SOUTHERN POWER EQUIPMENT COMPANY PVT LTD., BANGALORE CONTENTS 1. Handling, Receipts and Storage 2. Installation 3. Commission 4.

Operation 5. Periodic Maintenance Daily Quarterly Half-Yearly Yearly 5/7 Yearly

6. Trouble Shooting 7. Useful I.S Specifications for Transformer 8. Drawings.

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HANDLING RECEIPT AND STORAGE HANDLING: For lifting Transformer, use appropriate lifting devices and lugs. Weight of the heaviest package has been indicated on it. Do not use Lugs provided for partial lifting e.g for active part, conservator, etc or other parts for lifting transformer. Use all lugs to avoid undue stressing. Ensure slings do not touch components. RECEIVING: Transformer should be carefully examined for Transit Damages. External damages can indicate severe internal damages. Similarly, packed components should also be carefully unpacked and examined for Transit damages. Check that all materials listed in the Packing Slip/Delivery Challan are received. All shortages and transit damages must be immediately reported to the suppliers.

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STORAGE: When required to store for longer duration. i. Fit the Silica gel breather ii. Check weekly that colour of silica is blue. iii. Keep Transformer energized at a low voltage. iv. Jack up the Transformer and assemble rollers to allow free flow Of air from its bottom. v. The tap changer must be operated once in six months throughout its entire range. vi. Accessories like Bushings, Buchholtz Relay, Thermometers, Radiators and associated pipe work should be stored indoor. vii. Oil drums should be stored in a covered space with their curved surface on the floor and their bungs 45o down wards.

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INSTALLATION DOCUMENTS REQUIRED: i. General Arrangement Drawings of Transformer, Cable Box Marshalling Box etc ii. Schematic and Wiring Diagrams of O.L.T.C, R.T.CC, Marshalling Box etc., Ensure that drawings match with the apparatus supplied iii. Service Manual. EQUIPMENT AND TOOLS REQUIRED: i. Crane or chain pulley block along with wire rope, slings and DShackles. ii. Transformer Oil Filtering Machine with hoses. Capacity such as to Complete one pass in 8 to 10 hrs. iii. For EHV and Large rating Transformers: a. A Vacuum pump b. Oil Storage tank iv. Set of spanners v. Set of drum opener, crowbar, pipes, hammer, vinyl hose to draw oil samples, and to serve as oil level indicator. vi. Set of screw drivers, cutting pliers, screw spanners, pipe wrench. vii. Clean cotton cloth. viii. Oil BDV tester. ix. 500, 2500, 5000 V Megger as per Winding Voltage. x. Voltmeters, milli-ammeter. xi. Multi Meter xii. P.V.C Wires xiii. Electric Hand Lamp xiv. Brushes for painting xv. 25mm dia Manila Rope for bushing mounting INSTALLATION: i. Locate Transformer in a well ventilated place, leaving working space all Around. ii. Provide Rails for rollers. iii. Provide Oil Soak Pits and Separation Walls when required. iv. Assemble the dismantled components taking below-mentioned: a. Main tank: Lock the rollers. b. Bushings: Check for hairline cracks. Fully tighten test tapcap {used in condenser bushings for tan delta measurement}. c. Conservator and MOG :Check oil level in Transformer and OLTC

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conservator. Remove MOG locking lever. d. Buchholz Relay :Release Buchholz Relay floats. If test lever is provided, it must be the S {service} position. Arrow direction must be towards Conservator. e. Breathers: Main tank and OLTC are sometimes provided with separate Breathers. Transformer breather will be bigger compared to OLTC breather. Ensure that they are fitted accordingly. Check that color of silica gel is blue. Remove seas closing the openings. f. Radiators: Assemble only one radiator at a time. Let each radiator draws oil. Final tapping up should be only upto the filling mark. g. Marshalling Box: Fill oil in OTI and WTI packets. OTI and WTI bulbs must be lifted in respective pockets. Identifying labels are fixed near these pockets.Wire the terminals properly. h. All other fittings. EARTHING: Solidity earth the Transformer tank using the 2 Pads/bushes provided. Similarly earth Cable Box, Marshalling Box, etc. COMMISSIONING: CONFIRM HEALTHINESS OF ACTIVE PART BY THEFOLLOWING TESTS: i. Insulation Resistance: Bushing surface should be cleared using Carbon Tetra Chloride. Read value 1 minute after voltage application. Note Temperature. This measurement shall be done when weather is dry and Clean. ii. Ratio iii. Magnetizing Balance iv. Magnetizing Current v. Short Circuit vi. Vector Group Check CONFIRM PROPER CONDITIONS OF: i. Characteristics of Oil in min tank, OLTC, Cable Box {if oil filled} by checking BDV AND PPM values as given below: Sr.No. Characteristic Voltage Class Recommended {HSV} Values 1. BDV {Min} 72.5KV 40KV {rms} 72.5 145KV 50KV {rms} 145KV 60KV {rms} 2. PPM {Max.} 72.5KV 25ppm 72.5 145KV 20ppm 145KV 15ppm ii. Oil level in main Tank/OLTC Conservators, Main/OLTC breather,

