INTERNSHIP REPORT ON THE

INSTRUMENTATION OF
LIMESTONE STA
INTERNSHIP REPORT ON THE
INSTRUMENTATION OF
LIMESTONE STA

Construction and Internals of Power Transformer:

HV (high voltage) and LV (low voltage) sides:
HV side has windings around the core through the bushings. And the LV side having less
number of windings it comes out through the bushes. High quality insulated electric copper
conductors wrapped to special insulated table to be used for windings.

(a)

(b)

(c)

(d)

Drain Valve:
A transformer has drain valve at the bottom to replenish oil and drain out to flush
tank and check for internal corrosions.

Conservator Tank:
Then comes entire Transformer tank that is filled with oil. It has two purposes.
a) To cool down and reduce extra heat.
b) Act as an insulator.

Cooling is of ON (oil natural) and AN (air natural) type.

The hot oil by transformer actions goes up and cool oil comes down. Then hot oil is
entered the air cooling fans and get cooled and then goes down. Transformer that is
cooling the windings of a transformer gets cooled by air by natural action by the process
of ON and AN.
High Power transformer has a rubber diaphragm inside the conservator tank so that
air does not come in and direct contact with oil. This rubber diaphragm goes up or down
depending upon the temperature of the oil. Air is allowed to come inside the conservator
tank or expel outside the conservative the depending upon the movement of the rubber
diaphragm.
Transformer Core:

Transformer core is made up of steel laminations. To achieve high level of precision and
to control vibrations and sound level the proper cutting of plate is need to be done and
special care is taken out when stacking the laminations.
Bushings:

The high voltage conductors that pass through the grounding wall of a
transformer are known as bushings of a transformer.
The insulator and the external connections must have the strength to withstand
the short circuit.
Bushings are low cost compared to the high voltage assets that protect. Bushing
failures can have substantial consequences to the transformer, human safety and
environment.
Serious consequences could be occur when porcelain bushes fails. Shards of
porcelain could be launched and cause potential risks to the human safety and
surrounding objects.
The transformer oil is contaminated once it comes in contact with the atmosphere
The transformer oil can also be ignited and cause problems for the human safety
and environment

These serious consequences can be avoided by use of new CRS bushings.It

uses a solid insulation material there is a substantial decrease in human risks.

Breather:

Breather is an accessary of an oil filled transformer

It is attached to the oil conservator tank
Serves as the breathing point of the unit,
When the insulation oil of the transformer gets heated up, oil expands and goes
to the conservator tank
Oil pushes the air out of the conservator tank through the breather
Breather is filled with silica gel which adsorbs moisture.

When the insulation oil of the transformer cool down, oil retracts.
During retraction process, fresh air is sucked from the atmosphere through
breather.

i.
ii.

The basic purpose of silica is to absorb moisture.

As it absorbs moisture its color changes from
deep blue to light blue
Light blue to pink color.
Pink color indicates that silica gel has been saturated and it has to be replaced.
In atmosphere there is no pure dry air because it is mixture of moisture and dust
particles.

If the dust particles are allowed the oil of the transformer gets contaminated.
Therefore oil cup is used to collect dust particles when the air is sucked by the
breather.

Buchholzs Relay:
It is a mechanical device

By heating of the arc isulating material is destroyed and gas is released. So there
was need to collect the gas bubbles from the transformer to a place where quality
and quantity of the gas can be estimated.
So for this purpose buchollz named scientist gave the idea and this relay is
known by his name as buchollzs relay.

This relay is fitted in the pipe connecting the transformer tank with the
conservator tank.
It consists of two main floats.

When both the floats sink ,each of them short circuits two contacts by closing a
circuit so the fault could be detected.

It is also be capable to detect the low magnitude fault such as inter turn

fault,incipient winding fault and core fault etc.

Upper bucket is manually lower and cause the mercury switch to operate alarm.
Lower bucket is manually lower and cause the mercury switch to operate trip.

In mechanical interlock there are two positions:

a) T/L (Test Lock):

To test the function of the relay move the with skrew driver in anticlockwise
direction till the slot on the test key point towards the T/L position.

Both the floats will operate and mercury switch of upper and lower float will show
continuity.
During transportation or storage of the relay,the test key should remain in T/L
position.
During topping up of transformer oil the test key should remain in T/L position.

b) S (Service):

During commissioning of the relay the key should remain in service position.

