COMMISSIONING

OF
TRANSFORMERS AND REACTORS
A.K Goel,
Sr. DGM (HRD)
arunkgoel@powergrdindia.com
Ph-9599192366

07/09/2021 1
Transformer

07/09/2021 2
PRE-COMMISSIONING PROCEDURES -Purpose

 Pre-commissioning checks/ tests are the activities

carried out to ascertain the correctness,
completeness of installation and healthiness of the
equipment before its charging.

 Commissioning Team-

 Responsibilities of Commissioning team: The

responsibilities of the commissioning team are to
go through statutory clearances and standing
instructions before initial charging of new
equipment,.

07/09/2021 3
Contd.
 Witness Pre-Commissioning tests after erection of
individual equipment as per requirement of guidelines
issued by Corporate Asset Management or in line with
manufacturer's recommendation and test charging.
 Investigate failure of equipment during test charging,
declare commencement of trial operation and evaluate
guaranteed test results and recommend acceptance as
may be provided in the contract.
 List out deviations/ exception/ incomplete work, for
acceptance/ rejection. Proper documentation also to be
ensured by the Commissioning team based upon the
observations for the above for future reference

07/09/2021 4
Contd.
 The Team shall also go through the factory test reports.
If such tests have been repeated during pre-
commissioning, the Team shall list out deviations, if
any, in the results of pre-commissioning tests with
respect to the factory tests.

 In case of Transformers & Reactors, commissioning

team shall forward the Pre-Commissioning report along
with their recommendations to RHQ-AM and CC-AM for
charging clearance and CC-AM shall give the final
charging clearance after reviewing of the test results.

07/09/2021 5
 PROCESSES INVOLVED

 Checks after the receipt of Transformer/Reactor at site

 Insulating oil
 Internal inspection
 Tightness test with vacuum
 Oil filling and circulation
 Testing
 Preliminary checks before charging
 Checks of auxiliaries and protection
Charging
 Post commissioning checks

07/09/2021 6
 SAFETY
 All personals should be apprised of safety procedures
 Personnel protective equipment
 Warning signs
 Safety barriers
 Fully equipped and functional fire fighting system

07/09/2021 7
 CHECKS AFTER THE RECEIPT OF MAIN TANK AT SITE

 Nitrogen pressure or dry air pressure of the main tank

 Dew point of the nitrogen or dry air inside tank
 Core insulation test
 Impact recorder ( to be sent to manufacturer or if

software available can be analysed at site)

NOTE:- THE ABOVE MENTIONED CHECKS ARE
TO BE CARRIED OUT ON THE TRAILER ITSELF
BEFORE UNLOADING OF MAIN TANK

07/09/2021 8
 RECEIPT AND STORAGE OF
MATERIALS AT SITE
 Unpacking without damaging
 Any damaged or missing component to be intimated to the
manufacturer
 Materials repacked and stored if commissioning not
immediate
 Fragile instruments indoor storage eg:- oil level gauge,
temperature indicators etc.
 Packing cases to be placed on suitable supports to allow free
flow of air no water logging, easy for inspection and
handling/transportation,
 Proper drainage, no component gets submerged

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STORAGE OF MAIN TANK FOR LESS
THAN THREE MONTHS
 Main tank filled with nitrogen or dry air
 Daily check of pressure
 If drop in pressure found, dew point to be taken
 If drop in dew point, fresh nitrogen or dry air has to be

filled
 Leak has to be detected and tightened

07/09/2021 10
STORAGE OF MAIN TANK FOR MORE
THAN THREE MONTHS
 Filled with processed oil ( BDV > 70KV, moisture
content < 5ppm)
 BDV AND water CONTENT TESTED EVERY

THREE MONTHS
 If value beyond limits, oil filtration done

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 INSULATING OIL
 Oil in 209L drums or oil tanks
 Proper record of drums to be maintained
 To be checked for free moisture and appearance
 Oil sample to be sent to nearest lab for testing BDV >

50kv, moisture content < 40ppm, resistivity > 150x1012

ohm-cm, tan delta < 0.01 @90 0c
 Oil tanker- 02 samples
 209L oil drums- given table

