MODULE - 19

MAIN TRANSFORMER, STEP DOWN TRANSFORMER

AND GENERATOR CIRCUIT BREAKER
LOCAL OFFICE TRAINING COURSE

PUBLIC INTERNAL RESTRICTED CONFIDENTIAL

1
Description and Functions of Different Components

 PURPOSE
- This training course is necessary for introducing the inexperienced power plant personnel to the basic concepts and
theory of power station equipment and design; and has been specifically designed to cover the general aspects of
all major power plant equipment and systems within DATAN 7 Add-on Combined Cycle Power Plant scope. This
course also serves as a state-of-the-art review for more experienced personnel.

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CONTENT

Part 1 Description and Functions of Different Components

Part 2 Control of Dielectric strength of transformer oil

.
Part 3 Monitoring & Control of temperatures of transformers

Part 3 Principles of operation and maintenance criteria

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Description and Functions of Different Components Main Transformer

• Main Transformer (Generator Step-up Transformer: GSUT ST7) has two windings (one is delta connect and
another is star connected). The neutral point of the HV winding will be either isolated or solidly earthed depending
upon system operating conditions (shifted by Surge Arrester (LA) and Earthing Switch (DS: STT7N)). GSUT ST7
LV side is connected to Generator (STG7) through Isolated Phase Bus Duct (IPBD). GSUT ST7 HV side is
connected to 161 kV GIS through 161 kV XLPE cable. GSUT ST7 parameters are given below:
Rated Capacity: 386 MVA
Rated Voltage for HV Winding: 161 kV
Rated Voltage for LV Winding: 15.6 kV
Cooling: Oil Directed Air Forced (ODAF)
The high voltage winding of GSUT ST7 is equipped with manual de-energized tap changer.

- Functions:

 GSUT ST7 transmits the generated power to 161 kV GIS.

 Manual de-energized tap changer of GSUT ST7 regulates the voltage of 161 kV side if it is required.

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Description and Functions of Different Components Main Transformer
• Please refer to attached Annexure-A for the General Arrangement drawing for the Transformer. Different
Components of Main Transformer (Generator Step-up Transformer: GSUT ST7) and their functions are
described in the next slides:

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Description and Functions of Different Components Main Transformer

• Dial Type Temperature Indicator:

Dial Type Temperature Indicator for LV Winding.
Dial Type Temperature Indicator for Oil.
Typical alarm- and trip value (Ref: Similar Project):

- Functions: Indicates temperature in local and

provides signals to remote through contacts for
both the windings and Oil during alarm and trip condition.

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Description and Functions of Different Components Main Transformer

• Online Dissolved Gas and Moisture Monitoring Equipment:

It continuously measures the concentration of fault gases (H2, CO) dissolved in the transformer oil. It also
measures moisture (H2O). It helps to detect of transformer faults in early stage and can play an important role in
transformer asset management. A high-reliability solenoid pump draws oil from the transformer into the device
through the oil supply line. Once the oil has been analyzed, it is returned to the transformer through the oil return
line. It’s monitor accepts any supply voltage from 100 to 240 VAC with frequencies in the range of 50 to 60 Hz, and
from 100-220 VDC.

Make:

Model:

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Description and Functions of Different Components Main Transformer

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Description and Functions of Different Components Main Transformer

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Description and Functions of Different Components Main Transformer

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Description and Functions of Different Components Main Transformer

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Description and Functions of Different Components Main Transformer
 Functions:

 Gas Measurement: Thermal conductivity cell offers superior gas measurement range and accuracy.

 Dissolved Moisture Measurement: Capacitive sensor provides continuous and accurate readings of dissolved
moisture. Time-average and load-dependent moisture-in-oil readings can be used to estimate moisture absorption
in the cellulose insulation, a key risk factor for cellulose lifetime loss.

 Display and Data Transmission: For an easy integration of the monitor within existing operations, it has
numerous connection options and come standard with DNP3 and Modbus communication protocols. An optional
IEC61850 communication kit is also available.

 Continuous Enclosure and Oil Temperature Conditioning: It precisely control the oil temperature for both gas
extraction and moisture measurements. Also, the enclosure temperature is carefully regulated to ensure constant
conditions for the gas measurement system.

 Oil Sampling: Oil sample for testing can be collected by using this equipment.

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Description and Functions of Different Components Main Transformer

• Buchholz Relay:
Double element Buchholz Relay can be used for detecting minor or major faults. The relay should be mounted
in the connecting pipe between the transformer and the conservator tank. This pipe should be as long and as
straight as possible, and must be arranged to slope upwards, towards the conservator, at an angle within the
limits of 3 to 7 degrees to the horizontal.