Mounting of Bucholz relay:

Arrow on the relay should be pointing towards conservator tank.
The relay should be mounted within angle of 1 to 9 degrees.
The pipe at the apparatus side should be straight for a length of 5 times the
nominal diameter of the pipe bore.
The pipe at the conservator side should be straight for a length of 3 times the
nominal diameter of the pipe bore.
Sharp bends in the pipe work should be avoided
Transformer Nameplate :
Type
LPK No
Rated Power
Temp rise oil/winding amb.
No. of phases
Ins. Class
Rated frequency
Type of Cooling
Total Losses
Vector group
Rated Voltage HV/LV (No Load)
Rated Current HV/LV
Impedance Voltage
Duty
Winding Temp. Rise
Duration of short Circuit

TSUN 6338
20600246
2000 kVA
52C
3
A
50Hz
ONAN
27580W
Dyn 11
6300/415 V
183.3/2782.4 A
8.12 %
Cont.
53C
3 sec

HIGH VOlTAGE AND LOW VOLTAGE SIDES:

A
HIGH VOLTAGE
Connect
ion

Volts

Termi
nal
B

Tap
Changer
Connection

LOW VOLTAGE
Positi
on

Connect
ion

Volts

Termina
l

6615
6457.
5

DELTA

6300
6142.
5
5985

s
A5
C5
A4
C4
A6
C6
A3
C3
A7
C7

A4 B5
C4
A6 B4
C6
A3 B6
C3
A7 B3
C7
A2 B7
C2

B4
1
B6
2
B3
3

STAR

415

B7
4

0
a
b
c

B2
5

KVA:

The transformation capability of the transformer. It is always rated in KVA.

Volts at NO LOAD:

It has HV and LV voltages. HV side is known as primary side and LV side is known as
secondary side.
It tells that how much the primary side and secondary side will vary depending upon the
load factor.
The HV side does not vary unless and until we adjust switching tapes.
.
It has LV voltages of 6300 rated voltages. While the standard voltages at LV side are 415
volts.

Current (Amperes):

The current ratings at LV sides are 183.3,and 2782.4 at HV sides

At LV side as we step down the voltages up to 6300 volts our current increases up to
2782.4 A at LV side.

Phase:

Connections:
HV side is delta connected having voltage and currents at positions

Type of Cooling:
It is of two types.

a ) ON(oil natural) Cooling.

b ) AN (air natural) Cooling.

o Frequency:
Rated frequency is 50Hz.

o Weight:
Oil weight
Core and oil assembly weight
Liftable weight

1050kg
17000kgs
2355kg

Switching positions are at 360 round shaped circle starting from 1 to so on.
When we select position 1 the voltages are 145206V and current is 39.8A respectively.
The main purpose of positioning is to vary the HV side voltages depending on the load.
But these varying voltages are in the limit and we can vary to a small limit at each
postion means not in the limit of 1000V.
This variations of voltages at each position is set by the manufacturer.
The LV side voltages remains irrespective of the selected positions.

(a)

(b)

To achieve voltages of 145206V and current of 39.8A we have to adust switching

position 1.For this purpose we have to join 5 and 6 join taps as shown in above
figure.
Join taps tells us that we have to engage HV side windings to get the desired
position.
The number of windings actively involve in transformation process varies.

Transformer Testing
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We perform transformer testing in order to

locate the parameters of a transformer.

In order to access their conditions
put up the proper maintenance
check out proper working operation
save from any electrical hazards
have environmental and human safety
avoid from greater risk

BDV TESTING OF A POWER TRANSFORMER:

The oil works as insulating material and serves as coolant (exhaust heat being
produced in transformer).

Transformer oil deteriorates because of aging and moisture ingress, requiring

periodic testing.

In BDV testing, oil sample is subjected to a steadily increasing alternating voltage

until breakdown occurs in a BDV test kit.

The breakdown voltage is the voltage reached at the time of the first spark
appears between the electrodes.

The test is carried out six times on the same cell filling and the electric strength of
the oil is the arithmetic means of the six results obtained.

Testing kit has two electrodes having gap of 2.5 mm.

