TRANSFORMER CONSTRUCTION ,

TESTING AND M&R

Need of transformer

Generation voltage 11 KV
Transmission Voltage 66 KV/132KV
Distribution Voltage 11 KV & below
Transformer - To step-up or step-down the voltage
and transfer power from one a.c. voltage to
another a.c. voltage at the same frequency.
Transformer

Transformer

Power Station

consumer

low voltage
high voltage

high
voltage

low
voltage

Power transformer

Transformer :

A transformer is a static apparatus used for the

transferring power from one circuit to the other
without change in frequency.

It can raise or lower the voltage with a

corresponding decrease or increase in current.

The purpose of transformers is to transfer electrical

energy from systems of one voltage V1 to systems
of another voltage V2.

Basic requirements of Transformer

Voltage Ratio
MVA Rating & cooling
Vector group
OLTC
Percentage Impedance

No load loss
Load loss

Parts of transformer

Main tank

Buchholz relay

Radiators

MOG

Conservator

PRD

Tap changer

OTI

Silica breathers

WTI

Tests on Transformer:
1. Oil Test
2. Voltage Ratio Test

3. Current Ratio Test

4. Vector Group Test
5. Magnetic Balance Test

6. Magnetizing current Test

7. IR Test

Successful Electrical
Maintenance

PREVENTION is BETTER than CURE

MAINTENANCE is not the REPAIR work

PREVENTIVE MAINTENANCE

REPAIR or BREAKDOWN MAINTENANCE.

Maintenance Consists of..

Routine Inspection

Testing

Cleaning & Adjustments

Key to SUCCESS is.

DETECT INCIPIENT TROUBLE by- ROUTINE TESTS

- VISUAL
- AURAL
- TOUCH
- SMELL
- INSTRUMENTS

Distribution Transformer Maintenance

Transformer Body

Inspect For Rust & Leakage

Rectified

Rust Clean & Repaint

Leakage Investigate
- Leaking Joint to be
-Replace Gaskets

Distribution Transformer Maintenance

BREATHER
Silica-gel Dehydrating Breather
Colour of Crystals
Saturated Crystals Pink
Need Reactivation Blue
Oil seal .

Distribution Transformer Maintenance

Explosion Vent
Inspect Diaphragm Air tight joint with

Gaskets.

Gaskets
Shrink During Service
Check tightness of Bolts
Replace Leaking Gasket.

Distribution Transformer Maintenance

Transformer Insulation is the Root of the Problem

Oil & Cellulose Paper Interact.

By products decompose Insulation System

By-products : Increase Moisture Level

: Create Environment Overheat

-Fails

Transformer Oil Functions.

First : Serves as INSULATION to withstand the high

voltages present inside the transformer.
Second : It functions as the Heat Transfer medium to
dissipate Heat Generated within the transformer
winding.

Oil must maintain Good Electrical properties while

Resisting Thermal Degradation & oxidation.

Transformer - Oil
Just Like a car Transformer needs
REGULAR
Oil Conditioning
to rid it of Harmful Contaminants
That could SHORTEN its life.

Transformer Oil

1.

2.
3.
4.

Deterioration of Oil

Oxidation
In grace of Moisture
Solid Impurities
Contamination

Transformer Oil

Even with Best Maintenance Procedures

Chemical Reaction continues.

Remedy
Annual Oil Testing
Oil Testing uncovers several Potential Problems
Sample Contains Evidence of Soluble contaminants
- Dielectric contaminant
- Acid Materials

Testing of Oil Benefits

Tests indicate the Interior-Condition of

oil.

Prevents Un-scheduled outages.

Determines Trends, if any.

Tests on Oils
1.

2.
3.
4.

5.

Physical Appearance Colour

- Clarity
- Odour
Electric Strength Test
Crackle Test
Acidity Test
Insulation Resistance Test

OEM Recommendations..
1.

Hourly

2.
3.
4.
5.
6.

Daily
Monthly
Six Monthly
Yearly
Five Yearly

Load Amps
Temperature
Voltage
Breather
Oil Level
Gen. Observations
Oil Testing
Overall Inspection

BSES Practices.

Load readings taken once in 6 months.

Silica gel replaced before/after
mansoon.
Oil Testing once in 12 months.
Oil Filtered if B.D.V. is low.
Oil Replaced if acidity beyond 1 mg
kOH/gm.

ISO Norms.

Transformer Load Readings and

Inspection = Every Six Months.
Transformer Oil sampling for B.D.V.
Measurement = Every Year.
Transformer Oil Filteration & Oil Testing
= Every 4 Years.

DISTRIBUTION TRANSFORMERS FAILURE RATE IN BSES

Year

Total in
System

Units
Failed

% Failure

1996-97

3056

70

2.29

1997-98

3229

65

2.01

1998-99
1999-2000

3405
3583

40
35

1.17
0.98

Failuare Analysis

Certain Makes have performed Badly.

Failuares more in recent make & specific
Batches.

75% of failuares at 9 years or less.

