanical structure of the active part. The
performances influenced by magnetic core No load losses, No load current, Noise level and Inrush current.
CORE
LIST OF FIGURE 7 - CORE OF A TRANSFORMER
7. WINDING
Windings are necessary to get the required number of turns and to carry on the nominal current. The performances
influenced by windings load losses, load noise and Short circuit withstand capability.
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WINDING
MATERIAL CONSTRUCTION TYPE
CONTINOUS
COPPER(Cu) ALUMINIUM(Al) FLAT WIRE TRANSPOSED FOIL LAYER DISC HELICAL
CABLE
PAPER COVERED PAPER COVERED NETTING TYPE SINGLE MULTI
WINDING
LIST OF FIGURE 8 - WINDINGS OF A TRANSFORMER
7.1. STAR(Y) CONNECTION OF WINDINGS:

Advantages of Star ((Y)) connection:
• More economical for high-voltage windings
• Neutral point available
• Permits earthing directly or through an impedance
• Permits reduced insulation level at neutral
• Permits winding taps and tap-changer at neutral
• Permits single phase loading with neutral current
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LIST OF FIGURE 9 - STAR CONNECTED WINDING
7.2. DELTA(D) CONNECTION OF WINDINGS:

Advantages of Delta (D) connection:
• More economical for high-current, low-voltage windings
• In combination with a star winding it reduces the zero-phase sequence impedance of the transformer
LIST OF FIGURE 10 - DELTA CONNECTED WINDINGS
7.3. ZIG-ZAG CONNECTION OF WINDINGS

Advantages of a zig-zag (Z) connection:
• Permits neutral current loading with inherently low zero-sequence impedance
• Reduces voltage unbalance in systems where load is not evenly distributed between phases
• Permits creation of an artificial neutral for the system
LIST OF FIGURE 11 - ZIG ZAG CONNECTED WINDING
8. CONSERVATOR
Conservator is used on transformer for providing adequate space for expansion of oil when transformer is loaded
or when ambient temperature changes. It also conserves the insulating property of oil from deterioration and protects the
transformer against failure on that account. Conservator also acts as a reservoir for the transformer. Generally, two types of
conservators are used. One is conventional type which has MOG & prismatic gauge glass for oil indication, where as other
one comprises of an additional air cell separator to avoid entry of direct air to oil in conservator.
Conservators are so designed that the lower part acts as a sump in which impurities and sludge may collect. A
valve is fitted at the lowest portion of the conservator for draining and sampling. The Silica gel breather is connected to Air
cell. During service of the Transformer, the oil level in the conservator falls or rises and accordingly the air cell gets inflated
or deflated. When the air cell gets deflated the air inside the Air cell is pushed out through the breather and when the air cell
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is inflated outside air rushes in through the breather. However, in no case the transformer oil comes in contact with
atmospheric air, thereby decreasing the ageing rate. The space outside Air cell in the conservator is completely displaced by
filling oil in the conservator and venting air through top air vents provided on conservator.
LIST OF FIGURE 12 - CONSERVATOR OF A TRANSFORMER
9. BUCHHOLZ RELAY
Buchholz relay is a very sensitive, gas and oil operated instrument which detects low oil level, formation of gas
or development of sudden pressure inside the oil filled transformer. It has to be connected to protection circuits to give an
early audible alarm in case of low oil level and gas collection and to disconnect the transformer from supply in case of severe
fault inside the transformer. The nature of internal faults can be identified to a great extent by a chemical analysis of gas.
Buchholz relay will also give alarm or trip the breaker due to oil level falling below Buchholz relay. Buchholz relay is placed
on the pipe connecting the transformer tank and conservator.
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LIST OF FIGURE 13 - BUCHHOLZ OF A TRANSFORMER
10. PRESSURE RELIEF VALVE

The purpose of the pressure relief valve is to prevent mechanical damage to the transformer tank by releasing any
excess pressure over the set limit. The valve is basically a spring-loaded device, which closes automatically when the pressure
inside the tank drops to the set limit after releasing excess pressure over the preset limit.
11. EXPLOSION VENT

