Professional Documents
Culture Documents
TRANSFORMERS
CONTENTS
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
SECTION - 1
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
INTRODUCTION
PROLEC GE transformers are designed and manufactured with the highest
quality standards to provide efficient, reliable and long lasting service.
In order to achieve the intended performance of the transformer, the following
aspects should be taken care:
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
1.02.00 BASICS
1.02.01 PERSONAL SAFETY
Personal safety should be given first priority. Stop all activities, if unsafe working
conditions exist. All team members must follow safety practices in order to avoid
unsafe actions. For achieving the objectives, all those who are involved in the
erection, operation and maintenance of the transformer should be thorough with
instructions provided by the manufacturer.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
1.04.00 CAUTION
Recommendations when the Transformer is under Pressure or Vacuum.
If the transformer is pressurized or under vacuum do not attempt to open any
manhole cover or remove any devices bolted to the transformer. Severe personal
injury may occur.
For dry air/nitrogen shipments, use the upper filling valve to release the pressure
slowly. For oil filled shipments, release the pressure through the gas cabinet
sampling valve or through the vacuum pressure bleeder vent if applicable.
Failure to follow these instructions may cause severe personal injury, death or
equipment damage.
Pressure gauge reading could be inaccurate and zero reading should be
confirmed by releasing pressure from the upper filling valve or the vacuum
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
Maintain all grounds on transformer line terminals for a minimum of 6 hours after
oil filling or recirculation.
Polarization of insulating materials produces a voltage that sometimes takes
days to completely disappear.
1.06.00 INTERNAL ENVIRONMENT.
Only authorized and qualified personnel may go inside the transformer to perform
internal activities
• Large transformers are usually shipped with high quality dry air with less than
0.05% impurities and dew point -60°C or lower.
• Before going inside any transformer, verify that the internal environment
contains a minimum 19.5% oxygen and maximum of 50 ppm (parts per
million) CO for an exposure period of up to 8 hours. For further information,
refer the OSHA regulations.
• Internal components, insulation and oil can absorb oxygen thereby reducing
the overall content. Going inside a transformer with less than 19.5% oxygen
content will cause immediate faint, which would soon lead to asphyxiation and
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
death hazard.
• Continuously monitor the oxygen and CO content inside the transformer (top
and bottom).
• Once the transformer is opened, maintain the required level of oxygen by
means of a dry air source. Airflow must be maintained at all times.
• When any internal activities are performed inside the transformer, always post
a fully trained safety supervisor near the open manhole. He must have at all
time visual contact or other type of communication with the personnel inside
the transformer.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
touch these bushings; unless the bushing cap has been grounded for at least
5 minutes.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
a. Soak pits
b. Drain pits
c. Barrier walls
d. Fire detection system
e. Fire hydrant system
f. Fire mulsifyre system
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
Immediate hazards which will result in severe injury, death or property and
catastrophic equipment damage.
1.12.02 WARNING
Hazard or unsafe work practices which may result in severe injury, death or
property and catastrophic equipment damage.
1.12.03 CAUTION
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
Hazard or unsafe work practices which may result in minor injuries or property
and unnecessary equipment damage.
after reaching site. If storage is required for longer duration, the main body
should be filled up with oil.
Do not leave tertiary terminals unprotected outside the tank.
Do not allow WTI / OTI temperature to exceed 70°C during dry out of
transformer and filter machine temperature beyond 75°C
Do not parallel transformers, which do not fulfil the conditions for paralleling.
Do not over load the transformers beyond limit specified in IS: 6600.
Do not leave secondary terminals of any CT open.
Do not measure insulation resistance by using megger when the transformer
is under vacuum.
Do not stand on any vessel, which is under vacuum.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
SECTION – 2
GENERAL CONSTRUCTION
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
2.5 CONSERVATOR
Conservator is intended to take care of the expansion and contraction of
transformer oil, which takes place during normal operation of the transformer.
Wherever specified by Purchaser, flexible separator or air cell is provided in the
conservator to prevent direct contact of air with the transformer oil.
A smaller oil expansion vessel is provided for the On Load Tap Changer. Some
times the OLTC conservator may be made as a compartment at one end of the
main conservator.
Magnetic oil level gauge is fitted on the conservator which can give alarm/ trip in
the event of the oil level falling below the pre-set levels due to any loss of oil.
2.6 PRESSURE RELIEF DEVICE
A device for limiting high oil pressure build up inside the transformer during fault
conditions is fitted on top of the tank. The pressure relief device allows rapid
release of excessive pressure that may be generated in the event of a serious
fault. This device is fitted with a trip switch.
The pressure relief device has a spring loaded diaphragm, which provides rapid
amplification of its actuating force and will reset automatically, as soon as the
pressure inside the tank drops down to the pre-set pressure.
A bright colour coded mechanical indicator pin in the cover moves with the
diaphragm during the operation of the pressure relief device and is held in
position even after the diaphragm goes back to its original position. This pin is
clearly visible from ground level, which gives an indication that the device has
operated.
The indicator pin may be reset manually. The relief device is provided with a
shielded weatherproof alarm / trip contact and is operated by the movement of
the diaphragm.
For small Capacity transformers, an explosion vent is provided with a diaphragm,
which will rupture in the event of abnormal increase in internal pressure. Some
times the explosion vent is provided with double diaphragm such that the outer
one remains intact even after the inner one is ruptured. Rupturing of inside
diaphragm can be checked by viewing through the oil level gauge provided in
between the diaphragms.
2.7 GAS & OIL ACTUATED (BUCHHOLZ) RELAY
Gas and oil actuated relay is fitted in the feed pipe from the transformer tank to
the expansion vessel for collection of gas, if generated in the oil. The relay
operates on the fact that almost every type of fault in an oil immersed transformer
gives rise to generation of gas. This gas is collected in the body of the relay, and
is used to close the alarm switch. In the event of any severe fault, the sudden
increase in oil pressure causes an oil surge towards the expansion vessel and
this is used to close the trip contacts. This oil surge will impinge on the flap fitted
to the trip element causing it to rotate about its axis and thus bringing the
mercury switch to the closed circuit position, which in turn operates the tripping
device.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
In the event of serious oil loss from the transformer, both alarm and trip elements
operate in turn in the manner previously described for gas collection.
Two brass petcocks are fitted at the top of the relay body, the outlets of which are
threaded to take a bleed pipe if required for collection of gas samples.
In the pipe connection between On Load Tap Changer and its oil expansion
vessel a single float Oil Surge Relay is fitted. This relay operates on the principle
of oil surge impinging on a flap causing operation of the mercury switch
connected to the trip circuit. Gas actuated alarm switch is eliminated because the
gas generated during normal tap changing operation will give unnecessary
alarm.
2.8 SILICAGEL BREATHER
Expansion and contraction of oil cause breathing action. The silicagel-
dehydrating breather absorbs any humidity in the air breathed. An oil seal in the
air intake prevents external moisture being absorbed when no breathing occurs.
The breather container is filled with silicagel crystals. It is arranged such that the
air breathed must pass through it. The desiccant contains blue and white
crystals. When the silicagel is fully active, the blue crystals will have a deep blue
colour and changes to pink as it absorbs moisture. When saturated with moisture
and the charge contained should be replaced. The gel removed from the
breather may be arranged for regeneration and preserved for future use.
The size of the breather is chosen such that it can operate effectively over a
period of six months approximately. The factors, which influence the selection of
size of the silicagel breather required for a particular transformer, depend on
many factors like, the oil quantity in the transformer, the adsorption capacity of
silicagel, the loading pattern and the atmospheric conditions prevailing at site.
The loading pattern and the site conditions are difficult for the transformer
manufacturer to assess. Hence, the selection of breather is based on certain
assumptions and it is difficult to fix up a time schedule for the regeneration of
silicagel. It is advisable to have a periodic inspection (say monthly) of the
indicator so that the gel can be regenerated or replaced as soon it is saturated
with moisture.
2.9 WINDING TEMPERATURE INDICATORS
The winding temperature relay indicates the winding temperature of the
transformer and operates the alarm, trip and cooler control contacts. This
instrument operates on the principle of thermal imaging and it is not an actual
measurement.
Winding temperature indicator consists of a sensor bulb placed in oil filled pocket
in the transformer tank cover. The bulb is connected to the instrument housing by
means of two flexible capillary tubes. One capillary is connected to the
measuring bellow of the instrument and the other to a compensation bellow. The
measuring system is filled with a liquid, which changes its volume with rising
temperature. Inside the instrument is fitted with a heating resistance which is fed
by a current proportionate to the current flowing through the transformer winding.
The instrument is provided with a maximum temperature indicator. The heating
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
2.11 BUSHINGS
The high voltage connections pass from the windings to terminal bushings.
Terminal bushings upto 36 kV class, 3150 Amps, are normally of plain porcelain
and oil communicating type. Higher current rated bushings and bushings of 52
kV class and above will be of oil impregnated paper condenser type. The oil
inside the condenser bushings will not be communicating with the oil inside the
transformer. Oil level gauge is provided on the expansion chambers of the
condenser bushings.
Oil in the condenser bushing is hermetically sealed and it should not be disturbed
in normal operation. Oil level may be checked regularly and any oil leakage
should be reported to the bushing manufacturer for immediate attention.
While connecting the overhead transmission line conductor to the bushing
terminal, ensure that the line pull is limited to the cantilever strength of the
bushing. The cantilever strength of bushings as per IS: 2099 for various types of
bushings are as shown below.
Rated Voltage Cantilever Strength (kg.) – Ref. IS 2099
(kV) 800 1000 ~ 1600 2000 ~ 2500 3150
(Amps) (Amps) (Amps) (Amps)
52 102 127 204 320
72.5 & 123 102 127 204 408
145 & 245 127 163 254 408
420 254 254 320 510
2.12 TAP CHANGER
Tap changers of power transformer are specifically of two types-
1. On Load Tap changer
2. Off Circuit Tap changer
In the case of off circuit tap changer, the tap changing takes place only when the
transformer is de-energised, but in the case of on load tap changers the tap
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
changing takes place when the transformer is in operation. The tap changer can
be designed for changing the taps.
I. Manually
II. Automatically &
III. From remote
The On load tap changer will be a self-contained unit housed in the main
transformer tank. Since some amount of arcing takes place during the switching
operations from one tap to the other, the oil inside the tap selector will deteriorate
faster. Hence, this oil cannot be allowed to mix with the oil in the main
transformer. On load tap changer is provided with a separate conservator and oil
surge relay.
For details of construction and maintenance, please refer to the OLTC supplier's
manual attached with Specific Instructions at the end of this manual.
2.13 CONTROL & MONITORING SYSTEM
Local control and monitoring of the cooler, tap changer and alarm and trip
indicators is carried out at the marshalling kiosk. Automatic control of the tap
changer is carried out at the remote control panel.
2.14 FIRE DETECTION & FIRE FIGHTING SYSTEM
It is recommended to always install suitable fire detection and fighting system
with all transformers. CBIP Manual prescribes guidelines for the selection and
installation of Fire Protection System.
“Automatic Mulsifyre System” or “Drain and Stir System” with nitrogen injection
inside the transformer are more prominent among the fire fighting systems for
large capacity Power Transformers. In the Drain and Stir System, oil is partially
drained from the transformer and nitrogen gas is bubbled through the oil in the
transformer tank to stir and create a blanket of inert gas above the oil to quench
the fire.
Owner of the Transformer has to ensure provision of requisite Contacts/ Relays
in his control panel as per requirement specified in the Fire System Instruction
Manual for connecting the Fire Detection and Fire Fighting System.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
SECTION – 3
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
3.1 GENERAL
Depending on the restriction imposed by the weight and transport dimensions,
the transformer will be despatched either in oil filled or nitrogen gas filled
condition.
In case of transformer despatched without oil, the transformer will be pressurised
with dry air or nitrogen gas to minimise the likelihood of condensation or moisture
entering the tank.
Transformers are supplied, fitted with nitrogen gas cylinder to maintain positive
pressure during transportation and storage before erection.
While transformers are in transit, gas pressure must be checked on daily basis
and any loss of pressure must be made up by feeding gas from the cylinder. For
allowable range of pressure at various ambient temperatures, please refer to Fig.
3.I.
Accessories and cooler are despatched separately. All oil pipes and chambers
are despatched in sealed condition to avoid entry of water during transportation
and storage.
Fig. 3.1
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
3.2 PACKING
When any internal part like tap changer, CT's etc. are removed from the main
body for transportation, they shall be despatched in tanks filled with oil or dry
nitrogen gas or suitable measures are taken so that they do not absorb moisture.
All fragile parts such as temperature indicators, oil level gauges etc. shall be
carefully packed to avoid breakage in transit.
Air cell type conservator shall be despatched with air cell mounted inside the
conservator and inflated with air at a slightly positive pressure so that it remains
fully tight inside the conservator. This is to avoid relative movement of air cell
inside the conservator during transit and to avoid damages to air cell during
handling.
All blanking plates, valves guards etc., which are used exclusively for
transportation are painted with a different colour shade than the transformer
(normally post office red) and shall be preserved for future use.
3.3 RAIL TRANSPORT
Large capacity transformers are normally transported by rail due to
considerations of safety and economy. Depending on the weight and dimension
of the main body suitable wagons are selected for transport. It should be ensured
that the dimensions of the main body when it is loaded on the particular wagon
do not project beyond the limiting dimensions specified by the Railways.
Movement sanction should be obtained form all the Railways through which the
transformer has to be transported to site from the factory.
Detached parts are packed and normally despatched along with the main body
so that all parts are received at site along with the main unit.
3.4 LIFTING & JACKING
Transformers should be lifted only by using the lifting bollards provided on the
main body for the purpose. All the lifting bollards should be used simultaneously.
