TESLA TRANSFORMERS LTD

COMMISSIONING OF TRANSFORMER

After finalization of the erection work the following tests should be conducted :-

PRE TEST INSPECTION

(a) Sample of oil taken from the transformer and subjected to e l e c t r i c test
(break down value) of 50KV (RMS) as specified in IS: 335.
(b) Release trapped air through air release plugs and valve fitted for the purpose
on various fittings like radiators, bushing caps, tank cover, Bushing turrets etc.
(c) The float lever of the magnetic oil level indicator (if provided) should be
moved up and down between the end position to check that the mechanism
does not stick at any point. If the indicator has signaling contact they should
be checked at the same time for correct operation. Checking the gauge by
draining oil is a more positive test.
(d) Check whether g a s operated really (if provided) is mounted at angle by placing
a spirit l e v e l on the top of the relay. See that the conservator is filled up to the
filling oil level marked on plain oil gauge side and corresponding to the pointer
reading in MOG side. Check the operation of the alarm and trip contacts of the
relay independently by injecting air through the top cocks using a dry air bottle.
The air should b e released after the tests. Make sure that transformer oil runs
through pert cock of Buchholz relay.
(e) Check alarm and trip contacts of WTIs, Dial type thermometer, magnetic oil
gauge etc. (if provided).
(f) Ensure that off circuit switch handle is locked at the desired tap position
with padlock.
(g) Make sure that all valves except drain, filter and sampling valves are opened
(such as radiator valves, valves on the buchholz relay pipe line if
Provided).
(h) Check the condition of silicagel in the breather to ensure that silicagel in the
breather is active and colour is blue. Also check that the transformer oil is
filled in the silicagel breather upto the level indicated.
(i) Check tightness of external electrical connections to bushings.
(j) Give a physical check on all bushing for any crack or any breakage of
porcelain. Bushing with cracks or any other defects should be immediately
replaced.
(k) Check the neutral earthing if specified.
(l) Make sure that neutrals of HV / LV are effectively
earthed. (m) Tank should be effectively earthed at two
points.
(n) Check that the thermometer pockets on tank cover are filled with oil.
TESLA TRANSFORMERS LTD
(o) If the oil temperature indicator is not working satisfactorily, loosen and remove
the thermometer bulb from the pocket on the cover and place it with a
standard
TESLA TRANSFORMERS LTD

thermometer in a suitable vessel filled with transformer oil. Warm the oil slowly
while string it and take reading of the thermometers if an adjustment of the
transformer thermometer is necessary the same many be done. Also check
signaling contacts and set for the desired temperature.

For transformer furnished with thermometers for both oil and

winding temperature, the signaling contacts are recommended to be set to
operate at the following temperatures.
Alarm Trip
Oil Temperature 85 deg.C +/- 2deg.c 95 Deg.C +/- 2deg.C
Winding Temp. 100Deg.C +/- 2 Deg.C 110Deg.C +/- 2 deg.C

Higher winding temperature settings can be adopted in consultation with

manufacture.

(p) CT secondary terminals must be shorted and earthed if not in use.

(q) Check relief vent diaphragm for breakage. See that the bakelite diaphragm at
bottom and glass diaphragm at top are not ruptured.
(r) Check all the gasketed joints to ensure that there is no leakage of
transformer oil at any point.
(s) Clear off extraneous material like tools earthing rods, pieces of clothes,
waste etc.
(t) Lock the rollers for accidental movement on
rails. (u) Touching of paint may be done after erection.

TEST

Ratio, Polarity and phase

relationship

The ratio should be checked at all taps and between all the windings. Ratio is usually
checked by applying a single phase 230V (Approx) supply on the high voltage side and
measuring the voltage on the low voltage side at all tap positions. The measured voltage on
LV side shall
conform to declining trend between tap (min) to tap (max) position for all phases.
Polarity and interphone connections are checked while measuring the ratio. This can be
checked by the Avometer method. The primary and secondary windings are connected
together at points indicated in sketch shown below. A low voltage three phase supply is then
applied to the HV terminals. Voltage measurements are then taken between various pairs of
terminals as indicated in the diagram. Readings obtained should be the
vectorial sum of the separate voltages of each winding under consideration.
Insulation Resistance
The insulation resistance between winding and earth should be measured with a good
2500/1000 Volts megger and values should be compared to the test report values. It is
preferable to have a motor operated megger and the readings taken after one minute from
starting. Before measuring the insulation resistance, it should be made sure that the bushings
are cleaned thoroughly with clean cotton cloth. The lead wires of the meaggers should not have
joints. They should also give reading of more than maximum value readable on the megger.

Magnetizing Current
A three phase 415 Volts supply is given to the HV winding of the three phase transformer and
simultaneous current readings of the three phases are taken using low range AC ammeters
of the same accuracy class. Values should be recorded for the future reference.

Magnetic balance test

A single phase supply of approximately 230 Volts is applied to one phase of HV winding and the
induced voltage on other two HV phases measured separately. Test voltage should be applied to
HV winding only. Applying voltage LV winding may induce abnormal high voltage in HV
winding which may prove hazardous. Tests should be carried out on all three phases.
When single phase supply is given to middle phase the induced voltage measured on two
extreme phases should be approximately equal. If supply is given to one extreme phase,
induced voltage on middle phase is expected to be substantially high than the other extreme
phase. In each test the sum of the induced voltages on other two phases would be within +/-
5% of the applied voltage.
If abnormal voltage difference is observed on extreme phase, when voltage is applied to middle
phase, matter should be referred to TESLA works for advice, supported with the full test
observations. High impedance volt meter like ‘’AVOMETER’’ should be used for the test.
Tests should be carried out by connecting a series lamp (approx 25 watts capacity) at
supply side to restrict higher current , if any. A fault in winding may be suspected if the series
lamp glows brightly or the induced voltage readings on different phases indicate zero or very
low value.
230 Volts single phase supply be given between lines, if windings are delta connected
and induced voltages measured between the other two phases. Whereas supply is given to line
and neutral of one phase in case of star connected windings, induced voltages should be
measured between the line and neutral of other two phases.

