NABL

National Accreditation Board for

Testing and Calibration Laboratories
Department of Science & Technology, India
Certificate Number T-2179

SERVICE MANUAL
[FOR INSTALLATION, COMMISSIONING, OPERATION AND MAINTENANCE OF TRANSFORMERS]

VOLTAMP
TRANSFORMERS LIMITED
: REGD. OFFICE & WORKS :
MAKARPURA, VADODARA - 390 014, GUJARAT, INDIA.
PHONE : 0265 - 2642011, 3041403, 3041480
FAX NO. : 0265 - 2646774, 3041499
E-MAIL : voltamp@voltamptransformers.com
MARKETING : dt_offer@voltamptransformers.com
WEBSITE : www.voltamptransformers.com

: SAVLI UNIT :
At. Vadadala, Jarod-Samlaya Road,
Post. Garadhiya - 391 520, Taluka : Savli, Dist. Vadodara, Gujarat, INDIA.
Phone : 09374648493, 09374648522, 093746 48513, 81286 75081 - 82
Fax : 02667 - 251250
 VOLTAMP
TRANSFORMERS LIMITED

SERVICE MANUAL
[FOR INSTALLATION, COMMISSIONING, OPERATION AND MAINTENANCE OF TRANSFORMERS]
 VOLTAMP TRANSFORMERS LIMITED
REGD. OFFICE & WORKS: Phone : (0265) 2642011, 3041480/403
Makarpura, Vadodara-390 014, (Gujarat). Mktg. Dept. : (Direct) 3041429, 3041405
Email: voltamp@voltamptransformers.com Fax No. : (0265) 2646774, 3041499

BRANCH OFFICES CONTACT PERSONS TELEPHONE, FAX NOS. & E-MAIL

AHMEDABAD Phone No. (079) 30421884

312, Samnan-ll, Opp: Shell Petrol Pump, Fax No. (079) 30421883
100 ft. Anand Nagar Road, Dr. P.M. Parikh, Mob. 93775 69450, pmparikh_mktg@voltamptransformers.com
Satellite, Ahmedabad- 380 051. Mr. Sanjiv Antrolkar Mob. 81286 75079, sanjiv_exec@voltamptransformers.com

BANGALORE Phone No. (080) 33459070, 334590701

304, Regency Enclave, 4, Magrath Rd, Fax : (080) 33459077
Near Brigade Road Circle, Mr. K.T. Naidu Mob. 93530 11801, ktnaidu_blr@voltamptransformers.com
Bangalore-560 025. vtl_blr@voltamptransformers.com

BHUBANESHWAR SAS Phone No. 093371 38207

166, Kharvel Nagar, 1st Floor, Unit-ll, Mr. Chinmaya Samal Fax : (0674) 2539262
Bhubaneshwar-751 001. Mob. 99379 95103
bbsr_sas@voltamptransformers.com

CHANDIGHARH Office Mob : 093160 07160

S.C.O. No. 115, Sector 47-C, Mr. Manoj Handa Telefax : (0172) 2632655
Chandigarh-160 047. Mob. 93160 01251 (Resi.) (0172) 2631944
mhanda_chd@voltamptransformers.com

CHENNAI Phone No. (044) 28365495, 33455093, 33455097

2A - Ashirvad Apartment, 2nd Floor, No. 8, Fax No. (044) 28365234
17th Avenue, Harrington Road, Chetpet, Mr. K. Sasidharan Mob. 93800 03052 (Resi.) (044) 25514369
Chennai- 600 031. ks_vtlchn@voltamptransformers.com
Mr. H. Shankar Mob. 93800 03051, vtpl_chn@voltamptransformers.com
Mr. Mohan Mob. 98406 12908
Mr. T. K. Giri Mob. 91760 25534 sasik_vtlchn@voltamptransformers.com
Mr. Syed Ali (for services) Mob. 93800 17147 sas_chn@voltamptransformers.com

COIMBATORE
10B, Periyar Nagar, 3rd Street, Mr. C.S. Rajagopal Phone No. (0422) 2427191
Vadavalli, Coimbatore - 641 041. Mob. 093644 62112
coimbatore@voltamptransformers.com

DELHI Phone No. (011) 22439457, 22428331, 45641261

202-203, Aditya, 6 Preet Vihar Fax : (011) 22424988
Comercial Complex, delhi@voltamptransformers.com
Delhi - 110 092. Mr. S.S. Gupta Mob. 98100 66950, (Resi.) 22155126
ssgupta_delhi@voltamptransformers.com
subodh@voltamptransformers.com
Mr. V.K. Chhabra Mob. 93139 54302, (Resi.) 29220664
sasdel@voltamptransformers.com
Mr. S. Narayan Mob. 93139 54303
exec_delhi@voltamptransformers.com
offer_delhi@voltamptransformers.com
Mr. H.S. Shanker Mob. 93139 54303
Narayan sasdel@voltamptransformers.com
(for services)

GHAZIABAD Mr. R.B. Dhebar Mob. 93105 33636

910, Antriksh Green, B/h. Angel Mega Mall, dhebar_mktg@voltamptransformers.com
Kaushambi, Ghaziabad (U.P.).
 VOLTAMP TRANSFORMERS LIMITED
BRANCH OFFICES CONTACT PERSONS TELEPHONE, FAX NOS. & E-MAIL
JAMSHEDPUR
5/8, Block - B, Ganesh Vatika Anil Sur Path,
Kadma, Jamshedpur - 831 005.
KOLKATA
Unit No. 8, 7th Floor, AMP Vaisakkhi
Plot No. 112, Block AG, Sector-II,
Salt Lake City, Kolkata - 700 091.
MUMBAI
01, Ground Floor,
Siddhachal Building, Near Cosmos Bank,
Hanuman Road, Vile Parle (E),
Mumbai - 400 057.
NAGPUR
Flat No. 303, Gajanan-II Apartment, Plot No. 1,
Wanjari Nagar, Nagpur - 440 003.
PUNE
402, Monoplex Plaza, Near Deep Bunglow
Chowk, Shivaji Nagar, Pune - 411 016.
SECUNDERABAD
Flat No. 2/A, 2nd Floor, T.S.K. Chambers,
5-4-83 to 85, M.G. Road, Opp. Ranigunj
Bus Depot, Secunderabad - 500 003.
IN CHARGE - SERVICES
FOR REPAIR / OVERHAULING INQUIRIES,
TENDERS, REGISTRATIONS ETC.
FOR SPARES
FOR SERVICE
Mr. Partha Sarathi Mob. 97714 50247
Mandal partha_jsp@voltamptransformers.com
Phone No. (033) 23370349, 23371505
23370092 Telefax : (033) 24611508
vtl_kol@voltamptransformers.com
saskol@voltamptransformers.com
Mr. Suvendu Deb Mob. 99030 22541, suvendu@voltamptransformers.com
Mr. D.K. Pal Mob. 93321 63828, dkpal@voltamptransformers.com
Mr. N. R. Mukherjee nrmukherjee@voltamptransformers.com
Mr. Prabir Mukhopadhyay Mob. 99033 25098, saskol@voltamptransformers.com
(for services)
Office based Mob. 98925 07147
Phones : (022) 26135289, 26135192, 26135298
vtl_mumbai@voltamptransformers.com / vtplbomltd@gmail.com
Mr. T.G. Wilson Mob. 93207 02481 (Resi.) 28688413,
tgwilson_bom@voltamptransformers.com
Mr. Eric Noronha Mob. 93207 02482 (Resi.) 26371283
Mr. Manoj Chitale Mob. 93207 02483 (Resi.) 24379056
Mr. K.M. Shah Mob. 93215 10055, voltampservices.mumbai@gmail.com
(for services)
Fax No. 0712-2759932
Mr. Amit K. Mob. 93253 45556
Shrikhande vtl_nagpur@voltamptransformers.com
Phone No. (020) 25650612 / 15
Fax No. (020) 25653391
Mr. P.N. Jibi Mob. 93254 01171, pnjibi_pune@voltamptransformers.com
jibi@voltamptransformers.com,
offer_pune@voltamptransformers.com
Mr. Amit Brande Mob. 99607 00805, order_pune@voltamptransformers.com
Mr. Dattatray Chimane Mob. 73870 44411, sas_pune@voltamptransformers.com
(for services)
Phone No. (040) 27540426
Fax No. (040) 27540462
Mr. D.J. Chakraborty Mob. 93462 01231 (Resi.) 23742362
vtl_hyd@voltamptransformers.com
Mr. Rajiv Shukla Mob. 93462 15812
HEAD OFFICE SERVICES
Mr. Yogesh Shah Phone No. 0265 3041 491, Mob. 93775 69496
yogeshshah@voltamptransformers.com
Mr. Satyesh Joshi Phone No. 0265 3041 453, Mob. 93750 27749
sjoshi_sas@voltamptransformers.com
Mr. Dhaval Shah Phone No. 0265 3041 496, Mob. 96625 08233
spares@voltamptransformers.com
Mr. Rakesh Vishwakarma Phone No. 0265 3041 433, Mob. 96625 08200
service@voltamptransformers.com
 INDEX

INTRODUCTION : Page No.

1. Transport & Handling 1

1.1 General 1
1.2 Transport
1.3 Unloading & Handling
1.4 Storage
2. Fittings & Accessories. 3
2.1 Rating & terminal marking plate.
2.2 Tap Changing arrangement
2.2.1 Off-Circuit Tap changing switch
2.2.2 Off-Circuit Tap changing links
2.2.3 On-Load Tap changer
2.3 Earthing Terminals
2.4 Lifting Lugs
2.5 Valves
2.6 Bushings
2.6.1 Oil Communicating Type Bushings
2.6.2 Condenser Busings.
2.7 Cable Boxes
2.8 Bus-Duct Trunkings
2.9 “Marshalling Box”
2.10 Buchholz Relay
2.11 Radiators
2.12 Silica Gel Breather
2.13 Magnetic Oil Level Gauge
2.14 Oil Temperature Indicator
2.15 Winding Temperature Indicator
2.16 Repeater OTI & WTI Instrument
2.17 Resistance Temperature Detectors
2.18 Thermosyphon Filter
2.19 Flexible Seperator
2.20 Oil Filling Procedure
2.21 Oil Level Transmitter
2.22 On Load Tap Changer
3. Installation & Commissioning 11
3.1 General
3.2 Installation
3.2.1 Location
3.2.2 Foundation
3.2.3 Provision for Oil Draining
3.2.4 Assembly of dismantled components
3.2.4.1 Main Tank
3.2.4.2 Bushings
 3.2.4.3 Conservator & M.O.G.
3.2.4.4 Buchholz Relay
3.2.4.5 Breather
3.2.4.6 Radiators
3.2.4.7 Marshalling Box
3.2.4.8 Cable Box
3.2.4.9 Other fittings
3.2.5 Oil Sampling & Filtration
3.2.6 Air Release
3.3 Commissioning
3.3.1 Pre-commissioning Tests
3.3.1.1 Ratio Test
3.3.1.2 Vector Group Check Test
3.3.1.3 Magnetising Current Test
3.3.1.4 Magnetic Balance Test
3.3.1.5 Measurement of Insulation Resistance
3.3.1.6 Short Circuit Test
3.3.1.7 Parallel Operation
3.3.2 Other Relevant Details
3.3.3 Check Points
3.3.4 Energising
3.3.5 Tools & Instruments
3.3.6 Commissioning Report
i. Format for noting details of Oil BDV Test, Bushings, M.O.G. Buchholz Relay, Oil Surge Relay,
Breathers, Radiators & Radiator Valves, OTI, WTI, Cooling Fans.
ii. Format for noting test results of Ratio Test, Vector Group Check Test, Magnetising Current
Test, Magnetic Balance Test, Insulation Resistance Test, Short Circuit Test.
iii. Format for noting details of Control Panel/Protective Scheme, OLTC
iv. Commissioning check points.
4. Operation & Maintenance
4.1 Operation
4.2 Maintenance
4.2.1 General
4.2.2. Oil
4.2.3 Core & Winding
4.2.4 O.L.T.C.
4.2.5 Conservator & M.O.G.
4.2.6 Breather
4.2.7 Buchholz Relay
4.2.8 Pipe Work
4.2.9 Explosion Vent.
4.2.10 Gaskets
4.2.11 Temp. Indicators
4.2.12 Bushings
4.2.13 External Connections
4.3 Maintenance Schedule
4.4 Trouble Shooting
INTRODUCTION :
The purpose of this instruction manual is to guide the User on Installation, Commissioning Operation and Maintenance
of Power & Distribution Transformers manufactured by us.
While general guidance is given in this manual, for further details reference should be made to the following :

SPECIFICATION NO. TITLE

I.S. 2026 parts I to IV Power Transformers
I.S. 3639 Fittings & Accessories for power Transformers
I.S. 335 New Insulating Oil for Transformers & Switchgears
I.S. 10028 parts I to III Code of Practice for Selection, Installation & maintenance of Transformers
I.S. 1866 Code of Practice for maintenance of Insulating Oil.
I.S. 2099 Bushings.
I.S. 3347 Dimensions of Porcelain Transformer Bushings for use in lightly polluted atmosphere.
I.S. 6792 Method of determination of electric strength of insulating oil.
I.S. 8468 On-Load Tap changers
I.S. 8478 On-Load Tap changers Application Guide
I.S. 1646 Code of Practice for Earthing
I.S. 3043 Code of Practice for Earthing
I.S. 2705 Current Transformers
I.S. 3637 Specification for Gas-Operated Relay
I.S. 6600 Guide for loading of oil immersed transformers
I.S. 6272 Industrial Cooling Fans
- C.B.I.P. Manual on Transformers
- Indian Electricity Rules.