Care should be taken to use the correct size of sling for lifting and the lifting
angle should not exceed 600.
Safe loads of wire ropes and the multiplying factor to be used corresponding to
the lifting angles are shown in Fig. 3.2
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
For the purpose of jacking, only the jacking pads provided on the tank are to be
used. Capacity of Jacks should be at least 1.5 times the weight of transformer.
Put sufficient wooden/steel packing below the jack to support the weight. Do not
lift more than 30 mm at a time. Use all jacks simultaneously. Jacks should not be
left in the loaded position for long time. Transformer should be handled only in
the normal upright position.
3.6 LASHING
The transformer is lashed on all four sides by wire ropes or chain of adequate
size and is tightened using turnbuckles with locking facility. After the movement
of the consignment for a short distance the tightness should be checked.
3.7 ROAD TRANSPORT
Generally road transport is resorted to in case of smaller units and of site where
rail link is not available or where well developed road system exists.
Multi-axle tractors driven low-platform trailers are used for transport.
Prior to taking decision to transport the heavy consignment by road a route
survey has to be conducted to confirm strength of bridges and the road
worthiness and to identify constraints if any enroute.
Weak bridges if any should be strengthened with the help of, Highways
department.
A pilot vehicle with all-necessary tools and tackles and trained staff should be run
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
in front of the vehicle. Red flags and danger lamps should be exhibited on the
consignment.
Tightness of lashing should be verified at frequent intervals during movement.
3.8 WATER TRANSPORT
Special cares to be taken during manufacture, packing and despatch of
transformers which are to be shipped through high seas. Even if it is not specified
FIG. – 3.3
by the purchaser the transformer should be applied with anti corrosive coating
and packaging should be strong enough for possible rough handling enroute.
Accessories should have polythene covering and should contain silicagel or any
other suitable moisture absorbent.
3.9 SHIPMENT OF ACCESSORIES
Accessories are packed and despatched separately. Items, which are detached
from the main body for transportation, are listed on the outline drawing. These
will be transported in suitable crates.
Crates containing fragile items should be marked 'FRAGILE' and handled
carefully during loading on vehicle, shipment and unloading at site.
Crates containing accessories, which should not be kept upside down like
condenser bushings, control panel etc. should marked 'THIS SIDE UP' and
should be handled as per manufacturer's instruction only.
Caution symbols for handling are painted on the packing cases.
3.10 SHIPMENT OF OIL
Transformer oil is despatched to site in sealed steel drums or tankers.
When oil is filled in drums, there should be sufficient air space to allow for
expansion and contraction of oil due to variations in temperature.
Drums with oil should be stacked only in horizontal position. This will avoid
collection of water on top of the drum, which may be sucked in by the vacuum
created inside the drum due to the contraction of oil owing to changes in ambient
temperature.
Due to any reason, if the drums are kept in vertical position, drums should be
covered with polythene or tarpaulin sheet to avoid risk of water getting collected
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
The recorder graph (paper recording tape) should be kept by the customer for
any future reference.
Column 1 Column 2
Read from centreline Read full swing of arc
(refer to Figure 3.6) (refer to Figure 3.7)
Axis X Y Z X Y Z
Device max.
recording limit 6G 15 G 10 G 6G 15 G 10 G
mm Space
3.175 1 1.7g 3.5g 2.0g 1.0g 2.1g 1.2g
6.35 2 3.3g 7.0g 4.0g 2.0g 4.1g 2.4g
9.525 3 5.0g 10.5g 6.0g 3.0g 6.2g 3.5g
12.7 4 6.3g 14.0g 8.0g 3.9g 8.2g 4.7g
15.875 5 8.2g 17.5g 10.0g 4.9g 10.3g 5.9g
19.05 6 5.9g 12.4g 7.1g
22.225 7 6.7g 14.4g 8.2g
25.4 8 7.4g 16.5g 9.4g
27.00 8.5 7.8g 17.5g 10.0g
Table 3.5 Typical instrument recording limits and reading of impact recorder chart
This docuument and anyy information prrovided in thiss Manual are the confidential property of PR ROLEC GE and must not be
disclosed, copied or used
d for Manufactu
uring, Tendering g or for any othe
er purpose witho
out written perm
mission. PROLE
EC GE shall not
assume any
a responsibilitty or have any liiability resulting from such unauuthorised use of any informatio
on.
SECTION – 4
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
Read the entire instruction Manual carefully before attempting to enter inside
the main unit, handle, install, use or service the transformer. Failure to follow
instructions could result in severe personal injury, death or property damage
and may void the warranty.
IMPORTANT NOTICE
In order to preserve the agreed warranty on your
transformer, the following checklists, included in the
Section 11, must be completed, archived by the
customer and provided to PROLEC GE for future
warranty purposes.
• Receiving Inspection
• Storage Inspection (if applicable)
• Internal Inspection
• Transformer Erection Checklist
• Pre-Commissioning & Site Test Results
• Every Six Months and Annual Maintenance
Inspection
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
PROCESS DOCUMENTATION
Receiving
inspection
Transformer checklist
Receipt
Receiving
inspection
To be NO checklist
installed Storage
immediately
YES
Transformer
erection
Erection checklist
NO
Vacuum filling
process
Pre
commissioning
Pre commissioning checks & site
tests test results
Maintenance
Transformer inspection
operation & checklist
maintenance
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
These instructions do not intend to cover all possible contingencies, which may
occur during shipping, receiving handling and storing the transformer.
If you require further information, please contact PROLEC GE India Service
Department.
When a transformer arrives at site a careful external inspection must be made of
the unit, its cooling system and all sealed components, referring to the general
arrangement drawing and the shipping list.
Inspect all packing cases and loose components for damage or missing items.
Check whether the transformer has arrived at site with a positive gas pressure in
case of despatch without oil. In case of despatch of main body in oil filled
condition, the oil level should be checked. One transport oil level gauge is welded
near the top of the tank for indicating the level of oil in the tank.
Should the transformer arrive at site without pressure (owing to gas leakage) it
must be assumed that moisture has entered the tank and that the moisture will
have to be driven out. In such cases the manufacturer’s advice must be sought.
Confirm that case numbers match with the packing list. Check their contents tally
with the packing list if the packing case is damaged.
IMPORTANT:
If any scratches or damage to the paint is noticed on receipt of Main body or
Accessories, touchup painting should be done immediately over the damaged
area. For procedures of touchup painting, refer to “ Clause 5.23: Touchup
Painting at site”.
4.3 REPORT OF DAMAGE PARTS ETC.
If any damage is noticed, claim must be lodged with the insurance agency and
the matter must be reported promptly to the manufacturer. The report should
contain sufficient details of damaged parts and extent of damage so that the cost
of replacement /rectification can be worked out.
4.4 INSPECTION OF MAIN UNIT GAS FILLED
After receipt of consignment at site, gas pressure inside the tank and the
temperature at the time of measurement should be recorded. The value obtained
should be compared with the gas pressure versus temperature chart furnished in
the instruction manual. (Refer fig.– 3.1 of chapter 3)
4.5 INSPECTION OF MAIN UNIT OIL FILLED
Upon arrival at site, check oil level inside the tank. If a transparent oil level gauge
is not provided, the oil level can be measured by connecting a transparent hose
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
Fig. 4.1
Lift the main body of the transformer with a mobile crane and wire ropes. The
crane capacity must be at least 10% higher than the weight of consignment.
Lifting angle of ropes should be limited to 30 deg. to vertical.
Unloading must be done with maximum care, avoiding any jerking movements or
dropping.
Use only the lifting bollards/hooks for slinging while lifting.
For lifting with hydraulic jacks, the transformers are provided with jacking pads
dimensioned for lifting the complete transformer filled with oil.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
If the foundation of the transformer is not ready and if the transformers are to be
unloaded temporarily, it should be done on leveled hard surface. Under base of
the transformer should not rest on the ground as it will lead to rusting of the
transformer.
Place at least 300 to 400 mm wooden sleepers to facilitate jacking.
4.7 PLACING IN POSITION
If foundation is ready and if rail link between unloading point/storage place is
available, then the main body of the transformer must be moved on its own
rollers to the foundation where the transformer is to be erected finally.
If the transformer is not provided with rollers and if it is to be erected on its skid
base, the transformer must be slid to its final position using greased steel plates
to protect the plinth surface and make movement easier. The plates should form
a continuous surface and it must clear the final jacking areas.
The transformer must be pulled by using slings and winches. Use only the
specified haulage lugs for pulling. Pulling capacity of winches should be more
than (Main body weight x 0.15/4) tons. Pulleys should have a capacity of (Main
body weight x 0.15/2) tons.
When jacking (e.g. to remove steel plates), position the jacks under specified
jacking pads only. When jacking, ensure that all four jacks are operated
simultaneously.
Before lowering, clean all grease dirt etc. from the under base of the transformer.
4.8 UNPACKING AND INSPECTION OF ACCESSORIES
Crates / packages are to be opened carefully so that the tools used for opening
do not cause damage to the contents.
Drums containing transformer oil, which have been despatched separately, shall
be examined carefully for leakage.
In case of Condenser Bushings, oil level shall be checked. Porcelain should be
checked thoroughly for any crack or chipping. Any oil leakage or damage to
porcelain must immediately be reported.
Fragile instruments like oil level gauges, temperature indicators etc. are to be
inspected for breakage or other damages.
Any damage or short shipment should be reported to the manufacturer.
4.9 STORAGE OF MAIN BODY
4.9.1 GENERAL
It is preferable to erect the transformer immediately on receipt at site and fill with
transformer oil. However, if it is not possible, the following precautions should be
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
taken for storing the main body and accessories for longer duration:
Storage period Recommendation
Upto 90 days Store the transformer filled with dry air or nitrogen
(dew point of -50OC or lower)
Between 90 and 180 If the transformer has been filled with dry air, it
days should be evacuated and replaced with nitrogen.
More than 180 days The transformer must be vacuum filled with oil.
The storage area should be adequate and should be easily accessible for
inspection.
The surface on which it should be stored is strong and levelled.
Surrounding area of storage is not polluted and water does not accumulate in the
storage area.
Sufficient space is provided underneath for free flow of air and also for lifting,
jacking etc.
4.9.2 GAS FILLED STORAGE
It is recommended to keep the transformer oil filled immediately after receipt. If
oil can not be filled immediately after receipt of main body, it must be retained
with dry nitrogen gas filled at a positive pressure of 0.2 kg/ cm2 at about 20oC.
(Please ref. Fig.– 3.1 of Chapter 3 for Pressure Vs Temperature Chart).
The duration of gas filled storage should be limited to 90 days from the receipt of
main body at site.
If the pressure of gas inside drops due to leakage, the leakage point may be
detected by using soap water. The matter shall be reported to the manufacturer
for immediate corrective action.
Should it not be possible to rectify the leak immediately, the transformer must be
covered by putting a tarpaulin sheet over the whole tank until remedial measures
can be carried out.
Gasket must not be tightened indiscriminately as this could result in loss of
gasket property due to over compression.
Pressure inside the transformer should be monitored on daily basis and any
pressure drop should be made up by opening the cylinder and operating the
pressure regulator. The cylinder should be kept closed.
Before deciding on loss of pressure, the pressure versus temperature chart (Fig.
–3.1) shall be referred to.
If the storage period of transformer at site is expected to be beyond 180 days, it
is recommended to keep it filled with transformer oil.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
Accessories and parts must have indoor storage. If indoor storage is not
possible, a weatherproof tarpaulin must be used to cover accessories
wooden boxes.
The following points may be taken care of in order to keep accessories in good
condition without damage, rust and dust.
Check and confirm that all packing cases as per packing list are received in good
condition.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
If erection work is not likely to commence immediately the boxes, which are
opened for inspection, should be repacked and the packing list retained for future
reference and records.
All packing cases should be kept above ground on suitable support so as to allow
free circulation of air underneath. Water should not collect in the storage area.
There should be sufficient space for inspection, handling and transport.
All fragile items and instruments should be stored indoors.
If for any reason, the bushings were not stored according to the
recommendation mentioned above, they must be placed in vertical position
for 48 hours prior to testing or energisation.
The bushings must be stored in their shipping crate. If a bushing is not sored in
its shipping crate, precautions should be taken to provide adequate oil coverage
by positiong the upper end at a level higher than the lower end. An angle of
seven degrees or higher above horizontal must be maintained.
All crates should be kept as per the markings provided on the crates by
manufacturer. As a general rule, all control boxes such as RTCC Panel,
Marshalling Box, Drive Mechanism etc. should be kept indoors in vertical
position.
Crates should not be stacked one over the other.
Strictly adhere to the specific storage instruction provided by the manufacturer for
specific items.
Table - 1 may be referred to for further guidelines for storage and periodical
inspection of transformer accessories.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
SECTION – 5
INSTALLATION
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disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
5.0 INSTALLATION
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
Do not open any covers or fittings unless zero gauge pressure exists inside
the unit. Failure to release the pressure may cause equipment damage and
personal injury or death.
The items removed and shipped separately are listed on the outline drawing, such
as bushings, cooling equipment, oil pumps, gas and oil relays etc. Please refer to
the outline for accessories mounting location.
5.3 INTERNAL INSPECTION
Do not enter any transformer until the gas in the tank is replaced by dry air.
Oxygen content inside the transformer must be at least 19.5% before entering
the transformer. Dry air filled shipment does not imply that the oxygen content
test may be safely omitted. Oxygen content less than 19.5% may cause
drowsiness and/ or injury and death.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
Table -1
Selection of Samples from drums
No. of Drums in a Batch No. of Drums from which Samples to
be taken
2 to 5 2
6 to 20 3
21 to 50 4
61 to 100 7
101 to 200 10
201 to 400 15
401 and more 20
Samples for testing should be collected from the bottom of the drums.
