Testing & Maintenance of Transformers: Listing Type Test, Routine Test & Special Test As Per I.S. 2026-1981

Unit IV: Testing & maintenance of Transformer Ghatal Govt.
Polytechnic
Testing & maintenance of Transformers

Listing type test, routine test & special test as per I.S. 2026-1981:
List of Routine Tests:
a) Measurement of winding resistance.
b) Measurement of voltage ratio and check of phase displacement.
c) Measurement of short-circuit impedance and load loss.
d) Measurement of no-load loss and current.
e) Dielectric routine tests.
f) Tests on on-load tap-changers, where appropriate.
List of Type Tests
a) Temperature-rise test.
b) Dielectric type tests.
List of Special Tests
a) Dielectric special tests.
b) Determination of capacitances windings-to earth and between windings.
c) Determination of transient voltage transfer characteristics.
d) Measurement of zero-sequence impedance(s) on three-phase transformers.
e) Short-circuit withstand test
f) Determination of sound levels.
g) Measurement of the harmonics of the no-load current.
h) Measurement of the power taken by the fan and oil pump motors.
j) Measurement of insulation resistance to earth of the windings, and/or measurement of
dissipation factor (tan δ) of the insulation system capacitances.
I) Measurement of winding resistance:
The resistance of each winding, the terminals between which it is measured and the temperature
of the windings shall be recorded. Direct current shall be used for the measurement. In all
resistance measurements, care shall be taken that the effects of self-induction are minimized.
Dry-Type Transformers
Before measurement the transformer shall be at rest in a constant ambient temperature for at
least 3 hours. Winding resistance and winding temperature shall be measured at the same time.
The winding temperature shall be measured by sensors placed at representative positions,
preferably inside the set of windings, for example, in a duct between the high-voltage and low
voltage windings.
Oil-Immersed Type Transformers
After the transformer has been under oil without excitation for at least 3 hours, the average oil
temperature shall be determined and the temperature of the winding shall be deemed to be the
same as the average oil temperature. The average oil temperature is taken as the mean of the
top and bottom oil temperatures.
Prepared by Sanjoy Pondit, Lecturer, Department of Electrical Engineering, Ghatal Govt. Polytechnic
Unit IV: Testing & maintenance of Transformer Ghatal Govt. Polytechnic
In measuring the cold resistance for the purpose of temperature-rise determination, special
efforts shall be made to determine the average winding temperature accurately. Thus, the
difference in temperature between the top and bottom oil should be small. To obtain this result
more rapidly, the oil may be circulated by a pump.
II) Measurement of Voltage Ratio and Check of Phase Displacement
The voltage ratio shall be measured on each tapping. The polarity of single-phase transformers
and the connection symbol of three-phase transformers shall be checked.
III) Measurement of Short-Circuit Impedance and Load Loss
The short-circuit impedance and load loss for a pair of windings shall be measured at rated
frequency with approximately sinusoidal voltage applied to the terminals of one winding, with
the terminals of the other winding short-circuited, and with possible other windings open-
circuited. The supplied current should be equal to the relevant rated current (tapping current)
but shall not be less than 50 percent thereof. The measurements shall be performed quickly so
that temperature rises do not cause significant errors. The difference in temperature between
the top oil and the bottom oil shall be small enough to enable the mean temperature to be
determined accurately. If the cooling system is OF or OD, the pump may be used to mix the oil.
The measured value of load loss shall be multiplied with the square of the ratio of rated current
(tapping current) to test current. The resulting figure shall then be corrected to reference
temperature. The I2R loss (R being dc resistance) is taken as varying directly with the winding
resistance and all other losses inversely with the winding resistance.
On transformers having a tapped winding with tapping range exceeding ±5 percent, the short-
circuit impedance shall be measured on the principal tapping and the two extreme tapping.
On a three-winding transformer, measurements are performed on the three different two-
winding combinations. The results are re-calculated, allocating impedances and losses to
individual windings. Total losses for specified loading cases involving all these windings are
determined accordingly.
IV) Measurement of No-load Loss and Current
The no-load loss and the no-load current shall be measured on one of the windings at rated
frequency and at a voltage corresponding to rated voltage if the test is performed on the principal
tapping, or to the appropriate tapping voltage if the test is performed on another tapping. The
remaining winding or windings shall be left open-circuited and any windings which can be
connected in open delta shall have the delta closed.
The transformer shall be approximately at factory ambient temperature. For a three-phase
transformer the selection of the winding and the connection to the test power source shall be
made to provide, as far as possible, symmetrical and sinusoidal voltages across the three wound
limbs.
The test voltage shall be adjusted according to a voltmeter responsive to mean value of voltage
but scaled to read the r.m.s. voltage of a sinusoidal wave having the same mean value. The
reading of this voltmeter is U′.
At the same time, a voltmeter responsive to the r.m.s. value of voltage shall be connected in
parallel with the mean-value voltmeter and its indicated voltage U shall be recorded.
When a three-phase transformer is tested, the voltages shall be measured between line
terminals, if a delta connected winding is energized, and between phase and neutral terminals if
a YN or ZN connected winding is energized.
The test voltage wave shape is satisfactory if the readings U′ and U are equal within 3 percent.
The measured no-load loss is Pm, and the corrected no load loss is taken as:
𝑃𝑜 = 𝑃𝑚 (1 + 𝑑)
𝑈 ′ −𝑈
𝑑 = 𝑈 ′ (usually negative)
If the difference between voltmeter readings is larger than 3 percent, the validity of the test is
subject to agreement.
The r.m.s. value of no-load current is measured at the same time as the loss. For a three-phase
transformer, the mean value of readings in the three phases is taken.
V) Dielectric tests
The standard dielectric requirements are verified by dielectric tests. They shall, where applicable
and not otherwise agreed upon, be performed in the sequence as given below.
 Switching impulse test (SI) for the line terminal:
The test is intended to verify the switching impulse withstand strength of the line terminals and
its connected winding(s) to earth and other windings, the withstand strength between phases
and along the winding(s) under test.
The test is an essential requirement for transformers subjected to a long-duration induced
AC withstand voltage (ACLD) test.
 Lightning impulse test (LI) for the line terminals:
The test is intended to verify the impulse withstand strength of the transformer under test, when
the impulse is applied to its line terminals. If the lightning impulse test includes impulses chopped
on the tail (LIC), the impulse test is modified according to clause Test with lightning impulse
chopped on the tail.
 Lightning impulse test (LI) for the neutral terminal:
The test is intended to verify the impulse withstand voltage of the neutral terminal and it’s
connected winding(s) to earth and other windings, and along the winding(s) under test. This test
is required if a standard impulse withstand voltage for the neutral is specified.
 Separate source AC withstand voltage test (applied potential test):
The test is intended to verify the AC withstand strength of the line and neutral terminals and their
connected windings to earth and other windings.
 Short-duration induced AC withstand voltage test (ACSD):
The test is intended to verify the AC withstand strength of each line terminal and it’s connected
winding(s) to earth and other windings, the withstand strength between phases and along the
winding(s) under test. For Um > 72.5 kV, the test is normally performed with partial discharge
measurements to verify partial discharge free operation of the transformer under operating
conditions. By agreement between supplier and purchaser, the partial discharge measurements
may also be performed for Um ≤ 72.5 kV.
 long-duration induced AC voltage test (ACLD):
This test is not a design proving test, but a quality control test, and is intended to cover temporary
over voltages and continuous service stress. It verifies partial discharge-free operation of the
transformer under operating conditions.
VI) Tests on On-load Tap-Changers