07/09/2021 12
SAMPLES FROM DRUM

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OIL SAMPLING FROM DRUMS
 Oil drums vertical with lid upwards for 24 hours
 Clean the area around lid
 Use glass or brass tube to sample the oil
 Discard first two samples
 Suitable receptacle preferably glass bottles cleaned

with same oil then final sample taken

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 INTERNAL INSPECTION
PRECAUTIONS WHAT IS TO
DONE

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 PRECAUTIONS DURING INTERNAL
INSPECTION
 Along with manufacturer’s representative
 Dry and sunny weather
 Dry air should be used if main tank filled with nitrogen
 Avoid any foreign materials
 Loose materials should be removed from pockets
 Protective clothing and shoes
 Tools securely fastened
 An inventory of all materials taken inside tank to be
maintained and checked before closing of inspection
cover

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07/09/2021 17
07/09/2021 18
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INTERNAL INSPECTION INCLUDES
 Removal of any shipping blocking or temporary
support.
 Examination for indication of core shifting.
 Tests for unintentional core or core clamp grounds.
 Visual inspection of windings, leads, and connections

including clamping, bracing,

 Blocking, spacer alignment, phase barriers, oil boxes,

and coil wraps.

 Checks for dirt, metal particles, moisture, or other

foreign material.

07/09/2021 20
Erection of Transformer

07/09/2021 21
PRECAUTIONS DURING ERECTION-1
of 2
 Minimize exposure of active parts (core+coil)
 Presence of dry air ( dry air generators or dry air

cylinders )
 Transformer sealed off after working hours
 If tank has nitrogen then first vacuum then dry air

pushing. For safe breathing.

 A slight overpressure at night to check any leakage

(<30 mbar)

07/09/2021 22
PRECAUTIONS DURING ERECTION-2
of 2

 Check leakage if any leak detecting instruments or soap

solution or plastic bags tied around valves
 Get transformer under oil as soon as possible
 All fittings and auxiliaries with oil sealing to the tank

should be fitted first.

07/09/2021 23
 CONDITIONS OF EXPOSED FOR OIL
FILLED TRANSFORMERS
 Oil is drained out below the inspection covers
 Other exposure activities are as below:

1) bushing erections
2) jumper connections of bushings
3) fixing bushing turrets
4) core insulation checking (in case the checking point not accessible
outside)
5) buchholz relay pipe work fixing on cover
6) gas release pipes/equalizer pipe fixing
7) entering inside the tank for connections/inspection etc

DEPENDING UPON THE DURATION OF EXPOSURE OIL

PROCESSING (DRYING) AND OIL FILLING IS DONE

07/09/2021 24
 FINAL TIGHTNESS TEST WITH
VACUUM
 Before oil filling, leakage test is a must.
 Evacuate transformer from top of tank till pressure < 50mbar.

 Vacuum stopped.

 After 1 hour take pressure reading p1

 After 30 minutes reading p2

 (P2 – P1) x V < 3.6 ; V= VOLUME OF TANK (see rating plate)

 Take 2 to 3 readings, if ok , then leak test successful, and further

vacuum till 1torr done and maintained as per given table.

 If not , then leak attended

 OLTC chamber to be vacuumed simultaneously and vacuum

released simultaneously

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 VACUUM HOLDING
 After passing leakage test, vacuum maintained in tank
for the duration as mentioned below

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 OIL FILLING-1 of 3
 Transfer oil from drums to tanks for filtration
 Filtration done
 Oil parameter testing :
 1. Break down voltage (bdv) : 70kv (min.)
 2. Moisture content : 5 ppm (max.)
 3. Tan-delta at 90 °c : less than 0.01
 4. Interfacial tension : more than 0.035 n/m
 Nitrogen filled transformer to be oil filled under
vacuum

07/09/2021 27
 OIL FILLING-2 of 3
 Oil filled from bottom valve
 Oil fill speed in main tank < 5klph
 Oil filled in OLTC at atmospheric pressure
 Oil filled in cooler banks without vacuum at

atmospheric pressure
 Care must be taken not to pressurise the cooler bank

07/09/2021 28
 OIL FILLING-3 of 3
 Upon completion, open the top cooler isolating valve in
order to equalize the pressure in the cooler with the
transformer tank
 Before filling oil into the conservator, the air cell/

bellow to be inflated to 0.5 psig i.E.0.035kg/cm2 max.