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Cable Box{if oil filled} OTI AND WTI Packets. iii. Silica Gel Colour in Breathers of Transformer/OLTC {Blue} CONFIRM FOLLOWING VALVES/COVERS/CAPS ARE TIGHTLY CLOSED: i. All sampling, drain and filtration valves. ii. Conservator oil filling cap. iii. Air release value of Buchholz Relay. iv. No Oil leakage from any where. v. Test tap caps of all condenser bushings. CONFIRM FOLLOWING VALVES ARE FULLY OPEN: i. Top and Bottom Values of all Radiators. ii. Values on either side of Buchholz Relay. iii. OLTC Oil Surge Relay Shutt Off value. iv. Main Tank to Cable Box Value { if provided} CONFIRM PROPER OPERATION OF: i. Tapping Switch/OLTC ii. Alarm and Trip contacts of OTI, WTI, MOG, Buchholz Relay, OSR {on OLTC}, Pressure Release Value {whichever are provided} CONFIRM RELEASE OF: i. Air from all Bushings, all Bushings Pockets, Buchholz Relay,Main Tank Cover, all Radiators, OSR, OLTC Tank Cover. ii.Locks of MOG, Buchholz Relay,OSR. iii.Sealing Tapes of Breather of main Tank and OLTC. CONFIRM PROPER SETTINGS OF: i. Arcing Horn Gaps on HV and LV Bushings. ii. Alarm and Trip Temperatures on OTI typically 95c T-105 C iii. Temperatures on WTI for starting and stopping of cooling fans {if provided} iv. Pressure on Pressure relief value{if provided} v. release on circuit Breakers and Current and time settings on Relay {if provided}. vi. OLTC/Off circuit switch in desired positon and properly locked. vii. Current Ratio in case of multi-ratio CTs. CONFIRM THE FOLLOWING: i. All Bushing surfaces are clean. ii. All External connections are tight. iii. Main Tank,Cable Boxes, additional Neutral C.T., Secondary Terminals are properly earthed. iv. Arrow Heads of Buchholz Relay and OSR are painting towards respective conservators. v. Roller locking, if provided, has been done. vi. There is no oil seen in explosion Vent Slight Gas if provided.

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Vii Diaphragm at the top end of explosion Vent is intact. vii. Marshalling Box/Fan Control Cubicle/R.T.C.C. Panel are duly wired and earthed. OPERATIONAL: CONTROL ON HOURLY BASIS FOLLOWING: Sr. No. Item Recommended Action H1 Load Current If more than rated, reduce non-priority loads. H2 Voltage Control appropriate voltage H.V Voltage of H.V Variation and L.V Voltage for L.V variation. If OLTC is provided, change Tap Position appropriately. If off circuit tap switch is provided observations of several days can suggest a change in Tap Position. H3 OTI and WTI Check that observed temperatures are not Readings. high for the prevailing load and ambient temperature.

5. PERIODIC 5-1 DAILY Sr. Item No. D1 Oil levels in Transformer and OLTC

Recommended Action Check oil levels in respective conservators. Check that they are commensurate Ambient Temperature and Load. If low, top up with dry Transformer oil. Examine Transformer for leaks. Observe for oil in the sight glass of Explosion Vent. If present, indicates that lower Diaphragm is bust. Proceed as per trouble-shooting instruction Sr.No.7. If absent, confirms healthiness. Observe upper Diaphragms. If broken replace.

