A TRAINING REPORT ON

Transformer Repairing
Done at BSEB,Patna

By Mukesh kumar mishra

Electrical engineering 7th sem Roll-229/07 NIT Patna

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TRANSFORMER REPAIRING
First of all some tests are performed on the transformers some of which are used to access the condition of transformer; others are used to verify repair results or adequacy of design. Insulation condition assessment is fundamental to transformer operation. One or more of the following tests should be performed to gain information about insulation system. Some of the insulation condition tests are as follows:

1. Insulation Resistance Test

This test is performed to obtain three different winding insulation resistance values: high voltage to low voltage and ground; low voltage to high voltage and ground; and high voltage to low voltage. It can also be used to obtain insulation resistance between coreand ground when there is core to ground connector that can be removed so as to electrically isolate core from ground. If the transformer has more than two windings, then insulation resistance of each winding should be measured in turn with the other winding grounded.These insulation resistances should be measured with a DC insulation resistance tester i.e., a meg-ohmmeter. The test equipment should be suitably sized for the transformer or the winding to be tested and the test performed at a voltage level consistent with the voltage rating of the winding under test. Suggested test voltages are given in the table below: Winding voltage Class kv 1.2 2.5-5.0 8.7-15 Insulation Test voltage 1000 2500 5000

The recommended minimum one minute insulation resistance for oil filled transformers is given by the relation: R (minimum) = C*E/ (KVA^0.5), where R= minimum insulation resistance in megohms C=1.5 for transformer at 20 deg. Celsius: = 30 for untanked core and coils E= voltage rating in volts (phase to phase) for delta connected transformers and phase to neutral for wye-connected transformers KVA= rated capacity of windings under test The resistance should be corrected to reference temperature as follows: R (ref.) =K (t)*R (t) Where R (t) =measured values of resistance K (t) =correction factor for the temperature at which measurement was taken Recommended minimum insulation resistance for dry type transformers is given in the table below: winding voltage class kv 1.2 2.5 5.0 8.7 15.0 Insulation resistance in megohms 600 1000 1500 2000 3000

2. Polarisation index Test:

This is an extension of insulation resistance test. It has an advantage that moisture has little effect on the measurements. The same DC voltage used for one minute test is applied for ten minutes. Resistance measurements are recorded after one minute and ten 10 minutes. The polarisation index is the ratio of one minute resistance to 10 minute resistance. This test is more reliable for dry type insulation.

3. Recovery Voltage Test:

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This test is usually only performed for oil filled transformers. Specialized equipment (e.g. a known capacitance, an adjustable DC voltage source and two switches where the opening and closing sequence can be controlled automatically) is required to carry out this test. The peak voltage on the capacitor, the charge time and discharge time are parameters that are measured. These are sensitive to moisture and aging products in the insulation system. The change in these values over several tests may indicate degradation of insulationsystem.

4. Step Voltage Test:

This test is not usually performed on oil filled transformers. A controlled DC voltage is applied in steps, and as the voltage is increased, weak insulation will show decreased resistance and the changes in results over period show insulation degradation.

5. Insulation power factor Test:

This test is usually performed on equipment rated 4 KV or higher. It is an AC test in which the loss angle between voltage and current is measured, and the capacitances of the windings are measured, using a high voltage dissipation factor bridge. These readings are taken HV to (LV and Ground), LV to (HV and Ground) and HV to LV and corrected to common temperature base, usually 20 deg. Celsius. There are other tests that can be performed to assess its condition. These tests do not test the insulation system directly but provide meaningful information s about other components.