Make:
Model: 3DE/VO
DE: Double Element Relay.
3 : Suitable for 3 inch Pipe.
V: V means vibration. It means relay has reed switch.
O: Contact Remains normally open

Shock and vibration acting on conventional Mercury switch can cause a maloperation of the relay without any
fault. Magnet operated Reed switches were selected specifically for this purpose and has the following features:
 Ability to withstand power frequency vibrations up to 100 Hz.
 Ability to withstand vibration due to earthquake and blasting.

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Description and Functions of Different Components Main Transformer

The operating mechanism consists of a solid non-metallic cylinder (switch cylinder) containing the reed switch and
counterbalanced by a smaller solid metal cylinder. Both cylinders are jointed and free to rotate about the same axis.
The rotation of this mechanism is controlled by two stops. The reed switches are spring mounted within the switch
cylinders and protected from possible damage.

– Oil level shall be settable between 200 cc to 300 cc to operate the alarm contact.

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Description and Functions of Different Components Main Transformer

Functions: Normal Operation

 When the relay is empty of oil, the weight of the switch cylinder predominates and the switch system rests against
the bottom stop, the reed switch being in the closed-circuit position.

 Under normal conditions (full of oil), the operating force relies upon the below principle:

When a body is immersed in a liquid it appears to lose weight.

 When the relay is full of oil, both cylinders lose weight. Due to the different densities, the switch cylinder appears to
lose enough weight in comparison to the counterbalance cylinder. Hence counterbalance cylinder predominates
and rotate the whole system until it reaches the top stop, with the reed switch being in the open-circuit position.

Functions: Alarm Operation

 This operation happens when a specified volume of gas has collected in relay in case of incipient faults (below):
• Broken-down core bolt insulation and shorted laminations of core.
• Bad Electrical contacts (Sparking) and overheating of part of the windings.
• Oil leakage from the tank/radiators/tubes.
• Air ingress in the oil due to circulating pump mal-function.

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Description and Functions of Different Components Main Transformer

 In this case, the gas generated will collect in the top of the relay housing. As gas collects, the oil level will fall. This
results in gradual restoration of the apparently lost weight of the switch cylinder. It brings the magnet of the reed
switch into a position where it operates the alarm contact.

Functions: Trip Operation

 The trip element will be operated by an oil surge in the following fault conditions:
• Winding short circuits and earth fault.
• Puncture of bushings.
 In this case, the generation of the gas is so rapid that an oil surge is set up and it impinge upon the flap fitted to
operating mechanism to rotate about its pivots. Hence this operation brings the magnet of the reed switch into a
position where it operates the trip contact.

Function: Alarm and Trip Operation

 In the event of rapid oil loss from the transformer, both alarm and trip contacts operate (alarm contact first, then
trip contact). Alarm Operation and Trip Operation for this case have already been discussed above.

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Description and Functions of Different Components Main Transformer

• Conservator:
 Oil-immersed transformer operates with long stability. Hence prevention of the deterioration (oxidation) of the
oil is required. Oxidation is caused due to contact of oil with air, it increases due to oil temperature rise and
the presence of copper and iron. Conservator is an ideal device for resolving these problems by
preventing the deteriorated of the insulating oil.

 Make: Air Seal Cell Co. Ltd.

 Model: Air Seal Cell AP .

 In Air Seal Cell AP, the oil surface is completely isolated from the atmosphere by installing an oil-resistant
rubber cell in the interior of the conservator, so that atmospheric pressure is always maintained without
the necessity of employing intervening mediums. This prevents generation of air bubbles within the oil
and the condensation of moisture originating within the gas-filled space. The conservator is made of high-
grade cast iron and the tempered glass is used for the peep window. A gas vent cock is installed at the
top of the container to collect the gases.

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Description and Functions of Different Components Main Transformer

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Description and Functions of Different Components Main Transformer

Gas Detectors: Detectors are installed at the highest part of the conservator, which is filled with
transformer oil under normal conditions. If an abnormality originates in the rubber cell(rupture) and
atmospheric air invades the interior of the conservator, it will concentrate around the gas detector, to
activate the mercury switch interlocked-to the float in the interior and generate an alarm. Conditions can
also be observed through the peep window.

Vacuum Deaeration Oil Filling Method is used to save the rubber cell of conservator from abnormal
forces. Hence vacuum valve, vacuum equalizing, vacuum pump are used for this purpose.