By applying pressure (N2/compressed dry air) so that it
can take
 Breather pipe attachment
 Filling rate maximum 2klph
 Oil filled from main tank

07/09/2021 29
 HOT OIL CIRCULATION
 Oil extracted from bottom valve in main tank and
poured in from top valve
 Oil heated in filter machine till 60 0c. Above 70 0c oil

oxidises
 Circulation done for at least 2 times of tank volume.
 (At freezing ambient temperature the circulation time is

increased, circulate 3 times the volume at temperature

down to minus 20 ° c, increase to 4 times below that
temperature)

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 OIL PARAMETERS BEFORE
CHARGING
 Break down voltage (BDV) : 70 KV (min.)
 Moisture content : 5 ppm (max.)
 Tan-delta at 90 °c : 0.01 (max.)
 Total gas content : < 1%
 Resistivity at 90 °c : 6 x 10 ohm-cm (min.)
 Interfacial tension : 0.035 n/m (min.)
 *Oxidation stability (test method as per iec 61125 ,method c, test duration:

500 hour for inhibited oil)

A) acidity : 0.3 (mg koh /g) (max.)
B) sludge : 0.05 % (max.)
C) tan delta at 90 °c : 0.05 (max.)
 * Separate oil sample shall be taken and test results shall be submitted

within 45 days after commissioning for approval of POWERGRID.

07/09/2021 31
 CONDITIONS FOR
TRANSFORMER/REACTOR TO BE WET

WET TRANSFORMER/REACTOR MEANS THE

SOLID INSULATION HAS ABSORBED
MOISTURE

 If transformer/reactor received without positive

pressure
 If dry air not used during erection activities
 Overexposure of active part of transformer/ reactor

during erection (overexposure when exposure > 12 hrs)

07/09/2021 32
PROCEDURE FOR DRYING OUT OF WET
TRANSFORMER/REACTOR-1 of 2
 Carefully watched and recorded
 Fire fighting ready as we deal with heat and inflammable oil
 All openings of main tank for conservator, cooler banks,

OLTC etc shall be isolated and blanked

 Fill tank with N2 till positive pressure of 0.15 kg/cm 2
 Keep for 24 hours
 During this nitrogen circulation, heaters installed around

tank till 70-80 0c achieved by the core & winding indicated

in OTI.
 Check dew point.

07/09/2021 33
PROCEDURE FOR DRYING OUT OF WET
TRANSFORMER/REACTOR-2 of 2
 If dew point ok then oil filling done else
 Vacuum done till pressure of 1-5 tor for 48 hrs with

less than 40ml/hour condensate

 If more than 40 ml/hour comes then up to 96 hours
 After this again nitrogen circulation for 24 hours with

heating done, then dew point checked

 If achieved then ok, IF NOT THEN NITROGEN

CYCLE WITH HEATING INCREASED FOR 48

HOURS

07/09/2021 34
AFTER TRANSFOMER/REACTOR IS READY
WITH OIL FILLING AND CIRCULATION,
STANDING TIME IS GIVEN AS GIVEN IN
THE TABLE AND DURING THIS FURTHER
TESTS ARE PERFORMED

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PRECOMMISSIONING TESTS-1 of 2
 Core insulation test
 Earth pit resistance measurement
 Insulation resistance (IR) measurement
 Capacitance and tan delta measurement of bushings
 Capacitance and tan delta measurement of windings
 Turns ratio (voltage ratio)measurement
 Vector group and polarity
 Magnetic balance test
 Floating neutral point measurement

07/09/2021 36
PRECOMMISSIONING TESTS-2 of 2
 Measurement of short circuit impedance
 Exciting/magnetising current measurement
 Operational checks on OLTC
 Tests/check on bushing current transformers (BCTs)
 Operational check on protection system
 Stability of differential, REF of transformer/reactor
 Frequency response analysis measurement (FRA)
 Winding resistance measurement
 Dissolved gas analysis (DGA)

