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778778/E
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MAINTENANCE INSTRUCTIONS
FOR MEDIUM POWER
TRANSFORMERS

KONČAR – DISTRIBUTIVNI I SPECIJALNI TRANSFORMATORI d.d.

Address: Josipa Mokrovića 8, P. O. BOX 100, HR-10090 Zagreb, Croatia
Telephone: (+385 1) 3783 777, Fax: (+385 1) 3794 051
E-mail: info@koncar-dst.hr, internet: www.koncar-dst.hr
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CONTENT

1 INTRODUCTION .............................................................................................................. 1
2 PREVENTIVE MAINTENANCE PROGRAM .................................................................... 2
3 RECOMMENDED SCHEDULE FOR PERIODICALLY MAINTENANCE ......................... 2
4 TRANSFORMER OIL ....................................................................................................... 5
5 BUSHING AND JOINTS ................................................................................................... 6
6 OFF-CIRCUIT TAP CHANGER (OCTC) AND ON-LOAD TAP CHANGER (OLTC) ........ 6
7 BUCHHOLZ RELAY ......................................................................................................... 7
8 CONSERVATOR .............................................................................................................. 7
9 TRANSFORMER ACCESSORIES ................................................................................... 9
10 COOLING SYSTEM .......................................................................................................... 9
11 TRANSFORMER AND OLTC CONTROL CABINET........................................................ 9
12 CORROSION PROTECTION ......................................................................................... 10
13 POSSIBLE FAILURES AND ACTIONS .......................................................................... 10
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1 INTRODUCTION

Transformer is very important part of the electrical power system. The

primary purpose of the transformer maintenance is to ensure that the internal and
external parts of the transformer and accessories are kept in good condition and able
to operate safely at all times.
Transformer maintenance can be done as condition based or periodically
maintenance.
● Condition based maintenance is usually the most economical way of doing
maintenance. Recommended maintenance are done based on one or more of
the following: visual inspections, analysis of oil samples, electrical
measurements, test of equipment, measurements of temperatures,
monitoring.
● In periodic schedule, the frequency of inspection and maintenance
procedures will vary with the rating of the transformer, but the intervals
suggested in this document are recommended as minimum.

ATTENTION:
If transformer is going to be used as a spare or stand-by unit, it maintenance must be
equal to the transformer in service. Special care must be taken in monitoring the conditions
of the oil.

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2 PREVENTIVE MAINTENANCE PROGRAM

In most cases operators are familiar with the noise and behaviour that can
occur during transformer normal operation, which can help to discover some defects.
It is very important to write down the readings from the meters or gauges that are
generally installed. These readings can be very useful. If the readings are very
different from the ones obtained in normal conditions, careful revision should be
performed.
In addition, you should pay attention to the following:
o the temperature of the transformer is directly related to the life span
of the insulating materials, so it is necessary to pay close attention,
o oil level and volume changes in relationship to the temperature,
o in some instances some abnormal noise can be perceived,
o checking of loose pieces and valves,
o oil leaks.

3 RECOMMENDED SCHEDULE FOR PERIODICALLY

MAINTENANCE

For personal safety reasons, only a limited amount of maintenance activities

should be performed on the transformer when it is in operation. Be sure to follow the
recommended safety requirements before any maintenance activity is undertaken. In
all conditions national and site specific safety rules must be followed. For all actions if
anything is unclear service company should be contacted.

CAUTION:
Before performing any maintenance work near the transformer terminals, be sure the
transformer is de-energized. Before entering the area at the top of the transformer,
transformer terminals must be grounded. Failure to de-energize the transformer may lead to
equipment damage, severe personal injury or death.

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3.1 POWER TRANSFORMER AND ASSOCIATED EQUIPMENT

MAINTENANCE INSPECTION INTERVALS FOR ENERGIZED
TRANSFORMERS

INTERVAL CHECK AND MAINTENANCE LIST

 Check transformer load currents and voltages.