Dial Type Oil Level Gauge for Conservator: It indicates the oil level of the main transformer. When the
oil level attains a low value (0.2), it activates the alarm contact for remote indication. High level of oil is
indicated by 9.8. If the rubber cell breaks the insulating oil will enter into the cell. The rubber cell will
then gradually be lowered into the oil by its own weight, until on reaching the bottom, the low oil
level alarm will be activated.

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Description and Functions of Different Components Main Transformer

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Description and Functions of Different Components Main Transformer

• Cooler:
 Insulating oil heated up by the
transformer heat loss, flows in the upper
portion of the tank, then transmits into
cooler tubes. Then the hot oil cools down
by exchanging the heat with air while
flowing through tube. Finally, the cooled
oil is forced (by oil pump) to flow into the
transformer tank at the bottom elevation.
Ambient air is drawn by the blowers
installed in the cooler and then flows on
the surface of the tube and exchange
heat with the hot oil.

 Make: TATA Electric Company.

 Model: NEFP Type Standard Cooler.

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Description and Functions of Different Components Main Transformer

• Cooler Control Cabinet: Local control of

coolers are done from cooler control
cabinet.

• Dehydrating Breather: It removes dust

and moisture from the air which enters into
the conservator rubber cell during
breathing of transformer. During breathing
process, atmospheric air passes through
the vinyl sponge filter and the oil at the
bottom. So dust in the air eliminates then
air passes through cobalt chloride
impregnated silica gel (blue colour) to
absorb moisture. Finally, dry air enters into
the conservator rubber cell. Silica gel
colour turns into white when it is fully
absorbed by moisture.
 Make: Shihlin Silica Gel Breather

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Description and Functions of Different Components Main Transformer

• Gas Sampling Device: It is

connected to Buchholz relay
through a tube and helps for
sampling of gas collected in the
Buchholz relay. So, downtime of
the transformer is reduced.

Function: Sampling device is

normally filled with oil. When the
upper switch of the Buchholz relay
operated, gas is filled in the
Buchholz relay. Then the gas flows
into the sampling device. Now the
Buchholz relay is filled with oil
again. The gas can be collected
from oil sampling device by
operating gas outlet cock.

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Description and Functions of Different Components Main Transformer

• Oil Flow Indicator: It is fitted on an oil

circulating pump circuit

Function: It checks whether the oil

flows normally or not. When oil does not
flow, then the indicator comes at an
angle from vertical angel (marked by
STOP).

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Description and Functions of Different Components Main Transformer

• Partial Discharge (PD) Monitoring Device: Most frequent and

potential reason for power transformer failure is damage of insulation.
Partial discharge is one of the main reason for transformer failure. It is
the localized electrical breakdown in the small portion of the solid or
fluid insulation system which is under high voltage stress. Partial
discharge sensor detects insulation defects (corona, surface tracking,
arcing, voids). Partial discharge is mainly dependent on the voltage
stress. Comparison of other test methods with partial discharge
measurement are given below

Tan delta test can pass the defected insulator. But the same defect is
detected in PD sensor.

Insulation resistance test and several voltage tests can pass the
defected insulator. But the same defect is detected in PD sensor.

Dissolved gas analysis method can detect insulation failure in

transformer oil. But it can not detect the exact location of insulation
failure. But the same defect is detected in PD sensor.

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Description and Functions of Different Components Main Transformer
Dielectric strength of insulation decreases due to void formation inside insulation and the breakdown occurs in
form of sparks. Hence high frequency electromagnetic wave generates for nanosecond to millisecond range.
Thus, it degrades the insulation strength.

Partial discharge test is applicable the equipment rating over 3 kV. It should be done during equipment factory
acceptance test and type test. Online monitoring is a good solution for running equipment as preventive measures
to reduce downtime of the equipment. It can be measured in transformer, cable, MV and LV switchgears, bushing
insulators.

Make: Smart Diagnostic Monitoring Technologies Limited

Model: PDS-713 (UHF Partial discharge Sensor)
Ultra High Frequency (UHF: 200 MHZ to 1 GHZ) sensors should be installed as far as possible between each
other, in order to improve the precision of locating PD source when needed. Usually, 3 or 4-sensor installation is
recommended for detecting PD source in a transformer on at least two sides to achieve three-dimensional
positioning. Installation of three or four sides is recommended.

UHF sensors can also be installed on the top of the transformer tank can monitor the defects of the connecting
portion of bushing.