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Explosion Vent Diaphragms

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Breather on Transformer and Checks colour of Silica Gel. It should be blue. If OLTC Pink, replace by a spare charge. Charge removed should be heat treated for next usage. Oil level in condenser Bushings Oil should be seen in the sight glass, otherwise, refer to Bushing Service Manual for further action. Different manufacturers have different recommendations.

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5-2 Sr. No Q1 Q2 Q3 Q4 Q5 Q6 5-3 Sr. No. HY1

Quarterly Item Bushings Fan Motors OLTC driving mechanism OLTC controls and interlocks Breathers on Transformers and OLTC Ventilators {For indoor Transformers HALF-YEARLY Item Cable Boxes, Gasketed joints, gauges, external paint.

Recommended Action Clean the surface, Examine for Chips and Cracks. If necessary replace. Lubricants bearings off an Motors. Check controls and interlocks. Replace worn out contacts. Check oil level. Add if required. Check all circuits independently. Check step by step operation including limit switches. Check oil level in oil cup. Check that air passages are free. Recommended Action Inspect, Make good any deficiency noticed.

5-4 YEARLY Sr.No Item Y1 Oil Transformer

Y2 Y3 Y4 Y5

Gasket joints,Cable Box, Covers, etc. Surge Diverter Arcing horns Relays Alarms, etc Earth resistance

Recommended Action Check for {I} Die electric Strength, {ii}Water Content, {[iii}Acidity,{iv} Sludge. If the MVA and importance justify, test for dissolved Gas analysis. Check for tightness. If required, tighten. Clean, if dirty. Replace porcelain if cracked. Check for satisfactory operations and settings. Take suitable action if it measures high, compared to the initial value.

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5/7 YEARLY Overall Inspection Overall Inspection

5 Yearly for Transformers rated 3000KVA and below. 7 Yearly for Transformers greater than 3000KVA. Lift core and coil assembly. Wash by hosing down with clean dry oil. Tighten clamping nuts pressing the coil assembly and top and bottom yokes. Tank the core coil assembly in shortest possible time but not more than 8 hours. Circulate tank oil at 70 C for 2 passes by means of Filter Machine.

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Sr. No. 1. Alarm in OTI or WTI

TROUBLE SHOOTING Symptom

Possible Causes a} High Ambient Temp. b} Insufficient Cooling

Recommended Action Check OTI setting and if required, adjust setting appropriate to Ambient Temperature.

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Alarm in MOG

Check dust, cement, coal etc., deposits on Tank and Radiator surfaces. Oil leakage is conducive to dust collection. c} Overload Clean the affected surfaces. Check load current. If greater than rated, reduce load other than priority load. d} Sludge formation in Check oil for sludge. If required oil. filter oil a} Oil level gone down Top up conservator with fresh, dry Transformer oil. b} Terminals shorted in Clean terminals and their Terminal Box. surrounding space.

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Alarm in Buchholz Relay

a} Oil level gone down b} Terminals shorted in Terminal Box. c} Gas collected in Buchholz Relay.

4.

Output Voltage High or Low

Incorrect Tap Position

5. 6. 7. 8. 7.

Leakage through threaded joints or at gaskets. Leakage from welds. Oil explosion Vent Excessive Audible Noise

Insufficient or uneven compression. Imperfect weld A}Internal Fault B} Improper joints.

Top up conservator with fresh, dry transformer oil. Clean terminals and their surrounding space. Release gas, observe whether alarm comes again and after what time. Carry out dissolved Gas Analysis {DGA}. Check with previous results and identify the fault. If required, take manufacturers help. Check whether tap position Matches the input voltage. If not and if provided with an OLTC, adjust proper tap position. If provided with an off circuit switch, observe the consistency of voltage for a few days. If justified, change tap position with due precautions. Check and if required tighten Nuts and Bolts. Repair leaks by welding. Conduct Ratio and M.B tests and if fault is indicated, identify the fault. Tighten loose parts and all joints.

USEFUL I.S SPECIFICATIONS FOR TRANSFORMER i. I.S 10028 {Part II} 1981 Code of Practice for selection, Installation and maintenance of Transformers Installation. ii. I.S 10028 {Part III} 1981 Code of Practice for selection, Installation and maintenance of Transformers Maintenance. iii. I.S 1866:1983 REAFFIRMED 1991 Code of Practice for maintenance and supervision of mineral insulating oil in equipment.