Break Down Voltage Test Values:

What should be Break Down Voltage values for the following Transformers?
1. 22/0.4kV, 1000kVA
2. 0.4/125 KV, 160.9 KVA
3. 132/6.3 KV, 26 MVA
Above three transformers having different voltages. Take Higher side Voltages
1. 22,000 V
2. 125, 000 V
3. 132, 000 V
According to IS 6792:1992, BDV value should be
30 kV Minimum: Transformers up to 72.5 kV
40 kV Minimum: Transformers from 72.5 kV up to 170 kV
50 kV Minimum: Transformers from 172 kV up to 420 kV

Example-1: 22/0.4kV, 1000kVA

The BDV value should be greater than 30 KV (Voltage is 22000 V)

Example-2: 0.4/125 KV, 160.9 KVA

The BDV value should be greater than 40 KV (Voltage is 125,000 V, greater than
72,500 V)

Example-3: 132/6.3 KV, 26 MVA

The BDV value should be greater than 40 KV (Voltage is 132,000 V, greater than
72,500 V

(oil testing through drain valve)

(oil testing through buchholz relay)

Collection of Oil Samples:

Six samples of 37.5MVA 33KV / 11KV Transformer are taken. Time gap between each test is 5
minute. Electrode/arc gap in the testing kit is 2.5 mm.
Results are as follows
a. 85 kV
b. 89 kV
c. 75 kV
d. 90 kV
e. 88 kV
f.

65 kV

Such types of variation are often seen and cause confusion whether the unit is ready for
operation or not.
One common reason for variation in result is insufficient time gap between oil samples.
Instead of 5 minutes, time gap between each sample should be around 15-20 minutes.

The techniques used for oil sampling follow the guidelines of international recognized
standards that are known as:

ASTM (American Society for Testing Materials)

IEC (International Electro technical Commissioning)
AS (Australian Standards)
EPA (Environmental Protection Agency)

Bottle Sampling:

The recommended identified point is bottom drain valve

Lye absorbing pieces under drain valve to avoid ground to be contaminated by
the oil spills.
Place a container under the samling valve to capture oil

The main valve of the sampling point should be closed

Now carefully remove the bolts and nuts from the sampling port
Clean the sampling port with clean cotton
Now install the flinch adopter to the sampling port
Push the tubing of the flinch into the sample bottle and start to lose the valve
Gradually turn the bottle to allow the oil to swill and warm the bottle. It will help us
to prevent condensation
Dont shake the bottle as it will introduce moisture and air bubbles into the
sample
Tight the transformer drain valve and empty the tubing of flinch adopter

Glass Syringe and stopcock sampling:

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First identify the sampling valve which is bottom drain valve

Lye absorbing pads under drain valve to avoid ground to be contaminated by the
oil spills
Place a container to capture oil that is going to spill
The main valve of the transformer should be closed
Lose nuts and bolts to remove the sealing kit
Clean the sampling port with the neat piece of cotton
Install the flinch adopter at the sampling port

Ensure that the stopcock is attached to the syringe and attached the flinch tubing
to the stopcock
Set the stopcock at position 1 and push on the plunger
Note: Pulling on the plunger may results in formation of bubbles
Set stopcock at position 3 and press the plunger to swill the oil into the container
Then open the stopcock and fill the syringe up to 50mm,close stopcock and
remove the tubing, pack the syringe immediately into box, unblock the adopter,
install the sealing kit of sampling port
Remember that the oil remaining oil into the tubing and adopter should be flush
through to the waste container

Sampling using a buchholz sampling device:

Buchholz relay is introduced in conservator tank designed transformers.It is

introduced to provide protective functions and accumulate gases released from the
transformer.

(Buchholz relay b/w T/F and tank)

(Bubbles travelling towards the oil tank)

When due to some reasons gases are not dissolved in the insulating liquid they
evolve in the form of bubbles.
These bubbles find their way to the conservator through the pipe.

So these bubbles are removed by the Bucholz relay before they reach the
conservator tank and contaminate the oil.
The Bucholz samples are taken from the gas sampling device.
In case if device is not available samples are taken directly from the buchholz
Buchholz can be sampled either for oil or gas
If Bucholz contains humiliated gas then it need to be sampled and gas can be
released using variety of samples
We can use either glass syringes or gas sampling bags

First task is to accumulate gas through the buchholz into the sampling device

TO take samples through the sampling device open the bottom port of the
sampling device and allow the oil to drain,Notice that the oil level in the device
decreases
Now the sampling device is full of gas close the bottom port
Once the gas is collected in the device retrieve the gas by attaching the sampling
tubing to the top port of the sampling device and connect the sampling container
either the glass syringe or sampling bag
Now open the top port valve of the sampling device to release
Notice that the oil level will rise again as the gas is pushed out from the device
Note that all the gas is released by opening the top valve port till the oil start to
flow out through the tubing

DG(Dissolved Gas) Analysis of a power transformer:

DGA analysis is not for determining the quality of oil in the transformer.
It is carried out to determine any abnormalities in the internal winding or

paper insulating of transformer.