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Description and Functions of Different Components Main Transformer

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Description and Functions of Different Components Main Transformer
• No Voltage Tap Changer: Tap changer is moved from one position to another, the amount of the tap winding
connected into the circuit is changed. This movement changes the voltage ratio of the transformer. The de-
energized tap changer is usually installed into the high voltage circuit of the transformer and, most of the time, it is
used to adjust the primary voltage of the transformer within a 10 percent range in five steps.

Make: ABB
Type: DTW
Tap changer must be operated only when the transformer is completely de-energized. Never operate this type of
tap changer when the transformer is energized. Operation when the transformer is energized is dangerous and will
result in severe personal injury, property damage or death. he type DTW tap changer is a modular, bridging-type
(zigzag) tap changer with external operating mechanism. The tap changer is mounted in front of each phase coil,
parallel to the side of the transformer tank. The tap changer is supported by an insulating framework, which is part
of and attached to the transformer super-structure. It is composed of the following components:

Tap Deck: The type DTW tap changer is made up of individual tap decks (one or more per phase). It is unshielded
type and made of flat insulating plate and holds and orients both the moving and stationary contacts. It is bolted to
the transformer framework through the six bolt holes, which are located at each end of the tap deck. The tap decks
are connected to a common set of horizontal operating shafts through individual gear sets. The gear sets and
operating shafts are mounted on the tank wall-side.
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Description and Functions of Different Components Main Transformer

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Description and Functions of Different Components Main Transformer

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Description and Functions of Different Components Main Transformer
Stationary Contacts: It is made of silver platted copper and connected (bolted connection) to tap deck through
tinned copper mounting post (bolted connection).

Moving Contacts: The moving contact (copper flat) is the spring-loaded contact slides over the stationary
contacts. It is tipped with semi-spherical silver contact to maintain a positive, low resistance current path

Driving mechanism: It consists of the following elements:

 Worm Gear Set: The worm gear set is mounted to the tank wall side of the tap. This gear is contained within a
cast metal housing to hold the gear set. One full turn of the drive shaft rotates the moving contacts from one set
of stationary contacts to the next (30-degree rotation). The
worm driver terminates in a ball-shaped shaft end.

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Description and Functions of Different Components Main Transformer
 Interphase Shafts: The inter-phase shafts
are filament wound glass epoxy tubes and
slides over the ball-ends of the worm gear
drive shaft creating a ball-and-socket type of
joint. Each inter-phase shaft consists of two
pieces which telescope together. This
telescoping action allows the tap changer to
accommodate a range of phase-to-phase
spacing and eliminates the need for precise,
cut-to-length shafts. The telescoping action
makes assembly easy, accommodates some
misalignment and accommodates movement
due to thermal expansion of the transformer.

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Description and Functions of Different Components Main Transformer
 Telescoping input drive shaft: The telescoping input drive
shaft connects the external operating mechanism (in one end) to
the worm driver ball-shaped shaft end (in another end).

 Operating Mechanism: The operating mechanism (welded to

transformer tank) is sealed and drives the tap changer’s input
drive shaft. Generally, one revolution of the operating
mechanism moves the tap changer one position. However, there
are applications, where more than one revolution is required to
advance to the next position. A tap indicator dial is present in
the view port of the operating mechanism. It shows the number
of the tap position. A position number is only fully visible when
the tap changer is in position. To make a tap change, the
operator must perform two separate actions: pull the locking pin,
which frees the mechanism shaft and turn the operating handle.
The locking pin will not fully re-seat itself unless the tap changer
is fixed on a position. The tap changing mechanism contains
built-in positive mechanical stops, which prevent turning past the
lowest and highest positions.

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Description and Functions of Different Components Main Transformer

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Description and Functions of Different Components Main Transformer
 Double Deck Type Tap
Changer: In this tap changer,
an additional gear box is
needed when the transformer
has two rows of tap decks or
whenever the operating
mechanism is not in line with
the deck. The additional gear
box is mounted in the same
manner as the operating
mechanism. The telescoping
input drive coupled to the
additional gear box with the
worm driver ball-shaped shaft.
The connecting shaft assembly
between the operating
mechanism and the additional
gearbox allows the external
mechanical.

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Description and Functions of Different Components Main Transformer
• Pressure Relief Device: There
are two pressure relief device
mounted on the top of
transformer tank.

Make: Qualitrol, Model:

Series 208-60

Function: When short circuit

occurs, the transformer oil
vaporize and built the excessive
pressure. This pressure gets
released by pressure relief
device operation. Qualitrol
Series 208-60 opens within 2
millisecond.

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Description and Functions of Different Components Main Transformer
• Pump: It is used to
circulate the transformer oil
so that it gets cooled.