The purpose of the explosion vent is to prevent damage to transformer tank by releasing any excess pressure that
may be generated inside the tank. Sometimes conservator and explosion vent are connected with an equalizer pipe with or
without a valve. The pipe equalizes the pressure between conservator and explosion vent.
12. BREATHER
Whenever there is a change in the ambient temperature or in the load on oil-immersed transformer, there is a
change in the volume of oil in tank and conservator. This change forces the air above the oil level in the conservator to be
either pushed out or breathed in from outside atmosphere. Whenever the air is breathed in, there is a possibility of moisture
and dust from atmosphere to be sucked in. This is dangerous to the insulating properties of oil. Silica gel breathers are
provided to prevent this and to ensure that dry and clean air is breathed in and out through the breather.
Dry silica gel crystals, which are dark blue in color, have a very good capacity to absorb moisture. When the air
from outside is breathed in the conservator, it passes through the crystals and the moisture in the air is absorbed. Thus, the air
that reaches the conservator is dry. Dust particles are partly trapped in the oil seal and partly trapped by the crystals of the
silica gels. Silica gel crystals change their color from dark blue to pink depending upon absorption of certain quantity of
moisture. On turning pink efficiency of absorption of moisture is very low. Heating them can reactivate the crystals. The
moisture absorbed then gets evaporated and the crystals again turn dark blue and are ready for re-use.
The oil seal acts as a barrier between the outside air and the silica gel crystals inside the casing when there is no
flow of air. Thus, contact between the most air and the dry crystals is avoided and the moisture absorbing capacity is not used
up when not required. When there is sufficient pressure difference between the air inside the conservator and the outside air,
the oil levels in the two compartments of the oil seal change until the lower oil level just reaches the rim of the inverted cup.
Air then moves from high-pressure compartment to the low-pressure compartment in the oil seal. This happens both when
the air is breathed in and it is pushed out from the conservator. The oil also acts as coarse filter and removes dust and the
moisture from the outside air when it passes around the rim of the inverted cup.
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LIST OF FIGURE 14 - BREATHER OF A TRANSFORMER
13. MAGNETIC OIL LEVEL GAUGE PROTECTION

This is a direct oil level indicating device provided on conservator. The low oil level contacts provided on the
magnetic oil level indicators can be used for automatic alarm (or disconnection) When the oil level in the conservator falls to
a low level. This protection prevents transformers from damages attributed to loss of oil due to any reason.
14. CABLE BOXES:
14.1. AIR FILLED TYPE

Cable boxes are provided as per customer's requirement. These boxes are designed for receiving and protecting
cable ends and to ensure effective sealing of cable against ingress of moisture, dirt, dust and vermin. All cable boxes for
PVC or XLPE cables are designed with air clearances and hence these cable boxes are not required to be filled with
compound or oil. Cable boxes are provided with detachable gland plates. Earthing terminals are also provided on these
gland plates for earthing the armour of individual cables.
14.2. OIL FILLED TYPE

Oil Filled Cable boxes are provided with conservator to maintain oil level in cable box.
15. MARSHALLING KIOSK

The transformer is protected by fittings such as PRV, MOG, Buchholz relay, OSR etc. mounted on the transformer
at different locations. These fittings usually have contacts/terminals, which are connected to the protection scheme. In order
to facilitate connections of all such devices to the protective scheme, the leads of all protective device contacts are wired to a
weatherproof kiosk (since it is mounted in the outdoor) This kiosk also houses indicators for oil temperature, winding
temperature and heater.
This kiosk is also called Fan Control Cubicle when fans are provided for cooling. (for air natural cooling no fans
required but for air forced, fan/motor(s) required. similarly, for oil natural no pumps required but for oil forced, pumps are
required.)
Hinged lockable front door is provided with a glass window from which the temperature readings on the indicators
can be observed. The locking device is provided to prevent unauthorized tampering with accessories fitted in it. The entire
kiosk has a rain shed provided on top to prevent ingress of water due to heavy rains falling directly over the marshalling kiosk.
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It is also provided with door operated switch for internal lighting. To prevent internal condensation in moist
weather a heater with thermostat controlled/manual switch is provided. Mount the box at the location indicated on the General
Arrangement drawing. Remove the gland plate and drill holes for control cable glands as required. It should be noted that
control cables should always be terminated through cable glands to maintain the weatherproof nature of the terminal chamber.
Uncoil the capillary tubing of the OTI & WTI and lay suitably upto relevant pocket on cover. Use the brackets
supplied to support the capillary. Avoid sharp bends in the capillary tube to prevent breakages. Do not cut the capillary in
case of excess lengths.
16. OIL TEMPERATURE INDICATIOR