Abnormalities in the internal winding or paper insulation can be detected

by complete overhaul of transformer if DG Analysis is not carried out.

Due to faults that are happening inside the transformer heat will be

formed and due to this energy the long organic oil chain is getting broken.
As a result so many gases is formed such as CO2, C2H4, C2H2, C2H6,
C3H6, C3H8, CH4, CO, H2, O2, N2 etc.

The principal or key gases associated with each type of issue are shown below:
Hydrogen (H2): generated by partial discharges
and arcing
Methane (CH4): generated by relatively low elevated
temperatures (150 C).
Acetylene (C2H2): generated by arcing.
Ethane (C2H6): generated by high temperatures
(<300 C)
Ethylene (C2H4): generated by high temperatures
(>300 C)
Carbon Monoxide (CO): generated by oxidation of
cellulose insulation
Carbon Dioxide (CO2): generated by oxidation of
cellulose insulation

In DG analysis concentration of different gases like nitrogen, oxygen,

carbon monoxide, carbon dioxide, hydrogen, methane, ethane, ethylene
and acetylene etc. is determined.

Example:

26.25 MVA, 220/11.5 KV is being tripped by Bucholz relay. DG Analysis is

being carried out having following results

Gas

Concentration in ppm

H2

28

O2

173831

N2

593952

CH4

C2H4

C2H6

C2H2

C3H6+C3H8

CO2

615

CO

124

What could be interpreted from these results?

Permissible Limits:

Please see the chart

It gives the permissible Limits of Gas levels in relation to age of the

transformer
In your Transformer none of the above limit is exceeded.
If anything exceeded, then we can go for analysis of fault.

Therefore your Transformer is Healthy.

Please confirm whether the transformer is recently commissioned. In that
case, there is every possibility that the trapped air in the winding and
other areas During Hot Oil circulation get released due normal vibration
and collected at Buchollz relay.

Dissolved key gas concentration limits in ppm

Status

Normal

Modest Concern

H2
100

101-700

Major
Concern

Imminent
Risk

Transformer
Results as
mentioned
above

701-1800

>1800

28

CH4
C2 H
C2 H

50

121-400

401-1000

>1000

36-250

51-80

>80

50

51-100

101-200

>200

50

66-100

101-150

>150

351-570

571-1400

>1400

124

2500-4000

4001-10000

>10000

615

C2 H 6
CO

200

CO2

5000

Remarks:
Normal:

In this condition it is stated that below this level indicates that the transformer is

operating in a satisfactory manner.

If any individual gas concentration exceeds the specified level, it is needed to
investigate further

Modest Concern:

Within this range indicates greater than normal combustible gas concentrations.

Any individual

investigated.
Check either any trend is present or not.

combustible

gas

exceeding

specified

levels should

be

Major Concern:

Within this range indicates a high level of decomposition.

Any single combustible gas exceeding these levels should be investigated

immediately.
Take immediate action to establish a trend, as faults are probably present.

Imminent Risk:

Within this range indicates excessive decomposition of Beta Fluid and cellulose.
Continued operation could result in failure of the transformer.

Our Results:

The results shown here illustrates that the transformer is healthy and is in proper

working condition.
None of the limit is exceeded, so there is no need to go for the analysis of the
fault.

The following examples are extreme but serve to illustrate how the dissolved gas-in-oil test can be used
to highlight active problems.

EXAMPLE 14
The utility suspected that the magnetic shunt pads attached to the inside of this transformer tank had
come loose and were either touching the core (layered steel structure around which the copper winding is
installed) or were coming very close. The result was intermittent unintentional core grounding and stray
flux causing localized overheating of the oil.

EXAMPLE 25 It was suspected that a single line to ground through-fault caused the failure of this
transformer. The fault was of enough energy to destroy one of the windings. Acetylene was a predominant
gas possibly indicating that arcing may have occurred. The acetyleneto-ethylene ratio indicated the
problem could be either high temperature overheating of the oil, arcing or both. The problem was likely in
the winding because it involved cellulosic materials, as witnessed by the comparatively high carbon
monoxide and carbon dioxide concentrations.

EXAMPLE 35 A technician noticed that this transformer was enveloped in a cloud of steam during a
rainstorm. This prompted an investigation where it was found that the temperature indicator pegged. It
was estimated that the temperature in the unit had been greater than 200C. It was discovered also that
the unit became highly overloaded during some switching functions due to current imbalances in the three
phases. The condition probably existed on and off for two years. An internal investigation found the
cellulosic paper used as an insulant was brittle and crumbly. Again, the key gas indicators for this
condition were carbon monoxide and carbon dioxide.