Make: TEIKOKU
ELECTRIC MFG. CO. LTD.

Model: QK Series

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Description and Functions of Different Components Main Transformer
• Sudden Oil Pressure Relay: It is safety device which protects the transformer from potential damage caused by
internal faults. This relay is mainly to be installed the tank side of a transformer and uses microswitch for the
electric contact , which ensures switching and high reliability.

Make: HYODA INSTRUMENTS CORPORATION

Type: PVOA-Y2-2
Function: This relay quickly responds to fluctuations in the internal pressure and works even if a pressure
difference is slight. Therefore, the time between the occurrence of an accident and shutdown can be
extremely shortened.

When the internal pressure of the transformer tank rises rapidly due to an accident in the transformer,
the hydraulic pressure compresses the pressure-receiving bellows, which pushes up the movement
bellows. The motion of the top of the movement bellows pushes in the microswitch lever activating the
contact.

If hydraulic pressure fluctuation in the transformer are negligible, the microswitch will not be activated
regardless of the numerical value of the pressure.

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Description and Functions of Different Components Main Transformer

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Description and Functions of Different Components Main Transformer
• Sudden Oil Pressure Relay: It is safety device which protects the transformer from potential damage caused by
internal faults. This relay is mainly to be installed the tank side of a transformer and uses microswitch for the
electric contact , which ensures switching and high reliability.

Make: HYODA INSTRUMENTS CORPORATION

Type: PVOA-Y2-2
Function: This relay quickly responds to fluctuations in the internal pressure and works even if a pressure
difference is slight. Therefore, the time between the occurrence of an accident and shutdown can be
extremely shortened.

When the internal pressure of the transformer tank rises rapidly due to an accident in the transformer,
the hydraulic pressure compresses the pressure-receiving bellows, which pushes up the movement
bellows. The motion of the top of the movement bellows pushes in the microswitch lever activating the
contact.

If hydraulic pressure fluctuation in the transformer are negligible, the microswitch will not be activated
regardless of the numerical value of the pressure.

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Description and Functions of Different Components Main Transformer
 Bushing: There are two types of bushings:

 Solid type bushing: This bushing is typically made with a central conductor and porcelain or
epoxy insulators at either end and is used primarily at the lower voltages ( e.g 36 kV). Please
refer to attached Annexure-B for the detailed drawing of soild type bushing.

 Capacitance-graded (Condenser type) bushing: To limit the partial-discharge levels,

capacitance-graded bushing is used in higher voltage application. Condenser bushings should
include the protection against internal insulation breakdown and external flashover. There are
following type of condenser buhing:

• Oil Impregnated Paper (OIP) Bushing: Most common type of condenser bushing. Please
refer to attached Annexure-B for the detailed drawing of OIP bushing.

• Resin Impregnated Paper (RIP) Bushing: Most latest technology and costly in
comparison to OIP bushing. In this bushing, insulation paper will be impregnated with
epoxy resin which will give us dry and void-free bushings. SF6 or foam is used instead of
oil (OIP bushing). Fibre glass reinforced epoxy resin with shed is used as outer insulator
instead of porcelain. Porcelain housing catching flashover under wetting which will not be
happening in the case of silicone rubber. Please refer to attached Annexure-B for the
detailed drawing of RIP bushing.
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Description and Functions of Different Components Main Transformer
 Resistance Thermometer for Oil and Winding
Temperature (RTD): Resistance Thermometers
are used widely from -200 to + 6600 °C in
different processes to measure temperature.
Especially at low temperature, resistance
thermometers are preferred since their accuracy
is much better than thermocouples. Pt-100 and
Ni-100 elements have 100 ohms resistance value
at 0 °C. RTD changes the resistance due to
temperature change and generates electrical
signal (4-20 mA). It is used for windings and oil
temperature measurement.

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Description and Functions of Different Components of Step Down Transformer
 Components of Step Down Transformer are generally same (except the OLTC) as Main Transformer . For all the
component details and their functions for Step Down Transformer (Unit Auxiliary Transformer), please refer to the
previous slides. OLTC of Step Down Transformer is described below:

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Description and Functions of Different Components of Step Down Transformer

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Description and Functions of Different Components of GCB
 For general idea of all the component details and their functions, please refer to the Annexure-D prepared
from the operation manual of a similar type reference project.

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Control of Dielectric Strength of Transformer Oil

• Control of dielectric strength of transformer oil is done by the dissolved and undissolved gas analysis.