1. TRANSPORT & HANDLING

1.1 GENERAL :
All our Transformers are designed, manufactured and tested with due care. Routine Tests in accordance with I.S.
2026/IEC 60076/I.S. 1180 are carried out on all transformers. They will give long and trouble-free service when
properly installed, operated and maintained. In case anything abnormal occurs during the service, reference
should be made to us giving complete particulars as to the nature and the extent of abnormality together with the
name-plate particulars in order to assist Identification of the transformer. As efforts are being constantly made to
improve designs and services, the transformers supplied may differ in minor details from the date given here
under. Any additional information, if required, can be supplied on request.
1.2 Transport :
Transformer of rating 1250 KVA and above are generally despatched with their external fittings dismantled to the
extent required and weather-proof blanking plates are provided wherever necessary prior to despatch. External
arrangement drawings indicate various accessories, dismantled for transport, with asterisks against list of fittings
with an appropriate note.
Transformers are despatched in one of the following modes :
(a) Completely filled with oil upto 1000 KVA.
(b) With NITROGEN :
Large oil filled Transformers are not normally oil filled during shipping due to weight limitations. To protect
the active parts against moisture the transformer tank is filled with dry Nitrogen at a positive pressure of
2.5 PSI (0.175 Kg./cm2) at Voltamp works before dispatch. The Internal pressure at the time of shipment is
sticked on the tank.

1
 A Transformer despatched according to this method should normally be stored upto 3 months after arrival
at site.
(c) With oil covering coils and top yoke (approx. 40mm below top cover.) Oil for topping up, filling in radiators
etc. is despatched separately in sealed drums. Space above Oil level is filled with air at normal atmospheric
pressure.
Accessories such as conservator, radiators, oil filled bushings etc. which are despatched in different packages,
are given numbers and these numbers are indicated together with contents, in the packing list.
1.3 UNLOADING & HANDLING :
On receipt at site, transformers should be unloaded by means of crane or lifting devices of adequate capacity. All
lifting lugs must be used to avoid unbalanced lifting and undue stresses on lugs. Lifting lugs provided for partial
lifting (e.g. for active part, conservator etc.) must not be used for lifting complete transformer. Parts other than
lifting lugs must not be used for lifting. While slinging care should be taken to avoid slings touching other parts.
(Refer Fig. 21)
All other parts and case containing accessories should be unloaded by using lifting lugs. They should be handled
in their upright position as indicated on the cases.
Transformers should be carefully examined for transit damages. External damages could be indicative of severe
internal damages. Following should be particularly observed :
(a) Dents on tank wall.
(b) Damage to protruding parts like valves, sight glass etc.
(c) Oil leakage around or through welds.
Packed components should be carefully unpacked and all parts/components received should be examined for
transit damages.
Rollers should be used for shifting the transformer from one place to other. Roller axles or radiators should not be
slinged for the purpose of towing. Pulling holes provided on the tank for this purpose should only be used. (Ref.
Fig. 20).
Transformers of higher ratings are provided with four jacking pads. (Ref. Fig. 20). Each jacking pad is designed to
take approximately 25% of the total load. Under no circumstances, jacking should be used anywhere else other
than these specially provided pads.
1.4 STORAGE :
On receipt of the Transformer at site, it is desirable to install and commission the transformer with minimum
delay. In case, this is not possible, the silica-gel breather should be fitted. The breather incorporates an oil sealing
device which must be filled with oil to the marked level to be effective. A periodic watch should be kept on the
silica-gel breather to ensure that the gel is blue. The gel should be replaced or dehydrated immediately on its
turnings pink.
Goods Stored outdoors must not be placed directly on the ground and should be covered carefully with tarpaulin
or similar material.
It is advisable to check the condition of silica gel during storage atleast once a week and Break Down
Voltage (BDV) of oil atleast once in a month and should be maintained at a level of 50 KV. It is desirable to
keep the transformer energised even at a low voltage so that the oil temperature is about 10 to 15 C o o

higher than the surrounding ambient temperature.

- Even during temporary storage, it is recommended to mount rollers by jacking-up the transformers to
enable free flow of air underneath.
- The tap changer should be operated at six monthly intervals. Two or three runs from one end of the range
to the other are considered sufficient.
- Accessories like, bushings, buchholz relay, dial type temperature indicator, terminal box, radiators, all pipe
work, should be stored indoors till such time they are not required. It they are not stored properly, they are
likely to be damaged. The conservator pipe work and radiators are despatched with blanking plates and
these are to be stored with their blanking plates, in position.
It these are stored for a longer period like six months or so, it advisable to flush them with clean transformer oil
before use.

2
OIL DRUMS :
If oil received in drums is not likely to be used immediately, the drums should be stored in a covered space where
temperature variation is minimum. If it is necessary to store the drums outside, adequate protection must be provided.
Drums should not be stored standing on end but should be placed on their sides with the bung at 45 downwards.
o

It is very important the drums are stored free from fire and explosion hazards.
2. Fittings & Accessories :
2.1 Rating & Terminal Marking Plate : (R & D Plate)
The transformers is supplied with rating and terminal marking plate made out of noncorrosive metal. The plate
contains information concerning the rating, voltage ratio, weights, oil quantity, vector group etc. The plate also
includes unit Sr. No. and year of manufacturing.
2.2 Tap Changing Arrangement :
2.2.1 Off-Circuit Switch. (Ref. Fig. 1)
The transformers is normally fitted with an off-circuit tap changing switch to obtain required voltage ratio. It can
be hand-operated by a switch handle mounted either on tank cover or on the tank side. The locking devices is
fitted to the handle to lock in any tap position. The switch mechanism is such that it can be locked only when it is
located in its proper position and not in any intermediate position.
THE TRANSFORMERS MUST BE ISOLATED FROM ALL THE LIVE LINES, BEFORE OPERATING THE SWITCH.
Operating the switch when transformer is energised, will damage the switch contacts due to severe arcing
between the contacts and may damage transformer winding.
When the switch handle is provided on the side wall. it is necessary that Switch handle assembly is dismantled
before untanking.
2.2.2 Off-Circuit Ratio Changing links :
Sometimes links are provided inside the transformers tank to obtain required voltage ratio. Links are required to
be loosened and fixed in new required position as given in R & D Plate. Links are accessible from the inspection
cover. In case of conservator units, oil level has to be lowered below the inspection cover before unbolting
inspection cover.
2.2.3 On-Load Tap Changer :
The on-load tap changer is an optional fitting. The on-load tap changers are provided with local manual control,
local electrical control and remote electrical control. The automatic voltage regulation can also be provided as an
optional fittings.
The tappings are located on high voltage winding.
2.3 Earthing Terminals :
The core laminations assembly is connected to core clamping frame which is in turn connected to the tank. Two
earthing terminals are provided on the transformer tank. The earthing terminals should be connected to the
earthing.
2.4 Lifting Lugs :
Two/Four liftings lugs of adequate capacity are provided on tank sides/top cover to lift fully assembled
transformer filled with oil.
All lugs are designed for simultaneous use and must be used accordingly. Two/Four lifting lugs are All heavy
fittings are also provided with individuals lifting lugs.
2.5 Valves :
Every transformer is provided with drain cum filter valve at bottom of the tank, and filter valve at top of the tank.
Valves are fitted with plugs/blanking plates to stop oil coming out.
Mainly two types of valves are provided.
3
 (i) Wheel Valves.
(ii) Butterfly Valves.
The Wheel Valves are used either with female screw threads or with flanges. These are of gun-metal/cast iron
type.
Generally, one isolating Valve also known as shut off valve is provided for transformer upto 2000 KVA between
conservator and buchholz relay.
The Butterfly type cast-steel valves with the machined flanges are used at points of connection between tank and
detachable radiators.
2.6 BUSHINGS :
2.6.1 Oil Communicating Type : (Ref. Figs 2,3,4)
Transformers windings are connected to the external circuit through terminal bushings. The bushings are
installed on the cover or, on side walls of the transformer tank. The lower end of the bushing protrudes into the
tank and at both their ends are provided with suitable fasteners to connect the line leads inside the transformers
an external conductors outside it. Typical Bushing Assemblies are shown in Flgs. 2,3,4.
The shape and size of the bushings depend on the voltage class, type of current. Electrical performance of these
bushings conform to I.S. 2099 & I.S. 7421 Dimensional details and associated parts generally conform to IS-3
upto 36 KV class. Bushings of 1000 Volts are of two piece construction without arcing horns. whereas all other
bushings are of single piece porcelain type. Assembly and dismantling of single piece type bushing is possible
without disturbing the active part. For bushings of two piece construction, tank cover is required to be removed
for necessary access to the inner (lower) end of the bushings. These bushings are not detached at the time of
transportation.
2.6.2 Condenser Bushings : (Ref. Fig. 5)
Generally, Condenser Bushing are used for 72.5 KV and above. These bushings contain their own oil and are
sealed to retain the same. Whenever these bushings are mounted on bushing pockets or raised truncated
portions, air vent pipes are provided for carrying away air or gases from these pockets to Buchholz relay during
service Typical assembly is shown in Flg. 5.
These bushings are detached from the transformers and despatched separately, They are packed as per
manufacturers’ instructions. The draw through type lead is coiled and kept temporarily below the bushing
blanking plate (Ref. Fig. 6). The equipment required for mounting the bushings are (i) rope slings (ii) flexible steel
wire approx. 2mm in dia, of suitable length.
Typing procedure for mounting is as follows :
(i) Open the bushing case carefully and check it for transit damage and clean the bushing throughly.
(ii) Check whether the gasket on the pocket is in order. If not, clean the seat of the gasket and replace it by
new one.
(iii) Remove the locating pin (3). The cable bolt to be used on the unit is brazed to the end of the flexible draw
through type lead mentioned above.
(iv) Remove the blanking plate and uncoil the draw through type lead. Tie the Flexible Steel wire to the head of
the bolt fixed temporarily on the top of the cable bolt (2) to facilitate the threading of the main lead
through the bushing tube and at the same time preventing the lead form falling bank into the tank.
(v) Suitably raise the bushing and remove the protective cover at the oil end of the bushing. (Ref. Fig. 7)
(vi) Check that Oil Level in the bushing is appearing in the Oil Level indicating glass. In case it is not visible, do
not mount that bushing. Also do not attempt to fill oil at site as such bushing is most likely to fail in service.
(vii) During the lowering operation, thread the flexible steel wire through the inside tube of the busing and pull
it. Continue the operation till the bushing rests on its flange pocket. Bolt the two flanges and remove the
slings.
(viii) Hold the cable bolt in position, remove the flexible wire and insert the locking pin (3) to hold the cable bolt
remove the slings.
4
 (ix) Fix the terminal cap (1) in position by screwing it on the terminal bolt.
(x) For removing air from the central tube after oil filling, unscrew the terminal cap and press the terminal bolt
downward.
(xi) Fix upper and lower arcing horns and adjust the gap setting as per the required Insulation Co-ordination.