If oil is received in containers, oil sample shall be collected through the sampling
valve at the tank outlet or by means of thief dipper as suggested for sampling of
oil from drums. The container should be allowed to stand for atleast one hour
before drawing the sample.
Conduct the following tests for ascertaining the quality of oil.
a) Breakdown Voltage test
b) Moisture content test
c) Tan delta
d) Resistivity
If oil does not meet the specified criteria, oil should be filtered and stored in the
oil storage tank before filling in to the transformer.
While pumping oil from the barrels, the barrels may be tilted suitably to ensure
that complete oil is taken out from each barrel.
5.6 PRECAUTIONS:
During erection it is advisable that only one hand hole cover is opened at a time
in order to minimise the ingress of moisture. The hand hole cover should be
replaced as soon as the operation is completed.
Dry air of dew point –60oC or better must be fed through the inside of tank when
covers are removed in case of 400 kV and higher class of transformers to avoid
direct contact of winding insulation with moist air outside.
It is essential that the transformer be filled with oil immediately on completion of
each day’s work. The exposure of core and winding should not exceed 16 hours
at a stretch.
Insulation resistance between core frame and tank must be checked before oil
filling with a 2 kV megger, the insulation resistance must be compared with the
factory test results.
Measure the insulation resistance between:
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disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
a) HV – Earth (Tank)
b) LV/ IV – Earth (Tank)
c) HV – LV/ IV
d) Core Frame – Earth (Tank)
5.7 ERECTION PROCEDURE
The following sequence is flowed for the erection of large capacity transformers
at site.
a) Preparation for Installation
b) Placement of Main body on plinth
c) Receiving Inspection and Storage
d) Oil receiving and filtering
e) Replacing inert gas with Oil
f) Assemble Bushing turrets
g) Assembly Bushings and Cable Boxes
h) Assemble Coolers
i) Assemble Conservator
j) Assemble Pressure Release Device
k) Assemble H V Bushings
l) Assemble Accessories
m) Internal Lead connections
n) Control Wiring
o) Oil Leakage Tests
p) Oil Filling under Vacuum
q) Touch Up Painting
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
Open the bottom filter valve on the transformer and top air release valve on the
oil storage tank.
Oil should be filled upto a level above the top insulation of transformer winding.
A small gas space (approx. 5~10%) should be left above oil for expansion of oil.
During oil filling, if the filter press stops due to any reason, the top filter valve and
any other opening on the top of the transformer should be closed immediately to
prevent air getting into the transformer.
Oil level shall be continuously monitored during oil filling.
While filling oil directly from the barrels, the barrels shall be tilted suitably to
ensure that complete oil is taken from the barrels.
After filling oil, if the storage is expected to be for a long period, dry gas should
be filled above the oil at a pressure of 0.1 ~ 0.2 kg/cm2.
Assembling work should start from the bottom of the tank so that after initial oil
filling, oil need not be drained again for assembling work.
Tightness of all inside connection should be checked and proper locking shall be
provided.
Persons working inside the transformer or top of the transformer should not wear
wristwatches, pen, coins etc.
5.10 ERECTION OF PIPE WORK
All items of pipe work are match marked.
All joints are to be assembled with gasket only and without joining compounds or
grease.
Joints must be fully tightened only when the transformer has been fully erected;
by that stage the pipes can be centralised.
No joint must be under excessive assembled load as subsequent expansion or
contraction could cause leaks.
Ensure that all accessories belong to the same unit.
Vent piping system shall not be used to attach the safety harnesses. Using
this tubing as a safety hook up point, will cause damage to the tubing, leaks
on fittings and may cause an accident.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
While mounting the oil pump and oil flow indicators, care should be taken to
ensure the arrows indicating the oil flow direction are towards the transformer
tank.
While mounting radiators care should be taken to ensure that the weight is
balanced.
Ensure that a fresh gasket is used while mounting the radiators.
In case of separately mounted coolers, the oil pipes are provided with expansion
joints. Tack welded bars on expansion joints should be removed.
Fix the fan mounting frames and fans as indicated in the general arrangement
drawing.
Fan & mounting frame shall be connected to the earth grid.
5.12 CONSERVATOR
Mount the conservator as shown in G.A. Drawing.
Very often the small conservator for on load tap changer is attached to the main
conservator.
Usually the main conservator is provided with Magnetic Oil level Gauge having
low oil level alarm contacts and OLTC conservator is provided with oil sight
window.
Magnetic oil level gauge shall be mounted after attaching the float to the gauge.
Check and confirm free movement of float arm and proper locking of float to the
float arm.
Mount all valves as shown in GA drawing on the conservator.
Mount the connecting pipe with Buchholz relay from the main tank to the
conservator. Ensure direction of Buchholz Relay by the direction of arrow on
Buchholz Relay towards conservator.
Ensure to remove the Buchholz shipping spacer protection for the alarm and
trip switches.
Mount connecting pipe with oil surge relay from OLTC to the conservator.
Mount breather connecting pipes and silica gel breathers for the main tank and
OLTC conservators.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
The shipping plastic storage plugs must be removed to allow free breathing.
Failure to remove these plugs will cause a unit shut down and/ or cause
leaks at various gasket locations.
Keep air release valves open. Fix air filling adapter on breather pipe and inflate
the air cell at an air pressure indicated on the INSTRUCTION PLATE affixed on
the transformer and hold air pressure.
Open the air release valves and start oil filling from the bottom filter valve of the
transformer.
Observe the air release valves and as soon as oil starts overflowing, close the air
release valves one by one. Stop oil filling when all air release valves are closed.
Remove the air filling adapter.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
Continue oil filling and observe the Magnetic Oil Level Gauge (MOLG)
Stop the filling when the needle of MOLG shows the level corresponding to the
ambient temperature at the time of filling.
Fix silica gel breather.
CAUTION:
a) Do not open any of the air release valves after completion of oil filling. If air
release valve is opened, air will enter and oil level will drop.
b) The plain oil level gauge on the end cover of the conservator should
indicate full oil level always. If air enters the conservator, it can be seen by
a fall in the oil level in plain oil level gauge.
c) The plain oil level gauge should be monitored on regular basis.
FILLING PROCEDURE UNDER VACUUM IN CONSERVATOR
The conservator, with its separator, being set up and plugged in above the
transformer, is connected to its oil filling reserve by a pipe in its lower part.
Proceed as follows:
Create a vacuum in separator.
With the same source of vacuum, create a vacuum in the conservator.
Open the oil filling valve of the transformer. Because of the vacuum in the
conservator, the oil level rises automatically.
Stop the oil filling once the required volume in the conservator is attained.
While maintaining the conservator under vacuum, allow Dry Air or Nitrogen gas
to enter into the internal part of the separator. Then, the separator inflates by
itself, and takes all the free space due to the fact that the conservator was not
completely full. In particular, during the operation, the oil is going to rise to the top
of the conservator.
Inflate the separator at a maximum as shown in the INSTRUCTION PLATE.
Check on the vent-holes, and confirm that there is no more air in the conservator
or, if necessary, adjust the level.
CAUTION:
The above mentioned CAUTION regarding the opening of air release valves
after completion of oil filling is applicable for this case also.
5.13 PRESSURE RELIEF DEVICE
Mount PRD as per manufacturers leaflet and also the G.A. drawing of
Transformer.
Check operation of alarm/trip contacts.
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disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
adopt oil filled gear box. Oil, if required, shall be filled as per the manufacturer's
instructions.
Coupling up of drive mechanism and OLTC bevel gear shall be done only after
ensuring that both are at the same tap position. Normally the transformer is
despatched from the factory at rated Tap position.
Operate the DM manually from rated tap to tap no. 1 and then to the other
extreme tap position and bring back to rated tap.
Operate DM electrically. Check and confirm that for each impulse given in both
raise and lower directions, diverter switch operation sound is heard before the
motor stops. After hearing the sound, the travel of the tap position indicating disc
upto the green band shall be equal in both forward and backward crank
operation.
Verify the ratios on all taps using ratio meter or digital voltmeter.
5.17 CABLE BOX ASSEMBLY
If cable box is provided, the assembly shall be carried out referring to the cable
box assembly drawing provided in the Instruction Manual.
Cable sealing ends shall be fitted on to the end of the cable before it is inserted
and bolted on to the cable box.
Cable box assembly may be bolted to the disconnecting chamber on the
transformer tank.
Flexible connections shall be made between bushings and cable box bus bars
through the Inspection Cover.
5.18 INSTRUCTIONS REGARDING USAGE OF GASKETS
Gasket materials used are either Synthetic Rubber Bonded Cork (SRBC) sheet
or nitrile rubber.
SRBC material conforms to RC-70C of IS : 4253(Part II); thickness used are 6.0
mm and 10.0 mm.
Gaskets should be stored in stress free condition and must be protected from
moisture, oil and grease.
Synthetic rubber bonded cork sheets once used should not be used again.
Gasket seating surfaces should be smooth and free from scratches, oil, grease,
dirt etc.
Gasket should be properly located before tightening.
Gasket joints are designed with 40~50% compression.
Gasket joints should be tightened evenly with a diametrically opposite sequence.
Full compression should not be achieved in one go.
Over tightening will cause the gasket material to loose its properties and under
tightening may not prevent oil leakage.
5.19 CHECKING LEAK RATE UNDER VACUUM
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
COLUMN 1 2 3 4
BIL (kVp) Upto 350 450 ~ 550 650 ~ 750 825 ~ 1425
Initial Vacuum Level 2 Torr 1 Torr 0.5 Torr 0.25 Torr
Level of vacuum to be 2 Torr 2 Torr 1 Torr 1 Torr
maintained during oil
filling
Soaking period before 8 Hours 12 Hours 24 Hours 48 Hours
energising
Table 5.1 – Vacuum oil filling requirements
Minimum level of vacuum to be maintained during oil filling of transformers of
different voltage class are shown in Table 5.1. The vacuum shall preferably be
measured by using McLeod Vacuum Gauge.
After draining the oil completely from the transformer, vacuum should be pulled
from the oil filling hole on main conservator. If the conservator is fitted with air
cell, pressure equalising connection is required to avoid damage to the air cell.
For facilitating evacuation of main transformer and diverter switch compartment
of OLTC simultaneously, an equaliser pipe (Refer GA drawing for item number &
location) is supplied. This is to be fitted during evacuation and removed after
vacuum oil filling.
Before starting vacuum, all bolted connections shall be checked.
Radiator valves shall be kept open.
If explosion vent is provided, the pressure shall be equalised on either side of the
diaphragm to avoid damage to the diaphragm.
Vacuum shall be maintained for 6 hours.
The oil temperature during the start of filling shall be maintained at 50 ~ 60OC.
Oil may be injected through the bottom filter valve until the level reaches 35oC
marking on the Magnetic Oil Level Gauge of the conservator.
Initial oil filling shall be done at a slow rate (do not exceed 150 lpm) . Rise in oil
level per hour inside the transformer shall be limited to 300 mm.
Natural rubber hose shall not be used as sulphur in the rubber may react with oil.
Oil inlet valve shall be closed and after one hour the vacuum shall be broken.
Install all remaining components.
Oil level indicating vinyl hose can be removed by closing the bottom sampling
valve.
Vacuum gauges may be detached and breathers assembled in its position.
Pressure equalising connection provided for explosion vent diaphragm and
OLTC diverter chamber shall be removed.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
SECTION – 6
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
Leak Test @
(5 – 7 p.s.i)
Moisture content
Verification
No
No
Greater than or
Yes
equal to 1.8%?
No
Vacuum dry –
out Process
(According to
Appendix A.4)
Vacuum filling`
Process
(According to
Section 5.22)
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
SECTION – 7
COMMISSIONING
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
7.0 COMMISSIONING
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
properly.
All isolating switches are set at ON position.
Cooler control switch is set to AUTO.
All alarm circuits are reset.
OLTC to Transformer equalising pipe shall be removed after oil filling under
vacuum and the opening shall be coverd by blanking plate supplied with the
transformer.
CAUTION:
If there is a residual magnetism in the core, it can give erratic
readings.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
SECTION – 8
OPERATION
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disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
8.0 OPERATION
After the inspection and pre-commissioning tests are successfully completed the
transformer can be energised at no load.
Oil soaking/ settling duration of 2 days for transformers up to 245 kV class and 3
days for 400 kV and above class are recommended after completion of hot oil
circulation and before energising.
Excessive vibration if any on any part of the transformer shall be located and
rectified.
Transformer shall be observed for any abnormality.
If any gas is collected inside the Buchholz relay, it shall be analysed for its
combustibility. If gas is not combustible, it indicates air trapped inside the
transformer.
All instruments should be checked for any abnormal indication.
Check winding temperature and oil temperature readings at least once in every
shift.
Check and confirm that tap position indicators is same in local and remote
indicators.
Check and confirm that none of the alarms are indicated.
Ensure that cooler power supply isolator is ON.
Ensure that cooler control is in AUTO.
Ensure that pumps and fans are running smoothly as temperature dictates. If the
temperature is below the ON setting neither the pump nor fan should be running.
After watching the operation of the transformer at no load for 24 hours and
confirming that everything is normal, the transformer shall be taken on load.
Observe the rise in temperature of oil and winding temperature indicators.
While temperature is rising, confirm that fans and pumps are switched on
automatically at the preset temperatures.
While temperature is falling, observe that the pumps and fans are switched off at
preset temperature.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
SECTION – 9
MAINTENANCE
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
9.0 MAINTENANCE
Maintenance Schedule
Periodicity
Preventive Maintenance
Procedures Months Scheduled
3 6 12 outage
Replacement / Regeneration of
Silica gel Breather
Dissolved Gas Analysis
Oil Sampling
Buchholz Relay Functional Tests
Tan Delta & Capacitance
Measurement of Condenser
Bushings
OTI/ WTI Tests
Tap changer operation
Insulation Resistance of Windings
Oil Filtration
Surface Painting
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
9.3.3 Calibration
Remove the thermal sensing bulbs from the transformer and insert it into the hot
oil bath.