Dissolved gas analysis: It is done in case of buchholz alarm or trip. Sampling oil should be taken from the top
and middle location of transformer tank. It should also be done once in a year for checking of break down voltage
(BDV), chemical & physical properties. When C2H2 gas is found in the dissolved gas analysis results of insulation
oil , the transformer should be disconnected from supply as soon as possible because the gas can make some
explosion inside the transformer sooner. The measurement of the dielectric strength, acid value, resistively and
tangent δ is an excellent guide to determine whether the oil has deteriorated. Generally, the dielectric strength and
acid value are normally evaluated during maintenance. If these evaluations give unsatisfactory results, then only
further tests must be carried out on the insulating oil by authorized party. The samples should be taken before the
transformer is started up, after a longer period of operation or in case of breakdown.

Undissolved gas analysis: It is done in case of buchholz alarm or trip or if gas is found during regular checking.
Sampling gas should be collected from the inspection window compartment of the buchholz relay.

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Control of Dielectric Strength of Transformer Oil

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Control of Dielectric Strength of Transformer Oil

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Control of Dielectric Strength of Transformer Oil

If breakdown voltage is less then,oil filtration or replacement is required as per manufacture's guideline.

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Control of Dielectric Strength of Transformer Oil

If resistivity is fair or poor, oil filtration or replacement is required as per manufacture's guideline.

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Control of Dielectric Strength of Transformer Oil

If water content is fair or poor, oil filtration or replacement is required as per manufacture's guideline.

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Monitoring & Control of temperatures of transformers

• Monitoring:

- Local Monitoring: Transformer windings temperature and oil temperature are monitored locally by dial type
temperature indicators.

Remote Monitoring: Transformer windings temperature and oil temperature are detected by resistance
thermometers (RTD) and displayed in DCDAS (remote).

Alarm Signals:
 OIL TEMP HI.
 WDG TEMP HI
 BUCHHOLZ ALARM
 OIL LEVEL
 COOLER POWER FAIL
 AUXILIARY POWER FAIL
 COOLER FAULT

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Monitoring & Control of temperatures of transformers
- Trip Signals:
 OIL TEMP HI HI
 WDG TEMP HH TRIP
 BUCHHOLZ TRIP
 PRESSURE RELIF TRIP
 NLTC FAULT TRIP
Transformer temperature is controlled by the operation of Fan and Pumps.
Unit Transformer
Oil Natural Air Natural (ONAN): At low load, the transformer operates in natural ventilation (without fan).
Oil Natural Air Forced (ONAF) : At nominal load, the transformer operates in forced ventilation( with fan).
 Generator Step Up Transformer
ODAF or Oil Directed Air Forced Cooling of Transformer is the improved version of OFAF. Forced circulation
of oil directed to flow through predetermined paths in transformer winding. The cool oil entering the transformer
tank from cooler or radiator is passed through the winding where gaps for oil flow or pre-decided oil flowing paths
between insulated conductor are provided for ensuring faster rate of heat transfer.

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Principles of operation and maintenance criteria
• Operation of Unit Auxiliary Transformer Cooler:

- Manual operation for fans from Local Control panel:

 Local/ Remote (L/R) Selector Switch Position: Local.
 Automatic/ manual (A/M) selector switch: Manual.
 Press start pushbutton for fans starting operation and press stop pushbutton for fan stopping operation.
Manual operation for fans form DCDAS:
 Local/ Remote (L/R) Selector Switch Position: Remote.
 Start command is issued for fan starting and stop command is issued for fan stopping.
Automatic operation for fans form Local Control panel:
 Local/ Remote (L/R) Selector Switch Position: Local.
 Automatic/ manual (A/M) selector switch: Automatic.
 Start or Stop of fans done automatically by sensing the temperature of winding and oil.
Automatic operation for fans form DCDAS:
 Local/ Remote (L/R) Selector Switch Position: Remote.
 Command for Automatic operation for fans are issued from DCDAS.
 Start or Stop of fans done automatically by sensing the temperature of winding and oil.
 
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Principles of operation and maintenance criteria
• Operation of Generator Step Up Transformer Cooler:

- Manual operation for fans from Local Control panel:

 Local/ Remote (L/R) Selector Switch Position: Local.
 Automatic/ manual (A/M) selector switch: Manual.
 Press start pushbutton for fans starting operation and press stop pushbutton for fan stopping operation.
- Manual operation for pumps from Local Control panel:
 Local/ Remote (L/R) Selector Switch Position: Local.
 Automatic/ manual (A/M) selector switch: Manual.
 Press start pushbutton for pump starting operation and press stop pushbutton for pump stopping operation.
Manual operation for fans form DCDAS:
 Local/ Remote (L/R) Selector Switch Position: Remote.
 Start command is issued for fan starting and stop command is issued for fan stopping.
Manual operation for pumps form DCS:
 Local/ Remote (L/R) Selector Switch Position: Remote.
 Start command is issued for pump starting and stop command is issued for pump stopping.