 Check transformer for possible oil leakage.
 Observe any abnormal noises from the transformer.
Every site visit  Check of ambient, oil and winding temperature.
 Observe cooling fans.
(monthly)  Check of oil level.
 Check condition of silica gel in the breathers.
 Visual check of cable connections.
 Visual check of control cabinets.

 Observation and registration of counter information or

operation time of transformer, pumps, fans, OLTC, etc.
 Check and record readings on all indicating instruments.
 Examine the piping to the coolers or radiators and bolted
Quarterly
pipe joints for signs of oil leakage.
 Check the coolers or radiators for accumulation of dirt and
foreign material that might obstruct air flow.
 Inspect control cabinets of the transformer and the OLTC.

 Check bushing cleanliness in polluted environments and

visual check for cracks and unscrewed hardware.
 Check switchgear cable termination for pollution and
electrical tracking.
 Check transformer cables for deformation distance to
grounded metal parts.
Annually  Protective relay trip check, calibration of monitoring
equipment.
 Grounding system – check for loose, damaged or corroded
connections.
 Dissolved gas analysis and routine analysis of oil.
 Check bladder (inflate bladder (separator) up to 0,1 bar and
deaerate conservator following Mounting instructions).

CAUTION:
It may be necessary to de-energize the transformer to work in the areas where equipment
is close to the transformer line connections. Use proper safety procedures.
The control circuits may have dangerous voltage levels. Auxiliary power source must be
de-energized before working on any control components. Neglecting to do so may cause
personal injury or equipment damage.

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3.2 POWER TRANSFORMER AND ASSOCIATED EQUIPMENT

RECOMMENDED FREQUENCY OF MAINTENANCE INTERVALS
FOR DE-ENERGIZED TRANSFORMERS

INTERVAL CHECK AND MAINTENANCE LIST

 For the transformer equipped with forced oil cooling, check

the oil circulating pumps for any unusual noise or flutter of
the oil flow gauge.
 For transformers equipped with fans check functionality of
the fans and ensure there is no debris covering them or are
in the way of the blades.
 Take an oil sample from the main tank and any other oil-
filled compartment for DGA analysis.
 Perform same electrical test that were made at
commissioning.
Annually  Examine all bushings and interconnecting hardware for
(optimal) contamination and signs of electrical tracking, perform power
factor and capacitance measurement on the bushings (Only
for condenser type bushings).
 Inspect on load tap changer according to manufacturer
instructions.
 Inspect breathers and pressure relief valves or devices.
 Examine paint finish, particularly around welded joints.
 De-energize the auxiliary power source and inspect the
control equipment inside control cabinet.
 General repairs e.g. tightening bolts, replacement of
gaskets.

 Complete series of transformer electrical tests that were

done at commissioning.
 OLTC – according to manufacturer’s instructions, if any.
 Inspect alarm functionality for pressure relief device.
3 years
 Cleaning of complete switch gear, inspection and lubrication
of all associated devices including circuit breaker, wiring,
buses.
 All "annual" items not considered at one or two year interval.

6 years *  Complete service on OLTC (only certified personnel are

allowed to do this). *Depends on whether tap-changer is oil
or vacuum type.

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4 TRANSFORMER OIL

The purpose of the oil in oil immersed transformer is to act as an electrical

insulation and to transfer heat from the transformer’s active parts into the coolers. It
is hygroscopic and therefore it very easily absorbs moisture. Moisture balance
between the oil and the solid insulation implies that most of the moisture will be
absorbed by the paper insulation, but also by the oil.

The absorption of moisture could be prevented if the transformer oil is

separated from the atmosphere. This means hermetically sealed transformers or with
conservator with a rubber bag and silica gel breather. By the application of
conservator with silica gel breather only, the absorption of moisture could be
considerably slowed down. By this method it is necessary to check the breather at
regular intervals and renew the silica gel when 2/3 of silicagel change colour, unless
maintenance free air breather are used.