Oil testing is an important part of a utilitys electric apparatus condition assessment. As these cases
illustrate, dissolved gas-in-oil analysis is the most important diagnostic test for detecting a wide range of
problems

The principal or key gases associated with each type of issue

are shown below:
Hydrogen (H2): generated by partial discharges
and arcing
Methane (CH4): generated by relatively low elevated
temperatures (150 C).
Acetylene (C2H2): generated by arcing.
Ethane (C2H6): generated by high temperatures
(<300 C)
Ethylene (C2H4): generated by high temperatures
(>300 C)
Carbon Monoxide (CO): generated by oxidation of
cellulose insulation

 Carbon Dioxide (CO2): generated by oxidation of

cellulose insulation

Hydrogen
H
Status

Methane
CH4

Acetylen Ethylen
Carbon
Ethane
e
e
monoxide
C2 H

35

C2 H

50

C2 H6
65

Carbon
dioxide

CO

CO2

350

2500

Normal

100

120

Modest
concern

101-700

121-400 36-250

51-100 66-100 351-570

Major
Concern

701-1800

4011000

51-80

101-200

101150

571-1400

4001-10000

Imminent
Risk

>1800

>1000

>80

>200

>150

>1400

>10000

2500-4000

__________________

The insulating liquid is in contact with the internal components.

Gases formed by normal and abnormal events within the transformer are
dissolved in the oil.
By analyzing the volume, types, proportions, and rate of production of
dissolved gases, much diagnostic information can be gathered.
Therefore we perform the DG analysis to estimate the volume of
dissolved gases and to check the quality of oil.

Fault Gases:
Since these gases can reveal the faults of a transformer, they are known as "fault
gases".

Gases are produced by oxidation, vaporization, insulation decomposition, oil

breakdown and electrolytic action.

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Evaluation of Possible Faults by the Key Gas Method:

The four general fault types produce a unique gas that indicates the fault type.
Key Gas Method is used as an indication of which fault type to examine in greater
detail.
Fault Type: Thermal decomposition of Cellulose
Principal Gas: Carbon Monoxide
Characteristics: Decomposition products of cellulose include CO and CO2. If the
cellulose is saturated with Beta Fluid, the decomposition products will include
hydrocarbon oxides (as above)

Fault Type: Corona partial discharge:

Principal Gas: Hydrogen
Characteristics: Corona discharges produce hydrogen and methane. If the corona
occurs in cellulose, the gas profile will also include CO and CO2

Fault Type: Arcing

Principal Gas: acetylene
Characteristics: Arcing always generates large amounts of acetylene and hydrogen.
Carbon oxides may be present if the fault involves cellulose. Carbon may be present
in
the oil.

Dissolved Gas Sampling:

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Sampling Equipments
Sampling Flask:

A piece of firm is there at the top to protect the flasks

By using flasks to collect samples of nitrogen or oxygen biological activities can
be killed by mercury present in the flask

Lid of the flask has the rings that are fixed between the glass and the plunger to
covered properly

Sampling Rack:
Used to hold the sampling flasks
It has a clip and tubing and at the back it has a wrench to hold the gas cylinders

C02 Cylinder for sample collection:

Normally 5 ponds cylinder having 5 ponds C02 is used
Use small elastic belts to hold the cylinder
The regulator is used to control the flow
Tubing for sample collection:
Two thin nylon tubes are used
One for C02 and the other for water

Part 2:
How to do Sampling:
Remove the black vinyl cap and attach tygon tubing
Start the CO2 gas to flow
Insert the tubing from the cylinder into the flask
Flush the area between the o-rings with CO2 la

Inspection and Electrical maintenance of a power Transformer

The present maintenance trend is to reduce cost, which in some cases means
lengthening the intervals of time to do maintenance or eliminating the
maintenance completely.
The utility, or company, realizes some savings on manpower and material by
lengthening the maintenances cycle, but by doing this, the risk factor is
increased.
A few thousand dollars for a maintenance program could save your utility or
company a half-million dollar transformer.

 Inspection:

It First de-energize the transformer

Look for physical damages and check proper insulations
Loose connections and defective wires
The most important the signs of corrosions
Verify whether the cores or properly grounded or not
Load tap changer should be on the proper positions since at wrong positions it
may results in excessive load currents ,under voltage and over voltage conditions
Transformer itself should be properly grounded

To carry out inspection in more details following tests should be conducted.