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Principles of operation and maintenance criteria
• Operation of Generator Step Up Transformer Cooler:

- Manual operation for fans from Local Control panel:

 Local/ Remote (L/R) Selector Switch Position: Local.
 Automatic/ manual (A/M) selector switch: Manual.
 Press start pushbutton for fans starting operation and press stop pushbutton for fan stopping operation.
Automatic operation for fans and pumps form Local Control panel:
 Local/ Remote (L/R) Selector Switch Position: Local.
 Automatic/ manual (A/M) selector switch: Automatic.
 Start or Stop of fans and pumps done automatically by sensing the temperature of winding and oil.
Automatic operation for fans and pumps form DCDAS:
 Local/ Remote (L/R) Selector Switch Position: Remote.
 Command for Automatic operation for fans and pumps are issued from DCDAS.
 Start or Stop of fans and pumps done automatically by sensing the temperature of winding and oil.
 

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Principles of operation and maintenance criteria
• Operation of Unit Auxiliary Transformer On Load Tap Changer:

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Principles of operation and maintenance criteria
• Operation of Generator Step UpTransformer No Voltage Load Tap Changer: It is done by rotating the
operating handle of the operating mechanism.

 Operation of Generator Circuit Beaker: Please refer to the Annexure-E for the Operation.

 Maintenance Criteria of Unit Transformer (GSUT) and Step Down Transformer:

- a: Daily inspection, b: Schedule maintenance

 Transformer Tank and Conservator

Checking the oil and winding temperature (a): Read and note down the oil and winding temperature. If the
temperature is high find out whether the oil or winding temperature is caused due to overloading of transformer
for long duration or insufficient cooling. Take corrective measures.

Checking the dehydrating breather (a): To prevent moisture from entering the preservative, the silica gel (KC
granules) must be changed when the top layer of active ingredient has decreased to the red line. Also check
the level (red marked) of the oil sealing. Also check the level (marked in red) of the oil seal.

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Principles of operation and maintenance criteria
 Transformer Tank and Conservator

Checking the oil levels (a): The oil levels in the conservator or other vessels must be checked by reference to
the sight glasses or oil level indicators. The oil levels must be corresponding to the temperature markings on
the indicators. If the oil level is low, new dried oil shall be poured in the transformer after checking of leakage.

Checking the flanged joints and welds for oil leakage (a): All flanges, seals and welds must be checked for
oil leaks. Leaks, if any, must immediately be sealed by retightening the corresponding nut and bolts, replacing
the seals or by welding. Welding should only be done by an experienced welder or specialist from OEM may be
called such job. All applicable accident prevention regulations must be observed, in particular the fire protection
measures for work on oil transformers.

Noise (a) : Check any abnormal sound and vibration etc. Learn by hearing an average & regular sound; If an
irregular noise is heard, compare with remembered normal sound and further investigation should be done
immediately. Loose parts will vibrate when the transformer is running and add to the existing humming sound.

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Principles of operation and maintenance criteria
 Transformer Tank and Conservator

Checking the paint finish and cleaning the surface (b) : Clean the painted surface with a solvent soaked
rag or a steam jet blower. Mud, oil and grease must be completely removed. Grind the old paint coat slightly
and remove those parts where the coat that are loose. Brush the rusty parts by means of a wire brush until
bright metal surface appeared. The de-rusted parts shall then be covered with two coats of prime and then a
finish coat. The old paint coat that has slightly been ground and still adheres firmly to the metal ground must be
covered with finishing paint. If the old paint coat is very brittle and does not adhere firmly to the metal, it should
be completely removed by shot-blasting or by means of a paint stripper. The surface should then be covered
with a complete paint coat.
Checking the earthing systems (protective earthing) (a): In order to prevent current loops, the
transformer tank and the cooling system (if any), must be earthed with one earthing conductor of sufficient
cross section. Check that the earthing screw is correctly tightened and re-tighten it if necessary.

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Principles of operation and maintenance criteria
 Transformer Tap Changer

On Load Tap changer (a)

 Check operating sounds.

 Check whether the tap position is correct or not.

