General 11

5.3 Earthing of Magnetic Circuit

5.3.1 The magnetic circuit shall be earthed to the clamping structure at one point only
through a link placed in an accessible position beneath an inspection opening in the tank
cover. The connection to the link shall be on the same side of the core as the main earth
connection. The link should be brought out using bushing/terminal board on all transformers
above 31.5 MVA.

5.3.2 When magnetic circuits are subdivided into separate isolated sections by ducts
perpendicular to the plane of laminations all such sections should be earthed.

5.4 Earthing of Coil Clamping Rings

5.4.1 Where coil clamping rings are of metal at earth potential, each ring shall be connected
to the adjacent core clamping structure on the same side of transformer as the main earth
connections.

5.5 Size of Earthing Connections

5.5.1 All earthing connections with the exception of those from the individual coil clamping
rings shall have a cross-sectional area of not less than 0.8 cm2 . Connections inserted between
laminations of different sections of core as per clause 5.3.2 shall have a cross-sectional area
of not less than 0.2 cm2 .

6.0 TANKS

6.1 Tank Construction

(a) All transformer reactor tanks should generally be of conventional type i.e., tank body
with top cover, Bell shaped construction can be specified for 100 MVA and higher
rating transformer unless otherwise specified.
(b) Top cover of conventional type transformer and Bell type construction may be bolted
or welded to the tank body rim. Inspection covers shall always be bolted type.

6.1.1 The transformer tank and cover shall be fabricated from low carbon steel suitable for
welding and of adequate thickness. The tanks of all transformers shall be complete with all
accessories and shall be designed so as to allow the complete transformer in the tank and
filled with oil, to be lifted by crane or jacks, transportation by road, rail or ship/boat without
over straining any joints and without causing leakage of oil.

6.1.2 The transformer conservator tank, if equipped with an air cell, need not be designed
for full vacuum but a vacuum-tight valve should be provided in the Buchholz relay pipe
connection.

Alternatively an equalising connection may be provided between the inside of air cell and
conservator for evacuating the conservator along with air cell, which may be removed after
evacuation and oil filling.
12 Manual on Transformers

6.1.3 The main tank body excluding tap-changing compartments, radiators and coolers shall
be capable of withstanding vacuum given in the following table :
Vacuum
Highest system MVA rating gauge (mm of Hg)
voltage kV pressure kN/m 2

Up to 72 kV Up to 1.6 34.7 250

above 1.6 and up to 20 68.0 500
above 20 100.64 760
Above 72 kV for all MVA
ratings 100.64 760

6.1.4 The base of each tank shall be so designed that it shall be possible to move the
complete transformer unit by skidding in any direction without any damage when using
plates or rails.

6.1.5 Normally a detachable underbase will be used, but in case transport facilities permit, a
fixed underbase can be used.

6.1.6 Where the base is of a channel construction, it shall be designed to prevent retention
of water.

6.1.7 Tank stiffners shall be designed to prevent retention of water.

6.1.8 Wherever possible the transformer tank and its accessories shall be designed without
pockets where gas many collect. Where pockets cannot be avoided, pipes shall be provided
to vent the gas into the main expansion pipe. The vent pipes shall have a minimum inside
diameter of 15 mm except for short branch pipes which may be 6 mm minimum inside
diameter.

6.1.9 All joints other than those which may have to be broken shall be welded when
required they shall be double welded. All bolted joints to the tank shall be fitted with suitable
oil-tight gaskets which shall give a satisfactory service under the operating conditions and
guaranteed temperature rise conditions. Special attention shall be given to the methods of
making hot oil tight joints between the tank and the cover as also between the cover and the
bushing and all other outlets to ensure that the joints can be remade satisfactorily at site and
with ease with the help of semi-skilled labour.
6.2 Lifting and Haulage Facilities
6.2.1 Each tank shall be provided with :

(a) Lifting lugs suitable for lifting the transformer complete with oil

(b) A minimum of four jacking lugs, in accessible positions to enable the transformer
complete with oil, to be raised or lowered using hydraulic or screw jacks. The
minimum height of the lugs above the base shall be:

- Transformers upto and including 10 tonnes weight - 300 mm (approx.) so as to

accommodate suitable jacks beneath the jacking parts
 General 13

- Transformers above 10 tonnes weight - 500 mm (approx.) so as to

accommodate suitable jacks beneath the jacking lugs

(c) Suitable haulage holes shall be provided

6.2.2 To facilitate safe handling at site, the longitudinal and transverse axes and the centre
of gravity of main transformer tank should be marked permanently on all four sides.

6.3 Tank Cover

6.3.1 Each tank cover shall be of adequate strength, and shall not distort when lifted.
Inspection openings shall be provided as necessary to give easy access to bushings or
changing ratio or testing the earth connection. Each inspection opening shall be of ample size
for the purpose for which it is provided and at least two openings one at each end of the tank,
shall be provided.