2.7 Cable Boxes : (Refer Fig. 8, 9)

Cable boxes are designed for receiving and protecting cable ends. Insulating paper is most hygroscopic and all
paper insulated cable ends must be protected by suitable insulating compound. These cable boxes are provided
with brass wiping glands and are designed with clearances inside the box suitable for compound filling. The cable
box in such case must be filled with compound as marked as indicated in the drawling.
Cable boxes for PVC ar XLPE cables are designed with air clearances and hence these boxes are not required to be
filled with compound.
Cable boxes of 3.6 KV and above are provided with detachable gland plates. Earthing terminals are also provided
on these cable boxes for earthing the armouring of individual cables.
When Cable Boxes are provided with disconnecting chambers they permit removal of transformers for servicing
without disturbing cable terminations.
2.8 Busduct/trunkings : (Refer Fig. 10)
Some users prefer connections to load by means of busduct. Busduct is supplied by some other agency. However,
we provide suitable flanges/trunkings around transformer bushings for receiving the busduct.
The level of the busduct flanges from ground/rail level is indicated in the General Arrangement drawings of the
transformer. The complete details of busduct flange is furnished by us giving complete dimensional details for the
matching flanges, bolt spacing, bushing terminal details, etc.
2.9 Marshalling Box : (Refer Figs. 11, 12)
The transformer is provided with certain fittings directly mounted on the transformer at various locations. These
fittings are having electrical contacts or terminals which are required to be connected to the protection schemes
to give alarm/annunciation under abnormal conditions and if further required to disconnect the transformer form
mains. In order to facilitate connections of all such devices to the protective scheme, the cable form all such
contacts are wired upto a weather-proof terminal box, This box called marshalling box, is also used for housing
Oil Temperature Indication (OTI) and winding Temperature Indicator (WTI).
It has a hinged door with locking facility to prevent unauthorised access. The capillaries from OTI & WIT come
out from the bottom of the Marshalling box through suitably recessed gland plate thus preventing ingress of dust.
It has a hinged door with locking facility to prevent unauthorised access. The capillaries from OTI & WIT come
out from the bottom of the Marshalling box through suitably recessed gland plate thus preventing ingress of dust.
It has a detachable gland plate with glands through which cables enter and leave. It has a rain shed provided on
top to prevent rain falling directly over it. All these provisions make Marshalling Box a Weather-Proof enclosure.
2.10 Buchholz Relay : (Refer Fig. 13)
Buchholz Relay is a very sensitive, gas and oil operated apparatus which detects formation of gas or development
of sudden pressure inside the oil filled transformer. It is connected to protection circuits to give an early audible
alarm of gas collection and to disconnect the transformer from supply in case of severe fault inside the
transformer.
The basic function of the relay, is to initiate an electrical signal in the protection circuit when :
(a) Gas is a accumulated in the relay, as result of incipient fault.
(b) Surge of oil is developed on account of sudden increase in pressure inside the transformer due to severe
fault.
Buchholz Relay operates in the following manner :

5
 The relay comprises a housing containing two pivoted Buckets/Floats counter balanced by dead weights. Each
bucket assembly carries a mercury switch. The relay is fitted in the oil connection between conservator and tank.
Due to gas collection, the oil level inside the relay drops and the upper bucket moves down This tilts the mercury
switch bringing fluid mercury in such a position that it bridge the normally open (NO) contacts. Other probable
reasons for dropping of oil level in the relay are :
(a) Leakage of oil from main tank, conservator or relay itself.
(b) Collection of air in the relay which is trapped earlier in the tank and in the winding.
The lower bucket operates similar to upper bucket when level in the relay drops further. However, important
function of this relay is to disconnect transformer from circuit under sudden development of pressure inside the
transformer due to severe internal fault. In such cases, gas generation is rapid and displaced oil surges through
the relay impinging on the baffle plates causing lower bucket to tilt and close the Normally Open (NO) contact of
the mercury switch carried by it.
Upper bucket contacts (A) are connected to audible alarm - ‘A’ circuit and lower bucket contacts - (T)- are
connected to trip circuit.
The relay is mounted in position with associated piping and Isolating valves at works. In larger transformers, the
buchholz relay assembly is dismantled and sent separately. When Test Lever is provided, it is sent in ‘Test’
Position to prevent damage in transit. On receipt at site, check the relay for any damage to window glasses and
mercury switches.
Mount the Buchholz Relay between conservator and transformer tank cover alongwith piping & valves without
straining the pipe line. Isolating valve must be fully opended after mounting is completed. To ensure successful
operation of the relay the pipe work on either side of the relay is set inclined to horizontal by 3-5 .
o

MOUNT RELAY SUCH THAT ARROW DIRECTION POINTS TOWARDS CONSERVATOR

After filling oil in the transformer, air trapped inside the relay is to be released through the valve/petcock provided
on top of buchholz collection, it must be ensured that this valve is kept open and the pipe is full of oil. When gas is
collected, oil from pipe will flow out first and then gas will come out.
2.11 Radiators : (Refer Flg. 15)
The function of radiators is to limit the temperature of oil and winding by dissipating heat that is generated due to
losses within the transformer while in service. The number of sections per radiator and the number of radiators
per transformer will depend upon the losses and permissible temperature rise.
Distribution Transformers are normally provided with Radiators welded to tank. Owing to transport limitation and
possible transit. damages, power transformers are provided with detachable radiator with radiator valves (Ref.
Fg. 18). At the time of despatch, these radiators are detached and sent separately keeping the valves in position
on tank flanges.
- Each radiator consists of number of “Section made from pressed CRCA Sheets forming channels for oil
flow. These “Sections” are welded to Header Pipes at Top & Bottom. Detachable radiators are provided
with M.S. Flanges at Top & Bottom. Flanged radiators are fitted with Air Release Plug. Drain Plug, Lifting
Lug, etc.
- Bracing Straps, made from M.S. Flat are provided on radiators to prevent vibration of sections. Radiators
are cleaned internally to remove scales and a coat of varnish is applied. External surface cleaned off all rust
and one coat of Red Oxide primer is applied. which is followed by final painting.
2.12 Silica Gel Breather : (Refer Fig. 16)
Whenever there is a change in the ambient temperature or in the load of an oil immersed transformer there is a
change in oil temp. & hence in the volume of oil. Increase in oil volume, causes the air above the oil level in the
conservator to be pushed out and decrease causes air to be drawn in. Thus the transformer “Breathes”. When air
is breathed in, there is a possibility of moisture and dust from atmosphere to be sucked in. These contaminants
deteriorate the insulation properties of oil. Hence, Silica Gel Breather is provided which arrests moisture and dust
from the air drawn in.
A Typical - Silica Gel Breather has following main components :
(1) A Casing, (2) Silica Gel Crystals, (3) An oil seal at the lower end of casing.

6
 The casing has a window at the upper part for observation of the colour of the get crystals. It has flange
connection at the top for connecting the breather to the breather pipe. The lower part of the casing has at
its lower end an oil seal arrangement, a window for observation of oil level and an oil filling hole with
gasket and plug.
Due to the chemical affinity possessed by Silica Gel Crystals, they absorb moisture from the air drawn in. The
Colour of silica gel is blue when dry and turns pink when it is saturated with moisture. The colour of crystals can
be observed from outside of the casing.
Oil seal assembly at the lower end of the casing consists of a little quantity of oil with an inverted cup partly
dipped in the oil and a tube fixed at the centre of the cup.
The oil acts as a coarse filter and removes the dust form the outside air when it passes through oil. Silica gel
breather is despatches in a separate case.
2.13 Magnetic Oil level Gauge (MOG) : (Refer Fig. 14, 19)
This is a dial type oil level indicating device provided on large transformers with conservator at relatively high
levels from the ground. In large transformers conventional glass oil level indicators are difficult to observe due to
their heights and colour change/dust accumulation on the glass. Further, the low oil contacts provided on the
magnetic oil level indicator can be used for automatic alarm when the oil level in the conservator falls to a low
level. This Protection feature and clear visibility justify the cost of MOG on a bigger transformer.
It consists of two compartments :
(a) The oil side compartment which is fixed on the opening in the conservator.
(b) The pointer side compartment.
These Compartments are sealed against leakage of oil by a metallic diaphragm. On the oil side compartment,
there is a bevel gear wheel and it is positioned near the diaphragm. Movement of the float due to rise and fall of
oil level in the conservator results into circular motion of the driving magnet. A follower magnet is positioned in
the pointer side compartment near the diaphragm. This magnet has its poles face to face poles of driving magnet
from the oils side compartment coupling them magnetically. The movement of float is, therefore, transferred
through the diaphragm, eliminating direct oil light mechanical coupling.
At the other end of the axis of the driven magnet an indicating pointer is fitted. The dial is calibrated to show the
oil level in the conservator. The dial and the pointer area housed behind the front glass. The dial has three
positions marked. The follower magnet has also a cam fitted on it which operates a mercury switch. When this
magnet is at a position corresponding to low oil level the mercury switch closes the Normally open (NO) contacts.
These contacts are normally wired to give audible alarm. The contacts are brought to terminal box at the lower
end of the dial, for external connections.
2.14 Oil Temperature Indicator (O.T.I.) : (Refer Fig 11)
- Oil Temperature Indicator (O.T.I.) is generally provided on all transformers except for very small ratings.
The direct reading pointer arrangement in this Instrument greatly facilitates observation of working temp.
of oil. It also helps, if need be, in deciding the permissible overloads in accordance with I.S. 6600-1972.
Guide for loading of oil immersed transformers.
- A Typical - Oil temperature indicator consists of a Bourdon tube with a pointer arrangement mounted in a
case comprising of a reading dial and a glass cover. There is a temperature sensing bulb which
communicates to the Bourdon tube through the armoured capillary.
- The oil temperature indicator is provided with two pointers and associated contacts for protection of
transformers. Both the pointers are independently adjustable and can be set to desired temperature.
Setting of these pointers at required temperatures can be done from outside through the knob by using
special keys.
- The OTI is generally housed and wired upto terminal strip in the marshalling box having a glass window on
the door for observation. The length of capillary does not influence the accuracy of measurement and
extra length of capillary tubing must not be cut, as it would break communication between bulb and
Bourdon tube.