The Oil Temperature Indicator (OTI) measures the top oil temperature. It is used for control and protection of
transformer. The Oil temperature is measured with the help of sensing bulb immersed in the pocket by using liquid expansion
in the bulb through the capillary line to operating mechanism. A link and lever mechanism amplify this movement to the disc-
carrying pointer and switches, which indicates the temperature on the dial of the thermometer.
LIST OF FIGURE 15 - PT100 DETAILS
17. WINDING TEMPERATURE INDICATOR

For oil immersed transformers operating under varying loads, supervision of the winding temperature is of great
importance. The use of a winding temperature indicator permits the winding temperature to be constantly monitored and
harmful overloads can be avoided, by restricting the loads which lead to temperature rise beyond permissible limit. Winding
Temperature Indicator (WTI) measures the Hot Spot winding temperature. WTI is basically an OTI with additional specially
designed heater coil connected to CT secondary of the transformer which simulates the winding temperature. The life of
transformer depends on the winding temperature, which determines the deterioration of the insulating material.
For safe over loading of a transformer WTI is an important protection device. The winding temperature will be
depending upon the load (current through the winding) of the transformer and the temperature of oil. These two parameters
are measured and combined result is indicated as winding temperature. Winding temperature is measured by connecting the
CT secondary of the transformer through a shunt resistor inside the winding temperature indicator to the heater coil around
the operating bellows
18. COOLING SYSTEM

Whenever transformer is on ONAF condition fans are provided for cooling. These are mounted on brackets which
are fixed on tank wall or on ground. The fans are controlled from FCC and sometimes from RTCC and can be operated
manually or on auto mode. When fans are on auto mode they are switched on using one of the mercury switches of the WTI
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mounted in FCC. The setting of the switch should be such that no hunting takes place. For this the temperature differential
should be minimum 6 deg. To 7 deg. between switching ON and OFF of fans.
KIND OF COOLING MEDIUM SYMBOL

MINERAL OIL OR SYNTHETIC INSULATING FLUID WITH FLAME POINT < 300O C O
INSULATING FLUID WITH FLAME POINT > 300O C K
ASKAREL L
GAS G
WATER W
AIR A
SOLID INSULANT S
1st LETTER 2nd LETTER 3rd LETTER 4th LETTER

INDICATING THE COOLING MEDIUM THAT IS IN INDICATING THE COOLING MEDIUM THAT IS IN
CONTACT WITH WINDING CONTACT WITH EXTERNAL COOLING SYSTEM
KIND OF MEDIUM KIND OF CIRCUILATION KIND OF MEDIUM KIND OF CIRCUILATION
EXAMPLE
O N A N
LIST OF TABLE 3 - COOLING SYSTEM EXAMPLE
INTERNAL COOLING MEDIUM