With the tap-changer fully assembled on the transformer the following sequence of operations
shall be performed without failure:
a) With the transformer un-energized, eight complete cycles of operation (a cycle of operation
goes from one end of the tapping range to the other, and back again);
b) With the transformer un-energized, and with the auxiliary voltage reduced to 85 percent of its
rated value, one complete cycle of operation;
c) With the transformer energized at rated voltage and frequency at no load, one complete cycle
of operation; and
d) With one winding short-circuited and, as far as practicable, rated current in the tapped
winding, 10 tap-change operations across the range of two steps on each side from where a
coarse or reversing changeover selector operates, or otherwise from the middle tapping.
Insulation resistance Test
Measurement of insulation resistance is quite important. We normally take the reading of the
measurement at a certain time after application of test voltage. The standard duration of voltage
application are 1 minute or 10 minutes. Because of that, insulation resistance can also be referred
as 1 minute insulation resistance or 10 minute insulation resistance depending upon the duration
of the test.
The voltage, we apply for measurement of insulation resistance, is direct voltage.
When we apply direct voltage across the insulation, a current starts passing through the
insulation. This current has two main components.
a) The current flowing through the leakage path over the surface of the solid insulator. This
leakage path is formed mainly due to moisture, dust etc. which are naturally accumulated on
the surface of the solid insulator.
b) The current flowing through the volume of the insulator body.
The second component of the current is further divided in three components as mentioned
below.
i) As the insulation materials are essentially dielectric in nature, there will be a capacitive
charging current, appears just after application of test voltage. This current is instantaneous
in nature. It will effectively disappear within few moments. Hence, this current does not have
any effect on the reading of measurement if it is taken after 1 minute or more.
ii) There is another component of current called absorption current. It decays from high value to
zero. The insulation resistance value taken within first few minutes of test is largely dominated
by absorption current.
iii) Last but most important component of the current is conduction current. It remains steady
throughout the insulation resistance test. So after, charging current then absorption current
becomes insignificant, the test result is mainly predominated by this conduction current.
Thus finally, leakage current and conduction current come into picture at the time of taking
reading of insulation resistance. This is why the reading of insulation resistance is normally taken
after 15 seconds or 1 minute or sometimes after 10 minutes during the test.
There are three method for the testing of insulation resistance
A) Spot Reading Test