If the oil has been exposed to moisture, it is necessary to check its

breakdown voltage. Moisture in insulation is one of the dominant aging accelerators,
together with heat and oxygen. In order to maintain the quality of oil in service,
regular sampling and analysis (DGA and physical/chemical analysis) should be
performed on large distribution and power transformers.

In service, mineral oil degrades due to the conditions of use. Elevated

temperatures, oxygen, water and other catalysts accelerate degradation. Changes in
colour, formation of acidic compounds, gases formations and at an advanced stage
of oxidation, precipitation of sludge, may occur. Dielectric and in extreme cases,
thermal properties may be impaired. In addition to oxidation product, many other
undesirable contaminations such us solid particles and oil soluble polar compound
can accumulate in oil during service and affects its electrical properties. The present
of such contaminations and any degradation product of oil are indicated by a change
of one or more of the oil properties as describe in IEC 60422. According to results of
analysis oil in service may be classified as “good”, “fair” and “poor”. When oil is
classified as “poor” immediate actions is advisable – recondition (filtration, de-
humidification, de-gasification..) or complete change of oil is recommended.

The rate of increase of acidity of oil in service is a good indicator of the ageing
rate. Acidity has an impact on the degradation of cellulosic materials and may be
responsible for the corrosion of metal parts in a transformer. The acidity level is used
as a general rule for determining when oil should be replaced or reclaimed.

A change of oil is best to effect in hot state as in such conditions the oil has a
low viscosity.

The exchange of oil should be as efficient as possible because the mixture of

used and new oil is not recommended. The mixture of used and new oil gets the
properties of used oil.

It is also not recommended to mix new oils of different properties. According

to the experience, the mixing of new oils of different properties gives the properties of
such mixture worse than those of bad quality oil.

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If the oil is added after leakage, in which case the mixing quantity is less than
5%, it is sufficient that the oil which is added is dry and clean and least of same
quality as that in transformer.

The oil which has not been oxidised in a great deal, could be renewed
partially. Such a process, however, can be taken in consideration only with great
quantity of oil.

CAUTION:
Uninhibited and inhibited oils must not be mixed.

5 BUSHING AND JOINTS

Bushings generally do not require maintenance. Surface contamination is

caused by natural deposits (such as early morning dew, salt fog in sea coast
areas,etc.) and industrial pollution. Such contamination has often resulted in noisy
substations, damage of insulating surfaces, partial discharge, tracking flashover, and
loss of power. The porcelain insulators of the transformer bushings ought to be
cleaned during service outages as often as necessary. Use recommended cleaning
agents for cleaning the bushings. The condition of the external conductor and bus
bar joints of the transformer bushings shall be checked at regular intervals.
Maintenance of the bushings shall be performed according to the instructions given
by the bushings manufacturer.

6 OFF-CIRCUIT TAP CHANGER (OCTC ) AND ON-

LOAD TAP CHANGER (OLTC)

The transformation ratio can be adjusted with an off-circuit tap changer when
the transformer is not energized and with an on-load tap changer for the energized
transformers.
Generally a control shaft of the off-circuit tap changer is brought through the
transformer cover and it is provided with handle, position indicator and locking
device. Before putting transformer into operation locking device must be secured.
Off-circuit tap changers generally does not require maintenance, but it is
recommended that the off-circuit tap changer is moved from one extreme position to
the other a few times during service interruption, as it is used rarely. Changing
position can be performed either manually by a hand wheel (most cases) or by a
motor drive unit.
Maintenance of on-load tap changer shall be performed according to the
instructions given by the tap-changer manufacturer. It is very important to maintain
on-load tap changers according to tap changer producers instructions. Maintenance
interval and total expected lifetime depends on number of operations, current etc.

ATTENTION:
It is strongly recommended that only certified and trained personnel should undertake OCTC
and OLTC examination and maintenance.