O MINERAL OIL OR SYNTHETIC INSULATING LIQUID WITH FIRE POINT < 300OC
1st LETTER K INSULATING LIQUID WITH FIRE POINT > 300OC
L INSULATING LIQUID WITH NO MEASURABLE FIRE POINT
CIRCULATING MECHANISM FOR INTERNAL COOLING MEDIUM
N NATURAL THERMO-SIPHON FLOW THROUGH COOLING EQUIPMENT AND WINDINGS
F FORCED CIRCULATION THROUGH COOLING EQUIPMENT, THERMO-SIPHON FLOW IN
2nd LETTER WINDINGS
D FORCED CIRCULATION THROUGH COOLING EQUIPMENT, DIRECTED FROM THE
COOLING INTO ATLEAST THE MAIN WINDINGS
EXTERNAL COOLING MEDIUM
3rd LETTER A AIR
W WATER
CIRCULATING MECHANISM FOR EXTERNAL COOLING MEDIUM
4th LETTER N NATURAL CONVECTION
F FORCED CIRCULATION
LIST OF TABLE 4 - DETAILS OF COOLING SYSTEM
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18.1. RADIATOR
The working principle of a radiator is very simple. It just increases the surface area of transformer for dissipating heat of the
oil. The radiator of transformer accelerates the cooling rate of the transformer. Thus, it plays a vital role in increasing
loading capacity of an Electrical Transformers. Oil inside a transformer tank circulates continuously through the Radiators
and in the process, heat gets dissipated. Dissipation of heat in the transformer radiator can be accelerated further by the
force of air provided by means of fans
LIST OF FIGURE 16 - RADIATOR OF A COOLING SYSTEM
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ONAN
LIST OF FIGURE 17 - ONAN COOLING SYSTEM
OFAF
LIST OF FIGURE 18 - OFAF COOLING SYSTEM
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OFWF
LIST OF FIGURE 19 - OFWF COOLING SYSTEM
LIST OF FIGURE 20 - VARIOUS COOLING SYSTEM
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19. BUSHING
Bushing are used to run a current at high potential through a ground barrier.
BUSHING
EXTERNAL
INTERFACE CONSTRUCTION
COVER
NON-
CONDENSER
OIL TO AIR OIL TO OIL OIL TO SF6 CONDENSER PORCELAIN SILICON
TYPE
TYPE
OIL RESIN
IMPREGNATED IMPREGNATED
PAPER PAPER
BUSHING
LIST OF FIGURE 21 - BUSHING OF A TRANSFORMER
20. TAP CHANGER

To maintain the secondary voltage reasonably constant at the user's end when incoming voltage and/or load on
the transformer changes, it is necessary to adjust the voltage ratio (i.e. turns ratio of the windings) of the transformer. This is
achieved by operating the tap changing switch.
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TAP
CHANGER
OFF CIRCUIT NO LOAD ON LOAD

TAP TAP TAP
CHANGER CHANGER CHANGER
20.1. OFF CIRCUIT TAP CHANGER

As the name "Off Circuit" implies the transformer must be Electrically isolated from the mains, before operating
the switch. It is also dangerous to approach the location of the switch handle on a "live" transformer when bare live
terminals are in the neighborhood. The best practice is to switch off the secondary and primary sides of the transformer.
LIST OF FIGURE 22 - OCTC OF A TRANSFORMER
20.2. NO LOAD TAP CHANGER

Off-load tap changer is different from off-circuit tap changer, in that off-load tap changer shall be capable of
operation with the load disconnected and the winding still energized. All winding arrangements, i.e. linear, single bridging
and double bridging.
20.3. ON LOAD TAP CHANGER

On load tap changer (OLTC) functions in the same fashion as Off circuit tap changing switch. However, in cases
of OLTC the transformer needs not be electrically isolated from HV & LV side. The tap changer can be operated on load.
The tap changer is an integral part of the transformer. The on-load tap-changer is built in two separate sections, the
diverter switch, which has its own housing, and the tap selector. The tap selector is mounted below the diverter switch
housing and the complete unit is suspended from the transformer cover. The tap changer can be designed for changing
the taps either manually, automatically or from remote.
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LIST OF FIGURE 23 - OLTC OF A TRANSFORMER
20.3.1. COMPONENT
20.3.1.1. MOTOR DRIVE UNIT
This unit has got a motor diver and other necessary controls. Motor charges the spring to rapidly perform the
switching. Power is transferred via shaft & gear mechanism.
– Should rotate in both the directions
– Step-by-step operation
– Tap change in progress indication
– Tap change complete indication
– Sequence contact
– Remote Tap position control & indication
20.3.1.2. DIVERTER SWITCH

The diverter switch is of the high-speed, spring-operated type with resistors or reactors as transition impedance.
The diverter switch is designed as a system of moving and fixed contacts. Movement of the moving contact system is
controlled by a self-locking polygon link system with a set of helical springs. The link system is robust and has been
carefully tested. The fixed contacts are placed on the sides of the diverter switch, which are made of insulated board.
The diverter switch is equipped with plug-in contacts that automatically connect the switch with the tap selector when
the diverter switch is lowered into the housing. Mechanical coupling to the motor-drive mechanism is automatically
established when the driving pin enters the slot in the driving disc. The current-carrying contacts are made of copper or
copper and silver, and the breaking contacts of copper-tungsten. The design and dimensioning of the diverter switch
offers high reliability and long life with a minimum of maintenance and easy inspection.
Title Transformer
Date 2022-06-04 Page 26 of 36
LIST OF FIGURE 24 - DIVERTER SWITCH
20.3.1.2.1. RESISTOR TYPE