 Record the number of tap changing operations.
 Check the oil level gauge of OLTC conservator.
 Traversing all taps for cleaning the tap selector contacts If the tap changer is operated less than 3000 times
a year or is not moved through the entire tapping range, all taps should be traversed about 10 times on
(with the transformer de-energized) for the purpose of contact cleaning whenever the equipment is under
service.
 Motor Drive Unit: Check anti-corrosion coating of enclosure door gaskets and lock.
 Motor Drive Unit: Check cable termination.
 Motor Drive Unit: Check step-by-step control, locally and from control room limit switches, electrical and
mechanical checks contact deck and position indication
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Principles of operation and maintenance criteria
 Transformer Tap Changer

On Load Tap changer (a)

 Motor Drive Unit: If the motor drive housing is exposed to strong external vibrations, all bolts should be
checked for tight fit and re-tightened as far as necessary.
 Motor Drive Unit: If the motor drive housing is exposed to strong external vibrations, all bolts should be
checked for tight fit and re-tightened as far as necessary.
Off-load tap changer (b)
 Traversing all taps for cleaning the tap changer contacts: The copper parts of the contacts are
tarnishing when immersed in oil. The tarnishing film may cause a temperature rise of the contacts. The off-
load tap changer should therefore be moved through the entire tapping range (with the transformer de-
energized) at least once in a year for the purpose of cleaning the contacts.
 Checking the interlock: The end positions are secured mechanically. When the end position is reached,
the tap changer can only be moved in the opposite direction.

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Principles of operation and maintenance criteria
 Transformer Cooling system

Checking of Valve position (a)

 Checking the butterfly valves for correct position
 Check position of valves according to the label “Position of shutoff devices”.
 Checking the flanged joints and welds for oil leaks

Checking the oil circulating pumps (b): Before starting work on oil circulating pumps, ensure that the pumps
supply module is switched off isolated. Maintenance work is basically confined to monitoring the bearings. If
allowed by operating conditions, the bearings should be removed and cleaned after an interval of 2 years or as
soon as irregularities become apparent during operation.
Checking the fans (a): Fans shall be checked after a time interval of six months.
Cleaning the fans (b): The fans must be cleaned from time to time at least once in a year. Cleaning should be
done by compressed air.

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Principles of operation and maintenance criteria
 Transformer Cooling system

Cleaning the coolers (b) : No specific time interval for cleaning of coolers. The interval, are largely depended
upon the quality of air. The coolers must be cleaned when the oil temperature tends to rise while transformer
load and inlet temperatures of air remain constant. Cleaning should be done by compressed air or hydrant
spray after covering the fans with plastic sheets.
 Control cubicle and terminal box (a)

Checking the heating and lighting of the control cubicle: The thermostat of the control cubicle heating is to
be set to about 20 °C. Check the heating for correct functioning. Check cubicle lighting for correct functioning
with door opening.
Checking the enclosure for water tightness: Check anti-corrosion coating of enclosure, door gaskets and
lock. Clean the enclosure vent.
Contacts in motor circuit breakers and contactors: Check the contact condition and tightness of terminals.

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Principles of operation and maintenance criteria
 Transformer Buchholz Relay

Check the buchholz relay (a)

 Check the gas deposition in buchholz relay through the inspection window.
 Whitish gas: It is caused by the electric arc in contact with paper, cotton.
 Yellowish gas: It is caused by wood and cardboard.
 Greyish gas: It is caused by the breakdown of magnetic circuit.
 Black gas: It is caused by the arcing in the oil.
If alarm comes, then gas needs to be sampled. During commissioning and after oil filling, alarm may come for
short period of time due to air. For gas collection, first drain the oil from the inspection window compartment by
opening the bottom stop cock.
Checking the Buchholz Relay (b) : The alarm and trip floats must be mechanically operated. Check the alarm
and trip float in the local panel as well as in the control centre (DCDAS).
 Oil Flow Monitors (a) : Check the pointer location of oil flow monitor.

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Principles of operation and maintenance criteria
 Transformer Bushings

Checking the oil level in bushings (a), (b): Oil filled bushings is provided with oil gauge glasses. The oil level
in the oil gauge glass must be within the tolerance markings. If the oil level is found low, refill the bushing with
transformer oil. Also check the level of dust deposition and the overheating of terminal.

Cleaning the porcelain (b): The interval for cleaning of bushing is largely dependent upon local air quality.

Checking the bushing terminals (b): Check the tightness.

 Maintenance Criteria of Generator Circuit Breaker (GCB): Please refer to Annexure-F for GCB Maintenance.

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