7
 If the oil temperature increases beyond set limit due to overload or inadvertent closure of radiator valves or
insufficient air draft, the indicating pointer touches the present alarm pointer and actuates the alarm
contacts. The alarm contacts, when duly wired give an alarm. If the alarm is not attended and there is a further
increase of temperature, the trip contacts which are wired to the trip circuit will operate and isolate the
transformer form mains.
2.15 Winding Temperature Indicator (W.T.I.) Fef. Fig. 17)
A Winding Temp. Indicator (WTI) is an optional fitting and is provided when ordered. It is set to read Hot Spot
Temperature (HST).
A typical WTI arrangement comprises of the following :
(a) WTI Instrument having a temp. sensing blub and a capillary similar to O.T.I. In addition it is provided with
a heater coil around its operating bellow.
(b) A Current Transformer mounted on one of the transformer leads, sensing load current.
The bulb of the instrument is places in an oil filled pocket located on the top cover of the transformer similar to
O.T.I. pocket. The Heater Coil is fed by the W.T.I.C.T.
Thus the Temperature indicated by WTI accounts for
(i) Temp. of Top Oil and
(ii) Winding Gradient (Temp. Rise of winding over surrounding Oil) which is dependent on Load Current.
And is adjusted to read HST = [Top Oil Temp.] + 1.1 x Gradient
The Heater Coil is provided with an adjustable resistive shunt. (Ref. Fig. 24) in parallel which allows the
instrument to be adapted for a range of winding gradients.
The adjustable shunt by-passes certain amount of current (I ) from the C.T. Secondary Current (I ). Thus Heater
SH S

Coil Current.
I =I -I
H S SH

For the particular transformer, the shunt is adjusted at factory for the applicable Winding Gradient. WTI also has
Alarm & Trip contacts. For Fan cooled transformers auxiliary contacts of WIT are used for Fan switching.
2.16 REPEATER OTI & WTI INSTRUMENTS
Repeater OTI & WTI instruments are Optional Fittings and are provided when ordered. They enable readings
being taken in Control Room also. They are generally provided in the RTCC Panel, when it is a part of contract.
They are available in one of the following types :
(a) Simple Analog Repeater
(b) 4-20 mA d.c. Analog Repeater
(c) 4-20 mA. d.c. Digital Repeater
(d) 4-20 mA. d.c. Digital Repeater Plus signal for SCADA
They all require the Local Instrument to be provided with a precision potentiometer.
In cases (b), (c) & (d), they also require Auxiliary Devices like Power Supply Unit, Resistance to Current Converter
(RCXT) and/or Current to Current Converter (CCXT) etc. They are housed in a UNIT BOX mounted on the
transformer.
Wiring Diagrams and Interconnection Digrams necessary for the wiring of Marshalling Box, UNIT BOX and RTCC
Panel are supplied along with transformer.
2.17 OTI & WTI INSTRUMENTS OPERATED BY RESISTANCE TEMP. DETECTORS (RTD ) S

Temp. sensing can alternatively be done by Resistance Temp. Detectors (RTD ). Thus O.T.I. & W.T.I. can be
S

operated by RTD . When, so ordered, they are provided accordingly. In this case also Power Supply Unit and
S

RCTXT Unit will be required and they are provided in the Unit Box.
Here again Repeater Instruments are provided when ordered.
8
2.18 THERMOSYPHONE FILTER : (Ref. Fig. 25) Thermosyphones

Thermosyphone Filter is a device which continuously improves the quality of oil the transformer tank. It is an
optional fitting and is provided when ordered.

It is a container having perforated trays filled with Activated Alumina. It is fitted to the transformer tank similar to
a radiator with provision of isolating valves, air release plug, drain valve etc. Due to the convection current set up
in oil. flows continuously over the exposed surface of Activated Alumina (i.e. the adsorbent material) and in the
process, contaminants like moisture, organic acids etc. generated due to ageing of insulation, get collected in the
adsorbent material and thus improve the quality of oil.

Periodic recharging of adsorbent material is necessary.

2.19 FLEXIBLE SEPARATOR (Ref. Fig. 26)

Also known as ‘Diaphragm Conservator’ or ‘Rubber Diaphragm.’ It is an optional fitting and is provided when
ordered.

The ‘Flexible Separator’ is a sealed, nonporous flexible bag of a highly resistant fabric, coated externally to resist
transformer oil and internally to resist external atmosphere.

It is fitted inside the conservator such that variations in oil volume due to variations of temp. are taken up by the
Flexible Bag. Oil in conservator is sealed from the outside atmosphere by the mounting flange to which the
Flexible Bag is attached. Thus the atmospheric moisture and gases connot contaminate the oil inside the
conservator.

Fig. (a) shows the separator in inflated condition corresponding to low oil volume. When oil expands due to
increase in temp. atmosphere inside the separator is exhaled and the separator bad deflates as shown in Fig. (b).

Oil filling in the conservator is to be done as per the procedure given in 2.20.

2.20 OIL FILLING PROCEDURE FOR A CONSERVATOR PROVIDED WITH A FLEXIBLE SEPERATOR.

(1) Set up the separator inside the conservator by suspending it from the hooks provided.

(2) Keep the 2 Nos. 1/2”, SSF wheel valves at the top of the conservator open. Inflate the separator carefully
with an air pressure of not more than 2.p.s.i. A typical arrangement of Air inlet is shown in Fig. 26 (c).

(3) Adjust the pressure to a value between 1.5 & 2.0 p.s.i. and lock it. Observe for pressure drop for 12 hours.

(4) If there is no pressure drop, then the separator is leak-proof & proceed for oil filling. If there is leakage
contact us.

(5) Admit oil under slight pressure from the lower part of the conservator, till oil flows steadily from the 2
valves mentioned in (2) above. Close the valves.

(6) Admit further oil. Pressure will slightly increase. Remove compressor connection from the Air Inlet Valve.
Open this valve slightly to maintain pressure. Continue admitting oil slowly while maintaining pressure.
Separator will deflate. Stop filling when the MOG indicates filling level. Open the Air Inlet Valve completely
to equalise pressure inside the bag with atmospheric pressure.

IMPORTANT WARNINGS :

(1) When conservator provided with Flexible Separator is filled with oil as mentioned above, the Valves 1/2”

mentioned above must never be opened. It opened by mistake, the air-pressure acting on the separator
will deflate the separator.

(2) When it is necessary to open these valves, inflate the separator with a pressure of less then 2 p.s.i. and
then only open these valves.

9
 (3) Do not carry out any welding work on the conservator shell while separator is inside as it can damage the
separator.
2.2.1 OIL LEVEL TRANSMITTER : (Fig. 27)
When Oil Level in conservator is to be remotely monitored oil level transmitter is to be provided. It is an optional
fitting and is provided when ordered.
Transmitter System comprises of :
(i) Stainless Steel Rod which goes inside the conservator tank.
(ii) Transducer which gives electrical signal dependent on the oil level.
(iii) Power Supply / V-1 Module which provides 4-20 mA signal from the transducer output.
A typical arrangement is illustrated in Fig. 27.
2.2.3 ON LOAD TAP CHANGER (OLTC) : (Ref. Flags. 22 & 23)
OLTC is an optional device and is provided when ordered.
Tappings are located on High Voltage Winding of the Transformer.
One type of OLTC is fitted external to transformer main tank as shown in Fig. 22(a). In the other type, contacts
mounted on insulated cylinder are immersed in the transformer main tank as shown in Fig. 22 (b). In both the
types, Drive Mechanism (DM) is contained in a separate box.
Different arrangements used to effect tap changing are shown in Fig. 23. They are :
(a) Linear : Commonly used arrangement when no, of tap positions is moderate.
(b) Coarse/Fine : By means of a change-over contact, the tapping winding is connected in Forward (i.e.
Adding) or Reverse (i.e. Subtracting) direction w.r.t. main winding. Thus two voltages (i.e. tap positions)
are obtained for one position of moveable arm.
(c) Reverse/Forward : By means of a change-over contact, the tapping winding is connected in Forward (i.e.
Adding) or Reverse (i.e. Subtracting) direction w.r.t. main winding. Thus two voltages (i.e. tap positions)
are obtained for one position of moveable arm.
Arrangement (b) or (c) is used when no. of tap positions is large.
OLTC is generally operated electrically through a. Remote Tap Control Cubicle (RTCC) located in Control Room. A
Local electrical control is also provided in the DM, along. with a selector switch for Local or Remote Control. For
emergency manual operation, an operating handle is provided.
When Automatic Voltage Regulation (AVR) Relay is ordered and a Voltage Transformer (V.T.) is wired on the
Transformer output side (generally in user’s scope), the output voltage is compared - in the AVR Relay-with the
adjustable reference voltage and difference used to give command to OLTC so as to reduce the difference. Thus
the output voltage is automatically controlled to the preset value.
A Line Drop Compensator (LDC) is included in the AVR when specifically ordered R&X of the cable, connecting
transformer to load, are to be set by means of adjustable knobs. In such a case; voltage at the end of the cable
and not at transformer terminals, is controlled.
Direction of Power Flow is an important consideration in OLTC. Only some types are suitable for full power flow -
in terms of current and no. of operations - in the reverse direction. Other types have restrictions on the current
and no. of operations in the reverse direction. These details are given in the plate fitted to OLTC.
For further details, please refer to the OLTC manual and Schematic & Wiring Diagrams supplied along with the
transformer.

10
3. Installation & Commissioning :
3.1 General :
This section illustrates procedure for Installation & Commissioning of our transformers.
A format of “Commissioning Report” is included at the end of this section. Results of various precommissioning
tests as well as confirmation of check points are to be recorded in the Report. This Report would serve as a
handy record for future reference.
3.2 Installation :
3.2.1 Location :
The transformer should be kept in a well ventilated place, free from excessive dust, corrosive fumes etc.
Adequate ventilation is necessary for tank and radiators so that they can dissipate heat. There should be clear
space of about 1.25 m on all sides of the transformers if it is enclosed in a room.
3.2.2 Foundation
Foundation should be firm, horizontal and dry. where rollers are fitted, suitable rails should be provided.
3.2.3 Provisions for Oil Draining :
Necessary provisions for oil draining; in the event of a fire, should be made by way of Oil Soak Pits. Fire
separation walls should also be provided when necessary.
3.2.4 Assembly of Dismantled Components :
Various components dismantled for transportation should be duly assembled.
3.2.4.1 Main Tank :
Keep the main tank in the in its permanent position of operation. Lock the rollers to prevent any accidental
movement on rails. Draw an oil sample from the bottom of the tank and test it for Break-down-Voltage (BDV).
Note this value in “Commissioning Report”
3.2.4.2 Bushing :
Clean the bushings and check that there are no hair-cracks or other damages. Test IR value of each bushing
with a 500V Megger. It should be 100 M ohms or greater. Note details of Bushings in the “Commissioning
Report.” Mount all the bushings as described in 2.6 Ensure that the test tap cap is fully tightened, thus
positively grounding the same. Adjust the Arcing Horn Gaps in accordance with the Insulation Co-ordination
Note these values in the “Commissioning Report.”
3.2.4.3 Conservator & M.O.G. :
Note details of M.O.G. in the “Commissioning Report” If the M.O.G. is provided with a locking lever, it should be
removed. Mount the conservator. When there is an OLTC its conservator is some times provided separately or
by making a partitioned compartment in the main conservator. OLTC conservator, if separate, should also be
mounted.
3.2.4.4 Buchholz Relay :
Note details of “Buchholz Relay” for the transformer and of “Oil Surge Relay” for the OLTC in the
“Commissioning Report”. Buchholz Relay floats are tied to prevent transit damage. They should be released.
Also if ‘Test’ lever is provided, it should be in the working position. Mount the “Buchholz Relay” and the shut off
valves as described in 2.10 Similarly mount “Oil Surge Relay”.
3.2.4.5 Breathers :
Note details of Breathers, in the “Commissioning Report.” If OLTC is provided, it may have its own separate
breather. Note details of these Breathers also in the “Commissioning Report.” Check that the colour of Silica
Gel in Main Breather is Blue. Remove the rubber cap closing the breather pipe and fit the breather. Fill oil in the
oil cup and remove the seal which closes the breather opening. Similarly mount the OLTC breather.
3.2.4.6 Radiators :
Note the details of Radiators and Radiator Valves in the “Commissioning Report.” Mount the radiators as
outlined below :

11
 (i) Radiators are to be assembled only one at a time.
(ii) Oil required to fill in the radiators is sent separately in drums. Test oil sample from each drum for BDV.
Ensure it is more than minimum specified in I.S. 1866 for New Transformer.
(iii) Fill the conservator full using an oil filter machine, if available.
(iv) Clean one radiator externally. Remove blanking plates and clean the gaskets and radiator flanges. If
gaskets are damaged, use spare gaskets.
(v) If blanking plates are not in position and it is suspected that foreign material might have entered the
radiators, clean them internally by flushing fresh and clean transformer oil.
(vi) Oil might seep through the tank side radiator valves and be retained by the blanking plates. This oil
should be collected in a clean container at the time of removing top and bottom blanking plates.
(vii) Bring the radiator flanges close to the flanges on the tank. Ensure that tank gasket is in position. Fit by
means of bolts, nuts, spring washers etc.
(viii) Open the bottom radiator valve using the operating handle. Gradually unscrew the air release plug on
the top of the radiator, until air starts escaping. Air release plug should not be removed from the
engaging threads as it would be difficult to control oil coming out of it. Oil from main tank will now flow
in the radiator, driving out air from air release plug. When oil comes out steadily from the air release
plug and no more air comes through, close the air release plug. Open the top radiator valve. Oil level in
the conservator would now have fallen. Check that there is no oil leakage from the radiator itself and
the gasketted joints. Restore the oil level and assemble the next radiator in the same manner.
Assembly of radiators should be proceeded in only one direction-clockwise or anticlockwise. After filling
last radiator, oil level in conservator should be restored only upto the filling mark.
When OLTC compartment is provided in the main conservator, this compartment is to be separately
filled upto its filling mark.
3.2.4.7 Marshalling Box :
Marshalling box should be fitted in Position. Pockets of O.T.I. & W.T.I. should be filled with transformer oil.
Bulbs of O.T.I. & W.T.I. should be fitted in position in their respective pockets.
Set the ‘Alarm’ & ‘Trip’ contacts of O.T.I. & W.T.I. at required values. O.T.I. setting of A=85 C & T=95 C W.T.I.
o o

setting of A=95 C & T=105 C are considered good. They can be worked out to suit local conditions.
o o