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7 BUCHHOLZ RELAY

Buchholz relay is installed in the pipe between tank and conservator. It is

intended to alert the operator in case of an internal fault and the loss of insulating
liquid by tripping an alarm or shut-down pulse. In the event of partial discharges,
creeping currents, local overheating or excessive heat-up due to high currents
developing in metal parts, the insulating materials is subject to decomposition
resulting in gas formation. Gases accumulate in the Buchholz relay and displace the
insulating oil contained in it.
When a specific amount of gas has been collected, a floater will actuate a
contact. In the manner, the operating personal can detect possible faults early
enough to take suitable measures to prevent extension of the damage.
If high-energy arc discharging occurs inside the unit under protection, a very
rapid decomposition of the insulation material will be the result. The generated
pressure surge of the insulation oil travels through the pipe into the Buchholz relay.
At a specific flow rate, the generated flow actuates a magnetically held damper and
triggers a signal.
The same signal contacts are actuated by a floater coupled to a damper when
leakage in the pipe makes the oil level drop to the response level.
After that the relay has signalised alarm, check the colour and quantity of
accumulated gas through the window in the casing. The gas collected in casing of
the relay should be tested. If it is necessary, transformer active part should be taken
out of the tank, tested and repaired.
When the transformer is disconnected by the of gas relay, creation of gas in
transformer is also stopped. Several minutes should pass before the checking the
gas relay.
Interuptions without lasting effect in transformer sometimes do not cause
permanent defect though the gas relay has been activated. It is recommended,
however, that the transformer is connected without load after the relay casing has
been filled with oil. If the relay is activated immediately it means that transformer
definitely should be put out of operation and opened for inspection. It is not
recommended to put the transformer in operation again as this may result in further
faults.
The Buchholz relays are not sensitive to external influences. No special
maintenance is required during operation. During routine inspections of protection
devices, test also the function of Buchholz relay and check the alarm and tripping
devices connected to them. Check the Buchholz relay for leaks and proper sealing.
Any detected fault has to be removed at once.

8 CONSERVATOR

Conservator is used for expansion of oil during the different operating

conditions. Conservator can be with or without bladder (separator, rubber bag).
In case of a conservator with bladder (separator, rubber bag), during
breathing of a transformer, bladder is expanding / contracting with oil. Oil has no
direct contact with atmosphere. Inside of the bladder is open to atmosphere through
dessicant (silica gel) air breather. Transformer oil and air inside bladder is essentially
at atmospheric pressure, fig. 1.

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Figure 1.

Bladder failure relay is mounted on a top of a conservator for the purpose of

detecting air bubbles in oil. In case of a bladder rupture air will migrate into the relay,
fig. 2

Figure 2.
Also, there is no bladder that's impermeable and a little volume of air can
always migrate into the relay.

CAUTION:
Vacuum can be achieved inside transformer if the piping is not having sufficient diameter
or the air breather is blocked.
Never open the vent of a bladder failure relay without vacuum / pressure equipment.
Atmosphere will enter into relay and conservator. In that case, relay should be
recommissioned according to transformer mounting instructions.
After putting into operation, small quantities of air can be trapped inside transformer,
piping, etc. During first six months after putting into operation bladder relay can be
activated for that reason. Recommissioning of the relay is necessary. If no more activation
occurs, everything is in order. Later, during the years similar situation could happen, due to
oil leaks, or simply due to imperfection of a bladder. In that case, please contact
manufacturer / Service Company for further instructions.

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9 TRANSFORMER ACCESSORIES

Depending on customer requirements transformer can be equipped with

accessories (oil and winding temperture indicator, pressure relief device, oil level
indicator, bladder, silicagel breather, current transformers, etc.) that are not standard
for each transformer. For all transformer accessories it is recommended to be tested
yearly. Relays should be cleaned, lubricated and calibrated periodically in
accordance with manufacturer’s instructions. It is also necessary to check apparatus,
electric cables and conductors, signal and control devices in the control room. For
detailed informations please refer to manufacturer maintenance instructions.