Check the winding temperature readings up and down the scale at intervals of
5OC.
Confirm from control room that remote temperature readings are tallying with the
local readings.
Replace the sensing element into the transformer pocket.
Note: For any adjustment, see the manufacturer's catalogue.
9.3.4 SECONDARY INJECTION TESTS
9.3.5 ONAN Rating
Set the cooler supply isolator of OFF position.
Connect the secondary injection test set across the heater coil terminals.
Inject current and check the resultant gradient for ONAN rating.
If relay has not operated, increase gas pressure and repeat the test.
If the relay is found faculty replace it with a new one.
Open conservator shut off valve and release all gases trapped.
9.5 TAPCHANGER OPERATION
Regular inspection of tap changing equipment is not required because
mechanical operation of tap changer does not involve significant contact wear.
It is sufficient to operate the tap changer through the whole range of tap selector
positions twice a year.
The purpose of this check is to ensure correct mechanical operation of tap
changer.
Transformer shall be isolated and earthed.
Note the tap position.
Operate the tap changer through operating handle through entire range of tap
positions.
Return to the original tap position.
Set the local selector switch to LOCAL.
Press RAISE button and release. Check and confirm the tap position indication
has changed and that limit switch stops the tap changing at preset tap.
Repeat.
Press the LOWER button and release. Check and confirm that limit switch has
operated and tap position indication has changed.
Repeat till the tap position has returned to the original value.
Set the local selector switch to REMOTE.
9.6 OIL FILTRATION
Purpose of this maintenance is to improve the unsatisfactory condition of oil
found during sampling.
Transformer shall be isolated and earthed.
9.6.1 Tools and Materials
Oil conditioning plant (Filter Machine)
50 mm flexible hoses of sufficient length for oil inlet and outlet.
Hose adapters to match the flanges of top and bottom filter valves.
Cleaning cloths
9.6.2 Procedure
Remove the blanking plate from filter valves and connect the oil inlet hose to top
filter valve and oil outlet hose to the bottom filter valve.
Open the filter valves and start circulation of hot oil. Oil temperature shall be
55°C to 70°C.
Circulate the oil for 4 full passes.
Re sample and arrange to test.
Continue until oil condition is acceptable.
9.7 CORRECTIVE MAINTENANCE
All flange gaskets must be renewed wherever joints are dismantled.
Cleanliness of gasket surfaces and correct compression (40 % ~ 50% approx.) of
gasket must be ensured during reassembling.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
If the radiator is on a separate cooler bank, oil shall be filled into the radiator
bank through the bottom header valve by using the filter machine. If the radiator
is tank mounted, the oil from the oil tank should be pumped into the tank by using
the filter machine.
Close the air release plug on top as soon as oil starts flowing through the air
release plug.
Shut down the oil filter machine
Open top header isolating valve.
In case of separate cooler banks, air should be released through the top common
header air release plugs.
9.10 REMOVING AND RE FITTING FAN & MOTOR
9.10.1 Tools and materials
Forklift truck to take weight of fan and motor assembly.
9.10.2 Procedure
The transformer is to be isolated and earthed.
Set cooler supply isolator to OFF and lock the marshalling box.
Disconnect the fan motor supply wires.
Support the weight of fan and motor assembly by using fork lift truck.
Unbolt fan and motor form fan mounting frame.
Lower the fan from the fan-mounting frame.
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disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
SECTION – 10
TROUBLE SHOOTING
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
10.6 PUMPS
SYMPTOM POSSIBLE CAUSE REMEDY
Pump Motor Impeller binding Remove the pump and investigate
over heats the problem.
Insulation failure of Remove the pump and investigate
Motor Winding the problem.
Two phase operation Check power supply.
Remove pump and investigate the
Motor bearings worn
reason
Pump motor Remove pump and investigate the
Impeller damaged
vibrating reason
Pump bearing bushes Remove pump and investigate the
or rings worn. reason
Pump Valve not fully open Open the valve fully.
running; Impeller damaged or Remove pump and investigate the
but output worn reason
low. Speed too low Check electric supply.
10.7 FANS
SYMPTOM POSSIBLE CAUSE REMEDY
Remove the fan and investigate
Fan motor Motor bearing worn
reason.
overheats
Two phase operation Check electric supply
Fan vibrating Fan blades out of Balance the fan or replace
balance and noisy
Mounting bolts loose Check and tighten fasteners.
10.8 BUCHHOLZ RELAY
SYMPTOM POSSIBLE
REMEDY
CAUSE
Rate of Electrical Identity of Class of fault Inference
gas response of gas
evolution relay
NONE Trip None Oil surge Faulty operation of oil
mechanism pump
operated by
Sudden Large masses of
oil surge
vaporisation of metal heated Eg.:
oil at Earth fault, short
260~400OC circuit not causing
insulation failure.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
Boiling of Simultaneous
water in occurrence of a heat
exceptional producing fault and
cases entry of water into
the tank.
RAPID Alarm Air or inert Major leak due Fracture of tank,
operates and gas to mechanical pipe, or Buchholtz
repeats after fault relay casing or faulty
releasing oil circulating pump.
gas
Trip and Hydrogen Thermal
Local, very high
alarm decomposition
current, hot spot not
mechanism of oil above
involving insulation,
operates 400OC
arc over between
metal parts of
Terminal gear or
terminal to tank.
Hydrogen Thermal Local hot spots due
and carbon decomposition to
monoxide of oil and very high current
insulation faults in contact with
solid insulation.
Eg. Insulation failure
followed by arc
between insulated
conductors and
earth, short circuited
turn
etc.
MEDIUM Alarm Air or inert Air leaks or Fracture of tank pipe
operates and gas leakage due to or Buchholz relay
repeats mechanical casing or faulty oil
within fault. circulating pumps
minutes or Hydrogen Thermal Local hot spots not
hours after decomposition involving insulation,
each release of oil above faulty joint/ contacts,
O
of gas 400 C core faults causing
burning, an incipient
fault not involving
solid insulation
Eg. Core not properly
earthed
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
O2 (Oxygen)
N2 (Nitrogen)
CO2 (Carbon dioxide)
CO (Carbon monoxide)
H2 (Hydrogen)
CH4 (Methane)
C2H2 (Acetylene)
C2H4 (Ethylene)
C2H6 (Ethane)
C3H6 (Propylene)
C3H8 (Propane)
Table 10.6
"Normal" Values of Dissolved Key Gas Concentration Limits in oil of
Power Transformers in Service [Parts per Million – ppm].
(Ref. FIST 3-30* : October 2000)
Status H2 CH4 C2H2 C2H4 C2H6 CO CO2† TDCG‡
Condition 1 100 120 35 50 65 350 2500 720
Condition 2 101~ 121~ 36~ 51~ 66~ 351~ 2500~ 721~
700 400 50 100 100 570 4000 1920
Condition 3 701~ 401~ 51~ 101~ 101~ 571~ 4001~ 1921~
1800 1000 80 200 150 1400 10000 4630
Condition 4 >1800 >1000 >80 >200 >150 >1400 >10000 >4630
*
Ref: FIST 3-30 (Transformer Maintenance; Facilities, Instructions, Standards and
Techniques by United States Department of the Interior Bureau of Reclamation, Denver,
Colorado)
†
CO2 is not considered in the calculations for TDCG, because it is not a combustible gas
‡
TDCG means Total Dissolved Combustible Gas
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disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
Condition - 1
Total Dissolved Combustible Gas (TDCG) and any individual combustible gas
below this level indicate normal operation of the transformer. If any gas exceeds
the specified level, it needs investigation.
Condition - 2
TDCG and any individual combustible gas in this range indicate greater than
normal combustible gas level. A fault may be present. Further monitoring is
required.
Condition - 3
TDCG and any individual combustible gas in this range indicate a high level of
decomposition of cellulose insulation and / or oil.
Condition - 4
TDCG and any individual combustible gas in this range indicate excessive
decomposition of cellulose insulation and / or oil. Continued operation could result
in failure of the transformer.
Note:
A sudden increase in key gases and the rate of gas generation are more
important in evaluating a transformer than the amount of gas.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
Table 10.7
Action based on Dissolved Combustible Gas concentration.
Conditions TDCG Level or TDCG Sampling Intervals and Operating Actions for
Highest Generation Gas Generation Rates
Individual Gas Rates Sampling Operating Procedures
(Ref. Table 9.5) (ppm / day) Interval
Condition 1 720 ppm of Annually/ 6 Continue normal operation
TDCG or < 10 Monthly for
highest EHV Trf.
condition based 10 ~ 30 Quarterly
on individual Exercise caution. Analyse
gas from Table > 30 Monthly individual gases to find cause.
9.5 Determine load dependence.
Condition 2 < 10 Quarterly Exercise caution. Analyse
10 ~ 30 Monthly individual gases to find cause.
> 30 Monthly Determine load dependence.
Condition 3 < 10 Monthly Exercise caution. Analyse
10 ~ 30 Weekly individual gases to find cause.
> 30 Weekly Plan outage. Contact
manufacturer for advice.
Condition 4 < 10 Weekly Exercise caution. Analyse
individual gases to find cause.
10 ~ 30 Daily Plan outage. Contact
manufacturer for advice.
> 30 Daily Consider removal from service.
Contact manufacturer for advice
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
Table –10.8
Transformer Fault Types and the gases they produce.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
C2H2 (acetylene /hydrogen) : >2 & C2H2 >30 ppm indicates possibility
H2 of tap changer oil leaking into main tank
Note:
Ratios are to be calculated only if the concentrations of both the gases are
above the detection levels.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
SECTION – 11
CHECKLISTS
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disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
Additional comments
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
Inspected by
Name Signature
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
The same steps that are followed for less than three months of storage per that if the
transformer is going to be stored up to 6 ONLY approved gas that may be used to fill
the transformer is high purity nitrogen (-50°C / -58°F dew point or lower).
FOLLOW THESE STEPS IF THE UNIT IS GOING TO BE STORED more than 6 MONTHS
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
Notes:
1) If any damage is found during internal inspection, PROLEC GE should be
immediately notified.
2) For the purpose of this list, “tight” means that it cannot be moved applying the hand
force.
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disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
Additional comments
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
Inspected by
Name Signature
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disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
CUSTOMER : ……………………………………………………………
EQUIPMENT DETAILS: ……………………………………………………………
SITE : ……………………………………………………………
4 ERECTION
Mounting of rollers
Conservator mounted correctly
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disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
5 OIL FILLING
6 CABLING
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
7 BREATHERS
8
FANS
Cable termination
Cable glanding
Control cabinet clean & tidy
Heater supplied
Locking arrangement
Date:
Signature: ---------------------------------- ----------------------------------
Name: ---------------------------------- ----------------------------------
(FOR PROLECGE) (FOR CUSTOMER)
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disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
Date & Vacuum Ambient Relative Date & Vacuum Ambient Relative
Time Level Temperature Humidity Time Level Temperature Humidity
(Torr/ (OC) (%) (Torr/ (OC) (%)
millibar) millibar)
2
3
4
5
6
7
Result Reading
calculation 7–1=
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disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
Customer : ________________________________________________________
Site : ________________________________________________________
TRANSFORMER RATING:
MVA: _____________________ Ratio: ___________________________________
REMARKS
CHECK POINTS
9 Explosion vent
12 Aircell commissioned
MARSHALLING BOX
1 W.T.I. (Sl.No., Make & Model)
a. Transit lock released
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
C O.T.I. Repeater.
O.L.T.C. Operations :
a. Individual :
b. As Master :
c. As Follower :
Emergency Trip.
Out of step & MP Timer operation.
Operation of A.V.R. & L.D.C.
Operation of Pumps, NRV, Flow Indicators:
1 Direction of pump operation.
2 Manual operation.
3 Auto operation.
4 Stand-by changeover.
5 Non Return Valve operation.
6 Overload setting
7 Starting current
8 Running current
9 Stability of alarm & trip contacts of Buchholz relay during oil
pump starting by manual / Auto mode
10 Megger value (500 V / 1000 V Megger )
S I T E T E S T R E S U L T S:
Insulation Resistance:
Range, Make, kV rating & Type of tester:
1 Top oil Temperature:
2 Megger Values:
60 600 600
60 Sec.
Sec. Sec. Sec.
H.V. to L.V.: H.V. To
Earth
H.V. to T.V.: T.V. To
Earth
L.V. to T.V.: L.V. To
Earth
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disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
C. T. DETAILS
CHECK POINT
Continuity
Approx. Ratio
Polarity (Only for REF /
DIFFL. C.T)
Saturation check only
for PS class C.T's
TAN DELTA & CAPACITANCE TEST OF BUSHINGS:
NOTE: Please ensure that the bushings are absolutely clean and the test is caaried out
in dry weather conditions. Arcing horns if any, should be removed.
Bushing Sl. Make Rating A / V Tan delta Capacitance Megger value
No.
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disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
Apply single phase 240 or 440 volts on each HV line lead and ‘N’ or pair of HV line leads
and Measure LV voltage on all taps in all phases.
Tap HV Volts (applied) LV1 Volts LV2 / Tertiary
No.