Note details of O.T.I. & W.T.I. and their settings in the “Commissioning Report.”
3.2.4.8 Cable Box :
When Cable Boxes are provided they should be mounted and cable terminations done. Oil filled cable-boxes
should be duly filled with oil. In case of “Bus-Duct” connections, transformer is provided with a flange to
receive the bus-duct. Due connection and fitting should be done to over-head line by a terminal connector.
3.2.4.9 Other Fittings:
Note the details of other important fittings like fans in the “Commissioning Report” and mount these fittings.
3.2.5 Oil Sampling & Filteration :
Taking usual precautions, draw oil samples from Bottom & Top of main tank and from OLTC. They should be
tested for BDV. If they meet the requirements of I.S. 1866 for new transformers, no futher processing is
required. However if they do not meet the requirements, oil needs to be filtered till the required BDV is
obtained. Note the BDV values in the “Commissioning Report.”
3.2.6 Air Release :
Release air by slowly unscrewing Air Release Plugs provided at Bushings, Bushing Pockets, Buchholz Relay,
Main Tank Cover, Oil Surge Relay etc. From plain porcelain bushing of 11, 22 & 33 KV, air can be released by
loosening the nut pressing the rubber gasket and pressing the metal part down.

12
3.3 Commissioning :
3.3.1 Pre-Commissioning Test:
Prior to energising the transformer, several pre-commissioning tests are done. The objective of these tests is
to confirm that the transformer has not suffered damage during transit and also to check any inadvertent slips
in the factory tests, or supply.
3.3.1.1 Ratio Test :
Ratio between all the three corresponding H.V. & L.V. phases is to be measured on all taps. It is desirable to do
this test by a Ratio-meter. But if it is not available, a simple test of measuring voltages can also serve the
purpose.
Referring to R&D plate, find out which terminals of H.V. & L.V. correspond to one phase e.g. for a vector Group
of Dyn-11, H.V. Terminals 1U 1V & L.V. terminals 2U, 2N correspond to U phase. Apply single phase, 415V or
240V, AC., 50 Hz to H.V. side and measure voltage on the L.V. side. Measure these voltages on all taps and note
them in “Commissioning Report” Repeat for the other two phases. These observations should indicate a
consistent trend of variation in line with the details given in R&D Plates. Numerical values should
approximately check with the voltage ratio.
3.3.1.2 Vector Group Check Test :
Connect terminals 1U, 2U together. Apply 3 phase, 415V, 50Hz. AC. to H.V. terminals 1U, 1V, 1W. Measure
voltages between terminals 1V-2V, 1V-2W & 1W-2V, 1W-2W (or suitable other voltages if required). Check
that the measured voltages confirm the relative position of H.V. & L.V. vector group. For vector group Dyn-11,
the method is illustrated below.
1U, 2U

2N
2V
2W
2U

2V
2N
2W
1W 1V

H.V.. & L.V. vectors are shown independently positioned for Dyn-11. For the condition 1U & 2U connected
together, L.V. Vectors are redrawn as shown. With this configuration, Voltages 1V-2V & 1V-2W will be equal
while 1W-2V will be greater than 1W-2W.
The method can be extended to any other Vector Group. Note the observations in the “Commissioning
Report”.
3.3.1.3 Magnetising Current Test :
Apply 415 volts, 2 phase, AC. to the H.V. terminals, keeping the L.V. terminals open and tapping switch in the
normal position. Measure the 3 line currents, if possible simultaneously, otherwise one after the other.
Because the 3, phases of the magnetic circuit of the core not similar, the 3 line currents will be approximately
equal & V phase current around 80% of either on them. If H.V. is delta connected, V & W phase currents will be
approximately equal and U phase current around 110%.
In case of Power Transformers, such a test is done, some times, alongwith routine tests at the manufacturer
works. When done at site and results compared with the factory test confirms that there are no transit
damages to the core and windings. Note the observations in the “Commissioning Report”.

13
3.3.1.4 Magnetic Balance Test :
This is a simple test to detect shorted turns in a winding. Its principle is that shorted turns oppose
establishment of flux in that limb because of the current that circulates through the shorted turns.
As indicated in 3.3.2 apply single phase, 415 or 240V AC to such H.V. line terminals which would energies U
phase (outer limb) Use an averaging instrument like a Multimeter. Measure the voltage induced in the V phase
(Center limb) and W phase (other outer limb). Measure also the current drawn by the energised phase. In
case the H.V. Voltage is 66 KV and above the current drawn may be very small. In that case L.V. would
generally, be 11 KV of more. This lest can, then, be carried out on L.V. Side Center limb being nearer to the
energised limb, more flux passes through it and less flux in the outer limb. The division is around 70-30% &
hence the measured voltages will be having approx this proportion. Next, energise W phase and measure the
other two voltages as before, Results should be similar to previous ones. Then energise V phase (Center
limb). As both the outer limbs are symmetrically located w.r.t. center limb, flux will divide equally between
them. Hence the voltages measured on outer phases will be approx. equal. Also, for reasons explained earlier,
currents drawn when outer phases are excited, will be equal that center phase will be less (approx. 70%).
Thus these observations will confirm the healthiness of the windings.
In case one of the phases has shorted turns, it will draw a comparatively large current when it is energised.
When other phases are energised, flux and hence voltage in the shorted phase will be significantly reduced.
Hence all three observations will indicate the shorted phase. Note the observations in the “Commissioning
Report”.
When the Magnetic Balance Test indicates a shorted phase, commissioning cannot be undertaken. Contact us
immediately giving detailed test results.
3.3.1.5 Measurement of Insulation Resistance :
Measure Insulation Resistance (IR) between, windings and between windings and earth with a 2500/1000V
Megger, preferably motor driven, otherwise hand-driven. Before measuring I.R., thoroughly clean all the
bushings with clean cotton cloth, if required using Carbon Tetrachloride. Also, there should be no external
connections to the transformer terminals. Check and adjust if required, the infinity setting of the Megger. Lead
wires from the Megger to the transformer should run independently and be permanently clamped. They
should not have any joints. It is known that the I.R. reading continues to increase intially and for comparison
purpose, reading continues to increase initially and for comparison purpose, reading is to be taken at 1 minute
of energising. It is also know that I.R. value is dependent on temperature. Hence temperature at the time of
measurement should be noted. Compare the I.R. values measured, with the Factory results keeping in view
the temperature at the time of measurement. Note the observations in “Commissioning Report.” Also
measure and note the I.R. values of the Power Cables.
3.3.1.6 Short-Circuit Test :
For the H.V. side voltage and the % impedance, it would be possible to calculate the current which would flow
in the H.V. side, with 415V applied to it, while keeping L.V. side shorted. If the 415V source can feed that
current, a short-circuit test can be carried out.
This test would confirm proper contact engagement at all tap positions. Apply 3 Ph. 415V, 50 Hz to H.V. side,
keeping L.V. side shorted. Measure the 3 line currents at all tap positions. If the switch is an OFF-CIRCUIT
switch, supply has to be disconnected before changing tap. Note the observations in the “Commissioning
Report.” Note also details of OLTC, if any.
A Consistent trend indicates healthiness. If short-circuit test is not possible due to limitation of source, carry
out one tap changing operation over the entire range increasing as well as decreasing. Check the other modes
of OLTC operation and note in “Commissioning Report.”
3.3.1.7 Parallel Operation :
Sometimes the transformer to be commissioned is required to run in parallel with an existing transformer. In
this case, the following conditions must be fulfilled by the incoming transformer:
(1) Its voltage ratio is same as the existing transformer on all tappings.
(2) Its % Impedance is within + -1% of value of existing transformer.

14
 NOTE : Due to difference in % impedances, when one transformer reaches its rated load, the other
would share less than its rated load less than the sum of the two KVAs.
(3) Rated KVAs of the two transformers to be connected in parallel should not differ by more than 1.3 as
otherwise only marginal increase will be obtained in the capacity of the combination.
(4) Vector group is compatible. If the vector groups of the two are such that terminals to be paralleled have
a phase different then they cannot be connected in parallel. Hence only certain Vector Groups are
compatible with each other.
If possible, one should check zero voltage between the corresponding phases to be paralleled.
3.3.2 Other Relevant Details :
Other controlling and protecting equipments like C.T.s, Breakers, Relays etc. form a part of the transformer
installation. Note their details in “Commissioning Report.”
3.3.3 Check Points :
After completing installation and precommissioning tests, that the various points mentioned in the
“Commissioning Report” have been complied with compliance nothings should be made in the
“Commissioning Report.”
3.3.4 Energising :
When all the pre-commissioning tests are found satisfactory and all the check points are confirmed the
transformer can be energised on No load. It is preferable to keep settings of all protective relays to the
minimum. The transformer should be allowed to run on No-Load for about 3 hours. During this period, the
transformer should be observed for any abnormality in the hum and gas collection in the Buchholz Relay.
Sometimes during this period, trapped air is released and gets accumulated in Buchholz Relay.
At the end of this 3 hours period, transformer should be de-energised and air released from Bushings, Bushing
pockets, Buchholz Relay, Main tank cover, Radiators etc. The transformer should, then, be energised again
and then relays set at their desired settings. Transformer should then be gradually loaded reaching full load in
about 3 hours time. During the period and for further 3 hours, (i.e. total of 6 hours) transformer should be
under observation. Check that all instruments, O.T.I. & W.T.I., M.O.G. are reading properly and that all
radiators are uniformly hot. Check that there is no gas collection in Buchholz Relay. If everything is found in
order, the transformer can continue working.
The “Commissioning Report” should be duly signed by the Authorised representatives of all the participating
organisations.
3.3.5 TOOLS & INSTRUMENTS REQUIRED FOR INSTALLATION/MAINTENANCE OF TRANSFORMERS:
Tools :
The following tools are required at the time of installation of transformers:-
(a) 20mm or 12 mm Vinyl hose to take oil samples from drums. ... 1 No.
(b) Drum Opener. ... 1 No.
(c) Crow bar, Pipe roll, Hammers, etc. for
package shifting and opening. ... As required.
(d) 25mm dia Manila Rope. ... 50 Metres
(e) Chain Pulley Block-1 Ton capacity and lift ... 1 No.
about 10 metres.
(f) Small size screw spanners-100 mm long for ... 2 Nos.
nuts upto 6 mm size.
(g) Hand lamp for inside working. ... 1 No.
(h) Screw driver-200 mm & 300 mm long ... 1No. each.
(i) Pipe Wrench-250 mm size. ... 1 No.

15
 (j) Cutting Pliers (Insulated). ... 2 Nos.
(k) PVC Wire for connecting meters. ... As required.
(1) Spanners -
M - 24 .. 1
M - 20 .. 2
M - 16 .. 2
M - 12 .. 2
M - 10 .. 2
M - 8 .. 2
The following instruments are required for testing :
(a) Oil testing kit to test the break-down voltage of Transformer oil.
(b) 2500 Volts megger to measure the Insulation Resistance (IR) values.
(c) Two Voltmeters, one of 0-1000V range and another of 0-500V range, to read the L.T. side and the
applied voltage during voltage ratio test.
(d) One AVO meter.
3.3.6 COMMSSIONING REPORT :
Customer : Date
Order No. :
Transf. Sr. No.: Make :
Rating: Voltage Ratio:
Tapping Range : by off ckt. Switch/O.L.T.C.
Connection : Vector Group :
Installed at: Phone No. :
(1) Oil Test Results:
Details of Oil Test Set Make:
Type : Motorised/Manual, Gap : 2.5 mm
Observed BDV :
(a) Main Tank Oil : Before Filteration :
After Filteration :
(b) O.L.T.C. : Before Filteration :
After Filteration :
(c) Cable Box Oil : Before Filteration :
After Filteration :
(2) Details of Bushings :
(1) H.V. Bushings Make
KV
Sr. Nos.
(2) Arcing Horn Gap on H.V. Bushings
adjusted to .............. mm.
(3) L.V. Bushings Make
KV
Sr. Nos.
(4) Arcing Horn Gap on L.V. Bushing
adjusted to .............. mm.