Faliare rate goes down as size increases.

Causes : Faults on L.T. side on U/G cables.

Higher Temperature.

THANK YOU

P.R.V. (Pressure Relief Valve)

When oil pressure in the tank rises above predetermine safe limit this valves operates.

This equipment is of spring loaded type. When It

operates the part of @ 150mm dia of PRV up lifts and
allow in side tank pressure to drop.

Saves transformer to buckle or damage further.

Gives indication of valve operation by rising the flag.

Operates a micro switch that disconnect the

transformer from live circuit.

M.O.G. (Magnetic Oil Gauge).

This is used with conservator

It's purpose is to indicate the oil level in the

conservator vessel and to give alarm when the
oil level falls below a threshold limit.

SILICA GEL BREATHERS

Moisture is an enemy of transformer insulation

system
Whenever oil contracts transformer breaths in
through breathers.
With air lot of moisture which is present in the air
also go inside.
The silica gel present in the breathers absorb
moisture and only dry air goes inside.
After a certain level of absorption the color of
silica gel crystals change from blue to pink when
these particles should be recharged or replaced.

OTI (Oil Temperature Indicator)

This consists of a bulb dipped in a oil cup on the

cover of the transformer tank cover. This bulb is
connected to the meter placed in the marshalling
box meant for housing the equipment electrical
controls by means of a capillary.

This indicates the temperature of the top part of

the transformer oil which is the hottest part.

It gives alarms/trip contacts when temperature

exceeds than set values.

WTI (Winding temperature indicator)

Similar in construction to the OTI.

A current transformer injects current into the

heating coil of the equipment giving the extra
temperature gradient over the top oil temp. which
normally a winding is expected to have.

It gives alarms/trip contacts when temperature

exceeds than set values.

It also gives start/stop contacts for fans & pumps

to start and stop when temperature exceeds.

Oil test:

Collect samples of oil from main tank bottom,

Conservator, radiator and tap changer.

Oil breakdown test should withstand 60KV for 1

min. with 2.5mm gap. If the value is lower,
advice further dry out till this value is achieved,
before proceeding further.

Collect 5 liters of oil from the tank send to a

standard laboratory like ERDA for moisture
content, resistivity testing.

ERDA detail testing of oil

No.

Test

Requirement

Electric strength

Min. 60 KV

Water Content, ppm

Max. 15

Neutralization value mg KOH/g of oil

Max. 0.03

Sediment & sludge % by wt.

Non-detectable

Dielectric dissipation factor

Max. 0.015

Specific resistance, Ohm.cm

Min. 6x 10

Interfacial tension, mN/m

Min. 35

Flash point , deg.C

Min. 140 deg.C

Obtained
value

Remarks

Voltage Ratio Test:

Apply 3-Phase 400 Volts on HV side and measure
respective voltage on LV side.
Tap no.

ry (V)

yb (V)

br (V)

rn (V)

yn (V)

bn (V)

95.9

95.4

94.5

55.3

54.6

54.4

105.3

104.4

105.5

61.0

60.0

59.9

17

117.1

116.0

117.2

67.9

66.3

66.5

Current Ratio Test:

Apply 3-Phase 400 Volts on HV side keeping R-Y-B
phases shorted on LV side.
Measure the current on HV and LV side starting
from 1st tap to last tap.
Tap no. R (A)
1
6.4

9
17

8.1
10.7

Y (A)
6.0

B (A)
6.5

ryb (A)

7.8
10.4

8.2
10.8

32.5

Vector Group Test:

Short R-ph of HV & r-ph of LV.
Apply 3 phase, 440 V on HV side
Measure respective voltage as under:
Ry: 67 V

Bb: 346 V

RY: 408 V

Rb: 68 V

By: 347 V

YB: 410 V

Yy: 400V

Yb: 415V

BR: 415 V

rR

b n
B

y
Y

Magnetic Balance Test:

Apply 415 Volts on LV side between phase &
neutral.Measure voltage on respective LV
terminals as under.
Apply 415 Volts on two terminals of HV and
measure voltage on HV terminals as under:
HV
Winding

RY

YB

BR

RY=424

424

194

222

YB=424

392

424

BR=424

381

36.2

LV
Winding

rn

yn

bn

rn= 407

407

334

78

18.9

yn= 407

205

407

201

424

bn =407

79

332

407

Magnetizing Current Test:

Apply 3-Phase 400 volts on HV side with LV
open.Measure the current on HV side
Apply 3-Phase 400 volts on LV side with HV open.
Measure the current on LV side
Voltage Applied

Current measured

RY 440 V

R 11.11mA

YB 440 V

Y 07.62 mA

BR 440 V

B 10.95 mA

Insulation Resistance Test:

Dryness of insulation is determined by

measuring insulation resistance of winding.

It should be taken by 2.5 KV motorized Megger.