For this test, the mega-ohmmeter is connected across the insulation of the windings of the
machine being tested. A test voltage is applied for a fixed period of time, usually 60 seconds and
a reading is taken. The spot reading test should only be carried out when the winding
temperature is above the dew point'. The operator should make a note of the winding
temperature, so that it will be possible to correct the reading to a base temperature of 20°C.
B) Time-Resistance Testing
Method This method is fairly independent of temperature and often can give you conclusive
information without records of past tests. It is based on the absorption effect of good insulation
compared to that of moist or contaminated Insulation. Simply take successive readings at specific
times and note the differences in readings. Tests by this method are sometimes referred to as
absorption tests.
Good insulation shows a continual increase in resistance over a period of time (in the order of 5
to 10 minutes). This is caused by the absorption; good insulation shows this charge effect over a
time period much longer that the time required to charge the capacitance of the insulation.
If the insulation contains moisture or contaminants, the absorption effect is masked by a high
leakage current which stays at a fairly constant value - keeping the resistance reading low (R =
E/I).
The time-resistance testing is of value because it is independent of equipment size. The increase
in resistance for clean and dry insulation occurs in the same manner whether size is large or small.
C) Step Voltage Test
In this test, the operator applies two or more test voltages in steps. The recommended ratio for
the test voltage steps is 1 to 5. At each step, test voltage should be applied for the same length
of time, usually 60 seconds. The application of increased voltage creates electrical stresses on
internal insulation cracks. This can reveal aging and physical damage even in relatively dry and
clean insulation which would not have been apparent at lower voltages.
Impulse voltage withstand test
Lighting is a common phenomenon in transmission lines because of their tall height. This lightning
stroke on the line conductor causes impulse voltage. The terminal equipment of transmission line
such as power transformer then experiences this lightning impulse voltages. Again during all kind
of online switching operation in the system, there will be switching impulses occur in the
network. The magnitude of the switching impulses may be about 3.5 times the system voltage.
Insulation is one of the most important constituents of a transformer. Any weakness in the
insulation may cause failure of transformer. To ensure the effectiveness of the insulation system
of a transformer, it must confirms the dielectric test. But the power frequency withstand test
alone cannot be adequate to demonstrate the dielectric strength of a transformer. That is why
impulse test of transformer performed on it. Both lightning impulse test and switching impulse
test are included in this category of testing.
Performance of Impulse Test:

The test is performed with standard lightning impulses of negative polarity. The front time (T1)
and the time to half-value (T2) are defined in accordance with the standard.
Standard lightning impulse