16
 (3) Details of Magnetic Oil level Gauge :
Make :
Type :
Wired } : Alarm Yes / No.
for : Trip Yes / No.
Tested
for
} :
:
Alarm
Trip
Yes / No.
Yes / No.
4. Details of Buchholz & Oil Surge Relays :
4.1 Buchholz Relay :
Make :
Type :
Tested : Alarm Yes / No.
for : } : Trip Yes / No.
4.2 Oil Surge Relay (on OLTC)
Make :
Type :
Tested for : Trip Yes / No.
Notes :
(1) Both relays connected in
control circuitry Yes / No.
(2) Control Circuit Checked for
Operations through :
(a) Buchholz Relay Yes / No.
(b) Oil Surge Relay Yes / No.
5. Details of Breathers :
5.1 Main Tank Breather :
Make :
Type :
Colour of Silica Gel : Blue / Pink
Oil level in Breather : OK / Not Ok
5.2 OLTC Breather :
Make :
Type :
Colour of Silica Gel : Blue / Pink
Oil level in Breather : OK / Not Ok
6. Details of Radiators & Radiator Valves :
6.1 Radiators
Make :
Type :
No. :

17
6.2 Radiators Valves :
Make :
Type :
No. :
7. Details of O.T.I. & W.T.I. :
7.1 Oil Temp. Indicator :
Make :
Type :
Tested : Alarm Yes / No.
for : } Trip Yes / No.
Set :
} Alarm C.
o

for : Trip o
C.
7.2 Winding Temp. Indicator :
Make :
Type :
Tested : Alarm Yes / No.
for : } Trip Yes / No.
Set
for
:
:
} Alarm
Trip
o

o
C.
C.
7.3 Pressure Relief Valve :
Make :
Type :
Tested : Alarm Yes / No.
for : } Trip Yes / No.
Notes :
(1) O.T.I. & W.T.I. connected in
control circuitry Yes / No.
(2) Control Circuits : OTI Yes / No.
Operations through : WIT Yes / No.
through : P.R.V. Yes / No.
8. Details of Cooling Fans :
Make :
Type :
Nos. :
Fan Control through : OK / Not OK
W.T.I. checked
} : o
C.
Group I of fans set for o
C.
Group II of fans set for o
C.

18
9. Ratio Test :
Apply single phase, 415 or 240 Volts, AC. to those H.V. terminals, which will energise ‘U’ phase of transformer.
(This can be found from the R&D plate.) Measure L.V. Voltage for the same phase. Likewise measure for ‘V’ &
‘W’ phases also.

H.V. Voltage
applied Do Do Remarks
between
Terminals =

Tap L.V. Voltage

measured Do Do
between
Terminals =

1 (1) Checked OK for

consistent
Variation
YES/No.
2 (2) Checked OK for
Rated Voltage
17 Ratio
YES/No.

10. Vector Group Check Test:

Terminals 1U & 2U connected together. 3 Phase voltage applied to terminals 1U, 1V, 1W. Measured Voltages
Between Terminals :

Between Voltage Between Voltage

Terminals Terminals

Vector Diagram :
Observed Voltages Confirms Vector Group :

19
11. Magnetising Current Test
3 Phase Voltage applied to H.V. Winding - Star/Delta connected.
Voltages 1U-1V = 1V-1W = 1W-1U =
Tapping Switch in Position No : ......................................
Line Currents : U = mA, V= mA, W= mA
Line Currents checked OK for ......................................
connected H.V. Yes/No.
12. Magnetic Balance Test :

Sr. No. Voltage between terminals

Corresponding Corresponding Corresponding

To U Phase To U Phase To W Phase

1 Applied
Voltage =

Current
drawn =
2 Applied
Voltage =
Current
drawn =

3 Applied
Voltage =

Current
drawn =

Observed distribution of voltages confirms absence of any shorted turns. Yes/No.

13. Measurement of Insulation Resistance
(a) For Transformer :
(1) Between H. V. and Earth = .......... Mohms
(2) Between H. V. and L. V. = .......... Mohms
(3) Between L. V. and Earth = .......... Mohms
Transformer Top Oil Temp. = .......... C
o

Details of Megger :
(1) Make : (2) Sr. No :
(3) Voltage : (4) Range :
(b) For Power Cable
(1) Type : Rating :
(2) Tamp : ........ C
o

20
 (1) U Phase to earth Mohms.
(2) V Phase to earth Mohms.
(3) W Phase to earth Mohms.
(4) U Phase to V Phase Mohms.
(5) V Phase to W Phase Mohms.
(6) W Phase to U Phase Mohms.
REMARKS :
14. Short Circuit Test :
Applied Voltage = 3 phase, 50 Hz.
1U - 1V = 1V - 1W = 1W - 1U = Volts.
Tap I I I I
No. AU AV AW A LT
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17

15 Details of control Panel / Protective System :

(1) H.V. Circuit Breaker :
Make : Type :
MVA : I-rated :
KV : Release
Setting =

21
 (2) H.V.C.T. s:

Make : Type :
No. of Cores Accuracy Class
1.
2.
3.
4.

(3) Earth fault Relay (H.V. Side) :

Make : Type :
Mounted on Phase : Time :
Current Setting : Setting :
(4) Over-Current Relay (H.V. Side) :
Make : Type :
Mounted on Phase : Time :
Current Setting : Setting :
(5) L.V. Circuit Breaker :
Make : Type :
MVA : I-rated :
KV : Release Setting :
(6) L.V.C.T. s:
Make : Type :
No. of Cores Accuracy Class
1.
2.
3.
4.
(7) Earthfault/Overcurrent/Different Relay on L.V. side :
Make : Type :
Mounted on Phase :
Current : Time :
Setting : setting :
16. Details of O.L.T.C. :
Make : Type :
Type : Year :
(a) Manual Operation OK/Not OK
(b) Local Electrical Operation OK/Not OK
(c) Remote Electrical Operation OK/Not OK

22
17. Commissioning Check Points :
1. Oil Samples from main Tank and
O.L.T.C. have passed BDV requirement Yes / No.
1a. Bushing surfaces are cleaned. Yes / No.
2. Test Tap Caps are fully tightened Yes / No.
3. Arcing Horn-gaps are duly adjusted. Yes / No.
4. Oil level in main conservator is upto mark. Yes / No.
5. Oil level in O.L.T.C. Conservator in separate
Conservator or Compartment in main Yes / No.
conservator
6. M.O.G. lock is released Yes / No.
7. Buchholz Relay Test Lever is kept in Yes / No.
8. Buchholz Relay Test Lever is kept in Yes / No.
‘S’ position.
9. Buchholz Relay shut off valves on Yes / No.
both sides are open
10. Air Release valve of Buchholz Relay Yes / No.
is closed
11. Buchholz Relay arrow head is Yes / No.
pointing towards conservator
12. Lock of Oil Surge Relay (OSR) on
O.L.T.C. is released Yes / No.
13. OSR shut off valve is open. Yes / No.
14. OSR arrow-head is pointing towards Yes / No.
conservator
15. Colour of Silica Gel in main breather Yes / No.
is blue
16. Oil is filled in main Breather upto Yes / No.
level mark
17 Sealing Tape of main Breather is Yes / No.
removed
18 Colour of Silica Gel in O.L.T.C. Yes / No.
breather is blue.
19. Oil is filled in O.L.T.C. breather Yes / No.
upto level mark.
20. Sealing Tape of O.L.T.C. breather is Yes / No.
removed
21. All radiator Valves-Top and bottom Yes / No.
are open.
22. Valve connecting Main Tank to Cable Yes / No.
Box is open.
23. Oil is filled in Disconnecting Cable Yes / No.
Box upto Level Mark.
24. All sampling, drain and filtration Yes / No.
Valves are closed.

23
 25. Oil filling cap on main conservator is Yes / No.
duly filled.
26. There is no oil leakage from any where Yes / No.
27. Explosion vent diaphragms are intact Yes / No.
28. Oil is filled in O.T.I./W.T.I. Yes / No.
pockets.
29. Air released from :
(i) All Bushings Yes / No.
(ii) All Bushings Pockets Yes / No.
(iii) Buchholz Relay Yes / No.
(iv) Main Tank Cover Yes / No.
(v) All radiators Yes / No.
(vi) OSR on O.L.T.C. Yes / No.
(vii) O.L.T.C. Tank Cover Yes / No.
30. O.L.T.C. / Off circuit Tap Switch is in
the desired position and is properly locked. Yes / No.
31. Tank earthing is done. Yes / No.
32. Neutral earthing is duly done. Yes / No.
33. Rollers are locked. Yes / No.
34. C.T. secondary terminals if not Yes / No.
wired, are shorted and earthed.
35. Alarm & Trip contacts of O.T.I. & Yes / No.
W.T.I. are set at the required values.
36. External connections are duly Yes / No.
tightened.
18. Commissioning :
After carrying out installation and pre-commissioning tests and ensuring all check points. The transformer
was commissioned on ................................................ at .............................. Hrs. at No Load in our
presence Subsequently Load was also taken. Noting abnormal was observed during these operations.

for VOLTAMP TRANSFORMERS LTD.,

For Customer :
Name

Signature :

Name :

Designation :

24
4. Operation & Maintenance :
4.1 Operation :
I.S. 2026-1977 states that a Power Transformers loaded at its rated KVA will fulfil its normal life when its
hottest spot temperature (H.S.T.) is 98 C for an air temperature of 32 C. As the ambient air temperature
0 O

exceeds 32 C, the H.S.T. exceeds 98 C The insulation ageing (which decides the life of transformer) increase
O O

with increase of H.S.T. by 6 C doubles the rate of ageing (i.e. reduces the life by 50%) when the ambient air
O

temperature is lower than 32 C, the H.S.T. is lower than 98 C. The insulation ageing decreases thus increases
O

the life of transformer.

It is considered (by the I.S. 6600-1972), that periods of accelerated ageing due to higher ambient
temperature are compensated by the periods of reduced ageing due to lower ambient temperatures.
Sometimes a transformer may be required to deliver load higher than its rating. Guidance on overloading is
provided by I.S. 6600. Basis for this recommendation is as follows:
In a 24 hours loading, if ambient temperature is low and load for a substantial time duration is also low a short
time over load may be permitted such that equivalent ageing due to this varying load will be the same as that
of loading over a period of 24 hours.
4.2. Maintenance :
4.2.1 General :
Compared to most electrical equipments transformer requires relatively less maintenance. However in order
to obtain a long and trouble-free service from the transformer, it must be properly maintained. Maintenance
consists of regular inspection, testing and reconditioning when necessary. Principal object of maintenance is
to maintain the insulation in good condition. Moisture, dirt and high temperature causes insulation
deterioration i.e. ageing. Hence they must be prevented.
No work should be done on the transformer Unless it is disconnected from all external circuits and all winding
have been solidly earthed.
Naked lights and flames should be kept well away from the transformer.
Precautions must be taken to secure tools with tapes to prevent them from falling inside the tank.
Maintenance hints on main constituents of the transformer are given in the following paragraph.
Recommended frequency of maintenance is given at the end of the chapter. Detailed guidance on
Maintenance is given in I.S. 10028 (part II)-1981.
4.2.2 OIL :
In the transformer, oil is used as an insulating liquid as well as for cooling. It is necessary to maintain required
oil level and also to maintain thi oil in good condition. I.S. 1866 gives recommendations in details for the
maintenance of oil. A few guide lines are given here.
(i) Check if there is any leakage of oil. If noticed, corrective actions must be immediately taken.
(ii) The oil level should be checked at frequent intervals and if necessary, topping up should be done with
oil complying with I.S. 335.
(iii) Samples of oil should be taken at regular intervals and tested.
(iv) If the dielectric strength is below the value recommended in I.S. 1866, the oil should be duly filtered. It
may be noted that the products of decompositions viz. water, acids etc. remain in the oil and accelerate
the rate of ageing. Thus, timely treatment of oil is a must. The filtration will remove moisture, dust,
sludge etc. Removal of sludge is important as otherwise it can stick to coils and hamper the heat
dissipation from coils. However, if the results indicate that acidity needs to be improved, then a simple
filtration would not be sufficient and a Fullers Earth treatment would be required.
4.2.3 Core & Winding :
It is recommended that the core and windings are removed from the tank for visual inspection as per the
maintenance schedule given. Depending upon the arrangement provided, tap switch handle, connections to
bushings etc. may have to be disconnected before lifting up core and winding assembly.