6.3.2 The tank cover and inspection covers shall be provided with suitable lifting
arrangements. Unless otherwise approved inspection covers shall not weigh more than 25 kg
each.

6.3.3 The tank cover shall be fitted with pockets for a thermometer and for the bulbs of oil
and winding temperature indicators. Protection shall be provided, where necessary, for each
capillary tube.

6.3.4 The thermometer pocket shall be fitted with a captive screwed top to prevent the
ingress of water.

6.3.5 The pockets shall be located in the position of maximum oil temperature at CMR and
it shall be possible to remove the instrument bulbs without lowering the oil in the tank.

6.4 Axles and Wheels

6.4.1 Requirement of the roller will be specified for plinth mounted transformers. If
required only one set of roller of each size to be asked for.

6.4.2 If specified, transformers are to be provided with wheels and axles. They shall be of
such dimensions and so supported that under any service conditions they shall not deflect
sufficiently to interfere with the movement of the transformer. Suitable locking arrangements
will be provided to prevent the accidential movement of the transformer.

6.4.3 All wheels should be detachable and shall be made of cast iron or steel as required.

6.4.4 Wherever specified, flanged wheels shall be provided suitable for use on gauge track
as specified in the detailed specification and shall be so placed that pinchbar can be used to
move the transformer.

6.4.5 The direction of motion shall be specified in case of undirectional movement.

14 Manual on Transformers

6.4.6 If wheels are required to swivel, they shall be arranged so that they can be turned
through an angle of 90° when the tank is jacked up clear of the rails or floor. Means shall be
provided for locking the swivel movements in positions parallel to and at right angles to the
longitudinal axis of the tank.

6.5 Conservator Vessels, Oil Gauges and Breathers

6.5.1 A conservator complete with sump and drain valve shall be provided in such a
position as not to obstruct the electrical connections to the transformer having a capacity
between highest and lowest visible levels of 7.5% of the total cold oil volume in the
transformer and cooling equipment. The minimum indicated oil level shall be with the feed
pipe from the main tank covered with not less than 15 mm depth of oil and the indicated
range of oil level shall be from minimum to maximum.

6.5.2 If the sump is formed by extending the feed pipe inside the conservator vessel, this
extension shall be for at least 25 mm. The conservator shall be designed so that it can be
completely drained by means of the drain valve provided, when mounted as in service.

6.5.3 One end of the conservator shall be bolted into position so that it can be removed for
cleaning purposes.

6.5.4 Normally one oil gauge, magnetic/prismatic/plain type as specified shall be provided.

6.5.5 The oil level at 30°C shall be marked on the gauge.

6.5.6 Taps or valves shall not be fitted to oil gauge.

6.5.7 The oil connection from the transformer tank to the conservator vessel shall be
arranged at a rising angle of 3 to 9 degrees to the horizontal up to the Buchholz Relay and
shall consist of :

(a) For transformers up to and including 1000 kVA 25 mm inside diameter pipes as per
IS : 3639

(b) For transformers from 1001 to 10,000 kVA 50 mm inside diameter pipes as per
IS: 3639

(c) For transformers of over 10,000 kVA 80 mm inside diameter pipes as per IS : 3639

6.5.8 A valve shall be provided at the conservator to cut-off the oil supply to the
transformer, after providing a straight run of pipe for at least a length of five times the
internal diameter of the pipe on the tank side of the gas and oil actuated relay and at least
three times the internal diameter of the pipe on the conservator side of the gas and oil
actuated relay.

6.5.9 Each conservator vessel shall be fitted with a breather in which silica gel is the
dehydrating agent and designed so that :

(a) The passage of air is through the silica gel.

 General 15

(b) The external atmosphere is not continuously in contact with the silica gel.

(c) The moisture absorption indicated by a change in colour of the tinted crystals, can be
easily observed from distance.

(d) All breathers shall be mounted at approximately 1,400 mm above ground level.

(e) Self indicating (blue) silica gel contains the dye cobalt chloride which has potential
health hazards.

An alternative to the blue self indicating silica gel is SILICA GEL ORANGE with an
organic indicator. The colour changes from orange to light yellow as it absorbs
moisture.

6.5.10 One non-return valve, which may automatically cut off the flow of oil from
conservator towards the main tank may be provided in the pipe connection between the
Buchholz relay and conservator for transformers of 100 MVA and above.

6.6 Filter and Drain Valves sampling Devices and Air Release plugs

6.6.1 Each transformer shall be fitted with the following :

(a) The filter and drain valves as specified.

(b) A drain valve as specified below shall be fitted to each conservator.

For diameter up to 650 mm: Size of the valve 15 mm.