1. Winding resistance Test:

To obtain accurate results, this test is usually performed using a winding resistance bridge. On a new or rewound transformer this information can be used to determine copper or load losses that will occur in transformer and separate them from eddy current losses in the winding. This test can be also used to detect faulty joints or tap switch contacts within the winding. Note that whenmeasuring the resistance of HV winding on large transformer, it can take several minutes for equipments to reach stable value. R (ref.) =R (t)*(t (ref) +235)/ (t(c) +235) Where, Ref=reference temperature=temp. at which measurement was done

2. Transformer turns ratio Test:

Low voltage AC is applied to low voltage winding of the transformer, and the voltage inducted in the high voltage inducted inthe high voltage winding is measured through test set reference transformer and null meter. Using the TTR test set one can determine the polarity of transformer, phase relation and turns ratio. Measurements should be taken on all taps. Unsatisfactory results can be an indication of loos connections, tap changer misalignment, short circuits, incorrect turns after rewind or open circuits in the winding. Common TTR responses and associated transformer conditions are:

TTR reading
Low current and no output volts Normal current, output voltage low or unstable High current and difficulty in balancing of bridge

Transformer condition
Open turn in the excited winding Open turn in output winding High resistance in test leads or tap changer

3. Polarity Test:
This test can be usually measured with the TTR meter or alternatively, a low amplitude AC voltage source and voltmete can be used. One r terminal of the HV winding and LV winding are connected are connected together and the low amplitude source is connected to H V winding. The voltage across remaining terminals HV to LV is measured. The result, if greater than the voltage applied to HZV winding indicates that polarity is additive. Alternatively, if the voltage is lower than the voltage applied to HV winding, it indicates the polarity is subtractive.

4. Phase sequence Test:

This test is done to determine the phase relationship between the HV and LV winding. It has been particularly useful when the transformer has been rewound and connected following disassembly. It is recommended that this test be performed any time the leads from core and coil assembly are disconnected from the terminals. This test is similar to the polarity test except that line and neutral coil leads are connected as they would be in service.

5. NO Load Test:

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On new transformer this test is done to verify core or iron losses. On transformers that have been or about to be repaired this test is performed to determine whether there are shorts between laminations and to provide a reference for future tests. The low voltage winding is energized to the rated value. One wattmeter for 1 phase transformer and 2 or 3 watt meters for 3 phase transformer along with an ammeter and voltmeter is placed on the low voltage side, and the high voltage side is left open circuited. For a core in good condition the core loss should be roughly around one watt per pound of core steel or 2.2 watt per kg.This test also includes dielectric losses, stray losses and copper loss due to exciting current which is very small.

6. Single phase low voltage excitation test:

This test can be performed at regular intervals during the entire life of transformer and by comparing the test results the condition of a transformer can be assessed. A single phase 50/60 HZ test voltage of the 10 % of the rated voltage is applied to HV winding.For wye connected transformer the test voltage is applied in turn between the high voltage and the neutral, for delta connected transformers the test voltage is applied between the high voltage winding in turns and the third terminal is grounded. It is important to ensu that the re polarity of test lead remains same for all tests. The current, voltage and watts are recorded. When testing single phase transformers, the voltage is applied to high voltage terminals twice, the second time the test leads are reversed so that one originally at H1is place on H2, etc.The two currents should agree within 10%.For three phase transformers, the current through the coil on the centre leg of the core will be somewhat less than the current in the other two phases. The currents on the outside two phases should be 15% within eac other, and h the values for centre leg should not be more than outside leg. In all cases result from one test to another should agree within 5%.

7. Load loss test:

This test is done to determine the losses within a transformer due to resistance of HV and LV windings. The usual method is to energize the HV winding on 100% tap till the rated current is obtained, and short the LV winding and putting the measuring instrumentson the high voltage side. The watts measured are load losses and voltage required to circulate the rated current is called impedance voltage. The core losses can be neglected unless the impedance of the transformer is unusually high. In the latter case the core loss obtained at exciting current can be subtracted from the obtained result to get the accurate value or the copper loss. It is also ensured that the method used to shot LV winding does not appreciably change the resistance of the LV circuit; otherwise the measure results will be affected.

8. Single phase impedance test:

This test is used to perform impedance tests on single phase or three phase transformer windings using reduced currents. The key item when doing this test on three phase transformer is to establish single phase flux path in the core when testing each phase. T secondary he windings are shorted for the test, and then a single phase voltage is applied to each phase, one at atime, and the current is measured. The impedance can be calculated from the following formula %Z=(1/60)*(E(12)/I(12)+E(23)/I(23)+E(31)/I(31))*(KVA(3p hase)/(KV^2)(LL)) Where, LL represents lf line to line and E, I represents that if voltage is applied between lead 1 and lead2 then the current is taken of lead 1 or 2.