1. *Insulation Resistance:

Tap Change of Power Transformer

Regulating the voltage of a transformer is a requirement that often arises in a power

system
The voltage control is performed by changing the turns ratio.
This is done by provision of taps in the winding.

In an application it may be needed

1. To supply a desired voltage to the load.
2. To counter the voltage drops due to loads.
3. To counter the input supply voltage changes on load.

Fig 42: (Tap Changing and Buck Boost Arrangement)

Note: Taps are provided on the HV winding

The volts per turn available in large transformers is quite high and hence a
change of even one turn on the LV side represents a large percentage change in
the voltage.
Also the LV currents are normally too large to take out the tapping from the
windings. LV winding being the inner winding in a core type transformer adds to
the difficulty of taking out of the taps.
Hence irrespective of the end use for which tapping is putt, taps are provided on
the HV winding.

Buck-Boost Arrangement:

Provision of taps to control voltage is called tap changing.

In the case of power systems, voltage levels are sometimes changed by injecting
a suitable voltage in series with the line.
This may be called buck-boost arrangement. In addition to the magnitude, phase
of the injected voltage may be varied in power systems.

Tap Changing is affected when:

a) The transformer is on no load or No load Tap Changer (NLTC)

In this arrangement the tap positions are changed when the transformer is taken out of
the circuit and reconnected.

b) The load is still connected to the transformer or On Load Tap Changer (OLTC):

In this arrangement taps are changed without the interruption of the load current
As there is no permission of switching off the transformer during tap changing. The
tapping arrangement is placed in separate diverter tank attached to electrical power
transformer main tank.
Inside this tank, the tap selectors are generally arranged in a circular form. The diverter
switches have contacts operating in rapid sequence with usually four separate make and
break units.

Schemes of On-Load tap changing:

Reactor method:

This method employs an auxiliary reactor to assist tap changing. The reactor has a
center tapped winding on a magnetic core.

The two ends of the reactor are connected to the two bus bars to which tapping
switches of odd/even numbered taps are connected.

(Reactor Method of Tap Changer with table of switching)

When only one tap is connected to the reactor the shorting switch S is closed minimizing
the drop in the reactor.
The reactor can also be worked with both ends connected to two successive taps. In that
case the switch S must be kept open.
The reactor limits the circulating current between the taps in such a situation. Thus a
four step tapped winding is used for getting seven step voltage on the secondary (see
the table of switching).
Tap
1

Switches Closed
1,s

1,2

2,s

2,3

3,s

3,4

4,s

4,5

5,s

The advantages of this type of tap changer are:

1. Load need not be switched off.

2. More steps than taps are obtained.

3. Switches need not interrupt load current as an alternate path is always provided.

Major Objection:
The major objection in this scheme is that the reactor in the circuit is always generating extra
loss.

Parallel winding, transformer method:

In order to maintain the continuity of supply the primary winding is split into two parallel
circuits each circuit having the taps as shown in Fig. 44.
Two circuit breakers A and B are used in the two circuits. Initially tap 1a and 1b are
closed and the transformer is energized with full primary voltage.
To change the tap the circuit breaker A is opened momentarily and tap is moved from 1a
to 2a. Then circuit breaker A is closed.
When the circuit A is opened whole of the primary current of the transformer flows
through the circuit B.
A small difference in the number of turns between the two circuit exists. This produces a
circulating current between them.
Next, circuit breaker B is opened momentarily , the tap is changed from 1b to 2b and the
breaker is closed.
In this position the two circuits are similar and there is no circulating current.

Fig 44: (Parallel Primary Winding Tap Changer)

Note: The circulating current is controlled by careful selection of the leakage reactance.
Generally, parallel circuits are needed in primary and secondary to carry the large current in a

big transformer. Provision of taps switches and circuit breakers are to be additionally provided to
achieve tap changing in these machines.

Series booster method:

In this case a separate transformer is used to buck/boost the voltage of the main
transformer. The main transformer need not be having a tapped arrangement.
This arrangement can be added to an existing system also.
Fig. 42 shows the booster arrangement for a single phase supply. The reverser
switch reverses the polarity of the injected voltage and hence a boost is
converted into a buck and vice versa.
The power rating of this transformer need be a small fraction of the main
transformer as it is required to handle only the power associated with the injected
voltage.