1U- 1V- 2U- 2V-
1W-1U 2W-2U 3U-3V 3V-3W 3W-3U
1V 1W 2V 2W
1U- 1V- 2U-
1W-1N 2V-2N 2W-2N 3W-3N 3V-3N 3W-3N
1N 1N 2N
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
MAGNETIC BALANCE AT NORMAL TAP POSITION : (For star winding only)
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disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
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disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
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disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
DETAILS OF ACCESSORIES:
1 H.V.BUSHINGS:
Make:
Rating:
Sl. No.:
2 L.V.BUSHINGS:
Make:
Rating:
Sl. No.:
3 O.L.T.C. DETAILS:
Make:
Type:
Sl. No.:
4 FACIA DETAILS:
Make:
Sl. No.:
Model:
No. of windows :
Voltage:
5 PRESSURE RELIEF DEVICE:
Make:
Sl.No:
Pressure Setting:
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disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
Customer:
INSPECTED BY:
______________________________ ____________________________
NAME SIGNATURE
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disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
Customer:
Note:
1. All samples for oil testing should be drawn from the bottom/ top sampling valve
and it should be noted from where the sample is drawn.
2. Temperature of oil in the transformer at the time of sampling should be recorded.
INSPECTED BY:
______________________________ ____________________________
NAME SIGNATURE
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
Customer:
INSPECTED BY:
______________________________ ____________________________
NAME SIGNATURE
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
Customer:
INSPECTED BY:
______________________________ ____________________________
NAME SIGNATURE
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
Customer:
Note:
All electrical tests should be performed while the transformer is de-energised. Never
attempt to test a transformer while it is energised; doing so may cause severe damage to
property or death.
1 Thermography
2 Winding resistance
5 Excitation Current
6 Insulation Resistance
INSPECTED BY:
______________________________ ____________________________
NAME SIGNATURE
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disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
Customer:
INSPECTED BY:
______________________________ ____________________________
NAME SIGNATURE
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disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
SECTION - 12
REFERENCE STANDARDS
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disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
IEC 60567 (2005) Guide for the sampling of gases and of oil from
oil filled electrical equipment and for the
analysis of free and dissolved Gases.
IEC 60599 (2007) Guide to the interpretation of dissolved and free
gases in mineral oil-impregnated electrical
equipment in service.
IEC 60616 (1978) Terminal and tapping marking for power
transformers.
IEC 60628 (1985) Gassing of insulating liquids under electrical
stresses and ionisation.
IEC 60947 (Part 1 to 7) Low voltage switchgear and control gear.
IEC 61378-1 (1997) Converter Transformer for industrial application.
IEC 61378-2 (2001) Converter Transformer for HV DC application.
IEC 61378-3 (2006) Converter Transformers; Application Guide.
IEC 61639 (1996) Direct Connection between power transformer
and gas insulated metal enclosed switchgear for
rated voltages of 72.5kV and above.
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disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
SECTION - 13
TRANSFORMER ACCESSORIES
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
TEMPERATURE INDICATOR
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
1. APPLICATION
The Temperature indicator is used as an Oil Temperature Indicator (OTI) or as
Winding Temperature Indicator (WTI) for the protection of liquid immersed power
transformer. In the case of dry type transformers it is used as Temperature
Indicator (T.I.) to monitor the temperature of the windings.
2. SCOPE OF SUPPLY
OTI & TI: Instrument with specified Range, Number of control switches, length of
capillary and sensing bulb.
WTI: Same as 2.1 but fitted with specified thermal image device.
TRANSMITTER (OPTIONAL): A precision potentiometer is mounted inside the
case of OTI or WTI (2.1 or 2.2) to transmit the measured temperature to remote
point(s).
REPEATER (OPTIONAL): Analogue indicator supplied separately for remote
indication of the temperature measured by OTI or WTI (2.1 or 2.2)
3. OPERATION
The instrument operates as OTI when its sensing bulb is mounted in an oil filled
pocket located in the hottest oil of an oil immersed transformer.
The instrument operates as TI when its sensing bulb is exposed to the medium
adjacent to the windings of a dry type transformer.
When a proportionate load current of the transformer is passed through the
thermal image device, the instrument operates as a WTI integrating the simulated
temperature rise of the thermal image device and the top oil temperature
measured by the sensing bulb.
Remote indication of the temperature measured by the OTI or WTI is provided by
connecting the transmitter to the repeater either directly or through a resistance
transducer (resistance to current converter).
4. CONSTRUCTION
LIQUID-FILLED SYSTEM (Refer Fig. 1): A sensing bulb (25), a measuring
bellows (2) and a small bore capillary tube (24) connecting the two, form the
measuring system. A second bellows (16-compensating bellows)
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disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
connected with a second capillary (24) running parallel to the first capillary and
terminated at the head of the bulb from the temperature compensating system.
Both the systems are completely filled with the same liquid (other than mercury).
The two bellows are linked to a compensating lever (15) in such a manner that the
effect of ambient temperature changes on the capillary line and measuring
bellows is compensated. The movement of the measuring bellows is related only
to the temperature being measured by the sensing bulb. This movement is
amplified by the link and lever mechanism (6), which directly drives the rotating
disc (21) carrying the control switches. The same mechanism moves, through
rack and pinion a separately mounted indicating pointer (Fig. 2, 11) over a
calibrated dial. Head compensation is provided by sealing both the systems under
initial pressure, which is greater than the possible head pressure due to
differences in the elevation between the bulb and indicator.
MAXIMUM POINTER (RED COLOURED) located on the indicator lid, is
resettable from outside the case by a screw driver blade. Unscrew and remove
black cap to reach the screw driver-slot.
CAUTION: Never use the switch testing knob for setting the maximum pointer. If
used, the switch contacts will close and initiate the external control circuits when
the instrument is in operation.
SWITCH TESTING KNOB: It is fitted on the indicator lid to check mercury
switches setting and potentiometer operation. This knob when rotated moves the
indicating pointer, switch mechanism and potentiometer wiper together and
facilitates testing these circuits without opening the lid. Rotate the knob slowly and
steadily for an accurate check. Never allow the knob to spring back suddenly or
quickly, as this will cause damage.
THERMAL IMAGE DEVICE (Refer Fig. 1): A heater coil (3-Bellows Heater) is
fitted around the measuring bellow (2) and supplied from a current transformer in
the load circuit of transformer. The heater coil simulates hot-spot temperature of
the winding over top oil temperature for a given load. The measuring bellows
reacts to this simulated temperature rise in addition to the top oil temperature
measured by the sensing bulb and the instrument functions as a WTI displaying
the hottest spot temperature of the winding. An adjustable shunt resistor (17-
calibrating shunt) is provided for shunting portion of the current through the heater
coil to obtain precise thermal image.
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disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
FIG. 1
INDICAT
TOR
(LID & DIAL RE
EMOVED)
This docuument and anyy information prrovided in thiss Manual are the confidential property of PR ROLEC GE and must not be
disclosed, copied or used
d for Manufactu
uring, Tendering g or for any othe
er purpose witho
out written perm
mission. PROLE
EC GE shall not
assume any
a responsibilitty or have any liiability resulting from such unauuthorised use of any informatio
on.
5. PRE-INSTALLATION TESTING
EQUIPMENT:
1. Controlled constant temperature bath with continuously stirred liquid.
2. Certified Standard Thermometer.
3. A continuity test circuit.
4. High voltage breakdown tester.
5. A constant current source.
Note: Calibration baths are generally suitable for use only in workshop. If
required for use in the field, they should be used under cover and in a non
hazardous environment.
PRE-CONDITIONING: Before commencing any tests check the following: -
1. The instrument is as per purchaser specification.
2. The instrument is not damaged in any way and any such damage is
rectified before testing.
3. The instrument is mounted correctly. (Refer 6.1)
3. The shipping stop (22 - Fig. 1) is removed.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
OTI CALIBRATION: Place the sensing bulb of the temperature indicator under
test in the well-stirred constant temperature bath. Allow 5 minutes settling time
before taking readings. Check the reading near to but not less than minimum
value of the indicator scale. For increasing values of temperature, repeat the
procedure to obtain at least two further readings the highest value being near to
but not greater than the maximum scale value of the indicator. The readings
should agree with the standard thermometer within ± 1.5% f.s.d. (Maximum scale
value). Otherwise following adjustments should be made.
ZERO ADJUSTMENT: Use this adjustment for correcting readings near minimum
scale value. Referring to Fig. 1, firmly hold the tongue adjuster (50 by a 2BA
spanner and slacken the lock nut (4) with a second 2BA spanner. To move the
indicting pointer (19) up or down the scale, turn the tongue adjuster (5) by a small
amount anticlockwise or clockwise respectively. Re-tighten the lock nut holding
firmly the tongue adjuster. Do not twist the measuring bellows while carrying out
this adjustment as this may cause damage to the linkage/bellows.
SPAN ADJUSTMENT: Use this adjustment for correcting reading near the
maximum scale value. Referring to Fig. 1, slacken the shoulder screw (7) half a
turn but do not remove the same. Turn the range adjuster screw (8) anticlockwise
or clockwise to increase or decrease respectively the sweep of the pointer. Make
the adjustment in small increments and carefully. Half a turn in either direction
may correspond to approximately 0.5° reading. After adjustment, retighten the
shoulder screw.
Ensure that the lock nut (4) and shoulder screw (7) are properly tightened after
the above adjustments. Repeat the tests in cold and hot bath until the accuracy
limit of ± 1.5% f. s. d. is achieved.
WTI CALIBRATION: During Calibration, keep the instrument lid fixed in position.
Place the sensing bulb in the continuously stirred oil bath, the temperature of which
is maintained at the specified value. Allow 5 minutes setting time and apply the
specified current to the bellows heater and calibrating shunt network. The current
must remain switched on at specified value for at least 40 minutes before taking
reading. To achieve the readings within the accuracy limits or to reset the
temperature rise to a different value, the following adjustments should be made.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
GRADIENT ADJUSTMENT: After opening the instrument lid, carefully remove the
dial. Withdraw the calibrating shunt (17-Fig. 1) after removing the nut and retaining
washer. One adjustable centre band and two fixed bands at the ends are provided
in the shunt. One supply lead is connected to the centre band and the other lead to
the lower band on the shunt. Slacken the screw in the retaining clip of the centre
band. To reduce the temperature rise, move the centre band nearer to the lower
band, to increase the temperature rise reverse the procedure. Retighten the screw
on the centre band after adjustment. Replace the shunt, dial and lid. Repeat the
calibration, check after adjustments until the accuracy limits achieved.
SWITCH SETTING: The switch settings are adjustable as indicated below: -
Indicator Scale Range Switch setting adjustable Switch differential (close to
to close between open) adjustable between
0 - 120° C 40° C and 120° C 6° C and 80° C
20 - 120° C 50° C and 120° C 6° C and 90° C
30 - 120° C 50° C and 120° C 6° C and 100° C
0 - 150° C 45° C and 150° C 7.5° C and 105° C
0 - 240° C 80° C and 240° C 12° C and 160° C
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
NOTE: Unless specified otherwise, the instruments are supplied with minimum
switch differential.
Connect across the switch contacts the continuity test circuit and check the
correct operation of the switches at their set points to make (close) and break
(open) contacts. The switches should operate at set point within ± 2.5% of switch
setting arm pointer (10-Fig. 1) indication, otherwise the following adjustment
should be made.
SWITCH ADJUSTMENTS: Referring to Fig. 1 slacken switch setting screw (11)
on each switch setting arm (10). Move the left hand arm pointer over the switch
scale (9) to the required temperature for making (closing) contact and right hand
arm pointer to the required temperature for breaking (opening) contact. Retighten
both switch setting screws. By closing the left hand arm pointer to the right hand
arm pointer minimum differential is obtained. A built-in stop automatically sets the
minimum differential. While slackening and tightening the setting screw, steady
the disc with the other hand to prevent undue strain on the mechanism. The
indicating pointer can be moved with a finger in a clockwise direction to check the
operation of the switches at set points. By moving the pointer slowly and steadily,
an accurate check is obtained. Never allow the pointer to spring back suddenly or
quickly and also force the pointer in an anticlockwise direction. By doing so the
measuring bellows is likely to be damaged. An alternative procedure is to check
the switch operation while calibrating the instruments for temperature readings.
INSTALLATION
MOUNTING: Mount the instrument in a vertical position. Otherwise errors,
particularly in the horizontal plane, will upset the zero setting of the mercury
switches. Place a sprit level on the top of the indicator case to ensure correct
positioning and operation of the mercury switches.
If vibration exists at the mounting position, mount the indicator on a non-vibrating
structure. Suitable anti-vibration mountings are supplied. Do not use these
mountings during transport.
CAPILLARY LINE: Do not stretch hard twist or bend the capillary to a radius less
than 75 mm. Continuously support the capillary by suitable clips at intervals of 300
to 450 mm. Allow necessary slack at the bulb and for mounting and removing the
bulb without sharp bend at the joint. Wind in spiral (minimum dia. 150 mm) the
possible excess length of capillary close to the indicator or the bulb.
lift or carry the instrument by holding the capillary only. Before storing or
transporting, pack the instrument in the paper board box supplied. Before
lowering the instrument into the box, fix the shipping stop (22) and wind the
capillary in spiral close to the indicator (minimum, spiral dia 150 mm) locate all the
cushions before closing and sealing the box. Where necessary, provide additional
wooden packing case for transport.
IMPORTANT: When Anti-Vibration mountings are supplied, do not use these
during transport.
8. MAINTENANCE
Normally no maintenance is required for the temperature indicator. However,
adjustment or replacement of switches and resetting of the maximum pointer may
become necessary.
9. REPAIRS
If a mercury switch is damaged in anyway, it may be unclipped from the switch
carrier and the leads removed with a hot soldering iron. After re-soldering the
leads to a new switch and locating back the switch in the clip, the switch should
be re-balanced. This is done by making the switch to topple in its carrier at the
instant when the mercury flows toward or away from the electrodes. By sliding the
switch a little in the appropriate direction in the clip, correct topping is achieved.