Front time T1 = 1.2 μs ± 30%
Time to half-value T2 = 50 μs ± 20%
In practice, the impulse shape may deviate from the standard impulse when testing low-voltage
windings of high rated power and windings of high input capacitance. The impulse test is
performed with negative polarity voltages to avoid erratic flash overs in the external insulation
and test circuit. Waveform adjustments are necessary for most test objects. Experience gained
from results of tests on similar units or eventual pre-calculation can give guidance for selecting
components for the wave shaping circuit.
The test sequence consists of one reference impulse at 75% of full amplitude followed by the
specified number of voltage applications at full amplitude (according to IEC 60076-3 three full
impulses). The equipment for voltage and current signal recording consists of digital transient
recorder, monitor, computer, plotter and printer. The recordings at the two levels can be
compared directly for failure indication. For regulating transformers one phase is tested with the
on-load tap changer set for the rated voltage and the two other phases are tested in each of the
extreme positions.
Temperature rise test of oil & winding
The standard method for determination of the steady-state temperature-rise of oil-immersed
transformers on the test floor is the equivalent test in short-circuit connection.
Alternatively it may be agreed, in special cases, to perform a test with approximately rated
voltage and current by connection to a suitable load. This is mainly applicable to transformers
with low rated power.
A ‘back-to-back’ method may also be agreed. In this method, two transformers, one of which is
the transformer under test, are connected in parallel and excited at the rated voltage of the
transformer under test. By means of different voltage ratios or an injected voltage, rated current
is made to flow in the transformer under test.
Test to Steady State by Short-Circuit Method
During this test the transformer is not subjected to rated voltage and rated current
simultaneously, but to the calculated total losses, previously obtained by two separate
determinations of losses, namely load loss at reference temperature, and no-load loss.
The purpose of the test is twofold,
 To establish the top oil temperature-rise in steady-state condition with dissipation of total
losses.
 To establish the average winding temperature rise at rated current and with the top oil
temperature rise as determined above.
This is achieved in two steps:
a) Total loss injection: First the top oil and average oil temperature-rises are established when
the transformer is subjected to a test voltage such that the measured active power is equal to
the total losses of the transformer.
The test current will be above rated current to the extent necessary for producing an additional
amount of loss equal to the no-load loss, and the winding temperature rise will be
correspondingly elevated.
The oil temperature and cooling medium temperature are monitored, and the test is continued
until a steady-state oil temperature rise is established.
The test may be terminated when the rate of change of top oil temperature-rise has fallen below
1 k/h and has remained there for a period of 3 h. If discrete readings have been taken at regular
intervals, the mean value of the readings during the last hour is taken as the result of the test. If
continuous automatic recording is applied, the average value during the last hour is taken.
b) Rated current injection: When the top oil temperature rise has been established, the test shall
immediately continue with the test current reduced to rated current for the winding combination
connected. This condition is maintained for 1 h, with continuous observation of oil and cooling
medium temperatures.
Different methods of determining temp rise:
Back to back or Sumpner's test:
A load test on a transformer is necessary if its maximum temperature rise is to be determined. A
small transformer can be put on full load by means of a suitable load impedance. But for large
transformers, full load test is difficult, since it involves considerable waste of energy and a
suitable load, capable of absorbing full load power, is not easily available. However, large
transformers can be put on full load by means of Sumpner's or back to back test. The Sumpner's
test can also be used for calculating the efficiency of a transformer, though the latter can be
determined accurately from open-circuit and short circuit tests.
The back to back test on single-phase transformers requires two identical units. Fig. 1.33
illustrates the circuit for two single-phase transformers, where two primaries connected in
parallel, are energised at rated voltage and rated frequency. With secondaries open, the watt
meter W, records the core losses of both the transformers. The two secondaries are connected
in series with their polarities in phase opposition, which can be checked by means of a voltmeter.
The range of this voltmeter connected across terminals ab, should be double the rated voltage
of either transformer secondary. Zero voltmeter reading (Vab= 0) indicates the secondaries are
connected in opposition. Now, if the terminals ab are short-circuited, the current in the
secondary would be zero because Vab=0 and the wattmeter reading W₁ remains unaltered. In
case the voltmeter reads the sum of the two secondary voltages, the secondaries are in the same
phase. In order to bring them in phase opposition, terminals ad should be joined together to
result in zero voltage across terminals bc.
Sumpner's (or back to back) test on two identical single-phase transformers