For diameter above 650 mm : Size of the valve 25 mm.

(c) A robust oil sampling device shall be provided at the top and bottom of the main tank.
The sampling device shall not be fitted on the filter valves specified under (a) above.

(d) One 15 mm air release plug.

(e) For transformers above 100 MVA rating, one 100 mm bore valve shall be provided
for attaching vacuum connection and with provisions for attaching a vacuum gauge, a
pressure gauge or an oil level indicator.

6.6.2 All other valves opening to atmosphere shall be fitted with blank flanges.

6.7 Cooler and Radiator Connections

Valves and valve mountings shall be provided as specified under "Cooling Plant" Clause 7.

6.7.1 All valves shall be of gun-metal or cast steel or may have cast iron bodies with gun-
metal fittings. They shall be of full way type with internal screw and shall be opened by
turning counter clock-wise when facing the handwheel.
16 Manual on Transformers

6.7.2 Means shall be provided for padlocking the bottom valves in the open and closed
positions. This is required for the valves where opening device like hand-wheel, keys, etc.,
are the integral part.

6.7.3 Every valve shall be provided with an indicator to show clearly the position of the
valve.

6.7.4 All valves shall be provided with flanges having machined faces.

6.7.5 The drilling of valve flanges shall comply with the requirements of IS : 3639.

6.8 Pressure Relief Device

6.8.1 The pressure relief device shall be provided of sufficient sizes for rapid release of any
pressure that may be generated within the tank, and which might result in damage to the
equipment. The device shall operate at a static pressure of less than the hydraulic test
pressure for transformer tank. Means shall be provided to prevent the ingress of rain water.

6.8.2 Unless otherwise approved the relief device shall be mounted on the main tank, and, if
on the cover, shall be fitted with skirt projecting 25 mm inside the tank and of such a design
to prevent gas accumulation.

6.8.3 If a diphragm is used it shall be of suitable design and material and situated above
maximum oil level.

6.8.4 If a diaphragm is put at the base of pipe, an oil gauge is required on the stand pipe for
indicating fracture of diaphragm.

6.8.5 One of the following methods shall be used for relieving or equalising the pressure in
the pressure relief device:

(a) An equaliser pipe connecting the pressure relief device to the conservator, or

(b) The fitting of a silica gel breather to the pressure relief device. The breather being
mounted in a suitable position for access at ground level.

6.8.6 If specified, the pressure relief valve (spring operated type) capable of releasing the
pressure in the tank when it rises above a predetermined safe limit, shall be provided. It shall
be provided with a microswitch for actuating trip contact when it operates. It shall also give a
visual indication of valve operation by raising a flag. The flag and the switch shall remain
operated until they are reset manually. The operating pressure of the pressure relief valve
shall always be less than the tank test pressure. The microswitch shall have IP 55 protection
and the fasteners shall be of rust proof material.

6.8.7 An oil splashguard shall be provided to the pressure relief device to restrict spillage of
hot oil in the event of operation of the pressure relief device.
 General 17

6.9 Accommodation for Auxiliary Apparatus

6.9.1 If specified, facilities shall be provided for the mounting of internal/external neutral
current transformer(s) adjacent to the neutral terminal(s) and tank.
6.10 Earthing Terminal

6.10.1 Two earthing terminals capable of carrying for 4 seconds the full lower voltage, short-
circuit current of the transformer. Provision shall be made at positions close to each of the
bottom two corners of the tank for bolting the earthing terminals to the tank structure to suit
local conditions. The design of earthing terminals shall be as per IS 3639 - Part 3 (Fittings
and accessories for Power Transformers Part 3 : Earth Terminals.

6.11 Rating, Diagram and Property Plates

6.11.1 The following plates shall be fixed to the transformer tank at an average height of
about 1750 mm above ground level as shown in Figs. 2 and 3.

(a) A rating plate bearing the data specified in the appropriate clauses of IS : 2026

(b) A diagram plate showing the internal connections and also the voltage vector
relationship of the several windings in accordance with IS: 2026 and in addition a plan
view of the transformer, giving the correct physical relationship of the terminals.
When links are provided in accordance with clause 2.3 for changing the transformer
ratio, then approved means shall be provided for clearly indicating ratio for which the
transformer is connected. No load voltage shall be indicated for each tap.

(c) Where specified a plate showing the location and function of all valves and air release
cocks or plugs is to be provided. This plate shall also warn operators to refer to the
maintenance instructions before applying the vacuum treatment for drying (Fig. 4).

6.11.2 The above plates shall be of material capable to withstanding continuous outdoor
service.
6.12 Joints and Gaskets

6.12.1 All gaskets used for making oil tight joints shall be of proven material such as
granulated cork bonded with synthetic rubber or synthetic rubber gaskets conforming to
IS : 4253, unless otherwise specified.