07/09/2021 37
 CORE INSULATION TEST
 Done when the transformer/reactor is still on trailer, also
done when integrity of core insulation is affected, in
charged transformers when DGA indicates ethane,
ethylene and methane
 Disconnect the three terminals from each other ( core
clamp, core lamination and ground)
 Test the insulation between core clamp to ground and core
lamination to ground at 1kv ( should be > 10Mohm at 60
seconds )
 Connect the three terminals once again (normal condition)

07/09/2021 38
 EARTH PIT RESISTANCE
MEASUREMENT
 An earth tester kit is used
 Pit earthing connection removed from main grid
 Measurement by three point method
 Working of earth tester……
 Two spikes at a distance of 25m and 50m are placed in one line
 There is a dc generator
 Dc current converted to ac current using rectifier and fed to
spike to prevent electrolytic effect due to dc current
 Earth resistance is displayed which should be less than 1ohm, if
not the treatment with salt and charcoal is to be done

07/09/2021 39
 INSULATION RESISTANCE
MEASUREMENT-1 of 3
 Tests insulation between winding and tank and between
windings (rest of the windings being earthed)
 Neutral should be disconnected from earth
 A 5KV Insulation Tester is used

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INSULATION RESISTANCE
MEASUREMENT-2 of 3

07/09/2021 41
 INSULATION RESISTANCE
MEASUREMENT-3 of 3
 Two measuring factors, dielectric absorption
coefficient or index (DAI) & polarization index (PI)
 DAI=RATIO OF IR at 60 secs to IR at 15 secs, it

should be > 1.3 at 30 0C

 PI= RATIO OF IR at 600s to IR at 60s, it should be as

follows:-

07/09/2021 42
 CAPACITANCE AND TAN DELTA
MEASUREMENT OF BUSHINGS
 Measurement of loss in insulation of bushings
 Dissipation factor or loss factor (tan delta)= ratio of resistive
current to capacitive current
 Kit used= 10KV or 12 KV fully automated capacitance and tan
delta measurement kit
 C1 measurement in UST mode at 2KV and 10 KV (UST=
ungrounded sampling test mode)
 C2 in GSTg at 1KV (grounded sampling test with guard
mode )
 Limit is 0.5%
 WHAT IS C1 & C2 ?.....

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 CAPACITANCE AND TAN DELTA
MEASUREMENT OF WINDINGS-1 of 3
 The combination for C & tan ä measurement of
winding is same as that of measurement of IR value.

07/09/2021 44
 CAPACITANCE AND TAN DELTA
MEASUREMENT OF WINDINGS-2 of 3
 Winding combination for auto transformer.

07/09/2021 45
 CAPACITANCE AND TAN DELTA
MEASUREMENT OF WINDINGS-3 of 3

07/09/2021 46
TURNS RATIO MEASUREMENT
 Kit used= Automatic Transformer Turns Ratio Meter

07/09/2021 47
 VECTOR GROUP AND POLARITY-
Single Phase Transformers
 Purpose:- Paralleling of transformers

07/09/2021 48
 VECTOR GROUP AND POLARITY-
Three Phase Transformers
 Purpose:- Paralleling of transformers

07/09/2021 49
MAGNETIC BALANCE TEST-1 of 2
 Purpose:- Detect damage to winding during
transportation

07/09/2021 50
MAGNETIC BALANCE TEST-2 of 2

07/09/2021 51
 FLOATING NEUTRAL POINT
MEASUREMENT
 Purpose:- Detect fault in winding

07/09/2021 52
MEASUREMENT OF SHORT CIRCUIT
IMPEDANCE
 Purpose:- detect winding movement that usually
occurs due to heavy fault current or mechanical
damage during transportation or installation since
dispatch from the factory.