During tap changer operation resistors are connected for a short time across a tap to limit the bridging current and to
maintain continuity in the power supply. Main disadvantages of resistor type tap changers compared to reactor type
tap changers are number of tap leads is almost double and turns per tap must be whole turns. As these type of tap
changers do not have vacuum interrupters, shorter inspection intervals are needed. On-line filters are normally used
to keep the oil clean and to reduce the inspection intervals.
LIST OF FIGURE 25 - RESISTOR TYPE
Title Transformer
Date 2022-06-04 Page 27 of 36
20.3.1.2.2. REACTOR TYPE

The biggest advantage of reactor type tap changer over resistor type tap changer is that between two adjacent taps,
voltage can be equal to volts per turn multiplied by half turn i.e.½, 1½, 2½ etc. This is achieved by bridging the tap
with a reactor (preventive auto). Another advantage is that number of tap leads are almost half of that of a resistor
type tap changer. Use of vacuum interrupters permit longer inspection intervals, high contact life and keeps oil clean.
Disadvantage of reactor type tap changer is that it needs a preventive auto. In bridging position preventive auto losses
are added to the load losses. Preventive auto takes additional space inside the transformer and additional connections
are required. Gapped cores are typically used in the preventive auto resulting in additional noise.
LIST OF FIGURE 26 - REACTOR TYPE
20.3.1.3. TAP SELECTOR

The fixed contacts are mounted in a circle around the central shafts. The moving contacts are mounted on, and are operated
by, the shafts in the center of the selector. The moving contacts are connected, via current collectors, to the diverter switch
by means of paper insulated copper conductors. Depending on the load current, the moving contacts have either one, two,
or more contact arms in parallel with one, two or four contact fingers each. The fingers make contact at one end with the
fixed contact, and at the other with the current collector. The moving contacts slide on the fixed contacts and the current
collector rings, giving a wiping action which makes the contacts self-cleaning. This arrangement promotes good
conductivity and negligible contact wear.
Title Transformer
Date 2022-06-04 Page 28 of 36
LIST OF FIGURE 27 - TAP SELECTOR
20.3.1.4. SWITCHING SEQUENCE

The switching sequence & principle of OLTC with the various components are explained in the images below.
Title Transformer
Date 2022-06-04 Page 29 of 36
LIST OF FIGURE 28 - SWITCHING SEQUENCE
20.3.2. TAPPING VOLTAGE VARIATION

Taps can be as classified as below.
20.3.2.1. CONSTANT FLUX VARIABLE VOLTAGE.
The tapping voltage in any untapped winding is constant from tapping to tapping. The tapping voltages in the
tapped winding are proportional to the tapping factor. In other words, when tapping’s are provided in the
winding where voltage variation occurs and the per turn voltage remains constant irrespective of the tap
positions In CFVV, taps shall be provided on winding in which voltage variation is required. Winding is
constant from tapping to tapping i.e. volts per turn remains constant throughout the tap range.
20.3.2.2. VARIABLE FLUX VARIABLE VOLTAGE.

The tapping voltage in the tapped winding is constant from tapping to tapping. The tapping voltages in any
untapped winding are inversely proportional to the tapping factor. The flux density in core changes with every
tap position. In VFVV, taps are provided on the winding where voltage applied is constant.
20.3.2.3. COMBINED VARIABLE VOLTAGE.