High potential tests:

These tests are performed to confirm whether a particular transformer accessory can withstand electrical stress in service. This test can be performed either using AC or DC.For transformers rate above 34 kV, DC should not be used. The electrical stress is usually applied between the windings and the ground. The HV and the LV winding are tested separately with the winding not being tested is grounded. To avoid damage of insulation avoid application of high potential test voltage. High potential test should not be done on equipment with graded insulation system. That is because the insulation at the neutral end of the winding is less than that of the line end. Some of the high potential tests are as follows:

1.50/60 HZ High potential test:

A single phase AC supply is separately connected to HV and LV winding. The 50/60 HZ source should be sufficiently sized to provide the necessary charging current for the transformer under test and the waveform should be purely sinusoidal. The winding under test has all the terminals shorted and connected to the ground. The test voltage is raised to test value at a slow but controlled rate. Usually the test voltage is raised to 75% of the test value in 5 to 10 seconds and the rate of rise from there on is 2 to 3% of the test value per second. The test value is maintained for one minute and the voltage smoothly but rapidly decreased after that time. The equipment is considered to have passed the test if the test voltage is maintained for the one minute period without any disruptive discharge.

2. DC High potential test:

This test is performed using the same basic procedure as followed in 50/60 HZ test. In addition the AC supply to the DC set should be very stable to prevent unwanted oscillation of the test voltage. At the end of one minute the leakage current is recorded and the test voltage is quickly but smoothly reduced to zero. The leakage current recorded can be used as a reference for future high potential tests.

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3. High frequency induced potential test:
This test is performed to test the integrity of turn to turn insulation in single phase as well as three phase transformers and phase to phase insulation in three phase transformers. It may be also used for graded insulation system. This test is done at high frequency to reduce the exciting current required for energizing the transformer. Common frequencies are 120 HV up to 400 HZ.TO keep the severity of test essentially constant for the different frequencies, the duration of the test is limited to 7200 cycles. The test supply is connected to each phase of the LV winding of the transformer under test. The HV winding is left open. The voltage is raised smoothly to the tes value(less t than 15 seconds), held at this value for 7200 cycles and then quickly brought to zero(less than 5 seconds).The transformer is said to have passed the test if no disruptive discharge takes place during the test.

Test level accessories:

New or fully reconditioned accessories containing voltage sensing circuits should be tested at 1500 volts AC,50/60 HZ and current sensing circuits should be tested at 2.5 KV AC,50/60 HZ, both for one minute.

Gas in oil analysis:

During transformer operation, the deterioration of insulation material generates gases that are dissolved in oil. By determining the gases created and the rate of generation one can detect faults before they become catastrophic. Result from this test can inform the operator about localized or general overheating, arching or corona activity and deterioration of insulation paper.

Other oil tests:

Additional information can be obtained by furan analysis and oil quality tests. The former determines the quantity of furan (a byproduct of paper breakdown) in the fluid. The latter one is done to determine the condition of oil. Such things are moisture content, acidity; colour, interfacial tension power factor and dielectric strength are measured. By drying and reconditioning the oil using filters and diatomaceous earth, the oil can be virtually restored to the new condition. The physical condition of the paper can be determined by testing the tensile strength of small sample, or by determining the degree of polymerization.

Rewinding of Transformers:
The most common rewind is which is based on the original design. The win ding process has essentially three components: 1. The investigation of original failure 2. Gathering physical data for new coils, and 3. The actual winding of the new coils

Investigation:
The rewind process starts with the investigation of the failure that necessitated the rewinding process. Information gathered about this incident may be helpful in rewind process so that subsequent failures are avoided or delayed. Some of the features that one should look are: signs of overheating its probable cause, material incompatibility, reduced electrical clearances, and the mechanical failure of the components. If the faults are not located visually, then some of the tests described earlier are performed to assess the nature and location of the failure.