IR of 60sec/IR of 15sec (PI) should be greater

than 1.2 for good insulation.
15 seconds

60 seconds

60/15
seconds (PI)

HT to Earth

190 x 5

260 X 5

1.4

LT to Earth

200 X 5

330 X 5

1.6

HT to Earth

270 X 5

400 X 5

1.5

CORE to Earth

Differential Stability Test

Out Zone Testing : Apply 400 volts 3 Phase on HV
side keeping shorting after CTs for 11 KV Incomer.
Type of fault

R Phase
HV

RN
YN
BN
RY
YB
BR
RYB

LV

OP.

Y Phase
HV

LV

OP.

B Phase
HV

LV

OP.

REF Relay

Differential Stability Test

In Zone Testing : Apply 400 volts 3-Phase on HV side
keeping shorting for 11 KV Incomer before CTs.
Type of fault

R Phase
HV

RN
YN
BN
RY
YB
BR
RYB

LV

OP.

Y Phase
HV

LV

OP.

B Phase
HV

LV

OP.

REF Relay

Voltage transformation ratio:

Primary winding & Secondary winding
E1 = 4.44* f *N1* m
E2= 4.44* f *N2* m
E2 / E 1 = N1/ N2
Where N1 = Primary Turns
N2 = Secondary Turns
m = Flux
F = frequency
In our system we have different Voltage ratio
transformers: 220/132KV, 132/66KV, 132/33KV,
66/11KV, 33/11KV, 11/0.44KV.

% Impedance Voltage:

The Impedance voltage is defined as that voltage

having the rated frequency which must be
applied to the primary side of a transformer so
that the rated current Ir flows when secondary
terminals are shorted.

The rated impedance voltage is usually stated as

a percentage of the voltage rating Ur of the
winding to which the voltage is applied.

% Impedance = (Applied voltage/Rated

voltage)x100

MVA rating & cooling:

It defines the total output capacity of the

transformer in MVA at the given cooling like
ONAN, ONAF and OFAF.

Our 12.5MVA and 20MVA, 66/11kv transformers

are with ONAN cooling.

Our 30MVA,132/11kv and 50MVA,132/33KV

transformers are with ONAN/ONAF Cooling.

Our 65MVA &100MVA, 132/66kv and

150MVA,220/132kv transformers are with
ONAF/ONAF/OFAF Cooling

Vector group:

Yna0 for 220/132kv,132/66kv interconnecting

transformers. DYn1 for 132/11kv, 66/11kv and 33/11kv
distribution transformers.Ynyn0 for 132/33kv
transformers.

The vector group denotes the way the windings are

connected and the phase position of their respective
voltage vectors.

To identify the phase angle the vector of High voltage

winding is taken as a reference. The number multiplied
by 30 denotes the angle by which the vector of the LV
winding lags that of the HV winding.

OLTC: on load tap changer

It add or subtract turns from the main coil of HV

winding while RAISE or LOWER command is
given and maintains constant voltage on LV side.
Generally housed inside the transformer tank and
operation through local box/remote panel.
These are the standard products.
Selection is based on Winding connection,
current rating,range in terms of % of winding,
number of steps, independent operation, parallel
operation.

No load loss

It is basically the core material loss.

Core is the magnetic circuit through which flux
flows.The material used for core making is called
CRGO i.e cold rolled grain oriented steel.
It is the power loss that transformer consumes
when charged at Normal voltage and at No load.
It should be minimum as possible to reduce T & D
loss of the system.
We insist manufactures to use prime grade
imported first quality CRGO material for
manufacturing the core of the transformer.

load loss

It is basically the copper loss.

It is the power consumed by the transformer
when on load.
It will change at different load and tap position of
the transformer.

Transformer tank
Conventional tank: A tank
in which the cover is flat and
tank to cover junction is at the
top of the tank.

Bell type tank : A tank in

which the cover is not flat in
shape and the tank and cover
junction is near the bottom of
the tank .Tank is in two parts
top tank and bottom tank

Radiators

Tank mounted : Directly mounted on the tank

wall, if the size and numbers of radiators is small.

Separately mounted: Mounted separately on A

OR H frame structure and connected with main
tank through oil headers.

Selection of radiator banks mounting and its

positioning depends on MVA rating, type of cooling
like ONAF,ONAF and site space availability.

Arrangement need to be specified at the time

tendering for total L X B X H dimensions of
transformer, tank mounted,separately mounted,
HV side, LV side, on left side and right side.

Buchholz relay

Because of any internal fault heat is generated which

decomposes oil and insulation material resulting in
the formation of gases.
Alarm
Conservator

Transformer
Tank

These gases rise up and while approaching the

conservator passes through the buchholz relay.

Conservator

A conservator is a cylindrical vessel which provides

space for expansion of oil inside the transformer. A
conservator is always placed above the transformer

It supplies oil to the transformer when the

transformer oil cools and contracts in volume..

Air cell is rubber bag is fitted inside the transformer

conservator.When oil in transformer contracts ,it
sucks air into the this bag and when oil expands it
expels air from the bag. Thus Air Cell prevents
atmospheric oxygen to come in contact with the oil.