The transformer is specified using both principles, but applied to different parts of the range. This approach is
particularly used in instances of a large tapping range. A portion of the taps act as constant flux taps and the
remaining portion of the taps act as variable flux taps.
When the turns are changed on primary side, due to variation of incoming voltage on primary side, the control
is called constant flux variable voltage control. When the turns are changed on secondary side, due to variation
of incoming voltage on primary side, the control is called variable flux variable voltage control.
20.3.3. MOUNTING LOCATION
Title Transformer
Date 2022-06-04 Page 30 of 36
LIST OF FIGURE 29 - IN TANK TYPE OLTC
LIST OF FIGURE 30 - COMPARTMENT TYPE OLTC
20.3.4. PLACEMENT
The tapped portion of the winding may be located at one of the following locations, depending upon
the type of winding:
• At the line end of the winding;
• In the middle of the winding;
• At the star point.
The most common type of arrangements is the last two. This is because they give the least
electrical stress between the tap changer and earth; along with subjecting the tapings to less physical and
electrical stress from fault currents entering the line terminals.
Title Transformer
Date 2022-06-04 Page 31 of 36
LIST OF FIGURE 31 - WINDING ARRANGEMENT OF OLTC
The tapped portion of the winding may be located at one of the following locations, depending upon the type of winding
20.3.5. SWITCHING
20.3.5.1. LINEAR
Linear taps are simple to design and also economical. With commonly available tap changers
maximum number of linear taps that can be obtained are 17. When tap range is large and when more
steps are needed, linear taps are not suitable.
20.3.5.2. COARSE/FINE
A transformer with coarse/fine taps will have lower life cycle cost compared to a transformer with
reversing taps. This is due to lower losses for the taps below normal. Lower losses permit use of
smaller coolers. Multiple coarse/fine taps allow many more taps. Based on MVA and impedance if
short circuit forces are not high, then coarse/fine taps can be located in body of the main winding.
20.3.5.3. REVERSING
Reversing taps make designs less complicated compared to coarse/fine taps. A reversing tap winding
can be easily placed between core and LV winding, between LV winding and HV winding or outside
the HV winding. However reversing taps are not suitable for use in body of the main winding
Title Transformer
Date 2022-06-04 Page 32 of 36
LIST OF FIGURE 32 - SWITCHING SCHEME OF OLTC
20.3.6 CONTROL
TAP CHANGER CONTROLS
• Manual / Electrical
• Local / Remote
• Manual / Automatic
• Independent Operation
• Parallel Operation
– Group Control
– Master
– Follower
21. AUTOMATIC VOLTAGE REGULATING RELAY

This relay is used to operate OLTC to change the tap automatically & maintain desired voltage. The AVR relay
is being connected to LDC (Line Drop Compensation CT) which provides line current data. By this way the line voltage drop
is compensated in the relay
The term LDC stands for line drop compensation. The LDC CT supplies metered line current to a compensating
device in the voltage regulator controls. The compensating device effectively moves the voltage control point into the system
connected to the secondary winding.
LIST OF FIGURE 33 - AVR
Supplementary Control Functions AVR Relaying
Title Transformer
Date 2022-06-04 Page 33 of 36
1. Load Shedding
a. voltage setting override (± 10%)
2. Over Current / Under Voltage Supervision
a. inhibit control during fault conditions
3. Excessive Circulating Current
a. protects against parallel control failure
4. Under Current Inhibit
a. stops operations when low forward or reverse power
5. Reverse Current Operation
6. Auto/Manual/Remote Operations
7. Measurements
22. OIL SURGE RELAY

This relay used on OLTC to protect the transformer from fault developed in diverter switch housing. This relay
trips the breaker & isolate the transformer from power system.
23. RTCC PANEL

Whenever Transformer is provided with OLTC, if ordered, a separate Control Panel is provided called RTCC
(Remote Tap Change Control Cubicle). This Panel is located in the Control room from where OLTC operation is controlled.
Generally, RTCC is fitted with Raise & Lower push buttons for Raise/Lower command of OLTC, TPI (Tap Position Indicator)
for indicating tap number of OLTC. The other features like OTI & WTI repeaters, AVR, Voltmeters, etc. are provided on
RTCC on order and are not standard features.
24. RATING AND DIAGRAM PLATE