10 COOLING SYSTEM

The cooling equipment is the most important part in the normal daily
operation of a transformer. Special care, maintenance and inspection is necessary,
since any abnormality can reduce the life time of the transformer or cause serious
defects.
For radiator type cooling system (ONAN) check for oil leakage. If the
radiators are detechable, check that the valves are open.
If the transformer is equipped with forced oil cooling (OF), check the oil
circulating pumps for any unusual noise or flutter in the oil flow gauge.
If the transformer is equipped with air cooling (AF), examine the fans to
ensure there is no debris covering them or that the blades are blocked. Check to
make sure each fan is operational and that the blade rotation is correct.

11 TRANSFORMER AND OLTC CONTROL CABINET

De energize the auxiliary power source and inspect the control devices in
the control cabinet. Remove grease, oil or other contaminants. Do not soak the parts
with a cleaner, but use just enough to loosen grease or dirt so that it can be wiped
off. For cleaning small parts a small paint brush dipped into the cleaning solution is
good for getting into corners and crevices. Repair or replace any broken or
malfunctioning part, tighten all loose connections and eliminate any oil or water leaks
into the compartment.

ATTENTION:
If the transformer is de-energized, heather inside the control cabinet should be turned on,
especially in case of low ambient temperatures.

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12 CORROSION PROTECTION

Examine the paint finish, especially around welded joints and on accessory
items such as radiators, coolers, and associated piping. Check for paint peeling or
cracking and evidence of rust. Clean the affected areas by wire brushing, wipe with
clean dry cloth. Paint the area with the touch-up primer and final coat paint suppiled
with the transformer.

13 POSSIBLE FAILURES AND ACTION S

During transformer operation, protective equipment of the transformer can

give an alarm or cut off (trip) transformer from the network. In this case, immediately
investigation should be done. In some cases, it may be necessary to contact the
manufacturer for advice and which further actions should be taken.
On following page will be presented possible failures and actions.

CONTACT INFORMATION:

Končar - Distribution and Special Transformers, Inc.

Josipa Mokrovića 8, P.O. Box 100
HR-10090 Zagreb, Republic of Croatia

Fax: +385 1 3794 146

E-mail: servis@koncar-dst.hr
Fax: +385 1 3794 050
E-mail: sales.set@koncar-dst.hr