In Figure, it is assumed that voltage across ab is zero and the two secondaries are in phase
opposition. Now a voltage is injected in the secondary circuit by means of a voltage regulator,
fed from the source connected to the primaries or from a separate source. The injected voltage
is adjusted till rated current flows in the two series-connected secondaries. By transformer
action, primary windings also carry rated current. Note that the full load current in the primaries,
completes its path through the main bus bars (shown dotted) and, therefore, the reading of
wattmeter W, remains unaffected. It may be seen that the reading of voltmeter V₂ is equal to the
sum of leakage impedance drops in both the transformers. The low-injected voltage has given
rise to full load currents in primary and secondary windings, therefore, the full load ohmic losses
of both the transformers are measured by the wattmeter W₂. If Pc and Psc are the core and ohmic
losses in each transformer, then the reading of wattmeter W₁=2Pc and that of wattmeter W₂=
2Psc. The efficiency can now be determined by using this data.
It is seen from above that in Sumpner's test, even though the transformers are not supplying any
load current, yet full iron-loss occurs in their cores and full-load ohmic-loss occurs in their
windings. Net power input to the two transformers is (2Pc +2Psc). If temperature rise of the two
transformers is to be measured, then the two transformers are kept under rated loss conditions
for several hours till maximum stable temperature is reached.
If 2Io, is the no load current, then for the assumed directions of I o, and I2, the primary current of
transformer 1 is less (difference of I1 and Io) than the primary current of transformer 2 (sum of Io,
and I1). Therefore, the two transformers do not operate under identical conditions-one may have
slightly less temperature than the other.
Open delta test:
For performing the load test on single-phase transformers, two identical units are essential,
whereas the load test on three-phase transformers can be carried out on a single unit. For this
test, the primary and secondary windings are connected in delta, whatever the actual
transformer connections may be. The low-voltage winding is excited at normal voltage and
normal frequency. The wattmeters W₁ and W₂ record the total core loss. The h.v. winding in open
delta, is connected to auxiliary single-phase supply of any convenient frequency. The voltage
injected in the open delta is adjusted till full load current flows in it. Transformer action sets up
full load current in the l.v. winding also. As before, the readings of watt meters W₁ and W₂ are
unaffected and watt meter W, records the ohmic losses in all the three phases. Note that the
magnitude of the low-injected voltage in the open delta is equal to (full load current) 3ZeH, where
ZeH is the per phase equivalent leakage impedance on h.v. side. This method of load testing may
be called dummy load test on a three-phase transformer. In Figure, upper diagram shows l.v.
winding in delta, whereas the lower diagram shows its h.v. winding in open delta.
Dummy load test on a three-phase transformer
PREVENTIVE MAINTENANCE OF TRANSFORMER

For a long trouble free service, transformer should be given due attention regularly. The
programme of maintenance depends on the size of transformers, operating conditions and
location.
In large substations and grid substations a stand by transformer should be kept to be switched
on at a moment's notice in case of need. Such a stand by transformer should be maintained at
the same standard as the other installed transformer.
In case of transformer following faults may develop due to lack of maintenance or improper or
poor maintenance:
(i) Loose core bolts and clamps result into more vibrations of stampings and more noise
(ii) Improper supports and clamps for windings result in collapse of winding during external short
circuit faults.
(iii) Bad soldering results into more heating at joints and carbonizing of oil in contact with it
(iv) Oil leakage will reduce oil in tank resulting in overheating of transformers oil and windings.
(v) Dirt and dust deposited on the insulator's (bushings) will provide low resistance to leakage
current resulting into flash over and damaging the insulator.
(vi) If sludge is formed in transformer oil, it blocks free circulation of oil and results into
overheating.
(vii) Cracks or broken bushing may result into failure of transformer.
(viii) Loose connections in conducting parts due to overheating.
Recommended Maintenance Schedule of Transformer.
It is essential to have periodic preventive maintenance of power transformers. The earlier notion
that the transformer does not need maintenance is wrong. Transformer needs regular
maintenance for satisfactory service.
Before carrying out maintenance work on transformers, it should be disconnected from supply
by disconnecting load from secondary, opening contacts of dropout fuses and opening air-break
switch. The incoming supply line is then properly earthed. Then the maintenance work should
commence. The maintenance work should be carried out by authorized persons only, who should
carry out proper line clear certificate before commencement of work. He should not smoke while
working and if there is conservator etc. fitted to the tank the oil should be taken out from
conservator before opening tank.
The transformer maintenance includes the following:
(a) Routine daily inspection.
(b) Routine weekly inspection.
(c) Routine Monthly inspection.
(d) Quarterly inspection
(e) Annual inspection.
(f) Unscheduled maintenance.
(a) Hourly Maintenance: Hourly maintenance include the following inspections
(i) Check winding temperature.