Alarm Circuits
Tests
a) Buchholz relay – air injection test
Alarm & trip circuits
b) Oil temperature indicator – alarm & trip
circuits c) Magnetic oil level gauge – alarm
circuits
d) Winding temperature indicator – alarm & trip circuits.
Oil Sampling Test
Electric strength (break down voltage) should be 50 kv (RMS) when tested to IS 335-
1992 please see section 3 for other details.

COMMISSIONING

After tests are completed satisfactorily, the transformer may be energized from the incoming side
on no load and operated for one or two hours.

The transformer hum should be observed for any abnormality. After two hours transformer
may be switched off and the gas operated relay checked for gas collection. Sometimes
dissolved air or air bubbles comes out due to energizing which is misunderstood for gas. So in
case of gas collection it should be energized again. Other instruments may also be
checked for any abnormal indications. If everything is found satisfactory, the transformer
may be energized
again and loaded gradually.

The following details are to be furnished to the manufacturer after commissioning

:- a) Details of transformer including its serial number.
b) Date of Commissioning
c) Substation / generating station where commissioned.
d) Protection given to the transformer such as lightning arrester, differential protection,
circuit breaker on HV / LV etc.

The nature of the test conducted and the results of test should be recorded and made
available in the station as a permanent record for future reference.

Tools Required
(a) Screw drivers of appropriate
size. (b) Spanner of appropriate
size.

Transformer Oil
Oil is used as coolant and dielectric in the transformer and keeping it in good condition will
assist in preventing deterioration of the insulation, which is immersed in oil. Transformer oil is
always exposed to the air to some extent therefore in the course of time it may oxidize and form
sludge if the breather is defective, oil may also absorb moisture from air thus reducing dielectric
strength.

Oil supplied with transformer, generally complies with IS :

335.
Precautions :
(a) Oil is easily contaminated, it is very important while sampling the oil and filling the tank to
keep the oil free from contamination.
(b) All equipment used when handling the oil must be washed with clean transformer
oil before use. (The oil used for washing must be discarded). Particular attention shall
be paid to the cleanliness of bends, valves and other points where the dirt and moistures
tends to collect.
(c) For sampling the oil, glass containers with glass stoppers are preferred over the metal
type, which are susceptible to contamination by dirt etc. Cleanliness is essential
as small amount of dirt and water greatly affect the accuracy of test results. Was shall
not be used for sealing the sample oil bottles. However, the stopper can be
covered by a pack of silicagel tied in a piece cloth.
(d) Flexible steel hose is recommended for handling insulation oil, some kinds of synthetic
rubber hoses are also suitable, but only those known to be satisfactory should be used.
Ordinary rubber \ hose should not be used for this purpose as oil dissolves the sulphur
from the rubber and is there by contaminated. Hose used for handling oil should
be clean and free from loose dust, rust or scale.
(e) Transformer must always be disconnected from the electricity supply system before
the oil level in tanks is lowered.
(f) Oil must not be emptied near naked lights as vapour released is inflammable.
(g) Minute quantities of moisture (Particularly in the presence of fiber or dust)_ lower the
dielectric strength of the oil. Therefore to reduce the risk of condensation of the moisture
entering the oil containers should be taken into a warm room and should not be opened
until the entire body has attained the same temperature as the room.
(h) The oil level should be che3cked at frequent intervals and any excessive leakage of oil
investigated. There may be slight loss of oil by evaporation, this need not cause
concern if the tank is topped up at regular intervals.
(i) All minor leaks or sweating should be repaired as quickly as possible.
(j) Oil topping up should, generally comply with IS 335-1972 and preferably be from the
same source as the original oil. The oils from different crudes may not be completely
mixable and may separate into layers, however if they are made from same feed stock,
they can be mixed. New oil from a different source may be added, as made up only,
but not exceeding about 10%.
(k) Condition of oil can be checked by ascertaining its acidity and electric strength.
Both properties should be measured at regular intervals by method given in IS
335-
1972.
The acidity is normally between 0.3 to 0.5 mg KOH per g of oil, the cover should be
removed to ascertain the condition of the interior of the tank and core and windings, oil
should be treated or discarded if sludge or corrosion is evident.
It may be noted the reconditioning by centrifugal separation filtration does not
remove sludge, dust, dirt etc and will tend to retard the process of deterioration.
Filters with fullers earth will help to reduce acidity in the used oils and in addition
improve the resistively.
 Oil with excessive acidity should be reconditioned. Reconditioning can generally be
under taken only at the factory.
(l) Sample of the oil should be taken at regular intervals and tested to IS 335.
Recommended intervals for tests are mentioned in maintenance schedule.

Testing
Oil after filtration should meet the requirements as laid down under the clause
specification. However, to know the conditions the following preliminary tests can be carried out.
(a) Crackle test
A rough test can be made by closing one end of a piece of steel tube 2.54 cm dia (1
inch B.S. pipe is suitable), heating the closed end to just under dull red heat and plunging
it into the oil sample with the ear close to the open end. If the oil contains large moisture a
sharp crackle will be heard. Dry oil will only sizzle.

(b) Electric Strength

When tested in accordance with IIEC – 600296 and IS 6792 electric strength (Break
down voltage should not be less than 50 KVA RMS) test should be carried out six times
on the same sample and the result obtained will be arithmetic means of six result.