Note: One precaution to be taken with this arrangement is that the winding must not be
open circuited. If it gets open circuited the core (B in fig) gets highly saturated.
In spite of the small ratings and low voltages and flexibility, this method of voltage
control costs more mainly due to the additional floor space it needs. The methods of
Moving Coil Voltage Regulators:

Voltage regulation discussed so far basically use the principle of tap changing
and hence the voltage change takes place in steps.

Fig 45: (Moving Coil Voltage Regulator)

Applications like a.c. and d.c. motor speed control, illumination control by
dimmers, electro-chemistry and voltage stabilizers need continuous control of
voltage. This can be obtained with the help of moving coil voltage regulators.

Fig. 45 shows the physical arrangement of one such transformer. a, b are the two
primary windings wound on a long core, wound in the opposite sense. Thus the
flux produced by each winding takes a path through the air to link the winding.

These fluxes link their secondaries a2 and b2.A short circuited moving coil s is
wound on the same limb and is capable of being held at any desired
position.This moving coil alters the inductances of the two primaries.

The sharing of the total applied voltage thus becomes different and also the
induced emf in the secondaries a2 and b2. The total secondary voltage in the
present case varies from 10 percent to 20 percent of the input in a continuous
manner.

The
turns
ratios
of
a1:a2
and
b1:b2
are
4.86
and
10.6
respectively.5/4.86+95/10.6= 10% when s is in the top position. In the bottom

position it becomes 95/4.86+5/10.6= 20%. By selecting proper ratios for the

secondaries a2 and b2 one can get the desired voltage variation.

Sliding contact regulators:

These have two winding or auto transformer like construction.
The winding from which the output is taken is bared and a sliding contact taps
the voltage.

Fig 45: (Sliding Contact Regulator)

The minimum step size of voltage change obtainable is the voltage across a
single turn.

The conductor is chosen on the basis of the maximum load current on output
side. In smaller ratings this is highly cost effective.

Two winding arrangements are also possible. The two winding arrangement
provides electrical isolation also.

Electrical Maintenance:

It involves fault diagnosis, routine servicing and repair of electrical components

By this smooth running of production can be governed

Electriacal maintenance involves:
Preventive maintenance
Operational maintenance
Corrective maintenance

(a)

(c)

(b)

(d)

Preventive maintenance:

It depends upon the RCM analysis

It is performed to avoid failures ,unnecessary production loss and safety
violations

Cast Resin Transformers (CRT):

CRT are dry type Transformers and maintenance free

Insulation failure due to overheating of winding is the cause for failure of
Transformer winding. To monitor rise of temperature in CRT temperature sensors
are located at various points inside winding and are connected to the tripping
controls of the breakers.
Carry out routine cleaning of dust specially when the transformers are installed
outdoor. Dust formation along with moisture causes insulation failure and flash
over. If air bubbles remain in the castings it will cause insulation failure.

We can replace the oil filled transformers in most of the substations to avoid the
transformer failure for at least ten years.

Operational maintenance:

It is the care and minor maintenance of equipment

It consists of inspecting ,cleaning ,servicing ,preserving ,lubricating and adjusting
It also includes the minor parts replacement

Corrective maintenance:

It involves the regular task to maintain system in optimum operating condition

In this maintenance equipment is maintained after breakdown
It is the most expensive type
Its major functions includes:
Eliminating breakdown
Eliminating deviation
Eliminating unnecessary repairs

Precautions to be taken before starting Maintenance:

The transformer should be disconnected from supply

Windings and Tank should be solidly earthed
Flame should not kept near the transformer at the time of maintenance work
The manufacturers recommendations must be followed for maintenance

Maintenance Schedule of Power Transformer as per Standard Specifications:

ISI 1886-1967 Recommended Maintenance

Maintenance Schedule for Transformers of Capacities 1000kVA and above
S.No
.

Inspection
Frequency

Item to be
inspected

Inspection Notes

Hourly

Hourly

Ambient
Temperature
Ambient
Temperature

Hourly

Hourly

Oil
Temperature
Load ampere

Hourly

Voltage

Daily

Oil level in
transformer

Daily

Daily

Oil level in
bushings
Leakage of
water into
cooler

Replace if crack or
broken

Daily

If Broken

10

Daily

Relief
diaphragm
Dehydrating
Breather

11

Quarterly

Bushing

Example for short

circuit etc.
If silica gel is pink
,check by spare
charge, The old
charge may be
reactivated for use
again
Clean or replace

12

Quarterly

Oil in
Transformer

13

Quarterly

Cooler for

Check that
temperature rise is
reasonable

Check against the

rated figures
Check against the
rated figures
Check against
transformeroil level

Check that air

passage is free,
Check color of active
agent, examine for
cracks and dust
deposits
Check for dielectric
strength and water
content
Quality of Oil

Lubricate bearings

Actions required if
abnormal
Conditions

Shutdown the
transformer and
investigate either
persistently higher
than normal

If low,top up for with

dry oil examine
transformer for leaks
.