After correctly balancing the switch, check the operation at preset temperature. If
necessary re-zero the switch scale by slackening the switch zeroing screw (12-
Fig. 1) at the top of the switch scale and rotating the scale to required position.
Retighten the screw after adjustment. If the bellows, bulb or capillary are
damaged, repairs can be done only at the manufacturer's factory.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
CONTENTS
I. General
2. Applications
3. Advantages
4. Construction
5. Functional Test
6. Electrical Connection
7. Installation and Maintenance
8. Basic Characteristics
9. Function
10. Operating Characteristics
11. Relays for use in areas of Seismic Disturbances
12. Specifications of Relays
13. Overall Dimensional drawing
14. Dimensions and ratings
PREFACE
The ever increasing demand for electrical energy goes together with the demand for
more and more efficient and reliable "protection devices'' for power, distribution and
supply facilities. In the field of power supply, transformers represent key installations that
demand effective protection to ensure the constant availability of electrical energy.
One of the most essential devices to protect a transformer is a Buchholz relay. For more
than 20 years, Buchholz relays have been manufactured in India. They are made by an
experienced staff of skilled workers, highly qualified technicians and engineers ensuring
a high degree of precision and quality.
A wide range of type corresponding to the BIS & International Standards are available to
meet the many requirements of manufacturers and users of transformers.
1. GENERAL
Power Transformers are considered to be a highly reliable type of equipment, yet,
in order to ensure the continuity of service that modern conditions demand,
protective devices are required. The purpose of such devices is to disconnect
faulty apparatus before large-scale damage is caused by ‘a’ fault to the apparatus
or to other connected apparatus. Such devices generally respond to a change in
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
the current or pressure arising from the faults and are used for either signalling or
tripping the circuits.
Protective devices in the ideal case must be sensitive to all faults, simple in
operation, robust for service and economically feasible. Considering liquid
immersed transformers, a near-ideal 'protective device' is available in the form of
Gas and Oil relay described here. The relay operates on the well-known fact that
almost every type of electric fault in a `liquid immersed transformer' gives rise to
gas. This gas is collected in the body of the relay and is used in some way or
other to close the alarm or the tripping circuit
The principle of the Gas and Oil relay was first successfully demonstrated and
utilised by 'Buchholz' many years back. In a series of experiments carried out
extensively in Germany it was proved that the Relay is capable of bringing to light
incipient fault thereby preventing further spreading of the fault and extensive
damage and thus saving expensive and protracted repairs. So successful is the
principle of this Relay that despite the continued search for better protective
devices in other electrical fields the Gas-and-Oil Relay is still on its own in
providing protection against a variety of faults.
2. APPLICATIONS
Double element relays can be used in detecting minor faults in a transformer. The
alarm element will operate, after a specified volume of gas has collected to give
an alarm indication. Examples of incipient faults are -
a) Broken-down core bolt insulation
b) Shorted laminations
c) Bad contacts
d) Overheating of part of windings.
The alarm element will also operate in the event of oil leakage, or if air gets into
the oil system.
The trip element will be operated by an oil surge in the event of more serious fault
such as -
a) Earth faults
b) Winding short circuits
c) Puncture of bushings
d) Short circuit between phases
The trip element will also be operated if a rapid loss of oil occurs. Single element
relays can be used to detect either incipient or major faults in oil filled potential
transformers, reactors, capacitors etc. A special single element relay is available
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
This docuument and anyy information prrovided in thiss Manual are the confidential property of PR ROLEC GE and must not be
disclosed, copied or used
d for Manufactu
uring, Tendering g or for any othe
er purpose witho
out written perm
mission. PROLE
EC GE shall not
assume any
a responsibilitty or have any liiability resulting from such unauuthorised use of any informatio
on.
4. CONSTRUCTION
The Buchholz relay essentially consists of enclosure 1 i.e. an oil tight container
and an inserted assembly 2 comprising of two pivoted elements fitted with
switches (Refer fig. above). The enclosure is provided with inlet 1.1 and outlet 1.2
for the liquid. To allow connection of pipes, the enclosure openings can be
designed with pipe thread or flange.
The front inspection glass is provided with a graduation (100 to 300 cm³) to allow
readings the accumulated volume of gas and observe colour of gas for fault
analysis.
For checking the function of the inserted assembly a Test Key (1.3) is provided.
There is also a visual indication on the scale (1.4) of service and Test/Locking
position, in the form of movement of red indicator on the reading scale. This
allows the testing of the alarm and Trip circuits before installation and even when
the transformer is in service.
Just above the inspection glass an arrow shows the specified direction of flow of
the insulation liquid to the conservator. Enclosure 1 and its inserted Assembly
cover are made out of Cast Iron.
5. FUNCTIONAL TEST
5.1 Testing the relay Function with the test key.
A test system is provided in the Buchholz relay that allows the functional test of
the upper and lower switching system.
To test the relay function loosen the nut (1.5) on the Test Key (1.3) and rotate the
key with a screwdriver in the Anticlockwise direction till the SLOT on the TEST.
Key points towards the T/L position. Both the alarm (upper switching system) and
Trip (lower switching system) will show continuity.
On bringing the SLOT on the Test Key to S (service) position by rotating the
'key' clockwise the Alarm and Trip circuits will not show continuity. The circuits will
be actuated to 'ON' position only when there will be a fault in the transformer.
Repeat the functional test each time a relay is started or maintenance completed.
5.2 Testing the relay Function with the Test Pump. Screw the test pump/Air bottle to
the test cock. Open the test cock and pump air gently into the Buchholz relay until
the upper switching system operates.
For operating the lower switching system air has to be pumped suddenly with a
jerk which will in turn operated the lower switching system.
6. ELECTRICAL CONNECTION
To allow installation of the 'signal wire' open the terminal box cover comprising of
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disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
the nameplate and the instruction sticker on the backside. Then pass the wire
through one of the two-conduit screwings (1.6) into the terminal box. By using
either one or the other openings, facility is given for the cable to enter the terminal
box from the left or right. The upper two studs are terminals for the Alarm
switching circuit and are denoted by A. Likewise the lower two studs are
terminals or the Trip switching circuit and are denoted by T.
7. INSTALLATION
7.1 Installation in to pipeline.
For installing the relay into pipeline proceed as follows:
- See that the Buchholz relay is positioned with the arrow pointing towards the
conservator, the connection box is in the Y plane (vertical) and to Test cock.
(1.7) and air vent cock (1.8) are at the top.
- Mount the Buchholz relay as close as possible to the tank in the pipeline
between transformer and conservator.
- Keep pipe bends as wide as possible between transformer and conservator.
- Make sure pipe ascends to the conservator at angle between three degree to
seven degrees.
- See that the relay enclosure is not subjected to stress. If necessary, use
expansion compensators.
- Ensure that he slot on the Test Key remains in the T/L (Test/Locking) position
during storage or loose transportation of the relay.
- Ensure that the slot on the Test Key remains in the 'S' (Service) position and
the Test Key Bolt is Tightened just before commissioning of the relay.
7.2 Filling with insulation Liquid
To fill the Buchholz relay, proceed as described below:
- Remove the protective acorn nut (1.9) from the air vent cock.
- Open the air vent cock to let air escape until insulation liquid emerges.
- Shut the air vent cock.
- Check liquid level in conservator.
7.3 Maintenance
The Buchholz relays are not sensitive to external influences. No servicing is
needed during operation. On routine inspections of the protection equipment, test
the function of the Buchholz relay as described earlier and check the alarm and
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
The symbol /VO following their type markings indicate that the relays contain
Reed switches and normally open type
The symbol /S following their type markings of all relays mentioned indicate that
the relays are suitable for Silicon Oil normally used in Electro static precipitator
transformers.
All relays mentioned above are normally open types. Normally closed type relays
can also be supplied on request.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
The outward appearance of these relays are exactly the same as those with
mercury switches but they are distinguished from them by the symbol /VO
following their type marking. The latter V (for vibration) indicates that the relay
contains reed switches and the latter O that the contacts are normally open. Thus
a Type GOR 2/VO signifies a 50 mm. (pipe size). Double float relay with normally
open Reed Switches.
OPERATION
In the double element relay, collection of gas causes the oil level within the relay
to fall. This in turn causes the upper element to rotate on its pivots, bringing the
magnet it carries into a position where it operates the Alarm Switch.
An oil surge through the relay will cause the lower element to rotate about its
pivots and its magnet into a position so as to operate the tripping switch.
CONNECTIONS
The terminal box and the terminals are the same as that of mercury switch type
relays. In the reed switch relays, each reed switch is protected by, an inductor in
series. These inductors are intended to protect the reed switch contacts from the
effects of capacitive loads, such as are imposed by long leads or pilot cables, and
must not be removed from relays in service.
Protection of reed switch contacts against the effects of inductive loads, such as
those imposed by contactors and Electro-Magnetic relays, is achieved by means
of a diode wired across each load. This diode must be rated with forward current
at least as high as the steady load current and connected observing polarity so as
to absorb the back e.m.f.. These diodes are not provided with the relay.
The Mounting position and Testing on site procedure are same as that of 'Mercury
Switch type' Buchholz relay.
OPERATING CHARACTERISTICS
All double element relays are adjusted so that their performances lie within the
limits given in table 14. In addition the Reed Switch Relay is capable of
withstanding shocks of up to 4g. Such shocks will not of themselves cause the
relay to operate.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
H DATA:
SWITCH
TYPE ------------------------------------------------------------ Normally O
Open
CONTACT
T RATlNG ------------------------- 250VA
2 A.C
C. (r.m.s.) o
or D.C. ma
ax.
SWITCHIN
NG CURRENT ----------------------------------- 5A A C o
or D.C. max
x.
SWITCHIN
NG VOLTA
AGE ------------------------------------------ 300 V D.C. max.
------------------------------- 240 Volts A.C. (r.m.s.) max.
m
BREAKDO
OWN VOLT
TAGE ------------------------------------ 650 Voltss D.C. min
n.
INITIAL CONTACT RESISTAN
R NCE --------------------------- 70 millli-ohms ma
ax.
RESONAN
NT FREQU hen 700 Hz.
UENCY -------------------------------- greater th
ACTUATIN
NG TIME (Including
( Bounce) --------------- 2 milli-seco
onds (Typical)
WITCHES HAVE RH
THESE SW HODIUM CONTACT
C T, LOCATE
ED MIDWA
AY ALONG
G
THE LENNGTH OFF THEIR GLASS TUBES, THE TUBBES CONNTAIN AN
N
ATMOSPHHERE OF NITROGE
EN.
PROTECT
TION OF REED
R SWITCH CON
NTACTS:
This docuument and anyy information prrovided in thiss Manual are the confidential property of PR ROLEC GE and must not be
disclosed, copied or used
d for Manufactu
uring, Tendering g or for any othe
er purpose witho
out written perm
mission. PROLE
EC GE shall not
assume any
a responsibilitty or have any liiability resulting from such unauuthorised use of any informatio
on.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
IMPOR
RTANT
The va
arious partt of a relayy including
g the body
y, form one complette calibrate
ed unit and
must not be interr changed with
w those of other re elays.
We sttrongly recommend that rela ay shouldd not be taken ap part, and under no
circumstances sh
hould any alteration
a b made to
be o the angle
e of the fla
ap on the trrip element.
as been co
This ha orrectly adjusted during manufa
acturing.
RELLAY
TYP
PE
GOR R1
RELLAY
TYP
PE
SR
R1
This docuument and anyy information prrovided in thiss Manual are the confidential property of PR ROLEC GE and must not be
disclosed, copied or used
d for Manufactu
uring, Tendering g or for any othe
er purpose witho
out written perm
mission. PROLE
EC GE shall not
assume any
a responsibilitty or have any liiability resulting from such unauuthorised use of any informatio
on.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
CONTENTS
5. Installation
9. Safety
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
open the top cover of the wooden case and inspect the bushings thoroughly for
any transit damage. Ensure all the accessories are received in good condition and
report, in case found to be missing.
Note: Any damage or shortages should be reported immediately.
Bushing should be handled only with mechanical lifting arrangements, such as the
illustrated in Fig. 5.
When bushings are taken out of the packing case, they must not be allowed to
rest on the lower part of the bushing. The operation is best carried out two lifting
gears and two ropes as shown in Fig. 6. One rope is slung around the lower end
of the metallic flange and let directly to the hook of the first crane and the other
passed around the shell, between two sheds and then led to the hook of the
second crane. The bushing is raised sufficiently in the same inclination angle as in
the packing case with hoists and then lowered at the flange end. When positioning
the bushing upright (Fig. 7), care should be taken to avoid any shocks, jerks or
scratch to the oil end porcelain and bottom stress shield. On no account the
bushing should be balanced on rope, passed around the porcelain at it’s centre of
gravity.
4. CHECKS BEFORE INSTALLATION:
i) Mount the bushing vertically on a suitable stand and clean the surface
thoroughly with a dry cloth, particularly the oil end. Inspect the bushing
physically for any leakage or damage on the porcelains. The oil end and inner
portion of the central tube should be further cleaned with transformer oil. Care
should be taken to prevent scratching of the painted surface of the bottom
stress shield / base plate.
ii) Check oil level of the bushing in vertical position. The oil level should be such
that the oil level is clearly visible through the oil sight glass provided on the
bushing. The oil level is filled in the factory upto the mid point of the sight
glass, which is considered to be the normal oil level. The oil in the prismatic
type sight glass can be identified by the
highlighting of the red colour reflector at any position mounted from vertical
upto a maximum of 30 degrees.
iii) Ensure the top terminal is tightened firmly with its gasket provided to avoid
water / moisture entry into the transformer.
iv) Measure and record the IR values of the bushing with a 2.5 kV meggar. The
recommended values are:
4000 Meg ohms (Min) between oil end terminal or top and test tap.
1500 Meg ohms (Min) between test tap and flange with 1 kV meggar.
The IR values may vary due to the atmospheric condition (humidity), surface
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
cleanliness of the porcelains, dryness of test tap etc. In such cases, preheating of
porcelains, terminals test tap etc., with hot air is recommended.