07/09/2021 53
EXCITING/MAGNETIZING CURRENT
MEASUREMENT
 Purpose:- It is performed to locate defects in the magnetic core
structure, shifting of windings, failure in turn to turn insulation or
problem in tap changers
 Change in reluctance of magnetic circuit thus affecting the current required
to establish flux in the core.
 Done before all DC tests ( DC may cause saturation of winding)
 Single phase voltage upto 10KV applied on one winding while the rest of
the winding are open

07/09/2021 54
 FREQUENCY RESPONSE
ANALYSIS(FRA)
 Purpose:- To assess the mechanical integrity of the
transformer which may get disturbed due to
transportation shocks.
 Done after erection and oil filling. Results compared with
factory value
 The FRA signatures should be analyzed in conjunction with
Impact Recorder readings

07/09/2021 55
07/09/2021 56
 WINDING RESISTANCE
MEASUREMENT-1 of 2
 Purpose:- It is carried out to calculate the I2R losses and to calculate
winding temperature at the end of a temperature rise test. It is also
done at site to ensure healthiness of a transformer that is to check
loose connections, broken strands of conductor, high contact resistance
in tap changers, high voltage leads and bushings etc.
 The winding resistance shall be preferably done when the difference in the
top and bottom temperature of the winding (temperature of oil in steady-
state condition) is equal to or less than 5 °C.
 The winding resistance should preferably be carried out last after
completion of all other LV tests, as after this test core gets saturated
and tests like magnetizing current, magnetic balance etc. carried out
after winding test may be affected and indicate a misleading results,
if the core is not de-magnetized before carrying out these tests.

07/09/2021 57
 WINDING RESISTANCE
MEASUREMENT-2 of 2
 Measurement done using Automatic Kit
 At all taps in forward and reverse direction, resistance
measured between HV to IV winding
 At normal tap between IV-N winding
 In LV winding between phases
 All the readings taken converted to reading at 75 0C with
formula

07/09/2021 58
OPERATIONAL CHECKS ON OLTC
 Purpose:- Tap changer functioning properly
 Manual operation of drive. Tap position in drive and TC should be same.
 Motor drive push button test. Should get switched off automatically after
one switching operation
 Changeover from 9b to 10 and vice versa requires high torque. Tap
changer end position to be checked to see there is no slipping over causing
failure
 Continuity of winding at all taps to be checked. At no point should the
voltage should indicate zero
 With the transformer energised at rated voltage and frequency but on no
load, one complete cycle of operation to be taken

07/09/2021 59
TESTS/ CHECKS ON BUSHING CURRENT TRANSFORMERS (BCTs)-1 of 2

 Continuity of all cores using multi meter

 Polarity using a 9V battery .
 Secondary winding resistance tests of individual cores of
Bushing CTs using a multi-meter
 Insulation Resistance Measurement of winding to earth and
between winding to winding for all HV, IV and LV turrets
 Current Ratio test:- Apply 20%, 40% and 80% of rated
current on the primary and measure the secondary current.
(Permissible limit: Protection core-±3% and Metering
core- ±0.5%)

07/09/2021 60
TESTS/ CHECKS ON BUSHING CURRENT
TRANSFORMERS (BCTs)-2 of 2
 Magnetising Curve Performance:- (Not done for metering
core)
 Purpose:- To check that the current transformer is
working in the linear region of its magnetising curve.
 Various values of Knee point voltage (0.25, 0.5,0.75, 1, 1.10)
applied to primary and then secondary current measured to
see the linear relationship of Voltage and current. It should
not saturate even at 1.1 Knee Point voltage

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DISSOLVED GAS ANALYSIS OF OIL
SAMPLE

07/09/2021 62
 OPERATIONAL CHECKS ON
PROTECTION SYSTEM
 Breather silica gel is blue in Main Tank, OLTC
 MOG level ok
 Marshalling Box and other kiosks OK
 Valves OK
 Checks on Cooling System such as (1) Checks on cooling fans-rotation,
speed & Control (Manual /temp /load) setting checks (2) Checks on
Cooling pumps- rotation, vibration/noise, oil flow direction
 OTI&WTI check, calibration, cooler control, alarm, trip settings
 Check on gas actuated relays such as PRD, Buchholz relay, Oil Surge
Relay
 Contact Resistance Measurement of Terminal connectors
 Checks on Transformer/ Reactor protection (differential, REF, Over-
current & stability tests etc.)