• OEM LOGO
• CUSTOMER NAME
• CORE MATERIAL
• TRANSFORMER / AUTO TRANSFORMER / POWER TRANSFORMER
• DESIGN STANDARD
• SERIAL NUMBER & CONTRACT NUMBER
• TRANSFORMER MODEL NUMBER
• NUMBER OF PHASES
• YEAR OF MANUFACTURE
• RATED FREQUENCY
• VECTOR GROUP
• NUMBER OF WINDINGS
• RATED POWER
• VOLTAGE RATING (WITH RESPECT TO WINDINGS) - VOLTAGE RATING SHALL BE
SEPARATED BY A DASH (-)
• TAP VOLTAGES OF THE INDIVIDUAL WINDING SHALL BE SEPARATED BY A SLASH (/)
• FULL LOAD CURRENT (WITH RESPECT TO WINDINGS)
• INSULATION LEVELS (WITH RESPECT TO WINDINGS)
• COOLING SYSTEM
• TAPPING RANGE / STEPS
• NO OF TAPS
• TEMPERATURE RISE - WINDING
• TEMPERATURE RISE - OIL
• MAXIMUM AMBIENT TEMPERATURE
Title Transformer
Date 2022-06-04 Page 34 of 36
• IMPEDANCE VOLTAGE (WITH RESPECT TO WINDINGS) - MAXIMUM/PRINCIPAL/MINIMUM

TAP
• MASS - TOTAL/OIL MAIN TANK/TRANSPORT/UNTANKING/TANK FITTINGS/ OIL LTC
COMPARTMENT/ACTIVE PART
• QUANTITY - OIL
• NOISE LEVEL
• BIL OF EACH WINDINGS & BUSHINGS
• CONNECTION DIAGRAM
• POSITIVE AND NEGATIVE OPERATING PRESSURE
• INSTALLLATION & OPERATING INSTRUCTIONS
• CONDUCTOR MATERIAL OF EACH WINDING
• LAYOUT SKETCH - PHYSICAL LOCATION (BUSHINGS / LOAD TAP CHANGING
COMPARTMENT / OPERATING HANDLE)
• MADE IN LOCATION
• DIAGRAM DRAWING NUMBER
• VALVE SCHEDULE DIAGRAM PLATE
• VALVE SYMBOLS DESCRIPTION
• VALVE AND PIPING DIAGRAM
25. PRELIMINARY DESIGN DETAILS

• LOCATION (INDOOR / OUTDOOR)
• ALTITUDE
• AMBIENT AIR TEMPERATURE (MAXIMUM/MINIMUM/DAILY AVERAGE/YEARKY
AVERAGE)
• HUMIDITY
• FREQUENCY
• SINUSOIDAL SUPPLY VOLTAGE
• SINGLE / TWO / THREE PHASE
• LIFE EXPECTANCY
• POWER RATING AND OPERATING CONDITION
• TYPE OF COOLING REQUIREMENT (DRY TYPE/SINGLE/MIXED COOLING)
• NO OF WINDING REQUIREMENT
• OVERLOAD CAPABILITY
• MAXIMUM CONTINOUS VOLTAGE & TEMPORARY OVER VOLTAGE
• ABNORMAL CONDITION - ELECTRICAL
• TAPPING REQUIREMENT
• NOISE
• CLEARANCE
• PHYSICAL ARRANGEMENT (MAXIMUM DIEMENSION FOLLOWED FOR VARIOUS
EQUIPMENT)
• CORE REQUIREMENT
• WINDING REQUIREMENT
• TERMINATION
• INSULATOR
• INSULATION MEDIUM
• TAP CHANGERS
• TERMINAL MARKINGS AND BUSHINGS
• CABLE SEALING BOX AND DISCONNECTING CHAMBERS
• CURRENT TRANSFORMER REQUIREMENTS
• AUXILLIARY SUPPLY
• TERMINAL/MARSHALLING BOX
• TERMINAL BLOCK GROUPS, WIRING AND CABING
Title Transformer
Date 2022-06-04 Page 35 of 36
• VALVES AND OIL SAMPLING DEVICES

• LABELLING, NAME PLATE & DIAGRAM PLATE
• TANK & CONSEVATOR REQUIREMENT
• MECHANICAL PROTECTION
• DEHYDRATING BREATHERS
• OIL INDICATOR/LEVEL/ALARM
• COOLING ARRANGEMENT
• DRAWINGS AND MANUALS
• SPECIAL TOOLS AND EQUIPMENT
• TYPE TEST REQUIREMENT WITH REPORT FORMAT
• ERECTION REQUIREMENT
• TRANSPORTATION REQIUIREMENT
26. ACTIVE PART
Title Transformer
Date 2022-06-04 Page 36 of 36
LIST OF FIGURE 34 - ACTIVE PARTS OF A TRANSFORMER