Take suitable action

to restore Quality of
Oil
Replace burnt or

bearing
motors and
operating
mechanisms

check gear box,

Examine contacts
check manual
controls and
interlocks
Test for pressure

worn contacts or
other parts

14

Half Yearly

Oil Cooler

15

Half Yearly
Yearly

Check for acidity and

sludge
Test Oil

Filter or replace

16
17

Yearly

Oil in
Transformer
Oil filled
bushing
Gasket joints

18

Yearly

Cable Boxes

19

Yearly

20

Yearly

SurgeDiverter
s and Gaps
Relays,
Alarms and
their circuits

Check for sealing

arrangement for
filling holes. Examine
compounds for
cracks
Examine for cracks
and dust deposits
Examine Relay and
Alarm Contacts
,Their operations
,Fuses ,Check Relay
accuracy etc.

Tighten the bolts

evenly to avoid
uneven pressure
Replace Gaskets if
leaking

21

Yearly

22

a) 5 Yearly

b) 7-10
Yearly

Filter or replace

Clean or replace

Earth
Resistance
a )1000 to
3000 kVA

Overall inspection
including lifting of
core and coils

Clean the
components and
replace fuses and
contacts if
necessary. Change
the settings if
necessary
Take suitable actions
if resistance is high
Wash by hosing
down with clean dry
oil

b ) above
3000kVA

Overall inspection
including lifting of
core and coils

Wash by hosing
down with clean dry
oil

ISI 1886-1967 Recommended Maintenance

Maintenance Schedule for Transformers of Capacities less than 1000kVA

S.No
.

Inspection
Frequency

Item to be
inspected

Inspection Notes

Hourly

Load Current

Hourly

Voltage

Daily

Dehydrating
Breather

Check against rated

figures
Check against rated
figures
Check that air
passages are clear,
Check color of
active agent

Monthly

Oil level in
Transformer

Check the
transformer oil level

Quarterly

Bushings

Half Yearly

Non-Conservator
tank

Examine for cracks

and deposits
Check for moisture
under cover

Yearly

Oil in transformer

Yearly

Earth Resistance

Yearly

Relays ,Alarms
and their circuits

Check for dielectric

strength and water
content, Check for
acidity and sludge

Examine Relay and

alarm contacts, their
operation fuse etc.

Actions required if
abnormal
Conditions

If Silica Gel is
pink ,Change by
spare charge.The
old charge may be
reactivated for use
again
If low top up with
dry oil. Examine
transformer for
leaks
Clean or replace
Improve
ventilation ,Check
oil
Take suitable
actions to improve
quality of oil
Take suitable
actions if Earth
Resistance is high
Clean the
components and
replace contacts

Check relay
accuracy etc.

10

2 Yearly

11

5 Yearly

Non Conservator
Transformers

Internal inspection
above core
Overall inspection
including lifting coils

and fuses if
necessary. Change
the setting if
necessary
Filter oil regardless
of conditions
Wash with clean dry
oil

NOTE:
One of the reasons for failure of distribution transformers is the supply of sub-standard
transformers, which is a result of improper vendor rating and lack of routine test prior to
dispatch by the manufacturer & issue for use. It is therefore proposed as follows:

Vendors should be approved only after confirming the adequacy of the

manufacturing & testing facilities at the works.
Procurement should be on the guaranteed technical particulars and not
necessarily L-I rate.
Routine tests should be observed at the works and the transformer should be
tested prior to issue for utilization.

Maintenance Tests:
Two important tests that could prevent field failure are:
1. Using an infrared scan on a transformer could locate hot spots.
By using this test we could detect system overloads, loose defective
components and damaged switchgears
An infrared camera is used to detect the hotspots
Hotspots are easily eliminated before before they cause failures
IR Thermography technique is used in these cameras
IR Thermography Inspection helps:

Increase equipment life

Reduce downtime

Electrical thermography inspections save money

Prevent catastrophic failure

Lower repair costs

Lower risk

Prevent lost production

Non-destructive Infrared testing

2. Dissolved gas analysis test of the oil by a lab