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Equipment Indication, fault, alarm Probable fault Action Special conditions for repair work
Tighten the bolts on the flange, check oil level indicator. Remove oil leaks
Transformer must be offline when working above the cover level (near
Tank, transformer tank cover, conservator Oil leakage Gasket leaking according to enviromental procedures. Small leaks are not critical for transformer
HV/LV/MV bushings or any other high voltage parts)
operation.
Repairing on site is allowed only to certified personnel (welders, etc.). Radiator
can be removed (if neccessary) for a repair, in that case, oil temperature should During dismantling/assemble of a radiator, the transformer must be
Radiator/Coolers Oil leakage Mechanical damage, gasket leaking
be monitored. Repairing on site is allowed only to certified personnel (welders, offline. Remove leaks according to enviromental procedures.
etc.).
Normal condition, silica gel is changing color due to Change silicagel when 2/3 of silicagel has changed color. Check oil level in oil level
Silica gel changed colour No other conditions
moisture trap.
Dehydrating breather
No oil or improper oil level in oil trap (oil cup) Non - adequate maintenance Add / remove (replace) oil in oil trap. Oil must be stored according to enviromental procedures.
Check temperatures, loads, oil level, check that fans are running (cooling system,
Transformer in high load condition, fans are not
Alarm cooling groups schedule). Compare oil and winding temperature indicator. No other conditions
working properly, temperature indicator broken
Inform manufacturer / service company
Oil temperature
Check temperatures, loads, oil level, check that fans are running (cooling system,
Transformer in high load condition, fans are not Fault must be investigated / analyzed by experts before transformer
Tripping cooling groups schedule). Compare oil and winding temperature indicator.
working properly, temperature indicator broken can be energized
Inform manufacturer / service company
Check temperatures, loads, oil level, check that fans are running (cooling system,
Transformer in high load condition, fans are not
Alarm cooling groups schedule). Compare oil and winding temperature indicator. No other conditions
working properly, temperature indicator broken
Inform manufacturer / service company
Winding temperature
Check temperatures, loads, oil level, check that fans are running (cooling system,
Transformer in high load condition, fans are not Fault must be investigated / analyzed by experts before transformer
Tripping cooling groups schedule). Compare oil and winding temperature indicator.
working properly, temperature indicator broken can be energized
Inform manufacturer / service company
Air inside transformer, gas relay broken, hot spot in
Check gas relay functions, take oil sample from transformer (routine and DGA)
Gas alarm transformer winding, internal short circuit in No other conditions
and send it for analysis. Inform manufacturer / service company.
tranformer,
Gas relay Hot spot in transformer winding, internal short Check gas relay functions, take oil sample from transformer (routine and DGA) Fault must be investigated / analyzed by experts before transformer
Gas tripping
circuit in tranformer and send it for analysis. Inform manufacturer / service company. can be energized
Hot spot in transformer winding, internal short Check gas relay functions, take oil sample from transformer (routine and DGA) Fault must be investigated / analyzed by experts before transformer
Gas relay flow tripping
circuit in transformer and send it for analysis. Inform manufacturer / service company. can be energized
Too much oil filled to transformer (overfilling),
Upper (max) level alarm Check oil level indicator, inform manufacturer / service company. No other conditions
indicator broken
Oil level indicator for transformer main tank Check oil level indicator, check for oil leakage. Inform manufacturer / service
Low (min) level alarm Oil leakage, indicator broken No other conditions
company.
Indicator broken or a normal condition (oil level Check oil level indicator, check for oil leakage. Inform manufacturer / service
Indicator value is not indicating correctly No other conditions
indicator is not a thermometer) company.
Check oil level indicator, check for oil leakage. Inform manufacturer / service
Upper (max) level alarm Too much oil filled to OLTC, indicator broken No other conditions
company.
Check oil level indicator, check for oil leakage. Inform manufacturer / service
Oil level indicator for transformer OLTC Low (min) level alarm Oil leakage, indicator broken No other conditions
company.
Indicator broken or a normal condition (oil level Check oil level indicator, check for oil leakage. Inform manufacturer / service
Indicator value is not indicating correctly No other conditions
indicator is not a thermometer) company.
Check relay, change gasket / flange if needed. Inform manufacturer / service
Bladder protective relay (separator bag relay) alarm / tripping Leaking gasket or bag rupture Recommisioning according to mounting instructions
company.
Internal short circuit in transformers, pressure relief Check pressure relief device, check for oil, inform manufacturer / service Fault must be investigated / analyzed by experts before transformer
Transformer tank pressure relief valve (PRD) Pressure tripping ( 2 contacts)
valve broken, overfilling of a transformer company can be energized
Internal short circuit in transformers, pressure relief Check pressure relief device, check for oil, inform manufacturer / service Fault must be investigated / analyzed by experts before transformer
OLTC pressure relief valve Pressure tripping ( 2 contacts)
valve broken, overfilling of a OLTC company can be energized
Hot spot in OLTC winding, internal short circuit in Fault must be investigated / analyzed by experts before transformer
OLTC protection relay Oil flow tripping Check OLTC protection relay, inform manufacturer / service company
OLTC, relay broken can be energized
OLTC motor not stepping, motor protection Fault must be investigated / analyzed by experts before transformer
OLTC Motor drive Unit OLTC motor malfunction, some internal fault in OLTC Check OLTC motor protection, inform manufacturer / service company
tripping can be energized
Check protection circuit (current values) check fans
Miniatury circuit breakers (motor protection) Tripping Inform manufacturer / service company if fault is not found. No other conditions
(rotation, debris), change fan if needed,

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