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Title Transformer

14.2. OIL FILLED TYPE .................................................................................................................................................. 17

LIST OF TABLE 1 - DEFINITIONS OF A TRANSFORMER

LIST OF FIGURE 1 - POWER FLOW DIAGRAM OF TRANSFORMER

LIST OF FIGURE 2 – VARIOUS PARTS OF A TRANSFORMER

LIST OF FIGURE 3 - TRANSFORMER EQUATION

4.2. RATED VOLTAGE

4.3. INSULATION CLASS

4.4. NO LOAD LOSS

4.5. LOAD LOSS

LIST OF FIGURE 4 - LOSSES IN A TRANSFORMER

4.6. SHORT CIRCUIT VOLTAGE

4.7. SHORT CIRCUIT IMPEDANCE

Zcc e Vcc expressed in percentage value have the same values

4.8. INSULATION LIFE (IEC 60076-7)

LIST OF TABLE 2 - INSULATION LIFE OF A TRANSFORMER

4.9. SITE TEMPERATURE

LIST OF FIGURE 5 - THERMAL MODEL OF A TRANSFORMER(IEC)

4.10. HIGHEST VOLTAGE FOR EQUIPMENT (Um)

LIST OF FIGURE 6 - CONNECTION GROUPS OF A TRANSFORMER

LIST OF FIGURE 7 - CORE OF A TRANSFORMER

MATERIAL CONSTRUCTION TYPE

PAPER COVERED PAPER COVERED NETTING TYPE SINGLE MULTI

LIST OF FIGURE 8 - WINDINGS OF A TRANSFORMER

7.1. STAR(Y) CONNECTION OF WINDINGS:

LIST OF FIGURE 9 - STAR CONNECTED WINDING

7.2. DELTA(D) CONNECTION OF WINDINGS:

LIST OF FIGURE 10 - DELTA CONNECTED WINDINGS

7.3. ZIG-ZAG CONNECTION OF WINDINGS

LIST OF FIGURE 11 - ZIG ZAG CONNECTED WINDING

LIST OF FIGURE 12 - CONSERVATOR OF A TRANSFORMER

LIST OF FIGURE 13 - BUCHHOLZ OF A TRANSFORMER

10. PRESSURE RELIEF VALVE

11. EXPLOSION VENT

LIST OF FIGURE 14 - BREATHER OF A TRANSFORMER

13. MAGNETIC OIL LEVEL GAUGE PROTECTION

14. CABLE BOXES:

14.1. AIR FILLED TYPE

14.2. OIL FILLED TYPE

15. MARSHALLING KIOSK

16. OIL TEMPERATURE INDICATIOR

LIST OF FIGURE 15 - PT100 DETAILS

17. WINDING TEMPERATURE INDICATOR

18. COOLING SYSTEM

KIND OF COOLING MEDIUM SYMBOL

1st LETTER 2nd LETTER 3rd LETTER 4th LETTER

LIST OF TABLE 3 - COOLING SYSTEM EXAMPLE

INTERNAL COOLING MEDIUM

LIST OF TABLE 4 - DETAILS OF COOLING SYSTEM

LIST OF FIGURE 16 - RADIATOR OF A COOLING SYSTEM

LIST OF FIGURE 17 - ONAN COOLING SYSTEM

LIST OF FIGURE 18 - OFAF COOLING SYSTEM

LIST OF FIGURE 19 - OFWF COOLING SYSTEM

LIST OF FIGURE 20 - VARIOUS COOLING SYSTEM

LIST OF FIGURE 21 - BUSHING OF A TRANSFORMER

20. TAP CHANGER

OFF CIRCUIT NO LOAD ON LOAD

20.1. OFF CIRCUIT TAP CHANGER

LIST OF FIGURE 22 - OCTC OF A TRANSFORMER

20.2. NO LOAD TAP CHANGER

20.3. ON LOAD TAP CHANGER

LIST OF FIGURE 23 - OLTC OF A TRANSFORMER