25
 The windings should be examined and if sludge has been deposited it should be washed away with oil jet. Any
loose nut and bolt should be tightened.
Adjust tie rods / coil clamping screws provided to remove any slackness of windings. This is important as
slackness in windings will permit movement of coils under the action of Short Circuit force and epeated coil
movement can wear out insulation and give rise to a fault.
4.2.4 On Load Tap Changer :
On load tap changer is, normally, mounted on the tank in the separate housing and connected to winding
leads through copper studs fixed on an insulated terminal board. Terminal board is oil-tight. Hence oil in the
tank need not be lowered for attending O.L.T.C.
In some other types O.L.T.C. is housed in the main tank by suitable mounting on the top cover. Here again
O.L.T.C. oil in which arcing takes place is not allowed to mix with the main tank oil.
Please refer to O.L.T.C. manual for operation and maintenance instruction of O.L.T.C.
4.2.5 Conservator & Oil level Indicator :
The inside of conservator should be cleaned by flushing, clean Transformer oil to remove sludge and other
impurities. In bigger transformers, detachable end plate is provided to facilitate cleaning of conservator.
- Oil gauge glass should be cleaned. If the glass is found broken, the same should be replaced.
- Magnetic oil gauge is also to be attended while cleaning the conservator. The mechanism should be
inspected and cleaned. Float should be checked to see that there is no oil in the float. The operation of
alarm and trip contacts should to be checked.
4.2.6 Silica Gel Dehydrating Breather :
Breather should be examined to ascertain if the silica gel requires changing. More frequent inspections are
needed when the climate is humid and when transformer is subjected to fluctuating load. The colour of Silica
Gel crystals in the breather acts as an indicator as it changes from blue to pink when saturated with moisture.
When majority of crystals have turined pink, the silica gel should be reactivated by heating in oven or a
shallow pan at a temperature of 150 C to 200 C until the original colour is gained. This usually takes 2 to 3
o o

hours. Oil cp should be cleaned to remove dust and dirty oil. Oil seal should be filled with fresh oil.
4.2.7 Buchholz Relay :
Routine operation and mechanical inspection should be carried out as per the manufacturers’ instructions.
4.2.8 Pipe Work :
The pipe work should be inspected for leakages, which may be due to bad seated joints. Joints should be re-
made, and leakage stopped.
4.2.9 Explosion Vent :
The diaphragm at the exposed end of the explosion vent should be inspected and replaced if damaged.
Failure to replace the diaphragm quickly may allow the ingress of moisture in the transformer.
Whenever bottom diaphragm ruptures, oil rises oil rises inside the explosion vent pipe and is visible in the oil
level indicator on explosion vent. If diaphragm is broken because of fault in the transformer, inspection should
be carried out to determine the nature and cause of the fault.
4.2.10 Gaskets :
Gaskets sometimes shrink during service. It is, therefore, necessary to check the tightness of all bolts,
fasteners of gasketted joints. The bolts should be tightened evenly around the joints to avoid uneven
pressure. Leaking gaskets should be replaced as soon as the circumstances permit.
4.2.11 Temperature Indicators :
The capillary tubing should be fastened down again if it has become loose. Dial glass should be kept clean. It
should be replaced if damaged, to prevent damage to the pointer. Temperature indicators found reading
incorrectly should be calibrated with standard thermometer using hot water bath. Check the pockets for
presence of water an if found, clean the pocket and refill with fresh oil and seal the opening properly. If
armour of capillary is exposed, then retaping must be done by PVC tapes.

26
4.2.12 Bushing :
Porcelain insulators should be cleaned and minutely examined for any cracks, chipping off & other defects. All
such bushings should be replaced. In case of any sign of oil leakage from the condenser bushings the matter
should be referred to us.
4.2.13 External connections Including Earthing :
Check all external electrical connections including earthing. They should be tight. If they appear blackened or
corroded, unbolt the connection and clean with emery paper. Remake the connections and give a heavy
coating of conducting grease. It is particularly important that heavy current carrying connections are properly
made as any lose connections give rise to heat generation & temperature rise which could be detrimental to
the connection.
4.3 Maintenance Schedule :
Recommended maintenance schedule given below. However, depending on the local situation and
importance of transformer frequency may be increased.
Sr. Inspection Items to be Inspection Notes Action required if inspection shows
No. Frequency Inspected Unsatisfactory conditions
1 2 3 4 5

1. Hourly (i) Ambient Temp. - -

(ii) Winding Tep. Check that the temp. Shut down the transformer and inventing
(iii) Oil Temperature rise is reasonable if either is persistently higher.
than normal.
(iv) Load (amperes) check against Control load.
(v) Voltage rated figure Adjust tap.

2. Daily (i) Oil level in Transformer Check against If low, top up with dry oil, examine
on load transformer oil transformer for leaks.
tap changer temperature
(ii) Explosion vent - Replace if cracked or broken.
(iii) Dehydrating check colour of If silicagel is pink change by spare
breather the active agent and charge.
that opening is not The old charge may be reactivated for
clogged. further use.

3. Quarterly (i) Bushing Examine for cracks Clean or replace as necessary.

and dirt deposits.
(ii) Oil in Transformer Check for dielectric Take suitable action to restore quality
and tap strength and of oil
changer. water content.
(iii) Cooler fan and Lubricate bearings, Replace burn or wom out contacts or
pump bearings and check gear box other parts.
motors & operating Examine contacts.
mechanism. check manual control
and interlocks.
(iv) On load tap check oil.
changer driving
mechanism.
(v) On load tap Check all circuits
changer automatic independently.
control. Check step by step
operations including
limit switches.
27
 (vi) Dehydrating Check oil level in Make up oil if required.
breather. oil cup.
(vii) Ventilators Check that air passages
(In case of indoor are free.
transformers).

4 Yearly (or (i) Oil in transformer Check the acidity Filter or replace.
earlier if and sludge.
transformer
can conveniently
be taken out
for checking)
(ii) Insulation Compare with values Process if required.
resistance. at the time of
commissioning
(iii) Gasketted joints. Tighten the bolts evenly to
avoid uneven pressure.
(iv) Cable Boxes. Check for sealing Replace gaskets. if leaking.
arrangements or filling
holes. Examine
compound for cracks.
Check moisture condensate
if any in air filled boxes.
(v) Relay alarms, Examine relay and Clean the components or replace
their circuits, alarm contacts and contacts and fuses, if necessary.
etc. their operation, Change the setting if necessary.
fuses, etc. Check
relay accuracy, etc.
(vi) Temperature Pockets holding Oil to be replenished, if required.
Indicator thermometers should
be checked.
(vii) Dial type Check pointer for Adjust if required.
Oil gauge freedom of movements.
(viii) Paint work Should be inspected. Any painting or retouching should be
done if necessary.
(ix) Earth resistance - Take suitable action if earth
resistance is high.
(x) Surge diverter Examine for cracks Clean or replace.
and gap and dirt deposits

5. Two years (xi) Non-conservator Internal inspection Filter oil regardless or condition.
transformers above care.
-do- (xii) Coil conservator Internal inspection Should be thoroughly cleaned
-do- (xiii) Buchholz relay Mechanical inspection Adjust floats, switches etc. as
required.
6. 5 years (xiv) Transformers Overall inspection Wash by hosing down with clean dry
upto 3 MVA including lifting of oil. Tighten coil clamping arrangements
core and coils and other bolts, nuts, if loose.
7. 7 to 10 Years (xv) Transformers -do- -do-
above 3 MVA

28
4.4 Trouble - Shooting :
At the time of commissioning or periodic maintenance if any abnormalities are observed, corrective action
should be taken immediately. Guidance for this is given in I.S. 10028 (part III) - Maintenance.
For a transformer in service, indication of trouble is given by the various alarms provided. These alarms must
be accepted and corrective action initiated immediately.
In the case of a severe fault or if alarm is not attended the transformer is tripped by the Tripping circuits. This
is a very undesirable situation and should, possibly, be avoided.
If tripping and subsequent investigation indicates internal faults, transformer has to be taken out of service.
Analysis of gas collected in Buchholz Realy can give indication regarding nature of fault.
Several other methods of testing to assist preventive maintenance are available.

29
 5 7 2

1
4

1. GEAR
6 2. MOVING ARM
3. FIX ARM

30
4. CONTACT STUD
5. MOVING CONTACT
6. SWITCH HANDLE ASSLY
7. SWITCH SUPPORT

FIG-1 : TYPICAL TAPPING SWITCH ASSEEMBLY

FIG - 2 FIG - 3
BUSHING ASSEMBLY BUSHING ASSEMBLY
FOR 11, 22, 33 kV / 250 Amps. FOR 11, 22, 33 kV / 630 Amps.

1. BUSHING CLAMPING RING

2. STEM.
3. UPPER SPARK GAP HORN
4. BUSHING
5. LOWER SPARK GAP HORN

31
FIG - 4
BUSHING ASSEMBLY FOR 11, 22, 33 kV / 1000, 2000, 3150 Amps.

1. STEM.
2. UPPER SPARK GAP HORN
3. LOWER SPARK GAP HORN
5
4. BUSHING CLAMPING RING
5. CONNECTING LUG.

1 6. BUSHING

32
FIG - 5
72.5 kV / 400A, 145-245KV/800A CONDENSER BUSHING ASSEMBLY (TYPICAL)
30Æ

1 80

6
REFER G.A. DRG.

4
2

7 5

5
1. TERMINAL CAP
8
2. CABLE BOLT
3. PIN
4. DUMMY BOLT
5. GASKET
6. UPPER SPARK GAP HORN
7. LOWER SPARK GAP HORN.
8. MEASURING CAP
9. AIR VENT SCREW

33
FIG - 6 : DESPATCH ARRANGEMENT

BLANKING PLATE

COTTON
TAP TIE
BUSHING MOUNTING
POCKET

MAIN LEAD FROM

TRANSFORMER

FIG - 7 : LIFTING OF CONDENSER BUSHING (TYPICAL)

15O

PROTECTIVE COVER

34
 2 3 4 5

1U 1V 1W

6
1. BUSHING
2. FLEXIBLE JUMPER
3. BUSBAR. 7
4. EPOXY INSULATOR
8
5. LUGS FOR CABLE CONN.
6. EARTHING BUSH. FIG - 8 : TYPICAL CABLE BOX (7.2/12kV)
7. GLAND PLATE TROPOLENE (XLPE) CABLE
8. CABLE GLAND
9. COMPOUND FILLING PLUG
10. COMPOUND DRAIN PLUG
11. WIPING GLAND
} (FIG-9)
9
2 3 4 5

COMPOUND LEVEL

1U 1V 1W

7
10
11

FIG - 9 : TYPICAL CABLE BOX DISCONNECTION TYPE (PILC)

35
FIG - 10 :
TYPICAL BUSDUCT THUNKING ARRANGEMENT

4
6

1. FLANGE FOR TOP ENTRY.

2. BUSDUCT FLANGE.
3. L. V. NEUTRAL CONNECTOR JUMPER.
4. NEUTRAL JUMPER.
5. L. V. BUSHINGS.
6. FLANGE FOR SIDE ENTRY.

36
FIG - 11 : TYPICAL MARSHALING BOX (SINGLE METER)

1
2

8 7
1. RAIN HOOD
2. MAIN BOX
3. GLASS WINDOW
4. THERMOMETER
5. TERMINAL STRIP
6. EARTHING BUSH
7. INCOMING CABLE GLAND
8. OUT GOING CABLE GLAND