(ii) Check oil temperature.
(iii) Check ambient temperature.
(iv) Check load. Adjust load to keep the temperature rise within a permissible limit.
(v) Check voltage
(vi) Check against rated figure, start fans, if required.
(b) Daily Maintenance: Daily maintenance includes:
(i) Check oil level add dry oil, if level is low.
(i) Check tank and radiators for unusual noise.
(ii) Check oil level in main tank bushings.
(iv) Check relief vents whether normal or open.
(v) Check whether cooling water is flowing, whether oil circulation pump is operating when
necessary, whether start fans if, necessary.
(vi) Check that air passages are clear.
(vii) Check the colour of silica gel in the breather, colour should be blue. If the colour of the silica
gel becomes pink, replace them.
(viii) Check relay panel, temperature indicators and confirm normal condition (ix) Check position
of tap-changer.
(x) See that all control/alarm/power supply circuits switches are closed and fuses in the circuit
are well placed.
(c) Monthly Maintenance: Monthly maintenance includes:
(i) Check the oil level in the transformers if required then add dry oil.
(ii) Check and record oil temperature. Oil level varies with change in temperature.
(iii) Check bushing surface for signs of chipping, dirt, oil, film etc.
(iv) Check presence of nets, vines, shrubs etc., in the neighbourhood of
(v) Check the leakage.
(vi) Check terminal connections, earthing connections for tightness
(vii) Other checks mentioned in daily checks.
(d) Quarterly Maintenance: It includes:
(i) Examine for cracks and dirt deposits on the bushing of the transformer.
(ii) Check for proper working of cooling fans, circulating pump etc.
(e) Half Yearly Maintenance: Half-yearly maintenance includes:
(i) Check dielectric strength of oil.
(ii) Check for proper working of cooling fans, circulating pump etc.
(iii) Check bushes and insulator.
(iv) Check cable boxes, filter etc.
(v) Replace oil.
(vi) Check for moisture under cover.
(vii) Other checks mentioned in daily, monthly, quarterly checks.
(f) Yearly Maintenance: Following things should be observed and carried out in yearly
maintenance:
(i) Check foundation for cracking and settling. A slight shift of the transformers may break
bushings or connecting oil or water lines. See that rail stops are firmly in place to hold transformer
in position on the rail. Check transfer car and matching of its rails with transformer deck rails at
each positions, weld metal work as needed.
(ii) Clean dirt and oil from radiating surfaces. Repaint as necessary stop excessive vibration of
radiator tubes, tighten loose or vibrating parts. Check for unusual internal noises Inspect oil and
water piping valves, and plugs. Manipulate radiator cut-off valves to see that they are in
operating condition and secure in the open position see that all oil drain valves which can be
operated without wrenches are plugged or locked to prevent unauthorized opening.
(iii) See that relief diaphragm is in operating condition and closes tightly. The non-shattering type
diaphragm should be actuated to see that it is not stuck shut from rust or paint. Make that
material used in shattering-type diaphragm is not too thick or tough to be broken by reasonable
internal pressure. See that screens and baffles in the vents or breathers are not obstructed or
broken. If breathers are of dehydrating type, check chemicals and replace it, if depleted.
(iv) Clean dirty gauge glasses and connections. Check oil level indicators and relays for proper
operation. Replenish oil if below normal. Drain out and replace bushing oil if dirty or discoloured.
(v) Check external supply and drain piping for leaks. Flush out cooling coils of heat exchanger
water passages with air and water.
Test coils for leaks by applying air pressure to coils and absorbing for bubbles rising in oil and
drop in air pressure with supply valve closed, or use a hydrostatic pressure test. A pressure of
about 75 pounds per square inch is recommended. If water scale is present, circulate a solution
of 25 per cent hydrochloric acid and water through the coils until clean. The flush out thoroughly.
Clean external surfaces of coils.
(vi) Check water flow indicators and relays for proper operation.
(vii) Clean and test water tubes similar to cooling coil, check for oil and water leaks.
(viii) Check motors and control.
(ix) Check calibration of temperature indicators and relays, check and clean relay contacts and
operating mechanism.
(x) Check setting and operation of regulator and relay, see that gauges are indicating properly.
(xi) Check for gas leaks dry applying liquid soap on all joints valves, connections etc., with gas
pressures raised to the maximum recommended by the transformers manufacture.
(xii) Clean porcelain with water, chloroethylene, or other suitable cleaner. Repair chipped spots
by painting with lacquer such as red glyptal. Inspect gaskets for leaks tighten bolts, check power
factor, check oil sample from bottom of bushing for dielectric strength and presence of water
which may be entering at top. Replace or replenish oil, if necessary.