This is only an indicative test, however, the healthiness of the bushings can be
known only after measurement of Tan delta & capacitance values.
v) Capacitance and Tan delta values of the bushing should be measured between
the top terminal and test tap at 2 kV to 10 kV (Maximum). The measurement
should be preferably carried out indoors with RH not exceeding 60% and at
ambient temperature, with the facilities and procedure as described as described
below:
Schering Bridge
Standard loss free capacitor
High voltage supply
Necessary screened connecting leads.
Place the bushing vertically on suitable stand. Remove the threaded test tap
cover. Insert a plug / clip into the central stud of the test tap and connect to the
Schering Bridge through a screened cable. The flange body should be grounded.
Connect the high voltage supply to the top terminal. Measure the capacitance &
tan delta value of bushing upto a maximum of 10 kV.
Note:
The voltage applied on the bushing should be limited to 10 kV, when the
bottom end is not immersed in oil. Utmost care should be taken to avoid any
contact with the bushing during testing as this may result in fatal injury to the
personnel.
The test tap should be dry, free from any moisture condensation and dirt
deposition. The threaded test tap cover should be fixed back to the test tap,
immediately after the test.
Factory test values of tan delta and capacitance are indicated in the test report of
individual bushing at working voltages. However, site values may vary, as they do
not resemble factory test conditions. The site values recorded at the time of
commissioning should be taken as the reference values for comparison with
future measurements. The bushing can be commissioned, if tan delta value
measured is less than or equal to 0.007, and capacitance value as per the factory
test value with maximum variation of 10%. If higher values are obtained, please
contact PROLECGE, Customer Service Department giving full details of testing
arrangement, for further advice.
Note:
The bushing should be kept vertical or mounted on transformer for a minimum
period of 24 hours before application of voltage.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
5. INSTALLATION:
Please refer to Fig. 8
The bushing is suitable for installation for a
maximum angle of 30 degrees from
vertical. During the lowering of the bushing
into the transformer, extreme care should
be taken to prevent the lower porcelain
hitting the wall of the tank. The bushing
should be so mounted on the transformer
that the oil sight glass is visible from the
ground level. Ensure the visibility of the oil
level to the naked eye.
Maximum stress experienced by the
bushing is at the bottom stress shield
during testing. Hence sufficient care should
be taken to avoid any flashover from the
stress shield to the wall of the turret. The
flashover voltage depends on the
clearance maintained in oil between the
stress shield and turret, oil quality, surface
smoothness, presence of barriers,
shape of the stress shield and turret etc.
The recommended size of the turret to be
maintained for various voltage class of
bushings is given in the manufacturer’s
booklet / respective drawings.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
at the bottom end of the cable bolt and braze the cable into it. Insert an M8 bolt at
the upper end of the cable bolt and tie a wire or a fish cord on to it.
Clean the gasket seating surface on top face of the transformer and place the
gasket in position. Lift the bushing above the transformer turret and clean the
bottom end of the bushing.
Lower the bushing slowly into the transformer, simultaneously pull the transformer
cable brazed with cable bolt through the central tube with the help of the fish cord.
Secure the cable bolt to the central tube with the cable bolt pin. Remove the fish
cord. Bolt the bushing into position taking care to correctly position the gasket
joint. Ensure the threads on the terminal and the cable bolt are clean. Tighten the
terminal to the cable bolt ensuring full thread engagement for proper current
transfer.
Sometimes the cable bolt is supplied along with the brazed flexible lead upto the
flange seat with a half connector at bottom end. In such cases the flexible lead
from the transformer winding should be brazed to the other half connector and
should be fastened with the draw lead connector of the bushing using bolts and
nuts.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
CAUTION:
THE TEST TAP WILL ALWAYS BE EARTHED AS LONG AS THE THREADED
CAP IS FIXED (Fig. 2a). HENCE THE CAP SHOULD NEVER BE KEPT OPEN.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
SILICAGEL BREATHER
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
MAINTENANCE
Inspect the breather on monthly basis; more frequently, if found necessary by
experience (eg. highly humid atmosphere).
When the breather is first installed, the crystals have a blue tint, and after a period
of operation, the colour of the tinted crystals gradually changes to pink; this is an
indication that the silicagel is becoming saturated and losing its absorbent
properties. When there is a preponderance of pink crystals the geI should be
changed or reactivated.
Silicagel may be reactivated by heating in a shallow pan at a temperature of 150°
C to 200° C for two to three hours when the crystals should have regained their
original blue tint.
Before filling the container with silicagel, clean and dry all parts of the breather.
Verify that the oil Level in the oil cup is correct when reassembling.
Ensure that the breather is not choked and is free for passage of air.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
SILICA
AGEL BR
REATHE
ER
TYPE 2
This docuument and anyy information prrovided in thiss Manual are the confidential property of PR ROLEC GE and must not be
disclosed, copied or used
d for Manufactu
uring, Tendering g or for any othe
er purpose witho
out written perm
mission. PROLE
EC GE shall not
assume any
a responsibilitty or have any liiability resulting from such unauuthorised use of any informatio
on.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
SIDE
E VIEW FRON
NT VIEW
S LIST F OR FIG . 1
PARTS
Sr. No.. DESCRIPTION MA
ATL. Sr. No.
N DES
SCRIPTION
N MATL.
M
1. Float 50 p x 100 Brasss 7. Bolts 'B'-6 Nos.- M
M6 M.S.
M
2. Terminal Box
B Casst Al. 8. Base with Mtg. Ho oles Cast.
C Al.
3. Cover for T.
T B. Casst Al. 9. Limit stoppers Brass
B
4. Dial Body wiith switch housiing Casst Al. 10. Gear with lever Brass
B
5. Mercury sw witch Glasss 11. Float Arm 9.5 p tuube Brass
B
6. Nut for Swwitch Adj. Brasss 12. Check Nut Brass
B
Fig. 1
This docuument and anyy information prrovided in thiss Manual are the confidential property of PR ROLEC GE and must not be
disclosed, copied or used
d for Manufactu
uring, Tendering g or for any othe
er purpose witho
out written perm
mission. PROLE
EC GE shall not
assume any
a responsibilitty or have any liiability resulting from such unauuthorised use of any informatio
on.
This docuument and anyy information prrovided in thiss Manual are the confidential property of PR ROLEC GE and must not be
disclosed, copied or used
d for Manufactu
uring, Tendering g or for any othe
er purpose witho
out written perm
mission. PROLE
EC GE shall not
assume any
a responsibilitty or have any liiability resulting from such unauuthorised use of any informatio
on.
APPLICATION
This model of indicator is manufactured considering Transformer application. It
can also be used as Content Gauge on other tanks where level of liquid inside the
tank is required to be indicated continuously on a dial.
CONSTRUCTION, WORKING & FEATURES
A float is used as sensor of liquid level inside the conservator (tank). Swing of
hinged float due to change in liquid level is utilised to indicate level on a calibrated
dial and to operate a switch for external alarm unit.
Use of magnetic coupling in the indicator achieves complete sealing off of liquid
inside the conservator from surrounding atmosphere. This results in avoiding any
leakage of costly oil and avoiding contamination of insulating oil due to seepage of
surrounding air in the conservator.
The glass mercury switch is nylon encapsulated to avoid breakage and spilling of
mercury. Switch is accessible for servicing while indicator is mounted on the
conservator without any necessity of draining the oil.
CALIBRATION
The standard calibration of dial is Empty, 1/4, 1/2, 3/4, Full. Calibration of marks
Empty & Full is done after leaving 65 mm from bottom and top of conservator to
avoid striking of float to conservator wall. Different calibrations are done to suit
customer's needs.
MOUNTING
In fig. 2, indicator is shown mounted by keeping dial and mounting pad in vertical
position. However, indicator can be mounted in titled position towards ground
(max 30°) for easy viewing by fixing mounting pad at desired angle. The position
of indicator on the conservator can be selected to suit site condition. Float
mechanism passes through the hole in pad (see Fig. 2).
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
SPECIFICATIONS
1. Operating Liquid : Transformer Oil to IS: 335
2. Working Temperature : 0 to 100° C of Oil
3. Working Pressure : 0 to 4 kg/cm²
4. Environment : For Indoor & Outdoor use
5. Size : See Fig. 2 & 3
6. Weight : 6.6 Kg. with Float & Float-arm
7. Mounting Specifications : See Fig. 2 & 3
8. Float Travel : Float moves in right angle plane to
seating face (See Fig.2)
9. Electrical witch : One SPST Mercury Switch
10. Contact Rating : 5 Amps 240 V.AC. 50 Hz. 1.2 Amps
240 V.DC.
11. Switch Setting : Normally Open Closes when oil level
drops to Empty level.
Switch opens automatically when oil
level rises.
12. Dial Size : 250 mm dia.
13. Dial Position : Vertical or Inclined
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
PRESS
SURE
E RELIEF
F DEV
VICE
E
This docuument and anyy information prrovided in thiss Manual are the confidential property of PR ROLEC GE and must not be
disclosed, copied or used
d for Manufactu
uring, Tendering g or for any othe
er purpose witho
out written perm
mission. PROLE
EC GE shall not
assume any
a responsibilitty or have any liiability resulting from such unauuthorised use of any informatio
on.
GLOSSARY OF TERMS
1. APPLICATION:
This PRV is designed to be used on Power Transformer. When pressure in the
tank rises above predetermined safe limit this valve operates and performs
following functions.
Allows the pressure to drop by instantaneously opening a port of about 150
mm diameter.
Gives visual indication of valve operation by rising a flag.
Operates a micro switch.
This switch has 1 NO and 1 NC contacts (Four terminals). Hence switch can be
effectively used in control circuit.
2. SPECIFlCATIONS:
See Drg. No. CS-601-R-3.
3. TESTS:
Tests are carried out as per test certificate attached to this leaflet.
4. CONSTRUCTION & WORKING:
(Refer Drg. CS-601-R-3)
This PRV has an integral flange with six holes for mounting. The valve can be
mounted vertically or horizontally on the tank. The PRV has got a port of about
150 mm dia. This port is sealed by a stainless steel diaphragm. The diaphragm
rests on an 'O' ring (3) and is kept pressed by two heavy-duty springs, thereby
keeping the port closed. The other side of the diaphragm is exposed to tank
pressure. Whenever the pressure in the tank rises due to any reason, the same
pressure acts on the diaphragm from inside. When pressure rises above
predetermined safe limit the diaphragm gets lifted from its seat. This lifting is
instantaneous and allows vapours, gases or liquid to come out of tank depending
upon the position of valve on tank.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
The diaphragm restores its position as soon as pressure in the tank drops below
set limit. The lift of the diaphragm is utilised to operate flag ( 10) and micro switch
( 11) with the help of rod (8). The flag and switch remain operated until they are
reset manually.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
This docuument and anyy information prrovided in thiss Manual are the confidential property of PR ROLEC GE and must not be
disclosed, copied or used
d for Manufactu
uring, Tendering g or for any othe
er purpose witho
out written perm
mission. PROLE
EC GE shall not
assume any
a responsibilitty or have any liiability resulting from such unauuthorised use of any informatio
on.
7. INSTALLATION
Each valve should be cleaned from inside (tank side) with compressed air jet. All
particles should be removed from tank side. While cleaning, care should be taken
that the jet does not attack the switch and the flag mechanism. The PRV should
be installed considering the following aspects.
The indicating flag (10) is easily seen from distance, The valve is accessible for
manual resetting and for routine manual checking. While installing remove dirt and
clean the mounting surface, remove all traces of oil, grease.
The rubber gasket supplied with the valve should be properly cleaned & be
located properly in the recess carefully.
All the bolts should be tightened evenly so that equal pressure is exerted on
gasket and base.
Connect control circuits to terminal plate provided in the switch box through cable
gland (14).
As per wiring diagram (ref. fig. 1 drg. CS-601-R-3), check the operation of flag and
switch by lifting operating rod (8) and confirm that both controls operate as
required.
The PRV can be put to service.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
9. GENERAL NOTES:
Store the valve on its base duly packed in polythene bag to ensure that dirt or
other solid particles do not enter the valve port from tank side.
Do not remove the protection cover on flag box and switch box when it is stored.
Keep the flat gasket (2) duly tied to the valve. Remove it only when it is to be
installed. This gasket should be kept dry.
After installation of valve on transformer, test periodically the functioning of
switch operation and flag operation by lifting the operating rod manually.
This will ensure the switch operation and flag operation when valve opens due to
rise in pressure inside the tank.
It is not possible to change the operating pressure at site.
The valve gaskets are of entirely different nature for synthetic liquid and
transformer oil. Hence use proper valve for liquid as described on product label.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
E AUS
EXHA ST FA
AN
This docuument and anyy information prrovided in thiss Manual are the confidential property of PR ROLEC GE and must not be
disclosed, copied or used
d for Manufactu
uring, Tendering g or for any othe
er purpose witho
out written perm
mission. PROLE
EC GE shall not
assume any
a responsibilitty or have any liiability resulting from such unauuthorised use of any informatio
on.
COOLING FANS
GENERAL
Exhaust type cooling fans used on transformers are designed to operate outdoors
in all weather conditions. Generally the following sizes of fans are used.
MOTORS
The fans are powered by totally enclosed, squirrel cage induction motors. The
motors are adequately rated to give reliable service for many years.
IMPELLER
The impeller is designed to give maximum volume at minimum noise level with
minimum power consumption.