8 7

FIG - 12 : TYPICAL MARSHALING BOX (DOUBLE METER)

37
FIG - 13 ASSEMBLY OF BUCHHOLZ RELY

1. CONSERVATOR
2. CONSERVATOR SUMP
3. CONSERVATOR PIPE
4. SHUT OFF VALE
5. DOUBLE FLOAT BUCHHOLZ RELAY
6. GASKET
7. FLANGE FOR CONSERVATOR PIPE
8. GASKET

8 7 5 6 4 6 3 2 1

FIG - 14 : ASSEMBLEY OF MAGNETIC OIL LEVEL GAUGE

1. CONSERVATOR
MAXIMUM OIL LEVEL
2. CURB OF CONSERVATOR
3. GASKET
4. END COVER
5. OIL LEVEL GAUGE FIXING FLANGE
6. GASKET
7. MAGNETIC OIL LEVEL GAUGE
MAXIMUM OIL LEVEL 8. ALARM CONTACT
9. FLOAT

1 9 2 3 4 8 5 6 6

38
 FIG - 15 : TYPICAL PRESSED SHEET RADIATORS
6
4
1

5
(a) HEADER PIPES PERPENDICULAR TO FLANGES
1. MOUNTING FLANGE
2. PRESSED SHEET RADIATOR
3. STIFFENER
4. LIFTING LUGS
5. DRAIN PLUG.
6. AIR RELEASE PLUGE

4 6
1

(b) HEADER PIPES PARALLEL TO FLANGES

39
FIG - 16 : TYPICAL SILICA GEL BREATHER

1
M
6

5
B

1. TOP LID.
2. TRANS. ACRYLIC CYLINDER
3. SILICA GEL
4. BOTTOM LID.
5. OIL CUP
6. GEL FILLING PLUG

40
FIG-17 : TYPICAL WINDING TEMP. INDICATOR (W.T.I)
W. T. I

HEATER
COIL
P1 TERMINALS
C.T.
P2 BULE
LEADS

CAPILLARY

TRANSFORMER

FIG - 18 : RADIATOR VALVE ASSEMBLE

1 2 3 4 9 10 3 5 9 8 7
1. TANK
2. RADIATOR FLAGE
(PROVIDED-ON TANK)
3. CORK SHEET (GASKET)
4. RADIATOR VALVE
5. RADIATOR FLANGE
6. RADIATOR
7. FIXING BOLT
8. NUT
6 9. SPRING WASHER
10 LOCK NUT

41
 FIG - 19 : TYPICAL CONSERVATOR WITH MAGNETIC OIL LEVEL
GAUGE & BUCHHOLZ RELAY ASSEMBLY

2 8
5 9

7
1. PRESSURE EQUALIZER PIPE
2. EXPLOSION VENT
3. SHUT-OFF VALVES
4. BUCHHOLZ RELAY
5. MAGNETIC OIL LEVEL GAUGE
6. DRAIN VALVE /PLUG
7. SILICA GEL BREATHER
8. CONSERVATOR
9. PLAIN OIL LEVEL GAUGE

2
9

CONSERVATOR WITH PLAN OIL LEVEL GAUGE FOR DISTRIBUTION TRASFORMER

42
FIG - 20 : TYPICAL ARRANGEMENT OF JACKING PAD & PULLING HOLE

1
5
3
7
4 1. JACKING PAD
2. PULLING HOLE
3. BASE CHANNEL
4. ROLLER
5. BOTTOM PLATE OF TANK
6. SIDE PLATE OF TANK
7. JACK
8. ROPE
2
8

FIG - 21 : TANK AND COVER LIFTING ARRANGEMENT

8
4
1

7
6
2
5
3

1. COVER LIFTING LUGS 5. TANK BODY

2. TANK LIFTING LUGS 6. CURB
3. TANK STIFFENER 7. GASKET
4. LIFTING HOOL 8. SLING

43
FIG - 22 : OLTC MOUNTING ARRANGEMENTS

(A) MOUNTED ON TANK SIDE WALL

TANK

BARRIER BOARD

OLTC

MOVABLE CONTACT
FIXED CONTACT
PHASE BOARD
OLTC LEADS

TRANSFORMER LEADS

(B) MOUNTED ON TOP COVER

DIVERTER SWITCH

PRE. SELECTOR

TANK

OLTC

TRANSFORMER
LEADS

44
FIG - 23 : DIFFERENT TAP CHANGING ARRANGEMENTS

MAIN WINDING MAIN WINDING

(A) LINEAR

TAPPING
WINDING

COARSE TAP
WINDING
CHANGE
OVER
CONTACT

MAIN WINDING

FINE
TAP
WINDING

TAPPING
WINDING
(B) COARSE / FINE

CHANGE
OVER CONTACT
(C) REVERSE / FORWARD

45
FIG - 24 : ADJUSTABLE SHUNT IN W. T. I

HEATER
COIL
h

sh
s

SECONDARY
W.T.I.C.T.

46
 FIG - 25 : THERMOSYPHON FILTER

3
2

TRANSFORMER
ACTIVATED
5 ALUMINA

TRANSFORMER 9
WIRE MESH
TRAY

6
8
THERMOSYPHON FILTER
INTERNAL ARRANGEMENT

9. SUPPORTING ANGLE
8. BOTTOM SHUT OFF VALUE
7. BOTTOM CONNECTING PIPE
6. DRAIN VALVE
5. THERMOSYPHON FILTER
WITH TRAY ASSLY & ALUMINA
4. COVER
3. TOP CONNECTING PIPE
2. AIR RELEASE PLUG
1. TOP SHUT OFF VALVE

SR. NO. DISCRIPTION

47
(FIG - 26 : FLEXIBLE SEPARATOR

(A) INFLATED (OIL VOLUME AT THE FILLING LEVEL)

BREATHER
PIPE

FLEXIBLE
SEPARATOR

MOG

OIL INLET

(B) INFLATED (INCREASED OIL VOLUME - AIR WITH IN THE SEPARATOR EXPELLED OUT)

BREATHER PIPE

FLEXIBLE
SEPARATOR

MOG

OIL INLET

(C) ARRANGEMENT FOR OIL FILLING IN CONSERVAROR)

AIR INLET VALVE

Pr. GAUGE

48
FIG - 27 : OIL LEVEL TRANSMITTER

MOUNTING AND CONNECTION DETAILS

PVC. Flange Mounted

with Transducer
TRANSDUCER TO POWER SUPPLY / V-1
Transducer Mounting MODULE
Flange Assembly
Rubber
Hook up wire gasket
Metal Flange
Welded To Tank
120

OIL - TANK

318mm Long, 1.5 inch

Stainless Steel rod

JUNCTION BOX
FIXED ON TRANSDUCER
POWER SUPPLY / V-I MODULE
GREEN
GRAY
BLUE
RED

1 2 3 4 5 6 7 8 9 10 11 12
}

N P P TO 4-20
IF IF ma DC
110v 220v INDICATOR

49
FIG - 28 : INTERCONNECTION DIAGRAM FOR SIMPLE
ANALOG (MOVING COIL) REPEATER.

OUT DOORS IN DOORS

MARSHALING BOX CONTROL ROOM

LOCAL TEMPERATURE MOVING COIL REPEATER

INDICATOR

15 16 17 12 13 14
12 13 14 (MIN.) (W) (Max.)

NF
90-F130V
N IF
80-260V
AUX. SUPPLY
ac/dc
SHIELD

ISOLATED 3 WIRE
SIGNAL LEADS
TOTAL RESISTANCE Max. 210 ohms
(max 70 for EACH LEAD)

Make : - PERFECT CONTROLS

50
 FIG - 29 : INTERCONNECTION DIAGRAM FOR 4 -20 mA dc (i) ANALOG (ii) DIGITAL REPEATER

MARSHALING BOX CONTRO ROOM

1 3

15 16 12 13 14 17 18
11 12 13

51
OV 90-260V
ac/dc
AUX. SUPPLY

4-20 mA dc

TO INDICATOR

B
NOTE : RECORDER / SCADA CAN
A ALSO BE CONNECTED
IN SERIES.

1. LOCAL INDICATOR
2. PRECISION POTENTIOMETER
MAKE- PERFECT CONTROLS
3. RESISTANCE TO CURRENT CONVERTER & POWER SUPPLY UNIT
 FIG - 30 : INTERCONNECTION DIAGRAM FOR RTD (PT-100) O.T.I.

OUT DOORS INDOORS

TRANSFORMER MARSHALING BOX CONTROL ROOM
RCXT UNIT POWER SUPPLY UNIT

11 10 1 2 3 7 9 10 11 12 13

B B
OV 90-260V
ac/dc
AUX. SUPPLY

52
INDICATOR/
}TORECORDER/D.A.S
A
LOOP RESISTANCE
MAX. 500 OHMS.

1 2 3

MAKE- PERFECT CONTROLS

SEMSPR UNIT
 FIG - 31 : INTERCONNECTION DIAGRAM FOR RTD (PT-100) WTI

OUT DOORS INDOORS

TRANSFORMER MARSHALING BOX CONTROL ROOM
RCXT UNIT POWER SUPPLY UNIT

11 10 1 2 3 7 9 10 11 12 13

B B
OV 90-260V
ac/dc
AUX. SUPPLY

53
INDICATOR/
}TORECORDER/D.A.S
A
LOOP RESISTANCE
MAX. 500 OHMS.

1 2 3 4 5 SHUNT RESISTOR UNIT

4 5 4 5

FROM WTI CT
Voltamp Transformers Limited www.voltamptransformers.com

Regd. Office & Works : Makarpura, VADODARA-390014, GUJARAT (INDIA).

REGD. OFFICE
& WORKS PHONE FAX E-MAIL ID

VADODARA +91 - 265-264 2011 +91 - 265-264 6774 voltamp@voltamptransformers.com

+91 - 265-304 1403 +91 - 265-304 1499
+91 - 265-304 1480
SAVALI +91 - 93746 48493 +91 - 02667-251250
+91 - 93746 48522
+91 - 93746 48513
+91 - 8128675081-82
BRANCH
1 AHMEDABAD +91 - 79-304 21884 +91 - 79-304 21883 pmparikh_mktg@voltamptransformers.com
+91 - 79-304 21883
2 BANGALORE +91 - 80-334 59070 +91 - 80-334 59077 ktnaidu_blr@voltamptransformers.com
3 CHANDIGARH +91 - 172-263 2655 +91 - 172-263 1944 mhanda_chd@voltamptransformers.com
4 CHENNAI +91 - 44-283 65495 +91 - 44-283 65234 vtpl_chn@voltamptransformers.com
+91 - 44-334 55093 +91 - 44-334 55087
+91 - 44-334 55097
5 COIMBATORE +91 - 936 446 2112 coimbtore@voltamptransformers.com
6 DELHI +91 - 11-224 39457 +91 - 11-224 24988 ssgupta_delhi@voltamptransformers.com
+91 - 11-224 28331 subodh@voltamptransformers.com
7 GHAZIABAD +91 - 931 053 3636 dhebar_mktg@voltamptransformers.com
8 JAMSHEDPUR +91 - 977 145 0247 partha_jsp@voltamptransformers.com
9 KOLKATTA +91 - 33-246 10091 +91 - 33-246 11508 suvendu@voltamptransformers.com

10 MUMBAI +91 - 22-261 35289 +91 - 22-261 35296 vti_mumbai@voltamptransformers.com

+91 - 22-261 35192 vtplbomltd@gmail.com
UDAY : +91 98250 75597

11 NAGPUR +91 - 932 534 5556 vtl_nagpur@voltamptransformers.com

11 PUNE +91 - 20-256 50612 +91 - 20-256 53391 order_pune@voltamptransformers.com
+91 - 20-256 56509 sas_pune@voltamptransformers.com
12 SECUNDERABAD +91 - 40-275 40426 +91 - 40-275 40462 vtl_hyd@voltamptransformers.com