Gathering data:
From the nameplate, the core and coil assembly and by removing the back winding coils, one should gather the following inform ation:
y y y y y y y y y y y

Nameplate data Basic coil design (cylindrical, spiral sheet wound, or disc) Physical dimensions of the coil Electrical clearance dimensions; phase to phase and phase to ground Number of turns Direction the coils are wound Tap locations (physical and electrical) Insulation material Size of the conductors Number of the conductors in parallel Conductor material

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y y

Coil resistance Special features such as extra supports, tying, main lead strength

Winding coils:
This should be done in clean environment using a winding form made for particular coil being wound. The winding form may be ametal cylinder upon which ground insulation is applied or it can be pressboard insulation that needs no additional ground insulation. The winding is built up according to the data obtained from original. Particular attention is given to the size of the cooling ducts, wire compaction and tension, tap locations, crossovers, connections and splices. Proper tension on the conductor ensures a tight, solid coil. The tension should not be as great as to stretch the conductor. All crossovers and leads should have additional insulation applie to avoid d mechanical breakdown of conductor insulation during processing or service. Connections are made using a T joint (brazed or MIGwelded) and separately insulated. Splices within the coil are made using a scarf joint or simple buttjoint (brazed or MIG-welded), then separately insulated. Care should be made to minimize the insulation build. Once the coil is complete, resistance and physica dimensions l are checked. Coils for dry type transformers are dried and dipped or vacuum impregnated with a thermosetting resin. Coils for liquid filled type transformers with a rating less than 25 KV, can be also dried and dipped or vacuum impregnated as cured resin gives the coil additional strength to withstand through faults.

Core laminations:
Cores are generally stacked cores or wound cores.

Stacked cores, Disassembly:

Since these cores are generally other than rectangular or square cross sections, an accurate dimensioned sketch should be made of the core cross section prior to disassembly. In addition, one should note the number of lamination stacked together. This is usually two or three but can be more. In most cases the, it will only be the yoke that will be unstacked. Upon removal all laminations should be stacked together in the same order that they are to be put back and be well supported for the storage in safe location. Laminations from the dry type transformers should be bonded together cured resin if the core and coil assembly are dipped as a unit. This makes unstacking of laminations difficult and require extra care to avoid damaging them. Lamination should be well supported during storage in safe, dry location.

Stacked cores, Assembly:

Prior to the assembly, the laminations and the clamping structure should be cleaned. The laminations should be inspected forsigns of insulation breakdown, and for burrs that should be removed .The blocking between core legs and coil should be installed atthis time to centre the coils and secure them to the core. During assembly of the yokes, the assembly the laminations are replaced according to the sketch prepared prior to disassembly. Make sure that lamination butt tightly against each other at all joints. Excessive gaps can drastically reduce the flux density in the core. Once all the laminations are in place.The clamping assembly is put in place, insulated and securing bolts torqued to recommended values. Next the transformer coils should be ratio tested to confirm overall ratio and electrical location of all taps.

Wound core, Disassembly:

These cores are often difficult o disassemble. The number of laminations stacked together should be noted prior to disassembly. Accurate overall dimensions should be recorded. The bands securing the laminations are cut and laminations are carefully removed. The urge to straighten the lamination upon removal should be avoided. Too much bending will change the characteristics of the laminationsand also make the assembly difficult. The complete disassembly of the core is avoided. The fewer laminations remove, the easier will be the proper assembly of the core. When the laminations are removed they are well supported and store in safe, dry location.

Wound core, Assembly:

Prior to the assembly the laminations and clamping structure should be cleaned. The lamination should be inspected for insula tion breakdown and for burrs that should be removed. During assembly it is critical that butt joints are tight. This can be very difficult to achieve on some transformers. To help in this process the core can be tightened and banded in stages. That is installing a few laminations and applying temporary bands to tighten them. The temporary bands are removed before additional laminations are installed. Once all laminations are installed, the final clamping bands are applied and steel clamping structure is put in place, insulated and b torque to olts correct values. The coils are ratio tested at this point to ensure proper ratio and correct location of electrical location of the taps.

Connections:
There are essentially two connections that should be made when winding a transformer, those in the winding and those externalto the winding. All connections should be carefully prepared to ensure mechanical and electrical integrity.