(xiii) Check top settings and adjustment at terminal board to see that they agree with diaphragms.
Check insulation resistance of wiring with devices connected. Check ratio and phase-angle
adjustments of potential devices if changes have been made in secondary connections and
burden. Tighten connections, including potential device top, into bushing.
(xvi) Tighten all bus and ground connections. Refinish joint contact surfaces if they have been
overheating. Inspect ground cable to see that it is not loose or broken.
(xv) Lower the oil level to atleast the top of the core. Inspect for saludge on core and windings.
Inspect under side of cover for moisture and rust and clean up. Check connections at terminal
board, tighten all bolted connections, core bolts, etc., within reach.
(xvi) Inspect contacts and clean if reachable on internal inspection. If not reachable for visual
inspection, check each position with wheatstone bridge across winding to detect poor contact.
Work adjusted back and forth over complete range several times.
(xvii) Check contact pressure. Check contact operating mechanism. Tighton connections and
other bolts.
(xviii) Chcck condition of contacts and refinish of burned or corroded.
(xix) Check contact springs, operating rods and levers, chock closing and operating positions with
respect to position of main contacts.
(xx) Inspect fuses or circuit breakers on all power, control and alarm supplies to auxiliary
equipment and devices.
(xxi) Check the insulation resistance between each winding and between each winding and
ground.
(xxii) Check the dielectric strength of insulating oil in the main and auxiliary tanks and oil filled
bushings.
(xxiii) Check earth resistance.
(xxiv) Check lighting arrestors.
(xxv) Check for ceiling arrangement for fitting.
(xxvi) Run tap changer or regulator through several complete cycles by both control relay and
manual control and observe contacts and mechanism for proper operation.
(g) Two-yearly Maintenance: Two-yearly Maintenance includes:
(i) Internal inspection of the core.
(ii) Filter oil and fill filtered oil in the tank and conservator of the oil.
(iii) Checks mentioned in yearly maintenance.
(h) Five-yearly Maintenance: Five-yearly maintenance includes:
(i) Carry out overall inspection of the transformer including tighting of core and coils as
mentioned earlier in yearly maintenance.
(ii) Clean the transformer with dry transformer oil.
(iii) Open tank for cleaning and reassembling.
(i) Unscheduled Maintenance: Unscheduled maintenance is the type of maintenance which is
not schedule as per instructions mentioned in the manual by company. It includes:
(i) If the transformer has been properly maintained and not overheated and barring internal
failure, it should not require untanking within the normal life. If sludge has been allowed to from
due to overheating and oxidation of the oil, transformer should be untanked and the core, coils
oil passages, tank and water cooling coils are washed down with clean oil under pressure to
remove sludge and other accumulations which prevent proper circulation of the oil. Inflammable
liquids should not be used in cleaning the core, coils or inside of tank. While untanked, check for
loose laminations, core bolts insulating blocks etc. and other pertinent features on the check list,
(ii) The necessity for filtering and/or reclaiming the insulating oil will depend on the results
obtained from the oil dielectric and oil acidity tests. It may be more economical to replace the oil
in small transformers rather than filters and reclaim it.
The acidity of the insulating oil in the main tank should be checked at intervals of not more than
five years. Transformers operating at high temperature or showing signs of sludging or dark
colour of the oil should be checked more frequently. Oil may be checked in the field with a
dielectric test kit or samples sent to laboratory.
Major substations having transformer rated 1 MVA and above are usually attended at all times
such installations can have hourly, weekly, monthly inspection.
Medium size transformers, between 0.6 MVA and 1 MVA are used in smaller substations. They
can also have daily, weekly and monthly inspection.
Small transformers below 500 kVA are often installed in unattended sub-stations. Such
transformers can have quarterly maintenance.

Testing & Maintenance of Transformers: Listing Type Test, Routine Test & Special Test As Per I.S. 2026-1981

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Testing & Maintenance of Transformers: Listing Type Test, Routine Test & Special Test As Per I.S. 2026-1981

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Unit IV: Testing & maintenance of Transformer Ghatal Govt.

Testing & maintenance of Transformers

VI) Tests on On-load Tap-Changers

A) Spot Reading Test

Performance of Impulse Test:

Standard lightning impulse

Sumpner's (or back to back) test on two identical single-phase transformers

Dummy load test on a three-phase transformer

PREVENTIVE MAINTENANCE OF TRANSFORMER

(i) Check winding temperature.

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