For reducing vibrations, special shoes made of rubber are provided at fixing points
of fan lugs.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
MOUNTIING
1. Thee arm is se
ecured by the resilie
ent mountin
ng caps, w which are placed
p ove
er
the rubber so
ockets and secured tot the diap
phragm witth 8 screw ws, nuts and
wasshers provvided. The lock wash hers should be fitted
d under th
he heads of
o
the screws.
2. Rub
bber socke ets fitted to
t arms. To
T be fitted w come in
d so that fflat side will
con
ntact with th
he diaphra agm.
3. Arm
ms to be se
ecured to motor
m by th
he 4 screws in motor carton.
NO
OTE: Lock washers
w arre supplied
d and shou
uld be fitted
d.
4. Setscrew in blade
b shou
uld engage e in dimple
e nearest the end of
o the shafft.
Afte
er blade is fitted, see
e that split pin
p 5 is rep
placed in e
end of shafft.
C
CONSTR
RUCTIONAL DETA
AILS
This docuument and anyy information prrovided in thiss Manual are the confidential property of PR ROLEC GE and must not be
disclosed, copied or used
d for Manufactu
uring, Tendering g or for any othe
er purpose witho
out written perm
mission. PROLE
EC GE shall not
assume any
a responsibilitty or have any liiability resulting from such unauuthorised use of any informatio
on.
No. PAR
RT NAME No. PART N
NAME
1 TER
RMINAL BLOOCK 14 WIN
NG FIXING BBOLT
2 BAL
LL BEARINGG 15 SPL
LIT PIN
3 ATOR WINDING
STA 16 SHAAFT
4 EAR
RTH SCREW W 17 HUBB FIXING BO
OLT
5 ROT
TOR STAMP PING 18 HUBB
6 ATOR STAMPING
STA 19 BAL
LL BEARING G
7 RES
SILIENT CAPP 20 LUB
BRICATOR S SCREW
8 RUB
BBER SLEEV VE 21 MOUNTING AR RM
9 BAC
CK COVER FIXING
F SCR
REW 22 MOTOR FIXING G BOLT
100 BAC
CK COVER 23 DIE CAST AL. R
ROTOR
111 FAN
N FIXING BO
OLT 24 CH.. HD. SCREWW
122 WIN
NG 25 DIA
APHRAGM
133 CH. HD. SCREW
W
This docuument and anyy information prrovided in thiss Manual are the confidential property of PR ROLEC GE and must not be
disclosed, copied or used
d for Manufactu
uring, Tendering g or for any othe
er purpose witho
out written perm
mission. PROLE
EC GE shall not
assume any
a responsibilitty or have any liiability resulting from such unauuthorised use of any informatio
on.
APPENDIX
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
Where:
• PVC = Corrected Vapor Pressure in μHg
• PA = Atmospheric Pressure in kg/ cm2
• PT = Transformer Tank Pressure in kg/ cm2
• PV = Dew Point Vapor Pressure in μHg (from A.1.1.7 - )
A.1.1.13 - Measure and record insulation package temperature. The temperature of
the core and coil assembly may be determined by reading the
temperature of the gas inside the transformer from the dew point
measurement device. As an alternative, this temperature may be
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
TEMPERATURE OC
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
According to IEEE Std. C57.93.1995 – “Guide for Installation of Liquid Immersed Power
Transformers”, there are mainly four methods that may be used to dry the insulation in
case the moisture content is beyond the acceptable value. In this section, a brief
description of two of them is given to inform the customer about the different choices
available to achieve the required insulation dryness. However, it is recommended that
the user interested in having more information and detail on this matter; consult IEEE
Std. C57.93.1995.
A.2 - Disclaimer.
Even though all the methods described in this section are industry-wide recognized
methods; their inclusion in this manual is for informational purposes only. It is the
sole responsibility of the customer to choose the method most suitable to their
particular environmental conditions or equipment availability. GE-PROLEC will not
be held liable for any damage or injury that the use of any of these methods may
cause.
A.3 - Circulating Hot Oil Method.
This method requires the use of a suitable oil filter plus an oil heater. The heater
must be capable of rising and maintaining a top oil temperature of approximately
85°C as the oil is circulated in the transformer tank until the insulation is dry. As the
oil circulates through the core and coil, it picks up the moisture contained in the
insulation and takes it to the processing equipment, where the moisture is removed
from the oil. Any steps taken to maintain hot oil the temperature in the transformer
will result in a much quicker moisture removal process. Where possible, it is
recommended to insulate the tank and piping of the transformer and keep the
radiator or cooler valves closed. The effectiveness of this method will depend upon
the water removal capabilities of the filter system, either if a blotter-press filter or a
vacuum-drier filter is used. Sometimes, this method is used as a preparation
process. When the oil filling process is to be performed under cold weather
conditions (less than 10°C ambient temperature), Hot Oil Recirculation may be
used to heat the core and coils before starting a vacuum drying process.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
Fig. A.2 A typical hot oil process under cold ambient temperature conditions
(Transformer main body is covered with tarpaulins)
A.4 High Vacuum Method.
This is probably one of the most commonly used methods to dry a transformer.
It requires a vacuum pump capable of pumping down to an absolute pressure
of 0.05 mmHg or 50 μHg or 0.05 Torr and an optional refrigerated vapor trap to
collect the water. After the tank has being completely sealed, a vacuum hose
should be connected to the transformer. Either a specially designated valve or
the flange for the mechanical pressure relief device is generally used for this
purpose. The extraction of moisture begins as soon as the residual vapor
pressure in the tank is reduced below the vapor pressure of the water in the
insulation. The temperature of the insulation system must be above zero
degrees centigrade. The dry out will be much faster if the insulation
temperature is 85°C. The vacuum should be maintained as long as water is
being removed from the transformer. Each manufacturer establishes a series
of guidelines to use as reference for the duration of this process.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
Notes:
This table is for steel plate to steel plate application. Do not use it for bushing
installation.
When Prolec GE employs stainless steel fasteners for external transformer
application, the customer is advised to use an anti – seize lubricant on threads of
these fasteners during assembly.
When thread lubricant is used for assembly, the amount of torque to achieve the
same effect is about 70 ~ 75% of the torque value specified in the above table.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
When gaskets are installed in retaining groves, a proper seal will be achieved when the
mating flanges are flush with each other. Additional torque will not improve the seal.
Tightening the fasteners in an “X” pattern to the list values will provide oil and air seal. If
flanges cannot be pulled flush, the device should be removed and the surface examined
to determined to determine the cause; misaligned or entrapped gasket, foreign material,
damage, etc.
Internal fasteners.
Electrical connections between the internal flexible/ cables require that the mating
surfaces be flush and full contact. After tightening, the contact surface should be verified.
Component Bolt/ thread size Pitch of Thread Torque value
(mm) (mm) (kg. cm.) (ft. lb.)
Radiators 16 2.00 1437 104
Radiator valves 16 2.00 1437 104
Radiator top & ½ “ NPT 1.8 249 18
bottom plugs
Man hole covers 12 1.75 719 52
Gas & oil relay 12 1.75 719 52
16 2.00 1437 104
Bushings with 12 1.75 304 22
metal flange 16 2.00 622 45
20 2.50 954 69
Bushing w/ 12 1.75 276 20
porcelain flange 16 2.00 346 25
20 2.50 415 30
Bushing turrets 12 1.75 719 52
16 2.00 1437 104
20 2.50 1820 130
Valves/ flanges/ 12 1.75 719 52
Air release pipes 16 2.00 1437 104
20 2.50 1820 130
Insulation Studs 12 1.75 69 5
(internal fasteners) 16 2.00 124 9
20 2.50 235 17
Temperature ½ “ NPT 1.8 249 18
indicator 3
/8“ NPT 1.4 152 11
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
Current Transformers
Introduction
Current transformers (CT’s) are installed in power transformers as a source of current for
relaying and metering purposes and in connection with winding temperature devices and
line-drop compensators. CT’s will safely carry a continuous current and a momentary
over load equal to that of the equipment in which they were originally furnished. CT’s
have output currents proportional to their primary currents and are designed with varying
degrees of accuracy, depending on the application. When furnished for a particular
purpose a CT should not be used in any other application without checking its
characteristics. Refer to (IS 2075 (Parts 1 ~ 4) & IEC6044 (Parts 1 & 6): for Standard
Requirement of Instrument Transformers) for accuracy classes of relaying and metering
CT’s.
Receiving, Handling and Storage.
Current transformers are normally shipped installed, completely assembled and ready for
service except when ordered as renewal or spare parts. CT’s mounted in removable
bushing turrets are left in the turret when it is removed for shipment are to be installed
with the adapter turret as an assembly. When ordered as renewal parts, carefully
disassemble the CT shipping crate to avoid winding damage. Always lay the CT flat
during handling or storage and store in a dry protected area.
Description.
Two types of CT’s are used in power transformers, the bushing type and the cable or bus
bar type. The bushing type consists of a ribbon-wound core of high permeability, low loss
silicon steel on which a coil is wound.
When the transformer bushing is installed through the CT, the CT serves as a secondary
and the bushing as a one-turn primary winding. The manufacture of a cable or bus bar
CT is identical to a bushing type, except it has a smaller internal diameter for the
primary. They are installed internal on the main winding superstructure and use a cable
or copper bus bar as their primary. Cable is used for looping through the CT if more than
a one-turn primary is required.
Current transformer when applied to bushing and cable or bus bar CT’s refers only to the
core and its secondary winding. The CT in itself does not provide adequate insulation for
full circuit voltage between primary and secondary and therefore depends on the
bushing, cable, bus bar, or other material for this insulation.
Secondary windings are of the distributed type, with turns equally spaced around the
circumference of the CT core. This distribution gives the CT a low leakage reactance,
thus maintaining a high degree of accuracy when the transformer is subjected to over
load currents. This winding may be tapped to obtain multi-ratio characteristics when
required.
The polarities of primary and secondary currents are subtractive as shown in view
drawing. The H1 mark on the secondary coil indicates the polarity of the primary
conductor with reference to the secondary terminal. When current in the primary
conductor flows toward the H1 side of the CT, current in the secondary coil flows out
from the terminal X1. With any combination of taps, the tap numerically nearest terminal
X1 has the same polarity as X1.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
CT Outlet.
Secondary leads from CT’s are brought out of the transformer through a CT terminal box
that is located on bushing turret, the cover or sidewall of the transformer. The
transformer nameplate lists the current ratios and all characteristics for the various taps
of each CT.
Insulation Resistance.
Checking the current transformer for accidental grounding or low leakage resistance may
be performed with either a 500 or 1000 volt “Megger”. Short circuit the secondary
windings, disconnect all external leads from the terminal boards and Megger the
resistance between the secondary winding and station ground. This resistance should
have a value in mega ohms. If the resistance is unusually low, the transformer and
secondary leads should be inspected for accidental grounding.
Maintenance.
CT’s rarely will require attention other than occasional inspection to see that all
connections are clean and tight and that the leads have not been damaged. However, if
it is necessary to perform an excitation, ratio, ratio and phase angle or insulation
resistance test while primary current is flowing in a CT, it is vital that great care is taken
in changing burdens or taps to assure that the secondary is not accidentally open-
circuited.
Connections.
CAUTION: The secondary circuit of an energized CT MUST NOT be opened at any time.
It must be burdened with a load or short-circuited with a screw at the terminal connection
block. If the secondary is opened with current flowing in the primary, an excessive peak
voltage of many thousands of volts will develop in the secondary that will cause a hazard
to personnel and can magnetize the core and possibly damage insulation.
Installation.
CT’s shipped apart from the transformer should have their condition checked before
installing. Should moisture have entered during transit or storage it is important that the
CT be dried in an oven for 24 hours at a temperature no greater than 90ºC.
Testing.
When testing is required, the following recommendations are useful.
Excitation Test.
CT excitation characteristics can be checked, whether in or out of the
transformer, by injecting a current of the correct frequency through the primary
or secondary of the CT. When current is applied to the primary the induced
voltage can be measured across any two secondary leads. Refer to the
following circuit drawing:
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
This test is an open-circuit test and must be performed without any load except
the averaging voltmeter connected to the current transformer. The results
obtained may be reduced to a common basis or number of secondary turns
because both the ampere-turns and the volts per turn are constant for any
single value of excitation. When performing this test first demagnetize the core.
This is done automatically by checking the excitation at the saturation voltage
first and then reducing the current slowly to check the next point without
interrupting the circuit and continuing until the lowest point desired has been
taken. Note that the power transformer must be de-energized since the
excitation current must be under control. If the excitation current is high, it may
indicate that a shorted turn exists which could affect the CT ratio.
Ratio (Relay CT)
Inject a voltage to the secondary, with the primary open circuited as follows:
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.
The resistance should be increased from zero to a magnitude that the ammeter reading
will decrease to at least one half of its original value. Then gradually reduce the
resistance to zero and repeat the process several times. To determine the magnitude of
the resistance needed, obtain the CT saturation voltage from the excitation curve and
divide this amount by one-half of the recorded secondary current. This quotient can then
be adjusted to the tap being used. Therefore, if the saturation level for a CT is 100 volts
on a given tap and the recorded secondary current is 5 amps, the required resistance
would be 100/2.5 or 40 ohms.
To de-magnetize the CT core with the power transformer de-energized, refer to the
excitation curve and determine the amount of secondary current required to saturate the
core. Be aware of the turns ratio and tap being used, gradually apply saturation current
to either the primary or secondary with the other winding open-circuited. Use diagrams 1
or 2. Then slowly reduce the current to zero. Repeat the process several times.
This document and any information provided in this Manual are the confidential property of PROLEC GE and must not be
disclosed, copied or used for Manufacturing, Tendering or for any other purpose without written permission. PROLEC GE shall not
assume any responsibility or have any liability resulting from such unauthorised use of any information.