Connections in the winding:

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There are many methods of making joints and splices. Following is a example only. Connections in the winding canbe used for connecting various parts of winding (as in disc type winding), to splice in another spool of wire, or to provide tap connections for the winding. In all cases joints should be prepared and insulated not only to ensure electrical and mechanical integrity but to take up as littlespace as possible. For a splice to meet these needs within the winding a brazed or MIG-welded scarf joint or butt joint is often used. Soldered or crimped connections are not recommended for this application. The two connecting pieces should be carefully prepared to ensure that all local insulation is removed and good fit of one piece against other is achieved. Once the brazing or welding is complete, all sharp protrusions and flux material should be removed. Strand insulation can be restored by applying a few layers of appropriate insulation. If the coil contains wire which is smaller than NO. 14 AWG, splices within the winding should be avoided. If the join is a tap connection, then a T joint can be used. If the joint connects two parts of winding, such as in disc type winding, a lap joint can b used if space permits; e otherwise butt or scarf joint may be used. In all cases sharp protrusions should be removed after brazing or welding is complete. An additional piece of sheet insulation is often wrapped around the joint to protect adjacent turns.Where tap leads exit the winding, they are securely tied into the winding to avoid breaking the conductor at this point.

External connections:
In most transformers external connections are usually made to extend the tap leads or main leads or to install a lug or similar connection device to the end of leads. A piece of multi strand cable or wire can be attached to the coil conductor where the wire exitsthe winding, or the connection can be made well outside the coil. If the connection is made outside the coil conductor, then the wire used for this purpose can be attached to the magnet wire by brazing, welding, soldering or by using a crimp connector. Brazing or welding creates most secure connection but requires additional skill. In addition, any fluxes or cleaning agents should be removed after the connection is made. Crimp connectors should be used to join dissimilar metals, or for attaching lugs or similar connection devices to end of the leads.

Insulating connections:
When these connections require insulation, the material should have proper voltage and temperature ratings and be rated for use in air or for use under dielectric fluid. The insulation should reach beyond connection in each direction to establish a creepage path to suit the voltage of winding and to suit the environment (air or submerged in liquid dielectric).the insulation should be secured in such a manner that it will not fall off during processing or service. In addition suitable sleeving is usually installed over any wire thatextends beyond the coil.

Leads:
The requirements for dry type and liquid filled transformers differ slightly. The leads for dry type transformers often have to withstand high temperatures. Leads for liquid type transformers have to withstand submersion in dielectric fluid. When multistrand wire or cable is connected to the coil conductor, the cable or wire conductor is sized using a current density that is the same as or preferably lower than that used for coil conductor. As a guide one can use a conductor the same as or a larger size than that used by original manufacturer. One small transformer the coil conductor is often used as a lead. In this case a sleeve is usually placed over the wire for addedmechanical and electrical strength.

Transformer repair, Dry type:

There are three basic levels of repairing: verifying service suitability, overhaul, and rewind or major component replacement. An outline for these three levels of basic service follows.

Checking the service suitability:

All nameplate data should be recorded as described earlier. The following tests should be performed thereafter: HV to LV, HV to G with LV grounded, LV to G with HV grounded ratio check and winding resistance on all phases on all taps; energize the LV to attain full voltage, recording the magnetizing current and energizing voltage. After tests the process of equipment check is initiated. All the accessories and enclosures (if available) are checked for mechanical damage, noting the items inspected those that are damaged and the nature of the damage. The operation of any cooling fan or control is verified. Any standoff insulator in the enclosure or top of transformer is checked for cracks or chips. All insulators are cleaned subsequently. The security of all taps and lead connections is verified. Any insu lted support used for HV winding lead or tap connections is checked for mechanical security or damaged components. Bolted joints on all bus connections are checked for tightness. All data and list of damaged items is made.

Overhaul:
The process of overhaul is performed to refurbish the transformer and accessories. All possible repairs are carried out according to the list. In addition, after cleaning the core and coil assembly, a coating of insulating resin may be applied. The enclosure may be sandblasted before painting to achieve a better result.