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 RESTRICTED EARTH FAULT
PROTECTION-1 of 3
 Purpose:- To detect faults within the
Transformer/Reactor

07/09/2021 64
 RESTRICTED EARTH FAULT
PROTECTION-2 of 3
 Two ways to conduct: (1) through Primary test Tap (M point)
if available (2) using actual earthing if M point not available
 Through Primary Test Tap
 Measure the spill current in REF relay which should be nearly zero.
 Switch off Current Injection.
 Reverse the polarity of R phase Bushing CT and again start Current
Injection.
 Appreciable spill current will appear in REF relay.
 Repeat the same procedure for Y and B phases and note down the
results.
 This test has to be performed from both HV side & LV side w.r.t.
Neutral.
Testing of Reactor will be done similarly

07/09/2021 65
 RESTRICTED EARTH FAULT
PROTECTION-3 of 3
 Primary test tap not available
 Apply 440V three phase voltage at three phase bushing of H.V. side with
 the help of three phase variac.
 Earth the R phase of the LV side (through isolator earth switch or
discharge rod).
 Measure the spill voltage (in mV)/ spill current (in mA) at REF relay
which should be nearly zero.
 Reverse the polarity of R phase Bushing CT and again switch on 440V
supply.
 Appreciable spill voltage/ current will appear in REF relay.
 Repeat the same procedure for Y and B phases and note down the results
in formats.
.
Testing of Reactor will be done similarly

07/09/2021 66
 CHECK LIST FOR ENERGISATION OF
TRANSFORMER/ REACTOR-1 of 2
 Release air at the high points, like oil communicating bushings, buchholz
petcock, tank cover and the cooling devices including headers, radiators,
pumps, expansion joints etc. of the transformer. Air release should be resorted
from low points to high points.
 Check tightness
 Check that the valves are in the correct position
 Silica gel in breather is blue and oil cup is fill with oil
 CC, CL properly grounded
 Check oil level in main tank and OLTC conservators, bushings
 Connection of terminal connectors
 Bushing CT terminal properly shorted and earthed
 Neutral bushing earthed
 Tan delta test taps earthed

07/09/2021 67
 CHECK LIST FOR ENERGISATION OF
TRANSFORMER/ REACTOR-2 of 2
 Tap position should be same at control cubicle and the tap head
 Step by step operation- local and remote electrical operation as well as manual operation and parallel
operation, if any
 Electric and mechanical limit switches and protective relays
 Oil parameter results should conform to the limits mentioned
 Check OTI and WTI settings
 Ensure oil in thermometer pockets as well as OTI and WTI pockets
 Installation of buchholz relay, Oil surge relay, PRD
 Check Insulation resistance of auxiliary circuit at 2KV
 Check the earthing of main tank and cooler banks at two different places
 Measure the supply of the auxiliary circuits
 Check the direction of installation of oil pumps
 Check the direction of rotation of the pumps and fans
 Check the working of the oil flow indicators
 Check the setting of the thermal overload relays, heating and lighting of cubicles
 Check the protection of the Transformer/reactor

07/09/2021 68
 POST COMMISSIONING CHECKS/TESTS
FOR TRANSFORMERS AND REACTORS

 Thermo-vision Scanning:- To be done after 24 hours of charging to detect

any hot spots and then after a week.
 Oil sample to be sent after 24 hours of charging for DGA testing
 Online Moisture measurement
 Vibration measurement of reactors :-Movement of the core-coil assembly
and shielding structure caused by the time –varying magnetic forces
results in vibration of the tank and ancillary equipment. These
vibrations have detrimental effects such as excessive stress on the core-
coil assembly

07/09/2021 69
Thanks

07/09/2021 70
 CHARGING OF
TRANSFORMER/REACTOR
 Just before charging, an oil sample has to be taken for DGA, BDV, and
moisture measurement
 The equipment charged from incoming side whether 400 or 220 KV on no
load
 Initial Magnetising current is very high depending upon the moment of cycle
 Transformer should be kept on no load for 12 hours
 During this time, vibrations, abnormal cracking noise, etc. are to be observed
 After that it may be checked for gas collection.
 After successful charging, performance of transformer / rector should be
checked under loading; OTI/WTI readings should be monitored for 24 hours
and ensured that they are as per loading.
 DGA samples may be sent as per Standard practice (after 24 hrs of
energizing, one week, 15 days, one month and three months after charging,
thereafter as per normal frequency of 6 months ).

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