Rewinding:

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For this first of all the nature of fault is determine and fault is located as described earlier. Now the dismantling of the transformer is done. If necessary, the core and the coil assembly are removed from the enclosure. All of the superstructure and lead support system is removed. Upper clamping structure, upper blocking and insulation are removed between the core and the clamping structure. Store all components neatly for reassembly. Top yoke is unstacked as described. The lamination should be well supported. The coils can be now removed for the core by removing first the blocking between the core and the coil ground insulation. Using suitably fashioned lifting hooks, the coils can be lifted from the core limbs. Coils are well support at this stage to prevent unnecessary damage. Once removed from the core, the coil can be placed in the winding lathe, unwound. Depending on the coil construction the HV and LV windings are separated and replace any one of these. Winding of the new coils is done as described earlier. After this, reassembly is done. For thisthe coils are set on the core limbs using the same equipment used to remove them. The core is then assembled as described earlier. If the transformer has a wound core, the core should be placed in and around the coils as described ealier.The blocking or insulation lay between the core and ers coils are installed to centre the coil and to secure the core and coil assembly. On wound core unitsthis materials also prevents the core from damaging the winding. Install the core clamping structure and items for the superstructure. Ensure that the clamping structure is properly insulated from the core. At this time, install the blocking between the top of the coils and clamping structure. The position of the clamping structure should be properly adjusted to ensure that the blocks are tight. Once the bolts for the clamping structure are properly tightened, the lead support structure is properly installed and the line leads and tap leads are properly secured. Once the transformer is completely assembled, the unit should be tested to ensure that repair was successful. Recommended tests are ratio check (TTR), phase relation and polarity check, winding resistance, insulation resistance, AC or DC high potential test, induced potential test, core loss test and copper loss test. Optional tests are power factor test, recovery voltage test and DC step voltage.

Transformer repair, liquid type:

The operations to repair a liquid filled transformer are similar to those for dry type transformers. Most of the additional work requires relates to the dielectric fluid and the tank.

Checking the service suitability:

First of all nameplate data should be recorded and if applicable, the PCB concentration should be verified. Then following tests should be performed, the insulation resistance HV to LV, HV to G with LV grounded, LV to G with HV grounded; ratio check and winding resistance on all phases on all taps; if possible the LV winding is energized to attain full voltage and recording the magnetizing currentand energizing voltage. Now the process of equipment check is started. All accessories are checked for mechanical damage noting the items inspected those that are damaged and the nature of the damage. Verify the operations of any cooling fans and controls. Check radiators, threaded fittings and gaskets for leaks. Bushings are checked for cracks and then are cleaned. The proper operation of the tap changer is checked, if any. Alternatively, security of the tap connections in the tank is checked.

Overhaul:
The overhaul operation requires considerably more work for oil filled transformes.The purpose is to refurbish the transformer and accessories. A quick visual inspection is done to identify and record any mechanical damage to the tank or radiators and any fluid leaks that may exist. The following tests should be performed: insulation resistance HV to LV, HV to G with LV grounded, LV to G with HV grounded, ratio check all phases on all taps, winding resistance check. Take oil samples for PCB analysis, quality analysis,and gas in oil analysis, and furan analysis. The oil should be drained from the tank and stored in tanks specially designated for the purpose. This will protect the coil from contamination by other substances. The PCB concentration is determined before commencing any draining procedures. While draining the oil from the transformer any contaminant in or floating on the coil can foul the transformer winding. A filter should be used in the suction line to prevent any contamination or damage to the pump. Precautionary measures should be taken to prevent all leaks. Once the oil is drained, all components are removed such as the conservator, the bushings, tap switch operators and temperature gauge wells. The cover is then removed by removing the clamp that holds it in place, unbolting it or cutting the weld. For the latter case, the tank should be purged with pressurized with nitrogen prior to cutting the weld. Bushing should be removed pr protected from the metal splatter. After the cover is removed, any remaining accessories that require access from inside the tank can be removed. The core and coil assembly can then be lifted from the tank. The core and coil assembly is allowed to drain over the tank for a short time and is then place on the floor d over a drip tray. The assembly is covered with a polyethylene sheet. With the unit well lit, the detailed inspection of the core and coil assembly, the inside of the tank and all the accessories that were removed, is done. Items that require special attention are tap changer and its connection, the core clamping assembly, insulation between core and clamping structure, blocking, coil insulation, coil leads ,any accessible conductor joints, the bushings, the insideof the tank, the conservator, the radiator and all accessories. Tests performed at this time are insulation resistance between core and clamping structure, functional tests on all the accessories, and degree of polymerization test on the paper. All items are cleaned using methods appropriate for each item. The core and coil assembly is flushed using oil at very low pressure. The tank, cover, conservator, control boxes, bushing terminal boxes should be sandblasted and thoroughly cleaned. After sandblasting and prior to the cleaning is the appropriate time to add or replace any radiators or cooling tubes. Gaskets and seals are replaced with material

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resistant to deterioration by transformer oil. The oil should be processed to remove particulates, gas, acids or alternatively it should be replaced with new oil. Once all the repairs are complete, reassembly is started. Reassembly of the transformer is started with drying of the core and coil assembly. This is best accomplished by placing the core and coils into an oven where temperature does not exceed 95 degree Celsius. Dissipation factor measurements can be taken during the drying cycle when the insulation is dry. It is made sure that the absorbent material is around the base of the core and coil assembly to soak the oil draining from the insulation. When the core and coil assembly is removed from the oven or drying tank, the clamping bolts should be checked for tightness. The assembly is then lifted, and lowered into the tank and hold down supports are installed and suppor ted. The tank is then quickly filled with oil up to top of the transformer core. The oil should be at or above room temperature, preferably above. All sidewall components are installed replacing any damaged control wiring. The cover and all cover mounted instruments are installed. The transformer is filled with remaining oil till correct oil level is reached as shown on the oil levelgauge. The security of all joints is confirmed by pressurizing the transformer tank with 3 psig of dry air and inspecting all joints for leaks Finally, following tests are recommended. Insulation resistance core to ground, insulation resistances between each winding and between each winding and the ground, turns ratio test, phase relation check or polarity check, winding resistance test, open circuit core loss, copper loss, AC high potential test for HV and LV windings, and an induced potential test. Once all tests are complete, oil samples should be taken for gas-in-oil analysis and quality assessment. Now the transformer can be prepared for shipment.

Rewinding:
If the fault initiated the need for rewinding, then first the nature and location of fault is determined as described ealier.The core and coil assembly is then removed and the extent of the damage is determined. All of the superstructure and lead support system is removed. Upper clamping structure, upper blocking and insulation between core and clamping structure is removed. All the components are stored neatly for reassembly. The top yoke is unstacked as described earlier. To free the coil from the core all blocking between core and ground insulation s hould be removed. Using suitably fashioned lifting hooks, the coils can be carefully lifted from the core limbs. It is important to support the coils well at this stage to prevent unnecessary damage. Once removed from the core the coil can be placed in the winding lathe, unwound. Depending on coil construction, the HV and LV windings are separated and any one of them is replaced. Winding of the new coils is done as described earlier. Now the process of reassembly is initiated. The coils are set on the core limbs using the same equipment used to remove them. If the transformer has a wound core, the core should be placed in and around the coils. The blocking of insulation layers between core and coils are installed to centre the coil and to secure core and coil assembly. On wound core units the material also prevents the core from damaging the winding. The core clamping structure and the superstructure is installed. It is ensured that the clamping structure is properly insulated from the core. At this time the blocking between the top of the coils and clamping structure is installed. The position of the clamping structure should be adjusted to ensure that all the blocks are tight. Once the bolts securing the clamping structure are properly tightened, lead support structure is installed and line leads and tap leads are secured. Finally, when the transformer is completely assembled, the unit is tested to ensure that the repair was successful and to provide a record of transformer condition after the repair. Now following tests are recommended, ratio check (TTR), phase relation and polarity check, winding resistance, insulation resistance, AC or DC high potential test, induced potential test, core loss test and the copper loss test. Optional tests are power factor test, recovery voltage test and DC step voltage. Now the transformer is ready for shipment.

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